Yamaha Model Cv115e 115hp 2 stroke Outboard Repair Manual – PDF DOWNLOAD

Marine

Outboards 161

CV115E SERVICE MANUAL

YAMAHA MOTOR CO.,LTD. LIT-18616-00-56 •

A 100001·

•

CV115E SERVICE MANUAL 1990 Yamaha Motor Corporation, U.S.A. 1st Edition, April 1990 All rights reserved.

No part of this publication may be reproduced or transmitted in any from or by any means including photocopying and recording without the written permission of the copyright holder. Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature.

Printed in Japan PIN lIT·18616·00-56

A 20000-0

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

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

AJOOOO 0

INDEX GENERAL INFORMATION

-

-y

GEN INFO

SPECIFICATION GENERAL SERVICE FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT ELECTRICAL SYSTEM TROUBLE-SHOOTING

?

•

CHAPTER 1 GENERAL INFORMATION HOW TO USE THIS MANUAL MANUAL FORMAT THE ILLUSTRATIONS REFERENCES WARNINGS. CAUTIONS AND NOTES SYMBOLS

CHAPTER 4 FUEL SYSTEM .11 ".11 1·1

I·' 11 12

IDENTIFICATION SERIAL NUMBER ENGINE SERIAL NUMBER STARTING SERIAL NUMBERS

· .13 1·3

SAFETY WHILE WORKING FIRE PREVENTION VENTILATION ..

SELF·PROTECTION .

OILS. GREASES AND SEALING FLUIDS GOOD WORKING PRACTICES DISASSEMBLY AND ASSEMBLY

14 .. 1·4 .1·4 1·4 .. 14 14 .14

SPECIAL TOOLS SPECIAL TOOLS FOR TUNE·UP SPECIAL TOOLS FOR ENGINE SERVICE SPECIAL TOOLS FOR LOWER UNIT SERVICE SPECIAL TOOLS FOR POWER TRIM AND TILT SERVICE ..

SEALING AGENTS AND LUBRICANTS

· 1·3

'·3

.... 1·5 " .I 5 1·5 15 1·6 16

CHAPTER 2 SPECIFICATION GENERAL SPECIFICATIONS ................................ 2·1 MAINTENANCE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . .

ENGINE. . ..•.........................................

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

DIMENTION 1 .. . .....................................

DIMENTION 2 ..........................................

TIGHTENING TORQUE ........................... .

23 23 25 2.7 2·9

.2·10

CHAPTER 3 GENERAL SERVICE PREDEUVERY SERVICE CONTENTS ELECTRIC WIRING FUEL LINE GEAR OIL LEVEL ..

OPERATION OF CONTROLS AND MOVING PARTS FUEL LEAKAGE WA TER LEAKAGE .

EXHAUST LEAKAGE. ENGINE AND LOWER UNIT NOISE IDLE·SPEED IGNITION TIMING MOTOR EXTERIOR INSTRUCTING THE NEW OWNER PERIODIC SERVICE MAINTENANCE SCHEDULE ..

ANODE BATIERY CARBURETOR .

CARBURETOR LINK CARBURETOR PICKUP TIMING CYLINDER HEAD BOLTS. ENGINE MOUNTING BOLTS. AND FL¥WHEEL NUT FUEL FILTER FUEL TANK AND FUEL LINE. GEAR OIL GREASE POINTS IDLE SPEED IGNITION TIMING ADJUSTMENT. OUTBOARD MOTOR BODY POWER TRIM AND TILT FLUID. PROPELLER. SPARK PLUG.

31 31

3·2

fUEL SYSTEM

EXPLODED DIAGRAM REMOVAL CLEANING AND INSPECTION INSTALLATION.

CARBURETOR. EXPLODED DIAGRAM REMOVAL AND DISASSEMBLY CLEANING INSPECTION ASSEMBLY AND INSTALLATION

4·1 ·41 41 4·2 43

. ......... 4·4

4·4 ·4·5 ··4·5 ··4·5 4·7

CHAPTER 5 POWER UNIT 51

EXPLODED DIAGRAM PREPARATION FOR OVERHAUL REMOVAL

54

DISASSEMBLY

5·5

INSPECTION CYLINDER HEAD CYLINDER BLOCK ..

PISTON. PISTON RING PISTON PIN AND SMALL END BEARING CRANKSHAFT REED VALVE. THERMOSTAT BALL BEARING CRANK DISK SEAL RINGS

5·7

ASSEMBLY AND ADJUSTMENT. CRANKSHAFT .

PISTON SMALL END BEARINGS AND PISTON ASSEMBLY CRANK UPPER BEARING HOUSING CRANK LOWER OIL SEAL HOUSING CRANK CYLINDER ASSEMBLY CYLINDER HEAD AND EXHAUST COVER .

INTAKE MANIFOLD DRAIN LESS HOSES ENGINE STOPPER.

57

58 5·9 510 5· 11 5·11 512 .512 · .. 5-13 · .5-13

".514 514 " 5-14

".515 516 · .. 5-16

516 . 5-20 521 ... 521 · .5-22

3-!j

·36 36

INSTALLATION

37 37 · 37 37 37

CHAPTER 6 LOWER UNIT

37 · 37 37

38 38 38 .39 310 .310 .311

311 312 312

312 312

313 313

· 317 318 · 318 . . 318

·5-22

EXPLODED DIAGRAM PREPARATION FOR REMOVAL REMOVAL. DISASSEMBLY. INSPECTION GEAR CASE BEARING HOUSING .

CLAWWASHER .

RING·NUT. WATER PUMP HOUSING IMPELLER. DRIVE·SHAFT HOUSING GEARS BEARINGS. CLUTCH DOG AND COMPONENTS DRIVE·SHAFT PROPELLER SHAFT DRIVE·SHAFT SLEEVE .

SHIFT .cAM AND SHIFTSLIDER .

PROPELLER/TRIM TAB/ANODE

· .. 6-1 .6·2 · .6·2 . .. 6·3 ... 6-6

6-6 . ....... 6-6 6·6

6·6 6·6 . ... 67 6·1

6·7 · 6·1 · . 6·7

6-8 .. 6·8 6-8

.6·9 .6·9

ASSEMBL Y AND ADJUSTMENT ASSEMBLY SHIM SELECTION MEASURING THE BACKLASH. WATER PUMP INSTALLATION PROPELLER INSTALLATION LOWER UNIT LEAKAGE CHECK INSTALLATION

. 6·10 6·,0 6·14 6·18 6·20 6-21 . 6·21

STARTER MOTOR EXPLODED DIAGRAM REMOVAL DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION.

813 813 814 814 814 817 818

......... 6-22

CHAPTER 9 TROUBILE·SHOOTING

CHAPTER 7 BRACKET UNIT EXPLOOED DlAGAAM .

BRACKET UNIT .

POWER TRIM AND TilT UNIT UPPER CASING AND BOTTOM COWLING REMOVAL. UPPER CASING AND BOTTOM COWLING. DISASSEMBLY ....

INSPECTION. ASSEMBLY. BAACKET UNIT DISASSEMBLY INSPECTION. ASSEMBLY ...

· . 7·1

ENGINE WILL NOT START .

· .9-2

]·4

ROUGH IDLING.

· .9-8

75

ENGINE STALLS

·76

. ... 7·9 7·g

711 711 7·14 · . 7·15 · . 7 17

· . 7·19

CHAPTER 8 ELECTRICAL SYSTEM

WIRING DIAGRAM REMOVAL FLYWHEEL MAGNETO CLEANING, INSPECTION AND REPAIR SPARK·PLUG PULSER COIL CHARGE COIL LIGHTING COIL. IGNITION COIL REPLACEMENT OF SPARK·PLUG CAP COl UNIT CHOKE SALENOID STARTER RELAY POWER TRIM AND TILT RELAY RECTIFIER REGULATOR FUSE THERMO·SWITCH WIRING HARNESS TRIM AND TIL T SWITCH TERMINAL ASSEMBLY BATTERY INSTALLATION. FL YWHEEl MAGNETO

· .9-10

POWER TRIM AND TILT SYSTEM

· .9-11

GEAR SHIFT IS IMPOSSIBLE OR HARD

· .9-13

· .. 77

717 717 · 7·17

ELECTRICAL COMPONENTS .

EXPLODED DIAGRAM

.9-9

ENGINE WILL NOT STOP .

··1·6 · .. 7·6

·7-8

PTfT MOTOR. DISASSEMBLY .

INSPECTION. ASSEMBLY

9-1 · .9-1

7·2

· . 77 · .. 77 . 77

POWER TRIM AND TILT UNIT .

DISASSEMBLY. INSPECTION ....... .

ASSEMBLY FILLING WITH HYDRAULIC FLUID AND AlA-BLEEDING. HYDRAULIC FLUID PRESSURE TEST INSTALLATION.

TROUBLE·SHooTING DIAGRAM. HOW TO TROUBLE·SHOOT

7·'

··81 ·81 83

·84 84

85 85 85

85 85 86 86 87 88 88

89 89 810 810 811 812 . 812 . 812 812 812

1~~lll

__________________ CHAPTER 1 GENERAL INFORMATION

HOW TO USE THIS MANUAL . .................................... ,-, MANUAL FORMAT ........................................... ,-, THE ILLUSTRATIONS ......................................... 1-' REFERENCES ............................................... 1-1 WARNINGS, CAUTIONS AND NOTES ............................ 1-1 SYMBOLS ................................................... 1-2

IDENTIFICATION ................................................ 1-3 SERIAL NUMBER ............................................. 1-3 ENGINE SERIAL NUMBER ..................................... 1-3 STARTING SERIAL NUMBERS .................................. '-3

SAFETY WHILE WORKING . ....................................... 1-4 FIRE PREVENTION ........................................... 1-4 VENTI LATION ................................................ '-4 SELF·PROTECTION .. , ........................................ 1-4 OILS, GREASES AND SEALING FLUIDS .......................... 1-4 GOOD WORKING PRACTICES .................................. '-4 DISASSEMBLY AND ASSEMBLY ...... , ......................... 1-4

SPECIAL TOOLS ................................................ 1-5 SPECIAL TOOLS FOR TUNE-UP ................ '" .............. 1·5 SPECIAL TOOLS FOR ENGINE SERViCE ......................... '·5 SPECIAL TOOLS FOR LOWER UNIT SERViCE ..................... 1-5 SPECIAL TOOLS FOR POWER TRI M AN D TI LT SERVICE ........... 1-6 SEALING AGENTS AND LUBRICANTS ........................... 1-6

II I -'I I---------------------------------------------------N GNEFO

,

HOW TO USE THIS MANUAL

A500011

HOW TO USE THIS MANUAL MANUAL FORMAT This manual provides the mechanic with descriptions of the operations of disassembly, repair, assembly, adjustment and inspection, each of which is presented in a sequential, step-by-step procedure.

To assist you to find your way about this manual, the Section Title and Major Heading is given at the head of every page.

An Index to contents is provided on the first page of each Section.

THE ILLUSTRATIONS Some illustrations in this manual may differ from the model you have. This is because a procedure described may relate to several models, though only one may be illustrated. (The name of model described will be mentioned in the description).

To help you identify components and understand the correct procedures of disassembly and assembly, exploded diagrams are provided. Steps in the procedures are numbered thus: 1), 2), 3), Parts shown in the illustrations are identified thus: W, (V, @.

REFERENCES These have been kept to a minimum; however, when you are referred to another section of the manual, you are told the page number to go to.

WARNINGS, CAUTIONS AND NOTES Attention is drawn to the various Warnings, Cautions and Notes which distinguish important information in this manual in the following ways.

A

WARNING

CAUTION: NOTE:

A WARNING indicates special procedures which must be followed to prevent personal injury or damage to the equipment.

A CAUTION indicates special procedures which must be followed to prevent damage to the eQui pment.

NOTE provides key information to make procedures easier to perform or clearer to understand.

, 1

_ . ' __________________ HOW TO USE THIS MANUAL II_ GNEFONI~I 1

2

SYMBOLS

3

4

CD

1~~!11 ISPEC! r;t-I

Symbols T' to (~> are designed as thumb-tabs to signal the content of a chapter:

®

I;RE:c!§t IIFUELI.I IPOWR!al ILOWR! ~ I IBRKTI1I.' IIELECI.1 5

@ \:4) @

®

6

7

(J)

@ CID

General Information Specification General Service Fuel System Power Unit Lower Unit Bracket Unit Electrical System Trouble-shooting

8

9

IJ~¥~!

10

12

14

16

?•

~

I 11

§

13

~

15

1

m

17

Symbols @ to

~ ~

I I

®

indicate specific data:

Recommended fl uid , Lubricant 1 Engine speed Tightening torque 1 Wear limit, Clearance 1 Resistance (0), Voltage (V), Electric current (A)

[I]

Symbols ® to @ in an exploded diagram indicate grade of lubricant and location of lubrication point:

1 -m

I

Apply Yamalube two--cycle outboard oil 1 Apply Yamaha gear-case lube , Apply Yamaha marine grease (All purpose)

18

~Mi'L-

Symbols @ to ® in an exploded diagram indicate grade of sealing or locking agent, and location of application point: @ Apply Gasket maker®

® Apply Loctite® NOTE: ________________________ In this manual, the above symbols may not be used in every case.

'-2

N GNEFO

II

I -'I I--------------------------------------------------I

IDENTIFICATION

A600051'

IDENTIFICATION SERIAL NUMBER The serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket.

NOTE: _______________________

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

Model name 2 Approved model No .

3 Transom height @ Serial number

$

.JAPON

ENGINE SERIAL NUMBER The engine serial number is stamped on the starboard side of the cylinder body.

STARTING SERIAL NUMBERS The starting serial number blocks are as follows:

CV115E L: 320363-

'-3

N GNEFO I

II

-9I

A 70000¡ 1

I---------------------------------------------------SAFETY WHILE WORKING

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

1. While working, maintain good standards of personal and industrial hygiene.

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

3. Avoid skin contact with lubricants; do not, for example, place a soiled wiping-rag in one's pocket.

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

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

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

FIRE PREVENTION Gasoline is highly flammable.

Petroleum vapour is explosive if ignited. Do not smoke while handling gasoline, and keep it away from heat, sparks, and open flames.

VENTILATION Petroleum vapour is heavier than air and if inhaled in large quantities will not support life.

Engine exhaust gases are harmful to breathe.

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

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

GOOD WORKING PRACTICES 1. The right tools Use the special tools that are advised to protect parts from damage. Use the right tool in the right manner - don't improvise.

2. Tightening torque Follow the torque tightening instructions.

When tightening bolts, nuts and screws, tighten the larger sizes first, and tighten inner-positioned fixings before outerpositioned ones.

3. Non-reusable items Always use new gaskets, packings, O-rings, split-pins and circlips etc on reassembly.

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

Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is allimportant, and by adopting good safety practises. any risk is minimised. A summary of the most important precautions is as follows:

DISASSEMBLY AND ASSEMBLY 1. Clean parts with com pressed-ai r on disassembling them.

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

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

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

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

1-4

II

N GNEFO

I

-'I1

ABOOOO·O'

I---------------------------------------------------SPECIAL TOOLS SPECIAL TOOLS

The use of correct special tools recommended by Yamaha will aid the work and enable accurate assembly and tune-up. Improvisations and use of improper tools can cause damage to the equipment.

SPECIAL TOOLS FOR TUNE-UP TOOL NAME

NO.

PART NO.

1

Compression gauge

YU-33223-1

2

Tachometer

YU-8036-A

3

Digital multimeter

YU-34899-A

4

Timing light

YM-33277

5

Dial indicator

YU-3097

6

Test propeller

YB-1624

SPECIAL TOOLS FOR ENGINE SERVICE TOOL NAME

NO.

PART NO.

1

Engine lifting hook

YB-6202

2

Connecting rod bearing installer

YB-6240

3

Crankshaft bearing installer

YB-6205

4

Oil seal installer

YB-6195

5

Driver handle

YB-6071

6

Piston slider

YB-34454

7

Flywheel magneto holder

YB-6139

8

Flywheel magneto puller

YB-6117

9

Micrometer (75'" 100 mm)

YU-3009

10

Calipers (0 -- 200 mm)

YU-3005

11

Feeler gauge (in)

YU-26900-8

12

Feeler gauge (mm)

YU-26900-9

13

Cylinder bore gauge (50'" 100 mm)

YU·3017

SPECIAL TOOLS FOR LOWER UNIT SERVICE PART NO.

TOOL NAME

NO.

1

Gland nut wrench

YB-34447

2

Bearing housing puller (Hook)

YB-6207

3

Drive-shaft holder

YB-6201

4

Slide hammer

YB-6096

5

Drive-shaft pu Iler

YB-34449

6

Needle bearing installer and remover

YB·6194 1-5

_ . I __________________ SPECIAL TOOLS IIGNEFONI~I

.

PART NO.

TOOL NAME

NO.

YB-6219

Bearing splitter

7

-Needle bearing installer and remover

8

YB-6196 ~"'~~--

YB·34432

Pinion shim selecting tool

9

---------

-.~---.-

10

Forward gear shim selecting tool

Y8-34446

11

Needle bearing and tapered roller bearing installer

YB-6200

Oil seal installer

YB·6195

Reverse gear shim gauge

YB-34468-A

12

I

13 14

I

Y8-6213

Drive-shaft needle bearing depth stopper

15

Bearing cup installer

16

Backlash adjusting plate

I I

YB-6199 YB-7003

".~-

YU·34481

17

Magnetic flexible dial base

18

Backlash indicator gauge

Y8-6265

19

Micrometer (0'"'-' 25 mm)

YU-3006

i

SPECIAL TOOLS FOR POWER TRIM AND TILT SERVICE TOOL NAME

NO.

PART NO.

1

Trim and tilt cylinder wrench

YB·6175

2

Trim and tilt oil pressure gauge

YB·6181

3

Union seat seal installer

YB·6188

SEALING AGENTS AND LUBRICANTS NO.

TOOL NAME

PART NO. (U.S.A)

PART NO. (CANADA)

1

Gasket maker

907 -907 40-01 -00

90790-74001-00

2

Marine grease

LUB-GREAS-14-00

ACC-11000-90-00

3

Power trim and tilt fluid

LUB-PWRTF-11-00

4

Gear case lube

LUB-GEAR L-ll-DO

ACC-l1000-85-00

5

Yamalube two cycle outboard oil

ACC-11000-07-01

ACC-1l000-20-12

1-6

CHAPTER 2 SPECIFICATION GENERAL SPECIFICATIONS ..................................

2-1

MAINTENANCE SPECIFICATIONS. . . . . . . . . . . . . . . . . .. . . . . .. . . . ..

ENGINE. . . . .. . . .. . . . . .. . . .. . . . . . .. . . . . . .. . .. . .. . . . . .. ...

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

DIMENTION 1 ........ , .. . . .. . .. . . . .. . . .. . . .. .. .. . . .. . . . ..

DIMENTION 2 • . . . . . . .. . • . . .. . . . . . . . . . . . • . . • . . . . • . . . . • • . ••

2-3 2-3

2-5 2-7 2-9

TIGHTENING TORQUE . ...................................... 2-10

ISPEC [ ,.,.. [

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Model

Unit

CV115E

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) kg (Ib) kg (Ib)

828 (32.S) 602 (23.7) 1,437 (56.6) 1,564 (61.6) 508 (20.0) 635 (25.0) 156 (343.2) 160 (352.0)

kW/rpm (PS/rpm) rpm

84.6/5,500 ( 115/5,500) 4,500 ~ 5,500

Speed range at idling

rpm

700 -- 800

Speed range at troling

rpm

600 - 700 49 ( 12.9)

Overall length Overall width Overall heigh t Boat transom height

(L) (UL)

(L) (UL)

Weight (Aluminum prop.) (L) (UL) Maximum output Speed range at full-throttle

( /h (US gal)

Maximum fuel consumption

Engine type Number of cylinders Total displacement

(Imp gal)

(10.8)

stroke

2 4 1,730 (105.57) 90 x 68 (3.54 x 2.68) 5.7 * B8HS-10 (NGK) ** BRBHS-10 (NGK)

cm J (cu. in) mm x mm (in)

Bore and stroke Compression ratio Spark plug

I I

Number of carburetor Carburetor starting system Intake system Scavenging system

I I I

Exhaust system Lubrication system Cooling system Ignition system Starting system Fuel Fuel tank capaci ty

((US gal)

Propeller boss Oil injection Water C.D.1.

Electric Regular gasoline 24 (6.34)

(Imp gal)

(5.27)

I

i I

(Option)

2 Choke Reed valve Schnurle (Loop charge)

Yamalube two cycle

Engine oil type

*Plug cap without resistance * * Plug cap with resistence 2-1

ISPECI rr--I

GENERAL SPECIFICATIONS

Item Gear oi I type Gear oil quantity Trim angle (at 12° transom) Tilt-up angle (from transom) Steering angle Transmission Gear ratio Reduction system Clutch type Propeller direction (rear view) Propeller drive system Propeller type Propeller No. balance x diameter x pitch

Model Unit

cm 3 (US OZ,lmp oz) Degree Degree Degree

CV115E Hypoid SAE =:: 90 790 (26.69, 27.82) -4 - 16 78 70

F-N-R 13/26 (2.0) Spiral bevel gear Dog clutch Clockwise Spline K,P (3 x 12,5/8" x 21"

inch

~K)

(3 x 13" )( 19" -K) (3 x 13" )( 23" ~K) (3 x 13" x 25" -K)

Stainless steel: (3)( 13" )( 17" -K) 13" x 19" ~K) 13" x 21" -K) 13" x 23" -K) 13" x 25" -K) 13-1/2" x 14" -K)

(3 x 13-' /4" x 17" -K) (3 x 13-1/2")( 15" -K) (3)( 13-5/8")( 13" -K)

(3 x (3)( (3 x (3 x (3)(

(3 x 14" x 11" -K)

13 x 13-1/2" x 16" -K)

High performance; (3 x 14" )( 20" -P) (3 x 14" x 22" -P) (3 x 14" x 24" -P) (3 x 14" )( 26" -P) (3 x 14" x 28" -P)

2-2

ISPECi f1"'" I MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Unit

Item

Cyl i nder head Warpage limit

Cylinder Bore size Taper limit Out of round limit

EB

Piston Piston to cylinder clearance ( Regulation) Over size Piston size "0"

0.1 (0.0039)

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

90.00 -- 90.02 (3.543 -- 3.544) 0.08 (0.0031) 0.05 (0.0020)

mm

0.080 '" 0.085 10.0031 ,... 0.0033) 90.50 (3.563) 89.92 -- 89.94 (3.540 -- 3.541) 10.00 (0.394)

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

Piston ring Type (Top, 2nd) Sectional sketch "B" (Top, 2nd) Sectional sketch "T" (Top, 2nd)

mm (in)

mm (in)

mm

End gap (Top, 2nd)

CVl15E

mm (in)

(in)

Measuring point IIH"

Model

(in)

!

2·3

Keystone 1.97 -- 1.99 (0.078)

2.70 ..... 2.90 (0.106 - 0.114)

0.30 -- 0.40 (0.0118 - 0.0157)

ISPECI rr-I Side clearance

MAINTENANCE SPECIFICATIONS

Item

Unit

(Top, 2nd)

mm (in)

1------

Madei

CV115E

0.02~' 0.06 (D. 0008 ",-, 0. 0024)

- - -..""----..- . - - - - . - - - - -.. -----4!----""".-.-.. "-",,------,,,,··,,1

Crankshaft Maximum deflection Connecting-rod Side clearance Axial play

mm (in)

0.02 (0.0008)

"-.------"---."".."""-+--.----"--".-.".-.. -",,., ...-.,,--t"-·--------"--·-_·,,··,,··,,·,,·,, "-"'''-''---''''''-''''''''''''_.. "... "-""",,.,,-,,--1

mm (in) mm (in)

0.20"'" 0.32 (0.0079 '" 0.0126) 2.0 (0.079)

_ . . -.. . . ". . .,,_"~---,,_.-.-._-._._-_ _ _ _ _--+-_._""--..-.. . ----.--!---------.-,,--,,-,,-.-.--.-,,--..- - - - f Carburetor Stamp mark Main jet Main air jet Pilot jet Pilot air jet Pilot screw turns out Float height

Valve seat side dia.

Idling-speed Trolling-speed Reed valve Valve stopper height

Maximum reed warp

# #

6E5-12 180 290

78 60

# # turns mm (in)

4.0 (0.16)

mm (in) r/min

1.2 (0.05) 700 ", 800

r/min

600 -- 700

mm

6.2"-' 6.8 (0.244 '" 0.268) 0.9 (0.035)

5/8

±

1/4

_ _ _......- - - - -...m··f·-··,,·--...........;--····"··m.".."... --f-- ..----------"""."..".-.------.---..- - - - - -..""'",,.----~

(in) mm (in)

2-4

ISPECi ~ I MAINTENANCE SPECIFICATIONS ELECTRICAL Item

Model

Unit

CV115E ~+---------.---.~

. . . . . - -..--..-

Ignition system Ignition timing (at idling) Ignition timing (at full throttle) Piston position (at full throttle)

5±1 25 ± 1 3.91 ± 0.20 (0.154 ± 0.008) 4± 1 840'" 1,260

degrees ATDC degrees BTDC

mm BTDC (in BTDC)

Cam roller pick-up timing Charging coi I resistance 0 at 20°C (68 F)

degrees A TOC

n

(Brown - Red)

102'" 153 Pulser coi I resistance at 20°C (68° F) Ignition coil resistance 0 at 20°C (68 F) (Primary) Ignition coil resistance at 20°C (68° Fl (Secondary) Spark plug gap

(Black/Red

Blue)

288'" 432 0.2'" 0.3 kn

2.0 - 3.0

mm (_in_)_

0.9'" 1.0

L . .__{_0_.0_3_5_"'"'_0_,_03_9_}_ _ _

.. _ .

--4

COl unit Black/White 'L {B/W (1)

Brown (Brl

Black/White 2· (B!W2.)

Blue (L)

Black/White ·3' (B!W (3')

Red IR)

Black/White (4) (B/W 14})

Black/Red (BIR) White/Red (WIR) White/Bldck

:WiBI

White/Yellow (WlY) White/Green (WIG)

Over-rev.

Qround

OR 105--

195 '3757 68-

(5) II\I/R

e·

4872 140--

102

260

'3757

4872

3654

112208

II\IIS

7. II\IIY

14 P

15 B

11 H111l

If, OR

1. When making this resistance test, disconect the lead from the over rev, terminal.

2. The asterisk (.) indicates that the tester needle should swing toward "0" and slowly swing back to stay at the specified value.

2-5

ISPECi ~ I MAINTENANCE SPECIFICATIONS Item

Model

Unit

CVl15E

Lighting system Lighting coi I resistance

n

0.48 - 0.72

sec. kW

1.1

mm (in) mm (in)

Overrunning 16(0.63) 12(0.47)

n

2.4 -- 3.6

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

0.5 -- 0.8 (0.020 -- 0.031) 0.2 (0.008) 33 (1.30)

mm (in)

31 (1.22)

mm (in)

2.5 - 5.0 (0.098 "" O. 197)

Ampere

20

n

3.5 --- 3.9

Starter motor Rating Output Clutch type Brush length Brush wear limit Starter reley solenoid coil resistance at 20° C (68° F) Commutator under cut Commutator under cut repair Commutator outside diameter Commutator outside diameter repair limit

Pinion/Ring gear gap

30

Others Fuse Choke solenoid resistance at 20°C (68° F)

Rectifire regurator

W

Rectifier check

'~

CD

Black

CD

Black

~"

'~

(2)

@

Green

Red

Conti· nuity

Contj· nuity

Green

Dlscontl· nuity

~""""-~

Conti· nuity

@ Red

Disconti· nuity

Disconti· nuity

"~

@

2·6

ISPECI r;r-I

MAINTENANCE SPECIFICATIONS

DIMENTION 1

A

2-7

ISPECi ~I __M_A_IN_T_E_N_A_N_C_E_S_PE_C_IF_I_C_AT_I_O_N_S__________ Model

Unit

Symbol (Used in diagram)

CVl15E

,A (Max)

degree

35

81 (Max)

degree

78

82 (Max negative trim angle)

degree

4

mm (in)

482 (19.0)

(L)

mm (in)

515 (20.3)

(UL)

mm (in)

642 (25.3)

C 0

301 (11.9)

E

mm (in)

F

mm (in)

424 (16.7)

G

mm (in)

79 (3.11 )

H

mm (in)

347 (13.7)

I

I

(L)

mm (in)

840 (33. 'I)

J

( L)

mm (in)

929 (36.6)

K

mm (in)

508 (20.0)

L

mm

730 (28.7)

(in)

M

mm (in)

N

mm (in)

539 (21.2)

0

mm (in)

213 (8.39)

mm (in)

616 (243)

p

I

I :

a R (Twin engine center to center distance)

degree

I

mm (in)

2¡8

660 26

ISPECI rr--I

MAINTENANCE SPECIFICATIONS

DIMENTION 2

H I

4J\.-1----+ -I+I-~-J-

J

-+l+-J----+ K

M

N

p

Unit

Item Engine mounting position

Model

CV115E "A" H'B" "C'" I.fO" I/E'I

I'F" I'G'I

4'H'" "1'"

I'J'I 1'K" "L'I liM" '''N'l

1'0'" "P" "0" i/R

il

"S'" "T"

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

2-9

--

--

--

--

---

50.8 (2.0) 69.3 (2.7) 87.8 (3.5) 106.3 (4.2)

-254.0 (10.0) 309.5 (12.2) 165.1 (6.5) 127.0 (5.0)

--13.0 (0.51) 12.7 (0.50)

ISPEC\ ~ I MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE Part to be tightened

Part name

Thread size

O'ty

Bolt

Ml0 x Pl.25

6

Tightening torque Nm

Remarks

m-kg ft.lb

ENGINE: 1st Crankcase

2nd 1st

Bolt

20

2.0

40

4.0

29

10

1.0

7.2

1.8 .

13

1.5

11

3.0 --

22

0.4

2.9

M8 x Pl.25

8 18 --- - -1st 15 Cylinder head Bolt M8 x P1.25 20 2nd 30 ,-,- --,--"'-- >------,---_._,", "-1-'- ,-, 1st 4 23 I Exhaust cover Bolt M6 x Pl.0 ! 8 2nd I ---,-Flywheel Nut 1 i 160 2nd

"'"

--~--,-

..

---,

.

--

~

Intake manifold

--

~-~----

2nd 1st 2nd

Electric motor mounting

21

-

6

.-._-

Bolt

M6 x Pl.0

4

Bolt

M6 x Pl.0

12 '

-

Apply lOC-TITE

25

2.1 2.-5

4

0.4

15 I 18'---

!

---h-

0.8

29 I .

Apply LOC·TITE 5.8 '

0.4

2.9

0.8

5.8

3

1 8 30

3.0

22

1

15

1.5

11

M 10 x P1.25

2

55

5.5

40

75

7.5

54

M8 x P1.25

Bolt

--.",'~-,

I

I

~: f~M-t ~Pply-OIL

-

Spark plug 1st

,

~~.

Bolt, nut I M8 x Pl.25

Power unit

Thermostat cover

~~

"

-.~

I

"-~~~-~--

15

Apply SCREW LOCK

UPPER CASE AND GEAR CASE: Nut

Bracket bolt Upper side mount rubber

Nut

-

---~

~

Lower side mount rubber

Nut

M14xPl.5

2

Pinion nut

Nut

-

1

95

9.5

69

Ring nut

Nut

-

1

145

105

Lower case mounting

Bolt

7

40

14.5 4.0

1

55

M8 x Pl.25 -----.~-

Propeller

-

Nut

I--

29

Apply LOC-TITE

,.

5.5

40

85

8.5

62

85

8.5

62 3.6

POWER TRIM AND TILT: Tilt cylinder end screw Trim cylinder end screw

--I-

--

~--------

Reservoir plug

Bolt

Through-bolt

Bolt

Grommet bolt

-

Power trim and tilt unit mounting

Bolt

-

---

----

..

1 ~

-~--.

,

..

---

--

2

""-

"-_.

-- -

1

5.0

0.5

2

4.0

0.4

1

13

---

r-

t---- ,. -- 1 - - - - 1--

M8 x Pl.25

6

2.9 9.4

---

3.5

Nut A

80lt 8

8mm mm mm mm mm

M5 M6 M& M10 M12

10 12 14 17 2-10

35

1.3.------

-- ..

_.-----

,-

-

25

I

<------

I Apply

LOC-TITE

General torque specifications m.kg ft·lb Nm

5.0 8.0 18 36

43

0.5 0.8 1.& 3.6 4.3

3.6 5.8 13 25 31

D10005 O'

CHAPTER 3 GENERAL SERVICE PREDELIVERY SERVICE .......................................... 3-1 CONTENTS .................................................. 3-1 ELECTRIC WIRING ........................................... 3-2 FUEL LINE .................................................. 3-5 GEAR OIL LEVEL ............................................. 3-6 OPERATION OF CONTROLS AND MOVING PARTS ................ 3·6 FUEL LEAKAGE .............................................. 3-7 WATER LEAKAGE ....................................... ·····3-7 EXHAUST LEAKAGE .......................................... 3-7 ENGINE AND LOWER UNIT NOISE .............................. 3-7 IDLE·SPEED ......................................... - ....... 3-7 IGNITION TIMING ............................................ 3-7 MOTOR EXTERIOR ........................................... 3·7 INSTRUCTING THE NEW OWNER ............................... 3-7

PERIODIC SERVICE .............................................. 3-8 MAINTENANCE SCHEDULE .................................... 3-8 ANODE ....... , .......................................... · .. 3-8 BATTERY ................................................... 3-9 CARBURETOR .............................................. 3-10 CARBURETOR LINK ......................................... 3-10 CARBURETOR PICKUP TIMING ................................ 3-11 CYLINDER HEAD BOLTS, ENGINE MOUNTING BOLTS, AND FLYWHEEL NUT ............................................ 3-11 FUEL FILTER ............................................... 3-12 FUEL TANK AND FUEL LINE .................................. 3-12 GEAR OIL .................................................. 3-12 GREASE POINTS ............................................ 3-12 IDLE-SPEED ................................................ 3-13 IGNITION TIMING ADJUSTMENT· ............................. 3-13 OUTBOARD MOTOR BODY ................................... 3-17 POWER TRIM AND TILT FLUID ................................ 3-18

PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-18 SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 18

I;R;~ltill __PR_E_D_E_L_IV_E_R_Y__SE_R_V_I_C_E________________ 020005-0'

PREDELIVERY SERVICE CV115E 1 2 3

4

5 6 7

8 9 10 11 12 13

Contents Electric wiring Fuel line Gear oil level Operation of controls and moving parts Fuel leakage Water leakage Exhaust leakage Engine and lower unit noise Idle-speed Ignition timing Motor exterior Instructing the new owner

Refer page

3路1 3路2 3-5 3路6 3-6 3-7 3-7 3-7 3-7 3-7 3-7 3-7 3路7

,_/

,,-. ,~,

0

(--

J

...J

021000-0'

CONTENTS On unpacking, check that all accessories to the model are included.

CVl15E

Outboard motor Fuel tank Remote control box Remote control cables Service tools Emergency starter rope Tachometer Trim meter Wi re harness and cables Motor mounting parts Stearing guide attachment Spare spark plug Owner's manual Option

3-1

f

;:~cl§t

I

PREDELIVERY SERVICE

022000·0

ELECTRIC WIRING Check that all leads and connectors are properly connected.

Lead wire

Spaire fuse

Fuse

A: To trim meter B: To battery C: To battery (B' D: To wire harness

L : Blue R : Red

B : Black G : Green Br : Brown Sb : Sky blue

Lg : Light green 3-2

1;:~cIยงt

I

PREDELIVERY SERVICE

-------------------------------------------------------

AtB ~_ 10P Consent A G~~Y_ I"/_G pBP Lg , Br '--L '-Br

'W~.L:g

B~

~

8-'

R : Red B : Black G : Green P : Pink 0 : Orange W : White L : Blue Br : Brown Gy . Gray B/W: B lack/White W/R: White/Red B/R: Black/Red W/B: White/Black W/Y: White/Yellow W/G: White/Green

3-3

A: To trim meter B: To battery 8 c: To battery CB 0: To wire harness E: To ignition coil F: To remote control box G: To tachometer

PREDELIVERY SERVICE 1;:~cI§t I--------------------------------------------

Gy : Gray R

: Red

P

: Pink

B : Black B/W: Black/White

3·4

I;:~clยงt I

PREDELIVERY SERVICE

022500-0

FUEL LINE Check that the fuel line is correctly installed.

3-5

1;:~cl~I __PR_E_D_E_L_I_V_E_R_Y_S_E_R_V_IC_E_________________ D23ooo¡0

GEAR OIL LEVEL

Remove the oil-drain and oil-level plugs, and add the gear oil through the oil-drain hole until it overflows from the oil-level hole. Re-fit the plugs. (The oil level plug first).

D235oo¡,

OPERATION OF CONTROLS AND MOVING PARTS

1. Check for correct operation of the shift control.

2. Check for correct operation of the tilt-lock mechanism.

3. Check for smooth operation of the steering control.

4. Check for smooth operation of the throttle control.

5. Check for correct operation of the spark advancer.

6. Check for correct operation of the power trim and tilt unit.

7. Check for correct operation of the choke system.

8. Noting the following WARNING and CAUTION, check for correct operation of the starting system.

A WARNING Before attempting to check the starter system, replace the propeller with the specified test propeller, and make the tests with the motor placed in a test tank.

CAUTION: Use a 50 : 1 gasoline-oil mixture to start the engine.

3-6

9. Check for correct operation of the engine stop system.

I;:~cl§t I PREDELIVERY SERVICE D24500-0

FUEL LEAKAGE Check for fuel leakage.

D25000-0

WATER LEAKAGE Check for water leakage.

D255OO-0

EXHAUST LEAKAGE Check for exhaust leakage.

D26ooo-0

ENGINE AND LOWER UNIT NOISE Check the engine and lower unit for abnormal noise.

D26505-0

IDLE·SPEED Check that the engine speed at fully-closed throttle is correct. Refer to page 2·' .

027005-0

IGNITION TIMING Check that the ignition timing at fully-closed and fully-open throttle positions is correct.

Refer to page 2-5.

D27500-0

MOTOR EXTERIOR Check the motor exterior for any flaking of the paint, and if necessary touch-up with paint of the original colour.

D28000·1

INSTRUCTING THE NEW OWNER Instruct the new owner on the operation of all controls and the break-in procedure. Also advise him on propeller-to-boat matching.

3-7

I;:~cI §t I

PERIODIC SERVICE

030005·0'

PERIODIC SERVICE MAINTENANCE SCHEDULE The following chart may be taken as a helpful guide to the intervals between maintenance procedures.

~

Item Anode Battery Carburetor Carburetor link Carburetor pickup timing Cylinder head bolts, engine mounting bolts, and flywheel nut Fuel filter Fuel tank and fuel line Gear oil Grease point Idle-speed Ignition timing Outboard motor body Power trim and tilt fluid Propeller Spark plug

Initial 10 hours (Break-in)

50 hours (3 months)

Every 100 hours 200 hours (1 year) (6 months)

·

.: (every -. month)

,

3-8 3-9 3-10 3-10 3-11

-

~

·

- J ~.

'-'-

--

..

"

~

Refer page

·

"

I !

3-11

I!

.-,

.--

--,

I

i

.-'

,j

I

..

-,'

-

I

..

-

--

~

j

i

..

./

~

.J

./

..

-

--

I

I I

I

I

I

I

i

I

I

3-12 3-12 3-12 3-12 3-13 3-13 3-17 3-18 3-18 3-18

D3HlOO-O

ANODE Inspect the anode. If it is worn out, replace it with a new one. If scaling of the surface is evident, remove the anode and clean it with a wire brush, and remove all trace of oil or grease. After cleaning, polish the contact surfaces of the anode mount, and re-install.

CAUTION: Never paint the anode. To ensure good electri· cal contact, keep the anode contact surface clean of oil or grease.

3-8

~s~GR~;~~~'*~~~~~I __PE_R_IO_D_IC__S_E_RV_IC_E______________________ NOTE: _____________________________________________________

03,300 C'

BATIERY

Replace the battery if: 1. The voltage does not rise to an open-circuit value of at least 2.2 volts per cell, or bubbles fail to rise even after many hours of charging; 2. The plates show a whitish colour, or there is an accumulation of material in the bottom of the cell, indicating that sulphation of one or more cells has occurred; 3. Specific gravity readings after a long slow charge indicate one or more cells to be lower than the rest; 4. There is visible warping or buckling of plates or insulators in any cell.

Recommended battery capacity: Rating ......... 12V 70AH (252 kC) Minimum cold crank performance ........ 380 Amps at -17.8°C (0 F) Minimum reserve capacity: ...... 124 minutes at 26.7°C (80°F) 0

1) The electrolyte level should be between the upper and lower level marks. Top-up with distilled water.

CAUTION: Water other than distilled water contain miner· als which are harmful to the battery; top up only with distilled water.

A

WARNING

Battery electrolyte contains sulphuric acid which is poisonous and corrosive, ie., it can cause skin bums and damage to eyes. Avoid all contact with the skin, eyes, or clothing.

First Aid: Eyes: flush with water for fifteen minutes (if necessary holding the eye open with clean fingers), and get prompt medical attention.

Internal: Do not make the casualty vomit. Give plenty of water to dilute the acid. Add if possi· ble, 2 tablespoons of chalk, milk of magnesia, plaster or whitewash to a pint of water.

Skin bums: Thoroughly flood the part with water. Remove contaminated clothing. Bathe the part in an alkaline solution such as two teaspoons of baking soda (bicarbonate of soda) or washing soda (carbonate of soda) to one pint of warm water.

Batteries produce explosive gases. Keep sparks and flames away. Do not smoke where batter· ies are charged or stored. Ventilate the area when charging or using batteries in any enclose space.

KEEP BATIERIES AND ELECTROLYTE OUT OF THE REACH OF CHILDREN.

2) Before first use, the battery must receive its initial electrical charge.

CAUTION: Failure to initially charge the battery before first use, or allowing the electrolyte level to be be· low the lower level mark will cause premature failure of the battery.

Charging: Charge at 4.0 amperes for 10 hours or until the specific gravity reaches 1.280 at 2O-deg.C (68-deg.F).

3) Thoroughly clean the battery terminals, and tightly connect the leads to the terminals.

Lightly grease the terminals and connectors with petroleum jelly.

CAUTION: 1. When removing the battery disconnect the negative terminal (Black lead) first.

2. When installing the battery connect the positive terminal (Red lead) first.

3-9

I;:~cI §t I

PERIODIC SERVICE 031600-0

CARBURETIOR 1) Check the fuel passages and air passages for fouling or clogging. Clean fouled parts with suitable cleaning solvent and blowout clogged passages with compressed air.

2) Check the needle-valve for wear, and replace it if worn.

031905·1

CARBURETOR LINK 1) Loosen the roller adjusting screw (clockwise) and the throttle arm adjusting screw (clockwise).

2) Loosen the idle adjusting screw.

NOTE: _________________________ Make sure that the all throttle valves are fully closed.

3) With the throttle valves of the upper and lower carburetors being full-closed, tighten the roller adjusting screw and the throttle arm adjusting screw.

NOTE: _______________________ Remove the play of the throttle link and throttle arm ball joint so that the upper and lower throttle valves operate simultaneously.

4) Tighten the idle adjusting screw into the original position.

CD

Throttle arm adjusting screw Roller adjusting screw @ Idle adjusting screw

®

NOTE: _______________________ 1. After adjusting the carburetor link, make the pickup timing adjustment.

3-10

I;:~cI tit I

PERIODIC SERVICE 031700-1

CARBURETOR PICKUP TIMING NOTE: ________________________

Before adjusting the carburetor pickup timing, be sure to adjust the carburetor link and ignition timing.

1) Remove the throttle cam control link.

2) Turn the flywheel rotor so that the timing plate points to 4-degrees ATDC. 3) Align the marking on the pulser assembly arm with the timing mark on the flywheel rotor.

~ ---~-

T fJC 1 i.I..

1

10

Il~J--

~

ff7

-

I

~

---

"' ..

4) Once loosen the roller adjusting screw, and tighten it so that the marking position on the throttle cam comes in contact with the roller.

NOTE: _______________________

Use care so that the throttle valve does not open during operation in step 4 above.

5) While keeping the throttle cam in the position specified in step 4 above, adjust the length of throttle cam control link and install the link.

D32()()()¡0

CYLINDER HEAD BOLTS, ENGINE MOUNTING BOLTS AND FLYWHEEL NUT 1) Retighten to specifications.

2) Check other fixings and tighten if necessary.

3-11

D32300·0

FUEL FILTER Clean the strainer of dust and impurities .

.;::;c··· .. ,.···

_._.

,

..

032600-0

FUEL TANK AND FUEL LINE 1) Check the fuel tank and fuel line for leaks.

2) Clean the fuel tank thoroughly.

D32905-0

GEAR OIL 1) Drain the gear oil thoroughly, and pour in new oil.

2) Check for water or metallic sediment in the drained oil.

NOTE: _______________________ If the gear oil becomes "milky", check the gear case oil seals for water entry.

D33150-0 ....

__..

GREASE POINTS

_-----...,

3·12

I;i~cI §t I

PERIODIC SERVICE 033005·0'

IDLE·SPEED NOTE: _______________________

Before making idle-speed adjustment, be sure to adjust the ignition timing properly_

1) Tum out each pilot screw to specification from completely tightened position.

CAUTION: Be careful not to tighten the pilot screw too much, or its end could be damaged.

Tum out:

518 Tums

2) Screw in the idle adjusting screw 1-1/8 tums from the position at which the throttle valve begins to move.

3) After warming up the engine, check that the idle speed is within specification. If out of specification, adjust it by tuming the idle adjusting screw.

Iell

kIkHpeect 700 - 800 rpm

033305'()'

IGNITION TIMING ADJUSTMENT Timing plate adjustment 1) Install a dial-gauge in the spark-plug hole of No.1 cylinder.

NOT~

_______________________

For easy timing-plate adjustment, it is advisable to. remove the spark plugs from all the cylinders.

3-13

I;:~cl§t

I

PERIODIC SERVICE 2) Slowly turn the flywheel CLOCKWISE, and set the piston at following position.

CAUTION: Be sure to tum the flywheel clockwise, or the impellor blade will be twisted the other way, thus reducing pump performance.

Piston position: 3.91 mm BTOC

3) Set the timing-plate at following position.

Timing plate position: 25-degrees BTOC

NOTE: _______________________ After tightening the screw, paint over the screwhead to discourage tampering with the adjustment.

3¡14

1;:~cI§t I PERIODIC SERVICE Not use a timing light 1) Adjust the lengths of the magneto control link and throttle cam control link to specifications.

Magneto control link length CD: 60.0 mm (2.36 in) Throttle cam control link length @: 53.0 mm (2.09 in)

2) Tum the flywheel rotor so that the timing plate points to 5-degrees ATDC.

3) Adjust the length of the fully retarded adjusting screw so that when the fullyretarded adjusting screw contacts the stopper, the marking on the pulser assembly arm aligns with the timing mark on the flywheel rotor.

I~

=---1 ---- -----

---=00------

J:~-­ ~~ "9

NOTE: _______________________ The nut in the magneto control lever should be 2 mm (0.08 in) off from the end of the magneto control lever.

4) Turn the flywheel rotor so that the timing plate points to specifications.

Flywheel position: 2S-degrees BlOC

3·15

I::~cl §t I

PERIODIC SERVICE 5) Adjust the length of the fully-advanced adjusting screw so that when the magneto control lever contacts the fully-advanced 00justing screw, the marking on the pulser assembly arm aligns with the timing mark on the flywheel rotor.

~ I

--

Use a timing light NOTE: ______________________ _ Before adjusting, be sure to warm up the engine.

1) Check that the timing plate position is correct. (Refer to page 3-13.)

2) Adjust the lengths of both magneto control link and throttle cam control link to specifications.

Magneto control link length (f): 60.0 mm (2.36 in) ThroHle cam control link length 53.0 mm (2.09 in)

ÂŽ:

3) Clamp the timing light to the No. 1 cylinder high-tension cord.

3¡16

I;RE~cI tit I

PERIODIC SERVICE 4) While keeping the stopper in contact with the fully~retarded adjusting screw, measure the fully-retarded ignition timing with the timing light.

If the timing is out of specification, adjust it by turning the fully-retarded adjusting screw.

NOTE: ________________________ When measuring the ignition timing on the fully-retarded side, keep the specified idle-speed (Refer to page 2-1 ).

Fully-retarded side ignition timing: 5¡degrees ATDe 5) While keeping the magneto control lever in

contact with the fully-advanced adjusting screw, measure the ignition timing with the timing light.

If the timing is out of specification, adjust it by turning the fully¡advanced adjusting screw.

NOTE: ________________________ When measuring the fully-advanced ignition timing, shift into forward and keep the engine speed at 4,500 rpm or higher.

Fully advanced side ignition timing: 2S.cJegrees BTDC

D34500-0

OUTBOARD MOTOR BODY 1) Visually inspect the outboard motor body for crack or corrosion.

3-17

1;:~I~I __p_E_R_IO_D_I_C_S_E_R_V_IC_E____________________ D34605-0

POWER TRIM AND TILT FLUID 1) Tilt-up the motor, and lock it with the tiltlock lever.

2) Remove the fluid-level plug to check the fluid level, with the motor tilted-up. The fluid level should be immediately below the fluid level-hole. If the fluid level is low, top up with the recommended fluid.

3) Re-fit the fluid-level plug, and tighten it.

(J)

~~

~

â&#x20AC;˘V

Recommended fluid: Yamaha power trim & tilt fluid

034900-0

PROPELLER 1) Check the blades for wear, damage, cavitation erosion.

2) Check the splines for wear and damage.

D35000-0'

SPARK PLUG 1. Check the electrode condition and state of wear, note the insulator colour and the electrode gap.

2. Clean the spark plug with spark-plug cleaner if necessary. Use a wire gauge to adjust the plug gap to specification.

3. If the electrode becomes too worn, replace the spark plug.

4. When installing the spark plug, clean the gasket surface, wipe off any grime there may be on the surface of the spark plug, and screw in the spark plug to the correct torque.

Standard spark plugs: (Plug cap without NGK B8HS-10 resistance) NGK BR¡8HS10

art:::

(Plug cap with resistance)

Spark plug gap: 0.9 - 1.0 mm (0.035 - 0.039 in)

0.9-1.0 mm , (0.035 - 0.039 in) I

Tightening torque: 20 Nm (2.0 m.kg, 14 tt.lb)

......... ---...

3-18

E10005·1·

CHAPTER 4 FUEL SYSTEM FUEL SYSTEM . ................................................. 4.'

EXPLODED DIAGRAM ......................................... 4.'

REMOVAL ................................................... 4-' CLEANING AND INSPECTION ....... , .......................... 4.2 INSTALLATION ............................................... 4-3

CARBURETOR . ................................................. 4-4 EXPLODED DIAGRAM ......................................... 4-4 REMOVAL AND DISASSEMBLY ................................. 4-5 CLEANING .................................................. 4-5 INSPECTION ................................................. 4-5 ASSEMBLY AND INSTALLATION ................................ 4-7

IFUELI.I ----------------------------------------------------FUEL SYSTEM

E20005¡1

FUEL SYSTEM EXPLODED DIAGRAM

E21510¡0

REMOVAL

A WARNING 1. Fire Prevention Gasoline is highly flammable. Petroleum vapour is explosive if ignited. Do not smoke while handling gasoline, and keep it away from heat, sparks, and open flames.

2. Ventilation Petroleum vapour is heavier than air and if inhaled in large quantities will not support life. Engine exhaust gases are harmful to breathe. When test-running an engine indoors, maintain good ventilation.

3. Spillage Remember that fuel remains in the fuel hose between the tuel joint and the carburetor. Drain all remaining fuel out into a container, or soak it up with a cloth so that the fuel does not spill on to the bottom cowling.

4. Leaks Failure to check for and correct fuel leaks may result in fire or explosion.

1) Referring to the exploded diagram, remove the fuel line.

4-1

IFUEL I. I-----------------------------------------------FUEL SYSTEM

E2101O·0

CLEANING AND INSPECTION Fuel tank (Option) 1) Add a small quantity of a suitable cleaning solvent into the fuel tank and thoroughly clean the tank interior by shaking the tank.

2) Drain off the cleaning solvent completely.

E21020-0

Fuel meter complete 1) Using a soft brush and solvent, clean the strainer on the end of the suction pipe, and blow-dry it with compressed air.

2) Visually inspect the strainer for damage, and replace the fuel meter complete if reo quired.

3) Inspect the fuel meter components for cracks, and replace the fuel meter complete if required.

4) Re~install the fuel meter complete with the rubber gasket to the fuel tank, ensuring that there are no leaks between the fuel meter and the fuel tank.

E21030·0

Priming pump 1) Visually inspect for cracks or breaks in the priming-pump and fuel-hoses, and replace them if required.

2) Check the operation of the check-valve by blowing into the pump.

E21040·0

Fuel filter 1) Remove the filter-cup and filter.

2) Visually inspect the filter body for cracks or damage to the thread, and replace if required.

3) Using a soft brush and solvent, clean the filter element thoroughly. Inspect the filter element for breakage or distortion, and replace if required.

4) Using a soft brush and solvent, clean the filter-cup thoroughly. Inspect the filter-cup for cracks or thread damage, and replace if required.

5) Place the O-ring on the filter body, install the element, and screw in the filter cup.

4-2

IFUEL IwI

FUEL SYSTEM E21050-0

Fuel joints 1) Inspect the fuel joints for leaks and cracks, and replace as required.

E21060·0

Fuel pump 1) Using a screwdriver, disassemble the fuel pump.

2) Visually inspect the pump body for cracks, and replace if required.

3) Inspect the valves for cracks or distortion, and replace if required.

4) Inspect the diaphragm for sign of damage, perforation or stretching, and replace if required.

5) Assemble the fuel pump with new gaskets.

E22005·0

INSTALLATION 1) Referring to the exploded diagram, install the fuel system.

NOTE: ________________________

1. When connecting the fuel hoses to the fuel pump and fuel filter, follow the direction of flow indicated by the embossed arrows.

2. Place the clips in position, connect the hoses, and tighten the clips. Check for leaks.

4·3

I FUEL 'MOO

I~ I .'"

CARBURETOR

CARBURETOR EXPLODED DIAGRAM ~ Needle valve ~

Main jet @ Slow air jet

®

Main nozzle

@ Pilot screw @ Float

4-4

IFUELI.1 -----------------------------------------------------CARBURETOR

[31005-0

REMOVAL AND DISASSEMBLY

A

WARNING

At this step, ensure there is no spillage of gasoline on removing the connections.

1) Remove the silencer cover, disconnect the fuel hose, then remove the carburettor, 2) Referring to the exploded diagram, use a screwdriver to disassemble the carburettor.

E31500-0

CLEANING 1) Using solvent, clean the components thoroughly, and blow-dry them with compressed air.

A

WARNING

Protect your eyes with suitable safety spectacles or safety goggles when using compressed air. Protect your eyes and the eyes of other per¡ sons by directing the flow of compressed-air downward, noting that solvent and small parts may be blown off.

CAUTION: Do not use steel wire for cleaning the jets as this may enlarge the jet diameters and seriously affect performance.

E32005-1'

INSPECTION Carburetor body 1) Inspect the carburetor body for cracks or clogging of the passages,

4-5

IFUEL I â&#x20AC;˘

I

CARBURETOR Needle valve 1) Inspect the needle valve for free movement and wear, and replace if required.

Main jet 1) Inspect the main jet for wear and stuffing, and replace if required.

Slow air jet 1) Inspect the slow air jet for wear and stuffing, and replace if required.

Main nozzle 1) Inspect the main nozzle for wear and stuff¡ ing, and replace if required.

Pilot screw 1) Inspect the needle of pilot screw for wear, and replace if required.

4-6

IFUEL Iâ&#x20AC;˘ I

CARBURETOR Float 1) Visually inspect the float for damage or cracks, and replace if required.

2) Measure the float height. If it is higher or lower than the specified float height, recheck the valve seat and needle-valve.

Specified float height: 16.0 mm (0.63 in)

E33300¡1

ASSEMBLY AND INSTALLATION 1) Screw in the main nozzle until tight.

2) Install the needle-valve on the float, attach the float to the carburetor body with the float-pin.

3) Referring to the exploded diagram, assemble the carburetor.

4) Referring to the exploded diagram, install the carburetor assembly and the silencer to the intake manifold.

4-7

G 1000~O'

CHAPTER 5 POWER UNIT EXPLODED DIAGRAM .... ........................................ 5-1 PREPARATION FOR OVERHAUL . .................................. 5·3 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-4 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5·5 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-7 CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-7 CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-8 PISTON ..................................................... 5-9 PISTON RI NG ................................................ 5-10 PISTON PIN AND SMALL END BEARING ......................... 5-11 CRANKSHAFT ............................................... 5-11 REED VALVE ................................................ 5-12 THERMOSTAT ............................................... 5-12 BALL BEARING .............................................. 5-13 CRANK DISK SEAL RINGS ..................................... 5-13

ASSEMBLY AND ADJUSTMENT . ................................... 5-14 CRANKSHAFT ............................................... 5-14 PISTON ..................................................... 5-14 SMALL END BEARINGS AND PISTON ASSEMBLY ................. 5-15 CRANK UPPER BEARING HOUSING ...... , ...................... 5-16 CRANK LOWER OIL SEAL HOUSING ............................ 5-16 CRANK CYLINDER ASSEMBLY ................................. 5-16 CYLINDER HEAD AND EXHAUST COVER ........................ 5-20 INTAKE MANIFOLD ........................................... 5-21 DRAINLESS HOSES .......................................... 5-21 ENGINE STOPPER ............................................ 5-22

INSTALLATION . ................................................. 5-22

Ip~RI_I~EX~P~L~O~D~ED~D~IA~G~R~A=M_ _ _ _ _ _ __ G20000-0

EXPLODED DIAGRAM (C Cylinder cover (2) Exhaust cover

Bearing housing (4) Oi I seal housing

5--'

EXPLODED DIAGRAM

5-2

IpOWRlal

PREPARATION FOR OVERHAUL G30000-0

PREPARATION FOR OVERHAUL 1. Clean all dirt, mud, dust and foreign material from the engine before the engine is removed and disassembled.

2. To ensure that you can perform the work cleanly and effiCiently, check that you have the proper tools and cleaning equipment before commencing engine removal and disassembly.

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

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

5-3

Ip~RI_I_R_E_M_OV_A_L_________ G400050'

REMOVAL 1) Remove the electrical system parts referring to page 8·' .

2) Remove the fuel system parts referring to page 4·1.

3) Disconnect the hoses and control cabes referring to the illustrations.

4) Remove the apron and power installation bolts, and then remove the power head from the upper casing.

5) Using the special service tool. Insert the hoist hook the engine lifting hook, and lift up the power head.

YB-6202

A

WARNING

1. Make sure the clamp brackets are fasten to the repair stand.

2. The hoist rope must be free from damage and strong enough to lift up the power head. Should it break, you may get injured by the engine.

NOTE: _______________________ 1. Before lifting up, check to see that all bolts, pi pes and wi res are removed from the pow· er head.

2. Use care so that the power head is lifted up perpendicularly. Never lift it up di· agonally.

5·4

IPOWRlal

REMOVALIDISASSEMBL Y 6) The cylinder side of the engine is heavier.

So force a wooden bar into the bap be~ tween the exhaust cover and the bottom cowling when lifting up the power head.

CAUTION: When using the bar, be careful not to damage the bottom cowling.

G50005¡0

OISASSEMBLY Referring to the exploded diagram, disassem¡ ble the power head.

1) Drainless hose 2) Cylinder head, thermostat and thermosensor.

3) Exhaust cover and cyl inder cover 4) Bearing housing bolt and oil seal housing bolt.

5) Crank case 6) Connecting rod cap and needle bearing

NOTE: _______________________ Keep the connecting rod caps and needle bearings separately by each cylinder.

7) Crankshaft, seal ring and needle bearing

Ip~RI~I_D_IS_A_~_E_M_B_LY_ _ _ _ _ _ _ _ _ __ 8) Piston

~ ~

-$0 j ~--

()

NOTE: _________________________ ~

Keep the pistons, small-end needle bearings and connecting rods separately by each cylinder.

~e-I~

,

9) Crank lower bearing and oil pump drive gear Using special service tool and press.

YB-6219

~

10) Crank upper bearing Using special service tool and press.

YB¡6205

~ ~;:)

5-6

IpOWRla'_IN_S_PE_C_T_IO_N_ _ _ _ _ _ _ _ _ __ G61000-0'

INSPECTION CYLINDER HEAD Cleaning 1) Using a gasket scraper, Remove all traces of gasket material from the cylinder head.

2) Using a round scraper, remove carbon deposits from the combustion chamber.

CAUTION: Do not scratch the surfaces of the cylinder and combustion chamber.

3) Using a soft brush, clean the water jacket.

Inspection 1) Using a precision straight-edge and feelergauge, measure the surface contacting the cylinder block for warping.

Maximum allowable warp: 0.10 mm (0.004 in) If the degree of warping exceeds this specification, re-surface the cylinder-head as follows: Place 400-600 grit wet-or-dry sand paper on the surface-plate, and resurface the cylinderhead using a figure-eight sanding pattern.

5-7

I~~I~I_IN_S_PE_C_T_IO_N___________ G61501·0·

CYLIN DER BLOCK Cleaning 1) Using a gasket-scraper, remove all traces of gasket material from the cylinder-block surface.

2) Using a soft brush and solvent, clean the cyl i nder-block.

Inspection 1) Visually inspect the cylinder sleeves for cracks and scratches.

If cracks are found, replace the cylinder block.

If scratches are found, check the degree of out-of-round, and then hone the cylinder or re-bore it if require.

2) Using a cylinder-gauge, measure the cylinder bore at three positions in the thrust and axial directions.

CD Axial direction @ Thrust direction --t---t-----+--

A: 10 mm (0.4 in) below the cylinder top B: 10 mm (0.4 in) above the exhaust port C: 5 mm (0.2 in) below the scavenging port

2

NOTE: _______________________ Do not place the cylinder-gauge on the port hole.

-----tM-liiP--t-. A _-;;;:---It1-It--+

8

c

Maximum allowable taper: 0.08 mm (0.003 in) Maximum allowable out-of·round: 0.05 mm (0_002 in)

If diameter is greater than the maximum allowable, hone or rebore the cylinder or, if necessary, replace the cylinder-block.

5-8

IPOWRlal_IN_S_PE_C_T_IO_N_ _ _ _ _ _ _ _ _ __ G62000¡0¡

PISTON Cleaning 1) Using a gasket-scraper, remove the carbon from the piston top.

2) Using a broken ring, clean the ring grooves.

CAUTION: The top ring is a keystone-type ring; therefore, do not use a broken top ring for cleaning the other ring grooves, nor use a broken ring from a lower groove for cleaning the top groove.

3) Using a soft brush and solvent, thoroughly clean the piston. If necessary, use 600-800 grit wet-or-dry sand paper to remove score marks or varnish.

Inspection 1) Using a micrometer, measure the piston diameter at right angles to the piston-pin centerline, 10 mm (0.4 in) above the bottom edge.

Piston diameter: Standard: 89.92 - 89.94 mm (3.540 - 3.541 in)

2) Using the measured cylinder bore diameter in thrust directions, subtract the piston diameter measurement from the cylinder bore diameter measurement.

Piston clearance (Regulation): 0.080 - 0.085 mm (0.0031 - 0.0033 in) If this clearance is greater than the maximum, replace all pistons to standard or oversize, and/or rebore all cylinders.

Oversize piston: 90.50 mm (3.56 in)

5-9

IPOWRlal_IN_S_PE_C_T_IO_N_ _ _ _ _ _ _ _ _ __ G62505¡0¡

PISTON RING Inspection 1) Using a feeler gauge, measure the clearance between the piston ring and the groove land.

Side clearance: 0.02 - 0.06 mm (0.0008 - 0.0024 in)

If the clearance is not within the specifications, replace the piston.

2) Insert the piston ring into the cylinder. Using a piston, push the piston ring a little beyond the bottom of the ring travel to a depth of 20 mm (0.8 in) from the top of the cylinder block.

CAUTION: Take care not to scratch the piston. Using a thickness gauge, measure the end-gap.

Ring end gap: 0.30 - 0.40 mm (0.012 - 0.016 in)

If the clearance is greater than the maximum, replace the piston-ring and/or piston.

NOTE: _______________________

If the clearance is greater than maximum even with a new piston ring, rebore the cylinder and use an over-size piston and piston-ring.

5-10

I~~I~I_IN_S_PE_C_T_IO_N___________ G63001-0

PISTON PIN AND SMALL END BEARING Cleaning 1) Use a soft brush and solvent to clean the parts.

Inspection 1) Visually inspect for surface defects, breakage, scratches and pitting. If it is decided to replace the small end bearings, replace them all.

G63505-0'

CRANKSHAFT Inspection 1) Place the crankshaft on a crankshaft-aligner or on V-blocks.

2) USing a dial gauge, measure the connecting-rod axial play.

.::61 I ~

Maximum axial play: 2.00 mm (0.08 in)

If this axial play is greater than the specified maximum, replace the connecting-rod.

3) Using feeler gauges, measure the connecting-rod side clearance.

Connecting-rod side clearance: 0.20 '" 0.32 mm (0.0079 .... 0.0126 in) If this side clearance exceeds the specification, replace the connecting-rod.

4) Using dial gauges, measure the deflection .

~~ 1

Maximum deflection: 0.02 mm (0.008 in)

.

r: I.;i

~

I:

w

.w.~¡u¡

If the deflection is greater than specified maximum, replace the crankshaft.

!

.'-----'

.

5-11

Ip~RI~I_I_N_SP_E_C_TI_O_N_ _ _ _ _ _ _ _ _ __ G64ooo-0'

REED VALVE Inspection 1) Visually inspect for warping of the reed valve. If warped, measure the distortion with feeler gauges.

I~ Maximum reed warp: 0.90 mm (0.035 in)

If the amount of warping is greater than specification, replace the reed valve.

2) Using a vernier caliper, measure the valve stopper height.

Valve stopper height: 6.20 - 6.80 mm (0.244 - 0.268 in) If the valve stopper height is outside the specification, adjust it by bending.

3) Visually inspect for cracks on the reed valve. If cracks are found, replace the reed valve.

G64500-0'

THERMOSTAT Cleaning 1) Using a soft brush and water, remove all traces of salt, dirt or corrosion.

Inspection 1) Visually inspect the thermostat for damage.

If the thermostat is damaged, or if it opens when cold, replace it.

2) Immerse the thermostat in water, and heat the water gradually. Check the valve opening temperature and the valve lift.

I~

Water temperature

Valve lift

Below 48 - 52째C (118-126째F) Above 60째C (140째F)

o mm Minimum 3 mm (0.12 in)

If the valve opening and or temperature and valve-lift are not within the specifications, replace the thermostat.

5-12

IpOWRlal_'N_S_PE_C_T_'O_N___________ G65000-0·

BALL BEARING Cleaning 1) Using a soft brush and solvent, thoroughly clean the bearing. Dry it with air, and sparingly lubricate it with 2-stroke outboard motor oil.

CAUTION: Blow~ry the bearing without spinning it or mak· ing scratches on the bearing balls.

Inspection 1) Hold the bearing inner race and slowly tum the bearing outer race with your fingers. If any rough spots are felt, replace the bearing.

G67000-0·

CRANK DISC SEAL RINGS Inspection 1) Measure the seal ring wears.

~ Seal

.:61 I

D=r,

ring wear limit: 0.10 mm (0.004 in)

If this wear is greater than specification, replace the seal ring.

5-13

IPOWRlal

ASSEMBLY AND ADJUSTMENT G71105·0

ASSEMBLY AND ADJUSTMENT CRANKSHAFT 1) Put the oil injection pump drive gear on to the crankshaft, and press in the bearing.

CAUTION: When reassembling the lower crank bearing and the oil-pump drive gear, the taper side of the drive gear and the seal-cap side of the bearing should be installed towards the crank side, as shown in the illustration.

2) Fit the crank disc seal rings and the crankshaft center bearing into the crankshaft.

G72005·0

PISTON 1) Install the 1st and 2nd piston rings into the each ring grooves with the marking facing upward.

2) Align each ring end-gap with their locating pins.

5-14

IpOWR!al

ASSEMBLY AND ADJUSTMENT G73005·0·

SMALL END BEARINGS AND PISTON ASSEMBLY 1) Count the small-end bearing needles.

I Number of needles per piston: 3O-pcs CAUTION: Do not use a mixture of new and used bearing needles in the same small end.

2) Using the special service tool. Install the bearings in the connecting-rod small end, and place washers on both sides.

YB-6106

3) Insert the piston-pin into the piston.

CAUTION: 1. The washer should be placed with their convex sides facing the piston.

2. Install the connecting rod into the piston so that its mold marie "YAMAHA" faces in the same direction as the "UP" marie on the piston crown.

4) Lubricate each bearing with 2-stroke outboard-motor oil.

5·15

Ip~Rlal_A_~_E_M_B_L_Y_A_N_D_A_D_JU_S_T_M_E_N_T_ _ _ _ __

,

G71115-0

YB-6205

r1\~ \ A' .')

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YB-6195

,

YB-6195

CRANK UPPER BEARING HOUSING 1) Using special service tool, press in the bearing.

2) Using special service tool, force·fit the oil seal.

071125·0

CRANK LOWER OIL SEAL HOUSING 1) Using special service tool, force·fit the oil seal.

YB·6071

G7400S·0·

CRANK CYLINDER ASSEMBLY 1) Install the anodes in the water jackets in both right and left cylinder banks.

2) Install the oil injection pump shaft bushing.

NOTE: ________________________

The bushing should be inserted with the slit facing toward the crank lower oil seal housing.

Ip~RI_I_A_~_E_M_B_L_Y_A_N_D_A_D_JU_S_T_M_E_N_T_ _ _ _ __ 3) Put the crankshaft on the cylinder body.

NOTE: _______________________ 1. Fit crankshaft center bearing locating holes over the locating pins on the cylinder body.

2. Arrange the seal rings so that all ring end gaps face upward.

4) Slip the crank upper bearing housing and the crank lower oil seal housing over the crankshaft.

5) Arrow mark on the upper bearing housing face toward the exhaust cover and temporai Iy tighten the bolts.

6) The two tabs of the lower oil seal housing face toward the exhaust cover and ternporaily tighten the bolts.

7) Lubricate each cylinder wall and piston with 2-stroke outboard-motor oil.

5¡17

IpOWRIIII_A_s_s_EM_B_Ly_A_N_D_A_D_J_U_S_T_M_E_N_T_ _ _ _ __ YB-34454

8) Insert the piston into the cylinder.

CAUTION: 1. The piston crown has two marks, "P" and

"S".

P: Port side S: Starboard side 2. The "UP" mark on the piston crown should be on the flywheel side.

9) The connecting rod bolt should be tightened in the following manner.

CD

Lubricate each big end bearing and cap bolt with 2-strok outboard-motor oil. ÂŽ Tighten the bolts to 1st step specified torque. @ Check to see that the cap and rod ends are aligned.

If not aligned, do the above prcedure again. @ Tighten to the specification. @ Loosen the bolts 112 turn, and tighten the specified torque.

1st step: 17.0 Nm (1.7 m.kg, 12.0 ft.lb) 2nd step: 34.0 Nm (3.4 m.kg, 24 ft.lb) 10) Film-coat the cylinder-block mating surface with Gasket Maker or equivalent.

11) Install the dowel-pins_

ASSEMBLY AND ADJUSTMENT 12) Match the cylinder-block and tighten the bolts in sequence and in two steps of torque.

1st step: MS bolts: 10.0 Nm M10 bolts: 20.0 Nm 2nd step: MS bolts: 1S.0 Nm M10 bolts: 40.0 Nm

(1.0 m.kg, 7.2 ft.lb)

(2.0 m.kg, 14.0 ft.lb)

(1.S m.kg, 13.0 ft.lb) (4.0 m.kg, 29.0 ft.lb)

13) Tighten the crank upper bearing housing and lower oil seal housing bolts in sequence and in two steps of torque.

Bearing housing, oil seal housing: 1st: 4.0 Nm (0.4 m-kg, 2.9 ft.lb) 2nd: S.O Nm (O.S m.kg, 5.S ft.lb)

14) Check that the crankshaft turns smoothly.

15) Insert the driven gear.

5-19

IpOWRlal

ASSEMBL Y AND ADJUSTMENT G75015路0路

CYLINDER HEAD AND EXHAUST COVER 1) Install the gaskets, cylinder-head cover, thermoswitch, thermostat and exhaust cover.

2) Tighten the bolts in two sequence and in two steps of torque.

Cylinder head: 1st: 15.0 Nm (1.5 m路kg, 11.0 ft路lb) 2nd: 30.0 Nm (3.0 m.kg, 22.0 ft.lb)

5

4

16

'.'

17

18

Cylinder head cover, exhaust cover: 1st: 4.0 Nm (0.4 m.kg, 2.9 ft.lb) 2nd: 8.0 Nm (0.8 m-kg, 5.8 tt.lb)

19

v W " '"'''--'''~'~-"1: Q '

".10 @ 11

12

13'

Q 3

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0

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~.--.11102~2' 21

20

5-20

IPOWRIIlI

ASSEMBLY AND ADJUSTMENT 0"160050'

INTAKE MANIFOLD 1) Install the reed-valve assembly, and new gasket to the intake manifold.

2) Install the manifold assembly and new gasket to the crankcase, and tighten the bolts in sequence and in two steps of torque.

Intake manifold: 1st step: 4.0 Nm (0.4 m-kg, 2.9 ft-Ib) 2nd step: 8.0 Nm (0.8 m-kg, 5.8 ft-Ib)

G"16015·0

DRAINLESS HOSES 1) Refering to the illustrations, connect the drainless hoses.

5-21

\pOWRlal

ASSEMBLY AND ADJUSTMENT I INSTALLATION G77015路0

f~ ~ ~I f

ENGINE STOPPER

" .

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S

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1) Install the "P" mark side should be on the port side, and the "S" mark side on the starboard side the cylinder body.

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G80005路0路

INSTALLATION 1) Install locating pins in position on the exhaust guide.

2) Align the locating-pin holes on the gasket with dowel pins, and place the gasket on the bottom cowling.

3) Using the special service tool, lift up the power unit with the hoist, and place it on the upper casing.

YB路6202

CAUTION: 1. Screw the eyenut until tight.

2. Hook the hoist firmly on to the eyenut so that it will not come off the eyenut.

3. The hoist must be rugged enough to suspend the engine.

4) Tighten the power head mounting-bolts to the specified torque.

Power head: 21 Nm (2.1 m.kg, 15 ft.lb)

5) Connect the hoses, cables and wires referring to pages 3-2 -- 3-5.

5-22

IpOWRIa:1

INSTALLATION 6) Bolt-on the apron.

7) Install the fuel system referring to page 4~ 1 .

8) Install the electrical system referring to page 8-1.

9) Check the fittings installation, cable con-

nections and functions before starting the engine to check operation and to check for leaks.

5-23

H 100050'

CHAPTER 6 LOWER UNIT EXPLODED DIAGRAM ......................................... 6-1 PREPARATION FOR REMOVAL . .................................6-2 REMOVAL ...................................................6-2 DISASSEMBLY . ...... " .......................................6·3 INSPECTION ........ , ....................................... 6·6 GEAR CASE ..............................................

BEARING HOUSING .......................................

CLAW·WASHER ...........................................

RING-NUT ................................................

WATER PUMP HOUSING ............ , . , ......... , ..........

IMPELLER .. ,., ........... ' ....... , ......................

DRIVE·SHAFT HOUSING ................. , ............... ,.

GEARS ........................................ , .........

BEARINGS ...............................................

CLUTCH DOG AND COMPONENTS ..........................

DRIVE-SHAFT ....... , ............... ,....................

PROPELLER SHAFT ...................... , . . . . . . . . . . . . . . . .

DRIVE-SHAFT SLEEVE .................... , ............... , SHIFT-CAM AND SHIFT-SLIDER .............................

PROPELLER/TRIM TAB/ANODE .............................

6·6 6-6 6-6 6·6 6·6 6·7 6·7 6·7 6-7 6-7 6-8 6-8 6-8 6-9 6-9

ASSEMBLY AND ADJUSTMENT . .......... , .... , ................6·10 ASSEMBLY ..... , .......................................6-10 SHIM SELECTION .........................................6-14 MEASURING THE BACKLASH ............................... 6-18 WATER PUMP INSTALLATION .... ,', .. " ...................6-20 PROPELLER INSTALLATION ............................ , ... 6·21 LOWER UNIT LEAKAGE CHECK .......... , .................. 6·21

INSTALLATION . .............................................6-22

EXPLODED DIAG RAM EXPLODED DIAGRAM

6-1

~~~~I_:_~_~_~_\_~_\_T_IO_N_FO_R_R_E_M_O_V_A_L_/_ _ _ _ __ 120005-0

PREPARATION FOR REMOVAL 1) Remove the nut and washer, and remove the propeller and spacer from the propeller shaft.

2) Drain the gear oil by removing the plugs from the oil-filling hole and the oil-level hole.

1300050

REMOVAL 1) Set the shift lever into the neutral position.

2) Pull out the pitot tube.

3) Remove the bolts and remove the lower unit complete.

NOTE: _______________________ 1. One installation bolt is behind the trim-tab, therefore, first remove the trim-tab, and then remove the installation bolt.

2. Before removing the trim tab, put a mark indicating its position on the anti-cavitation plate.

6-2

ILOWR!

*" !

DISASSEMBLY 140005¡0

DISASSEMBLY Referring to the exploded diagram, disassemble the lower unit.

1) Water pump housing, impeller and woodruff key.

2) Drive-shaft bearing housing.

3) Shift-rod

NOTE: ________________________ The shift-rod can be removed, only when shift is in the neutral position.

4) Ring-nut and tab-washer

YB-34447

NOTE: ______________________ To remove the ring-nut, straighten the lobe of the tab-washer by use of a screwdriver, then remove the ring-nut.

5) Bearing-housing and propeller shaft assembly.

YB-6207

CAUTION: Be sure that the shift¡rod is removed before removing the propeller shaft.

When not removed the shift cam engages with the shifter, preventing front propeller shaft.

YB-6117 ~:-~ s:-~

~

6) Pinion nut and pinion

YB-6201

6-3

IlOWR!

*-1 ------------------------------------------------DISASSEMBL Y

7) Drive-shaft and pinion

YB-34449

NOTE: ________________________

If the pinion is stuck to the drive shaft, use a special service tool.

YB-6096

/

8) Forward gear and bearing

YB-6096

/7'

9) Forward gear bearing outer race

t).Y" lr"f

<~~

~

10) Sleeve and drive-shaft needle bearing.

YB-6194

YB-S071

11) Reverse gear and bearing

YB-6096

6·4

ILOWRI *'" I

DISASSEMBLY YB-6219

12) Reverse gear bearing

YB-6196

13) Oil seal and needle bearing

.J.

°reO,:

,

0

14) Forward gear bearing

YB·6219

NOTE: _______________________ Be carefull so that the bearing is not crushed, when the bearing separater is fastened.

15) Forward gear needle bearing

YB-6096

16) Drive shaft housing bearing

YB-6196

6-5

Iww~~I_I_N_SP_E_cr_I_O_N___________ 151005·0

INSPECTION GEAR CASE 1) Using a soft brush and solvent, clean the case and water passage.

2) Visually inspect the gear case for cracks, corrosion or distortion. If any crack or excessive corrosion is found, replace the gear case.

151500-0

BEARING HOUSING 1) Using a soft brush and solvent, clean the housing thoroughly.

2) Visually inspect the housing for cracks and corrosion. If any damage is found, replace the bearing housing.

152000·0

CLAW·WASHER 1) Visually inspect the washer for cracks. If any crack is found, replace the claw-washer.

152500·0

RING·NUT 1) Using a soft brush and solvent, clean the thread of the ring-nut.

2) Visually inspect the ring-nut for crack or damage to the thread. If cracked or damaged, replace the ring-nut.

153000-0

WATER PUMP HOUSING 1) Inspect the water pump housing for signs of twisting or scratches of the inner cartridge. If twisted or scratched excessively, replace the housing.

2) During the above operation, inspect the impeller plate, and replace this if damaged.

6-6

1~~~I_I_N_SP_E_cr_I_O_N_ _ _ _ _ _ _ _ _ __ 153500-0

IMPELLER 1) Visually inspect the impeller for cracks, distortion or burning. If any damage is found, replace the impeller.

154015-0

DRIVE·SHAFT HOUSING 1) Using a soft brush and solvent, clean the oil-seal housing.

2) Visually inspect the housing for cracks or corrosion. If a crack or excessive corrosion is found, replace the oil-seal housing.

154500-0

GEARS 1) Visually inspect the teeth and dogs on the gears for crack, peeling or distortion due to gear-crashing. If damage is found on any of the gears, replace with new one.

155000·0

BEARINGS 1) Inspect the bearings for pitting, scratching or rumbling (which may be detected by turning the bearing by hand), and replace them if they are not in good condition.

155500-0

CLUTCH DOG AND COMPONENTS 1) Visually inspect the clutch dog, looking par· ticularly for rounding of the dog edge, cracks and other signs of damage or wear.

If the dog is excessively rounded, inspect also the mating gear, and replace both if necessary.

6-7

~~~~I_IN_S_PE_C_T_IO_N_ _ _ _ _ _ _ _ _ __ 1560150'

DRIVE·SHAFT 1) Visually inspect the shaft, looking for grooved wear on the surface in contact with the bearings and oil-seals, and looking for wear on the splines. Replace if worn or damaged.

2) Check the drive shaft for deflection.

Using V-blocks and a dial gauge.

Maximum drive shaft deflection: 0.50 mm (0.02 in)

156025·0'

PROPELLER SHAFT 1) Visually inspect the shaft, looking for grooved wear on the surface in contact with the bearings and oil-seals, and looking for wear on the splines. Replace if worn or damaged.

2) Check the propeller shaft for deflection.

Using V-blocks and a dial gauge.

Maximum propeller shaft deflection: 0.02 mm (0.0008 in)

1563000

DRIVE·SHAFT SLEEVE 1) Visually inspect the sleeve for wear and cracks. If any damage is found, replace the sleeve.

6-8

1~~~I_I_N_SP_E_cr_I_O_N___________ SHIFT-CAM AND SHIFT-SLIDER 1) Visually inspect the shift-rod for signs of wear or damage, looking particularly for denting of the shift-cam and shift-slider, and replace if required.

157000·0'

PROPELLER/TRIM TAB/ANODE • Refer to CHAPTE R 3 for periodic inspection instructions.

6-9

ILOWRI ~ I ASSEMBLY AND ADJUSTMENT 161005·0'

ASSEMBLY AND ADJUSTMENT ASSEMBLY FOlWard gear shim selection 1) Refer to page 6-15.

Pinion shim selection 1) Refer to page 6~ 16.

Propeller-shaft housing 1) Install the washer and press-fit a ballbeari ng to the reverse gear.

YB·6196

2) Install a needle-bearing and oil seals, and

YB-6071

then press-fit the reverse gear complete into the bearing housing.

YB-6195

YB-6071

Reverse gear shim selection 1) Refer to page 6-17.

6·10

I~~~I_A_S_S_E_M_B_L_Y_A_N_D_A_D_J_U_~_M_E_N_T_ _ _ _ _ __

,

Drive shaft bearing housing 1} Install the needle bearing and new oil seals.

NOTE: ________________________ The protrusion on the bottom of the tool contacts the floor and serves as a stopper.

YB-6071

YB-6195

YB-S071

Forward gear 1) Install the needle bearing, and then forcetit the forward gear bearing.

YB-6200

YB-S071

YB-6200

6¡11

ILOWRI ~ I ASSEMBLY AND ADJUSTMENT Propeller shaft and clutch dog 1) Referring to the illustration, assemble the shift slider.

2) Insert the shift slider into the propeller shaft.

3) Fit the shifter to the shift slider and push it into the propeller shaft.

NOTE: ________________________ 1. Stop pushing the shifter in the neutral position.

4) Insert the cross pin into the clutch dog and fit the cross pin ring in the groove around the clutch dog.

NOTE: _________________________ 1. The clutch dog can be installed with the right side left or vice versa.

2. Make sure the clutch dog correctly moves to neutral, forward and reverse.

5) Set the clutch dog into the neutral position.

YB¡6194

~

Gear case

YB-S213

...

1) Install a new needle-bearing in position.

Q r-~ "

i"\

J

')i,

=LT~ ~-\

--..~

YB-S071

,.>i~

~,>.

2) Place the forward-gear shim-pack in position. Install the forward-gear bearing outer race on the shim-pack.

YB-S199

YB-6071

.,iJ11l" 6¡12

I

LOWRI

*'"

I

ASSEMBLY AND ADJUSTMENT 3) Place the forward-gear complete on to the outer race.

4) Align the drive-shaft sleeve locating-rib with the recess in the gear case, and place the drive-shaft sleeve into the gear case.

F

5) Place the drive-shaft in the gear case, and insert it into the pinion.

Using the speCial service tool, tighten the pinion nut to the specified torque.

YB-6201

u

Pinion nut: 95 Nm (9.5 m-kg, 68 tt-Ib)

6) Mount the thrust bearing, washer, shimpack and drive-shaft housing on the drive shaft and tighten the drive-shaft housing bolts.

7) Insert the propeller shaft complete into the

bearing housing and face the flat part of the shifter upward.

6-13

ILOWRI ~ I ASSEMBLY AND ADJUSTMENT 8) Place the reverse-gear shim in place, then install the bearing housing, aligning the keyway in the gear case with that in the bearing housing, and insert the key.

9) Insert the shift-rod into the slot in the shifter.

NOTE: _______________________

If the clutch dog is not in neutral or the flat part of the shifter does not face upward, it is impossible to install the shift rod .

•

10) Place the tab-washer in place, install a ringnut (with its embossed marks facing outward away from the bearing housing), tighten the ring-nut to the specified torque, and bend the lock-washer over the ring-nut to lock it.

Ring nut: 190 Nm (19 m.kg, 140 tt·lb) Forward gear backlash check 1) Refer to page 6-19.

Reverse gear backlash check 1) Refer to page 6-19.

IbI505·'

SHIM SELECTION NOTE: _________________________

1. When reassembling the lower unit with the original gear case and inner parts, shim selection is not required.

2. When replacing the gear case only, read the numeral preceded by "F,R,P", and adjust the shims according to the difference between numerals of the original gear-case and the new gear-case.

3. If the bearing(s) and/or gear(s) are replaced, carry out the shim selection.

6-14

I

LOWRI

~

I

ASSEMBLY AND ADJUSTMENT Forward gear shim 1) Find forward gear shim thickness (n) by selecting shims until the specified measurement (M) with the special tool is obtained.

Specified Measurement (M) 1.60 mm + F/100 mm

NOTE: If the F value is negative (-), then subtract the F value from the measurement.

2) F is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in O.Ol-mm units. If the F mark is missing or unreadable, assume an F mark of "0", and check the backlash when the unit is assembled.

Example: If F mark is

II

+ 5", then M

= 1,60 +

(+ 5)1100 mm 1.60 + 0.05 mm = 1.65 mm (0.065 in.)

If F mark is "-3", then M

ÂŽ YB-3

1.60 + (-3)/100 1.60 0.03 mm 1. 57 mm (0.062 in.)

3) Assemble the shimming gauge with the forward bearing and original shims as shown in the illustration. Tighten the nut four turns after contacting the spring.

YB-34446-1 YB-34446-7 YB-34446-5 YB-34446-3

~.

=

NOTE: If the original shims are unavailable, start with a 0.50mm shim.

ÂŽ

{~ ......

4) Using feeler gauges set at the specified measurement (M) established above, check the fit between the shimming gauge and the upper disc of the tool.

YB-5 ~...............~l---SHIM

5) If the feeler gauge(s) will not fit, then add additional shims until the feeler gauge(s) (set at the M specification) just fit between the tool surfaces.

e

6) If the feeler gauge(s) are a loose fit, then remove shims until the feeler gauge(s) (set at the M specification) just fit between the tool surfaces.

YB-7~

YB-1~

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

6-15

ILOWR! ~ ! ASSEMBLY AND ADJUSTMENT Pinion shim 1) Find pinion gear shim thickness (T3) by selecting shims until the specified measurement (M) with the special tool is obtained.

- - ------- - - - - ------Ir-HI--1H- ~

T3

Specified Measurement (M) 1.00 mm + P/100 mm

NOTE: If the P value is negative (-), then subtract the P value from the measurement.

SHIM

BEARING-@

2) P is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the P mark is missing or unreadable, assume an P mark of "0", and check the backlash when the unit is assembled.

YB-34432-11

~4 mJ]

~)l C//-

WASHER

---

Example: If P mark is " + 5", then M = 100 + (+ 5)/100 mm 100 + 0.05 mm = 1.05 mm (0.041 in.)

/'~)

YB-34432-6

If P mark is "-- 3", then M

1.00 + (-3)/100 1.00 - 0.03 mm 0.97 mm (0.038 in.)

3) Assemble the shimming gauge with the drive shaft, bearing, and original shims as shown in the illustration. Bolt the bearing housing to the special tool with at least two bolts.

NOTE: If the original shims are unavailable, start with a 0.50mm shim.

4) Install the pinion on the drive shaft, and tighten the nut to the specified torque.

5) Using feeler gauges set at the specified measurement 1M) established above, check the fit between the shimming gauge and lower surface of the pinion as shown.

6) If the feeler gauge(s) will not fit, then add additional shims until the feeler gauge(s) (set at the M specification) just fit between the tool surfaces.

7) If the feeler gauge(s) are a loose fit, then remove shims until the feeler gauge(s) (set at the M specification) just fit between the tool surfaces.

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

6-16

ILOWRI ~

I

ASSEMBLY AND ADJUSTMENT Reverse gear shim 1) Find reverse gear shim thickness (T2) by selecting shims until the specified measurement (R) with the special tool is obtained.

Specified Measurement eM} 1.80 mm - R/100 mm

NOTE: If the R value is negative (-), then add the R value to the measurement.

2) R is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the R mark is missing or unreadable, assume an R mark of "0", and check the backlash when the unit is assembled.

R

Example: If R mark is " + 5", then M = 1.80 - (+ 5)1100 mm 1.80 -0.05 mm 1.75 mm (0.069 in.)

If R mark is "- 3", then M YB¡34468¡2

1.80 - (-3)/100 1.80 + 0.03 mm 1.83 mm (0.072 in.)

3) Place the original shims on the thrust washer mounted on the bearing housing, and place the shimming gauge on top of the shims as shown in the illustration.

SHIMS

NOTE: If the original shims are unavailable, start with a 0.50mm shim.

NOTE: Be sure to remove the O-ring from under the thrust washer.

4) Using feeler gauges set at the specified measurement (M) established above, check the fit between the shimming gauge and the reverse gear. Force the shimming gauge against the shims and thrust washer when checking the fit.

5) If the feeler gauge(s) will not fit, then add additional shims until the feeler gauge(s) (set at the M specification) just fit between the tool and the gear.

6) If the feeler gauge(s) are a loose fit, then remove shims until the feeler gauge(s) (set at the M specification) just fit between the tool and the gear.

Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm 6-17

!lOWR! ~!

YU-3097

ASSEMBL V AND ADJUSTMENT 1630151

YB·7003

MEASURING THE BACKLASH NOTE: ______________________ _

r:~

?

YU·34481

1. When measure the backlash, do not install the water pump.

YB-6265

,~

1) Place the shift·rod in neutral.

2) Install a dial-gauge on to the gear-case.

3) Install a backlash indicator-gauge (Special service tool) on the drive-shaft, and make the dial-gauge stem contact the mark on the i nd icator·gauge.

j.

~~ ..

NOTE: Measure both the forward gear backlash and the reverse gear backlash before making any shim changes. If both backlash measurements are less than specified, the pinion shim may be too large.

If both backlash measurements are greater than specified, the pinion shim may be too small.

RecheCk the pinion shim selection.

6·18

ILOWRI ~ I ASSEMBLY AND ADJUSTMENT Forward gear 1) Install a bearing-housing puller (Special service tool) in the bearing-housing, to en· gage with the center bolt of the propeller shaft.

VB-6207 i~

~~

::1

VB·6117

2) While lifting the drive shaft slightly, slowly turn the drive-shaft in and out, and read the dial-gauge when the drive shaft stops in each di rection.

3) Determine the shim size according to the chart.

Forward gear backlash ~_."_"

__ ' •••

Decrease or increase

~n"~""~_~,,,~,,~"~~~

Thickness of shim to be Less than decrease (mm) = 0.32 mm (0.013 in) (0.39 -, measurement) ...x 1.25 ..... .

-"-.~.~~-~-.--

0.32 - 0.45 mm (0.013 - 0.018 in) ,-.. -....... -.. .. ~,~---------,~

~~,,~--~

.....-.-..

,.,.,

Decrease or increase will be unnecessary... ...

----_... _-_........... _... _ - - - - " ""."

,

-...-..~

~,.,

....... "-""

... ..-., .... ~,

-,~.~

Thickness of shim to be More than increase (mm) 0.45 mm (0.018 in) (measurement .,'" 0.39) x 1.25

Reverse gear 1) Install a propeller on the propeller shaft, with the front side facing backward, fit the nut and tighten.

6-19

~W~~I_A_S_S_E_M_B_L_Y_A_N_D_A_D_JU_S_T_M_E_N_T_ _ _ _ _ __ 2) While lifting the drive shaft slightlYl slowly turn the drive-shaft in and out, and read the dial-gauge when the drive-shaft stops in each direction.

3) Determine the shim size according to the chart.

Reverse gear backlash

-.".".....

,.""

...-.---.------.--,-".'"....

Decrease or increase ~

Thickness of shim to be Less than decrease (mm) = 0.80 mm (0.031 in) (0.96 x 1.25 _ - .. ...... _.......-_measurement) ..... _---_._._........._ ......_ - - 0.80-1.12 mm Decrease or increase (0.031 0.044 in) will be unnecessary ! - - - - - - _.... _----_...... _ - - , - ,,,,,._-._......,--_......._---_ ...... __._ .............Thickness of shim to be More than increase (mm) 1.12 mm (0.044 in) (measurement 0.96) x 1.25 â&#x20AC;˘â&#x20AC;˘........._...

__ ..

_-_

'--""" ...

,,...

1640010

WATER PUMP INSTALLATION 1) Aligning with the dowel-pins, install the plate on the gear-case.

2) Install the key in the keyway on the driveshaft, and insert the impeller.

3) Grease the impeller, and install the waterpump housing, tuming the drive-shaft clockwise, then tighten the bolts.

6-20

ILOWRI

*'"

I ASSEMBLY AND ADJUSTMENT 164500-0

PROPELLER INSTALLATION 1) Install the spacers, propeller, and washer over the propeller shaft and tighten the propeller nut. Then install the cotter pin.

Propeller nut:

SO-60 Nm (5.0-6.0 m·kg, 36 - 43 ft·lb)

165000-0

LOWER UNIT LEAKAGE CHECK 1) Tighten the gear-oil<irain screw, and connect the tester to the oil-level hole.

2) Pump the tester, and apply a pressure of 1.0 kgf/sq.cm (1.020 bar).

Then place the gear case in the water tank.

3) Check that the pressure is held at 1.0 kgf/sq.cm (1.020 bar) for 10 seconds.

NOTE: ________________________

If the pressure falls, the leakage from lower unit is unacceptable, requiring re-inspection of its com ponent parts.

6-21

ILOWRI *"" I INSTALLATION 170005路0'

INSlALLAliON 1) Align the center line of the shift lever with the arrow mark on the bottom cowling.

2) Grease the spline of the drive-shaft and the water-tube outer face, align the water-tube and drive-shaft, install the lower unit and tighten the bolts to the specified torque.

Lower case mounting bolt: 40 Nm (4.0 m.kg, 29 ft路lb) 3) Connect the pitot, tube and secure it with the clip.

4) Install a new trim-tab on the gear-case.

NOTE: ________________________ Be sure to align the marks put on both of the trim-tab and gear-case when they were removed.

5) Fill with fresh gear oil through the oil plughole until oil flows out through the levelplug hole, then secure the plugs in these two holes.

6) Install the spacers, propeller, washer, and propeller nut over the propeller shaft.

Propeller nut: 55 Nm (5.5 m.kg, 40 ft路lb)

7) Align the recess in the propeller nut with

the hole in the propeller shaft and insert the cotter pin into the hole. Be sure to bend the cotter pin ends.

6路22

Kl0005·0·

CHAPTER 7 BRACKET UNIT EXPLODED DIAGRAM ............................................ 7-' BRACKET UNIT .............................................. 7.'

POWER TRIM AND TILT UNIT .................................. 7-2 UPPER CASING AND BOTTOM COWLING ......................... 7.4

REMOVAL . ..................................................... 7-5 UPPER CASING AND BOTTOM COWLING . .......................... 7-6 DISASSEMBLY ............................................... 7-6 INSPECTION ................................................. 7.6 ASSEMBLY .................................................. 7-7

BRACKET UNIT . ................................................ 7-7 DISASSEMBLY ............................................... 7-7 INSPECTION ................................................. 7-7 ASSEMBLy .................................................. 7..8

POWER TRIM AND TILT UNIT . .................................... 7-9 DISASSEM BLY ............................................... 7-9 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -11 ASSEMBLY ................................................. 7-11 FILLING WITH HYDRAULIC FLUID AND AIR-BLEEDING ............ 7-14 HYDRAULIC FLUID PRESSURE TEST ................ : .......... 7-15 INSTALLATION .............................................. 7-'7

PTJT MOTOR . ................................................. 7-17 DISASSEMBLY .............................................. 7-17 INSPECTION .................. '.' ............................ 7.17 ASSEMBLY ................................................. 7-19

EXPLODED DIAGRAM EXPLODED DIAGRAM BRACKET UNIT

7-1

IBRKTj1l' I

EXPLODED DIAGRAM

POWER TRIM AND TILT UNIT

7·2

IBRKTI1[ I

EXPLODED DIAGRAM

K13000-0

CD

Power trim and tilt motor

(g) Gear pump

@ Down-relief valve

®

Main valve 2-way check valve Reservoir Up-relief valve Manual valve ® Tilt cylinder 'i.0> Absorber valve @ Free piston @ Trim cylinder

@ CID (J) @

7-3

IBRKTI1[ I EXPLODED DIAGRAM G20000-0

UPPER CASING AND BOTTOM COWLING

~, ~-1'"" ,"

2' Nm (2.' m.kg, 15 ft.lb)

IJ~---"'-'

,

-,

a-

I

r:s>/ '

-2-'-Nm-(2,-'-m.-kg-,'-5-ft.-lbl....,

® ©l

i:

51 A \'

~-~-

t(,

I.'

~~~

'tJL~--

l

J,I,I

,I _ill-}RA LON~_", _ _ _,_.J

,

7-4

lL__~

~

)

~,{.d·y

I

:

IBRKTI~I_R_E_M_O_V_A_L______________________ K20005¡0

REMOVAL

1) Referring to the chapter 5, remove the power unit.

2) Referring to the chapter 6, remove the lower unit.

3) Remove the swivel¡bracket from the upper casing.

CAUTION: Lay the outboard motor on the floor to carry out this removal.

4) Remove the cramp~bracket and the power trim and tilt unit from the swivel-bracket.

NOTE: ________________________ If it is not necessary to service the upper casing and swivel bracket, carry out removal from step 4.

7-5

"'1 I 11&.

BRKT

REMOVAL/ _U_P_P_E_R_C_A_S_IN_G_A_N_D_B_O_T_T_O_M_C_O_W_LI_N_G_ _ __

K25505-0

UPPER CASING AND BOTTOM COWLING DISASSEMBLY 1) Referring to the exploded diagram, disassemble the upper casing and bottom cowling.

INSPECTION Shift mechanism 1) Visually inspect the shift rod and bushing for wear and salt deposits. Apply grease or replace them as required.

Exhaust manifold 1) Visually inspect the exhaust manifold and exhaust pipe for carbon accumulation and salt deposits. Remove the carbon and salt deposits if required.

7-6

IBRKTI1Ir I_~_~_~_~_~_~_~_~_I~_?_T_A_N_D_B_O_T_TO__M_C_O_W_L_IN_G_I______ Mount rubber 1) Visually inspect the mount rubber, and replace them if they show signs of peeling, cracking or wear.

Water tube 1) Visually inspect the water tube and water seal rubber sealing surface for water leakage. Replace them if damaged.

Tilt lock lever 1) Check the springs, bushings and tilt lock lever for wear and damage. Replace them if required.

ASSEMBLY 1) Referring to the exploded diagram, assemble the upper casing and bottom cowling.

K25605¡0

BRACKET UNIT OISASSEMBLY 1) Referring to the exploded diagram, disassemble the bracket unit.

INSPECTION Mount rubber 1) Visually inspect the mount rubber, and replace them if they show signs of peeling, cracking or wear.

7-7

IBRKTI1f I BRACKET UNIT Collar 1) Inspect the collar, and replace them if cracked.

Trim sender 1) Connect the leads of the trim sender, and make sure that the trim-level indicater follows the moving and angle of the lever of the trim sender when the lever is moved from (A) to (6). .....

A

CD

A

Marking

ASSEMBLY 1) Referring to the exploded diagram, assemble the bracket unit.

Adjusting the trim sender 1) Place the motor in the down position.

2) Connect the leads of the trim sender.

3) Loosen the trim sender screws.

4) Make an adjustment so that the trim level indicater aligns with the lowest down marking.

CD ÂŽ

Trim sender screw Pivot screw

NOTE: _______________________ To adjust the trim sender position, tum the trim sender on pivot screw.

7-8

IBRKTI1[ I

POWER TRIM AND TILT UNIT K51015¡0

POWER TRIM AND TILT UNIT DISASSEMBLY Referring to the exploded diagram, disassemble the power trim and tilt unit.

CAUTION: 1. Do not wipe components of the hydraulic system with rags or paper tissues etc, as fibers from such entering the system will cause malfunction.

2. After removing the tilt-motor or oil-reservoir, do not depress the tilt¡rod or trim-rod which may cause hydraulic fluid to be ejected from the port.

1) Turn the manual valve fully towards the manual position.

2) Remove the delivery pipes and the hydraulic-fluid level-plug.

3) Remove the hydraulic-fluid reservoir and the tilt-motor.

4) Remove the strainer, connector-shaft and the gear-pump.

5) Remove the a-rings and the down reliefvalve complete.

CAUTION: Do not disassemble the gear-pump unit which is factory-adjusted, but replace the gear-pump unit complete if necessary.

6) Losen the bolt and remove the up-relief valve complete and filter.

7) Remove the check valve complete.

8) Loosen the valve seat screw, and remove the valve support pin and the stopper.

7-9

POWER TRIM AND TILT UNIT IBRKTI ~ I---------------------------------------------------9) Using the special service tool, loosen the trim-cylinder end-screw, and pull out the trim-piston and components.

YB¡6115

r'I

10) Using the special service tool, loosen the tilt-cylinder end-screw, and pull out the tiltpiston and the free-piston.

YB-6115

11) Remove the tilt-cylinder.

12) Remove the main valves and the shuttlepiston.

13) Remove the circlip, and remove the manualvalve and components.

7-10

IBRKTI"I' I

POWER TRIM AND TILT UNIT K53000·0

INSPECTION Tilt-rod and trim-rod 1) Clean these components using a soft brush and solvent, and inspect them carefully. If there are light scratches on the surfaces, these may be polished off using fine wetor-dry sandpaper (440 - 600 grit), but if there is excessives scratching, replace the components.

2} Clean all the parts thoroughly using a soft brush and solvent, and dry them with compressed ai r.

3) Inspect the tilt-cylinder and pump-unit, and replace them if they are badly corroded.

K54005·0·

ASSEMBLY

NOTE: _________________________

The components in this assembly are to be lightly coated with hydraulic fluid before assembly.

1) Install the manual-valve to the body with new O-ri ngs.

8

7

CD

O-ring (fitted into the body) Valve seat Manual release spring Adapter Valve seat O-ring (() Manual valve @ Circlip

@ @ @ @ @

3, 1

2

2) Install new O-ring on the shuttle-piston, and insert the piston into the body; then install the main valves with new a-rings. \

13

9

10 11

® ®

Return spring O-ring @ Shuttle-piston @ O-ring (j) Main valve

7 -11

IBRKTI1[ I POWER TRIM AND TILT UNIT 3) Install the up-relief valve with new O-ring, and tighten the locking-bolt to the specified torque.

CD

Filter

@ O-ring

~ Up-relief valve complete

Locking bolt: 6.0 Nm (0.6 m.kg, 4.3 tt.lb) 4) Install the check valve complete.

@ Check valve 5) Install the down relief-valve and the gearpump complete with new O-rings, tighten the screws, and fit the connector-shaft and filter, then fill with hydraulic fluid.

Socket head screw:

7.0 Nm (0.7 m.kg, 5.1 tt.lb)

!

Down relief-valve complete 6 O-ring 7 Gear pump 8 Can nectar shaft @ Filter

6) Align the connector-shaft keyway with the motor-shaft projection, and install the motor with new O-rings.

7) Install the hydraulic-fluid reservoir with new C-ring.

8) Install the valve support pin and shaft, and tighten the valve seat screw with new O-ring.

CD

Shaft

@ Valve support pin @ Spring @ O-ring

CID Valve seat

7-12

IBRKTI1[ I

POWER TRIM AND TILT UNIT 9) Install the tilt-cylinder

YB-6175

CD

®

Bushing Tilt-cylinder

10) Fit a new O-ring and the back-up ring to the free-piston, and install it into the tilt-cylinder.

@ Free-piston

®

g

-

0>

-

~

7

11) Fit new O-ring and the back-up ring to the tilt-piston, and install the piston in the tiltcylinder. Fill the cylinder with hydraulic fluid, tighten the end-screw to the specified torque.

6

0--

5 - 4 _0 _ _

-

3

ful

.~

85 Nm (8.5 m.kg, 61 't.lb)

Back-up ring a-ring 8 Tilt piston

c1o, ./

;;h~

End·screw:

~

2

,

a-ring

@ Back-up ring

8

-1

12) Fit a new O-ring and the back-up ring to the trim-piston, fit new O-rings and a new oilseal to the end-screw, and install the trimpiston complete in the cylinder. Fill the cylinder with hydraulic fluid, and install and using the special service tool, tighten the end-screw to the specified torque.

End-screw: 85 Nm (8.5 m-kg, 61 't-Ib)

~

a-ring 2 Back-up ring 3 Trim-piston @ a-ring @ End-screw @ Oil-seal

YB-6175

7·13

IBRKTI1[ I

POWERTRIMANDTIlTUNIT 13) Install the deliver pipes and secure the clip fixings to the specified torque.

Clip fixing: 19 Nm (1.9 m.kg, 13 ft.lb)

I

I

~ K55005·0·

FILLING WITH HYDRAULIC FLUID AND AIR·BLEEDING 1) Pour in the fluid until it overflows from the oil-level plug-hole, and install the reservoir plug .

•'{}>

Yamaha power trim & tilt fluid

2) Turn the manual-valve fully towards manualtilt. Depress the tilt-rod fully, and then pull it up fully, and repeat these operations two or three times. Then turn the manual-valve fully towards power-tilt.

3) Check the level of the hyraulic fluid at fully tilted up, top up with fluid if necessary. Insert and tighten the fluid-level plug.

4) Connect the leads to a battery to check the function.

Trim and tilt up ............ Blue (+) Green (-) Trim and tilt down .......... Green (+) Blue (-) 7-14

IBRKTI'iI' I

POWER TRIM AND TILT UNIT K55505¡0¡

HYDRAULIC FLUID PRESSURE TEST Drive the motor to check trim and tilt up and down operation and fluid leakage.

1) Set the manual valve to the manual tilt position.

NOTE: _________________________ Turn the manual valve toward the manual tilt until it stops.

2) Connect the pressure gauge.

NOTE: _______________________

YB-6181

Only a set of hoses is available so that both of the trim and tilt pressures can not be measured at the same time.

3) Connect the leads to a battery to check the fluid discharge pressure during upoperation.

Trim and tilt up . . . . . . . .

~:~~~)

I

NOTE: _________________________

The motor should be operated within three seconds after trim and tilt up-operation.

A: Tilt operating pressure B: Trim operating pressure

During up operation: A: 0 - 5 kglcm 2 (0 - 71 psi) B: 0 - 5 kglcm 2 (0 - 71 psi)

At the end of up-operation: A: 0 kglcm 2 (0 psi) B: 95 - 115 kglcm2 (1,351 - 1,636 psi)

7-15

ISRKTI1[ I POWER TRIM AND TilT UNIT 4) Connect the leads to a battery to check the fluid discharge pressure during downoperation.

Trim and tilt down . . . . . . . . . . Green (+) Blue (-)

NOTE: ________________________ The motor should be operated within three seconds after trim and tilt down..aperation.

EEl

e At the end of down operation: A: 41 - 55 kg/cm 2 (583 - 782 psi) B: 6 -11 kglcm2 (85 -157 psi)

5) Remove the fluid pressure gauge.

NOTE: When the fluid pressure gauge has been removed, be sure to tum the manual valve toward the power trim side until it stops.

Union replacement NOTE: seat ______________________ _

V8-6188

4)

1. After the tilt-unit hydraulic-pressure measurements have been made many times, the union seat on the hydraulic-fluid pressuregauge mount may fracture, resulting in leakage of fluid. Therefore, after making such measurements, check for leakage and replace the union seat if required.

<J'

1) Using a tap, remove the union seat.

2) Using the special service tool, drive the new union-seat with light blows from a plastic hammer.

7 ¡16

IBRKTI1[ I

POWER TRIM AND TILT UNIT/ PT/T MOTOR 3) Install the pipes to the unions.

K56000·0

INSTALLATION 1) Referring to the exploded diagram, install the power trim and tilt unit to the bracket.

K61(I05·0

PTIT MOTOR DISASSEMBLY 1) Loosen the through-bolts and remove the commutator end·frame, brush holder and stator.

K62005·0·

INSPECTION Annature coil 1) Visually inspect the commutator surface, and if it shows signs of roughness polish it with 6OO-grit wet-or-dry sandpaper.

2) Measure the outside diameter of the commutator by use of a vernier caliper. If the diameter is less than the specified minimum outside diameter, replace the armature complete.

Commutator outside diameter.

Standard: 29.0 mm (1.142 in) Minimum: 27.0 mm (1.063 in) 7·17

IBRKTI~

PT_/T_M_O_T_O_R______________________

I_ _

3) Measure the mica undercutting. If the undercut is less than the specification, scrape between the segments with a hacksaw blade and then carefully remove all particles of metal and mica with compressed air.

Mica undercut: 0.4 - 0.8 mm (0.02 - 0.03 in)

4) Check the continuity and insulation. If there is open circuit between commutator segments, or there is continuity between segments and the cor, replace the armature complete.

rI

I

I

--_--II

I I

l ______ --'

I

'- _______ ..J

Brushes 1) Measure the size of the brushes by use of a vernier caliper. Replace the brush if it is less than the specified minimum size, or if the brush is worn or damaged.

u~ I

I

I

I

I I

I I

Brush size:

Standard: 11.5 mm (0.453 in) Minimum: 7.5 mm (0.295 in)

L..----J

Brush-holder 1) Check the insulation between the brushholders and the holder base, and replace the brush-holder if there is continuity between them.

7¡18

IBRKTI~ I__PT_/T_M_O_TO_R______________________ K63005路0路

~ o

ASSEMBLY 1) Place the O-ring on the end路frame and install the stator, then align the locatingmarks.

,~

~ 2) Place the O-ring on the stator complete and install the brush holder and commutator end-cap, then align the locating-marks.

3) Install the through-bolts and tighten them to the specified torque.

NOTE: ________________________ Adjust the brush holder position so that the through路bolt can positioned in the cut in the brush holder.

ThroughMbolts: 4.0 Nm (0.4 m-kg, 2.9 tt-Ib)

4) Connect the leads to a battery to make sure the motor operates smoothly.

Right tum . . . . . . . . . . . . . .... Blue (+) Green ( ) Left tum .................. Green (+) Blue ( )

7-19

Ml0()()'iO'

CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ...................................... 8-1 EXPLODED DIAGRAM ......................................... 8-1 WIRING DIAGRAM ............................................... 8-3 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 FLYWHEEL MAGNETO ........................................ 8-4 CLEANING, INSPECTION AND REPAIR ............................. 8-5 SPARK路PLUG .................. , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 PULSER COIL ................................................ 8-5 CHARGE COIL ............................................... 8-5 LIGHTING COIL .............................................. 8-5 IGNITION COIL .............................................. 8-6 REPLACEM ENT OF SPARK-PLUG CAP ........................... 8-6 COl UNIT ................................................... 8-7 CHOKE SALENOID ........................................... 8-8 8TARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 POWER TRIM AND TILT RELAY ................................ 8-9 RECTIFIER REGULATOR ....................................... 8-9 FUSE ...................................................... 8-10 TH ERMO-SWITCH .... - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 WIRING HARNESS .......................................... 8-" TERMINAL ASSEMBLY ....................................... 8-'2 BATIERY .................................................. 8-12 INSTALLATION ................................................. 8-12 FLYWHEEL MAGNETO ....................................... 8-12 STARTER MOTOR ..............................................

EXPLODED DIAGRAM ........................................

REMOVAL ..................................................

DISASSEMBLY ............................. _................

INSPECTION ................................................

ASSEMBLY .................................................

INSTALLATION ..............................................

8-13 8-13 8-14 8路14 8路14

8-17 8路18

ELECTRICAL COMPO NENTS ELECTRICAL COMPON ENTS EXPLODED DIAGRAM

8·'

I

ELEC

I

. .

I

ELeCTRICAL COMPONENTS

.,...--------, ,/// 11!J,~)J I (

I

I I I

I

I I I I

I I I

I I I I

I

Q

~

~~

ij))~ .~J

I I I

I I I

L_________ ~

8-2

m rm

:4)

to)

i~ i

® LP.J

1

3)

/(~ ~~

'I ~

--:===J S

, -.-

--

-

".

I t t \

n

~=~12

IJ.l

L-='-J

:E

fil2X

,-cJ<)--~~

-:XJZ

C)

,

I

; :1

'I • .c'- ~ >{.,

IfffI

.tqc:;t :I~ I

I

"

1.

\

tv

-»0

C

l> 3:

z C)

~

"

I

00

~ :!:!

l<i' • I I

i> C) ::D :\'

•

1 B Black

l>

1

3:

~

!

Bf Brown G Green Gy Grey L

Blue

0 Orange P Pink

1 Ignition coil

R Red

2; Thermo switch

Sb Sky-blue W White Y

Yellow

Lg Light-green

3 Lighting coil 4:Charge coil 5) Pu Iser coil ,6) Rectifier regulator

7) Fuse (20A) ~8)

Starter motor '9) Starter relay :10) Power trim and tilt relay 1r, Trim sensor t2~1 Power trim and tilt motor

ta: Power trim and tilt switch 14,' Main switch

15,: Over heat buzzer 16: Neutral switch

It Choke switch lever Engine stop switch

19\ Battery 2aTachometer (Option) Trim meter @ Choke solenoid @C.D.1. unit

ctv

C)

JJ

IElEClib I__RE_M_O_V_A_L_______________________ M40005¡0

REMOVAL FLYWHEEL MAGNETO 1) Remove the flywheel cover.

2) Using the special service tool, loosen the flywheel nut.

3) Using the special service tool, remove the flywheel rotor.

VB-6117

~

1. Place the flywheel nut flush on the crankshaft.

2. To prevent damage to the engine or tools, screw in the flywheel magneto-puller set¡ bolts evenly and completely so that the puller plate is parallel to the flywheel.

3. When removing the flywheel magneto, lift it up w~ile tilting it slightly. Do not allow the magneto to contact the timing plate.

q=p

8-4

I 1.1 ELEC

REMOVAL! CLEANING, INSPECTION AND REPAIR 4) Remove the woodruff key from the crankshaft keyway by use of a screwdriver.

NOTE: _________________________

Take especial care not to damage the surface of the crankshaft.

M51000·0·

CLEANING, INSPECTION

AND REPAIR SPARK·PLUG • Refer to page 3-18.

M51505·0

PULSER COIL 1) Check the resistance of the pulser coil.

Pulser coil resistance: White/Red-WhiteNeliow 360n±2O% at 20 deg.C (68 deg.F) White/Black-White/Green 360n±2O% at 20 deg.C (68 deg.F) M51805·0·

CHARGE COIL 1) Check the resistance of the charge coils.

Charge coil resistance: Brown-Red 1,05On±20% at 20 deg.C (68 deg.F) Black/Red-Blue 1270±2O% at 20 deg.C (68 deg.F) M52005·0·

LIGHTING COIL 1) Check the resistance of the lighting coil.

Lighting coil resistance: Green-Green O.60±2O% at 20 deg.C (68 deg.F)

8-5

IELECI

i& I_C_L_E_A_N_I_N_G_r_IN_S_P_EC_T_I_O_N_A_N_D__R_E_PA_I_R________ M52505-0'

IGNITION COIL 1) Inspect the high-tension cables for damage and crack.

2) Check the resistance of the primary coil.

Primary coil resistance: Black-BlackIWhite O_2S!l±2O% at 20 deg.C (68 deg.F) 3) Check the resistance of the secondary coil.

Secondary coil resistance: Black-Secondary lead 2.Sk!l±2O% at 20 deg.C (68 deg.F) M". lona 0

+

REPLACEMENT OF SPARK·PLUG CAP (Nonnal plug cap) 1) Remove the spark-plug cap by pulling the cap, and remove the plug-<;ap spring from the high-tension cable.

~----- -----

2) Cut about 5 mm (0.2 in) off the end of the high-tension cable.

3) Referring to the diagram, strip about 5 mm (0.2 in) of the insulation off the end of the high-tension cable, and fit the plug capspring.

e9L.....-__ -..i-

~

5 mm (0.2 in)

~, ~-

4) Push the cap-spring into the plug-<;ap.

-

l' Bend

2 Contact (Resistor plug cap) 1) Remove the spark-plug cap by turning the cap.

2) Install the spark-plug cap to the hightension cable.

8-6

1 I .1 ELEC

CLEANING, INSPECTION AND REPAIR

M53505-0"

COl UNIT 1) Check the COl unit as specified using the pocket tester.

~

(0

~'

BlackIWhite (j) (BIW (1)

0

~m

® (BIW ®)

~

~

Brown (Br) Blue (L)

BlacklWhite @ (BIW @)

~

~

Red (R)

BlacklWhite @ (BIW @) White (W)

~

Black/Red (B/R)

~

~ rgj

Pink (P)

~

~

Black (B)

~ (Otf]J:.~ ~

~

BlacklWhite

I - - - 1----.-.--.-.-" ... ---

~

-

Over rev. (OR)

White/Red (W/R) White/Black (W/B) WhiteNeliow (WN) White/Green (WIG)

0)

\@Y

!~ C-:)

(D

Br

Charge

@R

@W

77-

77-

77-

77-

143 *6496 2943 6090 6090 6090

143 '6496 5684 2944 6090 6090

143 '64-

143 '6496 5684 6090

00

~

00

77-

77-

77-

84-

143 *6496

143 '64-

77-

77~

77-

143

143 *6496

143 *6496

~ 64-

6090

143 '6090 77·143 *6496 5684 6090

156 *64-

96

143 *6496

143

~ 77-

00

4)

143 *6496

~

BIW@ (jJ) (Coil 3)

@J (Coil

143 '6496

W/Y

77-

1 BIW (~) ®J (Coil 2)

B/W (4)

143 '6496

W/B

00

@WIG

77-

W/R

00

(J) W/Y

77-

BIR 77-

B/WeD @(CoiI1)

@W/B

(Coil 2)

77-

R

98182

(§) W/R

(Coil 1)

BIW@ (Coil 3)

105195 *98182

143 '6496 6090 6496 6496 6496

@ SIR

B/W~

L

~ 3.65.4 91169 98182

~~ 6090 6496 6496 64-

l~,

WIG

96

84156 "6496 6090 6496 6496

B/W@ (Coil 4) 77143

W

P

B

OR

68102

5684 2944

1218 1218 1218 1218

140260 6090 140260 6090 122227 140260 140260 140260

57

105195 4872 140260 4872 112208 119221 119221 119221

00

00

00

00

00

00

00

00

00

00

00

.:x>

00

00

00

00

00

00

00

00

00

~

00

00

:x>

96

5684 6090 2944 6090

'6496

96

00

00

00

00

00

00

00

00

00

00

00

00

00

~

00

00

00

co

00

00

00

00

00

ao

~

00

00

00

00

:x>

00

00

00

00

co

00

~

00

00

00

00

00

ao

00

00

00

ce

00

00

6496 6496

1'"'~ 6090

i""

f--.

@P

00

ao

00

00

00

@B

11.817.8

3.7 5.5

11.817.8

3.65.5

3.7 -

00

00

(j§) OR

00

c¢

00

00

5.5

3.75.5

3.24.9

00

c¢

cc

-

00

3.7 5.5 00

Over-rev.

112208 '105195 112208 98182

96 6496 6496

98182 98182

Ground

Stop

B/W (1)

Sr

3.65.4 105195. *91 169 91 169 98182 98182

(2)L

Ignition

Pulser

00

00

00

00

00

3.04.6

3.24.8

3.04.6

3.14.7

2436

00

00

00

00

00

~ 2842 00

'3757 68102 *3757 3654 3757 3757 37-

00

l~ 00

00

17 26

~

NOTE: __________________________________________________________ 1. When making this resistance test, disconect the lead from the over rev. terminal.

2. The asterisk (*) indicates that the tester needle should swing toward "0" and slowly swing back to stay at the specified value.

8-7

I 1.1 ElEC

CLEANING, INSPECTION AND REPAIR M5450S·0·

CHOKE SOLENOID 1) Measure the resistance of the choke solenoid.

Choke solenoid resistance: 3.7 ±O.3f2 at 20 deg.C (68 deg.F)

M55005·Q

STARTER RELAY 1) Check for continuity between the terminals and the ends of the Black and Brown leads.

2) Test to ensure there is no continuity between terminals.

3) Check the relay operation.

Connect a tester between the terminals of the starter relay. Connect the leads of the starter-relay to a 12·V battery:

Brown lead ...................... ( + ) Black lead. . . . . . . . . . . . . . . . . . . . . . . ( - )

Battery voltage: 12V 4) Check that there is continuity between the starter relay terminals. If the operation is not as specified, replace the starter relay.

8-8

IELECI

~ I~C_LE_A_N_I_N_G_,_IN_S_PE_C_T_I_O_N_A_N_D_R_E_P_A_IR~~~~ M55505-0

...----{ (D

POWER TRIM AND TILT RELAY 1) Connect the Black and Sky-blue leads to a tester.

If no continuity, replace the relay.

® L-f---f----(>

®

.-------D

@

'----,......"jrw-----... ~--O-lOOOr-O--.....!J-J'-)

2) Connect the Black and Light-green leads to a tester.

If no continuity, replace the relay.

@

®

CD

Green Blue ~ Light-green @ Sky-blue

®

CID Red @ Black 3) Connect the Light-green and Black leads to a 12-V battery, and check that there is continuity between the Green and Red leads.

If no continuity, replace the relay.

Light-green lead ..... ,............. ( + ) Black lead ....................... ( - )

4) Connect the Sky-blue and Black leads to a 12V Battery, and check that there is continuity between the Blue and Red leads.

If no continuity, replace the relay.

Sky-blue lead .................... ( + ) Black lead ....................... ( - )

M56S0S·0

RECTIFIER REGULATOR 1) Check the continuity of the rectifier.

If continuity is not as specified, replace the rectifier regulator.

~ Rectifier check CD ~ G) ~ ® Black

Black

Green

®

Red

8-9

Discontinuity

Disconti· nuity

®

®

Green

Red

Conti· nuity

Continuity

~ Discontinuity

Conti-,,.. nuity

~

I ElEC 1 . . 1 CLEANING, INSPECTION AND REPAIR M5700,O'

FUSE 1) Check the continuity of the fuse. If the fuse is blown, replace with a fuse of correct rating.

Fuse rating: 20A

M57305·0

THERMO·SWITCH 1) Immerse the thermo-switch in water. While heating the water, check the continuity at the specified temperature.

2) While cooling the water, check the continuity at the specified temperature.

If continuity is not as specified, replace the thermo-switch.

Unit: °C (0 F) Temperature

Continuity

Discontinuity I I

87 ± 3 (189 ± 37)

I

I

67 ± 7 (153 ± 45)

-- _....

I

_____ .JI

8-10

I 1.1 ELEC

CLEANING. INSPECTION AND REPAIR M58JOO·O

WIRING HARNESS 1) Check the continuity between the coupler side and each connector. Cores and pins of identical colors must be connected or a continuity test can not be made.

2) If any of the cores is open~circuit, replace the wiring harness.

B : Br : B/R: G : G/R: L : Lg : P :

,,::t} -' B'_~~

•B

Sb 19

8·11

Black Brown Black/Red Green Green/Red Blue Light Green Pink

R : Sb : W : Y : Y/R: BIW: Gy :

Red Sky blue White Yellow Yellow/Red BlacklWhite Gray

IELECI ~ 1_~_~_:_~_N_~_~_i_:_~_:_PE_C_T_IO~N_A_N_D_R_E_P_A_I_R_/~~~_ TERMINAL ASSEMBLY 1) Inspect the terminal assembly and replace it if its cracked.

M58900·0·

BAITERY • Refer to page 3-9.

INSTALLATION FLYWHEEL MAGNETO 1) Referring to the exploded diagram, install the pulser coil assembly and the stator assembly.

2) Install the flywheel rotor on the crank-shaft so that the woodruff key fits in the keyway in the crankshaft and flywheel rotor.

3) USing the special service tOOl, tighten the flywheel nut to the specified torque.

YB-6139

Flywheel nut: 160 Nm (16 m·kg, 115 ft.lb)

4) Install the flywheel cover.

8-12

[ ElEC

1.1

STARTER MOTOR STARTER MOTOR

EXPLODED DIAGRAM

30 Nm (3.0 m.kg, 22 ft.lb)

W Pinion

cover

~ Clip

@ Pinion stopper

速

Spring

@ Pinion (starter-clutch)

速 Front cover (J) O-ring

@ Washers

速 速

(j]) @ (j) @

Commutator Stator Brushes Brush holder Brush springs Rear cover

8-13

IElEC I i. I

STARTER MOTOR M71505-0

REMOVAL 1) Disconnect the wires and remove the starter-motor.

M72000-0

DISASSEMBL Y 1) Remove the pinion cover.

2) Remove the pinion (starter-clutch). Using a screw-driver, pry off the cI i p.

3) Remove the two through-bolts and pull out the rear cover, if necessarily uSing light blows with a plastic hammer.

4) Remove the field frame by applying light blows with a plastic hammer, and remove the armature.

M73000-0

INSPECTION Pinion 1) Inspect the pinion and inner teeth for wear or damage, and check ease of pinion sliding motion, and replace if damaged.

2) Inspect the flywheel gear and replace if worn or damaged.

Starter clutch 1) Check the clutch movement. Rotate the pinion clockwise, and check that it turns freely. Also try to rotate the pinion counterclockwise and confirm that it locks.

8-14

IElEcl .. I__ST_A_R_T_E_R_M_O_T_O_R___________________ Brushes 1) Check the brushes for wear.

If the size is less than the minimum specifi· cation, replace the brush·holder assemblies complete.

Brushes, size: Standard: 16.0 mm (0.630 in) Minimum: 12.0 mm (0.472 in) Brush·holder 1) Check for continuity between the brushholder and earth. If there is continuity, replace the brush·holder assembly.

Commutator 1) Inspect the commutator surfaces and if these are dirty or burnt, clean with 400-grit wet-or-dry sandpaper.

NOTE: ________________________

When gripping the commutator in a vise, place wooden pieces between the commutator and the vise so that the commutator can be protected against damage.

2) Inspect the commutator deflection with a dialgauge and block, and replace the commutator if the deflection is out of specifi· cation.

If the deflection is greater than the specified deflection, replace the armature.

Maximum deflection: 0.05 mm (0.002 in)

3) Measure the diameter of the commutator.

If the commutator is diameter is out of specification, replace the armature.

Standard diameter.

33 mm (1.30 in) Minimum diameter.

31 mm (1.22 in) 8·15

1 '_.1 ELEC

STARTER MOTOR 4) Measure the commutation mica undercut depth.

If the undercut depth is less than the speci¡ fied minimum, cut it with a hacksaw blade, and then remove all particles of mica and metal by com pressed ai r.

Standard undercut depth: 0.65 mm (0.026 in) Minimum undercut depth: 0.20 mm (0.008 in) Armature 1) Test to check that the commutator is not earthed to the shaft or laminations, and if such continuity is found, replace the armature.

2) Inspect the commutation for open circuit by checking for continuity between segments. If any segment is not in continuity, replace the armature.

8-16

IELEC I .. I STARTER MOTOR M7400~O

ASSEMBLY 1) Apply a thin coat of Yamaha Grease A to the rear cover bushing, and install the armature in the rear cover assembly.

NOTE: ________________________ 1. Using a slotted-head screwdriver, contract brush springs (two of the three springs), and insert the armature shaft in the rear cover.

2. Adjust the brush holder position so that the through-bolt can move in.

3. Take care not to scratch the brush or contaminate it with grease.

2) Assemble the stator, aligning the recess on the rear cover with the projection on the stator, and ensuring that the O-ring fits correctly in the rear cover groove.

3) Mount the washer-pack on the armature shaft. Sparingly apply Yamaha Marine Grease to the front cover bushing, ensure that the O-ring fits to the armature shaft, and insert the shaft into the front cover.

4) Insert the through-bolts into the rear cover, and screw them into the front cover.

8-17

I Iit I ELEC

STARTER MOTOR 5) Mount the pinion, spring and pinion-stopper on the armature shaft.

6) Hold down the pinion-stopper by hand, and fit the clip into the groove in the shaft. Use a socket-wrench that fits properly over the armature shaft. Reform the clip by use of pliers. Lift up the pinion-stopper until its bottom contacts the clip.

M75000-0'

INSTALLATION 1) Place the starter-motor on the starter-motor stay, and tighten the bolts to specified torque.

Tightening torque: 30 Nm (3.0 m¡kg, 22 tt.lb) 2) Connect the positive and negative wires to the starter-motor.

8¡18

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CHAPTER 9 TROUBLE·SHOOTING TROUBLE·SHOOTING DIAGRAM ................................. 9-1 HOW TO TROUBLE-SHOOT .................................. 9-1 ENGINE WILL NOT START ..................................... 9-2 ROUGH IDLING ............................................... 9-8 ENGIN E STALLS .............................................. 9-9 ENGINE WilL NOT STOP ..................................... 9-10 POWER TRIM AN D TilT SYSTEM ............................... 9-11 GEAR SHIFT IS IMPOSSIBLE OR HARD ......................... 9-13

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TROUBLE·SHOOTING DIAGRAM

020000-0

TROUBLE·SHOOTING DIAGRAM

Basic checking ----:-~:~• • •""tI Symptoms of • • •III1"~~'Re~p~a~ir~o~r~a~d~j~Us~t)• • • Check the equipment visually ,. trouble I ,. I or by operating according to pre-delivery check or periodic check procedures.

...

.,.

........,.tt....Simulation l

test

.... r

--------Symptom of trouble L...atrJ is evident

Locating the possible cause of trouble

r

~~ Repair or adjust

Discover the conditions under with the equipment went out of order, and reproduce the same conditions

I

•

"

I

Confirmatory test

I

,,~ ~4",,----.

HOW TO TROUBLE-SHOOT 1) In case of trouble, first check the equipment according to the pre-delivery check and periodic check procedures.

2) Conduct a test under simulated conditions, and investigate the symptom of trouble.

3) Repair the defect, and conduct a confirmatory test to make sure that the cause of the trouble has been removed.

4) When the symptom of trouble cannot be reproduced, set up conditions similar to those in which the trouble occurred, and conduct a test again.

9-1

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ENGINE WILL NOT START

•

0450011'

ENGINE WILL NOT START Does the starter-motor run with the starter-switch on?

YES

II..

,.> GO TO OJ

(P. 9-3)

.NO NO

II..

,.. GO TO [Il (P. 94)

Can the flywheel be turned by hand?

{} YES NO Are the battery cables connected?

{7 YES Are the battery terminal-connections loose?

II..

,.. Connect. (P. 3·9)

YES

...}

,.. Tighten. (P. 3·9)

+NO NO Is the battery in good condition?

II..

,..

YES

"'II,,'"

YES

II..

,.)

Is the fuse blown?

~NO Does the starter relay make operating sound?

Recharge.

Check using a battery tester.

Replace if necessary. (P. 3·9)

Replace. (P. 8-'0)

YES

.NO NO

{7 YES Does the wiring harness conduct properly?

...

,.

Are the terminal connected correctly?

Correct them. (P. 3-2 -3-4)

NO

~ IReplace. (P. 3-2 -3-4)

NO

:I

{.7 YES Does the key-switch have good contact?

Replace.

{.7 YES NO

YES

...

,.

Does the starter-relay function normally?

.JJ,~

9-2

Replace. (P. 8-8 )

I I

IJ~¥~: ? I

ENGINE WILL NOT START

·If the relay chatters, turn off the power immediately to prevent damage to the relay. Charge the battery completely and re-check the relay. If it still chatters, either the battery or the starter motor may be faulty - Check.

~ YES NO

Does the terminal on the secondary side (connected to starter-motor) conduct?

II.

"

~YES

YES

Check the starter-motor. (P. 8-14 -.. 8-16) Is any trouble found?

.NO

... ,.

Replace the starter-relay. (P. 8-8)

Repair. (P. 8-13-8-18)

RE-CHECK

[]

Is either the starter-pinion or the flywheel gear broken?

..-NO

YES

II.

,.)

NO

...

,.

Is there enough fuel in the tank?

Replace. (P. 8-14)

Add fuel.

-{} YES NO

II.

,.

Can the crankshaft be turned by hand?

GO TO []] (P. 9-4)

-{} YES NO

Is the compression in the specific pressure?

-{} YES

II.

,.

NO

II.

,.

Is a blue strong spark produced?

GO TO

[1J

(P. 9-5)

GO TO

[1J

(P. 9-5)

-{} YES NO

II.

,.

Does fuel reach the carburetor?

GO TO [[] (P. 9-6)

-{} YES Do both the carburetor linkage and valve operate normally?

NO

YES Is the carburetor overflowing?

YES

Does water collect in the float-bowl?

.NO

II. )

,.

II.

" 9-3

Correct this. (P. 3-10)

"

-{} YES

..-NO

II.

Check the float and needlevalve. (P. 4-7)

Clean the float-bowl. (P.4·5)

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ENGINE WILL NOT START

•

YES

I.

,

Is any jet clogged-up?

~NO

NO

Is the ignition timing correct?

.,.

Clean. (P.4-6)

Check the flywheel woodruff key for damage. (P. 8·5)

{J,. YES Does the reed-valve form good sealing or no damage?

.u.

NO

Replace the reed-valve assembly. (P.5·12)

II.

,.

YES

Check the leakage of compression from the crankcase.

Is the compression of crankcase normally?

NO

---.. Check the followi ng parts and

,.

replace as necessary: (P.5-15) 1) Oil·sea 2) O-ring 3) Crankcase - cracked, distortion, scratches on mating surfaces.

YES

~j

YES Is there any damage on the cylinder?

lr

..,.

)

Replace the crank cylinder as· sembly. (P.5·15)

NO

RE·CHECK

YES

Remove the lower unit and can the flywheel be turned by hand?

II.

,.

NO

~

,.

Check the piston and cylinder.

(P. 5-7-5-10) Is any piston seizure found?

YES

I.

,.

Check the lower unit; (P. 6-6) 1) Impeller blades are caught; 2) Gear/bearing damaged; 3) Shim adjustment wrong

Replace the piston and crank cylinder.

"NO NO

Is connecting-rod bearing in good condition?

{j,

II.

r

Replace. (P. 5-11)

YES NO

Is crankshaft bearing in good condition?

~YES RE·CHECK

9-4

~

r

Replace. (P.5-13)

IJ~¥~ ?

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[!]

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ENGINE WILL NOT START

NO Is the spark-plug installed correctly?

to.

Install it correctly. (P. 3-18)

I"

~YES

NO

Does the piston face correct direction?

to.

I"

Correct. (P.5-1S)

~YES YES

Remove the cylinder-head and check, is the piston holed?

to.

,.

INO

NO

....

,.

Is the head gasket in good condition?

Replace. (P. 5-3)

Replace. (P. 5-3)

~YES YES

Is the piston or cylinder cracked, scratched or deformed?

--..

,.

Replace. (P. 5-3 )

+NO YES

....

,.

)

Is the piston ring damaged or worn?

Replace. (P.5-3)

.NO NO Are the seal-ring in good condition?

IlL

,.

Replace. (P. 5-3)

~YES RE-CHECK

NO Does the key-switch have good condition?

...

Replace.

I"

{}YES YES Is each connection loose?

IlL

,..) Tighten.

.NO YES

)

.NO

NO

~YES

NO

Is the spark-plug in good condition?

...

,.

~YES

NO

Is the spark-plug gap correct?

...

I"

YES

9·5

Replace. (P. 3-18)

... Replace it with correct type .

,.

Is the spark-plug type correct?

-u.

....

,.

Is the spark-plug cracked?

(P.3-18)

Replace. (P. 3-18)

Adjust it. (P.3·18)

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ENGINE WILL NOT START NO

Does the spark-plug cap have no leaks?

.,.u,. YES YES

Is the high-tension cable damaged or leaky?

.,.

Replace. (P. 8-6 )

..

,.> Replace. (P. 8-6 )

..-NO NO

Are the COl-unit terminals connected correctly?

.. ,.

Connect correctly. (P. 3-3)

~YES

Are the ignition-coil, source--coil and pulser coil all in good condition?

NO

.,.u,.YES NO Is the COl-unit in good condition?

lit..

,.

Replace. (P. 8-5 - 8- 6))

.,.

Replace. (P. 8- 7

..

Add fuel. (P. 4-2)

~

~YES

NO

,.

Is there sufficient fuel in the tank?

.,.u,. YES YES Is the fuel dirty?

.. ,.

Clean. (P. 4-2)

..,.

Clean it. (P. 4-2)

)

+NO

YES Is the fuel-tank filter clogged-up?

}

~NO YES

}

..-NO NO

Is the O-ring in the connector in good condition, and is it fitted correctly?

.. ,.

Is the fuel meter suction pipe clogged-up?

{J,. YES YES

.,. . ,.

Is the fuel joint of tank clogged-up?

Replace. (P. 4-2 )

Replace and fit correctly.

(P. 4-1)

Clean or replace. (P. 4·3 )

.... NO

YES Is the fuel-hose cracked or damaged? .NO 9-6

lit..

,.

Replace. (P. 4-1)

IS

L

.? I_~~~~~~~~~

. THRTBG ,

. ENGINE Will NOT START

Does the embossed arrow on the priming pump face towards the engine?

I

NO

... Correct the pump position .

,.

(P.4-2)

~YES NO Does the

priming~pump

function correctly?

II.

,.

Replace. (P. 4-2)

{7YES Does the fuel joint of engine side function normally?

NO

II.

,.

Replace. (P. 4-3 )

{7YES YES

II.

,.

Is the fuel filter clogged-up? ....NO

NO

Disassemble the fuel-pump and check (P.4-3). Is the diaphragm in good condition?

...

II'

Replace. (P.4-2)

Replace. (P. 4-3)

~YES YES

II.

,.

Is the check valve cracked or leaking? ....NO

NO

Are the fuel hoses connected correctly?

~YES RE-CHECK

9·7

II.

,.

Replace. (P. 4·3)

Correct them. (P. 4-1)

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ROUGH IDLING

•

050005·1'

ROUGH IDLING

I~l_s_t_he~fu_e_l_fr_e_Sh_?~~~~~~~~~~.N.O~.~.1 Re~~e U

the fuel

YES NO

Are all wiring connections tight?

lit..

,.

Tighten. (P. 3-2 -3.4)

~ YES

NO

--.

,.. Tighten, (P.3-18)

Are the spark-plugs tightly screwed in? ~YES

NO Does sparking take place in all cylinders?

..,..

GO TO @] (P, 9-4)

~YES

Is the lighting coil used to supply a heavy load?

+NO Are the ignition sequence and timing correct?

YES

NO

~YES. Are the settings of the carburetor correct?

...

,.. Disconnect the load.

NO

..,.

Correct this. (P. 3-13)

..

,.. Correct the setting.

(P. 3-11)

{ } YES YES Is the magneto base loose?

;W;NO NO Does the reed-valve seal effectively?

..u.. YES Does the flywheel have excessive run-out?

~NO

YES

Does the compression meet the specified pressure?

~

..,.. lito.

Replace the reed-valve. (P.5-12)

Check the crankshaft and its

,..> bearing.

NO

Does the fuel-pump operate normally?

..u.. YES

~1 Replace the magneto base.

NO

....

.

Replace. (P.4-3)

lit..

Inspect the cylinder head gasket and piston rings for wear and damage. (P. 5-3)

..

YES

RE-CHECK

9·8

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ENGINE STALLS

•

060005·1'

ENGINE STALLS (A) The engine stalls in any gear.

NO ~YES

NO

Is the engine warmed-up?

~YES

NO

NO

Is the choke placed in the set position?

~YES Are idling speed and ignition-timing correct?

-u. YES

Is the fuel filter clogged, or is there water in it?

"NO

Are the fuel·pump and fuel·line in good condition?

~YES Is a blue spark produced when the engine stalls?

.u..

Correct. (P. 3·5)

:I

Warm it up.

Does the choke function normally?

~YES

a...

,.

Is the fuel-hose connected correctly?

.,.

Repair. (P. 4·5)

a...

Place in set position.

,..

NO

YES

a...

,.

Correct this, (P. 3-13 -3-17)

.,.

Clean the carburetor and fuel filter. (P, 4-2)

)

NO

NO

..

,.

GO TO [[] (P. 9-5)

.

,.

Check the ignition coil and COl unit. (P. 8-6 - 8-7)

YES YES

Has the engine ever overheated?

.. ,.

)

9-9

Check the piston and cylinder for signs of seizure. (P. 5·8 - 5·10)

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ENGINE STALLS/ENGINE WILL NOT STOP

(8) Engine stalls when gear is changed.

In addition to the above check points, go through the following:

YES Is something coiled around the propeller?

..

,.

)

Remove it. (P. 3·18)

.... NO

YES Is the propeller stiff to turn in neutral?

.)

--y

Disassemble the lower unit and check. (P. 6-1)

-.-NO

NO Is the spark-plug tight?

~

YES

NO

Is the spark-plug gap correct? ~

..

-y

YES

NO

Is the spark-plug in good condition?

~ YES

..

-y

NO

Is the head-gasket in good condition?

..

.. ..

-y

Tighten. (P.3-18)

Adjust. (P. 3-18)

Replace. (P. 3-18)

Replace. (P. 5-3)

~ YES Disassemble the lower unit and check.

(P. 6-1)

070000-0·

ENGINE WILL NOT STOP Does earthing the White lead of the COl unit stop the engine? ~YES

Does the wiring harness have a broken lead?

NO

YES

-.-NO Check the stop-switch and key-switch.

9-10

.

,.

..

,.

Replace the COl unit. (P. 8-7)

Replace the wiring harness.

(P.8-13)

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POWER TRIM AND TILT SYSTEM

POWER TRIM AND TILT SYSTEM (A) The motor will not turns over.

NO Is the battery in good condition?

~YES

to..

"

I NO

to..

Are the battery cables connected?

"

~YES

Connect them. (P. 3-9)

:I

NO

Are the battery terminal-connections tight?

Recharge or replace. (P. 3-9)

~YES

..

NO Does the relay make an operating sound?

"

Check for a broken lead or disconnection. (P. 8-9 ) GOOD_.u

YES "I

I

Tighten. (P. 3·9)

Replace the relay.

(P. 8- 9) YES

-.-

NO

Does the motor turn over when removed the engine.

to..

"

.{}YES

NO

Remove the gear-pump. Can the gearpump be moved lightly by hand?

~YES Disassemble the relief valve and check it.

(P. 7-9)

9-"

Replace or connect.

II

~

Does the motor turn over when connected directly to the battery?

INOGOOD

..,.

Disassemble the motor and check.

(P.7-17)

Replace the gear-pump. (P. 7-12)

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POWER TRIM AND TILT SYSTEM

(B) The motor turns out.

YES Is there leakage of fluid?

a... }

"

~NO NO

....a...

,.

Is the hydraulic-fluid level correct?

Tighten or replace the union seat, or replace O-ring. (P.7-16)

Top-up. (P. 7-14)

~YES

YES

"

..-NO Turn the manual valve to manual. Is the friction excessive?

"'NO

a...

> Bleed. (P.7-14)

Is air present in the hydraulic-fluid?

YES

}.

Overhaul the tilt/trim piston and 7- 9 )

,.> cylinder. (P.

NO

Is the hydraulic pressure correct?

a...

"

~YES RE-CHECK

9·12

Check the hydraulic system.

(P.7-15)

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GEAR SHIFTING IS IMPOSSIBLE OR HARD

090005·0·

GEAR SHIFTING IS IMPOSSIBLE OR HARD

A

WARNING

STOP THE ENGINE. Do not start the engine during following inspections. Remove the Battery terminals.

Turn the propeller and check that the gears are in "Neutral" and "Forward".

Gear are not in "Neutral" and "Forward" ...Gears are faulty.

Gear are in "Neutral" and "Forward" ... Remote control is faulty.

Are there irregularities of the remote control box?

...u.- YES Is the connection of cable and connector correct?

...u.- YES Is the movement of remote control cable smoothly?

.u.

NO

Check the shift rod.

NO

NO

Adjust.

...... Clean rust or salt of the cable. Re· place it, if necessary.

NO

:I ;I

Correct this or replace it.

NO

Connect.

...u.-YES Are the dogs of clutch dog or gear, damaged?

I

,.

...u.-YES Is the shift handle or shift lever connected correctly?

II.

,.

YES

Does the link inside remote control box operate normally?

:I

YES

I I

II.

,.> Replace. (P. 6·7)

~NO Is the shift-cam, shift-slider or shifter damaged?

~NO

YES

YES

Is the cross pin or cross pin ring broken?

~NO RE-CHECK

9·13

>1 Replace. (P. 6-9) II.

,.> Replace. (P. 6-9)

I