F25C

SERVICE MANUAL

290539 6D5-28197-5F-11
 NOTICE

This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.

Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.

Important information 1

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.

CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.

NOTE:
A NOTE provides key information to make procedures easier or clearer.

F25C
SERVICE MANUAL
©2003 by Yamaha Motor Co., Ltd.
1st Edition, November 2003
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
 Contents
General information GEN
INFO
1
Specifications
SPEC 2
Periodic checks and adjustments CHK
ADJ
3
Fuel system
FUEL 4
Power unit
POWR 5
Lower unit
LOWR 6
Bracket unit
BRKT 7
– +

Electrical systems
ELEC 8
Troubleshooting TRBL
SHTG
9
Index
 GEN
INFO
General information

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

Manual format............................................................................................ 1-1
Symbols..................................................................................................... 1-2 1
Safety while working......................................................................................1-3
Fire prevention........................................................................................... 1-3
Ventilation..................................................................................................1-3
Self-protection ........................................................................................... 1-3
Parts, lubricants, and sealants ..................................................................1-3
Good working practices .............................................................................1-4
2
Disassembly and assembly ....................................................................... 1-4

Identification...................................................................................................1-5
Applicable models .....................................................................................1-5
Serial number ............................................................................................ 1-5
3
Propeller selection ......................................................................................... 1-5
Propeller size............................................................................................. 1-5
Selection.................................................................................................... 1-6
4
Predelivery checks ........................................................................................1-6
Checking the fuel system ..........................................................................1-6
Checking the engine oil level..................................................................... 1-6
Checking the gear oil level ........................................................................ 1-6
5
Checking the outboard motor mounting height.......................................... 1-7

6
Checking the remote control cables (remote control model) ..................... 1-7
Checking the steering system ...................................................................1-8
Checking the gear shift and throttle operation...........................................1-8
Checking the engine stop lanyard switch .................................................. 1-9
Checking the cooling water pilot holes ......................................................1-9
Test run ..................................................................................................... 1-9
Break-in ................................................................................................... 1-10
After test run ............................................................................................ 1-10 7
8
9
6D55F11
 GEN
INFO General information
How to use this manual 1

Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the information below as a guide for effective and quality service.

1 Parts are shown and detailed in an exploded diagram and are listed in the components list.
2 Tightening torque specifications are provided in the exploded diagrams and after a numbered
step with tightening instructions.
3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant
and lubrication point.
4 The components list consists of part names and part quantities, as well as bolt and screw dimen-
sions.
5 Service points regarding removal, checking, and installation are shown in individual illustrations
to explain the relevant procedure.

NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”

LOWR
Lower unit
3 2 1
Lower unit

LOWR
Lower unit
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.

S62Y6740K

CAUTION:
Do not reuse the bearing, always replace
S62Y6850K it with a new one.

Drive shaft holder 4 1: 90890-06518

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

Disassembling the forward gear

1. Remove the taper roller bearing from the

4 forward gear using a press.

6-19 62Y5A11

1-1 6D55F11
 How to use this manual
Symbols
The symbols below are designed to indicate the content of a chapter.
General information Fuel system Bracket unit
GEN
INFO FUEL BRKT 1
Specifications Power unit Electrical systems

SPEC POWR ELEC – +

2
Periodic checks and adjustments Lower unit Troubleshooting
CHK
ADJ LOWR TRBL
SHTG 3
Symbols 1 to 6 indicate specific data.

1 2 3 4
T.
R.

5 6
4
1
2
3
4
Special tool
Specified oil or fluid
Specified engine speed
Specified tightening torque
5 Specified measurement
6 Specified electrical value
(resistance, voltage, electric current)
5
Symbols 7 to C in an exploded diagram indicate the grade of lubricant and the lubrication point.

7 8 9 0 A B C
6
A M D C I

7
E G

7 Apply Yamaha 4-stroke motor oil A Apply corrosion resistant grease

8 Apply gear oil (Yamaha grease D)
9 Apply water resistant grease (Yamaha grease A) B Apply low temperature resistant grease
0 Apply molybdenum disulfide grease (Yamaha grease C)
C Apply injector grease

Symbols D to I in an exploded diagram indicate the type of sealant or locking agent and the appli-
8
cation point.

D
GM
E
4
F
LT

271
G
LT

242
H
LT

572
I

SS
9
D Apply Gasket Maker G Apply LOCTITE 242 (blue)
E Apply Yamabond No. 4 H Apply LOCTITE 572
F Apply LOCTITE 271 (red) I Apply silicon sealant

6D55F11 1-2
 GEN
INFO General information
Safety while working 1

To prevent an accident or injury and to

ensure quality service, follow the safety pro-
cedures provided below.

Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.

Parts, lubricants, and sealants

Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the out-
board motor.

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

1. Maintain good standards of personal and

industrial hygiene.

2. Change and wash clothing as soon as

possible if soiled with lubricants.

3. Avoid contact with skin. Do not, for

Self-protection example, place a soiled rag in your
pocket.
Protect your eyes by wearing safety glasses
or safety goggles during all operations involv-
4. Wash hands and any other part of the
ing drilling and grinding, or when using an air
body thoroughly with soap and hot water
compressor.
after contact with a lubricant or lubricant
Protect your hands and feet by wearing pro-
soiled clothing has been made.
tective gloves and safety shoes when neces-
sary. 5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.

1-3 6D55F11
 Safety while working
6. Keep a supply of clean, lint-free cloths for Disassembly and assembly
wiping up spills, etc. 1. Use compressed air to remove dust and
dirt during disassembly.
Good working practices
Special service tools
Use the recommended special service tools
to protect parts from damage. Use the right
2. Apply engine oil to the contact surfaces
of moving parts before assembly. 1
tool in the right manner—do not improvise.

2
3
3. Install bearings with the manufacture

4
identification mark in the direction indi-
Tightening torques cated in the installation procedure. In
Follow the tightening torque specifications addition, be sure to lubricate the bearings
provided throughout the manual. When tight- liberally.
ening nuts, bolts, and screws, tighten the

5
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 parts seal before installation.
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, etc., when installing or 5. Check that moving parts operate nor-

6
assembling parts. mally after assembly.

7
8
9
6D55F11 1-4
 GEN
INFO General information
Identification 1 Propeller selection 1

Applicable models The performance of a boat and outboard

This manual covers the following models. motor will be critically affected by the size
and type of propeller you choose. Propellers
Applicable models greatly affect boat speed, acceleration,
F25CMH, F25CM engine life, fuel economy, and even boating
and steering capabilities. An incorrect choice
Serial number could adversely affect performance and
The outboard motor serial number is could also seriously damage the engine.
stamped on a label attached to the port Use the following information as a guide for
clamp bracket. selecting a propeller that meets the operating
conditions of the boat and the outboard
motor.

Propeller size
The size of the propeller is indicated on a
propeller blade, on the propeller boss end, on
the side of the propeller boss.

× -
a b c

S69W1030

1 Model name × -
2 Approved model code a b c
3 Transom height
4 Serial number

Approved Starting
Model name S69W1040
model code serial No.
S: 1000001–
F25CMH
6D5 L: 1000001–
F25CM L: 1000001–

× -
a b c

S69W1050

1-5 6D55F11
 Identification / Propeller selection / Predelivery checks
a Propeller diameter (in inches)
b Propeller pitch (in inches) CAUTION:
c Propeller type (propeller mark)
This is a 4-stroke engine. Never use pre-

1
mixed fuel.
Selection
When the engine speed is at the full throttle
operating range (5,000–6,000 r/min), the Checking the engine oil level
ideal propeller for the boat is one that pro- 1. Check the engine oil level.
vides maximum performance in relation to
boat speed and fuel consumption.
Propeller size (in)
9 7/8 × 8 - F
Material 2
9 7/8 × 9 - F
9 7/8 × 10 1/2 - F
9 7/8 × 11 1/4 - F
9 7/8 × 12 - F
Aluminum 3
9 7/8 × 13 - F
9 7/8 × 14 - F

Predelivery checks 1
NOTE:
If the engine oil is below the minimum level
mark b, add sufficient oil until the level is
between a and b.
4
To make the delivery process smooth and
efficient, the predelivery checks should be
completed as explained below.

Checking the fuel system

Recommended engine oil:
4-stroke motor oil
API: SE, SF, SG, SH, or SJ
5
1. Check that the fuel hoses are securely SAE: 10W-30 or 10W-40
connected and that the fuel tank is full
with fuel.
Oil quantity:
With oil filter replacement:
1.9 L (2.0 US qt, 1.7 Imp qt)
6
Checking the gear oil level
1. Check the gear oil level.
7
8
S60V1290

9
6D55F11 1-6
 GEN
INFO General information
Checking the outboard motor
mounting height
2 1
1. Check that the anti-cavitation plate is
between the bottom of the boat and a
maximum of 25 mm (1 in) a below it. If
the mounting height is too high, cavita-
tion will occur and propulsion will be
reduced. Also, the engine speed will
increase abnormally and cause the
S6D51040
engine to overheat. If the mounting
height is too low, water resistance will
3. Check that the shift link lever 3 is verti-
increase and reduce engine efficiency.
cal to the mating surfaces of the engine.

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.

a
2. Check that the clamp brackets are
S6D53190
secured with the clamp screws.

Checking the remote control cables WARNING

(remote control model) The shift/throttle cable joint must be
1. Set the remote control lever to the neu- screwed in a minimum of 8.0 mm (0.31 in)
tral position and fully close the throttle a.
lever.

2. Check that the throttle cam 1 contacts

the fully closed stopper 2.

1-7 6D55F11
 Predelivery checks
Checking the steering system Checking the gear shift and throttle
1. Check the steering friction for proper operation
adjustment. 1. Check that the gear shift operates
smoothly when the remote control lever
or shift lever is shifted from neutral to for-
ward or reverse. 1
2. Check that the throttle operates smoothly
when the throttle grip (tiller handle
model) is turned from the fully closed
position to the fully open position a.
Check that the throttle operates smoothly
2
when the remote control lever (remote
NOTE:
• To increase the friction, turn the friction
adjusting bolt in direction a.
control model) is shifted from forward or
reverse to the fully open positions a.

R
3

0
N

FAST
START
• To decrease the friction, turn the friction

%
adjusting bolt in direction b.

100
2. Check that the steering operates F
smoothly.

N
a S6D51090
5
F R

S6D51070
a 6
a

S6D51130
7
S6D51080
8
3. Check that there is no interference with
wires or hoses when the outboard motor
is steered.
9
6D55F11 1-8
 GEN
INFO General information
Checking the engine stop lanyard Checking the cooling water pilot
switch holes
1. Check that the engine turns off when the 1. Check that cooling water is discharged
engine stop lanyard switch is pushed or from the cooling water pilot holes.
the engine stop lanyard is pulled from the
engine stop lanyard switch.

S6D53140

S6D51100 Test run

1. Start the engine, and then check that the
gear shift operates smoothly.

2. Check the engine idle speed after the

engine has been warmed up.

3. Operate at trolling speed.

4. Run the outboard motor for 1 hour at

S6D51110 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.

NOTE:
The test run is part of the break-in operation.

È To outboard motor

1-9 6D55F11
 Predelivery checks
Break-in
During the test run, perform the break-in
operation in the following three stages.

1
1. One hour a at 2,000 r/min or at approxi-
mately half throttle

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

and 1 minute out of every 10 at full throt-

2
tle

3. Eight hours c at any speed, however,

avoid running at full speed for more than
5 minutes

a b c
3
È 0 1 2 10
4
S69J1240

5
È Hour

After test run

1. Check for water in the gear oil.

6
2. Check for fuel leakage in the cowling.

3. Flush the cooling water passage with

fresh water using the flushing kit and with
the engine running at idle.

7
8
9
6D55F11 1-10
 GEN
INFO General information

— MEMO —

1-11 6D55F11
SPEC

Specifications

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

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

Power unit..................................................................................................2-3
1
Lower unit ..................................................................................................2-7
Electrical .................................................................................................... 2-7
Dimensions................................................................................................2-9

Tightening torques....................................................................................... 2-11

2
Specified torques.....................................................................................2-11

3
General torques....................................................................................... 2-13

4
5
6
7
8
9
6D55F11
SPEC
Specifications
General specifications 2

Model
Item Unit
F25CMH F25CM
Dimension
Overall length mm (in) 1,151 (45.3) 703 (27.7)
Overall width mm (in) 430 (16.9) 376 (14.8)
Overall height
(S) mm (in) 1,148 (45.2) —
(L) mm (in) 1,275 (50.2)
Boat transom height
(S) mm (in) 381 (15.0) —
(L) mm (in) 508 (20.0)
Weight
(with aluminium propeller)
(S) kg (lb) 62.0 (137) —
(L) kg (lb) 64.0 (141) 63.0 (139)
Performance
Maximum output kW (hp) 18.4 (25.0) at 5,500 r/min
Full throttle operating range r/min 5,000–6,000
Maximum fuel consumption L (US gal, 9.2 (2.4, 2.0) at 6,000 r/min
lmp gal)/hr
Engine idle speed r/min 925–1,025
Power unit
Type In-line, 4-stroke, SOHC, 4 valves
Cylinder quantity L2
Total displacement cm3 (cu. in) 498 (30.4)
Bore × stroke mm (in) 65.0 × 75.0 (2.56 × 2.95)
Compression ratio 9.87
Control system Tiller handle Remote control
Starting system Manual
Enrichment system Prime Start
Ignition system Microcomputer (CDI)
Maximum generator output V, W 12, 80
Spark plug DPR6EA-9 (NGK)
Cooling system Water
Exhaust system Propeller boss
Lubrication system Wet sump

2-1 6D55F11
 General specifications

Model
Item Unit
F25CMH F25CM
Fuel and oil
Fuel type
Fuel minimum rating
Engine oil
Engine oil grade
RON(*1)

API
Regular unleaded gasoline
86
4-stroke motor oil
SE, SF, SG, SH, or SJ
1
SAE 10W-30 or 10W-40
Engine oil quantity
(without oil filter replacement) L (US qt,
lmp qt)
1.7 (1.8, 1.5) 2
(with oil filter replacement) L (US qt, 1.9 (2.0, 1.7)

3
lmp qt)
Gear oil type Hypoid gear oil
Gear oil grade(*2) API GL-4
SAE 90
Gear oil quantity cm3 (US oz, 320 (10.8, 11.3)

Bracket unit
Tilt angle
(at 12° boat transom)
lmp oz)

Degree 8, 12, 16, 20, 24

4
Tilt-up angle Degree 64
Shallow water drive angle
Steering angle
Drive unit
Degree
Degree
29, 43
45 + 45 5
Gear shift positions F-N-R
Gear ratio
Reduction gear type
Clutch type
Propeller shaft type
2.08 (27/13)
Spiral bevel gear
Dog clutch
Spline
6
Propeller direction (rear view) Clockwise
Propeller identification mark
(*1)
(*2)
RON: Research Octane Number
Meeting both API and SAE requirements
F
7
8
9
6D55F11 2-2
 SPEC
Specifications
Maintenance specification 2

Power unit
Model
Item Unit
F25CMH F25CM
Power unit
Minimum compression kPa 810 (8.1, 115)
pressure(*1) (kgf/cm2, psi)
Lubrication oil pressure(*2) kPa 80 (0.8, 11) at engine idle speed
(kgf/cm2, psi)
Cylinder heads
Warpage limit mm (in) 0.10 (0.0039)

(lines indicate straightedge

position)
Cylinder head journal inside mm (in) 37.000–37.025 (1.4567–1.4577)
diameter
Cylinders
Bore size mm (in) 65.000–65.015 (2.5590–2.5596)
Taper limit mm (in) 0.08 (0.0032)
Out-of-round limit mm (in) 0.05 (0.0020)
Pistons
Piston diameter (D) mm (in) 64.950–64.965 (2.5571–2.5577)
Measuring point (H) mm (in) 2.0 (0.08)
Piston-to-cylinder clearance mm (in) 0.035–0.065 (0.0014–0.0026)
Piston pin boss bore mm (in) 15.974–15.985 (0.6289–0.6293)
Oversize piston diameter
1st mm (in) 65.200–65.215 (2.5669–2.5675)
2nd mm (in) 65.450–65.465 (2.5768–2.5774)
Piston pins
Outside diameter mm (in) 15.965–15.970 (0.6285–0.6287)
(*1) Measure conditions:
• Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs removed from all cylinders.
The figures are for reference only.
• Since this outboard motor is equipped with an automatic decompression mechanism, accurate data may
be difficult to obtain due to differences in the way the starer rope is pulled.
(*2) The figures are for reference only.

2-3 6D55F11
 Maintenance specification

Model
Item Unit
F25CMH F25CM
Piston rings
Top ring
Dimension B
Dimension T
End gap
mm (in)
mm (in)
mm (in)
1.17–1.19 (0.0461–0.0469)
2.25–2.45 (0.0885–0.0965)
0.15–0.30 (0.0059–0.0118)
1
Side clearance mm (in) 0.02–0.06 (0.0008–0.0024)
Oversize diameter
1st
2nd
mm (in)
mm (in)
65.250 (2.5689)
65.500 (2.5787)
2
2nd ring
Dimension B
Dimension T
End gap
Side clearance
mm (in)
mm (in)
mm (in)
mm (in)
1.47–1.49 (0.0579–0.0587)
2.60–2.80 (0.1024–0.1102)
0.30–0.50 (0.0118–0.0197)
0.02–0.06 (0.0008–0.0024)
3
Oversize diameter
1st
2nd
Oil ring
mm (in)
mm (in)
65.250 (2.5689)
65.500 (2.5787) 4
Dimension B mm (in) 2.36–2.48 (0.0929–0.0976)
Dimension T
End gap
Side clearance
Oversize diameter
mm (in)
mm (in)
mm (in)
2.75 (0.1083)
0.20–0.70 (0.0079–0.0276)
0.04–0.18 (0.0016–0.0070)
5
1st mm (in) 65.250 (2.5689)
2nd
Camshafts
Intake and exhaust
mm (in)

mm (in)
65.500 (2.5787)

30.834–31.034 (1.2139–1.2218)
6
(A)

7
Intake and exhaust mm (in) 25.90–26.10 (1.0197–1.0276)
(B)
Camshaft journal diameter mm (in) 36.925–36.945 (1.4537–1.4545)
(top)
Camshaft journal diameter mm (in) 36.935–36.955 (1.4541–1.4549)
(center)
Camshaft journal oil clearance
Camshaft runout limit
Rocker arm shaft
mm (in)
mm (in)
0.050–0.090 (0.0020–0.0035)
0.03 (0.0012)
8
Rocker arm shaft outside mm (in) 15.971–15.991 (0.6288–0.6296)
diameter
Rocker arms
Rocker arm inside diameter mm (in) 16.000–16.018 (0.6299–0.6306)
9
6D55F11 2-4
SPEC
Specifications

Model
Item Unit
F25CMH F25CM
Valves
Valve clearance (cold)
Intake mm (in) 0.15–0.25 (0.006–0.010)
Exhaust mm (in) 0.25–0.35 (0.010–0.014)
Head diameter (A)
Intake mm (in) 31.90–32.10 (1.256–1.264)
Exhaust mm (in) 25.90–26.10 (1.020–1.028)
Face width (B)
Intake mm (in) 1.84–2.97 (0.072–0.117)
Exhaust mm (in) 1.98–3.11 (0.078–0.122)
Seat contact width (C)
Intake and exhaust mm (in) 0.9–1.1 (0.035–0.043)
Margin thickness (D)
Intake mm (in) 0.8 (0.0315)
Exhaust mm (in) 0.9 (0.0354)
Stem diameter
Intake mm (in) 5.475–5.490 (0.2156–0.2161)
Exhaust mm (in) 5.460–5.475 (0.2150–0.2156)
Guide inside diameter
Intake and exhaust mm (in) 5.500–5.512 (0.2165–0.2170)
Stem-to-guide clearance
Intake and exhaust mm (in) 0.025–0.052 (0.0010–0.0020)
Stem runout limit mm (in) 0.03 (0.0012)
Valve springs
Free length mm (in) 39.85 (1.5689)
Minimum free length mm (in) 25.80 (1.0157)
Tilt limit mm (in) 1.7 (0.07)
Connecting rods
Small-end inside diameter mm (in) 15.985–15.998 (0.6293–0.6298)
Big-end inside diameter mm (in) 36.000–36.024 (1.4173–1.4183)
Crankpin oil clearance mm (in) 0.020–0.052 (0.0008–0.0020)
Big-end bearing thickness
A Blue mm (in) 1.494–1.498 (0.0588–0.0590)
B Black mm (in) 1.490–1.494 (0.0587–0.0588)
C Brown mm (in) 1.486–1.490 (0.0585–0.0587)
Crankshaft
Crankshaft journal diameter mm (in) 42.984–43.000 (1.6923–1.6929)
Crankpin diameter mm (in) 32.984–33.000 (1.2986–1.2992)
Crankpin width mm (in) 21.000–21.070 (0.8268–0.8295)
Runout limit mm (in) 0.05 (0.0020)

2-5 6D55F11
 Maintenance specification

Model
Item Unit
F25CMH F25CM
Crankcase
Crankshaft main journal oil
clearance
Crankcase main journal
bearing thickness
mm (in) 0.012–0.044 (0.0005–0.0017)
1
A Blue mm (in) 1.498–1.502 (0.0590–0.0591)
B
C
Oil pump
Black
Brown
mm (in)
mm (in)
1.494–1.498 (0.0588–0.0590)
1.490–1.494 (0.0587–0.0588) 2
Type Trochoid
Outer rotor-to-housing
clearance
Outer rotor-to-inner rotor
clearance limit
mm (in)

mm (in)
0.09–0.15 (0.0035–0.0059)

0.12 (0.047) 3
Rotor-to-cover clearance mm (in) 0.03–0.08 (0.0012–0.0031)
Relief valve operating
pressure
Thermostats
Opening temperature
kPa
(kgf/cm2, psi)

°C (°F)
382–442 (3.82–4.42, 55.4–64.1)

58–62 (136–144)
4
Fully open temperature °C (°F) 70 (158)
Valve open lower limit
Fuel pump
Discharge
mm (in)

L (US gal,
3.0 (0.12)

70 (18.5, 15.4) at 3,000 r/min

5
lmp gal)/hr
Pressure

Plunger stroke
Carburetor
kPa
(kgf/cm2, psi)
mm (in)
49 (0.49, 7.1)

5.85–9.65 (0.23–0.38)
6
Identification mark 65W11
Main jet
Pilot jet
Pilot screw
#
#
turns out
112
50
1 5/8–2 5/8
7
Float height mm (in) 8.7–9.7 (0.34–0.38)
Manual starter
Starter rope length mm (in) 1,625–1,727 (63.98–67.99)
8
9
6D55F11 2-6
 SPEC
Specifications
Lower unit
Model
Item Unit
F25CMH F25CM
Gear backlash
Pinion-to-forward gear mm (in) 0.30–0.72 (0.0118–0.0283)
Pinion-to-reverse gear mm (in) 0.92–1.65 (0.0362–0.0650)
Pinion shims mm 0.7, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6
Forward gear shims mm 1.0, 1.1, 1.2, 1.3, 1.4
Reverse gear shims mm 1.0, 1.1, 1.2, 1.3

Electrical
Model
Item Unit
F25CMH F25CM
Ignition and ignition control
system
Ignition timing (cylinder #1) Degree BTDC 8.5 at engine idle speed
Degree BTDC 30 at 6,000 r/min
Spark plug gap mm (in) 0.8–0.9 (0.031–0.035)
Ignition coil resistance
Primary coil (O – B)
at 20 °C (68 °F) Ω 0.08–0.11
Secondary coil
(spark plug wire –
spark plug wire)
at 20 °C (68 °F) kΩ 3.4–4.7
CDI unit output peak voltage
(B/W – O)
at cranking (loaded) V 120.0
at 1,500 r/min (loaded) V 120.0
at 3,500 r/min (loaded) V 130.0
Pulser coil output peak voltage
(R – W)
at cranking (unloaded) V 6.0
at cranking (loaded) V 5.7
at 1,500 r/min (loaded) V 14.0
at 3,500 r/min (loaded) V 20.4
Pulser coil resistance(*1) Ω 300–350
(R – W)
(*1)
The figures are for reference only.

2-7 6D55F11
 Maintenance specification

Model
Item Unit
F25CMH F25CM
Charge coil output peak
voltage (G/W – W/G)
at cranking (unloaded)
at cranking (loaded)
at 1,500 r/min (loaded)
V
V
V
170.0
130.0
140.0
1
at 3,500 r/min (loaded) V 140.0
Charge coil resistance(*1)

at 20 °C (68 °F)
(G/W – W/G)
Ω 660–710
2
Power bobbin output peak

3
voltage (Y/B – Y/B)
at cranking (unloaded) V 10.0
at 1,500 r/min (unloaded) V 38.9
at 3,500 r/min (unloaded) V 80.0
at cranking (loaded) V 5.5
at 1,500 r/min (loaded)
at 3,500 r/min (loaded)
Power bobbin resistance(*1)
V
V
30.0
80.0 4
(Y/B – Y/B)
Ω

5
at 20 °C (68 °F) 6.50–7.20
Lighting coil output peak
voltage (Y – Y)
at cranking (unloaded) V 9.4
at 1,500 r/min (unloaded) V 46.0
at 3,500 r/min (unloaded)
Lighting coil resistance(*1)

at 20 °C (68 °F)
(Y – Y)
V

Ω
95.0

0.90–1.10
6
Enrichment control system
Prime Start
7
Plunger extended length a(*1)
Prime Start resistance(*2)
(Y – Y)
mm (in) 10.7–15.4 (0.42–0.61)
8
at 20 °C (68 °F) Ω 17.7–18.7
(*1)
(*2)
The figures are for reference only.
Measuring condition:
Prime Start plunger length is 10.7 mm (0.42 in).
The figures are for reference only.
9
6D55F11 2-8
 SPEC
Specifications
Dimensions
Exterior
* Tiller handle model only

400 (15.7) mm (in)

45˚
222 (8.7)*
631 (24.8)*

185 (7.3)
572 (22.5)*
S: 763 (30.0)
363 (14.3)* L: 877 (34.5)
296 (11.7)* 580 (22.8)
190 (7.5)*
65 (2.6)
698 (27.5)

441 (17.4)

184 (7.2)*
42 (1.7)
37 (1.5)*
S: 423 (16.7)
144 (5.7) L: 550 (21.7)
S: 707 (27.8)
L: 834 (32.8)

S: 615 (24.2)
L: 686 (27.0)

S: 84
(
L: 10 3.3)
2 (4.0
)
˚
64

12˚

S: 43 (1.7) 4˚
22 (0.9)

L: 34 (1.3)
432 (17.0)

S6D52010

2-9 6D55F11
 Maintenance specification
Clamp bracket

1
2
3
4
5
6
7
8
9
6D55F11 2-10
SPEC
Specifications
Tightening torques 2

Specified torques
Tightening torques
Part to be tightened Thread size
N·m kgf·m ft·lb
Fuel system
Fuel pump mounting bolt M6 8 0.8 5.9
Fuel pump screw M5 3 0.3 2.2
Carburetor bracket bolt M6 8 0.8 5.9
Throttle link rod screw M4 1 0.1 0.7
Power unit
Power unit mounting bolt M8 21 2.1 15.5
Apron bolt M6 10 1.0 7.4
Start-in-gear protection cable bolt M5 5 0.5 3.7
Manual starter roller bolt M6 8 0.8 5.9
Starter rope guide bolt M6 3 0.3 2.2
Sheave drum bolt — 15 1.5 11.1
Starter pulley bolt M8 25 2.5 18.4
Flywheel magnet nut M20 157 15.7 115.8
Stator coil bolt M5 6 0.6 4.4
Driven sprocket bolt M10 38 3.8 28.0
Pulser coil bolt M5 5 0.5 3.7
CDI unit bolt M6 5 0.5 3.7
CDI unit bracket bolt M6 5 0.5 3.7
Ignition coil bolt M6 8 0.8 5.9
1st 6 0.6 4.4
M6
2nd 12 1.2 8.9
Cylinder head bolt
1st 23 2.3 17.0
M9
2nd 46 4.6 34.0
Spark plug — 17 1.7 12.5
Oil pump screw M6 4 0.4 3.0
Rocker arm locknut M6 14 1.4 10.3
Rocker arm shaft bolt M8 18 1.8 13.3
Thermostat cover bolt M6 7 0.7 5.2
1st 6 0.6 4.4
Exhaust cover bolt M6
2nd 12 1.2 8.9
Oil filter — 18 1.8 13.3
Oil filter union bolt — 40 4.0 29.5
Balancer cover bolt M6 12 1.2 8.9
Balancer piston nut M20 157 15.7 115.8
1st 6 0.6 4.4
M6
2nd 12 1.2 8.9
Crankcase bolt
1st 15 1.5 11.1
M8
2nd 30 3.0 22.1
1st 6 0.6 4.4
Connecting rod bolt M6
2nd 17 1.7 12.5

2-11 6D55F11
 Tightening torques

Tightening torques
Part to be tightened Thread size
N·m kgf·m ft·lb
Lower unit
Gear oil drain screw
Gear oil check screw
Lower case mounting bolt
Cooling water inlet cover screw
—
—
M10
M5
9
9
37
4
0.9
0.9
3.7
0.4
6.6
6.6
27.3
3.0
1
Propeller nut M14 34 3.4 25.1
Propeller shaft housing bolt
Pinion nut
Bracket unit
M6
M10
11
50
1.1
5.0
8.1
36.9 2
Tiller handle bracket nut M10 10 1.0 7.4
Self-locking nut
Engine stop lanyard switch nut
Exhaust manifold bolt
Throttle grip screw
M10
—
M6
M5
22
2
10
3
2.2
0.2
1.0
0.3
16.2
1.5
7.4
2.2
3
Shift rod lever bracket bolt M6 10 1.0 7.4
Spring hook bolt
Shift rod lever spring bolt
Retaining plate bolt
M6
M6
M6
10
10
10
1.0
1.0
1.0
7.4
7.4
7.4
4
Upper mounting nut M8 24 2.4 17.7
Upper mount bolt
Mount housing nut
Steering friction bolt
Engine oil drain bolt
M8
M10
M8
M14
27
54
4
27
2.7
5.4
0.4
2.7
20.0
39.8
3.0
20.0
5
Upper case bolt M8 21 2.1 15.5
Exhaust manifold bolt
Baffle plate screw
Self-locking nut
M6
M5
M22
10
2
45
1.0
0.2
4.5
7.4
1.5
33.2
6
Tilt stopper plate nut M8 24 2.4 17.7
Grease nipple
Tilt lever screw
—
M5
3
4
0.3
0.4
2.2
3.0
7
8
9
6D55F11 2-12
 SPEC
Specifications
General torques
This chart specifies tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifications
for special components or assemblies are
provided in applicable sections of this man-
ual. To avoid warpage, tighten multi-fastener
assemblies in a crisscross fashion and pro-
gressive stages until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads.
Components should be at room temperature.

General torque
Nut (A) Bolt (B) specifications
N·m kgf·m ft·lb
8 mm M5 5 0.5 3.6
10 mm M6 8 0.8 5.8
12 mm M8 18 1.8 13
14 mm M10 36 3.6 25
17 mm M12 43 4.3 31

2-13 6D55F11
 CHK
ADJ
Periodic checks and adjustments

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

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

Top cowling .................................................................................................... 3-3
Checking the top cowling...........................................................................3-3

Fuel system .................................................................................................... 3-3

Checking the fuel joint and fuel hoses (fuel joint-to-carburetor) ................ 3-3
2
Checking the fuel filter ............................................................................... 3-3

Power unit....................................................................................................... 3-4

Checking the engine oil .............................................................................3-4
Changing the engine oil.............................................................................3-4
3
Replacing the oil filter ................................................................................ 3-5
Checking the timing belt ............................................................................3-5
Checking the spark plugs ..........................................................................3-6
Checking the thermostat............................................................................3-6
Checking the cooling water passage.........................................................3-7
4
Control system ............................................................................................... 3-7
Adjusting the throttle link ...........................................................................3-7
Adjusting the throttle cables (tiller handle model)...................................... 3-8
Adjusting the throttle cable (remote control model) ...................................3-8
5
Checking the gear shift operation (tiller handle model) ............................. 3-9
Checking the gear shift operation (remote control model).........................3-9
Checking the start-in-gear protection ........................................................3-9
Checking the engine idle speed ..............................................................3-10
Checking the ignition timing..................................................................... 3-10
6
Bracket ..........................................................................................................3-11
Checking the tilt operation ....................................................................... 3-11

Lower unit ..................................................................................................... 3-11

7
Checking the gear oil level ...................................................................... 3-11
Changing the gear oil .............................................................................. 3-12
Checking the lower unit for air leakage ...................................................3-12
Checking the propeller............................................................................. 3-12
8
General..........................................................................................................3-13
Checking the anodes............................................................................... 3-13
Lubricating the outboard motor................................................................3-13 9
6D55F11
 CHK
ADJ Periodic checks and adjustments
Special service tools 3

Oil filter wrench

90890-01426

Digital tachometer
90890-06760

Timing light
90890-03141

Leakage tester
90890-06840

3-1 6D55F11
 Special service tools / Maintenance interval chart
Maintenance interval chart 3

Use the following chart as a guideline for general maintenance.

Adjust the maintenance intervals according to the operating conditions of the outboard motor.

Item

Anode (external)
Remarks

Check/replace
Initial Every
10 hours 50 hours 100 hours 200 hours
(1 month) (3 months) (6 months) (1 year)
1
Anodes (internal) Check/replace
Cooling water passages
Top cowling
Fuel filter (can be disassembled)
Clean
Check
Check/replace
2
Fuel system Check
Fuel tank
(Yamaha portable tank)
Gear oil
Lubrication points
Check/clean

Change
Lubricate
3
Engine idle speed Check/adjust
(carburetor models)
Propeller and cotter pin
Shift link/shift cable
Check/replace
Check/adjust
4
Thermostat Check

5
Throttle link/throttle cable/ Check/adjust
throttle pick-up timing
Water pump Check
Engine oil Check/change
Oil filter (cartridge) Replace
Spark plug(s)

Timing belt
Valve clearance (OHC)
Clean/adjust/
replace
Check/replace
Check/adjust
6
NOTE:
• When operating in salt water, turbid or muddy water, the engine should be flushed with clean
water after each use.
7
• When using lead or high-sulfur gasoline, checking valve clearance may be required more fre-

8
quently than every 100 hours.

Every
Item Remarks
500 hours (2.5 years) 1,000 hours (5 years)

9
Timing belt Replace

6D55F11 3-2
 CHK
ADJ Periodic checks and adjustments
Top cowling 3

Checking the top cowling

1. Check the fitting by pushing the cowling
with both hands. Adjust if necessary.

Fuel system 3

Checking the fuel joint and fuel

S6D53010 hoses (fuel joint-to-carburetor)
1. Check the fuel hose connections and fuel
2. Loosen the nuts 1. joints for leaks. Replace if necessary.
Also, check the fuel filter 1, fuel pump
3. Move the hook 2 up or down slightly to 2, and carburetor 3 for leaks or deterio-
adjust its position. ration. Replace if necessary.

a
2 3

1
2
1
b S6D53020 S6D53040

NOTE:
• To loosen the fitting, move the hook in
Checking the fuel filter
1. Check the fuel filter element 1 for dirt
direction a.
and residue and check the fuel filter cup
• To tighten the fitting, move the hook in
2 for foreign substances and cracks.
direction b.
Clean the cup with straight gasoline and
replace the element if necessary.
4. Tighten the nuts.

5. Check the fitting again and, if necessary,

repeat steps 2–4.

6. Check the water separator drain holes for

obstructions. Clean if necessary.

3-3 6D55F11
 Top cowling / Fuel system / Power unit

NOTE:
Be sure not to spill any fuel when removing
the fuel filter cup.

Power unit
Checking the engine oil
3
1
1. Place the outboard motor in an upright
position.

2. Remove the engine oil dipstick, wipe it

clean, and then insert it back into the oil
3. Place a drain pan under the drain hole,
2
and then remove the drain bolt 2 and let
filler hole. the oil drain completely.

3. Remove the dipstick again to check the

oil level and to check the oil for discolora-
tion and its viscosity.
2 3
4
5
S6D53080

NOTE:
Be sure to clean up any oil spills.

NOTE:
• Change the oil if it appears milky or dirty.
• If the engine oil is below the minimum level
mark b, add sufficient oil until the level is
4. Install the drain bolt, and then tighten it to
the specified torque.

Drain bolt:
6
27 N·m (2.7 kgf·m, 20.0 ft·lb)
T.

between a and b.
R.

Changing the engine oil

1. Start the engine, warm it up, and then
5. Pour the specified amount of the recom-
mended engine oil into the oil filler hole.
7
turn it off. Recommended engine oil:

2. Remove the engine oil dipstick and oil

filler cap 1.
4-stroke motor oil
API: SE, SF, SG, SH, or SJ
SAE: 10W-30 or 10W-40
Oil quantity:
8
Without oil filter replacement:
1.7 L (1.8 US qt, 1.5 Imp qt)

6. Install the oil filler cap and dipstick, and

9
then start the engine and warm it up for 5
minutes.

6D55F11 3-4
 CHK
ADJ Periodic checks and adjustments
7. Turn the engine off, and then check the
oil level and correct it if necessary. Oil filter:
18 N·m (1.8 kgf·m, 13.3 ft·lb)

T.
R.
Replacing the oil filter
1. Drain the engine oil. 5. Pour the specified amount of the recom-
mended engine oil into the oil filler hole.
2. Place a rag under the oil filter 1, and
then remove the oil filter using the oil fil- Recommended engine oil:
ter wrench. 4-stroke motor oil
API: SE, SF, SG, SH, or SJ
SAE: 10W-30 or 10W-40
Oil quantity:
With oil filter replacement:
1.9 L (2.0 US qt, 1.7 Imp qt)

6. Install the oil filler cap and dipstick, and

then start the engine and warm it up for 5
minutes.

7. Turn the engine off, and then check the

NOTE:
• Wait more than 5 minutes after turning the oil level and correct it if necessary.
engine off to replace the oil filter.
• Be sure to clean up any oil spills.
Checking the timing belt
1. Remove the manual starter.

2. While turning the flywheel magnet clock-

Oil filter wrench: 90890-01426 wise, check the interior and the exterior
of the timing belt for cracks, damage, or
3. Apply a thin coat of engine oil to the O- wear. Replace if necessary.
ring of the new oil filter.
3. Turn the flywheel magnet clockwise to
4. Install the oil filter, and then tighten it to transfer the slack of the timing belt from
the specified torque using the oil filter port to starboard, and then lightly hold
wrench. the flywheel magnet in place.

4. Slightly push the timing belt with your fin-

ger between the drive gear and driven
gear, and then measure the belt slack.
Replace the timing belt if above specifi-
cation.

S6D53110

3-5 6D55F11
 Power unit
5. Install the spark plugs, tighten them fin-
NOTE: ger tight, then to the specified torque
The valve system of this model will not be using a spark plug wrench.
damaged even if the timing belt breaks.
Spark plug:
17 N·m (1.7 kgf·m, 12.5 ft·lb) 1

T.
R.
Timing belt slack a:
Within 13 mm (0.5 in)
Checking the thermostat
Checking the spark plugs
1. Disconnect the spark plug caps, and then
remove the spark plugs.
1. Remove the cover 1 and thermostat 2.

2
2. Clean the electrodes 1 with a spark plug
cleaner or wire brush. Replace the spark
plug if necessary. 3
2. Suspend the thermostat in a container of
water.
4
5
3. Place a thermometer in the water and
slowly heat the water.

3. Check the electrodes for erosion and

excessive carbon or other deposits, and
the gasket for damage. Replace the
spark plug if necessary.

4. Check the spark plug gap a. Adjust if out

6
of specification.
S69J5E40
7
8
Specified spark plug:
DPR6EA-9 (NGK)
Spark plug gap a:
9
0.8–0.9 mm (0.031–0.035 in)

6D55F11 3-6
 CHK
ADJ Periodic checks and adjustments
4. Check the thermostat valve opening at 3. Check for water flow at the cooling water
the specified water temperatures. pilot holes. If there is no water flow,
Replace if out of specification. check the cooling water passages inside
the outboard motor.

S6D53140
Water
Valve lift a
temperature Control system 3

0.05 mm Adjusting the throttle link

58–62 °C
(0.0020 in)
(136–144 °F) NOTE:
(valve begins to lift)
For tiller handle models, adjust the throttle
above more than link after adjusting the throttle cable.
70 °C (158 °F) 3.0 mm (0.12 in)
1. Loosen the screw 1.
5. Install the thermostat and cover, and
then tighten the cover bolts to the speci- 2. Turn the throttle cam 2 clockwise until it
fied torque. contacts the stopper 3, and then hold it
in that position.
Thermostat cover bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
T.
R.

Checking the cooling water passage

1. Check the cooling water inlet cover 1
and cooling water inlet for clogs. Clean if
necessary.

1 NOTE:
For remote control models, the throttle cam
cannot be turned unless the remote control
lever is shifted to forward.

S6D53130
3. Turn the throttle lever 4 clockwise so
that the throttle valve is fully open.
2. Place the lower unit in water, and then
start the engine. 4. Tighten the screw.

3-7 6D55F11
 Power unit / Control system
5. Operate the throttle cam to check that
the throttle valve fully opens and fully
closes.

Adjusting the throttle cables

(tiller handle model)
1. Turn the throttle grip to the fully open
1
position.

2. Loosen the locknut 1, and then turn the

adjusting nut 2 to adjust the throttle
cable 3. Adjusting the throttle cable
S6D53210

2
(remote control model)

3
3. Tighten the locknut. 1. Loosen the locknut 1, remove the clip
2, and then disconnect the throttle cable
joint 3.
1
2 3 2. Contact the throttle cam 4 to the stopper

4
5.

5 4

5
S6D53220
2 1
4. Turn the throttle grip to the fully close
position.

5. Loosen the locknut 4, and then turn the 3

6
S6D53180
adjusting nut 5 to adjust the throttle
cable 6. 3. Adjust the position of the throttle cable
joint until its hole is aligned with the set
6. Tighten the locknut. pin on the throttle cam.

7
4 5 6
S6D53310
a 8
S6D53190

7. Check the throttle grip for smooth opera-

tion and, if necessary, repeat steps 1–6.
WARNING
The throttle cable joint must be screwed
in a minimum of 8.0 mm (0.31 in) a.
9
4. Connect the cable joint, install the clip,
and then tighten the locknut.

6D55F11 3-8
 CHK
ADJ Periodic checks and adjustments
5. Check the throttle cable for smooth oper-
ation and, if necessary, repeat steps 1–4.

Checking the gear shift operation

(tiller handle model)
1. Check that the gear shift operates
smoothly when shifting it from neutral to
forward or reverse. Adjust the adjusting
nut 1 if necessary.

R
N 4. Adjust the position of the shift cable joint
until its hole is aligned with the set pin on
the shift link lever.
F

S6D53320

S6D53190

1 WARNING
The shift cable joint must be screwed in a
minimum of 8.0 mm (0.31 in) a.
S6D53330

5. Connect the cable joint, install the clip,

Checking the gear shift operation
and then tighten the locknut.
(remote control model)
1. Check that the gear shift operates 6. Check the gear shift for smooth operation
smoothly when the remote control lever and, if necessary, repeat steps 3–5.
is shifted from neutral to forward or
reverse. Adjust the shift cable length if Checking the start-in-gear protection
necessary.
CAUTION:
2. Shift the remote control lever to neutral.
Be sure to remove the engine stop lan-
NOTE: yard switch clip before checking the start-
After shifting the remote control lever to neu- in-gear protection.
tral, check that the shift link lever 1 is vertical
1. Shift the remote control lever or shift
to the mating surfaces of the engine.
lever to forward or reverse, then pull the
starter handle.
3. Loosen the locknut 2, remove the clip
3, and then disconnect the shift cable 2. Check the operation of the start-in-gear
joint 4. protection cable. If the starter rope can
be pulled out normally, adjust the start-in-
gear protection cable.

3-9 6D55F11
 Control system
3. Turn the throttle stop screw 2 in direc-
NOTE: tion a or b until the specified engine
If the starter rope cannot be pulled out, the idle speed is obtained.
start-in-gear protection is working correctly.

3. Shift the remote control lever or shift

lever to neutral.
1
4. Loosen the bolt 1, and then adjust the
plate 2 until the mark a on the cable
connector is aligned with the mark b on
the manual starter case.
2
5. Tighten the bolt.
NOTE:
• To increase the idle speed, turn the throttle
stop screw in direction a.
• To decrease the idle speed, turn the throttle
3
stop screw in direction b.

Checking the ignition timing

1. Start the engine and warm it up for 5 min-
4
utes.

Checking the engine idle speed

1. Start the engine and warm it up for 5 min-
2. Attach the special service tool to spark
plug wire #1, and then check the engine
idle speed.
5
utes.

2. Attach the special service tool to spark

plug wire #1 1, and then check the
engine idle speed. Adjust if out of specifi-
Digital tachometer: 90890-06760
6
cation. Engine idle speed: 925–1,025 r/min
1
3. Attach the special service tool to spark
plug wire #1.
7
8
S6D53150

Digital tachometer: 90890-06760 9

Engine idle speed: 925–1,025 r/min
Timing light: 90890-03141

6D55F11 3-10
 CHK
ADJ Periodic checks and adjustments
4. Check that the a is specified timing on
the flywheel magnet.

Lower unit 3

Checking the gear oil level

Ignition timing at engine idle speed: 1. Fully tilt the outboard motor down.
BTDC 8.5°
2. Remove the check screw 1, and then
Bracket 3
check the gear oil level in the lower case.
Checking the tilt operation
1. Fully tilt the outboard motor up and down
a few times and check the entire tilt
range for smooth operation. Check the tilt
mechanism if necessary.

1
S60V3320

NOTE:
• If the oil is at the correct level, the oil should
overflow out of the check hole when the
check screw is removed.
• If necessary, add sufficient gear oil of the
recommended type until it overflows out of
the check hole.

3. Install the check screw.

S6D53360

2. Fully tilt the outboard motor up, then sup-

port it with the tilt stop lever 1 to check
the lock mechanism of the lever.

3-11 6D55F11
 Control system / Bracket / Lower unit
Changing the gear oil Checking the lower unit for air
1. Tilt the outboard motor up slightly. leakage
1. Remove the check screw 1, and then

1
2. Place a drain pan under the drain screw install the special service tool.
1, remove the drain screw, then the
check screw 2 and let the oil drain com-
pletely.

2
Leakage tester: 90890-06840
3
2. Apply the specified pressure to check
that the pressure is maintained in the
lower unit for at least 10 seconds.
4
3. Check the oil for metal and discoloration, CAUTION:
and its viscosity. Check the internal parts
of the lower case if necessary.

4. Insert a gear oil tube or gear oil pump

Do not over pressurize the lower unit, oth-
erwise the oil seals can be damaged.
5
into the drain hole and slowly fill the gear NOTE:

6
oil until oil flows out of the check hole and Cover the check hole with a rag when remov-
no air bubbles are visible. ing the special service tool from the lower
unit.

Lower unit holding pressure:

100 kPa (1.0 kgf/cm2, 14 psi)

3. If pressure drops below specification,

7
check the drive shaft and propeller shaft

Recommended gear oil:

oil seals for damage.

Checking the propeller

1. Check the propeller blades and splines
8
Hypoid gear oil for cracks, damage, or wear. Replace if
SAE: 90
Oil quantity:
320 cm3 (10.8 US oz, 11.3 Imp oz)
necessary.

9
5. Install the check screw and quickly install
the drain screw.

6D55F11 3-12
 CHK
ADJ Periodic checks and adjustments
General 3

Checking the anodes

1. Check the anodes for scales, grease, or
oil. Clean if necessary.

S6D53240

È
A

CAUTION:
Do not oil, grease, or paint the anodes,
otherwise they will be ineffective.
S6D53290

2. Replace the anodes if excessively È Tiller handle model

eroded. NOTE:
Apply grease to the grease nipples until it
Lubricating the outboard motor flows from the bushings a.
1. Apply water resistant grease to the areas
shown.
2. Apply corrosion resistant grease to the
A area shown.

S6D53260

3-13 6D55F11
 FUEL

Fuel system

Special service tools .....................................................................................4-1

Hose routing ...................................................................................................4-2 1

Fuel hoses and fuel filter............................................................................... 4-3

Fuel pump ....................................................................................................... 4-4

Checking the fuel pump.............................................................................4-5
Disassembling the fuel pump .................................................................... 4-5
2
Checking the diaphragms and valves........................................................4-6
Assembling the fuel pump ......................................................................... 4-6
Checking the fuel joint ............................................................................... 4-7

Carburetor unit ............................................................................................... 4-8

3
Carburetor....................................................................................................... 4-9
Removing the carburetor .........................................................................4-11
Checking the carburetor ..........................................................................4-11
Checking the Prime Start.........................................................................4-12
4
Assembling the carburetor....................................................................... 4-12
Adjusting the throttle stop screw..............................................................4-13
5
6
7
8
9
6D55F11
 FUEL
Fuel system
Special service tools 4

Vacuum/pressure pump gauge set

90890-06756

4-1 6D55F11
 Special service tools / Hose routing
Hose routing 4

1
1

2 1
2
1
3 3
5 5 4

3
2 4
1
4

5
1

6
3

4 2
S6D54010
7
1
2
3
4
Blowby hoses
Fuel hose (fuel joint-to-fuel filter)
Fuel hose (fuel filter-to-fuel pump)
Fuel hose (fuel pump-to-carburetor)
8
5 Pilot water hose

9
6D55F11 4-2
 FUEL
Fuel system
Fuel hoses and fuel filter 4

No. Part name Q’ty Remarks

1 Fuel joint 1
2 Bolt 1 M6 × 25 mm
3 Fuel hose 1
4 Bolt 1 M8 × 14 mm
5 Nut 1
6 Bracket 1
7 Fuel filter 1
8 Fuel filter element 1
9 O-ring 1 Not reusable
10 Cup 1
11 Fuel hose 1
12 Fuel hose 1
13 Fuel pump 1
14 O-ring 1 Not reusable
15 Bracket 1
16 Bolt 2 M6 × 30 mm

4-3 6D55F11
 Fuel hoses and fuel filter / Fuel pump
Fuel pump 4

1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Screw 4 ø5 × 43 mm
2
3
4
5
Cover
Gasket
Diaphragm
Fuel pump body 2 assembly
1
1
1
1
Not reusable
Not reusable 7
6 Nut 4
7
8
9
10
Pin
Plunger
Spring
Fuel pump body 1
1
1
1
1
8
11 Spring 1
12 Diaphragm 1

9
6D55F11 4-4
 FUEL
Fuel system
Checking the fuel pump 6. Apply the specified positive pressure and
1. Place a drain pan under the fuel hose check that there is no air leakage. Disas-
connections, and then disconnect the semble the fuel pump if necessary.
fuel hoses from the fuel pump.

2. Connect the special service tool to the

fuel pump inlet.

3. Cover the fuel pump outlet with a finger,

and then apply the specified positive
pressure. Check that there is no air leak-
age.

NOTE:
Assemble the fuel pump valves to the fuel
pump body, and moisten the inside of the fuel
pump with gasoline to ensure a good seal.

Specified pressure:
50 kPa (0.5 kgf/cm2, 7.3 psi)

Vacuum/pressure pump gauge set: Disassembling the fuel pump

90890-06756 1. Disassemble the fuel pump as shown.

Specified pressure:
50 kPa (0.5 kgf/cm2, 7.3 psi)

4. Apply the specified negative pressure

and check that there is no air leakage.

2. Push down on the plunger and the dia-

phragm, turn fuel pump body 1 1
approximately 90° to a position where the
Specified pressure: pin 2 can be removed easily, and then
30 kPa (0.3 kgf/cm2, 4.4 psi) remove the pin.

5. Connect the special service tool to the

fuel pump outlet.

4-5 6D55F11
 Fuel pump

1
3. Turn fuel pump body 1 2 approximately
2
90°, and then push down on the plunger
several times to make sure that the pin
does not come out.
3
3. Slowly let up on the plunger and dia-
4
phragm, and then remove them.

Checking the diaphragms and valves

1. Check the diaphragms for tears and the
valves for cracks. Replace if necessary. NOTE:
Make sure that the gasket and diaphragm are
5
Assembling the fuel pump kept in place through the assembly process.

NOTE:
Clean the parts and soak the valves and the
diaphragms in gasoline before assembly to
6
obtain prompt operation of the fuel pump
when starting the engine.

1. Align the plunger and diaphragm installa-

tion holes a, and then install the plunger
7
into the diaphragm.

2. Push down on the plunger and the dia-

phragm, and then install the pin 1.
8
9
6D55F11 4-6
 FUEL
Fuel system
Checking the fuel joint
1. Visually check the fuel hose connector
for cracks or damage.

2. Connect the special service tool at the

outlet of fuel hose connector.

3. Apply the specified pressure to check

that the pressure is maintained for 10
seconds. Replace the fuel hose connec-
tor of necessary.

Vacuum/pressure pump gauge set:

90890-06756

Fuel hose connector holding

pressure:
50 kPa (0.5 kgf/cm2, 7.3 psi)

4-7 6D55F11
 Fuel pump / Carburetor unit
Carburetor unit 4

1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Bolt 3 M6 × 25 mm
2
3
4
5
Fuel hose
Plastic tie
Blowby hose
Bolt
1
1
1
2
Not reusable

M6 × 100 mm
7
6 Intake silencer 1
7
8
9
10
Joint
Seal
O-ring
Plate
1
1
1
1
Not reusable
8
11 Bracket 1
12
13
14
O-ring
Spacer
Carburetor
2
1
1
Not reusable

9
6D55F11 4-8
 FUEL
Fuel system
Carburetor 4

No. Part name Q’ty Remarks

1 Throttle link rod 1
2 Screw 1 ø4 × 5 mm
3 Screw 1 ø4 × 10 mm
4 Retainer 1
5 Prime Start 1
6 O-ring 1 Not reusable
7 Screw 3 ø4 × 10 mm
8 Cover 1
9 Gasket 1 Not reusable
10 Throttle stop screw 1
11 Spring 1
12 Pilot screw 1
13 O-ring 1 Not reusable
14 Spring 1

4-9 6D55F11
 Carburetor
4

1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Carburetor body 1
2
3
4
5
Float chamber
Gasket
Plunger rod
Plunger
1
1
1
1
Not reusable
7
6 Spring 1
7
8
9
10
Circlip
Ball
Drain screw
Screw
1
1
1
4 ø4 × 13 mm
8
11 Screw 1 ø4 × 7 mm
12
13
14
15
Float
Needle valve
Main jet
Main nozzle
1
1
1
1
9
16 Plug 1
17 Pilot jet 1

6D55F11 4-10
 FUEL
Fuel system
Removing the carburetor
1. Remove the manual starter.

2. Disconnect the throttle link rod and Prime

Start connectors.

3. Disconnect the fuel hose.

4. Disconnect the blowby hose 1.

CAUTION:
• Direct the compressed air downward,
otherwise cleaning solvent may be
1 blown into your eyes or small parts of
the carburetor may be blown off.
• Do not use steel wire for cleaning the
jets, otherwise the jet diameters may be
S6D54160
enlarged, which may seriously affect
performance.
5. Remove the bolts 2, then the carburetor
assembly 3.
3. Check the main jet, pilot jet, and main
nozzle for dirt or residue. Clean if neces-
sary.

4. Check the pilot screw and needle valve

for bends or wear. Replace if necessary.

6. Remove the intake silencer and bracket S6D54200

from the carburetor.

5. Check the float for deterioration. Replace
Checking the carburetor if necessary.
1. Check the air and fuel passages and jets,
for dirt and foreign matter. Clean the car- 6. Measure the float height a. Replace the
buretor body with a petroleum based sol- float and needle valve as a set, if out of
vent if necessary. specification.

2. Blow compressed air into all passages

and jets.

4-11 6D55F11
 Carburetor

Prime Start plunger extended

length a (reference data):
10.7–15.4 mm (0.42–0.61 in)
Time (min)
0
1
Length (mm [in])
10.7 (0.42)
12.6 (0.50)
1
2
3 14.1 (0.56)
5 14.8 (0.58)
NOTE: 7 15.3 (0.60)
• The float should be resting on the needle 10 15.4 (0.61)
valve 1, but not compressing it.
• Take measurements at the float position
shown opposite its pivoted side.
4. Measure the prime start resistance when
the prime start plunger length is 10.7 mm
(0.42 in).
3
Float height a: Prime Start resistance
8.7–9.7 mm (0.34–0.38 in)

Checking the Prime Start

1. Measure the length of the Prime Start
(reference data):
Yellow (Y) – Yellow (Y)
17.7–18.7 Ω at 20 °C (68 °F)
4
plunger.

5
Assembling the carburetor
1. Install the main nozzle 1, main jet 2,
2. Connect the Prime Start yellow (Y) leads
pilot jet 3, and plug 4 to the carburetor
to a 12 V battery as shown.
body as shown.
3. Measure the plunger length a after
applying power for the times indicated in
the following table. Replace if out of
specification.
4

3
2
6
1

7
8
S6D54110
9
6D55F11 4-12
 FUEL
Fuel system
2. Install the needle valve 5, float 6, float
pin 7, and screw 8 as shown, and then
the check the float for smooth operation.

7
6 5
8

NOTE:
S6D54120 For remote control models, the throttle cam
cannot be turned unless the remote control
NOTE: lever is shifted to forward.
• Place the needle valve in the valve seat
when installing the float to the carburetor
body. 7. Turn the throttle lever B clockwise so
• Fit the float pin into the slit on the carbure- that the throttle valve is fully open.
tor body and lock it with the screw.
8. Tighten the screw C.

3. Install the pilot screw 9, turn it in until it 9. Operate the throttle cam to check that
is lightly seated, then out the specified the throttle valve fully opens and fully
number of turns. closes.

Adjusting the throttle stop screw

1. Start the engine and warm it up for 5 min-
utes.

Engine idle speed: 925–1,025 r/min

2. Turn the throttle stop screw 1 in direc-

tion a or b until the specified engine
idle speed is obtained.
Pilot screw setting:
1 5/8–2 5/8 turns out

4. Install the carburetor assembly.

5. Connect the throttle link rod to the carbu-

retor throttle lever.

6. Turn the throttle cam 0 clockwise until it

contacts the stopper A, and then hold it
in that position.

4-13 6D55F11
 Carburetor

NOTE:
• To increase the idle speed, turn the throttle
stop screw in direction a.
• To decrease the idle speed, turn the throttle
stop screw in direction b. 1
Engine idle speed: 925–1,025 r/min

2
3
4
5
6
7
8
9
6D55F11 4-14
POWR

Power unit

Special service tools .....................................................................................5-1

Power unit....................................................................................................... 5-3

Checking the compression pressure .........................................................5-3
Checking the oil pressure ..........................................................................5-3
Checking the valve clearance.................................................................... 5-4
Disassembling the manual starter ........................................................... 5-13
Checking the spiral spring ....................................................................... 5-13
Measuring the starter rope ...................................................................... 5-13
Assembling the manual starter ................................................................5-13
Installing the starter rope .........................................................................5-14
Removing the timing belt and sprockets.................................................. 5-15
Checking the timing belt and sprockets...................................................5-17
Installing the sprockets and timing belt....................................................5-17
Removing the power unit.........................................................................5-18

Cylinder head ...............................................................................................5-20

Removing the cylinder head .................................................................... 5-23
Checking the valve springs...................................................................... 5-24
Checking the valves ................................................................................ 5-24
Checking the valve guides....................................................................... 5-25
Replacing the valve guides...................................................................... 5-25
Checking the valve seat ..........................................................................5-26
Refacing the valve seat ...........................................................................5-26
Checking the rocker arms and rocker arm shaft...................................... 5-28
Checking the camshaft ............................................................................5-29
Checking the cylinder head ..................................................................... 5-29
Checking the oil pump ............................................................................. 5-30
Installing the valves ................................................................................. 5-30
Installing the camshaft............................................................................. 5-31
Installing the rocker arm shaft assembly ................................................. 5-32
Installing the oil pump.............................................................................. 5-32

6D55F11
 Cylinder block ..............................................................................................5-33
Disassembling the cylinder block ............................................................ 5-36
Checking the balancer............................................................................. 5-37
Checking the piston diameter .................................................................. 5-37
Checking the cylinder bore ...................................................................... 5-37
Checking the piston clearance ................................................................5-38
Checking the piston rings ........................................................................5-38
Checking the piston ring grooves ............................................................ 5-39
1
Checking the piston ring side clearance.................................................. 5-39
Checking the piston pin boss bore .......................................................... 5-39
Checking the piston pin ...........................................................................5-39
Checking the connecting rod small end inside diameter ......................... 5-40
Checking the connecting rod big end side clearance ..............................5-40
2
Checking the crankshaft ..........................................................................5-40
Checking the crankpin oil clearance........................................................ 5-41
Selecting the connecting rod bearing ......................................................5-42
Checking the crankshaft main journal oil clearance ................................5-42
Selecting the crankshaft main bearing ....................................................5-43
3
Assembling the pistons and cylinder block.............................................. 5-44

4
Installing the cylinder head ...................................................................... 5-47
Installing the power unit...........................................................................5-49

5
6
7
8
9
6D55F11
POWR
Power unit
Special service tools 5

Compression gauge Valve spring compressor attachment

90890-03160 90890-06320

Flywheel holder Valve guide remover/installer

90890-06522 90890-06801

Universal clutch holder Valve guide reamer

90890-04086 90890-06804

Flywheel puller Valve seat cutter holder

90890-06521 90890-06316

Valve spring compressor Valve seat cutter

90890-04019 90890-06312, 90890-06315, 90890-06323,
90890-06325, 90890-06327, 90890-06328

5-1 6D55F11
 Special service tools

1
Bearing outer race attachment
90890-06626

2
Driver rod LS
3
90890-06606

4
Oil filter wrench
5
90890-01426

6
Piston slider
90890-06529
7
8
9
6D55F11 5-2
POWR
Power unit
Power unit 5
5. If the compression pressure is below
Checking the compression pressure specification and the compression pres-
1. Start the engine, warm it up for 5 min- sure for each cylinder is unbalanced, add
utes, and then turn it off. a small amount of engine oil to the cylin-
der, and then check the pressure again.
2. Remove the clip from the engine stop
NOTE:
lanyard switch.
• If the compression pressure increases,
check the pistons and piston rings for wear.
3. Remove the spark plug caps and all
Replace if necessary.
spark plugs, and then install the special
• If the compression pressure does not
service tools into a spark plug hole.
increase, check the valve clearance, valve,
valve seat, cylinder sleeve, cylinder head
gasket, and cylinder head. Adjust or
replace if necessary.

Checking the oil pressure

1. Place a rag under the oil pressure switch.
1
S6D55050
2. Remove the oil pressure switch, and then
install an oil pressure gauge 1 to the oil
pressure switch installation hole.
CAUTION:
Before removing the spark plugs, blow
compressed air in the spark plug well to 1
clear out any dirt or dust that may fall into
the cylinder.

Compression gauge 1:
90890-03160
S6D55060
4. Fully open the throttle, crank the engine
until the reading on the compression NOTE:
gauge stabilizes, and then check the Use a general pressure gauge.
compression pressure.

NOTE: 3. Start the engine and warm it up for 5 min-

Since this outboard motor is equipped with utes.
an automatic decompression mechanism,
accurate data may be difficult to obtain due to 4. Check the oil pressure. Check the oil
differences in the way the starter rope is pump, oil leakage, and oil strainer if out
pulled. of specification.

Oil pressure (reference data):

Minimum compression pressure 80 kPa (0.8 kgf/cm2, 11 psi) at
(reference data): engine idle speed
810 kPa (8.1 kgf/cm2, 115 psi)

5-3 6D55F11
 Power unit
Checking the valve clearance 7. Check the intake and exhaust valve
1. Remove the manual starter. clearances for cylinder #2. Adjust if out of
specification.
2. Remove the fuel pump 1.

3. Disconnect the ignition coil connectors

and spark plug caps 2 and remove the
1
spark plugs and cylinder head cover 3.

2
3
2
3
1

S6D55070

4. Turn the flywheel magnet clockwise and

align the “ ” mark a on the driven
sprocket with the “ ” mark b on the cyl-
4
inder head. NOTE:

5
• Check the valve clearance when the engine
is cold.
• Note the measurement.

Valve clearance:
Intake d:
0.15–0.25 mm (0.006–0.010 in)
Exhaust e:
6
0.25–0.35 mm (0.010–0.014 in)

7
8
5. Check the intake and exhaust valve
clearances for cylinder #1. Adjust if out of
specification.

6. Turn the flywheel magnet clockwise and

9
align the “ ” mark c on the driven
sprocket with the “ ” mark b on the cyl-
inder head.

6D55F11 5-4
POWR
Power unit
8. Loosen the rocker arm locknut 4, and
then turn the adjusting screw 5 until the
specified valve clearance is obtained.

4 5

f g

S6D55100

NOTE:
• To decrease the valve clearance, turn the
adjusting screw in direction f.
• To increase the valve clearance, turn the
adjusting screw in direction g.

9. Tighten the rocker arm locknut to the

specified torque, and then check the
valve clearance again. Adjust if neces-
sary.

Rocker arm locknut 4:

14 N·m (1.4 kgf·m, 10.3 ft·lb)
T.
R.

10. Install the cylinder head cover, fuel pump

bolts, spark plugs, spark plug caps, and
manual starter.

5-5 6D55F11
 Power unit
5

1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Bolt 1 M5 × 13 mm
2
3
4
5
Washer
Clip
Start-in-gear protection cable
Bolt
1
2
1
4 M6 × 25 mm
7
6 Manual starter 1
7
8
9
10
Bolt
Power unit
Dipstick
Dowel
1
1
1
2
M6 × 12 mm

8
11 Bolt 2 M6 × 14 mm
12
13
14
15
Gasket
Bolt
Apron
Bolt
1
8
1
2
Not reusable
M8 × 80 mm

M6 × 25 mm
9
6D55F11 5-6
POWR
Power unit
5

No. Part name Q’ty Remarks

1 Bolt 3 M8 × 12 mm
2 Starter pulley 1
3 Nut 1
4 Washer 1
5 Flywheel magnet 1
6 Spacer 1
7 Bolt 3 M5 × 25 mm
8 Stator coil 1
9 Woodruff key 1
10 Woodruff key 1
11 Drive sprocket 1
12 Driven sprocket 1
13 Pulser coil 1
14 Bolt 2 M5 × 16 mm
15 Washer 1
16 Bolt 1 M10 × 40 mm
17 Timing belt 1

5-7 6D55F11
 Power unit
5

5 N • m (0.5 kgf • m, 3.7 ft • Ib) 8 N • m (0.8 kgf • m, 5.9 ft • Ib) 2

1
T.
T.

R.
R.

3
23 24 25 1
22 26

7
8

9
54

2
6

3
A
5 4
10
19 11
13 12
20 21

4
17 14
18
5 N • m (0.5 kgf • m, 3.7 ft • Ib)
T.
R.

15

16
5
No. Part name Q’ty Remarks
S6D55040
6
1 Ignition coil 1
2
3
4
5
Bolt
Holder
Grommet
Spark plug cap
2
1
2
2
M6 × 30 mm

7
6 Plastic tie 2 Not reusable
7
8
9
10
Retainer
Bolt
Thermo sensor
Oil pressure switch
1
1
1
1
M6 × 12 mm
8
11 Cap 1
12
13
14
15
Oil pressure switch lead
Holder
Bolt
Bolt
1
1
1
1
M6 × 16 mm
9
16 Wiring harness 1
17 Bolt 3 M6 × 45 mm

6D55F11 5-8
POWR
Power unit
5

5 N • m (0.5 kgf • m, 3.7 ft • Ib) 8 N • m (0.8 kgf • m, 5.9 ft • Ib) 2

T.
T.

R.
R.

3
23 24 25 1
22 26

7
8
54

6
A
5 4
10
19 11
13 12
20 21
17 14
18
5 N • m (0.5 kgf • m, 3.7 ft • Ib)
T.
R.

15

16

S6D55040

No. Part name Q’ty Remarks

18 CDI unit 1
19 Bracket 1
20 Bolt 1 M5 × 16 mm
21 Holder 1
22 Bolt 3 M6 × 25 mm
23 Collar 3
24 Grommet 3
25 Bolt 1 M6 × 16 mm
26 Holder 1

5-9 6D55F11
 Power unit
5

1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Bolt 1 M6 × 55 mm
2
3
4
5
Washer
Throttle control lever
Spacer
Throttle cam
1
1
1
1
7
6 Bolt 1 M6 × 10 mm
7
8
9
10
Bracket
Bolt
Washer
Shift link lever
1
1
1
1
M6 × 25 mm, Remote control model
Remote control model
Remote control model
8
11 Collar 1 Remote control model
12
13
14
Shift link rod
Washer
Clip
1
1
1
Remote control model
Remote control model
Remote control model
9
6D55F11 5-10
POWR
Power unit
5

1 30
8 N • m (0.8 kgf • m, 5.9 ft • Ib) 2
T.
R.

3
5
A 4
6

8 7

10
29
25 28
23 A
24
11 14
12 A
27
13 22
21
13 26
3 N • m (0.3 kgf • m, 2.2 ft • Ib)
T.
R.

15
A
20
19
16
17

15 N • m (1.5 kgf • m, 11.1 ft • Ib) 18 S6D55020

T.
R.

No. Part name Q’ty Remarks

1 Bolt 1 M6 × 30 mm
2 Washer 1
3 Roller 1
4 Collar 1
5 Manual starter case 1
6 Guide 1
7 Starter rope 1
8 Nut 2
9 Starter rope guide 1
10 Damper 1
11 Manual starter handle 1
12 Cover 1
13 Oil pressure warning indicator 1
14 Bolt 2 M6 × 20 mm
15 Spring 2
16 Drive pawl 2
17 Circlip 2

5-11 6D55F11
 Power unit
5

1
30
8 N • m (0.8 kgf • m, 5.9 ft • Ib) 2
T.
R.

3
5
A 4
6

9
8 7
2
3
10
29
25 28
23 A
24
11 14
12 A

13
13 22
21
27

26
4
3 N • m (0.3 kgf • m, 2.2 ft • Ib)

5
T.
R.

15
A
20
19
16
17

15 N • m (1.5 kgf • m, 11.1 ft • Ib) 18 S6D55020

6
T.
R.

No. Part name Q’ty Remarks

18 Bolt 1
19
20
21
22
Drive plate
Spring
Sheave drum
Cartridge spring
1
1
1
1
7
23 Spring washer 1
24
25
26
27
Lock cam base plate
Spring
Bolt
Lock cam retainer
1
1
3
1
M5 × 25 mm
8
28 Lock cam 1
29
30
Spring
Cover
1
1
9
6D55F11 5-12
POWR
Power unit
Disassembling the manual starter Measuring the starter rope
1. Remove the lock cam retainer, and then 1. Measure the starter rope length. Replace
remove the lock cam base plate 1 and if the length is out of specification.
lock cam 2.
Starter rope length:
1,625–1,727 mm (63.98–67.99 in)
1
Assembling the manual starter
1. Install the spring washer 1 and cartridge
spring 2 into the manual starter case.
2

b
1
S6D55310

2. Remove the drive plate 3 and drive a

pawls 4.
2
c
3
S6D55340

NOTE:
4 • Install the spring washer with its projections
a facing down towards the manual starter
case.
4 • Position the end b of the cartridge spring
S6D55320
into the indentation c in the manual starter
case.
3. Remove the sheave drum 5, cartridge
spring 6, spring washer 7, and starter
rope 8. 2. Install the sheave drum 3 into the man-
ual starter case.

3 f

7 d
8 e
6
5 S6D55350

NOTE:
S6D55330
Position the projections d on the cartridge
spring case and the end e of the cartridge
spring into the indentations f in the sheave
Checking the spiral spring
drum.
1. Check the spiral spring for cracks, bends,
or damage. Replace the cartridge spring
if necessary.

5-13 6D55F11
 Power unit
3. Install the drive pawls 4. 3. Turn the sheave drum clockwise until the
rope hole a and manual starter roller b
4. Install the spring 5 and drive plate 6, are aligned. Hold the sheave drum in this
and then tighten the bolt 7 to the speci-

1
position.
fied torque.

6
7

5
4 2
3
4
S6D55360

NOTE:
Sheave drum bolt 7: If the sheave drum is turned less than 90°
15 N·m (1.5 kgf·m, 11.1 ft·lb) (from where if stopped to where the rope hole
T.
R.

and roller align), turn it one full turn clockwise

Installing the starter rope
1. Tie a knot on the end of the starter rope.
until the hole and roller align again.

4. Pass the starter rope 2 through the rope

4
hole in the sheave drum and out through
the manual starter case 3, and then
install the starter rope to the manual
starter handle 4.
5
6
NOTE:
Tie a knot at the end of the starter rope as
shown in the illustration.

2. Wind the sheave drum 1 counterclock-

7
wise until it stops.

NOTE:
8
Be sure to leave 12–20 mm (0.47–0.79 in) at
the end c of the starter rope.
9
6D55F11 5-14
POWR
Power unit
5. Pull the manual starter handle several
times to check that the sheave drum
turns smoothly and to check the starter
rope for slack. Repeat steps 2–4 if nec-
essary.

NOTE:
When checking the manual starter operation,
pull the manual starter handle while pushing
the start-in-gear protection lock cam so that it 3. Remove the starter pulley 1.
contacts the sheave drum.

6. Pull the manual starter handle to extend

the starter rope completely, then mea-
sure the starter rope length. Adjust if the
starter rope length is out of specification.

Universal clutch holder:

90890-04086

4. Loosen the flywheel magnet nut.

S6D55B10

Starter rope length (reference data):

1,470 mm (57.9 in)

Removing the timing belt and

sprockets
1. Remove the manual starter.

2. Turn the flywheel magnet clockwise and

align the “ ” mark a on the driven
sprocket with the “ ” mark b on the cyl-
inder head.

5-15 6D55F11
 Power unit
6. Disconnect the charge coil connectors
CAUTION: and power bobbin connectors, and
Apply force in the direction of the arrows remove the stator coil 2.

1
shown to prevent the flywheel holder from
slipping off easily.

Flywheel holder: 90890-06522

5. Remove the flywheel magnet, then the

woodruff key.
2
7. Remove the timing belt 3 from the
driven sprocket and then from the drive
sprocket.
3
3 4
S6D55130
5
8. Remove the drive sprocket.

9. Remove the driven sprocket. 6

7
CAUTION:
To prevent damage to the engine or tools,
screw in the puller set bolts evenly and
completely so that the puller plate is par-
allel to the flywheel magnet.

NOTE:
Apply force to the crankshaft end until the fly-
8
wheel magnet comes off the tapered portion
Flywheel holder: 90890-06522
of the crankshaft.

Flywheel puller: 90890-06521

9
6D55F11 5-16
POWR
Power unit
Checking the timing belt and
sprockets
1. Check the interior and exterior of the tim-
ing belt for cracks, damage, or wear.
Replace if necessary.

2. Check the drive sprocket and driven

sprockets for cracks, damage, or wear.
Replace if necessary.

Installing the sprockets and timing

belt
1. Install the driven sprocket 1, and then
tighten the bolt to the specified torque.
4. Install a new timing belt 3 to the drive
sprocket and then to the driven sprocket
with its part number in the upright posi-
tion.

Flywheel holder: 90890-06522

S6D55150

Driven sprocket bolt:

38 N·m (3.8 kgf·m, 28.0 ft·lb) CAUTION:
T.
R.

• Do not to damage the timing belt during

2. Check that “ ” mark a on the driven installation.
sprocket is aligned with the “ ” mark b • Do not twist, turn inside out, or bend the
on the cylinder head. Align if necessary. timing belt beyond the maximum limit of
25 mm (1.0 in), otherwise it can be dam-
aged.
• Do not get oil or grease on the timing
belt.

NOTE:
When installing the timing belt, lift the drive
sprocket slightly to ease installation. Be care-
ful the Woodruff key for the drive sprocket
does not slide out of position.
3. Install the drive sprocket 2, and then
check that the mark c on the drive
5. Turn the drive sprocket clockwise two
sprocket is aligned with the mark d on
turns, and then check that the alignment
the cylinder block. Align if necessary.
marks are aligned.

5-17 6D55F11
 Power unit

NOTE:
Do not turn the drive sprocket counterclock-
wise, otherwise the valve system may be
damaged.

6. Install the stator coil, and connect the

1
charge coil connectors and power bobbin
connectors.

7. Install the Woodruff key, then the fly-

wheel magnet.
Universal clutch holder:
2
90890-04086

Starter pulley bolt:

25 N·m (2.5 kgf·m, 18.4 ft·lb)
3
T.
R.
9. Install the manual starter.

Removing the power unit

NOTE:
4
It is recommended to loosen the flywheel
CAUTION:
Apply force in the direction of the arrows
shown to prevent the flywheel holder from
slipping off easily.
magnet nut before removing the power unit to
improve working efficiency.

1. Remove the manual starter.

5
NOTE:
Apply engine oil to the flywheel magnet nut
before installation.
2. Disconnect the throttle cables (tiller han-
dle model), or throttle cable and shift
cable (remote control model). 6
3. Remove the blowby hose and dipstick.

Flywheel holder: 90890-06522 4. Disconnect the fuel hose, engine stop

lanyard switch leads, and cooling water
pilot hose.
7
Flywheel magnet nut:
157 N·m (15.7 kgf·m, 115.8 ft·lb)
8
T.
R.

8. Install the starter pulley, and then tighten

the bolts to the specified torque.

9
6D55F11 5-18
POWR
Power unit
5. Remove the apron 1, and then remove
the power unit by removing the bolts 2.

6. Remove the flywheel magnet, then the

woodruff key.

5-19 6D55F11
 Power unit / Cylinder head
Cylinder head 5

1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Cylinder head 1
2
3
4
5
Gasket
Dowel
Bolt
Bolt
1
2
6
3
Not reusable

M9 × 95 mm
M6 × 25 mm
7
6 O-ring 1 Not reusable
7
8
9
10
O-ring
O-ring
Oil pump assembly
Bolt
1
1
1
4
Not reusable
Not reusable

M6 × 35 mm
8
11 Gasket 1 Not reusable
12
13
14
15
Bolt
Cylinder head cover
O-ring
Oil filler cap
5
1
1
1
M6 × 20 mm

9
16 Bolt 2 M6 × 20 mm
17 Plate 2

6D55F11 5-20
POWR
Power unit
5

No. Part name Q’ty Remarks

18 Cover 2
19 Bolt 2 M5 × 12 mm
20 Anode 2
21 Grommet 2
22 Spark plug 2

5-21 6D55F11
 Cylinder head
5

1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Exhaust valve 2
2
3
4
5
Intake valve
Valve spring seat
Valve seal
Valve spring
2
4
4
4
Not reusable 7
6 Valve spring retainer 4
7
8
9
10
Valve cotter
Rocker arm assembly
Rocker arm retainer
Bolt
8
4
2
3 M8 × 30 mm
8
11 Stopper guide 1
12
13
14
15
Tensioner
Rocker arm shaft
Retaining bolt
Gasket
1
1
1
1 Not reusable
9
16 Camshaft 1
17 Oil seal 1 Not reusable

6D55F11 5-22
POWR
Power unit
Removing the cylinder head
1. Remove the cylinder head cover.

2. Remove the cylinder head bolts in the

sequence shown.

$
#
%
&

± !
S6D55450

6. Remove the intake and exhaust valves.

CAUTION:
Do not scratch or damage the mating sur-
faces of the cylinder head and cylinder
block.

3. Remove the oil pump assembly 1.

4. Remove the rocker arm assembly 2,

and rocker arm shaft 3. NOTE:
Be sure to keep the valves, springs, and
other parts in the order as they were
3 removed.

2 Valve spring compressor 6:

90890-04019
Valve spring compressor
attachment 7:
S6D55470 90890-06320

5. Remove the retaining bolt 4, then the

camshaft 5.

5-23 6D55F11
 Cylinder head
Checking the valve springs
1. Measure the valve spring free length a. Valve margin thickness a:
Replace if below specification. Intake: 0.8 mm (0.0315 in)
Exhaust: 0.9 mm (0.0354 in)

3. Measure the valve stem diameter b.

Replace if out of specification.
1
2
Valve spring free length a:
39.85 mm (1.5689 in) 3
2. Measure the valve spring tilt b. Replace
Valve stem diameter b:
if above specification.
Intake:
5.475–5.490 mm
(0.2156–0.2161 in)
4
Exhaust:
5.460–5.475 mm
(0.2150–0.2156 in)

4. Measure the valve stem runout. Replace

5
if above specification.

Valve spring tilt limit b:

1.7 mm (0.07 in)
6
Checking the valves
1. Check the valve face for pitting or wear.
Replace if necessary.
7
2. Measure the valve margin thickness a.
Replace if below specification.
Valve stem runout limit:
0.03 mm (0.0012 in)
8
9
6D55F11 5-24
POWR
Power unit
Checking the valve guides
Valve guide remover/installer:
NOTE: 90890-06801
Before checking the valve guide make sure
that the valve stem diameter is within specifi- 2. Install a new valve guide 2 by striking
cation. the special service tool from the cam-
shaft side until the valve guide clip 3
1. Measure the valve guide inside diameter
contacts the cylinder head.
a.

NOTE:
Valve guide inside diameter a: Apply engine oil to the surface of the new
Intake and exhaust: valve guide.
5.500–5.512 mm
(0.2165–0.2170 in)
Valve guide remover/installer:
2. Calculate the valve stem-to-valve guide 90890-06801
clearance as follows. Replace the valve
guide if out of specification. 3. Insert the special service tool into the
valve guide 2, and then ream the valve
Valve stem-to-valve guide clearance guide.
= valve guide inside diameter – valve
stem diameter:
Intake and exhaust:
0.025–0.052 mm
(0.0010–0.0020 in)

Replacing the valve guides

1. Remove the valve guide 1 by striking
the special service tool from the combus-
tion chamber side.
NOTE:
• Turn the valve guide reamer clockwise to
ream the valve guide.
• Do not turn the reamer counterclockwise
when removing the reamer.

Valve guide reamer: 90890-06804

5-25 6D55F11
 Cylinder head
4. Measure the valve guide inside diameter.

Valve guide inside diameter:

Intake and exhaust:
5.500–5.512 mm
(0.2165–0.2170 in) 1
Checking the valve seat
1. Eliminate carbon deposits from the valve
with a scraper.

2. Apply a thin, even layer of Mechanic’s

2
blueing dye (Dykem) onto the valve seat.

3. Lap the valve slowly on the valve seat

with a valve lapper (commercially avail-
able) as shown.
Valve seat contact width a:
Intake and exhaust:
3
0.9–1.1 mm (0.035–0.043 in)

Refacing the valve seat

1. Reface the valve seat with the valve seat
cutters.
4
5
6
4. Measure the valve seat contact width a
where the blueing dye is adhered to the
valve face. Reface the valve seat if the
valve is not seated properly or if the valve
seat contact width is out of specification.
Replace the valve guide if the valve seat
contact is uneven.
Valve seat cutter holder:
90890-06316
Valve seat cutter:
30° (intake): 90890-06327
7
30° (exhaust): 90890-06328
45° (intake): 90890-06325
45° (exhaust): 90890-06312
60° (intake): 90890-06323
60° (exhaust): 90890-06315
8
9
6D55F11 5-26
POWR
Power unit
2. Cut the surface of the valve seat with a
45° cutter by turning the cutter clockwise
until the valve seat face has become b
smooth.

60˚

S69J5890

b Previous contact width

5. Use a 45° cutter to adjust the contact

S6D55540 width of the valve seat to specification.

b
c

45˚
S69J5900

a Slag or rough surface b Previous contact width

c Specified contact width
CAUTION:
6. If the valve seat contact area is too wide
Do not over cut the valve seat. Be sure to
and situated in the center of the valve
turn the cutter evenly downward at a pres-
face, use a 30° cutter to cut the top edge
sure of 40–50 N (4–5 kgf, 8.8–11 lbf) to
of the valve seat and a 60° cutter to cut
prevent chatter marks.
the bottom edge to center the area and
set its width.
3. Use a 30° cutter to adjust the contact
width of the top edge of the valve seat.

30˚ b Previous contact width

S69J5880

b Previous contact width

4. Use a 60° cutter to adjust the contact

width of the bottom edge of the valve
seat.

5-27 6D55F11
 Cylinder head
7. If the valve seat contact area is too nar-
row and situated near the top edge of the CAUTION:
valve face, use a 30° cutter to cut the top Do not get the lapping compound on the

1
edge of the valve seat. If necessary, use valve stem and valve guide.
a 45° cutter to center the area and set its
width.
10. After every lapping procedure, be sure to
clean off any remaining lapping com-
pound from the cylinder head and the
valve.

11. Check the valve seat contact area of the

valve again.
2
b Previous contact width
Checking the rocker arms and rocker
arm shaft
1. Check the rocker arms, rocker arm shaft,
3
and rocker arm contact surface a for
8. If the valve seat contact area is too nar-

4
wear. Replace if necessary.
row and situated near the bottom edge of
the valve face, use a 60° cutter to cut the 2. Measure the rocker arm inside diameter
bottom edge of the valve seat. If neces- b and rocker arm shaft outside diameter
sary, use a 45° cutter to center the area c. Replace if out of specification.

5
and set its width.

6
b Previous contact width

9. Apply a thin, even layer of lapping com-

Rocker arm inside diameter b:
16.000–16.018 mm
(0.6299–0.6306 in)
7
pound onto the valve seat, and then lap Rocker arm shaft outside
the valve using a valve lapper (commer-

8
diameter c:
cially available). 15.971–15.991 mm
(0.6288–0.6296 in)

9
6D55F11 5-28
POWR
Power unit
Checking the camshaft
1. Measure the cam lobe. Replace if out of
specification.

Camshaft journal diameter c:

36.925–36.945 mm
(1.4537–1.4545 in)
Cam lobe a: Camshaft journal diameter d:
Intake and exhaust: 36.935–36.955 mm
30.834–31.034 mm (1.4541–1.4549 in)
(1.2139–1.2218 in) Cylinder head journal inside
Cam lobe b: diameter e:
Intake and exhaust: 37.000–37.025 mm
25.90–26.10 mm (1.4567–1.4577 in)
(1.0197–1.0276 in)
4. Calculate the camshaft journal oil clear-
2. Measure the camshaft runout. Replace if ance as follows. Replace the camshaft
above specification. and cylinder head as a set if out of speci-
fication.

Camshaft journal oil clearance =

Cylinder head journal inside
diameter e – Camshaft journal
diameter c, d:
0.050–0.090 mm
(0.0020–0.0035 in)

5. Check the decompression actuator for

damage or wear. Replace the camshaft if
Camshaft runout limit: necessary.
0.03 mm (0.0012 in)
Checking the cylinder head
3. Measure the camshaft journal diameters 1. Eliminate carbon deposits from the com-
c and d, and cylinder head journal bustion chambers and check for deterio-
inside diameter e. Replace the camshaft ration.
and cylinder head if out of specification.
2. Check the cylinder head warpage using a
straightedge 1 and thickness gauge 2
in six directions as shown. Replace if
above specification.

5-29 6D55F11
 Cylinder head

1
2

1
S6D55560

2
3
Cylinder head warpage limit:
S6D55570
Clearance a:
0.09–0.15 mm (0.0035–0.0059 in)
Clearance b:
4
0.10 mm (0.0039 in) Within 0.12 mm (0.047 in)

Checking the oil pump

1. Measure the oil pump rotor clearances
as shown. Replace if out of specification.
Clearance c:
0.03–0.08 mm (0.0012–0.0031 in)

Installing the valves

5
1. Install a new valve seal 1 into the valve
guide.
6
1

E
7
S62Y5590

8
9
6D55F11 5-30
POWR
Power unit
2. Install the valve 2, valve spring seat 3, 4. Lightly tap the valve spring retainer with
valve spring 4, and valve spring retainer a plastic hammer to set the valve cotter
5 in the sequence shown, and then securely.
attach the special service tool.

Installing the camshaft

1. Install a new oil seal 1.

1
NOTE: 3
Face the fine pitch side a of the valve spring
toward the spring seat.

Valve spring compressor 6:

90890-04019 2
Valve spring compressor
attachment 7:
90890-06320
S6D55620
3. Compress the valve spring, and then
install the valve cotter 8 using a thin Bearing outer race attachment 2:
screwdriver with a small amount of 90890-06626
grease applied to it. Driver rod LS 3: 90890-06606

2. Install the camshaft 4 in the direction

shown, then the retaining bolt 5.

5-31 6D55F11
 Cylinder head

1
Rocker arm shaft bolt:
S6D55660

2
18 N·m (1.8 kgf·m, 13.3 ft·lb)

T.
R.
Installing the rocker arm shaft
assembly
Installing the oil pump
1. Install the oil pump 1 by aligning the oil
pump drive shaft a with the camshaft pin
3
1. Assemble the rocker arm assemblies 1 b.
and rocker arm shaft 2, and then install
the tensioner 3, rocker arm retainers 4,
and stopper guide 5 to the rocker arm
shaft by installing the bolts 6.
4
c
1
5
S6D55670

6
7
NOTE:
Make sure that the arrow marks a on the
tensioner and stopper guide are facing up.
8
2. Install the rocker arm shaft assembly to

9
the cylinder head by installing the bolts, NOTE:
and then tighten them to the specified Before installing the oil pump, be sure to fill it
torque. with a small amount of engine oil through the
oil passages c.

6D55F11 5-32
POWR
Power unit
Cylinder block 5

No. Part name Q’ty Remarks

1 Oil filter 1
2 Union bolt 1
3 Exhaust cover 1
4 Holder 2
5 Bolt 9 M6 × 35 mm
6 Thermostat cover 1
7 Gasket 1 Not reusable
8 Thermostat 1
9 Gasket 1 Not reusable
10 Bolt 1 M8 × 35 mm
11 Engine hanger 1
12 Filter 1 Steel
13 Gasket 1 Not reusable
14 Plug 1 Steel
15 Gasket 1 Not reusable
16 Cover 1
17 Bolt 4 M6 × 20 mm

5-33 6D55F11
 Cylinder block
5

1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Nut 1
2
3
4
5
Balancer piston
Cover
O-ring
Bolt
1
1
1
4
Not reusable
M6 × 20 mm
7
6 Bolt 6 M8 × 82 mm
7
8
9
10
Bolt
Crankcase
Main bearing
Bolt
6
1
6
4
M6 × 35 mm

8
11 Connecting rod assembly 2
12
13
14
15
Connecting rod bearing
Oil seal
Balancer rod
Crankshaft
4
1
1
1
Not reusable
9
16 Oil seal 1 Not reusable
17 Dowel 2

6D55F11 5-34
POWR
Power unit
5

No. Part name Q’ty Remarks

18 Cylinder block 1
19 Piston ring assembly 2
20 Piston 2
21 Piston pin 2
22 Clip 4 Not reusable

5-35 6D55F11
 Cylinder block
Disassembling the cylinder block
1. Remove the thermostat cover and
exhaust cover by removing the bolts in

1
the sequence shown.

2
3
S6D55730

2. Remove the oil filter. 5. Remove the crankcase bolts in the

sequence shown.

4
NOTE:
S6D55760
5
Be sure to clean up any oil spills.

6
6. Remove the connecting rod bolts and the
connecting rod caps, and then remove
the connecting rod and piston assem-
Oil filter wrench: 90890-01426 blies.

7
7. Remove the crankshaft and oil seals.
3. Remove the cover 1.

4. Remove the nut 2, then the balancer

piston 3.

8
9
6D55F11 5-36
POWR
Power unit
8. Remove the piston pin clips 4 and pis-
ton pin, and then remove the piston. Piston diameter a:
64.950–64.965 mm
(2.5571–2.5577 in)
Measuring point b:
2.0 mm (0.08 in) up from the
bottom of the piston skirt
Oversize piston diameter:
Oversize 1st:
65.200–65.215 mm
(2.5669–2.5675 in)
Oversize 2nd:
65.450–65.465 mm
NOTE:
(2.5768–2.5774 in)
• Be sure to keep the bearings in the order as
they were removed.
• Mark each piston with an identification Checking the cylinder bore
number a of the corresponding cylinder. 1. Measure the cylinder bore (D1–D6) at
• Do not mix the connecting rods and caps. measuring points a, b, and c, and in
Keep them organized in their proper direction d (D1, D3, D5), which is parallel
groups. to the crankshaft, and direction e (D2,
D4, D6), which is at a right angle to the
crankshaft.
Checking the balancer
1. Check the balancer piston for cracks or
wear. Replace the balancer piston if nec- a
essary. b D2 D1 d
c

2. Check the balancer rod for cracks or D4 D3 e

wear. Replace the balancer rod if neces-
D6 D5
sary.

Checking the piston diameter S69J5B70

1. Measure the piston outside diameter at a 20 mm (0.8 in)

the specified measuring point. Replace if b 40 mm (1.6 in)
c 60 mm (2.4 in)
out of specification.
Cylinder bore (D1–D6):
65.000–65.015 mm
(2.5590–2.5596 in)

2. Calculate the taper limit. Replace the cyl-

inder block if above specification.

Taper limit:
D1–D5 (direction d)
D2–D6 (direction e)
0.08 mm (0.0032 in)

3. Calculate the out-of-round limit. Replace

the cylinder block if above specification.

5-37 6D55F11
 Cylinder block
3. Check the piston ring end gap d at the
Out-of-round limit: specified measuring point. Replace if out
D2–D1 (measuring point a) of specification.
D6–D5 (measuring point c)
0.05 mm (0.0020 in)

Checking the piston clearance

1
1. Replace the piston and piston rings as a
set or the cylinder block, or all parts if out
of specification.

Piston clearance:
2
0.035–0.065 mm
(0.0014–0.0026 in)

Checking the piston rings

1. Check the piston ring dimensions of B
3
and T. Replace if out of specification.

4
Piston ring end gap d:
Top ring:
0.15–0.30 mm
(0.0059–0.0118 in)
2nd ring:
5
0.30–0.50 mm

Piston ring dimensions:

Top ring a:
B: 1.17–1.19 mm
(0.0118–0.0197 in)
Oil ring:
0.20–0.70 mm
(0.0079–0.0276 in)
6
(0.0461–0.0469 in) Measuring point e: 20 mm (0.8 in)
T: 2.25–2.45 mm
(0.0885–0.0965 in)
2nd ring b:
B: 1.47–1.49 mm
7
(0.0579–0.0587 in)
T: 2.60–2.80 mm
(0.1024–0.1102 in)
Oil ring c:
8
B: 2.36–2.48 mm

9
(0.0929–0.0976 in)
T: 2.75 mm (0.1083 in)

2. Level the piston ring 1 in the cylinder

with a piston crown.

6D55F11 5-38
POWR
Power unit
Checking the piston ring grooves
1. Measure the piston ring grooves. Piston ring side clearance:
Replace the piston if out of specification. Top ring a:
0.02–0.06 mm
(0.0008–0.0024 in)
2nd ring b:
0.02–0.06 mm
(0.0008–0.0024 in)
Oil ring c:
0.04–0.18 mm
(0.0016–0.0070 in)

Checking the piston pin boss bore

1. Measure the piston pin boss bore.
Replace the piston if out of specification.

Piston ring groove:

Top ring a:
1.21–1.23 mm
(0.0476–0.0484 in)
2nd ring b:
1.51–1.53 mm
(0.0594–0.0602 in)
Oil ring c:
2.52–2.54 mm Piston pin boss bore:
(0.0992–0.1000 in) 15.974–15.985 mm
(0.6289–0.6293 in)
Checking the piston ring side
clearance Checking the piston pin
1. Measure the piston ring side clearance. 1. Measure the piston pin diameter.
Replace the piston and piston rings as a Replace if out of specification.
set if out of specification.

Piston pin diameter:

15.965–15.970 mm
(0.6285–0.6287 in)

5-39 6D55F11
 Cylinder block
Checking the connecting rod small
end inside diameter
1. Measure the connecting rod small end
inside diameter a. Replace the connect-
ing rod if out of specification.
1
a

S6D55810

2
b

Connecting rod small end inside

3
diameter a:

4
15.985–15.998 mm c
S6D55820
(0.6293–0.6298 in)
Crankshaft journal diameter a:
Checking the connecting rod big end 42.984–43.000 mm
side clearance (1.6923–1.6929 in)
1. Measure the connecting rod big end side
clearance a. Replace the connecting
rod or crankshaft, or both if out of specifi-
Crankpin diameter b:
32.984–33.000 mm
(1.2986–1.2992 in)
5
cation. Crankpin width c:

6
21.000–21.070 mm
(0.8268–0.8295 in)
a
2. Measure the crankshaft runout. Replace
a
the crankshaft if above specification.

S6D55800
7
Connecting rod big end side
clearance a:
0.05–0.22 mm (0.0020–0.0087 in)
8
S6D55830

9
Checking the crankshaft
1. Measure the crankshaft journal diameter Crankshaft runout limit:
a, crankpin diameter b, and crankpin 0.05 mm (0.0020 in)
width c. Replace the crankshaft if out of
specification.

6D55F11 5-40
POWR
Power unit
Checking the crankpin oil clearance
1. Clean the bearings and the connecting
rod.

2. Install the upper bearing into the con-

necting rod 1 and the lower bearing into
the connecting rod cap 2.

NOTE:
• Install the connecting rod bearings in their NOTE:
original positions. Make sure that the marks b of the connect-
• Insert the projection a of each bearing into ing rod faces towards the flywheel magnet
the slots in the connecting rod cap and con- side of the crankshaft.
necting rod.

5. Tighten the connecting rod bolts to the

3. Put a piece of Plastigauge (PG-1) onto specified torques in two stages.
the crankpin, parallel to the crankshaft.

NOTE:
NOTE: Do not turn the connecting rod until the
Be sure not to put the Plastigauge (PG-1) crankpin oil clearance measurement has
over the oil hole in the crankpin of the crank- been completed.
shaft.

Connecting rod bolt:

4. Install the connecting rod to the crankpin 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
T.
R.

3. 2nd: 17 N·m (1.7 kgf·m, 12.5 ft·lb)

5-41 6D55F11
 Cylinder block
6. Remove the connecting rod cap and
measure the width of the compressed Connecting rod
Bearing color b
Plastigauge (PG-1) on each crankpin. mark a
A Blue

1
Replace the connecting rod bearing if out
of specification. B Black
C Brown

Checking the crankshaft main

journal oil clearance
1. Clean the bearings, main journals, and
bearing portions of the crankcase and
cylinder block.
2
Crankpin oil clearance:
2. Place the cylinder block upside down on
a bench.

3. Install half of the bearings 1 and the

3
0.020–0.052 mm
crankshaft 2 into the cylinder block 3.

4
(0.0008–0.0020 in)

Selecting the connecting rod bearing

1. When replacing the connecting rod bear-
ing, select the suitable bearing as fol-
lows.

2. Check the connecting rod mark a. 5

NOTE:
• Install the main bearings in their original
positions.
6
• Insert the projection a of each bearing into
the slots in the cylinder block.
7
3. Select the suitable color b for the con-
necting rod bearing from the table.

8
9
6D55F11 5-42
POWR
Power unit
4. Put a piece of Plastigauge (PG-1) on
each main journal parallel to the crank-
shaft.

Crankshaft main journal oil

clearance:
0.012–0.044 mm
NOTE: (0.0005–0.0017 in)
Do not put the Plastigauge (PG-1) over the
oil hole in the main journals of the crankshaft.
Selecting the crankshaft main
bearing
5. Install the remaining half of the bearings 1. When replacing the main bearing, select
into the crankcase. the suitable bearing as follows.

NOTE: 2. Check the cylinder block mark a on the

• Install the main bearings in their original cylinder block.
positions.
• Insert the projection of each bearing into 3. Select the suitable color b for the main
the slots in the crankcase. bearing from the table.

6. Install the crankcase onto the cylinder

block.

7. Apply engine oil to the threads of the

crankcase bolts and tighten them to the
specified torques in two stages.

Crankcase bolt (M8):

1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
T.
R.

2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb) Cylinder block mark

Bearing color b
Crankcase bolt (M6): a
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) A Blue
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
B Black

8. Remove the crankcase, and then mea- C Brown

sure the width of the compressed Plasti-
gauge (PG-1) on each main journal.
Replace the main bearing if out of speci-
fication.

5-43 6D55F11
 Cylinder block
Assembling the pistons and cylinder
block d 45˚ 45˚
#3 #2
1. Assemble the piston 1, connecting rod UP

2, piston pin 3, and piston pin clips 4.

UP
63P

#5
#4
5
T

#1,#4 #5 1
#3 6

2
#2 7
#1

E
T
d

3
S6D55900

CAUTION:
Do not scratch the pistons or break the
piston rings.

NOTE:
After installing the piston rings, check that
they move smoothly.
4
NOTE:
• Face the embossed “Y” mark a on the
connecting rod in the same direction as the
“UP” mark b on the piston.
4. Install the upper bearing into the con-
necting rod and the lower bearing into
the connecting rod cap 8.
5
• Always use new piston pin clips, and do not
allow the piston pin clip end to align with the
piston pin slot c.
6
2. Install the oil ring 5, second ring 6, and
top ring 7 onto each piston with the “T”
marks d of the second ring and the top
ring facing upward. 7
3. Offset the piston ring end gaps as
shown. NOTE:
• Install the connecting rod bearings in their
original positions.
• Insert the projection e of each bearing into
8
the slots in the connecting rod cap and con-
necting rod.
9
6D55F11 5-44
POWR
Power unit
5. Install the piston with the “UP” mark on
the piston crown facing towards the fly-
wheel magnet.

NOTE:
Apply engine oil to the side of the pistons and NOTE:
piston rings before installation. Apply engine oil to the inner oil seals before
installation.

Piston slider: 90890-06529

9. Install the connecting rod caps D to the
connecting rods, and then tighten the
6. Install half of the main bearings 9 into connecting rod bolts to the specified
the cylinder block 0. torques in two stages.

9 g E

E D

f S6D55920

NOTE:
• Install the main bearings in their original
positions. S6D55950
• Insert the projection f of each bearing into
the slots in the cylinder block. NOTE:
• Align the alignment marks g on the con-
necting rod cap and connecting rod.
7. Install the balancer rod onto the crank- • Apply engine oil to the connecting rod bolts
shaft. before installation.
8. Set the crankshaft A and oil seals B and
C into the cylinder block as shown. Connecting rod bolt:
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
T.
R.

2nd: 17 N·m (1.7 kgf·m, 12.5 ft·lb)

5-45 6D55F11
 Cylinder block
10. Install half of the main bearings into the
crankcase. 1–6 Crankcase bolt (M8):
1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)

T.
R.
NOTE: 2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
• Install the main bearings in their original
positions.
• Insert the projection of each bearing into
the slots in the crankcase.
7–B Crankcase 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)
1
2
14. Install the balancer piston E into the
11. Apply sealant to the mating surface of crankcase, and then tighten the balancer
the crankcase. piston nut F to the specified torque.

15. Install a new O-ring and the balancer

3
cover G, and then tighten the bolts H to
the specified torque.

4
NOTE:
Do not get any sealant on the main bearings.

12. Install the crankcase onto the cylinder

5
block.

13. Tighten the crankcase bolts to the speci-

fied torques in two stages and in the
sequence shown.
NOTE:
Apply engine oil to the balancer piston nut
6
and balancer cover bolts before installation.

E Balancer piston nut F:

157 N·m (15.7 kgf·m, 115.8 ft·lb)
7
T.
R.

Balancer cover bolt H:

12 N·m (1.2 kgf·m, 8.9 ft·lb)

S6D55970
8
NOTE:
Apply engine oil to the crankcase bolts before
installation. 9
6D55F11 5-46
POWR
Power unit
16. Before installing the oil filter, be sure to
supply engine oil to the oil passage h.

S6D55A10

S6D55990 Exhaust cover bolt:

1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)

T.
R.
17. Install the oil filter, and then tighten it to 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
the specified torque using the oil filter Thermostat cover bolt:
wrench. 7 N·m (0.7 kgf·m, 5.2 ft·lb)

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.

$
#

NOTE:
²! ±(
Apply a thin coat of engine oil to the O-ring of
the new oil filter before installation. E

% &
S6D55690
Oil filter wrench: 90890-01426
CAUTION:
Do not reuse the cylinder head gasket,
Oil filter:
always replace it with a new one.
18 N·m (1.8 kgf·m, 13.3 ft·lb)
T.
R.

18. Install a new gasket and the exhaust NOTE:

cover. • Apply engine oil to the cylinder head bolts
before installation.
19. Install the thermostat and thermostat • Tighten the bolts to the specified torques in
cover, and then tighten the bolts to the two stages.
specified torques in two stages and in the
sequence shown.

5-47 6D55F11
 Cylinder block

Cylinder head bolt (M9):

1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb)
T.
R.

2nd: 46 N·m (4.6 kgf·m, 34.0 ft·lb)

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)
1
2
2. Install the cylinder head cover, and then
tighten the bolts.

3. Install the driven sprocket 1, and then

tighten the bolt to the specified torque.

6. Install the timing belt 3 to the drive

sprocket and then to the driven sprocket
3
with its part number in the upright posi-

4
tion.

Flywheel holder: 90890-06522

5
Driven sprocket bolt:

6
S6D55150
38 N·m (3.8 kgf·m, 28.0 ft·lb)
T.
R.

CAUTION:
4. Check that “ ” mark a on the driven Do not to damage the timing belt during
sprocket is aligned with the “ ” mark b installation.

7
on the cylinder head. Align if necessary.

NOTE:
When installing the timing belt, lift the drive
sprocket slightly to ease installation. Be care-
ful the Woodruff key for the drive sprocket
does not slide out of position.
8
5. Install the drive sprocket 2, and then
check that the mark c on the drive
9
sprocket is aligned with the mark d on
the cylinder block. Align if necessary.

6D55F11 5-48
POWR
Power unit
7. Adjust the valve clearance. 6. Connect the blowby hose 7.

Valve clearance:
Intake:
0.15–0.25 mm (0.006–0.010 in) 7
Exhaust:
0.25–0.35 mm (0.010–0.014 in)

NOTE:
For adjustment procedures, see “Checking
S6D55A50
the valve clearance”.
7. Connect the throttle cable 8 and shift
Installing the power unit cable 9 (remote control model), or throt-
1. Clean the power unit mating surface, and tle cables 0 (tiller handle model), and
install the dowels 1 and a new gasket then adjust their lengths. For adjustment
2. procedures, see Chapter 3.

2. Install the power unit 3 by installing the

bolts 4, then tightening them to the 9
specified torque.

3. Install the apron 5 by installing the bolts

6, then tightening them to the specified
torque.
8
S6D55A60

S6D55A70

8. Install the stator coil.

9. Install the Woodruff key.

Power unit mounting bolt 4:
21 N·m (2.1 kgf·m, 15.5 ft·lb)
T.
R.

Apron bolt 6:
10 N·m (1.0 kgf·m, 7.4 ft·lb)

4. Connect the engine stop lanyard switch

leads, cooling water pilot hose, and fuel
hose.

5. Install the dipstick.

5-49 6D55F11
 Cylinder block
10. Install the flywheel magnet. 12. Install all parts removed during disas-
sembly.

1
2
CAUTION:

3
Apply force in the direction of the arrows
shown to prevent the flywheel holder from
slipping off easily.

NOTE:
Apply engine oil to the flywheel magnet nut
before installation. 4
Flywheel holder: 90890-06522

Flywheel magnet nut:

5
157 N·m (15.7 kgf·m, 115.8 ft·lb)
T.
R.

11. Install the starter pulley, and then tighten

the bolts to the specified torque. 6
7
8
Universal clutch holder:
90890-04086

Starter pulley bolt:

9
25 N·m (2.5 kgf·m, 18.4 ft·lb)
T.
R.

6D55F11 5-50
POWR
Power unit

— MEMO —

5-51 6D55F11
LOWR

Lower unit

Special service tools .....................................................................................6-1

Lower unit ....................................................................................................... 6-4

Removing the lower unit ............................................................................6-7
1
Removing the water pump......................................................................... 6-7
Checking the water pump..........................................................................6-8

Propeller shaft housing ................................................................................. 6-9

Removing the propeller shaft housing assembly..................................... 6-11
2
Disassembling the propeller shaft assembly ...........................................6-11

3
Disassembling the propeller shaft housing.............................................. 6-11
Disassembling the oil seal housing ......................................................... 6-12
Checking the propeller shaft housing ......................................................6-12
Checking the propeller shaft and shift rod ............................................... 6-12
Assembling the propeller shaft assembly ................................................ 6-12
Assembling the propeller shaft housing...................................................6-13
Assembling the oil seal housing ..............................................................6-14

Drive shaft and lower case..........................................................................6-15

4
Removing the drive shaft.........................................................................6-16
Disassembling the drive shaft.................................................................. 6-16
Disassembling the forward gear ..............................................................6-16
Disassembling the lower case .................................................................6-16
Checking the pinion and forward gear.....................................................6-17
Checking the bearings............................................................................. 6-17
5
Checking the drive shaft ..........................................................................6-17
Checking the lower case .........................................................................6-17
Assembling the lower case...................................................................... 6-17
Assembling the forward gear................................................................... 6-18
Assembling the drive shaft ...................................................................... 6-18
6
Installing the pinion.................................................................................. 6-19
Installing the propeller shaft housing .......................................................6-19
Installing the water pump and shift rod....................................................6-19
Installing the lower unit ............................................................................6-21 7
Shimming...................................................................................................... 6-23
Shimming.................................................................................................6-24
Selecting the pinion shims....................................................................... 6-24
Selecting the forward gear shims ............................................................ 6-25
Selecting the reverse gear shims ............................................................ 6-26
8
Backlash ....................................................................................................... 6-27
Measuring the forward and reverse gear backlash .................................6-27 9
6D55F11
LOWR
Lower unit
Special service tools 6

Bearing housing puller claw S Bearing puller assembly

90890-06564 90890-06535

Stopper guide plate Needle bearing attachment

90890-06501 90890-06608, 90890-06611, 90890-06615

Center bolt Driver rod L3

90890-06504 90890-06652

Bearing separator Ball bearing attachment

90890-06534 90890-06635, 90890-06637

Stopper guide stand Driver rod LS

90890-06538 90890-06606

6-1 6D55F11
 Special service tools

1
Driver rod SS Bearing outer race attachment
90890-06604 90890-06625, 90890-06628

2
Bearing depth plate Driver rod LL
3
90890-06603 90890-06605

4
Bearing inner race attachment Pinion height gauge
5
90890-06640, 90890-06643, 90890-06644 90890-06710

6
Drive shaft holder 3
90890-06517
Pinion height gauge plate B
90890-06712
7
8
Driver rod SL
90890-06602
Digital caliper
90890-06704
9
6D55F11 6-2
LOWR
Lower unit

Shimming plate
90890-06701

Backlash indicator
90890-06706

Magnet base plate

90890-07003

Dial gauge set

90890-01252

Magnet base B
90890-06844

6-3 6D55F11
 Special service tools / Lower unit
Lower unit 6

1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Lower unit 1
2
3
4
5
Check screw
Gasket
Drain screw
Adjusting nut
1
2
1
1
Not reusable
7
6 Locknut 1
7
8
9
10
Cooling water inlet cover
Nut
Bolt
Washer
2
2
1
1
M6 × 35 mm
8
11 Anode 1
12
13
14
15
Screw
Bolt
Bolt
Trim tab
2
4
1
1
ø5 × 26 mm
M10 × 35 mm
M6 × 20 mm
9
16 Spacer 1
17 Propeller 1

6D55F11 6-4
LOWR
Lower unit
6

No. Part name Q’ty Remarks

18 Collar 1
19 Washer 1
20 Nut 1
21 Cotter pin 1 Not reusable
22 Dowel 2

6-5 6D55F11
 Lower unit
6

1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Water tube 1 L-transom model
2

3
O-ring

O-ring
2

1
Not reusable
L-transom model
Not reusable
S-transom model
7
4 Water tube 1 S-transom model

6
7
5 O-ring

Bolt
Extension plate
1

4
1
Not reusable
S-transom model
M6 × 40 mm 8
8 Cover 1
9
10
11
12
Water pump housing
Insert cartridge
O-ring
Impeller
1
1
1
1
Not reusable
9
13 Outer plate cartridge 1
14 Woodruff key 1

6D55F11 6-6
LOWR
Lower unit
Removing the lower unit 4. Loosen the locknut 3, and then remove
1. Drain the gear oil. the adjusting nut 4.

5. Loosen the bolts 5, and then remove the

lower unit from the upper case.

2. Shift the remote control lever or shift

lever to neutral, place a block of wood
between the anti-cavitation plate and
propeller to keep the propeller from turn-
ing, and then remove the propeller nut
and propeller.

Removing the water pump

1. Remove the water pump assembly.

WARNING
• Do not hold the propeller with your
hands when loosening or tightening it.
• Be sure to remove the clip from the
engine stop lanyard switch.
• Put a block of wood between the anti-
cavitation plate and propeller to keep
the propeller from turning.

3. Remove the anode 1 and trim tab 2. È S-transom model

É L-transom model
NOTE:
Note the trim tab position.

6-7 6D55F11
 Lower unit
Checking the water pump
1. Check the water pump housing for defor-
mation. Replace if necessary.

2. Check the impeller and insert cartridge

for cracks or wear. Replace if necessary. 1
3. Check the Woodruff key 1 and the key-
way a in the drive shaft for wear.
Replace if necessary.

1
2
a

3
S6D56050

4
5
6
7
8
9
6D55F11 6-8
LOWR
Lower unit
Propeller shaft housing 6

No. Part name Q’ty Remarks

1 Shift plunger 1
2 Dog clutch 1
3 Cross pin 1
4 Spring 1
5 Spring 1
6 Propeller shaft 1
7 Washer 1
8 Reverse gear 1
9 Reverse gear shim —
10 O-ring 1 Not reusable
11 Ball bearing 1 Not reusable
12 O-ring 2 Not reusable
13 Propeller shaft housing 1
14 Needle bearing 1
15 Oil seal 2 Not reusable
16 Oil seal 2 Not reusable
17 Water seal 1

6-9 6D55F11
 Propeller shaft housing
6

1
2
3
4
5
No. Part name Q’ty Remarks
6
18 Bolt 2 M6 × 25 mm
19
20
21
22
Shift rod bracket
Shift rod plate
O-ring
Oil seal housing
1
1
1
1
Not reusable 7
23 Dowel 3
24
25
Gasket
Shift rod
1
1
Not reusable

8
9
6D55F11 6-10
LOWR
Lower unit
Removing the propeller shaft
housing assembly
1. Remove the bolts, and then pull out the
propeller shaft housing assembly.

Bearing housing puller claw S 1: Bearing separator 1: 90890-06534

90890-06564 Stopper guide plate 2: 90890-06501
Stopper guide plate 2: 90890-06501 Stopper guide stand 3:
Center bolt 3: 90890-06504 90890-06538
Bearing puller assembly 4:
Disassembling the propeller shaft 90890-06535
assembly
1. Remove the spring 1, then the cross pin 2. Remove the ball bearing.
2, dog clutch 3, shift plunger 4, and
spring 5.

CAUTION:
Do not reuse the bearing, always replace
Disassembling the propeller shaft it with a new one.
housing
1. Remove the reverse gear and reverse Stopper guide plate 5: 90890-06501
gear shim(s). Stopper guide stand 6:
90890-06538
Bearing puller assembly 7:
90890-06535

3. Remove the oil seals and needle bear-

ing.

6-11 6D55F11
 Propeller shaft housing
2. Check the propeller shaft for bends or
wear. Replace if necessary.

3. Measure the propeller shaft runout.

1
Needle bearing attachment 8:
2
90890-06615
Driver rod L3 9: 90890-06652 S6D56510

Disassembling the oil seal housing

1. Remove the oil seals.
Runout limit: 0.02 mm (0.0008 in) 3
4
4. Check the dog clutch and shift plunger
for cracks or wear. Replace if necessary.

Assembling the propeller shaft

assembly
1. Install the dog clutch as shown.

5
Ball bearing attachment 1:
90890-06637
Driver rod LS 2: 90890-06606 6
Checking the propeller shaft housing
1. Clean the propeller shaft housing using a
soft brush and cleaning solvent, and then
check it for cracks. Replace if necessary.
NOTE:
Install the dog clutch 1 with the “F” mark a
7
facing toward the shift plunger.
2. Check the teeth and dogs of the reverse
gear for cracks or wear. Replace the
gear if necessary.

3. Check the bearings for pitting or rum-

8
bling. Replace if necessary.

Checking the propeller shaft and

shift rod
1. Check the shift rod cracks or wear.
9
Replace if necessary.

6D55F11 6-12
LOWR
Lower unit
Assembling the propeller shaft
housing Needle bearing attachment 4:
1. Install the needle bearing into the propel- 90890-06611
ler shaft housing to the specified depth. Driver rod L3 5: 90890-06652

Depth d:
13.0–13.5 mm (0.512–0.532 in)
Depth e:
6.0–6.5 mm (0.236–0.256 in)

3. Install the original shim(s) 6 and new

ball bearing 7 onto the reverse gear 8
using a press.

NOTE:
• Install the needle bearing with the manufac-
ture identification mark a facing toward the
reverse gear.
• When using the driver rod, do not strike the
special service tool in a manner that will
force the stopper c out of place.

Driver rod SS 1: 90890-06604

Needle bearing attachment 2: CAUTION:
90890-06615 Add or remove shim(s), if necessary, if
Bearing depth plate 3: 90890-06603 replacing the reverse gear, ball bearing,
propeller shaft housing, or lower case.
Depth b:
31.0–31.5 mm (1.22–1.24 in) NOTE:
Install the ball bearing with the manufacturer
2. Apply grease to new oil seals, and then identification mark f facing inward (reverse
install them into the propeller shaft hous- gear side).
ing to the specified depth.
Bearing inner race attachment 9:
90890-06640

4. Install the reverse gear assembly into the

propeller shaft housing using a press.

NOTE:
Install an oil seal halfway into the propeller
shaft housing, then the other oil seal.

6-13 6D55F11
 Propeller shaft housing

1
2
3
Needle bearing attachment 0:
90890-06608 4
Assembling the oil seal housing
1. Apply grease to new oil seals, and then
install them into the oil seal housing to
the specified depth.
5
6
7
Ball bearing attachment 1:
90890-06635
Driver rod LS 2: 90890-06606 8
Depth a:
5.5–6.0 mm (0.217–0.236 in)

9
6D55F11 6-14
LOWR
Lower unit
Drive shaft and lower case 6

No. Part name Q’ty Remarks

1 Drive shaft 1
2 Taper roller bearing assembly 1 Not reusable
3 Pinion shim —
4 Sleeve 1
5 Needle bearing 1
6 Pinion 1
7 Nut 1
8 Forward gear shim —
9 Taper roller bearing assembly 1 Not reusable
10 Forward gear 1
11 Lower case 1

6-15 6D55F11
 Drive shaft and lower case
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward

1
gear.

CAUTION:
2
Do not reuse the bearing, always replace

3
S68S6150 it with a new one.

Drive shaft holder 3 1: 90890-06517

Bearing separator 1: 90890-06534

Disassembling the drive shaft

1. Install the pinion nut 1, tighten it finger
tight, and then remove the drive shaft
bearing 2 using a press.
Disassembling the lower case
1. Remove the taper roller bearing outer
race and shim(s).
4
5
6
7
NOTE:
CAUTION:
Install the claws as shown.
• Do not press the drive shaft threads a
directly.
• Do not reuse the bearing, always Bearing puller assembly 1:
replace it with a new one. 90890-06535

Bearing inner race attachment 3:

90890-06643
Stopper guide plate 2: 90890-06501
8
Disassembling the forward gear
1. Remove the taper roller bearing from the
forward gear using a press.
9
6D55F11 6-16
LOWR
Lower unit
2. Remove the drive shaft bearing outer Checking the drive shaft
race, shim(s), and drive shaft sleeve. 1. Check the drive shaft for bends or wear.
Replace if necessary.

2. Measure the drive shaft runout.

NOTE:
Install the claws as shown. S6D56520

Stopper guide plate 3: 90890-06501 Runout limit: 0.5 mm (0.020 in)

Stopper guide stand 4:
90890-06538
Bearing puller assembly 5: Checking the lower case
90890-06535 1. Check the skeg and torpedo for cracks or
damage. Replace the lower case if nec-
3. Remove the needle bearing. essary.

Assembling the lower case

1. Install the needle bearing into the lower
case to the specified depth.

Needle bearing attachment 6:

90890-06615
Driver rod L3 7: 90890-06652
NOTE:
Checking the pinion and forward • Install the needle bearing with the manufac-
gear ture identification mark a facing up.
1. Check the teeth of the pinion, and the • When using the driver rod, do not strike the
teeth and dogs of the forward gear for special service tool in a manner that will
cracks or wear. Replace if necessary. force the stopper b out of place.

Checking the bearings

1. Check the bearings for pitting or rum- Driver rod SL 1: 90890-06602
bling. Replace if necessary. Needle bearing attachment 2:
90890-06615
Bearing depth plate 3: 90890-06603

6-17 6D55F11
 Drive shaft and lower case

Depth c: CAUTION:
185–186 mm (7.283–7.323 in) Add or remove shim(s), if necessary, if

1
replacing the forward gear or lower case.
2. Install the sleeve, original shim(s), and
drive shaft bearing outer race.
Bearing outer race attachment 6:
90890-06625
Driver rod LL 7: 90890-06605

Assembling the forward gear

1. Install a new taper roller bearing into the
2
forward gear using a press.

3
CAUTION:
4
Add or remove shim(s), if necessary, if
replacing the pinion or lower case.

NOTE:
Bearing inner race attachment 1:
90890-06644 5
• Apply gear oil to the inside and outside of
Assembling the drive shaft

6
the sleeve before installation.
1. Install a new drive shaft bearing onto the
• Install the sleeve with the projection d fac-
drive shaft using a press.
ing forward.

Bearing outer race attachment 4:

90890-06628
Driver rod LS 5: 90890-06606 7
3. Install the original shim(s) and taper roller

8
bearing outer race.

Bearing inner race attachment 1:

90890-06643

9
6D55F11 6-18
LOWR
Lower unit
Installing the pinion
1. Install the forward gear, then the drive
LT
shaft assembly, pinion, and pinion nut,
572 5
and then tighten the nut to the specified
torque.
4
1
G

S6D56260

Propeller shaft housing bolt:

11 N·m (1.1 kgf·m, 8.1 ft·lb)

T.
R.
S68S6410 Installing the water pump and shift
rod
Drive shaft holder 3 1: 90890-06517 1. Install the shift rod 1, new gasket 2,
and oil seal housing 3.

2. Install the shift rod plate 4, and shift rod

Pinion nut:
bracket 5, and then tighten the bolts 6.
50 N·m (5.0 kgf·m, 36.9 ft·lb)
T.
R.

Installing the propeller shaft housing

1. Install the washer 1 and propeller shaft
assembly 2 into the propeller shaft
housing assembly 3.

2. Apply grease to the new O-rings.

3. Install the outer plate cartridge, and then

install the woodruff key into the drive
shaft.
3. Install the propeller shaft housing assem- 4. Align the groove in the impeller 7 with
bly 4 into the lower case, and then the Woodruff key 8, and then install the
tighten the bolts 5 to the specified impeller onto the drive shaft.
torque.

6-19 6D55F11
 Drive shaft and lower case

C
c
A

d 1
2
B

5. Install the new O-ring 9 and insert car-

tridge 0 into the pump housing A, and
then apply grease to the inside of the
insert cartridge.

9
0
3
S6D56300
b

A
NOTE:
• When installing the pump housing, apply
grease to the inside of the housing, and
4
a then turn the drive shaft clockwise while

5
A pushing down the pump housing.
S6D56290
• Align the cover projection c with the hole
d in the pump housing.
NOTE:
Align the insert cartridge projection a with
the hole b in the pump housing. 7. Install the extension plate D, and then

6. Install the pump housing assembly B

into the lower case, and then install the
tighten the bolts E.
6
cover C.

7
8
È S-transom model
É L-transom model 9
6D55F11 6-20
LOWR
Lower unit
Installing the lower unit 5. Install the trim tab 5 to its original posi-
1. Set the remote control lever or shift lever tion, and then tighten the trim tab bolt 6.
to reverse.
È
R
N

S6D56310

É
N
F R

Lower case mounting bolt 2:

S6D56320
37 N·m (3.7 kgf·m, 27.3 ft·lb)
T.
R.

È Tiller handle model

É Remote control model
Length a: 8–9 mm (0.31–0.35 in)

6. Install the propeller and propeller nut,

and then tighten the nut finger tight.
Place a block of wood between the anti-
cavitation plate and propeller to keep the
propeller from turning, and then tighten
the nut to the specified torque.

2. Install the two dowels 1 into the lower

unit.

3. Install the lower unit into the upper case,

and then tighten the lower case mounting
bolts 2 to the specified torque.

4. Turn the adjusting nut 3 to the specified

length a, and then tighten the locknut
4.

6-21 6D55F11
 Drive shaft and lower case
8. Install the check screw and quickly install
the drain screw.

1
WARNING
2
• Do not hold the propeller with your

3
hands when loosening or tightening it.
• Be sure to remove the clip from the
engine stop lanyard switch.
• Put a block of wood between the anti-
cavitation plate and propeller to keep
the propeller from turning.

NOTE:
If the grooves in the propeller nut 7 do not
4
align with the cotter pin hole, tighten the nut
until they are aligned.

Propeller nut 7:
5
34 N·m (3.4 kgf·m, 25.1 ft·lb)
T.
R.

7. Insert a gear oil tube or gear oil pump

into the drain hole and slowly fill the gear
oil until oil flows out of the check hole and
6
no air bubbles are visible.

7
8
Recommended gear oil:
Hypoid gear oil
9
SAE: 90
Oil quantity:
320 cm3 (10.8 US oz, 11.3 Imp oz)

6D55F11 6-22
LOWR
Lower unit
Shimming 6

T3

B3
A3

42.5

T1 T2
24.0 24.0
B1 B2
A1 A2
S6D56370

6-23 6D55F11
 Shimming
Shimming 2. Install the pinion and pinion nut, and then
tighten the nut to the specified torque.
NOTE:
• Shimming is not required when assembling Pinion nut:
the original lower case and inner parts. 50 N·m (5.0 kgf·m, 36.9 ft·lb)
1

T.
R.
• Shimming is required when assembling the
original inner parts and a new lower case. 3. Measure the distance (M3) between the
• Shimming is required when replacing the special service tool and the pinion as
inner part(s).

2
shown.

Selecting the pinion shims

1. Install the special service tools onto the
drive shaft 1.

3
Digital caliper 4: 90890-06704
4
5
6
NOTE:
• Select the shim thickness (T3) by using the
specified measurement(s) and the calcula-
7
tion formula.
• Install the special service tool onto the drive
shaft so that the shaft is at the center of the
hole.
• Tighten the wing nuts another 1/4 of a turn
8
after they contact the plate 2.

Pinion height gauge plate B 2:

90890-06712
9
Pinion height gauge 3:
90890-06710

6D55F11 6-24
LOWR
Lower unit
4. Calculate the pinion shim thickness (T3) Example:
as shown in the examples below. If “T3” is 1.25 mm, then the pinion shim is 1.3
mm.
If “T3” is 1.75 mm, then the pinion shims are
0.7 and 1.1 mm.
+5 +5
-1
Selecting the forward gear shims
a
1. Turn the taper roller bearing outer race
1 two or three times to seat the rollers,
and then measure the bearing height
(M1) as shown.
S6D56390

NOTE:
“P” is the deviation of the lower case dimen-
sion from standard. The “P” mark a is
stamped on the anode mounting surface of
the lower case in 0.01 mm units. If the “P”
mark is unreadable, assume that “P” is zero
and check the backlash when the unit is
assembled.

Calculation formula:
Pinion shim thickness (T3) =
M3 – 27.00 – P/100

Example:
If “M3” is 28.30 mm and “P” is (+5), then
T3 = 28.30 – 27.00 – (+5)/100 mm
= 1.3 – 0.05 mm
= 1.25 mm
NOTE:
5. Select the pinion shim(s) (T3) as follows.
• Select the shim thickness (T1) by using the
Calculated numeral Shim size to specified measurement(s) and the calcula-
use tion formula.
More than Up to
• Measure the bearing outer race at three
1.10 1.20 1.2 points to find the height average.
1.20 1.30 1.3
1.30 1.40 1.4
Shimming plate 2: 90890-06701
1.40 1.50 1.5 Digital caliper 3: 90890-06704
1.50 1.60 1.6
1.60 1.70 0.7 + 1.0 2. Calculate the forward gear shim thick-
1.70 1.83 0.7 + 1.1 ness (T1) as shown in the examples
below.
Available shim thicknesses:
0.7, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, and
1.6 mm

6-25 6D55F11
 Shimming
Selecting the reverse gear shims
1. Install the ball bearing onto the propeller
a
shaft housing.

1
+5 +5
-1
2. Measure the bearing housing height (M2)
as shown.

NOTE:
S6D56400

“F” is the deviation of the lower case dimen-

2
sion from standard. The “F” mark a is
stamped on the anode mounting surface of
the lower case in 0.01 mm units. If the “F”
mark is unreadable, assume that “F” is zero
and check the backlash when the unit is
3
assembled.

Calculation formula:
Forward gear shim thickness (T1) =
4
17.50 + F/100 – M1

Example:
If “M1” is 16.25 mm and “F” is (+5), then
T1 = 17.50 + (+5)/100 – 16.25 mm
5
= 17.50 + 0.05 – 16.25 mm
= 1.30 mm

3. Select the forward gear shim(s) (T1) as

follows.
NOTE:
6
• Select the shim thickness (T2) by using the

7
Calculated numeral Shim size to specified measurement(s) and the calcula-
use tion formula.
More than Up to
• Measure the bearing housing at three
0.99 1.10 1.0 points to find the height average.
1.10 1.20 1.1
1.20
1.30
1.40
1.30
1.40
1.50
1.2
1.3
1.4
Shimming plate 1: 90890-06701
Digital caliper 2: 90890-06704 8
Available shim thicknesses:
1.0, 1.1, 1.2, 1.3, and 1.4 mm

Example:
9
If “T1” is 1.15 mm, then the forward gear
shim is 1.1 mm.
If “T1” is 1.30 mm, then the forward gear
shim is 1.2 mm.

6D55F11 6-26
LOWR
Lower unit
3. Calculate the reverse gear shim thick- Example:
ness (T2) as shown in the examples If “T2” is 1.05 mm, then the reverse gear
below. shim is 1.0 mm.
If “T2” is 1.20 mm, then the reverse gear
a shim is 1.1 mm.

+5
-1
+5 Backlash 6

Measuring the forward and reverse

gear backlash
1. Remove the water pump assembly.

2. Set the gear shift to the neutral position

S6D56430
at the lower unit.
NOTE:
“R” is the deviation of the lower case dimen- 3. Install the special service tools so that it
sion from standard. The “R” mark a is pushes against the propeller shaft.
stamped on the anode mounting surface of
the lower case in 0.01 mm units. If the “R”
mark is unreadable, assume that “R” is zero
and check the backlash when the unit is
assembled.

Calculation formula:
Reverse gear shim thickness (T2) =
80.00 + R/100 – M2

Example: NOTE:
If “M2” is 78.79 mm and “R” is (–1), then Tighten the center bolt while turning the drive
T2 = 80.00 + (–1)/100 – 78.79 mm shaft until the drive shaft can no longer be
= 80.00 – 0.01 – 78.79 mm turned.
= 1.20 mm
Bearing housing puller claw S 1:
4. Select the reverse gear shim(s) (T2) as
90890-06564
follows.
Stopper guide plate 2: 90890-06501
Calculated numeral Shim size to Center bolt 3: 90890-06504
More than Up to use
4. Install the backlash indicator onto the
0.99 1.10 1.0
drive shaft (16.0 mm [0.63 in] in diame-
1.10 1.20 1.1 ter), then the dial gauge onto the lower
1.20 1.30 1.2 unit.
1.30 1.32 1.3

Available shim thicknesses:

1.0, 1.1, 1.2, and 1.3 mm

6-27 6D55F11
 Shimming / Backlash
7. Remove the special service tools from
the propeller shaft.

8. Apply a load to the reverse gear by

installing the propeller 8 (without the
spacer 9), the collar 0, then the washer
A as shown.
1
2
NOTE:
Install the dial gauge so that the plunger a
contacts the mark b on the backlash indica-
3
tor. NOTE:

Backlash indicator 4: 90890-06706

Magnet base plate 5: 90890-07003
Tighten the propeller nut B while turning the
drive shaft until the drive shaft can no longer
be turned.
4
Dial gauge set 6: 90890-01252
Magnet base B 7: 90890-06844

5. Slowly turn the drive shaft clockwise and

9. Slowly turn the drive shaft clockwise and
counterclockwise and measure the back-
lash when the drive shaft stops in each
direction.
5
counterclockwise and measure the back-
lash when the drive shaft stops in each
direction.

Forward gear backlash:

6
0.30–0.72 mm (0.0118–0.0283 in)

6. Add or remove shim(s) if out of specifica-

tion. 7
Forward gear
Shim thickness
backlash
Less than
0.30 mm (0.0118 in)
More than
To be decreased by
(0.51 – M) × 0.49
To be increased by
8
0.72 mm (0.0283 in) (M – 0.51) × 0.49 Reverse gear backlash:
M: Measurement

Available shim thicknesses:

0.92–1.65 mm (0.0362–0.0650 in)
9
1.0, 1.1, 1.2, 1.3, and 1.4 mm

6D55F11 6-28
LOWR
Lower unit
10. Add or remove shim(s) if out of specifica-
tion.

Reverse gear
Shim thickness
backlash
Less than To be decreased by
0.92 mm (0.0362 in) (1.29 – M) × 0.49
More than To be increased by
1.65 mm (0.0650 in) (M – 1.29) × 0.49

M: Measurement

Available shim thicknesses:

1.0, 1.1, 1.2, and 1.3 mm

11. Remove the special service tools, and

then install the water pump assembly.

6-29 6D55F11
BRKT

Bracket unit

Tiller handle .................................................................................................... 7-1

Assembling the tiller handle....................................................................... 7-3

Bottom cowling .............................................................................................. 7-4

1
Upper case, steering arm ..............................................................................7-6
Draining the engine oil............................................................................. 7-10
Disassembling the oil pan........................................................................7-10
Checking the oil strainer ..........................................................................7-10
2
Checking the oil pan ................................................................................ 7-10

3
Assembling the oil pan ............................................................................7-10
Removing the steering arm ..................................................................... 7-11
Installing the steering arm ....................................................................... 7-12
Installing the upper case..........................................................................7-12

4
Clamp brackets, swivel bracket.................................................................. 7-13
Removing the clamp brackets .................................................................7-16
Disassembling the swivel bracket............................................................ 7-16
Assembling the swivel bracket ................................................................7-16
Installing the clamp brackets ................................................................... 7-17

5
6
7
8
9
6D55F11
BRKT
Bracket unit
Tiller handle 7

No. Part name Q’ty Remarks

1 Throttle cable 2
2 Engine stop lanyard switch 1
3 Nut 1
4 Grommet 1
5 Shift link rod 1
6 Shift lever 1
7 Washer 1
8 Wave washer 1
9 Collar 1
10 Nut 1
11 Bolt 1 M6 × 30 mm
12 Self-locking nut 1
13 Nut 1
14 Cable guide 1
15 Bushing 1
16 Steering bracket 1
17 Plastic washer 1

7-1 6D55F11
 Tiller handle
7

1
2
3
4
5
No. Part name Q’ty Remarks
6
18 Metal washer 2
19
20
21
22
Wave washer
Bushing
Tiller handle bracket
Throttle friction adjuster
2
1
1
1
7
23 Throttle grip 1
24
25
26
27
Screw
Washer
Spring
Bushing
1
1
1
1
ø5 × 25 mm

8
28 Throttle shaft 1
29
30
31
32
Friction piece
Bolt
Plate
Nut
1
2
1
2
M6 × 20 mm
9
33 Engine stop lanyard 1

6D55F11 7-2
BRKT
Bracket unit
Assembling the tiller handle
NOTE:
1. Install the engine stop lanyard switch 1
• Route the engine stop lanyard switch lead
to the tiller handle bracket 2. Tighten the
9 and throttle cables 0 and A as shown.
nut to the specified torque.
• Install the corrugated tubes B so that they
2. Install the throttle cables 3 and 4 to the contact the tiller handle bracket C.
throttle shaft 5.
Tiller handle bracket nut 7:
A
3 10 N·m (1.0 kgf·m, 7.4 ft·lb)

T.
R.
Self-locking nut 8:
4 22 N·m (2.2 kgf·m, 16.2 ft·lb)

5 2
1

S6D57020

Engine stop lanyard switch nut:

2 N·m (0.2 kgf·m, 1.5 ft·lb)
T.
R.

3. Install the shift lever to the steering

bracket 6.

4. Install the washers and bushings into the

steering bracket 6.

5. Install the tiller handle bracket to the

steering bracket 6, tighten the tiller han-
dle bracket nut 7 to the specified torque,
and then tighten the self-locking nut 8 to
the specified torque.

C
0
A

7B
8 S6D57030

7-3 6D55F11
 Tiller handle / Bottom cowling
Bottom cowling 7

1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Shift rod lever joint 1 Remote control model
2
3
4
5
Bolt
Bracket
Start-in-gear protection lever
Shift rod lever
4
2
1
1
M6 × 25 mm

7
6 Shift rod 1
7
8
9
10
Bottom cowling
Rubber seal
Grommet
Grommet
1
1
6
1 Remote control model
8
11 Grommet 1 Remote control model
12
13
14
15
Grommet
Socket cord assembly
Cable holder
Bolt
1
1
1
1
Tiller handle model
Remote control model

M6 × 20 mm
9
16 Spring 1
17 Bolt 4 M6 × 30 mm

6D55F11 7-4
BRKT
Bracket unit
7

No. Part name Q’ty Remarks

18 Grommet 4
19 Collar 4
20 Water outlet 1
21 Bolt 1
22 Hook 1
23 Bolt 1 M6 × 20 mm
24 Lever 1
25 Bushing 1
26 Bushing 1
27 Wave washer 1
28 Washer 1
29 Cowling lock lever 1
30 Grommet 1 Tiller handle model
31 Grommet 1 Remote control model
32 Cable guide 1 Remote control model
33 Bolt 2 M6 × 30 mm
34 Retaining plate 1

7-5 6D55F11
 Bottom cowling / Upper case, steering arm
Upper case, steering arm 7

1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Mount housing 2
2
3
4
5
Rubber damper
Rubber damper
Bolt
Bolt
2
1
2
2
M10 × 80 mm
M10 × 120 mm
7
6 Nut 4
7
8
9
10
Screw
Ground lead
Grease nipple
Bolt
1
1
1
3
ø6 × 8 mm

M8 × 30 mm
8
11 Upper mount 1
12
13
14
15
Plate
Bolt
Upper case assembly
Nut
1
2
1
2
M8 × 185 mm
9
16 Steering arm 1
17 Washer 1

6D55F11 7-6
BRKT
Bracket unit
7

No. Part name Q’ty Remarks

18 Bushing 1
19 Straight key 1
20 Bushing 1
21 O-ring 1 Not reusable
22 Bushing 1
23 Nut 2 Remote control model
24 Washer 2 Remote control model
25 Steering hook 1 Remote control model
26 Bolt 1 M8 × 20 mm
27 Rubber seal 1

7-7 6D55F11
 Upper case, steering arm
7

1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Upper case 1
2
3
4
5
Screw
Baffle plate
Dowel
Bolt
2
1
2
4
ø5 × 15 mm

M8 × 30 mm
7
6 Gasket 1
7
8
9
10
Bolt
Washer
Bracket
Exhaust manifold
3
3
1
1
M6 × 50 mm

8
11 Gasket 1 Not reusable
12
13
14
15
Oil pan
Gasket
Drain bolt
Damper
1
1
1
1
Not reusable
M14 × 12 mm
9
16 Dowel 2
17 Bolt 10 M6 × 25 mm

6D55F11 7-8
BRKT
Bracket unit
7

No. Part name Q’ty Remarks

18 Gasket 1 Not reusable
19 Exhaust guide 1
20 Oil seal 1 Not reusable
21 Grommet 1
22 Anode 1
23 Cover 1
24 Bolt 1 M5 × 12 mm
25 Cover 1
26 Bolt 1 M6 × 20 mm
27 Cooling water pipe 1
28 Rubber seal 1
29 Bolt 2 M6 × 16 mm
30 Oil strainer 1
31 Bolt 3 M6 × 25 mm
32 Gasket 1 Not reusable
33 Relief valve housing 1
34 Relief valve 1

7-9 6D55F11
 Upper case, steering arm
Draining the engine oil 2. Check the cooling water pipe for defor-
1. Place a drain pan under the drain hole, mation or corrosion. Replace if neces-
and then remove the drain bolt and let sary.

1
the oil drain completely.
3. Check the relief valve for clogs or dam-
2. Remove the upper and lower mounting age. Replace if necessary.
nuts, and then remove the upper case.
Assembling the oil pan

2
3. Remove the muffler assembly from the 1. Install new gaskets onto the exhaust
upper case. guide 1.

Disassembling the oil pan 2. Install the relief valve assembly 2 and
1. Remove the exhaust manifold and seal bolts.

3
from the oil pan.

2. Remove the oil pan 1 from the exhaust

guide 2.

3. Remove the oil strainer 3 and relief

valve assembly 4 from the exhaust
guide 2. 4
5
6
3. Install the oil strainer 3 and bolts.

7
Checking the oil strainer
1. Check the oil strainer for dirt and residue.
8
Clean if necessary.

Checking the oil pan

1. Check the exhaust guide and exhaust
manifold for damage or corrosion.
9
Replace if necessary.

6D55F11 7-10
 BRKT
Bracket unit
4. Install the cooling water pipe 4.

5. Install the oil pan 5 and bolts, and then

tighten the bolts finger tight.

6. Install the exhaust manifold 6, seal, and

bolts, and then tighten the bolts finger
tight.

7. Tighten the oil pan bolts 7, and tighten

the exhaust manifold bolts 8 to the
specified torque.

Engine oil drain bolt:

27 N·m (2.7 kgf·m, 20.0 ft·lb)
T.
R.

Upper case bolt 0:

21 N·m (2.1 kgf·m, 15.5 ft·lb)

11. Install the upper mount A and bolts B

into the upper case, and then tighten the
bolts to the specified torque.

Exhaust manifold bolt 8:

10 N·m (1.0 kgf·m, 7.4 ft·lb)
T.
R.

8. Install the muffler assembly 9 into the

upper case.

9. Install a new gasket and the engine oil

drain bolt, and then tighten the bolt to the Upper mount bolt:
specified torque. 27 N·m (2.7 kgf·m, 20.0 ft·lb)
T.
R.

10. Install the upper case bolts 0, and then

Removing the steering arm
tighten them to the specified torque.
1. Remove the steering arm from the swivel
bracket by pulling the arm off the bracket.

7-11 6D55F11
 Upper case, steering arm
Installing the steering arm 4. Tighten the lower mounting nuts 5 to the
1. Install the washer 1, bushing 2, and specified torque, then tighten the lower
straight key 3 onto the steering arm 4. mounting nuts 7 to the specified torque.

2. Place the swivel bracket 5 in an upright

position, and then install the steering arm
onto the bracket.
1
2
3
4
3. Install the bushing 6, new O-ring 7, and Upper mounting nut 2:
bushing 8 onto the swivel bracket. 24 N·m (2.4 kgf·m, 17.7 ft·lb)

5
T.
R.

Lower mounting nut 5 and 7:

54 N·m (5.4 kgf·m, 39.8 ft·lb)

6
Installing the upper case
1. Install the upper mounting bolts into the
7
swivel bracket 1.

2. Install the upper mounting nuts 2 and

then tighten them to the specified torque. 8
3. Install the lower mount housing 3, lower
mounting bolts 4, lower mounting nuts
5, lower mounting bolts 6, and lower
mounting nuts 7, and then tighten the
nuts finger tight.
9
6D55F11 7-12
BRKT
Bracket unit
Clamp brackets, swivel bracket 7

No. Part name Q’ty Remarks

1 Tilt pin 1
2 Spring 1
3 Bolt 1 M8 × 255 mm
4 Collar 1
5 Washer 1
6 Nut 1
7 Cap nut 2
8 Self-locking nut 2
9 Plate 1
10 Through tube 1
11 Clamp bracket 1
12 Washer 2
13 Bushing 2
14 Swivel bracket 1
15 Clamp bracket 1
16 Nut 2
17 Washer 2

7-13 6D55F11
 Clamp brackets, swivel bracket
7

1
2
3
4
5
No. Part name Q’ty Remarks
6
18 Plastic washer 2
19
20
21
22
Tilt stopper plate
Wave washer
Bolt
Pin
2
2
2
1
7
23 Bushing 2
24
25
26
27
Pin
Circlip
Collar
Bushing
1
2
1
1
8
28 Grease nipple 3

9
6D55F11 7-14
BRKT
Bracket unit
7

No. Part name Q’ty Remarks

1 Spring 1
2 Tilt lock rod 1
3 Tilt lever 1
4 Screw 1 ø5 × 5 mm
5 Collar 1
6 Circlip 1
7 Tilt lock lever 1
8 Bushing 1
9 Pin 1
10 Bushing 1
11 Tilt support bar 1
12 Spring 2
13 Pin 1 1
14 Pin 2 1
15 Tilt lock plate 2
16 Tilt lock arm 1
17 Collar 1

7-15 6D55F11
 Clamp brackets, swivel bracket
Removing the clamp brackets 3. Install the tilt support bar A and pin B,
1. Remove the tilt pin, and then remove the and then insert the tilt lock lever C par-
clamp bracket bolt, clamp bracket nut, tially into the swivel bracket.

1
and collar.

2. Remove the tilt stopper plate nuts and tilt

stopper plate bolts.

2
3. Remove the cap nuts, then the self-lock-
ing nuts and plate.

4. Remove the through tube, then disas-

semble the clamp brackets.

5. Remove the pins, tilt stopper plates, and

bushings. 3
Disassembling the swivel bracket
1. Remove the tilt lock lever, tilt lever

4
4. Hook the tilt lock rod D onto the tilt lever
spring, tilt lock rod, pin, and tilt support E and the pin 2 3, hook the spring F
bar. onto the tilt lever E and the tilt support
bar A, and then insert the tilt lock lever
2. Remove the bushings and collar. C into the tilt lever E completely.
3. Remove the pin 1, pin 2, collar, tilt lock
plates, tilt lock arm, and springs.

Assembling the swivel bracket

5
1. Install the tilt lock arm 1, tilt lock plates
2, pin 2 3, pin 1 4, collar 5, springs 6
to the swivel bracket 7. 6
7
8
2. Install the bushings 8 and 9 and collar
9
0 to the swivel bracket.

6D55F11 7-16
 BRKT
Bracket unit
5. Install the screw G to the tilt lever E,
and then install the circlip H to the pin Tilt stopper plate nut:
24 N·m (2.4 kgf·m, 17.7 ft·lb)

T.
B.

R.
Self-locking nut 1:
45 N·m (4.5 kgf·m, 33.2 ft·lb)
G
H Clamp bracket nut 4:
E 8 N·m (0.8 kgf·m, 5.9 ft·lb)
B
6. Apply water resistant grease to the
grease nipples.

S6D57220

NOTE:
After installation, check the tilt lock lever for
proper operation.

Tilt lever screw:

4 N·m (0.4 kgf·m, 3.0 ft·lb)
T.
R.

NOTE:
Installing the clamp brackets Apply the grease until it comes out of the
1. Install the bushings, tilt stopper plates, bushings a.
and pins to the swivel bracket assembly.

2. Assemble the clamp brackets, washers,

and swivel bracket, and then install the
through tube.

3. Install the plate, tighten the self-locking

nuts 1 to the specified torque, and then
tighten the cap nuts.

4. Install the tilt stopper plate bolts and tilt

stopper plate nuts, and then tighten the
nuts to the specified torque.

5. Install the collar 2 and clamp bracket

bolt 3, and then tighten the clamp
bracket nut 4 to the specified torque.

7-17 6D55F11
 – +
ELEC

Electrical systems

Special service tools .....................................................................................8-1

Checking the electrical components............................................................ 8-2

Measuring the peak voltage ...................................................................... 8-2
1
Measuring the lower resistance.................................................................8-2

Electrical components................................................................................... 8-3

Front and aft views .................................................................................... 8-3
Port and starboard views...........................................................................8-4
2
Wiring diagram .......................................................................................... 8-5

3
Checking the ignition spark gap ................................................................8-7
Checking the spark plug caps ...................................................................8-7
Checking the ignition coil...........................................................................8-7
Checking the CDI unit................................................................................ 8-8
Checking the pulser coil ............................................................................8-8
Checking the charge coil ...........................................................................8-9
Checking the power bobbin ....................................................................... 8-9
Checking the lighting coil...........................................................................8-9
Checking the engine stop lanyard switch ................................................ 8-10
Checking the thermo sensor.................................................................... 8-10
4
Checking the oil pressure switch ............................................................. 8-10
Checking the oil pressure warning indicator............................................8-11
5
6
7
8
9
6D55F11
 – +
ELEC
Electrical systems
Special service tools 8

Ignition tester
90890-06754

Digital circuit tester

90890-03174

Peak voltage adapter B

90890-03172

Test harness (2 pins)

New: 90890-06868
Current: 90890-06768

Vacuum/pressure pump gauge set

90890-06756

8-1 6D55F11
 Special service tools / Checking the electrical components
Checking the electrical Measuring the lower resistance
components 8
When measuring a resistance of 10 Ω or less
Measuring the peak voltage with the digital circuit tester, the correct mea-

1
surement cannot be obtained due to the
NOTE: internal resistance of the tester. To obtain the
Before troubleshooting the peak voltage, correct value, subtract the internal resistance
check that all electrical connections are tight from the displayed measurement.
and free from corrosion, and that the battery
NOTE:
is fully charged to 12 V.

The condition of the ignition system can be

determined by measuring the peak voltage.
To obtain the internal resistance of the digital
circuit tester, connect both of its probes and
check the display.
2
Cranking speed is effected by many factors,
such as fouled or weak spark plugs, or a
weak battery. If one of these factors is
present, the peak voltage will be lower than
specification. In addition, if the peak voltage
Correct value =
displayed measurement – internal
resistance
3
is lower than specification the engine will not
operate properly.
4
DC V

5
WARNING
When checking the peak voltage, do not
S69J8020

6
touch any of the connections of the digital
tester leads.

NOTE:
7
• Use the peak voltage adapter with the digi-

8
tal circuit tester.
• When measuring the peak voltage, set the
selector on the digital circuit tester to the
DC voltage mode.
• Connect the positive pin on the peak volt-
age adapter to the positive terminal of the
digital circuit tester.
9
6D55F11 8-2
 – +
ELEC
Electrical systems
Electrical components 8

Front and aft views

1 CDI unit
2 Ignition coil
3 Engine stop lanyard switch coupler
(remote control model)

8-3 6D55F11
 Electrical components
Port and starboard views

1
2
3
4
5
6
7
8
1 Oil pressure switch
2

9
Thermo sensor
3 Pulser coil
4 Spark plugs
5 Prime Start

6D55F11 8-4
 – +
ELEC
Electrical systems
Wiring diagram

1 CDI unit Color code

2 Oil pressure switch B : Black
3 Stator coil O : Orange
4 Pulser coil P : Pink
5 Thermo sensor R : Red
6 Ignition coil W : White
7 Wiring harness Y : Yellow
8 Prime Start B/W : Black/white
9 Engine stop lanyard switch Br/B : Brown/black
0 Oil pressure warning indicator G/W : Green/white
P/W : Pink/white
R/W : Red/white
W/G : White/green
Y/B : Yellow/black
Y/R : Yellow/red

8-5 6D55F11
 F25CMH, F25CM

6D55F11
3

4 Y
Y

R W

1 C
5
W/G Y/B
B
2 G/W Y/B

P R/W B Br/B Br/B

A
R/W P Y W/G B O W/G Y/B
Br/B Y/R Y G/W P/W B/W P G/W Y/B B B Br/B Br/B

6
B/W B
Y/R Y/R O O

0
P P/W

9
W W

Y/B Y/B
Y Y
7
A B C
Br/B Y Y G/W B
R/W P Y/R W/G W
Y Y

8 R
R/W

B P/W O B/W

S6D5WD01

8-6
Electrical components

9
8
7
6
5
4
3
2
1
 – +
ELEC
Electrical systems
Checking the ignition spark gap
1. Disconnect the spark plug caps from the
spark plugs.

2. Connect a spark plug cap to the special

service tool.

2. Measure the spark plug cap resistance.

Replace if out of specification.

S6D58040

Ignition tester: 90890-06754

3. Crank the engine and observe the spark

through the discharge window of the
spark gap tester. Check the ignition sys-
tem if the spark is weak.
Spark plug cap resistance: 4–6 kΩ

Checking the ignition coil

1. Remove the spark plug caps from the
spark plug wires by turning the caps
counterclockwise.

2. Disconnect the ignition coil connectors.

S6D58050
3. Measure the ignition coil resistance.
WARNING Replace if out of specification.
• Do not touch any of the connections of
the spark gap tester leads.
• Do not let sparks leak out of the
removed spark plug caps.
• Keep flammable gas or liquids away,
since this test can produce sparks.

Checking the spark plug caps

S6D58070
1. Remove the spark plug caps from the
spark plug wires by turning the caps
counterclockwise.

8-7 6D55F11
 Electrical components

Ignition coil resistance: R W

Primary coil:
Orange (O) – Black (B)
0.08–0.11 Ω at 20 °C (68 °F)
Secondary coil:
Spark plug wire – spark plug wire
R/W B 1
3.4–4.7 kΩ at 20 °C (68 °F)

Checking the CDI unit

1. Measure the CDI unit output peak volt-
age. If below specification, measure the
S6D58090

Digital circuit tester: 90890-03174

2
Peak voltage adapter B:
pulser coil output peak voltage. Replace
90890-03172
the CDI unit if the output peak voltage of
the pulser coil is above specification.
Test harness (2 pins):
New: 90890-06868
Current: 90890-06768
3
r/min
Pulser coil output peak voltage:
Red (R) – White (W)
Unloaded Loaded
4
Cranking 1,500 3,500

Digital circuit tester: 90890-03174

DC V 6.0 5.7

Pulser coil resistance

14.0 20.4
5
Peak voltage adapter B: (reference data):

6
90890-03172 Red (R) – White (W)
300–350 Ω at 20 °C (68 °F)

CDI unit output peak voltage:

Black/white (B/W) – Orange (O)

r/min

DC V
Cranking
120
Loaded
1,500
120
3,500
130
7
8
Checking the pulser coil
1. Disconnect the pulser coil coupler.

2. Connect the test harness (2 pins) to the

pulser coil.

3. Measure the pulser coil output peak volt-

age. Replace the pulser coil if below
specification.
9
6D55F11 8-8
 – +
ELEC
Electrical systems
Checking the charge coil
1. Measure the charge coil output peak volt- Digital circuit tester: 90890-03174
age. Replace the stator coil if below Peak voltage adapter B:
specification. 90890-03172

Power bobbin output peak voltage:

Yellow/black (Y/B) –
Yellow/black (Y/B)
Unloaded
r/min
Cranking 1,500 3,500
DC V 10.0 38.9 80.0
Loaded
r/min
Cranking 1,500 3,500
Digital circuit tester: 90890-03174 DC V 5.5 30.0 80.0
Peak voltage adapter B:
90890-03172
Power bobbin resistance
(reference data):
Charge coil output peak voltage: Yellow/black (Y/B) –
Green/white (G/W) – Yellow/black (Y/B)
White/green (W/G) 6.50–7.20 Ω at 20 °C (68 °F)
Unloaded Loaded
r/min Checking the lighting coil
Cranking 1,500 3,500
1. Measure the lighting coil output peak
DC V 170 130 140 140
voltage. Replace the stator coil if below
specification.
Charge coil resistance
(reference data):
Green/white (G/W) –
White/green (W/G)
660–710 Ω at 20 °C (68 °F)

Checking the power bobbin

1. Measure the power bobbin output peak
voltage. Replace the stator coil if below
specification.
Digital circuit tester: 90890-03174
Peak voltage adapter B:
90890-03172

Lighting coil output peak voltage:

Yellow (Y) – Yellow (Y)
Unloaded
r/min
Cranking 1,500 3,500
DC V 9.4 46.0 95.0

8-9 6D55F11
 Electrical components
2. Measure the thermo sensor resistance.
Lighting coil resistance Replace if out of specification.
(reference data):
Yellow (Y) – Yellow (Y) Thermo sensor resistance:
0.90–1.10 Ω at 20 °C (68 °F)

Checking the engine stop lanyard

Brown/black (Br/B) –
Brown/black (Br/B)
at 20 °C (68 °F): 1.13–1.38 kΩ
1
switch at 50 °C (122 °F): 324–396 Ω
at 80 °C (176 °F): 113–139 Ω
1. Check the engine stop lanyard switch for
continuity. Replace if out of specification.
Checking the oil pressure switch
1. Connect the special service tool to the oil
2
pressure switch.

2. Slowly operate the special service tool.

3
4
5
Switch position
Lead color
White (W) Black (B)
3. Check the switch for continuity at the
specified pressure. Replace if there is no
6
Clip removed a continuity.
Clip installed b
Engine stop button
pushed c
Vacuum/pressure pump gauge set:
90890-06756 7
Checking the thermo sensor

8
Specified oil pressure:
1. Place the thermo sensor in a container of 15.5 kPa (0.16 kgf/cm2, 2.25 psi)
water and slowly heat the water.

9
S69J8250

6D55F11 8-10
 – +
ELEC
Electrical systems
Checking the oil pressure warning
indicator
1. Connect a penlight battery (1.5 V) to the
oil pressure warning indicator (LED).
Replace if it does not light.

CAUTION:
Only use a penlight battery (1.5 V) when
checking the LED. Other batteries (e.g.,
alkaline batteries or high-voltage batter-
ies) will damage the diode.

NOTE:
• The LED will not light if the penlight battery
voltage is less than 1.5 V.
• The LED only allows current to flow in one
direction. Therefore, if the LED does not
light, reverse the connection.
• If the oil pressure warning indicator is
installed to the outboard motor, start the
engine and ground the pink (P) lead to
check if the LED lights.

8-11 6D55F11
TRBL
SHTG
Troubleshooting

Power unit....................................................................................................... 9-1

1
2
3
4
5
6
7
8
9
6D55F11
TRBL
SHTG Troubleshooting

NOTE:
• Before troubleshooting the outboard motor, check the compression pressure, valve clearance, the
mounting and rigging of the outboard motor, and the operation of the manual starter. Also, make
sure that specified fuel has been used.
• Check that all electrical connections are tight and free from corrosion.
• To diagnose a mechanical malfunction, use the troubleshooting charts for each trouble located in
this chapter. Also, when checking and maintaining the outboard motor, see Chapters 3–8 for safe
maintenance procedures.

Power unit 9

Symptom 1: Engine does not start, or starting the engine is difficult.

• Manual starter is operating normally.
• Air vent screw on the fuel tank is open.

Ignition system

Check the engine stop lanyard

switch for continuity (with clip
installed).

Yes Replace the engine stop lan-

Is there continuity?
yard switch.
No

Check the condition of the spark

plugs.

No Clean, adjust, or replace the

Good condition?
spark plugs.
Yes

Check the ignition spark using

the spark gap tester.

WARNING
• Do not touch any of the connections of the spark gap tester leads.
• Do not let sparks leak out of the removed spark plug caps.
• Keep flammable gas and liquids away, since this test can produce
sparks.

Continued on next page.

9-1 6D55F11
 Power unit

Good spark?

No
Yes
Check the fuel system.
1
Check the ignition coil resis-
tance.
2
No
Good condition? Replace the ignition coil.

Yes
Check the spark plug cap resis-
tance and the spark plug caps
3
for salt buildup.

Good condition?
No Repair or replace the spark plug
caps.
4
Yes

Check the charge coil output

peak voltage.
5
Good condition?

Yes
No
Replace the stator coil.
6
Check the pulser coil output
peak voltage or resistance.
7
No
Good condition? Replace the pulser coil.

Yes

Check the CDI unit output peak

8
voltage.

9
Continued on next page.

6D55F11 9-2
TRBL
SHTG Troubleshooting

Yes
Good condition? Check the fuel system.

No

Replace the CDI unit.

Fuel system

Check the fuel filter for clogs

and the hoses for leaks.

Yes Repair or replace the defective

Clogs or leaks?
parts.
No

Check the fuel pump dia-

phragms.

Yes
Cracks or damage? Replace the diaphragms.

No
Disassemble the carburetor and
check the internal parts for
clogs, debris, or wear.

Clogs, debris, Yes Clean or replace the defective

or wear? parts.
No

Check the ignition system.

9-3 6D55F11
 Power unit
Symptom 2: Engine speed at wide open throttle is low, engine speed decreases, or engine
stalls (poor acceleration or poor deceleration).
Symptom 3: Engine speed not stable at low speeds.

1
• Air vent screw on the fuel tank is open.
• Check the throttle cable and link operation.
• Check the ignition system.

Fuel system

Check the fuel filter for clogs

and the hoses for leaks.
2
Clogs or leaks?

No
Yes Repair or replace the defective
parts. 3
4
Check the fuel pump dia-
phragms.

Yes
Cracks or damage? Replace the diaphragms.

No

Check the throttle valve opera-

5
tion.

Good condition?
No Repair or replace the defective
parts.
6
7
Yes

Check the pilot screw setting.

Continued on next page.

8
9
6D55F11 9-4
TRBL
SHTG Troubleshooting

No
Within specification? Adjust the pilot screw.

Yes
Disassemble the carburetor and
check the internal parts for
clogs, debris, or wear.

Clogs, debris, Yes Clean or replace the defective

or wear? parts.
No

Check the ignition system or

lubrication system.

9-5 6D55F11
 Power unit
Lubrication system

1
Check the engine oil level.

No Add engine oil to the correct

At specified level?
level.
Yes

Check the oil pressure.

2
Within specification?
No Check the oil pump for debris or
oil leaks.
3
Yes

Debris or leaks?

Yes
No Check the oil
passage. 4
Check the oil pressure switch.
Clean or replace the defective
parts.
5
No
Good condition?

6
Replace the oil pressure switch.

Yes

Check the thermo sensor.

Good condition?
No
Replace the thermo sensor.
7
Yes

Check the ignition system or the

fuel system.
8
9
6D55F11 9-6
Index

A. Checking the crankshaft main journal oil

clearance ................................................ 5-42
Adjusting the throttle cable
Checking the cylinder bore ....................... 5-37
(remote control model)..............................3-8
Checking the cylinder head ...................... 5-29
Adjusting the throttle cables
Checking the diaphragms and valves......... 4-6
(tiller handle model) ..................................3-8
Checking the drive shaft ........................... 6-17
Adjusting the throttle link.............................3-7
Checking the electrical components........... 8-2
Adjusting the throttle stop screw ...............4-13
Checking the engine idle speed ............... 3-10
After test run .............................................1-10
Checking the engine oil .............................. 3-4
Applicable models.......................................1-5
Checking the engine oil level...................... 1-6
Assembling the carburetor ........................4-12
Checking the engine stop lanyard
Assembling the drive shaft........................6-18
switch...............................................1-9, 8-10
Assembling the forward gear ....................6-18
Checking the fuel filter ................................ 3-3
Assembling the fuel pump...........................4-6
Checking the fuel joint ................................ 4-7
Assembling the lower case .......................6-17
Checking the fuel joint and fuel hoses
Assembling the manual starter .................5-13
(fuel joint-to-carburetor) ............................ 3-3
Assembling the oil pan..............................7-10
Checking the fuel pump.............................. 4-5
Assembling the oil seal housing................6-14
Checking the fuel system ........................... 1-6
Assembling the pistons and
Checking the gear oil level ................1-6, 3-11
cylinder block ..........................................5-44
Checking the gear shift and
Assembling the propeller shaft
throttle operation....................................... 1-8
assembly.................................................6-12
Checking the gear shift operation
Assembling the propeller shaft housing ....6-13
(remote control model) ............................. 3-9
Assembling the swivel bracket..................7-16
Checking the gear shift operation
Assembling the tiller handle ........................7-3
(tiller handle model) .................................. 3-9
Checking the ignition coil............................ 8-7
B. Checking the ignition spark gap ................. 8-7
Backlash ...................................................6-27 Checking the ignition timing...................... 3-10
Bottom cowling............................................7-4 Checking the lighting coil............................ 8-9
Bracket......................................................3-11 Checking the lower case .......................... 6-17
Break-in.....................................................1-10 Checking the lower unit for air leakage .... 3-12
Checking the oil pan ................................. 7-10
C. Checking the oil pressure ........................... 5-3
Carburetor...................................................4-9 Checking the oil pressure switch .............. 8-10
Carburetor unit ............................................4-8 Checking the oil pressure warning
Changing the engine oil ..............................3-4 indicator .................................................. 8-11
Changing the gear oil................................3-12 Checking the oil pump .............................. 5-30
Checking the anodes ................................3-13 Checking the oil strainer ........................... 7-10
Checking the balancer ..............................5-37 Checking the outboard motor mounting
Checking the bearings ..............................6-17 height........................................................ 1-7
Checking the camshaft .............................5-29 Checking the pinion and forward gear...... 6-17
Checking the carburetor............................4-11 Checking the piston clearance ................. 5-38
Checking the CDI unit .................................8-8 Checking the piston diameter ................... 5-37
Checking the charge coil.............................8-9 Checking the piston pin ............................ 5-39
Checking the compression pressure...........5-3 Checking the piston pin boss bore ........... 5-39
Checking the connecting rod big end Checking the piston ring grooves ............. 5-39
side clearance.........................................5-40 Checking the piston ring side clearance... 5-39
Checking the connecting rod small end Checking the piston rings ......................... 5-38
inside diameter........................................5-40 Checking the power bobbin ........................ 8-9
Checking the cooling water passage ..........3-7 Checking the Prime Start.......................... 4-12
Checking the cooling water pilot holes........1-9 Checking the propeller.............................. 3-12
Checking the crankpin oil clearance .........5-41 Checking the propeller shaft and
Checking the crankshaft ...........................5-40 shift rod................................................... 6-12

i-1 6D55F11
 Index
Checking the propeller shaft housing........6-12 F.
Checking the pulser coil..............................8-8
Fire prevention............................................ 1-3
Checking the remote control cables
Front and aft views ..................................... 8-3
(remote control model)..............................1-7

1
Fuel hoses and fuel filter ............................ 4-3
Checking the rocker arms and
Fuel pump................................................... 4-4
rocker arm shaft ......................................5-28
Fuel system ................................................ 3-3
Checking the spark plug caps.....................8-7
Checking the spark plugs............................3-6
Checking the spiral spring.........................5-13 G.
Checking the start-in-gear protection..........3-9
Checking the steering system.....................1-8
Checking the thermo sensor .....................8-10
Checking the thermostat .............................3-6
General..................................................... 3-13
General specifications ................................ 2-1
General torques........................................ 2-13
Good working practices .............................. 1-4
2
Checking the tilt operation ........................3-11
Checking the timing belt..............................3-5
Checking the timing belt and sprockets ....5-17
Checking the top cowling ............................3-3
Checking the valve clearance .....................5-4
H.
Hose routing ............................................... 4-2
How to use this manual .............................. 1-1 3
Checking the valve guides ........................5-25
I.

4
Checking the valve seat............................5-26
Checking the valve springs .......................5-24 Identification ............................................... 1-5
Checking the valves..................................5-24 Installing the camshaft.............................. 5-31
Installing the clamp brackets .................... 7-17
Checking the water pump ...........................6-8
Clamp brackets, swivel bracket ................7-13 Installing the cylinder head ....................... 5-47
Control system ............................................3-7 Installing the lower unit ............................. 6-21

D.
Cylinder block ...........................................5-33
Cylinder head............................................5-20
Installing the oil pump............................... 5-32
Installing the pinion................................... 6-19
Installing the power unit............................ 5-49
Installing the propeller shaft housing ........ 6-19
5
Installing the rocker arm shaft assembly .. 5-32

6
Dimensions .................................................2-9 Installing the sprockets and timing belt..... 5-17
Disassembling the cylinder block..............5-36 Installing the starter rope .......................... 5-14
Disassembling the drive shaft ...................6-16 Installing the steering arm ........................ 7-12
Disassembling the forward gear ...............6-16 Installing the upper case........................... 7-12
Disassembling the fuel pump......................4-5 Installing the valves .................................. 5-30
Disassembling the lower case ..................6-16

7
Installing the water pump and shift rod..... 6-19
Disassembling the manual starter.............5-13
Disassembling the oil pan .........................7-10
Disassembling the oil seal housing...........6-12
L.
Disassembling the propeller shaft Lower unit .................................. 2-7, 3-11, 6-4
Lubricating the outboard motor................. 3-13
assembly.................................................6-11
Disassembling the propeller shaft
housing ...................................................6-11
Disassembling the swivel bracket .............7-16
Disassembly and assembly ........................1-4
M.
Maintenance interval chart ......................... 3-2
Maintenance specification .......................... 2-3
8
Draining the engine oil ..............................7-10 Manual format............................................. 1-1

E.
Drive shaft and lower case........................6-15

Electrical .....................................................2-7
Measuring the forward and reverse gear
backlash ................................................. 6-27
Measuring the lower resistance.................. 8-2
Measuring the peak voltage ....................... 8-2
9
Measuring the starter rope ....................... 5-13
Electrical components.................................8-3

6D55F11 i-2
Index

P. W.
Parts, lubricants, and sealants....................1-3 Wiring diagram ........................................... 8-5
Port and starboard views ............................8-4
Power unit ............................ 2-3, 3-4, 5-3, 9-1
Predelivery checks......................................1-6
Propeller selection ......................................1-5
Propeller shaft housing ...............................6-9
Propeller size ..............................................1-5

R.
Refacing the valve seat.............................5-26
Removing the carburetor ..........................4-11
Removing the clamp brackets...................7-16
Removing the cylinder head .....................5-23
Removing the drive shaft ..........................6-16
Removing the lower unit .............................6-7
Removing the power unit ..........................5-18
Removing the propeller shaft housing
assembly.................................................6-11
Removing the steering arm.......................7-11
Removing the timing belt and sprockets ...5-15
Removing the water pump ..........................6-7
Replacing the oil filter..................................3-5
Replacing the valve guides .......................5-25

S.
Safety while working ...................................1-3
Selecting the connecting rod bearing........5-42
Selecting the crankshaft main bearing......5-43
Selecting the forward gear shims..............6-25
Selecting the pinion shims ........................6-24
Selecting the reverse gear shims..............6-26
Selection .....................................................1-6
Self-protection.............................................1-3
Serial number..............................................1-5
Shimming ........................................ 6-23, 6-24
Special service tools .... 3-1, 4-1, 5-1, 6-1, 8-1
Specified torques ......................................2-11
Symbols ......................................................1-2

T.
Test run.......................................................1-9
Tightening torques ....................................2-11
Tiller handle ................................................7-1
Top cowling.................................................3-3

U.
Upper case, steering arm............................7-6

V.
Ventilation ...................................................1-3

i-3 6D55F11
 YAMAHA MOTOR CO., LTD.

Printed in Japan
Nov. 2003 – 0.4 × 1 CR
(E) Printed on recycled paper