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Yamaha F30A Service Manual

Other manuals for F30A: Owner's Manual, Owner's Manual

Summary of F30A

  • Page 1

    F30a f40b service manual 67c-28197-3k-11.

  • Page 2: Notice

    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 conc...

  • Page 3: Contents

    Contents general information 1 gen info specification 2 spec periodic check and adjustment 3 chk adj fuel system 4 fuel power unit 5 powr lower unit 6 lowr bracket unit 7 brkt electrical system 8 elec troubleshooting 9 trbl shtg index – +.

  • Page 5: Gen

    67c3k11 gen info 1 2 3 4 5 6 7 8 9 general information how to use this manual ................................................................................. 1-1 manual format............................................................................................ 1-1 symbol.......................

  • Page 6: Gen

    Gen info general information 1-1 67c3k11 how to use this manual manual format the format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. • parts are shown and detailed in an exploded d...

  • Page 7: Gen

    67c3k11 1-2 1 2 3 4 5 6 7 8 9 symbol the symbols below are designed to indicate the content of a chapter. General information specification periodic check and adjustment fuel system power unit lower unit bracket unit electrical system troubleshooting gen info spec chk adj fuel powr lowr brkt elec tr...

  • Page 8: Gen

    Gen info general information 1-3 67c3k11 abbreviation the following abbreviations are used in this service manual. Sealant and locking agent table the following table contains sealants, locking agents, and lubricants used in this service manual that are not listed on page 1-2. Abbreviation descripti...

  • Page 9: Safety While Working

    67c3k11 1-4 1 2 3 4 5 6 7 8 9 safety while working 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. Ventilatio...

  • Page 10: Gen

    Gen info general information 1-5 67c3k11 6. Maintain good standards of personal and industrial hygiene. Good working practice special service tool use the recommended special service tools to protect parts from damage. Use the right tool in the right manner—do not improvise. Tightening torque follow...

  • Page 11: Identification

    67c3k11 1-6 1 2 3 4 5 6 7 8 9 identification model this manual covers the following models. Serial number the outboard motor serial number is stamped on a label attached to the port clamp bracket. 1 model name 2 approved model code 3 transom height 4 serial number applicable model f30amhd, f30aeht, ...

  • Page 12: Gen

    Gen info general information 1-7 67c3k11 special service tool oil filter wrench 90890-01426 digital tachometer 90890-06760 timing light 90890-03141 leakage tester 90890-06840 vacuum/pressure pump gauge set 90890-06756 pilot screw adjusting tool 90890-03154 vacuum gauge 90890-03094 compression gauge ...

  • Page 13

    67c3k11 1-8 1 2 3 4 5 6 7 8 9 valve spring compressor 90890-04019 valve spring compressor attachment 90890-06320 valve guide remover/installer 90890-06801 valve guide reamer 90890-06804 valve seat cutter holder 90890-06316 valve seat cutter 90890-06312, 90890-06323, 90890-06325, 90890-06327, 90890-0...

  • Page 14: Gen

    Gen info general information 1-9 67c3k11 stopper guide plate 90890-06501 stopper guide stand 90890-06538 bearing puller assembly 90890-06535 driver rod l3 90890-06652 needle bearing attachment 90890-06612, 90890-06614 driver rod ss 90890-06604 bearing depth plate 90890-06603 ball bearing attachment ...

  • Page 15

    67c3k11 1-10 1 2 3 4 5 6 7 8 9 drive shaft holder 3 90890-06517 pinion nut holder 90890-06715 bearing outer race puller assembly 90890-06523 driver rod ll 90890-06605 bearing outer race attachment 90890-06622, 90890-06627 driver rod sl 90890-06602 ball bearing attachment 90890-06634 bearing inner ra...

  • Page 16: Gen

    Gen info general information 1-11 67c3k11 pinion height gauge plate b 90890-06712 digital caliper 90890-06704 center bolt 90890-06504 bearing housing puller claw s 90890-06564 backlash indicator 90890-06706 magnet base plate 90890-07003 dial gauge set 90890-01252 magnet base b 90890-06844 bushing in...

  • Page 17

    67c3k11 1-12 1 2 3 4 5 6 7 8 9 needle bearing attachment 90890-06615 cylinder-end screw wrench 90890-06568 peak voltage adapter b 90890-03172 test harness (2 pins) 90890-06867 ignition tester 90890-06754 test harness (2 pins) 90890-06868 special service tool.

  • Page 18: Gen

    Gen info general information 1-13 67c3k11 propeller selection the performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabiliti...

  • Page 19: Predelivery Check

    67c3k11 1-14 1 2 3 4 5 6 7 8 9 predelivery check to make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is between the bottom of the boat and a maximum of 25...

  • Page 20: Gen

    Gen info general information 1-15 67c3k11 checking the gear oil level 1. Check the gear oil level. Note: if the oil is at the correct level, a small amount of oil should overflow out of the check hole when the gear oil check screw is removed. Checking the battery (e and w model) 1. Check the battery...

  • Page 21

    67c3k11 1-16 1 2 3 4 5 6 7 8 9 note: center the shift arm 5 in its free play c and the shift cable 6 in its free play d, and then connect the shift cable. Checking the gear shift and throttle operation 1. Check that the throttle operates smoothly when the throttle grip is turned from the fully close...

  • Page 22: Gen

    Gen info general information 1-17 67c3k11 checking the steering system 1. Check the steering friction for proper adjustment. (h model) note: • to increase the friction, move the steering lock lever in direction a. • to decrease the friction, move the steering lock lever in direction b. 2. Check that...

  • Page 23

    67c3k11 1-18 1 2 3 4 5 6 7 8 9 È h model É r model (remote control lever) Ê r model (bottom cowling) 2. Check that there is no abnormal noise produced when the outboard motor is tilted up or down. 3. Check that there is no interference with leads, cables, or hoses when steering the motor in its full...

  • Page 24: Gen

    Gen info general information 1-19 67c3k11 3. Check that the engine turns off when the clip is pulled from the engine shut-off switch. È h model É r model checking the cooling water pilot hole 1. Place the lower unit in water, and then start the engine. 2. Check for water flow at the cooling water pi...

  • Page 25

    67c3k11 1-20 1 2 3 4 5 6 7 8 9 4. After the 1st 10 hours of operation: operate the engine normally. È hour after the test run 1. Check for water in the gear oil. 2. Check for fuel leakage in the cowling. 3. Flush the cooling water passages with fresh water using the flushing kit and with the engine ...

  • Page 26: Gen

    Gen info general information 1-21 67c3k11 — memo —.

  • Page 27: Spec

    67c3k11 spec 1 2 3 4 5 6 7 8 9 specification general specification .................................................................................... 2-1 maintenance specification ............................................................................ 2-7 power unit..............................

  • Page 28: Spec

    Spec specification 2-1 67c3k11 general specification item unit model f30amhd f40bmhd f40bwhd f40bed dimension overall length mm (in) 1,332 (52.4) 700 (27.6) overall width mm (in) 378 (14.9) overall height (s) mm (in) 1,246 (49.1) — (l) mm (in) 1,369 (53.9) 1,340 (52.8) transom height (s) mm (in) 410...

  • Page 29

    67c3k11 2-2 1 2 3 4 5 6 7 8 9 ignition control system cdi (micro computer) advanced type micro computer ignition timing at 850 r/min degree atdc 5 ± 2 maximum generator output w, a 85, 6.0 — v, a — 12, 15.0 spark plug dpr6ea-9 (ngk) cooling system water exhaust system propeller boss lubrication syst...

  • Page 30: Spec

    Spec specification 2-3 67c3k11 electrical battery minimum capacity cca/en a — 430 20hr/iec ah — 70 electrolyte specific gravity at 20 °c (68 °f) — 1.280 item unit model f30amhd f40bmhd f40bwhd f40bed.

  • Page 31

    67c3k11 2-4 1 2 3 4 5 6 7 8 9 item unit model f30aeht f30aet f40bwht f40bet dimension overall length mm (in) 1,332 (52.4) 700 (27.6) 1,332 (52.4) 700 (27.6) overall width mm (in) 378 (14.9) overall height (s) mm (in) — 1,217 (47.9) — 1,217 (47.9) (l) mm (in) 1,340 (52.8) 1,340 (52.8) 1,369 (53.9) 1,...

  • Page 32: Spec

    Spec specification 2-5 67c3k11 ignition control system cdi (micro computer) advanced type micro computer ignition timing at 850 r/min degree atdc 5 ± 2 maximum generator output v, a 12, 15.0 spark plug dpr6ea-9 (ngk) cooling system water exhaust system propeller boss lubrication system wet sump fuel...

  • Page 33

    67c3k11 2-6 1 2 3 4 5 6 7 8 9 electrical battery minimum capacity cca/en a 430 20hr/iec ah 70 electrolyte specific gravity at 20 °c (68 °f) 1.280 item unit model f30aeht f30aet f40bwht f40bet general specification.

  • Page 34: Spec

    Spec specification 2-7 67c3k11 maintenance specification power unit item unit model f30amhd f40bmhd f40bwhd f40bed power unit minimum compression pressure (*1) kpa (kgf/cm 2 , psi) 600 (6.0, 87.0) 380 (8.3, 120.4) oil pressure (*2) kpa (kgf/cm 2 , psi) 210 (2.1, 30.5) at 52 °c (126 °f) with sl 10w-3...

  • Page 35

    67c3k11 2-8 1 2 3 4 5 6 7 8 9 rocker arm shaft outside diameter mm (in) 15.971–15.991 (0.6288–0.6296) rocker arm inside diameter mm (in) 16.000–16.018 (0.6299–0.6306) valve valve clearance (cold) intake mm (in) 0.20 ± 0.05 (0.008 ± 0.002) exhaust mm (in) 0.30 ± 0.05 (0.012 ± 0.002) head diameter (a)...

  • Page 36: Spec

    Spec specification 2-9 67c3k11 piston piston diameter (d) mm (in) 64.950–64.965 (2.5571–2.5577) measuring point (h) mm (in) 2.0 (0.08) piston clearance (*1) 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) 65.200–65.2...

  • Page 37

    67c3k11 2-10 1 2 3 4 5 6 7 8 9 fuel system 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) crankshaft runout limit mm (in) 0.05 (0.0020) crankcase crankshaft jour...

  • Page 38: Spec

    Spec specification 2-11 67c3k11 lower unit fuel pump fuel pump holding pressure fuel inlet positive pressure kpa (kgf/cm 2 , psi) 50 (0.5, 7.3) fuel inlet negative pressure kpa (kgf/cm 2 , psi) 30 (0.3, 4.4) fuel outlet positive pressure kpa (kgf/cm 2 , psi) 50 (0.5, 7.3) fuel joint holding pressure...

  • Page 39

    67c3k11 2-12 1 2 3 4 5 6 7 8 9 electrical item unit model f30amhd f40bmhd f40bwhd f40bed ignition and ignition control system spark plug gap mm (in) 0.8–0.9 (0.031–0.035) spark plug cap resistance (*1) k Ω 4.0–6.0 ignition coil resistance (*1) primary coil (o – b/w) at 20 °c (68 °f) Ω 0.18–0.24 seco...

  • Page 40: Spec

    Spec specification 2-13 67c3k11 fuel control system prime start resistance (*1) (y – y) at 20 °c (68 °f) Ω 20.0–23.0 prime start plunger length (*1) mm (in) 10.7 (0.42) starting system power bobbin output peak voltage (y/b – y/b) at cranking (loaded) v 7.0 at 1,500 r/min (loaded) v 28.0 at 3,500 r/m...

  • Page 41

    67c3k11 2-14 1 2 3 4 5 6 7 8 9 power unit item unit model f30aeht f30aet f40bwht f40bet power unit minimum compression pressure (*1) kpa (kgf/cm 2 , psi) 830 (8.3, 120.4) oil pressure (*2) kpa (kgf/cm 2 , psi) 210 (2.1, 30.5) at 52 °c (126 °f) with sl 10w-30 engine oil and at engine idle speed cylin...

  • Page 42: Spec

    Spec specification 2-15 67c3k11 rocker arm inside diameter mm (in) 16.000–16.018 (0.6299–0.6306) valve valve clearance (cold) intake mm (in) 0.20 ± 0.05 (0.008 ± 0.002) exhaust mm (in) 0.30 ± 0.05 (0.012 ± 0.002) head diameter (a) intake mm (in) 31.9–32.1 (1.256–1.264) exhaust mm (in) 25.9–26.1 (1.0...

  • Page 43

    67c3k11 2-16 1 2 3 4 5 6 7 8 9 piston piston diameter (d) mm (in) 64.950–64.965 (2.5571–2.5577) measuring point (h) mm (in) 2.0 (0.08) piston clearance (*1) 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) 65.200–65.2...

  • Page 44: Spec

    Spec specification 2-17 67c3k11 fuel system 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) crankshaft runout limit mm (in) 0.05 (0.0020) crankcase crankshaft jou...

  • Page 45

    67c3k11 2-18 1 2 3 4 5 6 7 8 9 lower unit pilot jet (p.J.) (for europe) — #40 — #40 (for oceania) #40 #38 pilot screw (p.S.) turns out 1 7/8 ± 1/2 2 ± 1/2 engine idle speed r/min 850 ± 50 fuel pump fuel pump holding pressure fuel inlet positive pressure kpa (kgf/cm 2 , psi) 50 (0.5, 7.3) fuel inlet ...

  • Page 46: Spec

    Spec specification 2-19 67c3k11 electrical item unit model f30aeht f30aet f40bwht f40bet ignition and ignition control system spark plug gap mm (in) 0.8–0.9 (0.031–0.035) spark plug cap resistance (*1) k Ω 4.0–6.0 ignition coil resistance (*1) primary coil (o – b/w) at 20 °c (68 °f) Ω 0.18–0.24 seco...

  • Page 47

    67c3k11 2-20 1 2 3 4 5 6 7 8 9 fuel control system prime start resistance (*1) (y – y) at 20 °c (68 °f) Ω 20.0–23.0 prime start plunger length (*1) mm (in) 10.7 (0.42) starting system power bobbin output peak voltage (y/b – y/b) at cranking (loaded) v 7.0 at 1,500 r/min (loaded) v 28.0 at 3,500 r/mi...

  • Page 48: Spec

    Spec specification 2-21 67c3k11 ptt system trim sensor setting resistance (*1) (p – b) at 20 °c (68 °f) Ω 9–11 trim sensor resistance (*1) (p – b) at 20 °c (68 °f) Ω 238.8–378.8 ptt motor output kw 0.18 brushes standard length mm (in) 6.0 (0.24) wear limit mm (in) 3.0 (0.12) commutator standard diam...

  • Page 49

    67c3k11 2-22 1 2 3 4 5 6 7 8 9 dimension exterior f30amhd, f40bmhd (for europe) (s-transom model) s67c2002 mim (in) 12˚ 605 (23.8) –4˚ 753 (29.6) 754 (29.7) 24 (0.9) 384 (15.1) 763 (30.0) 814 (32.0) 569 (22.4) 234 (9.2) 175 (6.9) 65 (2.6) 522 (20.6) 294 (11.6) 493 (19.4) 411 (16.2) 175 (6.9) 43 (1.7...

  • Page 50: Spec

    Spec specification 2-23 67c3k11 exterior f30amhd, f40bmhd (for europe), f30aeht, f40bwhd, f40bwht (for oceania) (l-transom model) s67c2003 mim (in) 189 (7.4) 124 (4.9) 313 (12.3) 688 (27.1) 40˚ 671 (26.4) –4˚ 753 (29.6) 877 (34.5) 24 (0.9) 384 (15.1) 763 (30.0) 923 (36.3) 569 (22.4) 234 (9.2) 175 (6...

  • Page 51

    67c3k11 2-24 1 2 3 4 5 6 7 8 9 exterior f30aet, f40bet (for europe) (s-transom model) s67c2001 mim (in) 189 (7.4) 313 (12.3) 40˚ 12˚ 62˚ 600 (23.6) –4˚ 708 (27.9) 754 (29.7) 24 (0.9) 354 (13.9) 814 (32.0) 569 (22.4) 132 (5.2) 65 (2.6) 522 (20.6) 286 (11.3) 465 (18.3) 411 (16.2) 175 (6.9) 43 (1.7) 15...

  • Page 52: Spec

    Spec specification 2-25 67c3k11 exterior f30aet, f40bed, f40bet (for europe), f30aet, f40bet (for oceania) (l-tran- som model) s67c2004 mim (in) 522 (20.6) –4˚ 189 (7.4) 313 (12.3) 40˚ 12˚ 666 (26.2) 708 (27.9) 877 (34.5) 24 (0.9) 354 (13.9) 923 (36.3) 569 (22.4) 132 (5.2) 65 (2.6) 286 (11.3) 465 (1...

  • Page 53

    67c3k11 2-26 1 2 3 4 5 6 7 8 9 clamp bracket s67c2005 mim (in) 180 (7.1) 180 (7.1) 124.5 (4.9) 124.5 (4.9) 338 (13.3) 254 (10.0) 55.5 (2.2) 57 (2.2) 13 (0.5) 18.5 (0.7) 50.8 (2.0) 13 (0.5) 163.5 (6.4) 163.5 (6.4) maintenance specification.

  • Page 54: Spec

    Spec specification 2-27 67c3k11 tightening torque specified torque part to be tightened thread size tightening torques n·m kgf·m ft·lb fuel system fuel joint bolt m6 8 0.8 5.9 fuel pump screw m5 3 0.3 2.2 fuel pump valve screw m3 0.5 0.05 0.37 carburetor assembly bolt m6 8 0.8 5.9 carburetor unit bo...

  • Page 55

    67c3k11 2-28 1 2 3 4 5 6 7 8 9 union bolt — 40 4.0 29.5 oil pump assembly bolt m6 8 0.8 5.9 thermostat cover bolt m6 7 0.7 5.2 exhaust cover bolt 1st m6 6 0.6 4.4 2nd 12 1.2 8.9 crankcase bolt 1st m8 15 1.5 11.1 2nd 30 3.0 22.1 1st m6 6 0.6 4.4 2nd 12 1.2 8.9 connecting rod cap bolt 1st m6 6 0.6 4.4...

  • Page 56: Spec

    Spec specification 2-29 67c3k11 general torque 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-...

  • Page 57: Chk

    67c3k11 chk adj 1 2 3 4 5 6 7 8 9 periodic check and adjustment maintenance interval chart............................................................................ 3-1 top cowling .................................................................................................... 3-3 checking the...

  • Page 58: Chk

    Chk adj periodic check and adjustment 3-1 67c3k11 maintenance interval chart use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Item remarks initial every refer to page 20 hours (3 months) 100 ...

  • Page 59

    67c3k11 3-2 1 2 3 4 5 6 7 8 9 note: • when operating in muddy, turbid, or salt water, the engine should be flushed with clean water after each use. • when using leaded or high-sulfur gasoline, checking the valve clearances may be required more frequently than every 500 hours. Throttle link/throttle ...

  • Page 60: Chk

    Chk adj periodic check and adjustment 3-3 67c3k11 top cowling checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. 2. Loosen the nuts 1. 3. Move the hook 2 up or down slightly to adjust its position. Note: • to tighten the fitting, move the hook ...

  • Page 61: Power Unit

    67c3k11 3-4 1 2 3 4 5 6 7 8 9 caution: when replacing the fuel filter 1, the arrow mark a must point toward the fuel pump. Note: be sure not to spill any fuel when removing the fuel filter 1. Draining the fuel 1. Place a rag 1 or container under the car- buretor fuel drain hole, and then remove the ...

  • Page 62: Chk

    Chk adj periodic check and adjustment 3-5 67c3k11 3. Place a drain pan under the drain hole, and then remove the engine oil drain bolt 2 and let the oil drain completely. Note: • be sure to clean up any oil spills. • when using an oil changer to change the engine oil, insert the oil changer hose int...

  • Page 63

    67c3k11 3-6 1 2 3 4 5 6 7 8 9 6. Install the oil filler cap and oil dipstick, and then start the engine and warm it up. 7. Turn the engine off, and then check the oil level and that there is no oil leakage. If the oil level is low, add engine oil to the correct level. Checking the timing belt cautio...

  • Page 64: Chk

    Chk adj periodic check and adjustment 3-7 67c3k11 6. Connect the spark plug caps. Checking the thermostat 1. Remove the thermostat cover 1 and thermostat 2. Caution: do not reuse the gasket 3, always replace it with a new one. 2. Suspend the thermostat in a container of water. 3. Place a thermometer...

  • Page 65: Control System

    67c3k11 3-8 1 2 3 4 5 6 7 8 9 control system adjusting the throttle link 1. Loosen the throttle link adjusting screw 1. Note: the throttle link adjusting screw 1 has left- hand threads, therefore, turn it clockwise to loosen it. 2. Turn the throttle cam 2 to the fully open position and contact it to...

  • Page 66: Chk

    Chk adj periodic check and adjustment 3-9 67c3k11 2. Check that the throttle cam 4 contacts the fully closed stopper a on the throttle cam bracket 5. 3. Adjust the position of the throttle cable joint 3 until its hole is aligned with the set pin on the throttle cam 4. Warning the throttle cable join...

  • Page 67

    67c3k11 3-10 1 2 3 4 5 6 7 8 9 5. Adjust the position of the shift cable joint 3 until its hole is aligned with the set pin on the shift arm 4. Warning the shift cable joint must be screwed in a minimum depth of 8.0 mm (0.31 in) a. Note: center the shift arm 4 in its free play b and the shift cable ...

  • Page 68: Chk

    Chk adj periodic check and adjustment 3-11 67c3k11 2. Set the shift lever to the n position and loosen the locknut 1. Align the cable end a with the mark b on the manual starter cover by turning the adjusting nut 2. 3. Tighten the locknut 1. Checking the engine idle speed 1. Start the engine and war...

  • Page 69: Bracket Unit

    67c3k11 3-12 1 2 3 4 5 6 7 8 9 bracket unit checking the steering operation (h model) note: lubricate the swivel bracket before checking the steering operation. 1. Move the steering lock lever 1 to posi- tion a and check that the steering is locked. Move the steering lock lever 1 to posi- tion b and...

  • Page 70: Chk

    Chk adj periodic check and adjustment 3-13 67c3k11 checking the ptt fluid level 1. Tilt the outboard motor to the fully up position, and then support it with the tilt stop lever. Warning after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard moto...

  • Page 71

    67c3k11 3-14 1 2 3 4 5 6 7 8 9 3. Check the oil for metal and discoloration, and its viscosity. Check the internal parts of the lower case if necessary. 4. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill with gear oil until oil flows out of the check hole and no air bubbl...

  • Page 72: Chk

    Chk adj periodic check and adjustment 3-15 67c3k11 checking the propeller 1. Check the propeller blades and splines. Replace the propeller if cracked, dam- aged, or worn. Note: when replacing the propeller, see “propeller selection” (1-13) and select a propeller of the same size as originally instal...

  • Page 73

    67c3k11 3-16 1 2 3 4 5 6 7 8 9 checking the battery 1. Check the battery electrolyte level. If the level is at or below the minimum level mark a, add distilled water until the level is between the maximum and minimum level marks. 2. Check the specific gravity of the electro- lyte. Fully charge the b...

  • Page 74: Chk

    Chk adj periodic check and adjustment 3-17 67c3k11 lubricating the outboard motor 1. Apply water resistant grease to the areas shown. È h model note: apply grease until it flows from the bushings a. 2. Apply low temperature resistant grease to the areas shown. (e and w model) 3. Apply corrosion resi...

  • Page 75: Fuel

    67c3k11 fuel 1 2 3 4 5 6 7 8 9 fuel system hose routing ................................................................................................... 4-1 fuel hose, blowby hose, and cooling water hose...................................... 4-1 fuel pump, fuel filter, and fuel joint ...............

  • Page 76: Fuel

    Fuel fuel system 4-1 67c3k11 hose routing fuel hose, blowby hose, and cooling water hose 1 fuel hoses (fuel pump to carburetor assembly) 2 blowby hose (cylinder head cover to intake silencer) 3 breather hoses (carburetor to carburetor joint) 4 flushing hose (flushing hose adapter to exhaust cover) 5...

  • Page 77

    67c3k11 4-2 1 2 3 4 5 6 7 8 9 fuel pump, fuel filter, and fuel joint no. Part name q’ty remarks 1 bolt 2 m6 × 30 mm 2 cover 1 3 fuel pump 1 4 o-ring 1 not reusable 5 clamp 2 6 clamp 1 7 fuel hose 1 8 fuel hose 1 9 fuel hose 1 10 clamp 3 11 fuel filter 1 12 fuel hose 1 13 bolt 4 m6 × 25 mm 14 plate 1...

  • Page 78: Fuel

    Fuel fuel system 4-3 67c3k11 no. Part name q’ty remarks 1 screw 4 ø5 × 43 mm 2 cover 1 3 diaphragm 1 not reusable 4 fuel pump body 2 assembly 1 5 diaphragm 1 6 spring 1 7 fuel pump body 1 1 8 nut 4 9 spring 1 10 plunger 1 11 pin 1 s67c4003 1 1 6 5 4 3 2 1 9 8 8 10 7 11 r . . 0.5 n · m (0.05 kgf · m,...

  • Page 79

    67c3k11 4-4 1 2 3 4 5 6 7 8 9 checking the fuel pump 1. Connect the special service tool to the fuel pump inlet. 2. Cover the fuel pump outlets with your fin- gers, and then apply the specified posi- tive pressure. Check that there is no air leakage. 3. Apply the specified negative pressure and chec...

  • Page 80: Fuel

    Fuel fuel system 4-5 67c3k11 checking the fuel joint 1. Check the fuel joint. Replace if cracked or damaged. 2. Connect the special service tool to the fuel joint outlet. 3. Apply the specified positive pressure. Replace the fuel joint if the specified pressure cannot be maintained for at least 10 s...

  • Page 81

    67c3k11 4-6 1 2 3 4 5 6 7 8 9 assembling the fuel pump note: clean the parts and soak the valves and the diaphragms in gasoline before assembly. 1. Install the plunger 1 and diaphragm into fuel pump body 1 2, and then install the pin 3 to the plunger. Note: • align the pin installation holes a with ...

  • Page 82: Fuel

    Fuel fuel system 4-7 67c3k11 carburetor unit no. Part name q’ty remarks 1 blowby hose 1 2 clamp 1 3 clamp 2 4 clamp 1 5 fuel hose 1 6 fuel hose 1 7 fuel hose 1 8 bolt 6 m6 × 25 mm 9 bolt 2 m6 × 20 mm 10 holder 1 11 collar 1 12 throttle link rod 1 13 carburetor unit 1 14 dowel 2 s67c4016 t r . . 8 n ...

  • Page 83

    67c3k11 4-8 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 carburetor joint assembly 1 2 plug 2 3 o-ring 9 not reusable 4 insulator 1 5 hose 3 6 carburetor #1 1 7 carburetor #2 1 8 carburetor #3 1 9 fuel hose 1 10 fuel hose 1 11 fuel hose 1 12 cotter pin 3 13 washer 3 14 screw 2 ø6 × 10 mm 15 dashpo...

  • Page 84: Fuel

    Fuel fuel system 4-9 67c3k11 no. Part name q’ty remarks 18 plate 1 19 o-ring 3 not reusable 20 bolt 6 m6 × 90 mm 21 bolt 5 m6 × 20 mm 22 bolt 1 m6 × 20 mm 23 intake silencer 1 24 hose 4 25 bracket 1 26 plastic tie 8 27 holder 1 s67c4037 4 3 3 1 3 9 10 11 18 19 20 27 20 20 20 17 23 20 21 21 6 8 2 t r...

  • Page 85

    67c3k11 4-10 1 2 3 4 5 6 7 8 9 carburetor no. Part name q’ty remarks 1 screw 3 ø4 × 9 mm 2 cover 1 3 gasket 1 not reusable 4 throttle stop screw 1 5 spring 1 6 carburetor body 1 7 needle valve 1 8 pilot jet 1 9 plug 1 10 main nozzle 1 11 main jet 1 12 prime start 1 13 screw 1 ø4 × 9 mm 14 retainer 1...

  • Page 86: Fuel

    Fuel fuel system 4-11 67c3k11 no. Part name q’ty remarks 18 o-ring 1 not reusable 19 pilot screw 1 for europe 20 pilot screw 1 for oceania 21 gasket 1 not reusable 22 float 1 23 float pin 1 24 screw 1 ø4 × 8 mm 25 screw 1 ø3 × 6 mm 26 plunger 1 27 spring 1 28 float chamber 1 29 screw 4 ø4 × 14 mm s6...

  • Page 87

    67c3k11 4-12 1 2 3 4 5 6 7 8 9 removing the carburetor 1. Disconnect the fuel hoses 1 and blowby hose 2. 2. Disconnect the throttle link rod 3. 3. Disconnect the prime start leads 4. 4. Remove the bolts 5 and 6, and then remove the carburetor unit 7. 5. Remove the bolts 8, intake silencer 9, bolts 0...

  • Page 88: Fuel

    Fuel fuel system 4-13 67c3k11 2. Blow compressed air into all passages and jets. Warning wear appropriate protective eye gear dur- ing the cleaning process to prevent any eye injury by the blown-off debris or liq- uid. 3. Check the main jet, pilot jet, and main nozzle. Clean if there is dirt or resi...

  • Page 89

    67c3k11 4-14 1 2 3 4 5 6 7 8 9 assembling the carburetor note: see the exploded diagram for assembly (4- 10). 1. Install the pilot jet 1, plug 2, main noz- zle 3, and main jet 4 to the carburetor body as shown. 2. Install the needle valve 5, float 6, float pin 7, and screw 8 as shown, and then check...

  • Page 90: Fuel

    Fuel fuel system 4-15 67c3k11 installing the carburetor 1. Install the carburetor joint assembly 1, carburetor assemblies 2, throttle link plate 3, and plate 4, and then tighten the bolts 5 to the specified torque. 2. Install the intake silencer 6, and then tighten the bolts 7 and 8 to the speci- fi...

  • Page 91

    67c3k11 4-16 1 2 3 4 5 6 7 8 9 4. Turn the pilot screw 1 in direction a until it is lightly seated, and then turn it in direction b the specified number of turns. È for europe É for oceania note: adjust the pilot screw setting within the spec- ified number of turns out so that the engine idle speed ...

  • Page 92: Fuel

    Fuel fuel system 4-17 67c3k11 synchronizing the carburetor caution: do not adjust the carburetors when they are operating properly. Excessive adjust- ment may cause poor engine perfor- mance. 1. Remove the plugs 1, and then attach the special service tool to the intake manifold as shown. 2. Start th...

  • Page 93

    67c3k11 4-18 1 2 3 4 5 6 7 8 9 3. Turn the throttle grip (h model) or move the remote control lever (r model) until the engine speed is 3,750 ± 50 r/min. 4. Turn the adjusting screw 2 until it is just touching the stopper 3. 5. Rev the engine a few times and check the dashpot operation. Repeat steps...

  • Page 94: Powr

    Powr 67c3k11 power unit power unit (check and adjustment).............................................................. 5-1 checking the compression pressure ......................................................... 5-1 checking the oil pressure .........................................................

  • Page 95

    67c3k11 1 2 3 4 5 6 7 8 9 cylinder block .............................................................................................. 5-40 disassembling the cylinder block ............................................................ 5-42 checking the piston diameter ..................................

  • Page 96: Powr

    Powr power unit 5-1 67c3k11 power unit (check and adjustment) checking the compression pressure 1. Start the engine, warm it up, and then turn it off. 2. Remove the clip from the engine shut-off switch. 3. Disconnect the spark plug caps, remove the spark plugs, and then install the spe- cial service...

  • Page 97

    67c3k11 5-2 1 2 3 4 5 6 7 8 9 note: because the prime start operates when the engine is started, the engine idle speed will be above specification. Therefore, measure the oil pressure after the engine has been warmed up. 3. Measure the oil pressure. If out of specifi- cation, check the oil pump and ...

  • Page 98: Powr

    Powr power unit 5-3 67c3k11 6. Loosen the rocker arm locknut 6, and then turn the adjusting screw 7 until the specified valve clearance is obtained. Note: • to decrease the valve clearance, turn the adjusting screw 7 in direction e. • to increase the valve clearance, turn the adjusting screw 7 in di...

  • Page 99

    67c3k11 5-4 1 2 3 4 5 6 7 8 9 4. Remove the flywheel magnet, woodruff key and spring washer. Caution: to prevent damage to the engine or tools, screw in the puller set bolts evenly and completely so that the flywheel puller is parallel to the flywheel magnet. Note: apply force to the crankshaft end ...

  • Page 100: Powr

    Powr power unit 5-5 67c3k11 7. Remove the timing belt 3 from the driven sprocket, and then remove it from the drive sprocket. Caution: unless directed to do so in the following instructions, do not turn the drive sprocket or driven sprocket when the tim- ing belt is not installed. Otherwise the pis-...

  • Page 101

    67c3k11 5-6 1 2 3 4 5 6 7 8 9 note: • be sure to remove any grease from the tapered portion h of the crankshaft and the inner surface k of the flywheel magnet 8. • apply engine oil to the threads m of the fly- wheel magnet nut 9 and upper and lower surfaces n of the washer before installa- tion. 12....

  • Page 102: Powr

    Powr power unit 5-7 67c3k11 manual starter (m and w model) no. Part name q’ty remarks 1 start-in-gear protection cable 1 2 spring 1 3 bolt 4 m6 × 25 mm 4 cap 1 5 starter handle 1 6 starter rope 1 1,750 mm (68.9 in) (reference data) 7 damper 1 8 bolt 3 m6 × 25 mm 9 collar 3 10 starter rope guide 1 11...

  • Page 103

    67c3k11 5-8 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 18 bolt 1 m6 × 25 mm 19 spiral spring 1 20 e-clip 1 21 sheave drum 1 22 drive pawl 1 23 drive pawl spring 2 1 24 spring 1 25 drive pawl spring 1 1 26 drive plate 1 27 bolt 1 m6 × 15 mm s67c5025 e 1 a a lt 271 lt 271 a a 2 26 27 25 18 17 16 9 8...

  • Page 104: Powr

    Powr power unit 5-9 67c3k11 disassembling the manual starter 1. While holding the starter rope 1, turn the sheave drum 2 in the direction of the arrow shown until there is no tension in the spiral spring. Note: push the starter plunger 3 in the direction of the arrow shown while turning the sheave d...

  • Page 105

    67c3k11 5-10 1 2 3 4 5 6 7 8 9 3. Check the sheave drum. Replace if cracked or damaged. 4. Check the spiral spring. Replace if bent, cracked, or damaged. 5. Check the starter handle. Replace if cracked or damaged. 6. Check the starter rope. Replace if dam- aged. Note: • when replacing the starter ro...

  • Page 106: Powr

    Powr power unit 5-11 67c3k11 5. Install the spiral spring 8 into the manual starter cover 9. Note: hook the end c of the spiral spring 8 onto the cut-out d in the manual starter cover 9. 6. Install the sheave drum 2 into the man- ual starter cover 9. Note: • when installing the sheave drum 2, set th...

  • Page 107

    67c3k11 5-12 1 2 3 4 5 6 7 8 9 11. Install the manual starter onto the power unit, and then connect the start-in-gear protection cable. Note: • place the start-in-gear protection cable in its original position, making sure to route it correctly. • to adjust the start-in-gear protection cable, see “c...

  • Page 108: Powr

    Powr power unit 5-13 67c3k11 power unit power unit assembly no. Part name q’ty remarks 1 manual starter 1 m and w model 2 driven sprocket cover 1 m and w model 3 flywheel magnet cover 1 e model 4 oil dipstick 1 5 throttle cable 1 6 shift cable 1 7 start-in-gear protection cable 1 m and w model 8 pow...

  • Page 109

    67c3k11 5-14 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 18 10-pin main harness 1 e and w model 19 bolt 8 m8 × 80 mm 20 bolt 2 m6 × 16 mm 21 screw 2 ø6 × 25 mm 22 nut 2 23 apron 1 24 bolt 4 m6 × 25 mm/m and w model 25 bolt 1 m6 × 18 mm/m and w model 26 grommet 1 m and w model 27 plastic tie 2 28 cl...

  • Page 110: Powr

    Powr power unit 5-15 67c3k11 starter motor, starter relay, and ptt relay (e and w model) no. Part name q’ty remarks 1 starter motor 1 2 starter motor lead 1 3 bolt 3 m8 × 50 mm 4 collar 2 ptt model 5 grommet 2 ptt model 6 ptt relay bracket 1 ptt model 7 bolt 2 m6 × 30 mm/ptt model 8 ptt relay 1 ptt ...

  • Page 111

    67c3k11 5-16 1 2 3 4 5 6 7 8 9 ignition coil, cdi unit, and rectifier regulator no. Part name q’ty remarks 1 bolt 2 m5 × 16 mm 2 pulser coil 1 3 bolt 3 m6 × 45 mm 4 cdi unit 1 5 bolt 3 m6 × 25 mm 6 washer 3 7 bracket 1 8 grommet 3 9 collar 3 10 spark plug 3 11 spark plug cap 3 12 ignition coil 3 13 ...

  • Page 112: Powr

    Powr power unit 5-17 67c3k11 no. Part name q’ty remarks 18 oil pressure switch lead 1 19 rectifier regulator 1 e and w model 20 holder 1 21 bolt 2 m6 × 40 mm 22 thermo sensor 1 23 wiring harness 1 24 bolt 2 m6 × 12 mm 25 plastic tie 3 26 bolt 2 m5 × 12 mm 27 bracket 1 e and w model s67c5042 10 19 2 ...

  • Page 113

    67c3k11 5-18 1 2 3 4 5 6 7 8 9 throttle cam no. Part name q’ty remarks 1 bolt 1 m8 × 12 mm 2 ground lead 1 3 bolt 1 m6 × 12 mm 4 nut 1 5 accelerator lever 1 6 collar 1 7 bolt 1 m6 × 25 mm 8 bushing 1 9 cotter pin 1 10 clip 1 11 throttle link rod 1 12 bracket 1 13 shift link rod 1 14 bolt 1 m6 × 14 m...

  • Page 114: Powr

    Powr power unit 5-19 67c3k11 no. Part name q’ty remarks 18 spring 1 19 throttle cam 1 20 collar 1 21 bolt 1 m6 × 45 mm s67c5043 19 18 20 12 17 16 14 8 9 11 21 15 1 2 13 6 5 4 7 10 a t r . . 8 n · m (0.8 kgf · m, 5.9 ft · ib) t r . . 8 n · m (0.8 kgf · m, 5.9 ft · ib) t r . . 8 n · m (0.8 kgf · m, 5....

  • Page 115

    67c3k11 5-20 1 2 3 4 5 6 7 8 9 removing the power unit 1. Disconnect the start-in-gear protection cable. (m and w model) disconnect the battery cables 1. (e and w model) 2. Disconnect the ptt motor leads 2. (ptt model) disconnect the ptt switch coupler 3 and trim sensor coupler 4. (r model with ptt)...

  • Page 116: Powr

    Powr power unit 5-21 67c3k11 7. Remove the oil dipstick and apron, and then remove the mounting bolts c. 8. Remove the power unit d, gasket e, and dowels f. S67c5047 e d c c c c f.

  • Page 117: Timing Belt and Sprocket

    67c3k11 5-22 1 2 3 4 5 6 7 8 9 timing belt and sprocket no. Part name q’ty remarks 1 nut 1 width across flats: 30 mm 2 washer 1 3 bolt 4 m6 × 10 mm/m and w model 4 starter hub 1 m and w model 5 flywheel magnet 1 6 bolt 3 m5 × 25 mm/m model/m5 × 30 mm/e and w model 7 stator assembly 1 8 spring washer...

  • Page 118: Powr

    Powr power unit 5-23 67c3k11 removing the timing belt and sprocket 1. Remove the manual starter and driven sprocket cover. (m and w model) remove the flywheel magnet cover. (e model) 2. Align the “1 ” mark a on the driven sprocket 1 with the “ ” mark b on the cylinder head. 3. Remove the flywheel ma...

  • Page 119

    67c3k11 5-24 1 2 3 4 5 6 7 8 9 checking the timing belt and sprocket 1. Check the interior and exterior of the tim- ing belt. Replace if cracked, damaged, or worn. 2. Check the drive sprocket and driven sprocket. Replace if cracked, damaged, or worn. Installing the sprocket and timing belt caution: ...

  • Page 120: Powr

    Powr power unit 5-25 67c3k11 5. Align the notch c in the drive sprocket with the “ ” mark d on the cylinder block. 6. Install the timing belt 8 onto the drive sprocket, and then install it onto the driven sprocket so that the part number e on the belt is in the upright position. Caution: • do not tw...

  • Page 121: Cylinder Head

    67c3k11 5-26 1 2 3 4 5 6 7 8 9 cylinder head no. Part name q’ty remarks 1 dowel 2 2 gasket 1 not reusable 3 cylinder head assembly 1 4 bolt 8 m9 × 95 mm 5 bolt 4 m6 × 25 mm 6 screw 4 ø4 × 10 mm 7 plate 1 8 gasket 1 not reusable 9 cylinder head cover 1 10 bolt 7 m6 × 20 mm 11 oil filler cap 1 12 bolt...

  • Page 122: Powr

    Powr power unit 5-27 67c3k11 no. Part name q’ty remarks 1 oil seal 1 not reusable 2 bolt 1 3 gasket 1 not reusable 4 cylinder head 1 5 exhaust valve 3 6 intake valve 3 7 camshaft 1 8 o-ring 1 not reusable 9 o-ring 1 not reusable 10 o-ring 1 not reusable 11 oil pump assembly 1 12 bolt 4 m6 × 45 mm 13...

  • Page 123

    67c3k11 5-28 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 18 valve guide 6 not reusable 19 locknut 6 20 adjusting screw 6 21 rocker arm 6 22 bolt 4 m8 × 30 mm 23 retainer 2 24 retainer 1 25 spring 1 26 retainer 1 27 spring 1 28 rocker arm shaft 1 s67c5067 m m 19 19 20 20 20 19 21 19 27 23 2 3 1 4 18...

  • Page 124: Powr

    Powr power unit 5-29 67c3k11 removing the cylinder head 1. Remove the cylinder head cover. 2. Remove the cylinder head bolts in the sequence shown. Caution: do not scratch or damage the mating sur- faces of the cylinder head and cylinder block. Disassembling the cylinder head 1. Remove the oil pump ...

  • Page 125

    67c3k11 5-30 1 2 3 4 5 6 7 8 9 checking the cylinder head 1. Eliminate carbon deposits from the com- bustion chambers and check the cylinder head for damage or scratches. 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in the directions shown. Replace the cyl- inder h...

  • Page 126: Powr

    Powr power unit 5-31 67c3k11 3. Measure the valve stem diameter b. Replace the valve if out of specification. 4. Measure the valve stem runout. Replace the valve if above specification. Checking the valve guide note: before checking a valve guide, make sure that the valve stem diameter is within spe...

  • Page 127

    67c3k11 5-32 1 2 3 4 5 6 7 8 9 3. Insert the special service tool 1 into the camshaft end of a new valve guide 3, and then strike the tool to drive the guide into the cylinder head. Note: • apply engine oil to the surface of a new valve guide 3 before installation. • make sure that the circlip 4 con...

  • Page 128: Powr

    Powr power unit 5-33 67c3k11 4. Determine the valve seat contact width a by measuring the blueing dye marking on the valve face. Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specifi- cation. Check the valve guide if the valve seat contact wid...

  • Page 129

    67c3k11 5-34 1 2 3 4 5 6 7 8 9 b previous contact width 4. Use a 60° cutter to adjust the contact width of the bottom edge of the valve seat. B previous contact width 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. B previous contact width c specified contact widt...

  • Page 130: Powr

    Powr power unit 5-35 67c3k11 9. If the valve seat contact area is too nar- row and situated near the bottom edge of the valve face, use a 60° cutter to cut the bottom edge of the valve seat, and then use a 45° cutter to center the area and set its width. B previous contact width 10. After refacing t...

  • Page 131

    67c3k11 5-36 1 2 3 4 5 6 7 8 9 2. Measure the camshaft runout. Replace if above specification. 3. Measure the camshaft journal diameters c and d, and the cylinder head journal inside diameters e. Replace the cam- shaft, cylinder head, or both if out of specification. 4. Check the automatic decompres...

  • Page 132: Powr

    Powr power unit 5-37 67c3k11 2. Install the valve 2, valve spring seat 3, valve spring 4, and valve spring retainer 5 in the sequence shown, and then attach the special service tools. Note: face the wide-pitched spring end a, identi- fied by the paint mark, toward the valve spring retainer 5. 3. Com...

  • Page 133

    67c3k11 5-38 1 2 3 4 5 6 7 8 9 7. Align the dowel hole b in the camshaft with the “ ” mark c on the cylinder head as shown. 8. Install the rocker arms d, rocker arm shaft e, springs f, and retainers g into the cylinder head, and then tighten the bolts h to the specified torque. 9. Install the oil pu...

  • Page 134: Powr

    Powr power unit 5-39 67c3k11 installing the cylinder head 1. Install a new gasket, the dowels, and the cylinder head, and then tighten the bolts to the specified torques in the sequence shown. Caution: do not reuse the cylinder head gasket, always replace it with a new one. Note: • apply engine oil ...

  • Page 135: Cylinder Block

    67c3k11 5-40 1 2 3 4 5 6 7 8 9 cylinder block no. Part name q’ty remarks 1 bolt 8 m8 × 82 mm 2 crankcase 1 3 bolt 8 m6 × 35 mm 4 main bearing 8 5 bolt 6 m6 × 30 mm 6 connecting rod 3 7 connecting rod bearing 6 8 oil seal 1 not reusable 9 crankshaft 1 10 oil seal 1 not reusable 11 dowel 2 12 cylinder...

  • Page 136: Powr

    Powr power unit 5-41 67c3k11 no. Part name q’ty remarks 18 piston ring set 3 19 bolt 10 m6 × 35 mm 20 thermostat cover 1 21 gasket 1 not reusable 22 thermostat 1 23 exhaust cover 1 24 gasket 1 not reusable 25 oil filter 1 26 union bolt 1 s67c5118 2 4 4 8 10 11 13 14 6 15 18 7 5 4 4 3 3 4 6 7 4 9 11 ...

  • Page 137

    67c3k11 5-42 1 2 3 4 5 6 7 8 9 disassembling the cylinder block 1. Remove the thermostat cover bolts and exhaust cover bolts in the sequence shown, and then remove the thermostat cover 1, thermostat, and exhaust cover 2. 2. Remove the oil filter 3 using a 64 mm (2.5 in) oil filter wrench. 3. Remove ...

  • Page 138: Powr

    Powr power unit 5-43 67c3k11 checking the piston diameter 1. Measure the piston diameter a at the specified measuring point b. Replace if out of specification. Checking the cylinder bore 1. Measure the cylinder bore (d 1 –d 6 ) at measuring points a, b, and c, and in direction d (d 1 , d 3 , d 5 ), ...

  • Page 139

    67c3k11 5-44 1 2 3 4 5 6 7 8 9 checking the piston ring end gap 1. Level the piston ring 1 in the cylinder with a piston crown at the specified mea- suring point a. 2. Measure the piston ring end gap b. Note: the figures are for reference only. Depend- ing on how the parts are assembled, the actual ...

  • Page 140: Powr

    Powr power unit 5-45 67c3k11 checking the piston ring side clearance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. Checking the piston pin boss bore 1. Measure the piston pin boss bore. Replace the piston if out of specification. Che...

  • Page 141

    67c3k11 5-46 1 2 3 4 5 6 7 8 9 checking the connecting rod big end side clearance 1. Measure the connecting rod big end side clearance a. Checking the crankshaft 1. Measure the crankshaft journal diame- ters a, crankpin diameters b, and crankpin widths c. Replace the crank- shaft if out of specifica...

  • Page 142: Powr

    Powr power unit 5-47 67c3k11 3. Install the connecting rod 1 and bear- ings to the crankpin 2. Note: make sure that the projections a on the con- necting rod and connecting rod cap face towards the flywheel magnet end È of the crankshaft. 4. Tighten the connecting rod cap bolts to the specified torq...

  • Page 143

    67c3k11 5-48 1 2 3 4 5 6 7 8 9 checking the crankshaft journal oil clearance 1. Clean the main bearings, crankshaft jour- nals, and bearing portions of the crank- case and cylinder block. 2. Place the cylinder block upside down on a bench. 3. Install half of the main bearings 1 and the crankshaft 2 ...

  • Page 144: Powr

    Powr power unit 5-49 67c3k11 6. Install the crankcase onto the cylinder block, and then tighten the crankcase bolts to the specified torques in 2 stages and in the sequence shown. Note: • apply engine oil to the threads of the crank- case bolts. • do not turn the crankshaft until the crank- shaft jo...

  • Page 145

    67c3k11 5-50 1 2 3 4 5 6 7 8 9 caution: do not reuse the piston pin clips 4, always replace them with new ones. Note: • before assembly, make sure that the identi- fication numbers a made on the piston and connecting rod 2 during removal are the same. • face the projection b on the connecting rod 2 ...

  • Page 146: Powr

    Powr power unit 5-51 67c3k11 6. Install the oil seals a and b onto the crankshaft c as shown, and then install the crankshaft into the cylinder block. Note: apply engine oil to the inside of each oil seal before installation. 7. Install the connecting rod caps d to the connecting rods, and then tigh...

  • Page 147

    67c3k11 5-52 1 2 3 4 5 6 7 8 9 11. Install the union bolt e and tighten it to the specified torque. 12. Install the oil filter f, and then tighten it to the specified torque using a 64 mm (2.5 in) oil filter wrench. Note: • before installing the oil filter f, be sure to supply engine oil to the oil ...

  • Page 148: Powr

    Powr power unit 5-53 67c3k11 3. Install the apron and oil dipstick. 4. Connect the shift link rod 5, and then install the clip 6. 5. Connect the throttle cable and shift cable, and then adjust them. Note: to adjust the throttle cable and shift cable, see “adjusting the throttle cable” (3-8) and “che...

  • Page 149

    67c3k11 5-54 1 2 3 4 5 6 7 8 9 10. Connect the start-in-gear protection cable. (m and w model) note: to connect the start-in-gear protection cable, see “checking the start-in-gear protection (m and w model)” (3-10). Cylinder block.

  • Page 150: Powr

    Powr power unit 5-55 67c3k11 — memo —.

  • Page 151: Lowr

    67c3k11 lowr 1 2 3 4 5 6 7 8 9 lower unit lower unit ....................................................................................................... 6-1 removing the lower unit ............................................................................ 6-4 removing the water pump..............

  • Page 152: Lowr

    Lowr lower unit 6-1 67c3k11 lower unit no. Part name q’ty remarks 1 locknut 1 2 adjusting nut 1 3 dowel 2 4 bolt 1 m8 × 35 mm 5 check screw 1 6 gasket 2 not reusable 7 cooling water inlet cover 1 8 cooling water inlet cover 1 9 nut 1 10 screw 1 ø5 × 25 mm 11 bolt 4 m10 × 40 mm 12 drain screw 1 13 lo...

  • Page 153

    67c3k11 6-2 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 18 spacer 1 19 propeller 1 20 spacer 1 21 bushing 1 22 propeller nut 1 23 cotter pin 1 not reusable 24 plastic tie 2 25 speedometer hose 1 s67c6001 t r . . 4 n · m (0.4 kgf · m, 3.0 ft · ib) t r . . 39 n · m (3.9 kgf · m, 28.8 ft · ib) t r . ....

  • Page 154: Lowr

    Lowr lower unit 6-3 67c3k11 no. Part name q’ty remarks 1 collar 1 2 rubber spacer 1 3 bolt 4 m8 × 30 mm 4 water pump housing 1 5 insert cartridge 1 6 impeller 1 7 o-ring 1 not reusable 8 dowel 2 9 outer plate cartridge 1 10 gasket 1 not reusable 11 woodruff key 1 12 rubber seal 1 13 plate 1 s67c6002...

  • Page 155

    67c3k11 6-4 1 2 3 4 5 6 7 8 9 removing the lower unit 1. Drain the gear oil. 2. Set the gear shift to the n position, place a block of wood between the anti-cavita- tion plate and propeller to keep the pro- peller from turning, and then remove the propeller nut and propeller. Warning • do not hold t...

  • Page 156: Lowr

    Lowr lower unit 6-5 67c3k11 removing the water pump 1. Remove the water pump housing 1 and impeller 2. 2. Remove the woodruff key 3 from the drive shaft, and then remove the outer plate cartridge 4. 3. Remove the dowels 5 from the lower case. Checking the water pump 1. Check the water pump housing. ...

  • Page 157: Propeller Shaft Housing

    67c3k11 6-6 1 2 3 4 5 6 7 8 9 propeller shaft housing no. Part name q’ty remarks 1 shift plunger 1 2 cross pin 1 3 dog clutch 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...

  • Page 158: Lowr

    Lowr lower unit 6-7 67c3k11 removing the propeller shaft housing assembly 1. Remove the bolts 1 from the propeller shaft housing. 2. Remove the propeller shaft housing assembly 2. Note: • insert flat-head screwdrivers between the propeller shaft housing assembly 2 and the lower case to pry the assem...

  • Page 159

    67c3k11 6-8 1 2 3 4 5 6 7 8 9 3. Remove the oil seals and needle bear- ing. Caution: do not reuse the needle bearing, always replace it with a new one. Checking the propeller shaft housing 1. Clean the propeller shaft housing, and then check it. Replace if cracked or dam- aged. 2. Check the teeth an...

  • Page 160: Lowr

    Lowr lower unit 6-9 67c3k11 assembling the propeller shaft housing assembly 1. Install a new needle bearing into the pro- peller shaft housing to the specified depth a. Note: install the needle bearing with the manufac- ture identification mark b facing toward the oil seal (propeller side). 2. Apply...

  • Page 161

    67c3k11 6-10 1 2 3 4 5 6 7 8 9 note: after installing the reverse gear and shim(s), check that the gear rotates smoothly. Driver rod ls 4: 90890-06606 ball bearing attachment 7: 90890-06633 s67c6089 4 7 g propeller shaft housing.

  • Page 162: Lowr

    Lowr lower unit 6-11 67c3k11 drive shaft and lower case no. Part name q’ty remarks 1 o-ring 1 not reusable 2 shift rod housing 1 3 o-ring 1 not reusable 4 washer 1 5 shift rod 1 l-transom model/s-transom model 6 taper roller bearing 1 not reusable 7 pinion shim — 8 drive shaft sleeve 1 9 needle bear...

  • Page 163

    67c3k11 6-12 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 18 forward gear shim — 19 taper roller bearing 1 not reusable 20 forward gear 1 s67c6026 a a 2 3 4 1 6 11 12 14 15 13 10 7 8 9 17 20 16 5 8 18 19 9 g g g g a a t r . . 74 n · m (7.4 kgf · m, 54.6 ft · ib) bow bow drive shaft and lower case.

  • Page 164: Lowr

    Lowr lower unit 6-13 67c3k11 removing the drive shaft, oil seal housing, and shift rod 1. Remove the oil seal housing 1, washer 2, shift rod housing 3, washer 4, and shift rod 5. 2. Remove the pinion nut. 3. Remove the drive shaft and pinion. 4. Pull out the forward gear. 5. Remove the taper roller ...

  • Page 165

    67c3k11 6-14 1 2 3 4 5 6 7 8 9 disassembling the lower case 1. Remove the taper roller bearing outer race and forward gear shim(s). Caution: do not reuse the bearing, always replace it with a new one. Note: fit the hooks of the puller claw into the slots a in the lower case. 2. Remove the taper roll...

  • Page 166: Lowr

    Lowr lower unit 6-15 67c3k11 2. Measure the drive shaft runout. Replace if above specification. Checking the shift rod 1. Check the shift rod. Replace if bent or worn. Checking the lower case 1. Check the skeg, torpedo, and anti-cavita- tion plate. Replace the lower case if cracked or damaged. Assem...

  • Page 167

    67c3k11 6-16 1 2 3 4 5 6 7 8 9 note: be sure to select the pinion shim(s) if replac- ing the pinion, taper roller bearing, or lower case. To select the shims, see “shimming” (6-21). Assembling the forward gear 1. Install a new taper roller bearing onto the forward gear. Assembling the oil seal housi...

  • Page 168: Lowr

    Lowr lower unit 6-17 67c3k11 installing the shift rod, oil seal housing, and drive shaft 1. Install the forward gear assembly 1 into the lower case. 2. Install the drive shaft 2, and then install the pinion 3 and pinion nut 4 to the shaft. Note: when installing the pinion 3, lift up the drive shaft ...

  • Page 169

    67c3k11 6-18 1 2 3 4 5 6 7 8 9 3. Check that the shifting mechanism works properly and smoothly. Installing the water pump 1. Install the dowels 1, a new gasket 2, and the outer plate cartridge 3. 2. Install the woodruff key 4 and impeller 5 to the drive shaft. Note: when installing the impeller 5 o...

  • Page 170: Lowr

    Lowr lower unit 6-19 67c3k11 4. Install the water pump housing 8 onto the lower case, and then install the rub- ber spacer 9 and collar 0. Caution: do not turn the drive shaft counterclock- wise, otherwise the water pump impeller may be damaged. Note: • apply grease to the inside of the water pump h...

  • Page 171

    67c3k11 6-20 1 2 3 4 5 6 7 8 9 note: after connecting the shift rod 8, check that the gear shift operates properly. 6. Install the anode 0, trim tab a, and cooling water inlet covers b, and then tighten the trim tab bolt c and cooling water inlet cover screw d to the speci- fied torques. 7. Install ...

  • Page 172: Lowr

    Lowr lower unit 6-21 67c3k11 shimming s67c6063 t1 t2 b2 a2 fr p t3 b3 a3 42.0 t1 t2 b1 28.0 28.0 b2 a2 a1.

  • Page 173

    67c3k11 6-22 1 2 3 4 5 6 7 8 9 shimming note: • shimming is not required when assembling the original lower case and inner parts. • shimming is required when assembling the original inner parts and a new lower case. • shimming is required when replacing the inner part(s). Selecting the pinion shim 1...

  • Page 174: Lowr

    Lowr lower unit 6-23 67c3k11 4. Calculate the pinion shim thickness (t3) as shown in the examples below. Note: “p” is the deviation of the lower case dimen- sion from standard. The “p” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “p” mark is unreadabl...

  • Page 175

    67c3k11 6-24 1 2 3 4 5 6 7 8 9 note: “f” is the deviation of the lower case dimen- sion from standard. The “f” mark a is stamped on the trim tab 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 assembl...

  • Page 176: Lowr

    Lowr lower unit 6-25 67c3k11 2. Measure the propeller shaft housing height (m3) as shown. M3 = m3’ – 10 mm note: measure the propeller shaft housing at 4 points to find the height average. 3. Calculate the reverse gear shim thick- ness (t2) as shown in the examples below. Note: “r” is the deviation ...

  • Page 177: Backlash

    67c3k11 6-26 1 2 3 4 5 6 7 8 9 example: if “t2” is 1.20 mm, then the reverse gear shim thickness is 1.18 mm. If “t2” is 1.24 mm, then the reverse gear shim thickness is 1.22 mm. Backlash measuring the forward and reverse gear backlash note: remove the water pump assembly before measuring the backlas...

  • Page 178: Lowr

    Lowr lower unit 6-27 67c3k11 8. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash between where the drive shaft stops in each direction. Note: • push the drive shaft downward, and then turn it. • measure the backlash at 4 points to find the average. 9. Adjust the ...

  • Page 179

    67c3k11 6-28 1 2 3 4 5 6 7 8 9 15. Remove the special service tools and propeller, and then install the water pump assembly. Note: to install the water pump assembly, see “installing the water pump” (6-18). 16. Fill the lower unit with gear oil to the cor- rect level. Backlash.

  • Page 180: Brkt

    Brkt 67c3k11 bracket unit tiller handle (h model) .................................................................................. 7-1 removing the tiller handle ......................................................................... 7-6 installing the tiller handle ................................

  • Page 181

    67c3k11 1 2 3 4 5 6 7 8 9 ptt cylinder ................................................................................................. 7-46 disassembling the ptt cylinder .............................................................. 7-47 checking the tilt cylinder and piston ........................

  • Page 182: Brkt

    Brkt bracket unit 7-1 67c3k11 tiller handle (h model) no. Part name q’ty remarks 1 tiller handle assembly 1 2 shift cable 1 3 throttle cable 1 4 clip 2 5 bolt 3 m6 × 25 mm 6 retaining plate 1 7 cable holder 1 8 grommet 1 9 grommet 1 m model 10 grommet 1 e and w model 11 washer 2 12 self-locking nut ...

  • Page 183

    67c3k11 7-2 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 engine start switch 1 e and w model 2 plug 1 m model 3 engine shut-off switch 1 4 cover 1 5 10-pin main harness 1 e and w model 6 warning indicator harness 1 e and w model 7 screw 2 ø6 × 19 mm/e and w model 8 warning indicator assembly 1 e a...

  • Page 184: Brkt

    Brkt bracket unit 7-3 67c3k11 no. Part name q’ty remarks 1 shift lever 1 2 screw 2 ø6 × 15 mm 3 bolt 1 m8 × 40 mm 4 bushing 2 5 grommet 1 6 tiller handle 1 7 washer 2 8 collar 2 9 self-locking nut 1 10 washer 1 11 tiller handle bracket 1 12 collar 1 13 wave washer 1 14 washer 1 15 bolt 1 m12 × 80 mm...

  • Page 185

    67c3k11 7-4 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 18 holder 2 19 cable bracket 1 20 bolt 2 m6 × 14 mm 21 holder 1 22 clip 2 23 throttle cable 1 24 shift cable 1 25 shift link assembly 1 26 throttle lever 1 27 e-clip 1 28 screw 2 ø3 × 15 mm 29 throttle rod 1 30 neutral switch 1 e and w model 3...

  • Page 186: Brkt

    Brkt bracket unit 7-5 67c3k11 no. Part name q’ty remarks 35 cap 1 36 screw 1 ø5 × 22 mm 37 grip 1 38 bushing 1 39 cotter pin 1 40 washer 2 41 throttle rod cam 1 42 collar 1 43 spring seat 2 44 spring 1 45 bushing 1 46 nut 1 47 friction piece 1 48 cotter pin 1 not reusable 49 throttle friction adjust...

  • Page 187

    67c3k11 7-6 1 2 3 4 5 6 7 8 9 removing the tiller handle 1. Disconnect the engine shut-off switch leads (m model), or 10-pin main harness and warning indicator assembly coupler (e and w model). Note: to disconnect the leads or wiring harness, see “electrical component and wiring har- ness routing” (...

  • Page 188: Brkt

    Brkt bracket unit 7-7 67c3k11 4. Install the throttle friction adjuster 7, and then install a new cotter pin 8. 5. Install the bushing 9, throttle grip 0, and ptt switch a (ptt model). Note: fasten the ptt switch lead b with the hold- ers e. (ptt model) 6. Install the throttle cable holder c and shi...

  • Page 189: Friction Plate (H Model)

    67c3k11 7-8 1 2 3 4 5 6 7 8 9 friction plate (h model) no. Part name q’ty remarks 1 bolt 1 m5 × 20 mm 2 steering lock shaft 1 3 bracket 1 4 collar 1 short 5 washer 2 6 self-locking nut 2 7 washer 2 8 steering lock lever 1 9 friction piece 2 10 collar 1 long 11 friction plate 1 12 steering lock washe...

  • Page 190: Brkt

    Brkt bracket unit 7-9 67c3k11 disassembling the friction plate 1. Remove the tiller handle and friction plate bolts 1, and then remove the fric- tion plate assembly from the swivel bracket. 2. Disassemble the friction plate assembly. Note: see the exploded diagram for disassembly (7-8). Assembling t...

  • Page 191

    67c3k11 7-10 1 2 3 4 5 6 7 8 9 note: to check and adjust the friction plate, see “checking the steering operation (h model)” (3-12). T r . . Friction plate self-locking nut 5: 4 n·m (0.4 kgf·m, 3.0 ft·lb) s67c7014 5 4 e friction plate (h model).

  • Page 192: Brkt

    Brkt bracket unit 7-11 67c3k11 bottom cowling no. Part name q’ty remarks 1 adapter 1 2 flushing hose 1 3 bracket 1 4 screw 2 ø6 × 19 mm 5 bolt 1 m6 × 16 mm 6 bolt 1 m6 × 25 mm 7 fuel joint 1 8 grommet 1 d model 9 grommet 1 ptt model 10 bolt 4 m6 × 25 mm 11 washer 1 12 clip 2 13 shift rod lever 1 14 ...

  • Page 193

    67c3k11 7-12 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 18 shift rod 1 19 grommet 1 20 bolt 1 m6 × 20 mm 21 spring 1 22 grommet 4 23 bolt 4 m6 × 30 mm 24 grommet 4 25 collar 4 26 water outlet 1 27 collar 2 28 grommet 2 29 bolt 1 m6 × 25 mm 30 plate 1 31 cooling water hose 3 32 bolt 1 m6 × 14 mm 33...

  • Page 194: Brkt

    Brkt bracket unit 7-13 67c3k11 no. Part name q’ty remarks 35 bushing 1 36 bushing 1 37 wave washer 1 38 washer 1 39 cowling lock lever 1 40 bolt 1 m6 × 20 mm/h model with ptt 41 holder 1 ptt model 42 bolt 2 m6 × 20 mm/r model with ptt 43 bracket 1 r model with ptt 44 ptt switch 1 r model with ptt 45...

  • Page 195: Upper Case and Steering Arm

    67c3k11 7-14 1 2 3 4 5 6 7 8 9 upper case and steering arm no. Part name q’ty remarks 1 steering arm 1 2 stud bolt 2 3 nut 2 4 washer 1 5 bushing 1 1 6 o-ring 2 not reusable 7 bushing 2 2 8 plate 1 9 gasket 1 not reusable 10 bolt 1 m6 × 20 mm 11 ground lead 1 Ó: l-transom model/Ú: s-transom model 12...

  • Page 196: Brkt

    Brkt bracket unit 7-15 67c3k11 no. Part name q’ty remarks 18 nut 2 19 washer 2 20 bolt 2 m8 × 20 mm/l-transom model 21 lower mount cover 1 l-transom model 22 bolt 3 m8 × 30 mm 23 bolt 2 m8 × 175 mm 24 upper mount 1 25 upper case assembly 1 26 bolt 4 m8 × 30 mm 27 lower mount housing 2 28 bolt 2 m12 ...

  • Page 197

    67c3k11 7-16 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 screw 2 ø5 × 16 mm 2 baffle plate 1 3 dowel 2 4 upper case 1 5 bolt 4 m8 × 30 mm 6 grommet 1 7 gasket 1 not reusable / l-transom model 8 plug 1 m14 × 12 mm/l-transom model 9 grommet 1 l-transom model 10 drive shaft bushing 1 l-transom model...

  • Page 198: Brkt

    Brkt bracket unit 7-17 67c3k11 no. Part name q’ty remarks 1 oil seal 1 not reusable 2 exhaust guide 1 3 bolt 1 m6 × 20 mm 4 plate 1 5 bolt 1 m5 × 12 mm 6 cover 1 7 anode 1 8 grommet 1 9 gasket 1 not reusable 10 gasket 1 not reusable 11 relief valve assembly 1 12 bolt 3 m6 × 25 mm 13 bolt 2 m6 × 16 m...

  • Page 199

    67c3k11 7-18 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 18 oil pan 1 19 bolt 10 m6 × 25 mm 20 drain bolt 1 21 gasket 1 not reusable 22 damper 1 l-transom model 23 damper 1 s-transom model 24 gasket 1 not reusable 25 exhaust manifold 1 26 bolt 3 m6 × 50 mm 27 gasket 1 not reusable 28 muffler 1 l-tr...

  • Page 200: Brkt

    Brkt bracket unit 7-19 67c3k11 removing the upper case note: drain the engine oil before removing the upper case assembly. 1. Remove the lower mount cover 1. (l- transom model) 2. Remove the ground lead 2 and speed- ometer hose. 3. Remove the lower mount housings 3, and then remove the upper and low...

  • Page 201

    67c3k11 7-20 1 2 3 4 5 6 7 8 9 8. Remove the oil seal j and anode k from the exhaust guide. È s-transom model 9. Remove the circlip l, collar m, and drive shaft bushing n from the upper case 5. (l-transom model) checking the muffler, exhaust manifold, oil pan, and exhaust guide 1. Check the muffler,...

  • Page 202: Brkt

    Brkt bracket unit 7-21 67c3k11 assembling the upper case 1. Install the drive shaft bushing 1 and col- lar 2 into the upper case 3, and then install the circlip 4. (l-transom model) 2. Install a new oil seal 7 into the exhaust guide 8. 3. Install the dowels 9, the cooling water pipe 0, new gaskets a...

  • Page 203

    67c3k11 7-22 1 2 3 4 5 6 7 8 9 8. Install the dowels m and oil pan assem- bly n, and then tighten the upper case bolts o to the specified torque. 9. Install the upper mount p, and then tighten the bolts q. È s-transom model 10. Install the damper and engine oil drain bolt r, and then tighten the dra...

  • Page 204: Brkt

    Brkt bracket unit 7-23 67c3k11 installing the steering arm 1. Install the washer 1, bushing 1 2, a new o-ring 3, and bushing 2 4 onto the steering arm 5. 2. Place the swivel bracket 6 in an upright position, and then install the steering arm onto the bracket. 3. Install bushing 2 7, a new o-ring 8, ...

  • Page 205

    67c3k11 7-24 1 2 3 4 5 6 7 8 9 t r . . Upper mounting nut 4: 24 n·m (2.4 kgf·m, 17.7 ft·lb) grease nipple: 3 n·m (0.3 kgf·m, 2.2 ft·lb) s67c7031 l s bow lt 572 lt lt 271 lt 2 6 1 6 1 3 9 7 4 8 5 upper case and steering arm.

  • Page 206: Brkt

    Brkt bracket unit 7-25 67c3k11 hydraulic tilt unit and ptt unit no. Part name q’ty remarks 1 e-clip 2 2 shaft 1 3 bushing 1 4 bushing 2 5 plastic tie 2 ptt model 6 bolt 2 m8 × 15 mm 7 washer 2 8 shaft 1 9 bushing 2 10 bushing 1 ptt model 11 ptt unit 1 ptt model 12 bolt 2 m6 × 10 mm/ptt model 13 hydr...

  • Page 207

    67c3k11 7-26 1 2 3 4 5 6 7 8 9 clamp bracket and swivel bracket no. Part name q’ty remarks 1 cap 2 2 self-locking nut 1 3 bolt 1 m6 × 14 mm/r model with ptt 4 holder 1 r model with ptt 5 nut 2 6 washer 2 7 stopper 2 m10 × 45 mm/È d model/É ptt model 8 bolt 2 m6 × 25 mm 9 anode 1 10 clamp bracket 1 s...

  • Page 208: Brkt

    Brkt bracket unit 7-27 67c3k11 no. Part name q’ty remarks 18 holder 1 19 bolt 2 m6 × 12 mm/with friction plate 20 spring washer 2 with friction plate 21 bolt 2 m6 × 14 mm/ptt model 22 ground lead 1 short/ptt model 23 ground lead 1 long/ptt model 24 ground lead 1 d model 25 clamp bracket 1 port 26 th...

  • Page 209

    67c3k11 7-28 1 2 3 4 5 6 7 8 9 removing the hydraulic tilt unit 1. Tilt the outboard motor to the fully up position, and then support it with the tilt stop lever. Warning after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- den...

  • Page 210: Brkt

    Brkt bracket unit 7-29 67c3k11 4. Remove the bolts 5 and disconnect the ground leads 6 from the ptt unit 7. 5. Remove the bolts 8, washers 9, bush- ings 0, and shaft a. 6. Remove the e-clips b, shaft c, and bushing d. 7. Remove the ptt unit 7, and then remove the bushings e. Removing the clamp brack...

  • Page 211

    67c3k11 7-30 1 2 3 4 5 6 7 8 9 3. Install the bolt 5, and then tighten it. 4. Install the self-locking nut 6 onto the through tube 4, and then tighten it to the specified torque. 5. Install the ground lead(s) 7 and bolts 8 to the brackets. 6. Install the anode 9 and then tighten the bolts 0 to the s...

  • Page 212: Brkt

    Brkt bracket unit 7-31 67c3k11 2. Install the collar 1 onto the hydraulic tilt unit 2. 3. Install the hydraulic tilt unit 2, collar 3, bushings 4, shaft 5, and washers 6 onto the clamp brackets 7, and then tighten the bolts 8. 4. Install a bushing 9 to the hydraulic tilt unit 2 and install a bushing...

  • Page 213

    67c3k11 7-32 1 2 3 4 5 6 7 8 9 note: install the ground lead terminals b and c as shown. 7. Pass the ptt motor lead d through the hole a in the clamp bracket 6 (stbd). 8. Fasten the ptt motor lead d to the clamp bracket 6 with a plastic ties e. 9. Fasten the ptt motor lead d and trim sensor lead f w...

  • Page 214: Brkt

    Brkt bracket unit 7-33 67c3k11 5. Tilt the outboard motor to the fully up position, and then support it with the tilt stop lever. Warning after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower if the ptt unit should l...

  • Page 215: Ptt Motor

    67c3k11 7-34 1 2 3 4 5 6 7 8 9 ptt motor no. Part name q’ty remarks 1 ptt motor assembly 1 2 stator 1 3 screw 2 ø4 × 10 mm 4 o-ring 1 not reusable 5 armature 1 6 screw 1 ø4 × 8 mm 7 screw 2 ø4 × 10 mm 8 spring 2 9 brush 1 long lead 10 brush 1 short lead 11 bolt 4 m6 × 20 mm 12 ptt motor base 1 13 oi...

  • Page 216: Brkt

    Brkt bracket unit 7-35 67c3k11 disassembling the ptt motor 1. Remove the ptt unit from the bracket. Note: to remove the ptt unit, see “removing the ptt unit” (7-28). 2. Fully extend the tilt ram, and then open the manual valve 1 by turning it clock- wise. Warning make sure that the tilt ram is fully...

  • Page 217

    67c3k11 7-36 1 2 3 4 5 6 7 8 9 6. Remove the brush holder screws b, brushes c, brush springs d, and oil seal from the ptt motor base 9. Checking the ptt motor 1. Check the commutator. Clean with 600- grit sandpaper and compressed air if dirty. 2. Measure the commutator diameter. Replace the armature...

  • Page 218: Brkt

    Brkt bracket unit 7-37 67c3k11 checking the brush holder and brush 1. Check the brush holder assembly for continuity. Replace the ptt motor base if out of specification. Note: the brush holder and circuit breaker cannot be removed from the ptt motor base; if either part is damaged, replace the ptt m...

  • Page 219

    67c3k11 7-38 1 2 3 4 5 6 7 8 9 3. Push the brushes into the holders, and then install the armature assembly 8 and tighten the armature plate screw 9. 4. Install a new o-ring = and the stator a to the ptt motor base 7, and then tighten the screws b. Note: align the rounded section c of the stator a w...

  • Page 220: Brkt

    Brkt bracket unit 7-39 67c3k11 ptt gear pump no. Part name q’ty remarks 1 bolt 4 m4 × 25 mm 2 gear pump assembly 1 3 o-ring 2 not reusable 4 spring 1 5 valve pin 1 6 main valve seal 1 7 filter 2 8 o-ring 2 not reusable 9 bolt 3 m6 × 75 mm 10 gear pump housing 1 11 circlip 1 12 manual valve 1 13 o-ri...

  • Page 221

    67c3k11 7-40 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 18 main valve assembly 2 19 main valve 2 20 o-ring 2 not reusable 21 o-ring 2 not reusable 22 o-ring 2 not reusable 23 shuttle piston 1 24 o-ring 1 not reusable 25 o-ring 2 not reusable 26 ball 2 27 absorber valve pin 2 28 spring 2 29 o-ring ...

  • Page 222: Brkt

    Brkt bracket unit 7-41 67c3k11 no. Part name q’ty remarks 35 valve pin 1 36 valve pin seal 1 37 o-ring 1 not reusable 38 relief valve 1 39 o-ring 1 not reusable 40 valve lock screw 1 s67c7076 20 33 1 1 9 35 36 34 9 19 18 20 21 22 35 36 38 39 40 37 32 lt 271 t r . . 3 n · m (0.3 kgf · m, 2.2 ft · ib)...

  • Page 223

    67c3k11 7-42 1 2 3 4 5 6 7 8 9 disassembling the gear pump 1. Remove the bolts 1, and then remove the gear pump housing 2. 2. Remove the balls 3, absorber valve pins 4, and filter 5. 3. Remove the bolts 6, and then remove the gear pump assembly 7. 4. Remove the valve pin 8, main valve seal 9, and fi...

  • Page 224: Brkt

    Brkt bracket unit 7-43 67c3k11 7. Remove the valve lock screw e and relief valve assembly f. 8. Remove the valve lock screw g, valve pin h, and valve pin seal i from the relief valve j. Note: when disassembling the relief valve assem- bly f, be sure to note the number of times the valve lock screw g...

  • Page 225

    67c3k11 7-44 1 2 3 4 5 6 7 8 9 note: see the exploded diagram for the filter instal- lation positions (7-39). Assembling the gear pump caution: • do not use a rag when assembling the ptt unit as dust and particles on the ptt unit components can lead to poor performance. • do not reuse the o-rings, a...

  • Page 226: Brkt

    Brkt bracket unit 7-45 67c3k11 5. Install the filters a, main valve seal b, and valve pin c. 6. Install the gear pump assembly d, and then tighten the bolts e to the specified torque. 7. Install the filter f, absorber valve pins g, balls h, and gear pump housing i, and then tighten the bolts j to th...

  • Page 227: Ptt Cylinder

    67c3k11 7-46 1 2 3 4 5 6 7 8 9 ptt cylinder no. Part name q’ty remarks 1 tilt ram assembly 1 2 dust seal 1 not reusable 3 o-ring 1 not reusable 4 o-ring 1 not reusable 5 backup ring 1 6 free piston assembly 1 7 o-ring 1 not reusable 8 cylinder 1 s67c7087 7 1 6 8 lt 271 t r . . 90 n · m (9.0 kgf · m,...

  • Page 228: Brkt

    Brkt bracket unit 7-47 67c3k11 disassembling the ptt cylinder 1. Hold the cylinder 1 in a vise using alumi- num plates a on both sides. 2. Loosen the tilt cylinder end screw, and then remove the tilt ram assembly 2. Warning make sure that the ram is fully extended before removing the end screw. 3. D...

  • Page 229

    67c3k11 7-48 1 2 3 4 5 6 7 8 9 4. Check the absorber valves 8. Clean if there is dirt or residue. Assembling the tilt cylinder caution: • do not use a rag when assembling the ptt unit as dust and particles on the ptt unit components can lead to poor performance. • do not reuse the dust seal and o-ri...

  • Page 230: Brkt

    Brkt bracket unit 7-49 67c3k11 4. Hold the tilt ram in a vise using aluminum plates a on both sides. 5. Install the balls 0, absorber valve pins a, springs b, and balls c as shown. 6. Install the washer d and bolt e to the tilt piston 8, and then tighten the bolt to the specified torque. 7. Install ...

  • Page 231

    67c3k11 7-50 1 2 3 4 5 6 7 8 9 13. Install the ptt motor to the ptt gear pump housing. Note: to install the ptt motor, see “assembling the ptt motor” (7-37). Bleeding the ptt unit note: make sure that the tilt ram is fully extended. 1. Place the ptt unit in an upright position. 2. Turn the manual va...

  • Page 232: Brkt

    Brkt bracket unit 7-51 67c3k11 5. Connect the ptt motor leads to the bat- tery terminals to fully retract the tilt ram. 6. Reverse the ptt motor leads between the battery terminals to fully extend the tilt ram. Note: • repeat steps 5–6 to fully extend and retract the tilt ram 4 to 5 times. • if the ...

  • Page 233: Ptt Electrical System

    67c3k11 7-52 1 2 3 4 5 6 7 8 9 note: connect the ptt motor leads directly to the battery terminals when the power unit is not installed. To connect the ptt motor leads, see “bleeding the ptt unit” (7-50). 2. Let the fluid settle for 5 minutes with the outboard motor tilted down. 3. Push the ptt swit...

  • Page 234: Brkt

    Brkt bracket unit 7-53 67c3k11 checking the ptt relay 1. Check the ptt relay for continuity. Replace if out of specification. 2. Connect the positive battery lead to the light green (lg) lead 5, and the negative battery lead to the black (b) lead 1 as shown, and then check the ptt relay for continui...

  • Page 235

    67c3k11 7-54 1 2 3 4 5 6 7 8 9 checking the ptt switch 1. Check the ptt switch for continuity. Replace if out of specification. È h model É r model checking the trim sensor 1. Measure the trim sensor resistance. Adjust the trim sensor if out of specifica- tion. Note: • turn the trim sensor lever 1 f...

  • Page 236: Brkt

    Brkt bracket unit 7-55 67c3k11 — memo —.

  • Page 237: Elec

    67c3k11 elec – + 1 2 3 4 5 6 7 8 9 electrical system electrical component and wiring harness routing...................................... 8-1 top view .................................................................................................... 8-1 bow view .....................................

  • Page 238: Elec

    Elec electrical system – + 8-1 67c3k11 electrical component and wiring harness routing top view 1 ignition coil 2 spark plug 3 pulser coil 4 oil pressure switch 5 starter motor (e and w model) 6 cdi unit 7 stator assembly 8 prime start s67c8001 5 6 3 1 2 4 8 7.

  • Page 239

    67c3k11 8-2 1 2 3 4 5 6 7 8 9 bow view + e and w model , m model 1 cdi unit 2 starter motor (e and w model) 3 rectifier regulator (e and w model) 4 10-pin main harness coupler (e and w model) 5 battery cable (e and w model) 6 10-pin main harness (e and w model) 7 warning indicator assembly lead (h m...

  • Page 240: Elec

    Elec electrical system – + 8-3 67c3k11 port view 1 cdi unit 2 starter motor (e and w model) 3 starter relay (e and w model) 4 pulser coil 5 rectifier regulator (e and w model) 6 ignition coils 7 ptt terminal (ptt model) 8 ptt switch (r model with ptt) 9 thermo sensor 0 ptt relay (ptt model) È fasten...

  • Page 241

    67c3k11 8-4 1 2 3 4 5 6 7 8 9 Ì align the positioning tape on the wiring harness with the bottom of the starter motor. Í install the terminal so that it is facing upward, within ± 15° of vertical. S67c8006 3 4 5 2 1 0 8 9 7 6 Ê Ë Ì Í È É electrical component and wiring harness routing.

  • Page 242: Elec

    Elec electrical system – + 8-5 67c3k11 tiller handle + e and w model , m model - ptt model . Except for ptt model 1 engine start switch (e and w model) 2 engine shut-off switch 3 warning buzzer (e and w model) 4 ptt switch (ptt model) 5 warning indicator assembly (e and w model) 6 warning indicator ...

  • Page 243

    67c3k11 8-6 1 2 3 4 5 6 7 8 9 É position the warning indicator coupler between the engine start switch and the engine shut-off switch, making sure that it is vertical. (e and w model) Ê bend the 10-pin main harness as shown in the illustration, and then connect the harness coupler. The bend should b...

  • Page 244: Elec

    Elec electrical system – + 8-7 67c3k11 checking the electrical component measuring the peak voltage to check the electrical components or mea- sure the peak voltage, use the special ser- vice tools. A faulty electrical component can be easily checked by measuring the peak voltage. The specified engi...

  • Page 245

    67c3k11 8-8 1 2 3 4 5 6 7 8 9 starter motor (e and w model) no. Part name q’ty remarks 1 pinion stopper set 1 2 nut 1 width across flats: 14.2 mm (9/16 in) 3 washer 1 4 pinion stopper 2 5 spring 1 6 pinion 1 7 bolt 2 m6 × 125 mm/width across flats: 9.5 mm (3/8 in) 8 cover 1 9 washer 1 10 armature 1 ...

  • Page 246: Elec

    Elec electrical system – + 8-9 67c3k11 removing the starter motor 1. Remove the starter motor from the power unit. Note: • check the engine start switch, neutral switch, starter relay, and fuse before removing the starter motor. • to remove the starter motor, see “starter motor, starter relay, and p...

  • Page 247

    67c3k11 8-10 1 2 3 4 5 6 7 8 9 3. Remove the nut 0, spacer a, and bolts b, and then remove the brush set c and brush holder d from the bracket e. Checking the starter motor pinion 1. Check the pinion teeth. Replace the pin- ion if cracked or worn. 2. Check the pinion for smooth operation. Note: turn...

  • Page 248: Elec

    Elec electrical system – + 8-11 67c3k11 3. Measure the commutator undercut a. Replace the armature if below specifica- tion. 4. Check the armature for continuity. Replace the armature if out of specifica- tion. Checking the brush holder and brush 1. Check the brush holder assembly for continuity. Re...

  • Page 249

    67c3k11 8-12 1 2 3 4 5 6 7 8 9 1. Install the brush holder 1 and brush set 2 into the bracket 3, and then tighten the bolts 4. 2. Install the spacer 5 and nut 6. 3. Install the cover 7, pinion 8, pinion stoppers 9, spring 0, and washer a to the armature b, and then tighten the nut c to the specified...

  • Page 250: Elec

    Elec electrical system – + 8-13 67c3k11 installing the starter motor 1. Install the starter motor to the power unit. 2. Connect the wiring harness to the starter motor, and then fasten the wiring har- ness. Note: to connect the wiring harness to the starter motor, see “electrical component and wirin...

  • Page 251

    67c3k11 8-14 1 2 3 4 5 6 7 8 9 È h model É r model Ê 7-pin main harness model 5. Connect the 10-pin (7-pin) main harness coupler. Checking the neutral switch (e and w model) note: be sure to check the engine start switch for continuity before checking the neutral switch. 1. Set the shift lever or re...

  • Page 252: Elec

    Elec electrical system – + 8-15 67c3k11 checking the starter relay (e and w model) 1. Disconnect the starter relay 1 coupler. 2. Connect the special service tool 2 to the starter relay coupler (wiring harness end). 3. Set the shift lever or remote control lever to the n position. 4. Turn the engine ...

  • Page 253

    67c3k11 8-16 1 2 3 4 5 6 7 8 9 3. Crank the engine and check for a spark. If there is no spark, check the ignition system. Warning • do not touch any of the connections of the special service tool. • be sure to install the special service tool to the spark plug cap so that sparks do not leak out. • ...

  • Page 254: Elec

    Elec electrical system – + 8-17 67c3k11 checking the pulser coil 1. Disconnect the pulser coil 1 coupler. 2. Connect the special service tool 2 to the pulser coil coupler. 3. Measure the pulser coil 1 output peak voltage. Replace if below specification. Note: • to prevent the engine from starting wh...

  • Page 255

    67c3k11 8-18 1 2 3 4 5 6 7 8 9 note: • to prevent the engine from starting when cranking it, be sure to disconnect all spark plug caps. • do not remove the clip from the engine shut-off switch. • if measuring the output peak voltage under the unloaded conditions, disconnect the charge coil connector...

  • Page 256: Elec

    Elec electrical system – + 8-19 67c3k11 2. Check the engine shut-off switch 1 for continuity between the engine shut-off switch connector and ground terminal (engine shut-off switch end). Replace if out of specification. 3. Connect the engine shut-off switch con- nector and ground terminal. Checking...

  • Page 257

    67c3k11 8-20 1 2 3 4 5 6 7 8 9 3. Measure the cdi unit 3 output peak voltage. Replace if below specification. Note: • to prevent the engine from starting when cranking it, be sure to disconnect all spark plug caps. • do not remove the clip from the engine shut-off switch. • when using the manual sta...

  • Page 258: Elec

    Elec electrical system – + 8-21 67c3k11 checking the thermo sensor 1. Disconnect the thermo sensor 1 cou- pler. 2. Connect jumper leads (thin terminals) 2 (commercially available) to the thermo sensor coupler (wiring harness end) as shown. 3. Start the engine, and then measure the input voltage at t...

  • Page 259

    67c3k11 8-22 1 2 3 4 5 6 7 8 9 3. Push the engine stop button. (m model) turn the engine start switch to “off.” (e and w model) 4. Check the oil pressure switch 1 for con- tinuity when the engine is stopped and when it is running. Check the oil pressure and oil pressure switch if out of specifica- t...

  • Page 260: Elec

    Elec electrical system – + 8-23 67c3k11 7. Check the oil pressure switch for continu- ity at the specified pressures. Replace if out of specification. Note: slowly operate the special service tool. Note: apply pressure to the oil pressure switch gradually. The oil pressure switch is operat- ing corr...

  • Page 261

    67c3k11 8-24 1 2 3 4 5 6 7 8 9 È m model É e and w model 10. Connect the yellow/red (y/r) lead (m model) or yellow (y) lead (e and w model) to the positive penlight battery terminal (1.5 v) and connect the pink/white (p/w) lead to the negative ter- minal, and then check that the oil pres- sure warni...

  • Page 262: Elec

    Elec electrical system – + 8-25 67c3k11 checking the power bobbin (for prime start) 1. Measure the power bobbin 1 output peak voltage. Replace the stator assem- bly if below specification. Note: • to prevent the engine from starting when cranking it, be sure to disconnect all spark plug caps. • do n...

  • Page 263

    67c3k11 8-26 1 2 3 4 5 6 7 8 9 3. Measure the lighting coil resistance. Replace if out of specification. 4. Connect the lighting coil connectors. Checking the rectifier regulator (e and w model) 1. Measure the rectifier regulator 1 out- put peak voltage. Check the rectifier regulator for continuity ...

  • Page 264: Elec

    Elec electrical system – + 8-27 67c3k11 3. Check the rectifier regulator for conti- nuity. Replace if out of specification. Note: the voltage values given in the table are for reference only. If voltage is produced, there is continuity, and, if there is an overload, there is no continuity. Refer to ...

  • Page 265: Trbl

    67c3k11 trbl shtg 1 2 3 4 5 6 7 8 9 troubleshooting troubleshooting the outboard motor........................................................... 9-1 troubleshooting table format..................................................................... 9-1 troubleshooting the power unit ....................

  • Page 266: Trbl

    Trbl shtg troubleshooting 9-1 67c3k11 troubleshooting the outboard motor note: before troubleshooting the outboard motor: • make sure that fresh fuel of the specified type has been used. • make sure that the battery is fully charged. • be sure to check that the couplers, connectors, and battery term...

  • Page 267

    67c3k11 9-2 1 2 3 4 5 6 7 8 9 symptom 1: engine does not crank (e and w model) starter rope operates, but the engine does not crank manual starter mal- function — disassemble and check the manual starter. 5-9 damaged flywheel magnet woodruff key — check the flywheel magnet woodruff key. 5-22 symptom...

  • Page 268: Trbl

    Trbl shtg troubleshooting 9-3 67c3k11 symptom 1: engine does not start (engine cranks) starter motor oper- ates, but the engine does not crank stuck piston seizure or rust disassemble and check the power unit. 5-1 piston lock due to water in the com- bustion chamber — stuck drive shaft buildup of fo...

  • Page 269

    67c3k11 9-4 1 2 3 4 5 6 7 8 9 fuel not supplied pinched or kinked fuel hose — check the fuel hoses and fuel hose joint. 3-3 clogged fuel filter — replace the fuel fil- ter. 3-3 fuel pump malfunc- tion — disassemble and check the fuel pump. 4-4 carburetor malfunc- tion malfunction of the carburetor i...

  • Page 270: Trbl

    Trbl shtg troubleshooting 9-5 67c3k11 symptom 1: unstable engine idle speed, poor acceleration, poor performance, limited engine speed, or engine stalls symptom 2 cause 1 cause 2 checking step refer to page intermittent spark spark plug malfunc- tion — check the spark plug. 3-6 spark plug cap mal- f...

  • Page 271

    67c3k11 9-6 1 2 3 4 5 6 7 8 9 symptom 1: high engine idle speed low compression pressure valve clearance not adjusted correctly — adjust the valve clearance. 5-2 damaged cylinder head gasket — disassemble and check the cylinder head and power unit. 5-29 5-42 damaged valve scratched piston or cylinde...

  • Page 272: Trbl

    Trbl shtg troubleshooting 9-7 67c3k11 symptom 1: limited engine speed symptom 2 cause 1 cause 2 checking step refer to page • buzzer comes on (e and w model) • overheat warning indicator comes on • cooling water does not dis- charge from the cooling water pilot hole clogged cooling water inlet — che...

  • Page 273

    67c3k11 9-8 1 2 3 4 5 6 7 8 9 troubleshooting the ptt unit (ptt model) symptom 1: ptt unit does not operate symptom 2 cause 1 cause 2 checking step refer to page ptt motor does not operate blown fuse — check the fuse. 8-13 ptt switch mal- function — check the ptt switch. 7-54 ptt relay malfunc- tion...

  • Page 274: Trbl

    Trbl shtg troubleshooting 9-9 67c3k11 symptom 1: ptt unit does not hold the outboard motor up troubleshooting the lower unit symptom 1: shift mechanism of the forward gear and reverse gear does not operate properly symptom 2 cause 1 cause 2 checking step refer to page — manual valve left open manual...

  • Page 275

    67c3k11 9-10 1 2 3 4 5 6 7 8 9 symptom 1: cooling water does not discharge from the cooling water pilot hole symptom 2 cause 1 cause 2 checking step refer to page — clogged cooling water inlet — check the cooling water inlets. 3-7 clogged cooling water passages — check the cooling water passages. 3-...

  • Page 276

    Index i-1 67c3k11 a. Abbreviation ................................................1-3 adjusting the dashpot ...............................4-17 adjusting the pilot screw ...........................4-15 adjusting the throttle cable..........................3-8 adjusting the throttle link................

  • Page 277

    67c3k11 i-2 1 2 3 4 5 6 7 8 9 index checking the muffler, exhaust manifold, oil pan, and exhaust guide ......................7-20 checking the neutral switch (e and w model) .....................................8-14 checking the oil pressure ...........................5-1 checking the oil pressure s...

  • Page 278

    Index i-3 67c3k11 friction plate (h model)...............................7-8 fuel hose, blowby hose, and cooling water hose .............................4-1 fuel pump, fuel filter, and fuel joint .............4-2 fuel system..............................2-10 , 2-17 , 3-3 g. General ....................

  • Page 279

    67c3k11 i-4 1 2 3 4 5 6 7 8 9 index self-protection.............................................1-4 serial number..............................................1-6 shimming ........................................ 6-21 , 6-22 special service tool .....................................1-7 specified tor...

  • Page 280: Wiring Diagram

    Wiring diagram f30amhd, f40bmhd 1 cdi unit 2 stator assembly 3 pulser coil 4 thermo sensor 5 ignition coil 6 spark plug 7 oil pressure switch 8 warning indicator assembly 9 engine shut-off switch 0 prime start color code b : black o : orange p : pink r : red w : white y : yellow b/o : black/orange b...

  • Page 281: Wiring Diagram

    Wiring diagram f30aeht, f30aet, f40bwhd, f40bwht, f40bed, f40bet 1 cdi unit 2 stator assembly 3 pulser coil 4 thermo sensor 5 ignition coil 6 spark plug 7 ptt switch (bottom cowling) (r model with ptt) 8 rectifier regulator 9 oil pressure switch 0 fuse (20 a) a starter relay b starter motor c ptt mo...

  • Page 283

    Yamaha motor co., ltd. Printed in china aug. 2007 – 1.2 × 1 cr (e).

  • Page 284

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  • Page 285

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