E9.9D E15D - PT. KBA€¦ · E9.9D SERVICE MANUAL 290492 6B4-28197-5E-11 E15D. NOTICE This manual...

E9.9D

SERVICE MANUAL

6B4-28197-5E-11290492

E15D

NOTICE

This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trainedmechanics when performing maintenance procedures and repairs to Yamaha equipment. It hasbeen written to suit the needs of persons who have a basic understanding of the mechanical andelectrical concepts and procedures inherent in the work, for without such knowledge attemptedrepairs or service to the equipment could render it unsafe or unfit for use.

Because Yamaha has a policy of continuously improving its products, models may differ in detailfrom the descriptions and illustrations given in this publication. Use only the latest edition of thismanual. Authorized Yamaha dealers are notified periodically of modifications and significantchanges in specifications and procedures, and these are incorporated in successive editions of thismanual.

Important informationParticularly important information is distinguished in this manual by the following notations:

Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

wFailure to follow WARNING instructions could result in severe injury or death to the machineoperator, a bystander, or a person inspecting or repairing the outboard motor.

cCA CAUTION indicates special precautions that must be taken to avoid damage to the out-board motor.

NOTE:A NOTE provides key information to make procedures easier or clearer.

E9.9D, E15DSERVICE MANUAL

©2002 by Yamaha Motor Co., Ltd.1st Edition, October 2002

All rights reserved.Any reprinting or unauthorized use without the written permission of

Yamaha Motor Co., Ltd.is expressly prohibited.

Printed in Japan

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Specifications

General information

Periodic checks and adjustments

Fuel system

Power unit

Bracket unit

Electrical systems

Troubleshooting

Index

Contents

Lower unit

9876

21GEN

INFO

SPEC

CHKADJ

FUEL

POWR

LOWR

BRKT

ELEC

TRBLSHTG

345

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General information

How to use this manual.................................................................................1-1Manual format............................................................................................1-1Symbols .....................................................................................................1-2

Safety while working......................................................................................1-3Fire prevention ...........................................................................................1-3Ventilation ..................................................................................................1-3Self-protection............................................................................................1-3Parts, lubricants, and sealants ..................................................................1-3Good working practices .............................................................................1-4Disassembly and assembly .......................................................................1-4

Identification ...................................................................................................1-5Applicable model .......................................................................................1-5Serial number ............................................................................................1-5

Technical features and descriptions ............................................................1-6Top cowling ................................................................................................1-6Cylinder head.............................................................................................1-7Carburetor..................................................................................................1-8Tiller handle ...............................................................................................1-9Ignition control system.............................................................................1-10Side shift ..................................................................................................1-11Tilt support system ..................................................................................1-12Exhaust components (optional) ...............................................................1-13Splash guard (optional) ...........................................................................1-14Cooling system ........................................................................................1-15

Propeller selection .......................................................................................1-16Propeller size ...........................................................................................1-16Selection ..................................................................................................1-16

Predelivery checks.......................................................................................1-16Checking the fuel system ........................................................................1-16Checking the gear oil ...............................................................................1-16Checking the outboard motor mounting height .......................................1-17Checking the steering system .................................................................1-17Checking the gear shift and throttle operation.........................................1-17Checking the engine shut-off switch........................................................1-18Checking the cooling water pilot hole ......................................................1-18Test run ....................................................................................................1-18Break-in ...................................................................................................1-18After test run ............................................................................................1-19

GENINFO

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GENINFO

1- 6B45E11

General information

1-1

How to use this manualManual formatThe 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.2 Tightening torque specifications are provided in the exploded diagrams and after a numbered

step with tightening instructions.3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant

and lubrication point.4 The components list consists of part names and quantities, as well as bolt and screw dimensions.5 Service points regarding removal, checking, and installation are shown in individual illustrations

to explain the relevant procedure.

NOTE:For troubleshooting procedures, see Chapter 9, “Troubleshooting.”

LOWRLower unit

6-5 62Y5A11

Lower unit

No. Part name Q’ty Remarks

1 Lower unit 1

2 Plastic tie 1 Not reusable

3 Hose 1

4 Check screw 1

5 Gasket 2 Not reusable

6 Dowel pin 2

7 Bolt 4 M10 40 mm

8 Drain screw 1

9 Grommet 1

10 Bolt 1 M10 45 mm

11 Bolt 1 M8 60 mm

12 Thrust washer 1

13 Propeller 1

14 Washer 1

15 Washer 1

16 Cotter pin 1 Not reusable

17 Propeller nut 1

18 Trim tab 1

LOWRLower unit

6-19 62Y5A11

Removing the drive shaft1. Remove the drive shaft assembly and

pinion, and then pull out the forwardgear.

Disassembling the drive shaft1. Install the pinion nut , tighten it finger

tight, and then remove the drive shaftbearing using a press.

CAUTION:• Do not press the drive shaft threads

directly. Do not reuse the bearing, always

replace it with a new one.

Disassembling the forward gear1. Remove the taper roller bearing from the

forward gear using a press.

CAUTION:Do not reuse the bearing, always replaceit with a new one.

2. Remove the needle bearing from the for-ward gear.

CAUTION:Do not reuse the bearing, always replaceit with a new one.

Drive shaft holder 4 : 90890-06518Pinion nut holder : 90890-06505Socket adapter 2 : 90890-06507

Bearing inner race attachment :90890-06639

S62Y6850K

Bearing separator : 90890-06534

Stopper guide plate : 90890-06501Stopper guide stand :

90890-06538Bearing puller : 90890-06535Bearing puller claw 1 :

90890-06536

S62Y6740K

3 2 1

1

2

3

3

2

3

4

5

1

4

5

a

×

××

1

2

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INFO

SymbolsThe symbols below indicate the content of a chapter.

General information Fuel system Bracket unit

Specifications Power unit Electrical systems

Periodic checks and adjustments Lower unit Troubleshooting

Symbols 1 to 6 indicate specific data.

1 Special tool2 Specified oil or fluid3 Specified engine speed4 Specified tightening torque

5 Specified measurement6 Specified electrical value

(resistance, voltage, electric current)

Symbols 7 to w in an exploded diagram or illustration indicate the grade of lubricant and the lubri-cation point.

7 Apply Yamaha 2-stroke motor oil8 Apply water resistant grease (Yamaha grease A)9 Apply molybdenum disulfide grease0 Apply corrosion resistant grease

(Yamaha grease D)

q Apply low temperature resistant grease(Yamaha grease C)

w Apply injector grease

Symbols e to i in an exploded diagram or illustration indicate the type of sealant or locking agentand the application point.

e Apply Gasket Makerr Apply Yamabond No. 4t Apply LOCTITE 271 (red)

y Apply LOCTITE 242 (blue)u Apply LOCTITE 572i Apply silicon sealant

FUEL BRKT

SPEC POWR ELEC

CHKADJ LOWR TRBL

SHTG

1 2 3 4 5 6

C

7 8 9 0 q w

e r t y u i

How to use this manual

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GENINFO

1-3 6B45E11

General information

Safety while workingTo prevent an accident or injury and to ensurequality service, follow the safety proceduresprovided below.Fire preventionGasoline is highly flammable.Keep gasoline and all flammable productsaway from heat, sparks, and open flames.

VentilationGasoline vapor and exhaust gas are heavierthan air and extremely poisonous. If inhaledin large quantities they may cause loss ofconsciousness and death within a short time.When test running an engine indoors (e.g., ina water tank) be sure to do so where ade-quate ventilation can be maintained.

Self-protectionProtect your eyes by wearing safety glassesor safety goggles during all operations involv-ing drilling and grinding, or when using an aircompressor.Protect your hands and feet by wearing pro-tective gloves and safety shoes when neces-sary.

Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants,and sealants or those recommended byYamaha, when servicing or repairing the out-board motor.

Under normal conditions, the lubricants men-tioned in this manual should not harm or behazardous to your skin. However, you shouldfollow these precautions to minimize any riskwhen working with lubricants.

1. Maintain good standards of personal andindustrial hygiene.

2. Change and wash clothing as soon aspossible if soiled with lubricants.

3. Avoid contact with skin. Do not, for exam-ple, place a soiled rag in your pocket.

4. Wash hands and any other part of thebody thoroughly with soap and hot waterafter contact with a lubricant or lubricantsoiled clothing has been made.

5. To protect your skin, apply a protectivecream to your hands before working onthe outboard motor.

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6. Keep a supply of clean, lint-free cloths forwiping up spills, etc.

Good working practicesSpecial service toolsUse the recommended special service toolsto protect parts from damage. Use the righttool in the right manner–do not improvise.

Tightening torquesFollow the tightening torque specificationsprovided throughout the manual. When tight-ening nuts, bolts, and screws, tighten thelarge sizes first, and tighten fasteners startingin the center and moving outward.Non-reusable partsAlways use new gaskets, seals, O-rings, cot-ter pins, circlips, etc., when installing orassembling parts.

Disassembly and assembly1. Use compressed air to remove dust and

dirt during disassembly.

2. Apply engine oil to the contact surfacesof moving parts before assembly.

3. Install bearings with the manufactureidentification mark in the direction indicat-ed in the installation procedure. In addi-tion, be sure to lubricate the bearings lib-erally.

4. Apply a thin coat of water-resistantgrease to the lip and periphery of an oilseal before installation.

5. Check that moving parts operate normal-ly after assembly.

Safety while working

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GENINFO

1-5 6B45E11

General information

IdentificationApplicable modelThis manual covers the following models.

Serial numberThe outboard motor serial number isstamped on a label attached to the portclamp bracket.

1 Model name2 Approved model code3 Transom height4 Serial number

Applicable models

E9.9DMH, E15DMH

Model nameApproved Starting

model code serial No.

S: 1000001–

E9.9DMH 6B3K L: 1000001–

X: 1000001–

S: 1000001–

E15DMH 6B4K L: 1000001–

X: 1000001–

6B410010

YAMAHA MOTOR CO., LTD.MADE IN JAPANPAYS D'ORIGINE JAPON

13

24

6B410020

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Technical features and descriptionsTop cowlingA thicker top cowling of 2.8 mm (0.11 in) and an aluminum air intake duct are adopted to increaserigidity.A large rubber seal is adopted for the mating face of the top cowling.Also, the inner lip height of 6 mm (0.24 in) is molded around the bottom cowling.Thereby, better waterproofing is obtained at the mating surface between the top and bottom cowl-ings.A water sink is designed into the starter cover to drain the water entering from the starter rope hole.

Identification/Technical features and descriptions

6mm (0.24 in)

2.8 mm (0.11 in)

1

3

4

2

1 Aluminum air intake duct2 Large size rubber seal3 Starter cover4 Drain hose

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General information

Cylinder headThe hemispherical combustion chambers have been adopted to increase combustion efficiency.The cylinder head cover is incorporated to circulate the cooling water, which increases cooling of thecylinder head.These designs give stability to engine power output.

1

2

1 Hemispherical combustion chambers2 Water jacket

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Technical features and descriptions

1

2

CarburetorOne carburetor with fuel pump is adopted for a simple fuel system.The carburetor is designed to mount on the crankcase with two long bolts at the front flange.Also, the intake silencer is designed to mount independently on the carburetor.Therefore, easier servicing is obtained.

1 Intake silencer2 Fuel pump

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General information

Tiller handleA thicker and larger steering bracket is adopted to increase durability.The tiller handle is mounted by dual side brackets to increase reliability.The throttle cable grommet is obliquely installed into the bottom cowling to prevent the cables fromhard bending.Also, a deep throttle cable end holder is formed into the tiller handle to obtain easier assembly.A large throttle control grip with throttle indicator and throttle friction are adopted for easier opera-tion.

1

2

3

4

5

6

1 Throttle cable grommet2 Tiller handle side bracket3 Deep cable holder4 Steering bracket5 Throttle friction6 Throttle indicator

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Ignition control systemA CDI unit with electronic ignition timing advance system is adopted.This allows a simple structure in the flywheel magneto, and maintenance free for the ignition timingand for the advance timing to obtain easier servicing.

6B4-00

60 mm (2.36 in) 7

6 m

m (

2.99

in)

1

å

Ignition timing controlWith the signal timing and interval from the pulser coil, the ECU carries out a calculation and con-trols the ignition timing under the various engine speed.The control of ignition timing is as follows.

(1) Normal operationThe ignition timing is controlled as shown in the chart in fig. 1, after 10 seconds after the enginestarts.

35

30

25

20

15

10

5

0

-50 1,000 2,000 3,000 4,000 5,000 6,000

Fig

∫

ç

∂

Fig. 1

1 ID markå CDI unit

∫ Ignition timing under normaloperation

ç Crank angle (degrees)∂ Engine speed (r/min)

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GENINFO

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General information

(2) When the engine startsThe ignition timing is fixed to BTDC10 degrees for 10 seconds after the engine starts. Thereafter,the ignition timing is put into that of normal operation by retarding 1 degree per 0.25 second.

(3) When the engine acceleratesThe CDI unit adjusts the ignition timing momentarily, when the engine speed changes 300 r/min per0.1 second while the engine is running between 1,000 r/min and 3,200 r/min.Thereafter, the ignition timing immediately returns to that of normal operation.

Side shiftA large shift lever is incorporated into the side of the bottom cowling to drive the shift rod directlyand a large shift tension plate is adopted, which obtains exact shifting operation.This simple shifting system obtains reliability and easier servicing.Also, the start-in-gear protection device is incorporated to allow the engine to be started only whenin neutral, which increases reliability.

1

2

3

4

5

1 Shift-in-gear detector2 Shift rod3 Start-in-gear protector4 Shift tension plate5 Shift lever

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Tilt support systemTwin tilt supports with slots are adopted to increase durability and reliability of the outboard motor`ssupport system in the tilted up position.

1

2

1 Tilt lever2 Tilt support

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GENINFO

1-13 6B45E11

General information

Exhaust components (optional)The cylindrical components for the exhaust passage have been externally and internally paintedafter an anodic oxide coating is given to make a film for additional corrosion-resistance.

1

2

å

1 Exhaust manifold2 Propeller shaft bearing housing

å Anodic oxide coating and additional painting

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Splash guard (optional)A splash plate with a long skirt is adopted to cover the lower mount area and prevent water sprayfrom rising up when the outboard motor is used at high level water surface conditions.

1

1 Splash guard with long skirt

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GENINFO

1-15 6B45E11

General information

Cooling systemThe impeller material is changed to increase cooling water supply while the engine is running at lowspeed.A cylinder head cover is incorporated to circulate cooling water, thereby the cooling efficiency isincreased.

5

7

8

9

10

3

4

6

1

2

12

11

8. Thermostat

7. Cylinder head

1. Cooling water inlet

2. Water pump

3. Exhaust guide

4. Exhaust outer cover5. Pilot hole

6. Cylinder

9. Cylinder head cover

10. Upper case

Atmosphere

Atmosphere

11. Lower case

12. Propeller boss

å

∫

ç

å Cold water∫ Hot waterç Exhaust gas and water

Cooling water flow diagram

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Propeller selectionThe performance of a boat and outboardmotor will be critically affected by the size andtype of propeller you choose. Propellersgreatly affect boat speed, acceleration,engine life, fuel economy, and even boatingand steering capabilities. An incorrect choicecould adversely affect performance and couldalso seriously damage the engine.Use the following information as a guide forselecting a propeller that meets the operatingconditions of the boat and the outboardmotor.

Propeller sizeThe size of the propeller is indicated on theoutside of the propeller boss.

a Propeller diameter (in inches)b Propeller pitch (in inches)c Propeller type (propeller mark)

SelectionWhen the engine speed is at the full throttleoperating range (4,500–5,500 r/min), theideal propeller for the boat is one that pro-vides maximum performance in relation toboat speed and fuel consumption.

Predelivery checksTo make the delivery process smooth andefficient, the predelivery checks should becompleted as explained below.

Checking the fuel system1. Check that the fuel hose is securely con-

nected and that the fuel tank is filled withfuel.

cCUse pre-mixed fuel only.Fuel and oil mixing ratio is 50:1. For break-in period, 25:1 mixture shall be used.

Checking the gear oil1. Check the gear oil level.

NOTE:The gear oil level should be at the brim of thecheck hole.

Propeller size (in) Material

9 1/2 × 6 1/2 - J

9 3/4 × 6 1/2 - J

9 1/4 × 8 - J

9 3/4 × 8 - JAluminum

9 1/4 × 9 - J

9 1/4 × 10 - J

9 1/4 × 11 - J

9 1/4 × 12 - J

6B410030

-

a b c

6B410040

6B410050

Technical features and descriptions/Propeller selection/Predelivery checks

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1-17

Checking the outboard motormounting height1. Check that the anti-cavitation plate is

between the bottom of the boat and amaximum of 25 mm (1 in) a below it. Ifthe mounting height is too high, cavitationwill occur and propulsion will be reduced.Also, the engine speed will increaseabnormally and cause the engine to over-heat. If the mounting height is too low,water resistance will increase and reduceengine efficiency.

NOTE:The optimum mounting height is affected bythe combination of the boat and the outboardmotor. To determine the optimum mountingheight, test run the outboard motor at differ-ent heights.

2. Check that the clamp brackets aresecured with the clamp screws.

Checking the steering system1. Check the steering friction for proper

adjustment.

2. Check that the steering operates smooth-ly.

Checking the gear shift and throttleoperation1. Check that the gear shift operates

smoothly when the shift lever is shiftedfrom neutral into forward.

2. Check that the throttle operates smoothlywhen the throttle grip is turned from thefully closed position to the fully open posi-tion a.

0—25mm(0—1in.) 6B410060

a

6B410070

6B410080

N

R F

6B410090

a

6B410100

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Checking the engine shut-off switch1. Check that the engine turns off when the

engine shut-off switch is pushed or theengine shut-off cord is pulled from theengine shut-off switch.

Checking the cooling water pilothole1. Check that cooling water is discharged

from the cooling water pilot hole.

Test run1. Start the engine, then check that the gear

shift operates smoothly.

2. Check the engine idle speed after theengine has been warmed up.

3. Operate at trolling speed.

4. Perform the break-in procedure up tostep 3 as listed below.

NOTE:The test run is part of the break-in operation.

Break-inDuring the test run, perform the break-inoperation in the following 4 stages.1. 10 minutes a at the lowest possible

speed. A fast idle in neutral is best.

2. 50 minutes b at 1/2 throttle (approxi-mately 3,000 r/min) or less. Vary enginespeed occasionally. On an easy-planingboat, accelerate at full throttle onto plane,then immediately reduce the throttle to3,000 r/min or less.

3. 1 hour c at 3/4 throttle (approximately4,000 r/min). Vary engine speed occa-sionally. Run at full throttle for 1 minute,the allow about 10 minutes of operationat 3/4 throttle or less to let the enginecool.

4. 8 hours d at any speed, but avoid oper-ating at full throttle for more than 5 min-utes at a time. Let the engine coolbetween full-throttle runs. Vary enginespeed occasionally.

å Hours

6B410110

6B410120

6B410130

6B410150

0 1 2 10

Predelivery checks

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1-19

After test run1. Check for water in the gear oil.

2 Check for fuel leakage in the cowling.

3 After a test run and while the engine is atidle, flush the cooling water passageswith fresh water using the flushing kit.

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SPEC

Specifications

General specifications...................................................................................2-1

Maintenance specifications ..........................................................................2-3Power unit .................................................................................................2-3Lower unit ..................................................................................................2-4Electrical ....................................................................................................2-5Dimensions ................................................................................................2-6

Tightening torques.........................................................................................2-8Specified torques .......................................................................................2-8General torques .........................................................................................2-9

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SPEC

2-1 6B45E11

Specifications

General specifications

Item UnitModel

E9.9DHM E15DMHDimensions

Overall length mm (in) 878 (34.6)Overall width mm (in) 363 (14.3)Overall height

(S) mm (in) 1,062 (41.8)(L) mm (in) 1,189 (46.8)(X) mm (in) 1,333 (52.5)

Transom height(S) mm (in) 441 (17.4)(L) mm (in) 568 (22.4)(X) mm (in) 710 (28.0)

Boat transom height(S) mm (in) 381 (15.0)(L) mm (in) 508 (20.0)(X) mm (in) 686 (27.0)

Dry weight(S) kg (lb) 38 (84)(L) kg (lb) 40 (88)(X) kg (lb) 41 (90)

PerformanceMaximum output kW (hp) 7.3 (9.9) @ 5,000 r/min 11.0 (15.0) @ 5,000 r/minFull throttle operating range r/min 4,500–5,500Maximum fuel consumption L (US gal,lmp gal)/hr 6.9 (1.82, 1.52) @ 5,500 r/min 7.7 (2.03, 1.69) @ 5,500 r/minIdle speed r/min 1,000–1,100

Power unitEngine type 2-stroke, TwinTotal displacement cm3 (cu. in) 246 (15.0)Bore x stroke mm (in) 56.0 × 50.0 (2.20 × 1.97)Compression ratio 7.0Control system Tiller handleStarting system Manual starterEnrichment system Choke valveIgnition control system CDIIgnition timing Degree TDC–BTDC 30Maximum generator output (*1) V-W 12–80Spark plug (NGK) B8HS–10, BR8HS–10Cooling system WaterExhaust system Propeller bossLubrication system Pre-mixed fuel (1/50)

(*1) Lighting coil equipped model (option)

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General specifications

Item UnitModel

E9.9DHM E15DMHFuel and oil

Fuel type Regular gasolineEngine oil 2-stroke outboard motor oilEngine oil grade NMMA-certified TC-W3Gear oil type Hypoid gear oilGear oil grade (*2) API GL-4

SAE 90Gear oil quantity L (US oz, 0.25 (8.5, 8.8)

lmp oz)Bracket unit

Trim angle (*3) Degree 8, 12, 16, 20Tilt-up angle Degree 67Steering angle Degree 40 + 40

Drive unitGear shift positions F-N-RGear ratio 2.08 (27/13)Reduction gear type Spiral bevel gearClutch type Dog clutchPropeller shaft type SplinePropeller direction (rear view) ClockwisePropeller ID mark J

(*2) Meeting both API and SAE requirements(*3) At 12–degree boat transom

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SPEC

2-3 6B45E11

Specifications

Maintenance specificationsPower unit

Item UnitModel

E9.9DHM E15DMHPower unit

Minimum compression kPa 560 (5.6, 81.6)pressure (*1) (kgf/cm2, psi)

Cylinder headWarpage limit mm (in) 0.1 (0.004)

(lines indicate straightedgeposition)

CylinderBore size mm (in) 56.00–56.02 (2.20–2.21)Wear limit mm (in) 56.1 (2.21)Taper limit mm (in) 0.08 (0.0031)Out-of-round limit mm (in) 0.05 (0.0020)

PistonPiston diameter (D) mm (in) 55.940–55.985 (2.2024–2.2041)Measuring point (H) mm (in) 10 (0.394)

Piston-to-cylinder clearance mm (in) 0.035–0.040 (0.0014–0.0016)Piston pin boss bore mm (in) 14.004–14.015 (0.5513–0.5518)Piston over size (1st) mm (in) + 0.25

mm (in) 56.190–56.235 (2.2122–2.2139)(2nd) mm (in) + 0.50

mm (in) 56.440–56.485 (2.2220–2.2238)Piston pin

Outside diameter mm (in) 13.996–14.000 (0.5510–0.5512)Piston ringsTop ring

Dimension B mm (in) 1.98–2.00 (0.078–0.079)Dimension T mm (in) 2.4–2.6 (0.09–0.10)End gap mm (in) 0.15–0.35 (0.0059–0.0138)Side clearance mm (in) 0.02–0.06 (0.0008–0.0024)

2nd ringDimension B mm (in) 1.96–1.98 (0.077–0.078)Dimension T mm (in) 2.4–2.6 (0.09–0.10)End gap mm (in) 0.15–0.35 (0.0059–0.0138)Side clearance mm (in) 0.04–0.08 (0.0016–0.0031)

Reed valveValve stopper height mm (in) 1.2–1.4 (0.00473–0.0550) 5.9–6.1 (0.2323–0.2402)Valve vending limit mm (in) 0.2 (0.0078)

(*1) Measuring conditions:Ambient temperature 20°C (68°F), wide open throttle, with spark plugs removed from all cylinders.The figures are for reference only.

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Maintenance specifications

Item UnitModel

E9.9DHM E15DMHConnecting rod

Small end inside diameter mm (in) 18.000–18.011 (0.7087–0.7091)Big end inside diameter mm (in) 28.039–28.052 (1.1039–1.1044)

CrankshaftCrank width (A) mm (in) 46.90–46.95 (1.8465–1.8484)

(B) mm (in) 25.9–26.1 (1.0197–1.0276)

Crankpin diameter mm (in) 20.028–20.039 (0.788–0.789)Runout limit (D) mm (in) 0.03 (0.0012)Big end side clearance (E) mm (in) 0.3–0.8 (0.0118–0.0315)Maximum small end axial play (F) mm (in) 2.0 (0.08)

CrankcaseMain journal inside diameter mm (in) 51.952–51.977 (2.045–2.046)

ThermostatOpening temperature °C (°F) 48–52 (118–126)Fully open temperature °C (°F) 60 (140)Valve open lower limit mm (in) 3 (0.12)

CarburetorID mark 6B300 6B400Float height mm (in) 12.5–15.5 (0.49–0.55)Valve seat size mm (in) 1.2 (0.05)Main jet (M.J.) #110 #108Main nozzle (M.N.) mm (in) 3 (0.12)Main air jet (M.A.J.) #120Pilot jet (P.J.) #48Pilot air jet (P.A.J.) #75Pilot screw (P.S.) turns out 7/8–1 3/8

Manual starterStarter rope length mm (in) 1,850–2,050 (72.8–80.7)

Lower unit

Item UnitModel

E9.9DHM E15DMHGear backlash

Pinion forward mm (in) 0.19–0.86 (0.0075–0.0339)Pinion reverse mm (in) 0.96–1.65 (0.0378–0.0650)Pinion shims mm 1.13, 1.2Forward shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50Reverse shims mm 0.10, 0.20, 0.30, 0.40, 0.50

A

D DE

F

B

6B45E11-02 12/9/02 17:33 Page 5

SPEC

2-5 6B45E11

Specifications

Electrical

Item UnitModel

E9.9DHM E15DMHIgnition system

Ignition timing Degree BTDC 30Ignition spark gap mm (in) 6 (0.24)Spark plug cap resistance kΩ 4.0–6.0Ignition coil resistancePrimary coil (O–B) Ω 0.16–0.24Secondary coil(spark plug wire–spark plug wire) kΩ 3.92–5.88Pulser coil peak voltage@ Cranking (no load) V 4.0@ Cranking (load) V 5.0@ 1,500 r/min (load) V 11.0@ 3,500 r/min (load) V 22.0Pulser coil resistance (W/G–B) Ω 232–348Charge coil peak voltage@ Cranking (no load) V 190@ Cranking (load) V 180@ 1,500 r/min (load) V 250@ 3,500 r/min (load) V 200Charge coil resistance (Br–L) Ω 248–372CDI unit output peak voltage(O–B)@ Cranking (no load) V 160@ Cranking (load) V 160@ 1,500 r/min (load) V 230@ 3,500 r/min (load) V 180

Lighting systemLighting voltage(minimum) @3,000 V 11.5(maximum) @5,500 V 14.0–17.5Lighting coil peak voltage@ Cranking (no load) V 7.0@ 1,500 r/min (no load) V 18.0@ 3,500 r/min (no load) V 37.0Lighting coil resistance (G–G) Ω 0.16–0.24

6B45E11-02 12/9/02 17:33 Page 6

6B45E11 2-6

987654321

Maintenance specifications

357 (14.0)

162 (6.4)

6B4001M

356

(14.

0)13

5 (5

.3)

133

(5.2

)

34 (

1.4)

24 (

0.9)

17 (

0.7)

474

(18.

7)

S:5

69 (

22.4

)L

:638

(25

.2)

S:7

06 (

27.8

)L

:833

(32

.8)

S:4

41 (

17.4

)L

:568

(22

.4)

S:79 (3.1)L:78 (3.1)

L:4 (0.2)

555

(21.

9)

190

(7.5

)17

3 (6

.8) 14

5 (5

.7)

185

(7.3

)

493

(19.

4)28

0 (1

1.0)

334 (13.2)

165 (6.5)

473 (18.6)

405 (15.9)

73 (2.9)

708 (27.9)

X:7

14 (

28.1

)

X:9

75 (

38.4

)

X:7

10 (

28.0

)

X:14 (0.6)

X:78 (3.1)

DimensionsExterior

mm (in)

6B45E11-02 12/9/02 17:33 Page 7

SPEC

2-7 6B45E11

Specifications

92.6 (3.6)

2 (0.1)

106.3 (4.2)

67.3 (2.6) 67.3 (2.6)

92.6 (3.6) 30 (1.2)

60 (2.4)

6B4002M

79 (

3.1)

8.3 (0.3)

50 (

2.0)

157

(6.2

)

106.3 (4.2)

Clamp bracket

mm (in)

6B45E11-02 12/9/02 17:33 Page 8

6B45E11 2-8

987654321

Maintenance specifications/Tightening torques

Tightening torquesSpecified torques

Part to be tightened Thread sizeTightening torques

N·m kgf·m ft·lbPower unit

Crankcase bolt1st

M815 1.5 11

2nd 29 2.9 22

Cylinder head bolt1st

M78 0.8 5.8

2nd 16 1.6 12

Cylinder head cover bolt1st

M66 0.6 4.4

2nd 12 1.2 8.7

Exhaust outer cover bolt1st

M66 0.6 4.4

2nd 12 1.2 8.7Flywheel nut (M12) 100 10 74Throttle link screw M4 1.3 0.13 0.9Power unit mount bolt M8 22 2.2 16

Thermostat cover bolt1st

M66 0.6 4.4

2nd 12 1.2 8.7Engine shut-off switch nut (M16) 3.5 0.4 2.5Spark plug M14 25 2.5 18Intake silencer bolt M5 2.5 0.3 2.2DRIVE UNITExhaust guide bolt M6 12 1.2 8.7Drain screw M8 9.0 0.9 6.6Pinion nut (M8) 25 2.5 18Propeller nut (M10) 17 1.7 12BRACKET UNITGrease nipple (M6) 3 0.3 2.2Lower rubber mount cover nut M8 20 2.0 14Clamp bracket through nut (M12) 12 1.2 9.0Throttle grip mount screw M5 1.6 0.16 1.2Tilt support pivot nut (M6) 12 1.2 8.7Ground lead screw M6 2.5 0.2 1.8Upper rubber mount nut (M8) 21 2.1 15

6B45E11-02 12/9/02 17:33 Page 9

2-9 6B45E11

SPEC Specifications

General torquesThis chart specifies tightening torques forstandard fasteners with a standard ISOthread pitch. Tightening torque specificationsfor special components or assemblies areprovided in applicable sections of this manu-al.To avoid warpage, tighten multi-fastenerassemblies in a crisscross fashion and pro-gressive stages until the specified torque isreached. Unless otherwise specified, torquespecifications require clean, dry threads.Components should be at room temperature.

General torqueNut (A) Bolt (B) specifications

N·m kgf·m ft·lb8 mm M5 5 0.5 3.6

10 mm M6 8 0.8 5.812 mm M8 18 1.8 1314 mm M10 36 3.6 2617 mm M12 43 4.3 31

6B45E11-02 12/9/02 17:33 Page 10

6B45E11

987654321

3

1Periodic checks and adjustments

Special service tools......................................................................................3-1

Maintenance interval chart............................................................................3-2

Fuel system ....................................................................................................3-3Checking the fuel joint and fuel hoses (fuel joint to carburetor) ................3-3Checking the fuel filter ...............................................................................3-3

Power unit .......................................................................................................3-3Checking the spark plugs ..........................................................................3-3Checking the thermostat............................................................................3-4Checking the cooling water passages .......................................................3-4

Control system ...............................................................................................3-5Checking the throttle cable operation ........................................................3-5Checking the gearshift operation...............................................................3-5Checking the start-in-gear protection ........................................................3-5Checking the engine idle speed ................................................................3-6Checking the ignition timing.......................................................................3-6

Bracket ............................................................................................................3-7Checking the tilt operation .........................................................................3-7

Lower unit .......................................................................................................3-7Checking the gear oil level.........................................................................3-7Replacing the gear oil................................................................................3-8Checking the lower unit for air leakage .....................................................3-8Checking the propeller...............................................................................3-9

General ............................................................................................................3-9Checking the anode...................................................................................3-9Checking the top cowling...........................................................................3-9Lubricating the outboard motor..................................................................3-9

CHKADJ

6B45E11-03 12/9/02 17:33 Page 1

CHKADJ

6B45E113-1

Special service tools

Periodic checks and adjustmentsCHKADJ

Digital tachometer90890-06760

Timing light90890-03141

Leakage tester90890-06840

6B45E11-03 12/9/02 17:33 Page 2

6B45E11

987654321

3-2

3

1Maintenance interval chartUse the following chart as a guideline for general maintenance.Adjust the maintenance intervals according to the operating conditions of the outboard motor.

Maintenance interval chart

Initial Every ReferItem Remarks 10 hours 50 hours 100 hours 200 hours to

(Break-in) (3 months) (6 months) (1 year) page

Spark plug Cleaning/Adjustment/Replacement 1 1 1 3-3

Greasing points Greasing 1 3-9Gear oil Change 1 1 3-7Fuel system Inspection 1 3-3Fuel filter Cleaning/Replacement 1 1 1 3-3Separate fuel tank *1 Cleaning 1 —Idling speed Adjustment 1 3-6Anode Inspection/Replacement 1 3-9Outboard motor exterior Inspection 1 1 3-9Cooling water passages *2 Cleaning 1 1 3-4

Propeller and cotter pin Inspection/Replacement 1 1 3-9Carburetor setting Inspection/Adjustment 1 1 4-9Ignition timing Inspection 1 1 3-6Bolts and nuts Retightening 1 1 —

NOTE:(*1) If equipped.(*2) When operating in salt water, turbid or muddy water, the engine should be flushed with clean

water after each use.

6B45E11-03 12/9/02 17:33 Page 3

CHKADJ

3-3 6B45E11


Fuel systemChecking the fuel joint and fuelhoses (fuel joint to carburetor)1. Check the fuel hose connections and fuel

joint 1 for leaks. Replace if necessary.Also, check the fuel filter 2, fuel pump 3and carburetor 4 for leaks, and the fuelhoses for leaks and deterioration.Replace if necessary.

Checking the fuel filter1. Check the fuel filter element 1 for dirt

and residue and check the fuel filter cup2 for foreign substances and cracks.Clean with straight gasoline and replacethe cup if necessary.

NOTE:Be sure not to spill any fuel when removingthe fuel filter cup.

Power unitChecking the spark plugs1. Disconnect the high-tension cords, then

remove the spark plugs.

2. Clean the electrodes 1 with a spark plugcleaner or wire brush. Replace the sparkplug if necessary.

3. Check the electrodes for erosion andexcessive carbon or other deposits, andthe gasket for damage. Replace thespark plug if necessary.

4. Check the spark plug gap a. Adjust if outof specification.

1

2

3

4

6B430010

Spark plug gap a:0.9–1.0 mm (0.03–0.04 in)

6B430030

a

6B430025

1

6B430020

2

1

Specified spark plug:B8HS-10 (NGK)BR8HS-10 (NGK)

6B45E11-03 12/9/02 17:33 Page 4

6B45E11 3-4

987654321

5. Install the spark plug, tighten it fingertight b, then to the specified torque witha spark plug wrench c.

Checking the thermostat1. Remove the thermostat cover 1, gasket

2, and thermostat 3.

2. Suspend the thermostat in a container ofwater.

3. Place a thermometer in the water andslowly heat the water.

4. Check the thermostat valve opening atthe specified water temperatures.Replace if out of specification.

5. Install the thermostat, new gasket, andthermostat cover.

Checking the cooling water passages1. Check the cooling water inlet cover 1

and cooling water inlet for clogging.Clean if necessary.

2. Place the lower unit in water, then startthe engine.

Spark plug:25 N·m (2.5 kgf·m, 18 ft·lb)

6B430060

6B430050

21

3

6B430090

1

6B430070

Fuel system/Power unit

b

c 6B430040

Water temperature Valve lift abelow

50°C (122°F)0 mm (0 in)

above more than60°C (140°F) 3 mm (0.12 in)

6B45E11-03 12/9/02 17:33 Page 5

CHKADJ

3-5 6B45E11


3. Check for water flow at the cooling waterpilot hole. If there is no water flow, checkthe cooling water passages.

Control systemChecking the throttle cable operation1. Check the throttle cables for smooth

operation, looseness, fraying or damage.Replace if necessary.

2. With the throttle grip in the fully closedposition, check that the throttle stopscrew comes in contact with the throttlestopper plate. Adjust if necessary.

Checking the gearshift operation1. Check that the gearshift operates

smoothly when shifting from neutral intoforward and reverse. Adjust the shift rod ifnecessary.

Checking the start-in-gear protection

cCBe sure to remove the engine shut-offswitch clip before checking the start-in-gear protection.

1. Set the shift lever in the forward orreverse position, then pull the starterhandle.

2. Check the operation of the start-in-gearprotection cable. If the starter rope can bepulled out normally, adjust the start-in-gear protection cable.

NOTE:If the starter rope cannot be pulled out, thestart-in-gear protection is working correctly.

3. Set the shift lever in the neutral positionand loosen the lock nut 1. Align thestarter plunger 2 with the mark a on thestarter case to adjust the cable adjuster.

6B410130

6B430110

6B430310

12a

N

R F

6B410090

6B45E11-03 12/9/02 17:33 Page 6

Timing light: 90890-03141

Checking the engine idle speed1. Start the engine and warm it up for 5 min-

utes.

2. Attach the special service tool to high-tension cord #1 1, then check the engineidle speed. Adjust if out of specification.

3. Turn the throttle stop screw 2 in directiona or b until the specified engine idlespeed is obtained.

NOTE:9 To increase the idle speed, turn the throttle

stop screw in direction a.9 To decrease the idle speed, turn the throttle

stop screw in direction b.

4. After adjusting the idle speed, rev theengine a few times and let it idle for atleast 15 seconds to check the stability ofthe engine.

6B45E11 3-6

987654321

Control system

1

6B430120

1

6B430150

6B430160

Digital tachometer: 90890-06760

Engine idle speed:1,000–1,100 r/min

Digital tachometer: 90890-06760

Engine idle speed:1,000–1,100 r/min

Checking the ignition timing1. Start the engine and warm it up for 5 min-

utes.

2. Attach the special service tool to high-tension cord #1 1, and then check theengine idle speed.

3. Attach the special service tool to high-tension cord #1 1.

1

6B430120

bb

2

aa

6B430130

6B45E11-03 12/9/02 17:34 Page 7

2. Fully tilt the outboard motor up, then sup-port it with the tilt support lever 1 tocheck the lock mechanism of the lever.

Lower unitChecking the gear oil level1 Fully tilt the outboard motor down.

2. Remove the check screw 1, then checkthe gear oil level in the lower case.

NOTE:The gear oil level should be at the brim of thecheck hole.

3. If necessary, add sufficient gear oil of therecommended type to the correct level.

4. Install the check screw, then tighten it tothe specified torque.

Recommended gear oil:Hypoid gear oilSAE: 90

CHKADJ

3-7 6B45E11


6B4301901

6B430195

1

Check screw:9 N·m (0.9 kgf·m, 6.6 ft·lb)

4. Check that the TDC line a on the fly-wheel magnet is aligned with the lineabove the starter case window b.

BracketChecking the tilt operation1. Fully tilt the outboard motor up and down

a few times and check the entire tilt rangefor smooth operation. Check the tiltmechanism if necessary.

6B430170

bb

aa

6B430180

6B45E11-03 12/9/02 17:34 Page 8

5. Install the check screw, quickly install thedrain screw, then tighten them to the spec-ified torque.

Checking the lower unit for air leak-age

cCDo not over pressurize the lower unit, oth-erwise the oil seals may be damaged.

1. Remove the check screw 1, then installthe special service tool.

2. Apply the specified pressure to checkwhether the lower unit can hold it for atleast 10 seconds.

3. If pressure drops below specification,check the drive shaft, propeller shaft oilseals, shift rod, and drain screw for dam-age.

6B45E11 3-8

987654321

Replacing the gear oil1. Fully tilt the outboard motor down.

2. Place a drain pan under the drain screw3, remove the drain screw, then thecheck screw 4 to drain the oil.

3. Check the oil for metal, discoloration, andviscosity. Check the internal parts of thelower case if necessary.

4. Insert the gear oil tube into the drain holeand slowly fill the gear oil until oil flowsout of the check hole and no air bubblesare visible.

3

4

6B430200

6B430210

Leakage tester: 90890-06840

Bracket/Lower unit

Check and drain screw:9 N·m (0.9 kgf·m, 6.6 ft·lb)

Lower unit holding pressure:100 kPa (1.0 kgf/cm2, 14 psi)

6B430220

1


Oil quantity:0.25 L (8.5 US oz, 8.8 Imp oz)

6B45E11-03 12/9/02 17:34 Page 9

CHKADJ

3-9 6B45E11


2. Check the top cowling for cracks or otherdamage. Replace if necessary.

3. Check the hooks and rivets for wear ordamage. Repair if necessary.

4. Check the rubber trim for wear, deteriora-tion or damage. Replace if necessary.

5. Check the lock mechanism for wear ordamage. Repair if necessary.

Lubricating the outboard motor1. Apply water resistant grease to the areas

shown.

6B430260

6B430290

6B430270

Checking the propeller1. Check the propeller blades and splines

for cracks, damage, or wear. Replace ifnecessary.

GeneralChecking the anode1. Check the anode for scales, grease, and

oil. Clean if necessary.

cCDo not oil, grease, or paint the anode, oth-erwise it will be ineffective.

2. Replace the anode if excessively eroded.

Checking the top cowling1. Check the fitting of the top cowling by

pushing on it with both hands.

6B430230

6B430240

6B430250

6B45E11-03 12/9/02 17:34 Page 10

6B45E11 3-10

987654321

NOTE:Apply grease to the grease nipple until it flowsfrom the bushings a.

2. Apply corrosion resistant grease to thearea shown.

6B430300

6B430280

a

General

6B45E11-03 12/9/02 17:34 Page 11

CHKADJ

3-11 6B45E11

— MEMO —

6B45E11-03 12/9/02 17:34 Page 12

6B45E11

987654321

Fuel system


Hose routing ...................................................................................................4-2Fuel hoses and cooling water hose...........................................................4-2

Intake silencer, carburetor.............................................................................4-3

Fuel filter, fuel joint ........................................................................................4-4Checking the fuel joint ...............................................................................4-5Checking the fuel filter ...............................................................................4-5

Carburetor, fuel pump....................................................................................4-6Disassembling the carburetor ....................................................................4-8Checking the carburetor ............................................................................4-8Assembling the carburetor.........................................................................4-9Disassembling the fuel pump ....................................................................4-9Assembling the fuel pump .........................................................................4-9

FUEL

6B45E11-04 12/9/02 17:34 Page 1

FUEL

4-1 6B45E11

Fuel system


Vacuum/pressure pump gauge set90890-06756

Digital caliper90890-06704

6B45E11-04 12/9/02 17:34 Page 2

6B45E11 4-2

987654321

Special service tools/Hose routing

Hose routingFuel hoses and cooling water hose

1 Fuel hose (fuel joint to fuel filter)2 Fuel hose (fuel filter to fuel pump)3 Pilot water hose

1

2

3

6B440010

6B45E11-04 12/9/02 17:34 Page 3

FUEL

4-3 6B45E11

Fuel system

Intake silencer, carburetor

3 N·m (0.3 kgf·m, 2.2 ft·lb)

8 N·m (0.8 kgf·m, 5.8 ft·lb)

6B44010E2.5 N·m (0.3 kgf·m, 2.2 ft·lb)

No. Part name Q’ty Remarks1 Intake silencer 12 O-ring 13 Screw 2 M5 × 28 mm4 Bolt 2 M6 × 95 mm5 Carburetor 16 Choke knob 17 Grommet 18 Seal 1

Not reusable

6B45E11-04 12/9/02 17:34 Page 4

6B45E11 4-4

987654321

Intake silencer, carburetor/Fuel filter, fuel joint

Fuel filter, fuel joint

6B44020E

18 N·m (1.8 kgf·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)

No. Part name Q’ty Remarks1 Fuel joint 12 Bolt 1 M6 × 10 mm3 Fuel filter 14 Nut 15 Hose 16 Hose 17 Clip 48 Bracket 19 Bolt 1 M6 × 20 mm10 Fuel filter cap 111 Fuel filter cup 112 Fuel filter element 113 O-ring 1 Not reusable

6B45E11-04 12/9/02 17:34 Page 5

FUEL

4-5 6B45E11

Fuel system

Checking the fuel joint1. Visually check the fuel hose connector for

cracks or damage.

2. Connect the special service tool at theoutlet of fuel hose connector.

3. Apply the specified pressure to checkthat the pressure is maintained for 10seconds. Replace the fuel hose connec-tor if necessary.

Checking the fuel filter1. Check the fuel filter element 3 for clog-

ging, contamination, or foreign sub-stances, and check the fuel filter cup 4for cracks or leakage. Clean with straightgasoline, or replace if necessary.

NOTE:Apply a thin coat of gasoline to the O-ring 5before assembling the fuel filter cup.

6B440020

Vacuum/pressure pump gauge set:90890-06756

Fuel hose connector holding pres-sure:

50 kPa (0.5 kgf/cm2)

4

3

5

6B440030

6B45E11-04 12/9/02 17:34 Page 6

6B45E11 4-6

987654321

Carburetor, fuel pump

6B44030E

No. Part name Q’ty Remarks1 Carburetor body 12 Pilot air screw 13 Spring 14 Plate 15 Gasket 16 Screw 4 M4 × 10 mm7 Pilot jet 18 Rubber cap 19 Throttle stop screw 110 Spring 111 O-ring 112 Float chamber 113 Main nozzle 114 Main jet 115 Screw 4 M4 × 16 mm16 Gasket 117 Drain screw 1

Not reusable

Not reusable

Not reusable

Fuel filter, fuel joint/Carburetor, fuel pump

6B45E11-04 12/9/02 17:34 Page 7

No. Part name Q’ty Remarks18 Float 119 Needle valve set 120 Screw 121 Nut 122 Screw 4 M4 × 25 mm23 Fuel pump cover 124 Diaphragm 125 Fuel pump body 126 Diaphragm 127 Gasket 128 Seat valve 129 Joint 1

Not reusable

Not reusable

Not reusable

FUEL

4-7 6B45E11

Fuel system

6B44030E

6B45E11-04 12/9/02 17:34 Page 8

6B45E11 4-8

987654321

Carburetor, fuel pump

Disassembling the carburetor

NOTE:9Write down how many turns you have actu-

ally turned out the pilot screw.9 Disassembled jets and other components

should be sorted out and kept in order, sothat they can be re-assembled in their orig-inal positions.

Checking the carburetor1. Clean the fuel and air passages and the

carburetor body, and blow off any clog-ging with compressed air.

wWear appropriate protective eye gear dur-ing the cleaning process to prevent anyeye injury by the blown-off debris or liq-uid.

cCDo not use steel wire and the like forcleaning the carburetor. Do not try to dis-assemble the main nozzle if it does notcome out easily. Excessive force may seri-ously impair performance.

NOTE:Clean the needle valve, main jet, and pilot jetafter removal.

2. Check the carburetor body for cracks ordamage. Replace if necessary.

3. Check the pilot screws and needle valvesfor bending or stepped wear. Replace ifnecessary.

4. Check the main jet, pilot jet, and mainnozzle for clogging and contamination.Clean or replace whenever appropriate.

5. Check the float for damage, and makesure it is at the appropriate height a.Replace the float or needle or both if nec-essary.

NOTE:9 Measure the float height as shown.9 The float should be resting on the needle

valve, but not compressing it.9 Measure the distance a from the carbure-

tor mating face to the float bottom. Turn thecarburetor upside-down to make the mea-surement.

6B440040

a

6B440050

Vertical position of the float a:12.5–15.5 mm (0.49–0.55 in)

6B45E11-04 12/9/02 17:34 Page 9

FUEL

4-9 6B45E11

Fuel system

Assembling the carburetorRefer to the following points when assem-bling the carburetor.

cC9 Do not apply excessive force to push in

the needle valve.9 Do not apply excessive force to screw in

the pilot screw.

NOTE:Install the pilot screw 1 and turn it in until itis lightly seated, then turn it out by the speci-fied number of turns.

Disassembling the fuel pump1. Remove the fuel pump from the carbure-

tor and disassemble it to check thediaphragms and gasket for damage orbreakage.

2. Check the seat valve for bending or dam-age. Also check the fuel pump body fordamage.

3. Clean out the fouling on the fuel pumpbody.

Assembling the fuel pump

NOTE:Clean the parts, and keep the seat valve andthe diaphragm in gasoline before assembly toobtain prompt operation of the pump whenthe engine starts.

1. Mount the seat valves on the pump body.

2. Mount the diaphragms, gasket, andcover.

NOTE:Use the bolts to keep the gasket anddiaphragms in place while assembling thefuel pump.

Pilot screw 1 turn-out:7/8–1 3/8

6B440070

6B440090

6B440080

1

6B440060

6B45E11-04 12/9/02 17:34 Page 10

6B45E11 4-10

987654321

— MEMO —

6B45E11-04 12/9/02 17:34 Page 11

POWR

6B45E11

Power unit


Power unit .......................................................................................................5-4Checking the compression pressure .........................................................5-4

Removing the power unit ............................................................................5-11Removing the flywheel magnet ...............................................................5-12Removing the electrical components.......................................................5-12Disassembling the oil seal housing .........................................................5-12Checking the oil seal housing..................................................................5-13Assembling the oil seal housing ..............................................................5-13Disassembling the manual starter ...........................................................5-14Checking the spiral spring .......................................................................5-14Checking the drive pawl...........................................................................5-14Checking the drain hose..........................................................................5-15Measuring the starter rope ......................................................................5-15Assembling the manual starter ................................................................5-15

Reed valve.....................................................................................................5-17Removing the reed valve assembly.........................................................5-18Checking the reed valves ........................................................................5-18

Cylinder head, exhaust covers ...................................................................5-19Removing the exhaust covers .................................................................5-20Checking the exhaust covers...................................................................5-20Removing the cylinder head ....................................................................5-20Checking the anode and cylinder head ...................................................5-21

Cylinder block...............................................................................................5-22Removing the crankcase .........................................................................5-23Removing the crankshaft assembly.........................................................5-23Checking the cylinder block .....................................................................5-24

Crankshaft, piston........................................................................................5-25Disassembling the piston.........................................................................5-26Checking the pistons ...............................................................................5-26Disassembling the crankshaft..................................................................5-28Assembling the crankshaft.......................................................................5-30Checking the crankshaft ..........................................................................5-34Assembling the piston..............................................................................5-34Installing the crankshaft ...........................................................................5-35Installing the crankcase ...........................................................................5-35Installing the cylinder head ......................................................................5-35Installing the exhaust covers ...................................................................5-37Installing the reed valve ...........................................................................5-37Installing the electrical components.........................................................5-37

6B45E11-05 12/9/02 17:35 Page 2

6B45E11

987654321

Installing the throttle cam assembly ........................................................5-37Installing the spark plugs .........................................................................5-38Installing the flywheel assembly ..............................................................5-38Installing the manual starter ....................................................................5-38Installing the carburetor ...........................................................................5-38Installing the fuel filter and hoses ............................................................5-38Installing the oil seal housing ..................................................................5-39Installing the power unit ...........................................................................5-39Installing the throttle cables .....................................................................5-39Installing the throttle link ..........................................................................5-40Installing the start-in-gear protection cable .............................................5-40

6B45E11-05 12/9/02 17:35 Page 3

POWR

5-1 6B45E11

Power unit


Compression gauge90890-03160

Flywheel holder90890-06522

Flywheel puller90890-06521

Crankshaft aligner90890-03107

Driver rod L390890-06652

Needle bearing attachment90890-06609, 90890-06616

Bearing Separator90890-06534

Crank jig set 90890-02421

Flange90890-02351

Body90890-02352

6B45E11-05 12/9/02 17:35 Page 4

6B45E11 5-2

987654321


Bolt90890-02353

Washer90890-02354

Bushing-5 (B-5)90890-02359

B-5

Bushing-7 (B-7)90890-02361

B-7

Bushing-11 (B-11)90890-02365

B-11

Height ring-5 (H-5)90890-02371

H-5

Height ring-13 (H-13)90890-02379

H-13

Pressure plate90890-02384

Press body90890-02385

Plate A90890-02386

6B45E11-05 12/9/02 17:35 Page 5

POWR

5-3 6B45E11

Power unit

Plate B90890-02387

Pressure pin A90890-02389

A

Bearing pressure B90890-02392

B

Support90890-02394

Spacer B90890-02396

B

Bearing inner race attachment90890-06644

Small end bearing installer90890-06543

6B45E11-05 12/9/02 17:35 Page 6

6B45E11 5-4

987654321

Special service tool/Power unit

Power unitChecking the compression pressure1. Start the engine, warm it up for 5 min-

utes, and then turn it off.

2. Remove the engine shut-off cord from theengine shut-off switch.

3. Remove both spark plugs, then install thespecial service tool to the #1 spark plughole.

cCBefore removing the spark plugs, blowcompressed air in the spark plug well toclear out any dirt or dust that may fall intothe cylinder.

4. Fully open the throttle, pull the starterrope, and check the compression pres-sure 3 times.

NOTE:Do not pull the choke knob when checkingthe compression pressure.

5. If the measured compression pressure isbelow specification, or it varies amongthe cylinders, add a small amount ofengine oil to the cylinder, and check thepressure again.

NOTE:9 If the compression pressure increases,

check the piston, piston rings and cylinderbore for wear. Replace if necessary.9 If the compression pressure does not

change, check the cylinder head gasketand cylinder head. Correct or replace if nec-essary.

Compression gauge 1:90890-03160

1

6B450010

Minimum compression pressure(reference data):

560 kPa (5.6 kgf/cm2, 81.6 psi)

6B45E11-05 12/9/02 17:35 Page 7

POWR

5-5 6B45E11

Power unit

6B45010E

8 N·m (0.8 kgf·m, 5.8 ft·lb)

22 N·m (2.2 kgf·m, 16 ft·lb)

No. Part name Q’ty Remarks1 Power unit 12 Hose 13 Clip 14 Throttle cable 25 Bolt 1 M6 × 10 mm6 Engine shut-off switch lead 17 Link 18 Choke knob 19 O-ring 110 Spacer 111 Oil seal 112 Oil seal 213 Oil seal housing 114 Gasket 115 Dowel 216 Bolt 6 M8 × 50 mm17 Bolt 1 M6 × 16 mm

Not reusable

Not reusable

Not reusable

Not reusable

6B45E11-05 12/9/02 17:35 Page 8

6B45E11 5-6

987654321

Power unit

6B45020E

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)

No. Part name Q’ty Remarks1 Start-in-gear protection cable 12 Starter case 13 Rope guide 14 Rope guide 15 Collar 36 Sheave drum 17 Drive pawl 18 Spiral spring 19 Drive plate 110 Spring 111 Spring 112 Return spring 113 Circlip 114 Bolt 1 M6 × 15 mm15 Starter rope 116 Stopper 117 Starter plunger 1

6B45E11-05 12/9/02 17:35 Page 9

POWR

5-7 6B45E11

Power unit

6B45020E

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)

No. Part name Q’ty Remarks18 Spring 119 Cotter pin 120 Washer 121 Cover 122 Starter handle 123 Damper 124 Rubber seal 125 Drain hose 126 Bolt 2 M6 × 30 mm27 Bolt 3 M6 × 25 mm28 Hose 1

Not reusable

6B45E11-05 12/9/02 17:35 Page 10

6B45E11 5-8

987654321

Power unit

6B45030E

100 N·m (10.0 kgf·m, 74 ft·lb)

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)

No. Part name Q’ty Remarks1 Flywheel magnet assembly 12 Woodruff key 13 Washer 14 Nut 15 Charge coil 16 Bolt 2 M6 × 20 mm7 Pulser coil 18 Bolt 2 M6 × 16 mm9 Clamp 110 Lighting coil 1 [option]11 Collar 2 [option]12 Bolt 2 M6 × 40 mm [option]

6B45E11-05 12/9/02 17:35 Page 11

POWR

5-9 6B45E11

Power unit

6B45040E

8 N·m (0.8 kgf·m, 5.8 ft·lb)

8 N·m (0.8 kgf·m, 5.8 ft·lb)

No. Part name Q’ty Remarks1 Ignition coil 12 Bolt 2 M6 × 16 mm3 Bracket 14 Bolt 2 M6 × 14 mm5 CDI unit 16 Bolt 2 M6 × 20 mm7 Clamp 18 Clamp 19 Clamp 110 Tube 111 Spark plug cap 2 #1: z, #2: x

6B45E11-05 12/9/02 17:35 Page 12

6B45E11 5-10

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Power unit

6B45050E

8 N·m (0.8 kgf·m, 5.8 ft·lb)

No. Part name Q’ty Remarks1 Throttle cable stay 12 Collar 13 Bolt 1 M6 × 65 mm4 Free axle lever 15 Spring 16 Bolt 1 M6 × 12 mm7 Pully 18 Joint 1

6B45E11-05 12/9/02 17:35 Page 13

POWR

5-11 6B45E11

Power unit

Removing the power unit1. Remove the manual starter assembly 1

and start-in-gear protection cable 2.

NOTE:If the power unit is to be disassembled, it isrecommended to loosen the nut on the fly-wheel magnet assembly before removing thepower unit to improve working efficiency.

2. Disconnect the engine shut-off switchlead and CDI unit lead.

3. Remove the intake silencer.

4. Disconnect the choke link rod 3 andthrottle rink rod 4.

5. Disconnect the throttle cables and shiftlink rod 5.

6. Remove the carburetor, fuel filter andbracket.

7. Disconnect the pilot water hose 6.

8. Lift up the power unit after removing thebolts. Remove the dowels 7.

9. Remove the bolt and oil seal housing 8.

6B450040

5

66B450050

6B450060

7

6B45001A

12

6B450030

43

6B450020

6B450070

8

6B45E11-05 12/9/02 17:35 Page 14

6B45E11 5-12

987654321

Removing the power unit

Removing the flywheel magnet1. Remove the nut on the flywheel magnet.

cCApply force in the direction of the arrowsshown.While working, do not allow the fly-wheel holder to slip off the flywheel.

2. Remove the flywheel magnet.

cC9 Screw in the flywheel puller set bolts

evenly to the full extent.9 Make sure the puller plate is set parallel

with the flywheel magnet.

NOTE:Screw in the flywheel puller set bolt until theflywheel magnet comes off completely.

3. Remove the Woodruff key.

Removing the electrical components1. Remove the charge coil 1 and pulser

coil 2.

2. Remove the spark plug caps 3, CDI unit4, ignition coil 5 and spark plugs.

Disassembling the oil seal housing1. Remove the O-ring and oil seals.

Flywheel holder: 90890-06522

Flywheel puller: 90890-06521

6B450080

6B450090

1

2

6B450050

4

53

6B450110

6B450120

6B45E11-05 12/9/02 17:35 Page 15

POWR

5-13 6B45E11

Power unit

Checking the oil seal housing1. Check the oil seal housing for cracks,

damage, or corrosion. Replace if neces-sary.

Assembling the oil seal housing1. Apply grease to the new oil seals, then

install them into the oil seal housing.

2. Apply grease to the new oil seal, theninstall it into the oil seal housing.

3. Install the new O-ring.

6B450130

6B450160

AA

1

2

6B450140

3

4

AA

6B450150

Driver rod L3 1: 90890-06652Needle bearing attachment 2:

90890-06616

Driver rod L3 3: 90890-06652Needle bearing attachment 4:

90890-06609

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6B45E11 5-14

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Disassembling the manual starter1. Remove the drive plate 1 and spring 2.

wThe sheave drum can pop out. Hold thesheave drum with your hand, then pull itout.

2. Remove the sheave drum 3.

wThe spiral spring can pop out. Cover thespiral spring with cloths, then pull out thesheave drum.

3. Remove the spiral spring 4 from thestarter case.

wThe spiral spring can pop out. To removethe spring, cover it with cloths.

4. Remove the starter rope 5.

5. Remove the drive pawl 6 and springs 7from the sheave drum.

Checking the spiral spring1. Check the spiral spring for cracks, bends,

or damage. Replace if necessary.

Checking the drive pawl1. Check the drive pawl for cracks or dam-

age. Replace if necessary.

1

2

6B450170

4

3

6B450180

5

6

7

6B450190

6B450200

6B450210

6B45E11-05 12/9/02 17:35 Page 17

POWR

5-15 6B45E11

Power unit

Checking the drain hose1. Check the drain hose for clogging, cracks

or damage.

Measuring the starter rope1. Measure the starter rope length. Replace

if the length is out of specification.

Assembling the manual starter1. Install the starter rope 1 into the sheave

drum 2.

2. Install the drive pawl 3 and springs 4.

3. Install the manual starter handle 5.

NOTE:9 Tie a knot at the end of the starter rope as

shown in the illustration.9 Be sure to leave 5–10 mm at the end a of

the starter rope.

6B450220

4. Wind the starter rope 1 twice around thesheave drum 2 in the direction of thearrow shown in the illustration.

NOTE:After winding the starter rope around thesheave drum, install the starter rope in thenotch b.

5. Install the spiral spring 6 into the startercase.

NOTE:Bend the outer end c of the spiral springonto the cutout d of the starter case.

1

35

2

4

a

a6B450230

2

1

1

2

b

6B450240

6

c d6B450250

Starter rope length:1,850–2,050 mm (72.8–80.7 in)

6B45E11-05 12/9/02 17:35 Page 18

6. Install the sheave drum 2 into the startercase 7.

NOTE:Install the sheave drum, then set the spiralspring by turning the sheave drum.

7. Install the spring 8 drive plate 9.

8. Turn the sheave drum 2 3 times in thedirection of the arrow shown, and thenremove the starter rope from the notche.

NOTE:Hold the starter plunger 0 while turning thesheave drum as shown.

6B45E11 5-16

987654321


2

7

6B450260

8

9

6B450270

9. Pull the manual starter handle 5 severaltimes to check that the sheave drumturns smoothly and to check the starterrope for slack. Repeat steps 4–8 if nec-essary.

10. Pull the manual starter handle complete-ly, then measure the starter rope length.Adjust if the starter rope length is out ofspecification.

5

6B450290

6B450300

Starter rope length:1,700–1,800 mm (66.9–70.8 in)

0

e

2 6B450280

6B45E11-05 12/9/02 17:35 Page 19

POWR

5-17 6B45E11

Power unit

6B45060E

1 N·m (0.1 kgf·m, 0.7 ft·lb)

3 N·m (0.3 kgf·m, 2.2 ft·lb)

8 N·m (0.8 kgf·m, 5.8 ft·lb)

No. Part name Q’ty Remarks1 Bolt 3 M6 × 20 mm2 Hose 13 Clip 14 Screw 35 Washer 36 Reed valve stopper 27 Reed valve 28 Support 1

Reed valve

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6B45E11 5-18

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Reed valve

Removing the reed valve assembly1. Remove the reed valve assembly.

Checking the reed valves1. Check the reed valves for cracks or dam-

age. Replace if necessary.

2. Check the reed valves for bending.Measure the valve stopper height.Replace if the bending or height exceedsthe specified limit.

6B450310

6B450320

Valve bending limit:0.2 mm (0.08 in)

Valve stopper height:E9.9D:

1.2–1.4 mm (0.00473–0.00550 in)

E15D:5.9–6.1 mm (0.2323–0.2402 in)

6B450330

6B45E11-05 12/9/02 17:35 Page 21

POWR

5-19 6B45E11

Power unit

2 N·m (0.2 kgf·m,1.4 ft·lb)

5 N·m (0.5 kgf·m, 3.6 ft·lb)

12 N·m (1.2 kgf·m, 8.7 ft·lb)

6 N·m (0.6 kgf·m, 4.4 ft·lb)

6 N·m (0.6 kgf·m, 4.4 ft·lb)

12 N·m (1.2 kgf·m, 8.7 ft·lb)

8 N·m (0.8 kgf·m, 5.8 ft·lb)

16 N·m (1.6 kgf·m, 1.2 ft·lb)

6 N·m (0.6 kgf·m, 4.4 ft·lb)

12 N·m (1.2 kgf·m, 8.7 ft·lb)

25 N·m (2.5 kgf·m, 18 ft·lb)

6B45070E

No. Part name Q’ty Remarks1 Spark plug 22 Gasket 13 Cylinder head 14 Gasket 15 Cylinder head cover 16 Gasket 17 Thermostat cover 18 Thermostat 19 Bolt 4 M6 × 25 mm

10 Anode 111 Bolt 6 M6 × 16 mm12 Bolt 11 M7 × 35 mm13 Exhaust outer cover 114 Exhaust inner cover 115 Gasket 1 t = 1.0 mm16 Gasket 1 t = 0.5 mm17 Bolt 13 M6 × 30 mm

Not reusable

Not reusable

Not reusable

Not reusable

Not reusable

Cylinder head, exhaust covers

6B45E11-05 12/9/02 17:35 Page 22

6B45E11 5-20

987654321

Cylinder head, exhaust covers

Removing the exhaust covers1. Remove the exhaust outer and inner cov-

ers.

NOTE:Insert a flat-head screwdriver between thepry tabs to pry off the cover.

Checking the exhaust covers1. Check the exhaust covers for distortion or

corrosion. Replace if necessary.

Removing the cylinder head1. Remove the spark plugs.

2. Remove the thermostat cover and thethermostat.

3. Remove the cylinder head cover.

4. Remove the cylinder head.

6B450340

6B430051

6B450360

6B450970

6B450980

6B45E11-05 12/9/02 17:35 Page 23

POWR

5-21 6B45E11

Power unit

Checking the anode and cylinderhead1. Check the anode on the cylinder block.

Clean the anode’s surface, and replace ifit has been eroded into half its size orsmaller.

cCDo not oil, grease, or the anodes, other-wise they will not be able to prevent gal-vanic corrosion effectively.

2. Clean the mineral deposits and contami-nation on the cylinder head. Also checkfor possible corrosion on the cylinderhead. Replace if necessary.

3. Remove the carbon deposits on the sur-face of the combustion chamber.

cCDo not scratch the mating face of thecylinder head and cylinder block.

4. Check the cylinder head warpage.Replace the cylinder head if measuredwarpage exceeds the specified limit.

NOTE:Check the warpage in the directions shown,using a straightedge and a thickness gauge.

Warpage limit: 0.1 mm (0.004 in)

6B450380

6B450390

6B450370

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6B45E11 5-22

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Cylinder block

6B45080E

8 N·m (0.8 kgf·m, 5.8 ft·lb)

15 N·m (1.5 kgf·m, 11 ft·lb)

29 N·m (2.9 kgf·m, 22 ft·lb)

No. Part name Q’ty Remarks1 Crankcase 12 Washer 13 Cylinder block 14 Crankshaft 15 Oil seal 16 Spacer 17 Dowel pin 28 Bolt 6 M8 × 60 mm9 Hose 210 Clip 411 Joint 212 Arm 113 Collar 114 Spring 115 Bolt 1 M6 × 20 mm16 Joint 1

Not reusable

Cylinder block

6B45E11-05 12/9/02 17:35 Page 25

POWR

5-23 6B45E11

Power unit

Removing the crankcase1. Remove the crankcase.

NOTE:Insert a flat-head screw driver between thepry tabs to pry off the crankcase.

2. Check the crankcase for corrosion. Alsocheck the mating face of the crankcaseand the cylinder block for possible distor-tion.

Removing the crankshaft assembly1. Remove the crankshaft.

6B450400 6B450420

6B450410

6B45E11-05 12/9/02 17:35 Page 26

a: 10 mm (0.039 in) from the cylinder headtop surface

b: 5 mm (0.20 in) above the exhaust portupper edge

c: 5 mm (0.20 in) below the scavenging portlower edge

NOTE:9 Measure the cylinder bore diameter at the 6

positions shown.9 To obtain the cylinder bore diameter (D),

select the largest of the D1-D6 measure-ments.9 Taper (T) is obtained by subtracting D5 from

D1, and D6 from D2 and selecting the max-imum value.9 To obtain the roundness (R), calculate each

of the differences between D1 and D2, D3and D4, and D5 and D6. Use the largest ofthe differences for the roundness (R) figure.9 Oversize pistons are available in two sizes.

6B45E11 5-24

987654321

Cylinder block

Checking the cylinder block

cCDo not scratch the mating face of thecylinder head and cylinder block.

1. Check the cylinder sleeves for cracks ordamage.

2. Remove any rust or deposits on the cool-ing water passage walls, and check forcorrosion. Clean or replace if necessary.

3. Remove the carbon deposits on theexhaust passage walls, and check forcracks or damage. Replace if necessary.

4. Measure the cylinder bore with a cylindergauge. Calculate the cylinder bore diame-ter (D), taper (T), and roundness (R). If theresults exceed the specified limit, reborethe cylinder sleeve, or replace the cylinderblock.

Specified limits Cylinder bore diameter (D):

56.1 mm (2.21 in) at 20°C (68°F)

Taper (T): 0.08 mm (0.0031 in) Out of round (R):

0.05 mm (0.0020 in) at 20°C (68°F)

6B450430

6B450440

Oversize piston:1st: 56.190–56.235 mm

(2.2122–2.2139 in) 2nd: 56.440–56.485 mm

(2.2220–2.2238 in)

6B45E11-05 12/9/02 17:35 Page 27

POWR

5-25 6B45E11

Power unit

6B45090E

A

No. Part name Q’ty Remarks1 Needle bearing 502 Washer 43 Piston pin clip 44 Piston pin 25 Piston 26 Piston ring set 27 Crank 1 18 Bearing 29 Crank 2 110 Roller bearing 111 Labyrinth seal 112 Crank 3 113 Connecting Rod 214 Roller bearing 215 Washer 416 Crank pin 217 Crank 4 1

Crankshaft, piston

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6B45E11 5-26

987654321

Crankshaft, piston

Disassembling the piston1. Remove the piston pin clip, and then

remove the piston pin.

2. Separate the piston from the connectingrod.

3. Remove the bearing and washers at theconnecting rod small end.

4. Remove the piston rings.

cCThe disassembled pistons, piston rings,piston pins, and bearings must be sortedout and kept in order so that the compo-nents from different cylinders will not bemixed up.

Checking the pistons1. Check the piston outside diameter.

Replace the piston if the diameter is outof specification.

2. Check the piston clearance. Replace thepiston and the piston ring, or the cylinderblock if out of specification.

3. Check the piston ring dimensions of Band T. Replace the piston ring if thedimension is out of specification.

4. Check the piston ring side clearance.Replace the piston and the piston ringsas a set if the measurement is out ofspecification.

NOTE:9 Install the piston rings in accordance with

the specification, and measure the pistonring side clearance with a thickness gauge.9When measuring the piston ring side clear-

ance, be sure the piston ring's outside(peripheral) face is flush with the piston'sexternal surface.

Piston outside diameter:55.940–55.985 mm (2.2024–2.2041 in) at 20°C (68°F)a: 10 mm (0.394 in)

Piston ring dimensions Top ring 1:

B: 1.98–2.00 mm (0.078–0.079 in) T: 2.4–2.6 mm (0.09–0.10 in)

Second ring 2:B: 1.96–1.98 mm (0.077–0.078 in)T: 2.4–2.6 mm (0.09–0.10 in)

at 20°C (68°F)

Piston clearance:0.035–0.040 mm (0.0014–0.0016 in) at 20°C (68°F)

6B450450

T

B

T 6B450460

B

1

2

6B450500

6B45E11-05 12/9/02 17:35 Page 29

5. Measure the piston ring end gaps.Replace the piston ring if the measure-ment is out of specification.

NOTE:Push in the piston ring with the piston crownto the specified measuring position H in thecylinder.Make sure that the cylinder sleeve bore diam-eter falls within the specified limit.

POWR

5-27 6B45E11

Power unit

6. Measure the piston pin boss inside diam-eter. Replace the piston if the measure-ment is out of specification.

7. Measure the piston pin outside diameter.Replace the piston pin if the measure-ment is out of specification.

Piston ring end gap:0.15–0.35 mm (0.0059–0.0138 in) at 20°C (68°F) H: 20 mm (0.79 in)

Piston pin boss inside diameter:14.004–14.015 mm (0.5513–0.5518 in) at 20°C (68°F)

Piston pin outside diameter:13.996–14.000 mm (0.5510–0.5512 in) at 20°C (68°F)

6B450510

6B450520

6B450530

Piston ring side clearance:Top 0.02–0.06 mm

(0.0008–0.0024 in) 2nd 0.04–0.08 mm

(0.0016–0.0031 in)at 20°C (68°F)

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6B45E11 5-28

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Crankshaft, piston

Disassembling the crankshaft1. Remove the upper and lower bearings.

2. Insert plate A 1 between crank 1 2 andcrank 2 3. Place pressure pin A 4 in theend of the crank pin 5.

NOTE:Remove the bearing before starting this pro-cedure.

3. Remove the crank pin by applying pres-sure to pressure pin A 4 with a hydraulicpress.

cC9 Apply pressure to pressure pin A slowly.9 Hold pressure pin A in line with the

press screw spindle.

NOTE:9When forcing out the crank pin, use care so

that the crank does not fall.9 To remove crank 4, follow the same proce-

dure.

Bearing separator: 90890-06534

Insert plate A 1: 90890-02386 Pressure pin A 4: 90890-02389

6B450540

6B450550

5

6B450560

6B45E11-05 12/9/02 17:36 Page 31

POWR

5-29 6B45E11

Power unit

4. Insert the support jig 1 between crank 2and 3 2. Place pressure pin A 3 on theshaft, and force it out using a hydraulicpress.

5. Remove the roller bearing 4 from theinner race 5.

6. By forcing pressure pin A 7 with ahydraulic press, remove the crank pin oncranks 2 and 3.

NOTE:Pressure pin A should be pressed downstraight.

7. Using the bearing separator, slightlymove the inner race off the shaft.

NOTE:Use care not to scratch the shaft.

6B450600

6B450570

6B450580

7 6

Insert plate A 6: 90890-02386 Pressure pin A 7: 90890-02389Support jig 1: 90890-02394

Pressure pin A 3: 90890-02389

6B450590

6B45E11-05 12/9/02 17:36 Page 32

6B45E11 5-30

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Crankshaft, piston

Assembling the crankshaft

cC9When reassembling the crankshaft,

wash all component parts in cleankerosene (do not use gasoline).9 Do not reuse bearings, always replace

them with new ones.

1. When the inner race has been previouslyremoved, use plate A and install the innerrace 1 onto crank 2 by using a drill pressand the bearing inner race attachment2. Carefully press the inner race onto thecrank pin.

2. Insert spacer B 3 into the crank pin holeof crank 2 or 4.

3. Apply engine oil to the crank pin andinsert it into the crank pin hole by tappingit with a copper hammer.

cC9 Take care so that the crank pin is set

squarely into the crank web.9 Do not apply force in excess of 5 tons.

NOTE:Follow the same procedure for both crank 2and crank 4 to press-fit the crank pins.

4. Insert the proper bushing 1 or 2 into thebody 3, to assemble cranks 1 and 2.

NOTE:9 Use B-5 1 with crank 2 when the bearing

inner race has been removed. Use B-11 2when the bearing inner race is installed.9 Align the slot in the height ring with the slot

in the body.

Plate A: 90890-02386Bearing inner race attachment 2:

90890-06644

6B450610

Spacer B 3: 90890-02396 Support jig 4: 90890-02394

6B450620

4

3

6B450630

6B450640

1

3

1

2

B-5

B-11

6B45E11-05 12/9/02 17:36 Page 33

POWR

5-31 6B45E11

Power unit

5. Place the height ring (H-5) 4 in the body.

6. Set crank 2 or crank 4 on the special ser-vice tool.

7. Mount the washer and big-end bearing 1on the crank pin.

8. Mount the connecting rod and washer onthe crank pin.

NOTE:The model number 2 on the connecting rodshould face up.

9. Install bushing 3 or 4 on the pressureplate 5.

10. Install crank 1 or crank 3.

NOTE:Apply engine oil to the crank pin.

6B450650

4

Flange: 90890-02351 Body 3: 90890-02352 For crank 1 with the inner raceremoved, and crank 4

Bushing-5 (B-5) 1: 90890-02359 For crank 1with the inner raceinstalled

Bushing-11 (B-11) 2:90890-02565

Height ring-5 (H-5) 4:90890-02371

6B450660

6B450680

3

4

B-5

B-7

5

6B450670

For crank 1 Bushing-5 (B-5) 3: 90890-02359

For crank 3 Bushing-7 (B-7) 4: 90890-02361 Pressure plate 5: 90890-02384

6B450690

6B45E11-05 12/9/02 17:36 Page 34

6B45E11 5-32

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Crankshaft, piston

11. Align the crank pin hole in crank 1 orcrank 3 with the crank pin fitted to crank2 or crank 4 and place the pressure platein the body.

12. Insert the press body 1, and press-fitcrank 1 or crank 3 onto the crank pin.

cCDo not apply force in excess of 5 tons.

13. Measure the width a of the assembledcrankshaft using calipers. Measurementsshould be made at positions 1 to 5.

NOTE:If any of the measurements is out of specifi-cation, reassemble the crankshaft.

14. Install the roller bearing 1 onto crank 2.

NOTE:Make sure the pin a side of the bearingfaces crank 1.

6B450700

Press body 1: 90890-02385

6B450710

1

Crank width:46.90–46.95 mm (1.8465–1.8484 in)

6B450720

a

6B450730

a1

6B45E11-05 12/9/02 17:36 Page 35

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5-33 6B45E11

Power unit

15. Insert plate A 1 between crank 3 andcrank 4, and install the labyrinth seal 2on crank 3, before connecting crankshaftassemblies 1 and 2.

16. Insert plate B 1 between crank 1 andcrank 2, then place crank 2 onto crank 3.

NOTE:Align the matching marks a on cranks 2 and3.

17. Place the height-ring 1 and press body2 on plate B 3 and press-fit crank 2 intocrank 3.

cCDo not apply force in excess of 7 tons.

18. To install the upper and lower bearings,use bearing pressure B 1 and the bear-ing inner race attachment 2, and press-fit the bearings.

NOTE:9 Install the upper bearing so that the dowel

pin a faces the drive shaft side.9 Install the lower bearing so that the dowel

pin b faces the magneto side.

Plate A 1: 90890-02386

6B450740

Bearing pressure B 1:90890-02392

Bearing inner race attachment 2:90890-06644

6B450760

1

a

Height ring-13 (H-13) 1:90890-02379

Press body 2: 90890-02385Plate B 3: 90890-02387

6B450780

1

2

a

b

6B450770

1

2

3

6B45E11-05 12/9/02 17:36 Page 36

6B45E11 5-34

987654321

Crankshaft, piston

Checking the crankshaft1. Measure the crankshaft run-out a at the

positions as shown. If out of specification,adjust the crankshaft.

2. Slowly turn the crankshaft. If it does notturn smoothly, disassemble the crank-shaft and correct or replace any parts asnecessary.

Assembling the piston1. Install the piston rings 1, 2.

NOTE:Install the piston rings with the recess for thelocating pin facing up toward the pistoncrown.

2. Install the needle bearings 1, washers2, piston pin 3, and new clips 4.

NOTE:9 Make sure that the piston and piston pin

bearings are installed in their original com-bination.9 Use the small end bearing installer 5 to

install the needle bearings.9 Make sure that the up mark on the piston

crown faces the flywheel side.

Crankshaft run-out a:0–0.03 mm (0–0.0012 in)

Crankshaft aligner: 90890-03107

6B450790

Small end bearing installer 5:90890-06543

6B450820

6B450800

6B450810

2

1

6B45E11-05 12/9/02 17:36 Page 37

POWR

5-35 6B45E11

Power unit

Installing the crankshaft1. Install the washer, spacer and oil seal

onto the crankshaft.

2. Install the pistons and crankshaft into thecylinder block.

NOTE:9 Insert the bearing pins a in the slots in the

cylinder block.9 Align the labyrinth seal ring b with the slot

in the cylinder block.

Installing the crankcase

1. Install the dowels.

2. Install the crankcase.

NOTE:Clean the mating face of the cylinder blockand crankcase.Apply a thin coating of Gasket Maker on themating face so that it will not be squeezed outof the edge.

3. Tighten the crankcase bolts.

NOTE:Tighten the bolts to the specified torques intwo stages and in the sequence shown.Apply some engine oil on each bolt’s threads.

Installing the cylinder head1. Install the anode into the cylinder block.

6B450830a b a a

6B450840

E

6B450850

6 2 3

415

Crankcase bolt:1st:

15 N·m (1.5 kgf·m, 11 ft·lb) 2nd:

29 N·m (2.9 kgf·m, 22 ft·lb)

6B450370

6B45E11-05 12/9/02 17:36 Page 38

6B45E11 5-36

987654321

Crankshaft, piston

2. Install the cylinder head gasket and cylin-der head.

NOTE:9 Tighten the cylinder head bolts in the

sequence shown.9 Apply some engine oil on each bolt’s

threads.

3. Install the cylinder head cover gasket andcylinder head cover.

NOTE:Tighten the cylinder head cover bolts to thespecified torque in two stages.

4. Install the thermostat gasket, and thethermostat cover.

NOTE:Tighten the thermostat cover bolts to thespecified torques in two stages.

1

2

3

45

6

7

8 9

0

q

E6B450860

Cylinder head bolt:1st: 8 N·m (0.8 kgf·m, 5.8 ft·lb) 2nd:16 N·m (1.6 kgf·m, 12 ft·lb)

E6B450870

Cylinder head cover bolt:1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.7 ft·lb)

6B430051

Thermostat cover bolt:1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.7 ft·lb)

6B45E11-05 12/9/02 17:36 Page 39

POWR

5-37 6B45E11

Power unit

Installing the exhaust covers1. Install the inner exhaust cover and gas-

ket.

2. Install the outer exhaust cover and gas-ket.

NOTE:Tighten the exhaust outer cover bolts to thespecified torque in two stages and in thesequence shown.

Installing the reed valve1. Install the reed valve into the crankcase.

NOTE:Tighten the reed valve bolts to the specifiedtorque in two stages.

2. Install the hoses.

Installing the electrical components1. Install the pulser coil, charge coil, ignition

coil and CDI unit.

NOTE:For wire routing, see Chapter 8, "Wire rout-ing".

2. Connect each lead correctly.

Installing the throttle cam assembly1. Install the throttle cam assembly on the

crankcase.

Exhaust outer cover bolt:1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.7 ft·lb)

6B450880

1

23

45

6

7

8

9

0

qwe 6B450890

Reed valve:1st: 3 N·m (0.3 kgf·m, 2.2 ft·lb) 2nd: 8 N·m (0.8 kgf·m, 5.8 ft·lb)

6B450310

6B450990

6B45E11-05 12/9/02 17:36 Page 40

6B45E11 5-38

987654321

Crankshaft, piston

Installing the spark plugs1. Install the spark plugs, and tighten to the

torque specified.

2. Connect the spark plug caps.

Installing the flywheel assembly1. Install the Woodruff key into the crank-

shaft.

NOTE:Clean the oil on the tapered portion of thecrankshaft and flywheel magnet.

2. Set the flywheel magnet on to the crank-shaft, aligning the slot with the Woodruffkey.

3. Apply engine oil to the flywheel magnetnut threads and tighten the flywheel mag-net nut.

cCApply force in the direction of the arrowsshown.While working, do not allow the fly-wheel holder to slip off the flywheel.

Installing the manual starter1. Install the manual starter.

Installing the carburetor1. Install the carburetor and intake silencer

onto the power unit.

Installing the fuel filter and hoses1. Install the fuel filter onto the bracket on

the crankcase. Connect the fuel hose.

Spark plug:25 N·m (2.5 kgf·m, 18 ft·lb)

Flywheel magnet:100 N·m (10 kgf·m, 74 ft·lb)

Manual starter:8 N·m (0.8 kgf·m, 5.8 ft·lb)

Flywheel holder: 90890-06522

6B450910

6B450920

6B451000

6B45E11-05 12/9/02 17:36 Page 41

POWR

5-39 6B45E11

Power unit

Installing the oil seal housing1. Install the oil seal housing onto the power

unit.

Installing the power unit1. Clean the mating face of the power unit

and the upper case, and install dowelsand a new gasket.

2. Install the power unit, and tighten thebolts.

Installing the throttle cables1. Install throttle cable 1 onto the throttle

cable stay.

NOTE:Be sure the throttle grip is in the fully openposition when installing the throttle cable.

2. Adjust the throttle cable adjusting nut 3so that the free axle lever 4 cam comesinto contact with the pulley 5 cam, thentighten the lock nut.

3. Install throttle cable 2 onto the throttlecable stay.

4. Adjust the throttle cable adjusting nut 6so that the free axle lever 4 cam comesinto contact with the pulley 5 cam, thentighten the lock nut.

6B450941

Power unit:22 N·m (2.2 kgf·m, 16 ft·lb)

6B450950

6B450960

Oil seal housing:8 N·m (0.8 kgf·m, 5.8 ft·lb)

6B450930

6B45E11-05 12/9/02 17:36 Page 42

6B45E11 5-40

987654321

Crankshaft, piston

5. Turn the throttle grip from fully closed tofully open and back, and check throttlecables 1 and 2 for slack. Remove anyslack in the cables by following step 2 or3 as necessary.

Installing the throttle link1. Set the carburetor throttle lever 1 so that

it comes into contact with the stopper 2.

2. Connect the throttle link 3 to the freeaxle lever and carburetor throttle lever 1

3. While pushing the carburetor throttlelever 1 and throttle link 3 in the direc-tion shown, tighten the screw 4 to hold itin place.

4. Turn the throttle grip from fully closed tofully open and back, and check that thecarburetor throttle lever fully closes.Adjust by repeating steps 2 and 3 if nec-essary.

Installing the start-in-gear protectioncable1. Put the gear shift in neutral.

2. Install the start-in-gear protection cable.

NOTE:9 Install the spring end of the start-in-gear

protection cable on the starter plunger 1.9 Install the start-in-gear protection cable

outer end so that it comes into contact withthe starter case outer end connection point2.9 Install the start-in-gear protection cable

grommet on the starter case, and install theadjusting nut end of the cable on the lever3.

3. Using the adjusting nut 4, align thestarter plunger 1 with the mark a on thestarter case.

6B430111

21

4

3

N

R F

6B410091

6B451010

6B430311

41a 3

2

6B45E11-05 12/9/02 17:36 Page 43

POWR

5-41 6B45E11

Power unit

4. Check that the starter rope can be pulledwith the the gear shift in neutral. Alsocheck that the starter rope cannot bepulled with the gear shift in forward andreverse. Adjust the start-in-gear protec-tion cable if necessary.

5. Connect the choke rod.

6. Connect the engine shut-off switch leadand ground lead.

7. Connect the pilot water hose and fuelhose.

6B451020

6B45E11-05 12/9/02 17:36 Page 44

6B45E11

987654321

LOWR

Lower unit


Lower unit .......................................................................................................6-4

Water pump.....................................................................................................6-5

Propeller shaft, propeller shaft housing ......................................................6-6Removing the lower unit ............................................................................6-7Removing the water pump and shift rod....................................................6-7Checking the water pump and shift rod.....................................................6-8Removing the propeller shaft housing assembly.......................................6-9Disassembling the propeller shaft housing assembly................................6-9Checking the propeller shaft housing assembly ......................................6-10Assembling the propeller shaft housing assembly ..................................6-10Disassembling the propeller shaft assembly ...........................................6-11Checking the propeller shaft assembly....................................................6-12Assembling the propeller shaft assembly ................................................6-12

Drive shaft, shift rod, lower case................................................................6-13Removing the drive shaft and forward gear.............................................6-15Disassembling the lower case .................................................................6-15Checking and disassembling the bearing housing ..................................6-16Assembling the bearing housing .............................................................6-16Checking the forward gear.......................................................................6-17Assembling the forward gear ...................................................................6-17Checking the drive shaft ..........................................................................6-17Checking the pinion gear.........................................................................6-18

Assembling the lower unit ..........................................................................6-18Installing the lower case ..........................................................................6-18Installing the water pump.........................................................................6-20Installing the lower unit ............................................................................6-21

Shimming ......................................................................................................6-23Selecting the pinion shims.......................................................................6-24Selecting the forward gear shims ............................................................6-24Selecting the reverse gear shims ............................................................6-25

Backlash........................................................................................................6-26Measuring the forward and reverse gear backlash .................................6-26

6B45E11-06 12/9/02 17:37 Page 1

LOWR

6-1 6B45E11

Lower unit


Dial gauge set90890-01252

Stopper guide plate90890-06501

Center bolt90890-06504

Drive shaft holder 190890-06515

Bearing Separator90890-06534

Bearing puller assembly90890-06535

Stopper guide stand90890-06538

Bearing housing puller claw S90890-06564

Driver rod SL90890-06602

Bearing depth plate90890-06603

6B45E11-06 12/9/02 17:37 Page 2

6B45E11 6-2

987654321


Driver rod SS90890-06604

Driver rod LL90890-06605

Driver rod LS90890-06606

Needle bearing attachment90890-06613, 90890-06616

Needle bearing attachment90890-06617

Bearing outer race attachment90890-06625, 06627

Bearing inner race attachment90890-06644

Bushing attachment90890-06649

Driver rod L390890-06652

Shimming plate90890-06701

6B45E11-06 12/9/02 17:37 Page 3

LOWR

6-3 6B45E11

Lower unit

Digital caliper90890-06704

Magnet base90890-06841

Backlash indicator90890-06706

Magnet base plate90890-07003

6B45E11-06 12/9/02 17:37 Page 4

6B45E11 6-4

987654321

Lower unit

Lower unit

6B46010E9 N·m (0.9 kgf·m, 6.6 ft·lb)

9 N·m (0.9 kgf·m, 6.6 ft·lb)

9 N·m (0.9 kgf·m, 6.6 ft·lb)

18 N·m (1.8 kgf·m, 13 ft·lb)

17 N·m (1.7 kgf·m, 12 ft·lb)

4.3 N·m (0.43 kgf·m, 3 ft·lb)

No. Part name Q’ty Remarks1 Bolt 1 M8 × 35mm2 Anode 13 Special washer 14 Bolt 1 M6 × 20mm5 Screw 16 Inlet cover 17 Cotter pin 18 Propeller nut 19 Washer 110 Propeller 111 Spacer 112 Screw 313 Gasket 314 Lower case 115 Rubber seal 116 Dowel 217 Shift rod 1

Not reusable

Not reusable

6B45E11-06 12/9/02 17:37 Page 5

LOWR

6-5 6B45E11

Lower unit

Water pump

6B46030E

8 N·m (0.8 kgf·m, 5.8 ft·lb)

No. Part name Q’ty Remarks1 Screw 12 Cover 13 Water seal rubber 14 Water pump housing 15 Insert cartridge 16 Impeller 17 Woodruff key 18 Outer plate cartridge 19 Gasket 210 Dowel 211 Bracket 112 Plate 213 Bolt 2 M6 × 45mm14 Shift rod 115 Washer 116 Boot 117 Nut 1

Not reusable

6B45E11-06 12/9/02 17:37 Page 6

6B45E11 6-6

987654321

Propeller shaft, propeller shaft housing

8 N·m (0.8 kgf·m, 5.8 ft·lb)

6B46020E

3.0 — 3.5 mm(0.12 — 0.14 in)

0 mm

No. Part name Q’ty Remarks1 Bolt 1 M6 × 20mm2 Oil seal 23 O-ring 14 Needle bearing 15 Ball bearing 16 Propeller shaft housing 17 Reverse gear shim 18 O-ring 19 Washer 110 Reverse gear 111 Propeller shaft 112 Spring 113 Cross pin ring 114 Cross pin 115 Dog clutch 116 Shift plunger 1

Not reusable

Not reusable

Not reusable

Not reusable

Not reusable

Water pump/Propeller shaft, propeller shaft housing

6B45E11-06 12/9/02 17:37 Page 7

LOWR

6-7 6B45E11

Lower unit

Removing the lower unit1. Remove the clip for the engine shut-off

switch.

2. Set the gear shift in the neutral position.

3. Remove the drain screw 3, then thecheck screw 4 to drain the gear oil.

4. Remove the cotter pin.

5. Place a block of wood between the anti-cavitation plate and the propeller, andremove the propeller.

w9 Place a block of wood between the anti-

cavitation plate and the propeller. Do nottouch the propeller with your hands.9 Remove the clip for the engine shut-off

switch to prevent the engine from start-ing.

6. Disconnect the shift rod. Loosen theadjuster while holding the lock nut.

NOTE:Set the gear shift in reverse first.

7. Tilt up the outboard motor and removethe lower unit after removing the bolts.

8. Remove the anode and cooling waterinlet cover.

Removing the water pump and shiftrod1. Remove the water pump 1 and the shift

rod 2.

NOTE:9 Remove the Woodruff key from the drive

shaft, then the outer plate cartridge.9 Make sure the dowels were removed from

the lower case.

3

4

6B430200

6B460010

6B460020

6B460030

2

1

6B45E11-06 12/9/02 17:37 Page 8

6B45E11 6-8

987654321

Propeller shaft, Propeller shaft housing

Checking the water pump and shiftrod1. Check the water pump housing 1 for

deformation. Also check the insert car-tridge 2 for wear or deformation.

2. When the insert cartridge is removed,insert the projection on the insert car-tridge into the water pump housing holeat the time of reassembly.

NOTE:When installing the insert cartridge, insert theprojection on the insert cartridge into thewater pump housing hole.

3. Check the impeller for cracks or wear.Replace if necessary.

4. Check the Woodruff key 4 and thegroove a for wear. Replace if necessary.

5. Check the outer plate cartridge for cracksor damage. Replace if necessary.

6. Check the shift rod for deformation orwear. Replace if necessary.

2

1

6B460040

a

4

6B460060

6B4600702

1

6B460050

6B460055

6B460080

6B45E11-06 12/9/02 17:37 Page 9

LOWR

6-9 6B45E11

Lower unit

Removing the propeller shaft housing assembly1. Remove the bolts and remove the pro-

peller shaft housing assembly by pryingthe tabs apart with slot-head screw-drivers.

NOTE:Make sure that the shims left in the lowercase have been removed.

Disassembling the propeller shafthousing assembly1. Remove the reverse gear.

2. Check that the bearing spins smoothly inthe housing. Check for roughness, wear,and damage.

3. Remove the ball bearing.

4. Remove the oil seals, then remove theneedle bearing.

NOTE:When the oil seal or the needle bearing isremoved, always replace them with newones.

6B460090

6B460120

1

2

2

3

1

6B460110

6B460100

6B460620

Stopper guide plate 1:90890-06501

Stopper guide stand 2:90890-06538

Bearing puller assembly 3:90890-06535

Driver rod L3 1:90890-06652

Needle bearing attachment 2:90890-06616

6B45E11-06 12/9/02 17:37 Page 10

6B45E11 6-10

987654321


Assembling the propeller shafthousing assembly1. Install a new needle bearing into the pro-

peller shaft housing to the specifieddepth using a press.

6B460130

6B460140

cCShimming is required when the reversegear, ball bearing, or propeller shaft hous-ing is replaced.

Checking the propeller shaft housing assembly1. Clean the propeller shaft housing and

check it for cracks, corrosion, or damage.Replace if necessary.

2. Check the teeth and dogs of the reversegear for cracks or wear. Replace the gearif necessary.

6B460150

a

2

1

Driver rod SS 1:90890-06604


Installation depth a :0 mm (0 in)

6B45E11-06 12/9/02 17:37 Page 11

LOWR

6-11 6B45E11

Lower unit

6B460190

1

2

3

4

5

4. Install the reverse gear into the propellershaft housing.

NOTE:Shimming is required when the reverse gearor ball bearing is replaced.

Disassembling the propeller shaftassembly1. Remove the shift plunger 1.

2. Remove the cross pin ring 2, pull out thecross pin 3, and remove the dog clutch4.

3. Pull out the spring 5.

Bearing outer race attachment 6:90890-06627

Driver rod LS 7:90890-06606

2. Install new oil seals into the propellershaft housing to the specified depth.

NOTE:First, drive the inner oil seal halfway into thepropeller shaft housing, and then drive in theouter oil seal to the specified depth.

3. Install the ball bearing into the propellershaft housing.

6B460160

b

4

5



Installation depth b:3.0–3.5 mm (0.1181–0.1378 in)

6B460170

67

6B460180

6B45E11-06 12/9/02 17:37 Page 12

6B45E11 6-12

987654321

Checking the propeller shaft assembly1. Check the propeller shaft for bends or

wear. Replace if necessary.

2. Measure the propeller shaft run-out.

3. Check the dog clutch for breakage orwear. Replace if necessary.


Assembling the propeller shaftassembly1. Insert the spring 1.

2. Install the dog clutch 2 so that the “F”mark faces the forward gear, and insertthe cross pin 3.

3. Install the cross pin ring 4 and shiftplunger 5.

6B460200

6B460210

Run-out limit: 0.05 mm (0.0020 in)

234

5

6B460230

1

6B460220

6B45E11-06 12/9/02 17:37 Page 13

LOWR

6-13 6B45E11

Lower unit

Drive shaft, shift rod, lower case

6B46040E

25 N·m (2.5 kgf·m, 18 ft·lb)

8 —

9 m

m(0

.31

— 0

.35

in)

182.

2 —

182

.7 m

m(7

.17

— 7

.19

in)

No. Part name Q’ty Remarks1 Water seal rubber 12 Set plate 13 Screw 14 Water tube 15 Water seal rubber 16 Pinion gear nut 17 Pinion gear 18 Forward gear 19 Taper roller bearing 110 Forward gear shim 1 As required11 Pinion gear shim 1 As required12 Thrust bearing 113 Needle roller bearing 114 Drive shaft 115 Drive shaft sleeve 1

Not reusable

Not reusable

6B45E11-06 12/9/02 17:37 Page 14

6B45E11 6-14

987654321


6B46040E

25 N·m (2.5 kgf·m, 18 ft·lb)

8 —

9 m

m(0

.31

— 0

.35

in)

182.

2 —

182

.7 m

m(7

.17

— 7

.19

in)

No. Part name Q’ty Remarks16 Bushing 117 Bearing housing 118 Gasket 119 Oil seal 220 Cover 121 Dowel 122 Extension 1 X transom23 Bolt 4 M8 × 35mm: X transom24 Dowel 2 X transom

Not reusable

Not reusable

6B45E11-06 12/9/02 17:37 Page 15

LOWR

6-15 6B45E11

Lower unit

Removing the drive shaft and forward gear

NOTE:Shimming is required when the forward gearor taper roller bearing is replaced.

1. Loosen the pinion nut.

2. Remove the pinion gear, shim, thrustbearing, and washer, then remove thedrive shaft.

3. Remove the bearing housing.

4. Remove the drive shaft sleeve.

5. Remove the forward gear.

Disassembling the lower case1. Remove the taper roller bearing outer

race.

NOTE:Install the puller claw as shown.

2. Remove the needle bearing.

6B460240

1

Drive shaft holder 1 1:90890-06515

6B460250

1

2


Bearing puller assembly 2:90890-06535


Driver rod L3 2:90890-06652

6B460260

2

1

6B45E11-06 12/9/02 17:38 Page 16

6B45E11 6-16

987654321


Checking and disassembling thebearing housing1. Check the bearing housing for cracks or

damage. Also check the bushing for wear,and the oil seals for damage.Disassemble if necessary.

2. Remove the cover and the oil seals.

3. Remove the bushing.

NOTE:When the bushing and oil seals are removed,always replace them with new ones.

Assembling the bearing housing1. Install the bushing using a press.

NOTE:Align the grooves in the bushing with the slitin the bearing housing.

2. First, drive the inner oil seal halfway intothe drive shaft housing, then drive in theouter oil seal to the specified depth.

3. Install the cover.

6B460270

2

1

E

6B460280

1

2

Bushing attachment 1:90890-06649

Driver rod L3 2:90890-06652


Driver rod LS 5:90890-06606

Installation depth b:8.0–9.0 mm (0.3149–0.3543 in)


Bushing attachment 2:90890-06649

6B450290

AA

5

4b

6B45E11-06 12/9/02 17:38 Page 17

6B460300

12

3

LOWR

6-17 6B45E11

Lower unit

Checking the drive shaft1. Check the drive shaft for bends or wear.

Replace the shaft if necessary.

2. Measure the drive shaft run-out.

3. Check the needle bearing and the thrustbearing for run-out or roughness.Replace if necessary.

cCShimming is required when the thrustbearing is replaced.

Run-out limit:0.5 mm (0.0197 in)

6B460310

E

4

6B460320

6B460330

Bearing separator 1:90890-06534



Checking the forward gear1. Check the teeth and dogs of the forward

gear for cracks or wear. Also check thebearing for run-out or roughness.Disassemble if necessary.

2. Remove the bearing

NOTE:When the taper roller bearing is removedalways replace it with a new one.

Assembling the forward gear1. Install a new taper roller bearing.

NOTE:Shimming is required when the taper rollerbearing is replaced.

Bearing inner race attachment 4:90890-06644

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6B45E11 6-18

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Assembling the lower unit

Checking the pinion gear1. Check the pinion gear teeth for cracks or

wear.

Assembling the lower unitInstalling the lower case1. Install the shims and the taper roller bear-

ing outer race.

cCShimming is required when the forwardgear, the taper roller bearing, or the lowercase is replaced. Record the measuredheight of the bearing.

2. Install the needle bearing.

3. Install the forward gear assembly.

6B460340

E 6B460350

12

Bearing outer race attachment 1:90890-06625

Driver rod LL 2:90890-06605

6B460360

54

3

a


Driver rod SL 4:90890-06602

Bearing depth plate 5:90890-06603

Depth a:182.2–182.7 mm (7.17–7.19 in)

6B45E11-06 12/9/02 17:38 Page 19

LOWR

6-19 6B45E11

Lower unit

6. Install the propeller shaft assembly.

7. Install the shift rod assembly, and tightenthe screw.

Drive shaft holder 1 5:90890-06515

Pinion nut:25 N·m (2.5 kgf·m, 18 ft·lb)

6B460380

5 6B460400

4. Install the drive shaft sleeve, bearinghousing assembly, driveshaft, washer,thrust bearing, shim, and pinion gear.

cC9 Shimming is required when the drive

shaft housing or the drive shaft isreplaced.9 Shimming is required when the thrust

bearing is replaced.

NOTE:Install the drive shaft by lifting it up slightly,then aligning its splines with the pinion gear.

5. Tighten the pinion nut.

6B460370

6B460390

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8. Install the shim(s), washer, and propellershaft housing assembly.

9. Install the propeller housing and tightenthe bolts.

10. Make sure that the shifting mechanismworks properly.

NOTE:Change the shift rod position to forward, toreverse, and to neutral. Make sure that thepropeller shaft rotating direction is correct inforward and in reverse. Also make sure thatthe position is correct in neutral.

Installing the water pump1. Install the gasket 1 , the dowels 2, the

outer plate cartridge 3, and the secondgasket 4.

2. Install the Woodruff key 5 into the driveshaft.

3. Install the impeller 6 after aligning it withthe Woodruff key.

NOTE:9 Align the groove on the impeller with the

Woodruff key.9 Apply Yamaha grease A on the sliding face

between the impeller and the outer platecartridge.

6B460410

6B460420

Propeller housing bolt:8 N·m (0.8 kgf·m, 5.8 ft·lb)

6B460430

AA

6B460450

5

6

6B460440

2 4

3

1

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6-21 6B45E11

Lower unit

4. Install the water seal rubber and waterpump housing cover into the water pumphousing assembly, then install the waterpump housing on the lower case.

NOTE:To install the water pump housing, applyYamaha grease A to the inner face of thewater pump housing assembly, and then turnthe drive shaft clockwise while pushing downon the pump housing.

Installing the lower unit1. Install the dowels into the lower case.

2. Put the gear shift lever in reverse. Makesure that the shift rod is in the reverseposition. Install the lower unit onto theupper case, and tighten the lower casebolts to the specified torque.

NOTE:9 Screw in the lock nut completely.9 Push the shift rod down to shift into reverse.

3. Connect the shift rod.

NOTE:Screw the connecting nut down until it comesin contact with the lock nut.

4. Install the anode and inlet cover to theiroriginal positions and tighten the anodebolt to the specified torque.

6B460460

Water pump housing bolts:8 N·m (0.8 kgf·m, 5.8 ft·lb)

Anode bolt:18 N·m (1.8 kgf·m, 13 ft·lb)

Lower case bolt:18 N·m (1.8 kgf·m, 13 ft·lb)

6B460470

6B460480

6B460020

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7. Install the check screw, and quickly installthe drain screw.

5. Install the propeller and the propeller nut.Place a block of wood between the anti-cavitation plate and the propeller to keepthe propeller from turning. Then tightenthe nut to the specified torque.

w9 Place a block of wood between the anti-

cavitation plate and the propeller. Do nottouch the propeller with your hands.9 Remove the clip for the engine shut-off

switch to prevent the engine from start-ing.

NOTE:If the grooves in the propeller nut do not alignwith the cotter pin hole, tighten the nut furtheruntil they are aligned.

6. Insert the gear oil tube into the drain holeand fill the gear oil until it flows out of thecheck hole and no air bubbles are visible.

6B460500

6B430210

6B460510

Propeller nut:17 N·m (1.7 kgf·m, 12 ft·lb)


Oil quantity:0.25 L (8.5 US oz, 8.8 Imp oz)

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6-23 6B45E11

Lower unit

ShimmingT

3M

1

T2

M3-10 mm (0.39 in)T1 M2

6B460531

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Shimming

Shimming

NOTE:9 Shimming is not required when assembling

the original lower case and inner parts.9 Shimming is required when assembling the

original inner parts and a new lower case.9 Shimming is required when replacing the

inner part(s).

Selecting the pinion shims1. Measure the thickness (M1) of the roller

bearing with the special service tool.

NOTE:9 Measure the roller bearing at 3 points to

find the clearance average.9 Select the shim thickness (T3) by using the

specified measurement and the calculationformula.

2. Calculate the pinion shim thickness.

3. Select the pinion shim(s) (T3) as follows.

Selecting the forward gear shims1. Turn the taper roller bearing outer race 1

two or three times to seat the rollers,then measure the bearing height (M2) asshown.

NOTE:9 Select the shim thickness (T1) by using the

specified measurement(s) and the calcula-tion formula.9 Measure the bearing outer race at three

points to find the height average.

6B460540

1

M1

Digital caliper 1:90890-06704

Pinion shim thickness(T3) = M1 - 6.00

Shimming plate 2:90890-06701


Available shims:1.13 and 1.20

Calculated numeralmore than less than

Use shim

1.13 1.20 1.131.20 1.30 1.20

6B460550

M2

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6-25 6B45E11

Lower unit

2. Calculate the shim thickness.

3. Select the forward gear shim(s) (T1) asfollows.

Selecting the reverse gear shims1. Remove the reverse gear shim and install

the reverse gear into the end cap.

2. Measure (M3) as shown.

3. Calculate the shim thickness.Available shim thicknesses:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

Reverse gear shim thickness(T2) = 80.52 - M3

Available shims:0.10, 0.20, 0.30, 0.40, and 0.50

Shimming plate 1:90890-06701


Calculated numeralat 1/100th place Use shim

more than less than0.00 0.02 0.000.02 0.05 0.020.05 0.08 0.050.08 0.10 0.08

Forward gear shim thickness(T1) = 16.55 - M2

6B460560

1

2

6B460570

M3

Calculated numeralat 1/100th place Use shim

more than less than0.30 0.40 0.300.40 0.50 0.400.50 0.60 0.500.60 0.70 0.60

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Backlash

BacklashMeasuring the forward and reversegear backlash1. Remove the water pump assembly.

2. Set the gearshift to the neutral position.

3. Install the special service tool so that itpushes against the propeller shaft.

NOTE:Tighten the center bolt while turning the driveshaft until the drive shaft can no longer beturned.

4. Turn the lower unit upside down.

5. Install the backlash indicator onto thedrive shaft (13 mm [0.51 in] in diameter),then the dial gauge onto the lower unit.

NOTE:Install the dial gauge so that the plunger acontacts the mark b on the backlash indica-tor.

6. Slowly turn the drive shaft clockwise andcounterclockwise and measure the back-lash when the drive shaft stops in eachdirection.

6B460430

6B460590

6

7

8

9

a

b

6B460580

3

4

5

Bearing housing puller claw S 3:90890-06564


Center bolt 5:90890-06504

Forward gear backlash:0.19–0.86 mm (0.0075–0.0339 in)

Backlash indicator 6:90890-06706

Magnet base plate 7:90890-07003

Dial gauge set 8:90890-01252

Magnet base 9:90890-06841

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6-27 6B45E11

Lower unit

7. Add or remove shims if out of specifica-tion.

M: Measurement

8. Remove the special service tools fromthe propeller shaft.

9. Apply a load to the reverse gear byinstalling the propeller 0 without thespacer q, then the washer w and nut eas shown.

10. Tighten the propeller nut.

11. Slowly turn the drive shaft clockwise andcounterclockwise and measure the back-lash when the drive shaft stops in eachdirection.

12. Add or remove shims if out of specifica-tion.

M: Measurement

13. Remove the special service tools, theninstall the water pump assembly.

Available shim thicknesses:0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

Reverse gear backlash:0.96–1.65 mm (0.0378–0.650 in)

Available shim thicknesses:0.10, 0.20, 0.30, 0.40, and 0.50 mm

0q

w

e

6B460600

Propeller nut:5 N·m (0.5 kgf·m, 3.6 ft·lb)

6B460610

Reverse gearShim thickness

backlashLess than To be decreased by

0.96 mm (0.0378 in) (1.3 - M) × 0.43More than To be increased by

1.65 mm (0.650 in) (M - 1.3) × 0.43

Forward gearShim thickness

backlashLess than To be decreased by

0.19 mm (0.0075 in) (0.52 - M) × 0.43More than To be increased by

0.86 mm (0.0339 in) (M - 0.52) × 0.43

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6B45E11

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BRKT

Bracket unit

Tiller handle ....................................................................................................7-1

Bottom cowling ..............................................................................................7-3

Upper case......................................................................................................7-5Removing the muffler assembly ................................................................7-7Disassembling the muffler assembly .........................................................7-7Disassembling the upper case ..................................................................7-7Checking the upper case...........................................................................7-8Assembling the upper case .......................................................................7-9

Swivel bracket ..............................................................................................7-11

Clamp bracket...............................................................................................7-12

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BRKT

7-1 6B45E11

Bracket unit

6B47010E

18 N·m (1.8 kgf·m, 13 ft·lb)

18 N·m (1.8 kgf·m, 13 ft·lb)

1.6 N·m (0.16kgf·m, 1.2 ft·lb)

No. Part name Q’ty Remarks1 Tiller handle 12 Bushing 13 Bushing 14 Washer 15 Wave washer 16 Cover 17 Bolt 1 M8 × 30 mm8 Bolt 1 M8 × 50 mm9 Throttle fricton adjuster 110 Friction piece 111 Cotter pin 112 Nut 113 Throttle grip 114 Rubber grip 115 Screw 116 Washer 217 Spring 1

Tiller handle

6B45E11-07 12/9/02 17:39 Page 2

6B45E11 7-2

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Tiller handle

6B47010E

18 N·m (1.8 kgf·m, 13 ft·lb)

18 N·m (1.8 kgf·m, 13 ft·lb)

1.6 N·m (0.16kgf·m, 1.2 ft·lb)

No. Part name Q’ty Remarks18 Bushing 119 Throttle lever 120 Throttle cable 2

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7-3 6B45E11

Bracket unit

6B47020E

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)

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)

3.5 N·m (0.4 kgf·m, 2.5 ft·lb)

No. Part name Q’ty Remarks1 Shift handle 12 Shift rod lever 1 13 Screw 14 Shift rod lever 2 15 Screw 16 Spring 17 Bolt 1 M6 × 16 mm8 Shift rod 19 Bracket 110 Bolt 2 M6 × 25 mm11 Grommet 112 Fuel joint 113 Bolt 1 M6 × 20 mm14 Seal 115 Engine shut-off switch 116 Spring hook 117 Bolt 1 M6 × 16 mm

Bottom cowling

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6B45E11 7-4

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Bottom cowling

6B47020E


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)

8 N·m (0.8 kgf·m, 5.8 ft·lb)

3.5 N·m (0.4 kgf·m, 2.5 ft·lb)

No. Part name Q’ty Remarks18 Spring 119 Hook 120 Bushing 121 Bushing 122 Washer 123 Lever 124 Bolt 1 M6 × 14 mm25 Choke knob 126 Grommet 127 Seal 128 Bolt 4 M6 × 14 mm29 Rubber seal 130 Nut 131 Upper cowling 1

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7-5 6B45E11

Bracket unit


8 N·m (0.8 kgf·m, 5.8 ft·lb)

20 N·m (2.0 kgf·m, 14 ft·lb)

21 N·m (2.1 kgf·m, 15 ft·lb)

20 N·m (2.0 kgf·m, 14 ft·lb)

8 N·m (0.8 kgf·m, 5.8 ft·lb)

6B47030E

No. Part name Q’ty Remarks1 Upper case 12 Bolt 4 M6 × 25 mm3 Protector 14 Rubber seal 15 Plate 16 Exhaust manifold 17 Rubber seal 18 Pipe 19 Circlip 1 Except S transom models10 Drive shaft bushing 1 Except S transom models11 Dowel 212 Gasket 113 Bolt 6 M6 × 20 mm14 Bolt 2 M6 × 30 mm15 Exhaust guide 116 Gasket 117 Screw 1 M6 × 12 mm

Not reusable

Not reusable

Upper case

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6B45E11 7-6

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Upper case


8 N·m (0.8 kgf·m, 5.8 ft·lb)

20 N·m (2.0 kgf·m, 14 ft·lb)

21 N·m (2.1 kgf·m, 15 ft·lb)

20 N·m (2.0 kgf·m, 14 ft·lb)

8 N·m (0.8 kgf·m, 5.8 ft·lb)

6B47030E

No. Part name Q’ty Remarks18 Ground lead 119 Upper mount 220 Bolt 4 M6 × 25 mm21 Washer 222 Washer 223 Rubber washer 224 Nut 225 Rubber seal 226 Mount housing 227 Bolt 2 M8 × 85 mm28 Bolt 1 M8 × 55 mm29 Nut 330 Lower mount 1 131 Lower mount 2 232 Nut 4 [option]33 Splash plate 1 [option]34 Bolt 4

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7-7 6B45E11

Bracket unit

Removing the muffler assembly

1. Remove the muffler assembly from theupper case.

Disassembling the muffler assembly

1. Remove the exhaust manifold and gasketfrom the exhaust guide.

2. Remove the water tube and water sealrubber from the muffler.

Disassembling the upper case

1. Remove the upper mount brackets.

2. Remove the lower mount brackets.

6B470010

6B470020

6B470110

6B470030

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6B45E11 7-8

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Upper case

3. Remove the protector, rubber seal andrubber seal plate.

4. Remove the circlip and drive shaft bush-ing (for L and X transom models).

Checking the upper case1. Check the water tube for deformation or

corrosion. Replace if necessary.

2. Check the exhaust guide, exhaust mani-fold for damage or corrosion. Replace ifnecessary.

3. Check the protector and rubber seal platefor damage or corrosion. Replace if nec-essary.

4. Check the rubber seal for cracks, deteri-nation and damage. Replace if neces-sary.

6B470040

6B470050

6B470060

6B470070

6B470080

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BRKT

7-9 6B45E11

Bracket unit

Assembling the upper case1. Install the drive shaft bushing and circlip

into the upper case on L and X transommodels.

2. Install the rubber seal plate, rubber sealand protector into the upper case.

3. Install the exhaust manifold and a newgasket onto the exhaust guide and tight-en the bolts.

4. Install the water seal and water tube intothe exhaust manifold.

Protector:8 N·m (0.8 kgf·m, 5.8 ft·lb)

Exhaust manifold:8 N·m (0.8 kgf·m, 5.8 ft·lb)

6B470051

6B470040

6B470090

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6B45E11 7-10

987654321

Upper case

5. Install the upper mount bracket and lowermount bracket.

NOTE:Install the rubber seal so that the mark facesup, and the grooves fit completely into theholes in the upper case.

6. Install the muffler assembly into theupper case.

Upper case:8 N·m (0.8 kgf·m, 5.8 ft·lb)

Upper mount:21 N·m (2.1 kgf·m, 15 ft·lb)

Lower mount:20 N·m (2.0 kgf·m, 14 ft·lb)

6B4701006B470010

Muffler assembly:12 N·m (1.2 kgf·m, 8.7 ft·lb)

6B45E11-07 12/9/02 17:39 Page 11

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7-11 6B45E11

Bracket unit

6B47040E

8 N·m (0.8 kgf·m, 5.8 ft·lb)

3 N·m (0.3 kgf·m, 2.2 ft·lb)

No. Part name Q’ty Remarks1 Grease nipple 12 Ground lead 13 Friction piece 14 Spring 15 Washer 16 Seal 17 Bolt 1 M8 × 25 mm8 Steering bracket 19 Dowel 210 Bolt 3 M6 × 25 mm11 Steering pivot 112 Washer 113 Bushing 114 Bushing 115 O-ring 116 Bushing 117 Bolt 2 M6 × 105 mm

Not reusable

Swivel bracket

6B45E11-07 12/9/02 17:39 Page 12

6B45E11 7-12

987654321

Swivel bracket/Clamp bracket

6B47050E

12 N·m (1.2 kgf·m, 8.7 ft·lb)

12 N·m (1.2 kgf·m, 8.7 ft·lb)

2.5 N·m (0.2 kgf·m, 1.8 ft·lb)

8 N·m (0.8 kgf·m, 5.8 ft·lb)

No. Part name Q’ty Remarks1 Port clamp bracket 12 Starboad clamp bracket 13 Ground lead 14 Screw 15 Clamp handle 26 Pin 27 Clamp screw 28 Clamp pad 29 Bolt 1 M12 × 19010 Washer 211 Bushing 212 Plate 113 Nut 114 Collar 115 Bolt 1 M6 × 14516 Washer 317 Nut 1

Clamp bracket

6B45E11-07 12/9/02 17:39 Page 13

BRKT

7-13 6B45E11

Bracket unit

6B47050E

12 N·m (1.2 kgf·m, 8.7 ft·lb)

12 N·m (1.2 kgf·m, 8.7 ft·lb)

2.5 N·m (0.2 kgf·m, 1.8 ft·lb)

8 N·m (0.8 kgf·m, 5.8 ft·lb)

No. Part name Q’ty Remarks18 Tilt rod 119 Spring 120 Swivel bracket 121 Grease nipple 322 Tilt lever 123 Spring 124 Rod 125 Tilt lever 2 126 Pin 127 Circlip 128 Rod 129 Tilt lock plate 1 130 Tilt lock plate 2 131 Collar 132 Shaft 133 Shaft 134 Circlip 2

6B45E11-07 12/9/02 17:39 Page 14

6B45E11 7-14

987654321

Clamp bracket

6B47050E

12 N·m (1.2 kgf·m, 8.7 ft·lb)

12 N·m (1.2 kgf·m, 8.7 ft·lb)

2.5 N·m (0.2 kgf·m, 1.8 ft·lb)

8 N·m (0.8 kgf·m, 5.8 ft·lb)

No. Part name Q’ty Remarks35 Spring 236 Bolt 237 Tilt stop lever 138 Stopper 239 Pin 140 Spring 141 Nut 242 Wave washer 243 Washer 144 Circlip 145 Shallow water drive lever 146 Spring 147 Washer 148 Bolt 1 M6 × 8 mm: X transom model49 Bolt 150 Cotter pin 151 Nut 152 Washer 1

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7-15 6B45E11

Bracket unit

— MEMO —

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6B45E11

987654321

ELEC

Electrical systems


Checking the electrical components............................................................8-2Measuring the peak voltage ......................................................................8-2Measuring low resistance ..........................................................................8-2

Electrical components...................................................................................8-3Starboard view...........................................................................................8-3

Wiring harness ...............................................................................................8-4Checking the engine shut-off switch..........................................................8-5Checking the ignition spark gap ................................................................8-5Checking and replacing the spark plug caps (Standard type) ..................8-6Checking the plug cap (with resister type) ................................................8-6Checking the ignition coil ...........................................................................8-7Checking the pulser coil ............................................................................8-7Checking the charge coil ...........................................................................8-8Checking the CDI unit................................................................................8-9Checking the lighting coil (option)..............................................................8-9

6B45E11-08 12/9/02 17:40 Page 1

ELEC

8-1 6B45E11

Electrical systems


Ignition tester90890-06754

Digital circuit tester90890-03174

Peak voltage adaptor B90890-03172

6B45E11-08 12/9/02 17:40 Page 2

6B45E11 8-2

987654321

Special service tools/Checking the electrical components

Checking the electrical componentsMeasuring the peak voltage

NOTE:Before troubleshooting the peak voltage,check that all electrical connections are tightand free from corrosion.

The condition of the ignition system can bedetermined by measuring the peak voltage.Cranking speed is affected by many factors,such as fouled or weak spark plug. If one ofthese factors is present, the peak voltage willbe lower than specification. In addition, if thepeak voltage is lower than specification theengine will not operate properly.

wWhen checking the peak voltage, do nottouch any of the connections of the digitalcircuit tester leads.

NOTE:9 Use the peak voltage adaptor with the digi-

tal circuit tester.9When measuring the peak voltage, set the

selector on the digital circuit tester to theDC voltage mode.9 Connect the positive pin on the peak volt-

age adaptor to the positive terminal of thedigital circuit tester.

Measuring low resistanceWhen measuring a resistance of 10 or lesswith the digital circuit tester, the correct mea-surement cannot be obtained because of theinternal resistance of the tester. To obtain thecorrect value, subtract the internal resistancefrom the displayed measurement.

NOTE:Obtain the internal resistance of the digitalcircuit tester by connecting both of its probesand checking the display.

6B480010

Correct value =displayed measurement- internal resistance

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ELEC

8-3 6B45E11

Electrical systems

Electrical componentsStarboard view

1

2

2 3

4 56

7

6B480020

1 Spark plug cap2 Spark plug3 Ignition coil4 Charge coil5 Pulser coil6 Lighting coil (option)7 Engine shut-off switch

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6B45E11 8-4

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Electrical components/Ignition system

B

BB B

G

G

O L

1

2

W Br W/G

B BO LW Br W/G

1

2 3

4

5

6

7

7

6B4003M

Wiring harness

1 Ignition coil2 Charge coil3 Pulser coil4 CDI unit5 Engine shut-off switch6 Lighting coil (option)7 Spark plug

B : BlackBr : BrownG : GreenL : BlueO : OrangeW : WhiteW/G: White/Green

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ELEC

8-5 6B45E11

Electrical systems

Checking the ignition spark gap1. Disconnect the spark plug caps from the

spark plugs.2. Connect the spark gap tester to the spark

plug cap.

3. Set the specified spark gap length on theadjusting knob.

Ignition tester: 90890-06754

6B480030

Ignition spark gap: 6 mm (0.24 in)

6B480040

Checking the engine shut-off switch1. Check the engine shut-off switch for con-

tinuity. Replace if there is no continuity.

Lead color

White (W) Black (B)

Clip removed aClip installed bEngine shut-off button pushed c

6B480160

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6B45E11 8-6

987654321

Ignition system

4. Crank the engine and observe the sparkthrough the discharge window of thespark gap tester. If it does not work prop-erly, check the plug cap, ignition coil, orthe specified peak voltages.

w9 Do not touch any of the connections of

the spark gap tester leads.9 Do not let sparks leak out of the

removed spark plug caps.9 Keep flammable gas or liquids away,

since this test can produce sparks.

Checking and replacing the sparkplug caps (Standard type)1. Check the spark plug caps for cracks or

damage. Replace if necessary.

2. Remove the spark plug cap 1 from thespark plug wire 2.

3. Check the spark plug wire for damage orcracks and the connector for damage orcorrosion. Replace if necessary.

Checking the plug cap (with resister type)1. Remove the spark plug cap 1 from the

spark plug wire 2 by turning the capcounterclockwise.

2. Measure the spark plug cap 1 resis-tance.

6B480050

6B480060

6B480070

21

6B480090

6B480080

Spark plug cap resistance:4.0 – 6.0 kΩ

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8-7 6B45E11

Electrical systems

Checking the pulser coil1. Connect the digital circuit tester with

peak voltage adaptor B to the connector.

2. Measure the pulser coil output peak volt-age. If the measurement is below specifi-cation, check the leads and measure thepulser coil resistance. Replace the pulsercoil if necessary.

Digital circuit tester: 90890-3174Peak voltage adaptor B:

90890-03172

Pulser coil peak voltage:White/green (W/G) – Black (B)

r/minUnloaded Loaded

Cranking 1,500 3,500DC V 4.0 5.0 11.0 22.0

6B480120

BW/G

BW/G

3. Replace the plug cap 1 if the resistanceis out of specification.

4. Install the spark plug cap 1 on the sparkplug wire 2 by turning the cap clockwise.

Checking the ignition coil1. Remove the spark plug cap from the

spark plug.

2. Disconnect the ignition coil lead.

3. Measure the ignition coil resistance.Replace if out of specification.

å

∫

Ignition coil resistance:å Primary coil:

Orange (O) – Black (B)0.16 – 0.24Ω at 20°C (68°F)

∫ Secondary coil:Spark plug wire – Spark plug wire

3.92 – 5.88 kΩ at 20°C (68°F)

6B480100O

B

6B480110

6B45E11-08 12/9/02 17:40 Page 8

6B45E11 8-8

987654321

Ignition system

6B480130

BW/G

Pulser coil resistance (use as refer-ence):

White/green (W/G) – Black (B)232 – 348 Ω at 20°C (68°F)

Digital circuit tester: 90890-03174Peak voltage adapter B:

90890-03172

Charge coil peak voltage:Brown (Br) – Blue (L)

r/minUnloaded Loaded

Cranking 1,500 3,500DC V 190 180 250 200

Charge coil resistance(use as reference):

Brown (Br) – Blue (L)248 – 372 Ω at 20°C (68°F)

6B480150

LBrChecking the charge coil1. Measure the charge coil output peak volt-

age. If the measurement is below specifi-cation, check the leads, and measure thecharge coil resistance. Replace if neces-sary.

6B480140

L

L

Br

Br

6B45E11-08 12/9/02 17:40 Page 9

ELEC

8-9 6B45E11

Electrical systems

Checking the CDI unit1. Connect the digital circuit test leads to

the orange and black leads from the CDIunit.

2. Measure the CDI unit output peak volt-age. If the measurement is below specifi-cation, check the lead, and measure thepeak output voltages of the pulser andcharge coils.

NOTE:Replace the CDI unit if output peak voltagesof the pulser and charge coils are on or abovespecification and the CDI unit output peakvoltage is below specification.

Checking the lighting coil (option)1. Connect the digital circuit tester lead to

the lighting coil.

2. Measure the lighting coil output peakvoltage. If the measurement is belowspecification, check the lead and mea-sure the lighting coil resistance. Replaceif necessary.


90890-03172

CDI unit output peak voltage:Orange-ground lead

r/minLoaded

Cranking 1,500 3,500DC V 160 230 180

6B480170

OB

OB


90890-03172

Lighting coil peak voltage:Green (G) – Green (G)

r/minUnloaded

Cranking 1,500 3,500DC V 7.0 18.0 37.0

Lighting coil resistance(use as reference):

Green (G) – Green (G)0.16 – 0.24 Ω at 20°C (68°F)

6B480180

GG

6B45E11-08 12/9/02 17:40 Page 10

6B45E11

987654321

TRBLSHTGTRBLSHTG

Troubleshooting

Power unit .......................................................................................................9-1Ignition system...........................................................................................9-1Fuel system ...............................................................................................9-3Compression pressure...............................................................................9-4

Lower unit .......................................................................................................9-6

6B45E11-09 12/9/02 17:41 Page 1

TRBLSHTG

9-1 6B45E11

TRBLSHTG 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 Chapters4–8 for safe maintenance procedures.9 Check that all electrical connections are tight and free from corrosion.

Power unitSymptom: Manual starter turns but engine will not start.9 Check the ignition system, fuel system, and the compression pressure as listed below.9 Be sure the air vent screw on the fuel tank is open.

Ignition system

Check the engine shut-off switch for continuity.

Check the condition of the spark plugs.

Check the ignition spark using the spark gap tester.

Measure the ignition coil resistance.

Replace the engine shut-off switch.

Is there continuity?

(continued on following page)

Yes

Yes

Yes

Clean and replace as required. No

Check the spark plug connectors or caps for deterioration.

No

Replace the connectors or caps as necessary.

Yes

Replace the ignition coil. No

No

Insert the clip into the engine shut-off switch.

Are they in good condition?

Is a good spark being produced?

No

Yes

Is there any deterioration?

Is resistance within specification?

w9 Do not touch any of the con-

nections of the spark gaptester leads.9 Do not let sparks leak out of

the removed spark plugcaps.9 Keep flammable gas or liq-

uids away, since this test canproduce sparks.

6B45E11-09 12/9/02 17:41 Page 2

6B45E11 9-2

987654321

Power unit

Ignition system (continued from previous page)

Check the ignition timing.

Check the fuel system and compression pressure.

Measure the charge coil peak output voltage.

Yes

Yes

No

CDI unit is in good operating condition.

Yes

Replace the charge coil. No

Replace the pulser coil. No

Replace the CDI unit.

Measure the pulser coil peak output voltage.

No

Yes

Yes

Does the peak voltage exceed specification values?

Does the peak output voltage exceed specifi-cation values?

Does the peak output voltage exceed specifi-cation values?

Is the ignition timing correct?

Measure the CDI unit peak voltage.

6B45E11-09 12/9/02 17:41 Page 3

TRBLSHTG

9-3 6B45E11

Troubleshooting

Fuel system9 Consult this chart after the ignition system has been checked.

Check the fuel hoses for kinks or fuel leakage.

Check for water accumulation or clogging of the fuel filter.

No

Yes Clean the fuel system from the fuel tank to the fuel filter.

Yes Correct or replace the faulty parts.

YesReplace the fuel pump.

No Disassemble the carburetor and clean the internal parts. Adjust or replace as necessary.

Are there any kinks or fuel leakage?

Check the fuel pump for leakage or internal damage.

No

Is there any leakage or inter-nal damage?

Check the operation of the carburetor.

Check the compression pressure.

Yes

Is the carburetor operat-ing correctly?

No

Is there water or residue?

6B45E11-09 12/9/02 17:41 Page 4

6B45E11 9-4

987654321

Power unit

Compression pressure9 Consult this chart after the ignition and fuel systems have been checked.

Does the compression pressure increase?

Does the pressure exceed the specification values?

Add a small amount of engine oil into the cylinder through the spark plug hole.

Measure the compression pressure.

No

YesCheck each component again.

YesCheck the piston, piston rings, and cylinder bore for wear or damage. Correct or replace if worn or damaged.

Check the cylinder head gasket and cylinder head for wear or damage. Replace if worn or damaged.

No

6B45E11-09 12/9/02 17:41 Page 5

TRBLSHTG

9-5 6B45E11

Troubleshooting

Symptom: The engine idle speed does not remain steady.

Check the operation of the carburetor.

Check the throttle cable and link operation.

Yes

No Adjust the throttle cable and throttle link.

YesCheck the ignition system chart.

No Adjust the pilot screw according to specifications.

YesUsing compressed air, clean the pilot screw, needle valve, main and pilot jets, and main nozzle. Replace any damaged parts.

Is the carburetor operat-ing correctly?

Are they operat-ing correctly?

Check the pilot screw.

Yes

Is the pilot screw setting correct?

Disassemble the carburetor and check the internal parts.

Check the throttle valve for smooth operation.

No

Are the fuel or air passages clogged?

YesCorrect or replace the carburetor.

Check the reed valve and replace if necessary.

No

Does the throttle valve stick?

No

6B45E11-09 12/9/02 17:41 Page 6

6B45E11 9-6

987654321

Power unit/Lower unit

Lower unitSymptom: The forward and reverse gear shift mechanism does not operate

properly.

Check the shift rod connection.

Check the shift lever operation.

Yes

No

No

Check the shift lever shaft and spring.

Connect correctly or replace the shift rod as necessary.

No Replace the spring and shift plunger as necessary.

Is it connected properly and in good condition?

Is it operating correctly?

Disassemble the lower case and check the dog clutch operation.

Yes

Is it in good operating condition?

Check the dog clutch and forward and reverse gears and replace if necessary.

Yes

6B45E11-09 12/9/02 17:41 Page 7

i-1 6B45E11

Index

A.After test run .............................................1-19Applicable model.........................................1-5Assembling the bearing housing...............6-16Assembling the carburetor ..........................4-9Assembling the crankshaft ........................5-30Assembling the forward gear ....................6-17Assembling the fuel pump...........................4-9Assembling the lower unit .........................6-18Assembling the manual starter .................5-15Assembling the oil seal housing................5-13Assembling the piston ...............................5-34Assembling the propeller shaft

assembly .................................................6-12Assembling the propeller shaft housing

assembly .................................................6-10Assembling the upper case.........................7-9

B.Backlash....................................................6-26Bottom cowling............................................7-3Bracket ........................................................3-7Break-in.....................................................1-18

C.Carburetor ...................................................1-8Carburetor, fuel pump .................................4-6Checking and disassembling the bearing

housing....................................................6-16Checking and replacing the spark plug

caps (Standard type).................................8-6Checking the anode ....................................3-9Checking the anode and cylinder head ....5-21Checking the carburetor..............................4-8Checking the CDI unit .................................8-9Checking the charge coil.............................8-8Checking the compression pressure...........5-4Checking the cooling water passages ........3-4Checking the cooling water pilot hole .......1-18Checking the crankshaft............................5-34Checking the cylinder block ......................5-24Checking the drain hose ...........................5-15Checking the drive pawl ............................5-14Checking the drive shaft ...........................6-17Checking the electrical components ...........8-2Checking the engine idle speed..................3-6Checking the engine shut-off switch ..1-18, 8-5Checking the exhaust covers ....................5-20Checking the forward gear ........................6-17Checking the fuel filter .........................3-3, 4-5Checking the fuel joint.................................4-5Checking the fuel joint and fuel hoses (fuel

joint to carburetor) .....................................3-3

Checking the fuel system..........................1-16Checking the gear oil ................................1-16Checking the gear oil level ..........................3-7Checking the gear shift and throttle

operation .................................................1-17Checking the gearshift operation ................3-5Checking the ignition coil ............................8-7Checking the ignition spark gap..................8-5Checking the ignition timing ........................3-6Checking the lighting coil (option) ...............8-9Checking the lower unit for air leakage.......3-8Checking the oil seal housing ...................5-13Checking the outboard motor mounting

height ......................................................1-17Checking the pinion gear ..........................6-18Checking the pistons.................................5-26Checking the plug cap

(with resister type).....................................8-6Checking the propeller shaft assembly .....6-12Checking the propeller shaft housing

assembly .................................................6-10Checking the propeller ................................3-9Checking the pulser coil ..............................8-7Checking the reed valves..........................5-18Checking the spark plugs............................3-3Checking the spiral spring.........................5-14Checking the start-in-gear protection..........3-5Checking the steering system...................1-17Checking the thermostat .............................3-4Checking the throttle cable operation .........3-5Checking the tilt operation ..........................3-7Checking the top cowling ............................3-9Checking the upper case ............................7-8Checking the water pump and shift rod ......6-8Clamp bracket ...........................................7-12Compression pressure ................................9-4Control system ............................................3-5Cooling system..........................................1-15Crankshaft, piston .....................................5-25Cylinder block............................................5-22Cylinder head ..............................................1-7Cylinder head, exhaust covers..................5-19

D.Dimensions .................................................2-6Disassembling the carburetor .................... 4-8Disassembling the crankshaft ...................5-28Disassembling the fuel pump..................... 4-9Disassembling the lower case...................6-15Disassembling the manual starter.............5-14Disassembling the muffler assembly...........7-7Disassembling the oil seal housing...........5-12Disassembling the piston ..........................5-26

6B45E11-index 12/9/02 17:42 Page 2

6B45E11 i-2

987654321

Disassembling the propeller shaft assembly .................................................6-11

Disassembling the propeller shaft housingassembly ...................................................6-9

Disassembling the upper case....................7-7Disassembly and assembly.........................1-4Drive shaft, shift rod, lower case...............6-13

E.Electrical......................................................2-5Electrical components .................................8-3Exhaust components (optional) ................1-13

F.Fire prevention ............................................1-3Fuel filter, fuel joint ......................................4-4Fuel hoses and cooling water hose ............4-2Fuel system .........................................3-3, 9-3

G.General specifications.................................2-1General torques ..........................................2-9General........................................................3-9Good working practices ..............................1-4

H.Hose routing................................................4-2How to use this manual...............................1-1

I.Identification ................................................1-5Ignition control system ..............................1-10Ignition system ............................................9-1Installing the carburetor ........................... 5-38Installing the crankcase ........................... 5-35Installing the crankshaft ............................5-35Installing the cylinder head .......................5-35Installing the electrical components ..........5-37Installing the exhaust covers.....................5-37Installing the flywheel assembly................5-38Installing the fuel filter and hoses .............5-38Installing the lower case............................6-18Installing the lower unit .............................6-21Installing the manual starter......................5-38Installing the oil seal housing....................5-39Installing the power unit ............................5-39Installing the reed valve ............................5-37Installing the spark plugs ..........................5-38Installing the start-in-gear protection

cable........................................................5-40Installing the throttle cables ......................5-39

Installing the throttle cam assembly..........5-37Installing the throttle link ...........................5-40Installing the water pump ..........................6-20Intake silencer, carburetor...........................4-3

L.Lower unit..............................2-4, 3-7, 6-4, 9-6Lubricating the outboard motor ...................3-9

M.Maintenance interval chart..........................3-2Maintenance specifications .........................2-3Manual format .............................................1-1Measuring low resistance ...........................8-2Measuring the forward and reverse gear

backlash ..................................................6-26Measuring the peak voltage........................8-2Measuring the starter rope........................5-15

P.Parts, lubricants, and sealants....................1-3Power unit..............................2-3, 3-3, 5-4, 9-1Predelivery checks ....................................1-16Propeller selection.....................................1-16Propeller shaft, propeller shaft housing ......6-6Propeller size ............................................1-16

R.Reed valve ................................................5-17Removing the crankcase ......................... 5-23Removing the crankshaft assembly ..........5-23Removing the cylinder head .....................5-20Removing the drive shaft and forward

gear .........................................................6-15Removing the electrical components ........5-12Removing the exhaust covers...................5-20Removing the flywheel magnet.................5-12Removing the lower unit..............................6-7Removing the muffler assembly..................7-7Removing the power unit ..........................5-11Removing the propeller shaft housing

assembly ...................................................6-9Removing the reed valve assembly ..........5-18Removing the water pump and shift rod .....6-7Replacing the gear oil .................................3-8

S.Safety while working ...................................1-3Selecting the forward gear shims..............6-24Selecting the pinion shims ........................6-24Selecting the reverse gear shims..............6-25

6B45E11-index 12/9/02 17:42 Page 3

i-3 6B45E11

Index

Selection ...................................................1-16Self-protection .............................................1-3Serial number..............................................1-5Shimming ..................................................6-23Side shift ...................................................1-11Special service tools ......3-1, 4-1, 5-1, 6-1, 8-1Specified torques ........................................2-8Splash guard (optional) .............................1-14Starboard view ............................................8-3Swivel bracket ...........................................7-11Symbols ......................................................1-2

T.Technical features and descriptions............1-6Test run .....................................................1-18Tightening torques ......................................2-8Tiller handle .........................................1-9, 7-1Tilt support system....................................1-12Top cowling .................................................1-6

U.Upper case..................................................7-5

V.Ventilation....................................................1-3

W.Water pump.................................................6-5Wiring harness ............................................8-4

6B45E11-index 12/9/02 17:42 Page 4

YAMAHA MOTOR CO., LTD.

Printed in JapanNov. 2002 – 1.4 × 1 !(E) Printed on recycled paper

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E9.9D E15D - PT. KBA€¦ · E9.9D SERVICE MANUAL 290492 6B4-28197-5E-11 E15D. NOTICE This manual...

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