Yahi Ei Outboards CV55E SERVICE MANUAL yCVSSE SERVICE MANUAL ©1989 Yamaha Motor Corporation, U.S.A. 1st Edition, April 1989 Alll rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means including photocopying and recording without the written permission of the copyright holder. ‘Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature. Printed in U.S.A. PIN LIT-18616-00-43NOTICE This manual has been prepared by the Yamahe Motor Company primarily for use by Yamaha deal- ers ard 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 under- standing of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because the Yamaha Motor Company Ltd has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorised Yamaha dealers are notified periodically of modifi- cations and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.~ INDEX GENERAL INFORMATION ae INFO SPECIFICATION GENERAL SERVICE FUEL SYSTEM POWER UNIT LOWER UNIT 8 8 S| i [SO g val | Zen 2 [ail 28s0| 79 BRACKET UNIT 3 4 ELECTRICAL SYSTEM m 7 mn oO TROUBLE-SHOOTING a4 TD] ni arCHAPTER 1 GENERAL INFORMATION HOW TO USE THIS MANUAL ....... 000.00. ese cee MANUAL FORMAT THE ILLUSTRATIONS, : oc REFERENCES «222.2... cee ceee ee eee ee WARNINGS, CAUTIONS AND NOTES SYMBOLS IDENTIFICATION ‘SERIAL NUMBER ENGINE SERIAL NUMBER... STARTING SERIAL NUMBERS. SAFETY WHILE WORKING : ecnne FIRE PREVENTION 02.00.20 000ec0ceeev seen VENTILATION SELF-PROTECTION OILS, GREASES AND SEALING FLUIDS ........ GOOD WORKING PRACTICES. ..... DISASSEMBLY AND ASSEMBLY ‘SPECIAL TOOLS : ‘SPECIAL TOOLS FOR TUNE-UP SPECIAL TOOLS FOR ENGINE SERVICE SPECIAL TOOLS FOR LOWER UNIT SERVICE SEALING AGENTS AND LUBRICANTS . CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS MAINTENANCE SPECIFICATIONS ..... ENGINE .... ei ELECTRICAL DIMENSION ........ TIGHTENING TORQUE 4 att 4 14 ott 12 13 13 13 13 14 14 weet old 14 14 14 AS AS AS 16 16 24 23 23 26 27 210CHAPTER 3 GENERAL SERVICE PREDELIVERY SERVICE... 22.02. ot CONTENTS ........... ELECTRIC WIRING ...... FUEL LINE.. GEAR OIL LEVEL ceeeeee OPERATION OF CONTROLS AND MOVING PARTS 34 FUEL LEAKAGE a8) WATER LEAKAGE 235 EXHAUST LEAKAGE coos cee BS ENGINE AND LOWER UNIT NOISE - 35 IDLE-SPEED IGNITION TIMING MOTOR EXTERIOR : INSTRUCTING THE NEW OWNER - PERIODIC SERVICE ........ : Bor ococomoss 36 MAINTENANCE SCHEDULE... 36 ANODE BATTERY ... 37 CARBURETOR 238 CARBURETOR LINK ADJUSTMENT ....... ee: CHOKE SOLENOID . 38 CYLINDER HEAD BOLTS, ENGINE MOUNTING BOLTS, AND FLYWHEEL NUT FUEL FILTER....... FUEL TANK AND FUEL LINE . GEAR OIL. IDLE-SPEED . IGNITION TIMING ADJUSTMENT. PROPELLER. . SPARK PLUG. .CHAPTER 4 FUEL SYSTEM FUEL SYSTEM. 0.2.00. cc ecco cccveee ee eee ee eeeeeeereee wd CLEANING AND INSPECTION ce wo 2 INSTALLATION .... . cd CARBURETOR... 45 REMOVAL AND DISASSEMBLY cece AB INSPECTION 47 ASSEMBLY = : a 48 INSTALLATION S 5e6000 49 CHAPTER 5 POWER UNIT EXPLODED DIAGRAM ........ ee eee 51 PREPARATION FOR OVERHAUL ... Sapopne 52 REMOVAL .........--0020055 ce BR DISASSEMBLY .......... or 55 INSPECTION ........ CYLINDER HEAD . CYLINDER BLOCK PISTON .. PISTON RING .. PISTON PIN AND SMALL END BEARING é GRANKSHAFT : cece ee 2510 REED VALVE ree ee 510 THERMOSTAT ao coos Bat CRANKSHAFT MAIN BEARING ....- : oo ASSEMBLY AND ADJUSTMENT en 512 CRANKSHAFT MAIN BEARING ...... 2 SZ PISTON 512 SMALL END BEARINGS AND PISTON ASSEMBLY 512 CONNECTING ROD BIG END BEARING ASSEMBLY ............543 OIL SEAL HOUSING ‘i Apeep 514 CRANK CYLINDER ASSEMBLY 518CYLINDER HEAD AND EXHAUST COVER we coves 516 DRAINLESS HOSE . 516 INTAKE MANIFOLD ....... S17 FUEL SYSTEM AND ELECTRICAL SYSTEM SAT INSTALLATION =e le CHAPTER 6 LOWER UNIT EXPLODED DIAGRAM : ce eee teense eens BA PREPARATION FOR REMOVAL Fr AsSer noes 62) DISASSEMBLY INSPECTION ...... GEAR CASE... BEARING HOUSING CLAW.WASHER, RING-NUT WATER PUMP HOUSING IMPELLER ........ cee ceveeees OILSEAL HOUSING (Water pump housing 2) ..... cece BT GEARS .... - 67 BEARINGS ........ 67 CLUTCH DOG AND COMPONENTS « er DRIVE AND PROPELLER SHAFTS 68 DRIVE SHAFT SLEEVE. 68 PROPELLERITRIM TABJANODE .........-- 0+ coe BB. ASSEMBLY AND ADJUSTMENT covet eceee eee -69 SHIM SELECTION ..... 000. 0000000eereeeeee eee . - 69 ASSEMBLY ... 613 BACKLASH ... 615 WATER PUMP INSTALLATION = 647 LOWER UNIT LEAKAGE CHECK 617 INSTALLATION Bopeopoeeee core ceenee Cle.EXPLODED DIAGRAM BRACKET... . UPPER CASING REMOVAL INSPECTION ..... MOUNTING-BOLT RUBBER MOUNTS COLLAR CHAPTER 7 BRACKET UNIT : 7A 72 73 73 ASSEMBLY ...... 74 INSTALLATION. . 278 CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS . et COMPONENTS at WIRING DIAGRAM fee on 82 REMOTE CONTROL BOX. : ce 83 REMOVAL 84 MAGNETO BASE 84 CLEANING, INSPECTION AND REPAIR 86 SPARK-PLUG 86 PULSER COILS 2222.22 86 CHARGE COIL........... Fee BB LIGHTING COIL 86 IGNITION COIL... : 87 REPLACEMENT OF SPARK-PLUG CAP .... : a7 CDI UNIT -88 CHOKE SOLENOID - 89STARTER RELAY ooo goo oueecouceeguneccanscon --89 RECTIFIER . vee cece BO FUSE ve wee 810 THERMO-SWITCH ceceee cece BAO WIRING HARNESS ... cece BA TERMINAL ASSEMBLY ... . ve 8A BALE ant INSTALLATION peep eeeo ae : ant FLYWHEEL MAGNETO....... . ant STARTER MOTOR cee . 12 REMOVAL . cece eee BAZ DISASSEMBLY be ceteceeeee eens BAZ INSPECTION . cecce cece BAB ASSEMBLY ... coe - BAS INSTALLATION 816 CHAPTER 9 TROUBLE-SHOOTING TROUBLESHOOTING DIAGRAM ........ cece HOW TO TROUBLE-SHOOT......... beens a ENGINE WILL NOT START +92 ROUGH IDLING —— 98 ENGINE STALLS . ceeeeees =. 90) ENGINE WILL NOT STOP ce 10 GEAR SHIFT IS IMPOSSIBLE OR HARD co StINFO CHAPTER 1 GENERAL INFORMATION HOW TO USE THIS MANUAL . MANUAL FORMAT THE ILLUSTRATIONS . REFERENCES WARNINGS, CAUTIONS AND NOTES SYMBOLS IDENTIFICATION SERIAL NUMBER ENGINE SERIAL NUMBER STARTING SERIAL NUMBERS SAFETY WHILE WORKING FIRE PREVENTION VENTILATION ‘SELF-PROTECTION OILS, GREASES AND SEALING FLUIDS GOOD WORKING PRACTICES DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS SPECIAL TOOLS FOR TUNE-UP . SPECIAL TOOLS FOR ENGINE SERVICE SPECIAL TOOLS FOR LOWER UNIT SERVICE ... SEALING AGENTS AND LUBRICANTS dt wt dt 4 1 12 13 13 13 13 14 14 14 14 14, 14 14 15 5 tS 16 16GEN INFO HOW TO USE THIS MANUAL 7 HOW TO USE THIS MANUAL MANUAL FORMAT This manual provides the mechanic with descriptions of the operations of disassembly, repair, assembly, adjustment and inspection, each of which is presented in a sequential, step-by-step procedure. To assist you to find your way about this manual, the Section Title and Major Heading is given at the head of every page. ‘An Index to contents is provided on the first page of each Section, THE ILLUSTRATIONS ‘Some illustrations in this manual may differ from the model you have. This is because a proce- dure described may relate to several models, though only one may be illustrated. (The name of model described will be mentioned in the description) To help you identify components and understand the correct procedures of disassembly and as- sembly, exploded diagrams are provided. Steps in the procedures are numbered thus: 1), 2), 3) Parts shown in the illustrations are identified thus: (1), 2), @). REFERENCES These have been kept to a minimum; however, when you are referred to another section of the ‘manual, you are told the page number to go to. WARNINGS, CAUTIONS AND NOTES Attention is drawn to the various Warnings, Cautions and Notes which distinguish important in- formation in this manual in the following ways. AX The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING: CAUTION: ‘A CAUTION motor. icates special precautions that must be taken to avoid damage to the outboard NOTE: A NOTE provides key information to make procedures easier or clearer. 4HOW TO USE THIS MANUAL oD @ RS al fe SY a3 8 = oe | of 6 (i) @ 4 om eo ae 12 SYMBOLS Symbols (D to @) are designed as thumb-tabs to signal the content of a chapter: @) General Information ® Specitication ® General Service (4) Fuel System ) Power Unit © Lower Unit @ Bracket Unit ) Electrical System @ Trouble-shooting Symbols 40 to 4 indicate specific data: 4 Recommended fluid @) Lubricant ‘ Engine speed &3 Tightening torque 43 Wear limit, Clearance Resistance (2), Voltage (V), Electric current (A) Symbols (8 to 48 in an exploded diagram indi cate grade of lubricant and location of lubrica- tion point: ® Apply Yamalube two-cycle outboard oil ) Apply Yamaha gear-case lube ® Apply Yamana marine grease (Al! purpose) Symbols 49 and @ in an exploded diagram indi cate grade of sealing or locking agent, and lo- cation of application point: 9 Apply Gasket maker* ® Apply Loctite NOTE: In this manual, the above symbols may not be used in every case.YAMAHA MOTOR CO. cl 13 IDENTIFICATION SERIAL NUMBER The serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket. @ Serial number NoTe; ——_____ As an antitheft measure, a special label on which the outboard motor serial number is stamped is bonded to the portside of the clamp bracket. The label is specially treated so that Peeling it off causes cracks across the serial fnumber. ) Model name @ Approved model No. ) Transom height @ Serial number ENGINE SERIAL NUMBER The engine serial number is stamped on the port side of the oylinder body. STARTING SERIAL NUMBERS The starting serial number blocks are as follows: L: 319716 ~GEN INFO SAFETY WHILE WORKING SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline is highly flammable. Petroleum vapour is explosive if ignited. Do not smoke while handling gasoline, and keep it away from heat, sparks, and open flames. VENTILATION Petroleum vapour is heavier than air and if in- haled in large quantities will not support life. Engine exhaust gases are harmful to breathe. When testrunning an engine indoors, maintain good ventilation. SELF-PROTECTION Protect your eyes with suitable safety specta oles or safety goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves or pro- tective shoes if appropriate to the work you are doing. OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha. Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all- important, and by adopting good safety prac- tises. any risk is minimised. A summary of the most important precautions is as follows: 1. While working, maintain good standards of personal and industrial hygiene. 2. Clothing which has become contaminated with lubricants should be changed as soon as practicable, and laundered before further use. 3. Avoid skin contact with lubricants; do not, for example, place a soiled wiping-rag in ‘one’s pocket. 14 4. Hands, and any other part of the body which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with hot water and soap as soon as practicable. To protect the skin, the application of a suitable barrier cream to the hands before working is recommended. 6. A supply of clean lint-free cloths should be available for wiping purposes. GOOD WORKING PRACTICES 1. The right tools Use the special tools that are advised to protect parts from damage. Use the right tool in the right manner - don't improvise. 2. Tightening torque Follow the torque tightening instructions. When tightening bolts, nuts and screws, tighten the larger sizes first, and tighten innerpositioned fixings before outer- positioned ones. 3, Non-reusable items Always use new gaskets, packings, Orings, splittpins and circlips etc on reassembly, DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressedaair on disas sembling them 2. Oil the contact surfaces of moving parts on assembly. 3. After assembly, check that moving parts ‘operate normally. 4, Install bearings with the manufacturer's ‘markings on the side exposed to view, and liberally oil the bearings. 5. When installing oil seals, apply a light coat ing of water-resistant grease to the outside diameter.GEN INFO SPECIAL TOOLS SPECIAL TOOLS ‘The use of correct special tools recommended by Yamaha will aid the work and enable accurate assembly and tune-up. Improvisations and use of improper tools can cause damage to the equipment. ‘SPECIAL TOOLS FOR TUNE-UP No. TOOL NAME 1 | Compression gauge Tachometer Ignition coil tester Dial gauge set 7_| Test propeller SPECIAL TOOLS FOR ENGINE SERVICE PART NUMBER, Yu-33223, Yu-33261 Yu-3097 YB-1611 No. | TOOL NAME Flywheel magneto holder Con-rod small end bearing installer 4 | Bearing separator 5__| Piston ring installer PART NUMBER:GEN | INFO SPECIAL TOOLS SPECIAL TOOLS FOR LOWER UNIT SERVICE TOOL NAME | __ PART NUMBER 1 | Bearing separater — | _YB629 2 | Grand nut wrench | ~ye60 Souler ara ae al eer | Forward gear bearing cup installer | Pinion nut torqui 9 | Bearing housing puller 10_| Slide hammer & attach ~-YB34481 8.7003 _YB6265 11 | Magnetic flexible dial base 42_| Magnet plate 13 | Backlash indicator roa SEALING AGENTS AND LUBRICANTS No. PART NAME PART NUMBER Gasket maker __907-9074001-00 Marine grease Power trimtit fluid Gear case lube (11 02) _ | Yamalube two-cycle outboard oil Rev, 2/11/91SPEC uo CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 24 MAINTENANCE SPECIFICATIONS ........ 2.0... -0000000ee eee 23 ENGINE ......... sevens 2B ELECTRICAL . 25 DIMENSION 27 TIGHTENING TORQUE 210SPEC |u| GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Speed range at fullthrottle Number of cylinders Total displacement Bore and stroke Compression ratio em? (cwin) mmocmm tin) | Spark plug INGK] Carburetor Carburetor starting system Intake system | Scavenging system Exhaust system Lubrication system Cooling system Ignition system Starting system fem ij Unit ‘Overall length = mmm (in) } Overall width mm (in) Overall height (L) ‘mm (in) 4,904 (61.3) Boat transom height (L) mm (in 519 20.4) i. _ ko db) | 91 (2006) _ _| Maximum out put W (hpyirpm 40.4 (65)5,500 Average maximum power KW (hpyrom 760 (46.36) 82x72 (8.23283) 65:1 BaHs-10 2 Choke Reed valve ‘Schndrle (Loop charged) Propeller boss Premixed Water CL. Electric Fuel Regular gasoline Fuel tank capacity CUS ga} 24 (6.34) Mixing ratio "50:4 Engine oil type Yamalube two-cycle Engine cil grade Tow Gear oil (type) Hypoid gear oil SAE #90 Gear oil (quantity) em’ (US 02) $00 (16.89) Trim angle degree Be, 12", 16°, 20°, 24° Tiltup angle degree 75° Shallow water angle degree — Steering angle degree 60° Transmission j FN Gear ratio 19/24 (1.85) Reduction system | | Spiral bevel gear Clutch type Dog eluteh Propeller direction | Clockwise Propoller drive system Spline Propeller type | is 24SPEC | u™| GENERAL SPECIFICATIONS tem | Unit Propeller ~ _ No. of blades x diameter | in | 3x 10-314 16 pitch | 3x 10-314 17 3x 11x15 | 3x11 118x 13, 3x11-38x 12 Bx 1-414 3x 11-5IB x11 3x 1-3/4 10 3x 12-1129 ! (sus) i 3x 10-114 14 3x 10-114 x15 3x 10-114 x16 3x 11-112x 13 | Bx 113/412 l 8x12%11 22SPEC u™ MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE | Gyinder Head Warpage limit (Lines indicate straightedge) Cylinder Bore size Taper limit Qut of round limit Piston: Piston to cylinder clearance Piston size “D” Measuring Point “H” versa: t3t | hd ottset Piston Ring: Sectional skoton ‘Top ing 2nd ring y cle End gap [Installed] Top ring | 2nd ring Side clearance Top ting 2nd ring mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) 82.00 ~ 82.02 (8.228 ~3.229) 0.08 (0.003) __| 0.05 (0.002) _ 0.060 ~-0.065 (0.0024 ~ 0.0026) 0.1 (0.004) 81.936 ~ 81.960 (3.2258 ~ 3.2268) 10 (0.4) 82.25 (3.238) 82.50 (3.248) 15.0059) Key stone 2.0 (0.079) 25 (0.098) Prain 20 (0.079) | 25 (0.086) 0.4~06 (0.016 ~0.024) 04-06 (0.016- 0.024) 0.03 ~0.088 (0.0012 ~ 0.0026) 0.03 ~0.07 (0.0012 ~0.0028) 23| MAINTENANCE SPECIFICATIONS Granikshatt rane wich "A" rank wiath “B° Maximum deflection “6 Carburetor: ‘Stamp mark Main jet Main air jet Pilot jet Pilot air jet Pilot screw Float height Starter jet Valve seat size j Idling speed Trolling speed Reed valve: Thickness Stopper height Maximum reed warp mm (in) mm (in) mm (in) ee # Turns out mm (in) rimin min mm (in) mm (in) mm (in) | 164.+.0.2 (6.46 0.008) 0.02 (0.0008) | ares 160 125 80 100 24 19.1 (0.752004) 16 11050~ 1,150 , 750-850 0.25 (0.010) | 8620.2 mm (0.34+0.008) Los 0.020) 24SPEC y= MAINTENANCE SPECIFICATIONS OI unit TWAG2-12 ELECTRICAL tem Unit LL Ignition system: Ignition timing ATDC degree ar mm (in) lanition timing [at full throttle] | BTDC degree mm (in) Cam roller pick-up ignition timing BTDC degree Charging coil resistance [20°C (68°F) @ 203223 Pulser coil resistance [20°C (68°F)] a 7828 ignition colt j Primary coil resistance [20°C (68°F)] 2 0.25+0.05 Secondary coil resistance [20°C (68°F) ko 25205 Spark plug INGK) ‘Spark plug gap 0.9~1.0 (0.035 ~0.039) ao) Bat ink [soon oe | RP] BR! venow| Gry [Ora = : fee | | — ae {of | as malta e | wale |e a ae oo pron js.mm] = = [aw 0 |e a | tH net] 10.50 [seem ~ | = |mwl ee ee! woe | wen | |e White “| js; e)° 3 Block | t lL Br: Brown tT Blue enfon) 2 |\ lan ele A: Red | WIR : WhitefRee — Nee eee \WIB : White/Black as) ae] © | o ee WIY : White/Yellow WIG : White/Green = eee eee BIW: BlackWhite | P Pink wet | me) | | os . Y Yellow | | ss}us|e | @ as|e se: No continuity ‘© : Nocdle swings once and returns to home position. 25SPEC u™ MAINTENANCE SPECIFICATIONS Item | Rectitire regurefor 654-8197060 > No continuity NOTE: —— When resistance is measured at less than 1002. it can be said that there is continuity. item Unit ~ Lighting system: Lighting Coil resistance STD (12V BOW) (20°C (68°F) 2 0.29+0.03 Startermotor Rating Sec | 90 Out put ew |10 Clutch type Over running Brush length mm (in) 16.0 (0.63) | 120 (0.47) Commutator under cut | mm fin) 05~08 (002-003) “ | tam cin) 0.2 (0.008) Commutator outside diameter mm (in) 33 (1.30) “ mm in) 31122) Pinionfring gear gap mm (in) | 8~5 @.12~020) Others | Fuse A 2 Choke solenoid resistance a 40204 [20°C (68°F) Starter relay ‘Solenoid coil resistance a 3203 [20°C (68°F 26MAINTENANCE SPECIFICATIONS DIMENSION 27SPEC u™| MAINTENANCE SPECIFICATIONS Symbol (Used in diagram) A (Max) B (Max) Twin engine center to center distance R Unit degree degree mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mom Gn) mm Gn) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) 28 T Model | CV55E E | oa 206 (159) | 519 20.4 1975 (7.78) | 275 (10.8) 62 2.44) 254 (100) 405 (159) | 877 (34.5) | 425 .16.7) 660 (26.0) 480 (189) 190 (75) | 490 18,SPEC | MAINTENANCE SPECIFICATIONS CENTERLINE TOP OF TRANSOM tem Engine mounting position Diameter Diameter Moael Unit CvSSE am Gn) 508 200) mm (in) 185 (073) mm (in) 185 073) fmm (in) 185 (073) mm (in) 2032 (8.00) mm (in) 258" (10.0) mm (in) 555 (2.19) mm tin) 149. 687, mm (in) 09437) tm (in) 1236 (4.87) mam (in) Mi2 Screw mm (in) 13, 51) mam (in) 1305) 29240 SPEC u™ | MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE T T weael tem a aS rank case iM [Nm ekg, eb) 2112.87 M0 | Nm (rnekg, 10) | 4 (40, 29) Connecting rod bolt Nm (mskg, ft-lb) 2 3.2, 23) 9 | Cylinder head bolt Nem (mekg, flO) 3 80, 22) € | Exhaust cover bolt Nm (mekg, ftelb) 75 (0.8, 5.4) © | intake manifold Nm (mskg, ft-lb) st | Spark plug Nm (mekg, ftelfs) 2B (25, 18) a Nim (ek ft) 1 (6 110) fe ee 2 ei, 1) Beste motor mounting Nim grckg, He) neu 3 Unper mount robber nut [Nn ekg fy ean & | tower mount rubber nut Nm (mck te Bass) ie Rm ing I) tea 85 | ping nut Nm (mokg, ftlb) 13 (13, 98 © 3 | Pinion nut | New (mek, tet) 33 5, 35! Lower case mounting bolt ——_| Nm (mkg, ft=ib) 3 7, 26) S Propeller nut Nm (mekg, ft-lb) | BS (3.5, 25) General torque specifications ceaalaare This chart specifies the torques for tightening Nut Bolt specifications standard fastners with standard clean dry ISO ft-lb threads at room temperature. Torque specifi- 36 | cations for special components or assemblies 58 are given in applicable sections of this manu- 8 al. To avoid causing warpage, tighten mul- 25 | tifastener assemblies in crisscross fashion, in progressive stages until the specified torque is reached,GEN | SRVC CHAPTER 3 GENERAL SERVICE PREDELIVERY SERVICE at CONTENTS: oe a1 ELECTRIC WIRING 232 FUEL LINE : 39 GEAR OIL LEVEL .... ek OPERATION OF CONTROLS AND MOVING PARTS . 34 FUEL LEAKAGE 35 WATER LEAKAGE : 35 EXHAUST LEAKAGE 35 ENGINE AND LOWER UNIT NOISE ... : 28S IDLESPEED 0.22.00... cee ee ee we ce eeeee eee BS IGNITION TIMING .. : : 285 MOTOR EXTERIOR 5 35 INSTRUCTING THE NEW OWNER oo PERIODIC SERVICE 36 MAINTENANCE SCHEDULE 36 ANODE e 50 2-36 BATTERY cee BT CARBURETOR ee seers BE CARBURETOR LINK ADJUSTMENT ...0...0csccccscsesecseee 38 CHOKE SOLENOID ..... se BB CYLINDER HEAD BOLTS, ENGINE MOUNTING BOLTS, AND FLYWHEEL NUT FUEL FILTER FUEL TANK AND FUEL LINE GEAR OIL . IDLE-SPEED te : IGNITION TIMING ADJUSTMENT ........ 000200000 PROPELLER......... . cee coe SPARK PLUG -. 347GEN SRVC | PREDELIVERY SERVICE PREDELIVERY SERVICE ia Reter page 1 Contents 2 Electric wiring 3 Fuel line (gasoline and oil) 4 Gear oil level | 5 Oseration of controls and moving parts 6 Fuel leakage 7 Water leakage 8 Exhaust leakage 9 Engine and lower unit noise 10 Idle-speed 11 Ignition timing 12 Motor exterior 18 Instruction the new owner CONTENTS (On unpacking, check that all accessories to the model are included. Model Contents ies ‘utboad motor Fuel tank Remato contro! box Service tools Emergency starter rope Moter mounting parts Remote control cables Spare spark plugs Owner's manual 34Check that all leads and connectors are properly connected. 32 Gyo Wer Lwe ew 6 To starter relay B : Black R : Red 'B To starter motor Br: Brown Sb. Sky blue IC To starter relay G :Green = W : White ID) To battery @ Gy : Gray Y _: Yellow IE| To battery © Lo: Blue W/R : White/Red Lg = Light green W/B : White/Black © © Orange B/W : Black/WhiteGEN | SRVC 'Q PREDELIVERY SERVICE FUEL LINE Check that the fuel line is correctly installed. @ Carburetor Fuel filter 3) Fuel pump 23aa GEN SRVC PREDELIVERY SERVICE GEAR OIL LEVEL Remove the oildrain and oiHlevel plugs, and add the gear oil through the oildrain hole until it overfiows from the oiblevel hole. Refit the plugs. (The oil level plug first) OPERATION OF CONTROLS AND MOVING PARTS 1. Check for correct operation of the shift control. 2. Check for correct operation of the tiltlock mechanism. Check for smooth operation of the steer: ing control Check for smooth operation of the throttle control. Check for correct operation of the spark ad: vancer. Check for correct operation of the choke system, 7. Noting the following WARNING and CAU- TION, check for correct operation of the starting system. WARNING: Before attempting to check the starter system, replace the propeller with the specified test propeller, and make the tests with the motor placed in a test tank. CAUTION: Use a 25 : engine. gasoline-oil mixture to start the 8. Check for correct operation of the engine stop systemGEN SRVC | PREDELIVERY SERVICE 35 FUEL LEAKAGE Check for fuel leakage. WATER LEAKAGE Check for water leakage, EXHAUST LEAKAGE Check for exhaust leacage. ENGINE AND LOWER UNIT NOISE Check the engine and lower unit for abnormal noise. IDLE-SPEED Check that the engine speed at fully-closed throttle is correct IGNITION TIMING Check that the ignition timing at fully-closed and fully-open throttle positions is correct. MOTOR EXTERIOR Check the motor exterior for any flaking of the paint, and if necessary touch-up with paint of the original colour. INSTRUCTING THE NEW OWNER Instruct the new owner on the operation of all controls and the breakin procedure. Also ad- vise him on propellero-boat matching.GEN SRVC | PERIODIC SERVICE PERIODIC SERVICE MAINTENANCE SCHEDULE The following chart may be taken as a helpful guide to the intervals between maintenance brocedies imal re Toure 7 2 eu) tr sae ven | ees | rman | enti | “trys | anode aoe ee Bate er [eater Choke solenoid Cylinder head bolts, engine ‘mounting bolts, and flywheel nut Fuel filter Fuel tank ard fuel ne Gear oil idle-speed Ignition timing | Propetier ‘Spark plug [ Throttie control ink ANODE Inspect the anode. If it is worn out, replace it with a new one. If scaling of the surface is evi- dent, remove the anode and clean it with a wi brush, and remove all trace of oil or grease. Af- ter cleaning, polish the contact surfaces of the anode mount, and reinstall CAUTION: Never paint the anode. To ensure good electri- cal contact, keep the anode contact surface lean of oil or grease. 36PERIODIC SERVICE Recommended battery capacity: Rating .. 12V OAH (252 kC) Minimum cold crank performance 380 Amps at 17.8°C (10°F) Minimum reserve capacity: 124 minutes at 26.7°C (80°F) 1) The electrolyte level should be between the upper and lower level marks. Top-up with distilled water. CAUTION: Water other than distilled water contain miner- als which are harmful to the battery; top-up only with distilled water. 2) Before first use, the battery must receive its initial electrical charge. CAUTION: Failure to initially charge the battery before first use, or allowing the electrolyte level to be be- low the lower level mark will cause premature failure of the battery. Charging: Charge at 7.0 amperes for 10 hours or until the specific gravity reaches 1.280 at 20.deg.C (68-deg.F). 3) Thoroughly clean the battery terminals, and tightly connect the leads to the terminals. Lightly grease the terminals and connectors, with petroleum jelly, NOTE: Replace the battery ift 1. The voltage does not rise to an open-circuit value of at least 22 volts per cell, or bub: bles fail to rise even after many hours of charging; 2. The plates show a whitish colour, or there is an accumulation of material in the bot- tom of the cell, indicating that suiphation of one or more cells has occurred; 37 3. Specific gravity readings after a long slow charge indicate one or more cells to te low: er than the rest; 4, There is visible warping or buckling of plates or insulators in any cell, 4) When removing or installing the battery, proceed as follows: When removing: Disconnect the negative terminal (black leao) first When installing: Connect the positive ter: minal (red lead) first ARNING: Battery electrolyte contains sulphuric acid which is poisonous and corrosive, ié., it can cause skin burns and damage to eyes. Avoid all contact with the skin, eyes, or clothing. First Aid: Eyes: flush with water for fifteen minutes (if necessary holding the eye open with clean fingers), and get prompt medical attention. Intemal: Do not make the casualty vomit. Give plenty of water to dilute the acid. Add if possi- ble, 2 tablespoons of chalk, milk of magnesia, plaster or whitewash to a pint of water. ‘Skin bums: Thoroughly flood the part with water. Remove contaminated clothing. Bathe the part in an alkaline solution such as two teaspoons of baking soda (bicarbonate of soda) or washing soda (carbonate of soda) to one pint of warm water. Batteries produce explosive gases. Keep sparks. and flames away. Do not smoke where batter- 6 are charged or stored. Ventilate the area when charging or using batteries in any enclose space. KEEP BATTERIES AND ELECTROLYTE OUT OF THE REACH OF CHILDREN.PERIODIC SERVICE 38 CARBURETOR 1) Check the fuel passages and air passages for fouling or clogging. Clean fouled parts with suitable cleaning solvent and blow out clogged passages with compressed air. 2)Check the needle-valve for wear, and replace it if worn CARBURETOR LINK ADJUSTMENT 41) Loosen the carburetor idle adjust screw and fully close the throttle valve. 2) Connect the accelerator lever rod to both upper and lower carburetors. 3) Pull up the upper carburetor ball joint to re: move the play of upper and lower carbure- tor ball joints and tighten the lock screw. Make sure the throttle valves in the upper and lower carburetors open simultaneously. CHOKE SOLENOID 4) Fully open the choke valve, hook the pull wire to the choke lever pin, and hold it with the Oxing.~GEN_ SRVC PERIODIC SERVICE 39 CYLINDER HEAD BOLTS, ENGINE MOUNTING BOLTS, AND FLYWHEEL NUT 1) Retighten to specifications. 2)Check other fixings and tighten if necessary. FUEL FILTER Clean the strainer of dust and impurities. Strainer body Strainer O-ring @ Strainer cup FUEL TANK AND FUEL LINE 1) Check the fuel tank and fuel line for leaks. 2) Clean the fuel tank thoroughly. GEAR OIL 1) Drain the gear olf thoroughly, and pour in new oil. 2) Check for water or metallic sediment in the drained oil NOTE: If the gear oil becomes “milky”, check the gear case oil seals and shift boot for water entry. IDLE-SPEED 1) Tum the pilot screw until itis lightly seated 2) Tum the pilot screw outward to the speci fied setting, fied turns out: 2 tums plus/minus 4/4 tumsGEN SRVC PERIODIC SERVICE 3:10 3) Start the motor, and allow it to warm up for a few minutes. 4) Set the idle-speed to the specified level by setting the throttle stopscrew. Use a tachometer for checking the speed when adjusting the motor speed. Nove: ——__ Turing the throttle stop-screw clockwise in- creases the motor speed; turning it counter- clockwise decreases the motor speed. [A] Idle speed: 1,050~ 1,150 rlmi IGNITION TIMING ADJUSTMENT 1. Timing plate position adjustment If the timing plate is moved even alittle dur- ing inspection or repair operation, it should be set in the following way: This adjustment must be made before ad- justing the ignition timing. 1) Remove the spark plugs from the cylinders. 2) Install a dial-gauge in the spark-plug hole of No. 1 cylinder. NOTE: For easy timing:plate adjustment, it is advisa- ble to remove the spark plugs from all the oylinders. 3) Slowly turn the flywheel CLOCKWISE, and stop it when the piston is at TDC. CAUTION: Be sure to tum the flywheel clockwise, or the impellor blade will be twisted the other way, thus reducing pump performance.GEN SRVC PERIODIC SERVICE 4) If the end of the timing plate is not aligned with the TDC mark on the CDI magneto ro- tor, loosen the timing plate set sorew, align the timing plate end with the TDC mark, then tighten the screw. 5) Remove the dial gauge from the No.1 cylinder and install the spark plugs for each oylinder. NOTE; — After tightening the screw, paint over the screw. head to discourage tampering with the ad- justment 2. Full advanced position 1) Remove the link joints. Turn the magneto base stopper screw on the crankcase side so that the screw comes off the magneto base. 2)Tumn the flywheel magneto rotor counter- clockwise so that specified value on the timing mark aligns with the timing plate. 26°1° BTDC 4730.34 mm BTDC 3) Turning the magneto base counterciock- wise, align the mark on the flywheel check window with the mark on the pulser coilPERIODIC SERVICE 4) Adjust the magneto base stopper screw (on ‘the advance side) so that it contacts the magneto base stopper. 3. Full retarded position 1) Turn the magneto base stopper screw on the cylinder side so that the screw moves off the magneto base. 2) Turning the flywheel magneto rotor coun- terclockwise so that the specified ignition timing position aligns with the timing plate. 5°41? ATDC 3) Moving the magneto base, align the mark on the flywheel check window with the mark on the pulser coil 4) Adjust the magneto base stopper screw so that the magneto base contacts the stopper. 342PERIODIC SERVICE Throttle control link adjustment 1. Joint link adjustment 1) Adjust the joint link length to specified value and connect it to the magneto base and magneto control level 1 Joint link length: 500.4 mm 2, Pickup point adjustment 4} Set the ignition timing to the idle position by moving magneto control lever 3. (12, the flywheel magneto base stopper is in con- tact with the stopper bolt on the cylinder side) 2) Adjust the length of each accelerator link properly, and connect one of them to ‘magneto control lever 3 and the other to ac: celerator cam ball joint A=138.5 mm (5.45 in) 3) Tum the flywheel magneto rotor clockwise 80 that the ignition timing position on the timing mark aligns with the timing plate. Pick-up timing: BTDC 4°=-1°[GEN SRVC & PERIODIC SERVICE 344 Ignition timing adjustment using a timing light CAUTION: When checking ignition timing using a light, be sure to replace the propeller with the specified test propeller, and make tests with the machine placed in a test tank. Make sure the engine runs at more than 4,500 rpm. BENIN Be careful not to touch any rotating parts (such as the C.D.L. magneto rotor), C.D.I. unit, or ig: n coil while making the adjustment. Clip the timing light to the No.1 cylinder high- tension wire. 1. Fullretarded position a, Start the engine, and fully retard the ig- nition timing b. Direct the timing light to the timing plate and the timing indicator, and note the mark to which the timing plate points. 5°.41° ATDCPERIODIC SERVICE 6. If the timing plate fails to point to the specified ignition timing, align the igni- tion timing mark with timing plate by ad- justing the screw. 2. Fulladvanced position a. Fully advance the ignition timing, NOTE: Make sure the engine runs at more than 4,500 rpm. b. Direct the timing light to the timing plate and the timing indicator, and note the mark to which the timing plate points. 26° .1° BTDC 6. If the timing plate fails to point to the specified ignition timing, loosen the lock nut. Next, align the ignition timing ‘mark with the timing plate by adjusting the screw, and tighten the lock nut. 3. Pick-up timing a. Fully retard the ignition timingPERIODIC SERVICE 316 b. Set the motor idle speed to the speci- fied level by adjusting the throttle stop screw. Turning the throttle stop screw in (clockwise) increases the motor ‘speed; turning it out (counterclockwise) decreases the motor speed. Use a tachometer for checking and adjusting the motor speed. (>| Idle speed: 1,050 ~ 1,150 rimin ©. Bring the throttle cam to lightly contact the throttle lever roller. (The throttle valve should not open.) d. Adjust the accelerator link length and connect magneto control lever io the accelerator cam. PROPELLER 1) Check the blades for wear, damage, cavi tation erosion, 2) Check the splines for wear and damage.PERIODIC SERVICE (0.035 ~ 0.039 in) SPARK PLUG 1. Check the electrods condition and state of ‘wear, note the insulator colour and the elec- trode gap. 2. Clean the spark plug with spark-plug clean- erif necessary. Use a wire gauge to adjust the plug gap to specification. 3, If the electrode becomes too worn, replace the spark plug ‘4, When installing the plug, clean the gasket surface, wipe off eny grime there may be on the surface of the spark plug, and screw in the spark plug to the correct torque. Standard spark plugs: NGK B8HS-10 Spark plug gap: 0.9~1.0 mm (0.035 ~ 0.039 in) NS] Tightening torque: 23~27 Nm (2.3~27 m-kg, 16.6~ 195 it-lb)FUEL q CHAPTER 4 FUEL SYSTEM FUEL SYSTEM . CLEANING AND INSPECTION INSTALLATION . CARBURETOR bec weve REMOVAL AND DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION at 42 Ae 45 46 4? 48FUEL FUEL SYSTEM a FUEL SYSTEM D Carburetor @ Eust pump assembly &) Fai fiter assembly 4) Fuel joint Priming pump Fuel moter sseombly Fuel tank cap ® Fuel tank ay= FUEL # FUEL SYSTEM WARNING: 1. Fire Prevention Gasoline is highly flammable. Petroleum vapour is explosive if ignited. Do not smoke while handling gasoline, and keep it away from heat, sparks, and open flames. 2. Ventilation Petroleum vapour is heavier than air and if inhaled in large quantities will not support life. Engine exhaust gases are harmful to breathe. When testrunning an engine in- doors, maintain good ventilation. 3. Spillage Remember that fuel remains in the fuel hose between the fuel joint and the carbu- retor, Drain all remaining fuel out into a con- tainer, or soak it up with a cloth so that the fuel does not spill on to the bottom cowling. 4, Leaks Failure to check for and correct fuel leaks may result in fire or explosion. CLEANING AND INSPECTION Fuel tank 1) Add a small quantity of a suitable cleaning solvent into the fuel tank and thoroughly clean the tank interior by shaking the tank. 2) Drain off the cleaning solvent completely.FUEL i FUEL SYSTEM Fuel meter complete 1) Using a soft brush and solvent, clean the strainer on the end of the suction pipe, and blow-dry it with compressed air. 2) Visually inspect the strainer for damage, and replace the fuel meter complete if re- quired. 3) Inspect the fuel meter components for cracks, and replace the fuel meter complete if required 4) Re-install the fuel meter complete with the rubber gasket to the fuel tank, ensuring that there are no leaks between the fuel meter and the fuel tank @ Fuel meter assembly @® Suction pipe @ Fuel strainer Priming pump. 1) Visually inspect for cracks or breaks in the priming-pump and fuel-hoses, and replace them if required. 2) Check the operation of the check-valve by blowing into the pump. ) Priming valve ) Arrow mark ) Check valve (inlet) 2) Check valve (outlet) Fuel filter 1) First removing the nut and filter-cap, disas- semble the fuel filter. 2) Visually inspect the filter body for cracks ‘or damage to the thread, and replace if re- quired. 43FUEL SYSTEM 44 3) Using a soft brush and solvent, clean the fer element thoroughly. Inspect the filter element for breakage or distortion, and replace if required 4) Using a soft brush and solvent, clean the filter-cup thoroughly. Inspect the filte-cup for cracks or thread damage, and replace if required 5) Place the O-ring on the filter body, install the element, and screw in the filter cup, Fuel joints 1) Inspect the fue! joints for leaks and cracks, and replace as required. Fuel pump 1) Using a screwdriver, disassemble the fuel pump. 2) Visually inspect the pump body for cracks, and replace if required. 3) Inspect the valves for cracks or distortion, and replace if required 4) Inspect the diaphragm for sign of damage, perforation or stretching, and replace if re- quired, 5) Assemble the fuel pump with new gaskets, INSTALLATION Referting to the diagram, install the fuel system. Note the following points. ‘When connecting the fuel hoses to the fuel pump and fue! filter, follow the direction of flow indicated by the embossed arrows. Place the clips in position, connect the hoses, and tighten the clips. Check for leaks.FUEL ¥ CARBURETOR CARBURETOR @ Pilot screw ® Drain screw ® Needle vaive @ Float chamber @ Pilot jet Thvottle stop screw @ Main nozzle GQ Pilot air jet dD Main air jetFUEL 4 CARBURETOR 46 REMOVAL AND DISASSEMBLY At this step, ensure there is no spillage of gaso- line on removing the connections. 1) Remove the silencer cover, disconnect the fuel hose, then remove the carburetor. 2) Referring to the diagram, use a screwdriver to disassemble the carburetor. 3) Using solvent, clean the components thoroughly, and blow-dry them with com: pressed air, SENT Protect your eyes with suitable safety specta- cles or safety goggles when using compressed . Protect your eyes and the eyes of other per- sons by directing the flow of compressed-air downward, noting that solvent and small parts, may be blown off. CAUTION: Do not use steel wire for cleaning the jets as this may enlarge the jet diameters and seriously affect performance.FUEL e CARBURETOR INSPECTION Carburetor body 1) Inspect the carburetor body for cracks or clogging of the passages. Needle valve 1) Inspect the needle vaive for free movement ® and wear, and replace if required. | AUD, S . Pilot screw 1) Inspect the pilot screw for wear, and replace it required, Collar 4) Inspect the collar at the end of the acceleratorarm for wear, and replace if re- quired Float 4) Visually inspect the float for damage or cracks, and replace if required 2) Measure the float height. If it is greater or less than the specified float height, recheck the valve seat and needle-valve. a7FUEL = WZ | carBureToR 48 ASSEMBLY 1) Insert the main nozzle fully, and screw in the main jet until tight. 2) Install in the pilot jet fully, and sequre the plug screw. 3) Install the needle-valve on the float, attach the float to the carburetor body with float- pin. 4) Install a new Oxing to the float-chamber, in stall it to the carburetor body. and secure with the screws, 5) Install the pilot air jet and main air jet to the carburetor body. 6) Install the pilot-screw with its spring, screw it in tight and then screw it back the speci- fied number of turns out.CARBURETOR CAUTION: Do not cause damage to the tip of the pilot screw by over-tightening it. Pilot screw (turns out): 2 tums PLUSIMINUS 1/4 tums INSTALLATION 1) Install the carburetors and plate with new gaskets. 2) Connect the fuel hoses to the carburetors, and fit the hose-clios over the recesses to ensure leak-proof connections. 3) Connect the choke link-rods, choke lever and accelleratorlever rod to each car- buretor. 4) Hook the choke-solenoid pull-wire on to the choke arm, and hold it in position with the Oring. 49POWR Gy CHAPTER 5 POWER UNIT EXPLODED DIAGRAM PREPARATION FOR OVERHAUL REMOVAL . DISASSEMBLY INSPECTION CYLINDER HEAD CYLINDER BLOCK PISTON .... PISTON RING PISTON PIN AND SMALL END BEARING CRANKSHAFT REED VALVE THERMOSTAT CRANKSHAFT MAIN BEARING ASSEMBLY AND ADJUSTMENT CRANKSHAFT MAIN BEARING PISTON... 00... 0ceecs cece cesses eeeee eee SMALL END BEARINGS AND PISTON ASSEMBLY CONNECTING ROD BIG END BEARING ASSEMBLY OIL SEAL HOUSING CRANK CYLINDER ASSEMBLY . : CYLINDER HEAD AND EXHAUST COVER DRAINLESS HOSE INTAKE MANIFOLD FUEL SYSTEM AND ELECTRICAL SYSTEM....... INSTALLATION .. BA 52 52 55 57 - 59 = 540 510 540 St 251 512 52 512 512 513 Bg 515 516 516 S17 BAT 518@ Cylinder head cover POWR EXPLODED DIAGRAM EXPLODED DIAGRAM @ Piston pin ctip 2} Head cover gasket 9 Piston pin @ Cylinder head & Bearing @ Cylinder head gasket {2 Oil seal & Thermostat 3 Oring © Thermostat cover @ Exhaust cover gasket ® Exhaust outer cover 4 Oil seal housing 5 Intake manifold (18 Valve seat packing aD Reed valve assembly 40 Nm (4.0 m.kg, 29 ft.tb) 12 Nm (1.2 mkg, 8.7 Fb) me ‘30 Nm (3.0 mikg, 22 Feb) StPOWR PREPARATION FOR 52 OVERHAUL/REMOVAL PREPARATION FOR OVERHAUL 4, Clean all dirt, mud, dust and foreign material from the engine before the engine is re- moved and disassembled, 2.To ensure that you can perform the work cleanly and efficiently, check that you have the proper tools and cleaning equipment before commencing engine removal and disassembly. 3, During engine disassembly, as parts are dis- assembled, clean them and place them in trays in their order of disassembly. This will speed up assembly and help ensure that all parts are correctly reinstalled. NOTE: ——_____ When disassembling the engine, keep mated parts together, e.g., cylinder and piston and other parts that have been ‘mated’ through nor- mal wear. Mated sets should be reused on reassembly, or replaced complete. REMOVAL 1) Remove the electrical system parts refer- ing to page &1 @ Battery cables 2) Remove the fuel system parts and hose referring to page 4-1 @ Fuel hose on the strainer ® Cooling water pilot hoseREMOVAL 3) Remove the throttle cable and the shift cable. @ Hair pin Shift cable joint }) Throttle cable joint ® Lever look 4) Remove the choke link. @ Choke link '5) Remove the shift rod lever pin, and remove the shift rod lever. 6) Remove the front and rear aprons 7) Remove the power head installation bolts, and then remove the power head from the upper casing, 53. POWR) a DISASSEMBLY NOTE: The power head may be difficult to separate trom the bottom cowling because of a stuck gasket holding them together. If this is the case lever it off the bottom cowling with a piece wood. Use care not to damage the bottom cowling or power head with the wood. 8) Remove the dowel pins from bottom cow!- ing or power head. To protect the dowel pins against damage, cover them with rags. 54POWR DISASSEMBLY DISASSEMBLY Disassemble the power head, referring to the exploded diagram. 1) Cylinder head 2) Intake manifold 3) Exhaust cover and thermostat cover 4) Oil seal housing Using the oil seal remover, remove the oil ‘seal one by one from housing. §) Crankcase Remove the two dowel pins. 6) Connecting rod caps, needle bearings and ball bearing. 7) Crankshaft and connecting rod. 8) Piston & Piston pin 9) Piston rings. Note the following points: 1. When disassembling the piston and piston pin, place a tray under the connecting rod to catch the needle bearings. 2. Only carry out exchange of the crankshaft bearing if the bearing is malfunctioning, 86POWR INSPECTION [Al 56 INSPECTION CYLINDER HEAD Cleaning 1) Using a gasket scraper, Remove all traces of gasket material from the cylinder head. 2)Using a round scraper, remove carbon deposits from the combustion chamber. CAUTION: Do not scratch the surfaces of the cylinder and combustion chamber. 3) Using a soft brush, clean the water jacket. Inspection 4) Using a precision straightedge and feeler- gauge, measure the surface contacting the cylinder block for warping Maximum allowable warp: O.4_mm (0.004 in) Al Lines indicate straighted measurement It the degree of warping exceeds this specification, re-surface the cylinderhead as follows: Place 400-600 grit wetordry paper on the surface-plate, and resurface the cylinder- head using a figure-eight sanding patter.POWR INSPECTION CYLINDER BLOCK Cleaning 1) Using a gasket-scraper, remove all traces of gasket material from the cylinderblock surface, 2) Using a soft brush and solvent, clean the cylinder block. Inspection 1) Visually inspect the cylinder sleeves for racks and soratches. If cracks are found, replace the cylinder block If scratches are found, check the degree of ‘out-of-round, and then hone the cylinder or re-bore it if necessary. 2}Using a cylindergauge, measure the cylinder bore at three positions in the thrust and axial directions. Axial direction Thrust direction A: 10 mm (04 in) below the cylinder top 8B: 5 mm (02 in) above the exhaust port C: 5 mm (02 in) below the scavenging port NOTE: Do not place the cylindergauge on the port hole. Maximum allowable taper: 0.08 mm (0.003 in) Maximum allowable out-of-round: 0.05 mm (0.002 in) \f diameter is greater than the maximum al- lowable, hone or rebore the cylinder or, if necessary, replace the cylinder-block. 57INSPECTION 58 PISTON Cleaning 1) Using a gasketscraper, remove the carbon from the piston top. 2) Using a broken ring, clean the ring grooves. CAUTION: ‘The top ring is a keystone-type ring; therefore, do not use a broken top ring for cleaning the ‘other ring grooves, nor use a broken ring from a lower groove for cleaning the top groove. 3) Using a soft brush and solvent, thoroughly clean the piston. if necessary, use 600~ 800 grit wet-ordry sandpaper to remove score marks or vatnish Inspection 1) Using a micrometer, measure the piston di- ameter at right angles to the piston-pin centreline, 10 mm (0.4 in) above the bottom edge. iston diameter: Standard: 81.935 ~81.960 mm (8.2258 ~ 3.2268 in) 2) Using the measured cylinder bore diameter in thrust directions, subtract the piston di- ameter measurement from the cylinder bore diameter measurement Piston clearance: 0.060 ~ 0.065 mm (0.0024 ~0.0026 in) If this clearance is greater than the maxi- mum, replace the piston to standard or oversize, andlor rebore the cylinder. Oversize piston: Ast; 82.25 mm (3.24 in) 2nd: 82.50 mm (3.248 in)POWR INSPECTION ry ly Ass 7 PISTON RING Inspection 1) Using a feeler gauge, measure the clear ance between the piston ring and the groove land. Side clearance: Top ting: 0.030~0.065 mm. (0.0012 ~ 0.0026 in) 2nd: 0.030 ~0.070 mm (0.0012~0,0028 in) If the clearance is not within the specifica: tions, replace the piston. |] Top (BI 2nd 2) Insert the piston ring into the cylinder. Us- ing a piston, push the piston ring a little be- yond the bottom of the ring travel to a depth of 20 mm (08 in) from the top of the cylinder block. CAUTION: Take care not to scratch the piston. Using a thickness gauge, measure the end-gap. AA Ring end gap (Installed imum: 0.4 mm (0.016 in) Maximum: 0.6 mm (0.024 in) If the clearance is greater than the maxi mum, replace the piston-ring andior piston. NOTE: If the clearance is greater than maximum even with a new piston ring, rebore the cylinder and Use an oversize piston and piston-ring, 59POWR eS INSPECTION 510 PISTON PIN AND SMALL END BEARING Cleaning 1) Use a soft brush and solvent to clean the parts, Inspection 4) Visually inspect for surtace detects, break: ‘age, scratches and pitting. If it is decided to replace the small end bearings, replace them all CRANKSHAFT Inspection 4) Using dial gauges, measure the deflection. ‘Maximum defiecti ‘mm (0.0008 ) If the deflection Is greater than specified maximum, correct the alignment by use of a brass hammer and a wedge. REED VALVE Inspection 4) Visually inspect for warping of the reed valve. If warped, measure the distortion with. feeler gauges. Maximum reed warp: 0.5 mm (0.020 in) If the amount of warping is greater than specification, replace the reed valve. 2) Using a vernier caliper, measure the valve stopper hight. Valve stopper height: 8.60.2 (0.34 + 0.008 in) If the valve stopper height is outside the specification, adjust it by bending. 3) Visually inspect for cracks on the reed valve. If cracks are found, replace the reed valve.POWR INSPECTION THERMOSTAT Cleaning 1) Using a soft brush and water, remove all traces of salt, dirt or corrosion. Inspection 1) Visually inspect the thermostat for damage. If the thermostat is damaged, or if it opens when cold, replace it. 2) Immerse the thermostat in water, and heat the water gradually. Check the valve open ing temperature and the valve lift Water temperature Below 58°C (136.4°F)| 0 mm Above Minimum 62°C (143.6°F)__| 3 mm (0.12 in) If the valve opening and or temperature and valveift are not within the specifications, replace the thermostat. CRANKSHAFT MAIN BEARING Cleaning 1) Using a soft brush and solvent, thoroughly clean the bearing. Dry it with air, and spar- ingly lubricate it with 2stroke outboard. motor oil CAUTION: Blow.dry the bearing without spinning it or mak- ing scratches on the bearing balls. Inspection 1) Hold the bearing inner race and slowly tum the bearing outer race with your fingers. If any rough spots are felt, replace the bearing, 511ASSEMBLY AND ADJUSTMENT YB6107 © ASSEMBLY AND ADJUSTMENT CRANKSHAFT MAIN BEARING 1) Press in the crank lower bearing to the crankshaft. CAUTION: When reassembling the lower crank bearing, the seal-cap side of the bearing should be in- stalled toward the crank side, as show in the illustration. 2) Lubricate the bearing with 2-stroke outboard motor oil PISTON 1) Install the plain rng into the 2nd ring grooves with the markings facing upward. 2) Install the keystone ring into the top ring groove with the marking facing upward. 3) Align each ring end-gap with their locating pins. SMALL END BEARINGS AND PISTON ASSEMBLY 1) Count the small-end bearing needies. Number of needles per smallend: 28-pcs. CAUTION: Do not use a mixture of new and used bearing needles in the same small end. 2) Using the special service tool. Install the bearings in the connectingod small end, and place washers on both sides. ‘CAUTION: ‘The washer should be placed with their con- vex sides facing the piston. 512POWR @y ASSEMBLY AND ADJUSTMENT YAMAHA 3) Insert the piston-pin into the piston 4) Align the “UP” mark on the piston crown towards the crankshaft tapered end. Install the piston in the connecting-rod small end, insert the piston-pin, and then install new piston-pin clips, 5) Lubricate each bearing with 2-stroke outboard-motor oi CONNECTING ROD BIG END BEARING ASSEMBLY 4) Install the piston, ‘Align the ring ends with locating pins in the grooves, and using the piston slider, push the piston into the cylinder. NOTE: ‘The UP mark on the piston crown should be on the flywheel side. Be sure to apply oil to the piston and cylinder wall 2) Place the crankshaft on the cylinder, and align the lower bearing locating pin with the locating pin hole on the cylinder, and fit the crankshaft correctly to the cylinder. 513|POWR Sy ASSEMBLY AND ADJUSTMENT 3) Install the bearing in the big end and install the cap. The cap bolts should be tightened in the following manner. a, Lightly screw in the bolts by hand while making sure the cap and rod ends are aligned completely. Then, tighten the bolts to half of the specified torque. Next, tighten to the specification. Check to see that the cap and rod ends are aligned. If not aligned, do the above procedure all over again. b. Loosen the bolts 1/2 tum, and tighten them to half of the specitied torque. Then, tighten to the specification NOTE: Replace the cap bolts each time the connect: ing rod is disassembled. mM Connecting rod big end: Ast step: 47, Nm (1.7 mekg. 12 ftelb) 2nd step: 35 Nm (8.5 mekg, 25 ft-lb} OIL SEAL HOUSING 1) Press-fit the oil seals one by one. CAUTION: ‘The direction of the oil seal must be as shown in the illustration, otherwise damage will be caused. NOTE: 514 When press-fitting the oil seal, be sure that it faces in the correct direction. 2) Fit new O-ing in the grooves in the cil seal housing outer surtaces.ASSEMBLY AND ADJUSTMENT 3) After installing the oil seal and O-ring, pack oil seal lip and outer surface of O-ring with Yamaha marine grease NOTE: Avoid cutting or stretching the oil seal hous- ing O-ring, 4) Install the oil seal housing onto the cylinder, and align the bolt holes. I<, | Oil seal housing bolt: 8 Nm (08 m-kg, 5.8 ft-lb) CRANK CYLINDER ASSEMBLY 41) Align each locating-pin of the bearings and labyrinth-seals with each cut on the oylinderblock, then fit the crank assembly in place. 2) Film-coat the cylinder-block mating surface with Gasket Maker or equivalent 3) Install the dowel-pins. 4) Match the cylinder-block and tighten the bolts In sequence and in two steps of torque. Ting eee RS; [anata (1.2 m-kg, 9 ft-lb) 0 Nm (4.0 m+kg, 29 ft+Ib) 5) Check that the crankshaft tums smoothly. 51Sa POW ASSEMBLY AND ADJUSTMENT CYLINDER HEAD AND EXHAUST COVER 1) Install the gaskets, cylinder-head cover and exhaust cover, 2) Tighten the bolts in two sequences and in two steps of torque. Bl Tightening sequence NK Cylinder head: ‘Ast step: 415. Nm (1.5 m-kg, 11 ft-lb) 2nd step: 30 Nm (3.0 mekg, 22 ft-lb) [BI Tightening sequence Cylinder head cover : Thermostat cover: 8 Nm (0.8 m-kg, 5.8 ftsIb) [C Tightening sequence Exhaust cover: Ast step: 4.Nm (0.4 mskg, 29 ft-lb) 2nd step: 8 Nm (08 m-kg, 58 ft-lb) 3) Install the thermostat, gasket and cover. DRAINLESS HOSE Fit two clips around the drainless hose. Connect one end of the hose to the delivery side of the check vaive and the other end to the joint on the intake side, and lock with the clips. 516INTAKE MANIFOLD 1) Install the reed-vaive assembly, and the reedvalve plate to the intake POWR ASSEMBLY AND ADJUSTMENT gasket manifold, 2) Install the manifold assembly to the crank- case, and tighten the bolts in sequence and in two steps of torque. ‘Al Tightening sequence IQ» | Intake manifold: 8 Nm (0.8 m-kg, 5.8 ft-lb) FUEL SYSTEM AND ELECTRICAL SYSTEM 1) Install the fuel system referring to page 4-1 2) Install the electrical system referring to page 841 517T POWR) eS INSTALLATION INSTALLATION 4} Install locating pins in position on the ex- haust guide. 2) Align the locating-pin holes on the gasket with dowel pins, and place the gasket on the bottom cowling 3) Install the power head onto the bottom cowling, tighten the mounting-bolts to the specified torque, ‘Mounting bolts: 21.Nm (21 15 ftelb) 4) Connect the hoses, cables and wires refer- ring to pages 3.2. 5) Bolt-on the apron. 6) Check the fittings installation, cable con- nections and functions before starting the ‘engine to check operation and to check for leaks, referring to page 3.5 518LOWR & CHAPTER 6 LOWER UNIT EXPLODED DIAGRAM : 61 PREPARATION FOR REMOVAL oD 62 DISASSEMBLY 62 INSPECTION 20.2.0... 0.0 0eecccceeeeeteeeeeeeee : 66 GEAR CASE... ceveeeee ce 68 BEARING HOUSING . ceveeeee es ce vee eens 66 CLAWWASHER...... 0... : : oo 86 RING-NUT, 66 WATER PUMP HOUSING : 66 IMPELLER 7 : 67 OIL-SEAL HOUSING (Water pump housing 2) 67 GEARS : — : enon 67 BEARINGS : ce cetteeteee neers ee 67 CLUTCH DOG AND COMPONENTS . 67 DRIVE AND PROPELLER SHAFTS 68 DRIVE SHAFT SLEEVE 68 PROPELLERITRIM TABIANODE, 68 ASSEMBLY AND ADJUSTMENT 69 SHIM SELECTION 69 ASSEMBLY on 613 BACKLASH ..... 615 WATER PUMP INSTALLATION 617 LOWER UNIT LEAKAGE CHECK 617 INSTALLATION 618LOWR € EXPLODED DIAGRAM EXPLODED DIAGRAM @ Water pump housing Shitt cam @ Bearing housing @ Water pump gasket 3 Shift plunger Needle bearing artridge outer plate & Shitt slide Claw washer ) Gartridge outer plate gasket (Forward gear % Ring nut |) Oil-seal housing Clutch dog Spacer © Water pump gasket 8 Cross pin Propeller @ Drive shatt Propeller shaft @ Nut & Woodrutt key Reverse gear ® Water tube © Drive shatt sleeve @ Oring 0 Needle bearing @ BearingRPEPARATION FOR REMOVAL/DISASSEMBLY 62 PREPARATION FOR REMOVAL 1) Remove the nut and washer, and remove the propeller and spacer from the propeller shaft 2) Drain the gear oil by removing the plugs from the oilfilling hole and the oitlevel hole. Be sure to remove the cil filing plug first. Referring page 3-4. 3) Set the shift lever nto neutral position. 4) Tilt up the lower unit, and lock it with the tilt look lever 5) Remove the trim tab. Before removing it, put ‘a mark indicating its position on the anti cavitation plate. 6) Remove the bolts. DISASSEMBLY 1) Referring to the exploded diagram, disas- semble the lower unit. 1. Water pump housing and insert car- tridge. 2, Impeller and woodrutt key. 3, Oil-seal housing (Water pump housing 2). Remove the oil seals, if necessary. Using special service tool 4, Shiftrod.DISASSEMBLY YB-6048 5. Ring-nut and claw-washer. Using special service tool, NOTE; — To remove a ring-nut: straighten the lobe of the claw-washer by use of a screwdriver, then at tach and tum it in the derection to the off mark the special service tool. @ Claw washer ® Ring nut @ Special service tool (YB-6048) 6. Bearing housing Using special service tool (Bearing housing puller 7. Propeller shaft assembly 8, Cross-pin ring, cross-pin and clutch-dog @ Clutch dog ® Cross pin & Cross pin ing Noe SS It is necessary to hold the spring with the shift plunger when removing the cross pin. Other wise, the shift slide and spring will jump out,DISASSEMBLY ye-6096_| 64 9, Reverse gear and bearing Using special service tool 10. Oil seals and needle bearing. Using special service tool 11. Pinion nut, plain bearing and pinion Using special service tool NOTE: — For ease of reassembly and adjustment, keep, shim packs in their groups as removed. 12. Drive shaft and forward gear 13. Foward gear bearing outer race. Using special service tool (Slide hum- mer puller) ——————— For ease of reassembly and adjustment, keep shim packs in their groups as removed, 14. Drive shaft bearing outer race. Using special service tool 18. Drive shaft sleeve, 16. Drive shaft needle bearing, Using special service toolLOWR] & DISASSEMBLY yee | 17. Reverse gear bearing and forward gear bearing. ALS f ‘Separate the bearing from the gear. 65 Using special service tool and hydraul- ic press, 18. Drive shaft bearing Install the nut on the threaded portion of the drive shaft and screw it in so that ‘the side of the nut is flush with the end of the drive shaft. The drive sha't can now be removed using a hydraulic press. NOTE: Use care not to bend the drive shaft, since it is longINSPECTION INSPECTION GEAR CASE 1) Using a soft brush and solvent, clean the case and water passage. 2) Visually inspect the gear case for cracks, corrosion or distortion. If any crack or ex- cessive corrosion is found, replace the gear case. 3) Check the water inlet cover and water pas- sage for clogging BEARING HOUSING 1) Using a soft brush and solvent, clean the housing thoroughly. 2) Visually inspect the housing for cracks and corrosion. If any damage is found, replace the bearing housing. CLAW-WASHER 1) Visually inspect the washer for cracks. If a crack is found, replace the claw-washer. RING-NUT 1) Using a soft brush and solvent, clean the thread of the ring-rut. 2) Visually inspect the ring-nut for cracks or damage to the thread. If cracked or damaged, replace the ring-nut WATER PUMP HOUSING 1) Inspect the water pump housing for signs of twisting or scratches of the inner car tridge. If twisted, orif it is scratched exces sively, replace the housing 2) During the above operation, inspect the im eller plate, and replace this if damaged. 66INSPECTION 67 IMPELLER 4} Visually inspect the impeller for cracks, dis- tortion or burning. f any damage is found, replace the impeller OIL‘SEAL HOUSING (Water pump housing 2) 1) Using a soft brush and solvent, clean the oitseal housing 2) Visually inspect the housing for cracks or corrosion. If a crack andlor excessive cor- rosion is found, replace the oitseal housing, GEARS 4) Visually inspect the teeth and dogs on the gears for cracks, peeling of distortion due to gear-crashing, f damage is found on any of the gears, replace with new one. BEARINGS 1) Inspect the bearings for pitting, scratching ‘or rumbling (which may be detected by tum: ing the bearing by hand), and replace them if they are not in good condition. CLUTCH DOG AND COMPONENTS 4) Visually inspect the clutch dog, looking par- ticularly for rounding of the dog edge, cracks and other signs of damage or wear. If the dog is excessively rounded, inspect also the mating gear, and replace both if necessary.INSPECTION DRIVE AND PROPELLER SHAFTS 1) Visually inspect the shafts, looking for ‘grooved wear on the surface in contact with the bearings and oilseals, and checking for wear on the splines. Replace if worn or damaged, DRIVE SHAFT SLEEVE 1) Visually inspect the sieeve for wear and cracks. If any damage is found, replace the sleeve. PROPELLER/TRIM TABIANODE *Refer to CHAPTER 3-16 for periodic in- spection instructions. 68ASSEMBLY AND ADJUSTMENT Rev. 2/11/91 ASSEMBLY AND ADJUSTMENT SHIM SELECTION NOTE: ——_______ 4. When reassembling the lower unit with the original gear case and inner parts, shim selection is not required ‘When replacing the gear case only, read the numeral preceded by “F,R,P", and adjust the shims according to the difference be- tween numerals of the original gearcase and the new gear-case, If the bearing(s) andior gear(s) are replaced, carry out the shim selection Pinion gear shim 1)Find pinion gear shim thickness (T3) by selecting shims until the specified meas- urement (M) with the special tool is ob- tained. Specified Measurement (M)= 0.20 mm + P/100 mm »NOTE: If the P value is negative (—), then subtract the P value from the measurement. 2) P is the deviation of the lower case dimen: sion from standard, It is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the P_mark is missing or unreadable, assume an P mark of “0” and check the backlash when the unit is as- sembled. Example: IF P mark is "45", then M = 0.20 + (+5}/100 mm = 0.20 + 0.05 mm = 0.25 mm (0.010 in} = 0.20 + (—3)/100 mm 0.20 - 0.03 mm 0.17 mm (0.007 in) IEP mark is "3", then M 69LOWR) € ASSEMBLY AND ADJUSTMENT > yesaasz 20 ¥B30432-11 yB36432.10 BEARING 3) Assemble the shimming gauge with the drive shaft, bearing, and shims as shown in the illustration. Boit the bearing housing to the special tool with at least two bolts. NOTE: If the original shims are unavailable, start with a 0.50 mm shim, 4) install the pinion on the drive shaft, and tighten tne nut to the specified torque. 5) Using feeler gauges set at the specified measurement (M) established above, check the fit between the shimming gauge and lower surface of the pinion as shown. 6) If the feeler gauge(s) will not fit, then add additional shims until the feeler gauge(s) {set at the M_ specification) just fit between the tool surfaces. 7)If the feeler gaugefs) are a loose fit, then remove shims until the feeler gauge(s) (set at the M_ specification) just fit between the tool surfaces. “available shim thicknesses: 0.05, 0.08, 0.12, 0.30 and 0.50 mm Forward gear shim 1) Find forward gear shim thickness (T1) by selecting shims until the specified meas: urement (M) with the special tool is ob- tained [Ay J Specitiod Measurement (i) = 2.20 mm + F/100 mm NOTE: lf the F value is negative {-), then subtract the F value from the measurement. 2) F is the deviation of the lower case dimen- sion from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the F mark is missing or unreadable, assume an F mark of "0", and check the backlash when the unit is as- sembled, Example Rev, 2/11/91 WF mark is then M = 2.20 + (+5)/100 mm 2.20 + 0.05 mm = 2.25 mm (0.089 in) HF mark is “3°, then M = 2.20 + (~3)/100 mm = 2.20 ~ 0.03 mm ee = 2.17 mm (0,085 in}