Lit 18616 01 35

ee Ei Outboards e __F9.9B | | T9.9U | F9.9U SERVICE MANUAL 198 Pgs LIT-18616-01-35 290237NOTICE This manual has been prepared by the Yamaha Motor Company Ltd. primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understand- ing 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 modifica- tions and significant changes in specifications and procedures, and these are incorporated in suc- cessive editions of this manual FSB, F9.9A, F9.9B SERVICE MANUAL ©1995 Yamaha Motor Co., LTD. 1st Edition, July 1995 All rights reserved. No part of this pul n may be repro- duced or transmitted in any form or by any means including photocopying and record- ing 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 sy tem of any nature. Printed in Japan PIN LIT-18616-01-35& HOW TO USE THIS MANUAL, MANUAL FORMAT Al of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., + Bearing Pitting/Damage —+ Replace. To assist your 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) 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. ‘SPECIFICATIONS ‘These are given in bold type at each procedure. Its not necessary to leave the section dealing with the procedure in order to look up the specifications. Itis important to note the differences in specifications of models, Where a procedure relates to more than one model, the main differences in specificarions will be shown in a following table. il] room | reoew Model] Foam FeBEM FeBE | TO.eMHIF9.9AM |T9.9EHIFS.9AEM] TOSERIFOGAE Staring systom | Marvalstan | Eloctiestar | Electicstat | Manualstat | Elocvicstan | Enevicstart Control system | Manual contr | Manual contol | Remote contol | Manual cont | Manual control | Renote control Titsystom Marualtit | Manuaiut | Maruatut | Manuals | Manual tit] Manual pO Modell ro oururs.gent| Fa98EM Fo.98E am | Staring sysiom | Manvalstar | Electicstar | Electic start Contrat system | Manuel conta! | Manual contol | Remote contol Titsystem Manvalit | Manuattt | Manual at2e 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. &S The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! & WARNING Fallure to follow WARNING Instructions could result in severe injury or death to the machine ‘operator, a bystander, or a person inspecting or repairing the outboard motor. CAUTION: ACAUTION indicates special precautions that must be taken to avold damage to the outboard motor. NOTE: A NOTE provides key information to make procedures easier or clearer.HOW TO READ DESCRIPTIONS 1. An easy-to-see disassembly illustration is mainly provided for a disassembly job. 2, Numbers are given in the order of a disassembly job in the disassembly illustration. 8. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks. The meanings of the symbol marks are given on the next page. 4, Ajob instruction chart accompanies the assembly illustration, providing the order of jobs, names of parts, notes in jobs, etc. 5. In addition to the disassembly illustration, “REMOVAL POINTS” is provided to supplement in detail the explanation which does or cannot necessarily cover the main jobs. 6. Jobs necessary before and after those which are not included in the disassembly illustration are explained before the same illustration as related jobs. @ Section @© Remarks @ Preparation for removal © Removal points @ Order of removal © Extent of removal @ Part name @ Symbol mark © ay @ Exploded diagram tH gt i |r® @ GEN | F |||SPEC| o= ® @ INSP Q FUEL ® S| ‘SYMBOLS Symbols @ to © are designed as thumbtabs to indicate the content of a chapter. @ General Information ® Specifications @® Periodic Inspection and Adjustment @ Fuel System ® Power Unit © Lower Unit ® Bracket Unit ® Electrical System ® Trouble-analysis Symbols @ to 4B indicate specific data: @® Special Too! GD Specified liquid @D Specified grease ® Specified engine speed ® Specified torque @® Specified measurement ® Specified electrical value [Resistance (2), Voltage (V), Electric current A) Symbol @ to @ in an exploded diagram indicate grade of lubricant and location of lubricar tion point: @® Apply Yamaha engine oil ® Apply Yamaha gear-case lubricant ® Apply molybdenum disulfide oil @® Apply water resistant grease (Yamaha marine grease A, Yamaha marine grease) Symbols @) to @ in an exploded diagram indicate grade of sealing or locking agent, and location of application point: @ Apply Gasket Maker® @ Apply LOCTITE® No. 271 (Red LOCTITE) @ Apply LOCTITE® No. 242 (Blue LOCTITE) @ Apply LOCTITE® No. 572 NOTE: In this manual, the above symbols may not be used in every case.INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT >e Bg FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT ELECTRICAL SYSTEM TROUBLE-ANALYSIS Po m i oa c 2 1 23.5 mt 3S | al] 9° e 52 mil 2 |= = |4 = & |mt CHAPTER 1 GENERAL INFORMATION IDENTIFICATION .. SERIAL NUMBER STARTING SERIAL NUMBERS SAFETY WHILE WORKING 1-2 FIRE PREVENTION 1-2 VENTILATION 1-2 SELF-PROTECTION 1-2 OILS, GREASES AND SEALING FLUIDS 1-2 GOOD WORKING PRACTICES 1-8 DISASSEMBLY AND ASSEMBLY 1-4 SPECIAL TOOLS “6 MEASURING... 16 REMOVAL AND INSTALLATIONGEN INFO. t IDENTIFICATION YAMAHA MOTOR CO., LTO. fj MADE IN JAPAN PSeeketc raya) 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: For USA model: As an anti-theft 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 cranks across the serial number, ® @ Model name @ Approved model No. @ Transom height @ Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as follows: Approved Approved Model Approved | serial Number Model Approved | serial Number FORM 5: 000385 ~ | 79 oMHiF9. 9AM ee L:301411 - :703199 ~ 200748 ~ 471124 ~ FeBEM 67 ooeee_ | TOSEHFOOAEM | 5, ea ae : 100264 ~ 00071 L: 400858 ~_| T9.9ERIF9.9AE 411409 ~ 762032 ~ F9.9MHIF9.9BM ee | 307212 ~ Fo9EHIF9BEM | 6G9 ee 500329 ~ FoeBE 101244 = 401799 ~GEN INFO 7 | SAFETY WHILE WORKING GE> SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be follow- ‘ed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline (petrol), and keep it away from heat, sparks, and open flames. VENTILATION Petroleum vapor is heavier than air and it in- haled in large quantities will not support life. Engine exhaust gases are harmful tc breathe. When test-running an engine indoors, maintain good ventilation. ‘SELF-PROTECTION Protect your eyes with suitable safety spec- tacles 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 of appropriate to the work you are doing. OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by ‘Yamaha.ne q SAFETY WHILE WORKING & Under normal conditions of use, there should be no hazards from the use of the lubricants. ‘mentioned in this manual, but safety is all- important, and by adopting good safety practises, any risk is minimized. ‘A summary of the most important precautions is as follow: 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 wising- rag in one's pocket. 4, Hands, and any other part of the body which have been in contact with \ubri- ccants or lubricant-contaminated clothing, should be thoroughly washed with hot water and soap as soon as practicable, 5. To protect the skin, the application of a suitable barrier cream to the hands before working is recommended. 6. A supply of clean lint-free cloths should be available for wiping purposes. GOOD WORKING PRACTICES 1. The right tools Use the special tools that are advised to protect parts from damage. Use the Fight tool in the right manner — don’t improvise. 2. Tightening torque Follow the torque tightening instructions. ‘When tightening bolts, nuts and screws, tighten the large sizes first, and tighten inner-positioned fixings before cuter positioned ones. 13GEN INFO SAFETY WHILE WORKING c> 14 3. Non-reusable items Always use new gaskets, packings, O- rings, oil seals, split-pins and circlips etc. on reassembly. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed-air on dis- assembling 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.GEN INFO SPECIAL TOOLS 0800-06781 16 & 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. NOTE: @For U.S.A. and Canada, use part number starting with “J-", “YB-", "YM-", "YU-" or "YW". For others, use part number starting with “90890-” MEASURING 1. Dial guage and stand PIN. YU-3097, YU-1256 90890-01252 2. Digital multi meter PIN. J-39299 90890-06752 3. CDI tester P/N. YU-91022-B 4, Compression guage PIN. YU-33223 90890-06751 5, Timing light P/N. YM-33277-A 90890-03141 6. Tachometer P/N. YU-8036-A 90890-06760 7. Mity Vac PIN. YB-35956 90890-06756 8. Backlash indicator P/N. YB-6265 90890-06706 9, Magnet base PIN. YU-34481 ‘90890-06705Ree SPECIAL TOOLS ce Oven REMOVAL AND INSTALLATION 1, Flywheel puller P/N. YB-6117 90890-06521 2, Stopper guide plate P/N. 90890-06501 3. Flywheel holder P/N. YB-6139 90890-06522 4, Drive shaft holder P/N. YB-6228 90890-06515 5. Piston ring installer PIN. YB-34454 90890-06529 6. Bearing separator P/N. YB-6219 90890-06534 7. Shaft holder P/N. 90890-06069 8. Bearing puller P/N. 90890-06535 9. Valve spring compressor PIN. YM-1253 90890-04019 10. Valve guide remover P/N. YM-1122 90890-06801 11, Stopper guide stand P/N. 90890-06538 12. Valve guide installer P/N. YB-6308 90890-06802 13. Drive rod P/N. YB-6229, YB-6071 90890-06602 90890-06604 90890-06605 ‘90890-06606 16SPECIAL TOOLS eS 14. Needle bearing attachment (T9.9/F9.9A) P/N. YB-6298 90890-06618 15. Valve guide reamer P/N. YM-1196 90890-06804 16. Needle bearing attachment (F8B, F9.9/F9.9B) P/N. YB-6230, YB-6081 90890-06617 90890-06616 17. Valve seat cutter set P/N. YM-91043-C 90890-06803, 18. Valve adjuster PIN. YM-8035 90890-01311 19. Oil seal installer PIN. YB-6022 20. Pinion nut holder PIN. YB-6078 21. Bearing installer P/N. YB-6015, YB-6085 90890-06632 90890-06625 22, Pinion height gauge (T9.9/F9.9A) PIN. YB-6299, 23, Pinion height gauge (F8B, F9.9/F9.9B) PIN, YB-34232 24, Bearing housing puller PIN. YB-06234 90890-06503 25, Slide hammer set PIN. YB-6096 26. Center bolt P/N. 90890-06504 27. Shimming plate P/N. 90890-06701 28. Bearing depth plate P/N. 90890-06603, WSPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS . PROPELLER SELECTION MAINTENANCE SPECIFICATIONS ENGINE .... ELECTRICAL DIMENSION .. TIGHTENING TORQUE ... GENERAL TORQUE SPECIFICATIONS.SPEC GENERAL SPECIFICATIONS. -o GENERAL SPECIFICATIONS Wocer = cal roa Fem Fone Overal engin immo) wai) 375 26) Overall with mm (in) 430 (16:9) 325 (12.8) Overal height (8) | min) 1,008 8.5) . & | mmin) 1,181 (44) uy | amen) = Boat ransom height (S) | mméin) 381 (150) © | mminy 508 (2000) wy | mmm én = Weight (without propeller) (S) kg (Io) as 43.0 43.5 wo ‘kg (Ib) 42.5 44.0 445 (UL) kg (lb) = Maximum ouput Te (hype 59 (6v5,000 Speed range a ultra ‘om 4.500 ~ 5,500 Speed range aiding om 95050 Speed range at troling ‘pm 85050 Maximum fuel consumption £m (USiinp gal) 33. Engine ype sroke OE Number of eyingers 2 Total gsplacement cm? (ein) 232 (14.16) Bore ad stroke mmx mm 59.0 x424 (in x in) (2.32 « 1.67) Compression ratio 23:1 Spark plug NGK number CRSHS Number of carouretor 1 Carburetor starting system Prim start Manifold arrangement ross tow Exhaust system Proper boss Lubrication system Wit sump Ignition system cL Starting system ~“Wanaalsianer—] Eieciie staner— Fuel rating PON? 3 Engine ol ype °3 SAE 10W-30, 10W-40 API SE, SF, SE-SF, SE-SF-CC Engine oil pan capacity é (US/mp at) 1.0 (1,06/0.88) Gear oil type ‘Hypoid gear oil SAE 9074 Gear oll capacity. ‘om? (US/imp 02), 185 (6.25/61) Tit angle at 12° Goal wansom Degree 8.12, 16,20 Twp angle at 12° poatansom | Degree 0 Shaiow water angle Degree Tit angie +20 = Steering angle (ett + rahi) Degree ea Gear shit position PNR Gear rato 13:27 (208) Reduction system Spiel bovel gear Propeler crecton (Rear vew) Clock wise Propeller drive system Spline “1: Over head camshatt "2: Pump Octane Number; (Research octane + Motor octane)/2 *3: YAMALUBE 4 is recommended "4: GEAR CASE LUBE is recommended in U.S.A. *5: Forward-Neutral-Reverse 24SPEC GENERAL SPECIFICATIONS eS Model trem = TOSMH/FO9AM [TOSEH/FOOAEM | TOSER/FOSAE Overall ienath ram (in) ‘993 (39.1) 575(226) Overall width ‘mm (in) 430 (169) 325(128) Overall height ©] mmiiny = 1051 (41.4) ] — mméin) 1176 (46.4) (UL) | mm(iny 1254 (49.4) Boat transom height ©] mminy = 361 (150) (Q] mm in) 508 (200) (UH | mmiin) 635 (250) Weight (without propeller) (S) | kg (Ib) = 445 (98) W] kam 435 (96) 450 (99) 455 (100) wo] kab) 44097) 4535 (100) 460(101), Maximum output kW (np)/tpm 74 (88)/4500 Speed range at fullihrottle rpm 4000-5000 Speed range at idling rpm 1150450 Speed range at troling rom 1000-450 Maximum fuel consumption uh 33 (US/imp gal) (087/073) Engine type ‘stroke OHO“ Number of cylinders 2 Total displacement ‘om? (cu. in) 282(14.16) Bore and Stroke mm Xm 590x424 (in Xin) (232 x167) Compression ratio 93:1 Spark plug NGK number GRGHS Number of carburetor 1 Carburetor starting system Prime start Manifold arrangement Cross flow Exhaust system Propeller boss Lubrication system Wet sump Ignition system COL Starting system Manual starter Electric starter Fuel rating PONT? a6 Engine oil ype *3 SAE 10W-30, 10W-40 APL SE, SF, SE-SF, SE-SF-CC Engine oil pan capacity e(uS/imp at) 10 (1.06/08) Gear oil type Hypoid gear oi! SAE 90"4 Gear oll capacity em? (US/Imp 02) 320 (10.82/11.26) Tit angle at 12" boat transom Degree 8, 12, 16,20 Tilt-up angle at 12*boat transom | Degree 70 Shallow water angle Degree = Steering angle (left +right) Degree 37+37 Gear shitt position FAN-AS Gear ratio 13:98 (292) Reduction system Spiral bevel gear Propeller direction (Rear view) ‘Clock wise Propeller drive system Spline *1: Over head camshaft *2; Pump Octane Number; (Research octane + Motor octane)/2 *3: YAMALUBE 4 is recommended *4: GEAR CASE LUBE is recommende in U.S.A "5: Forward-Neutral-Reverse 22SPEC! =| GENERAL SPECIFICATIONS ce Toael fom ome F9.9MH/F9.9BM_ F9.9BEM F9.9BE oa egt San Gay ay 2a ow Ta] Bra Overall wth men in) REA fear af wesa Teas] — SEE vera height S 1004 (895), oO mm (in) 1131 (44.5) (UL) mm (in). _ Boat transom height {s) mm (in) 381 (15.0) (lL) mm (in) 508 (20.0) (UL) mm (in) = Weight without prope (S)| kab) men 730 (65) 73560 (uy) kg (Ib) 425 (94) 44.0 (97) 445 (98) (Ut) | _ka (to) = ‘Maximum outa |W teem 7a @9)/5000 Speed range atfull-throtte | pm ‘4500-5500 Speed range at idling | pm 95050 Speed range a roling ‘pm 850 150 Maximum fuel consumption tn 38 See |_(US/Imp gal) (1.00/0.84) Engine Woe Teoke OHS Number of eylinders 2 Total displacement ‘om? (cu. in) 232 (14.16) Bore and Stroke rm Xm 580x424 ‘n xin) 22 xt6r) corneas rato o3:1 Spark pug NGK number crens Number of carburetor 1 Carburetor string system Prime stat Manfod arrangement | Gross tow Exhaust system | Propeller boss: Librcstionaystom Wt sump Ignition sytarn cot Starting syst Manualstarter | __Electric starter Foal rating PON" 36 Engine ol ype" SAE 1ow-20, 10-40 | APL SE, SF, SE-SF, SE-SF-CC_ Engine oll pan capacty t(Usring a) ‘o(108/088) Gearol ype Hypold gear ol sae 20°8, Gear ol eapecity om? (U8/Imo 02) 185 626/651) Titangle at 17 boat vansom ~] Degree 6.1, 16,20 Titupangle at 12boatvancom) Degree 70 Shallow wator angle Decree Titangie +20 = Slering angle (t+ right) Dearee or +37 Gear shit postion ENR Gear rao 13:27 208) eduction system Spiel bevel gear Propel ection (Rearview) Glock wise Propeller drive system Spline "1: Except for Europe and Canada *2: For Europe and Canada "3: Over head camshaft *4: Pump Octane Number; (Research octane "5: YAMALUBE 4 is recommended + Motor octane)/2 *6: GEAR CASE LUBE is recommende in U.S.A. *7: Forward-Neutral-Reverse 23SPEC} y™| GENERAL SPECIFICATIONS PROPELLER SELECTION 79.9/F9.9A, Material (Propeller identification mark) “Remarks ‘Aluminium (R) *Dual thrust Plastic (F) Available propeller (Number of blades x Diameter x pitch) 3 x 11-8/4" x 9-1/4" 3x 11-8/4" x 9.1/4" 3x 11-9/4" x 11" 3X 11-3/4" x 12-4/4" FSB, F9.9/F9.9B Material (Propeller identification mark) ‘Aluminium J) “Remarks el) “Dual thrust Available propeller 3X9-1/4" XB" 3X 9-9/4" X6-112" (Number of blades x Diameter x pitch) | 3x9-1/4" x9" 3x9-9/4" xe" 3 X9-4/4" x 9-3/4" 3x 9-4/4" x 10-1/2" 3x 9-1/4" x12" 3X 9-4/2" x 6-1/2"SPEC] y™| MAINTENANCE SPECIFICATIONS eS MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit Fea | T9.9F99A | Fo.9ir99B CYLINDER HEAD: mm (in) 0.1 (0.004) Warp limit . * Lines indicate straightedge measurement & CYLINDER; Bore size mm (in) 59,00 ~ 59.02 (2.928 ~ 2.924) Wear limit mm (in) 59.1 (2.826) Taper limit mm (in) 0.08 (0.003) CAMSHAFT: Cam dimensions Intake “A mm (in) | 24.541 ~ 24.644 (0.966 ~ 0.970) Intake "8" mm (in) | 20.187 ~ 20.297 (0.793 ~ 0.797) Exhaust "A" A | mm (in) | 24.578 ~ 24.678 (0.968 ~ 0.972) Exhaust “8° | | mm (in) | 20.178 ~ 20.278 (0.794 ~ 0.798) —8 ‘Camshaft runout limit mm (in) 0.1 (0,004) ‘CAM BELT: Cam belt type Coged belt Belt slack mm (in) 0 ~ 10 0 ~ 0.4) 25SPEC) g™| MAINTENANCE SPECIFICATIONS Model Item Unit Fes | T99/F9.9A | F9.9F8.9B VALVE, VALVE SEAT, VALVE GUIDE: Valve clearance (cold): IN. mm (in) 0.15 ~ 0.20 (0.0059 ~ 0.0079) EX, mm (in) 0.20 ~ 0.25 (0.0079 ~ 0,008) Valve dimensions S i Head da Faco width Seat with Margin thickness, "A" Head dia. IN. mm (in) 25.9 ~ 26.1 (1.020 ~ 1.028) EX mm (in) 24.9 ~ 22.1 (0.862 ~ 0.870) Face width IN, mm (in) 1.98 ~ 3.11 (0.078 ~ 0.122) EX mm (in) 1.98 ~ 3.11 (0.078 ~ 0.122) "C* Seat width IN, mm (in) 0.6 ~ 0.8 (0.024 ~ 0.031) x. mm (in) 0.6 ~ 0.8 (0.024 ~ 0.031) "D’ Margin thickness IN. mm (in) 05 ~ 0.9 (0.020 ~ 0.035) EX mm (in) 05 ~ 09 (0.020 ~ 0.035) Stem outside dia. IN mm (in) 5.475 ~ 5.490 (0.2156 ~ 0.2161) x. mm (in) 5.460 ~ 5.475 (0.2150 ~ 0.2158) Guide inside dia IN mm (in) 5.500 ~ 5.512 (0.2165 ~ 0.2170) Ex. mm (in) 5,500 ~ 5512 (0.2165 ~ 0.2170) Stem-to-guide clearance IN. mm (in) 0.010 ~ 0.037 (0.0004 ~ 0.0015) EX. mm (in) 0.025 ~ 0.052 (0.0010 ~ 0.0020) ‘Stem runout limit mm (in) | 0.016 (0.0008) lent =[SPEC OU" | MAINTENANCE SPECIFICATIONS © Model on ee F8B T9.9/F9.9A | F9.9/FO9B VALVE SPRING: Set length (Valve closed) IN. mm (in) 24.4 (0.96) Ex. mm (in) 24.4 (0.96) Compressible forth IN N (kg, Ib) 90 ~ 100 (9.0 ~ 100, 19.8 ~ 22.0) (installed) EX. IN (kg. b) 90 ~ 100 (9.0 ~ 10.0, 19.8 ~ 22.0) Tilt imit® : IN mm (in) 1.4 (0.043) al x mm (in) 134 (0.048) Direction of winding IN. Left hand EX Left hand PISTON: Piston to cylinder clearance mm (in) | 00035 ~ 0.065 (0.0014 ~ 0.0026) Piston side “D” mmi(in)| 58.950 ~ 58.965 (2.3209 ~ 2.3215) Measuring point "H" mm (in) 10 (0.39) Overside ist mm (in) 59.25 (2.933) 1 2nd mm (in) 59,50 (2.343) PISTON RING: Top ring: Type : Plain (Barrel face) Dimensions (B XT) mm (in) 1.5 X23 (0.06 x 0.09) End gap (Installec) || mm (in) 0.15 ~ 0,80 (0.006 ~ 0.012) Limit mm (in) 050 (0.020) Side clearance (Installed) mm (in) 0.04 ~ 0.08 (0.002 ~ 0.003) 2nd ring Type Plain (Taper face) Dimensions (B xT) 8 | mm (in) 4.5 X 2.4 (0.06 x 0.09) End gap (Installec) mm (in) 0.15 ~ 0.30 (0.006 ~0.012) Limit mT. mm (in) 050 (0.020) Site clearance (stag mm (in) 0.03 ~ 0.07 (0.001 ~0.003) il ring — Dimensions (B XT) | p=, mm (in) 2.4 X 2.5 (0.09 X 0.10) End gap (Installec) Ly | 0.20 ~ 0.70 (0.008 ~ 0.028) ‘CONNECTING ROD: Oil clearance (Big end) mm (in) 0.021 ~ 0.045 (0.0008 ~0.0018) "1: Except for USA 27SPEC] U™ | MAINTENANCE SPECIFICATIONS > : Model tem Unit FeB T9.9/F9.9A | F9.9/F9.9B Crank width “A mm (in) 1237 ~ 123.9 (487 ~ 488) Runout limit “B" mm (in) 0.02 (0.0008) Main bearing clearance mm (in) 0.005 ~0,043 (0.0002 ~ 0.0017) Grankcase mark-Bearing color A-Blue, B-Black, C-Brown CARBURETOR: 6606": | 6Ga05*1 | 6G905"1 Stamped mark ei710°2 | eGaio2 | 6Gs10°2 Main Nozzle mm (in) 22 (0087) Main Jet (MJ) + 86" 82°2 Pilot jet (Pd) 4 48 Pilot screw (turn out) (PS) Turns 3a —2 Valve seat size (VS) mm (in) $1.2 (0.047) Float height” mm 25541 (in) (1004) 4 Le ig He Idling speed rpm | 950450 ] 1.150150 | 980350 Trolling speed rpm | 850450 | 100050 | 860+50 THERMOSTAT: Valve opening temperature “CCF 58~62 (136-144) Full open temperature “cry 70 (188) Valve lift (at full open temp.) mm (in) 3 (0.12) “1 Except for Swiss *2 For Swiss 28SPEC) y™| MAINTENANCE SPECIFICATIONS Model ttem Unit FeB T9.9/F9.9A | F9.9/F9.9B FUEL PUMP: ‘Consumption 2 /h, rpm) Min 18.0, 2,750 Diaphragm stroke mm (in) 2.4 (0.0945) Plunger stroke mm (in) 5.8 (0.2283) LUBRICATION SYSTEM: il filter type: Steel mesh Oil pump type: Torochoid type Outer rotor to mm (in) 0.06 ~ 0.11 (0.0024 ~ 0.0049) housing Inner rotor to outer mm (in) 0.02 ~ 0.15 (0.0008 ~ 0.0059) rotor © Rotor to housing 7 mm (in) 0.02 ~ 0.07 (0.0020 ~ 0.0028) © : Relief valve operating pressure kpa 388 ~ 450 (kg/em2, (8.88 ~ 4.50, 55.19 ~ 64.00) psi) 29ISPEC| MAINTENANCE SPECIFICATIONS ELECTRICAL item Unit Model FeB_ | 19.9F9.9A | F99IF9.9B TGNITION SYSTEM: Ignition timing (full retard) | Degrees 5+3BTDOt (full advance) | Degrees 35+3BTDC "1 Piston position mm (in) 4.78 + 0.76 (0.188 + 0.030) CDI output vation ao Chr ot cap a Pulser coil output Vitcanirg | 8 % 3 Spark plug gap mm(in) 0.6 ~ 0.7 (0.024 ~ 0.028) IGNITION CONTROL SYSTEM: — = = = = Gil pressure switch (continue) {kPa tkaem ps] 0+10(0+0.1,0+1.4) (discontinue) |kPa tka‘em psi) 60410 (0.6+0.1,85+1.4) Oil pressure indicator lamp output v More than 65 STARTING SYSTEM: pee Ss Fuse VA 12-20 Starter motor Output kw 0.8 Brush length mm (in) 9.0 ~ 12.5 (0.35 ~ 0.49) Commutator diameter mm (in) 29.0 ~ 90.0 (1.14 ~ 1.18) Commutator under cut mm (in) 0.2 ~ 0.8 (0.01 ~ 0.03) Rating Sec. 30 CHARGING SYSTEM: = Lighting coil outout V at ecanking 8 8 8 Vat 1500rmin] 14 10 "1 ENRICHMENT CONTROL SYSTEM: ~ ~ Valve heater col resistance at 20°C (68°F) a 0.24 ~ 0.96 “1: Before top dead center 210SPEC) yg | MAINTENANCE SPECIFICATIONS <>) DIMENSION BIS. Model ‘Symbol (Used in diagram) Unit T99/F9.9A F8B, F9.9/F9.9B H4 s mm (in) 482 (17.0) cE mm (in) 559 (22.0) UL mm (in) 635 (25.0) = B13 ‘mm (in) 114 (45) Bia mm (in) 126 (5.0) a mm (in) 33 (1.3) c2 mm (in) 65 (2.6)SPEC} y™| MAINTENANCE SPECIFICATIONS QS TIGHTENING TORQUE, Tightening torque Part to be tghtaned | Pat name | Thresd se] OY Hine Trvkgl tui] ROMS ENGINE: __ 06 [43 Connecting rod M6 aa cieloz —@) ae 6 os [43] ig a =| aailrar Me | | ‘Q ener sd ws |e es 30 | 30 Oil element assembly = M24 ie ese Exhaust cover Bot | M6 7 [72 Rock arm adjusting screw | Lock nut M5 iE Drive gear Nut __M24 1 [2B Driven gear Bolt M6 1 [a3 Flywheel Nut 1 | 100 Spark plug = Mio oe eiae |e it mounting Bott M8 6 | | 24 [UPPERCASE AND GEAR CASE: _ Pinion nl 26 Exhaust guide m: 2 {0 | 10 Relief vaive 1 | 8 [08 Bracket bolt : 1 [7 [47 Sofiia eee ceo |ia 3] Upper side mount rubber | __ Nut Wiemee|e2) 25 Propeller | Nut M10 1 13 | 94 | | Plug draia| = mis | 1 oa sa) Manifold exhaust mounting | Mé 12 | 87 | Bottom cowiing mounting M8 2a | 15 General torque = nut (a) | Bott (e) | _ specifications GENERAL TORQUE SPECIFICATIONS This chart specifies the torque for tightening }— 4 standard fasteners with standard clean dry ISO Sloan threads at room temperature. Torque specifica- adem tions for special components or assemblies are 12mm given in applicable sections of this manual. To 7 a avoid causing warpage, tighten multfastener assemblies in crisscross fashion, in progressive stages until the specified torque is reached. rm © 212INSP Q ADJ CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT PERIODIC SERVICE ... MAINTENANCE SCHEDULE ANODE PROPELLER BATTERY . fae ENGINE OIL LEVEL CHECK .. ENGINE OIL REPLACEMENT. GEAR OIL LEVEL CHECK ... GEAR OIL REPLACEMENT . SPARK PLUG. . TIMING BELT ee VALVE CLEARANCE ADJUSTMENT ... ‘SHIFT CABLE ADJUSTMENT. . fone STARTN GEAR PROTECTION ADJUSTMENT. NEUTRAL OPENING LIMIT ADJUSTMENT . : PILOT SCREW ADJUSTMENT (Except for Swiss)...--..........24.. 842 IDLE SPEED ADJUSTMENT ....... : THROTTLE LINK ADJUSTMENT . THROTTLE CABLE ADJUSTMENT. IGNITION TIMING CHECKINSP ADJ Qa PERIODIC SERVICE oa PERIODIC SERVICE MAINTENANCE SCHEDULE The following chart may be taken as a helpful guide to the intervals between maintenance procedures, ial Even Peter em Torous | s0hows | 100haus | 200hous | pogo (Breakin) _| months) | (months) | (1 year) ‘redo © © ° a Batery ° 3 1 mont) Bots and nuts ° ° = Carburetor ° ° ~ Colina water passages ° ° - Engine of ° 9 38 Fel strainer ° ° ° = Foettank ° - Gearoi ° ° 35 ‘Greasng points ° = Ile speed ° 313 Igriton timing ° ° 315 Giiter ° ° 3 ° Outboard motor body ° ° Propeller ° ° 2 Spark pug ° ° 36 Timing bet ° ” rato ink ° 3 aia vaive cearanco ° 9 38 ANODE 1. Inspect: + Anode Wear/Damage > Replace. CAUTION; — Do not paint the anode, or the outboardmay be corrode 2. Clean: + Anode Use a wire brush. NOTE: 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 electrical contact, keep the anode contact surface clean of oil or grease. 34INSP ADJ PERIODIC SERVICE PROPELLER 1. Inspect: + Propeller + Spline Wear/Damage — Replace. BATTERY WARNING Battery electrolyte is poisonous and dan- gerous, causing severe burns, ete. It contains sulfuric acid, Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL; Flush INTERNAL; Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. EYES; Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases: Ke sparks, flame, cigarettes, etc. away. Venti- late when charging or using in a closed space. Always wear eye protection when working near batteries. KEEP OUT OF REACH OF CHILDREN. NoT! Batteries vary among manufacturers. Therefore the following procedures may not always apply. Consult your battery ‘manufacturer's instructions. ‘Disconnect the black negative lead first to prevent the risk of shorting. 1. Inspect: © Battery fluid level © Battery fluid specific gravityINSP ADJ Q PERIODIC SERVICE So ENGINE OIL LEVEL CHECK 1,Place the outboard motor in an upright position. 2. Check: + Engine oil level Oil level should be between the maximum F and minimum L marks. Oil level is 1ow-+Add oil to proper lavel. Recommended oil: SAE: 10W-30, 10W-40 API: SE, SF, SE-SF, SE-SF-CC ENGINE OIL REPLACEMENT 1.Place the outboard motor in an upright position. 2, Place a suitable container under the outboard motor. 3. Remove: + Oil filler cap * Drain bolt Drain the engine oil. 4, Remove: + Oil filter assembly 33itt Qa PERIODIC SERVICE 34 5. Inspect: + Oil filter element © Damage —- Replace. Foul/Clog — Clean. 6. Clean: + Oil filter element Blow out dustin the element fromthe outer surface using compressed air. 7. Install: * Drain bolt © *Oil filter assembly @) Drain bolt: 8Nm (0.8 m-kg, 5.8 ft-Ib) Oil fitter assembly: 8Nm (0.8 m-kg, 5.8 ft-Ib) 8. Fill + Engine oil Recommended oil: SAE: 10W-30, 10W-40 API: SE, SF, SE-SF, SE-SF-CC Oil capacity: 1.0 € (1.06 US qt, 0.88 Imp qt) 9. Check: + Engine oil level Refer to page 3-3. 10. Install: + Oil filler capPay Q PERIODIC SERVICE GEAR OIL LEVEL CHECK 1. Place the outboard motor in an upright position. 2. Check: + Gear oil level Oil level is low — Add oil to proper level. Checking steps: + Remove the oil drain and oil level plugs. + Add the gear oil through the oil drain hole until it over flows from the oil level hole. x? Recommended oil: Hypoid gear oil (SAE 90) + Install the oil level plug. + Install the oil drain plug. GEAR OIL REPLACEMENT 1.Place the outboard motor in an upright Position. 2. Place a suitable container under the outboard motor. 3. Remove: + Oil drain plug + Oil level plug Drain the gear oil 4. Fill * Gear oil Recommended oil Hypoid gear oil (SAE 90) Oil capacity: T9,9/F9.9A: 320 cm? (10.82 us 07, 11.26 Imp oz) FSB, F9.9/F9.9B: 185 cm? (6.25 us oz, 6.51 Imp oz) 5. Check: + Gear oil level 6. Install: + Oil level plug + Oil drain plug 35INSP ADJ PERIODIC SERVICE ce SPARK PLUG 1. Remove: + Spark plug 2. Inspect: + Electrode D Wear/Damage —> Replace. Insulator color @ Distinctly different color —- Check the engine condition. Medium to light tan color: Normal Whitish color: Lean fuel mixture Plugged fuel mixture Air leak Wrong settings Blackish color: Excesive idling Electrical malfunction Rich carburation Defective spark plug 3. Clean: + Spark plug Clean the spark plug with a spark plug cleaner or wire brush. 4, Inspect: * Spark plug type Incorrect —- Replace. Standard spark plug: NGK CRSHS (F8B) NGK CR6HS (T9.9/F9.9A, F9.9/F9.9B) 5. Measure: + Spark plug gap @ Out of specification —- Regap. Use a wire gauge. ‘Spark plug gap: 0.6 ~ 0.7mm (0.024 ~ 0.028 in)INSP ADJ PERIODIC SERVICE eS 6. Tighten: + Spark plug NOTE: a Before installing a spark plug, clean the gasket surface and plug surface. Also it is suggested to apply a thin film of Anti Seize Compound to the spark plug threads to prevent future thread seizure. Sa ‘Spark plug: 13 Nm (1.3 mrkg, 9.4 ft-lb) NOTE: —__ Ifa torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turns @ part finger tight @ . Have the spark plug torqued to the correct value as soon as possible with a torque wrench, TIMING BELT 1. Inspect: + Timing belt Wear/Damage —- Replace. 2. Check: + Timing belt slack @ Push the timing belt with your finger. Out of specification —- Replace. Timing belt slack: 0 ~ 10 mm (0 ~ 0.4 in) a7INSP ADJ PERIODIC SERVICE eS VALVE CLEARANCE ADJUSTMENT NOTE: +The valve clearance must be adjusted when the engine is cool to the touch. + Adjust the valve clearance when the piston is at the Top Dead Center (T.D.C) on compres sion stroke. 1, Remove: + Screw @ +Hinge pin @ + Flywheel cover @) 2, Remove: + Bolt D + Clamp lever @ 3. Remove: + Hose + Bolt O + Cylinder head cover @ 4, Measure: + Valve clearance @ Out of specification —- Adjust. Valve clearance (cold): Intake: 0.15~0.20 mm. (0.0059 ~0.0079 in) Exhaust: 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) 38PERIODIC SERVICE Measurement steps: + Tum the crankshaft clockwise. Align the “1” on the driven gear with the mark on the cylinder head @) when #1 piston is at TDC on compression stroke. NOTE: —— + When measuring the vaive clearance at the #2 cylinder, turn the driven gear 180° so that the "2" marked on the driven gear aligns with the mark on the cylinder head. + Measure the valve clearance using a feeler gauge @. 5. Adjust: + Valve clearance ‘Adjustment steps: + Loosen the lock nut @. + Insert the specified feeler gauge @ into the clearance between the valve stem end and the adjust bolt, + Adjust the adjust bolt using a valve adjuster ®. Ye _] Valve adjuster: ‘YM-08035/90890-01311 ‘Tighten the lock nut with the feeler gauge inserted. Na | Lock nut: 8 Nm (0.8 mkg, 5.8 ftlb) NOTE: —_________ Lock the adjust bolt so that it does not move. 39INSP ADJ PERIODIC SERVICE 6. Measure: * Valve clearance Out of specification > Readjust. NOTE: Ht too loose or too tight, readjust the valve clearance. 7. Apply: + Engine oil To valve stem and adjust bolt. 8. Install +Seal + Cylinder head cover = Bolt @ + Hose Install + Clamp lever D Bolt @ 10. Install: + Flywheel cover © + Hinge pin @ + Collar +*Screw @INSP ADJ PERIODIC SERVICE GED) SHIFT CABLE ADJUSTMENT 1. Adjust: + Shift cable length Adjustment steps: + Loosen the lock nut . + Remove the cable end @. + Set the shift lever to neutral + Set the shift arm to neutral. + Turn the cable end in or out until adjustment is suitable. it the cable end to the pin marked with ‘M" on the shift arm. «Push the cable end stopper @ to securethe cable end. + Tighten the lock nut. START-IN GEAR PROTECTION ADJUSTMENT in gear protection operation Incorrect —» Adjust. in gear protection cable length ‘Adjustment steps: + Set the shift lever to neutral. ‘+ Remove the hinge pin and throw down the front panel @. + Loosen the lock nut @. + Adjust the adjuster @) so that the arrow marks @ on the lock arms ©) align with each other. + Tighten the lock nut. 311INSP ADJ PERIODIC SERVICE ej) NEUTRAL OPENING LIMIT ADJUSTMENT 1, Check: + Neutral opening contro! operation Incorrect — Adjust. 2. Adjust: * Accelerator arm position. Adjustment steps: Attach the tachometer. i Tachometer: ‘YU-8036-A/90890-06760 * Set the shift lever to neutral. + Start the engine. *Turn the throttle grip so that the engine speed is specified. Cy] Enaine speee: 3,200.50 rpm + Loosen the bolt D. + Contact the accelerator arm @ and shift rod ink @. ighten the bolt PILOT SCREW ADJUSTMENT (Except for Swiss) 1. Adjust: + Pilot screw Adjustment steps: *Screw in the pilot screw @ until itis lightly seated. ‘*Back out by the specified number of tums. Pilot screw: 3.41 tums out 312INSP Q ADJ PERIODIC SERVICE & IDLE SPEED ADJUSTMENT 1. Start the engine and let it warm up. 2. Attach: *Tachometer To spark plug lead. GZ] Tachometer: ‘YU-8036-A/90890-06760 3, Measure: sIdle speed Out of specification—Adjust Idle speed: ‘T9.9/F9.9A: 1,150 + 50 rpm FBB, F9.9/F9.9B: 950 +: 50 rpm 4, Adjust: «Idle speed ‘Adjustment steps: + Tur the throttle stop screw Qin or out until specified idle speed is obtained. Turning in — Idle speed becomes higher. Turning out —> Idle speed becomes lower. NOTE: ‘After adjusting the engine idle speed, the throttle link should be adjusted. 3413INSP ADJ PERIODIC SERVICE THROTTLE LINK ADJUSTMENT NOTE: Engine idling speed should be adjusted properly before adjusting the throttle link 1. Check: + Full-open position Incorrect — Adjust. Checking steps: +Pull the accelerator arm @ to the full-open side. + Check the throttle lever @ to the full-open position. 2. Adjust: + Throttle link length ‘Adjustment steps: + Loosen the lock nut @. + Turn the adjust nut Qin or out until adjustment is suitable. “Tighten the lock nut. 314 3. Check: + Throttle link free play @ No free play — Replace the throttle link Checking steps: «Push the accelerator arm @ to the full closed side. +Make sure the throttle lever is on the full-closed position. + Check that the throttle link @ has free play ‘on the throttle lever side.INSP Q ADJ PERIODIC SERVICE QS THROTTLE CABLE ADJUSTMENT NOTE: Engine idle speed and throttle link should be adjusted properly before adjusting the throttle cable. 1. Check: +Full-open position Incorrect + Adjust. Checking steps: + Tum the throttle grip to the fullopen side. + Check the throttle lever @ to the full-cpen position. 2. Adjust: + Throttle cable length Adjustment steps: + Loosen the lock nut ®. + Remove the cable end @. Pull the accelerator arm to the full-open side. + Tur the cable end in or out until adjustment is suitable. “Fit the cable end to the pin marked with “M" on the accelerator arm. Push the cable end stopper @ to secure the cable end. = Tighten the lock nut. IGNITION TIMING CHECK NOTE: Ignition timing is advanced by the CDI unit automatically. Therefore only the checking procedure is shown in this section. 318INSP ADJ PERIODIC SERVICE 1. Attach: *Tachometer light To spark plug lead for #1 oylinder. Tachometer: ‘YU-8036-A/90890-06760 Timing tight: YU-33277-A/90890-03141 2. Check: + Ignition timing Incorrect firing range —- Check flywheel and/or pickup assembly. ‘Checking steps: + Warm up the engine and setitat the specified speed. 75] Engine speed: ‘T9.9/F9.9A: 1,150 + 50 rpm FEB, F9.9/F9.9B: 950 + 50 rpm + Direct the timing light toward the flywheel magneto base ©. + Visually check the stationary pointer @ to verify itis within the required firing range @) indicated on the flywheel.FUEL | fg) CHAPTER 4 FUEL SYSTEM FUEL SYSTEM . ee FUEL LINE LAYOUT. eel PREPARATION FOR REMOVAL ... REMOVAL POINTS .. Diaphragm INSPECTION .. Fuel joint Fuel strainer Fuel PUMP ern ASSEMBLY AND INSTALLATION Fuel pump ... CARBURETOR PREPARATION FOR REMOVAL... NOTE ON REMOVAL AND REASSEMBLY REMOVAL POINTS .. Joint ... INSPECTION ..... Carburetor body .. Pilot screw Jet and nozzle Needle valve Float ... Diaphragm .. Filter Check valve .. Electrothermal valve . = ASSEMBLY AND INSTALLATION «noFUEL B® FUEL SYSTEM & FUEL SYSTEM FUEL LINE LAYOUT Check that the fuel line is correctly installed. Except for Swiss @ Fuel joint @ Fuel strainer @® Fuel pump @ Oil separator © Carburet © Thermostat coverFUEL BD FUEL SYSTEM 2S PREPARATION FOR REMOVAL * Remove the top cowling. + Gasoline (petrol) is highly flammable and explosive. Handle with special care. + Failure to check for fuel leakage may result In fire or explosion. Z See For Suse Extent of removal: — @ Fuel joint removal @ Fuel pump removal © Fuel pump disassembly Extent of removal_] Order Part name oy Bot 1 Fuel joint 1 Fuel strainer 1 Screw 2 Fuel pump. 1 ‘Serew 4 1 1 1 1 1 2 1 1 1 2 1 4 Remarks Disconnect the hose. Disconnect the hose. Disconnect the hose. Pump body Diaphragm Plunger Spring Diaphragm spring Screw Plate Check valve 5 [Pump cover ‘Screw Cover Seal | (For Swiss) (For Swiss) (For Swiss) 42e mi » FUEL SYSTEM QS REMOVAL POINTS DIAPHRAGM 1, Remove: + Diaphragm @ CAUTION: — Push the plunger and hold the plate @, turn the diaphragm 90°. INSPECTION FUEL JOINT 1. Measure: + Fuel joint operation Impossible to maintain the specified pressure for 10 sec, —> Replace. Measuring steps: Attach the Mity Vac. # Mity Vac: ‘YB-35956 / 90890-06756 + Apply the specified pressure. Specified pressure: 50 kPa (0.5 kg/cm?, 7.1 psi) FUEL STRAINER 1. Inspect: +Fuel strainer of) Crack/Leak/Clog —> Replace. FUEL PUMP 1. Inspect: Check valve © + Diaphragm @ Damage —- Replace. 43FUEL FUEL SYSTEM 2. Inspect: + Spring @ Diaphragm spring @ Damage —- Replace. ASSEMBLY AND INSTALLATION FUEL PUMP 4. Install +Pump body @ + Diaphragm spring @ + Spring @ + Plunger @ NOTE: Align the recess in the plunger with the pump. body. 2. Install: + Diaphragm @ CU S Push the plunger and hold the plate @, then turn the diaphragm 90°, 3. Install: = Pump cover ® Check valve @ +Plate @ +Screw @ NOTE: nny Align the recess in the check valve and plate with the projection of the pump cover. 44FUEL FUEL SYSTEM 45 4. Install: «Pump body @ + Pump cover @ + Screw @ cet eee sereeenesneeeteenieeeeesteeteesnsneeesoreeee After installing, check the smooth movement of the plunger. 5, Measure: + Fuel pump operation Impossible to maintain the specified pressure for 10 sec. —- Replace. Measuring steps: *Attach the Mity Vac to the inlet of the fuel pump. GZ] Mity Vac YB-35956 / 90890-06756 Cover the outlet of the fuel pump. + Apply the specified pressure. Specified pressure: 50 kPa (0.5 kg/em?, 7.1 psi) 6. Measure: + Fuel pump operation Impossible to maintain the specified pressure for 10 sec. > Replace. Measuring steps: Attach the Mity Vac to the outlet. AI Mity Vac: ‘YB-35956 / 90890-06756 + Apply the specified pressure. Specified pressure: 50 kPa (0.5 kg/cm?, 7.1 psi) 7. Install: +O-ing @ NOTE: Always use a new O-ring.FUEL SYSTEM 46 8. Install: (Except for Swiss) +Fuel pump @ “Screw @ Hose @) +Hose @ Clamp © 8. Install: (For Swiss) +Fuel pump © +Screw ® +Hose © +Hose @ *Clamp © sHose © +Hose *ClampFUEL BD CARBURETOR f<>) CARBURETOR rN ATs) PREPARATION FOR REMOVAL * Remove the top cowling. * Disconnect the wire lead. trol) is highly flammable and Handle with special care. Failure to check for fuel leakage may result in fire or explosion.FUEL we CARBURETOR QS NOTE ON REMOVAL AND REASSEMBLY + With the engine mounted, the following parts can be removed. + Before inspection, the removed parts should be cleaned and blow out all passages anc jets with compressed air. + After removing the carburetor, cover the carburetor joint preventing foreign material from entering. Extent of removal: @ Carburetor removal @ Electrothermal valve removal @ Carburetor disassembly Extent of removal [Order Part name ay Remarks 1 | Throttle link 1 | Disconnect the link lod. @ 2 | Funnel 1 3 | Nut 2 4 | Carburetor 1 | [8 | Screw 2 | | & | Bleswothermal valve 1 7 | Clip 1 > 8 | Screw 4 9. | Float chamber 1 } (10 Pin 1 11 | Float 7 | | 12 | Needte valve 1 | | 13. | Screw 2 14 | Cover 1 18. | Diaphragm . 1 1 [16 [Fitter i REMOVAL POINTS JOINT 1, Disconnect: + Throttle link © + Fuel hose @ 48FUEL CARBURETOR INSPECTION CARBURETOR BODY 1. Inspect: + Carburetor body Crack/Damage —> Replace. Contamination — Clean. WARNING. Protect your eyes with suitable safety spec- tacles or safety goggles when using compressed air. NOTE: + Use a petroleum based solvent for cleaning, Blow out all passages with compressed air. + Never use a wire, PILOT SCREW 1. Inspect: + Pilot screw Bend/Wear —- Replace. JET AND NOZZLE 1. Inspect: + Main jet + Pilot jet + Check valve * Main nozzle Contamination —- Replace. NEEDLE VALVE 1. Inspect: +'Needle valve Grooved wear —> Replace. 49FUEL Bw CARBURETOR FLOAT 1. Inspect: + Float es Crack/Damage —+ Replace. > YXs DIAPHRAGM 1. Inspect: + Diaphragm Damage — Replace. FILTER 1. Inspect: + Filter Contamination —- Clean. Damage —- Replace. CHECK VALVE 1. Inspect: * Check valve Damage —- Replace. ELECTROTHERMAL VALVE 1. Inspect: + Needle valve @ +Piston valve @ Wear/Damage — Replace. 410FUEL | fh) CARBURETOR 2. Measure: + Electrothermal valve resistance Out of specification + Replace. Black — Black 48 ~ 7.2 0 at 20°C (68°F) il Electrothermal valve resistance: 3. Check: +Piston valve height @) No change->Replace. Checking steps: +Connect the 12 V battery. + Wait for several minutes. *Check the piston height. ASSEMBLY AND INSTALLATION 1. Install: + Float chamber @ + Spring @ = Diaphragm @) + Cover @ +Screw ©) 2. Install: +Pilot jet © +Oxing @ + Seal cap @ +Main nozzle @ NOTE: Position the nozzle so that the cutaway of the nozzle faces the intake manifold. 3. Install: +Sorew @ Main jet @ Nove: Align the slit in the main nozzle with the screw hole in the carburetor.FUEL CARBURETOR 412 4. Install: + Needle valve *Float @) NOTE: Install the valve into the float hinge. 5. Install: + Float D +Pin@ NOTE: ae ————$ After installing, check the smooth movement of the float. 6. Measure: + Float height @ Out of specification — Fold the tab ® to adjust float arm height. as Float height: 25.5 1 mm (1.00 +0.04 in) NOTE: The float should be resting on the needle valve, but not compressing the needle valve. 7. Install: + O-ring D +Drain screw @ + Gasket @ + Drain screw @CARBURETOR 8. Install +Filter D Check valve @ *Gasket @) +Float chamber @) + Screw ® 9. Install: O-ring O + Electrothermal valve @ +Plate @ +Screw @ 10. Install: *Spring ® *Pilot screw @) +Seal cap @) NOTE: After placing the seal cap on the pilot screw, fit it to the groove in the carburetor. 11. Adjust: «Pilot screw @ ‘Adjustment steps: + Screw in the pilot screw until it is lightly seated. + Back out by the specified number of turns. Pilot screw (Except for Swiss): 3:1 tums out 12. Install: +Rod © Washer @) +Clip @ NOTE: Always use a new clip. 413FUEL “i CARBURETOR 13. Install: @ 14, Connect: + Throttle link @ + Fuel hose @ 15. Connect: Le +Wire lead @ 16. instal: +Gasket «Funnel 2) *Serew @) 17. Adjust: *ldle speed Refer to page 3-13.POWR) CHAPTER 5 POWER UNIT POWER UNIT REMOVAL ....nmsnenmnnernnn sens Sef PREPARATION FOR REMOVAL .. NOTE ON REMOVAL AND REASSEMBLY REMOVAL POINTS .. Starter grip Stop wire INSTALLATION Power Unit... Recoil starter Battery lead .. Flywheel cover CYLINDER, PISTON AND CRANKSHAFT PREPARATION FOR REMOVAL . NOTE ON REMOVAL AND REASSEMBLY REMOVAL POINTS Flywheel magneto .. Timing belt Drive gear .. E INSPECTION AND REPAIR Flywheel magneto .. a ST Drive gear Timing belt Thermostat .. Cylinder .. Piston .. Piston clearance .. PistoM iM nr Piston ring . Crankshaft : — 512 Crankshaft main bearing clearance 513 Combination of crankcase and bearing 514 Connecting rod oil clearance : . 515 ‘ASSEMBLY AND INSTALLATION 516 Piston and connecting rod 5:16 Cylinder and crankcase 5-16 Exhaust cover .. 518 Timing belt... 5-19 Oil pressure switch Thermostat Starter motor ... Flywheel magneto .....POWR) CYLINDER HEAD, VALVE AND CAMSHAFT PREPARATION FOR REMOVAL . NOTE ON REMOVAL AND REASSEMBLY REMOVAL POINTS, Cylinder head Rocker shaft Driven gear Valve .. : INSPECTION AND REPAIR Oil separator .. Oil pump Rocker shaft and rocker arm .. Valve lifter... Camshaft Cylinder head Valve .. Valve spring ... ASSEMBLY AND INSTALLATION ... Oil pump assembly .. Cylinder head . Cylinder head COVE wwnnnsn Intake manifold ll separator RECOIL STARTER ............ : PREPARATION FOR REMOVAL .... REMOVAL POINTS Starter rope ..... Spiral spring INSPECTION .... Starter rope Spiral spring Sneave drum and starter housin, Pinion c ASSEMBLY AND INSTALLATION .. . 6-23 5-24 5-24 5.24 5-24 5-25 - 5:25 ve 5226 . 5:26 . 5-26 . 6-26 . 6-27 5.27 5.28 5.33 534 5-35 5:35 5-35 5.39 5:39 5:39 5-41 . 5-41 . 5-42 5-42 ~ 543 . 543 5-43 5-43 5-49 5-43 5-44POWR Si POWER UNIT REMOVAL POWER UNIT REMOVAL PREPARATION FOR REMOVAL * Drain the engine cil. * Remove the oil level gauge. * Remove the top cowling * Disconnect the stop switch leads. * Remove the terminal cover. * Disconnect the oil lamp lead. > [21 Nm (2.1 kg, 15 feb) 1POWR| Se POWER UNIT REMOVAL © NOTE ON REMOVAL AND REASSEMBLY + After removing the power unit, protect the lubricating system, including the oil pan and relief valve, from dust and di Extent of removal: @ Power unit removal Extent of removal | Order Part name Lary Remarks ] 1 Fuel hose 1 2 | Blow by hose 1 3 Water hose = 4 ‘Water hose 1 5 |[Waterhose | 6 ‘Screw 1 7 Hinge pin 1 8 Flywheel cover 1 9 | Grip cover 1 } Recoil starter model only 10 _| Starter grip 1 Refer to “REMOVAL POINTS". Ww Neutral starting device cable _ 12 ‘| Battery lead 1 Electric starter mode! only 13° | Screw 2 14 | Apron 2 15_| Bolt 6 16 _| Power unit REMOVAL POINTS STARTER GRIP 1. Remove: + Starter grip D NOTE: a When removing the starter grip, pull out the starter rope and make a knot in the rope so that, the rope is not pulled into the starter. STOP WIRE 1. Remove: + Lock nut + Start-in gear protect OTe Do not remove the stop wire before removing the starter grip, or it is impossible to pull out the starter rope when removing it. n cable @) 82POWR POWER UNIT REMOVAL & INSTALLATION POWER UNIT 1. Apply: + Gasket maker Onto both face of the gasket. NOTE; Clean the contacting surface of crankcase. 2. Install: + Gasket O + Dowel pin @ +Oxing @ +Seal@ 3. Install: + Power unit D Liga renee tere treneerneternetenneernetnennieenns +f the crankshaft splines do not mesh with the drive shaft splines, turn the flywheel a little so that they can mesh. + Use care not to pinch the lead and pipe. 4. Install: +Bolt O Na Bolt: 21.Nm (2.1 m-kg, 15 ftlb) 5. Install: Apron + Screw @ 53POWR) POWER UNIT REMOVAL eS 6. Install: + Oil level gauge © 7. Connect + Water hose (1) *Water hose @) * Water hose @) * Blow by hose @ + Fuel hose @) RECOIL STARTER 1. Install: + Start-in gear protection wire @ + Lock nut @ 2. Adjust: +Start-in gear protection cable length Refer to page 3-11 3. Install: + Starter grip © NOTE: Pass the starter rope through the front panel and starter grip, and make a knot in the end of the rope, then put it into the starter grip. 4. Install: *Grip cover ® NOTE: Aiter installing the grip cover, untie the knot, and let the rope wind around the starter.POWR POWER UNIT REMOVAL eS BATTERY LEAD 1. Install: + Battery lead D Refer to page 8-2 ~ NOTE: Connect the battery lead to both of the starter motor and starter relay. FLYWHEEL COVER: 1. Install: * Grommet @) *Collar @ + Flywheel cover ® * Hinge pin @ + Screw @) NOTE: ——$——— ‘Secure the L-shaped portion to the holder. 2. Install: + Electrical leads + Terminal cover + Screw Refer to page 8-1 ~ 8-4. 3, Connect: + Throttle link © 4. Adjust: * Throttle link length Refer to page 3-14. 55POWR) @}POWR' CYLINDER, PISTON AND CRANKSHAFT QS CYLINDER, PISTON AND CRANKSHAFT PREPARATION FOR REMOVAL * Remove the power unit. * Remove the following parts: *CD1 unit Ignition coil + Rectifier regulator Tet 6 Nm (08 mig, 43 FB) 4 she venmtaman erm) | ip] yg —o a 8 23 Nm (2.3 mrkg, 17 fib) | fst 1S Nm (15 ekg, 17 ftHB) D 2nd: 30 Nm (3.0 mkg, 23 ftib) 100 Nm (10 mrkg, 72 fib)Frown NOTE ON REMOVAL AND REASSEMBLY + Before servicing, clean the power unit. CYLINDER, PISTON AND CRANKSHAFT ce + Note the piston and connecting rod for cylinder #1 and #2, their should be reset in the originally + Remove connectng rod, its cap should be kept as a set, do not mix. Extent of removal: @ Thermostat removal @ Piston removal @ Stator assembly removal @ Cylinder body disassembly Extent of removal | Order Part name Qty Remarks ® Thermostat cover Thermostat Nut Flywheel magneto Stator assembly Refer to “REMOVAL POINTS" Stator bracket Timing belt Bolt Crankcase Bolt Refer to “REMOVAL POINTS’, Connecting cap Drive gear Circlip Piston pin Refer to “REMOVAL POINTS", Piston Exhaust cover (Outer) Exhaust cover (inner) Cylinder body 7 2 3 4 5 6 7 8 9 10 W 12 | Crankshaft 13, 14 15 16 7 18 19 aaan|wasan|ssgss|sees5 REMOVAL POINTS FLYWHEEL MAGNETO 1. Remove: + Nut yr Flywheel holder: YB-6139 / 90890-06522 2, Remove: + Flywheel magneto EZ Flywheel puller: YB-6117 / 90890-06521 87POWR! S CYLINDER, PISTON AND CRANKSHAFT S C2, ae TIMING BELT 1. Remove: + Timing belt © NOS Remove the timing belt at the driven gear side. DRIVE GEAR 1, Remove: Lock nut = Drive gear @) GZ] Shaft holder: Va 1-90890-06069 NOTE: Before removing the lock nut, straighten the lock washer tab. INSPECTION AND REPAIR FLYWHEEL MAGNETO 1. Inspect: + Flywheel teeth @ Wear/Damage — Replace. DRIVE GEAR 1. Inspect: + Drive gear Wear/Damage -> Replace. 58POWR e CYLINDER, PISTON AND CRANKSHAFT S TIMING BELT 4. Inspect: + Timing belt Stretch/Wear/Damage — Replace. THERMOSTAT 1, Inspect: + Thermostat Stick/Damage —> Replace. 2. Measure: + Valve opening temperature + Valve lift Out of specification —- Replace. AA Water temperature] Valve lift Below 58-62°C (ie uae] 0mm (0 in) : in.3 mm Above 70°C (158F) | 94 in) Measurement steps: + Suspend thermostat in a vessel. + Place reliable thermometer in a water. + Heat water slowly. + Observe thermometer, while stirring water continually. CYLINDER 1. Inspect: + Water jacket Mineral deposits/Corrosion — Clean. + Cylinder inner surface Score marks -» Repair or replace. Use #600 ~ 800 grit wet sandpaper. 59POWR: eS CYLINDER, PISTON AND CRANKSHAFT QS ‘0mm (2.4) a) ee : Dard Oy |= Ail re 2, Measure: + Cylinder bore “D" Use cylinder gauge. Out of specification — Rebore or Replace. NOTE: Measure the cylinder bore "D” in parallel. Then, the average of the measurement. a Standard = |W limit Cylinder [59.00 ~ 59.02 mm |59.1 mm bore D: | (2.323 ~ 2.324 in) | (2.326 in) ‘Cylinder = 0.08 mm. taper T: (0.003 in) D = Maximum Dia (D, ~ Dg) T = (Maximum D, or D) — (Minimum Ds or Ds) PISTON 1. Inspect: + Piston wall Wear/Scratch/Damage —- Replace. 2. Measure: «Piston diameter Use a micrometer. Out of specification —- Replace. a [Distance @| Piston dia. [Standard] 10mm {58.950 ~ 58.965 mm| (0.39 in) _|(2,3209 ~ 2.3215 in) Over 1 [59.25 mm (2.339 in)*| size 2 [59.50 mm (2.343 in) * Except for USA NOTE: Measure specific distance @ from the bottom edge. 6-10POWR CYLINDER, PISTON AND CRANKSHAFT eS But PISTON CLEARANCE 1. Calculate: Piston clearance Out of specification —- Replace piston and piston ring and/or cylinder. piston —_|_[cyunper | [Piston CLEARANCE |~| BORE DIAMETER Piston clearance: 0.035 ~ 0.065 mm (0.0014 ~ 0.0026 in) PISTON PIN 1. Inspect: +*Piston pin Signs of heat discoloration + Replace. 2. Measure: +Piston pin diameter Use a micrometer @. Out of specification —- Replace. Piston pin diameter: 13.996 ~ 14.000 mm (0.5510 ~ 0.5512 in) 8. Check: + Free play (When the piston pin isinto small ‘end of connecting rod.) There should be no noticeable play. Free play exists + Replace the pin and/or connecting rod as required.POWR! CYLINDER, PISTON AND CRANKSHAFT <>) 4, Check + Free play (When the piston pin is in place of the piston.) There should be no noticeable play. Free play exists —- Replace the pin and/or piston. PISTON RING 1. Measure: + Side clearance Using a feeler gauge @. Out of specification —- Replace piston and/or ring, As Side clearanc Top | 0.04 - 0.08 mm (0.002 ~ 0.00: and | 0.03 ~ 0.07 mm (0.001 ~ 0.003 in) 2, Measure: + End gap Using a feeler gauge. Out of specification —- Replace. A End gap: Top | 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) 2nd | 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) oi | 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) NOTE: Install the piston ring into the cylinder. Push the ring with the piston crown. CRANKSHAFT 1, Measure: + Runout Use a V-blocks and dial gauge. Out of specification —- Replace. Runout: 0.02 mm (0.0008 in) 512POWR CYLINDER, PISTON AND CRANKSHAFT ap} CRANKSHAFT MAIN BEARING CLEARANCE 1, Measure: + Oil clearance (Main journal) ut of specification —- Replace bearing. ‘Main bearing clearance: 0.005 ~ 0.043 mm (0.0002 ~ 0.0017 in) Measurement steps: CAUTION: —— Do not interchange the bearings. They must be installed in their original posi- tions, or the correct oil clearance may not be obtained causing engine damage. + Clean the bearings, main journals and bearing portions of the crankcase and cylinder body. +Place the cylinder body on a bench in an upside down position. + Install half of the bearings @ and crankshaft @ into the cylinder body @. NOTE: Align the projection @ of the bearing with the notch in the cylinder body. + Puta piece of plastigauge onto the crankshaft journal surface. Install half of the bearings @ into the crankcase. NOTE: Align the projection of the bearing with the notch in the crankcase. + Do not turn crankshaft until clearance measurement has been completed. 513POWR' eS CYLINDER, PISTON AND CRANKSHAFT eS B14 + Tighten the bolts in sequence and two steps of torque. Na Bolt (M8): Ast: 15 Nm (1.5 mrkg, 11 ftlb) 2nd: 30 Nm (3.0 mkg, 22 ftb) Bolt (M6): ist: 6 Nm (0.6 mkg, 4.3 ftb) 2nd: 12 Nm (1.2 mkg, 8.7 ftib) + Remove the bolts and the crankcase. *Measure the compressed plastigauge width on each main journal. COMBINATION OF CRANKCASE AND BEARING 1. Crankcase: Mark @ Housing size . 33,082 ~ 33.040 mm (1.3005 ~ 1.3008 in) : 33.024 ~ 33.032 mm (1.3002 ~ 1.3005 in) c 33.016 ~ 33.024 mm (1.2998 ~ 1.3002 in) 2. Bearing: Indication © Bearing size a 1.508 ~ 1.512 mm (0.0594 ~ 0.0595 in) 1.504 ~ 1.508 mm cee (0.0592 ~ 0.0594 in) 1.500 ~ 1.504 mm ca (0.0591 ~ 0.0592 in) 3. Combination: ‘Combine the crankcase and bearing by the following chart. Crankcase mark | Bearing indication A Blue Black BrowneS CYLINDER, PISTON AND CRANKSHAFT QB CONNECTING ROD OIL CLEARANCE 1. Measure: + Oil clearance Out of specification — Replace connecting rod and cap as a set. ‘Connecting rod oil clearance 0.021 ~ 0.045 mm (0.0008 ~ 0.0018 in) Measurement steps: CAUTION: ——_____ + Assemble the connecting rod and the cap referring the marking. +Do not assemble connecting rodand the cap with #1 and #2 togeth + Clean the bearing portions of the connecting rod. + Install the connecting rod to the crankshaft. Put a piece of plastigauge onto the crank pin. + Install the connecting rod cap. OT + Make sure that the “6G803" marks on the connecting rods face toward flywheel side of the crankshaft. + Do not turn the connecting rod or crankshaft until clearance measurement has been completed. * Tighten the bolts in sequence in twosteps of torque. mM Bolt (M8): 1st: 6 Nm (0.6 m-kg, 4.3 ftib) 2nd: 12 Nm (1.2 kg, 8.7 ftb) «Remove the bolts and the connecting rod cap. +Measure the compressed plastigauge width on each crank pin. 515CYLINDER, PISTON AND CRANKSHAFT ASSEMBLY AND INSTALLATION PISTON AND CONNECTING ROD 1, Install: + Expander ring @ + Side ring @ 2. Install: Piston ring (2nd) © +Piston ring (top) @ NOTE: Align the piston ring gap with the pin of the piston, + Oil the pistons and rings liberally. 3. Install: +Piston @ +Connecting rod @ + Piston pin @ *Circlip ® Nore; +Mold mark @ faces in the same direction as the "UP* mark on the piston, + Always use a new circlip. Oil the pistons, piston pins and connecting rods liberally. CYLINDER AND CRANKCASE 1, Install: + Piston assembly + Cylinder body @ ton slid YB-34454 / 90890-06529 CR The piston should be installed with the “UP” mark on the piston crown facing toward the flywheel side. 516POWR CYLINDER, PISTON AND CRANKSHAFT S a NOTE: *Position the ring end gaps before insert the piston. ‘Align the piston ring gap (top and 2nd) with the pin of the piston. @Side rail end gap Expander ring end gap ©Piston ring (2nd) end gap @Piston ring (top) end gap 2. Install: + Crankshaft main bearing ® NOTE: Align the projection of the bearings with the Rotch in the cylinder body and crankcase. 8. Install: + Thrust plate @) +Crankshatt @) NOTE: «Install the thrust plates so that the oil groove @ side is on the crank side. + When installing the crankshaft on the cylinder body, be sure to fit the thrust plate tab in the cut of the cylinder body. 4. Install: + Connecting cap @) + Bolt @ CAUTION: + Assembly the connecting rod and its cap referring the marking. +Do not assemble connecting rod and cap with #1 and #2 together. 617 NOTE: Oil the connecting cap and crank pin liberally. SJ Bolt: Ast: 6Nm (0.6 m-kg, 4.3 ft-Ib) 2nd: 13 Nm (1.3 m-kg, 9.4 ft-lb)POWR' CYLINDER, PISTON AND CRANKSHAFT SS 5. Install: «Dowel pin ® + Oil seal (upper) @ + Oil seal (lower) @ NOTE: Install the oil seal with its manufacture’s marks ‘or numbers facing outward, 6. Apply: + Gasket maker Onto the crankcase. NOTE: + Clean the contacting surface of the crankcase and cylinder body before applying the Gasket maker. + Gasket maker should be so applied that itdoes not overflow the contacting surface. 7. Install: +Crankcase © + Bolt (Ma) @ «Bolt (Mé) @ NOTE: ——EEEE Tighten the bolts in sequence in two steps of tor~ que. Na Bolt: M8 1st: 15 Nm (1.5 mkg, 11 ftlb) 2nd: 30 Nm (3.0 mkg, 22 ftlb) M6 1st: 6 Nm (0.6 mkg, 4.3 ftlb) 2nd: 12 Nm (1.2 mkg, 8.7 ft-lb) EXHAUST COVER 1. Install: «Gasket © + Exhaust cover (inner) @ + Exhaust cover (outer) @ Bolt @ NOTE: — Tighten the boltsin sequence in two steps of torque. 518POWR CYLINDER, PISTON AND CRANKSHAFT ce} 7) Os oy TIMING BELT 1. Install: + Washer @ + Woodruff key @ + Drive gear @) * Washer @ NOTE: + The projections on the drive gear should the holes in the washers. "TOP" mark side should face upward. 2. Install: + Lock washer + Nut NOTE: + Insert the projection of the lock washer to be matched with the “TOP* mark. + After tightening the nut, bend the lock washer ‘over the nut. Shaft holder: / 90890-06069 Sa ‘Nut: 23 Nm (2.3 mrkg, 17 tb) 3. Align: + Drive gear mark + Cylinder body mark © NOTE: a Turn the crankshaft clockwise. 519CYLINDER, PISTON 5.20 AND CRANKSHAFT 4. Align: + Drive gear mark @ + Cylinder head mark ©) NOTE: Tum the camshaft clockwise. 5. Install: +Timing beit CAUTION: + Protect the belt from water and oil. + Do not use an iron fever when installing the belt. + Use care not to scratch the belt. NOUS +Be sure that the "YAMAHA" mark is not inverted. + Place the timing belt around the drive gear and then around the driven gear. + When placing the timing belt around the driven gear, lock both drive and driven gears sc that they do not turn. OIL PRESSURE SWITCH 1. Install + Oil pressure switch OD [ 2. Install: + Switch lead @ +Screw @ +Cover @ NOTE: Route the switch lead over the recess in the cylinder body. im Oil pressure switch: 9Nm (0.9 m-kg, 6.5 ft-Ib) Screw: 2.Nm (0.2 mkg, 1.4 ftib)POWR' CYLINDER, PISTON AND CRANKSHAFT THERMOSTAT 1. Install: + Thermostat O + Gasket @ + Thermostat cover @) + Bolt @ + By-pass hose ©) NOTE: Always use a new gasket. STARTER MOTOR 1. Install + Bracket @ + Bolt @ 2. Install: + Battery lead @ =Nut @ + Starter motor @ *Bolt@ | ‘Nut: 4 Nm (0.4 mkg, 2.9 ftb) 521 8. Install: +Relay bracket, + Starter relay assembly + Bolt @ “Battery lead @ + Washer @ +Nut © NOTE: + Secure, together with the starter relay ground lead @. + Connect the battery lead to both of the starter, motor and starter relay. mM Nut: 4.Nm (0.4 mkg, 2.9 ft1b)POWR a CYLINDER, PISTON AND CRANKSHAFT FLYWHEEL MAGNETO 1. Install: Dowel pin @ + Stator bracket @ +Screw @ + Stator assembly @ +Bolt © Woodruff key ©) 2. Install: + Flywheel magneto @ Washer @) =Nut @ Flywheel holder: YB-6139 / 90890-06522 Nut: 100 Nm (10 mkg, 72 fb) 52Powel]POWR: CYLINDER HEAD, VALVE AND CAMSHAFT QS CYLINDER HEAD, VALVE AND CAMSHAFT PREPARATION FOR REMOVAL * Remove the power unit. Remove the following parts: + CDI unit +Reetifier regulator + Ignition coil + Flywheel magneto + Stator assembly * Timing belt 2 Nm (0.2 mkg, 1.4 ftib) 8 Nm (0.8 mkg, 6.8 ftib) 13 Nm (1.3 mg, 9.4 FB) a B ce D 18 Nm (1.8 mkg, 19 fb) Yet 15 Nm (1.5 mkg, 11 fib) 2nd: 30 Nm (3.0 mkg, 22 ftib) 623POWR: S| CYLINDER HEAD, VALVE AND CAMSHAFT eS NOTE ON REMOVAL AND REASSEMBLY + Before servicing, clean the power unit + Remove any gasket adhered to the contacting surface. + Take care not to scratch the contacting surfaces when removing the cylinder and cylinder head. + For reassembly, the removed parts shouldbe cleaned with solvent, and apply gear oil to the sliding surfaces. Extent of removal: @ Intake manifold removal @ Oil pump assembly removal ® Cylinder head removal @ Valve disassembly Extent of removal | Order Part name ay Remarks ro ‘ | | | Bolt Intake manifold Bolt Cylinder head cover Bolt Cylinder head Bolt Oil pump assembly Adjust screw Valve lifter Rocker shaft Rocker arm Bolt Driven gear Camshaft Refer to “REMOVAL POINTS" | Refer to “REMOVAL POINTS”. | Loosen the screw. Refer to “REMOVAL POINTS". Valve cotter valve (intake) Spring retainer Valve (exhaust) nywaltssan|patet|oiaso | Refer to “REMOVAL POINTS’ REMOVAL POINTS CYLINDER HEAD 1, Remove: + Cylinder head ® Nore: — *To remove the cylinder head, insert a bar between the cylinder head and cylirder body, and then separate it. ‘Do not to scratch the gasket contact surfaces, by the screw driver. ROCKER SHAFT 4. Loosen: + Lock nut D + Adjust screw @ Valve adjuster: YB-8035 / 90890-01311 5.24POWR' CYLINDER HEAD, VALVE AND CAMSHAFT eS 2, Remove: + Rocker shatt © NOTE: Use M10 bolt to extract the rocker shaft. DRIVEN GEAR 1. Remove: + Bolt D + Driven gear @) Flywheel holder: Z|“ Ve-6130 7 90090-06522 VALVE 1, Remove: +Valve cotter ® +Valve @ 4 Valve spring compressor: YM-1253 / 90890-04019 CC ————— Hold down the valve spring and remove the valve cotter. 2. Remove: + Valve lifter + Spring retainer +Valve @ Valve spring compressor: YM-1253 / 90890-04019 \F OTe Hold down the valve spring, remove the valve lifter and slide out the retainer. 525POWR e CYLINDER HEAD, VALVE AND CAMSHAFT > pf INSPECTION AND REPAIR OIL SEPARATOR 1, Measure: + Reed valve warpage @ Out of specification —- Replace. Reed valve warpage limit: 0.2 mm (0.008 in) lL PUMP 1. Measure: + Clearance (between outer rotor D and pump housing ® + Clearance © (between inner rotor @ and outer rotor D) + Clearance © (between out rotor @ and pump housing ® Use a feeler gauge. Out of specification —- Replace oil pump assembly. AX Clearance: 0.06 ~ 0.11 mm ® (0.0024 ~ 0.0043 in) 526 0.02 ~ 0.15 mm (0.0008 ~ 0.0059 in) 0.02 ~ 0.07 mm (0.0020 ~ 0.0028 in) ROCKER SHAFT AND ROCKER ARM 1, Measure: + Rocker shaft diameter Out of specification —+ Replace. Rocker shaft diameter: 12.94 ~ 12.95 mm (0.509 ~ 0.510 in)CYLINDER HEAD, VALVE AND CAMSHAFT Cc) 2. Inspect: + Rocker arm @ Scratch/Damage — Replace. + Adjust screw @ Wear/Damage — Replace. 3. Check: +Free play (When the rocker shaft is in place of the rocker arm.) There should be no noticeable play. Free play exists —- Replace the rccker shaft and/or rocker arm. VALVE LIFTER 1. Inspect: + Valve lifter Scratch/Damage — Replace. CAMSHAFT 1. Inspect: + Cam lobes Pitting/ScratchBlue discoloration > Replace. 2, Measure: +Cam lobe length @ +Cam lobe length ©) Out of specification + Replace. 6aPOWR) S| CYLINDER HEAD, VALVE AND CAMSHAFT GED Cam lobe length: i 24.541 ~ 24.641 mm ® (0.966 ~ 0.970 EX 24.578 ~ 24.678 mm (0.968 ~ 0.972 in) i 20.137 ~ 20.237 mm ® (0.793 ~ 0.797 in) i 20.178 ~ 20.278 mm (0.794 ~ 0.798 in) 628 CYLINDER HEAD 1. Inspect: + Water jacket Mineral deposits/Corrosion — Clean. + Combustion chamber Carbon deposits > Clean. Use a round scraper. 2, Measure: + Cylinder head warpage Use a straightedge and thickness gauge. ‘Out of specification + Replace the valve Warpage limit: 0.1 mm (0.004 in) Resurfacement steps: +Place a 400 ~ 600 grit wet sandpaper on the surface plate. +Resurface the head using a figure-eight sanding pattern. NOTE: Rotate the head several times to avoid removing too much material from one side. 8. Inspect: +Valve guide O Wear/Damage — Replace.POWR| eS CYLINDER HEAD, VALVE AND CAMSHAFT QD 4, Measure: *Valve guide bore @ Use a bore gauge @. ut of specification + Replace the valve guide. ot: Valve guide bore: IN 5.500 ~ 5.512 mm EX (0.2165 ~ 0.2170 in) Replacement steps: NOTE: Heat the cylinder head in an oven to 200°C (292'F) to ease guide removal and installation and to maintain correct interference fit. +Remove the valve guide using the valve guide remover. Valve guide remover: YM-1122 / 90890-06801 + Install the circlip and valve guide (new) using the valve guide installer and valve guide remover. ¢Z_] Valve guide instal 7 YB-6308 / 90890-06802 After installing the valve guide, bore the valve guide using the valve guide reamer®) to obtain proper stem-to-guide clearance. Valve guide reamer YM-1196 / 90890-06804 5. Eliminate: + Carbon deposit from valve face and valve seat. 6. Inspect: + Valve seat Wear/Pitting —+ Reface the valve seat 529POWR x CYLINDER HEAD, VALVE AND CAMSHAFT 7, Measure: + Valve seat width @ ut of specification — Resurface. a IN EX Valve seat width: 0.6 ~ 0.8 mm (0.024 ~ 0.031 in) 530 Measurement steps: + Apply the Mechanic's bluing dye @ to the valve face. + Install the valve into the cylinder head. + Press the valve through the valve guide onto the valve seat to make a clear pattern. + Measure the valve seat width. Wherever the valve seat and valve face made contact, bluing will have been removed. 8. Reface: *Valve seat Use a 30°, 45° and 85° valve seat cutter. When twisting cutter, keep an even downward pressure (4 ~ 5 kg) to prevent chatter marks.POWR' CYLINDER HEAD, VALVE AND CAMSHAFT eS Cut sections as follows. Section Cutter A as y 8 45° ye A c 30° Refacing steps: [A] Vaive seat is centered on valve face but ! ! itis too wide. 1 1 ox Valve seat cutter set | Desired result Ss Use | 85° cutter | To reduce valve I lightly [30° cutter | seat width. 1B] Valve seat is in middle of the valve face but it is too narrow. Valve seat cutter set| Desired result To achieve a os Use | 45° cutter | uniform valve seat width. [© Valve seat is too narrow and it is near valve margin. Valve seat cutter set] Desired result 1 1 1 1 Sent : 85° cutter, | To center the seat Oe, Use first__| and to achieve its 45° cutter | width. [D) Vatve seat is too narrow and it is loceted near the bottom edge of the valve face. Valve seat cutter set] Desired result Use t__| and to increase its \ 45° cutter | Width. Se 80° cutter, |To center the seat 531POWR: eS CYLINDER HEAD, VALVE AND CAMSHAFT 9. Lap: Valve face + Valve seat Oe After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: + Apply a coarse lapping compound to the valve face. CAUTION: — Be sure no compound enters the gap between the valve stem and guide. *Apply a molybdenum disulfide oil to the valve stem. + Install the valve into the oylinder head. + Tum the valve until the valve face and valve seat are evenly polished, then clean off all compound. NOTE: — To obtain the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. “Apply the fine lapping compound to the valve face and repeat the above steps. NOTE: Be sure to clean off all compound from the valve face and valve seat ater every lapping operation. 532 + Apply the Mechanic’s bluing dye to the valve face. ‘Install the valve into the cylinder head. + Press the valve through the valve guide and onto the valve seat to mark a clear pattern.POWR CYLINDER HEAD, VALVE AND CAMSHAFT SS + Measure the valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat. VALVE 1. Inspect: *Valve face Carbon deposits —- Clean. Pitting/Wear —> Grind the face. + Valve stem end Mushroom shape or diameter larger than rest of stem — Replace. 2. Measure: + Margin thickness @ Out of specification + Replace. A Margin thickness: IN 0.5 ~ 0.9 mm Ex (0.020 ~ 0.035 in) 3. Measure: + Valve stem diameter @ Out of specification Replace. A Valve stem diameter: IN 5.475 ~ 5.490 (0.2156 ~ 0.2161 in) EX 5.460 ~ 5.475 mm (0.2150 ~0.2156 in) 4, Measure: + Valve stem runout Out of specification ~ Replace. A Stem runout limit IN 0.016 mm EX (0.0006 in) 533|PowR Ge CYLINDER HEAD, VALVE AND CAMSHAFT & NOT + Always replace the guide if the valve is replaced. «Always replace the oil seal if the valve is removed. VALVE SPRING 1. Measure: + Compressed force Out of specification - Replace. —-® Compressed force: WN |setionstn@ |e ~ Sov ke, Ex. | 24.4.mm (096 In) | 8 Dao 2. Measure: + Spring tt Out of specification + Repiace. A Tilt limit: 1.1. mm (0.043 in) 534POWR| CYLINDER HEAD, VALVE AND CAMSHAFT ASSEMBLY AND INSTALLATION OIL PUMP ASSEMBLY 4. Install: +Pump housing @ + Outer rotor @ ‘+ Inner rotor @ +Shatt @ + Oring © +Pump cover © +Screw D NOT a ‘Align the shaft with the hole in the inner rotor shaft and insert. *Oil the rotors liberally before installing the Pump cover. CYLINDER HEAD 1. Install Oil seal © *Screw @ + Anode @) +O-ring @ +Bolt® NOTE: Sas eaniesaeanissusemae Install the oil seal with its manufacture's marks ‘or numbers facing outward. Na Bolt: 18 Nm (1.8 mkg, 13 ft1b) 2. Apply: + Engine oil Onto vaive and oil seal NOTE: Always use a new oil seal.POWR CYLINDER HEAD, VALVE AND CAMSHAFT =o 3. Install: *Valve (intake) Oil seal @ + Spring seat @ +Valve spring ® + Spring retainer ©) +Valve cotter © Valve spring compressor: ‘YM-1253 / 90890-04019 NOTE: —_______—_ +Hold down the valve spring and install the valve cotter. = Secure the valve cotter onto the valve stem by tapping it lightly with a piece of wood. 4. Install: = Valve (exhaust) D Oil seal @ «Spring seat @ + Valve spring @ + Spring retainer ©) +Valve lifter © 2] Valve spring compressor: 7 YM-1253 / 90890-04019 NOTE: + Hold down the valve spring, install the spring retainer and slide in the retainer. + Secure the vaive lifter onto the valve stem by tapping it lightly with a piece of wood. 5-36CYLINDER HEAD, VALVE AND CAMSHAFT 2 5. Install: Camshaft D + Washer @) + Woodruff key @ + Driven gear @ Washer ©) Bolt © Flywheel holder: YB-6139 / 90890-06522 Bolt: 13 Nm (1.3 mkg, 9.4 ftib) | hye 6. Apply: + Engine oil ‘Onto rocker shaft and rocker arm. 7. Install: Rocker shaft (exhaust) Collar @ + Rocker arm @ ‘+ Compression spring (short) @ Collar © + Rocker arm @ + Compression spring (short) @ NOTE: 637 Install the rocker shaft so that the internal thread side is on your side. 8. Install: «Rocker shaft (intake) © + Compression spring (long) @ + Rocker arm @) +Collar @ «Compression spring (short) ©) + Rocker arm ©)POWR) q| CYLINDER HEAD, VALVE AND CAMSHAFT QS 5.98 9. Install: + O-ring ® Oil pump assembly @ + Bolt @ NOTE: Align the recess in the oil pump shaft with the camshaft projection. 10. Install: +Oxing ® + Dowel pin @ + Gasket @ inder head assembly @ 5 Nm (1.5 mkg, 11 ftb) 10 Nm (3.0 m-kg, 22 ftlb) CAUTION: When installing the cylinder head on the cylinder body, set the piston at bottom dead center (BDC); otherwise, the piston may butt against valves, thus damaging them. OT + Apply the engine oil to the thread of each cylinder head fixing bolt and seat surface. + Tighten the bolts in sequence and two steps of torque, 11. Install: «Timing belt Refer to page 5-20. 12. Adjust: *Valve clearance Refer to page 3-8.CYLINDER HEAD, VALVE AND CAMSHAFT CYLINDER HEAD COVER 1. Install: +Seal © + Cylinder head cover @) «Bolt @ + O-ring @ +Oil filer cap ©) INTAKE MANIFOLD 1. Install: + Stud bolt © + Gasket @) «Intake manifold @) OIL SEPARATOR 1. Install: + Reed valve © Washer @) *Screw @ & mM Screw: 2.Nm (0.2 mkg, 1.4 ftlb) 2. Install: + Oil separator body @ + Gasket @ + Breather @ +Screw @ Gasket © Cover © +Screw @CYLINDER HEAD, VALVE AND CAMSHAFT eS) NOTE: Always use a new gasket. | Screw: 2.Nm (0.2 kg, 1.4 ftlb) 3. Install: +Oil separator © +Screw @ + Hose (long) @ + Hose (short) @ +Hose (breather) © 540POWR RECOIL STARTER @® RECOIL STARTER = PREPARATION FOR REMOVAL * Remove the power unit. + Wear a proper safety gogle and gloves for * Flemove the flywheel magneto, protect your id hands. «Use care, the spiral jumps out and may injure a person. + When removing the sheave drum, use care ‘so that the spiral spring does not jump out.= POWR eS RECOIL STARTER QS Extent of removal: @) Recoil starter removal @ Starter rope removal @ Recoil starter disassembly Extent of removal | Order Part name Qty Remarks ] of 1 | Bolt 3 2 | Recoil starter assembly 1 3 Bolt - 4 | Guide plate 1 | 5 _| Bolt 1_| Loosen the lock nut 6 Pin 1 7 Pinion 1 2 | Bott 4 9 | Stopper arm i to_| Bott 3 “| 11 | Cover 1 12. | Cotter pin 1 43. | Drum stopper 4 14 | Bolt 1 45_| Roller 4 _ _ 13 | Sarwerope” 1) | Reter to “REMOVAL POINTS” 18 | Spiral spring 1 Refer to "REMOVAL POINTS”. REMOVAL POINTS STARTER ROPE 1, Remove: + Sheave drum D + Starter rope @ a Insert a slotted-head screwdriver into the hole in the sheave drum, and remove the spiral spring from the sheave drum by pushing the spring.POWR S| RECOIL STARTER 2 SPIRAL SPRING 1, Remove: + Spiral spring @ NOTE: Hold the starter housing @ with the spiral spring facing downward. Insert a standard-head screw driver into the hole in the sheave drum shaft, and push the sprial spring out. INSPECTION STARTER ROPE 1. Inspect: + Starter rope Damage -- Replace. SPIRAL SPRING 1. Inspect: + Sprial spring Wear/Damage —> Replace. ‘SHEAVE DRUM AND STARTER HOUSING 1. Inspect: + Sheave drum @ + Starter housing @ Damage — Replace. PINION 1. Inspect: *Pinion Damage ~» Replace. 543POWR) RECOIL STARTER & ASSEMBLY AND INSTALLATION 1. Install: + Starter housing D + Thrust washer @) + Spiral spring @ NOTE: 1. After installing the new spiral spring, cut the wire holding the spring, 2. When reusing the spiral spring, set the lead- ing end first in the housing and then fit one turn each time. Use special care. The spring can easily come off. The spiral spring may jump out so use special care. 2. Install: +Starter rope @ +Sheave drum @ NOTE: +Make a knot on one end. + Pass the rope through the hole in the sheave drum and wind it 5.5 turns around the drum. + Place the rope in the recess on the drum. 3. Install: + Bushing *Roller @) +Washer @ + Spring washer © *Bolt © oo After installing, route the starter rope between the starter roller and starter housing. 544 4. Install: + Starter housing © NOTE: Fit the spiral spring hook into the sheave drum. groovePOWR| RECOIL STARTER oz? 545 5. Install: Drum stopper + Stopper spring @ +Collar @) +*Washer @ + Cotter pin @ 6. Install + Cover ® + Spring washer @ + Bolt @ 7. Install: *Arm spring D + Stopper arm @ Washer @ + Spring washer @ +Bolt © CAUTION: Firmly hold the rope or the rope will be pulled in. NOTE: + Hook the spring onto the starter hou: stopper arm. + Align the arrow marks on the collar and stopper arm, + After assembling, wind the rope 4 turns clockwise around the sheave drum to contract the spring. While holding the rope firmly, tie the rope temporarily to the starter roller.POWR' RECOIL STARTER 5-46 8. Install: Washer ® = Bushing @ +Pinion @ «Friction spring @ +Pin® = Washer © + Bolt @ *Lock nut © CAUTION: Do not open the spring end gap to fit it, or the gap will become large, thus making the spring unusable. It should be fit in the same manner as a piston ring. 9. Install: + Protector D + Damper @) + Guide plate @ + Spring washer @ +Bolt © NOTE: Put the protector into the loop of the friction spring 10. Install: + Recoll starter assembly @ +Bolt @ 11. Install: + Start in-gear protection wire Refer to page 5-4.LOWR' CHAPTER 6 LOWER UNIT LOWER UNIT... : . PREPARATION FOR REMOVAL (T9.9/F9.9A) NOTE ON REMOVAL AND REASSEMBLY .. PREPARATION FOR REMOVAL (F8B, F9.9/F9.98).... NOTE ON REMOVAL AND REASSEMBLY .. REMOVAL POINTS .. Shift shatt.. Pinion gear Needle bearing .. Bearing outer race Reverse gear complete ..... Forward gear complete (F8B, F9.9/F9.98).. INSPECTION AND REPAIR LOWEr CSE enn Bearing housing .. Water pump housing Impeller ... Shift shaft Gear .. Bearing ... Drive shaft Propeller shaft Dog clutch Sleeve . Propeller/anode ASSEMBLY AND INSTALLATION 6-10 Forward gear 6-10 Propeller shaft 6-10 Reverse gear ... 610 Oil seal housing ett o 612 615 - 617 619 6-23 6-23 6-26 Lower case .. —— ‘Shim selection (For USA and CANADA).. Shim selection (Except for USA and CANADA). Backlash measurement Water pump Lower unit PropellerA] 26Nm (2.6 m-kg, 19 ft-Ib) B | 13Nm (1.3 m-kg,9.4 ft-1b) PREPARATION FOR REMOVAL (T9.9/F9.9A) * Drain the gear oil. LOWR| € LOWER UNIT LOWER UNIT 61LOWR' LOWER UNIT &e NOTE ON REMOVAL AND REASSEMBLY + Tilt up the engine a little, this provides easier oil draining. + Remove any gasket adhered to the contacting surface. +The shim pack will be re-use therefore use care not to damage when removing. + For reassembly, the removed parts should be cleaned with solvent. Extent of removal: — @ Lower unit removal @ Impelier remove @ Lower unit disassembly Extent of removal] Order Part name ary Remarks Corer in | Nat Propeller | ‘Spacer Nut Bolt Lower unit Bolt 10 _| Water pump housing 1 2 3 4 5 _| Lock nut é 7 8 9 11 | impelier 12 | Woodrut key 13 | Gasket |] 44 | Outer piate 15 _| Screw | | |46—Y shift shart | Reter to REMOVAL POINTS" o 17° | Bolt | 18 | Reverse goar complete Roter to"REMOVAL POINTS" 19 | Propeler shaft complete 20_| Nut Roterto“REMOVAL FOINTS" 21 | Pinion gear 22 | Thrust bearing 23 | Pinion gear shim 24 | Drive shaft 25 _| Forward gear complete 26 | Oil seal housing 27 | Sleeve 28 | Needle bearing | 29 | Bearing outer race | 30_| Reverse gear Refer to “REMOVAL FOINTS” Refer to “REMOVAL FOINTS” 31 | Reverse gear shim 32 | Ball bearing 33. | Needle bearing 34 | Cross pin ring } | 35 | Gross pin | 36 | Dog clutch 37 | Taperroller bearing 38 | Forward gear shim 39_| Foeward gear 62LOWR| et LOWER UNIT PREPARATION FOR REMOVAL (FEB, F9.9/F9.9B) * Drain the gear oil. a 26 Nm (2.6 m-kg, 19 ft-lb) eo 13 Nm (1.3 m-kg,9.4 ft-lb) way 63LOWR| LOWER UNIT & NOTE ON REMOVAL AND REASSEMBLY + Tilt up the engine a litte, this provides easier oil draining. + Remove any gasket adhered to the contacting surface. +The shim pack vill be re-use therefore use care not to damage when removing. +For reassembly, the removed parts should be cleaned with solvent. Extent of removat — @ Lower unit removal @ Impeller remove @ Lower unit disassembly Extent ofremoval_| Order Part name Qty Remarks Cotter pin Nut Propeller Spacer Nut Bolt Lower unit Bolt 10 _| Water pump housing 1 2 3 4 | 5 _| Lock nut 6 7 8 9 11 | Impeller 12_| Woodruff key 13. | Gasket 14 | Outer plate 15 | Screw 16 | Shit shaft ler to "REMOVAL POINTS 17 | Bot ® | 12 | Reverse gear compote Rotor to “REMOVAL POINTS: 19 | Propelier shaft complete 20_| Nut Reter to “REMOVAL POINTS: 21 | Pinion gear 22 | Thrust bearing 23 | Pinion gear shim 24 | Drive shaft 25 _| Forward gear complete 26 | Oilseal housing 27 | Sleeve 28 | Needle bearing 29° | Bearing outer race 30_| Forward gear shim Refer to "REMOVAL POINTS". Refer to “REMOVAL POINTS". 31 | Reverse gear 32 | Reverse gear shim 33 | Ball bearing 34 | Needle bearing 35 _| Cross pin ring } | Reter to “REMOVAL POINTS” | 36 “| Gross pin | 37 | Dogelutch 38 | Taper roller bearing 39_| Foeward gear Refer to "REMOVAL POINTS". 64LOWER UNIT REMOVAL POINTS SHIFT SHAFT 1. Remove: +Sorew © + Bracket @ + Shift shaft @ ON Push the projections of the bracket evenly (as shown in the illustration) and pull the bracket up. PINION GEAR 1. Remove: Nut + Pinion gear @) Pinion nut holder: YB-6078 Drive shatt holder: YB-6226/90890-06515 T9.9/F9.0A @ al eee, ‘o 1 F9.9/F9.98 TH @ 65 NEEDLE BEARING 1. Remove: + Needle bearing ® i Drive rod: ‘YB-6229/90890-06602 Needle bearing attachment: T9.9/F9.9A: YB-6298/90890-06618 F9.9/F9.9B: YB-6230/90890-06617 BEARING OUTER RACE 1. Remove: + Bearing outer race @) + Forward gear shim (F8B, F9,9/F9.9B only) @ Slide hammer set: YB-6096 ..... Stopper guide plat 90890-06538 For USA and CANADA (B) Except for USA and CANADA. eeo0eLOWR| t LOWER UNIT REVERSE GEAR COMPLETE 1, Remove: + Ball bearing @ ‘Slide hammer set: YB-6096 .. ‘Stopper guide plate: 90890-06501 ... Bearing puller: 90890-06535 Stopper guide 90890-06538 6ee8 For USA and CANADA Except for USA and CANADA 2, Remove: + Oil seal © + Needle bearing @ Drive rod: YB-6071/90890-06604 Needle bearing attachment: ‘YB-6081/90890-06616 ve FORWARD GEAR COMPLETE (F8B, F9.9/F9.9B) 1. Remove: + Taper roller bearing @ + Forward gear @ Bearing separator: ‘YB-6219/90890-06534 66Lown € LOWER UNIT INSPECTION AND REPAIR LOWER CASE 1. Clean: + Gear case Use a soft brush and solvent. 2. Inspect: + Water passage Mineral deposits/Corrosion — Clean. 3. Inspect: + Lower case Grack/Damage —» Replace. BEARING HOUSING 1. Clean: + Bearing housing Use a soft brush and solvent. 2. Inspect: + Bearing housing Crack/Damage —- Replace. WATER PUMP HOUSING 1. Inspect: + Water pump housing Crack/Damage —- Replace. IMPELLER 1. Inspect: Impeller Crack/Damage —> Replace. 67LOWR| t | LOWER UNIT SHIFT SHAFT 1. Inspect: + Shift plunger Wear/Damage —- Replace. 2. Inspect: + Boot aa Break/Damage — Replace. GEAR 4, Inspect: +Teeth + Dogs Wear/Damage — Replace, BEARING 1. Inspect: + Bearing Pitting/Rumbling — Replace. DRIVE SHAFT 1. Inspect: * Drive shaft Wear/Damage —- Replace. 68ILOWR' € LOWER UNIT PROPELLER SHAFT 1. Inspect: + Propeller shaft Wear/Damage —> Replace. DOG CLUTCH 1. Inspect: oa + Dog clutch 6 Wear/Damage —- Replace. SLEEVE 1. Inspect: + Sleeve 6 5 Wear/Damage —» Replace. PROPELLER/ANODE Refer to page 3-1 ~ 3.2. 69LOWR| t LOWER UNIT T9.9/F9.9A eS ASSEMBLY AND INSTALLATION FORWARD GEAR 1. Install: (T9.9/F9.9A) +Forward gear shim @ ‘+ Taper roller bearing @ + Forward gear @) NOTE: The shim is installed for T9.9/F9.9A model only. T9.9/F9.9A —O 1. Install: (F8B, F9.9/F9.9B) + Taper roller bearing @ + Forward gear @) PROPELLER SHAFT 1. Install: Spring D +Plunger @ + Dog clutch @ *Cross pin @ + Cross pin ring © NOTE: Install the clutch with “F” mark toward the forward gear side. REVERSE GEAR 4. Install: «Needle bearing @ Drive rod: YB-6071/90890-06604 Needle bearing attachment: ‘YB-6081/90890-06616 F9.9/F9.98 8 FeB, \ mo} Depth T9.9/F9.9A: 0 mm (0 in) F8B, F9.9/F9.9B: 0 mm (0 in) NOTE: Install the needle bearing with its manutacture's marks or numbers toward the propeller side, 610LOWR € LOWER UNIT —@ 2. Install: Oil seal © Oil seal installer: ‘YB-6078 Drive rod: YB-6229 Depth ©: 79.9/F9.9A: 4.5 ~ 5.0 mm (0.18 ~ 0.20 in) FSB, F9.9/F9.9B: 5 mm (0.12 ~ 0.14 in) 3. Install: + Ball bearing @ FZ Bearing installer: YB-6015/90890-06632 Drive rod: YB-6071/90890-06606 NOTE: ——— Install the bearing with its manufacture’s marks or numbers facing outward. 4. Install: + O-ring @ + Reverse gear shim @ + Reverse gear @ +Oxing @ OIL SEAL HOUSING 1. Install; +O-ring © Oil seal installer: YB-6022 Drive rod: YB-6229 611LOWR| LOWER UNIT ne © T9.9/F9.9A -@ F8B, F9.9/F9.9B @ LOWER CASE 1. Install: (T9.9/F9.9A) + Bearing outer race © (¢Z_| Bearing installer: Z| _ ve-s08s/90890-06625 Drive rod: YB-6071/90890-06605 1. Install: (F8B, F9.9/F9.9B) + Forward gear shim @ + Bearing outer race @ Bearing installer: ‘YB-6085/90890-06625 Drive rod: YB-6071/90890-06605 NOTE: ‘The shim is installed for F9.9/F9.9B model only. 2. Install: «Needle bearing © 612 Ez ,] Drive rod: YB-6229 Needle bearing installer: YB-6231 Needle bearing attachment: 79.9: YB-6298 F9.9: YB-6230 Drive rod: 90890-06602 Bearing depth plate: ‘90890-06603 Needle bearing attachment: F9.9A: 90890-06618 F9.9B: 90890-06617 [A] For USA and CANADA [B] Except for USA and CANADA aA Depth @: 79.9/F9.9A: 199.6 ~ 200.1 mm eS © @ ©© © 8 (7.86 ~ 7.88 in) FSB, F9.9/F9.9B: 182.2 ~ 182.7 mm (7.17 ~ 7.19 in)LOWR| € LOWER UNIT & NOTE: ———— Install the bearing with its manufacture’s marks or numbers facing outward. 3. Install: + Dowel pin © + Sleeve @ + Gasket @ Oil seal housing @ NOTE: Install the sleeve with projection side backward. 4. Install: + Forward gear complete 5. Install: + Drive shatt © Pinion gear shim @ + Washer (thick) @ +Bearing @ «Washer (thin) ©) +Pinion gear @ Nut @ JF Pinion nut holder: YB-6078 Drive shaft holder: ‘YB-6228/90890-06515 Nut: 26 Nm (2.6 m-kg, 19 ft-lb) 613LOWR| € LOWER UNIT 6. Install: + Shift shaft © + Bracket @ + Screw @ 7. Install + Propeller shaft complete © + Reverse gear complete @) + Bolt @ 8. Check: + Shift cam operation Unsmooth operation —- Repair. Note: —__ Check that the dog clutch shifts to “Forward”, “Neutral” and “Reverse” correctly.LOWR LOWER UNIT SHIM SELECTION (For USA and CANADA) NOTE: —_— Ss +When reassembling the lower unit with the original gear case and inner parts, shim selection is not required. +When replacing the gear case or inner parts, carry out the shim selection. 1, Measure: «Pinion gear clearance Out of specification —- Adjust. ay Clearance: 79.9: 0.45 ~ 0.55 mm F9.9 F9.9; 1.15 ~ 1.25 mm Measurement steps: “Install the drive shaft components and tighten the nut to the specified torque. + Attach the shimming tool into the gear case. FZ Pinion height gauge: ‘79.9: YB-6299 F9.9: YB-34232 + Measure the clearance and determine the shim thickness. 139 Less than To be decreased by 0.45 mm (0.50 ~ measurement) ‘More than To be increased by 0.55 mm (measurement ~ 0.50) Foo Less than To be decreased by 1.15 mm (1.20 - measurement) More than To be increased by 1.25 mm (measurement - 1.20)LOWER UNIT Example: (F8B, F9.9/F9.9B) If measurement = 1.02 mm Decrease shim thickness by .20 — 1.02 18 mm If measurement = 1.32 mm Increase shim thickness by 32 — 1.20 0.12 mm 3%] “avaliable shim thickness: 0.10, 0.14, 0.18 and 0.50 mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: + Forward and reverse shim selection will be done by “BACKLASH MEASUREMENT” section, + Since the smallest shim available is 0.10 mm, if the measurement is between (T9.9) 0.45 and 0.55 mm or (F9.9) 1.15 and 1.25 mm do not change the shim. 616Low LOWER UNIT ‘SHIM SELECTION (Except for USA and CANADA) NOTE: ——___ + When reassembling the lower unit with the original gear case and inner parts, shim selection is not required. + When replacing the gear case or inner parts, carry out the shim selection. 1. Adjust: * Pinion shim thickness Adjustment steps: «Measure the thicknesses (Mv3) of bearing and washer. Digital caliper: 90890-06704 +Use the following equation to calculate the pi- rion shim thickness (T3). F9.9A: 0.10, 0.14, 0.18, 0.35 and 0.50 mm FEB, F9.9B: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm e7LOWER UNIT 2, Adjust: + Forward gear shim thickness Adjustment steps: + Measure the dimension (Mv1). 4 ‘Shimming plate: 90890-06701 Digital caliper: 90890-06704 *Use the following equation to calculate the pi- rion shim thickness (T1). As F9.9A: T1 = 16.50 — Mv1 FSB, F9.9B: T1 = 16.60 — Mvt ‘Available shim thickness: F9.9A: 0.10, 0.14, 0.18 and 0.50 mm FSB, F9.9B: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm. 3. Adjust: + Reverse gear shim thickness Adjustment steps: Measure the dimension (Mv2). A} ‘Shimming plate: 90890-06701 Digital caliper: 90890-06704 =Use the following equation to calculate the pi- rion shim thickness (T2), F9.9A: T2 = 81.00 — Mv2 F8B, F9.9B: T2 = 80.57 — Mv2 ‘Available shim thickness: F9.9A: 0.10, 0.14, 0.18, 0.35 and 0.50 mm. F8B, F9.9B: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm e18LOW! LOWER UNIT BACKLASH MEASUREMENT NOTE: Both forward and reverse gear backlash should be measured. + If both the forward and reverse gear backlash are larger than specified, the pinion may be too high + If both the forward and reverse gear backlash are smaller than specified, the pinion may be too low. + If either of these conditions exists, then check the pinion shim selection, 1, Measure: Forward gear backlash Out of specification —- Adjust. a4 Backlash: T9.9/F9.9A: 0.26 ~ 0.77 mm FSB, F9.9/F9.9B: 0.23 ~ 0.70 mm Measurement steps: +Place the shift shaft in neutral. + Load the forward gear with the bearing housing puller on the propeller shaft. NOT = Lightly tighten by hand until the pressure of the propeller shaft on the forward gear re- stricts movement enough to allow backlash measurement. (2 Bearing housing puller: 7 ‘YB-6234/90890-06503 Universal puller YB-6117 ‘Stopper guide stand: ‘90890-06501 Center bot: 90890-06504 “Set the lower unit upside down. ‘Attach the backlash indicator on the drive shatt. * Attach the dial gauge on the gear case, and make the dial gauge stem contact the mark ‘on the indicator. 619LOWR| t LOWER UNIT 2.) Dial gauge: |Z] vu-s097/20890.01252 Magnet base: YU-34481/90890-06705 Backlash indicator: ‘YB-6265/90890-06706 =While pulling the drive shaft downward, slowly turn the drive shaft clockwise and ‘counterclockwise then measure the backlash when the drive shaft stops at each direction. *Determine the shims to be added or removed according to the specified. 79.9/F9.9A Less than To be decreased by 0.26 mm (0.51 ~ measurement) 25 More than To be increased by 0.77 mm (measurement - 0.51) 25 FSB, F9.9/F9.9B Less than To be decreased by 0.23 mm (0.47 ~ measurement) 23 More than To be increased by 0.70 mm (measurement - 0.47) 23 Example: (T9.9/F9.9A) if measurement = 0.25 mm Decrease shim thickness by = (0.51 — 0.25)/25 = 0.26/25 = 0.10 mm If measurement = 1.26 mm Increase shim thickness by 1.26 — 0.51)/2.5 .75/2.5 = 0.3 mm As Available shim thickness: 9.9/F9.9A: 0.10, 0.14, 0.18, 0.35 and 0.50 mm FBB, F9.9/F9.9B: 0.10, 0.12, 0.15, 0.18, 6-20LOWwR| LOWER UNIT <>) NOTE: Since the smallest shim available is 0.10 mm, if the measurement is between (T9.9/F9.9A) 0.26 and 0.77 mm or (F8B, F9.9/F9.9B) 0.23, and 0.70 mm do not change the shim. 2. Measure: + Reverse gear backlash Out of specification —- Adjust. Backlash: 79.9/F9.9A: 0.51 ~ 1.02mm FSB, F9.9/F9.9B: 0.82 ~ 1.16 mm Measurement steps: +Place the shift shaft in neutral. + Load the reverse gear by installing the pro- eller without the front side spacer () and tighten the nut NOM Lightly tighten by hand until the pressure of the propeller shaft on the reverse gear re- sticts movement enough to allow backlash measurement. + Set the lower unit upside down. + Attach the backlash indicator on the drive shaft. + Attach the dial gauge on the gear case, and make the dial gauge stem contact the mark. on the indicator. A Dial gauge: ‘YU-3097/90890-01252 Magnet base: YU-34481/90890-06705 Backlash indicator: ‘YB-6265/90890-06706 621LOWR' LOWER UNIT eS +While pulling the drive shaft downward, slowly turn the drive shaft clockwise and counterclockwise then measure the backlash when the drive shaft stops at each direction. “Determine the shims to be added or removed according to the specified. 19.9/F9.9A Less than To be decreased by 0.54 mm, (0.77 - measurement) 25 More than To be increased by 1.02 mm FSB, F9.9/F9.9B Less than To be decreased by 0.82 mm (0.99 ~ measurement) 23 More than To be increased by 1.17 mm (measurement - 0.99) 23 Example: (F8B, T9.9/F9.9B) If measurement = 0.74 mm Decrease shim thickness by (0.99 — 0.74)/2.3 0.25/2.3 = 0.11 mm Hf measurement = 1.79 mm Increase shim thickness by (1.79 ~ 0.99)/2.3 0.80/2.3 = 0.35 mm Available shim thickness: 9.9/F9.9A: 0.10, 0.14, 0.18, 0.35 and 0.50 mm F8B, F9.9/F9.9B: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm. NOTE: Since the smallest shim available is 0.10 mm, if the measurement is between (T9.9/F9.9A) 0.51 and 1.02 mm or (F8B, F9.9/F9.9B) 0.82 and 1.17 mm do not change the shim. 622LOWR| t | LOWER UNIT ma © WATER PUMP 1. Install: + Dowel pin ® + Gasket @ + Outer plate @ Gasket @ + Woodruff key © + Impeller © 2. Install: «Insert cartridge © Bushing @ + Cover @) + Screw @ = Water pump housing @) +Plate @) + Bolt ® NOTE: + Apply the impeller with waer resistant grease. + Tur the drive shaft clockwise, when installing the water pump housing. LOWER UNIT 4. Install + Dowel pin @ + Lower unit @ Bolt @ NOTE: + Set the shift cam to the reverse position. + Hold the shift rod nut in the lowest position. + Insert the drive shaft into the crankshaft, insert the water tube into the water seal, and insert the shift rod into the upper casing.LOWR' LOWER UNIT 2. Install: + Shift rod © + Shift lever @ Nut @ Lock nut @ NOTE: ——— Install the nut on the shift lever side and screw it in 5 turns. 3. Check: + Pressure Impossible to maintain the specified pressure for 10 seconds + Reinstall. Checking steps: “Attach the Mity Vac to the oil level hole. & + Apply the specified pressure. % Mity Vac: ‘YB-35956/90890-06756 ‘Specified pressure: 100 kPa (1.0 kg/cm? 14.2 psi) 4, Fil: + Gear oil Refer to page 3-5. PROPELLER 4. install (T9.9/F9.9A) + Spacer = Washer @) + Propeller @) +Nut @ + Cotter pin 6) ‘Nut: Nx) 43. Nm (1.3 m-kg, 9.4 ft-Ib) 7. Install: (F8B, F9.9/F9.9B) Nut: 13. Nm (1.3 m:kg, 9.4 ft-Ib) 624€ | LOWER UNIT fa) oo If the propeller nut does not align with the propeller shaft hole when the nut is tightened to specification, turn it in further so that they align. 6-25BRKT| CHAPTER 7 BRACKET UNIT UPPER CASING AND BOTTOM COWLING .........6..00.000 ois PREPARATION FOR REMOVAL LT INSPECTION ... Sop pee ee 12 Clamp lever 5 : : 72 Bottom cowling ce u78 Oil pan and exhaust guide : : is Este Mend so 73 Upper casing fee 73 ii strainer... 73 Shift mechanism. 74 Sealing parts Sunes 74 Mount rubber... ceseeee : ceveeee ee ASSEMBLY AND INSTALLATION 75 Upper casing 7 Bottom cowling 78 BRACKET UNIT rai PREPARATION FOR REMOVAL ...... at REMOVAL POINTS ........ : 742 Spring... Se eoeseae oS 742 INSPECTION 273 Clamp and swivel bracket 743 Tilt plate . 73 ASSEMBLY AND INSTALLATION - 73 STEERING HANDLE : a 76 PREPARATION FOR REMOVAL (T9.9/F9.9A for Europe and Canada F8B, F9.9/F9.9B) 7.416 PREPARATION FOR REMOVAL (F9.9/F9.9B except for Europe and Canada) . 7a? RENOVAL POINTS a TAB Ring nut 718 INSPECTION 718 Shift and throttle cables 18 Steering handle ...... 748 ASSEMBLY AND INSTALLATION -7A9 Steering handle (T9.9/F9.9A for Europe and Canada F883, F9.9/F9.98) ...7-19 Steering handle (F9.9/F9.9B except for Europe and Canada) .... 724Tr UPPER CASING AND BOTTOM COWLING UPPER CASING AND BOTTOM COWLING PREPARATION FOR REMOVAL, * Remove the power unit. BRKT — * Remove the ground lead at the swivel bracket side.BRKT UPPER CASING AND BOTTOM COWLING Extent of removat @ Bottom cowling removal @) Upper casing removal @ Mount rubber removal Extent of removal | Order Part name ay Remarks 1 | 4 | Cable end (Throttiey 1 | 2 | Cable end (Shift) 1 | T9.9/F9.9A model only. | 3 | Screw 1 | 4 | Shift lever 1 | F8B, F9.9/F9.9B medel only | 5 | Bot = 1 aoe oO 6 | Shift rod pin 1 2 lee 3 | 8 | Shift stay 1 | 9 | Panel stay 1 | 10 _| Bolt 4 pe 11 | Bottom cowling 1 | 12. | Bott 2 | 13. | Bolt 9 J] | aa | exhaust ide 1 15__| Dowel pin 2 16 | Rubber seal 1 17. | Oilseal \1 | 18 | Pipe lea | 19. | Relief valve 1 20_| Seal 1 { 21 | Oilpan 1 @ 22 | Dowel pin 2 et 23 | Upper casing 7 } 24 | Bott 3 | 25 _| Rubber housing ee 26 | Mount rubber (Side) 2 ® 27 | Mount rubber (Under) d | 28 | Nut 2 29 | Bolt 2 30__| Clamp 2__| Loosen the screw. 31_| Mount rubber (Upper) li INSPECTION CLAMP LEVER 1, Inspect: «Clamp lever \ Wear/Damage —» Replace. 72BRKT T | UPPER CASING AND BOTTOM COWLING & BOTTOM COWLING 1. Inspect: *Bottom cowling Crack/Damage —» Replace. OIL PAN AND EXHAUST GUIDE 4. Inspect: +Oil pan + Exhaust guide Crack/Damage —> Replace. EXHAUST MANIFOLD 1, Inspect: + Exhaust manifold Carbon deposits — Clean. Crack/Corrosion —+ Replace. UPPER CASING 1. Inspect: + Upper casing Crack/Damage —» Replace. OIL STRAINER 1. Inspect: + Oil strainer Contamination — Clean. Damage — Replace. 73o eS 74 BRKT UPPER CASING AND BOTTOM COWLING ‘SHIFT MECHANISM 1. Inspect: + Shift rod + Shift link + Bushing *Cable end Wear/Damage —> Replace. SEALING PARTS 1. Inspect: + Rubber seal Crack/Damage —> Replace. MOUNT RUBBER 1. Inspect: + Mount rubber Wear/Damage — Replace.BRKT UPPER CASING AND BOTTOM COWLING eS ASSEMBLY AND INSTALLATION UPPER CASING 1. Install: Mount rubber @ Rubber seal @ Clamp @ +Plate@ + Bolt © NOTE: The clamp should be installed with the screwed side facing downward. Na ‘Screw: 3.Nm (0.3 mkg, 2.2 fttb) Install: * Upper casing (i) +Seal@ + Stopper @ + Mount rubber @ Bolt © + Hose @) +Seal@ 2 Install: + Upper casing + Bracket @ +Nut @ Na) Nut: 25 Nm (2.5 mkg, 18 fb) 7878 BRKT UPPER CASING AND BOTTOM COWLING QS 4. Install: «Mount rubber (Under) © Mount rubber (Side) @ + Rubber housing @ + Ground lead @ Bolt ® 5. Install: +Seal D Gasket @ + Exhaust manifold @ +Oil pan@ Bolt © Na Bolt: 12 Nm (1.2 m-kg, 8.7 ft-lb) WO Align the exhaust manifold with the oil pan hole. + Always use a new gasket. 6. Install: + Oil strainer © Bolt @ O-ring @ Drain plug @ + Rubber damper ©) Na Drain plug: 8.Nm (0.8 mkg, 5.8 ft¥b) 7. Install: Grommet + Water tube @ NOTE: ‘Align the hole in the oil pan wit tion in the grommet. ‘Install the water tube so that it position is not reversed the projecBRKT Tr UPPEER CASING AND BOTTOM COWLING & 8, Install: + Exhaust guide @ * O-ring @ + Relief valve @) *Grommet @ «Pipe guide @) + Screw ® + Pipe @ ‘+ Rubber seal ® Sd CAUTION: —— Coat the screw with blue LOCTITE® (242). Relief vaive: 8 Nm (0.8 mkg, 5.8 ttib) Install: * Oil seal @) * Washer 2) + Pipe @ * Bushing @ + Nut ® +Seal® + Gasket ® = Bolt ® fy] Nut: 5. Nm (0.5 mekg, 3.6 ftelb) Bolt: 10. Nm (1.0 mekg, 7.3 ft-lb) ay NOTE: + Always use a new oil seal + Torque the bolts in the sequence embossed on the exhaust guide. ‘Install the pipes with their water discharge end facing the oil par ). Install: + Dowel pin © + Gasket @ + Bolt @ NOTE: Always use a new gasket.BRKT D UPPER CASING AND BOTTOM COWLING 11. Apply: + Gasket maker ‘Onto both face of the gasket. NOTE: Clean the contacting surface of crankcase. 12. Install Dowel pin ® Gasket @ + O-ring @ + Rubber seal @ + Rubber seal ©) NOTE: Always use a new gasket. 78 BOTTOM COWLING 1. Install: + Grommet © + Collar @ 2. Install: + Shift stay O +Panel stay @ + Bolt @ + Front pane! @ + Seal rubber ©) + Hinge pin © + Cotter pin + Grommet (shift rod) ® NOTE: Always use a new cotter pin. ja)BRKT) UPPER CASING AND BOTTOM COWLING Lely 3. Install: + Grommet © + Fuel joint @ +Bolt@ +Fuel hose @ +Clip © + Engine stop switch © Ng | Engine stop switch: 4.Nm (0.4 mkg, 2.9 ftib) 4. Install: + Bottom cowling @ + Washer @ + Bolt @ 5. Install: + Grommet (shift shaft) © +Grommet @ + Water hose @ 2 Install: + Lever stay D + Washer @) *Bushing @ +Clamp lever @ + Collar © + Wave washer © + Washer 2) + Bolt © + Rubber seal @) + Bolt @BRKT UPPER CASING AND BOTTOM COWLING QS 7. Install: += Shift link O *Bushing @ * Shift lever @ * Shift arm @ + Accelerator stopper ©) + Shift arm © + Accelerator arm @ +Bushing ® +Bolt © + Shift rod @ Pin ® Washer @ + Cotter pin ® *Cotter pin ® + Spring ® + Bracket © + Bolt @ 8. Install: (F8BM, T9.9MH/F9.9AM, F9,9MH/F9.9BM) +Stay =Bolt @ + Guide © + Start in-gear protection wire @ Install: (F8BE, F8BEM, F9.9AE, T9.9EH/ F9.9AEM, F9.9BE, F9.9EH/F9.9BEM) +Stay O + Bolt @ Sp, g + Neutral switch @BRKT 1 BRACKET UNIT © iar BRACKET UNIT PREPARATION FOR REMOVAL, * Remove the power unit. * Remove the upper casing and bottom cowling. [IER 2k, 7 FB) 25 Nm (65 mkg. 32 1b) om F8B, F9.9/F9.9B model on . €BRKT BRACKET UNIT Extent of removal: @ Swivel bracket removal @ Swivel bracket disassembly @ Clamp bracket removal [Extent of removal] Order Part name Qty Remarks 1 | Bott 2 2. | Steering bracket 1 3 | Bolt 1 4 | Dowel pin 2 5_| Steering shaft 1 6 | Washer 1 7 | Bushing 1 8 | Friction plate 1 9 | Swivel bracket al 40_| Bushing 4 | 11 | Oring 1 12. | Bushing 1 @ 13° | Tilt pin 1 | 14 | Nut 2 | |15__| Nut (me) ae il oe 1 | 16 | Clamp bracket 2 17 | Nut 2 18 | Pin 1 OS latin 1 || T29F99A model only 20 | Pin 1 21 | Tilt plate (Inner) 1 22. | Spring 2 | Refer to “REMOVAL POINTS” 23 | Pin 1 Tilt plate (Outer) 1 Drive lever 1_| F8B, F9.9/F9.98 model only REMOVAL POINTS SPRING 1. Remove: *Clip “Pin D *Tilt plate (Inner) 2) “Spring @ NOTE: Align the holes of the tit plate (Inner) and (Outer) @, and removing the pin 712BRKT BRACKET UNIT INSPECTION CLAMP AND SWIVEL BRACKET 1. Inspect: ‘Clamp bracket ‘*Swivel bracket Crack/Damage-+Replace. TILT PLATE 1. Inspect: “Tilt plate Crack/Damage—-Replace, ASSEMBLY AND INSTALLATION Install: (T9.9/F9.9A model) sTilt plate (Outer) @ Pin @ *Collor @) Spacer @) “Clip © Install: (F8B, F9.9/F9.9B model) *Tilt plate (Outer) D “Drive lever (2) “Clip © Install: “Spring Tilt plate (Inner) Q) “Pin @ Clip NOTE: —____ Align the holes of the tttplate (Inner) and (Outer), after installing the pin. 713BRKT BRACKET UNIT la 3. Install (T9.9/F9.9A model) ‘*Rod (Long) @) ‘*Rod (Short) (2) sTilt lever @) sPin Clip 4, Install *Rod (Short) @ “Spring @ sLever @) Install *Clamp bolt ‘Bushing @) 0} Install: Clamp bolt sLever @ *Bushing (Short) @) “Bushing (Long) @) NOTE: Install the bushings with punch mark side inward, 7. Install «Plate @ “Control plate @ *Screw @) Nut @ “Bolt © *Washer © eNut @BRKT iT | BRACKET UNIT > 8. Install: Lock plate @) Washer @) “Bolt @ *Washer plate @) *Nut © Nut 12Nm (1.2 mekg, 8.7 ftelb) 9. Install: ‘Washer (1) Clamp bracket @) “Bolt @ *Collor @ ‘Washer @) ‘*Nut © *Plate @ onut @ Nut (Clamp bolt}: 45 Nm (45 mekg, 325 ftelb) 10. Install: Bolt @ ‘Washer (wave) (2) Washer plate @) sNut @ 11. Install: *Steering shaft ® Pin @ *Steering bracket @) sBolt @ Washer 6) “Bushing © = 13 Nm (1.3 mekg, 9.4 ft-lb) 12. Install: “Friction piece ‘*Bushing @) *O-ing @) *Bushing @ *Ground lead @BRKT STEERING HANDLE eS STEERING HANDLE PREPARATION FOR REMOVAL (T9.9/F9.9A for Europe and Canada F8B, F9.9/F9.9B) * Disconnect the control cables at engine side. * Disconnect the wire leads. A 4 Nm (0.4 mrkg, 2.9 ftib) eo 4 Extent of removal; @® Cable removal @ Steering handle disassembly [Extent of removal [Order Part name Remarks, | 3 | Bay plate itting plat Bott?» Bracket Ring nut, | | | Refer to "REMOVAL POINTS". Bolt Steering handle 1 OVO mAwr- Handle or landle gr Handle orp ‘Steering handle (Left) Bigering Shift arm joaralanana|s' ig Es loSTEERING HANDLE PREPARATION FOR REMOVAL (F9.9/F9.9B except for Europe and Canada) * Disconnect the control cables at engine side. Extent of removal: @ Cable removal and Steering handle disassembly Extent of removal | Order Part name. Q'ty Remarks T ‘Screw Fitting plate Bolt Bracket Ring nut Refer to "REMOVAL POINTS’. Bushing Steering handle 1 Screw Handle grip Screw Baldeoso wrens Steering handle 2 Throttle cable Jalota aa|aanwan rarSTEERING HANDLE eS REMOVAL POINTS RING NUT 1. Remove: Ring nut © + Washer @ + Washer (Wave) @ + Washer (Nylon) @ NOTE: +Tum the steering handle backward, +Fita standard-head screwdriver into the slit in the ring nut. + Set the screwdriver using the steering bracket as a fulcrum. + Turn steering handle forward and loosen the ring nut. + Repeat this operation until the ring nut comes off. INSPECTION SHIFT AND THROTTLE CABLES 1. Inspect: Shift cable + Throttle cable Bend/Damage —- Replace. Unsmooth operation —- Replace. STEERING HANDLE 1, Inspect: + Steering handle Crack/Damage — Replace. 7.18BRKT STEERING HANDLE © ASSEMBLY AND INSTALLATION STEERING HANDLE (T9.9/F9.9A for Europe and Canada FSB, F9.9/F9.9B) 4. Install: + Spring © Bolt @ + Steering handle (right) @ Stop switch @ Nut © ‘Nut: 4.Nm (0.4 m-kg, 2.9 ft-Ib) 2. Install: Grommet © + Throttle cable @ NOTE: Fit the inner cable end in the groove, and fit the outer cable end into the hole. 3. Install: = Shift arm © *Shitt cable @ +Collar @ Washer @ + Cotter pin © 4, Install: + Bushing @ + Shift lever @ +Wave washer @) + Shift arm @ + Washer 6) Bolt © + Nut © NOTE: 719 + Align the shift lever shaft end with the hole in the shift arm. Fit the shift arm collar to the Neutral position of the spring.r STEERING HANDLE 5. Install: + Steering handle (left) © Screw @ NOTE: + When installing steering handle, fit the throttle and shift cables correctly in place. + After installing steering handle, make sure the movement of shift lever by moving it. 6. Install + Steering grip D + Friction piece @ «Spring @ +Washer @ + Washer (Nylon) 6) + Screw © + Handle grip © NOTE: Fit the handle grip correctly. 7. Install: + Steering handle @ + Bolt (short) @ Bolt (long) @ 8. Install: + Steering bracket © + Bushing @ + Washer (Nylon) @) +Washer @ + Wave washer ©) + Ring nut © + Tube OT Pass the throttle and shift cables and stop switch leads through the steering hardle on the steering bracket. 7-20STEERING HANDLE 9. Tighten: + Ring nut D NOTE: ‘Screw in the ring nut by hand until tight, and fit asiotted-head screwdriver into the sit in the ring nut. Lock the screwdriver with the steering bracket, and tighten the ring nut by moving the steering handle back and forth. 72 10. Install: Nut D * Bracket @ *Bolt @) + Shift cable ® * Throttle cable @) * Stopper bracket ©) + Fitting plate @ + Screw ® NOTE: When installing the st ft cable, set the shift lever in the forward position. 11, Adjust Throttle cable length Refer to page 3-15. STEERING HANDLE (F9.9/F9.9B except for Europe and Canada) 4. Install: + Throttle cable D + Steering handle (upper) @ + Steering handle (under) @ +Nut @ + Screw © NOTE: Fit the inner cable end in the groove, and fit the outer cable end into the hole. 2. Install: + Steering grip © Friction piece @ * Spring @ + Washer @ + Washer (Nylon) © +Screw © +Handle grip NOTE: Fit the handle grip correctly.BRKT! T| STEERING HANDLE eS 3. Install: + Steering bracket D Bushing @ Washer (Nylon) @ Washer @ + Wave washer ©) Ring nut © Tube @ NOTE: Pass the throttle cable through the steering handle on the steering bracket. 4. Tighten: nut © NOTE: Screw in the ring nut by hand until tight, and fit asslotted-head screwdriver into the slitin the ring nut. Lock the screwdriver with the steering bracket, and tighten the ring nut by moving the steering handle back and forth. 5. Install + Nut D * Bracket ® «Bolt @ * Throttle cable ® + Stopper bracket ) + Fitting plate © + Screw @ 6. Adjust: Throttle cable length Refer to page 3-15. 7-22ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS MANUAL STARTER MODEL .. ELECTRICAL STARTER MODEL REMOTE CONTROL MODEL T9. REMOTE CONTROL MODEL F8BE, F9.9BE ELECTRICAL ANALYSIS. INSPECTION ... Peak voltage measurement Low resistance measuremen IGNITION SYSTEM... WIRING DIAGRAM IGNITION SPARK GAP... CDI SYSTEM PEAK VOLTAGE .. ‘SPARK PLUG ‘SPARK PLUG CAP... ENGINE STOP SWITCH MAIN SWITCH... IGNITION CONTROL SYSTEM. WIRING DIAGRAM. OIL PRESSURE SWITCH. OIL PRESSURE INDICATOR LAMP. STARTING SYSTEM. WIRING DIAGRAM. BATTERY sssnsesscsnsnesene FUSE .. WIRING HARNESS. WIRING CONNECTION ENGINE STOP SWITCH... MAIN SWITCH. STARTER SWITCH NEUTRAL SWITCH. ‘STARTER RELAY.ELEC STARTER MOTOR... SERVICE POINTS .. Pinion removal. Pinion inspectior Armature inspection. Brush holder inspection... Cover inspection... CHARGING SYSTEM WIRING DIAGRAI CHARGING SYSTEM PEAK VOLTAGE . RECTIFIER REGULATOR (T9.9/F9.9A)... RECTIFIER REGULATOR (F8B, F9.9/F9.9B) FUSE BATTERY ENRICHMENT CONTROL SYSTEM. VALVE HEATER COIL. ELECTROTHERMAL VALVIELEC ELECTRICAL COMPONENTS a2) ELECTRICAL COMPONENTS MANUAL STARTER MODEL © Lighting coil @ Ignition coil @ Ground @ CDi unit © Pulser coil/Charge coil @ Oil-pressure switch © Rectifier regulator © Ground © CDlunit @ Engine stop switch © Oit-pressure indicator-lamp @ Electrothermal valve WIR: White/Red — G_: Green O : Orange GW: Green Write Ro :Red P Pink YIR : Yellow/RedELEC|("_*]| evectricat comPONENTS < ELECTRICAL STARTER MODEL © Lighting coil ® Ignition coil WR: WhiteiRed = G_: Green ® Ground @ COl unit Br: Brown ©: Orange @ Fuse holder @ Engine stop switch LL: Blue GW: Green/White @ Fuse holder ® Oi-pressure B Black R : Red @ Pulser coil/Charge coil indicator-lamp_ W White BMW : Black/White © Oil pressure switch @ Starter-switch P :Pink © Rectifier regulator @ Starter relay YIR : Yellow/Red ® Ground ® Electrothermal valve © CDi unit azELEC fa ELECTRICAL COMPONENTS <> REMOTE CONTROL MODEL T9.9ER/F9.9AE @ Lighting coit @® Ground WIR:WhiteRed — G_: Green ® Ground © CDI unit Br: Brown O : Orange @ Fuse holder ® Ignition coil Lo Blue GM: GreenWhite @ Fuse holder ® CDI unit B Black R :Red © Pulser coil/Charge coil @ Wiring-harness Ww : White B/W : BlackWhite © Oit-pressure switch @ Starter relay Pp: Pink Y :Yellow © Rectifier regulator @ Electrothermal valve Y/R. : Yellow/RedELECTRICAL COMPONENTS REMOTE CONTROL MODEL F8BE, F9.9BE @ Lighting coil @ Ground WIR: White/Red G_: Green @ Ground © COI unit Br: ©: Orerge @ Fuse holder ® Ignition coil e GM: GreenWhite @ Fuse holder ® COlunit B Ro: Red © Pulser coilCharge coil @ Wiring-harness w: BW : BlacuWhite @ Oil-pressure switch Starter relay ca Y 3 Yellow © Rectifier regulator @ Electrothermal valve Y/R =: Yellow/Red aaELECTRICAL ANALYSIS ze 3s ELECTRICAL ANALYSIS INSPECTION All measuring instruments should be han- dled with special care, or the correct m surement is impossi On an instrument powered by dry batter- les, they should be checked for voltage periodically and replaced, if necessary. NOTE: “Q—O" indicates the terminals between which there is a continuity of electricity; ie., a closed circuit at the respective switch position. Peak voltage measurement NOTE: The coil output varies greatly cranking speed. ‘© Cranking the cold engine with the plugs in and a weak battery cannot be found proper readings. J-39299 Peak volt adapter: YU-39991 Low resistance measurement When measuring the resistance of 102 or less using the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance. To obtain the correct value, subtract this internal resistance from the displayed measurement. Correct value Displayed measurement - Internal resistance NoTE: The internal resistance of the tester can be obtained by connecting both of its terminals.ELEC|{*_*]| icnrmion system 2S IGNITION SYSTEM WIRING DIAGRAM Be stant] i © Spark plug Br: Brown Ignition coit L Blue © Charge coil W/R : White/Red @ Pulser coil B/O : Black/Orange © Main switch BWW : Black/White © Stop switch W :White © Engine stop switch B Black @ 7P coupler © CDi unit ] Except for remoie control model (B| For remote control model [C] T9.9MH/F9.9AM, T9.9EH/F9.9AEM a6ELEC IGNITION SYSTEM IGNITION SPARK GAP PRG ‘© While taking spark check be careful not to touch any connection of lead wires of the “Ignition spark gap tester”. When doing the spark test, take special care not to allow leakage from the removed plug cap. This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity. 1. Check: @ Ignition spark gap Out of specification -> Peak voltage measurement. <| Spark gap: __ ‘9 mm (0.35 in) Checking steps: © Adjust the spark gap to specification by turning the adjusting knob. Spark gap tester: ‘YM-34487/90890-06754 Connect the sparkplug cap to the spark gap tester. @ Remove the spark plugs from the engine. @ Cranking the engine and check sparks of ignition system seen through discharge window.ELEC F IGNITION SYSTEM <-> a8 CDI SYSTEM PEAK VOLTAGE POG While taking CDI unit check be careful not to touch any connection of lead wires. NOTE: elf there is no spark, or the spark is weak, continue with the CDi test. Ifa good spark is obtained, the problem is not with the CDI system, but possibly the spark plug or other component is defective, 1. Measure: © CDI unit output (test #1) Below specification > Replace ig tion coil. CDI output: 150 V at cranking 210 V at 1,500 r/min 150 V at cranking 210 V at 1,500 r/min 19.9/F9.98 F8B, F9.9/F9.9B Measurement steps: @ Connect the tester @ to the CDI unit @ as shown. © Sot the tester dial to specification. © Cranking or starting the engine.IGNITION SYSTEM > 2. Measure: © Charge coil output (test #2) Below spe > Replace charge coil 160 V at cranking 230 V at 1,500 r/min 160 V at cranking 220 V at 1,500 r/min ‘Measurement steps: © Connect the tester @ to the charge coil ®as shown. © Set the tester dial to specification. el ‘© Cranking or starting the engine. 3. Measure: © Pulser coil output (test #3) Beyond specification + Replace CDI unit. Below specification — Replace pulser coil, ii Pulser coil output: 7 Vat cranking TSSIF99A | a9 y at 1,500 r/min FSB, 5 Vat cranking F9.9/F9.9B | 8 V at 1,500 r/min Measurement steps: Connect the tester @ to the pulser coil @as shown. © Set the tester dial to specification. © Cranking or starting the engine SPARK PLUG Refer to the “GENERAL” section in chapter 3.SPARK PLUG CAP 1. Inspect: © Spark plug cap Loosen — Tighten. Crack/Damage —» Replace. Replacement steps: © Remove the spark-plug cap by turning the cap counterclockwise. @ Install the sparkplug cap by turning the cap clockwise until it stops. 2. Measure: (For Canada and Europe) © Spark plug cap resistance Out of specification — Replace. a0 ‘Spark plug cap resistance: 4.0 ~6.0kO ENGINE STOP SWITCH 1, Check: @ Continuity Out of specification — Replace. Leads color pi White | Black qa9)_| installed F994 | Removed o—}—o Installed FSB, | Removed o-+-0 F9.9/ F9.9B | Install and depress the | O—}—o buttonELEC|[_*]| icnrmion system 2S MAIN SWITCH 1. Check: © Continuity Out of specification -> Replace. Leads color Black| Red |Yellow|Brown| 1—O anELEC ia) IGNITION CONTROL SYSTEM eS IGNITION CONTROL SYSTEM WIRING DIAGRAM © CDI unit B : Black ® Oil pressure ind cator-lamp L :Blue © Oil pressure switch P Pink YIR : YellowiRed Except for remote model Bl For remote model anIGNITION CONTROL SYSTEM a OIL PRESSURE SWITCH 1, Measure: © Continuity Out of specification -» Replace. Measurement steps: ‘© Connect a Mity Vac @. @ Connect a tester @. Mity Vac: ‘YB-35956/90890-06756 © Apply the specified pressure. a Oil pressure switch: 02 10kPa (0+ 0.1 kg/om?, 0+ 1.4 psi) | Continuity 60+ 10 kPa {0.6 + 0.1 kg/em?, Discontinuity 8.5 + 1.4 psi) OIL PRESSURE INDICATOR LAMP 1. Check: © Oil pressure indicator lamp operation Out of specification— Replace. Checking steps: © Connect the digital tester for engine side leads. @ Pink lead — Positive terminal © Black lead - Negative terminal © Start the engine. © Check the voltage of output. Output voltags More than AC 65 V ‘© Stop the engine. Connect the oil pressure indicator lamp to engine side leads. © Start the engine, © Check the oil pressure indicator lamp for green indication. 813ELEC|[_*]| icnrion conTROL system an PRG OINS Be careful not to touch the ignition sys- Item leads while performing testing. High voltage electric shock may cause injury. Make the test with the motor placed in a test tank. 9 the oil pressure indicator| lamp operation, oil pressure switch should be tested.STARTING SYSTEM 2S STARTING SYSTEM WIRING DIAGRAM © Fuse Bl For remote control model © 7P coupler For switch panel model © Main switch Except for remote contro! model @ Starter motor B : Black @ Battery Br: Brown @ Starter switch R :Red @® Neutral switch @© Starter relayELEC|("__“]] startinc system BATTERY Refer to the “GENERAL” section in chapter 3. FUSE 1. Check: © Fuse Blown — Replace. WIRING HARNESS: 1. Check: © Continuity Discontinuity — Replace. WIRING CONNECTION 1. Check: © Wiring connection Poor connection — Correct. ENGINE STOP SWITCH Refer to the “IGNITION SYSTEM" sec tion. MAIN SWITCH Refer to the “IGNITION SYSTEM" section. STARTER SWITCH 1. Check: © Continuity Out of specific: a Free Leads color Red Brown Push o—+—o NEUTRAL SWITCH 1. Check: © Continuity Out of specification ~> Replace. nil Length ree [195 ~ 205mm @® | (0.77 ~0.81 in) Push 185 Leads color Brown Brown a6ELEC STARTING SYSTEM eS STARTER RELAY 1. Inspect: \ © Brown lead terminal @ Black lead terminal Loose — Tighten. 2. Check: © Relay operation Does not function > Replace. Checking steps: Connect the tester between the terminals of the starter relay as shown. © Connect a 12 V battery. 817ELEC|["_*] STARTER MOTOR STARTER MOTOR Extent of removal: @ Starter motor disassembly A [4 Nm (04 mkg, 29 fei) @ Brush disassembly Extent of removal Order Part name Remarks @ Clip Pinion stopper Spring Pinion Through bolt Iways use a new circlip Refer to “REMOVAL POINTS” Rear cover Washer Stator Armature Washer t=0.25 mm t=2.0 mm Washer Washer Front cover Screw Brush holder 0.15 mm .0 mm, 7 2 3 4 5 6 7 8 9 10 TT 12 13 4 15 16 7 Brush spring Brush | nv sassy eseg 818STARTER MOTOR SERVICE POINTS Pinion removal 1. Remove: © Clip @® NOTE: Using a pry-bar, pry off the clip. n inspection 1. Inspect: © Pinion teeth Wear/Damage — Replace. 2. Check: © Clutch movement Damage — Replace. NOTE: Rotate the pinion clockwise, and check that it freely. Also try to rotate the pinion counterclockwise and confirm that it locks. Armature inspection 1. Inspect: ‘© Commutator Dirty > Clean with #600 abrasive paper. 2. Measure: © Commutator diameter Out of specification — Replace. Afar 29.0 ~ 30.0 mm (1.14 ~ 1.18 in) a9ELEC|["_“]| starter MoToR 3S 3. Check: © Commutator under cut Clog/Dirty > Clean. NOTE: Removal all particles metal by compressed air. 4. Inspect © Armature coil continuity Out of specification + Replace. Commutator segments | Continuity Segment - Laminations | Discontinuity Segment - Shaft Discontinuity Brush holder inspection 1. Measu © Brush length @ ut of specification —+ Replace. <| Brush length ©: 9.0 ~ 12.5 mm (0.35 ~ 0.49 2. Check: © Brush holder continuity Out of specification -> Replace. [rail Brush holder continuity: Brush holder () - Base @ Cover inspection 1. Inspect: © Cover bushing Wear/Damage — Replace the cover. 8.20ELEC CHARGING SYSTEM 2) CHARGING SYSTEM WIRING DIAGRAM @ Rectifier regulator ‘or T9.9/F9.9A @ Lighting coil ‘or F8B, F9.9/F9.98 © 2P connector [© For remote control model @ 7P coupler D For manual starter mode! © Battery [E] For electrical starter model © Fuse G Green GW: GreenMhite R :Red B Black 21CHARGING SYSTEM & CHARGING SYSTEM PEAK VOLTAGE 1, Measure: @ Lighting coil output Beyond specification —» Rectifier regulator/rectifier measurement. Below specification > Replace lighting coil. Lighting coil output: 822 8 Vat cranking 10 V at 1,500 r/min 8 Vat cranking 11 V at 1,500 r/min T9.9/F9.9A F8B, F9.9/F9.9B Measurement steps: © Connect the tester @ to the recti regulator @/rectifier © as shown. © Set the tester dial to specification. © Cranking or starting the engine. RECTIFIER REGULATOR (T9.9/F9.9A) 1. Measure: © Voltage drop Out of specification > Replace. Measurement steps: @ Select the function switch of digital tester to Diode inspection mode. @ Measure the voltage drop. Tose] 2 2 SNS" | on | creew | ocrsen | wins | cred ae fese-o7a] + fore-rae] > Dereoiine oso on + [aae~oop [aceon fosoasefors- v0] eae] ote [oss oas|os0-omilaso—oma|as—oas] * Measured value is not affected by tester leads connection.ELEC CHARGING SYSTEM > RECTIFIER REGULATOR (F8B, F9.9/F9.9B) 1. Check: © Continuity Out of specification > Replace. NOTE: Digital tester can not be used for this inspection. Tester @ © © Green] Groon | @ Red | @ Black Tester White [@ Green = @ GreenWhite| = Red aie fe Btsok te | exon | azote continuity. iscontinuity. FUSE Refer to the “STARTING SYSTEM” section, BATTERY Refer to the “GENERAL" section in chapter 3. 823ELEC a) ENRICHMENT CONTROL SYSTEM > ENRICHMENT CONTROL SYSTEM © Valve heater coil B : Black ® Electrothermal valve VALVE HEATER COIL 1, Measure: © Valve heater coil resistance Out of specification — Replace. Valve heater coil resistance: Black (B) — Black (B) 0.24 ~ 0.36 © at 20°C (68°F) NOTE: When measuring the resistance of 10 © or less using the digital tester the correct measurement cannot be obtained. Refer to “Lower resistance measurement”. ELECTROTHERMAL VALVE Refer to the “CARBURETOR” section in chapter 4. 8.26TRBL |? | AN CHAPTER 9 TROUBLE-ANALYSIS ‘TROUBLE ANALYSIS. TROUBLE ANALYSIS CHART.TRBL ANL TROUBLE ANALYSIS <> TROUBLE ANALYSIS NOTE: The following items should be checked before the “Trouble analysis” chart is consulted. 1, The battery is charged and its specific gravity is within specification, 2. There are no incorrect wiring connections. 3. Wiring connections are properly secured and are not rusty. 4. The lanyard is attached to the engine stop switch. 5, The shift position is neutral. 6. Fuel is reaching the carburetor. 7. The rigging and engine settings are correct. 8.Engine is free from any “Hull problem” TROUBLE ANALYSIS CHART Problem Check g § 5 A 3\2 z zie ly gl}, |e |e b 5/58 Zis leis Reference. 5 le & 5 g olf é a z & Related part ane 22/2/28 (2 [2 [2 Els (8 le |e 32/25 18 |g a le lo |S ie wlzle [ele lee le fe 2 ja ls 5/2155 |5 [5 /& 8 18 /E 2 |S 2|2 | [2 |e [2 [5 [2 [8 a |B |e FUEL SYSTEM oO oO 0 Fuel hose 4 0 r td 0 Fuel joint 4 Olo O Fuel filter 4 = io Fuel pump 4 ojo O° Carburetor _ 4 o|o @ Idle speed 3 = '@ Pilot screw a POWER UNIT ojo ° oO Spark plug 3 oto Co} ~_[ Compression 3 oO Timing belt = O ~ | Tappet clearance 3 olo 0 [ IN, EX. valve 3 olo O° ne IN, EX. valve seat a oe . S Cylinder head gasket 5 oe BHmigee Piston ring 5 sie O| Piston 5 oO Thermostat 5 oO ‘Water passage 5 aTREL| 4 ANL! TROUBLE ANALYSIS: cE> Problem Check Reference Related part eae ENGINE WiLL NOT START ENGINE STALLS ROUGH IDLING IRREGULAR WARNING INDICATION, POOR DECELERATION ENGINE WiLL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING LOOSE TILT HOLDING SHIFTING DIFFICULT POOR BATTERY CHARGING LOWER UNIT Neutral position Clutch Gear Water inlet ‘Water pump Propeller shaft Shifter/Pin | ‘Shift cam ja Shilijshahees Tower case BRACKET UNIT oO Bracket iE lo Mount rubber 7 ELECTRICAL Ignition system o [Starting system 20] 0/0] 0) 0] 0] a] 0] 0] loo|ojo| jO}O o oO Enrichment control system Ignition control system 10} 10] 109] 00] co| co}

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