Professional Documents
Culture Documents
EK40J
SERVICE MANUAL
6H9-28197-5G-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!
w
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.
cC
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
EK40G/EK40J
SERVICE MANUAL
©2004 by Yamaha Motor Co., Ltd.
1st Edition, August 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
Contents
3
Disassembly and assembly ..................................................................... 1-4
8
9
6H95G11 1-
GEN
INFO General information
1 Parts are shown and detailed in an exploded diagram and are listed in the components list.
2 Tightening torque specifications are provided in the exploded diagrams and after a numbered
step with tightening instructions.
3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant
and lubrication point.
4 The components list consists of part names and quantities, as well as bolt and screw dimensions.
5 Service points regarding removal, checking, and installation are shown in individual illustrations
to explain the relevant procedure.
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
LOWR
Lower unit
3 2 1
Lower unit
LOWR
Lower unit
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.
S62Y6740K
CAUTION:
Do not reuse the bearing, always replace
S62Y6850K it with a new one.
6-19 62Y5A11
1-
1-1 6H95G11
How to use this manual
Symbols
The symbols below indicate the content of a chapter.
General information Fuel system Bracket unit
GEN
INFO FUEL BRKT
1
Specifications Power unit Electrical systems
SPEC POWR
Troubleshooting
2
CHK
ADJ LOWR TRBL
SHTG
3
Symbols 1 to 6 indicate specific data.
1 2 3 4 5 6
4
1
2
3
4
Special tool
Specified oil or fluid
Specified engine speed
Specified tightening torque
5 Specified measurement
6 Specified electrical value
(resistance, voltage, electric current) 5
Symbols 7 to e in an exploded diagram or illustration indicate the grade of lubricant and the lubri-
cation point.
7 8 9 0 q w e
6
C
7
8
Apply Yamaha 2-stroke motor oil
Apply gear oil
q Apply corrosion resistant grease
(Yamaha grease D)
7
9 Apply water resistant grease (Yamaha grease A) w Apply low temperature resistant grease
0 Apply molybdenum disulfide grease (Yamaha grease C)
e Apply injector grease
Symbols r to o in an exploded diagram or illustration indicate the type of sealant or locking agent
8
and the application point.
r t y u i o
9
r Apply Gasket Maker u Apply LOCTITE 242 (blue)
t Apply Three bond 1104J i Apply LOCTITE 572
y Apply LOCTITE 271 (red) o Apply silicon sealant
6H95G11 1-2
GEN
INFO General information
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where ade-
Under normal conditions, the lubricants men-
quate ventilation can be maintained.
tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1-
1-3 6H95G11
Safety while working
1
Good working practices
Special service tools 2. Apply engine oil to the contact surfaces
Use the recommended special service tools of moving parts before assembly.
to protect parts from damage. Use the right
tool in the right manner–do not improvise.
2
3. Install bearings with the manufacture
3
identification mark in the direction indicat-
Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening nuts, bolts, and screws, tighten the
ed in the installation procedure. In addi-
tion, be sure to lubricate the bearings lib-
erally. 4
large sizes first, and tighten fasteners starting 4. Apply a thin coat of water-resistant
in the center and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, etc., when installing or
grease to the lip and periphery of an oil
seal before installation.
6
7
8
9
6H95G11 1-4
GEN
INFO General information
Propeller size
The size of the propeller is indicated on the
outside of the propeller boss or the propeller
blade.
6F610010
3 1 × -
4 a b c
2
YAMAHA MOTOR CO., LTD. 6B410030
MADE IN JAPAN
PAYS D'ORIGINE JAPON
6B410020
1 Model name × −
2 Approved model code a b c
3 Transom height
4 Serial number
Approved Starting
Model name 6F610030
model code serial No.
EK40G 6F5K 1006117– a Propeller diameter (in inches)
EK40J 6H9K 1001748– b Propeller pitch (in inches)
c Propeller type (propeller mark)
1-
1-5 6H95G11
Propeller selection/Predelivery checks
Selection
When the engine speed is at the full throttle
operating range (4,500–5,500 r/min), the
1
ideal propeller for the boat is one that pro-
vides maximum performance in relation to
boat speed and fuel consumption.
EK40G
Propeller size (in) Material
11 3/4 × 7 1/2 - H
11 3/4 × 8 3/4 - H
11 3/4 × 10 - H
2
Aluminum
11 1/2 × 11 - H
11 1/2 × 12 - H
11 1/2 × 13 - H
11 1/2 × 13 1/2 - H 6H910040
3
cC
EK40J
Propeller size (in)
12 1/4 × 9 - G
Material
Use pre-mixed fuel only.
Fuel and oil mixing ratio is 30:1. For
break-in period, gasoline: 25:1, kerosene:
4
11 3/4 × 10 - G 30:1 mixture shall be used.
11 5/8 × 11 - G
12 × 11 - G
11 3/8 × 12 - G
Checking the gear oil
1. Check the gear oil level. 5
11 3/4 × 12 - G
11 1/8 × 13 - G
11 1/2 × 13 - G
10 1/4 × 14 - G
Aluminum
6
11 1/4 × 14 - G
10 1/4 × 15 - G
11 × 15 - G
10 1/4 × 16 - G
Checking the battery (W)
6F630195 7
10 3/4 × 16 - G
1. Check the capacity, electrolyte level, and
10 3/4 × 17 - G
Predelivery checks
specified gravity of the battery.
9
20HR/IEC: 40 Ah
efficient, the predelivery checks should be
Electrolyte specified gravity:
completed as explained below.
1.280 at 20°C (68°F)
6H95G11 1-6
GEN
INFO General information
6F610060
3. Check that the shift lever 2 is in the neu-
tral position.
N 2
a 0—25mm
(0—1in.) 6B410060 R F
NOTE:
The optimum mounting height is affected by
the combination of the boat and the outboard
6F610070
motor. To determine the optimum mounting
height, test run the outboard motor at differ-
ent heights
NOTE:
Check the throttle valve fully open, after set-
ting the remote control cables.
1-
1-7 6H95G11
Predelivery checks
Checking the steering system Checking the gear shift and throttle
1. Check the steering friction for proper operation
adjustment. 1. Check that the gear shift operates
1
smoothly when the shift lever or remote
control lever is shifted from neutral to for-
b ward or reverse.
2
a ly when the throttle grip (tiller handle
model) is turned from the fully closed
position to the fully open position a.
6F610080 Check that the throttle operates smooth-
NOTE: ly when the remote control lever (remote
9 To increase the friction, turn the friction
adjusting bolt in direction a.
9 To decrease the friction, turn the friction
adjusting bolt in direction b.
control model) is shifted from forward or
reverse to the fully open positions a.
3
4
R
N
2. Check that the steering operates smooth-
ly. F
F
N
R
6F610110
5
6F610090 a
6
a
6F610120
7
6F610100
9
6H95G11 1-8
GEN
INFO General information
6F610130
NOTE:
The test run is part of the break-in operation.
6F610150
1-9 6H95G11
Predelivery checks
1
2. Check for fuel leakage in the cowling.
speed. A fast idle in neutral is best.
3. Flush the cooling water passage with
2. 50 minutes b at 1/2 throttle (approxi- fresh water using the flushing kit and with
mately 3,000 r/min) or less. Vary engine the engine running at idle.
2
speed occasionally. On an easy-planing
boat, accelerate at full throttle onto plane,
then immediately reduce the throttle to
3,000 r/min or less.
3
3. 1 hour c at 3/4 throttle (approximately
4,000 r/min). Vary engine speed occa-
sionally. Run at full throttle for 1 minute,
the allow about 10 minutes of operation
at 3/4 throttle or less to let the engine
cool.
6
0 1 2 10 7
8
6F610180
å Hours
9
6H95G11 1-10
GEN
INFO
— MEMO —
1-11 6H95G11
SPEC
Specifications
General specification
Model
Item Unit
EK40GMH EK40JMH EK40JW
Dimensions
Overall length mm (in) 997 (39.3) 692 (27.2)
Overall width mm (in) 484 (19.1) 363 (14.3)
Overall height
(S) mm (in) 1,215 (47.8) 1,208 (47.6)
(L) mm (in) 1,342 (52.8) 1,335 (52.6) –
Boat transom height
(S) mm (in) 381 (15.0)
(L) mm (in) 508 (20.2) –
Weight
(with aluminum propeller)
(S) kg (lb) 65.0 (143) 70.0 (154)
(L) kg (lb) 68.0 (150) 72.0 (159) –
Performance
Maximum output kW (hp) 29.4 (40) at 5,000 r/min
Full throttle operating range r/min 4,500–5,500
Maximum fuel consumption L (US gal, 19.5 (5.2, 4.3) at 5,500 r/min
lmp gal)/hr
Engine idle speed r/min 1,050–1,150
Power unit
Engine type 2-stroke, L
Cylinder quantity 2
Total displacement cm3 (cu. in) 669 (40.82)
Bore x stroke mm (in) 78.0 × 70.0 (3.07 × 2.76)
Compression ratio 5.00
Intake system Reed valve
Scavenging system Loop charge
Control system Tiller handle Remote control
Starting system Manual Manual and
electric
Fuel system Carburetor
Ignition control system CDI
Maximum generator output (W) V, A (80) (80) 12, 6
Starting enrichment Choke valve
Spark plug (NGK) B7HS (NGK)
Cooling system Water
Exhaust system Under water Propeller boss
Lubrication system Pre-mixed fuel
2-1 6H95G11
General specification
Model
Item Unit
EK40GMH EK40JMH EK40JW
Fuel and oil
Fuel type
Engine oil
Engine oil grade
Gear oil type
NMMA-certified
Regular gasoline and kerosene
2-stroke outboard motor oil
TC-W3
Hypoid gear oil
1
Gear oil grade (*1) API GL-4
Bracket unit
SAE
cm3 (US oz,
lmp oz)
90
315 (10.65, 11.11)
2
Trim angle Degree 8, 12, 16, 20, 24
(at 12° boat transom)
Tilt-up angle
Steering angle
Degree
Degree
67
45 + 45
3
Drive unit
4
Gear shift positions F-N-R
Gear ratio 1.85 (24/13) 2.00 (26/13)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Share pin Spline
Propeller direction (rear view)
Propeller ID mark
Electrical
Battery minimum capacity (*2)
H
Clockwise
G
5
CCA/EN — — 347
20HR/IEC
(*1) Meeting both API and SAE requirements
(*2) CCA: Cold Cranking Ampere
— — 40
6
EN: European Norm (European standard)
7
IEC: International Electrotechnical Commission
8
9
6H95G11 2-2
SPEC Specifications
Maintenance specification
Power unit
Model
Item Unit
EK40GMH EK40JMH EK40JW
Power unit
Minimum compression kPa 400 (4.0, 58)
pressure (*1) (kgf/cm2, psi)
Cylinder head
Warpage limit mm (in) 0.1 (0.0039)
2-3 6H95G11
Maintenance specification
Model
Item Unit
EK40GMH EK40JMH EK40JW
Piston rings
Top ring
Dimension B
Dimension T
End gap
mm
mm
mm
(in)
(in)
(in)
1.970–1.990 (0.0776–0.0783)
2.500–2.700 (0.0984–0.1063)
0.30–0.50 (0.0118–0.0197)
1
Side clearance mm (in) 0.02–0.06 (0.0008–0.0024)
Oversize diameter
1st
2nd
2nd piston ring
mm (in)
mm (in)
78.25 (3.0807)
78.50 (3.0906)
2
Dimension B mm (in) 1.970–1.990 (0.0776–0.0783)
Dimension T
End gap
Side clearance
mm
mm
mm
(in)
(in)
(in)
2.500–2.700 (0.0984–0.1063)
0.30–0.50 (0.0118–0.0197)
0.03–0.07 (0.0012–0.0028)
3
Oversize diameter
1st mm (in) 78.25 (3.0807)
2nd
Connecting rods
Small-end inside diameter
mm (in)
mm (in)
78.50 (3.0906)
24.900–24.912 (0.9803–0.9808)
4
Big-end side clearance mm (in) 0.200–0.700 (0.0079–0.0276)
5
Small-end axial play limit mm (in) 2.0 (0.08)
Crankshaft
Crankshaft width A mm (in) 61.40–61.45 (2.4173–2.4193)
Crankshaft width B mm (in) 41.38–41.60 (1.6291–1.6378)
Crankpin diameter mm (in) 26.995–27.000 (1.0627–1.0629)
Runout limit mm (in) 0.03 (0.0012)
6
Thermostat
7
Opening temperature °C (°F) 58–62 (136–144)
Fully open temperature
Valve open lower limit
Reed valves
°C (°F)
mm (in)
70 (158)
3.0 (0.12) 8
Valve bending limit mm (in) 0.2 (0.0079)
9
Valve stopper height B mm (in) 2.2–2.6 (0.087–0.102)
Valve stopper height C mm (in) 4.0–4.4 (0.157–0.173)
B
C
6H95G11 2-4
SPEC Specifications
Model
Item Unit
EK40GMH EK40JMH EK40JW
Carburetor
ID mark 6F542 6H903
Kerosene Gasoline Kerosene Gasoline
Main jet (M.J.) # 145 – 140 –
Main air jet (M.A.J.) ø1.70 – ø1.70 –
Main nozzle (M.N.) mm (in) 3.2 (0.13) – 3.2 (0.13) –
Pilot jet (P.J.) # 90 60 90 60
Pilot air jet (P.A.J.) ø1.00 ø1.20 ø1.00 ø1.20
Pilot screw (P.S.) turns out 3/4 – 1 1/4 3/4 – 1 1/4
Valve seat size mm (in) 2.0 (0.08) 1.2 (0.05) 2.0 (0.08) 1.2 (0.05)
Float height mm (in) 12.0–13.0 4.0–5.0 12.0–13.0 4.0–5.0
(0.47–0.51) (0.16–0.20) (0.47–0.51) (0.16–0.20)
Lower unit
Model
Item Unit
EK40GMH EK40JMH EK40JW
Gear backlash
Pinion-to-forward mm (in) 0.05–0.24 0.19–0.47
(0.0020-0.0094) (0.0075-0.0185)
Pinion-to-reverse mm (in) 0.40–0.59 0.76–1.04
(0.0157–0.0232) (0.0299–0.0409)
Pinion gear shims mm 0.70, 0.75, 0.05, 0.08, 0.12, 0.30, 0.50
0.80, 0.85
Forward gear shims mm 0.70, 0.80, 0.05, 0.08, 0.12, 0.30, 0.50
0.90,
Reverse gear shims mm 1.00, 1.10, 1.20 0.05, 0.08, 0.12, 0.30, 0.50
1.80, 1.90, 2.00,
2.10, 2.20, 2.30,
2.40, 2.50
Electrical
Model
Item Unit
EK40GMH EK40JMH EK40JW
Ignition and ignition control
system
Ignition timing (full retard) Degree BTDC 9 at engine idle speed
Ignition timing (full advanced) Degree BTDC 23
Ignition spark gap mm (in) 0.6–0.7 (0.024–0.028)
Ignition coil resistance
Primary coil (O–B) Ω 0.26–0.35
at 20°C (68°F)
2-5 6H95G11
Maintenance specification
Model
Item Unit
EK40GMH EK40JMH EK40JW
Secondary coil
(spark plug wire–spark plug wire)
at 20°C (68°F)
CDI unit output peak voltage
(O–B)
kΩ 6.8–10.2
1
at Cranking (loaded) V 160
at 1,500 r/min (loaded)
at 3,500 r/min (loaded)
Pulser coil output peak voltage
(W/R–B, W/B–B)
V
V
185
170
2
at Cranking (unloaded) V 10.0
at Cranking (loaded)
at 1,500 r/min (loaded)
at 3,500 r/min (loaded)
V
V
V
10.0
30.0
66.0
3
Pulser coil resistance (W/R–B) Ω 16.2–19.8
Ω
4
Pulser coil resistance (W/B–B) 16.2–19.8
Charge coil output peak
voltage (Positive side: Br–
Negative side: L)
at Cranking (unloaded) V 150
5
at Cranking (loaded) V 140
at 1,500 r/min (loaded) V 190
at 3,500 r/min (loaded) V 180
Charge coil resistance (Br–L) Ω 243–297
Starter motor
Type
Brushes
Length limit
Armature
mm (in)
—
—
—
—
Bendix
9.0 (0.35)
6
Commutator undercut limit mm (in) — — 0.2 (0.01)
Charging system
Fuse
Lighting coil output peak
voltage (G–G)
A – — 20 7
at Cranking (unloaded) V 6.0
at 1,500 r/min (unloaded)
at 3,500 r/min (unloaded)
Lighting coil resistance (G–G)
V
V
Ω
17.0
38.0
0.32–0.39
8
Rectifier output peak voltage
9
(R–B)
at 1,500 r/min (unloaded) V 13
at 3,500 r/min (unloaded) V 13
6H95G11 2-6
2-7
*MH
S: 771 (30.4) EK40JW
L : 898 (35.5) S: 764 (30.1)
695 (27.4)
Exterior
SPEC
S: 444 (17.5)
L: 570 (22.4)
Dimensions
162 (6.4)
EK40JW EK40JW 602 (23.7)* 360 (14.2)
175 (6.9) S: 421 (16.6)
444 (17.5)
127 (5.0)
45 (1.8) 294 (11.6)*
30 (1.2)*
94 (3.
7)
Specifications
193 (7.6)*
427 (16.8)
188 (7.4)
72 (2.8)
EK40JW
504 (19.8)
478 (18.9)
421 (16.6)
L: 897 (35.3)
S: 784 (30.9)
EK40JW
205 (8.07)
S: 797 (33.4)
S: 622 (24.5)
L: 691 (27.2) 533 (20.1)*
6H95G11
mm (in)
6H92001M
Maintenance specification
Clamp bracket
mm (in)
1
2
134.5 (5.3)
93.5 (3.68)
134.5 (5.3)
93.5 (3.68)
3
32 (1.26)
4
57 (2.24)
50 (1.97)
5
217.5 (8.56)
10.5 (0.41)
33 (1.30)
249 (9.80)
60 (2.36)
10.5 (0.41)
16.5 (0.65)
6
124.5 (4.9) 124.5 (4.9)
7
8
6F62002M
9
6H95G11 2-8
SPEC Specifications
Tightening torques
Specified torques
Tightening torques
Part to be tightened Thread size
N·m kgf·m ft·lb
Fuel system
Main jet — 4 0.4 3.0
Power unit
Power unit mounting bolt M8 21 2.1 15.5
Flywheel nut M20 160 16 115
Manual starter nut M6 10 1.0 7.2
Manual starter bolt M6 15 1.5 11.1
Starter motor bolt M8 29 2.9 21
Starter relay terminal nut M6 4 0.4 3.0
1st 15 1.5 11.1
Cylinder head bolt M8
2nd 30 3.0 22
Cylinder head cover bolt M6 12 1.2 8.7
Exhaust outer cover bolt M6 8 0.8 5.8
1st 20 2.0 15
Crankcase bolt M8
2nd 40 4.0 29.5
Spark plug M14 25 2.5 18
Lower unit
Check screw — 9 0.9 6.6
Drain screw — 9 0.9 6.6
Lower case mounting bolt M8 21 2.1 15.5
1st 4 0.4 3.0
Lower case cap bolt (EK40G) M6
2nd 8 0.8 5.8
Cooling water inlet cover (EK40J) M5 4 0.4 3.0
Propeller nut (EK40J) M16 35 3.5 25.3
Propeller shaft housing ring nut (EK40J) — 90 9.0 65
Pinion nut (EK40J) M12 74 7.4 54.6
Bracket unit
Throttle grip screw M5 3 0.3 2.2
Engine stop lanyard switch nut — 5 0.5 3.6
Upper mount nut M8 28 2.8 20
Lower mount nut M12 55 5.5 40
1st 14 1.4 10
Clamp bolt M8
2nd 24 2.4 17.7
Self locking nut M22 45 4.5 33
Bracket nut M6 24 2.4 17.7
Clamp pad bolt M6 10 1.0 7.2
Tilt lever bolt M5 4 0.4 3.0
Grease nipple — 3 0.3 2.2
2-9 6H95G11
Tightening torques
General torques
This chart specifies tightening torques for
standard fasteners with a standard ISO
1
thread pitch. Tightening torque specifications
for special components or assemblies are
provided in applicable sections of this manu-
al.
To avoid warpage, tighten multi-fastener
assemblies in a crisscross fashion and pro-
gressive stages until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads.
2
Components should be at room temperature.
— MEMO —
2-11 6H95G11
CHK
ADJ
Periodic checks and adjustments
4
Checking the cooling water passages ..................................................... 3-4
9
Lubricating the outboard motor ............................................................. 3-10
6H95G11
CHK
ADJ Periodic checks and adjustments
Digital tachometer
90890-06760
Leakage tester
90890-06840
3-1 6H95G11
Special service tools/Maintenance interval chart
Item Actions
Initial Every
10 hours 50 hours 100 hours 200 hours
(Break-in) (3 months) (6 months) (1 year)
Refer
to
page
1
Anode (s) (external) Check / replace 1 1 3-9
Anode (s) (internal) Check / replace 1 5-30
Battery
Cooling water passages
Cowling clamp
Check / charge
Clean
Check
1
1 1
1
3-9
3-4
3-3
2
Fuel filter (can be dis-
Check / clean 1 1 1 3-3
3
assembled)
Fuel system Check 1 1 1 3-3
Fuel tank (Yamaha por-
Check / clean 1 —
table tank)
Gear oil Change 1 1 3-8
Lubrication points
Idling speed (carbure-
tor model)
Propeller and cotter pin
Lubricate
Check / adjust
Check / replace
1
1
1
1
1
3-10
3-7
3-9
4
Shift link / shift cable Check / adjust 1 3-7
Thermostat
Throttle link / throttle
cable / throttle pick-up
timing
Check
Check / adjust
1
1
3-4
3-5,
3-6
5
Water pump Check 1 6-10, 6-32
Spark plug
NOTE:
Clean / adjust / replace 1 1 1 3-3
When operating in salt water, turbid or muddy water, the engine should be flushed with clean water
6
after each use.
7
8
9
6H95G11 3-2
CHK
ADJ Periodic checks and adjustments
Power unit
Checking the spark plugs
1. Disconnect the spark plug caps, and then
remove the spark plugs.
2. Clean the electrodes 1 with a spark plug
cleaner or wire brush. Replace the spark
plug if necessary.
6F630010
1
Fuel system
Checking the fuel joint and fuel
hoses (fuel joint-to-carburetor)
1. Check the fuel hose connections and fuel
joint 1 for leaks. Replace if necessary.
Also, check the fuel filter 2, fuel pump 6B430025
3-3 6H95G11
Fuel system/Power unit
1
Checking the cooling water pas-
2 sages
1. Check the cooling water inlet cover 1,
screw 2 and cooling water inlet for clog-
ging. Clean if necessary.
3
1 6H930040
å
2 2
2. Suspend the thermostat in a container of
water. 3
3. Place a thermometer in the water and 6F630060
2
1
2
5
6F630070
6B430060
å EK40G
6B430070
8
Water
9
Valve lift a
temperature
58–62°C 0 mm (0 in)
(136–147°F) (valve begins to tilt)
above more than 6F610170
6H95G11 3-4
CHK
ADJ Periodic checks and adjustments
1 2
3. Turn the throttle grip or remote control 4 6F630085
lever in the fully opened position and
adjust the throttle arm 2 until its contacts 4. Turn the throttle grip to the fully closed
with the stopper. position.
4. Tighten the throttle arm adjusting screw 5. Loosen the locknut 5 and adjust the
1. length of the throttle cable (close-side) 6
with the adjusting nut 7 until the stopper
8 on the pulley contact the stopper plate
b on the bracket, then tighten the lock-
nut.
1
2
5
b 7
6F630080 6
6F630090
3-5 6H95G11
Control system
6. Fully open and close the throttle grip and 4. Adjust the position of the cable end 5
make sure the stopper on the pulley con- until it is aligned with the hole on the pul-
tacts the stopper on the bracket (at the ley.
1
fully opened position) and stopper on the
bracket contacts the stopper on the pul- 5
ley (at the fully closed position). If proper
contacts are not made, repeat the proce-
dure.
1
a
7
1. Check that the gear shift operates
smoothly when shifting from neutral to
forward or reverse. Adjust the shift rod if
2 necessary.
4
6F630100
R
N
F
8
6F630130
9
2. Set the gear shift to the neutral position.
6H95G11 3-6
CHK
ADJ Periodic checks and adjustments
Checking the gear shift operation Checking the engine idle speed
(W) 1. Start the engine and warm it up for 5 min-
1. Check that the gear shift operates utes.
smoothly when shifting it from neutral to 2. Attach the special service tool to spark
forward or reverse. Adjust the shift cable plug wire #1 1, and then check the
length if necessary. engine idle speed. Adjust if out of specifi-
cation.
2. Set the gear shift to the neutral position.
1 N 3 6F630160
2
Digital tachometer: 90890-06760
R F
4
b a
6H930170
a
6F610077
NOTE:
w 9 To increase the idle speed, turn the throttle
The shift/throttle cable end must be stop screw in direction a.
screwed in a minimum of 8.0 mm (0.31 in) 9 To decrease the idle speed, turn the throttle
a. stop screw in direction b.
6. Install the cable joint 1 and tighten the 4. If the specified engine idle speed cannot
adjusting nut. be obtained, adjust the throttle cable(s).
3-7 6H95G11
Bracket/Lower unit
1
a few times and check the entire tilt range
for smooth operation. check screw 2 and let the oil drain com-
pletely.
2
2
3
6F630180
6F630200
1
6
7
6F630210
8
6F630190
6H95G11 3-8
CHK
ADJ Periodic checks and adjustments
∫
1
6F630310
6F630230
å EK40G
Leakage tester: 90890-06840 ∫ EK40J
General 6F630240
Checking the anodes
1. Check the anodes and trim tab for scales, 2. Check the specific gravity of the elec-
grease, and oil. Clean if necessary. trolyte. Fully charge the battery if below
specification.
3-9 6H95G11
General
w
Battery electrolyte is dangerous; it con-
tains sulfuric acid which is poisonous and
highly caustic.
9 Avoid bodily contact with electrolyte as
it can cause severe burns or permanent
eye injury.
A
1
9 Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
9 SKIN – Wash with water.
9 EYES – Flush with water for 15 minutes
a
6F630250
2
and get immediate medical attention.
Antidote (INTERNAL):
9 Drink large quantities of water or milk
followed with milk of magnesia, beaten A A
3
egg, or vegetable oil. Get immediate A
medical attention.
4
6F630260
9 Charge batteries in a well-ventilated
area.
9 Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
5
lighted cigarettes).
9 DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE A
OUT OF REACH OF CHILDREN.
6
6F630270
å
NOTE:
9 Batteries vary per manufacturer. The proce- A
7
6F630280
Electrolyte specific gravity:
1.280 at 20° C (68° F)
å
A
8
Lubricating the outboard motor
9
1. Apply water resistant grease to the areas
shown.
NOTE:
Apply grease to the grease nipple until it
6F630290
flows from the bushings a.
å Tiller handle model
6H95G11 3-10
CHK
ADJ Periodic checks and adjustments
6F630300
6B430300
3-11 6H95G11
FUEL
Fuel system
4
Disassembling the fuel pump ................................................................ 4-15
Assembling the fuel pump ..................................................................... 4-15
Checking the fuel joint ........................................................................... 4-15
5
6
7
8
9
6H95G11
FUEL Fuel system
Digital caliper
90890-06704
4-1 6H95G11
Special service tools/Hose routing
Hose routing
1
2
5 6 7 3
5
4
4
6 7
5
1
6
2
7
3 6H94010E
Fuel line
6H94020E
4-3 6H95G11
Fuel line
1
2
3
4
5
No. Part name Q’ty Remarks
6H94020E
6
18 Fuel filter element 2
19
20
21
22
O-ring
Cup
Screw
Intake silencer
2
2
3
1
ø6 × 30 mm
7
23 O-ring 1 Not reusable
24
25
26
Screw
Link lever
Pin
4
1
1
ø6 × 12 mm
8
27 Choke rod 1
9
28 Collar 1
29 Link rod 1
30 Nut 4
31 Washer 4
32 Gasket 1 Not reusable
33 Carburetor assembly 1
34 Gasket 1 Not reusable
6H95G11 4-4
FUEL Fuel system
Carburetor
4-5 6H95G11
Carburetor
1
2
3
4
5
No.
4 N·m (0.4 kgf·m, 3.0 ft·lb)
9
28 Main nozzle 2
29 Carburetor body 1
30 Pilot jet 4
31 Float pin 1
32 Float 1
33 Needle valve 1
34 Valve seat 1
6H95G11 4-6
FUEL Fuel system
4-7 6H95G11
Carburetor
1
2
3
4
5
No.
4 N·m (0.4 kgf·m, 3.0 ft·lb)
Not reusable
7
57 Ball seat 1
58
59
60
Ball
Spring
Gasket
1
1
1 Not reusable
8
61 Carburetor body 1
ø5 × 16 mm
9
62 Screw 8
63 Screw 2 ø6 × 19 mm
64 Starter plunger 1
65 Spring 1
66 Float chamber 1
67 Screw 4 ø5 × 12 mm
68 Holder 1
6H95G11 4-8
FUEL Fuel system
6F640060
6D440025 b
cC 1
9 Direct the compressed air downward,
otherwise cleaning solvent may be
blown into your eyes or small parts of
6H940065
the carburetor may be blown off.
9 Do not use steel wire for cleaning the NOTE:
jets, otherwise the jet diameters may be 9 The float should be resting on the needle
enlarged, which may seriously affect valve 1, but not compressing it.
performance. 9 Measure the height a from the gasket to
the float as shown for the kerosene side.
9 Measure the height b from the gasket to
3. Check the main jet, pilot jet, and main the float as shown for the gasoline side.
nozzle for dirt or residue. Clean if neces-
sary.
Digital caliper 2: 90890-06704
4. Check the pilot screw and needle valve
for bends or wear. Replace if necessary.
Float height a: (kerosene)
12.5—13.0 mm (0.47—0.51 in)
Float height a: (gasoline)
4.0—5.0 mm (0.16—0.20 in)
4-9 6H95G11
Carburetor
Assembling the carburetor 4. Install the pilot jet w, new gasket and
1. Install the starter jet 1 and check valve cover to the carburetor body of the
2, then install the plunger 3 onto the kerosene side as shown.
1
float chamber of the gasoline side.
w w
2
3 1
6H940080
2
3
6H940120 5. Install the needle valve e, float r, float
2. Install the starter plunger 4, new gasket arm t, and float pin y, gasoline side
5, spring 6, ball 7, ball seat 8, new float, and then the check the float for
gasket 9 and valve seat 0 onto the car- smooth operation.
buretor body of the gasoline side. å
4
e y
4
r
6H940090
5
∫
5 y
6
8 7
9
0
6H940130
t
e
6
3. Install the main jet q onto the float cham-
ber of the kerosene side.
q
6H940095
7
å:Kerosene side
∫:Gasoline side
NOTE:
Place the needle valve in the valve seat when
8
installing the float to the carburetor.
Main jet:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
6H940140
6H95G11 4-10
FUEL Fuel system
7. Install a new O-ring u, and new gasket Adjusting the throttle stop screw
i, onto the carburetor body of the gaso- 1. Start the engine and warm it up for 5 min-
line side, and then install the carburetor utes.
body of the kerosene side.
2. Turn the throttle stop screw 1 in direc-
tion a or b until the specified engine idle
speed is obtained.
i
1
b a
u
6H940110
6H940150
NOTE:
8. Install the pilot screw, turn it in until it is 9 To increase the idle speed, turn the throttle
lightly seated, then out the specified stop screw in direction a.
number of turns. 9 To decrease the idle speed, turn the throttle
stop screw in direction b.
NOTE:
9 Adjust the throttle cable whenever the car-
buretor has been disassembled or the
engine idle speed has been adjusted.
9 For adjustment procedures, see Chapter3.
4-11 6H95G11
Carburetor/Fuel pump
Fuel pump
1
2
3
4
5
No. Part name Q’ty Remarks
6H94030E
6
1 Screw 3 ø5 × 30 mm
2
3
4
5
Cover
Diaphragm
Gasket
Fuel pump body
1
1
1
1
Not reusable
7
6 Diaphragm 1
7
8
9
Spring
Spring plate
Gasket
1
1
1 Not reusable
8
10 Check valve 2
9
11 Cover 1
12 Gasket 1 Not reusable
13 Diaphragm 1
14 Pump body 1
15 Gasket 1 Not reusable
16 Diaphragm 1
17 Cover 1
6H95G11 4-12
FUEL Fuel system
6H94030E
4-13 6H95G11
Fuel pump
Checking the fuel pump 5. Connect the special service tool to the
1. Place a drain pan under the fuel hose fuel pump outlet c or d.
connections, and then disconnect the
1
fuel hoses from the fuel pump.
d
2. Connect the special service tool to the
fuel pump inlet a or b.
c
2
3. Cover the fuel pump outlet c or d with a
finger, and then apply the specified posi-
tive pressure. Check that there is not air
6H940030
leakage.
Specified pressure:
c
b
50 kPa (0.5 kgf/cm2, 7.3 psi)
6H940010
Disassemble the fuel pump if necessary.
NOTE:
Assemble the fuel pump valve to the fuel
4
Connecting location:
pump body, and moisten the inside of fuel
5
a Gasoline inlet pump with gasoline to ensure a better seal.
b Kerosene inlet
c Gasoline outlet
d Kerosene outlet 7. lastly, connect the special service tool to
Vacuum/pressure pump gauge set: the inlet a or b, and then apply the pos-
6
90890-06756 itive pressure, check that there is smooth
blow from outlet c or d.
Specified pressure: Reassemble the fuel pump if necessary.
50 kPa (0.5 kgf/cm2, 7.3 psi)
c
4. Apply the specified negative pressure
and check that there is no air leakage.
d
b
7
a
6H940040
8
6H940020
9
Specified pressure:
30 kPa (0.3 kgf/cm2, 4.4 psi)
6H95G11 4-14
FUEL Fuel system
3. Check the valves for bends or damage. Checking the fuel joint
Replace if necessary. Also, check the fuel 1. Visually check the fuel joint for cracks or
pump body for damage. Replace if nec- damage.
essary.
2. Connect the special service tool at the
4. Clean the fuel pump body. outlet of fuel joint.
1
6B740020
6F640040
Specified pressure:
50 kPa (0.5 kgf/cm2, 7.3 psi)
2. Install the spring 2, spring plate 3, new
gaskets 4, the diaphragms 5, and cov-
ers 6.
6
4
5
4 3 5
4
2
6 6
5
45
6H940050
4-15 6H95G11
POWR
Power unit
Special service tools ................................................................................... 5-1
2
Checking the drive pawl ........................................................................ 5-13
Measuring the starter rope .................................................................... 5-13
Assembling the manual starter .............................................................. 5-14
Removing the power unit ....................................................................... 5-15
Removing the flywheel magnet ............................................................. 5-16
Removing the electrical components .................................................... 5-17
Removing the throttle pulley assembly ................................................. 5-17
Disassembling the base assembly ........................................................ 5-18
Assembling the base assembly ............................................................. 5-18
3
Reed valves ................................................................................................ 5-19
Removing the reed valve assembly ...................................................... 5-21
Checking the reed valves ...................................................................... 5-21 4
Cylinder head ............................................................................................. 5-22
Removing the cylinder head .................................................................. 5-24
Checking the cylinder head ...................................................................
Removing the exhaust cover .................................................................
Checking the exhaust cover ..................................................................
5-24
5-24
5-24
5
Crankcase ................................................................................................... 5-25
Removing the crankcase ....................................................................... 5-27
Removing the crankshaft assembly and oil seal housing ..................... 5-27
Checking the cylinder bore .................................................................... 5-27
Disassembling the oil seal housing ....................................................... 5-28
6
Checking the oil seal housing ............................................................... 5-28
Assembling the oil seal housing ............................................................ 5-28
Disassembling the piston ...................................................................... 5-28
Checking the piston diameter ................................................................ 5-29
Checking the piston clearance .............................................................. 5-29
7
Checking the piston rings ...................................................................... 5-29
Checking the piston ring side clearance ............................................... 5-30
Checking the piston pin boss bore ........................................................ 5-30
Checking the piston pin ......................................................................... 5-30
Checking the internal anodes ................................................................ 5-30
8
Disassembling the crankshaft ............................................................... 5-30
Checking the crankpin ........................................................................... 5-32
Assembling the crankshaft .................................................................... 5-32
Checking the crankshaft ........................................................................ 5-36
Installing the crankshaft bearings .......................................................... 5-36
9
Assembling the piston ........................................................................... 5-37
Assembling the power unit .................................................................... 5-37
Installing the power unit ......................................................................... 5-39
6H95G11
POWR Power unit
5-1 6H95G11
Special service tools
1
Body Pressure plate
90890-02352 90890-02384
2
Bolt Press body
3
90890-02353 90890-02385
4
5
B
B-9
6
C
Bushing-9 (D30)
90890-02363
Bearing pressure C
90890-02393
7
B-12 8
Bushing-12 (D35)
90890-02366
Support
90890-02394
9
6H95G11 5-2
POWR Power unit
H-18
Plate C
90890-02402
Pressure pin C
90890-02403
Spacer C
90890-02404
5-3 6H95G11
Special service tools/Power unit
1
utes, and then turn it off. a small amount of engine oil to the cylin-
ders, and then check the compression
2. Remove the clip from the engine stop pressure again.
lanyard switch. NOTE:
9 If the compression pressure increases,
3. Remove the spark plug caps and all
spark plugs, and then install the special
service tools into a spark plug hole.
check the pistons and piston rings for wear.
Replace if necessary.
9 If the compression pressure does not
increase, check the cylinder head gasket,
2
and cylinder head. Replace if necessary.
3
6F650010
4
cC
Before removing the spark plugs, blow
compressed air in the spark plug well to
clear out any dirt or dust that may fall into
the cylinder.
5
Compression gauge:
90890-03160 6
4. Fully open the throttle, and then crank the
engine until the reading on the compres-
sion gauge stabilizes.
NOTE:
7
Do not pull the choke knob when checking
8
the compression pressure.
9
6H95G11 5-4
POWR Power unit
W MH
5-5 6H95G11
Power unit
M8 × 14 mm
7
8 Starter pulley 1
9
10
11
12
Nut
Washer
Pulser coil
Screw
1
1
2
4 ø5 × 24 mm
8
13 Charge coil 1
14
15
16
Screw
Light coil
Screw
4
1
1
ø6 × 25 mm
ø4 × 6 mm
9
6H95G11 5-6
POWR Power unit
MH
6F65050E
5-7 6H95G11
Power unit
1
2
3
4
5
6F65040E
No.
1
2
Starter motor
Starter relay
Part name Q’ty
1
1
Remarks
6
3 Bracket 1
4
5
6
7
Bolt
Spiral tube
Cap
Nut
2
1
3
3
M6 × 12 mm
7
8 Spring washer 3
9
10
11
12
Starter motor lead
Battery negative lead
Bolt
Washer
1
1
2
2
M8 × 16 mm
8
13 Collar 2
14
15
16
Bracket
Bracket
CDI unit
1
1
1
9
17 Bolt 2 M6 × 20 mm
All components are for W model only.
6H95G11 5-8
POWR Power unit
6F65040E
5-9 6H95G11
Power unit
1
2
3
4
5
6F65060E
No.
1
2
Bolt
Collar
Part name Q’ty
1
1
M6 × 30 mm
Remarks
6
3 Throttle control lever 1
4
5
6
7
Throttle pulley
Throttle cable
Bracket
Bolt
1
2
1
1 M6 × 15 mm
7
8 Link rod 1
9 Joint 2
8
9
6H95G11 5-10
POWR Power unit
6F65020E
5-11 6H95G11
Power unit
1
2
3
4
15 N·m (1.5 kgf·m, 11.1 ft·lb) 5
6F65020E
No.
18
19
Washer
Cover
Part name Q’ty
2
1
Remarks
6
20 Manual starter handle 1
21
22
23
24
Damper
Starter rope guide
Starter rope
Start-in-gear protection cable
1
1
1
1
7
25 Plunger 1
26 Spring 1
8
9
6H95G11 5-12
POWR Power unit
Disassembling the manual starter 4. Remove the spiral spring 9 from the
1. Turn the sheave drum 1 clockwise until manual starter case.
the spiral spring is free.
2 9
3
1 6F650040
a 6F650020
NOTE: w
9 Turn the sheave drum so that the notch on The spiral spring can pop out. To remove
the outer surface of the sheave drum faces the spring, cover it with cloths.
toward the manual starter handle.
9 Pass the starter rope 2 through the notch
a. 5. Remove the starter rope 0.
9 When turn the sheave drum, pulling the
start-in-protection cable 3.
w
The spiral spring can pop out. Cover the
spiral spring with cloths, then pull out the
sheave drum.
5-13 6H95G11
Power unit
Assembling the manual starter 5. Install the spiral spring 4 into the starter
1. Install the starter rope 1 into the sheave case.
drum 2.
1
NOTE:
4
6F650080
2
Install the outer end c of the spiral spring
1
onto the pin d of the starter case.
3
6. Install the sheave drum into the manual
2 3 starter case 5.
a 5
4
NOTE:
6F650060
6
9 Be sure to leave 5.0—10.0 mm (0.2—0.4
NOTE:
in) at the end a of the starter rope.
Install the sheave drum, then set the spiral
spring by turning the sheave drum.
4. Wind the starter rope 1-1/2 around the
sheave drum in the direction of the arrow
shown in the illustration.
7. Install the drive pawl spring 6, drive pawl
7, spring 8 and drive plate 9.
9
7
b 7 8
8
6
NOTE:
6F650070
6H95G11 5-14
POWR Power unit
8. Turn the sheave drum 3 times in the Removing the power unit
direction of the arrow shown, and then NOTE:
remove the starter rope from the notch It is recommended to loosen the flywheel
e. magnet nut before removing the power unit to
improve working efficiency.
e 6F650110
1
NOTE:
Pull the start-in-gear protection cable 0 while
turning the sheave drum as shown.
6H950140
9. Pull the manual starter handle several
times to check that the sheave drum 2. Remove the choke link rod 2 and intake
turns smoothly and to check the starter silencer 3.
rope for slack. Repeat steps 4—8 if nec-
essary.
2 6H900190
f
4
6H950160
6F650130
4. Disconnect the remote control cables 8. Remove the apron, and then remove the
(remote control model) or throttle cables power unit by removing the bolts.
(tiller handle model).
5
1
5
6H950180
2
Removing the flywheel magnet
6H950150 cC
6F650200
5
7. Disconnect the engine stop lanyard Apply force in the direction of the arrows
switch leads 7 (MH), CDI unit couplers
8, Ignition coil leads 9 and rectifier (W)
leads 0, thermoswitch leads q, fuel
shown. While working, do not allow the
flywheel holder to slip off the flywheel.
6
hose and pilot water hose.
Flywheel holder: 90890-06522
9 8
7
0
å
8
q
9
7
8
6F650170
9
å MH model
6H95G11 5-16
POWR Power unit
1
6B450090
cC 6F650210
To prevent damage to the engine or tools, 3. Remove the spark plug caps from the
screw in the flywheel puller set bolts spark plugs, and then remove the ignition
evenly and completely so that the fly- coil 3.
wheel
puller plate is parallel to the flywheel mag-
Removing the throttle pulley assembly
net.
1. Removing the throttle pulley assembly.
NOTE:
Apply force to the crankshaft end until the fly-
wheel magnet comes off the tapered portion
of the crankshaft.
5-17 6H95G11
Power unit
1
6F650240
2
Assembling the base assembly
1. Apply grease to a new oil seal, then
install it into the base assembly.
3
2
3
1
4
Needle bearing attachment 1:
6F650250
5
90890-06654
6
Driver rod L3 2: 90890-06652
7
8
9
6H95G11 5-18
POWR Power unit
Reed valves
6H95070E
5-19 6H95G11
Reed valves
1
2
3
4
5
6
6H95070E
7
19 Bolt 1
8
9
6H95G11 5-20
POWR Power unit
Removing the reed valve assembly 2. Measure the valve stopper height b and
1. Remove the hoses 1. c. Replace if out of specification.
2
5
4
1
6F650270
a
6H950280
5-21 6H95G11
Cylinder head
Cylinder head
1
2
25 N·m (2.5 kgf·m, 18 ft·lb)
3
15 N·m (1.5 kgf·m, 11 ft·lb)
30 N·m (3.0 kgf·m, 22 ft·lb)
6
1 Gasket 1 Not reusable
7
2 Cylinder head 1
3 Thermoswitch 1
4 Bolt 1 M6 × 14 mm
5 Holder 1
6 Cover 1
7 Gasket 1
8
Not reusable
8 Bolt 4 M6 × 30 mm
9 Thermostat 1
10 Spark plug 2
11 Bolt 11 M8 × 0 mm
12
13
14
15
Bolt
Cylinder head cover
Gasket
Screw
5
1
1
1
M6 × 25 mm
Not reusable
9
16 Anode 1
17 Screw 2
6H95G11 5-22
POWR Power unit
6H95080E
5-23 6H95G11
Cylinder head
6H950300
4
cC
Do not scratch or damage the mating sur-
faces of the cylinder head and cylinder
block.
5
Checking the cylinder head
1. Eliminate carbon deposits from the com-
bustion chambers and check for deterio-
ration or corrosion.
Checking the exhaust cover
6F605330
6
1. Check the exhaust cover for distortion or
7
corrosion. Replace if necessary.
2. Check the cylinder head warpage using a
straightedge 1 and thickness gauge 2
in four directions as shown. Replace if
above specification.
8
9
6H95G11 5-24
POWR Power unit
Crankcase
5-25 6H95G11
Crankcase
1
2
3
4
5
No. Part name Q’ty Remarks
6F65100E
6
1 Crank 3 1
7
2 Washer 4
3 Roller bearing 2
4 Connecting rod 2
5 Needle bearing 56
6 Circlip 4 Not reusable
7
8
9
10
Piston
Piston pin
Piston ring set
Crank pin
2
2
2
2
8
11 Crank 4 1
12
13
14
15
Ball bearing
Labyrinth seal
Roller bearing assembly
Crank 2
1
1
1
1
Not reusable
9
16 Crank 1 1
17 Ball bearing 1 Not reusable
6H95G11 5-26
POWR Power unit
6F650350
6F650360
6F650356
NOTE:
Insert a flat-head screw driver between the
pry tabs to pry off the crankcase.
a: 10.0 mm (0.39 in) from the cylinder head top
surface
b: 5.0 mm (0.20 in) above the exhaust port
upper edge
c: 5.0 mm (0.20 in) below the scavenging port
lower edge
Cylinder gauge 1:
90890-06759
5-27 6H95G11
Crankcase
2. Calculate the taper limit. Replace or 2. Apply grease to new oil seals, then install
rebore the cylinder block if above specifi- them into the oil seal housing.
cation.
4
Taper limit:
D1 — D5 (direction d)
D2 — D6 (direction e)
0.08 mm (0.0032 in)
3
5 1
6
3. Calculate the out-of-round limit. Replace
or rebore the cylinder block if above
specification.
Out of round limit:
6F650400
2
D2 — D1 (direction a) Needle bearing attachment 3:
D6 — D5 (direction c)
0.05 mm (0.0020 in)
6H95G11 5-28
POWR Power unit
T
b
B
T 6B450460
5-29 6H95G11
Crankcase
1
Replace the piston and piston rings as a
set if out of specification.
2
(0.7833—0.7835 in)
6F650450
vanic corrosion effectively.
6B450545
9
Bearing separator: 90890-06534
6H95G11 5-30
POWR Power unit
2. Insert the plate C 1 between crank 1 2 4. Remove the washers, roller bearing and
and crank 2 3. Place pressure pin C 4 connecting rod.
in the end of the crank pin 5. 5. Insert the support 6 between crank 2
and 3 7 with crank 3 on top. Place pres-
sure pin B 8 on the shaft, and force it out
using a press.
2 4
3
1 5
6B450550
6F650470
cC
9 Apply pressure to pressure pin C
slowly.
9 Hold pressure pin C in line with the
press screw spindle.
NOTE: NOTE:
9 When forcing out the crank pin, use care so Pressure pin C should be pressed down
that the crank does not fall. straight.
9 To remove crank 4, follow the same proce-
dure. Plate C 1: 90890-02402
Pressure pin C 4: 90890-02403
5-31 6H95G11
Crankcase
1
6B450600
Spacer C 1: 90890-02404
Support 2: 90890-02394
2
NOTE:
Use care not to scratch the shaft.
2. Apply engine oil to the crankpin and
insert it into the crankpin hole by tapping
it with a copper hammer, and then install
the crankpin using a press.
3
Checking the crankpin
4
1. Measure the crankpin diameter. Replace
if out of specification.
5
cC
Crankpin diameter:
26.995—27.000 mm
9 Take care so that the crank pin is set
squarely into the crank web.
9 Do not apply force in excess of 5 tons.
6
(1.0627—1.0629 in)
8
wash all component parts in clean press.
kerosene (do not use gasoline).
9 Do not reuse bearings, always replace
them with new ones.
6F650530
Spacer C 1: 90890-02404
6 6F650540
NOTE:
9 Take care so that spacer C 1 does not fall
out of the crank, turn the crank over so that
the crankpin is on top, and then insert the
6B450650 crank into the special service tool.
NOTE: 9 The model number a on the connecting
Align the slot in the height ring with the slot in rod should face up.
the body.
5-33 6H95G11
Crankcase
8. Install the bushing 7 on the pressure 11. Insert the press body 9, and install crank
plate 8. 1 (or crank 3) onto the crankpin using a
press.
cC
Do not apply force in excess of 5 tons.
1
NOTE:
2
9
When installing crank 3 to the pressure plate,
do not use the bushing 7.
6B450690
NOTE:
6B450700
g f
9
Apply engine oil to the crankpin.
6B450720
6H95G11 5-34
POWR Power unit
Crankshaft width b: q
61.40–61.45 mm
(2.4173–2.4193 in)
w NOTE:
Align the alignment marks i on cranks 2 and
3
3.
0
q
Plate C q: 90890-02402
6F650560
17. Place the press body 9 on plate C and
install the crank 2 into crank 3 using a
press.
Plate C q: 90890-02402
Bushing-9 (D30) 3: 90890-02363
Bearing pressure C w:
90890-02393
h
E cC
Do not apply force in excess of 7 tons.
6F650570
5-35 6H95G11
Crankcase
1
out of specification. press.
6B450780
3
NOTE:
Crankshaft width a:
61.40–61.45 mm
(2.4173–2.4193 in)
Crankshaft width b:
9 Install the upper bearing so that the manu-
facture identification mark a faces the fly-
wheel magnet side.
4
9 Install the lower bearing so that the dowel
41.38–41.60 mm b faces the flywheel magnet side.
(1.6291–1.6378 in)
Connecting rod small-end axial play
limit: Bearing pressure C 1:
90890-02393
5
2.0 mm (0.08 in)
7
c
6B450800
8
Crankshaft runout limit c:
6B450790
9
0.03 mm (0.0012 in)
Crankshaft aligner:
90890-03107
6H95G11 5-36
POWR Power unit
6B450810
NOTE:
Install the piston rings with the recess for the
locating pin facing up toward the piston
crown.
4
2
2 6F650630
4 NOTE:
6 9 Apply engine oil to the pistons, piston rings
3 and bearings before installation.
9 Align the dowels of the bearings with the
slot 1 on the cylinder block.
9 Align the rings 2 with the grooves in the
7 cylinder block.
6F650610
NOTE:
9 Make sure that the piston and piston pin
bearings are installed in their original com-
bination.
9 Use the small end bearing installer 7 to
install the needle bearings.
9 Make sure that the up mark on the piston
crown faces the flywheel magnet side.
5-37 6H95G11
Crankcase
1
NOTE:
6F650640
2
Do not get any sealant on the crankshaft jour- 6F605335
nals.
NOTE:
Apply LOCTITE 572 to the exhaust cover
3
4. Install the crankcase onto the cylinder bolts before installation.
block, and then tighten the crankcase
bolts to the specified torques in two
stages and in the sequence shown.
Exhaust outer cover bolt:
8 N·m (0.8 kgf·m, 5.8 ft·lb)
4
5
6. Install a new cylinder head gasket, the
cylinder head, thermoswitch, a new cylin-
der head cover gasket, and cylinder head
cover, and then tighten the cylinder head
bolts to the specified torques in two
6
stages and in the sequence shown.
NOTE:
6F650650
6H950670
9
cover, and then tighten the bolts to the
specified torques in two stages and in the
sequence shown.
6H95G11 5-38
POWR Power unit
NOTE:
Apply LOCTITE 572 to the power unit mount-
10. Install the reed valve assembly and the
ing bolts before installation.
intake manifold assembly, and then tight-
en the intake manifold bolts 4 to the
specified torques in two stages. Power unit mounting bolt 4:
21 N·m (2.1 kgf·m, 15.5 ft·lb)
11. Connect the hoses 5.
4. Connect the fuel hose and pilot water
hose.
5
6F650680
5-39 6H95G11
Crankcase
7. Tighten the flywheel magnet nut to the 10. Install the manual starter and start-in-
specified torque. gear protection cable 6, and then adjust
it length. For adjustment procedures, see
1
Chapter 3.
2
cC 6H950710
NOTE:
Apply engine oil to the flywheel magnet nut
before installation.
4
Flywheel holder: 90890-06522 5
Flywheel magnet nut:
160 N·m (16.0 kgf·m, 115 ft·lb)
8
9
6H95G11 5-40
LOWR
Lower unit
6H95G11
Propeller shaft housing ............................................................................. 6-33
Removing the propeller shaft housing assembly .................................. 6-34
Disassembling the propeller shaft assembly ......................................... 6-34
Disassembling the propeller shaft housing ........................................... 6-34
Checking the propeller shaft housing .................................................... 6-35
Checking the propeller shaft .................................................................. 6-35
Assembling the propeller shaft assembly .............................................. 6-35
1
Assembling the propeller shaft housing ................................................ 6-36
6-1 6H95G11
Special service tools
1
Stopper guide stand
90890-06538
Driver rod LS
90890-06606 2
3
Driver rod SL
4
Needle bearing attachment
90890-06602 90890-06608, 90890-06613,
90890-06616, 90890-06653
5
Bearing depth plate Needle bearing attachment
90890-06603 90890-06614
6
Driver rod SS Bearing outer race attachment
7
90890-06604 90890-06622
8
Driver rod LL Ball bearing attachment
9
90890-06605 90890-06634, 90890-06637
6H95G11 6-2
LOWR Lower unit
6-3 6H95G11
Special service tools
1
Backlash indicator
90890-06706
2
3
4
5
6
7
8
9
6H95G11 6-4
LOWR Lower unit
6-5 6H95G11
Lower unit (EK40G)
1
21 N·m (2.1 kgf·m, 15.5 ft·lb) 2
3
4
5
No.
9 N·m (0.9 kgf·m, 6.6 ft·lb)
17
6F66060E
6-7 6H95G11
Lower unit (EK40G)
1
2
17
3
4
5
No. Part name Q’ty Remarks
6F66060E
6
18 Bolt 2 M8 × 45 mm
19
20
Screw
Gasket
1
1 Not reusable
7
8
9
6H95G11 6-8
LOWR Lower unit
Removing the lower unit 3. Loosen the locknut 1, and then remove
1. Drain the gear oil. the adjusting nut 2.
1
2
6F660010
6F660025
w 1
9 Do not hold the propeller with your
hands when loosening or tightening it. 2
9 Be sure to disconnect the battery leads
from the battery and the clip from the 2
engine stop lanyard switch.
9 Put a block of wood between the anti-
cavitation plate and propeller to keep the
propeller from turning.
1
6F660595
NOTE:
Before removing the shift rod assembly 1,
remove the screw 2.
6-9 6H95G11
Lower unit (EK40G)
1
mation. Replace if necessary.
5
6
7
8
9
6H95G11 6-10
LOWR Lower unit
6-11 6H95G11
Propeller shaft housing
1
2
3
4
4 N·m (0.4 kgf·m, 3.0 ft·lb)
5
8 N·m (0.8 kgf·m, 5.8 ft·lb)
5
6F660610
6
5
6 3
4
6F660080
6-13 6H95G11
Propeller shaft housing
Disassembling the forward gear 3. Check the dog clutch and shift plunger for
1. Remove the taper roller bearing and cracks or wear. Replace if necessary.
shim(s) from the forward gear.
1
Assembling the forward gear
1. Install the original shim(s) 1 and the
taper roller bearing 2 into the forward
gear 3.
6F660215
2
1
2
Checking the propeller shaft housing
1. Clean the propeller shaft housing using a
soft brush and cleaning solvent, and then
check it for cracks. Replace if necessary.
3
6F660785
3
cC
2. Check the teeth and dogs of the forward
gear and reverse gear for cracks or wear.
Replace the gear if necessary.
Add or remove the shim(s), if necessary, if
replacing the reverse gear, propeller shaft
housing, or lower case.
4
3. Check the bearings for pitting or rum-
bling. Replace if necessary.
6F660140
NOTE:
Install the dog clutch 1 with the “F” mark a
facing toward the shift plunger.
8
6F660130
Assembling the propeller shaft 3. Install the original shim(s) 5 onto pro-
housing peller shaft housing 6, then install the
reverse gear assembly into the propeller
1. Apply grease to new oil seals, and then shaft housing.
install them into the propeller shaft hous-
ing to the specified depth. 6
5
1
6F660660
2
6F660650 cC
NOTE: Add or remove the shim(s), if necessary, if
Install an oil seal halfway into the propeller replacing the reverse gear, propeller shaft
shaft housing, then the other oil seal. housing, or lower case.
6F660670
6-15 6H95G11
Drive shaft and lower case
1
2
3
4
5
No. Part name Q’ty Remarks
6F66080E
6
1 Drive shaft 1
2
3
4
5
Circlip
Pinion gear
Roller bearing assembly
Pinion gear shim —
1
1
1
7
6 Thrust bearing 1
7
8
9
Needle bearing
Sleeve
Needle bearing
1
1
1
8
10 Washer 1
9
11 Oil seal 2 Not reusable
12 Lower case 1
6H95G11 6-16
LOWR Lower unit
6F660690
8
cC 7
When removing the drive shaft assembly,
take care to falling the drive shaft assem- 6F660720
bly.
Needle bearing attachment 7 :
90890-06614
Disassembling the lower case Driver rod L3 8: 90890-06652
1. Remove the roller bearing assembly 1,
thrust bearing 2, drive shaft needle
Checking the pinion gear
bearing 3 and drive shaft sleeve.
1. Check the teeth of the pinion for cracks
1 or wear. Replace if necessary.
4
5
2 Checking the bearings
1. Check the bearings for pitting or rum-
3 bling. Replace if necessary.
6
Checking the drive shaft
1. Check the drive shaft for bends or wear.
6F660700
Replace if necessary.
4
5
6
6F660260
6-17 6H95G11
Drive shaft and lower case
1
damage. Replace the lower case and 3. Install the sleeve and needle bearing into
lower case cap if necessary. the lower case to the specified depth.
3
6
8
e
2
c
3
a d
2
7
1
6F660740
4
6F660750
NOTE:
NOTE: 9 Install the needle bearing with the manufac-
Be careful not to the let the stopper get out of ture identification mark c facing up.
position when using the driver rod SS. 9 Be careful not to the let the stopper e get
5
out of position when using the driver rod SL.
9 Apply gear oil to the inside and outside of
Ball bearing attachment 1: the sleeve before installation.
90890-06616
Driver rod SS 2: Driver rod SL 6 : 90890-06602
6
90890-06604 Needle bearing attachment 7:
Bearing depth plate 3: 90890-06613
90890-06603 Bearing depth plate 8:
90890-06603
Depth a:
24.7—25.3 mm (0.97—1.00 in)
4
8
b
6F660760
9
Ball bearing attachment 4:
90890-06637
Driver rod SS 5:
90890-06604
6H95G11 6-18
LOWR Lower unit
4. Install the thrust bearing and roller bear- Installing the propeller shaft housing
ing assembly. 1. Install the washer 1 and propeller shaft
assembly 2 into the propeller shaft
housing assembly 3.
6F660770
NOTE: 3
Apply gear oil to the inside and outside of the 1 6F660910
thrust washer and roller bearing outer race
before installation. 4. Fit the new seal into the lower case cap.
a
Ball bearing attachment 9:
90890-06631
Driver rod LS 0:
90890-06606
NOTE:
Cut the seal so that it projects out a about
0.8 mm (0.03 in) from the lower case cap.
cC
Do not pull the seal.
6F660790
NOTE:
Take care the rollers will not fall off.
6-19 6H95G11
Drive shaft and lower case
5. Apply sealant to the mating surface of the Installing the water pump and shift
lower case cap and propeller shaft cap. rod
1. Install the shift rod assembly 1.
1
6. Install the propeller shaft housing assem-
bly 4 on to the lower case.
4 1
2
NOTE:
a
6F660806 2
3
Insert the pins a in the slot or hole of the
lower case.
5
in the lower case. Then install the screw 2 as
shown.
m ,
c v
x z 2. Install the dowel 3, a new gasket 4, oil
n
.
b
6F660805
seal housing 5, dowels 6, a new gasket
7 and the outer plate cartridge 8.
6
Lower case cap bolt :
1st: 4 N·m (0.4 kgf·m, 3.0 ft·lb)
2nd: 8 N·m (0.8 kgf·m, 5.8 ft·lb)
3 8
7
6
7
6 5
4
8
6F660820
w
6F660380 1
NOTE: 4
Align the insert cartridge projection a with
the hole b in the pump housing.
2
6. Install the seal e, a new gasket r, and 2
pump housing assembly t into the lower
case, tighten the bolts y.
y y
3
6H960830
NOTE:
t Screw the adjusting nut 4 down until it light-
e ly seated, and then tighten the locknut.
r
Lower case mounting bolt 3:
21 N·m (2.1 kgf·m, 15.5 ft·lb)
6F660395
6-21 6H95G11
Drive shaft and lower case
1
anti-cavitation plate and propeller to keep
the propeller from turning, and then tight-
en the nut to the specified torque.
2
API: GL-4
6F660840
SAE: 90
Oil quantity:
315 cm3
(10.65 US oz, 11.11 Imp oz)
3
8. Install the check screw and quickly install
the drain screw.
4
6F660850 5
w
9 Do not hold the propeller with your
hands when loosening or tightening it.
9 Be sure to disconnect the battery leads
from the battery and the clip from the
6
engine stop lanyard switch.
9 Put a block of wood between the anti-
cavitation plate and propeller to keep the
propeller from turning.
7
NOTE:
If the hole in the propeller nut 5 do not align
with the cotter pin hole, tighten or loosen the
8
nut until they are aligned.
6H95G11 6-22
LOWR Lower unit
Shimming
6F660860
6-23 6H95G11
Shimming
Shimming
NOTE: 5
9 Shimming is not required when assembling
the original lower case and inner parts.
9 Shimming is required when assembling the
original inner parts and a new lower case.
9 Shimming is required when replacing the
M 1
inner part(s).
1 4
Digital caliper 5: 90890-06704
3
2 3 Calculation formula:
Pinion shim thickness (T) =
M - 24.50
Example:
4
6F660870 If “T” is 26.06 mm,
NOTE:
9 Remove the shim(s) 2 from pinion gear,
then measuring.
T =26.06 - 24.50
=1.56
8
If “T” is 1.65 mm, then the pinion shim is
1.60 mm.
2. Measure the distance (M) between the If “T” is 1.56 mm, then the pinion shim is
special service tool and the pinion as 1.55 mm.
shown.
Selecting the forward and reverse
gear shims
NOTE:
9
Select the forward and reverse gear shim
thickness by measuring the backlash.
6H95G11 6-24
LOWR Lower unit
6F660920
6F660890
5. Set the gear shift to the neutral position Available shim thicknesses:
at the lower unit. 0.70, 0.80, 0.90, 1.00, and
1.10, 1.20 mm
6. Install the dial gauge onto the lower unit
and set the dial gauge.
9. Hold the drive shaft and slowly turn the
reverse gear clockwise and counter-
1
clockwise, then measure the backlash
when the gear stops in each direction.
6F660900
NOTE:
Set the dial gauge plunger vertical position
from the center of gear teeth.
6-25 6H95G11
Backlash
1
6F660930
2
Available shim thicknesses:
1.80, 1.90, 2.00, 2.10, 2.20, 2.30,
2.40, and 2.50 mm
m ,
7
c v
x
n
.
z
b 8
6F660805
9 N·m (0.9 kgf·m, 6.6 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6H96010E
6-27 6H95G11
Lower unit (EK40J)
1
2
21 N·m (2.1 kgf·m, 15.5 ft·lb)
3
4
35 N·m (3.5 kgf·m, 25.3 ft·lb)
5
No.
9 N·m (0.9 kgf·m, 6.6 ft·lb)
Remarks
6H96010E
6
18 Bolt 6 M8 × 30 mm
19
20
21
Water inlet cover
Screw
Nut
2
1
1
7
8
9
6H95G11 6-28
LOWR Lower unit
6F66020E
6-29 6H95G11
Lower unit (EK40J)
1
2
3
4
5
No. Part name Q’ty Remarks
6F66020E
6
18 Dowel 2
19
20
21
Bolt
Screw
Gasket
2
1
1
M8 × 45 mm
Not reusable
7
8
9
6H95G11 6-30
LOWR Lower unit
Removing the lower unit 3. Mark the trim tab 1 at the area shown,
1. Drain the gear oil. and then remove it.
2
3
6F660010
6H960030
w
9 Do not hold the propeller with your
hands when loosening or tightening it.
9 Be sure to disconnect the battery leads
from the battery and the clip from the
engine stop lanyard switch.
9 Put a block of wood between the anti-
cavitation plate and propeller to keep the
propeller from turning.
6-31 6H95G11
Lower unit (EK40J)
Removing the water pump and shift 4. Check the shift rod for cracks or wear.
rod Replace if necessary.
1. Remove the water pump assembly and
1
shift rod assembly 1.
1
2
2
3
1
6F660350
4
5
NOTE:
Before removing the shift rod assembly 1,
remove the screw 2.
a
8
1
9
6F660050
6H95G11 6-32
LOWR Lower unit
6F66030E
6-33 6H95G11
Propeller shaft housing
1
shaft housing, use the special service 90890-06503
tools. Center bolt 6: 90890-06504
1
assembly
1. Remove the spring 1, then the cross pin
2, dog clutch 3, spring 4, slider 5, and
shift plunger 6.
2
2
6F600060
1
2
3
5
3
6
4
3
6F660080
4
Disassembling the propeller shaft
NOTE:
6F660070
9
90890-06501
Stopper guide stand 3:
90890-06538
4
Bearing puller assembly 4:
90890-06535
6B460580
6H95G11 6-34
LOWR Lower unit
2. Remove the ball bearing. 3. Check the bearings for pitting or rum-
bling. Replace if necessary.
cC
Do not reuse the bearing, always replace
it with a new one.
6F660130
a
1
6-35 6H95G11
Propeller shaft housing
Assembling the propeller shaft 3. Install the washer 6 and new ball bear-
housing ing 7 onto the reverse gear 8 using a
1. Install the needle bearing into the pro- press.
1
peller shaft housing to the specified
depth.
8 6
1
3
2
b a 9
7
6F660170
2
NOTE:
6F660150
4
5
6F660180
7
Needle bearing attachment 0:
90890-06608
8
6F660160
NOTE:
Install an oil seal halfway into the propeller
shaft housing, then the other oil seal.
9
Driver rod LS 4: 90890-06606
Ball bearing attachment 5:
90890-06637
6H95G11 6-36
LOWR Lower unit
6-37 6H95G11
Drive shaft and lower case
1
1 1
2
6F660190
6F660210
2
Drive shaft holder 3 1:
90890-06517
Pinion nut holder 2:
New: 90890-06715
cC
Do not reuse the bearing, always replace
it with a new one.
3
Current: 90890-06505
7
directly.
9 When removing the drive shaft bearing,
do not damage the drive shaft collar 4.
9 Do not reuse the bearing, always replace
it with a new one.
8
Bearing inner race attachment 3:
90890-06641
9
6H95G11 6-38
LOWR Lower unit
a
1 Needle bearing attachment 5 :
6F660230
90890-06614
NOTE: Driver rod L3 6: 90890-06652
Install the claws a as shown.
Checking the pinion and forward
gear
Bearing outer race puller 1. Check the teeth of the pinion, and the
assembly 1:90890-06523 teeth and dogs of the forward gear for
cracks or wear. Replace if necessary.
2. Remove the drive shaft bearing outer
race, shim(s), and drive shaft sleeve. Checking the bearings
1. Check the bearings for pitting or rum-
bling. Replace if necessary.
2
Checking the drive shaft
1. Check the drive shaft for bends or wear.
4
Replace if necessary.
6-39 6H95G11
Drive shaft and lower case
Assembling the oil seal housing 2. Install the sleeve, original shim(s), and
1. Apply grease to new oil seals, and then drive shaft bearing outer race.
install them into the oil seal housing.
2
1
5
4
5
1
6F660270
4 2
Ball bearing attachment 1:
90890-06653
Driver rod L3 2: 90890-06652 cC
d
6F660290
3
Add or remove shim(s), if necessary, if
4
replacing the pinion or lower case.
Assembling the lower case
1. Install the needle bearing into the lower
case to the specified depth. NOTE:
9 Apply gear oil to the inside and outside of
the sleeve before installation.
9 Install the sleeve with the projection d fac-
ing forward. 5
Bearing outer race attachment 4:
NOTE:
90890-06627
Driver rod LS 5: 90890-06606
3. Install the original shim(s) and taper roller
6
bearing outer race.
9 Install the needle bearing with the manufac-
ture identification mark a facing up.
9 Be careful not to let the stopper b get out
of position when using the driver rod SL.
7
7
8
Driver rod SL 1 : 90890-06602
G
Needle bearing attachment 2 :
90890-06614
Bearing depth plate 3 : 90890-06603 6
6B460350
cC
Depth c :
182.5 — 183.0 mm
(7.19 — 7.20 in)
Add or remove shim(s), if necessary, if
replacing the forward gear or lower case. 9
Bearing outer race attachment 6:
90890-06622
Driver rod LL 7: 90890-06605
6H95G11 6-40
LOWR Lower unit
1 Pinion nut:
74 N·m (7.4 kgf·m, 54.6 ft·lb)
6F660320
cC
Add or remove shim(s), if necessary, if
replacing the reverse gear, propeller shaft
2
6F60300 housing, or lower case.
6-41 6H95G11
Drive shaft and lower case
3. Install the propeller shaft housing assem- Installing the water pump and shift
bly 5 and lock washer 6 into the lower rod
case, and then tighten the ring nut 7 to 1. Install the shift rod assembly 1.
1
the specified torque.
6
7
1 2
3
6F660340
8 2
4
9
1
6F660350
NOTE:
5
6F660075 Align the slit on the shift cam 1 with the hole
in the lower case. Then install the screw 2 as
shown.
6
2. Install a new gasket 3, the outer plate
cartridge 4.
4
6
3
NOTE:
6F600065
9
6F660360
Ring nut :
90 N·m (9.0 kgf·m, 65 ft·lb)
6H95G11 6-42
LOWR Lower unit
3. Install the Woodruff key into the drive 6. Install the seal 9, a new gasket 0 and
shaft. pump housing assembly q into the lower
case, tighten the bolts w.
4. Align the groove in the impeller 5 with
the Woodruff key 6, and then install the
w w
impeller onto the drive shaft.
6 q
9
0
6F660375
7
a NOTE:
When installing the pump housing, apply
grease to the inside of the housing, and then
b turn the drive shaft clockwise while pushing
down the pump housing.
8
6F660385
NOTE:
Align the insert cartridge projection a with
the hole b in the pump housing.
6-43 6H95G11
Drive shaft and lower case
Installing the lower unit 7. Install the propeller and propeller nut,
1. Set the gear shift to the reverse position and then tighten the nut finger tight.
at the lower unit. Make sure that the shift Place a block of wood between the anti-
1
rod is in the reverse position. cavitation plate and propeller to keep the
propeller from turning, and then tighten
2. Screw in the locknut 1 completely. the nut to the specified torque.
2
unit.
7
4. Install the lower unit into the upper case,
and then tighten the lower case mounting
bolts 3 to the specified torque.
5. Connect the shift rod.
4
9 Do not hold the propeller with your
hands when loosening or tightening it.
9 Be sure to disconnect the battery leads
from the battery and the clip from the
6
3 engine stop lanyard switch.
NOTE:
6H960400
9 Put a block of wood between the anti-
cavitation plate and propeller to keep the
propeller from turning.
7
Screw the adjusting nut 6 down until it light-
ly seated, and then tighten the locknut.
Propeller nut 7:
35 N·m (3.5 kgf·m, 25.3 ft·lb)
9
6H95G11 6-44
LOWR Lower unit
6F630210
6-45 6H95G11
Drive shaft and lower case/Shimming
Shimming
®
ƒ
π
1
2
T3
3
M3
4
5
6
7
T1 T2
M1 M2
6F660440
8
9
6H95G11 6-46
LOWR Lower unit
a
F
R P+5
6F660480
NOTE:
NOTE:
9 Select the shim thickness (T3) by using the
“P” is the deviation of the lower case dimen-
specified measurement(s) and the calcula-
sion from standard. The “P” mark a is
tion formula.
stamped on the trim tab mounting surface of
9 Install the special service tool onto the drive
the lower case in 0.01 mm units. If the “P”
shaft so that the shaft is at the center of the
mark is unreadable, assume that “P” is zero
hole.
and check the backlash when the unit is
9 Tighten the wing nuts another 1/4 of a turn
assembled.
after they contact the plate 2.
6-47 6H95G11
Shimming
Example:
If “M3” is 26.05 mm and “P” is (+5), then
T3 = 26.05 – 25.5 – (+5)/100 mm
1
= 0.55 – 0.05 mm
= 0.60 mm
Example:
If “T3” is 0.43 mm, then the pinion shim is
0.45 mm.
9 Measure the bearing outer race at three
points to find the height average. 4
If “T3” is 0.38 mm, then the pinion shim is Shimming plate 2: 90890-06701
0.38 mm.
6
below.
then measure the bearing height (M1) as
shown.
a
F+5
7
R P
8
6F660500
T1
6F660490
NOTE:
“F” is the deviation of the lower case dimen-
sion from standard. The “F” mark a is
9
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the “F”
mark is unreadable, assume that “F” is zero
and check the backlash when the unit is
assembled.
6H95G11 6-48
LOWR Lower unit
Calculation formula:
Forward gear shim thickness (T1) =
25.70 + F/100 – M1
Example: 2
If “M1” is 25.30 mm and “F” is (+4), then 1
T1 = 25.70 + (+4)/100 – 25.30 mm
= 25.70 + 0.04 – 25.30 mm
= 0.44 mm M2
6F660530
NOTE:
“R” is the deviation of the lower case dimen-
sion from standard. The “R” mark a is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the “R”
mark is unreadable, assume that “R” is zero
T2 6F660510 and check the backlash when the unit is
assembled.
6-49 6H95G11
Shimming
Calculation formula:
Reverse gear shim thickness (T2) =
M2 – 26.90 – R/100
Example:
If “M2” is 27.32 mm and “R” is (+5), then
T2 = 27.32 mm – 26.90 mm – (+5)/100
1
= 27.32 – 26.90 + 0.05
= 0.47 mm
5
4. Install the backlash indicator onto the
drive shaft (16.0 mm [0.63 in] in diame-
Example:
ter), then the dial gauge onto the lower
If “T2” is 0.47 mm, then the reverse gear
unit.
shim is 0.48 mm.
If “T2” is 0.41 mm, then the reverse gear
shim is 0.42 mm.
Backlash
6
Measuring the forward and reverse
gear backlash
1. Remove the water pump assembly.
6H95G11 6-50
LOWR Lower unit
5. Slowly turn the drive shaft clockwise and 9. Slowly turn the drive shaft clockwise and
counterclockwise and measure the back- counterclockwise and measure the back-
lash when the drive shaft stops in each lash when the drive shaft stops in each
direction. direction.
Forward gear backlash:
0.19– 0.47 mm (0.0075– 0.0185 in)
M: Measurement
Reverse gear backlash:
Available shim thicknesses: 0.76– 1.04 mm
0.05, 0.08, 0.12, 0.30, and (0.0299– 0.0409 in)
0.50 mm
10. Add or remove the shim(s) if out of spec-
7. Remove the special service tools from ification.
the propeller shaft. Reverse gear
Shim thickness
backlash
8. Apply a load to the reverse gear by Less than To be increased by
installing the propeller 8 (without the 0.76 mm (0.0299 in) (0.9 - M) × 0.53
washer 9), then the spacer 0 as shown. More than To be decreased by
9 1.04 mm (0.0409 in) (M - 0.9) × 0.53
q
M: Measurement
0
Available shim thicknesses:
0.05, 0.08, 0.12, 0.30, and
0.50 mm
8
6F660560
11. Remove the special service tools, and
then install the water pump assembly.
NOTE:
Tighten the propeller nut q while turning the
drive shaft until the drive shaft can no longer
be turned.
6-51 6H95G11
BRKT
Bracket unit
4
Removing the clamp brackets ............................................................... 7-18
Disassembling the swivel bracket ......................................................... 7-18
Assembling the swivel bracket .............................................................. 7-18
Installing the clamp brackets ................................................................. 7-18
Installing the pivot shaft ......................................................................... 7-19
5
6
7
8
9
6H95G11
BRKT Bracket unit
Driver rod L3
90890-06652
7-1 6H95G11
Tiller handle (MH)
1
2
3
4
5
No.
3 N·m (0.3 kgf·m, 2.2 ft·lb)
6
1 Throttle cable 2
7
2 Self locking nut 1
3 Bolt 1 M12 × 68 mm
4 Washer 1
5 Collar 1
6 Plastic washer 2
7
8
9
10
Metal washer
Wave washer
Tiller handle bracket
Throttle friction adjuster
2
1
1
1
8
11 Throttle grip 1
12
13
14
15
Screw
Washer
Spring
Bushing
1
2
1
1
9
16 Throttle shaft 1
17 Friction piece 1
6H95G11 7-2
BRKT Bracket unit
7-3 6H95G11
Tiller handle (MH)
2 3
1
1
2
NOTE:
4
6F670010
3
Route the throttle cable as shown and clamp
the cable protector 4.
4
2. Install the throttle shaft 5 to the tiller
handle bracket.
5 d
5
c
a
b 6
6F670020
7
NOTE:
When install the throttle shaft, align the marks
on the pinion a with tiller handle bracket b
and throttle shaft c with stay d.
8
9
6H95G11 7-4
BRKT Bracket unit
Bottom cowling
7-5 6H95G11
Bottom cowling
1
2
W
3
4
5
5 N·m (0.5 kgf·m, 3.6 ft·lb)
6
18 Rubber seal 1
7
19 Collar 4
20 Choke knob 1
21 Grommet 1
22 Retaining plate 1
23 Bolt 2 M6 × 20 mm
24
25
26
27
Engine stop lanyard switch
Grommet
Bolt
Locknut
1
4
4
1
MH model
M6 × 30 mm 8
28 Adjusting nut 1
29
30
31
32
Pin
Shaft
Boot
Nut
1
1
1
4
9
33 Hose 1
6H95G11 7-6
BRKT Bracket unit
6F67040E
7-7 6H95G11
Upper case, pivot shaft
6
1 Cover 2
7
2 Lower mount 2
3 Bolt 2 M12 × 130 mm
4 Washer 4
5 Bolt 4 M6 × 25 mm
6 Cover 1
8
7 Nut 2
8 Nut 2
9 Washer 4
10 Bracket 2
11 Upper mount 2
12
13
14
15
Bolt
Bolt
Bracket
Damper
4
2
1
1
M8 × 50 mm
M6 × 25 mm
9
16 Nut 2
17 Bolt 4 M6 × 25 mm
6H95G11 7-8
BRKT Bracket unit
7-9 6H95G11
Upper case, pivot shaft
1
2
3
4
5
14 N·m (1.4 kgf·m, 10 ft·lb)
24 N·m (2.4 kgf·m, 17.7 ft·lb)
6
1 Bolt 2 M8 × 30 mm
M8 × 35 mm
7
2 Bolt 2
3 Steering bracket 1
4 Dowel 2
5 Pivot shaft 1
6 Washer 1
8
7 Bushing 1
8 Straight key 1
9 Spring 1
10 Rubber seal 1
11 Bolt 1 M8 × 25 mm
12
13
14
15
Bushing
Oil seal
Washer
Mount housing
1
1
1
1
Not reusable
9
16 Clamp 1
17 Bolt 4 M8 × 45 mm
6H95G11 7-10
BRKT Bracket unit
Disassembling the upper case 4. Remove the circlip 7 and the drive shaft
1. Remove the muffler assembly 1 and bushing 8 from the upper case. (EK40J:
gasket 2 from the upper case 3. L transom model)
1
2
3
8
7
6F670050
2. Remove the exhaust manifold 4 and 2. Check the cooling water pipe for defor-
cooling water pipe 5. mation or corrosion. Replace if neces-
sary.
6F670040
6F670060
7-11 6H95G11
Upper case, pivot shaft
Assembling the upper case 3. Install the protector, and then install the
1. Install the drive shaft bushing and the cir- muffler assembly into the uppercase.
clip to the upper case. (EK40J: L transom
1
model)
A
2
6F670070
6F670080
Upper mount nuts 6:
28 N·m (2.8 kgf·m, 20 ft·lb)
7
8
9
6H95G11 7-12
BRKT Bracket unit
6F670035
6F670130
6F670135
7-13 6H95G11
Upper case, pivot shaft/Clamp brackets, swivel bracket
7
2 Nut 2
3 Washer 2
4 Bolt 1 M8 × 230 mm
5 Tube 1
6 Washer 1
7
8
9
10
Clamp handle
Pin
Clamp screw
Bolt
2
2
2
2 M6 × 12 mm
8
11 Clamp pad 2
12
13
14
15
Clamp bracket
Clamp bracket
Washer
Nut
1
1
2
2
9
16 Through tube 1
17 Cap 2
6H95G11 7-14
BRKT Bracket unit
7-15 6H95G11
Clamp brackets, swivel bracket
1
4 N·m (0.4 kgf·m, 3.0 ft·lb) 2
3
4
5
No. Part name Q’ty Remarks
6F67060E
6
1 Tilt lock lever 1
7
2 Stopper plate (starboard side) 1
3 Spring 1
4 Bolt 1 M5 × 10 mm
5 Circlip 3
6 Tilt lever 1
7
8
9
10
Tilt lock rod
Tilt lock plate
Spring
Cotter pin
1
1
2
3
8
11 Pin 1
12
13
14
15
Pin
Tilt lock arm
Tilt lock plate
Collar
1
1
1
1
9
16 Spring 1
17 Stopper shaft 1
6H95G11 7-16
BRKT Bracket unit
6F67060E
7-17 6H95G11
Clamp brackets, swivel bracket
Removing the clamp brackets 3. Install the circlip q, spring w and collar
1. Remove the tilt pin, and then remove the e, then install the circlip r.
clamp bracket bolt, clamp bracket nut
0
1
and collar.
9
8
2. Remove the cap nuts, then the self-lock-
ing nuts and plate.
2
3. Remove the tilt both stopper plate, cir-
clips and tilt stopper plate shafts. q
w
4. Remove the clamp bracket bolt, then dis- e
assemble the clamp brackets.
r
5. Remove the pins and tilt stopper plates.
u
y
6F670140
7
7 NOTE:
6
2 After installation, check the tilt lock lever for
proper operation.
9
4
2
1 3 Installing the clamp brackets
6F670110
1. Install the bushings, tilt stopper plates,
2. Install the plastic washer 8, tilt stopper and pins to the swivel bracket assembly.
plate 9 and then install the tilt lock lever
0 partially into the swivel bracket.
6H95G11 7-18
BRKT Bracket unit
2. Assemble the clamp brackets, washers, 3. Install the bushing 6, a new oil seal 7,
and swivel bracket, and then install the and the washer 8 onto the swivel brack-
clamp bracket bolt. et.
3. Install the plate, tighten the self-locking 4. Install the dowels 9, steering bracket 0,
nuts 1 to the specified torque, and then lower mount clamp q and lower mount
tighten the cap nuts. case w onto the swivel bracket. Then
tighten the bolt e to specified torque.
4. Install the tilt stopper plate bolts and cir-
9
clips.
q
2 3 4 e w 6F670170
6F670150
Self-locking nut 1 :
45 N·m (4.5 kgf·m, 33 ft·lb)
Clamp bracket nut 4:
24 N·m (2.4 kgf·m, 17.7 ft·lb)
3
NOTE:
2 Apply the grease until it comes out of the
bushings.
1
4
6F670160
7-19 6H95G11
ELEC
Electrical systems
5
Checking the charge coil ......................................................................... 8-9
Checking the thermoswitch ................................................................... 8-10
Checking the engine stop lanyard switch (MH) ..................................... 8-10
Ignition tester
90890-06754
8-1 6H95G11
Special service tools/Checking the electrical components
1
surement cannot be obtained because of the
internal resistance of the tester. To obtain the
NOTE: correct value, subtract the internal resistance
Before troubleshooting the peak voltage, from the displayed measurement.
check that all electrical connections are tight
and free from corrosion.
2
Correct value =
displayed measurement
The condition of the ignition system can be - internal resistance
determined by measuring the peak voltage.
Cranking speed is affected by many factors,
NOTE:
3
such as fouled or weak spark plug. If one of
Obtain the internal resistance of the digital
these factors is present, the peak voltage will
circuit tester by connecting both of its probes
be lower than specification. In addition, if the
and checking the display.
peak voltage is lower than specification the
engine will not operate properly.
4
5
6B480010
w
When checking the peak voltage, do not
6
touch any of the connections of the digital
circuit tester leads.
NOTE:
9 Use the peak voltage adaptor with the digi-
7
tal circuit tester.
9 When measuring the peak voltage, set the
selector on the digital circuit tester to the
DC voltage mode.
8
9 Connect the positive pin on the peak volt-
age adaptor to the positive terminal of the
digital circuit tester.
9
6H95G11 8-2
ELEC Electrical systems
Electrical components
Top view
MH
7
3
2 1
6H980010
1 CDI unit
2 Starter motor (W)
3 Starter relay (W)
4 Spark plug
5 Thermoswitch
6 Engine stop lanyard switch (WH)
7 Engine stop button (MH: if equipped)
8-3 6H95G11
Electrical components
1
2
3
2
4
1
5
3
6
7
6F680030
8
1 Spark plug
2 Ignition coil
3 CDI unit
9
6H95G11 8-4
ELEC Electrical systems
4
3
7 6
6F680040
1 Spark plug
2 Ignition coil
3 Starter relay
4 Starter motor
5 CDI unit
6 Rectifier
7 Fuse
8-5 6H95G11
Electrical components/Wring diagram
B/W
Br
L
W
B
A B 2
W/B
W/R
B
P
3
3
W/B
5
W/R
4
4
Br
L
G
B
G
B
6
L Br W/B
B
W/R
W
2
5
A
P W
W
B
O B
6
G G
B
B O
B O
7
7
B
8
8
B
1
B
B
8
B
B
P
6F68010M
6H95G11 8-6
ELEC Electrical systems
7
―
+
B
B/W
W/R
Br
B
B
B
B
R
8
B/O
W
W/B
L
Br
P
B
Br
Br
Br
9
M
B
4
Br
W/B
6
G
W/R
5
R
Br
L
G
G
B
L Br W/B
Br
B
G
B
R
W/R
3
A
P W
B
O B
0
G
R
B
G
G
G
R R G G
G
2
R
B
B
B O
B O
B B B
q
w
w
B
1
B
B
B
B
P
6H98030M
Ignition and ignition control sys- 3. Measure the ignition coil resistance.
tem Replace if out of specification.
Checking the ignition spark gap
1. Disconnect the spark plug caps from the
spark plugs.
2. Connect a spark plug cap to the special
service tool. ∫
1
2
å
3
B
O 6F680240
6F680050
Ignition coil resistance:
å Primary coil:
Ignition tester: 90890-06754 Orange (O) — Black (B)
0.26 — 0.35Ω at 20°C (68°F)
∫ Secondary coil:
Spark plug wire —
4
3. Crank the engine and observe the spark
through the discharge window of the Spark plug wire
spark gap tester. Check the ignition sys-
tem if the spark is weak.
6.8 — 10.2 kΩ at 20°C (68°F)
9
since this test can produce sparks.
6B480070
Checking the ignition coil
1. Remove the spark plug cap from the
spark plug.
6H95G11 8-8
ELEC Electrical systems
Unloaded Loaded
6F680090 r/min
Cranking 1,500 3,500
DC V 150 140 190 180
Digital circuit tester: 90890-3174
Peak voltage adaptor B: Charge coil resistance
90890-03172 (reference data):
Test harness (4-pins): Brown (Br) — Blue (L)
New: 90890-06871 243 — 297 Ω at 20°C (68°F)
Current: 90890-06771
8-9 6H95G11
Ignition and ignition control system
1
continuity. Replace if there is no continu-
ity.
2
2. Check the switch for continuity at the
specified temperatures. Replace if out of
specification. 3
4
6B480160
a Temperature
Switch position
Clip removed a
Lead color
White (W) Black (B) 5
b Time
Clip installed b
c
d
No continuity
Continuity
Thermoswitch continuity
Engine shut-off
button pushed c 6
temperature:
7
Pink (P) — Black (B)
e: 84 — 90 °C (183 — 194°F)
f: 60 — 74 °C (140 — 165°F)
8
9
6H95G11 8-10
ELEC Electrical systems
Starting system
Checking the fuse (W)
1. Check the fuse for continuity. Replace if
there is no continuity.
8-11 6H95G11
Starting system/Starter motor
1
2
1.0mm
0.15mm
2.0mm
3
4
0.25mm 5
0.25mm
6
1 Clip 1
7
2 Pinion stopper 1
3 Spring 1
4 Pinion assembly 1
5 Bolt 2
6 Housing 1
7
8
9
10
Washer set
O-ring
Armature assembly
Bracket
1
1
1
1
Not reusable
8
11 Brush holder 1
12
13
Brush
Yoke assembly
2
1
9
6H95G11 8-12
ELEC Electrical systems
1 6F680160
NOTE:
Remove the clip with a thin screwdriver.
a
Checking the starter motor pinion
1. Check the teeth of the pinion for cracks
or wear. Replace if necessary. Commutator diameter limit a:
29.0 mm (1.14 in)
2. Check for smooth operation. Replace if
necessary.
3. Measure the commutator undercut b.
Replace the armature if below specifica-
tion.
NOTE:
Turn the pinion counterclockwise to check
6F680180
that it operates smoothly and turn it clockwise
to check that it locks in place.
Commutator undercut limit b:
0.2 mm (0.01 in)
8-13 6H95G11
Starter motor/Charging system
4. Check the armature for continuity. 2. Check the brush holder assembly for
Replace if out of specifications. continuity. Replace if out of specifica-
tions.
1
1
c d e
6F680190
2
6F680210
2
Armature continuity
Brush holder 1 —
No continuity
3
Segment – Armature shaft e No continuity Brush base 2
a
Charging system
Checking the rectifier (W)
1. Measure the rectifier output peak volt-
5
age. If below specification, measure the
lighting coil output peak voltage. Replace
the rectifier if the output peak voltage of
the lighting coil is above specification. 6
6F680200
6F680220 8
NOTE:
9
After starting the engine, disconnect the out-
put lead (red lead) 1 of the rectifier when
measuring the output peak voltage.
6H95G11 8-14
ELEC Electrical systems
G G
G G
6F680245
8-15 6H95G11
TRBL
SHTG
Troubleshooting
3
4
5
6
7
8
9
6H95G11
TRBL
SHTG Troubleshooting
NOTE:
9 To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble
located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters
4–8 for safe maintenance procedures.
9 Check that all electrical connections are tight and free from corrosion.
Power unit
Symptom: Manual starter turns and or starter motor operate but engine will not
start.
9 Check the ignition system, fuel system, and the compression pressure as listed below.
9 Be sure the air vent screw on the fuel tank is open.
Ignition system
Check the engine stop lanyard
switch and or engine stop button
for continuity (with clip installed).
Yes
Is there any
Yes Replace the ignition coil or caps
deterioration or
as necessary.
damage?
No
Measure the ignition coil
resistance.
Is resistance
No
within Replace the ignition coil.
specification?
Yes
(continued on following page)
9-1 6H95G11
Power unit
Yes
Check the CDI unit output
peak voltage. 1
Does the out-
put peak voltage
exceed specifi-
cation values?
No
Yes Check the connection
of the leads from CDI unit.
2
Check the charge coil output
peak voltage.
3
Does the out-
4
put peak voltage No
Replace the charge coil.
exceed specifi-
cation values?
Yes
Check the pulser coil output
peak voltage.
6
Replace the pulser coil.
exceed specifi-
cation values?
Yes
7
Replace the CDI unit.
No Does the
engine start?
Fuel system
9 Consult this chart after the ignition system has been checked.
Is there any
Yes
leakage or inter- Replace the fuel pump.
nal damage?
No
Check the operation of the
carburetor.
Does the
carburetor set- Disassemble the carburetor and
No
ting and throttle clean the internal parts. Adjust or
link operating replace as necessary.
correctly?
Yes
9-3 6H95G11
Power unit
Compression pressure
9 Consult this chart after the ignition and fuel systems have been checked.
Is the
Yes
carburetor operat- Check the ignition system chart.
ing correctly?
No
9-5 6H95G11
Power unit/Lower unit
Lower unit
Symptom: The forward and reverse gear shift mechanism does not operate
properly.
Is it connected
3
No Connect correctly or replace the
properly and in
4
shift rod as necessary.
good condition?
Yes
Disassemble the lower case and
check the dog clutch operation.
Is it in good
operating
No Replace the spring and shift
plunger as necessary.
5
condition?
Yes
Check the dog clutch and
forward and reverse gears and
6
replace if necessary.
7
8
9
6H95G11 9-6
TRBL
SHTG Troubleshooting
Electrical system
Symptom: The starter motor does not operate. (W)
9 Engine stop lanyard switch is operating normally.
Starting system
Yes
Is there blown? Replace the fuse.
No
Check the battery for fully
charged.
No
Is there continuity? Replace the engine start switch.
Yes
Check the wireharness for
connecting condition and battery
positive lead, terminal, ground
lead bolt for damage and loosen.
Is there
continuity or No Adjust position or replace the
correctly neutral switch.
position?
9-7 6H95G11
Electrical
1
Check the starter relay for
continuity.
No
2
Is there continuity? Replace the starter relay.
Yes
Disassemble and check the
starter motor.
3
Symptom: The battery loses power quickly. (W)
4
9 Be sure the electrolyte level and gravity are specific condition.
9 Be sure the wireharness, couplers and connectores are good connection.
Charging system 5
Check the rectifier output peak
voltage.
Yes
equipment on the boat.
7
Check the lighting coil output
8
peak voltage.
9
exceed specifi-
cation values?
Yes
6H95G11 9-8
Index
3
Cylinder head .......................................... 5-22 Installing the drive shaft ................. 6-19, 6-41
Installing the lower unit ........................... 6-21
Installing the lower unit ........................... 6-44
D. Installing the oil seal housing .................. 6-41
Dimensions ............................................... 2-7
Installing the pivot shaft .......................... 7-19
Disassembling the base assembly ......... 5-18
4
Installing the power unit .......................... 5-39
Disassembling the carburetor ................... 4-9
Installing the propeller shaft
Disassembling the crankshaft ................. 5-30
housing .........................................6-19, 6-41
Disassembling the drive shaft ................. 6-38
Installing the water pump and
Disassembling the forward gear .... 6-14, 6-38
shift rod ........................................ 6-20, 6-42
Disassembling the fuel pump .................. 4-15
Disassembling the lower case ....... 6-17, 6-39
Disassembling the manual starter .......... 5-13
Disassembling the
oil seal housing ............................ 5-28, 6-38
L.
Lower unit (EK40G) .................................. 6-5
Lower unit (EK40J) ................................. 6-27
5
Disassembling the piston ........................ 5-28 Lower unit ................................... 2-5, 3-8, 9-6
6
Disassembling the propeller shaft Lubricating the outboard motor ............... 3-10
assembly ...................................... 6-13, 6-34
Disassembling the propeller shaft M.
housing ........................................ 6-13, 6-34 Maintenance interval chart ........................ 3-2
Disassembling the swivel bracket ........... 7-18 Maintenance specification ......................... 2-3
Disassembling the upper case ................ 7-11
7
Manual format ........................................... 1-1
Disassembly and assembly ...................... 1-4 Measuring low resistance ......................... 8-2
Drive shaft and lower case ............ 6-16, 6-37 Measuring the forward and
reverse gear backlash ................. 6-25, 6-50
E. Measuring the peak voltage ...................... 8-2
8
Electrical ................................................... 2-5 Measuring the starter rope ...................... 5-13
Electrical components ............................... 8-3
Electrical system ....................................... 9-7 P.
Parts, lubricants, and sealants .................. 1-3
F. Power unit ........................... 2-3, 3-3, 5-4, 9-1
9
Fire prevention .......................................... 1-3 Predelivery checks .................................... 1-6
Fuel line .................................................... 4-3 Propeller selection .................................... 1-5
Fuel pump ............................................... 4-10 Propeller shaft housing .................. 6-11, 6-33
Fuel system ....................................... 3-3, 9-3 Propeller size ............................................ 1-5
G. R.
General ..................................................... 3-9 Reed valves ............................................ 5-19
General specification ................................ 2-1 Removing the clamp brackets ................ 7-18
6H95G11 i-2
Index
S.
Safety while working ................................. 1-3
Selecting the forward and
reverse gear shims ................................6-24
Selecting the forward gear shims ........... 6-48
Selecting the pinion shims ............. 6-24, 6-47
Selecting the reverse gear shims ........... 6-49
Selection ................................................... 1-6
Self-protection ........................................... 1-3
Serial number ............................................ 1-5
Shimming .................... 6-23, 6-24, 6-46, 6-47
Special service tools
............................. 3-1, 4-1, 5-1, 6-1, 7-1, 8-1
Specified torques ...................................... 2-9
Starboard view (MH) ................................. 8-4
Starboard view (W) ................................... 8-5
Starter motor (W) .................................... 8-12
Starting system ................................ 8-11, 9-7
Symbols .................................................... 1-2
T.
Test run ..................................................... 1-9
Tightening torques .................................... 2-9
Tiller handle (MH) ..................................... 7-2
Top cowling ............................................... 3-3
Top view .................................................... 8-3
i-3 6H95G11
YAMAHA MOTOR CO., LTD.
Printed in Japan
Aug. 2004 – 0.3 × 1 !
(E) Printed on recycled paper