Service Manual: Yamaha Motor Co., LTD

S6AJ5K11_Cover-7mm 07.10.
15 9:42 Page 1
F20C
F20C
SERVICE MANUAL
YAMAHA MOTOR CO., LTD.
Printed in Japan
Oct. 2007 – 0.4 × 1 ! 6AJ-28197-5K-11
(E) Printed on recycled paper
S6AJ5K11_Cover-7mm 07.10.15 9:42 Page 2
NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
Important information
Particularly important information is distinguished in this manual by the following notations:
Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
w
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
cC
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
F20C
SERVICE MANUAL
©2007 by Yamaha Motor Co., Ltd.
1st Edition, October 2007
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
Contents
General information GEN

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

Manual format ..........................................................................................
Symbol .....................................................................................................
Abbreviation .............................................................................................
Sealant and locking agent table ..............................................................
1-1
1-2
1-3
1-3
1
Safety while working ...................................................................................
Fire prevention .........................................................................................
Ventilation ................................................................................................
1-4
1-4
1-4
2
Self-protection ......................................................................................... 1-4
3
Part, lubricant, and sealant ...................................................................... 1-4
Good working practice ............................................................................. 1-5
Disassembly and assembly ..................................................................... 1-5
Identification ................................................................................................. 1-6

Model ....................................................................................................... 1-6
Serial number .......................................................................................... 1-6
4
Special service tool ..................................................................................... 1-7
Propeller selection ..................................................................................... 1-12

Propeller size ......................................................................................... 1-12
Selection ................................................................................................ 1-12
5
Predelivery check ....................................................................................... 1-12
Checking the outboard motor mounting height ..................................... 1-13
Removing the intake silencer protective covering ................................. 1-13
Checking the fuel system ...................................................................... 1-13
6
Checking the engine oil level ................................................................. 1-13
Checking the gear oil level .................................................................... 1-14
Checking the gear shift and throttle operation ...................................... 1-14
Checking the steering system ............................................................... 1-15
7
Checking the tilt system ........................................................................ 1-15
8
Checking the engine shut-off switch ...................................................... 1-16
Checking the cooling water pilot hole .................................................... 1-16
Test run .................................................................................................. 1-16
Break-in ................................................................................................. 1-17
After test run .......................................................................................... 1-17
9
Precaution when transporting or storing the outboard motor ................ 1-17
6AJ5K11 1-
GEN
INFO General information
How to use this manual

Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand.Use the information below as a guide for effective and quality service.
9 Parts are shown and detailed in an exploded diagram and are listed in the component list (see 1
in the figure below for an example page).
9 The component list consists of part names and quantities, as well as bolt and screw dimensions
(see 2 in the figure below).
9 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
lubrication point (see 3 in the figure below).
9 Tightening torque specifications are provided in the exploded diagrams (see 4 in the figure below
for an example), and in the related detailed instructions. Some torque specifications are listed in
stages as torque figures or angles in degrees.
9 Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see 5 in the figure below for an example page).
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
4
1
1-1
1- 6AJ5K11
How to use this manual
Symbol
The symbols below are designed to indicate the content of a chapter.
General information Fuel system Bracket unit
GEN
INFO FUEL BRKT
1
Specification Power unit Electrical system
SPEC
Periodic check and adjustment

POWR
Lower unit
ELEC
Troubleshooting
2
CHK
ADJ LOWR TRBL
SHTG
3
Symbols 1 to 6 indicate specific data.
1 2 3 4 5 6
4
1
2
3
4
Special service tool
Specified oil or fluid
Specified engine speed
Specified tightening torque
5 Specified measurement
6 Specified electrical value
(resistance, voltage, electric current) 5
Symbols 7 to e in an exploded diagram or illustration indicate the grade of lubricant and the lubri-
cation point.
7 8 9 0 q w e
6
C
7
8
Apply
Apply
4-stroke motor oil
gear oil
q Apply corrosion resistant grease
(Yamaha grease D)
7
9 Apply water resistant grease (Yamaha grease A) w Apply low temperature resistant grease
0 Apply molybdenum disulfide grease (Yamaha grease C)
e Apply injector grease
Symbols r to o in an exploded diagram or illustration indicate the type of sealant or locking agent
8
and the application point.
r t y u i o
9
r Apply Gasket Maker u Apply LOCTITE 242 (blue)
t Apply ThreeBond 1104J i Apply LOCTITE 572
y Apply LOCTITE 271 (red) o Apply silicone sealant
6AJ5K11 1-2
GEN
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
API American Petroleum Institute
BOW Bow end
CDI Capacitor Discharge Ignition
EX Exhaust
IN Intake
PORT Port side
SAE Society of Automotive Engineers
STBD Starboard side
TDC Top Dead Center
WD Wiring Diagram
Sealant and locking agent table

The following table contains sealants, locking agents, and greases used in this service manual that
are not listed on page 1-2.
Symbol Name Application Manufacturer
LOCTITE 518 Sealant Henkel

S518
1342
ThreeBond 1342 Sealant ThreeBond
1-3 6AJ5K11
How to use this manual / Safety while working
Safety while working

To prevent an accident or injury and to ensure
quality service, follow the safety procedures
1
provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Part, lubricant, and sealant
Use only genuine Yamaha parts, lubricants,
2
and sealants or those recommended by
Yamaha, when servicing or repairing the out-
board motor.
3
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
4
in large quantities, they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where ade-
Under normal conditions, the lubricants men-
tioned in this manual should not harm or be
5
quate ventilation can be maintained.
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Avoid contact with skin. Do not, for exam-

6
ple, place a soiled rag in your pocket.
2. Wash hands and any other part of the

body thoroughly with soap and hot water
after contact with a lubricant or lubricant
7
soiled clothing has been made.
Self-protection
Protect your eyes by wearing safety glasses
or safety goggles during all operations involv-
ing drilling and grinding, or when using an air
3. Change and wash clothing as soon as
possible if soiled with lubricants.
8
compressor. 4. To protect your skin, apply a protective
Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
sary.
cream to your hands before working on
the outboard motor.
5. Keep a supply of clean, lint-free cloths for

9
wiping up spills, etc.
6AJ5K11 1-4
GEN
6. Maintain good standards of personal and Disassembly and assembly

industrial hygiene. 1. Use compressed air to remove dust and
dirt during disassembly.
Good working practice
Special service tool 2. Apply engine oil to the contact surfaces
Use the recommended special service tools of moving parts before assembly.
to protect parts from damage. Use the right
tool in the right manner–do not improvise.
3. Install bearings with the manufacture

S6AL1040 identification mark in the direction indicat-
Tightening torque ed in the installation procedure. In addi-
Follow the tightening torque specifications tion, be sure to lubricate the bearings lib-
provided throughout the manual. When tight- erally.
ening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting 4. Apply a thin coat of water resistant
in the center and moving outward. grease to the lip and periphery of an oil
Non-reusable part seal before installation.
Always use new gaskets, seals, O-rings, cot-
5. Check that moving parts operate normal-
ter pins, circlips, etc., when installing or
ly after assembly.
assembling parts.
1-5 6AJ5K11
Safety while working / Identification
Identification
Model
This manual covers the following models.
Applicable model
F20CMH 1
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
2
3
S6AG1010
4
5
6
1 Model name
2 Approved model code
3
4
Transom height
Serial number
Model name
Approved Starting
7
model code serial No.
F20C 6AJ 1000001–
8
9
6AJ5K11 1-6
GEN
Oil filter wrench Compression gauge

90890-01426 90890-03160
Digital tachometer Flywheel holder

90890-06760 90890-06522
Timing light Flywheel puller

90890-03141 90890-06521
Leakage tester Shaft holder

90890-06840 90890-06069
Vacuum/pressure pump gauge set Valve spring compressor

90890-06756 90890-04019
1-7 6AJ5K11
1
Valve spring compressor attachment
90890-06320
Needle bearing attachment
90890-06612, 90890-06613, 90890-06616,
90890-06653
2
3
Valve guide remover/installer
90890-06801
Driver rod L3
90890-06652 4
5
6
Valve guide reamer Piston slider
90890-06804 90890-06529
7
Valve seat cutter holder Stopper guide plate
90890-06316 90890-06501
8
Valve seat cutter
9
90890-06312, 90890-06315, 90890-06323, Center bolt
90890-06555, 90890-06818, 90890-06819 90890-06504
6AJ5K11 1-8
GEN
Bearing housing puller claw S Drive shaft holder 1

90890-06564 90890-06515
Bearing puller assembly Bushing attachment

90890-06535 90890-06649
Stopper guide stand Bearing separator

90890-06538 90890-06534
Driver rod LS Needle bearing attachment

90890-06606 90890-06617, 90890-06618
Ball bearing attachment Bearing outer race attachment

90890-06632 90890-06625
1-9 6AJ5K11
1
Driver rod LL
90890-06605
Digital caliper
90890-06704
2
3
Driver rod SL
90890-06602
Backlash indicator
90890-06706 4
5
6
Bearing depth plate Magnet base plate
90890-06603 90890-07003
7
Bearing inner race attachment Dial gauge set
90890-06644 90890-01252
8
9
Shimming plate Magnet base B
90890-06701 90890-06844
6AJ5K11 1-10
GEN
Digital circuit tester

90890-03174
Peak voltage adapter B

90890-03172
Ignition tester
90890-06754
1-11 6AJ5K11
Special service tool / Propeller selection / Predelivery check
Propeller selection a Propeller diameter (in inches)

The performance of a boat and outboard b Propeller pitch (in inches)
motor will be critically affected by the size and c Propeller type (propeller mark)
1
type of propeller you choose. Propellers
greatly affect boat speed, acceleration, Selection
engine life, fuel economy, and even boating When the engine speed is at the full throttle
and steering capabilities. An incorrect choice operating range (5,000–6,000 r/min), the
could adversely affect performance and could ideal propeller for the boat is one that pro-
vides maximum performance in relation to
2
also seriously damage the engine.
Use the following information as a guide for boat speed and fuel consumption.
selecting a propeller that meets the operating Propeller size (in) Material
conditions of the boat and the outboard 9 1/4 × 9 3/4 - J
motor.
9 1/4 × 10 1/2 - J
Propeller size
The size of the propeller is indicated on a pro-
peller blade, on the propeller boss end, and
9 1/4 × 12 - J
9 1/4 × 9 - J1
9 1/4 × 10 - J1
Aluminum 3
on the side of the propeller boss. 9 1/4 × 11 - J1
× -
9 1/4 × 12 - J1
Predelivery check
4
a b c To make the delivery process smooth and
efficient, the predelivery checks should be
completed as explained below. 5
S69W1030
× -
6
7
a b c
S69W1040
8
×
9
-
a b c
S69W1050
6AJ5K11 1-12
GEN
Checking the outboard motor cC

mounting height
A protective covering 1 is installed on the
1. Check that the anti-cavitation plate is
intake silencer when the outboard motor
between the bottom of the boat and a
is shipped from the factory and must be
maximum of 25 mm (1 in) a below it. If
removed before starting the engine for the
the mounting height is too high, cavitation
first time.
will occur and propulsion will be reduced.
Also, the engine speed will increase
abnormally and cause the engine to over-
heat. If the mounting height is too low, Checking the fuel system
water resistance will increase and reduce 1. Check that the fuel hoses are securely
engine efficiency. connected and that the fuel tank is full
with fuel.
S6D51030
NOTE:
The optimum mounting height is affected by
the combination of the boat and the outboard
motor. To determine the optimum mounting
height, test run the outboard motor at differ-
ent heights.
S6AG1040
2. Check that the clamp brackets are
secured with the clamp bolts. cC
This is a 4-stroke engine. Never use pre-
mixed fuel or 2-stroke outboard motor oil.
Removing the intake silencer
protective covering
1. Remove the protective covering 1 from
the intake silencer. Checking the engine oil level
1. Check the engine oil level.
1
S6AG1030
S6AG1050
1-13 6AJ5K11
Predelivery check
NOTE: 2. Check that the gear shift operates

If the engine oil is below the minimum level smoothly when the shift lever is shifted
mark a, add sufficient oil until the level is from the neutral position to forward or
1
between a and b. reverse.
Recommended engine oil: R

4-stroke motor oil N
API: SE, SF, SG, SH, SJ, or SL
SAE: 5W-30, 10W-30, or 10W-40
Engine oil quantity:
Without oil filter replacement: F a
2
1.6 L (1.69 US qt, 1.41 Imp qt) 1
3
6AJ10020
NOTE:
Checking the gear oil level 9 The shift lever cannot be operated unless
1. Check the gear oil level. the throttle grip is in the fully closed posi-
tion.
9 The resistance of the throttle grip can be
adjusted using the throttle friction adjuster
1.
4
6AJ10010
3. Check that the shift lever cannot be set to
the forward or reverse position when the
grip is not in the fully closed position.
5
NOTE:
6
4. Set the shift lever to the forward or
If the oil is at the correct level, a small amount reverse position, and then check that the
of oil should overflow out of the check hole starter handle cannot be pulled. If the
when the gear oil check screw is removed. starter rope can be pulled out normally,
adjust the start-in-gear protection cable.
Checking the gear shift and throttle

operation
1. Check that the throttle operates smoothly
7
R
when the throttle grip is turned from the
8
N
fully closed position to the fully open posi-
tion a.
F 6AJ10050
NOTE:
To adjust the start-in-gear protection cable,
see “Checking the start-in-gear protection” (3-
9
10).
6AJ5K11 1-14
GEN
Checking the steering system Checking the tilt system

1. Check the steering friction for proper 1. Set the tilt lock lever 1 to the release
adjustment. position a and fully tilt the outboard
motor up. Check that the outboard motor
tilts up smoothly and automatically locks
in 3 positions when it is tilted up.
a
b 1
S6AG1100
NOTE: a
9 To increase the friction, move the steering S6AG1250
lock lever in direction a.
9 To decrease the friction, move the steering
lock lever in direction b.
2. Check that the steering operates smooth-

ly.
å
S66T1060
S6AG1150
3. Check that there is no interference with
leads, cables, or hoses when the out-
board motor is steered.
1-15 6AJ5K11
Predelivery check
2. Set the tilt lock lever 1 to the lock posi- Checking the cooling water pilot
tion b, slightly tilt the outboard motor up, hole
and then fully tilt it down. Check that the 1. Place the lower unit in water, and then
1
outboard motor tilts down smoothly and start the engine.
automatically locks in the fully tilted down
position. 2. Check for water flow at the cooling water
pilot hole.
b
1
2
1 S6AG1260 3
3. Check that there is no interference with
leads, cables, or hoses when the tilted up
outboard motor is steered.
6AJ10040 4
NOTE:
Checking the engine shut-off switch
5
Make sure that the cooling water hoses are
1. Check that the engine turns off when the securely connected and that the flushing
engine shut-off switch is pushed. hose joint adapter 1 is not loose or dam-
aged.
Test run
1. Start the engine, and then check that the
6
gear shift operates smoothly.
S66T1080
2. Check the engine idle speed after the
engine has been warmed up. 7
2. Check that the engine turns off when the 3. Operate at trolling speed.
8
clip is pulled from the engine shut-off
switch. 4. Run the outboard motor for 1 hour at
2,000 r/min or at half throttle, then for
another hour at 3,000 r/min or at 3/4
throttle.
5. Check that the outboard motor does not

tilt up when shifting into reverse and that
water does not flow in over the transom.
9
NOTE:
S66T1090 The test run is part of the break-in operation.
6AJ5K11 1-16
GEN
Break-in Precaution when transporting or

During the test run, perform the break-in storing the outboard motor
operation in the following 3 stages. 1. Transport and store the outboard motor
1. 1 hour a at 2,000 r/min or at approxi- only as shown. Otherwise, engine dam-
mately half throttle. age could result from leaking oil.
2. 1 hour b at 3,000 r/min or 3/4 throttle

and 1 minute out of every 10 at full throt-
tle.
3. 8 hours c with the engine at any speed.

However, avoid operating at full throttle
for more than 5 minutes at a time.
6AJ10060
a b c
å 0 1 2 10
S69J1240
å Hour
After test run

1. Check for water in the gear oil.
2. Check for fuel leakage in the cowling.
3. Flush the cooling water passages with

fresh water using the flushing kit and with
the engine running at idle.
cC
Be sure to supply sufficient water and
water pressure when flushing the cooling
water passages. If sufficient water and
sufficient water pressure are not supplied,
the engine can overheat.
NOTE:
When using the flushing device (flushing
hose joint adapter), flush the cooling water
passages without starting the engine.
1-17 6AJ5K11
SPEC
Specification
General specification ................................................................................... 2-1
Maintenance specification .......................................................................... 2-3

Power unit ................................................................................................ 2-3
1
Fuel system ............................................................................................. 2-7
2
Lower unit ................................................................................................ 2-7
Electrical .................................................................................................. 2-8
Dimension .............................................................................................. 2-10
Tightening torque ....................................................................................... 2-12

Specified torque ..................................................................................... 2-12
General torque ....................................................................................... 2-14 3
4
5
6
7
8
9
6AJ5K11
SPEC
Specification
General specification
Model
Item Unit
F20CMH
Dimension
Overall length mm (in) 1,048 (41.3)
Overall width mm (in) 420 (16.5)
Overall height
(S) mm (in) 1,078 (42.4)
(L) mm (in) 1,205 (47.4)
Transom height
(S) mm (in) 438 (17.2)
(L) mm (in) 565 (22.2)
Boat transom height
(S) mm (in) 381 (15.0)
(L) mm (in) 508 (20.0)
Weight
(with aluminum propeller)
(S) kg (lb) 52.7 (116)
(L) kg (lb) 54.7 (120)
Performance
Maximum output kW (HP) 14.7 (20) at 5,500 r/min
Full throttle operating range r/min 5,000–6,000
Maximum fuel consumption L (US gal, 6.8 (1.8, 1.5) at 5,500 r/min
Imp gal)/hr
Engine idle speed r/min 1,050 ± 50
Power unit
Type 4-stroke L
Cylinder quantity 2
Total displacement cm3 (cu. in) 362 (22.1)
Bore × stroke mm (in) 63.0 × 58.1 (2.48 × 2.29)
Compression ratio 9.3
Control system Tiller handle
Starting system Manual
Fuel system Carburetor
Enrichment system Prime Start
Ignition control system CDI (micro computer)
Advanced type Micro computer
Ignition timing at 1,050 r/min TDC
Maximum generator output V, A 12, 10.0
Spark plug DPR6EB-9 (NGK)
Cooling system Water
Exhaust system Propeller boss
Lubrication system Wet sump
2-1 6AJ5K11
General specification
Model
Item Unit
F20CMH
Fuel and oil
Fuel type
Engine oil type
Engine oil grade (*1) API
SAE
Regular unleaded gasoline
4-stroke motor oil
SE, SF, SG, SH, SJ, or SL
5W-30, 10W-30, or 10W-40
1
Engine oil quantity
(without oil filter replacement)
(with oil filter replacement)

L (US qt,
Imp qt)
L (US qt,
Imp qt)
1.6 (1.69, 1.41)
1.8 (1.90, 1.58)

2
Gear oil type Hypoid gear oil
Gear oil grade
Gear oil quantity

(*2) API
SAE
cm3 (US oz,
Imp oz)
GL-4
90
300 (10.14, 10.58)
3
Bracket unit
Trim angle
(at 12° boat transom)
Tilt-up angle
Degree
Degree
0.0, 4.0, 8.0, 12.0
71
4
Steering angle Degree 45 + 45
5
Drive unit
Gear shift positions F-N-R
Gear ratio 2.08 (27/13)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type
Propeller direction (rear view)
Propeller mark
(*1)
Spline
Clockwise
J, J1 6
If the recommended engine oil grades are not available, use engine oil with an API classification of SH, SJ,
7
or SL and an SAE classification of 15W-40, 20W-40, or 20W-50.
(*2) Meeting both API and SAE requirements
8
9
6AJ5K11 2-2
SPEC
Specification
Maintenance specification
Power unit
Model
Item Unit
F20CMH
Power unit
Minimum compression kPa 730 (7.3, 105.9)
pressure (*1) (kgf/cm2, psi)
Oil pressure (*2) kPa 400 (4.0, 58.0) at 1,050 r/min
(kgf/cm2, psi)
Cylinder head
Warpage limit mm (in) 0.10 (0.0039)
(lines indicate straightedge

position)
Cylinder head journal inside mm (in) 22.000–22.021 (0.8661–0.8670)
diameter (A)
Cylinder head journal inside mm (in) 34.000–34.025 (1.3386–1.3396)
diameter (B)
A
B
Camshaft
Intake (A) mm (in) 28.546–28.646 (1.1239–1.1278)
Exhaust (A) mm (in) 28.582–28.682 (1.1253–1.1292)
Intake and mm (in) 23.95–24.05 (0.9429–0.9468)
exhaust (B)
(*1) Measuring conditions:
Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs removed from all cylinders. Since
this outboard motor is equipped with an automatic decompression mechanism, the compression pressure
may vary depending on the speed at which the starter handle is pulled when using the manual starter to
crank the engine.
The figures are for reference only.
(*2) For details of the checking method, see “Checking the oil pressure” (5-1).
2-3 6AJ5K11
Model
Item Unit
F20CMH
Camshaft journal diameter (C) mm (in) 21.967–21.980 (0.8648–0.8654)
Camshaft journal diameter (D)
C
mm (in) 33.935–33.955 (1.3360–1.3368)
1
D
Camshaft runout limit

Rocker arm shaft
mm (in) 0.03 (0.0012)
2
Outside diameter mm (in) 12.941–12.951 (0.5095–0.5099)
Rocker arm
Inside diameter
Valve
Valve clearance (cold)
mm (in) 13.000–13.018 (0.5118–0.5125) 3
Intake mm (in) 0.15–0.25 (0.006–0.010)
Exhaust
Head diameter (A)
Intake
mm (in)
mm (in)
0.25–0.35 (0.010–0.014)
27.9–28.1 (1.10–1.11)
4
Exhaust mm (in) 24.0–24.2 (0.94–0.95)
5
Face width (B)
Intake mm (in) 1.98–2.40 (0.0780–0.0945)
Exhaust mm (in) 1.98–3.11 (0.0780–0.1224)
Seat contact width (C)
Intake and exhaust mm (in) 1.2–1.6 (0.047–0.063)
Margin thickness (D)
Intake
Exhaust
Stem diameter
mm (in)
mm (in)
0.8–1.2 (0.0315–0.0472)
1.0–1.4 (0.0394–0.0551) 6
Intake mm (in) 5.475–5.490 (0.2156–0.2161)
Exhaust
Stem runout limit
Guide inside diameter
Intake and exhaust
mm (in)
mm (in)
mm (in)
5.460–5.475 (0.2150–0.2156)
0.01 (0.0004)
5.500–5.512 (0.2165–0.2170)
7
Stem-to-guide clearance
Intake
Exhaust
Guide installation position
Intake and exhaust
mm (in)
mm (in)
mm (in)
0.010–0.037 (0.0004–0.0015)
0.025–0.052 (0.0010–0.0020)
10.8 ± 0.2 (0.4 ± 0.01)

8
Valve spring
Free length
Tilt limit
mm (in)
mm (in)
32.63 (1.2846)
1.4 (0.055) 9
6AJ5K11 2-4
SPEC
Specification
Model
Item Unit
F20CMH
Cylinder
Bore size mm (in) 63.000–63.015 (2.4803–2.4809)
Piston
Piston diameter (D) mm (in) 62.950–62.965 (2.4783–2.4789)
Measuring point (H) mm (in) 3.5 (0.14)
Piston clearance (*1) mm (in) 0.035–0.065 (0.0014–0.0026)
Piston pin boss bore mm (in) 16.004–16.015 (0.6301–0.6305)
Oversize piston diameter
1st mm (in) 63.200–63.215 (2.4882–2.4888)
2nd mm (in) 63.450–63.465 (2.4980–2.4986)
Piston ring groove
Top ring mm (in) 1.21–1.23 (0.0476–0.0484)
2nd ring mm (in) 1.21–1.23 (0.0476–0.0484)
Oil ring mm (in) 2.51–2.53 (0.0988–0.0996)
Piston pin
Outside diameter mm (in) 15.995–16.000 (0.6297–0.6299)
Piston ring
Top ring Barrel
Dimension B mm (in) 1.17–1.19 (0.0461–0.0469)
Dimension T mm (in) 2.25–2.45 (0.0886–0.0965)
End gap (*1) mm (in) 0.15–0.30 (0.0059–0.0118)
Side clearance mm (in) 0.02–0.06 (0.0008–0.0024)
2nd ring Taper
Dimension B mm (in) 1.17–1.19 (0.0461–0.0469)
Dimension T mm (in) 2.4–2.6 (0.0945–0.1024)
End gap (*1) mm (in) 0.25–0.4 (0.0098–0.0157)
Oil ring
Dimension B mm (in) 2.34–2.46 (0.0921–0.0969)
Dimension T (*1) mm (in) 2.75 (0.1083)
End gap (*1) mm (in) 0.2–0.7 (0.0079–0.0276)
Connecting rod
Small end inside diameter mm (in) 16.015–16.029 (0.6305–0.6311)
Big end inside diameter mm (in) 34.030–34.042 (1.3398–1.3402)
Big end side clearance (*1) mm (in) 0.05–0.22 (0.0020–0.0087)
Crankpin oil clearance (*1) mm (in) 0.021–0.045 (0.0008–0.0018)
(*1) The figures are for reference only.
2-5 6AJ5K11
Model
Item Unit
F20CMH
Crankshaft
Crankshaft journal diameter
Crankpin diameter
Crankpin width
Crankshaft run-out limit
mm
mm
mm
mm
(in)
(in)
(in)
(in)
36.997–37.009 (1.4566–1.4570)
33.997–34.009 (1.3385–1.3389)
21.000–21.070 (0.8268–0.8295)
0.05 (0.0020)
1
Crankcase
Crankshaft journal oil
clearance (*1)
Upper and lower crankcase
main journal bearing thickness
mm(in) 0.011–0.039 (0.0004–0.0015)
2
A - (Blue) mm (in) 1.502–1.506 (0.0591–0.0593)
B - (Black)
C - (Brown)
Oil pump
mm (in)
mm (in)
1.498–1.502 (0.0590–0.0591)
1.494–1.498 (0.0588–0.0590) 3
Type Trochoid
4
Outer rotor-to-housing mm (in) 0.09–0.15 (0.0035–0.0059)
clearance
Outer rotor-to-inner rotor mm (in) Within 0.12 (0.0047)
clearance
Rotor-to-cover clearance mm (in) 0.03–0.08 (0.0012–0.0031)
Relief valve opening pressure
Thermostat
Opening temperature
kPa
(kgf/cm2, psi)
350–450 (3.5–4.5, 49.8–64.0)
5
at 0.05 mm (0.0020 in) °C (°F) 58–62 (136–144)
Fully open temperature
Valve open lower limit
Manual starter
Starter rope length
°C (°F)
mm (in)
mm (in)
70 (158)
3.0 (0.12)
1,800 (70.9)
6
Starter rope pulling length mm (in) 1,400–1,600 (55.12–62.99)
7
8
9
6AJ5K11 2-6
SPEC
Specification
Fuel system
Model
Item Unit
F20CMH
Carburetor
ID mark 6AH20
Float height mm (in) 15.0 ± 1.0 (0.60 ± 0.04)
Valve seat size mm (in) 1.0 (0.04)
Main jet (M.J.) #118
Main nozzle (M.N.) mm (in) 2.4 (0.09)
Pilot jet (P.J.) #45
Pilot screw (P.S.) turns out 2 3/4 ± 1/2
Idle speed r/min 1,050 ± 50
Fuel pump
Fuel pump holding pressure
Fuel inlet positive pressure kPa 50 (0.5, 7.3)
(kgf/cm2, psi)
Fuel inlet negative pressure kPa 30 (0.3, 4.4)
(kgf/cm2, psi)
Fuel outlet positive pressure kPa 50 (0.5, 7.3)
(kgf/cm2, psi)
Fuel joint holding pressure
Positive pressure kPa 50 (0.5, 7.3)
(kgf/cm2, psi)
Fuel filter assembly holding
pressure
Positive pressure kPa 200 (2.0, 29.0)
(kgf/cm2, psi)
Lower unit
Model
Item Unit
F20CMH
Lower unit
Holding pressure kPa 100 (1.0, 14)
(kgf/cm2, psi)
Gear backlash
Pinion-to-forward gear mm (in) 0.18–0.87 (0.0071–0.0343)
Pinion-to-reverse gear mm (in) 0.95–1.66 (0.0374–0.0654)
Pinion shims mm 1.13, 1.20
Forward gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Reverse gear shims mm 0.1, 0.2, 0.3, 0.4, 0.5
Propeller shaft
Runout limit mm (in) 0.05 (0.0020)
Drive shaft
Runout limit mm (in) 1.0 (0.0394)
2-7 6AJ5K11
Electrical
Model
Item Unit
F20CMH
Ignition and ignition control
system
Spark plug gap
Spark plug cap resistance
mm (in)
kΩ
0.8–0.9 (0.031–0.035)
3.75–6.25
1
Ignition coil resistance
Primary coil
at 20 °C (68 °F)
Secondary coil
(O – B)
(spark plug wire –

Ω 0.26–0.35 2
spark plug wire)
at 20 °C (68 °F)
Pulser coil output peak voltage
(W/R – B)
kΩ 6.8–10.2
3
at cranking (unloaded) V 5.1
4
at cranking (loaded) V 2.6
at 1,500 r/min (loaded) V 5.3
Pulser coil resistance (*1)
(W/R – B)
at 20 °C (68 °F)
Pulser coil air gap
Charge coil output peak
voltage (B/R – G/R)
Ω
mm (in)
152–228
0.35–1.35 (0.0138–0.0531)
5
at cranking (unloaded) V 60
at cranking (loaded)
at 1,500 r/min (loaded)
Charge coil resistance (*1)
V
V
V
140
150
150
6
(B/R – G/R)
at 20 °C (68 °F)
CDI unit output peak voltage
at cranking (loaded)
(O – B)
Ω
V
25.5–34.5
130
7
at 1,500 r/min (loaded) V 140
(*1)
V 140
8
9
6AJ5K11 2-8
SPEC
Specification
Model
Item Unit
F20CMH
Thermoswitch
ON temperature °C (°F) 76–84 (169–183)
OFF temperature °C (°F) 63–77 (145–171)
Oil pressure switch
Specified oil pressure kPa 29.4–68.6 (0.294–0.686, 4.263–9.947)
(kgf/cm2, psi)
Fuel control system
Prime Start resistance (*1)
(L – L)
at 24 °C (75 °F) Ω 16.4–24.8
Prime Start plunger length (*1)
at 24 °C (75 °F) mm (in) 10.7 (0.42)
Starting system
Power bobbin output peak
voltage (L – L)
at 1,500 r/min (unloaded) V 27.8
at cranking (loaded) V 9.5
Power bobbin resistance (*2)
(L – L)
at 20 °C (68 °F) Ω 0.77–1.04
Charging system
Lighting coil output peak
voltage (G – G)
Lighting coil resistance (*2)
(G – G)
at 20 °C (68 °F) Ω 0.31–0.43
(*1) Ambient temperature 24 °C (75 °F), with no power supplied.
2-9 6AJ5K11
Dimension
Exterior F20CMH
mm (in)
1
2
341 (13.4)
45˚
210 (8.3) 210 (8.3)
3
176 (6.9)
598 (23.5)
4
559 (22.0) S: 730 (28.7)
L: 847 (33.3)
5
381 (15.0)
219 (8.6) 489 (19.3)
66 (2.6)
6
570 (22.4)
580 (22.8)
399 (15.7)
377 (14.8)
7
37 (1.5)
44 (1.7)
S: 438 (17.2)
133 (5.2) L: 565 (22.2)
237 (9.3)
S: 701 (27.6)
L: 828 (32.6)
8
S: 616 (24.3)
L: 694 (27.3)
S: 64
L: 82 (2.5)
(3.2)
12˚ 71˚
9
19 (0.7)
S: 9 (0.4) –4˚
L: 18 (0.7) 387 (15.2)
S6AG2010
6AJ5K11 2-10
SPEC
Specification
Clamp bracket F20CMH
mm (in)
70.5 (2.8) 70.5 (2.8)

76.5 (3.0)
8.3 (0.3)
48 (1.9)
187.5 (7.4)
18 (0.7)
67 (2.6)
95.3 (3.8) 95.3 (3.8)
32 (1.3)
110 (4.3)
S6AG2050
2-11 6AJ5K11
Maintenance specification / Tightening torque
Tightening torque
Specified torque
Tightening torques
Part to be tightened Thread size
Fuel system
Fuel filter cup
Fuel filter assembly bracket bolt
—
M8
N·m
2.5
18
kgf·m
0.25
1.8
ft·lb
1.84
13.3
1
Fuel joint bolt M6 8 0.8 5.9
Fuel pump screw
Fuel pump valve screw
Throttle link stopper screw
—
—
—
2
0.5
1.3
0.2
0.05
0.13
1.5
0.37
0.94
2
Power unit
Manual starter bolt
Drive plate screw
Manual starter drain cover screw
1st
M6
—
—
8
5.4
1.5
27
0.8
0.54
0.15
2.7
5.9
3.9
1.11
19.9
3
Power unit mounting bolt M8
2nd 27 2.7 19.9
Apron screw
Ground lead bolt
Ignition coil bolt
—
M6
M6
2.5
8
7
0.25
0.8
0.7
1.84
5.9
5.2
4
Spark plug — 17 1.7 12.5
5
Pulser coil bolt M5 4 0.4 3.0
CDI unit bracket bolt M6 8 0.8 5.9
CDI unit M6 8 0.8 5.9
Junction box bolt M6 8 0.8 5.9
Stator coil assembly bolt M6 8 0.8 5.9
Holder bracket bolt
Thermoswitch bolt
Holder bracket bolt
Oil pressure switch
M6
M6
M6
—
8
8
8
8
0.8
0.8
0.8
0.8
5.9
5.9
5.9
5.9
6
Oil pressure switch lead bolt M4 2 0.2 1.5
Wiring harness bracket bolt
Throttle cam bracket bolt
Throttle cam bolt
M8
M6
M6
18
8
8
1.8
0.8
0.8
13.3
5.9
5.9
7
Throttle cable bracket bolt M6 8 0.8 5.9
Flywheel magnet nut
Drive sprocket nut
Driven sprocket bolt
Intake manifold bolt
—
—
M8
M6
108
110
22
8
10.8
11.0
2.2
0.8
79.7
81.1
16.2
5.9
8
Cylinder head cover bolt M6 8 0.8 5.9
Blowby plate screw
1st
2nd
—
M6
2
6
12
0.2
0.6
1.2
1.5
4.4
8.9
9
Cylinder head bolt 1st 15 1.5 11.1
2nd M9 29 2.9 21.4
3rd 60°
6AJ5K11 2-12
SPEC
Specification
Tightening torques
N·m kgf·m ft·lb
Anode plug — 18 1.8 13.3
Rocker arm locknut — 14 1.4 10.3
Oil pump screw — 5 0.5 3.7
Anode screw — 2 0.2 1.5
Thermostat cover bolt M6 8 0.8 5.9
Oil filter — 18 1.8 13.3
1st 6 0.6 4.4
Exhaust cover bolt M6
2nd 12 1.2 8.9
1st 6 0.6 4.4
M6
2nd 12 1.2 8.9
Crankcase bolt
1st 14 1.4 10.3
M8
2nd 27 2.7 19.9
1st 6 0.6 4.4
Connecting rod cap bolt M6
2nd 12 1.2 8.9
Lower unit
Gear oil drain screw — 9 0.9 6.6
Gear oil check screw — 9 0.9 6.6
Lower case mounting bolt M8 18 1.8 13.3
Propeller nut — 17 1.7 12.5
Cooling water inlet cover screw — 5 0.5 3.7
Anode bolt M6 8 0.8 5.9
Trim tab bolt M6 8 0.8 5.9
Water pump housing bolt M8 18 1.8 13.3
Propeller shaft housing bolt M6 8 0.8 5.9
Pinion nut — 25 2.5 18.4
Bracket unit
Steering bracket cover screw — 4 0.4 3.0
Grommet screw — 2 0.2 1.5
Throttle cable holder bolt M6 8 0.8 5.9
Shift lever bolt M6 8 0.8 5.9
Tiller handle bracket cover bolt M6 8 0.8 5.9
Throttle shaft holder bolt M6 8 0.8 5.9
Throttle grip screw — 3 0.3 2.2
Engine shut-off switch nut — 2 0.2 1.5
Friction plate bolt M5 7 0.7 5.2
Friction plate bolt M8 18 1.8 13.3
Friction self-locking nut — 6 0.6 4.4
Flushing hose adapter screw — 2 0.2 1.5
Upper mounting nut — 40 4.0 29.5
1st 15 1.5 11.1
Mount housing nut 2nd — 28 2.8 20.7
3rd 32 3.2 23.6
Plate bolt M6 8 0.8 5.9
2-
2-13 6AJ5K11
Tightening torque
Tightening torques
N·m kgf·m ft·lb
Upper mount bolt M8 30 3.0 22.1
Engine oil drain bolt
Oil pan bolt
Exhaust manifold bolt
Oil pan assembly bolt
M14
M8
M6
M8
27
18
8
18
2.7
1.8
0.8
1.8
19.9
13.3
5.9
13.3
1
Oil strainer bolt M6 8 0.8 5.9
Self-locking nut
Tilt stopper plate bolt
Grease nipple
—
—
—
19
8
3
1.9
0.8
0.3
14.0
5.9
2.2
2
General torque
This chart specifies tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifications
3
for special components or assemblies are
provided in applicable sections of this manu-
al. To avoid warpage, tighten multi-fastener
assemblies in a crisscross fashion and pro-
gressive stages until the specified torque is
4
reached. Unless otherwise specified, torque
specifications require clean, dry threads.
Components should be at room temperature.
General torque
5
Nut (A) Bolt (B) specifications
8 mm
10 mm
12 mm
M5
M6
M8
N·m kgf·m ft·lb
5
8
18
0.5
0.8
1.8 13.3
3.7
5.9
6
14 mm M10 36 3.6 26.6
17 mm M12 43 4.3 31.7
7
8
S69J2150
9
6AJ5K11 2-14
SPEC
Specification
— MEMO —
2-15 6AJ5K11
CHK
ADJ
Periodic check and adjustment
Maintenance interval chart .......................................................................... 3-1
Top cowling .................................................................................................. 3-3

Checking the top cowling ......................................................................... 3-3
1
Fuel system .................................................................................................. 3-3
Checking the fuel joint and fuel hose (fuel joint-to-carburetor) ............... 3-3
Checking the fuel filter ............................................................................. 3-4
Draining the fuel ...................................................................................... 3-4
2
Power unit .....................................................................................................
Checking the engine oil ...........................................................................
Changing the engine oil ...........................................................................
Replacing the oil filter ..............................................................................
3-4
3-4
3-4
3-5
3
Checking the timing belt .......................................................................... 3-6
Checking the spark plug ..........................................................................
Checking the thermostat .........................................................................
Checking the cooling water passage .......................................................
3-6
3-7
3-8
4
Control system ............................................................................................. 3-8
Adjusting the throttle cable ...................................................................... 3-8
Adjusting the throttle link ......................................................................... 3-9
Checking the gear shift operation ............................................................ 3-9
5
Checking the start-in-gear protection .................................................... 3-10
Checking the engine idle speed ............................................................ 3-10
Checking the ignition timing .................................................................. 3-11
Bracket unit ................................................................................................ 3-12

6
Checking the steering operation ............................................................ 3-12
Checking the tilt operation ..................................................................... 3-12
Lower unit ................................................................................................... 3-12

7
Checking the gear oil ............................................................................. 3-12
Changing the gear oil ............................................................................
Checking the lower unit for air leakage .................................................
Checking the propeller ...........................................................................
3-13
3-14
3-14 8
General ........................................................................................................ 3-14
Checking the anode ............................................................................... 3-14
Lubricating the outboard motor ............................................................. 3-15 9
6AJ5K11
CHK
ADJ Periodic check and adjustment
Maintenance interval chart

Use the following chart as a guideline for general maintenance.
Adjust the maintenance intervals according to the operating conditions of the outboard motor.
Initial Every
Refer to
Item Remarks 20 hours 100 hours 300 hours 500 hours page
(3 months) (1 year) (3 years) (5 years)
Anode(s) (external) Check/replace 1 3-14
Anode(s) (cylinder head,
Check/replace 1 3-14
thermostat cover)
Anode(s) (exhaust cover,
Replace 1 3-14
cover joint)
Cooling water leakage Check/replace 1 1 3-8
Cowling clamp Check 1 3-3
Engine starting condition/
Check 1 1 –
noise
Engine idle speed/noise Check 1 1 3-10
Engine oil Change 1 1 3-4
Engine oil filter (cartridge) Replace 1 3-5
Fuel filter Check/replace 1 1 3-4
Fuel pump Check/replace 1 4-6
Fuel/oil leakage 3-3
Check 1 1
5-1
Fuel hose Check/replace 1 1 3-3
Fuel hose Replace 1 4-1
Gear oil Change 1 1 3-13
Lubrication points Lubricate 1 1 3-15
Impeller/water pump housing Check/replace 1 6-5
Impeller/water pump housing Replace 1 6-5
Propeller/propeller nut/
Check/replace 1 1 3-14
cotter pin
Shift link/shift cable Check/adjust/ 3-8
1 1
replace 3-9
Spark plugs Check/adjust/
1 3-6
replace
Spark plug caps/
Check/replace 1 1 8-8
spark plug wires
Pilot water Check 1 1 3-8
Throttle link/throttle cable/ Check/adjust/ 3-8
1 1
throttle pick-up timing replace 3-9
Thermostat Check/replace 1 3-7
Timing belt Check/replace 1 3-6
Valve clearance Check/adjust 1 5-2
Water inlet Check 1 1 3-8
Engine shut-off switch Check/replace 1 1 8-10
Wiring harness connections/
Check/replace 1 1 8-1 to 8-6
lead coupler connections
(Yamaha) Fuel tank Check/clean 1 —
3-1 6AJ5K11
Maintenance interval chart
NOTE:
When operating in muddy, turbid, or salt water, the engine should be flushed with clean water after
each use.
Item Remarks
Every
1000 hours
Refer to
page
1
Exhaust guide/
Check/replace 1 7-16
exhaust manifold
Timing belt Replace 1 5-3
2
3
4
5
6
7
8
9
6AJ5K11 3-2
CHK
Top cowling
Checking the top cowling
1. Check the fitting by pushing the cowling
with both hands. Adjust if necessary.
S6AG3010
2. Loosen the bolts 1.

S6AG3030
3. Move the hook 2 up or down slightly to
adjust its position.
Fuel system
a Checking the fuel joint and fuel
2 hose (fuel joint-to-carburetor)
1. Check the fuel hose connections for
leaks. Also, check the fuel joint 1, fuel
hoses, fuel filter 2, fuel pump 3, and
carburetor 4. Replace if there is leakage
b 1 or deterioration.
S6AG3020
4 2
NOTE:
9 To tighten the fitting, move the hook 2 in
direction a. 1
9 To loosen the fitting, move the hook 2 in
direction b. 3
4. Tighten the bolts 1. S6AG3040
5. Check the fitting again and, if necessary,

repeat steps 2–4.
6. Check the air intake duct. Clean if there

are obstructions.
3-3 6AJ5K11
Top cowling / Fuel system / Power unit
Checking the fuel filter 2. Remove the oil dipstick, wipe it clean,
1. Check the fuel filter element 1. Clean if and then completely insert it back into the
there is dirt or residue and replace if oil dipstick hole.
damaged.
2. Check the fuel filter cup 2. Clean with

straight gasoline if there are foreign sub-
3. Remove the oil dipstick again to check
the oil level and to check the oil for dis-
coloration and its viscosity.
1
stances and replace if cracked.
1
b
2
a
S6AG3050
S6AG1050
3
NOTE:
NOTE:
Be sure not to spill any fuel when removing
the fuel filter cup.
9 If the oil appears milky or dirty, check for
and repair the cause, and then change the
oil.
4
9 If the engine oil is below the minimum level
mark a, add sufficient oil until the level is
Fuel filter cup 2:
2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
between a and b.
5
Changing the engine oil
6
Draining the fuel
1. Start the engine, warm it up, and then
1. Place a container 1 or rag under the car-
turn it off.
buretor fuel drain hole, and then remove
the fuel drain screw 2 and let the fuel
2. Remove the oil dipstick and oil filler cap
drain completely.
1.
2
7
1 8
1 S6AG3060
S6AG3070
Power unit
Checking the engine oil
9
1. Place the outboard motor in an upright
position.
6AJ5K11 3-4
CHK
3. Place a drain pan under the drain hole, Replacing the oil filter
and then remove the engine oil drain bolt 1. Drain the engine oil or use an oil changer
2 and let the oil drain completely. to extract it.
2. Place a rag under the oil filter, and then

remove the oil filter using a 64 mm (2.5
2 in) oil filter wrench 1.
6AJ30010
NOTE:
9 Be sure to clean up any oil spills.
9 When using an oil changer to change the 6AJ30020
engine oil, insert the oil changer hose into

the oil dipstick hole. NOTE:
9 Wait more than 5 minutes after turning the
engine off to replace the oil filter.
4. Install a new gasket and engine oil drain 9 Be sure to clean up any oil spills.
bolt 2, and then tighten it to the specified
torque.
Oil filter wrench 1: 90890-01426
Engine oil drain bolt 2:
27 N·m (2.7 kgf·m, 19.9 ft·lb)
3. Apply a thin coat of engine oil to the O-
5. Pour the specified amount of the recom- ring of the new oil filter.
mended engine oil into the oil filler hole.
4. Install the oil filter, and then tighten it to
Recommended engine oil: the specified torque using a 64 mm (2.5
4-stroke motor oil in) oil filter wrench.
SAE: 5W-30, 10W-30, or 10W-40
Without oil filter replacement:
1.6 L (1.69 US qt, 1.41 Imp qt)
6. Install the oil filler cap and oil dipstick,

and then start the engine and warm it up.
E 6AJ30030
7. Turn the engine off, wait a few minutes,
and then check the oil level and that there
is no oil leakage. If the oil level is low, add Oil filter:
engine oil to the correct level. 18 N·m (1.8 kgf·m, 13.3 ft·lb)
3-5 6AJ5K11
Power unit
5. Pour the specified amount of the recom- Checking the spark plug
mended engine oil into the oil filler hole. 1. Disconnect the spark plug caps and
remove the spark plugs.
Recommended engine oil:
4-stroke motor oil
SAE: 5W-30, 10W-30, or 10W-40
2. Clean the electrodes 1 with a spark plug
cleaner or wire brush. 1
With oil filter replacement:
1.8 L (1.90 US qt, 1.58 Imp qt)
6. Install the oil filler cap and oil dipstick,

2
and then start the engine and warm it up.
7. Turn the engine off, wait a few minutes,

and then check the oil level and that there
is no oil leakage. If the oil level is low, add
S69J3190 3
engine oil to the correct level. 3. Check the spark plug. Replace if the elec-
Checking the timing belt

trodes are eroded or there is excessive
carbon or other deposits, or if the gasket
is damaged.
4
cC 4. Check the spark plug gap a. Replace the
Do not turn the flywheel magnet counter-
clockwise, otherwise the water pump
impeller may be damaged.
spark plug if out of specification.
5
1. Remove the sprocket cover and manual
starter.
2. While turning the flywheel magnet clock-

6
wise, check the interior a and the exteri-
or b of the timing belt. Replace the tim-
ing belt if cracked, damaged, or worn.
NOTE:
Repeat steps 2–4 for each spark plug.
S69J3200
7
a Specified spark plug:
DPR6EB-9 (NGK)
Spark plug gap a:
8
0.8–0.9 mm (0.031–0.035 in)
NOTE:
b
S6AG3110 5. Install the spark plugs, tighten them tem-
porarily, and then tighten them to the
specified torque using a spark plug
9
To replace the timing belt, see “Replacing the wrench.
timing belt” (5-3).
Spark plug:
17 N·m (1.7 kgf·m, 12.5 ft·lb)
6AJ5K11 3-6
CHK
6. Connect the spark plug caps. 6. Measure the thermostat valve opening a
at the specified water temperatures.
Replace the thermostat if out of specifi-
Checking the thermostat cation.
starter.
2. Remove the thermoswitch 1 and discon-

nect the cooling water hose 2.
3. Remove the thermostat cover 3 and

thermostat 4.
S6AL3100
Water
3 Valve opening a
temperature
1
0.05 mm
5 58–62 °C (0.0020 in)
4
2 (136–144°F) (valve begins to
open)
6AJ30040
above more than
cC 70 °C (158 °F) 3.0 mm (0.12 in)
Do not reuse the gasket 5, always replace
it with a new one. 7. Install a new gasket, thermostat, and
thermostat cover, and then tighten the
thermostat cover bolts to the specified
NOTE: torque.
It is recommended to check the thermostat
cover anode before installing the thermostat Thermostat cover bolt:
cover. 8 N·m (0.8 kgf·m, 5.9 ft·lb)
8. Connect the cooling water hose and

4. Suspend the thermostat in a container of
install the thermoswitch.
water.
Thermoswitch bolt:
5. Place a thermometer in the water and 8 N·m (0.8 kgf·m, 5.9 ft·lb)
slowly heat the water.
9. Install the manual starter and sprocket
cover.
Manual starter bolt:

8 N·m (0.8 kgf·m, 5.9 ft·lb)
S69J5E40
3-7 6AJ5K11
Power unit / Control system
Checking the cooling water passage Control system

1. Check the cooling water inlet covers 1 Adjusting the throttle cable
and cooling water inlets. Clean if clogged. 1. Disconnect the throttle link rod 1 from
1
the free accel lever.
1
2. Loosen the locknuts 2 and 3, and then
1 turn the adjusting nuts 4 and 5 to
loosen the throttle cables 6 and 7.
6AJ30050
1 6 2 4
2
3
7 3 5 S6AG3300J
3. Turn the throttle grip to the fully open

position and hold it in place.
4
S6AG3170
4. Turn the adjusting nut 5 so that the fully
2. Place the lower unit in water, and then

start the engine.
open stopper a on the throttle cam con-
tacts the throttle cam bracket as shown,
and then tighten the locknut 3.
5
NOTE:
3. Check for water flow at the cooling water
pilot hole. If there is no water flow, check
the cooling water passages inside the
outboard motor.
Be careful not to pull the outer cables too
much towards the power unit as they could be
pulled out of the tiller handle grommet. If the
outer cables are pulled out of the grommet,
6
see “Assembling the tiller handle” (7-3).
5. Turn the adjusting nut 4 to remove the

slack in the throttle cable 6, and then
7
tighten the locknut 2.
6
2
4 8
6AJ10045
a
3
5 9
S6AG3330J
6AJ5K11 3-8
CHK
6. Turn the throttle grip to the fully open and 2. Turn the throttle grip to the fully open
fully closed positions and check that the position and hold it in place. Check that
fully open stopper a and fully closed the fully open stopper 2 on the throttle
stopper b on the throttle cam contact cam contacts the throttle cam bracket a.
throttle cam bracket as shown. Repeat
NOTE:
steps 2–5 if necessary.
If the fully open stopper 2 does not contact
å the throttle cam bracket a, adjust the throttle
cables. See “Adjusting the throttle cable” (3-
a 8).
3. Turn the carburetor throttle lever 3 clock-

wise so that it contacts the carburetor
body b as shown.
∫ 4. Turn the free accel lever 4 clockwise

until it contacts the throttle cam c.
5. Tighten the throttle link stopper screw 1.

b Throttle link stopper screw 1:
1.3 N·m (0.13 kgf·m, 0.94 ft·lb)
6AJ30060
6. Turn the throttle grip to the fully open and
å Fully open position
fully closed positions and check that the
∫ Fully closed position
throttle cam operates smoothly.
NOTE:
7. Connect the throttle link rod 1 to the free
After adjusting the throttle link, adjust the
accel lever. engine idle speed. See “Checking the engine
NOTE: idle speed” (3-10).
After adjusting the throttle cables, adjust the
throttle link.
Checking the gear shift operation
1. Check that the gear shift operates
Adjusting the throttle link smoothly when the shift lever is shifted
1. Loosen the throttle link stopper screw 1. from the neutral position to forward or
reverse. Adjust the shift rod adjusting nut
1 3
1 if necessary.
b
4 c
2 R
a N
S6AG3350J
F S6AG1140
3-9 6AJ5K11
Control system
1. Set the shift lever to the forward or

reverse position, and then check that the
starter handle cannot be pulled. If the
1
starter rope can be pulled out normally,
adjust the start-in-gear protection cable.
1
2. Set the shift lever to the neutral position
and loosen the locknut 1. Align the cable
NOTE:
S6AG3471
To adjust the shift rod adjusting nut 1, see

end a with the mark b on the manual
starter cover by turning the adjusting nut
2. 2
“Installing the lower unit” (6-17). 3. Tighten the locknut 1.
2. Turn the throttle grip to the fully closed

position so that the throttle cam is in posi-
a
3
tion a, and then check that the shift stop-
per 2 is pulled in to position b and that
the shift lever can be operated. Next, turn
the throttle grip to the fully open position
so that the throttle cam is in position c,
b
4
and then check that the shift stopper 2 is
pushed out to position d and that the
shift lever cannot be operated.
c a
N 2
5
bd
1 S6AG3140
6
2
S6AG3460 Checking the engine idle speed
1. Start the engine and warm it up for 10
minutes.
7
NOTE:
Checking the start-in-gear
protection
cC
Be sure to remove the clip from the engine
Because the Prime Start operates when the
engine is started, the engine idle speed will
be above specification. Therefore, check and
adjust the engine idle speed after the engine
8
shut-off switch before checking the start- has been warmed up.
in-gear protection.
9
6AJ5K11 3-10
CHK
2. Attach the special service tool to spark Checking the ignition timing
plug wire #1 1, and then check the 1. Start the engine and warm it up for 10
engine idle speed. Adjust if out of specifi- minutes.
cation. NOTE:
be above specification. Therefore, check and
1 adjust the engine idle speed after the engine
has been warmed up.
2. Attach the special service tool to spark

6AJ30070 plug wire #1.
Digital tachometer: 90890-06760
Engine idle speed: 1,050 ± 50 r/min
3. Turn the throttle stop screw 2 in direction 6AJ30080

a or b until the specified engine idle
speed is obtained.
Timing light: 90890-03141
3. Check that the pointer a is aligned with

2
the “T” mark on the flywheel magnet as
shown.
b a
S6AG3160
5 T
NOTE:
9 To increase the engine idle speed, turn the a
throttle stop screw 2 in direction a.
9 To decrease the engine idle speed, turn the
throttle stop screw 2 in direction b. S6AG3190
4. After adjusting the engine idle speed, rev Ignition timing at 1,050 r/min: TDC
the engine a few times and let it idle to
check the stability of the engine.
3-11 6AJ5K11
Control system / Bracket unit / Lower unit
Bracket unit Checking the tilt operation

Checking the steering operation 1. Fully tilt the outboard motor up and down
a few times and check the entire tilt range
NOTE:
for smooth operation. Check the tilt
Lubricate the swivel bracket before checking
the steering operation.
mechanism if necessary.
NOTE:
To check the tilt operation, see “Checking the
1
1. Move the steering lock lever 1 to posi- tilt system (1-15).
tion a and check that the steering is
locked.
Move the steering lock lever 1 to posi-
tion b and check that the steering oper- Lower unit
2
ates smoothly. Checking the gear oil
1. Fully tilt the outboard motor down.
2. Remove the gear oil check screw 1, and

then check the gear oil level in the lower
3
case. Also, check the oil for discoloration
b
a
1
and its viscosity.
1
4
6AJ30090
2. Adjust the self-locking nut 2 until steer-

ing operation is properly.
5
2 NOTE:
6AJ10015
9 If the oil is at the correct level, a small

6
amount of oil should overflow out of the
S6AG3430
check hole when the gear oil check screw is
removed.
9 If the oil appears milky or dirty, check for
and repair the cause, and then change the
7
NOTE: oil.
9 Tighten or loosen the self-locking nut 2 at
the steering lock lever in the position a.
9 To increase the friction, tighten the self-
locking nut 2.
9 If necessary, add sufficient gear oil of the
recommended type until it overflows out of
the check hole.
8
9 To decrease the friction, loosen the self-
locking nut 2.
9 If it is necessary to disassemble the friction
plate, see “Disassembling the friction
plate”(7-6).
Recommended gear oil:
Hypoid gear oil
API: GL-4
SAE: 90
9
6AJ5K11 3-12
CHK
3. Install a new gasket and the gear oil

check screw 1, and then tighten the gear
oil check screw to the specified torque.
Gear oil check screw 1:

9 N·m (0.9 kgf·m, 6.6 ft·lb)
Changing the gear oil

1. Tilt the outboard motor so that the gear
oil drain hole is at the lowest point possi-
ble
6AJ30100
2. Place a drain pan under the gear oil drain

hole, remove the gear oil drain screw 1, Recommended gear oil:
then the gear oil check screw 2, and let Hypoid gear oil
the oil drain completely. API: GL-4
SAE: 90
Gear oil quantity:
300 cm3
2 (10.14 US oz, 10.58 Imp oz)
5. Install new gaskets and gear oil check

1 screw 2, and quickly install the gear oil
drain screw 1, and then tighten them to
the specified torque.
Gear oil check screw 2:

9 N·m (0.9 kgf·m, 6.6 ft·lb)
69D30140 Gear oil drain screw 1:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
3. Check the oil for metal, discoloration, and

its viscosity. Check the internal parts of
the lower unit if necessary.
4. Insert a gear oil pump or gear oil tube

into the drain hole and slowly fill with gear
oil until oil flows out of the check hole and
no air bubbles are visible.
3-13 6AJ5K11
Lower unit / General
Checking the lower unit for air NOTE:

leakage When replacing the propeller, see “Propeller
1. Remove the gear oil check screw 1, and selection” (1-12) and select a propeller of the
same size as originally installed.
1
then install the special service tool.
2. Apply the specified pressure to check

that the pressure is maintained in the
lower unit for at least 10 seconds.
General
Checking the anode
1. Check the anodes. Clean the anodes if
there are scales, grease, or oil. 2
S6P23390
3
cC
Do not apply over specified pressure to
the lower unit, otherwise the oil seals
S6AG3270
4
could be damaged.
NOTE:
Cover the check hole with a rag when remov-
ing the special service tool from the lower
5
unit.
Leakage tester: 90890-06840

S6AG3260 6
Lower unit holding pressure:
100 kPa (1.0 kgf/cm2, 14 psi) 7
3. If the specified pressure cannot be main-
tained, check the lower case, propeller
shaft, drive shaft, shift rod, O-rings, and
oil seals for damage. If necessary, disas-
semble the lower unit.
8
Checking the propeller
1. Check the propeller blades and splines.
Replace the propeller if cracked, dam-
9
aged, or worn.
S6AG3250
6AJ5K11 3-14
CHK
A
S6AG3320 6AJ30120
cC
Do not oil, grease, or paint the anodes,
otherwise they will be ineffective. A
NOTE:
9 Replace the anodes if excessively eroded.
In addition, check the ground lead.
9 If it is necessary to disassemble the out-
6AJ30130
board motor to check an anode, refer to the
applicable disassembly procedure in this
manual.
A
Lubricating the outboard motor

1. Apply water resistant grease to the areas
shown.
A
a
6AJ30140
A NOTE:
Apply grease until it flows from the bushings
a.
A 6AJ30150 2. Apply corrosion resistant grease to the

area shown.
6AJ30110 S6D53300
3-15 6AJ5K11
FUEL
Fuel system
Hose routing ................................................................................................. 4-1

Fuel hose, blowby hose, and cooling water hose .................................... 4-1
Fuel filter ....................................................................................................... 4-2

1
Checking the fuel filter assembly ............................................................. 4-3
Checking the fuel joint ............................................................................. 4-3
Fuel pump .....................................................................................................

Checking the fuel pump ...........................................................................
4-4
4-6
2
Disassembling the fuel pump .................................................................. 4-6
Checking the diaphragm and valve .........................................................
Assembling the fuel pump .......................................................................
Carburetor unit ............................................................................................. 4-9

4-7
4-7
3
Carburetor .............................................................................................. 4-10
Removing the carburetor ....................................................................... 4-12
Disassembling the carburetor ................................................................ 4-12
Checking the carburetor ........................................................................ 4-12
4
Checking the Prime Start ...................................................................... 4-13
Assembling the carburetor ..................................................................... 4-13
Installing the carburetor ......................................................................... 4-14
Adjusting the pilot screw ........................................................................ 4-15 5
6
7
8
9
6AJ5K11
FUEL Fuel system
Hose routing
Fuel hose, blowby hose, and cooling water hose
7
4
7
q
B
2 1 3 6
B
8
0
4
0
6
9 q
5 6 6AJ40010
1 Cooling water hose (exhaust cover-to-joint) 0 Fuel hose (fuel filter assembly-to-fuel pump)
2 Cooling water hose (exhaust cover-to-joint) q Fuel hose (fuel pump-to-carburetor assembly)
3 Cooling water hose (joint-to-joint)
4 Cooling water hose (joint-to-fuel pump)
5 Cooling water hose
(fuel pump-to-cooling water pilot hole)
(flushing hose joint adapter-to-joint)
(thermostat cover-to-cylinder block)
8 Blowby hose
(cylinder head cover-to-intake silencer)
9 Fuel hose (fuel joint-to-fuel filter assembly)
4-1 6AJ5K11
Hose routing / Fuel filter
Fuel filter
1
2
18 N·m (1.8 kgf·m, 13.3 ft·lb)
3
8 N·m (0.8 kgf·m, 5.9 ft·lb)
4
5
No. Part name
2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
Q’ty Remarks
6AJ4010E
6
1 Bolt 1 M8 × 16 mm
2
3
4
5
Bracket
Nut
Fuel hose
Fuel filter assembly
1
1
1
1
7
6 Fuel filter element 1
7
8
9
10
O-ring
Fuel filter cup
Bolt
Fuel joint
1
1
1
1
Not reusable
M6 × 20 mm
8
11 Seal 1
12
13
Fuel hose
Clamp
1
3 9
6AJ5K11 4-2
FUEL Fuel system
Checking the fuel filter assembly 3. Apply the specified positive pressure.
NOTE: Replace the fuel joint if the specified
To check the fuel filter element, see pressure cannot be maintained for at
“Checking the fuel filter” (3-4). least 10 seconds.
1. Connect a vacuum/pressure pump gauge

and a meter to the fuel inlet 1.
2. Cover the fuel outlet 2 with your finger, 2

and then apply the specified positive
1
pressure. Replace the O-ring, fuel filter
cup, or fuel filter assembly if the specified 6AJ40030
pressure cannot be maintained for at
least 15 seconds.
Vacuum/pressure pump gauge
set 1:
1
90890-06756
2 200 0
Specified positive pressure:

50 kPa (0.5 kgf/cm2, 7.3 psi)
1
6AJ40020
NOTE:
Use a commercially available vacuum/pres-
sure pump gauge and meter that can be
pressurized up to 200 kPa (2.0 kgf/cm2, 29.0
psi).

200 kPa (2.0 kgf/cm2, 29.0 psi)
Checking the fuel joint

1. Check the fuel joint. Replace if cracked or
damaged.
2. Connect the special service tool 1 to the

fuel joint outlet 2.
4-3 6AJ5K11
Fuel filter / Fuel pump
Fuel pump
1
2
9
10
5
3
10
4
1
9
8
7 3
5
OUT
IN
6
4
2
9
No. Part name Q’ty Remarks

S6AG4030
6
1 Fuel pump 1
2
3
4
5
Fuel hose
Cooling water hose
Bolt
Cooling water hose
1
1
2
1
M6 × 30 mm
7
6 Fuel hose 1
7
8
9
10
O-ring
Holder
Clamp
Plastic tie
1
2
4
2
Not reusable
8
9
6AJ5K11 4-4
FUEL Fuel system
2 N·m (0.2 kgf·m, 1.5 ft·lb)
0.5 N·m (0.05 kgf·m, 0.37 ft·lb)
2 N·m (0.2 kgf·m, 1.5 ft·lb) 6AJ4020E

1 Screw 4 ø4 × 30 mm
2 Cover 1
3 Diaphragm 1 Not reusable
4 Fuel pump body 2 1
5 Nut 4
6 Pin 1
7 Plunger 1
8 Spring 1
9 Fuel pump body 1 1
10 Spring 1
11 Diaphragm 1
13 Check valve 2
4-5 6AJ5K11
Fuel pump
Checking the fuel pump

1. Connect the special service tool 1 to the
fuel pump inlet 2.
3
2. Cover the fuel pump outlet 3 with your
finger, and then apply the specified posi-
tive pressure. Check that there is no air
OUT
IN
1
leakage.
OUT
IN
3 Specified positive pressure:
50 kPa (0.5 kgf/cm2, 7.3 psi)
6AJ40060
2
3
2
1 Disassembling the fuel pump

1. Disassemble the fuel pump as shown.
6AJ40040
Vacuum/pressure pump gauge

set 1:
90890-06756
4
50 kPa (0.5 kgf/cm2, 7.3 psi) 5
3. Apply the specified negative pressure
6
and check that there is no air leakage.
6AJ40070
OUT
IN
7
8
6AJ40050
Specified negative pressure:

30 kPa (0.3 kgf/cm2, 4.4 psi)
4. Connect the special service tool to the

fuel pump outlet 3.
5. Apply the specified positive pressure and

9
check that there is no air leakage.
6AJ5K11 4-6
FUEL Fuel system
2. Remove the pin 1 from the plunger 2, Assembling the fuel pump
and then disassemble fuel pump body 1 NOTE:
3. Clean the parts and soak the valves and the
diaphragms in gasoline before assembly.
2
1. Install the plunger 1 and diaphragm into
3
fuel pump body 1 2 and then install the
pin 3 to the plunger 1.
90˚
S6AG4120J
1
3
a
2
S6AG4140
1
S6AG4130
2
NOTE:
9 Push down on the plunger 2 and the 90˚
diaphragm, turn fuel pump body 1 3
approximately 90° to a position where the
pin 1 can be removed easily.
9 Slowly release on the plunger 2 and b
diaphragm, and then remove them.
b 6AJ40090
Checking the diaphragm and valve
1. Check the diaphragms and valves. NOTE:
Replace the diaphragms if torn and the 9 Align the pin installation holes a with the
valves if cracked. slot in fuel pump body 1 2, and then install
the pin 3 while pushing the plunger 1 and
diaphragm completely inward.
9 Turn fuel pump body 1 2 until the pin 3 is
90° from the slots in fuel pump body 1 2.
9 Make sure that the projections b on the
diaphragm fit correctly into fuel pump body
1 2.
2. Assemble the fuel pump as shown.
6AJ40080
4-
4-7 6AJ5K11
Fuel pump
1
4
5
2
5
4 6AJ40100
3
NOTE:
9 Moisten the inside of the fuel pump with
gasoline to ensure a good seal.
9 Make sure that the diaphragms are kept in
4
place through the assembly process.
9 After assembling the fuel pump, check it for
air leaks. See “Checking the fuel pump” (4-
6). 5
Fuel pump screw 4:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
Fuel pump valve screw 5:
0.5 N·m (0.05 kgf·m, 0.37 ft·lb)
6
7
8
9
6AJ5K11 4-8
FUEL Fuel system
Carburetor unit
10
9
3 6 8
11 7
4
5 12
4
2
S6AG4010

1 Intake silencer 1
2 Blowby hose 1
3 Carburetor assembly 1
4 Gasket 2 Not reusable
5 Spacer 1
6 Grommet 1
7 Bolt 2 M6 × 100 mm
8 Bolt 1
9 O-ring 1 Not reusable
10 Plastic tie 1
11 Throttle link rod 1
12 Clamp 1
4-9 6AJ5K11
Carburetor unit
Carburetor
1
2
3
4
1.3 N·m (0.13 kgf·m, 0.94 ft·lb)
5
6AJ4030E
6
2
3
4
5
Screw
Retainer
Prime Start
Screw
1
1
1
3
ø4 × 10 mm
ø4 × 10 mm
7
6 Cover 1
7
8
9
10
Gasket
Throttle stop screw
Spring
O-ring
1
1
1
1
Not reusable
Not reusable
8
11 Spring 1
12
13
14
Screw
Protector
Carburetor body
2
1
1
ø4 × 8 mm
9
15 Float chamber 1
17 Plunger rod 1
6AJ5K11 4-10
FUEL Fuel system
1.3 N·m (0.13 kgf·m, 0.94 ft·lb)
6AJ4030E

18 Plunger 1
19 Spring 1
20 Circlip 1
21 Ball 1
23 Drain screw 1
24 Gasket 1
25 Screw 4 ø4 × 13 mm
27 Pin 1
28 Float 1
29 Needle valve 1
30 Main jet 1
31 Main nozzle 1
32 Plug 1
33 Pilot jet 1
34 Pilot screw 1
4-11 6AJ5K11
Carburetor unit
Removing the carburetor Checking the carburetor

1. Disconnect the fuel hose 1, and the 1. Check the air and fuel passages and jets.
blowby hose 2. Clean the carburetor body if there is dirt
or foreign material.
2
2. Blow compressed air into all passages
and jets.
1
1
S6AG4170
2
2. Disconnect the throttle link rod and Prime
Start connectors.
NOTE:
S6AG4190
3
The Prime Start connectors are located in the w
junction box 3.
3. Remove the bolts 4 and 5, and then

Wear appropriate protective eye gear dur-
ing the cleaning process to prevent any
eye injury by the blown-off debris or liq-
4
uid.
remove the intake silencer 6 and carbu-
retor assembly 7.
8 3
3. Check the main jet, pilot jet, and main
nozzle. Clean if there is dirt or residue.
5
5
cC
6
Do not use steel wire for cleaning the jets,
otherwise the jet diameters may be
enlarged, which may seriously affect per-
6
formance.
7
4
5
4. Check the pilot screw and needle valve.
Replace if worn or deformed.
7
8
6AJ40110
NOTE:
Before removing the bolts 5, remove the fuel
filter and remove the Prime Start lead from
the holder 8.
Disassembling the carburetor

S6AG4200
9
NOTE: 5. Check the float. Replace if cracked or
See the exploded diagram for disassembly deformed.
(4-10).
6AJ5K11 4-12
FUEL Fuel system
6. Measure the float height a. Replace the 2. Measure the length of the Prime Start
float 1 or needle valve 2 if out of speci- plunger before supplying power.
fication.
Prime Start plunger length before
supplying power (reference data):
10.7 mm (0.42 in) at 24 °C (75 °F)
3. Connect the Prime Start blue (L) leads to

a 12 V battery as shown. Measure the
plunger length a after supplying power
for 10 minutes.
S6AG4220
a
1
2
a
L L
S6AG4210
NOTE: S6AG4230
9 Measure the float height when it is resting
on the needle valve 2. Do not push down Prime Start plunger length a after
on the float. supplying power (reference data):
9 Take measurements at the float position 15.0 mm (0.59 in) at 24 °C (75 °F)
shown opposite its pivoted side.
Float height a: Assembling the carburetor

15.0 ± 1.0 mm (0.60 ± 0.04 in) 1. Install the main nozzle 1, main jet 2,
pilot jet 3, and plug 4 to the carburetor
body as shown.
Checking the Prime Start 4 2
1. Measure the Prime Start resistance
when the Prime Start is cold. 3
1
NOTE:
Ambient temperature 24 °C (75 °F), with no
power supplied.
Prime Start resistance 6AJ40120
(reference data):
Blue (L) – Blue (L)
16.4–24.8 Ω at 24 °C (75 °F)
4-13 6AJ5K11
Carburetor unit
2. Install the needle valve 5, float 6, float 2. Connect the throttle link rod to the carbu-
pin 7, and screw 8 as shown, and then retor throttle lever and the Prime Start
check the float for smooth operation. connectors.
6
5 7
8
7
5 1
4
S6AG4250
2
6
3
3
3. Install the pilot screw 9, turn it in until it
is lightly seated, and then turn it out the 1 5
2
specified number of turns. 1 6AJ40115
NOTE:
9 To adjust the throttle link rod, see “Adjusting
the throttle link” (3-9).
9 Place the Prime Start connectors in the
4
junction box 7 after connecting them.
9
S6AG4260
3. Adjust the engine idle speed.
NOTE:
5
If the carburetor has been assembled, adjust
Pilot screw setting:
2 3/4 ± 1/2 turns out
the pilot screw, and then adjust the engine
idle speed. See “Adjusting the pilot screw” (4-
15).
6
Installing the carburetor
1. Install the new gaskets 1, spacer 2,
carburetor assembly 3, intake silencer
4, bolts 5 and 6.
7
NOTE:
8
Install the fuel filter after tightening the bolts
and fastening the Prime Start lead with the
holder.
9
6AJ5K11 4-14
FUEL Fuel system
Adjusting the pilot screw Pilot screw setting:

1. Adjust the throttle stop screw. 2 3/4 ± 1/2 turns out
NOTE:
If the carburetor was disassembled, turn the 5. Turn the throttle stop screw 2 in direction
throttle stop screw in until it contacts the car- c or d until the specified engine idle
buretor throttle lever, and then turn it in about speed is obtained.
1 3/4 turns to tighten it temporarily.

minutes. 2
NOTE:
d c
9 Because the Prime Start operates when the
be above specification. Therefore, check S6AG4310
and adjust the engine idle speed after the
engine has been warmed up. NOTE:
9 If the engine idle speed does not decrease 9 To increase the engine idle speed, turn the
after the engine has been warmed up for 10 throttle stop screw 2 in direction c.
minutes or more, check the Prime Start sys- 9 To decrease the engine idle speed, turn the
tem as it may be malfunctioning. throttle stop screw 2 in direction d.
3. Attach the special service tool to spark

plug wire #1. Engine idle speed: 1,050 ± 50 r/min
Digital tachometer: 90890-06760 6. After adjusting the engine idle speed, rev
the engine a few times and let it idle to
check the stability of the engine.
4. Turn the pilot screw 1 in direction a until
it is lightly seated, and then turn it in
direction b the specified number of
turns.
b 1 a
S6AG4290
NOTE:
Adjust the pilot screw setting within the spec-
ified number of turns out so that the engine
idle speed is stable.
4-15 6AJ5K11
Carburetor unit
— MEMO —
1
2
3
4
5
6
7
8
9
6AJ5K11 4-16
POWR
Power unit
Power unit (check and adjustment) ........................................................... 5-1

Checking the compression pressure ....................................................... 5-1
Checking the oil pressure ........................................................................ 5-1
Checking the valve clearance .................................................................. 5-2
Replacing the timing belt ......................................................................... 5-3
Manual starter .............................................................................................. 5-7

Disassembling the manual starter ........................................................... 5-9
Assembling the manual starter .............................................................. 5-10
Power unit ................................................................................................... 5-13

Power unit assembly .............................................................................. 5-13
Ignition coil ............................................................................................. 5-15
CDI unit and junction box ...................................................................... 5-16
Bracket ................................................................................................... 5-18
Throttle cam ........................................................................................... 5-20
Removing the power unit ....................................................................... 5-21
Timing belt and sprocket .......................................................................... 5-23

Removing the timing belt and sprocket ................................................. 5-24
Checking the timing belt and sprocket .................................................. 5-25
Installing the sprocket and timing belt ................................................... 5-25
Cylinder head ............................................................................................. 5-28

Removing the cylinder head .................................................................. 5-31
Disassembling the cylinder head ........................................................... 5-31
Checking the cylinder head ................................................................... 5-32
Checking the valve spring ..................................................................... 5-32
Checking the valve ................................................................................ 5-33
Checking the valve guide ...................................................................... 5-33
Replacing the valve guide ..................................................................... 5-34
Checking the valve seat ........................................................................ 5-34
Refacing the valve seat ......................................................................... 5-35
Checking the rocker arm and rocker arm shaft ..................................... 5-37
Checking the camshaft .......................................................................... 5-37
Assembling the cylinder head ............................................................... 5-38
Installing the cylinder head .................................................................... 5-41
Checking the oil pump ........................................................................... 5-41
6AJ5K11
Cylinder block ............................................................................................ 5-43
Disassembling the cylinder block .......................................................... 5-45
Checking the piston diameter ................................................................ 5-46
Checking the cylinder bore .................................................................... 5-46
Checking the piston clearance .............................................................. 5-46
Checking the piston ring ........................................................................ 5-47
Checking the piston ring end gap .......................................................... 5-47
1
Checking the piston ring groove ............................................................ 5-47
2
Checking the piston ring side clearance ............................................... 5-48
Checking the piston pin boss bore ........................................................ 5-48
Checking the piston pin diameter .......................................................... 5-48
Checking the connecting rod small and big end inside diameter .......... 5-48
Checking the connecting rod big end side clearance ........................... 5-49
3
Checking the crankshaft ........................................................................ 5-49
Checking the crankpin oil clearance ...................................................... 5-49
Checking the crankshaft journal oil clearance ....................................... 5-50
Selecting the crankshaft main bearing .................................................. 5-52
Assembling the cylinder block ............................................................... 5-52
Installing the power unit ......................................................................... 5-55
4
5
6
7
8
9
6AJ5K11
POWR Power unit
Power unit (check and Minimum compression pressure

adjustment) (reference data):
Checking the compression pressure 730 kPa (7.3 kgf/cm2, 105.9 psi)
1. Start the engine, warm it up, and then
turn it off. 6. If the compression pressure is below
specification or the compression pres-
2. Remove the clip from the engine shut-off sure for each cylinder is unbalanced, add
switch. a small amount of engine oil to the cylin-
der, and then measure the pressure
3. Disconnect the spark plug caps, remove again.
the spark plugs, and then install the spe-
NOTE:
cial service tool 1 into a spark plug hole.
9 If the compression pressure increases,
1 check the pistons and piston rings. Replace
if worn.
9 If the compression pressure does not
increase, check the valve clearances,
valves, valve seats, cylinder sleeves, cylin-
der head gasket, and cylinder head. Adjust
or replace if necessary.
6AJ50020
cC Checking the oil pressure

1. Remove the oil pressure switch, and then
Before removing the spark plugs, remove
install an oil pressure gauge 1 to the oil
any dirt or dust in the spark plug wells
pressure switch installation hole.
that may fall into the cylinders.
1
Compression gauge 1:
90890-03160
4. Fully open the throttle.
5. Crank the engine until the reading on the

compression gauge stabilizes, and then 6AJ50010
measure the compression pressure.
NOTE:
NOTE:
Use a commercially available oil pressure
Since this outboard motor is equipped with an
gauge 1.
automatic decompression mechanism, the
compression pressure may vary depending
on the speed at which the starter handle is
pulled when using the manual starter to crank
minutes.
the engine.
5-1 6AJ5K11
Power unit (check and adjustment)
NOTE:
engine is started, the engine idle speed will 6
1
be above specification. Therefore, measure
the oil pressure after the engine has been
warmed up.
2
3. Measure the oil pressure. Check the oil
pump and oil strainer, and for oil leakage
b
if out of specification.
Oil pressure (reference data):

S6AG5050
400 kPa (4.0 kgf/cm2, 58.0 psi) at
1,050 r/min 5. Measure the intake and exhaust valve
clearances for cylinder #1. Adjust if out of
specification.
3
Checking the valve clearance
NOTE:
Measure the valve clearances when the
engine is cold.
4
#1
5
starter. EX IN
#2
2. Disconnect the spark plug caps and
3. Remove the cooling water hoses 1, fuel

hoses 2, fuel pump 3, blowby hose 4,
and cylinder head cover 5.
d c
6
5
4
Valve clearance:
6AJ50100
7
1 Intake c:
3 2
S6AG5035
0.15–0.25 mm (0.006–0.010 in)
Exhaust d:
0.25–0.35 mm (0.010–0.014 in)
8
9
4. Turn the flywheel magnet clockwise and
align the “1 ▲” mark a on the driven
sprocket 6 with the “▲” mark b on the
cylinder head.
6AJ5K11 5-2
POWR Power unit
6. Loosen the rocker arm locknut 7, and Replacing the timing belt
then turn the adjusting screw 8 until the cC
specified valve clearance is obtained.
Do not turn the flywheel magnet counter-
clockwise, otherwise the water pump
8 impeller may be damaged.
7 NOTE:
To remove and install the timing belt, drive
e sprocket, and driven sprocket, see
“Removing the timing belt and sprocket” (5-
f 24) and “Installing the sprocket and timing
S6AG5060
belt” (5-25).
NOTE:
9 To decrease the valve clearance, turn the
1. Disconnect the spark plug caps and
adjusting screw in direction e.
9 To increase the valve clearance, turn the
adjusting screw in direction f.
2. Remove the thermoswitch 1 and cooling
water hose 2 from the thermostat cover.
7. Tighten the rocker arm locknut to the
specified torque. 1
Rocker arm locknut 7: 2

14 N·m (1.4 kgf·m, 10.3 ft·lb)
8. Turn the flywheel magnet an additional

360° clockwise and align the “▲” mark g
on the driven sprocket with the “▲” mark S6AG5040
h on the cylinder head.

3. Remove the flywheel magnet nut.
h
S6AG5G30
w
S6AG5051
Apply force in the direction of the arrows
shown to prevent the flywheel holder from
9. Repeat steps 5–7 for cylinder #2. slipping off easily.
10. Install all parts removed during removal.
5-3 6AJ5K11
NOTE: 5. Remove the stator coil assembly bolts 3,

Use a 24 mm socket to loosen the flywheel and then remove the stator coil assembly.
magnet nut.
3 3
Flywheel holder: 90890-06522 1

4. Remove the
Woodruff key.
flywheel magnet and
S6AG5090
2
6. Align the “1 ▲” mark a on the driven
cylinder head. 3
S63P5280 4
4
a
b
5
cC
S63P5290
c d
S6AG5055
6
To prevent damage to the engine or tools,
screw in the puller set bolts evenly and
completely so that the flywheel puller is
parallel to the flywheel magnet.
7
8
NOTE:
Apply force to the crankshaft end until the fly- S6AG5B25
wheel magnet comes off the tapered portion

NOTE:
of the crankshaft.
Check that the mark c on the drive sprocket
and the mark d on the cylinder block are
Flywheel puller: 90890-06521

aligned.
9
6AJ5K11 5-4
POWR Power unit
7. Remove the timing belt 5 from the driven NOTE:

sprocket, and then remove it from the Before installing the timing belt, make sure
drive sprocket. that the marks on the drive sprocket and dri-
ven sprocket are aligned with the marks on
5 the cylinder block and cylinder head.
X
1-X
24
H -46
6A
9. Turn the drive sprocket clockwise 2 turns,

and then check that the alignment marks
f and g are aligned.
f
S6AG5101
g
cC
Unless directed to do so in the following
instructions, do not turn the drive sprock-
5
et or driven sprocket when the timing belt
is not installed. Otherwise the pistons and
valves will collide with each other and be S6AG5100
damaged.
10. Install the stator coil assembly 6 with
bolts 7.
8. Install a new timing belt 5 onto the drive
sprocket, and then install it onto the dri- 11. Install the Woodruff key 8, and then
ven sprocket with its part number in the install the flywheel magnet 9.
upright position e.
0
5 e m 9
62
41
-XX n
H-4
6A
E n 7
6
9
S6AG5110 k 8 h
cC
9 Do not twist, turn inside out, or bend the
S6AG5120
timing belt beyond the maximum limit of
25 mm (1.0 in), otherwise it can be dam- NOTE:
aged. 9 Be sure to remove any grease from the
9 Do not get oil or grease on the timing tapered portion of the crankshaft h and fly-
belt. wheel magnet k.
9 Apply engine oil to the threads m of the fly-
wheel magnet nut 0 and washer n before
installation.
5-5 6AJ5K11
12. Tighten the flywheel magnet nut to the

specified torque.
1
S6AG5G40
2
w
Apply force in the direction of the arrows
shown to prevent the flywheel holder from
slipping off easily.
3
Flywheel holder: 90890-06522
4
Stator coil assembly bolt 7:
8 N·m (0.8 kgf·m, 5.9 ft·lb)
Flywheel magnet nut 0:
108 N·m (10.8 kgf·m, 79.7 ft·lb)
5
13. Install all parts removed during disas-
sembly.
6
7
8
9
6AJ5K11 5-6
POWR Power unit
Manual starter
21 20
21 22 21
11
8 N·m (0.8 kgf·m, 5.9 ft·lb)
16
12
17 4
19
9
13
E A
15 3 8
18 14 2 7
15 A
6 3
5
A
10 7 8
1.5 N·m (0.15 kgf·m, 1.11 ft·lb)
.
R.
23
5.4 N·m (0.54 kgf·m, 3.9 ft·lb)
S6AG5500J

1 Cover 1
2 Sheave drum 1
3 Drive pawl 1
4 Spiral spring 1
5 Drive plate 1
6 Drive pawl spring 1 1
7 Spring 1
8 Drive pawl spring 2 1
9 E-clip 1
10 Screw 1 ø5 × 20 mm
11 Spring 1
12 Starter plunger 1
13 Cover 1
14 Drain hose 1
15 Screw 2 ø4 × 16 mm
16 Packing 1 Not reusable
17 Starter handle 1
5-7 6AJ5K11
Manual starter
21 20
21 22 21
8 N·m (0.8 kgf·m, 5.9 ft·lb)

11
1
1
16
12
2
17 4
19
13
E A
9
3 8
3
15
18 14 2 7
15
6
A
3 4
5
1.5 N·m (0.15 kgf·m, 1.11 ft·lb)

A
10 7 8
5
.
R.
23
5.4 N·m (0.54 kgf·m, 3.9 ft·lb)

S6AG5500J
6
18 Cap 1
19
20
21
22
Starter rope
Start-in-gear protection cable
Bolt
Spring
1
1
3
1
1,800 mm (70.9 in)
M6 × 20 mm
7
23 Driven sprocket cover 1
8
9
6AJ5K11 5-8
POWR Power unit
Disassembling the manual starter 4. Remove the starter rope 5 and E-clip 6,
1. Remove the drive plate 1 and drive pawl and then remove the drive pawl 7 and
spring 1 2. springs 8 from the sheave drum.
1 7
6
2
7
8
S6AG5510
w 5
The sheave drum can pop out. Hold the
sheave drum with your hand, and then S6AG5530
remove the drive plate.

5. Check the drive pawl, E-clip, starter
plunger, and drive plate. Replace if
2. Remove the sheave drum 3.
cracked or damaged.
6. Check the springs. Replace if bent,

4
cracked, or damaged.
3 S6AG5550
S6AG5520
w 7. Check the sheave drum. Replace if

The spiral spring can pop out. Cover the cracked or damaged.
spiral spring with rags, and then pull out
the sheave drum. 8. Check the spiral spring. Replace if
cracked, bent, or damaged.
3. Remove the spiral spring 4 from the

manual starter cover.
w
The spiral spring can pop out. Cover the
spiral spring with rags when removing it.
S6AG5540
5-9 6AJ5K11
Manual starter
9. Check the starter handle. Replace if 4. Wind the starter rope 1 twice around the
cracked or damaged. sheave drum 2 in the direction of the
arrow shown in the illustration.
1
10. Check the starter rope. Replace if dam-
aged.
NOTE: 1 b
9 When replacing the starter rope with a new
one, make sure that the length is approxi- 1
mately 1,800 mm (70.9 in).
9 Be sure to use a genuine Yamaha starter
rope.
2
2
S6AG5570
2
Assembling the manual starter
1. Install the starter rope 1 into the sheave
drum 2.
NOTE:
After winding the starter rope 1 around the
sheave drum 2, install the starter rope in the
notch b.
3
NOTE:
Before installing the cover 3, route the starter
rope through the manual starter cover. 5. Install the spiral spring 8 into the manu-
al starter cover.
4
2. Install the drive pawl 4, starter plunger
5, springs 6, and E-clip.
3. Install the starter handle 7.

5
2 4
5
3
8
c d
S6AG5580
6
6 NOTE:
7
7
Hook the end c of the spiral spring 8 onto the
cut-out d in the starter cover.
1
1
E
8
a
NOTE:
S6AG5560
9
9 Tie a knot at the end of the starter rope as
shown in the illustration.
9 Be sure to leave 12–20 mm (0.47–0.79 in)
at the end a of the starter rope.
6AJ5K11 5-10
POWR Power unit
6. Install the sheave drum 2 into the manu- NOTE:

al starter cover 9. Hold the starter plunger e while turning the
sheave drum as shown.
f
e 9. Remove the starter rope from the notch
b, and then fit the starter rope into the
9 groove in the sheave drum.
NOTE:
9 Be sure to hold the sheave drum with your
S6AG5590
hand so that it turns slowly.
9 Allow the spring force to slowly turn the
NOTE: drum as the starter rope winds around the
9 When installing the sheave drum, set the drum.
spiral spring by turning the sheave drum.
9 Hook the end e of the spiral spring 8 onto
the cut-out f in the sheave drum 2. 10. Pull the starter handle 7 several times to
check that the sheave drum turns
smoothly and to check the starter rope for
7. Install the drive pawl spring 1 0 and slack. Repeat steps 4–9 if necessary.
drive plate q. e
w
q
A
7 S6AG5620
S6AG5600
NOTE:
Drive plate screw w: Hold the starter plunger e while pulling the
5.4 N·m (0.54 kgf·m, 3.9 ft·lb) starter handle 7.
8. Turn the sheave drum 2 4 turns in the 11. Install the manual starter onto the power
direction of the arrow shown. unit, tighten the bolts to the specified
torque, and then connect the start-in-
gear protection cable.
b
e Manual starter bolt:
8 N·m (0.8 kgf·m, 5.9 ft·lb)
2 S6AG5610
5-11 6AJ5K11
Manual starter
NOTE:
9 Route the start-in-gear protection cable in
its original position.
9 To adjust the start-in-gear protection cable,
see “Checking the start-in-gear protection”
(3-10). 1
12. Pull the starter handle completely, and
then measure the starter rope length g.
2
g
3
Starter rope pulling length g:
S6AG5630
4
1,400–1,600 mm (55.12–62.99 in)
5
6
7
8
9
6AJ5K11 5-12
POWR Power unit
Power unit
Power unit assembly
8 N·m (0.8 kgf·m, 5.9 ft·lb)
BOW
LT 27 N·m (2.7 kgf·m, 19.9 ft·lb)

572 27 N·m (2.7 kgf·m, 19.9 ft·lb)
2.5 N·m (0.25 kgf·m, 1.84 ft·lb) 6AJ5010E

1 Power unit 1
3 Dowel 2
4 Bolt 6 M8 × 85 mm
5 Oil dipstick 1
6 Bracket 1
7 Bolt 2 M6 × 20 mm
8 Bracket 1
9 Bolt 1 M6 × 20 mm
10 Warning indicator assembly 1
11 Packing 1
12 Screw 1 ø6 × 12 mm
13 Engine shut-off switch lead 2
14 Bolt 1 M6 × 14 mm
15 Apron 1
16 Screw 2 ø6 × 30 mm
17 Nut 2
5-
5-13 6AJ5K11
Power unit
1
8 N·m (0.8 kgf·m, 5.9 ft·lb)
2
3
BOW
4
5
LT 27 N·m (2.7 kgf·m, 19.9 ft·lb)
6
572 27 N·m (2.7 kgf·m, 19.9 ft·lb)
2.5 N·m (0.25 kgf·m, 1.84 ft·lb) 6AJ5010E

18 Retaining plate 1
19
20
21
22
Bolt
Throttle cable
Bolt
Shift rod cam
2
2
2
1
M6 × 30 mm
M6 × 14 mm
7
23 Bolt 2 M6 × 20 mm
24 Start-in-gear protection cable 1
8
9
6AJ5K11 5-14
POWR Power unit
Ignition coil
7 N·m (0.7 kgf·m, 5.2 ft·lb)
17 N·m (1.7 kgf·m, 12.5 ft·lb)
6AJ5020E

1 Holder 1
2 Holder 1
3 Ignition coil 1
4 Spark plug cap 2
5 Bolt 2 M6 × 25 mm
6 Spark plug 2
5-
5-15 6AJ5K11
Power unit
CDI unit and junction box
4 N·m (0.4 kgf·m, 3.0 ft·lb)

8 N·m (0.8 kgf·m, 5.9 ft·lb)
1
2
8 N·m (0.8 kgf·m, 5.9 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb)

3
8 N·m (0.8 kgf·m, 5.9 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb) 4

5
No.
8 N·m (0.8 kgf·m, 5.9 ft·lb)
Part name Q’ty Remarks

6AJ5030E
6
1 Junction box cover 1
2
3
4
5
Junction box
Damper
Bolt
Bracket
1
1
2
1
M6 × 14 mm
7
6 Bolt 2 M6 × 20 mm
7
8
9
10
Holder
Grommet
CDI unit
Bolt
1
2
1
1 M6 × 20 mm
8
11 Bolt 1 M6 × 20 mm
12
13
14
Bracket
Bolt
Grommet
1
3
3
M6 × 25 mm 9
15 Collar 3
16 Bracket 1
17 Holder 2
6AJ5K11 5-16
POWR Power unit
4 N·m (0.4 kgf·m, 3.0 ft·lb)

8 N·m (0.8 kgf·m, 5.9 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb)

6AJ5030E

18 Bolt 2 M6 × 16 mm
19 Pulser coil 1
20 Bolt 2 M5 × 12 mm
21 Stator coil assembly 1
22 Bolt 3 M6 × 30 mm
23 Wiring harness 1
5-17 6AJ5K11
Power unit
Bracket
8 N·m (0.8 kgf·m, 5.9 ft·lb)
1
A
2
8 N·m (0.8 kgf·m, 5.9 ft·lb)
3
4
LT
572
8 N·m (0.8 kgf·m, 5.9 ft·lb)
18 N·m (1.8 kgf·m, 13.3 ft·lb)
5
6
2 N·m (0.2 kgf·m, 1.5 ft·lb)
6AJ5040E

1 Thermoswitch 1
2
3
4
5
Plate
Bolt
Bracket
Bolt
1
1
1
2
M6 × 14 mm
M6 × 14 mm
7
6 Holder 2
7
8
9
10
Holder
Washer
Screw
Holder
1
1
1
1
ø6 × 10 mm
8
11 Bracket 1
12
13
14
Bolt
Bolt
Holder
2
1
1
M8 × 25 mm
M8 × 16 mm 9
15 Bolt 1 M6 × 15 mm
16 Oil pressure switch 1
17 Oil pressure switch lead 1
6AJ5K11 5-18
POWR Power unit
8 N·m (0.8 kgf·m, 5.9 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb)
LT
572
8 N·m (0.8 kgf·m, 5.9 ft·lb)
18 N·m (1.8 kgf·m, 13.3 ft·lb)
2 N·m (0.2 kgf·m, 1.5 ft·lb)

6AJ5040E

18 Wiring harness 1
19 Holder 1
20 Holder 1
21 Plastic tie 2
5-19 6AJ5K11
Power unit
Throttle cam
8 N·m (0.8 kgf·m, 5.9 ft·lb)

1
2
9 A
2 10
11 A
12 15
14
8
11
3
3
4
1
2
13
5
6 7
4
8 N·m (0.8 kgf·m, 5.9 ft·lb)
M
5
8 N·m (0.8 kgf·m, 5.9 ft·lb)

S6AG5750
6
1 Bracket 1
2
3
4
5
Bolt
Throttle cam
Shaft
Free accel lever
2
1
1
1
M6 × 14 mm
7
6 Washer 1
7
8
9
10
Bolt
Spring
Clip
Stopper
1
1
1
1
M6 × 45 mm
8
11 Washer 2
12
13
14
Collar
Bracket
Bolt
1
1
2 M6 × 14 mm
9
15 Throttle cable 2
6AJ5K11 5-20
POWR Power unit
Removing the power unit 5. Remove the junction box bracket 9.

1. Disconnect the start-in-gear protection
cable, and then remove the sprocket 6. Remove the warning indicator assembly
cover and manual starter. 0 and bracket q.
2. Disconnect the flushing hose 1, cooling

water hose 2, and fuel hose 3.
q 0
6AJ50050
7. Disconnect the throttle cables from the

1 2 3 S6AG5D00
throttle cam.
3. Remove the junction box cover, and then 8. Remove the bolts w, and then remove
remove the plastic tie 4 and clamps 5. the shift rod cam e.
4. Disconnect the engine shut-off switch

lead 6. Remove the bolt 7 and engine
shut-off switch lead (B) terminal 8.
4 5 6
w
e w
6AJ50060
9. Remove the dipstick and apron, and then

9 remove the mounting bolts r.
6AJ50030
6AJ50040
5-21 6AJ5K11
Power unit
10. Remove the power unit t, gasket y,

and dowels u.
1
2
BOW t
y
u u
3
r r
r S6AG5D70
4
5
6
7
8
9
6AJ5K11 5-22
POWR Power unit
Timing belt and sprocket
108 N·m (10.8 kgf·m, 79.7 ft·lb) 1

7 8
11 9 E 2
22 N·m (2.2 kgf·m, 16.2 ft·lb) 3
14 8 N·m (0.8 kgf·m, 5.9 ft·lb)
15
E
6 4 4
7
X 4
1-X
6 24
H-4
6A 5
E
8
13 9
10
11
110 N·m (11.0 kgf·m, 81.1 ft·lb)

12
S6AG5680J

1 Nut 1 Width across flats: 24 mm
2 Washer 1
3 Flywheel magnet 1
4 Bolt 3 M6 × 30 mm
5 Stator coil assembly 1
6 Timing belt 1
7 Nut 1 Width across flats: 41 mm
8 Retaining plate 1
9 Drive sprocket 1
10 Woodruff key 1
11 Woodruff key 1
12 Woodruff key 1
13 Driven sprocket 1
14 Bolt 1 M8 × 25 mm
15 Washer 1
5-23 6AJ5K11
Removing the timing belt and 2

sprocket
-XX
41
1. Remove the flywheel magnet and stator AH
-462
6
1
coil assembly.
NOTE:
See “Replacing the timing belt” (5-3).
2. Align the “1 ▲” mark a on the driven

cylinder head. cC
S6AG5H90
Unless directed to do so in the following

2
1
et or driven sprocket when the timing belt
is not installed. Otherwise the pistons and
valves will collide with each other and be
3
damaged.
a
4. Align the mark e on the drive sprocket
with the mating surface f of the
4
b crankcase and cylinder block by turning
5
the crankshaft clockwise approximately
90° gradually.
S6AG5H80
c d
e f
6
NOTE:
S6AG5B25
cC
S6AG5A50
7
Do not turn the crankshaft more than 90°.
Check that the mark c on the drive sprocket
8
Otherwise the piston and valves will col-
and the mark d on the cylinder block are lide with each other and be damaged.
aligned.
3. Remove the timing belt 2 from the driven

sprocket, and then remove it from the
drive sprocket. 9
6AJ5K11 5-24
POWR Power unit
5. Hold the driven sprocket using the spe-

cial service tool 4, and then remove the Shaft holder 5: 90890-06069
driven sprocket bolt 3.
8. Remove the retaining plate, drive sprock-

et, and Woodruff key.
4
Checking the timing belt and
3
sprocket
1. Check the interior and exterior of the tim-
ing belt. Replace if cracked, damaged, or
S6AG5B30J
worn.
NOTE:
2. Check the drive sprocket and driven
Make sure that the driven sprocket does not
sprocket. Replace if cracked, damaged,
turn when loosening the driven sprocket bolt.
or worn.
Flywheel holder 4: 90890-06522 Installing the sprocket and timing

belt
6. Remove the driven sprocket and cC
Woodruff key. Unless directed to do so in the following
7. Install the power unit onto the special et or driven sprocket when the timing belt
service tool 5 as shown, and then is not installed. Otherwise the pistons and
remove the drive sprocket nut 6. valves will collide with each other and be
damaged.
7
6
1. Check that the keyway a in the crank-
shaft and the mating surface b of the
crankcase and cylinder block are aligned.
5
a
S6AG5A70 b
NOTE: S6AG5A90
9 Use a deep 41 mm socket 7 to loosen the
drive sprocket nut 6.
9 Make sure that the power unit does not turn 2. Install the Woodruff key 1, drive sprock-
when loosening the drive sprocket nut 6. et 2, and retaining plate 3, and then
install the drive sprocket nut 4 temporar-
ily.
5-25 6AJ5K11
4 0
3 9 E
E
4 3
8
1
2 1 2
1 7
S6AG5A80
3. Install the power unit onto the special ser-

vice tool 5, and then tighten the drive
S6AG5B40
5. Hold the driven sprocket using the spe-

cial service tool q, and then tighten the
2
sprocket nut 4 to the specified torque. driven sprocket bolt 0 to the specified
6
torque.
0
3
4 q
4
5
S6AG5B50J
5 NOTE:
S6AG5B00 Make sure that the driven sprocket does not
turn when tightening the driven sprocket bolt.
6
NOTE:
9 Use a deep 41 mm socket 6 to tighten the
drive sprocket nut. Flywheel holder q: 90890-06522
9 Make sure that the power unit does not turn
when tightening the drive sprocket nut.
Shaft holder 5: 90890-06069

Driven sprocket bolt 0:
22 N·m (2.2 kgf·m, 16.2 ft·lb)
7
Drive sprocket nut 4:
110 N·m (11.0 kgf·m, 81.1 ft·lb)
8
4. Install the Woodruff key 7, driven
9
sprocket 8, and washer 9, and then
install the driven sprocket bolt 0 tem-
porarily.
6AJ5K11 5-26
POWR Power unit
6. Align the “1 ▲” mark c on the driven cC

sprocket 8 with the “▲” mark d on the
9 Do not twist, turn inside out, or bend the
cylinder head.
timing belt beyond the maximum limit of
25 mm (1.0 in), otherwise it can be dam-
aged.
8 9 Do not get oil or grease on the timing
belt.
9. Turn the drive sprocket clockwise 2 turns,

c and then check that the alignment marks
h and k are aligned.
d h
S6AG5H81 k
7. Align the mark e on the drive sprocket

w
with the mark f on the cylinder block by
turning the crankshaft counterclockwise
approximately 90° gradually. S6AG5102
e f
10. Install the stator coil assembly and fly-
wheel magnet.
NOTE:
See “Replacing the timing belt” (5-3).
S6AG5B20
8. Install the timing belt w onto the drive

sprocket, and then install it onto the dri-
ven sprocket with its part number in the
upright position g.
w g
X
1-X
24
H-46
6A
S6AG5115
5-27 6AJ5K11
Timing belt and sprocket / Cylinder head
Cylinder head
8 N·m (0.8 kgf·m, 5.9 ft·lb) 2 8 N·m (0.8 kgf·m, 5.9 ft·lb) 13
2
2 N·m (0.2 kgf·m, 1.5 ft·lb)
11
13
1
2 9
2
6 8
5
10
2
1
3
E
7
10
6
LT
271
12
13
3
18 N·m (1.8 kgf·m, 13.3 ft·lb)
15 N·m (1.5 kgf·m, 11.1 ft·lb)
4
14 17 29 N·m (2.9 kgf·m, 21.4 ft·lb)
4 A 60˚
7 6 N·m (0.6 kgf·m, 4.4 ft·lb)
15 12 N·m (1.2 kgf·m, 8.9 ft·lb)
16
LT
271
7 17
LT
16
A 15
14
5
271
No. Part name

2 N·m (0.2 kgf·m, 1.5 ft·lb)
Q’ty
18 N·m (1.8 kgf·m, 13.3 ft·lb)
Remarks
S6AG5650
6
1 Intake manifold 1
2
3
4
5
Bolt
Gasket
Gasket
Cylinder head assembly
4
1
1
1
M6 × 55 mm
Not reusable
Not reusable 7
6 Bolt 6 M9 × 84 mm
7
8
9
10
Bolt
Plate
Gasket
Screw
3
1
1
4
M6 × 25 mm
Not reusable
ø4 × 9 mm
8
12
13
14
Cylinder head cover
Bolt
Plug
1
5
2
M6 × 20 mm
Not reusable
9
15 O-ring 2
16 Anode 2
17 Screw 2 ø5 × 24 mm
6AJ5K11 5-28
POWR Power unit
14 N·m (1.4 kgf·m, 10.3 ft·lb) E
E E
E
E
M
E
E
E
E 6AJ5050E

1 Cylinder head 1
2 Valve spring seat 4
3 Shaft 1
4 Intake valve 2
5 Exhaust valve 2
6 Valve spring 4
7 Valve spring retainer 4
8 Valve cotter 8
9 Valve seal 4 Not reusable
10 Collar 2
11 Bolt 1 M6 × 12 mm
12 Plate 1
13 Bolt 3 M6 × 35 mm
14 Oil pump assembly 1
15 Rocker arm 4
16 Adjusting screw 4
17 Locknut 4
5-29 6AJ5K11
Cylinder head
14 N·m (1.4 kgf·m, 10.3 ft·lb) E
1
E
E
2
E
3
E E
E 4
E
E
E
M
E
E
5
M
No. Part name

E
Q’ty Remarks
6AJ5050E
6
18 Camshaft 1
19
20
21
22
Pin
Oil seal
Valve guide
Gasket
1
1
4
1
Not reusable
Not reusable
Not reusable
7
23 Spring 2
8
9
6AJ5K11 5-30
POWR Power unit
Removing the cylinder head 6

5
1. Remove the cylinder head cover. 4 4
6
5
2. Remove the cylinder head bolts in the
3
sequence shown. 2
6
S6AG5160
NOTE:
9 Loosen the locknut and adjust screw to
slack off the tension, before remove the
rocker arm shaft.
6AJ50070 9 Be sure to keep the parts in the order as
they were removed.
cC
Do not scratch or damage the mating sur-
faces of the cylinder head and cylinder 3. Remove the camshaft 7, and then
block. remove the oil seal 8.
7
Disassembling the cylinder head
8
1. Remove the oil pump assembly 1.
S6AG5170
4. Remove the intake and exhaust valves.
S6AG5150
9
NOTE:
0
To disassemble, check, and assemble the oil
pump, see “Checking the oil pump” (5-41).
2. Remove the plate 2 from the cylinder

head, pull out the shaft 3, and then
remove the springs 4, collars 5, and
rocker arms 6.
S6AG5130
5-31 6AJ5K11
Cylinder head
NOTE: Checking the valve spring

Be sure to keep the valves, springs, and other 1. Measure the valve spring free length a.
parts in the order as they were removed. Replace if below specification.
Valve spring compressor 9:

90890-04019
1
Valve spring compressor
attachment 0: 90890-06320
Checking the cylinder head a S68V5775

2
1. Eliminate carbon deposits from the com-
bustion chambers and check for deterio-
ration.
2. Check the cylinder head warpage using a

Valve spring free length a:
32.63 mm (1.2846 in) 3
straightedge 1 and thickness gauge 2 2. Measure the valve spring tilt b. Replace
in the directions shown. Replace the
cylinder head assembly if above specifi-
cation.
if above specification.
4
2
1
5
S69J5730
S6AG5260
Valve spring tilt limit b:
1.4 mm (0.055 in)
6
7
S6AG5270
8
Cylinder head warpage limit:
0.10 mm (0.0039 in)
9
6AJ5K11 5-32
POWR Power unit
Checking the valve

1. Check the valve face. Replace the valve if
pitted or worn.
2. Measure the valve margin thickness a.

Replace the valve if out of specification.
S69J5760
Valve stem runout limit:

0.01 mm (0.0004 in)
S69J5740 Checking the valve guide

NOTE:
Valve margin thickness a: Before checking a valve guide, make sure
Intake: that the valve stem diameter is within specifi-
0.8–1.2 mm (0.0315–0.0472 in) cation.
Exhaust:
1.0–1.4 mm (0.0394–0.0551 in)
1. Measure the valve guide inside diameter
3. Measure the valve stem diameter b. a.
Replace the valve if out of specification.
S6D55490
S69J5750
Valve guide inside diameter a:
Valve stem diameter b: Intake and exhaust:
Intake: 5.500–5.512 mm
5.475–5.490 mm (0.2165–0.2170 in)
(0.2156–0.2161 in)
Exhaust: 2. Calculate the valve-stem-to-valve-guide
5.460–5.475 mm clearance as follows. Replace the valve
(0.2150–0.2156 in) guide if out of specification.
4. Measure the valve stem runout. Replace

the valve if above specification.
5-33 6AJ5K11
Cylinder head
Valve-stem-to-valve-guide clearance Valve guide remover/installer 3:

= valve guide inside diameter – 90890-06801
valve stem diameter:
Intake:
0.010–0.037 mm
(0.0004–0.0015 in)
Exhaust:
Valve guide height a:
Intake and exhaust:
10.8 ± 0.2 mm (0.4 ± 0.01 in)
1
0.025–0.052 mm
(0.0010–0.0020 in) 4. Insert the special service tool into the
valve guide 2, and then ream the valve
guide. 2
Replacing the valve guide 4
1. Remove the valve seal.
2. Remove the valve guide 1 by striking the

special service tool from the combustion
3
chamber side. 2
1
E
S6AG5190 4
NOTE:
9 Apply engine oil to the inner surface of the
S6AG5181
valve guide before reaming it.
9 Turn the valve guide reamer clockwise to
ream the valve guide.
5
9 Do not turn the reamer counterclockwise
6
when removing it.
Valve guide remover/installer: 9 Be sure to clean the valve guide after ream-
90890-06801 ing it.
3. Install a new valve guide 2 using the
7
Valve guide reamer 4:
special service tool 3 from the camshaft
90890-06804
side to the specified height a.
5. Measure the valve guide inside diameter.

2
3
8
Valve guide inside diameter:
Intake and exhaust:
5.500–5.512 mm
(0.2165–0.2170 in)
a
NOTE:
E
S6AG5180
Checking the valve seat
1. Eliminate carbon deposits from the valve.
9
Apply engine oil to the surface of the new
2. Apply a thin, even layer of Mechanic’s
valve guide before installation.
blueing dye (Dykem) onto the valve seat.
6AJ5K11 5-34
POWR Power unit
3. Press the valve slowly against the valve Refacing the valve seat
seat with a valve lapper as shown. 1. Reface the valve seat with the valve seat
cutters.
S6AG5200
S69J5850
4. Measure the valve seat contact width a

where the blueing dye is adhered to the Valve seat cutter holder:
valve face. Reface the valve seat if the 90890-06316
valve is not seated properly or if the valve Valve seat cutter:
seat contact width is out of specification. 30° (intake): 90890-06818
Check the valve guide if the valve seat 30° (exhaust): 90890-06819
contact is uneven. 45° (intake): 90890-06555
45° (exhaust): 90890-06312
60° (intake): 90890-06323
60° (exhaust): 90890-06315
2. Cut the surface of the valve seat with a

45° cutter by turning the cutter clockwise
until the valve seat face has become
smooth.
S69J5830
S6AG5210
45˚
a
S69J5840
Valve seat contact width a:

Intake and exhaust:
1.2–1.6 mm (0.047–0.063 in) S6AG5J20J
a Slag or rough surface
5-35 6AJ5K11
Cylinder head
cC 6. Check the valve seat contact area of the

valve.
Do not over cut the valve seat. Be sure to
turn the cutter evenly downward at a pres- NOTE:
sure of 40–50 N (4–5 kgf, 8.8–11 lbf) to pre-
vent chatter marks.
To check the valve seat contact area, see
“Checking the valve seat” (5-34).
1
3. Use a 30° cutter to adjust the contact 7. If the valve seat contact area is too wide
width of the top edge of the valve seat.
30˚
and situated in the center of the valve
face, use a 30° cutter to cut the top edge
of the valve seat and a 60° cutter to cut
the bottom edge to center the area and
2
b
set its width.
30˚
b
3
b Previous contact width
S6AG5J60J
4. Use a 60° cutter to adjust the contact 60˚

4
S6AG5J30J
width of the bottom edge of the valve
seat.
b
8. If the valve seat contact area is too nar-

5
row and situated near the top edge of the
valve face, use a 30° cutter to cut the top
edge of the valve seat, and then use a
45° cutter to center the area and set its
width.
6
60˚

S6AG5J70J
30˚
b
7
5. Use a 45° cutter to adjust the contact
8
width of the valve seat to specification.
b S6AG5J40J
c
45˚
9
S6AG5J80J

c Specified contact width
6AJ5K11 5-36
POWR Power unit
9. If the valve seat contact area is too nar- Checking the rocker arm and rocker
row and situated near the bottom edge of arm shaft
the valve face, use a 60° cutter to cut the 1. Check the rocker arms, rocker arm shaft,
bottom edge of the valve seat, and then and rocker arm contact surface a.
use a 45° cutter to center the area and Replace if worn.
set its width.
2. Measure the rocker arm inside diameter
b and rocker arm shaft outside diameter
c. Replace if out of specification.
b
a
b c
60˚
S6AG5J50J
S6AG5230
10. After refacing the valve seat to the speci-
fied contact width, apply a thin, even layer
of lapping compound onto the valve seat, Rocker arm inside diameter b:
and then lap the valve using a valve lap- 13.000–13.018 mm
per. (0.5118–0.5125 in)
Rocker arm shaft outside
diameter c:
12.941–12.951 mm
(0.5095–0.5099 in)
Checking the camshaft

1. Measure the cam lobe. Replace if out of
S6AG5220 specification.
cC
Do not get the lapping compound on the
valve stem and valve guide.
11. After every lapping procedure, be sure to

clean off any remaining lapping com-
pound from the cylinder head and the S69J5950
valve.
12. Check the valve seat contact area of the

valve again.
NOTE:
To check the valve seat contact area, see
“Checking the valve seat” (5-34).
5-37 6AJ5K11
Cylinder head
Cam lobe a: Camshaft journal diameter c:

Intake: 21.967–21.980 mm
28.546–28.646 mm (0.8648–0.8654 in)
(1.1239–1.1278 in)
Exhaust:
28.582–28.682 mm
(1.1253–1.1292 in)
Camshaft journal diameter d:
33.935–33.955 mm
(1.3360–1.3368 in)
Cylinder head journal inside
1
Cam lobe b: diameter e:
Intake and exhaust:
23.95–24.05 mm
(0.9429–0.9468 in)
22.000–22.021 mm
(0.8661–0.8670 in)
Cylinder head journal inside
diameter f:
2
2. Measure the camshaft runout. Replace if 34.000–34.025 mm
above specification. (1.3386–1.3396 in)
4. Check the automatic decompression

3
actuator. Replace the camshaft if dam-
4
aged or worn.
Camshaft runout limit:

S6AG5240
5
0.03 mm (0.0012 in)
6
S6AG5245
3. Measure the camshaft journal diameters

c and d and the cylinder head journal
inside diameters e and f. Replace the Assembling the cylinder head
camshaft, cylinder head, or both if out of 1. Install a new valve seal 1 onto the valve
specification.
e
f
c
guide.
1
7
d
E
8
S6AG5250 S6AG5280
9
6AJ5K11 5-38
POWR Power unit
2. Install the valve 2, valve spring seat 3, 4. Lightly tap the valve spring retainer with a
valve spring 4, and valve spring retainer plastic hammer to set the valve cotters 8
5 in the sequence shown, and then securely.
attach the special service tools.
a
6 5
7
E
S6AG5300
4
8 8
3
S6AG5290
S6AG5310
NOTE:
Face the wide pitch spring end a, identified by 5. Install a new oil seal 9.
the paint mark, toward the valve spring retain-
er 5. 0
q
Valve spring compressor 6:
90890-04019
Valve spring compressor 9
E
attachment 7: 90890-06320
3. Compress the valve spring, and then

install the valve cotters 8.
8 S6AG5330
Driver rod L3 0: 90890-06652

Needle bearing attachment q:
90890-06653
S6AG5291
5-39 6AJ5K11
Cylinder head
6. Install the camshaft w in the direction 9. Install the oil pump by aligning the slot d
shown. in the oil pump drive shaft with the
camshaft pin i.
w
E
M
e
1
E e
S6AG5340
S6AG5380
2
3
7. Align the keyway b in the camshaft with
the mark c on the cylinder head as
shown.
4
d
5
c b i
S6AG5350
S6AG5390
8. Install the rocker arms e, springs r, and

NOTE:
collars t into the cylinder head, and then
install the shaft y and plate u.
r
e
t
r
9 To disassemble, check, and assemble the
oil pump, see “Checking the oil pump” (5-
41).
9 Before installing the oil pump, be sure to fill
6
e
it with a small amount of engine oil through
e
t
y
u
the oil passages e.
7
S6AG5370
8
9
6AJ5K11 5-40
POWR Power unit
Installing the cylinder head

1. Install a new gasket and the cylinder
head, and then tighten the bolts to the
specified torques in the sequence shown.
1
S6AG5430
2. Check the inner surface of the oil pump

case. Replace the oil pump assembly if
scratched.
a 60˚
3. Measure the oil pump rotor clearances as
E shown. Replace the oil pump assembly if
out of specification.
6AJ50080
cC
Do not reuse the cylinder head gasket,
always replace it with a new one.
NOTE:
9 Apply engine oil to the cylinder head bolts
before installation.
S6D55580
9 Tighten the bolts to the specified torques in
3 stages.
9 Make a mark a on cylinder head bolts (M9)
and the cylinder head, and then tighten the
bolts 60° from the mark.
a b
Cylinder head bolt (M9):

1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
2nd: 29 N·m (2.9 kgf·m, 21.4 ft·lb)
3rd: 60°
Cylinder head bolt (M6):
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) c
Checking the oil pump

1. Remove the oil pump screws 1 and dis- S6AG5420
assemble the oil pump.
5-
5-41 6AJ5K11
Cylinder head
Clearance a:
0.09–0.15 mm (0.0035–0.0059 in)
Clearance b:
Within 0.12 mm (0.0047 in)
Clearance c:
0.03–0.08 mm (0.0012–0.0031 in) 1
4. Assemble the oil pump, and then tighten
the oil pump screws 1 to the specified
torque. 2
3
C
2
C 4
1342
5
6
1 6AJ50090
NOTE:
When assembling the oil pump, face the “C”
mark on each rotor 2 up.
Oil pump screw 1:

5 N·m (0.5 kgf·m, 3.7 ft·lb)
7
8
9
6AJ5K11 5-42
POWR Power unit
Cylinder block
8 N·m (0.8 kgf·m, 5.9 ft·lb)

UP
LT
271
2 N·m (0.2 kgf·m, 1.5 ft·lb)
S518
E
14 N·m (1.4 kgf·m, 10.3 ft·lb)
27 N·m (2.7 kgf·m, 19.9 ft·lb) E
E
S518
LT
E LT 271
271
18 N·m (1.8 kgf·m, 13.3 ft·lb)

6 N·m (0.6 kgf·m, 4.4 ft·lb)
E 12 N·m (1.2 kgf·m, 8.9 ft·lb)
2 N·m (0.2 kgf·m, 1.5 ft·lb)
6 N·m (0.6 kgf·m, 4.4 ft·lb)
18 N·m (1.8 kgf·m, 13.3 ft·lb)
12 N·m (1.2 kgf·m, 8.9 ft·lb) 6AJ5060E

1 Cylinder block 1
3 Thermostat 1
5 Anode 2
6 Thermostat cover 1
7 Bolt 3 M6 × 25 mm
8 Oil filter 1
10 Exhaust cover 1
11 Bolt 7 M6 × 25 mm
12 Plug 1
13 Anode 1
14 Screw 1 ø4 × 16 mm
15 Piston ring set 2
16 Clip 4 Not reusable
17 Piston pin 2
5-
5-43 6AJ5K11
Cylinder block
8 N·m (0.8 kgf·m, 5.9 ft·lb)

UP
1
LT
271
2 N·m (0.2 kgf·m, 1.5 ft·lb)

2
S518
E
3
14 N·m (1.4 kgf·m, 10.3 ft·lb)
27 N·m (2.7 kgf·m, 19.9 ft·lb) E
E
4
S518
LT
E LT 271
271
E
18 N·m (1.8 kgf·m, 13.3 ft·lb)
6 N·m (0.6 kgf·m, 4.4 ft·lb)
12 N·m (1.2 kgf·m, 8.9 ft·lb)
5
2 N·m (0.2 kgf·m, 1.5 ft·lb)
6
6 N·m (0.6 kgf·m, 4.4 ft·lb)
18 N·m (1.8 kgf·m, 13.3 ft·lb)
12 N·m (1.2 kgf·m, 8.9 ft·lb) 6AJ5060E

18 Piston 2
19
20
21
22
Connecting rod
Bolt
Oil seal
Crankshaft
2
4
1
1
M6 × 36 mm
Not reusable 7
23 Main bearing 4
24
25
26
27
Oil seal
Crankcase
Bolt
Bolt
1
1
6
4
Not reusable
M6 × 40 mm
M8 × 65 mm
8
9
6AJ5K11 5-44
POWR Power unit
Disassembling the cylinder block 5. Remove the connecting rod cap bolts and
1. Remove the exhaust cover bolts in the connecting rod caps, and then remove
sequence shown, and then remove the the connecting rod and piston assem-
exhaust cover. blies.
S6AG5790
2. Remove the thermostat cover.
S6AG5A10J
3. Remove the oil filter using a 64 mm (2.5
in) oil filter wrench.
6. Remove the crankshaft, main bearings
and oil seals.
NOTE:
Be sure to keep the main bearings in the
order as they were removed.
7. Remove the piston pin clips 1 and piston

S6AG5810 pin, and then remove the piston.
b 1
Oil filter wrench: 90890-01426 a

1
1
4. Remove the crankcase bolts in the
1
sequence shown, and then remove the

1
crankcase.
UP
1 S6AG5840
NOTE:
9 Mark each piston with an identification
number a of the corresponding cylinder.
9 To avoid interchanging the connecting rods
and connecting rod caps, mark each with
an identification mark b and be sure to
S6AG5820
keep them in the order as they were
removed.
8. Remove the piston rings.
5-45 6AJ5K11
Cylinder block
Checking the piston diameter Cylinder bore (D1–D6):

1. Measure the piston diameter at the spec- 63.000–63.015 mm
ified measuring point. Replace if out of (2.4803–2.4809 in)
specification.
Checking the piston clearance

1. Check the piston clearances if replacing
1
the piston, the piston ring set, the cylin-
der block, or all parts.
NOTE:
The figures are for reference only. Depending
2
S6AG5850
on how the parts are assembled, the actual
Piston diameter a:
62.950–62.965 mm
measurements may not be within the speci-
fied ranges.
3
(2.4783–2.4789 in) Piston clearance (reference data):
Measuring point b:
3.5 mm (0.14 in) up from the
bottom of the piston skirt
Oversize piston diameter:
0.035–0.065 mm
(0.0014–0.0026 in)
4
Oversize 1st:
5
63.200–63.215 mm
(2.4882–2.4888 in)
Oversize 2nd:
63.450–63.465 mm
(2.4980–2.4986 in)
Checking the cylinder bore

6
1. Measure the cylinder bore (D1–D6) at
measuring points a, b, and c, and in
direction d (D1, D3, D5), which is parallel
to the crankshaft, and in direction e (D2,
D4, D6), which is at a right angle to the
7
crankshaft.
c
b a D2 D1 d
8
D4 D3 e
D6 D5
S69J5B70
9
a 20 mm (0.8 in)
b 40 mm (1.6 in)
c 60 mm (2.4 in)
6AJ5K11 5-46
POWR Power unit
Checking the piston ring

1. Measure the piston ring dimensions B
and T. Replace the piston ring set if out of
specification.
S69J5B80
b a
Piston ring dimensions:
Top ring a:
B: 1.17–1.19 mm S6AG5860
(0.0461–0.0469 in) NOTE:

T: 2.25–2.45 mm The figures are for reference only. Depending
(0.0886–0.0965 in) on how the parts are assembled, the actual
2nd ring b: measurements may not be within the speci-
B: 1.17–1.19 mm fied ranges.
(0.0461–0.0469 in)
T: 2.4–2.6 mm
(0.0945–0.1024 in) Piston ring end gap a (reference
Oil ring c: data):
B: 2.34–2.46 mm Top ring:
(0.0921–0.0969 in) 0.15–0.30 mm
T(reference data): 2.75 mm (0.0059–0.0118 in)
(0.1083 in) 2nd ring:
0.25–0.4 mm
(0.0098–0.0157 in)
Oil ring:
Checking the piston ring end gap 0.2–0.7 mm (0.0079–0.0276 in)
1. Level the piston ring 1 in the cylinder Measuring point b (reference data):
with a piston crown. 20 mm (0.8 in)
2. Measure the piston ring end gap a at the

specified measuring point b.
Checking the piston ring groove
1. Measure the piston ring grooves.
Replace the piston if out of specification.
5-47 6AJ5K11
Cylinder block
Checking the piston pin boss bore

1. Measure the piston pin boss bore.
Replace the piston if out of specification.
a
1
2
S6AG5870
Piston ring groove:

Top ring a: S6AG5890
1.21–1.23 mm
(0.0476–0.0484 in)
2nd ring b:
1.21–1.23 mm
(0.0476–0.0484 in)
NOTE:
When measuring the piston pin boss bore, do
not measure it at the ring groove a.
3
Oil ring c:
2.51–2.53 mm
(0.0988–0.0996 in)
Piston pin boss bore:
16.004–16.015 mm
(0.6301–0.6305 in)
4
Checking the piston ring side
clearance
1. Measure the piston ring side clearance.
Replace the piston and piston rings as a
Checking the piston pin diameter
1. Measure the piston pin diameter.
Replace if out of specification.
5
set if out of specification.
6
S6AG5880
S69J5C30
7
Piston pin diameter:
Piston ring side clearance:
Top ring a:
0.02–0.06 mm
15.995–16.000 mm
(0.6297–0.6299 in) 8
(0.0008–0.0024 in)
2nd ring b:
0.02–0.06 mm
(0.0008–0.0024 in)
Oil ring c:
Checking the connecting rod small
and big end inside diameter
1. Tighten the connecting rod cap bolts to
the specified torques in 2 stages.
9
0.05–0.19 mm
(0.0020–0.0075 in) Connecting rod cap bolt:
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
6AJ5K11 5-48
POWR Power unit
2. Measure the connecting rod small end

inside diameter a and big end inside
diameter b. Replace the connecting rod
b
a
a
S6AG5910
a
b
S6AG5H70
Connecting rod small end inside

diameter a:
16.015–16.029 mm
(0.6305–0.6311 in) c
c S6AG5920
Connecting rod big end inside diam-
eter b:
Crankshaft journal diameter a:
34.030–34.042 mm
36.997–37.009 mm
(1.3398–1.3402 in)
(1.4566–1.4570 in)
Crankpin diameter b:
33.997–34.009 mm
Checking the connecting rod big (1.3385–1.3389 in)
end side clearance Crankpin width c:
1. Measure the connecting rod big end side 21.000–21.070 mm
clearance a. (0.8268–0.8295 in)
2. Measure the crankshaft runout. Replace

a if above specification.
a
S6D55800
Connecting rod big end side clear-

ance a (reference data): S6AG5930
0.05–0.22 mm (0.0020–0.0087 in)
Crankshaft runout limit:
0.05 mm (0.0020 in)
Checking the crankshaft
1. Measure the crankshaft journal diameter
a, crankpin diameter b, and crankpin Checking the crankpin oil clearance
width c. Replace the crankshaft if out of 1. Clean the contact surfaces of the con-
specification. necting rod and crankpin.
5-49 6AJ5K11
Cylinder block
2. Put a piece of Plastigauge (PG-1) onto

the crankpin, parallel to the crankshaft.
1
S69J5D00
NOTE:
S62Y5980
Do not turn the connecting rod until the

crankpin oil clearance measurement has
2
NOTE: been completed.
Be sure not to put the Plastigauge (PG-1)
over the oil hole in the crankpin of the crank-
shaft. Connecting rod cap bolt:
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
3
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
3. Install the connecting rod 1 to the
crankpin 2. 5. Remove the connecting rod cap and
measure the width of the compressed
4
a Plastigauge (PG-1) on each crankpin.
5
Check the connecting rods and crank-
1 shaft if out of specification and, if neces-
sary, replace them as a set.
6
E
2
S69J5D30 7
Crankpin oil clearance (reference
1 data):
8
S6AG5940
0.021–0.045 mm
NOTE: (0.0008–0.0018 in)
Make sure that the projections a of the con-
necting rod face towards the flywheel magnet
side å of the crankshaft.
4. Tighten the connecting rod cap bolts to

Checking the crankshaft journal oil
clearance
1. Clean the main bearings, crankshaft jour-
nals, and bearing portions of the
9
the specified torques in 2 stages.
crankcase and cylinder block.
2. Place the cylinder block upside down on

a bench.
6AJ5K11 5-50
POWR Power unit
3. Install half of the main bearings 1 and 6. Install the crankcase onto the cylinder
the crankshaft 2 into the cylinder block block.
3.
NOTE:
Apply engine oil to the threads of the
3
crankcase bolts.
2
7. Tighten the crankcase bolts to the speci-

fied torques in 2 stages and in the
sequence shown.
1
a
S6D55860
NOTE:
9 Install the main bearings in their original
positions.
9 Insert the projection a of each bearing into
the slots in the cylinder block.
E S6AG5830
4. Put a piece of Plastigauge (PG-1) on NOTE:

each crankshaft journal parallel to the Do not turn the crankshaft until the crankshaft
crankshaft. journal oil clearance measurement has been
completed.
Crankcase bolt z–v (M8):

1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
2nd: 27 N·m (2.7 kgf·m, 19.9 ft·lb)
Crankcase bolt b–⁄0 (M6):
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
S6D55870
NOTE: 8. Gently remove the crankcase, and then

Be sure not to put the Plastigauge (PG-1) measure the width of the compressed
over the oil hole in each main journal of the Plastigauge (PG-1) on each crankshaft
crankshaft. journal. Replace the main bearings if out
of specification.
5. Install the remaining half of the main

bearings into the crankcase.
NOTE:
positions.
9 Insert the projection of each bearing into
the slots in the crankcase.
S6D55880
5-51 6AJ5K11
Cylinder block
NOTE: Stamped marks

When loosening the crankcase bolts, loosen Bearing color c
a and c
them in the opposite order used for tighten-
A Blue
ing.
Crankshaft journal oil clearance

(reference data):
B
C
Black
Brown
1
0.011–0.039 mm Assembling the cylinder block
(0.0004–0.0015 in) 1. Assemble the piston 1, connecting rod
2, piston pin 3, and piston pin clips 4.
a
2
Selecting the crankshaft main
bearing
1. Check the stamped marks a and b on
the crankcase and cylinder block.
1
2
3
a E
1
#1 #2
4
E
3
UP
4
4 c
b
a
c
cC
E S6AG5960
5
Do not reuse the piston pin clips 4,
6
always replace them with new ones.
NOTE:
9 Face the projections a on the connecting
rod in the same direction as the “UP” mark
7
b S6AG5950 b on the piston.
9 Do not allow the piston pin clip end to align
NOTE:
with the piston pin slot c.
The stamped mark a for the main bearing of
crankshaft journal #1 is on the crankcase
cover and the stamped mark b for the main
bearing of crankshaft journal #2 is on the
cylinder block. 8
2. Select the suitable bearing color c for
the main bearing from the table.
9
6AJ5K11 5-52
POWR Power unit
2. Install the oil ring 5, 2nd ring 6, and top NOTE:

ring 7 onto each piston. Apply engine oil to the side of the pistons and
piston rings before installation.
NOTE:
Make sure that the “T” marks d of the 2nd
ring and the top ring are facing upward.
Piston slider 8: 90890-06529
3. Offset the piston ring end gaps as shown.

5. Install half of the main bearings 9 into
d 45˚ 45˚ the cylinder block 0.
#3 #2
UP
0
T
UP
63P
5
#5 #1,#4 #5
#4 9
#3 6 E
#2 7
#1
e S6AG5990
E
T
d
NOTE:
S6D55900
cC positions.
Do not scratch the pistons or break the 9 Insert the projection e of each bearing into
piston rings. the slots in the cylinder block.
NOTE:
6. Install the crankshaft q and oil seals w
After installing the piston rings, check that
and e into the cylinder block as shown.
they move smoothly.
q
E
4. Install the piston with the “UP” mark on
the piston crown facing towards the fly-
wheel magnet. e
UP
8 E
w
S6AG5A00
S6AG5980
NOTE:
Apply engine oil to the inside of the oil seals
before installation.
5-53 6AJ5K11
Cylinder block
7. Install the connecting rod caps r to the

connecting rods, and then tighten the
E
connecting rod cap bolts to the specified
1
torques in 2 stages.
E S518
E
f
r
E
å f
NOTE:
S6AG5A20
Do not get any sealant on the main bearings.

2
10. Install the crankcase onto the cylinder
block.
NOTE:
3
S6AG5A10 Apply engine oil to the threads of the
NOTE:
9 Make sure that the projections f on the
connecting rod cap face towards the fly-
crankcase bolts.
11. Tighten the crankcase bolts to the speci-

4
wheel magnet end å of the crankshaft. fied torques in 2 stages and in the
9 Apply engine oil to the connecting rod cap
bolts before installation.
9 After tightening the connecting rod cap
bolts, check that the crankshaft rotates
sequence shown.
5
smoothly.
Connecting rod cap bolt:

1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
6
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
7
E S6AG5830
8. Install the remaining half of the main

bearings into the crankcase. Crankcase bolt z–v (M8):
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
NOTE:
2nd: 27 N·m (2.7 kgf·m, 19.9 ft·lb)
positions.
9 Insert the projection of each bearing into
the slots in the crankcase.
Crankcase bolt b–⁄0 (M6):
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 8
9. Apply sealant to the mating surface of the
crankcase. 9
6AJ5K11 5-54
POWR Power unit
12. Install the oil filter, and then tighten it to Exhaust cover bolt:
the specified torque using a 64 mm (2.5 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
in) oil filter wrench. 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
g
Installing the power unit
E 1. Clean the power unit mating surface, and
then install the dowels 1, a new gasket
2, and the power unit 3.
cC
S6AG5A40 Do not reuse the gasket, always replace
with a new one.
NOTE:
9 Before installing the oil filter, be sure to sup-
ply engine oil to the oil passage g. 2. Install the mounting bolts 4, and then
9 Apply a thin coat of engine oil to the O-ring tighten them to the specified torque.
of the new oil filter before installation.
Oil filter wrench: 90890-01426
3
Oil filter: BOW
18 N·m (1.8 kgf·m, 13.3 ft·lb) 2
1 1
13. Install a new gasket, the thermostat, and
the thermostat cover.
Thermostat cover bolt:

8 N·m (0.8 kgf·m, 5.9 ft·lb)
LT
14. Install a new gasket and the exhaust 572
4
cover, and then tighten the bolts to the 4 4 S6AG5H50
specified torques in 2 stages and in the

sequence shown. NOTE:
Before installing the power unit, be sure to
remove the fuel pump to prevent damaging it.
Power unit mounting bolt:

1st: 27 N·m (2.7 kgf·m, 19.9 ft·lb)
2nd: 27 N·m (2.7 kgf·m, 19.9 ft·lb)
3. Install the apron and dipstick.

S6AG5800
4. Install the shift rod cam 5, and then

tighten the bolts 6.
5-55 6AJ5K11
Cylinder block
NOTE:
When installing the throttle cam 9 to the
7
bracket r, be sure to hook the end a of the
7 spring onto the projection b of the bracket as
shown.
1
Bolt e: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
6
5 6 6. Turn the throttle cam 9 counterclockwise
c until the fully open stopper d on the
2
6AJ50065 cam contacts the throttle cam bracket,
3
and then release e it and check that the
NOTE:
fully closed stopper f on the cam con-
Before installing the shift rod cam 5, make
tacts the bracket due to the spring force.
sure that the shift link rods 7 is installed cor-
rectly. e 9
5. Install the spring 8, throttle cam 9, shaft

0, free accel lever q, washer w, and
d c
4
bolt e, and then tighten the bolt to the
specified torque.
r
f
S6AG5780 5
NOTE:
If the fully closed stopper f does not contact
8
9
0 q
w e
the bracket, check that the spring is installed
correctly. If the end a of the spring is not
hooked onto the projection b on the bracket,
6
repeat steps 5–6.
7. Install the throttle cables onto the throttle

cam 9, and then adjust the throttle
7
M cables.
a b S6AG5770
NOTE:
9 To adjust the throttle cables, see “Adjusting
the throttle cable” (3-8).
9 Install the steering bracket cover after
8
adjusting the throttle cables.
9
6AJ5K11 5-56
POWR Power unit
8. Install the bracket t and warning indica- 11. Fasten the lead with the plastic tie a and
tor assembly y. holders s, and then install the junction
box cover.
12. Connect the flushing hose d, cooling

water hose f, and fuel hose g.
t y
6AJ50055
9. Install the junction box bracket u.
10. Connect the engine shut-off switch lead d f g S6AG5D01
i. Install the engine shut-off switch lead

(B) terminal o using the bolt p. 13. Install the manual starter and sprocket
cover, and then connect the start-in-gear
protection cable.
NOTE:
a s i To connect the start-in-gear protection cable,
see “Checking the start-in-gear protection” (3-
10).
14. Pour the specified amount of the recom-

mended engine oil into the oil filler hole.
NOTE:
u For the specified amount and recommended
6AJ50035
engine oil, see “Changing the engine oil” (3-
4).
6AJ50045
5-57 6AJ5K11
LOWR
Lower unit
Lower unit ..................................................................................................... 6-1

Removing the lower unit ..........................................................................
Removing the water pump ......................................................................
Checking the water pump ........................................................................
6-4
6-5
6-5
1
Propeller shaft housing ............................................................................... 6-6
Removing the propeller shaft housing assembly ..................................... 6-7
Disassembling the propeller shaft assembly ........................................... 6-7
Disassembling the propeller shaft housing assembly ............................. 6-7
2
Checking the propeller shaft housing ...................................................... 6-8
3
Checking the propeller shaft .................................................................... 6-8
Assembling the propeller shaft assembly ................................................ 6-8
Assembling the propeller shaft housing .................................................. 6-9
Drive shaft and lower case ....................................................................... 6-11

Removing the drive shaft, drive shaft housing, and shift rod ................ 6-12
Disassembling the drive shaft housing .................................................. 6-12
Disassembling the forward gear ............................................................ 6-12
Disassembling the lower case ............................................................... 6-13
4
Checking the pinion and forward gear ................................................... 6-13
Checking the bearing ............................................................................ 6-13
Checking the drive shaft ........................................................................ 6-13
Checking the shift rod ............................................................................ 6-13
Checking the lower case ....................................................................... 6-14
5
Assembling the lower case .................................................................... 6-14
Assembling the forward gear ................................................................. 6-14
Assembling the drive shaft housing ....................................................... 6-15
Installing the shift rod, drive shaft housing, and drive shaft .................. 6-15
6
Installing the propeller shaft housing ..................................................... 6-16
Installing the water pump ...................................................................... 6-16
Installing the lower unit .......................................................................... 6-17
Shimming .................................................................................................... 6-20

7
Shimming ............................................................................................... 6-21
Selecting the pinion shim ......................................................................
Selecting the forward gear shim ............................................................
Selecting the reverse gear shim ............................................................
6-21
6-21
6-22
8
Backlash ..................................................................................................... 6-23
Measuring the forward and reverse gear backlash ............................... 6-23
9
6AJ5K11
LOWR Lower unit
Lower unit
1
1104J 17 N·m (1.7 kgf·m, 12.5 ft·lb)
12
14 18 N·m (1.8 kgf·m, 13.3 ft·lb)
13
14 LT
1104J 572
15
16
3
7
11
8
9
10
D
19
17
20 16
4
5 LT
2
572
LT 17 LT 21
572 18
3
572 22
18 N·m (1.8 kgf·m, 13.3 ft·lb)
6 8 N·m (0.8 kgf·m, 5.9 ft·lb)
S6AG6010J
9 N·m (0.9 kgf·m, 6.6 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb)

1 Rubber seal 1
2 Lower case 1
3 Bolt 4 M8 × 30 mm
4 Anode 1
5 Special washer 1 Not reusable
6 Bolt 1 M6 × 35 mm
7 Cotter pin 1 Not reusable
8 Propeller nut 1
9 Washer 1
10 Propeller 1
11 Spacer 1
12 Adjusting nut 1
13 Locknut 1
14 Dowel 2
15 Check screw 1
17 Cooling water inlet cover 2
6-1 6AJ5K11
Lower unit
12
M
1
1104J 17 N·m (1.7 kgf·m, 12.5 ft·lb)
1
14 18 N·m (1.8 kgf·m, 13.3 ft·lb)
13
15
16
14
1104J
LT
572
2
3
3
7
11
8
9
10
D
19
17
20 16
4
4
2
LT
572
3
17
18
5
LT
572
LT
572
22
21
5
18 N·m (1.8 kgf·m, 13.3 ft·lb)
6 8 N·m (0.8 kgf·m, 5.9 ft·lb)
No.
9 N·m (0.9 kgf·m, 6.6 ft·lb)
Part name
5 N·m (0.5 kgf·m, 3.7 ft·lb)
Q’ty Remarks
S6AG6010J
6
18 Screw 1
19
20
21
22
Nut
Drain screw
Trim tab
Bolt
1
1
1
1 M6 × 16 mm
7
8
9
6AJ5K11 6-2
LOWR Lower unit
8
8 18 N·m (1.8 kgf·m, 13.3 ft·lb)
LT
9 9 572
A
7
3
1
A
4
A
2
5
A
10
6
18 N·m (1.8 kgf·m, 13.3 ft·lb)
LT
4
572
11
2
A
S6AG6020J

1 Woodruff key 1
2 Impeller 1
3 Water pump housing 1
4 Insert cartridge 1
6 Dowel 2
7 Rubber seal 1
8 Bolt 4 M8 × 45 mm
9 Plate 2
10 Bolt 2 M8 × 25 mm
11 Outer plate cartridge 1
6-3 6AJ5K11
Lower unit
Removing the lower unit 4. Remove the locknut 2.

1. Drain the gear oil.
2
1
3
NOTE:
S6AG6421
2
Be sure to remove the locknut from the shift
S6AG6030
rod before removing the lower unit.
5. Remove the lower unit by removing the

3
2. Set the gear shift to the neutral position, lower case mounting bolts 4.
place a block of wood between the anti-
cavitation plate and propeller to keep the
propeller from turning, and then remove
the propeller nut and propeller.
6. Remove the trim tab 5, anode 6, and
cooling water inlet covers.
4
4
5
S6AG6040
5
6
w
Do not hold the propeller with your hands
when loosening or tightening it.
7
6
3. Loosen the locknut 2 while holding the
adjusting nut 1, and then turn the adjust-
ing nut to disconnect the shift rod 3.
4 S6AG6050J
8
NOTE:
9
Set the gear shift to the neutral position
before disconnecting the shift rod.
6AJ5K11 6-4
LOWR Lower unit
Removing the water pump

1. Remove the water pump housing 1 and
impeller 2.
2. Remove the Woodruff key 3 from the

drive shaft, and then remove the outer
plate cartridge 4.
3. Remove the dowels 5 from the lower

case.
3
1
5
4
S6AG6060J
Checking the water pump

1. Check the water pump housing. Replace
if deformed.
NOTE:
If the engine overheated, the inside of the
water pump housing may be deformed, there-
fore be sure to remove the insert cartridge
when checking the housing.
2. Check the impeller, insert cartridge, and

outer plate cartridge. Replace if cracked
or worn.
3. Check the Woodruff key and the keyway

in the drive shaft. Replace if worn or
deformed.
6-5 6AJ5K11
Lower unit / Propeller shaft housing
Propeller shaft housing
16
1
5
F 3
2
4
1
15
15
2
13
A
LT
572
G
11
A
3
8 N·m (0.8 kgf·m, 5.9 ft·lb)
14
13
11
15
16
4
12
6 7
G
R
9
G
10
8
5
14

S6AG6070
6
1 Shift plunger 1
2
3
4
5
Dog clutch
Cross pin
Cross pin ring
Spring
1
1
1
1
7
6 Washer 1
7
8
9
10
Reverse gear
O-ring
Reverse gear shim
Ball bearing
—
1
1
1
Not reusable
Not reusable
8
11 Needle bearing 1 Not reusable
12
13
14
O-ring
Bolt
1
2
1
Not reusable
M6 × 20 mm
Not reusable
9
15 Oil seal 2
16 Propeller shaft 1
6AJ5K11 6-6
LOWR Lower unit
Removing the propeller shaft Disassembling the propeller shaft

housing assembly housing assembly
1. Remove the bolts from the propeller shaft 1. Remove the reverse gear and shim(s).
housing.
2. Remove the propeller shaft housing 1,

and then remove the propeller shaft 2.
5 2 4
S6AG6100
2. Remove the ball bearing.

3
2
1
1
S6AG6080
3
Stopper guide plate 3: 90890-06501
Center bolt 4: 90890-06504
Bearing housing puller claw S 5: 4
90890-06564
S6AG6110
Disassembling the propeller shaft
assembly cC
1. Remove the shift plunger 1 from the pro-
Do not reuse the bearing, always replace it
peller shaft.
with a new one.
2. Remove the cross pin ring 2, and then

remove the cross pin 3 and dog clutch Stopper guide plate 1: 90890-06501
4. Center bolt 2: 90890-06504
Bearing puller assembly 3:
3. Pull out the spring 5 from the propeller 90890-06535
shaft. Stopper guide stand 4:
90890-06538
2
4
3. Remove the oil seals and the needle
1 bearing.
5
S6AG6090
6-7 6AJ5K11
Propeller shaft runout limit:

0.05 mm (0.0020 in)
5
6
3. Check the dog clutch, shift plunger, and
cross pin. Replace if cracked or worn.
1
Assembling the propeller shaft
assembly
1. Insert the spring 1 into the propeller
shaft.
2
S6AG6120
3
2. Install the dog clutch 2, cross pin 3, and
cC cross pin ring 4.
Do not reuse the bearing, always replace it NOTE:
with a new one. Install the dog clutch with the “F” mark facing
toward the forward gear.
Driver rod L3 5: 90890-06652

Needle bearing attachment 6:
90890-06616
3. Install the shift plunger 5.
4
4
Checking the propeller shaft

housing
5
2
5
1. Clean the propeller shaft housing, and 3
6
then check it. Replace if cracked or dam-
aged. F 1
S6AG6150
2. Check the teeth and dogs of the reverse
gear. Replace the reverse gear if cracked
or worn.
Checking the propeller shaft

5
4 3
2
1
7
1. Check the propeller shaft. Replace if
damaged or worn.
2. Measure the propeller shaft runout.

Replace if above specification.
S6AG6140
8
9
S6AG6130
6AJ5K11 6-8
LOWR Lower unit
Assembling the propeller shaft NOTE:

housing Install an oil seal halfway into the propeller
1. Install a new needle bearing into the pro- shaft housing, and then install the other oil
peller shaft housing to the specified seal.
depth using a press.
Driver rod L3 3: 90890-06652

90890-06613
1
Installation depth a:
3.0–3.5 mm (0.12–0.14 in)
G
2 3. Install a new ball bearing into the pro-

peller shaft housing.
S6AG6160
5
NOTE:
6
Install the needle bearing with the manufac-
ture identification mark facing toward the oil
seal (propeller side).
Driver rod L3 1: 90890-06652 G

90890-06616
S6AG6180
2. Apply grease to new oil seals, and then

NOTE:
install them into the propeller shaft hous-
Install the ball bearing with the manufacture
ing to the specified depth a.
identification mark facing toward the reverse
gear.
A
Driver rod LS 5: 90890-06606
3 Ball bearing attachment 6:
a 90890-06632
4
4. Install the reverse gear and original

shim(s) into the propeller shaft housing.
S6AG6170
6-9 6AJ5K11
1
2
G
S6AG6190
NOTE:
9 Be sure to select the reverse gear shim(s) if
replacing the propeller shaft housing, ball
bearing, or lower case. To select the shims,
see “Shimming” (6-20).
9 After installing the reverse gear and
shim(s), check that the reverse gear rotates
3
smoothly.
4
5
6
7
8
9
6AJ5K11 6-10
LOWR Lower unit
Drive shaft and lower case
1
3 14
13
4 A
12
2 1
15
3
16
13
12
11
5
10
G
9
G
6
7
G
8
G 25 N·m (2.5 kgf·m, 18.4 ft·lb)
S6AG6560

1 Drive shaft 1 L-transom model/S-transom model
2 Drive shaft housing 1
3 Drive shaft sleeve 1
4 Needle bearing 1 Not reusable
5 Pinion shim —
6 Forward gear 1
7 Taper roller bearing 1 Not reusable
8 Forward gear shim —
9 Pinion nut 1
10 Pinion 1
11 Thrust bearing 1
12 Bushing 1
13 Oil seal 2 Not reusable
16 Shift rod 1 L-transom model/S-transom model
6-11 6AJ5K11
Removing the drive shaft, drive Disassembling the drive shaft

shaft housing, and shift rod housing
1. Remove the pinion nut. 1. Remove the oil seals and bushing.
1 1
1 1
2
2
S6AG6200
2
S6AG6230
3
4
Driver rod L3 1: 90890-06652
Drive shaft holder 1 1: 90890-06515
Bushing attachment 2:
90890-06649
2. Remove the pinion, pinion shim(s), and
thrust bearing.
3. Remove the drive shaft, and then remove

the drive shaft housing assembly, gasket,
and shift rod.
Disassembling the forward gear
1. Remove the taper roller bearing from the
forward gear using a press.
5
2
1 6
S6AG6220
S6AG6240J
7
cC
cC
Be sure to remove the drive shaft before
removing the drive shaft housing from the
lower case.
Do not reuse the bearing, always replace it
with a new one. 8
4. Remove the drive shaft sleeve.
5. Pull out the forward gear.

90890-06616
Bearing separator 2: 90890-06534 9
6AJ5K11 6-12
LOWR Lower unit
Disassembling the lower case NOTE:

1. Remove the taper roller bearing outer Be sure to remove the forward gear before
race and forward gear shim(s). removing the needle bearing.
Driver rod L3: 90890-06652

Needle bearing attachment:
1 90890-06617
2 a Checking the pinion and forward

3
gear
1. Check the teeth of the pinion, and the
teeth and dogs of the forward gear.
Replace the pinion or forward gear if
S6AG6250
cracked or worn.
cC
Do not reuse the bearing, always replace it Checking the bearing
with a new one. 1. Check the bearings. Replace if pitted or if
there is rumbling.
NOTE:
Fit the hooks of the puller claw into the slots Checking the drive shaft
a in the lower case. 1. Check the drive shaft. Replace if bent or
worn.
Center bolt 2: 90890-06504 2. Measure the drive shaft runout. Replace
Bearing puller assembly 3: if above specification.
90890-06535
2. Remove the needle bearing from the

lower case.
S6AG6270
Drive shaft runout limit:

1.0 mm (0.0394 in)
S6AG6260
cC Checking the shift rod

Do not reuse the bearing, always replace it 1. Check the shift rod. Replace if bent or
with a new one. worn.
6-13 6AJ5K11
Checking the lower case NOTE:

1. Check the skeg, torpedo, and anti-cavita- 9 Install the needle bearing with the manufac-
tion plate. Replace the lower case if ture identification mark a facing upward.
cracked or damaged. 9 Install the stopper b onto the driver rod SL
Assembling the lower case

at the installation depth c as shown. Install
the needle bearing until the stopper b con-
tacts the bearing depth plate 6.
1
1. Install the original forward gear shim(s)
1 and new taper roller bearing outer
race 2.
Driver rod SL 5: 90890-06602
Bearing depth plate 6: 90890-06603
2
90890-06617
4 3
1 2
Installation depth c:
172.7–173.2 mm (6.80–6.82 in)
3
G
NOTE:
12 S6AG6280 Assembling the forward gear
1. Install a new taper roller bearing onto the
forward gear using a press.
4
Be sure to select the forward gear shim(s) if
5
replacing the lower case or taper roller bear-
ing. To select the shims, see “Shimming” (6-
20). 1
Driver rod LL 3: 90890-06605

Bearing outer race attachment 4:
90890-06625 G
S6AG6300
6
2. Install a new needle bearing into the
Bearing inner race attachment 1:
5
lower case to the specified depth c.
6
5
90890-06644
7
b
8
6
a
9
7
G 7
S6AG6290
6AJ5K11 6-14
LOWR Lower unit
Assembling the drive shaft housing Driver rod L3 3: 90890-06652

1. Install the bushing into the drive shaft Needle bearing attachment 4:
housing using a press. 90890-06613
a
Installation depth c:
1 7.0–8.0 mm (0.28–0.31 in)
b
Installing the shift rod, drive shaft

housing, and drive shaft
1. Install the forward gear assembly 1 into
G
the lower case.
2
2. Install the drive shaft sleeve 2 into the
S6AG6310 lower case.
NOTE:
NOTE: Install the drive shaft sleeve 2 with the hole
Align a groove a in the bushing with the hole a facing forward.
b in the drive shaft housing.
3. Install the shift rod, a new gasket 3, and

Driver rod L3 1: 90890-06652
the drive shaft housing assembly 4.
Bushing attachment 2:
90890-06649 NOTE:
Make sure that the projection b on the gas-
2. Apply grease to new oil seals, and then ket is toward the port side.
install them into the drive shaft housing to
the specified depth.
4. Install the drive shaft 5, thrust bearing
6, original pinion shim(s) 7, pinion 8,
and pinion nut 9 into the lower case.
3
c 4 5
3
b
2
4
A
a
S6AG6320
NOTE:
Install an oil seal halfway into the drive shaft 6
housing, and then install the other oil seal. 7
G
9 8
1 G
S6AG6330J
6-15 6AJ5K11
NOTE: 2. Install the washer 2 and propeller shaft

9 When installing the pinion, lift up the drive housing assembly 3 into the lower case,
shaft slightly and align the gear and shaft and then tighten the bolts 4 to the spec-
splines.
1
ified torque.
9 Be sure to select the pinion shim(s) if
replacing the pinion, thrust bearing, or A 4
lower case. To select the shims, see
“Shimming” (6-20).
5. Tighten the pinion nut to the specified

torque.
2 3
2
G
3
S6AG6360
Propeller shaft housing bolt 4:

8 N·m (0.8 kgf·m, 5.9 ft·lb)
0
3. Check that the shifting mechanism works
properly and smoothly.
F
4
F
S6AG6340
N
R
N
5
Drive shaft holder 1 0: R
90890-06515
Pinion nut 9:
25 N·m (2.5 kgf·m, 18.4 ft·lb)
S6AG6371
6
Installing the water pump
Installing the propeller shaft

housing
1. Install the dowels 1 and outer plate car-
tridge 2.
1
7
1. Install the propeller shaft assembly 1 A
8
into the lower case.
1 2
9
G
S6AG6341
S6AG6380
6AJ5K11 6-16
LOWR Lower unit
2. Install the Woodruff key 3 and impeller 9 9

4 to the drive shaft.
LT
572
A 4
A
9 8
3 9
LT
S6AG6390
572
LT
572 S6AG6400
NOTE:
When installing the impeller 4 onto the drive
cC
shaft, align the groove in the impeller with the
Woodruff key 3. Do not turn the drive shaft counterclock-
wise, otherwise the water pump impeller
may be damaged.
3. Install the insert cartridge 5 and a new
O-ring 6 into the pump housing. NOTE:
9 Apply grease to the inside of the water
6 pump housing.
9 While turning the drive shaft clockwise,
a push down on the water pump housing and
install it.
b 9 Align the projection on the rubber seal 8
with the hole in the pump housing.
5
A
S6AG6570
5. Tighten the water pump housing bolts 9
NOTE: to the specified torque.
Align the insert cartridge projection a with Water pump housing bolt 9:
the hole b in the pump housing. 18 N·m (1.8 kgf·m, 13.3 ft·lb)
4. Install the water pump housing assembly

7 into the lower case, and then install Installing the lower unit
the rubber seal 8. 1. Set the shift lever to the neutral position.
2. Set the shift rod to the neutral position.
6-17 6AJ5K11
NOTE:
F
The adjusting nut 4 must be screwed in a
F
N minimum of 8.0 mm (0.31 in) a.
R
N
R
5. Tighten the locknut 3.
NOTE:
1
After connecting the shift rod, check that the
S6AG6370
3. Install the lower unit to the upper case,

and then tighten the lower case mounting
gear shift operates properly.
6. Install the anode 6, trim tab 7, and inlet

2
bolts 1 to the specified torque. covers 8, and then tighten the bolts to
2
2 the specified torque.
3
1104J
LT
1
8 7
4
572 S6AG6410 6
NOTE:
9 Before installing the lower unit to the upper
case, install the dowels 2 into the lower 8
LT
572 5
case. LT
S6AG6430
6
572
9 Before installing the lower unit, make sure
that the locknut is removed from the shift NOTE:
rod. Install the trim tab in its original position.
Lower case mounting bolt 1:
7
Anode bolt:
Trim tab bolt:
4. Install the locknut 3, and then screw the 8 N·m (0.8 kgf·m, 5.9 ft·lb)
adjusting nut 4 onto the shift rod 5.
4
8
3 a
5
S6AG6420
9
6AJ5K11 6-18
LOWR Lower unit
7. Install the propeller 9 and propeller nut

0. Place a block of wood between the
anti-cavitation plate and propeller to keep
the propeller from turning, and then tight-
en the nut to the specified torque.
9 0
S6AG6440
S6AG6720
w
Do not hold the propeller with your hands
when loosening or tightening it.
NOTE:
If the grooves in the propeller nut do not align
with the cotter pin hole, tighten the nut until
they are aligned.
Propeller nut:
17 N·m (1.7 kgf·m, 12.5 ft·lb)
8. Fill the gear oil to the correct level.
Recommended gear oil:

Hypoid gear oil
API: GL-4
SAE: 90
Gear oil quantity:
300 cm3
(10.14 US oz, 10.58 Imp oz)
6-19 6AJ5K11
Drive shaft and lower case / Shimming
Shimming
1
2
3
4
M1
5
6
T3
7
8
T2
9
M4
T1 M2 M3
S6AG6450
6AJ5K11 6-20
LOWR Lower unit
Shimming Shim thickness

Calculated number
NOTE: (mm)
9 Shimming is not required when assembling 1.14–1.20 1.13
the original lower case and inner parts. 1.21–1.30 1.20
9 Shimming is required when assembling the
original inner parts and a new lower case.
Available shim thicknesses:
9 Shimming is required when replacing the
1.13 and 1.20 mm
inner part(s).
Selecting the forward gear shim

Selecting the pinion shim 1. Turn the taper roller bearing outer race 1
1. Measure the thickness (M1) of the thrust 2 or 3 times to seat the rollers, and then
bearing. measure the bearing height (M2) as
shown.
2
1
M1
M2
S6AG6460
3 S6AG6470J
NOTE:
9 Select the shim thickness (T3) by using the NOTE:
specified measurement(s) and the calcula- 9 Select the shim thickness (T1) by using the
tion formula. specified measurement(s) and the calcula-
9 Measure the thrust bearing at 4 points to tion formula.
find the thickness average. 9 Measure the bearing outer race at 4 points
to find the height average.
Digital caliper 1: 90890-06704

Shimming plate 3: 90890-06701
2. Calculate the pinion shim thickness.
2. Calculate the forward gear shim thick-
Calculation formula:
ness.
Pinion shim thickness (T3) =
6.05 – M1 Calculation formula:
Forward gear shim thickness (T1) =
3. Select the pinion shim(s) (T3) as follows. 16.60 – M2
3. Select the forward gear shim(s) (T1) as

follows.
6-21 6AJ5K11
Shimming
Calculated number 2
Rounded number 1
at 1/100th place 10 mm
(0.39 in)
1, 2 0
3, 4, 5
6, 7, 8
9, 10
2
5
8
M3’ M3
1
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm M3 = M3’–10 mm
NOTE:
S6AG6490J
2
Example: Measure the propeller shaft housing at 4
If “T1” is 0.23 mm, then the forward gear shim
is 0.22 mm.
If “T1” is 0.30 mm, then the forward gear shim
is 0.28 mm.
points to find the height average.

3
Shimming plate 2: 90890-06701
Selecting the reverse gear shim

1. Remove the reverse gear and reverse
gear shim(s) from the propeller shaft
4
housing.
2. Measure the propeller shaft housing

height (M3) as shown.
5
1
6
2
7
8
S6AG6480
9
6AJ5K11 6-22
LOWR Lower unit
3. Turn the ball bearing 2 or 3 times, and Shim thickness

then measure the height from the ball Calculated number
(mm)
bearing (M4) as shown. 0.31–0.40 0.30
0.41–0.50 0.40
0.51–0.60 0.50
0.61–0.70 0.60
1

0.1, 0.2, 0.3, 0.4, and 0.5 mm
2
Backlash
Measuring the forward and reverse
gear backlash
NOTE:
9 Remove the water pump assembly before
measuring the backlash.
9 Secure the drive shaft housing to the lower
S6AG6500
case using 6 bolts (M8 – 25 mm).
2 1
10 mm 1. Install the lower unit onto a repair stand.
(0.39 in)
2. Set the shift rod to the neutral position at

M4’ M4
the lower unit.
F
F
S6AG6510J N
R
N
M4 = M4’–10 mm
NOTE:
R
9 Select the shim thickness (T2) by using the
specified measurement(s) and the calcula-
S6AG6371
tion formula.
9 Measure the height from the ball bearing at
4 points to find the height average. 3. Turn the lower unit so that the propeller
shaft is facing down.
4. Calculate the reverse gear shim thick-

4. Install the special service tools.
ness.
Calculate formula: 5. Tighten the center bolt 3 to the specified

Reverse gear shim thickness (T2) = torque while turning the drive shaft.
57.85 – (M3 – M4)
5. Select the reverse gear shim(s) (T2) as

follows.
6-23 6AJ5K11
Shimming / Backlash
NOTE:
Install the dial gauge so that the plunger tip a
is aligned with the mark b on the backlash
1
indicator.
Backlash indicator: 90890-06706

2 Magnet base plate: 90890-07003
1 Dial gauge set: 90890-01252
3 Magnet base B: 90890-06844
8. Slowly turn the drive shaft clockwise and

2
S6AG6520 counterclockwise and measure the back-

Bearing housing puller claw S 2:
90890-06564
lash when the drive shaft stops in each
direction.
NOTE:
9 Pull the drive shaft downward, and then turn
3
Center bolt 3: 90890-06504 it.
Center bolt 3:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
9 Measure the backlash at 4 points to find the
average. 4
Forward gear backlash:
6. Turn the lower unit upside down.
7. Install the backlash indicator onto the

drive shaft (13 mm [0.51 in] in diameter),
0.18–0.87 mm (0.0071–0.0343 in)
9. Adjust the current shim thickness if the

5
forward gear backlash is out of specifica-
and then install the dial gauge.
6
tion.
Forward gear
Shim thickness
backlash
Less than To be decreased by
0.18 mm (0.0071 in) (0.53 – M) × 0.43
More than To be increased by
0.87 mm (0.0343 in) (M – 0.53) × 0.43 7
M: Measurement
a
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
8
9
10. Remove the special service tools from
b the propeller shaft.
S6AG6530
6AJ5K11 6-24
LOWR Lower unit
11. Install the propeller, washer, and nut, Reverse gear backlash:
without installing the spacer 4. 0.95–1.66 mm (0.0374–0.0654 in)
4
15. Adjust the current shim thickness if the
reverse gear backlash is out of specifica-
tion.
Reverse gear
Shim thickness
backlash
Less than To be decreased by
S6AG6540
0.95 mm (0.0374 in) (1.31 – M) × 0.43
More than To be increased by
1.66 mm (0.0654 in) (M – 1.31) × 0.43
12. Tighten the propeller nut to the specified
torque. M: Measurement
Propeller nut: Available shim thicknesses:

2 N·m (0.2 kgf·m, 1.5 ft·lb) 0.1, 0.2, 0.3, 0.4, and 0.5 mm
13. Turn the lower unit upside down. 16. Remove the special service tools and
propeller, and then install the water pump
14. Slowly turn the drive shaft clockwise and assembly.
counterclockwise and measure the back- NOTE:
lash when the drive shaft stops in each Install the spacer and propeller.
direction.
17. Fill the gear oil to the correct level.
S6AG6550
NOTE:
9 Pull the drive shaft downward, and then
turn it.
9 Measure the backlash at 4 points to find the
average.
6-25 6AJ5K11
BRKT
Bracket unit
Tiller handle .................................................................................................. 7-1

Disassembling the tiller handle ................................................................ 7-3
Assembling the tiller handle .................................................................... 7-3
1
Friction plate ................................................................................................ 7-5
Disassembling the friction plate ............................................................... 7-6
Assembling the friction plate ................................................................... 7-6
Bottom cowling ............................................................................................ 7-8

2
Upper case and steering arm ................................................................... 7-11
Removing the upper case ..................................................................... 7-15
Disassembling the upper case .............................................................. 7-15
Checking the drive shaft bushing (L-transom model) ............................ 7-15
3
Disassembling the exhaust manifold, oil pan, and exhaust guide ......... 7-15
Checking the exhaust manifold, oil pan, and exhaust guide ................. 7-16
Checking the oil strainer ........................................................................ 7-16
Assembling the exhaust guide, oil pan, and exhaust manifold .............. 7-16
4
Assembling the upper case ................................................................... 7-17
Removing the steering arm ................................................................... 7-18
Installing the steering arm ..................................................................... 7-18
Installing the upper case ....................................................................... 7-19 5
Clamp bracket and swivel bracket ........................................................... 7-20
Removing the clamp bracket .................................................................
Disassembling the swivel bracket ..........................................................
Assembling the swivel bracket ...............................................................
Installing the clamp bracket ...................................................................
7-22
7-22
7-23
7-24
6
7
8
9
6AJ5K11
BRKT Bracket unit
Tiller handle
4 N·m (0.4 kgf·m, 3.0 ft·lb)

2 N·m (0.2 kgf·m, 1.5 ft·lb)
4 N·m (0.4 kgf·m, 3.0 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb)
A A
2 N·m (0.2 kgf·m, 1.5 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb)
LT
572 3 N·m (0.3 kgf·m, 2.2 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb) 6AJ7010E

1 Throttle cable 2
3 Steering bracket cover 1
5 Bolt 1 M6 × 14 mm
6 Holder 1
7 Shift lever 1
8 Shift link rod 1
9 Bolt 1 M6 × 40 mm
10 Collar 1
11 Wave washer 1
12 Throttle grip 1
13 Throttle grip 1
14 Screw 1 ø5 × 25 mm
15 Engine shut-off switch 1
16 Wave washer 2
17 Washer 2
7-1 6AJ5K11
Tiller handle
4 N·m (0.4 kgf·m, 3.0 ft·lb)

2 N·m (0.2 kgf·m, 1.5 ft·lb)
4 N·m (0.4 kgf·m, 3.0 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb)

1
A
2
8 N·m (0.8 kgf·m, 5.9 ft·lb)
A A
3
2 N·m (0.2 kgf·m, 1.5 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb)
A
4
A
5
LT
No.
572 3 N·m (0.3 kgf·m, 2.2 ft·lb)
Part name Q’ty

8 N·m (0.8 kgf·m, 5.9 ft·lb)
Remarks
6AJ7010E
6
18 Bushing 1
19
20
21
22
Grommet
Tiller handle bracket
Bushing
Tiller handle bracket cover
1
1
1
1
7
23 Bolt 2 M6 × 55 mm
24
25
26
27
Throttle friction adjuster
Friction piece
Throttle shaft
Plate
1
1
1
1
8
28 Bolt 2 M6 × 20 mm
29
30
31
Bushing
Spring
Washer
1
1
2
9
6AJ5K11 7-2
BRKT Bracket unit
Disassembling the tiller handle 4. Remove the tiller handle.

1. Remove the steering bracket cover 1.
NOTE:
See the exploded diagram for disassembly
(7-1).
1
Assembling the tiller handle
NOTE:
See the exploded diagram for assembly (7-1).
S6AG7A60
1. Install the engine shut-off switch 1 to the

2. Disconnect the engine shut-off switch tiller handle bracket 2. Tighten the nut
leads 2 and remove the leads from their 3 to the specified torque. Pass the lead
holders. through the grommet.
2
2
1
6AJ70010
6AJ70020
Engine shut-off switch nut 3:

2 N·m (0.2 kgf·m, 1.5 ft·lb)
2. Install the friction piece 4 and throttle

2
cables 5 onto the throttle shaft, and then
install the throttle shaft assembly into the
tiller handle bracket 2.
6AJ50046 A
3. Disconnect the throttle cables 3 from the 5

4
throttle cam 4.
2
4 6AJ70030
S6AG7A80
7-3 6AJ5K11
Tiller handle
3. Install the throttle friction adjuster 6, and 7. Install the tiller handle bracket to the
then install the cotter pin 7. steering bracket, and then install the tiller
handle bracket cover and tighten the
1
4. Install the plate 8, and tighten the bolts bolts to the specified torque.
9 to the specified torque.
Tiller handle bracket cover bolt:
8 N·m (0.8 kgf·m, 5.9 ft·lb)
7 9 8
8. Connect the throttle cables to the throttle
cam.
9. Connect the engine shut-off switch lead

2
and fasten the leads.
6 a b
NOTE:
9 To route the throttle cables and engine shut-
off switch lead, see “Electrical component
and wiring harness routing” (8-1).
3
9 To adjust the throttle cables, see “Adjusting
4
6AJ70040
the throttle cable” (3-8).
NOTE: 9 When adjusting the throttle cables, make
9 When routing the engine shut-off switch sure the ends b of the outer cables are not
lead, make sure that it is not pinched by the pulled out of the grommet.
9 Install the steering bracket cover after
5
plate 8 and that there is no slack in the
lead in the area a shown. adjusting the throttle cables.
9 Make sure that the ends b of the outer
throttle cables are fitted securely into the
grommet as shown.
Throttle shaft holder bolt 9:

8 N·m (0.8 kgf·m, 5.9 ft·lb)
6
5. Install the bushing, washers and spring
onto the throttle shaft.
6. Install the throttle grip onto the tiller han-

7
dle bracket, and then tighten the screw to
the specified torque.
Throttle grip screw:

3 N·m (0.3 kgf·m, 2.2 ft·lb)
8
9
6AJ5K11 7-4
BRKT Bracket unit
Friction plate
7 N·m (0.7 kgf·m, 5.2 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb)
TOP
LT
572
9.0 mm
3.8 mm
8.0 mm
18 N·m (1.8 kgf·m, 13.3 ft·lb)
5.4 mm
6 N·m (0.6 kgf·m, 4.4 ft·lb) LT
572
7 N·m (0.7 kgf·m, 5.2 ft·lb) 6AJ7020E

1 Bolt 1 M5 × 20 mm
2 Bracket 1
3 Washer 2
4 Steering lock shaft 1
5 Steering lock lever 1
6 Collar 1 Short
7 Friction piece 2
8 Friction plate 1
9 Collar 1 Long
10 Steering lock washer 1
11 Self-locking nut 1
12 Bolt 2 M5 × 14 mm
13 Washer 2
14 Bolt 2 M8 × 16 mm
7-5 6AJ5K11
Friction plate
Disassembling the friction plate b

1. Remove the friction plate bolts 1 and 2, c
and then remove the friction plate
assembly from the swivel bracket.
1
1 1
NOTE:
S6AG7B01
If the steering lock shaft is not aligned with

2
2 position b, turn it less than 90° c until it is
3
S6AG7A90
aligned.
NOTE:
Before removing the friction plate bolts 1,
2. Assemble the friction plate assembly.
turn the outboard motor all the way to port or
starboard.
2. Disassemble the friction plate assembly.

3
4
NOTE:
See the exploded diagram for disassembly
(7-5). TOP
5
Assembling the friction plate
1. Turn the steering lock shaft 1 until it is
flush with the end a of the nut 2 on the
plate.
4
6
7
1 2 LT
5
a 572 6AJ70050
1
NOTE:
9 Face the “TOP” mark on the steering lock
a
8
lever up.
9 Be sure to install the collars 3 and 4 in
2 the correct positions; the collar lengths are
S6AG7B00
different.
Friction plate bolt 5:

7 N·m (0.7 kgf·m, 5.2 ft·lb) 9
6AJ5K11 7-6
BRKT Bracket unit
3. Install the friction plate assembly onto the NOTE:

swivel bracket and tighten the friction To check and adjust the friction plate, see
plate bolts 6 and 7 temporarily. “Checking the steering operation” (3-12).
Self-locking nut 9:
6 N·m (0.6 kgf·m, 4.4 ft·lb)
6 6
LT
7 572 7 6AJ70180
NOTE:
Before installing the friction plate bolts 6,
turn the outboard motor all the way to port or
starboard.
4. Tighten the friction plate bolts 6 and 7

to the specified torques.
Friction plate bolt (M5) 6:

7 N·m (0.7 kgf·m, 5.2 ft·lb)
Friction plate bolt (M8) 7:
18 N·m (1.8 kgf·m, 13.3 ft·lb)
5. Move the steering lock lever 8 to posi-

tion d, and then tighten the self-locking
nut 9 to the specified torque.
S6AG7B20
7-7 6AJ5K11
Friction plate / Bottom cowling
Bottom cowling
BOW
1
2
A
STBD
A
2 N·m (0.2 kgf·m, 1.5 ft·lb)

3
4
5
6AJ7030E
6
1 Adapter 1
2
3
4
5
Gasket
Flushing hose joint adapter
Flushing hose joint adapter
Warning indicator assembly
1
1
1
1
7
6 Bracket 1
7
8
9
10
Bolt
Screw
Grommet
Plastic tie
2
2
1
1
M6 × 10 mm
ø6 × 20 mm
Not reusable
8
11 Seal 1
12
13
14
Bolt
Fuel joint
Plug
1
1
1
M6 × 20 mm
9
15 Bottom cowling 1
16 Grommet 1
17 Retaining plate 1
6AJ5K11 7-8
BRKT Bracket unit
BOW
A
STBD
A
2 N·m (0.2 kgf·m, 1.5 ft·lb)
6AJ7030E

18 Bolt 2 M6 × 30 mm
19 Damper 1
20 Grommet 1
21 Grommet 1
22 Plug 1
23 Start-in-gear protection cable 1
24 Shift rod 1 L-transom model/S-transom model
25 Nut 1
26 Flushing hose 1
27 Grommet 1
28 Bolt 4 M6 × 35 mm
29 Grommet 4
30 Collar 4
31 Grommet 2
32 Bolt 1 M6 × 20 mm
33 Plate 1
34 Grommet 1
7-9 6AJ5K11
Bottom cowling
BOW
1
2
A
STBD
A
2 N·m (0.2 kgf·m, 1.5 ft·lb)

3
4
5
6AJ7030E
6
35 Bolt 4 M6 × 12 mm
36
37
38
39
Holder
Fuel hose
Handgrip
Cowling lock lever
1
1
2
1
7
40 Bolt 1 M6 × 12 mm
41
42
43
44
Rubber seal
Water outlet
Shift rod lever joint
Pin
1
1
1
2
8
45 Bracket 2
46
47
48
Shift rod lever
Plate
Shift rod arm
1
1
1
9
6AJ5K11 7-10
BRKT Bracket unit
Upper case and steering arm
28 N·m (2.8 kgf·m, 20.7 ft·lb)
40 N·m (4.0 kgf·m, 29.5 ft·lb)
2 N·m (0.2 kgf·m, 1.5 ft·lb)
BOW
A
LT
572
3 N·m (0.3 kgf·m, 2.2 ft·lb)

8 N·m (0.8 kgf·m, 5.9 ft·lb) 6AJ7040E

1 Mount housing 2
2 Rubber damper 2 Large
3 Rubber damper 2 Small
4 Rubber damper 1
5 Bolt 2 M8 × 85 mm
6 Bolt 2 M8 × 105 mm
7 Nut 4
8 Bolt 1 M5 × 10 mm
9 Ground lead 1
10 Grease nipple 1
11 Bolt 1 M6 × 8 mm
12 Plate 1
13 Nut 2
14 Upper case assembly 1 L-transom model/S-transom model
15 Plate 1
16 Steering arm 1 L-transom model/S-transom model
17 Washer 1
7-11 6AJ5K11
4 N·m (0.4 kgf·m, 3.0 ft·lb)

28 N·m (2.8 kgf·m, 20.7 ft·lb)
32 N·m (3.2 kgf·m, 23.6 ft·lb)
40 N·m (4.0 kgf·m, 29.5 ft·lb)
1
2
2 N·m (0.2 kgf·m, 1.5 ft·lb)
A
3
4
BOW
A
LT
572
5
No.
3 N·m (0.3 kgf·m, 2.2 ft·lb)
Part name Q’ty

8 N·m (0.8 kgf·m, 5.9 ft·lb)
Remarks
6AJ7040E
6
18 Bushing 1 1
19
20
21
22
Bushing 2
O-ring
Plate
Steering bracket cover
1
1
1
1
Not reusable
7
23 Screw 1 ø6 × 20 mm
24 Screw 4 ø6 × 18 mm
8
9
6AJ5K11 7-12
BRKT Bracket unit
A LT
572
LT
572
LT LT LT
572 572 572
LT
572
LT
572
8 N·m (0.8 kgf·m, 5.9 ft·lb)
LT
572
LT
A 572 18 N·m (1.8 kgf·m, 13.3 ft·lb)
LT
LT 572
572 18 N·m (1.8 kgf·m, 13.3 ft·lb) 27 N·m (2.7 kgf·m, 19.9 ft·lb) 6AJ7050E

1 Grommet 1
2 Water pipe 1 L-transom model/S-transom model
3 Upper mount 1
4 Bolt 2 M8 × 30 mm
5 Exhaust guide 1
6 Oil seal 1 Not reusable
8 Oil strainer 1
9 Bolt 3 M6 × 16 mm
10 Baffle plate 1
11 Seal 1
12 Pipe 1
13 Oil pan 1
14 Dowel 2
15 Bolt 2 M8 × 30 mm
16 Damper 1
7-13 6AJ5K11
LT
572
LT
572 1
2
LT LT LT
572 572 572
LT
572
A
3
8 N·m (0.8 kgf·m, 5.9 ft·lb)
LT
LT
572 4
572
A
LT
572 18 N·m (1.8 kgf·m, 13.3 ft·lb)
5
LT
6
LT 572
572 18 N·m (1.8 kgf·m, 13.3 ft·lb) 27 N·m (2.7 kgf·m, 19.9 ft·lb) 6AJ7050E

18 Drain bolt 1
19
20
21
22
Gasket
Exhaust manifold
Bolt
Rubber seal
1
1
4
1
Not reusable
L-transom model
M6 × 25 mm
7
23 Water pipe guide 1
24
25
26
27
Dowel
Upper case
Drive shaft bushing
Circlip
2
1
1
1
L-transom model
L-transom model only
L-transom model only
8
28 Bolt 6 M8 × 30 mm
29
30
Exhaust manifold
Upper case
1
1
S-transom model
S-transom model 9
6AJ5K11 7-14
BRKT Bracket unit
Removing the upper case

1
NOTE: 2
9 Drain the engine oil before removing the
upper case assembly.
9 Be sure to remove the shift rod assembly
before removing the upper case assembly
from the clamp bracket.
1. Remove the ground lead terminal 1 from

the swivel bracket.
2. Remove the mount housings 2, and then 3

remove the rubber dampers 3.
3. Remove the upper mounting nuts 4, and

then remove the upper case assembly. S6AG7530
4
4. Remove the circlip 4, and then remove
the drive shaft bushing 5. (L-transom
model)
3
6
6
7
3 7 5
2 3 5
2
3 4
3
1
S6AG7540
Driver rod L3 6: 90890-06652

6AJ70060
90890-06618
Disassembling the upper case Checking the drive shaft bushing

1. Remove the engine oil drain bolt and (L-transom model)
damper. 1. Check the drive shaft bushing. Replace if
cracked or worn.
2. Remove the water pipe 1, and upper
mount 2 from the upper case assembly.
Disassembling the exhaust mani-
3. Remove the oil pan assembly bolts 3,
fold, oil pan, and exhaust guide
1. Remove the exhaust manifold 1 and
and then remove the oil pan assembly
gasket 2 from the oil pan 3.
from the upper case.
7-15 6AJ5K11
Checking the exhaust manifold, oil

pan, and exhaust guide
3 1. Check the exhaust manifold, oil pan and
1
exhaust guide. Replace if cracked or cor-
roded.
2
å NOTE:
Clean the removed parts before checking
them.
1 Checking the oil strainer

2
1. Check the oil strainer. Clean if there is dirt
3
1 and residue.
Assembling the exhaust guide, oil

S6AG7560 pan, and exhaust manifold
å S-transom model 1. Install a new oil seal 1 into the exhaust
2. Remove the oil pan 3 from the exhaust

guide 4, and then remove the baffle
guide 2.
3
4 1
A
4
plate 5.
3. Remove the oil strainer 6 and the gasket

7 from the exhaust guide.
2
5
4. Remove the oil seal 8 from the exhaust
6
guide. S6AG7580J
Driver rod L3 3: 90890-06652

4
90890-06612
8
7
7
6
5 8
3
6AJ70070
9
6AJ5K11 7-16
BRKT Bracket unit
2. Install the dowels 5 and a new gasket 6 5. Install a new gasket e, the exhaust man-
onto the exhaust guide 7. ifold r, and the rubber seal t, and then
tighten the exhaust manifold bolts y to
3. Install the oil strainer 8 and oil strainer the specified torque.
bolts 9, and then tighten the bolts to the
specified torque. t å
y
9 9 LT y r
572
8 y
9 e LT
572
y r
6
LT
5
572
5
6AJ70080
7
å S-transom model
S6AG7600
Exhaust manifold bolt y:
8 N·m (0.8 kgf·m, 5.9 ft·lb)
Oil strainer bolt 9:
8 N·m (0.8 kgf·m, 5.9 ft·lb)
Assembling the upper case

4. Install the baffle plate 0 and oil pan q,
1. Install the drive shaft bushing 1 into the
and then tighten the oil pan bolts w to the
upper case, and then install the circlip 2.
specified torque.
(L-transom model)
w
LT
1
572
2
LT
3
A
572
q
4
0
6AJ70090
NOTE:
After installing the drive shaft bushing, apply
S6AG7620 grease to the inside of the bushing.
Oil pan bolt w:

18 N·m (1.8 kgf·m, 13.3 ft·lb) Driver rod L3 3: 90890-06652
90890-06613
7-17 6AJ5K11
2. Install the water pipe guide 5 onto the Removing the steering arm
upper case. 1. Remove the steering arm 1 from the
swivel bracket 2 by pulling the arm off
the bracket.
1
3. Install the dowels 6, oil pan assembly 7,
and oil pan assembly bolts 8, and then
tighten the bolts to the specified torque.
4. Install the upper mount 9, and then tight-

en the upper mount bolts 0 to the spec-
ified torque.
5. Install the water pipe q.

1
2
2
3
A
q
5 A 0
6 6 LT
S6AG7711
572
9
4
LT
LT
572 NOTE:
572
8 To disassemble the clamp brackets, see
“Removing the clamp bracket” (7-22).
8
5
q
7
Installing the steering arm
1. Install the washer 1 and bushing 1 2
onto the steering arm.
5
NOTE:
6AJ70100
2. Place the swivel bracket 3 in an upright
position, and then install the steering arm
onto the swivel bracket.
6
Be sure to pass the water pipe q through the
3. Install bushing 2 4, a new O-ring 5, and
water pipe guide 5.
Oil pan assembly bolt 8:

the plate 6 onto the swivel bracket.
7
18 N·m (1.8 kgf·m, 13.3 ft·lb)
8
Upper mount bolt 0:
30 N·m (3.0 kgf·m, 22.1 ft·lb)
6. Install the damper and engine oil drain A
bolt, and then tighten the drain bolt to the 3

specified torque.
Engine oil drain bolt:

27 N·m (2.7 kgf·m, 19.9 ft·lb)
A
1
2 4
5
9
A 6
S6AG7710
6AJ5K11 7-18
BRKT Bracket unit
4. Apply grease to the grease nipple 7 on 5. Install the ground lead terminal q to the
the swivel bracket until it comes out from swivel bracket.
the upper bushing a.
6. Install the ground lead terminal w to the
upper case as shown.
2
a
7
0
A 4
6AJ30115 1
0 5
NOTE: 6 3 4
To assemble the clamp brackets, see
“Installing the clamp bracket” (7-24). 6
e 3
qw
Installing the upper case LT 7 9

B
572 8
1. Install the upper case assembly 1 to the
clamp bracket. 8 A
9 6AJ70130
2. Install the plate and upper mounting nuts

e q
2, and then tighten the upper mounting
nuts to the specified torque.
3. Install the rubber dampers 3 (small), 4 a

(large), and 5 (front), and then install the
mount housings 6 and ground lead ter- 7
w
minal 7 using the mount housing bolts
8 and 9 and the mount housing nuts 0. A B
S6AG7680J
NOTE:
9 Be sure to remove any oil from the mount
Upper mounting nut 2:
housing bolts 8 and 9.
40 N·m (4.0 kgf·m, 29.5 ft·lb)
9 Install the ground lead terminal 7 so that it
Mount housing nut 0:
is within the range a shown.
1st : 15 N·m (1.5 kgf·m, 11.1 ft·lb)
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
4. Tighten the mount housing nuts 0 to the 3rd : 32 N·m (3.2 kgf·m, 23.6 ft·lb)
specified torques in 3 stages and in the Grease nipple e:
sequence shown. 3 N·m (0.3 kgf·m, 2.2 ft·lb)
NOTE:
Tighten the mount housing nuts 0 evenly
and in the following order: z–x–c–v.
7-19 6AJ5K11
Upper case and steering arm / Clamp bracket and swivel bracket
Clamp bracket and swivel bracket
16
10 15
14
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
1
T.
R.
14
A
12
2
A A 14
15
5 16
9
17
19 N · m (1.9 kgf · m, 14.0 ft · Ib)

12
A
11
14 3
T.
R.
4
A
A
6
8
7 2
6 1
5
13
8 A
a b 3
LT
242
3 N · m (0.3 kgf · m, 2.2 ft · Ib)
6
a b
T.
R.
6AJ7060E

1 Tilt pin 1
2
3
4
5
Spring
Bolt
Collar
Nut
1
1
1
1
M6 × 155 mm
7
6 Self-locking nut 2
7
8
9
10
Hanger
Through tube
Swivel bracket
Clamp bracket
1
1
1
1
L-transom model/S-transom model
STBD
8
11 Clamp bracket 1 PORT
12
13
14
Bushing
Grease nipple
Bolt
2
1
4
9
15 Wave washer 2
16 Tilt stopper plate 2
17 Tilt lock lever 1
6AJ5K11 7-20
BRKT Bracket unit
2 3
a 2
6 5
5
1
6 b 10 4
A 5
b
3
A
5
5 4 9
a
13
7
16
5
8 14
12 17
10
15
17
11
11 S6AG7400

1 Tilt lock lever 1
2 Tilt lock rod 1 1 a>b
3 Tilt lever 1
4 Spring 1 a>b
5 E-clip 4
6 Tilt lever shaft 1
7 Stopper shaft 1
8 Receiver assembly 1
9 Swivel bracket 1 L-transom model/S-transom model
10 Tilt lock rod 2 1
11 Collar 2
12 Tilt lock plate 1 1
13 Tilt lock plate 2 1
14 Tilt lock shaft 1
15 E-clip 1
16 Reverse lock shaft 1
17 Spring 2
7-21 6AJ5K11
Removing the clamp bracket Disassembling the swivel bracket

1. Remove the tilt pin 1, and then remove 1. Remove the spring 1. Remove the E-
the clamp bracket bolt 2, clamp bracket clips 2 from the tilt lever shaft 3, and
nut, and collar. then pull out the shaft and remove the tilt
2. Remove the tilt stopper plate bolts 3

(swivel bracket side).
lever 4 and tilt lock rod 2 5.
3
4
2
1
2
3. Remove the self-locking nut 4 and hang-
er 5.
2
4. Remove the through tube 6 and tilt lock
lever 7, and then disassemble the clamp
brackets.
NOTE:
Unhook tilt lock rod 1 8 from the tilt lock lever
7 when removing it.
NOTE:
5 1 S6AG7410
Unhook tilt lock rod 2 5 from the tilt lever 4

3
when removing it.
5. Remove the tilt stopper plate bolts 9

(clamp bracket side) and tilt stopper
plates 0.
2. Remove the E-clip 6 from the stopper
shaft 7, and then pull out the shaft and
4
remove the receiver assembly 8.
3
0
9
9
3
2
5
0
8
7
4
6
6
3 1
7
7 2
5
8
4 S6AG7950
1
5
6 2 6AJ70140 8
9
6AJ5K11 7-22
BRKT Bracket unit
3. Remove the E-clip 9 from the reverse 2. Pass the reverse lock shaft 7 through
lock shaft 0, and then pull out the shaft. the swivel bracket and tilt lock plate 2 1,
and then install the E-clip 8. Hook the
4. Remove the springs q. springs 9 onto tilt lock plate 1 2, and
then hook them onto the holes a in the
5. Remove the E-clip w from the tilt lock swivel bracket.
shaft e, and then pull out the shaft and
remove the collars r, tilt lock rod 2 5, tilt
a a
lock plate 1 t, and tilt lock plate 2 y.
0
9 9
e
y
1
5 8
t 9
7 2
w 6AJ70150
NOTE:
r q S6AG7960 After installing the E-clip, turn it to make sure
that it is installed securely.
Assembling the swivel bracket 3. Install the stopper shaft 0 and receiver
1. Assemble tilt lock plate 2 1, tilt lock plate assembly q to the swivel bracket w, and
1 2, the collars 3, tilt lock rod 2 4, and then install the E-clip e.
the tilt lock shaft 5, and then install the
E-clip 6. 4. Hook tilt lock rod 2 4, the spring r, and
tilt lock rod 1 t onto the tilt lever y.
5 1
5. Install the tilt lever shaft u into the swiv-
2 el bracket w, making sure to pass the
4 6 shaft through the receiver assembly q
and tilt lever y, and then install the E-
clips i.
3 S6AG7970
NOTE:
After installing the E-clip, turn it to make sure
that it is installed securely.
7-23 6AJ5K11
6. Hook the spring r onto the receiver Tilt stopper plate bolt 2:
assembly q. 8 N·m (0.8 kgf·m, 5.9 ft·lb)
t
u
A
i w
2. Tighten the self-locking nut 3 complete-
ly onto the shorter threaded end of the
through tube 4.
1
y A
0 i
r
e
a
4
b 3
2
q
NOTE:
A
4
S6AG7A20J
a b A
S6AG7801 3
9 See the exploded diagram for the installa- 3. Assemble the clamp brackets 5 and
tion directions of the spring r and tilt lock
rod 1 t (7-21).
9 Make sure that the E-clips are installed
swivel bracket 6, and then install the
through tube 4 from the port side.
NOTE:
4
securely. Before installing the through tube 4, hook tilt
Installing the clamp bracket

1. Install the tilt stopper plates 1 and tilt
lock rod 1 7 onto the tilt lock lever 8.
4. Install the hanger 9, self-locking nut 0

5
onto the through tube, and then tighten it
stopper plate bolts 2 to the clamp brack-
ets, and then tighten the bolts to the
specified torque.
to the specified torque.
Self-locking nut 0:
19 N·m (1.9 kgf·m,14.0 ft·lb)
6
0 A
1
2
9 5
q
6
A
2
1
5. Install the tilt stopper plates 1 and tilt
stopper plate bolts q to the swivel brack-
et, and then tighten the bolts to the spec-
ified torque.
7
q
r
A
8
w
5
4
3
Tilt stopper plate bolt q:
8 N·m (0.8 kgf·m,5.9 ft·lb)
6. Install the collar w and clamp bracket

8
bolt e, and then tighten the clamp brack-
7
8
A
e
t
et nut r.
7. Install the tilt pin t.

9
LT
242 6AJ70170
6AJ5K11 7-24
BRKT Bracket unit
8. Apply grease to all grease nipples.

c
A A
6AJ70160
NOTE:
9 Apply grease until it flows from the bushings
c.
9 To check the tilt operation, see “Checking
the tilt system” (1-15).
7-25 6AJ5K11
ELEC
Electrical system
Electrical component and wiring harness routing ................................... 8-1

Top view ...................................................................................................
Bow view ..................................................................................................
Port view ..................................................................................................
8-1
8-3
8-5
1
Checking the electrical component ........................................................... 8-7
Measuring the peak voltage .................................................................... 8-7
Ignition and ignition control system .......................................................... 8-8

2
Checking the ignition spark ..................................................................... 8-8
Checking the spark plug cap ................................................................... 8-8
Checking the ignition coil ......................................................................... 8-8
Checking the pulser coil .......................................................................... 8-9
Checking the charge coil ......................................................................... 8-9
3
Checking the engine shut-off switch ...................................................... 8-10
Engine electric control system ................................................................. 8-11

Checking the CDI unit ........................................................................... 8-11
4
Checking the thermoswitch ................................................................... 8-11
Checking the oil pressure switch ........................................................... 8-12
Checking the warning indicator assembly ............................................. 8-13
Checking the power bobbin (for Prime Start) ........................................ 8-14 5
Charging system ........................................................................................ 8-15
Checking the lighting coil ....................................................................... 8-15
6
7
8
9
6AJ5K11
ELEC Electrical system
Electrical component and wiring harness routing

Top view
å
1 2
B B ∆
3 C
∫
C
¬ ˚ D
D
4 9
ç
q
5
µ A
q w q w
q 7 6 E
ƒ ´ ∂
B-B C-C
˜
6 q
8 0
© ˙ E D-D
6AJ80010
1 Prime Start 7 Pulser coil

2 Thermoswitch 8 Warning indicator assembly
3 Ignition coil 9 Engine shut-off switch
4 Oil pressure switch 0 Warning indicator assembly coupler
5 Stator coil assembly (charge coil, lighting coil, q Engine shut-off switch lead
and power bobbin) w Throttle cable
6 CDI unit
8-1 6AJ5K11
å Fasten the thermoswitch lead and cooling water hose with a plastic tie.
∫ Fasten the thermoswitch lead with the holder.
ç Fasten the stator coil assembly lead and lighting coil lead with the holder.
∂ Fasten the engine shut-off switch lead and Prime Start lead with the holder.
´
ƒ
©
Fasten the Prime Start lead and Intake silencer with a plastic tie.
Fasten the engine shut-off switch lead with a plastic tie. Install the plastic tie as shown and cut off the
excess end of the tie to 3 mm (0.12 in) or less.
Route the warning indicator assembly lead between the brackets.
1
˙ Insert the warning indicator assembly coupler into the plate. Cover the edge of the coupler with the pro-
tective tube so that it does not contact the leads.
∆
˚
¬
µ
Be sure there is no pinching or slacking of the engine shut-off switch lead.
Fasten the engine shut-off switch lead and throttle cables with the holder.
Pass the engine shut-off switch lead and throttle cables through the grommet.
Pass the engine shut-off switch lead and throttle cables through the grommet, and then fasten the grom-
2
met with a plastic tie.
3
˜ Fasten the wiring harness with plastic ties. Install the plastic tie as shown and cut off the excess end of
the tie to 3 mm (0.12 in) or less.
4
5
6
7
8
9
6AJ5K11 8-2
Bow view
∫ ç ∂ ´ ƒ ©
6 5 1 7 3
5 ˙
A 4∆
´ ˚
7 8
t
r 9
µ
e 0
¬w
q
A-A 6AJ80020
1 Pulser coil 9 Pulser coil connector (W/R)

2 CDI unit 0 Engine shut-off switch connector (W)
3 Junction box q Prime Start connectors (L)
4 Warning indicator assembly coupler w Tachometer connector (G)
5 Engine shut-off switch lead e Charge coil connector (B/R)
6 Prime Start lead r Charge coil connector (G/R)
7 Charge coil lead (B/R, G/R) t Pulser coil connector (B)
8 Engine shut-off switch lead (B)
8-3 6AJ5K11
å Fasten the engine shut-off switch lead with a plastic tie. Install the plastic tie as shown and cut off the
excess end of the tie to 3 mm (0.12 in) or less.
∫ Fasten the engine shut-off switch lead and Prime Start lead with the holder.
ç Pass the engine shut-off switch lead and Prime Start lead through the grommet.
∂ Pass the pulser coil lead through the grommet.
´ Fold the charge coil lead (B/R, G/R) back, connect it to the lead connectors (B/R, G/R), and then fasten
it with the holder.
ƒ Be sure not to pinch the wiring harness and leads with the holder cover.
1
© Fasten the stator coil assembly lead, wiring harness, and engine shut-off switch lead (B) with the holder.
˙ Fasten the stator coil assembly lead, wiring harness, engine shut-off switch lead (B), and warning indica-
tor assembly lead with the holder.
∆ Insert the warning indicator assembly coupler into the plate. Cover the edge of the coupler with the pro-
tective tube so that it does not contact the leads.
˚ Fasten the engine shut-off switch lead (B) with the holder.
2
¬ Insert the rubber plug into the Tachometer connector.
3
µ The connectors can be fastened in any position in the holder. However, do not fasten the pulser coil con-
nector (W/R) and engine shut-off switch connector (W) in lowest opening in the holder.
4
5
6
7
8
9
6AJ5K11 8-4
Port view
† ¨
w e
q
√
r
∆0
y t
A B-B
å ∫ ç ∂ ´ƒ © ˙∆ ˚ ¬
1 2 3 4 0 5
C B
A
9 C
7 6
∑ ® π ˜ µ
C-C 6AJ80030
1 CDI unit 9 Engine shut-off switch lead (B)

2 Pulser coil 0 Oil pressure switch lead (P)
3 Stator coil assembly (charge coil, lighting coil, q Thermoswitch connector (Gy/B)
and power bobbin) w Lighting coil connectors (G)
4 Oil pressure switch e Ignition coil connector (O)
5 Thermoswitch r Ignition coil connector (B)
6 Ignition coil t Thermoswitch connector (B)
7 Wiring harness y Oil pressure switch connector (P)
8 Stator coil assembly lead
8-5 6AJ5K11
å Fasten the wiring harness with plastic ties. Install the plastic tie as shown and cut off the excess end of
the tie to 3 mm (0.12 in) or less.
∫ Fasten the engine shut-off switch lead (B) and stator coil assembly lead with the holder. Position this
holder between the plastic ties as shown.
ç Fasten the wiring harness, engine shut-off switch lead (B), and stator coil assembly lead with the holder.
∂ Fasten the lighting coil leads, wiring harness, and ground lead with the holder.
´ Fasten the stator coil assembly lead and lighting coil lead with the holder.
ƒ Screw in the oil pressure switch until 2 threads are engaged, then apply LOCTITE 572 to the exposed
1
switch threads, and then tighten the switch to the specified torque.
© Install the terminal of oil pressure switch lead so that the lead is routed as shown. Tighten the bolt to the
specified torque, and then install the cap. Do not apply grease to the terminal and bolt.
˙ Fasten the thermoswitch lead with the holder.
∆ Fold the oil pressure switch lead (P) back, connect it to the lead connector (P), and then fasten it with the
holder.
2
˚ Fasten the thermoswitch lead and cooling water hose with a plastic tie.
3
¬ Fasten the ignition coil lead with the holder.
µ Fasten the spark plug wire and cooling water hose with the holder.
˜ Fasten the spark plug wires with the holder.
π Install the terminals of the engine shut-off switch lead and wiring harness ground lead using the bolt, and
then apply Yamaha grease A to the terminals and bolt.
® Fasten the wiring harness with a plastic tie.
ß Fasten the wiring harness at the white tape with plastic ties.
† Install the terminal of the ground lead using the bolt, making sure that the crimped section of the terminal
that secures the ground lead is facing outward as shown.
¨ Insert the rubber plugs into the lighting coil connectors.
4
√ The connectors can be fastened in any position in the area shown.
∑ Install the plastic ties as shown.
5
6
7
8
9
6AJ5K11 8-6
Checking the electrical NOTE:

component 9 Before measuring the peak voltage, check
all wiring for proper connection and corro-
Measuring the peak voltage
sion, and check that the battery is fully
To check the electrical components or mea-
charged.
sure the peak voltage, use the special service
9 Use the peak voltage adapter B with the
tools. A faulty electrical component can be
recommended digital circuit tester.
easily checked by measuring the peak volt-
9 Connect the positive pin of peak voltage
age. The specified engine speed when mea-
adapter B to the positive terminal of the dig-
suring the peak voltage is affected by many
ital tester, and the negative pin to the nega-
factors, such as fouled spark plugs or a weak
tive terminal.
battery. If one of these factors is present, the
9 When measuring the peak voltage, set the
peak voltage cannot be measured properly.
selector on the digital circuit tester to the
DC voltage mode.
DC V
Digital circuit tester: 90890-03174
Peak voltage adapter B:
90890-03172
S6AL8010
w
When checking the peak voltage, do not
touch any of the connections of the digital
tester leads.
cC
When testing the voltage between the ter-
minals of an electrical component with the
digital tester, do not allow any of the leads
to touch any metal parts. If touched, the
electrical component can short and be
damaged.
8-7 6AJ5K11
Checking the electrical component / Ignition and ignition control system
Ignition and ignition control Checking the spark plug cap

system 1. Remove the spark plug caps from the
spark plug wires by turning the caps
Checking the ignition spark
counterclockwise.
1. Disconnect the spark plug caps from the
spark plugs.
NOTE:
1
To prevent the engine from starting when
cranking it, be sure to disconnect both spark
plug caps.
2
2. Connect the special service tool to the
S6AG8030
spark plug cap.
Ignition tester: 90890-06754 2. Measure the spark plug cap resistance.

Replace if out of specification.
3
4
3. Crank the engine and check for a spark.
If there is no spark, check the ignition
system.
S6AG8040
5
6
Spark plug cap resistance:
3.75–6.25 kΩ
6AJ80040
w
Checking the ignition coil
7
9 Do not touch any of the connections of
1. Disconnect the ignition coil connectors.
the special service tool.
9 Be sure to install the special service tool
2. Remove the spark plug caps from the
to the spark plug cap so that sparks do
spark plug wires by turning the caps
not leak out.
counterclockwise.
9 Keep flammable gas or liquids away,
since this test can produce sparks.
NOTE:
8
9 Do not remove the clip from the engine
shut-off switch.
9 Repeat steps 2–3 for each spark plug cap. 9
6AJ5K11 8-8
3. Measure the ignition coil resistance. NOTE:

Replace if out of specification. 9 To prevent the engine from starting when
cranking it, be sure to disconnect both
spark plug caps.
shut-off switch.
9 If measuring the output peak voltage under
B the unloaded conditions, disconnect the
connectors.
9 The cranking voltage values may vary
O depending on the speed at which the
S6AG8050
starter handle is pulled.
Ignition coil resistance:

Primary coil: Pulser coil output peak voltage:
Orange (O) – Black (B) White/red (W/R) – Black (B)
0.26–0.35 Ω at 20 °C (68 °F) Unloaded Loaded
r/min
Secondary coil: Cranking 1,500 3,500
Spark plug wire – Spark plug wire DC V 5.1 2.6 5.3 8.4
6.8–10.2 kΩ at 20 °C (68 °F)
2. Disconnect the pulser coil connectors.
4. Install the spark plug caps to the spark
plug wires by turning the caps clockwise, 3. Measure the pulser coil resistance.
and then connect the ignition coil con- Replace if out of specification.
nectors.
Pulser coil resistance
(reference data):
White/red (W/R) – Black (B)
Checking the pulser coil
152–228 Ω at 20 °C (68 °F)
1. Measure the pulser coil 1 output peak
voltage. Replace if below specification.
4. Connect the pulser coil connectors.
Checking the charge coil

1. Measure the charge coil 1 output peak
voltage. Replace the stator coil assembly
if below specification.
1
7 W/R W/R
B
B
6AJ80050
8-9 6AJ5K11
Ignition and ignition control system
4. Connect the charge coil connectors.
1
Checking the engine shut-off switch
1. Disconnect the engine shut-off switch 1
connector and terminal.
8
G/R
B/R
G/R
B/R
1
B 2
6AJ80060
3
NOTE:
9 To prevent the engine from starting when
spark plug caps.
9 W W
B
1
4
shut-off switch.
the unloaded conditions, disconnect the
connectors.
6AJ80070
2. Check the engine shut-off switch 1 for

continuity between the engine shut-off
5
9 The cranking voltage values may vary switch connector and terminal (engine
depending on the speed at which the
shut-off switch end). Replace if out of
specification. 6
Charge coil output peak voltage: a b
r/min
DC V
Black/red (B/R) – Green/red (G/R)
Unloaded
Cranking
60 140
Loaded
1,500
150
3,500
150
7
2. Disconnect the charge coil connectors.
3. Measure the charge coil resistance.

c
W B 8
Replace the stator coil assembly if out of
9
specification.
Charge coil resistance

(reference data):
Black/red (B/R) – Green/red (G/R)
25.5–34.5 Ω at 20 °C (68 °F) 6AJ80080
6AJ5K11 8-10
Engine shut-off switch continuity: CDI unit output peak voltage:

Orange (O) – Black (B)
White (W) – Black (B)
Switch position Continuity Loaded
r/min
Cranking 1,500 3,500
Clip installed a No
DC V 130 140 140
Engine stop button
Yes
pushed b
Clip removed c Yes
Checking the thermoswitch
1. Disconnect the thermoswitch 1 connec-
3. Connect the engine shut-off switch con- tors.
nector and terminal.
2. Start the engine, and then measure the
input voltage at the thermoswitch con-
Engine electric control system nectors (wiring harness end). Check the
Checking the CDI unit wiring harness and CDI unit if below
1. Measure the CDI unit 1 output peak volt- specification.
age. Replace if below specification.
1
14 Gy/B Gy/B
17 B
18 O O B
1
B
B B
6AJ80100
6AJ80090
Thermoswitch input voltage
NOTE: (reference data):
9 To prevent the engine from starting when Gray/black (Gy/B) – Black (B)
cranking it, be sure to disconnect both 7.5 V at 1,050 r/min
spark plug caps.
3. Turn the engine off.
shut-off switch.
4. Remove the thermoswitch.
9 Be sure to check the charge coil and pulser
coil before measuring the CDI unit output
peak voltage.
8-11 6AJ5K11
Ignition and ignition control system / Engine electric control system
5. Place the thermoswitch in a container of

water and slowly heat the water.
Gy/B B
1
S6AG8100 13 P P
1
2
3
6. Check the thermoswitch for continuity at
the specified temperatures. Replace if out
of specification.
6AJ80110
Oil pressure switch input voltage

(reference data):
Pink (P) – Ground
4
12 V at 1,050 r/min
a Temperature
S6AL8880
3. Turn the engine off.
4. Check the oil pressure switch 1 for con-

5
b Time tinuity when the engine is stopped and
6
c No continuity
when it is running. Check the oil pressure
d Continuity
and oil pressure switch if out of specifica-
Thermoswitch continuity tion.
temperature:
Gray/black (Gy/B) – Black (B)
e: 76–84 °C (169–183 °F)
f: 63–77 °C (145–171 °F) 7
7. Install the thermoswitch, and then con-
8
nect the thermoswitch connectors.
Checking the oil pressure switch 1

1. Disconnect the oil pressure switch 1
P P
9
13
connector. 1
2. Start the engine, and then measure the

input voltage between the oil pressure
switch connector (wiring harness end)
and the ground. Check the wiring har- 6AJ80120
ness and CDI unit if below specification.
6AJ5K11 8-12
NOTE: Oil pressure switch continuity:

To check the oil pressure, see “Checking the Oil pressure switch terminal a –
oil pressure” (5-1). Ground (switch body)
Oil pressure Continuity
Oil pressure switch continuity: 49.0 kPa (0.490 kgf/cm2,
Yes
Pink (P) – Ground 7.105 psi) below
49.0 kPa (0.490 kgf/cm2,
Engine condition Continuity No
7.105 psi) above
Stopped Yes
Running No 8. Install the oil pressure switch, and then
connect the oil pressure switch connec-
5. Remove the oil pressure switch. tor.
NOTE:
6. Connect the special service tool to the oil To install the oil pressure switch, see
pressure switch. “Electrical component and wiring harness
routing” (8-5).
7. Check the oil pressure switch 1 for con-
tinuity at the specified pressure. Replace
Checking the warning indicator
assembly
a 1 1. Disconnect the thermoswitch connectors,
and then ground the gray/black (Gy/B)
lead (wiring harness end).
2. Start the engine and operate it at engine

idle speed for at least 120 seconds, and
then check that the overheat warning
indicator comes on. Check the warning
indicator assembly if it does not come on.
S68V8640 3. Disconnect the oil pressure switch con-

nector, and then ground the pink (P) lead
NOTE: (wiring harness end).
9 Slowly operate the special service tool.
9 Apply the pressure to the oil pressure 4. Start the engine, increase the engine
switch gradually. The oil pressure switch is speed to approximately 2,000 r/min, and
normal if continuity is changed to no conti- check that the oil pressure warning indi-
nuity at the pressure is 49.0 ± 19.6 kPa cator comes on after 10 seconds. Check
(0.490 ± 0.19 kgf/cm2, 7.105 ± 2.8 psi). the warning indicator assembly if it does
not come on.
Vacuum/pressure pump gauge set: 5. Turn the engine off.

90890-06756
6. Connect the thermoswitch connectors
and oil pressure switch connector.
7. Disconnect the warning indicator assem-

bly coupler.
8-13 6AJ5K11
Engine electric control system
8. Connect the yellow/black (Y/B) lead to Checking the power bobbin

the positive penlight battery terminal (1.5 (for Prime Start)
V) and connect the pink/black (P/B) lead 1. Measure the power bobbin 1 output
1
to the negative terminal, and then check peak voltage. Replace the stator coil
that the warning indicator comes on. assembly if below specification.
Replace the warning indicator assembly
if it does not come on.
Y/B
+ 2
LED2
P/B
-
S6AG8300
L L
3
1
L
9. Connect the yellow/red (Y/R) lead to the
positive penlight battery terminal (1.5 V)
and connect the pink/white (P/W) lead to
the negative terminal, and then check
2
L
4
6AJ80130
that the warning indicator comes on.
Replace the warning indicator assembly
if it does not come on.
NOTE:
5
spark plug caps.
6
Y/R +
shut-off switch.
LED1
the unloaded conditions, disconnect the
P/W - connectors.
cC
S6AG8290
9 Measurements under the unloaded condi-
7
9 Only use a penlight battery (1.5 V) when tion or when the Prime Start 2 is malfunc-
checking the LEDs. Other batteries (e.g.,
alkaline batteries or high-voltage batter-
ies) will damage the diodes.
9 Do not apply more than 1.7 V to the leads
tioning may not be possible at 1,500 r/min
because the engine speed may be too high.
8
Power bobbin output peak voltage:
when checking the LEDs.
NOTE:
A feature of LEDs is that they only allow cur-
r/min
DC V
Blue (L) – Blue (L)
Cranking
10.3
Unloaded
1,500
27.8
3,500
63.2
9
rent to flow in one direction.
Loaded
r/min
DC V 9.5 27.5 61.6
6AJ5K11 8-14
2. Disconnect the power bobbin connectors. Lighting coil output peak voltage:
Green (G) – Green (G)
3. Measure the power bobbin resistance.
Unloaded
Replace the stator coil assembly if out of r/min
specification.
DC V 13.4 33.2 75.4
Power bobbin resistance
(reference data): 2. Measure the lighting coil resistance.
Blue (L) – Blue (L) Replace the stator coil assembly if out of
0.77–1.04 Ω at 20 °C (68 °F) specification.
Lighting coil resistance

4. Connect the power bobbin connectors. (reference data):
Green (G) – Green (G)
0.31–0.43 Ω at 20 °C (68 °F)
Charging system
Checking the lighting coil
1. Measure the lighting coil 1 output peak
voltage. Replace the stator coil assembly
if below specification.
G
1
G
6AJ80140
NOTE:
spark plug caps.
shut-off switch.
8-15 6AJ5K11
TRBL
SHTG
Troubleshooting
Troubleshooting the outboard motor ......................................................... 9-1

Troubleshooting table format ...................................................................
Troubleshooting the power unit ................................................................
Troubleshooting the lower unit .................................................................
9-1
9-1
9-6
1
2
3
4
5
6
7
8
9
6AJ5K11
TRBL
SHTG Troubleshooting
Troubleshooting the outboard motor

NOTE:
Before troubleshooting the outboard motor:
9 Make sure that fresh fuel of the specified type has been used.
9 Be sure to check that the couplers and connectors are securely connected.
9 When checking the input voltage of a part, the coupler or connector must be disconnected.
However, be careful not to short-circuit the wiring harness.
9 Perform the troubleshooting as described in the following tables.
Troubleshooting table format

Troubleshooting consists of the following 4 items.
Symptom 1: Specific trouble conditions
Symptom 2: Trouble conditions of an area or individual part
Cause 1: The content considered as the trouble causes of symptom 2.
Cause 2: The content considered as the trouble causes of cause 1.
Troubleshooting the power unit

Symptom 1: Engine does not crank
Refer
Symptom 2 Cause 1 Cause 2 Checking step to
page
Starter rope does Shift lever not in the Set the shift lever to 3-9
—
not operate neutral position the neutral position.
Start-in-gear protec- Adjust the start-in- 3-10
tion cable not — gear protection
adjusted correctly cable.
Manual starter mal- Disassemble and 5-9
function — check the manual
starter.
Stuck piston Disassemble and 5-13
Piston lock due to check the power
— unit.
water in the com-
bustion chamber
Stuck drive shaft Buildup of foreign Disassemble and 7-15
material on the check the upper
drive shaft and case. (L-transom
bushing model only)
Malfunction of the Disassemble and 6-12
lower unit internal check the lower
parts unit.
Starter rope Manual starter mal- Disassemble and 5-9
operates, but the function check the manual
—
engine does not starter.
crank
9-1 6AJ5K11
Symptom 1: Engine does not start (engine cranks)

Refer
Spark plug does

not spark
Spark plug malfunc-
tion
—
Check the spark
plug.
page
3-6 1
Spark plug cap mal- Check the spark 8-8
—
2
function plug cap.
Ignition coil mal- Check the ignition 8-8
—
function coil.
Engine shut-off Check the engine 8-10
—
switch malfunction shut-off switch.
Charge coil mal-
function
Pulser coil malfunc-
—
—
Check the charge
coil.
Check the pulser
8-9
8-9
3
tion coil.
Fuel not supplied

CDI unit malfunc-
tion
Pinched or kinked
fuel hose
—
—
Check the CDI unit.
Check the fuel

hoses and fuel
8-11
3-3
4
hose joint.
Clogged fuel filter
Fuel pump malfunc-

—
Clean or replace
the fuel filter.
Disassemble and
3-4
4-6
5
tion — check the fuel
Carburetor malfunc-
tion
Malfunction of the
carburetor internal
parts
pump.
Disassemble and
check the carbure-
tor.
4-12 6
7
Prime Start mal- Check the Prime 4-13
—
function Start.
Low compression Valve clearance not Adjust the valve 5-2
—
pressure adjusted correctly clearance.
Damaged cylinder Disassemble and 5-31
head gasket
Damaged valve
Valve stuck to valve —
check the cylinder
head and power
unit.
5-45
8
guide
Scratched piston
and piston ring(s)
9
6AJ5K11 9-2
TRBL
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, limited engine
speed, or engine stalls
Refer
page
Intermittent spark Spark plug malfunc- Check the spark 3-6
—
tion plug.
Spark plug cap mal- Check the spark 8-8
—
function plug cap.
Ignition coil mal- Check the ignition 8-8
—
function coil.
Engine shut-off Check the engine 8-10
—
switch malfunction shut-off switch.
Charge coil mal- Check the charge 8-9
—
function coil.
Pulser coil malfunc- Check the pulser 8-9
—
tion coil.
CDI unit malfunc- Check the CDI unit. 8-11
—
tion
Incorrect fuel and Pinched or kinked Check the fuel 3-3
air amount sup- fuel hose — hoses and fuel
plied hose joint.
Clogged fuel filter Clean or replace 3-4
—
the fuel filter.
Fuel pump malfunc- Disassemble and 4-6
tion — check the fuel
pump.
Carburetor malfunc- Throttle stop screw Adjust the throttle 3-10
tion not adjusted cor- stop screw.
rectly
Pilot screw not Adjust the pilot 4-15
adjusted correctly screw.
Malfunction of the Disassemble and 4-12
carburetor internal check the carbure-
parts tor.
Prime Start system Prime Start mal- Check the Prime 4-13
—
malfunction function Start.
Power bobbin mal- Check the power 8-14
—
function bobbin.
9-3 6AJ5K11
Refer
page
Low compression
pressure
Valve clearance not
adjusted correctly
Automatic decom-
pression actuator
—
Adjust the valve
clearance.
Disassemble and
check the cylinder
5-2
5-31
5-37
1
malfunction head and power 5-45
Damaged cylinder
head gasket
Damaged valve
—
unit.
2
Scratched piston
Throttle valve does

not fully open
and piston ring(s)
Throttle control sys-
tem malfunction
Throttle cables not
adjusted correctly
Check and adjust
the throttle cables.
3-8 3
Throttle link not Check and adjust 3-9
—
Air leakage (carbu-
retor to cylinder
head)
adjusted correctly
Damaged gaskets,
spacer, and intake
manifold (carburetor
the throttle link.
Check the gaskets,
spacer, and intake
manifold (carburetor
4-12
5-28
4
to cylinder head) to cylinder head).
Symptom 1: High engine idle speed
Refer
5
Prime Start system

malfunction
Prime Start mal-
function
—
Check the Prime
Start.
page
4-13 6
Power bobbin mal- Check the power 8-14
—
7
function bobbin.
Engine speed does Carburetor malfunc- Throttle stop screw Adjust the throttle 3-10
not decrease when tion not adjusted cor- stop screw.
throttle cam is in rectly
fully closed position Pilot screw not Adjust the pilot 4-15
adjusted correctly
Malfunction of the
carburetor internal
screw.
Disassemble and
check the carbure-
4-12 8
parts tor.
Throttle cam does

not return to fully
tem malfunction
tem malfunction
Throttle link not
adjusted correctly
Throttle cables not
adjusted correctly
Check and adjust
the throttle link.
Check and adjust
the throttle cables.
3-9
3-8
9
closed position Throttle cam not Check the throttle 5-55
installed correctly cam.
6AJ5K11 9-4
TRBL
Symptom 1: Limited engine speed (below 2,000 r/min)

Refer
page
9 Overheat warning Clogged cooling Check the cooling 3-8
—
indicator comes water inlet water inlets.
on Clogged cooling Check the cooling 3-8
9 Cooling water water passages water passages.
does not dis- —
Cooling water leak-
charge from the
age
cooling water
pilot hole Damaged water Check the water 7-15
pipe or incorrect — pipe and its installa-
installation tion.
Water pump mal- Damaged water Check the impeller. 6-5
function pump impeller Check the Woodruff 6-5
key.
Water leakage from Check the water 6-5
water pump hous- pump housing.
ing Check the insert 6-5
cartridge.
Check the outer 6-5
plate cartridge.
Thermostat mal- Check the thermo- 3-7
—
function stat.
Thermoswitch mal- Check the ther- 8-11
—
function moswitch.
Oil pressure warn- Insufficient engine Add sufficient oil. 3-4
—
ing indicator oil
comes on Engine oil pressure Check the oil pres- 5-1
—
decrease sure.
Oil pump malfunc- Check the oil pump. 5-41
tion
Clogged oil strainer Check the oil 7-16
strainer.
Clogged oil pas- Check the engine 5-31
sages oil passages (power
unit and oil pump).
Clogged oil filter Replace the oil fil- 3-5
ter.
Oil pressure switch Check the oil pres- 8-12
—
malfunction sure switch.
9-5 6AJ5K11
Troubleshooting the lower unit

Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate properly
Refer
Symptom 2 Cause 1
Throttle open
Cause 2
—
Checking step
Turn the throttle

cam to the fully
to
page
3-8
1
closed position.
Shift rod cam mal-
function
—
Detent malfunction
Check the shift link
rod.
Check the shift rod
3-9
5-13
2
cam.
3
—
Shift rod operation Shift rod not con- Check the connec- 6-17
malfunction nected correctly tion of the shift rod.
Shift rod not Adjust the shift rod. 6-17
adjusted correctly
Shift mechanism
malfunction (in
lower unit)
—
Disassemble and
check the lower
unit.
6-7
4
5
6
7
8
9
6AJ5K11 9-6
Index
A. Checking the crankshaft ......................... 5-49

Abbreviation .............................................. 1-3 Checking the crankshaft journal oil
Adjusting the pilot screw ......................... 4-15 clearance .............................................. 5-50
Adjusting the throttle cable ....................... 3-8 Checking the cylinder bore ..................... 5-46
Adjusting the throttle link ........................... 3-9 Checking the cylinder head .................... 5-32
After test run ........................................... 1-17 Checking the diaphragm and valve ........... 4-7
Assembling the carburetor ...................... 4-13 Checking the drive shaft ......................... 6-13
Assembling the cylinder block ................. 5-52 Checking the drive shaft bushing
Assembling the cylinder head ................. 5-38 (L-transom model) ................................. 7-15
Assembling the drive shaft housing ........ 6-15 Checking the electrical component ........... 8-7
Assembling the exhaust guide, oil pan, Checking the engine idle speed .............. 3-10
and exhaust manifold ............................ 7-16 Checking the engine oil ............................ 3-4
Assembling the forward gear .................. 6-14 Checking the engine oil level .................. 1-13
Assembling the friction plate ..................... 7-6 Checking the engine shut-off
Assembling the fuel pump ........................ 4-7 switch ........................................... 1-16, 8-10
Assembling the lower case ..................... 6-14 Checking the exhaust manifold, oil pan,
Assembling the manual starter ............... 5-10 and exhaust guide ................................. 7-16
Assembling the propeller shaft Checking the fuel filter .............................. 3-4
assembly ................................................. 6-8 Checking the fuel filter assembly .............. 4-3
Assembling the propeller shaft housing .... 6-9 Checking the fuel joint .............................. 4-3
Assembling the swivel bracket ................ 7-23 Checking the fuel joint and fuel hose (fuel
Assembling the tiller handle ...................... 7-3 joint-to-carburetor) ................................... 3-3
Assembling the upper case .................... 7-17 Checking the fuel pump ............................ 4-6
Checking the fuel system ........................ 1-13
Checking the gear oil .............................. 3-12
B. Checking the gear oil level ...................... 1-14
Backlash .................................................. 6-23
Checking the gear shift and throttle
Bottom cowling .......................................... 7-8
operation ............................................... 1-14
Bow view ................................................... 8-3
Checking the gear shift operation ............. 3-9
Bracket .................................................... 5-18
Checking the ignition coil .......................... 8-8
Bracket unit ............................................. 3-12
Checking the ignition spark ....................... 8-8
Break-in ................................................... 1-17
Checking the ignition timing .................... 3-11
Checking the lighting coil ........................ 8-15
C. Checking the lower case ......................... 6-14
Carburetor ............................................... 4-10 Checking the lower unit for air leakage ... 3-14
Carburetor unit .......................................... 4-9 Checking the oil pressure ......................... 5-1
CDI unit and junction box ........................ 5-16 Checking the oil pressure switch ............ 8-12
Changing the engine oil ............................ 3-4 Checking the oil pump ............................ 5-41
Changing the gear oil .............................. 3-13 Checking the oil strainer ......................... 7-16
Charging system ..................................... 8-15 Checking the outboard motor mounting
Checking the anode ................................ 3-14 height .................................................... 1-13
Checking the bearing .............................. 6-13 Checking the pinion and forward gear .... 6-13
Checking the camshaft ........................... 5-37 Checking the piston clearance ................ 5-46
Checking the carburetor .......................... 4-12 Checking the piston diameter ................. 5-46
Checking the CDI unit ............................. 8-11 Checking the piston pin boss bore ......... 5-48
Checking the charge coil .......................... 8-9 Checking the piston pin diameter ........... 5-48
Checking the compression pressure ........ 5-1 Checking the piston ring ......................... 5-47
Checking the connecting rod big end Checking the piston ring end gap ........... 5-47
side clearance ....................................... 5-49 Checking the piston ring groove ............. 5-47
Checking the connecting rod small and Checking the piston ring side
big end inside diameter ......................... 5-48 clearance .............................................. 5-48
Checking the cooling water passage ........ 3-8 Checking the power bobbin (for Prime
Checking the cooling water pilot hole ..... 1-16 Start) ..................................................... 8-14
Checking the crankpin oil clearance ....... 5-49 Checking the Prime Start ........................ 4-13
i-1 6AJ5K11
Index
Checking the propeller ............................ 3-14 Draining the fuel ........................................ 3-4
Checking the propeller shaft ..................... 6-8 Drive shaft and lower case ..................... 6-11
Checking the propeller shaft housing ....... 6-8
Checking the pulser coil ............................ 8-9
E.
Checking the rocker arm and rocker arm
shaft ...................................................... 5-37
Checking the shift rod ............................. 6-13
Checking the spark plug ........................... 3-6
Electrical ................................................... 2-8
Electrical component and wiring harness
routing ..................................................... 8-1
1
Engine electric control system ................ 8-11
Checking the spark plug cap .................... 8-8
Checking the start-in-gear protection ...... 3-10
Checking the steering operation ............. 3-12
Checking the steering system ................. 1-15
Checking the thermostat ........................... 3-7
F.
Fire prevention ..........................................
Friction plate .............................................
1-4
7-5
2
Checking the thermoswitch ..................... 8-11 Fuel filter ................................................... 4-2
3
Checking the tilt operation ...................... 3-12 Fuel hose, blowby hose, and cooling
Checking the tilt system .......................... 1-15 water hose .............................................. 4-1
Checking the timing belt ........................... 3-6 Fuel pump ................................................. 4-4
Checking the timing belt and sprocket .... 5-25 Fuel system ....................................... 2-7, 3-3
Checking the top cowling .......................... 3-3
G.
4
Checking the valve .................................. 5-33
Checking the valve clearance ................... 5-2 General ................................................... 3-14
Checking the valve guide ........................ 5-33 General specification ................................ 2-1
Checking the valve seat .......................... 5-34 General torque ........................................ 2-14
Checking the valve spring ....................... 5-32 Good working practice .............................. 1-5
Checking the warning indicator
assembly ............................................... 8-13
Checking the water pump ......................... 6-5
Clamp bracket and swivel bracket .......... 7-20
Control system .......................................... 3-8
H.
Hose routing .............................................. 4-1
How to use this manual ............................ 1-1
5
Cylinder block .......................................... 5-43
D.
Cylinder head .......................................... 5-28
Dimension ............................................... 2-10

I.
Identification .............................................. 1-6
Ignition and ignition control system .......... 8-8
Ignition coil .............................................. 5-15
6
Disassembling the carburetor ................. 4-12 Installing the carburetor .......................... 4-14
Disassembling the cylinder block ............ 5-45
Disassembling the cylinder head ............ 5-31
Disassembling the drive shaft housing ... 6-12
Disassembling the exhaust manifold,
Installing the clamp bracket .................... 7-24
Installing the cylinder head ..................... 5-41
Installing the lower unit ........................... 6-17
Installing the power unit .......................... 5-55
7
oil pan, and exhaust guide .................... 7-15 Installing the propeller shaft housing ...... 6-16
Disassembling the forward gear ............. 6-12
Disassembling the friction plate ................ 7-6
Disassembling the fuel pump .................... 4-6
Disassembling the lower case ................ 6-13
Installing the shift rod, drive shaft
housing, and drive shaft ........................ 6-15
Installing the sprocket and timing belt ..... 5-25
Installing the steering arm ...................... 7-18
8
Disassembling the manual starter ............ 5-9 Installing the upper case ......................... 7-19
9
Disassembling the propeller shaft Installing the water pump ........................ 6-16
assembly ................................................. 6-7
Disassembling the propeller shaft housing L.
assembly ................................................. 6-7 Lower unit ................................. 2-7, 3-12, 6-1
Disassembling the swivel bracket ........... 7-22 Lubricating the outboard motor ............... 3-15
Disassembling the tiller handle ................. 7-3
Disassembling the upper case ................ 7-15
Disassembly and assembly ...................... 1-5 M.
Maintenance interval chart ........................ 3-1
6AJ5K11 i-2
Index
Maintenance specification ......................... 2-3 Shimming ................................................ 6-20

Manual format ........................................... 1-1 Special service tool ................................... 1-7
Manual starter ........................................... 5-7 Specified torque ...................................... 2-12
Measuring the forward and reverse gear Symbol ...................................................... 1-2
backlash ................................................ 6-23
Measuring the peak voltage ...................... 8-7
Model ........................................................ 1-6
T.
Test run ................................................... 1-16
Throttle cam ............................................ 5-20
P. Tightening torque .................................... 2-12
Part, lubricant, and sealant ....................... 1-4 Tiller handle .............................................. 7-1
Port view ................................................... 8-5 Timing belt and sprocket ......................... 5-23
Power unit ................................. 2-3, 3-4, 5-13 Top cowling ............................................... 3-3
Power unit (check and adjustment) ........... 5-1 Top view .................................................... 8-1
Power unit assembly ............................... 5-13 Troubleshooting table format ..................... 9-1
Precaution when transporting or storing Troubleshooting the lower unit .................. 9-6
the outboard motor ............................... 1-17 Troubleshooting the outboard motor ......... 9-1
Predelivery check .................................... 1-12 Troubleshooting the power unit ................. 9-1
Propeller selection .................................. 1-12
Propeller shaft housing ............................. 6-6
Propeller size .......................................... 1-12
U.
Upper case and steering arm ................. 7-11
R. V.
Refacing the valve seat ........................... 5-35
Ventilation .................................................. 1-4
Removing the carburetor ........................ 4-12
Removing the clamp bracket .................. 7-22
Removing the cylinder head ................... 5-31
Removing the drive shaft, drive shaft
housing, and shift rod ........................... 6-12
Removing the intake silencer protective
covering ................................................. 1-13
Removing the lower unit ........................... 6-4
Removing the power unit ........................ 5-21
Removing the propeller shaft housing
assembly ................................................. 6-7
Removing the steering arm .................... 7-18
Removing the timing belt and sprocket ... 5-24
Removing the upper case ....................... 7-15
Removing the water pump ........................ 6-5
Replacing the oil filter ............................... 3-5
Replacing the timing belt .......................... 5-3
Replacing the valve guide ....................... 5-34
S.
Safety while working ................................. 1-4
Sealant and locking agent table ................ 1-3
Selecting the crankshaft main bearing ... 5-52
Selecting the forward gear shim ............. 6-21
Selecting the pinion shim ........................ 6-21
Selecting the reverse gear shim ............. 6-22
Selection ................................................. 1-12
Self-protection ........................................... 1-4
Serial number ............................................ 1-6
i-3 6AJ5K11
Index
— MEMO —
1
2
3
4
5
6
7
8
9
6AJ5K11 i-4
Wiring diagram
F20CMH
Color code
1 CDI unit B : Black
2 Stator coil assembly (charge coil) G : Green
3 Stator coil assembly (power bobbin) L : Blue
4 Stator coil assembly (lighting coil) O : Orange
5 Pulser coil P : Pink
6 Prime Start W : White
7 Ignition coil B/R : Black/red
8 Spark plug G/R : Green/red
9 Thermoswitch Gy/B : Gray/black
0 Oil pressure switch P/B : Pink/black
q Engine shut-off switch P/W : Pink/white
w Warning indicator assembly W/R : White/red
Y/B : Yellow/black
Y/R : Yellow/red
å To tachometer
NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
Important information
Particularly important information is distinguished in this manual by the following notations:
Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
w
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
cC
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
F20C
SERVICE MANUAL
©2007 by Yamaha Motor Co., Ltd.
1st Edition, October 2007
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
F20C
F20C
SERVICE MANUAL
YAMAHA MOTOR CO., LTD.
Printed in Japan
Oct. 2007 – 0.4 × 1 ! 6AJ-28197-5K-11
(E) Printed on recycled paper
WD6AJ5K
07.9.25 11:50
F20CMH
Page 1
L L
L L
G
B/R B/R
G/R G/R
1 G
2 P/B
3
4 Y/B
5 G
6 G/R
7 W/R W/R W/R
8 B/R
9 W
B B
10
11 P/W
12 B
13 P
14 Gy/B
15 Y/R
16
17 B
18 O O O
B B
Gy/B Gy/B
B B
Y/B 1 Y/B
P/B 3 P/B
Y/R 2 Y/R
P/W 4 P/W
P P
W W
B
B B B
B

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S6AJ5K11_Cover-7mm 07.10.

General information GEN

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

Identification ................................................................................................. 1-6

Propeller selection ..................................................................................... 1-12

How to use this manual

Periodic check and adjustment

Sealant and locking agent table

LOCTITE 518 Sealant Henkel

Safety while working

1. Avoid contact with skin. Do not, for exam-

2. Wash hands and any other part of the

5. Keep a supply of clean, lint-free cloths for

6. Maintain good standards of personal and Disassembly and assembly

3. Install bearings with the manufacture

Special service tool

Oil filter wrench Compression gauge

Digital tachometer Flywheel holder

Timing light Flywheel puller

Leakage tester Shaft holder

Vacuum/pressure pump gauge set Valve spring compressor

Bearing housing puller claw S Drive shaft holder 1

Bearing puller assembly Bushing attachment

Stopper guide stand Bearing separator

Driver rod LS Needle bearing attachment

Ball bearing attachment Bearing outer race attachment

Digital circuit tester

Peak voltage adapter B

Propeller selection a Propeller diameter (in inches)

Checking the outboard motor cC

NOTE: 2. Check that the gear shift operates

Recommended engine oil: R

Checking the gear shift and throttle

Checking the steering system Checking the tilt system

2. Check that the steering operates smooth-

5. Check that the outboard motor does not

Break-in Precaution when transporting or

2. 1 hour b at 3,000 r/min or 3/4 throttle

3. 8 hours c with the engine at any speed.

After test run

2. Check for fuel leakage in the cowling.

3. Flush the cooling water passages with

General specification ................................................................................... 2-1

Maintenance specification .......................................................................... 2-3

Tightening torque ....................................................................................... 2-12

(with oil filter replacement)

1.8 (1.90, 1.58)

Gear oil quantity

(lines indicate straightedge

The figures are for reference only.

Camshaft runout limit

10.8 ± 0.2 (0.4 ± 0.01)

(spark plug wire –

70.5 (2.8) 70.5 (2.8)

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

Top cowling .................................................................................................. 3-3

Bracket unit ................................................................................................ 3-12

Lower unit ................................................................................................... 3-12

Maintenance interval chart

2. Loosen the bolts 1.

4. Tighten the bolts 1. S6AG3040

5. Check the fitting again and, if necessary,

6. Check the air intake duct. Clean if there