Page 1
EK40G
EK40J
SERVICE MANUAL
6H9-28197-5G-11
Page 2
NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
Important information
Particularly important information is distinguished in this manual by the following notations:
Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
w
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
cC
A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
EK40G/EK40J
SERVICE MANUAL
©2004 by Yamaha Motor Co., Ltd.
1st Edition, August 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
Page 3
Contents
General information
Specifications
Periodic checks and adjustments
Fuel system
Power unit
GEN
INFO
SPEC
CHK
ADJ
FUEL
POWR
1
2
3
4
5
Lower unit
Bracket unit
Electrical systems
Troubleshooting
Index
LOWR
BRKT
ELEC
TRBL
SHTG
6
7
8
9
Page 4
Page 5
GEN
INFO
General information
How to use this manual ............................................................................... 1-1
Manual format .......................................................................................... 1-1
Symbols ................................................................................................... 1-2
Safety while working ................................................................................... 1-3
Fire prevention ......................................................................................... 1-3
Ventilation ................................................................................................ 1-3
Self-protection ......................................................................................... 1-3
Parts, lubricants, and sealants ................................................................ 1-3
Good working practices ........................................................................... 1-4
Disassembly and assembly ..................................................................... 1-4
1
2
Identification ................................................................................................. 1-5
Applicable model ..................................................................................... 1-5
Serial number .......................................................................................... 1-5
Propeller selection ....................................................................................... 1-5
Propeller size ........................................................................................... 1-5
Selection .................................................................................................. 1-6
Predelivery checks ...................................................................................... 1-6
Checking the fuel system ........................................................................ 1-6
Checking the gear oil level ...................................................................... 1-6
Checking the battery (W) ......................................................................... 1-6
Checking the outboard motor mounting height ....................................... 1-7
Checking the remote control cables (remote control model) .................. 1-7
Checking the steering system ................................................................. 1-8
Checking the gear shift and throttle operation ........................................ 1-8
Checking the engine start switch, engine stop lanyard switch and engine
stop button ............................................................................................... 1-9
Checking the cooling water pilot hole ...................................................... 1-9
Test run .................................................................................................... 1-9
Break-in ................................................................................................. 1-10
After test run .......................................................................................... 1-10
3
4
5
6
7
6H95G11
8
9
1-
Page 6
GEN
LOWR
Lower unit
6-5
62Y5A11
Lower unit
No. Part name Q’ty Remarks
1 Lower unit 1
2 Plastic tie 1
Not reusable
3Hose 1
4 Check screw 1
5 Gasket 2
Not reusable
6 Dowel pin 2
7 Bolt 4 M10 40 mm
8 Drain screw 1
9Grommet 1
10 Bolt 1 M10 45 mm
11 Bolt 1 M8 60 mm
12 Thrust washer 1
13 Propeller 1
14 Washer 1
15 Washer 1
16 Cotter pin 1
Not reusable
17 Propeller nut 1
18 Trim tab 1
LOWR
Lower unit
6-19
62Y5A11
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.
Disassembling the drive shaft
1. Install the pinion nut , tighten it finger
tight, and then remove the drive shaft
bearing using a press.
CAUTION:
• Do not press the drive shaft threads
directly.
Do not reuse the bearing, always
replace it with a new one.
Disassembling the forward gear
1. Remove the taper roller bearing from the
forward gear using a press.
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
2. Remove the needle bearing from the forward gear.
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
Drive shaft holder 4 : 90890-06518
Pinion nut holder : 90890-06505
Socket adapter 2 : 90890-06507
Bearing inner race attachment :
90890-06639
S62Y6850K
Bearing separator : 90890-06534
Stopper guide plate : 90890-06501
Stopper guide stand :
90890-06538
Bearing puller : 90890-06535
Bearing puller claw 1 :
90890-06536
S62Y6740K
3
2
1
1
2
3
3
2
3
4
5
1
4
5
a
×
×
×
1
2
INFO
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to understand. Use the information below as a guide for effective and quality service.
1 Parts are shown and detailed in an exploded diagram and are listed in the components list.
2 Tightening torque specifications are provided in the exploded diagrams and after a numbered
step with tightening instructions.
3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant
and lubrication point.
4 The components list consists of part names and quantities, as well as bolt and screw dimensions.
5 Service points regarding removal, checking, and installation are shown in individual illustrations
to explain the relevant procedure.
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
General information
1-
1-1
6H95G11
Page 7
C
How to use this manual
Symbols
The symbols below indicate the content of a chapter.
General information Fuel system Bracket unit
GEN
INFO
Specifications Power unit Electrical systems
SPEC POWR ELEC
Periodic checks and adjustments
CHK
ADJ
Symbols 1 to 6 indicate specific data.
123456
1 Special tool
2 Specified oil or fluid
3 Specified engine speed
4 Specified tightening torque
FUEL BRKT
Lower unit Troubleshooting
LOWR
5 Specified measurement
6 Specified electrical value
(resistance, voltage, electric current)
TRBL
SHTG
1
2
3
4
5
Symbols 7 to e in an exploded diagram or illustration indicate the grade of lubricant and the lubrication point.
78 0qwe
7 Apply Yamaha 2-stroke motor oil
8 Apply gear oil
9 Apply water resistant grease (Yamaha grease A)
0 Apply molybdenum disulfide grease
Symbols r to o in an exploded diagram or illustration indicate the type of sealant or locking agent
and the application point.
rtyuio
r Apply Gasket Maker
t Apply Three bond 1104J
y Apply LOCTITE 271 (red)
6H95G11
9
q Apply corrosion resistant grease
(Yamaha grease D)
w Apply low temperature resistant grease
(Yamaha grease C)
e Apply injector grease
u Apply LOCTITE 242 (blue)
i Apply LOCTITE 572
o Apply silicon sealant
6
7
8
9
1-2
Page 8
GEN
INFO
Safety while working
To prevent an accident or injury and to ensure
quality service, follow the safety procedures
provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
General information
Parts, lubricants, and sealants
Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the outboard motor.
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where adequate ventilation can be maintained.
Self-protection
Protect your eyes by wearing safety glasses
or safety goggles during all operations involving drilling and grinding, or when using an air
compressor.
Protect your hands and feet by wearing protective gloves and safety shoes when necessary.
Under normal conditions, the lubricants mentioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
3. Avoid contact with skin. Do not, for example, place a soiled rag in your pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.
1-
1-3
6H95G11
Page 9
Safety while working
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
Good working practices
Special service tools
Use the recommended special service tools
to protect parts from damage. Use the right
tool in the right manner–do not improvise.
Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When tightening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cotter pins, circlips, etc., when installing or
assembling parts.
Disassembly and assembly
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply engine oil to the contact surfaces
of moving parts before assembly.
3. Install bearings with the manufacture
identification mark in the direction indicated in the installation procedure. In addition, be sure to lubricate the bearings liberally.
4. Apply a thin coat of water-resistant
grease to the lip and periphery of an oil
seal before installation.
5. Check that moving parts operate normally after assembly.
1
2
3
4
5
6
7
8
9
6H95G11
1-4
Page 10
GEN
6F610010
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
1
3
2
4
6B410020
6B410030
× -
a
bc
6F610030
×−
a
bc
INFO
General information
Identification
Applicable model
This manual covers the following models.
Applicable models
EK40GMH, EK40JMH, EK40JW
Serial number
The outboard motor serial number is
stamped on a label attached to the port clamp
bracket.
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 capabilities. An incorrect choice
could adversely affect performance and could
also seriously damage the engine.
Use the following information as a guide for
selecting a propeller that meets the operating
conditions of the boat and the outboard
motor.
Propeller size
The size of the propeller is indicated on the
outside of the propeller boss or the propeller
blade.
1 Model name
2 Approved model code
3 Transom height
4 Serial number
Model name
EK40G 6F5K 1006117–
EK40J 6H9K 1001748–
1-
1-5
Approved Starting
model code serial No.
a Propeller diameter (in inches)
b Propeller pitch (in inches)
c Propeller type (propeller mark)
6H95G11
Page 11
Selection
When the engine speed is at the full throttle
operating range (4,500–5,500 r/min), the
ideal propeller for the boat is one that provides maximum performance in relation to
boat speed and fuel consumption.
EK40G
Propeller size (in) Material
11 3/4 × 7 1/2 - H
11 3/4 × 8 3/4 - H
11 3/4 × 10 - H
Aluminum
11 1/2 × 11 - H
11 1/2 × 12 - H
11 1/2 × 13 - H
11 1/2 × 13 1/2 - H
EK40J
Propeller size (in) Material
12 1/4 × 9 - G
11 3/4 × 10 - G
11 5/8 × 11 - G
12 × 11 - G
11 3/8 × 12 - G
11 3/4 × 12 - G
11 1/8 × 13 - G
Aluminum
11 1/2 × 13 - G
10 1/4 × 14 - G
11 1/4 × 14 - G
10 1/4 × 15 - G
11 × 15 - G
10 1/4 × 16 - G
10 3/4 × 16 - G
10 3/4 × 17 - G
Predelivery checks
To make the delivery process smooth and
efficient, the predelivery checks should be
completed as explained below.
Propeller selection/Predelivery checks
6H910040
cC
Use pre-mixed fuel only.
Fuel and oil mixing ratio is 30:1. For
break-in period, gasoline: 25:1, kerosene:
30:1 mixture shall be used.
Checking the gear oil
1. Check the gear oil level.
6F630195
Checking the battery (W)
1. Check the capacity, electrolyte level, and
specified gravity of the battery.
Recommended battery capacity:
CCA/EN: 347 A
20HR/IEC: 40 Ah
Electrolyte specified gravity:
1.280 at 20°C (68°F)
1
2
3
4
5
6
7
8
9
Checking the fuel system
1. Check that the fuel hose is securely connected and that the fuel tank is filled with
fuel.
6H95G11
1-6
Page 12
GEN
0—25mm
(0—1in.)
6B410060
a
1
a
6F610060
N
R
F
2
6F610070
b
6F610075
INFO
2. Check that the positive and negative battery leads are securely connected.
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 mm (1 in) a below it. If
the mounting height is too high, cavitation
will occur and propulsion will be reduced.
Also, the engine speed will increase
abnormally and cause the engine to overheat. If the mounting height is too low,
water resistance will increase and reduce
engine efficiency.
General information
3. Check that the shift lever 2 is in the neu-
tral position.
NOTE:
The optimum mounting height is affected by
the combination of the boat and the outboard
motor. To determine the optimum mounting
height, test run the outboard motor at different heights
2. Check that the clamp brackets are
secured with the clamp screws.
Checking the remote control cables
(remote control model)
1. Set the remote control lever to the neutral
position and fully close the throttle lever.
2. Check that the throttle pulley 1 is in its
fully closed position, and check the pulley
is contact the fully stopper a on the
bracket.
w
The shift/throttle cable joint must be
screwed in a minimum of 8.0 mm (0.31 in)
b.
NOTE:
Check the throttle valve fully open, after setting the remote control cables.
1-
1-7
6H95G11
Page 13
Predelivery checks
a
b
6F610080
6F610110
a
R
N
F
6F610120
F
N
R
a
a
6F610100
6F610090
Checking the steering system
1. Check the steering friction for proper
adjustment.
NOTE:
9 To increase the friction, turn the friction
adjusting bolt in direction a.
9 To decrease the friction, turn the friction
adjusting bolt in direction b.
2. Check that the steering operates smoothly.
Checking the gear shift and throttle
operation
1. Check that the gear shift operates
smoothly when the shift lever or remote
control lever is shifted from neutral to forward or reverse.
2. Check that the throttle operates smoothly when the throttle grip (tiller handle
model) is turned from the fully closed
position to the fully open position a.
Check that the throttle operates smoothly when the remote control lever (remote
control model) is shifted from forward or
reverse to the fully open positions a.
1
2
3
4
3. Check that there is no interference with
wires or hoses when the outboard motor
is steered.
5
6
7
8
9
6H95G11
1-8
Page 14
GEN
6F610130
6F610140
6F610150
6F610170
INFO
Checking the engine start switch,
engine stop lanyard switch and
engine stop button
1. Check that the engine starts when the
engine start switch is turned to START.
(remote control model)
2. Check that the engine turns off when the
engine start switch is turned to OFF.
(remote control model)
General information
Checking the cooling water pilot
hole
1. Check that cooling water is discharged
from the cooling water pilot hole.
3. Check that the engine turns off when the
engine stop lanyard switch (and or
engine stop button) is pushed or the
engine stop lanyard is pulled from the
engine stop lanyard switch.
Test run
1. Start the engine, then check that the gear
shift operates smoothly.
2. Check the engine idle speed after the
engine has been warmed up.
3. Operate at trolling speed.
4. Run the outboard motor for 1 hour at
3,000 r/min or at half throttle, then for
another hour at 4,000 r/min or at 3/4
throttle.
5. Check that the outboard motor does not
tilt up when shifting into reverse and that
water does not flow in over the transom.
NOTE:
The test run is part of the break-in operation.
1-9
6H95G11
Page 15
Predelivery checks
6F610180
0
12 10
Break-in
During the test run, perform the break-in
operation in the following 5 stages.
1. 10 minutes a at the lowest possible
speed. A fast idle in neutral is best.
2. 50 minutes b at 1/2 throttle (approxi-
mately 3,000 r/min) or less. Vary engine
speed occasionally. On an easy-planing
boat, accelerate at full throttle onto plane,
then immediately reduce the throttle to
3,000 r/min or less.
3. 1 hour c at 3/4 throttle (approximately
4,000 r/min). Vary engine speed occasionally. Run at full throttle for 1 minute,
the allow about 10 minutes of operation
at 3/4 throttle or less to let the engine
cool.
4. 8 hours d at any speed, but avoid oper-
ating at full throttle for more than 5 minutes at a time. Let the engine cool
between full-throttle runs. Vary engine
speed occasionally.
After test run
1. Check for water in the gear oil.
2. Check for fuel leakage in the cowling.
3. Flush the cooling water passage with
fresh water using the flushing kit and with
the engine running at idle.
1
2
3
4
5
5. After the first 10hours. Use standard premix ratio of fuel and oil. Refer to page 1-
6.
å Hours
6
7
8
9
6H95G11
1-10
Page 16
GEN
INFO
— MEMO —
1-11
6H95G11
Page 17
SPEC
Specifications
General specification ................................................................................... 2-1
Maintenance specification .......................................................................... 2-3
Power unit ................................................................................................ 2-3
Lower unit ................................................................................................ 2-5
Electrical .................................................................................................. 2-5
Dimensions .............................................................................................. 2-7
Tightening torques ....................................................................................... 2-9
Specified torques ..................................................................................... 2-9
General torques ..................................................................................... 2-10
1
2
3
4
5
6
7
8
9
6H95G11
Page 18
SPEC
Specifications
General specification
Item Unit
Dimensions
Overall length mm (in) 997 (39.3) 692 (27.2)
Overall width mm (in) 484 (19.1) 363 (14.3)
Overall height
(S) mm (in) 1,215 (47.8) 1,208 (47.6)
(L) mm (in) 1,342 (52.8) 1,335 (52.6) –
Boat transom height
(S) mm (in) 381 (15.0)
(L) mm (in) 508 (20.2) –
Weight
(with aluminum propeller)
(S) kg (lb) 65.0 (143) 70.0 (154)
(L) kg (lb) 68.0 (150) 72.0 (159) –
Performance
Maximum output kW (hp) 29.4 (40) at 5,000 r/min
Full throttle operating range r/min 4,500–5,500
Maximum fuel consumption L (US gal, 19.5 (5.2, 4.3) at 5,500 r/min
lmp gal)/hr
Engine idle speed r/min 1,050–1,150
Power unit
Engine type 2-stroke, L
Cylinder quantity 2
3
Total displacement cm
Bore x stroke mm (in) 78.0 × 70.0 (3.07 × 2.76)
Compression ratio 5.00
Intake system Reed valve
Scavenging system Loop charge
Control system Tiller handle Remote control
Starting system Manual Manual and
Fuel system Carburetor
Ignition control system CDI
Maximum generator output (W) V, A (80) (80) 12, 6
Starting enrichment Choke valve
Spark plug (NGK) B7HS (NGK)
Cooling system Water
Exhaust system Under water Propeller boss
Lubrication system Pre-mixed fuel
(cu. in) 669 (40.82)
EK40GMH EK40JMH EK40JW
Model
electric
2-1
6H95G11
Page 19
General specification
Item Unit
Fuel and oil
Fuel type Regular gasoline and kerosene
Engine oil 2-stroke outboard motor oil
Engine oil grade
Gear oil type Hypoid gear oil
Gear oil grade (*1) API GL-4
Gear oil quantity cm
Bracket unit
Trim angle Degree 8, 12, 16, 20, 24
(at 12° boat transom)
Tilt-up angle Degree 67
Steering angle Degree 45 + 45
Drive unit
Gear shift positions F-N-R
Gear ratio 1.85 (24/13) 2.00 (26/13)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Share pin Spline
Propeller direction (rear view) Clockwise
Propeller ID mark H G
Electrical
Battery minimum capacity (*2)
CCA/EN — — 347
20HR/IEC — — 40
NMMA-certified
SAE 90
3
(US oz, 315 (10.65, 11.11)
lmp oz)
EK40GMH EK40JMH EK40JW
Model
TC-W3
1
2
3
4
5
(*1) Meeting both API and SAE requirements
(*2) CCA: Cold Cranking Ampere
EN: European Norm (European standard)
IEC: International Electrotechnical Commission
6
7
8
9
6H95G11
2-2
Page 20
SPEC
Specifications
Maintenance specification
Power unit
Item Unit
Power unit
Minimum compression kPa 400 (4.0, 58)
pressure (*1) (kgf/cm2, psi)
Cylinder head
Warpage limit mm (in) 0.1 (0.0039)
(lines indicate straightedge
position)
Cylinders
Bore size mm (in) 78.000–78.020 (3.0709–3.0716)
Wear limit mm (in) 78.100 (3.0700)
Taper limit mm (in) 0.08 (0.0032)
Out-of-round limit mm (in) 0.05 (0.0020)
Pistons
Piston diameter (D) mm (in) 77.940–77.965 (3.0685–3.0695)
Measuring point (H) mm (in) 10.0 (0.39)
Piston-to-cylinder clearance mm (in) 0.055–0.060 (0.0022–0.0024)
(limit) 0.110 (0.0043)
Piston pin boss bore mm (in) 19.904–19.915 (0.7836–0.7841)
Oversize piston
1st mm (in) 0.25 (0.010)
2nd mm (in) 0.50 (0.020)
Oversize piston diameter
1st mm (in) 78.190–78.215 (3.0783–3.0793)
2nd mm (in) 78.440–78.465 (3.0882–3.0892)
Piston pins
Outside diameter mm (in) 19.895–19.900 (0.7833–0.7835)
EK40GMH EK40JMH EK40JW
Model
(*1) Measuring conditions:
Ambient temperature 20°C (68°F), wide open throttle, with spark plugs removed from all cylinders.
The figures are for reference only.
2-3
6H95G11
Page 21
Maintenance specification
B
C
Item Unit
Piston rings
Top ring
Dimension B mm (in) 1.970–1.990 (0.0776–0.0783)
Dimension T mm (in) 2.500–2.700 (0.0984–0.1063)
End gap mm (in) 0.30–0.50 (0.0118–0.0197)
Side clearance mm (in) 0.02–0.06 (0.0008–0.0024)
Oversize diameter
1st mm (in) 78.25 (3.0807)
2nd mm (in) 78.50 (3.0906)
2nd piston ring
Dimension B mm (in) 1.970–1.990 (0.0776–0.0783)
Dimension T mm (in) 2.500–2.700 (0.0984–0.1063)
End gap mm (in) 0.30–0.50 (0.0118–0.0197)
Side clearance mm (in) 0.03–0.07 (0.0012–0.0028)
Oversize diameter
1st mm (in) 78.25 (3.0807)
2nd mm (in) 78.50 (3.0906)
Connecting rods
Small-end inside diameter mm (in) 24.900–24.912 (0.9803–0.9808)
Big-end side clearance mm (in) 0.200–0.700 (0.0079–0.0276)
Small-end axial play limit mm (in) 2.0 (0.08)
Crankshaft
Crankshaft width A mm (in) 61.40–61.45 (2.4173–2.4193)
Crankshaft width B mm (in) 41.38–41.60 (1.6291–1.6378)
Crankpin diameter mm (in) 26.995–27.000 (1.0627–1.0629)
Runout limit mm (in) 0.03 (0.0012)
EK40GMH EK40JMH EK40JW
Model
1
2
3
4
5
Thermostat
Opening temperature °C (°F) 58–62 (136–144)
Fully open temperature °C (°F) 70 (158)
Valve open lower limit mm (in) 3.0 (0.12)
Reed valves
Valve bending limit mm (in) 0.2 (0.0079)
Valve stopper height B mm (in) 2.2–2.6 (0.087–0.102)
Valve stopper height C mm (in) 4.0–4.4 (0.157–0.173)
6
7
8
9
6H95G11
2-4
Page 22
SPEC
Specifications
Item Unit
Carburetor
ID mark 6F542 6H903
Main jet (M.J.) # 145 – 140 –
Main air jet (M.A.J.) ø1.70 –ø1.70 –
Main nozzle (M.N.) mm (in)
Pilot jet (P.J.) # 90 60 90 60
Pilot air jet (P.A.J.) ø1.00 ø1.20 ø1.00 ø1.20
Pilot screw (P.S.) turns out 3/4 – 1 1/4 3/4 – 1 1/4
Valve seat size mm (in)
Float height mm (in)
EK40GMH EK40JMH EK40JW
Kerosene Gasoline
3.2 (0.13
2.0 (0.08) 1.2 (0.05)
12.0–13.0 4.0–5.0
(0.47–0.51) (0.16–0.20)
) – 3.2 (0.13) –
Model
Kerosene Gasoline
2.0 (0.08) 1.2 (0.05)
12.0–13.0 4.0–5.0
(0.47–0.51) (0.16–0.20)
Lower unit
Item Unit
Gear backlash
Pinion-to-forward mm (in)
Pinion-to-reverse mm (in)
Pinion gear shims mm
Forward gear shims mm
Reverse gear shims mm
EK40GMH EK40JMH EK40JW
0.05–0.24
(0.0020-0.0094)
0.40–0.59
(0.0157–0.0232
0.70, 0.75,
0.80, 0.85
0.70, 0.80,
0.90,
1.00, 1.10, 1.20
1.80, 1.90, 2.00,
2.10, 2.20, 2.30,
2.40, 2.50
)
Model
0.19–0.47
(0.0075-0.0185)
0.76–1.04
(0.0299–0.0409)
0.05, 0.08, 0.12, 0.30, 0.50
0.05, 0.08, 0.12, 0.30, 0.50
0.05, 0.08, 0.12, 0.30, 0.50
Electrical
Item Unit
Ignition and ignition control
system
Ignition timing (full retard) Degree BTDC 9 at engine idle speed
Ignition timing (full advanced) Degree BTDC 23
Ignition spark gap mm (in) 0.6–0.7 (0.024–0.028)
Ignition coil resistance
Primary coil (O–B) Ω 0.26–0.35
at 20°C (68°F)
EK40GMH EK40JMH EK40JW
Model
2-5
6H95G11
Page 23
Maintenance specification
Item Unit
Secondary coil
(spark plug wire–spark plug wire)
at 20°C (68°F)
CDI unit output peak voltage
(O–B)
at Cranking (loaded) V 160
at 1,500 r/min (loaded) V 185
at 3,500 r/min (loaded) V 170
Pulser coil output peak voltage
(W/R–B, W/B–B)
at Cranking (unloaded) V 10.0
at Cranking (loaded) V 10.0
at 1,500 r/min (loaded) V 30.0
at 3,500 r/min (loaded) V 66.0
Pulser coil resistance (W/R–B) Ω 16.2–19.8
Pulser coil resistance (W/B–B) Ω 16.2–19.8
Charge coil output peak
voltage (Positive side: Br–
Negative side: L)
at Cranking (unloaded) V 150
at Cranking (loaded) V 140
at 1,500 r/min (loaded) V 190
at 3,500 r/min (loaded) V 180
Charge coil resistance (Br–L) Ω 243–297
Starter motor
Type
Brushes ——Bendix
Length limit mm (in) ——9.0 (0.35)
Armature
Commutator undercut limit mm (in) ——0.2 (0.01)
Charging system
Fuse A –—20
Lighting coil output peak
voltage (G–G)
at Cranking (unloaded) V 6.0
at 1,500 r/min (unloaded) V 17.0
at 3,500 r/min (unloaded) V 38.0
Lighting coil resistance (G–G)
Rectifier output peak voltage
(R–B)
at 1,500 r/min (unloaded) V 13
at 3,500 r/min (unloaded) V 13
kΩ 6.8–10.2
Ω 0.32–0.39
EK40GMH EK40JMH EK40JW
Model
1
2
3
4
5
6
7
8
9
6H95G11
2-6
Page 24
SPEC
421 (16.6)
6H92001M
444 (17.5)
162 (6.4)
EK40JW
175 (6.9)
127 (5.0)
45 (1.8)
30 (1.2)*
533 (20.1)*
S: 622 (24.5)
L: 691 (27.2)
EK40JW
S: 764 (30.1)
EK40JW
S: 421 (16.6)
94 (3.7)
695 (27.4)
294 (11.6)*
205 (8.07)
602 (23.7)* 360 (14.2)
427 (16.8)
188 (7.4) 504 (19.8)
72 (2.8)
S: 784 (30.9)
L: 897 (35.3)
193 (7.6)*
S: 771 (30.4)
L: 898 (35.5)
EK40JW
478 (18.9)
EK40JW
S: 797 (33.4)
S: 444 (17.5)
L: 570 (22.4)
Dimensions
Exterior
Specifications
mm (in)
*MH
2-7
6H95G11
Page 25
60 (2.36)
33 (1.30)
124.5 (4.9)
16.5 (0.65)
10.5 (0.41)
93.5 (3.68)
134.5 (5.3)
217.5 (8.56)
249 (9.80)
57 (2.24)
50 (1.97)
32 (1.26)
124.5 (4.9)
93.5 (3.68)
134.5 (5.3)
10.5 (0.41)
6F62002M
Clamp bracket
Maintenance specification
mm (in)
1
2
3
4
5
6
7
6H95G11
8
9
2-8
Page 26
SPEC
Specifications
Tightening torques
Specified torques
Part to be tightened Thread size
Fuel system
Main jet — 4 0.4 3.0
Power unit
Power unit mounting bolt M8 21 2.1 15.5
Flywheel nut M20 160 16 115
Manual starter nut M6 10 1.0 7.2
Manual starter bolt M6 15 1.5 11.1
Starter motor bolt M8 29 2.9 21
Starter relay terminal nut M6 4 0.4 3.0
Cylinder head bolt
Cylinder head cover bolt M6 12 1.2 8.7
Exhaust outer cover bolt M6 8 0.8 5.8
Crankcase bolt
Spark plug M14 25 2.5 18
Lower unit
Check screw — 9 0.9 6.6
Drain screw — 9 0.9 6.6
Lower case mounting bolt M8 21 2.1 15.5
Lower case cap bolt (EK40G)
Cooling water inlet cover (EK40J) M5 4 0.4 3.0
Propeller nut (EK40J) M16 35 3.5 25.3
Propeller shaft housing ring nut (EK40J) — 90 9.0 65
Pinion nut (EK40J) M12 74 7.4 54.6
Bracket unit
Throttle grip screw M5 3 0.3 2.2
Engine stop lanyard switch nut — 5 0.5 3.6
Upper mount nut M8 28 2.8 20
Lower mount nut M12 55 5.5 40
Clamp bolt
Self locking nut M22 45 4.5 33
Bracket nut M6 24 2.4 17.7
Clamp pad bolt M6 10 1.0 7.2
Tilt lever bolt M5 4 0.4 3.0
Grease nipple — 3 0.3 2.2
1st
2nd 30 3.0 22
1st
2nd 40 4.0 29.5
1st
2nd 8 0.8 5.8
1st
2nd 24 2.4 17.7
M8
M8
M6
M8
Tightening torques
N·m kgf·mft·lb
15 1.5 11.1
20 2.0 15
4 0.4 3.0
14 1.4 10
2-9
6H95G11
Page 27
General torques
General torque
Nut (A) Bolt (B)
specifications
N·m kgf·mft·lb
8 mm M5 5 0.5 3.6
10 mm M6 8 0.8 5.8
12 mm M8 18 1.8 13
14 mm M10 36 3.6 26
17 mm M12 43 4.3 31
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 manual.
To avoid warpage, tighten multi-fastener
assemblies in a crisscross fashion and progressive stages until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads.
Components should be at room temperature.
Tightening torques
1
2
3
4
5
6
7
8
6H95G11
9
2-10
Page 28
SPEC
— MEMO —
2-11
6H95G11
Page 29
CHK
ADJ
Periodic checks and adjustments
Special service tools ................................................................................... 3-1
Maintenance interval chart .......................................................................... 3-2
Top cowling .................................................................................................. 3-3
Checking the top cowling ........................................................................ 3-3
Fuel system .................................................................................................. 3-3
Checking the fuel joint and fuel hoses (fuel joint-to-carburetor) ............. 3-3
Checking the fuel filters ........................................................................... 3-3
Power unit ..................................................................................................... 3-3
Checking the spark plugs ........................................................................ 3-3
Checking the thermostat ......................................................................... 3-4
Checking the cooling water passages ..................................................... 3-4
Control system ............................................................................................. 3-5
Adjusting the start-in-gear protection ...................................................... 3-5
Adjusting the throttle link position ............................................................ 3-5
Adjusting the throttle cable (MH) ............................................................. 3-5
Adjusting the throttle cable (W) ............................................................... 3-6
Checking the gear shift operation (MH) .................................................. 3-6
Checking the engine idle speed .............................................................. 3-7
Checking the gear shift operation (W) ..................................................... 3-7
1
1
2
3
3
4
5
Bracket .......................................................................................................... 3-8
Checking the tilt operation ....................................................................... 3-8
Lower unit ..................................................................................................... 3-8
Checking the gear oil level ...................................................................... 3-8
Changing the gear oil .............................................................................. 3-8
Checking the lower unit for air leakage ................................................... 3-9
Checking the propeller ............................................................................ 3-9
General .......................................................................................................... 3-9
Checking the anodes ............................................................................... 3-9
Checking the battery (W) ......................................................................... 3-9
Lubricating the outboard motor ............................................................. 3-10
6
7
8
9
6H95G11
Page 30
CHK
Digital tachometer
90890-06760
Leakage tester
90890-06840
CHK
ADJ
ADJ
Periodic checks and adjustments
Special service tools
3-1
6H95G11
Page 31
Special service tools/Maintenance interval chart
Maintenance interval chart
Use the following chart as a guideline for general maintenance.
Adjust the maintenance intervals according to the operating conditions of the outboard motor.
Initial Every Refer
Item Actions
Anode (s) (external) Check / replace 11 3-9
Anode (s) (internal) Check / replace 1 5-30
Battery Check / charge 1 3-9
Cooling water passages Clean 11 3-4
Cowling clamp Check 1 3-3
Fuel filter (can be disassembled)
Fuel system Check 111 3-3
Fuel tank (Yamaha portable tank)
Gear oil Change 113-8
Lubrication points Lubricate 1 3-10
Idling speed (carburetor model)
Propeller and cotter pin Check / replace 11 3-9
Shift link / shift cable Check / adjust 1 3-7
Thermostat Check 1 3-4
Throttle link / throttle
cable / throttle pick-up Check / adjust 1
timing
Water pump Check 1
Spark plug Clean / adjust / replace 111 3-3
Check / clean 111 3-3
Check / clean 1 —
Check / adjust 113-7
10 hours 50 hours 100 hours 200 hours to
(Break-in) (3 months) (6 months) (1 year)
page
3-5,
3-6
6-10, 6-32
1
1
2
3
3
4
5
NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed with clean water
after each use.
6
7
8
9
6H95G11
3-2
Page 32
CHK
6F630010
2
3
4
1
6H930020
6B430030
a
6B430025
1
6B430020
2
1
ADJ
Periodic checks and adjustments
Top cowling
Checking the top cowling
1. Check the fitting by pushing the cowling
with both hands.
Fuel system
Checking the fuel joint and fuel
hoses (fuel joint-to-carburetor)
1. Check the fuel hose connections and fuel
joint
1 for leaks. Replace if necessary.
Also, check the fuel filter 2, fuel pump
3, and carburetor 4 for leaks or deterioration. Replace if necessary.
NOTE:
Be sure not to spill any fuel when removing
the fuel filter cup.
Power unit
Checking the spark plugs
1. Disconnect the spark plug caps, and then
remove the spark plugs.
2. Clean the electrodes 1 with a spark plug
cleaner or wire brush. Replace the spark
plug if necessary.
3. Check the electrodes for erosion and
excessive carbon or other deposits, and
the gasket for damage. Replace the
spark plug if necessary.
4. Check the spark plug gap a. Adjust if out
of specification.
Checking the fuel filters
1. Check the fuel filter element 1 for dirt
and residue and check the fuel filter cup
2 for foreign substances and cracks.
Clean the cup with straight gasoline and
replace the element if necessary.
3-3
Specified spark plug:
B7HS (NGK)
Spark plug gap a:
0.6—0.7 mm (0.024—0.028 in)
5. Install the spark plug, tighten it finger
tight, then to the specified torque with a
spark plug wrench.
Spark plug:
25 N·m (2.5 kgf·m, 18 ft·lb)
6H95G11
Page 33
6B430060
1
2
3
6H930040
6B430070
Fuel system/Power unit
6F610170
Checking the thermostat
1. Remove the thermostat cover 1, gasket
2, and thermostat 3.
2. Suspend the thermostat in a container of
water.
3. Place a thermometer in the water and
slowly heat the water.
5. Install the thermostat and thermostat
cover, and then tighten the cover bolts.
Checking the cooling water passages
1. Check the cooling water inlet cover 1,
screw 2 and cooling water inlet for clogging. Clean if necessary.
å
2
6F630060
∫
1
1
2
3
4
4. Check the thermostat valve opening at
the specified water temperatures.
Replace if out of specification.
Water
temperature
58–62°C
(136–147°F)
above more than
70°C (158°F)
Valve lift a
0 mm (0 in)
(
valve begins to tilt
3.0 mm (0.12 in)
1
2
å EK40G
∫ EK40J
1
2
6F630070
5
6
2. Place the lower unit in water, then start
the engine.
3. Check for water flow at the cooling water
pilot hole. If there is no water flow, check
the cooling water passage inside the outboard motor.
7
8
9
)
6H95G11
3-4
Page 34
CHK
6F630085
1
2
3
4
a
6F630090
5
6
7
8
b
6F630050
1
2
a
b
1
2
6F630080
ADJ
Periodic checks and adjustments
Control system
Adjusting the start-in-gear protection
1. Set the gear shift to the neutral position.
2. Loosen the lock nut 1, and then adjust
the start-in-gear protection adjusting nut
2 until the top of the plunger a aligns
with the centre of the hole in the starter
case b.
Adjusting the throttle link position
1. Check that the throttle link and throttle
pulley for smooth operation. Adjust if necessary.
Adjusting the throttle cable
(MH)
NOTE:
Before adjusting the throttle cables, the throttle stop screw should be properly adjusted.
1. Check the throttle cables for smooth
operation, looseness, fraying or damage.
Replace if necessary.
2. With the throttle grip in the fully opened
position, check that the stopper on the
pulley contact with the stopper on the
bracket. Adjust if necessary.
3. Loosen the locknut 1 and adjust the
throttle cable (open-side) 2 with the
adjusting nut 3 until the stopper 4 on
the pulley contact the stopper plate a on
the bracket, then tighten the locknut.
2. loosen the throttle arm adjusting screw
1.
3. Turn the throttle grip or remote control
lever in the fully opened position and
adjust the throttle arm 2 until its contacts
with the stopper.
4. Tighten the throttle arm adjusting screw
1.
3-5
4. Turn the throttle grip to the fully closed
position.
5. Loosen the locknut 5 and adjust the
length of the throttle cable (close-side) 6
with the adjusting nut 7 until the stopper
8 on the pulley contact the stopper plate
b on the bracket, then tighten the locknut.
6H95G11
Page 35
Control system
1
a
2
3
4
6F630100
b
6F610075
5
R
N
F
6F630130
6. Fully open and close the throttle grip and
make sure the stopper on the pulley contacts the stopper on the bracket (at the
fully opened position) and stopper on the
bracket contacts the stopper on the pulley (at the fully closed position). If proper
contacts are not made, repeat the procedure.
Adjusting the throttle cable (W)
1. Check that the throttle cable for smooth
operation, looseness, fraying or damage.
Replace if necessary.
2. Check that the stopper 1 on the pulley is
contact the stopper plate a on the bracket when the remote control lever is in
neutral and the throttle lever is fully
closed position. Adjust the throttle cable
length if necessary.
4. Adjust the position of the cable end 5
until it is aligned with the hole on the pulley.
w
The shift/throttle cable end must be
screwed in a minimum of 8.0 mm (0.31in)
b.
5. Install the cable joint 3 and tighten the
adjusting nut.
1
2
3
4
3. Loosen the adjusting nut 2, remove the
cable joint 3, and then remove the throttle cable 4.
6. Check the throttle cable for smooth operation.
NOTE:
If the remote control cables cannot be properly adjusted at the engine side, make adjustments at the remote control side.
Checking the gear shift operation
(MH)
1. Check that the gear shift operates
smoothly when shifting from neutral to
forward or reverse. Adjust the shift rod if
necessary.
5
6
7
8
6H95G11
9
2. Set the gear shift to the neutral position.
3-6
Page 36
CHK
a
4
6F610077
N
R
F
3
1
2
6F630135
ADJ
Periodic checks and adjustments
Checking the gear shift operation
(W)
1. Check that the gear shift operates
smoothly when shifting it from neutral to
forward or reverse. Adjust the shift cable
length if necessary.
2. Set the gear shift to the neutral position.
3. Remove the cable joint 1, and then disconnect the shift cable 2.
4. Set the shift lever 3 to the neutral position.
Checking the engine idle speed
1. Start the engine and warm it up for 5 minutes.
2. Attach the special service tool to spark
plug wire #1 1, and then check the
engine idle speed. Adjust if out of specification.
1
6F630160
Digital tachometer: 90890-06760
Engine idle speed:
1,050—1,150 r/min
5. Adjust the position of the cable end 4
until it is aligned with the hole of the shift
lever.
w
The shift/throttle cable end must be
screwed in a minimum of 8.0 mm (0.31 in)
a.
6. Install the cable joint 1 and tighten the
adjusting nut.
3. Turn the throttle stop screw 2 in direction a or b until the specified engine idle
speed is obtained.
2
b
a
6H930170
NOTE:
9 To increase the idle speed, turn the throttle
stop screw in direction a.
9 To decrease the idle speed, turn the throttle
stop screw in direction b.
4. If the specified engine idle speed cannot
be obtained, adjust the throttle cable(s).
7. Check the gear shift for smooth operation
3-7
and, if necessary, repeat steps 2—6.
6H95G11
Page 37
Bracket/Lower unit
6F630180
6F630200
1
2
6F630190
1
Bracket
Checking the tilt operation
1. Fully tilt the outboard motor up and down
a few times and check the entire tilt range
for smooth operation.
Lower unit
Checking the gear oil level
1 Fully tilt the outboard motor down.
2. Remove the check screw 1, and then
check the gear oil level in the lower case.
Changing the gear oil
1. Fully tilt the outboard motor down.
2. Place a drain pan under the drain screw
1, remove the drain screw, then the
check screw 2 and let the oil drain completely.
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 the gear oil
until oil flows out of the check hole and no
air bubbles are visible.
1
2
3
4
5
Recommended gear oil:
Hypoid gear oil
API: GL-4
SAE: 90
Recommended gear oil:
Hypoid gear oil
API: GL-4
SAE: 90
Oil quantity:
315 cm
(10.65 US oz, 11.11 Imp oz)
Check and drain screw:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
3
6
7
6F630210
8
9
6H95G11
3-8
Page 38
CHK
6F630310
1
ADJ
Periodic checks and adjustments
Checking the lower unit for air leakage
cC
Do not over pressurize the lower unit, otherwise the oil seals may be damaged.
1. Remove the check screw 1, and then
install the special service tool.
Leakage tester: 90890-06840
å
6F630220
∫
6F630230
å EK40G
∫ EK40J
2. Apply the specified pressure to check
that the pressure is maintained in the
lower unit for at least 10 seconds.
NOTE:
Cover the check hole with a rag when removing the special service tool from the lower
unit.
Lower unit holding pressure:
100 kPa (1.0 kgf/cm
3. If pressure drops below specification,
check the drive shaft, propeller shaft oil
seals, shift rod, and drain screw for damage.
2
, 14 psi)
Checking the propeller
1. Check the propeller blades and splines
for cracks, damage, or wear. Replace if
necessary.
cC
Do not oil, grease, or paint the anodes or
the trim tab, otherwise they will be ineffective.
2. Replace the anodes or trim tab if excessively eroded.
Checking the battery (W)
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.
a
General
Checking the anodes
1. Check the anodes and trim tab for scales,
grease, and oil. Clean if necessary.
3-9
6F630240
2. Check the specific gravity of the electrolyte. Fully charge the battery if below
specification.
6H95G11
Page 39
w
A
6F630250
A
6F630260
A
A
a
A
6F630270
Battery electrolyte is dangerous; it contains sulfuric acid which is poisonous and
highly caustic.
9 Avoid bodily contact with electrolyte as
it can cause severe burns or permanent
eye injury.
9 Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
9 SKIN – Wash with water.
9 EYES – Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
9 Drink large quantities of water or milk
followed with milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
9 Charge batteries in a well-ventilated
area.
9 Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
9 DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
General
1
2
3
4
5
NOTE:
9 Batteries vary per manufacturer. The proce-
dures mentioned in this manual may not
always apply, therefore, consult the instruc-
tion manual of the battery.
9 Disconnect the negative battery lead first,
then the positive battery lead.
Electrolyte specific gravity:
1.280 at 20° C (68° F)
å
6
A
A
7
6F630280
å
8
Lubricating the outboard motor
1. Apply water resistant grease to the areas
shown.
A
9
NOTE:
Apply grease to the grease nipple until it
flows from the bushings a.
6F630290
å Tiller handle model
6H95G11
3-10
Page 40
CHK
6F630300
6B430300
ADJ
2. Apply low temperature resistant grease
to the area shown.
3. Apply corrosion resistant grease to the
area shown.
Periodic checks and adjustments
3-11
6H95G11
Page 41
FUEL
Fuel system
Special service tools ................................................................................... 4-1
Hose routing ................................................................................................. 4-2
Fuel line ........................................................................................................ 4-3
Carburetor ..................................................................................................... 4-5
Disassembling the carburetor .................................................................. 4-9
Checking the carburetor .......................................................................... 4-9
Assembling the carburetor .................................................................... 4-10
Adjusting the throttle stop screw ............................................................ 4-11
Fuel pump ................................................................................................... 4-12
Checking the fuel pump ......................................................................... 4-14
Disassembling the fuel pump ................................................................ 4-15
Assembling the fuel pump ..................................................................... 4-15
Checking the fuel joint ........................................................................... 4-15
1
2
3
4
5
6
7
8
9
6H95G11
Page 42
FUEL
Vacuum/pressure pump gauge set
90890-06756
Digital caliper
90890-06704
Fuel system
Special service tools
4-1
6H95G11
Page 43
Hose routing
1
2
3
5
4
6
5
6
7
7
6H94010E
Special service tools/Hose routing
1
2
3
1 Fuel hose (Fuel joint-to-fuel filter: For Gasoline)
2 Fuel hose (Fuel joint-to-fuel filter: For Kerosene)
3 Fuel hose (Fuel filter-to-fuel pump: For Gasoline)
4 Fuel hose (Fuel filter-to-fuel pump: For Kerosene)
5 Fuel hose (Fuel pump-to-carburetor: For Gasoline)
6 Fuel hose (Fuel pump-to-carburetor: For Kerosene)
7 Pilot water hose
4
5
6
7
8
6H95G11
9
4-2
Page 44
FUEL
6H94020E
Fuel line
Fuel system
No. Part name Q’ty Remarks
1 Clip 12
2 Fuel hose 1
3 Fuel hose 1
4 Bolt 1 M6 × 25 mm
5 Fuel joint 1
6 Grommet 1
7 Fuel hose 1
8 Fuel hose 1
9 Fuel hose 1
10 Fuel hose 1
11 Bolt 2 M6 × 55 mm
12 Fuel pump 1
13 Gasket 1
14 Nut 2
15 Bolt 1
16 Bracket 1
17 Fuel filter assembly 2
Not reusable
Not reusable
4-3
6H95G11
Page 45
Fuel line
6H94020E
1
2
3
No. Part name Q’ty Remarks
18 Fuel filter element 2
19 O-ring 2
20 Cup 2
21 Screw 3 ø6 × 30 mm
22 Intake silencer 1
23 O-ring 1
24 Screw 4 ø6 × 12 mm
25 Link lever 1
26 Pin 1
27 Choke rod 1
28 Collar 1
29 Link rod 1
30 Nut 4
31 Washer 4
32 Gasket 1
33 Carburetor assembly 1
34 Gasket 1
Not reusable
Not reusable
Not reusable
4
5
6
7
8
9
6H95G11
4-4
Page 46
FUEL
4 N·m (0.4 kgf·m, 3.0 ft·lb)
6H94040E
Carburetor
Fuel system
No. Part name Q’ty Remarks
1 Damper 1
2 Hose 2
3 Screw 4 ø4 × 14 mm
4 Cover 1
5 Gasket 1
6 Throttle stop screw 1
7 Spring 1
8 Pilot screw 2
9 Spring 2
10 O-ring 2
11 Screw 1 ø4 × 5 mm
12 Gasket 1
13 Washer 1
14 Joint 1
15 Link rod 1
16 Nut 1
17 Washer 1
Not reusable
Not reusable
4-5
6H95G11
Page 47
Carburetor
4 N·m (0.4 kgf·m, 3.0 ft·lb)
6H94040E
1
2
3
No. Part name Q’ty Remarks
18 Lever 1
19 Pump lever assembly 1
20 Cam 1
21 Screw 1 ø4 × 5 mm
22 Gasket 1
23 Drain screw 1
24 Gasket 1
25 Screw 4 ø5 × 16 mm
26 Main jet 2
27 Gasket 2
28 Main nozzle 2
29 Carburetor body 1
30 Pilot jet 4
31 Float pin 1
32 Float 1
33 Needle valve 1
34 Valve seat 1
Not reusable
Not reusable
Not reusable
4
5
6
7
8
9
6H95G11
4-6
Page 48
FUEL
4 N·m (0.4 kgf·m, 3.0 ft·lb)
6H94040E
Fuel system
No. Part name Q’ty Remarks
35 Gasket 1
Not reusable
36 Float chamber 1
37 Nozzle 1
38 Gasket 1
39 O-ring 1
40 O-ring 1
Not reusable
Not reusable
Not reusable
41 Stopper 1
42 Plunger 1
43 Drain screw 1
44 Gasket 1
Not reusable
45 Drain screw 1
46 Gasket 1
Not reusable
47 Check valve 1
48 Starter jet 1
49 Gasket 1
Not reusable
50 Float 1
51 Float pin 1
4-7
6H95G11
Page 49
Carburetor
4 N·m (0.4 kgf·m, 3.0 ft·lb)
6H94040E
1
2
3
No. Part name Q’ty Remarks
52 Float arm 1
53 Needle valve 1
54 Screw 1 ø4 × 5 mm
55 Valve seat 1
56 Gasket 1
57 Ball seat 1
58 Ball 1
59 Spring 1
60 Gasket 1
61 Carburetor body 1
62 Screw 8 ø5 × 16 mm
63 Screw 2 ø6 × 19 mm
64 Starter plunger 1
65 Spring 1
66 Float chamber 1
67 Screw 4 ø5 × 12 mm
68 Holder 1
Not reusable
Not reusable
4
5
6
7
8
9
6H95G11
4-8
Page 50
FUEL
6F640060
a
1
2
6D440025
6B440040
Fuel system
Disassembling the carburetor
NOTE:
9 Before disassembling the carburetor, make
sure to note the number of times the pilot
screw is turned out from the seated position
to its set position.
9 Disassembled jets and other components
should be sorted out and kept in order, so
that they can be re-assembled in their original positions.
Checking the carburetor
1. Check the air and fuel passages and jets,
for dirt and foreign matter. Clean the carburetor body with a petroleum based solvent if necessary.
2. Blow compressed air into all passages
and jets.
5. Check the float for deterioration. Replace
if necessary.
6. Measure the float height
a for the
kerosene and b for the gasoline.
Replace the float and needle valve as a
set, if out of specification.
cC
9 Direct the compressed air downward,
otherwise cleaning solvent may be
blown into your eyes or small parts of
the carburetor may be blown off.
9 Do not use steel wire for cleaning the
jets, otherwise the jet diameters may be
enlarged, which may seriously affect
performance.
3. Check the main jet, pilot jet, and main
nozzle for dirt or residue. Clean if necessary.
4. Check the pilot screw and needle valve
for bends or wear. Replace if necessary.
b
1
6H940065
NOTE:
9 The float should be resting on the needle
valve 1, but not compressing it.
9 Measure the height a from the gasket to
the float as shown for the kerosene side.
9 Measure the height b from the gasket to
the float as shown for the gasoline side.
Digital caliper 2: 90890-06704
Float height a: (kerosene)
12.5—13.0 mm (0.47—0.51 in)
Float height a: (gasoline)
4.0—5.0 mm (0.16—0.20 in)
4-9
6H95G11
Page 51
Carburetor
Assembling the carburetor
1. Install the starter jet 1 and check valve
2, then install the plunger 3 onto the
float chamber of the gasoline side.
2
3
2. Install the starter plunger 4, new gasket
5, spring 6, ball 7, ball seat 8, new
gasket 9 and valve seat 0 onto the carburetor body of the gasoline side.
1
6H940120
4. Install the pilot jet w, new gasket and
cover to the carburetor body of the
kerosene side as shown.
w
5. Install the needle valve e, float r, float
arm t, and float pin y, gasoline side
float, and then the check the float for
smooth operation.
å
w
6H940080
ye
1
2
3
4
4
5
6
8
3. Install the main jet q onto the float cham-
ber of the kerosene side.
7
q
9
0
6H940130
r
6H940090
∫
t
å:Kerosene side
∫:Gasoline side
NOTE:
Place the needle valve in the valve seat when
installing the float to the carburetor.
y
e
6H940095
5
6
7
8
6H95G11
Main jet:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
6H940140
6. Install the new gasket onto the each carburetor body, and then install the float
chamber.
4-10
9
Page 52
FUEL
6H940110
a
b
1
Fuel system
7. Install a new O-ring u, and new gasket
i, onto the carburetor body of the gaso-
line side, and then install the carburetor
body of the kerosene side.
i
u
6H940150
8. Install the pilot screw, turn it in until it is
lightly seated, then out the specified
number of turns.
Adjusting the throttle stop screw
1. Start the engine and warm it up for 5 minutes.
2. Turn the throttle stop screw 1 in direction a or b until the specified engine idle
speed is obtained.
NOTE:
9 To increase the idle speed, turn the throttle
stop screw in direction a.
9 To decrease the idle speed, turn the throttle
stop screw in direction b.
NOTE:
9 Adjust the throttle cable whenever the car-
buretor has been disassembled or the
engine idle speed has been adjusted.
9 For adjustment procedures, see Chapter3.
Pilot screw setting:
3/4 —1 1/4 turns out
9. Install the carburetor assembly.
Engine idle speed:
1,050—1,150 r/min
4-11
6H95G11
Page 53
Fuel pump
6H94030E
Carburetor/Fuel pump
1
2
3
No. Part name Q’ty Remarks
1 Screw 3 ø5 × 30 mm
2 Cover 1
3 Diaphragm 1
4 Gasket 1
5 Fuel pump body 1
6 Diaphragm 1
7 Spring 1
8 Spring plate 1
9 Gasket 1
10 Check valve 2
11 Cover 1
12 Gasket 1
13 Diaphragm 1
14 Pump body 1
15 Gasket 1
16 Diaphragm 1
17 Cover 1
Not reusable
Not reusable
Not reusable
Not reusable
4
5
6
7
8
9
6H95G11
4-12
Page 54
FUEL
6H94030E
Fuel system
No. Part name Q’ty Remarks
18 Check valve 2
19 Screw 4 ø5 × 24 mm
4-13
6H95G11
Page 55
Fuel pump
6H940020
Checking the fuel pump
1. Place a drain pan under the fuel hose
connections, and then disconnect the
fuel hoses from the fuel pump.
2. Connect the special service tool to the
fuel pump inlet a or b.
3. Cover the fuel pump outlet c or d with a
finger, and then apply the specified positive pressure. Check that there is not air
leakage.
c
b
d
a
6H940010
Connecting location:
a Gasoline inlet
b Kerosene inlet
c Gasoline outlet
d Kerosene outlet
Vacuum/pressure pump gauge set:
90890-06756
Specified pressure:
50 kPa (0.5 kgf/cm
2
, 7.3 psi)
5. Connect the special service tool to the
fuel pump outlet c or d.
d
c
6H940030
Specified pressure:
50 kPa (0.5 kgf/cm
6. Apply the specified positive pressure and
check that there is no air leakage.
Disassemble the fuel pump if necessary.
NOTE:
Assemble the fuel pump valve to the fuel
pump body, and moisten the inside of fuel
pump with gasoline to ensure a better seal.
7. lastly, connect the special service tool to
the inlet a or b, and then apply the positive pressure, check that there is smooth
blow from outlet c or d.
Reassemble the fuel pump if necessary.
2
, 7.3 psi)
1
2
3
4
5
6
4. Apply the specified negative pressure
and check that there is no air leakage.
Specified pressure:
30 kPa (0.3 kgf/cm
6H95G11
2
, 4.4 psi)
d
a
c
b
6H940040
4-14
7
8
9
Page 56
FUEL
6B740020
1
1
6F640040
6H940050
2
3
4
6
5
4
5
6
4
4
5
5
6
Fuel system
Disassembling the fuel pump
1. Disassemble the fuel pump.
2. Check the diaphragms for tears or damage. Replace if necessary.
3. Check the valves for bends or damage.
Replace if necessary. Also, check the fuel
pump body for damage. Replace if necessary.
4. Clean the fuel pump body.
Assembling the fuel pump
NOTE:
Clean the parts and soak the valves and the
diaphragms in gasoline before assembly to
obtain prompt operation of the fuel pump
when starting the engine.
1. Install the valves 1 onto the fuel pump
body.
NOTE:
Make sure that the gaskets and diaphragms
are kept in place through the assembly
process.
Checking the fuel joint
1. Visually check the fuel joint for cracks or
damage.
2. Connect the special service tool at the
outlet of fuel joint.
3. Apply the specified pressure to check
that the pressure is maintained for 10
seconds. Replace the fuel joint if necessary.
2. Install the spring 2, spring plate 3, new
gaskets 4, the diaphragms 5, and covers 6.
Vacuum/pressure pump gauge set:
90890-06756
Specified pressure:
50 kPa (0.5 kgf/cm
2
, 7.3 psi)
4-15
6H95G11
Page 57
POWR
Power unit
Special service tools ................................................................................... 5-1
Power unit ..................................................................................................... 5-4
Checking the compression pressure ....................................................... 5-4
Disassembling the manual starter ......................................................... 5-13
Checking the spiral spring ..................................................................... 5-13
Checking the drive pawl ........................................................................ 5-13
Measuring the starter rope .................................................................... 5-13
Assembling the manual starter .............................................................. 5-14
Removing the power unit ....................................................................... 5-15
Removing the flywheel magnet ............................................................. 5-16
Removing the electrical components .................................................... 5-17
Removing the throttle pulley assembly ................................................. 5-17
Disassembling the base assembly ........................................................ 5-18
Assembling the base assembly ............................................................. 5-18
Reed valves ................................................................................................ 5-19
Removing the reed valve assembly ...................................................... 5-21
Checking the reed valves ...................................................................... 5-21
1
2
3
4
Cylinder head ............................................................................................. 5-22
Removing the cylinder head .................................................................. 5-24
Checking the cylinder head ................................................................... 5-24
Removing the exhaust cover ................................................................. 5-24
Checking the exhaust cover .................................................................. 5-24
Crankcase ................................................................................................... 5-25
Removing the crankcase ....................................................................... 5-27
Removing the crankshaft assembly and oil seal housing ..................... 5-27
Checking the cylinder bore .................................................................... 5-27
Disassembling the oil seal housing ....................................................... 5-28
Checking the oil seal housing ............................................................... 5-28
Assembling the oil seal housing ............................................................ 5-28
Disassembling the piston ...................................................................... 5-28
Checking the piston diameter ................................................................ 5-29
Checking the piston clearance .............................................................. 5-29
Checking the piston rings ...................................................................... 5-29
Checking the piston ring side clearance ............................................... 5-30
Checking the piston pin boss bore ........................................................ 5-30
Checking the piston pin ......................................................................... 5-30
Checking the internal anodes ................................................................ 5-30
Disassembling the crankshaft ............................................................... 5-30
Checking the crankpin ........................................................................... 5-32
Assembling the crankshaft .................................................................... 5-32
Checking the crankshaft ........................................................................ 5-36
Installing the crankshaft bearings .......................................................... 5-36
Assembling the piston ........................................................................... 5-37
Assembling the power unit .................................................................... 5-37
Installing the power unit ......................................................................... 5-39
5
6
7
8
9
6H95G11
Page 58
POWR
Compression gauge
90890-03160
Flywheel holder
90890-06522
Flywheel puller
90890-06521
Crankshaft aligner
90890-03107
Driver rod LS
90890-06606
Bearing Separator
90890-06534
Crank jig set
90890-02422
Flange
90890-02351
Driver rod L3
90890-06652
Needle bearing attachment
90890-06613, 90890-06628,
90890-06631, 90890-06654
Power unit
Special service tools
5-1
6H95G11
Page 59
Special service tools
Body
90890-02352
Bolt
90890-02353
Washer
90890-02354
Bushing-9 (D30)
90890-02363
B-9
Bushing-12 (D35)
90890-02366
B-12
Pressure plate
90890-02384
Press body
90890-02385
Pressure pin B
90890-02390
B
Bearing pressure C
90890-02393
C
Support
90890-02394
1
2
3
4
5
6
7
8
6H95G11
9
5-2
Page 60
POWR
Height ring (H-18)
90890-02401
H-18
Plate C
90890-02402
Pressure pin C
90890-02403
Spacer C
90890-02404
C
Small end bearing installer
90890-06527
Cylinder gauge
90890-06759
Power unit
5-3
6H95G11
Page 61
Special service tools/Power unit
Power unit
Checking the compression pressure
1. Start the engine, warm it up for 5 minutes, and then turn it off.
2. Remove the clip from the engine stop
lanyard switch.
3. Remove the spark plug caps and all
spark plugs, and then install the special
service tools into a spark plug hole.
6F650010
5. If the compression pressure is below
specification and the compression pressure for each cylinder is unbalanced, add
a small amount of engine oil to the cylinders, and then check the compression
pressure again.
NOTE:
9 If the compression pressure increases,
check the pistons and piston rings for wear.
Replace if necessary.
9 If the compression pressure does not
increase, check the cylinder head gasket,
and cylinder head. Replace if necessary.
1
2
3
4
cC
Before removing the spark plugs, blow
compressed air in the spark plug well to
clear out any dirt or dust that may fall into
the cylinder.
Compression gauge:
90890-03160
4. Fully open the throttle, and then crank the
engine until the reading on the compression gauge stabilizes.
NOTE:
Do not pull the choke knob when checking
the compression pressure.
Minimum compression pressure
(reference data):
400 kPa (4.0 kgf/cm
2
, 58 psi)
5
6
7
8
6H95G11
9
5-4
Page 62
POWR
6H95010E
21 N·m (2.1 kgf·m, 15.5 ft·lb)
W
MH
Power unit
No. Part name Q’ty Remarks
1 Power unit 1
2 Manual starter assembly 1
3 Collar 3
4 Grommet 6
5 Bolt 3 M8 × 35 mm
6 Gasket 1
7 Bolt 2 M6 × 12 mm
8 Dowel pin 2
9 Bolt 2 M6 × 25 mm
10 Bolt 8 M8 × 40 mm
11 Apron 1
12 Spiral tube 1
13 Corrugated tube 1
Not reusable
5-5
6H95G11
Page 63
Power unit
6H95030E
160 N·m (16 kgf·m, 115 ft·lb)
MH
1
2
3
No. Part name Q’ty Remarks
1 Flywheel magnet 1
2 Base assembly 1
3 Bolt 3 M6 × 40 mm
4 Oil seal 1
5 O-ring 1
6 Woodruff key 1
7 Bolt 3 M8 × 14 mm
8 Starter pulley 1
9 Nut 1
10 Washer 1
11 Pulser coil 2
12 Screw 4 ø5 × 24 mm
13 Charge coil 1
14 Screw 4 ø6 × 25 mm
15 Light coil 1
16 Screw 1 ø4 × 6 mm
4
5
6
Not reusable
Not reusable
7
8
9
6H95G11
5-6
Page 64
POWR
6F65050E
29 N·m (2.9 kgf·m, 21 ft·lb)
MH
Power unit
No. Part name Q’ty Remarks
1 Electric starter unit and 1 W model
CDI unit assembly
2 CDI unit assembly 1
3 Bolt 3 M8 × 48 mm
4 Bolt 3 M6 × 30 mm
5 Bolt 2 M8 × 25 mm
6 Bolt 1 M6 × 16 mm
7 Ignition coil 1
8 Bolt 2 M6 × 25 mm
9 Clamp 1
10 Plug cap 2
5-7
6H95G11
Page 65
Power unit
6F65040E
4 N·m (0.4 kgf·m, 3.0 ft·lb)
29 N·m (2.9 kgf·m, 21 ft·lb)
1
2
3
No. Part name Q’ty Remarks
1 Starter motor 1
2 Starter relay 1
3 Bracket 1
4 Bolt 2 M6 × 12 mm
5 Spiral tube 1
6 Cap 3
7 Nut 3
8 Spring washer 3
9 Starter motor lead 1
10 Battery negative lead 1
11 Bolt 2 M8 × 16 mm
12 Washer 2
13 Collar 2
14 Bracket 1
15 Bracket 1
16 CDI unit 1
17 Bolt 2 M6 × 20 mm
4
5
6
7
8
9
All components are for W model only.
6H95G11
5-8
Page 66
POWR
6F65040E
4 N·m (0.4 kgf·m, 3.0 ft·lb)
29 N·m (2.9 kgf·m, 21 ft·lb)
Power unit
No. Part name Q’ty Remarks
18 Rectifier 1
19 Screw 1 ø6 × 25 mm
20 Bolt 1 M6 × 16 mm
21 Battery positive lead 1
22 Cap 1
All components are for W model only.
5-9
6H95G11
Page 67
Power unit
6F65060E
1
2
3
No. Part name Q’ty Remarks
1 Bolt 1 M6 × 30 mm
2 Collar 1
3 Throttle control lever 1
4 Throttle pulley 1
5 Throttle cable 2
6 Bracket 1
7 Bolt 1 M6 × 15 mm
8 Link rod 1
9 Joint 2
4
5
6
7
8
6H95G11
9
5-10
Page 68
POWR
6F65020E
10 N·m (1.0 kgf·m, 7.2 ft·lb)
15 N·m (1.5 kgf·m, 11.1 ft·lb)
Power unit
No. Part name Q’ty Remarks
1 Manual starter case 1
2 Spiral spring 1
3 Washer 1
4 Sheave drum 1
5 Spring 1
6 Drive pawl 1
7 Spring 1
8 Washer 1
9 Drive plate 1
10 Washer 1
11 Bolt 1 M8 × 30 mm
12 Collar 1
13 Nut 1
14 Bolt 1 M6 × 20 mm
15 Collar 1
16 Roller 1
17 Bolt 2 M6 × 16 mm
5-11
6H95G11
Page 69
Power unit
6F65020E
10 N·m (1.0 kgf·m, 7.2 ft·lb)
15 N·m (1.5 kgf·m, 11.1 ft·lb)
1
2
3
No. Part name Q’ty Remarks
18 Washer 2
19 Cover 1
20 Manual starter handle 1
21 Damper 1
22 Starter rope guide 1
23 Starter rope 1
24 Start-in-gear protection cable 1
25 Plunger 1
26 Spring 1
4
5
6
7
8
6H95G11
9
5-12
Page 70
POWR
6F650040
9
6F650050
0
6F650020
1
2
a
3
6F650030
7
6
8
4
5
Power unit
Disassembling the manual starter
1. Turn the sheave drum 1 clockwise until
the spiral spring is free.
NOTE:
9 Turn the sheave drum so that the notch on
the outer surface of the sheave drum faces
toward the manual starter handle.
9 Pass the starter rope 2 through the notch
a.
9 When turn the sheave drum, pulling the
start-in-protection cable 3.
4. Remove the spiral spring 9 from the
manual starter case.
w
The spiral spring can pop out. To remove
the spring, cover it with cloths.
5. Remove the starter rope 0.
2. Remove the bolt, drive plate 4, spring
5, drive pawl 6 and drive pawl spring
7.
w
The sheave drum can pop out. Hold the
sheave drum with your hand, then pull it
out.
3. Remove the sheave drum8.
Checking the spiral spring
1. Check the spiral spring for cracks, bends,
or damage. Replace if necessary.
Checking the drive pawl
1. Check the drive pawl for cracks or damage. Replace if necessary.
Measuring the starter rope
1. Measure the starter rope length. Replace
if the length is below specification.
Starter rope length:
1,900 mm (74.8 in)
w
The spiral spring can pop out. Cover the
spiral spring with cloths, then pull out the
sheave drum.
5-13
6H95G11
Page 71
Power unit
6F650060
a
1
2
3
c
d
4
6F650080
5
6F650090
6F650070
b
6F650100
6
7
9
8
Assembling the manual starter
1. Install the starter rope 1 into the sheave
drum 2.
2. Install the drive pawl and springs.
3. Install the manual starter handle 3.
5. Install the spiral spring 4 into the starter
case.
1
2
NOTE:
Install the outer end c of the spiral spring
onto the pin d of the starter case.
3
6. Install the sheave drum into the manual
starter case 5.
4
NOTE:
9 Tie a knot at the end of the starter rope as
shown in the illustration.
9 Be sure to leave 5.0—10.0 mm (0.2—0.4
in) at the end a of the starter rope.
4. Wind the starter rope 1-1/2 around the
sheave drum in the direction of the arrow
shown in the illustration.
NOTE:
After winding the starter rope around the
sheave drum, install the starter rope in the
notch b.
NOTE:
Install the sheave drum, then set the spiral
spring by turning the sheave drum.
7. Install the drive pawl spring 6, drive pawl
7, spring 8 and drive plate 9.
5
6
7
8
9
6H95G11
5-14
Page 72
POWR
6F650110
e
0
6H950140
1
6F600120
3
2
6H900190
6H950160
4
f
6F650130
Power unit
8. Turn the sheave drum 3 times in the
direction of the arrow shown, and then
remove the starter rope from the notch
e.
NOTE:
Pull the start-in-gear protection cable 0 while
turning the sheave drum as shown.
9. Pull the manual starter handle several
times to check that the sheave drum
turns smoothly and to check the starter
rope for slack. Repeat steps 4—8 if necessary.
Removing the power unit
NOTE:
It is recommended to loosen the flywheel
magnet nut before removing the power unit to
improve working efficiency.
1. Disconnect the start-in-gear protection
cable 1, and then remove the manual
starter.
2. Remove the choke link rod 2 and intake
silencer 3.
10. Pull the manual starter handle completely, then measure the starter rope length.
Adjust if the starter rope length is out of
specification.
Starter rope length f:
1,300–1,500 mm (51.2–59.1 in)
5-15
3. Disconnect the throttle link rod 4.
6H95G11
Page 73
Power unit
6F650170
5
5
6H950150
6
6H950180
6F650200
6F650170
8
0
7
8
9
9
q
å
4. Disconnect the remote control cables
(remote control model) or throttle cables
(tiller handle model).
5. Disconnect the battery leads and ground
leads 5. (W)
6. Disconnect the shift link rod 6.
8. Remove the apron, and then remove the
power unit by removing the bolts.
Removing the flywheel magnet
1. Remove the starter pulley, and then
loosen the flywheel magnet nut.
1
2
3
4
7. Disconnect the engine stop lanyard
switch leads 7 (MH), CDI unit couplers
8, Ignition coil leads 9 and rectifier (W)
leads 0, thermoswitch leads q, fuel
hose and pilot water hose.
å MH model
cC
Apply force in the direction of the arrows
shown. While working, do not allow the
flywheel holder to slip off the flywheel.
Flywheel holder: 90890-06522
5
6
7
8
9
6H95G11
5-16
Page 74
POWR
6B450090
6F650210
2
3
1
6F650230
Power unit
2. Remove the flywheel magnet.
Removing the electrical components
1. Remove the bracket 1. (W: CDI unit,
starter motor, starter relay and rectifier)
2. Remove the base assembly 2.
cC
To prevent damage to the engine or tools,
screw in the flywheel puller set bolts
evenly and completely so that the flywheel
puller plate is parallel to the flywheel magnet.
NOTE:
Apply force to the crankshaft end until the flywheel magnet comes off the tapered portion
of the crankshaft.
Flywheel puller: 90890-06521
3. Remove the Woodruff key.
3. Remove the spark plug caps from the
spark plugs, and then remove the ignition
coil 3.
Removing the throttle pulley assembly
1. Removing the throttle pulley assembly.
5-17
6H95G11
Page 75
Disassembling the base assembly
6F650240
6F650250
1
2
3
1. Remove the O-ring and oil seal.
Assembling the base assembly
1. Apply grease to a new oil seal, then
install it into the base assembly.
Power unit
1
2
3
Needle bearing attachment 1:
90890-06654
Driver rod L3 2: 90890-06652
2. Install a new O-ring 3.
4
5
6
7
8
6H95G11
9
5-18
Page 76
POWR
6H95070E
Reed valves
Power unit
No. Part name Q’ty Remarks
1 Intake manifold #1 1
2 Reed valve assembly #1 1
3 Gasket 1
4 Intake manifold #2 1
5 Reed valve assembly #2 1
6 Gasket 1
7 Gasket 1
8 Gasket 1
9 Bolt 2 M6 × 65 mm
10 Screw 4 ø5 × 12 mm
11 Clip 10
12 Hose 5
13 Bolt 7 M6 × 25 mm
14 Arm 1
15 Collar 1
16 Bracket 1
17 Bracket 1
Not reusable
Not reusable
Not reusable
Not reusable
5-19
6H95G11
Page 77
Reed valves
6H95070E
1
2
3
No. Part name Q’ty Remarks
18 Bolt 1 M6 × 30 mm
19 Bolt 1 M6 × 15 mm
4
5
6
7
8
6H95G11
9
5-20
Page 78
POWR
6F650260
2
1
3
6F650270
2
1
4
5
a
6H950280
Power unit
Removing the reed valve assembly
1. Remove the hoses 1.
2. Remove the intake manifold bolts 2, and
then remove the intake manifold cover,
gasket and reed valve assembly #1 3.
2. Measure the valve stopper height b and
c. Replace if out of specification.
b
c
6H950290
Valve stopper height b:
2.2—2.6 mm (0.87—0.102 in)
Valve stopper height c:
4.0—4.4 mm (0.157—0.173 in)
3. Remove the stay 4, intake manifold and
reed valve assembly #2 5.
Checking the reed valves
1. Check the reed valves for bends a.
Replace if above specification.
Valve bend limit a:
0.20 mm (0.0079 in)
5-21
6H95G11
Page 79
6H95080E
15 N·m (1.5 kgf·m, 11 ft·lb)
30 N·m (3.0 kgf·m, 22 ft·lb)
12 N·m (1.2 kgf·m, 8.7 ft·lb)
25 N·m (2.5 kgf·m, 18 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)
Cylinder head
Cylinder head
1
2
3
No. Part name Q’ty Remarks
1 Gasket 1
2 Cylinder head 1
3 Thermoswitch 1
4 Bolt 1 M6 × 14 mm
5 Holder 1
6 Cover 1
7 Gasket 1
8 Bolt 4 M6 × 30 mm
9 Thermostat 1
10 Spark plug 2
11 Bolt 11 M8 × 0 mm
12 Bolt 5 M6 × 25 mm
13 Cylinder head cover 1
14 Gasket 1
15 Screw 1
16 Anode 1
17 Screw 2
Not reusable
Not reusable
Not reusable
4
5
6
7
8
9
6H95G11
5-22
Page 80
POWR
6H95080E
15 N·m (1.5 kgf·m, 11 ft·lb)
30 N·m (3.0 kgf·m, 22 ft·lb)
12 N·m (1.2 kgf·m, 8.7 ft·lb)
25 N·m (2.5 kgf·m, 18 ft·lb)
8 N·m (0.8 kgf·m, 5.8 ft·lb)
Power unit
No. Part name Q’ty Remarks
18 Anode 1
19 Bolt 16 M6 × 25 mm
20 Exhaust outer cover 1
21 Gasket 1
Not reusable
22 Exhaust inner cover 1
23 Gasket 1
Not reusable
24 Hose 1
5-23
6H95G11
Page 81
Removing the cylinder head
6F605330
1. Remove the spark plugs, thermostat
cover, thermostat and thermoswitch.
2. Remove the cylinder head cover bolts 1.
3. Remove the cylinder head bolts in the
sequence shown.
Cylinder head
1
1
1
6H950300
cC
Do not scratch or damage the mating surfaces of the cylinder head and cylinder
block.
Checking the cylinder head
1. Eliminate carbon deposits from the combustion chambers and check for deterioration or corrosion.
2. Check the cylinder head warpage using a
straightedge 1 and thickness gauge 2
in four directions as shown. Replace if
above specification.
Cylinder head warpage limit:
0.1 mm (0.0039 in)
Removing the exhaust cover
1. Remove the exhaust cover bolts in the
sequence shown.
Checking the exhaust cover
1. Check the exhaust cover for distortion or
corrosion. Replace if necessary.
2
3
4
5
6
7
6H95G11
8
9
5-24
Page 82
POWR
6F65090E
20 N·m (2.0 kgf·m, 15 ft·lb)
40 N·m (4.0 kgf·m, 29.5 ft·lb)
Crankcase
Power unit
No. Part name Q’ty Remarks
1 Crankshaft assembly 1
2 Cylinder Block 1
3 Anode 1
4 Bolt 1 M6 × 16 mm
5 Oil seal 2
6 Oil seal 1
7 O-ring 1
8 O-ring 1
9 Oil seal housing 1
10 Circlip 1
11 Crankcase 1
12 Bolt 10 M10 × 55 mm
13 Bolt 4 M8 × 35 mm
14 Bracket 1
15 Bracket 1
16 Bolt 1 M8 × 35 mm
17 Engine hanger 1
Not reusable
Not reusable
Not reusable
Not reusable
5-25
6H95G11
Page 83
Crankcase
6F65100E
1
2
3
No. Part name Q’ty Remarks
1 Crank 3 1
2 Washer 4
3 Roller bearing 2
4 Connecting rod 2
5 Needle bearing 56
6 Circlip 4
7 Piston 2
8 Piston pin 2
9 Piston ring set 2
10 Crank pin 2
11 Crank 4 1
12 Ball bearing 1
13 Labyrinth seal 1
14 Roller bearing assembly 1
15 Crank 2 1
16 Crank 1 1
17 Ball bearing 1
Not reusable
Not reusable
Not reusable
4
5
6
7
8
9
6H95G11
5-26
Page 84
6F650350
6F650360
6F650355
6F650356
POWR
Power unit
Removing the crankcase
1. Remove the crankcase bolts in the
sequence shown.
Removing the crankshaft assembly
and oil seal housing
1. Remove the crankshaft assembly and oil
seal housing.
NOTE:
Insert a flat-head screw driver between the
pry tabs to pry off the crankcase.
Checking the cylinder bore
1. Measure the cylinder bore (D1 — D6) at
measuring points a, b, and c, and in
direction d (D
to the crankshaft, and direction e (D
D
4, D6), which is at a right angle to the
crankshaft.
a: 10.0 mm (0.39 in) from the cylinder head top
surface
b: 5.0 mm (0.20 in) above the exhaust port
upper edge
c: 5.0 mm (0.20 in) below the scavenging port
lower edge
1, D3, D
5), which is parallel
2,
5-27
Cylinder bore diameter (D1 — D6):
78.000 — 78.020mm
(3.0709 — 3.0716 in)
Cylinder gauge 1:
90890-06759
6H95G11
Page 85
Crankcase
6F650390
1
2
2. Calculate the taper limit. Replace or
rebore the cylinder block if above specification.
Taper limit:
D
1 — D5 (direction d)
D
2 — D6 (direction e)
0.08 mm (0.0032 in)
3. Calculate the out-of-round limit. Replace
or rebore the cylinder block if above
specification.
Out of round limit:
D
2 — D1 (direction a)
D
6 — D5 (direction c)
0.05 mm (0.0020 in)
Disassembling the oil seal housing
1. Remove the O-ring and oil seals.
2. Apply grease to new oil seals, then install
them into the oil seal housing.
4
3
5
6
6F650400
Needle bearing attachment 3:
90890-06631
Driver rod LS 4:90890-06606
3. Install the circlip 5, apply grease to new
O-rings 6, and then install them.
Disassembling the piston
1. Remove the clips with pliers, and then
remove the piston pin.
1
2
3
4
6F650380
Checking the oil seal housing
1. Check the oil seal housing for cracks,
damage, or corrosion. Replace if necessary.
Assembling the oil seal housing
1. Apply grease to new oil seals, then install
them into the oil seal housing.
2. Separate the piston from the connecting
rod.
3. Remove the bearing and washers at the
connecting rod small end.
4. Remove the top ring and 2nd piston ring.
5
6
7
8
9
6H95G11
Needle bearing attachment 1:
90890-06613
Driver rod L3 2:90890-06652
5-28
Page 86
POWR
T
B
T
6B450460
B
a
b
Power unit
Checking the piston diameter
1. Measure the piston outside diameter at
the specified measuring point. Replace if
out of specification.
Piston outside diameter:
77.940—77.965 mm
(3.0685—3.0695 in)
Measuring point a:
10.0 mm (0.39 in) up from the
bottom of the piston skirt.
Oversize piston diameter:
1st:
78.190—78.215 mm
(3.0783—3.0793 in)
2nd:
78.440—78.465 mm
(3.0882—3.0892 in)
Checking the piston rings
1. Check the piston ring dimensions of B
and T. Replace if out of specification.
Piston ring dimensions
Top ring a and 2nd piston ring b:
B: 1.970—1.990 mm
(0.0776—0.0783 in)
T: 2.500—2.700 mm
(0.0984—0.1063 in)
2. Level the piston rings 1 in a cylinder with
a piston crown.
3. Check the piston ring end gap c at the
specified measuring point. Replace if out
of specification.
Checking the piston clearance
1. Calculate the piston clearance using the
piston outside diameter and the cylinder
bore specifications. Replace the piston
and piston rings as a set or the cylinder
block or all parts, or rebore the cylinder if
out of specification.
Piston clearance:
0.055–0.060 mm
(0.0022–0.0024 in)
d
1
1
c
6F650430
Piston ring end gap c:
Top ring and 2nd piston ring:
0.30—0.50 mm
(0.0118—0.0197 in)
Measuring point d:
10.0 mm (0.39 in)
5-29
6H95G11
Page 87
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.
Crankcase
1
6B450530
6F650440
Piston ring side clearance:
Top ring:
0.02—0.06 mm
(0.0008—0.0024 in)
2nd piston ring:
0.03—0.07 mm
(0.0012—0.0028 in)
Checking the piston pin boss bore
1. Measure the piston pin boss bore.
Replace the piston if out of specification.
Piston pin diameter:
19.895—19.00 mm
(0.7833—0.7835 in)
Checking the internal anodes
1. Check the anodes on the cylinder block.
Clean the anode’s surface and replace if
it has been eroded into half size or smaller.
6H950455
cC
Do not oil, grease, or the anodes, otherwise they will not be able to prevent galvanic corrosion effectively.
2
3
4
5
6
6F650450
Piston pin boss bore:
19.904—19.915 mm
(0.7836—0.7841 in)
Checking the piston pin
1. Measure the piston pin outside diameter.
Replace if out of specification.
6H95G11
7
Disassembling the crankshaft
1. Remove the upper and lower bearings.
8
9
6B450545
Bearing separator: 90890-06534
5-30
Page 88
POWR
6B450550
1
3
2
4
5
6F650470
9
0
6B450560
Power unit
2. Insert the plate C 1 between crank 1 2
and crank 2 3. Place pressure pin C 4
in the end of the crank pin 5.
NOTE:
Remove the bearing before starting this procedures.
Plate C 1: 90890-02402
Pressure pin C 4: 90890-02403
4. Remove the washers, roller bearing and
connecting rod.
5. Insert the support 6 between crank 2
and 3 7 with crank 3 on top. Place pressure pin B 8 on the shaft, and force it out
using a press.
Support 6: 90890-02394
Pressure pin B 8: 90890-02390
6. Remove the roller bearing 9 from the
inner race 0.
3. Remove the crank pin by applying pres-
sure to pressure pin C 4 with a press.
cC
9 Apply pressure to pressure pin C
slowly.
9 Hold pressure pin C in line with the
press screw spindle.
NOTE:
9 When forcing out the crank pin, use care so
that the crank does not fall.
9 To remove crank 4, follow the same proce-
dure.
5-31
7. Remove the crankpin between cranks 2
and 3 by applying pressure to pressure
pin C using a press.
NOTE:
Pressure pin C should be pressed down
straight.
Plate C 1: 90890-02402
Pressure pin C 4: 90890-02403
6H95G11
Page 89
8. Using the bearing separator to slightly
6B450600
move the inner race off the shaft, and
then remove the inner race.
Crankcase
1
NOTE:
Use care not to scratch the shaft.
Checking the crankpin
1. Measure the crankpin diameter. Replace
if out of specification.
Crankpin diameter:
26.995—27.000 mm
(1.0627—1.0629 in)
Spacer C 1: 90890-02404
Support 2: 90890-02394
2. Apply engine oil to the crankpin and
insert it into the crankpin hole by tapping
it with a copper hammer, and then install
the crankpin using a press.
cC
9 Take care so that the crank pin is set
squarely into the crank web.
9 Do not apply force in excess of 5 tons.
2
3
4
5
6
Assembling the crankshaft
cC
9 When reassembling the crankshaft,
wash all component parts in clean
kerosene (do not use gasoline).
9 Do not reuse bearings, always replace
them with new ones.
1. Insert spacer C 1 into the crankpin hole
of crank 2 (or crank 4).
6H95G11
NOTE:
Follow the same procedure for both crank 2
and crank 4 to install the crankpins using a
press.
5-32
7
8
9
Page 90
POWR
6F650540
E
1
a
6F650530
1
1
Power unit
3. Insert the bushing 3 into the body 4.
Spacer C 1: 90890-02404
6. Set crank 2 (or crank 4) on the special
service tool.
7. Mount the washers, roller bearing, and
connecting rod on the crankpin.
Bushing-9 (D30) 3: 90890-02363
Body4: 90890-02352
Flange5: 90890-02351
4. Place the height ring 6 in the body.
6
6B450650
NOTE:
Align the slot in the height ring with the slot in
the body.
Height ring (H-18) 6:
90890-02401
NOTE:
9 Take care so that spacer C 1 does not fall
out of the crank, turn the crank over so that
the crankpin is on top, and then insert the
crank into the special service tool.
9 The model number a on the connecting
rod should face up.
5. Set the spacer on the crank 2 (or crank
4).
5-33
6H95G11
Page 91
Crankcase
6B450710
9
6B450720
b
c
d
e
g
f
6B450700
8. Install the bushing 7 on the pressure
plate 8.
NOTE:
When installing crank 3 to the pressure plate,
do not use the bushing 7.
Bushing-12 (D35) 7: 90890-02366
Pressure plate 8: 90890-02384
9. Install crank 1 (or crank 3) to the pressure plate.
11. Insert the press body 9, and install crank
1 (or crank 3) onto the crankpin using a
press.
cC
Do not apply force in excess of 5 tons.
1
2
3
4
E
10. Align the crankpin hole in crank 1 (or
crank 3) with the crankpin fitted to crank
2 (or crank 4) and place the pressure
plate in the body.
NOTE:
Apply engine oil to the crankpin.
6B450690
Press body 9: 90890-02385
12. Measure the width b of the assembled
crankshaft using calipers. Measurements
should be made at positions c to g.
5
6
7
8
9
6H95G11
5-34
Page 92
POWR
6F650560
0
q
w
3
6F650570
E
e
h
q
Power unit
NOTE:
If any of the measurements are out of specification, reassemble the crankshaft.
Crankshaft width b:
61.40–61.45 mm
(2.4173–2.4193 in)
13. Install the inner race 0 onto crank 2 by
using a press and the bushing 3.
Carefully press the inner race onto the
shaft.
Plate C q: 90890-02402
Bushing-9 (D30) 3: 90890-02363
Bearing pressure C w:
90890-02393
16. Insert plate C q between crank 3 and
crank 4, then place them onto the crankshaft assemblies 1 and 2.
NOTE:
Align the alignment marks i on cranks 2 and
3.
Plate C q: 90890-02402
17. Place the press body 9 on plate C and
install the crank 2 into crank 3 using a
press.
14. Install the roller bearing e onto crank 2.
NOTE:
Make sure the pin h side of the bearing
faces crank 2.
15. Insert plate C q between crank 1 and
crank 2, and install the labyrinth ring on
crank 3, before connecting crankshaft
assemblies 3 and 4.
5-35
cC
Do not apply force in excess of 7 tons.
Press body 9: 90890-02385
6H95G11
Page 93
Crankcase
6B450800
6B450780
1
a
b
6B450790
c
c
c
Checking the crankshaft
1. Measure the crankshaft widths a and b.
Repair or disassemble the crankshaft if
out of specification.
2. Measure the connecting rod small end
axial play. Replace the bearing and connecting rod if above specification.
Crankshaft width a:
61.40–61.45 mm
(2.4173–2.4193 in)
Crankshaft width b:
41.38–41.60 mm
(1.6291–1.6378 in)
Connecting rod small-end axial play
limit:
2.0 mm (0.08 in)
Installing the crankshaft bearings
1. Install the upper and lower bearings
using the bearing pressure C 1 and a
press.
NOTE:
9 Install the upper bearing so that the manu-
facture identification mark a faces the fly-
wheel magnet side.
9 Install the lower bearing so that the dowel
b faces the flywheel magnet side.
Bearing pressure C 1:
90890-02393
1
2
3
4
5
3. Measure the crankshaft runout. Repair or
disassemble the crankshaft if above
specification.
Crankshaft runout limit c:
0.03 mm (0.0012 in)
Crankshaft aligner:
90890-03107
2. Slowly turn the crankshaft and connecting rods. If it does not turn smoothly, disassemble the crankshaft and adjust or
replace any parts as necessary.
6
7
8
9
6H95G11
5-36
Page 94
POWR
6B450810
2
1
6F650610
3
7
6
4
4
5
6
6F650620
Power unit
Assembling the piston
1. Install the 2nd piston ring 1 and top ring
2 onto the pistons.
NOTE:
Install the piston rings with the recess for the
locating pin facing up toward the piston
crown.
2. Install the needle bearings 3, washers
4, piston pin 5, and new clips 6.
Assembling the power unit
1. Install the oil seal housing to the crankshaft assembly.
2. Install the crankshaft assembly into the
cylinder block.
1 1
NOTE:
9 Make sure that the piston and piston pin
bearings are installed in their original combination.
9 Use the small end bearing installer 7 to
install the needle bearings.
9 Make sure that the up mark on the piston
crown faces the flywheel magnet side.
Small end bearing installer 7:
90890-06527
2
2
6F650630
NOTE:
9 Apply engine oil to the pistons, piston rings
and bearings before installation.
9 Align the dowels of the bearings with the
slot 1 on the cylinder block.
9 Align the rings 2 with the grooves in the
cylinder block.
5-37
6H95G11
Page 95
3. Apply sealant to the mating surface of the
6F650640
3
3
6H950670
6F650650
6F605335
crankcase.
NOTE:
Do not get any sealant on the crankshaft journals.
4. Install the crankcase onto the cylinder
block, and then tighten the crankcase
bolts to the specified torques in two
stages and in the sequence shown.
Crankcase
NOTE:
Apply LOCTITE 572 to the exhaust cover
bolts before installation.
Exhaust outer cover bolt:
8 N·m (0.8 kgf·m, 5.8 ft·lb)
1
2
3
4
NOTE:
Apply engine oil to the crankcase bolts before
installation.
Crankcase bolt:
1st:
20 N·m (2.0 kgf·m, 15 ft·lb)
2nd:
40 N·m (4.0 kgf·m, 29.5 ft·lb)
6. Install a new cylinder head gasket, the
cylinder head, thermoswitch, a new cylinder head cover gasket, and cylinder head
cover, and then tighten the cylinder head
bolts to the specified torques in two
stages and in the sequence shown.
7. Install the cylinder head cover bolts 3,
and then tighten the bolts to the specified
torques in two stages.
5
6
7
8
5. Install a new gasket and the exhaust
cover, and then tighten the bolts to the
specified torques in two stages and in the
sequence shown.
6H95G11
9
5-38
Page 96
POWR
6F650680
4
5
6H950690
5
4
1
1
2
3
Power unit
NOTE:
Apply LOCTITE 572 to the cylinder head
bolts and the cylinder head cover bolts before
installation.
Cylinder head bolt:
1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
2nd:30 N·m (3.0 kgf·m, 22 ft·lb)
Cylinder head cover bolt 3:
12 N·m (1.2 kgf·m, 8.7 ft·lb)
8. Install the thermostat, a new gasket and
thermostat cover.
9. Install the spark plugs, tighten them finger tight, then to the specified torque with
a spark plug wrench.
Spark plug:
25 N·m (2.5 kgf·m, 18 ft·lb)
10. Install the reed valve assembly and the
intake manifold assembly, and then tighten the intake manifold bolts 4 to the
specified torques in two stages.
Installing the power unit
1. Clean the power unit mating surface, and
install the dowels 1 and a new gasket
2.
2. Install the power unit 3, and then tighten
the power unit mounting bolts 4 to the
specified torque.
3. Install the apron 5.
NOTE:
Apply LOCTITE 572 to the power unit mounting bolts before installation.
Power unit mounting bolt 4:
21 N·m (2.1 kgf·m, 15.5 ft·lb)
11. Connect the hoses 5.
12. Install the throttle pulley assembly, and
the electrical components to the power
unit.
4. Connect the fuel hose and pilot water
hose.
5. Connect the engine stop lanyard switch
leads (MH).
6. Install the Woodruff key and flywheel
magnet.
5-39
6H95G11
Page 97
Crankcase
6H950710
6
7. Tighten the flywheel magnet nut to the
specified torque.
cC
Apply force in the direction of the arrows
shown, to prevent the flywheel holder
from slipping off easily.
NOTE:
Apply engine oil to the flywheel magnet nut
before installation.
10. Install the manual starter and start-in-
gear protection cable 6, and then adjust
it length. For adjustment procedures, see
Chapter 3.
11. Connect the battery leads (W).
12. Install all removed parts.
1
2
3
4
Flywheel holder: 90890-06522
Flywheel magnet nut:
160 N·m (16.0 kgf·m, 115 ft·lb)
8. Install the starter pulley.
9. Connect the remote control cables
(remote control model) or the throttle
cables (tiller handle model), and then
adjust their length. For adjustment procedures, see Chapter 3.
5
6
7
8
9
6H95G11
5-40
Page 98
LOWR
LOWR
Lower unit
Special service tools ................................................................................... 6-1
Lower unit (EK40G) ...................................................................................... 6-5
Removing the lower unit .......................................................................... 6-5
Removing the water pump and shift rod ................................................. 6-5
Checking the water pump and shift rod .................................................. 6-5
Propeller shaft housing ............................................................................. 6-11
Removing the propeller shaft housing assembly .................................. 6-13
Disassembling the propeller shaft assembly ......................................... 6-13
Disassembling the propeller shaft housing ........................................... 6-13
Disassembling the forward gear ............................................................ 6-14
Checking the propeller shaft housing .................................................... 6-14
Checking the propeller shaft .................................................................. 6-14
Assembling the forward gear ................................................................. 6-14
Assembling the propeller shaft assembly .............................................. 6-14
Assembling the propeller shaft housing ................................................ 6-15
Drive shaft and lower case ....................................................................... 6-16
Removing the drive shaft ....................................................................... 6-17
Disassembling the lower case ............................................................... 6-17
Checking the pinion gear ....................................................................... 6-17
Checking the bearings ........................................................................... 6-17
Checking the drive shaft ........................................................................ 6-17
Checking the lower case and lower case cap ....................................... 6-18
Assembling the lower case .....................................................................6-18
Installing the drive shaft ......................................................................... 6-19
Installing the propeller shaft housing ......................................................6-19
Installing the water pump and shift rod ................................................. 6-20
Installing the lower unit .......................................................................... 6-21
Shimming .................................................................................................... 6-23
Shimming ............................................................................................... 6-24
Selecting the pinion shims ..................................................................... 6-24
Selecting the forward and reverse gear shims .......................................6-24
Backlash ................................................................................................ 6-25
Measuring the forward and reverse gear backlash ............................... 6-25
Lower unit (EK40J) .................................................................................... 6-27
Removing the lower unit ........................................................................ 6-31
Removing the water pump and shift rod ............................................... 6-32
Checking the water pump and shift rod ................................................ 6-32
6H95G11
Page 99
Propeller shaft housing ............................................................................. 6-33
Removing the propeller shaft housing assembly .................................. 6-34
Disassembling the propeller shaft assembly ......................................... 6-34
Disassembling the propeller shaft housing ........................................... 6-34
Checking the propeller shaft housing .................................................... 6-35
Checking the propeller shaft .................................................................. 6-35
Assembling the propeller shaft assembly .............................................. 6-35
Assembling the propeller shaft housing ................................................ 6-36
1
Drive shaft and lower case ....................................................................... 6-37
Removing the drive shaft ....................................................................... 6-38
Disassembling the drive shaft ............................................................... 6-38
Disassembling the forward gear ............................................................ 6-38
Disassembling the oil seal housing ....................................................... 6-38
Disassembling the lower case ............................................................... 6-39
Checking the pinion and forward gear .................................................. 6-39
Checking the bearings ........................................................................... 6-39
Checking the drive shaft ........................................................................ 6-39
Checking the lower case ....................................................................... 6-39
Assembling the oil seal housing ............................................................ 6-40
Assembling the lower case .................................................................... 6-40
Assembling the forward gear ................................................................. 6-41
Assembling the drive shaft .................................................................... 6-41
Installing the drive shaft ......................................................................... 6-41
Installing the oil seal housing ................................................................ 6-41
Installing the propeller shaft housing ..................................................... 6-41
Installing the water pump and shift rod ................................................. 6-42
Installing the lower unit .......................................................................... 6-44
Shimming .................................................................................................... 6-46
Shimming ............................................................................................... 6-47
Selecting the pinion shims ..................................................................... 6-47
Selecting the forward gear shims .......................................................... 6-48
Selecting the reverse gear shims .......................................................... 6-49
Backlash ................................................................................................ 6-50
Measuring the forward and reverse gear backlash ............................... 6-50
2
3
4
5
6
7
6H95G11
8
9
Page 100
LOWR
Dial gauge set
90890-01252
Stopper guide plate
90890-06501
Bearing puller assembly
90890-06535
Drive shaft holder 3
90890-06517
Bearing outer race puller assembly
90890-06523
Bearing Separator
90890-06534
Ring nut wrench extension
90890-06513
Bearing housing puller claw M
90890-06503
Center bolt
90890-06504
Ring nut wrench
90890-06510
Lower unit
Special service tools
6-1
6H95G11
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