(6BV)

(6BW)

(6BX)

(6BV)

(6BX)

90894-62942-03
 PREFACE
This service guide has been issued to describe the major different points between new F4 [6BV]/
F5 [6BW] /F6 [6BX] and conventional F4 [67D].
We hope this guide will be useful to understand new product structure and mechanism, and support
your service activities.

In this guide particularly important information is distinguished in the following ways.

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 products.

NOTICE
A NOTICE indicates special precautions that must be taken to avoid damages to the prod-
ucts.

The descriptions herein are based on the latest specifications available at the time when this guide
has issued.
For further information, refer to the appropriate service manual and/or service bulletin.
Specifications and descriptions are subject to change without notice.
Photo or figure may be slightly different from the actual model.
For PDF file, access the service portal site that is maintained by Yamaha Motor Co., Ltd.

© 2009 Yamaha Motor Co.,Ltd.

All rights reserved.
Produced by Service Division,
ME Business Unit,
Marine Business Operations
Aug. 2009
 CONTENTS
OUTLINE OF FEATURES ................................................................................................ 1

TECHNICAL FEATURES AND DESCRIPTIONS .......................................................... 2

1. FRIENDLY DESIGN .................................................................................................... 2
2. FORCED THROTTLE OPERATION ........................................................................... 3
3. TILLER HANDLE MOUNT........................................................................................... 4
4. FUEL SYSTEM............................................................................................................ 5
1) FUEL LINE ............................................................................................................. 5
5. LUBRICATION SYSTEM............................................................................................. 6
1) LUBRICATION INSPECTION WINDOW................................................................ 7
2) NEW OIL/ GAS SEPARATION SYSTEM............................................................... 8
6. ELECTRICAL SYSTEM............................................................................................... 9
1) FLYWHEEL MAGNETO ......................................................................................... 9
2) DIGITAL CDI SYSTEM ........................................................................................ 10
7. OVER-REV CONTROL ............................................................................................. 10

RIGGING INFORMATION .............................................................................................. 11

1. DIMENSIONS............................................................................................................ 11
1) MOTOR EXTERIOR............................................................................................. 11
2) CLAMP BRACKET ............................................................................................... 12
2. LIGHTING COIL KIT INSTALLATION (OP FOR EU/ CAN) ...................................... 13
1) LIGHTING COIL KIT CONTENTS........................................................................ 13
2) INSTALLATION PROCEDURE ............................................................................ 14
3. PROPELLER SELECTION........................................................................................ 16
1) WOT OPERATING RANGE ................................................................................. 16
2) PROPELLER APPLICATIONS............................................................................. 16

SERVICE INFORMATION .............................................................................................. 17

1. GENERAL SPECIFICATIONS .................................................................................. 17
2. TIGHTENING TORQUES.......................................................................................... 19
1) SPECIFIED TORQUES (SNIPPET) ..................................................................... 19
2) GENERAL TORQUES ......................................................................................... 20
3. SERVICE DATA (SNIPPET) ..................................................................................... 20
4. PISTON RING INSTALLATION................................................................................. 21
5. TALLY MARK ............................................................................................................ 21
1) CAMSHAFT AND CRANKSHAFT TIMING TALLY MARK................................... 21
2) CON-ROD AND CAP TALLY MARK .................................................................... 21

WIRING DIAGRAM .......................................................................................................... 22

1. F4BMH, F4MHA/ F5AMH/ F6CMH, F6MHA ............................................................. 22
 OUTLINE OF FEATURES
NEW F4 [6BV], F5 [6BW] and F6 [6BX] OVERALL FEATURES;
• New F4, F5 and F6 which have been matured and enhanced from previous F4 [67D].
• Use-friendly and convenient design.
• Low exhaust gas emission conformed with EPA, CARB , EU1, and JMIA (Japan) regula-
tions.
• Recyclable components 98% (weight percent)

POWER UNIT
• White colored top cowl w/ new
graphics (EU)
• Built-in small primary fuel pump
ELECTRICAL • 2-way fuel supply system
• Digital CDI system (built-in & portable fuel tanks)
• Over-rev limiter • Fuel joint cap
• Lighting coil kit (OP) • Slanted fuel filler w/ strainer
• Hollow camshaft w/ automatic
decompression device
• Oil lubrication pump
• Lubrication check window
• 3 positions for horizontal storing
• Forced throttle operation system
• Start-in-gear protection
• Large clamp lever for top cowl

CLAMP BRACKET/
UPPER-CASE
• Short tiller handle
w/ balance weight
• Large shift lever
• Ergonomic large carrying
handle & front grasp
• Automatic reverse lock
• 3-stage shallow water drive
LOWER DRIVE UNIT
• Same as previous F4
• New 8-1/4” pitch prop
(weedless type)

Fig. 1 Outboard motor outline

1
 TECHNICAL FEATURES AND DESCRIPTIONS
1. FRIENDLY DESIGN
The operation devices such as choke knob, stop switch, fuel joint, fuel cock, fuel filler and start han-
dle have been gathered in the front area.
The following designs have been employed to easily handle and operate the engine.

Removable strainer:
Serviceability
Slanted fuel filler:
Easy to pour fuel

Fuel joint cap: Protection

Side storing base

Large shift lever:

Easy to shift

Front grasp: Easy to mount engine Front storing base

Large clamp lever:

Easy to remove/ install
top cowl

Large carrying handle:

Easy to transport
Side storing base

Fig. 2 Friendly design

2
2. FORCED THROTTLE OPERATION
Compared with previous F4, twin throttle wires have been used for the forced open/ close throttle
operation system, which will obtain further reliability.

Lock nut torque:

4 Nm, 0.4 kgf·m, 3 ft·lb

Idle stopper

WOT stopper

Fig. 3 Forced throttle

3
3. TILLER HANDLE MOUNT
To reduce the vibration conducting to the tiller handle, the following design has been adopted.

Short tiller handle w/ balance weight:

The amplitude can be reduced at the handle end.

Handle mount method:

The handle has been mounted onto the bottom cowl with the rubber bushing.
Besides, the bottom cowl is mounted onto the engine with the rubber bushing.

Rubber bushing

Balance weight

Bottom-cowl

Rubber bushing

Fig. 4 Vibration reduction structure

4
4. FUEL SYSTEM
The fuel system outline is shown below.
To obtain sure engine start, the carburetor has been positioned lower than previous F4.
This can allow stable fuel supply into the carburetor from the built-in tank when starting the engine.
Besides, the small primary fuel pump has been employed to supply the fuel into carburetor even if
the fuel level in built-in tank has been lowered or the fuel in carburetor is empty.

Carburetor
Previous F4 position Built-in fuel tank

Fuel Level
New F4/5/6 position
[Lower 60 mm, 2.4 in]

Fuel
feed
pump
Fuel bypass hose
Portable
Fuel
fuel tank
filter
Fuel cock

Small primary pump

w/ check valve

Fig. 5 Fuel system outline

1) FUEL LINE

Built-in fuel tank

w/ filler cap strainer

Fuel selector Portable fuel tank

Fuel joint Primary pump
cock (valve) w/ filler cap strainer

Cowling inside
In-line
fuel filter

Small built-in
Carburetor Fuel feed pump primary pump
w/ check valve

Fig. 6 Fuel line

5
5. LUBRICATION SYSTEM
The trochoid pump is directly connected to the camshaft, and sunk into the oil sump.
The oil passes through the hollow camshaft, and is supplied to the moving parts due to leaking from
the parts clearance and spattering by crankshaft rotation.
Besides, the leaking oil from upper crankshaft journal bearing is accumulated into the hole of crank
pin and supplied to the con-rod big-end through the oil passage of crank pin.
* The automatic decompression system is the same as previous F4.

Crankshaft journal BRG

Crankshaft,
Piston, valve
Camshaft crankpin hole
and related parts
(con-rod big-end)

Oil pump
[Trocoid pump]
Force feed
Droplet/
Strainer spatter

Oil sump (crankcase)

Fig. 7 Oil flow diagram

Oil

Fig. 8 Oil pump location

6
1) LUBRICATION INSPECTION WINDOW
This engine does not have the oil warning system.
Therefore, the lubrication inspection window is useful to check the lubrication status when the
engine is running.
* The oil quantity inspection has to carry out with the oil dipstick in case of pre-operation checks, etc.

Inspection window

Fig. 9 Inspection window

7
2) NEW OIL/ GAS SEPARATION SYSTEM
On previous F4, the engine position was recommended so that the tiller handle faces to the ground
to prevent the oil from leaking when transporting and storing.
However, due to the blow-by-gas hose arrangement, new F4/5/6 will be allowed the 3 horizontal
positions as shown for easier handling.

Previous F4:
Only one position (Handle down) to prevent oil from leaking

New F4/5/6:
3 positions allowed due to oil leak prevention system

Blow-by-gas hose
Oil level
Oil return hose

High-raised
blow-by-gas
hose Oil return
hose

Silencer w/ blow-by-gas/ Separated oil (to return to oil sump)

The high-raised blow-by-gas
hose prevents the oil from oil separator Blow-by-gas/ oil remained in hose
leaking when storing the engine
in the position as shown. Separated gas
(to re-burn to combustion chamber)

Fig. 10 Motor position for transport, storage, etc.

8
6. ELECTRICAL SYSTEM
1) FLYWHEEL MAGNETO
Compact and simple ignition system, Digital CDI, has been employed.
The exciter (charge) coil and ignition coil have been unified.
The ignition is greatly affected by the electric power that is generated by the exciter coil.
Therefore, the air gap of coil is important to maintain proper ignition.

CDI unit ID:

6BV: F4
Digital CDI unit 6BW: F5
6BX: F6

Air gap:
0.5 mm, 0.02 in

M6 bolt:
10 Nm, 1.0 kgf·m, 7.4 ft·lb

Fig. 11 Flywheel magneto

9
2) DIGITAL CDI SYSTEM
On the previous F4, the ignition timing has been fixed.
However, new F4/5/6 has the variable ignition timing to obtain the optimization.
The ignition system is activated as follows;

Before igniting:
When the magnet of flywheel starts passing through the exciter coil, the coil starts generating the
electric power and the electric current [i1] starts flowing.
Then, the electric power is charged into the condenser [C1].

Engine
Condenser
stop SW
[C1] IG coil

Spark plug
Flywheel [i1]
Thyristor [S1]
Exciter coil

Ignition control
circuit

Fig. 12 Circuit state before igniting

Just igniting:
When the magnet has crossed over the coil, the timing is calculated by the signal which carried out
the waveform shaping of the voltage generated in the coil, and the thyristor [S1] is opened by the
electric current [i2] from the control circuit.
Just then, the electric power in condenser is instantly discharged to the ignition primary coil, which
results of igniting the spark plug.

Engine
Condenser
stop SW
[C1] IG coil

Spark plug
Flywheel
Thyristor [S1]
Exciter coil

[i2]

Ignition control
circuit

Fig. 13 Circuit state just igniting

7. OVER-REV CONTROL
This outboard motor is equipped with the over-revolution control system to protect the engine from a
damage.
If the engine speed exceeded 5900 rpm, the ignition is shut off.
When the engine speed dropped below 5900 rpm, the ignition reactivates.

10
 RIGGING INFORMATION
1. DIMENSIONS
1) MOTOR EXTERIOR
F4BMH, F4MHA
F5AMH
F6CMH, F6MHA
mm (in)

90
˚
325 (12.8)
181 (7.1)

153 (6.0)
222 (8.7)
425 (16.7)

130 (5.1) 409 (16.1)

341 (13.4)

S: 635 (25.0)
383 (15.1) L: 753 (29.6)
63 (2.5)
503 (19.8)

430 (16.9)
395 (15.6)
191 (7.5)
39 (1.5)
0.6 (0.02)
S: 435 (17.1)
L: 562 (22.1)

134 (5.3)
S: 644 (25.4)
L: 771 (30.4)

S: 71
(
L: 93 2.8)
S: 555 (21.9)
L: 637 (25.1)

(3.7)
104 (4.1)

12˚
˚
64

259 (10.2)

11
2) CLAMP BRACKET
mm (in)
C/L
82.5 (3.2) 82.5 (3.2)
55 (2.2) 55 (2.2)
47.5 (1.9)
136 (5.4)

22 (0.2)
58 (2.3)

12
2. LIGHTING COIL KIT INSTALLATION (OP FOR EU/ CAN)
For charging to a battery, the lighting coil kit is available as an optional component.

1) LIGHTING COIL KIT CONTENTS

KIT P/N: 6BX-W8130-A0
Part name P/N Q’ty Note
Flywheel 6BX-85550-A0 1 With magnet
Lighting coil 6BX-85510-A0 1 Stator coil
Bolt 97595-06520 3 For coil
Rectifier/ regulator 6BX-81960-00 1
Bolt 97595-06516 2 For rec/ reg
Wire leads 6BX-81949-00 1 With grommet and fuse (20A)
Clamp 90464-30009 1
Clamp stay 6BX-82581-00 1
Plate 6BX-82388-00 1 For mounting fuse box
Bolt 90109-06M80 1 For plate
Clamp 90465-08371 1

Shows the main

components

Fig. 14 Optional lighting coil kit

13
2) INSTALLATION PROCEDURE 5) Remove the grommet on bottom-cowl, and
pass the wire lead through the cowl.
Bolt M6 torque: 6) Install the grommet of wire lead onto the
10 Nm, 1.0 kgf•m, 7.4 ft•lb bottom-cowl, install the clamp to the fuel
Flywheel nut (M12) torque: joint bolt, and route the wire lead.
60 Nm, 6.1 kgf•m, 44 ft•lb

1) Remove the original flywheel.

2) Install the stator coil.

Wire lead

Wire lead clamp

3) Install the rectifier/ regulator.

4) Install the optional flywheel.

14
7) Install the plate, and attach the fuse box to
it.
Plate for fuse box

8) Attach the ground terminals to the clamp

stay bolt, connect the bullet terminals, and
secure them with the clamp as shown.

9) Check that the installed components do

not interfere in the moving part and sharper
edge.

15
3. PROPELLER SELECTION
The estimated and chosen propeller may be standardly installed to the motor from the factory.
However, you should select the best matched propeller to obtain the highest operation performance
due to the hull type, boat weight, purpose of use, etc.
Therefore, some propellers which have different pitch are obtainable.
Besides, several propeller series are prepared for purpose of boat use.
For a greater operating load, a smaller-pitch propeller is more suitable as it enables the correct
engine speed at WOT (wide-open-throttle) to be maintained.
Conversely, a large-pitch propeller is more suitable for a smaller operating load.

1) WOT OPERATING RANGE

With WOT operation and under a maximum boat load, the engine speed should be within the upper
half of the WOT speed range.
Select a propeller which fulfills this requirement.

WOT operating range:

F4: 4000 – 5000 rpm
F5/F6: 4500 – 5500 rpm

NOTICE
Do not exceed the WOT speed range, as an overheat or engine damage could occur.

If the engine exceeds the WOT speed range, replace a propeller to larger-pitch.
Conversely if the engine does not reach the specified range, a smaller-pitch propeller is suitable.
* The engine speed at WOT operation will change approximately 200 rpm if the propeller pitch has been
changed one inch.
However, this varies due to the propeller type, boat type and weight, etc.

2) PROPELLER APPLICATIONS
Yamaha genuine propellers have been prepared for the best fitting to the drive-casing shape of
Yamaha outboard motor, therefore this combination will obtain the best operation performance.
Model Dia. (in) Pitch (in) Mark Material Part number Remarks
F4B 7 1/4 6 1/2 BA Aluminum 6E0-45949-00-EL
F5A 7 1/2 7 BA Aluminum 6E0-45943-01-EL
F6C 7 1/2 8 BA Aluminum 6E0-45941-01-EL
7 1/4 8 1/4 BA Aluminum 6E0-45952-00-EL New, Weedless
F4A[6BV]
F6A[6BX]

16
 SERVICE INFORMATION
1. GENERAL SPECIFICATIONS
Item Model
US/ CA F4MHA — F6MHA
Global F4BMH F5AMH F6CMH
Model prefix code 6BV 6BW 6BX
Starting serial # 1000001 1000001 1000001
DIMENSIONS & WEIGHT
Overall length 539 mm, 21.2 in
Overall width 403 mm, 15.9 in
S: 1039 mm, 40.9 in
Overall height
L: 1166 mm, 45.9 in
S: 435 mm, 17.1 in
Motor transom height
L: 562 mm, 22.1 in
Dry weight w/ a typical AL prop S: 27 kg, 60 lb
(for reference) L: 28 kg, 62 lb
ENGINE UNIT
Engine type 4-stroke, Single, OHV
Prop shaft power output 2.9 kW (4 ps) @4500 rpm 3.7 kW (5 ps) @5000 rpm 4.4 kW (6 ps) @5000 rpm
Total displacement 139 cm3, 8.5 ci
Bore × Stroke 62.0 × 46.0 mm, 2.44 × 1.81 in
1.4 L/h, 1.5 US qt, 1.8 L/h, 1.9 US qt, 2.0 L/h, 2.1 US qt,
Fuel consumption
1.2 Imp qt @4500 rpm 1.6 Imp qt @5000 rpm 1.8 Imp qt @5000 rpm
WOT operating range 4000 – 5000 rpm 4500 – 5500 rpm 4500 – 5500 rpm
Idle speed 1500 rpm
Compression ratio 8.9
Control system Tiller handle
Starting system Manual
Starting enrichment system Choke valve
Cooling system Water
Exhaust system Under water
Lubrication system Wet sump
FUEL & OIL
Fuel classification Regular unleaded gasoline
Fuel rating RON91/ PON86
Built-in tank qty 1.1 L, 1.2 US qt, 1.0 Imp qt
Engine oil classification 4-stroke motor oil
Engine oil grade API: SE, SF, SG, SH, SJ, SL (*1)
(Meeting both API and SAE
SAE: 5W-30, 10W-30, 10W-40
requirements)
Engine oil qty 600 ml, 0.6 US qt, 0.5 Imp qt
Gear oil classification Hypoid gear oil
Gear oil grade
API: GL-4
(Meeting both API and SAE
SAE: #90
requirements)
Gear oil qty 100 ml, 0.1 US qt, 0.1 Imp qt
BRACKET & DRIVE UNIT
Trim angle
4, 8, 12, 16, 20 deg.
(at 12-deg boat transom)
Tilt-up hold angle 64 deg.
Shallow water tilt angle 30, 42, 54 deg.
Steering angle (P + S) 90 + 90 deg.
Gear shift positions F-N-R

17
 Item Model
US/ CA F4MHA — F6MHA
Global F4BMH F5AMH F6CMH
Gear ratio 2.08
Reduction gear type Bevel gear
Clutch type Dog clutch
Prop fitting Spline
Prop rotation R/H
Prop ID mark BA
ELECTRICAL
Ignition control system Digital CDI
Ignition timing BTDC8 - BTDC34.5 BTDC8 - BTDC21 BTDC8 - BTDC32
Generator output (OP) DC 12V - 6 amps
Spark plug #/ gap CR6HSB/ 0.7 mm, 0.028 in
(*1) If 15W-40, 20W-40 or 20W-50 oil is used, select SH, SJ or SL grade.
(*2) Do not expose the coolant inlets to the position upper than water surface while cruising in shallow-water.

18
2. TIGHTENING TORQUES
1) SPECIFIED TORQUES (SNIPPET)
Tightening torques
Part to be tightened Stalk size Q’ty
Nm kgf•m ft•lb
POWER UNIT
1st 13 1.3 9.6
Cylinder head bolt M8 4
2nd 28 2.9 21
Thermostat cover bolt M6 3 8.0 0.8 5.9
Cylinder head cover bolt M6 5 8.0 0.8 5.9
1st 5.0 0.5 3.7
Crankcase bolt M6 10
2nd 11 1.1 8.1
Oil drain bolt M8 1 18 1.8 13
1st 6.0 0.6 4.4
Con-rod cap bolt M7 2
2nd 12 1.2 8.9
Locker arm stud bolt M6 2 10 1.0 7.4
Valve clearance AJT nut (M6) 2 10 1.0 7.4
EX prove plug M8 1 20 2.0 15
Anode mount screw M5 1 2.0 0.2 1.5
Spark plug M10 1 13 1.3 9.2
Flywheel nut (M12) 1 60 6.1 44
Fuel pump bolt M6 2 6.5 0.7 4.8
Driveshaft oil seal HSG bolt M8 1 18 1.8 13
IG coil bolt M6 2 10 1.0 7.4
IN manifold bolt M6 2 11 1.1 8.3
Tiller handle mount bolt M8 1 29 2.9 21
Rear carrying handle bolt M8 2 19 1.9 14
Fuel joint bolt M6 1 8.0 0.8 5.9
Bottom cowl mount bolt M6 4 8.0 0.8 5.9
Bottom cover bolt M6 4 8.0 0.8 5.9
BRACKET/ UPPER CASE/ DRIVE UNIT
Gear case mount bolt M6 2 S:11/ L:15 S:1.1/ L:1.5 S:7.7/ L:11
Shift rod joint bolt M6 1 16 1.6 12
Shift lever mount bolt M8 1 19 1.9 14
Engine mount bolt M6 9 12 1.2 8.9
Through tube nut (M8) 1 15 1.5 11
Gear oil plug M8 2 8.5 0.9 6.3

19
2) GENERAL TORQUES Nut Bolt Tightening torques
This chart specifies the tightening torques for Across
Stalk (B) Nm kgf•m ft•lb
standard bolts or nuts with a standard ISO flats (A)
thread pitch. 8 mm M5 5 0.5 4
To avoid warpage of the components, tighten 10 mm M6 8 0.8 6
the fasteners with a crisscross pattern and pro- 12 mm M8 18 1.8 13
gressive stage until the specific torque is 14 mm M10 36 3.6 27
obtained. 17 mm M12 52 5.2 38
Proper tightening torques will be obtained 22 mm M14 72 7.2 53
under clean and dry threads at room tempera-
ture.

3. SERVICE DATA (SNIPPET)

Item Data Note
Valve clearance IN/ EX 0.08 – 0.12 mm, 0.0031 – 0.0047 in Cold engine
Piston clearance 35 – 65 micron
6BV0/ (1-3/8) EU
F4 carburetor ID/ Pilot screw 6BV1/ NA US/ CAN
6BV2/ (1-3/8) JPN, OTH
6BW0/ (2-1/2) EU
F5 carburetor ID/ Pilot screw 6BW1/ NA US/ CAN
6BW2/ (2-1/2) JPN, OTH
6BX0/ (1-3/8) EU
F6 carburetor ID/ Pilot screw 6BX1/ NA US/ CAN
6BX2/ (1-3/8) JPN, OTH
IG coil air gap 0.5 mm, 0.020 in
Thermostat open temp. 60°C, 140°F
Lighting coil (G - G) 0.71 – 0.86 Ω Stator coil (OP)
Spark plug cap Approx. 5 kΩ
* ( ): Tentative data.
* Electrical resistance should be measured at room temperature.
* For further service data information, see the service manual.

20
4. PISTON RING INSTALLATION

Top ring end gap

Oil ring spacer end gap Put the hook of oil ring upper rail into the
piston hole
* This is to fix the end gap position to avoid
the oil leak when storing horizontally.

UP
10˚

N
Oil ring upper rail For 2nd ring, face [N] mark to up
end gap
Oil ring lower rail Piston ring oversize mark
end gap 1st O/S: N25
2nd O/S: N50
2nd ring end gap

Fig. 15 Piston ring installation

5. TALLY MARK
1) CAMSHAFT AND CRANKSHAFT TIMING TALLY MARK

Camshaft

Timing tally marks

Crankshaft

Fig. 16 Tally mark

2) CON-ROD AND CAP TALLY MARK

Tally mark

Face YAMAHA letters upward

Fig. 17 Tally mark

21
 F5AMH
Lighting coil kit (OP)
Rectifier/Regulator
G G

CDI
1. F4BMH, F4MHA

F6CMH, F6MHA

G G
magneto

Digital W
R CDI unit Spark
B
plug
Lighting coil
R

22
Fuse
[20A] Cylinder
B head

R
B

R
WIRING DIAGRAM

Battery B

Cylinder body Engine

stop SW

Wire color description

Color code Wire color
B Black
G Green
R Red
W White
 YAMAHA MOTOR CO., LTD.
Produced in Japan
Sep. 2009 –0.02 × 1NP
(E)
G20090722034590