Yamaha LIT 18616 T8 00

F6Z
F8Z
SERVICE MANUAL
LIT-18616-02-19 68T-28197-ZA-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.
F6Z, F8Z
SERVICE MANUAL
©2000 by Yamaha Motor Corporation, USA
1st Edition, April 2000
All rights reserved.
Any reprinting or unauthorized use without the
written permission of Yamaha Motor
Corporation, USA is expressly prohibited.
Printed in USA
P/N LIT-18616-02-19
HOW TO USE THIS MANUAL
MANUAL FORMAT
All of the procedures in this manual are organised in a sequential, step-by-step format. The
information has been compiled to provide the mechanic with an easy to read, handly
reference that contains comprehensive explanations of all disassembly, repair, assembly, and
inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and
the course of action required will follow the symbol, e.g.,
•Bearings
Pitting/scratches ➔ Replace.
To assist you in finding your way through this manual, the section title and major heading is
given at the top of every page.
MODEL INDICATION
Multiple models are referred to in this manual and their model indications are noted as
follows.
Model name (W/W) F6AMH F8CMH
USA and Canada name F6MH F8MH
Indication F6AMH F8CMH
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the
appropriate section or chapter.
IMPORTANT INFORMATION
In this Service Manual particularly important information is distinguished in the following
ways.
The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
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.
CAUTION
A CAUTION indicates special precautions that must be taken to avoid damage to the
outboard motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
1 The main points regarding removing/installing and disassembly/assembly procedure are
shown in the exploded views.
2 The numbers in the exploded views indicate the required sequence of the procedure and
should be observed accordingly.
3 Symbols are used in the exploded views to indicate important aspects of the procedure.
A list of meanings for these symbols is provided on the following page.
4 It is important to refer to the job instruction charts at the same time as the exploded
views.
These charts list the sequence that the procedures should be carried out in, as well as
providing exploded on part names, quantities, dimensions and important points relating
to each relevant task.
Example:
O-ring 39.5 x 2.5 mm: inside diameter (D) x ring diameter (d)
5 In addition to tightening torques, the dimensions of the bolts and screws are also
mentioned.
Example:
Bolt and screw size 10 x 25 mm : bolt and screw diameter (D) x length (L)
6 In addition to the exploded views and job instruction charts, this manual provides
individual illustrations when further explanations are required to explain the relevant
procedure.
SYMBOLS
Symbols 1 to 9 are designed as thumb-tabs
1 2 to indicate the content of a chapter.
1 General information
2 Specifications
3 Periodic check and adjustment
4 Fuel system
3 4
5 Power unit
6 Lower unit
7 Bracket unit
8 Electrical system
5 6 9 Trouble analysis
Symbols : to E indicate specific data.

7 8
> Special tool
A Specified liquid
B Specified engine speed
C Specified torque
9 D Specified measurement
E Specified electrical value
[Resistance (Ω), Voltage (V), Electrical
current (A)]
0 A B
Symbols F to I in an exploded diagram
indicate the grade of lubricant and the
location of the lubricant point.
F Apply Yamaha 4-stroke motor oil
C D E G Apply water resistant grease
(Yamaha grease A, Yamaha marine
grease)
H Apply Yamaha grease D
I Apply molybdenum disufied oil
F G H
Symbols J to O in an exploded diagram
indicate the grade of the sealing or locking
agent and the location of the application
point.
I J Apply Gasket Maker®
K Apply Yamabond #4
(Yamaha bond number 4)
L Apply LOCTITE® No.271 (Red LOCTITE)
J K L M Apply LOCTITE® No.242 (Red LOCTITE)
N Apply LOCTITE® No.572
O Apply silicon sealant
M N O
CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECK AND
ADJUSTMENT 3
FUEL SYSTEM
4
POWER UNIT 5
LOWER UNIT
6
BRACKET UNIT 7
ELECTRICAL SYSTEM 8
TROUBLE ANALYSIS 9
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION...............................................................................................1-1
SERIAL NUMBER .......................................................................................1-1
STARTING SERIAL NUMBERS .................................................................1-1
1
SAFETY WHILE WORKING ..............................................................................1-2
FIRE PREVENTION .....................................................................................1-2
VENTILATION.............................................................................................1-2
SELF-PROTECTION ....................................................................................1-2
OILS, GREASES AND SEALING FLUIDS ..................................................1-2
GOOD WORKING PRACTICES ..................................................................1-3
DISASSEMBLY AND ASSEMBLY .............................................................1-4
SPECIAL TOOLS ...............................................................................................1-5

MEASURING ..............................................................................................1-5
REMOVING AND INSTALLING .................................................................1-7
IDENTIFICATION
IDENTIFICATION
SERIAL NUMBER
The outboard motor’s serial number is
stamped on a label which is attached to the
port clamp bracket.
NOTE:
As an antitheft measure, a special label on
which the outboard motor’s serial number
is stamped is bonded to the port clamp
bracket. The label is specially treated so
that peeling it off causes cracks across the
serial number.
1 Model name
2 Approval model code
3 Transom height
4 Serial number
STARTING SERIAL NUMBERS

The starting serial number blocks are as
follows:
Model name Applicable Starting

World USA, model serial
wide Canada code number
S:000101-
F6AMH F6MH 68R
L:300101-
S:000101-
F8CMH F8MH 68T
L:300101-
1-1
SAFETY WHILE WORKING
The procedures given in this manual are
those recommended by Yamaha to be
followed by Yamaha dealers and their
mechanics.
FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Petroleum vapor is explosive if ignited.
Do not smoke while handling gasoline and
keep it away from heat, sparks and open
flames.
VENTILATION
Petroleum vapor is heavier than air and is
deadly if inhaled in large quantities. Engine
exhaust gases are harmful to breathe.
When test-running an engine indoors,
maintain good ventilation.
SELF-PROTECTION
Protect your eyes with suitable safety
glasses or safety goggles, when grinding
or when doing any operation which may
cause particles to fly off. Protect hands and
feet by wearing safety gloves or protective
shoes if appropriate to the work you are
doing.
OILS, GREASES AND SEALING FLUIDS

Use only genuine Yamaha oils, greases and
sealing fluids or those recommended by
Yamaha.
1-2
Under normal conditions or use, there
should be no hazards from the use of the
lubricants mentioned in this manual, but
safety is all- important, and by adopting
good safety practices, any risk is
minimized. A summary of the most
important precautions is as follows:
1. While working, maintain good
standards of personal and industrial
hygiene.
2. Clothing which has become
contaminated with lubricants should
be changed as soon as practicable, and
laundered before further use.
3. Avoid skin contact with lubricants: do
not, for example, place a soiled
wipingrag in your pocket.
4. Hands and any other parts of the body
which have been in contact with
lubricants or lubricant-contaminated
clothing, should be thoroughly washed
with hot water and soap as soon as
practicable.
5. To protect the skin, the application of a
suitable barrier cream to the hands
before working, is recommended.
6. A supply of clean lint-free cloths
should be available for wiping
purposes.
GOOD WORKING PRACTICES

1. The right tools
Use the recommended special tools to
protect parts from damage. Use the
right tool in the right manner-do not
improvise.
2. Tightening torque
Follow the tightening torque
instructions. When tightening bolts,
nuts and screws, tighten the large sizes
first, and tighten inner-positioned
fixings before outer-positioned ones.
1-3
3. Non-reusable items
Always use new gaskets, packings, O-
rings, split-pins, circlips, etc., on
reassembly.
DISASSEMBLY AND ASSEMBLY

1. Clean parts with compressed air when
disassembling.
2. Oil the contact surfaces of moving
parts before assembly.
3. After assembly, check that moving

parts operate normally.
4. Install bearings with the manufacturers

markings on the side exposed to view,
and liberally oil the bearings.
5. When installing oil seals, apply a light
coating of water-resistant grease to the
outside diameter.
1-4
SPECIAL TOOLS
SPECIAL TOOLS
Using the correct special tools
recommended by Yamaha, will aid the
work and enable accurate assembly and
tune-up.
Improvising and using improper tools can
damage the equipment.
NOTE:
For U.S.A. and Canada, use part numbers
that start with “J-”, “YB-” “YM-”, “YU-”
or”YW-”.
For other countries, use part numbers
that start with “90890-”.
MEASURING
1 Engine tachometer
P/N. YU-08036-B .......................... a
1a b 90890-06760 ......................... b
2 Compression gauge
P/N. YU-33223
90890-03160
2 3 3 Timing light
P/N. YM-33277-A
90890-03141
4 Mity vac
P/N. YB-35956-A............................ a
4 ab 5 90890-06756...........................b
5 Leakage tester
P/N. N.A.
90890-06762
6a b 6Digital circuit tester

P/N. YU-34899-A............................a
90890-06752 ......................... b
7 Peak voltage tester

P/N. YU-39991 .............................. a
7a b
90890-03172 ......................... b
8 Spark gap tester

P/N. YM-34487 .............................. a
90890-06754 ......................... b
8a b
1-5
SPECIAL TOOLS
9 Bearing house puller
9 0
P/N. YB-06234
N.A
0 Universal puller
A B P/N. YB-06117
N.A.
A Dial gauge stand

P/N. YU-03097
C D 90890-01252
B Magnet base
P/N. YU-34481
90890-06705
C Backlash indicator
P/N. YU-06265
90890-06706
D Magnetic base attaching plate

P/N. YB-07003
90890-07003
1-6
SPECIAL TOOLS
1a b REMOVING AND INSTALLING
1 Flywheel holder
P/N. YB-06139 ............................... a
90890-06522 ......................... b
2 Universal puller
2a b P/N. YB-06117 ............................... a
90890-06521 ......................... b
3 Valve spring compressor
P/N. YM-01253
90890-04019
3 4
4 Valve spring compressor attachment
P/N. YM-04108
90890-04108
5 Valve guide remover
5 6 P/N. N.A.
90890-06801
6 Valve guide installer
P/N. YM-01122
90890-06801
7
7 Valve guide reamer
P/N. N.A.
90890-06804
8 Valve seat cutter set
8a b P/N. YM-91043-C .......................... a
90890-06803 ......................... b
9 Valve seat lapper
P/N. N.A.
90890-04101
9 0
0 Piston slider
P/N. YU-33294
90890-05158
A Slide hammer handle
A B P/N. YB-06096
90890-06531
B Stopper guide plate
P/N. N.A.
90890-06501
C
C Stopper guide stand
P/N. N.A.
90890-06538
1-7
SPECIAL TOOLS
D D Bearing puller assembly
P/N. N.A.
90890-06535
E Bushing installer center bolt
P/N. YB-06029 ............................... a
Ea b 90890-06601 ......................... b
F Driver rod (small)
P/N. YB-06229 ............................... a
90890-06652 ......................... b
Fa b G Driver rod (large)
P/N. YB-06071 ............................... a
90890-06606 ......................... b
H Driver rod (short)
P/N. N.A.
Ga b 90890-06604
I P/N. Bearing/oil seal attachment
P/N. YB-06197, YB-06298,
YB-06230, YB-06112,
YB-06611, YB-37350.............. a
H 90890-06653, 90890-06649,
90890-06617, 90890-06614,
90890-0661............................ b
J Bearing/oil seal attachment
P/N. YB-06167 ............................... a
Ia b 90890-06634 .......................... b
K Bearing/oil seal attachment
P/N. YB-06028 ............................... a
90890-06650 .......................... b
Ja b L Crankshaft holder
P/N. YB-06561
90890-06561
Ka b
1-8
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS (F6AMH/F6MH) ................................................2-1
GENERAL SPECIFICATIONS (F8CMH/F8MH) ................................................2-3
MAINTENANCE SPECIFICATIONS..................................................................2-5
POWER UNIT..............................................................................................2-5
LOWER UNIT..............................................................................................2-8
ELECTRICAL ...............................................................................................2-9
2
OUTBOARD DIMENSIONS......................................................................2-11
BRACKET DIMENSIONS..........................................................................2-13
TIGHTENING TORQUES ................................................................................2-14

SPECIFIED TORQUES ..............................................................................2-14
GENERAL TORQUES ...............................................................................2-16
GENERAL SPECIFICATIONS (F6AMH/F6MH)
Model
Item World wide Unit F6AMH
USA, Canada F6MH
DIMENSION
Overall length mm (in) 1,031 (40.6)
Overall width mm (in) 419 (16.5)
Overall height
(S) mm (in) 998 (39.3)
(L) mm (in) 1,125 (44.3)
WEIGHT
(with aluminum propeller)
(S) kg(lb) 38.0 (83.8)
(L) kg(lb) 39.5 (87.1)
PERFORMANCE
Maximum output (ISO) kW (hp) @ 4.4 (6.0) @ 5,000
r/min
Full throttle operating range r/min 4,500 - 5,500
Maximum fuel consumption L (US gal, Imp 2.5 (0.66, 0.55)
gal)/h @ 5,500
r/min
POWER UNIT
Type 4 stroke, SOHC, in-line
Number of cylinders 2
Total displacement cm3 (cu.in) 197 (11.8)
Bore x stroke mm (in) 56.0 x 40.0 (2.2 x 1.6)
Compression ratio 8.79
Compression pressure kPa (kgf/cm2, 950 (9.5, 135.1)
psi)
Number of carburetors 1
Control system Tiller control
Starting system Manual
Ignition control system CDI
Alternator type One lighting coil / Two lighting coils
Alternator output V-A 12 - 6
Enrichment system Choke type
Spark plug BR6HS-10
Exhaust system Propeller boss
Lubrication system Wet sump
Ignition timing Degree (BTDC) 5 - 30
2-1
Model
Item World wide Unit F6AMH
USA, Canada F6MH
FUEL AND OIL
Fuel type Unleaded regular gasoline
Fuel rating PON(* 1 ) 86
Engine oil type RON(* 2 ) 91
Engine oil grade 4-stroke engine oil
API SE, SF, SG or SH
SAE 10W-30, 10W-40
Total quantity cm3 (US oz, 800 (27.0, 28.2)
lmp oz)
Gear oil type Hypoid gear oil
Gear oil grade GL-4 (SAE #90)
Gear oil capacity cm3 (US oz, 150 (5.1, 5.3)
Imp oz)
BRACKET
Tilt angle Degree 78
Shallow water drive angle Degree 24, 37
Steering angle (right + left) Degree 45 + 45
DRIVE UNIT
Gear positions F-N-R
Gear ratio (gear/pinion) 2.08 (27/13)
Gear type Straight bevel gear
Propeller direction Clockwise (Back view)
Propeller drive system Spline
Propeller ID mark N
ELECTRICAL
Battery capacity Ah (kC) 40 (144)
Cold cranking performance A 145 - 380
(* 1 ) PON : Pump Octane Number
(* 2 ) RON : Research Octane Number
2-2
GENERAL SPECIFICATIONS (F8CMH/F8MH)
Model
Item World wide Unit F8CMH
USA, Canada F8MH
DIMENSION
Overall length mm (in) 1,031 (40.6)
Overall height
(S) mm (in) 998 (39.3)
(L) mm (in) 1,125 (44.3)
WEIGHT
(S) kg (lb) 38.0 (83.8)
(L) kg (lb) 39.5 (87.1)
PERFORMANCE
Maximum output (ISO) kW (hp) @ 5.9 (8.0) @ 5,500
r/min
Full throttle operating range r/min 5,000 - 6,000
Maximum fuel consumption L (US gal, Imp 3.3 (0.87, 0.73)
gal)/h @ 5,500
r/min
POWER UNIT
Total displacement cm3 (cu.in) 197 (11.8)
Compression pressure kPa (kgf/cm2, 950 (9.5, 135.1)
psi)
Starting system Manual
Alternator type One lighting coil / Two lighting coils
Alternator output V-A 12 - 6
Spark plug BR6HS-10
2-3
Model
Item World wide Unit F8CMH
USA, Canada F8MH
FUEL AND OIL
Fuel rating PON(* 1 ) 86
Engine oil type RON(* 2 ) 91
SAE 10W-30, 10W-40
lmp oz)
Imp oz)
BRACKET
Tilt angle Degree 78
Shallow water drive angle Degree 24, 37
Steering angle (right + left) Degree 45 + 45
DRIVE UNIT
Gear type Straight bevel gear
Propeller ID mark N
ELECTRICAL
2-4
MAINTENANCE SPECIFICATIONS
POWER UNIT
Model
Item World wide Unit F6AMH F8CMH
USA, Canada F6MH F8MH
CYLINDER HEAD
Warpage mm (in) 0.1 (0.004)
limit
CYLINDER BODY
Bore (D1, D2) mm (in) 56.000 - 56.015 (2.2047 - 2.2053)
Taper limit mm (in) 0.08 (0.0031)
Out-of-round limit mm (in) 0.05 (0.0020)
ROCKER ARM
Rocker arminside mm (in) 13.000 - 13.018 (0.5118 - 0.5125)
diameter a
ROCKER ARM SHAFT

Rocker shaft mm (in) 12.941 - 12.951 (0.5095 - 0.5099)
outside
diameter b
CAMSHAFT
Intake (A) mm (in) 23.45 - 23.55 (0.9232 - 0.9271)
Intake (B) mm (in) 23.45 - 23.55 (0.9232 - 0.9271)
Exhaust (A) mm (in) 19.95 - 20.05 (0.7854 - 0.7893)
Exhaust (B) mm (in) 19.95 - 20.05 (0.7854 - 0.7893)
Cylinder head mm (in) 17.975 - 17.991 (0.7077 - 0.7083)
Journal diameter
Oil pump housing journal mm (in) 15.975 - 15.991 (0.6289 - 0.6296)
diameter
Camshaft round limit mm (in) 0.03 (0.0012)
VALVE
Valve clearance IN mm (in) 0.15 - 0.20 (0.006 - 0.008)
EX mm (in) 0.20 - 0.25 (0.008 - 0.010)
Valve dimensions
Head dimension “A” IN mm (in) 23.9 - 24.1 (0.94 - 0.95)

EX mm (in) 21.9 - 22.1 (0.86 - 0.87)
2-5
Model
Face width “B” IN mm (in) 1.84 - 2.26 (0.072 - 0.089)
EX mm (in) 1.84 - 2.26 (0.072 - 0.089)
Seat width”C” IN mm (in) 0.6 - 0.8 (0.023 - 0.031)
EX mm (in) 0.6 - 0.8 (0.023 - 0.031)
Mergin thickness “D” IN mm (in) 0.7 (0.027)
EX mm (in) 1.0 (0.039)
Stem outside diameter IN mm (in) 5.475 - 5.490 (0.2156 - 0.2161)
EX mm (in) 5.460 - 5.475 (0.2150 - 0.2156)
Valve guide inside IN mm (in) 5.500 - 5.512 (0.2165 - 0.2170)
diameter EX mm (in) 5.500 - 5.512 (0.2165 - 0.2170)
Stem-to-guide clearance IN mm (in) 0.010 - 0.037 (0.0004 - 0.0015)
EX mm (in) 0.025 - 0.052 (0.0010 - 0.0020)
Stem runout limit IN mm (in) 0.03 (0.0012)
EX mm (in) 0.03 (0.0012)
VALVE SPRING
Free length mm (in) 27.6 (1.09)
limit
Tilt limit mm (in) 1.0 (0.04)
PISTON
Piston-to-cylinder clearance mm (in) 0.035-0.065 (0.0014-0.0026)
Piston mm (in) 55.950-55.965 (2.2028-2.2033)
diameter (D)
Measuring mm (in) 1.5 (0.06)
point (H)
Pin boss inside diameter mm (in) 14.004-14.015 (0.5513-0.5518)
Oversize piston diameter
1st mm (in) 56.200-56.215 (2.2126-2.2132)
2nd mm (in) 56.450-56.465 (2.2224-2.2230)
PISTON PIN
Outside mm (in) 13.996-14.000 (0.5510-0.5512)
Diameter (D)
PISTON RING
Top ring mm (in)
Dimension (B) mm (in) 1.2 (0.05)
Dimension (T) mm (in) 2.05 (0.08)
End gap (installed) mm (in) 0.15-0.30 (0.006-0.012)
Side clearance mm (in) 0.04-0.08 (0.0016-0.0031)
2-6
Model
2nd ring
End gap (installed) mm (in) 0.30 - 0.45 (0.012 - 0.018)
Side clearance mm (in) 0.03 - 0.07(0.012 - 0.0028)
Oil ring
CONNECTING ROD
Small end inside diameter mm (in) 14.015 - 14.029 (0.5518 - 0.5523)
Big end inside diameter mm (in) 27.030 - 27.042 (1.0642 - 1.0646)
Big end oil clearance mm (in) 0.030 - 0.042 (0.0012 - 0.0017)
Big end-to-crank pin side mm (in) 0.05 - 0.22 (0.002 - 0.009)
clearance
CRANKSHAFT
Crankcase journal diameter mm (in) 29.997 - 30.009 (1.1810 - 1.1815)
Crank pin journal diameter mm (in) 26.997 - 27.009 (1.0629 - 1.0633)
Runout limit mm (in) 0.03 (0.0012)
CRANKCASE
Crankshaft journal inside mm (in) 33.016 - 33.040 (1.3000 - 1.3008)
diameter
Crankshaft journal oil clearance mm (in) 0.011 - 0.039 (0.0004 - 0.0015)
(bearing installed)
Bearing mark color mm (in) A:Blue 33.032 - 33.040 (1.3005 - 1.3008)
B:Black 33.024 - 33.032 (1.30016 - 1.3005)
C:Brown 33.016 - 33.024 (1.2998 - 1.30016)
THERMOSTAT
Full-close temperature °C (°F) Below 60 (140)
Valve opening temperature °C (°F) 58 - 62 (136.4 - 143.6)
Full-open temperature °C (°F) Abobe 70 (158)
Valve lift mm (in) 3 (0.12)
FUEL PUMP
Discharge (@ 2,750 r/min) L/h(US gal/h, Above 12 (3.17, 2.64)
lmp gal/h)
Maximum pressure kPa (kg/cm2 , Below 117.6 (1.2, 17.1)
(@ 2,750 r/min) psi)
diaphragm stroke mm (in) 2.4 - 4.8 (0.095 - 0.189)
Plunger stroke mm (in) 3.525 - 6.575 (0.139 - 0.259)
2-7
Model
OIL PUMP
Discharge (@ 3,000 r/min) L/h (US gal/h, Abobe 3.5 (0.925, 0.77)
Imp gal/h)
Outer rotor-housing mm (in) 0.10 - 0.15 (0.004 - 0.006)
clearance a
Outer rotor-inner rotor mm (in) 0.04 - 0.14 (0.002 - 0.006)
clearance b
Rotor-housing clearance c mm (in) 0.03 - 0.09 (0.001 - 0.004)
CARBURETOR
Stamped mark
68R-00 (F6AMH/F6MH) 68T-00 (F8CMH/F8MH)
68R-20 (F6AMH for SAV) 68T-20 (F8CMH for SAV)
69F-20 (F6BMH) 68T-30 (F8CW)
Main jet # 74 74
Pilot jet # 39 39
Float height a mm (in) 19.0 - 20.0 19.0 - 20.0
(0.75 - 0.79) (0.75 - 0.79)
Idle speed r/min 1,050 ± 50 1,050 ± 50
LOWER UNIT
Model
GEAR BACKLASH
Pinion - Forward gear mm (in) 0.88 - 1.26 (0.0346 - 0.0496)
Pinion - Reverse gear mm (in) 1.01 - 1.38 (0.0398 - 0.0543)
Pinion shim thickness mm 1.9, 2.0, 2.1, 2.2
Forward gear shim thickness mm 0.10, 0.12, 0.15, 0.18, 0.30
Reverse gear shim thickness mm 0.1
2-8
ELECTRICAL
Model
IGNITION SYSTEM
Charge coil output peak voltage
(Br – L)
@ cranking (opened) V 112
@ cranking (closed) V 154
@ 1,500 r/min V 185
@ 3,500 r/min V 185
Pulser coil output peak voltage
(W/R – B)
@ cranking (opened) V 7.0
@ cranking (closed) V 3.5
@ 1,500 r/min V 7.0
@ 3,500 r/min V 10.5
CDI unit output peak voltage
(O – B)
@ 1,500 r/min V 168
@ 3,500 r/min V 168
Ignition spark gap mm (in) 0.9 (0.04)
Charge coil resistance (Br – L) Ω 232 - 348
Pulser coil resistance (W/R – B) Ω 240 - 360
Ignition coil resistance
Primary (O – B) Ω 0.6
Secondary (Between outputs) kΩ 8.75
Spark plug cap resistance kΩ 4.3
IGNITION CONTROL SYSTEM
Oil pressure switch operating kPa (kg/cm2 , 14.7 (0.15, 2.13) 14.7 (0.15, 2.13)
pressure psi)
Oil pressure control speed r/min 2,000 ± 150 2,000 ± 150
Engine speed limiter control r/min F6A: 6,200 ± 100 6,200 ± 100
speed
STARTING SYSTEM
Fuse A 10
Fuel enrichment solenoid Ω 4
resistance
2-9
Model
STARTER MOTOR
Type Bendix
Rating Second 30
Output kW 0.6
Brush length mm (in) 12.5 (0.49)
Brush length limit mm (in) 9.0 (0.35)
Commutator diameter mm (in) 30.0 (1.18)
Commutator diameter limit mm (in) 29.0 (1.14)
CHARGING SYSTEM
(ONE LIGHTING COIL MODEL)
Lighting coil output peak
voltage (G – G)
@ 1,500 r/min (opened) V 14
Rectifier output peak voltage
(R – B)
@ cranking (closed) V —
@ 1,500 r/min (opened) V 13.3
@ 3,500 r/min (opened) V 32.2
Charging current A @ 5,000 r/min 5.5
Lighting coil resistance (G–G) Ω 0.24 - 0.36
CHARGING SYSTEM
(TWO LIGHTING COILS MODEL)
voltage (G – G)
@ 1,500 r/min (opened) V 33.6
@ 3,500 r/min (opened) V 77.0
Rectifier/regulator output peak
voltage(R – B)
Charging current A @ 5,000 r/min 6
2-10
OUTBOARD DIMENSIONS
2-11
Symbol Model
World wide Unit F6AMH F8CMH
L1 mm (in) 430 (16.9)
L2 mm (in) 121.5 (4.8)
L3 mm (in) 601 (23.7)
L4 mm (in) 355 (14.0)
L5 (S) mm (in) 72 (2.8)
(L) mm (in) 98.5 (3.9)
L6 (S) mm (in) 705.5 (27.8)
(L) mm (in) 822 (32.4)
L7 mm (in) 271 (10.7)
L8 mm (in) 189 (7.4)
L9 mm (in) —
L10 mm (in) 66.5 (2.6)
H1 (S) mm (in) 681.5 (26.9)
(L) mm (in) 808.5 (31.8)
H2 mm (in) 317 (12.5)
H3 mm (in) 123 (4.8)
H4 (S) mm (in) 435.5 (17.1)
(L) mm (in) 562.5 (22.1)
H5 mm (in) 675.5 (26.6)
H6 (S) mm (in) 593.5 (23.4)
(L) mm (in) 546 (21.5)
H7 mm (in) 202.5 (8.0)
H8 mm (in) 4 (0.16)
H9 mm (in) 528 (20.8)
H10 mm (in) 32 (1.3)
H11 mm (in) —
W1 mm (in) 171.5 (6.8)
W2 mm (in) 247.5 (9.7)
W3 mm (in) 158.5 (6.2)
W4 mm (in) 158.5 (6.2)
W5 mm (in) 285.5 (11.2)
W6 mm (in) 654 (25.7)
A1 Degree 45
A2 Degree 66
A3 Degree —
2-12
BRACKET DIMENSIONS
Symbol Model
World wide Unit F6AMH F8CMH
B1 mm (in) 70.5 (2.8)
B2 mm (in) 198 (7.8)
B3 mm (in) 95.3 (3.8)
B4 mm (in) 112 (4.4)
B5 mm (in) 105.3 (4.1)
B6 mm (in) 207 (8.1)
B7 mm (in) —
B8 mm (in) —
B9 mm (in) 18 (0.7)
B10 mm (in) —
B11 mm (in) —
B12 mm (in) —
C1 mm (in) 28 (1.1)
C2 mm (in) 65 (2.6)
C3 mm (in) —
D1 mm (in) 8.3 (0.3)
D2 mm (in) 8.3 (0.3)
D3 mm (in) —
D4 mm (in) —
T1 mm (in) —
2-13
TIGHTENING TORQUES
TIGHTENING TORQUES
SPECIFIED TORQUES
Part Thread Tightening torques

Parts to be tightened Q’ty Remarks
name size Nm kgfm ftlb
TOP COWLING
Top cowling hook mounting Bolt M5 2 5 0.5 3.7
FUEL SYSTEM
Fuel joint mounting Bolt M6 1 8 0.8 5.9
Fuel pump housing Screw M4 4 1.5 0.15 1.11
Fuel pump check valve Screw M3 2 0.5 0.05 0.37
Throttle axle link lock Screw M5 1 1.5 0.15 1.1
POWER UNIT
Breather cover mounting Screw M4 5 2 0.2 1.5
Fuel enrichment solenoid mounting Screw M4 4 2 0.2 1.5
1st 6 0.6 4.4
Intake manifold mounting Bolt M6 5
2nd 12 1.2 8.8
Manual starter drive plate mounting Screw — 1 6 0.6 4.4
Flywheel rotor mounting Nut M12 1 100 10 72
Drive gear mounting Nut M24 1 36 3.6 26.5
Driven gear mounting Bolt M6 1 12 1.2 8.8
Thermostat housing cover mounting Bolt M6 2 8 0.8 5.9
Power unit mounting Bolt M8 6 21 2.1 15.5
Relief valve assembly — M14 1 8 0.8 5.9
Throttle link bracket mounting Bolt M6 2 8 0.8 5.9
Plug M16 1 18 1.8 13.3
Anode mounting
Screw M5 1 2 0.2 1.5
1st 6 0.6 4.4
Exhaust outer cover mounting Bolt M6 5
2nd 12 1.2 8.8
Spark plug — M14 2 25 2.5 18.4
1st 15 1.5 11.1
Bolt M8 6
2nd 30 3.0 22.1
Cylinder head mounting
1st 6 0.6 4.4
Bolt M6 3
2nd 12 1.2 8.8
Oil pump assembly mounting Bolt M6 3 8 0.8 5.9
Oil pump housing Screw M6 2 5 0.5 3.7
Rocker arm locknut Nut M5 4 8 0.8 5.9
1st 15 1.5 11.1
Crankcase mounting Bolt M8 6
2nd 30 3.0 22.1
1st 6 0.6 4.4
Connecting rod mounting Bolt M7 4
2nd 12 1.2 8.1
LOWER UNIT
Apron mounting Screw M6 2 4 0.4 2.9
Exhaust gas measuring Bolt M8 1 18 1.8 13.3
Engine oil drain Plug M10 1 24 2.4 17.8
Drain plug damper mounting Screw M5 1 2 0.2 1.5
Oil pan mounting Bolt M8 2 21 2.1 15.5
Muffler mounting Bolt M6 2 12 1.2 8.8
Gear oil level check Plug M8 1 7 0.7 5.1
Gear oil drain Plug M8 1 7 0.7 5.1
Propeller mounting (STD) Nut M10 1 17 1.7 12.5
Propeller mounting (DUAL) Nut M10 1 20 2.0 14.7
2-14
TIGHTENING TORQUES
Part Thread Tightening torques

Parts to be tightened Q’ty Remarks
name size Nm kgfm ftlb
Water inlet cover mounting Screw M5 1 5 0.5 3.7
Ground terminal mounting Screw M5 1 2 0.2 1.5
BRACKET
Shift handle mounting Bolt M5 1 3.5 0.35 2.6
Cowling clamp mounting Bolt M6 1 8 0.8 5.9
Bottom cowling mounting Bolt M6 4 8 0.8 5.9
Handle bracket mounting Nut M10 2 36 3.6 26.5
Handle throttle grip Screw M5 1 3.5 0.35 2.6
Handle throttle shaft plate mounting Screw M5 2 3.5 0.35 2.6
Handle mounting (outside) Nut M10 1 22 2.2 16.2
Handle mounting (inside) Nut M10 1 10 1.0 7.4
Handle shift cable stay mounting Bolt M6 1 8 0.8 5.9
Handle shift lever mounting Bolt M8 1 18 1.8 13.3
Handle rubber bushing mounting Screw M6 3 3.5 0.35 2.6
Adapter bracket mounting (*1) Bolt M6 2 8 0.8 5.9
Adapter mounting (*1) Screw M6 1 2 0.2 1.5
Upper mount Nut M8 2 21 2.1 15.5
Upper mount rubbler mounting Bolt M6 2 12 1.2 8.8
Lower mount Bolt M6 4 15 1.5 11.1
Clamp bracket cap Nut — 2 13 1.3 9.6
Stopper mounting Bolt M6 4 8 0.8 5.9
Pivot shaft lock Bolt M6 1 4 0.4 2.9
Grease nipple Nipple — 1 3 0.3 2.2
Steering friction plate mounting Bolt M5 2 5.4 0.54 3.9
Steering friction piece mounting Bolt M5 1 5.4 0.54 3.9
Steering friction self locking Nut M10 1 4 0.4 2.9
Neutral switch stay mounting Bolt M6 2 10 1.0 7.4
Recoil starter cable mounting Bolt M6 1 or 2 10 1.0 7.4
Ground lead mounting Screw M5 1 2.5 0.25 1.8
ELECTRICAL
Charge coil mounting Bolt M6 2 12 1.2 8.8
Pulser coil mounting Bolt M5 2 5 0.5 3.7
Lighting coil mounting Bolt M6 2 or 4 12 1.2 8.8
Lighting coil lead clamp mounting (*2) Bolt M6 2 8 0.8 5.9
CDI unit mounting Bolt M6 2 8 0.8 5.9
Ignition coil mounting Bolt M6 2 8 0.8 5.9
Rectifier mounting (*2) Screw M5 1 3.5 0.35 2.6
Rectifier bracket mounting (*2) Bolt M8 2 18 1.8 13.3
Rectifier/regulator mounting Bolt M6 1 8 0.8 5.9
Oil pressure switch — PT1/8 1 9 0.9 6.6
Oil pressure switch terminal Screw M4 1 2 0.2 1.5
Starter motor bracket mounting Bolt M8 3 21 2.1 15.5
Starter motor mounting Bolt M8 2 21 2.1 15.5
Starter motor positive (+) terminal Nut M6 1 4 0.4 2.9
Starter motor negative (-) terminal Bolt M8 1 18 1.8 13.3
Starter relay terminal Bolt M6 2 4 0.4 2.9
Starter relay fitting plate mounting Bolt M6 1 8 0.8 5.9
Lead coupler clamp mounting Screw — 2 1 0.1 0.7
Ground terminal mounting Bolt M6 2 8 0.8 5.9
*1: For water-flushing model
*2: For One lighting coil model
2-15
TIGHTENING TORQUES
General torque GENERAL TORQUES

Nut (A) Bolt (B) specifications This chart specifies tightening torques for
Nm kgfm ftlb standard fasteners with a standard ISO
8 mm M5 5 0.5 3.6 thread pitch. Tightening torque
10 mm M6 8 0.8 5.8 specifications for special components or
12 mm M8 18 1.8 13 assemblies are provided in applicable
sections of this manual. To avoid warpage,
14 mm M10 36 3.6 25
tighten multifastener assemblies in a
17 mm M12 43 4.3 31
crisscross fashion and progressive stages
until the specified tightening torque is
reached.
Unless otherwise specified, tightening
torque specifications require clean, dry
threads.
Components should be at room
temperature.
2-16
CHAPTER 3
PERIODIC CHECK AND ADJUSTMENT
MAINTENANCE INTERVAL CHART ............................................................... 3-1
TOP COWLING ................................................................................................ 3-2

CHECKING THE WATER DRAIN HOLE ................................................... 3-2
CHECKING THE TOP COWLING FIT ....................................................... 3-2
FUEL SYSTEM ................................................................................................ 3-3

CHECKING THE FUEL LINE ..................................................................... 3-3
CONTROL SYSTEM ........................................................................................ 3-4

ADJUSTING THE SHIFT CONTROL CABLE ............................................3-4
ADJUSTING THE THROTTLE CONTROL CABLES ................................ 3-5
ADJUSTING THE THROTTLE AXLE LINK ............................................... 3-6
ADJUSTING THE ENGINE IDLING SPEED ............................................. 3-7
3
ADJUSTING THE START-IN-GEAR PROTECTION DEVICE.................... 3-8
POWER UNIT .................................................................................................. 3-9

CHECKING THE ENGINE OIL LEVEL ....................................................... 3-9
REPLACING THE ENGINE OIL ................................................................. 3-9
ADJUSTING THE VALVE CLEARANCE ................................................ 3-10
MEASURING THE COMPRESSION PRESSURE .................................. 3-12
CHECKING THE IGNITION TIMING ...................................................... 3-13
CHECKING THE TIMING BELT .............................................................. 3-14
COOLING SYSTEM ....................................................................................... 3-14

CHECKING THE COOLING WATER DISCHARGE ................................ 3-14
LOWER UNIT ................................................................................................ 3-15

CHECKING THE GEAR OIL LEVEL ......................................................... 3-15
CHANGING AND CHECKING THE GEAR OIL LEVEL ........................... 3-15
CHECKING THE LOWER UNIT (FOR AIR LEAKS) ................................ 3-16
GENERAL ...................................................................................................... 3-17

CHECKING THE ANODE ........................................................................ 3-17
CHECKING THE BATTERY ..................................................................... 3-17
CHECKING THE SPARK PLUGS ............................................................ 3-18
LUBRICATION POINTS ...........................................................................3-20
MAINTENANCE INTERVAL CHART
Use the following chart as a guide to general maintenance intervals.
Dependant on operating conditions, adjust the maintenance intervals accordingly.
Initial Every
Refer to
Item Remarks 10 hours 50 hours 100 hours 200 hours
page
(Brake-in) (3 months) (6 months) (1 year)
TOP COWLING:
Water drain hole Check 3-2
Top cowling fit Check 3-2
FUEL SYSTEM:
Fuel line Check 3-3
Fuel filter Check/clean/ 3-3
replace
Fuel tank (*1) Clean –
POWER UNIT:
Engine oil Check/replace 3-9
Timing belt Check/replace 3-14
Valve clearance Check/adjust 3-10
Ignition timing Check 3-13
Thermostat Check/replace 5-26
Water leakage Check –
Motor exterior Check –
Exhaust leakage Check –
Cooling water passage Check 3-14
CONTROL SYSTEM:
Shift cable Check/adjust 3-4
Throttle cables Check/adjust 3-5
Throttle axle link Check/adjust 3-6
Engine idling speed Check/adjust 3-7
Start-in-gear protection device Check/adjust 3-8
LOWER UNIT:
Gear oil Change 3-15
Lower unit leakage Check 3-16
Propeller Check/replace 6-3
GENERAL:
Anode Check/replace 3-17
Battery Check/replace (every 1 month) 3-17
Spark plug Cleaning/ 3-18
adjust/
replace
Wiring and connector Check/ –
reconnect
Bolts and nuts Tighten –
Lubrication points Grease 3-20
*1.......If Yamaha portable fuel tank is used.
3-1
TOP COWLING
TOP COWLING
CHECKING THE WATER DRAIN HOLE
Check:
Water drain hole 1
Obstruction Clean.
CHECKING THE TOP COWLING FIT

1. Check:
Top cowling fit
Loose/unlatched Adjust the top
cowling hook.
2. Adjust:
Top cowling hook position
Adjusting steps:
(1)Loosen the bolt 1 approximately 1/4
of a turn.
(2)Move the top cowling hook 2 either
up or down slightly.
NOTE:
Moving the hook toward the seal will
loosen the top cowling.
Moving the hook away from the seal will
tighten the top cowling.
(3)Secure the bolt 1.
Top cowling hook bolt:

5 Nm (0.5 kgfm, 3.7 ftlb)
(4)Check the top cowling fitting and

repeat the adjustment necessary.
3-2
FUEL SYSTEM
FUEL SYSTEM
CHECKING THE FUEL LINE
Check:
Fuel line
Cracks/damage/leak Replace the
defective part(s).
Refer to “REMOVING/INSTALLING
THE FUEL JOINT, FUEL FILTER AND
FUEL PUMP” on page 4-1.
CAUTION:
When replacing the fuel filter, the arrow
mark must face toward the fuel pump.
3-3
CONTROL SYSTEM
CONTROL SYSTEM
ADJUSTING THE SHIFT CONTROL
CABLE
1. Check:
Shift control cable
Damage Replace.
Incorrect shift handle position/poor
shifting Adjust.
2. Adjust:
Shift control cable
Adjusting steps:
(1)Move the shift handle so the shift rod
lever 1 is in the neutral position.
(2)Remove the locknut 2.
(3)Set the shift handle to the neutral
position. Then, hold it in this position.
(4)Adjust the shift control cable 3 to the
proper length with the adjusting nut
4.
(5)Install the locknut 2 and tighten it.
(6)Move the shift handle to the forward,
neutral, and reverse positions and
make sure it shifts smoothly and
correctly.
If the shifting operations unsmooth or
incorrect, repeat the above procedure
NOTE:
If the shift handle cannot be set to the
reverse position, rotate the propeller
slightly then operate.
3-4
CONTROL SYSTEM
ADJUSTING THE THROTTLE CONTROL
CABLES
NOTE:
Before adjusting the throttle control cables,
make sure that the shift control cable is
properly adjusted (for long handle model
only).
1. Check:
Throttle control cables
Damage Replace.
Excessive slack or the stoppers do
not contact each other Adjust.
2. Adjust:
Throttle control cables
Adjusting steps:
(1)Turn the throttle grip to the fully-
opened position.
(2)Loosen the locknut 1.
(3)Adjust the length of the throttle wire 2
with the adjusting nut 3 until the
stopper portion a on the pulley 4
contacts the stopper portion b on the
throttle wire stay 5.
(4)Tighten the locknut 1.
(5)Loosen locknut 6.
(6)Adjust the length of the throttle wire 7
with the adjusting nut 8.
NOTE:
Adjust the length so that there is no
clearance between the drum hole of pulley
4 and the drum at the tip of decelerator
cable 7.

(8)Fully open and close the throttle grip
and make sure the stopper portion a
contacts the stopper portion b (at the
fully opened position), and the stopper
c portion contacts the stopper portion
d (at the fully-closed position).
If proper contact is not made, repeat
the above procedure.
3-5
CONTROL SYSTEM
ADJUSTING THE THROTTLE AXLE
LINK
NOTE:
Before adjusting the throttle axle link, make
sure that the throttle control cables is
properly adjusted.
1. Check:
Throttle axle link
Bend/damage Replace.
Incorrect position Adjust.
2. Adjust:
Throttle axle link
Adjusting steps:
(1)Loosen lock screw 1.
(2)Turn the throttle grip to the fully open
position.
(3)Hold so that the rear side face a of
free axle lever 2 is in contact with the
actuating portion b of pulley 3.
(4)Turn throttle link 4 fully clockwise
until it stops, then tighten lock screw
1.
Lock screw:
1.5 Nm (0.15 kgfm, 1.1 ftlb)
(5)Operate the throttle grip to the fully
open position and fully closed
position, and check that carburetor
throttle link 4 opens and closes fully. If
it does not move properly, carry out
the above procedure again.
3-6
CONTROL SYSTEM
ADJUSTING THE ENGINE IDLING
SPEED
NOTE:
Before adjusting the engine idling speed,
make sure the throttle axle link is
properly adjusted.
Before adjusting the engine idling speed,
warm-up the engine. Correct adjustment
cannot be obtained when the engine is
cold.
1. Measure:
Engine idling speed
Out of specification Adjust.
Engine idling speed:

1,050 ± 50 r/min
Measuring steps:
(1)Start the engine and allow it to warm
up for several minutes.
(2)Attach the engine tachometer 1 to the
spark plug lead 2 of the cylinder #1.
Engine tachometer:
YU-08036-A/90890-06760
(3)Measure the engine idling speed.
2. Adjust:
Engine idling speed
Adjusting steps:
(1)Turn the throttle stop screw 3 in
direction a or b until the specified
engine idling speed is obtained.
Engine idling speed

Direction a increases.
Engine idling speed
Direction b decreases.
3-7
CONTROL SYSTEM
ADJUSTING THE START-IN-GEAR
PROTECTION DEVICE
1. Check:
Start-in-gear protection device
operation
Incorrect Adjust.
2. Adjust:
Start-in-gear protection cable.
Adjusting steps:
(1)Set the shift lever in the neutral
position.
(3)Adjust the adjusting nut 2 so that the
point a on the wire connector 3
aligns with the mark b on the starter
cover.
(4)Tighten locknut 1.
NOTE:
Shift the shift lever into neutral and make
sure the starter can be pulled. If it cannot
be pulled, repeat the above procedure.
3-8
POWER UNIT
POWER UNIT
CHECKING THE ENGINE OIL LEVEL
Check:
Engine oil level
(At engine stopped)
Above a Check if there is any
fuel or water mixed with the engine
oil. If no abnormality is found, drain
the oil until the level is between a
and b.
Below b Add engine oil so that
the level is between a and b.
REPLACING THE ENGINE OIL

1. Remove:
Oil filler cap 1
Drain plug 2
2. Install:
Drain plug 2
Drain plug:
24 Nm (2.4 kgfm, 17.8 ftlb)
3. Fill:
Engine oil 3
(into the crank case)
Recommended engine oil:

4-stroke engine oil
API: SE, SF, SG or SH
SAE: 10W-30, 10W-40
Oil quantity:
800cm3 (27.0 US oz, 28.2 lmp oz)
4. Install:
Oil filler cap 1
5. Check:
Engine oil level
Refer to “CHECKING THE ENGINE
OIL LEVEL” on page 3-9
NOTE:
Run the engine for several minutes, turn
it off, and check the oil level.
If the engine oil is still not at proper level,
add/drain as needed.
3-9
POWER UNIT
ADJUSTING THE VALVE CLEARANCE
NOTE:
Valve clearance adjustment shoule be
carried out when the engine is “cold”.
1. Remove:
Recoil starter 1
Dust cover 2
Fuel pump 3
Cylinder head cover 4
2. Check:
Intake valve clearance a
Exhaust valve clearance b
Out of specification Adjust.
Valve clearance (when engine is

cold)
Intake valve a:
0.15 – 0.20 mm (0.006 – 0.008 in)
Exhaust valve b:
0.20 – 0.25 mm (0.008 – 0.010 in)
Checking steps:
(1)Turn the crankshaft and align the “∆1”
mark on the driven gear 5 and “∆”
mark on the thermostat cover 6.
(2)Check the intake valve clearance a
and exhaust valve clearance b on the
cylinder #1 using the feeler gauge 7.
(3)Turn the crankshaft 360° and align the
“∆2” mark on the driven gear 5 and
“∆” mark on the thermostat cover 6.
3-10
POWER UNIT
3. Adjust:
Adjusting steps:
(2)Turn the adjusting screw 9 in or out
until the specified valve clearance is
obtained.
Locknut:
(4)Perform the above steps for all valves
which clearance are out of
specification.
4. Recheck:
NOTE:
If any valve clearance is still out of
specification, repeat all of the valve
clearance adjustment steps until the
specified clearance is obtained.
5. Install:
Cylinder head cover 4
Fuel pump 3
Dust cover 2
Recoil starter 1
NOTE:
Tighten the cylinder head cover bolt in
sequence.
3-11
POWER UNIT
MEASURING THE COMPRESSION
PRESSURE
NOTE:
Before measuring the compression
pressure, warm-up the engine. Correct
measurement cannot be obtained when the
engine is cold.
Measure:
Compression pressure
Below minimum compression
pressure Check the valve
clearance, valve face, valve seat,
piston rings, cylinder sleeve, piston,
cylinder head gasket and cylinder
head.
Compression pressure (Reference

value):
950 kPa (9.5 kgf/cm2 , 135.1 psi)
Measuring steps:
(1)Checking the valve clearance.
Refer to “ADJUSTING THE VALVE
CLEARANCE” on page 3-10.
(2)Remove the spark plugs 1.
CAUTION:
Before removing the spark plugs, use
compressed air to blow away dirt
accumulated in the spark plug well to
prevent it from falling into the cylinder
that is being tested.
(3)Install the compression gauge 2 into
the spark plug hole to be measured.
Compression gauge:
YU-33223/90890-03160
(4)Open the throttle valve wide.
(5)Crank the engine using the recoil
starter (manual starter model) or
starter motor (electric starter model)
until the reading on the compression
gauge stabilizes.
(6)Remove the compressin gauge 2.
(7)Install the spark plugs 1.
Spark plug:
25 Nm (2.5 kgfm, 18.4 ftlb)
3-12
POWER UNIT
CHECKING THE IGNITION TIMING
NOTE:
Ignition timing is automatically controlled
by the CDI unit. Therefore, only checking
the procedure is shown in this section.
Before ignition timing, warm-up the
engine. Correct checking cannot be
obtained when the engine is cold.
Check:
Ignition timing
Incorrect firing range Check the
ignition system components.
Ignition timing:
At idling speed: 5° range
At 4,500 r/min speed: 30° range
Checking steps:
(1)Start the engine and allow it to warm
up for several minutes.
(2)Attach the engine tachometer and the
timing light 1 to the spark plug lead 2
of cylinder #1.
Engine tachometer:
YU-8036-B/90890-06760
Timing light:
YM-33277-A/90890-03141
(3)Aim the timing light 1 at the flywheel
cover 3 and make sure the stationary
pointer 4 is with in the firing range 5
and 6 when engine is running with
specified speed.
3-13
COOLING SYSTEM
CHECKING THE TIMING BELT
1. Remove:
Recoil starter 1
Dust cover 2
2. Check:
Timing belt
Wear/damage Replace.
NOTE:
Install the timing belt with the part name
facing up.
3. Install:
Dust cover 2
Recoil starter 1
COOLING SYSTEM
CHECKING THE COOLING WATER
DISCHARGE
Check:
Cooling water discharge
Dose not flow Clean and check the
cooling water passage.
Checking steps:
(1)Place the lower unit in water.
(2)Start the engine.
(3)Check that water flows from the pilot
water outlet.
3-14
LOWER UNIT
LOWER UNIT
CHECKING THE GEAR OIL LEVEL
Check:
Gear oil level
Level is low Add gear oil to the
proper level.
CHANGING AND CHECKING THE GEAR

OIL LEVEL
1. Check:
Gear oil
Milky oil Replace the oil seal.
Slug oil Check the gears,
bearings, and clutch dog.
Checking steps:
(1)Tilt up the outboard slightly.
(2)Place a container under the gear oil
drain screw 1.
(3)Remove the gear oil drain screw 1
and gear oil level check screw 2.
2. Fill
Gear oil
(with the specified amount of the
recommended gear oil.)
Recommended gear oil

GEAR CASE LUBE (USA) or Hypoid
gear oil, SAE #90
Oil capacity:
150 cm3 (5.07 US oz, 5.28 lmp oz)
Filling steps:
(1)Place the outboard in an upright
position.
(2)Insert the gear oil tube into the drain
hole and slowly fill the gear oil until oil
flows out of the check hole and no air
bubbles are visible.
(3)Install the gear oil level check screw 2
and then quickly install the gear oil
drain screw 1.
Gear oil level check screw:

Gear oil drain screw:
3-15
LOWER UNIT
CHECKING THE LOWER UNIT (FOR AIR
LEAKS)
Check:
Lower unit holding pressure
Pressure drops Check the seals
and components.
Lower unit holding pressure:

100 kPa (1.0 kgf/cm2 , 14.2 psi) for
10 seconds
Checking steps:
CAUTION:
Do not overpressurize the lower unit.
Excessive pressure may damage the oil
seals.
(1)Remove the gear oil level check screw.
(2)Install the leakage tester 1 or mity vac
into the check hole.
Leakage tester:
NA/90890-06762
Mity vac:
YB-35956-A/90890-06756
(3)Apply the specified pressure.

(4)The lower unit should hold the
specified pressure for 10 seconds.
(5)Remove the pressure tester 1, then
install the gear oil level check screw.
Gear oil level check screw:

3-16
GENERAL
GENERAL
CHECKING THE ANODE
Check:
Anode (engine side)
Anode (lower unit)
Scales Clean.
Oil/grease Clean.
Excessive wear/damage Replace.
CAUTION:
Do not oil, grease, or paint the anode, or it
will no operate properly.
Anode mounting plug (engine):

18 Nm (1.8 kgfm, 13.3 ftlb)
Anode mounting screw (engine):
CHECKING THE BATTERY
WARNING
Battery electrolytic fluid is dangerous; it
contains sulfuric acid and therefore is
poisonous and highly caustic.
Always follow these preventive measures:
Avoid bodily contact with electrolytic
fluid as it can cause severe burns or
permanent eye injury.
Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
SKIN - Flush with water.
EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
Drink large quantities of water or milk
followed by milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
Batteries also generate explosive hydrogen
gas; therefore, you should always follow
these preventive measures:
Change batteries in a well-ventilated
area.
Keep batteries away from fire, soarks, or
open flames (e.g., welding equipment,
lighted cigarettes, etc.).
3-17
GENERAL
DO NOT SMOKE when charging or
handling batteries.
KEEP BATTERIES AND ELECTROLYTIC
FLUID OUT OF REACH OF CHILDREN.
NOTE:
Batteries vary among manufacturers.
Therefore, the following procedures may
not always apply. Consult your battery
manufacturer’s instructions.
First, disconnect the negative lead, then
the positive lead.
Check:
Electrolyte level
Below the minimum level a Add
distilled water to the proper level.
Electrolyte specific gravity
Less than specification Recharge
the battery.
Electrolyte specific gravity:

1.280 at 20°C (68°F)
CHECKING THE SPARK PLUGS

1. Spark plug type:
BR6HS-10
2. Check:
Electrodes 1
Cracks/excessive wear Replace.
Insulator color 2
Distinctly different color Check the
engine condition.
Color guide:
Medium to light tancolor
Normal
Whitish color
Lean fuel mixture
Plugged jet(-s)
Wrong setting
Blackish color
Rich mixture
Excessive oil usage
Defective ignition system
Defective spark plug
3. Clean:
Spark plug
(with a spark plug cleaner or wire
brush).
3-18
GENERAL
4. Measure:
Spark plug gap a
Out of specification Replace.
Spark plug gap:

0.9 - 1.0 mm (0.035 - 0.039 in)
5. Tighten:
Spark plug
Spark plug:
25 Nm (2.5 kgfm, 18.4 ftlb)
NOTE:
Before installing the spark plug, clean the
gasket surface and spark plug surface.
Also, it is suggested to apply a thin film
of anti-seize compound to the spark plug
threads to prevent thread seizure.
If a torque wrench is not available, a good
estimate of the correct tightening torque
is to finger tighten a the spark plug and
then tighten it another 1/4 to 1/2 of a turn
b.
3-19
GENERAL
LUBRICATION POINTS
Apply:
Water resistant grease
NOTE:
Use a grease gun.
3-20
GENERAL
3-21
CHAPTER 4
FUEL SYSTEM
FUEL JOINT, FUEL FILTER AND FUEL PUMP ...............................................4-1

REMOVING/INSTALLING THE FUEL JOINT, FUEL FILTER AND
FUEL PUMP ...............................................................................................4-1
CHECKING THE FUEL JOINT ...................................................................4-2
CHECKING THE FUEL FILTER ..................................................................4-2
INSTALLING THE FUEL FILTER ...............................................................4-2
FUEL PUMP ......................................................................................................4-3

DISASSEMBLING/ASSEMBLING THE FUEL PUMP ...............................4-3
CHECKING THE FUEL PUMP ...................................................................4-4
ASSEMBLING THE FUEL PUMP ..............................................................4-4
INTAKE SYSTEM .............................................................................................4-5

REMOVING/INSTALLING THE INTAKE SYSTEM ...................................4-5
INSTALLING THE INTAKE MANIFOLD ....................................................4-7
CARBURETOR ..................................................................................................4-8
DISASSEMBLING/ASSEMBLING THE CARBURETOR ...........................4-8
DISASSEMBLING THE CARBURETOR ..................................................4-10
4
CHECKING THE CARBURETOR .............................................................4-10
ASSEMBLING THE CARBURETOR ........................................................4-11
FUEL JOINT, FUEL FILTER AND FUEL PUMP
REMOVING/INSTALLING THE FUEL JOINT, FUEL FILTER AND FUEL PUMP
Step Job/Part Q'ty Remarks

1 Clip 2
2 Fuel hose 1
3 Bolt (with washer) 1
4 Fuel joint 1
5 Clip 2
6 Fuel hose (with tube) 1
7 Fuel filter 1
8 Clip 1
9 Fuel hose (with tube) 1
11 Fuel pump assembly 1
12 O-ring 1 2.7 x 2.3mm Not reusable
For installation, reverse the removal
procedure.
4-1
CHECKING THE FUEL JOINT
1. Check:
Fuel joint
Cracks/leak/clog/damage Replace.
2. Check:
Fuel joint operation
Impossible to maintain the specified
pressure for 10 sec. Replace.
NOTE:
Do not overpressurize the fuel joint.
Excessive pressure may cause air to leak
out.
Checking steps:
(1)Attach the mity vac.
Mity vac:
YB-3956-A/90890-06756
(2)Apply the specified pressure.
Specified pressure:
50 kpa (0.5 kgf/cm2, 7.1 psi)
CHECKING THE FUEL FILTER

Check:
Fuel filter
Cracks/leak/clog/ Replace.
INSTALLING THE FUEL FILTER

Install:
Fuel filter
NOTE:
Install the fuel filter with arrow mark facing
towards the fuel pump.
4-2
FUEL PUMP
FUEL PUMP
DISASSEMBLING/ASSEMBLING THE FUEL PUMP

1 Screw 4
2 Nut 4
3 Body #3 1
4 Diaphragm 1
5 Screw 2
6 Check valve 2
7 Body #2 1
8 Pin 1
9 Plunger 1
10 Plunger spring 1
11 Diaphragm 1
12 Diaphragm spring 1
13 Body #1 1 For installation, reverse the removal
procedure.
4-3
FUEL PUMP
CHECKING THE FUEL PUMP
Check:
Diaphragms
Damage Replace.
ASSEMBLING THE FUEL PUMP

Install:
Body #1
Body #2
Body #3
NOTE:
Install so that notched portion a of body
#1, joint portion b of body #2, and casting
mold letter c of body #3 are in the relative
positions shown in the diagram on the left.
4-4
INTAKE SYSTEM
INTAKE SYSTEM
REMOVING/INSTALLING THE INTAKE SYSTEM

1 Breather hose 1
3 Clamp 1
4 Water pilot hose 1
5 Clamp 1
6 Water Hose 1
7 Throttle axle link 1
8 Choke rod 1
9 Link joint 1
10 Choke knob 1
12 Coller 2
13 Silensor assembly 1
1 Continued on next page.
4-5
INTAKE SYSTEM

14 O-ring 1 31.5 x 2.4 mm Not reusable
15 Carburetor 1
16 Gasket 2 Not reusable
17 Insulator 1
18 Clamp 1
19 Fuel hose 1
20 Bolt 2
21 Bolt 3
22 Clamp 1
23 Intake manifold 1

procedure.
4-6
INTAKE SYSTEM
INSTALLING THE INTAKE MANIFOLD
Install:
Intake manifold
NOTE:
Tighten the intake manifold mounting bolt
in sequence and two steps of torque.
Intake manifold mounting bolt:

1st: 6.0 Nm (0.6 kfgm, 4.4 ftlb)
2nd: 12.0 Nm (1.2 kfgm,
8.8 ftlb)
4-7
CARBURETOR
CARBURETOR
DISASSEMBLING/ASSEMBLING THE CARBURETOR

1 Drain plug 1
3 Throttle stop screw 1
4 Spring 1
5 Screw 1
6 Screw (with washer) 1
7 Cover plate 1
8 Cover gasket 1 Not reusable
10 Float chamber 1
11 O-ring 1 48 x 1.8 mm Not reusable
12 Float pin 1
13 Float 1
Continued on next page.
4-8
CARBURETOR

14 Needle valve 1
15 Main jet 1
16 Pilot 1
17 Plug 1
18 Main nozzle 1
19 Body assembly 1

procedure.
4-9
CARBURETOR
DISASSEMBLING THE CARBURETOR
Remove:
Float pin 1
Float 2
Needle valve
NOTE:
Tap float pin 1 in the direction of arrow a
of carburetor body 3 and in the reverse
direction with a pin to remove.
CHECKING THE CARBURETOR

NOTE:
Before disassembling the carburetor, make
sure to note the number of times the pilot
screw is turned out from the seated
position to its set position.
CAUTION:
Do not use steel-wire for cleaning the jets.
This may enlarge the jet diameters and
seriously affect performance.
1. Check:
Carburetor body
Cracks/damage Replace.
Contamination Clean.
2. Check:
Needle valve
Pilot screw
Grooved wear Replace.
3. Check:
Main nozzle
Main jet
Pilot jet
Contamination Clean.
4. Check:
Float
5. Check:
O-ring
Wear/cracks/damage Replace.
4-10
CARBURETOR
ASSEMBLING THE CARBURETOR
NOTE:
Before assembling the carburetor, make
sure to turn out the pilot screw the same
number of times, as noted before
disassembly, from the seated position to
the set position.
1. Install:
y Needle valve 3
y Float 1
y Float pin 2
NOTE:
y When setting the float 1 into the
carburetor body, hook the needle valve 3
into the float 1 and insert the needle
valve seat.
y Tap float pin 2 in the direction of arrow a
of carburetor body 4 and with a pin to
install.
y After installation,make sure that the float
1 operates smoothly.
2. Measure:
y Float hight b
Out of specification Æ Replace.
Float height b:
19.0 - 20.0 mm (0.75 - 0.79 in)
NOTE:
y Make sure to tilt the carburetor body
clockwise 45° for needle valve with spring
no load, when measuring the float height
b.
y Take measurement at the side end of the
float, as shown.
4-11
CHAPTER 5
POWER UNIT
MANUAL STARTER .........................................................................................5-1

REMOVING/INSTALLING THE MANUAL STARTER ...............................5-1
INSTALLING THE DUST COVER GROMMET ..........................................5-2
ADJUSTING THE START-IN-GEAR PROTECTION DEVICE ....................5-2
DISASSEMBLING/ASSEMBLING THE MANUAL STARTER ..................5-3
DISASSEMBLING THE MANUAL STARTER ...........................................5-5
CHECKING THE MANUAL STARTER ......................................................5-6
ASSEMBLING THE MANUAL STARTER .................................................5-6
FLYWHEEL ROTOR ..........................................................................................5-9

REMOVING/INSTALLING THE FLYWHEEL ROTOR ................................5-9
REMOVING THE FLYWHEEL ROTOR ....................................................5-10
INSTALLING THE FLYWHEEL ROTOR ..................................................5-11
POWER UNIT .................................................................................................5-12

DISCONNECTING/CONNECTING THE ELECTRICAL LEADS ...............5-12
DISCONNECTING/CONNECTING THE CABLES AND HOSE ...............5-13
ADJUSTING THE THROTTLE CONTROL CABLE(S) .............................5-14
REMOVING/INSTALLING THE POWER UNIT .......................................5-15
INSTALLING THE POWER UNIT ............................................................5-16
REMOVING/INSTALLING THE THROTTLE LINK AND RIGHT SIDE
ELECTRICAL COMPONENTS .................................................................5-17
REMOVING/INSTALLING THE LEFT SIDE ELECTRICAL
COMPONENTS 1 (ONE LIGHTING COIL MODEL) ................................5-19
COMPONENTS 2 (ONE LIGHTING COIL MODEL) ................................5-20
COMPONENTS 1(TWO LIGHTING COILS MODEL) ..............................5-21
COMPONENTS 2(TWO LIGHTING COILS MODEL) ..............................5-22
THERMOSTAT, TIMING BELT AND GEARS ................................................5-23

REMOVING/INSTALLING THE THERMOSTAT, TIMING
BELT AND GEARS ..................................................................................5-23
REMOVING THE TIMING BELT ..............................................................5-25
REMOVING THE DRIVE GEAR ...............................................................5-25
REMOVING THE DRIVEN GEAR ............................................................5-25
CHECKING THE THERMOSTAT .............................................................5-26
CHECKING THE TIMING BELT ...............................................................5-26
INSTALLING THE DRIVEN GEAR ...........................................................5-26
INSTALLING THE DRIVE GEAR .............................................................5-27
INSTALLING THE TIMING BELT ............................................................5-28
ADJUSTING THE VALVE CLEARANCE .................................................5-28
ANODE AND EXHAUST COVER ..................................................................5-29
REMOVING/INSTALLING THE ANODE AND EXHAUST COVER .........5-29
CHECKING THE ANODE .........................................................................5-30
INSTALLING THE EXHAUST COVER ....................................................5-30
CYLINDER HEAD AND OIL PUMP ................................................................5-31

REMOVING/INSTALLING THE CYLINDER HEAD AND OIL PUMP ......5-31
CHECKING THE SPARK PLUG ...............................................................5-33
INSTALLING THE OIL PUMP ..................................................................5-33
INSTALLING THE CYLINDER HEAD ......................................................5-33
INSTALLING THE CYLINDER HEAD COVER .........................................5-34
OIL PUMP .......................................................................................................5-35

DISASSEMBLING/ASSEMBLING THE OIL PUMP ................................5-35
CHECKING THE OIL PUMP .....................................................................5-36
ASSEMBLING THE OIL PUMP ...............................................................5-36
CAMSHAFT AND VALVES ............................................................................5-37

REMOVING/INSTALLING THE CAMSHAFT AND VALVES ..................5-37
REMOVING THE VALVE .........................................................................5-39
CHECKING THE VALVE AND VALVE GUIDE ........................................5-39
CHECKING THE VALVE SPRING ............................................................5-40
CHECKING THE ROCKER ARM ROCKER ARM SHAFT .......................5-41
CHECKING THE CAMSHAFT ..................................................................5-41
CHECKING THE CYLINDER HEAD .........................................................5-42
REPLACING THE VALVE GUIDE ............................................................5-42
REFACING THE VALVE SEAT ................................................................5-43
INSTALLING THE VALVE .......................................................................5-45
INSTALLING THE CAMSHAFT OIL SEAL ..............................................5-45
CRANKSHAFT, PISTON AND CYLINDER BODY .........................................5-46

5
REMOVING/INSTALLING THE CRANKSHAFT, PISTON AND
CYLINDER BODY .....................................................................................5-46
DISASSEMBLING/ASSEMBLING THE PISTON AND CONNECTING
ROD ..........................................................................................................5-47
CHECKING THE CYLINDER BODY .........................................................5-48
CHECKING THE PISTON .........................................................................5-48
CALCULATING THE PISTON-TO-CYLINDER CLEARANCE ..................5-49
CHECKING THE PISTON PIN ..................................................................5-49
CHECKING THE PISTON RING ...............................................................5-50
CHECKING THE CRANKSHAFT ..............................................................5-50
CHECKING THE CRANKSHAFT-PLAIN BEARING OIL CLEARANCE ...5-51
CHECKING THE CRANKSHAFT-CONNECTING ROD OIL
CLEARANCE .............................................................................................5-53
INSTALLING THE PISTON RING ............................................................5-55
INSTALLING THE CONNECTING ROD ..................................................5-55
INSTALLING THE PISTON AND CONNECTING ROD ...........................5-56
INSTALLING THE OIL SEAL ...................................................................5-56
INSTALLING THE CRANKCASE .............................................................5-56
MANUAL STARTER
MANUAL STARTER
REMOVING/INSTALLING THE MANUAL STARTER

1 Start-in-gear protection cable 1
3 Manual starter assembly 1
4 Dust cover 1
5 Grommet 3

procedure.
5-1
MANUAL STARTER
INSTALLING THE DUST COVER
GROMMET
Install:
Dust cover grommet
NOTE:
Set the grommet so that the large flange
diameter is at the bottom and install to the
dust cover.
ADJUSTING THE START-IN-GEAR

PROTECTION DEVICE
Adjust:
Start-in-gear protection device
Refer to “ADJUSTING THE START-
IN-GEAR PROTECTION DEVICE” on
page 3-8.
5-2
MANUAL STARTER
DISASSEMBLING/ASSEMBLING THE MANUAL STARTER

1 Wire assembly 1
2 Return spring 1
3 Screw 1
4 Drive plate 1
5 Drive spring 1
6 Sheave drum assembly 1
7 Circlip 1
8 Drive pawl 1
9 Return spring 1
10 Spring 1
11 Sheave dram 1
12 Starter spring 1
13 Cover
5-3
MANUAL STARTER

14 Starter handle 1
15 Dumper 1
16 Starter wire 1 1,500mm
17 Return spring 1
18 Stopper 1
19 Coller 1
20 Starter case 1

procedure.
5-4
MANUAL STARTER
DISASSEMBLING THE MANUAL
STARTER
1. Rotate:
Sheave drum 1
NOTE:
Before removing the drive plate and drive
spring, turn the sheave drum to make the
starter spring inside the sleeve drum free.
Rotating steps:
(1)Turn the sheave drum 1 so that the
cutaway a on the outer surface of the
sheave drum faces toward the starter
handle.
(2)Pass the starter wire 2 through the
cutaway a.
(3)Turn the sheave drum 1 clockwise
until the starter spring is free.
2. Remove:
Screw 3
Drive plate 4
Drive spring 5
Sheave drum 1
WARNING
When removing the sheave drum, be
sure to turn the sheave drum upside
down to prevent the starter spring from
popping up at you.
Do not leave the sheave drum removed.
The starter spring may pop out.
3. Remove:
Starter spring 6
WARNING
Be careful so that the starter spring does
not pop out when removing it.
Remove it by allowing it out one turn of
the winding each time.
5-5
MANUAL STARTER
CHECKING THE MANUAL STARTER
1. Check:
Start-in-gear protection lever
Cracks/wear/damage Replace.
2. Check:
Drive pawl
Drive spring
Damage Replace.
3. Check:
Sheave drum
4. Check:
Return springs
Damage Replace.
5. Check:
Starter wire
Frayed/wear/damage Replace.
NOTE:
When replacing the starter wire, cut it to
the specified length and then burn its end
so it will not unravel.
Apply water resistant grease onto the
new starter wire.
Starter wire length:

1,500 mm (59.1 in)
ASSEMBLING THE MANUAL STARTER

1. Install:
Starter spring 1
WARNING
When installing the starter spring onto the
starter case, use care so that the starter
spring does not pop out. To help the spring
stay compressed, wind it from the outside,
one turn each time.
5-6
MANUAL STARTER
2. Install:
Starter wire 2
Installing steps:
(1)Insert the starter wire 2 through the
wire holes and then tie a knot on the
end of the wire.
(2)Place the starter wire at the cutaway of
the sheave drum.
3. Install:
Sheave drum 3
NOTE:
Position the inner end of the starter spring
on the retainer post of sheave drum.
4. Install:
Drive spring 4
Drive plate 5
Screw 6
Installing steps:
(1)Install drive spring 4 to drive plate 5.
(2)Pass the tip of drive spring 4 through
the coil portion of return spring 7, and
install drive plate 5 to the sheave
drum.
(3)Install screw 6.
5-7
MANUAL STARTER
5. Set:
Starter spring
Setting steps:
(1)Place the starter wire 2 at the cutaway
a of the sheave drum 3.
(2)Wind the sheave drum 3 5 turns
counterclockwise with the starter wire
2.
(3)Remove starter wire 2 from cutaway
a, then wind on sheave drum 3.
6. Check:
Manual starter operation
Rough operation Repair.
NOTE:
When checking the manual starter only,
release the start-in-gear protection device.
5-8
FLYWHEEL ROTOR
FLYWHEEL ROTOR
REMOVING/INSTALLING THE FLYWHEEL ROTOR

1 Nut 1
2 Washer 1
3 Flywheel rotor 1
4 Woodruff key 1

procedure.
5-9
FLYWHEEL ROTOR
A REMOVING THE FLYWHEEL ROTOR
1. Remove:
Flywheel rotor nut
Flywheel holder:
YB-06139/90890-06522
A For USA and Canada
B Except for USA and Canada
NOTE:
The major load should be applied in the
B direction of the arrows. If the load is not
applied as shown, the flywheel holder may
easily slip off of the flywheel rotor.
A B 2. Remove:
Flywheel rotor
Universal puller:
YB-06117/90890-06521
CAUTION:
Keep the nut side flush with the
crankshaft end until the flywheel rotor
comes off the tapered portion of the
crankshaft.
To prevent damage to the engine or
tools, screw in the universal puller bolts
evenly and completely so that the
universal puller plate is parallel to the
flywheel rotor.
5-10
FLYWHEEL ROTOR
A INSTALLING THE FLYWHEEL ROTOR
Install:
Flywheel rotor nut
Flywheel holder:
YB-06139/90890-06522
NOTE:
The major load should be applied in the
B direction of the arrows. If the load is not
applied as shown, the flywheel holder may
easily slip off of the flywheel rotor.
5-11
POWER UNIT
POWER UNIT
DISCONNECTING/CONNECTING THE ELECTRICAL LEADS

2 Engine stop switch connector and 2 White, Black
terminal
3 Emergency signal light connector 2 Yellow/red, Pink

procedure.
5-12
POWER UNIT
DISCONNECTING/CONNECTING THE CABLES AND HOSE

Engine oil drain Refer to “REPLACING THE ENGINE OIL” on
page 3-9.
1 Throttle cable 2
2 Nut 1
3 Shift cable 1
4 Oil level gauge 1
5 Water hose 1

procedure.
5-13
POWER UNIT
CABLE(S)
Adjust:
Throttle control cable(s)
Refer to “ADJUSTING THE
THROTTLE CONTROL CABLES” on
page 3-5.
5-14
POWER UNIT
REMOVING/INSTALLING THE POWER UNIT

2 Nut 2
3 Apron 1
4 Plug 2
5 Apron 1
6 Rubber seal 1
8 Power unit 1
9 Relief valve assembly 1
12 Dowel pin 2
procedure.
5-15
POWER UNIT
INSTALLING THE POWER UNIT
Install:
Power unit
NOTE:
Tighten the power unit mounting bolt by
the order shown in the diagram on the
left.
Tighten up the exhaust guide mounting
bolt at the same time.
5-16
POWER UNIT
REMOVING/INSTALLING THE THROTTLE LINK AND RIGHT SIDE ELECTRICAL

COMPONENTS

3 Washer 1
4 Collar 1
5 Throttle control lever 1
6 Link joint 1
7 Throttle control cam 1
8 Bracket 1
9 Screw 1
10 Oil pressure switch lead 1 Pink
11 Oil pressure switch 1
12 Bolt 2
13 Attachment 1
5-17
POWER UNIT

14 Pulser coil 1

procedure.
5-18
POWER UNIT
REMOVING/INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 1 (ONE

LIGHTING COIL MODEL)

2 Rectifier 1 4 leads (Black, Red, Green x 2)
4 Ignition coil 1 2 leads (Orange, Black)
6 Bracket 1

procedure.
5-19
POWER UNIT
REMOVING/INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 2 (ONE

LIGHTING COIL MODEL)

1 Clamp 1 Not reusable
2 Bolt (with washer) 2 Not reusable
3 Charge coil 1 2 leads (Blue, Brown)
5 Clamp 1
7 Lighting coil 1 2 leads (Green x 2)
8 Screw 2
9 Coupler clamp 1
11 CDI unit 1 13 leads

procedure.
5-20
POWER UNIT
REMOVING/INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 1 (TWO

LIGHTING COILS MODEL)

3 Ignition coil 1 2 leads (Orange, Black)
5 Clamp 1
8 Rectifier/regulator 1 4 leads (Black, Red, Green x 2)
11 Starter motor bracket 1

procedure.
5-21
POWER UNIT
REMOVING/INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 2 (TWO

LIGHTING COILS MODEL)

3 Charge coil 1 2 leads (Blue, Brown)
5 Lighting coil 1 2 leads (Green x 2)
6 Screw 2
7 Coupler clamp 1
9 CDI unit 1 13 leads

procedure.
5-22
THERMOSTAT, TIMING BELT AND GEARS
REMOVING/INSTALLING THE THERMOSTAT, TIMING BELT AND GEARS

2 Water hose 1
4 Thermostat cover 1
6 Thermostat 1
7 Timing belt 1
8 Nut 1
9 Lock washer 1
10 Plate washer 1
11 Drive gear 1
12 Woodruff key 1
13 Bolt 1
5-23

14 Plate washer 1
15 Driven gear 1
16 Woodruff key 1
17 Plate washer 1

procedure.
5-24
REMOVING THE TIMING BELT
Remove:
Timing belt 1
NOTE:
Turn the drive gear 2 and align the “∆1”
mark on the driven gear 3 and “∆” mark
on the thermostat housing cover 4
(portion a).
REMOVING THE DRIVE GEAR

Remove:
Drive gear nut
Crankshaft holder:
YB-06561/90890-06561
NOTE:
Loosen the drive gear nut with a 30 mm
deep socket.
B A REMOVING THE DRIVEN GEAR

Remove:
Driven gear bolt
Flywheel holder:
YB-06139/90890-06522
5-25
CHECKING THE THERMOSTAT
Measure:
Valve operating temperature
Valve lift a
Water temperature Valve lift
Below 0 mm
60 °C(140 °F) (0 in)
Above Min.3 mm
70 °C(158 °F) (0.12 in)
Measuring steps:
(1)Suspend the thermostat in a container
filled with water.
(2)Place a thermostat in the water.
(3)Slowly heat the water.
(4)While stirring the water, check that the
thermometer opens at the specified
temperature.
CHECKING THE TIMING BELT

Check:
Timing belt
Refer to “CHECKING THE TIMING
BELT” on page 3-14.
INSTALLING THE DRIVEN GEAR

1. Install:
Driven gear
NOTE:
Install the driven gear so that counter mark
(∆) is at the top.
2. Install:
B A
Driven gear bolt
Flywheel holder :
YB-06139/90890-06522
5-26
INSTALLING THE DRIVE GEAR
1. Install:
Woodruff key 1
Drive gear 2
Washer 3
Lock washer 4
NOTE:
Install the washer as shown in the
diagram on the left so that the curvature
extends in the upward direction. (It is in
the reverse direction from the curvature
of the flange of the drive gear.)
Pass the tab of the lock washer through
the hole in the drive gear and washer.
2. Install:
Drive gear nut
Crankshaft holder:
YB-06561/90890-06561
NOTE:
Tighten the drive gear nut with a 30 mm
deep socket.
3. Bend:
Lock washer 5
NOTE:
Bend the lock washer securely.
5-27
INSTALLING THE TIMING BELT
Install:
Timing belt 5
Installing steps:
(1)Turn the drive gear 1 and align the
washer groove on the drive gear and
“∆” mark on the cylinder body 2
(portin a).
(2)Turn the driven gear 3 and align the
“∆1” mark on the driven gear and “∆”
mark on the thermostat cover 4
(portin b).
(3)Install the timing belt 5.
NOTE:
Install the timing belt with the part name
facing up.
(4)Turn the crankshaft clockwise 2 turns

and make sure the drive gear and
driven gear are correctly aligned with
the timing marks.

Adjust:
Valve clearance
Refer to the “ADJUSTING THE
VALVE CLEARANCE” on page 3-10.
5-28
ANODE AND EXHAUST COVER
REMOVING/INSTALLING THE ANODE AND EXHAUST COVER

1 Plug 1
2 O-ring 1 Not reusable
3 Screw 1
5 Anode 1
7 Exhaust cover 1

procedure.
5-29
CHECKING THE ANODE
Check:
Anode
Refer to “CHECKING THE ANODE”
on page 3-17.
INSTALLING THE EXHAUST COVER

Install:
Exhaust cover
NOTE:
Tighten the exhaust cover bolt in sequence
and two steps of torque.
Exhaust cover mounting bolt:

1st: 6.0 Nm (0.6 kfgm, 4.4 ftlb)
2nd: 12.0 Nm (1.2 kfgm,
8.8 ftlb)
5-30
CYLINDER HEAD AND OIL PUMP
REMOVING/INSTALLING THE CYLINDER HEAD AND OIL PUMP

1 Spark plug 2
2 Oil filler cap 1
3 O-ring 1 25.0 x 3.0 mm
5 Cylinder head cover 1
6 Cover seal 1
8 Breather cover 1
13 Cylinder head assembly 1
5-31

14 Cylinder head gasket 1 Not reusable
15 Dowel pin 2
17 Oil pump assembly 1
18 Oil pump gasket 1 Not reusable

procedure.
5-32
CHECKING THE SPARK PLUG
Check:
Spark plug
Refer to “CHECKING THE SPARK
PLUGS” on page 3-18.
INSTALLING THE OIL PUMP

Install:
Oil pump
NOTE:
Before installing to the cylinder head, add a
drop of approx. 1 cc of Yamaha 4-stroke
outboard motor oil from suction port a or
discharge port b.
INSTALLING THE CYLINDER HEAD

Install:
Cylinder head
NOTE:
Tighten the cylinder head mounting bolt in
sequence and two steps of torque.
Cylinder head mounting bolt

1st:
M8: 15 Nm (1.5 kgfm, 11.1 ftlb)
M6: 6 Nm (0.6 kgfm, 4.4 ftlb)
2nd:
M8: 30 Nm (3.0 kgfm, 22.1 ftlb)
M6: 12 Nm (1.2 kgfm, 8.8 ftlb)
5-33
INSTALLING THE CYLINDER HEAD
COVER
Install:
Cylinder head cover
NOTE:
Tighten the cylinder head mounting bolt in
sequence.
5-34
OIL PUMP
OIL PUMP
DISASSEMBLING/ASSEMBLING THE OIL PUMP

1 Screw 2
2 Pump cover 1
4 Inner rotor 1
5 Shaft 1
6 Pin 1
7 Outer rotor 1
8 Oil pump housing 1

procedure.
5-35
OIL PUMP
CHECKING THE OIL PUMP
Measure:
Oil pump clearances a, b, and c
Oil pump clearances:
a: 0.10 - 0.15 mm
(0.004 - 0.006 in)
b: 0.04 - 0.14 mm
(0.002 - 0.006 in)
c: 0.03 - 0.09 mm
(0.001 - 0.004 in)
ASSEMBLING THE OIL PUMP

Install:
Outer rotor 1
Inner rotor 2
NOTE:
The “ “ mark a on the outer rotor 1
faces towards the pump cover side.
The “ “ mark b on the inner rotor 2
faces towards the oil pump housing side.
5-36
CAMSHAFT AND VALVES
CAMSHAFT AND VALVES
REMOVING/INSTALLING THE CAMSHAFT AND VALVES

1 Locknut 4
2 Rocker arm adjusting screw 4
3 Rocker shaft 1
4 Spring 2
5 Collar 1
6 Collar 3
7 Rocker arm 4
8 Cam shaft 1
9 Oil seal 1 Not reusable
10 Valve spring lock 4
11 Valve spring retainer 4
12 Valve spring 4
13 Valve spring seat 4
5-37
CAMSHAFT AND VALVES

14 Intake valve 2
15 Exhaust valve 2
16 Valve stem oil seal 4 Not reusable
17 Cylinder head 1

procedure.
5-38
CAMSHAFT AND VALVES
REMOVING THE VALVE
Remove:
Valve spring lock 1
Valve spring retainer 2
Valve spring 3
Valve spring seat 4
Intake valve or exhaust valve 5
Valve spring compressor:

YM-01253/90890-04019
Attachment:
YM-04018/90890-04018
NOTE:
Set the attachment on to the center of the
spring retainer.
Do not overtighten the valve spring
compressor.
CHECKING THE VALVE AND VALVE

GUIDE
1. Measure:
Valve guide inside diameter a
Valve guide inside diameter a
(intake guide and exhaust guide):
5.500 - 5.512 mm
(0.2165 - 0.2170 in)
2. Measure:
Valve seat width b
Valve seat width b
(intake valve and exhaust valve):
0.6 - 0.8 mm (0.023 - 0.031 in)
3. Measure:
Valve margin thickness c
Valve margin thickness c
0.7 mm (0.027 in)
5-39
CAMSHAFT AND VALVES
4. Measure:
Valve stem outside diameter d
Valve stem outside diameter d:
Intake valve: 5.475 - 5.490 mm
(0.2156 - 0.2161 in)
Exhaust valve: 5.460 - 5.475 mm
(0.2150 - 0.2156 in)
5. Measure:
Valve stem runout
Valve stem runout limit
0.03 mm (0.0012 in)
NOTE:
When replacing the valve, always use a
new valve guide and valve stem oil seal.
CHECKING THE VALVE SPRING

1. Measure:
Valve spring free length a
Valve spring free length limit a:
27.6 mm (1.09 in)
2. Measure:
Valve spring tilt b
Valve spring tilt limit b:
1.0 mm (0.04 in)
5-40
CAMSHAFT AND VALVES
CHECKING THE ROCKER ARM
ROCKER ARM SHAFT
1. Measure:
Rocker arm inside diameter a
Rocker arm inside diameter a:
13.000 - 13.018 mm
(0.5118 - 0.5125 in)
2. Measure:
Rocker arm shaft outside diameter
b
Rocker arm shaft outside diameter
b:
12.941 - 12.951 mm
(0.5095 - 0.5099 in)
CHECKING THE CAMSHAFT

Measure:
Camshaft lobe diameter a and b
Camshaft lobe diameter (intake
cam and exhaust cam):
a: 23.45 - 23.55 mm
(0.9232 - 0.9271 in)
b: 19.95 - 20.05 mm
(0.7854 - 0.7893 in)
5-41
CAMSHAFT AND VALVES
CHECKING THE CYLINDER HEAD
Measure:
Cylinder head warpage
Out of specification Resurface or
replace.
Warpage limit:
0.1 mm (0.004 in)
Resurfacing steps:
(1)Place a 400 - 600 grit wet sandpaper on
the surface plate.
(2)Resurface the cylinder head using a
figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the
cylinder head several times.
REPLACING THE VALVE GUIDE

Replace:
Valve guide
Replacing steps:
NOTE:
Heat the cylinder head in an oven to 200°C
(392°F) to ease valve guide removal and
installation and maintain the correct
interference fit.
(1)Remove the valve guide using the

valve guide remover.
Valve guide remover:
N.A./90890-06801
(2)Make a counter mark at the protrusion
dimension position from the cylinder
head on the new valveguide. Valve
guide protrusion dimension a.
Projection dimension of the valve
guide a:
7.8 - 8.3 mm (0.307 - 0.327 in)
(3)Using a valve guide installer, press fit

the valve guide so that the counter
mark on the valve guide is aligned with
the end face of the cylinder head.
Valve guide installer:
YM-01112/90890-06801
5-42
CAMSHAFT AND VALVES
(4)Bore the valve guide using the valve
guide reamer.
Valve guide reamer:
NA/90890-06804
NOTE:
When installing and removing the valve
guide reamer, apply machining oil and turn
the reamer clockwise
REFACING THE VALVE SEAT

NOTE:
After refacing the valve seat or replacing
the valve and valve guide, lap the valve
seat and valve face.
Reface:
Valve seat
CAUTION:
When turning the valve seat cutter, keep
an even downward pressure (4 - 5 kg) to
prevent chatter mark.
Valve seat width

0.6 - 0.8 mm (0.02 - 0.03 in)
Valve seat cutter set:

YM-91043-C/90890-06803
Valve seat lapper:
NA/90890-04101
Cut section of follows

Section Cutter
A 90°
B 45°
C 30°
5-43
CAMSHAFT AND VALVES
A Refacing steps:
A Valve seat is centered on valve face but
it is too wide.
Valve cutter seat Desired result
Use 90° cutter To reduce the valve
lightly 30° cutter seat width
B B Valve seat is in the middle of the valve

face but it is too narrow.
To increase the valve
Use 45° cutter
seat width
C C Valve seat is too narrow and it is near

the valve margin.
90° cutter To center the valve
Use
45° cutter seat and set it width
D D Valve seat is too narrow and it is near

the valve stem.
30° cutter To center the valve
Use
45° cutter seat and set it width
5-44
CAMSHAFT AND VALVES
INSTALLING THE VALVE
Install:
Intake valve or exhaust valve 5
Valve spring seat 4
Valve spring 3
Valve spring retainer 2
Valve spring lock 1
Valve spring compressor:

YM-01253/90890-04019
Attachment:
YM-04108/90890-04108
NOTE:
Set the attachment on to the center of the
spring retainer.
Do not overtighten the valve spring
compressor.
INSTALLING THE CAMSHAFT OIL SEAL

Install:
Cam shaft oil seal 1
Driver rod:
YM-06229/90890-06652
Attachment:
YB-06197/90890-06653
NOTE:
Press fit the oil seal to the stepped portion
of the cylinder head and check that it is not
at an angle.
5-45
CRANKSHAFT, PISTON AND CYLINDER BODY
REMOVING/INSTALLING THE CRANKSHAFT, PISTON AND CYLINDER BODY

2 Crankcase 1
3 Dowel pin 4
4 Connecting rod bolt 2
5 Connecting rod cap 4
6 Crankshaft 2
9 Piston and connecting rod 2
10 Plain bearing 2
11 Cylinder body 1

procedure.
5-46
DISASSEMBLING/ASSEMBLING THE PISTON AND CONNECTING ROD

1 Circlip 4
2 Piston pin 2
3 Connecting rod 2
4 Top ring 2
5 2nd ring 2
6 Oil ring 2
7 Piston 2

procedure.
5-47
CHECKING THE CYLINDER BODY
Measure:
Cylinder bore (with a cylinder bore
gauge)
Out of specification Rebore the
cylinder or replace the cylinder
body.
Standard Wear limit
H1: 20 mm (0.8 in)

Measuring
H2: 40 mm (1.6 in)
point “H”
H2: 60 mm (2.4 in)
Cylinder bore 56.000 - 56.015mm
“D” (2.2047 - 2.2053 in)
Taper limit 0.08 mm
––
“T” (0.0031 in)
Out of round 0.05 mm
––
limit “R” (0.0020 in)
D= Maximum D1, D2, D3, D4, D5 or D6
T= (Maximum D1 or D2) - (Minimum D5 or
D6)
R= Maximum (D1 or D2) or (D3 or D4) or
(D5 or D6)
NOTE:
Measure the cylinder bore in parallel and at
a right angle to the chankshaft. Then
average the measurement.
CHECKING THE PISTON

1. Measure:
Piston diameter (with a micrometer)
Out of specification Replace the
piston.
Measuring point 1.5 mm
“H” (0.06 in)
Standard Piston 55.950 - 55.965 mm
diameter “D” (2.2028 - 2.2033 in)
Over size piston diameter:
1st: 56.200 - 56.215mm
(2.2126 - 2.2132 in)
2nd: 56.450 - 56.465 mm
(2.2224 - 2.2230 in)
5-48
NOTE:
When measuring the piston diameter,
position the micrometer in relation to the
piston pin hole as shown.
2. Measure:
Piston pin boss inside diameter
(with a micrometer)
piston.
Piston pin boss inside diameter:
14.004 - 14.015 mm
(0.5513 - 0.5518 in)
CALCULATING THE PISTON-TO-

CYLINDER CLEARANCE
Calculate:
Piston-to-cylinder clearance a
piston and piston rings, the cylinder
or both.
Piston-to- Cylinder
Piston
cylinder = bore –
diameter
clearance diameter
Piston-to-cylinder clearance a:
0.035 - 0.065 mm
(0.0014 - 0.0026 in)
CHECKING THE PISTON PIN

Measure:
Piston pin outside diameter
piston pin.
Piston pin outside diameter:
13.996 - 14.000 mm
(0.5510 - 0.5512 in)
5-49
CHECKING THE PISTON RING
1. Measure:
End gap a
piston ring.
Top ring end gap:
0.15 - 0.30 mm(0.006 - 0.012 in)
2nd ring end gap:
0.30 - 0.45 mm(0.012 - 0.018 in)
Oil ring end gap:
0.20 - 0.70 mm(0.008 - 0.028 in)
NOTE:
Push the piston ring into the cylinder with
the piston crown.
2. Measure:
Side clearance b and c
piston and piston rings as a set.
Top ring side clearance b:
0.04 - 0.08 mm(0.0016 - 0.0031 in)
2nd ring side clearance c:
0.03 - 0.07 mm(0.0012 - 0.0028 in)
CHECKING THE CRANKSHAFT

Measure:
Crankshaft runout
crankshaft.
Crankshaft runout limit:
0.03 mm (0.0012 in)
5-50
CHECKING THE CRANKSHAFT-PLAIN
BEARING OIL CLEARANCE
NOTE:
Make sure that the crankshaft is qualified
before initiating the following procedure.
1. Measure:
Crankshaft-plain bearing oil
clearance
upper and lower plain bearing as a
set.
Crankshaft-plain bearing oil
clearance:
0.011 - 0.039mm
(0.0004 - 0.0015 in)
NOTE:
Measure the oil clearance at room
temperature (20°C (68°F))
Measuring steps:
CAUTION:
Install the plain bearings in their original
positions. Incorrect oil clearance
measurements can lead to engine damage.
(1)Clean the plain bearings, main journal
of the crankshaft, and plain bearing
portion of the cylinder body and
crankcase.
(2)Place the cylinder body 2 upside
down on a bench.
(3)Install the half of the plain bearings 1
to the cylinder body 2 and the
crankcase 3.
NOTE:
Set the part of the plain bearing with the
tab in tab groove a, and insert the part
with no tab in corner b.
(4)Install the crankshaft 4 to the cylinder

body 2.
(5)Put a piece of Plastigauge® on each
main journal in parallel to the
crankshaft.
NOTE:
Do not put a Plastigauge® over the oil hole
in the main journal of the crankshaft.
5-51
(6)Install the crankcase 3 onto cylinder
body 2.
(7)Tighten the crankcase mounting bolt
5.
NOTE:
Apply engine oil onto the thread and seat
of the crankcase mounting bolt.
Tighten the crankcase mounting bolt in
Crank case mounting bolt:

1st: 15 Nm (1.5 kgfm, 11.1 ftlb)
2nd: 30 Nm (3.0 kgfm, 22.1 ftlb)
(8)Loosen the crankcase mounting bolt 5
and remove the crankcase 2 .
(9)Measure the width of compressed
Plastigauge® on each main journal.
2. Select:
Plain bearing
Select the suitable plain bearing
from the table below.
Plain bearing selection table
Upper journal Lower journal Bearing
size mark c size mark d color e
A Blue
B Black
C Brown
5-52
CHECKING THE CRANKSHAFT-
CONNECTING ROD OIL CLEARANCE
NOTE:
Make sure that the crankshaft is qualified
before initiating the following procedure.
Measure:
Crankshaft-connecting rod oil
clearance
connecting rod and cap as a set.
Crankshaft-connecting rod oil
clearance:
0.030 - 0.042 mm
(0.0012 - 0.0017 in)
NOTE:
Keep each connecting rods and caps as a
set.
Measure the oil clearance at room
temperature (20°C (68°F))
Measuring steps:
CAUTION:
Install the connecting rods and caps in
their original positions. Incorrect oil
clearance measurements can lead to
engine damage.
NOTE:
Make sure that the “YAMAHA” mark a
on the connecting rod faces toward the
flywheel side.
Align the “∆“ marks b on the connecting
rod and cap when assembling.
(1)Clean the bearing portion of the

connecting rod and crank pin journal
of the crankshaft.
(2)Install the connecting rod onto the
crankshaft.
(3)Put a piece of Plastigauge® on crank
pin journal in parallel to the crankshaft.
NOTE:
Do not put a Plastigauge® over the oil hole
in the crank pin journal of the crankshaft.
5-53
(4)Install the connecting rod cap onto the
crankshaft.
(5)Tighten the connecting rod mounting
bolt.
NOTE:
Apply engine oil onto the thread and seat
of the connecting rod mounting bolt.
Tighten the connecting rod mounting bolt
in two steps of torque.
Connecting rod mounting bolt:

1st: 6 Nm (0.6 kgfm, 4.4 ftlb)
2nd: 11 Nm (1.1 kgfm, 8.1 ftlb)
(6)Loosen the connecting rod mounting
bolt and remove the connecting rod
and cap.
(7)Measure the width of compressed on
crank pin journal.
5-54
INSTALLING THE PISTON RING
1. Install:
Oil ring 1
2nd ring 2
Top ring 3
NOTE:
When installing oil ring, first install the
expander ring and then the side rails.
When installing the 2nd ring and top ring,
make sure the “N” mark faces upward.
After installing the piston rings, check
that they move smoothly.
2. Set:
Set the piston ring end gaps as shown.
Top ring end gap a
2nd ring end gap b
Oil ring Upper side rail end gap c
Oil ring expander ring end gap a
Oil ring lower side rail end gap d
INSTALLING THE CONNECTING ROD

Install:
Piston 1
Connecting rod 2
Piston pin 3
Circlip 4
NOTE:
Install the connecting rod with “YAMAHA”
mark facing towards the “UP” mark on the
piston crown.
5-55
INSTALLING THE PISTON AND
CONNECTING ROD
1. Install:
Piston and connecting rod
Piston slider:
YU-33294/90890-05158
NOTE:
Install the piston with “UP” mark on the
piston crown facing toward the flywheel
side.
2. Install:
Connecting rod cap
NOTE:
Align the “∆“ marks on the connecting rod
and cap when installing.
INSTALLING THE OIL SEAL

Install:
Oil seal 1 and 2
CAUTION:
Do not install the oil seals after
tightening the crankcase mounting bolts,
this can damage the oil seals.
To prevent the inclined seal installation,
install the oil seals, crankshaft and
crankcase, finger tighten the mounting
bolts then lightly knock the seal.
INSTALLING THE CRANKCASE

Install:
Crankcase
NOTE:
When Gasket Maker is applied, prevent
it from sticking to the inner surface of the
plain bearing.
Tighten the crankcase mounting bolt in
5-56
CHAPTER 6
LOWER UNIT
LOWER UNIT ...................................................................................................6-1

REMOVING/INSTALLING THE LOWER UNIT ..........................................6-1
REMOVING THE PROPELLER ..................................................................6-3
CHECKING THE PROPELLER ....................................................................6-3
CHECKING THE ANODE ...........................................................................6-3
INSTALLING THE LOWER UNIT ..............................................................6-3
INSTALLING THE PROPELLER .................................................................6-4
WATER PUMP ..................................................................................................6-5

REMOVING/INSTALLING THE WATER PUMP ........................................6-5
CHECKING THE WATER PUMP HOUSING, CARTRIDGE
INSERT AND IMPELLER ...........................................................................6-6
PROPELLER SHAFT HOUSING AND PROPELLER SHAFT ............................6-7

REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING
ASSEMBLY AND PROPELLER SHAFT ASSEMBLY ................................6-7
INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY .............6-8
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT
ASSEMBLY .................................................................................................6-9
CHECKING THE DOG CLUTCH ..............................................................6-10
CHECKING THE PROPELLER SHAFT .....................................................6-10
ASSEMBLING THE PROPELLER SHAFT ASSEMBLY ...........................6-10
HOUSING ASSEMBLY ............................................................................6-11
DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY ..6-12
CHECKING THE REVERSE GEAR ...........................................................6-12
CHECKING THE BALL BEARING ............................................................6-12
CHECKING THE PROPELLER SHAFT HOUSING ...................................6-13
ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY ........6-13
DRIVE SHAFT AND FORWARD GEAR .........................................................6-15

REMOVING/INSTALLING THE DRIVE SHAFT AND FORWARD
GEAR ........................................................................................................6-15
REMOVING THE BALL BEARING ...........................................................6-16
CHECKING THE PINION .........................................................................6-16
CHECKING THE DRIVE SHAFT ...............................................................6-16
CHECKING THE FORWARD GEAR .........................................................6-16
CHECKING THE BALL BEARING ............................................................6-16
INSTALLING THE BALL BEARING .........................................................6-17
BEARING HOUSING, SHIFT CAM AND LOWER CASE ...............................6-18

REMOVING/INSTALLING THE BEARING HOUSING, SHIFT
CAM AND LOWER CASE ........................................................................6-18
REMOVING THE SOLID BUSHING ........................................................6-19
DISASSEMBLING THE BEARING HOUSING ........................................6-19
CHECKING THE COLLER ........................................................................6-19
CHECKING THE SHIFT CAM ..................................................................6-19
CHECKING THE LOWER CASE ..............................................................6-19
ASSEMBLING THE BEARING HOUSING ..............................................6-20
INSTALLING THE SOLID BUSHING ......................................................6-21
BACKLASH .....................................................................................................6-22
MEASURING THE FORWARD GEAR BACKLASH ................................6-22
MEASURING THE REVERSE GEAR BACKLASH ...................................6-23
6
LOWER UNIT
LOWER UNIT
REMOVING/INSTALLING THE LOWER UNIT

1 Slit pin 1
2 Nut 1
3 Plate washer 1
4 Propeller 1
5 Spacer 1
6 Bolt 1
7 Anode 1
8 Screw 1
9 Nut 1
10 Water inlet cover 2
11 Nut (short) 1
12 Nut (long) 1
6-1
LOWER UNIT

14 Lower unit 1
15 Seal rubber 1
16 Dowel pin 2

procedure.
6-2
LOWER UNIT
REMOVING THE PROPELLER
Remove:
Propeller
WARNING
Do not hold the propeller with your hands
when removing or installing it. Be sure to
remove the battery leads from the
batteries and the lanyard engine stop
swith. Put a block of wood between the
cavitation plate and propeller to keep the
propeller from turning.
CHECKING THE PROPELLER

Check:
Blades
Splines
Cracks/damage/wear Replace.
CHECKING THE ANODE

Check:
Anode
Refer to “CHECKING THE ANODE”
on page 3-17.
INSTALLING THE LOWER UNIT

Connect:
Shift rod and shift cam
Connecting steps:
(1)Screw in locknut 1 to the bottom end
of the thread of shift cam 2.
(2)Push down shift cam 2 and mesh the
dog clutch with the reverse gear.
(3)Set the shift lever to the reverse
position, then push down shift rod 3.
(4)Screw nut 4 into shift cam 2.
Nut tighten-in length a:

8 - 9 mm (0.31 - 0.35 in)
(5)Secure with locknut 1.
6-3
LOWER UNIT
INSTALLING THE PROPELLER
Install:
Propeller
WARNING
Do not hold the propeller with your hands
when removing or installing it. Be sure to
remove the battery leads from the
batteries and the lanyard engine stop
swith. Put a block of wood between the
cavitation plate and propeller to keep the
propeller from turning.
6-4
WATER PUMP
WATER PUMP
REMOVING/INSTALLING THE WATER PUMP

1 Water seal rubber 1
2 Bolt 4
3 Plate 2
4 Water pump housing 1
5 Cartridge insert 1
7 Impeller 1
8 Woodruff key 1
9 Bolt 2
10 Cartridge outer plate 1
11 Dowel pin 2

procedure.
6-5
WATER PUMP
CHECKING THE WATER PUMP
HOUSING, CARTRIDGE INSERT AND
IMPELLER
1. Check:
Water pump housing
Cartridge insert
2. Check:
Impeller
Cracks/damage/wear Replace.
CHECKING THE WOODRUFF KEY

Check:
Woodruff key
Damage/wear Replace.
INSTALLING THE CARTRIDGE INSERT

AND WATER PUMP HOUSING
1. Install:
Water pump housing 1
Cartridge insert 2
NOTE:
When installing the cartridge insert 2,
align its projection with the hole in the
water pump housing 1.
2. Install:
Water pump housing and cartridge
insert 3
NOTE:
When installing the water pump housing
and insert cartridge 3, turn the impeller
clockwise.
6-6
PROPELLER SHAFT HOUSING AND PROPELLER
PROPELLER SHAFT HOUSING AND PROPELLER SHAFT
REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY AND
PROPELLER SHAFT ASSEMBLY

Gear oil drain Refer to “CHANGING AND CHECKING THE
GEAR OIL LEVEL” on page 3-15.
2 Propeller shaft housing assembly 1
3 Plate washer 1
4 Propeller shaft assembly 1

procedure.
6-7
INSTALLING THE PROPELLER SHAFT
HOUSING ASSEMBLY
Install:
Propeller shaft housing assembly
NOTE:
Install the propeller shaft housing
assembly with the arrow mark facing up.
6-8
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY

1 Shift plunger 1
2 Cross pin ring 1
3 Cross pin 1
4 Clutch dog 1
5 Compression spring 1
6 Propeller shaft 1

procedure.
6-9
CHECKING THE DOG CLUTCH
Check:
Clutch dog
CHECKING THE PROPELLER SHAFT

Check:
Propeller shaft
ASSEMBLING THE PROPELLER SHAFT

ASSEMBLY
1. Install:
Clutch dog
NOTE:
Install the clutch dog with “F” mark
towards the forward gear side.
2. Install:
Compression spring 1
Cross pin 3
NOTE:
Compress the compression spring 1 so
that it is behind the cross pin hole in clutch
dog 2, then install cross pin 3.
6-10
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY

1 Reverse gear 1
2 Gear adjusting shim *
5 Ball bearing 1
7 Solid bushing 1
8 Propeller shaft housing 1

procedure.
*: as required
6-11
A DISASSEMBLING THE PROPELLER
SHAFT HOUSING ASSEMBLY
1. Remove:
Ball bearing
Slide hammer handle 1:

YB-06096
Stopper guide plate 2:
90890-06501
Bearing puller 3:
90890-06535
B Stopper guide stand 4:
90890-06538
2. Remove:
Solid bushing
Driver rod:
YB-06229/90890-06652
Attachment:
YB-06298/90890-06649
CHECKING THE REVERSE GEAR

Check:
Teeth
CHECKING THE BALL BEARING

Check:
Ball bearing
Pitting/rumbling Replace.
NOTE:
Rotate the bearing and check if it turns
smoothly.
6-12
HOUSING
1. Clean:
Propeller shaft housing (with a soft
brush and solvent)
2. Check:
Propeller shaft housing
ASSEMBLING THE PROPELLER SHAFT

HOUSING ASSEMBLY
1. Install:
Solid bushing
Driver rod:
YB-06229/90890-06652
Attachment:
YB-06230/90890-06617
2. Install:
Oil seal
Oil seal mounting depth:

a : 10.0 - 10.5 mm
(0.393 - 0.413 in)
b : 3.0 - 3.5 mm
(0.118 - 0.138 in)
Driver rod:
YB-06071/90890-06605
Attachment:
YB-06112/90890-06614
NOTE:
Check the mounting depth of each oil seal
and press fit.
6-13
3. Install:
Ball bearing
Driver rod:
YB-06071/90890-06605
Attachment:
YB-06167/90890-06634
NOTE:
Install the ball bearing with its
manufacturer’s mark facing towards the
reverse gear.
6-14
DRIVE SHAFT AND FORWARD GEAR
REMOVING/INSTALLING THE DRIVE SHAFT AND FORWARD GEAR

1 Circlip 1
2 Pinion 1
3 Pinion adjusting shim *
4 Drive shaft 1
5 Forward gear 1
6 Ball bearing 1
7 Gear adjusting shim *

procedure.
*: as required
6-15
A REMOVING THE BALL BEARING
Remove:
Ball bearing
Adjusting shim(s)
Slide hammer handle 1:

YB-06096
Bearing puller 2:
90890-06535
90890-06501
B
CHECKING THE PINION

Check:
Teeth
CHECKING THE DRIVE SHAFT

Check:
Drive shaft
CHECKING THE FORWARD GEAR

Check:
Teeth
CHECKING THE BALL BEARING

Check:
Ball bearing
Pitting/rumbling Replace.
NOTE:
smoothly.
6-16
INSTALLING THE BALL BEARING
Install:
Gear adjusting shim(s)
Ball bearing
Driver rod:
YB-06071/90890-06604
Attachment:
YB-06167/90890-06634
NOTE:
Install the ball bearing with its
manufacturer’s mark facing towards the
forward gear.
6-17
BEARING HOUSING, SHIFT CAM AND LOWER CASE
REMOVING/INSTALLING THE BEARING HOUSING, SHIFT CAM AND LOWER CASE

1 Bearing housing assembly 1
3 Coller 1
4 Shift cam 1
5 Solid bushing 1
6 Lower case 1
9 Solid bushing 1
10 Bearing housing 1
11 Dowel pin
For installation, reverse the removal procedure.
6-18
REMOVING THE SOLID BUSHING
Remove:
Solid bushing
Driver rod:
YB-06229/90890-06652
Attachment:
YB-06028/90890-06650
DISASSEMBLING THE BEARING

HOUSING
Remove:
Solid bushing
Driver rod:
YB-06229/90890-06652
Bushing attachment:
YB-06028/90890-06650
CHECKING THE COLLER

Check:
Collar
CHECKING THE SHIFT CAM

Check:
Shift cam
CHECKING THE LOWER CASE

1. Clean:
Lower case (with a soft grush and
solvent).
6-19
2. Check:
Water passage
Mineral deposits/corrosion Clean.
3. Check:
Lower case
ASSEMBLING THE BEARING HOUSING

1. Install:
Solid bushing
Driver rod:
YB-06229/90890-06652
Attachment:
YB-06028/90890-06650
2. Install:
Oil seal
Oil seal mounting depth a:

6.0 - 6.5 mm (0.236 - 0.256 in)
Driver rod:
YB-06071/90890-06652
Attachment :
YB-06611/90890-06614
NOTE:
Press fit both oil seals at the same time to
the mounting depth.
6-20
INSTALLING THE SOLID BUSHING
Install:
Solid bushing
Bushing installer center bolt 1:

YB-06029/90890-06601
Attachment 2:
YB-37350/90890-06616
NOTE:
Pull up the solid bushing until the flange is
in tight contact with the lower case.
6-21
BACKLASH
BACKLASH
NOTE:
Both forward gear backlash and reverse
gear backlash be measured.
If both forward gear backlash and reverse
gear backlash are smaller than specified,
the pinion may be too low.
If either of these conditions exist, then
check the pinion shim selection.
MEASURING THE FORWARD GEAR

BACKLASH
Measure:
Forward gear backlash
Out of specification Adjust
Forward gear backlash:
0.88 - 1.26 mm (0.0346 - 0.0496 in)
Measuring steps:
(1)Place the shift cam in neutral.
(2)Load the forward gear with the bearing
housing puller on the propeller shaft.
Bearing housing puller:
YB-06234/NA
Universal puller:
YB-06117/NA
Center bolt:
(3)Set the lower unit upside down.

(4)Attach the dial gauge on the lower
case, and make the dial gauge stem
contact the mark on the backlash
indicator.
Backlash indicator:
YB-06265/90890-06706
Magnet base:
YU-34481/90890-06705
Magnet base attaching plate:
YB-07003/90890-07003
Dial gauge stand:
YU-03097/90890-01252
(5)While pulling the drive shaft

downward, slowly turn the drive shaft
clockwise and counterclockwise then
measure the backlash when the drive
shaft stops at each direction.
6-22
BACKLASH
(6)Determine the shims to be added or
removed according to the specified.
Forward gear
Shim thickness
backlash
Less than To be decreased by
0.88 mm (0.0346 in)
(1.07 - Measurement)
2.52
More than To be decreased by
1.26 mm (0.0496 in)
(Measurement - 1.07)
2.52
Available shim thickness: 0.10, 0.12, 0.15, 0.18,
0.30 mm
NOTE:
Since the smallest shim available is
0.10 mm, if the measurement is between
0.88 mm and 1.26 mm, do not change the
shim.
MEASURING THE REVERSE GEAR

BACKLASH
Measure:
Reverse gear backlash
Out of specification Adjust
Reverse gear backlash:
1.01 - 1.38 mm (0.0398 - 0.0543 in)
Measuring steps:
(1)Place the shift cam in neutral.
(2)Load the reverse gear by installing the
propeller without the front side spacer
1, and tighten the nut.
Propeller nut:
(3)Set the lower unit upside down.

(4)Attach the dial gauge on the lower
case, and make the dial gauge stem
contact the mark on the backlash
indicator.
6-23
BACKLASH
Backlash indicator:
YB-06265/90890-06706
Magnet base:
YU-34481/90890-06705
Magnetic base attaching plate:
YB-07003/90890-07003
Dial gauge stand:
YU-03097/90890-01252
(5)While pulling the drive shaft

downward, slowly turn the drive shaft
clockwise and counterclockwise then
measure the backlash when the drive
shaft stops at each direction.
(6)Determine the shims to be added or
removed according to the specified.
Reverse gear
Shim thickness
backlash
1.01 mm (0.0398 in)
(1.2 - Measurement)
2.52
More than To be decreased by
1.38 mm (0.0543 in)
(Measurement - 1.2)
2.52
Available shim thickness: 0.10
NOTE:
Since the smallest shim available is
0.10 mm, if the measurement is between
1.01 mm and 1.38 mm, do not change the
shim.
6-24
CHAPTER 7
BRACKET UNIT
STEERING HANDLE ........................................................................................7-1

REMOVING/INSTALLING THE STEERING HANDLE ..............................7-1
INSTALLING THE STEERING HANDLE ...................................................7-3
ADJUSTING THE THROTTLE CONTROL CABLES .................................7-3
ADJUSTING THE SHIFT CABLE ...............................................................7-3
DISASSEMBLING/ASSEMBLING THE STEERING HANDLE ...................7-4
ASSEMBLING THE STEERING HANDLE .................................................7-6
SHIFT LEVER ....................................................................................................7-7

REMOVING/INSTALLING THE SHIFT LEVER...........................................7-7
BOTTOM COWLING ........................................................................................7-9

REMOVING/INSTALLING THE BOTTOM COWLING ...............................7-9
UPPER CASE ..................................................................................................7-11

REMOVING/INSTALLING THE UPPER CASE ........................................7-11
INSTALLING THE LOWER MOUNT .......................................................7-12
DISASSEMBLING/ASSEMBLING THE UPPER CASE ...........................7-13
INSTALLING THE OIL SEAL ...................................................................7-15
INSTALLING THE MUFFLER ..................................................................7-15
SWIVEL AND STEERING BRACKET .............................................................7-16

REMOVING/INSTALLING THE SWIVEL AND STEERING BRACKET ..7-16
STEERING FRICTION .....................................................................................7-17

DISASSEMBLING/ASSEMBLING THE STEERING FRICTION ..............7-17
ASSEMBLING THE STEERING FRICTION .............................................7-18
CLAMP BRACKET ..........................................................................................7-19

REMOVING/INSTALLING THE CLAMP BRACKET ................................7-19
INSTALLING THE CLAMP BRACKET PLATE .........................................7-21
7
SWIVEL BRACKET .........................................................................................7-22
DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET ..................7-22
STEERING HANDLE
STEERING HANDLE
REMOVING/INSTALLING THE STEERING HANDLE

1 Throttle cable 2
2 Stop switch lead 1
3 Nut 1
4 Shift cable 1
5 Grommet 1
6 Nylone nut 1
7 Nut 1
8 Cover 1
9 Bushing 1
10 Steering handle assembly 1
11 Plate washer 2
12 Plate washer 2
13 Wave washer 1
7-1
STEERING HANDLE

14 Bushing 1
15 Grommet 1
16 Nut 2
17 Bracket 1
18 Stud bolt 2

procedure.
7-2
STEERING HANDLE
INSTALLING THE STEERING HANDLE
Install:
Steering handle
NOTE:
Pass the stop switch lead wire together
with the throttle wire through the
corrugated tube, pass under the throttle
wire, and then insert in the grommet of the
bottom cowling.

CABLES
Adjust:
Throttle cables
Refer to “ADJUSTING THE
THROTTLE CONTROL CABLES” on
page 3-5.
ADJUSTING THE SHIFT CABLE

Adjust:
Shift cable
Refer to “ADJUSTING THE SHIFT
CONTROL CABLE” on page 3-4.
7-3
STEERING HANDLE
DISASSEMBLING/ASSEMBLING THE STEERING HANDLE

1 Rubber bushing 1
3 Shift handle 1
5 Shift lever 1
6 Bushing 2
7 Wave washer 1
8 Plate washer 1
9 Cable clamp 1
10 Circlip 1
11 Handle cam plate 1
12 Shift cable 1
13 Bolt 1
7-4
STEERING HANDLE

14 Spring 1
15 Bracket 1
16 Bolt 1
17 Cable clamp 1
18 Steering handle 1

procedure.
7-5
STEERING HANDLE
ASSEMBLING THE STEERING HANDLE
1. Install:
Stop switch 1
NOTE:
Install stop switch 1, then pull switch
lead 2 out from the hole in steering
handle 3.
Fit switch lead 2 between steering
handle 3 and stop switch 1 so that there
is no interference with the throttle shaft.
2. Install:
Throttle cables 4
Throttle shaft 5
NOTE:
Pass throttle cable 4 through the hole in
steering handle 3, then connect to
throttle shaft 5.
Install throttle shaft 5 to steering handle
3.
7-6
SHIFT LEVER
SHIFT LEVER
REMOVING/INSTALLING THE SHIFT LEVER

1 Bolt 1
2 Manual starter cable bracket 1
3 Nut 1
4 Clip 1
5 Shift rod 1
6 Grommet 1
7 Grommet 1
8 Bolt 1
9 Stopper 1
10 Spring 1
11 Split pin 1
12 Cable end 1
13 Plate washer 2
7-7
SHIFT LEVER

14 Bolt 2
15 Shift rod lever 1
16 Pin 1
17 Clamp 1
18 Bracket 2

procedure.
7-8
BOTTOM COWLING
BOTTOM COWLING
REMOVING/INSTALLING THE BOTTOM COWLING

1 Bolt 2
2 Fitting plate 1
3 Grommet 1
4 Grommet 1
5 Hose joint 1
6 Hose joint 1
8 Pipe 1
9 Screw 2
10 Adapter 1
12 Plate 1
13 Grommet 1
7-9
BOTTOM COWLING

14 Emergency signal light 1
16 Cowling clamp 1
18 Bottom cowling 1
19 Rubber seal 1
20 Coller 4
21 Grommet 4
22 Hose nipple 1
23 Rubber seal 2
24 Grommet 1

procedure.
7-10
UPPER CASE
UPPER CASE
REMOVING/INSTALLING THE UPPER CASE

1 Water tube 1
2 Water seal rubber 1
5 Nut 4
6 Lower mount rubber housing 2
7 Lower front mount rubber 1
8 Lower side mount rubber 2
9 Screw 1
10 Nut 2
11 Plate 1
12 Upper case 1
procedure.
7-11
UPPER CASE
INSTALLING THE LOWER MOUNT
1. Install:
Lower front mount rubber
NOTE:
Set the “UP” mark upward.
2. Install:
Lower mount rubber housing
NOTE:
Install the mounting bolt while
confirming the identifying “V” mark on
its head.
Pass the stop switch lead wire together
with the throttle wire through the
corrugated tube, pass under the throttle
wire, and then insert in the grommet of
the bottom cowling.
Tighten 2 front bolts 1 to the specified
torque, then tighten 2 rear bolts 2 to the
specified torque.
Finally, check that all 4 bolts are tightened
to the specified torque.
7-12
UPPER CASE
DISASSEMBLING/ASSEMBLING THE UPPER CASE

2 Upper side mount rubber 1
4 Exhaust guide 1
5 Clip 1
6 Oil strainer 1
9 Pin 2
10 Hose 1
11 Screw 1
12 Plate 1
13 Damper 1
7-13
UPPER CASE

14 Oil drain plug 1
15 Gasket 1
17 Oil pan 4
18 Pin 1
20 Muffler 2
22 Plate 1
23 Grommet 1
24 Upper case 1
1
procedure.
7-14
UPPER CASE
Install:
Oil seal
Driver rod:
YB-06071/90890-06604
Attachment:
YB-06112/90890-06614
INSTALLING THE MUFFLER

Install:
Muffler
NOTE:
Apply Three Bond®1207B to o marked
portion of muffler installation and check
that there is no clearance after the muffler
is installed.
Control the applied amount so that Three
Bond® 1207B does not stick to the water
passage.
Do not start the engine until 6 hours
elapse after application.
7-15
SWIVEL AND STEERING BRACKET
SWIVEL AND STEERING BRACKET
REMOVING/INSTALLING THE SWIVEL AND STEERING BRACKET

1 Bolt 2
3 Steering friction 1
4 Bolt 1
5 Seal rubber 1
6 Steering bracket 1
7 Pivot shaft bushing 1
8 Friction piece 1
9 Bushing 1
10 O-ring 1 30 x 3.8 mm Not reusable
11 Bushing 1
12 Clamp bracket 1
procedure.
7-16
STEERING FRICTION
STEERING FRICTION
DISASSEMBLING/ASSEMBLING THE STEERING FRICTION

1 Lock nut 1
2 Plate washer 1
4 Friction piece 2
5 Collar 1
6 Friction plate 1
7 Coller 1
8 Plate washer 2
9 Lock nob 1
10 Lock shaft 1
11 Friction plate 1

procedure.
7-17
STEERING FRICTION
ASSEMBLING THE STEERING
FRICTION
Install:
Lock nob
NOTE:
Set the “TOP” mark upward.
7-18
CLAMP BRACKET
CLAMP BRACKET
REMOVING/INSTALLING THE CLAMP BRACKET

1 Tilt rod 1
2 Nut 1
3 Plain washer 1
4 Bolt 1
5 Bolt 2
6 Clamp bracket cap 2
7 Clamp bracket plate 1
8 Through tube 1
9 Coller 1
10 Swivel bracket 1
11 Bushing 2
12 Clamp bracket 1
13 Clamp bracket 1
7-19
CLAMP BRACKET

14 Bolt 2
15 Stopper 2
16 Wave washer 2

procedure.
7-20
CLAMP BRACKET
INSTALLING THE CLAMP BRACKET
PLATE
Install:
Clamp bracket plate 1
NOTE:
Turn clamp bracket plate 1 down until it
contacts stopper boss 2 of the clamp
bracket.
7-21
SWIVEL BRACKET
SWIVEL BRACKET
DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET

1 Tension spring 1
2 Circlip 1
3 Tilt lock shaft 1
4 Tilt lock rod 1
5 Tilt lock plate 1
6 Tension spring 2
7 Circlip 1
8 Reverse lock shaft 1
9 Tilt lock plate 1
10 Tilt lever 1
11 Tilt lock rod 1
12 Circlip 1
13 Stopper shaft 1
7-22
SWIVEL BRACKET

14 Circlip 1
15 Tilt lever 1
16 Circlip 1
17 Tilt lever shaft 1
18 Receiver 1
19 Grease nipple 1
20 Wire lead 1
21 Swivel bracket 1

procedure.
7-23
CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS ..........................................................................8-1

(ONE LIGHTING COIL MODEL) ................................................................8-1
Top view and left side view .....................................................................8-1
Details of the wiring harness connection ...............................................8-2
(TWO LIGHTING COILS MODEL) .............................................................8-3
Top view, front view and left side view ..................................................8-3
Details of the wiring harness connection ...............................................8-4
ELECTRICAL COMPONENTS ANALYSIS .......................................................8-5

DIGITAL CIRCUIT TESTER ........................................................................8-5
MEASURING THE PEAK VOLTAGE .........................................................8-5
PEAK VOLTAGE ADAPTOR ......................................................................8-5
MEASURING A LOW RESISTANCE .........................................................8-6
IGNITION SYSTEM ..........................................................................................8-7

CHECKING THE SPARK PLUGS ...............................................................8-8
CHECKING THE IGNITION SPARK GAP ..................................................8-8
CHECKING THE SPARK PLUG CAPS AND IGNITION COIL ...................8-8
CHECKING THE CHARGE COIL ..............................................................8-10
CHECKING THE PULSER COIL ...............................................................8-10
CHECKING THE CDI UNIT ......................................................................8-11
IGNITION CONTROL SYSTEM .....................................................................8-12

CHECKING THE ENGINE STOP SWITCH ..............................................8-13
CHECKING THE PULSER COIL ...............................................................8-13
CHECKING THE OIL PRESSURE SWITCH .............................................8-14
CHECKING EMERGENCY SIGNAL LIGHT .............................................8-14
CHARGING SYSTEM .....................................................................................8-15

(ONE LIGHTING COIL MODEL) ..............................................................8-15
(TWO LIGHTING COILS MODEL) ...........................................................8-16
CHECKING THE BATTERY ......................................................................8-17
CHECKING THE LIGHTING COIL ............................................................8-17
CHECKING THE RECTIFIER AND RECTIFIER/REGULATOR .................8-18
8
ELECTRICAL COMPONENTS
Top view and left side view
1 Pulser coil A Short handle model

2 Emergency signal light B Long handle model
3 Lighting coil
4 Oil pressure switch
5 Spark plug
6 Charge coil
7 CDI unit
8 Rectifier
9 Ignition coil
8-1
Details of the wiring harness connection
A To lighting coil G : Green W : White

B To charge coil R : Red Y : Yellow
C To pulser coil L : Blue
D To emergency signal light Br : Brown
E To stop switch W/R : White/Red
F To oil pressure switch B : Black
O : Orange
P : Pink
Y/R : Yellow/Red
8-2
Top view, front view and left side view
B A
1 Pulser coil A Short handle model

2 Emergency signal light B Long handle model
3 Lighting coil
4 Oil pressure switch
5 Spark plug
6 Charge coil
7 CDI unit
8 Rectifier/regulator
9 Ignition coil
8-3
Details of the wiring harness connection
A To lighting coil R : Red W : White

B To charge coil G : Green Y : Yellow
C To pulser coil G/W : Green/White O : Orange
D To emergency signal light L : Blue
E To stop switch Br : Brown
F To oil pressure switch W/R : White/Red
B : Black
P : Pink
Y/R :Yellow/Red
8-4
ELECTRICAL COMPONENTS ANALYSIS
ANALYSIS
DIGITAL CIRCUIT TESTER
Digital circuit tester:

YU-34899-A/90890-06752
NOTE:
“ ” indicates a continuity of
electricity which means a closed circuit at
the respective switch position.
MEASURING THE PEAK VOLTAGE
WARNING
When checking the peak voltage do not
touch any of the connections of the digital
tester lead wires.
NOTE:
When checking the condition of the
ignition system it is useful to know the
peak voltage.
Cranking speed is dependant on many
factors (e.g., fouled or weak spark plugs,
a weak battery). If one of three is
defective, the peak voltage will be lower
than specification.
If the peak voltage measurement is not
within specification the engine will not
operate properly.
PEAK VOLTAGE ADAPTOR

NOTE:
The peak voltage adaptor should be with
the digital circuit tester.
Peak voltage adaptor:

YU-39991/90890-03172
8-5
ELECTRICAL COMPONENTS ANALYSIS
NOTE:
When measuring the peak voltage, set
the selector to the DC voltage mode.
Make sure the peak voltage adapter lead
are properly installed in the digital tester.
Make sure the positive pin (the “+” mark
facing up as shown) on the peak voltage
adapter is installed into the positive
terminal of the digital tester.
The test harness is needed for the
following tests.
Measuring steps:
(1)Connect the peak voltage adapter
probes to the connectors.
(2)Start or crank the engine and observe
the measurement.
MEASURING A LOW RESISTANCE

When measuring a resistance of 10 Ω or
less with the digital tester, the correct
measurement cannot be obtained because
of the tester’s internal resistance.
To obtain the correct value, subtract the
internal resistance from the displayed
measurement.
Correct value:
Displayed measurement - internal
resistance
NOTE:
The internal resistance of the digital tester
can be obtained by connecting both of its
probes.
8-6
IGNITION SYSTEM
IGNITION SYSTEM
1 CDI unit B : Black

2 Pulser coil W/R : White/Red
3 Charge coil Br : Brown
4 Ignition coil L : Blue
5 Spark plug O : Orange
8-7
IGNITION SYSTEM
CHECKING THE SPARK PLUGS
Check:
Spark plugs
Refer to “CHECKING THE SPARK
PLUGS” on page 3-18.
CHECKING THE IGNITION SPARK GAP
WARNING
Do not touch any of the connections of
the spark gap tester lead wire.
Do not let sparks leak out of the removed
spark plug cap.
Keep flammable gas or liquids away,
since this test can produce spark.
Check:
Ignition spark gap
Above specification Replace the
spark plug.
Ignition spark gap:

0.9 mm (0.04 in)
Checking steps:
(1)Remove the spark plugs from the
engine.
(2)Connect a spark plug cap to the spark
gap tester.
(3)Set the spark gap length on the
adjusting knob.
Spark gap tester:

YM-34487/90890-06754
(4)Crank the engine and observe the
spark through the discharge window of
the spark gap tester.
CHECKING THE SPARK PLUG CAPS

AND IGNITION COIL
1. Check:
Spark plug cap 1
High tension code 2
Ignition coil 3
Loosen connection Tighten.
Replacing steps:
(1)To remove the spark plug cap or high
tension code, turn it counterclockwise.
8-8
IGNITION SYSTEM
(2)To install the spark plug cap or high
tension code, turn it clockwise until it
is tightened.
2. Measure:
Spark plug cap resistance
Spark plug cap resistance:

4.3 kΩ *
*: Measured value.
A 3. Measure:
Primary A
Secondary B

Primary A Secondary B
Orange (O) - Output port -
Black (B) Output port
B 0.6 Ω * 8.75 kΩ *
*: Measured value.
8-9
IGNITION SYSTEM
CHECKING THE CHARGE COIL
Measure:
Below specification Replace the
charge coil.

Brown (Br) - Blue (L)
Cranking
r/min. 1,500 3,500
Opened Closed
D.C.V 112 154 185 185

YU-39991/90890-03172
Charge coil resistance

Brown (Br) - Blue (L)
Reference value 232 - 348 Ω
CHECKING THE PULSER COIL

Measure:
pulser coil.

White/Red (W/R) - Black (B)
Cranking
r/min. 1,500 3,500
Opened Closed
D.C.V 7.0 3.5 7.0 10.5

YU-39991/90890-03172
Pulser coil resistance

White/Red (W/R) - Black (B)
Reference value 240 - 360 Ω
8-10
IGNITION SYSTEM
CHECKING THE CDI UNIT
Measure:
CDI unit.

Orange (O) - Black (B)
Cranking
r/min. 1,500 3,500
Opened Closed
D.C.V 53.2 140 168 168

YU-39991/90890-03172
NOTE:
Before measuring CDI unit output peak
voltage, make sure that no abnormality is
observed on the charge coil and the pulser
coil.
8-11
1 Emergency signal light Y/R : Yellow/Red

2 CDI unit P : Pink
3 Pulser coil B : Black
4 Charge coil W/R : White/Red
5 Oil pressure switch Br : Brown
L : Blue
8-12
A CHECKING THE ENGINE STOP SWITCH
Check:
Engine stop switch continuity
Leads color
White (W) Black (B)
B Remove the
Lock plate A
Install the
Lock plate B
Push the
button C
CHECKING THE PULSER COIL

Check:
Refer to “CHECKING THE PULSER
COIL” on page 8-10.
8-13
CHECKING THE OIL PRESSURE
SWITCH
Check:
Oil pressure switch continuity
Oil pressure switch continuity

pressure:
14.7 kPa (0.15 kgf/cm2 ,
No continuity
2.13 psi) and above
14.7 kPa (0.15 kgf/cm2 ,
Continuity
2.13 psi) and below
Measuring steps:
(1)Remove the silensor assembly and
carburetor.
Refer to “REMOVING/INSTALLING THE
INTAKE SYSTEM” on page 4-5
(2)Remove the oil pressure switch.
(3)Connect the mity vac as shown.
Mity vac:
YB-35956-A/90890-06756
(4)Slowly operate the mity vac.
(5)Measure the continuity when the
specified pressure is reached.
CHECKING EMERGENCY SIGNAL

LIGHT
Check:
Emergency signal light lighting
No lighting Replace.
Battery voltage:
12 V
Yellow/Red (Y/R) lead Positive

terminal.
Pink (P) lead Negative terminal.
NOTE:
LED has an direction for electrical current.
Therefore try reverse connection if there is
no lighting.
8-14
CHARGING SYSTEM
CHARGING SYSTEM
1 Battery R : Red
2 Fuse (10A) G : Green
3 Rectifier B : Black
4 Lighting coil
8-15
CHARGING SYSTEM
CHARGING SYSTEM
1 Battery R : Red
3 Rectifier/regulator G/W : Green/White
4 Lighting coil B : Black
8-16
CHARGING SYSTEM
CHECKING THE BATTERY
Check:
Battery electrolyte level and specific
gravity
Refer to “CHECKING THE BATTERY”
on page 3-17.
CHECKING THE LIGHTING COIL

Measure:
Lighting coil output peak voltage
lighting coil.

(One lighting coil model):
Green (G) - Green (G)
Cranking 1,500 3,500
r/min
Opened Closed Opened Opened
D.C.V 3.5 3.5 14 33
Lighting coil resistance

(One lighting coil model):
Reference value 0.24 - 0.36 Ω

(Two lighting coils model):
r/min
D.C.V 8.4 8.4 33.6 77.0
Lighting coil resistance

(Two lighting coils model):
Reference value 0.61 - 0.91 Ω

YU-39991/90890-03172
8-17
CHARGING SYSTEM
A CHECKING THE RECTIFIER AND
RECTIFIER/REGULATOR
Measure:
Rectifier output peak voltage
voltage
rectifier or rectifier/regulator.
Rectifier output peak voltage A

Red (R) - Black (B)
r/min
D.C.V 2.8 — 13.3 32.2
NOTE:
When measuring closed (cranking),
1500 r/min, and 3500 r/min, disconnect the
positive (+) terminal of the battery.
B
voltage B
Red (R) - Black (B)
r/min
D.C.V 7.7 — 27 27
NOTE:
When measuring closed (cranking), 1500
r/min, and 3500 r/min, disconnect the
positive (+) terminal of the battery.

YU-39991/90890-03172
NOTE:
Before measuring the rectifier or the
rectifier/regulator peak voltage, make sure
that no abnormality is observed on the
lighting coil.
8-18
CHAPTER 9
TROUBLE ANALYSIS
TROUBLE ANALYSIS ......................................................................................9-1

TROUBLE ANALYSIS CHART ..................................................................9-1
TROUBLE SHOOTING FOR PEAK VOLTAGE ................................................9-3
9
TROUBLE ANALYSIS
TROUBLE ANALYSIS
NOTE:
Following items should be obtained before “trouble analysis”.
1. The battery is charged and its specified gravity is within specification.
2. There is no incorrect wiring connection.
3. Wiring connections are properly secured and are not any rusty.
4. The lanyard is installed onto the engine stop switch.
5. The shift position is in neutral.
6. Fuel is reaching the carburetor.
7. The rigging and engine setting are correct.
8. Engine is free from any “Hull problem”.
TROUBLE ANALYSIS CHART

Trouble mode Check element
IRREGULAR WARNING INDICATION
POOR BATTERY CHARGING
ENGINE WILL NOT START
ENGINE WILL NOT STOP

POOR PERFORMANCE
SHIFTING DIFFICULT
Reference
Relative part
LOOSE STEERING
chapter
ENGINE STALLS
ROUGH IDLING
OVERHEATING
FUEL SYSTEM
Fuel hose 4
Fuel joint 4
Fuel filter 4
Fuel pump 4
Carburetor 4
Throttle stop screw 3
Pilot screw 3
Main jet 4
Pilot jet 4
Choke link 4
Throttle cable 4
POWER UNIT
Spark plugs 3
Compression 5
Timing belt 5
Valve clearance 5
Intake and exhaust valve 5
Intake and exhaust valve seat 5
Cylinder head gasket 5
Piston rings 5
Piston 5
Thermostat 5
Water passage 5
9-1
TROUBLE ANALYSIS
Trouble mode Check element
IRREGULAR WARNING INDICATION

POOR BATTERY CHARGING
ENGINE WILL NOT START
ENGINE WILL NOT STOP

POOR PERFORMANCE
SHIFTING DIFFICULT
Reference
Relative part
LOOSE STEERING
chapter
ENGINE STALLS
ROUGH IDLING
OVERHEATING
LOWER UNIT
Neutral position 6
Clutch 6
Gears 6
Water inlet 6
Water pump 6
Propeller shaft and propeller 6
Shifter/Pin 6
Shift cam 6
Shift rod or Shift cable 6
Lower case 6
Shim adjustment 6
BRACKET UNIT
Bracket 7
Mount rubber 7
Steering friction 7
ELECTRICAL
Ignition system 8
Ignition control system 8
Starting system 8
Charging system 8
9-2
TROUBLE SHOOTING FOR PEAK VOLTAGE
TROUBLE SHOOTING FOR PEAK VOLTAGE
Items Symptoms
1. Poor starting No firing. The starter motor cranks the engine, but no firing takes
place in the cylinder.
Firing takes place in the cylinder, but the engine stops soon.
Start-up time is too long. The engine will not start-up easily.
2. Unstable idling The engine speed is not stable at idle.
speed The engine stalls when the throttle lever is opened.
The engine stalls after it is warmed-up.
3. Unstable engine The engine does not run smoothly.
speed The engine speed drops during acceleration.
Check the ignition system.

1) Check the harness couplers toignition coil, CDI unit, pulser coil, and charge coil.
NG
Contamination, Loose connection Clean
OK Corrosion Correct
2) Check the spark gap.
OK
Above specification Replace the spark plug.
NG
3) Check theplug cap.
NG
Out of specification Replace
OK
4) Check the ignition coils.
NG
Out of specification Replace
OK
5) Check the CDI unit output peak voltage.
OK
Above specification Replace the ignition coil.
NG
6) Check the charge coil output peak voltage.
NG
Below specification Replace the charge coil.
OK
7) Check the pulser coil output peak voltage.
NG
Below specification Replace the pulser coil.
OK
Replace the CDI Unit.
9-3
YAMAHA MOTOR CO., LTD.
Printed in USA
Apr. 2000 - x 1
(F6AMH, F8CMH)
Printed on recycled paper

F6MH, F8MH (FOR ONE LIGHTING COIL MODEL)
WIRING DIAGRAM
6 Lighting coil
5 Pulser coil
B
4 Oil pressure 7 Charge coil
switch W/R
M4
P G G Br L
A Bracket
1 CDI unit G G
9 Ignition coil
P B W/R Br L
O
Y/R P W B O B L Br W/R B P Y Y
R
G G
R B
P B W/R Br L G 8 Rectifier 10 Spark
G O B
plugs
0.5W
2 Emergency Y/R P
AVX1.25B
signal light M6 M6
O B
Y/R
P
B
3 Stop
switch
0.5W
B: Black
Br: Brown
0.5B 0.5B
G: Green
L: Blue
B Optional parts
O: Orange
AVX1.25B AVX1.25B P: Pink
R: Red
W: White
AVX1.25R AVX1.25R
Y: Yellow
W/R: White/red
12 Fuse(10A) Y/R: Yellow/red
M10 M10
C If there is no size specified for the lead wire,

11 Battery the size is AVX0.75f.
WIRING DIAGRAM F6MH, F8MH (FOR TWO LIGHTING COILS MODEL)
6 Lighting coil
5 Pulser coil
B
4 Oil pressure 7 Charge coil
switch W/R
M4
P G G Br L
A Bracket
1 CDI unit G G B Optional parts 9 Ignition coil

P B W/R Br L
O
G/W G
R B
G
P B W/R Br L G 8 Rectifier/
regulator 10 Spark
O B
G/W plugs
R
0.5W
2 Emergency Y/R P
AVX1.25B
signal light M6 M6
O B
Y/R
P
B
3 Stop
switch
0.5W
B: Black
Br: Brown
0.5B 0.5B G: Green
L: Blue
B Optional parts
O: Orange
AVX1.25B AVX1.25B P: Pink
R: Red
W: White
AVX1.25R AVX1.25R
Y: Yellow
G/W: Green/white
12 Fuse(10A) W/R: White/red
Y/R: Yellow/red
M10 M10
C If there is no size specified for the lead wire,

11 Battery the size is AVX0.75f.
T8PH
T8PR
SUPPLEMENTARY
SERVICE MANUAL
LIT-18616-02-31 69G-28197-1A-1X
NOTICE
This Supplementary Service Manual has been prepared to introduce new service and data
for the T8PH, T8PR. For complete service information procedures, it is necessary to use this
Supplementary Service Manual together with the following manual.
F6Z, F8Z SERVICE MANUAL: 68T-28197-ZA-11

LIT-18616-02-19
T8PH, T8PR
SUPPLEMENTARY SERVICE MANUAL
©2000 by Yamaha Motor Corporation, USA
1st Edition, October 2000
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-31
MANUAL FORMAT
All of the procedures in this manual are organised in a sequential, step-by-step format. The
information has been compiled to provide the mechanic with an easy to read, handly
reference that contains comprehensive explanations of all disassembly, repair, assembly, and
inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and
the course of action required will follow the symbol, e.g.,
•Bearings
Pitting/scratches ➔ Replace.
To assist you in finding your way through this manual, the section title and major heading is
given at the top of every page.
MODEL INDICATION
Multiple models are referred to in this manual and their model indications are noted as
follows.
Model name (W/W) FT8DMH FT8DE FT8DEP FT8DEHP
USA and Canada name T8MH T8ER T8PR T8PH
Indication FT8DMH FT8DE FT8DEP FT8DEHP
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the
appropriate section or chapter.
IMPORTANT INFORMATION
In this Service Manual particularly important information is distinguished in the following
ways.
The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
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.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the
outboard motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
1 The main points regarding removing/installing and disassembly/assembly procedure are
shown in the exploded views.
2 The numbers in the exploded views indicate the required sequence of the procedure and
should be observed accordingly.
3 Symbols are used in the exploded views to indicate important aspects of the procedure.
A list of meanings for these symbols is provided on the following page.
4 In addition to tightening torques, the dimensions of the bolts and screws are also
mentioned.
Example:
Bolt and screw size 10 x 25 mm : bolt and screw diameter (D) x length (L)
5 In addition to the exploded views and job instruction charts, this manual provides
individual illustrations when further explanations are required to explain the relevant
procedure.
SYMBOLS
Symbols 1 to 9 are designed as thumb-
1 2 tabs to indicate the content of a chapter.
1 General information
2 Specifications
3 Periodic check and adjustment
3 4 4 Fuel system
5 Power unit
6 Lower unit
5 6 7 Bracket unit
8 Electrical system
9 Trouble analysis
7 8
Symbols : to E indicate specific data.
: Special tool
A Specified liquid
9 B Specified engine speed
C Specified torque
D Specified measurement
E Specified electrical value
0 A B [Resistance (Ω), Voltage (V), Electrical
current (A)]
Symbols F to I in an exploded diagram

C D E indicate the grade of lubricant and the
location of the lubricant point.
F Apply Yamaha 4-stroke motor oil
G Apply water resistant grease
(Yamaha grease A, Yamaha marine
F G H grease)
H Apply Yamaha grease D
I Apply molybdenum disulfide grease
Symbols J to O in an exploded diagram

I J K indicate the grade of the sealing or locking
agent and the location of the application
point.
J Apply Gasket Maker®
L M N K Apply Yamabond #4
(Yamaha bond number 4)
L Apply LOCTITE® No.271 (Red LOCTITE)
M Apply LOCTITE® No.242 (Red LOCTITE)
O N Apply LOCTITE® No.572
O Apply silicon sealant
GENERAL INFORMATION
IDENTIFICATION ................................................................................................. 1
SERIAL NUMBER ......................................................................................... 1
STARTING SERIAL NUMBERS ................................................................... 1
SPECIAL TOOLS ................................................................................................. 2
REMOVAL AND INSTALLATION ................................................................ 2
SPECIFICATIONS
GENERAL SPECIFICATIONS (T8PH/T8MH/FT8DMH) ..................................... 3
GENERAL SPECIFICATIONS (FT8DEP/T8PR, FT8DE/T8ER) ........................... 5
MAINTENANCE SPECIFICATIONS .................................................................... 7
POWER UNIT ................................................................................................ 7
LOWER UNIT .............................................................................................. 10
ELECTRICAL ............................................................................................... 11
OUTBOARD DIMENSIONS (T8PH/T8MH/FT8DMH) ................................ 13
OUTBOARD DIMENSIONS (FT8DEP/T8PR, FT8DE/T8ER) ...................... 15
BRACKET DIMENSION (FT8DMH/T8MH, FT8DE/T8ER) .......................... 17
BRACKET DIMENSION (FT8DEP/T8PR/T8PH) .......................................... 18
TIGHTENING TORQUES .................................................................................. 19
SPECIFIED TORQUES ................................................................................ 19
GENERAL TORQUES ................................................................................. 21
PERIODIC CHECK AND ADJUSTMENT

MAINTENANCE INTERVAL CHART ................................................................ 22
POWER UNIT ..................................................................................................... 23
ADJUSTING THE VALVE CLEARANCE .................................................... 23
POWER TILT SYSTEM....................................................................................... 24
CHECKING THE POWER TILT (PT) FLUID LEVEL .................................... 24
GENERAL .......................................................................................................... 24
CHECKING THE ANODE ............................................................................ 24
LOWER UNIT
LOWER UNIT .................................................................................................... 25
REMOVING/INSTALLING THE LOWER UNIT .......................................... 25
WATER PUMP ................................................................................................... 27
REMOVING/INSTALLING THE WATER PUMP ......................................... 27
CHECKING THE IMPELLER HOUSING ..................................................... 28
CHECKING THE IMPELLER AND IMPELLER HOUSING CUP .................. 28
INSTALLING THE IMPELLER HOUSING CUP .......................................... 28
PROPELLER SHAFT HOUSING AND PROPELLER SHAFT ............................. 29
REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASS’Y
AND PROPELLER SHAFT ASS’Y ............................................................... 29
REMOVING THE PROPELLER SHAFT HOUSING ASS’Y ......................... 30
PROPELLER SHAFT ASS’Y .............................................................................. 31
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASS'Y ........ 31
CHECKING THE DOG CLUTCH ................................................................. 32
CHECKING THE PROPELLER SHAFT ........................................................ 32
PROPELLER SHAFT HOUSING ASS’Y ............................................................ 33
HOUSING ASS'Y ........................................................................................ 33
DISASSEMBLING THE PROPELLER SHAFT HOUSING ASS'Y .............. 34
CHECKING THE GEARS ............................................................................. 34
CHECKING THE BEARING ......................................................................... 35
CHECKING THE PROPELLER SHAFT HOUSING ...................................... 35
ASSEMBLING PROPELLER SHAFT HOUSING ASS'Y ............................ 35
DRIVE SHAFT, FORWARD GEAR, SHIFT ROD AND OIL SEAL HOUSING ... 37
REMOVING/INSTALLING THE DRIVE SHAFT,
FORWARD GEAR AND SHAFT ROD ......................................................... 37
REMOVING THE PINION AND FORWARD GEAR .................................... 39
DISASSEMBLING THE OIL SEAL HOUSING ASS'Y ................................ 39
INSTALLING THE SLEEVE ......................................................................... 39
DISASSEMBLING THE LOWER CASE ...................................................... 40
CHECKING THE PINION AND FORWARD GEAR ..................................... 41
CHECKING THE DRIVE SHAFT .................................................................. 41
CHECKING THE SHIFT CAM ..................................................................... 41
CHECKING THE BEARING ......................................................................... 41
CHECKING THE SLEEVE ............................................................................ 41
CHECKING THE LOWER CASE ................................................................. 41
ASSEMBLING THE LOWER CASE ............................................................ 41
ASSEMBLING THE OIL SEAL HOUSING ASS'Y ...................................... 42
ASSEMBLING THE FORWARD GEAR ...................................................... 42
SHIMMING (FOR USA AND CANADA) ........................................................... 43
SELECTING THE PINION SHIMS .............................................................. 43
SHIMMING (EXCEPT FOR USA AND CANADA) ............................................ 44
SELECTING THE PINION SHIMS .............................................................. 44
SELECTING THE FORWARD GEAR SHIMS ............................................. 45
SELECTING THE REVERSE GEAR SHIMS ................................................ 46
BACKLASH MEASUREMENT .......................................................................... 47
MEASURING THE FORWARD GEAR BACKLASH ................................... 47
MEASURING THE REVERSE GEAR BACKLASH ...................................... 48
BRACKET UNIT
UPPER CASE ..................................................................................................... 50
DISASSEMBLING/ASSEMBLING THE UPPER CASE .............................. 50
STEERING FRICTION ........................................................................................ 52
DISASSEMBLING/ASSEMBLING THE STEERING FRICTION ................. 52
POWER TILT (PT) UNIT .................................................................................... 53
DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 1 ............... 53
INSTALLING THE RELIEF VALVE .............................................................. 55
DISASSEMBLING/ASSEMBLING THE PT MOTOR .................................. 56
REMOVING THE ARMATURE ................................................................... 57
CHECKING THE PT MOTOR ...................................................................... 57
CHECKING THE PT MOTOR ASSEMBLY ................................................. 59
INSTALLING THE OIL SEAL ...................................................................... 59
DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 2 ............... 60
DISASSEMBLING/ASSEMBLING THE POWER TILT (PT) CYLINDER .... 62
DISASSEMBLING THE POWER TILT (PT) CYLINDER ............................. 64
ASSEMBLING THE POWER TILT (PT) CYLINDER ................................... 65
REMOVING/INSTALLING THE POWER TILT (PT) UNIT .......................... 69
ELECTRICAL SYSTEM
STARTER MOTOR ............................................................................................ 71
DISASSEMBLING/ASSEMBLING THE STARTER MOTOR ...................... 71
REMOVING THE PINION ........................................................................... 73
CHECKING THE PINION ............................................................................ 73
CHECKING THE ARMATURE .................................................................... 73
CHECKING THE BRUSH HOLDER ............................................................. 74
POWER TILT (PT) SYSTEM .............................................................................. 75
POWER TILT (PT) SYSTEM (T8PR/FT8DEP) ............................................. 75
POWER TILT (PT) SYSTEM (T8PH) ........................................................... 76
CHECKING THE PT SWITCH ..................................................................... 77
CHECKING THE PT RELAY ........................................................................ 77
IDENTIFICATION
IDENTIFICATION
SERIAL NUMBER
The outboard motor’s serial number is
stamped on a label which is attached to the
port clamp bracket.
NOTE:
As an antitheft measure, a special label on
which the outboard motor’s serial number
is stamped is bonded to the port clamp
bracket. The label is specially treated so
that peeling it off causes cracks across the
serial number.
1 Model name
2 Approval model code
3 Transom height
4 Serial number
STARTING SERIAL NUMBERS

The starting serial number blocks are as
follows:
Model name Applicable Starting

World USA/ model serial
wide Canada code number
L: 350101-
FT8DMH T8MH 69G
X: 650101-
L: 400101-
FT8DE T8ER 69G
X: 700101-
L: 500101-
FT8DEP T8PR 69G
X: 750101-
L: 550101-
FT8DEHP T8PH 69G
X: 850101-
1
SPECIAL TOOLS
SPECIAL TOOLS
Using the correct special tools
recommended by Yamaha, will aid the
work and enable accurate assembly and
tune-up.
Improvising and using improper tools can
damage the equipment.
NOTE:
O For U.S.A. and Canada, use part numbers
that start with “J-”, “YB-” “YM-”, “YU-”
or “YW-”.
O For other countries, use part numbers
that start with “90890-”.
1 REMOVAL AND INSTALLATION

1 Power tilt wrench:
P/N. YB-06560
90890-06560
2 Needle bearing:
2a b P/N. YB-06112, YB-06196 .............. a
90890-06614........................... b
3 Driver rod L3:

P/N. YB-06071 ................................ a
3a b 90890-06652........................... b
4 Drive shaft holder:

P/N. YB-06565
90890-06565
4 5 5 Pinion nut holder:
P/N. YB-06078
2
GENERAL SPECIFICATIONS (T8PH/T8MH/
FT8DMH)
GENERAL SPECIFICATIONS (T8PH/T8MH/FT8DMH)
Model
Item Unit
T8PH T8MH FT8DMH
DIMENSION
Overall length mm (in) 1,038 (40.9) 1,038 (40.9)
Overall width mm (in) 371 (14.6) 371 (14.6) 358 (14.1)
Overall height
(L) mm (in) 1,187 (46.7) 1,187 (46.7)
(X) mm (in) 1,255 (49.4) — 1,255 (49.4)
Boat transom height
(L) mm (in) 508 (20.0) 508 (20.0)
(X) mm (in) 635 (25.0) — 635 (25.0)
WEIGHT
(L) kg (lb) 52.0 (114.6) 44.0 (97.0)
(X) kg (lb) 53.0 (116.8) — 45.0 (99.2)
PERFORMANCE
Maximum output (ISO) kW (hp)@r/min 5.9 (8.0)@5,500
Full throttle operating range r/min 5,000 – 6,000
Maximum fuel consumption L (US gal/h, 3.3 (0.87, 0.73)
Imp gal/h)
@6,000 r/min
POWER UNIT
Total displacement 3
cm (cu. in) 197 (11.8)
Compression pressure kPa (kgf/cm2,psi) 950 (9.5, 135.1)
Starting system Electric starter Manual
Alternator type One-lighting coil / Two-lighting coils
Alternator output V–A 12 – 6
Spark plug BR6HS-10
Ignition timing Degree (BTDC) 5 – 30
3
GENERAL SPECIFICATIONS (T8PH/T8MH/
FT8DMH)
Model
Item Unit
T8PH T8MH FT8DMH
FUEL AND OIL
Fuel rating PON (*1) 86
Engine oil type RON (*2) 91
SAE 10W-30, 10W-40
Imp oz)
Imp oz)
BRACKET
Tilt angle Degrees 78 78
Shallow water drive angle Degrees — 24, 37
Steering angle (right + left) Degrees 40 + 40 45 + 45
DRIVE UNIT
Gear ratio (gear/pinioin) 2.92 (38/13)
Gear type Spairal bevel gear
Propeller ID mark R
ELECTRICAL
Cold cranking performance A 145 – 380
(*1) PON : Pump Octane Number

(*2) RON : Research Octane Number
4
GENERAL SPECIFICATIONS (FT8DEP/T8PR,
FT8DE/T8ER)
GENERAL SPECIFICATIONS (FT8DEP/T8PR, FT8DE/T8ER)
Model
Item World wide Unit FT8DEP FT8DE
USA, Canada T8PR T8ER
DIMENSION
Overall length mm (in) 552 (21.7)
Overall height
(L) mm (in) 1,187 (46.7)
(X) mm (in) 1,255 (49.4)
Boat transom height
(L) mm (in) 508 (20.0)
(X) mm (in) 635 (25.0)
WEIGHT
(L) kg (lb) 49.0 (108.0) 44.0 (97.0)
(X) kg (lb) 50.0 (110.0) 45.0 (99.2)
PERFORMANCE
Maximum output (ISO) kW (hp)@r/min 5.9 (8.0)@5,500
Full throttle operating range r/min 5,000 – 6,000
Maximum fuel consumption L (US gal/h, 3.3 (0.87, 0.73)
Imp gal/h)
@6,000 r/min
POWER UNIT
Total displacement cm3 (cu. in) 197 (11.8)
Compression pressure kPa (kgf/cm2,psi) 950 (9.5, 135.1)
Control system Remote control
Starting system Electric starter
Alternator type One-lighting coil / Two-lighting coils
Alternator output V–A 12 – 6
Spark plug BR6HS-10
Ignition timing Degree (BTDC) 5 – 30
5
GENERAL SPECIFICATIONS (FT8DEP/T8PR,
FT8DE/T8ER)
Model
Item World wide Unit FT8DEP FT8DE
FUEL AND OIL
Fuel rating PON (*1) 86
Engine oil type RON (*2) 91
SAE 10W-30, 10W-40
lmp oz)
Imp oz)
BRACKET
Tilt angle Degree 78 78
Shallow water drive angle Degree - 24, 37
Steering angle (right + left) Degree 40 + 40 45 + 45
DRIVE UNIT
Gear type Spairal bevel gear
Propeller ID mark R
ELECTRICAL

6
POWER UNIT
Model
Item World wide Unit FT8DMH FT8DE FT8DEP -
USA, Canada T8MH T8ER T8PR T8PH
CYLINDER HEAD
Warpage mm (in) 0.1 (0.004)
limit
CYLINDER BODY
Bore (D1, D2) mm (in) 56.000 - 56.015 (2.2047 - 2.2053)
Taper limit mm (in) 0.08 (0.0031)
Out-of-round limit mm (in) 0.05 (0.0020)
ROCKER ARM
Rocker arminside mm (in) 13.000 - 13.018 (0.5118 - 0.5125)
diameter a
ROCKER ARM SHAFT

Rocker shaft mm (in) 12.941 - 12.951 (0.5095 - 0.5099)
outside
diameter b
CAMSHAFT
Intake (A) mm (in) 23.45 - 23.55 (0.9232 - 0.9271)
Intake (B) mm (in) 19.95 - 20.05 (0.7854 - 0.7893)
Exhaust (A) mm (in) 23.45 - 23.55 (0.9232 - 0.9271)
Exhaust (B) mm (in) 19.95 - 20.05 (0.7854 - 0.7893)
Cylinder head mm (in) 17.975 - 17.991 (0.7077 - 0.7083)
Journal diameter
Oil pump housing journal mm (in) 15.975 - 15.991 (0.6289 - 0.6296)
diameter
Camshaft round limit mm (in) 0.03 (0.0012)
VALVE
Valve clearance IN mm (in) 0.15 - 0.20 (0.006 - 0.008)
EX mm (in) 0.20 - 0.25 (0.008 - 0.010)
Valve dimensions
Head dimension “A” IN mm (in) 23.9 - 24.1 (0.94 - 0.95)

EX mm (in) 21.9 - 22.1 (0.86 - 0.87)
7
Model
Face width “B” IN mm (in) 1.84 - 2.26 (0.072 - 0.089)
EX mm (in) 1.84 - 2.26 (0.072 - 0.089)
Seat width”C” IN mm (in) 0.6 - 0.8 (0.023 - 0.031)
EX mm (in) 0.6 - 0.8 (0.023 - 0.031)
Mergin thickness “D” IN mm (in) 0.7 (0.027)
EX mm (in) 1.0 (0.039)
Stem diameter IN mm (in) 5.475 - 5.490 (0.2156 - 0.2161)
EX mm (in) 5.460 - 5.475 (0.2150 - 0.2156)
Valve guide inside diameter IN mm (in) 5.500 - 5.512 (0.2165 - 0.2170)
EX mm (in) 5.500 - 5.512 (0.2165 - 0.2170)
Stem-to-guide clearance IN mm (in) 0.010 - 0.037 (0.0004 - 0.0015)
EX mm (in) 0.025 - 0.052 (0.0010 - 0.0020)
Stem runout limit IN mm (in) 0.03 (0.0012)
EX mm (in) 0.03 (0.0012)
VALVE SPRING
limit
Tilt limit mm (in) 1.0 (0.04)
PISTON
Piston-to-cylinder clearance mm (in) 0.035 - 0.065 (0.0014 - 0.0026)
Piston diameter mm (in) 55.950 - 55.965 (2.2028 - 2.2033)
(D)
Measuring mm (in) 1.5 (0.06)
point (H)
Pin boss inside diameter mm (in) 14.004 - 14.015 (0.5513 - 0.5518)
Oversize piston diameter
1st mm (in) 56.200 - 56.215 (2.2126 - 2.2132)
2nd mm (in) 56.450 - 56.465 (2.2224 - 2.2230)
PISTON PIN
Outside mm (in) 13.996 - 14.000 (0.5510 - 0.5512)
Diameter (D)
PISTON RING
Top ring mm (in)
Side clearance mm (in) 0.04 - 0.08 (0.0016 - 0.0031)
8
Model
2nd ring
Side clearance mm (in) 0.03 - 0.07 (0.012 - 0.0028)
Oil ring
CONNECTING ROD
Small end inside diameter mm (in) 14.015 - 14.029 (0.5518 - 0.5523)
Big end inside diameter mm (in) 27.030 - 27.042 (1.0642 - 1.0646)
Big end oil clearance mm (in) 0.030 - 0.042 (0.0012 - 0.0017)
Big end-to-crank pin side mm (in) 0.05 - 0.22 (0.002 - 0.009)
clearance
CRANKSHAFT
Crankcase journal diameter mm (in) 29.997 - 30.009 (1.1810 - 1.1815)
Crank pin journal diameter mm (in) 26.997 - 27.009 (1.0629 - 1.0633)
Runout limit mm (in) 0.03 (0.0012)
CRANKCASE
Crankshaft journal inside mm (in) 33.016 - 33.040 (1.3000 -1.3008)
diameter
Crankshaft journal oil clearance mm (in) 0.011 - 0.039 (0.0004 - 0.0015)
(bearing installed)
Bearing mark color mm (in)
A:Blue 33.032 - 33.040 (1.3005 - 1.3008)
B:Black 33.024 - 33.032 (1.30016 - 1.3005)
C:Brown 33.016 - 33.024 (1.2998 - 1.30016)
THERMOSTAT
Full-close temperature °C (°F) 60 (140)
Valve opening temperature °C (°F) 58 - 62 (136.4 - 143.6)
Full-open temperature °C (°F) 70 (158)
Valve lift mm (in) 3 (0.12)
FUEL PUMP
Discharge (@ 2,750 r/min) L/h(US gal/h, 12 (3.17, 2.64)
lmp gal/h)
Maximum pressure kPa (kg/cm2 , 117.6 (1.2, 17.1)
(@ 2,750 r/min) psi)
Diaphragm stroke mm (in) 2.4 - 4.8 (0.095 - 0.189)
Plunger stroke mm (in) 3.525 - 6.575 (0.139 - 0.259)
9
Model
OIL PUMP
Discharge (@ 3,000 r/min) L/h (US gal/h, 3.5 (0.925, 0.77)
Imp gal/h)
Outer rotor-housing clearance a mm (in) 0.10 - 0.15 (0.004 - 0.006)
Outer rotor-inner rotor clearance mm (in) 0.04 - 0.14 (0.002 - 0.006)
b
Rotor-housing clearance c mm (in) 0.03 - 0.09 (0.001 - 0.004)
CARBURETOR
Stamped mark 68T-00 (FT8DMH)
68T-30 (FT8DE, FT8DEP)
68T-40 (T8PR, T8ER)
68T-10 (T8PH, T8MH)
68T-50 (for SAV)
Main jet # 74
Pilot jet # 39
Float height a mm (in) 19.0 - 20.0
(0.75 - 0.79)
Idle speed r/min 1,050 ± 50
LOWER UNIT
Model
GEAR BACKLASH
Pinion - Forward gear mm (in) 0.20 - 1.15 (0.008 - 0.045)
Pinion - Reverse gear mm (in) 0.66 - 1.56 (0.026 - 0.061)
Pinion shim thickness mm 1.13, 1.2
Forward gear shim thickness mm 0.1, 0.2, 0.3, 0.4
Reverse gear shim thickness mm 0.1, 0.2, 0.3
10
ELECTRICAL
Model
IGNITION SYSTEM
(Br – L)
@ cranking (opened) V 112
@ 1,500 r/min V 185
@ 3,500 r/min V 185
(W/R – B)
@ 1,500 r/min V 7.0
@ 3,500 r/min V 10.5
(O – B)
@ 1,500 r/min V 168
@ 3,500 r/min V 168
Ignition spark gap mm (in) 0.9 (0.04)
Charge coil resistance (Br – L) Ω 232 - 348
Pulser coil resistance (W/R – B) Ω 240 - 360
Primary (O – B) Ω 0.26 - 0.35
Secondary (Between outputs) kΩ 6.80 - 10.20
Spark plug cap resistance kΩ 4.3
Oil pressure switch operating kPa (kg/cm2 , psi) 14.7 (0.15, 2.13)
pressure
Oil pressure control speed r/min 2,000 ± 150
Engine speed limiter control r/min 6,200 ± 100
speed
STARTING SYSTEM
Fuse A 10
Fuel enrichment solenoid Ω 4
resistance
11
Model
STARTER MOTOR
Type Bendix
Rating Second 30
Output kW 0.6
Brush length mm (in) 12.5 (0.49)
Brush length limit mm (in) 9.0 (0.35)
Commutator diameter limit mm (in) 29.0 (1.14)
CHARGING SYSTEM
voltage (G – G)
Rectifier output peak voltage (R – B)
@ 1,500 r/min (opened) V 13.3
@ 3,500 r/min (opened) V 32.2
Charging current A @ 5,000 r/min 5.5
CHARGING SYSTEM
(G – G)
@ 1,500 r/min (opened) V 33.6
@ 3,500 r/min (opened) V 77.0
voltage (R – B)
Charging current A @ 5,000 r/min 6
Model
Item World wide Unit FT8DEP FT8DEHP
USA, Canada T8PR T8PH
POWER TILT (PT) UNIT
Fluid
Fluid type ATF Dexron ΙΙ
Motor
Brush length mm (in) 6 (0.25)
Limit mm (in) 3 (0.12)
Limit mm (in) 15.5 (0.61)
12
OUTBOARD DIMENSIONS (T8PH/T8MH/FT8DMH)
13
Model
Symbol Unit
T8PH T8MH FT8DMH
L1 mm (in) 430 (16.9)
L2 mm (in) 122 (4.8)
L3 mm (in) 608 (23.9)
L4 mm (in) 367 (14.4)
L5 mm (in) 99 (3.9)
L6 (L) mm (in) 879 (34.6)
(X) mm (in) 941 (37.0) — 941 (37.0)
L7 mm (in) 271 (10.7)
L8 mm (in) 190 (7.5)
L9 mm (in) —
L10 mm (in) 67 (2.6)
H1 (L) mm (in) 869 (34.2)
(X) mm (in) 937 (36.9) — 937 (36.9)
H2 mm (in) 318 (12.5)
H3 mm (in) 157 (6.2)
H4 (L) mm (in) 557 (21.9)
(X) mm (in) 625 (24.6) — 625 (24.6)
H5 mm (in) 673 (26.5)
H6 (L) mm (in) 717 (28.2)
(X) mm (in) 757 (29.8) — 757 (29.8)
H7 mm (in) 203 (8.0)
H8 mm (in) 5 (0.2)
H9 mm (in) 529 (20.8)
H10 mm (in) 32 (1.3)
H11 mm (in) —
W1 mm (in) 172 (6.8) 159 (6.3)
W2 mm (in) 199 (7.8)
W3 mm (in) 159 (6.3)
W4 mm (in) 159 (6.3)
W5 mm (in) 326 (12.8) 379 (14.9)
W6 mm (in) 586 (23.1) 619 (24.4)
A1 Degree 40 45
A2 Degree 66
A3 Degree —
14
OUTBOARD DIMENSIONS (FT8DEP/T8PR, FT8DE/T8ER)
15
Symbol Model
World wide Unit FT8DEP FT8DE
L1 mm (in) 430 (16.9)
L2 mm (in) 122 (4.8)
L3 mm (in) —
L4 mm (in) 367 (14.4)
L5 mm (in) 99 (3.9)
L6 (L) mm (in) 879 (34.6)
(X) mm (in) 941 (37.0)
L7 mm (in) 271 (10.7)
L8 mm (in) 225 (8.9)
L9 mm (in) —
L10 mm (in) 67 (2.6)
H1 (L) mm (in) 869 (34.2)
(X) mm (in) 937 (36.9)
H2 mm (in) 318 (12.5)
H3 mm (in) 157 (6.2)
H4 (L) mm (in) 557 (21.9)
(X) mm (in) 625 (24.6)
H5 mm (in) —
H6 (L) mm (in) 717 (28.2)
(X) mm (in) 757 (29.8)
H7 mm (in) 203 (8.0)
H8 mm (in) 5 (0.2)
H9 mm (in) 529 (20.8)
H10 mm (in) 32 (1.3)
H11 mm (in) —
W1 mm (in) 177 (7.0)
W2 mm (in) 135 (5.3)
W3 mm (in) 159 (6.3)
W4 mm (in) 159 (6.3)
W5 mm (in) 271 (10.7) 286 (11.3)
W6 mm (in) 271 (10.7) 286 (11.3)
A1 Degree 40 45
A2 Degree 66
A3 Degree —
16
BRACKET DIMENSION (FT8DMH/T8MH, FT8DE/T8ER)
Symbol Model
World wide Unit FT8DMH FT8DE
USA, Canada T8MH T8ER
B1 mm (in) 70.5 (2.8)
B2 mm (in) 180.5 (7.2)
B3 mm (in) 95.3 (3.8)
B4 mm (in) 94.5 (3.7)
B5 mm (in) 105.3 (4.1)
B6 mm (in) 189.5 (7.5)
B7 mm (in) —
B8 mm (in) —
B9 mm (in) 18 (0.7)
B10 mm (in) —
B11 mm (in) —
B12 mm (in) —
C1 mm (in) 28 (1.1)
C2 mm (in) 65 (2.6)
C3 mm (in) —
D1 mm (in) 8.3 (0.3)
D2 mm (in) 8.3 (0.3)
D3 mm (in) —
D4 mm (in) —
T mm (in) —
17
BRACKET DIMENSION (FT8DEP/T8PR/T8PH)
Model
Symbol Unit
T8PH T8PR FT8DEP
B1 mm (in) 95.3 (3.8)
B2 mm (in) 275.5 (10.8)
B3 mm (in) 95.3 (3.8)
B4 mm (in) 94.5 (3.7)
B5 mm (in) 111 (4.4)
B6 mm (in) 325.5 (12.8)
B7 mm (in) 155.5 (6.1)
B8 mm (in) —
B9 mm (in) 18 (0.7)
B10 mm (in) —
B11 mm (in) 73.5 (2.9)
B12 mm (in) 69.5 (2.7)
C1 mm (in) 41 (1.6)
C2 mm (in) 65 (2.6)
C3 mm (in) —
D1 mm (in) 8.3 (0.3)
D2 mm (in) 10 (0.4)
D3 mm (in) —
D4 mm (in) —
T mm (in) —
18
TIGHTENING TORQUES
TIGHTENING TORQUES
SPECIFIED TORQUES
Part Thread Tigtening torque
Part to tightened Q’ty Remarks
name size NOm kgfOm ftOlb
FUEL SYSTEM
Fuel pump housing Screw M4 4 1.5 0.15 1.11
Fuel pump check valve Screw M3 2 0.5 0.05 0.37
Throttle axle link lock Screw M5 1 1.5 0.15 1.1
POWER UNIT
Breather cover mounting Screw M4 5 2 0.2 1.5
572
LT
Fuel enrichment solenoid mounting Screw M4 4 2 0.2 1.5
1st 6 0.6 4.4
Intake manifold mounting Bolt M6 5
2nd 12 1.2 8.8
Manual starter drive plate mounting Screw – 1 6 0.6 4.4
Flywheel rotor mounting Nut M12 1 100 10 72
E
Drive gear mounting Nut M24 1 36 3.6 26.5
E
Driven gear mounting Bolt M6 1 12 1.2 8.8
E
Power unit mounting Bolt M8 6 21 2.1 15.5
572
LT
Relief valve assembly – M14 1 8 0.8 5.9
Plug M16 1 18 1.8 13.3
Anode mounting
Screw M5 1 2 0.2 1.5
1st 6 0.6 4.4
Exhaust outer cover mounting Bolt M6 5
2nd 12 1.2 8.8
Spark plug – M14 2 25 2.5 18.4
1st 15 1.5 11.1
E
Bolt M8 6
2nd 30 3.0 22.1
E
Cylinder head mounting
1st 6 0.6 4.4
E
Bolt M6 3
2nd 12 1.2 8.8
E
Oil pump housing Screw M6 2 5 0.5 3.7
Rocker arm locknut Nut M5 4 8 0.8 5.9 E
1st 15 1.5 11.1

E
Crankcase mounting Bolt M8 6

2nd 30 3.0 22.1
E
1st 6 0.6 4.4

E
Connecting rod mounting Bolt M7 4

2nd 12 1.2 8.1
E
LOWER UNIT
Apron mounting Screw M6 2 4 0.4 2.9
Engine oil drain Plug M10 1 24 2.4 17.8
Drain plug damper mounting Screw M5 1 2 0.2 1.5
572
LT
Oil pan mounting Bolt M8 2 21 2.1 15.5

572
LT
Muffler mounting Bolt M6 2 12 1.2 8.8

572
LT
Gear oil level check Plug M8 1 7 0.7 5.1

Gear oil drain Plug M8 1 7 0.7 5.1
Propeller mounting (STD) Nut M10 1 17 1.7 12.5
Water inlet cover mounting Screw M5 1 5 0.5 3.7
Ground terminal mounting Screw M5 1 2 0.2 1.5
Pinion gear Nut M8 1 25.0 2.5 18.4
19
TIGHTENING TORQUES
Part Thread Tigtening torque

Part to tightened Q’ty Remarks
name size Nm
● kgf m
● ft lb
●
BRACKET
Shift handle mounting Bolt M5 1 3.5 0.35 2.6
Handle bracket mounting Nut M10 2 36 3.6 26.5
Handle throttle grip Screw M5 1 3.5 0.35 2.6
Handle throttle shaft plate mounting Screw M5 2 3.5 0.35 2.6
Handle mounting (outside) Nut M10 1 22 2.2 16.2
Handle mounting (inside) Nut M10 1 10 1.0 7.4
Handle rubber bushing mounting Screw M6 3 3.5 0.35 2.6
572
LT
Adapter mounting (*1) Screw M6 1 2 0.2 1.5
Upper mount Nut M8 2 21 2.1 15.5
Upper mount rubber mounting Bolt M6 2 12 1.2 8.8
572
LT
Lower mount Bolt M6 4 15 1.5 11.1
Clamp bracket cap Nut – 2 13 1.3 9.6
Pivot shaft lock Bolt M6 1 4 0.4 2.9
Grease nipple Nipple – 1 3 0.3 2.2
Steering friction plate mounting Bolt M5 2 5.4 0.54 3.9
Steering friction piece mounting Bolt M5 1 5.4 0.54 3.9
Neutral switch stay mounting Bolt M6 2 10 1.0 7.4
Recoil starter cable mounting Bolt M6 1 or 2 10 1.0 7.4
Ground lead mounting Screw M5 1 2.5 0.25 1.8
572
LT
POWER TILT UNIT
Reservoir cap Screw M10 1 5 0.5 3.6
Cylinder end screw Nut M33 1 45 4.5 32
Tilt piston Bolt M12 1 45 4.5 32
ELECTRICAL
Charge coil mounting Bolt M6 2 12 1.2 8.8
Lighting coil mounting Bolt M6 2 or 4 12 1.2 8.8
Rectifier mounting (*2) Screw M5 1 3.5 0.35 2.6
Oil pressure switch – PT1/8 1 9 0.9 6.6
572
LT
Oil pressure switch terminal Screw M4 1 2 0.2 1.5
Starter motor bracket mounting Bolt M8 3 21 2.1 15.5
Starter motor mounting Bolt M8 2 21 2.1 15.5
Starter motor positive (+) terminal Nut M6 1 4 0.4 2.9
Starter relay terminal Bolt M6 2 4 0.4 2.9
Lead coupler clamp mounting Screw – 2 1 0.1 0.7
*1 : For water-flushing model

*2 : For One-lighting coil model
20
TIGHTENING TORQUES
General torque GENERAL TORQUES

Nut (A) Bolt (B) specifications This chart specifies tightening torques for
Nm
●
kgf m●
ft lb
●
standard fasteners with a standard ISO
8 mm M5 5 0.5 3.6 thread pitch. Tightening torque specifications
10 mm M6 8 0.8 5.8 for special components or assemblies are
12 mm M8 18 1.8 13 provided in applicable sections of this
14 mm M10 36 3.6 25 manual to avoid warpage, tighten
17 mm M12 43 4.3 31 multifastener assemblies in a crisscross
fashion and progressive stages until the
specified tightening torque is reached. Unless
otherwise specified, tightening torque
specifications require clean, dry threads.
Components should be at room temperature.
21
Use the following chart as a guide to general maintenance intervals.
Dependant on operating conditions, adjust the maintenance intervals accordingly.
Initial Every
Item Remarks 10 hours 50 hours 100 hours 200 hours
(Brake-in) (3 months) (6 months) (1 year)
TOP COWLING:
Water drain hole Check { {
Top cowling fit Check { {
FUEL SYSTEM:
Fuel line Check {
Fuel filter Check/clean/ { { {
replace
Fuel tank (*1) Clean {
POWER UNIT:
Engine oil Check/replace { {
Timing belt Check/replace {
Valve clearance Check/adjust { {
Ignition timing Check {
Thermostat Check/replace {
Water leakage Check { { {
Motor exterior Check { {
Exhaust leakage Check { { {
Cooling water passage Check { {
CONTROL SYSTEM:
Shift cable Check/adjust {
Throttle cables Check/adjust {
Throttle axle link Check/adjust {
Engine idling speed Check/adjust { {
Start-in-gear protection device Check/adjust { {
LOWER UNIT:
Gear oil Change { {
Lower unit leakage Check {
Propeller Check/replace { {
POWER TILT SYSTEM:
Power tilt fluid Check/change { { { {
GENERAL:
Anode Check/replace { {
Battery Check/replace { (every 1 month)
Spark plug Cleaning/ { { {
adjust/ replace
Wiring and connector Check/ { {
reconnect
Bolts and nuts Tighten { {
Lubrication points Grease {
*1.......If Yamaha portable fuel tank is used.
22
POWER UNIT
POWER UNIT
NOTE:
Valve clearance adjustment shoule be
carried out when the engine is “cold”.
1. Remove:
y Recoil starter 1
y Dust cover 2
y Fuel pump 3
y Cylinder head cover 4
2. Check:
y Intake valve clearance a
y Exhaust valve clearance b
Out of specification Æ Adjust.
Valve clearance (when engine is

cold)
Intake valve a:
0.15 – 0.20 mm (0.006 – 0.008 in)
Exhaust valve b:
0.20 – 0.25 mm (0.008 – 0.010 in)
Checking steps:
(1)Turn the crankshaft and align the “∆1”
mark on the driven gear 5 and “∆”
mark on the thermostat cover 6.
(3)Turn the crankshaft 360° and align the
“∆2” mark on the driven gear 5 and
“∆” mark on the thermostat cover 6.
23
POWER TILT SYSTEM/ GENERAL
POWER TILT SYSTEM / GENERAL
CHECKING THE POWER TILT (PT)

FLUID LEVEL
WARNING
After tilting up the outboard, be sure to
support it with the tilt lock knob.
Otherwise, the outboard could suddenly
lower if the power tilt unit should lose
fluid pressure.
1. Check:
y Power tilt fluid level
Level is low Æ Add fluid to the
proper level.
Checking steps:
(1) Tilt up the outboard and lock it
with tilt lock knob 1.
(2) Remove the reservoir cap 2.
(3) Check that the fluid level is
directly below the fluid level
checking hole a.
NOTE:
The fluid level should be directly below the
check hole as shown.
2. Add:
Recommended hydraulic fluid:
ATF Dexron II
Reservoir cap:
5 N m (0.5 kgf m, 3.6 ft lb)
● ● ●
GENERAL
CHECKING THE ANODE
1. Check:
y Anode (engine)
y Anode (clamp bracket)
y Anode (lower unit)
Scales Æ Clean.
Oil/grease Æ Clean.
Excessive wear (half worn) damage
Æ Replace.
CAUTION:
Do not oil, grease, or paint the anode, or it
will not operate properly.
24
LOWER UNIT
LOWER UNIT
REMOVING/INSTALLING THE LOWER UNIT

1 Pin, split 1
2 Nut 1
3 Washer 1
4 Spacer 1
5 Propeller 1
6 Washer 1
7 Spacer 1
8 Locknut 1
9 Adjusting nut 1
10 Bolt 4
11 Stud bolt/nut (for X-transom models) 4/4
12 Extension (for X-transom models) 1
13 Dowel pin (for X-transom models) 2
25
LOWER UNIT

14 Lower unit 1
15 Dowel pin 2
16 Rubber seal 1
17 Screw 1
18 Nut 1
19 Water inlet grill 2
20 Bolt 1
21 Toothed washer 1
22 Anode 1

procedure.
26
WATER PUMP
WATER PUMP
REMOVING/INSTALLING THE WATER PUMP

Lower unit
1 Bolt 4
2 Plate 2
3 Impeller housing 1
4 O-ring 1
5 Impeller 1
6 Impeller housing cup 1
7 Woodruff key 1
8 Bolt 2
9 Dowel pin 2
10 Metal gasket 1
11 Rubber seal 1
procedure.
27
WATER PUMP
CHECKING THE IMPELLER HOUSING
Check:
y Impeller housing
Cracks/damage Æ Replace.
CHECKING THE IMPELLER AND

IMPELLER HOUSING CUP
Check:
y Impeller
y Impeller housing cup
INSTALLING THE IMPELLER

HOUSING CUP
Install:
y Impeller housing cup
NOTE:
To install the impeller housing cup, turn the
drive shaft clockwise. Do not turn the drive
shaft counterclockwise after installation.
28
SHAFT
PROPELLER SHAFT HOUSING AND PROPELLER SHAFT
REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASS’Y AND
PROPELLER SHAFT ASS’Y

Gear oil
Propeller
1 Bolt 2
2 Propeller shaft housing ass’y 1
3 Thrust washer 1
4 Propeller shaft ass’y 1

procedure.
29
SHAFT
A REMOVING THE PROPELLER SHAFT
HOUSING ASS’Y
Remove:
O Propeller shaft housing ass’y
Bearing housing puller claw:

YB-06234 1/90890-06503 3
Universal puller 2:
YB-06117
90890-06501
B
Center bolt 5:
90890-06504
A For USA and CANADA
B Except for USA and CANADA
30
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASS'Y

1 Spring 1
2 Cross pin 1
3 Dog clutch 1
4 Shift plunger 1
5 Spring 1
6 Propeller shaft 1
For assembly, reverse the disassembly

procedure.
31
CHECKING THE DOG CLUTCH
Check:
y Dog clutch
Wear/damage Æ Replace.

Check:
y Propeller shaft
32
PROPELLER SHAFT HOUSING ASS’Y
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASS'Y

Propeller shaft housing ass’y
1 Reverse gear 1
2 Reverse gear shim *
5 Ball bearing 1
7 Needle bearing 1
8 Propeller shaft housing 1

procedure.
*: as required
33
DISASSEMBLING THE PROPELLER
SHAFT HOUSING ASS'Y
1. Remove:
y Reverse gear
y Reverse shim(s)
y Ball bearing
Bearing separator 1:
YB-06216/90890-06534
Slide hammer set 2:
YB-06096
A
90890-06501
Bearing puller 4:
90890-06535
Stopper guide stand 5:
90890-06538
1.
B
2. Remove:
y Oil seals
y Needle bearing
Slide hammer set 1:

YB-06096
Driver rod 2:
YB-06071/90890-06604
Needle bearing attachment 3:
YB-06081/90890-06616
CHECKING THE GEARS

Check:
y Teeth
y Dog clutch
34
CHECKING THE BEARING
Check:
y Bearing
Pitting/rumbling Æ Replace.
NOTE:
smoothly.

HOUSING
1. Clean:
y Propeller shaft housing
(with a soft brush and solvent)
2. Check:
y Propeller shaft housing
ASSEMBLING PROPELLER SHAFT

HOUSING ASS'Y
1. Install:
y Needle bearing
Needle bearing depth a:

0 mm (0 in)
Driver rod 1:
YB-06071/90890-06604
YB-06081/90890-06616
NOTE:
Install the needle bearing with its manufac-
turer’s marks b fasing up
35
2. Install:
O Oil seals
Oil seal depth a:

4.5 - 5.0 mm (0.18 - 0.20 in)
Oil seal installer 1:

(Needle bearing attachment)
N.A./90980-06614
Driver rod 2:
YB-06071/90890-06604
NOTE:
First, fully install the lower oil seal and then
the upper.
3. Install:
O Ball bearing
NOTE:
Install the ball bearing with its manufactur-
er’s marks a facing towards the reverse
gear.
Driver rod 1:
YB-06071/90890-06606
Ball bearing attachment 2:
YB-06015/90890-06632
4. Install:
O Reverse gear shim(s) 1
O Reverse gear 2
36
DRIVE SHAFT, FORWARD GEAR, SHIFT ROD AND
OIL SEAL HOUSING
DRIVE SHAFT, FORWARD GEAR, SHIFT ROD AND OIL SEAL HOUSING
REMOVING/INSTALLING THE DRIVE SHAFT, FORWARD GEAR AND SHAFT ROD

Propeller shaft ass’y
Water pump
1 Pinion nut 1
2 Pinion 1
3 Washer 1
4 Thrust bearing 1
5 Pinion shim *
6 Drive shaft 1
7 Forward gear ass’y 1/*
(along with the tapered roller bearing
and forward gear shim)
8 Oil seal housing ass’y 1
9 Metal gasket 1
*: as required
37
OIL SEAL HOUSING

10 Shift rod 1
11 Sleeve 1
12 Needle bearing 1
13 Forward gear bearing outer race 1
15 Bushing 1 Not reusable
16 Oil seal housing ass’y 1

procedure.
38
OIL SEAL HOUSING
REMOVING THE PINION AND
FORWARD GEAR
1. Remove :
O Pinion nut.
Driver shaft holder 1:

YB-06565/90890-06565
Pinion nut holder 2:
YB-06078/N.A.
2. Remove :
O Pinion 1
O Forward gear 2
(along with the tapered roller
bearing and forward gear shim)
DISASSEMBLING THE OIL SEAL

HOUSING ASS'Y
Remove:
O Bushing
Bushing attachment:
YB-06028/90890-06649
Driver rod:
YB-06229/90890-06604
INSTALLING THE SLEEVE

Install:
O Sleeve 1
CAUTION:
Install the sleeve with its hole facing
forward.
39
OIL SEAL HOUSING
DISASSEMBLING THE LOWER CASE
1. Remove:
O Needle bearing
Driver rod 1:
YB-06229/90890-06602
YB-06230/90890-06617
A 2. Remove:
O Forward gear bearing outer race
O Forward gear shim(s)
Slide hammer set 1:

YB-06096
90890-06501
Bearing outer race puller 3:
90890-06535
Stopper guide stand 4:
90890-06538
B
NOTE:
Make sure the bearing outer race puller
sliding on the gear case, attaching to the
outer race and shim’s bottom at
horizontally.
40
OIL SEAL HOUSING
CHECKING THE PINION AND
FORWARD GEAR
Check:
y Teeth
y Dog clutch
CHECKING THE DRIVE SHAFT
Check:
y Bearing
CHECKING THE SHIFT CAM
Check:
y Shift cam
CHECKING THE BEARING
Check:
y Bearing
Pitting/rumbling Æ Replace.
CHECKING THE SLEEVE
Check:
y Sleeve
CHECKING THE LOWER CASE

1. Clean:
y Gear case
(with a soft brush and solvent)
2. Check:
y Water passage
Mineral deposits/corrosion Æ Clean.
3. Check:
y Lower case
Cracks/damage Æ Replace
ASSEMBLING THE LOWER CASE

1. Install:
y Tapered roller bearing outer race 1
Bearing installer:
(Bearing outer race attachment)
YB-06085/90890-06625
Driver rod:
YB-06071/90890-06605
41
OIL SEAL HOUSING
A 2. Install:
O Needle bearing
Needle bearing depth a:

0.7 - 1.2 mm (0.03 - 0.05 in)
Needle bearing depth b, S:
189.3 - 189.8 mm (7.45 - 7.47 in)
Driver rod 1:
YB-06229/90890-06602
Drive shaft needle bearing
B depth stop 2:
YB-06231
YB-06230/90890-06617
Bearing depth plate 4:
90890-06603

NOTE:
Install the drive shaft needle bearing with
the manufacturer’s marks facing up.
ASSEMBLING THE OIL SEAL

HOUSING ASS'Y
1. Install:
O Bushing
Bushing attachment:
YB-06028/90890-06649
Driver rod:
YB-06229/90890-06604
2. Install:
O Oil seal 1
Depth a:
7.0 - 8.0 mm (0.28 - 0.31 in)
Driver rod 2:
YB-06071/90890-06604
Bearing installer 3:
(Bearing inner race attachment)
YB-06022/90890-06613
ASSEMBLING THE FORWARD GEAR
Install:
O Tapered roller bearing
(to the forward gear)
Bearing inner race attachment 1:
90890-06644
42
SHIMMING (FOR USA AND CANADA)
SHIMMING (FOR USA AND
CANADA)
NOTE:
• There is no need to select shims when
reassembling with the original case and
inner parts.
• Shim calculations are required when
reassembling with the original inner parts
and a new case (the difference between
the original inner parts and the new
case).
• Measurements and adjustments are
required when replacing an inner part(s).
SELECTING THE PINION SHIMS

Measure:
y Pinion clearance
(with a thickness gauge )
Out of specification Æ Adjust
Specified clearance a:
0.47 mm - 0.52 mm (0.018 - 0.02 in)
Measuring steps:
(1) Install the drive shaft components
and tighten the pinion nut.
(2) Install the bearing shim selector 1
onto the gear case, not onto the
tapered roller bearing.
Pinion nut:
25 Nym (2.5 kgfym, 18 ftylb)
(3) Attach the bearing shim

selector 1.
Bearing shim selector:
YB-6299 1
(4) Measure the clearance a with a

thickness gauge and determine
the proper shim to use.
Less than
Use a 1.13 mm shim
3.5 mm
More than
Use a 1.20 mm shim
3.7 mm
43
SHIMMING (EXCEPT FOR USA AND CANADA)
SHIMMING (EXCEPT FOR USA
AND CANADA)
NOTE:
• There is no need to select shims when
reassembling with the original case and
inner parts.
• Shim calculations are required when
reassembling with the original inner parts
and a new case.
• Measurements and adjustments are
required when replacing an inner part(s).
SELECTING THE PINION SHIMS

1. Measure:
O Measurement (Mv3)
Digital caliper:
90890-06704
NOTE:
Measure the thickness (Mv3) of the bearing
and washer.
2. Calculate:
O Pinion shim thickness (T3)
Pinion shim thickness:

(T3) = 6.05 - Mv3 mm
3. Select:
O Pinion shim
Calculated numeral
Shim
more than or less
1.13 1.20 1.13
1.20 1.30 1.20
Available shim thickness:
1.13 and 1.20 mm
44
SELECTING THE FORWARD GEAR
SHIMS
NOTE:
Find the forward gear shim thickness (T1)
by selecting shims until the specified mea-
surement (Mv1) is obtained with the spe-
cial tool.
1. Measure:
O Measurement (Mv1)
Shimming plate:
90890-06701
Digital caliper:
90890-06704
NOTE:
Measure the length between the shimming
plate and the bearing outer race after turn-
ing the outer race 2 or 3 times.
2. Calculate:
O Forward gear shim thickness (T1)
Forward gear shim thickness:

(T1) = 16.50 - Mv1
3. Select:
O Forward gear shim
Calculated numeral
Shim
more than or less
0 0.1 — (0)
0.1 0.2 0.1
0.2 0.3 0.2
0.3 0.4 0.3
0.4 0.5 0.4
0.1, 0.2, 0.3 and 0.4 mm
45
SELECTING THE REVERSE GEAR
SHIMS
NOTE:
Find the reverse gear shim thickness (T2)
by selecting shims until the specified mea-
surement (Mv2) is obtained with the spe-
cial tool.
1. Measure:
O Measurement (Mv2)
Shimming plate:
90890-06701
Digital caliper:
90890-06704
NOTE:
Remove the shim(s) before measuring.
2. Calculate:
O Reverse gear shim thickness (T2)
Reverse gear shim thickness:

(T2) = 81.00 - Mv2
3. Select:
O Reverse gear shim
Calculated numeral
Shim
more than or less
0 0.1 — (0)
0.1 0.2 0.1
0.2 0.3 0.2
0.3 0.32 0.3
0.1, 0.2 and 0.3 mm
46
BACKLASH MEASUREMENT
NOTE:
• Do not install the water pump compo-
nents when measuring the backlash.
• Measure both the forward and reverse
gear backlashes.
• If both the forward and reverse gear
back-lashes are larger than specification,
the pinion gear may be too high.
• If both the forward and reverse gear
back-lashes are smaller than
specification, the pinion gear may be too
low.
• If either of these conditions exist, then
check the pinion gear shim(s) selection.
MEASURING THE FORWARD GEAR

BACKLASH
1. Measure:
y Forward gear backlash
Forward gear backlash:

0.20 - 1.15 mm (0.008 - 0.045 in)
Measuring steps:
(1) Position the bearing housing
puller so that it pushes against the
propeller shaft.
Bearing housing puller claw:

YB-06234/90890-06503
Universal puller:
YB-06117
Stopper guide plate:
90890-06501
Center bolt:
90890-06504
(2) Set the lower unit upside down.
Center bolt:
5 Nym (0.5 kgfym, 3.6 ftylb)
47
(3) Attach the backlash indicator 1
onto the drive shaft (12.8 mm (0.5
in) in diameter) as shown.
Backlash indicator:
YB-06265/90890-06706
(4) Attach the dial gauge onto the

lower unit and have the dial gauge
plunger contact the mark on the
backlash indicator.
Base plate:
YB-07003/90890-07003
Dial gauge set:
YU-03097/90890-01252
Magneto base:
YU-3448/90890-06705
(5) Slowly turn the drive shaft

clockwise and counterclockwise.
When the drive shaft stops in each
direction, measure the backlash.
2. Adjust:
y Forward gear backlash
Remove or add shim(s).
NOTE:
Adjust the shim(s) to be added or removed
according to specification.
Forward gear
Shim thickness
backlash
0.20 mm (0.008 in) (0.68 - M) x 0.39
More than To be increased by
1.15 mm (0.045 in) (M - 0.68) x 0.39
0.1, 0.2, 0.3 and 0.4 mm
M: Measurement
MEASURING THE REVERSE GEAR

BACKLASH
1. Measure:
y Reverse gear backlash
Reverse gear backlash:
0.66 - 1.56 mm (0.026 - 0.061 in)
48
Measuring steps:
(1) Load the reverse gear by installing
the propeller 1 collar 2 and then
tighten the propeller nut.
(2) Set the lower unit upside down.
Propeller nut:
5 NOm (0.5 kgfOm, 3.6 ftOlb)
(3) Attach the backlash indicator 3

onto the drive shaft (12.8 mm (0.5
in) in diameter) as shown.
Backlash indicator:
YB-06265/90890-06706
(4) Attach the dial gauge onto the

lower unit and have the dial gauge
plunger contact the mark on the
backlash indicator.
Base plate:
YB-07003/90890-07003
Dial gauge set:
YU-03097/90890-01252
Magneto base:
YU-34481/90890-06705
(5) Slowly turn the drive shaft

clockwise and counterclockwise
and when the drive shaft stops in
each direction, measure the
backlash.
1.
2. Adjust:
O Reverse gear backlash
Remove or add shim(s).
NOTE:
Adjust the shim(s) to be added or removed
according to specification.
Reverse gear
Shim thickness
backlash
0.66 mm (0.026 in) (1.11 - M) x 0.39
More than To be increased by
1.56 mm (0.061 in) (M - 1.11) x 0.39
0.1, 0.2 and 0.3 mm
M: Measurement
49
UPPER CASE
UPPER CASE
DISASSEMBLING/ASSEMBLING THE UPPER CASE

2 Upper side mount rubber 1
4 Exhaust guide 1
5 Clip 1
6 Oil strainer 1
9 Pin 2
10 Hose 1
11 Screw 1
12 Plate 1
13 Damper 1
50
UPPER CASE

14 Oil drain plug 1
15 Gasket 1
17 Oil pan 4
18 Pin 1
20 Muffer 2
22 Plate 1
23 Grommet 1
24 Upper case 1

procedure.
51
STEERING FRICTION
STEERING FRICTION
DISASSEMBLING/ASSEMBLING THE STEERING FRICTION

1 Lock nut 1
2 Plate washer 1
4 Friction piece 2
5 Collar 1
6 Friction Plats 1
7 Collar 1
8 Plate washer 2
9 Lock nob 1
10 Lock shaft 1
11 Friction plate 1

procedure.
52
DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 1

1 Reservoir cap 1
3 Bolt 4
4 PT motor 1
7 Manual release rod 1
8 Pin 1
10 Sponge 1 Not reusable
11 Spring 2 Outside diameter 5.0 x Length 17.0 mm
12 Manual release pin 2
53

14 Absorver valve pin 2
15 Ball 2
18 Valve pin 2
19 Valve seal 2

procedure.
54
INSTALLING THE RELIEF VALVE
Install:
O Valve seal 1
O Valve pin 2
O Spring 3
NOTE:
Be careful to install the valve seal facing in
the correct direction.
55
DISASSEMBLING/ASSEMBLING THE PT MOTOR

2 Yoke assembly 1 43.9 x 1.5 mm Not reusable
5 Armatuer 1
7 Brush 2
8 Brush spring 2
10 End frame 1

procedure.
56
REMOVING THE ARMATURE
1. Remove:
y Screw 1
y Brush 2
y Armature 3
NOTE:
Push brush 2 to the inside, then remove
armature 3.
CHECKING THE PT MOTOR

1. Check:
y Commutator
Dirt Æ Clean with 600 grit
sandpaper.
2. Check:
y Commutator undercut
Obstruction Æ Clean.
NOTE:
Remove all metal particles with
compressed air.
3. Measure:
y Commutator diameter a
Commutator diameter limit:
15.5 mm (0.61 in)
57
4. Measure:
y Armature coil continuity
Armature coil continuity
Commutator segments Continuity

No
Segment - laminations
continuity
No
Segment - shaft
continuity
5. Measure:
y Brush length a
Brush length limit:
3 mm (0.12 in)
6. Check:
y End frame
7. Check:
y Yoke bushing
58
CHECKING THE PT MOTOR
ASSEMBLY
1. Check:
y PT motor operation
Incorrect operation Æ Repair.
PT motor operation
Motor turns
Blue (+), Green (-)
clockwise
Motor turns
Green (+), Blue (-)
counterclockwise

1. Install:
y Oil seal
Oil seal attachment:

YB-06112/90890-06614
Driver rod:
YB-06071/90890-06652
59
DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 2

1 Bolt 6
2 Gear pump housing 1
3 Gear 2
4 Dowel pin 4
5 Top chamber shuttle piston 1
8 Bottom chamber shuttle piston 1
9 Circlip 2
10 Valve seal 2
11 Valve seat 2
13 Main valve 2
60

15 Filter 2
16 O-ring 2 8.5 mm x 1.5 mm Not reusable
17 Ball 2
19 Plate 2

procedure.
61
DISASSEMBLING/ASSEMBLING THE POWER TILT (PT) CYLINDER

1 Tilt ram assembly 1
2 Free piston 1
4 Backing ring 1
5 Tilt cylinder 1
7 Cylinder 1
10 Backup ring 1
11 Tilt piston 1
12 Ball 1
13 Pin 1
62

15 Dowel pin 1
16 End screw 1
18 Backup ring 1
19 Dust seal 1 Not reusable
20 Tilt ram 1

procedure.
63
DISASSEMBLING THE POWER TILT
(PT) CYLINDER
WARNING
O To prevent the hydraulic fluid from
spurting out due to internal pressure, the
outboard should be kept fully tilted up
(the tilt rod at full length).
O After removing the tilt motor or oil
reservoir, do not push the tilt rod down.
This may cause hydraulic fluid to spurt
out from the port.
CAUTION:
Do not wipe hydraulic system components
with rags, paper, tissues, or the like, as
fibers from such material will cause
malfunctions if they enter the system.
1. Loosen:
O End screw
Power tilt wrench:

YB-06560 / 90890-06560
2. Loosen:
O Tilt ram
Power tilt wrench:

YB-06560 / 90890-06560
NOTE:
Hold the protruded portion a of the tilt
piston with the aluminium plate 1 and
turn to loose the tilt ram.
64
ASSEMBLING THE POWER TILT (PT)
CYLINDER
1. Tighten:
O Tilt ram
Power tilt wrench:

YB-06560 / 90890-06560
Tilt piston:
45 NOm (4.5 kgfOm, 32 ftOlb)
NOTE:
Hold the protruded portion a of the tilt
piston with the aluminium plate 1 and
tighten the tilt ram.
2. Fill:
O Fluid
Filling steps
(1) Fill the cylinder with the fluid to
about 70 %.
Recommended PT fluid:
ATF Dexron II
NOTE:
Put the fluid with the free piston 1
installed at the bottom of the cylinder.
(2) Install the tilt ram assembly.

NOTE:
The tilt ram assembly is to be installed with
the tilt piston 2 and end screw 3 in close
contact.
3. Tighten:
O End screw
Power tilt wrench:

YB-06560 / 90890-06560
End screw:
45 NOm (4.5 kgfOm, 32 ftOlb)
65
4. Bleed:
O Air
Bleeding step:
(1) Open the manual valve 1.
(2) Manually push in the tilt ram to its

fully contracted state.
(3) Remove the reservoir cap 2 and

supply the fluid to the prescribed
level.
Reservoir cap:
5 NOm (0.5 kgfOm, 3.6 ftOlb)
(4) Close the manual valve 1.
66
(5) Connect the PT motor lead to the
battery and place the tilt ram in it
fully extended state.
NOTE:
• When the tilt ram is unstable or does not
move, supply the fluid to the prescribed
level.
• Repeat until the tilt ram is placed in its
fully extended state.
• Close the reservoir cap during operation.
Battery
Tilt ram PT motor lead
terminal
Blue (+)
Up
Green (-)
(6) Alternately connect the PT motor

leads to the battery and extend
and contract the cylinder about
four or five times.
NOTE:
• Operate the tilt ram to the full stroke and
relieve it for about 2 seconds at each
stroke end.
O Place the tilt ram finally in its fully
extended state
Battery
Tilt ram PT motor lead
terminal
Blue (+)
Up
Green (-)
Green (+)
Down
Blue (-)
67
(7) Open the manual valve, leave it to
stand for about 1 second and
close it.
NOTE:
Check the fluid level and replenish if short.
(8) Leave it to stand for about 3

minutes and then repeat steps (6)
and (7).
NOTE:
• Repeat for about four or five times until
the up relief sound is confirmed without
delay when the cylinder extends.
• Finally confirm the fluid level.
(9) Install the power tilt (PT) unit to
the outboard motor.
NOTE:
Carrying and working should be done with
the power tilt (PT) unit erected.
(10)Operate the PT switch to move

down the outboard motor, relieve
it for about 1 second, and then
immediately move up the
outboard motor.
NOTE:
• For moving up the outboard motor, stop
it at about half the stroke.
• If it does not stop, air removal is not
complete. Take the steps (6) and (7) with
it installed to the outboard motor.
• Immediately after the tilt up, check that
the outboard motor does not descend.
Finally recheck the operation in this
procedure.
68
REMOVING/INSTALLING THE POWER TILT (PT) UNIT

1 PT motor lead 1
2 Clamp 1
4 Circlip 1
5 Pin 1
6 Bushing 1
7 Bushing 2
8 Bolt 2
9 Washer 2
10 Pin 1
11 Bushing 2
12 Bushing 1
13 Collar 1
69

14 Power tilt (PT) unit 1

procedure.
70
STARTER MOTOR
STARTER MOTOR
DISASSEMBLING/ASSEMBLING THE STARTER MOTOR

1 Clip 1
2 Pinion stopper 1
3 Spring 1
4 Pinion 1
5 Through bolt 2
6 Front cover 1
7 Washer 1
8 Washer 1
9 Washer 1
10 Starter body 1
11 Armature assembly 1
12 Washer 1
13 Nut 1
71
STARTER MOTOR

14 Spring washer 1
15 Nut 1
16 Spring washer 1
17 Plate washer 1
18 Bushing 1
19 O-ring 1
20 Screw 2
21 Brush holder 1
22 Spring 2
23 Brush 2
24 Bushing 1
25 Rear cover 1
26 O-ring 2 For installation, reverse the removal
procedure.
72
STARTER MOTOR
REMOVING THE PINION
Remove:
y Clip 1
NOTE:
Using a pry-bar, pry off the clip.
CHECKING THE PINION

1. Check:
y Pinion teeth
2. Check:
y Clutch movement
Damage Æ Replace.
NOTE:
Rotate the pinion clockwise, and check that
it freely. Also try to rotate the pinion
counterclockwise and confirm that it locks.
CHECKING THE ARMATURE

1. Check:
y Commutator
Dirty Æ Clean (with #600 abrasive
paper).
2. Measure:
y Commutator diameter
Out of specification Æ Replace
Commutator diameter limit:

29.0 mm (1.14 in)
73
STARTER MOTOR
3. Check:
y Commutator under cut
Clog/dirty Æ Clean.
NOTE:
Remove all particle metal by compressed
air.
4. Check:
y Armature coil continuity
Armature coil continuity:
Commutator segments Continuity

Segment - Laminations No continuity
Segment - Shaft No continuity
CHECKING THE BRUSH HOLDER

1. Measure:
y Brush length a
Brush length limit:

9.0 mm (0.35 in)
2. Check:
y Brush holder continuity
Brush holder continuity:
Brush holder 1 - Base 2 No continuity
74
POWER TILT (PT) SYSTEM
POWER TILT (PT) SYSTEM (T8PR/FT8DEP)
1 Battery B : Black
3 PT switch L : Blue
4 PT relay Lg : Light green
5 Terminal R : Red
6 PT motor Sb : Sky blue
75
POWER TILT (PT) SYSTEM (T8PH)
1 Battery B : Black
2 PT relay G : Green
3 Terminal L : Blue
4 PT motor Lg : Light green
5 PT switch R : Red
6 Fuse (10A) Sb : Sky blue
76
CHECKING THE PT SWITCH
Check:
y PT switch continuity
Leads color
Light
Sky blue
Switch Red (R) green
(Sb)
position (Lg)
Up
Free
Down
CHECKING THE PT RELAY

1. Check:
y PT relay continuity
PT relay continuity
Sky blue (Sb) - Black (B) Continuity

Light green (Lg) - Black (B)
Blue (L) - Black (B) Continuity
Green (G) - Black (B)
Blue (L) - Red (R) No continuity
Green (G) - Red (R)
A To battery
2. Check:
y PT relay operation
No continuity Æ Replace.
Checking steps:
(1) Connect the digital tester between
PT relay Blue (L) lead and Red (R)
lead.
(2) Connect a 12-V battery as shown.
Sky blue (Sb) lead Æ Positive terminal

Black (B) lead Æ Negative terminal
77
(3) Check that there is continuity
between the PT relay terminals.
(4) Connect the tester between PT
relay Green (G) lead and Red (R)
lead.
(5) Connect a 12-V battery as shown.
Light green (Lg) lead Æ Positive terminal

Black (B) lead Æ Negative terminal
(6) Check that there is continuity

between the PT relay terminals.
78
YAMAHA MOTOR CORPORATION, USA
Printed in USA
Oct. 2000 -1.66 x 1 SY
(T8PH, T8PR)
Printed on recycled paper

T8PH
WIRING DIAGRAM 10 Oil pressure switch
M4
P
5 Lighting coil
1 CDI unit
4 Pulser coil
B A Bracket
6 Charge coil
W/R
G 8 Rectifier/
G G Br L
G/W regulator
R
7 Starting motor
AVX1.25B
2 Emergency
signal light Y/R P M6 M8
Y/R
M6
AV 8.0B
P B
AV 8.0B
B
9 Ignition coil
3 Stop
O
switch P B W/R Br L G G
11 Spark
P B W/R Br L G/W G G G
Br O B plugs
12 Nutral
switch
Br M6 O B
Br 15 Starter relay
0.5B
B B
M6 M6
13 Starter
switch
R
R B
AV 8.0B
17 Terminal ass'y
AV 8.0B
AVX3.0 L
R
G
L AVX3.0
G/W G
AV 8.0B AV 1.25R AV 1.25R AV 1.25R
M8 M10 R
- + 16 Fuse(10A) AVX3.0
AVX3.0
Lg Lg B
19 PT/T relay L
14 Battery R
B: Black R: Red Sb 3.0G
Br: Brown Sb: Sky blue Lg
Sb 3.0L
G: Green W: White Sb R Lg
L: Blue Y: Yellow
O: Orange G/W: Green/white Sb R Lg Sb Lg
UP 20 PT/T
B If there is no size specified for the lead wire, P: Pink W/R: White/red FREE switch
the size is AVX0.75f. Lg: Light green Y/R: Yellow/red DOWN
18 PT/T motor
T8PR
WIRING DIAGRAM 3 Fuel enrich 10 Oil pressure
solenoid switch
M4
P
5 Lighting coil
1 CDI unit
4 Pulser coil
B A Bracket
6 Charge coil
W/R
G 8 Rectifier/
G G Br L
G/W regulator
R
L B
AVX1.25B
7 Starting motor
2 Emergency Y/R P M6 M8
signal light W
Y/R L B M6
AV 8.0B
AV 8.0B
P
1.25R
9 Ignition coil
G AV0.75f G B
L B
Lg W O
AV0.75f W
AV0.75f L P W/R Br L G G
AV0.75f G
B
AV1.25B
AV1.25R 11 Spark
Sb AV0.75Sb O B plugs
AV0.75Lg P B W/R Br L G/W G G G
1.25Br L M6
AV1.25Br
2.0B
O B
AV1.25B
B B B
Br 13 Starter relay
M6 M6
15 Terminal ass'y
L L
R
AV 8.0B AVX3.0
G
AVX3.0
B
AVX3.0
B
AV 8.0B
AVX3.0
R AV 1.25R
G G
14 Fuse(10A) R
R G/W
AV 8.0B AV 1.25R AV 1.25R AV 1.25R 3.0G
M8 M10
3.0L
- +
Lg Lg
Sb
17 PT/T relay
Sb Sb
Lg
Lg Lg
12 Battery
Lg Sb R Sb 16 PT/T motor
Lg Sb R
Sb Lg
Sb Lg
B: Black R: Red
Br: Brown Sb: Sky blue
R
G: Green W: White R
18 Trailer L: Blue Y: Yellow
switch Sb Lg O: Orange G/W: Green/white
Sb R Lg P: Pink W/R: White/red C If there is no size specified for the lead wire,
UP
FREE Lg: Light green Y/R: Yellow/red the size is AVX0.75f.
DOWN B For USA

Yamaha LIT 18616 T8 00

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Yamaha LIT 18616 T8 00

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F6Z

Model name (W/W) F6AMH F8CMH

USA and Canada name F6MH F8MH

Indication F6AMH F8CMH

Symbols : to E indicate specific data.

SPECIAL TOOLS ...............................................................................................1-5

STARTING SERIAL NUMBERS

Model name Applicable Starting

OILS, GREASES AND SEALING FLUIDS

GOOD WORKING PRACTICES

DISASSEMBLY AND ASSEMBLY

3. After assembly, check that moving

4. Install bearings with the manufacturers

6a b 6Digital circuit tester

7 Peak voltage tester

8 Spark gap tester

A Dial gauge stand

D Magnetic base attaching plate

GENERAL SPECIFICATIONS (F6AMH/F6MH) ................................................2-1

GENERAL SPECIFICATIONS (F8CMH/F8MH) ................................................2-3

TIGHTENING TORQUES ................................................................................2-14

ROCKER ARM SHAFT

Head dimension “A” IN mm (in) 23.9 - 24.1 (0.94 - 0.95)

Tilt limit mm (in) 1.0 (0.04)

Idle speed r/min 1,050 ± 50 1,050 ± 50

Part Thread Tightening torques

Part Thread Tightening torques

General torque GENERAL TORQUES

MAINTENANCE INTERVAL CHART ............................................................... 3-1

TOP COWLING ................................................................................................ 3-2

FUEL SYSTEM ................................................................................................ 3-3

CONTROL SYSTEM ........................................................................................ 3-4

POWER UNIT .................................................................................................. 3-9

COOLING SYSTEM ....................................................................................... 3-14

LOWER UNIT ................................................................................................ 3-15

GENERAL ...................................................................................................... 3-17

*1.......If Yamaha portable fuel tank is used.

CHECKING THE TOP COWLING FIT

(3)Secure the bolt 1.

Top cowling hook bolt:

(4)Check the top cowling fitting and

(7)Tighten the locknut 6.

Engine idling speed:

Engine idling speed

REPLACING THE ENGINE OIL

Recommended engine oil:

Valve clearance (when engine is

Compression pressure (Reference

CHANGING AND CHECKING THE GEAR

Recommended gear oil

Gear oil level check screw:

Lower unit holding pressure:

(3)Apply the specified pressure.

Gear oil level check screw:

Anode mounting plug (engine):

CHECKING THE BATTERY

Electrolyte specific gravity:

CHECKING THE SPARK PLUGS

Spark plug gap: