Pike 99

Pike 9,9
SERVICE MANUAL
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NOTICE
This manual has been prepared by Selva primarily for use by Selva dealers and their trained
mechanics when performing maintenance procedures and repairs to Selva 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 Selva 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 Selva dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
Important information 1
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.

Contents
General information GEN
INFO
1
Specification
SPEC 2
Periodic check and adjustment CHK
ADJ
3
Fuel system
FUEL 4
Power unit
POWR 5
Lower unit
LOWR 6
Bracket unit
BRKT 7
– +
Electrical system
ELEC 8
Troubleshooting TRBL
SHTG
9
Index

GEN
INFO
General information
How to use this manual ................................................................................. 1-1

Manual format............................................................................................ 1-1
Symbol....................................................................................................... 1-2
Abbreviation............................................................................................... 1-3
Sealant and locking agent table ................................................................1-3
1
Safety while working......................................................................................1-4
Fire prevention........................................................................................... 1-4
Ventilation..................................................................................................1-4
Self-protection ........................................................................................... 1-4
2
Part, lubricant, and sealant........................................................................ 1-4
Good working practice............................................................................... 1-5
Disassembly and assembly ....................................................................... 1-5
Identification...................................................................................................1-6
3
Model......................................................................................................... 1-6
Serial number ............................................................................................ 1-6
Special service tool .......................................................................................1-7

4
Propeller selection ....................................................................................... 1-12
Propeller size........................................................................................... 1-12
Selection.................................................................................................. 1-12 5
Predelivery check ........................................................................................ 1-13
Checking the outboard motor mounting height........................................ 1-13
Removing the intake silencer protective covering ................................... 1-13
Checking the fuel system ........................................................................1-13
Checking the engine oil level................................................................... 1-13
6
Checking the gear oil level ...................................................................... 1-14
Checking the battery (E model) ...............................................................1-14
Connecting the throttle cable and shift cable (R model).......................... 1-14
Checking the gear shift and throttle operation.........................................1-15
Checking the steering system .................................................................1-16
7
Checking the tilt system (MT model) .......................................................1-17
8
Checking the PT system (PT model).......................................................1-17
Checking the engine start button or switch and engine shut-off switch... 1-17
Checking the cooling water pilot hole ......................................................1-19
Test run ................................................................................................... 1-19
Break-in ................................................................................................... 1-19
After test run ............................................................................................ 1-19
Precaution when transporting or storing the outboard motor .................. 1-20
9
6AU3K11

GEN
INFO General information
How to use this manual 1
Manual format 1
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the information below as a guide for effective and quality service.
• Parts are shown and detailed in an exploded diagram and are listed in the component list (see 1
in the figure below for an example page).
• The component list consists of part names and quantities, as well as bolt and screw dimensions
(see 2 in the figure below).
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
lubrication point (see 3 in the figure below).
• Tightening torque specifications are provided in the exploded diagrams (see 4 in the figure below
for an example), and in the related detailed instructions. Some torque specifications are listed in
stages as torque figures or angles in degrees.
• Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see 5 in the figure below for an example page).
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
4
1
1-1 6AU3K11

How to use this manual
Symbol 1
The symbols below are designed to indicate the content of a chapter.

General information Fuel system Bracket unit
GEN
INFO
FUEL BRKT 1
Specification Power unit Electrical system
SPEC POWR ELEC – +

2
Periodic check and adjustment Lower unit Troubleshooting
CHK
ADJ
Symbols 1 to 6 indicate specific data.
LOWR TRBL
SHTG 3
1 2 3 4
T.
R.
5 6
4
1
2
3
4
Special service tool
Specified oil or fluid
Specified engine speed
Specified tightening torque
5 Specified measurement
6 Specified electrical value
(resistance, voltage, electric current) 5
Symbols 7 to C in an exploded diagram or illustration indicate the grade of lubricant and the lubri-
cation point.
7 8 9 0 A B C
6
A M D C I
7
E G
7 Apply 4-stroke motor oil A Apply corrosion resistant grease

8 Apply gear oil (Yamaha grease D)
9 Apply water resistant grease (Yamaha grease A) B Apply low temperature resistant grease
0 Apply molybdenum disulfide grease (Yamaha grease C)
C Apply injector grease
Symbols D to I in an exploded diagram or illustration indicate the type of sealant or locking agent
and the application point.
8
D
GM
E
1104J
F
LT
271
G
LT
242
H
LT
572
I
SS 9
D Apply Gasket Maker G Apply LOCTITE 242 (blue)
E Apply ThreeBond 1104J H Apply LOCTITE 572
F Apply LOCTITE 271 (red) I Apply silicone sealant
6AU3K11 1-2

GEN
Abbreviation 1
The following abbreviations are used in this service manual.

Abbreviation Description
API American Petroleum Institute
BOW Bow end
BTDC Before Top Dead Center
CCA Cold Cranking Ampere
CDI Capacitor Discharge Ignition
E model Electric starter model
EN European Norm (European standard)
EX Exhaust
F position Forward position
H model Tiller handle model
IEC International Electrotechnical Commission
IN Intake
M model Manual starter model
MT Manual tilt
N position Neutral position
PORT Port side
PT Power tilt
R model Remote control model
R position Reverse position
SAE Society of Automotive Engineers
STBD Starboard side
WD Wiring Diagram
Sealant and locking agent table 1
The following table contains sealants, locking agents, and lubricants used in this service manual
that are not listed on page 1-2.
Symbol Name Application Manufacturer
LOCTITE 518 Sealant Henkel

518
ThreeBond 1207B Sealant ThreeBond

1207B
ME-1 Antirust lubricant

ME-1
1-3 6AU3K11

How to use this manual / Safety while working
Safety while working 1
To prevent an accident or injury and to

ensure quality service, follow the safety pro-
cedures provided below.
Fire prevention
Gasoline is highly flammable.
1
1
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Part, lubricant, and sealant 1

2
Use only genuine Selva parts, lubricants,
3
and sealants or those recommended by
Selva, when servicing or repairing the out-
board motor.
Ventilation
Gasoline vapor and exhaust gas are heavier
1
4
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 ade-
Under normal conditions, the lubricants men-
5
tioned in this manual should not harm or be
quate ventilation can be maintained.
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants. 6
1. Avoid contact with skin. Do not, for
example, place a soiled rag in your
pocket. 7
2. Wash hands and any other part of the
Self-protection
Protect your eyes by wearing safety glasses
1
or safety goggles during all operations involv-

body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made. 8
3. Change and wash clothing as soon as
ing drilling and grinding, or when using an air
compressor.
Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
possible if soiled with lubricants.
4. To protect your skin, apply a protective

cream to your hands before working on
9
sary. the outboard motor.
5. Keep a supply of clean, lint-free cloths for

wiping up spills, etc.
6AU3K11 1-4

GEN
6. Maintain good standards of personal and Disassembly and assembly 1
industrial hygiene. 1. Use compressed air to remove dust and

dirt during disassembly.
Good working practice 1
Special service tool 2. Apply oil or fluid to the contact surfaces

Use the recommended special service tools of moving parts before assembly.
to protect parts from damage. Use the right
tool in the right manner—do not improvise.
3. Install bearings with the manufacture

identification mark in the direction indi-
Tightening torque cated in the installation procedure. In
Follow the tightening torque specifications addition, be sure to lubricate the bearings
provided throughout the manual. When tight- liberally.
ening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting 4. Apply a thin coat of water resistant
in the center and moving outward. grease to the lip and periphery of an oil
Non-reusable part seal before installation.
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, etc., when installing or 5. Check that moving parts operate nor-
assembling parts. mally after assembly.
1-5 6AU3K11

Safety while working / Identification
Identification 1
Approved Starting
Model 1 Model name
model code serial No.
This manual covers the following models.
F9.9F 6AU 1000001–
Pike 9.9
Applicable model FT9.9G 6AV 1000001–
1
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
1
2
È
3
S6AG1010
4
É
5
S6AU1010
6
È MT model
É PT model
7
8
1
2
Model name
Approved model code
9
3 Transom height
4 Serial number
6AU3K11 1-6

GEN
Special service tool 1
Digital tachometer Compression gauge

90890-06760 90890-03160
Timing light Tappet adjusting tool

90890-03141 90890-01311
Leakage tester Flywheel holder

90890-06840 90890-06522
Vacuum/pressure pump gauge set Flywheel puller

90890-06756 90890-06521
Pilot screw adjusting tool Shaft holder

90890-03154 90890-06561
1-7 6AU3K11

1
Valve spring compressor Valve seat cutter
90890-04019 90890-06312, 90890-06315, 90890-06328,
90890-06813, 90890-06814, 90890-06815
2
Valve spring compressor attachment
3
90890-06320 Driver rod L3
90890-06652
4
Valve guide remover/installer
5
90890-06801 Needle bearing attachment
90890-06613, 90890-06614, 90890-06616,
90890-06653
6
Valve guide reamer
90890-06804
7
Piston slider
90890-06843
8
Valve seat cutter holder
90890-06316
Stopper guide plate
9
90890-06501
6AU3K11 1-8

GEN
Bearing puller assembly Ball bearing attachment

90890-06535 90890-06634
Stopper guide stand Bushing attachment

90890-06538 90890-06650
Bushing attachment Driver rod LL

90890-06649 90890-06605
Needle bearing attachment Bushing installer center bolt

90890-06617 90890-06601
Driver rod LS Bearing housing puller claw S

90890-06606 90890-06564
1-9 6AU3K11

1
Center bolt Ball bearing attachment
90890-06504 90890-06632
2
Backlash indicator Bearing outer race attachment
3
90890-06706 90890-06625
4
Magnet base plate Driver rod SL
5
90890-07003 90890-06602
6
Dial gauge set
90890-01252
Bearing depth plate
90890-06603
7
8
Magnet base B
90890-06844
Digital caliper
90890-06704
9
6AU3K11 1-10

GEN
Shimming plate Ignition tester

90890-06701 90890-06754
Needle bearing attachment

90890-06615
Power tilt wrench

90890-06560
Digital circuit tester

90890-03174
Peak voltage adapter B

90890-03172
1-11 6AU3K11

Special service tool / Propeller selection
Propeller selection 1 Selection 1
The performance of a boat and outboard When the engine speed is at the full throttle
motor will be critically affected by the size operating range (5,000–6,000 r/min), the
1
and type of propeller you choose. Propellers ideal propeller for the boat is one that pro-
greatly affect boat speed, acceleration, vides maximum performance in relation to
engine life, fuel economy, and even boating boat speed and fuel consumption.
and steering capabilities. An incorrect choice
could adversely affect performance and Model Propeller size (in) Material
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
8 1/2 × 6 1/2 - N
8 1/2 × 7 1/2 - N
8 1/2 × 8 - N
2
3LNH9.9 8 1/2 × 8 1/2 - N
motor.
Propeller size
The size of the propeller is indicated on a
propeller blade and on the side of the propel-
1
8 1/2 × 9 1/4 - N
9×5-N
9×7-N Aluminum
3

ler boss.

4
× -
a b c
5
S69W1040
6
a
× -
b c 7
S69W1050
a Propeller diameter (in inches)

b Propeller pitch (in inches)
c Propeller type (propeller mark)
8
9
6AU3K11 1-12

GEN
Predelivery check 1
1
To make the delivery process smooth and
efficient, the predelivery checks should be
completed as explained below.
Checking the outboard motor

mounting height 1
1. Check that the anti-cavitation plate is

between the bottom of the boat and a S6AU1016
maximum of 25 mm (1 in) a below it. If
the mounting height is too high, cavita- CAUTION:
tion will occur and propulsion will be
A protective covering 1 is installed on
reduced. Also, the engine speed will
the intake silencer when the outboard
increase abnormally and cause the
motor is shipped from the factory and
engine to overheat. If the mounting
must be removed before starting the
height is too low, water resistance will
engine for the first time.
increase and reduce engine efficiency.
Checking the fuel system 1
1. Check that the fuel hoses are securely

connected and that the fuel tank is full
with fuel.
S6D51030
NOTE:
The optimum mounting height is affected by
the combination of the boat and the outboard
motor. To determine the optimum mounting
height, test run the outboard motor at differ-
ent heights.
2. Check that the clamp brackets are

secured with the clamp bolts.
Removing the intake silencer

protective covering 1
S6AU1017
1. Remove the protective covering 1 from

the intake silencer. CAUTION:
This is a 4-stroke engine. Never use pre-
mixed fuel or 2-stroke outboard motor oil.
Checking the engine oil level 1
1. Check the engine oil level.
1-13 6AU3K11

Predelivery check
NOTE:
If the oil is at the correct level, a small
amount of oil should overflow out of the
b
a
check hole when the gear oil check screw is
removed. 1
Checking the battery (E model)
2
1
S6AU1018 1. Check the battery capacity, electrolyte

level, and specific gravity of the electro-
NOTE: lyte.
If the engine oil is below the minimum level
mark a, add sufficient oil until the level is Recommended battery capacity:
between a and b.
Recommended engine oil:

CCA/EN: 347.0 A
20HR/IEC: 40.0 Ah
Electrolyte specific gravity:
1.280 at 20 °C (68 °F)
3
4-stroke motor oil
API: SE, SF, SG, SH, SJ, or SL
SAE: 5W-30, 10W-30, or 10W-40
Engine oil quantity:
0.8 L (0.85 US qt, 0.70 Imp qt)
2. Check that the positive and negative bat-
tery cables are securely connected. 4
Connecting the throttle cable and
shift cable (R model)
5
1
Checking the gear oil level 1
1. Check the gear oil level. NOTE:

To adjust the throttle cable and shift cable,
È see “Adjusting the throttle cable (R model)”
(3-8) or “Checking the gear shift operation (R
model)” (3-10).
1. Set the remote control lever to the N

position and the throttle lever to the fully
6
closed position.
É
S6AU1043 7
8
È Except for high thrust model
É For high thrust model
S6AU1019 9
6AU3K11 1-14

GEN
2. Turn the throttle cam 1 counterclock-
wise until the fully closed stopper a on WARNING
the cam contacts the fully closed stopper The shift/throttle cable joint must be
b on the throttle cable bracket 2 and screwed in a minimum of 8.0 mm (0.31 in)
hold it in that position. Connect the throt- c.
tle cable 3 to the throttle cam, and then
install the clip 4.
Checking the gear shift and throttle
1 2 1 operation 1
b 1. Check that the throttle operates smoothly

when the throttle grip is turned from the
fully closed position to the fully open
a position a. (H model)
2 Check that the throttle operates smoothly
when the remote control lever is shifted
4 from the F position or R position to the
3 S6AU1020
fully open position a. (R model)
NOTE: 2. Check that the gear shift operates
Pull the throttle cable 3 toward the engine to smoothly when the shift lever or remote
remove any free play in the cable before con- control lever is shifted from the N position
necting the throttle cable joint. to the F position or R position.
È
3. Check that the shift lever 5 is in the N
position as shown. Connect the shift
cable 6 to the shift lever, and then install N
R
the clip 7.
F
N 5
1 a
R F
7 S6AU1044
É
N
R
F
6
S6AU1021
a
1 S6AU1023
c
S6AU1022
1-15 6AU3K11

Predelivery check
Ê NOTE:
N
To adjust the start-in-gear protection cable,
F R
see “Checking the start-in-gear protection (M
a
model)” (3-11).
Checking the steering system 1

1
a
1. Check the steering friction for proper
1
È H model (short)
É H model (long)
Ê R model
S6AU1024 adjustment. (H model)
2
NOTE:
The resistance of the throttle grip (H model)
or remote control lever (R model) can be
adjusted using the throttle friction adjuster 1. a
3
b
3. Set the shift lever to the F position or R
position, and then check that the starter
handle cannot be pulled. If the starter
NOTE:
S6AU1027
• To increase the friction, move the steering

4
rope can be pulled out normally, adjust lock lever in direction a.
È
the start-in-gear protection cable. (M
model)
• To decrease the friction, move the steering
lock lever in direction b.
5
2. Check that the steering operates
6
smoothly.
R N
F È
É
N
S6AU1045
7
R
8
F S6AU1028
È H model (short)
É H model (long)
S6AU1026
9
S6AU1029
È H model
É R model
6AU3K11 1-16

GEN
3. Check that there is no interference with
leads, cables, or hoses when the out-
board motor is steered.
Checking the tilt system (MT model) 1

b
1. Set the tilt lock lever 1 to the release
position a and fully tilt the outboard
motor up. Check that the outboard motor
tilts up smoothly and automatically locks
in 3 positions when it is tilted up. 1 S6AU1032
Checking the PT system (PT model) 1
1. Check that the outboard motor tilts up

and down smoothly when operating the
PT switch.
1
È É UP
DN
a
S6AU1030
DN
UP
S6AU1033
È H model
É R model
2. Check that there is no abnormal noise

produced when the outboard motor is
tilted up or down.

leads, cables, or hoses when the tilted-
up outboard motor is steered.
Checking the engine start button or

switch and engine shut-off switch 1
S6AU1031
1. Check that the engine starts when the
engine start button is pushed. (H model)
Check that the engine starts when the
leads, cables, or hoses when the tilted-
engine start switch is turned to “START.”
up outboard motor is steered.
(R model)
3. Set the tilt lock lever 1 to the lock posi-
tion b, slightly tilt the outboard motor up,
and then fully tilt it down. Check that the
outboard motor tilts down smoothly and
automatically locks in the fully tilted down
position.
1-17 6AU3K11

Predelivery check
È Ê
1
É
S6AU1034
È H model (short)
É H model (long)
Ê R model
S6AU1035
2
3. Check that the engine turns off when the
clip is pulled from the engine shut-off
switch.
3
È
È H model
É R model
S6AU1035
4
2. Check that the engine turns off when the
engine shut-off switch is pushed. (H
model)
Check that the engine turns off when the
engine start switch is turned to “OFF.” (R
S6AU1048
5
É
model)
È
6
S6AU1038
7
Ê
S6AU1047
É
8
È H model (short)
9
S6AU1036 É H model (long)
Ê R model
6AU3K11 1-18

GEN
Checking the cooling water pilot
NOTE:
hole 1
The test run is part of the break-in operation.

1. Place the lower unit in water, and then
start the engine.
Break-in 1
2. Check for water flow at the cooling water Run the engine under load (in gear with a
pilot hole. propeller installed) for 10 hours as follows.
1. For the 1st hour a of operation:
Run the engine at varying speeds up to
2,000 r/min or approximately half throttle.
1 2. For the 2nd hour b of operation:

Increase engine speed as much as nec-
essary to put the boat on plane (but avoid
full-throttle operation), then back off on
the throttle while keeping the boat at a
planing speed.
3. Remaining 8 hours c:
Run the engine at any speed. However,
S6AU1040
avoid operating at full throttle for more
than 5 minutes at a time.
NOTE:
Make sure that the cooling water hoses are
4. After the 1st 10 hours:
securely connected and that the flushing
Operate the engine normally.
hose joint adapter 1 (for Europe) is not loose
or damaged.
Test run 1 a b c
1. Start the engine, and then check that the
gear shift operates smoothly.
È 0 1 2 10
2. Check the engine idle speed after the
engine has been warmed up.
S69J1240
3. Operate at trolling speed. È Hour
4. Run the outboard motor for 1 hour at After test run 1
varying speeds up to 2,000 r/min or 1. Check for water in the gear oil.
approximately half throttle, then, for
2. Check for fuel leakage in the cowling.
another hour, increase engine speed as
much as necessary to put the boat on
3. Flush the cooling water passages with
plane (but avoid full-throttle operation).
fresh water using the flushing kit and with
the engine running at idle.
5. Check that the outboard motor does not
tilt up when shifting into reverse and that
water does not flow in over the transom.
1-19 6AU3K11

Predelivery check
CAUTION:
Be sure to supply sufficient water and
1
water pressure when flushing the cooling
water passages. If sufficient water and
sufficient water pressure are not supplied,
the engine can overheat.
NOTE:
When using the flushing device (flushing
hose joint adapter [for Europe]), flush the
cooling water passages without starting the
2
engine.
Precaution when transporting or

storing the outboard motor 1
3
1. When transporting or storing the out-
board motor while removed from a boat,
keep the outboard motor in the attitude
shown or use an outboard motor stand.
4
5
6
7
8
9
6AU3K11 1-20

GEN
— MEMO —
1-21 6AU3K11

SPEC
Specification
General specification.....................................................................................2-1
Maintenance specification ............................................................................2-4

Power unit..................................................................................................2-4
1
Fuel system ............................................................................................... 2-7
Lower unit ..................................................................................................2-8
Electrical .................................................................................................... 2-9
Dimension................................................................................................2-12 2
Tightening torque......................................................................................... 2-19
3
Specified torque....................................................................................... 2-19
General torque......................................................................................... 2-21
4
5
6
7
8
9
6AU3K11

SPEC
Specification
General specification 2
Model
Item Unit
3LNH
Dimension
Overall length
(For Europe) mm (in) 927 1,038 573 (22.6)
(36.5) (40.9)
(For Oceania) mm (in) 1,038 — 573 (22.6)
(40.9)
Overall width
(For Europe) mm (in) 377 371 335 (13.2)
(14.8) (14.6)
(For Oceania) mm (in) 371 — 335 (13.2)
(14.6)
Overall height
(S) mm (in) 998 —
(39.3)
(L) mm (in) 1,125 1,187 (46.7)
(44.3)
(X) mm (in) — 1,255 (49.4)
Transom height
(S) mm (in) 430 —
(16.9)
(L) mm (in) 557 552 (21.7) 557
(21.9) (21.9)
(X) mm (in) — 620 (24.4) 625
(24.6)
Boat transom height
(S) mm (in) 381 —
(15.0)
(L) mm (in) 508 (20.0)
(X) mm (in) — 635 (25.0)
Weight
(with aluminum propeller)
(S)
(For Europe) kg (lb) 39.9 (88) —
(For Oceania) kg (lb) 41.5 (92) —
(L)
(For Europe) kg (lb) 40.9 (90) 44.3 (98) 44.4 (98) 49.1 (108)
(For Oceania) kg (lb) 42.5 (94) — 44.4 (98) 49.1 (108)
(X) kg (lb) — 45.4 45.5 50.2
(100) (100) (111)
2-1 6AU3K11

General specification
Model
Item Unit
3LNH
Performance
Maximum output
Full throttle operating range
Maximum fuel consumption
kW (HP)
r/min
L (US gal,
Imp gal)/hr
7.3 (9.9) at 5,500 r/min
5,000–6,000
3.9 (1.0, 0.9) at 6,000 r/min
1
Engine idle speed r/min 1,050 ± 50
Power unit
Type
Cylinder quantity
4-stroke L
2
2
Total displacement cm3 (cu. in) 212 (12.9)
Bore × stroke
Compression ratio
Control system
Starting system
mm (in) 56.0 × 43.0 (2.20 × 1.69)
Tiller handle
Manual
9.4
Remote control
Electric
3
Fuel system Carburetor
Enrichment system
Ignition control system
Advanced type
Choke valve
CDI (micro computer)
Micro computer
4
Ignition timing
at 1,050 r/min
Maximum generator output
Spark plug
Degree
V, W
V, A
12, 80
—
BTDC 5 ± 3
BR6HS-10 (NGK)
—
12, 6.0
5
Cooling system Water
Exhaust system
Lubrication system
Fuel and oil
Propeller boss
Wet sump 6
Fuel type Regular unleaded gasoline
7
Engine oil type 4-stroke motor oil
Engine oil grade(*1) API SE, SF, SG, SH, SJ, or SL
SAE 5W-30, 10W-30, or 10W-40
Engine oil quantity L (US qt, 0.8 (0.85, 0.70)
Imp qt)
Gear oil type
Gear oil grade(*2)
3
API
SAE
Hypoid gear oil
GL-4
90
8
Gear oil quantity cm (US oz, 150 370 (12.51, 13.05)
Imp oz) (5.07,
(*1)
5.29)
If the recommended engine oil grades are not available, use engine oil with an API classification of SH, SJ,
or SL and an SAE classification of 15W-40, 20W-40, or 20W-50.
(*2) Meeting both API and SAE requirements
9
6AU3K11 2-2

SPEC
Specification
Model
Item Unit
3LNH
Bracket unit
Trim angle Degree 0.0, 4.0, 8.0, 12.0 —
(at 12° boat transom)
Tilt-up angle Degree 71 74
Steering angle Degree 43 + 43 38 + 38
PT system
Fluid type — ATF
Dexron II
Drive unit
Gear shift positions F-N-R
Gear ratio 2.08 2.92 (38/13)
(27/13)
Reduction gear type Straight Spiral bevel gear
bevel
gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction (rear view) Clockwise
Propeller mark N R
Electrical
Battery minimum capacity
CCA/EN A — 347.0
20HR/IEC Ah — 40.0
Electrolyte specific gravity
at 20 °C (68 °F) — 1.280
2-3 6AU3K11

General specification / Maintenance specification
Maintenance specification 2
Power unit 2
Model
Power unit
Item
Minimum compression
Unit
kPa
3LNH
630 (63, 91.4) 700 (7.0, 101.5)

1
pressure(*1) (kgf/cm2, psi)
Cylinder head
Warpage limit mm (in) 0.10 (0.0039)
2
3
(lines indicate straightedge
4
position)
Cylinder head journal inside mm (in) 18.000–18.018 (0.7087–0.7094)
diameter (A)
A
5
6
Camshaft
Intake and mm (in) 23.45–23.55 (0.9232–0.9272)
exhaust (A)
Intake and mm (in) 19.95–20.05 (0.7854–0.7894)
exhaust (B)
Camshaft journal diameter (C) mm (in) 17.975–17.991 (0.7077–0.7083)
7
C
Camshaft runout limit mm (in) 0.03 (0.0012)

8
Rocker arm shaft
Outside diameter
(*1) Measuring conditions:
mm (in) 12.941–12.951 (0.5095–0.5099)
Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs removed from all cylinders.
The figures are for reference only.
9
6AU3K11 2-4

SPEC
Specification
Model
Item Unit
3LNH
Rocker arm
Inside diameter mm (in) 13.000–13.018 (0.5118–0.5125)
Valve
Valve clearance (cold)
Intake mm (in) 0.15–0.20 (0.006–0.008)
Exhaust mm (in) 0.20–0.25 (0.008–0.010)
Head diameter (A)
Intake mm (in) 23.9–24.1 (0.94–0.95)
Exhaust mm (in) 21.9–22.1 (0.86–0.87)
Face width (B)
Intake and exhaust mm (in) 1.84–2.26 (0.0724–0.0890)
Seat contact width (C)
Margin thickness (D)
Intake mm (in) 0.7 (0.028)
Exhaust mm (in) 1.0 (0.039)
Stem diameter
Intake mm (in) 5.475–5.490 (0.2156–0.2161)
Exhaust mm (in) 5.460–5.475 (0.2150–0.2156)
Stem runout limit mm (in) 0.01 (0.0004)
Guide inside diameter
Stem-to-guide clearance
Intake mm (in) 0.010–0.037 (0.0004–0.0015)
Exhaust mm (in) 0.025–0.052 (0.0010–0.0020)
Guide height mm (in) 8.05 ± 0.25 (0.32 ± 0.01)
Valve spring
Free length mm (in) 27.6 (1.0866)
Tilt limit mm (in) 1.0 (0.039)
Cylinder
Bore size mm (in) 56.000–56.015 (2.2047–2.2053)
2-5 6AU3K11

Maintenance specification
Model
Item Unit
3LNH
Piston
Piston diameter (D)
Measuring point (H)
Piston clearance(*1)
Piston pin boss bore
mm (in)
mm (in)
mm (in)
mm (in)
55.950–55.965 (2.2028–2.2033)
1.5 (0.06)
0.035–0.065 (0.0014–0.0026)
14.004–14.015 (0.5513–0.5518)
1
Oversize piston diameter
1st
2nd
Piston ring groove
mm (in)
mm (in)
56.200–56.215 (2.2126–2.2132)
56.450–56.465 (2.2224–2.2230) 2
Top ring mm (in) 1.23–1.25 (0.0484–0.0492)
2nd ring
Oil ring
Piston pin
Outside diameter
mm (in)
mm (in)
mm (in)
1.52–1.54 (0.0598–0.0606)
2.51–2.53 (0.0988–0.0996)
13.996–14.000 (0.5510–0.5512)
3
Piston ring
Top ring
Dimension B
Dimension T
T
B
mm (in)
mm (in)
Barrel
1.17–1.19 (0.0461–0.0469)
1.95–2.15 (0.0768–0.0846)
4
End gap(*1) mm (in) 0.15–0.30 (0.0059–0.0118)
Side clearance
2nd ring
Dimension B
Dimension T
B
mm (in)
mm (in)
mm (in)
0.04–0.08 (0.0016–0.0031)
Plain
1.47–1.49 (0.0579–0.0587)
2.40–2.60 (0.0945–0.1024)
5
T
End gap(*1) mm (in) 0.30–0.45 (0.0118–0.0177)
Side clearance
Oil ring
Dimension B
mm (in)
mm (in)
0.03–0.07 (0.0012–0.0028)
2.35–2.50 (0.0925–0.0984)
6
Dimension T mm (in) 2.30–2.60 (0.0906–0.1024)
End gap(*1)
Side clearance
Connecting rod
Small end inside diameter
mm (in)
mm (in)
mm (in)
0.20–0.70 (0.0079–0.0276)
0.01–0.18 (0.0004–0.0071)
14.015–14.029 (0.5518–0.5523)
7
Big end inside diameter mm (in) 27.030–27.042 (1.0642–1.0646)
Big end side clearance(*1)
Crankpin oil clearance(*1)
Crankshaft
mm (in)
mm (in)
0.05–0.22 (0.0020–0.0087)
0.021–0.045 (0.0008–0.0018) 8
Crankshaft journal diameter mm (in) 30.002–30.014 (1.0582–1.0586)
9
Crankpin diameter mm (in) 26.997–27.009 (1.0629–1.0633)
Crankpin width mm (in) 21.000–21.070 (0.8268–0.8295)
Crankshaft runout limit mm (in) 0.05 (0.0020)
(*1) The figures are for reference only.
6AU3K11 2-6

SPEC
Specification
Model
Item Unit
3LNH
Crankcase
Crankshaft journal oil mm (in) 0.006–0.034 (0.0002–0.0013)
clearance(*1)
Upper and lower crankcase
main journal bearing thickness
A - (Blue) mm (in) 1.502–1.506 (0.0591–0.0593)
B - (Black) mm (in) 1.498–1.502 (0.0590–0.0591)
C - (Brown) mm (in) 1.494–1.498 (0.0588–0.0590)
Oil pump
Type Trochoid
Relief valve opening pressure kPa 390–450 (3.90–4.50, 56.6–65.3)
(kgf/cm2, psi)
Thermostat
Opening temperature
at 0.05 mm (0.0020 in) °C (°F) 58–62 (136–144)
Fully open temperature °C (°F) 70 (158)
Valve open lower limit mm (in) 3.0 (0.12)
Manual starter
Starter rope length mm (in) 1,900 (74.8) —
Starter rope pulling length mm (in) 1,400–1,600 —
(55.12–62.99)
Fuel system 2
Model
Item Unit
3LNH
Carburetor
ID mark
(For Europe) 6AU20 6AU50
(For Oceania) 6AU00 — 6AU30
Float height mm (in) 20.0–21.0 (0.79–0.83)
Valve seat size mm (in) 0.7 (0.03)
Main jet (M.J.)
(For Europe) #86
(For Oceania) #90 — #90
Main nozzle (M.N.) mm (in) 2.0 (0.08)
Pilot jet (P.J.) #40
Pilot screw (P.S.)
(For Europe) turns out 1 5/8
(For Oceania) turns out 1 5/8 — 1 5/8
Engine idle speed r/min 1,050 ± 50
2-7 6AU3K11

Model
Item Unit
3LNH
Fuel pump
Fuel pump holding pressure
Fuel inlet positive pressure
Fuel inlet negative pressure

kPa
(kgf/cm2, psi)
kPa
50 (0.5, 7.3)
30 (0.3, 4.4)
1
(kgf/cm2, psi)
Fuel outlet positive pressure
Fuel joint holding pressure

kPa
(kgf/cm2, psi)
50 (0.5, 7.3)
2
Positive pressure kPa 50 (0.5, 7.3)
3
(kgf/cm2, psi)
Fuel filter assembly holding
pressure
Positive pressure kPa 200 (2.0, 29.0)
(kgf/cm2, psi)
Lower unit
Item Unit
3LNH
Model
2
4
Lower unit
Holding pressure
Gear backlash
kPa
(kgf/cm2, psi)
100 (1.0, 14)
5
Pinion-to-forward gear(*1) mm (in) 0.50– 0.76–2.30 (0.0299–0.0906)
Pinion-to-reverse gear(*1) mm (in)

2.27
(0.0197–
0.0894)
0.50– 0.76–2.30 (0.0299–0.0906)
6
2.27
Pinion shims mm
(0.0197–
0.0894)
1.9, 2.0,
2.1, 2.2
1.13, 1.20
7
Forward gear shims mm 0.10, 0.1, 0.2, 0.3, 0.4
0.12,
0.15,
0.18,
8
0.30
Reverse gear shims mm 0.1 0.1, 0.2, 0.3
Propeller shaft
Runout limit mm (in) 0.05
(0.0020)
0.02 (0.0008) 9
(*1) Figures obtained using the special service tools.
6AU3K11 2-8

SPEC
Specification
Model
Item Unit
3LNH
Drive shaft
Runout limit mm (in) 1.0
(0.0394) 0.5 (0.0197)
Electrical 2
Model
Item Unit
3LNH
Ignition and ignition control
system
Spark plug gap mm (in) 0.9–1.0 (0.035–0.039)
Spark plug cap resistance(*1) kΩ 4.0–6.0
Ignition coil resistance(*1)
Primary coil (O – B)
at 20 °C (68 °F) Ω 0.26–0.35
Secondary coil
(spark plug wire –
spark plug wire)
at 20 °C (68 °F) kΩ 6.8–10.2
Pulser coil output peak voltage
(W/R – B)
at cranking (unloaded) V 7.0
at cranking (loaded) V 3.5
at 1,500 r/min (loaded) V 7.0
at 3,500 r/min (loaded) V 10.5
Pulser coil resistance(*1)
(W/R – B)
at 20 °C (68 °F) Ω 240–360
Charge coil output peak
voltage (Br – L)
at cranking (unloaded) V 140
at cranking (loaded) V 160
at 1,500 r/min (loaded) V 180
Charge coil resistance(*1)
(Br – L)
at 20 °C (68 °F) Ω 232–348
CDI unit output peak voltage(*1)
(O – B)
at cranking (loaded) V 140
2-9 6AU3K11

Model
Item Unit
3LNH
Oil pressure switch
Specified oil pressure
Fuel control system

Choke solenoid resistance(*1)
kPa
(kgf/cm2, psi)
14.7 (0.147, 2.132)
1
(L – B)
at 20 °C (68 °F)
Starter motor
Type
Ω —
—
4.0
Bendix
2
Output kW — 0.60
Cranking time limit
Stator motor clearance
Wear limit
Second
mm (in)
mm (in)
—
—
—
30
0.05–0.25
(0.002–0.010)
0.6 (0.02)
3
Brushes
Standard length
Wear limit
Commutator
mm (in)
mm (in)
—
—
12.5 (0.49)
9.0 (0.35) 4
Standard diameter mm (in) — 30.0 (1.18)
5
Wear limit mm (in) — 29.0 (1.14)
Standard undercut mm (in) — 0.5–0.8 (0.02–0.03)
Pinion stopper height mm (in) — 52 (2.05)
Charging system
Fuse
Lighting coil (1 coil) output
peak voltage
at cranking (unloaded)
(G – G)
A
V 6.1
10
—
6
at 1,500 r/min (unloaded) V 14.6 —
at 3,500 r/min (unloaded)
Lighting coil (1 coil)
resistance(*1) (G – G)
V 33.1 —
7
at 20 °C (68 °F) Ω 0.24–0.36 —
Lighting coil (2 coils) output
peak voltage (G/W – G)
at cranking (unloaded)
at 1,500 r/min (unloaded)
V
V
16.1
33.3
8
at 3,500 r/min (unloaded) V 79.1
Lighting coil (2 coils)
resistance(*1)
at 20 °C (68 °F)
(G/W – G)
Ω 0.61–0.91
9
6AU3K11 2-10

SPEC
Specification
Model
Item Unit
3LNH
Rectifier output peak voltage
(R – Ground)
at 1,500 r/min (unloaded) V 13 —
at 3,500 r/min (unloaded) V 19 —
Rectifier Regulator output
peak voltage (R – Ground)
PT motor
Output kW — 0.18
Brushes
Standard length mm (in) — 6.0 (0.24)
Commutator
Standard diameter mm (in) — 16.5
(0.65)
Wear limit mm (in) — 15.5
(0.61)
Standard undercut mm (in) — 1.00
(0.039)
Wear limit mm (in) — 0.50
(0.020)
2-11 6AU3K11

Dimension 2
Exterior3LNH0

279 (11.0)
43˚
mim (in)
1
(6.8)
(6.3)
172
159
2
(6.3)
159
(7.2)
(8.2)
181
206
524 (20.6)
3
497 (19.6)
274 (10.8)
S: 708 (27.9)
L: 825 (32.5)
4
121 (4.8) 431 (17.0)
66 (2.6)
5
533 (21.0)
568 (22.4)
6
323 (12.8)
206 (8.2)
7
37 (1.5)
8 (0.4)
S: 431 (17.0)
L: 558 (22.0)
138
(5.5)
S: 18 (0.7)
S: 677 (26.7)
L: 804 (31.7)
L: 27 (1.1)
S: 604 (23.8)
L: 682 (26.9)
S: 49
L: 67 (2.0)
71˚
8
(4.9)
(2.7)
123
9
12˚
19 (0.8)
–4˚
356 (14.1)
S6AU2006
6AU3K11 2-12

Exterior3LNH(
mim (in)
1
279 (11.0)
43˚
(7.0)
(6.3)
177
159
2
(6.3)
159
274 (10.8)
121
L: 891 (35.1)
X: 954 (37.6) 3
(4.8) 431 (17.0)
66 (2.6)
4
533 (21.0)
5
323 (12.8)
206 (8.2)
6
37 (1.5)
8 (0.4)
138
(5.5)
L: 552 (21.8)
X: 620 (24.4)
27 (1.1)
7
L: 864 (34.1)
X: 932 (36.7)
L: 730 (28.8)
X: 771 (30.4)
67 (2.7
)
71˚
(6.2)
157
12˚
8
19 (0.8)
–4˚
367 (14.5)
S6AU2009
9
6AU3K11 2-16

Clamp bracket
mm (in)
1
70.5 (2.8) 70.5 (2.8) 2
76.5 (3.1) 3
8.3 (0.4)
4
48 (1.9)
187.5 (7.4)
18 (0.7)
95.3 (3.8) 95.3 (3.8)

67 (2.7)
5
32 (1.3)
110 (4.4)
6
7
8
S6AU2012
9
6AU3K11 2-18

SPEC
Specification
Tightening torque 2
Specified torque 2
Tightening torques
Part to be tightened Thread size
N·m kgf·m ft·lb
Fuel system
Fuel joint bolt M6 8 0.8 5.9
Fuel pump screw M4 2 0.2 1.5
Fuel pump valve screw M3 0.5 0.05 0.37
Power unit
Drive plate screw (M model) M5 5 0.5 3.7
Power unit mounting bolt M8 21 2.1 15.5
Apron screw M6 2.5 0.25 1.84
Ignition coil bolt M6 8 0.8 5.9
Ignition coil bracket bolt (1 lighting coil) M8 18 1.8 13.3
Rectifier screw (1 lighting coil) M5 3.5 0.35 2.6
Rectifier Regulator bolt (2 lighting coils) M6 8 0.8 5.9
Spark plug — 24 2.4 17.7
Pulser coil bolt M5 5 0.5 3.7
CDI unit bolt M6 8 0.8 5.9
Starter motor bolt (E model) M8 21 2.1 15.5
Negative battery cable bolt (E model) M8 18 1.8 13.3
Charge coil bolt M6 12 1.2 8.9
Starter motor lead nut (E model) — 4 0.4 3.0
Starter motor terminal nut (E model) — 0.4 0.04 0.30
Starter relay lead bolt (E model) M6 4 0.4 3.0
Starter motor bracket bolt (E model) M8 21 2.1 15.5
Oil pressure switch — 8 0.8 5.9
Oil pressure switch lead bolt — 2 0.2 1.5
Throttle cam bolt M6 8 0.8 5.9
Throttle cable bracket bolt M6 8 0.8 5.9
Flywheel magnet nut — 98 9.8 72.3
Drive sprocket nut — 36 3.6 26.6
Driven sprocket bolt M6 12 1.2 8.9
1st 6 0.6 4.4
Intake manifold bolt M6
2nd 12 1.2 8.9
Cylinder head cover bolt M6 8 0.8 5.9
Blowby plate screw M4 2 0.2 1.5
1st 15 1.5 11.1
M8
2nd 29 2.9 21.4
Cylinder head bolt
1st 6 0.6 4.4
M6
2nd 12 1.2 8.9
Anode plug — 18 1.8 13.3
Rocker arm locknut — 7 0.7 5.2
Oil pump assembly bolt M6 8 0.8 5.9
Oil pump screw M6 5 0.5 3.7
2-19 6AU3K11

Tightening torque
Tightening torques
N·m kgf·m ft·lb
Anode screw M5 2 0.2 1.5
Thermostat cover bolt
Relief valve
Exhaust cover bolt

1st
2nd
M6
—
M6
8
8
6
12
0.8
0.8
0.6
1.2
5.9
5.9
4.4
8.9
1
1st 15 1.5 11.1
Crankcase bolt
Connecting rod cap bolt

2nd
1st
2nd
M8
M7
30
6
11
3.0
0.6
1.1
22.1
4.4
8.1
2
Lower unit
Gear oil drain screw
Gear oil check screw
Lower case mounting bolt
Lower case mounting nut (X-transom model)
—
—
M8
—
9
9
18
18
0.9
0.9
1.8
1.8
6.6
6.6
13.3
13.3
3
Propeller nut — 17 1.7 12.5
Propeller nut (high thrust model)
Cooling water inlet cover screw
Anode bolt
—
M5
M6
21
2
8
2.1
0.2
0.8
15.5
1.5
5.9
4
Water pump housing bolt M8 18 1.8 13.3
Propeller shaft housing bolt
Pinion nut (high thrust model)
Bracket unit
Shift lever bolt (H model [short]/R model)
M6
—
M5
8
25
3
0.8
2.5
0.3
5.9
18.4
2.2
5
Shift lever bolt (H model [long]) M8 18 1.8 13.3
Shift lever screw (H model [long])
Tiller handle bracket nut (H model)
Tiller handle assembly nut (H model [short])
M6
—
—
3
36
22
0.3
3.6
2.2
2.2
26.6
16.2
6
Tiller handle assembly nut (H model [long]) — 10 1.0 7.4
Tiller handle assembly self-locking nut (H
model [long])
Throttle grip screw (H model)
PT switch screw (PT model)
—
M5
M6
22
3
6
2.2
0.3
0.6
16.2
2.2
4.4
7
PT switch bracket screw (PT model) M6 4 0.4 3.0
Engine shut-off switch nut (H model)
Friction plate assembly bolt (H model)
Friction plate bolt (H model)
—
M5
M5
2
7
7
0.2
0.7
0.7
1.5
5.2
5.2
8
Friction plate bolt (H model) M8 18 1.8 13.3
9
Friction self-locking nut (H model) — 6 0.6 4.4
Flushing hose adapter screw M6 2 0.2 1.5
Cowling lock lever bolt M6 8 0.8 5.9
Upper mounting nut — 20 2.0 14.8
1st 7 0.7 5.2
Mount housing nut 2nd — 12 1.2 8.9
3rd 14 1.4 10.3
6AU3K11 2-20

SPEC
Specification
Tightening torques
N·m kgf·m ft·lb
Upper mount bolt M6 11 1.1 8.1
Engine oil drain bolt — 24 2.4 17.7
Oil pan bolt M8 21 2.1 15.5
Exhaust manifold bolt M6 11 1.1 8.1
Upper case bolt M8 18 1.8 13.3
Shift rod grommet plate bolt M6 8 0.8 5.9
Self-locking nut — 19 1.9 14.0
Tilt stopper plate bolt (MT model) — 8 0.8 5.9
Anode bolt (PT model) M6 8 0.8 5.9
Stopper nut (PT model) — 24 2.4 17.7
Ground lead bolt (PT model) M6 8 0.8 5.9
PT unit mounting shaft bolt (PT model) M8 18 1.8 13.3
Grease nipple — 3 0.3 2.2
PT unit (PT model)
PT motor assembly bolt M5 5 0.5 3.7
Reservoir cap — 5 0.5 3.7
Gear housing bolt M5 5 0.5 3.7
Tilt cylinder end screw — 45 4.5 33.2
Tilt ram — 45 4.5 33.2
General torque 2
This chart specifies tightening torques for

standard fasteners with a standard ISO
thread pitch. Tightening torque specifications
for special components or assemblies are
provided in applicable sections of this man-
ual. To avoid warpage, tighten multi-fastener
assemblies in a crisscross fashion and pro-
gressive stages until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads.
Components should be at room temperature.
General torque
Nut (A) Bolt (B) specifications
N·m kgf·m ft·lb
8 mm M5 5 0.5 3.7
10 mm M6 8 0.8 5.9
12 mm M8 18 1.8 13.3
14 mm M10 36 3.6 26.6
17 mm M12 43 4.3 31.7
2-21 6AU3K11

CHK
ADJ
Periodic check and adjustment
Maintenance interval chart............................................................................3-1
Top cowling .................................................................................................... 3-3

Checking the top cowling...........................................................................3-3
1
Fuel system .................................................................................................... 3-3
Checking the fuel joint and fuel hose (fuel joint-to-carburetor) .................. 3-3
Checking the fuel filter ............................................................................... 3-3
Draining the fuel ........................................................................................3-4
2
Power unit....................................................................................................... 3-4
Checking the engine oil .............................................................................3-4
Changing the engine oil.............................................................................3-4
Checking the timing belt ............................................................................3-5
3
Checking the spark plug ............................................................................3-5
4
Checking the thermostat............................................................................3-6
Checking the cooling water passage.........................................................3-7
Control system ............................................................................................... 3-7

Adjusting the throttle cable (H model) .......................................................3-7
Adjusting the throttle cable (R model) .......................................................3-8
Adjusting the throttle link ...........................................................................3-9
Checking the gear shift operation (H model) ...........................................3-10
Checking the gear shift operation (R model) ...........................................3-10
5
Checking the start-in-gear protection (M model) ..................................... 3-11
6
Checking the engine idle speed ..............................................................3-11
Checking the ignition timing..................................................................... 3-12
Bracket unit .................................................................................................. 3-12

Checking the steering operation (H model) ............................................. 3-12
Checking the tilt operation (MT model)....................................................3-13
Checking the tilt operation (PT model) ....................................................3-13
Checking the PT fluid level ...................................................................... 3-13 7
Lower unit ..................................................................................................... 3-14
Checking the gear oil............................................................................... 3-14
Changing the gear oil .............................................................................. 3-14
Checking the lower unit for air leakage ...................................................3-15
Checking the propeller............................................................................. 3-15
8
General..........................................................................................................3-16
Checking the anode................................................................................. 3-16
Checking the battery................................................................................ 3-16
Lubricating the outboard motor................................................................3-17
9
6AU3K11

CHK
ADJ Periodic check and adjustment
Maintenance interval chart 3
Use the following chart as a guideline for general maintenance.

Adjust the maintenance intervals according to the operating conditions of the outboard motor.
Initial Every Refer to
Item Remarks 20 hours 100 hours 300 hours 500 hours
(3 months) (1 year) (3 years) (5 years)
page
Anode(s) (external) Check/replace 3-16
Anode(s) (cylinder head, Check/replace 3-16
thermostat cover)
Battery Check/charge/ 3-16
replace
Cooling water leakage Check/replace 3-7
Cowling clamp Check 3-3
Engine starting condition/ Check —
noise
Engine idle speed/noise Check 3-11
Engine oil Replace 3-4
Engine oil filter (built into oil Check/clean/ 7-22
pan) replace
Fuel filter Replace 3-3
Fuel pump Check/replace 4-4
Fuel/oil leakage Check 3-3
Fuel pipe Check/replace 3-3
Fuel pipe Replace 4-1
Gear oil Replace 3-14
Greasing points Lubricate 3-17
Impeller/water pump housing Check/replace 6-5, 6-25
Impeller/water pump housing Replace 6-5, 6-25
PT unit Check 3-13
Propeller/propeller nut/cotter Check/replace 6-1, 6-21
pin
Shift link/shift cable Check/adjust/ 3-10
replace
Spark plug(s) Check/adjust/ 3-5
replace
Spark plug caps/spark plug Check/replace 8-30
wires
Pilot water Check 3-7
Throttle link/throttle cable/ Check/adjust/ 3-7, 3-8,
throttle pick-up timing replace 3-9
Thermostat Check/replace 3-6
Timing belt Check/ 3-5
replace(*1)
Valve clearance Check/adjust 5-1
Water inlet Check 3-7
(*1) Check and, if defective, replace.
3-1 6AU3K11

Maintenance interval chart
Initial Every Refer to

Item Remarks 20 hours 100 hours 300 hours 500 hours
(3 months) (1 year) (3 years) (5 years)
page
Main switch/stop switch/choke Check/replace 8-26, 8-27,
switch
Wire harness connections/
wire coupler connections
Check/replace
8-33
8-1 1
(Selva) Fuel tank Check/clean —
NOTE:
• When operating in salt water, turbid or muddy water, the engine should be flushed with clean
water after each use.
2
• When using leaded or high-sulfur gasoline, checking the valve clearances may be required more
frequently than every 500 hours.
Item Remarks
Every Refer to
3
1,000 hours page
Exhaust guide/exhaust
manifold
Timing belt
Check/replace
Replace
7-22
5-3
4
5
6
7
8
9
6AU3K11 3-2

CHK
Top cowling 3
Checking the top cowling 3
1. Check the fitting by pushing the cowling

with both hands. Adjust if necessary.
S6AU3001
2. Loosen the bolts 1.
3. Move the hook 2 up or down slightly to S6AU3003
adjust its position.

Fuel system 3
Checking the fuel joint and fuel hose

a (fuel joint-to-carburetor) 3
2 1. Check the fuel hose connections for

leaks. Also, check the fuel joint 1, fuel
hoses, fuel filter 2, fuel pump 3, and
carburetor 4. Replace if there is leakage
or deterioration.
b 1
S6AG3020
4 1
NOTE:
• To tighten the fitting, move the hook 2 in
direction a. 3
• To loosen the fitting, move the hook 2 in
direction b.
4. Tighten the bolts 1. 2 S6AU3004
5. Check the fitting again and, if necessary, Checking the fuel filter 3
repeat steps 2–4. 1. Check the fuel filter 1. Replace if there is

residue or if it is cracked or damaged.
6. Check the air intake duct. Clean if there
are obstructions.
3-3 6AU3K11

Top cowling / Fuel system / Power unit
a
1
CAUTION:
a S6AU3005
NOTE:
S6AU1018
• If the oil appears milky or dirty, check for

2
When replacing the fuel filter 1, the arrow
and repair the cause, and then change the
mark a must face toward the fuel pump.
NOTE:
Be sure not to spill any fuel when removing
oil.
• If the engine oil is below the minimum level
mark a, add sufficient oil until the level is
between a and b.
3
the fuel filter 1.
Draining the fuel

1. Place a container 1 or rag under the car-
3
Changing the engine oil
1. Start the engine, warm it up, and then
turn it off.
3
4
buretor fuel drain hole, and then remove
the fuel drain screw 2 and let the fuel
drain completely.
2. Remove the oil dipstick and oil filler cap
1. 5
2
1
6
1
Power unit
S6AU3006
3
S6AU3008
7
Checking the engine oil
8
3
1. Place the outboard motor in an upright

position.
2. Remove the oil dipstick, wipe it clean,

and then insert it back into the oil dipstick
hole.
3. Remove the oil dipstick again to check

9
the oil level and to check the oil for dis-
coloration and its viscosity.
6AU3K11 3-4

CHK
3. Place a drain pan under the drain hole, Checking the timing belt 3
and then remove the engine oil drain bolt

2 and let the oil drain completely. CAUTION:
Do not turn the flywheel magnet counter-
clockwise, otherwise the water pump
2 impeller may be damaged.
1. Remove the driven sprocket cover and

manual starter. (M model)
Remove the driven sprocket cover and
flywheel magnet cover. (E model)
S6AU3009 2. While turning the flywheel magnet clock-

wise, check the interior a and the exte-
NOTE: rior b of the timing belt. Replace the
• Be sure to clean up any oil spills.
timing belt if cracked, damaged, or worn.
• When using an oil changer to change the
engine oil, insert the oil changer hose into
the oil dipstick hole.
a
4. Install the engine oil drain bolt 2, and

then tighten it to the specified torque.
Engine oil drain bolt 2:

24 N·m (2.4 kgf·m, 17.7 ft·lb)
T.
R.
b S6AU3012
5. Pour the specified amount of the recom- NOTE:

mended engine oil into the oil filler hole. To replace the timing belt, see “Replacing the
timing belt” (5-3).
Recommended engine oil:
4-stroke motor oil
API: SE, SF, SG, SH, SJ, or SL Checking the spark plug 3
SAE: 5W-30, 10W-30, or 10W-40 1. Disconnect the spark plug caps and
Engine oil quantity: remove the spark plugs.
0.8 L (0.85 US qt, 0.70 Imp qt)
2. Clean the electrodes 1 with a spark plug
6. Install the oil filler cap and oil dipstick, cleaner or wire brush.
and then start the engine and warm it up.
7. Turn the engine off, and then check the

oil level and that there is no oil leakage. If
the oil level is low, add engine oil to the
correct level.
3-5 6AU3K11

Power unit
3. Check the spark plug. Replace if the
electrodes are eroded or there is exces-
sive carbon or other deposits, or if the
1
1
gasket is damaged.
2
4. Check the spark plug gap a. Adjust the
spark plug gap if out of specification. 3
CAUTION:
S6AU3015
2
Do not reuse the gasket 3, always
3
replace it with a new one.
4. Suspend the thermostat in a container of

water.
NOTE:
Perform steps 2–4 for each spark plug.
Specified spark plug:

5. Place a thermometer in the water and
slowly heat the water. 4
BR6HS-10 (NGK)
Spark plug gap a:
0.9–1.0 mm (0.035–0.039 in)
5. Install the spark plugs, tighten them tem-

5
porarily, and then tighten them to the
specified torque using a spark plug
wrench.
Spark plug:
S69J5E40
6
24 N·m (2.4 kgf·m, 17.7 ft·lb)
T.
R.
6. Connect the spark plug caps. 7

Checking the thermostat 3
8
1. Remove the driven sprocket cover and
manual starter. (M model)
Remove the driven sprocket cover and
flywheel magnet cover. (E model)
9
2. Disconnect the cooling water hose.
3. Remove the thermostat cover 1 and

thermostat 2.
6AU3K11 3-6

CHK
6. Measure the thermostat valve opening a 3. Check for water flow at the cooling water
at the specified water temperatures. pilot hole. If there is no water flow, check
Replace the thermostat if out of specifi- the cooling water passages inside the
cation. outboard motor.
Water
Valve opening a
temperature
S6AU3020
0.05 mm
58–62 °C (0.0020 in)
(136–144 °F) (valve begins to Control system 3
open) Adjusting the throttle cable (H

Above More than model) 3
70 °C (158 °F) 3.0 mm (0.12 in) 1. Disconnect the throttle link rod 1 from
the free accel lever.
7. Install a new gasket, the thermostat, and
the thermostat cover, and then tighten 2. Loosen the locknuts 2 and 3, and then
the thermostat cover bolts to the speci- turn the adjusting nuts 4 and 5 to
fied torque. loosen the throttle cables 6 and 7.
Thermostat cover bolt: 6 2

4
8 N·m (0.8 kgf·m, 5.9 ft·lb)
T.
R.
Checking the cooling water passage 3
1. Check the cooling water inlet covers 1

and cooling water inlets. Clean if
clogged.
1 7 3 5 S6AU3021
1
3. Turn the throttle grip to the fully open
1 position and hold it in place.
4. Turn the adjusting nut 4 so that the fully

open stopper a on the throttle cam con-
tacts the throttle cable bracket as shown,
and then tighten the locknut 2.
S6D53130
2. Place the lower unit in water, and then

start the engine.
3-7 6AU3K11

Power unit / Control system
NOTE: É
Be careful not to pull the outer cables too
much towards the power unit as they could
be pulled out of the holes in the pivot section
of the tiller handle. If the outer cables are
pulled out of the tiller handle, see “Installing
the tiller handle” (7-3) or “Installing the tiller
b 1
handle” (7-8).
5. Turn the adjusting nut 5 to remove the

slack in the throttle cable 7, and then
È Fully open position
É Fully closed position
S6AU3023
2
tighten the locknut 3. 7. Connect the throttle link rod 1 to the free
6 2 4
accel lever.
NOTE:
After adjusting the throttle cables, adjust the
3
throttle link.
a
Adjusting the throttle cable (R
model) 3
4
7 3 5 S6AU3022 1. Disconnect the throttle link rod 1 from
6. Turn the throttle grip to the fully open and

fully closed positions and check that the
fully open stopper a and fully closed
the free accel lever.
2. Loosen the locknut 2, remove the clip

3, and then disconnect the throttle cable
5
stopper b on the throttle cam contact the joint 4.
È
throttle cable bracket as shown. Repeat
steps 2–5 if necessary.
1 6 5
6
3
a
5
7
a 4
2 7 S6AU3024
S6AU3059 3. Set the remote control lever to the N

position. 8
4. Check that the fully closed stopper a on
the throttle cam contacts the throttle
cable bracket 5.
9
6AU3K11 3-8

CHK
5. Adjust the position of the throttle cable
É
joint 4 until its hole is aligned with the
set pin on the throttle cam 6.
S6AU3026
È Fully open position

b É Fully closed position
S6AG1090
8. Connect the throttle link rod 1 to the free
WARNING accel lever.
The throttle cable joint must be screwed NOTE:
in a minimum of 8.0 mm (0.31 in) b. After adjusting the throttle cable, adjust the
throttle link.
NOTE:
Pull the throttle cable 7 towards the engine
Adjusting the throttle link 3
to remove any free play in the cable before

1. Loosen the throttle link stopper screw 1.
adjusting the position of the throttle cable
joint. b
3
4
6. Connect the throttle cable joint 4, install 2
the clip 3, and then tighten the locknut
2.
1
7. Set the remote control lever to the fully
a
open and fully closed positions and
c S6AU3027
check that the fully open stopper c and
fully closed stopper a on the throttle
2. Turn the throttle grip (H model) or remote
cam contact the throttle cable bracket as
control lever (R model) to the fully open
shown.
position and hold it in place. Check that
È the fully open stopper 2 on the throttle
cam contacts the throttle cable bracket
a.
NOTE:
If the fully open stopper 2 does not contact
c the throttle cable bracket a, adjust the throt-
tle cable(s). See “Adjusting the throttle cable
(H model)” (3-7) or “Adjusting the throttle
S6AU3060
cable (R model)” (3-8).
3. Turn the carburetor throttle lever 3

clockwise so that it contacts the carbure-
tor body b as shown.
3-9 6AU3K11

Control system
4. Turn the free accel lever 4 counterclock-
wise until it contacts the throttle cam c.
5. Tighten the throttle link stopper screw 1.
6. Turn the throttle grip (H model) or remote

control lever (R model) to the fully open
and fully closed positions and check that
1
1
the throttle cam operates smoothly.
NOTE:
After adjusting the throttle link, adjust the
engine idle speed. See “Checking the engine
NOTE:
S6AU3029
To adjust the shift rod adjusting nut 1, see

2
idle speed” (3-11). “Installing the lower unit” (6-15) or “Installing
Checking the gear shift operation

(H model) 3
the lower unit” (6-37).
Checking the gear shift operation

3
1. Check that the gear shift operates (R model)
4
3
smoothly when the shift lever is shifted 1. Check that the gear shift operates
from the N position to the F position or R smoothly when the remote control lever
position. Adjust the shift rod adjusting nut is shifted from the N position to the F
1 if necessary. position or R position. Adjust the shift
cable length and shift rod adjusting nut if
È
R N
necessary.

position.
5
F
S6AU3028
3. Loosen the locknut 1, remove the clip
2, and then disconnect the shift cable
joint 3.
6
É
R
N
F 2
7
S6AU3063
3 1 S6AU3031
8
È H model (short)
É H model (long)
9
6AU3K11 3-10

CHK
4. Adjust the position of the shift cable joint 1. Set the shift lever to the F position or R
until its hole is aligned with the set pin on position, and then check that the starter
the shift rod lever joint. handle cannot be pulled. If the starter
rope can be pulled out normally, adjust
the start-in-gear protection cable.
2. Set the shift lever to the N position and

loosen the locknut 1. Align the cable
end a with the mark b on the manual
starter cover by turning the adjusting nut
a 2.
S6AG3130 3. Tighten the locknut 1.
WARNING a
The shift cable joint must be screwed in a
minimum of 8.0 mm (0.31 in) a.
b
5. Connect the shift cable joint 3, install the
clip 2, and then tighten the locknut 1.
6. Adjust the shift rod adjusting nut 4.
2
4
1 S6AU3034
S6AU3033
Checking the engine idle speed 3
NOTE: 1. Start the engine and warm it up.

To adjust the shift rod adjusting nut 4, see
“Installing the lower unit” (6-15) or “Installing 2. Attach the special service tool to spark
the lower unit” (6-37). plug wire #1 1, and then check the
engine idle speed. Adjust if out of specifi-
cation.
7. Check the gear shift for smooth opera-
tion.
Checking the start-in-gear protection

(M model) 3
1
CAUTION:
Be sure to remove the clip from the
engine shut-off switch before checking
S6AU3035
the start-in-gear protection.
3-11 6AU3K11

Control system / Bracket unit
3. Check that the pointer a is aligned with
Digital tachometer: 90890-06760 the “5” mark on the flywheel magnet as
shown.
Engine idle speed: 1,050 ± 50 r/min
5 T
1
3. Turn the throttle stop screw 2 in direc-
tion a or b until the specified engine
idle speed is obtained.
a
2
S6AU3038
2
Ignition timing at 1,050 r/min:
BTDC 5 ± 3° 3
b a Bracket unit 3
NOTE:
S6AU3036
Checking the steering operation (H
model)
NOTE:
3
4
• To increase the engine idle speed, turn the Lubricate the swivel bracket before checking
throttle stop screw 2 in direction a.
• To decrease the engine idle speed, turn the
throttle stop screw 2 in direction b.
the steering operation.
1. Move the steering lock lever 1 to posi-

tion a and check that the steering is
5
locked.
4. After adjusting the engine idle speed, rev
the engine a few times and let it idle to
check the stability of the engine.
Move the steering lock lever 1 to posi-
tion b and check that the steering oper-
ates smoothly. 6
Checking the ignition timing 3
1. Start the engine and warm it up.
2. Attach the special service tool to spark

plug wire #1 1.
7
1
b
a
S6AU3039
8
1
S6AU3037
9
Timing light: 90890-03141
6AU3K11 3-12

CHK
2. Adjust the self-locking nut 2 until the
steering operation is proper.
S6AG3220
S6AG3430 Checking the PT fluid level 3
1. Fully tilt the outboard motor up, and then

Checking the tilt operation (MT support it with the tilt stop lever.
model) 3
1. Fully tilt the outboard motor up and down WARNING

a few times and check the entire tilt After tilting up the outboard motor, be
range for smooth operation. Check the tilt sure to support it with the tilt stop lever.
mechanism if necessary. Otherwise, the outboard motor could sud-
denly lower if the PT unit should lose fluid
NOTE: pressure.
To check the tilt operation, see “Checking the
tilt system (MT model)” (1-17).
2. Remove the reservoir cap 1, and then
check the fluid level in the reservoir.
Checking the tilt operation (PT
model) 3
1. Fully tilt the outboard motor up and down

a few times and check the entire tilt
range for smooth operation. Check the
PT fluid level if necessary.
1
NOTE:
• To check the PT fluid level, see “Checking
the PT fluid level” (3-13). S6AG3230
• Be sure to listen to the winding sound of the
PT motor for smooth operation. NOTE:
If the fluid is at the correct level, a small
amount of fluid should overflow out of the
2. Fully tilt the outboard motor up, and then filler hole when the cap is removed.
support it with the tilt stop lever to check
the lock mechanism of the lever.
3. If necessary, add sufficient fluid of the
recommended type until it overflows out
of the filler hole.
Recommended PT fluid:
ATF Dexron II
3-13 6AU3K11

Bracket unit / Lower unit
4. Install a new O-ring and the reservoir cap
1, and then tighten the cap to the speci- Recommended gear oil:
fied torque. Hypoid gear oil
API: GL-4
Reservoir cap 1:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
SAE: 90
1
T.
R.
4. Install a new gasket and the gear oil

Lower unit 3
check screw 1, and then tighten the
2
Checking the gear oil 3
gear oil check screw to the specified
1. Fully tilt the outboard motor down. torque.
2. Remove the gear oil check screw 1, and Gear oil check screw 1:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
T.
R.
then check the gear oil level in the lower
È
case. Also, check the oil for discoloration
and its viscosity. Changing the gear oil
1. Fully tilt the outboard motor down.
3
3
1 2. Place a drain pan under the gear oil drain
hole, remove the gear oil drain screw 1,
then the gear oil check screw 2, and let
the oil drain completely.
4
È
2
É
S6AU3061
1
5
1
6
È Except for high thrust model
S6AU3043
É
S6AU3062
7
2
8
NOTE:
• If the oil is at the correct level, a small
amount of oil should overflow out of the
check hole when the gear oil check screw 1
1 is removed.
9
• If the oil appears milky or dirty, check for
and repair the cause, and then change the
oil.
3. If necessary, add sufficient gear oil of the

S6AU3044
recommended type until it overflows out
of the check hole. È Except for high thrust model
6AU3K11 3-14

CHK
3. Check the oil for metal and discoloration,
and its viscosity. Check the internal parts
of the lower case if necessary.
4. Insert a gear oil tube or gear oil pump

into the drain hole and slowly fill with
gear oil until oil flows out of the check
hole and no air bubbles are visible.
Leakage tester: 90890-06840
2. Apply the specified pressure and check

that the pressure is maintained in the
lower unit for at least 10 seconds.
CAUTION:
Do not overpressurize the lower unit, oth-
erwise the oil seals can be damaged.
S6AU3045
Recommended gear oil: NOTE:

Hypoid gear oil Cover the check hole with a rag when remov-
API: GL-4 ing the special service tool from the lower
SAE: 90 unit.
Gear oil quantity:
Except for high thrust model: Lower unit holding pressure:
150 cm3 100 kPa (1.0 kgf/cm2, 14 psi)
(5.07 US oz, 5.29 Imp oz)
For high thrust model:
3. If the specified pressure cannot be main-
370 cm3
tained, check the propeller shaft, drive
(12.51 US oz, 13.05 Imp oz)
shaft, shift rod, O-rings, and oil seals for
damage. If necessary, check each shaft
5. Install new gaskets and the gear oil for bends and damage.
check screw 2, quickly install the gear
oil drain screw 1, and then tighten them Checking the propeller 3
to the specified torque. 1. Check the propeller blades and splines.

Replace the propeller if cracked, dam-
Gear oil check screw 2 and drain
aged, or worn.
screw 1: 9 N·m (0.9 kgf·m, 6.6 ft·lb)
T.
R.
NOTE:
Checking the lower unit for air When replacing the propeller, see “Propeller
leakage 3
selection” (1-12) and select a propeller of the
1. Remove the gear oil check screw 1, and same size as originally installed.
then install the special service tool.
3-15 6AU3K11

Lower unit / General
General 3
Checking the anode 3

CAUTION:
1. Check the anodes. Clean the anodes if Do not oil, grease, or paint the anodes,
1
there are scales, grease, or oil. otherwise they will be ineffective.
NOTE:
• Replace the anodes if excessively eroded.
In addition, check the ground lead.
• If it is necessary to disassemble the out-
board motor to check an anode, refer to the
applicable disassembly procedure in this
manual.
2
È
S6AU3048
Checking the battery

1. Check the battery electrolyte level. If the
level is at or below the minimum level
3
3
mark a, add distilled water until the level
is between the maximum and minimum
level marks. 4
É
S6AG3280
5
S69J3620
2. Check the specific gravity of the electro-

6
lyte. Fully charge the battery if below
Ê
S6AU3050
specification.
7
8
È PT model
É Except for high thrust model
Ê For high thrust model
S6AU3052
9
6AU3K11 3-16

CHK
WARNING a
Battery electrolyte is dangerous; it con-
tains sulfuric acid which is poisonous and
A
highly caustic.
Always follow these preventive measures:
• Avoid bodily contact with electrolyte as
it can cause severe burns or permanent a
eye injury. A
S6AG3450
• Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
• SKIN – Wash with water.
• EYES – Flush with water for 15 minutes a
and get immediate medical attention.
Antidote (INTERNAL):
• Drink large quantities of water or milk
followed with milk of magnesia, beaten
egg, or vegetable oil. Get immediate A S6AG3440
medical attention.
Batteries generate explosive, hydrogen È
gas. Always follow these preventive mea- A
sures:
• Charge batteries in a well-ventilated
area.
• Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or han- S6AU3056
dling batteries. È H model
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN. NOTE:
Apply grease until it flows from the bushings
a.
NOTE:
• Batteries vary per manufacturer. The pro-
cedures mentioned in this manual may not 2. Apply low temperature resistant grease
always apply, therefore, consult the instruc- to the areas shown.
tion manual of the battery.
• Disconnect the negative battery cable first,
then the positive battery cable.
C
Electrolyte specific gravity:

1.280 at 20 °C (68 °F)
Lubricating the outboard motor 3
S6AU3057
1. Apply water resistant grease to the areas
shown.
3-17 6AU3K11

General
3. Apply corrosion resistant grease to the
area shown.
1
2
3
4
5
6
7
8
9
6AU3K11 3-18

CHK
— MEMO —
3-19 6AU3K11

FUEL
Fuel system
Hose routing ...................................................................................................4-1

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

1
Checking the fuel pump.............................................................................4-4
Checking the fuel filter ............................................................................... 4-4
Checking the fuel joint ............................................................................... 4-5
Disassembling the fuel pump .................................................................... 4-5
Checking the diaphragm and valve ........................................................... 4-5
Assembling the fuel pump ......................................................................... 4-6
2
Carburetor unit ............................................................................................... 4-7
Carburetor .................................................................................................4-9
Removing the carburetor .........................................................................4-11
Disassembling the carburetor.................................................................. 4-11
3
Checking the carburetor ..........................................................................4-11
Assembling the carburetor....................................................................... 4-12
Installing the carburetor ...........................................................................4-13
Adjusting the pilot screw..........................................................................4-13
4
5
6
7
8
9
6AU3K11

FUEL
Fuel system
Hose routing 4
Fuel hose, blowby hose, and cooling water hose 4
1 2
3
7 6 5
S6AU4001
1 Cooling water hose 8 Fuel hose (fuel pump-to-carburetor assembly)

(thermostat cover-to-cylinder block)
2 Blowby hose
(cylinder head cover-to-intake silencer)
3 Fuel hose (fuel joint-to-fuel filter assembly)
4 Flushing hose
(flushing hose adapter-to-intake manifold)
(for Europe)
5 Cooling water hose
(exhaust cover-to-exhaust)
6 Cooling water hose
(intake manifold-to-cooling water pilot hole)
7 Fuel hose (fuel filter assembly-to-fuel pump)
4-1 6AU3K11

Hose routing / Fuel pump, fuel filter, and fuel joint
Fuel pump, fuel filter, and fuel joint 4
12
1
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
T.
R.
5
10
11
2
4
1
4
3
3
4
9
2
4
6
4
8
5
7
No. Part name

4
Q’ty Remarks
S6AU4005
6
1 Fuel pump 1
2
3
4
5
Bolt
O-ring
Clamp
Fuel hose
2
1
5
1
M6 × 30 mm
Not reusable
7
6 Fuel hose 1
7
8
9
10
Fuel filter
Fuel hose
Plastic tie
Seal
1
1
1
1
8
11 Fuel joint 1
12 Bolt 1 M6 × 25 mm
9
6AU3K11 4-2

FUEL
Fuel system
4
13
10
10 12
2 N · m (0.2 kgf · m, 1.5 ft · Ib) 11
.
R.
6
9
8
1 4 7
7
OU
T 5 5
IN 4
9
3
2
0.5 N · m (0.05 kgf · m, 0.37 ft · lb)
.
R.
1 1
2 N · m (0.2 kgf · m, 1.5 ft · Ib)
.
R.
S6AU4006
No. Part name Q’ty Remarks

1 Screw 4 ø4 × 30 mm
2 Cover 1
3 Diaphragm 1 Not reusable
5 Check valve 2
6 Fuel pump body 2 1
7 Diaphragm 1
8 Spring 1
9 Fuel pump body 1 1
10 Nut 4
11 Spring 1
12 Plunger 1
13 Pin 1
4-3 6AU3K11

Fuel pump, fuel filter, and fuel joint
Checking the fuel pump 4
1. Connect the special service tool to the

fuel pump inlet.
2. Cover the fuel pump outlet with your fin-

ger, and then apply the specified positive
pressure. Check that there is no air leak-
OUT
IN
1
age.
OUT
Specified positive pressure:
S6AU4009
2
50 kPa (0.5 kgf/cm2, 7.3 psi)
IN
Checking the fuel filter

NOTE:
4
3
S6AU4007 To check the fuel filter, see “Checking the
fuel filter” (3-3).
Vacuum/pressure pump gauge set:
90890-06756 1. Connect a vacuum/pressure pump
gauge and a meter to the fuel inlet.
4
Specified positive pressure: 2. Cover the fuel outlet with your finger, and
50 kPa (0.5 kgf/cm2, 7.3 psi)
3. Apply the specified negative pressure

then apply the specified positive pres-
sure. Replace the fuel filter if the speci-
fied pressure cannot be maintained for at
least 10 seconds.
5
and check that there is no air leakage.
OUT
IN
6
200 0
S6AU4003
7
S6AU4008
Specified negative pressure:

30 kPa (0.3 kgf/cm2, 4.4 psi)
NOTE:
Use a commercially available vacuum/pres-
sure pump gauge and meter that can be
pressurized up to 200 kPa (2.0 kgf/cm2, 29.0
8
psi).
fuel pump outlet.
5. Apply the specified positive pressure and

check that there is no air leakage.
Specified positive pressure:
200 kPa (2.0 kgf/cm2, 29.0 psi)
9
6AU3K11 4-4

FUEL
Fuel system
Checking the fuel joint 4
1. Check the fuel joint. Replace if cracked 2

or damaged.
3
fuel joint outlet.
90˚
3. Apply the specified positive pressure.
Replace the fuel joint if the specified
pressure cannot be maintained for at S6AU4011
least 10 seconds.
S6AU4012
S6AU4004
NOTE:
Vacuum/pressure pump gauge set: • Push the plunger 2 and diaphragm com-
90890-06756 pletely inward, and then turn fuel pump
body 1 3 approximately 90° to a position
where the pin 1 can be removed easily.
Specified positive pressure: • Slowly release on the plunger 2 and dia-
50 kPa (0.5 kgf/cm2, 7.3 psi) phragm, and then remove them.
Disassembling the fuel pump 4
1. Disassemble the fuel pump as shown. Checking the diaphragm and valve 4
1. Check the diaphragms 1 and valves 2.

Replace the diaphragms if torn and the
valves if cracked.
2
OU
T 2
OU
T 1
IN
IN
S6AU4010 1
2. Remove the pin 1 from the plunger 2,

S6AU4013
and then disassemble fuel pump body 1
3.
4-5 6AU3K11

Fuel pump, fuel filter, and fuel joint
Assembling the fuel pump 4
NOTE:
Clean the parts and soak the valves and the
diaphragms in gasoline before assembly.
1. Install the plunger 1 and diaphragm into

fuel pump body 1 2, and then install the
1
pin 3 to the plunger 1.
1 2
OU
T
a
2
3
IN
3
S6AU4016
S6AU4014
2
NOTE:
• Moisten the inside of the fuel pump with
gasoline to ensure a good seal.
4
• Make sure that the diaphragms are kept in
5
90˚ place through the assembly process.
• After disassembling and assembling the
fuel pump, check it for air leaks. See
“Checking the fuel pump” (4-4).
b
b 2 S6AU4015
6
NOTE:
• Align the pin installation holes a with the
slot in fuel pump body 1 2, and then install
the pin 3 while pushing the plunger 1 and
7
diaphragm completely inward.
• Turn fuel pump body 1 2 until the pin 3 is
90° from the slot in the body.
• Make sure that the projections b on the
diaphragm fit correctly into fuel pump body
8
1 2.
2. Assemble the fuel pump as shown.

9
6AU3K11 4-6

FUEL
Fuel system
Carburetor unit 4
6 3
7 3
1 2
4
5
11
13 12
14
8 18
9 10
12
27
24 23 17 15
19
27 4 20
19
16
26 21 1 6 N · m (0.6 kgf · m, 4.4 ft · lb)

12 N · m (1.2 kgf · m, 8.9 ft · lb)
T.
2
R.
1 25
22 S6AU4017

1 Plastic tie 2
2 O-ring 1 R model
3 Bolt 2 M6 × 12 mm
4 Holder 2
5 Choke solenoid 1 R model
6 Choke knob 1
7 Choke knob guide 1
8 Blowby hose 1
9 Fuel hose 1
10 Clamp 1
11 Bolt 2 M6 × 85 mm
12 Collar 2
13 Intake silencer 1
14 O-ring 1 Not reusable
15 Choke rod 1
16 Throttle link rod 1
4-7 6AU3K11

Carburetor unit
4
6 3
7 3
1
5
2
4 1
12
11
2
13
9
8
10
18
14
3
12
27
24 23
19
17 15 4
27 4 20
5
19
16
26 21 1 6 N · m (0.6 kgf · m, 4.4 ft · lb)

12 N · m (1.2 kgf · m, 8.9 ft · lb)
T.
2
R.
No.
1 25
Part name
22
Q’ty Remarks
S6AU4017
6
18 Carburetor assembly 1
19
20
21
22
Gasket
Spacer
Bolt
Bolt
2
1
3
2
Not reusable
M6 × 35 mm
M6 × 25 mm
7
23 Intake manifold 1
24
25
26
27
Gasket
Cooling water hose
Flushing hose
Dowel
1
1
1
2
Not reusable
For Europe
8
9
6AU3K11 4-8

FUEL
Fuel system
Carburetor 4
1
1 6 21
7
2
8
22
23
3 9
9
24
4
5 25
17 18
26
19 20
10 11 27
28
12
23
24
15 13
25
16 14 26
29
27 28
31
32 30
S6AU4018

2 Cover 1
3 Gasket 1 Not reusable
4 Plug 1
5 Carburetor body 1
6 Throttle stop screw 1 ø4 × 20 mm
7 Spring 1
8 Boot 1
9 Plunger rod 1
10 Pilot screw 1 For Europe
11 Pilot screw 1 For Oceania
13 Main nozzle 1
14 Plug 1
15 Pilot jet 1
16 Main jet 1
17 Float pin 1
4-9 6AU3K11

Carburetor unit
4
1
1
1 6 21
7
2
8
22
5
3
4
9
9
23
24
25
2
3
17 18
26
19 20
10 11 27
28
15 13
12
23
24
25
4
16
5
14 26
29
27 28
31
6
32 30
S6AU4018

19
20
21
22
Needle valve
Float
Float chamber assembly
Screw
1
1
1
1 ø3 × 6 mm
7
23 Plunger rod guide 1
24
25
26
27
O-ring
Plunger
Spring
Circlip
1
1
1
1
Not reusable
8
28 Ball 1
29
30
31
32
Float chamber
Drain screw
Gasket
Screw
1
1
1
2
Not reusable
ø4 × 10 mm
9
6AU3K11 4-10

FUEL
Fuel system
Removing the carburetor 4
1. Disconnect the fuel hose 1 and blowby 1 a

hose 2.
2
2 3
S6AU4035
NOTE:
S6AU4020
Remove the float pin 1 in the direction of the
arrow shown, which is opposite to the arrow
2. Disconnect the throttle link rod 3 and mark a on the carburetor body 3.
choke rod 4.
Checking the carburetor 4
3. Disconnect the choke solenoid coupler

1. Check the air and fuel passages and jets.
5. (R model)
Clean the carburetor body if there is dirt
NOTE: or foreign material.
The choke solenoid coupler 5 is located
under the junction box 6. 2. Blow compressed air into all passages
and jets.
4. Remove the bolts 7, and then remove

the intake silencer 8 and carburetor
assembly 9.
6
5
S6AU4022
7
8 WARNING
Wear appropriate protective eye gear dur-
ing the cleaning process to prevent any
7
eye injury by the blown-off debris or liq-
uid.
4
9 3 S6AU4021
3. Check the main jet, pilot jet, and main
Disassembling the carburetor 4
nozzle. Clean if there is dirt or residue.
NOTE: CAUTION:
See the exploded diagram for disassembly Do not use steel wire clean the jets, other-
(4-9). wise the jet diameters may be enlarged,
which may seriously affect performance.
1. Remove the float pin 1, float 2, and
needle valve.
4-11 6AU3K11

Carburetor unit
4. Check the pilot screw and needle valve.
Replace if worn or deformed. 2
4
1
3 1
S6AG4200
S6AU4027
2. Install the needle valve, float 5, and float

2
pin 6 as shown, and then check the float
5. Check the float. Replace if cracked or for smooth operation.
deformed.
6. Measure the float height a. Replace the

6
5
a 3
float 1 or needle valve if out of specifica-
tion. 7
45˚
1
4
5
S6AU4028
NOTE:
Install the float pin 6 in the direction of the
a arrow mark a on the carburetor body 7.
6
S6AU4024
NOTE:
• When measuring the float height a, hold
the carburetor body at a 45° angle as
shown so that there is no load on the nee-
dle valve spring.
• Take measurements at the float position
shown opposite its pivoting side.
7
Float height a:
20.0–21.0 mm (0.79–0.83 in)
Assembling the carburetor 4

8
1. Install the pilot jet 1, main jet 2, main
nozzle 3, and plug 4 to the carburetor
body as shown. 9
6AU3K11 4-12

FUEL
Fuel system
3. Install the pilot screw 8, turn it in until it
is lightly seated, and then turn it out the 9
specified number of turns. 6
4 5
8
È 9
5
É
8 8
S6AU4030
7
È For Europe 1 2 1 3 S6AU4031
É For Oceania
NOTE:
Pilot screw adjusting tool 9 (for • To adjust the throttle link rod, see “Adjust-
Europe): 90890-03154 ing the throttle link” (3-9).
• Place the choke solenoid coupler 6 under
the junction box 9 after connecting it.
Pilot screw setting: 1 5/8 turns out
4. Adjust the engine idle speed.

Installing the carburetor 4
1. Install new gaskets 1, the spacer 2, the NOTE:

If the carburetor has been disassembled and
carburetor assembly 3, and the intake
assembled, adjust the pilot screw, and then
silencer 4 using the bolts 5.
adjust the engine idle speed. See “Adjusting
NOTE: the pilot screw” (4-13).
Install the spacer 2 with the chamfered side
facing toward the intake manifold.
Adjusting the pilot screw 4
1. Adjust the throttle stop screw.

2. Connect the choke solenoid coupler 6.
(R model) NOTE:
If the carburetor was disassembled, turn the
3. Connect the throttle link rod 7 to the car- throttle stop screw in until it contacts the car-
buretor throttle lever and the choke rod buretor throttle lever, and then turn it in about
8 to the carburetor choke lever. 1 1/2–1 3/4 turns to tighten it temporarily.
2. Start the engine and warm it up.
3. Attach the special service tool to spark

plug wire #1.
Digital tachometer: 90890-06760
4-13 6AU3K11

Carburetor unit
4. Turn the pilot screw 1 in direction a
until it is lightly seated, and then turn it in NOTE:
direction b the specified number of • To increase the engine idle speed, turn the
throttle stop screw 3 in direction c.
1
turns.
• To decrease the engine idle speed, turn the
È throttle stop screw 3 in direction d.
2
Engine idle speed: 1,050 ± 50 r/min
6. After adjusting the engine idle speed, rev

the engine a few times and let it idle to
2
b 1 a
check the stability of the engine.
3
S6AU4033
4
b 1 a
5
S6AU4032
È For Europe
É For Oceania
Pilot screw adjusting tool 2 (for

Europe): 90890-03154
Pilot screw setting: 1 5/8 turns out

6
5. Turn the throttle stop screw 3 in direc-
tion c or d until the specified engine
idle speed is obtained.
7
3
8
d c
S6AU4034
9
6AU3K11 4-14

POWR
Power unit
Power unit (check and adjustment).............................................................. 5-1

Checking the compression pressure .........................................................5-1
Checking the valve clearance.................................................................... 5-1
Replacing the timing belt ...........................................................................5-3
Manual starter (M model)............................................................................... 5-6

Disassembling the manual starter ............................................................. 5-8
Checking the manual starter...................................................................... 5-8
Assembling the manual starter ..................................................................5-9
Power unit..................................................................................................... 5-12

Power unit assembly ............................................................................... 5-12
Ignition coil, CDI unit, and Rectifier (M model) ........................................ 5-14
Ignition coil, CDI unit, and Rectifier Regulator (E model) ........................ 5-15
Throttle cam and oil pressure switch .......................................................5-17
Removing the power unit.........................................................................5-18
Timing belt and sprocket............................................................................. 5-19

Removing the timing belt and sprocket ...................................................5-21
Checking the timing belt and sprocket.....................................................5-22
Installing the sprocket and timing belt .....................................................5-22
Cylinder head ...............................................................................................5-25

Removing the cylinder head .................................................................... 5-28
Disassembling the cylinder head............................................................. 5-28
Checking the cylinder head ..................................................................... 5-29
Checking the valve spring ....................................................................... 5-29
Checking the valve .................................................................................. 5-30
Checking the valve guide ........................................................................5-30
Replacing the valve guide ....................................................................... 5-31
Checking the valve seat ..........................................................................5-31
Refacing the valve seat ...........................................................................5-32
Checking the rocker arm and rocker arm shaft ....................................... 5-34
Checking the camshaft ............................................................................5-35
Assembling the cylinder head.................................................................. 5-35
Installing the cylinder head ...................................................................... 5-37
Checking the oil pump ............................................................................. 5-37
6AU3K11

Cylinder block ..............................................................................................5-39
Disassembling the cylinder block ............................................................ 5-41
Checking the piston diameter .................................................................. 5-42
Checking the cylinder bore ...................................................................... 5-42
Checking the piston clearance ................................................................5-42
Checking the piston ring ..........................................................................5-43
Checking the piston ring end gap ............................................................ 5-43
Checking the piston ring groove ..............................................................5-43
1
Checking the piston ring side clearance.................................................. 5-44
Checking the piston pin boss bore .......................................................... 5-44
Checking the piston pin diameter ............................................................ 5-44
Checking the connecting rod small end inside diameter and
big end inside diameter..........................................................................5-44
2
Checking the connecting rod big end side clearance ..............................5-45
Checking the crankshaft ..........................................................................5-45
Checking the crankpin oil clearance........................................................ 5-45
Checking the crankshaft journal oil clearance .........................................5-46
Selecting the crankshaft main bearing ....................................................5-48
3
Assembling the cylinder block .................................................................5-48
4
Installing the power unit...........................................................................5-51
5
6
7
8
9
6AU3K11

POWR
Power unit
Power unit (check and 6. If the compression pressure is below
adjustment) 5
specification or the compression pres-
sure for each cylinder is unbalanced, add
Checking the compression pressure 5
a small amount of engine oil to the cylin-

1. Start the engine, warm it up, and then
der, and then measure the pressure
turn it off.
again.
2. Remove the clip from the engine shut-off NOTE:
switch. • If the compression pressure increases,
check the pistons and piston rings. Replace
3. Disconnect the spark plug caps, remove if worn.
the spark plugs, and then install the spe- • If the compression pressure does not
cial service tool 1 into a spark plug hole. increase, check the valve clearances,
1 valves, valve seats, cylinder sleeves, cylin-
der head gasket, and cylinder head. Adjust
or replace if necessary.
Checking the valve clearance 5
NOTE:
Measure the valve clearances when the
S6AU5001 engine is cold.
CAUTION: 1. Remove the driven sprocket cover and

Before removing the spark plugs, remove manual starter. (M model)
any dirt or dust in the spark plug wells Remove the driven sprocket cover and
that may fall into the cylinders. flywheel magnet cover. (E model)
2. Disconnect the spark plug caps and

Compression gauge 1: remove the spark plugs.
90890-03160
3. Remove the fuel hoses 1, fuel pump 2,
4. Fully open the throttle and fully push in blowby hose 3, and cylinder head cover
the choke knob. 4.
5. Crank the engine until the reading on the 3

compression gauge stabilizes, and then
measure the compression pressure.
2
Minimum compression pressure
(reference data):
630 kPa (6.3 kgf/cm2, 91.4 psi)
(M model) 4
700 kPa (7.0 kgf/cm2, 101.5 psi) 1 S6AU5003
(E model)
4. Turn the flywheel magnet clockwise and
align the “1 ” mark a on the driven
sprocket 5 with the “ ” mark b on the
thermostat cover.
5-1 6AU3K11

Power unit (check and adjustment)
a
8 e
f 7
6 1
b
5. Measure the intake and exhaust valve

S6AU5004
NOTE:
S6AU5174
• To decrease the valve clearance, turn the

2
clearances for cylinder #1. Adjust if out of
specification. adjusting screw in direction e.
IN
• To increase the valve clearance, turn the
adjusting screw in direction f. 3
Tappet adjusting tool 8:
#1
#2
EX
IN
90890-01311
7. Tighten the rocker arm locknut 6 to the

specified torque.
4
EX
Rocker arm locknut 6:
7 N·m (0.7 kgf·m, 5.2 ft·lb) 5
T.
R.
8. Turn the flywheel magnet an additional

c d 360° clockwise and align the “2 ” mark
IN EX
S6AU5005
g on the driven sprocket with the “ ”
mark b on the thermostat cover. 6
7
NOTE:
Note the measurement data.
Valve clearance: g
Intake c:
0.15–0.20 mm (0.006–0.008 in)
Exhaust d:
0.20–0.25 mm (0.008–0.010 in)
b
S6AU5007 8
9. Repeat steps 5–7 for cylinder #2.
6. Loosen the rocker arm locknut 6, and
then turn the adjusting screw 7 until the
specified valve clearance is obtained.
10. Install all parts removed during removal.
9
6AU3K11 5-2

POWR
Power unit
Replacing the timing belt 5
NOTE:
CAUTION: Use a 22 mm socket to loosen the flywheel
magnet nut.
Do not turn the flywheel magnet counter-
clockwise, otherwise the water pump
impeller may be damaged.
Flywheel holder: 90890-06522
NOTE:
To remove and install the timing belt, drive 4. Remove the flywheel magnet and Woo-
sprocket, and driven sprocket, see “Remov- druff key.
ing the timing belt and sprocket” (5-21) and
“Installing the sprocket and timing belt” (5-
22).
1. Disconnect the spark plug caps and

remove the spark plugs.
2. Disconnect the cooling water hose 1

from the thermostat cover.
S6AU5008
3. Remove the flywheel magnet nut.

CAUTION:
To prevent damage to the engine or tools,
screw in the puller set bolts evenly and
completely so that the flywheel puller is
parallel to the flywheel magnet.
NOTE:
Apply force to the crankshaft end until the fly-
S6AG5G30 wheel magnet comes off the tapered portion
of the crankshaft.
WARNING
Apply force in the direction of the arrows
shown to prevent the flywheel holder from Flywheel puller: 90890-06521
slipping off easily.
5. Remove the charge coil 2.
5-3 6AU3K11

Power unit (check and adjustment)
4
-XX
41
1
62
X-4
XX
2
6. Align the “1 ” mark a on the driven

S6AU5015
CAUTION:
S6AU5018
2
sprocket 3 with the “ ” mark b on the Unless directed to do so in the following
thermostat cover.
3
instructions, do not turn the drive
sprocket or driven sprocket when the tim-
ing belt is not installed. Otherwise the pis-
3 tons and valves will collide with each
other and be damaged.
a
b
8. Install a new timing belt 4 onto the drive
sprocket, and then install it onto the
4
driven sprocket with its part number e in
5
S6AU5016 the upright position.
d 4 e
c 62
41
-XX
X-4
XX
6
7
S6AU5017 S6AU5019
NOTE: CAUTION:
Check that the notch c in the drive sprocket
• Do not twist, turn inside out, or bend the
and the “ ” mark d on the cylinder block are
timing belt beyond the maximum limit of
aligned.
7. Remove the timing belt 4 from the

driven sprocket, and then remove it from
25 mm (1.0 in), otherwise it can be dam-
aged.
• Do not get oil or grease on the timing
belt.
8
the drive sprocket.
NOTE:
Before installing the timing belt, make sure
that the notch on the drive sprocket and the
9
mark on the driven sprocket are aligned with
the marks on the cylinder block and thermo-
stat cover.
6AU3K11 5-4

POWR
Power unit
9. Turn the drive sprocket clockwise 2
turns, and then check that the parts are
aligned at the areas f and g as shown.
g f
S6AG5G40
WARNING
S6AU5020 Apply force in the direction of the arrows
shown to prevent the flywheel holder from
10. Install the charge coil 2 and tighten the slipping off easily.
charge coil bolts 5 to the specified
torque.
Flywheel holder: 90890-06522
11. Install the Woodruff key 6, and then
install the flywheel magnet 7.
8 Charge coil bolt 5:

m 7 12 N·m (1.2 kgf·m, 8.9 ft·lb)
T.
R.
n Flywheel magnet nut 8:

98 N·m (9.8 kgf·m, 72.3 ft·lb)
E n
13. Install all parts removed during disas-
k 7 5 sembly.
LT
6 271 h
S6AU5021
NOTE:
• Be sure to remove any grease from the
tapered portion h of the crankshaft and the
inner surface k of the flywheel magnet.
• Apply engine oil to the threads m of the fly-
wheel magnet nut 8 and upper and lower
surfaces n of the washer before installa-
tion.
12. Tighten the flywheel magnet nut 8 to the

specified torque.
5-5 6AU3K11

Power unit (check and adjustment) / Manual starter (M model)
Manual starter (M model) 5
3 2
4
1 2 2
5
A
1 5 1
6
10
11
7
2
9 12
E
14 13
3
19
15
16 17 18
4
A 16
5 N · m (0.5 kgf · m, 3.7 ft · Ib)

20
21
18
17
5
T.
R.

S6AU5024
6
1 Start-in-gear protection cable 1
2
3
4
5
Bolt
Spring
Starter plunger
Spring
3
1
1
1
M6 × 20 mm
7
6 Cover 1
7
8
9
10
Fuse puller
Cap
Starter handle
Starter rope
1
1
1
1
E model
1,900 mm (74.8 in) (reference data)

8
11 Damper 1
12
13
14
15
Spiral spring
Sheave drum assembly
E-clip
Sheave drum
1
1
1
1
9
16 Drive pawl 1
17 Drive pawl spring 2 1
6AU3K11 5-6

POWR
Power unit
5
3 2
4
1 2 2 A
5 1 5
7
11
10
9 12
14 13
E
16 17 18
15
19
A 16
17
20 18
21
5 N · m (0.5 kgf · m, 3.7 ft · Ib)
T.
R.
S6AU5024

18 Spring 1
19 Drive pawl spring 1 1
20 Drive plate 1
21 Screw 1 ø5 × 20 mm
5-7 6AU3K11

Manual starter (M model)
Disassembling the manual starter 5 5. Remove the starter rope 1 and E-clip 6,
1. While holding the starter rope 1, turn the and then remove the drive pawl 7, drive
sheave drum 2 in the direction of the pawl spring 2 8, and spring 9 from the
sheave drum 2.
1
arrow shown until there is no tension in
the spiral spring.
7
6
2 1
8
7
2
9
2
S6AU5175
2. Remove the drive plate 3 and drive pawl

1 3
spring 1 4. S6AU5027
4
3 Checking the manual starter
1. Check the drive pawl, E-clip, starter
plunger, and drive plate. Replace if
5
4
cracked or damaged.
2. Check the springs. Replace if bent,

cracked, or damaged. 5
S6AU5025
3. Remove the sheave drum 2.

6
5
2
S6AG5550
7
4. Remove the spiral spring 5 from the
S6AU5026
8
manual starter cover.
WARNING
The spiral spring can pop out. Cover the
spiral spring with rags when removing it.
9
6AU3K11 5-8

POWR
Power unit
3. Check the sheave drum. Replace if
cracked or damaged. 4
4. Check the spiral spring. Replace if
cracked, bent, or damaged.
2 3
5
7
6
S6AG5540
1 a
5. Check the starter handle. Replace if
cracked or damaged. S6AU5030
6. Check the starter rope. Replace if dam- NOTE:

aged. • Tie a knot at the end of the starter rope as
shown in the illustration.
NOTE:
• Be sure to leave 12–20 mm (0.47–0.79 in)
• When replacing the starter rope with a new
a at the end of the starter rope.
one, make sure that the length is approxi-
mately 1,900 mm (74.8 in).
• Be sure to use a genuine Selva starter 4. Wind the starter rope 1 twice around the
rope. sheave drum 2 in the direction of the
arrow shown.
Assembling the manual starter 5
1. Install the starter rope 1 into the sheave

drum 2. 1
b
2. Install the drive pawl 3, starter plunger 1

4, drive pawl spring 2 5, spring 6, and
2
E-clip.
3. Install the starter handle 7. 2 S6AU5031
NOTE:
After winding the starter rope 1 around the
sheave drum 2, install the starter rope in the
notch b.
5. Install the spiral spring 8 into the manual

starter cover 9.
5-9 6AU3K11

Manual starter (M model)
8. Turn the sheave drum 2 4 turns in the
direction of the arrow shown.
4
b 2
1
c d
NOTE:
9 8
Hook the end c of the spiral spring 8 onto

S6AU5032
S6AU5035
2
the cut-out d in the manual starter cover 9. NOTE:
6. Install the sheave drum 2 into the man-

ual starter cover 9.
Hold the starter plunger 4 while turning the
sheave drum as shown. 3
9. Remove the starter rope from the notch
2
9
f
e
b, and then fit it into the groove in the
sheave drum.
NOTE:
4
• Be sure to hold the sheave drum with your
S6AU5033
hand so that it turns slowly.
• Allow the spring force to slowly turn the
drum as the starter rope winds around the
drum.
5
NOTE:
• When installing the sheave drum, set the
spiral spring by turning the sheave drum.
• Hook the end e of the spiral spring 8 onto
10. Pull the starter handle 7 several times to
check that the sheave drum turns
smoothly and to check the starter rope
6
the cut-out f in the sheave drum 2. for slack. Repeat steps 4–9 if necessary.
7. Install drive pawl spring 1 =, the drive

plate A, and the screw B.
4
4
7
B
A
A
0
8
7 S6AU5036
S6AU5034
NOTE:
Hold the starter plunger 4 while pulling the
starter handle 7.
9
Drive plate screw B:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
T.
R.
6AU3K11 5-10

POWR
Power unit
11. Install the manual starter onto the power
unit, and then connect the start-in-gear
protection cable.
NOTE:
• Route the start-in-gear protection cable in
its original position.
• To adjust the start-in-gear protection cable,
see “Checking the start-in-gear protection
(M model)” (3-11).
12. Pull the starter handle to extend the

starter rope completely, and then mea-
sure the starter rope length g.
S6AU5037
Starter rope pulling length g:

1,400–1,600 mm (55.12–62.99 in)
5-11 6AU3K11

Manual starter (M model) / Power unit
Power unit 5
Power unit assembly 5
2
1
3
6
2 3
1
BOW
7
4
5
17 4
2
9
10
12
8
3
13 6 18 N · m (1.8 kgf · m, 13.3 ft · Ib)
11
T.
R.
22 2.5 N · m (0.25 kgf · m, 1.84 ft · Ib)
4
T.
R.
15 16 23
14
17
21
18
24
5
19
25
20
LT
571
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
6
T.
R.
21 N · m (2.1 kgf · m, 15.5 ft · Ib) 20 20 S6AU5038

T.
R.

1
2
3
4
Manual starter
Flywheel magnet cover
Driven sprocket cover
Oil dipstick
1
1
1
1
M model
E model
7
5 Throttle cable 2 H model
6
7
8
9
Choke rod
Power unit
Bolt
Negative battery cable
1
1
1
1
M6 × 12 mm
E model
8
10 Bolt 1 M8 × 16 mm/E model
11
12
13
14
Gasket
Dowel
Start-in-gear protection cable
Cooling water hose
1
2
1
1
Not reusable
M model
9
15 Cooling water hose 1
16 Flushing hose 1 For Europe
17 Fuel hose 1
6AU3K11 5-12

POWR
Power unit
5
2 3 2 3
1 6
BOW
7
5
17 4
4
9
10
5
8
13 6 12
11 18 N · m (1.8 kgf · m, 13.3 ft · Ib)
T.
R.
22 2.5 N · m (0.25 kgf · m, 1.84 ft · Ib)
T.
R.
15 16 23
14
17
24
21
18
19
25
LT
20 571
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
T.
R.
21 N · m (2.1 kgf · m, 15.5 ft · Ib) 20 20 S6AU5038

T.
R.

18 Starter motor lead 1 E model
20 Bolt 6 M8 × 75 mm
21 10-pin coupler harness 1 R model
22 Throttle cable 1 R model
23 Apron 1
24 Screw 2 ø6 × 30 mm
25 Nut 2
5-13 6AU3K11

Power unit
Ignition coil, CDI unit, and Rectifier (M model) 5
1 5 N · m (0.5 kgf · m, 3.7 ft · Ib)
T.
R.
1
24 N · m (2.4 kgf · m, 17.7 ft · Ib)
1
T.
R.
2
2
7
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
3
T.
R.
8
10
3
4
9
4
5
4
6
11
12 13
5
14
3.5 N · m (0.35 kgf · m, 2.6 ft · Ib)
6
14
T.
R.
8 N · m (0.8 kgf · m, 5.9 ft · Ib)

8 N · m (0.8 kgf · m, 5.9 ft · Ib)
T.
R.
S6AU5176
T.
R.

1 Bolt 2 M5 × 10 mm
7
2 Pulser coil 1
3 CDI unit 1
4 Bolt 2 M6 × 20 mm
5 Junction box 1
7
8
9
10
Spark plug
Bolt
Bolt
Bracket
2
1
2
1
M6 × 12 mm
M8 × 12 mm 8
11 Rectifier 1
12
13
14
Screw
Ignition coil
Bolt
1
1
2
ø5 × 25 mm
M6 × 25 mm
9
6AU3K11 5-14

POWR
Power unit
Ignition coil, CDI unit, and Rectifier Regulator (E model) 5
1 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 12 21 N · m (2.1 kgf · m, 15.5 ft · Ib)
T.
T.
R.
R.
4 N · m (0.4 kgf · m, 3.0 ft · Ib) 12 8 N · m (0.8 kgf · m, 5.9 ft · Ib)
1
T.
R.
T.
R.
2 24 N · m (2.4 kgf · m, 17.7 ft · Ib)
13
T.
R.
20
9 11
10
21
14
14
23
16
17
3 5
6
18
15
22
7
4 19
6
21 N · m (2.1 kgf · m, 15.5 ft · Ib)
T.
R.
8 N · m (0.8 kgf · m, 5.9 ft · Ib)

8
T.
8 N · m (0.8 kgf · m, 5.9 ft · Ib)

R.
T.
R.
S6AU5040

1 Bolt 2 M5 × 10 mm
2 Pulser coil 1
3 Fuse holder assembly 1
4 Fuse holder bracket 1
5 CDI unit 1
6 Bolt 2 M6 × 20 mm
7 Junction box 1
9 Starter motor lead 1
10 Nut 1
11 Washer 1
12 Bolt 2 M8 × 25 mm
13 Starter motor 1
14 Spark plug 2
15 Starter motor bracket 1
16 Holder 1
17 Bolt 1 M6 × 12 mm
5-15 6AU3K11

Power unit
5
1 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 12 21 N · m (2.1 kgf · m, 15.5 ft · Ib)
T.
T.
R.
R.
1
1
T.
R.
T.
R.
2 24 N · m (2.4 kgf · m, 17.7 ft · Ib)
13
T.
R.
20
9 11
2
10
21
14
14
3
23
3 5
16
17 4
6
18
4
6
15
7
19
22
5
21 N · m (2.1 kgf · m, 15.5 ft · Ib)
T.
R.
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
6
8
T.
8 N · m (0.8 kgf · m, 5.9 ft · Ib)

R.
T.
R.
S6AU5040

18 Bolt 2 M8 × 55 mm
19
20
21
22
Bolt
Rectifier Regulator
Bolt
Ignition coil
1
1
1
1
M8 × 40 mm
M6 × 12 mm 7
23 Bolt 2 M6 × 25 mm
8
9
6AU3K11 5-16

POWR
Power unit
Throttle cam and oil pressure switch 5
4 12
5 13
6
8
A
10
11
1
9
7
LT
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
T.
R.
572
2
8 N · m (0.8 kgf · m, 5.9 ft · Ib) 2 N · m (0.2 kgf · m, 1.5 ft · Ib)
T.
R.
T.
R.
S6AU5045

1 Oil pressure switch 1
2 Oil pressure switch lead 1
3 Throttle cable bracket 1
4 Throttle cable 2 H model
5 Throttle cam 1
6 Free accel lever 1
7 Clip 1
8 Collar 1
9 Washer 1
10 Bolt 1 M6 × 45 mm
11 Bolt 1 M6 × 12 mm
12 Throttle cable 1 R model
13 Clip 1 R model
5-17 6AU3K11

Power unit
Removing the power unit 5
NOTE:
1. Disconnect the start-in-gear protection
To disconnect the leads, see “Electrical com-
cable, and then remove the driven
ponent and wiring harness routing” (8-1).
1
sprocket cover and manual starter. (M
model)
Remove the driven sprocket cover and 5. Disconnect the flushing hose 8 (for
flywheel magnet cover. (E model) Europe), cooling water hoses 9, and fuel
hose =.
2. Disconnect the battery cables 1, battery
lead 2, and starter motor lead 3. (E
model) 2
3 5
1
8
3
2 0 9 S6AU5046
1
6. Disconnect the throttle cables from the
throttle cam. (H model)
Disconnect the throttle cable joint from
4
the throttle cam. (R model)
4
S6AU5047
3. Disconnect the PT switch coupler 4, PT

7. Remove the choke rod, dipstick, and
apron, and then remove the mounting
bolts A.
5
switch lead (R) 5, and PT relay lead (G,
6
L) 6, and remove the PT relay 7. (PT
model)
8. Remove the power unit B, gasket C,
and dowels D.
6
B
7
D
7
S6AU5048
4. Disconnect the engine shut-off switch

C
8
leads, oil pressure warning indicator
leads, and engine start button leads. (H
model)
Disconnect the 10-pin main harness from
the power unit. (R model) A
9
A A S6AU5052
6AU3K11 5-18

POWR
Power unit
Timing belt and sprocket 5

T.
T.
R.
R.
4
1
4
2
3 5 LT
271
E 12 N · m (1.2 kgf · m, 8.9 ft · Ib)
T.
R.
6
36 N · m (3.6 kgf · m, 26.6 ft · Ib)

T.
R.
7 15
7 8
16
8
9 17
9
10 12
13 11
13 18
12
10 19
LT
242
14
S6AU5053

1 Nut 1 Width across flats: 22 mm
2 Washer 1
3 Flywheel magnet 1
4 Bolt 2 M6 × 25 mm
5 Charge coil 1
6 Timing belt 1
7 Nut 1 Width across flats: 30 mm
8 Lock washer 1
9 Retaining plate 1
10 Drive sprocket 1
11 Woodruff key 1
12 Woodruff key 1
13 Bolt 4 M6 × 30 mm
14 Lighting coil 2
15 Bolt 1 M6 × 14 mm
16 Washer 1
17 Driven sprocket 1
5-19 6AU3K11

Timing belt and sprocket
5
1
T.
T.
R.
R.
4
1
4
2
3 5 LT
271
E 12 N · m (1.2 kgf · m, 8.9 ft · Ib)
T.
R.
6
36 N · m (3.6 kgf · m, 26.6 ft · Ib)
3
T.
R.
7 15
7 8
16
8
9 17
4
9
10 12
13 11
13 18
12
10 19
LT
242
14
5
S6AU5053
6
18 Washer 1
19 Woodruff key 1
7
8
9
6AU3K11 5-20

POWR
Power unit
Removing the timing belt and
sprocket 5
2
1. Remove the flywheel magnet, charge 41
-XX
62
coil, and lighting coil(s). X-4
XX
NOTE:
See “Replacing the timing belt” (5-3).
2. Align the “1 ” mark a on the driven S6AU5056

sprocket 1 with the “ ” mark b on the
thermostat cover. CAUTION:
Unless directed to do so in the following
instructions, do not turn the drive
1 sprocket or driven sprocket when the tim-
ing belt is not installed. Otherwise the pis-
tons and valves will collide with each
a
other and be damaged.
b
4. Align the notch c in the drive sprocket
S6AU5054
with the mating surface e of the crank-
case and cylinder block by turning the
d
crankshaft clockwise approximately 90°
c gradually.
c e
S6AU5055
NOTE:
Check that the notch c in the drive sprocket
S6AU5057
and the “ ” mark d on the cylinder block are
aligned.
5. Hold the driven sprocket using the spe-
cial service tool 3, and then remove the
3. Remove the timing belt 2 from the driven sprocket bolt 4.
driven sprocket, and then remove it from
the drive sprocket.
S6AU5059
5-21 6AU3K11

Installing the sprocket and timing
NOTE:
Make sure that the driven sprocket does not
belt 5
turn when loosening the driven sprocket bolt.
1
CAUTION:
Unless directed to do so in the following
instructions, do not turn the crankshaft or
Flywheel holder 3: 90890-06522
camshaft when the timing belt is not
installed. Otherwise the pistons and
6. Remove the driven sprocket and Woo-
druff key.
7. Install the power unit to the special ser-

valves will collide with each other and be
damaged.
1. Align the keyway a in the crankshaft

2
vice tool 5 as shown, and then remove with the mating surface b of the crank-
the drive sprocket nut 6. case and cylinder block.
a
3
5
4
b S6AU5061
2. Install the Woodruff key 1, drive

sprocket 2, retaining plate 3, and lock
5
67 washer 4, and then install the drive
S6AU5060
NOTE:
Use a deep 30 mm socket 7 to loosen the
drive sprocket nut 6.
sprocket nut 5 temporarily.
5
4 1
6
3
Shaft holder 5: 90890-06561 2 7

8. Remove the lock washer, retaining plate,
drive sprocket, and Woodruff key.
Checking the timing belt and

sprocket 5
S6AU5062
8
1. Check the interior and exterior of the tim-
ing belt. Replace if cracked, damaged, or
worn.
2. Check the drive sprocket and driven

9
sprocket. Replace if cracked, damaged,
or worn.
6AU3K11 5-22

POWR
Power unit
3. Install the power unit to the special ser-
vice tool 6, and then tighten the drive B
sprocket nut 5 to the specified torque. E A
9
6
0
8
S6AU5064
6. Hold the driven sprocket using the spe-

cial service tool C, and then tighten the
driven sprocket bolt B to the specified
torque.
5 7
S6AU5063 B
C
NOTE:
Use a deep 30 mm socket 7 to tighten the
drive sprocket nut.
Shaft holder 6: 90890-06561

S6AU5066
NOTE:
Drive sprocket nut 5: Make sure that the driven sprocket does not
36 N·m (3.6 kgf·m, 26.6 ft·lb)
T.
R.
turn when tightening the driven sprocket bolt.
4. Bend the lock washer 4 along a flat side

of the nut. Flywheel holder C: 90890-06522
4
Driven sprocket bolt B:
12 N·m (1.2 kgf·m, 8.9 ft·lb)
T.
R.
7. Align the “1 ” mark c on the driven

sprocket = with the “ ” mark d on the
thermostat cover.
S6AU5179
5. Install the washer 8, Woodruff key 9,

0
driven sprocket =, and washer A, and
then install the driven sprocket bolt B
temporarily. c
S6AU5067
5-23 6AU3K11

8. Align the notch e in the drive sprocket
with the “ ” mark f on the cylinder h
k
block by turning the crankshaft counter-
1
clockwise approximately 90° gradually.
f
D
e
S6AU5070
11. Install the charge coil, lighting coil(s), and

2
flywheel magnet.
3
S6AU5068
NOTE:
9. Install the timing belt D onto the drive See “Replacing the timing belt” (5-3).
sprocket, and then install it onto the
driven sprocket with its part number g in
4
the upright position.
D g
-XX
41
62
X-4
XX
5
6
S6AU5069
CAUTION:
• Do not twist, turn inside out, or bend the
timing belt beyond the maximum limit of
25 mm (1.0 in), otherwise it can be dam-
aged.
• Do not get oil or grease on the timing
belt.
7
10. Turn the drive sprocket clockwise 2
turns, and then check that the parts are
aligned at the areas h and k as shown.
8
9
6AU3K11 5-24

POWR
Power unit
Cylinder head 5
T.
T.
R.
R.
5 6
2 N · m (0.2 kgf · m, 1.5 ft · Ib)
T.
R.
9 15
13
1 2 12 16
14
7 11 17
4 3
8
9
8
1 LT
271
2
A
3
10 16
4 9
LT
6 271 5 10 A
9
7 1 15 N · m (1.5 kgf · m, 11.1 ft · lb)
29 N · m (2.9 kgf · m, 21.4 ft · lb)
T.
2
R.
E
8
1 6 N · m (0.6 kgf · m, 4.4 ft · lb)

12 N · m (1.2 kgf · m, 8.9 ft · lb)
T.
2
R.
E S6AU5071

1 Plug 1
3 Anode 1
5 Cylinder head assembly 1
7 Dowel 2
8 Bolt 3 M6 × 70 mm
9 Bolt 4 M8 × 74 mm
10 Bolt 2 M8 × 60 mm
11 Screw 5 ø4 × 10 mm
12 Plate 1
15 Cylinder head cover 1
16 Bolt 4 M6 × 20 mm
17 Oil filler cap 1
5-25 6AU3K11

Cylinder head
5
1 7 N · m (0.7 kgf · m, 5.2 ft · Ib)
T.
R.
9
E
10 17
ME-1
2 18
11
2
E
12 9
3 19
13 10
14
4 15 18
E 11 E
3
16 12 17
13 9
3 17
E
14 10
15 11 18
16 12 E
4 9
4
E
13
E
14 10 19
5
6 E 15 11
16 18
E
12
20
5
13
M 14
E
15
16 21
7 E
6
E
8 8 N · m (0.8 kgf · m, 5.9 ft · Ib) S6AU5072

T.
R.

1 Oil seal 1 Not reusable
2
3
4
5
Cylinder head
Intake valve
Exhaust valve
Camshaft
1
2
2
1
7
7
8
9
10
Oil pump assembly
Bolt
Locknut
Adjusting screw
1
3
4
4
M6 × 30 mm
8
11 Valve cotter 4
12
13
14
15
Valve spring retainer
Valve spring
Valve seal
Valve spring seat
4
4
4
4
Not reusable
9
16 Valve guide 4 Not reusable
17 Collar 3
6AU3K11 5-26

POWR
Power unit
5
1 7 N · m (0.7 kgf · m, 5.2 ft · Ib)
T.
R.
9
E
10 17
ME-1
2 18
11 E
12 9
3 19
13 10
14
4 15 18
E 11 E
16 12 17
13 9
3 17
E
14 10
15 11 18
16 12 E
4 9
E
13
E
14 10 19
5
6 E 15 11
16 18
E
12
13 20
M 14
E
15
16 21
7 E
E
8 8 N · m (0.8 kgf · m, 5.9 ft · Ib) S6AU5072

T.
R.

18 Rocker arm 4
19 Spring 2
20 Collar 1
21 Shaft 1
5-27 6AU3K11

Cylinder head
Removing the cylinder head 5
1. Remove the cylinder head cover. 4 3 4 3 5 2
1
2. Remove the cylinder head bolts in the
sequence shown.
5 4
1
9 8
3 NOTE:
6 6 S6AU5075
• Loosen the locknuts and adjusting screws

2
6 7
2 to ease the tension on the rocker arm shaft
CAUTION:
S6AU5073 before pulling it out.
• Be sure to keep the parts in the order as
they were removed.
3
Do not scratch or damage the mating sur-
4
faces of the cylinder head and cylinder 3. Remove the camshaft 7 and oil seal 8.
block.
8
Disassembling the cylinder head 5
7
1. Remove the oil pump assembly 1.
1
5
S6AU5076
6
7
S6AU5074
NOTE:
To disassemble, check, and assemble the oil
pump, see “Checking the oil pump” (5-37).
2. Pull out the rocker arm shaft 2, and then

remove the springs 3, collars 4 and 5,
and rocker arms 6.
8
9
6AU3K11 5-28

POWR
Power unit
4. Remove the intake and exhaust valves.
2
1
S6AU5078
S6AU5079
NOTE:
Be sure to keep the valves, springs, and Cylinder head warpage limit:
other parts in the order as they were 0.10 mm (0.0039 in)
removed.
Checking the valve spring 5
1. Measure the valve spring free length a.

Valve spring compressor 9:
Replace if below specification.
90890-04019
Valve spring compressor
attachment 0: 90890-06320
Checking the cylinder head 5
1. Eliminate carbon deposits from the com-

bustion chambers and check for deterio-
ration.
2. Check the cylinder head warpage using a a S68V5775
straightedge 1 and thickness gauge 2

in the directions shown. Replace the cyl- Valve spring free length a:
inder head assembly if above specifica- 27.6 mm (1.0866 in)
tion.
2. Measure the valve spring tilt b. Replace
if above specification.
5-29 6AU3K11

Cylinder head
Valve stem diameter b:

Intake:
5.475–5.490 mm
(0.2156–0.2161 in)
Exhaust:
5.460–5.475 mm
1
(0.2150–0.2156 in)
Valve spring tilt limit b:

4. Measure the valve stem runout. Replace
the valve if above specification. 2
1.0 mm (0.039 in)
Checking the valve

1. Check the valve face. Replace the valve
if pitted or worn.
5
3
4
2. Measure the valve margin thickness a.
Replace the valve if out of specification.
Valve stem runout limit:

0.01 mm (0.0004 in)
Checking the valve guide 5

5
NOTE:
Valve margin thickness a:

Before checking a valve guide, make sure
that the valve stem diameter is within specifi-
cation. 6
Intake: 0.7 mm (0.028 in) 1. Measure the valve guide inside diameter
7
Exhaust: 1.0 mm (0.039 in) a.
3. Measure the valve stem diameter b.

Replace the valve if out of specification.
a
8
9
S6AU5085
Valve guide inside diameter a:

Intake and exhaust:
5.500–5.512 mm
(0.2165–0.2170 in)
6AU3K11 5-30

POWR
Power unit
2. Calculate the valve-stem-to-valve-guide
clearance as follows. Replace the valve NOTE:
guide if out of specification. Apply engine oil to the surface of a new valve
guide 3 before installation.
Valve-stem-to-valve-guide clearance
= valve guide inside diameter – valve
Valve guide remover/installer 2:
stem diameter:
90890-06801
Intake:
0.010–0.037 mm
(0.0004–0.0015 in) Valve guide height a:
Exhaust: Intake and exhaust:
0.025–0.052 mm 8.05 ± 0.25 mm (0.32 ± 0.01 in)
(0.0010–0.0020 in)
4. Insert the special service tool 4 into the
Replacing the valve guide 5
valve guide 3, and then ream the valve
1. Remove the valve seal. guide.
2. Remove the valve guide 1 by striking 4

the special service tool 2 from the com-
bustion chamber side.
3
1 2
E
S6AU5088
NOTE:
• Apply engine oil to the inner surface of the
S6AU5086 valve guide before reaming it.
• Turn the valve guide reamer clockwise to
Valve guide remover/installer 2: ream the valve guide.
90890-06801 • Do not turn the reamer counterclockwise
when removing it.
3. Install a new valve guide 3 using the • Be sure to clean the valve guide after ream-
special service tool 2 from the camshaft ing it.
side to the specified height a.
Valve guide reamer 4: 90890-06804

3
2
5. Measure the valve guide inside diameter.
Valve guide inside diameter:

Intake and exhaust:
a 5.500–5.512 mm
E
S6AU5087
(0.2165–0.2170 in)
Checking the valve seat 5
1. Eliminate carbon deposits from the valve.
5-31 6AU3K11

Cylinder head
2. Apply a thin, even layer of Mechanic’s
blueing dye (Dykem) onto the valve seat. Valve seat contact width a:
Intake and exhaust:
3. Press the valve lightly against the valve 0.6–0.8 mm (0.024–0.031 in)
seat with a valve lapper as shown.
Refacing the valve seat 5
1. Reface the valve seat with the valve seat

1
cutters.
2
S6AU5089
4. Measure the valve seat contact width a

3
where the blueing dye is adhered to the
valve face. Reface the valve seat if the
valve is not seated properly or if the valve
seat contact width is out of specification.
Check the valve guide if the valve seat
Valve seat cutter holder:
90890-06316
Valve seat cutter:
4
contact is uneven. 30° (intake): 90890-06328
30° (exhaust): 90890-06815
45° (intake): 90890-06312
45° (exhaust): 90890-06814
60° (intake): 90890-06315
5
60° (exhaust): 90890-06813
6
7
8
S68V5720
9
6AU3K11 5-32

POWR
Power unit
2. Cut the surface of the valve seat with a
45° cutter by turning the cutter clockwise
until the valve seat face has become b
smooth.
60˚
S6AG5J70J
b Previous contact width
5. Use a 45° cutter to adjust the contact

S6AU5095 width of the valve seat to specification.
45˚ b
a c
45˚
S6AG5J80J
S6AG5J20J
a Slag or rough surface b Previous contact width

c Specified contact width
CAUTION:
6. Check the valve seat contact area of the
Do not over cut the valve seat. Be sure to
valve.
turn the cutter evenly downward at a pres-
sure of 40–50 N (4–5 kgf, 8.8–11 lbf) to NOTE:
prevent chatter marks. To check the valve seat contact area, see
“Checking the valve seat” (5-31).

width of the top edge of the valve seat. 7. If the valve seat contact area is too wide
and situated in the center of the valve
30˚ face, use a 30° cutter to cut the top edge
b of the valve seat and a 60° cutter to cut
the bottom edge to center the area and
set its width.
30˚
b
S6AG5J60J

width of the bottom edge of the valve 60˚
seat. S6AG5J30J
5-33 6AU3K11

Cylinder head
8. If the valve seat contact area is too nar-
row and situated near the top edge of the CAUTION:
valve face, use a 30° cutter to cut the top Do not get the lapping compound on the
1
edge of the valve seat, and then use a valve stem and valve guide.
45° cutter to center the area and set its
width.
11. After every lapping procedure, be sure to
clean off any remaining lapping com-
30˚ pound from the cylinder head and the
b
valve.
12. Check the valve seat contact area of the

valve again.
2
S6AG5J40J
NOTE:
To check the valve seat contact area, see
“Checking the valve seat” (5-31).
3
9. If the valve seat contact area is too nar-
row and situated near the bottom edge of
the valve face, use a 60° cutter to cut the
bottom edge of the valve seat, and then
Checking the rocker arm and rocker
arm shaft
1. Check the rocker arms, rocker arm shaft,
and contact surface a of each rocker
5
4
use a 45° cutter to center the area and
arm. Replace if worn.
5
set its width.
2. Measure the rocker arm inside diameter
b and rocker arm shaft outside diameter
b c. Replace if out of specification.
c 6
60˚
b
7
S6AG5J50J

a
10. After refacing the valve seat to the speci-
S6AU5104
fied contact width, apply a thin, even
layer of lapping compound onto the valve
seat, and then lap the valve using a valve
lapper.
Rocker arm inside diameter b:
13.000–13.018 mm
(0.5118–0.5125 in)
Rocker arm shaft outside
8
diameter c:
12.941–12.951 mm
(0.5095–0.5099 in) 9
S6AU5103
6AU3K11 5-34

POWR
Power unit
Checking the camshaft 5
1. Measure the cam lobe. Replace if out of

specification. d
c
S6AU5107
Camshaft journal diameter c:

17.975–17.991 mm
(0.7077–0.7083 in)
Cam lobe a: Cylinder head journal inside
Intake and exhaust: diameter d:
23.45–23.55 mm 18.000–18.018 mm
(0.9232–0.9272 in) (0.7087–0.7094 in)
Cam lobe b:
Intake and exhaust: Assembling the cylinder head 5
19.95–20.05 mm 1. Install a new valve seal 1 onto the valve

(0.7854–0.7894 in) guide.
2. Measure the camshaft runout. Replace if 1

above specification.
E
S6AU5109
2. Install the valve 2, valve spring seat 3,

S6AU5106 valve spring 4, and valve spring retainer
5 in the sequence shown, and then
Camshaft runout limit: attach the special service tools.
0.03 mm (0.0012 in)
3. Measure the camshaft journal diameter

c and the cylinder head journal inside
diameter d. Replace the camshaft, cylin-
der head, or both if out of specification.
5-35 6AU3K11

Cylinder head
4. Install a new oil seal 9.
9
1
ME-1
2
Driver rod L3 0: 90890-06652
S6AU5115
3
Needle bearing attachment A:
4
90890-06653
Valve spring compressor 6:
90890-04019 5. Install the camshaft B in the direction
Valve spring compressor shown.
attachment 7: 90890-06320
3. Compress the valve spring, and then

install the valve cotter 8. M
M
E
5
E
B
S6AU5116
6
6. Align the keyway a in the camshaft with
the “ ” mark b on the cylinder head as
shown. 7
a
8
b
S6AU5113 S6AU5117 9
NOTE:
Make sure that the valve cotter 8 is fitted
securely into the groove in the valve.
6AU3K11 5-36

POWR
Power unit
7. Install the rocker arms C, springs D,
and collars E and F into the cylinder Oil pump assembly bolt:
8 N·m (0.8 kgf·m, 5.9 ft·lb)
T.
head, and then install the rocker arm
R.
shaft G.
Installing the cylinder head 5
F D F D E G 1. Install a new gasket, the dowels, and the

cylinder head, and then tighten the bolts
to the specified torques in the sequence
shown.
5 6
E C E C E E S6AU5118 9
1 2
8. Install the oil pump assembly by aligning
7
the slot c in the oil pump drive shaft with
E 3 E
the camshaft pin H. 4 8
S6AU5121
CAUTION:
Do not reuse the cylinder head gasket,
always replace it with a new one.
NOTE:
d • Apply engine oil to the cylinder head bolts
S6AU5119 before installation.
• Tighten the bolts to the specified torques in
2 stages.
Cylinder head bolt (M8):

1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
T.
R.
E 2nd: 29 N·m (2.9 kgf·m, 21.4 ft·lb)

Cylinder head bolt (M6):
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
H d
c
Checking the oil pump 5
1. Remove the oil pump screws 1 and dis-

S6AU5120 assemble the oil pump.
NOTE:
• To disassemble, check, and assemble the
oil pump, see “Checking the oil pump” (5-
37).
• Before installing the oil pump assembly, be
sure to fill it with a small amount of engine
oil through the oil passages d.
5-37 6AU3K11

Cylinder head
1
1
2. Check the inner surface of the oil pump

S6AU5122
2
housing. Replace the oil pump assembly
if scratched.
3. Assemble the oil pump, and then tighten

the oil pump screws 1 to the specified
3
torque.
a
4
2
3
5
b
6
1
1
LT
572 S6AU5125 7
NOTE:
• The punch mark a on the outer rotor 2
faces towards the oil pump cover.
• The punch mark b on the inner rotor 3
faces towards the oil pump housing.
8
Oil pump screw 1:
5 N·m (0.5 kgf·m, 3.7 ft·lb) 9
T.
R.
6AU3K11 5-38

POWR
Power unit
Cylinder block 5
11 13 8 N · m (0.8 kgf · m, 5.9 ft · Ib)
T.
R.
10 12
23
14
15 20
1 6 N · m (0.6 kgf · m, 4.4 ft · lb)
12 N · m (1.2 kgf · m, 8.9 ft · lb) 16
T.
2
R.
E
E
22
5 9
7 21 E
6 4
1 15 N · m (1.5 kgf · m, 11.1 ft · lb)
7 20
2 30 N · m (3.0 kgf · m, 22.1 ft · lb)
T.
R.
E
17
2 518 4
3
3 9 18
7
7 19
1 518
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
T.
R.
E
8
1 6 N · m (0.6 kgf · m, 4.4 ft · lb)

11 N · m (1.1 kgf · m, 8.1 ft · lb)
T.
E 2
R.
1
S6AU5126

1 Bolt 6 M8 × 65 mm
2 Crankcase 1
3 Bolt 4 M7 × 35 mm
4 Connecting rod 2
6 Crankshaft 1
7 Main bearing 4
9 Dowel 2
10 Bolt 5 M6 × 25 mm
11 Exhaust cover 1
13 Bolt 2 M6 × 20 mm
14 Thermostat cover 1
15 Thermostat 1
17 Cylinder block 1
5-39 6AU3K11

Cylinder block
5
13 8 N · m (0.8 kgf · m, 5.9 ft · Ib)
1
11
T.
R.
10 12
23
14
15 20
1 6 N · m (0.6 kgf · m, 4.4 ft · lb)
12 N · m (1.2 kgf · m, 8.9 ft · lb) 16
2
T.
2
R.
E
E
22
9
3
5 21
7 E
6 4
1 15 N · m (1.5 kgf · m, 11.1 ft · lb)
7 20
2 30 N · m (3.0 kgf · m, 22.1 ft · lb)
T.
R.
E
17
2 518 4
3
3
7
9 18 4
7 19
5
1 518
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
T.
R.
E
8
1 6 N · m (0.6 kgf · m, 4.4 ft · lb)
6
11 N · m (1.1 kgf · m, 8.1 ft · lb)
T.
E 2
R.
1
S6AU5126

19
20
21
22
Relief valve
Clip
Piston pin
Piston
1
4
2
2
Not reusable
7
23 Piston ring set 2
8
9
6AU3K11 5-40

POWR
Power unit
Disassembling the cylinder block 5
1. Remove the exhaust cover bolts in the

sequence shown, and then remove the 3
exhaust cover 1.
4
1 1
4
S6AU5177
5
3 NOTE:
2 Insert a flat-head screwdriver between the
S6AU5127
tabs 4 of the crankcase and the cylinder
block to separate them.
2. Remove the thermostat cover, thermo-
stat, and gasket. 6. Remove the connecting rod caps 5, and
then remove the connecting rod and pis-
3. Remove the relief valve 2.
ton assemblies.
S6AU5128
4. Remove the crankcase bolts in the

sequence shown.
S6AU5178
2 1 7. Remove the crankshaft, main bearings

and oil seals.
6 5 NOTE:
Be sure to keep the main bearings in the
order as they were removed.
3 4 S6AU5129
8. Remove the piston pin clips 6 and pis-

5. Remove the crankcase 3. ton pin 7, and then remove the piston
8.
5-41 6AU3K11

Cylinder block
Checking the cylinder bore 5
a 1. Measure the cylinder bore (D1–D6) at

6 measuring points a, b, and c, and in
1
direction d (D1, D3, D5), which is parallel
to the crankshaft, and in direction e (D2,
D4, D6), which is at a right angle to the
crankshaft.
a 6
NOTE:
8 7 S6AU5130
To avoid interchanging the pistons, connect-

c
b a D2 D1 d 2
D4 D3 e
ing rods, and connecting rod caps, mark
each with an identification number a of the
corresponding cylinder and be sure to keep
them in the order as they were removed.
D6 D5
S69J5B70
3
a 20 mm (0.8 in)
4
b 40 mm (1.6 in)
9. Remove the piston rings.
c 60 mm (2.4 in)
Checking the piston diameter 5
Cylinder bore (D1–D6):

1. Measure the piston diameter at the spec- 56.000–56.015 mm
ified measuring point. Replace if out of (2.2047–2.2053 in)
specification.
Checking the piston clearance
1. Check the piston clearances if replacing
5
5
the piston, piston ring set, cylinder block,
or all parts.
NOTE:
The figures are for reference only. Depend-
6
ing on how the parts are assembled, the
7
actual measurements may not be within the
specified ranges.
Piston diameter a:
55.950–55.965 mm Piston clearance (reference data):
(2.2028–2.2033 in) 0.035–0.065 mm
Measuring point b:
1.5 mm (0.06 in) up from the
bottom of the piston skirt
Oversize piston diameter:
(0.0014–0.0026 in)
8
Oversize 1st:
56.200–56.215 mm
(2.2126–2.2132 in)
Oversize 2nd:
9
56.450–56.465 mm
(2.2224–2.2230 in)
6AU3K11 5-42

POWR
Power unit
Checking the piston ring 5
1. Measure the piston ring dimensions B

and T. Replace the piston ring set if out
of specification.
a b
B B
T T
c B
T 1
S6AU5133
a b
Piston ring dimensions:
Top ring a:
B: 1.17–1.19 mm S6AU5134
(0.0461–0.0469 in)
T: 1.95–2.15 mm NOTE:
(0.0768–0.0846 in) The figures are for reference only. Depend-
2nd ring b: ing on how the parts are assembled, the
B: 1.47–1.49 mm actual measurements may not be within the
(0.0579–0.0587 in) specified ranges.
T: 2.40–2.60 mm
(0.0945–0.1024 in)
Piston ring end gap b (reference
Oil ring c:
data):
B: 2.35–2.50 mm
Top ring:
(0.0925–0.0984 in)
0.15–0.30 mm
T: 2.30–2.60 mm
(0.0059–0.0118 in)
(0.0906–0.1024 in)
2nd ring:
0.30–0.45 mm
Checking the piston ring end gap 5
(0.0118–0.0177 in)
1. Level the piston ring 1 in the cylinder Oil ring:
with a piston crown at the specified mea- 0.20–0.70 mm
suring point a. (0.0079–0.0276 in)
Measuring point a (reference data):
2. Measure the piston ring end gap b. 10 mm (0.4 in)
Checking the piston ring groove 5
1. Measure the piston ring grooves.

Replace the piston if out of specification.
5-43 6AU3K11

Cylinder block
Checking the piston pin boss bore 5
1. Measure the piston pin boss bore.

Replace the piston if out of specification.
1
Piston ring groove:
S6AU5135
2
Top ring a: S6AU5137
1.23–1.25 mm
(0.0484–0.0492 in)
2nd ring b:
1.52–1.54 mm
Piston pin boss bore:
14.004–14.015 mm
(0.5513–0.5518 in)
3
(0.0598–0.0606 in)
Oil ring c:
2.51–2.53 mm
(0.0988–0.0996 in)
Checking the piston pin diameter
1. Measure the piston pin diameter.
Replace if out of specification.
5
4
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.
5
5
6
Piston pin diameter:
S6AU5136
13.996–14.000 mm
(0.5510–0.5512 in)
Checking the connecting rod small

7
end inside diameter and big end
Piston ring side clearance:
Top ring a:
0.04–0.08 mm
(0.0016–0.0031 in)
inside diameter
1. Tighten the connecting rod cap bolts to
the specified torques in 2 stages.
5
8
2nd ring b:
9
Connecting rod cap bolt:
0.03–0.07 mm 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
T.
R.
(0.0012–0.0028 in) 2nd: 11 N·m (1.1 kgf·m, 8.1 ft·lb)

Oil ring c:
0.01–0.18 mm
(0.0004–0.0071 in)
6AU3K11 5-44

POWR
Power unit
2. Measure the connecting rod small end
inside diameter a and big end inside
diameter b. Replace the connecting rod
if out of specification.
a a S6AU5141
b
S6AU5139
Connecting rod small end inside

diameter a:
14.015–14.029 mm
(0.5518–0.5523 in) c
Connecting rod big end inside c S6AU5142
diameter b:
27.030–27.042 mm Crankshaft journal diameter a:
(1.0642–1.0646 in) 30.002–30.014 mm
(1.0582–1.0586 in)
Crankpin diameter b:
Checking the connecting rod big end
26.997–27.009 mm
side clearance 5
(1.0629–1.0633 in)
1. Measure the connecting rod big end side
Crankpin width c:
clearance a.
21.000–21.070 mm
(0.8268–0.8295 in)
2. Measure the crankshaft runout. Replace

a
a
S6AU5140
Connecting rod big end side

clearance a (reference data):
0.05–0.22 mm (0.0020–0.0087 in)
S6AU5143
Checking the crankshaft 5
Crankshaft runout limit:

1. Measure the crankshaft journal diame- 0.05 mm (0.0020 in)
ters a, crankpin diameters b, and
crankpin widths c. Replace the crank-
Checking the crankpin oil clearance 5
shaft if out of specification.

1. Clean the contact surfaces of the con-
necting rod and crankpin.
5-45 6AU3K11

Cylinder block
2. Put a piece of Plastigauge (PG-1) onto
the crankpin, parallel to the crankshaft.
1
S6AU5144 NOTE:
S6AU5146
Do not turn the connecting rod until the

2
NOTE: crankpin oil clearance measurement has
Be sure not to put the Plastigauge (PG-1)
over the oil hole in the crankpin of the crank-
shaft.
been completed.

3
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
T.
R. 4
3. Install the connecting rod 1 to the crank- 2nd: 11 N·m (1.1 kgf·m, 8.1 ft·lb)
pin 2.
5. Remove the connecting rod cap and
1 measure the width of the compressed
a
Plastigauge (PG-1) on the crankpin.
E
Check the connecting rods and crank-
shaft if out of specification and replace
the defective parts.
5
È
6
È
2 S6AU5147
7
1
S6AU5145 Crankpin oil clearance (reference
NOTE:
Make sure that the “ ” marks a of the con-
necting rod face towards the flywheel magnet
data):
0.021–0.045 mm
(0.0008–0.0018 in)
8
end È of the crankshaft.
9
Checking the crankshaft journal oil
clearance 5
4. Tighten the connecting rod cap bolts to 1. Clean the main bearings, crankshaft jour-
the specified torques in 2 stages. nals, and bearing portions of the crank-
case and cylinder block.
6AU3K11 5-46

POWR
Power unit
2. Place the cylinder block upside down on 6. Install the crankcase onto the cylinder
a bench. block.
3. Install half of the main bearings 1 and NOTE:

the crankshaft 2 into the cylinder block Apply engine oil to the threads of the crank-
3. case bolts.
7. Tighten the crankcase bolts to the speci-

fied torques in 2 stages and in the
sequence shown.
5 6
1 2
NOTE:
• Install the main bearings in their original E
positions.
• Insert the projection a of each bearing into 4 3 S6AU5150
the slots in the cylinder block.

NOTE:
Do not turn the crankshaft until the crankshaft
4. Put a piece of Plastigauge (PG-1) on journal oil clearance measurement has been
each crankshaft journal parallel to the completed.
crankshaft.
Crankcase bolt:
1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
T.
R.
2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
8. Gently remove the crankcase, and then

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

bearings into the crankcase.
NOTE:
• Install the main bearings in their original
positions.
• Insert the projection of each bearing into
the slots in the crankcase.
5-47 6AU3K11

Cylinder block
Assembling the cylinder block 5
NOTE:
1. Assemble the piston 1, connecting rod
When loosening the crankcase bolts, loosen
2, piston pin 3, and piston pin clips 4.
them in the opposite order used for tighten-
ing.
Crankshaft journal oil clearance 4 1

2 a
b
1
(reference data):
0.006–0.034 mm
(0.0002–0.0013 in)
Selecting the crankshaft main a 3

E
E
UP
bearing
3
5
1. Check the stamped marks a and b on 4

the crankcase. c
E
S6AU5153
#1 #2
CAUTION:
Do not reuse the piston pin clips 4,
always replace them with new ones.
4
5
NOTE:
• Before assembly, make sure that the identi-
fication numbers a made on the piston and
a c connecting rod during removal are the
same.
6
• Face the “ ” mark b on the connecting
rod in the same direction as the “UP” mark
c on the piston.
b
NOTE:
The stamped mark a is for the main bear-
S6AU5152
7
ings of crankshaft journal #1 and the
8
stamped mark b is for the main bearings of
crankshaft journal #2.
2. Select the suitable bearing color c for

the main bearings from the table.
Stamped marks
a and b
Bearing color c 9
A Blue
B Black
C Brown
6AU3K11 5-48

POWR
Power unit
2. Install the oil ring 5, 2nd ring 6, and top
ring 7 onto each piston. NOTE:
Apply engine oil to the side of each piston
NOTE: and the piston rings before installation.
Make sure that the “N” marks d of the 2nd
ring and the top ring are facing upward.
Piston slider 8: 90890-06843
3. Offset the piston ring end gaps as
shown. 5. Install half of the main bearings 9 into
the cylinder block 0.
d 45˚ 45˚
#3 #2 0
UP
N
UP
5
#1,#4 #5
9
#5
#4 E
#3 6
#2 7
#1
e S6AU5157
E
N
d NOTE:
S6AU5154 • Install the main bearings in their original
positions.
CAUTION: • Insert the projection e of each bearing into
Do not scratch the pistons or break the the slots in the cylinder block.
piston rings.
6. Install the crankshaft A and oil seals B
NOTE: and C into the cylinder block as shown.
After installing the piston rings, check that
they move smoothly. A
E
4. Install the piston with the “UP” mark on

the piston crown facing towards the fly- C
wheel magnet.
E B
UP
S6AU5158
NOTE:
8 S6AU5156 Apply engine oil to the inside of each oil seal
before installation.
5-49 6AU3K11

Cylinder block
7. Install the connecting rod caps D to the
connecting rods, and then tighten the
connecting rod cap bolts to the specified
E
1
torques in 2 stages.
518
E
E
D
È
E
f
NOTE:
S6AU5160
Do not get any sealant on the main bearings.

2
10. Install the crankcase onto the cylinder
block, and then tighten the crankcase
bolts to the specified torques in 2 stages
3
S6AU5159
and in the sequence shown.
NOTE:
• Make sure that the “ ” marks f on the
connecting rod cap face towards the fly- 5 6
4
wheel magnet end È of the crankshaft.
5
• Apply engine oil to the connecting rod cap
bolts before installation. 1 2
• After tightening the connecting rod cap
E
bolts, check that the crankshaft rotates
smoothly. 4 3 S6AU5150

1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
NOTE:
Apply engine oil to the threads of the crank- 6
T.
R.
case bolts before installation.

2nd: 11 N·m (1.1 kgf·m, 8.1 ft·lb)
8. Install the remaining half of the main Crankcase bolt:

1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 7
T.
bearings into the crankcase.

R.
2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb)

NOTE:
• Install the main bearings in their original
positions.
• Insert the projection of each bearing into
the slots in the crankcase.
8
9. Apply sealant to the mating surface of
the crankcase. 9
6AU3K11 5-50

POWR
Power unit
11. Install the relief valve E and tighten it to 2. Install the dowels 1, a new gasket 2,
the specified torque. and the power unit 3, and then tighten
the mounting bolts 4 to the specified
torque.
CAUTION:
Do not reuse the gasket, always replace it
with a new one.
E
2 3
E S6AU5162
6
NOTE: BOW
Apply a thin coat of engine oil to the O-ring of
5
the relief valve E before installation.
3
17 4
1
Relief valve E:
8 N·m (0.8 kgf·m, 5.9 ft·lb) 2
T.
R.
12. Install a new gasket, the thermostat, and

the thermostat cover.
Thermostat cover bolt:

8 N·m (0.8 kgf·m, 5.9 ft·lb)
T.
R.
4
4 4 S6AU5164
13. Install a new gasket and the exhaust
cover F, and then tighten the bolts to the Power unit mounting bolt 4:
specified torques in 2 stages and in the 21 N·m (2.1 kgf·m, 15.5 ft·lb)
T.
R.
sequence shown.
3. Install the apron, dipstick, and choke rod.
5 4. Connect the throttle cables onto the

F throttle cam, and then adjust the cables.
2
(H model)
1
Connect the throttle cable joint onto the
3 throttle cam, and then adjust the throttle
4 cable. (R model)
S6AU5163
NOTE:
To adjust the throttle cable(s), see “Adjusting
Exhaust cover bolt: the throttle cable (H model)” (3-7) or “Adjust-
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
T.
R.
ing the throttle cable (R model)” (3-8).

2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
Installing the power unit 5

5. Connect the flushing hose 5 (for
1. Clean the power unit mating surface. Europe), cooling water hoses 6, and fuel
hose 7.
5-51 6AU3K11

Cylinder block
1
5
7 6 S6AU5172
6. Connect the engine shut-off switch leads,

2
oil pressure warning indicator leads, and
engine start button leads. (H model)
Connect the 10-pin main harness to the
power unit. (R model)
NOTE:
3
To connect the leads, see “Electrical compo-
nent and wiring harness routing” (8-1).
7. Install the PT relay and connect the PT

4
relay lead, PT switch coupler, and PT
switch lead. (PT model)
8. Connect the battery cables, battery lead,

and starter motor lead. (E model)
5
9. Install the manual starter and driven
sprocket cover, and then connect the
start-in-gear protection cable. (M model)
Install the flywheel magnet cover and
6
driven sprocket cover. (E model)
NOTE:
To connect the start-in-gear protection cable,
see “Checking the start-in-gear protection (M
7
model)” (3-11).
8
9
6AU3K11 5-52

LOWR
Lower unit
Lower unit ....................................................................................................... 6-1

Removing the lower unit ............................................................................6-4
Removing the water pump......................................................................... 6-5
Checking the water pump..........................................................................6-5
Propeller shaft housing ................................................................................. 6-6

Removing the propeller shaft housing assembly....................................... 6-7
Disassembling the propeller shaft assembly .............................................6-7
Disassembling the propeller shaft housing assembly................................6-7
Checking the propeller shaft housing ........................................................6-8
Checking the propeller shaft...................................................................... 6-8
Assembling the propeller shaft assembly .................................................. 6-8
Assembling the propeller shaft housing.....................................................6-9
Drive shaft and lower case..........................................................................6-10

Removing the drive shaft, drive shaft housing, and shift rod................... 6-11
Disassembling the drive shaft housing ....................................................6-11
Disassembling the lower case .................................................................6-11
Checking the pinion and forward gear.....................................................6-12
Checking the bearing............................................................................... 6-12
Checking the drive shaft ..........................................................................6-12
Checking the shift rod.............................................................................. 6-12
Checking the lower case .........................................................................6-12
Assembling the lower case...................................................................... 6-12
Assembling the drive shaft housing......................................................... 6-13
Installing the shift rod, drive shaft housing, and drive shaft.....................6-13
Installing the propeller shaft housing .......................................................6-14
Installing the water pump.........................................................................6-15
Installing the lower unit ............................................................................6-15
Backlash ....................................................................................................... 6-17

Measuring the forward and reverse gear backlash .................................6-17
6AU3K11

Lower unit (high thrust model) ................................................................... 6-21
Removing the lower unit ..........................................................................6-24
Removing the water pump....................................................................... 6-25
Checking the water pump........................................................................6-25
Propeller shaft housing (high thrust model) ............................................. 6-26

Removing the propeller shaft housing assembly..................................... 6-27
1
Disassembling the propeller shaft assembly ...........................................6-27
Disassembling the propeller shaft housing assembly..............................6-27
Checking the propeller shaft housing ......................................................6-28
Checking the propeller shaft.................................................................... 6-28
Assembling the propeller shaft assembly ................................................ 6-28
Assembling the propeller shaft housing...................................................6-29
2
Drive shaft and lower case (high thrust model) ........................................ 6-31
Removing the drive shaft, drive shaft housing, and shift rod................... 6-32
Disassembling the drive shaft housing ....................................................6-32
3
Disassembling the lower case .................................................................6-32
Checking the pinion and forward gear.....................................................6-33
Checking the bearing............................................................................... 6-33
Checking the drive shaft ..........................................................................6-33
Checking the shift rod.............................................................................. 6-33
Checking the lower case .........................................................................6-33
4
Assembling the lower case...................................................................... 6-33
Assembling the drive shaft housing......................................................... 6-34
Installing the shift rod, drive shaft housing, and drive shaft.....................6-35
Installing the propeller shaft housing .......................................................6-35
Installing the water pump.........................................................................6-36
5
Installing the lower unit ............................................................................6-37
Shimming (high thrust model) .................................................................... 6-39

Shimming.................................................................................................6-40
Selecting the pinion shim.........................................................................6-40
6
Selecting the forward gear shim ..............................................................6-40
Selecting the reverse gear shim ..............................................................6-41
Backlash (high thrust model)...................................................................... 6-42

Measuring the forward and reverse gear backlash .................................6-42
7
8
9
6AU3K11

LOWR
Lower unit
Lower unit 6
4
17 N · m (1.7 kgf · m, 12.5 ft · Ib)
1
T.
R.
3 18 N · m (1.8 kgf · m, 13.3 ft · Ib)
T.
R.
2
3 LT
5 572
6
21
17 20
13 19
18
9
7 D 14
11 6
15
12 LT
LT 572
8
572 16
13 10
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
T.
R.
18 N · m (1.8 kgf · m, 13.3 ft · Ib)

.T
R.
2 N · m (0.2 kgf · m, 1.5 ft · Ib)

9 N · m (0.9 kgf · m, 6.6 ft · Ib)
T.
R.
T.
S6AU6001
R.

1 Adjusting nut 1
2 Locknut 1
3 Dowel 2
4 Rubber seal 1
5 Check screw 1
7 Cooling water inlet cover 1 Short
8 Cooling water inlet cover 1 Long
9 Nut 1
10 Screw 1 ø5 × 16 mm
11 Drain screw 1
12 Lower case 1
13 Bolt 4 M8 × 35 mm
14 Anode 1
15 Special washer 1 Not reusable
16 Bolt 1 M6 × 16 mm
17 Spacer 1
6-1 6AU3K11

Lower unit
6
1
M
4
17 N · m (1.7 kgf · m, 12.5 ft · Ib)
1
T.
R.
3 18 N · m (1.8 kgf · m, 13.3 ft · Ib)
T.
R.
2
5
6
3 LT
572
2
21
13
17
18
19
20
3
9
11
7
6 D 14
15
4
12
LT
572
13
8
10
16
LT
572
5
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
T.
R.
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
6
.T
R.
2 N · m (0.2 kgf · m, 1.5 ft · Ib)

9 N · m (0.9 kgf · m, 6.6 ft · Ib)
T.
R.
T.
S6AU6001
R.

18 Propeller 1
19
20
21
Washer
Propeller nut
Cotter pin
1
1
1 Not reusable 7
8
9
6AU3K11 6-2

LOWR
Lower unit
6
1
1
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
T.
R.
2 2
LT
572
A
3
4
11
A
5
A
6
7
A
8
18 N · m (1.8 kgf · m, 13.3 ft · Ib) 9
T.
R.
5
LT
572
10
6
A
S6AU6002

1 Bolt 4 M8 × 45 mm
2 Plate 2
3 Rubber seal 1
4 Water pump housing 1
5 Insert cartridge 1
6 Impeller 1
8 Bolt 2 M8 × 25 mm
9 Dowel 2
10 Outer plate cartridge 1
11 Woodruff key 1
6-3 6AU3K11

Lower unit
Removing the lower unit 6 4. Remove the locknut 1.
1. Drain the gear oil.
1
1
3
NOTE:
S6AU6005 2
Be sure to remove the locknut from the shift
S6AU6003
rod before removing the lower unit.
5. Remove the lower unit by removing the

3
2. Set the gear shift to the N position, place lower case mounting bolts 4.
a block of wood between the anti-cavita-
tion plate and propeller to keep the pro-
peller from turning, and then remove the
propeller nut and propeller.
6. Remove the anode 5 and cooling water
inlet covers 6. 4
5
S6AU6004
5
4
6
WARNING
• Do not hold the propeller with your
hands when loosening or tightening it.
• Be sure to disconnect the battery cables
6
7
from the battery and remove the clip
from the engine shut-off switch. (E
model)
4 6 S6AU6006
8
3. Loosen the locknut 1 while holding the
adjusting nut 2, and then turn the adjust-
ing nut to disconnect the shift rod 3.
NOTE:
9
Set the gear shift to the R position before dis-
connecting the shift rod.
6AU3K11 6-4

LOWR
Lower unit
Removing the water pump 6
1. Remove the water pump housing 1 and

impeller 2.
2. Remove the Woodruff key 3 from the

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

case.
3
1
5
4
S6AU6007
Checking the water pump 6
1. Check the water pump housing. Replace

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

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

in the drive shaft. Replace if worn or
deformed.
6-5 6AU3K11

Lower unit / Propeller shaft housing
Propeller shaft housing 6
6
1
2
3
4
5
16
2
F 1 16
D
A
LT
572
14
G
A
3
15
4
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
.
R.
14 15 16
13 6
12
7 8
9
G
10
11
5
G 13

S6AU6008
6
1 Cross pin 1
2
3
4
5
Dog clutch
Cross pin ring
Shift plunger
Spring
1
1
1
1
7
6 Propeller shaft 1
7
8
9
10
Washer
Reverse gear
Reverse gear shim
Ball bearing
1
1
—
1 Not reusable
8
12
13
14
15
O-ring
Propeller shaft housing
Bolt
Bushing
1
1
2
1
Not reusable
M6 × 16 mm
Not reusable
9
6AU3K11 6-6

LOWR
Lower unit
Removing the propeller shaft Disassembling the propeller shaft
housing assembly 6 housing assembly 6
1. Remove the bolts 1 from the propeller 1. Remove the reverse gear and shim(s).
shaft housing.
2. Remove the propeller shaft housing

assembly 2.
2 1 S6AU6012
2. Remove the ball bearing.
S6AU6009
1
NOTE:
• Insert flat-head screwdrivers between the
propeller shaft housing assembly and the
lower case to pry the assembly loose. 2
• If the propeller shaft housing assembly is
stuck to the lower case, use the special ser-
vice tools. See “Backlash” (6-17). 3
Disassembling the propeller shaft

assembly 6
S6AU6014
1. Remove the shift plunger 1 from the
propeller shaft. CAUTION:
Do not reuse the bearing, always replace
2. Remove the cross pin ring 2, and then
it with a new one.
remove the cross pin 3 and dog clutch
4.
Stopper guide plate 1: 90890-06501
3. Pull out the spring 5 from the propeller Bearing puller assembly 2:
shaft. 90890-06535
Stopper guide stand 3:
2 90890-06538
4
1 3. Remove the oil seals and bushing.
5
S6AU6011
6-7 6AU3K11

Propeller shaft runout limit:

0.05 mm (0.0020 in)
4
5
5
3. Check the dog clutch, shift plunger, and
cross pin. Replace if cracked or worn. 1
Assembling the propeller shaft
assembly
1. Insert the spring 1 into the propeller
shaft.
6
2
2. Install the dog clutch 2, cross pin 3,
and cross pin ring 4.
3
S6AU6016
CAUTION: NOTE:
Do not reuse the bushing, always replace Install the dog clutch with the “F” mark facing
it with a new one. toward the forward gear.
Driver rod L3 4: 90890-06652

Bushing attachment 5:
3. Install the shift plunger 5. 4
90890-06649 4
2
Checking the propeller shaft
housing
1. Clean the propeller shaft housing, and
6
5
3
5
then check it. Replace if cracked or dam-
aged.
2. Check the teeth and dogs of the reverse

gear. Replace the reverse gear if cracked
F 1
S6AU6018
6
or worn.
7
4
5 3 2
1
6
1. Check the propeller shaft. Replace if

damaged or worn.
2. Measure the propeller shaft runout.

Replace if above specification. S6AU6019
8
9
S6AG6130
6AU3K11 6-8

LOWR
Lower unit
housing 6
Installation depth a:
1. Install a new bushing into the propeller 3.0–3.5 mm (0.12–0.14 in)
shaft housing to the specified depth.
3. Install a new ball bearing into the propel-
ler shaft housing.
1
5
6
G
G
S6AU6021
Driver rod L3 1: 90890-06652 S6AU6025
Needle bearing attachment 2:

90890-06617 NOTE:
Install the ball bearing with the manufacture
identification mark facing toward the reverse
2. Apply grease to new oil seals, and then
gear.
install them into the propeller shaft hous-
ing to the specified depth a.
Driver rod LS 5: 90890-06606
Ball bearing attachment 6:
90890-06634
A
4. Install the reverse gear and original
3
a shim(s) into the propeller shaft housing.
4
S6AU6023
G
NOTE: S6AU6026
Install an oil seal halfway into the propeller
shaft housing, and then install the other oil NOTE:
seal. After installing the reverse gear and shim(s),
check that the gear rotates smoothly.
Driver rod L3 3: 90890-06652
90890-06614
6-9 6AU3K11

Propeller shaft housing / Drive shaft and lower case
Drive shaft and lower case 6
8
3
5
1
13 A
6
2 4
7
8
2
3
1
5
9
3
6
10
11
4
G
12
14
15
16
G
5
G
No. Part name Q’ty

13
Remarks
S6AU6027
6
1 Shift rod 1 L-transom model/S-transom model
2
3
4
5
Gasket
Drive shaft sleeve
O-ring
Oil seal
1
1
1
2
Not reusable
Not reusable
Not reusable
7
6 Bushing 1
7
8
9
10
Drive shaft housing
Drive shaft
Clip
Thrust washer
1
1
1
1
L-transom model/S-transom model
8
11 Pinion 1
12
13
14
15
E-clip
Bushing
Forward gear shim
Ball bearing
1
1
—
1
Not reusable
Not reusable
9
16 Forward gear 1
6AU3K11 6-10

LOWR
Lower unit
Removing the drive shaft, drive shaft
housing, and shift rod 6
1. Remove the E-clip 1, pinion 2, and 1

thrust washer 3.
2
3
S6AU6031
2
1 Driver rod L3 1: 90890-06652
S6AU6028 90890-06650
2. Remove the drive shaft, drive shaft hous- Disassembling the lower case 6
ing assembly 4, gasket 5, and shift rod 1. Remove the ball bearing and forward
6. gear shim(s).
4
1
5
2
S6AU6029
3. Remove the drive shaft sleeve.
4. Pull out the forward gear. S6AU6035
Disassembling the drive shaft CAUTION:

housing 6

1. Remove the oil seals and bushing. it with a new one.

Bearing puller assembly 2:
90890-06535
2. Remove the bushing from the lower

case.
6-11 6AU3K11

Drive shaft and lower case
Checking the shift rod 6
1. Check the shift rod. Replace if bent or

worn.
4
3
4
Checking the lower case
1. Check the skeg, torpedo, and anti-cavita-
tion plate. Replace the lower case if
6
1
cracked or damaged.
CAUTION:
S6AU6158
Assembling the lower case
1. Install the original forward gear shim(s)
1 and a new ball bearing 2.
6
2
Do not reuse the bushing, always replace
3
it with a new one.
4 3
Driver rod L3 3: 90890-06652
90890-06650 1 2
Checking the pinion and forward

gear 6
12
G
S6AU6039
4
1. Check the teeth of the pinion, and the
5
teeth and dogs of the forward gear. NOTE:
Replace the pinion or forward gear if Install the ball bearing with the manufacture
identification mark facing toward the forward
cracked or worn.
gear.
Checking the bearing 6
1. Check the bearings. Replace if pitted or if

there is rumbling.
Checking the drive shaft 6

Driver rod LL 3: 90890-06605
90890-06634
6
1. Check the drive shaft. Replace if bent or
worn.
2. Measure the drive shaft runout. Replace

7
8
S6AU6037
9
Drive shaft runout limit:
1.0 mm (0.0394 in)
6AU3K11 6-12

LOWR
Lower unit
2. Install a new bushing 5 into the lower 2. Apply grease to new oil seals, and then
case. install them into the drive shaft housing
to the specified depth.
6
3 4
a
5
7
G 4
A
S6AU6041
S6AU6047
NOTE:
Install the bushing until its flange is in tight NOTE:
contact with the lower case. Install an oil seal halfway into the drive shaft
housing, and then install the other oil seal.
Bushing installer center bolt 6:

90890-06601 Driver rod L3 3: 90890-06652
Needle bearing attachment 7: Needle bearing attachment 4:
90890-06616 90890-06614
Assembling the drive shaft housing 6
1. Install the bushing into the drive shaft 6.0–6.5 mm (0.24–0.26 in)
housing.
Installing the shift rod, drive shaft
housing, and drive shaft 6
1 1. Install the forward gear 1 into the lower

case.
2 2. Install the drive shaft sleeve 2 into the

lower case.
3. Install the shift rod, a new gasket 3, and

G the drive shaft housing assembly 4.
2
NOTE:
Make sure that the projection a on the gas-
S6AU6045
ket is toward the starboard side.
Driver rod L3 1: 90890-06652

Bushing attachment 2: 4. Install the drive shaft 5, thrust washer
90890-06650 6, pinion 7, and E-clip 8 to the drive
shaft.
6-13 6AU3K11

D A 4
4
3 a
5
LT
1
2
572
2 3
G
S6AU6051
2
6 a
1
7
8
G
3
G S6AU6048
NOTE:
When installing the pinion, lift up the drive
shaft slightly and align the pinion and shaft NOTE:
Install the propeller shaft housing assembly
S6AU6157
4
splines.
with the arrow mark a facing upward.
Installing the propeller shaft housing

1. Install the propeller shaft assembly 1
6
Propeller shaft housing bolt 4:

8 N·m (0.8 kgf·m, 5.9 ft·lb)
5
T.
R.
into the lower case.
1
3. Check that the shifting mechanism works
properly and smoothly. 6
F F
G S6AU6050
N
R
N
7
R
2. Install the washer 2 and propeller shaft

housing assembly 3 into the lower case,
and then tighten the bolts 4 to the speci-
S6AU6052
8
fied torque.
9
6AU3K11 6-14

LOWR
Lower unit
Installing the water pump 6
NOTE:
1. Install the dowels 1 and outer plate car-
Align the insert cartridge projection a with
tridge 2.
the hole b in the water pump housing.
1
A
4. Install the water pump housing assembly
7 into the lower case, and then install
the rubber seal 8.
2
0 0
LT
572
A
9
8
S6AU6053
7
2. Install the Woodruff key 3 and impeller
4 to the drive shaft. 9
LT
572
LT
572 S6AU6056
A 4
CAUTION:
Do not turn the drive shaft counterclock-
wise, otherwise the water pump impeller
may be damaged.
3
S6AG6390 NOTE:
• Apply grease to the inside of the water
NOTE: pump housing.
When installing the impeller 4 onto the drive
• While turning the drive shaft clockwise,
shaft, align the groove in the impeller with the
push down on the water pump housing and
Woodruff key 3.
install it.
• Align the projections on the rubber seal 8
3. Install the insert cartridge 5 and a new with the holes in the water pump housing.
O-ring 6 into the water pump housing.
5. Tighten the water pump housing bolts 9
6 and = to the specified torque.
a Water pump housing bolt 9 and =:

18 N·m (1.8 kgf·m, 13.3 ft·lb)
T.
R.
b
Installing the lower unit 6
5 1. Set the shift lever to the R position. (H

A
S6AG6570 model)
Set the remote control lever to the R
position. (R model)
6-15 6AU3K11

2. Set the shift rod to the R position.
F F 6
R
N 5
7
a 1
R
S6AU6057
Screwed-in length a:
S6AU6059
2
3. Install the lower unit to the upper case, 8.0–9.0 mm (0.31–0.35 in)
and then tighten the lower case mounting
bolts 1 to the specified torque.
3
4
2
5. Tighten the locknut 5.
NOTE:
After connecting the shift rod, check that the
3
2
gear shift operates properly.
1
6. Install the anode 8 and cooling water
inlet covers 9, and then tighten the
4
anode bolt to the specified torque.
NOTE:
LT
572
S6AU6058
• Before installing the lower unit to the upper

5
case, install the dowels 2 into the lower
case.
• Before installing the lower unit, make sure
that the locknut is removed from the shift
rod.
9 8
6
• When installing the lower unit, make sure
that the water pipe 3 is inserted securely
into the rubber seal 4.
9 LT
572
S6AU6060
7
Lower case mounting bolt 1:
18 N·m (1.8 kgf·m, 13.3 ft·lb)
8
T.
Anode bolt:
R.
8 N·m (0.8 kgf·m, 5.9 ft·lb)

T.
R.
4. Install the locknut 5, and then screw the

adjusting nut 6 onto the shift rod 7.
9
6AU3K11 6-16

LOWR
Lower unit
7. Install the propeller = and propeller nut
A. Place a block of wood between the Recommended gear oil:
anti-cavitation plate and propeller to keep Hypoid gear oil
the propeller from turning, and then API: GL-4
tighten the nut to the specified torque. SAE: 90
Gear oil quantity:
0 A 150 cm3
(5.07 US oz, 5.29 Imp oz)
Backlash 6
Measuring the forward and reverse

gear backlash 6
D
NOTE:
S6AU6061
Remove the water pump assembly before
measuring the backlash.
1. Install the lower unit onto a repair stand.
2. Set the shift rod to the N position at the

lower unit.
F F
S6AU6062
N
N
WARNING R
R
S6AU6052
model) 3. Install the special service tools.
4. Tighten the center bolt 1 to the specified

NOTE: torque while turning the drive shaft.
If the grooves in the propeller nut do not align
with the cotter pin hole, tighten the nut until
they are aligned.
Propeller nut:
17 N·m (1.7 kgf·m, 12.5 ft·lb)
T.
R.
8. Fill the lower unit with gear oil to the cor-

rect level.
6-17 6AU3K11

Drive shaft and lower case / Backlash
1
5
2
13
4
7
2
a
S6AU6074
b
6
3
S6AU6076
Center bolt 1: 90890-06504

Bearing housing puller claw S 3:
NOTE:
Install the dial gauge so that the plunger tip
a is aligned with the mark b on the back-
4
90890-06564 lash indicator.
Center bolt 1:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
Backlash indicator 4: 90890-06706
Magnet base plate 5: 90890-07003
5
T.
R.
Dial gauge set 6: 90890-01252

Magnet base B 7: 90890-06844
6
5. Turn the lower unit upside down.
6. Install the backlash indicator onto the 7. Slowly turn the drive shaft clockwise and
drive shaft (11.8 mm [0.46 in] in diame- counterclockwise and measure the back-
ter), and then install the dial gauge. lash when the drive shaft stops in each
7
direction.
NOTE:
• Pull the drive shaft downward, and then
turn it.
• Measure the backlash at 4 points to find the
average.
Forward gear backlash:

8
0.50– 2.27 mm (0.0197– 0.0894 in)
9
6AU3K11 6-18

LOWR
Lower unit
8. Adjust the current shim thickness if the
forward gear backlash is out of specifica-
tion.
Forward gear
Shim thickness
backlash
Less than To be decreased by
0.50 mm (0.0197 in) (1.39 – M) × 0.40
More than To be increased by
2.27 mm (0.0894 in) (M – 1.39) × 0.40
M: Measurement
Available shim thicknesses:

0.10, 0.12, 0.15, 0.18, and 0.30 mm
9. Remove the special service tools from

the propeller shaft. S6AU6078
10. Install the propeller, washer, and propel- NOTE:

ler nut, without installing the spacer 8. • Pull the drive shaft downward, and then
turn it.
8 • Measure the backlash at 4 points to find the
average.
Reverse gear backlash:

0.50–2.27 mm (0.0197–0.0894 in)

S6AU6077 reverse gear backlash is out of specifica-
tion.
11. Tighten the propeller nut to the specified
torque. Reverse gear
Shim thickness
backlash
Propeller nut: Less than To be decreased by
2 N·m (0.2 kgf·m, 1.5 ft·lb) 0.50 mm (0.0197 in) (1.39 – M) × 0.40
T.
R.

12. Slowly turn the drive shaft clockwise and 2.27 mm (0.0894 in) (M – 1.39) × 0.40
counterclockwise and measure the back-
lash when the drive shaft stops in each M: Measurement
direction.
Available shim thicknesses: 0.1 mm
14. Turn the lower unit upright.
15. Remove the special service tools and

propeller, and then install the water pump
assembly.
6-19 6AU3K11

Backlash
NOTE:
To install the water pump assembly, see
“Installing the water pump” (6-15).
rect level.
1
2
3
4
5
6
7
8
9
6AU3K11 6-20

LOWR
Lower unit
Lower unit (high thrust model) 6
27 28 a
M
LT
b
1 4 572
29
29
2 3 30
31
3 32
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
5
T.
R.
6 18
D
26
19
17 25
24
21
20
9
7
11 6 D
13 LT
12 23
8 14 572
LT
10 15 22
572
13 21 N · m (2.1 kgf · m, 15.5 ft · Ib)
T.
R.
LT
16
T.
T.
R.
R.

T.
T.
R.
R.
2 N · m (0.2 kgf · m, 1.5 ft · Ib) S6AU6079

T.
R.

1 Adjusting nut 1
2 Locknut 1
3 Dowel 2
4 Rubber seal 1
5 Check screw 1
7 Cooling water inlet cover 1
8 Cooling water inlet cover 1
9 Nut 1
10 Screw 1 ø5 × 20 mm
11 Drain screw 1
12 Lower case 1
13 Bolt 4 M8 × 30 mm/L-transom model
14 Anode 1
15 Special washer 1 Not reusable
16 Bolt 1 M6 × 30 mm
17 Spacer 1
6-21 6AU3K11

Lower unit (high thrust model)
6
27 28 a
1
M
4
LT
572
29
b 1
29
2 3 30
5
3
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
31
32 2
T.
R.
6 18
D
26
17
19
21
24
25
3
20
9
7
11 6 D 4
13 LT
5
12 23
8 14 572
LT
10 15 22
572
13 21 N · m (2.1 kgf · m, 15.5 ft · Ib)
T.
R.
LT
16
T.
T.
R.
R.
9 N · m (0.9 kgf · m, 6.6 ft · Ib)
6
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
T.
T.
R.
R.
2 N · m (0.2 kgf · m, 1.5 ft · Ib) S6AU6079

T.
R.

18 Clip 1
19
20
21
22
Washer
Propeller
Spacer
Propeller
1
1
1
1
7
23 Deflector 1
24
25
26
27
Washer
Propeller nut
Cotter pin
Stud bolt
1
1
1
4
Not reusable
a > b/X-transom model
8
28 Rubber seal 1 X-transom model
29
30
31
32
Dowel
Extension
Washer
Nut
2
1
4
4
X-transom model
X-transom model
X-transom model
X-transom model
9
6AU3K11 6-22

LOWR
Lower unit
6
1
1
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
T.
R.
2 2
LT
572
11
4
5 A
A
6
7
A
18 N · m (1.8 kgf · m, 13.3 ft · Ib) 8

9
T.
R.
5
LT
572
6 10
A
S6AU6080

1 Bolt 4 M8 × 45 mm
2 Plate 2
3 Rubber seal 1
4 Water pump housing 1
5 Insert cartridge 1
6 Impeller 1
8 Bolt 2 M8 × 25 mm
9 Dowel 2
10 Outer plate cartridge 1
11 Woodruff key 1
6-23 6AU3K11

Lower unit (high thrust model)
Removing the lower unit 6 4. Remove the locknut 1.
1. Drain the gear oil.
1
1
3
NOTE:
S6AU6005 2
Be sure to remove the locknut from the shift
S6AU6081
rod before removing the lower unit.
5. Remove the lower unit by removing the

3
2. Set the gear shift to the N position, place lower case mounting bolts 4.
a block of wood between the anti-cavita-
tion plate and propeller to keep the pro-
peller from turning, and then remove the
propeller nut and propeller.
6. Remove the anode 5 and cooling water
inlet covers 6. 4
5
4
S6AU6004
6
6
5
WARNING
• Be sure to disconnect the battery cables 6
7
8
4
from the engine shut-off switch. (E S6AU6084
model)
3. Loosen the locknut 1 while holding the

adjusting nut 2, and then turn the adjust-
ing nut to disconnect the shift rod 3.
NOTE:
9
Set the gear shift to the R position before dis-
connecting the shift rod.
6AU3K11 6-24

LOWR
Lower unit
Removing the water pump 6
1. Remove the water pump housing 1 and

impeller 2.
2. Remove the Woodruff key 3 from the

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

case.
3
1
5
4
S6AU6085
Checking the water pump 6
1. Check the water pump housing. Replace

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

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

in the drive shaft. Replace if worn or
deformed.
6-25 6AU3K11

Lower unit (high thrust model) / Propeller shaft housing (high thrust model)
Propeller shaft housing (high thrust model) 6
6
1
2
5
4
3
2
16
F 1 16
3
14
LT G
572
A
A
15
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
4
T.
R.
14 16
15
13 6
12
7 8
R
9
G
10
11
5
G 13

S6AU6086
6
1 Cross pin 1
2
3
4
5
Dog clutch
Cross pin ring
Shift plunger
Spring
1
1
1
1
7
6 Propeller shaft 1
7
8
9
10
Washer
Reverse gear
Reverse gear shim
Ball bearing
1
1
—
1 Not reusable
8
12
13
14
15
O-ring
Bolt
Needle bearing
1
1
2
1
Not reusable
M6 × 25 mm
Not reusable
9
6AU3K11 6-26

LOWR
Lower unit
Removing the propeller shaft Disassembling the propeller shaft
housing assembly 6 housing assembly 6
1. Remove the bolts 1 from the propeller 1. Remove the reverse gear and shim(s).
shaft housing.
2. Remove the propeller shaft housing

assembly 2.
2 1 S6AU6090
2. Remove the ball bearing.
S6AU6009
1
NOTE:
• Insert flat-head screwdrivers between the
propeller shaft housing assembly and the
lower case to pry the assembly loose. 2
• If the propeller shaft housing assembly is
stuck to the lower case, use the special ser-
vice tools. See “Backlash (high thrust 3
model)” (6-42).
Disassembling the propeller shaft S6AU6092

assembly 6
1. Remove the shift plunger 1 from the CAUTION:

propeller shaft. Do not reuse the bearing, always replace
it with a new one.
2. Remove the cross pin ring 2, and then
remove the cross pin 3 and dog clutch
4. Stopper guide plate 1: 90890-06501
3. Pull out the spring 5 from the propeller 90890-06535
shaft. Stopper guide stand 3:
90890-06538
2
4 3. Remove the oil seals and needle bear-
1 ing.
5
S6AU6089
6-27 6AU3K11

Propeller shaft housing (high thrust model)
Propeller shaft runout limit:

0.02 mm (0.0008 in)
4
5
5 3. Check the dog clutch, shift plunger, and
cross pin. Replace if cracked or worn. 1
assembly
1. Insert the spring 1 into the propeller
shaft.
6
2
2. Install the dog clutch 2, cross pin 3,
and cross pin ring 4.
3
S6AU6094
CAUTION: NOTE:
Do not reuse the bearing, always replace Install the dog clutch with the “F” mark facing
it with a new one. toward the forward gear.
Driver rod L3 4: 90890-06652

3. Install the shift plunger 5. 4
90890-06616 4
2
housing
1. Clean the propeller shaft housing, and
6
5
3
5
then check it. Replace if cracked or dam-
aged.
2. Check the teeth and dogs of the reverse

gear. Replace the reverse gear if cracked
F 1
S6AU6096
6
or worn.
7
4
5 3 2
1
6
1. Check the propeller shaft. Replace if

damaged or worn.
2. Measure the propeller shaft runout.

Replace if above specification. S6AU6097
8
9
S6AU6095
6AU3K11 6-28

LOWR
Lower unit
housing 6
1. Install a new needle bearing into the pro-

peller shaft housing to the specified A
depth a.
3
b 4
a
1
G S6AU6101
2
NOTE:
Install an oil seal halfway into the propeller
shaft housing, and then install the other oil
seal.
S6AU6099
NOTE: Driver rod L3 3: 90890-06652

Install the needle bearing with the manufac-
ture identification mark facing toward the oil
90890-06613
seals (propeller side).
Installation depth b:
Driver rod L3 1: 90890-06652 4.5–5.0 mm (0.18–0.20 in)
90890-06616
3. Install a new ball bearing into the propel-
ler shaft housing.
0 ± 0.25 mm (0 ± 0.01 in)
2. Apply grease to new oil seals, and then 5

install them into the propeller shaft hous-
6
ing to the specified depth b.
S6AU6103
NOTE:
Install the ball bearing with the manufacture
identification mark facing toward the reverse
gear.
6-29 6AU3K11

Propeller shaft housing (high thrust model)
Driver rod LS 5: 90890-06606

90890-06632
4. Install the reverse gear and original

shim(s) into the propeller shaft housing.
1
2
G
S6AU6104
3
NOTE:
• Be sure to select the reverse gear shim(s) if
replacing the propeller shaft housing, ball
bearing, or lower case. To select the shims,
4
see “Shimming (high thrust model)” (6-39).
• After installing the reverse gear and
shim(s), check that the gear rotates
smoothly. 5
6
7
8
9
6AU3K11 6-30

LOWR
Lower unit
Drive shaft and lower case (high thrust model) 6
9
3
6
4 A
7
2 8 9
5
3
4
1
6
7 10
11
10
16 11
G
12 G
13
G
15
F
14 G
G
25 N · m (2.5 kgf · m, 18.4 ft · Ib)
T.
R.
S6AU6105

1 Shift rod 1 L-transom model/X-transom model
3 Drive shaft sleeve 1
4 Needle bearing 1 Not reusable
7 Bushing 1
8 Drive shaft housing 1
9 Drive shaft 1 L-transom model/X-transom model
10 Pinion shim —
11 Roller bearing 1
12 Pinion 1
13 Pinion nut 1
14 Taper roller bearing 1 Not reusable
15 Forward gear shim —
16 Forward gear 1
6-31 6AU3K11

Drive shaft and lower case (high thrust model)
Removing the drive shaft, drive shaft
housing, and shift rod 6
1. Remove the pinion nut.
2
1
1 1
2
2
3
S6AU6109
Driver rod L3 1: 90890-06652

S6AU6106 Bushing attachment 2:
90890-06649
2. Remove the pinion, pinion shim(s), and
roller bearing.
3. Remove the drive shaft, and then remove

Disassembling the lower case
1. Remove the taper roller bearing outer
race and forward gear shim(s).
6
4
the drive shaft housing assembly 1, gas-
ket 2, and shift rod 3.
3
1
5
1
2
2
a 6
CAUTION:
S6AU6107
Be sure to remove the drive shaft before

S6AU6113
7
removing the drive shaft housing assem- CAUTION:
bly from the lower case.
4. Remove the drive shaft sleeve.

it with a new one. 8
NOTE:
9
5. Pull out the forward gear. Fit the hooks of the puller claw into the slots
a in the lower case.
Disassembling the drive shaft
housing 6
1. Remove the oil seals and bushing. Stopper guide plate 1: 90890-06501
90890-06535
6AU3K11 6-32

LOWR
Lower unit
2. Remove the needle bearing from the
lower case. Drive shaft runout limit:
0.5 mm (0.0197 in)
3 Checking the shift rod 6
1. Check the shift rod. Replace if bent or

worn.
4
4 Checking the lower case 6
1. Check the skeg, torpedo, and anti-cavita-

S6AU6114
tion plate. Replace the lower case if
cracked or damaged.
CAUTION: Assembling the lower case 6
Do not reuse the bearing, always replace 1. Install a new taper roller bearing outer
it with a new one. race 1.
Driver rod L3 3: 90890-06652

90890-06617 3 2
Checking the pinion and forward 1

gear 6
1. Check the teeth of the pinion, and the G
teeth and dogs of the forward gear. 1 S6AU6117
Replace the pinion or forward gear if

cracked or worn. Driver rod LL 2: 90890-06605
Bearing outer race attachment 3:
Checking the bearing 6
90890-06625
1. Check the bearings. Replace if pitted or if
there is rumbling. 2. Install a new needle bearing into the
lower case to the specified depth a.
Checking the drive shaft 6
1. Check the drive shaft. Replace if bent or 5

worn. 4
4
2. Measure the drive shaft runout. Replace 5 c
if above specification. b
6 a
G 6
S6AU6119
S6AU6115
6-33 6AU3K11

NOTE:
• Install the needle bearing with the manufac-
ture identification mark b facing upward.
• Install the stopper c onto the driver rod SL
at the installation depth a as shown. Install
the needle bearing until the stopper c con-
tacts the special service tool 5.
3
c 1
Driver rod SL 4: 90890-06602
Bearing depth plate 5: 90890-06603
A
4 2
90890-06617
3
S6AU6125
Installation depth a: NOTE:

Install an oil seal halfway into the drive shaft
189.3–189.8 mm (7.45–7.47 in)
housing, and then install the other oil seal.
Assembling the drive shaft housing

1. Install the bushing into the drive shaft
housing.
6
Driver rod L3 3: 90890-06652

90890-06613
4
a
2
1
b
Installation depth c:
7.0–8.0 mm (0.28–0.31 in) 5
G
6
2
NOTE:
S6AU6123
7
Align a groove a in the bushing with the hole
b in the drive shaft housing.
Driver rod L3 1: 90890-06652

8
90890-06649
2. Apply grease to new oil seals, and then

install them into the drive shaft housing
9
to the specified depth c.
6AU3K11 6-34

LOWR
Lower unit
NOTE:
housing, and drive shaft 6
• When installing the pinion, lift up the drive

1. Install the forward gear assembly 1 into
shaft slightly and align the pinion and shaft
the lower case.
splines.
• Be sure to select the pinion shim(s) if
2. Install the drive shaft sleeve 2 into the
replacing the pinion, roller bearing, or lower
lower case.
case. To select the shim, see “Shimming
NOTE: (high thrust model)” (6-39).
Install the drive shaft sleeve 2 with the hole
a facing forward.
5. Tighten the pinion nut = to the specified
torque.
3. Install the shift rod 3, a new gasket 4,
and the drive shaft housing assembly 5.
NOTE:
Make sure that the projection b on the gas-
ket is toward the port side.
4. Install the drive shaft 6, original pinion

shim(s) 7, roller bearing 8, pinion 9,
and pinion nut = to the drive shaft.
5
S6AU6127
4 6
b Pinion nut =:
25 N·m (2.5 kgf·m, 18.4 ft·lb)
T.
R.
a Installing the propeller shaft housing 6
1. Install the propeller shaft assembly 1

into the lower case.
3 7 G
1
8
G
9
1 0
G S6AU6126
G S6AG6341
2. Install the washer 2 and propeller shaft

housing assembly 3 into the lower case,
and then tighten the bolts 4 to the speci-
fied torque.
6-35 6AU3K11

A 4
A 4
LT
1
572
2 3 3
G
Propeller shaft housing bolt 4:

S6AU6129
NOTE:
S6AG6390
When installing the impeller 4 onto the drive

2
8 N·m (0.8 kgf·m, 5.9 ft·lb)
T.
R.
shaft, align the groove in the impeller with the

3. Check that the shifting mechanism works
properly and smoothly.
Woodruff key 3.
3. Install the insert cartridge 5 and a new

3
F F O-ring 6 into the water pump housing.
R
N 6 4
a
R
S6AU6130
b
5
5
Installing the water pump 6
A
S6AG6570
1. Install the dowels 1 and outer plate car-
tridge 2.
1
NOTE:
Align the insert cartridge projection a with
the hole b in the water pump housing.
6
A
2 7
8
2. Install the Woodruff key 3 and impeller
4 to the drive shaft.
S6AG6380
9
6AU3K11 6-36

LOWR
Lower unit
4. Install the water pump housing assembly
7 into the lower case, and then install F
F
the rubber seal 8.
N
0 0 N
R
LT
R
572
A
9 S6AU6135
8
3. Install the lower unit to the upper case,

7
and then tighten the lower case mounting
bolts 1 to the specified torque.
9
LT
572 3 2
LT
4
572 S6AU6134 2
CAUTION:
Do not turn the drive shaft counterclock-
wise, otherwise the water pump impeller 1
may be damaged.
LT
S6AU6136
572
NOTE:
• Apply grease to the inside of the water NOTE:
pump housing. • Before installing the lower unit to the upper
• While turning the drive shaft clockwise, case, install the dowels 2 into the lower
push down on the water pump housing and case.
install it. • Before installing the lower unit, make sure
• Align the projections on the rubber seal 8 that the locknut is removed from the shift
with the holes in the water pump housing. rod.
• When installing the lower unit, make sure
that the water pipe 3 is inserted securely
5. Tighten the water pump housing bolts 9 into the rubber seal 4.
and = to the specified torque.
Water pump housing bolt 9 and =: Lower case mounting bolt 1:

18 N·m (1.8 kgf·m, 13.3 ft·lb)
T.
18 N·m (1.8 kgf·m, 13.3 ft·lb)

T.
R.
R.
Installing the lower unit 6

4. Install the locknut 5, and then screw the
1. Set the shift lever to the R position. (H adjusting nut 6 onto the shift rod 7.
model)
Set the remote control lever to the R
position. (R model)
2. Set the shift rod to the R position.
6-37 6AU3K11

D 0 A
5
7
a 1
D
Screwed-in length a:
S6AU6059 S6AU6139
2
8.0–9.0 mm (0.31–0.35 in)
5. Tighten the locknut 5.
NOTE:
After connecting the shift rod, check that the
3
gear shift operates properly.
6. Install the anode 8 and cooling water

inlet covers 9, and then tighten the
WARNING
S6AU6062
4
anode bolt to the specified torque.
5
model)
9 8
NOTE:
If the holes in the propeller nut do not align
with the cotter pin hole, tighten the nut until
6
they are aligned.
9 LT
572 Propeller nut:
21 N·m (2.1 kgf·m, 15.5 ft·lb)
7
T.
R.
S6AU6138
Anode bolt:
8 N·m (0.8 kgf·m, 5.9 ft·lb)
8
T.
rect level.
R.
7. Install the propeller = and propeller nut Recommended gear oil:

A. Place a block of wood between the Hypoid gear oil
anti-cavitation plate and propeller to keep
the propeller from turning, and then
tighten the nut to the specified torque.
API: GL-4
SAE: 90
Gear oil quantity:
9
370 cm3
(12.51 US oz, 13.05 Imp oz)
6AU3K11 6-38

LOWR
Lower unit
Shimming (high thrust model) 6
T3
M1
M4 T2
M2 T1 M3
S6AU6141
6-39 6AU3K11

Shimming (high thrust model)
Shimming 6
Shim thickness
Calculated number
NOTE: (mm)
• Shimming is not required when assembling 1.14–1.20 1.13
the original lower case and inner parts.
• Shimming is required when assembling the
original inner parts and a new lower case.
• Shimming is required when replacing the
1.21–1.30

1.20
1
inner part(s). 1.13 and 1.20 mm
Selecting the pinion shim

1. Measure the thickness (M1) of the roller
6
Selecting the forward gear shim
1. Turn the taper roller bearing outer race
6 2
1 2 or 3 times to seat the rollers, and
bearing.
3
then measure the bearing height (M2) as
shown.
2
1
4
M1
S6AU6142
M2
5
NOTE:
• Select the shim thickness (T3) by using the
specified measurement(s) and the calcula-
tion formula.
NOTE:
3 S6AG6470J

6
• Measure the roller bearing at 4 points to
7
tion formula.
find the thickness average. • Measure the bearing outer race at 4 points
to find the height average.
Digital caliper 1: 90890-06704

Digital caliper 2: 90890-06704
2. Calculate the pinion shim thickness.
Calculation formula:
Shimming plate 3: 90890-06701
2. Calculate the forward gear shim thick-

8
ness.
Pinion shim thickness (T3) =
6.05 – M1
3. Select the pinion shim(s) (T3) as follows.

Calculation formula:
Forward gear shim thickness (T1) =
16.50 – M2
9
6AU3K11 6-40

LOWR
Lower unit
3. Select the forward gear shim(s) (T1) as
follows. 1 2
10 mm
Shim thickness (0.39 in)
Calculated number
(mm)
0.00–0.10 — M3’ M3
0.11–0.20 0.10
0.21–0.30 0.20
0.31–0.40 0.30 S6AG6490J
0.41–0.50 0.40 M3 = M3’ – 10 mm
NOTE:
Available shim thicknesses: Measure the propeller shaft housing at 4
0.10, 0.20, 0.30, and 0.40 mm points to find the height average.
Example:
If “T1” is 0.23 mm, then the forward gear Digital caliper 1: 90890-06704
shim thickness is 0.20 mm. Shimming plate 2: 90890-06701
If “T1” is 0.30 mm, then the forward gear
shim thickness is 0.20 mm. 3. Turn the ball bearing 2 or 3 times, and
then measure the height from the ball
Selecting the reverse gear shim 6
bearing (M4) as shown.
1. Remove the reverse gear and reverse
gear shim(s) from the propeller shaft
housing.
1
2. Measure the propeller shaft housing
height (M3) as shown.
2
1
S6AG6500
S6AG6480
6-41 6AU3K11

Shimming (high thrust model) / Backlash (high thrust model)
Backlash (high thrust model) 6
2 1 Measuring the forward and reverse

10 mm
(0.39 in) gear backlash 6
M4’ M4
NOTE:
• Remove the water pump assembly before
measuring the backlash.
1
• Secure the drive shaft housing to the lower
M4 = M4’ – 10 mm
NOTE:
S6AG6510J
case using 6 bolts (M8 × 25 mm).
1. Install the lower unit onto a repair stand. 2

2. Set the shift rod to the N position at the
3
lower unit.
tion formula.
• Measure the height from the ball bearing at F F
4 points to find the height average.
N
4
N
4. Calculate the reverse gear shim thick- R

ness. R
Calculate formula: S6AU6130

Reverse gear shim thickness (T2) =
58.05 – (M3 – M4)
5. Select the reverse gear shim(s) (T2) as

3. Turn the lower unit so that the propeller
shaft is facing down.
5
follows. 4. Install the special service tools.
Calculated number
0.00–0.10
Shim thickness
(mm)
—
6
0.11–0.20 0.1
0.21–0.30
0.31–0.32
0.2
0.3 7
0.1, 0.2, and 0.3 mm
8
9
6AU3K11 6-42

LOWR
Lower unit
5. Tighten the center bolt 1 to the specified
torque while turning the drive shaft. NOTE:
Install the dial gauge so that the plunger tip
a is aligned with the mark b on the back-
lash indicator.
Backlash indicator 4: 90890-06706

Magnet base plate 5: 90890-07003
Dial gauge set 6: 90890-01252
3 Magnet base B 7: 90890-06844
2
1 8. Slowly turn the drive shaft clockwise and
counterclockwise and measure the back-
lash when the drive shaft stops in each
S6AU6152 direction.
NOTE:
Center bolt 1: 90890-06504 • Pull the drive shaft downward, and then
Stopper guide plate 2: 90890-06501 turn it.
Bearing housing puller claw S 3: • Measure the backlash at 4 points to find the
90890-06564 average.
Center bolt 1:
Forward gear backlash:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
T.
R.
0.76–2.30 mm (0.0299–0.0906 in)
6. Turn the lower unit upside down.

7. Install the backlash indicator onto the forward gear backlash is out of specifica-
drive shaft (12.8 mm [0.50 in] in diame- tion.
ter), and then install the dial gauge. Forward gear
Shim thickness
backlash
Less than To be decreased by
0.76 mm (0.0299 in) (1.53 – M) × 0.39
2.30 mm (0.0906 in) (M – 1.53) × 0.39
M: Measurement
5 Available shim thicknesses:

0.10, 0.20, 0.30, and 0.40 mm
7 10. Remove the special service tools from

a 4 the propeller shaft.
6
b
S6AU6154
6-43 6AU3K11

Backlash (high thrust model)
11. Install the propeller, spacer 8, and nut,
without installing the spacer 9. Reverse gear backlash:
0.76–2.30 mm (0.0299–0.0906 in)
9
reverse gear backlash is out of specifica-
tion.
1
8
Reverse gear
S6AU6155
backlash
Less than
Shim thickness
To be decreased by
0.76 mm (0.0299 in) (1.53 – M) × 0.39
2
12. Tighten the propeller nut to the specified
torque.
Propeller nut:
2.30 mm (0.0906 in) (M – 1.53) × 0.39
M: Measurement 3
2 N·m (0.2 kgf·m, 1.5 ft·lb)
T.

R.
4
0.1, 0.2, and 0.3 mm
13. Slowly turn the drive shaft clockwise and
counterclockwise and measure the back- 15. Turn the lower unit upright.
lash when the drive shaft stops in each
direction. 16. Remove the special service tools and
5
propeller, and then install the water pump
assembly.
NOTE:
To install the water pump assembly, see
“Installing the water pump” (6-36).
rect level.
6
7
S6AU6156
8
NOTE:
• Pull the drive shaft downward, and then
turn it.
• Measure the backlash at 4 points to find the
average.
9
6AU3K11 6-44

BRKT
Bracket unit
Tiller handle (short)........................................................................................7-1

Removing the tiller handle ......................................................................... 7-3
Installing the tiller handle ...........................................................................7-3
Tiller handle (long) ......................................................................................... 7-5

Removing the tiller handle ......................................................................... 7-8
Installing the tiller handle ...........................................................................7-8
Friction plate (H model) ............................................................................... 7-11

Disassembling the friction plate...............................................................7-12
Assembling the friction plate.................................................................... 7-12
Bottom cowling ............................................................................................ 7-14
Upper case and steering arm...................................................................... 7-17

Removing the upper case........................................................................7-21
Disassembling the upper case ................................................................7-21
Checking the exhaust manifold, oil pan, and exhaust guide ................... 7-22
Checking the oil strainer ..........................................................................7-22
Assembling the upper case ..................................................................... 7-22
Removing the steering arm ..................................................................... 7-23
Installing the steering arm ....................................................................... 7-23
Installing the upper case..........................................................................7-24
Clamp bracket and swivel bracket (MT model) .........................................7-26

Removing the clamp bracket ................................................................... 7-28
Disassembling the swivel bracket............................................................ 7-28
Assembling the swivel bracket ................................................................7-29
Installing the clamp bracket ..................................................................... 7-30
Clamp bracket and swivel bracket (PT model)..........................................7-31

Removing the PT unit .............................................................................. 7-33
Removing the clamp bracket ................................................................... 7-33
Installing the clamp bracket ..................................................................... 7-34
Installing the PT unit ................................................................................ 7-34
PT motor ....................................................................................................... 7-36

Disassembling the PT motor ................................................................... 7-37
Checking the PT motor............................................................................7-38
Checking the brush holder and brush......................................................7-39
Assembling the PT motor ........................................................................7-39
6AU3K11

PT gear pump ...............................................................................................7-41
Disassembling the gear pump .................................................................7-44
Checking the gear pump .........................................................................7-44
Checking the valve seal...........................................................................7-44
Checking the filter....................................................................................7-44
Assembling the gear pump...................................................................... 7-45 1
PT cylinder.................................................................................................... 7-47
Disassembling the tilt cylinder .................................................................7-49
Checking the tilt cylinder and piston ........................................................ 7-49
Assembling the tilt cylinder ...................................................................... 7-50
Bleeding the PT unit ................................................................................ 7-52
2
3
PT electrical system ....................................................................................7-54
Checking the fuse....................................................................................7-54
Checking the PT relay ............................................................................. 7-54
Checking the PT switch ...........................................................................7-55
4
5
6
7
8
9
6AU3K11

BRKT
Bracket unit
Tiller handle (short) 7
1
22 N · m (2.2 kgf · m, 16.2 ft · Ib)
T.
R.
7
3
4
5
6
8
10
11
12 A
11
A
13
2
2 9 A
36 N · m (3.6 kgf · m, 26.6 ft · Ib)

T.
R.
7
14
S6AU7111

1 Throttle cable 2
2 Nut 2
3 Nut 1
4 Plate 1
5 Bushing 1
6 Plug 1 M model
7 Engine start button 1 E model
8 Tiller handle bracket 1
9 Stud bolt 2
10 Bushing 1
11 Washer 2
12 Wave washer 2
13 Bushing 1
14 Tiller handle assembly 1
7-1 6AU3K11

Tiller handle (short)
7
2 N · m (0.2 kgf · m, 1.5 ft · Ib)

1
T.
1
R.
6
3
6
2
2
5
14
A
3
A
4
A
13
15
12
11
8
9
10
5
7
3 N · m (0.3 kgf · m, 2.2 ft · Ib) S6AU7112

6
T.
R.

1 Throttle cable 2
2
3
4
5
Tiller handle
Throttle friction adjuster
Cotter pin
Friction piece
1
1
1
1
7
6 Engine shut-off switch 1
7
8
9
10
Screw
Grip
Washer
Spring
1
1
1
1
ø5 × 20 mm
8
11 Washer 1
12
13
14
15
Bushing
Throttle shaft
Plate
Screw
1
1
1
2 ø5 × 11 mm
9
6AU3K11 7-2

BRKT
Bracket unit
Removing the tiller handle 7 3. Install the engine shut-off switch 3 to the
1. Disconnect the engine shut-off switch tiller handle 4, and then tighten the nut
leads and engine start button leads (E 5 to the specified torque. Pass the
model). engine shut-off switch lead through a
hole in the pivot section of the tiller han-
NOTE: dle.
To disconnect the leads, see “Electrical com-
ponent and wiring harness routing” (8-1). 5
4
2. Disconnect the throttle cables 1 from the
throttle cam 2.
2
3
S6AU7119
1
6 4
a
S6AU7117
3. Remove the tiller handle.
NOTE:
See the exploded diagram for disassembly S6AU7120
(7-2).
NOTE:
Route the engine shut-off switch lead 6 as
Installing the tiller handle 7
shown, making sure to fit it securely into the
1. Assemble the tiller handle. notch a in the tiller handle 4.
NOTE:
See the exploded diagram for assembly (7- Engine shut-off switch nut 5:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
T.
R.
2).
4. Connect the throttle cable ends to the

2. Install the throttle friction adjuster 1, and throttle pulley 7.
then install the cotter pin 2.
8
7
2
1 S6AU7121
S6AU7118
7-3 6AU3K11

Tiller handle (short)
NOTE:
Make sure that the ends b of the outer throt-
tle cables 8 are fitted securely into the holes
in the pivot section of the tiller handle as
shown. 1
5. Install the tiller handle assembly to the
tiller handle bracket, and then tighten the
nut to the specified torque.
Tiller handle assembly nut:

2
22 N·m (2.2 kgf·m, 16.2 ft·lb)
T.
R.
6. Install the tiller handle assembly to the

steering bracket, and then tighten the
nuts to the specified torque.
3
Tiller handle bracket nut:
36 N·m (3.6 kgf·m, 26.6 ft·lb) 4
T.
R.
7. Connect the throttle cables to the throttle

cam.
NOTE:
• To adjust the throttle cables, see “Adjusting
the throttle cable (H model)” (3-7).
5
• When adjusting the throttle cables, make
sure that the ends b of the outer cables
are not pulled out of the holes in the pivot
section of the tiller handle.
6
8. Connect the engine shut-off switch leads
and engine start button lead (E model).
7
8
9
6AU3K11 7-4

BRKT
Bracket unit
Tiller handle (long) 7
1 22 N · m (2.2 kgf · m, 16.2 ft · Ib)
T.
R.
10 N · m (1.0 kgf · m, 7.4 ft · Ib)
T.
R.
10
7
5 8
9
A
6
2 11
13
14
15 A
14
3
16
12
4
4 10
36 N · m (3.6 kgf · m, 26.6 ft · Ib)

17
T.
R.
S6AU7001

1 Throttle cable 2
2 Nut 1
3 Shift cable 1
4 Nut 2
5 Self-locking nut 1
6 Nut 1
7 Plate 1
8 Bushing 1
9 Plug 1 M model
10 Engine start button 1 E model
11 Tiller handle bracket 1
12 Stud bolt 2
13 Bushing 1
14 Washer 2
15 Wave washer 2
16 Bushing 1
17 Tiller handle assembly 1
7-5 6AU3K11

Tiller handle (long)
7
12 13
3 N · m (0.3 kgf · m, 2.2 ft · Ib) 9
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
1
T.
R.
10
T.
R.
2 N · m (0.2 kgf · m, 1.5 ft · Ib)
T.
R.
1 14 15
2 11
8
33
34 17 18
2
32 16 17
2
1
3
31 34
6 N · m (0.6 kgf · m, 4.4 ft · Ib) 3
T.
R.
LT
19
571
LT 1
4 21
4
571
5 10 20
6 A
30
A 6 A
7 A
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
T.
R.
23
A
28
29
5
22 27
10 30
26
3 N · m (0.3 kgf · m, 2.2 ft · Ib) 24
25 S6AU7110
6
T.
R.

1 Shift lever 1
2
3
4
5
Screw
Bolt
Washer
Wave washer
3
1
1
1
ø6 × 10 mm
M8 × 30 mm
7
6 Bushing 2
7
8
9
10
Shift lever cam
E-clip
Holder
Bolt
1
1
1
4 M6 × 16 mm
8
11 Holder 1
12
13
14
15
Shift cable
Throttle cable
Throttle friction adjuster
Cotter pin
1
2
1
1
9
16 Friction piece 1
17 Engine shut-off switch 1
6AU3K11 7-6

BRKT
Bracket unit
7
12 13
3 N · m (0.3 kgf · m, 2.2 ft · Ib) 9
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
T.
R.
10
T.
R.
2 N · m (0.2 kgf · m, 1.5 ft · Ib)
T.
R.
1 14 15
2 11
34 17 18
8
33
32 16 17
2
31 34
1 6 N · m (0.6 kgf · m, 4.4 ft · Ib)
3
T.
R.
LT
19
571
LT 1
571 4 21
5 10 20
6 A
30
A 6 A
7 A
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
T.
R.
A
29
28
23
22 27
10 30
26
3 N · m (0.3 kgf · m, 2.2 ft · Ib)
25 S6AU7110
24
T.
R.

18 Tiller handle 1
19 Plate 1
20 Bolt 1 M6 × 20 mm
21 Spring 2
22 Screw 1 ø5 × 20 mm
23 Grip 1
24 Washer 1
25 Spring 1
26 Washer 1
27 Bushing 1
28 Throttle shaft 1
29 Plate 1
30 Plastic tie 2
31 PT switch 1 PT model
32 Bracket 1 PT model
33 Screw 2 ø6 × 16 mm/PT model
34 Screw 3 ø6 × 16 mm/PT model
7-7 6AU3K11

Removing the tiller handle 7
NOTE:
1. Disconnect the engine shut-off switch
See the exploded diagram for assembly (7-
leads, engine start button leads (E
6).
1
model), and PT switch leads (PT model).
2. Remove the manual starter. (M model) 2. Install the shift lever cam 1 and cam
Remove the PT relay, PT relay bracket springs 2.
(PT model), starter relay, and starter
2
relay bracket. (E model)
NOTE:
To remove the parts, see “Electrical compo-
nent and wiring harness routing” (8-1).
A
3. Remove the nut 1 and disconnect the

shift cable 2. 2
A
1
S6AU7122
3
1
2
3. Install the throttle friction adjuster 3, and
then install the cotter pin 4.
4
4
S6AU7003
5
4. Disconnect the throttle cables 3 from the
throttle cam 4.
2
4
3 S6AU7005
6
3
7
5. Remove the tiller handle.
S6AU7004
8
NOTE:
See the exploded diagram for disassembly
(7-6).
9
Installing the tiller handle 7
1. Assemble the tiller handle.
6AU3K11 7-8

BRKT
Bracket unit
4. Install the engine shut-off switch 5 to the
tiller handle 6, and then tighten the nut 6 E
C
7 to the specified torque. Pass the
engine shut-off switch lead through a
hole in the pivot section of the tiller han-
dle. b b
5. Install the PT switch 8 to the bracket 9,
and then tighten the bracket screws 0 to a
the specified torque. (PT model) D S6AU7007
6. Install the PT switch 8 to the tiller handle NOTE:

6, and then tighten the PT switch • When routing the engine shut-off switch
screws A and B to the specified torque. lead, make sure that it does not contact the
(PT model) throttle shaft D in the area a.
• Make sure that the ends b of the outer
throttle cables E are fitted securely into the
7 holes in the pivot section of the tiller handle
B as shown.
6
0 8. Install the tiller handle assembly to the
tiller handle bracket, and then tighten the
9 nuts to the specified torque.
A 5
Tiller handle assembly nut:
8 10 N·m (1.0 kgf·m, 7.4 ft·lb)
T.
R.
Tiller handle assembly self-locking

nut: 22 N·m (2.2 kgf·m, 16.2 ft·lb)
S6AU7006
NOTE: 9. Install the tiller handle assembly to the

Tighten the screws A, and then tighten the steering bracket, and then tighten the
screw B. nuts to the specified torque.
Tiller handle bracket nut:

Engine shut-off switch nut 7: 36 N·m (3.6 kgf·m, 26.6 ft·lb)
T.
R.
2 N·m (0.2 kgf·m, 1.5 ft·lb)

T.
R.
PT switch bracket screw 0: 10. Connect the throttle cables to the throttle
4 N·m (0.4 kgf·m, 3.0 ft·lb) cam.
PT switch screw A and B:
6 N·m (0.6 kgf·m, 4.4 ft·lb) NOTE:
• To adjust the throttle cables, see “Adjusting
7. Connect the throttle cable ends to the the throttle cable (H model)” (3-7).
throttle pulley C. • When adjusting the throttle cables, make
sure that the ends b of the outer cables
are not pulled out of the holes in the pivot
section of the tiller handle.
7-9 6AU3K11

11. Connect the engine shut-off switch leads,
engine start button leads (E model), and
PT switch leads (PT model).
1
2
3
4
5
6
7
8
9
6AU3K11 7-10

BRKT
Bracket unit
Friction plate (H model) 7
1 2 1
2 3
2
6
3
4
7 N · m (0.7 kgf · m, 5.2 ft · Ib)
T.
5
R.
7 N · m (0.7 kgf · m, 5.2 ft · Ib)
T.
R.
4
6 5
TOP
7
8
13
3
14 9.0 mm
13
14 3.8 mm
9
10 7 9 8.0 mm
18 N · m (1.8 kgf · m, 13.3 ft · Ib) 11
T.
R.
5.4 mm
LT
6 N · m (0.6 kgf · m, 4.4 ft · Ib) 572
T.
R.
7 N · m (0.7 kgf · m, 5.2 ft · Ib) 12 S6AU7009

T.
R.

1 Steering lock shaft 1
2 Bracket 1
3 Collar 1 Short
4 Bolt 2 M5 × 14 mm
5 Washer 2
6 Steering lock lever 1
7 Friction piece 2
8 Friction plate 1
9 Collar 1 Long
10 Steering lock washer 1
12 Bolt 1 M5 × 20 mm
13 Washer 2
14 Bolt 2 M8 × 16 mm
7-11 6AU3K11

Friction plate (H model)
Disassembling the friction plate 7
1. Remove the friction plate bolts 1 and 2, b c

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

2
2 position b, turn it less than 90° c until it is
3
S6AG7A90
aligned.
NOTE:
Before removing the friction plate bolts 1,
2. Assemble the friction plate assembly.
turn the outboard motor all the way to port or
starboard.
4
NOTE:
• See the exploded diagram for assembly (7-
11).
2. Disassemble the friction plate assembly.
• Face the “TOP” mark on the steering lock
NOTE: lever up.
See the exploded diagram for disassembly
(7-11).
• Be sure to install the collars in the correct
positions; the collar lengths are different.
5
Assembling the friction plate 7
1. Turn the steering lock shaft 1 until it is

flush with the end a of the nut 2 on the
bracket. 6
1 2
1
a
7
a
2 S6AG7B00 8
9
6AU3K11 7-12

BRKT
Bracket unit
3. Install the friction plate assembly onto the
swivel bracket and tighten the friction NOTE:
plate bolts 3 and 4 temporarily. To check and adjust the friction plate, see
“Checking the steering operation (H model)”
(3-12).
Friction self-locking nut 6:

6 N·m (0.6 kgf·m, 4.4 ft·lb)
T.
R.
4 4
3
S6AU7013
NOTE:
Before installing the friction plate bolts 4,
turn the outboard motor all the way to port or
starboard.
4. Tighten the friction plate bolts 3 and 4

to the specified torques.
Friction plate bolt (M8) 3:

18 N·m (1.8 kgf·m, 13.3 ft·lb)
T.
R.
Friction plate bolt (M5) 4:

7 N·m (0.7 kgf·m, 5.2 ft·lb)
5. Move the steering lock lever 5 to posi-

tion d, and then tighten the self-locking
nut 6 to the specified torque.
S6AG7B20
7-13 6AU3K11

Friction plate (H model) / Bottom cowling
Bottom cowling 7
3 N · m (0.3 kgf · m, 2.2 ft · Ib)

29
T.
R.
2 3 4
5
6
7
12
A
16
13 14 18
26
27
26
30
1
8 15 19
1
9
21 21
17 20 28
15
A
31
2
11 14 32
51
49
47
10 22
21
23
32
24
32 33 3
46 34
25
50
14
45
32
4
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
T.
R.
5
35 37
38 36
44
35 39
36 35
48 39
24
43
2 N · m (0.2 kgf · m, 1.5 ft · Ib) 42 41 40 36 S6AU7015
6
T.
R.

1 Flushing hose 1 For Europe
2
3
4
5
Grommet
Grommet
Grommet
Shift lever
1
1
1
1
For Oceania
PT model 7
6 Bolt 1 M5 × 16 mm
7
8
9
10
O-ring
Bolt
Retaining plate
Grommet
1
2
1
1
Not reusable
M6 × 25 mm
H model
8
11 Grommet 1 R model
12
13
14
15
Holder
Holder
Bolt
Bracket
1
1
3
2
PT model
M6 × 25 mm
9
16 Start-in-gear protection cable 1 M model
17 Shift rod lever 1
6AU3K11 7-14

BRKT
Bracket unit
7
3 N · m (0.3 kgf · m, 2.2 ft · Ib)

29
T.
R.
6 A 30
5 16
3 4 26
2 13 14 18
7 27
12 26
8 15 19
17 20 28
9 A
1 21 21
15
31
11 14 32
10 22 24
21 32 33
49
51 23
32
47 46 34
25
14
50 32
45 8 N · m (0.8 kgf · m, 5.9 ft · Ib)
T.
R.
35 37
38 36
44
35 39
36 35
48 39
43 24
2 N · m (0.2 kgf · m, 1.5 ft · Ib) 42 41 40 36 S6AU7015
T.
R.

18 Bolt 1 M6 × 20 mm
19 Bracket 1
20 Clip 1
21 Bolt 3 M6 × 20 mm/PT model
22 Bracket 1 PT model
23 Spring 2
24 Shift rod 1
25 Grommet 1
28 Bracket 1 E model
29 Bracket 1 E model
30 Starter relay 1 E model
31 Cooling water hose 1
32 Bolt 4 M6 × 35 mm
33 Cowling lock lever 1
34 Bolt 1 M6 × 12 mm
7-15 6AU3K11

Bottom cowling
7
3 N · m (0.3 kgf · m, 2.2 ft · Ib)

29
T.
R.
2 3 4
5
6
7
12
A
16
13 14 18
26
27
26
30
1
8 15 19
1
9
21 21
17 20 28
15
A
31
2
11 14 32
51
49
47
10 22
21
23
32
24
32 33 3
46 34
25
50
14
45
32
4
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
T.
R.
5
35 37
38 36
44
35 39
36 35
48 39
24
43
2 N · m (0.2 kgf · m, 1.5 ft · Ib) 42 41 40 36 S6AU7015
6
T.
R.

35 Grommet 4
36
37
38
39
Collar
Rubber seal
Water outlet
Grommet
4
1
1
2
7
40 Grommet 1 H model
41
42
43
44
Grommet
Screw
Bracket
Fuel joint
1
2
1
1
R model
ø6 × 20 mm
H model
8
45 Bracket 1 H model
46
47
48
49
Bolt
Cable guide
Adapter
Bolt
2
1
1
2
M6 × 10 mm/H model
H model
M6 × 12 mm/R model
9
50 Nut 2 R model
51 Bracket 1 R model
6AU3K11 7-16

BRKT
Bracket unit
Upper case and steering arm 7
20 N · m (2.0 kgf · m, 14.8 ft · Ib)
T.
R.
A
8
10 9
11
1 2
3 12
A
A
15 14 13
7 16
4 14
A 16
5 15
6
3 N · m (0.3 kgf · m, 2.2 ft · Ib) 17 20
T.
R.
21
1 7 N · m (0.7 kgf · m, 5.2 ft · lb) LT
UP
2 12 N · m (1.2 kgf · m, 8.9 ft · Ib) 572

T.
R.
3 14 N · m (1.4 kgf · m, 10.3 ft · Ib) BOW 19 18
S6AU7016

1 Steering arm 1 L-transom model/S-transom model
2 Washer 1
3 Bushing 1 1
4 Bushing 2 1
6 Plate 1
7 Grease nipple 1
8 Water seal rubber 1
9 Water pipe 1 L-transom model/S-transom model
10 Hose 1
11 Nut 2
12 Plate 1
13 Upper case assembly 1 L-transom model/S-transom model
14 Rubber damper 2
15 Mount housing 2
16 Nut 4
17 Rubber damper 1
7-17 6AU3K11

Upper case and steering arm
7
20 N · m (2.0 kgf · m, 14.8 ft · Ib)
T.
R.
A
8
10 9
11
1 2
3 12
2
A
A
15 14 13
3
7 16
A
4
16
14 4
5 15
6
3 N · m (0.3 kgf · m, 2.2 ft · Ib) 17 20
5
T.
R.
21
1 7 N · m (0.7 kgf · m, 5.2 ft · lb) LT
UP
2 12 N · m (1.2 kgf · m, 8.9 ft · Ib) 572

T.
R.
3 14 N · m (1.4 kgf · m, 10.3 ft · Ib) BOW 19 18

S6AU7016
6
18 Bolt 2 M6 × 55 mm
19
20
21
Ground lead
Bolt
Screw
1
2
1
M6 × 85 mm
ø5 × 7 mm 7
8
9
6AU3K11 7-18

BRKT
Bracket unit
7
11 N · m (1.1 kgf · m, 8.1 ft · Ib) 8 8 11 N · m (1.1 kgf · m, 8.1 ft · Ib)
T.
R.
T.
R.
LT
1 572
LT 10 LT
LT 11 9 572
572
572
2
12 E
1207B
15
17
A
7 A
13 16
A
14
18
1104J 21 N · m (2.1 kgf · m, 15.5 ft · Ib)
T.
R.
3 19
26 LT
20 572
7 22
23 26
UP 24
7 LT
25
572
4
LT 18 N · m (1.8 kgf · m, 13.3 ft · Ib) LT
21
T.
R.
5 572 572 24 N · m (2.4 kgf · m, 17.7 ft · Ib)

T.
R.
8 N · m (0.8 kgf · m, 5.9 ft · Ib) S6AU7017

6
T.
R.

1 Bolt 2 M6 × 14 mm
2 Exhaust manifold 1
3 Upper case 1 L-transom model/S-transom model
4 Plate 1
5 Grommet 1
6 Bolt 1 M6 × 8 mm
7 Bolt 4 M8 × 35 mm
8 Bolt 2 M6 × 25 mm
9 Upper mount 1
10 Bolt 1 M8 × 14 mm
11 Washer 1
12 Exhaust guide 1
15 Grommet 1
16 Oil strainer 1
17 Baffle plate 1
7-19 6AU3K11

7
11 N · m (1.1 kgf · m, 8.1 ft · Ib) 8 8 11 N · m (1.1 kgf · m, 8.1 ft · Ib)
T.
R.
1
T.
R.
LT
1 572
LT 10 LT
LT 11 9 572
572
572
2
12 E
1207B
A
15
17
2
7
3
A
13 16
A
14
18
1104J 21 N · m (2.1 kgf · m, 15.5 ft · Ib)
T.
4
R.
3 19
26 LT
20 572
7 LT
7
572
UP
22
23
24
25
26
5
4
LT 18 N · m (1.8 kgf · m, 13.3 ft · Ib) LT
6
21
T.
R.
5 572 572 24 N · m (2.4 kgf · m, 17.7 ft · Ib)

T.
R.
8 N · m (0.8 kgf · m, 5.9 ft · Ib) S6AU7017

6
T.
R.

18 Dowel 2
19
20
21
22
Oil pan
Rubber seal
Screw
Grommet
1
1
1
1
ø5 × 7 mm 7
23 Plate 1
24
25
26
Gasket
Drain bolt
Bolt
1
1
2
Not reusable
M8 × 30 mm
8
9
6AU3K11 7-20

BRKT
Bracket unit
Removing the upper case 7
NOTE:
• Drain the engine oil before removing the
upper case assembly.
• Be sure to remove the shift rod assembly 1
before removing the upper case assembly 2
from the clamp bracket.
1. Remove the ground lead terminal 1 from

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

then remove the rubber dampers 3. 3
3. Remove the water pipe 4.
4. Remove the upper mounting nuts 5, and

S6AU7019
then remove the upper case assembly.
4. Remove the oil pan 4 from the exhaust

4 5 guide 5, baffle plate 6, and gasket 7.
5. Remove the oil strainer 8 from the

exhaust guide.
1
6. Remove the oil seal 9 from the exhaust
2 guide.
3
3
5
2
9
3
7
S6AU7018
6 8
Disassembling the upper case 7
4
1. Remove the engine oil drain bolt and
grommet.
2. Remove the upper mount 1 from the

upper case assembly.
S6AU7023
3. Remove the oil pan assembly 2 from the
upper case 3.
7. Remove the exhaust manifold = from
the upper case 3.
7-21 6AU3K11

Exhaust manifold bolt 3:

11 N·m (1.1 kgf·m, 8.1 ft·lb)
T.
R.
3 0
2. Install a new oil seal 4 into the exhaust
guide 5. 1
A
6
2
4
7
5
3
S6AU7022
Checking the exhaust manifold, oil S6AU7025
pan, and exhaust guide 7
1. Check the exhaust manifold, oil pan, and Driver rod L3 6: 90890-06652
exhaust guide. Replace if cracked or cor-
roded.
NOTE:
90890-06614
3. Install the oil strainer 8, the dowels 9,

4
Clean the removed parts before checking and a new gasket = onto the exhaust
5
them. guide 5.
Checking the oil strainer 7

8
1. Check the oil strainer. Clean if there is
6
dirt or residue.
E
Assembling the upper case 7 0
1. Install the exhaust manifold 1 to the
9
upper case 2, and then tighten the
9
exhaust manifold bolts 3 to the specified
torque.
1207B 3
5 7
1
S6AU7026
LT
572
8
2
9
S6AU7028
6AU3K11 7-22

BRKT
Bracket unit
4. Install the baffle plate A and rubber seal
B to the oil pan C, and then tighten the Upper case bolt G:
oil pan bolts D to the specified torque. 18 N·m (1.8 kgf·m, 13.3 ft·lb)
T.
R.
Upper mount bolt I:
D 11 N·m (1.1 kgf·m, 8.1 ft·lb)
LT
572
LT 7. Install the grommet and engine oil drain
572 bolt J, and then tighten the drain bolt to
C the specified torque.
A
Engine oil drain bolt J:
B
A 24 N·m (2.4 kgf·m, 17.7 ft·lb)
T.
R.
Removing the steering arm 7
1. Remove the steering arm 1 from the

swivel bracket 2 by pulling the arm off
S6AU7027
the bracket.
Oil pan bolt D:
21 N·m (2.1 kgf·m, 15.5 ft·lb) 2
T.
R.
5. Install the dowels E and oil pan assem-

bly F, and then tighten the upper case 1
bolts G to the specified torque.
6. Install the upper mount H, and then

tighten the upper mount bolts I to the
specified torque.
I F
LT S6AU7032
572
NOTE:
1104J H To disassemble the clamp brackets, see
E “Removing the clamp bracket” (7-28) or
E “Removing the clamp bracket” (7-33).
Installing the steering arm 7
LT
J 1. Install the washer 1 and bushing 1 2
572 onto the steering arm.
G
2. Place the swivel bracket 3 in an upright
position, and then install the steering arm
onto the swivel bracket.
S6AU7031
3. Install bushing 2 4, a new O-ring 5, and
NOTE: the plate 6 onto the swivel bracket.
Apply sealant (1104J) to the mating surface.
7-23 6AU3K11

NOTE:
Install the ground lead terminal 7 so that it is
3 within the range a (30°) shown.
5. Tighten the mount housing nuts 0 to the

specified torques in 3 stages and in the
1
sequence shown.
2
A
4 NOTE:
1 Tighten the mount housing nuts 0 evenly
5 and in the following order: 1–2–3–4.
A A 6
2
3
S6AU7033
6. Install the ground lead terminal A to the
4. Apply grease to the grease nipple 7 on swivel bracket.
the swivel bracket until it comes out from
the upper bushing a. 7. Install the water pipe B.
a
B 2
4
A
7 A
0
C
6
4 1
5
S6AG7740
0
NOTE:
To assemble the clamp brackets, see “Install-
ing the clamp bracket” (7-30) or “Installing the
5
4
6
9
6
clamp bracket” (7-34).
3
7
UP
Installing the upper case 7 8

7
BOW S6AU7035
1. Install the upper case assembly 1 to the
clamp bracket.
C A
3
2. Install the plate and upper mounting nuts
2, and then tighten the upper mounting
nuts to the specified torque. a
1 4
8
3. Install the ground lead terminal 3 to the 2 7 3
upper case as shown.
4. Install the rubber dampers 4 and 5

(front), and then install the mount hous-
A
S6AU7036 9
ings 6 and ground lead terminal 7
using the mount housing bolts 8 and 9
and the mount housing nuts 0.
6AU3K11 7-24

BRKT
Bracket unit
Upper mounting nut 2:

20 N·m (2.0 kgf·m, 14.8 ft·lb)
T.
R.
Mount housing nut 0:

1st: 7 N·m (0.7 kgf·m, 5.2 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
3rd: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
Grease nipple C:
3 N·m (0.3 kgf·m, 2.2 ft·lb)
7-25 6AU3K11

Upper case and steering arm / Clamp bracket and swivel bracket (MT model)
Clamp bracket and swivel bracket (MT model) 7
10
5 11
9
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
1
T.
R.
9
A
4
8
7
A A
12
9
11
10 2
6
19 N · m (1.9 kgf · m, 14.0 ft · Ib)

8
A
9 3
13
T.
R.
4
A
1 A
3
2 14
5
17 15
3 A
a b 16
LT
242
a b 3 N · m (0.3 kgf · m, 2.2 ft · Ib)
6
T.
R.
S6AU7037

2
3
4
5
Plate
Through tube
Nut
Clamp bracket
1
1
1
1 STBD
7
6 Collar 1
7
8
9
10
Tilt lock lever
Bushing
Bolt
Tilt stopper plate
1
2
4
2
8
11 Wave washer 2
12
13
14
15
Swivel bracket
Clamp bracket
Spring
Tilt pin
1
1
1
1
L-transom model/S-transom model
PORT
9
16 Bolt 1 M6 × 155 mm
17 Grease nipple 1
6AU3K11 7-26

BRKT
Bracket unit
7
3 6
a 3
1 7
7
2
1 b 10 8
A 7
b
6
A
7
7 8 9
a
12
5
13
7
4 11
16 14
10
15
14
17
17 S6AU7038

1 Tilt lever shaft 1
2 Tilt lock lever 1
3 Tilt lock rod 1 1 a>b
4 Tilt support bar 1
5 Stopper shaft 1
6 Tilt lever 1
7 E-clip 4
8 Spring 1 a>b
9 Swivel bracket 1 L-transom model/S-transom model
10 Tilt lock rod 2 1
11 Pin 1 1
12 Tilt lock plate 2 1
13 Pin 2 1
14 Spring 2
15 E-clip 1
16 Tilt lock plate 1 1
17 Collar 2
7-27 6AU3K11

Clamp bracket and swivel bracket (MT model)
Removing the clamp bracket 7
4 5 3
1. Remove the tilt pin 1, clamp bracket nut
2, and clamp bracket bolt 3.
3
2. Remove the tilt stopper plate bolts 4
(swivel bracket side).
1
1
3. Remove the self-locking nuts 5 and 6 2
plate 6.
4. Remove the through tube 7, tilt lock

lever 8, and collar 9, and then disas- NOTE:
S6AU7040
Unhook tilt lock rod 2 6 from the tilt lever 5

2
semble the clamp brackets.
when removing the lever.
NOTE:
Unhook tilt lock rod 1 0 from the tilt lock
lever 8 when removing the lever. 2. Remove the E-clip 7 from the stopper
shaft 8, and then pull out the shaft and
3
remove the tilt support bar 2.
5. Remove the tilt stopper plate bolts A
(clamp bracket side) and tilt stopper
plates B.
4
B 7
5
A
4
A
B
0 8
8
2 4 2
S6AU7041
6
5
9
5
1
7
6
7
Disassembling the swivel bracket

3 S6AU7039
7
8
1. Unhook the spring 1 from the tilt support
bar 2. Remove the E-clips 3 from the
tilt lever shaft 4, and then pull out the
shaft and remove the tilt lever 5. 9
6AU3K11 7-28

BRKT
Bracket unit
3. Remove the springs 9.
4. Remove the E-clip 0 from pin 2 A, and a a

then pull out the pin.
5. Remove the E-clip B from pin 1 C, and 8 8

then pull out the pin and remove the col-
lars D, tilt lock rod 2 E, tilt lock plate 1 1
F, and tilt lock plate 2 G.
5
A
C
G 7 2
S6AU7044
E NOTE:
After installing the E-clip, turn it to make sure
F 0 that it is installed securely.
B
3. Install the stopper shaft 9 and tilt sup-
port bar 0 to the swivel bracket A, and
then install the E-clip B.
D 9 S6AU7042
4. Hook tilt lock rod 2 C, the spring D, and

Assembling the swivel bracket
tilt lock rod 1 E onto the tilt lever F.
7
1. Assemble tilt lock plate 2 1, tilt lock plate

1 2, the collars 3, tilt lock rod 2 4, and 5. Install the tilt lever shaft G into the swivel
pin 1 5, and then install the E-clip 6. bracket A, making sure to pass the shaft
through the tilt support bar 0 and tilt
5 lever F, and then install the E-clips H.
1
6. Hook the spring D onto the tilt support
2
6 bar 0.
4
E
G
H A
A
3 S6AG7970
NOTE: F
After installing the E-clip, turn it to make sure
that it is installed securely.
B
D
9 H
2. Pass pin 2 7 through the swivel bracket
and tilt lock plate 2 1, and then install
0 C
the E-clip. Hook the springs 8 onto tilt A
lock plate 1 2, and then hook them onto S6AG7A20J
the holes a in the swivel bracket.
7-29 6AU3K11

Clamp bracket and swivel bracket (MT model)
3. Assemble the clamp brackets 5 and
NOTE: swivel bracket 6, and then install the
• See the exploded diagram for the installa- collar 7, clamp bracket bolt 8, and
tion directions of the spring D and tilt lock through tube 4 from the port side.
rod 1 E (7-27).
• Make sure that the E-clips are installed
securely.
NOTE:
When installing the through tube 4, hook tilt
lock rod 1 9 onto the tilt lock lever 0.
1
Installing the clamp bracket
1. Install the tilt stopper plates 1 and tilt
stopper plate bolts 2 (clamp bracket
side) to the clamp brackets, and then
7
4. Install the self-locking nut A onto the

through tube 4, and then tighten it to the
specified torque.
2
tighten the bolts to the specified torque.
Tilt stopper plate bolt 2:

Self-locking nut A:
19 N·m (1.9 kgf·m, 14.0 ft·lb)
3
T.
R.
8 N·m (0.8 kgf·m, 5.9 ft·lb)
T.
R.
5. Tighten the clamp bracket nut B.
A A
5
1
2
2
6. Install the tilt stopper plates 1 and tilt
stopper plate bolts C (swivel bracket
side) to the swivel bracket, and then
tighten the bolts to the specified torque.
4
C A 1
6 C Tilt stopper plate bolt C:
8 N·m (0.8 kgf·m, 5.9 ft·lb) 5
T.
R.
B
0
5 7. Install the tilt pin D.
A 7 4
9
0
3
8. Apply grease to all grease nipples until it
comes out from the areas a. 6
A a
8
LT
242
2. Tighten the self-locking nut 3 completely

D
S6AU7046 A
7
onto the shorter threaded end of the
8
a
through tube 4.
A
S6AU7048
A
NOTE:
a b 3 To check the tilt operation, see “Checking the
4 tilt system (MT model)” (1-17).
9
a b A
S6AG7801
6AU3K11 7-30

BRKT
Bracket unit
Clamp bracket and swivel bracket (PT model) 7
19 N · m (1.9 kgf · m, 14.0 ft · Ib) 17
T.
R.
1 24 N · m (2.4 kgf · m, 17.7 ft · Ib) a b
T.
R.
2
6 10
11
A
a b
12 14
3 A 15 3 N · m (0.3 kgf · m, 2.2 ft · Ib)
T.
4
R.
7 5 24 N · m (2.4 kgf · m, 17.7 ft · Ib)
T.
R.
12 16
8 A
LT 9 13
242
A 23
24
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
T.
R.
8 N · m (0.8 kgf · m, 5.9 ft · Ib)

T.
R.
25 17
A
2
25 22 1
18
19
28 5 4
29
26 20 9 A
27 A LT
242
A 21
8 7
A
24 18 N · m (1.8 kgf · m, 13.3 ft · Ib)

T.
R.
8 N · m (0.8 kgf · m, 5.9 ft · Ib) S6AU7049

T.
R.

1 Cap 2
3 Plate 1
4 Nut 2
5 Washer 2
6 Clamp bracket 1 STBD
7 Bolt 2 M8 × 16 mm
8 Washer 2
9 Collar 2
10 Shaft 1
11 Collar 1
12 Collar 2
13 Stopper 1 1
14 Swivel bracket 1
15 E-clip 1 Not reusable
16 Clamp bracket 1 PORT
17 Through tube 1
7-31 6AU3K11

Clamp bracket and swivel bracket (PT model)
7
19 N · m (1.9 kgf · m, 14.0 ft · Ib) 17
T.
1
R.
24 N · m (2.4 kgf · m, 17.7 ft · Ib) a b
1
T.
R.
2
6 10
11
A
a b
3
12
A
14
15 3 N · m (0.3 kgf · m, 2.2 ft · Ib)
2
T.
4
R.
7 5 24 N · m (2.4 kgf · m, 17.7 ft · Ib)
T.
R.
12 16
8
3
A
LT 9 13
242
A 23
24
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
T.
R.
8 N · m (0.8 kgf · m, 5.9 ft · Ib)

T.
R.
25 17
A
4
2
25 22 1
18
19
28 5 4
29
26 20 9 A
A
27
A
A
21
8 7
LT
242
5
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
6
24
T.
R.
8 N · m (0.8 kgf · m, 5.9 ft · Ib) S6AU7049

T.
R.

18 Stopper 2 1
19
20
21
22
Bolt
Anode
Shaft
Grease nipple
2
1
1
1
M6 × 25 mm
7
23 Ground lead 1
24
25
26
27
Bolt
Collar
PT unit
Collar
2
2
1
1
M6 × 10 mm
8
28 Plastic tie 1
29 Collar 1
9
6AU3K11 7-32

BRKT
Bracket unit
Removing the PT unit 7
6. Remove the PT unit 6, and then remove
1. Fully tilt the outboard motor up, and then the collar E.
support it with the tilt stop lever.
E
C
D 0
6
78
9 B 4
S6AG7771 5
WARNING
After tilting up the outboard motor, be 9
sure to support it with the tilt stop lever. A
8
Otherwise, the outboard motor could sud- 7
denly lower if the PT unit should lose fluid
pressure. S6AU7052
Removing the clamp bracket 7
NOTE:
1. Remove the ground lead terminal 1,
If the PT unit does not operate, open the
self-locking nuts 2, and through tube 3,
manual valve by turning it counterclockwise,
and then remove the clamp brackets 4.
and then tilt the outboard motor up manually.
2. Remove the plastic tie 1 from the clamp

bracket 2, and then pull out the PT
motor lead 3.
4
3
2
2 4
1
S6AG7770
3. Remove the bolt 4 and ground lead 5 3

from the PT unit 6. 2 S6AU7053
4. Remove the bolts 7, washers 8, collars NOTE:

9 and =, and shaft A. Be sure to remove the ground lead terminal
1 before removing the self-locking nuts 2.
5. Remove the E-clip B, shaft C, and collar
D, and then remove the upper end of the
tilt rod from the swivel bracket.
7-33 6AU3K11

Clamp bracket and swivel bracket (PT model)
Installing the clamp bracket 7
1. Tighten the self-locking nut 1 completely Self-locking nut 5:

19 N·m (1.9 kgf·m, 14.0 ft·lb)
T.
R.
onto the shorter threaded end of the
through tube 2. Ground lead bolt 7:
a
A
b 1
8 N·m (0.8 kgf·m, 5.9 ft·lb)
Anode bolt 8:
8 N·m (0.8 kgf·m, 5.9 ft·lb)
1
2 Stopper nut A:
2
24 N·m (2.4 kgf·m, 17.7 ft·lb)
Installing the PT unit 7
a b A 1. Fully tilt the outboard motor up, and then

support it with the tilt stop lever.
3
S6AG7800
2. Assemble the clamp brackets 3 and

swivel bracket 4, and then install the
through tube 2 from the port side.
3. Install the self-locking nut 5 onto the

through tube 2, and then tighten it to the
specified torque.
4
S6AU7056
4. Install the ground lead terminals 6 to the
brackets using the bolt 7 and bolts 8.
5. Install stopper 1 9, stopper 2 =, and the

WARNING
After tilting the outboard motor up, be
sure to support it with the tilt stop lever.
5
stopper nuts A.
5
A
4
A
6
3
A
9
3
2
7
8
7
0
8
A
6 B
S6AU7055 9
NOTE:
Install the anode B with the projection facing
towards the bow.
6AU3K11 7-34

BRKT
Bracket unit
2. Install the collar 1 onto the PT unit 2. 6. Pass the PT motor lead E through the
hole a in the clamp bracket (STBD).
3. Install the PT unit 2, collars 3 and 4,
shaft 5, and washers 6 onto the clamp 7. Fasten the PT motor lead E to the clamp
brackets 7, and then tighten the bolts 8 bracket with a plastic tie F.
to the specified torque.
4. Install the collars 9 and 0, upper end of

the tilt ram, shaft A, and E-clip B to the E
swivel bracket.
F a
5. Install the ground lead terminal C to the
PT unit 2. b
0 S6AU7058
A
A
NOTE:
1 Route the PT motor lead E to the front of
2
A stopper 1 b.
9 3
8. Apply grease to all grease nipples until it
86 B
4 A
comes out from the areas c.
D C
c
A
7
4 A
A 5
6
8
A
S6AU7057 c
A
S6AU7059
C D
BOW
S6AU7113
NOTE:
Install the ground lead C as shown.
PT unit mounting shaft bolt 8:

18 N·m (1.8 kgf·m, 13.3 ft·lb)
T.
R.
Ground lead bolt D:

8 N·m (0.8 kgf·m, 5.9 ft·lb)
7-35 6AU3K11

Clamp bracket and swivel bracket (PT model) / PT motor
PT motor 7
6
a
b
1
7
17 13
a
6
b
9 8 4 2
14 12 11
13
10 3
9 5 9 7
16
15
10
6
8
4
3
4
5 N · m (0.5 kgf · m, 3.7 ft · Ib)
T.
R.
10
5 N · m (0.5 kgf · m, 3.7 ft · Ib)

5
7
9
2
1
5
T.
R.
8 1

S6AU7060
6
2
3
4
5
Stator
O-ring
Armature
Screw
1
1
1
1
Not reusable
ø4 × 8 mm
7
6 Brush 1 Long lead
7
8
9
10
Brush
Screw
Brush spring
Bolt
1
2
2
4
Short lead
ø4 × 10 mm
M5 × 25 mm
8
11 PT motor base 1
12
13
14
15
Gasket
Oil seal
O-ring
O-ring
1
1
1
1
Not reusable
Not reusable
Not reusable
Not reusable
9
16 Manual valve 1
17 Reservoir cap 1
6AU3K11 7-36

BRKT
Bracket unit
Disassembling the PT motor 7
1. Remove the PT unit from the bracket. 3 2
NOTE:
To remove the PT unit, see “Removing the
PT unit” (7-33).
2
2. Fully extend the tilt ram, and then open

the manual valve 1 by turning it counter- 6
clockwise. 5
4
7
S6AU7062
5. Remove the stator 8 and O-ring 9 from

the PT motor base 0.
WARNING 8
Make sure that the tilt ram is fully
extended before removing the PT motor,
otherwise fluid can spurt out from the unit 0
due to internal pressure.
9
NOTE:
To prevent the internal PT unit parts from fall-
S6AU7063
ing out, lay the PT unit on its side so that the
PT motor is in an upright position before
removing it. 6. Remove the armature plate screw A,
and then remove the armature assembly
B.
3. Remove the PT motor base bolts 2, and
then remove the PT motor assembly 3 A B
and gasket 4 from the tilt cylinder.
4. Remove the manual valve 5, O-ring 6,

and pin 7.
S6AU7064
7-37 6AU3K11

PT motor
NOTE: Motor commutator standard

• Push the brushes apart, and then remove diameter: 16.5 mm (0.65 in)
the armature assembly. Wear limit: 15.5 mm (0.61 in)
• Do not remove the bearing from the arma-
ture assembly. 3. Measure the commutator undercut a.
Replace the armature if below specifica-
1
7. Remove the brush holder screws C, tion.
C
brushes D, brush springs E, and oil seal
from the PT motor base 0.
D C
2
E E
3
0
Checking the PT motor

S6AG7125
7
Motor commutator standard
undercut a: 1.00 mm (0.039 in)
Wear limit: 0.50 mm (0.020 in)
4
1. Check the commutator. Clean with 600-
grit sandpaper and compressed air if
dirty.
4. Check the armature for continuity.
Replace the armature if out of specifica-
tion. 5
b
c
d
6
2. Measure the commutator diameter.
S6AU7066
S6AG7087
7
Replace the armature if below specifica- Armature continuity
tion.
Checking point
Commutator segments b
Continuity
Yes
8
Segment – Armature core c No
Segment – Armature shaft d No
5. Check the bearing. Replace the armature

if damaged.
9
S6AU7067
6AU3K11 7-38

BRKT
Bracket unit
Checking the brush holder and
brush 7
Motor brush standard length:
1. Check the brush holder assembly for 6.0 mm (0.24 in)
continuity. Replace the PT motor base if Wear limit a: 3.0 mm (0.12 in)
out of specification.
Assembling the PT motor 7
4
1 CAUTION:
• Do not reuse the oil seal and O-ring,
• Do not allow grease or oil to contact the
commutator of the armature.
2
3
1. Install a new oil seal into the PT motor
1 base as shown.
3 G
1
4 2 2
L S6AG7090
NOTE:
The brush holder and circuit breaker cannot
be removed from the PT motor base assem-
bly; if either part is damaged, replace the PT
motor base. S6AU7072
Driver rod L3 1: 90890-06652

PT motor base continuity Needle bearing attachment 2:
90890-06615
Checking point Continuity
Terminal 1 – 3 (G) 2. Install the brush springs 3, brush (short
Yes lead) 4, brush (long lead) 5, and brush
Terminal 2 – 4 (L)
For all terminal combinations holder screws 6 to the PT motor base 7
No as shown.
not listed above.
6 a 5 4 b 6
2. Measure the length of each brush.
Replace the brushes if below specifica-
tion. 3 3
S6AU7073
Brush lead length: a > b
7-39 6AU3K11

PT motor
3. Push the brushes into the holders, and
then install the armature assembly 8 I
G
and tighten the armature plate screw 9.
9 8
I 1
H
C
E
D
2
S6AU7074
F
4. Install a new O-ring = and the stator A
to the PT motor base 7, and then tighten
the screws B.
3
S6AU7076
A
B
7
T.
R.
PT motor assembly bolt I:
5 N·m (0.5 kgf·m, 3.7 ft·lb) 4
c 0
d
S6AU7075
5
NOTE:
Align the rounded section c of the stator A
with the rounded section d of the PT motor
base 7.
6
5. Install a new O-ring C, the pin D, the
manual valve E, and a new O-ring F to
the PT motor assembly G.
7
6. Install a new gasket H and the PT motor
assembly G to the tilt cylinder, and then
tighten the PT motor assembly bolts I to
the specified torque.
8
9
6AU3K11 7-40

BRKT
Bracket unit
PT gear pump 7
22
6
9 6
30 9 12
4
12
23
29
28 5 N · m (0.5 kgf · m, 3.7 ft · Ib)
27
T.
R.
26
37 38 25
24
22 8 7 6, 9
17 21
20
18 19
35 17
34 16 11
33
8
36 7
10 6
36
35
34 15
33 10
14 5
14 13 4
29 13 12 8 2
28 31 12 1
27 7
26 9
25
32 24
31
30 3
5 N · m (0.5 kgf · m, 3.7 ft · Ib) 20 S6AU7077
T.
19
R.

2 Manual valve 1
3 Pin 1
4 Spring 1
5 Manual release pin 2
6 Spring 1 Length: 14.6 mm (0.57 in)
7 Valve pin 2
8 Valve seal 2
9 Spring 1 Length: 18.3 mm (0.72 in)
10 Bolt 6 M5 × 25 mm
11 Filter 1
12 Spring 2
13 Absorber valve pin 2
14 Ball 2
15 Gear pump housing 1
16 Drive gear 1
17 Pin 2
7-41 6AU3K11

PT gear pump
7
22
30
6
9 12
9 6
1
4
12
29
28
27
23
5 N · m (0.5 kgf · m, 3.7 ft · Ib)
2
T.
R.
26
37 38 25
3
24
22 8 7 6, 9
17 21
20
18 19
35 17
34 16 11
4
33
8
36 7
10 6
36
35
34 15
10
5
33 5
14
14 13 4
29 13 12 8 2
28 31 12 1
27 7
26 9
25
32 24
31
5 N · m (0.5 kgf · m, 3.7 ft · Ib)
30
20 3 S6AU7077
6
T.
19
R.

18 Driven gear 1
19
20
21
22
E-clip
Main valve seal
O-ring
Shuttle piston 1
2
2
1
1
Not reusable 7
23 Down-main valve 1
24
25
26
27
O-ring
Valve seat
Main valve
Spring
2
2
2
2
Not reusable
8
28 Spacer 2
29
30
31
32
Filter
Shuttle piston 2
Spring
Up-main valve
2
1
2
1
9
34 Ball 2
6AU3K11 7-42

BRKT
Bracket unit
7
22
6
9 6
30 9 12
4
12
23
29
28 5 N · m (0.5 kgf · m, 3.7 ft · Ib)
27
T.
R.
26
37 38 25
24
22 8 7 6, 9
17 21
20
18 19
35 17
34 16 11
33
8
36 7
10 6
36
35
34 15
33 10
14 5
14 13 4
29 13 12 8 2
28 31 12 1
27 7
26 9
25
32 24
31
30 3
5 N · m (0.5 kgf · m, 3.7 ft · Ib) 20 S6AU7077
T.
19
R.

35 Spring 2
36 Dowel 2
37 Reservoir cap 1
7-43 6AU3K11

PT gear pump
Disassembling the gear pump 7 Checking the gear pump 7
1. Remove the manual valve 1, filter 2 1. Check the drive gear and driven gear.
manual release pins 3, valve seals 4, Replace if damaged or excessively worn.
and balls 5.
2. Check the gear pump housing. Replace if
scratched. 1
Checking the valve seal 7
1. Check the valve seals 1 and absorber
2
valve pins 2. Replace if damaged.
1
2
1
4
2
2 1
3
3
5
4
S6AU7078
2. Check the main valves 3. Replace if
S6AG7185
4
damaged.
2. Remove the gear pump housing 6, shut-
tle piston 1 7 and shuttle piston 2 8.
7
3 5
6 3
8
6
S6AG7180
3. Remove the down-main valve 9, up-

S6AU7079
3. Check the manual valve and spring.
Replace if damaged. 7
main valve 0, balls A, dowels B, drive Checking the filter 7
8
gear C, and driven gear D. 1. Check the gear pump filters. Clean if
there is dirt or residue.
NOTE:
D C 0
9 See the exploded diagram for the filter instal-
lation positions (7-41).
B
A
9
B
S6AU7080
6AU3K11 7-44

BRKT
Bracket unit
Assembling the gear pump 7
7 8
CAUTION:
• Do not use a rag when assembling the
PT unit as dust and particles on the PT
unit components can lead to poor per-
formance.
• Do not reuse the O-rings, always replace
them with new ones.
S6AU7085
NOTE: NOTE:
Lubricate the parts with ATF Dexron II during Be sure to install shuttle piston 1 7 and shut-
assembly. tle piston 2 8 in the correct positions; the pis-
ton shapes are different.
1. Install the drive gear 1, driven gear 2,
balls 3, dowels 4, and main valves 5
to the tilt cylinder 6. Gear housing bolt 0:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
T.
R.
2 4. Install the balls A, valve seals B, man-
1 5
5
ual release pins C, spring D, and filter
E to the gear pump housing.
4
E F G
3
6 G F
C
A
4 S6AG7190 D
A C DG
2. Install shuttle piston 1 7 and shuttle pis-
B
ton 2 8 to the gear pump housing 9, C
and then install the housing to the tilt cyl- F
inder.
B A
3. Install the gear housing bolts 0, and
then tighten the bolts to the specified
torque. S6AU7086
7 5. Install the manual valve H and a new O-

9 ring I to the PT motor base.
6. Install a new gasket J and the PT motor

assembly K to the tilt cylinder, and then
8 tighten the PT motor assembly bolts L to
0 the specified torque.
S6AU7084
7-45 6AU3K11

PT gear pump
K L
L
1
J H
2
I
3
S6AU7114
PT motor assembly bolt L:

5 N·m (0.5 kgf·m, 3.7 ft·lb) 4
T.
R.
5
6
7
8
9
6AU3K11 7-46

BRKT
Bracket unit
PT cylinder 7
45 N · m (4.5 kgf · m, 33.2 ft · Ib)
T.
R.
45 N · m (4.5 kgf · m, 33.2 ft · Ib)
T.
R.
2
16
16 17
18
A LT
17 21
271
3
3 18
6
4 5
7
4
1
5 9 19 22 23
6 10 8
11
7 12
9
10 14
13 15
11
20
12
14
5 N · m (0.5 kgf · m, 3.7 ft · Ib)
15
T.
R.
S6AU7087

1 Tilt ram assembly 1
2 Tilt ram 1
3 Dust seal 1 Not reusable
4 Tilt cylinder end screw 1
6 Backup ring 1
8 Absorber valve 1
9 Ball 1
10 Pin 1
11 Spring 1
12 Dowel 1
13 Tilt piston 1
15 Backup ring 1
16 Free piston 1
17 Backup ring 1
7-47 6AU3K11

PT cylinder
7
45 N · m (4.5 kgf · m, 33.2 ft · Ib)
T.
R.
45 N · m (4.5 kgf · m, 33.2 ft · Ib)
T.
R.
2
16
16 17
3
A LT
271
3
17
18
18
21
2
6
1
4
5 9
7
4
5
19 22 23
3
6 10 8
4
11
7 12
9
10 14
13 15
5
11
20
12
14
5 N · m (0.5 kgf · m, 3.7 ft · Ib)
15
T.
R.

S6AU7087
6
19
20
21
22
Tilt cylinder
O-ring
Cylinder
Reservoir cap
1
1
1
1
Not reusable
7
8
9
6AU3K11 7-48

BRKT
Bracket unit
Disassembling the tilt cylinder 7
5. Hold the tilt piston 5 in a vise using alu-
1. Hold the cylinder 1 in a vise using alumi- minum plates on both sides, and then
num plates a on both sides. remove the tilt piston 5 and tilt cylinder
end screw 6 from the tilt ram 7.
2. Loosen the tilt cylinder end screw, and
then remove the tilt ram assembly.
6 2
1 5
2
S6AU7091
a
S6AG7215
Power tilt wrench 2: 90890-06560
WARNING
Make sure that the ram is fully extended 6. Remove the absorber valve 8 from the
before removing the end screw. tilt piston 5.
Power tilt wrench 2: 90890-06560
8
3. Drain the PT fluid.
4. Remove the tilt cylinder 3 and free pis-

ton 4 from the cylinder 1.
4 5
S6AU7090
3 1 Checking the tilt cylinder and piston 7
1. Check the tilt cylinder 1. Replace if

cracked or scratched.
2. Check the tilt piston 2, free piston 3,

and backup rings 4 and 5. Replace if
S6AG7250
3. Check the tilt cylinder end screw 6, dust

seal 7, and backup ring 8. Replace if
7-49 6AU3K11

PT cylinder
4. Check the tilt ram 9. Polish with 400–
600-grit sandpaper if there is light rust or NOTE:
replace if bent or excessively corroded. Lubricate the parts with ATF Dexron II during
assembly.
9
3
1. Install a new dust seal 1, new O-rings 2
and 3, and the backup ring 4 into the tilt
cylinder end screw 5.
1
2
5
1
7
A
5 1
6
4
3 2
8
2
1 2
4
3
5
S6AG7300
3
4
S6AU7092
2. Install the tilt cylinder end screw 5 to the
tilt ram 6.
3. Install the ball 7, pin 8, spring 9, and

4
5. Check the absorber valve 0. Clean if dowel 0 to the tilt ram 6.
there is dirt or residue.
0
9
5
0
LT
8
7
6
6
271
S6AU7116
7
S6AU7093
Assembling the tilt cylinder
CAUTION:
7
8
• Do not use a rag when assembling the
PT unit as dust and particles on the PT
unit components can lead to poor per-
formance.
• Do not reuse the dust seal and O-rings,
9
6AU3K11 7-50

BRKT
Bracket unit
4. Install the tilt piston A.
A 9
C
D
S6AU7096
S6AU7115
7. Install a new O-ring E to the tilt cylinder
NOTE: F, and then install the tilt cylinder into
Tighten the tilt piston temporarily, and then the cylinder G.
check that the spring 9 is visible through the
oil hole in the piston when the tilt ram assem-
bly is upright.
G
F
5. Hold the tilt piston A in a vise using alu-
minum plates on both sides, and then
tighten the tilt ram 6 to the specified E
torque.
S6AU7097
8. Install the PT gear pump, PT motor

assembly, and reservoir cap to the tilt
6
cylinder.
5 B
NOTE:
A To install the PT motor assembly and gear
pump assembly, see “Assembling the gear
pump” (7-45).
9. Fill the cylinder with the recommended

S6AU7095 PT fluid to about 60%.
Power tilt wrench B: 90890-06560 ATF Dexron II
10. Install the backup ring H and a new O-

Tilt ram 6: ring I to the free piston J, and then
45 N·m (4.5 kgf·m, 33.2 ft·lb)
T.
install the free piston into the cylinder G.

R.
6. Install a new O-ring C and the backup

ring D onto the tilt piston.
7-51 6AU3K11

PT cylinder
J J
H
H
I
1
B
I
S6AU7098
11. Place the tilt cylinder end screw 5 at the

2
bottom of the tilt ram 6.
3
S6AU7100
12. Install the tilt ram assembly into the cylin-
der.
Power tilt wrench B: 90890-06560
6 T.
R.
Tilt cylinder end screw 5:
45 N·m (4.5 kgf·m, 33.2 ft·lb) 4
Bleeding the PT unit 7
NOTE:
Make sure that the tilt ram is fully extended.
1. Place the PT unit in an upright position.

5
5
2. Turn the manual valve 1 clockwise 90°
to close it.
6
7
S6AU7099
13. Tighten the tilt cylinder end screw to the

specified torque.
8
9
6AU3K11 7-52

BRKT
Bracket unit
3. Remove the reservoir cap 2, and then
check the fluid level in the reservoir. Battery
Ram PT motor lead
terminal
Green (G) +
Down
Blue (L) -
6. Reverse the PT motor leads between the

battery terminals to fully extend the tilt
ram.
NOTE:
• If the fluid is at the correct level, a small
filler hole.
• If fluid is below the correct level, add the
recommended PT fluid.
Battery
Recommended PT fluid: Ram PT motor lead
terminal
ATF Dexron II
Blue (L) +
Up
4. Install the reservoir cap 2, and then Green (G) -
tighten it to the specified torque.
NOTE:
Reservoir cap 2: • Repeat steps 5–6 to fully extend and retract
5 N·m (0.5 kgf·m, 3.7 ft·lb)
T.
R.
the tilt ram 4 to 5 times.

• If the tilt ram does not move up and down
5. Connect the PT motor leads to the bat- easily, push and pull on the ram to assist
tery terminals to fully retract the tilt ram. the operation.
7. Fully extend the tilt ram.
8. Remove the reservoir cap, and then

check the fluid level in the reservoir.
WARNING
Make sure that the tilt ram is fully
extended when removing the reservoir
cap, otherwise fluid can spurt out from
the unit due to internal pressure.
7-53 6AU3K11

PT cylinder / PT electrical system
NOTE:
1
• If the fluid is at the correct level, a small
filler hole when the cap is removed.
• If the fluid is below the correct level, add the
recommended PT fluid.
2
3
B
R
G
L
Sb
1
Lg
4
ATF Dexron II
9. Install the reservoir cap, and then tighten

1 2
Sb Lg
2
B R
it to the specified torque. 3 5 6
NOTE:
If the fluid is below the correct level in step 8,
repeat steps 5–9 until the fluid remains at the
G
L
Lg
Sb
4
3
S6AU7106
correct level.
Reservoir cap:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
PT relay continuity 4
T.
Black (B) 1 – Green (G) 3

R.
Black (B) 1 – Blue (L) 4

PT electrical system
Checking the fuse
1. Check the fuse for continuity. Replace if
7
7
Black (B) 1 –
Sky blue (Sb) 5
Black (B) 1 –
Light green (Lg) 6
Continuity
5
there is no continuity.
Red (R) 2 – Green (G) 3
NOTE:
• For the location of the fuse, see “Electrical
component and wiring harness routing” (8-
1).
Red (R) 2 – Blue (L) 4
No continuity
6
• To check the fuse, see “Checking the fuse
(E model)” (8-26).
Checking the PT relay 7

7
1. Check the PT relay for continuity.
8
9
6AU3K11 7-54

BRKT
Bracket unit
2. Connect the positive battery lead to the
light green (Lg) lead 6, and the negative PT relay continuity
battery lead to the black (B) terminal 1
as shown, and then check the PT relay Red (R) 2 – Blue (L) 4 Continuity
for continuity. Replace the PT relay if out
Red (R) 2 – Green (G) 3
of specification. No continuity
Green (G) 3 – Blue (L) 4
1 Checking the PT switch 7
2 1. Check the PT switch for continuity.

B Replace if out of specification.
R
G
L Sb
3
Lg
4
Lg Sb
R
5 6
DN
UP
Sb Lg
Lg
Sb
S6AU7107
R S6AG7890
PT relay continuity
Lead color
Red (R) 2 – Green (G) 3 Continuity
Switch Sky blue Red (R) Light
Red (R) 2 – Blue (L) 4 position (Sb) green
No continuity
Green (G) 3 – Blue (L) 4 (Lg)
Free
3. Connect the positive battery lead to the
sky blue (Sb) lead 5, and the negative Up
battery lead to the black (B) terminal 1 Down
as shown, and then check the PT relay
for continuity. Replace the PT relay if out
of specification.
1
2
B
R
3 G
L Sb
Lg
4
5 6
Sb
Lg
S6AU7108
7-55 6AU3K11

Electrical system
Electrical component and wiring harness routing...................................... 8-1

Top view .................................................................................................... 8-1
Bow view ...................................................................................................8-9
Port view.................................................................................................. 8-11
1
Checking the electrical component............................................................ 8-19
Measuring the peak voltage .................................................................... 8-19
Starter motor (E model) ............................................................................... 8-20

2
Removing the starter motor ..................................................................... 8-22
3
Checking the starter motor operation ......................................................8-22
Checking the starter motor pinion............................................................ 8-22
Disassembling the starter motor..............................................................8-22
Checking the starter motor ...................................................................... 8-23
Checking the brush holder and brush......................................................8-24
Assembling the starter motor................................................................... 8-25
Installing the starter motor ....................................................................... 8-26
Starting system ............................................................................................ 8-26

4
Checking the fuse (E model) ................................................................... 8-26
Checking the engine start button (H model with electric starter) ............. 8-26
Checking the engine start switch (R model) ............................................8-27
Checking the neutral switch (H model with electric starter).....................8-27
Checking the neutral switch (R model)....................................................8-28
Checking the starter relay (E model) .......................................................8-29
5
Ignition and ignition control system .......................................................... 8-30
Checking the ignition spark ..................................................................... 8-30
Checking the spark plug cap ................................................................... 8-30
6
Checking the ignition coil.........................................................................8-31
Checking the pulser coil ..........................................................................8-31
Checking the charge coil .........................................................................8-32
Checking the engine shut-off switch (H model) ....................................... 8-33
Checking the engine shut-off switch (R model) ....................................... 8-33
7
8
Engine electric control system ................................................................... 8-34
Checking the CDI unit.............................................................................. 8-34
Checking the oil pressure switch ............................................................. 8-34
Checking the warning indicator assembly ............................................... 8-35
Checking the choke solenoid (R model).................................................. 8-36
Charging system (E model).........................................................................8-36

Checking the lighting coil.........................................................................8-36
Checking the Rectifier ............................................................................. 8-37
9
Checking the Rectifier Regulator............................................................. 8-39
6AU3K11

– +
ELEC
Electrical system
Electrical component and wiring harness routing 8
Top view 8
H model with 1 lighting coil
È 0
2
3 Í
A
4
5 A
6
1 Ê
A
9 B
7
8
Ë
9 B
+
A
8 9 C
Ë
C
9 Ì
,
S6AU8001
+ H model (short) 5 Rectifier

, H model (long) 6 Charge coil
7 CDI unit
1 Lighting coil 8 Pulser coil
2 Oil pressure switch 9 Warning indicator
3 Spark plug 0 Lighting coil leads (G, G)
4 Ignition coil A Engine shut-off switch lead
8-1 6AU3K11

Electrical component and wiring harness routing
È Route the oil pressure switch lead in the direction shown.
É Fit the oil pressure switch lead into the groove in the driven sprocket cover.
Ê Bend the side of the junction box inward as shown.
Ë To tiller handle
Ì
Í
Route the warning indicator lead under the shift cable.
Fit the lighting coil lead into the holder before installing the lighting coil and holder.
1
2
3
4
5
6
7
8
9
6AU3K11 8-2

– +
ELEC
Electrical system
8
H model with 2 lighting coils
È
3
4
2
5
9
1 Ê
8 A
6
7
Ë
+ 8 A
9
7 8 B
Ë
B
8 Ì
,
S6AU8002
+ H model (short) 7 Pulser coil

, H model (long) 8 Warning indicator
9 Engine shut-off switch lead
1 Lighting coils
2 Oil pressure switch
3 Spark plug
4 Rectifier Regulator
5 Charge coil
6 CDI unit
8-3 6AU3K11

È Route the oil pressure switch lead in the direction shown.
É Fit the oil pressure switch lead into the groove in the driven sprocket cover.
Ê Bend the side of the junction box outward as shown.
Ë To tiller handle
Ì Route the warning indicator lead under the shift cable.
1
2
3
4
5
6
7
8
9
6AU3K11 8-4

– +
ELEC
Electrical system
8
H model with electric starter
Ê
3
2 4
6
1 + C
Ì
D
É 7
E
B 8
È A A Í
9
A 0 ,
C
A
D
E
A A F Í
A Î
S6AU8003
+ MT model 7 CDI unit

, PT model 8 Neutral switch
9 Fuse (10 A)
1 Lighting coils 0 PT relay (PT model)
2 Oil pressure switch A Warning indicator
3 Spark plug B Pulser coil
4 Rectifier Regulator C Engine shut-off switch lead
5 Starter motor D Engine start button lead
6 Charge coil E Battery cable
8-5 6AU3K11

F PT switch lead (PT model)
È Install the terminal plate, making sure that it contacts the PT relay. (PT model)
É Route the lighting coil lead to the outside of the crankcase pin.
Ê
Ë
Ì
Í
Route the oil pressure switch lead in the direction shown.
Fit the oil pressure switch lead into the groove in the driven sprocket cover.
Bend the side of the junction box outward as shown.
Route the battery cable under the bracket.
1
Î Route the warning indicator lead under the shift cable.
Ï Fasten the PT motor lead with the holder, making sure that there is no slack in the lead. (PT model)
2
3
4
5
6
7
8
9
6AU3K11 8-6

– +
ELEC
Electrical system
8
R model
3
4
Ê 5
6
2
7
1 Ì
8
É
D C
È
9
A
0
A B C
A
B
S6AU8004C
1 Lighting coils 0 PT relay (PT model)

2 Oil pressure switch A Pulser coil
3 Choke solenoid B Warning indicator
4 Spark plug C Battery cable
5 Rectifier Regulator D 10-pin main harness
6 Starter motor
7 Charge coil
8 CDI unit
9 Fuse (10 A)
8-7 6AU3K11

È Install the terminal plate, making sure that it contacts the PT relay. (PT model)
É Route the lighting coil lead to the outside of the crankcase pin.
Ê Route the oil pressure switch lead in the direction shown.
Ë Fit the oil pressure switch lead into the groove in the driven sprocket cover.
Ì
Í
Bend the side of the junction box outward as shown.
Fasten the PT motor lead with the holder, making sure that there is no slack in the lead. (PT model)
1
2
3
4
5
6
7
8
9
6AU3K11 8-8

– +
ELEC
Electrical system
Bow view 8
2
1
3
È 5
É 2
7 1
A
8 3
A Ê
B
8
0
B 9
6
4
5
S6AU8005
1 Pulser coil 0 PT relay lead (R)

2 Fuse (10 A) (E model)
3 Starter motor (E model)
4 Starter relay (E model)
5 Neutral switch (E model)
6 PT relay (PT model)
7 PT motor leads (Sb, Lg)
8 PT relay leads (Sb, Lg)
9 Negative battery cable
8-9 6AU3K11

È Pass the PT motor leads (Sb, Lg) and PT relay leads (Sb, Lg) through the caps, and then connect the
leads to the terminals and cover the connections with the caps. Be sure to pass leads of the same color
through the caps and connect them to the same terminal. (PT model)
É Fasten the PT relay leads (Sb, Lg, R) (PT model), PT motor lead (PT model), and wiring harness
connector (R) to the bracket with a plastic tie.
Ê Install the terminals of the negative battery cable and PT relay lead (R) (PT model) using the bolt as
shown. 1
2
3
4
5
6
7
8
9
6AU3K11 8-10

– +
ELEC
Electrical system
Port view 8
M model with 1 lighting coil
2
1
3 4
4
A
É
È
Ë È
Ê
È
5 6
7
8
0 9
A
B C
A-A
S6AU8062
1 Pulser coil 8 Charge coil connectors (charge coil to CDI

2 Rectifier unit) (L, Br)
3 Ignition coil 9 Ignition coil connectors (ignition coil to CDI
4 Spark plugs unit) (O, B)
5 Rectifier connector (R) 0 Oil pressure switch connector (oil pressure
6 Pulser coil connectors (pulser coil to CDI unit) switch to CDI unit) (P)
(W/R, B) A Warning indicator connectors (warning
7 Rectifier connectors (Rectifier to CDI unit) indicator to CDI unit) (Y/R, P)
(G, G)
8-11 6AU3K11

B Engine shut-off switch connector (engine shut-off switch to CDI unit) (Y)
C Emergency circuit connector (CDI unit to CDI unit) (W)
È 15 mm (0.59 in)
É
Ê
Ë
55 mm (2.17 in)
35 mm (1.38 in)
Fasten the charge coil lead and lighting coil lead with a plastic tie as shown so that they are not pinched
when the flywheel magnet and ignition coil bracket are installed.
1
2
3
4
5
6
7
8
9
6AU3K11 8-12

– +
ELEC
Electrical system
8
M model and E model with 2 lighting coils
1 2 3 4
5 3
C 4
C B
A
7
Ë È 6
A
È
É
6 Ê
È
1 2 3 4
5
8 4
D
D
A
7
Ì
Ë È
B
6 É
È
Ê
È
9 0 0 A
C B C B
D
9 D
E F E
G H F
G H
C-C D-D S6AU8063
1 Fuse (10 A) (E model) 0 Rectifier Regulator connector (Rectifier

2 Pulser coil Regulator to fuse and engine start button) (R)
3 Starter motor (E model) A Rectifier Regulator connector (Rectifier
4 Rectifier Regulator Regulator to PT switch) (R)
5 Spark plugs B Pulser coil connectors (pulser coil to CDI unit)
6 Ignition coil (W/R, B)
7 Starter relay (E model) C Rectifier Regulator connectors (Rectifier
8 PT relay (PT model) Regulator to CDI unit) (G, G/W)
9 Rectifier Regulator connector (G)
8-13 6AU3K11

D Charge coil connectors (charge coil to CDI unit) (L, Br)
E Oil pressure switch connector (oil pressure switch to CDI unit) (P)
F Warning indicator connectors (warning indicator to CDI unit) (Y/R, P)
G Engine shut-off switch connector (engine shut-off switch to CDI unit) (Y)
H
È
É
Emergency circuit connector (CDI unit to CDI unit) (W)
35 mm (1.38 in)
15 mm (0.59 in)
1
Ê 55 mm (2.17 in)
Ë Fasten the charge coil lead and lighting coil lead with a plastic tie as shown so that they are not pinched
when the flywheel magnet and ignition coil bracket are installed.
Ì Fasten the Rectifier Regulator lead to the starter motor bracket with plastic ties before installing the starter
motor. Cut off the excess end of each plastic tie.
2
3
4
5
6
7
8
9
6AU3K11 8-14

– +
ELEC
Electrical system
8
H model (short)
É
A 4
A +
È
2
1
B
C 3
B
Ë
3
C
S6AU8064
+ E model
1 Warning indicator
2 Engine shut-off switch
3 Engine start button (E model)
4 Engine shut-off switch lead
8-15 6AU3K11

È Route the engine shut-off switch lead under the throttle cables.
É Route the engine shut-off switch lead as shown, making sure that the lead does not contact the throttle
shaft.
Ê Fasten the engine start button lead at the white tape with a plastic tie. Install the plastic tie as shown. (E
model)
Ë Align the blue tape on the engine start button lead with the grommet in the bottom cowling. Position the
slack in the engine start button lead toward the tiller handle. (E model) 1
2
3
4
5
6
7
8
9
6AU3K11 8-16

– +
ELEC
Electrical system
8
H model (long)
É
2 +
È
B 3
A
Ë
3
B
S6AU8065
+ E model
1 Warning indicator
2 Engine shut-off switch
3 Engine start button
8-17 6AU3K11

È Route the engine shut-off switch lead under the throttle cables.
É Route the engine shut-off switch lead along the tiller handle bracket so that it does not contact the throttle
shaft, and then route it and the throttle cables through the corrugated tube.
Ê Fasten the engine start button lead at the white tape with a plastic tie. Install the plastic tie as shown. (E
model)
Ë Align the blue tape on the engine start button lead with the grommet in the bottom cowling. Position the
slack in the engine start button lead toward the tiller handle. (E model) 1
2
3
4
5
6
7
8
9
6AU3K11 8-18

– +
ELEC
Electrical system
Checking the electrical
NOTE:
component 8
• Before measuring the peak voltage, check
Measuring the peak voltage 8
all wiring for proper connection and corro-
To check the electrical components or mea- sion, and check that the battery is fully
sure the peak voltage, use the special ser- charged.
vice tools. A faulty electrical component can • Use the peak voltage adapter B with the
be easily checked by measuring the peak recommended digital circuit tester.
voltage. The specified engine speed when • Connect the positive pin of peak voltage
measuring the peak voltage is affected by adapter B to the positive terminal of the dig-
many factors, such as fouled spark plugs or a ital tester, and the negative pin to the nega-
weak battery. If one of these factors is tive terminal.
present, the peak voltage cannot be mea- • When measuring the peak voltage, set the
sured properly. selector on the digital circuit tester to the
DC voltage mode.
DC V Digital circuit tester: 90890-03174

Peak voltage adapter B:
90890-03172
S6AL8010
WARNING
When checking the peak voltage, do not
touch any of the connections of the digital
tester leads.
CAUTION:
When testing the voltage between the ter-
minals of an electrical component with
the digital tester, do not allow any of the
leads to touch any metal parts. If touched,
the electrical component can short and be
damaged.
8-19 6AU3K11

Checking the electrical component / Starter motor (E model)
Starter motor (E model) 8
1
1 11 1
2
2 3 13
4
3
5
14
7
15
2
16
6 17
7
8
18
19
3
9
10
C 21
20
24
25
21
23
15
23
4
22 22
26
11
23
28
27
27
28
23
18
15
5
12
0.4 N · m (0.04 kgf · m, 0.30 ft · lb) S6AU8008

6
T.
R.

1 Clip 1 Not reusable
2
3
4
5
Pinion stopper
Spring
Pinion stopper set
Pinion
1
1
1
1
7
6 Cover 1
7
8
9
10
O-ring
Washer
Shim
Washer
2
1
—
1
Not reusable
t = 1.0 mm
t = 2.0 mm
8
11 Armature 1
12
13
14
15
Washer
Stator
Brush holder assembly
Brush spring
1
1
1
2
t = 0.25 mm
9
17 Brush 2 assembly 1
6AU3K11 8-20

– +
ELEC
Electrical system
8
1 11 1
2
2 3 13
4
3 7
5
14
15
16
6 17
7 18
19
8
9
20
10 15
23
24 21 23
C 21
25 22
22 26
11 27 15
28
18
23 27 23
28
12
0.4 N · m (0.04 kgf · m, 0.30 ft · lb) S6AU8008

T.
R.

18 Brush 1 1
19 Spacer 1
20 Bracket 1
21 O-ring 2
22 Washer 2
23 Bolt 2 M5 × 120 mm
24 O-ring 1
25 Spacer 1
26 Washer 1
27 Spring washer 2
28 Nut 2
8-21 6AU3K11

Starter motor (E model)
Removing the starter motor 8
1. Remove the starter motor from the power WARNING

unit. Do not place any objects near the pinion
or touch it. The pinion 9 moves slightly
NOTE:
• Check the engine start switch or engine
start button, neutral switch, starter relay,
and fuse before removing the starter motor.
away from the starter motor body and
rotates at high speed. 1
• To remove the starter motor, see “Ignition NOTE:
coil, CDI unit, and Rectifier Regulator (E
model)” (5-15).
• Check the starter motor operation for a few
seconds.
• If the starter motor is disassembled for
maintenance, be sure to check the opera-
2
Checking the starter motor operation tion again after assembling it.
3
8
1. Hold the starter motor in a vise using alu-

minum plates on both sides.
4. Disconnect the negative battery cable
2. Connect the positive battery cable 1 to and positive battery cable from the bat-
the starter relay terminal 2, connect the tery terminals.
starter motor lead 3 to the starter motor
positive terminal 4, and connect the
negative battery cable 5 to the starter
Checking the starter motor pinion
CAUTION:
8
4
motor body 6.
Be sure to disconnect the battery cables
3. Connect the starter relay lead (brown) 7
to the positive battery terminal. Connect
the starter relay lead (black) 8 to the
before checking the starter motor pinion.
1. Check the pinion teeth. Replace the pin-

ion if cracked or worn.
5
negative battery terminal to check the
starter motor operation.
9
6
5
2. Check the pinion for smooth operation.
NOTE:
Turn the pinion counterclockwise to check
6
that it operates smoothly and turn it clockwise
4
1
3 8
to check that it locks in place.
Disassembling the starter motor 8

7
1. Slide the pinion stopper 1 down as
8
2 7 shown, and then remove the clip 2, pin-
1 7 2 3 4 ion stopper, and spring.
R R
Br 2
B B
8 5
6
S6AU8009
1 9
S6AU8010
6AU3K11 8-22

– +
ELEC
Electrical system
2. Turn the pinion 3 clockwise, and then
remove the pinion. A
0
9
S6AU8011
8 8
7 7
3. Remove the cover 4, stator 5, armature S6AU8013
6, and washer.
Checking the starter motor 8
1. Check the commutator. Clean with 600-

4
grit sandpaper and compressed air if
5 dirty.
6
S6AG8440
2. Measure the commutator diameter.

S6AU8012 tion.
4. Remove the nuts 7, spring washers 8,

washer 9, spacer =, and screws A,
and then remove the brush holder
assembly B from the bracket C.
S6AG8450J
Commutator standard diameter:

30.0 mm (1.18 in)
8-23 6AU3K11

Starter motor (E model)
3. Measure the commutator undercut a.
2
tion.
1
1
3
3 1 2
2
3
S6AG8470
Commutator standard undercut a:
0.5–0.8 mm (0.02–0.03 in)
Brush holder assembly continuity
Checking points Continuity
4. Check the armature for continuity.
Replace the armature if out of specifica-
tion.
Brush 1 – Terminal 3
Brush 1 – Brush 2
Brush 2 – Terminal 3
Yes
No
4
5
2. Measure the length of each brush.
Replace if below specification.
b d
c
S6AU8017 6
Armature continuity
Checking points
Commutator segments b
Continuity
Yes Brush standard length:
7
Segment – Armature core c No 12.5 mm (0.49 in)
Wear limit a: 9.0 mm (0.35 in)
Segment – Armature shaft d
Checking the brush holder and

brush
No
8
8
1. Check the brush holder assembly for
continuity. Replace if out of specification.
9
6AU3K11 8-24

– +
ELEC
Electrical system
Assembling the starter motor 8
E
CAUTION: A
b
Do not allow grease or oil to contact the
commutator of the armature. a
D
C b
1. Install the brush holder assembly 1 into
the bracket 2, and then tighten the B
screws 3.
c 2
2. Install the O-ring 4, spacer 5, washer
6, and spring washer 7, and then 0
tighten the nut 8 to the specified torque.
3 1 9
F S6AU8021
1
2 a A E
2
2
4
5 c b d
S6AU8022
6
7 NOTE:
8 • Install the stator so that the line mark a is
S6AU8020
toward the bracket 2.
Starter motor terminal nut 8: • Align the projections b on the stator A
0.4 N·m (0.04 kgf·m, 0.30 ft·lb) with the groove c in the bracket 2 and the
T.
R.
groove d in the cover E.

3. Install the washer 9 and armature 0
into the bracket 2. 5. Install the pinion G, spring H, and pinion
stopper I.
4. Install the stator A, washer B, shim(s)
C, washer D, and cover E, and then 6. Slide the pinion stopper down, and then
tighten the bolts F. install a new clip J.
8-25 6AU3K11

Starter motor (E model) / Starting system
Checking the engine start button (H
J J model with electric starter) 8
I 1. Disconnect the engine start button 1
H
H
connectors.
2. Measure the input voltage between the

connector (wiring harness end) of the
1
G G engine start button 1 and the ground.
NOTE:
S6AG8510
• Install the pinion stopper I in the direction

Check the fuse 2 and wiring harness if
below specification.
2
shown.
• Check the starter motor operation again
after assembling it. 3
Installing the starter motor
4
8
1. Install the starter motor to the power unit.

1 2
2. Connect the wiring harness to the starter
motor, and then fasten the wiring har- R R
Br R
ness.
20A
5
Br R
Br
NOTE: R
To connect the wiring harness to the starter
motor, see “Electrical component and wiring
harness routing” (8-1). S6AU8025
Starting system
Checking the fuse (E model)
8
8
Engine start button input voltage
(reference data):
Red (R) – Ground
6
1. Check the fuse for continuity. Replace if 12 V (battery voltage)
there is no continuity.
7
8
NOTE:
S6AU8024
For the location of the fuse, see “Electrical

9
component and wiring harness routing” (8-1).
6AU3K11 8-26

– +
ELEC
Electrical system
3. Check the engine start button 1 for con-
tinuity between the engine start button Engine start switch input voltage
connectors (engine start button end). (reference data):
Replace if out of specification. Red (R) – Ground
12 V (battery voltage)
1 Br
R position.
4. Check the engine start switch for continu-

b
a ity at the 10-pin main harness coupler
(remote control box end). Check the wir-
ing harness and neutral switch, or
S6AG8180 replace the engine start switch if out of
specification.
Engine start button continuity:
Red (R) – Brown (Br) ON (PUSH)
OFF START (PUSH)
Button position Continuity
Free a No
Pushed b Yes
4. Connect the connectors of the engine

start button 1.
3
Checking the engine start switch (R 4
model) 8
1
1. Disconnect the 10-pin main harness cou- 6
pler. 2 5 S6AU8028
2. Measure the input voltage between the Lead color

10-pin main harness coupler (outboard White Black Red Yellow Brown Blue
motor end) and the ground. Check the Switch (W) (B) (R) (Y) (Br) (L)
fuse and wiring harness if below specifi- position 1 2 3 4 5 6
cation. OFF
ON
ON
(PUSH)
START
START
(PUSH)
R
5. Connect the 10-pin main harness cou-

pler.
Checking the neutral switch (H

S6AU8027
model with electric starter) 8
1. Disconnect the neutral switch 1 connec-

tors.
8-27 6AU3K11

Starting system
2. Push the engine start button 2, and then
measure the input voltage between the Neutral switch continuity:
neutral switch connector (engine start Brown (Br) – Brown (Br)
1
button end) and the ground. Check the Switch position Continuity
engine start button and wiring harness if
Pushed a (N
below specification. Yes
position)
Free b (F position or
No
R position)
4. Connect the connectors of the neutral

switch 1.
2
Checking the neutral switch (R
2
R
model)
NOTE:
Be sure to check the engine start switch for
8
3
Br continuity before checking the neutral switch.
1
Br
Br
Br
position.
4
B
2. Turn the engine start switch to “START,”
Neutral switch input voltage

(reference data):
S6AU8029
and then check the neutral switch for
continuity at the 10-pin main harness
coupler (remote control box end).
5
Brown (Br) – Ground
12 V (battery voltage)
3. Check the neutral switch 1 for continuity

between the neutral switch connectors
6
(neutral switch end). Replace if out of
specification.
Br 7
1
Br
8
a
b S6AG8220
9
6AU3K11 8-28

– +
ELEC
Electrical system
3. Set the remote control lever to the F posi- 3. Push the engine start button, and then
tion or R position, and then check the measure the input voltage between the
neutral switch for continuity. Check the starter relay connector (neutral switch
wiring harness or replace the neutral end) and the ground. Check the engine
switch if out of specification. start button, neutral switch, wiring har-
ness, and ground lead if below specifica-
ON
OFF START tion. (H model)
Turn the engine start switch to “START,”
and then measure the input voltage
between the starter relay connector (neu-
tral switch end) and the ground. Check
the engine start switch, neutral switch (in
the remote control box), wiring harness,
and ground lead if below specification. (R
1
model)
2 S6AU8031
Lead color
Red (R) Brown

Remote control lever
1 (Br) 2
position
N position
1
F position or R
position Br Br
B
4. Turn the engine start switch to “OFF.”

pler.
S6AU8032
Checking the starter relay (E model) 8
1. Disconnect the starter relay 1 connec- Starter relay input voltage

tor. (reference data):
Brown (Br) – Ground
2. Set the shift lever or remote control lever 12 V (battery voltage)
to the N position.
4. Disconnect the battery cables, and then
remove the starter relay.
5. Connect the digital circuit tester leads to

the starter relay terminals.
8-29 6AU3K11

Starting system / Ignition and ignition control system
6. Connect the brown (Br) lead of the
starter relay to the positive battery termi- OK
nal and connect the black (B) lead to the
1
negative battery terminal. Check for con-
tinuity between the starter relay termi-
nals. Replace if there is no continuity.
7. Disconnect the brown (Br) or black (B)
2
lead of the starter relay from a battery
terminal. Check that there is no continuity S6AU8034
between the starter relay terminals.

Replace if there is continuity. WARNING
• Do not touch any of the connections of
3
the special service tool.
• Be sure to install the special service tool
to the spark plug cap so that sparks do
not leak out.
• Keep flammable gas or liquids away,
Br B
S6AU8033
since this test can produce sparks.
NOTE:
Repeat steps 2–3 for each spark plug cap.
4
5
8. Install the starter relay, and then connect
the battery cables, starter relay connec-
Checking the spark plug cap 8
tor, and starter relay leads.

1. Remove the spark plug caps from the
spark plug wires by turning the caps
Ignition and ignition control
counterclockwise.
system
Checking the ignition spark
1. Disconnect the spark plug caps from the
spark plugs.
8
6
NOTE:
To prevent the engine from starting when
cranking it, be sure to disconnect both spark
plug caps.
7
S6AG8030
2. Connect the spark plug cap to the special

service tool. 8
Ignition tester: 90890-06754
3. Crank the engine and check for a spark.

If there is no spark, check the ignition
9
system.
6AU3K11 8-30

– +
ELEC
Electrical system
2. Measure the spark plug cap resistance. Checking the pulser coil 8
Replace if out of specification. 1. Measure the pulser coil 1 output peak

voltage. Replace if below specification.
S6AG8040
Spark plug cap resistance (reference

1
data): 4.0–6.0 kΩ
W/R W/R
Checking the ignition coil 8

B
B
1. Disconnect the ignition coil connectors.
2. Remove the spark plug caps from the

spark plug wires by turning the caps S6AU8038
counterclockwise.
NOTE:
3. Measure the ignition coil resistance. • To prevent the engine from starting when
Replace if out of specification. cranking it, be sure to disconnect both
spark plug caps.
• Do not remove the clip from the engine
shut-off switch.
• If measuring the output peak voltage under
the unloaded conditions, disconnect the
B connectors.
• When using the manual starter to crank the
engine, the voltage values may vary
O depending on the speed at which the
S6AG8050
starter handle is pulled.
Ignition coil resistance (reference

data): Pulser coil output peak voltage:
Primary coil: White/red (W/R) – Black (B)
Orange (O) – Black (B)
Unloaded Loaded
0.26–0.35 Ω at 20 °C (68 °F) r/min
Secondary coil: Cranking 1,500 3,500
Spark plug wire – Spark plug wire DC V 7.0 3.5 7.0 10.5
6.8–10.2 kΩ at 20 °C (68 °F)
2. Disconnect the pulser coil connectors.
4. Install the spark plug caps to the spark
3. Measure the pulser coil resistance.
plug wires by turning the caps clockwise,
and then connect the ignition coil con-
nectors.
8-31 6AU3K11

Ignition and ignition control system
Pulser coil resistance (reference Charge coil output peak voltage:

data): Brown (Br) – Blue (L)
White/red (W/R) – Black (B)
240–360 Ω at 20 °C (68 °F)
4. Connect the pulser coil connectors.

r/min
DC V
Unloaded
Cranking
140 160
Loaded
1,500
180
3,500
180
1
2. Disconnect the charge coil connectors.
2
Checking the charge coil 8
1. Measure the charge coil 1 output peak

3. Measure the charge coil resistance.
voltage. Replace the stator coil assembly
if below specification.
Charge coil resistance (reference
data):
Brown (Br) – Blue (L)
232–348 Ω at 20 °C (68 °F)
3
4. Connect the charge coil connectors.
4
1
L
Br
L
Br
5
NOTE:
S6AU8039
6
• To prevent the engine from starting when
cranking it, be sure to disconnect both
spark plug caps.
shut-off switch.
7
• If measuring the output peak voltage under
the unloaded conditions, disconnect the
connectors.
8
depending on the speed at which the
9
6AU3K11 8-32

– +
ELEC
Electrical system
Checking the engine shut-off switch
(H model) 8
Engine shut-off switch continuity:
1. Disconnect the engine shut-off switch 1 White (W) – Black (B)
connector and terminal. Switch position Continuity
Clip installed a No
Engine stop button
Yes
pushed b
Clip removed c Yes
3. Connect the engine shut-off switch con-

nector and terminal.

(R model) 8
1. Disconnect the 10-pin main harness cou-

1 pler.
W W
B
2. Turn the engine start switch to “ON,” and
then check the engine shut-off switch for
continuity at the 10-pin main harness
S6AU8040 coupler (remote control box end). Check
the wiring harness or replace the engine
2. Check the engine shut-off switch 1 for shut-off switch if out of specification.
continuity between the engine shut-off ON
switch connector and terminal (engine OFF START
shut-off switch end). Replace if out of
specification.
a b
c
2 S6AU8042
W B
Engine shut-off switch continuity:

White (W) 1 – Black (B) 2
Switch position Continuity
Clip installed No
Clip removed Yes
S6AG8150
3. Turn the engine start switch to “OFF.”

pler.
8-33 6AU3K11

Ignition and ignition control system / Engine electric control system
Engine electric control system 8
2. Start the engine, and then measure the
Checking the CDI unit 8
input voltage between the oil pressure
1. Measure the CDI unit 1 output peak switch connector (wiring harness end)
1
voltage. Replace if below specification. and the ground. Check the wiring har-
ness if below specification.
2
O O
P P
1 3
1
B B
S6AU8043
4
S6AU8047
NOTE:
spark plug caps.
Oil pressure switch input voltage
(reference data):
Pink (P) – Ground
5
• Do not remove the clip from the engine 10–12 V
shut-off switch.
depending on the speed at which the
3. Push the engine stop button. (H model)
Turn the engine start switch to “OFF.” (R
model)
6
• Be sure to check the charge coil and pulser
coil before measuring the CDI unit output
peak voltage.
7
CDI unit output peak voltage
(reference data):
Orange (O) – Black (B)
8
Loaded
r/min
9
Cranking 1,500 3,500
DC V 140 170 170
Checking the oil pressure switch 8
1. Disconnect the oil pressure switch 1

connector.
6AU3K11 8-34

– +
ELEC
Electrical system
4. Check the oil pressure switch 1 for con-
tinuity when the engine is stopped and NOTE:
when it is running. Check the oil pressure Slowly operate the special service tool.
and oil pressure switch if out of specifica-
tion. Vacuum/pressure pump gauge set:
90890-06756
Oil pressure switch continuity:

Oil pressure switch – Ground
Oil pressure Continuity
More than 14.7 kPa
No
(0.147 kgf/cm2, 2.132 psi)
Less than 14.7kPa
Yes
(0.147 kgf/cm2, 2.132 psi)
1
P P
NOTE:
Apply pressure to the oil pressure switch
gradually. The oil pressure switch is operat-
ing correctly if the digital tester indication
changes from continuity to no continuity in
S6AU8048 the range of 14.7 ± 4.9 kPa (0.147 ±
0.049 kgf/cm2, 2.132 ± 0.711 psi).
Oil pressure switch continuity:
Oil pressure switch – Ground
8. Install the oil pressure switch, and then
Engine condition Continuity
connect the oil pressure switch connec-
Stopped Yes tor.
Running No
Checking the warning indicator
5. Remove the oil pressure switch. assembly 8
1. Disconnect the oil pressure switch con-

6. Connect the special service tool to the oil nector, and then ground the pink (P) lead
pressure switch. (wiring harness end).
7. Check the oil pressure switch for continu- 2. Start the engine, increase the engine
ity at the specified pressures. Replace if speed to approximately 2,000 r/min, and
out of specification. check that the oil pressure warning indi-
cator comes on.
3. Push the engine stop button. (H model)

Turn the engine start switch to “OFF.” (R
model)
4. Connect the oil pressure switch lead ter-

minal.
S6AG8130 5. Disconnect the warning indicator assem-

bly coupler.
8-35 6AU3K11

Engine electric control system / Charging system (E model)
6. Connect the yellow/red (Y/R) lead to the 3. Measure the choke solenoid 1 resis-
positive penlight battery terminal (1.5 V) tance. Replace if out of specification.
and connect the pink (P) lead to the neg-
1
ative terminal, and then check that the
warning indicator comes on. Replace the
warning indicator assembly if it does not
come on.
Y/R
Y/R
2
+ 1
3
LED
- + -
P
S6AU8051
B
L
4
CAUTION:
• Only use a penlight battery (1.5 V) when S6AU8058
checking the LED. Other batteries (e.g.,

alkaline batteries or high-voltage batter- Choke solenoid resistance
ies) will damage the diode. (reference data):
• Do not apply more than 1.7 V to the
leads when checking the LED.
Blue (L) – Black (B)
4.0 Ω at 20 °C (68 °F)
4. Connect the choke solenoid 1 coupler.

5
NOTE:
A feature of an LED is that it only allows cur-
rent to flow in one direction.
Checking the choke solenoid (R

Charging system (E model)
Checking the lighting coil
1. Disconnect the lighting coil connectors.
8
8
6
model)
7
8
1. Push the engine start switch at the “ON”

or “START” position, and then check the
operation of the choke solenoid 1.
Check the choke solenoid resistance if it
8
does not operate.
ON (PUSH)
OFF START (PUSH)
1
9
S6AU8052
2. Disconnect the choke solenoid coupler.
6AU3K11 8-36

– +
ELEC
Electrical system
2. Measure the lighting coil 1 output peak
voltage. Replace if below specification. Lighting coil (1 coil) output peak
voltage:
È Green (G) – Green (G)
Unloaded
r/min
Cranking 1,500 3,500
DC V 6.1 14.6 33.1
Lighting coil (2 coils) output peak

voltage:
Green/White (G/W) – Green (G)
1
R Unloaded
r/min
G G Cranking 1,500 3,500
G G DC V 16.1 33.3 79.1
B
3. Measure the lighting coil resistance.
S6AU8053
Lighting coil (1 coil) resistance
É (reference data):
Green (G) – Green (G)
0.24–0.36 Ω at 20 °C (68 °F)
Lighting coil (2 coils) resistance
(reference data):
Green/White (G/W) – Green (G)
0.61–0.91 Ω at 20 °C (68 °F)
4. Connect the lighting coil connectors.

1
R
Checking the Rectifier 8
G/W G/W
G G 1. Measure the Rectifier 1 output peak
voltage. Check the Rectifier for continuity
B if the output peak voltage is below speci-
fication.
S6AU8059
È Lighting coil (1 coil)

É Lighting coil (2 coils)
NOTE:
spark plug caps.
shut-off switch.
8-37 6AU3K11

B5
G2
G3
1
R4
2 G
4 R
3 G
2
G
G R 5 B S6AU8055
G G
1
b
a
3
S6AU8054
NOTE:
• Do not use peak voltage adapter B when
measuring the Rectifier output peak volt- NOTE:
Be sure to set the measurement range a,
S6S18360
4
age.
and display the mark b by pushing the
5
• Be sure to check the lighting coil before
measuring the Rectifier output peak volt- “SHIFT” switch when checking the Rectifier
age. continuity.
Rectifier output peak voltage:
6
Rectifier continuity (testing diode)
Red (R) – Ground
Unloaded Tester lead Display value (V) Conti-
r/min + - (reference data) nuity
1,500 3,500
DC V 13 19 G2 R4 0.416 Yes
2. Disconnect the Rectifier connector and

terminal.
G2
G2
G3
B5
G3
R4
OL
OL
0.415
No
No
Yes
7
3. Check the Rectifier for continuity. G3 B5 OL No
NOTE:
The voltage values given in the table are for
G3
B5
B5
G2
R4
G2
OL
0.849
0.487
No
Yes
Yes
8
reference only. If voltage is produced, there B5 G3 0.492 Yes
is continuity, and, if there is an overload,
there is no continuity. Refer to the table to
determine if there should or should not be
continuity and replace the Rectifier if out of
R4
R4
R4
B5
G2
G3
OL
OL
OL
No
No
No
9
specification. OL: Indicates an overload
6AU3K11 8-38

– +
ELEC
Electrical system
Checking the Rectifier Regulator 8
NOTE:
1. Measure the Rectifier Regulator 1 out-
The voltage values given in the table are for
put peak voltage. Check the Rectifier
reference only. If voltage is produced, there
Regulator for continuity if the output peak
is continuity, and, if there is an overload,
voltage is below specification.
there is no continuity. Refer to the table to
determine if there should or should not be
continuity and replace the Rectifier Regulator
if out of specification.
G/W3
4G
G4
R
G/W G/W R5
G G
B6
B
5R
R
1 3G/W
4G
2
6B
S6AU8060
S6AU8061
NOTE:
• Measure the Rectifier Regulator output
peak voltage with the connector (R) 2 dis-
connected.
• Do not use peak voltage adapter B when
b
measuring the Rectifier Regulator output
peak voltage. a
• Be sure to check the lighting coil before
measuring the Rectifier Regulator output S6S18360
peak voltage.
NOTE:
Be sure to set the measurement range a,
Rectifier Regulator output peak and display the mark b by pushing the
voltage: “SHIFT” switch when checking the Rectifier
Red (R) – Ground Regulator continuity.
Loaded
r/min
1,500 3,500
DC V 13 13
2. Disconnect the Rectifier Regulator con-

nector and terminal.
3. Check the Rectifier Regulator for conti-

nuity. Replace if out of specification.
8-39 6AU3K11

Rectifier Regulator continuity

(testing diode)
Tester lead
+
G/W 3
-
R5
Display value (V) Conti-
(reference data) nuity
0.364 Yes
1
G/W 3 B6 0.741 Yes
G/W 3
G4
G4
G4
R5
B6
1.117
0.444
OL
Yes
Yes
No
2
G4 G/W 3 OL No
B6
B6
B6
R5
G/W 3
G4
0.772
0.432
0.434
Yes
Yes
Yes
3
R5 B6 OL No
R5
R5
G/W 3
G4
OL: Indicates an overload
OL
OL
No
No
4
5
6
7
8
9
6AU3K11 8-40

– +
ELEC
Electrical system
— MEMO —
8-41 6AU3K11

TRBL
SHTG
Troubleshooting
Troubleshooting the outboard motor........................................................... 9-1

Troubleshooting table format..................................................................... 9-1
Troubleshooting the power unit .................................................................9-1
Troubleshooting the PT unit (PT model).................................................... 9-7
Troubleshooting the lower unit ..................................................................9-8
1
2
3
4
5
6
7
8
9
6AU3K11

TRBL
SHTG Troubleshooting
Troubleshooting the outboard motor 9
NOTE:
Before troubleshooting the outboard motor:
• Make sure that fresh fuel of the specified type has been used.
• Make sure that the battery is fully charged.
• Be sure to check that the couplers, connectors, and battery terminals are securely connected.
• When checking the input voltage of a part, the coupler or connector must be disconnected. How-
ever, be careful not to short-circuit the wiring harness.
• Perform the troubleshooting as described in the following tables.
Troubleshooting table format 9
Troubleshooting consists of the following 4 items.

Symptom 1: Specific trouble conditions
Symptom 2: Trouble conditions of an area or individual part
Cause 1: Content considered as the trouble causes of symptom 2
Cause 2: Content considered as the trouble causes of cause 1
Troubleshooting the power unit 9
Symptom 1: Engine does not crank (M model)
Refer
Symptom 2 Cause 1 Cause 2 Checking step to
page
Starter rope does Shift lever not in the Set the shift lever to 3-10
—
not operate N position the N position.
Start-in-gear pro- Adjust the start-in- 3-11
tection cable not — gear protection
adjusted correctly cable.
Manual starter mal- Disassemble and 5-8
function — check the manual
starter.
Stuck piston Seizure or rust Disassemble and 5-1
Piston lock due to check the power
water in the com- — unit.
bustion chamber
Stuck drive shaft Buildup of foreign Disassemble and 6-11
material on the check the lower 6-32
spline of drive shaft unit.
and bushing
Malfunction of the
lower unit internal
parts
9-1 6AU3K11

Troubleshooting the outboard motor
Refer
page
Starter rope
operates, but the
engine does not
crank
Manual starter mal-
function
Damaged flywheel
—
Disassemble and
check the manual
starter.
Check the flywheel
5-8
5-19
1
magnet Woodruff — magnet Woodruff
key
Symptom 1: Engine does not crank (E model)

key.
2
Refer
Symptom 2
Starter motor does

not operate
Cause 1
Shift lever or
remote control lever
Cause 2
—
Checking step
Set the shift lever or

remote control lever
to
page
3-10
3
not in the N position to the N position.
Blown fuse
Engine start button
or engine start
—
—
Check the fuse.
Check the engine
start button or
8-26
8-26
8-27
4
switch malfunction engine start switch.
Neutral switch mal-
function
Starter relay mal-
—
—
Check the neutral
switch.
Check the starter
8-27
8-28
8-29
5
function relay.
Short or open con-
nection in starter
motor circuit
Starter motor mal-
—
Check the wiring
harness continuity.
Disassemble and
WD
8-22
6
function — check the starter
WD: See the wiring diagram.

motor.
7
8
9
6AU3K11 9-2

TRBL
Refer
page
Starter motor oper- Stuck piston Seizure or rust Disassemble and 5-1
ates, but the engine Piston lock due to check the power
does not crank water in the com- — unit.
bustion chamber
Stuck drive shaft Buildup of foreign Disassemble and 6-11
material on the check the lower 6-32
spline of drive shaft unit.
and bushing
Malfunction of the
lower unit internal
parts
Starter motor mal- Disassemble and 8-22
function — check the starter
motor.
Damaged flywheel Check the flywheel 5-19
magnet Woodruff — magnet Woodruff
key key.
Symptom 1: Engine does not start (engine cranks)
Refer
page
Spark plug does not Spark plug malfunc- Check the spark 3-5
—
spark tion plug.
Spark plug cap mal- Check the spark 8-30
—
function plug cap.
Ignition coil mal- Check the ignition 8-31
—
function coil.
Engine shut-off Check the engine 8-33
—
switch malfunction shut-off switch.
Charge coil mal- Check the charge 8-32
—
function coil.
Pulser coil malfunc- Check the pulser 8-31
—
tion coil.
Short or open con- Check the wiring WD
nection in ignition — harness continuity.
circuit
CDI unit malfunc- Check the CDI unit. 8-34
—
tion
9-3 6AU3K11

Refer
page
Fuel not supplied Pinched or kinked
fuel hose
Clogged fuel filter

—
Check the fuel
hoses and fuel hose
joint.
Replace the fuel fil-
3-3
3-3
1
—
ter.
Fuel pump malfunc-
tion —
Disassemble and
check the fuel
pump.
4-4
2
Carburetor malfunc- Malfunction of the Disassemble and 4-11
Low compression
pressure
tion
Valve clearance not

adjusted correctly
carburetor internal
parts
—
check the carbure-
tor.
Adjust the valve
clearance.
5-1
3
4
Damaged cylinder Disassemble and 5-28
head gasket check the cylinder 5-41
Damaged valve head and power
unit.
Valve stuck to valve
guide —
Scratched piston or
cylinder
Damaged or worn
5
piston ring
6
7
8
9
6AU3K11 9-4

TRBL
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, limited
engine speed, or engine stalls
Refer
page
Intermittent spark Spark plug malfunc- Check the spark 3-5
—
tion plug.
Spark plug cap mal- Check the spark 8-30
—
function plug cap.
Ignition coil mal- Check the ignition 8-31
—
function coil.
Engine shut-off Check the engine 8-33
—
switch malfunction shut-off switch.
Charge coil mal- Check the charge 8-32
—
function coil.
Pulser coil malfunc- Check the pulser 8-31
—
tion coil.
nection in ignition — harness continuity.
circuit
CDI unit malfunc- Check the CDI unit. 8-34
—
tion
Incorrect fuel and Pinched or kinked Check the fuel 3-3
air amount supplied fuel hose — hoses and fuel hose
joint.
Clogged fuel filter Replace the fuel fil- 3-3
—
ter.
Fuel pump malfunc- Disassemble and 4-4
tion — check the fuel
pump.
Carburetor malfunc- Throttle stop screw Adjust the throttle 3-11
tion not adjusted cor- stop screw.
rectly
Pilot screw not Adjust the pilot 4-13
adjusted correctly screw.
Malfunction of the Disassemble and 4-11
carburetor internal check the carbure-
parts tor.
9-5 6AU3K11

Refer
page
Low compression
pressure
Valve clearance not
adjusted correctly
Damaged cylinder
head gasket
—
Adjust the valve
clearance.
Disassemble and
check the cylinder
5-1
5-28
5-41
1
head and power
2
Damaged valve
— unit.
Scratched piston or
cylinder
Damaged or worn
piston ring
Throttle valve does
not fully open
Throttle control sys-
tem malfunction
Throttle cable(s) not
adjusted correctly
Throttle link rod not
Check and adjust
the throttle cable(s).
Check and adjust
3-7
3-8
3-9
3
adjusted correctly the throttle link rod.
—
Air leakage into
intake manifold
(carburetor to cylin-
der head)
Damaged gaskets,
spacer, and intake
manifold (carbure-
tor to cylinder head)
Check the gaskets,
spacer, and intake
manifold (carbure-
tor to cylinder
4-11
4
head).
Symptom 1: High engine idle speed
Refer
5
Engine speed does

not decrease when
throttle control lever
Carburetor malfunc-
tion
Throttle stop screw
not adjusted cor-
rectly
Adjust the throttle
stop screw.
page
3-11
6
is in fully closed Pilot screw not Adjust the pilot 4-13
position adjusted correctly
Malfunction of the
carburetor internal
screw.
Disassemble and
check the carbure-
4-11 7
parts tor.
Throttle control
lever does not
return to fully closed
position
Throttle control
system malfunction
Throttle cable(s) not
adjusted correctly
Throttle link rod not
adjusted correctly
Check and adjust
the throttle cable(s).
Check and adjust
the throttle link rod.
3-7
3-8
3-9
8
Throttle cam not Check the throttle 5-17
installed correctly cam.
9
6AU3K11 9-6

TRBL
Symptom 1: Limited engine speed (below 2,000 r/min)
Refer
page
• Buzzer comes on Insufficient engine Add sufficient oil. 3-4
—
(R model) oil
• Oil pressure- Engine oil pressure Oil pump malfunc- Check the oil pump. 5-37
warning indicator decrease tion
comes on
Clogged oil strainer Check the oil 7-22
strainer.
Clogged oil pas- Check the engine 5-28
sages oil passages (power
unit and oil pump).
Oil pressure switch Check the oil pres- 8-34
—
malfunction sure switch.
Troubleshooting the PT unit (PT model) 9
Symptom 1: PT unit does not operate
Refer
page
PT motor does not Blown fuse — Check the fuse. 8-26
operate PT switch malfunc- Check the PT 7-55
—
tion switch.
PT relay malfunc- Check the PT relay. 7-54
—
tion
nection in PT motor — harness continuity.
circuit
PT motor malfunc- Disassemble and 7-37
—
tion check the PT motor.
PT motor operates, Manual valve left Manual valve mal- Check the manual 7-44
but the tilt ram does open function valve.
not extend Insufficient PT fluid — Add sufficient fluid. 3-13
PT fluid leakage Check the PT unit 7-49
—
for leakage.
Clogged filter Disassemble and 7-44
Clogged fluid pas- check the PT unit.
sages
—
Malfunction of the
PT unit internal
parts
9-7 6AU3K11

Symptom 1: PT unit does not hold the outboard motor up
Refer
Manual valve left

open
Manual valve mal-
function
Check the manual
valve.
page
7-44 1
Insufficient PT fluid — Add sufficient fluid. 3-13
—
PT fluid leakage
Air in PT fluid
—
—
Check the PT unit
for leakage.
Bleed the PT unit.
7-49
7-52
2
Clogged fluid pas- Disassemble and 7-44
3
sages check the PT unit.
Malfunction of the —
PT unit internal
parts
Troubleshooting the lower unit

Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate properly
Refer
9
4
Shift cable and shift

cable joint malfunc-
tion (R model)
—
Check and adjust
the shift cable and
shift cable joint. (R
page
3-10 5
model)
Remote control box
malfunction (R
model)
—
Check the remote
control box. (R
model)
3-10
6
Shift rod cam mal- Check the shift link 3-10
—
— function
Detent malfunction
rod.
Check the shift rod
cam.
7-14
7
Shift rod operation Shift rod not con- Check the connec- 6-15
malfunction nected correctly tion of the shift rod. 6-37
Shift mechanism
Shift rod not
adjusted correctly
Adjust the shift rod.
Disassemble and
6-15
6-37
6-7
8
malfunction (in — check the lower 6-27
lower unit) unit.
9
6AU3K11 9-8

TRBL
Symptom 1: Cooling water does not discharge from the cooling water pilot hole
Refer
page
Clogged cooling Check the cooling 3-7
—
water inlet water inlets.
Clogged cooling Check the cooling 3-7
water passages water passages.
Incorrectly con- —
nected cooling
water hose
Damaged water Check the water 6-15
pipe or incorrect — pipe and its installa- 6-37
installation tion.
—
Water pump mal- Damaged water Check the impeller. 6-5
function pump impeller 6-25
Check the Woo- 6-5
druff key. 6-25
Water leakage from Check the water 6-5
water pump hous- pump housing. 6-25
ing Check the insert 6-5
cartridge. 6-25
Check the outer 6-5
plate cartridge. 6-25
9-9 6AU3K11

Index
A. Checking the choke solenoid (R model)... 8-36

Checking the compression pressure .......... 5-1
Abbreviation ................................................1-3
Checking the connecting rod big end
Adjusting the pilot screw ...........................4-13
side clearance ........................................ 5-45
1
Adjusting the throttle cable (H model).........3-7
Checking the connecting rod small end
Adjusting the throttle cable (R model).........3-8
inside diameter and big end inside
Adjusting the throttle link.............................3-9
diameter.................................................. 5-44
After test run .............................................1-19
Checking the cooling water passage.......... 3-7
Assembling the carburetor ........................4-12
Checking the cooling water pilot hole ....... 1-19
2
Assembling the cylinder block...................5-48
Checking the crankpin oil clearance......... 5-45
Assembling the cylinder head ...................5-35
Checking the crankshaft ........................... 5-45
Assembling the drive shaft
Checking the crankshaft journal oil
housing ......................................... 6-13, 6-34
clearance ................................................ 5-46
Assembling the friction plate .....................7-12
Checking the cylinder bore ....................... 5-42
Assembling the fuel pump...........................4-6
Assembling the gear pump .......................7-45
Assembling the lower case ............. 6-12, 6-33
Assembling the manual starter ...................5-9
Checking the cylinder head ...................... 5-29
Checking the diaphragm and valve ............ 4-5
Checking the drive shaft ..................6-12, 6-33
Checking the electrical component........... 8-19
3
Checking the engine idle speed ............... 3-11
assembly......................................... 6-8, 6-28
4
Checking the engine oil .............................. 3-4
Checking the engine oil level.................... 1-13
housing ........................................... 6-9, 6-29
Assembling the PT motor..........................7-39
(H model)................................................ 8-33
Assembling the starter motor ....................8-25
Assembling the swivel bracket..................7-29
(R model)................................................ 8-33
B.
Assembling the tilt cylinder .......................7-50
Assembling the upper case.......................7-22
Checking the engine start button
(H model with electric starter)................. 8-26
Checking the engine start button or
switch and engine shut-off switch........... 1-17
5
Backlash ...................................................6-17 Checking the engine start switch
Backlash (high thrust model) ....................6-42
Bleeding the PT unit..................................7-52
Bottom cowling..........................................7-14
Bow view.....................................................8-9
(R model)................................................ 8-27
Checking the exhaust manifold, oil pan,
and exhaust guide .................................. 7-22
Checking the filter..................................... 7-44
6
Bracket unit ...............................................3-12 Checking the fuel filter .........................3-3, 4-4
7
Break-in.....................................................1-19 Checking the fuel joint ................................ 4-5
Checking the fuel joint and fuel hose
C. (fuel joint-to-carburetor) ............................ 3-3
Carburetor...................................................4-9 Checking the fuel pump.............................. 4-4
Carburetor unit ............................................4-7 Checking the fuel system ......................... 1-13
8
Changing the engine oil ..............................3-4 Checking the fuse..................................... 7-54
Changing the gear oil................................3-14 Checking the fuse (E model) .................... 8-26
Charging system (E model) ......................8-36 Checking the gear oil................................ 3-14
Checking the anode ..................................3-16 Checking the gear oil level ....................... 1-14
Checking the battery .................................3-16 Checking the gear pump .......................... 7-44
Checking the gear shift and throttle
9
Checking the battery (E model) ................1-14
Checking the bearing ...................... 6-12, 6-33 operation................................................. 1-15
Checking the brush holder and Checking the gear shift operation
brush ............................................. 7-39, 8-24 (H model)................................................ 3-10
Checking the camshaft .............................5-35 Checking the gear shift operation
Checking the carburetor............................4-11 (R model)................................................ 3-10
Checking the CDI unit ...............................8-34 Checking the ignition coil.......................... 8-31
Checking the charge coil...........................8-32 Checking the ignition spark ...................... 8-30
6AU3K11 i-1

Index
Checking the ignition timing ......................3-12 Checking the tilt operation (PT model) ..... 3-13
Checking the lighting coil ..........................8-36 Checking the tilt system (MT model) ........ 1-17
Checking the lower case................. 6-12, 6-33 Checking the timing belt ............................. 3-5
Checking the lower unit for air leakage.....3-15 Checking the timing belt and sprocket...... 5-22
Checking the manual starter .......................5-8 Checking the top cowling............................ 3-3
Checking the neutral switch Checking the valve ................................... 5-30
(H model with electric starter) .................8-27 Checking the valve clearance..................... 5-1
Checking the neutral switch (R model) .....8-28 Checking the valve guide ......................... 5-30
Checking the oil pressure switch ..............8-34 Checking the valve seal............................ 7-44
Checking the oil pump ..............................5-37 Checking the valve seat ........................... 5-31
Checking the oil strainer ...........................7-22 Checking the valve spring ........................ 5-29
Checking the outboard motor Checking the warning indicator
mounting height ......................................1-13 assembly ................................................ 8-35
Checking the pinion and forward Checking the water pump..................6-5, 6-25
gear............................................... 6-12, 6-33 Clamp bracket and swivel bracket
Checking the piston clearance..................5-42 (MT model) ............................................. 7-26
Checking the piston diameter ...................5-42 Clamp bracket and swivel bracket
Checking the piston pin boss bore............5-44 (PT model).............................................. 7-31
Checking the piston pin diameter..............5-44 Connecting the throttle cable and shift
Checking the piston ring ...........................5-43 cable (R model) ...................................... 1-14
Checking the piston ring end gap .............5-43 Control system............................................ 3-7
Checking the piston ring groove ...............5-43 Cylinder block ........................................... 5-39
Checking the piston ring side Cylinder head ........................................... 5-25
clearance ................................................5-44
Checking the propeller ..............................3-15 D.
Checking the propeller shaft ............. 6-8, 6-28
Dimension................................................. 2-12
Disassembling the carburetor................... 4-11
housing ........................................... 6-8, 6-28
Disassembling the cylinder block ............. 5-41
Checking the PT fluid level .......................3-13 Disassembling the cylinder head.............. 5-28
Checking the PT motor .............................7-38 Disassembling the drive shaft
Checking the PT relay...............................7-54
housing ..........................................6-11, 6-32
Checking the PT switch ............................7-55
Disassembling the friction plate................ 7-12
Checking the PT system (PT model) ........1-17
Disassembling the fuel pump ..................... 4-5
Checking the pulser coil............................8-31
Disassembling the gear pump .................. 7-44
Checking the Rectifier...............................8-37
Disassembling the lower case .........6-11, 6-32
Checking the Rectifier Regulator ..............8-39
Disassembling the manual starter .............. 5-8
Checking the rocker arm and rocker
arm shaft .................................................5-34
assembly .........................................6-7, 6-27
Checking the shift rod ..................... 6-12, 6-33
Checking the spark plug .............................3-5
housing assembly............................6-7, 6-27
Checking the spark plug cap.....................8-30
Disassembling the PT motor .................... 7-37
Checking the starter motor........................8-23
Disassembling the starter motor............... 8-22
Checking the starter motor operation........8-22
Disassembling the swivel bracket............. 7-28
Checking the starter motor pinion .............8-22
Disassembling the tilt cylinder .................. 7-49
Checking the starter relay (E model) ........8-29
Disassembling the upper case ................. 7-21
Checking the start-in-gear protection
Disassembly and assembly ........................ 1-5
(M model)................................................3-11
Draining the fuel ......................................... 3-4
Checking the steering operation
Drive shaft and lower case ....................... 6-10
(H model) ................................................3-12
Checking the steering system...................1-16
(high thrust model).................................. 6-31
Checking the thermostat .............................3-6
Checking the tilt cylinder and piston .........7-49
Checking the tilt operation (MT model) .....3-13
i-2 6AU3K11

Index
E. L.
Electrical .....................................................2-9 Lower unit .................................. 2-8, 3-14, 6-1
Electrical component and wiring Lower unit (high thrust model) .................. 6-21
1
harness routing .........................................8-1 Lubricating the outboard motor................. 3-17
Engine electric control system ..................8-34
M.
F. Maintenance interval chart ......................... 3-1
Fire prevention ............................................1-4 Maintenance specification .......................... 2-4
Friction plate (H model).............................7-11
Fuel hose, blowby hose, and cooling
water hose ................................................4-1
Fuel pump, fuel filter, and fuel joint .............4-2
Manual format............................................. 1-1
Manual starter (M model) ........................... 5-6
Measuring the forward and reverse
gear backlash ................................6-17, 6-42
2
Fuel system......................................... 2-7, 3-3 Measuring the peak voltage ..................... 8-19
3
Model.......................................................... 1-6
G.
General .....................................................3-16 P.
General specification ..................................2-1 Part, lubricant, and sealant......................... 1-4
General torque ..........................................2-21 Port view................................................... 8-11
H.
Good working practice ................................1-5
Hose routing................................................4-1
Power unit.................................. 2-4, 3-4, 5-12
Power unit (check and adjustment) ............ 5-1
Power unit assembly ................................ 5-12
Precaution when transporting or
4
storing the outboard motor ..................... 1-20
How to use this manual...............................1-1
5
Predelivery check ..................................... 1-13
Propeller selection .................................... 1-12
I. Propeller shaft housing............................... 6-6
Identification................................................1-6 Propeller shaft housing
Ignition and ignition control system...........8-30 (high thrust model).................................. 6-26
Ignition coil, CDI unit, and Rectifier Propeller size............................................ 1-12
(M model)................................................5-14
Ignition coil, CDI unit, and Rectifier
Regulator (E model)................................5-15
Installing the carburetor ............................4-13
PT cylinder................................................ 7-47
PT electrical system ................................. 7-54
PT gear pump........................................... 7-41
PT motor................................................... 7-36
6
Installing the clamp bracket ............ 7-30, 7-34
Installing the cylinder head .......................5-37
Installing the lower unit ................... 6-15, 6-37
Installing the power unit ............................5-51
Installing the propeller shaft
R.
Refacing the valve seat ............................ 5-32
Removing the carburetor .......................... 4-11
Removing the clamp bracket ...........7-28, 7-33
7
housing ......................................... 6-14, 6-35
Removing the cylinder head ..................... 5-28
8
Installing the PT unit .................................7-34
Removing the drive shaft, drive
housing, and drive shaft................ 6-13, 6-35 shaft housing, and shift rod ...........6-11, 6-32
Removing the intake silencer protective
Installing the sprocket and timing belt.......5-22
covering .................................................. 1-13
Installing the starter motor ........................8-26
Installing the steering arm.........................7-23 Removing the lower unit ....................6-4, 6-24
Installing the tiller handle .................... 7-3, 7-8
Installing the upper case ...........................7-24
Installing the water pump ................ 6-15, 6-36
Removing the power unit.......................... 5-18
Removing the propeller shaft
housing assembly............................6-7, 6-27
Removing the PT unit ............................... 7-33
9
Removing the starter motor ...................... 8-22
Removing the steering arm ...................... 7-23
Removing the tiller handle ...................7-3, 7-8
Removing the timing belt and sprocket .... 5-21
6AU3K11 i-3

Index
Removing the upper case .........................7-21
Removing the water pump ................ 6-5, 6-25
Replacing the timing belt.............................5-3
Replacing the valve guide.........................5-31
S.
Safety while working ...................................1-4
Sealant and locking agent table..................1-3
Selecting the crankshaft main bearing......5-48
Selecting the forward gear shim ...............6-40
Selecting the pinion shim ..........................6-40
Selecting the reverse gear shim ...............6-41
Selection ...................................................1-12
Self-protection.............................................1-4
Serial number..............................................1-6
Shimming ..................................................6-40
Shimming (high thrust model) ...................6-39
Special service tool .....................................1-7
Specified torque ........................................2-19
Starter motor (E model) ............................8-20
Starting system .........................................8-26
Symbol ........................................................1-2
T.
Test run.....................................................1-19
Throttle cam and oil pressure switch ........5-17
Tightening torque ......................................2-19
Tiller handle (long) ......................................7-5
Tiller handle (short) .....................................7-1
Timing belt and sprocket...........................5-19
Top cowling.................................................3-3
Top view......................................................8-1
Troubleshooting table format ......................9-1
Troubleshooting the lower unit....................9-8
Troubleshooting the outboard motor...........9-1
Troubleshooting the power unit...................9-1
Troubleshooting the PT unit (PT model) .....9-7
U.
Upper case and steering arm....................7-17
V.
Ventilation ...................................................1-4
i-4 6AU3K11

Index
— MEMO —
1
2
3
4
5
6
7
8
9
6AU3K11 i-5

Wiring diagram
Pike 9.9 M
1 CDI unit Color code

2 Pulser coil B : Black
3 Lighting coil (1 coil) Br : Brown
4 Lighting coil (2 coils) G : Green
5 Charge coil L : Blue
6 Oil pressure switch O : Orange
7 Rectifier P : Pink
8 Rectifier Regulator R : Red
9 Ignition coil W : White
0 Spark plug Y : Yellow
A Fuse (10 A) G/W : Green/white
B Battery W/R : White/red
C Engine shut-off switch Y/R : Yellow/red
D Oil pressure-warning indicator
È Optional

Wiring diagram
FT9.9GE, FT9.9GEP
1 CDI unit Color code
2 Choke solenoid B : Black
3 Pulser coil Br : Brown
4 Lighting coil G : Green
5 Charge coil L : Blue
6 Oil pressure switch Lg : Light green
7 Starter motor O : Orange
8 Rectifier Regulator P : Pink
9 Ignition coil R : Red
0 Spark plug Sb : Sky blue
A PT motor (PT model) W : White
B PT relay (PT model) Y : Yellow
C Fuse (10 A) G/W : Green/white
D Battery W/R : White/red
E Starter relay Y/R : Yellow/red
F Oil pressure-warning indicator
È To remote control box

É PT model

Pike 9.9 M
4
2
5
G/W
G
3
2 8 È
G/W
5
G
R
G/W
G
R
G
G
1 7 9
W/R
Br
P
B
G
G
G
0
W/R
Br
P
B
R
L
B
W/R
Y/R
Br
W
O
P
B
P
Y
L
O
B
G
R
P
Y/R
O
B
R
D
B
B
C
B
A 10A
R R
È
R
B

Pike 9.9 E
2
B
L
1 P 8
4 R
3 G/W
5 G
Y/R
W/R
Br
W
P
Y
O
B
B
P
L
B
B
L
P
Y/R
7 9
F
R
Sb
G
A
G
0
B
B
W/R
G/W
W
Br
G
P
B
O
B
Lg L
È G
B
W/R
Br
R
P
B
G/W
G
G
G
O
B
Sb
Br Lg
L
Br
B
Br
L L É
E G G
G
B
L
R
R
10A
B
B
R R R
G
C
L
D Sb
Lg A
A
A B
Sb
Lg

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Pike 9,9

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

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

Special service tool .......................................................................................1-7

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The symbols below are designed to indicate the content of a chapter.

SPEC POWR ELEC – +

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

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The following abbreviations are used in this service manual.

Sealant and locking agent table 1

LOCTITE 518 Sealant Henkel

ThreeBond 1207B Sealant ThreeBond

ME-1 Antirust lubricant

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To prevent an accident or injury and to

Part, lubricant, and sealant 1

or safety goggles during all operations involv-

4. To protect your skin, apply a protective

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

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industrial hygiene. 1. Use compressed air to remove dust and

Special service tool 2. Apply oil or fluid to the contact surfaces

3. Install bearings with the manufacture

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Digital tachometer Compression gauge

Timing light Tappet adjusting tool

Leakage tester Flywheel holder

Vacuum/pressure pump gauge set Flywheel puller

Pilot screw adjusting tool Shaft holder

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Bearing puller assembly Ball bearing attachment

Stopper guide stand Bushing attachment

Bushing attachment Driver rod LL

Needle bearing attachment Bushing installer center bolt

Driver rod LS Bearing housing puller claw S

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Shimming plate Ignition tester

Needle bearing attachment

Power tilt wrench

Digital circuit tester

Peak voltage adapter B

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a Propeller diameter (in inches)

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Checking the outboard motor

1. Check that the anti-cavitation plate is

Checking the fuel system 1

1. Check that the fuel hoses are securely

2. Check that the clamp brackets are

Removing the intake silencer

1. Remove the protective covering 1 from