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9.

9C 15C

SERVICE MANUAL
LIT-18616-02-59 63V-28197-1F-11

NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.

Important information
Particularly important information is distinguished in this manual by the following notations: Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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

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A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE: A NOTE provides key information to make procedures easier or clearer.

9.9C/15C SERVICE MANUAL ©2003 by by Yamaha Motor Corporation, USA 1st Edition, December 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA LIT-18616-02-59

Model name USA and CANADA name Indication

9.9C 9.9CMH 9.9

15C 15CMH 15

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9CMH 15FMH 15CMH Approved model code 682K 684K Staring serial No. S:1009214 S:1019178 .9FMH 9.Model World wide USA 9.

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0 (79) 7.3 (1.0 12–80 12–40/80 B7HS-10 Water Propeller boss Pre-mixed fuel and oil (100:1) Regular gasoline 2-stroke outboard motor oil TC-W3 Hypoid gear oil GL-4 90 250.500 5.82) cm (cu.0 (15.97) 6.500 r/min 7. 8.01) 56.000 r/min r/min L (US gal. 1.3) 381 (15. Twin 446.500-5.80 :1 Tiller handle Manual starter Choke valve CDI ATDC 5. lmp oz) (*1) With Aluminum propeller (*2) Meeting both API and SAE requirements 2-1 .1 (1.9C 873 (34. 1.1) @ 5.3.4) 332 (13.0 × 50.9) 11.9) 440 (17.0 (2.500 r/min 700–800 2-stroke.lmp gal)/hr r/min 4.0 (8.0 (15) 15C kg (lb) (*1) kW (hp) @ 5.0–BTDC 30.040 (40.45. in) mm (in) 3 Degree V-W (NGK) NMMA-certified API SAE cm3 (US oz.20 × 1.SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Item Dimensions Overall length Overall width Overall height Transom height Boat transom height Dry weight Performance Maximum output Full throttle operating range Maximum fuel consumption Idle speed Power unit Engine type Total displacement Bore x stroke Compression ratio Control system Starting system Enrichment system Ignition control system Ignition timing Maximum generator output Spark plug Cooling system Exhaust system Lubrication system Fuel and oil Fuel type Engine oil Engine oil grade Gear oil type Gear oil grade (*2) Gear oil quantity Unit mm mm mm mm mm (in) (in) (in) (in) (in) Model 9.9.1) 1.6) @ 5.3 (9.0) 36.

20.0. 12.SPEC Item GENERAL SPECIFICATIONS Unit Degree Degree Degree Model 9.0.0 67.9C 15C 8.0 F-N-R 2.08 (27/13) Spiral bevel gear Dog clutch Spline Clockwise J Bracket unit Tilt angle Tilt-up angle Steering angle Drive unit Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction (rear view) Propeller ID mark 2-2 .0 45.0.0 + 45. 16.

0020) 55.08 (0.0039) 56.800 (0.15–0.35 (0.996–14.90–26.0008–0.7091) 28.1 (0.011 (0.02–0.60 (0.0315) 2.2024–2.035–0.39) 0.0024) Barrel 1.0012) 0.200 (0.09 14.015 (0.10 (0.940–55.300–0.7087–0.0772–0.000–18.0118–0.0 (0.95 (1.020 (2.0014–0.0 (0.0059–0.03) 15C Cylinder head Warpage limit Cylinder Bore size Wear limit Taper limit Out-of-round limit Piston Piston diameter (D) Measuring point (H) Piston-to-cylinder clearance Wear limit Piston pin boss bore Piston pin Outside diameter Piston rings Top ring Dimension B Dimension T End gap Side clearance 2nd ring Dimension B Dimension T End gap Side clearance Reed valve Valve stopper height Valve vending limit Connecting rod Small end inside diameter Big end inside diameter Crankshaft Crank width (A) (B) mm (in) mm (in) mm (in) mm (in) mm (in) mm mm mm mm mm mm mm mm (in) (in) (in) (in) (in) (in) (in) (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) Runout limit (D) Big end side clearance (E) Maximum small end axial play (F) mm (in) mm (in) mm (in) 0.60 (0.85–1.9–6.98 (0.03) 5.00 (0.85) 25.02–1.6–0.04–0.SPEC ENGINE Item MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS Unit mm (in) mm mm mm mm (in) (in) (in) (in) Model 9.004–14.06 (0.2055) 56.052 (1.0059–0.0016–0.03 (0.98–2.0016) 0.5510–0.08 (0.35 (0.040 (0.000 (0.7 (0.0032) 0.10 (1.1044) 46.90–46.0138) 0.0079) 18.1039–1.23–0.40–2.05 (0.000–56.0780) 2.2041) 10.0780–0.21) 0.15–0.0032) 0.985 (2.2047-2.0945–0.9C 0.02–0.40–2.1 (2.08) 2-3 .0787) 2.039–28.96–1.24) 0.5518) 13.1024) 0.1024) 0.5513–0.5512) Keystone 1.0945–0.0138) 0.

4.) Pilot air jet (P. 0.0 (118.9C 15C Thermostat Opening temperature Fully open temperature Valve open lower limit Carburetor ID mark Float height Valve seat size Main jet (M.) Main air jet (M. 0.00) 3.1.3.18.12.0374–0.95–1.86 (0.2.60) 60.0 (0. 0.49–0.J.J.12) 63V10 12.) LOWER UNIT Item Gear backlash Pinion forward Pinion reverse Pinion shims Forward shims Reverse shims 48. 1.5 2-4 .05) #110 3.A.19–0.0339) 0. 0.5–15. 0.5 (0.SPEC Item MAINTENANCE SPECIFICATIONS Unit °C (°F) °C (°F) mm (in) Model 9.9C 15C 0.2 (0.30.N.0075–0.A.61) 1.65 (0.0 (140.50 0.15.J.J.12) #120 #48 #75 mm (in) mm (in) mm (in) Unit mm (in) mm (in) mm mm mm Model 9.13.) Main nozzle (M. 0. 0.0650) 1.) Pilot jet (P.40.0–52. 0. 0.0 (0.2 0.10. 0.40–125.

18) 56.00 248.D.D.00–372.20) 15C 2-5 .500 Lighting coil resistance (G–G) DIMENSIONS A.0–6.0 (2.5 14.16–0.C.0 210.32) 30.039 ) 0.6–2.500 r/min (load) Lighting system Lighting voltage (minimum) @3.035–0.00–528. 0.0 (17.0 V V Ω 11.0 A.5 0.C.T.D.000 (maximum) @5.T.C.T.C.SPEC ELCTRICAL Item MAINTENANCE SPECIFICATIONS Unit Degree Degree Degree Degree mm (in) Ω kΩ Ω Ω Model 9.00 V V V 120. 29.0–17.T.C.0 170.4 (B.D.1 B. 4.0 (1. 0. B/W–B) @ Cranking (load) @ 1.9–1.9C 15C Ignition system Ignition timing (full retarded) (full advanced) Piston position (full retarded) (full advanced) Spark plug gap Ignition coil resistance Primary coil (B/W–B) Secondary coil (B/W–spark plug wire) Pulser coil resistance (B/W–B) Charge coil resistance (Br–L) CDI Unit output peak voltage (B/O–B.07 1.0 B.0 (0.05–0.0–4.9C 440.16–0.T.18) 0.24 mm (in) Symbol H4 C1 C2 :S Unit mm (in) mm (in) mm (in) Model 9.500 r/min (load) @ 3.0–31.5 352. 4.D.

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turbid or muddy water. the engine should be flushed with clean water after each use.INSP ADJ MAINTENANCE INTERVAL CHART Item Actions Cleaning / adjustment / replacement Greasing Change Inspection Inspection / cleaning Inspection / cleaning Inspection / adjustment Inspection / replacement Inspection / replacement Cleaning Inspection / replacement Inspection / adjustment Inspection / adjustment Inspection Inspection Inspection Initial 10 hours 50 hours (1 month) (3 months) 1 1 1 1 1 Every 100 hours 200 hours (6 months) (1 year) 1 1 1 1 1 1 Spark plug(s) Greasing points Gear oil Fuel system Fuel filter (can be disassembled) Fuel tank (Yamaha portable tank) Idling speed (carburetor models) Anode(s) (external) Anode(s) (internal) Cooling water passages Propeller and cotter pin Throttle link / throttle cable / throttle pick-up timing Shift link / shift cable Thermostat Water pump Cowling clamp 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 NOTE: When operating in salt water. 3-1 .

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INSP ADJ CONTROL SYSTEM/LOWER UNIT 3-6 .

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FUEL CARBURETOR REMOVAL 4-1 .

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FUEL CARBURETOR REMOVAL 4-3 .

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FUEL CARBURETOR 4-5 .

1 1 4 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 4 1 1 1 2 2 2 1 1 4 x 14 mm 4 x 10 mm Follow the left “Step for removal. Refer to the “CARBURETOR REMOVAL” section in chapter 4. Reverse the removal steps for installation.FUEL CARBURETOR REMOVAL AND INSTALLATION CHART Step Procedure/Part name CARBURETOR DISASSEMBLY Carburetor assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 Drain screw Washer Screw (with washer) Float chamber Float chamber packing Screw Arm pin Float Clip Needle valve Cap Pilot jet Main jet Main nozzle Screw (with washer) Plate Packing Stopping screw Spring Carburetor body FUEL PUMP DISASSEMBLY Screw (with washer) Pump cover Diaphragm Pump body Screw Seat valve Nut Diaphragm Diaphragm gasket Q’ty Service points Follow the left “Step for removal. 4-6 .

make sure to note number of times the pilot screw is turned out from the seated position to its set position.FUEL CARBURETOR SERVICE POINTS NOTE: 8 Before disassembling the carburetor. 8 Do not use steelwire for cleaning the jets as this may enlarge the jet diameters and seriously affect performance. 4-7 .

make sure to turn the pilot screw the same number of times. 4-8 .FUEL CARBURETOR Carburetor assembly NOTE: Before assembling the carburetor. as noted before disassembly. from the seated position to its set position.

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POWR POWER UNIT REMOVAL 5-2 .

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LOWR LOWER UNIT REMOVAL 6-1 .

LOWR LOWER UNIT REMOVAL 6-2 .

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LOWR DRIVE SHAFT. FORWARD GEAR AND SHIFT ROD 6-10 .

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BRKT STEERING HANDLE AND SHIFT LEVER 7-1 .

BRKT STEERING HANDLE AND SHIFT LEVER 7-2 .

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BRKT UPPER CASE AND EXHAUST MANIFOLD 7-6 .

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BRKT CRAMP BRACKET 7-9 .

BRKT CRAMP BRACKET 7-10 .

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ELEC .

ELEC ELECTRICAL COMPONENTS 8-1 .

ELEC ELECTRICAL COMPONENTS 8-2 .

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ELEC IGNITION SYSTEM 8-5 .

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ELEC IGNITION SYSTEM 8-10 .

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ELEC STARTING SYSTEM 8-12 .

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YAMAHA MOTOR CORPORATION. USA Printed in USA .