Yamaha F8c Outboard Service Repair Manual Pid Range 60r 1016506 Current Mfg April 2005 And Newer

F6Z F8Z

SERVICE MANUAL LIT-18616-02-19

68T-28197-ZA-11

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

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

F6Z, F8Z SERVICE MANUAL Š2000 by Yamaha Motor Corporation, USA 1st Edition, April 2000 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited.

Printed in USA P/N LIT-18616-02-19

HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organised in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handly reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., •Bearings Pitting/scratches ➔ Replace.

To assist you in finding your way through this manual, the section title and major heading is given at the top of every page.

MODEL INDICATION Multiple models are referred to in this manual and their model indications are noted as follows.

Model name (W/W) USA and Canada name Indication

F6AMH

F8CMH

F6MH

F8MH

F6AMH

F8CMH

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

CROSS REFERENCES The cross references have been kept to a minimum. Cross references will direct you to the appropriate section or chapter.

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IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways.

The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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

CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.

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

HOW TO USE THIS MANUAL 1 The main points regarding removing/installing and disassembly/assembly procedure are shown in the exploded views.

2 The numbers in the exploded views indicate the required sequence of the procedure and should 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 exploded views.

These charts list the sequence that the procedures should be carried out in, as well as providing exploded on part names, quantities, dimensions and important points relating to 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 also mentioned.

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 provides individual illustrations when further explanations are required to explain the relevant procedure.

SYMBOLS 1

2

3

4

5

6

7

8

Symbols 1 to 9 are designed as thumb-tabs to indicate the content of a chapter.

1 General information 2 Specifications 3 Periodic check and adjustment 4 Fuel system 5 Power unit 6 Lower unit 7 Bracket unit 8 Electrical system 9 Trouble analysis

Symbols : to E indicate specific data. > Special tool A Specified liquid B Specified engine speed C Specified torque D Specified measurement E Specified electrical value [Resistance (Ω), Voltage (V), Electrical current (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 diagram indicate the grade of lubricant and the location of the lubricant point.

F Apply Yamaha 4-stroke motor oil G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply Yamaha grease D I Apply molybdenum disufied oil Symbols J to O in an exploded diagram indicate the grade of the sealing or locking agent and the location of the application point.

J Apply Gasket Maker® K 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.572 O Apply silicon sealant

CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECK AND ADJUSTMENT FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT ELECTRICAL SYSTEM TROUBLE ANALYSIS

1 2 3 4 5 6 7 8 9

CHAPTER 1 GENERAL INFORMATION

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

1

IDENTIFICATION IDENTIFICATION SERIAL NUMBER The outboard motor’s serial number is stamped on a label which is attached to the port clamp bracket.

NOTE: As an antitheft measure, a special label on which the outboard motor’s serial number is stamped is bonded to the port clamp bracket. The label is specially treated so that peeling it off causes cracks across the serial number.

1 2 3 4

Model name Approval model code Transom height Serial number

STARTING SERIAL NUMBERS The starting serial number blocks are as follows: Model name World USA, wide Canada

1-1

Applicable model code

F6AMH

F6MH

68R

F8CMH

F8MH

68T

Starting serial number S:000101L:300101S:000101L:300101-

SAFETY WHILE WORKING SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics.

FIRE PREVENTION Gasoline (petrol) is highly flammable.

Petroleum vapor is explosive if ignited.

Do not smoke while handling gasoline and keep it away from heat, sparks and open flames.

VENTILATION Petroleum vapor is heavier than air and is deadly if inhaled in large quantities. Engine exhaust gases are harmful to breathe.

When test-running an engine indoors, maintain good ventilation.

SELF-PROTECTION Protect your eyes with suitable safety glasses or safety goggles, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves or protective shoes if appropriate to the work you are doing.

OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha.

1-2

SAFETY WHILE WORKING Under normal conditions or use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all- important, and by adopting good safety practices, any risk is minimized. A summary of the most important precautions is as follows: 1. While working, maintain good standards of personal and industrial hygiene.

2. Clothing which has become contaminated with lubricants should be changed as soon as practicable, and laundered before further use.

3. Avoid skin contact with lubricants: do not, for example, place a soiled wipingrag in your pocket.

4. Hands and any other parts of the body which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with hot water and soap as soon as practicable.

5. To protect the skin, the application of a suitable barrier cream to the hands before working, is recommended.

6. A supply of clean lint-free cloths should be available for wiping purposes.

GOOD WORKING PRACTICES 1. The right tools Use the recommended special tools to protect parts from damage. Use the right tool in the right manner-do not improvise.

2. Tightening torque Follow the tightening torque instructions. When tightening bolts, nuts and screws, tighten the large sizes first, and tighten inner-positioned fixings before outer-positioned ones.

1-3

SAFETY WHILE WORKING 3. Non-reusable items Always use new gaskets, packings, Orings, split-pins, circlips, etc., on reassembly.

DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed air when disassembling.

2. Oil the contact surfaces of moving parts before assembly.

3. After assembly, check that moving parts operate normally.

4. Install bearings with the manufacturers markings on the side exposed to view, and liberally oil the bearings.

5. When installing oil seals, apply a light coating of water-resistant grease to the outside diameter.

1-4

SPECIAL TOOLS SPECIAL TOOLS Using the correct special tools recommended by Yamaha, will aid the work and enable accurate assembly and tune-up.

Improvising and using improper tools can damage the equipment.

NOTE:

For U.S.A. and Canada, use part numbers that start with “J-”, “YB-” “YM-”, “YU-” or”YW-”.

For other countries, use part numbers that start with “90890-”.

MEASURING

1a

1 Engine tachometer P/N. YU-08036-B ..........................

90890-06760 .........................

b

a b

2 Compression gauge P/N. YU-33223 90890-03160 2

4 ab

3 Timing light P/N. YM-33277-A 90890-03141

3

4 Mity vac P/N. YB-35956-A............................ a 90890-06756...........................b

5

5 Leakage tester P/N. N.A. 90890-06762 6a

7a

b

6Digital circuit tester P/N. YU-34899-A............................a 90890-06752 ......................... b 7 Peak voltage tester P/N. YU-39991 .............................. a 90890-03172 ......................... b

b

8 Spark gap tester P/N. YM-34487 .............................. a 90890-06754 ......................... b 8a

b

1-5

SPECIAL TOOLS 9

9 Bearing house puller

0

P/N.

YB-06234 N.A

0 Universal puller A

P/N.

B

YB-06117 N.A.

A Dial gauge stand P/N. C

D

YU-03097 90890-01252

B Magnet base P/N.

YU-34481 90890-06705

C Backlash indicator P/N.

YU-06265 90890-06706

D Magnetic base attaching plate P/N.

1-6

YB-07003 90890-07003

SPECIAL TOOLS 1a

REMOVING AND INSTALLING

b

1 Flywheel holder P/N.

YB-06139 ............................... a 90890-06522 ......................... b

2 Universal puller 2a

b

P/N.

YB-06117 ............................... a 90890-06521 ......................... b

3 Valve spring compressor P/N. 3

4

YM-01253 90890-04019

4 Valve spring compressor attachment P/N.

YM-04108 90890-04108

5 Valve guide remover 5

6

P/N.

N.A. 90890-06801

6 Valve guide installer P/N. 7

YM-01122 90890-06801

7 Valve guide reamer P/N.

N.A. 90890-06804

8 Valve seat cutter set 8a

b

P/N.

YM-91043-C .......................... a 90890-06803 ......................... b

9 Valve seat lapper P/N. 9

0

N.A. 90890-04101

0 Piston slider P/N.

YU-33294 90890-05158

A Slide hammer handle A

B

P/N.

YB-06096 90890-06531

B Stopper guide plate P/N. C

N.A. 90890-06501

C Stopper guide stand P/N.

1-7

N.A. 90890-06538

SPECIAL TOOLS D Bearing puller assembly

D

P/N.

N.A. 90890-06535

E Bushing installer center bolt Ea

P/N.

b

YB-06029 ............................... a 90890-06601 ......................... b

F Driver rod (small) P/N. Fa

YB-06229 ............................... a 90890-06652 ......................... b

G Driver rod (large)

b

P/N.

YB-06071 ............................... a 90890-06606 ......................... b

H Driver rod (short) P/N. Ga

b

N.A. 90890-06604

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

H

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

J Bearing/oil seal attachment P/N. Ia

b

YB-06167 ............................... a 90890-06634 .......................... b

K Bearing/oil seal attachment P/N.

Ja

L Crankshaft holder

b

P/N.

Ka

YB-06028 ............................... a 90890-06650 .......................... b

b

L

1-8

YB-06561 90890-06561

CHAPTER 2 SPECIFICATIONS

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

2

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