1987 1992 Yamaha 30hp 2 Stroke Outboard Repair Manual

1987 - 1992 MOTEUR HORS-BORD

MANUEL D’ATELIER

Model : 30ELD, 30ELF, 30ELG, 30ELH, 30ELRP, 30ELRQ, 30MLHQ, 30MSHP, 30MSHQ, 30OLF, 30OSF, 30SD, 30SF, 30SG, 30SH

6J8281972100 *6J8281972100*

FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the 30EH. For complete information on servit is necessary to use this Supice procedures, with Manual together Service plementary manual: following

30J Service Manual (6J8-28197-70)

30EH SUPPLEMENTARY SERVICE MANUAL Š1986 by Yamaha Motor Co., Ltd. 1st Edition, August 1986 All rights reserved. Any reprinting or use without the written unauthorized Yamaha Motor Co., Ltd. of permission is expressly prohibited.

Printed in Japan

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30EH EXTERNAL

VIEW

J

CONTENTS

GENERAL INFORMATION

?

GEN

INFO

AND ADJUSTMENTS PERIODIC INSPECTIONS POWER HEAD OVERHAUL

Po-W-R_

ELECTRICAL SYSTEM

ELEC[

APPENDICES

t,©,

AP-PX_'i

I GEN CHAPTER 1 GENERAL INFORMATION OUTBOARD MOTOR IDENTIFICATION ..........................

MODEL AND SERIAL NUMBER ................................

ENGINE SERIAL NUMBER ....................................

1-1 1-1 1-1

TECHNICAL FEATURES ........................................

ELECTRICAL .................................................

OIL INJECTION SYSTEM .....................................

1-2 1-2 1-6

?l

INFO

OUTBOARD MOTOR IDENTIFICATION GENERAL

INFORMATION

OUTBOARD MOTOR IDENTIFICATION

MODEL AND SERIAL NUMBER The model and the serial number plate is attached to port side clamp bracket.

(_) Number plate

(9 / ·

Starting

Serial Number

YAMAHA [.............. iiiiiJ_"_J!?_?_?_J:i_ii_?j?_i'i:.?_iii_q 3DELH _ "] 30ESH 450214 150126_ :_:_ !!iiiiiiiiiiiiiiiiiiiiiiiiiiiiii_iiii !iI I /Y^M^.^M,,TO. CO.,LTD.\ I

/MADE ,_/ PAYS (_

IN J_PAN D'ORIGINE _

,./APON

_

! \ J

(_) Model name (_) Approved model No. (_) Transam height (_ Serial number ENGINE SERIAL NUMBER

'_'[_.')

_:_)

The engine serial number is stamped on the plate attached to the cylinder body.

NOTE: Designs and specifications are subject to change

_}[_

1-1

without notice.

Q Engine serial number

I TECHNICAL .

Warning lam?

_

"_-"_-_

,.ol? I

_Oil / __

ELECTRICAL Warning system The overheat warning system over-rev, limiter and

_.

_ __

tank Oil tank l_.l /"'"-_ ens°r

',, ]V,

[_[_1 I I

_-_CDI I ___

' Thermo sensor

Gasolinetank

FEATURES

oil level warning system are employed to increase

unit Oilinjection

Buzzer RemoteI1_Dazzery aa'.eIrFh pump control L_t_ j ,-box

l

TECHNICAL

_/

.

I

Top cowling I Oil tank filler

O'I-_ J_

FEATURES

GEN

the reliability of the engine.

'_.__'J

Overheat warning system When cylinder head temperature exceeds a predetermined level, the thermoswitch on the cylinder head is activated and engine speed is gradually reduced. The system therefore prevents

Effectof systemson engine speed

6,_ _A

the engine from overheating.

In addition, the overheat warning lamp (LED) on

t E 4,0_ 3,_ A s,_0 2,0m_ t--

B

c_ _.0_

UJ

o

s

,0 ,s Time (sec.)_

model the warning buzzer in the control box sounds to warn the operator that the engine temperature istoo high. the bottom cowling will flash. On the electric start Overrev limiter Over revolution may occur due to sudden changes in engine load. This device prevents engine damage due to over revolution.

A: Overrev limiter B: Overheatwarningsystem_ oil _eve[warningsystem The above curves are approximate; the actual engine speed will vary depending on changes in engine load.

Warning system Warning light Buzzer Speed down

Over heat

Oil level

Rev limit

ON

ON

--

ON

ON

--

ON

ON

ON

Oil level warning system The oil level sensor in the oil tank detects the remaining oil level and warn the operator of it by means of the oil level warning lights if the remainlng oil level comes lower and it is risky to continue cruising, the red warning light and buzzer comes on and at the same time, the engine speed will automatically falls to 2,000 r/min as an alarm.

NOTE: This warning system also operate when oil filter in the Tank is clogged.

1-2

J GEN Charging

I

-qq

r--

_-i- T_ [_.

I "__

I

_ ]_'[ [-- ___!

, the negative _ AS indicated by the arrow coil charge from the On theis output side ofand the other the condenser. stored incurrent flows

_-i_

cuit and drives the overheat and over-rev, J_l __. I'lr-_-_

@ll_--_-----_:

@11-

1_

trolcircuit.

I,

hand. the positive current flowstothe

con-

';_ /

I_

power cir-

,ÂŽ

''

L .................

Sparking

(_ =---_

_----_ ____ -.____1:___.

-_ I r--_.-,--J ,

i @

' , , J_I_

'/ r-

_I "",

J-

_

_ "r.'i _dr_lJ._

--_ _

;,_11_

,.11_----I',._l_ I*_

The output

current

from

the pulser coil flows

thus turSCR gate, to the filterSCR the noise through on, theelecis turned When ningonSCR. tric charge stored in the condenser is discharged and flows to the primary winding of the ignition ed in the secondarywinding, thus causing a spark

,, 'l

, =,

,,

, I I m L_ .___._

I ,

e

_

I

_

tt :!

;__.

...........

_

(5) t--I (6) _ ,_ _ , t__.7_._,J_ I I-'-_---i

_

I

'_ ,_ I

r':.... ¡ L"JL_q_...___. _.J,_,,_i ,, ,_,,_, _.._%__...... _'-_-____ 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Over-rev. limiter release terminal Voltage control circuit Power circuit Noise filter Waveform shaping circuit Frequency-voltageconvertor circuit Noise filter Switch 8- timer circuit Over-rev. 8- overheat control circuit CDI unit Charge coil Pulser coil Lighting coil CDI magneto Thermo switch Oil level switch Engine stop switch No. 1 cylinder No. 2 cylinder No. 3 cylinder

to jump acrossthe spark plug gap.

I GEN TECHN ICAL FEATURES

¢11

!,

@11_

_i_

_

%>

_

r_--I--

¢

I I

tor circuit to the SCR4 gate, thus turning it on.

_e_

As indicated by _, this shortcircuits the charge coil output to the ground so that the engine

DII[ .

misfires. engine alternates firing and misfiring to keep The

]

engine speed from rising to higher than the setting.the

:__n

,,m_-] mi _

'-_-_

- - _, !

_

/

_'[---_--L/

I]_i

_,

_

[-

'_11

_

'_, I

Overreving: When the engine speed reaches the setting, current m flows from the frequency-voltage conver-

Q _-- -e .__fi____=_ --

[_ INFOI

_,

I

I(_)

'

I

...... e_,,_ · _-.___'_z_l_'_'_'_'---

Over.ea.,n.

When the cylinder head temperature exceeds the

............ _,__

--_-]

i

@l_--__ ell (_ll_'__'_, ell____---l'.; (_)=

I [-_!-'---_''

_11_

_

i)_J=_ 'F-_ I

!

e _

setting, the thermoswitch

IR _J_ __'_

O. of the in the a short-circuit forms output charge coil the direction on and thus, is turned This makestheenginemisfiresothattheengine

'

speed decreases to the setting.

I

I

I

f

SCR4 hand, other the the flush warning overheat circuit power On the (LED). rent fromlamp

m_-_ !

I r ...........

I _,F__-i_----L_-4-_--_f_

Ii--_-l_l

turn on and the cur-

limiter release terminal 1. Over-rev. control circuit Voltage Power circuit Noise filter shaping circuit Waveform circuit convertor Frequency-voltage Noise filter Switch 6t timer circuit 8' overheat control circuit Over-rev, CDI unit Charge coil Pulser coil coil Lighting CDI magneto Thermo switch Oil level switch Engine stop switch No. 1 cylinder No. 2 cylinder No. 3 cylinder

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

1-4

INFO

TECHNICALFEATURES

;

[____._

u_'i_-ii !' ._[---_--I_ /I-L,

_____-_@ll_

@ll,l__-_ L

'F_

r-O;__-!

l?;_j

,_-_ _l

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

1-5

ti i _

down Oil remaining If thelevel

,

J_

--=-__ _

_11_,

Iow and it

comes on and at the same time, the engine speed is risky to continue cruising, the red warning light will automatically falls to 2,000r/min as an alarm.

be operated maybuzzer The buzzer in warning is built warning starting model, electric system.

For

t MI

_

oil level is extremely

' ÂŽ!

Over-rev. limiter release terminal Voltage control circuit Power circuit Noise filter Waveform shaping circuit convertor circuit Frequency-voltage Noise filter Switch Er timer circuit Over-rev. Er overheat control circuit CDI unit Charge coil Pulser coil Lighting coil CDI magneto Thermo switch Oil level switch Engine stop switch No. 1 cylinder No. 2 cylinder No. 3 cylinder

with warning

light.

FEATURES

[GEN

OIL INJECTION SYSTEM Since the oilinjection system is used, it is unnecestank.

Gasoline

and oil are stored separately in different tanks, then oil and gasoline are automatically mixed.

'___1

sary to pre-mix gasoline and oil to refill the fuel Only for the first ten hours of operation, 50: I gasoline-oil mixture is necessary.

1. Pre-mix gasoline-oil fuel is unnecessary.

2. The oil mixing ratio is determined automatically depending on the throttle opening and engine speed. Oil is injected into the intake manifold at the rates of about 200: 1 at Iow and idling speeds and about 100: 1 at high speeds.

Since the oil injection rate varies according to the needs of the engine, no oil will be wasted, leading to better oil economy and less carbon deposits.

3. The oil tank is built in the cowling, and the oil tank filler is provided on the exterior of the top cowling for easy oil refilling.

Oil tank capacity:

0.8 liters 0.9 U.S. qt 0.7 I.M.P. qt

1-6

GEN I INF0

I

I TECHNICALFEATURES Oil Level Sensor The oil level sensor detects the oil level in the oil tank, and when the oil level is Iow, it gives a signal to the oil level warning system, thus turning on the light, buzzer and reducing the engine speed.

NOTE: 1. The oil level can change depending on the method of installation and the angle of the boat during operation.

2. If oil is added to the oil tank without stopping the engine after the red oil warning light is on, the engine speed will not rise to more than 2,000r/min.

To increase the engine speed, the main switch must be turned off once.

3. The oil level warning system displays warnings similar to the oil filter clogging warning system and the overheat warning system. For easy troubleshooting, it is advisable to check for engine overheating first and then, check the oil level, and finally check the oil filter for clogging.

1-7

TEC""'CA'" I ATU" I Oil Injection t

The oil injection pump sends the measured

_:_ Cylinder

To No. 3

Pump

amount of oil to be injected directly into the intake manifold, where, it enters the intake port together with the mixture and lubricates the cylinders and the crankcase journal.

To No.2 Cylinde

:_,4p

To No.1 Cylinder

Operation (_) The worm shaft of the oil pump is driven by a drive gear pressed on to the lower end of the crankshaft. (_ The plunger cam of the oil pump is driven by the worm gear and shaft. With this movement the oil is pumped. (_) The amount of oil is controlled by the movement of the plunger. With every one turn, the oil for each cylinder is pumped, and the check valves between delivery hoses also avoid to back-flow.

Therefore, the amount of oil is directly related to the revolutions of the crankshaft.

' '_

(_) The plunger cam is also controlled by the opening of the throttle.

J

_

speeds is different in orderhigh to eliminate This way, the ratioagain, at extreme and Iow waste and assure the proper amount of lubri-

;.- ._.p_ __

cation.

t Plunger

cam

Worm shaft

lever shaft

_

system oil manufactured exclu-

_Pump Oil injection

Oil the oiltoinjection It is for necessary use the

pumplever

sively for outboard motors. But, since the properties oil injected by the oil injection system may vary with the brand, it is recomended to USE YAMALUBE 1 TWO-CYCLE OUTBOARD OIL, if it not available, another 2-stroke engine oil with mIA certified TC-W may be used which can be used in a temperature range of 60째C to -- 10째C (140째F to 14째F).

Do not put any different kind of oil in the oil tank.

Mixing of oils may cause a chemical reaction. Be sure no foreign matter such as dirt, water, etc. enters the tank.

1-8

ADJ INSP PERIODIC

CHAPTER 2 INSPECTION AND ADJUSTMENTS

PRE-DELIVERY SERVICE ..........................................

FUEL ...........................................................

OIL INJECTION .................................................

2-1 2-1 2-1

BREAK IN THE ENGINE ...........................................

2-2

PREDELIVERY CHECK .............................................

2-3

OIL INJECTION

.................................................

2-3

....................

PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ................................................

MAINTENANCE INTERVAL CHARTS ..............................

PERIODIC MAINTENANCE .......................................

LUBRICATION INTERVALS .......................................

2-4 2-4 2-4 2-4 2-4

OIL INJECTION SYSTEM ..........................................

OIL PUMP LINK ADJUSTMENT ..................................

2-5 2-5

_1_

ir_

ADJ INSP

SERVICE PRE-DELIVERY PRE-DELIVERY

SERVICE

FUEL *Check the fuel hoses for secure connection. · Premix fuel for break-in o Mixing ratio: 50: 1 o Octane number: 90 or more (R.O.N.)

OIL INJECTION *Make sure correctly. · Make sure · Make sure · Make sure

the oil level warning

2-1

is wired

control links are engaged the oil hoses are correctly connected. the oil tank is full filled of oil.

· Make sure the oil level warning normally.

system

system

operates

BREAK-IN THE ENGINE BREAK-IN

INSP ADj

THE ENGINE

A period of break-in is required to allow the mating surfaces of all moving parts to wear evenly when new. This procedure will ensure maximum performance and engine life.

In the test run, break-in operation is performed in the following three stages (at 4,000 r/min (r/min) or at 3 4 throttle) and the final stage breakin opeation should be conducted by a dealer.

If it is impossible, it is advisable that the user perform the final break-in operation.

In this case, the importance of break-in operation should be stressed and explained to the user.

Procedure: Break-in Period 10 hours

1. Run the engine at trolling speeds (The lowest

Mixing ratio: Gasoline: Oil

possible speed) for the first 10 minutes.

2. With an easy planing boat, bring it into the planing position; then, immediately reduce the throttle to approximately 3,000 r/rain (onehalf throttle), continue running at this throt-

50: 1

0 _

_ 10min.

1 --

t

50 min.

1 hour 2

t

tie setting for 50 minutes. tie (approximate) while maintaining planing.

3. Bring the boat into the planing statesetting and throtContinue running at this throttle for NOTE: Runone(1)hour. at full throttle for approximately one (1) out of every 10 minutes.

8 hours

4. For the next eight (8) hours, avoid continuous full throttle operation for more than five (5) minutes.

5. After the first 10 hours, use straight gasoline for normal operation of the precision blend system.

10 CAUTION: Failure to follow the break-in operation procedure may result in severe engine damage,

2-2

ADJ _i _ INSP

CHECK PRE-DELIVERY PRE-DELIVERY CHECK OIL INJECTION *Make sure oil is supplied to the intake manifold. · Remove the delivery hose from the oil injection pump and make sure of oil delivery. .

CAuTiON .

." '.' '

..

_ .

After finishing the check, besure to connect the delivery hose. Do not run the engine without connecting the hose.

eCheck for leakage from the oil delivery hose. · Air blead can be done automatically.

2-3

INSP ADJ

PERIODIC INSPECTIONS AND ADJUSTMENTS PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION

MAINTENANCE

This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable outboard operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to outboards already in service and to new outboards that are being prepared for sale. All service technicians should be familiar with this entire chapter.

The following charts should be considered strictly as a guide to general maintenance and lubrication intervals.

Depending on operating conditions (e.g., fishing, cruising, water skiing, etc.), the intervals of maintenance should be changed. For instance, when the outboard motor has been used on stormy or rough seas, the intervals should be shortened.

PERIODIC

INTERVAL

CHARTS

MAINTENANCE Unit: hours Thereafter

Initial Item

Remarks 10

I

50

100

t Oil injection pump

LUBRICATION

Check oil delivery/Replace

if necessary

every 100 Off season

Every 6 month

0

INTERVALS Unit: hours Thereafter

Item

Remarks

Oil injection pump return spring Apply oil

Type (Recommended lubricants)

YAMALUBE

1

Initial 10

50

100

O

every Off 100 season O

2-4

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL