1984-1993 Yamaha 6 8hp 2-stroke Outboards Repair Manual - PDF DOWNLOAD

1984 - 1993 OUTBOARD

SERVICE MANUAL

Model : 6LH, 6LJ, 6MSHP, 6MSHQ, 6MSHR, 6SD, 6SF, 6SG, 6SH, 6SJ, 8LD, 8LJ, 8LK, 8LN, 8MLHP, 8MLHQ, 8MLHR, 8MSHP, 8MSHQ, 8MSHR, 8SD, 8SF, 8SG, 8SH, 8SJ, 8SK, 8SN

6G1281972100 *6G1281972100*

MANUAL 8NSERVICE Š1986 by Yamaha Motor Corp., USA 1st Edition - April 1983 2nd Printing - March 1986 - JEM D-172 All rightsreserved.Any reprintingor unauthorizeduse withoutthe written permissionof Yamaha Motor Corporation, U.S.A., is expresslyprohibited.

PRINTED IN U.S.A.

P/N LIT-18616-00-03

NOTICE This manual has been written by the Yamaha Motor Company primarily for use by Yamaha dealersand their qualified mechanics.It is not possibleto put an entire mechanic'seducation into one manual, so it is assumedthat persons using this manual to perform maintenance and repairs on Yamaha outboard motors have a basic understandingof the mechanical concepts and procedures inherent to outboard motor repair technology. Without suchknowledge, attempted repairs or service to this model may render it unfit for use and/or unsafe.

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured

by Yamaha. Modifications and significant changesin specificationsor procedureswill be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.

Particularly important information is distinguished in this manual by the following notations: NOTE: A NOTE provides key information procedures easier or clearer.

to make

A CAUTION indicates special procedures that must be followed to avoid damage to the outboard motor, WARNING: A WARNING indicates special procedures that must be followed to avoid injury to an outboard motor operator or person inspectingor repairing an outboard motor.

OVERSEAS SERVICE OVERSEAS OPERATIONS YAMAHA MOTOR CO., LTD.

8N EXTERNAL

VIEW

GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS FUEL SYSTEM AN D CARBURETION POWER HEAD OVERHAU L LOWER UNIT OVERHAU L _ELECTRICAL RECOIL STARTER APPENDICES

o.

..

¢,P

_".

GENERAL

INFORMATION

OUTBOARD MOTOR IDENTI FICATION SPECIAL TOOLS

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

The proper special tools are necessary for complete and accurate tune-up and assembly.

Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques.

For Tune-up 1. Compression gauge P/N. YU-33223

Model and serialnumber The model and serial number plate isattached to the port clamp bracket.

_

r-w/:, L_

2. Timing light P/N. YU-33277

This timing light is used for checking the ignition timing.

1-1

For engine service

3. Tachometer

1. Flywheel magneto holder P/N. YB-06139

P/N. YU-08036

This

tachometer

is used for

This tool

checking

is used for removing

tening the flywheel

the engine speed,

and tigh-

securing nut.

2. Flywheel magneto puller P/N. YU-33270

This tool wheel.

is used for removing

the fly-

3, Dial gauge set 1 P/N. YU-01256 (14mm hole addaptor) 2. P/N. YU-03097 (Gauge)

3. P/N. YU-01037 (Stand) 4. P/N. YU-01038 (Bolt)

/

[__

ÂŽ

This dial gauge set is used for determing the gear shim.

1-2

4. Attachment

For lower unit service

P/N. YB-06022

1. Handle P/N. YB-6071 Attachment P/N. YB-06016

YB-06021

YB-06016

YB6071

P/N. YB-06021

__)

_

This tool is used for installing the bushing. (Use handle P/N. YB-6071 )

_

5. Handle A P/N. YB-06027 Handle B P/N. YB-06028 Rot driver P/N. YB-06229

' Theses tools are used when installing the oil seal.

2. Attachment P/No YB-06016

YB.06027

YB-06028

YB-06229

This tool is used for installing the bearThese tools are used for removing the

ing. (use handle P/N. YB-6071)

bushing.

6. Attachment P/N. YB-6025

3. Driver head P/N. YB-06167

This tool is used for installing the bush-

tool is used for installing the taper This roller bearing outer race. (Use handle P/N. YB-6071 )

ing and oil seal. (Use handle P/N.YB-6071) 1-3

2. Ignition coil tester P/N. YU-33261

7, Bushing installer assembly P/N. YB-06029

This tool is used for installing the bushing.

8. Dial gauge stand P/N. YB-7003 Backlash indicator rod P/N. YB-6265

SEALING AGENTS AND LUBRICANTS Sealingagents 1. Yamaha Bond No.4 P/N. ACC-11001-30-00

Lubricants

YB-6265 1

all(Yamaha grease P/N LUB1. Water grease, purposeresistant GREAS-13-00) 2. Yamaha gear case lube, P/N LUBGEAR L-11-00

}

These tools are used for measuring the backlash for the forward/reverse gear.

For electrical components 1. Yamaha pocket tester P/N. YU-03112

1-4

COOLING SYSTEM This outboard motor employs an open-circuit, direct cooling-system. As a preventive measure against over-cooling the engine, a thermostat is used, which controls the engine operating temperature properly.

Cooling water flow

Upper casing

I

rbl

, 00e xhau, i1 C_,,oderhead "1 (OPEN)

Thermostat

'Thermostat

[

l

I

Cylinder head(Upper)

1

t

Cylinder head (Lower)

]

I

Exhaust cover (Lower)

]

[

Exhaust cover (Upper)

,J

I

Cylinder body (Right)

]

[

Cylinder body (Left)

I

]

Cylinder body (Upper)

I

1

Cylinder body (Left)

'1

'

1

"l

Pilot water

J

(Rightli body I Cylinder [

Upper casing

l

[

Water tube

1

[

Water pump

J

Cooling water inlet

]

1-5

PROPELLER TION

AND

PROPELLER

SELEC-

The performance of a propeller has a direct effect on that of both the boat and outboard motor. It is safe to say that the propeller greatly affects the boat speed, acceleration, engine life, fuel economy, and even boating and steering qualities. Therefore, the selection of the right propeller for the user's boat is of vital significance,

Movement of the propeller in the water: As the propeller turns in the direction of the arrow, it pushes water backwards which in turn develops a reaction force that thrusts the boat forward. That is, the propeller displaces water in an astern direction and, at the same time, on the forward surface (blade back) of the propeller, a negative pressure is produced, thus sucking water. In this way, the propeller produces the "thrust" to drive the boat.

Function of the propeller: As the propeller turns a negative pressure is created on the aft surface of the propeller blade, and a positive pressure on the back of the blade. This produces the thrust required

/_ \

ever, that the same propeller can never serve well for different types of boats.

In order to bring boat performance into full to play, movethe it is necessaryto boat ahead. selectthe The point right is, propelhowler for the specific use being made of the boat, such as water skiing, cruising, fishing, racing, etc. When a boat has to be used for various purposes, several different types of propellerswill be needed.

In addition, the material the propeller is made of and where the boat is used (e.g., rivers, seas, shallows, rock-bound waters, etc.) are also important. Whatever the purpose of the boat, always make it a habit to always carry spare propellers and hand tools. In caseof heavy propeller damage, you will be able to boat to sail for a nearby

C_

_T-_ //

Propeller pitch: The pitch of a propeller is the distancethe propeller will advance or move forward in one complete turn. (It isthe sameasthe pitch (lead) of a screw.)

I

//_

_

811/2'

port.

rely on the spare propeller to enable your

i__"

=_ 7-1/2 pitch propeller

8-1/2 pitch propeller i

1-6

I

The propeller size is indicated on the back of the blade. x

8-1/2

7-1/2 -N

speed and fuel consumption. mounted on propeller The boat relation tomotors in outboard performance maximum at the Yamaha factory is designed for standardoperatingcondition.

Therefore, it cannot meet the operating conditions of every boat.

In other words, the right propeller must be selected according to the type, displacement and load of the boat.

Propeller type

l Type d'h_lice Propeller pitch

Pasdel'h61ice diameter Diam_tredel'h_lice

Propeller

I

I

\ The pitch indicated by thepropeller size is a theoretical (designed) pitch, and the actual forward motion achieved at each revolution is smaller than the theoretical pitch. The difference is known asthe slip of the propeller.

In reality, water is a fluid substancewhich gives way a little under the pressureof the propeller blades. A 10% to 15% slip ratio is consideredto be proper.

i

i

ÂŽ ÂŽ 1.

2.

3.

4.

Propeller selection: When the engine speed is in the range from 4,500 to 5,500 r/min at full-throttle, the right propeller for the boat is one which gives

I

I

IÂŽi

Actual blade tip curve Theoretical blade tip curve Actual forward movement Theoretical forward movement

5. Slip

1-7

Dual thrust propeller The 8N factory installed propeller isdesigned for bossexhaust but a dual thrust propeller is available as optional equipment. Exhaust gas produced by propeller boss exhaust systems is forced out through the propeller bossand therefore, when boat direction is reversed,the propeller tends to turn in the exhaust gas, reducing boat speed. Similarly, lossof speed occurs when a boat in forward motion is braked, as braking requires the gear to be shifted into reverse.The dual thrust propeller was designedto rectify this problem.

When the boat movesahead, the exhaust gas streams out through the propeller boss, but when the boat direction is reversed,the exhaust gasisforced out through the bossto the outside of the gearcase.

i

\

\__ Route of exhaust gas at forward gear

'\\ Route of exhaust gasat reverse gear

1-8

CHAPTER 2.

PERIODIC INSPECTIONS AND ADJUSTMENTS PRE-DELIVERY SERVICE .......................................

Handling notes of cardboard crates .............................

Handling instruction marks ...................................

Notes on transportation ......................................

Unpacking ................................................

Predelivery check ...........................................

Predelivery service ..........................................

Test-run (on the test tank) ....................................

Clean up ..................................................

Delivery ..................................................

2-1 2-1 2-1 2-1 2-1 2-2 2-2 2-2 2-2 2-2

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

Introduction ...............................................

Maintenance interval charts ...................................

Periodic maintenance ........................................

Lubrication intervals ........................................

2-3 2-3 2-3 2-3 2-4

POWER HEAD .................................................

Spark plug ................................................

Ignition timing adjustment ....................................

Throttle linkage adjustment at wide open throttle ..................

Limited throttle opening starting device..........................

Idle speedadjustment ........................................

Gear oil ..................................................

Test propeller ..............................................

2-5 2-5 2-5 2-7 2-8 2-8 2-9 2-9

PERIODIC INSPECTIONS PRE-DELIVERY

AND ADJUSTMENTS

SERVICE

Handling notes of cardboard crates You will find the following marks on the crate sides. Read the explanation of these marks carefully when handling a crate,

Notes on transportation Observe the following in crate transportation.

• Select a level, dry, and well-ventilated place for strage.

• Do not stack crates more than 6.

• When moving or transporting a crate, take special care not to drop or bump it.

Unpacking Occasionally, crate material will vary depending on the number of outboard motor packed in a crate, but the uncrating procedure is basically the same for Yamaha outboard motor.

Handling instruction

marks

This arrow mark indicates the top of the crate. Be sure to load, unload, or store the crate with this mark pointing upward.

This

mark

U

indicates

that the crate should

be kept dry. Also avoid excessively humid places for storage.

This

mark

indicates

that

the crate

is fragile. Do not drop the crate it to sharp bumps or shocks.

content

or subject

2-1

Predelivery check [] Contained in the packing

Test-run (on the test tank) [] Outboard motor test-run

o Fuel tank o Owner's manual o Servicetool

o Check the recoil starterfor pruper operation. o Checkthe motor for abnormal noises. o Check to see whether cooling water is spoutingout of the pilot hole. o Check the motor for quick responceand steady idle.

Predeliveryservice [] Check motor exterior o Check for scratches or deformation. o Patch up any scratched or peeled-off surface with a paint of identical color. o Check the gear oil level. [] Fuel tank o Check the fuel hoses for secure connection.

Clean up Clean the outboard motor thoroughly after the test. Wipe the outboard motor with a clean rag. During the wipe down, check all components fc nicks, scratches or other signs of damage.

[] Fuel line (For motor) o Drain stale fuel from the lines and fuel filter while avoiding contact of fuel with the motor. [] Throttle grip o Check the throttle grip for smooth operation. The grip should be smooth yet tight enough to stay in position when the hand is released. If not, adjust it.

Delivery When the outboard motor is delivered to the new owner, make sure he is familiar with all the operating controls. Advise him of break-in procedures. Let him know if there are any service or operational problems peculiar to his locale that may require extra attention on his part.

[] Shift lever o Check the shift lever for smooth operation (forward, neutral and reverse),

[] Steering o Check the steering for smooth operation.

Tightening the friction bolt makes the steering handle stiff to turn.

[] Electrical o Make sure all wire connections are correct.

2-2

PERIODIC

INSPECTIONS

AND

ADJUSTMENTS

Introduction

Maintenance

This sary

Chapter includes all information necesto perform recommended inspections

The following charts should be considered strictly as a guide to general maintenance

and

adjustments.

and lubrication

nance more

These

procedures, reliable

if

outboard

preventive

mainte-

followed,

will

motor

operation

ensure

Depending

and

fishing,

interval

on

crusing,

charts

intervals. operating water

conditions

skiing, etc.),

(e.g.,

the inter-

a longer service life. The need for costly overhaul work will be greatly reduced. This infor-

vals of maintenance should be changed. For instance, when the outboard motor has been

mation service

used on stormy or rough should be shortened.

being

applies to outboard motor already in and to new outboard motor that are prepared

cians should ter.

Periodic

for

sale. All

be familiar

service

seas, the

intervals

techni-

with this entire chap-

maintenance Unit: hours Initial Item

Remarks

Thereafter every

10

50

100

100

Off season

0

©

©

0

©

O

©

©

©

O

Fuel tank

Clean/Flush

©

Fuel line (Full tank)

Check all hoses for cracking and leakage/ Replace if necessary

©

Fuel filter

Clean/Flush

O

Fuel line (Motor)

Check for cracking and leakage/Replace if necessary

O

©

©

©

Carburetor

Check operation/Adjust

O

©

O

©

Spark plug (s)

Inspect/Clean and adjust/Replace necessary

O

©

O

O

O

O

O

if necessary if

©

Cylinder head cover

Check headcover bolts for tighteness/ Torque bolts to specification if necessary

O

Ignition timing

Check/Adjust

©

O

O

©

Ignition and throttle synchro-mechanism

Check ignition and throttle synchromechanism for proper operation/ Adjust if necessary

O

O

O

O

Throttle

Check throttle mechanism for proper operation/Adjust if necessary

©

©

O

©

Cooling system

Check pilot water/Check water pump and water passage if necessary

O

O

O

O

O

Anode

Check wear/Replace

O

O

O

©

O

Propeller

Check propeller blade/Replace if necessary

O

O

©

O

O

Cotter pin (propeller nut)

Check for breakage or wear /Replace if necessary

0

0

0

0

0

mechanism

if necessary

if necessary

2-3

O

Lubrication intervals Unit: hours

Item

Remarks

TYPE (Recommended lubricants)

Thereafter

Initial

every 10

50

100

100

off season

Throttle link

.Apply grease lightly

check

O

O

O

Throttle grip/housing

Apply grease lightly

check

0

•0

0

Bottom cowling clamp lever journal

Apply greasefully

0

0

0

0

Shift lever journal

Apply greasefully

O

O

O

O

Throttle link journal

Apply greasefully

O

O

O

O

Shift mechanism

Apply grease lightly

check

O

©

O

Steering pivot shaft

Apply greasefully

©

O

O

Clamp bolt

Apply grease lightly

Tilt mechanism

Apply grease lightly

©

O

©

Gear oil

Replace

O

O

©

Propeller shaft

Apply grease lightly

O

©

O

Recoil starter

Apply grease lightly

Drive shaft

Apply grease lightly

_

(Yamahaall-purpose grease,P/N LUBGREAS-13-00)

©

"

©

Every 50 hours O Yamahagear case lube, P/N LUB-GEARL-11-00)

©

check

© (Yamahaall-purpose grease, P/N LUBGREAS-13-00)

When assembled When assembled

2-4

._

POWER HEAD

b. Clip the timing light to the upper cylinder high-tensionwire.

Spark plug 1. Check electrode condition and wear, insulatorcolor, and electrode gap.

2. Clean the spark plug with spark plug cleaner if necessary.Use a wire gaugeto

NOTE: If clipped to the lower cylinder high-tension wire, the timing light will not work. Be sure to clip to the upper cylinder high-tension wire.

adjust the pluggap to specification, 3. If the electrode becomestoo worn, replace the spark plug.

4. When installing the plug, always clean the gasket surface, wipe off any grime that might be presenton the surface of the spark plug, and torque the spark plug properly.

|_ "(_

Standard spark plug: R-7HS10 (NGK) Spark plug gap: 0.9 ~ 1.0ram (0.035 ~ 0.04in) Spark plug tightening torque: 20Nm (2.0m-kg, 14ft.lb)

1. Upper cylinder high-tension wire

2. Timing light clip

c. Start the engine, and fully advance the ignition timing.

Ignition timing adjustment Adjust the ignition timing asfollows:

NOTE: 1. Before starting ignition timing tion.

2. After starting timing at the

NOTE: Ignition timing adjustment must be made with the engine running in a test tank.

1. Full advanced position a. Remove the joint link between the CDI magneto base and magneto control lever.

the engine, do not set the at the full-advanced posithe engine, set the ignition full-advanced position by

moving the CDI magneto base.

WARNING: When moving the CDI magneto base,be careful not to touch the flywheel rotor.

1. Magneto base stopper

2-5

2. CDI magneto base

d. Direct the timing light to the timing plate and the timing indicator and make sure of the timing mark to which the timing plate points.

NOTE: Be sure to use a timing light when aligning the timing plate with the 35° position. g. Bring the magneto basestopper into contact with the stopper on the full-advanced side of the CDI magneto base, and tighten the bolt.

1. Timing plate 2. Timing indicator

3. CDI magneto rotor

(_)__-'_"-_-_ (_"

e. If the timing plate is not aligned with the specified mark on the timing indicator, loosenthe stopper bolt.

Specified position: 35° + 1° BTDC

1. Magneto base stopper 2. COl magneto

3. Full-aovanced side stopper

base

NOTE:

0

During the above operation, to move the magneto base.

__

h,

I_

After

tightening

the

magneto

be careful not

base

stop-

per bolt, checknot thepoint timing platerepeat position.

If it does to 35°,

_-_-_

the procedures in e, f, and g above so i. that When timing plate is to adjusted thethe timing plate points 35°. correctly, stop the engine. j, After adjusting the ignition timing, connect the joint link (connected to the CDI magneto base) to the magneto control lever at the ball joint.

k. base stopper f. Move the CDI magneto base little by little by hand, and when the timing plate points to 35° on the timing indicator, stop turning the CDI magneto base.

1. Magneto

__"

1. Joint link 1. Timing plate

2-6

2. Magneto control lever

3. By turning the tight-side throttle wire adjust bolt, bring the carburetor throttle lever into contact with the stopper, and lock the adjust bolt with the lock nut.

2. Full-retarded position It is unnecessary to adjust the ignition timing at the full-retarded position, since it is automatically adjusted when the timing at the full-advanced position

_

has been correctly set. throttle 1. Remove the joint link between the CDI magneto base and magneto control lever.

Throttle linkage adjustment at wide open

//___ _

_

I,.,,,,

J

__J

L_ ---_ 3_

" __

2. Twist the throttle stops,

3. Adjust bolt

6.

Lock nut

wire should have a

sligth amount of slack.

_ /

4. Carburetor throttle lever 5. Stopper

NOTE: The loose-side throttle

"_--:_, _

-

. Tight-side throttle wire 2. Loose-side throttle wire

4. While keeping the tight-side throttle wire adjust bolt in the position specified in c. above, bring the full-advanced side stopper into contact with the magneto base stopper, and adjust the length of the joint link, then connect the magneto base to the magneto control lever,

I I grip to FAST until

2-7

1. CDI magneto base

4. Joint link

2, Full-advanced side stopper 3. Magneto base stopper

5. Magneto control lever

5. Turn the throttle grip from FAST to SLOW a few times, and make sure that when it is at FAST, the stopper on the full-advanced side of the CDI magneto is in contact with the magneto base stopper and at the sametime, the carburetor throttle lever is in contact with the wide open throttle stopper. If either or neither one is in contact, repeat the procedures in 1. to 4. above until all thesestopperscome in contact.

Idle speedadjustment 1. Turn the pilot screw until it is lightly seated.

Limited throttle opening starting device 1. Turn the throttle position. .....

grip to the SLOW 2. Turn out the pilot screw to specification.

I ,otscrew urnsoutl 2. Turn the wire adjust bolt so that the plunger tip is flush with the starter case surface.

-.'

i

= i

few minutes.

4. Set the motor idle speedto the specified level by adjusting the throttle stop 3. Start the motor, and warm it:up for a screw.Turning the throttle stop screw in (clockwise) increasesthe motor speed; creasesthe motor speed. Use a tachoturning it out (counterclockwise) demeter for checking and adjusting the

__ I

ÂŽ

I I

Idle speed: 850 +-50 r/min motor speed.

1. Plunger 2. Starter case

3. Wire adjust bolt

_8

¸

Test propeller Whenever the motor is tested (for instance, before it is delivered to the customer or after being overhauled) be sure to use a test tank and test propeller. If the originally mounted propeller is used, the test tank may overflow or the water level may fluctuate sharply, thus causing cavitation with a marked increasein rpm or propeller slip. Therefore, it is impossible to check if the motor has been correctly overhauled.

The test propeller is designedto turn stably even in the test tank. If the tachometer readingsare within the specified speedrangewhen the motor is run with the test propeller, the motor isconsideredto be properly serviced.

If the engine speed is far below the specified speed, the motor will have to be checked again.

Gear oil 1. Oil levelcheck Remove the oil level plug and check whether the oil level it is up to the bottom drim of the hole. If it is not up to this level, replenishoil.

NOTE: Be sure the motor is positioned straight up when checkingthe oil level,

Specified motor speed: 1. Oil level plug

5,300 _ 5,500r/min

2. Oil drain plug

2. Oil replacement a. Place an empty oil can under the gear case and remove the oil drain plug (lower) using a slotted-head screwdriver. b. Next, remove the oil level plug (upper). c. Inject Yamaha gear case lube, P/N LUBGEARL-11-00, into the oil drain plug hole (lower). d. When the oil begins to flow out of the upper oil level plug hole, tighten the plug. Next, screw in the lower oil drain plug.

_. ,:_

Replace the gear oil after the first 10 hours of operation and check the oil every 100 hours.

2-9

CHAPTER 3. FUEL SYSTEM AND CARBURETION DESCRIPTION

3-1

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

3-2

FUEL SYSTEM (From fuel tank) ..................................

Description ...............................................

3-2

Removal .................................................

Cleaning,inspectionand repair ................................

3-3 3-4

Installation ...............................................

3-5

FUEL SYSTEM (From bottom cowlingto carburetor) .................

Description .............................................

..

3-6 3-6

Removal .................................................

3-6

Cleaning,inspectionand repair ................................

3-7

Installation .....

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

CARBURETION ..............................................

Description ...............................................

3-7

3-9 3-9

Functionsof the carburetor ..................................

3-10

Removal .................................................

Disassembly ..............................................

3-14 3-14

Cleaning,Inspectionand Repair ...............................

3-16

Assembly ................................................

Installation ...............................................

3-17 3-19

FUEL SYSTEM AND CARBURETION DESCRIPTION The fuel systemcomprisesthe fuel tank, carburetor, and fuel line connectingthe tank to the carburetor.

The fuel system can be divided largely into two sections,that is, the sectionfrom the fuel tank to the bottom cowling joint, and the

Fuel system

(For

other section from the bottom cowling joint to the carburetor.

The fuel system plays a vitally important role which greatly affects engine performance and therefore, special care should be exercised in servicingthe engine.

Fuel system

motor)

(For

tank)

ÂŽ

ÂŽ

1. Fuel tank 2.

3.

4.

5.

Fuel joint Fuel hose Priming pump Fuel joint

6. Fuel hose 7. Fuel filter 8. Fuel pump 9. Carburetor

3-1

FUEL SYSTEM (From fuel tank) Description The fuel tank assembly is made up of a 14 liter (3.7 US gal) fuel tank, fuel meter comp., fuel hoses,joints, and priming pump.

The priming pump has check valves at its inlet and outlet. By squeezing the priming pump, fuel can be suppliedfrom the fuel tank to the carburetor.

1. Fuel meter housing The fuel meter housing has a strainer

_)Priming

pump

to remove dust and impurities from the fuel.

®

on the end of the suction pipej® in order (_

,;

_2_

_

_lm Fuel flow

1. Priming valve 2. Arrow mark 1. Fuel meter housing 2. Suction pipe

3.

Fuel strainer

2. Fuel hose The fuel hose from the fuel tank to the engine is held to the meter housing with a band and connected to the hose joint attached to the engine. A priming pump is installed near the center of the fuel hose and used to supply fuel to the carburetor when starting the engine.

®

®

\

® 1.

2.

3.

Fuel tank Fuel meter housing Fuel hose

_

4. Priming pump 5. Fuel joint

3-2

3.

4.

Cheek valve linlet) Cheek valve (outlet)

3

The fuel joint attached to the end of the fuel to the joint attached hose is to be connected to the bottom cowling.

When either one of the fuel joints is connected to the mating joint, the steel ball in the fuel joint is pushed in, and thus the valve on the engine side is opened.

Removal WARNING: Gasoline is highly inflammable and explosive.

Avoid smoking while servicing the fuel systern. Also, keep away open flames and sparks.

1. Fuel meter housing Remove the four screws and pull the fuel meter housing out of the fuel tank.

;,;_,_<_y;_:,_;_ the fuel joint to the engine, be sure to loosen the air vent screw in the fuel tank cap. If not, fuel may spout out of

When connecting

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

_<_,; _

the joint on the fuel tank side.

Joint on the fuel hoseside

2. Priming pump and fuel joint Hold the fuel hose joint with your hand, insert a slotted-head screwdriver into the band end gap, and loosen the band by prying the band ends. Push the hose end out of the band with the screwdriver.

.

Joint on the bottom cowling

.... ® • Packing 2. O-ring 3. Steel ball 4.

®

® 5.

O-ring

6. Valve 7. Spring

_

Spring 1.

3-3

Fuel hose band

....

Cleaning,inspectionand repair Fuel system trouble, in most cases, stems from fuel leakage, a clogged strainer, or a jammed or worn check valve. To check the fuel system,proceed asfollows:

3. Primingpump and fuel joints Check the priming pump and fuel hoses for cracks or holes and replace them as required. Also, check the operation of the check valveby blowing into it.

®

Add a small quantity of suitable cleaning solvent to the fuel tank and thorou1. ghly Fuel tank clean the tank interior by shaking the tank. After cleaning, drain off the cleaningsolventcompletely.

2. Fuel meter housing Thoroughly clean the strainer on the end of the suction pipe with suitable cleaning solvent and blow it dry with com-

®

_ ®

A W

NOTE: Avoidpressed blowing air.the strainer from the suction pipe joint side.

41m B

A W

1. Checkvalve(inlet)

Do not remove the rubber cap on the end of the strainer.

_== B

2. Checkvalve(outlet)

Check valve

Blow from A side

Closes

(inlet)

Blow from B side

Opens

Check valve

Blow from A side

Closes

(outlet)

Blow from B side

Opens

NOTE: The check valveson the inlet and outlet sides are of the same type. After checking the check valves, put marks on them so that they can easily be distinguished.

_t

3-4

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

c. Pass the fuel hose through the band, inend of the sert the fuel joint into the hose, and hold the hose with the band.

1. Always use new gasketsto prevent fuel leakage past joints.

2. To prevent the fuel from leaking past the fuel hose joints, replace any fatigued fuel hose bands.

1. Fuel meter housing Fit the fuel strainer to the end of the suction pipe.

d. Place the gasket on the tank, and place the suction pipe, in the tank, and secure them with screws.

_/

2. Fuel hose a. Install the check valve (outlet) on the side (in the direction of the arrow) of the priming pump and the other one (inlet) on the opposite side, then secure the valves with bands.

1

;_';!

\ÂŽ 1. Priming valve 2. Check valve (outlet)

\ÂŽ 3. Check valve (inlet) 4. Bands

b. Connect the long nose to the check valve (inlet), and clamp it with the band.

Likewise, connect the short hoseto the check valve (outlet), and clamp it with the band.

3-5

Gasket

FUEL SYSTEM (From bottom cowling to carburetor)

Removal WARNING:

Description: The fuel system (from bottom cowling to carburetor) consistsof the fuel joint (attached to the bottom cowling), fuel filter, and carburetor. Particularly, the carburetor has a

Gasoline ishighly inflammable and explosive.

Avoid smoking while servicing the fuel system. Also, keep away open flames and sparks.

great effect on engine output and therefore it must be servicedwith specialcare.

a. Remove the clip holding the fuel hose from the fuel hose insert fitted to the fuel joint. b. Remove the fuel hose from the fuel

1. Fuel joint (engineside)

1. Fuel filter

joint.

The fuel filter removes any water or impurities contained in the fuel to keep them from entering the engine,

NOTE: It is advisable to insert a slotted-head screwdriver between the fuel hose and fuel joint and pry out the hosefor easyremoval.

2. Carburetor This single-barrel type carburetor uses a butterfly throttle valve and incorporates a fuel pump. When starting the engine,

1.

2.

the choke valve is closed and thus a rich mixture is supplied to the engine for easy starting.

The pump has a diaphragm which is operated by changes in the crankcase pressure, and a check valve is installed in each of the inlet and outlet of the pump.

The movement of the diaphragm draws fuel and sends it to the carburetor float chamber. When air flows through the venturi, a vacuum is produced around it so that the fuel is sprayed into the main bore (air horn). The fuel flow changes properly depending on the engine speed.

3-6

Fuel joint Fuel hose

3.

Clip

c. Disconnect the choke link on the carburetor side.

1. Choke

link

Cleaning, inspection,and repair

d. Remove the three screws, and remove the front lower panel and bracket.

Fuel system trouble, in most cases, stems heck°rathe e.

ToStrainer'c cloggedvalv checka fUelorleakage,worn jammedfr°m

%

=

fuel system, proceed asfollows:

_v._o, i

1. Fuel joint and fuel hoses After cleaning the fuel joint, push the valve pin and blow the fuel joint with compressed air from the fuel hoseside.

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

Front

1.

panel

If fuel hosesare cracked or aged, they should be replaced.

e. Remove the bolt from the lower part of the bracket, and removethe fuel joint.

2. Fuel filter Remove the dust and dirt in the fuel strainer with a cleaning agent, and blow the strainer in the opposite direction to the arrow mark on it with compressed air.

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

1.

Bracket

2.

Fuel

joint

2. Removing the fuel strainer Remove the clip holding the hose to each end of the fuel strainer, and remove the fuel hose.

NOTE: It is advisable to insert a slotted-head screwInstallation

driver between the fuel hose and fuel joint and pry out the hose for easy removal.

o To prevent the fuel from leaking past the fuel hose joints, replace any fatigued fuel hose bands or clips.

3-7

1. Fuel joint (Engine side) Bring the fuel joint into the bracket from its front, and screw in the bolt from the lower side.

3. Secure the bracket to the front panel with the threescrews.

1. Front panel

2. Fuel filter a. Fit one end of the fuel hose over the fuel joint and the other end over the fuel filter, then clip on both ends.

Be sure the arrow marked on the filter is on the hose side.

1. Fuel joint 2. Fuel hose

3.

Fuel filter

b. Connect the fuel hose coming from the carburetor to the fuel joint, and clip on it.

3-8

CARBURETION Description The carburetor is a single-barrel, butterfly throttle valve type. It incorporates a diaphragm fuel pump which is operated by crankcase pressure pulses. The throttle valve is interlocked with the throttle grip and controls the engine speed.

1. Pump cover 2. Gasket

9. Float 10. Main jet

3. Diaphragm 4. Check valve 5. Fuel pump body 6. Diaphragm 7. Gasket 8. Float chamber

1 1. Main nozzle 12. Slow jet 13.

14.

15.

16.

Seal Mixing chamber Pilot screw Needle valve

3-9

Functions of the carburetor 1. Flows of fuel and air (Starting) When starting the engine, usethe choke, if necessary. By closing the choke valve, a rich mixture is supplied to help the enginestart easily, When the engine is started with the choke valve closed, the air in the carburetor is sucked rapidly into the crank-

case, and thus a partial vacuum is produced in the main bore. As a result, fuel is sucked through the main nozzle into the main bore and vaporized by the air streaming in through the hole in the choke valve before entering the crankcase.

ÂŽ

Fuel Air

I

Mixture

1.

2.

Main jet Main nozzle

3.

Choke

!

4.

5.

Air passage Pilot jet

valve

3-10

2. Flows of fuel and air (At low speeds) In the low speed range (idling and trolling), the throttle valve is almost closed, When the crankcase pressure lowers, airfuel mixtures are sprayed into the main bore through the pilot outlet and bypass, The air sucked through the pilot air jet is mixed with the fuel sucked through

When the throttle valve opens and passes the bypass hole (or holes), fuel streams into the main bore. There are two bypass holes, and fuel is sprayed through one or two bypass holes depending on the throttle opening.

the pilot jet, and the resultant mixture is metered by the pilot screw and sprayed into the main bore.

NOTE: The pilot screw meters the flow of fuel at low speeds,and thus stabilizes the engine speed.

So it must be set to specification.

®

Fuel

®

Air Mixture

• Pilot air jet 2. Pilot jet 3. Pilot screw

4. Pilot outlet 5. Bypass

3-11

3. Flows of fuel and air (At medium speeds) When the throttle valve further opens, mixtures are supplied through the pilot outlet and two bypass holes. In addition,

r

I

I rI II I

<x,.:_ (_

11 ii II

II II

Fuel

Air

Mixture

1. Pilot air jet

4. Pilot outlet

2. Pilot jet 3. Pilot screw

5. Bypass 6. Main nozzle.

fuel is supplied little by little through the main nozzle depending on the throttie opening.

3-12

I II II

4. Flows of throttle)

fuel

and air (At

wide

open ized by air streams. Note that even at wide open throttle, mixtures are supplied through the pilot outlet and bypass holes in the low speed circuit.

At wide open throttle, the fuel metered by the main jet is mixed with the air metered by the main air jet in the main nozzle, and the resultant mixture is sucked into the main bore where it is vapor-

Fuel @

Air Mixture

1. Main jet 2. Main air jet 3. Main nozzle

6. Pilot jet 7. Pilotscrew 8. Pilot outlet

4. Throttle valve 5. Pilot air jet

9,

Bypass

3-13

Disassembly

Removal

1. Using a slotted-headscrewdriver,remove the pilot screw with the spring.

1. Before removing the carburetor, the front panel must be removed. For front panel removal, refer to page3-8.

2. Disconnect the link (connecting the throttle control lever to the throttle arm) on the throttle arm side.

!!:i iii!i!!ill

1. Pilot

screw

2. Spring

2. Remove the float chamber set screws, and remove the float chamber.

1.

Throttle

2. Throttle

control

lever

3.

3. Remove the float hinge pin lock screw, and remove the hinge pin and float at the same time.

Link

arm

3. Remove the two bolts, and remove the silencer cover and carburetor from the intake manifold.

1.

Carburetor

2.

Silencer

NOTE: 1. Both hinge pin and float can be removed, together with the needle valve.

2, The valve seat cannot be removed from the carburetor.

cover

1.

2.

3-14

valve

Float

3.

Needle

Float hinge pin

4.

Valve seat

4. Remove the hinge pin and needle valve from the float,

7. Remove the seal, and using a slottedhead screwdriver, remove the pilot jet.

1. Float hinge pin

1. Seal

5. Using a slotted-head the main jet.

screwdriver,

remove

_ i, _

1. Main jet

1, Air jet cover

6. By pushing the main nozzle projecting from the venturi, remove it toward the

9. Fuel pump Remove the

main jet.

1.

Main

Pilot jet

8. Remove the plate, and remove the main and slow air jet covers and bypass cover.

.......

! '_tj

2.

e

;_

2.

,,i

,

Bypass cover

screws

securing

the

fuel

pump to the carburetor and disassemble the fue pump cover, gaskets, dia_

phragms, and fuel pump body.

nozzle

3-15

(_

Cleaning, inspectionand repair

_

Check the carburetor body, its parts and the fuel and air passagesfor fouling or clogging. Clean fouled parts with suitable cleaning solvent, and blow out 1. Checking fuel and air passages clogged passageswith compressed air.

(_) @_.__

/_

WARNING: cover â&#x20AC;˘ Pump 2. Diaphragm (outer) 3. Gasket (outer)

Be sureto direct compressedair downward as cleaningsolvent may get in your eyes or those of other persons, or small carburetor parts may be blown off.

body Pump 4.

5. Diaphragm (inner) 6. Gasket (inner)

NOTE: o Remove the screws securing the check valves from the fuel pump body.

2. Checking the needle valve Check the needle valve for wear and re1.

Check valve 2. Screw

3.

place if

Nut

worn.

Goodcondition

3-16

Unsuitable

3. Checking the pilot screw Check the pilot screw for wear and replace it as required.

Good condition

Assembly _'_;_:_:'_"_:'_:_:_ Always use new gaskets as a preventive measure againstfuel leakage.

Unsuitable

1. Insert the main nozzle into the main jet

n scre n 4. Checking jets and nozzle Check the air and fuel jets and nozzle for clogging, and clean, if necessary.....

5. Checking diaphragms Check the diaphragms for stretches or deformation them as required,

1. Main nozzle

2. Main jet

breakage,

and replace

2. Screw the pilot jet into the tapped hole, and plug the hole with the rubber seal.

7

6. Checking check valves Check the check valves for cracks or chips and replace them as required.

3-17

1. pilotjet

2. Seal

3. Install the needle valve on the float, insert the hinge pin into the float hinge, and lock the hinge pin with the screw.

NOTE : 1. The hinge pin should be fit in the slit in the carburetor and locked with the screw.

2. When installing the float in the carburetor, placethe needlevalve in the valveseat.

......

iiiiii! iili i

5. Hold the float chamber to the mixing chamber with the four screws.

NOTE: Make sure the rubber seal is attached to the float chamber.

1. Float chamber

1. Float 2. Needle valve

3. Valveseat 4. Hingepin

2. Rubber seal

6. Install the spring, and screw in the pilot screw until lightly seated. Then back it out as specified.

4. Float height Place the carburetor in an inverted position, and measure the distance from the contact surface of the float chamber with the mixing chamber to the top of the float using vernier calipers. If the distance measured is out of the specification, replace the needle valve or float.

Specified distance: 14 -+2 mm (0.55 -+0.08 in)

3-18

NOTE: Never screw in the pilot screw too hard. Stop screwing it in when it is lightly seated.

Turns out of pilot screw: 1-1/8 -+1/4 turns out

2. Place the carburetor and silencer cover in the bottom cowling, and insert the bolts from the front of the bottom cowling into the silencer cover and carbure-

Place the covers on the main and pilot air jet holes and bypass holes, and hold the plate with the two bolts,

tor, then screw it into the intake manifold.

(_

1. Main and pilot air jet cover 2. Bypass cover

7. Fuel pump Secure the

check

3. Plate

valves

to

the

link to the carbuarm, and connect the fuel pump and fuel filter by the fuel hose.

3. Connect

fuel

retor

pump body with screws and nuts. gaskets, diaphragm, the two Install

the throttle

throttle

fuel pump body, gasket, diaphragm, and fuel pump cover, in that order, with screws and washers.

:ii

1. Throttle

link

Installation 1. Fit the two small holes in the gasket over the projections on the intake manifold.

4. For the procedure for choke link conpanel installation, and front nection refer to page 3- 8.

3-19

CHAPTER 4. POWER HEAD OVERHAUL DESCRIPTION

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

4-1

PREPARATION FOR REMOVAL ..................................

4-1

POWER HEAD REMOVAL .......................................

Wiring removal .............................................

Fuel hose .................................................

Choke link ................................................

Throttle wire ..............................................

Power head mounting bolt ....................................

Exhaust manifold ...........................................

4-1 4-1 4-2 4-2 4-2 4-3 4-3

POWER HEAD DISASSEMBLY .................................

Manual starter .............................................

Electric system .............................................

CDI magneto ..............................................

Magneto base ..............................................

Intake silencer, carburetor ....................................

Intake manifold and reed valve assembly .........................

Cylinder head cover and thermostat .............................

Exhaust covers .............................................

Magneto basecontrol device ...................................

Oil seal housing (Crank upper) .................................

Oil seal housing (Crank lower) .................................

Crankcase ................................................

Crankshaft ................................................

Piston pin and piston ........................................

.\. 4-4 4-4 4-5 4-5 4-7 4-7 4-7 4-8 4-8 4-8 4-9 4-9 4-10 4-10 4-1 1

INSPECTION AND REPAIR ......................................

Cylinder body and crankcase ..................................

Piston ....................................................

Piston clearance ............................................

Piston rings... .............................................

Piston pins and bearings ......................................

Crankshaft ................................................

4-1 1 4-11 4-13 4-13 4-14 4-14 4-15

REED VALVE ASSEMBLY .......................................

Inspection ................................................

Crankshaft main bearings .....................................

4-15 4-16 4-16

ENGINE ASSEMBLY AND ADJUSTMENT ..........................

Important information. ......................................

Pistonand crankshaft ........................................

Oil sealhousing .... . .......................................

Crank upper oil sealhousing...................................

Crank lower oil sealhousing ...................................

Cylinder body .............................................

Thermostat and cylinder head cover .............................

Exhaust covers .............................................

Reed valveassemblyand intake manifold .........................

Oil sealhousing ............................................

Starter stay ................................................

CDI magneto ..............................................

Starter ...................................................

Magneto basecontrol device ...................................

Limited throttle opening device ................................

Tool bag holder ............................................

Exhaust manifold ...........................................

Carburetor and silencercover ..................................

Engine installation ..........................................

Engineexternal parts installation ...............................

4-17 4-17 4-17 4-18 4-18 4-18 4-18 4-21 4-21 4-22 4-22 4-22 4-23 4-24 4-24 4-26 4-27 4-27 4-27 4-27 4-28

POWER HEAD OVERHAUL DESCRIPTION The power head is made up of in-line twin cylinders, whose bore and stroke are 50mm (1.65in).

(1.97in) and42mm is 165cc displacement piston The total sparks in (6.6in). To produce simultaneous ge ignidischar or capacit a rs, the two cylinde

POWER HEAD REMOVAL Wiring removal the leads 1. Remove the collar holding o coming from the CDI magnet base and CDI unit.

tion (CDI) system is used.

This model employs a cross scavenging system, and has an integrated cylinder and cylinder head.

PREPARATION

FOR REMOVAL

1. All dirt, mud, salt, and foreign material must be cleaned from the engine before the engine is removed and disassembled.

This will help keep foreign material out of the engine.

2. Before engine removal and disassembly, be sure that you have the proper tools and cleaning equipment. With them you can perform your work cleanly and effi-

2. Disconnect the white lead of the stop switch at the joint.

Next, remove the bolt holding the black lead, and disconnect the ground lead.

ciently.

NOTE: The ground leads (black) of both CDI unit and stop switch are fastened together.

NOTE: When disassembling the engine, keep "mated" parts together. This includes cylinder, piston, and other parts that have been "mated" parts must be through normal wear. "Mated" d. replace reused as an assembly or

........:.... = !;

clean all engine disassembly, 3. During in their trays in parts and place them up speed order of disassembly. This will assembly and help assure that all parts are correctly reinstalled in the engine.

4. Secure an engine stand to a bench with 1. Whitelead

a vice.

2. Black lead (stop switch) 3. Black lead (CDI unit)

4-1

Fuel hose Remove the clip on the outlet side of the fuel filter, and remove the fuel hose from the filter.

Throttle wire 1. Loosen the lock nuts of the two throttle wire adjust bolts, and remove the adjust bolts from the throttle wire stay.

NOTE: When disconnecting the fuel supply pipe, take care that fuel does not flow into the bottom cowling. Fuel can cause the mount rubbers and grommets to separate or become damaged.

1, Adjust bolts 2. Lock nuts

.3. Throttle wire stay

2. Remove the two throttle wire ends from the throttle control lever.

1. Filter 2. Fuel pipe

3.

Fuel pipe clip

Choke link Disconnect the choke link from the joint on the carburetor side.

1. Throttle lever

1. Choke link

4-2

control

2. Throttle

wire end

Power head mounting bolt

Exhaust manifold 1. Remove the three bolts, and remove the exhaust manifold from the cylinder body.

The power head can be removed by simply removing the 6 securing bolts,

NOTE: 2. After removing the exhaust manifold, insert the crankshaft into the engine stand gripped in a vice on a bench.

The power head may not easily separate from the bottom cowling due to the gasket stuck to them. If so, lever it off the bottom cowling with a piece of wood.

Use care not to damage the bottom cowling or power head with a piece of wood.

Remove the dowel pins from the bottom cowling or power head.

To protect the dowel pins against damage, cover then with rags.

1. Engine stand

1. Dowel pin

4-3

POWER HEAD DISASSEMBLY Manual starter 1. Remove the bolt securing the limited throttle opening starting device, and re-

3. Loosen the band and take off the tool bag from the tool bag holder.

Next, remove the tool bag holder from the cylinder body.

move the starter stop plunger by pulling the wire.

1. Starter stop plunger ::i:

2. Remove the three starter assembly mounting bolts, and remove the starter assembly.

NOTE: The limited throttle opening starting device wire stay is fastened to the starter case set bolt.

4-4

.....

I

CDI magneto 1. Remove the flywheel cover from the flywheel.

Electric system 1. CDlunit Disconnect all of the leads (connecting the CDI unit, CDI magneto base, and ignition coil) at the joints.

=

1.

Flywheel

cover

2. Loosen the flywheel nut using the flywheel magneto holder and a 22mm socket wrench.

â&#x20AC;˘ 2. Remove the two bolts, and remove the CDI unit.

WARNING: The flywheel magneto holder must be held so that the major load is carried by the straight end,

3. Ignition coil Remove the spark plug caps from each upper and lower spark plug. Remove the bolts and remove the ignition coil from the cylinder body.

The correct use of the flywheel magneto holder.

II

lo,, !_

4-5

o

I.----'----'J

_

movement of Direction

The major load must be carried in the direction of the arrow. If not, the holder can easily slip off.

3. Remove the CDI magneto with the flywheel magneto puller.

Keep the nut side flush with the crankshaft end until the flywheel comes off the tapered portion of the crankshaft.

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

WARNING: Crankshaft

1,

Align surface

_-_

Be sure to hold the open-end wrench correctly so that it does not slip off the fly-

comes off the tapered end of the crankshaft.

2. wheel The flywheel magneto must magneto puller puller when set thebolts flywheel be tightened evenly so that the flywheel magneto puller plate is held in parallel to the flywheel top.

4/

4. Remove the woodruff crankshaft keyway,

4-6

key from the

3. Remove the three bolts, remove the base retainer and friction plate, and remove the retainer ring from the base retainer.

Magneto base 1. Remove the three panhead screws, Disconnect the joint link (connecting the magneto control lever to the CDI magneto base) at the magneto control lever side, and remove the CDI magneto base set bolts.

1.

Base retainer

2.

Friction

3.

Retainer

ring

plate

Intake silencer, carburetor Refer to page 3-14.

Intake manifold and reed valve assembly Remove the bolts, and remove the intake manifold and reed valve assembly.

2. By turning the CDI magneto base in and out, lift it up so it can be removed. remove the bushing from the Then, cylinder body or the CDI magneto base.

Handling of the reed valve 1. Keep away from direct sunlight, which will deteriorate the valve seat rubber.

2. Keep free from sand and moisture.

Even fine sand can break the reed petals if it goes in between the stoppers and reed petals.

Stoppers can easily get rusty and so should be kept free from moisture. The cylinder can be damaged by rust if it is present.

For these reasons the reed valve aseembly should be stored with care when it is re-

1. Bushing

moved.

4-7

Cylinder headcover and thermostat 1. Remove the spark plugs from each cylinder, 2. Remove the cylinder head cover bolts and remove the cylinder headcover.

Exhaust covers Remove the bolts securingthe exhaust cover, and remove the exhaust outer and inner covers.

NOTE: 1. To remove the covers, inserta slotted-head screwdriverbetweenthe lugsof both covers and the exhaust manifold, and pry them out.

2. Be careful not to scratch the surfacesof coverswith the gasketwith the screwdriver.

3. Remove the collar and thermostat from the cylinder body.

1. Collar

Magneto basecontrol device 1. Remove the screwsfrom the bracket to which the magneto control lever is attached, and remove the magneto control lever, pulley, and free acceleration lever from throttle wire stay.

2. Thermostat

_JiL

1. Magneto control lever 2. Bracket 3. Pulley

4-8

4. Free acceleration lever 5. Throttle wire stay

2. Remove the limited throttle device from the starter case.

opening

Oil seal housing (Crank upper) Insert a slotted-head screwdriver between the tabs of the oil seal housing and crankcase,

_ _'

and separate the oil seal housing crankcase by prying it out.

from

the

3. Remove the bolts securing the throttle wire stay and remove the throttle wire stay from cylinder body.

Oil seal housing (Crank lower) 1. Dismount the engine from the engine stand and place it on a bench with the cylinder head side down.

G

â&#x20AC;˘

i!

4. Remove the starter stay from the crank case.

2. After removing bolt and loosening crankcase bolts, pull out the oil seal housing while hitting it lightly with a plastic hammer.

1. Starter stay (Port side)

2. Starter stay (Starboard side)

4-9

Crankcase

Crankshaft

1. Remove the crankcase bolts, insert a slotted-head screwdriver between the ' tabs on both the right and left sides of the crankcase and cylinder and pry the two apart.

1. Lift the crankshaft bearings up off the crankcase by tapping on both ends of the crankshafts.

NOTE: Be careful not to insert the screwdriver between the crankcase and cylinder.

2. Hold down the cylinders and remove the crankshaft together with the pistons.

,

H 6

2. Remove the two dowe pins from the crankcase or cylinder body. Cover the pins with rags to protect them from damage when being held with pliers.

4-10

Piston pin and piston 1. Remove the piston piston.

INSPECTION pin clip

from

AND REPAIR

the Cylinder body and crankcase 1. Using a rounded scraper, remove any carbon deposits from combustion chamber. Take care to avoid damaging the spark plug threads. Do not use a sharp instrument. Avoid scratching the aluminum.

..........

ii

When decarbonizing the combustion chamber, use care not to scratch the cylinder wall.

2. Remove the other piston push out the piston pin.

pin clip,

and

WI o

2. Visually check the cylinder walls for scratches. If vertical scratches are evident, the cylinder should be replaced.

3. Remove any deposits from the cylinder exhaust port.

4. Check the cylinder body water jacket and cooling water passages for dirt, salt, sand or other deposits and clean as required. Also patch up any part from which anti-corrosion paint has come off.

If the water jacket or passage is corroded, replace the cylinder assembly (cylinder body and crankcase).

NOTE: The pistons and bearings should be put aside separately for the upper and lower cylinders,

4-11

5. Checking the cylinder bore Using a cylinder gauge set to standard bore size, measure the cylinder.

Measure front-to-rear and side-to-side at top, center and bottom just above the exhaust port. Take minimum and maximum measurements.

No oversize pistons are provided for the 8C because of its construction. There-

Maximum allowable taper: 0.08mm (0.003in) Maximum allowable out-of-round: 0.05mm (0.002in)

fore, if the cylinder bore diameter exceeds the specification, both cylinder and piston must be replaced. Otherwise,

1 /_'-_--_>_

engine power loss will result.

Cylinder bore

2 ___

Standard

Wear limit

+0.02 50 0 mm +0.00079 in) (1.96 0

50.1 mm (1.97in)

%,

...... /,_--_ 3

|

1. Cylinder gauge

4-12

--_

Piston 1. Remove any carbon deposits from the piston crown,

Piston clearance 1. Measure the outside diameter piston at the piston skirt.

Measurement should be made at 10mm (0.4in) above the bottom the piston. Place the micrometer angles to the piston pin.

of the a point edge of at right

1

ii ,o

j

2. Carefully remove any carbon deposits from the ring grooves with the filed end of a ring.

2. Determine piston clearance as follows: Minimum bore measurement - Maximum piston measurement = Piston clearance EXAMPLE: 50.000mm (1.96in) - 49.960mm (1.967in) = 0.040mm (0.0016in) Piston clearance: 0.040 ~ 0.045mm (0.0016 _ 0.0018in)

3. Remove all score marks and lacquer deposits from the sides of the piston using 600 _ 800 grit wet sandpaper.

Sand in a crisscross pattern. Do not sand excessively.

If the clearance exceeds the specification, replace the cylinder or piston so that the clearance is within the specification.

In this case, be sure to measure the cylinder bore and piston diameters, and determine the clearance.

If the clearance is excessive, the engine becomes noisy, and power loss will result due to blow-by.

If either one of the cylinders has excessive piston clearance, the whole cylinder body must be replaced.

.....

........

4-13

Pistonrings 1. Measurethe end gap of each piston ring.

Insert a ring into the cylinder and push it approximately 70ram (2.76in)into the cylinder. Push with the piston skirt so the ring will be at a right angle to the cylinder bore.

2. Measure the ring end gap with a feeler gauge. If the end gap exceedstolerance, replacethe whole set of rings.

.....

Ring end gap installed Top/Second Minimum: O.35mm Maximum: 0.15mm (O.014in) (O.O06in)

I

r ,l Top

Ringendgap

3. Piston ring/ring groove fit must have correct clearance. If the piston and ring have already been usedin the engine,the ring must be removed, the ring groove cleaned of carbon, then the ring should be reinstalled. Use a feeler gauge to measure the gap between the ring and the ring groove.

0.02 _ 0.06ram Side clearance

Top 2nd

1

(0.0008_ 0.0024in) 0.04 _ 0.08ram (0.0016_ 0.0030in)

4-14

1

l

2nd

Piston pinsand bearings 1. Apply a light film of oil to the pin and the bearing surfaces. Install in the connecting rod smallend to inspectfor wear.

Check for play.

There should be no noticeable vertical play. If play exists,check the connecting rod small end for wear. Replace the pin, connecting rod and/or bearing as required.

2. The piston pin should have no noticeable free play in the piston. If the piston pin is loose, replace the pin and/or piston.

3. Check the pin and bearing for signs of heat discoloration. If excessive(indentation on pin etc.), replace the pin and bearing.

4. Check the piston pins and bearingsfor fretting or pitching and replace them as required.

Crankshaft 1. Check the connecting rod axial play at the small end to determine the amount, of wear of the crank pin and the bearing at the big end.

If small end play exceeds tolerance, disassemble the crankshaft and check the connecting rod, crank pin and big end bearing, Replace defective parts. Play after reassembly should be within specification.

I

Rod axial play: 2mm (O.08in)

REED VALVE ASSEMBLY Inspection 1. Inspect the reed petals for signs of fatigue cracks. The reed petals should fit flush or nearly flush against the neoprene seats. If in doubt as to sealing ability, apply suction to the carburetor side of the assembly. Leakage should be slightto moderate.

2. Check valve stopper clearance. If beyond tolerance, adjust the stopper or replace as required.

I

Valve stopper clearance: 4.5 -+0.2mm (0.177 -+0.008in)

2. Check the connecting rod side clearance at the big end.

If axial play exceeds tolerance, disassemble the crankshaft and replace any worn parts. Big end axial play should be within specification,

I

/

/

If clearance is 0.1mm (0.004in) more or less than specified, replace the valve stopper.

Rodside clearance Maximum

Minimum 0.2-

0.7mm (0.008 ~ 0.03in)

3. Crankshaft runout a. Support the crankshaft at both ends on V-blocks. Rotate the crankshaft in the V-blocks and measure the runout at the main bearing journals. Use a dial gauge. b. Check crankshaft assembly runout (misalignment of crankshaft parts).

Dial gauge readings should be within specification.

Correct any misalignment by tapping the flywheel with a brass hammer and/or by using a wedge.

3. Check the reed valve for bending and if beyond tolerance, replace.

Reed valve bending limit: 0.6mm (0.024in)

Deflection tolerance i

Left side

/ Right side Center l 0.03mm (0.001 in)

4-15

4. During reassembly, clean the block, reed and stopper plate thoroughly. Apply a

L

_J

threads of the Phillips screws. Tighten each screw gradually to avoid warping. holding agent, such as "Loc Tite" to the

_(_

iNOTE: Torque: 1Nm (0.1m.kg, 0,7ft.lb) i During reassembly, note the cut in the lower corner of the reed and stopper plate. Use as an aid for direction of reed installation.

_ 1. Bearing separator

_ 2. Press

Installation Place the plate under either the upper or lower connecting rod big end, slip the bearing, over the crankshaft, and press-fit the bearing.

i

1. After placing the plate under the big end, make sure the connecting rod is properly positioned in the plate.

2. When press-fitting the bearing, be sure to force the inner race. Do not force the outer race.

â&#x20AC;˘

Crankshaft main bearings Thoroughly clean the crankshaft, sparingly oil both the upper and lower ball bearingsand slowly turn the outer raceswith your hand.

If rough spots are noticed, replace the ball bearing(s).

Removal As shown, hold the upper and lower bearings with the bearing separator and force the crankshaft out with a press.

_.'

(_

_

_i

1.

When removing the Crankshaft, hold with your hand so that it will not fall off.

4-16

Plate

ENGINE ASSEMBLY AND ADJUSTMENT 3. Before fitting the connecting rod small end bearings, give them a small quantity of 2-stroke engine oil, and install the bearing in the connecting rod needle small end.

Important information 1. Gasket and seal All gaskets and sealsshould be replaced when the engine is overhauled. All gasket surfaces and oil seal lips must be cleaned.

2. During reassembly, apply the proper type of oil to all engine moving parts and all bearings.

3. Circlip Always replace piston pin clips after one use. Replace distorted circlips.

Piston and crankshaft 1. Fit the piston rings into the grooves.

1. Bearing

4. Apply a thin coat of outboard motor oil to the piston pin, and insert it into the hole so that it is flush with the boss end.

gagpwit atn nd oc ch n rnge pnea 2Aig 1. Piston

2. Piston pin

5. With the UP mark facing toward the crankshaft tapered end, insert the connecting rod into the piston so that the small end hole aligns with the piston pin.

.... =

NOTE: 1. Take care not to scratch the piston or break piston rings.

2. Make sure all piston rings are fitted with the markings facing upward.

3. Piston rings should be replaced as a set: 4. After fitting the rings, check that they move smoothly.

4-17

"_

6. Connect the lower cylinder connecting rod to the piston pin.

3. After installingthe oil seals, pack the lips with water-resistant grease (Yamaha allLUBP/N grease, purpose GREAS-13-00)

Oil sealhousing NOTE: When press-fitting the oil seal, be sure that it

4. Fit new O-rings in the grooves in their outer surfaces.

faces in the correct direction.

Crank upper oil seal housing Using the jig, press-fit the oil seal to the oil sealhousing.

¸ iiiiiii!iiiiiiiiii i !!i!!i

Cyli nder body 1. Thoroughly clean the bench, and place

.... ....

1.

Jig

' 2.

the cylinder body with the head side down.

Apply the outboard motor oil to the

Oil seal housing

Crank lower oil seal housing 1. Using the jig, press-fit the two oil seals (smallerin outside diameter) one by one......

upper and lower cylinders.

_ii_ _ _ __i_i

2. Apply

the outboard motor oil to the

upper and lower cylinder their ring grooves.

2. Using the jig, press-fit the oil seal (larger in outside diameter),

4-18

pistons

and

c. Push down the crankshaft so it fits in the cylinder body. Be sure to fit the upper, center and lower bearing locating pins, as seal circlips, into well as the labyrinth

3. Align the piston ring end gaps with the respective locating pins.

the cylinder

i¸¸

_:_ _

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

4. Piston installation a. Holding the crankshaft,

.

body.

_i

insert the upper 2. Circlip

1. Locatingpin

cylinder piston into the upper cylinder while holding down the piston rings so

d. Drive two dowel pins into the mating body with the surface of the cylinder crankcase.

that they do not catch the cylinder bottom edge. When the second ring is in the cylinder, stop inserting the piston, NOTE: Hold the crankshaft cylinder body.

at a right angle to the _:

_

_ "'_

_o

5. Align the bolt holes in the oil seal housing and the bottom of the cylinder body.

NOTE: the crankshaft, b. By turning piston into cylinder lower cylinder.

Avoid cutting ingO-ring.

insert the the lower

4-19

or stretching

the oil seal hous-

6. Crankcase Place the crankcase on the cylinder body and tighten the bolts.

7. Bolt the oil seal housing to the bottom of the cylinder body.

Tightening torque: 8Nm (0.8m-kg, 5.8ft.lb)

NOTE: Apply Yamaha Bond No.4 to both mating surfaces of the crankcase and cylinder body.

8. Insert the crankshaft into the engine stand which was used in disassembling the engine.

Tightening sequence and torque: Tightening torq0e: 1st step M6 6Nm (0.6m-kg, 4.3ft.lb) 2nd step M6 12Nm (l.2m-kg, 8.7ft.lb)

4

--03

_)1

20

4-20

Exhaust covers Make surethe contact surfacesof the cylinder body, exhaust inner cover and outer cover with the gasketsare free of dust.

Thermostat and cylinder head cover Install the thermostat and collar in the cylinder body, install the cylinder head cover, and tighten the head bolts, .......

Install the gaskets and exhaust covers in the order shown and tighten the bolts.

:=

2. Thermostat

1, Collar

Tightening order and tightening torque:

3

23

Exhaust inner cover Exhaust outer cover

Tightening order and tightening torque:

4

_.#_7

3.

4.

1. Cylinder body 2. Gasket

)1

5

_-_

Tightening torque: 8Nm (0.8m-kg, 5.8ft.lb) 1st step M6 2nd step M6

_5

Tighteningtorque: 6Nm (0.6m-kg, 4.3ft.lb) 1ststep M6 2rid step M6 10Nrn (l.0m-kg, 7.1ft.lb)

10Nm (l.0m-kg, 7.Tft.lb)

NOTE: 1. Avoid applying sealing compound to the gasket.

2. The bolt located in the lower left part of the cylinder head cover is used to clamp the high-tension wire c_amp.

4-21

Reed valveassemblyand intake manifold Fasten the reed valve assembly and intake manifold to the crankcase,

Oil sealhousing Fit the O-ring in the groovearound the crank upper oil seal housing, and align the bolt holes in the crankcase with the holes in the housing, and install the housingon the crankshaft. Use care so that the O-ringdoesnot fall off.

!i!Ei:iiiiii;

1. Reed vave assembly 2. Gasket

3.

Intake manifold

NOTE: Make sure the reed valve assemblyand crankcaseare free of dust and dirt.

1

6

2

1. Starter stay

Tightening

3. Crankshaft

Starter stay Bolt the starter staysto the crankcase.

Tighteningorder and tightening torque: 5

1. ,'o" ring 2. Oilsealhousing

torque:

(Port side)

1Nm (0.1m-kg, 0.7ft.lb)

4-22

2. Starter stay (Starboard side)

3. CDI magneto a. Slip the CDI magneto over the boss located between the cylinder and crankcase so that the base stopper is positioned on the stopper plate side. Next, align the bolt hole in the friction plate with the hole in the magneto base and screw in the bolt.

CDI magneto 1. Magneto base retainer Placethe magneto base friction plate and retainer on the cylinder body, and bolt them to the cylinder body. Next, fit the retainer ring to the retainer, ....

NOTE: After installing the magneto base, assemble the joint link.

11

[ iiii!iiiiii+i

_i'%iiiii!i!?

Magneto Retainer

1.

2.

base friction

plate

3.

Retainer

))

ring

_iiii!i

NOTE: Apply anti-freeze grease (Yamaha all-purpose grease, P/N LUB-GREAS-13-00) to the retainer ring. b. Fit the woodruff key into the crankshaft groove.

2. Fit the bushing in the oil seal housing boss.

NOTE: Apply a thin coat of anti-freeze grease (Yamaha all-purpose grease, P/N LUBGREAS-13-00) to both inner and outer surfaces of the bushing.

1. Woodruff

key

c. Install the flywheel rotor on the crankshaft so that the woodruff key fits into the keyway.

1.

Bushing

4-23

Magneto basecontrol device 1. Install the throttle wire stay on the cyl inder body.

d. Lock the flywheel rotor with the washer and nut.

) 105Nm torque: g, 75.2ft.lb ng (10.hm-k Tighteni

1

1. Throttle wire stay

2. Place the free acceleration lever and pulley on the throttle wire stay, and insert the magneto control lever shaft into the free acceleration lever and pulley, then install the magneto control lever between the bracket and throttle

e. Bolt the starter pulley to the flywheel rotor,

wire stay.

1. Starter pully

Starter Secure the starter to the cylinder body and starter stayswith the bolts.

(_ 1. Throttle wire stay 2. Free acceleration ever

NOTE: The starter set bolt on the starboard side is also usedto fasten the limited throttle openingdevicewire stay.

5.

er

2. Wire stay

4-24

Bracket

3. Magneto control lever 4. Pully

7. Install the CDI unit in the upper part of the cylinder body, and connect the leads coming from the CDI unit and ignition

3. Install the joint link on the free acceleration lever,

COil.

::

:::_@:

......

1 Be sure to connect

"co ors.

NOTE:

2. Do not connect

the leads of identical

the ground

lead (with a cir-

J, cular terminal)

.& .........

1.

2. Joint

Free acceleration lever

coming

from the CDI unit.

link

4. Connect the joint (connecting the magneto control lever to the magneto base) to the magneto control lever.

'....

4k

5. Install the spark plugs in tile cylinders.

6. Insta{I the ignition coil on the cylinder body. !ilili;iii

4-25

3. Install the spring and plunger on the other wire end, bring the wire end into the starter case hole, and tighten the bolt.

Limited throttle opening device 1. Bolt the collar and arm to the starboard sidestarter stay.

2. Install the wire end (having the adjust bolt) on the arm, bring the adjust bolt into the cut in the wire stay, and tighten the lock nut.

,,_

NOTE: When tightening the lock nut, be sure to push the adjust bolt deep into the cut. _ :___

_

_;_

= =

1, Starter stop plunger

i,

4-26

Engine installation 1. Drive in the two dowel pins.

2. Place the gasket on the upper casing so that the dowel pin holes align.

Tool bag holder Secure the tool bag holder to the cylinder body with the two bolts. Next install the tool bag into the tool holder and tighten the band.

NOTE: It is unnecessary to apply a sealing compound to the gasket.

_:

3. Remove the engine from the engine stand, and insert the drive shaft into the crankshaft.

NOTE: If the splines will not come in complete mesh, pull the starter rope a little so that they are in mesh correctly.

Exhaust manifold Bolt the exhaust manifold gasket to the cylinder body.

4. Tighten the engine mount bolts.

Tightening torque: 8Nm (0.8m-kg, 5.8ft.lb)

!

Carburetor and silencer cover For the procedure for carburetor and silencer cover installation, refer to page3-19.

4-27

.....

Engineexternal parts installation 1. Enginestop switch leads a. Bolt the black lead of the stop-switch

2. Fuel hose Fit the fuel hose (from the carburetor) over the outlet side of the fuel filter, and clip it on.

and black lead (with a circular terminal) (coming from the CDI unit) to the cylinder body.

1.

2.

1. CDI unit

ground

lead

2.

Stop lead

switch

Filter Fuel pipe

3.

Fuel pipe clip

ground

b. Connect the white lead of the CDI unit to the white lead of the stop switch, and bring the leads of the CDI unit, CDI magneto base, and ignition coil together into the tube.

3. Throttle wire a. Twist the throttle grip from SLOW to FAST a few times, and when it is turned to FAST, fit the wire end of the pullside of the throttle wire to the slit (on the bottom cowling side) in the pulley, and fit the other end to the slit on the cylinder body side.

1. Pully !iii

ii

4-28

2.

Throttle

wires

b. Fit each of the throttle wire adjust bo_ts into the slot in the bracket, and hold each with the lock nuts on both sides of the bracket.

NOTE : When tightening adjust bolt.

the lock nuts, push down the

4. Secure the front panel to the bottom cowling with the three screws.

5. Insert the choke link intothe arm attached to the choke shaft on the carburetor side.

4-29

CHAPTER 5. LOWER UNIT OVERHAUL DESCRIPTION

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

PREPARATION

FOR REMOVAL

5-1

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

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

GEAR CASE REMOVAL

UPPER CASING REMOVAL

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

5-1 5-1 5-2

Bottom cowling ............................................

Upper casing ...............................................

Steering handle .............................................

5-2

Steering bracket ............................................

Clamp brackets and tilt mechanism .............................

5-6

INSPECTION,

CLEANING

AND REPAIR

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

Top cowling clamp lever ......................................

Bottom cowling ............................................

Shift lever and shift mechanism ................................

Throttle wires and throttle control shaft .........................

Clamp bracket and swivel bracket ..............................

5-4 5-5 5-8 5-9 5-9 5-9 5-9 5-9 5-9

Tilt mechanism .............................................

Upper case and mount rubber .................................

5-10

UNIT ASSEMBLY .....................................

Clamp bracket and swivel bracket ..............................

Steering bracket ............................................

5-10

Upper casing and mount rubber ................................

Bottom cowling ............................................

Tilt mechanism .............................................

5-12 5-13

BRACKET

STEERING

HANDLE

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

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

GEAR CASE DISASSEMBLY Preparation for disassembly ...................................

Water pump ...............................................

Bearing housing and propeller shaft .............................

5-10

5-10 5-11

5-16 5-17 5-19 5-19 5-19 5-19

Gear case .................................................

Clutch dog ................................................

Bearing housing ............................................

5-20

Forward gear ..............................................

5-22

5-21 5-21

â&#x20AC;¢ .............

INSPECTION, CLEANING AND REPAIR .............

Water pump ...............................................

Gearsand bearings ..........................................

Propeller shaft, clutch dog,and propeller .........................

Drive shaft ................................................

Shift cam .................................................

Gear case .................................................

5-22 5-22 5-22 5-23 5-23 5-23 5-23

GEAR CASE ASSEMBLY ........................................ .........................................

Gear case ........ ......................

Oil sealhousing ...................... ............................

Clutch dog crosspin and shift spring

5-24 5-24 5-25 5-27

GEAR SHIM ADJUSTMENT ......................................

Preparationfor adjustment .................................... ................................

Gear backlash ...............

5-28 5-28 5-28

Determining the pinion gearposition ............................

Measuringthe backlashof forward gearand reversegear ............. . .................

ASSEMBLING THE GEAR CASE UNIT ........... .................................

Lubricating gearoil ........

GEAR CASE INSTALLATION

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

5-29 5-29 5-31 5-32 5-32

LOWER UNIT OVERHAUL FOR REMOVAL

PREPARATION

DESCRIPTION gases forced out of the engine the exhaust pipe in the engine in the upper casing, in which

1. All dirt, salt, dust, and foreign material must be cleaned from the engine before the lower unit is removed and disas-

the exhaust gas pressure is decreased, â&#x20AC;˘ At low speeds, the exhaust gases flow through provided in the upper part of the labyrinth the upper casing and stream out into the air.

At normal cruising speed, the cooling water in the upper casing is forced out by the exhaust gas pressure and rotary motion of the propeller and as a result, the exhaust gases stream out of the propeller boss.

sembled. This will help keep foreign material out of the lower unit.

2. Before lower unit removal and disassembly, be sure that you have the proper tools and cleaning equipment. With them you can perform a clean and efficient job.

3. During lower unit disassembly, clean all parts and place them in trays in their

The cooling water inlet is provided in the gear case, and water is sucked by the water pump located in the upper part of the gear

order of disassembly. This will speed up assembly and help assure that all parts in the lower reinstalled "are correctly unit.

case and supplied to the engine. is an open type The cooling water circuit and thus, the engine is always cooled by new

the gear case, disassembling 4. Before drain the gear oil into a tray. Use care not to spill the oil on the floor.

water.

The impeller in the water pump is keyed to the drive shaft so that the water flow rate is

5. When disassembling a repair stand.

The exhaust flow through and expand

controlled

the lower unit,

use

depending on the engine speed.

GEAR CASE REMOVAL It is possible to remove the gear case from removing powerthe upper case without head.

The gear case has both forward and reverse gears (straight bevel gears) and a clutch dog.

By sliding the clutch dog back and forth by moving the plunger, the rotating direction of the propeller is changed.

If disassembly

of the lower

unit or bracket

unit is required, it is necessary to assembly (refer to the powerhead head removal page 4-1).

connecter

bolt

and remove the shift rod connecter shift rod.

from

1. Loosen

remove power-

1. Shift

5-1

the

rod connecter

shift

rod

UPPER CASING REMOVAL Bottom cowling _1. Remove the power head; refer to page 4-1.

2. Remove the bolts (four) securing the upper casing and gear case,and remove the gearcase.

2. Remove the stop switch 'and choke knob from the front panel bracket.

NOTE: When removing the gear casetilt up the lower unit.

.............'

1. Stop switch

_

_.........

2. Choke knob

3. For the removal of the fuel joint, refer to page 3-6.

4. Top cowling clamp lever Turn the clamp leverdownward, remove the bolt on the clamp hook, and remove the clamp lever.

1. Clamp lever 2. Clamp hook

3. Bolt

5. Shift lever Remove the screw holding the shift lever from the inside of the bottom cowling, and pul the lever outward.

i¸ iii;!!ii!iii!iiiii

1.

5-2

Sl_ift lever

6. Shift rod shaft a. Remove the bolts from the shift rod shaft brackets. Pull up the shift rod shaft without removing the shift rod shaft, so that the Iooating pin comes off.

c. Remove the brackets (right and left) from the shift r:od shaft.

1.

Shift

rod

shaft

bracket

2.

Shift

rod

shaft

d. Remove the shift leaf spring from the bottom cowling.

b. Turn the shift rod shaft 180° backward, and remove the shift rod from the notch in the shift rod shaft.

.......

:

wire grommet e. Remove the throttle from the bottom cowling, and slip it off the throttle wire.

1.

5-3

Grommet

2.

Throttle

wires

f. By pulling the shift rod upward, remove it from the tilt lock attached to the swivelbracket,

Bottom cowl,ng Remove the four bolts securingthe upper casing and bottom cowling, and removethe bottom cowling from the upper casing.

Upper casing 1. Pull the water tube out of the upper casing.

NOTE: Tilt up the upper casing. While moving tilt lock plate and tilt lock arm with hand, pull the shift rod upward with other hand, and remove the shift rod from tilt lock arm.

the one the the 1. Watertube

2. Remove the lower mount rubber housing and remove the lower front and lower side mount rubber.

Remove the shift rod from the bottom cowling, together with the boot.

1. Shift rod

2.

2. Grommet

Boot

5-4

er hous3. Remove the upper mount rubb upper ing and remove the upper side and front and upper casing.

NOTE : is nt rubber housing Use When the upper mou es off. com g casin r uppe the ved, remo care so that it does not fall off.

er, and 3. Remove the bushing, wave wash washer from the steering bracket.

0,_-_ ...... ........ ............... _ ......

3. Wave washer 4. Washer

1. Steering bracket 2. Bushing

the throttle 4. Remove the cotter pin from bolt, and remove the throttle friction bolt. friction

Steering handle wire grommet the throttle 1. Remove ket, and slip brac fitted to the steering . the grommet off the throttle wire

ÂŽ 1. Throttle

friction

bolt

2. Cotter pin

w and re5. Remove the steering grip scre steering move the steering grip from the handle.

1. Throttle wire

3. Steering bracket

2, Grommet

steering 2. Remove the bolt holding the plate, on fricti the handle hinge, remove the from le and remove the steering hand steering bracket.

NOTE : pushing Be careful so that the spring lost. throttle control shaft will not be

ÂŽ

1, Steering friction

1. Steering handle 2. Steering grip 3. Screw

plate

5-5

4.

Throttle control shaft

5. Spring

the

6. Remove the two 5mm (0.2in) pan head screws and remove the throttle control shaft,

Steering bracket 1. Set the swivel bracket in the full-tilted up position.

.... tlb

_

:_

NOTE: 7. Remove the throttle wires cable end from the throttle control shaft and remove the throttle wire from the steering handle.

Lock the swivel bracket stopper shaft.

firmly

with

the

2. Unhook the shallow water drive and reverse lock plate torsion spring.

J

1. Shallow water drive

8. Remove the throttle friction piece from the throttle control shaft,

3. Remove the circlip from the reverse lock shaft, and remove the reverse lock

ÂŽ (_

1. Throttle

control

3. Torsion spring

2. Reverse lockplate

shaft from the swivel bracket. Next, remove the shallow water drive arm, torsion spring, and reverse lock plate.

shaft

2.

Throttle

friction

piece

t. Circlip

5_

2. Reverse lock shaft

_'

1.

Tilt

lock

control

shaft

2.

7. Remove the friction plate, bushings, Oring, and washers from the swivel bracket.

lock lock arm

4. Remove the circlip from the tilt control shaft, and remove the tilt control shaft and tilt lock control from the swivel bracket.

NOTE:

_

The bushing and washer on the upper side may come off together with the steering pivot shaft. In this case, remove them from

7 (_

the shaft.

(__

Circlip

from

bolt

5. Remove the steering friction the swive bracket.

1.

2.

(_

1.

Swivel

bracket

2.

Steering

6. Remove the steering the swivel bracket.

friction

pivot

bolt

shaft

from

iiiil iiii_i

5-7

Bushing O-ring

3.

Washer

5. Remove the 8mm (0.32in) bolt securing the carrying handle from swivel bracket.

Clamp bracketsand tilt mechanism 1. Remove thetilt rod.

2. Remove the bolt, nut, and collar securing the starboard and port clamp brackets.

1.

1.

Starboard

clamp bracket

2.

Port clamp bracket

Carrying

handle

6. Remove the bolt securing the steering bracket stopper from the swivelbracket.

3. Remove the clamp bracket nuts, and remove the starboard sideclamp bracket and friction piece.

1. Steering stopper

4. Remove the clamp bolt, and remove the swivelbracket and friction piece.

5-8

bracket

INSPECTION,

CLEANING

AND

Wash all parts in detergent dry with compressed air.

REPAIR

and blow

Throttle

wires and throttle

control shaft

Check the throttle wires for rust, breaks, and bends.

Also, check the smooth movement of the inner wire, and check the throttle shaft for

them

bends. Repair, replace, or grease, as required.

Top cowling clamp lever Check the top cowling clamp lever, clamp arm, and bushings for wear and salt deposits.

Clean or replace parts as required.

i

Clamp bracket and swivel bracket 1. Check the transom clamp screws for salt deposits. Apply grease as required.

2. Check the friction piece for wear. Replace it, if worn.

Bottom cowling Check the bottom

cowling

3. Check the pivot shaft bushings (top, upper, lower, and bottom) for wear and

for cranks or da-

mage. Replace it if damaged,

salt accumulation.

Apply place part(s) as required.

Shift lever and shift mechanism.

Check the shift lever, shift lever shaft, shaft rod, and leaf spring for wear and salt deposits.

Clean or replace .... parts as required.

_i___

il

5-9

grease or re-

Tilt mechanism Check the reverselock plate, tilt lock control arm, shallow water drive arm torsion spring and shaft for wear and damage.

Replaceparts asrequired.

3. Check the water tube and water seal rubber sealingsurfacefor water leakage.

Replaceif damaged.

BRACKET UNIT ASSEMBLY

Upper caseand mount rubber 1. Check the mount rubbers for damage and wear. Replaceparts if damaged.

2. Check the contact surface of the upper casing with the engine for scratches and water leakage, Replace if damaged,

Clamp bracket and swivelbracket 1. Put up both port and starboard side clamp bracketson the repair stand.

2. Place the swivel bracket between both brackets, and place friction pieces between the clamp brackets and the swivel bracket. Insert the clamp bolt into the clamp and swivel bracketsfrom the starboard side, install the nut on the end of the bolt, and tighten to specification.

i

8Nm (0.8m-kg, 5.8ft.lb) Tightening torque: 5-10

I

3. Secure both ends of the clamp bracket with bolts, the clamp Pass the tilt rod through bracket.

\

piece, and 3. Install the bushing, friction the swivel of part upper washer in the order. bracket, in that NOTE: should face to-

The cutaway of the bushing ward the friction piece.

\

...._.-_ y _'¸ _!!!!!!iii_

1. Bolt 2. Collar

3. Nut 4. Tilt rod

Steering bracket 1. Bring the O-r,ing into the hollow through which the pivot shaft is inserted, and fit it in the groove.

NOTE: 1. Always use a new O-ring.

2. Fit the O-ring correctly the swivel bracket,

1. Frictionpice 2. Bushing

3. Washer

4. Install the bushing and lower part of the swivel holding down the washer the pivot shaft into the from its top.

in the groove in

washer in the bracket. While by hand, insert swivel bracket

I i!i!

ii i!!ii!i

.... !=_=!

I_ iiii!iiii;i; i_i_!

_

1. Bushing

1. O-ring

2. Bolt the steering bracket swivel bracket.

2. Washer

........

stopper to the

1. Steering bracket stopper

5-11

5. Fit the throttle steering bracket,

wire grommet to the

2. Install the upper side mount rubber in the port side upper mount rubber housing.

_q

1. Grommet

Upper casingand mount rubber 3. Fit the upper case over the upper side

Fit the grommet in the hole in the upper case into which the shift rod is inserted,

mount rubber. While holding the upper case by hand, install the upper side mount rubber in the housing, and hold it with two bolts.

NOTE: On the short transom model, the grommet is used, and on the long transom model, the boot isused.

I

8Nm (0.8m-kg, 5.8ft.lb)

1. Insert the upper front mount rubber in the slot in the steering bracket, and install the starboard side mount rubber in the upper side mount rubber housing, NOTE: Hook the upper side mount rubber on to the housing rib.

On the long transom model, the upper casing boot should be fit over the pivot shaft.

I.

5-12

Boot

I

4. Install the lower side mount rubbers in the right and left side mount rubber housings,

2.

1. Mount rubber housing

between

1. Attach the shift rod boot to the bottom cowling, and insert the shift rod into the boot. Next, install the rubber seal on the mating surface of the bottom cowling with the upper casing.

ÂŽ

ÂŽ

g. Place

cowling

Bottom

the

lower the pivot

Lower side mount

front shaft

mount

rubber

rubber

and upper

casNOTE:

ing.

its lip faces downward.

The

U

rubber

seal should

be so installed

that

Seat Bottom

O

1, Lower front mount

Lip

rubber

6. Install both right and left side mount rubbers, and hold them with bolts.

NOTE: The lower front mount rubber should be set between the two bolts.

grommets lars in the bottom cowling.

Install

Tightening torque: 8Nm (0.8m-kg, 5.8ft.lb)

5-13

the four

and four

col-

5. Position the shift rod shaft so that the end (having a cut) of the arm attached to the shaft faces downward and mate the shift rod with the cut, then insert the shift rod into the hole in the other arm.

2. While inserting the shift rod into the hole in the pivot shaft, place the bottom cowling on the upper casing and bolt it to the/ upper casing, NOTE: When placing the bottom cowling on the upper casing, use care so that the rubber seal aoes not come off the bottom cowling.

6. Turn the shift shaft 180° backward, and install the bracket on the bottom cowling.

3. Install the shift leaf spring in the bottom cowling.

4. Install the brackets on both sides of the shift rod shaft.

NOTE: The brackets should be so positioned that their round corner sides face outward.

5-14

9. Fit the grommet to the side of the bottom cowling, which is opposite the shift lever.

Fit the bushing (for supporting the water tube) to the upper casing, insert the water tube into the upper casing from its top, and install the water tube

7. Fit the O-ring in the groove around the shift lever, and insert the shift lever into the bottom cowling from its outer side. Connect the shift lever to the shift rod shaft, and hold it with the screw,

in the upper casing.

Bottom cowling

1. Shift lever

3.

2. O-ring

4. Shift rod shaft

8. Install the bushings in the rear part of the bottom cowling, mount the wave washer on the top cowling clamp lever, insert the lever into the bottom cowling, and the clamp hook, and tighten the screw and nut.

/

t. Grommet NOTE: Coat the end of the water tube with grease sparingly, and the water tube can now be inserted easily.

.....

Bushing 2. Wave washer

3. Top cowling clamp lever 4. Clamp hook

1. Water tube

5-15

2. Grommet

4. Hold the shallow water drive arm, reverse lock plate, and torsion spring to the swivel bracket with the reverselock shaft.

Tilt mechanism 1. Place the upper casing in the full-tilt up position,

2. Position the tilt lock arm with the arrow mark pointing upward, and insert the shift rod into the arrow-marked end

1. Shallow

water

drwe arm _

lockplate 2. Reverse

3." Torsion

spring

lockshaft 4. Reverse

5. Hook the torsion spring on to the shallow water drive arm and reverse lock

of the arm.

plate.

ÂŽ

1. Tilt

lock arm

NOTE: The tilt lock arm should be positioned so that it is between the shift rod stopper:

3. Insert the tilt lock arm into the swivel bracket, and hold it with the circlip.

g,/

1.

Tilt

lock arm shaft

2.

Tilt

lock arm

5-16

waterdrive 1 Shallow 2. Reverse lockplate

spring 3. Torsion

6. Tilt down the upper casing.

HANDLE

STEERING

3. Fit the throttle wire end to the throttle control shaft, and connect the throttle control shaft to the steering handle.

1. Pass the two throttle wires through the steering handle hinge from its outside,

NOTE: The throttle friction correct direction.

1. Throttle

piece should face in the

wires

the throttle

2. Insert throttle

friction

control

shaft

into the

piece.

NOTE: 4. Hold the plate with the two screws.

piece should be inserted shaft so that its control into the throttle threaded portion is on the side opposite to the side from which the throttle wire comes out.

The throttle

1. Throttle

friction

friction

piece

2. Throttle

5. Install the spring and washer on the from shaft projecting control throttle the grip side of the steering handle, grip, and secure it install the throttle with the screw.

control shaft

5-17

8. Mount the washer on the steering wire handle, and pass the throttle through the hole in the steering bracket, then into the hole in the steering friction plate. Next, thread the throttle wires into the hole in the steering bracket and bottom cowling.

NOTE: When installing the throttle grip, hold the grip in place, align the bolt hole in the throttie control shaft with the bolt hole in the grip by pushing theshaft,

6. Screw the throttle friction adjust bolt into the steering handle from the outer side, mount the washer on the bolt end, and lock it with the cotter pin.

(_)

1. Washer

7. Install the washer, wave washer, and bushing on the steering bracket from the inner side of the steering bracket.

1.

Friction plate

9. Passthe throttle wires through the grommet, and fit the grommet to the bottom cowling.

,(_)

1. Steering bracket 2. Bushing

3. Wave washer 4. Washer

5-18

GEAR CASE DISASSEBMLY Preparationfor disassembly Remove the gearcasefrom the upper casing.

See page5-2 for removal.

To disassemble the gear case, hold it with a repair stand. If no repair stand is available, grip the skeg in a vise. To protect the skeg against damage, wrap it with a rag.

Water pump 1. Remove the bolts on the water pump housing, and remove the water pump housing from the gear case.

Bearing housing and propeller shaft 1. Remove the oil drain plug and oil level plug and drain the gear oil.

NOTE: 1. Be sure to remove the drain plug first.

2. Let the gear oil drain into a tray so that it will not spill on the floor.

3. Should any gear oil spill on the floor, wipe it off immediately with rags.

2. Remove the cotter pin, propeller nut, washer, and propeller. Next, remove the propeller front spacer.

3. Remove the bearing housing bolt, fit a slotted-head screwdriver into one of the two notches in the bearing housing

2. Remove the impeller and woodruff key from the drive shaft, and remove the outer plate cartridge and water pump gaskets,

flange, and pry the housing off slightly.

By pulling the propeller shaft, remove the bearing housing from the lower casing.

t

3. Remove the two locating pins attached to the bearing housing or the water pump housing.

NOTE: When removing the locating pins;' use care not to scratch them. It is advisable to protect the pins with a rag.

5-19

1.

Bearing

housing

2.

Propeller

shaft

Gear case 1. Remove the drive shaft circlip fitted under the pinion in the gear case, and pull out the drive shaft upward. Remove the pinion, thrust washer, and forward gear.

3. Pull the shift cam out of the gear case.

1. Shift cam

4. Remove the drive shaft sleeve from the _

gear case.

1. Circlip

â&#x20AC;˘ I. Pinion 2. Thrust washer

3.

5. Using the jig, drive above the pinion.

Forward gear

2. Remove the bolt, remove the oil seal housing from the upper casing, and remove the boot from the oi seal housing.

1. Boot

5-20

out the bushing

6. Using the bearing puller, remove the forward gear taper roller bearing outer race from the gear case.

NOTE:

Clutch dog 1. Remove the propeller shaft from the bearing housing and remove the washer from the propeller shaft.

2. Remove the cross pin ring from the clutch dog, and place the propeller shaft on a work bench, with the forward gear side facing downward. Using a pin punch, drive out the cross pin.

The gear adjust shim can be removed, but it cannot be reused,

'_,_,_

_

NOTE: When removing the cross pin, be careful so that the spring does not jump out of the propeller shaft.

7. Using the jigs, remove the oil seals and bushing from the oil seal housing.

!_ ........

..............._ _,_ ......... =

1. Remove the reverse gear from the bearBearing housing ing housing, together with the ball bearing.

2. Insert the bearing separator between the gear and ball bearing, and remove the reverse gear using a hydraulic press.

5-21

3. Using the jig, remove the oil seal from the bearinghousing.

4. Usingthe handle, removethe bushing,

INSPECTION, CLEANING AND REPAIR Wash component parts in detergent and blow them dry with compressedair.

1. Check the impeller for wear, 2. Check the cartridge outer plate for wear and scratches.

WaterCheck pumpthe water inlet cover for clogging with dust.

,_......

I J:

Forward gear Insert the bearing separator between the gear and taper roller bearing, and remove the gear usinga hydraulic press.

,..=

Gearsand bearings 1. Check. the forward, reverse, and pinion gearsfor wear and damage.

If any one of gears is damaged, all gears should be replaced.

NOTE:

2. Check the taper roller bearing, needle bearing and ball bearing for wear and scratches.

NOTE: Replacement of the taper roller bearing should be made as an assembly of the inner race and outer race.

5-22

Drive shaft

Propeller shaft, clutch dog, and propeller 1. Check the propeller shaft for runout.

1. Check the drive shaft for runout. Place the drive shaft on V-blocks, and measure

Place the propeller shaft on V-blocks, and measure the propeller shaft runout with a dial gauge.

i

the drive shaft runout with a dial gauge.

Maximum propeller shaft runout: O.02mm (O.O008in)

0.4mm (0.016in) Maximum drive shaft runout:

_'_ /_

1. Dial gauge 2. Propeller shaft

L

3.

1. Dial gauge 2. Drive shaft

V-block

2. Check the contact

3.

V-block

the contact surface of the drive shaft with the oil seal for grooved wear.

3. Check the drive shaft splines both engine and pinion side.

for

4. Check the ball bearing and needle bearing for grooved wear.

4. Check the clutch dog and splines for wear.

5. Check the compression spring for fatique and check the plunger for wear.

6. Check the propeller blades and splines for wear and scratches.

7. Check the propeller threads,

(8in)

2. Check

surfaces of propeller

shaft with oil seals for grooved wear. shaft splines 3. Check the propeller wear.

_

60ram 12.4in)

50ram (2in)

11.2in)

lO.4in)

_-_

200ram

Shift cam 1. Check the shift plunger contact surface for wear.

2. Check the shift rod boot for wear and scratches.

nut for damage on

Gear case 1. Check the painted surfaces for flaking and corrosion.

2. Check the cracks.

gear case for damage and

3. Check the water inlet for clogging.

4. Check the water passage for clogging.

5. Check the anode for melting.

5-23

GEAR CASE ASSEMBLY

NOTE: 1. Always use new gaskets, oil sealsand Orings. The use of any used oil seal or Oring may result in oil leakage due to invisible scratchesor stretches.

2. Forward gear taper roller bearing. a. Install a shim(s) having the same thicknessas one(s) removed in disassembling in the gear case, and install the outer race. Screw the drive rod attachment over the drive rod, install the driver head, and drive in the outer race.

//_

2. Apply grease to parts where specified.

Gear case Place the gear case in an inverted position and install it on the repair stand.

(_

_ L_

J

1. Using the bushing installer, install the bushing.

NOTE: The outer race should be driven in squarely. ,# the taper roller bearing inner race in the forward gear.

NOTE : Place the plate of the bushing installer on the contact surface of the gear case with the upper casing, and insert the center bolt into the

NOTE: When driving in the bearing, be sure to press the inner race. Never pressthe roller retainer or the rollers.

_

gear housing through the holes in the plate and drive shaft. Fit the bushing over the center bolt, and install the stopper nut. Hold the

the nut, then install and bolt in center gear case. thetighten the bushing I

5-24

_

_ l

_

Oil seal housing 1. Boot Install the boot on the oil seal housing, 2. Bushing Using the jig force-fit the bushing into the oil seal housing.

4. Shift cam a. Insert the shift cam rod into the oil seal housing boot.

q

gear __

b. Fit the drive shaft sleeve to the

case.

â&#x20AC;˘........._

3. Oil seal Using the jig force-fit the oil seals into the oil seal housing, one by one.

c. Insert the shift cam into the gear caseso that the cam lobe faces toward the gear. ii!

NOTE: iMakerectioSUren, d the oil seal lip faces in the correct

ii_

5-25

_ ............... ........

d. Insert the drive shaft sleeve into the end of the oil seal housing, and bolt the oil seal housing to the gear case.

2. Install each oil seal in the attachment, and press-fit it in place.

iiiii!ii_iii iiilii

=_ iiiiiiii_ii_ii _¸_%

i"i"iiiiiii'iil

5. Reversegearand bearing housing a. Bushing and oil seal 1. Using the jig force-fit the bushing into the bearing housing from the oil seal side.

NOTE: Be sure that the oil seal lip is on the correct side. (%

1. Bearing housing 2. Attachment

3.

Oil seal

b. Ball bearing }

ing.

Force-fit the ball bearing into the bear-

,_Q_)

When force-fitting the ball bearing, never press the inner race. Be sure to press the outer

_\

t 1. Bearing housing 2. Bushing

--_(_j_

race.

NOTE :

3. Attachment

5-26

c. Reversegear Attach the shim (which was removed in disassembling) or a new shim having the same thickness as the original shim to the reverse gear, and fit the gearover the

ball bearing in the bearing housing,

l_I

."

3. Mount the washer on the reverse gear side of the propeller shaft, and insert the propeller shaft into the bearing housing.

Clutch dog crosspin and shift spring 1. Install the clutch dog so that its cross pin hole is aligned with the slot in the splinedportion of the propeller shaft.

The clutch dog should be installed with the "F" mark facing toward forward gear.

2. Insert the shift spring into the open end of the propeller shaft.

Push the spring, and insert the cross pin into the hole in the clutch dog. Bring it out of the other side hole in the clutch dog. Do not pass the pin through inside the spring. Fit the cross pin ring to the groove around the clutch dog, and fit the cross pin ring to hold the cross pin.

5-27

GEAR SHIM ADJUSTMENT Preparation for adjustment Before making a shim adjustment,

Gear backlash "A" clearance (called "backlash")

all parts

should be thoroughly cleaned and blown with compressed air. Shim adjustr_ents should be made with the water pump removed,

between the two mating gears in order to take into account possible errors in machining, center-to-center distance tolerance, deformation due to load or thermal expansion and oil film thickness. Shim adjustments are required if the following parts are replaced.

J

Shim adjustment No.

J_

_

__ _"

_ _

_,_

is allowed

_

Replacedpart Gear case

©

2

Propeller shaft taper roller bearing

©

3

Ball bearing

4

Pinion gear

5

Forward gear

7 6

Bearing housing Reversegear

Forward gearshim

__/_ _, "_a _ _ (_._

Forward gear Reversegear

1

Pinion ©

© © O © ©

6_ _ Reversegearshim

Pinion gearshim

©

I Shim thickness 0.05mm, 0.08mm 0.12mm 0.30m m, 0.5mm

5-28

Measuring the backlash of forward gear and reversegear 1. Insert the shift plunger into the propeller shaft, and install the propeller shaft in the gear housing, together with the bearing housing. Tighten the bolt to the specification.

Determining the pinion gear position 1. Fit the circlip to the pinion side of the drive shaft,

_/

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

2,,

Tightening torque: 8Nm (0.8 m-kg, 5.eft.lb)

1. Circlip

___

2. Install the forward gear, pinion shim, and pinion, in the gear case, in that order, and insert the drive shaft into the gearcase from the water pump side.

Next, secure the pinion to the drive shaft with the circlip.

NOTE: Set the gear case so that the drive shaft is in a horizontal position.

*

2. Install the dial gauge on the dial gauge stand and install it on the gearcase.

3. Install the backlash indicator rod on the drive shaft, and bring the dial gauge stem into contact the "30A" on the indicator rod.

/

Use the shim which was removed in disassembling or a new shim having the same thiokness as the original shim. The shims are available in the following four thicknesses: 1.9mm (0.75in), 2.0mm (0.79in), (0.83in), and 2.2mm (0.87in).

2.1mm

5-29

__

1. Dial gauge stand 2. Dial gauge

/_

3. Backlash indicator

rod

4. Forward gear a. Shift into forward gear by pulling the shift rod upward, b. Lock the propeller shaft, and gently turn the drive shaft in and out while pushing it downward. When a click is felt, stop turning and read the maximum deflection of the needle.

NOTE: 1. Lock the propeller shaft tightly.

2. Do not turn the drive shaft quickly, or the accurate measurement of gear backlash will be impossible.

c. Move the shift rod back to neutral, hold the propeller shaft by hand, and give the drive shaft a 30° to45 ° clockwise turn.

NOTE: This operation is required to give the reverse gear a preload.

30

T

45°

L

3. Take a note of the dial gauge readings.

_

l

ii

____

(_

_

the drive shaft in and out while pushing the shift rod downward, it down.

When a click isand felt,gently note turn the

•

_

5. Reversegear a. Shift into neutral by operating the shift rod. b. By pushing the shift rod, shift into reverse, and while rotating the drive shaft clockwise, check to see that the propeller shaft turns counterclockwise.

C,

5-30

NOTE: maximum dial gauge reading.

1. Lock the propeller shaft firmly.

2. Do not turn the drive shaft quicly, or the accurate measurement will be impossible.

3. Take a note of the dial gauge readings.

ii

6. Selection of shims The backlashes of the forward

THE GEAR CASE UNIT

ASSEMBLING and re-

verse gears are as follows:

After backlash pump.

adjustment,

1. Drive the two

dowel

install

the water

pins into

the oil

seal housing.

Standard backlash Forward gear

0.25 _ 0.75mm (0.01 _ 0.03in)

Reversegear

0.25 _ 0.75mm (0.01 _ O.03in)

backlash is out of the specifiIf the measured and/or forward the pinion, replace cation, that so one proper the with shim gear reverse to the specifican be adjusted the backlash cation.

If either of the forward and reverse gears has 1. Dowelpins

change the backlash within the specification, other gear shim to adjust to the specified gear

2. Install the outer plate cartridge and gaskey to the ket and fit the woodruff drive shaft.

should be done backlash. This adjustment without changing the pinion gear shim.

3. Mount

the

impeller

on the drive shaft

so that the impeller keyway fits over the drive shaft woodruff key.

Give the impeller blades a light coat of grease.

1. Outer plate cartridge 2. Gasket

3. Woodruff

key

NOTE: There is a rubber

membrane

in the impeller

keyway. Hold the impeller with the rubber membrane on the up side, and mount it on the drive shaft while taking care not to break the membrane.

5-31

4. By turning the drive shaft clockwise, install the water pump housing, and securewith three bolts.

,.

il

GEAR CASE INSTALLATION 1. Check that the clutch dog shifts correctly to "Forward," "Neutral" and "Reverse" by pulling or pushingthe shift cam, shift into "REVERSE" for installation.

2. Set shift rod (on the engine side) to Reverse.

3. Install the gearcaseto the upper case.

Make sure that the drive shaft splines firmly fit into the crankshaft splinesand that the water tube fits firmly into the water pump.

1. The drive shaft splinesand crankshaft must be lubricated before assembly.

2.

In the case of the long transom model, NOTE: insert the shift rod into the boot attached to the upper casing. Use care so that the boot does not slip off the upper casing.

Lubricating gearoil Add Yamaha gear case lube, P/N LUBGEARL-11-00, through the oil drain plug hole until the oil flows out of the oil levelplug hole.

Oil capacity

r---,_

J

160cm3 (cc) 5.4 US oz

4. Next, tighten the four bolts to secure the upper caseand gearcase.

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

5-32

Tightening torque: 8Nm (0.8m-kg, 5.8ft.lb)

I

I

5. Hold the shift rod (connected to the upper casing) and the shift rod (connected to the lower casing) with the shift rod connector, and secure it with bolts.

1. Shift rod connecter

6. Feed water-resistant grease (Yamaha allpurpose grease, P/N LUBGREAS-13-00) into the nipple.

5-33

CHAPTER 6. ELECTRICAL

DESCRIPTION

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

WIRING DIAGRAM

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

...

IGNITION SYSTEM INSPECTION AND REPLACEMENT ............

Pulser coil .................................................

Charge coil ................................................

Lighting coil ...............................................

CDI unit ..................................................

Ignition coil ...........................................

Spark plug cap replacement ...................................

Direct current resistancetest ..................................

Ignition spark gap test .......................................

OTHER ELECTRICAL PARTS INSPECTION .........................

Engine stop button ..........................................

6-1 6-1 6-2 6-2 6-2 6-2 6-3 :. • • 6-4 6-4 6-5 6-5 6-7 6-7

ELECTRICAL NOTE: When checking the resistance of electrical parts using the Pocket Tester, make a zero adjustment of the tester each time. Otherwise, measurements may be incorrect.

DESCRIPTION This model employs the capacitor discharge ignition (CDI) system in which a single ignition coil is used to produce sparks simultaneously in both the upper and lower cylinders. However, ignition only takes place in the cylinder which is on the compression stroke.

1_

The lighting coil delivers an output of 80W using a 4-pole magneto.

- '_-_l

WARNING: Before starting the disassembly,assembly or checking of electrical parts, be sureto remove the spark plug cap.

Electrical parts should be handled with the following care: 1. Protect from severeshocks.

2. Keepaway from heat.

3. Avoid extremely humid places.

WIRING DIAGRAM

Br_Br

B EE3<_B---

J

---

I _11

2. CDI magneto unit coil Ignition 1. CDI 3.

G

(_

v

I

6-1

IÂŽ

: White/Red W/R : Brown Br stop button Engine 4. : Black B W

: White

G R O

: Green : Red : Orange

IGNITION SYSTEM REPLACEMENT

INSPECTION

AND

Pulsercoil

Lighting coil

1. Disconnect the pulsercoil leadsfrom the CDI unit and connect the pocket tester asshown, 2. Check the resistance of the pulser coil windings with the pocket tester. If the resistance is not within specification, replace the pulser coil assembly.

1. Black

.....

Lighting coil resistance: 0.4£ -+10% at 20°C (68°F) (Green - Green)

2. White/Red

Pulsercoil resistance: 102£z + 10% at 20°C (68° F) (White/Red - Black) Chargecoil 1. Disconnect the charge coil leads from the CDI unit and connect the pocket tester asshown.

2. Check the resistance of the charge coil windings with the pocket tester. If the resistance is not within specification, replacethe charge coil assembly. ,=

\,

1. Black

Check the resistanceof the lighting coil windings with the pocket tester. If the resistance is not within specification replacethe lighting coil assembly.

2. Brown

Charge coil resistance: 909. -+10% at 20°C (68°C) (Brown- Black) 6-2

CDI unit as specified

1. Check the CDI unit the pocket tester.

using

ester _ 696-10

(_

_Tester

_

Ground

W

B

T "_

B

oo

[-_

Charge

Br

oo

79

[_

Ignition

0

oo

oo

White

Br:

Brown

B:

Charge

Black

9.4

•

o_

W/R:

oo .....

No continuity

discharge the condenser by having the ignition coil lead (orange) touch the grounding lead (black).

For this test, be sure to use the Yamaha Pocket Tester. Any other tester will not show a correct resistance.

2. If resistance is far from replace the CDI unit.

specification,

6-3

oo

White/Red

Needle swingsonce and returns to home position

this test, be sure to

•

oo

_

• .....

• When checking the CDI unit, be sure to set the ohmmeter in the _ x 1,000 range.

• Needle swings once and returns to home position.

The pocket tester needle deflects from the infinite ,,oo" to the 200 _ 300 k_ range and

Ignition

Pulser

Unit: k_ + 20% at 20°C (68°F) 0 W/R Br

....

Ground

NOTE:

swings back to "_o', Each time you perform

_

[]

W: B

Stop

O:

Orange

4. As shown below, break up the exposed inner wires on the end of the high-tension cord.

5. Fit the spring over the high-tension cord so that it contacts the inner wires.

Ignition coil Visual check Check the high-tension cable and spark plug cap for cracks or breaks,

Bend Contact

....

6. Install the cap.

Spark plug cap replacement 1. Remove the spark plug cap from the

NOTE: Apply a thin coat of greaseto the spring and fit the high-tensioncord into the spark plug cap.

high-tensioncord.

2. Straighten the bent end of the spring and remove the spring.

3. Cut the high-tension cord insulator about 5mm from its end to expose the inner wires.

NOTE: Take care not to cut the inner wires.

5mm

6-4

Direct current resistance test Use the pocket tester to determine the resisof the primary and tance and continuity

Ignition spark gap test

secondary coil windings.

Be careful not to touch the ignition coil and testing. An while performing its vicinity electric shock may cause injury.

WARNING:

NOTE: the secondary leads resisWhen performing tance test, disconnect the spark plug cap.

NOTE: To perform a spark test, it is recommended that the Coil Tester be used as this manual

Primary coil test

starter model is not provided with a battery.

To check the strength of a spark using an Electro Tester requires a 12-volt battery as opposed to a Coil Tester, with which spark tests can readily be performed on any manual starter model. The Coil Tester can be ordered through Yamaha YU-33261.

dealerships

under part

No.

Test by pulling the starter handle NOTE: To clip on the high-tension cable, remove the plug cap and clip on the core wires of the cable. Wires (conductor) can also be inserted into the plug cap as shown and clipped on.

Secondary coil test ili:i

,_

1. Connect the secondary lead wire of the Coil Tester to the ignition coil as shown.

Standard value: Primary coil resistance: 0.4£ -+ 10% at 20°C (68°F) Secondary coil resistance: 3.5k£ -+ 10% at 20°C (68°F) NOTE: 1. Measure the resistance of the ignition coil and, if either primary coil or the secondary recoil resistance is far off specification, place the ignition coil.

2. If the resistance measured is slightly off install the ignition coil onto specification, the engine and check spark strength.

6-5

2. By turning the "GAP. ADJ" knob, set the spark gap to 8mm (0.3tin).

o, C

3. Check spark strength by starter rope a strong pull.

giving the

4. If the spark can jump at least across an 8mm (0.31in) gap, the ignition coil is considered to be in good condition. If it cannot, the ignition coil should be replaced.

6-6

7. Turn the "CDI."

voltage selector switch

PARTSlNSPECTION

OTHER ELECTRICAL

to

Engine stop button CDI unit. thebutton from the ground leads stop engine ct the lead Disconne 1. and

=_

1. White

2.

B_ack

2. Check the stop button as specified using the pocket tester.

8. Turn on the "GAP. ADJ" knob and increase the gap to maximum unless misfire occurs first.

Minimum spark gap: 8mm (0.31in)

] /

NOTE: The performance of the ignition coil will be affected by heat. The spark test should therefore be performed at intervals of 5 to 10 minutes for correct test results.

....

......

Released: Pushed:

Discontinuity Continuity

Color:

White - Black

3. If the element is broken, replace the entire unit.

6-7

CHAPTER 7. RECOIL STARTER DESCRIPTION REMOVAL

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

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

7-1 7-1

......

DISASSEMBLY .......................................... .........

Removingthe drive pawl ............................ pe .......................

Removingthe sheavedrum and starterro ..............

Removingthe starter spring .....................

7-2 7-2 7-2 7-3

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

INSPECTION AND REPAIR .....................

Drive pawl ................................................

Starter rope ............................................... ....

Starter spring .......................................... ..... ....... ....... .......

Starter housingshaft ..............

Sheavedrum ...............................................

7-4 7-4 7-4 7-4 7-4 7-4

..

ASSEMBLY ................................................. ....

Starter spring .......................................... .............

Starter rope and sheavedrum ..................... .................

Drive pawl and drive pawl spring ..............

7-5 7-5 7-5 7-7

INSTALLATION

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

7-7

RECOIL STARTER DESCRIPTION The recoil starter consists mainly of the starter rope, sheavedrum, starter spring, drive pawl, and drive pawl spring, The drive pawl engagesthe sheavedrum with the flywheel, and the spiral spring rewinds the starter rope.

REMOVAL 1. Remove the starter stop plunger from the starter case. ...................... ,

NOTE : When the starter handle is pulled out, the starter spring works against it and therefore, the starter handle must not be released.

f_/ ].

_

Starter stop p_unger

2. Remove the three starter assembly mounting bolts, and remove the starter assembly.

ÂŽ4 1. Starter handle 2. Starter rope 3. Starter stop plunger 4. Starter housing shaft 5. Sheave retainer bolt

6.

7.

Drive pawl Drive pawl spring

8. Sheave drum 9. Starter spring 10. Starter housing

7-1

DISASSEMBLY Removingthe drive pawl Remove circlip securing the drive pawl, and removethe drive pawl and drive pawl spring,

Removingthe sheavedrum and starter rope 1. Turn the sheavedrum so that the cut on the outer surface of the sheave drum facestoward the starter handle.

2. Passthe starter rope through the cut.

3. Turn the sheave drum clockwise until the starter spring is free.

....... _'

1. Drive pawl circlip

1. Drive pawl spring

4. Remove the starter handle seal, and bring the knotted end of the starter rope out of the starter handle. Undo the knot and remove the handle from the rope.

7-2

5. Remove the nut and bolt at the center of the starter case, and remove the sheave drum from the starter case. When removing the sheave drum, hold down the starter spring with a screw driver inserted into the hole in the sheave drum so that the starter spring will not spring out.

r retainebolt 1. Sheave

..... shaft 2. Starterhousing

Undo the knot of the starter rope, and remove it from the sheave drum.

Removingthe starter spring Hold the spring with one hand, and unfold the spring from its center with the other hand. Be careful so that the spring does not jump out.

WARNING: When removing the sheave drum, be sureto set the spring free and remove the sheave retainer bolt. Otherwise, the starter spring may jump out, endangeringother person,

WARNING: When removingor installing the starter spring, use care not to injure your hand. It is advisable to wear gloves.

7-3

INSPECTION AND REPAIR Drive pawl Check the drive pawl for cracks,chips, excessive wear or other defect, and replace it, as required,

Starter housingshaft Check the starter housing shaft for cracks, chips, excessive wear, or other defect, and replaceit asrequired.

Crace _7

_

Broke n

lace â&#x20AC;˘

Drive )awl

_p

Replace

Starter spring

Starter rope Check the starter rope for wear or breaks and replaceas required,

_7

/ Replace _,I _.... '_'- Worn '; Starter housing shaft

Sheave drum Check the sheave drum for cracks, chips, or other defect, and replaceit asrequired.

Sheave drum

tWorn

Replace Starter rope

Length: 1,650mm (65in)

J_

NOTE: When replacingthe starter rope, cut it to the specified length (1,650mm or 65in), and burn the rope end so that it will not ravel.

Cracked

Starter spring Check the starter spring for distorted ends or breaks,and replaceasrequired.

Also check for wear or breakageof the starter spring retainer posts.

7-4

Replace

ASSEMBLY Starter spring Hook the outer end of the starter spring onto the spring pin attached to the starter case, and put the spring into the starter case by winding it counterclockwise.

2. Wind the rope one and a half turns onto the sheave drum.

3. Place the rope at the cutaway.

New starter springs come held in a steel hoop. To install, hook the outer end onto the spring pin first, place into the starter case, and then remove the steel hoop. Apply antifreeze grease (Yamaha all-purpose grease, P/N LUB-GREAS-13-00) to the inner surface of the starter case.

__===_ '

_ , _

4. Place the sheave drum

_

the starter !1

_

on the sha ft of

housing and position

the in-

spring pin of the sheave drum.

____'_____WI __

ner

end of

the

starter

sprirlg

on the

5. Place the sheave drum in the starter case and secure with the sheave retainer bolt and nut.

Starter rope and sheave drum 1. Make a knot in the starter rope, leaving a 20 to 25mm (0.8 to 1.0in) portion of the rope end, and insert the end of the

_j_

roe into the ,heave

,

drum.

_

(0.8 _ 1.0in) 7-5

@

"

'

/__,."_t'_

NOTE: Coat the sheave retainer bolt and nut with locking agent and tighten,

8. Place the starter rope across the cut in the sheave drum, and rotate the sheave drum 3 turns counterclockwise, together with the starter rope. Release your hand from the sheave drum to let the rope wind around it.

(. _ a_ _ "°N..................."'

NOTE: Mold the starter case so that it does not turn.

6. Insert the end of the rope into the hole in the starter case, and further, insert it into the starter handle.

i_ii!ii!!_i! _i_!_i_i '_:_':_

7. As shown, make a knot in the end of the rope, put the knot in the starter handle, and install the cover.

l

7-6

INSTALLATION Secure the starter assembly to the power unit with three bolts, and install the plunger (a component of the limited throttle opening starting device) to the starter case.

Drive pawl and drive pawl spring Hook the drive pawl spring onto the drive pawl, and install the drive pawl on the boss, then hook the drive pawl spring onto the starter housing shaft. Secure the drive pawl with the circlip.

Limited throttle opening starting device adjustment" Refer to page 2-8 ,

By pulling out the starter rope, check the operation of the drive pawl, smooth movement of the rope, and winding up of the rope without slack.

7-7

CHAPTER 8. APPENDICES SPECIFICATIONS

â&#x20AC;¢

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

General specifications........................................

Maintenancespecifications ....................................

TIGHTENING

TORQUE .........................................

GENERAL TORQUE SPECIFICATIONS TROUBLESHOOTING EXPLODED DIAGRAMS

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

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

8-1

8-1 8-3 8-7 8-7 8-8 8-12

APPENDICES SPECIFICATIONS Generalspecifications 8N

Model

Item Dimensions: Overall length Overall width

475mm (18.7in) 342mm { 13.5in)

Overall height

S : 977mm(38.5in) L : 1,103mm (43.4in) UL: 1,167mm (45.9in)

Transom height (Boat transom)

S : L : UL:

381mm (15.0in) 508mm (20.0in) 560mm (22.0in)

S: 26.0kg (57.31bs) L: 27.0kg (59.61bs)

Weight

Performance: 4,500 _ 5,500r/min

Full throttle operating range Maximum output -'1 Maximum fuel consumption -*2

(rpm)

(rpm) 5.9kW(8.0hp)/5,500r/min 4.3L/H (1.12 USgal/h)

Engine: Engine type Number of cylinders Total piston displacement Bore and stroke

2-stroke 2 165 cm 3 (co) (6.6 cu.in.)

50mm x 42mm (1.97in x 1.65in) 7.0

Compression ratio Intake system Scavenging system

Reed valve Cross scavenging Under water (propeller boss) Pre-mixed gasoline & oil

Exhaust system Lubrication system Cooling system Starting system Ignition system

Water Recoil hand starter C.D.I. B-7HS10 0.9 _ 1.0 mm (0.035 _ 0.039 in) Choke type 12V 80W

Spark plug Plug gap Carburetor starting system Lighting coil out put Bracket:

5 step

Tilt position

4째 _ 20 째 75 째 37 째

Trim angle Tilt-up angle Shallow water cruising angle Shallow water cruising position

1

Fuel and oil: Pre-mixed gasoline & oil

Fuel Mixing ratio (gas & oil) Gear oil type Gear oil quantity

100 : 1 Hypoid gear oil # 90 160 cm 3 (cc)

Fuel tank capacity

14 litter (3.7 US gal)

8-1

Item

Model

8N

Drive unit: Transmission Gear ratio

Forward - Neutral - Reverse 2.08 (27/13)

Reduction system Clutch type Turning direction of propeller

Bevel gear Dog clutch Clockwise

Propeller drive system

Spline

Propeller: Number of blades x Diameter x pitch type *3

3 x 8-1/2 in x 7-1/2 in 3 x 8-1/2 in x 8-1/2 in 3x9inx7in

Remarks: The data indicated by "1 is propeller shaft horse power.

Fuel consumption *2 varies according to boat type and load.

The propellers marked with *3 is dual thrust type.

Specifications are subject to change without prior notice.

8-2

Maintenance

specifications

1. Engine

Cylinder: Bore size

50 mm 11.97 in) 0.08 mm (0.003 in) 0.05 mm (0.002 in)

Taper limit Out of round limit Piston: _ _"

Piston size/ Measuring point* Piston clearance 1st Oversize 2nd

_ _

__

10 mm (0.4 in) 0.040 _ 0.045 mm 10.0016 _ 0.0018 in) * 0.5 mm (0.02 in) Exhaust side

-_

/-

Offset

50 mm (1.97 in)/

_j _'

2nd ring

Top ring

Piston ring:

T

T

Sectional sketch

B

B Plain

Keystone B

End gap (Installed) Side clearance

_-0.01 = z_0.O 3 mm -0.0004 .... u'u/u-0.0012

in)

_-0.01 B = Z_o.03 mm -0.0004 I.... 'u'u/_-0.0012

T= 2+0,1mm (0.079 + 0.004 in)

mm T=2+0.1 (0.079 + 0.004 in)

0.15 _ 0.35 mm (0.006 _ 0.014 in)

O.15 _ 0.35mm (0.006 _ 0.014 in)

0.02 _ 0.06 mm (0.0008 _ 0.0024 in)

0.03 _ 0.07 mm (0.0012 _ 0.0028 in)

D

Crankshaft:

ctB

_.

.B

_ t

B

in)

Run out limit "B"

-0.002 40-0.05 -0.10 mm (1.57_0.004 0.03 mm (0.0012 in)

Connecting rod big end side clearance "C"

0.2 _ 0.7 mm (0.008 _ 0.03 in)

Small end freeplay limit "D"

2 mm (0,08 in)

Crank width "A"

_

8-3

in)

Model Item

8N

Carburetor: Stamped mark Choke bore Venturi bore

6Gll 0 27 mm (1.06 in) 17 mm (0.669 in)

Main bore Main nozzle

21 mm (0.827 in) 2.4 Dia mm (0.094 Dia in) h = 6 mm (0.236 in)

Main nozzle bleed

Main jet Main air jet Pilot outlet

AB1 : 0.7 Dia mm x 4 (0.027 Dia in x 4) AB2:0.7 Dia mm x 4 (0.027 Dia in x 4) AB6:0.7 Dia mm x 2 (0.027 Dia in x 2) (M.J.) (M.A.J.) (P.O.)

# 98 # 110 1.4 Dia mm (0.055 Dia in)

Pilot jet

(P.J.)

Pilot air jet Bypass 1 Bypass 2 Pilot screw (turns out)

(P.A.J.) (B.P.1) (B.P.2) (P.S.)

#80 0.8 Dia mm (0.03 Dia in) 0.8 Dia mm (0.03 Dia in) 1-1/8 + 1/4

Throttle valve angle Valve seat size

(Th.V.) (V.S.)

13 ° 1.2 Dia mm (0.047 Dia in)

#45

Float level (gauge): Idling speed Trolling speed

Thickness*

14 + 2 mm (0o000 + 0.078 in) 850 _ 950 r/min 750 _ 850 r/min

*

0.15 mm (0.06 in) 4.5 + 0.2 mm (0.177 + 0.008 in)

Valve lift Bending Reed valve: limit

0.6 mm (0.024 in)

______

8-4

2. Electrical Model 8N

Item CDI magneto: Model/Manufacturer Pulser coil resistance (Color)

F280-68 LRP/H ITACHI 102_ -+10% at 20°C (68°F) (White/Red - Black) 90_-+ 10% at 20°C (68°F) (Brown -Black)

Charging coil resistance (Color) Ignition system Ignition timing (B.T,D.C,)

C.D.I. 4° _ 35 °

CDI unit: T IA01/H ITACH I

Model/Manufacture Resistance

Unit: k_Q + 20% at 20°C (68°F) Ground

Stop

Tes'ter O

W

Tester Q_ _

Charge Br

W/R

O

oo

oo

oo

oo

9.4

oo

•

oo

•

W

Ground

B

oo

Charge

Br

oo

79

Pulser

W/R

11

18

38

O

oo

_

o_

W: •

Br: Brown

White

_

B:

Ignition

B

Stop

Ignition

Pulser

Black

_

•

_ oo

W/R:White/Red

.....

Needle swings once and returns to home position

.....

No continuity

O:

Orange

NOTE: •

When checking the CDI unit, be sure to set the ohmmeter in the _ x 1,000

range.

Needle swings once and returns to home position.

The pocket tester needle deflects from the infinite ,,oo,, to the 200 _ 300k_, range and swings back to ,,oo,, Each time you perform this test, be sure to discharge the condenser by having the ignition coil lead (orange) touch the grounding lead (black).

•

Ignition coil: Model/Manufacturer

CM62-22F/H

ITACHI

Minimum spark gap Primary winding resistance

0.15_

8 mm (0.3 in) -+20% at 20°C (68°F)

Secondary winding resistance

3.5k_

+-20% at 20°C (68°F)

Charging system : Type Model/Manufacturer Lighting voltage Lighting coil resistance (Color)

CD t magneto F280-68 LRP/HITACHI 1.5V or more at 3,000 r/rain, 15 + 1.5V at 5,500 r/min 0.4_ + 10% at 20°C (68°F) (Green - Green)

8-5

3. Lower casing unit

Model

Item

8N

Lowercasingunit Drive shaftrunout

0.4 mm (0.016 in)

200 mm

(_ 18in) "1

Propeller

50 mm

60 mm

12 in)

12.4 in)

shaft runout 100 mm

0.02

, (4 in) ]J lOmm _ (0.4 in) I-4

(_

1 I

II

_ _

30mm (1.2 in)

8-6

mm (0.0008

in)

TORQUE

TIGHTENING

Tightening torque Part name

Part to be tightened

Thread size

Remarks

Q'ty Nm

ft-_b

_

ENGINE: 1st

Bolt

M6 x PI.0

10

6.0

0.6

4.3

2nd

Bolt

M6 x PI.0

10

12

1.2

8.7

Cylinder head

1st

Bolt

M6 x P1.0

7

8.0

0.8

5.8

cover

2nd

Bolt

M6 x PI.0

7

10

1.0

7.7

1st

Bolt

M6 x P1.0

10

6.0

0.6

4.3

2nd

Bolt

M6 x PI.0

10

10

1.0

7.1

2

28

2.8

20

1

45

4.5

32

Crankcase

Exhaust cover Spark plug

Nut

Flywheel

Apply oil

UPPER CASE AND GEAR CASE: Clamp bracket

Nut

8

0.8

5.8

Propeller

Nut

17

1.7

12

Shift rod connector

Bolt

10

1.0

7.1

GENERAL

TORQUE

chart teners with

specifies

This

Torque

standard

specifications

M6 x P1.0

SPECIFICATIONS for

torque I.S.O.

pitch

for

special

standard

fas-

treads. components

in the applicable are included warpage, To avoid book. this in a crissassemblies multi-fastener tighten until stages ve progressi in and cross fashion otherwise Unless is reached. torque full

or assemblies of sections

specified,

torque

dry threads. temperature.

specifications

Components

should

call for

clean,

be at room

8-7

A

B

(Nut)

(Bolt)

General torque specifications ft-_b m-kg Nm

8 mm

M5

4.0

0.4

2.9

10 mm

M6

8.0

0.8

5.8

12mm

M8

18

1.8

13

14mm

M10

36

3.6

25

17 mm

M12

42

4.2

30

TROUBLE ENGINE

I

SHOOTING

FUEL

DOES NOT START

I

DThere is no fuel in the carburetor

• • •

Fuel tank ..................

Primingpump ...............

Fuel hoses..................

Empty or fuel level is low Cracked,Defective Leakage,Flattened,Broken

; There is fuel in the carburetor

•

I

SPARK

I

Fuel tank

Fuel is deteriorated

or

dirty

, Spark is weak • Spark plug ..................

• • • • •

Incorrect gap, Carbon deposit Dirty, Oily or burnt Faulty, No contact Defective Defective Defective Defective

Plug cap ...................

Ignition coil .................

CDI unit ...................

Pulsercoil ..................

Chargecoil .................

; Spark is strong pressure • Compression

COMPRESSION

I

J Compression

Incorrect

pressure is incorrect

• Gasket ....................

• Oil seal ....................

• Reedvalve..................

Air leakage Worn Broken

• Piston,Cylinder wall...........

Pistonring

Worn, Broken,Scuffed

8-8

ENGINE TURNS OVER BUT STALLS ENGINE RUNS IRREGULARLY, STOPS OR IDLES ROUGHLY

FUEL

I

l _

• • • • •

p

Fuel tank ..................

Fuel hoses ..................

Fuel filter ..................

Fuel pump .................

Carburetor .................

Fuel is deteriorated or dirty Leakage, Bent, Kinked, Flattened Broken Clogged Worn or broken, gasket is cracked and leaky Needle valve is worn Pilot passagesare clogged Choke is closed Water is in mixture

i

SPARK

_

•

Sparkplug

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

•

CDI unit

•

Ignition timing

Spark is weak, lncorrectgap, Dirty or burned Defective; Check resistance

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

Check timing

I COMPRESSION I

LI

• •

Oil seal ....................

Reed valve ..................

•

Piston, Cylinder wall,

•

Piston ring ..................

Gasket ....................

Worn Broken Worn, Broken, Scuffed Air leakage

8-9

Carbon deposits,

POWER LOSS

I BO_ _-I-I

• Distribution of load on boat ......

• Boat hull ...................

Improper load distribution, Overload.

Fouledwith seaweeds and shells.

• Tilt angle ..................

• Transomheight ..............

Improper Low or high, Air draw Cavitation

LOWER UNIT---I

Incorrect size

1_[

_.

FUrL

I i

• Water inlet .................

• Water pump .................

Propeller ....................

Clogged Worn, Broken Bent, Broken, Loosely fit,

• • • • •

Fuel is deteriorated orr dirty Leakage,Bent, Kinked Flattened, Broken Clogged Worn or broken,Gasketiscrackedand leaky Needlevalveisworn Pilot passages areclogged,Chokeis closed Water is in mixture

Fuel tank ..................

Fuel hoses..................

Fuel filter ..................

Fuel pump .................

Carburetor .................

i

I

SPAR K

/

_

• Spark plug ..................

Spark is weak, Incorrect gap, carbon deposits, dirty, oily or burned Defective;check resistante Checktiming

• CDI unit ...................

• Ignitiontiming ...............

I COMPRESSION

L_l

I

• Oil seat ....................

• Reedvalve ..................

• Piston, Cylinder wall ...........

Piston ring • Gasket ....................

8-10

Worn Broken Worn, Broken, Scuffed Air leakage

MISFIRES

ENGINE

to find cause.

First check for spark

r

1 •

l FUEL _

SPARK

GEAR

I-_

•

Sparkplug

• • •

Plug cap ...................

Ignition coil .................

CDI unit ...................

•

Ignition

Fuel is deteriorated Clogged Clogged

or dirty

Incorrect gap, Carbon deposits, Dirty, Oily or burned Broken or not tightly fitted

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

Defective; check resistance Defective; check resistance Check timing

timing ...............

IS IMPOSSIBLE

SHIFTING

Move shift "Reverse".

• •

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

Carburetor Fuel tank Fuel filter

handle

to

"Neutral",

"Forward"

and

Turn propeller and check that gears are in "Neutral", "Forward" and "Reverse".

WARNING: Do not start engine during

I LOWER

UNIT

this inspection,

I

I .

•

With lower unit removed ......... check gear shifting by operating links

Adjust linkage on engine side

• • •

Dogs of clutch dog or gears .......

Shift cam, Shift plunger .........

Cross pin, Cross pin ring .........

Damaged Worn Broken

8-11

EXPLODED

DIAGRAMS

Power head

Water resistantgrease

Yamaha Bond No.4

: (Yamaha greaseA) Locking agent

___

I'N_(°'4mkg' 2'9'"'I _1

__? ,

8Nm (0.8m-kg, 5.8ft.lb)

1 1Nm (1.1 m-kg, 7.9ft.lb)

7 m

1 lmk

7

,tlb

.....

•

5 8ft Ib)

I

_Nm 0._,_.,_, (0.8m-kg.

"

/

_.v-i _E=j

_._

__=

_ "

_(_t_

d

,

_

/

_____

I1

_

8Nm (0 8m-kg

_

8Nm (0.8m-kg. 5.8ft.,b,

@(_; _"1__)_ ._"_'_._

ll___

8-12

8Nm (0.8m-kg, 5.8ft.lb)

I

]

Upper casing unit

I 8Nm (0.8m-kg, 5.Sft.lb) 1

lNm 10.8-kg, 5,8ft.lb)

[8Nm Io.sm-kg. _._,,.,ol l D

/

!

"\

\

/

[SNm [18Nm

(0.8m-kg, 5.8ft.lb)

(l.8m-kg,

_>"_

13ft.,b)

jJ'_ / //x

8-13

[8Nrn

(0.Sm-kg, 5.8ft,lb)

]

Gear case

I 8Nm (0.8m-kg, 5.8ft.lb)

/

8-14

I

FOREWORD This Supplementary ServiceManual hasbeen prepared to introduce new data for the 6J. For complete information on service procedures, it is necessaryto use this Supplementary Service Manual together with following manual:

8C Service Manual (No. 6G 1-28197-75)

6J SUPPLEMENTARY SERVICE MANUAL (_ 1985 by Yamaha Motor Co., Ltd. 1st Edition. AUGUST 1985

L

All rights reserved.Any reprinting or unauthorized use without the written permissionof Yamaha Motor Co., Ltd. is expresslyprohibited.

Printed in Japan

APPENDICES SPECI FICATIONS General

specifications

Item

Model

6J

Dimensions: Overall length Overall width

475mm (18.7in) 342mm (13.5in)

Overall height

S L

Transom height (Boat transom)

S : L :

Weight

S : L :

: 977mm (38.5in) : 1,104mm (43.5in) 381mm (15.0in) 508ram (20.0in) 27kg (59.41b) 27.5kg (60.51b)

Performance: Full throttle operating range Maximum output -* 1 Maximum fuel consumption -*2

4,000 _ 5,000r/min (rpm) 4.4kW(6.0hp)/5,000r/min (rpm) 3.6 L/H (0.95 US gal/H, 0.79 Imp gal/H)

Engine: Engine type Number of cylinders Total piston displacement Bore and stroke

2-stroke 2 165 cm 3 (10.1 cu.in.)

50mm x 42ram (1.97in x 1.65in)

Compression ratio Intake system Scavenging system

7.0 Reed valve Cross scavenging

Exhaust system Lubrication system Cooling system Starting system

Under water (propeller boss) Pre-mixed gasoline & oil Water Recoil hand starter

Ignition system Spark plug Plug gap Carburetor starting system Lighting coil out put

C.D.I. B R-7 HS10 0.9 _ 1.0 mm (0.035 _ 0.039 in) Choke type 12V 80W

Bracket: Tilt position Trim angle Tilt-up angle Shallow water cruising angle Shallow water cruising position Fuel and oil: Fuel Mixing ratio (gas & oil) Gear oil type Gear oil quantity Fuel tank capacity

5 step 4 째 _ 20 째 75 째 37 째 1

Pre-mixed gasoline & oil 100 : 1 Hypoid gear oil _ 90 160 cm3 (5.4 US oz, 5.6 Imp oz) 14 litter (3.7 US gal, 3.1 Imp gal)

Model Item

6J

Drive unit: Transmission

Forward - Neutral - Reverse

Gear ratio

2.08 (27/13)

Reduction system Clutch type Turning direction of propeller

Spiral bevel gear Dog clutch Clockwise

Propeller drive system

Spline

Propeller: Number of blades x Diameter x pitch type

3 x 8-1/2 in x 8-1/2 in - N 3 x 8-1/2 in x 7-1/2 in - N 3 x 8-1/2 in x 6-1/2 in - N *3

3x9inx7in-N

Remarks: The data indicated by "1 is propeller shaft horse power.

Fuel consumption *2 varies according to boat type and load.

The propellers marked with *3 is dual thrust type.

Specifications are subject to change without prior notice.

Maintenance specifications 1. Engine

Model

6J

4tern Cylinder: Boresize Taper limit Out of round limit

50 mm (1.97 in) 0.08 mm (0.003 in) 0.05 mm (0.002 in)

Piston: Pistonsize/ Measuringpoint* Pistonclearance

tJ ¢

_j\_Q

i Offset

50 mm (1.97 in)/ 10 mm (0.4 in) 0.040 "" 0.045 mm (0.0016 "" 0.0018 in)

J

I---_ *

l

-,J

0.5 mm (0.02 in) Exhaustside

Pistonring:

Top ring

Sectionalsketch

2nd ring

T

T B

B

I

-

End gap (Installed) Sideclearance Crankshaft:

Crankwidth "A"

Keystone

Plain

,,-0 01 B = z_0:03 mm -0 0004 (0"079-0:0012 in) T= 2 +0.1mm (0.079 + 0.004 in)

.-0.01 B = z_0.03 mm -0.0004 (0"079-0.0012 in) T=2+0.1 mm (0.079 + 0.004 in)

0.15 _ 0.35 mm (0.006 _ 0.014 in)

0.15 _ 0.35turn (0.005 _ 0.014 in)

0.02 _ 0.06 mm (0.0008 _ 0.0024 in)

0.03 _ 0.07 mm (0.0012 _ 0.0028 in)

D

A

40-0.05 mm -0 002 ( 1.57_0:004 in) -0.10

Run out limit "B" , Connectingrod big end sideclearance"C'

0.03 mm (0.0012 in) 0.2 _ 0.7 mm (0.008 _ 0.03 in)

Smallend freeplay limit "D"

2 mm (0.08 in)

3

Model Item

6J

Carburetor: Stamped mark

6H600

Choke bore Venturi bore Main bore Main nozzle

27 mm (1.06 in) 17 mm (0.669 in) 21 mm (0,827 in) 2.2 Die mm (0.087 Die in) h = 6 mm (0.236 in)

Main nozzle bleed

ABI : 0.8 Die mmx 4 (0.031 Die in x 4) AB2 : 0.8 Die mm x 4 (0.031 Die in x 4) AB6 : 0.8 Die mm x 4 (0.031 Die in x 4)

Main jet Main air jet

(M.J.) (M.A.J.)

Pilot outlet Pilot jet

(P.O.) (P.J.)

Pilot air jet Bypass 1 Bypass 2 Pilot screw (turns out)

(P.A.J.) (B.P.1) (B.P.2) (P.S.)

Throttle valve angle Valve seat size Float level (gauge): Idling speed Trolling speed

(Th.V.) (V.S.)

Thickness* Valve lift Bending Reed valve: limit

# 98 # 110 0.95 Die mm (0.037 Die in) #45 # 0.8 Die mm 0.8 Die mm 1-1/8

75 (0.03 Die in) (0.03 Die in) +- 1/4

13° 1.2 Die mm (0.047 Die in) 14 -+2 mm (0.55 + 0.079 in) 900 +-50 r/min 800 -+50 r/min

*

0.15 mm (0.06 in) 4.5 +-0.2 mm (0.177 + 0.008 in) 0.6 mm (0.024 in)

______

4

2. Electrical

Model

Item

6J

CDI magneto: Model/Manufacturer Pulsercoil resistance (Color)

F280-68 LRP/H ITACHI 102_ -+10% at 20°C (68°F) (White/Red - Black)

Charging coil resistance (Color) Ignition system Ignition timing (B.T.D.C.)

90_-+ 10% at 20°C (68°F) (Brown -Black) C.D.I. 4 ° _+1° _ 35 ° + 1°

CDI unit: Model/Manufacture

T IA01/HITACHI

Resistance Unit: k_, + 20% at 20°C (68°F)

r (_

Stop W

Ground B

Charge Br

Pulser W/R

oo

oo

oo

9.4

oo

•

oo

•

Stop

W

Ground

B.

oo

Charge

Br

oo

79

Pulser

W/R

11

18

Ignition W:

O

White

• ..... oo .....

NOTE:

_

r

_

_

Br: Brown

_

B:

Black

_ 38

Ignition O oo

_

_

J

• _

W/R: White/Red

O:

Orange

Needle swings once and returns to home position No continuity

•

When checking the CDI unit, be sure to set the ohmmeter in the _ x 1,000 range.

• Needle swings once and returns to home position.

The pocket tester needle deflects from the infinite ,,oo,, to the 200 _ 300k_ range and swings back to ,,oo,,

Each time you perform this test, be sure to discharge the condenser by having the ignition coil lead (orange) touch the grounding lead (black).

Ignition coil: Model/Manufacturer Minimum spark gap

CM62-22F/H ITACHI 8 mm (0.3 in)

Primary winding resistance Secondary winding resistance

0.15_ + 20% at 20°C (68°F) 3.5k_ -+20% at 20°C (68°F)

Charging system: Type Model/Manufacturer Lighting voltage Lighting coil resistance (Color)

CDI magneto F280-68 LRP/H ITACHI 1.5V or more at 3,000 r/min, 15 + 1.5V at 5,500 r/min 0.4_, -+10% at 20°C (68°F) (Green - Green)

5

3. Lower casing unit

Model

Item Lower

6J

casing unit

Drive

shaft runout

0.4 mm

200 mm (_ 18 in)

Propeller

50 mm

60 mm 12.4 in)

shaft runout 100 mm

0.02 mm (0.0008

I

Ih

_ _

in)

-i

12 in)

10 mm I_ (0.4 in) l-I

(0.016

30 mm (1.2 in)

6

in)

TIGHTENING

TORQUE

Part to be tightened

Part name

Thread size

Q'ty

Tight_ --

NmImkgIttlb I

....

Remarks

ENGINE: Crankcase Cylinder head cover Exhaust Cover

1st

Bolt

M6 x PI.0

10

6.0

0.6

4.3

2nd

Bolt

M6 x P1.0

10

12

1.2

8.7

1st 2nd

Bolt Bolt

M6 x P1.0 M6 x P1.0

7 7

8.0 10

0.8 1.0

5.8 7.7

1st

Bolt

M6 x PI.0

10

6.0

0.6

4.3

2rid

Bolt

M6 x P1.0

10

10

1.0

7.1

2

28

2.8

20

1

45

4.5

32

8

0.8

5.8

Spark plug Flywheel

Nut

Apply oil

UPPER CASE AND GEAR CASE: Clampbracket

Nut

Propeller

Nut

Shift rod connector

Bolt

GENERAL

TORQUE

M6 x PI.0

17

1.7

12

10

1.0

7.1

,

SPECIFICATIONS

This chart specifies torque for standard fasteners with standard I.S.O. pitch treads.

Torque specifications for special components

A (Nut)

B (Bolt)

8 mm

M5

4.0

0.4

2.9

o.r assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and in progressive stages until full torque is reached, Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.

10 mm

M6

8.0

0.8

5.8

12ram 14 mm 17 mm

M8 M10 M12

18 36 42

1.8 3.6 4.2

13 25 30

'"

.

7

General torque specifications Nm m-kg ft-lt

DIAGRAMS

EXPLODED Recoil starter

AGENT:

GREASE:

_

SEALING

(Water-resistant grease) : Yamaha grease A

_

: Locking agent (NEJI-LOCK®)

(Anti-freeze grease) : Yamaha grease C

_,]

: Locking agent (LOC-TITE ®)

grease Dgrease) : Yamaha (Anti-corrosion : Yamaha Bond No. 4

I

i

y'O U

Ignition system

/

Q

Ignition coil

Mag__neto

9

/ CDI unit

'

Intake system

_}

/'-__'_

,,.,o) i___. l _._ (_.Im__. , _11 '

Nm

-

(1.1m-kg,7.9ft.lb)

_

g

C)

-10-

Power head

r

% lONm (l.0m-kg,

='e %

,_,t,_,

SD

Pistonto cylinderclearance I ,

1B6_rl_g

i

Crankshaftrun out limit I

I

.

0.040 _ 0.045 mm (0.0016 in_ 0.0018 in)

1lom,l.o 7.2ft.lb)

_

mL,,-I_

_/._

oo_mm_O__ )....._ __

2.4-42.4

--11

--

Upper casing

J

"-1

I

10Nm(1.0m-kg,7.2ft.lb) J . I

\

-12-

Bracket unit

-13-

Gear

case

I j_

_--S I _

II rsh,m,,, \o_ U !O.O,,.m O.08mm

I_

1,./

_

O

/__

_iP

J / o._mm

_',_"-_

Shim(s)

\

J 0.30ram 0.5turn

"

\ ,,4,/

0

Pin ion

S"_

_

S_15_28.6

%_-..._

_'_/.,_

__'_

i ,OOmmO Revmm rse e r O.08mm

13.1-49.4

'_°"

,__"_

"1_?,_oosmm 0.30mm

--14--

0.5mm

AVANT-PROPOS Ce suppl6ment au manuel d'atelier a 6t6 pr6par6 pour introduire les nouvelles donn6es pour les 6J. Pour une information compl6te concernant les proc6dures d'entretien, il est n6cessaire d'utiliser ce suppl6ment au manuel d'atelier ensemble avec le manuel suivants:

(No. 6G1-28197-75) 8C Manuel d'Atelier

6J SUPPLI_MENT AU MANUEL D'ATELIER @ 1985 de Yamaha Motor Co., Ltd. l&e Edition, AOI]T 1985 Tous droits r6serv6s.

Toute r6impression ou utilisation sans la permission 6crite de la Yamaha Motor Co., Ltd. est formeUement interdite.

Imprim6 au Japon

]

APPENDICES CARACTI_RISTIQUES Specifications

g_n_rales

Description

Mod6le

6J

Dimensions: Longueur hors-tout Largeur hors-tout Hauteur hors-tout

475 mm (18,7 po) 342 mm (13,5 po) S: 977 mm (38,5 po) L: 1.104 mm (43,5 po) S: 381 mm (15,0 po) L: 508 mm (20,0 po) S : 27 kg (59,4 lb) L: 27,5 kg (60,5 lb)

Hauteur du tableau arri_re (Poupe du bateau) Poids Performances: Plage d'utilisation _ acc616ration maximale tr/mn Puissance maximale -* 1 Cons0mmation maximale de carburant *2

4.000 _ 5.000 tr/mn 4,4kW(6,0cv)/5.000 tr/mn 3,6 L/H (0,95 gal. am6r/h, 0,79 gal. imp/h)

Moteur: Type Nombre de cylindres Cylindr6e totale A16sageet course Taux de compression Admission Balayage Echappement Graissage Refroidissement

2-temps 2 165 cm 3 (10,1 po 3) 50 mm x 42 mm (1,97 po x 1,65 po) 7,0 Par soupape _ anches Balayage transversal Par le moyeu d'h_lice Par pr6m61ange d'essence et d'huile Par eau Lanceur manuel _ retour automatique C.D.I. BR-7HS10 0,9 mm _ 1,0 mm (0,035 po _ 0,039 po) Volet de d6part (Etrangleur) 12V 80W

D6marrage Allumage Bougie Intervalle des _lectrodes de bougie Dispositif de d6part _ froid D6bit de la bobine d'6clairage Etriers: Position de relevage Angle d'inclinaison (Assiette) Angle de relevage Angle de navigation en eaux peu profondes Position de navigation en eaux peu profondes

5 4째 _ 20 째 75 째 37 째 1

Carburant et huile: Carburant Taux du m_lange Type d'huile du boitier de l'h61ice Quantit6 d'huile du boitier de l'h61ice Capacit6 du r6servoir d'essence

Pr6m_lange d'essence et d'huile 100 : 1 Huile SAE No.90 pour engrenages hypoi'des 160 cm 3 (5,4 oz. am6r, 5,6 oz. imp) 14 litter (3,7 gal. am6r, 3,1 gal. imp)

--1--

_

--

ModUle Description

6J

Transmission: Boite de vitesses

Marche avant

Rapport de d_multiplication Syst_me de r_duction Type d'embrayage Rotation de l'h61ice Entrainement de l'h61ice

Point mort - Marche arribre

2,08 (27/13) Engrenage conique g denture Crabot A droite Cannelures

H_lices: Nombre de pales x diam_tre x calage

*3

3 3 3 3

x x x x

8-1/2 pox 8-1/2 po -N 8-1/2 pox 7-1/2 po -N 8-1/2 pox 6-1/2 po-N 9 pox 7 po -N

Remarques: Le puissance donn6es en *1 est prises g l'arbre de l'h_lice.

La consommation de carburant *2 varie suivant le type de bateau et la charge.

Le h61ice indiqu_es par *3 est du type/l pouss6e double.

Ces specifications peuvent 6tre chang6es sans pr6avis.

Sp6cification

pour l'entretien

1. Moteur

_

Mod61e

6J

Description Cylindre: A16sage Limite de conieit6 Limite d'ovalisation

50 mm (1,97 po) 0,08 mm (0,003 po) 0,05 mm (0,002 po)

Piston: â&#x20AC;˘ Dimension du piston/ point de mesure* Tol6rance de jeu Apr6s rectification du bloc D6ealage

I

_

50 mm (1,97 po)/ :°

10 mm (0,4 po) 0,040 _ 0,045 mm (0,0016 _ 0,0018 po)

Q . ./_ /

-/

Segments:

0,5 mm (0,02 po) c6t6 6chappement Segment du sommet

Coupes des segments

T_

2e segment

B

T_.

Trap6zofdal

Jeu lat6ral

Vilebrequin:

Rectangulaire

.,-0,01 003mm ,,, ,,',,-0,0004 , tu'u/_-0,0012 po) T= 2-+0,1 mm (0,079 -+0,004 po)

_-0,01 B =z 0,03mm m n_o-0,0004 _"'"'"-0,0012 po) T = 2-+0,1 mm (0,079 -+0,004 po)

0,15 (0,006 0,02 (0,0008

0,15 (0,006 0,03 (0,0012

B=z

Eeartement des bees (Install6s)

_ 0,35 mm _ 0,014 po) _ 0,06 mm _ 0,0024 po)

_D

B

.B

B

_

A. Largeur entre flasques (Ext.) B. Fl6che maximale

-0,05 -0,002 40 0,10 mm (1,57_0,004 po) 0,03 mm (0,0012 po)

C. Jeu lateral de t_te de bielle

0,2 _ 0,7 mm (0,008 _ 0,03 po)

D. D6fiexion du pied de bieUe

2 mm (0,08 po)

_ 0,35 mm _ 0,014 po) _ 0,07 mm _ 0,0028 po)

Modble

Description

6J

Carburateur: Marque estamp_e Al_sage de l'6trangleur A16sage du diffuseur Al_sage principal Buse principale

6H600 27 mm (1,06 po) 17 mm (0,669 po) 21 mm (0,827 po) 2,2 Diamm (0,087 Dia po) h = 6 mm (0,236 po)

Purge de buse principale

Gicleur

principal Gicleur d'air principal Sortie de ralenti Gicleur de ralenti Gicleur d'air du ralenti D_rivation t D_rivation 2 Vis de ralenti

AB1 : 0,8 Diamm x 4 (0,031 Dia po x 4) AB2 : 0,8 Dia mm x 4 (0,031 Dia pox 4) AB6 : 0,8 Diamm x 4 (0,031 Dia po x 4) # 98 # 110 0,95 Dia mm (0,037 Dia po)

(M.J.) (M.A.J.) (P.O.) (P.J.)

# # 0,8 Dia mm 0,8 Diamm

(P.A.J.) (B.P.1) (B.P.2) (P.S.)

(hombre de tours en d_vissant) Angle d'ouverture du papillon Dimension du si+ge de pointeau Niveau de flotteur

Dia po) (0,03 Dia po) 1-118 + 1/4

(Th.V.) (V.S.)

13 ° 1,2 Dia mm (0,047 Dia po) 14 +-2 mm (0,55 + 0,078 po) 900 + 50 tr/mn 800 + 50 tr/mn

R_gime de ralenti R_gime de ralenti embray_

Epaisseur* Lev6e de clapet Soupape anches: Limite _ de torsion

* _

45 75 (0,03

/'_'_-_ i

4

0,15 mm (0,06 po) 4,5 -+0,2 mm (0,177 -+0,008 po) 0,6 mm (0,024 po)

2. El6ments

61ectriques Mod61e

Description

6J

Magn6to CDI Mod61e/Fabricant Rdsistance de la bobine d'impulsions (Couleur) R6sistance de la bobine de charge (Couleur) Syst6me d'allumage: Calage (Av.PMH)

F280-68 LRP/HITACHI 102_2 -+10% fi 20°C (68°F) (Blanc/Rouge Noir) 90f_ -+10% fi 20°C (68°F) (Brun Noir) CDI 4 ° + 1° _ 35 ° + 1°

Bloc CDI: Mod61e/Fabricant

TIA01 [HITACHI

R6sistance

Unit6:k_2 + 20% _ 20°C (68°F) "__6tre (_) Arr_t Ohmmetre O-'"--_ W Arr_t W _ Masse

B

oo

Charge

Br

oo

O W/R

oo 11

Allumage Impulsion W: Blanc • ..... oo .....

Br: Brun

Masse B oo

Charge Br oo

"]_

9,4 79

Noir

38 W/R:

Allumage O oo

oo

•

oo

•

__

118 oo B:

Impulsion W/R oo

-'_

Blanc/Rouge

_..

O:

Orange

L'aiguiUe d6vie une fois et revient _ sa position d6part Pas de continuit6

N.B.: • Lors de la v6rification du bloc CDI, s'assurer de placer l'ohmm6tre sur la plage _2 x 1.000.

• L'aiguille d6vie une fois et revient _ sa position de d6part.

L'aiguille du testeur portatif d6vie de la position "inf'mi" (_o) _ la position 200 300ki2 et retourne _ la position (co).

Oublier de d6charger le condensateur en court-circuitant le fil de la bobine d'allumage (orange) et le f'd de masse (noir).

Bobine d'allumage: Mod61e/Fabricant Intensit6 minimum de l'6tincelle R6sistance de l'enroulement primaire R6sistance de l'enroulement secondaire Type d'alimentation: Type Mod61e/Fabricant Tension d'6clairage R6sistance de la bobine (Couleur)

CM62-22F/HITACHI 8 mm (0,3 po) 0,15_2 -+20% _ 20°C (68°F) 3,5k_2 -+20% _ 20°C (68°F) Magn6to CDI F280-68 LRP/HITACHI 11,5V ou plus _ 3.000 tr/mn, 15 -+ 1,5V fi 5.500 tr/mn 0,4_2 -+10% _ 20°C (68°F) (Vert - Vert)

3. Commandes

et groupe

inf6rieur

Mod61e Description

6J

Groupe

inf6rieur: F16che de l'arbre de transimission

0,4 mm (0,016

po)

200 mm

50 mm (2 po)

60 mm (2,4 po)

F16che de l'arbre de l'h61ice 100 mm (4 po) 10mm (0,4 po) _1__

0,02 mm (0,0008

.(_ 1 "',,

'_

30mm (1,2 po)

po)

COUPLES

DE SERRAGE

Pi6ce fi serrer

Description

Dimensions des filets

Couple de serrage Q't6

Nm

m-kg

/ Remarques

pi-lb

MOTEUR:

] 1er

Boulon

M6 x P 1,0

10

6,0

0,6

4,3

2e

Boulon

M6 x P1,0

10

12

1,2

8,7

ler

Boulon

M6 x P1,0

7

8,0

0,8

5,8

2e

Boulon

M6 x P1,0

7

10

1,0

7,1

Couvercle

ler

Boulon

M6 x P1,0

10

6,0

0,6

4,3

d'6chappement

2e

Boulon

M6 x P1,0

10

10

1,0

7,1

2

28

2,8

20

i

45

4,5

32

Carter

Culasse

Bougie Volant

/_crou

Huiler avant

FOURREAU ET BOITIER D'HELICE: Etrier de presses

l_crou

8

0,8

4,3

H_lice

l_crou

17

1,7

12

Connecteur de tiged'inversion

Boulon

10

1,0

7,1

SPt_CIFICATIONS COUPLE

M6 x P1,0

GI_NI_RALES

Sp6cifications

A

B

(Ecrou)

(Boulon)

les in-

8mm 10 mm

M5 M6

4,0 8,0

0,4 0,8

2,9 5,8

dans les sections appropri6es de ce Pour 6viter toute d6formation des

12mm

M8

18

1,8

13

14 mm

M10

36

3,6

25

17mm

M12

42

4,2

30

Ce tableau sp6cifie les couples les boulons et 6crous avec

de serrage pour filets standard

I.S.O. Les sp6cifications de couple composants ou ensembles sp6ciaux diqu6es manuel.

DE

,

pour sont

ensembles ayant de nombreux points d'attache, serrer en suivant un ordre entrecrois6, par 6tapes progressives, jusqu'_ ce que le couple final soit atteint.

A moins d'instructions contraires, les sp6cifications de couple s'entendent pour des filetages propres et secs. Les composants doivent 6tre _ temp6rature ambiante.

A

g6n6rales de couple Nm m-kg pi-lb

VUES EN ECLATE Lanceur

fi rappel GRAISSE:

_

AGENT D't_TANCHI_ITI_

- Graisse Yamaha A (Graisse r6sistant fi l'eau)

_

• Agente de traba (NEJI-LOCK®)

: Graisse Yamaha C (Graisse antigel)

_'_1_

: Agente de traba (LOC-TITE®)

" Graisse Yamaha D (Graisse anticorrosion)

\

\

_

: Yamaha Bond No. 4

Allumage

/

__'_

._._"

.

B°bme d'allumage

_5Nm

_..

(4,5m-kg, 32ft.lb)I

@__J_

/

X,.",-_'--_--_-'Y_

Volant support%_

de ma__

Bloc C.D.I

\

',,\

V°lant magn_tique "_.

/

I

)

.../[

_0m_ss_on '_

ftlb _ J__ \ _I_ _

_

_

i

I?

_[

I i 1Nm (1,1m-kg, 7,9ft.lb)

J

@

C)

-10-

1

T6te motrice

___._ ikO. _

,o.m_,Om-k_

Li.\\

7,2ft.lb)

SD-

O _-_

_,_x_

I Jeu entre piston et cylindre

_-_

I

0,040_0,045mm

_,_

L2,OO16o,oo1_ _o)

¢ "_ 7,2ft.lb)

vflebrequin Limite de faux-rond de 0,03 mm (0,0012 po)

__

R62_e2ent

1( .__

-11--

t

Fourreau

"-1 10Nm(1.0m-kg.7.2ft.lb) I "--I

__" -12-

Support

9 _/

I 8Nm (0,8m-kg, 5,8ft.lb) I

_

/ /

--13--

Boftier

d'h_lice

I j_ _-

]_"

A

/_

U

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Yamaha Motor Canada Ltd. 480 Gordon Baker Road Toronto, ON M2H 3B4