Yamaha F6Z F8Z

F6ZF8Z

SERVICE MANUALLIT-18616-02-19

68T-28197-ZA-11

NOTICEThis manual has been prepared by Yamaha primarily for use by Yamaha dealers and theirtrained mechanics when performing maintenance procedures and repairs to Yamahaequipment. It has been written to suit the needs of persons who have a basic understandingof the mechanical and electrical concepts and procedures inherent in the work, for withoutsuch knowledge attempted repairs or service to the equipment could render it unsafe or unfitfor use.Because Yamaha has a policy of continuously improving its products, models may differ indetail from the descriptions and illustrations given in this publication. Use only the latestedition of this manual. Authorized Yamaha dealers are notified periodically of modificationsand significant changes in specifications and procedures, and these are incorporated insuccessive editions of this manual.

F6Z, F8ZSERVICE MANUAL2000 by Yamaha Motor Corporation, USA1st Edition, April 2000All rights reserved.Any reprinting or unauthorized use without thewritten permission of Yamaha MotorCorporation, USA is expressly prohibited.Printed in USAP/N LIT-18616-02-19

HOW TO USE THIS MANUALMANUAL FORMATAll of the procedures in this manual are organised in a sequential, step-by-step format. Theinformation has been compiled to provide the mechanic with an easy to read, handlyreference that contains comprehensive explanations of all disassembly, repair, assembly, andinspection operations.In this revised format, the condition of a faulty component will precede an arrow symbol andthe course of action required will follow the symbol, e.g.,BearingsPitting/scratches Replace.To assist you in finding your way through this manual, the section title and major heading isgiven at the top of every page.

MODEL INDICATIONMultiple models are referred to in this manual and their model indications are noted asfollows.Model name (W/W)USA and Canada nameIndication

F6AMH

F8CMH

F6MH

F8MH

F6AMH

F8CMH

ILLUSTRATIONSThe illustrations within this service manual represent all of the designated models.

CROSS REFERENCESThe cross references have been kept to a minimum. Cross references will direct you to theappropriate section or chapter.

IMPORTANT INFORMATIONIn this Service Manual particularly important information is distinguished in the followingways.The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

WARNINGFailure 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.

CAUTIONA CAUTION indicates special precautions that must be taken to avoid damage to theoutboard motor.

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

HOW TO USE THIS MANUAL1 The main points regarding removing/installing and disassembly/assembly procedure areshown in the exploded views.2 The numbers in the exploded views indicate the required sequence of the procedure andshould be observed accordingly.3 Symbols are used in the exploded views to indicate important aspects of the procedure.A list of meanings for these symbols is provided on the following page.4 It is important to refer to the job instruction charts at the same time as the explodedviews.These charts list the sequence that the procedures should be carried out in, as well asproviding exploded on part names, quantities, dimensions and important points relatingto each relevant task.Example:O-ring 39.5 x 2.5 mm: inside diameter (D) x ring diameter (d)

5 In addition to tightening torques, the dimensions of the bolts and screws are alsomentioned.Example:Bolt and screw size 10 x 25 mm : bolt and screw diameter (D) x length (L)

6 In addition to the exploded views and job instruction charts, this manual providesindividual illustrations when further explanations are required to explain the relevantprocedure.

SYMBOLS1

2

3

4

5

6

7

8

Symbols 1 to 9 are designed as thumb-tabsto indicate the content of a chapter.1 General information2 Specifications3 Periodic check and adjustment4 Fuel system5 Power unit6 Lower unit7 Bracket unit8 Electrical system9 Trouble analysis

Symbols : to E indicate specific data.> Special toolA Specified liquidB Specified engine speedC Specified torqueD Specified measurementE Specified electrical value[Resistance (), Voltage (V), Electricalcurrent (A)]

9

0

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

Symbols F to I in an exploded diagramindicate the grade of lubricant and thelocation of the lubricant point.F Apply Yamaha 4-stroke motor oilG Apply water resistant grease(Yamaha grease A, Yamaha marinegrease)H Apply Yamaha grease DI Apply molybdenum disufied oilSymbols J to O in an exploded diagramindicate the grade of the sealing or lockingagent and the location of the applicationpoint.J Apply Gasket MakerK Apply Yamabond #4(Yamaha bond number 4)L Apply LOCTITE No.271 (Red LOCTITE)M Apply LOCTITE No.242 (Red LOCTITE)N Apply LOCTITE No.572O Apply silicon sealant

CONTENTSGENERAL INFORMATIONSPECIFICATIONSPERIODIC CHECK ANDADJUSTMENTFUEL SYSTEMPOWER UNITLOWER UNITBRACKET UNITELECTRICAL SYSTEMTROUBLE ANALYSIS

123456789

CHAPTER 1GENERAL INFORMATION

IDENTIFICATION...............................................................................................1-1SERIAL NUMBER .......................................................................................1-1STARTING SERIAL NUMBERS .................................................................1-1SAFETY WHILE WORKING ..............................................................................1-2FIRE PREVENTION .....................................................................................1-2VENTILATION.............................................................................................1-2SELF-PROTECTION ....................................................................................1-2OILS, GREASES AND SEALING FLUIDS ..................................................1-2GOOD WORKING PRACTICES ..................................................................1-3DISASSEMBLY AND ASSEMBLY .............................................................1-4SPECIAL TOOLS ...............................................................................................1-5MEASURING ..............................................................................................1-5REMOVING AND INSTALLING .................................................................1-7

1

IDENTIFICATIONIDENTIFICATIONSERIAL NUMBERThe outboard motors serial number isstamped on a label which is attached to theport clamp bracket.

NOTE:As an antitheft measure, a special label onwhich the outboard motors serial numberis stamped is bonded to the port clampbracket. The label is specially treated sothat peeling it off causes cracks across theserial number.

1234

Model nameApproval model codeTransom heightSerial number

STARTING SERIAL NUMBERSThe starting serial number blocks are asfollows:Model nameWorldUSA,wideCanada

1-1

Applicablemodelcode

F6AMH

F6MH

68R

F8CMH

F8MH

68T

StartingserialnumberS:000101L:300101S:000101L:300101-

SAFETY WHILE WORKINGSAFETY WHILE WORKINGThe procedures given in this manual arethose recommended by Yamaha to befollowed by Yamaha dealers and theirmechanics.

FIRE PREVENTIONGasoline (petrol) is highly flammable.Petroleum vapor is explosive if ignited.Do not smoke while handling gasoline andkeep it away from heat, sparks and openflames.

VENTILATIONPetroleum vapor is heavier than air and isdeadly if inhaled in large quantities. Engineexhaust gases are harmful to breathe.When test-running an engine indoors,maintain good ventilation.

SELF-PROTECTIONProtect your eyes with suitable safetyglasses or safety goggles, when grindingor when doing any operation which maycause particles to fly off. Protect hands andfeet by wearing safety gloves or protectiveshoes if appropriate to the work you aredoing.

OILS, GREASES AND SEALING FLUIDSUse only genuine Yamaha oils, greases andsealing fluids or those recommended byYamaha.

1-2

SAFETY WHILE WORKINGUnder normal conditions or use, thereshould be no hazards from the use of thelubricants mentioned in this manual, butsafety is all- important, and by adoptinggood safety practices, any risk isminimized. A summary of the mostimportant precautions is as follows:1. While working, maintain goodstandards of personal and industrialhygiene.2. Clothing which has becomecontaminated with lubricants shouldbe changed as soon as practicable, andlaundered before further use.3. Avoid skin contact with lubricants: donot, for example, place a soiledwipingrag in your pocket.4. Hands and any other parts of the bodywhich have been in contact withlubricants or lubricant-contaminatedclothing, should be thoroughly washedwith hot water and soap as soon aspracticable.5. To protect the skin, the application of asuitable barrier cream to the handsbefore working, is recommended.6. A supply of clean lint-free clothsshould be available for wipingpurposes.

GOOD WORKING PRACTICES1. The right toolsUse the recommended special tools toprotect parts from damage. Use theright tool in the right manner-do notimprovise.2. Tightening torqueFollow the tightening torqueinstructions. When tightening bolts,nuts and screws, tighten the large sizesfirst, and tighten inner-positionedfixings before outer-positioned ones.

1-3

SAFETY WHILE WORKING3. Non-reusable itemsAlways use new gaskets, packings, Orings, split-pins, circlips, etc., onreassembly.

DISASSEMBLY AND ASSEMBLY1. Clean parts with compressed air whendisassembling.2. Oil the contact surfaces of movingparts before assembly.

3. After assembly, check that movingparts operate normally.

4. Install bearings with the manufacturersmarkings on the side exposed to view,and liberally oil the bearings.5. When installing oil seals, apply a lightcoating of water-resistant grease to theoutside diameter.

1-4

SPECIAL TOOLSSPECIAL TOOLSUsing the correct special toolsrecommended by Yamaha, will aid thework and enable accurate assembly andtune-up.Improvising and using improper tools candamage the equipment.

NOTE:

For U.S.A. and Canada, use part numbersthat start with J-, YB- YM-, YU-orYW-.For other countries, use part numbersthat start with 90890-.

MEASURING

1a

1 Engine tachometerP/N. YU-08036-B ..........................90890-06760 .........................

b

ab

2 Compression gaugeP/N. YU-3322390890-031602

4 ab

3 Timing lightP/N. YM-33277-A90890-03141

3

4 Mity vacP/N. YB-35956-A............................ a90890-06756...........................b

5

5 Leakage testerP/N. N.A.90890-067626a

7a

b

6Digital circuit testerP/N. YU-34899-A............................a90890-06752 ......................... b7 Peak voltage testerP/N. YU-39991 .............................. a90890-03172 ......................... b

b

8 Spark gap testerP/N. YM-34487 .............................. a90890-06754 ......................... b8a

b

1-5

SPECIAL TOOLS9

9 Bearing house puller

0

P/N.

YB-06234N.A

0 Universal pullerA

P/N.

B

YB-06117N.A.

A Dial gauge standP/N.C

D

YU-0309790890-01252

B Magnet baseP/N.

YU-3448190890-06705

C Backlash indicatorP/N.

YU-0626590890-06706

D Magnetic base attaching plateP/N.

1-6

YB-0700390890-07003

SPECIAL TOOLS1a

REMOVING AND INSTALLING

b

1 Flywheel holderP/N.

YB-06139 ............................... a90890-06522 ......................... b

2 Universal puller2a

b

P/N.

YB-06117 ............................... a90890-06521 ......................... b

3 Valve spring compressorP/N.3

4

YM-0125390890-04019

4 Valve spring compressor attachmentP/N.

YM-0410890890-04108

5 Valve guide remover5

6

P/N.

N.A.90890-06801

6 Valve guide installerP/N.7

YM-0112290890-06801

7 Valve guide reamerP/N.

N.A.90890-06804

8 Valve seat cutter set8a

b

P/N.

YM-91043-C .......................... a90890-06803 ......................... b

9 Valve seat lapperP/N.9

0

N.A.90890-04101

0 Piston sliderP/N.

YU-3329490890-05158

A Slide hammer handleA

B

P/N.

YB-0609690890-06531

B Stopper guide plateP/N.C

N.A.90890-06501

C Stopper guide standP/N.

1-7

N.A.90890-06538

SPECIAL TOOLSD Bearing puller assembly

D

P/N.

N.A.90890-06535

E Bushing installer center boltEa

P/N.

b

YB-06029 ............................... a90890-06601 ......................... b

F Driver rod (small)P/N.Fa

YB-06229 ............................... a90890-06652 ......................... b

G Driver rod (large)

b

P/N.

YB-06071 ............................... a90890-06606 ......................... b

H Driver rod (short)P/N.Ga

b

N.A.90890-06604

I P/N. Bearing/oil seal attachmentP/N.

H

YB-06197, YB-06298,YB-06230, YB-06112,YB-06611, YB-37350.............. a90890-06653, 90890-06649,90890-06617, 90890-06614,90890-0661............................ b

J Bearing/oil seal attachmentP/N.Ia

b

YB-06167 ............................... a90890-06634 .......................... b

K Bearing/oil seal attachmentP/N.

Ja

L Crankshaft holder

b

P/N.

Ka

YB-06028 ............................... a90890-06650 .......................... b

b

L

1-8

YB-0656190890-06561

CHAPTER 2SPECIFICATIONS

GENERAL SPECIFICATIONS (F6AMH/F6MH) ................................................2-1GENERAL SPECIFICATIONS (F8CMH/F8MH) ................................................2-3MAINTENANCE SPECIFICATIONS..................................................................2-5POWER UNIT..............................................................................................2-5LOWER UNIT..............................................................................................2-8ELECTRICAL ...............................................................................................2-9OUTBOARD DIMENSIONS......................................................................2-11BRACKET DIMENSIONS..........................................................................2-13TIGHTENING TORQUES ................................................................................2-14SPECIFIED TORQUES ..............................................................................2-14GENERAL TORQUES ...............................................................................2-16

2

GENERAL SPECIFICATIONS (F6AMH/F6MH)GENERAL SPECIFICATIONS (F6AMH/F6MH)Item

World wideUSA, Canada

DIMENSIONOverall lengthOverall widthOverall height(S)(L)WEIGHT(with aluminum propeller)(S)(L)PERFORMANCEMaximum output (ISO)Full throttle operating rangeMaximum fuel consumption

POWER UNITTypeNumber of cylindersTotal displacementBore x strokeCompression ratioCompression pressureNumber of carburetorsControl systemStarting systemIgnition control systemAlternator typeAlternator outputEnrichment systemSpark plugExhaust systemLubrication systemIgnition timing

Unit

ModelF6AMHF6MH

mm (in)mm (in)

1,031 (40.6)419 (16.5)

mm (in)mm (in)

998 (39.3)1,125 (44.3)

kg(lb)kg(lb)

38.0 (83.8)39.5 (87.1)

kW (hp) @r/minr/minL (US gal, Impgal)/h @ 5,500r/min

4.4 (6.0) @ 5,0004,500 - 5,5002.5 (0.66, 0.55)

4 stroke, SOHC, in-line2197 (11.8)56.0 x 40.0 (2.2 x 1.6)8.79950 (9.5, 135.1)

cm3 (cu.in)mm (in)kPa (kgf/cm2,psi)

V-A

Degree (BTDC)

2-1

1Tiller controlManualCDIOne lighting coil / Two lighting coils12 - 6Choke typeBR6HS-10Propeller bossWet sump5 - 30

GENERAL SPECIFICATIONS (F6AMH/F6MH)

ItemFUEL AND OILFuel typeFuel ratingEngine oil typeEngine oil grade

Total quantityGear oil typeGear oil gradeGear oil capacity


ModelF6AMHF6MH

Unit

Unleaded regular gasoline86914-stroke engine oilAPI SE, SF, SG or SHSAE 10W-30, 10W-40800 (27.0, 28.2)

PON(* 1 )RON(* 2 )

cm3 (US oz,lmp oz)

Hypoid gear oilGL-4 (SAE #90)150 (5.1, 5.3)

cm3 (US oz,Imp oz)

BRACKETTilt angleShallow water drive angleSteering angle (right + left)DRIVE UNITGear positionsGear ratio (gear/pinion)Gear typePropeller directionPropeller drive systemPropeller ID markELECTRICALBattery capacityCold cranking performance(* 1 ) PON : Pump Octane Number(* 2 ) RON : Research Octane Number

DegreeDegreeDegree

7824, 3745 + 45F-N-R2.08 (27/13)Straight bevel gearClockwise (Back view)SplineN

Ah (kC)A

40 (144)145 - 380

2-2

GENERAL SPECIFICATIONS (F8CMH/F8MH)GENERAL SPECIFICATIONS (F8CMH/F8MH)Item


DIMENSIONOverall lengthOverall widthOverall height(S)(L)WEIGHT(with aluminum propeller)(S)(L)PERFORMANCEMaximum output (ISO)Full throttle operating rangeMaximum fuel consumption

POWER UNITTypeNumber of cylindersTotal displacementBore x strokeCompression ratioCompression pressureNumber of carburetorsControl systemStarting systemIgnition control systemAlternator typeAlternator outputEnrichment systemSpark plugExhaust systemLubrication systemIgnition timing

Unit

ModelF8CMHF8MH

mm (in)mm (in)

1,031 (40.6)419 (16.5)

mm (in)mm (in)

998 (39.3)1,125 (44.3)

kg (lb)kg (lb)

38.0 (83.8)39.5 (87.1)

kW (hp) @r/minr/minL (US gal, Impgal)/h @ 5,500r/min

5.9 (8.0) @ 5,5005,000 - 6,0003.3 (0.87, 0.73)

4 stroke, SOHC, in-line2197 (11.8)56.0 x 40.0 (2.2 x 1.6)8.79950 (9.5, 135.1)

cm3 (cu.in)mm (in)kPa (kgf/cm2,psi)

V-A

Degree (BTDC)

2-3

1Tiller controlManualCDIOne lighting coil / Two lighting coils12 - 6Choke typeBR6HS-10Propeller bossWet sump5 - 30

GENERAL SPECIFICATIONS (F8CMH/F8MH)

ItemFUEL AND OILFuel typeFuel ratingEngine oil typeEngine oil grade

Total quantityGear oil typeGear oil gradeGear oil capacity


ModelF8CMHF8MH

Unit

Unleaded regular gasoline86914-stroke engine oilAPI SE, SF, SG or SHSAE 10W-30, 10W-40800 (27.0, 28.2)

PON(* 1 )RON(* 2 )

cm3 (US oz,lmp oz)

Hypoid gear oilGL-4 (SAE #90)150 (5.1, 5.3)

cm3 (US oz,Imp oz)

BRACKETTilt angleShallow water drive angleSteering angle (right + left)DRIVE UNITGear positionsGear ratio (gear/pinion)Gear typePropeller directionPropeller drive systemPropeller ID markELECTRICALBattery capacityCold cranking performance(* 1 ) PON : Pump Octane Number(* 2 ) RON : Research Octane Number

DegreeDegreeDegree

7824, 3745 + 45F-N-R2.08 (27/13)Straight bevel gearClockwise (Back view)SplineN

Ah (kC)A

40 (144)145 - 380

2-4

MAINTENANCE SPECIFICATIONSMAINTENANCE SPECIFICATIONSPOWER UNITModelItem


CYLINDER HEADWarpagelimit

Unit

F6AMHF6MH

F8CMHF8MH

mm (in)

0.1 (0.004)

mm (in)mm (in)mm (in)

56.000 - 56.015 (2.2047 - 2.2053)0.08 (0.0031)0.05 (0.0020)

mm (in)

13.000 - 13.018 (0.5118 - 0.5125)

mm (in)

12.941 - 12.951 (0.5095 - 0.5099)

mm (in)mm (in)mm (in)mm (in)mm (in)

23.45 - 23.55 (0.9232 - 0.9271)23.45 - 23.55 (0.9232 - 0.9271)19.95 - 20.05 (0.7854 - 0.7893)19.95 - 20.05 (0.7854 - 0.7893)17.975 - 17.991 (0.7077 - 0.7083)

mm (in)

15.975 - 15.991 (0.6289 - 0.6296)

mm (in)

0.03 (0.0012)

INEX

mm (in)mm (in)

0.15 - 0.20 (0.006 - 0.008)0.20 - 0.25 (0.008 - 0.010)

INEX

mm (in)mm (in)

23.9 - 24.1 (0.94 - 0.95)21.9 - 22.1 (0.86 - 0.87)

CYLINDER BODYBore (D1, D2)Taper limitOut-of-round limitROCKER ARMRocker arminsidediameter

a

ROCKER ARM SHAFTRocker shaftoutsidediameter

b

CAMSHAFTIntake (A)Intake (B)Exhaust (A)Exhaust (B)Cylinder headJournal diameterOil pump housing journaldiameterCamshaft round limitVALVEValve clearanceValve dimensions

Head dimension A

2-5

MAINTENANCE SPECIFICATIONS

Item

World wideUSA, CanadaFace width BINEXSeat widthCINEXMergin thickness DINEXStem outside diameterINEXValve guide insideINdiameterEXStem-to-guide clearanceINEXStem runout limitINEXVALVE SPRINGFree lengthFree lengthlimitTilt limit

PISTONPiston-to-cylinder clearancePistondiameter (D)Measuringpoint (H)Pin boss inside diameterOversize piston diameter1st2ndPISTON PINOutsideDiameter (D)PISTON RINGTop ringDimension (B)Dimension (T)End gap (installed)Side clearance

mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)

ModelF6AMHF8CMHF6MHF8MH1.84 - 2.26 (0.072 - 0.089)1.84 - 2.26 (0.072 - 0.089)0.6 - 0.8 (0.023 - 0.031)0.6 - 0.8 (0.023 - 0.031)0.7 (0.027)1.0 (0.039)5.475 - 5.490 (0.2156 - 0.2161)5.460 - 5.475 (0.2150 - 0.2156)5.500 - 5.512 (0.2165 - 0.2170)5.500 - 5.512 (0.2165 - 0.2170)0.010 - 0.037 (0.0004 - 0.0015)0.025 - 0.052 (0.0010 - 0.0020)0.03 (0.0012)0.03 (0.0012)

mm (in)mm (in)

27.6 (1.09)27.6 (1.09)

mm (in)

1.0 (0.04)

mm (in)mm (in)

0.035-0.065 (0.0014-0.0026)55.950-55.965 (2.2028-2.2033)

mm (in)

1.5 (0.06)

mm (in)

14.004-14.015 (0.5513-0.5518)

mm (in)mm (in)

56.200-56.215 (2.2126-2.2132)56.450-56.465 (2.2224-2.2230)

mm (in)

13.996-14.000 (0.5510-0.5512)

mm (in)mm (in)mm (in)mm (in)mm (in)

1.2 (0.05)2.05 (0.08)0.15-0.30 (0.006-0.012)0.04-0.08 (0.0016-0.0031)

Unit

2-6

MAINTENANCE SPECIFICATIONSModelItem


2nd ringDimension (B)Dimension (T)End gap (installed)Side clearanceOil ringDimension (B)Dimension (T)End gap (installed)CONNECTING RODSmall end inside diameterBig end inside diameterBig end oil clearanceBig end-to-crank pin sideclearanceCRANKSHAFTCrankcase journal diameterCrank pin journal diameterRunout limit

CRANKCASECrankshaft journal insidediameterCrankshaft journal oil clearance(bearing installed)Bearing mark color

THERMOSTATFull-close temperatureValve opening temperatureFull-open temperatureValve liftFUEL PUMPDischarge (@ 2,750 r/min)Maximum pressure(@ 2,750 r/min)diaphragm strokePlunger stroke

Unit

F6AMHF6MH

F8CMHF8MH

mm (in)mm (in)mm (in)mm (in)

1.5 (0.06)2.5 (0.10)0.30 - 0.45 (0.012 - 0.018)0.03 - 0.07(0.012 - 0.0028)


2.5 (0.10)2.45 (0.10)0.20 - 0.70 (0.008 - 0.028)

mm (in)mm (in)mm (in)mm (in)

14.015 - 14.029 (0.5518 - 0.5523)27.030 - 27.042 (1.0642 - 1.0646)0.030 - 0.042 (0.0012 - 0.0017)0.05 - 0.22 (0.002 - 0.009)


29.997 - 30.009 (1.1810 - 1.1815)26.997 - 27.009 (1.0629 - 1.0633)0.03 (0.0012)

mm (in)

33.016 - 33.040 (1.3000 - 1.3008)

mm (in)

0.011 - 0.039 (0.0004 - 0.0015)

mm (in)

A:Blue 33.032 - 33.040 (1.3005 - 1.3008)B:Black 33.024 - 33.032 (1.30016 - 1.3005)C:Brown 33.016 - 33.024 (1.2998 - 1.30016)

C (F)C (F)C (F)mm (in)

Below 60 (140)58 - 62 (136.4 - 143.6)Abobe 70 (158)3 (0.12)

L/h(US gal/h,lmp gal/h)kPa (kg/cm2 ,psi)mm (in)mm (in)

Above 12 (3.17, 2.64)Below 117.6 (1.2, 17.1)2.4 - 4.8 (0.095 - 0.189)3.525 - 6.575 (0.139 - 0.259)

2-7



OIL PUMPDischarge (@ 3,000 r/min)Outer rotor-housingclearanceOuter rotor-inner rotorclearanceRotor-housing clearance

Unit

F6AMHF6MH

F8CMHF8MH

L/h (US gal/h,Imp gal/h)mm (in)

Abobe 3.5 (0.925, 0.77)0.10 - 0.15 (0.004 - 0.006)

mm (in)

0.04 - 0.14 (0.002 - 0.006)

mm (in)

0.03 - 0.09 (0.001 - 0.004)

ab

c

CARBURETORStamped mark

Main jetPilot jetFloat height

##mm (in)

a

Idle speed

68R-00 (F6AMH/F6MH) 68T-00 (F8CMH/F8MH)68R-20 (F6AMH for SAV) 68T-20 (F8CMH for SAV)69F-20 (F6BMH)68T-30 (F8CW)7474393919.0 - 20.019.0 - 20.0(0.75 - 0.79)(0.75 - 0.79)

r/min

1,050 50

Unit

F6AMHF6MH

1,050 50

LOWER UNITModelItem


GEAR BACKLASHPinion - Forward gearPinion - Reverse gearPinion shim thicknessForward gear shim thicknessReverse gear shim thickness

mm (in)mm (in)mmmmmm

F8CMHF8MH

0.88 - 1.26 (0.0346 - 0.0496)1.01 - 1.38 (0.0398 - 0.0543)1.9, 2.0, 2.1, 2.20.10, 0.12, 0.15, 0.18, 0.300.1

2-8

MAINTENANCE SPECIFICATIONSELECTRICALModelItem

World wideUnitUSA, CanadaIGNITION SYSTEMIgnition timingDegree (BTDC)Charge coil output peak voltage(Br L)@ cranking (opened)V@ cranking (closed)V@ 1,500 r/minV@ 3,500 r/minVPulser coil output peak voltage(W/R B)@ cranking (opened)V@ cranking (closed)V@ 1,500 r/minV@ 3,500 r/minVCDI unit output peak voltage(O B)@ cranking (opened)V@ cranking (closed)V@ 1,500 r/minV@ 3,500 r/minVIgnition spark gapmm (in)Charge coil resistance (Br L)Pulser coil resistance (W/R B)Ignition coil resistancePrimary (O B)Secondary (Between outputs)kSpark plug cap resistancekIGNITION CONTROL SYSTEMOil pressure switch operatingkPa (kg/cm2 ,pressurepsi)Oil pressure control speedr/minEngine speed limiter controlr/minspeedSTARTING SYSTEMFuseAFuel enrichment solenoidresistance

2-9

F6AMHF6MH

F8CMHF8MH5 - 30

112154185185

7.03.57.010.5

53.21401681680.9 (0.04)232 - 348240 - 3600.68.754.314.7 (0.15, 2.13)

14.7 (0.15, 2.13)

2,000 150F6A: 6,200 100

2,000 1506,200 100

104



Unit

F6AMHF6MH

STARTER MOTORTypeRatingSecondOutputkWBrush lengthmm (in)Brush length limitmm (in)Commutator diametermm (in)Commutator diameter limitmm (in)CHARGING SYSTEM(ONE LIGHTING COIL MODEL)Lighting coil output peakvoltage (G G)@ cranking (opened)V@ cranking (closed)V@ 1,500 r/min (opened)V@ 3,500 r/min (opened)VRectifier output peak voltage(R B)@ cranking (opened)V@ cranking (closed)V@ 1,500 r/min (opened)V@ 3,500 r/min (opened)VCharging currentA @ 5,000 r/minLighting coil resistance (GG)CHARGING SYSTEM(TWO LIGHTING COILS MODEL)Lighting coil output peakvoltage (G G)@ cranking (opened)V@ cranking (closed)V@ 1,500 r/min (opened)V@ 3,500 r/min (opened)VRectifier/regulator output peakvoltage(R B)@ cranking (opened)V@ cranking (closed)V@ 1,500 r/min (opened)V@ 3,500 r/min (opened)VCharging currentA @ 5,000 r/minLighting coil resistance (GG)

2-10

F8CMHF8MHBendix300.612.5 (0.49)9.0 (0.35)30.0 (1.18)29.0 (1.14)

3.53.51433

2.813.332.25.50.24 - 0.36

8.48.433.677.0

7.7272760.61 - 0.91

MAINTENANCE SPECIFICATIONSOUTBOARD DIMENSIONS

2-11

MAINTENANCE SPECIFICATIONSSymbol

Model

World wide

Unit

USA, Canada

F6AMH

F8CMH

F6MH

F8MH

L1

mm (in)

430 (16.9)

L2

mm (in)

121.5 (4.8)

L3

mm (in)

601 (23.7)

L4

mm (in)

355 (14.0)

(S)

mm (in)

72 (2.8)

(L)

mm (in)

98.5 (3.9)

(S)

mm (in)

705.5 (27.8)

(L)

mm (in)

822 (32.4)

L7

mm (in)

271 (10.7)

L8

mm (in)

189 (7.4)

L9

mm (in)

L10

mm (in)

66.5 (2.6)

(S)

mm (in)

681.5 (26.9)

(L)

mm (in)

808.5 (31.8)

H2

mm (in)

317 (12.5)

H3

mm (in)

123 (4.8)

(S)

mm (in)

435.5 (17.1)

(L)

mm (in)

562.5 (22.1)

mm (in)

675.5 (26.6)

(S)

mm (in)

593.5 (23.4)

(L)

mm (in)

546 (21.5)

H7

mm (in)

202.5 (8.0)

H8

mm (in)

4 (0.16)

H9

mm (in)

528 (20.8)

H10

mm (in)

32 (1.3)

H11

mm (in)

W1

mm (in)

171.5 (6.8)

W2

mm (in)

247.5 (9.7)

W3

mm (in)

158.5 (6.2)

W4

mm (in)

158.5 (6.2)

W5

mm (in)

285.5 (11.2)

W6

mm (in)

654 (25.7)

A1

Degree

45

A2

Degree

66

A3

Degree

L5L6

H1

H4H5H6

2-12

MAINTENANCE SPECIFICATIONSBRACKET DIMENSIONS

SymbolWorld wideUSA, CanadaB1B2B3B4B5B6B7B8B9B10B11B12C1C2C3D1D2D3D4T1

ModelUnit

F6AMHF6MH

mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)mm (in)

F8CMHF8MH70.5 (2.8)198 (7.8)95.3 (3.8)112 (4.4)105.3 (4.1)207 (8.1)18 (0.7)28 (1.1)65 (2.6)8.3 (0.3)8.3 (0.3)

2-13

TIGHTENING TORQUESTIGHTENING TORQUESSPECIFIED TORQUESPart Threadnamesize

Parts to be tightenedTOP COWLINGTop cowling hook mountingFUEL SYSTEMFuel joint mountingFuel pump housingFuel pump check valveThrottle axle link lockPOWER UNITBreather cover mountingFuel enrichment solenoid mountingIntake manifold mounting

1st2nd

Manual starter drive plate mountingFlywheel rotor mountingDrive gear mountingDriven gear mountingThermostat housing cover mountingPower unit mountingRelief valve assemblyThrottle link bracket mountingAnode mountingExhaust outer cover mounting

1st2nd

Spark plugCylinder head mounting

1st2nd1st2nd

Oil pump assembly mountingOil pump housingRocker arm locknutCrankcase mountingConnecting rod mountingLOWER UNITApron mountingExhaust gas measuringEngine oil drainDrain plug damper mountingOil pan mountingMuffler mountingGear oil level checkGear oil drainPropeller mounting (STD)Propeller mounting (DUAL)

1st2nd1st2nd

Qty

Tightening torquesNm kgfm ftlb

Bolt

M5

2

5

0.5

3.7

BoltScrewScrewScrew

M6M4M3M5

1421

81.50.51.5

0.80.150.050.15

5.91.110.371.1

ScrewScrew

M4M4

54

Bolt

M6

5

ScrewNutNutBoltBoltBoltBoltPlugScrew

M12M24M6M6M8M14M6M16M5

1111261211

Bolt

M6

5

M14

2

Bolt

M8

6

Bolt

M6

3

BoltScrewNut

M6M6M5

324

Bolt

M8

6

Bolt

M7

4

2261261003612821881826122515306128581530612

0.20.20.61.20.6103.61.20.82.10.80.81.80.20.61.22.51.53.00.61.20.80.50.81.53.00.61.2

1.51.54.48.84.47226.58.85.915.55.95.913.31.54.48.818.411.122.14.48.85.93.75.911.122.14.48.1

ScrewBoltPlugScrewBoltBoltPlugPlugNutNut

M6M8M10M5M8M6M8M8M10M10

2111221111

4182422112771720

0.41.82.40.22.11.20.70.71.72.0

2.913.317.81.515.58.85.15.112.514.7

2-14

Remarks

TIGHTENING TORQUESParts to be tightenedWater inlet cover mountingGround terminal mountingBRACKETShift handle mountingCowling clamp mountingBottom cowling mountingHandle bracket mountingHandle throttle gripHandle throttle shaft plate mountingHandle mounting (outside)Handle mounting (inside)Handle shift cable stay mountingHandle shift lever mountingHandle rubber bushing mountingAdapter bracket mounting (*1)Adapter mounting (*1)Upper mountUpper mount rubbler mountingLower mountClamp bracket capStopper mountingPivot shaft lockGrease nippleSteering friction plate mountingSteering friction piece mountingSteering friction self lockingNeutral switch stay mountingRecoil starter cable mountingGround lead mountingELECTRICALCharge coil mountingPulser coil mountingLighting coil mountingLighting coil lead clamp mounting (*2)CDI unit mountingIgnition coil mountingRectifier mounting (*2)Rectifier bracket mounting (*2)Rectifier/regulator mountingOil pressure switchOil pressure switch terminalStarter motor bracket mountingStarter motor mountingStarter motor positive (+) terminalStarter motor negative (-) terminalStarter relay terminalStarter relay fitting plate mountingLead coupler clamp mountingGround terminal mounting*1: For water-flushing model*2: For One lighting coil model

Part ThreadnamesizeScrewM5ScrewM5

Qty11

Tightening torquesNm kgfm ftlb50.53.720.21.5

BoltBoltBoltNutScrewScrewNutNutBoltBoltScrewBoltScrewNutBoltBoltNutBoltBoltNippleBoltBoltNutBoltBoltScrew

M5M6M6M10M5M5M10M10M6M8M6M6M6M8M6M6M6M6M5M5M10M6M6M5

1142121111321224241121121 or 21

3.588363.53.522108183.582211215138435.45.4410102.5

0.350.80.83.60.350.352.21.00.81.80.350.80.22.11.21.51.30.80.40.30.540.540.41.01.00.25

2.65.95.926.52.62.616.27.45.913.32.65.91.515.58.811.19.65.92.92.23.93.92.97.47.41.8

BoltBoltBoltBoltBoltBoltScrewBoltBoltScrewBoltBoltNutBoltBoltBoltScrewBolt

M6M5M6M6M6M6M5M8M6PT1/8M4M8M8M6M8M6M6M6

222 or 42221211132112122

125128883.51889221214184818

1.20.51.20.80.80.80.351.80.80.90.22.12.10.41.80.40.80.10.8

8.83.78.85.95.95.92.613.35.96.61.515.515.52.913.32.95.90.75.9

2-15

Remarks

TIGHTENING TORQUES

Nut (A)

Bolt (B)

8 mm10 mm12 mm14 mm17 mm

M5M6M8M10M12

GENERAL TORQUES

General torquespecificationskgfmftlbNm50.53.680.85.8181.813363.625434.331

This chart specifies tightening torques forstandard fasteners with a standard ISOthread pitch. Tightening torquespecifications for special components orassemblies are provided in applicablesections of this manual. To avoid warpage,tighten multifastener assemblies in acrisscross fashion and progressive stagesuntil the specified tightening torque isreached.Unless otherwise specified, tighteningtorque specifications require clean, drythreads.Components should be at roomtemperature.

2-16

CHAPTER 3PERIODIC CHECK AND ADJUSTMENT

MAINTENANCE INTERVAL CHART ............................................................... 3-1TOP COWLING ................................................................................................ 3-2CHECKING THE WATER DRAIN HOLE ................................................... 3-2CHECKING THE TOP COWLING FIT ....................................................... 3-2FUEL SYSTEM ................................................................................................ 3-3CHECKING THE FUEL LINE ..................................................................... 3-3CONTROL SYSTEM ........................................................................................ 3-4ADJUSTING THE SHIFT CONTROL CABLE ............................................3-4ADJUSTING THE THROTTLE CONTROL CABLES ................................ 3-5ADJUSTING THE THROTTLE AXLE LINK ............................................... 3-6ADJUSTING THE ENGINE IDLING SPEED ............................................. 3-7ADJUSTING THE START-IN-GEAR PROTECTION DEVICE.................... 3-8POWER UNIT .................................................................................................. 3-9CHECKING THE ENGINE OIL LEVEL ....................................................... 3-9REPLACING THE ENGINE OIL ................................................................. 3-9ADJUSTING THE VALVE CLEARANCE ................................................ 3-10MEASURING THE COMPRESSION PRESSURE .................................. 3-12CHECKING THE IGNITION TIMING ...................................................... 3-13CHECKING THE TIMING BELT .............................................................. 3-14COOLING SYSTEM ....................................................................................... 3-14CHECKING THE COOLING WATER DISCHARGE ................................ 3-14LOWER UNIT ................................................................................................CHECKING THE GEAR OIL LEVEL .........................................................CHANGING AND CHECKING THE GEAR OIL LEVEL ...........................CHECKING THE LOWER UNIT (FOR AIR LEAKS) ................................

3-153-153-153-16

GENERAL ...................................................................................................... 3-17CHECKING THE ANODE ........................................................................ 3-17CHECKING THE BATTERY ..................................................................... 3-17CHECKING THE SPARK PLUGS ............................................................ 3-18LUBRICATION POINTS ...........................................................................3-20

3

MAINTENANCE INTERVAL CHARTMAINTENANCE INTERVAL CHARTUse the following chart as a guide to general maintenance intervals.Dependant on operating conditions, adjust the maintenance intervals accordingly.

ItemTOP COWLING:Water drain holeTop cowling fitFUEL SYSTEM:Fuel lineFuel filter

Fuel tank (*1)POWER UNIT:Engine oilTiming beltValve clearanceIgnition timingThermostatWater leakageMotor exteriorExhaust leakageCooling water passageCONTROL SYSTEM:Shift cableThrottle cablesThrottle axle linkEngine idling speedStart-in-gear protection deviceLOWER UNIT:Gear oilLower unit leakagePropellerGENERAL:AnodeBatterySpark plug

Wiring and connectorBolts and nutsLubrication points

Remarks

CheckCheckCheckCheck/clean/replaceCleanCheck/replaceCheck/replaceCheck/adjustCheckCheck/replaceCheckCheckCheckCheckCheck/adjustCheck/adjustCheck/adjustCheck/adjustCheck/adjustChangeCheckCheck/replaceCheck/replaceCheck/replaceCleaning/adjust/replaceCheck/reconnectTightenGrease

InitialEveryRefer to10 hours 50 hours 100 hours 200 hourspage(Brake-in) (3 months) (6 months) (1 year)

3-33-3

*1.......If Yamaha portable fuel tank is used.

3-1

(every 1 month)

3-93-143-103-135-263-143-43-53-63-73-83-153-166-33-173-173-18

3-23-2

3-20

TOP COWLINGTOP COWLINGCHECKING THE WATER DRAIN HOLECheck: Water drain hole 1Obstruction Clean.

CHECKING THE TOP COWLING FIT1. Check: Top cowling fitLoose/unlatched Adjust the topcowling hook.

2. Adjust: Top cowling hook positionAdjusting steps:(1)Loosen the bolt 1 approximately 1/4of a turn.(2)Move the top cowling hook 2 eitherup or down slightly.

NOTE:

Moving the hook toward the seal willloosen the top cowling.Moving the hook away from the seal willtighten the top cowling.(3)Secure the bolt 1.Top cowling hook bolt:5 Nm (0.5 kgfm, 3.7 ftlb)(4)Check the top cowling fitting andrepeat the adjustment necessary.

3-2

FUEL SYSTEMFUEL SYSTEMCHECKING THE FUEL LINECheck: Fuel lineCracks/damage/leak Replace thedefective part(s).Refer to REMOVING/INSTALLINGTHE FUEL JOINT, FUEL FILTER ANDFUEL PUMP on page 4-1.

CAUTION:When replacing the fuel filter, the arrowmark must face toward the fuel pump.

3-3

CONTROL SYSTEMCONTROL SYSTEMADJUSTING THE SHIFT CONTROLCABLE1. Check: Shift control cableDamage Replace.Incorrect shift handle position/poorshifting Adjust.2. Adjust: Shift control cableAdjusting steps:(1)Move the shift handle so the shift rodlever 1 is in the neutral position.(2)Remove the locknut 2.(3)Set the shift handle to the neutralposition. Then, hold it in this position.(4)Adjust the shift control cable 3 to theproper length with the adjusting nut4.(5)Install the locknut 2 and tighten it.(6)Move the shift handle to the forward,neutral, and reverse positions andmake sure it shifts smoothly andcorrectly.If the shifting operations unsmooth orincorrect, repeat the above procedure

NOTE:If the shift handle cannot be set to thereverse position, rotate the propellerslightly then operate.

3-4

CONTROL SYSTEMADJUSTING THE THROTTLE CONTROLCABLESNOTE:Before adjusting the throttle control cables,make sure that the shift control cable isproperly adjusted (for long handle modelonly).1. Check: Throttle control cablesDamage Replace.Excessive slack or the stoppers donot contact each other Adjust.2. Adjust: Throttle control cablesAdjusting steps:(1)Turn the throttle grip to the fullyopened position.(2)Loosen the locknut 1.(3)Adjust the length of the throttle wire 2with the adjusting nut 3 until thestopper portion a on the pulley 4contacts the stopper portion b on thethrottle wire stay 5.(4)Tighten the locknut 1.(5)Loosen locknut 6.(6)Adjust the length of the throttle wire 7with the adjusting nut 8.

NOTE:Adjust the length so that there is noclearance between the drum hole of pulley4 and the drum at the tip of deceleratorcable 7.(7)Tighten the locknut 6.(8)Fully open and close the throttle gripand make sure the stopper portion acontacts the stopper portion b (at thefully opened position), and the stopperc portion contacts the stopper portiond (at the fully-closed position).If proper contact is not made, repeatthe above procedure.

3-5

CONTROL SYSTEMADJUSTING THE THROTTLE AXLELINKNOTE:Before adjusting the throttle axle link, makesure that the throttle control cables isproperly adjusted.1. Check: Throttle axle linkBend/damage Replace.Incorrect position Adjust.2. Adjust: Throttle axle linkAdjusting steps:(1)Loosen lock screw 1.(2)Turn the throttle grip to the fully openposition.(3)Hold so that the rear side face a offree axle lever 2 is in contact with theactuating portion b of pulley 3.(4)Turn throttle link 4 fully clockwiseuntil it stops, then tighten lock screw1.Lock screw:1.5 Nm (0.15 kgfm, 1.1 ftlb)(5)Operate the throttle grip to the fullyopen position and fully closedposition, and check that carburetorthrottle link 4 opens and closes fully. Ifit does not move properly, carry outthe above procedure again.

3-6

CONTROL SYSTEMADJUSTING THE ENGINE IDLINGSPEEDNOTE:

Before adjusting the engine idling speed,make sure the throttle axle link isproperly adjusted.Before adjusting the engine idling speed,warm-up the engine. Correct adjustmentcannot be obtained when the engine iscold.1. Measure: Engine idling speedOut of specification Adjust.Engine idling speed:1,050 50 r/min

Measuring steps:(1)Start the engine and allow it to warmup for several minutes.(2)Attach the engine tachometer 1 to thespark plug lead 2 of the cylinder #1.Engine tachometer:YU-08036-A/90890-06760(3)Measure the engine idling speed.2. Adjust: Engine idling speedAdjusting steps:(1)Turn the throttle stop screw 3 indirection a or b until the specifiedengine idling speed is obtained.

3-7

Direction

a

Direction

b

Engine idling speedincreases.Engine idling speeddecreases.

CONTROL SYSTEMADJUSTING THE START-IN-GEARPROTECTION DEVICE1. Check: Start-in-gear protection deviceoperationIncorrect Adjust.2. Adjust: Start-in-gear protection cable.Adjusting steps:(1)Set the shift lever in the neutralposition.(2)Loosen the locknut 1.(3)Adjust the adjusting nut 2 so that thepoint a on the wire connector 3aligns with the mark b on the startercover.(4)Tighten locknut 1.

NOTE:Shift the shift lever into neutral and makesure the starter can be pulled. If it cannotbe pulled, repeat the above procedure.

3-8

POWER UNITPOWER UNITCHECKING THE ENGINE OIL LEVELCheck: Engine oil level(At engine stopped)Above a Check if there is anyfuel or water mixed with the engineoil. If no abnormality is found, drainthe oil until the level is between aand b.Below b Add engine oil so thatthe level is between a and b.

REPLACING THE ENGINE OIL1. Remove: Oil filler cap 1 Drain plug 22. Install: Drain plug 2Drain plug:24 Nm (2.4 kgfm, 17.8 ftlb)3. Fill: Engine oil 3(into the crank case)Recommended engine oil:4-stroke engine oilAPI: SE, SF, SG or SHSAE: 10W-30, 10W-40Oil quantity:800cm3 (27.0 US oz, 28.2 lmp oz)4. Install: Oil filler cap 15. Check: Engine oil levelRefer to CHECKING THE ENGINEOIL LEVEL on page 3-9

NOTE:

3-9

Run the engine for several minutes, turnit off, and check the oil level.If the engine oil is still not at proper level,add/drain as needed.

POWER UNITADJUSTING THE VALVE CLEARANCENOTE:Valve clearance adjustment shoule becarried out when the engine is cold.1. Remove: Recoil starter 1 Dust cover 2 Fuel pump 3 Cylinder head cover 42. Check: Intake valve clearance a Exhaust valve clearance bOut of specification Adjust.Valve clearance (when engine iscold)Intake valve a:0.15 0.20 mm (0.006 0.008 in)Exhaust valve b:0.20 0.25 mm (0.008 0.010 in)Checking steps:(1)Turn the crankshaft and align the 1mark on the driven gear 5 and mark on the thermostat cover 6.(2)Check the intake valve clearance aand exhaust valve clearance b on thecylinder #1 using the feeler gauge 7.(3)Turn the crankshaft 360 and align the2 mark on the driven gear 5 and mark on the thermostat cover 6.(4)Check the intake valve clearance aand exhaust valve clearance b on thecylinder #2 using the feeler gauge 7.

3-10

POWER UNIT3. Adjust: Intake valve clearance a Exhaust valve clearance bAdjusting steps:(1)Loosen the locknut 8.(2)Turn the adjusting screw 9 in or outuntil the specified valve clearance isobtained.(3)Tighten the locknut 8.Locknut:8 Nm (0.8 kgfm, 5.9 ftlb)(4)Perform the above steps for all valveswhich clearance are out ofspecification.4. Recheck: Intake valve clearance a Exhaust valve clearance b

NOTE:If any valve clearance is still out ofspecification, repeat all of the valveclearance adjustment steps until thespecified clearance is obtained.5. Install: Cylinder head cover 4 Fuel pump 3 Dust cover 2 Recoil starter 1

NOTE:Tighten the cylinder head cover bolt insequence.

3-11

POWER UNITMEASURING THE COMPRESSIONPRESSURENOTE:Before measuring the compressionpressure, warm-up the engine. Correctmeasurement cannot be obtained when theengine is cold.Measure: Compression pressureBelow minimum compressionpressure Check the valveclearance, valve face, valve seat,piston rings, cylinder sleeve, piston,cylinder head gasket and cylinderhead.Compression pressure (Referencevalue):950 kPa (9.5 kgf/cm2 , 135.1 psi)Measuring steps:(1)Checking the valve clearance.Refer to ADJUSTING THE VALVECLEARANCE on page 3-10.(2)Remove the spark plugs 1.

CAUTION:Before removing the spark plugs, usecompressed air to blow away dirtaccumulated in the spark plug well toprevent it from falling into the cylinderthat is being tested.(3)Install the compression gauge 2 intothe spark plug hole to be measured.Compression gauge:YU-33223/90890-03160(4)Open the throttle valve wide.(5)Crank the engine using the recoilstarter (manual starter model) orstarter motor (electric starter model)until the reading on the compressiongauge stabilizes.(6)Remove the compressin gauge 2.(7)Install the spark plugs 1.Spark plug:25 Nm (2.5 kgfm, 18.4 ftlb)

3-12

POWER UNITCHECKING THE IGNITION TIMINGNOTE:

Ignition timing is automatically controlledby the CDI unit. Therefore, only checkingthe procedure is shown in this section.Before ignition timing, warm-up theengine. Correct checking cannot beobtained when the engine is cold.Check: Ignition timingIncorrect firing range Check theignition system components.Ignition timing:At idling speed: 5 rangeAt 4,500 r/min speed: 30 range

Checking steps:(1)Start the engine and allow it to warmup for several minutes.(2)Attach the engine tachometer and thetiming light 1 to the spark plug lead 2of cylinder #1.Engine tachometer:YU-8036-B/90890-06760Timing light:YM-33277-A/90890-03141(3)Aim the timing light 1 at the flywheelcover 3 and make sure the stationarypointer 4 is with in the firing range 5and 6 when engine is running withspecified speed.

3-13

COOLING SYSTEMCHECKING THE TIMING BELT1. Remove: Recoil starter 1 Dust cover 2

2. Check: Timing beltWear/damage Replace.

NOTE:Install the timing belt with the part namefacing up.3. Install: Dust cover 2 Recoil starter 1

COOLING SYSTEMCHECKING THE COOLING WATERDISCHARGECheck: Cooling water dischargeDose not flow Clean and check thecooling water passage.Checking steps:(1)Place the lower unit in water.(2)Start the engine.(3)Check that water flows from the pilotwater outlet.

3-14

LOWER UNITLOWER UNITCHECKING THE GEAR OIL LEVELCheck: Gear oil levelLevel is low Add gear oil to theproper level.

CHANGING AND CHECKING THE GEAROIL LEVEL1. Check: Gear oilMilky oil Replace the oil seal.Slug oil Check the gears,bearings, and clutch dog.Checking steps:(1)Tilt up the outboard slightly.(2)Place a container under the gear oildrain screw 1.(3)Remove the gear oil drain screw 1and gear oil level check screw 2.

2. Fill Gear oil(with the specified amount of therecommended gear oil.)Recommended gear oilGEAR CASE LUBE (USA) or Hypoidgear oil, SAE #90Oil capacity:150 cm3 (5.07 US oz, 5.28 lmp oz)Filling steps:(1)Place the outboard in an uprightposition.(2)Insert the gear oil tube into the drainhole and slowly fill the gear oil until oilflows out of the check hole and no airbubbles are visible.(3)Install the gear oil level check screw 2and then quickly install the gear oildrain screw 1.Gear oil level check screw:7 Nm (0.7 kgfm, 5.1 ftlb)Gear oil drain screw:7 Nm (0.7 kgfm, 5.1 ftlb)

3-15

LOWER UNITCHECKING THE LOWER UNIT (FOR AIRLEAKS)Check: Lower unit holding pressurePressure drops Check the sealsand components.Lower unit holding pressure:100 kPa (1.0 kgf/cm2 , 14.2 psi) for10 secondsChecking steps:

CAUTION:Do not overpressurize the lower unit.Excessive pressure may damage the oilseals.(1)Remove the gear oil level check screw.(2)Install the leakage tester 1 or mity vacinto the check hole.Leakage tester:NA/90890-06762Mity vac:YB-35956-A/90890-06756(3)Apply the specified pressure.(4)The lower unit should hold thespecified pressure for 10 seconds.(5)Remove the pressure tester 1, theninstall the gear oil level check screw.Gear oil level check screw:7 Nm (0.7 kgfm, 5.1 ftlb)

3-16

GENERALGENERALCHECKING THE ANODECheck: Anode (engine side) Anode (lower unit)Scales Clean.Oil/grease Clean.Excessive wear/damage Replace.

CAUTION:Do not oil, grease, or paint the anode, or itwill no operate properly.Anode mounting plug (engine):18 Nm (1.8 kgfm, 13.3 ftlb)Anode mounting screw (engine):2 Nm (0.2 kgfm, 1.5 ftlb)

CHECKING THE BATTERYWARNINGBattery electrolytic fluid is dangerous; itcontains sulfuric acid and therefore ispoisonous and highly caustic.Always follow these preventive measures: Avoid bodily contact with electrolyticfluid as it can cause severe burns orpermanent eye injury. Wear protective eye gear when handlingor working near batteries.Antidote (EXTERNAL): SKIN - Flush with water. EYES - Flush with water for 15 minutesand get immediate medical attention.Antidote (INTERNAL): Drink large quantities of water or milkfollowed by milk of magnesia, beatenegg, or vegetable oil. Get immediatemedical attention.Batteries also generate explosive hydrogengas; therefore, you should always followthese preventive measures: Change batteries in a well-ventilatedarea. Keep batteries away from fire, soarks, oropen flames (e.g., welding equipment,lighted cigarettes, etc.).

3-17

GENERALDO NOT SMOKE when charging orhandling batteries.KEEP BATTERIES AND ELECTROLYTICFLUID OUT OF REACH OF CHILDREN.

NOTE:

Batteries vary among manufacturers.Therefore, the following procedures maynot always apply. Consult your batterymanufacturers instructions.First, disconnect the negative lead, thenthe positive lead.Check: Electrolyte levelBelow the minimum level a Adddistilled water to the proper level. Electrolyte specific gravityLess than specification Rechargethe battery.Electrolyte specific gravity:1.280 at 20C (68F)

CHECKING THE SPARK PLUGS1. Spark plug type: BR6HS-102. Check: Electrodes 1Cracks/excessive wear Replace. Insulator color 2Distinctly different color Check theengine condition.Color guide:Medium to light tancolorNormalWhitish color Lean fuel mixture Plugged jet(-s) Wrong settingBlackish color Rich mixture Excessive oil usage Defective ignition system Defective spark plug3. Clean: Spark plug(with a spark plug cleaner or wirebrush).

3-18

GENERAL4. Measure: Spark plug gap aOut of specification Replace.Spark plug gap:0.9 - 1.0 mm (0.035 - 0.039 in)

5. Tighten: Spark plugSpark plug:25 Nm (2.5 kgfm, 18.4 ftlb)

NOTE:

3-19

Before installing the spark plug, clean thegasket surface and spark plug surface.Also, it is suggested to apply a thin filmof anti-seize compound to the spark plugthreads to prevent thread seizure.If a torque wrench is not available, a goodestimate of the correct tightening torqueis to finger tighten a the spark plug andthen tighten it another 1/4 to 1/2 of a turnb.

GENERALLUBRICATION POINTSApply: Water resistant grease

NOTE:Use a grease gun.

3-20

GENERAL

3-21

CHAPTER 4FUEL SYSTEMFUEL JOINT, FUEL FILTER AND FUEL PUMP ...............................................4-1REMOVING/INSTALLING THE FUEL JOINT, FUEL FILTER ANDFUEL PUMP ...............................................................................................4-1CHECKING THE FUEL JOINT ...................................................................4-2CHECKING THE FUEL FILTER ..................................................................4-2INSTALLING THE FUEL FILTER ...............................................................4-2FUEL PUMP ......................................................................................................4-3DISASSEMBLING/ASSEMBLING THE FUEL PUMP ...............................4-3CHECKING THE FUEL PUMP ...................................................................4-4ASSEMBLING THE FUEL PUMP ..............................................................4-4INTAKE SYSTEM .............................................................................................4-5REMOVING/INSTALLING THE INTAKE SYSTEM ...................................4-5INSTALLING THE INTAKE MANIFOLD ....................................................4-7CARBURETOR ..................................................................................................4-8DISASSEMBLING/ASSEMBLING THE CARBURETOR ...........................4-8DISASSEMBLING THE CARBURETOR ..................................................4-10CHECKING THE CARBURETOR .............................................................4-10ASSEMBLING THE CARBURETOR ........................................................4-11

4

FUEL JOINT, FUEL FILTER AND FUEL PUMPFUEL JOINT, FUEL FILTER AND FUEL PUMPREMOVING/INSTALLING THE FUEL JOINT, FUEL FILTER AND FUEL PUMP

Step123456789101112

Job/PartClipFuel hoseBolt (with washer)Fuel jointClipFuel hose (with tube)Fuel filterClipFuel hose (with tube)Bolt (with washer)Fuel pump assemblyO-ring

Q'ty211121111211

4-1

Remarks

2.7 x 2.3mm Not reusableFor installation, reverse the removalprocedure.

FUEL JOINT, FUEL FILTER AND FUEL PUMPCHECKING THE FUEL JOINT1. Check: Fuel jointCracks/leak/clog/damage Replace.

2. Check: Fuel joint operationImpossible to maintain the specifiedpressure for 10 sec. Replace.

NOTE:Do not overpressurize the fuel joint.Excessive pressure may cause air to leakout.Checking steps:(1)Attach the mity vac.Mity vac:YB-3956-A/90890-06756(2)Apply the specified pressure.Specified pressure:50 kpa (0.5 kgf/cm2, 7.1 psi)

CHECKING THE FUEL FILTERCheck: Fuel filterCracks/leak/clog/ Replace.

INSTALLING THE FUEL FILTERInstall: Fuel filter

NOTE:Install the fuel filter with arrow mark facingtowards the fuel pump.

4-2

FUEL PUMPFUEL PUMPDISASSEMBLING/ASSEMBLING THE FUEL PUMP

Step12345678910111213

Job/PartScrewNutBody #3DiaphragmScrewCheck valveBody #2PinPlungerPlunger springDiaphragmDiaphragm springBody #1

Q'ty4411221111111

4-3

Remarks

For installation, reverse the removalprocedure.

FUEL PUMPCHECKING THE FUEL PUMPCheck: DiaphragmsDamage Replace.

ASSEMBLING THE FUEL PUMPInstall: Body #1 Body #2 Body #3

NOTE:Install so that notched portion a of body#1, joint portion b of body #2, and castingmold letter c of body #3 are in the relativepositions shown in the diagram on the left.

4-4

INTAKE SYSTEMINTAKE SYSTEMREMOVING/INSTALLING THE INTAKE SYSTEM

Step12345678910111213

Job/PartBreather hoseBolt (with washer)ClampWater pilot hoseClampWater HoseThrottle axle linkChoke rodLink jointChoke knobBolt (with washer)CollerSilensor assembly

Q'ty11111111112211

4-5

Remarks

Continued on next page.

INTAKE SYSTEM

Step1415161718192021222324

Job/PartO-ringCarburetorGasketInsulatorClampFuel hoseBoltBoltClampIntake manifoldGasket

Q'ty11211123111

Remarks31.5 x 2.4 mm Not reusableNot reusable

Not reusableFor installation, reverse the removalprocedure.

4-6

INTAKE SYSTEMINSTALLING THE INTAKE MANIFOLDInstall: Intake manifold

NOTE:Tighten the intake manifold mounting boltin sequence and two steps of torque.Intake manifold mounting bolt:1st: 6.0 Nm (0.6 kfgm, 4.4 ftlb)2nd: 12.0 Nm (1.2 kfgm,8.8 ftlb)

4-7

CARBURETORCARBURETORDISASSEMBLING/ASSEMBLING THE CARBURETOR

Step12345678910111213

Job/PartDrain plugGasketThrottle stop screwSpringScrewScrew (with washer)Cover plateCover gasketScrew (with washer)Float chamberO-ringFloat pinFloat

Q'ty1111111111148 x 1.8 mm11

RemarksNot reusable

Not reusable

Not reusable


4-8

CARBURETOR

Step141516171819

Job/PartNeedle valveMain jetPilotPlugMain nozzleBody assembly

Q'ty111111

Remarks


4-9

CARBURETORDISASSEMBLING THE CARBURETORRemove: Float pin 1 Float 2 Needle valve

NOTE:

Tap float pin 1 in the direction of arrow aof carburetor body 3 and in the reversedirection with a pin to remove.

CHECKING THE CARBURETORNOTE:Before disassembling the carburetor, makesure to note the number of times the pilotscrew is turned out from the seatedposition to its set position.

CAUTION:Do not use steel-wire for cleaning the jets.This may enlarge the jet diameters andseriously affect performance.1. Check: Carburetor bodyCracks/damage Replace.Contamination Clean.2. Check: Needle valve Pilot screwGrooved wear Replace.3. Check: Main nozzle Main jet Pilot jetContamination Clean.4. Check: FloatCracks/damage Replace.5. Check: O-ringWear/cracks/damage Replace.

4-10

CARBURETORASSEMBLING THE CARBURETORNOTE:Before assembling the carburetor, makesure to turn out the pilot screw the samenumber of times, as noted beforedisassembly, from the seated position tothe set position.1. Install:y Needle valve 3y Float 1y Float pin 2

NOTE:y

y

y

When setting the float 1 into thecarburetor body, hook the needle valve 3into the float 1 and insert the needlevalve seat.Tap float pin 2 in the direction of arrow aof carburetor body 4 and with a pin toinstall.After installation,make sure that the float1 operates smoothly.

2. Measure:y Float hight bOut of specification Replace.Float height b:19.0 - 20.0 mm (0.75 - 0.79 in)

NOTE:y

y

4-11

Make sure to tilt the carburetor bodyclockwise 45 for needle valve with springno load, when measuring the float heightb.Take measurement at the side end of thefloat, as shown.

CHAPTER 5POWER UNITMANUAL STARTER .........................................................................................5-1REMOVING/INSTALLING THE MANUAL STARTER ...............................5-1INSTALLING THE DUST COVER GROMMET ..........................................5-2ADJUSTING THE START-IN-GEAR PROTECTION DEVICE ....................5-2DISASSEMBLING/ASSEMBLING THE MANUAL STARTER ..................5-3DISASSEMBLING THE MANUAL STARTER ...........................................5-5CHECKING THE MANUAL STARTER ......................................................5-6ASSEMBLING THE MANUAL STARTER .................................................5-6FLYWHEEL ROTOR ..........................................................................................5-9REMOVING/INSTALLING THE FLYWHEEL ROTOR ................................5-9REMOVING THE FLYWHEEL ROTOR ....................................................5-10INSTALLING THE FLYWHEEL ROTOR ..................................................5-11POWER UNIT .................................................................................................5-12DISCONNECTING/CONNECTING THE ELECTRICAL LEADS ...............5-12DISCONNECTING/CONNECTING THE CABLES AND HOSE ...............5-13ADJUSTING THE THROTTLE CONTROL CABLE(S) .............................5-14REMOVING/INSTALLING THE POWER UNIT .......................................5-15INSTALLING THE POWER UNIT ............................................................5-16REMOVING/INSTALLING THE THROTTLE LINK AND RIGHT SIDEELECTRICAL COMPONENTS .................................................................5-17REMOVING/INSTALLING THE LEFT SIDE ELECTRICALCOMPONENTS 1 (ONE LIGHTING COIL MODEL) ................................5-19REMOVING/INSTALLING THE LEFT SIDE ELECTRICALCOMPONENTS 2 (ONE LIGHTING COIL MODEL) ................................5-20REMOVING/INSTALLING THE LEFT SIDE ELECTRICALCOMPONENTS 1(TWO LIGHTING COILS MODEL) ..............................5-21REMOVING/INSTALLING THE LEFT SIDE ELECTRICALCOMPONENTS 2(TWO LIGHTING COILS MODEL) ..............................5-22THERMOSTAT, TIMING BELT AND GEARS ................................................5-23REMOVING/INSTALLING THE THERMOSTAT, TIMINGBELT AND GEARS ..................................................................................5-23REMOVING THE TIMING BELT ..............................................................5-25REMOVING THE DRIVE GEAR ...............................................................5-25REMOVING THE DRIVEN GEAR ............................................................5-25CHECKING THE THERMOSTAT .............................................................5-26CHECKING THE TIMING BELT ...............................................................5-26INSTALLING THE DRIVEN GEAR ...........................................................5-26INSTALLING THE DRIVE GEAR .............................................................5-27INSTALLING THE TIMING BELT ............................................................5-28ADJUSTING THE VALVE CLEARANCE .................................................5-28

ANODE AND EXHAUST COVER ..................................................................5-29REMOVING/INSTALLING THE ANODE AND EXHAUST COVER .........5-29CHECKING THE ANODE .........................................................................5-30INSTALLING THE EXHAUST COVER ....................................................5-30CYLINDER HEAD AND OIL PUMP ................................................................5-31REMOVING/INSTALLING THE CYLINDER HEAD AND OIL PUMP ......5-31CHECKING THE SPARK PLUG ...............................................................5-33INSTALLING THE OIL PUMP ..................................................................5-33INSTALLING THE CYLINDER HEAD ......................................................5-33INSTALLING THE CYLINDER HEAD COVER .........................................5-34OIL PUMP .......................................................................................................5-35DISASSEMBLING/ASSEMBLING THE OIL PUMP ................................5-35CHECKING THE OIL PUMP .....................................................................5-36ASSEMBLING THE OIL PUMP ...............................................................5-36CAMSHAFT AND VALVES ............................................................................5-37REMOVING/INSTALLING THE CAMSHAFT AND VALVES ..................5-37REMOVING THE VALVE .........................................................................5-39CHECKING THE VALVE AND VALVE GUIDE ........................................5-39CHECKING THE VALVE SPRING ............................................................5-40CHECKING THE ROCKER ARM ROCKER ARM SHAFT .......................5-41CHECKING THE CAMSHAFT ..................................................................5-41CHECKING THE CYLINDER HEAD .........................................................5-42REPLACING THE VALVE GUIDE ............................................................5-42REFACING THE VALVE SEAT ................................................................5-43INSTALLING THE VALVE .......................................................................5-45INSTALLING THE CAMSHAFT OIL SEAL ..............................................5-45CRANKSHAFT, PISTON AND CYLINDER BODY .........................................5-46REMOVING/INSTALLING THE CRANKSHAFT, PISTON ANDCYLINDER BODY .....................................................................................5-46DISASSEMBLING/ASSEMBLING THE PISTON AND CONNECTINGROD ..........................................................................................................5-47CHECKING THE CYLINDER BODY .........................................................5-48CHECKING THE PISTON .........................................................................5-48CALCULATING THE PISTON-TO-CYLINDER CLEARANCE ..................5-49CHECKING THE PISTON PIN ..................................................................5-49CHECKING THE PISTON RING ...............................................................5-50CHECKING THE CRANKSHAFT ..............................................................5-50CHECKING THE CRANKSHAFT-PLAIN BEARING OIL CLEARANCE ...5-51CHECKING THE CRANKSHAFT-CONNECTING ROD OILCLEARANCE .............................................................................................5-53INSTALLING THE PISTON RING ............................................................5-55INSTALLING THE CONNECTING ROD ..................................................5-55INSTALLING THE PISTON AND CONNECTING ROD ...........................5-56INSTALLING THE OIL SEAL ...................................................................5-56INSTALLING THE CRANKCASE .............................................................5-56

5

MANUAL STARTERMANUAL STARTERREMOVING/INSTALLING THE MANUAL STARTER

Step12345

Job/PartStart-in-gear protection cableBolt (with washer)Manual starter assemblyDust coverGrommet

Q'ty13113

Remarks


5-1

MANUAL STARTERINSTALLING THE DUST COVERGROMMETInstall: Dust cover grommet

NOTE:Set the grommet so that the large flangediameter is at the bottom and install to thedust cover.

ADJUSTING THE START-IN-GEARPROTECTION DEVICEAdjust: Start-in-gear protection deviceRefer to ADJUSTING THE STARTIN-GEAR PROTECTION DEVICE onpage 3-8.

5-2

MANUAL STARTERDISASSEMBLING/ASSEMBLING THE MANUAL STARTER

Step12345678910111213

Job/PartWire assemblyReturn springScrewDrive plateDrive springSheave drum assemblyCirclipDrive pawlReturn springSpringSheave dramStarter springCover

Q'ty111111111111

Remarks


5-3

MANUAL STARTER

Step14151617181920

Job/PartStarter handleDumperStarter wireReturn springStopperCollerStarter case

Q'ty1111111

Remarks

1,500mm


5-4

MANUAL STARTERDISASSEMBLING THE MANUALSTARTER1. Rotate: Sheave drum 1

NOTE:Before removing the drive plate and drivespring, turn the sheave drum to make thestarter spring inside the sleeve drum free.Rotating steps:(1)Turn the sheave drum 1 so that thecutaway a on the outer surface of thesheave drum faces toward the starterhandle.(2)Pass the starter wire 2 through thecutaway a.(3)Turn the sheave drum 1 clockwiseuntil the starter spring is free.2. Remove: Screw 3 Drive plate 4 Drive spring 5 Sheave drum 1

WARNING

When removing the sheave drum, besure to turn the sheave drum upsidedown to prevent the starter spring frompopping up at you.Do not leave the sheave drum removed.The starter spring may pop out.3. Remove: Starter spring 6

WARNINGBe careful so that the starter spring doesnot pop out when removing it.Remove it by allowing it out one turn ofthe winding each time.

5-5

MANUAL STARTERCHECKING THE MANUAL STARTER1. Check: Start-in-gear protection leverCracks/wear/damage Replace.2. Check: Drive pawlCracks/wear/damage Replace. Drive springDamage Replace.3. Check: Sheave drumCracks/wear/damage Replace.4. Check: Return springsDamage Replace.5. Check: Starter wireFrayed/wear/damage Replace.

NOTE:

When replacing the starter wire, cut it tothe specified length and then burn its endso it will not unravel.Apply water resistant grease onto thenew starter wire.Starter wire length:1,500 mm (59.1 in)

ASSEMBLING THE MANUAL STARTER1. Install: Starter spring 1

WARNINGWhen installing the starter spring onto thestarter case, use care so that the starterspring does not pop out. To help the springstay compressed, wind it from the outside,one turn each time.

5-6

MANUAL STARTER2. Install: Starter wire 2Installing steps:(1)Insert the starter wire 2 through thewire holes and then tie a knot on theend of the wire.(2)Place the starter wire at the cutaway ofthe sheave drum.

3. Install: Sheave drum 3

NOTE:Position the inner end of the starter springon the retainer post of sheave drum.

4. Install: Drive spring 4 Drive plate 5 Screw 6Installing steps:(1)Install drive spring 4 to drive plate 5.(2)Pass the tip of drive spring 4 throughthe coil portion of return spring 7, andinstall drive plate 5 to the sheavedrum.(3)Install screw 6.

5-7

MANUAL STARTER5. Set: Starter springSetting steps:(1)Place the starter wire 2 at the cutawaya of the sheave drum 3.(2)Wind the sheave drum 3 5 turnscounterclockwise with the starter wire2.(3)Remove starter wire 2 from cutawaya, then wind on sheave drum 3.6. Check: Manual starter operationRough operation Repair.

NOTE:When checking the manual starter only,release the start-in-gear protection device.

5-8

FLYWHEEL ROTORFLYWHEEL ROTORREMOVING/INSTALLING THE FLYWHEEL ROTOR

Step1234

Job/PartNutWasherFlywheel rotorWoodruff key

Q'ty1111

Remarks


5-9

FLYWHEEL ROTORREMOVING THE FLYWHEEL ROTOR

A

1. Remove: Flywheel rotor nutFlywheel holder:YB-06139/90890-06522A For USA and CanadaB Except for USA and Canada

NOTE:The major load should be applied in thedirection of the arrows. If the load is notapplied as shown, the flywheel holder mayeasily slip off of the flywheel rotor.

B

A

2. Remove: Flywheel rotor

B

Universal puller:YB-06117/90890-06521A For USA and CanadaB Except for USA and Canada

CAUTION:

5-10

Keep the nut side flush with thecrankshaft end until the flywheel rotorcomes off the tapered portion of thecrankshaft.To prevent damage to the engine ortools, screw in the universal puller boltsevenly and completely so that theuniversal puller plate is parallel to theflywheel rotor.

FLYWHEEL ROTORINSTALLING THE FLYWHEEL ROTOR

A

Install: Flywheel rotor nutFlywheel holder:YB-06139/90890-06522A For USA and CanadaB Except for USA and Canada

NOTE:The major load should be applied in thedirection of the arrows. If the load is notapplied as shown, the flywheel holder mayeasily slip off of the flywheel rotor.

B

5-11

POWER UNITPOWER UNITDISCONNECTING/CONNECTING THE ELECTRICAL LEADS

StepJob/Part1Bolt (with washer)2Engine stop switch connector andterminal3Emergency signal light connector

Q'ty122

RemarksWhite, BlackYellow/red, Pink


5-12

POWER UNITDISCONNECTING/CONNECTING THE CABLES AND HOSE

Step

12345

Job/PartEngine oil drainThrottle cableNutShift cableOil level gaugeWater hose

Q'ty

RemarksRefer to REPLACING THE ENGINE OIL onpage 3-9.

21111


5-13

POWER UNITADJUSTING THE THROTTLE CONTROLCABLE(S)Adjust: Throttle control cable(s)Refer to ADJUSTING THETHROTTLE CONTROL CABLES onpage 3-5.

5-14

POWER UNITREMOVING/INSTALLING THE POWER UNIT

Step123456789101112

Job/PartScrew (with washer)NutApronPlugApronRubber sealBolt (with washer)Power unitRelief valve assemblyO-ringGasketDowel pin

Q'ty221211611112

Remarks

12.0 x 1.8 mm Not reusableNot reusableFor installation, reverse the removalprocedure.

5-15

POWER UNITINSTALLING THE POWER UNITInstall: Power unit

NOTE:

5-16

Tighten the power unit mounting bolt bythe order shown in the diagram on theleft.Tighten up the exhaust guide mountingbolt at the same time.

POWER UNITREMOVING/INSTALLING THE THROTTLE LINK AND RIGHT SIDE ELECTRICALCOMPONENTS

Step12345678910111213

Job/PartBolt (with washer)Bolt (with washer)WasherCollarThrottle control leverLink jointThrottle control camBracketScrewOil pressure switch leadOil pressure switchBoltAttachment

Q'ty1111111111121

Remarks

Pink


5-17

POWER UNIT

Step14 Pulser coil

Job/Part

Q'ty1

Remarks


5-18

POWER UNITREMOVING/INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 1 (ONELIGHTING COIL MODEL)

Step123456

Job/PartScrew (with washer)RectifierBolt (with washer)Ignition coilBolt (with washer)Bracket

Q'ty112121

Remarks4 leads (Black, Red, Green x 2)2 leads (Orange, Black)


5-19

POWER UNITREMOVING/INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 2 (ONELIGHTING COIL MODEL)

Step1234567891011

Job/PartClampBolt (with washer)Charge coilBolt (with washer)ClampBolt (with washer)Lighting coilScrewCoupler clampBolt (with washer)CDI unit

Q'ty12121212121

RemarksNot reusableNot reusable2 leads (Blue, Brown)

Not reusable2 leads (Green x 2)

13 leadsFor installation, reverse the removalprocedure.

5-20

POWER UNITREMOVING/INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 1 (TWOLIGHTING COILS MODEL)

Step1234567891011

Job/PartClampBolt (with washer)Ignition coilBolt (with washer)ClampClampBolt (with washer)Rectifier/regulatorBolt (with washer)Bolt (with washer)Starter motor bracket

Q'tyRemarks1Not reusable212 leads (Orange, Black)111Not reusable114 leads (Black, Red, Green x 2)211For installation, reverse the removalprocedure.

5-21

POWER UNITREMOVING/INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 2 (TWOLIGHTING COILS MODEL)

Step123456789

Job/PartClampBolt (with washer)Charge coilBolt (with washer)Lighting coilScrewCoupler clampBolt (with washer)CDI unit

Q'tyRemarks1Not reusable2Not reusable12 leads (Blue, Brown)4Not reusable12 leads (Green x 2)212113 leads


5-22

THERMOSTAT, TIMING BELT AND GEARSTHERMOSTAT, TIMING BELT AND GEARSREMOVING/INSTALLING THE THERMOSTAT, TIMING BELT AND GEARS

Step12345678910111213

Job/PartClampWater hoseBolt (with washer)Thermostat coverGasketThermostatTiming beltNutLock washerPlate washerDrive gearWoodruff keyBolt

Q'ty1Not reusable1211Not reusable11111111

Remarks


5-23

THERMOSTAT, TIMING BELT AND GEARS

Step14151617

Job/PartPlate washerDriven gearWoodruff keyPlate washer

Q'ty1111

Remarks


5-24

THERMOSTAT, TIMING BELT AND GEARSREMOVING THE TIMING BELTRemove: Timing belt 1

NOTE:Turn the drive gear 2 and align the 1mark on the driven gear 3 and markon the thermostat housing cover 4(portion a).

REMOVING THE DRIVE GEARRemove: Drive gear nutCrankshaft holder:YB-06561/90890-06561

NOTE:Loosen the drive gear nut with a 30 mmdeep socket.

B

REMOVING THE DRIVEN GEAR

A

Remove: Driven gear boltFlywheel holder:YB-06139/90890-06522A For USA and CanadaB Except for USA and Canada

5-25

THERMOSTAT, TIMING BELT AND GEARSCHECKING THE THERMOSTATMeasure: Valve operating temperature Valve lift aOut of specification Replace.Water temperatureBelow60 C(140 F)Above70 C(158 F)

Valve lift0 mm(0 in)Min.3 mm(0.12 in)

Measuring steps:(1)Suspend the thermostat in a containerfilled with water.(2)Place a thermostat in the water.(3)Slowly heat the water.(4)While stirring the water, check that thethermometer opens at the specifiedtemperature.

CHECKING THE TIMING BELTCheck: Timing beltRefer to CHECKING THE TIMINGBELT on page 3-14.

INSTALLING THE DRIVEN GEAR1. Install: Driven gear

NOTE:Install the driven gear so that counter mark() is at the top.

B

2. Install: Driven gear bolt

A

Flywheel holder :YB-06139/90890-06522A For USA and CanadaB Except for USA and Canada

5-26

THERMOSTAT, TIMING BELT AND GEARSINSTALLING THE DRIVE GEAR1. Install: Woodruff key 1 Drive gear 2 Washer 3 Lock washer 4

NOTE:

Install the washer as shown in thediagram on the left so that the curvatureextends in the upward direction. (It is inthe reverse direction from the curvatureof the flange of the drive gear.)Pass the tab of the lock washer throughthe hole in the drive gear and washer.2. Install: Drive gear nutCrankshaft holder:YB-06561/90890-06561

NOTE:Tighten the drive gear nut with a 30 mmdeep socket.3. Bend: Lock washer 5

NOTE:Bend the lock washer securely.

5-27

THERMOSTAT, TIMING BELT AND GEARSINSTALLING THE TIMING BELTInstall: Timing belt 5Installing steps:(1)Turn the drive gear 1 and align thewasher groove on the drive gear and mark on the cylinder body 2(portin a).(2)Turn the driven gear 3 and align the1 mark on the driven gear and mark on the thermostat cover 4(portin b).(3)Install the timing belt 5.

NOTE:Install the timing belt with the part namefacing up.(4)Turn the crankshaft clockwise 2 turnsand make sure the drive gear anddriven gear are correctly aligned withthe timing marks.

ADJUSTING THE VALVE CLEARANCEAdjust: Valve clearanceRefer to the ADJUSTING THEVALVE CLEARANCE on page 3-10.

5-28

ANODE AND EXHAUST COVERANODE AND EXHAUST COVERREMOVING/INSTALLING THE ANODE AND EXHAUST COVER

Step1235678

Job/PartPlugO-ringScrewAnodeBolt (with washer)Exhaust coverGasket

Q'ty11Not reusable11511Not reusable

Remarks


5-29

ANODE AND EXHAUST COVERCHECKING THE ANODECheck: AnodeRefer to CHECKING THE ANODEon page 3-17.

INSTALLING THE EXHAUST COVERInstall: Exhaust cover

NOTE:Tighten the exhaust cover bolt in sequenceand two steps of torque.Exhaust cover mounting bolt:1st: 6.0 Nm (0.6 kfgm, 4.4 ftlb)2nd: 12.0 Nm (1.2 kfgm,8.8 ftlb)

5-30

CYLINDER HEAD AND OIL PUMPCYLINDER HEAD AND OIL PUMPREMOVING/INSTALLING THE CYLINDER HEAD AND OIL PUMP

Step12345678910111213

Job/PartSpark plugOil filler capO-ringBolt (with washer)Cylinder head coverCover sealScrew (with washer)Breather coverCover gasketBolt (with washer)Bolt (with washer)Bolt (with washer)Cylinder head assembly

Q'ty21125.0 x 3.0 mm411511Not reusable3421

Remarks


5-31

CYLINDER HEAD AND OIL PUMP

Step1415161718

Job/PartCylinder head gasketDowel pinBolt (with washer)Oil pump assemblyOil pump gasket

Q'ty1Not reusable2311Not reusable

Remarks


5-32

CYLINDER HEAD AND OIL PUMPCHECKING THE SPARK PLUGCheck: Spark plugRefer to CHECKING THE SPARKPLUGS on page 3-18.

INSTALLING THE OIL PUMPInstall: Oil pump

NOTE:Before installing to the cylinder head, add adrop of approx. 1 cc of Yamaha 4-strokeoutboard motor oil from suction port a ordischarge port b.

INSTALLING THE CYLINDER HEADInstall: Cylinder head

NOTE:Tighten the cylinder head mounting bolt insequence and two steps of torque.Cylinder head mounting bolt1st:M8: 15 Nm (1.5 kgfm, 11.1 ftlb)M6: 6 Nm (0.6 kgfm, 4.4 ftlb)2nd:M8: 30 Nm (3.0 kgfm, 22.1 ftlb)M6: 12 Nm (1.2 kgfm, 8.8 ftlb)

5-33

CYLINDER HEAD AND OIL PUMPINSTALLING THE CYLINDER HEADCOVERInstall: Cylinder head cover

NOTE:Tighten the cylinder head mounting bolt insequence.

5-34

OIL PUMPOIL PUMPDISASSEMBLING/ASSEMBLING THE OIL PUMP

Step12345678

Job/PartScrewPump coverCover gasketInner rotorShaftPinOuter rotorOil pump housing

Q'ty211Not reusable11111

Remarks


5-35

OIL PUMPCHECKING THE OIL PUMPMeasure: Oil pump clearances a, b, and cOut of specification Replace.Oil pump clearances:a: 0.10 - 0.15 mm(0.004 - 0.006 in)b: 0.04 - 0.14 mm(0.002 - 0.006 in)c: 0.03 - 0.09 mm(0.001 - 0.004 in)

ASSEMBLING THE OIL PUMPInstall: Outer rotor 1 Inner rotor 2

NOTE:

5-36

The mark a on the outer rotor 1faces towards the pump cover side.The mark b on the inner rotor 2faces towards the oil pump housing side.

CAMSHAFT AND VALVESCAMSHAFT AND VALVESREMOVING/INSTALLING THE CAMSHAFT AND VALVES

Step12345678910111213

Job/PartLocknutRocker arm adjusting screwRocker shaftSpringCollarCollarRocker armCam shaftOil sealValve spring lockValve spring retainerValve springValve spring seat


Remarks


5-37

CAMSHAFT AND VALVES

Step14151617

Job/PartIntake valveExhaust valveValve stem oil sealCylinder head


Remarks


5-38

CAMSHAFT AND VALVESREMOVING THE VALVERemove: Valve spring lock 1 Valve spring retainer 2 Valve spring 3 Valve spring seat 4 Intake valve or exhaust valve 5Valve spring compressor:YM-01253/90890-04019Attachment:YM-04018/90890-04018

NOTE:

Set the attachment on to the center of thespring retainer.Do not overtighten the valve springcompressor.

CHECKING THE VALVE AND VALVEGUIDE1. Measure: Valve guide inside diameter aOut of specification Replace.Valve guide inside diameter a(intake guide and exhaust guide):5.500 - 5.512 mm(0.2165 - 0.2170 in)2. Measure: Valve seat width bOut of specification Replace.Valve seat width b(intake valve and exhaust valve):0.6 - 0.8 mm (0.023 - 0.031 in)

3. Measure: Valve margin thickness cOut of specification Replace.Valve margin thickness c(intake valve and exhaust valve):0.7 mm (0.027 in)

5-39

CAMSHAFT AND VALVES4. Measure: Valve stem outside diameter dOut of specification Replace.Valve stem outside diameter d:Intake valve:

5.475 - 5.490 mm(0.2156 - 0.2161 in)Exhaust valve: 5.460 - 5.475 mm(0.2150 - 0.2156 in)

5. Measure: Valve stem runoutOut of specification Replace.Valve stem runout limit(intake valve and exhaust valve):0.03 mm (0.0012 in)

NOTE:When replacing the valve, always use anew valve guide and valve stem oil seal.

CHECKING THE VALVE SPRING1. Measure: Valve spring free length aOut of specification Replace.Valve spring free length limit a:27.6 mm (1.09 in)

2. Measure: Valve spring tilt bOut of specification Replace.Valve spring tilt limit b:1.0 mm (0.04 in)

5-40

CAMSHAFT AND VALVESCHECKING THE ROCKER ARMROCKER ARM SHAFT1. Measure: Rocker arm inside diameter aOut of specification Replace.Rocker arm inside diameter a:13.000 - 13.018 mm(0.5118 - 0.5125 in)

2. Measure: Rocker arm shaft outside diameter

bOut of specification Replace.Rocker arm shaft outside diameterb:12.941 - 12.951 mm(0.5095 - 0.5099 in)

CHECKING THE CAMSHAFTMeasure: Camshaft lobe diameter a and bOut of specification Replace.Camshaft lobe diameter (intakecam and exhaust cam):a: 23.45 - 23.55 mm(0.9232 - 0.9271 in)b: 19.95 - 20.05 mm(0.7854 - 0.7893 in)

5-41

CAMSHAFT AND VALVESCHECKING THE CYLINDER HEADMeasure: Cylinder head warpageOut of specification Resurface orreplace.Warpage limit:0.1 mm (0.004 in)Resurfacing steps:(1)Place a 400 - 600 grit wet sandpaper onthe surface plate.(2)Resurface the cylinder head using afigure-eight sanding pattern.

NOTE:To ensure an even surface, rotate thecylinder head several times.

REPLACING THE VALVE GUIDEReplace: Valve guideReplacing steps:

NOTE:Heat the cylinder head in an oven to 200C(392F) to ease valve guide removal andinstallation and maintain the correctinterference fit.(1)Remove the valve guide using thevalve guide remover.Valve guide remover:N.A./90890-06801(2)Make a counter mark at the protrusiondimension position from the cylinderhead on the new valveguide. Valveguide protrusion dimension a.Projection dimension of the valveguide a:7.8 - 8.3 mm (0.307 - 0.327 in)(3)Using a valve guide installer, press fitthe valve guide so that the countermark on the valve guide is aligned withthe end face of the cylinder head.Valve guide installer:YM-01112/90890-06801

5-42

CAMSHAFT AND VALVES(4)Bore the valve guide using the valveguide reamer.Valve guide reamer:NA/90890-06804

NOTE:When installing and removing the valveguide reamer, apply machining oil and turnthe reamer clockwise

REFACING THE VALVE SEATNOTE:After refacing the valve seat or replacingthe valve and valve guide, lap the valveseat and valve face.Reface: Valve seat

CAUTION:When turning the valve seat cutter, keepan even downward pressure (4 - 5 kg) toprevent chatter mark.Valve seat width(intake valve and exhaust valve):0.6 - 0.8 mm (0.02 - 0.03 in)Valve seat cutter set:YM-91043-C/90890-06803Valve seat lapper:NA/90890-04101Cut section of followsSectionCutterA90B45C30

5-43

CAMSHAFT AND VALVESRefacing steps:A Valve seat is centered on valve face butit is too wide.

A

Valve cutter seat90 cutterUselightly30 cutter

Desired resultTo reduce the valveseat width

B Valve seat is in the middle of the valve

B

face but it is too narrow.Valve cutter seatUse

45 cutter

Desired resultTo increase the valveseat width

C Valve seat is too narrow and it is near

C

the valve margin.Valve cutter seat90 cutterUse45 cutter

Desired resultTo center the valveseat and set it width

D Valve seat is too narrow and it is near

D

the valve stem.Valve cutter seat30 cutterUse45 cutter

5-44

Desired resultTo center the valveseat and set it width

CAMSHAFT AND VALVESINSTALLING THE VALVEInstall: Intake valve or exhaust valve 5 Valve spring seat 4 Valve spring 3 Valve spring retainer 2 Valve spring lock 1Valve spring compressor:YM-01253/90890-04019Attachment:YM-04108/90890-04108

NOTE:

Set the attachment on to the center of thespring retainer.Do not overtighten the valve springcompressor.

INSTALLING THE CAMSHAFT OIL SEALInstall: Cam shaft oil seal 1Driver rod:YM-06229/90890-06652Attachment:YB-06197/90890-06653A For USA and CanadaB Except for USA and Canada

NOTE:Press fit the oil seal to the stepped portionof the cylinder head and check that it is notat an angle.

5-45

CRANKSHAFT, PISTON AND CYLINDER BODYCRANKSHAFT, PISTON AND CYLINDER BODYREMOVING/INSTALLING THE CRANKSHAFT, PISTON AND CYLINDER BODY

Step1234567891011

Job/PartBolt (with washer)CrankcaseDowel pinConnecting rod boltConnecting rod capCrankshaftOil sealOil sealPiston and connecting rodPlain bearingCylinder body

Q'ty6142421Not reusable1Not reusable221

Remarks


5-46

CRANKSHAFT, PISTON AND CYLINDER BODYDISASSEMBLING/ASSEMBLING THE PISTON AND CONNECTING ROD

Step1234567

Job/PartCirclipPiston pinConnecting rodTop ring2nd ringOil ringPiston

Q'ty4222222

Remarks


5-47

CRANKSHAFT, PISTON AND CYLINDER BODYCHECKING THE CYLINDER BODYMeasure: Cylinder bore (with a cylinder boregauge)Out of specification Rebore thecylinder or replace the cylinderbody.Standard

Wear limit

H1: 20 mm (0.8 in)H2: 40 mm (1.6 in)H2: 60 mm (2.4 in)Cylinder bore 56.000 - 56.015mmD(2.2047 - 2.2053 in)Taper limit0.08 mmT(0.0031 in)Out of round0.05 mmlimit R(0.0020 in)D=Maximum D1, D2, D3, D4, D5 or D6T=(Maximum D1 or D2) - (Minimum D5 orD6)R=Maximum (D1 or D2) or (D3 or D4) or(D5 or D6)Measuringpoint H

NOTE:Measure the cylinder bore in parallel and ata right angle to the chankshaft. Thenaverage the measurement.

CHECKING THE PISTON1. Measure: Piston diameter (with a micrometer)Out of specification Replace thepiston.Measuring pointH

1.5 mm(0.06 in)

Standard Piston 55.950 - 55.965 mmdiameter D(2.2028 - 2.2033 in)Over size piston diameter:1st:56.200 - 56.215mm(2.2126 - 2.2132 in)2nd: 56.450 - 56.465 mm(2.2224 - 2.2230 in)

5-48

CRANKSHAFT, PISTON AND CYLINDER BODYNOTE:When measuring the piston diameter,position the micrometer in relation to thepiston pin hole as shown.2. Measure: Piston pi

Date post:	18-Aug-2015
Category:	Documents
Upload:	rms10502472
View:	262 times
Download:	3 times

Yamaha F6Z F8Z

Documents