6b4-28197-5e-11 E15d PDF

E9.
9D
E15D
SERVICE MANUAL
290492 6B4-28197-5E-11
NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
Important information
Particularly important information is distinguished in this manual by the following notations:
Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
w
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
cC
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
E9.9D, E15D
SERVICE MANUAL
©2002 by Yamaha Motor Co., Ltd.
1st Edition, October 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
Contents
General information GEN

INFO
1
Specifications SPEC 2
Periodic checks and adjustments CHK
ADJ
3
Fuel system FUEL 4
Power unit POWR 5
Lower unit LOWR 6
Bracket unit BRKT 7
Electrical systems ELEC 8
Troubleshooting TRBL
SHTG
9
Index
GEN
INFO
General information
How to use this manual .................................................................................1-1

Manual format............................................................................................1-1
Symbols .....................................................................................................1-2
1
Safety while working......................................................................................1-3
Fire prevention ...........................................................................................1-3
Ventilation ..................................................................................................1-3
Self-protection............................................................................................1-3
Parts, lubricants, and sealants ..................................................................1-3
2
Good working practices .............................................................................1-4
3
Disassembly and assembly .......................................................................1-4
Identification ...................................................................................................1-5
Applicable model .......................................................................................1-5
Serial number ............................................................................................1-5
Technical features and descriptions ............................................................1-6

Top cowling ................................................................................................1-6
4
Cylinder head.............................................................................................1-7
Carburetor..................................................................................................1-8
Tiller handle ...............................................................................................1-9
Ignition control system .............................................................................1-10
Side shift ..................................................................................................1-11
5
Tilt support system ..................................................................................1-12
6
Exhaust components (optional) ...............................................................1-13
Splash guard (optional) ...........................................................................1-14
Cooling system ........................................................................................1-15
Propeller selection .......................................................................................1-16

Propeller size ...........................................................................................1-16
Selection ..................................................................................................1-16
7
Predelivery checks.......................................................................................1-16
8
Checking the fuel system ........................................................................1-16
Checking the gear oil...............................................................................1-16
Checking the outboard motor mounting height .......................................1-17
Checking the steering system .................................................................1-17
Checking the gear shift and throttle operation.........................................1-17
9
Checking the engine shut-off switch........................................................1-18
Checking the cooling water pilot hole ......................................................1-18
Test run ....................................................................................................1-18
Break-in ...................................................................................................1-18
After test run ............................................................................................1-19
6B45E11
GEN
INFO General information
How to use this manual

Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the information below as a guide for effective and quality service.
1 Parts are shown and detailed in an exploded diagram and are listed in the components list.
2 Tightening torque specifications are provided in the exploded diagrams and after a numbered
step with tightening instructions.
3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant
and lubrication point.
4 The components list consists of part names and quantities, as well as bolt and screw dimensions.
5 Service points regarding removal, checking, and installation are shown in individual illustrations
to explain the relevant procedure.
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
LOWR
Lower unit
3 2 1
Lower unit
LOWR
Lower unit
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.
S62Y6740K
CAUTION:
Do not reuse the bearing, always replace
S62Y6850K it with a new one.
Drive shaft holder 4 1 : 90890-06518

No. Part name Q’ty Remarks Pinion nut holder 2 : 90890-06505 Bearing separator 1 : 90890-06534
1 Lower unit 1 Socket adapter 2 3 : 90890-06507
2 Plastic tie 1 Not reusable
Disassembling the drive shaft 2. Remove the needle bearing from the for-
3 Hose 1 ward gear.
1. Install the pinion nut 1 , tighten it finger
4 Check screw 1
tight, and then remove the drive shaft
5 Gasket 2 Not reusable bearing 2 using a press.
6 Dowel pin 2
7 Bolt 4 M10 × 40 mm
8 Drain screw 1
9 Grommet 1
10 Bolt 1 M10 × 45 mm
11 Bolt 1 M8 × 60 mm
12 Thrust washer 1
13 Propeller 1 CAUTION:
14 Washer 1 Do not reuse the bearing, always replace
CAUTION: it with a new one.
15 Washer 1
16 Cotter pin 1 • Do not press the drive shaft threads a
Not reusable
directly. Stopper guide plate 2 : 90890-06501
17 Propeller nut 1
Do not reuse the bearing, always Stopper guide stand 3 :
18 Trim tab 1 replace it with a new one. 90890-06538
Bearing puller 4 : 90890-06535
Bearing puller claw 1 5 :
Bearing inner race attachment 3 :
6-5 62Y5A11 90890-06536
90890-06639
Disassembling the forward gear

1. Remove the taper roller bearing from the
forward gear using a press.
4
6-19 62Y5A11
1-
1-1 6B45E11
How to use this manual
Symbols
The symbols below indicate the content of a chapter.
General information Fuel system Bracket unit
GEN
INFO FUEL BRKT
1
Specifications Power unit Electrical systems
SPEC
Periodic checks and adjustments

POWR
Lower unit
ELEC
Troubleshooting
2
CHK
ADJ LOWR TRBL
SHTG
3
Symbols 1 to 6 indicate specific data.
1 2 3 4 5 6
4
1
2
3
4
Special tool
Specified oil or fluid
Specified engine speed
Specified tightening torque
5 Specified measurement
6 Specified electrical value
(resistance, voltage, electric current) 5
Symbols 7 to w in an exploded diagram or illustration indicate the grade of lubricant and the lubri-
cation point.
7 8 9 0 q w
6
C
7
8
Apply Yamaha 2-stroke motor oil
Apply water resistant grease (Yamaha grease A)
q Apply low temperature resistant grease
(Yamaha grease C)
7
9 Apply molybdenum disulfide grease w Apply injector grease
0 Apply corrosion resistant grease
(Yamaha grease D)
Symbols e to i in an exploded diagram or illustration indicate the type of sealant or locking agent
8
and the application point.
e r t y u i
9
e Apply Gasket Maker y Apply LOCTITE 242 (blue)
r Apply Yamabond No. 4 u Apply LOCTITE 572
t Apply LOCTITE 271 (red) i Apply silicon sealant
6B45E11 1-2
GEN
Safety while working

To prevent an accident or injury and to ensure
quality service, follow the safety procedures
provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Parts, lubricants, and sealants

Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the out-
board motor.
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where ade-
Under normal conditions, the lubricants men-
quate ventilation can be maintained.
tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and

industrial hygiene.
2. Change and wash clothing as soon as

possible if soiled with lubricants.
Self-protection 3. Avoid contact with skin. Do not, for exam-

Protect your eyes by wearing safety glasses ple, place a soiled rag in your pocket.
or safety goggles during all operations involv-
ing drilling and grinding, or when using an air 4. Wash hands and any other part of the
compressor. body thoroughly with soap and hot water
Protect your hands and feet by wearing pro- after contact with a lubricant or lubricant
tective gloves and safety shoes when neces- soiled clothing has been made.
sary.
5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.
1-3 6B45E11
Safety while working
6. Keep a supply of clean, lint-free cloths for Disassembly and assembly

wiping up spills, etc. 1. Use compressed air to remove dust and
dirt during disassembly.
1
Good working practices
Special service tools 2. Apply engine oil to the contact surfaces
Use the recommended special service tools of moving parts before assembly.
to protect parts from damage. Use the right
tool in the right manner–do not improvise.
2
3. Install bearings with the manufacture
3
identification mark in the direction indicat-
Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening nuts, bolts, and screws, tighten the
ed in the installation procedure. In addi-
tion, be sure to lubricate the bearings lib-
erally. 4
large sizes first, and tighten fasteners starting 4. Apply a thin coat of water-resistant
in the center and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, etc., when installing or
grease to the lip and periphery of an oil
seal before installation.
5. Check that moving parts operate normal-

5
ly after assembly.
assembling parts.
6
7
8
9
6B45E11 1-4
GEN
Identification
Applicable model
This manual covers the following models.
Applicable models
E9.9DMH, E15DMH
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
6B410010
3 1
4
2
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
6B410020
1 Model name
2 Approved model code
3 Transom height
4 Serial number
Approved Starting
Model name
model code serial No.
S: 1000001–
E9.9DMH 6B3K L: 1000001–
X: 1000001–
S: 1000001–
E15DMH 6B4K L: 1000001–
X: 1000001–
1-5 6B45E11
Identification/Technical features and descriptions
Technical features and descriptions

Top cowling
A thicker top cowling of 2.8 mm (0.11 in) and an aluminum air intake duct are adopted to increase
1
rigidity.
A large rubber seal is adopted for the mating face of the top cowling.
Also, the inner lip height of 6 mm (0.24 in) is molded around the bottom cowling.
Thereby, better waterproofing is obtained at the mating surface between the top and bottom cowl-
ings.
A water sink is designed into the starter cover to drain the water entering from the starter rope hole.
2
1
3
3
2.8 mm (0.11 in)
4
5
4
6mm (0.24 in)

6
2 7
1
2
3
Aluminum air intake duct
Large size rubber seal
Starter cover
8
4 Drain hose
9
6B45E11 1-6
GEN
Cylinder head
The hemispherical combustion chambers have been adopted to increase combustion efficiency.
The cylinder head cover is incorporated to circulate the cooling water, which increases cooling of the
cylinder head.
These designs give stability to engine power output.
1 Hemispherical combustion chambers

2 Water jacket
1-7 6B45E11
Carburetor
One carburetor with fuel pump is adopted for a simple fuel system.
The carburetor is designed to mount on the crankcase with two long bolts at the front flange.
Also, the intake silencer is designed to mount independently on the carburetor.
Therefore, easier servicing is obtained.
1
2
3
1
4
5
6
2
7
1 Intake silencer
2 Fuel pump
8
9
6B45E11 1-8
GEN
Tiller handle
A thicker and larger steering bracket is adopted to increase durability.
The tiller handle is mounted by dual side brackets to increase reliability.
The throttle cable grommet is obliquely installed into the bottom cowling to prevent the cables from
hard bending.
Also, a deep throttle cable end holder is formed into the tiller handle to obtain easier assembly.
A large throttle control grip with throttle indicator and throttle friction are adopted for easier opera-
tion.
1 Throttle cable grommet

2 Tiller handle side bracket
3 Deep cable holder
4 Steering bracket
5 Throttle friction
6 Throttle indicator
1-9 6B45E11
Ignition control system

A CDI unit with electronic ignition timing advance system is adopted.
This allows a simple structure in the flywheel magneto, and maintenance free for the ignition timing
and for the advance timing to obtain easier servicing.
60 mm (2.36 in)
1
1
2
76 mm (2.99 in)
6B4-00
1 ID mark
å CDI unit
3
å
4
Ignition timing control
With the signal timing and interval from the pulser coil, the ECU carries out a calculation and con-
trols the ignition timing under the various engine speed.
The control of ignition timing is as follows.
5
(1) Normal operation
The ignition timing is controlled as shown in the chart in fig. 1, after 10 seconds after the engine
starts. 6
∫
35
30
25
7
8
20
∫ Ignition timing under normal
ç 15 operation
ç Crank angle (degrees)
10
∂ Engine speed (r/min)
5
0
-5
0 1,000 2,000 3,000
∂
4,000 5,000 6,000 9
Fig.
Fig 1
6B45E11 1-10
GEN
(2) When the engine starts

The ignition timing is fixed to BTDC10 degrees for 10 seconds after the engine starts. Thereafter,
the ignition timing is put into that of normal operation by retarding 1 degree per 0.25 second.
(3) When the engine accelerates

The CDI unit adjusts the ignition timing momentarily, when the engine speed changes 300 r/min per
0.1 second while the engine is running between 1,000 r/min and 3,200 r/min.
Thereafter, the ignition timing immediately returns to that of normal operation.
Side shift
A large shift lever is incorporated into the side of the bottom cowling to drive the shift rod directly
and a large shift tension plate is adopted, which obtains exact shifting operation.
This simple shifting system obtains reliability and easier servicing.
Also, the start-in-gear protection device is incorporated to allow the engine to be started only when
in neutral, which increases reliability.
2
1 3
1 Shift-in-gear detector
2 Shift rod
3 Start-in-gear protector
4 Shift tension plate
5 Shift lever
1-11 6B45E11
Tilt support system

Twin tilt supports with slots are adopted to increase durability and reliability of the outboard motor`s
support system in the tilted up position.
1
1
2
3
4
2
5
6
1 Tilt lever
2 Tilt support 7
8
9
6B45E11 1-12
GEN
Exhaust components (optional)

The cylindrical components for the exhaust passage have been externally and internally painted
after an anodic oxide coating is given to make a film for additional corrosion-resistance.
1 Exhaust manifold
2 Propeller shaft bearing housing
å Anodic oxide coating and additional painting å
1-13 6B45E11
Splash guard (optional)

A splash plate with a long skirt is adopted to cover the lower mount area and prevent water spray
from rising up when the outboard motor is used at high level water surface conditions.
1
2
3
4
5
6
7
8
9
1
1 Splash guard with long skirt
6B45E11 1-14
GEN
Cooling system
The impeller material is changed to increase cooling water supply while the engine is running at low
speed.
A cylinder head cover is incorporated to circulate cooling water, thereby the cooling efficiency is
increased.
6 79
4
5
3
10
å 8. Thermostat 9. Cylinder head cover
∫
7. Cylinder head
2
ç 6. Cylinder
5. Pilot hole 4. Exhaust outer cover

1
3. Exhaust guide
11
Atmosphere 10. Upper case
2. Water pump 12
11. Lower case
12. Propeller boss

1. Cooling water inlet
Atmosphere
Cooling water flow diagram

å Cold water
∫ Hot water
ç Exhaust gas and water
1-15 6B45E11
Technical features and descriptions/Propeller selection/Predelivery checks
Propeller selection Predelivery checks

The performance of a boat and outboard To make the delivery process smooth and
motor will be critically affected by the size and efficient, the predelivery checks should be
1
type of propeller you choose. Propellers completed as explained below.
greatly affect boat speed, acceleration,
engine life, fuel economy, and even boating Checking the fuel system
and steering capabilities. An incorrect choice 1. Check that the fuel hose is securely con-
could adversely affect performance and could nected and that the fuel tank is filled with
2
also seriously damage the engine. fuel.
Use the following information as a guide for
selecting a propeller that meets the operating
conditions of the boat and the outboard
motor.
Propeller size
The size of the propeller is indicated on the
outside of the propeller boss.
3
4
6B410040
cC
Use pre-mixed fuel only.
-
Fuel and oil mixing ratio is 50:1. For break-
a b c
6B410030
in period, 25:1 mixture shall be used.
Checking the gear oil

1. Check the gear oil level.
5
a Propeller diameter (in inches)
b Propeller pitch (in inches)
c Propeller type (propeller mark)
Selection
6
When the engine speed is at the full throttle
operating range (4,500–5,500 r/min), the
ideal propeller for the boat is one that pro-
vides maximum performance in relation to
boat speed and fuel consumption. 6B410050
7
Propeller size (in)
9 1/2 × 6 1/2 - J
9 3/4 × 6 1/2 - J
Material NOTE:
The gear oil level should be at the brim of the
check hole. 8
9 1/4 × 8 - J
9 3/4 × 8 - J
9 1/4 × 9 - J
9 1/4 × 10 - J
Aluminum
9
9 1/4 × 11 - J
9 1/4 × 12 - J
6B45E11 1-16
GEN
Checking the outboard motor 2. Check that the steering operates smooth-
mounting height ly.
1. Check that the anti-cavitation plate is
between the bottom of the boat and a
maximum of 25 mm (1 in) a below it. If
the mounting height is too high, cavitation
will occur and propulsion will be reduced.
Also, the engine speed will increase
abnormally and cause the engine to over-
heat. If the mounting height is too low,
water resistance will increase and reduce 6B410080
engine efficiency.
Checking the gear shift and throttle
operation
1. Check that the gear shift operates
smoothly when the shift lever is shifted
from neutral into forward.
N
a 0—25mm
(0—1in.) 6B410060 R F
NOTE:
The optimum mounting height is affected by
the combination of the boat and the outboard
motor. To determine the optimum mounting 6B410090
height, test run the outboard motor at differ-
ent heights. 2. Check that the throttle operates smoothly
when the throttle grip is turned from the
2. Check that the clamp brackets are fully closed position to the fully open posi-
secured with the clamp screws. tion a.
Checking the steering system

1. Check the steering friction for proper
adjustment.
a
6B410100
6B410070
1-
1-17 6B45E11
Predelivery checks
Checking the engine shut-off switch Test run

1. Check that the engine turns off when the 1. Start the engine, then check that the gear
engine shut-off switch is pushed or the shift operates smoothly.
engine shut-off cord is pulled from the
engine shut-off switch. 2. Check the engine idle speed after the
engine has been warmed up. 1
3. Operate at trolling speed.
4. Perform the break-in procedure up to

step 3 as listed below.
NOTE:
2
The test run is part of the break-in operation.
6B410110
Break-in
During the test run, perform the break-in
operation in the following 4 stages.
3
1. 10 minutes a at the lowest possible
speed. A fast idle in neutral is best.
2. 50 minutes b at 1/2 throttle (approxi-

mately 3,000 r/min) or less. Vary engine
4
speed occasionally. On an easy-planing
Checking the cooling water pilot

hole
6B410120
boat, accelerate at full throttle onto plane,
then immediately reduce the throttle to
3,000 r/min or less.
5
1. Check that cooling water is discharged 3. 1 hour c at 3/4 throttle (approximately
from the cooling water pilot hole. 4,000 r/min). Vary engine speed occa-
sionally. Run at full throttle for 1 minute,
the allow about 10 minutes of operation
at 3/4 throttle or less to let the engine
6
cool.
4. 8 hours d at any speed, but avoid oper-

ating at full throttle for more than 5 min-
7
utes at a time. Let the engine cool
between full-throttle runs. Vary engine
6B410130 speed occasionally.
8
0 1 2 10
9
6B410150
å Hours
6B45E11 1-18
GEN
After test run

1. Check for water in the gear oil.
2 Check for fuel leakage in the cowling.
3 After a test run and while the engine is at

idle, flush the cooling water passages
with fresh water using the flushing kit.
1-
1-19 6B45E11
SPEC
Specifications
General specifications ...................................................................................2-1
Maintenance specifications ..........................................................................2-3

Power unit .................................................................................................2-3
1
Lower unit ..................................................................................................2-4
Electrical ....................................................................................................2-5
Dimensions ................................................................................................2-6
Tightening torques.........................................................................................2-8
2
Specified torques .......................................................................................2-8
General torques .........................................................................................2-9
3
4
5
6
7
8
9
6B45E11
SPEC Specifications
General specifications
Model
Item Unit
E9.9DHM E15DMH
Dimensions
Overall length mm (in) 878 (34.6)
Overall width mm (in) 363 (14.3)
Overall height
(S) mm (in) 1,062 (41.8)
(L) mm (in) 1,189 (46.8)
(X) mm (in) 1,333 (52.5)
Transom height
(S) mm (in) 441 (17.4)
(L) mm (in) 568 (22.4)
(X) mm (in) 710 (28.0)
Boat transom height
(S) mm (in) 381 (15.0)
(L) mm (in) 508 (20.0)
(X) mm (in) 686 (27.0)
Dry weight
(S) kg (lb) 38 (84)
(L) kg (lb) 40 (88)
(X) kg (lb) 41 (90)
Performance
Maximum output kW (hp) 7.3 (9.9) @ 5,000 r/min 11.0 (15.0) @ 5,000 r/min
Full throttle operating range r/min 4,500–5,500
Maximum fuel consumption L (US gal,lmp gal)/hr 6.9 (1.82, 1.52) @ 5,500 r/min 7.7 (2.03, 1.69) @ 5,500 r/min
Idle speed r/min 1,000–1,100
Power unit
Engine type 2-stroke, Twin
Total displacement cm3 (cu. in) 246 (15.0)
Bore x stroke mm (in) 56.0 × 50.0 (2.20 × 1.97)
Compression ratio 7.0
Control system Tiller handle
Starting system Manual starter
Enrichment system Choke valve
Ignition control system CDI
Ignition timing Degree TDC–BTDC 30
Maximum generator output (*1) V-W 12–80
Spark plug (NGK) B8HS–10, BR8HS–10
Cooling system Water
Exhaust system Propeller boss
Lubrication system Pre-mixed fuel (1/50)
(*1) Lighting coil equipped model (option)
2-1 6B45E11
General specifications
Model
Item Unit
E9.9DHM E15DMH
Fuel and oil
Fuel type
Engine oil
Engine oil grade
Gear oil type
NMMA-certified
Regular gasoline
2-stroke outboard motor oil
TC-W3
Hypoid gear oil
1
Gear oil grade (*2) API GL-4
Gear oil quantity
Bracket unit
SAE
L (US oz,
lmp oz)
90
0.25 (8.5, 8.8)
2
Trim angle (*3) Degree 8, 12, 16, 20
Tilt-up angle
Steering angle
Drive unit
Degree
Degree
67
40 + 40 3
Gear shift positions F-N-R
4
Gear ratio 2.08 (27/13)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction (rear view) Clockwise
Propeller ID mark
(*2) Meeting both API and SAE requirements
(*3) At 12–degree boat transom
J
5
6
7
8
9
6B45E11 2-2
SPEC Specifications
Maintenance specifications
Power unit
Model
Item Unit
E9.9DHM E15DMH
Power unit
Minimum compression kPa 560 (5.6, 81.6)
pressure (*1) (kgf/cm2, psi)
Cylinder head
Warpage limit mm (in) 0.1 (0.004)
(lines indicate straightedge

position)
Cylinder
Bore size mm (in) 56.00–56.02 (2.20–2.21)
Wear limit mm (in) 56.1 (2.21)
Taper limit mm (in) 0.08 (0.0031)
Out-of-round limit mm (in) 0.05 (0.0020)
Piston
Piston diameter (D) mm (in) 55.940–55.985 (2.2024–2.2041)
Measuring point (H) mm (in) 10 (0.394)
Piston-to-cylinder clearance mm (in) 0.035–0.040 (0.0014–0.0016)

Piston pin boss bore mm (in) 14.004–14.015 (0.5513–0.5518)
Piston over size (1st) mm (in) + 0.25
mm (in) 56.190–56.235 (2.2122–2.2139)
(2nd) mm (in) + 0.50
mm (in) 56.440–56.485 (2.2220–2.2238)
Piston pin
Outside diameter mm (in) 13.996–14.000 (0.5510–0.5512)
Piston rings
Top ring
Dimension B mm (in) 1.98–2.00 (0.078–0.079)
Dimension T mm (in) 2.4–2.6 (0.09–0.10)
End gap mm (in) 0.15–0.35 (0.0059–0.0138)
Side clearance mm (in) 0.02–0.06 (0.0008–0.0024)
2nd ring
Dimension B mm (in) 1.96–1.98 (0.077–0.078)
Dimension T mm (in) 2.4–2.6 (0.09–0.10)
End gap mm (in) 0.15–0.35 (0.0059–0.0138)
Side clearance mm (in) 0.04–0.08 (0.0016–0.0031)
Reed valve
Valve stopper height mm (in) 1.2–1.4 (0.00473–0.0550) 5.9–6.1 (0.2323–0.2402)
Valve vending limit mm (in) 0.2 (0.0078)
(*1) Measuring conditions:

Ambient temperature 20°C (68°F), wide open throttle, with spark plugs removed from all cylinders.
The figures are for reference only.
2-3 6B45E11
Model
Item Unit
E9.9DHM E15DMH
Connecting rod
Small end inside diameter
Big end inside diameter
Crankshaft
Crank width
F
E (A)
mm (in)
mm (in)
mm (in)
18.000–18.011 (0.7087–0.7091)
28.039–28.052 (1.1039–1.1044)
46.90–46.95 (1.8465–1.8484)
1
D D
(B) mm (in) 25.9–26.1 (1.0197–1.0276)
Crankpin diameter
Runout limit
A B
(D)
mm
mm
(in)
(in)
20.028–20.039 (0.788–0.789)
0.03 (0.0012)
2
Big end side clearance (E) mm (in) 0.3–0.8 (0.0118–0.0315)
Maximum small end axial play (F)
Crankcase
Main journal inside diameter
mm (in)
mm (in)
2.0 (0.08)
51.952–51.977 (2.045–2.046)
3
Thermostat
4
Opening temperature °C (°F) 48–52 (118–126)
Fully open temperature °C (°F) 60 (140)
Valve open lower limit mm (in) 3 (0.12)
Carburetor
ID mark 6B300 6B400
Float height
Valve seat size
Main jet
Main nozzle
(M.J.)
(M.N.)
mm (in)
mm (in)
mm (in)
12.5–15.5 (0.49–0.55)
#110
1.2 (0.05)
3 (0.12)
#108 5
Main air jet (M.A.J.) #120
Pilot jet
Pilot air jet
Pilot screw
Manual starter
(P.J.)
(P.A.J.)
(P.S.) turns out
#48
#75
7/8–1 3/8
6
Starter rope length mm (in) 1,850–2,050 (72.8–80.7)
Lower unit
Model
7
Item Unit
E9.9DHM E15DMH
Gear backlash
Pinion forward
Pinion reverse
mm (in)
mm (in)
0.19–0.86 (0.0075–0.0339)
0.96–1.65 (0.0378–0.0650)
8
Pinion shims mm 1.13, 1.2
Forward shims
Reverse shims
mm
mm
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
0.10, 0.20, 0.30, 0.40, 0.50
9
6B45E11 2-4
SPEC Specifications
Electrical
Model
Item Unit
E9.9DHM E15DMH
Ignition system
Ignition timing Degree BTDC 30
Ignition spark gap mm (in) 6 (0.24)
Spark plug cap resistance kΩ 4.0–6.0
Ignition coil resistance
Primary coil (O–B) Ω 0.16–0.24
Secondary coil
(spark plug wire–spark plug wire) kΩ 3.92–5.88
Pulser coil peak voltage
@ Cranking (no load) V 4.0
@ Cranking (load) V 5.0
@ 1,500 r/min (load) V 11.0
@ 3,500 r/min (load) V 22.0
Pulser coil resistance (W/G–B) Ω 232–348
Charge coil peak voltage
@ Cranking (no load) V 190
@ Cranking (load) V 180
@ 1,500 r/min (load) V 250
@ 3,500 r/min (load) V 200
Charge coil resistance (Br–L) Ω 248–372
CDI unit output peak voltage
(O–B)
@ Cranking (no load) V 160
@ Cranking (load) V 160
@ 1,500 r/min (load) V 230
@ 3,500 r/min (load) V 180
Lighting system
Lighting voltage
(minimum) @3,000 V 11.5
(maximum) @5,500 V 14.0–17.5
Lighting coil peak voltage
@ Cranking (no load) V 7.0
@ 1,500 r/min (no load) V 18.0
@ 3,500 r/min (no load) V 37.0
Lighting coil resistance (G–G) Ω 0.16–0.24
2-5 6B45E11
S:706 (27.8)
6B45E11
L :833 (32.8)
17 (0.7) X:975 (38.4) 555 (21.9)
Exterior
S:441 (17.4)
Dimensions
L :568 (22.4) 493 (19.4) 280 (11.0)

135 (5.3) X:710 (28.0) 356 (14.0)
190 (7.5) 173 (6.8)
133 (5.2)
34 (1.4)
24 (0.9)
X:78
S:79 (
3.
(3.1)
3.1)
L :78 ( 1)
162 (6.4)
L :4 (0.2)
X:14 (0.6)
473 (18.6)
334 (13.2)
165 (6.5)
73 (2.9)
357 (14.0)
405 (15.9)
708 (27.9)
185 (7.3) 145 (5.7)
S:569 (22.4)
L :638 (25.2)
X:714 (28.1) 474 (18.7)
6B4001M
2-6
mm (in)
9
8
7
6
5
4
3
2
1
SPEC Specifications
Clamp bracket
mm (in)
106.3 (4.2) 106.3 (4.2)
67.3 (2.6) 67.3 (2.6)

50 (2.0)
79 (3.1)
157 (6.2)
8.
3
(0
.3
)
2 (0.1)
92.6 (3.6) 92.6 (3.6) 30 (1.2)
60 (2.4)
6B4002M
2-7 6B45E11
Maintenance specifications/Tightening torques
Tightening torques
Specified torques
Tightening torques
1
Part to be tightened Thread size
N·m kgf·m ft·lb
Power unit
1st 15 1.5 11
Crankcase bolt M8
2nd 29 2.9 22
1st 8 0.8 5.8
Cylinder head bolt
Cylinder head cover bolt

2nd
1st
2nd
M7
M6
16
6
12
1.6
0.6
1.2
12
4.4
8.7
2
1st 6 0.6 4.4
Exhaust outer cover bolt M6
Flywheel nut
Throttle link screw
Power unit mount bolt
2nd
(M12)
M4
M8
12
100
1.3
22
1.2
10
0.13
2.2
8.7
74
0.9
16
3
1st 6 0.6 4.4
Thermostat cover bolt
Engine shut-off switch nut

Spark plug
2nd
M6
(M16)
M14
12
3.5
25
1.2
0.4
2.5
8.7
2.5
18
4
Intake silencer bolt M5 2.5 0.3 2.2
5
DRIVE UNIT
Exhaust guide bolt M6 12 1.2 8.7
Drain screw M8 9.0 0.9 6.6
Pinion nut (M8) 25 2.5 18
Propeller nut (M10) 17 1.7 12
BRACKET UNIT
Grease nipple
Lower rubber mount cover nut
(M6)
M8
3
20
0.3
2.0
2.2
14
6
Clamp bracket through nut (M12) 12 1.2 9.0
7
Throttle grip mount screw M5 1.6 0.16 1.2
Tilt support pivot nut (M6) 12 1.2 8.7
Ground lead screw M6 2.5 0.2 1.8
Upper rubber mount nut (M8) 21 2.1 15
8
9
6B45E11 2-8
SPEC Specifications
General torques
This chart specifies tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifications
for special components or assemblies are
provided in applicable sections of this manu-
al.
To avoid warpage, tighten multi-fastener
assemblies in a crisscross fashion and pro-
gressive stages until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads.
Components should be at room temperature.
General torque
Nut (A) Bolt (B) specifications
N·m kgf·m ft·lb
8 mm M5 5 0.5 3.6
10 mm M6 8 0.8 5.8
12 mm M8 18 1.8 13
14 mm M10 36 3.6 26
17 mm M12 43 4.3 31
2-9 6B45E11
CHK
ADJ
Periodic checks and adjustments
Special service tools......................................................................................3-1
Maintenance interval chart............................................................................3-2 1

Fuel system ....................................................................................................3-3
Checking the fuel joint and fuel hoses (fuel joint to carburetor) ................3-3
Checking the fuel filter ...............................................................................3-3
Power unit .......................................................................................................3-3

2
Checking the spark plugs ..........................................................................3-3
Checking the thermostat............................................................................3-4
Checking the cooling water passages .......................................................3-4 3
Control system ...............................................................................................3-5
4
Checking the throttle cable operation ........................................................3-5
Checking the gearshift operation ...............................................................3-5
Checking the start-in-gear protection ........................................................3-5
Checking the engine idle speed ................................................................3-6
Checking the ignition timing.......................................................................3-6
Bracket ............................................................................................................3-7
Checking the tilt operation .........................................................................3-7
5
6
Lower unit .......................................................................................................3-7
Checking the gear oil level.........................................................................3-7
Replacing the gear oil................................................................................3-8
Checking the lower unit for air leakage .....................................................3-8
Checking the propeller...............................................................................3-9
General ............................................................................................................3-9
Checking the anode...................................................................................3-9
Checking the top cowling...........................................................................3-9
7
Lubricating the outboard motor..................................................................3-9
8
9
6B45E11
CHK
ADJ Periodic checks and adjustments
Special service tools
Digital tachometer
90890-06760
Timing light
90890-03141
Leakage tester
90890-06840
3-1 6B45E11
Maintenance interval chart
Maintenance interval chart

Use the following chart as a guideline for general maintenance.
Adjust the maintenance intervals according to the operating conditions of the outboard motor.
Item Remarks
Cleaning/Adjustment/
Initial Every
10 hours 50 hours 100 hours 200 hours
(Break-in) (3 months) (6 months) (1 year)
Refer
to
page
1
Spark plug 1 1 1 3-3
Replacement
Greasing points
Gear oil
Fuel system
Fuel filter
Greasing
Change
Inspection
Cleaning/Replacement
1
1 1
1
1
1
1
3-9
3-7
3-3
3-3
2
Separate fuel tank *1 Cleaning 1 —
Idling speed
Anode
Adjustment
Inspection/Replacement
Outboard motor exterior Inspection
1
1
1
1
3-6
3-9
3-9
3
Cooling water
Cleaning 1 1 3-4
4
passages *2
Propeller and cotter pin Inspection/Replacement 1 1 3-9
Carburetor setting Inspection/Adjustment 1 1 4-9
Ignition timing Inspection 1 1 3-6
Bolts and nuts Retightening 1 1 —
NOTE:
(*1) If equipped.
(*2) When operating in salt water, turbid or muddy water, the engine should be flushed with clean
water after each use.
5
6
7
8
9
6B45E11 3-2
CHK
Fuel system Power unit

Checking the fuel joint and fuel Checking the spark plugs
hoses (fuel joint to carburetor) 1. Disconnect the high-tension cords, then
1. Check the fuel hose connections and fuel remove the spark plugs.
joint 1 for leaks. Replace if necessary.
Also, check the fuel filter 2, fuel pump 3 2. Clean the electrodes 1 with a spark plug
and carburetor 4 for leaks, and the fuel cleaner or wire brush. Replace the spark
hoses for leaks and deterioration. plug if necessary.
Replace if necessary.
1
3
4
1 6B430025
2 6B430010
3. Check the electrodes for erosion and
Checking the fuel filter excessive carbon or other deposits, and
1. Check the fuel filter element 1 for dirt the gasket for damage. Replace the
and residue and check the fuel filter cup spark plug if necessary.
2 for foreign substances and cracks.
4. Check the spark plug gap a. Adjust if out
Clean with straight gasoline and replace
of specification.
the cup if necessary.
2 a
6B430020 6B430030
NOTE:
Be sure not to spill any fuel when removing Specified spark plug:
the fuel filter cup. B8HS-10 (NGK)
BR8HS-10 (NGK)
Spark plug gap a:

0.9–1.0 mm (0.03–0.04 in)
3-3 6B45E11
Fuel system/Power unit
5. Install the spark plug, tighten it finger 4. Check the thermostat valve opening at
tight b, then to the specified torque with the specified water temperatures.
a spark plug wrench c. Replace if out of specification.
1
b 2
c 6B430040 6B430070
Spark plug:
25 N·m (2.5 kgf·m, 18 ft·lb)
Water temperature
below
50°C (122°F)
Valve lift a
0 mm (0 in)
3
Checking the thermostat above more than
1. Remove the thermostat cover 1, gasket
2, and thermostat 3.
3
60°C (140°F) 3 mm (0.12 in)
5. Install the thermostat, new gasket, and

4
thermostat cover.
Checking the cooling water

passages
1. Check the cooling water inlet cover 1
5
1 and cooling water inlet for clogging.
6
2
Clean if necessary.
6B430050
2. Suspend the thermostat in a container of 1

water.
3. Place a thermometer in the water and

slowly heat the water.
7
8
9
6B430090
6B430060
2. Place the lower unit in water, then start
the engine.
6B45E11 3-4
CHK
3. Check for water flow at the cooling water Checking the start-in-gear
pilot hole. If there is no water flow, check protection
the cooling water passages.
cC
Be sure to remove the engine shut-off
switch clip before checking the start-in-
gear protection.
1. Set the shift lever in the forward or

reverse position, then pull the starter
handle.
6B410130
2. Check the operation of the start-in-gear
protection cable. If the starter rope can be
pulled out normally, adjust the start-in-
Control system gear protection cable.
Checking the throttle cable
NOTE:
operation
If the starter rope cannot be pulled out, the
1. Check the throttle cables for smooth
start-in-gear protection is working correctly.
operation, looseness, fraying or damage.
3. Set the shift lever in the neutral position
2. With the throttle grip in the fully closed
and loosen the lock nut 1. Align the
position, check that the throttle stop
starter plunger 2 with the mark a on the
screw comes in contact with the throttle
starter case to adjust the cable adjuster.
stopper plate. Adjust if necessary.
1
a 2
6B430110
Checking the gearshift operation

1. Check that the gearshift operates 6B430310
smoothly when shifting from neutral into
forward and reverse. Adjust the shift rod if
necessary.
R F
6B410090
3-5 6B45E11
Control system
Checking the engine idle speed Checking the ignition timing

1. Start the engine and warm it up for 5 min- 1. Start the engine and warm it up for 5 min-
utes. utes.
2. Attach the special service tool to high-

tension cord #1 1, then check the engine
idle speed. Adjust if out of specification.
2. Attach the special service tool to high-
tension cord #1 1, and then check the
engine idle speed.
1
1 1 2
6B430120 6B430120
3
Digital tachometer: 90890-06760 Digital tachometer: 90890-06760
4
Engine idle speed: Engine idle speed:
5
1,000–1,100 r/min 1,000–1,100 r/min
3. Turn the throttle stop screw 2 in direction 3. Attach the special service tool to high-
a or b until the specified engine idle tension cord #1 1.
speed is obtained.
1
6
b a
6B430150
7
2 6B430130
NOTE:
9 To increase the idle speed, turn the throttle
stop screw in direction a.
8
9 To decrease the idle speed, turn the throttle
stop screw in direction b.
4. After adjusting the idle speed, rev the 6B430160

9
engine a few times and let it idle for at
least 15 seconds to check the stability of
the engine.
Timing light: 90890-03141
6B45E11 3-6
CHK
4. Check that the TDC line a on the fly- 2. Fully tilt the outboard motor up, then sup-
wheel magnet is aligned with the line port it with the tilt support lever 1 to
above the starter case window b. check the lock mechanism of the lever.
1
6B430170 6B430190
Bracket Lower unit

Checking the tilt operation Checking the gear oil level
1. Fully tilt the outboard motor up and down 1 Fully tilt the outboard motor down.
a few times and check the entire tilt range
for smooth operation. Check the tilt 2. Remove the check screw 1, then check
mechanism if necessary. the gear oil level in the lower case.
1
6B430195
NOTE:
The gear oil level should be at the brim of the
check hole.
3. If necessary, add sufficient gear oil of the

6B430180 recommended type to the correct level.
Recommended gear oil:

Hypoid gear oil
SAE: 90
4. Install the check screw, then tighten it to

the specified torque.
Check screw:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
3-7 6B45E11
Bracket/Lower unit
Replacing the gear oil 5. Install the check screw, quickly install the
1. Fully tilt the outboard motor down. drain screw, then tighten them to the spec-
ified torque.
2. Place a drain pan under the drain screw
3, remove the drain screw, then the
check screw 4 to drain the oil.
Check and drain screw:
9 N·m (0.9 kgf·m, 6.6 ft·lb) 1
4
Checking the lower unit for air leak-
age
cC
2
Do not over pressurize the lower unit, oth-
3
3 erwise the oil seals may be damaged.
1. Remove the check screw 1, then install

the special service tool.
6B430200
1 4
3. Check the oil for metal, discoloration, and
viscosity. Check the internal parts of the
lower case if necessary.
4. Insert the gear oil tube into the drain hole

5
and slowly fill the gear oil until oil flows
out of the check hole and no air bubbles
are visible.
6B430220 6
Leakage tester: 90890-06840
2. Apply the specified pressure to check

7
whether the lower unit can hold it for at

6B430210 least 10 seconds.
Lower unit holding pressure:

8
100 kPa (1.0 kgf/cm2, 14 psi)
Hypoid gear oil
SAE: 90
Oil quantity:
0.25 L (8.5 US oz, 8.8 Imp oz)
3. If pressure drops below specification,
check the drive shaft, propeller shaft oil
9
seals, shift rod, and drain screw for dam-
age.
6B45E11 3-8
CHK
Checking the propeller 2. Check the top cowling for cracks or other
1. Check the propeller blades and splines damage. Replace if necessary.
for cracks, damage, or wear. Replace if
necessary. 3. Check the hooks and rivets for wear or
damage. Repair if necessary.
4. Check the rubber trim for wear, deteriora-

tion or damage. Replace if necessary.
5. Check the lock mechanism for wear or

damage. Repair if necessary.
Lubricating the outboard motor

6B430230
1. Apply water resistant grease to the areas
shown.
General
Checking the anode
1. Check the anode for scales, grease, and
oil. Clean if necessary.
6B430260
6B430240
cC
Do not oil, grease, or paint the anode, oth-
erwise it will be ineffective.
6B430270
2. Replace the anode if excessively eroded.
Checking the top cowling

1. Check the fitting of the top cowling by
pushing on it with both hands.
6B430290
6B430250
3-9 6B45E11
General
a
1
2
6B430280
NOTE:
Apply grease to the grease nipple until it flows
from the bushings a.
3
2. Apply corrosion resistant grease to the
area shown. 4
5
6B430300
6
7
8
9
6B45E11 3-10
CHK
ADJ
— MEMO —
3-11 6B45E11
FUEL
Fuel system
Hose routing ...................................................................................................4-2

Fuel hoses and cooling water hose...........................................................4-2
1
Intake silencer, carburetor.............................................................................4-3
Fuel filter, fuel joint ........................................................................................4-4

Checking the fuel joint ...............................................................................4-5
2
Checking the fuel filter ...............................................................................4-5
Carburetor, fuel pump....................................................................................4-6

Disassembling the carburetor ....................................................................4-8
3
Checking the carburetor ............................................................................4-8
4
Assembling the carburetor.........................................................................4-9
Disassembling the fuel pump ....................................................................4-9
Assembling the fuel pump .........................................................................4-9
5
6
7
8
9
6B45E11
FUEL Fuel system
Vacuum/pressure pump gauge set

90890-06756
Digital caliper
90890-06704
4-1 6B45E11
Special service tools/Hose routing
Hose routing
Fuel hoses and cooling water hose
1
2
3
3
1
4
2
5
6B440010
1 Fuel hose (fuel joint to fuel filter)

6
2 Fuel hose (fuel filter to fuel pump)
3 Pilot water hose
7
8
9
6B45E11 4-2
FUEL Fuel system
Intake silencer, carburetor
3 N·m (0.3 kgf·m, 2.2 ft·lb)

8 N·m (0.8 kgf·m, 5.8 ft·lb)
2.5 N·m (0.3 kgf·m, 2.2 ft·lb)

6B44010E
No. Part name Q’ty Remarks

1 Intake silencer 1
2 O-ring 1 Not reusable
3 Screw 2 M5 × 28 mm
4 Bolt 2 M6 × 95 mm
5 Carburetor 1
6 Choke knob 1
7 Grommet 1
8 Seal 1
4-3 6B45E11
Intake silencer, carburetor/Fuel filter, fuel joint
Fuel filter, fuel joint
18 N·m (1.8 kgf·m, 13 ft·lb) 1

2
8 N·m (0.8 kgf·m, 5.8 ft·lb) 3
4
5
8 N·m (0.8 kgf·m, 5.8 ft·lb)

6B44020E
6
1 Fuel joint 1
2
3
4
5
Bolt
Fuel filter
Nut
Hose
1
1
1
1
M6 × 10 mm
7
6 Hose 1
7
8
9
Clip
Bracket
Bolt
4
1
1 M6 × 20 mm
8
10 Fuel filter cap 1
9
11 Fuel filter cup 1
12 Fuel filter element 1
6B45E11 4-4
FUEL Fuel system
Checking the fuel joint

1. Visually check the fuel hose connector for
cracks or damage.
2. Connect the special service tool at the

outlet of fuel hose connector.
3. Apply the specified pressure to check

that the pressure is maintained for 10
seconds. Replace the fuel hose connec-
tor if necessary.
6B440020
Vacuum/pressure pump gauge set:

90890-06756
Fuel hose connector holding pres-

sure:
50 kPa (0.5 kgf/cm2)
Checking the fuel filter

1. Check the fuel filter element 3 for clog-
ging, contamination, or foreign sub-
stances, and check the fuel filter cup 4
for cracks or leakage. Clean with straight
gasoline, or replace if necessary.
4
6B440030
NOTE:
Apply a thin coat of gasoline to the O-ring 5
before assembling the fuel filter cup.
4-5 6B45E11
Fuel filter, fuel joint/Carburetor, fuel pump
Carburetor, fuel pump
1
2
3
4
5
6B44030E
6
1 Carburetor body 1
2
3
4
5
Pilot air screw
Spring
Plate
Gasket
1
1
1
1 Not reusable
7
6 Screw 4 M4 × 10 mm
7
8
9
Pilot jet
Rubber cap
Throttle stop screw
1
1
1
8
10 Spring 1
9
12 Float chamber 1
13 Main nozzle 1
14 Main jet 1
15 Screw 4 M4 × 16 mm
16 Gasket 1 Not reusable
17 Drain screw 1
6B45E11 4-6
FUEL Fuel system
6B44030E

18 Float 1
19 Needle valve set 1
20 Screw 1
21 Nut 1
22 Screw 4 M4 × 25 mm
23 Fuel pump cover 1
24 Diaphragm 1 Not reusable
25 Fuel pump body 1
26 Diaphragm 1 Not reusable
28 Seat valve 1
29 Joint 1
4-7 6B45E11
Carburetor, fuel pump
Disassembling the carburetor 4. Check the main jet, pilot jet, and main
NOTE: nozzle for clogging and contamination.
9 Write down how many turns you have actu- Clean or replace whenever appropriate.
ally turned out the pilot screw.
9 Disassembled jets and other components
should be sorted out and kept in order, so
that they can be re-assembled in their orig-
5. Check the float for damage, and make
sure it is at the appropriate height a.
Replace the float or needle or both if nec-
1
essary.
inal positions.
Checking the carburetor

1. Clean the fuel and air passages and the
carburetor body, and blow off any clog- a
2
ging with compressed air.
w
Wear appropriate protective eye gear dur-
ing the cleaning process to prevent any
3
6B440050
eye injury by the blown-off debris or liq-
uid.
cC
NOTE:
9 Measure the float height as shown.
9 The float should be resting on the needle
4
Do not use steel wire and the like for valve, but not compressing it.
9 Measure the distance a from the carbure-
cleaning the carburetor. Do not try to dis-
assemble the main nozzle if it does not
come out easily. Excessive force may seri-
ously impair performance.
tor mating face to the float bottom. Turn the
carburetor upside-down to make the mea-
surement.
5
NOTE:
Clean the needle valve, main jet, and pilot jet
after removal.
Vertical position of the float a:
12.5–15.5 mm (0.49–0.55 in)
6
2. Check the carburetor body for cracks or
damage. Replace if necessary.
3. Check the pilot screws and needle valves

7
for bending or stepped wear. Replace if
necessary.
8
9
6B440040
6B45E11 4-8
FUEL Fuel system
Assembling the carburetor 3. Clean out the fouling on the fuel pump
Refer to the following points when assem- body.
bling the carburetor.
cC Assembling the fuel pump
9 Do not apply excessive force to push in NOTE:
the needle valve. Clean the parts, and keep the seat valve and
9 Do not apply excessive force to screw in the diaphragm in gasoline before assembly to
the pilot screw. obtain prompt operation of the pump when
the engine starts.
NOTE:
1. Mount the seat valves on the pump body.
Install the pilot screw 1 and turn it in until it
is lightly seated, then turn it out by the speci-
fied number of turns.
6B440080
1
2. Mount the diaphragms, gasket, and
6B440060
cover.
Pilot screw 1 turn-out:

7/8–1 3/8
Disassembling the fuel pump

1. Remove the fuel pump from the carbure-
tor and disassemble it to check the
diaphragms and gasket for damage or 6B440090
breakage.
NOTE:
2. Check the seat valve for bending or dam- Use the bolts to keep the gasket and
age. Also check the fuel pump body for diaphragms in place while assembling the
damage. fuel pump.
6B440070
4-9 6B45E11
— MEMO —
1
2
3
4
5
6
7
8
9
6B45E11 4-10
POWR
Power unit
Power unit .......................................................................................................5-4

Checking the compression pressure .........................................................5-4
Removing the power unit ............................................................................5-11

Removing the flywheel magnet ...............................................................5-12
Removing the electrical components.......................................................5-12
Disassembling the oil seal housing .........................................................5-12
Checking the oil seal housing..................................................................5-13
Assembling the oil seal housing ..............................................................5-13
Disassembling the manual starter ...........................................................5-14
Checking the spiral spring .......................................................................5-14
Checking the drive pawl...........................................................................5-14
Checking the drain hose ..........................................................................5-15
Measuring the starter rope ......................................................................5-15
Assembling the manual starter ................................................................5-15
Reed valve.....................................................................................................5-17
Removing the reed valve assembly.........................................................5-18
Checking the reed valves ........................................................................5-18
Cylinder head, exhaust covers ...................................................................5-19

Removing the exhaust covers .................................................................5-20
Checking the exhaust covers...................................................................5-20
Removing the cylinder head ....................................................................5-20
Checking the anode and cylinder head ...................................................5-21
Cylinder block...............................................................................................5-22
Removing the crankcase .........................................................................5-23
Removing the crankshaft assembly.........................................................5-23
Checking the cylinder block .....................................................................5-24
Crankshaft, piston........................................................................................5-25
Disassembling the piston.........................................................................5-26
Checking the pistons ...............................................................................5-26
Disassembling the crankshaft..................................................................5-28
Assembling the crankshaft.......................................................................5-30
Checking the crankshaft ..........................................................................5-34
Assembling the piston..............................................................................5-34
Installing the crankshaft ...........................................................................5-35
Installing the crankcase ...........................................................................5-35
Installing the cylinder head ......................................................................5-35
Installing the exhaust covers ...................................................................5-37
Installing the reed valve ...........................................................................5-37
Installing the electrical components.........................................................5-37
6B45E11
Installing the throttle cam assembly ........................................................5-37
Installing
Installing
Installing
Installing
the
the
the
the
spark plugs .........................................................................5-38
flywheel assembly ..............................................................5-38
manual starter ....................................................................5-38
carburetor ...........................................................................5-38
1
Installing the fuel filter and hoses ............................................................5-38
Installing
Installing
Installing
Installing
the
the
the
the
oil seal housing ..................................................................5-39
power unit ...........................................................................5-39
throttle cables .....................................................................5-39
throttle link ..........................................................................5-40
2
Installing the start-in-gear protection cable .............................................5-40
3
4
5
6
7
8
9
6B45E11
POWR Power unit
Compression gauge Needle bearing attachment

90890-03160 90890-06609, 90890-06616
Flywheel holder Bearing Separator

90890-06522 90890-06534
Flywheel puller Crank jig set

90890-06521 90890-02421
Crankshaft aligner Flange

90890-03107 90890-02351
Driver rod L3 Body

90890-06652 90890-02352
5-1 6B45E11
H-5 1
Bolt Height ring-5 (H-5)
90890-02353 90890-02371
2
Washer Height ring-13 (H-13)
H-13
3
90890-02354 90890-02379
4
B-5
Bushing-5 (B-5) Pressure plate

5
90890-02359 90890-02384
B-7
6
Bushing-7 (B-7)
90890-02361
Press body
90890-02385
7
B-11 8
Bushing-11 (B-11)
90890-02365
Plate A
90890-02386
9
6B45E11 5-2
POWR Power unit
Plate B Bearing inner race attachment

90890-02387 90890-06644
Pressure pin A Small end bearing installer

90890-02389 90890-06543
Bearing pressure B
90890-02392
Support
90890-02394
Spacer B
90890-02396
5-3 6B45E11
Special service tool/Power unit
Power unit 5. If the measured compression pressure is

Checking the compression pressure below specification, or it varies among
1. Start the engine, warm it up for 5 min- the cylinders, add a small amount of
1
utes, and then turn it off. engine oil to the cylinder, and check the
pressure again.
2. Remove the engine shut-off cord from the
engine shut-off switch.
NOTE:
9 If the compression pressure increases,
2
3. Remove both spark plugs, then install the
check the piston, piston rings and cylinder
special service tool to the #1 spark plug
bore for wear. Replace if necessary.
hole.
9 If the compression pressure does not
change, check the cylinder head gasket
1
and cylinder head. Correct or replace if nec-
essary.
3
6B450010
4
cC
Before removing the spark plugs, blow
compressed air in the spark plug well to
clear out any dirt or dust that may fall into
5
the cylinder.
Compression gauge 1:
90890-03160
6
4. Fully open the throttle, pull the starter
rope, and check the compression pres-
sure 3 times.
7
NOTE:
Do not pull the choke knob when checking
the compression pressure.
Minimum compression pressure

8
(reference data):
560 kPa (5.6 kgf/cm2, 81.6 psi)
9
6B45E11 5-4
POWR Power unit
8 N·m (0.8 kgf·m, 5.8 ft·lb)
22 N·m (2.2 kgf·m, 16 ft·lb)
6B45010E

1 Power unit 1
2 Hose 1
3 Clip 1
4 Throttle cable 2
5 Bolt 1 M6 × 10 mm
6 Engine shut-off switch lead 1
7 Link 1
8 Choke knob 1
10 Spacer 1
11 Oil seal 1 Not reusable
13 Oil seal housing 1
15 Dowel 2
16 Bolt 6 M8 × 50 mm
17 Bolt 1 M6 × 16 mm
5-5 6B45E11
Power unit
1
2
3
8 N·m (0.8 kgf·m, 5.8 ft·lb)
4
8 N·m (0.8 kgf·m, 5.8 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)

6B45020E
5
No.
1
2
Part name
Start-in-gear protection cable
Starter case
Q’ty
1
1
Remarks
6
3 Rope guide 1
4
5
6
7
Rope guide
Collar
Sheave drum
Drive pawl
1
3
1
1
7
8 Spiral spring 1
9
10
11
12
Drive plate
Spring
Spring
Return spring
1
1
1
1
8
13 Circlip 1
14
15
16
Bolt
Starter rope
Stopper
1
1
1
M6 × 15 mm
9
17 Starter plunger 1
6B45E11 5-6
POWR Power unit
8 N·m (0.8 kgf·m, 5.8 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)

6B45020E

18 Spring 1
19 Cotter pin 1 Not reusable
20 Washer 1
21 Cover 1
22 Starter handle 1
23 Damper 1
24 Rubber seal 1
25 Drain hose 1
26 Bolt 2 M6 × 30 mm
27 Bolt 3 M6 × 25 mm
28 Hose 1
5-7 6B45E11
Power unit
100 N·m (10.0 kgf·m, 74 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)

8 N·m (0.8 kgf·m, 5.8 ft·lb)
1
8 N·m (0.8 kgf·m, 5.8 ft·lb)
2
3
4
6B45030E
5
No.
1
2
Part name
Flywheel magnet assembly
Woodruff key
Q’ty
1
1
Remarks
6
3 Washer 1
4
5
6
7
Nut
Charge coil
Bolt
Pulser coil
1
1
2
1
M6 × 20 mm
7
8 Bolt 2 M6 × 16 mm
9
10
11
12
Clamp
Lighting coil
Collar
Bolt
1
1
2
2
[option]
[option]
M6 × 40 mm [option]
8
9
6B45E11 5-8
POWR Power unit
8 N·m (0.8 kgf·m, 5.8 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)
6B45040E

1 Ignition coil 1
2 Bolt 2 M6 × 16 mm
3 Bracket 1
4 Bolt 2 M6 × 14 mm
5 CDI unit 1
6 Bolt 2 M6 × 20 mm
7 Clamp 1
8 Clamp 1
9 Clamp 1
10 Tube 1
11 Spark plug cap 2 #1: z, #2: x
5-9 6B45E11
Power unit
8 N·m (0.8 kgf·m, 5.8 ft·lb)
1
2
3
4
6B45050E
5
No.
1
2
Part name
Throttle cable stay
Collar
Q’ty
1
1
Remarks
6
3 Bolt 1 M6 × 65 mm
4
5
6
7
Free axle lever
Spring
Bolt
Pully
1
1
1
1
M6 × 12 mm
7
8 Joint 1
8
9
6B45E11 5-10
POWR Power unit
Removing the power unit 5. Disconnect the throttle cables and shift
1. Remove the manual starter assembly 1 link rod 5.
and start-in-gear protection cable 2.
1
2 5
6B450040
6B45001A
6. Remove the carburetor, fuel filter and
NOTE: bracket.
If the power unit is to be disassembled, it is
7. Disconnect the pilot water hose 6.
recommended to loosen the nut on the fly-
wheel magnet assembly before removing the
power unit to improve working efficiency.
2. Disconnect the engine shut-off switch

lead and CDI unit lead.
6
6B450050
8. Lift up the power unit after removing the

bolts. Remove the dowels 7.
7
6B450020
3. Remove the intake silencer.
4. Disconnect the choke link rod 3 and

throttle rink rod 4.
6B450060
9. Remove the bolt and oil seal housing 8.
4 8
3 6B450030
6B450070
5-11 6B45E11
Removing the power unit
Removing the flywheel magnet NOTE:

1. Remove the nut on the flywheel magnet. Screw in the flywheel puller set bolt until the
flywheel magnet comes off completely.
Flywheel puller: 90890-06521 1

2
3. Remove the Woodruff key.
6B450080 Removing the electrical components

1. Remove the charge coil 1 and pulser
cC coil 2.
Apply force in the direction of the arrows

shown. While working, do not allow the fly-
wheel holder to slip off the flywheel.
1 3
2
Flywheel holder: 90890-06522

4
2. Remove the flywheel magnet. 6B450050
2. Remove the spark plug caps 3, CDI unit

4, ignition coil 5 and spark plugs.
5
4
6
5
3
6B450110
7
8
Disassembling the oil seal housing
1. Remove the O-ring and oil seals.
6B450090
cC
9 Screw in the flywheel puller set bolts
evenly to the full extent.
9 Make sure the puller plate is set parallel
9
with the flywheel magnet.
6B450120
6B45E11 5-12
POWR Power unit
Checking the oil seal housing 3. Install the new O-ring.

1. Check the oil seal housing for cracks,
damage, or corrosion. Replace if neces-
sary.
6B450160
6B450130
Assembling the oil seal housing

1. Apply grease to the new oil seals, then
install them into the oil seal housing.
2
A
6B450140
Driver rod L3 1: 90890-06652

Needle bearing attachment 2:
90890-06616
2. Apply grease to the new oil seal, then

install it into the oil seal housing.
3
4
6B450150
Driver rod L3 3: 90890-06652

90890-06609
5-13 6B45E11
Disassembling the manual starter 4. Remove the starter rope 5.

1. Remove the drive plate 1 and spring 2.
5. Remove the drive pawl 6 and springs 7
from the sheave drum.
1
1
2 6
6B450170
7
2
w
The sheave drum can pop out. Hold the
sheave drum with your hand, then pull it
5
6B450190
3
out.
2. Remove the sheave drum 3.

Checking the spiral spring
1. Check the spiral spring for cracks, bends,
or damage. Replace if necessary.
4
4
5
3
6B450200
6
w
6B450180
Checking the drive pawl
1. Check the drive pawl for cracks or dam-
age. Replace if necessary.
7
8
The spiral spring can pop out. Cover the
spiral spring with cloths, then pull out the
sheave drum.
9
3. Remove the spiral spring 4 from the
starter case.
w 6B450210
The spiral spring can pop out. To remove
the spring, cover it with cloths.
6B45E11 5-14
POWR Power unit
Checking the drain hose 4. Wind the starter rope 1 twice around the
1. Check the drain hose for clogging, cracks sheave drum 2 in the direction of the
or damage. arrow shown in the illustration.
1
b
1
2
6B450220 2
6B450240
NOTE:
Measuring the starter rope After winding the starter rope around the
1. Measure the starter rope length. Replace
sheave drum, install the starter rope in the
if the length is out of specification.
notch b.
Starter rope length:
1,850–2,050 mm (72.8–80.7 in)
5. Install the spiral spring 6 into the starter
case.
Assembling the manual starter
1. Install the starter rope 1 into the sheave 6
drum 2.
2. Install the drive pawl 3 and springs 4.
3. Install the manual starter handle 5.
c d
6B450250
23
NOTE:
5
4 Bend the outer end c of the spiral spring
onto the cutout d of the starter case.
1 a
a
6B450230
NOTE:
9 Tie a knot at the end of the starter rope as
shown in the illustration.
9 Be sure to leave 5–10 mm at the end a of
the starter rope.
5-15 6B45E11
6. Install the sheave drum 2 into the starter 9. Pull the manual starter handle 5 several
case 7. times to check that the sheave drum
turns smoothly and to check the starter
2
1
rope for slack. Repeat steps 4–8 if nec-
essary.
7
6B450260
2
NOTE:
Install the sheave drum, then set the spiral
spring by turning the sheave drum.
7. Install the spring 8 drive plate 9.

6B450290
10. Pull the manual starter handle complete-

3
ly, then measure the starter rope length.
Adjust if the starter rope length is out of
specification.
4
9
8
6B450270
5
8. Turn the sheave drum 2 3 times in the
direction of the arrow shown, and then
remove the starter rope from the notch
Starter rope length:
6B450300
6
e.
1,700–1,800 mm (66.9–70.8 in)
e
7
0
8
2 6B450280
NOTE:
Hold the starter plunger 0 while turning the
sheave drum as shown.
9
6B45E11 5-16
POWR Power unit
Reed valve
1 N·m (0.1 kgf·m, 0.7 ft·lb)
3 N·m (0.3 kgf·m, 2.2 ft·lb)

8 N·m (0.8 kgf·m, 5.8 ft·lb)
6B45060E

1 Bolt 3 M6 × 20 mm
2 Hose 1
3 Clip 1
4 Screw 3
5 Washer 3
6 Reed valve stopper 2
7 Reed valve 2
8 Support 1
5-17 6B45E11
Reed valve
Removing the reed valve assembly

1. Remove the reed valve assembly.
1
2
6B450330
6B450310
Valve stopper height:
E9.9D:
1.2–1.4 mm
Checking the reed valves
1. Check the reed valves for cracks or dam-
age. Replace if necessary.
(0.00473–0.00550 in)
E15D:
5.9–6.1 mm (0.2323–0.2402 in)
3
2. Check the reed valves for bending.
Measure the valve stopper height.
Replace if the bending or height exceeds
the specified limit.
4
5
6B450320 6
Valve bending limit:
0.2 mm (0.08 in)
7
8
9
6B45E11 5-18
POWR Power unit
Cylinder head, exhaust covers
25 N·m (2.5 kgf·m, 18 ft·lb)

2 N·m (0.2 kgf·m,1.4 ft·lb)
5 N·m (0.5 kgf·m, 3.6 ft·lb)
6 N·m (0.6 kgf·m, 4.4 ft·lb)

12 N·m (1.2 kgf·m, 8.7 ft·lb)
6 N·m (0.6 kgf·m, 4.4 ft·lb)

12 N·m (1.2 kgf·m, 8.7 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)

16 N·m (1.6 kgf·m, 1.2 ft·lb)
6 N·m (0.6 kgf·m, 4.4 ft·lb)

12 N·m (1.2 kgf·m, 8.7 ft·lb) 6B45070E

1 Spark plug 2
3 Cylinder head 1
5 Cylinder head cover 1
7 Thermostat cover 1
8 Thermostat 1
9 Bolt 4 M6 × 25 mm
10 Anode 1
11 Bolt 6 M6 × 16 mm
12 Bolt 11 M7 × 35 mm
13 Exhaust outer cover 1
14 Exhaust inner cover 1
15 Gasket 1 Not reusable t = 1.0 mm
16 Gasket 1 Not reusable t = 0.5 mm
17 Bolt 13 M6 × 30 mm
5-19 6B45E11
Cylinder head, exhaust covers
Removing the exhaust covers Removing the cylinder head

1. Remove the exhaust outer and inner cov- 1. Remove the spark plugs.
ers.
2. Remove the thermostat cover and the
thermostat.
1
2
3. Remove the cylinder head cover.
6B430051
3
6B450340 4
NOTE:
Insert a flat-head screwdriver between the
pry tabs to pry off the cover.
6B450970
5
Checking the exhaust covers
6
1. Check the exhaust covers for distortion or 4. Remove the cylinder head.
corrosion. Replace if necessary.
7
6B450360
6B450980
8
9
6B45E11 5-20
POWR Power unit
Checking the anode and cylinder 4. Check the cylinder head warpage.
head Replace the cylinder head if measured
1. Check the anode on the cylinder block. warpage exceeds the specified limit.
Clean the anode’s surface, and replace if
it has been eroded into half its size or
smaller.
6B450380
6B450370
cC
Do not oil, grease, or the anodes, other-
wise they will not be able to prevent gal-
vanic corrosion effectively.
6B450390
2. Clean the mineral deposits and contami-
nation on the cylinder head. Also check
for possible corrosion on the cylinder Warpage limit: 0.1 mm (0.004 in)
head. Replace if necessary.
3. Remove the carbon deposits on the sur- NOTE:

face of the combustion chamber. Check the warpage in the directions shown,
using a straightedge and a thickness gauge.
cC
Do not scratch the mating face of the
cylinder head and cylinder block.
5-21 6B45E11
Cylinder block
Cylinder block
1
2
3
4
8 N·m (0.8 kgf·m, 5.8 ft·lb)
15 N·m (1.5 kgf·m, 11 ft·lb)

29 N·m (2.9 kgf·m, 22 ft·lb)
5
6B45080E
6
1 Crankcase 1
7
2 Washer 1
3 Cylinder block 1
4 Crankshaft 1
6 Spacer 1
8
7 Dowel pin 2
8 Bolt 6 M8 × 60 mm
9 Hose 2
10 Clip 4
11 Joint 2
12
13
14
15
Arm
Collar
Spring
Bolt
1
1
1
1 M6 × 20 mm
9
16 Joint 1
6B45E11 5-22
POWR Power unit
Removing the crankcase Removing the crankshaft assembly

1. Remove the crankcase. 1. Remove the crankshaft.
6B450420
6B450400
NOTE:
Insert a flat-head screw driver between the
pry tabs to pry off the crankcase.
2. Check the crankcase for corrosion. Also

check the mating face of the crankcase
and the cylinder block for possible distor-
tion.
6B450410
5-23 6B45E11
Cylinder block
Checking the cylinder block a: 10 mm (0.039 in) from the cylinder head
cC top surface
b: 5 mm (0.20 in) above the exhaust port
Do not scratch the mating face of the
1
upper edge
cylinder head and cylinder block.
c: 5 mm (0.20 in) below the scavenging port
lower edge
1. Check the cylinder sleeves for cracks or
damage. Specified limits
2
Cylinder bore diameter (D):
2. Remove any rust or deposits on the cool- 56.1 mm (2.21 in)
ing water passage walls, and check for at 20°C (68°F)
corrosion. Clean or replace if necessary. Taper (T): 0.08 mm (0.0031 in)
Out of round (R):
NOTE:
0.05 mm (0.0020 in)
at 20°C (68°F)
3
9 Measure the cylinder bore diameter at the 6
positions shown.
9 To obtain the cylinder bore diameter (D),
select the largest of the D1-D6 measure-
4
ments.
9 Taper (T) is obtained by subtracting D5 from
6B450430
D1, and D6 from D2 and selecting the max-
imum value.
9 To obtain the roundness (R), calculate each
5
3. Remove the carbon deposits on the of the differences between D1 and D2, D3
6
exhaust passage walls, and check for and D4, and D5 and D6. Use the largest of
cracks or damage. Replace if necessary. the differences for the roundness (R) figure.
9 Oversize pistons are available in two sizes.
4. Measure the cylinder bore with a cylinder
gauge. Calculate the cylinder bore diame-
Oversize piston:
ter (D), taper (T), and roundness (R). If the
results exceed the specified limit, rebore
the cylinder sleeve, or replace the cylinder
block.
1st: 56.190–56.235 mm
(2.2122–2.2139 in)
2nd: 56.440–56.485 mm
7
(2.2220–2.2238 in)
8
6B450440
9
6B45E11 5-24
POWR Power unit
Crankshaft, piston
6B45090E

1 Needle bearing 50
2 Washer 4
3 Piston pin clip 4
4 Piston pin 2
5 Piston 2
6 Piston ring set 2
7 Crank 1 1
8 Bearing 2
9 Crank 2 1
10 Roller bearing 1
11 Labyrinth seal 1
12 Crank 3 1
13 Connecting Rod 2
14 Roller bearing 2
15 Washer 4
16 Crank pin 2
17 Crank 4 1
5-25 6B45E11
Crankshaft, piston
Disassembling the piston 3. Check the piston ring dimensions of B

1. Remove the piston pin clip, and then and T. Replace the piston ring if the
remove the piston pin. dimension is out of specification.
2. Separate the piston from the connecting

rod.
B
1
1
3. Remove the bearing and washers at the
T
connecting rod small end.
4. Remove the piston rings. B

2
6B450460
2
cC T
The disassembled pistons, piston rings,

piston pins, and bearings must be sorted
out and kept in order so that the compo-
nents from different cylinders will not be
Piston ring dimensions
Top ring 1:
B: 1.98–2.00 mm (0.078–0.079 in)
3
T: 2.4–2.6 mm (0.09–0.10 in)
mixed up.
4
Second ring 2:
B: 1.96–1.98 mm (0.077–0.078 in)
T: 2.4–2.6 mm (0.09–0.10 in)
Checking the pistons at 20°C (68°F)
1. Check the piston outside diameter.
Replace the piston if the diameter is out
of specification. 4. Check the piston ring side clearance.
Replace the piston and the piston rings
as a set if the measurement is out of
specification.
5
6
Piston outside diameter:
6B450450
6B450500
7
55.940–55.985 mm
(2.2024–2.2041 in)
at 20°C (68°F)
a: 10 mm (0.394 in)
NOTE:
9 Install the piston rings in accordance with
the specification, and measure the piston
ring side clearance with a thickness gauge.
8
2. Check the piston clearance. Replace the 9 When measuring the piston ring side clear-
piston and the piston ring, or the cylinder
block if out of specification.
Piston clearance:
ance, be sure the piston ring's outside
(peripheral) face is flush with the piston's
external surface.
9
0.035–0.040 mm
(0.0014–0.0016 in)
at 20°C (68°F)
6B45E11 5-26
POWR Power unit
Piston ring side clearance: 6. Measure the piston pin boss inside diam-
Top 0.02–0.06 mm eter. Replace the piston if the measure-
(0.0008–0.0024 in) ment is out of specification.
2nd 0.04–0.08 mm
(0.0016–0.0031 in)
at 20°C (68°F)
5. Measure the piston ring end gaps.

Replace the piston ring if the measure-
ment is out of specification.
6B450520
Piston pin boss inside diameter:

14.004–14.015 mm
(0.5513–0.5518 in)
at 20°C (68°F)
7. Measure the piston pin outside diameter.

Replace the piston pin if the measure-
ment is out of specification.
6B450510
NOTE:
Push in the piston ring with the piston crown 6B450530
to the specified measuring position H in the
cylinder. Piston pin outside diameter:
Make sure that the cylinder sleeve bore diam- 13.996–14.000 mm
eter falls within the specified limit. (0.5510–0.5512 in)
at 20°C (68°F)
Piston ring end gap:
0.15–0.35 mm (0.0059–0.0138 in)
at 20°C (68°F)
H: 20 mm (0.79 in)
5-27 6B45E11
Crankshaft, piston
Disassembling the crankshaft 3. Remove the crank pin by applying pres-

1. Remove the upper and lower bearings. sure to pressure pin A 4 with a hydraulic
press.
cC
9 Apply pressure to pressure pin A slowly.
9 Hold pressure pin A in line with the
1
press screw spindle.
2
3
Bearing separator: 90890-06534
6B450540
NOTE:
6B450560
9 When forcing out the crank pin, use care so

4
that the crank does not fall.
2. Insert plate A 1 between crank 1 2 and

crank 2 3. Place pressure pin A 4 in the
end of the crank pin 5.
9 To remove crank 4, follow the same proce-
dure. 5
6
5
7
6B450550
8
NOTE:
Remove the bearing before starting this pro-
cedure.
9
Insert plate A 1: 90890-02386
Pressure pin A 4: 90890-02389
6B45E11 5-28
POWR Power unit
4. Insert the support jig 1 between crank 2 6. By forcing pressure pin A 7 with a
and 3 2. Place pressure pin A 3 on the hydraulic press, remove the crank pin on
shaft, and force it out using a hydraulic cranks 2 and 3.
press.
7 6
6B450580
NOTE:
Pressure pin A should be pressed down
straight.
6B450570
Insert plate A 6: 90890-02386

Support jig 1: 90890-02394 Pressure pin A 7: 90890-02389
Pressure pin A 3: 90890-02389
7. Using the bearing separator, slightly

5. Remove the roller bearing 4 from the
move the inner race off the shaft.
inner race 5.
6B450600
6B450590
NOTE:
Use care not to scratch the shaft.
5-29 6B45E11
Crankshaft, piston
Assembling the crankshaft 3. Apply engine oil to the crank pin and
cC insert it into the crank pin hole by tapping
it with a copper hammer.
9 When reassembling the crankshaft,
wash all component parts in clean
kerosene (do not use gasoline).
9 Do not reuse bearings, always replace
them with new ones.
1
1. When the inner race has been previously
removed, use plate A and install the inner
race 1 onto crank 2 by using a drill press
and the bearing inner race attachment 6B450630
2
2. Carefully press the inner race onto the
crank pin. cC
9 Take care so that the crank pin is set
squarely into the crank web.
3
9 Do not apply force in excess of 5 tons.
NOTE:
Follow the same procedure for both crank 2
and crank 4 to press-fit the crank pins.
4
Plate A: 90890-02386
6B450610
Bearing inner race attachment 2:

4. Insert the proper bushing 1 or 2 into the
body 3, to assemble cranks 1 and 2.
5
1
90890-06644
2. Insert spacer B 3 into the crank pin hole

of crank 2 or 4.
6
4
3
3
B-5
1
7
6B450620
B-11
2 8
Spacer B 3: 90890-02396
Support jig 4: 90890-02394
NOTE:
9 Use B-5 1 with crank 2 when the bearing
6B450640
9
inner race has been removed. Use B-11 2
when the bearing inner race is installed.
9 Align the slot in the height ring with the slot
in the body.
6B45E11 5-30
POWR Power unit
5. Place the height ring (H-5) 4 in the body. 8. Mount the connecting rod and washer on
the crank pin.
6B450650
6B450670
Flange: 90890-02351
Body 3: 90890-02352 NOTE:
For crank 1 with the inner race The model number 2 on the connecting rod
removed, and crank 4 should face up.
Bushing-5 (B-5) 1: 90890-02359
For crank 1with the inner race
installed 9. Install bushing 3 or 4 on the pressure
Bushing-11 (B-11) 2: plate 5.
90890-02565
Height ring-5 (H-5) 4: B-5 5
90890-02371 3
6. Set crank 2 or crank 4 on the special ser- B-7

vice tool. 4
7. Mount the washer and big-end bearing 1

on the crank pin. 6B450680
For crank 1
Bushing-5 (B-5) 3: 90890-02359
For crank 3
Bushing-7 (B-7) 4: 90890-02361
Pressure plate 5: 90890-02384
10. Install crank 1 or crank 3.

6B450660
NOTE:
Apply engine oil to the crank pin.
6B450690
5-31 6B45E11
Crankshaft, piston
11. Align the crank pin hole in crank 1 or 13. Measure the width a of the assembled
crank 3 with the crank pin fitted to crank crankshaft using calipers. Measurements
2 or crank 4 and place the pressure plate should be made at positions 1 to 5.
1
in the body.
2
6B450700
12. Insert the press body 1, and press-fit

crank 1 or crank 3 onto the crank pin.
3
cC
Do not apply force in excess of 5 tons. 6B450720 4
Crank width:
5
46.90–46.95 mm
(1.8465–1.8484 in)
1 NOTE:
If any of the measurements is out of specifi-
6
cation, reassemble the crankshaft.
14. Install the roller bearing 1 onto crank 2.
a
1
7
Press body 1: 90890-02385
6B450710
6B450730
8
NOTE:
Make sure the pin a side of the bearing
faces crank 1. 9
6B45E11 5-32
POWR Power unit
15. Insert plate A 1 between crank 3 and cC

crank 4, and install the labyrinth seal 2
Do not apply force in excess of 7 tons.
on crank 3, before connecting crankshaft
assemblies 1 and 2.
Height ring-13 (H-13) 1:
90890-02379
Press body 2: 90890-02385
Plate B 3: 90890-02387
18. To install the upper and lower bearings,

use bearing pressure B 1 and the bear-
ing inner race attachment 2, and press-
6B450740 fit the bearings.
Plate A 1: 90890-02386
a
16. Insert plate B 1 between crank 1 and 1
crank 2, then place crank 2 onto crank 3.
2
a b
1
6B450780
6B450760 Bearing pressure B 1:

90890-02392
NOTE: Bearing inner race attachment 2:
Align the matching marks a on cranks 2 and 90890-06644
3.
NOTE:
9 Install the upper bearing so that the dowel
17. Place the height-ring 1 and press body
pin a faces the drive shaft side.
2 on plate B 3 and press-fit crank 2 into
9 Install the lower bearing so that the dowel
crank 3.
pin b faces the magneto side.
1 3
6B450770
5-33 6B45E11
Crankshaft, piston
Checking the crankshaft Assembling the piston

1. Measure the crankshaft run-out a at the 1. Install the piston rings 1, 2.
positions as shown. If out of specification,
adjust the crankshaft. 2
1 1
6B450810
2
NOTE:
Install the piston rings with the recess for the
locating pin facing up toward the piston
crown.
3
6B450790
Crankshaft run-out a:
0–0.03 mm (0–0.0012 in)
2. Install the needle bearings 1, washers
2, piston pin 3, and new clips 4. 4
Crankshaft aligner: 90890-03107
2. Slowly turn the crankshaft. If it does not

5
turn smoothly, disassemble the crank-
shaft and correct or replace any parts as
necessary. 6
7
8
6B450820
6B450800
NOTE:
9 Make sure that the piston and piston pin
bearings are installed in their original com-
bination.
9 Use the small end bearing installer 5 to
install the needle bearings.
9 Make sure that the up mark on the piston
9
crown faces the flywheel side.
Small end bearing installer 5:

90890-06543
6B45E11 5-34
POWR Power unit
Installing the crankshaft NOTE:

1. Install the washer, spacer and oil seal Clean the mating face of the cylinder block
onto the crankshaft. and crankcase.
Apply a thin coating of Gasket Maker on the
2. Install the pistons and crankshaft into the mating face so that it will not be squeezed out
cylinder block. of the edge.
3. Tighten the crankcase bolts.
6 2 3
5
1 4 6B450850
a b a a 6B450830
NOTE:
NOTE: Tighten the bolts to the specified torques in
9 Insert the bearing pins a in the slots in the two stages and in the sequence shown.
cylinder block. Apply some engine oil on each bolt’s threads.
9 Align the labyrinth seal ring b with the slot
in the cylinder block. Crankcase bolt:
1st:
15 N·m (1.5 kgf·m, 11 ft·lb)
Installing the crankcase 2nd:
29 N·m (2.9 kgf·m, 22 ft·lb)
1. Install the dowels.
2. Install the crankcase. Installing the cylinder head

1. Install the anode into the cylinder block.
6B450370
6B450840
5-35 6B45E11
Crankshaft, piston
2. Install the cylinder head gasket and cylin- NOTE:

der head. Tighten the cylinder head cover bolts to the
specified torque in two stages.
1
q
0 Cylinder head cover bolt:
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
7 2nd: 12 N·m (1.2 kgf·m, 8.7 ft·lb)
6
3
2
1
4. Install the thermostat gasket, and the
thermostat cover.
2
4
5
3
NOTE:
E
8 9 6B450860
6B430051
4
9 Tighten the cylinder head bolts in the
NOTE:
5
sequence shown.
9 Apply some engine oil on each bolt’s Tighten the thermostat cover bolts to the
threads. specified torques in two stages.
Cylinder head bolt: Thermostat cover bolt:

1st: 8 N·m (0.8 kgf·m, 5.8 ft·lb)
2nd:16 N·m (1.6 kgf·m, 12 ft·lb)
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.7 ft·lb)
6
3. Install the cylinder head cover gasket and
cylinder head cover.
7
8
9
E
6B450870
6B45E11 5-36
POWR Power unit
Installing the exhaust covers Installing the reed valve

1. Install the inner exhaust cover and gas- 1. Install the reed valve into the crankcase.
ket.
2. Install the outer exhaust cover and gas-

ket.
6B450310
NOTE:
Tighten the reed valve bolts to the specified
torque in two stages.
Reed valve:
1st: 3 N·m (0.3 kgf·m, 2.2 ft·lb)
2nd: 8 N·m (0.8 kgf·m, 5.8 ft·lb)
6B450880
2. Install the hoses.
Installing the electrical components

9
1. Install the pulser coil, charge coil, ignition
coil and CDI unit.
0
NOTE:
For wire routing, see Chapter 8, "Wire rout-
ing".
4
5
1 2. Connect each lead correctly.

3 2
Installing the throttle cam assembly
8 1. Install the throttle cam assembly on the
6
crankcase.
e w 7 q 6B450890
NOTE:
Tighten the exhaust outer cover bolts to the
specified torque in two stages and in the
sequence shown.
6B450990
Exhaust outer cover bolt:

1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.7 ft·lb)
5-37 6B45E11
Crankshaft, piston
Installing the spark plugs Flywheel magnet:

1. Install the spark plugs, and tighten to the 100 N·m (10 kgf·m, 74 ft·lb)
torque specified.
Flywheel holder: 90890-06522

1
Installing the manual starter
1. Install the manual starter.
2
6B451000
Spark plug:
25 N·m (2.5 kgf·m, 18 ft·lb) 3
2. Connect the spark plug caps.
Installing the flywheel assembly

1. Install the Woodruff key into the crank-
shaft.
4
NOTE:
Clean the oil on the tapered portion of the
crankshaft and flywheel magnet.
6B450920
5
6
2. Set the flywheel magnet on to the crank- Manual starter:
shaft, aligning the slot with the Woodruff 8 N·m (0.8 kgf·m, 5.8 ft·lb)
key.
3. Apply engine oil to the flywheel magnet Installing the carburetor
7
nut threads and tighten the flywheel mag- 1. Install the carburetor and intake silencer
net nut. onto the power unit.
Installing the fuel filter and hoses

1. Install the fuel filter onto the bracket on
the crankcase. Connect the fuel hose.
8
cC
6B450910
9
Apply force in the direction of the arrows
shown. While working, do not allow the fly-
wheel holder to slip off the flywheel.
6B45E11 5-38
POWR Power unit
Installing the oil seal housing Installing the throttle cables

1. Install the oil seal housing onto the power 1. Install throttle cable 1 onto the throttle
unit. cable stay.
NOTE:
Be sure the throttle grip is in the fully open
position when installing the throttle cable.
2. Adjust the throttle cable adjusting nut 3

so that the free axle lever 4 cam comes
into contact with the pulley 5 cam, then
6B450930
tighten the lock nut.
Oil seal housing:

8 N·m (0.8 kgf·m, 5.8 ft·lb)
Installing the power unit

1. Clean the mating face of the power unit
and the upper case, and install dowels
and a new gasket.
2. Install the power unit, and tighten the

bolts.
6B450950
3. Install throttle cable 2 onto the throttle

cable stay.
4. Adjust the throttle cable adjusting nut 6

so that the free axle lever 4 cam comes
into contact with the pulley 5 cam, then
tighten the lock nut.
6B450941
Power unit:
22 N·m (2.2 kgf·m, 16 ft·lb)
6B450960
5-39 6B45E11
Crankshaft, piston
5. Turn the throttle grip from fully closed to 2. Install the start-in-gear protection cable.
fully open and back, and check throttle
cables 1 and 2 for slack. Remove any
1
slack in the cables by following step 2 or
3 as necessary.
Installing the throttle link

1. Set the carburetor throttle lever 1 so that
it comes into contact with the stopper 2.
2. Connect the throttle link 3 to the free

axle lever and carburetor throttle lever 1 NOTE:
6B451010 2
9 Install the spring end of the start-in-gear
3
2
1 protection cable on the starter plunger 1.
9 Install the start-in-gear protection cable
4 outer end so that it comes into contact with
the starter case outer end connection point
2.
3
6B430111
9 Install the start-in-gear protection cable
grommet on the starter case, and install the
adjusting nut end of the cable on the lever
4
3.
3. While pushing the carburetor throttle
lever 1 and throttle link 3 in the direc-
tion shown, tighten the screw 4 to hold it
in place.
3. Using the adjusting nut 4, align the
starter plunger 1 with the mark a on the
5
starter case.
4. Turn the throttle grip from fully closed to
fully open and back, and check that the
carburetor throttle lever fully closes.
Adjust by repeating steps 2 and 3 if nec-
6
2 4
essary. a 1 3
Installing the start-in-gear protection

cable
7
1. Put the gear shift in neutral.
R
N
F 6B430311
8
6B410091
9
6B45E11 5-40
POWR Power unit
4. Check that the starter rope can be pulled

with the the gear shift in neutral. Also
check that the starter rope cannot be
pulled with the gear shift in forward and
reverse. Adjust the start-in-gear protec-
tion cable if necessary.
5. Connect the choke rod.
6B451020
6. Connect the engine shut-off switch lead

and ground lead.
7. Connect the pilot water hose and fuel

hose.
5-41 6B45E11
LOWR
Lower unit
Lower unit .......................................................................................................6-4 1

Water pump.....................................................................................................6-5
Propeller shaft, propeller shaft housing ......................................................6-6

Removing the lower unit ............................................................................6-7
Removing the water pump and shift rod....................................................6-7
2
Checking the water pump and shift rod.....................................................6-8
Removing the propeller shaft housing assembly.......................................6-9
Disassembling the propeller shaft housing assembly................................6-9
Checking the propeller shaft housing assembly ......................................6-10
Assembling the propeller shaft housing assembly ..................................6-10
3
Disassembling the propeller shaft assembly ...........................................6-11
Checking the propeller shaft assembly....................................................6-12
Assembling the propeller shaft assembly ................................................6-12 4
Drive shaft, shift rod, lower case ................................................................6-13
Removing the drive shaft and forward gear.............................................6-15
Disassembling the lower case .................................................................6-15
Checking and disassembling the bearing housing ..................................6-16
Assembling the bearing housing .............................................................6-16
5
Checking the forward gear.......................................................................6-17
Assembling the forward gear ...................................................................6-17
Checking the drive shaft ..........................................................................6-17
Checking the pinion gear.........................................................................6-18
6
Assembling the lower unit ..........................................................................6-18
Installing the lower case ..........................................................................6-18
Installing the water pump.........................................................................6-20
Installing the lower unit ............................................................................6-21
7
Shimming ......................................................................................................6-23
Selecting the pinion shims.......................................................................6-24
Selecting the forward gear shims ............................................................6-24
Selecting the reverse gear shims ............................................................6-25
8
Backlash........................................................................................................6-26
Measuring the forward and reverse gear backlash .................................6-26 9
6B45E11
LOWR Lower unit
Dial gauge set Bearing puller assembly

90890-01252 90890-06535
Stopper guide plate Stopper guide stand

90890-06501 90890-06538
Center bolt Bearing housing puller claw S

90890-06504 90890-06564
Drive shaft holder 1 Driver rod SL

90890-06515 90890-06602
Bearing Separator Bearing depth plate

90890-06534 90890-06603
6-1 6B45E11
1
Driver rod SS
90890-06604
Bearing outer race attachment
90890-06625, 06627
2
3
Driver rod LL Bearing inner race attachment
90890-06605 90890-06644
4
5
Driver rod LS Bushing attachment
90890-06606 90890-06649
6
Needle bearing attachment Driver rod L3
7
90890-06613, 90890-06616 90890-06652
8
Needle bearing attachment Shimming plate
9
90890-06617 90890-06701
6B45E11 6-2
LOWR Lower unit
Digital caliper
90890-06704
Magnet base
90890-06841
Backlash indicator
90890-06706
Magnet base plate

90890-07003
6-3 6B45E11
Lower unit
Lower unit
9 N·m (0.9 kgf·m, 6.6 ft·lb)

17 N·m (1.7 kgf·m, 12 ft·lb)
1
18 N·m (1.8 kgf·m, 13 ft·lb)
2
3
4
5
9 N·m (0.9 kgf·m, 6.6 ft·lb)
No.
9 N·m (0.9 kgf·m, 6.6 ft·lb)
Part name Q’ty

4.3 N·m (0.43 kgf·m, 3 ft·lb)
Remarks
6B46010E
6
1 Bolt 1 M8 × 35mm
2
3
4
5
Anode
Special washer
Bolt
Screw
1
1
1
1
M6 × 20mm
7
6 Inlet cover 1
7
8
9
Cotter pin
Propeller nut
Washer
1
1
1
Not reusable
8
10 Propeller 1
11 Spacer 1
12
13
14
Screw
Gasket
Lower case
3
3
1
Not reusable 9
15 Rubber seal 1
16 Dowel 2
17 Shift rod 1
6B45E11 6-4
LOWR Lower unit
Water pump
8 N·m (0.8 kgf·m, 5.8 ft·lb)
6B46030E

1 Screw 1
2 Cover 1
3 Water seal rubber 1
4 Water pump housing 1
5 Insert cartridge 1
6 Impeller 1
7 Woodruff key 1
8 Outer plate cartridge 1
10 Dowel 2
11 Bracket 1
12 Plate 2
13 Bolt 2 M6 × 45mm
14 Shift rod 1
15 Washer 1
16 Boot 1
17 Nut 1
6-5 6B45E11
Water pump/Propeller shaft, propeller shaft housing
Propeller shaft, propeller shaft housing
1
2
8 N·m (0.8 kgf·m, 5.8 ft·lb)
3
4
0 mm
3.0 — 3.5 mm
(0.12 — 0.14 in)
5
6B46020E
6
1 Bolt 1 M6 × 20mm
2
3
4
5
Oil seal
O-ring
Needle bearing
Ball bearing
2
1
1
1
Not reusable
Not reusable
Not reusable
Not reusable
7
6 Propeller shaft housing 1
7
8
9
Reverse gear shim
O-ring
Washer
1
1
1
Not reusable 8
10 Reverse gear 1
11 Propeller shaft 1
12
13
14
Spring
Cross pin ring
Cross pin
1
1
1
9
15 Dog clutch 1
16 Shift plunger 1
6B45E11 6-6
LOWR Lower unit
Removing the lower unit 6. Disconnect the shift rod. Loosen the
1. Remove the clip for the engine shut-off adjuster while holding the lock nut.
switch. NOTE:
Set the gear shift in reverse first.
2. Set the gear shift in the neutral position.
7. Tilt up the outboard motor and remove
3. Remove the drain screw 3, then the
the lower unit after removing the bolts.
check screw 4 to drain the gear oil.
8. Remove the anode and cooling water
inlet cover.
4
6B430200
6B460020
4. Remove the cotter pin.
5. Place a block of wood between the anti- Removing the water pump and shift
cavitation plate and the propeller, and rod
remove the propeller. 1. Remove the water pump 1 and the shift
rod 2.
1
2
6B460010
w
9 Place a block of wood between the anti-
cavitation plate and the propeller. Do not
touch the propeller with your hands.
9 Remove the clip for the engine shut-off
switch to prevent the engine from start-
ing. 6B460030
NOTE:
9 Remove the Woodruff key from the drive
shaft, then the outer plate cartridge.
9 Make sure the dowels were removed from
the lower case.
6-7 6B45E11
Propeller shaft, Propeller shaft housing
Checking the water pump and shift 4. Check the Woodruff key 4 and the
rod groove a for wear. Replace if necessary.
1. Check the water pump housing 1 for
a
1
deformation. Also check the insert car-
tridge 2 for wear or deformation.
2 4
6B460060
2
2. When the insert cartridge is removed,
6B460040
5. Check the outer plate cartridge for cracks
or damage. Replace if necessary.
3
insert the projection on the insert car-
tridge into the water pump housing hole
at the time of reassembly.
4
1
2
6B460070
6. Check the shift rod for deformation or

5
wear. Replace if necessary.
NOTE:
6B460050
6
When installing the insert cartridge, insert the
projection on the insert cartridge into the
water pump housing hole.
7
6B460080
3. Check the impeller for cracks or wear.
8
9
6B460055
6B45E11 6-8
LOWR Lower unit
Removing the propeller shaft 3. Remove the ball bearing.

housing assembly
1. Remove the bolts and remove the pro-
peller shaft housing assembly by prying 1
the tabs apart with slot-head screw-
drivers.
6B460110
6B460090
NOTE: Stopper guide plate 1:

Make sure that the shims left in the lower 90890-06501
case have been removed. Stopper guide stand 2:
90890-06538
Disassembling the propeller shaft Bearing puller assembly 3:
90890-06535
housing assembly
1. Remove the reverse gear.
4. Remove the oil seals, then remove the
needle bearing.
6B460100 2
2. Check that the bearing spins smoothly in

the housing. Check for roughness, wear,
and damage.
6B460120
NOTE:
When the oil seal or the needle bearing is
removed, always replace them with new
ones.
6B460620
Driver rod L3 1:
90890-06652
90890-06616
6-9 6B45E11
cC Assembling the propeller shaft

housing assembly
Shimming is required when the reverse
1. Install a new needle bearing into the pro-
gear, ball bearing, or propeller shaft hous-
1
peller shaft housing to the specified
ing is replaced.
depth using a press.
Checking the propeller shaft
housing assembly
1. Clean the propeller shaft housing and
check it for cracks, corrosion, or damage.
1
2 2
a
3
4
6B460150
6B460130
Driver rod SS 1:
90890-06604
2. Check the teeth and dogs of the reverse
gear for cracks or wear. Replace the gear
if necessary.
90890-06616
Installation depth a :
5
0 mm (0 in)
6
6B460140
7
8
9
6B45E11 6-10
LOWR Lower unit
2. Install new oil seals into the propeller Bearing outer race attachment 6:
shaft housing to the specified depth. 90890-06627
Driver rod LS 7:
90890-06606
5
4. Install the reverse gear into the propeller
4 shaft housing.
6B460160
NOTE:
First, drive the inner oil seal halfway into the
propeller shaft housing, and then drive in the
outer oil seal to the specified depth.
6B460180
Needle bearing attachment 4: NOTE:

90890-06613 Shimming is required when the reverse gear
Driver rod SS 5: or ball bearing is replaced.
90890-06604
Disassembling the propeller shaft
Installation depth b: assembly
3.0–3.5 mm (0.1181–0.1378 in) 1. Remove the shift plunger 1.
2. Remove the cross pin ring 2, pull out the

3. Install the ball bearing into the propeller cross pin 3, and remove the dog clutch
shaft housing. 4.
7 6 3. Pull out the spring 5.
2
4
1
5
6B460190
6B460170
6-11 6B45E11
Checking the propeller shaft Assembling the propeller shaft

assembly assembly
1. Check the propeller shaft for bends or 1. Insert the spring 1.
1
2. Install the dog clutch 2 so that the “F”
mark faces the forward gear, and insert
the cross pin 3.
5
4 3
2
1 2
6B460200
2. Measure the propeller shaft run-out.

6B460230
3
3. Install the cross pin ring 4 and shift
plunger 5.
4
6B460210 5
Run-out limit: 0.05 mm (0.0020 in)
3. Check the dog clutch for breakage or

6
7
8
6B460220
9
6B45E11 6-12
LOWR Lower unit
Drive shaft, shift rod, lower case
(0.31 — 0.35 in)

8 — 9 mm
182.2 — 182.7 mm
(7.17 — 7.19 in)
25 N·m (2.5 kgf·m, 18 ft·lb)

6B46040E

2 Set plate 1
3 Screw 1
4 Water tube 1
6 Pinion gear nut 1
7 Pinion gear 1
8 Forward gear 1
9 Taper roller bearing 1 Not reusable
10 Forward gear shim 1 As required
11 Pinion gear shim 1 As required
12 Thrust bearing 1
13 Needle roller bearing 1 Not reusable
14 Drive shaft 1
15 Drive shaft sleeve 1
6-13 6B45E11
(0.31 — 0.35 in)

2
8 — 9 mm
3
4
182.2 — 182.7 mm
(7.17 — 7.19 in)
5
25 N·m (2.5 kgf·m, 18 ft·lb)

6B46040E
6
16 Bushing 1
17
18
19
20
Bearing housing
Gasket
Oil seal
Cover
1
1
2
1
Not reusable
Not reusable
7
21 Dowel 1
22
23
24
Extension
Bolt
Dowel
1
4
2
X transom
M8 × 35mm: X transom
X transom
8
9
6B45E11 6-14
LOWR Lower unit
Removing the drive shaft and Disassembling the lower case

forward gear 1. Remove the taper roller bearing outer
race.
NOTE:
Shimming is required when the forward gear
or taper roller bearing is replaced.
1. Loosen the pinion nut.

1
1 2
6B460250
NOTE:
Install the puller claw as shown.
6B460240
Stopper guide plate 1:
90890-06501
Drive shaft holder 1 1: Bearing puller assembly 2:
90890-06515 90890-06535
2. Remove the pinion gear, shim, thrust 2. Remove the needle bearing.
bearing, and washer, then remove the
drive shaft.
3. Remove the bearing housing.

2
4. Remove the drive shaft sleeve.
1
5. Remove the forward gear.
6B460260

90890-06617
Driver rod L3 2:
90890-06652
6-15 6B45E11
Checking and disassembling the NOTE:

bearing housing Align the grooves in the bushing with the slit
1. Check the bearing housing for cracks or in the bearing housing.
1
damage. Also check the bushing for wear,
and the oil seals for damage. Driver rod SS 1:
Disassemble if necessary. 90890-06604
Bushing attachment 2:
2. Remove the cover and the oil seals.
90890-06649
3. Remove the bushing.
2
2. First, drive the inner oil seal halfway into
the drive shaft housing, then drive in the
2
outer oil seal to the specified depth.
5
3
1
b
4
4
5
A
6B460270
6B450290
NOTE:
When the bushing and oil seals are removed,
always replace them with new ones. Needle bearing attachment 4:
6
90890-06613
Bushing attachment 1: Driver rod LS 5:
90890-06649 90890-06606
Driver rod L3 2:
90890-06652 Installation depth b:
Assembling the bearing housing

1. Install the bushing using a press.
8.0–9.0 mm (0.3149–0.3543 in)
3. Install the cover.

7
1
8
9
E
2
6B460280
6B45E11 6-16
LOWR Lower unit
Checking the forward gear Checking the drive shaft

1. Check the teeth and dogs of the forward 1. Check the drive shaft for bends or wear.
gear for cracks or wear. Also check the Replace the shaft if necessary.
bearing for run-out or roughness.
Disassemble if necessary.
2. Remove the bearing
3
1
2
6B460320
2. Measure the drive shaft run-out.
6B460300
Bearing separator 1:
90890-06534
90890-06616
Driver rod SS 3:
90890-06604 6B460330
NOTE:
When the taper roller bearing is removed Run-out limit:
always replace it with a new one. 0.5 mm (0.0197 in)
Assembling the forward gear 3. Check the needle bearing and the thrust
1. Install a new taper roller bearing.
bearing for run-out or roughness.
cC
Shimming is required when the thrust
4 bearing is replaced.
6B460310
NOTE:
Shimming is required when the taper roller
bearing is replaced.
Bearing inner race attachment 4:

90890-06644
6-17 6B45E11
Assembling the lower unit
Checking the pinion gear 2. Install the needle bearing.

1. Check the pinion gear teeth for cracks or
wear. 4
5
a
1
6B460340
3
6B460360 2

Installing the lower case
1. Install the shims and the taper roller bear-
90890-06617
Driver rod SL 4:
90890-06602
Bearing depth plate 5:
3
ing outer race. 90890-06603
Depth a:
182.2–182.7 mm (7.17–7.19 in)
4
1
2
3. Install the forward gear assembly.
5
E 6B460350
6
cC
Shimming is required when the forward
gear, the taper roller bearing, or the lower
case is replaced. Record the measured
7
height of the bearing.
Bearing outer race attachment 1:

90890-06625
8
Driver rod LL 2:
90890-06605
9
6B45E11 6-18
LOWR Lower unit
4. Install the drive shaft sleeve, bearing Drive shaft holder 1 5:

housing assembly, driveshaft, washer, 90890-06515
thrust bearing, shim, and pinion gear.
cC Pinion nut:
9 Shimming is required when the drive 25 N·m (2.5 kgf·m, 18 ft·lb)
shaft housing or the drive shaft is
replaced. 6. Install the propeller shaft assembly.
9 Shimming is required when the thrust
bearing is replaced.
6B460390
7. Install the shift rod assembly, and tighten

the screw.
6B460370
NOTE:
Install the drive shaft by lifting it up slightly,
then aligning its splines with the pinion gear.
5. Tighten the pinion nut.
5 6B460400
6B460380
6-19 6B45E11
Installing the water pump

8. Install the shim(s), washer, and propeller
1. Install the gasket 1 , the dowels 2, the
shaft housing assembly.
outer plate cartridge 3, and the second
gasket 4.
2 4
1
3
6B460410
1
2
9. Install the propeller housing and tighten
the bolts. 3
6B460440
4
6B460420
2. Install the Woodruff key 5 into the drive
shaft.
3. Install the impeller 6 after aligning it with

5
Propeller housing bolt: the Woodruff key.
6
8 N·m (0.8 kgf·m, 5.8 ft·lb)
10. Make sure that the shifting mechanism

works properly. A 6
7
8
5
6B460450
6B460430
NOTE:
Change the shift rod position to forward, to
reverse, and to neutral. Make sure that the
NOTE:
9 Align the groove on the impeller with the
Woodruff key.
9 Apply Yamaha grease A on the sliding face
9
propeller shaft rotating direction is correct in
between the impeller and the outer plate
forward and in reverse. Also make sure that
cartridge.
the position is correct in neutral.
6B45E11 6-20
LOWR Lower unit
4. Install the water seal rubber and water 2. Put the gear shift lever in reverse. Make
pump housing cover into the water pump sure that the shift rod is in the reverse
housing assembly, then install the water position. Install the lower unit onto the
pump housing on the lower case. upper case, and tighten the lower case
bolts to the specified torque.
Lower case bolt:

18 N·m (1.8 kgf·m, 13 ft·lb)
NOTE:
9 Screw in the lock nut completely.
9 Push the shift rod down to shift into reverse.
3. Connect the shift rod.

NOTE:
Screw the connecting nut down until it comes
in contact with the lock nut.
6B460460
NOTE:
To install the water pump housing, apply
Yamaha grease A to the inner face of the
water pump housing assembly, and then turn
the drive shaft clockwise while pushing down
on the pump housing.
6B460480
Water pump housing bolts:

8 N·m (0.8 kgf·m, 5.8 ft·lb) 4. Install the anode and inlet cover to their
original positions and tighten the anode
bolt to the specified torque.
Installing the lower unit
1. Install the dowels into the lower case.
6B460470
6B460020
Anode bolt:
18 N·m (1.8 kgf·m, 13 ft·lb)
6-21 6B45E11
5. Install the propeller and the propeller nut.

Place a block of wood between the anti-
cavitation plate and the propeller to keep
1
the propeller from turning. Then tighten
the nut to the specified torque.
2
6B430210

Hypoid gear oil
SAE: 90
6B460500 Oil quantity:
0.25 L (8.5 US oz, 8.8 Imp oz) 3
7. Install the check screw, and quickly install
the drain screw.
4
w
6B460510
5
9 Place a block of wood between the anti-
cavitation plate and the propeller. Do not
touch the propeller with your hands.
9 Remove the clip for the engine shut-off
switch to prevent the engine from start-
6
ing.
NOTE:
If the grooves in the propeller nut do not align
7
with the cotter pin hole, tighten the nut further
8
until they are aligned.
Propeller nut:
17 N·m (1.7 kgf·m, 12 ft·lb)
6. Insert the gear oil tube into the drain hole

and fill the gear oil until it flows out of the
check hole and no air bubbles are visible.
9
6B45E11 6-22
LOWR Lower unit
Shimming
M1
T3
T2
T1 M2 M3-10 mm (0.39 in)
6B460531
6-23 6B45E11
Shimming
Shimming 3. Select the pinion shim(s) (T3) as follows.

NOTE:
9 Shimming is not required when assembling Calculated numeral
Use shim
1
the original lower case and inner parts. more than less than
9 Shimming is required when assembling the 1.13 1.20 1.13
original inner parts and a new lower case. 1.20 1.30 1.20
9 Shimming is required when replacing the
inner part(s). Available shims:
Selecting the pinion shims

1. Measure the thickness (M1) of the roller
bearing with the special service tool.
1.13 and 1.20
Selecting the forward gear shims

2
1. Turn the taper roller bearing outer race 1
1
two or three times to seat the rollers,
then measure the bearing height (M2) as
shown.
3
4
M2
5
6
M1
6B460550
6B460540
NOTE: NOTE:
9 Measure the roller bearing at 3 points to 9 Select the shim thickness (T1) by using the
find the clearance average.
9 Select the shim thickness (T3) by using the
specified measurement and the calculation
formula.
specified measurement(s) and the calcula-
tion formula.
9 Measure the bearing outer race at three
points to find the height average.
7
Digital caliper 1:
90890-06704
Shimming plate 2:
90890-06701
Digital caliper 3:
8
90890-06704
2. Calculate the pinion shim thickness.
Pinion shim thickness

(T3) = M1 - 6.00
9
6B45E11 6-24
LOWR Lower unit
2. Calculate the shim thickness.
Forward gear shim thickness

(T1) = 16.55 - M2
M3
3. Select the forward gear shim(s) (T1) as
follows.
Calculated numeral 6B460570
at 1/100th place Use shim

more than less than
Shimming plate 1:
0.00 0.02 0.00
90890-06701
0.02 0.05 0.02
Digital caliper 2:
0.05 0.08 0.05
90890-06704
0.08 0.10 0.08
3. Calculate the shim thickness.

Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
Reverse gear shim thickness
and 0.50 mm
(T2) = 80.52 - M3
Selecting the reverse gear shims Calculated numeral

1. Remove the reverse gear shim and install at 1/100th place Use shim
the reverse gear into the end cap. more than less than
0.30 0.40 0.30
2. Measure (M3) as shown. 0.40 0.50 0.40
0.50 0.60 0.50
0.60 0.70 0.60
2 Available shims:
0.10, 0.20, 0.30, 0.40, and 0.50
6B460560
6-25 6B45E11
Backlash
Backlash 5. Install the backlash indicator onto the

Measuring the forward and reverse drive shaft (13 mm [0.51 in] in diameter),
gear backlash then the dial gauge onto the lower unit.
1. Remove the water pump assembly.
2. Set the gearshift to the neutral position. 1

7
a
2
9
6B460430
8 6
b
3
3. Install the special service tool so that it
pushes against the propeller shaft.
3 5 6B460590
4
NOTE:
Install the dial gauge so that the plunger a
contacts the mark b on the backlash indica-
tor. 5
Backlash indicator 6:
6
4
90890-06706
Magnet base plate 7:
90890-07003
Dial gauge set 8:
6B460580
90890-01252
NOTE:
Tighten the center bolt while turning the drive
shaft until the drive shaft can no longer be
Magnet base 9:
90890-06841 7
turned. 6. Slowly turn the drive shaft clockwise and
Bearing housing puller claw S 3:

90890-06564
counterclockwise and measure the back-
lash when the drive shaft stops in each
direction. 8
Stopper guide plate 4:
Forward gear backlash:
9
90890-06501
0.19–0.86 mm (0.0075–0.0339 in)
Center bolt 5:
90890-06504
4. Turn the lower unit upside down.
6B45E11 6-26
LOWR Lower unit
7. Add or remove shims if out of specifica-

tion.
Forward gear
Shim thickness
backlash
Less than To be decreased by
0.19 mm (0.0075 in) (0.52 - M) × 0.43
More than To be increased by
0.86 mm (0.0339 in) (M - 0.52) × 0.43
M: Measurement
Available shim thicknesses:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
and 0.50 mm
8. Remove the special service tools from

the propeller shaft. 6B460610
9. Apply a load to the reverse gear by

installing the propeller 0 without the Reverse gear backlash:
spacer q, then the washer w and nut e 0.96–1.65 mm (0.0378–0.650 in)
as shown.
12. Add or remove shims if out of specifica-
q 0 tion.
Reverse gear
Shim thickness
e backlash
w Less than To be decreased by
0.96 mm (0.0378 in) (1.3 - M) × 0.43
More than To be increased by
1.65 mm (0.650 in) (M - 1.3) × 0.43
6B460600
M: Measurement
10. Tighten the propeller nut. Available shim thicknesses:

0.10, 0.20, 0.30, 0.40, and
Propeller nut: 0.50 mm
5 N·m (0.5 kgf·m, 3.6 ft·lb)
13. Remove the special service tools, then

11. Slowly turn the drive shaft clockwise and install the water pump assembly.
counterclockwise and measure the back-
lash when the drive shaft stops in each
direction.
6-27 6B45E11
BRKT
Bracket unit
Tiller handle ....................................................................................................7-1
Bottom cowling ..............................................................................................7-3 1

Upper case ......................................................................................................7-5
Removing the muffler assembly ................................................................7-7
Disassembling the muffler assembly .........................................................7-7
Disassembling the upper case ..................................................................7-7
Checking the upper case...........................................................................7-8
2
Assembling the upper case .......................................................................7-9
Swivel bracket ..............................................................................................7-11 3

Clamp bracket...............................................................................................7-12
4
5
6
7
8
9
6B45E11
BRKT Bracket unit
Tiller handle
18 N·m (1.8 kgf·m, 13 ft·lb)
18 N·m (1.8 kgf·m, 13 ft·lb)
1.6 N·m (0.16kgf·m, 1.2 ft·lb) 6B47010E

1 Tiller handle 1
2 Bushing 1
3 Bushing 1
4 Washer 1
5 Wave washer 1
6 Cover 1
7 Bolt 1 M8 × 30 mm
8 Bolt 1 M8 × 50 mm
9 Throttle fricton adjuster 1
10 Friction piece 1
11 Cotter pin 1
12 Nut 1
13 Throttle grip 1
14 Rubber grip 1
15 Screw 1
16 Washer 2
17 Spring 1
7-1 6B45E11
Tiller handle
1
18 N·m (1.8 kgf·m, 13 ft·lb)
2
3
4
18 N·m (1.8 kgf·m, 13 ft·lb)
5
No. Part name
1.6 N·m (0.16kgf·m, 1.2 ft·lb)
Q’ty Remarks
6B47010E
6
18 Bushing 1
7
19 Throttle lever 1
20 Throttle cable 2
8
9
6B45E11 7-2
BRKT Bracket unit
Bottom cowling
8 N·m (0.8 kgf·m, 5.8 ft·lb)

8 N·m (0.8 kgf·m, 5.8 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)
3.5 N·m (0.4 kgf·m, 2.5 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)

6B47020E

1 Shift handle 1
2 Shift rod lever 1 1
3 Screw 1
4 Shift rod lever 2 1
5 Screw 1
6 Spring 1
7 Bolt 1 M6 × 16 mm
8 Shift rod 1
9 Bracket 1
10 Bolt 2 M6 × 25 mm
11 Grommet 1
12 Fuel joint 1
13 Bolt 1 M6 × 20 mm
14 Seal 1
15 Engine shut-off switch 1
16 Spring hook 1
17 Bolt 1 M6 × 16 mm
7-3 6B45E11
Bottom cowling
8 N·m (0.8 kgf·m, 5.8 ft·lb)
1
8 N·m (0.8 kgf·m, 5.8 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)
2
3
8 N·m (0.8 kgf·m, 5.8 ft·lb)
4
3.5 N·m (0.4 kgf·m, 2.5 ft·lb)
5
8 N·m (0.8 kgf·m, 5.8 ft·lb)

6B47020E
6
18 Spring 1
7
19 Hook 1
20 Bushing 1
21 Bushing 1
22 Washer 1
23 Lever 1
8
24 Bolt 1 M6 × 14 mm
25 Choke knob 1
26 Grommet 1
27 Seal 1
28 Bolt 4 M6 × 14 mm
29
30
31
Rubber seal
Nut
Upper cowling
1
1
1
9
6B45E11 7-4
BRKT Bracket unit
Upper case
8 N·m (0.8 kgf·m, 5.8 ft·lb) 12 N·m (1.2 kgf·m, 8.7 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)
20 N·m (2.0 kgf·m, 14 ft·lb)
21 N·m (2.1 kgf·m, 15 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)
20 N·m (2.0 kgf·m, 14 ft·lb) 6B47030E

1 Upper case 1
2 Bolt 4 M6 × 25 mm
3 Protector 1
4 Rubber seal 1
5 Plate 1
6 Exhaust manifold 1
7 Rubber seal 1
8 Pipe 1
9 Circlip 1 Except S transom models
10 Drive shaft bushing 1 Except S transom models
11 Dowel 2
13 Bolt 6 M6 × 20 mm
14 Bolt 2 M6 × 30 mm
15 Exhaust guide 1
17 Screw 1 M6 × 12 mm
7-5 6B45E11
Upper case
8 N·m (0.8 kgf·m, 5.8 ft·lb) 12 N·m (1.2 kgf·m, 8.7 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)

1
20 N·m (2.0 kgf·m, 14 ft·lb)
2
21 N·m (2.1 kgf·m, 15 ft·lb)
3
8 N·m (0.8 kgf·m, 5.8 ft·lb)
4
5
6
20 N·m (2.0 kgf·m, 14 ft·lb) 6B47030E

18 Ground lead 1
7
19 Upper mount 2
20 Bolt 4 M6 × 25 mm
21 Washer 2
22 Washer 2
23 Rubber washer 2
8
24 Nut 2
25 Rubber seal 2
26 Mount housing 2
27 Bolt 2 M8 × 85 mm
28 Bolt 1 M8 × 55 mm
29
30
31
32
Nut
Lower mount 1
Lower mount 2
Nut
3
1
2
4 [option]
9
33 Splash plate 1 [option]
34 Bolt 4
6B45E11 7-6
BRKT Bracket unit
Removing the muffler assembly Disassembling the upper case
1. Remove the muffler assembly from the 1. Remove the upper mount brackets.
upper case.
6B470110
6B470010
2. Remove the lower mount brackets.

Disassembling the muffler assembly
1. Remove the exhaust manifold and gasket

from the exhaust guide.
6B470030
6B470020
2. Remove the water tube and water seal

rubber from the muffler.
7-7 6B45E11
Upper case
3. Remove the protector, rubber seal and Checking the upper case
rubber seal plate. 1. Check the water tube for deformation or
corrosion. Replace if necessary.
1
6B470060
2
2. Check the exhaust guide, exhaust mani-
fold for damage or corrosion. Replace if
necessary. 3
6B470040
4. Remove the circlip and drive shaft bush-

4
ing (for L and X transom models).
6B470070
5
3. Check the protector and rubber seal plate
6
for damage or corrosion. Replace if nec-
essary.
4. Check the rubber seal for cracks, deteri-

nation and damage. Replace if neces-
7
6B470050
sary.
8
9
6B470080
6B45E11 7-8
BRKT Bracket unit
Assembling the upper case 3. Install the exhaust manifold and a new
1. Install the drive shaft bushing and circlip gasket onto the exhaust guide and tight-
into the upper case on L and X transom en the bolts.
models.
6B470051
2. Install the rubber seal plate, rubber seal

and protector into the upper case.
6B470090
Exhaust manifold:
8 N·m (0.8 kgf·m, 5.8 ft·lb)
4. Install the water seal and water tube into

the exhaust manifold.
6B470040
Protector:
8 N·m (0.8 kgf·m, 5.8 ft·lb)
7-9 6B45E11
Upper case
5. Install the upper mount bracket and lower 6. Install the muffler assembly into the
mount bracket. upper case.
1
2
3
NOTE:
6B470100
Muffler assembly:
6B470010
4
Install the rubber seal so that the mark faces
12 N·m (1.2 kgf·m, 8.7 ft·lb)
5
up, and the grooves fit completely into the
holes in the upper case.
Upper case:
8 N·m (0.8 kgf·m, 5.8 ft·lb)
Upper mount:
21 N·m (2.1 kgf·m, 15 ft·lb)
Lower mount:
6
20 N·m (2.0 kgf·m, 14 ft·lb)
7
8
9
6B45E11 7-10
BRKT Bracket unit
Swivel bracket
8 N·m (0.8 kgf·m, 5.8 ft·lb)
3 N·m (0.3 kgf·m, 2.2 ft·lb)
6B47040E

1 Grease nipple 1
2 Ground lead 1
3 Friction piece 1
4 Spring 1
5 Washer 1
6 Seal 1
7 Bolt 1 M8 × 25 mm
8 Steering bracket 1
9 Dowel 2
10 Bolt 3 M6 × 25 mm
11 Steering pivot 1
12 Washer 1
13 Bushing 1
14 Bushing 1
16 Bushing 1
17 Bolt 2 M6 × 105 mm
7-11 6B45E11
Swivel bracket/Clamp bracket
Clamp bracket
2.5 N·m (0.2 kgf·m, 1.8 ft·lb)
12 N·m (1.2 kgf·m, 8.7 ft·lb)

1
12 N·m (1.2 kgf·m, 8.7 ft·lb)
2
3
4
8 N·m (0.8 kgf·m, 5.8 ft·lb)
5
6B47050E
6
1 Port clamp bracket 1
7
2 Starboad clamp bracket 1
3 Ground lead 1
4 Screw 1
5 Clamp handle 2
6 Pin 2
8
7 Clamp screw 2
8 Clamp pad 2
9 Bolt 1 M12 × 190
10 Washer 2
11 Bushing 2
12
13
14
15
Plate
Nut
Collar
Bolt
1
1
1
1 M6 × 145
9
16 Washer 3
17 Nut 1
6B45E11 7-12
BRKT Bracket unit
2.5 N·m (0.2 kgf·m, 1.8 ft·lb)
12 N·m (1.2 kgf·m, 8.7 ft·lb)
12 N·m (1.2 kgf·m, 8.7 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)
6B47050E

18 Tilt rod 1
19 Spring 1
20 Swivel bracket 1
21 Grease nipple 3
22 Tilt lever 1
23 Spring 1
24 Rod 1
25 Tilt lever 2 1
26 Pin 1
27 Circlip 1
28 Rod 1
29 Tilt lock plate 1 1
30 Tilt lock plate 2 1
31 Collar 1
32 Shaft 1
33 Shaft 1
34 Circlip 2
7-13 6B45E11
Clamp bracket
2.5 N·m (0.2 kgf·m, 1.8 ft·lb)
12 N·m (1.2 kgf·m, 8.7 ft·lb)

1
12 N·m (1.2 kgf·m, 8.7 ft·lb)
2
3
4
8 N·m (0.8 kgf·m, 5.8 ft·lb)
6B47050E
5
No.
35
36
Spring
Bolt
Part name Q’ty
2
2
Remarks
6
37 Tilt stop lever 1
38
39
40
41
Stopper
Pin
Spring
Nut
2
1
1
2
7
42 Wave washer 2
43
44
45
46
Washer
Circlip
Shallow water drive lever
Spring
1
1
1
1
8
47 Washer 1
48
49
50
Bolt
Bolt
Cotter pin
1
1
1
M6 × 8 mm: X transom model
9
51 Nut 1
52 Washer 1
6B45E11 7-14
BRKT Bracket unit
— MEMO —
7-15 6B45E11
ELEC
Electrical systems
Checking the electrical components............................................................8-2

Measuring the peak voltage ......................................................................8-2
1
Measuring low resistance ..........................................................................8-2
Electrical components ...................................................................................8-3

Starboard view...........................................................................................8-3 2
Wiring harness ...............................................................................................8-4
Checking the engine shut-off switch..........................................................8-5
Checking the ignition spark gap ................................................................8-5
Checking and replacing the spark plug caps (Standard type) ..................8-6
Checking the plug cap (with resister type) ................................................8-6
3
Checking the ignition coil...........................................................................8-7
Checking the pulser coil ............................................................................8-7
Checking the charge coil ...........................................................................8-8
Checking the CDI unit................................................................................8-9
4
Checking the lighting coil (option)..............................................................8-9
5
6
7
8
9
6B45E11
ELEC Electrical systems
Ignition tester
90890-06754
Digital circuit tester

90890-03174
Peak voltage adaptor B

90890-03172
8-1 6B45E11
Special service tools/Checking the electrical components
Checking the electrical Measuring low resistance

components When measuring a resistance of 10 or less
with the digital circuit tester, the correct mea-
Measuring the peak voltage
surement cannot be obtained because of the
NOTE:
Before troubleshooting the peak voltage,
internal resistance of the tester. To obtain the
correct value, subtract the internal resistance
from the displayed measurement.
1
check that all electrical connections are tight
and free from corrosion.
2
Correct value =
displayed measurement
The condition of the ignition system can be - internal resistance
determined by measuring the peak voltage.
Cranking speed is affected by many factors,
NOTE:
3
such as fouled or weak spark plug. If one of
Obtain the internal resistance of the digital
these factors is present, the peak voltage will
circuit tester by connecting both of its probes
be lower than specification. In addition, if the
and checking the display.
peak voltage is lower than specification the
engine will not operate properly.
4
5
6B480010
w
When checking the peak voltage, do not
6
touch any of the connections of the digital
circuit tester leads.
NOTE:
9 Use the peak voltage adaptor with the digi-
7
tal circuit tester.
9 When measuring the peak voltage, set the
selector on the digital circuit tester to the
DC voltage mode.
8
9 Connect the positive pin on the peak volt-
age adaptor to the positive terminal of the
digital circuit tester.
9
6B45E11 8-2
Electrical components
Starboard view
6 4 5
2 3
6B480020
1 Spark plug cap

2 Spark plug
3 Ignition coil
4 Charge coil
5 Pulser coil
6 Lighting coil (option)
7 Engine shut-off switch
8-3 6B45E11
Electrical components/Ignition system
Wiring harness
1
G
2 3 2
G
7
1
1
6
3
7
4
2
W B O Br L W/G B
B
5
W B O Br L W/G B
5
4
6
6B4003M
7
8
1 Ignition coil B : Black
2
3
4
5
Charge coil
Pulser coil
CDI unit
Engine shut-off switch
Br : Brown
G : Green
L : Blue
O : Orange
9
6 Lighting coil (option) W : White
7 Spark plug W/G: White/Green
6B45E11 8-4
Checking the engine shut-off switch Checking the ignition spark gap
1. Check the engine shut-off switch for con- 1. Disconnect the spark plug caps from the
tinuity. Replace if there is no continuity. spark plugs.
2. Connect the spark gap tester to the spark
plug cap.
6B480030
Ignition tester: 90890-06754
3. Set the specified spark gap length on the

6B480160 adjusting knob.
Lead color
White (W) Black (B)
Clip removed a
Clip installed b
Engine shut-off
button pushed c
6B480040
Ignition spark gap: 6 mm (0.24 in)
8-5 6B45E11
Ignition system
4. Crank the engine and observe the spark 2. Remove the spark plug cap 1 from the
through the discharge window of the spark plug wire 2.
spark gap tester. If it does not work prop-
1 2
1
erly, check the plug cap, ignition coil, or
the specified peak voltages.
6B480070
2
w
6B480050
3. Check the spark plug wire for damage or
cracks and the connector for damage or
corrosion. Replace if necessary. 3
Checking the plug cap
4
9 Do not touch any of the connections of
the spark gap tester leads. (with resister type)
9 Do not let sparks leak out of the 1. Remove the spark plug cap 1 from the
removed spark plug caps. spark plug wire 2 by turning the cap
9 Keep flammable gas or liquids away, counterclockwise.
since this test can produce sparks.
Checking and replacing the spark

5
plug caps (Standard type)
1. Check the spark plug caps for cracks or
damage. Replace if necessary.
6B480080
6
2. Measure the spark plug cap 1 resis-
tance. 7
6B480060
8
6B480090 9
Spark plug cap resistance:
4.0 – 6.0 kΩ
6B45E11 8-6
3. Replace the plug cap 1 if the resistance Checking the pulser coil
is out of specification. 1. Connect the digital circuit tester with
peak voltage adaptor B to the connector.
4. Install the spark plug cap 1 on the spark
plug wire 2 by turning the cap clockwise. 2. Measure the pulser coil output peak volt-
age. If the measurement is below specifi-
Checking the ignition coil cation, check the leads and measure the
1. Remove the spark plug cap from the pulser coil resistance. Replace the pulser
spark plug. coil if necessary.
2. Disconnect the ignition coil lead.
3. Measure the ignition coil resistance.

Replace if out of specification.
W/G B
B W/G B
6B480120
O 6B480100
∫ Digital circuit tester: 90890-3174

Peak voltage adaptor B:
90890-03172
Pulser coil peak voltage:

White/green (W/G) – Black (B)
Unloaded Loaded
r/min
Cranking 1,500 3,500
DC V 4.0 5.0 11.0 22.0
6B480110
Ignition coil resistance:

å Primary coil:
Orange (O) – Black (B)
0.16 – 0.24Ω at 20°C (68°F)
∫ Secondary coil:
Spark plug wire – Spark plug
wire
3.92 – 5.88 kΩ at 20°C (68°F)
8-7 6B45E11
Ignition system
Digital circuit tester: 90890-03174

Peak voltage adapter B:
90890-03172
Charge coil peak voltage:

Brown (Br) – Blue (L)
1
Unloaded Loaded
r/min
2
Cranking 1,500 3,500
DC V 190 180 250 200
3
W/G B
6B480130
Pulser coil resistance (use as refer-

ence):
White/green (W/G) – Black (B)
4
232 – 348 Ω at 20°C (68°F)
Checking the charge coil

1. Measure the charge coil output peak volt-
Br L 5
age. If the measurement is below specifi-
6
6B480150
cation, check the leads, and measure the
charge coil resistance. Replace if neces-
sary. Charge coil resistance
(use as reference):
Brown (Br) – Blue (L)
248 – 372 Ω at 20°C (68°F)
7
8
Br L
9
Br L
6B480140
6B45E11 8-8
Checking the CDI unit Checking the lighting coil (option)

1. Connect the digital circuit test leads to 1. Connect the digital circuit tester lead to
the orange and black leads from the CDI the lighting coil.
unit.
2. Measure the lighting coil output peak
2. Measure the CDI unit output peak volt- voltage. If the measurement is below
age. If the measurement is below specifi- specification, check the lead and mea-
cation, check the lead, and measure the sure the lighting coil resistance. Replace
peak output voltages of the pulser and if necessary.
charge coils.
B O
G G
B O 6B480180
6B480170
Digital circuit tester: 90890-03174

Digital circuit tester: 90890-03174 Peak voltage adapter B:
Peak voltage adapter B: 90890-03172
90890-03172
Lighting coil peak voltage:
CDI unit output peak voltage: Green (G) – Green (G)
Orange-ground lead
Unloaded
r/min
Loaded Cranking 1,500 3,500
r/min
Cranking 1,500 3,500 DC V 7.0 18.0 37.0
DC V 160 230 180
Lighting coil resistance
NOTE: (use as reference):
Replace the CDI unit if output peak voltages Green (G) – Green (G)
of the pulser and charge coils are on or above 0.16 – 0.24 Ω at 20°C (68°F)
specification and the CDI unit output peak
voltage is below specification.
8-9 6B45E11
TRBL
SHTG
Troubleshooting
Power unit .......................................................................................................9-1

Ignition system...........................................................................................9-1
Fuel system ...............................................................................................9-3
Compression pressure...............................................................................9-4
1
Lower unit .......................................................................................................9-6
2
3
4
5
6
7
8
9
6B45E11
TRBL
SHTG Troubleshooting
NOTE:
9 To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble
located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters
4–8 for safe maintenance procedures.
9 Check that all electrical connections are tight and free from corrosion.
Power unit
Symptom: Manual starter turns but engine will not start.
9 Check the ignition system, fuel system, and the compression pressure as listed below.
9 Be sure the air vent screw on the fuel tank is open.
Ignition system
Check the engine shut-off switch

for continuity.
Insert the clip into the engine

shut-off switch.
w
Is there Yes Replace the engine shut-off
continuity? switch. 9 Do not touch any of the con-
nections of the spark gap
No tester leads.
Check the condition of the spark 9 Do not let sparks leak out of
plugs. the removed spark plug
caps.
9 Keep flammable gas or liq-
Are they in No
Clean and replace as required. uids away, since this test can
good condition?
produce sparks.
Yes
Check the ignition spark using
the spark gap tester.
Is a good spark No Check the spark plug connectors

being produced? or caps for deterioration.
Yes
Is there any Yes Replace the connectors or caps
deterioration? as necessary.
No
Measure the ignition coil
resistance.
Is resistance
No
within Replace the ignition coil.
specification?
Yes
(continued on following page)
9-1 6B45E11
Power unit
Ignition system (continued from previous page)
Yes
Measure the CDI unit peak
voltage.
1
Does the peak
2
voltage exceed Yes CDI unit is in good operating
specification condition.
values?
No
Measure the charge coil peak
output voltage.
Does the peak

3
output voltage No
4
Replace the charge coil.
exceed specifi-
cation values?
Yes
Measure the pulser coil peak
output voltage.
Does the peak

5
output voltage No
Replace the pulser coil.
6
exceed specifi-
cation values?
Yes
Check the ignition timing.
Is the ignition No
Replace the CDI unit.
7
timing correct?
Yes
Check the fuel system and
compression pressure.
8
9
6B45E11 9-2
TRBL
Fuel system
9 Consult this chart after the ignition system has been checked.
Check for water accumulation or

clogging of the fuel filter.
Is there water Yes Clean the fuel system from the

or residue? fuel tank to the fuel filter.
No
Check the fuel hoses for kinks or
fuel leakage.
Are there any

Yes Correct or replace the faulty
kinks or fuel
parts.
leakage?
No
Check the fuel pump for leakage
or internal damage.
Is there any
Yes
leakage or inter- Replace the fuel pump.
nal damage?
No
Check the operation of the
carburetor.
Is the Disassemble the carburetor and

No
carburetor operat- clean the internal parts. Adjust or
ing correctly? replace as necessary.
Yes
Check the compression pressure.
9-3 6B45E11
Power unit
Compression pressure
9 Consult this chart after the ignition and fuel systems have been checked.
Measure the compression

pressure.
1
Does the
2
pressure exceed Yes
Check each component again.
the specification
values?
No
Add a small amount of engine oil
into the cylinder through the
spark plug hole. 3
Does the Check the piston, piston rings,
compression
pressure
increase?
Yes and cylinder bore for wear or
damage. Correct or replace if
worn or damaged.
4
No
Check the cylinder head gasket
and cylinder head for wear or
damage. Replace if worn or
damaged.
5
6
7
8
9
6B45E11 9-4
TRBL
Symptom: The engine idle speed does not remain steady.
Check the throttle cable and link

operation.
Are they operat- No Adjust the throttle cable and

ing correctly? throttle link.
Yes
Check the operation of the
carburetor.
Is the
Yes
carburetor operat- Check the ignition system chart.
ing correctly?
No
Check the pilot screw.
Is the pilot screw No Adjust the pilot screw according

setting correct? to specifications.
Yes
Disassemble the carburetor and
check the internal parts.
Using compressed air, clean the

Are the fuel or
Yes pilot screw, needle valve, main
air passages
and pilot jets, and main nozzle.
clogged?
Replace any damaged parts.
No
Check the throttle valve for
smooth operation.
Does the throttle Yes

Correct or replace the carburetor.
valve stick?
No
Check the reed valve and
replace if necessary.
9-5 6B45E11
Power unit/Lower unit
Lower unit
Symptom: The forward and reverse gear shift mechanism does not operate
properly.
Check the shift lever operation.

1
Is it operating
correctly?
Yes
No Check the shift lever shaft and
spring. 2
3
Check the shift rod connection.
Is it connected
No Connect correctly or replace the
properly and in
shift rod as necessary.
good condition?
Yes
Disassemble the lower case and
4
check the dog clutch operation.
Is it in good
operating
No Replace the spring and shift
plunger as necessary.
5
condition?
Yes
Check the dog clutch and
forward and reverse gears and
replace if necessary.
6
7
8
9
6B45E11 9-6
Index
A. Checking the fuel system..........................1-16

After test run .............................................1-19 Checking the gear oil ................................1-16
Applicable model.........................................1-5 Checking the gear oil level ..........................3-7
Assembling the bearing housing...............6-16 Checking the gear shift and throttle
Assembling the carburetor ..........................4-9 operation .................................................1-17
Assembling the crankshaft ........................5-30 Checking the gearshift operation ................3-5
Assembling the forward gear ....................6-17 Checking the ignition coil ............................8-7
Assembling the fuel pump...........................4-9 Checking the ignition spark gap..................8-5
Assembling the lower unit .........................6-18 Checking the ignition timing ........................3-6
Assembling the manual starter .................5-15 Checking the lighting coil (option) ...............8-9
Assembling the oil seal housing................5-13 Checking the lower unit for air leakage.......3-8
Assembling the piston ...............................5-34 Checking the oil seal housing ...................5-13
Assembling the propeller shaft Checking the outboard motor mounting
assembly .................................................6-12 height ......................................................1-17
Assembling the propeller shaft housing Checking the pinion gear ..........................6-18
assembly .................................................6-10 Checking the pistons.................................5-26
Assembling the upper case.........................7-9 Checking the plug cap
(with resister type).....................................8-6
Checking the propeller shaft assembly .....6-12
B. Checking the propeller shaft housing
Backlash....................................................6-26
assembly .................................................6-10
Bottom cowling............................................7-3
Checking the propeller ................................3-9
Bracket ........................................................3-7
Checking the pulser coil..............................8-7
Break-in .....................................................1-18
Checking the reed valves..........................5-18
Checking the spark plugs............................3-3
C. Checking the spiral spring.........................5-14
Carburetor ...................................................1-8 Checking the start-in-gear protection..........3-5
Carburetor, fuel pump .................................4-6 Checking the steering system...................1-17
Checking and disassembling the bearing Checking the thermostat .............................3-4
housing....................................................6-16 Checking the throttle cable operation .........3-5
Checking and replacing the spark plug Checking the tilt operation ..........................3-7
caps (Standard type).................................8-6 Checking the top cowling ............................3-9
Checking the anode ....................................3-9 Checking the upper case ............................7-8
Checking the anode and cylinder head ....5-21 Checking the water pump and shift rod ......6-8
Checking the carburetor..............................4-8 Clamp bracket ...........................................7-12
Checking the CDI unit .................................8-9 Compression pressure ................................9-4
Checking the charge coil.............................8-8 Control system ............................................3-5
Checking the compression pressure...........5-4 Cooling system..........................................1-15
Checking the cooling water passages ........3-4 Crankshaft, piston .....................................5-25
Checking the cooling water pilot hole .......1-18 Cylinder block............................................5-22
Checking the crankshaft............................5-34 Cylinder head ..............................................1-7
Checking the cylinder block ......................5-24 Cylinder head, exhaust covers..................5-19
Checking the drain hose ...........................5-15
Checking the drive pawl ............................5-14
Checking the drive shaft ...........................6-17
D.
Dimensions .................................................2-6
Checking the electrical components ...........8-2
Disassembling the carburetor .................... 4-8
Checking the engine idle speed..................3-6
Disassembling the crankshaft ...................5-28
Checking the engine shut-off switch ..1-18, 8-5
Disassembling the fuel pump..................... 4-9
Checking the exhaust covers ....................5-20
Disassembling the lower case...................6-15
Checking the forward gear ........................6-17
Disassembling the manual starter.............5-14
Checking the fuel filter .........................3-3, 4-5
Disassembling the muffler assembly...........7-7
Checking the fuel joint.................................4-5
Disassembling the oil seal housing...........5-12
Checking the fuel joint and fuel hoses (fuel
Disassembling the piston ..........................5-26
joint to carburetor) .....................................3-3
i-1 6B45E11
Disassembling the propeller shaft Installing the throttle cam assembly..........5-37
assembly .................................................6-11 Installing the throttle link ...........................5-40
Disassembling the propeller shaft housing Installing the water pump ..........................6-20
assembly ...................................................6-9 Intake silencer, carburetor...........................4-3
Disassembling the upper case....................7-7
Disassembly and assembly.........................1-4
Drive shaft, shift rod, lower case...............6-13
L.
Lower unit..............................2-4, 3-7, 6-4, 9-6
1
Lubricating the outboard motor ...................3-9
E.
Electrical......................................................2-5
Electrical components .................................8-3
Exhaust components (optional) ................1-13
M.
Maintenance interval chart..........................3-2
Maintenance specifications .........................2-3
2
Manual format .............................................1-1
F.
3
Measuring low resistance ...........................8-2
Fire prevention ............................................1-3 Measuring the forward and reverse gear
Fuel filter, fuel joint ......................................4-4 backlash ..................................................6-26
Fuel hoses and cooling water hose ............4-2 Measuring the peak voltage........................8-2
Fuel system .........................................3-3, 9-3 Measuring the starter rope........................5-15
G.
General specifications.................................2-1
General torques ..........................................2-9
P.
Parts, lubricants, and sealants....................1-3
Power unit..............................2-3, 3-3, 5-4, 9-1
4
General........................................................3-9 Predelivery checks ....................................1-16
5
Good working practices ..............................1-4 Propeller selection.....................................1-16
Propeller shaft, propeller shaft housing ......6-6
Propeller size ............................................1-16
H.
Hose routing................................................4-2
How to use this manual...............................1-1 R.
I.
Identification ................................................1-5
Ignition control system ..............................1-10
Reed valve ................................................5-17
Removing the crankcase ......................... 5-23
Removing the crankshaft assembly ..........5-23
Removing the cylinder head .....................5-20
6
Removing the drive shaft and forward
Ignition system ............................................9-1
7
gear .........................................................6-15
Installing the carburetor ........................... 5-38
Removing the electrical components ........5-12
Installing the crankcase ........................... 5-35
Removing the exhaust covers ...................5-20
Installing the crankshaft ............................5-35
Removing the flywheel magnet.................5-12
Installing the cylinder head .......................5-35
Removing the lower unit..............................6-7
Installing the electrical components ..........5-37
Removing the muffler assembly..................7-7
Installing the exhaust covers.....................5-37
Installing the flywheel assembly................5-38
Installing the fuel filter and hoses .............5-38
Installing the lower case............................6-18
Removing the power unit ..........................5-11
Removing the propeller shaft housing
assembly ...................................................6-9
Removing the reed valve assembly ..........5-18
8
Installing the lower unit .............................6-21
Removing the water pump and shift rod .....6-7
9
Installing the manual starter......................5-38
Replacing the gear oil .................................3-8
Installing the oil seal housing ....................5-39
Installing the power unit ............................5-39
Installing the reed valve ............................5-37 S.
Installing the spark plugs ..........................5-38 Safety while working ...................................1-3
Installing the start-in-gear protection Selecting the forward gear shims..............6-24
cable........................................................5-40 Selecting the pinion shims ........................6-24
Installing the throttle cables ......................5-39 Selecting the reverse gear shims..............6-25
6B45E11 i-2
Index
Selection ...................................................1-16
Self-protection .............................................1-3
Serial number..............................................1-5
Shimming ..................................................6-23
Side shift ...................................................1-11
Special service tools ......3-1, 4-1, 5-1, 6-1, 8-1
Specified torques ........................................2-8
Splash guard (optional) .............................1-14
Starboard view ............................................8-3
Swivel bracket ...........................................7-11
Symbols ......................................................1-2
T.
Technical features and descriptions............1-6
Test run .....................................................1-18
Tightening torques ......................................2-8
Tiller handle .........................................1-9, 7-1
Tilt support system....................................1-12
Top cowling .................................................1-6
U.
Upper case..................................................7-5
V.
Ventilation....................................................1-3
W.
Water pump.................................................6-5
Wiring harness ............................................8-4
i-3 6B45E11
YAMAHA MOTOR CO., LTD.
Printed in Japan
Nov. 2002 – 1.4 × 1 !
(E) Printed on recycled paper

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E9.

General information GEN

How to use this manual .................................................................................1-1

Technical features and descriptions ............................................................1-6

Propeller selection .......................................................................................1-16

How to use this manual

Drive shaft holder 4 1 : 90890-06518

Disassembling the forward gear

Periodic checks and adjustments

Safety while working

Parts, lubricants, and sealants

1. Maintain good standards of personal and

2. Change and wash clothing as soon as

Self-protection 3. Avoid contact with skin. Do not, for exam-

6. Keep a supply of clean, lint-free cloths for Disassembly and assembly

5. Check that moving parts operate normal-

Technical features and descriptions

6mm (0.24 in)

1 Hemispherical combustion chambers

1 Throttle cable grommet

Ignition control system

(2) When the engine starts

(3) When the engine accelerates

Tilt support system

Exhaust components (optional)

å Anodic oxide coating and additional painting å

Splash guard (optional)

1 Splash guard with long skirt

å 8. Thermostat 9. Cylinder head cover

5. Pilot hole 4. Exhaust outer cover

12. Propeller boss

Cooling water flow diagram

Propeller selection Predelivery checks

Checking the gear oil

Checking the steering system

Checking the engine shut-off switch Test run

4. Perform the break-in procedure up to

2. 50 minutes b at 1/2 throttle (approxi-

Checking the cooling water pilot

4. 8 hours d at any speed, but avoid oper-

After test run

2 Check for fuel leakage in the cowling.

3 After a test run and while the engine is at

General specifications ...................................................................................2-1

Maintenance specifications ..........................................................................2-3

(*1) Lighting coil equipped model (option)

Gear oil quantity

(lines indicate straightedge

Piston-to-cylinder clearance mm (in) 0.035–0.040 (0.0014–0.0016)

(*1) Measuring conditions:

L :568 (22.4) 493 (19.4) 280 (11.0)

185 (7.3) 145 (5.7)

106.3 (4.2) 106.3 (4.2)

67.3 (2.6) 67.3 (2.6)

Cylinder head cover bolt

Engine shut-off switch nut

Special service tools......................................................................................3-1

Maintenance interval chart............................................................................3-2 1

Power unit .......................................................................................................3-3

Special service tools

Maintenance interval chart

Fuel system Power unit

Spark plug gap a: