RAW ETc Outboards 108 3T SERVICE MANUAL 7 YAMAHA MOTOR CORPORATION, U.S.A.NOTICE This manual has been prepared by the Yamaha Motor Corporation, U.S.A. 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 Corporation, U.S.A. has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this pub- lication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. 3T SERVICE MANUAL ©1994 Yamaha Motor Corporation, U.S.A. 1st Edition, April 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 with- out the written permission of the copyright holder. Such written permission must also be obtained before any part of this publication is a retrieval system of any nature. Printed in Japan P/N LIT-18616-01-12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 the procedure described may relate to several models, though only one may be illustrated. (The name of the model described will be mentioned in the description.) To help you identify components and understand the correct procedures of disassembly and assembly, exploded diagrams are provided. Steps in the procedures are numbered thus: 1), 2), 3). Parts shown in the illustrations are identified thus: ©, ®, @. REFERENCES These have been kept to a minimum, however, when you are referred to another section of the manual, you are told the page number to go to. SPECIFICATIONS These are given in bold type at each procedure. It is not necessary to leave the section deal- ing with the procedure in order to look up the specifications. Itis important to note the differences in specifications of models. Where a procedure relates to more than one model, the main differences in specifications will be shown in a following table. Model tem 3MH Starting system Manual start Control system Manual control Lubrication system _| Pre-mixedWARNINGS; CSPECIFICATIONS AUTIONS AND NOTES Attention is drawn to the various Warnings, Cautions and Notes which distinguish important information in this manual in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. A CAUTION indicates special precautions that must be taken to avoid damage to the out- board motor. NOTE: ANOTE provides key information to make procedures easier or clearer. IMPORTANT: This part has been subjected to change of specification during production.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-shooting Symbols @ to @ indicate specific data: © Special service too! @ Specified liquid @ Specified grease @ Specified engine speed @ Specified torque © Specified measurement © Specified electrical value [Re tance (Q), Voltage (V), Electric current (al Symbol @ to @ in an exploded diagram indi- cate grade of lubricant and location of lubrica- tion point: © Apply engine oil ® Apply gear oil ® Apply molybdenum disulfide oil @ Apply water resistant grease (Yamaha marine grease A, Yamaha marine grease) Symbols @ to @ in an exploded diagram indicate grade of sealing or locking agent, and location of application point: @ Apply Gasket maker® @ Apply LOCTITE® No. 271 (Red LOCTITE) @ Apply LOCTITE® No. 242 (Blue LOCTITE) @ Apply LOCTITE® No. 572 NOTE: In this manual, the above symbols may not be used in every case.~ INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT | FUEL SYSTEM | POWER UNIT LOWER UNIT ELECTRICAL SYSTEM TROUBLE-SHOOTINGGEN INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION . . . . on WW SERIAL NUMBER . ee wee cece ee ee DA ENGINE SERIAL NUMBER................--5 bees ww STARTING SERIAL NUMBERS. on wee Tl SAFETY WHILE WORKING .. . . 12 FIRE PREVENTION ....... eee VENTILATION 0. ss sscussusenusne 12 SELF-PROTECTION nee nee AZ OILS, GREASES AND SEALING FLUIDS ............... 242 GOOD WORKING PRACTICES dette SPECIAL TOOLS : DISASSEMBLY AND ASSEMBLY........ SPECIAL TOOLS FOR TUNE-UP : SPECIAL TOOLS FOR ENGINE SERVICE SPECIAL TOOLS FOR LOWER UNIT SERVICE . SEALING AGENTS AND LUBRICANTSGEN INFO IDENTIFICATION oT IDENTIFICATION ‘SERIAL NUMBER The serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket. NOTE: For U.S.A. model: As an anti-theft measure, a special label on which the outboard motor serial number is stamped is bonded to the portside of the clamp bracket. The label is specially treated so that peeling it off causes cracks across the serial number. ® Model name @® Approved model No. © Transom height @ Serial number ENGINE SERIAL NUMBER The engine serial number is stamped on the starboard side of the cylinder body. STARTING SERIAL NUMBERS The starting serial number blocks are as fol- lows: [Model | Approved model No. | Serial Number 3MHT LsGEl ES T 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 (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling, and keep it away from heat, sparks, and open flames. VENTILATION Petroleum vapor is heavier than air and itinhaled in large quantities will not 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 of appropriate to the work you are doing OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha.GEN INFO it SAFETY WHILE WORKING 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 risk is minimized. ‘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. 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 suit- able barrier cream to the hands before work- ing 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 pro- tect 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 large sizes first, and tighten inner- positioned fixings before outer-positioned ones.GEN INFO SAFETY WHILE WORKING 14 3. Non-reusable items Always use new gaskets, packings, O-rings, oil seals, split-pins and circlips etc. on reassembly. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed-air on disas- ‘sembling them. 2. Oil the contact surfaces of moving parts on assembly. 3, After assembly, check that moving parts op- erate normally. 4, Install bearings with the manufacturer's markings on the side exposed to view, and liberally oi the bearings. 5. When installing oil seals, apply a light coat- ing of water-resistant grease to the outside diameter.Me T SPECIAL TOOLS SPECIAL TOOLS The use of correct special tools recommended by Yamaha will aid the work and enable accur- ate assembly and tune-up. Improvisations and use of improper tools can cause damage to the equipment SPECIAL TOOLS FOR TUNE-UP Ref. No. Tool name Part number 1 | Compression gauge Yu-33223 2 _ | Tachometer YU-8036-A 3 _| Digital multimeter YU-34899-A 4 | Timing light YM-33277 5 _| CDI tester Yu-91022-B 6 _| Dial gauge set Yu-3097 7 _ | Backlash indicator gauge YB-6265 8 _| Backlash adjusting plate YB-7003 9 | Flexible magnetic dial indicator stand Yu-34481 SPECIAL TOOLS FOR ENGINE SERVICE Ref. No. Tool name Part number 1__| Flywheel magneto holder assembly YB-6139 Universal puller YB-6117 Bearing splitter plate YB-6219 SPECIAL TOOLS FOR LOWER UNIT SERVICE Ref. No. Tool name Part number 1_| Slide hammer & Attachment YB-6096 ‘SEALING AGENTS AND LUBRICANTS Ref. No. Part name Part number 1_| Gasket maker 90790-74001-00 Marine grease LUB-GEARS-14-00 Gear case lube (11 oz) LUB-GEARL-11-00 aloln Yamalube two-cycle outboard oil ACC-11000-07-01 15SPEC! y= CHAPTER 2 SPECIFICATIONS GENEARL SPECIFICATIONS MAINTENANCE SPECIFICATIONS . ... ENGINE ..... ELECTRICAL DIMENSIONS TIGHTENING TORQUE ... GENERAL TORQUE SPECIFICATIONSSPEC| y= GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model tem Unit aun Overall length ‘mm (in) 628 (24.7) Overall width mm (in) 289 (11.4) Overall height (s) mm (in) 997 (39.3) rn) mm (in) 1,124 (44.3) Boat transom height ‘s) mm (in) 381 (15.0) rs) mm (in) 1508 (20.0) Weight ‘s) kg (Ib) 165 (36:3) wo kg (lb) 175 (385) ‘Average maximum power kW (HP) at rnin | 22 (3)/5,000 Maximum operating range rimin 4,500 ~ 5,500 Maximum fuel consumption (US gal, Imp galjin | 2.0(0.53, 0.44/5,000 at r/min Engine type Two stroke Number of cylinder 1 Total displacement om? (cu.in) | 70(43) Bore and stroke mm (in) 46 * 42(1.81 X 1.65) Compression ratio 69 Spark plug (NGK) BEHS-10 Number of carburetor 1 Carburetor starting system Choke Intake system Reed valve Scavenging system Loop charged Exhaust system Under water Lubrication system Pre-mixed Fuel and oil Cooling system Water Ignition system COL Starting system Manual Fuel Regular gasoline Fuel rating PON.” Min. 86 Fuel tank capacity £ (US gal, Imp gal) | 1.4(0.37, 0.1) Mixing ratio 400:1 Engine oil type Two-cycle outboard oil TC-W3 Gear oil type Gear-case lube (Hypoid SAE #90) Gear oil quantity ‘em? (US oz, Imp 0z)| 75 (2.5, 26) Tilt angle 4", 8 12", 16%, 20° Tilt-up angle 76 Shallow water angle 32", 44" Steering angle 360" Transmission Forward-Neutral Gear ratio 2.08 (27/13) Reduction system Straight bevel gear Clutch type Dog clutch Propeller direction (Rear view) Clockwise Propeller drive system Spline Propeller series mark BS Propeller 3x TAIAXS (Number of blades x diamete’ x pitch) in 3x 7-1/4 x 5-4/2 Po “' Pump Octane Number (Research octane + Motor octane) / 2 24SPEC) y= MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS. ENGINE Item Unit — 3MH Gylinder Head: Warpage limit mm (in) | 0.4 (0.004) Oylinger: Bore size mm (in) | 46.00~46.02 (1.811~ 1.812) Taper limit mm (in) | 0.08 (0.003) Out of round timit mm (in) | 0.05 (0.002) Piston: Piston clearance mm (in) | 0.030~0.095 (0.0012~0.0014) mm tin) | 0.1 (0004) Piston size “D” mm (in) | 48.985~ 45,990 (1.8096 ~ 1.8106) Measuring point“ mm (in) | 10,04) Oversize: 1st mm (in) | 46.60 (1.831) Piston Ring: BxT Top mm (it) | 15x20 (0.06 0.08) 2nd mmm (it) | 1.520 (0.06 0.08) T G a 2nd ting End gap (installed) Top mm (in) 2nd mm (in) | 0.1~03 (0.004-0012) Side clearance Top mm (in) | 0020.6 (0.0008 ~0.0024) 2nd mm (in) | 008~0.07 (0.0012~0.0028) Crankshatt: CCrankwidth “A” mm (i) | 359~960 (1.41~1.42) Maximum deflection *C* mm (ie) | 0.08 (0.001) Connecting rod side ‘mm Gn) 03~06 (0.012~0.024) clearance “D* Maximum axial play “E” mm (in) 2.0(0.08) 22SPEC | UO" | MAINTENANCE SPECIFICATIONS a Unt Model tem ni aa Carburetor: ‘Stamp mark 61503 Main jet (Md) # 68 Main air jot (MAJ) * 96 Pilot jet (Pd) * 40 Pilot air jet (PAS) * 7 Pilot screw Ps) Tums out | 1-1/4 1/4 Float height (EH) mm (in) 142 (055.4008) Valve seat size mm (in) 61.2 (0.05) Idling speed imi 41,200:+50 Trolling speed amin 11050 4.50 Reed valve: Thickness mm (in) 02 (0.008) Valve stopper height <==; mm (in) 400.2 (0.160.008) Valve warp limit mm (in) __| 02 (0.008) 23SPEC | y™ | MAINTENANCE SPECIFICATIONS ELECTRICAL 1 unt Model Item ni am Ignition timing: lating Degree 6+2(BTDC) Full throttle Degree 218 (BTDO) rm (in) 176t82 (0.06923) Charge coil resistance (color) a 247.5~ 302.5 at 20°C (68°F)(Br-B) Pulser coll resistance 1 (color) a 29.7~ 96.3 at 20°C (68'F)(B-R/W) Pulser coil resistance 2 (color) a 279~341 at 20°C (68°F)(B-G/W) Ignition coi: Primary coil resistance (color) a 0.08~0.12 at 20°C (68'F)8-0) Secondary coll resistance (color) ko 2.08~3.12 at 20°C (68'FB-High tension) ‘Spark plug (NGK) B6HS10 Spark plug gap mm (in) 0.9~1.0 (0.035~0.039) CDI unit resistance ko Xe oN w |e few) aw} 8 | o wil = 3.'Nm (0.3 mekg, 2.2 ftelb) “2 S'S | 3.Nm (0.3 m+ kg, 2.2 ft Ib) 8 Nm (0.8 mekg, 5.8 ftelb)BRKT INSPECTION REMOVAL 1) Remove the apron. 2) Remove the swivel-bracket from the upper casing. CAUTION: Lay the outboard motor on the floor to cary out this removal. INSPECTION UPPER CASE 1) Using a soft brush and solvent, clean the case and water passage. 2) Visually inspect the upper case for cracks, corrosion or distortion. If any crack or ex- cessive corrosion is found, replace the gear case. MOUNTING-BOLT 1) Visually inspect the bolts, and replace all of them if any are bent or corroded. RUBBER MOUNTS 1) Visually inspect the rubber mounts, and replace them if they show signs of peeling, cracking or wear.BRKT ASSEMBLY COLLAR 1) Inspect the collars, and replace them if cracked. ASSEMBLY 1) Place the collars and rubber mounts, and install the swivel bracket covers. 2) Install the apron. 3) Install the tilt stopper device. 4) Install the tiltlock device.BRK ASSEMBLY 5) Install the carrying handle. 6) Install the clamp brackets. 74ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS WIRING DIAGRAM ...... REMOVAL MAGNETO BASE CLEANING, INSPECTION AND REPAIR ‘SPARK-PLUG ‘TESTING THE CDI SYSTEM. PULSER COILS. CHARGE COIL IGNITION COIL REPLACEMENT OF SPARK-PLUG CAP . CDI UNIT : STOP SWITCH . INSTALLATION ... FLYWHEEL MAGNETOELECELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS @ Flywheel rotor Charge coll Pulser coil 1 Pulser coil 2 & Ignition coil © Spark plug CDI unit Stop switch Nm (/ 4.Nm (0.4 mekg, 2.9 ftelb) 4.Nm (0.4 mekg, 2.9 ftelb) atELEC WIRING DIAGRAM WIRING DIAGRAM D Pulser coil 1 B : Black Pulser coil 2 Br : Brown ‘Charge coil G : Green @) Ignition coil © : Orange CDI unit R : Red ‘Stop switch W : White 82ELEC REMOVAL REMOVAL MAGNETO BASE 1) Remove the recoil starter. 2) Using the special service tool, loosen the fly- wheel nut unti itis flush with the crankshaft. CAUTION: The major load must be carried in the direc- tion of the arrows, for if not the holder may easily slip off. 3) Using the special service tool, remove the flywheel magneto. CAUTION: To prevent damage to the engine or tools, screw in the flywheel magneto-puller set- bolts evenly and completely so that the puller plate is parallel to the flywheel. 4)Remove the woodruff key from the crank- shaft keyway using a screwdriver. CAUTION: Take especial care not to damage the sur- face of the crankshaft. 83ELEC CLEANING, INSPECTION AND REPAIR CLEANING, INSPECTION AND REPAIR SPARK-PLUG ‘Refer to page 3-11 ‘TESTING THE CDI SYSTEM Using the 1-Y ignition-tester 1. High scale test: 1) Place switch in HIGH position. Plug the simulator into an electric outlet. 117VAC for ten seconds. 2) Remove the simulator from the outlet, and connect the “P” and “N” leads from the tester to the simulator as indicated (on the bottom of the simulator. 3) Set the tester dial to 50, or below. De- press the button on the simulator. The indicator lamp on the tester should light. 2. Low scale test: 1) Place switch in LOW position. 2) Set tester dial to 50, or below. 3) Connect yellow lead to negative terminal of 12V battery. Connect red lead to posi- tive terminal of 12V battery. Indicater lamp should light. If lamp does not light, check tester batteries. If they are installed correctly and are good, check the clip leads for faulty connections. If no fault can be found, refer to the warranty statement for instructions for sending the tester back to Electro-Specialities, inc. AWARNING Do not touch the plug pins on the simulator while depressing the button. A mild shock will result.ELEC F CLEANING, INSPECTION AND REPAIR 3. Pre-test procedure: 1) If there is no spark, or the spark is weak, continue with the CDI test. 2) If @ good spark is obtained, the problem is not with the CDI system, but possibly the spark-plug or other component is de~ fective. 4, Connection of 1~ Test #1 1) Disconnect the Orange lead from the ignition tester ignition coils. 2) Connect the tester’s “P” and “N” clip leads as shown, @ CDI unit @ Test #1: CDI unit output 5. Tests #2 and #3 1) Disconnect the Brown, Green/white and Red/leads, 2)Connect the testers “P” and “N” clip leads as shown. Pulser coil @ Charge coil @ Test #2: Magneto charge coil output @ Test #3: Magneto pulser coils output 85ELEC ‘The CDI system tests data (Tests. #1, #2 and #3) CLEANING, INSPECTION AND REPAIR Test TEST LEAD CONNECTIONS DIAL RANGE SEQUENCE PP “NP SETTING SWITCH TEST #1 CDI ouTPUT ORANGE (GROUND) 75 H TEST #2 eranee cous BROWN BLACK 80 H TEST #3 RNeeR con GREENWHITE BLACK 40 L TEST #3 NSE Com REDWHITE ELACK 80 L NOTE: The coil output varies greatly with cranking speed. Testing with the spark plug out and good cattery. Cranking the cold engine with the plugs in and a weak battery cannot be found proper readings. PULSER COILS 1)Check the resistance of the pulser coils. Pulser coil resistance: Black—Red/White: 29,7~36.39 at 20 deg.c (68 deg.F) Black—Green/White: 279~3419 at 20deg.C (68 deg-F) CHARGE COIL 1)Check the resistance of the charge coil, Brown—Black, (ail Charge coil resistance: 247.5~302.52 at 20 deg.C (68 deg.F) 86