SERVICE MANUAL T YAMAHA MOTOR CO.,LTD. 290206 @NOTICE ‘This manual has been prepared by the Yamaha Motor Company 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 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 ofthis manual Authorized Yamaha dealers are noified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. 2B, 2C aT SERVICE MANUAL © 1994 Yamaha Motor Co., Ltd 1st Edition, November 1994 All 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 writtenpermission must also be obtained beforeany part of this publication is stored in aretrieval system of any nature. Printed in Japan PIN 6A1-28197-24-11HOW TO USE THIS MANUAL MANUAL FORMAT Allof the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains ‘comprehensive explanations of all disassembly. repair. assembly, and inspection operations. Inthis revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., * Bearings Pitting/Damage + Replace. 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. MODEL INDICATION Multiple models are shown in this manual. These indications are noted as follows. Model name USAand CANADAname | Indication THE ILLUSTRATIONS Some illustrations in this manual may differ from the model you have. This is because a procedure described may relate to several models, though only one may be illustrated. (The name of model described will be mentioned in the description). REFERENCES These have been kepttoa minimum; however, when you are referred to another section of the manual, you are told the page number to go to.3) WARNINGS, CAUTIONS AND NOTES Attention is drawn to the various Warnings, Cautions and Notes which distinguish impor- tant information in this manual in the following ways. & The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS IN- VOLVED! AWARNING Failure to follow WARNING instructions could CAUTION: A CAUTION indicates spe to the out- board motor. precautions that must be taken to avoid damay NOTE: ANOTE provides key information to make procedures easier or clearer. IMPORTANT: This part has been subjected to change of specification during production.HOW TO READ DESCRIPTIONS 1. A disassembly installation job mainly consists of the exploded diagram (. 2. The numerical figures represented by the number (2) indicates the order o' the job steps. 3. The symbols represented by the number @ indicates the contents and notes of the job. For the meanings of the symbols, refer to the next page(s). 4. The REMOVAL AND INSTALLATION CHART @ is attached to the exploded diagram and explains the job steps, part names, notes for the jobs, etc. 5. The SERVICE POINTS, other than the exploded diagram, explains in detail the items difficult to explainin the exploded diagram or REMOVAL AND INSTALLATION CHART, the Service points requiring the detailed description © ,etc, aa 5 “RES {CED 572 SYMBOLS Symbols @ to © are designed as thumb- tabs to indicate the content of a chapter. @ General information @ Specifications @ Periodic Inspection and Adjustment @ Fuel System @ Power Unit © Lower Unit @ Bracket Unit @ Electrical System © Trouble-analysis Symbols (9 to @ indicate specific data: ® Special Tool © Specified liquid @ Specified engine speed @ Specified torque @ Specified measurement ® Specified electrical valve {Resistance (0), Voltage (V), Electric current (all Symbol @ to @ in an exploded diagram in- dicate grade of lubricant and location of lu- brication point: ® Apply Yamaha 2-stroke outoboard motor oil @ Apply Yamaha gear-case lubricant @ Apply molybdenum disulfide oi! @ Apply water resistant grease (Yamaha grease A, Yamaha marine grease) Symbols @ to @ in an exploded diagram indicate grade of sealing or locking agent, and location of application point: @® Apply Gasket maker? ) Apply LOCTITE® No. 271 (Red LOCTITE) @ Apply LOCTITE® No. 242 (Blue LOCTITE) ® Apply LOCTITE® No. 572 NOTE: In this manual, the above symbols may not be used in every case.INDEX 0) iy J GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL AND LUBRICATION SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT ELECTRICAL SYSTEM TROUBLE-ANALYSIS Pa m|—,|| @ Cc vu a = wo = ég|-> | | 1) 3 Al 2 ie 2 Gs mes) x 9 188)CHAPTER 1 GENERAL INFORMATION IDENTIFICATION SERIAL NUMBER....... 2 STARTING SERIAL NUMBERS... SAFETY WHILE WORKING..........0. FIRE PREVENTION ..... VENTILATION .... SELF-PROTECTION Tina OILS, GREASES AND SEALING FLUIDS ... GOOD WORKING PRACTICES........ DISASSEMBLY AND ASSEMBLY... SPECIAL TOOLS MEASURING «0000 . REMOVAL AND INSTALLATIONIDENTIFICATION IVa PAYS D'ORIGINE JAPON IDENTIFICATION SERIAL NUMBER The serial number of the outboard motor is stamped on the label attached to the upper part of the swivel bracket. NOTE: For USA model: Asan antitheft measure, a special label on which the outboard motor serial number is stamped is bonded to the upper part of the swivel bracket. The label is specially treated so that peeling it off causes cracks across the serial number. @ Model name ® Approved model No. @ Transom height @ Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as follows: Tpproved | STARTING eee model No._| SERIAL No 28 6At 170254~ 20 ere (027093- 14SAFETY WHILE WORKING ce 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 (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do no: smoke while handling petrol, and keep it away from heat, sparks, and open flames. VENTILATION Petroleum vapor is heavier than air and if inhaled in large quantities will no support life. Engine exhaust gases are harmful to breathe. When test-running an engine indoors, maintain good ventilation. SELF-PROTECTION Protect your eyes with suitable safety spectacles or safety goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves or protective shoes if appropriate to the work you are doing OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha.SAFETY WHILE WORKING 1:3 Under normal conditions of use, there should be no hazards from the use of the lubricants men- tioned in this manual, but safety is all-important, and by adopting good safety practises, any riskis minimized, ‘Asummary 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. 8. Avoid skin contact with lubricants; do not, for ‘example, place a soiled wiping-rag in one’s pocket. 4, Hands, and any other part of the body which have been in contact with lubricants or lubri- cant-contaminated clothing, should be thor- oughly washed with hot water and soap as soon as practicable. 5. To protect the skin, the application of a suitable barrier cream to the hands before working is recommended. 6. A supply of clean lint-free cloths should be available for wiping purposes. GOOD WORKING PRACTICES 1. The right tools Use the special tools that are advised to protect parts from damage. Use the right tool in the right manner- don't improvise. 2. Tightening torque Follow the torque tightening instructions. When tightening bolts, nuts and screws, tighten the larger sizes first, and tighten inner-positioned fixings before outer-posi- tioned ones.1-4 SAFETY WHILE WORKING ce 3. Non-reusable items ‘Always use new gaskets, packing, O-rings, split-pins and circlips etc. on reassembly. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed-air on disas- sembling them. 2. Oil the contact surfaces of moving parts on assembly. 3. After assembly, check that moving parts operate normally. 4, Installbearings with the manufacturer's mark- ings on the side exposed to view, and liber- ally oil the bearings. 5. When installing oil seals, apply alight coating of water-resistant grease to the outside di- ameter,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. NOTE: *For U.S.A. and Canada, use part number starting with “YB-", "YU-" or “YW-”. “For others, use part number starting with “90890-”. SQ?Re SPECIAL TOOLS MEASURING Tool No. USK and Gani iadal Except for USA and Canada (b) Use for Tachometer ‘Yu-08036-A_| 90890-06760 Idle speed [Dynamic spark tester ‘ym.4487 | 90890-06754 Ignition system Pressure tester YB-03595 '90890-06762 Lower case [Dial indicator ‘Yu-03097 90890-01252 Backlash [Backlash indicator 'YB-06265, "90890-06265, Backlash [Magnetic flexible stand Yu-34481 "90890-06705 Backlash Backlash adjusting plate 'YB-07008 Backlash Thickness gauge YU-26900.9 ‘Shimming Digital multimeter YU-34899-A Electrical Pocket tester REMOVAL AND INSTALLATION Tool name "Tool No- TSR and Canada] ExcoptTor USE and Ganada () Electrical Use for [Bearing separator 8.06219 '90890-06534 ‘Crank shaft bearing Fiywheet holder YB.06139 ‘90890-06522 Flywhee! Flywheel puller 8.06117 '90890-06521 Flywheel [Stopper quide plate NAL '20890-06501 Forward gear bearing Bearing outer rave puller clow NA. 90890-06535 Forward gear bearing [Stopper quide stand NA. '90890-06538 Forward gear bearing [Slide hammer set 'YB-06096 NAL Forward gear bearing Bearing installer ‘Y-06014 "90890-06638, Forward gear bearing Driver rod = S Drive shaft bushing remover NA, YB-06027 "20890-06606. ‘90890-06651 Forward gear bearing Drive shaft bushing [Bushing installer 8.06020 ‘90890-06601 Drive shat bushing Needle bearing installer YB.06169 NA, Drive shaft bushing Driver rod = YB-06071 {90890-06605 Drive shaft bushing Driver rod - M10 YB-06229 90890-06652 16 Forward gear Dearing. |orve shat bushingCED CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS. eB MAINTENANCE SPECIFICATIONS ENGINE cre LOWER .... ELECTRICAL... DIMENSION........ TIGHTENING TORQUE...... 2-6 ‘SPECIFIED TORQUE 26 26 GENERAL TORQUE ...sPec| v= | GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS ‘Approved model No. DIMENSION: Over.all length Overall width Overall height Boat transom height mm (in) mm (in) mm (in) mm (in) WEIGHT: Weight (PL) S. kg (by 10 (22.0) 9.8 (21.6) PERFORMANCE: ‘Output (180) KW (9) rom Full throttle operating range om L(US gal , mp Maximum fuel consumption |b OnSite 1.5 (2)/ 4500 4000-5000 1.3 (0.34,0.29) at 6000 1.4 (0.37,0.81) at 5000 ENGINE: Type Number of cylinder Bore X Stroke Total displacement Compression ratio Number of carburetor Intake system Scavenging system Control system ‘Starting system Ignition system Enrichment systom ‘Advance type ‘Spark plug (NGK) for CANADA and Europe Exhaust system Cooling system Lubrication system ‘mm (in) ‘om? (cuin) 2 stroke 1 38.0 96.0 (1.54 x 1.42) 43 (2.62) 7.40 42.0% 96.0 (1.65% 1.42) 50 (3.05) 8.30 1 Reed valve Loop charge Tiler contro! Manual col ‘Choke valve Fixed Under water Water Pre-mixed fuel & Oil 24SPEC] u= | GENERAL SPECIFICATIONS tom FUEL AND LUBRICATION: Fuel type Fuel tank capacity Engine oil type / Grade Gear oll ype Gear oll quantity Mixing ratio LS gal, Imp gal) ‘om? (US oz, Imp 02) Reguler gasoline 1.2 (0.32,0.26) Tews 2.Stroke outboard motor oil/ TCW3 48 (1.52,1.58) 100:1(GEN 50:1) BRACKET: Tit Angle Tiltup Angle ‘Steering Angle degree degree degree 4.8,12,16 B 360 [ORIVE UNIT: Gear Shift Position Gear Ratio Gear Type Clutch Type Propeller Direction Propeller Drive System Propeller Series Mark 22 Forword 2.08 (27/13) Zerol gear NA Clockwise Shear Pin AsPec| w= | MAINTENANCE SPECIFICATIONS ¢ MAINTENANCE SPECIFICATIONS ENGINE tem Unit [CYLINDER HEAD: Warpage limit mm (in) 0.1 (0.004) ICYLINDER: Bore size Wear limit Taper limit ut of round mit ‘mm (in) ‘mm (in) mm (in) mm (in) 39.00-39.02 (1.595~1.536) 39.10 (1.54) 42,00-42.02 (1.654-1.654) 42.10 (1.66) (0.08 (0.003) 0.05 (0.002) PISTON: Piston clearance Limit Diameter ‘Measuring point H Pin boss inside diameter Ring groove clearance Top Ring groove clearance 2nd Over size diameter 1st" Over size diameter 2nd mm (in) mm (in) mmm (in) mm (in) mm (n) mm (a) mm (in) mm (in) mm (in) 0.080-0.085 (0.0012-0.0014) 0.085 (0.0033) 3B.967- 38.586 (1.5341~1.5949) i_970-42.000 (1.6524-1.6535) 1010.39) 10,004 ~ 10.015 (0.9999 ~ 0.3943) (0.03-0.07 (0.007-0.008) 10.02-0.06 (0.00%-0.002) '0.03-0.07 (0.001-0.003) 39.25 (1.545) 39.50 (1.555) “42.25 (1.663) 42.50 (1.673) PISTON PIN: Diameter mm (in) 9.996- 10.000 (0. :3935-0.3937) PISTON RING (TOP): Type Dimensions (B xT) End gap (Installed) Limit mmm (in) mm (in) ‘mm (io) Plain Keystone 2.0K1.8 (0.0830.07) 0.10-0.30 (0.004-0.012) 0.50 (0.020) PISTON RING (2nd): Type Dimensions (B x) End gap (Installed) Limit mm (in) mm (in) mm (in) 2.0x1.8 (0.08%0.07) 0.10-0.30 (0. .004~0.012) 0.50 (0.020) CONNECTING ROD: ‘Small end diameter mm (in) 14.000-14.011 (0.5512-0.5516) CRANK SHAFT ASSEMBLY: (Crank width A unout limit D Big end side clearance E ‘Small ond axial play limit F mm (i) ‘mm (in) ‘mm (in) mm (in) 27.90-27.98 (1.098-1.100) (0.02 (0.001) 0.30-0.60 (0.012-0.024) 2.0 (0.08) REED VALVE: Valve stopper height Valve warpage limit “Except for U.S.A. mm (in) mm (in) 6,020.2 (0.2420.01) 0.3 (0.01),sPec| v= | MAINTENANCE SPECIFICATIONS Identification mark Float height 17.3205 (0.6820.02) Valve seat size 1.4 (0.06) Main jet (M..) Jet needie (J.N.) Cut away (C.A,) O75 [ENGINE SPEED: Idle speed 1,150#50 RECOIL STARTER: Starter rope length 1,900 (51.2) 2 F803 LOWER tem [GEAR BACKLASH: Pinion - Forward (S.S.T.) 027-099 Pinion shims. 03,04, 05 Propeller size (Aluminium) Ox T4 XAT Bx Ta KER Sx TE XS - Bx7-114 x5-172 Propeller sizo (Plastic) xT x4 TTest propeller t '90880-01601,YB-1601 4,400~4,700 24MAINTENANCE SPECIFICATIONS ELECTRICAL tom Unit 25 26 IGNITION TIMING: Ignition timing (ful advanced) | Degree BT.D.C. 1822 Piston position (full advanced)| mm (in) B.I.D.C. 1.11 +0.26 0.23 (0.044 +0.010 -0.009) [STATOR ASSEMBLY: Charge coil resistance (color) 916.8-987.2 (Brown-Earth) Pole number 4 ICOTUNTT: NOTE: — *" +" indicates that the pointer deflects once and returns to specification. co” mark is discontinuity. IGNITION COI: ‘Type (single / twin) Single Primary coll resistance (color) 0.18-0.24 (Orange-Black) Secondarily collresistance | _ ka (color) 2.72-8.68 (Black/White-High tension cord) |SPARK PLUG CAP: Type Standard ‘Type (for Canada and Europe] Resistance: = [SPARK PLUG: 0.6~0.7 (0.024~0.028) DIMENSION 497 (16.4) 100 (3.9) 95 (3.7) 23,(0.9) 60 (2.4) 25spec] v= | TIGHTENING TORQUE 6 TIGHTENING TORQUE SPECIFIED TORQUE Part to tightened Part name Tightening torque Nm meKg feb ENGINE: Flywheel magneto, 5 45 32, Intake manifold 05 36 1.0 72 Reed valve 04 07 [Spark plug 25 18 (Cylinder head 05 36 1.0 72 (Crank case 05 36 1.0 72 BRACKET: [Clamp bracket ‘General torque specifications Nm. mkg feb, 5.0 8.0 18 36 43 0.5 08 18 3.6 43 3.6 58 13 25 31 16 GENERAL TORQUE This chart specifies the torques for tightening standard fasteners with standard clean dry ISO threads at room temperature. Torque specifica- tions for special components or assemblies are given in applicable sections of this manual. To avoid causing warpage, tighten multifasteneras- semblies in criss-cross fashion, in progressive stages until the specified torque is reached.CHAPTER 3 RERIODIC INSPECTION AND ADJUSTMENBT MAINTENANCE INTERVAL CHART ... PERIODIC SERVICE .. CONTROL SYSTEM Idle speed adjustment... LOWER UNIT .... Gear oil = Lower unit leakage check GENERAL Anode .. Spark plug Grease pointsMAINTENANCE INTERVAL CHART CED MAINTENANCE INTERVAL CHART The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed. Tata Every Remarks TOhours | SOhours | 100 hours | 200 hours (Break-in) | (3 months) | (6 months) |_(1 year) Fuel hose inspection Fuel tank Cleaning Fuel cock filter element Cleaning [Cleaning Inspection Inspection Exhaust leakage Inspection [Cooling water passage _|Cleaning inspection/Adjustment (Change Lower unit leakage Inspection [Cotter pin and shear pin JInspection Inspection Inspection [Cleaning / Adjustment Replacement Wiring and connector | Adjustment/Reconnect, Botts and nuts Retightening Grease points IGreasing 34PERIODIC SERVICE <> PERIODIC SERVICE CONTROL SYSTEM Idle speed adjustment 1. Measure: “Idle speed Out of specification -+ Adjust. Idle speed: CY “102 50 pm Measuring steps: Start the engine and allow it to warm up for a few minutes. Attach the tachometer to the high tension lead. Tachometer: ‘YU-08036-A/90890-06760 2. Adjust *Idle speed Adjustment steps: Start the engine and allow it to warm up for a few minutes. *Attach the tachometer to the high tension lead. Tachometer: ‘YU-08036-A/90890-06760 “Adjust the idle adjusting screw () In or out until specified Idle speed is obtained. Turning in — Idle speed becomes higher. Turning out —~ Idle speed becomes lower. LOWER UNIT Gear oil 1. Check: “Gear oil Milky oil -* Replace the oll seal. Slag oil + Check the gear, bearing and dog. 32PERIODIC SERVICE <> 2. Check: “Gear oil level Oil level is low -> Add oil to proper level. 3, Replace: *Gear oil Replacement steps: *Place the outboard motor in an upright pos “Place a pan under the drain plug, +Remove the drain plug ©, then the oil level plug @ and drain the oil thoroughly. +Fill the gear oil through the drain hole unti it overfiows at the level hole. Recommended oil GEAR CASE LUBE (USA) or Hypoid gear oil, SAE #90 Oil capacity: 45 cm? (1.52 US 02, 1.58 Imp oz) Refit the oll level plug and then oll drain plu Lower unit leakage check 1. Check: “Pressure holding Pressure falls > Inspect seals and compo- nent parts, Checking steps: “Attach the tester to the oil-level hole. Pressure tester: YB-03595/90890-06762 ply the specified pressure. Pressu < uv 100 kPa (1.0 kg/em®, 14.2 psi) “Checkthat the pressure isheldatthe specified pressure for 10 seconds Do not over-pressurize. Excess pressure may cause the air to leak out.PERIODIC SERVICE 34 GENERAL ‘Anode 1. Inspect: *Anode Scale — Clean Oi/grease + Clean Corrode + Replace CAUTION: Do not oil, grease or paint the anode, or the function of the sacrificial anode will be spoiled. Spark plug 1. Inspect *Electrode Wear/Damage > Replace insulator color @ Distinctly different color + Check the en- gine condition Color guide: Normal: Medium to light tan color Whitish color: Lean fuel mixture *Plugged fuel mixture ir leak *Wrong setting Blackish color : Electrical malfunction “Defective spark plug “Defective ignition system “Rich mixture “Excessive idling 2. Clean: *Spark plug Clean the spark plug with a plug cleaner or wire brush.PERIODIC SERVICE 3. Inspect: «Spark plug type [AS] standard spark plug: a 2B: BSHS For CANADA and Europe: BRSHS 2C: B7HS 3. Measure: Electrodes gap (a) Out of specification» Regap. LAL iam ase -oxin | (A 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) 4, Tighten: *Spark plug NOTE: Before installing the spark plug, clean the gasket surface and the plug surface. ‘Spark plug: 25Nm (2.5m+kg, 18ft+lb) NOTE: Ia torque wrench is not available, a good esti- mate of the correct torque is a further 1/4 to 1/2 turns © on finger-tightened @ spark plug. Grease points 1. Apply: “Water resistant greaseCHAPTER 4 FUEL SYSTEM FUEL TANK AND FUEL COCK EXPLODED DIAGRAM. = REMOVAL AND INSTALLATION CHAR’ SERVICE POINTS Fuel hose inspection Fuel tank inspection Fuel cock inspection CARBURETOR REMOVAL EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART..... CARBURETOR ......-.-. EXPLODED DIAGRAM hen REMOVAL AND INSTALLATION CHART...... SERVICE POINTS... Carburetor inspectionFUEL TANK AND FUEL COCK L} FUEL TANK AND FUEL COCK EXPLODED DIAGRAM FUE Geese, ges = tl,| | FUEL TANK AND FUEL COCK REMOVAL AND INSTALLATION CHART Procedure/Pant name FUEL TANK AND FUEL COCK REMOVAL Screw ‘Screw (with washer) ‘Screw (with washer) ‘Screw (with washer) Plug cap cover Apron (left) ‘Apron (right) Bolt (with washer) Recoil starter assembly Clip Fuel hose (fuel cock - carburetor) Nut ‘Spring washer Plain washer Bolt Fuel tank assembly Grommet Fuel cock Service points Follow the left “Step” for removal. 6x 25mm 6x 40mm. 5x10mm Reverse the removal steps for installation. SERVICE POINTS Fuel hose inspection 1. Inspect: “Fuel hose Crack/Leak/Damage —* Replace. Clog— Clean. Fuel tank inspection 1. Inspect: “Fuel tank Fuel tank cap Crack/Leak/Damage —* Replace. Dirt + Clean. Fuel cock inspection 1. Inspect: *Fuel cock filter element Crack/Leak-+ Replace. Clog —* Clean.FUEL | | CARBURETOR REMOVAL CED CARBURETOR REMOVAL EXPLODED DIAGRAMProcedure/Part name | CARBURETOR REMOVAL REMOVAL AND INSTALLATION CHART Service points ‘CARBURETOR REMOVAL Apron Stop switch lead (white) Screw Ground lead (black) Clip Fuel hose (fuel cock - carburetor) Screw Carburetor assembly Screw Throttle lever knob Screw Silencer cover assembly Chock knob O-ring Screw Spring Plate Circtip Pin Accelation arm Bolt (with washer) Throttle lever link Carburetor assembly SILENCER COVER DISASSEMBLY Nut Ground lead Stop switch Bracket Silencer cover Follow the left “Step” for removal. Refer to "FUEL TANK AND FUEL COCK’. 5x8mm Reverse the removal steps for installation.| CARBURETOR ce CARBURETOR EXPLODED DIAGRAMProcedure/Part name CARBURETOR DISASSEMBLY Carburetor assembly Screw Clamp ‘Nut Spring washer Plate washer Choke valve shaft Choke valve Drain screw Gasket Throttle screw Mixing chamber screw | Throttle bar barrel Throttle valve Spring seat Spring Jet needle Circtip Throttle screw } Throttle link bracket Cap Throttle bar Spacer Screw Float chamber Float chamber gasket Screw Float Float pin Needle valve Main jet Main nozzle Idle adjusting screw Spring Carburetor body Oxring ‘Service points Follow the left “Step” for removal. Refer to “CARBURETOR REMOVAL”. NOTE: Loosen the throttle screw. Reverse the removal steps for installation.SERVICE POINTS CAUTION: Do not use steel wire for cleaning the jets as this may enlarge the jet diameters and seri- ously affect performance. Carburetor inspection 1. Inspect: “Carburetor body Crack/Damage + Replace. Contamination — Clean. 2. Inspect: sJet needle Bend/Wear -> Replace. 3. Inspect: “Main jet “Main nozzle Contamination — Clean. 4. Inspect: *Needle valve Grooved wear -* Replace. 5. Inspect: “Float Crack/Damage > Replace. 6. Measure: +Float height @ Out of specification —+ Fold the tab ©) to adjust float arm height. [AS Float height: PA 17.3 20.5 mm (0.68 + 0.02 in) NOTE: *The float should be resting on the needle valve, but not compressing the needle valve. *Take measurement at the end surface of the float opposite to its pivoted side. 47CHAPTER 5 POWER UNIT POWER UNIT REMOVAL EXPLODED DIAGRAM. REMOVAL AND INSTALLATION CHART ....s-cssesensen RECOIL STARTER... EXPLODED DIAGRAM. ...ee0 REMOVAL AND INSTALLATION CHART SERVICE POINTS cn - ‘Sheave drum removal Spiral spring removal Drive plate inspection .... Drive pawl and spring inspection. Sheave drum inspection Spiral spring inspection Starter rope inspection .. Starter rope installation Sheave drum installation .. Spiral spring setting ... Recoil starter checking FLYWHEEL MAGNETO AND MAGNETO BASE ........csecsnesnnninnsn 57 EXPLODED DIAGRAM... ae : : 5-7 REMOVAL AND INSTALLATION CHART eneeeeeenr 8, ‘SERVICE POINTS..... 5-8 Flywheel magneto removal 58 ELECTRICAL UNIT EXPLODED DIAGRAM... REMOVAL AND INSTALLATION CHART .. REED VALVE ..... - EXPLODED DIAGRAM .....cseoro 5-12 REMOVAL AND INSTALLATION CHART . 5-13 SERVICE POINTS... 5-13 Reed valve inspection ..CYLINDER HEAD EXPLODED DIAGRAM. = REMOVAL AND INSTALLATION CHART SERVICE POINTS... Cylinder head inspection CRANK CASE AND CYLINDER BODY EXPLODED DIAGRAM............. REMOVAL AND INSTALLATION CHART .. SERVICE POINTS..... ee Cylinder body inspection Piston to cylinder clearance Cylinder body and crankcase installation .. CRANK SHAFT AND PISTON .. 5-20 EXPLODED DIAGRAM. 5-20 REMOVAL AND INSTALLATION CHART .. 5-21 SERVICE POINTS.... Bearing removal... Piston inspection . Piston pin and small end bearing inspection Piston ring inspection .. Crankshaft inspection .. Piston and piston ring installationPowel Sz POWER UNIT REMOVAL <> POWER UNIT REMOVAL EXPLODED DIAGRAMPOWER UNIT REMOVAL CED REMOVAL AND INSTALLATION CHART “Service points | POWER UNIT REMOVAL Follow the left “Step” for removal. Apron, Refer to “FUEL TANK AND FUEL COCK” section in chapter 4. Bolt (with washer) 6x 25mm NOTE: Tighten the bolts in two steps of torque. Engine unit NOTE: Film-coat the exhaust guide mating surface with Gasket Marker or equivalent. Dowel pin Upper case gasket Reverse the removal steps for installation. 52RECOIL STARTER cE RECOIL STARTER EXPLODED DIAGRAMRECOIL STARTER e REMOVAL AND INSTALLATION CHART Procedure/Part name ‘Service points: RECOIL STARTER DISASSEMBLY —_—Follow the left “Step” for removal. Recoil starter assembly Refer to “FUEL TANK AND FUEL COCK” ‘section in chapter 4. Bolt Drive plate Drive paw! spring Drive paw! Spring Sheave drum Spiral spring When installing the new spiral spring, do not cut the wire holding the spring. When reusing the spiral spring, set the leading end first in the case and then fit one turn each time. Starter handle Rope 4,300 mm Starter case Reverse the removal steps for installation. SERVICE POINTS Sheave drum removal 1. Tur: *Sheave drum Turn the sheave drum clockwise until the spiral spring is free. NOTE: “Tum the sheave drum so that the cutaway on the outer surface of the sheave drum faces toward the starter handle. Pass the starter rope through the cut.RECOIL STARTER 55 2. Remove: *Sheave drum POTS When removing the sheave drum, be sure to turn the sheave drum upside downto prevent the spiral spring from popping up at you. NOTE: Insert a standard screwdriver into the hole in the sheave drum, and remove the spiral spring from the sheave drum by pushing the spring. Spiral spring removal 1, Remove: *Spiral spring Be careful so that the spiral spring does not pop out when removing it. Remove it by al- lowing it out one turn of the winding each time. Drive plate inspection 1. Inspect: “Drive plate Crack/Damage — Replace. Drive pawl and spring inspection 1. Inspect: *Drive paw! Crack/Wear/Damage —* Replace. Drive pawl spring Broken/Bent/Damage — Replace. Sheave drum inspection 1, Inspect: *Sheave drum Crack/Damage — Replace. Spiral spring inspection 1. Inspect: Spiral spring Broken/Bent/Damage —* Replace.RECOIL STARTER Starter rope inspection 1. Inspect: Starter rope Fray/Wear/Damage -* Replace. NOTE: When replacing the rope, cut it to the specified length and bum the rope end toprevent the end from frayed. (ZT starter rope length: KAY 1,300 mm (51.2 in) Starter rope installation 1. Install: “Starter rope NOTE: Insert the rope through the rope holes and knot the end, *Wind the rope 3-1/2 tus around the sheave drum. *Place the rope at the cutaway. Sheave drum installation 1. Install: *Sheave drum *Spiral spring NOTE: Position the inner end of the spiral spring on the retainer post of the sheave drum. Spiral spring setting 1. Set: *Spiral spring NOTE: Wind up the spring 3 tums counterclockwise with the starter rope. Recoil starter checking 1. Check: Starter operation Unsmooth operation —> Repair.powr| S| FLYWHEEL MAGNETO AND MAGNETO BASE CE > FLYWHEEL MAGNETO AND MAGNETO BASE EXPLODED DIAGRAM 45 Nm (4.5 mekg, 32 ft-lb)FLYWHEEL MAGNETO AND MAGNETO BASE CE> REMOVAL AND INSTALLATION CHART Procedure/Part name FLYWHEEL MAGNETO AND ‘Follow the left “Step” for removal. MAGNETO BASE REMOVAL Recoil starter assembly Refer to "FUEL TANK AND FUEL COCK” section in chapter 4. Screw 6x12mm Starter pulley Hole cover Flywheel nut Washer Flywheel magneto Woodrut key Bolt Base assembly MAGNETO BASE DISASSEMBLY — Screw Charge coil Base plate Reverse the removal steps for installation. SERVICE POINTS Flywheel magneto removal 1, Remove: +Flywheel nut [34] Flywheel holder: |7__ | ¥B-06139 / 90890-06522 | For USA and Canada Except for USA and Canada CAUTION: ‘The major load should be carried in the direc- tion of the arrows. Ifnot, the holder may easily slip off. 58FLYWHEEL MAGNETO AND MAGNETO BASE E> 2, Remove: “Flywheel magneto Flywheel puller: YB-06117 / 90890-06521 A) For USA and Canada Except for USA and Canada CAUTION: To prevent damage to the engine or tools, screw in the flywheel magneto- puller set- bolts evenly and completely so thatthe puller Plate is parallel to the flywheel. 59powrl Se | ELECTRICAL UNIT - ELECTRICAL UNIT EXPLODED DIAGRAM6 ELECTRICAL UNIT REMOVAL AND INSTALLATION CHART Procedure/Pant name ay Service points ELECTRICAL UNIT REMOVAL ~| Follow the left “Step” for removal. ‘Apron Refer to “FUEL TANK AND FUEL COCK" section in chapter 4. Clamp Pink and black leads Spark plug cap Bolt (with washer) 6x 20mm Ignition coil Charge coil lead (brown) Stop switch lead (white) Screw Ground lead (black) Bolt (with washer) CDI unit 1 2 3 4 5 6 7 8 9 3 Reverse the removal steps for installation. 5-11REED VALVE <>) REED VALVE EXPLODED DIAGRAM / 1st_[5 Nm (0.5 mckg, 3.6 ftlb) 2nd | 10 Nm(1.0 mekg, 7.2 fib)REED VALVE > REMOVAL AND INSTALLATION CHART EED VALVE REMOVAL Follow the left “Step” for removal. Recoil starter assembly Refer to "FUEL TANK AND FUEL COCK” | section in chapter 4, | Refer to “CARBURETOR REMOVAL" section in chapter 4. 4 | NOTE: | | Carburetor assembly | | | Tighten the bolts in sequence and in two | 1 | Bolt | steps of torque. Stay | Reed valve assembly | Reed valve gasket | REED VALVE DISASSEMBLY | ‘Screw (with washer) Valve stopper Reed valve | Reed valve body | | Reverse the removal steps for installation. SERVICE POINTS Reed valve inspection 1. Inspect: *Reed valve Crack/Damage -> Replace. 2. Measure: “Valve warpage @ Out of specification -» Replace. Valve warpage limit: (AX 2.3 mm (0.01 in) 3. Measure: *Valve Stopper height ©) Out of specification + Replace. [AS] vaive stopper height: 6.0 + 0.2 mm (0.24 + 0.01 in) 5-13PO = Powe GE CYLINDER HEAD CED CYLINDER HEAD EXPLODED DIAGRAM [1st_[ 5 Nm (0.5 mekg, 3.6 ft-lb) [2nd | 10 Nm(1.0 mekg, 7.2 ft-lb)CYLINDER HEAD cE REMOVAL AND INSTALLATION CHART Procedure/Part name ay Service points CYLINDER HEAD REMOVAL Follow the left “Step” for removal Fuel tank Refer to "FUEL TANK AND FUEL COCK” section in chapter 4. Bolt (with washer) 6x 10mm Fuel tank protector ‘Spark plug cap Spark plug Bolt (with washer) 6x 25mm Cylinder head NOTE: Tighten the bolts in sequence and in two steps of torque. Cylinder head gasket Reverse the removal steps for installation. SERVICE POINTS Cylinder head inspection 1. Inspect: “Water jacket Material deposi/Corrosion + Clean. “Cylinder inner surface Score marks —* Clean. Use #600 ~ 800 grt wet sandpaper. CAUTION: Do not scratch the mating surfaces of the cylinder head and cylinder body. 2, Measure: “Cylinder head warpage Use a straightedge and feeler gauge. Out of specification Rebore or replace. [ZS] warpage limit: (AY 0.1 mm (0.004 in) Resurfacing steps: Place a 400 ~ 600 grit wet sandpaper on the surface plate. “Resurface the head using a figure-eight sanding pattern. NOTE: Rotate the head several times to avoid remov- ing too much material from one side.POWR _ own] CRANK CASE AND CYLINDER BODY ceE> CRANK CASE AND CYLINDER BODY EXPLODED DIAGRAM 5 Nm (0.5 m-kg, 3.6 ft-lb) 10 Nm(1.0 m-kg, 7.2 ft-lb) 5-16CRANK CASE AND CYLINDER BODY ce REMOVAL AND INSTALLATION CHART Procedure/Part name ‘Service points, CRANK CASE AND CYLINDER Follow the left “Step” for removal BODY REMOVAL Power unit Refer to "POWER UNIT REMOVAL" . Magneto base assembly Refer to “FLYWHEEL MAGNETO AND MAGNETO BASE” . Reed valve Refer to “REED VALVE” . Cylinder head Refer to “CYLINDER HEAD” Clip Drain less hose Bolt (with washer) 6x40 mm Clamp Crank case Cylinder body NOTE: Film-coat the crank case mating surface with Gasket Marker or equivalent. Dowel pin ‘Check valve Hose joint Taper plug Reverse the removal steps for installation. SERVICE POINTS. Cylinder body inspection 4. Inspect: *Water jacket Material deposit/Corrosion -* Clean. “Cylinder inner surface Score marks — Clean. Use #600 ~ 800 grit wet sandpaper. CAUTION: Do not scratch the fitting surfaces of the crank case and cylinder body. 2. Inspect: “Exhaust wall Crack/Damage —* Replace. Carbon deposit + Clean. Use a round scraper. 5-17CRANK CASE AND CYLINDER BODY ce 3, Measure: *Cylinder bore “D” Use cylinder gauge. Out of specification > Rebore or replace. NOTE: — Measure the cylinder bore in parallel. Then, find the average of the measurement. Cylinder bore: 2B 39.00 ~ 39.02mm (1.535 ~ 1.536 in) 2C 42.00 ~ 42.02 mm (1.654 ~ 1.654 in) Wear limit: 2B 39.10 mm (1.54 in) 2C 42.10 mm (1.66 in) Taper limit “T": 0.08 mm (0.003 in) Out of round limit : 0.05 mm (0.002 in) Maximum Dia. (D1 ~ D6) (Maximum D1 of D2) - (minimut DS or D6) ‘A: 10 mm (0.4 in) below the cylinder top B: 5mm (0.2 in) above the exhaust port C: 5mm (0.2 in) below the scavenging port Piston to cylinder clearance 1. Calculate: “Piston clearance Cc ) ‘Out of specification — Replace piston and Le4 piston ring and/or cylinder. Piston clearancé 0.030 ~ 0.035 mm (0.0012 ~ 0.0014 in) Limit: 0.085 mm (0.0033 in) 5-18CRANK CASE AND CYLINDER BODY Cylinder body and crankcase installation 1. Install: “Cylinder body “Crankshaft and piston NOTE: *Align the piston ringend gaps with the respective locating pins. «Fitthe bearing locating pins in the cylinder body. 2. Apply: “Gasket maker Onto the mating surfaces of the crankcase and cylinder body, NOTE: *Clean the mating surfaces of the crankcase and cylinder body before applying the Gasket maker. “Gasket maker should be so applied that it does not overflow the mating surtace. 5-19pown| Gz CRANK SHAFT AND PISTON <>) CRANK SHAFT AND PISTON EXPLODED DIAGRAMCRANK SHAFT AND PISTON CED REMOVAL AND INSTALLATION CHART rocedure/Pant name Service points CRANK SHAFT AND PISTON Follow the left “Step” for removal. REMOVAL Crank case Refer to “CRANK CASE AND CYLINDER BODY". Crankshaft assembly NOTE: Remove the crankshaft by lightly tapping it with a plastic hammer. Oil seal Oil seal Plane washer Piston pin clip CAUTION: Always use the new clip. Piston pin ‘Small end bearing Piston NOTE: ‘Align the “UP* mark on the piston crown towards the crank shaft tapered end, Piston ring NOTE: Remove the piston ring from the piston by ‘opening the ring to the least possible width. Bearing cAuno:——™—CS— When installing the bearing, the s cap side should be installed towards the flywheel side. Reverse the removal steps for installation. SERVICE POINTS Bearing removal 1. Remove: “Bearing NOTE: Hold the bearing with the bearing separator, and forth out the crankshaft with a press. Bearing separator: ‘YB-06219 / 90890-06534 521Piston inspection 1. Measure: “Piston diameter“ Use a micrometer. Out of specification + Replace. Piston diameter: 2B: 38.967 ~ 38.986 mm (1.5341 ~ 1.5349 in) 2C: 41.970 ~ 42.000 mm (1.6524 ~ 1.6535 in) Measuring point “H”: 10 mm (0.39 in) Over size piston diameter: 2B 1*: 39.25 mm (1.545 in)* 2: 99.50 mm (1.555 in) 2C 1: 42.25 mm (1.663 in) 2: 42.50 mm (1.673 in) * : Except for U.S.A. 2, Measure: Piston pin boss inside diameter Use a micrometer. Out of specification + Replace. Piston pin boss inside diameter: 10.004 ~ 10.015 mm (0.3939 ~ 0.3943 in) ton pin and small end bearing inspection 1. Inspect: +Piston pin ‘Small end bearing Signs of heat discoloration -+ Replace. Scratch/Damage —* Replace. 2. Measure: “Piston pin diameter Use a micrometer. Out of specification + Replace. iston pin diameter: 9.996 ~ 10.000 mm (0.3935 ~ 0.3937 in) 5-22CRANK SHAFT AND PISTON 3. Check: Free play (when the piston pin is inserted in the piston.) There should be no noticeable for the play. Free play exists + Replace the pin and/or piston. Piston ring inspection 1. Inspect: “Piston ring Break/Damage —* Replace. 2. Measure: “End gap Use a thickness gauge. Out of specification + Replace. End gap: Top 0.10 ~ 0.30 mm (0.004 ~ 0.012 in) 2nd 0.10 ~ 0.30 mm) (0.004 ~ 0.012 in) Measuring point “! 20 mm (0.8 in) NOTE: Install the piston ring into the cylinder. Push the ring with the piston crown. 3. Measure: *Side clearance Use a thickness gauge. ‘Out of specification + Replace piston and/ orring Side clearance: 2B Top: 0.03 ~ 0.07 mm {6} (0.001 ~ 0.003 in) 2nd: 0.03 ~ 0.07 mm (B) (0.001 ~ 0.003 i Top: 0.02 ~ [A] (0.001 ~ 0.002 in) 2nd: 0.03 ~ 0.07 mm [B) (0.001 ~ 0.003 in) 5-23CRANK SHAFT AND PISTON Crankshaft inspection 1. Measure: *Crank width “A” ig end side clearance “E" Out of specification + Replace. Crank width: 27.90 ~ 27.95 mm (1.098 ~ 1.100 in) Big end side clearance: 0.30 ~ 0.60 mm. (0.012 ~ 0.024 in) 2. Measure: “Runout “D” Use a V-blocks and dial gauge. Out of specification + Replace. [A] Runout limit: 0.02 mm (0.001 in) 8. Measure: “Small end axial play Out of specification + Replace. ‘Small end axial play limit: 2.0 mm (0.08 in) 4, Inspect: *Crankshatt bearing Pitting/ Rumbling—> Replace. CAUTION: Do not spin bearing with air blower; this can damage the bearing. 5-24CRANK SHAFT AND PISTON CED Piston and piston ring installation 1. Install: +Piston ring (2nd) *Piston ring (top) TION: *Align the each ring end gap with their locating pins. After mating the rings, check that they move ‘smoothly.CHAPTER 6 LOWER UNIT LOWER UNIT AND PROPELLER . EXPLODED DIAGRAM. REMOVAL AND INSTALLATION CHART SERVICE POINTS . Pipe inspection .. Cotter pin and shear pi Propeller inspection inspection ... PINION GEAR, WATER PUMP AND FORWARD GEAR EXPLODED DIAGRAM. REMOVAL AND INSTALLATION CHART SERVICE POINTS....... Lower case cap inspection Pinion gear inspection Drive shaft inspection .. Insert cartridge and impeller inspection Water pump housing cover inspection Forward gear inspection .. LOWER CASE... 7 EXPLODED DIAGRAM... sesesnsneesen REMOVAL AND INSTALLATION CHART SERVICE POINT Forward gear bearing removal Drive shaft bushing removal .. Bearing inspection Lower case inspection ... Drive shaft bushing installation .. SHIMING coe 6-9 BACKLASH MEASUREMENT ... 89 Forward gear backlash ..LowR] | LOWER UNIT AND PROPELLER e LOWER UNIT AND PROPELLER EXPLODED DIAGRAMLOWER UNIT AND PROPELLER CED REMOVAL AND INSTALLATION CHART ‘Step Procedure/Part name oy "| LOWER UNIT REMOVAL | Follow the left “Step” for removal. 1 | Bolt (with washer) 2 | Lower unit 3 | Pipe 4 5 Plate Dowel pin PROPELLER REMOVAL Cotter pin Propeller Straight pin Reverse the removal steps for installation. SERVICE POINTS Pipe inspection 1, Inspect: “Pipe WeariCrack/Damage — Replace. Cotter pin and shear pin inspection 1. Inspect “Cotter pin “Shear pin Wear/Damage -* Replace Propeller inspection 1. Inspect: “Blade Wear/Crack/Damage —* Replace.Lown] | PINION GEAR, WATER PUMP AND FORWARD GEAR CE~ PINION GEAR, WATER PUMP AND FORWARD GEAR EXPLODED DIAGRAMPINION GEAR, WATER PUMP AND FORWARD GEAR REMOVAL AND INSTALLATION CHART Procedure/Part name Service points "PINION GEAR, WATER PUMP AND Follow the left “Step” for removal. Step FORWARD GEAR REMOVAL | Gear oil Refer to "LOWER UNIT” section in chapter 3 Lower unit Refer to “LOWER UNIT AND PROPELLER’. | Propeller Refer to “LOWER UNIT AND PROPELLER”. Bolt (with washer) 6x 14mm Lower case cap O-ting Oil seal Circlip Pinion giar Plate washer Pinion giar shim Bolt (with washer) Drive shaft Oil seal protector Insert cartridge NOTE: When installing the water pump housing, align the hole in it with the projection in the insert cartridge. Impeller NOTE: ‘When installing the impeller, turn the drive shaft clockwise. Dowel pin Cartridge outer plate Water pump housing cover Oil seal O-ring Dowel pin Water seal Forward gear Forward gear shim Reverse the removal steps for installation, 6-4PINION GEAR, WATER PUMP AND FORWARD GEAR SERVICE POINTS Lower case cap inspection 1. Clean: Lower case cap Use a soft brush and solvent. 2. Inspect: Lower case cap Crack/Damage -* Replace. Pinion gear inspection 1. Inspect: Teeth Wear/Damage — Replace. Drive shaft inspection 1. Inspect: *Drive shaft Wear/Damage — Replace. Insert cartridge and impeller inspection 1. Inspect: «Insert cartridge Impeller Crack/Damage — Replace. Water pump housing cover inspection 1. Inspect: “Water pump housing cover Crack/Damage -> Replace. Forward gear inspection 1. Inspect: *Teeth “Shaft ‘Wear/Damage + Replace 65Lown] | LOWER CASE cE> LOWER CASE EXPLODED DIAGRAMLOWER CASE ce REMOVAL AND INSTALLATION CHART Procedure/Part name LOWER CASE DISASSEMBLY Lower unit Service points Follow the left “Step” for removal. Refer to ‘LOWER UNIT AND PROPEL- LER’. Refer to “PINION GEAR, WATER PUMP ‘AND FORWARD GEAR’. 6x 12mm Forward gear Bolt (with washer) ‘Anode Bearing Oil seal Drive shaft bushing Drive shaft bushing Drive shaft bushing Lower case eVNoanene | Reverse the removal steps for installation. SERVICE POINT Forward gear bearing removal 1, Remove: “Forward gear bearing Slide hammer set: ‘YB-06096 Stopper guide plate: 90890-06501 Bearing outer race puller clow: 90890-06535 ‘Stopper guide stand: 90890-06538 (A) For USA and CANADA (5) Except for USA and CANADA Drive shaft bushing removal 1. Remove: *Drive shaft bushing Drive shaft bushing remover: ‘YB-06027/90890-06651 Driver rod: YB-06229/90890-06652LOWER CASE Bearing inspection 1. Inspect: “Bearing Pitting/Rlumbling + Replace. Lower case inspection 1. Clean: *Gear case Use a soft brush and solvent. 2. Inspect: “Water passage Mineral deposits/Corrosion — Clean. 3. Inspect: sLower case Crack/Damage —+ Replace. Drive shaft bushing installation 1. Install Drive shaft bushing Bearing installer: ‘YB-06027/90890-06651 Driver rod: ‘YB-06229/90890-06652 2. Install: “Drive shaft bushing Bushing installer: ‘YB-06029/90890-06601 Needle bearing installer: YB-06169 Bushing attchment: 90890-06651 (A) For USA and CANADA (5) Except for USA and CANADA.BACKLASH MEASUREMENT CED SHIMING BACKLASH MEASUREMENT NOTE: Do not install the water pump components when measuring the backlash. Forward gear backlash 1. Measure: *Forward gear backlash Out of specification + Adjust. [AS] Backtash: 0.27~0.99mm Measuring steps: Attach the backlash indicator on the drive shaft (11 mm in diameter). 2] Backlash indicator: iO ‘YB-06265/90890-06265, “Attach the dial gauge on the gear case, and make the dial gauge stem contact the mark on the indicator. Backlash adjusting plate: YB-07003 Dial gau YU-03097/90890-01252 Magnetic flexible stand: ‘YU-34481/90890-06705 While pulling the drive shaft and pushing the propelier shaft, slowly turn the drive shaft clockwise and counterclockwise; then, measure the backlash when the drive shaft stops in each direction 692. Adjust: “Forward gear shim NOTE: Adjust the shim to be added or removed accord- ing to specification. Forward gear | Shim thickness backlash Less than To be decreased by| 0.27 mm (0.63 - measurement) 0.47 More than’ To be increased by 0.99 mm (measurement - 0.63) x 0.47 Available shim thickness: 0.30, 0.40 and 0.50 mm 6-10CHAPTER 7 BRACKET UNIT UPPER CASE AND TILLER HANDLE EXPLODED DIAGRAM.....:cscrovo REMOVAL AND INSTALLATION CHART SERVICE POINTS... Soot Pivot shaft bushing inspection Tiller handle inspection .... CLAMP BRACKET............ EXPLODED DIAGRAM. REMOVAL AND INSTALLATION CHART.UPPER CASE AND TILLER HANDLE & UPPER CASE AND TILLER HANDLE EXPLODED DIAGRAMUPPER CASE AND TILLER HANDLE 3) REMOVAL AND INSTALLATION CHART Service points UPPER CASE REMOVAL Follow the left “Step” for removal. Power unit Refer to “POWER UNIT REMOVAL" sec- tion in chapter 5. Lower unit Refer to “LOWER UNIT AND PROPEL- LER’ section in chapter 6. Exhaust guide O-ring Exhaust guide gasket Water tube Water seal Bolt (with washer) Nut ‘Swivel bracket holder Pivot shaft bushing Upper case O-ring ‘Screw (with washer) Upper case cover Upper case cover gasket TILLER HANDLE REMOVAL Nut Bolt Copper washer Tiller handle assembly Copper washer Plate washer Spring washer Bolt (with washer) Plate Handle grip ‘Shear pin holder Reverse the removal steps for installation. SERVICE POINTS Pivot shaft bushing inspection 1. Inspect: ‘*Pivot shaft bushing WearlCrack/Damage -* Replace. Tiller handle inspection 1. Inspect: Tiller handle 7.2 WeariCrack/Damage ~ Replace.CLAMP BRACKET ce CLAMP BRACKET EXPLODED DIAGRAM 16 Nm (1.6 mkg, 11 ft-lb) |CLAMP BRACKET REMOVAL AND INSTALLATION CHART Procedure/Part name Service points CLAMP BRACKET REMOVAL Follow the left “Step” for removal. Upper case assembly Refer to “UPPER CASE AND TILLER HANDLE” Spring pin Wing nut Plate washer Bolt Nut Clamp bracket plate Clamp bracket RH Thrust bracket Plate washer ‘Swivel bracket Plate washer Clamp bracket LH Bott ©CavVonnons aeis Reverse the removal steps for installation. 74CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS... ELECTRICAL ANALYSIS INSPECTION... Low resistance measurement... IGNITION SYSTEM ss IGNITION SPARK GaP ..... SPARK PLUG....... SPARK PLUG CAP... IGNITION COLL... STOP SWITCH CHARGE COIL CDI UNIT sssssssELECTRICAL COMPONENTS ELECTRICAL COMPONENTS ® €Diunit ® Ignition coit 3) : Black : Brown : Orange : WhiteELECTRICAL ANALYSIS cCE> 82 ELECTRICAL ANALYSIS INSPECTION CAUTION: Allmeasuring instruments should be handled with special care, or the correct measure- ment is impossible. ‘On an instrument powered by dry batteries, they should be checked for voltage periodi- cally and replaced, if necessary. NOTE: "O---O" indicates the terminals between which there is a continuity of electricity; i., a closed circuit at the respective switch position. Low resistance measurement ‘When measuring the resistance of 10 @ or less using the digital tester, the correct measurement cannot be obtained because of the testers inter- nal resistance. To obtain the correct value, subtract this internal resistance from the displayed measurement. Correct value = Displayed measurement - Internal] resistance NOTE: The internal resistance of the tester can be ob- tained by connecting both of its terminals.IGNITION SYSTEM E> IGNITION SYSTEM ©0006 B : Black Ignition coil Br: Brown Charge coil Stop switch wowar? CDI unit * White a3IGNITION SYSTEM <> IGNITION SPARK GAP POG “While taking spark check be careful not to touch any connection of lead wires of the ‘ignition spark gap tester”. “When doing the spark test, take special care not to allow leakage from the removed plug cap. “This checkis likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity. 1. Check: *ignition spark gap Out of specification + Replace. [AS] spark gap: (ZA ‘9 mm (0.35 in) Checking steps: *Adjust the spark gap to specification by turning the adjusting knob. 22] Spark gap tester: J YM-34487/90890-06754 *Connect the sparkplug cap to the spark gap tester. “Remove the spark plug from the engine. “Cranking the engine and check sparks of ignition system seen through discharge win- dow.IGNITION SYSTEM > SPARK PLUG Refer to "GENERAL" section in chapter 3. SPARK PLUG CAP 1. Inspect: “Spark plug cap Loosen —* Tighten. Crack/Damage — Replace. 2, Measure: (For Canada and Europe) *Spark plug cap resistance Out of specification + Replace. ‘Spark plug cap resistance: 4.0 ~6.0k2 Replacement steps: (Except for Canada and Europe) +Remove the sparkplug cap by pulling the spark-plug cap. +Remove the plug-cap spring. Strip the insulation cover 5 mm (0.2 in) ®and spread the core wires outward. “Fit the plug-cap spring close to the spread core wires and bend the spring end for clamping. “Install the plug-cap spring into the spark-plug cap. Replacement steps: (For Canada and Europe) *Remove the spark-plug cap by turing the cap counterclockwise. +install the spark-plug cap by turning the cap clockwise until it stops.IGNITION SYSTEM >) IGNITION COIL 1. Inspect: *High tention cord Crsck/Damage + Replace. 2. Measure: “Secondary coil resistance Out of specification Replace. Primary coll resistance : Orange (0) - Black (B) 0.18 ~ 0.24.2 at 20°C (68°F) NOTE: J When measuring the resistance of 10 © or less using the digital tester, the correct measurement cannot be obtained. Refer to "Lower resistance measurement”. 3. Measure: *Secondary coil resistance Out of specification + Replace. ‘Secondary coil resistance : Orange (0)- High tension cord 2.7 ~ 3.7 kQ at 20°C (68°F) NOTE: Remove the sparkplug cap from high tension cord STOP SWITCH 4. Check: “Continuity Out of specification + Replace. Checkind leads color White (W) - Black (B) Push the buttonIGNITION SYSTEM cE> CHARGE COIL 1. Measure: “Charge coil resistance Out of specification + Replace. Charge coll resistance: Brown (Br) - Earth 316.8 ~ 387.2 0 at 20°C (68°F) CDI UNIT 1, Measure: *CDI unit resistance Out of specification + Replace. Pocket tester YU-03112/90890-03112 NOTE: *The resistance values will vary from meter to meter, especially with electronic digital meters. For some testers, polarity of leads is reversed. +" + “indicates that the pointer deflects once and returns to specification. +" mark is discontinuity. 87CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS 2c TROUBLE ANALYSIS CHART ..... 9-4 4TROUBLE ANALYSIS cE TROUBLE ANALYSIS NOTE: Following items should be obtained before “trouble analysi 1.There is no incorrect wiring connection. 2Wiring connections are surely engaged and without any rust. TROUBLE ANALYSIS CHART Reference Relative part Chapter ENGINE WILL NOT STOP POOR PERFORMANCE FUEL SYSTEM Carburetor Idle speed POWER UNIT ‘Compression Reed valve Cyiinder head gasket Piston ring Cylinder block Seal ‘Crank case Piston’ Bearing Water passage LOWER UNIT Gear Water inlet Water pump Propeller shaft Lower case Bracket ofofofofojo Ignition system, 8 oO ° oO ° ° ° ° ° ot