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Wahoo 15-20 - English

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1. SSS ee FI l PP gt Be D 3 pg ALS Gei w gt KS us I gt ei m EA s E C e d S ae s lt ees N aa 7 NE TIE j T 2 Q Vg RIG Ga DR gt L P E ees dl SONS d HOS ES o gt ASE gt gt E EEN 4 Turn the flywheel magnet clockwise and align the 1 A mark on the driven sprocket with the A mark on the cylinder head 6AG3 11 Power unit check and adjustment xT is S6AG5050 5 Measure the intake and exhaust valve clearances for cylinder 1 Adjust if out of Specification S6AG5G10 NOTE Note the measurement data Valve clearance Intake 0 15 0 25 mm 0 006 0 010 in Exhaust 0 25 0 35 mm 0 010 0 014 in 5 2 6 Loosen the rocker arm locknut and then turn the adjusting screw until the Specified valve clearance Is obtained S6AG5060 NOTE e To decrease the valve clearance turn the adjusting screw in direction e To increase the valve clearance turn the adjusting screw in direction 7 Tighten the rocker arm locknut to the specified torque Rocker arm locknut 14 N m 1 4 kgf m 10 3 ft lb 8 Turn the flywheel magnet an additional 360 clockwise and align the A mark on the driven sprocket with the A mark du on the cylinder head S6AG5051 9 Repeat steps 5 7 for cylinder 2 10 Install all parts removed during removal 5 3 Replacing the timing belt CAU
2. 0 05 mm 58 62 C 0 0020 in 136 144 F valve begins to open above more than 70 C 158 F 3 0 mm 0 12 in 7 Install the new gasket thermostat and thermostat cover and then tighten the thermostat cover bolts to the specified torque Thermostat cover bolt 8 N m 0 8 kgf m 5 9 ft lb 3 6 ADJ Periodic check and adjustment Checking the cooling water passage 1 3 7 Check the cooling water inlet covers and cooling water inlets clean if clogged 56D53130 S6AG3170 Place the lower unit in water and then Start the engine Check for water flow at the cooling water pilot hole If there is no water flow check the cooling water passages inside the outboard motor S6AG1230 Control system Adjusting the throttle cable tiller handle model L Disconnect the throttle link rod from the free accel lever Loosen the locknuts and and then turn the adjusting nuts and to loosen the throttle cables and Turn the throttle grip to the fully open position and hold it in place Turn the adjusting nut so that the fully open stopper on the throttle cam con tacts the throttle cam bracket as shown and then tighten the locknut NOTE Be careful not to pull the outer cables too much towards the power unit as they could be pulled out of the grommet If the outer cables are pulled out of the grommet see Assembling the tiller handl
3. L L at 20 C 68 F 0 77 1 04 C1 The figures are for reference only 2 Ambient temperature 24 C 75 F with no power supplied The figures are for reference only 2 13 BAG3J1 1 Maintenance specification Item Starter motor Type Output Cranking time limit Stator motor clearance Wear limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Standard undercut Wear limit Pinion stopper height Charging system Fuse Lighting coil output peak voltage G G at cranking unloaded at 1 500 r min unloaded at 3 500 r min unloaded Lighting coil resistance G G at 20 C 68 F Rectifier Regulator output peak voltage R B at 1 500 r min unloaded at 3 500 r min unloaded C1 The figures are for reference only 6AG3J11 Model Bendix 0 60 30 0 05 0 25 0 002 0 010 0 6 0 02 12 5 0 49 9 0 0 35 30 0 1 18 29 0 1 14 0 8 0 03 0 2 0 01 26 5 28 5 1 04 1 12 Bendix 0 60 30 0 05 0 25 0 002 0 010 0 6 0 02 12 5 0 49 9 0 0 35 30 0 1 18 29 0 1 14 0 8 0 03 0 2 0 01 26 5 28 5 1 04 1 12 2 14 SPEC EN Specification Ei Power tilt motor Output Brushes Standard length Wear limit Commutator Standard diameter Wear limit Standard undercut Wear limit 9 15 BAG3J1 1 Maintenance specification Power unit Item Unit ues E 221 2087 Power unit Minimum
4. 5 62 7 Install the throttle cables onto the throttle cam and then adjust the throttle cables Tiller handle model Install the cable joint onto the throttle cam 9 and then adjust the throttle cable Remote control model NOTE e To adjust the throttle cable s see Adjust ing the throttle cable tiller handle model 3 7 or Adjusting the throttle cable remote control model 3 8 e Install the steering bracket cover after adjusting the throttle cables Tiller handle model 8 Install the bracket 45 and warning indica tor assembly 46 S6AG5HO00 9 Install the junction box bracket 47 Man ual tilt model Install the power tilt relay 48 Power tilt model 10 Connect the engine stop lanyard switch lead W dg Install the engine stop lan yard switch lead B terminal using the bolt Connect the engine start button leads R and Br Manual tilt model Tiller handle model Connect the power tilt motor leads and power tilt relay leads and then install the terminal nuts Connect the power tilt switch coupler 27 and power tilt Switch lead R Power tilt model 5 63 AY LED E KO lO zl WIC CT Le d C be 3 e eee CH 69 S6AG5H10 A HS ceo amp Oe BIDVE NN TAN aC s O a l Va 1 d SE ON H J SI 1 di H Q S Sie SNE A S d PES e TOR FS S6AG5H20 Manual tilt model Tiller hand
5. 6AG 3 11 7 14 Bracket unit Removing the upper case NOTE e Drain the engine oil before removing the upper case assembly e Be sure to remove the shift rod assembly before removing the upper case assembly from the clamp bracket 1 Remove the ground lead terminal from the swivel bracket 2 Remove the mount housings and then remove the rubber dampers 3 Remove the upper mounting nuts 4 and then remove the upper case assembly Q S6AG7520 Disassembling the upper case 1 Remove the engine oil drain bolt and damper 2 Remove the water pipe and upper mount from the upper case assembly 3 Remove the oil pan assembly bolts and then remove the oil pan assembly from the upper case gy aD ho S6AG7530 4 Remove the circlip and then remove the drive shaft bushing L transom model S6AG7540 vz Driver rod L3 90890 06652 Needle bearing attachment 90890 06618 Checking the drive shaft bushing L transom model 1 Check the drive shaft bushing Replace if cracked or worn Disassembling the exhaust manifold oil pan and exhaust guide 1 Remove the exhaust manifold and gasket from the oil pan 6AG3 11 Upper case and steering arm Checking the exhaust manifold oil pan and exhaust guide 1 Check the exhaust manifold oil pan and exhaust guide Replace if cracked or cor roded NOTE 0 Clean the removed parts before checki
6. Fasten the wiring harness engine stop lanyard switch lead and stator coil assembly lead with the holder D Install the terminals of the engine stop lanyard switch lead and wiring harness ground lead using the bolt and then apply Selva grease to the terminals and bolt Fasten the lighting coil leads wiring harness and ground lead with the holder Install the terminal of the oil pressure switch lead so that the lead Is routed as shown Apply Selva grease to the terminal and bolt and then install the cap Insert the rubber plugs into the lighting coil connectors Fasten the ignition coil lead with the holder Fasten the wiring harness with plastic ties Install the plastic tle as shown and cut off the excess end of the tie to 3 mm 0 12 In or less Install the plastic ties as shown Install the terminal of the ground lead using the bolt making sure that the crimped section of the terminal that secures the ground lead is facing outward as shown The connectors can be fastened in any position in the holder 6AG 3 11 8 8 ELEC 7 ELEC W s Electrical system Electric starter model a Electric starter model without power tilt Pulser coil 2 Starter motor 3 Stator coil assembly charge coll lighting coil and power bobbin 4 Thermoswitch G Rectifier Regulator Ignition coil 8 9 S6AG 8370 Oil pressure switch Fuse 20 A Starter relay CDI unit 0
7. Replace the valve if out of specification 569J5750 Valve stem diameter Intake 5 475 5 490 mm 0 2156 0 2161 in Exhaust 5 460 5 475 mm 0 2150 0 2156 in 4 Measure the valve stem runout Replace the valve if above specification 5 39 S69J5760 Valve stem runout limit 0 01 mm 0 0004 in Checking the valve guide NOTE Before checking a valve guide make sure that the valve stem diameter is within specifi cation 1 Measure the valve guide inside diameter Q 56D55490 Valve guide inside diameter a Intake and exhaust 5 500 5 512 mm 0 2165 0 2170 in 2 Calculate the valve stem to valve guide clearance as follows Replace the valve guide if out of specification 6AG3 11 Cylinder head Valve stem to valve guide clearance valve guide inside diameter valve stem diameter Intake 0 010 0 037 mm 0 0004 0 0015 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Replacing the valve guide 1 Remove the valve seal 2 Remove the valve guide by striking the special service tool from the combus tion chamber side S6AG5181 Valve guide remover installer 90890 06801 3 Install a new valve guide using the special service tool from the camshaft side to the specified height S6AG5180 NOTE o Apply engine oil to the surface of the new valve guide before installation 6AG3 11 Valve guide remover inst
8. S6AG5520 WARNING The spiral spring can pop out Cover the spiral spring with rags and then pull out the sheave drum 3 Remove the spiral spring from the manual starter cover WARNING The spiral spring can pop out Cover the spiral spring with rags when removing it 4 Remove the starter rope and E clip and then remove the drive pawl and springs 8 from the sheave drum S6AG5530 5 Check the drive pawl E clip starter plunger and drive plate Replace if cracked or damaged 6 Check the springs Replace if bent cracked or damaged S6AG5550 7 Check the sheave drum Replace if cracked or damaged 8 Check the spiral spring Replace if cracked bent or damaged 6AG3J11 9 Check the starter handle Replace if cracked or damaged 10 Check the starter rope Replace if dam aged NOTE e When replacing the starter rope with a new one make sure that the length is approxi mately 1 800 mm 70 9 in e Be sure to use a genuine Selva starter rope Assembling the manual starter 1 Install the starter rope 1 into the sheave drum NOTE Before installing the cover route the Starter rope through the manual starter cover 2 Install the drive pawl starter plunger Springs and E clip 3 Install the starter handle S6AG5560 NOTE e Tie a knot at the end of the starter rope as Shown in the illustration e Be sure to leave 12 20 mm 0 47
9. 0 79 in at the end of the starter rope 6AG3 11 Manual starter manual starter model 4 Wind the starter rope 1 twice around the sheave drum in the direction of the arrow shown in the illustration S6AG5570 NOTE After winding the starter rope 07 around the sheave drum install the starter rope in the notch 5 Install the spiral spring 8 into the manual Starter cover FEVIK J gt 9 8 56AG5580 NOTE Hook the end of the spiral spring onto the cut out in the starter cover 6 Install the sheave drum into the man ual starter cover S6AG5590 NOTE e When installing the sheave drum set the Spiral spring by turning the sheave drum e Hook the end of the spiral spring 8 onto the cut out in the sheave drum 7 Install drive pawl spring 1 and the drive plate di and then tighten the screw 02 to the specified torque S6AG5600 Drive plate screw 2 7 N m 0 7 kgf m 5 2 ft lb 8 Turn the sheave drum 4 turns in the direction of the arrow shown S6AG5610 NOTE Hold the starter plunger 43 while turning the sheave drum as shown 9 Remove the starter rope from the notch b and then fit the starter rope into the groove in the sheave drum NOTE e Be sure to hold the sheave drum with your hand so that it turns slowly e Allow the spring force to slowly turn the drum as the starter rope winds around the drum 10 Pull th
10. 12 N m 1 2 kgf m 8 9 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 6 N m 0 6 kgf m 4 4 ft Ib XJ 18 N m 1 8 kgf m 13 3 ft Ib 12 N m 1 2 kgf m 8 9 ft Ib S6AG 5640 No Part name 1 Cylinder block 1 2 Gasket 1 3 Thermostat 1 4 Screw 2 oh x 25 mm 5 Anode 2 6 Thermostat cover 1 7 Bolt 3 M6 x 25 mm 8 Oil filter 1 9 Gasket 1 10 Exhaust cover 1 11 Bolt 7 M6 x 25 mm 12 Plug 1 13 Anode 1 14 Screw 1 od x 16 mm 15 Piston ring set 2 16 Clip 4 17 Piston pin 2 5 49 6AG3 11 Cylinder block YD 14 N m 1 4 kgf m 10 3 ft Ib 27 N m 2 7 kar m 19 9ft b amp LO 6N m 0 6 kgf m 4 4 ft Ib 12 N m 1 2 kgf m 8 9 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 6 N m 0 6 kgf m 4 4 ft Ib XJ 18 N m 1 8 kgf m 13 3 ft Ib 12 N m 1 2 kgf m 8 9 ft Ib S6AG 5640 Partname Piston Connecting rod Bolt Oil seal Crankshaft Main bearing Oil seal Crankcase Bolt Bolt NO M6 x 36 mm Not reusable Not reusable M6 x 40 mm M8 x 65 mm 2 4 1 1 4 1 1 6 4 6AG 3 11 5 50 Disassembling the cylinder block 1 Remove the exhaust cover bolts in the sequence shown and then remove the exhaust cover h Glen 156 S e DI gt GC O 090 6 5 59 BR 9 L S6AG5790 2 Remove the thermostat cover 3 Remove the oil filter using a 64 mm 2 5 in oil filter wrench
11. 2 Check the fuel filter cup Clean with Straight gasoline if there are foreign sub stances and replace if cracked S6AG 3050 NOTE Be sure not to spill any fuel when removing the fuel filter cup Draining the fuel 1 Place a container or rag under the car buretor fuel drain hole and then remove the fuel drain screw and let the fuel drain completely S AE pa S Sl TR S6AG3060 Power unit Checking the engine oil 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 3 3 Remove the oil dipstick again to check the oil level and to check the oil for dis coloration and its viscosity We L S6AG1050 NOTE SE e If the oil appears milky or dirty check for and repair the cause and then change the oil e If the engine oil is below the minimum level mark add sufficient oil until the level is between and Changing the engine oil 1 Start the engine warm it up and then turn it off 2 Remove the oil dipstick and oil filler cap QD BIL M JE CA AN i EV ON SE L SE A Pr e 3070 3 Place a drain pan under the drain hole and then remove the engine oil drain bolt and let the oil drain completely 6AG3 11 S6AG3080 NOTE e Be sure to clean up any oil spills e When using an oil changer to change the engine oil insert the oil changer hose
12. 4 Remove the crankcase bolts in the sequence shown and then remove the crankcase S6AG5820 5 51 5 Remove the connecting rod cap bolts and connecting rod caps and then remove the connecting rod and piston assemblies S6AG5A10 6 Remove the crankshaft main bearings and oil seals NOTE SE Be sure to keep the main bearings in the order as they were removed 7 Remove the piston pin clips O and pis ton pin and then remove the piston WS D S i NOTE e Mark each piston with an identification number of the corresponding cylinder e To avoid interchanging the connecting rods and connecting rod caps mark each with an identification mark and be sure to keep them in the order as they were removed 8 Remove the piston rings 6AG3 11 Checking the piston diameter 1 Measure the piston diameter at the spec ified measuring point Replace if out of Specification S6AG5850 Piston diameter 62 950 62 965 mm 2 4783 2 4789 in Measuring point amp 3 5 mm 0 14 in up from the bottom of the piston skirt Oversize piston diameter Oversize 1st 63 200 3 215 mm 2 4882 2 4888 in Oversize 2nd 63 450 63 465 mm 2 4980 2 4986 in Checking the cylinder bore 1 Measure the cylinder bore D D at measuring points and and in direction D D3 Ds which is parallel to the crankshaft and in direction D Da Del which Is at a right angle
13. 60 N m 6 0 kgf m 44 3 ft lb Bleeding the power tilt unit NOTE Make sure that the tilt ram is fully extended 1 Place the power tilt unit in an upright position 2 Turn the manual valve 07 clockwise 90 to close it S6AG7341 3 Remove the reservoir cap and then check the fluid level in the reservorr 6AG3 11 Power tilt cylinder power tilt model S6AG7360 NOTE _ _ e If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole e If fluid is below the correct level add the recommended fluid Ee Recommended power tilt fluid ATF Dexron II 4 Install the reservoir cap and then tighten it to the specified torque Reservoir cap 5 N m 0 5 kgf m 3 7 ft lb 7 46 Bracket unit 5 Connect the power tilt motor leads to the battery terminals to fully retract the tilt ram S6AG7380 Power tilt motor Battery Ram lead terminal Green G Down sel _ 6 Reverse the power tilt motor leads between the battery terminals to fully extend the tilt ram Blue L Green G 7 47 NOTE se e Repeat steps 5 6 to fully extend and retract the tilt ram 4 to 5 times e If the tit ram does not move up and down easily push and pull on the ram to assist the operation 7 Fully extend the tilt ram 8 Remove the reservoir cap and then check the fluid level in the reservorr WARNING Make sure th
14. Wahoo 15 Wahoo 20 SERVICE MANUAL AELK 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 Particularly important information is distinguished in this manual by the following notations N 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 eas
15. a 8 18 9 2 TRBL P SHTG Troubleshooting Symptom 1 Engine does not start engine cranks S park plug does not Spark S park plug malfunc tion Spark plug cap mal function Ignition coil mal function Engine stop lan yard switch mal function function Pulser coil malfunc CDI unit malfunc tion Pinched or kinked fuel hose Fuel not supplied Clogged fuel filter Fuel pump malfunc tion Carburetor malfunc tion function adjusted correctly head gasket Valve stuck to valve guide Scratched piston and piston ring s Low compression pressure 9 3 Malfunction of the carburetor internal Refer to Check the spark plug Check the spark plug cap Check the ignition coil w S Q U D H H 22 22 24 8 Check the engine stop lanyard switch 8 coll coll Check the fuel 23 23 25 3 2 hoses and fuel hose 3 3 Clean or replace the fuel filter Disassemble and check the fuel 4 6 Disassemble and 4 12 check the carbure tor Check the Prime Start Adjust the valve clearance Disassemble and check the cylinder head and power 4 13 5 2 5 37 5 51 6AG3J11 Troubleshooting the outboard motor Symptom 1 Unstable engine idle speed poor acceleration poor performance limited engine speed or engine stalls Refer Symptom 2 Cause 1 Cause 2 Checking step to age OD LO Inter
16. and then install the special service tool S6P23390 2 Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds CAUTION Do not over pressurize the lower unit oth erwise the oil seals can be damaged NOTE Cover the check hole with a rag when remov ing the special service tool from the lower unit Lower unit holding pressure 100 kPa 1 0 kgf cm2 14 5 psi 3 Ifthe specified pressure cannot be main tained check the propeller shaft drive Shaft shift rod O rings and oil seals for damage If necessary check each shaft for bends and damage Checking the propeller 1 Check the propeller blades and splines Replace the propeller if cracked dam aged or worn NOTE es When replacing the propeller see Propeller selection 1 12 and select a propeller of the Same size as originally installed 6AG3 11 General Checking the anode 1 Check the anodes Clean the anodes if there are scales grease or oil S6AG 3250 S6AG 3270 6AG3 11 Lower unit General S6AG 3280 S6AG 3320 CAUTION Do not oil grease or paint the anodes otherwise they will be ineffective NOTE e Replace the anodes if excessively eroded In addition check the ground lead e If it is necessary to disassemble the out board motor to check an anode refer to the applicable disassembly procedure in this manual ADJ Periodic check an
17. m 19 9 ft Ib S6AG5G90 Remarks Ignition coil and Rectifier Regulator 2 4N m 0 4 kgf m 3 0 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib S6AG5740 No Ponne oy Remarks Rectifier Regulator Electric starter model Nut Electric starter model Collar Electric starter model Grommet Electric starter model Screw op x 30 mm Electric starter model Holder Holder Ignition coll Spark plug cap Bolt Bolt Spark plug M6 x 25 mm M6 x 15 mm 1 2 3 4 5 6 7 8 9 10 11 NO k MA M k k k FM NN NN m N 5 17 6AG3J11 Power unit CDI unit and junction box manual tilt model Axe 8 N m 0 8 kgf m 5 9 ft Ib S6AG5710 Partname Ty J unction box cover J unction box Damper Bolt Bracket Bolt Holder Grommet CDI unit Bolt Bolt Bracket Bolt Grommet Collar Neutral switch Bracket M6 x 14 mm Mp x 20 mm M6 x 20 mm M6 x 20 mm A kd po Hi D d Oo Ln RUNE KA Fi U N M6 x 25 mm KA e kA O Ul A Tiller handle model with electric starter KA FA D D DU k KA KA KA A k NBT NF ob m sl 6AG 3 11 5 18 Ase 8 N m 0 8 kgf m 5 9 ft Ib Ase 8 N m 0 8 kgf m 5 9 ft Ib S6AG5710 Partname 2 M6 x 16 mm Holder Bolt Pulser coil Bolt M5 x 12 mm Stator coil assembly Bolt Wiring harness Wiring harness Plate spring M6 x 30 mm Tiller handle model Remote control model A k KA D KA KA k ND 5 19 6
18. tons and valves will collide with each other and be damaged 1 Check that the keyway in the crank shaft and the mating surface of the crankcase and cylinder block are aligned S6AG5A90 2 Install the Woodruff key drive Sprocket and retaining plate and then install the drive sprocket nut tem porarily 6AG3 11 S6AG5A80 3 Install the power unit onto the special service tool and then tighten the drive Sprocket nut to the specified torque S6AG5B00 NOTE e Use a deep 41 mm socket to tighten the drive sprocket nut e Make sure that the power unit does not turn when tightening the drive sprocket nut Shaft holder 90890 06069 Timing belt and sprocket N Cat NC AR IING 5 Hold the driven sprocket using the spe cial service tool AP and then tighten the driven sprocket bolt 40 to the specified torque N Le L ml HI AS e ec NOTE Make sure that the driven sprocket does not turn when tightening the driven sprocket bolt Flywheel holder 49 90890 06522 Driven sprocket bolt 49 22 N m 2 2 kgf m 16 2 ft lb Drive sprocket nut 110 N m 11 0 kgf m 81 1 ft lb 4 Install the Woodruff key driven Sprocket 8 and washer and then install the driven sprocket bolt o tempo rarily 6AG3 11 5 32 6 Align the 1 A mark on the driven sprocket 8 with the A mark on the cylinder head S6AG5H81
19. 10 Remove the dipstick and apron and then remove the mounting bolts 11 Remove the power unit gasket 4 and dowels G 6AG 3 11 5 28 Timing belt and sprocket 108 N m 10 8 kgf m 79 7 ft Ib S6AG 5680 Parinama Width across flats 24 mm Washer Flywheel magnet Bolt Stator coil assembly Timing belt Nut Retaining plate Drive sprocket Woodruff key Woodruff key Woodruff key Driven sprocket Bolt Washer M6 x 30 mm Width across flats 41 mm A KA A en Hi D JO Hi P D Ari RK WN KA k PrP k KA KA k k PP D FA KA KA Ul 5 29 6AG3 11 Timing belt and sprocket Removing the timing belt and sprocket 1 Remove the flywheel magnet and stator coil assembly NOTE See Replacing the timing belt 5 3 2 Align the 1 A mark on the driven sprocket with the A mark on the cylinder head NOTE Check that the mark on the drive sprocket and the mark on the cylinder block are aligned 3 Remove the timing belt from the driven sprocket and then remove it from the drive sprocket 6AG3 11 CAUTION Unless directed to do so in the following instructions do not turn the drive sprocket or driven sprocket when the tim ing belt is not installed Otherwise the pis tons and valves will collide with each other and be damaged 4 Align the mark on the drive sprocket with the mating surface of the crank case and cylinder block by turn
20. 7 Align the mark on the drive sprocket with the mark on the cylinder block by turning the crankshaft counterclockwise approximately 90 gradually S6AG5B20 8 Install the timing belt 012 onto the drive Sprocket and then install it onto the driven sprocket with its part number in the upright position 5 33 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 9 Turn the drive sprocket clockwise 2 turns and then check that the alignment marks O and amp are aligned eae II ACE NEES IT S6AG5102 10 Install the stator coil assembly and fly wheel magnet NOTE See Replacing the timing belt 5 3 6AG3 11 Cylinder head Axa 8 N m 0 8 kgf m 5 9 ft Ib A KA po Hi D d On Hi P IF KA kA k k FA bm SIH Ul B DI N Part name Intake manifold Bolt Gasket Gasket Cylinder head assembly Bolt Bolt Plate Gasket Screw Gasket Cylinder head cover Bolt Plug O ring Anode Screw 6AG3 11 N NNN OY k Ak k LA OFF k FF Timing belt and sprocket Cylinder head 8 N m 0 8 kgf m 5 9 ft Ib MG x 55 mm Not reusable Not reusable M9 x 84 mm M6 x 25 mm Not reusable 4 x 9 mm Not reusable M6 x 20 mm Not reusable 05 x 24 mm 15 N m 1 5 kgf m 11 1 ft Ib AL 29N m 2 9 kgf m 21 4 ft
21. Checking the Steering system ese ee e ee eee 1 16 Checking the tilt system manual tilt model 1 17 Checking the power tilt system power tilt model 1 17 Checking the engine start button or switch and engine stop lanyard SVE EE KE es atch NE 1 18 Checking the cooling water pilot hole sse eee 1 18 ET 1 19 Break EE EE ENE 1 19 EEE RENEE EE EE EE anatase 1 19 Precaution when transporting or storing the outboard motor 1 19 General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under stand Use the information below as a guide for effective and quality service s Parts are shown and detailed in an exploded diagram and are listed in the component list see in the figure below for an example page s The component list consists of part names and quantities as well as bolt and screw dimensions see in the figure below Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point see in the figure below s 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 installati
22. Cylinder head journal inside 22 000 22 021 0 8661 0 8670 diameter A Cylinder head journal inside 34 000 34 025 1 3386 1 3396 diameter B Camshaft fr Intake A lA 28 546 28 646 1 1239 1 1278 Exhaust A J 28 582 28 682 1 1253 1 1292 Intake and S 23 95 24 05 0 9429 0 9468 exhaust B 1 Measuring conditions Ambient temperature 20 C 68 F wide open throttle with spark plugs removed from all cylinders Since this outboard motor is equipped with an automatic decompression mechanism the compression pressure may vary depending on the speed at which the starter handle is pulled when using the manual starter to crank the engine Manual starter model The figures are for reference only 2 For details of the checking method see Checking the oil pressure 5 1 The figures are for reference only 2 7 GAG3J11 Maintenance specification mn T ER 20EBT i 21 967 21 980 0 8648 0 8654 33 935 33 955 1 3360 1 3368 Camshaft journal diameter C Camshaft journal diameter D Camshaft runout limit Rocker arm shaft Rocker arm Valve Valve clearance cold Intake i 0 15 0 25 0 006 0 010 Exhaust 0 25 0 35 0 010 0 014 Head diameter A Intake i 27 9 28 1 1 10 1 11 Exhaust 24 0 24 2 0 94 0 95 Face width B Intake B Exhaust Z Seat contact width C Intake and exhaust E Margin thickness D 0 03 0 0012 12 941 12 951 0 5095 0 5099 13 000
23. ENECO NE GE HUESEN 3 14 CE Mani Qing NE JEArf Ouse eee eee 3 14 Checking the lower unit for alr leakage sss ee eee eee eee eee 3 15 GENT NE NO T eee 3 15 Geneve 3 16 Checking NOE ver 3 16 CE NENNE 3 17 Lubricating the outboard moor esse sees eee 3 18 6AG3 11 ADJ Periodic check and adjustment Maintenance interval chart Use the following chartas a guideline for general maintenance Adjust the maintenance intervals according to the operating conditions of the outboard motor wie Every Refer to Item Remarks 10 hours 50 hours 100 hours 200 hours age 1 month 3 months Fr months 1 RE pag Checkireplace 36 Anodes ae a Check replace E 16 cylinder block thermostat cover Battery Chehare 0 30 Cooling waterpassages Clean 0 0 1 37 Tap ming Lie 01 32 Fuelfiter Liers 0 0 0 33 Fussen Jet fofof 1 0 Geri Liege SO of 344 Lubrication points Lubricate fol gt e Engineidlespeed Cheek o o n Powertitunt Le oon Propeller and cotterpn Checkrepace 0 O 316 E 1 f o 39 30 Thermostat LCechietkbee T of 36 poe pall TT throttle pick up timing S 9 Waterpump T Checkireplace o 65 fEngineoll chechan 0 0 33 Oilfiter cartridge Large o a 3 5 S park a Clean adjust replace Timing belt Check replace PO f 35 Valve clearance OHC Check 5 2 adjustment NOTE e When
24. Maintenance specification ssssssssssssssssssssssssssssssssssssssssssssssss sss sss ss sss 2 7 POW GE le SSS 2 7 ES EE 2 11 KON ee 2 12 VSO GG PRE EE at 2 12 POMERS 2 16 FUSA 2 19 EOWET De UE 2 20 Stelle ORT MR PEN mtn nnn E 2 21 MESSER 2 24 Tightening 1 Ur EE 2 30 Teilen e reide ee 2 30 General TO QU C8 eher 2 33 6AG3J11 SPEC EN Specification General specification uk Dimension Overall length Overall width Overall height S L Transom height S L Boat transom height S L Weight with aluminum propeller S L Performance Maximum output Full throttle operating range Maximum fuel consumption Engine idle speed Power unit Type Cylinder quantity Total displacement Bore x stroke Compression ratio Control system Starting system Fuel system Enrichment system Ignition control system 2 1 1 048 41 3 420 16 5 1 078 1 078 42 4 42 4 1 205 47 4 438 438 17 2 17 2 22 2 Pi p 381 381 15 0 15 0 508 20 0 kg Ib kg Ib 55 7 60 7 123 134 KW HP 11 0 15 at 14 7 20 at 5 500 r min 5 500 r min min L US gal 5 4 1 4 1 2 at 6 8 1 8 1 5 at Imp gal hr 5 500 r min 5 500 r min min 4 stroke L 2 cm cu in 362 22 1 mm in 63 0 x 58 1 2 48 x 2 29 9 3 Tiller handle Carburetor Prime Start CDI micro computer 6AG3J1 1 General specification si Micro computer Advanced type Ig
25. TOP mark on the steering lock lever up e Be sure to install the collars in the correct positions the collar lengths are different 7 6 Bracket unit 3 Install the friction plate assembly onto the Swivel bracket and tighten the friction plate bolts and temporarily NOTE To check and adjust the friction plate see Checking the steering operation tiller han L i dle model 3 13 E J WW Friction self locking nut 6 N m 0 6 kgf m 4 4 ft lb S6AG7B10 NOTE Before installing the friction plate bolts turn the outboard motor all the way to port or Starboard 4 Tighten the friction plate bolts and GO to the specified torques Friction plate bolt M8 18 N m 1 8 kgf m 13 3 ft lb Friction plate bolt M5 7 N m 0 7 kgf m 5 2 ft lb 5 Move the steering lock lever to posi tion and then tighten the self locking nut to the specified torque S6AG7B20 1 6AG 3 11 Friction plate tiller handle model Bottom cowling Bottom cowling Sa 2 N m As iO U 1 U 1 SCH S 22 w 31 ra Ga Se or 13 916 2 i J 13 ee Se ser ee 42 S6AG 7460 wei Patnane 09 Remar 1 Adapter Warning indicator assembly Bracket Tiller handle model Bolt M6 x 10 mm Tiller handle model Bracket Remote control model Bolt M6 x 14 mm Remote control model Holder P ower tilt model Screw 6
26. at 0 05 mm 0 0020 in 58 62 136 144 Fully open temperature 70 158 Valve open lower limit 3 0 0 12 C1 The figures are for reference only Fuel system mm ep er Carburetor ID mark For Europe 6AG50 6AH50 For Oceania 2 ang Float height i 15 0 1 0 0 59 0 04 Valve seat size i 1 0 0 04 Main jet M J For Europe 80 112 For Oceania 80 118 Main nozzle M N 2 2 0 09 2 4 0 09 Pilot jet P J 38 45 Pilot screw P S For Europe turns out 1 1 2 3 3 8 1 2 For Oceania turns out 23 4 1 2 Idle speed r min 1 050 50 9 19 BAG3J1 1 Maintenance specification Fuel pump Fuel pump holding pressure Fuel inlet positive pressure kPa kgf cm psi Fuel inlet negative pressure kPa kgf cm psi Fuel outlet positive pressure kPa kgf cm psi Fuel joint holding pressure Positive pressure kPa kgf cm psi Fuel filter assembly holding pressure Positive pressure kPa 200 2 0 29 0 kgf cm psi Lower unit Lower unit Holding pressure kPa 100 1 0 14 5 kgf cm psi Gear backlash Pinion to forward gear 0 18 0 87 0 0071 0 0343 Pinion to reverse gear 0 95 1 66 0 0374 0 0654 Pinion shims 1 13 1 20 Forward gear shims 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Reverse gear shims mm 0 1 0 2 0 3 0 4 0 5 Propeller shaft Drive shaft 6AG3J1 1 2 20 SPEC EN Specification Electrical Ignition and ignition control system Spark plug gap Spark
27. engine stop lanyard switch lead and neutral switch lead as shown Fasten the stator coil assembly lead wiring harness and fuse lead with a plastic tie Fasten the warning indicator assembly coupler stator coil assembly lead wiring harness and fuse lead with a plastic tie Install the plastic tie as shown Route the power tilt relay lead R B to the front of the holder making sure that it is not pinched Route the power tilt relay leads to the front of the holder making sure that they are not pinched and then fasten them with a plastic tie Install the plastic tie as shown The connectors can be fastened in any position in the holder 6AG 3 11 8 6 ELEC 7 ELEC W s Electrical system Port view Manual starter model Pulser coil Stator coil assembly charge coll lighting coil and power bobbin 3 Oil pressure switch 4 Thermoswitch Ignition coil 6 Engine stop lanyard switch lead Charge coil lead CDI unit 8 S6AG 8350 Lighting coil connectors G Ignition coil connector 0 07 Thermoswitch connector Gy B 02 Thermoswitch connector B 43 Ignition coil connector B Oil pressure switch connector P 5 Oil pressure switch lead P 6AG3 11 Electrical component and wiring harness routing Position the holder between the plastic ties Fasten the wiring harness at the white tape with a plastic tie
28. or Checking the gear shift operation remote control model 3 10 1 Set the remote control lever to the neu tral position and the throttle lever to the fully closed position 2 Check that the fully closed stopper on the throttle cam contacts the throttle cam bracket 1 Connect the throttle cable Q to the throttle cam and install the clip g K GO Sch EG d L Ly S6AG1070 NOTE SEH Pull the throttle cable toward the engine to remove any free play in the cable before con necting the throttle cable joint es d General information 3 Check that the shift rod lever joint Is in the neutral position as shown Connect the shift cable to the shift rod lever joint and install the clip O CEM muur t S6AG1090 WARNING The shift throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in Checking the gear shift and throttle operation 1 Check that the throttle operates smoothly when the throttle grip is turned from the fully closed position to the fully open position Tiller handle model Check that the throttle operates smoothly when the remote control lever is shifted from forward or reverse to the fully open position Remote control model 2 Check that the gear shift operates smoothly when the shift lever or remote control lever is shifted from the neutral position to forward or reverse S6AG1280 Tiller handle model Remo
29. the special service tool may not fit into the cb ak ab Sc ek ef ect ET ay SA ect ct GJ Needle bearing attachment lower case In that case use a special ser 7 90890 06610 vice tool with a smaller diameter Driver rod L3 90890 06652 Be sure to remove the forward gear before removing the needle bearing GALIJI d Disassembling the forward gear 1 Remove the taper roller bearing from the 22 Ball j forward gear using a press e Ball bearing attachment 90890 06655 Driver rod LL 90890 06605 6ALSI14 1 1 6AG3J11 How to use this manual Symbol The symbols below are designed to indicate the content of a chapter General information Fuel system Bracket unit FUEL BRKT 8 H e H a Specification Power unit Electrical system SPEC POWR ELEC Troubleshooting TRBL SHTO Periodic check and adjustment Lower unit CHK ADJ Special service tool Specified measurement 2 Specified oil or fluid 6 Specified electrical value 3 Specified engine speed resistance voltage electric current 4 Specified tightening torque Symbols to 43 in an exploded diagram or illustration indicate the grade of lubricant and the lubri cation point Apply 4 stroke motor oil 07 Apply corrosion resistant grease Apply gear oil Apply water resistant grease 02 Apply low temperature resistant grease Apply molybdenum disulfide grease 43 Apply injector grease Symbols 44 to 4
30. 10 Bracket unit Upper case and steering arm 15 N m 1 5 kgf m 11 1 ft Ib x 28 N m 2 8 kgf m 20 7 ft Ib 32 N m 3 2 kgf m 23 6 ft Ib 3 N m 0 3 kgf m 2 2 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib S6AG7500 No Paname 10 Remarks 1 Mount housing 2 2 Rubber damper 2 Large 3 Rubber damper 2 Small 4 Rubber damper 1 5 Bolt 2 M8x85mm 6 Bolt 2 M8 x 105 mm 7 Nut 4 8 Bolt 1 M5x10mm 9 Ground lead 1 10 Grease nipple 1 11 Bolt 1 M6 x 8 mm 12 Plate 1 13 Nut 2 14 Upper case assembly 1 L transom model S transom model 15 Plate 1 16 Steering arm 1 L transom model S transom model 17 Washer 1 7 11 6AG 3 11 Upper case and steering arm 15 N m 1 5 kgf m 11 1 ft Ib x 28 N m 2 8 kgf m 20 7 ft Ib 32 N m 3 2 kgf m 23 6 ft Ib 3 N m 0 3 kgf m 2 2 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib S6AG7500 No Paane oy Remarks 18 Bushing 1 1 19 Bushing 2 20 O ring 21 Plate 22 Steering bracket cover 23 Screw 24 Screw 25 Power tilt switch 26 Screw 27 Cover 28 Bolt 29 Steering hook 30 Bolt 31 Nut 6AG3J 11 Not reusable Remote control model ob x 20 mm Remote control model 6 x 18 mm R emote control model Remote control model with power tilt 6 x 20 mm Remote control model with power tilt Remote control model M6 x 30 mm R emote control model Remote control mode
31. 13 018 0 5118 0 5125 1 98 2 40 0 0780 0 0945 1 98 3 11 0 0780 0 1224 1 2 1 6 0 047 0 063 Intake Exhaust iN P Stem diameter Intake Exhaust Stem runout limit Guide inside diameter Intake and exhaust Stem to guide clearance Intake Exhaust Valve guide height Intake and exhaust Valve spring Free length Tilt limit 6AG3J11 0 8 1 2 0 0315 0 0472 1 0 1 4 0 0394 0 0551 5 475 5 490 0 2156 0 2161 5 460 5 475 0 2150 0 2156 0 01 0 0004 5 500 5 512 0 2165 0 2170 0 010 0 037 0 0004 0 0015 0 025 0 052 0 0010 0 0020 10 8 0 2 0 4 0 01 32 63 1 2846 1 4 0 055 2 8 SPEC EN Specification Dnt 7 1868 20M 20EBT_ Cylinder Bore size 63 000 63 015 2 4803 2 4809 Piston Piston diameter D Kaf i 62 950 62 965 2 4783 2 4789 Measuring point H 5 3 5 0 14 Piston clearance i 0 035 0 065 0 0014 0 0026 Piston pin boss bore 16 004 16 015 0 6301 0 6305 Oversize piston diameter 1st i 63 200 63 215 2 4882 2 4888 2nd 63 450 63 465 2 4980 2 4986 Piston ring groove Top ring 1 21 1 23 0 0476 0 0484 2nd ring 1 21 1 23 0 0476 0 0484 Oil ring 2 51 2 53 0 0988 0 0996 Piston pin mm in 15 995 16 000 0 6297 0 6299 Piston ring Top ring Barrel Dimension B 1 17 1 19 0 0461 0 0469 Dimension T 2 30 2 50 0 0906 0 0984 End gap i 0 15 0 30 0 0059 0 0118 Side clearance i 0 02 0 06 0 0008 0 0024 2nd ring Taper Dimension B 1 17 1 19 0 0
32. 2 12 2 21 Electrical component and wiring harness TOUTING ganen 8 1 Engine electric control system 8 25 F Fire prevention EE 1 4 Friction plate tiller handle model 7 5 FEE vr 4 2 Fuel hose blowby hose and COOIING Water NOS Camiran AE 4 1 FUE EE 4 4 SIE EE 2 11 2 19 3 2 G GEN 3 16 General SPECIFICATION see eee eee eee 2 1 General TOrMdUCe pissin ees unis 2 33 Good working practice sss sees ee eee eee 1 5 H OSG FOUUING ass 4 1 How to use this manual 1 1 L folge Lee EEN 1 6 Ignition and ignition control system 8 21 Ignition coil and Rectifier Regulator 5 17 Installing the carburetor ee ee ee ee 4 14 Installing the clamp bracket 7 24 7 28 Installing the cylinder head eee 5 47 Installing the lower unt 6 17 Installing the power tilt unt 7 28 6AG3 11 Installing the power unt 5 61 Installing the propeller shaft housing 6 16 Installing the shift rod drive shaft housing and drive shaft 6 15 Installing the sprocket and timing belt 5 31 Installing the starter motor eee eee ee 8 18 Installing the steering arm seeren 7 18 Installing the upper case 7 19 Installing the water Dump esse eee eee eee e 6 16 L Lower unt 2 12 2 20 3 14 6 1 Lubricating the outboard motor sss sss 3 18 M Maintenance interval chat 3 1 Maintenance specification see eee eee 2 7 Manuakomm l as a 1 1 Manual starter manual starter model 5 7
33. 2 Warming indicator To tachometer Color code B Black G Green L Blue O Orange P Pink W White B R Black red G R Green red Gy B Gray black P B Pink black DAN Pink white W R White red Y B Yellow black Yellow red Wiring diagram OD CDI unit Color code 2 Stator coil assembly charge coil B Black 3 Stator coil assembly power bobbin Br Brown 4 Stator coil assembly lighting coil G Ensen Pulser coil L Blue Primary Start Lg Lightgreen D Rectifier Regulator O Orange Fuse 20A P Pink 9 Starter motor R Red Starter relay Sb Sky blue 00 Battery W White Ignition coil B R Black red 3 Spark plug GR Green red Thermoswitch Gy B Gray black 5 Oil pressure switch P B Pink black Neutral switch P W Pink white 9 Engine start button W R White red Engine stop lanyard switch Y B Yellow black Warning indicator Y R Yellow red 20 Power tilt motor power tilt model Gi Terminal power tilt model 22 Power tilt relay power tilt model 3 Power tilt switch power tilt model Power tilt model To tachometer Wiring diagram CDI unit 2 Stator coil assembly charge coil 3 Stator coil assembly power bobbin 4 Stator coil assembly lighting coil Pulser coil 6 Primary Start Rectifier Regulator Fuse 20A 9 Starter motor Starter relay 11 Battery 2 Ignition coil 3 Spark plug Thermoswitch 5 Oil pressure
34. 6 20 RA Driver rod LL 90890 06605 S Bearing outer race attachment 90890 06625 2 Install a new needle bearing into the lower case to the specified depth S6AG 6290 NOTE e Install the needle bearing with the manufac ture identification mark facing upward e Install the stopper onto the driver rod SL at the installation depth as shown Install the needle bearing until the stopper con tacts the bearing depth plate 6AG3 11 Drive shaft and lower case vz Driver rod SL 90890 06602 Bearing depth plate 90890 06603 Needle bearing attachment 90890 06617 Installation depth 172 7 173 2 mm 6 80 6 82 in Assembling the forward gear L Install a new taper roller bearing onto the forward gear using a press 1 dd CD S6AG6300 D Bearing inner race attachment 90890 06644 Lower unit Assembling the drive shaft housing 1 Install the bushing into the drive shaft housing using a press t Ee d S6AG6310 NOTE _ ___ Align a groove in the bushing with the hole bd in the drive shaft housing RL Driver rod L3 90890 06652 Bushing attachment 90890 06649 2 Apply grease to new oil seals and then install them into the drive shaft housing to the specified depth S6AG 6320 NOTE Install an oil seal halfway into the drive shaft housing and then install the other oil seal vz Driver rod L3 90890 06
35. 951 mm 0 5095 0 5099 in Checking the camshaft 1 Measure the cam lobe Replace if out of Specification D S69J5950 6AG3 11 Cam lobe Gi Intake 28 546 28 646 mm 1 1239 1 1278 in Exhaust 28 582 28 682 mm 1 1253 1 1292 in Cam lobe bi Intake and exhaust 23 95 24 05 mm 0 9429 0 9468 in 2 Measure the camshaft runout Replace if above specification S6AG5240 Camshaft runout limit 0 03 mm 0 0012 in 3 Measure the camshaft journal diameters and and the cylinder head journal inside diameters and Replace the camshaft cylinder head or both if out of Specification S6AG 5250 6AG3 11 Cylinder head Camshaft journal diameter 21 967 21 980 mm 0 8648 0 8654 in Camshaft journal diameter 33 935 33 955 mm 1 3360 1 3368 in Cylinder head journal inside diameter 22 000 22 021 mm 0 8661 0 8670 in Cylinder head journal inside diameter 34 000 34 025 mm 1 3386 1 3396 in 4 Check the automatic decompression actuator Replace the camshaft if dam aged or worn S6AG5245 Assembling the cylinder head 1 Install a new valve seal 4 onto the valve guide S6AG 5280 5 44 2 Install the valve valve spring seat valve spring GO and valve spring retainer in the sequence shown and then attach the special service tools S6AG 5290 NOTE Face the wide pitch spring end identified by t
36. DUM D AKA 6 5 Propeller shaft NOUSING srsrarsnsveisszszetvetaastseycssssst vsr rersysye takaya 6 6 Removing the propeller shaft housing assemblv eee ee eee eee eee 6 7 Disassembling the propeller Shaft assembly eee eee e eee eee 6 7 Disassembling the propeller shaft housing aseemlbhy eee eee eee 6 7 Checking the propeller shaft housing sse eee eee eee eee eee 6 8 Checking the propeller chat 6 8 Assembling the propeller shaft assembly eee eee eee ee eee 6 8 Assembling the propeller Shaft housing esse eee ee eee eee ee eee 6 9 Drive shaft nd lower Eege EEN EERRENER REENEN 6 11 Removing the drive shaft drive shaft housing and shift mod 6 12 Disassembling the drive shaft houeimg sese ee eee eee eee 6 12 Disassembling the forward gear 6 12 Disassembling ME lower EE 6 13 Checking the pinion and forward gear 6 13 EET NE ENE AAN 6 13 CMECKING ENG dive SA ae 6 13 CASE KING the SN Ode 6 13 Checking ME JONE CASE EEN 6 13 Assembling one EE 6 14 Assembling the forward dear 6 14 Assembling the drive Shaft housimg esse ee eee eee 6 15 Installing the shift rod drive shaft housing and drive chat 6 15 Installing the propeller shaft housing eee eee eee eee eee eee 6 16 Installing the water pDump sss eee eee ee eee eee 6 16 Te r lt HIS TE lower Din EE 6 17 SRIMMIN Le E 6 20 SNEV 6 21 SEE NE ONION SN ae Need 6 21 Selecting the forward gear ehm 6 21 Selecting the reverse gear ehm 6 22 Backlash 6 23 Measurin
37. Ib y L I 6 N m 0 6 kgf m 4 4 ft Ib A 12N m 1 2 kgf m 8 9 ft Ib Remarks S6AG5650 5 34 For Europe S6AG5660 14 Oil pump assembly 15 Rocker arm 16 Adjusting screw 17 Locknut No Part name 1 Cylinder head 1 2 Valve spring seat 4 3 Shaft 1 4 Intake valve 2 5 Exhaust valve 2 6 Valve spring 4 7 Valve spring retainer 4 8 Valve cotter 8 9 Valve seal 4 10 Collar 2 11 Bolt 1 M6x12mm 12 Plate 1 13 Bolt 3 M6 x 35mm 1 4 4 4 5 35 6AG3 11 Cylinder head S6AG5660 Partname 1 Camshaft F15 F20 For Europe Pin Oil seal Not reusable Valve guide Gasket S pring 6AG 3 11 5 36 Removing the cylinder head 1 Remove the cylinder head cover 2 Remove the cylinder head bolts in the sequence shown S6AG5140 CAUTION Do not scratch or damage the mating sur faces of the cylinder head and cylinder block Disassembling the cylinder head 1 Remove the oil pump assembly S6AG5150 NOTE _ o To disassemble check and assemble the oil pump see Checking the oil pump 5 47 2 Remove the plate from the cylinder head pull out the shaft and then remove the springs collars and rocker arms 5 37 S6AG 5160 NOTE Loosen the locknut and adjust screw to Slack off the tension before remove the rocker arm shaft e Be sure to keep the parts in the order as they were removed 3
38. LER l S6AG 3220U A S Hd vie A After tilting the outboard motor up be sure to support it with the tilt stop lever 7 28 Bracket unit 2 Install the collar onto the power tilt unit 3 Install the power tilt unit collars shaft and washers onto the clamp bracket and then tighten the bolts to the specified torque 4 Install the collars upper end of the tilt ram shaft and E clip oo to the swivel bracket 5 Install the ground lead terminal on to the power tilt unit S6AG7820 NOTE Install the ground lead as shown Power tilt unit mounting shaft bolt O 18 N m 1 8 kgf m 13 3 ft lb Ground lead bolt 8 N m 0 8 kgf m 5 9 ft lb 6 Pass the power tilt motor lead 43 through the hole in the clamp bracket STBD 7 Fasten the power tilt motor lead 43 to the clamp bracket with a plastic tie 4 7 29 S6AG7830 NOTE Route the power tilt motor lead 43 to the front of the stopper 8 Apply grease to all grease nipples until it comes out from the areas S6AG 7840 6AG3 11 Clamp bracket and swivel bracket power tilt model Power tilt motor power tilt model Power tilt motor power tilt model hy 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib SRN m 0 5 kgf m 3 7 ft Ib S6AG7010 No Panname Joy Remarks 1 Screw 2 od x 10 mm 2 Stator 3 O ring 4 Armatur
39. Measure the Rectifier Regulator output peak voltage with the connector R dis connected e Do not use peak voltage adapter B when measuring the Rectifier Regulator output peak voltage e Be sure to check the lighting coil before measuring the Rectifier Regulator output peak voltage Rectifier Regulator output peak voltage Red R Black B Unloaded 1 500 3 500 8 30 ELEC 7 ELEC ay Electrical system 2 Disconnect the Rectifier Regulator con nector and terminal 3 Check the Rectifier Regulator for conti nuity Replace if out of specification S6AG 8280 56518360 NOTE _ ___ Be sure to set the measurement range and display the mark by pushing the SHIFT switch when checking the Rectifier Regulator continuity 8 31 Rectifier Regulator continuity testing diode eo reference data R om or aa R om or oa R 088 ce oa OL Indicates an overload B A AE S me E BAG 31 11 TRBL SHTG Troubleshooting Troubleshooting the outboard MOtOT s ssssssnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnan 9 1 TOVE NOM tanle ON 9 1 Troubleshooting the power unt 9 1 Troubleshooting the power tilt unit Power tilt model 9 7 Troubleshooting the lower unt 9 9 6AG3J 11 TRBL P SHTG e Troubleshooting Troubleshooting the outboard motor NOTE Before troubleshooting the outboard motor e Make sure that fresh fuel
40. Measuring the forward and reverse gear backlash sss 6 23 Measuring the peak voltage see eee 8 11 Deier E 1 6 P Part lubricant and sealant 1 4 Foer 8 7 Power tilt cylinder power tilt model 7 41 Power tilt electrical system power tilt model sese ses esse eee 7 47 Power tilt gear pump power tilt model 7 35 Power tilt motor power tilt model 7 30 Power unt 2 7 2 16 3 3 5 13 Power unit check and adjustment 5 1 Power unit assembly remote control modell 5 15 Power unit assembly tiller handle modell 5 13 Precaution when transporting or Storing the outboard MOtOTF sss esse 1 19 Predelivery check ccseesecsseseeeeeseeeeneeeeens 1 12 Propeller eelechon seene eee 1 12 Propeller Shaft housing eseese 6 6 Propeller SIZ EE 1 12 R Refacing the valve Seat Removing the carburetor sees eee Removing the clamp bracket Removing the cylinder head eeens Removing the drive shaft drive shaft housing and shift rod Index Removing the intake silencer protective V ENEE EE 1 13 ee Removing the lower unt 6 4 EE om Removing the power tilt unt 7 27 Removing the power unt 5 27 Removing the propeller shaft housing assembly eee eee eee eee e 6 7 Removing the starter MOtOTF sees ee eee 8 14 Removing the steering am 7 18 Removing the timing belt and sprocket 5 30 Removing the upper CaSe eerren 7 15 Removing the water pump sese eee e eee ee 6 5 Replacing
41. No gt Partname ty Remarks 18 Screw 2 4 x 8 mm 19 Spacer 1 20 Bracket 1 21 Bolt 2 M5 x 120 mm 22 O ring 2 23 Washer 2 24 O ring 1 25 Spacer 1 26 Washer 1 2 2 8 13 6AG3 11 Removing the starter motor 1 Remove the starter motor from the power unit NOTE e Check the engine start switch or engine Start button neutral switch starter relay and fuse before removing the starter motor e To remove the starter motor see Bracket electric starter model 5 24 Checking the starter motor operation 1 Hold the starter motor in a vise using alu minum plates on both sides 2 Connect the positive battery cable to the starter relay terminal connect the Starter motor lead to the starter motor positive terminal and connect the negative battery cable to the starter motor body 3 Connect the starter relay lead brown to the positive battery terminal Connect the starter relay lead black to the negative battery terminal to check the Starter motor operation S6AG 8390 6AG3J 11 Starter motor electric starter model WARNING Do not place any objects near the pinion or touch it The pinion moves slightly away from the starter motor body and rotates at high speed NOTE e Check the starter motor operation for a few seconds e If the starter motor is disassembled for maintenance be sure to check the opera tion again after assem
42. Plastigauge PG 1 on each crankshaft journal parallel to the crankshaft 56D55870 NOTE Be sure not to put the Plastigauge PG 1 over the oil hole in each main Journal of the crankshaft 5 Install the remaining half of the main bearings into the crankcase NOTE e Install the main bearings in their original positions e Insert the projection of each bearing into the slots in the crankcase 6 Install the crankcase onto the cylinder block NOTE ae Apply engine oil to the threads of the crank case bolts 7 Tighten the crankcase bolts to the speci fied torques in 2 stages and in the sequence shown S6AG5830 NOTE Do not turn the crankshaft until the crankshaft journal oil clearance measurement has been completed Crankcase bolt 1 44 M8 lst 14 N m 1 4 kgf m 10 3 ft lb 2nd 27 N m 2 7 kgf m 19 9 ft lb Crankcase bolt 5 n M6 lst 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 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 56D55880 6AG3 11 NOTE _ ___ When loosening the crankcase bolts loosen them in the opposite order used for tighten ing Crankshaft journal oil clearance reference data 0 011 0 039 mm 0 0004 0 0015 in Selecting the crankshaft main bearing 1 Check the stamped ma
43. Remove the camshaft and then remove the oil seal S6AG51 70 4 Remove the intake and exhaust valves af gt D N Ai FR S6AG5130 6AG3 11 Cylinder head NOTE _ ___ Be sure to keep the valves springs and other parts in the order as they were removed K Valve spring compressor 90890 04019 Valve spring compressor attachment 40 90890 06320 S68V5775 Valve spring free length Checking the cylinder head 32 63 mm 1 2846 in 1 Eliminate carbon deposits from the com bustion chambers and check for deterio 2 Measure the valve spring tilt amp Replace ration if above specification 2 Check the cylinder head warpage using a straightedge 07 and thickness gauge in the directions shown Replace the cyl inder head assembly if above specifica tion 569J5730 Valve spring tilt limit 1 4 mm 0 055 in S6AG 5260 S6AG 5270 Cylinder head warpage limit 0 10 mm 0 0039 in Checking the valve spring 1 Measure the valve spring free length Replace if below specification 6AG 3 11 5 38 Checking the valve 1 Check the valve face Replace the valve if pitted or worn 2 Measure the valve margin thickness Replace the valve if out of specification Si S69J5740 Valve margin thickness Gi Intake 0 8 1 2 mm 0 0315 0 0472 in E xhaust 1 0 1 4 mm 0 0394 0 0551 in 3 Measure the valve stem diameter
44. and then remove the tilt piston and tilt cylinder end screw 8 from the tilt ram assembly S6AG7235 Checking the tilt cylinder and piston 1 Check the cylinder liner Replace if cracked or scratched 2 Check the tilt piston free piston and backup rings and Replace if cracked or scratched 6AG3 11 3 Check the tilt cylinder end screw dust seal and backup ring Replace if cracked or scratched 4 Check the tilt ram Polish with 400 600 grit sandpaper if there Is light rust or replace if bent or excessively corroded S6AG7270 5 Check the tilt piston absorber valves 49 Clean if there is dirt or residue PS O IL veg NEB me Ma S6AG 7280 Mo o Assembling the tilt cylinder CAUTION e Do not use a rag when assembling the power tilt unit as dust and particles on the power tilt unit components can lead to poor performance e Do not reuse the O ring always replace it with a new one 6AG3 11 Power tilt cylinder power tilt model NOTE Lubricate the parts with ATF Dexron II during assembly 1 Install a new dust seal new O rings and and the backup ring GO into the tilt cylinder end screw CO Z geng fo Eeg gt EEG OS C EEE S6AG 7300 2 Install the tilt cylinder end screw and tilt piston to the tit ram 3 Hold the tilt piston in a vise using alumi num plates on both sides 4 Tighten the til
45. center and moving outward Non reusable part Always use new gaskets seals O rings cot ter pins circlips etc when installing or assembling parts S69J1060 1 5 Disassembly and assembly industrial hygiene 1 Use compressed air to remove dust and dirt during disassembly Apply engine oil to the contact surfaces of moving parts before assembly S69J1070 Install bearings with the manufacture identification mark in the direction indi cated in the installation procedure In addition be sure to lubricate the bearings liberally Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation Check that moving parts operate nor mally after assembly 6AG3J1 1 Identification Model This manual covers the following models Applicable model Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket S6AG1020 Manual tilt model Power tilt model 6AG3J11 Safety while working Identification DML S6AL1D00 a Model name 2 Approved model code 3 Transom height 4 Serial number Mediene Starting model code serial No 000001 1000001 1 6 es d General information Special service tool Oil filter wrench 90890 01426 Digital tachometer 90890 06760 Timing light 90890 03141 Leakage tester 90890 06840 Vacuum pressure pump gauge set 90890 06
46. connector B R 8 3 6AG3 11 Electrical component and wiring harness routing 02 Charge coil connector G R 02 Engine stop lanyard switch connector tiller handle model W Engine start button connector tiller handle model with electric starter Br 05 Engine start button connector tiller handle model with electric starter R Prime Start connectors L M Tachometer connector G Connector 10 pin main harness coupler to CDI unit remote control model W Connector 10 pin main harness coupler to CDI unit remote control model P GO Connector 10 pin main harness coupler to fuse remote control model R GU Connector 10 pin main harness coupler to CDI unit remote control model G Lead 10 pin main harness coupler to CDI unit remote control model P 23 Lead 10 pin main harness coupler to CDI unit remote control model W 4 Lead 10 pin main harness coupler to CDI unit remote control model G Pass the engine stop lanyard switch lead tiller handle model neutral switch lead tiller handle model with electric starter and Prime Start lead through the grommet Pass the pulser coil lead through the grommet Be sure not to pinch the wiring harness and leads with the holder cover D Fasten the stator coil assembly lead wiring harness fuse lead electric starter model neutral switch lead engine start button lead tiller handle model with electric starter and engine stop lanyard switch lead tiller h
47. cooling water passag 3 7 Checking the cooling water pilot hole 1 18 Checking the crankpin oil clearance 5 55 Checking the Crankshaft eee eee 5 55 Checking the crankshaft journal oil dearance eee eee 5 56 Checking the cylinder bore sss sese 5 52 Checking the cylinder head esse 5 38 Checking the diaphragm and valve 4 7 Checking the drive schaft 6 13 Checking the drive shaft bushing L transom modell 7 15 Checking the electrical component 8 11 Checking the engine idle Speed 3 11 Checking the engine ol 3 3 Checking the engine oil level 1 13 Checking the engine start button or Switch and engine stop lanyard switch 1 18 Checking the engine start button tiller handle model with electric EE 8 18 Checking the engine start switch remote control modell esse 8 19 Checking the engine stop lanyard switch remote control modell esse 8 24 Checking the engine stop lanyard switch tiller handle modell 8 24 Checking the exhaust manifold oil pan and exhaust goude 7 16 Checking Ne le 7 39 Checking the fuel filter 3 3 Checking the fuel filter assembly 4 3 Checking the fuel ont 4 3 Checking the fuel joint and fuel hose fuel joint to carburetor sees eee ee eee 3 2 Checking the fuel pump ees 4 6 Checking the fuel system see eee 1 13 Checking the fuse AAA 7 47 LI Index Checking the fuse electric star
48. does not Starter crank Manual starter mal Disassemble and function check the manual Starter 9 1 6AG3 11 Troubleshooting the outboard motor Symptom 1 Engine does not crank electric starter model got Symptom 2 Cause 1 Cause 2 Checking step a Setthe shift lever or remote control lever Shift lever or remote control lever Starter motor does not operate not in the neutral position Engine start button or engine start switch malfunction Short open or loose connection in starter motor circuit Starter motor mal function Stuck piston Piston lock due to water in the com bustion chamber Stuck drive shaft Buildup of foreign material on the drive shaft and bushing Malfunction of the lower unit internal Starter motor oper ates but the engine does not crank parts Starter motor mal function WD See the wiring diagram 6AG3J 11 to the neutral posi tion Bowtse Checkihe use Check the engine start button or engine start switch Neutral switch mal Check the neutral 8 19 function Switch 8 20 Starter relay mal Check the starter 8 21 function relay Check the wiring harness continuity Disassemble and check the starter motor Disassemble and check the power unit Disassemble and check the upper case L transom model only Disassemble and check the lower unit Disassemble and check the starter motor
49. each direction TO R GEN E im m A S6AG6550 NOTE 00 e Pull the drive shaft downward and then turn it e Measure the backlash at 4 points to find the average 6 25 Reverse gear backlash 0 95 1 66 mm 0 0374 0 0654 in 15 Adjust the current shim thickness if the reverse gear backlash is out of specifica tion Reverse gear ete Shim thickness To be decreased by Less than 0 95 mm 0 0374 in 1 31 M x 0 43 More than To be increased by 1 66 mm 0 0654 in M 1 31 x 0 43 M Measurement Available shim thicknesses 0 1 0 2 0 3 0 4 and 0 5 mm 16 Remove the special service tools and propeller and then install the water pump assembly NOTE Install the spacer and propeller 17 Fill the gear oil to the correct level 6AG3 11 Backlash MEMO 6AG 3 11 6 26 Bracket unit Tiller handle tiller handle model rrasnrvvrrnnnnnvevnnnnnnnevnnnnnnevennnnnvernnnnnnvernnnnnnr 7 1 Disassembling the tiller handle rrrrrrrvrarrrvnrrrrrvrrrrrrvsrerrsvsrrrrnsesrrrnssrrsensene 7 3 Assembling the tiller bhandle sss sese sees yeee 7 3 Friction plate tiller handle model ruuvrvnnnnnvrnnnnnnvevnnnnnnnnennnnnnnennnnnnnvennnnnnnerr 7 5 Disassembling the friction plate eee eee eee eee 7 6 ASSEMDINNG NE MEION Rn E EE 7 6 Bottom COWINING MET 7 8 Upper case and steering arm rsssrnvrnnnnnnnnnnnnnnnnernnnnnvevennnnnvevnnnnnnvevnnnnnneernnnnnr
50. from the battery and remove the clip from the engine stop lanyard switch Electric starter model NOTE 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 8 Fill the gear oil to the correct level Recommended gear oll Hypoid gear oil API GL 4 SAE 90 Gear oil quantity 300 cm 10 14 US oz 10 58 Imp oz 6AG3 11 Drive shaft and lower case Shimming Shimming T3 mf NM JJ TI T1 M2 M3 S6AG6450 6AG 3 11 6 20 Lower unit Shimming NOTE e Shimming IS not required when assembling the original lower case and inner parts e Shimming IS required when assembling the Original inner parts and a new lower case e Shimming is required when replacing the inner part s Selecting the pinion shim 1 Measure the thickness M1 of the thrust bearing S6AG 6460 NOTE 0 e Select the shim thickness T3 by using the specified measurement s and the calcula tion formula e Measure the thrust bearing at 4 points to find the thickness average Digital caliper a 90890 06704 2 Calculate the pinion shim thickness Calculation formula Pinion shim thickness T3 6 05 M1 3 Select the pinion shim s T3 as follows 6 21 Calculated number M thickness mm 121130 Available shim thicknesses 1 13 and 1 20 mm Selec
51. into the oil dipstick hole 4 Install the engine oil drain bolt and then tighten it to the specified torque Engine oil drain bolt 27 N m 2 7 kgf m 19 9 ft lb 5 Pour the specified amount of the recom mended engine oil into the oil filler hole Recommended engine oll 4 stroke motor oil API SE SF SG SH SJ or SL SAE 5W 30 10W 30 or 10W 40 Engine oil quantity Without oil filter replacement 1 6 L 1 69 US gt 1 41 Imp qt 6 Install the oil filler cap and oil dipstick and then start the engine and warm it up 7 Turn the engine off and then check the oil level and that there is no oil leakage If the oil level is low add engine oil to the correct level Replacing the oil filter 1 Drain the engine oil or use an oil changer to extract it 2 Place a rag under the oil filter and then remove the oil filter using a 64 mm 2 5 in oil filter wrench 6AG3 11 Fuel system Power unit GE S6AG 3090 NOTE SSS e Wait more than 5 minutes after turning the engine off to replace the oil filter e Be sure to clean up any oil spills Oil filter wrench 90890 01426 3 Apply a thin coat of engine oil to the O ring of the new oil filter 4 Install the oil filter and then tighten it to the specified torque using a 64 mm 2 5 in oil filter wrench F ii lt aoe a A S6AG3100 AN ae Ae EAN Oil filter 18 N m 1 8 kgf m
52. is damaged 4 Check the spark plug gap Adjust the Spark plug gap if out of specification 569J3200 NOTE Perform steps 2 for each spark plug Specified spark plug DPR6EB 9 NGK S park plug gap 0 8 0 9 mm 0 031 0 035 in 5 Install the spark plugs tighten them tem porarily and then tighten them to the Specified torque using a spark plug wrench S park plug 17 N m 1 7 kgf m 12 5 ft lb 6 Connect the spark plug caps 6AG3 11 Checking the thermostat 1 Remove the sprocket cover and manual Starter Manual starter model Remove the sprocket cover and flywheel magnet cover Electric starter model 2 Remove the thermoswitch and discon nect the cooling water hose NOTE To remove the manual starter or flywheel magnet cover see Removing the timing belt and sprocket 5 30 3 Remove the thermostat cover and thermostat S6AG 3120 CAUTION Do not reuse the gasket always replace it with a new one NOTE _ _ o It is recommended to check the thermostat cover anode before installing the thermostat cover 4 Suspend the thermostat in a container of water 5 Place a thermometer in the water and Slowly heat the water 6AG3 11 Power unit S69J5E40 6 Measure the thermostat valve opening at the specified water temperatures Replace the thermostat if out of specifi cation S6AL3100 Water temperature Valve opening
53. making sure that the stopper on the bracket contacts the cylinder body Install the terminals of the starter relay ground lead and Rectifier Regulator ground lead using the bolt and then apply Selva grease to the terminals and bolt Install the terminals of the positive battery cable and power tilt relay lead R using the bolt apply Selva grease to the terminals and bolt and then cover the terminals with the cap Install the terminals of the starter motor lead using the bolt and nut apply Selva grease to the terminals bolt and nut and then cover the terminals with the caps Install the starter motor lead terminal as shown R oute the starter relay lead Br and Rectifier Regulator ground lead between the starter relay and the Starter motor Make sure that the power tilt relay lead B is not routed in front of the holder P Route the battery cables as shown and fasten them with the holder R Fasten the wiring harness at the white tape with the holder Route the power tilt relay lead as shown Make sure that there is no slack in the battery cables Install the terminal of the negative battery cable using the bolt and then apply Selva grease to the terminal and bolt Install the terminal of the positive battery cable using the bolt and the terminals of the starter motor lead using the bolt and nut apply Selva grease to the terminals bolts and nut and then cover the terminals with the caps Fold the lead Y remote control mode
54. manual of the battery e Disconnect the negative battery cable first then the positive battery cable Electrolyte specific gravity 1 280 at 20 C 68 F 6AG3 11 General Lubricating the outboard motor 1 Apply water resistant grease to the areas shown CS S6AG3290 3 Apply corrosion resistant grease to the area shown S6AG 3440 56D53300 NI S6D53290 Tiller handle model NOTE _ __ Apply grease until it flows from the bushings 2 Apply low temperature resistant grease to the area shown 6AG 3 11 3 18 CHK ADJ D Periodic check and adjustment MEMO 6AG3 11 6AG3J 11 Fuel system IOS OUTING WE 4 1 Fuel hose blowby hose and Cooling water hose sss ee eee eee 4 1 l Rl Se 4 2 Checking the fuel filter Tle UT 4 3 CHEN the EL ON 4 3 Fe PIM Pre 4 4 CHECKING me ENN 4 6 Disassembling the fuel PIN EEN 4 6 Checking the diaphragm and Valve sse esse eee eee eee eee 4 7 Assembling the fuel sinis 4 7 Carburetor uni eene EENS 4 9 EE ee 4 10 REMOVING the carburetor erroa a a 4 12 Disassembling the carburetor sese eee eee 4 12 CNECKING NE carburetor se 4 12 CHECKING NG Pine SEL eege eben 4 13 Assembling the CAPDULAtON cccccceesccceesersueeceeeueesersuueeeaueueesaeesersaeueerengs 4 13 HEEN NE AM EE 4 14 Adjusting ME DIOLS CROW vaare 4 15 ne R Fuel system Hose routing Fuel hose blowby hose and cooling water hose ONE Q R SAS S
55. min or at approxi mately half throttle 1 19 2 1 hour at 3 000 r min or 3 4 throttle and 1 minute out of every 10 at full throt tle 3 8 hours with the engine at any speed However avoid operating at full throttle for more than 5 minutes at a time D A 0 1 2 10 569J1240 Hour After test run 1 Check for water in the gear oil 2 Check for fuel leakage in the cowling 3 Flush the cooling water passages with fresh water using the flushing kit and with the engine running at idle CAUTION Be sure to supply sufficient water and water pressure When flushing the cooling water passages If sufficient water and sufficient water pressure are not supplied the engine can overheat NOTE E When using the flushing device flushing hose joint adapter flush the cooling water passages without starting the engine Precaution when transporting or storing the outboard motor 1 Transport and store the outboard motor only as shown in the caution label Other wise engine damage could result from leaking oil 6AG3J1 1 Predelivery check CAUTION Transport and store the engine only as shown Otherwise engine damage could result from leaking oil me a 6G8 13444 41 S6AG1240 BAG3J11 1 20 Gs d General information MEMO 1 21 GAG3J11 Specification General specification iissvedesvctesesiavnantarsiacdessniuetesdnidnestaturvueniuveivenbanainienenennenes 2 1
56. mm Not reusable 4 x 10 mm Not reusable Not reusable 4 x 8 mm KA kA k FA k k PRP RP FA RUKKE KA KA kb Fi 6AG 3 11 4 10 ne R Fuel system S6AG 4050 No Parname oy Remarks 18 Gasket 1 19 Plunger rod 1 20 Plunger 1 21 Spring 1 22 Circlip 1 23 Ball 1 24 Drain screw 1 25 Screw 4 4x13mm 26 Screw 1 4x7 mm 27 Float 1 28 Needle valve 1 29 Main jet 1 30 Main nozzle 1 31 Pilot jet 1 For F20 32 Pilot jet 1 For F15 33 Pilot screw 1 For Europe 34 Pilot screw 1 For Oceania 4 11 6AG 3 11 Removing the carburetor 1 Disconnect the fuel hose 07 and the blowby hose S6AG4170 2 Disconnectthe throttle link rod and Prime Start connectors NOTE The Prime Start connectors are located in the junction box 3 Remove the bols and and then remove the intake silencer and carbu retor assembly S6AG4180 NOTE Before removing the bolts remove the fuel filter and remove the Prime Start lead from the holder Disassembling the carburetor NOTE See the exploded diagram for disassembly 4 10 6AG3J 11 Carburetor unit Checking the carburetor 1 Check the air and fuel passages and jets Clean the carburetor body if there is dirt or foreign material 2 Blow compressed air into all passages and jets S6AG4190 WARNING Wear appropriate protective eye gear dur ing the cleaning process t
57. of the specified type has been used e Make sure that the battery is fully charged e Be sure to check that the couplers connectors and battery terminals are securely connected e 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 e Perform the troubleshooting as described in the following tables Troubleshooting table format Troubleshooting consists of the following 4 items Symptom 1 Specific trouble conditions Symptom 2 Trouble conditions of an area or individual part Cause 1 The content considered as the trouble causes of symptom 2 Cause 2 The content considered as the trouble causes of cause 1 Troubleshooting the power unit Symptom 1 Engine does not crank manual starter model Starter rope does Shift lever not in the Setthe shift lever to 3 9 the neutral position Adjust the start in gear protection cable not operate neutral position Start in gear pro tection cable not adjusted correctly Disassemble and check the power unit Piston lock due to water in the com bustion chamber Stuck drive shaft Buildup of foreign Disassemble and material on the check the upper drive shaft and case L transom bushing model only Malfunction of the Disassemble and lower unit internal check the lower parts unit Starter rope Manual starter mal Disassemble and operates but the function check the manual engine
58. operating in salt water turbid or muddy water the engine should be flushed with clean water after each use e When using leaded or high sulfur gasoline checking the valve clearances may be required more frequently than every 100 hours Every ltem Remarks 500 hours 1 000 hours 2 5 re 5 M Refer to oa Timing bel Exhaust guide exhaust EE manifold 3 1 6AG3J 11 Maintenance interval chart Top cowling Fuel system Top cowling Checking the top cowling 1 Check the fitting by pushing the cowling with both hands Adjust if necessary N _ 2 Loosen the bolts 3 Move the hook up or down slightly to adjust its position S6AG3020 NOTE e To tighten the fitting move the hook in direction e To loosen the fitting move the hook in direction 4 Tighten the bolts 5 Check the fitting again and if necessary repeat steps 2 4 6 Check the air intake duct Clean if there are obstructions 6AG3 11 S6AG 3030 Fuel system Checking the fuel joint and fuel hose fuel joint to carburetor 1 Check the fuel hose connections for leaks Also check the fuel joint fuel hoses fuel filter fuel pump and carburetor 4 Replace if there is leakage or deterioration S6AG 3040 3 2 ADJ Periodic check and adjustment Checking the fuel filter 1 Check the fuel filter element Clean if there is dirt or residue and replace if damaged
59. or dirty check for and repair the cause and then change the oil 3 Ifnecessary add sufficient gear oil of the recommended type until it overflows out of the check hole Recommended gear oll Hypoid gear oll API GL 4 SAE 90 4 Install a new gasket and the gear oil check screw 07 and then tighten the gear oil check screw to the specified torque Gear oil check screw 9 N m 0 9 kgf m 6 6 ft lb Changing the gear oil 1 Fully tilt the outboard motor down 2 Place a drain pan under the gear oil drain hole remove the gear oil drain screw then the gear oil check screw Q and let the oil drain completely ga K ch IN Dy S6AG3510 E ADJ Periodic check and adjustment 3 Check the oil for metal 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 S60V3350 Recommended gear oll Hypoid gear oil API GL 4 SAE 90 Gear oil quantity 300 cm 10 14 US oz 10 58 Imp oz 5 Install new gaskets and gear oil check screw and quickly install the gear oil drain screw 1 and then tighten them to the specified torque Gear oil check screw and drain screw 1 9 N m 0 9 kgf m 6 6 ft lb Checking the lower unit for air leakage 1 Remove the gear oil check screw
60. out of the grommet e Install the steering bracket cover after adjusting the throttle cables 9 Connect the engine stop lanyard switch lead and power tilt switch lead power tilt model and fasten the leads 7 4 Bracket unit Friction plate tiller handle model S6AG7A50 Ko Tage Gy ee oO Bolt M5 x 20 mm Bracket Washer Steering lock shaft Steering lock lever Collar Friction piece Collar Steering lock washer Self locking nut Bolt Washer Bolt Short Long A e po Hi D d Oo Hi RUNE M5x18mm m N KA KJ KA KA RP k KM k RP RYN Fi M8 x 22 mm KA LA 7 5 6AG 3 11 Disassembling the friction plate 1 Remove the friction plate bolts and and then remove the friction plate assembly from the swivel bracket S6AG7A90 NOTE Before removing the friction plate bolts turn the outboard motor all the way to port or Starboard 2 Disassemble the friction plate assembly NOTE See the exploded diagram for disassembly 7 5 Assembling the friction plate 1 Turn the steering lock shaft until it Is flush with the end of the nut on the plate 7 S6AG7B00 6AG3 11 Friction plate tiller handle model S6AG7B01 NOTE o If the steering lock shaft is not aligned with position turn it less than 90 until it is aligned 2 Assemble the friction plate assembly NOTE e See the exploded diagram for assembly 7 5 e Face the
61. puller claw into the slots a in the lower case t2 Stopper guide plate 90890 06501 Center bolt 90890 06504 Bearing puller assembly 90890 06535 2 Remove the needle bearing from the lower case S6AG6260 CAUTION Do not reuse the bearing always replace it with a new one NOTE Be sure to remove the forward gear before removing the needle bearing RA Driver rod L3 90890 06652 Needle bearing attachment 90890 06617 Checking the pinion and forward gear 1 Check the teeth of the pinion and the teeth and dogs of the forward gear Replace the pinion or forward gear if cracked or worn Checking the bearing 1 Check the bearings Replace if pitted or if there is rumbling Checking the drive shaft 1 Check the drive shaft Replace if bent or worn 2 Measure the drive shaft runout Replace if above specification SSS gt S6AG 6270 Drive shaft runout limit 0 5 mm 0 0197 in Checking the shift rod 1 Check the shift rod Replace if bent or worn Checking the lower case 1 Check the skeg torpedo and anti cavita tion plate Replace the lower case if cracked or damaged 6AG3 11 Assembling the lower case 1 Install the original forward gear shim s GC and new taper roller bearing outer race Q S6AG 6280 NOTE Be sure to select the forward gear shim s if replacing the lower case or taper roller bear ing To select the shims see Shimming
62. switch lead B Neutral switch lead Br GO Power tilt switch connector R Gn Pulser coil connector B Connector 10 pin main harness coupler to CDI unit P G Lead 10 pin main harness coupler to CDI unit P 4 Connector 10 pin main harness coupler to fuse R Ge Lead 10 pin main harness coupler to CDI unit G Ge Connector 10 pin main harness coupler to CDI unit G 27 Lead 10 pin main harness coupler to CDI unit W Connector 10 pin main harness coupler to CDI unit W 99 Lead 10 pin main harness coupler to power tilt switch and power tilt relay Sb Lg Connector 10 pin main harness coupler to power tilt switch and power tilt relay Sb Connector 10 pin main harness coupler to power tilt switch and power tilt relay Lg Install the power tilt motor leads Sb Lg and power tilt relay leads Sb Lg to the terminals making sure to install the leads at angle of approximately 15 20 Pass the power tilt motor leads Sb Lg and power tilt switch leads Sb Lg through the caps and then connect the leads to the terminals Apply Selva grease to the connections and then cover them with the caps Be sure to pass leads of the same color through the caps and connect them to the same terminal Fasten the power tilt motor lead power tilt relay lead and power tilt switch lead with a plastic tie D Fasten the power tilt relay lead remote control model and power tilt switch lead with the holder Fold the c
63. temperature at 0 05 mm 0 0020 in 58 62 136 144 Fully open temperature 70 158 Valve open lower limit 3 0 0 12 Manual starter Starter rope length Starter rope pulling length C1 The figures are for reference only BAG3J11 9 10 SPEC EN Specification Fuel system Carburetor ID mark For Europe 6AG10 6AG50 6AH10 6AH50 For Oceania 6AG20 6AG60 6AH20 6AH60 Float height 15 0 1 0 0 59 0 04 Valve seat size 1 0 0 04 Main jet M J For Europe For Oceania Main nozzle M N Pilot jet P J Pilot screw P S For Europe turns out 80 112 80 118 2 2 0 09 2 4 0 09 38 45 1 1 2 31 2 3 3 8 1 2 1 2 For Oceania turns out 3 1 8 1 2 2 3 4 1 2 Idle speed r min 1 050 50 Fuel pump Fuel pump holding pressure Fuel inlet positive pressure kPa kgf cm psi Fuel inlet negative pressure kPa kgf cm psi Fuel outlet positive pressure kPa kgf cm psi Fuel joint holding pressure Positive pressure kPa kgf cm psi Fuel filter assembly holding pressure Positive pressure kPa 200 2 0 29 0 kgf cm psi 2 11 GAG3J11 Maintenance specification Lower unit Lower unit Holding pressure kPa 100 1 0 14 5 kgf cm psi Gear backlash Pinion to forward gear 0 18 0 87 0 0071 0 0343 Pinion to reverse gear 0 95 1 66 0 0374 0 0654 Pinion shims 1 13 1 20 Forward gear shims 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Reverse gear shims 0 1 0 2
64. the oil filter 3 4 Replacing the timing bet 5 3 Replacing the valve goude 5 40 S Safety while working sse see eee eee eee 1 4 Sealant and locking agent table 1 3 Selecting the crankshaft main bearing 5 58 Selecting the forward gear Shim 0 6 21 Selecting the PINION ehm 6 21 Selecting the reverse gear Shim 00 6 22 S ENN NG 1 12 Get porotecHon aada aa 1 4 ef une 1 6 Setting the remote control cable remote control modell 1 14 STAMI pennen 6 20 6 21 Special service Tool 1 7 SPENST tOrque SS 2 30 Starter motor electric starter model 8 12 SANS BEN aS 8 18 SI MOO a a 1 2 T TESCU ninaa 1 19 TONE EN are 5 26 Tightening Ordu sss esse ee eee eee eee 2 30 Tiller handle tiller handle modell 7 1 Timing belt and Sprocket eerren 5 29 TOP CO WINING HA 3 2 TOP VM 8 1 Troubleshooting table Tommat sees eee 9 1 Troubleshooting the lower unt 9 9 Troubleshooting the outboard motor 9 1 Troubleshooting the power tilt unit Power tilt modell 9 7 Troubleshooting the power unt 9 1 U Upper case and steering am 7 11 4 6AG3 11 Index MEMO 6AG 3 11 5 Wiring diagram CDI unit 2 Stator coil assembly charge coil 3 Stator coil assembly power bobbin 4 Stator coil assembly lighting coil Pulser coil 6 Primary Start Ignition coil Spark plug 9 Thermoswitch Oil pressure switch D Engine stop lanyard switch
65. the tilt system manual tilt model Set the tilt lock lever 07 to the release position 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 S6AG1150 Set the tilt lock lever to the lock posi tion 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 S6AG1260 3 Check that there is no interference with leads cables or hoses when the tilted up outboard motor is steered Checking the power tilt system power tilt model 1 Check that the outboard motor tilts up and down smoothly when operating the power tilt switch S6AG1160 Tiller handle model Remote control model 2 Check that there is no abnormal noise produced when the outboard motor is tilted up or down 3 Check that there is no interference with leads cables or hoses when the tilted up outboard motor is steered 6AG3J1 1 Checking the engine start button or switch and engine stop lanyard switch 1 Check that the engine starts when the engine start button is pushed Tiller han dle model Check that the engine starts when the engine start switch is turned to START Remote control model S60V1070 Tiller handle model Remote control model 2 Check that the engine turns off when the engine stop l
66. to the crankshaft 569J5B70 a 20 mm 0 8 in O 40 mm 1 6 in 60 mm 2 4 in 6AG3 11 Cylinder block Cylinder bore D D 63 000 63 015 mm 2 4803 2 4809 in Checking the piston clearance 1 Check the piston clearances if replacing the piston the piston ring set the cylin der block or all parts NOTE The figures are for reference only Depend ing on how the parts are assembled the actual measurements may not be within the specified ranges Piston clearance reference data 0 035 0 065 mm 0 0014 0 0026 in Checking the piston ring 1 Measure the piston ring dimensions B and T Replace the piston ring set if out of specification i oh T T al Piston ring dimensions Top ring B 1 17 1 19 mm 0 0461 0 0469 in T 2 30 2 50 mm 0 0906 0 0984 in 2nd ring B 1 17 1 19 mm 569J5B80 0 0461 0 0469 in T 2 4 2 6 mm 0 0945 0 1024 in Oil ring B 2 34 2 46 mm 0 0921 0 0969 in T 2 75 mm 0 1083 in Checking the piston ring end gap 1 Level the piston ring in the cylinder with a piston crown 2 Measure the piston ring end gap at the specified measuring point S6AG5860 NOTE The figures are for reference only Depend ing on how the parts are assembled the actual measurements may not be within the specified ranges Piston ring end gap reference data Top ring 0 15 0 30 mm 0 0059 0
67. transom model s S transom model 17 Bolt 2 M8 x 16 mm 7 25 6AG 3 11 Clamp bracket and swivel bracket power tilt model 16 0 go 13 19 N m 1 9 kgf m 14 0 ft Ib 24 N m 2 4 kgf m 17 7 ft Ib 6 H 13 A 10 24N m 2 4 kgf m 17 7 ft Ib 8N m 8 N m 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib S6AG7760 Part name l Remarks Washer Collar Shaft Anode Bolt Bolt Ground lead Collar P ower tilt motor lead P ower tilt unit Collar Collar Plastic tie M6 x20 mm Mp x 10 mm 2 2 1 1 2 2 1 2 1 1 1 1 1 6AG 3 11 7 20 Bracket unit Removing the power tilt unit 1 Fully tilt the outboard motor up and then Support it with the tilt stop lever S6AG7771 WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power tilt unit should lose fluid pressure NOTE _ If the power tilt unit does not operate open the manual valve by turning it counterclock wise and then tilt the outboard motor up manually 2 Remove the plastic tie from the clamp bracket and then pull out the power tilt motor lead S6AG7770 3 Remove the bolt and ground lead from the power tilt unit 4 Remove the bolts washers 7 collars 8 and shaft 7 27 5 Remove the E clip 40 shaft AY and collar 02
68. x 20 mm Grommet Bolt M6 x 20 mm Fuel joint Plug Engine start button Bottom cowling Grommet Plug Retaining plate E xcept for tiller handle model with electric starter Tiller handle model with electric starter Tiller handle model Remote control model KA k KA KA KA KA FA FA FA NR NR KM k kb 6AG 3 11 7 8 Bracket unit Sa 2 N m 1 1 I H s s s 139 We Fame pe 18 33 Bolt 34 Plate Bolt 2 19 Damper 1 20 Grommet 1 21 Grommet 1 22 Grommet 1 23 Plug 1 24 Plug 1 25 Plug 1 26 Start in gear protection cable 1 27 Shift rod 1 28 Flushing hose 1 29 Bolt 4 30 Grommet 4 31 Collar 4 32 Grommet 2 1 1 7 9 a AI PS ie E 7 J X E sf 31 U I d OT Remarks M6 x 30 mm Tiller handle model Remote control model S6AG 7460 Tiller handle model without electric starter Tiller handle model with electric starter Remote control model Manual starter model M6 x 35 mm M6 x 20 mm 6AG3 11 Bottom cowling S 2 Pre TD GE EN LD S6A G7460 No Peme 09 Remarks Grommet Bolt Holder Fuel hose Handgrip Cowling lock lever Bolt Rubber seal Water outlet Cable guide Bolt Shift rod lever joint Bracket Shift rod lever Shift rod arm M6x12mm Mp x 12 mm Remote control model M6 x 20 mm Remote control model KA k FA k k k k KA k k A k RAR 6AG 3 11 7
69. 0 Prime Start plunger length after Supplying power reference data 15 0 mm 0 59 in at 24 C 75 F Assembling the carburetor 1 Install the main nozzle 07 main jet pilot jet and plug to the carburetor body as shown d J O O a 75 S6AG4240 2 Install the needle valve float float pin and screw 8 as shown and then check the float for smooth operation 6AG3 11 a Q ER EE SAA S6AG4250 3 Install the pilot screw 9 turn It in until it is lightly seated and then turn it out the Specified number of turns S6AG4270 E S6AG4260 For Europe For Oceania Pilot screw adjusting tool dO for Europe 90890 03154 Pilot screw setting 15 12 1 2 turns out 20 3 1 2 1 2 turns out 6AH10 3 3 8 1 2 turns out 6AH50 6AG3 11 Carburetor unit Installing the carburetor 1 Install the new gaskets 1 spacer carburetor assembly and intake Silencer with the bolts NOTE Install the fuel filter after tightening the bolts and fastening the Prime Start lead with the holder 2 Connect the throttle link rod to the carbu retor throttle lever and the Prime Start connectors S6AG 4181 NOTE e To adjust the throttle link rod see Adjust ing the throttle link 3 9 e Place the Prime Start connectors in the Junction box after connecting them 3 Adjustthe engine idle speed NOTE o If the carburetor has been disassem
70. 0 12 6 568 22 4 840 33 1 448 17 6 575 22 6 372 14 6 414 16 3 pS E S TE AND Ee V 833 32 8 lom 4 18 0 7 386 15 2 19 0 7 2 25 40 566 22 3 643 25 3 mm in S6AG 2020 6AG3 11 Maintenance specification Exterior 15E 20E mm in S m a ri M S 730 28 7 321 12 6 i L 847 33 3 176 6 9 489 19 3 66 2 6 E PR er KS S fee N Si EE oS a 7 ADEN FON NN NN AN lon ST AA AM gL d 4 0 NN R EE reg Tonto S j mi ER 1 Ce SEN S S 9 0 4 4 L 18 0 7 387 15 2 ri S6AG 2030 6AG 3 11 2 26 SPEC a Specification Exterior 20ET mm in pf N Z Z g m aS 40 slk M e TSR 18 Pd LZ ES i ay FR Y 9 N AKP he S gt 0 ri S 727 28 6 309 12 2 L 840 33 1 488 19 2 N N LA N LO FT NN ae o F E NAN ST un ZS SA AE ode n wg NN m ST m 2 no SE R G 0 ri L 18 0 7 386 15 2 S6AG2040 2 21 6AG3J 11 Maintenance specification Clamp bracket 15M 15EB 15E 20M 20E mm in 70 5 2 8 70 5 2 8 es a NZ AN 37 NZ D LI 187 5 7 4 48 1 9 S6AG 2050 6AG 3 11 2 28 Specification Clamp bracket 20E B T 20E ST T SPEC mm in 95 3 3 8 95 3 3 8 pl EN L Z 609 8 ZT 9 SZE ee 7 O OT
71. 0 3 0 4 0 5 Propeller shaft Drive shaft Electrical Model T Ignition and ignition control system Spark plug gap i 0 8 0 9 0 031 0 035 Spark plug cap resistance 3 75 6 25 Ignition coil resistance Primary coil O B at 20 C 68 F 0 26 0 35 Secondary coil spark plug wire spark plug wire at 20 C 68 F Pulser coil output peak voltage W R B at cranking unloaded at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Pulser coil resistance W R B at 20 C 68 F 152 228 C1 The figures are for reference only 6AG3J11 2 12 SPEC EN Specification Charge coil output peak voltage B R G R at cranking unloaded at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Charge coil resistance B R G R at 20 C 68 F 25 5 34 5 CDI unit output peak voltage O B at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Thermoswitch ON temperature 76 84 169 183 OFF temperature 63 77 145 171 Oil pressure switch Specified oil pressure 29 4 58 81 0 294 0 5881 4 263 8 527 Fuel control system Prime Start resistance L L at 24 C 75 F 16 4 24 8 Prime Start plunger length i 10 7 0 42 Starting system Power bobbin output peak voltage L L at cranking unloaded at 1 500 r min unloaded at 3 500 r min unloaded at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Power bobbin resistance
72. 0118 in 2nd ring 0 25 0 4 mm 0 0098 0 0157 in Oil ring 0 2 0 7 mm 0 0079 0 0276 in Measuring point amp reference data 20 mm 0 8 in Checking the piston ring groove 1 Measure the piston ring grooves Replace the piston If out of specification 6AG3 11 10 je S6AG5870 Piston ring groove Top ring Gi 1 21 1 23 mm 0 0476 0 0484 in 2nd ring 1 21 1 23 mm 0 0476 0 0484 in Oil ring 2 51 2 53 mm 0 0988 0 0996 in 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 S6AG5880 Piston ring side clearance Top ring Gi 0 02 0 06 mm 0 0008 0 0024 in 2nd ring 0 02 0 06 mm 0 0008 0 0024 in Oil ring 0 05 0 19 mm 0 0020 0 0075 in 6AG3 11 Cylinder block Checking the piston pin boss bore 1 Measure the piston pin boss bore Replace the piston If out of specification S6AG5890 NOTE When measuring the piston pin boss bore do not measure it at the ring groove Piston pin boss bore 16 004 16 015 mm 0 6301 0 6305 in Checking the piston pin diameter 1 Measure the piston pin diameter Replace if out of specification 569J5C30 Piston pin diameter 15 995 16 000 mm 0 6297 0 6299 in Checking the connecting rod small and big end inside diameter 1 Tighten the connecting rod cap bo
73. 13 3 ft lb 5 Pour the specified amount of the recom mended engine oil into the oil filler hole Recommended engine oll 4 stroke motor oil API SE SF SG SH SJ or SL SAE 5W 30 10W 30 or 10W 40 Engine oil quantity With oil filter replacement 1 8 L 1 90 US gt 1 58 Imp qt 3 4 CHK Q ADJ Periodic check and adjustment 6 Install the oil filler cap and oil dipstick and then start the engine and warm it up 7 Turn the engine off and then check the oil level and that there is no oil leakage If the oil level is low add engine oil to the correct level Checking the timing belt CAUTION Do not turn the flywheel magnet counter clockwise otherwise the water pump impeller may be damaged 1 Remove the sprocket cover and manual Starter Manual starter model Remove the sprocket cover and flywheel magnet cover Electric starter model 2 While turning the flywheel magnet clock wise check the interior and the exte rior of the timing belt Replace the timing belt if cracked damaged or worn NOTE _ _ To replace the timing belt see Replacing the timing belt 5 3 Checking the spark plug 1 Disconnect the spark plug caps and remove the spark plugs 2 Clean the electrodes 1 with a spark plug cleaner or wire brush 3 5 569J3190 3 Check the spark plug Replace if the electrodes are eroded or there IS exces sive carbon or other deposits or if the gasket
74. 2 Setthe shift rod to the neutral position 6AG3 11 Drive shaft and lower case S6AG6370 3 Install the lower unit to the upper case and then tighten the lower case mounting bolts to the specified torque S6AG6410 NOTE SSS e Before installing the lower unit to the upper case install the dowels into the lower case e Before installing the lower unit make sure that the locknut is removed from the shift rod Lower case mounting bolt 18 N m 1 8 kgf m 13 3 ft lb 4 Install the locknut and then screw the adjusting nut onto the shift rod S6AG 6420 6AG3 11 NOTE The adjusting nut must be screwed in a minimum of 8 0 mm 0 31 in amp 5 Tighten the locknut NOTE After connecting the shift rod check that the gear shift operates properly 6 Install the anode trim tab and inlet covers 8 and then tighten the bolts to the specified torque S6AG 6430 NOTE Install the trim tab in its original position Anode bolt 8 N m 0 8 kgf m 5 9 ft lb Trim tab bolt 8 N m 0 8 kgf m 5 9 ft lb Lower unit 7 Install the propeller and propeller nut o Place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then tighten the nut to the specified torque WARNING e Do not hold the propeller with your hands when loosening or tightening it e Be sure to disconnect the battery cables
75. 461 0 0469 Dimension T i 2 4 2 6 0 0945 0 1024 End gap i 0 25 0 4 0 0098 0 0157 Side clearance 0 02 0 06 0 0008 0 0024 Oil ring Dimension B 2 34 2 46 0 0921 0 0969 Dimension T i 2 75 0 1083 End gap g i 0 2 0 7 0 0079 0 0276 Side clearance 0 05 0 19 0 0020 0 0075 Connecting rod Small end inside diameter i 16 015 16 029 0 6305 0 6311 Big end inside diameter 34 030 34 042 1 3398 1 3402 Big end side clearance i 0 05 0 22 0 0020 0 0087 Crankpin oil clearance i 0 021 0 045 0 0008 0 0018 C1 The figures are for reference only 2 9 G6AG3J11 Maintenance specification Model Po Model O Crankshaft Crankshaft journal diameter 36 997 37 009 1 4566 1 4570 Crankpin diameter 33 997 34 009 1 3385 1 3389 Crankpin width 21 000 21 070 0 8268 0 8295 Crankshaft runout limit 0 05 0 0020 Crankcase Crankshaft journal oil i 0 011 0 039 0 0004 0 0015 clearance Upper and lower crankcase main journal bearing thickness A Blue i 1 502 1 506 0 0591 0 0593 B Black 1 498 1 502 0 0590 0 0591 C Brown 1 494 1 498 0 0588 0 0590 Oil pump Type Trochoid Outer rotor to housing mm in 0 09 0 15 0 0035 0 0059 clearance Item Unit Outer rotor to inner rotor mm in Within 0 12 0 0047 clearance Rotor to cover clearance mm in 0 03 0 08 0 0012 0 0031 Relief valve opening pressure kPa 350 450 3 50 4 50 50 8 65 3 kgf cm psi Thermostat Opening
76. 5 40 Checking the valve Spring eee eee 5 38 Checking the warning indicator assembly eee eee eee 8 28 Checking the water pump sese eee eee e e 6 5 Clamp bracket and swivel bracket manual tilt modell sss esse eee eee 7 20 Clamp bracket and swivel bracket power tilt model cececsseeeeseseeeeeeeeerens 7 25 Control TT DEEN 3 7 Cylinder ls la na 5 49 Cylinder Nead mime 5 34 D Bue Se tant aise 2 24 Disassembling the carburetor 4 12 Disassembling the cylinder block 5 51 Disassembling the cylinder head 5 37 Disassembling the drive shaft housing 6 12 Disassembling the exhaust manifold oil pan and exhaust goude 7 15 Disassembling the forward gear 6 12 Disassembling the friction plate eee 7 6 Disassembling the fuel pump sese ee eee ee 4 6 6AG3 11 Disassembling the gear pump seese 7 38 Disassembling the lower case asese 6 13 Disassembling the manual starter 5 9 Disassembling the power tilt motor 7 31 Disassembling the propeller eee ss T EE 6 7 Disassembling the propeller Shaft housing assembly eee ee ee 6 7 Disassembling the starter motor 8 14 Disassembling the swivel bracket 7 22 Disassembling the tiller handle 08 7 3 Disassembling the tilt cylinder 7 43 Disassembling the upper case 7 15 Disassembly and assembly see eee e 1 5 Draining NE fU Elerin 3 3 Drive Shaft and lower case 6 11 E BICC U Gall EE
77. 652 Needle bearing attachment Go 90890 06613 Installation depth 7 0 8 0 mm 0 28 0 31 in Installing the shift rod drive shaft housing and drive shaft 1 Install the forward gear assembly into the lower case 2 Install the drive shaft sleeve into the lower case NOTE Install the drive shaft sleeve with the hole facing forward 3 Install the shift rod a new gasket and the drive shaft housing assembly GO NOTE i Make sure that the projection on the gas ket is toward the port side 4 Install the drive shaft thrust bearing Original pinion shim s pinion and pinion nut into the lower case 6AG3 11 NOTE e When installing the pinion lift up the drive Shaft slightly and align the gear and shaft Splines e Be sure to select the pinion shim s if replacing the pinion thrust bearing or lower case To select the shims see Shim ming 6 20 5 Tighten the pinion nut to the specified torque S6AG 6340 Pinion nut 25 N m 2 5 kgf m 18 4 ft lb Installing the propeller shaft housing 1 Install the propeller shaft assembly into the lower case S6AG6341 6AG3 11 Drive shaft and lower case 2 Install the washer and propeller shaft housing assembly into the lower case and then tighten the bolts to the speci fied torque S6AG 6360 Propeller shaft housing bolt 8 N m 0 8 kgf m 5 9 ft lb 3 Check
78. 6AG3 11 Ignition and ignition control system S6AG8150 Engine stop lanyard switch continuity White W Black B Cercle No pune pushed 3 Connect the engine stop lanyard switch connector and terminal Checking the engine stop lanyard switch remote control model 1 Disconnect the 10 pin main harness cou pler 8 24 sc 7 ELEC W i Electrical system 2 Turn the engine start switch to ON and then check the engine stop lanyard Switch for continuity at the 10 pin main harness coupler remote control box end Check the wiring harness or replace the engine stop lanyard switch if out of specification OFF 1 S6AG8160 Engine stop lanyard switch continuity White W Black B Cipinstaled woo Clip removed 3 Turn the engine start switch to OFF 4 Connect the 10 pin main harness cou pler Engine electric control system Checking the CDI unit 1 Measure the CDI unit output peak voltage Replace if below specification 8 25 L E NRT d Hr g Zeg NZ aon ln SH S6AG8080 NOTE e To prevent the engine from starting when cranking It be sure to disconnect both Spark plug caps e Do not remove the clip from the engine stop lanyard switch e When using the manual starter to crank the engine the voltage values may vary depending on the speed at which the Starter handle is pulled e Be sure to check the charge coil a
79. 6AG4280 Cooling water hose exhaust cover to joint Fuel hose fuel filter assembly to fuel pump Cooling water hose exhaust cover to joint dt Fuel hose fuel pump to carburetor assembly 3 Cooling water hose 4 Cooling water hose Cooling water hose fuel pump to cooling water pilot hole 6 Cooling water hose flushing hose adapter to joint Cooling water hose thermostat cover to cylinder block Blowby hose cylinder head cover to intake silencer Fuel hose fuel joint to fuel filter assembly joint to joint joint to fuel pump A 4 1 6AG 3 11 Hose routing Fuel filter Fuel filter 18 N m 1 8 kgf m 13 3 ft Ib S6AG 4020 No Remarks Bolt M8 x 14 mm Bracket Nut Fuel hose F uel filter element O ring Fuel filter cup Fuel filter assembly Bolt Fuel joint Seal Fuel hose Clamp Not reusable COND UW SS GO M FP M6 x 25 mm LU k KA FA k RP RPP RP RPP k Fi 6AG3 11 4 2 ne R Fuel system Checking the fuel filter assembly NOTE _ To check the fuel filter element see Check ing the fuel filter 3 3 1 Connect a vacuum pressure pump gauge and a meter to the fuel inlet 2 Cover the fuel outlet with your finger and then apply the specified positive pressure Replace the O ring fuel filter cup or fuel filter assembly if the specified pressure cannot be maintained for at least 15 seconds I S6AG4060 NOTE Use a com
80. 7 11 REMOVING the upper e T 7 15 Disassembling the Tee 7 15 Checking the drive shaft bushing L transom modell 7 15 Disassembling the exhaust manifold oil pan and exhaust guide 7 15 Checking the exhaust manifold oil pan and exhaust guide see 7 16 Checking ENG Ee e EE 7 16 Assembling the exhaust guide oil pan and exhaust manifold 0 7 16 ASSembpilng he Upper e vanene dd 7 17 REMOVING the steering am 7 18 iS ta ING VE STEEN ET EEN 7 18 Installing ME UPPErT E 7 19 Clamp bracket and swivel bracket manual tilt model cccsssecssssseeeessees 7 20 REMOVING the clamp bracket sese sees e eee eee ennenen 7 22 Disassembling the Swivel bracket eee eee eee ee 7 22 Assembling the swivel bracket AA 7 23 insta ling ME AMP Leg EE 7 24 Clamp bracket and swivel bracket power tilt model sccsssssseeeesssseees 7 25 REMOVING Te power TIE UIE vasene saadan 7 27 REMOVING the clamp bracket eee sees eee eee ennenen 7 27 Installing the camp bracket c rape TIGE naa a 7 28 Installing the DOW tilt UUs EE 7 28 Power tilt motor power tilt model rrrrrnnnnnnvrnnnnnnvennnnnnnvennnnnnnernnnnnnnernnnnnnr 7 30 Disassembling the power tilt motor eee eee eee eee eee 7 31 Checking TNE power let 7 32 Checking the brush holder and brush sese eee 7 33 Assembling the power tilt motor ss eee eee eee eee eee 7 33 6AG3 11 6AG3J 11 Power tilt gear pump power tilt modelJ rrrrrrrnnnnnvennnnnnnennnnnnnnnennnnnn
81. 7 ft lb 3rd 32 N m 3 2 kgf m 23 6 ft lb Grease nipple 43 3 N m 0 3 kgf m 2 2 ft lb 6AG3 11 Upper case and steering arm Clamp bracket and swivel bracket manual tilt model Clamp bracket and swivel bracket manual tilt model 16 10 AG L GN el E S6AG 7060 Remarks Part name Tilt pin Spring Bolt Collar Nut Self locking nut Hanger Through tube Swivel bracket Clamp bracket Clamp bracket Bushing Grease nipple Bolt Wave washer Tilt stopper plate Tilt lock lever Mp x 155 mm L transom model S transom model STBD PORT KA NN P k KM FA FA KA k k FA k KA bb Fi 6AG 3 11 7 20 Bracket unit UT 11 S6AG7400 No Patnam Joy rem 1 Tilt lock lever 1 2 Tiltlock rod 1 1 a gt 3 Tilt lever 1 4 Spring 1 a gt 5 E clip 4 6 Tiltlever shaft 1 7 Stopper shaft 1 8 Receiver assembly 1 9 Swivel bracket 1 L transom model transom model 10 Tilt lock rod 2 1 11 Collar 2 12 Tilt lock plate 1 1 13 Tilt lock plate 2 1 14 Tilt lock shaft 1 15 E clip 1 16 Reverse lock shaft 1 17 Spring 2 7 21 6AG 3 11 Clamp bracket and swivel bracket manual tilt model Removing the clamp bracket 1 Remove the tilt pin and then remove the clamp bracket bolt clamp bracket nut and collar 2 Remove the tilt stopper plate bolts Swivel bracket side 3 Remove the self locking nut and h
82. 70 Lighting coil connectors 02 Ignition coil connector O 02 Thermoswitch connector Gy B Thermoswitch connector B 05 Ignition coil connector B 6AG3 11 Electrical component and wiring harness routing Positive battery lead connector R OO Starter relay connector Br Oil pressure switch connector P Rectifier Regulator connector R GO Lead 10 pin main harness coupler to starter relay Br remote control model or neutral switch lead Br tiller handle model GD Fuse lead R Rectifier Regulator lead B 3 Oil pressure switch lead P 4 Rectifier Regulator connector R Install the terminals of the negative battery cable and power tilt relay lead B using the bolt making sure to install the negative battery cable terminal under the power tilt relay lead B terminal and then apply Selva grease to the terminals and bolt Fasten the wiring harness and leads in front of the starter motor with the holder Install the terminals of the engine stop lanyard switch ground lead tiller handle model wiring harness ground lead and negative battery cable using the bolt and then apply Selva grease to the terminals and bolt D Fasten the lighting coil leads wiring harness fuse leads and neutral switch lead tiller handle model with the holder Insert the rubber plug into the Rectifier Regulator connector R Fasten the ignition coil lead and Rectifier Regulator lead with the holder Install the fuse bracket
83. 756 1 7 Pilot screw adjusting tool 90890 03154 Compression gauge 90890 03160 Flywheel holder 90890 06522 Flywheel puller 90890 06521 De Shaft holder 90890 06069 6AG3J1 1 Valve spring compressor 90890 04019 50 i C Valve spring compressor attachment 90890 06320 a Valve guide remover installer 90890 06801 A Valve guide reamer 90890 06804 AN Valve seat cutter holder 90890 06316 6AG3J11 Special service tool Oe Valve seat cutter 90890 06312 90890 06315 90890 06323 90890 06555 90890 06818 90890 06819 Needle bearing attachment 90890 06612 90890 06613 90890 06614 90890 06616 90890 06653 Driver rod L3 90890 06652 d Piston slider 90890 06529 Stopper guide plate 90890 06501 1 8 Gs l General information Sn Center bolt 90890 06504 Bearing housing puller claw S 90890 06564 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 Driver rod SS 90890 06604 SS Driver rod LS 90890 06606 Ball bearing attachment 90890 06632 Drive shaft holder 1 90890 06515 Bushing attachment 90890 06649 Bearing separator 90890 06534 6AG3J1 1 Needle bearing attachment 90890 06617 90890 06618 Bearing outer race attachment 90890 06625 Driver rod LL 90890 06605 Driver rod SL 90890 06602 Bearing depth plate 90890 06603 6AG3J11 Special service tool L Bearing in
84. 9 in an exploded diagram or illustration indicate the type of sealant or locking agent and the application point Apply Gasket Maker OO Apply LOCTITE 242 blue Apply ThreeBond 1104J Apply LOCTITE 572 Apply LOCTITE 271 red Apply silicone sealant 6AG3J11 1 2 Gs l General information Abbreviation The following abbreviations are used in this service manual Sealant and locking agent table The following table contains sealants locking agents and greases used in this service manual that are not listed on page 1 2 Symbol Applicaton 1 3 6AG3J11 Safety while working To prevent an accident or injury and to ensure quality service follow the safety pro cedures provided below Fire prevention Gasoline is highly flammable Keep gasoline and all flammable products away from heat sparks and open flames 569J1010 Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous If inhaled in large quantities they may cause loss of consciousness and death within a short time When test running an engine indoors e g in a water tank be sure to do so where ade quate ventilation can be maintained 569J1020 Self protection Protect your eyes by wearing safety glasses or safety goggles during all operations involv 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 Sary 6
85. AG3 11 Power unit CDI unit and junction box power tilt model he 8 N m 0 8 kgf m 5 9 ft Ib a 8 N m S6AG5700 Partname Remarks J unction box cover J unction box Power tilt sub wiring harness Damper Holder Screw Bolt Terminal Bolt Bracket Power tilt relay Holder Grommet CDI unit Bolt Bolt Bracket Remote control model Remote control model 26 x 12 mm Remote control model Mp x 14 mm Mp x 12 mm A e A en Hi D d Oo Ln RUNE KA k kA bm Ln E W KJ M6 x20 mm M6 x 20 mm let KA KA KA KA KJ 4 KA KA KA KA D KA KA KA KA KA KA KA sl 6AG 3 11 5 20 S6AG5700 11 Part name Remarks Tiller handle model Remote control model 33 Wiring harness 34 Wiring harness 18 Bolt 3 M6 x 25 mm 19 Grommet 3 20 Collar 3 21 Neutral switch 1 Tiller handle model 22 Bracket 1 23 Plate spring 1 24 Bolt 2 M6 x 16 mm 25 Pulser coll 1 26 Bolt 2 M5x12mm 27 Cap 2 28 Bolt 2 M6 x 30 mm 29 Collar 2 30 Grommet 2 31 Stator coil assembly 1 32 Bolt 3 M6 x 30 mm 1 1 5 21 6AG3J 11 Power unit Bracket manual starter model P 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib Ae 8 N m 0 8 kgf m 5 9 ft Ib Axe 8 N m 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 2N m 0 2 kgf m 1 5 ft Ib S6AG5730 No parname Joy Rm 1 Thermoswitch Plate Bolt Bracket Bolt Holder Holder Was
86. AG3J11 How to use this manual Safety while working S69J1030 Part lubricant and sealant Use only genuine Selva parts lubricants and sealants or those recommended by Selva when servicing or repairing the out board motor 569J1040 Under normal conditions the lubricants men tioned in this manual should not harm or be hazardous to your skin However you should follow these precautions to minimize any risk when working with lubricants 1 Avoid contact with skin Do not for example place a soiled rag in your pocket 2 Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made 3 Change and wash clothing as soon as possible if soiled with lubricants 4 To protect your skin apply a protective cream to your hands before working on the outboard motor 5 Keep a supply of clean lint free cloths for wiping up spills etc 1 4 Gs l General information 6 Maintain good standards of personal and Good working practice Special service tool 2 Use the recommended special service tools to protect parts from damage Use the right tool in the right manner do not improvise S6AL1040 3 Tightening torque Follow the tightening torque specifications provided throughout the manual When tight ening nuts bolts and screws tighten the large sizes first and tighten fasteners starting 4 in the
87. E Be sure not to put the Plastigauge PG 1 over the oil hole in the crankpin of the crank shaft 3 Install the connecting rod 1 to the crank pin S6AG5940 NOTE Make sure that the projections of the con necting rod face towards the flywheel magnet Side A of the crankshaft 4 Tighten the connecting rod cap bolts to the specified torques in 2 stages 6AG3 11 Cylinder block S62Y5980 NOTE Do not turn the connecting rod until the crankpin oil clearance measurement has been completed Connecting rod cap bolt lst 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb 5 Remove the connecting rod cap and measure the width of the compressed Plastigauge PG 1 on each crankpin Check the connecting rods and crank Shaft if out of specification and if neces Sary replace them as a Set 569J5D30 Crankpin oil clearance reference data 0 021 0 045 mm 0 0008 0 0018 in Checking the crankshaft journal oil clearance 1 Clean the main bearings crankshaft jour nals and bearing portions of the crank case and cylinder block 2 Place the cylinder block upside down on a bench 5 56 3 Install half of the main bearings and the crankshaft into the cylinder block 3 56D55860 NOTE e Install the main bearings in their original positions e Insert the projection of each bearing into the slots in the cylinder block 4 Puta piece of
88. G3 11 Starting system 2 Push the engine start button and then measure the input voltage between the Neutral switch continuity neutral switch connector engine start Brown Br Brown Br button end and the ground Check the Switch position engine start button and wiring harness Pushed neutral if below specification Free forward or reverse 4 Connect the connectors of the neutral Switch Checking the neutral switch remote control model 1 Set the remote control lever to the neu tral forward or reverse position 2 Turn the engine start switch to START and then check the neutral switch for continuity at the 10 pin main harness coupler remote control box end Check the wiring harness or replace the neutral Switch if out of specification ON S6AG8210 OFF START Neutral switch input voltage reference data Brown Br Ground 12 V battery voltage 3 Check the neutral switch for continuity between the neutral switch connectors neutral switch end Replace if out of Specification S6AG8201 NOTE e Be sure to check the engine start switch for continuity before checking the neutral Switch e Check for continuity when the engine start Switch is turned to START S6AG 8220 Lead color Remote control lever Red R geet position Br Neutral 00 gt Forward or reverse gt 20 6AG3 11 0 ELEC 7 ELEC W i Electrica
89. Intake Exhaust Stem runout limit Guide inside diameter Intake and exhaust Stem to guide clearance Intake Exhaust Valve guide height Intake and exhaust Valve spring Free length Tilt limit Cylinder Bore size 2 17 0 15 0 25 0 006 0 010 0 25 0 35 0 010 0 014 27 9 28 1 1 10 1 11 24 0 24 2 0 94 0 95 1 98 2 40 0 0780 0 0945 1 98 3 11 0 0780 0 1224 1 2 1 6 0 047 0 063 0 8 1 2 0 0315 0 0472 1 0 1 4 0 0394 0 0551 5 475 5 490 0 2156 0 2161 5 460 5 475 0 2150 0 2156 0 01 0 0004 5 500 5 512 0 2165 0 2170 0 010 0 037 0 0004 0 0015 0 025 0 052 0 0010 0 0020 10 8 0 2 0 4 0 01 32 63 1 2846 1 4 0 055 63 000 63 015 2 4803 2 4809 6AG3J1 1 Maintenance specification Piston diameter D 62 950 62 965 2 4783 2 4789 Measuring point H i 3 5 0 14 Piston clearance i 0 035 0 065 0 0014 0 0026 Piston pin boss bore i 16 004 16 015 0 6301 0 6305 Oversize piston diameter 1st i 63 200 63 215 2 4882 2 4888 2nd 63 450 63 465 2 4980 2 4986 Piston ring groove Top ring 1 21 1 23 0 0476 0 0484 2nd ring 1 21 1 23 0 0476 0 0484 Oil ring 2 51 2 53 0 0988 0 0996 15 995 16 000 0 6297 0 6299 Piston ring Top ring Barrel Dimension B 1 17 1 19 0 0461 0 0469 Dimension T 2 30 2 50 0 0906 0 0984 End gap i 0 15 0 30 0 0059 0 0118 Side clearance i 0 02 0 06 0 0008 0 0024 2nd ring Taper Dimension B i 1 17 1 19 0 0461 0 0469 Dimens
90. Pinion Thrust bearing Bushing Oil seal Gasket O ring Shift rod 1 2 3 4 5 6 7 8 9 10 11 KA Fi U N Not reusable Not reusable Not reusable L transom model S transom model A e UI A G o aa oa a A KA OY 6 11 6AG 3 11 Removing the drive shaft drive shaft housing and shift rod 1 Remove the pinion nut S6AG 6200 2 Remove the pinion pinion shim s and thrust bearing 3 Remove the drive shaft and then remove the drive shaft housing assembly gas ket and shift rod S6AG6220 CAUTION Be sure to remove the drive shaft before removing the drive shaft housing from the lower case 4 Remove the drive shaft sleeve 5 Pull out the forward gear 6AG3 11 Drive shaft and lower case Disassembling the drive shaft housing 1 Remove the oil seals and bushing S6AG6230 MA Driver rod L3 90890 06652 Bushing attachment 90890 06649 Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press S6AG 6240 CAUTION Do not reuse the bearing always replace it with a new one vz Needle bearing attachment 90890 06616 Bearing separator 90890 06534 Lower unit Disassembling the lower case 1 Remove the taper roller bearing outer race and forward gear shim s S6AG 6250 CAUTION Do not reuse the bearing always replace it with a new one NOTE _ Fit the hooks of the
91. TION Do not turn the flywheel magnet counter clockwise otherwise the water pump impeller may be damaged NOTE To remove and install the timing belt drive Sprocket and driven sprocket see Remov ing the timing belt and sprocket 5 30 and Installing the sprocket and timing belt 5 31 1 Disconnect the spark plug caps and remove the spark plugs 2 Remove the thermoswitch and cooling water hose from the thermostat cover 2 N A J DJ LTE gd N lee S6AG5040 i Av 3 S6AG5G30 WARNING Apply force in the direction of the arrows shown to prevent the flywheel holder from Slipping off easily 6AG3 11 NOTE Use a 24 mm socket to loosen the flywheel magnet nut Flywheel holder 90890 06522 4 Remove the flywheel magnet and Woo druff key S63P5280 563P5290 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 wheel magnet comes off the tapered portion of the crankshaft Flywheel puller 90890 06521 5 Remove the stator coil assembly bolts 3 and then remove the stator coll assembly 6AG3 11 Power unit check and adjustment S6AG5090 6 Align the 1 A mark on the driven sprocket with the A mark on the cylinder head NOTE Check that the
92. US at replacement Imp at with oil filter replacement L US at Imp at 1 6 1 69 1 41 1 8 1 90 1 58 Gear oil type Gear oil grade API SAE Gear oil quantity cm US oz Imp 02 Hypoid gear oil GL 4 90 300 10 14 10 58 Bracket unit Trim angle at 12 boat transom Tilt up angle 71 63 71 63 71 67 71 67 Steering angle 45 45 40 40 45 45 40 40 Power tilt system Fluid type ATF ATF Dexron II Dexron II 0 0 4 0 8 0 12 0 Drive unit Gear shift positions F N R Gear ratio 2 08 27 13 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear view Clockwise Propeller mark J J1 1 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 2 5 G6AG3J11 General specification Electrical Battery minimum capacity CCA EN 20HR IEC Electrolyte specific gravity at 20 C 68 F 6AG3J11 2 6 SPEC Specification Maintenance specification Power unit Item Unit meee IER 20EBT Power unit Minimum compression kPa 730 860 730 860 pressure kgf cm psi 7 3 8 6 7 3 8 6 105 9 124 7 105 9 124 7 Oil pressure kPa 400 4 0 58 0 at engine idle speed kgf cm psi Cylinder head Warpage limit 0 10 0 0039 lines indicate straightedge position
93. X 38 1 5 95 3 3 8 95 3 3 8 S6AG 2060 6AG3 11 2 29 Maintenance specification Tightening torque Tightening torque Specified torque Part to be tightened Thread size Nm kgm St mu JF Figi ap pp 25 0235 184 Fueljontbot ME 8 08 59 Manual starter bolt manual starter model EE ED Drive plate screw manual starter model M5 f 7 07 52 Manual starter drain cover screw manual M4 15 0 15 1 11 starter model Power unit mounting bolt M8 57 53 199 Groundleadboi LW 8 08 59 Rectifier Regulator nut electric starter mode 4 04 30 enge D 17 25 Terminal bolt powerttitmodel me 8 08 59 CDi unitbracketbot 1 m 8 08 59 Corut ME 8 08 59 VE H E T EJ Power tilt unit coupler holder bolt power tilt M6 3 0 model Stator coll assembly bol 3 Holder bracket bolt m 8 og 59 Starter motor bolt electric starter model Negative battery cable bolt electric starter M8 18 1 8 13 3 model Starter motor lead nut electric starter model 4 04 30 Starter motor terminal nut electric starter 0 4 0 04 0 30 model Thermoswitch bot mw 8 og la Rectifier Regulator bracketbt me 8 os 59 Starter motor cover bolt electric starter mode M6 8 os 59 Oilpressure switch J 8 og 359 6AG 3 11 2 3 SPEC naan Specification Part to be t
94. able Not reusable d 2 2 2 1 1 2 2 2 2 2 2 1 2 2 2 2 7 36 Bracket unit 30 NW E o gt NW 5 N m 0 5 kgf m 3 7 ft Ib UQ l QS ESN S SS G Ecg 5 4 g 2 GL Sel ge d Remarks S6AG 7030 S pring Down main valve Up main valve Reservoir cap O ring Not reusable 1 37 6AG 3 11 Disassembling the gear pump 1 Remove the manual valve manual release pins relief valve seals and balls 2 Remove the gear housing bolts and then remove the gear pump housing plate and filters 3 Remove the shuttle pistons S6AG7150 4 Remove the down main valve 0 up main valve dd balls dd dowels 49 drive gear and driven gear 45 6AG3 11 Power tilt gear pump power tilt model vot 8 Ee SL o o 2 Dig Bi ke Og H 0 e e Q SE i F enn Checking the gear pump 1 Check the drive gear and driven gear Replace if damaged or excessively worn 2 Check the gear pump housing Replace if scratched Checking the valve seal 1 Check the valve seals and absorber valve pins Replace if damaged p yey Os p Se we ff lt D a lt A 7 00 Me Og b SS lt lt H S zm D H gt o o By gt RO S6AG7185 2 Check the main valves Replace if damaged E GC e Ga TG o Ha es Q Ch SS SC Op S6AG 7180 3 Check the manual valve and spring Replace i
95. ad if below specification Remote control model nals Replace if there Is no continuity S6AG8240 8 Install the starter relay and then connect the battery cables starter relay connec tor and starter relay lead Ignition and ignition control system Checking the ignition spark 1 Disconnect the spark plug caps from the Spark plugs S6AG8230 NOTE _ _ O O o To prevent the engine from starting when cranking it be sure to disconnect both spark plug caps 8 21 6AG3J 11 Starting system Ignition and ignition control system 2 Connect the spark plug cap to the special service tool Ignition tester 90890 06754 3 Crank the engine and check for a spark If there is no spark check the ignition system D Je FP LC 13 O Ch DNG S Be E ZX S6AG8020 AA WARNING e Do not touch any of the connections of the special service tool e Be sure to install the special service tool to the spark plug cap so that sparks do not leak out e Keep flammable gas or liquids away since this test can produce sparks NOTE Repeat steps 2 3 for each spark plug cap Checking the spark plug cap 1 Remove the spark plug caps from the Spark plug wires by turning the caps counterclockwise S6AG 8030 2 Measure the spark plug cap resistance Replace if out of specification 6AG3 11 S6AG 8040 Spark plug cap resistance 3 75 6 25 kQ Checking the ignition coil 1 Disconn
96. aller 90890 06801 Valve guide height amp Intake and exhaust 10 8 0 2 mm 0 4 0 01 in 4 Insert the special service tool into the valve guide and then ream the valve guide S6AG5190 NOTE o e Apply engine oil to the inner surface of the valve guide before reaming it e Turn the valve guide reamer clockwise to ream the valve guide e Do not turn the reamer counterclockwise when removing It e Be sure to clean the valve guide after ream ing It Valve guide inside diameter Intake and exhaust 5 500 5 512 mm 0 2165 0 2170 in Checking the valve seat 1 Eliminate carbon deposits from the valve 2 Apply a thin even layer of Mechanic s blueing dye Dykem onto the valve seat 5 40 3 Press the valve slowly against the valve Refacing the valve seat seat with a valve lapper as shown 1 Reface the valve seat with the valve seat cutters NT 569J5850 S6AG5200 4 Measure the valve seat contact width where the blueing dye is adhered to the Z Valve seat cutter holder valve face Reface the valve seat if the d 90890 06316 valve IS not seated properly or if the valve Valve seat cutter seat contact width is out of specification 30 intake 90890 06818 Check the valve guide if the valve seat 30 exhaust 90890 06819 contact is uneven 45 intake 90890 06555 45 exhaust 90890 06312 60 intake 90890 06323 60 exhaust 90890 06315 L 2 Cut th
97. alling the power unit be sure to remove the fuel pump to prevent damaging it Power unit mounting bolt lst 27 N m 2 7 kgf m 19 9 ft lb 2nd 27 N m 2 7 kgf m 19 9 ft lb 3 Install the apron and dipstick 4 Install the shift rod cam and then tighten the bolts 6AG3 11 LO 6 D 6 S6AG5H60 Tiller handle model Remote control model NOTE gt Before installing the shift rod cam make sure that the shift link rods tiller handle model or shift rod remote control model is installed correctly 5 Install the spring 8 throttle cam 9 shaft free accel lever washer 2 and bolt 43 and then tighten the bolt to the Specified torque S6AG5770 6AG3 11 Cylinder block NOTE When installing the throttle cam 9 to the bracket be sure to hook the end of the spring onto the projection of the bracket as shown Throttle cam bolt 8 N m 0 8 kgf m 5 9 ft lb 6 Turn the throttle cam 9 counterclock wise until the fully open stopper on the cam contacts the throttle cam bracket and then release it and check that the fully closed stopper on the cam contacts the bracket due to the Spring force S6AG5780 NOTE If the fully closed stopper does not contact the bracket check that the spring IS installed correctly If the end of the spring is not hooked onto the projection on the bracket repeat steps 5 6
98. and then remove the upper end of the tilt rod from the swivel bracket 6 Remove the power tilt unit and then remove the collar S6AG7780 Removing the clamp bracket 1 Remove the ground lead terminal 07 and self locking nuts of the through tube 3 and then remove the clamp brackets ur Q S6AG7790 6AG3 11 Clamp bracket and swivel bracket power tilt model NOTE Be sure to remove the ground lead terminal before removing the self locking nuts Installing the clamp bracket 1 Apply grease to the threads of the self locking nut and then tighten the nut completely onto the shorter threaded end of the through tube S6AG7800 2 Assemble the clamp brackets and Swivel bracket and then install the through tube from the port side 3 Install the self locking nut onto the through tube and then tighten it to the Specified torque 4 Install the ground lead terminals to the brackets using the bolts 5 Install the stoppers stopper nuts and plugs 40 6AG3J 11 S6AG7810 L transom model S transom model NOTE Install the anode 1 with the projection facing towards the bow S elf locking nut 19 N m 1 9 kgf m 14 0 ft lb Bolt O 8 N m 0 8 kgf m 5 9 ft lb Tilt stopper nut 24 N m 2 4 kgf m 17 7 ft lb Installing the power tit unit 1 Fully tilt the outboard motor up and then Support it with the tilt stop lever IR AS
99. andle model with the holder Cover the edge of the coupler with the protective tube so that it does not contact the leads Install the holder as shown The connectors can be fastened in any position in the holder However do not fasten the pulser coll connector W R and engine stop lanyard switch connector W in lowest opening in the holder Fold the charge coil lead B R G R back connect it to the lead connectors B R G R and then fasten it with the holder Fold the fuse lead R back and then connect it to the engine start button connector R Fasten the engine stop lanyard switch lead B and neutral switch lead Br tiller handle model with electric Starter with the holder 6AG3 11 8 4 ELEC 7 ELEC W s Electrical system Electric starter model with power tilt S 6AG 8340 a Tiller handle model CDI unit b Remote contro model P ower tilt relay Engine start button connector Br Neutral switch tiller handle model Connector engine start button to fuse R Q Pulser coil D Tachometer connector G 3 Cap 02 Charge coil connector B R 4 Coupler power tilt relay leads Sb Lg 02 Charge coil connector G R Coupler power tilt relay leads Sb Lg Engine stop lanyard switch connector W 6 J unction box 5 Prime Start connector L 8 5 6AG3 11 Electrical component and wiring harness routing Pulser coil connector W R 07 Charge coil lead BIR G R Engine stop lanyard
100. anger 4 Remove the through tube and tilt lock lever and then disassemble the clamp brackets NOTE Unhook tilt lock rod 1 from the tilt lock lever when removing it 5 Remove the tilt stopper plate bolts clamp bracket side and tilt stopper plates 0 S6AG7A40 Disassembling the swivel bracket 1 Remove the spring Remove the E clips from the tilt lever shaft and then pull out the shaft and remove the tilt lever and tilt lock rod 2 6AG3 11 S6AG7410 NOTE SE Unhook tilt lock rod 2 from the tilt lever Q when removing it 2 Remove the E clip from the stopper Shaft and then pull out the shaft and remove the receiver assembly 8 S6AG7950 7 22 L Bracket unit 3 Remove the E clip from the reverse lock shaft 49 and then pull out the shaft 4 Remove the springs 5 Remove the E clip di from the tilt lock Shaft 42 and then pull out the shaft and remove the collars tilt lock rod 2 oa tilt lock plate 1 45 and tilt lock plate 2 49 Ga 47 S6AG7960 Assembling the swivel bracket 1 Assemble tilt lock plate 2 tilt lock plate 1 the collars tilt lock rod 2 and the tilt lock shaft and then install the E clip S I Le sr sl gd S6AG7970 NOTE After installing the E clip turn it to make sure that it is installed securely 2 Pass the reverse lock shaft through the swivel bracket and tilt lock plate 2 and th
101. anyard switch is pushed Tiller handle model Check that the engine turns off when the engine start switch is turned to OFF Remote control model L EE KN S66T1080 6AG3J11 Predelivery check S60V1070 Tiller handle model Remote control model 3 Check that the engine turns off when the clip is pulled from the engine stop lan yard switch 56611090 3691220 Tiller handle model Remote control model Checking the cooling water pilot hole 1 Place the lower unit in water and then start the engine es d General information 2 Check for water flow at the cooling water pilot hole st 1 Jr Ze A a AS S6AG1230J NOTE a Make sure that the cooling water hoses are securely connected and that the flushing hose joint adapter 1 is not loose or dam aged Test run 1 Start the engine and then check that the gear shift operates smoothly 2 Check the engine idle speed after the engine has been warmed up 3 Operate at trolling speed 4 Run the outboard motor for 1 hour at 2 000 r min or at half throttle then for another hour at 3 000 r min or at 3 4 throttle 5 Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom NOTE The test run is part of the break in operation Break in During the test run perform the break in operation in the following 3 stages 1 1 hour at 2 000 r
102. art the engine and then measure the input voltage between the oil pressure Switch connector wiring harness end and the ground Check the wiring har ness If below specification EE EN OA Op N a Q V l A LIN HS E WE yy S6AG8120 Oil pressure switch input voltage reference data Pink P Ground 12 V battery voltage at engine idle speed 3 Push the engine stop button Tiller han dle model Turn the engine start switch to OFF Remote contro model 4 Check the oil pressure switch for con tinuity when the engine is stopped and when It Is running Check the oil pressure and oil pressure switch if out of specifica tion 8 2 RGA j Se d KS DR US II y4 S6AG8110 ofl Oil pressure switch continuity Engine condition Oil pressure switch Ground Continuity Stopped 5 6 U Remove the oil pressure switch Connect the special service tool to the oll pressure switch Check the oil pressure switch for continu ity at the specified pressure Replace if out of specification S6AG8130 NOTE Slowly operate the special service tool K Vacuum pressure pump gauge set 90890 06756 6AG3J11 Oil pressure switch continuity Oil pressure switch Ground mo Oil pressure 49 0 kPa 0 490 kgf cm 7 105 psi below 49 0 kPa 0 490 kgf cm 7 105 psi above 8 Install the oil pressure switch and then co
103. at is one that pro vides maximum performance in relation to boat speed and fuel consumption Propeller size in 91 4x93 4 J 91 4x101 2 J 91 4x12 J 91 4x9 J1 91 4x10 J1 91 4x11 J1 91 4x12 J1 Aluminum Predelivery check To make the delivery process smooth and efficient the predelivery checks should be completed as explained below Fy General information Checking the outboard motor mounting height 1 Check that the anti cavitation plate is between the bottom of the boat and a maximum of 25 mm 1 in below it If the mounting height is too high cavita tion will occur and propulsion will be reduced Also the engine speed will increase abnormally and cause the engine to overheat If the mounting height is too low water resistance will increase and reduce engine efficiency 56D51030 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 Remove the protective covering from the intake silencer CAUTION A protective covering 17 is installed on the intake silencer when the outboard motor is shipped from the factory and must be removed before starting the engine for the first time Checking the fuel system 1 Check th
104. at the fuel hoses are securely connected and that the fuel tank is full with fuel S6AG1040 CAUTION This is a 4 stroke engine Never use pre mixed fuel or 2 stroke outboard motor oil Checking the engine oil level 1 Check the engine oil level Ly h et Us J 7 lt UL H I i lO eS a S6AG1050 6AG3J11 NOTE If the engine oil is below the minimum level mark add sufficient oil until the level is between Q and O Recommended engine oil 4 stroke motor oil API SE SF SG SH SJ or SL SAE 5W 30 10W 30 or 10W 40 Engine oil quantity Without oil filter replacement 1 6 L 1 69 US at 1 41 Imp at Checking the gear oil level 1 Check the gear oil level S6AG1060 NOTE If the oil is at the correct level a small amount of oil should overflow out of the check hole when the gear oil check screw is removed Checking the battery electric starter model 1 Check the battery capacity electrolyte level and specific gravity of the electro lyte Recommended battery capacity CCA EN 347 0 A 2OHR IEC 40 0 Ah Electrolyte specific gravity 1 280 at 20 C 68 F 2 Check that the positive and negative bat tery cables are securely connected 6AG3J11 Predelivery check Setting the remote control cable remote control model NOTE SE To adjust the throttle cable and shift cable see Adjusting the throttle cable remote con trol model 3 8
105. at the tilt ram is fully extended when removing the reservoir cap otherwise fluid can spurt out from the unit due to internal pressure NOTE EE e If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole when the cap is removed e If the fluid is below the correct level add the recommended fluid NY Recommended power tilt fluid ATF Dexron II 9 Install the reservoir cap and then tighten it to the specified torque NOTE 0 If the fluid is below the correct level in step 8 repeat steps 5 9 until the fluid remains at the correct level Reservoir cap 5 N m 0 5 kgf m 3 7 ft lb Power tilt electrical system power tilt model Checking the fuse 1 Check the fuse for continuity Replace if there is no continuity 6AG3 11 Power tilt cylinder power tilt model Power tilt electrical system power tilt model 2 Connect the positive battery lead to the light green Lg lead and the negative battery lead to the terminal B as shown and then check the power tilt relay for continuity Replace the power tilt relay if out of specification SGAG7851 NOTE For the location of the fuse see Electrical component and wiring harness routing 8 1 Checking the power tilt relay 1 Check the power tilt relay for continuity Replace the power tilt relay if out of spec ification S6AG7870 C ver Power tilt relay continuity Terminal Ter
106. bled and assembled adjust the pilot screw and then adjust the engine idle speed See Adjusting the pilot screw 4 15 4 14 ne R Fuel system Adjusting the pilot screw 1 Adjust the throttle stop screw NOTE If the carburetor was disassembled turn the throttle stop screw In until it contacts the car buretor throttle lever and then turn it in about 1 3 4 turns to tighten it temporarily 2 Start the engine and warm it up for 10 minutes NOTE o e Because the Prime Start operates when the engine is started the engine idle speed will be above specification Therefore check and adjust the engine idle speed after the engine has been warmed up If the engine idle speed does not decrease after the engine has been warmed up for 10 minutes or more check the Prime Start system as it may be malfunctioning 3 Attach the special service tool to spark plug wire 1 Digital tachometer 90890 06760 4 Turn the pilot screw in direction until it is lightly seated and then turn it in direction the specified number of turns mag 0 AL J Fa S6AG4300 4 15 ES r NG F D For Europe For Oceania NOTE SS Adjust the pilot screw setting within the spec ified number of turns out so that the engine idle speed is stable RL Pilot screw adjusting tool for Europe 90890 03154 Pilot screw setting 15 1 1 2 turns out 20 31 2 1 2 turns out 6AH10 3 3 8 1 2 turn
107. bling it 4 Disconnect the negative battery cable and positive battery cable from the bat tery terminals Checking the starter motor pinion CAUTION Be sure to disconnect the battery cables before checking the starter motor pinion 1 Check the pinion teeth Replace the pin ion if cracked or worn 2 Check the pinion for smooth operation NOTE Turn the pinion counterclockwise to check that itoperates smoothly and turn it clockwise to check that it locks in place Disassembling the starter motor 1 Slide the pinion stopper O down as shown and then remove the clip pin ion stopper and Spring S6AG 8400 8 14 ELEC 7 ELEC W i Electrical system 2 Turn the pinion clockwise and then remove the pinion S6AG 8410 3 Remove the bolts and then remove S6AG8430 the cover stator armature and washer Checking the starter motor 1 Check the commutator Clean with 600 grit sandpaper and compressed air if 5 dirty S6AG 8440 2 Measure the commutator diameter Replace the armature if below specifica tion gt S6AG8420 4 Remove the nuts 8 spring washers washer 0 spacer and screws and then remove the brush holder assembly from the bracket q4 S6AG 8450 Commutator standard diameter 30 0 mm 1 18 in Wear limit 29 0 mm 1 14 in 8 15 6AG3 11 Starter motor electric starter model 3 Measure the commutator undercut Replace
108. ce reference data White red W R Black B 152 228 Q at 20 C 68 F 4 Connectthe pulser coil connectors Checking the charge coil 1 Measure the charge coil 07 output peak voltage Replace the stator coll assembly if below specification S6AG8070 NOTE gt e To prevent the engine from starting when cranking It be sure to disconnect both Spark plug caps e Do not remove the clip from the engine stop lanyard switch e If measuring the output peak voltage under the unloaded conditions disconnect the connectors e When using the manual starter to crank the engine the voltage values may vary depending on the speed at which the Starter handle is pulled 6AG3 11 Charge coil output peak voltage Black red B R Green red G R gege Loaded Crank Bev o 10 as 2 Disconnect the charge coil connectors 3 Measure the charge coil resistance Replace the stator coil assembly if out of Specification Charge coil resistance reference data Black red B R Green red G R 25 5 34 5 Q at 20 C 68 F 4 Connect the charge coil connectors Checking the engine stop lanyard switch tiller handle model 1 Disconnect the engine stop lanyard switch 1 connector and terminal S6AG8140 2 Check the engine stop lanyard switch for continuity between the engine stop lanyard switch connector and terminal engine stop lanyard switch end Replace if out of specification
109. compression kPa pressure kgf cm psi 860 8 6 124 7 400 4 0 58 0 at engine idle speed Oil pressure kPa kgf cm psi Cylinder head Warpage limit 0 10 0 0039 lines indicate straightedge position Cylinder head journal inside diameter A Cylinder head journal inside diameter B 22 000 22 021 0 8661 0 8670 34 000 34 025 1 3386 1 3396 Camshaft Intake A Exhaust A Intake and exhaust B 28 546 28 646 1 1239 1 1278 28 582 28 682 1 1253 1 1292 23 95 24 05 0 9429 0 9468 Camshaft journal diameter C Camshaft journal diameter D Camshaft runout limit 1 Measuring conditions 21 967 21 980 0 8648 0 8654 33 935 33 955 1 3360 1 3368 0 03 0 0012 Ambient temperature 20 C 68 F wide open throttle with spark plugs removed from all cylinders The figures are for reference only The figures are for reference only 6AG3J11 2 For details of the checking method see Checking the oil pressure 5 1 2 16 SPEC oe Specification Item Unit 15E 20E 20ET Rocker arm shaft Outside diameter mm in Rocker arm Inside diameter mm in 12 941 12 951 0 5095 0 5099 13 000 13 018 0 5118 0 5125 Valve Valve clearance cold Intake Exhaust Head diameter A Intake Exhaust Face width B Intake B Exhaust AS Seat contact width C Intake and exhaust Keg Margin thickness D Intake Exhaust Stem diameter
110. d O x T el N T r A S6AG3180 3 Check that the pointer is aligned with the T mark on the flywheel magnet as Shown ates ee Ba nm o ee TE S6AG 3190 Ignition timing at 1 050 r min TDC 1 59 CHK Q ADJ Periodic check and adjustment Bracket unit Checking the steering operation tiller handle model NOTE Lubricate the swivel bracket before checking the steering operation 1 Move the steering lock lever to posi tion and check that the steering is locked Move the steering lock lever to posi tion and check that the steering oper ates smoothly S6AG3480 2 Adjust the self locking nut until steer ing operation is properly S6AG3430 Checking the tilt operation manual tilt model 1 Fully tilt the outboard motor up and down a few times and check the entire tilt range for smooth operation Check the tilt mechanism if necessary NOTE To check the tilt operation see Checking the tilt system manual tilt model 1 17 Checking the tilt operation power tilt model 1 Fully tilt the outboard motor up and down a few times and check the entire tilt range for smooth operation Check the power tilt fluid level if necessary NOTE e To check the power tilt fluid level see Checking the power tilt fluid level 3 13 e Be sure to listen to the winding sound of the power tilt motor for smooth operation 2 Fully tilt the outboard mot
111. d adjustment EEN the battery Check the battery electrolyte level If the level is at or below the minimum level mark add distilled water until the level is between the maximum and minimum level marks S69 3620 2 Check the specific gravity of the electro lyte Fully charge the battery if below Specification WARNING Battery electrolyte is dangerous it con tains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures e Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury e Wear protective eye gear when handling or working near batteries Antidote EXTERNAL e SKIN Wash with water e EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL e Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries generate explosive hydrogen gas Always follow these preventive mea sures e Charge batteries in a well ventilated area e Keep batteries away from fire Sparks or open flames e g welding equipment lighted cigarettes e DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN NOTE e Batteries vary per manufacturer The pro cedures mentioned in this manual may not always apply therefore consult the instruc tion
112. d power 5 51 Damaged cylinder unit head gasket Damaged valve ae and piston ring s not fully open tem malfunction adjusted correctly the throttle cable s 3 8 Air leakage carbu Damaged gaskets Check the gaskets 4 12 retor to cylinder Spacer and intake spacer and intake 5 34 head manifold carbure manifold carbure tor to cylinder head tor to cylinder head pression actuator Symptom 1 High engine idle speed Refer Symptom 2 Cause 1 Cause 2 Checking step to page Prime Startsystem Prime Start ioe the Prime 4 13 malfunction te Power bobbin mal Check the power function bobbin Engine speed does Carburetor malfunc Throttle stop screw Adjust the throttle not decrease when tion not adjusted cor stop screw throttle control lever rectly is In fully closed Pilot screw not Adjust the pilot position adjusted correctly screw Malfunction of the Disassemble and carburetor internal check the carbure parts Or Throttle control Throttle control Throttle cable s not Check and adjust 3 7 lever does not system malfunction adjusted correctly the throttle cable s 3 8 return to fully closed Throttle cam not Check the throttle 5 61 position installed correctly cam 9 5 6AG3 11 Troubleshooting the outboard motor Symptom 1 Limited engine speed below 2 000 r min Refer Symptom 2 Cause 1 Cause 2 Checking step to page e Buzzer comes on Clogged c
113. d then measure the pressure again NOTE EE If the compression pressure increases check the pistons and piston rings Replace if worn If the compression pressure does not increase check the valve clearances valves valve seats cylinder sleeves cylin der head gasket and cylinder head Adjust or replace if necessary Checking the oil pressure 1 Remove the oil pressure switch and then install an oil pressure gauge 1 to the oil pressure switch installation hole A S6AG5010 NOTE Use a commercially available oil pressure gauge 0 2 Start the engine and warm it up for 10 minutes 6AG3 11 NOTE Because the Prime Start operates when the engine is started the engine idle speed will be above specification Therefore measure the oil pressure after the engine has been warmed up 3 Measure the oil pressure Check the oil pump and oil strainer and for oil leakage if out of specification Oil pressure reference data 400 kPa 4 0 kgf cm 58 0 psi at engine idle speed Checking the valve clearance NOTE Measure the valve clearances when the engine is cold 1 Remove the sprocket cover and manual Starter Manual starter model Remove the sprocket cover and flywheel magnet cover Electric starter model 2 Disconnect the spark plug caps and remove the spark plugs 3 Remove the cooling water hoses 1 fuel hoses fuel pump blowby hose and cylinder head cover
114. d torque is reached Unless otherwise specified torque specifications require clean dry threads Components should be at room temperature General torque Nut A Bolt B KE S69J2150 2 33 6AG3J 11 Periodic check and adjustment Maintenance interval chart rrrssnasvrnnnnnnnvnnnnnnnvevnnnnnnevennnnnvevnnnnnnnernnnnnnernnnnnnnenr 3 1 TOP COWNNO HE 3 2 Checking Me top TONO ae 3 2 Fuers RE 3 2 Checking the fuel joint and fuel hose fuel joint to carburetor esses 3 2 Checking THE MA EE 3 3 B e tHe EE 3 3 POWER Tt aa 3 3 Checking NE ENGINE Munin dead 3 3 CMANGING NE CHGING Olaisen ene 3 3 Replacing Me Ne ee 3 4 Checking the UNNI BE ve CT 3 5 checking NE SPANN 3 5 Checking the METMOS BL uante 3 6 Checking the cooling water passage 3 7 Sr SYS E 3 7 Adjusting the throttle cable tiller handle modell 3 7 Adjusting the throttle cable remote control modell 3 8 Adjusting TE NOTE MR ae 3 9 Checking the gear shift operation tiller handle modell 3 9 Checking the gear shift operation remote control modell 3 10 Checking the start in gear protection manual starter modell 3 11 Checking the engine idle enee 3 11 Checking ENS TOO UNN GN 3 12 Bracket HIE ccenn Aea a Aaa 3 13 Checking the steering operation tiller handle modell 3 13 Checking the tilt operation manual tilt modell 3 13 Checking the tilt operation power tilt modell 3 13 Checking the power tilt fluid vel sss sese see eee eee 3 13 BITTEN 3 14
115. e 7 3 5 Turn the adjusting nut to remove the Slack in the throttle cable and then tighten the locknut ld r y Vg 9 S 6AG 3330 r 7 le 6AG3 11 6 Turn the throttle grip to the fully open and fully closed positions and check that the fully open stopper and fully closed stopper on the throttle cam contact throttle cam bracket as shown Repeat Steps 2 5 if necessary S6AG3340 Fully open position Fully closed position 7 Connect the throttle link rod to the free accel lever NOTE After adjusting the throttle cables adjust the throttle link Tiller handle model After adjusting the throttle cable adjust the throttle link Remote control model Adjusting the throttle cable remote control model 1 Disconnect the throttle link rod from the free accel lever 2 Loosen the locknut remove the clip 3 and then disconnect the throttle cable joint 6AG3 11 Power unit Control system An n c y 7 S6AG3360 3 Set the remote control lever to the neu tral position 4 Check that the fully closed stopper on the cam contacts the throttle cam bracket 5 Adjust the position of the throttle cable joint until its hole is aligned with the set pin on the throttle cam 0 Comma S6AG 1090 WARNING The throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in NOTE Pull the throttle cable to
116. e 5 Screw 4 x 8 mm 6 Brush Long lead 7 Brush Short lead 8 Screw od x 10 mm 9 Brush spring 10 Bolt M5 x 25 mm 11 Power tilt motor base 12 Gasket 13 Oil seal 14 O ring 15 Manual valve 16 O ring 17 Reservoir cap 1 1 1 1 1 1 2 2 4 1 1 1 1 1 1 1 6AG3J 11 7 30 Bracket unit Disassembling the power tilt motor 1 Remove the power tilt unit from the bracket NOTE To remove the power tilt unit see Removing the power tilt unit 7 27 2 Fully extend the tilt ram and then open the manual valve 1 by turning it counter clockwise S6AG7335 WARNING Make sure that the tilt ram is fully extended before removing the power tilt motor otherwise fluid can spurt out from the unit due to internal pressure NOTE To prevent the internal power tilt unit parts from falling out lay the power tilt unit on its Side so that the power tit motor is in an upright position before removing it 3 Remove the bolts and then remove the power tilt motor assembly and gasket from the tilt cylinder 4 Remove the manual valve 6 O ring and pin 7 31 S6AG7070 Remove the stator 8 and O ring from the power tilt motor base 0 S6AG7145 Remove the armature plate screw and then remove the armature assembly S6AG7086 6AG3 11 NOTE ____ e Push the brushes apart and then remove the armature assembly e Do not remove the bearing fr
117. e bolts to the specified torque Power tilt motor base bolt 3 5 N m 0 5 kgf m 3 7 ft lb 6AG3J 11 Power tilt gear pump power tilt model 7 40 Bracket unit Power tilt cylinder power tilt model S6AG7040 No Parname oy Remarks 1 Tiltram assembly 1 2 Free piston 1 3 Backup ring 1 4 O ring 1 5 Cylinder liner 1 6 O ring 1 7 Cylinder 1 8 O ring 1 9 Bolt 1 M6 x 10 mm T30 10 O ring 1 11 Backup ring 1 12 Tilt piston 1 13 Ball 5 14 Pin 5 15 Spring 5 16 Tilt cylinder end screw 1 17 O ring 1 7 41 6AG3J 11 Power tilt cylinder power tilt model S6AG7040 Remarks Backup ring Dust Seal Not reusable Tilt ram Reservoir cap O ring Not reusable 6AG 3 11 7 42 Bracket unit Disassembling the tlt cylinder 1 Hold the tilt cylinder in a vise using aluminum plates on both sides 2 Loosen the tilt cylinder end screw and then remove the tilt ram assembly S6AG7215 WARNING Make sure that the ram is fully extended before removing the end screw Power tilt wrench 90890 06560 3 Drain the power tilt fluid 4 Remove the cylinder liner and free piston amp from the cylinder S6AG7250 7 43 5 Remove the bolt and then remove the piston absorber valves from the tilt piston S6AG7260 6 Hold the tilt piston in a vise using alu minum plates on both sides
118. e ee eee 8 29 Charging system electric starter model uuurnrnnnnnnnnnnnnnnnnnnnvevnnnnnnnnnvennnnnnn 8 29 Checking THE MO MUNG e UI 8 29 Checking ebechierRegulator A 8 30 evec 7 ELEC a Electrical system Electrical component and wiring harness routing Top view Ur wn i S6AG8310 a Remote control model Stator coil assembly charge coil lighting coil b Tiller handle model and power bobbin 6 Pulser coil Prime Start Neutral switch tiller handle model with electric Q Thermoswitch Starter 3 Ignition coll Warning indicator assembly 4 Oil pressure switch Engine start button tiller handle model with electric starter 8 1 6AG3 11 Electrical component and wiring harness routing Engine stop lanyard switch tiller handle model dt Power tilt switch power tilt model Fasten the engine stop lanyard switch lead tiller handle model power tilt motor lead power tilt model and power tilt switch lead power tilt model with a plastic tie Install the plastic tie as shown and cut off the excess end of the tie to 3 mm 0 12 In or less Fasten the thermoswitch lead with the holder Fasten the stator coil assembly lead with the holder D Fasten the engine stop lanyard switch lead tiller handle model power tilt motor lead power tilt model power tilt switch lead power tilt model neutral switch lead tiller handle model with electric starter and Prime Start lead with the hold
119. e ee eee e 6 14 Assembling the manual starter eee 5 10 Assembling the power tilt motor sees 7 33 Assembling the propeller shaft assembly 6 8 Assembling the propeller shaft housing 6 9 Assembling the starter motor esere 8 17 Assembling the swivel bracket eee 7 23 Assembling the tiller handle eeen 7 3 Assembling the tilt cylinder sss esse 7 44 Assembling the upper case 7 17 BYSTE Fs je 6 23 Bleeding the power tilt unt 7 46 Bottom COMING D 7 8 BOW VIEW san 8 3 Bracket electric starter modelt 5 24 Bracket manual starter model 5 22 BT L A atp 3 13 p fe GR EE EEE DEE MN 1 19 E E n 51H 19T EE 4 10 Carburetor Din EE 4 9 CDI unit and junction box manual tilt modell essen 5 18 CDI unit and junction box power tilt modell esse esse eee eee 5 20 Changing the engine ol 3 3 Changing the gear ol 3 14 Charging system electric starter modell 8 29 Checking the anode sese eee eee 3 16 6AG3 11 Checking the hatten AAA 3 17 Checking the battery electric starter modell 1 14 Checking the bearing 6 13 Checking the brush holder and brueh sss sese 7 33 8 16 Checking the camshaft 5 43 Checking the Carburetor sse eee eee 4 12 Checking the CDI unt 8 25 Checking the charge co 8 23 Checking the compression pressure 5 1 Checking the connecting rod big end side clearance essre 5 55 Checking the connecting rod small and big end inside diameter 5 54 Checking the
120. e starter handle several times to check that the sheave drum turns Smoothly and to check the starter rope for slack Repeat steps 4 9 if necessary S6AG5620 NOTE Hold the starter plunger 43 while pulling the starter handle 11 Install the manual starter onto the power unit tighten the bolts to the specified torque and then connect the start in gear protection cable Manual starter bolt 8 N m 0 8 kgf m 5 9 ft lb 6AG3 11 NOTE e Route the start in gear protection cable in its original position e To adjust the start in gear protection cable see Checking the start in gear protection manual starter model 3 11 12 Pull the starter handle completely and then measure the starter rope length S6AG5630 Starter rope pulling length 1 400 1 600 mm 55 12 62 99 in 6AG3 11 Manual starter manual starter model Power unit Power unit assembly tiller handle model 19 32 ee S6AG5G80 No Parname Q Remarks Power unit Gasket Dowel M8 x 85 mm Bolt Oil dipstick Bracket Bolt Bracket Bolt Warning indicator assembly Packing Screw Engine stop lanyard switch lead Bolt Engine start button lead Apron Screw M6 x 20 mm E xcept for power tilt model M6 x 20 mm A KA A en Hi D JO Ln P D Ari m N 6 x 12 mm KA Fi e LU M6 x 15 mm Electric starter model KA UT e o gt KA k A k KA k RP RP KA KA FA k RP OO FA KA F
121. e surface of the valve seat with a G 45 cutter by turning the cutter clockwise until the valve seat face has become smooth 569J5830 S6AG5210 569J5840 Valve seat contact width Intake and exhaust 1 2 1 6 mm 0 047 0 063 in S6AG5 20 a Slag or rough surface 5 41 6AG3J 11 CAUTION Do not over cut the valve seat Be sure to turn the cutter evenly downward at a pres sure of 40 50 N 4 5 kof 8 8 11 Ibf to prevent chatter marks 3 Use a 30 cutter to adjust the contact width of the top edge of the valve seat 30 gd S6AG5J 60 b Previous contact width 4 Use a 60 cutter to adjust the contact width of the bottom edge of the valve d i X S6AG5J 70J Previous contact width 5 Use a 45 cutter to adjust the contact width of the valve seat to specification fa S6AG5 80 Previous contact width Specified contact width 6AG3 11 Cylinder head 6 Check the valve seat contact area of the valve NOTE _ o o oO To check the valve seat contact area see Checking the valve seat 5 40 7 If the valve seat contact area is too wide and situated in the center of the valve face use a 30 cutter to cut the top edge of the valve seat and a 60 cutter to cut the bottom edge to center the area and set its width 60 S6AG5 30 b Previous contact width 8 If the valve seat contact area is too nar row and situated near the to
122. eal halfway into the propeller Shaft housing and then install the other oll Seal RL Driver rod L3 90890 06652 d Needle bearing attachment D h 90890 06613 L Installation depth 9 3 0 3 5 mm 0 12 0 14 in 3 Install new ball bearing into the propel ler shaft housing S6AG6160 NOTE Install the needle bearing with the manufac ture identification mark facing toward the oil seal propeller side Z Driver rod L3 90890 06652 Needle bearing attachment 90890 06616 2 Apply grease to new oil seals and then eerie install them into the propeller shaft hous ing to the specified depth NOTE Install the ball bearing with the manufacture identification mark facing toward the reverse gear Driver rod LS 90890 06606 Ball bearing attachment 90890 06632 4 Install the reverse gear and original shim s into the propeller shaft housing S6AG6170 6 9 6AG3 11 Propeller shaft housing S6AG6190 NOTE o e Be sure to select the reverse gear shim s if replacing the propeller shaft housing ball bearing or lower case To select the shims see Shimming 6 20 e After installing the reverse gear and shim s check that the reverse gear rotates smoothly 6AG3J 11 6 10 Lower unit Drive shaft and lower case Drive shaft Drive shaft housing Drive shaft sleeve Needle bearing Pinion shim Forward gear Taper roller bearing Forward gear shim Pinion nut
123. ect the ignition coil connectors 2 Remove the spark plug caps from the Spark plug wires by turning the caps counterclockwise 3 Measure the ignition coil resistance Replace if out of specification S6AG 8050 Ignition coil resistance Primary coil Orange 0 Black B 0 26 0 35 Q at 20 C 68 F Secondary coll Spark plug wire Spark plug wire 6 8 10 2 kQ at 20 C 68 F 4 Install the spark plug caps to the spark plug wires by turning the caps clockwise and then connect the ignition coil con nectors 8 22 ELEC 7 ELEC ay Electrical system Checking the pulser coil 1 Measure the pulser coil output peak voltage Replace if below specification L N RSA L DD E Gd R A WK ss P N S6AG 8060 NOTE 0 e To prevent the engine from starting when cranking It be sure to disconnect both Spark plug caps Do not remove the clip from the engine stop lanyard switch If measuring the output peak voltage under the unloaded conditions disconnect the connectors When using the manual starter to crank the engine the voltage values may vary depending on the speed at which the Starter handle is pulled Pulser coil output peak voltage White red W R Black B Unloaded Loaded r min Unloaded 1500 3 500 53 2 Disconnect the pulser coil connectors 3 Measure the pulser coil resistance Replace if out of specification 8 23 Pulser coil resistan
124. en install the E clip Hook the Springs 7 onto tilt lock plate 1 and then hook them onto the holes in the Swivel bracket 7 23 J o 2 Z My S6AG 7440 NOTE o After installing the E clip turn itto make sure that it is installed securely 3 Install the stopper shaft and receiver assembly 00 to the swivel bracket 4 and then install the E clip 09 4 Hook tilt lock rod 2 amp 3 the spring and tilt lock rod 1 45 onto the tilt lever 49 5 Install the tilt lever shaft into the swivel bracket on making sure to pass the shaft through the receiver assembly 49 and tilt lever 49 and then install the E clips 43 6 Hook the spring onto the receiver assembly 09 S6AG7A20 6AG3 11 Clamp bracket and swivel bracket manual tilt model NOTE _ ___ e See the exploded diagram for the installa tion directions of the spring and tilt lock rod 1 45 7 21 e Make sure that the E clips are installed securely Installing the clamp bracket 1 Install the tilt stopper plates and tilt Stopper plate bolts to the clamp brack ets and then tighten the bolts to the Specified torque Tilt stopper plate bolt 8 N m 0 8 kgf m 5 9 ft lb 547 SGAG7990 2 Tighten the self locking nut completely onto the shorter threaded end of the through tube GO S6AG7801 6AG3 11 3 Assemble the clamp brackets and Swivel bracket and then install the thro
125. ence data Red R Ground 12 V battery voltage ELEC 7 ELEC W i Electrical system 3 Check the engine start button 1 for con tinuity between the engine start button connectors engine start button end Replace if out of specification S6AG8180 Engine start button continuity Red R Brown Br Button position Pushed 4 Connect the connectors of the engine Start button Checking the engine start switch remote control model 1 Disconnect the 10 pin main harness cou pler 2 Measure the input voltage between the 10 pin main harness coupler outboard motor end and the ground Check the fuse and wiring harness if below specifi cation S6AG8190 Engine start switch input voltage reference data Red R Ground 12 V battery voltage 3 Set the remote control lever to the neu tral position 4 Check the engine start switch for continu ity at the 10 pin main harness coupler remote control box end Check the wir ing harness and neutral switch or replace the engine start switch if out of Specification ON OFF START S6AG8200 White Black Red Yellow Brown Switch W B R Y Br position Oil Gil oi Gi Se E SSES ER 5 Connect the 10 pin main harness cou pler OFF Le DN 10940 Checking the neutral switch tiller handle model with electric starter 1 Disconnect the neutral switch connec tors 6A
126. eplace it with a new one Z Stopper guide plate 90890 06501 d Center bolt 90890 06504 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 3 Remove the oil seals and the needle bearing 6AG3 11 S6AG6120 CAUTION Do not reuse the bearing always replace it with a new one YS Driver rod L3 90890 06652 d Needle bearing attachment 90890 06616 age king the propeller shaft housing Clean the propeller shaft housing and 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 Or worn Checking the propeller shaft 1 Check the propeller shaft Replace if damaged or worn 2 Measure the propeller shaft runout Replace if above specification S6AG6130 6AG3 11 Propeller shaft housing Propeller shaft runout limit 0 05 mm 0 0020 in 3 Check the dog clutch shift plunger and cross pin Replace if cracked or worn Assembling the propeller shaft assembly 1 Insert the spring into the propeller Shaft 2 Install the dog clutch cross pin and cross pin ring NOTE Install the dog clutch with the F mark facing toward the forward gear 3 Install the shift plunger S6AG6150 S6AG6140 6 8 Lower unit Assembling the propeller shaft housing 1 Install a new needle bearing into the pro peller shaft housing NOTE Install an oil s
127. er Fasten the engine stop lanyard switch lead tiller handle model power tilt motor lead power tilt model power tilt switch lead power tilt model and Prime Start lead with the holder Be sure to position the battery cables and wiring harness so that the white tape is to the inside of the bottom bracket Route the warning indicator assembly lead between the plate and the stay manual tilt model or power tilt relay power tilt model Install the plate making sure that it contacts the boss on the bottom cowling Bundle the power tilt switch lead by folding it at the white tape 2 locations on the lead and then fasten the folded sections with plastic ties making sure that the lead does not protrude past the edges of the steering bracket Be sure not to pinch the wiring harness in the area shown 6AG 3 11 8 2 ELEC 7 ELEC Electrical system Bow view Manual starter model with manual tilt WZ Mi 0K rd rs OO A A S6AG8320 a Tiller handle model with manual starter G Neutral switch lead tiller handle model with b Tiller handle model with electric starter electric starter Br Remote control model 6 Engine stop lanyard switch lead tiller handle model B Pulser coil Fuse lead electric starter model R J unction box Charge coil lead BIR G R 3 CDI unit Pulser coil connector B 4 Neutral switch Pulser coil connector W R tiller handle model with electric starter 07 Charge coil
128. er Bolt Starter motor Bolt Bolt Battery cable Power tilt relay lead Bolt Bolt Oil pressure switch Holder Oil pressure switch lead Wiring harness M6 x 14 mm M8 x 45 mm M8 x 35 mm Power tilt model M8 x 16 mm M6 x 15 mm KA kA k k FA k KA KA FA A k RP RP FA PF 5 25 6AG3 11 Power unit Throttle cam T X 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib S6AG5750 ESCHER Remarks 1 Bracket Bolt Throttle cam Shaft Free accel lever Washer Bolt Spring Clip Stopper Washer Collar Bracket Bolt Throttle cable M6 x 14 mm M6 x 45 mm Tiller handle model Tiller handle model Tiller handle model Tiller handle model Tiller handle model M6 x 14 mm Tiller handle model Tiller handle model 1 2 3 4 5 6 7 8 9 10 11 KA k Fi e GO N NN KA M k k k k k KA KA KA KJ KA Ul 6AG 3 11 5 26 Removing the power unit 1 Disconnect the start in gear protection cable and then remove the sprocket cover and manual starter Manual Starter model Remove the sprocket cover and flywheel magnet cover Electric starter model NOTE Before removing the flywheel magnet cover remove the junction box bracket bolts Power tilt model 2 Remove the retaining plate Disconnect the battery cables Electric starter model Disconnect the battery cables and 10 pin main harness coupler Remote control model 3 Disconnec
129. f damaged 7 38 Bracket unit Checking the filter 1 Check the gear pump filters Clean if there is dirt or residue NOTE See the exploded diagram for the filter instal lation position 7 35 Assembling the gear pump CAUTION e Do not use a rag when assembling the power tilt unit as dust and particles on the power tilt unit components can lead to poor performance e Do not reuse the O ring always replace it with a new one S6AG7201 NOTE 0 Lubricate the parts with ATF Dexron II during NOTE assembly Be sure to install shuttle piston 1 and shut tle piston 2 8 in the correct positions the pis 1 Install the drive gear driven gear ton shapes are different balls dowels and main valves to the tilt cylinder Gear housing bolt 2 5 N m 0 5 kgf m 3 7 ft lb 4 Install the balls 43 relief valve seals 4 manual release pins 45 and spring d6 to the tilt cylinder 5 Install the manual valve 017 and O ring gt to the power tilt motor base o g gt PNo S6AG 7190 2 Install shuttle piston 1 and shuttle pis ton 2 to the gear pump housing and then install the gear pump housing to the tilt cylinder 3 Install the filters plate 00 and gear housing bolts 2 and then tighten the bolts to the specified torque 7 39 6AG3J 11 6 Install a new gasket 2 and the power tilt motor assembly to the tilt cylinder and then tighten the power tilt motor bas
130. g m 5 9 ft Ib PQ S Ge Remarks Part name Tiller handle bracket Bushing Tiller handle bracket cover Bolt Throttle friction adjuster Friction piece Throttle pulley Plate Bolt Screw Bushing S pring Washer Bracket Screw Power tilt switch Screw M6 x 55 mm M6 x 20 mm 05 x 12 mm Power tilt model 6 x 16 mm P ower tilt model Power tilt model 6 x 20 mm P ower tilt model NFP D k KAJ k KA A KM kA RP KA RP NEF KA 6AG 3 11 7 2 Bracket unit Disassembling the tiller handle 1 Remove the steering bracket cover NO Disconnect the engine stop lanyard Switch leads and power tilt switch leads power tilt model and remove the leads from their holders e B S6AG7A71 anual tilt model ower tilt model i M P 3 Disconnect the throttle cables from the throttle cam 7 3 E T DA l y By Y Zb Ue Wi S6AG7A80 4 Remove the tiller handle NOTE o See the exploded diagram for disassembly 7 1 Assembling the tiller handle 1 Assemble the tiller handle NOTE See the exploded diagram for assembly 7 1 2 Install the throttle friction adjuster and then install the cotter pin S IG 3 Install the engine stop lanyard switch Gi to the tiller handle bracket Tighten the nut to the specified torque Pass the lead through the grommet S6AG7490 4 Install the power tilt switch to the bracket and then ti
131. g the forward and reverse gear backlash sees eee eee 6 23 6AG3J 11 Lower unit Lower unit 1 A KA po Hi D d Oo une IF KA kA k k FA bm SIH Ul BW N 6 1 hye 18 N m 1 8 kgf m 13 3 ft Ib 2 9 N m 0 9 kgf m 6 6 ft Ib Rubber seal Lower case Bolt Anode Special washer Bolt Cotter pin Propeller nut Washer Propeller S pacer Adjusting nut Locknut Dowel Check screw Gasket Cooling water inlet cover 8 N m 0 8 kgf m 5 9 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib Asa 5 N m 0 5 kgf m 3 7 ft Ib NN FA k k RP RP RP RP k k KA KA AR ty 1 M8 x 30 mm Not reusable M6 x 35 mm Not reusable Not reusable Remarks S6AG6010 6AG3 11 Lower unit T oe E TN L7 kgf m 12 5 ft Ib S6AG6010J No Remarks 18 Screw 19 Nut 20 Drain screw 21 Trim tab 22 Bolt M6 x 16 mm 6AG3 11 6 2 Lower unit S6AG6020 no pamname Joy Woodruff key Impeller Water pump housing Insert cartridge O ring Dowel Not reusable Rubber seal Bolt Plate Bolt Outer plate cartridge M8 x45 mm M8 x 25 mm A KA A en Hi D JO Hi P D Ari KA FA FA P k NPE KA KA KA 6 3 6AG3 11 Removing the lower unit 1 Drain the gear oil fo GB S6AG6030 2 Setthe gear shift to the neutral position place a block of wood between the anti cavitation plate and propeller to keep the propeller from tu
132. gative terminal and then check that the warning indicator comes on Replace the warning indicator assembly if it does not come on Az OLO ZARS LED1 Nd B P W O S6AG8290 CAUTION e Only use a penlight battery 1 5 V when checking the LEDs Other batteries e g alkaline batteries or high voltage batter les will damage the diodes e Do not apply more than 1 7 V to the leads when checking the LEDS NOTE A feature of LEDs is that they only allow cur rent to flow in one direction 8 28 ELEC 7 ELEC ay Electrical system Checking the power bobbin for Prime Start 1 Measure the power bobbin output peak voltage Replace the stator coil assembly if below specification ES AG fav UV S6AG8250 NOTE S e To prevent the engine from starting when cranking It be sure to disconnect both Spark plug caps Do not remove the clip from the engine stop lanyard switch If measuring the output peak voltage under the unloaded conditions disconnect the connectors When using the manual starter to crank the engine the voltage values may vary depending on the speed at which the Starter handle is pulled Measurements under the unloaded condi tion or when the Prime Start is malfunc tioning may not be possible at 1 500 r min because the engine speed may be too high 8 29 Power bobbin output peak voltage Blue L Blue L Unloaded Unloaded 2 Disconnec
133. ghten the bracket Screws to the specified torque Power tilt model 5 Install the power tilt switch to the tiller handle bracket Pass the lead through the grommet P ower tilt model 6AG3 11 S6AG7A00 NOTE S Tighten the screws 9 and then tighten the Screw OO Engine stop lanyard switch nut 2 N m 0 2 kgf m 1 5 ft lb Power tilt switch bracket screw 4 N m 0 4 kgf m 3 0 ft lb Power tilt switch screw and 40 4 N m 0 4 kgf m 3 0 ft lb 6 Connect the throttle cable ends to the throttle pulley On S6AG7480 6AG3 11 Tiller handle tiller handle model S6AG7470 NOTE SE e When routing the engine stop lanyard Switch lead and power tilt switch lead power tilt model make sure that it is not pinched by the plate 49 and that there Is no Slack in the lead in the area shown e Make sure that the ends of the outer throttle cables 43 are fitted securely into the grommet as shown 7 Install the tiller handle bracket to the steering bracket and then install the tiller handle bracket cover and tighten the bolts to the specified torque Tiller handle bracket cover bolt 8 N m 0 8 kgf m 5 9 ft lb 8 Connect the throttle cables to the throttle cam NOTE e To adjust the throttle cables see Adjusting the throttle cable tiller handle model 3 7 e When adjusting the throttle cables make sure the ends of the outer cables are not pulled
134. hanism of the forward gear and reverse gear does not operate properly Refer Symptom 2 Cause 1 Cause 2 Checking step to page 9 9 Throttle open tiller handle model Shift cable and shift cable joint malfunc tion remote control model Remote control box malfunction remote control model Shift rod cam mal function Shift rod operation malfunction Shift mechanism malfunction in lower unit Detent malfunction cam nected correctly tion of the shift rod adjusted correctly Turn the throttle cam to the fully closed position Tiller handle model Check and adjust the shift cable and shift cable joint Remote control model Check the remote control box Remote control model Disassemble and 6 7 check the lower unit 6AG3 11 A APER IO NE 1 3 Adjusting the pilot SCrew sss eee eee eee 4 15 Adjusting the throttle cable remote control modell 3 8 Adjusting the throttle cable tiller handle modell 3 7 Adjusting the throttle Imk esse eee eee 3 9 ME FT 1 19 Assembling the carburetor seeren 4 13 Assembling the cylinder block 5 58 Assembling the cylinder head sss esse 5 44 Assembling the drive shaft housing 6 15 Assembling the exhaust guide oil pan and exhaust manifold esee 7 16 Assembling the forward gear 6 14 Assembling the friction plate ee eee eee 7 6 Assembling the fuel pump e eee 4 7 Assembling the gear DUM eee ee 7 39 Assembling the lower CaSe ee
135. harge coil lead B R G R back connect it to the lead connectors B R G R and then fasten it with the holder Be sure not to pinch the wiring harness when installing the junction box cover Make sure that there is no Slack in the wiring harness or leads in the junction box Fasten the wiring harness Sb Lg and the leads on the port side of the holder with a plastic tie Install the plastic tie as shown Pass the pulser coil lead through the grommet Fasten the power tilt motor lead and power tilt switch lead on the starboard side of the damper with a plastic tie Install the plastic tie as shown making sure to fit it in the groove in the damper Fasten the neutral switch lead engine stop lanyard switch lead stator coil assembly lead wiring harness fuse lead and engine start button lead with a plastic tle as shown Fasten the warning indicator assembly coupler neutral switch lead engine stop lanyard switch lead stator coil assembly lead wiring harness fuse lead and engine start button lead with a plastic tie Install the plastic tie as shown Make sure that the power tilt relay leads do not contact the junction box cover Route the power tilt relay leads to the front of the holder making sure that they are not pinched and then fasten them with a plastic tie Install the plastic tie as shown P Route the power tilt relay lead Sb Lg to the front of the holder making sure that it is not pinched R Route the Prime Start lead
136. he crank case bolts 11 Tighten the crankcase bolts to the speci fied torques in 2 stages and in the sequence shown G ae Crankcase bolt 1 44 M8 lst 14 N m 1 4 kgf m 10 3 ft lb 2nd 27 N m 2 7 kgf m 19 9 ft lb Crankcase bolt 5 n M6 lst 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb 5 60 12 Install the oil filter and then tighten it to the specified torque using a 64 mm 2 5 in oil filter wrench S6AG5A40 NOTE e Before installing the oil filter be sure to supply engine oil to the oil passage e Apply a thin coat of engine oil to the O ring of the new oil filter before installation Oil filter wrench 90890 01426 Oil filter 18 N m 1 8 kgf m 13 3 ft lb 13 Install a new gasket the thermostat and the thermostat cover Thermostat cover bolt 8 N m 0 8 kgf m 5 9 ft lb 14 Install a new gasket and the exhaust cover and then tighten the bolts to the specified torques in 2 stages and in the sequence shown SS S6AG5800 5 61 Exhaust cover bolt lst 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb Installing the power unit 1 Clean the power unit mating surface and then install the dowels 1 a new gasket and the power unit CAUTION Do not reuse the gasket always replace it with a new one 2 Install the mounting bolts and then tighten them to the specified torque NOTE Before inst
137. he paint mark toward the valve spring retainer Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 06320 3 Compress the valve spring and then install the valve cotters 8 S6AG5291 4 Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters securely 5 45 S6AG5300 S6AG 5310 5 Install a new oil seal S6AG5330 vz Driver rod L3 40 90890 06652 Needle bearing attachment Op 90890 06653 6 Install the camshaft 02 in the direction shown 6AG3 11 S6AG5340 7 Align the keyway in the camshaft with the mark on the cylinder head as shown S6AG5350 8 Install the rocker arms 3 Springs and collars 45 into the cylinder head and then install the shaft 09 and plate S6AG5370 9 Install the oil pump by aligning the slot in the oil pump drive shaft with the cam Shaft pin 49 6AG3 11 Cylinder head S6AG 5390 NOTE e To disassemble check and assemble the oil pump see Checking the oil pump 5 47 e Before installing the oil pump be sure to fill it with a small amount of engine oil through the oil passages 5 46 Installing the cylinder head 1 Install a new gasket and the cylinder head and then tighten the bolts to the specified torques in the sequence shown D e D SR NES 1 O S e 2 IE 9 OE 3 S6AG 5440 CAUTION Do not reuse the cyli
138. her Screw Holder Bracket Bolt Bolt Holder Bolt Oil pressure switch Oil pressure switch lead Mp x 10 mm M6 x 14 mm 6 x 10 mm A e A en Hi D d Oo Ln RUN m N M8 x 25 mm M8 x 16 mm KA k KA Un RR VW M6 x 15 mm let KA KA KA KA KA KJ KA KA KA KA KA KJ KM Ka KA KA KA sl 6AG 3 11 5 22 he 8 N m 0 8 kgf m 5 9 ft Ib JBN m 0 8 kgf m 5 9 ft Ib Ase 8 N m 0 8 kgf m 5 9 ft Ib Ae 8 N m 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib S6AG5730 no Tage Joy ee O Wiring harness 1 Holder 1 Holder 1 Plastic tie 2 5 23 6AG3J 11 Power unit Bracket electric starter model Na 8 N m 0 8 kgf m 5 9 ft Ib Na 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 32 JAN m 0 4 kgf m 3 0 ft Ib J 2 N m 0 2 kgf m 1 5 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib JAN m 0 4 kgf m 3 0 ft Ib S6AG5720 No Partname Qy Remarks gt Thermoswitch Plate Bolt Bracket Bolt Holder Bracket Bolt Holder Holder Washer Screw Holder Starter relay Starter motor lead Bolt Fuse lead Mp x 10 mm M6 x 14 mm M6 x 14 mm A KA Ca e ui ON AJ Ou P A H m N 6 x 10 mm KA KA KA kb On UI SS W Mp x 10 mm KA KA KA k KA FA KA k KA KA KA KA KM KA KA KA ob KA sl 6AG 3 11 5 24 S6AG5720 Remarks Fuse Cap Cover Starter motor cov
139. i m sl 6 x 30 mm 5 13 6AG3 11 Power unit S6AG5G80 Ko Paname Joy Remarks Nut Retaining plate Bolt Throttle cable Bolt Shift rod cam Bolt Start in gear protection cable Nut Power tilt motor lead Cap Power tilt switch lead Bolt Washer Battery cable N M6 x 30 mm M6 x 14 mm E xcept for power tilt model M6 x 20 mm Manual starter model P ower tilt model Power tilt model P ower tilt model P ower tilt model M6 x 35 mm P ower tilt model P ower tilt model Electric starter model kA k FM MM FA FM KA FM KA FM N NWN kb 6AG 3 11 5 14 Power unit assembly remote control model 27 N m 2 7 kgf m 19 9 ft Ib X D l f 27 N m 2 7 kgf m 19 9 ft Ib S6AG5G90 Part name Remarks Not reusable M8 x 85 mm Power unit Gasket Dowel Bolt Oil dipstick Bracket Bolt Warning indicator assembly Packing Screw Power tilt motor lead Nut Cap Power tilt switch lead Bolt Washer Apron M6 x20 mm op x 12 mm P ower tilt model P ower tilt model Power tilt model P ower tilt model M6 x 35 mm P ower tilt model Power tilt model KA k FA KA 4 4 FA PRP RP k k k OO KJ KB 5 15 6AG3J 11 Part name Screw Nut Retaining plate Bolt Throttle cable Shift cable 10 pin main harness Battery cable Shift rod cam Bolt 6AG3 11 6 x 30 mm M6 x 30 mm M6 x 20 mm Power unit 27 N m 2 7 kgf m 19 9 ft Ib 27 N m 2 7 kgf
140. ier or clearer Contents 1 General information N Specification GO Periodic check and adjustment SE IA Fuel system opt C m IT 209 I LI O Lower unit O I Bracket unit ON Electrical system em mie 8 edit E O e JJ LL CO Troubleshooting UU L G SST 6AG3J11 General information How to use this manual anses 1 1 Manual OA 1 1 SYMP EE 1 2 ADDV EON aner 1 3 Sealant and locking agent table rrrrrrnnnnrrrnrnnnrnrrrnnnnnrvnrnnnnrrnnnnnnneennnnnnne 1 3 Safety While WOOP KING vreicss see sccecccsesrececwareadeeevsstewensuxecedetedacuwasscuaneonenseneewsexexsewnn 1 4 Firo JE CMTON DE 1 4 Verona 1 4 DE IFPI OLE CHOON usaeda eee 1 4 Part lubricant and eealant 1 4 GOOA WOKING EIE ES 1 5 Disassembly and assembly eee eee eee 1 5 JE Ve e TTT 1 6 MOE 1 6 SerialNumber regerar a A E 1 6 Special SEFVICE Oude 1 7 Propeller TE ln NEE 1 12 FOU Eee ARR 1 12 Sele 1 12 Predellverv CROCK E 1 12 Checking the outboard motor mounting begabt 1 13 Removing the intake silencer protective covering cesse eee eee ee e 1 13 Checking the fuel System sacian tnn aeia aa aE ENEN TE 1 13 Checking the engine ol evel surorii n ea 1 13 Checking the gear oil level sersa 1 14 Checking the battery electric starter model 1 14 Setting the remote control cable remote control model 1 14 Checking the gear shift and throttle operaton eee eee 1 15
141. ightened Thread size a bracket bolt manual starter M8 133 Throttle cam bracket bolt M6 8 08 59 aae cambo m 8 08 59 Throttle cable bracket bolt tiller handle model M6 8 08 59 Flywheel magnet nut tas 108 791 Drive sprocket nu p 4o eli Driven sprocket bol Teke maai ar Im zm 59 Cylinder head coverbo m I 8 os a RI w e 2 12 e Cylinder head bol M9 SCC w Anodepug O f 48 18 13 Rockeramlocknut D 14 103 Oilpumpserem m 8 05 37 Angie Sey m 2 02 15 Thermostatcoverbok mim JA EEE B ue 6 06 44 S 12 89 we LS 06 a Crankcase bolt 12 20 S ist 7 Connecting rod cap bolt M6 D 06 44 2 12 89 Lower unit Gearoildramseren 1 gt o 66 Gearolchecksrew 1 o o 66 Propert 1 7 247 25 Cooling waterinletcoverscrew 3 05 37 Angie bai ME 8 08 59 Trim tab bok Me 8 J 08 ap Proper status ak me 8 os so mm je t t aja Steering bracket cover screw 3 0 2 31 6AG3J 11 Tightening torque Tightening torques Part to be tightened Thread size po AE Grommetscrew maul Throttle cable holder bolt tiller handle model We 1 38 08 59 Shift lever bolt tiller handle model 1 81651 35 Tiller handle bracket cover bolt tiller handle M6 5 9 model Throttle pulley holder bolt tiler handle model M6 8 08 59 T
142. iller handle throttle pulley screw tiller handle M5 22 model Power tilt switch screw power tilt model eo Power tilt switch bracket screw power tilt M6 0 4 3 0 model Engine stop lanyard switch nut tiller handle model Friction plate bolt tiller handle model dE E a e Friction cion EE bolt tiller handle model ME E CC Friction self locking nut tiler handle model 6 06 44 Hesse ELTH Mount housing nut ES E N 08 59 ess 37 Sterng om cove Temas EES Uppermountbot H I 30 30 31 ipm m d8 d 3 Coster mz Oitpan assembly bot ie 0 3 rOi stainerbot mm Seong f fa 19 140 Til stopper plate bot manual tmo 8 08 59 Anode botipowersitmode H s os ss Ti stopper nut powertitmodel I a 24 MT Ground lead bolt powerttitmodel me e og 59 a unit RO shaft bolt er tilt M 8 Geseent pf gt pf 3 03 22 Power tilt unit power tilt model SPEC naan Specification Tightening torques ues 5 Gear housing bolt Tilt piston bolt Tilt cylinder end screw Tilt ram General torque This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch Tightening torque specifications for special components or assemblies are provided in applicable sections of this man ual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and pro gressive stages until the specifie
143. ing the crankshaft clockwise approximately 90 gradually US Q S6AG5A50 CAUTION Do not turn the crankshaft more than 90 Otherwise the piston and valves will col lide with each other and be damaged 5 30 5 Hold the driven sprocket using the spe cial service tool and then remove the driven sprocket bolt l an SA te lr CT o KA RE Gita S IO a HI D T NOTE Make sure that the driven sprocket does not turn when loosening the driven sprocket bolt Is Flywheel holder 90890 06522 6 Remove the driven sprocket and Woo druff key 7 Install the power unit onto the special service tool as shown and then remove the drive sprocket nut S6AG5A70 NOTE S e Use a deep 41 mm socket 7 to loosen the drive sprocket nut e Make sure that the power unit does not turn when loosening the drive sprocket nut 5 31 Shaft holder 90890 06069 8 Remove the retaining plate drive sprocket and Woodruff key Checking the timing belt and sprocket 1 Check the interior and exterior of the tim ing belt Replace if cracked damaged or worn 2 Check the drive sprocket and driven Sprocket Replace if cracked damaged Or worn Installing the sprocket and timing belt CAUTION Unless directed to do so in the following instructions do not turn the drive sprocket or driven sprocket when the tim ing belt is not installed Otherwise the pis
144. ion T 2 4 2 6 0 0945 0 1024 End gap i 0 25 0 4 0 0098 0 0157 Side clearance 0 02 0 06 0 0008 0 0024 Oil ring Dimension B i 2 34 2 46 0 0921 0 0969 Dimension T i 2 75 0 1083 End gap i 0 2 0 7 0 0079 0 0276 Side clearance T i 0 05 0 19 0 0020 0 0075 Connecting rod Small end inside diameter 16 015 16 029 0 6305 0 6311 Big end inside diameter 34 030 34 042 1 3398 1 3402 Big end side clearance i 0 05 0 22 0 0020 0 0087 Crankpin oil clearance i 0 021 0 045 0 0008 0 0018 Crankshaft Crankshaft journal diameter 36 997 37 009 1 4566 1 4570 Crankpin diameter 33 997 34 009 1 3385 1 3389 Crankpin width 21 000 21 070 0 8268 0 8295 Crankshaft runout limit 0 05 0 0020 C1 The figures are for reference only BAG3J11 2 18 SPEC naan Specification M Item Unit SE Model O e 26 2087 Crankcase Crankshaft journal oil i 0 011 0 039 0 0004 0 0015 clearance Upper and lower crankcase main journal bearing thickness A Blue 1 502 1 506 0 0591 0 0593 B Black i 1 498 1 502 0 0590 0 0591 C Brown 1 494 1 498 0 0588 0 0590 Oil pump Type Trochoid Outer rotor to housing mm in 0 09 0 15 0 0035 0 0059 clearance Outer rotor to inner rotor mm in Within 0 12 0 0047 clearance Rotor to cover clearance mm in 0 03 0 08 0 0012 0 0031 Relief valve opening pressure kPa 350 450 3 50 4 50 50 8 65 3 kgf cm psi Thermostat Opening temperature
145. l M8 x 25 mm R emote control model Remote control model NF P KA kA k KA FA KA kA k FA Fi 7 12 Bracket unit 30 N m 3 0 kgf m 22 1 ft Ib aS 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib Grommet 1 1 A KA A en Hi D d Oo une wn KA kA k k FA bm SIH Ul B WW N 7 13 Water pipe Upper mount Bolt Exhaust guide Oil seal Gasket Oil strainer Bolt Baffle plate Seal Pipe Oil pan Dowel Bolt Damper Gasket KA kA NNK k KA k D k k RP YPN FA ki m 5 9 ft I hye 8 N m 0 8 kgf b Y 572 A 26 27 N m 2 7 kgf m 19 9 ft Ib L transom model S transom model M8 x 30 mm Not reusable Not reusable M6 x 16 mm M8 x 30 mm Not reusable 1 8 Kor m 13 3 ft Ib S6AG 7510 6AG3 11 Upper case and steering arm 30 N m 3 0 kgf m 22 1 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 1 g on 8 N m 0 8 kgf m 5 9 ft Ib 572 18N m 1 8 kgf gt m 13 3 ft Ib 26 18N m 1 8 kgf m 13 3 ft Ib 27 N m 2 7 kgf m 19 9 it Ib S6AG7510 No Panname REGER Remarks Drain bolt Gasket Exhaust manifold L transom model Bolt M6 x 25 mm Rubber seal Water pipe guide Dowel Upper case Drive shaft bushing Circlip Bolt Exhaust manifold Upper case L transom model L transom model only L transom model only M8 x 30 mm S transom model S transom model KA KA On KA KA KA KJ KA FP P kA KA
146. l back and then fasten the connector and lead with the holder as shown Install the bent terminal of the wiring harness to the starter motor The connectors can be fastened in any position in the holder Fold the neutral switch lead Br back and then connect it to the starter relay connector Br Fold the fuse lead R back and then connect It to the positive battery cable connector Fasten the leads which were folded back with the holder Tiller handle model Fold the lead from 10 pin main harness coupler Br back and then connect it to the starter relay connector Br Fold the fuse lead R back and then connect it to the positive battery cable connector Fasten the leads which were folded back with the holder R emote control model AR 6AG 3 11 8 10 ELEC 7 ELEC ay Electrical system Checking the electrical component Measuring the peak voltage To check the electrical components or mea Sure the peak voltage use the special ser vice tools A faulty electrical component can be easily checked by measuring the peak voltage The specified engine speed when measuring the peak voltage is affected by many factors such as fouled spark plugs ora weak battery If one of these factors is present the peak voltage cannot be mea Sured properly 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
147. l half of the main bearings 9 into the cylinder block oo S6AG5990 NOTE SU e Install the main bearings in their original positions e Insert the projection of each bearing into the slots in the cylinder block 6 Install the crankshaft AP and oil seals 42 and 02 into the cylinder block as shown S6AG5A00 NOTE 00 Apply engine oil to the inside of the oil seals before installation 6AG3 11 7 Install the connecting rod caps 4 to the connecting rods and then tighten the connecting rod cap bolts to the specified torques in 2 stages S6AG5A10 NOTE e Make sure that the projections on the connecting rod cap face towards the fly wheel magnet end Al of the crankshaft e Apply engine oil to the connecting rod cap bolts before installation e After tightening the connecting rod cap bolts check that the crankshaft rotates Smoothly Connecting rod cap bolt lst 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb 8 Install the remaining half of the main bearings into the crankcase NOTE e Install the main bearings in their original positions e Insert the projection of each bearing into the slots in the crankcase 9 Apply sealant to the mating surface of the crankcase 6AG3 11 Cylinder block S6AG5A20 NOTE Do not get any sealant on the main bearings 10 Install the crankcase onto the cylinder block NOTE Apply engine oil to the threads of t
148. l system 3 Turn the engine start switch to OFF 4 Connect the 10 pin main harness cou pler Checking the starter relay electric starter model l Disconnect the starter relay 1 connec tor Starter relay input voltage reference data Brown Br Ground 12 V battery voltage Disconnect the battery cables and then remove the starter relay Connect the digital circuit tester leads to 2 Setthe shift lever or remote control lever the starter relay terminals to the neutral position Connect the brown Br lead of the 3 Push the engine start button and then Starter relay to the positive battery termi measure the input voltage between the Starter relay connector neutral switch end and the ground Check the engine nal and connect the black B lead to the negative battery terminal Check for con tinuity between the starter relay termi Start button neutral switch wiring har ness and ground lead if below specifica tion Tiller handle model 7 Disconnect the brown Br or black B Turn the engine start switch to START lead of the starter relay from a battery and then measure the input voltage terminal Check that there is no continuity between the starter relay connector neu between the starter relay terminals tral switch end and the ground Check Replace if there is continuity the engine start switch neutral switch in the remote control box wiring harness and ground le
149. l width Overall height S L Transom height L Boat transom height S L Weight with aluminum propeller S L Performance Maximum output Full throttle operating range Maximum fuel consumption Engine idle speed Power unit Type Cylinder quantity Total displacement Bore x stroke Compression ratio Control system Starting system Fuel system Enrichment system Ignition control system Advanced type Ignition timing at 1 050 r min 6AG3J11 General specification Model m me EI Er a 1 078 1 078 42 4 42 4 1 205 47 4 570 22 4 381 15 0 508 20 0 kW HP 11 0 15 at 14 7 20 at 5 500 r min 5 500 r min 5 000 6 000 5 r min L US gal 4 1 4 1 2 at 8 1 8 1 5 at Imp gal hr 5 500 r min 5 500 r min r min 1 050 50 4 stroke L 2 362 22 1 63 0 x 58 1 2 48 x 2 29 9 3 Remote control Electric Carburetor Prime Start CDI micro computer Micro computer cm cu in mm in TDC 1 5 2 4 SPEC naan Specification ltem Unit wedge we 208 2081 Maximum generator output 12 10 0 Spark plug DPR6EB 9 NGK Cooling system Water Exhaust system Propeller boss Lubrication system Wet sump Fuel and oil Fuel type Engine oil type Engine oil grade API SAE Regular unleaded gasoline 4 stroke motor oil SE SF SG SH SJ or SL 5W 30 10W 30 or 10W 40 Engine oil quantity without oil filter L
150. le model P ower tilt model NOTE Install the power tit motor leads and power tilt relay leads to the terminals making sure to install the leads at an angle of approximately 15 207 6AG3 11 11 Fasten the leads with the plastic ties 29 and holders 60 and then install the junc tion box cover 12 Connect the flushing hose j cooling water hose 62 and fuel hose 83 S6AG5D01 13 Connect the battery cables Electric Starter model Connect the battery cables and 10 pin main harness coupler Remote control model Install the retaining plate 14 Install the manual starter and sprocket cover and then connect the start in gear protection cable Manual starter model Install the flywheel magnet cover and Sprocket cover Electric starter model S6AG5D02 6AG3 11 Cylinder block NOTE Eh e To connect the start in gear protection cable see Checking the start in gear pro tection manual starter model 3 11 e Be sure to install the caps 65 on the bolts 4 for the flywheel magnet cover and junction box 15 Pour the specified amount of the recom mended engine oil into the oil filler hole NOTE a For the specified amount and recommended engine oil see Changing the engine oil 3 3 5 64 MEMO 5 65 6AG3 11 Lower unit EO WEE UNN ENEE 6 1 ClO WING le EE 6 4 REMOVING the water Dump sese ss sese eee eee seene nenen 6 5 Checking me water
151. lling the drive shaft bushing apply grease to the inside of the bushing Driver rod L3 90890 06652 Needle bearing attachment Go 90890 06613 2 Install the water pipe guide onto the upper case 3 Install the dowels oil pan assembly and oll pan assembly bolts and then tighten the bolts to the specified torque 6AG3 11 4 Install the upper mount and then tighten the upper mount bolts to the specified torque 5 Install the water pipe On S6AG 7660 NOTE _ Be sure to pass the water pipe di through the water pipe guide Oil pan assembly bolt 18 N m 1 8 kgf m 13 3 ft lb Upper mount bolt oo 30 N m 3 0 kgf m 22 1 ft lb 6 Install the damper and engine oil drain bolt and then tighten the drain bolt to the Specified torque Engine oil drain bolt 27 N m 2 7 kgf m 19 9 ft lb Removing the steering arm 1 Remove the steering arm M from the Swivel bracket by pulling the arm off the bracket 6AG3J 11 Upper case and steering arm o gt N a Qo CANY NI Oo cb s6ac7711 NOTE To disassemble the clamp brackets see Removing the clamp bracket 7 22 or Removing the clamp bracket 7 27 Installing the steering arm 1 Install the washer and bushing 1 onto the steering arm 2 Place the swivel bracket in an upright position and then install the steering arm onto the swivel bracket 3 Install b
152. lts to the specified torques in 2 stages Connecting rod cap bolt lst 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb 2 Measure the connecting rod small end inside diameter and big end inside diameter Replace the connecting rod if out of specification S6AG5H70 Connecting rod small end inside diameter 16 015 16 029 mm 0 6305 0 6311 in Connecting rod big end inside diameter 34 030 34 042 mm 1 3398 1 3402 in Checking the connecting rod big end side clearance 1 Measure the connecting rod big end side clearance 56D55800 Connecting rod big end side clearance reference data 0 05 0 22 mm 0 0020 0 0087 in Checking the crankshaft 1 Measure the crankshaft journal diameter a crankpin diameter and crankpin width Replace the crankshaft if out of Specification S6AG5910 S6AG5920 Crankshaft journal diameter 36 997 37 009 mm 1 4566 1 4570 in Crankpin diameter 33 997 34 009 mm 1 3385 1 3389 in Crankpin width 21 000 21 070 mm 0 8268 0 8295 in 2 Measure the crankshaft runout Replace if above specification S6AG 5930 Crankshaft runout limit 0 05 mm 0 0020 in Checking the crankpin oil clearance 1 Clean the contact surfaces of the con necting rod and crankpin 6AG3 11 2 Puta piece of Plastigauge PG 1 onto the crankpin parallel to the crankshaft S69J5D00 NOT
153. mark on the drive sprocket and the mark on the cylinder block are aligned 5 4 7 Remove the timing belt from the driven sprocket and then remove it from the drive sprocket 9 Turn the drive sprocket clockwise 2 turns and then check that the alignment marks and G are aligned CAUTION Unless directed to do so in the following instructions do not turn the drive sprocket or driven sprocket when the tim ing belt is not installed Otherwise the pis tons and valves will collide with each other and be damaged 8 Install a new timing belt onto the drive Sprocket and then install it onto the driven sprocket with its part number in the upright position CAUTION e 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 e Do not get oil or grease on the timing belt NOTE Before installing the timing belt make sure that the marks on the drive sprocket and driven sprocket are aligned with the marks on the cylinder block and cylinder head 5 5 10 Install the stator coil assembly with bolts D 11 Install the Woodruff key and then install the flywheel magnet NOTE e Be sure to remove any grease from the tapered portion of the crankshaft and fly wheel magnet e Apply engine oil to the threads of the fly wheel magnet nut and washer before installation Stator coil assembl
154. mercially available vacuum pres sure pump gauge and meter that can be pressurized up to 200 kPa 2 0 kgf cm 29 0 psi KL Vacuum pressure pump gauge commercially available Specified positive pressure 200 kPa 2 0 kgf cm 29 0 psi Checking the fuel joint 1 Check the fuel joint Replace if cracked or damaged 2 Connect the special service tool to the fuel joint outlet 4 3 3 Apply the specified positive pressure Replace the fuel joint if the specified pressure cannot be maintained for at least 10 seconds S6AG4070 vz Vacuum pressure pump gauge set 90890 06756 Specified positive pressure 50 kPa 0 5 kgf cm 7 3 psi 6AG3J11 Fuel filter Fuel pump Fuel pump Ma le OSS 7 DA E TI al E yA S6AG4030 Partname Fuel pump Fuel hose Cooling water hose Bolt M6 x 30 mm Cooling water hose Fuel hose O ring Holder Clamp Plastic tie 2 3 4 5 6 7 8 9 10 6AG3J 11 4 4 ry Fuel system Axe 0 5 N m 0 05 kgf m 0 37 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib S6AG4040 no Paname Joy Remarks Screw 4 x 30 mm Cover Diaphragm Fuel pump body 2 Nut Pin Plunger S pring Fuel pump body 1 S pring Diaphragm Screw Check valve D 1 2 3 4 5 6 7 8 9 10 11 03 x 5 mm m N N NFP RP RP RP KA k BRP kA KA KA LA 4 5 6AG3 11 Checking the fuel pump 1 Connect the special service tool to the fuel
155. minal Terminal Terminal ni Terminal Terminal S6AG7850 Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Continuity No continuity 6AG 3 11 7 48 Bracket unit 3 Connect the positive battery lead to the Sky blue Sb lead and the negative battery lead to the terminal B as Shown and then check the power tilt relay for continuity Replace the power tilt relay if out of specification S6AG7880 L W ol Power tilt relay continuity Terminal Terminal Terminal Terminal TR Terminal Terminal Checking the power tilt switch 1 Check the power tilt switch for continuity Replace the power tilt switch If out of Specification d KS S6AG7890 7 49 Switch Sky blue Lightgreen position Sb Kl 6AG3 11 6AG3 11 Electrical system Electrical component and wiring harness routing ruuervvnnnnnnnvnvnnnnnnnunennvnnnn 8 1 Ee E EE ME 8 1 SJ EVE EE 8 3 P ONC ee 8 7 Checking the electrical COMponent ssssssssssnnsnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 8 11 Measuring the peak voltage eee eee eee 8 11 Starter motor electric Starter modelJ r snrrrerrnnnnnvnnnnnnnnennnnnnnvennnnnnnvernnnnnnr 8 12 REMOVING the starter MOto ucria A 8 14 Checking the starter motor operation sese ee eee eee eee 8 14 Checking the starte
156. mittent spark Spark plug malfunc Check the spark tion plug Spark plug cap mal Check the spark function plug cap 8 Ignition coil mal Check the ignition 8 coll Check the engine stop lanyard switch function Engine stop lan yard switch mal UJ UT 22 22 24 8 function Charge coil mal Check the charge 8 function coil Pulser coil malfunc Check the pulser tion coil 8 CDI unit malfunc Check the CDI unit 8 23 23 25 tion Check the fuel 3 2 Pinched or kinked fuel hose Incorrect fuel and air amount supplied hoses and fuel hose Clean or replace 3 the fuel filter Disassemble and check the fuel Clogged fuel filter Fuel pump malfunc tion Es I I Carburetor malfunc tion Throttle stop screw Adjust the throttle 3 11 not adjusted cor stop screw rectly Pilot screw not Adjust the pilot 4 15 adjusted correctly screw Malfunction of the Disassemble and Carburetor internal check the carbure parts tor Prime Startsystem Prime Start mal Check the Prime 4 malfunction function S tart T KA N 13 8 29 Power bobbin mal Check the power function bobbin 6AG3J 11 9 4 TRBL c SHTG Troubleshooting Refer Symptom 2 Cause 1 Cause 2 Checking step to page Low compression Valve clearance not Adjust the valve 5 2 pressure adjusted correctly clearance Automatic decom Disassemble and 5 37 check the cylinder 5 43 malfunction head an
157. moving the timing belt ANd sprocket sss eee eee eee 5 30 Checking the timing belt and eprocket sss sees eee eee 5 31 Installing the sprocket and timing Delt 5 31 Cylinder head E 5 34 Removing ne Mere 5 37 Disassembling the cylinder heat 5 37 CHECKING Me aN eT d NE EE 5 38 Checking the valve Spring eee eee eee ee eee eee 5 38 Checking TGV E 5 39 CHECKING be e Ee Te LE 5 39 Replacing the valve goude 5 40 Checking NE VEN SE aa 5 40 Refacing the valve Sed Eureen 5 41 Checking the rocker arm and rocker arm shaft A 5 43 Checkngo me cams nat seede frie 5 43 Assembling the cylinder heat 5 44 lAstalling the Cynder Nedd isurien iian e aR 5 47 Checking NE ANN 5 47 6AG3 11 Cylinder DIOCK isisisi aaa Ke 5 49 Disassembling the cylinder block esse eee eee ee eee 5 51 Checking the piston dameter T 5 52 Checking the Cylinder bore AAA 5 52 Checking ME Piton CIEAKANC Hvad 5 52 CNECKING ME PISTON MG ae ai 5 53 Checking the piston ring end gan 5 53 Checking the piston ring groove esse eee eee eee 5 53 Checking the piston ring side Oearance eee ee eee eee 5 54 Checking the piston pin boss el 5 54 Checking the piston pin diameter esse ee eee eee eee 5 54 Checking the connecting rod small and big end inside diameter 5 54 Checking the connecting rod big end side clearance sese eee 5 55 ENECO ME CANNES 5 55 Checking the crankpin oil cearance eee eee ee eee e eee 5 55 Checking the crankshaft journal oil clearance rrrrrrra
158. n the cover e Install the stator so that the label is read 4 Install the stator o washer shim s from bottom to top as shown d3 washer 4 and cover 45 and then BOATS Rye Pole 5 Install the pinion spring 48 and pinion Stopper 49 6 Slide the pinion stopper down and then install a new clip 8 17 6AG 3 11 Starter motor electric starter model Starting system S6AG8510 NOTE e Install the pinion stopper 09 in the direction shown e Check the starter motor operation again after assembling it Installing the starter motor 1 Install the starter motor to the power unit 2 Install the wiring harness to the starter motor and then fasten the wiring har ness NOTE To wire the starter motor see Electrical component and wiring harness routing 8 1 Starting system Checking the fuse electric starter model 1 Check the fuse for continuity Replace if there is no continuity S6AG7851 NOTE For the location of the fuse see Electrical component and wiring harness routing 8 1 6AG3 11 Checking the engine start button tiller handle model with electric starter 1 Disconnect the engine start button connectors 2 Measure the input voltage between the connector wiring harness end of the engine start button and the ground Check the fuse and wiring harness if below specification S6AG8170 Engine start button input voltage refer
159. nd pulser coil before measuring the CDI unit output peak voltage CDI unit output peak voltage Orange 0 Black B cv Checking the thermoswitch 1 Disconnect the thermoswitch connec tors 2 Start the engine and then measure the input voltage at the thermoswitch con nectors wiring harness end Check the wiring harness if out of specification 6AG3 11 3 Ignition and ignition control system Engine electric control system SF T J A EN N G E AN A L E LRE TE S6AG8090 Thermoswitch input voltage reference data Gray black Gy B Black B 7 5 V at engine idle speed Push the engine stop button Tiller han dle model Turn the engine start switch to OFF Remote control model Remove the thermoswitch Place the thermoswitch in a container of water and slowly heat the water S6AG8100 000000000 DQ ef 7 S6AL8880 a Temperature 6 Time No continuity Continuity Thermoswitch continuity temperature Gray black Gy B Black B 76 84 C 169 183 F D 63 77 C 145 171 F 7 Install the thermoswitch and then con nect the thermoswitch connectors Checking the oil pressure switch 1 Disconnect the oil pressure switch con nector 6 Check the thermoswitch for continuity at the specified temperatures Replace if out of specification 6AG 3 11 8 26 ELEC 7 ELEC W i Electrical system 2 St
160. nder head gasket always replace it with a new one NOTE o e Apply engine oil to the cylinder head bolts before installation e Tighten the bolts to the specified torques in 3 stages e Make a mark on cylinder head bolts M9 and the cylinder head and then tighten the bolts 60 from the mark Cylinder head bolt 1 6 M9 lst 15 N m 1 5 kgf m 11 1 ft lb 2nd 29 N m 2 9 kgf m 21 4 ft lb 3rd 60 Cylinder head bolt 7 9 M6 lst 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb Checking the oil pump 1 Remove the oil pump screws 1 and dis assemble the oil pump 5 47 S6AG 5430 Check the inner surface of the oil pump case Replace the oil pump assembly if Scratched Measure the oil pump rotor clearances as shown Replace the oil pump assem bly if out of specification 56D55580 S6AG 5420 6AG3 11 Cylinder head Clearance 0 09 0 15 mm 0 0035 0 0059 in Clearance Within 0 12 mm 0 0047 in Clearance 0 03 0 08 mm 0 0012 0 0031 in 4 Assemble the oil pump and then tighten the oil pump screws C to the specified torque S6AG5670 NOTE When assembling the oil pump face the C mark on each rotor up Oil pump screw 07 5 N m 0 5 kgf m 3 7 ft lb 6AG 3 11 5 48 Cylinder block YD 14 N m 1 4 kgf m 10 3 ft Ib 27 N m 2 7 kar m 19 9ft b amp LO 6N m 0 6 kgf m 4 4 ft Ib
161. nenrnnnnn 7 35 Disassembling the gear PIMP EE 7 38 Checking GE NNN 7 38 Checking the valve SE 7 38 GINSENG Me NE RANG 7 39 Assembling the gear pDump eee 7 39 Power tilt cylinder power tilt model rnnuvrnnnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnvevennnnnnnnnne 7 41 Disassembling the tilt cylinder sss esse ee eee eee 7 43 Checking the tilt cylinder and PS Ouse 7 43 Assembling the tilt cylinder AAA 7 44 Bleeding THE DOW W UNUM ed 7 46 Power tilt electrical system power tilt model rasannuuvrnnnnnnnnnnnnnnnnnnnnuuunnr 7 47 B LZ a 21512 UN 7 47 Checking the power tilt relay Jang 7 48 Checking THE power TS Ne kes 7 49 Bracket unit Tiller handle tiller handle model ye 4 N m 0 4 kgf m 3 0 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 4N m 0 4 kgf m 3 0 ft Ib Ne 8 N m sg m 5 9 ft Ib C Ww KA K anu U K Q No Part name Remarks 1 Throttle cable 2 Screw 4 6 x 18 mm 3 Steering bracket cover 1 4 Screw 1 6 x 19 mm 5 Bolt 1 M6 x 18 mm 6 Holder 1 7 S hift lever 1 8 S hift link rod 1 9 Bolt 1 M6 x 40 mm 10 Collar 1 11 Wave washer 1 12 Tiller handle 1 13 Engine stop lanyard switch 1 14 Wave washer 2 15 Washer 2 16 Bushing 1 17 Grommet 1 7 1 6AG3J 11 Tiller handle tiller handle model ye 4 N m 0 4 kgf m 3 0 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 4N m 0 4 kgf m 3 0 ft Ib Ne 8 N m s
162. ner race attachment 90890 06644 Kg Shimming plate 90890 06701 Digital caliper 90890 06704 Backlash indicator 90890 06706 Magnet base plate 90890 07003 Gs l General information Dial gauge set Ignition tester 90890 01252 90890 06754 Magnet base B 90890 06844 Power tilt wrench 90890 06560 Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 1 11 6AG3J11 Special service tool Propeller selection Predelivery check Propeller selection The performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose Propellers greatly affect boat speed acceleration engine life fuel economy and even boating and steering capabilities An incorrect choice could adversely affect performance and could also seriously damage the engine Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor Propeller size The size of the propeller is indicated on a propeller blade on the propeller boss end and on the side of the propeller boss O C S69W1030 S69W1040 000x0 0 7 I I bd S69W1050 6AG3J11 Propeller diameter in inches amp Propeller pitch in inches Propeller type propeller mark Selection When the engine speed is at the full throttle operating range 5 000 6 000 r min the ideal propeller for the bo
163. ng them Checking the oil strainer 1 Check the oil strainer Clean if there is dirt and residue Assembling the exhaust guide oil pan and exhaust manifold S6AG7560 1 Install a new oil seal into the exhaust S transom model guide 2 Remove the oil pan from the exhaust guide GO and then remove the baffle plate 3 Remove the oil strainer and the gas ket from the exhaust guide 4 Remove the oil seal from the exhaust guide S6AG7580 vz Driver rod L3 90890 06652 d Needle bearing attachment 90890 06612 S6AG 7570 6AG 3 11 7 16 Bracket unit 2 Install the dowels and a new gasket onto the exhaust guide 3 Install the oil strainer and oil strainer bolts and then tighten the bolts to the Specified torque S6AG7600 Oil strainer bolt 8 N m 0 8 kgf m 5 9 ft lb 4 Install the baffle plate o and oil pan and then tighten the oil pan bolts 2 to the specified torque S6AG 7620 Oil pan bolt 4 18 N m 1 8 kgf m 13 3 ft lb 5 Install a new gasket 43 the exhaust man ifold 44 and the rubber seal 4 and then tighten the exhaust manifold bolts to the specified torque 7 17 S6AG7630 Exhaust manifold bolt og 8 N m 0 8 kgf m 5 9 ft lb Assembling the upper case 1 Install the drive shaft bushing into the upper case and then install the circlip L transom model S6AG7650 NOTE After insta
164. nition timing at 1 050 r min Maximum generator output Spark plug Cooling system Exhaust system Lubrication system Fuel and oil Fuel type Engine oil type Engine oil grade API SAE TDC 1 5 12 10 0 DPR6EB 9 NGK Water Propeller boss Wet sump Regular unleaded gasoline 4 stroke motor oil SE SF SG SH SJ or SL 5W 30 10W 30 or 10W 40 Engine oil quantity without oil filter L US at replacement Imp at with oil filter replacement L US at Imp at 1 6 1 69 1 41 1 8 1 90 1 58 Gear oil type Gear oil grade API SAE Gear oil quantity cm US oz Imp 02 Hypoid gear oil GL 4 90 300 10 14 10 58 Bracket unit Trim angle at 12 boat transom Tilt up angle 71 67 Steering angle 45 45 Power tilt system Fluid type ATF Drive unit Gear shift positions F N R Gear ratio 2 08 27 13 Reduction gear type Spiral bevel gear 0 0 4 0 8 0 12 0 Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear view Clockwise Propeller mark J J1 C1 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 6AG3J11 2 2 SPEC naan Specification Electrical Battery minimum capacity CCA EN 20HR IEC Electrolyte specific gravity at 20 C 68 F Model ode 2 3 G6AG3J11 Dimension Overall length Overal
165. nnect the oil pressure switch connec tor NOTE To check the oil pressure see Checking the oil pressure 5 1 Checking the warning indicator assembly 1 Disconnect the thermoswitch connectors and then ground the gray black Gy B lead wiring harness end 2 Start the engine and operate it at engine idle speed for at least 120 seconds and then check that the overheat warning indicator comes on 3 Disconnect the oil pressure switch con nector and then ground the pink P lead wiring harness end 4 Start the engine increase the engine speed to approximately 2 000 r min and check that the oil pressure warning indi cator comes on after 10 seconds 5 Push the engine stop button Tiller han dle model Turn the engine start switch to OFF Remote control model 6 Connect the thermoswitch connectors and oil pressure switch lead terminal 7 Disconnect the warning indicator assem bly coupler 6AG3 11 Engine electric control system 8 Connect the yellow black Y B lead to the positive penlight battery terminal 1 5 V and connect the pink black P B lead to the negative terminal and then check that the warning indicator comes on Replace the warning indicator assembly if it does not come on R l s Syr 704 FIN LED2 S6AG8300 9 Connect the yellow red Y R lead to the positive penlight battery terminal 1 5 V and connect the pink white P W lead to the ne
166. o prevent any eye injury by the blown off debris or liq uid 3 Check the main jet pilot jet and main nozzle Clean if there is dirt or residue CAUTION Do not use steel wire for cleaning the jets otherwise the jet diameters may be enlarged which may seriously affect per formance 4 Check the pilot screw and needle valve Replace if worn or deformed S6AG4200 5 Check the float Replace if cracked or deformed 4 12 ne R Fuel system 6 Measure the float height Replace the float or needle valve if out of speci fication S6AG 4220 S6AG4210 NOTE e Measure the float height when it is resting on the needle valve Do not push down on the float e Take measurements at the float position shown opposite its pivoted side Float height amp 15 0 1 0 mm 0 59 0 04 in Checking the Prime Start 1 Measure the Prime Start resistance when the Prime Start is cold NOTE Ambient temperature 24 C 75 F with no power supplied Prime Start resistance reference data Blue L Blue L 16 4 24 8 Q at 24 C 75 F 2 Measure the length of the Prime Start plunger before supplying power 4 13 Prime Start plunger length before Supplying power reference data 10 7 mm 0 42 in at 24 C 75 F 3 Connect the Prime Start blue L leads to a 12 V battery as shown Measure the plunger length after supplying power for 10 minutes S6AG 423
167. om the arma ture assembly 7 Remove the brush holder screws 3 brushes 4 springs 45 and oil seal from the power tilt motor base 0 S6AG7125 Checking the power tilt motor 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty S6AG 8440 2 Measure the commutator diameter Replace the armature if below specifica tion S6AG 8450 6AG3 11 Power tilt motor power tilt model Motor commutator standard diameter 16 5 mm 0 65 in Wear limit 15 5 mm 0 61 in 3 Measure the commutator undercut Replace the armature if below specifica tion S69J8410 Motor commutator standard undercut 1 00 mm 0 039 in Wear limit 0 50 mm 0 020 in 4 Check the armature for continuity Replace the armature if out of specifica tion ee 1 rm rm rm rm zm zm mm mm mm mm S6AG7087 II WM Armature continuity Commutator segments Segment Armature core Segment Armature shaft 7 32 Bracket unit 5 Check the bearing Replace if damaged NOTE gt e f the bearing is damaged replace the armature assembly e Do not reuse the oil seal Checking the brush holder and brush 1 Check the brush holder assembly for continuity Replace the power tilt motor base If out of specification S6AG7090 NOTE The brush holder and circuit breaker cannot be removed from the power tilt motor base assembly if either
168. on where necessary See in the figure below for an example page NOTE For troubleshooting procedures see Chapter 9 Troubleshooting Lower unit Lower unit regular rotation model _19 164 Nem 5 4 kof m 39 8 ft ib ME are lt j 42 Nm 4 2 kof m 31 0 ft eil 21 Y ES jf SE gang 18 i With 2 ne Z E ie 3 Drive shaft and lower case regular rotation model Removing the drive shaft 1 Remove the pinion nut SGALGANG Do not reuse the bearing always replace f d Drive shaft holder 6 7 90890 06520 it with a new one Pinion nut holder 90890 06715 Remove the drive shaft drive shaft hous Er Ve ol ALAF Nm 4 7 kgf m 34 7 ft Ib ing pinion thrust bearing spring and Jon ent m 3471 EI ENER RE Disassembling the lower case Pull out the forward gear 1 Remove the needle bearing from the lower case z ap ow min bf Go M ch Part name Qty Remarks T Lower unit Plate Rubber seal Check screw Gasket Bolt Crain screw Grommet Disassembiing the drive shaft housing 1 Remove the cover oil seals and needle bearing Not reusabie M10 x 45 mm X transom model Bolt Bolt Spacer Propeller Spacer Washer Cotter pin Propeller nut Trim tab MtO x 45 mm M10 x 70 mm X transom model ee SGALE280 Since the diameter of the passage in the Sahl Boat lower case and the diameter of the special service tool 1 are both 40 mm 1 57 in
169. ooling Check the cooling 3 remote control water inlet water inlets 7 model Clogged cooling Check the cooling 3 7 Overheat warning water passages water passages indicator comes on age ee EN does not dis Damaged water Check the water pipe or incorrect pipe and its installa installation Water pump mal Damaged water function pump impeller Check the Woo 6 5 ker Water leakage from 6 5 water pump hous pump housing cartridge plate cartridge charge from the cooling water pilot hole tion Thermostat mal Check the thermo function stat Thermoswitch mal Check the ther function moswitch Buzzer comes on Insufficient engine remote control oil model Oil pressure warn ing indicator comes on me Add sufficient oil Check the oil pres Sure Oil pump malfunc Check the oil pump tion Engine oil pressure decrease Clogged oil strainer Check the oil Strainer Clogged oil pas sages Check the engine 5 37 oil passages power unit and oil pump Clogged oil filter Replace the oil fil ter Oil pressure switch Check the oil pres 8 malfunction sure switch 6 5 6 5 3 6 8 25 3 3 5 1 5 47 7 16 3 4 26 6AG3J 11 9 6 TRBL P SHTG Troubleshooting Troubleshooting the power tilt unit Power tilt model Symptom 1 Power tilt unit does not operate Refer Symptom 2 Cause 1 Cause 2 Checking step to page Powertittrelay gier Check the fuse does not operate Po
170. or up and then Support it with the tilt stop lever to check the lock mechanism of the lever S6AG3220 Checking the power tilt fluid level 1 Fully tilt the outboard motor up and then Support it with the tilt stop lever WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power tilt unit should lose fluid pressure 2 Remove the reservoir cap 07 and then check the fluid level in the reservoir 6AG3 11 0 S6AG 3230 NOTE If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole when the cap Is removed 3 If necessary add sufficient fluid of the recommended type until it overflows out of the filler hole NY Recommended power tilt fluid ATF Dexron II 4 Install a new O ring and the reservoir cap and then tighten the cap to the speci fied torque Reservoir cap 5 N m 0 5 kgf m 3 7 ft lb Lower unit Checking the gear oil 1 Fully tilt the outboard motor down 2 Remove the gear oil check screw 1 and then check the gear oil level in the lower case Also check the oil for discoloration and its viscosity Tae S6AG3500 6AG3 11 Bracket unit Lower unit NOTE et If the oil is at the correct level a small amount of oil should overflow out of the check hole when the gear oil check screw is removed If the oil appears milky
171. own S6AG6500 10 mm 0 39 in S6AG6510 M4 M4 10 mm NOTE e Select the shim thickness T2 by using the Specified measurement s and the calcula tion formula e Measure the height from the ball bearing at 4 points to find the height average 4 Calculate the reverse gear shim thick ness Calculate formula Reverse gear shim thickness T2 57 85 M3 M4 5 Select the reverse gear shim s T2 as follows 6 23 0 31 0 40 0 41 0 50 0 51 0 60 0 61 0 70 Available shim thicknesses Calculated number m thickness mm 0 1 0 2 0 3 0 4 and 0 5 mm Backlash Measuring the forward and reverse gear backlash NOTE o e Remove the water pump assembly before measuring the backlash e Secure the drive shaft housing to the lower case using 6 bolts M8 x 25 mm 1 Install the lower unit onto a repair stand 2 Setthe shift rod to the neutral position at the lower unit S6AG6371 3 Turn the lower unit so that the propeller Shaft is facing down 4 Install the special service tools 5 Tighten the center bolt to the specified torque while turning the drive shaft 6AG3 11 Shimming Backlash NOTE Install the dial gauge so that the plunger tip is aligned with the mark on the back lash indicator Z Backlash indicator 90890 06706 d Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base B 90890 06844 8 Slowly t
172. p edge of the valve face use a 30 cutter to cut the top edge of the valve seat and then use a 45 cutter to center the area and set its width D y x S6AG5 40J b Previous contact width 9 If the valve seat contact area is too nar row and situated near the bottom edge of the valve face use a 60 cutter to cut the bottom edge of the valve seat and then use a 45 cutter to center the area and set its width p S6AG5 50 b Previous contact width 10 After refacing the valve seat to the speci fied contact width apply a thin even layer of lapping compound onto the valve seat and then lap the valve using a valve lapper S6AG5220 CAUTION Do not get the lapping compound on the valve stem and valve guide 11 After every lapping procedure be sure to clean off any remaining lapping com pound from the cylinder head and the valve 12 Check the valve seat contact area of the valve again NOTE _ To check the valve seat contact area see Checking the valve seat 5 40 5 43 Checking the rocker arm and rocker arm shaft 1 Check the rocker arms rocker arm shaft and rocker arm contact surface Replace if worn 2 Measure the rocker arm inside diameter b and rocker arm shaft outside diameter Replace if out of specification S6AG5230 Rocker arm inside diameter 13 000 13 018 mm 0 5118 0 5125 in Rocker arm shaft outside diameter 12 941 12
173. part is damaged replace the power tilt motor base i KC ol Power tilt motor base continuity Terminal G Men Terminal L For all terminal combinations No continuity not listed above 2 Measure the length of each brush Replace the brushes if below specifica tion 7 33 569J8430 Motor brush standard length 6 0 mm 0 24 in Wear limit amp 3 0 mm 0 12 in Assembling the power tilt motor CAUTION e Do not reuse the O ring always replace it with a new one e Do not allow grease or oil to contact the commutator of the armature 1 Install a new oil seal into the power tilt motor base as shown S6AG7100 Z Driver rod L3 90890 06652 Needle bearing attachment 90890 06614 2 Install the springs Gi brushes short lead and long lead and brush holder screws to the power tilt motor base as shown 6AG3 11 Power tilt motor power tilt model NOTE eet Align the rounded section of the stator with the rounded section of the power tilt motor base Ou Stator screw 2 5 N m 0 5 kgf m 3 7 ft lb S6AG7120 5 Install a new O ring 43 the pin 44 the Ny Brush holder screw manual valve 65 and a new O ring to S 5 N m 0 5 kgfm 3 7 ft lb the power tilt motor assembly 6 Install a new gasket 48 and the power tilt Brush lead length gt motor assembly to the tilt cylinder and then tighten the power tilt motor ba
174. plug cap resistance Ignition coil resistance Primary coil at 20 C 68 F Secondary coil spark plug wire Spark plug wire at 20 C 68 F Pulser coil output peak voltage W R B at cranking unloaded at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Pulser coil resistance W R B O B at 20 C 68 F Charge coil output peak voltage B R G R at cranking unloaded at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Charge coil resistance B R G R at 20 C 68 F CDI unit output peak voltage O B at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Thermoswitch ON temperature OFF temperature Oil pressure switch Specified oil pressure kgf cm psi C1 The figures are for reference only 2 21 0 8 0 9 0 031 0 035 3 75 6 25 0 26 0 35 152 228 25 5 34 5 76 84 169 183 63 77 145 171 29 4 58 81 0 294 0 5881 4 263 8 527 6AG3J1 1 Maintenance specification jor ei 205 oer Fuel control system Prime Start resistance L L at 24 C 75 F 16 4 24 8 Prime Start plunger length 10 7 0 42 Starting system Power bobbin output peak voltage L L at cranking unloaded at 1 500 r min unloaded at 3 500 r min unloaded at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Power bobbin resistance L L at 20 C 68 F 0 77 1 04 Starter motor Type Bendix Ou
175. 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 age S6AG4080 Vacuum pressure pump gauge set 90890 06756 Specified positive pressure 50 kPa 0 5 kgf cm2 7 3 psi 3 Apply the specified negative pressure and check that there is no air leakage S6AG4090 Specified negative pressure 30 kPa 0 3 kgf cm 4 4 psi 4 Connect the special service tool to the fuel pump outlet 5 Apply the specified positive pressure and check that there is no air leakage 6AG3 11 Fuel pump S6AG4100 Specified positive pressure 50 kPa 0 5 kgf cm 7 3 psi Disassembling the fuel pump L Disassemble the fuel pump as shown S6AG4110 4 6 ne R Fuel system 2 Remove the pin from the plunger and then disassemble the fuel pump body 1 S6AG4120 S6AG 4130 NOTE e Push down on the plunger and the dia phragm turn fuel pump body 1 approxi mately 90 to a position where the pin can be removed easily e Slowly release on the plunger and dia phragm and then remove them Checking the diaphragm and valve 1 Check the diaphragms and valves Replace the diaphragms if torn and the valves if cracked AQ A p S6AG4320 4 7 Assembling the fuel pump NOTE o Clean the parts and soak the valves and the diaphragms in gasoline before assembly 1 Ins
176. r by turning the adjusting nut 3 Tighten the locknut S6AG31 40 Checking the engine idle speed 1 Start the engine and warm it up for 10 minutes NOTE Because the Prime Start operates when the engine is started the engine idle speed will be above specification Therefore check and adjust the engine idle speed after the engine has been warmed up 2 Attach the special service tool to spark plug wire 1 07 and then check the engine idle speed Adjust if out of specifi cation 6AG3 11 Engine idle speed 1 050 50 r min 3 Turn the throttle stop screw Q In direc tion or until the specified engine idle speed is obtained lt S pe SLA ER S x CH THA I VRS 4d L AT YAT I TL S6AG3160 NOTE e To increase the engine idle speed turn the throttle stop screw Q in direction e To decrease the engine idle speed turn the throttle stop screw Q in direction 4 After adjusting the engine idle speed rev the engine a few times and let it idle to check the stability of the engine Checking the ignition timing 1 Start the engine and warm it up for 10 minutes NOTE Because the Prime Start operates when the engine is started the engine idle speed will be above specification Therefore check and adjust the engine idle speed after the engine has been warmed up 2 Attach the special service tool to spark plug wire 1 6AG3 11 Control system Qa
177. r motor pimion 8 14 Disassembling the starter moior see eee eee eee 8 14 CNECEKING UNE starter MODNET 8 15 Checking the brush holder and brueh sss eee eee 8 16 ASSEMDIING NE starter net 8 17 Installing the starter moor vszo rS g25 vsr 2 TK Ed erc R 2 Yr E y Ue Ye 4 NONN yaya 8 18 S cllk SyS teM NEE 8 18 Checking the fuse electric starter modell 8 18 Checking the engine start button tiller handle model with electric stater 8 18 Checking the engine start switch remote control modell 8 19 Checking the neutral switch tiller handle model with electric starter 8 19 Checking the neutral switch remote control modell 8 20 Checking the starter relay electric starter modell 8 21 Ignition and ignition control system sssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 8 21 Checking ENE INN NON SPA uran 8 21 CHECKING ME SPAK DUG CaP arsenal 8 22 Checking FE IOMINOI CO lue 8 22 CHECKING ME PUST UE 8 23 CHECKING ME NAGE e ET 8 23 Checking the engine stop lanyard switch tiller handle modell 8 24 Checking the engine stop lanyard switch remote control model 8 24 Engine electric control system rwrrrnnnnnnnnnnnnnnnnnnnnennnnnnnnnnvrnnunnnnnnnvevnnnnnnnununnr 8 25 checking FE ED Ur 8 25 CHECKING the THEN MOS el WEE 8 25 Checking the oil pressure ewitch eee eee eee 8 26 Checking the warning indicator assembly eee eee eee eee ee eee eee 8 28 Checking the power bobbin for Prime Start sees ee eee e
178. rks and on the crankcase and cylinder block S6AG 5950 NOTE The stamped mark for the main bearing of crankshaft journal 1 Is on the crankcase cover and the stamped mark for the main bearing of crankshaft journal 2 is on the cyl inder block 2 Select the suitable bearing color for the main bearing from the table 6AG3 11 Cylinder block Stamped marks ack Assembling the cylinder block 1 Assemble the piston connecting rod piston pin and piston pin clips CAUTION Do not reuse the piston pin clips always replace them with new ones NOTE e Face the projections on the connecting rod in the same direction as the UP mark BI on the piston e Do not allow the piston pin clip end to align with the piston pin slot 2 Install the oil ring 2nd ring and top ring onto each piston NOTE Make sure that the T marks di of the 2nd ring and the top ring are facing upward 3 Offset the piston ring end gaps as shown S6D55900 CAUTION Do not scratch the pistons or break the piston rings NOTE After installing the piston rings check that they move smoothly 4 Install the piston with the UP mark on the piston crown facing towards the fly wheel magnet S6AG 5980 NOTE SE Apply engine oil to the side of the pistons and piston rings before installation Piston slider 8 90890 06529 5 Instal
179. rning and then remove the propeller nut and propeller S6AG 6040 WARNING e Do not hold the propeller with your hands when loosening or tightening it e Be sure to disconnect the battery cables from the battery and remove the clip from the engine stop lanyard switch Electric starter model 3 Loosen the locknut Q while holding the adjusting nut 1 and then turn the adjust ing nut to disconnect the shift rod NOTE Set the gear shift to the neutral position before disconnecting the shift rod 6AG3 11 Lower unit 4 Remove the locknut S6AG6421 NOTE _ o Be sure to remove the locknut from the shift rod before removing the lower unit 5 Remove the lower unit by removing the lower case mounting bolts D Remove the trim tab anode and cooling water inlet covers S6AG6050 6 4 Lower unit Removing the water pump l Remove the water pump housing and impeller Remove the Woodruff key 27 from the drive shaft and then remove the outer plate cartridge Remove the dowels G from the lower case S6AG 6060 Checking the water pump 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 NO SR Check the impeller insert cartridge and outer plate cartridge Replace if cracked Or
180. rrrrrrrnrnerrrrrrssssrrrernn 5 56 Selecting the crankshaft main bearing sese eee ee eee e eee eee 5 58 Assembling the cylinder block AA 5 58 mMstalng TE POET Nunan de 5 61 6AG3J 11 Power unit check and adjustment Checking the compression pressure 1 Start the engine warm it up and then turn it off 2 Remove the clip from the engine stop lanyard switch 3 Disconnect the spark plug caps remove the spark plugs and then install the spe cial service tool 1 into a spark plug hole ER S6AG5020 CAUTION Before removing the spark plugs remove any dirt or dust in the spark plug wells that may fall into the cylinders vz Compression gauge 90890 03160 4 Fully open the throttle 5 Crank the engine until the reading on the compression gauge stabilizes and then measure the compression pressure NOTE Since this outboard motor is equipped with an automatic decompression mechanism the compression pressure may vary depend ing on the speed at which the starter handle is pulled when using the manual starter to crank the engine Manual starter model 5 1 Minimum compression pressure reference data 730 kPa 7 3 kgf cm 105 9 psi Manual starter model 860 kPa 8 6 kgf cm 124 7 psi Electric starter model 6 If the compression pressure is below specification or the compression pres sure for each cylinder is unbalanced add a small amount of engine oil to the cylin der an
181. s out 6AH50 5 Turn the throttle stop screw 27 in direc tion or until the specified engine idle speed is obtained VJ Le ROV 6AG3J11 NOTE e To increase the engine idle speed turn the throttle stop screw in direction e To decrease the engine idle speed turn the throttle stop screw in direction 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 check the stability of the engine 6AG3J 11 Carburetor unit 4 16 pour B _ Power unit Power unit check and adjustment sannuuvrnnnnnnnnnnnnnnnnnnnnnevnvnnnnnnnvenevnnnnnnunnenr 5 1 Checking the compression eT 5 1 CHECKING NE OMME SUE Henan 5 1 CHECKING R ne UE een e EE 5 2 Replacing the Tun ne BEE 5 3 Manual starter manual Starter modelJ anrrvrrnnnnnnevnnnnnnnevnnnnnnnennnnnnnernnnnnnnenr 5 7 Disassembling the manual Starter see ee eee eee eee eee 5 9 ASSEMDIING NE MaNUal Starte EE 5 10 Power TT E 5 13 Power unit assembly tiller handle modell 5 13 Power unit assembly remote control modell sss esse eee ee eee 5 15 Ignition coil and RechfierRegulator ee eee eee 5 17 CDI unit and junction box manual tilt modell 5 18 CDI unit and junction box power tilt modell sss esse sees eee eee 5 20 Bracket manual Starter modell 5 22 Bracket electric starter model 5 24 Ilan a ET 5 26 REMOVING the power unt 5 27 TAMING belt GNG S PIO EE 5 29 Re
182. se bolts 49 to the specified torque Ga Push the brushes into the holders and then install the armature and tighten the armature plate screw 8 to the speci fied torque S6AG7130 Armature plate screw 5 N m 0 5 kgf m 3 7 ft lb S6AG7075 T 4 Install a new O ring and the stator to the power tilt motor base di and then Power tilt motor base bolt og tighten the screws to the specified 5 N m 0 5 kgf m 3 7 ft lb torque S6AG7140 6AG3J 11 7 34 Bracket unit Power tilt gear pump power tilt model NNW Ox o gt NNW H 5 N m 0 5 kgf m 3 7 ft Ib S6AG 7030 Remarks 15 Filter 16 Gear pump housing 17 Drive gear 1 O ring 1 2 Manual valve 1 3 Pin 1 4 Spring 1 5 Manual release pin 2 6 Spring 1 Length 14 7 mm 0 58 in 7 Valve pin 2 8 Valve seal 2 9 Spring 1 Length 16 0 mm 0 63 in 10 Spring 2 11 Absorber valve pin 2 12 Ball 2 13 Bolt 6 M5 x 25 mm 14 Plate 1 2 1 1 7 35 6AG3 11 No 18 19 20 21 22 23 24 25 26 21 28 29 30 31 32 33 34 Driven gear Pin E clip Main valve seal O ring Shuttle piston 1 O ring Valve seat Main valve S pring S pacer Filter Shuttle piston 2 S pring Dowel O ring Ball 6AG3 11 Power tilt gear pump power tilt model NNW Ox o gt NNW H 5 N m 0 5 kgf m 3 7 ft Ib 20 S6AG 7030 Remarks Not reusable Not reusable Not reus
183. so that the throttle cam is in posi until its hole is aligned with the set pin on tion and then check that the shift the shift rod lever joint stopper is pulled in to position and that the shift lever can be operated Next turn the throttle grip to the fully open position so that the throttle cam is in posi tion and then check that the shift stopper is pushed out to position 24 Mpg and that the shift lever cannot be oper ated Gi S6AG 3130 N AA WARNING The shift cable joint must be screwed ina minimum of 8 0 mm 0 31 in 5 Connectthe shift cable joint install the clip and then tighten the locknut S6AG3460 6AG 3 11 3 10 7 ADJ Periodic check and adjustment 6 Adjustthe shift rod adjusting nut NOTE To adjust the shift rod adjusting nut see Installing the lower unit 6 17 7 Check the gear shift for smooth opera tion Checking the start in gear protection manual starter model CAUTION Be sure to remove the clip from the engine stop lanyard switch before check ing the start in gear protection 1 Set the shift lever to the forward or reverse position and then check that the starter 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 neutral position and loosen the locknut Align the cable end with the mark on the manual starter cove
184. switch Warning indicator M Power tilt motor power tilt model Terminal power tilt model Power tilt relay power tilt model 20 Power tilt switch power tilt model Power tilt model To remote control Color code B Black Br Brown G Green L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B R Black red G R Green red Gy B Gray black P B Pink black DAN Pink white W R White red Y B Yellow black Y R Yellow red Wahoo 15M Wahoo 20M B R ed Te B R Grp km GI oo 6 c dad LOCO INTRON 1 1 1 1 1 i 1 1 1 00 JOES ON 0 Gy B I lt Te Gy B D ell B P IT P T Wahoo 20EBT 7 Wahoo 15E Qe OG CS EG OG 98 OG QG OS L Lele L L _e L OG0000000 OOGGOGGB MD B R ed pn GIR sm C R Gell Kl G G LK G TE EISE Ia De HE Gr WR AT TE WR Br JCJ Br Br ef olf OG IL GOOG L re TR US d DOOOOGO OG OQGO0000000 GOGGOEGOMN OOGG B R _I gr Wahoo 20E Wahoo 20ET Wahoo 15E Gir LI cir wir LE wR Qa aszamo E gt EE A R
185. t ram to the specified torque a ID D e em 5 8 S6AG7245 Tilt ram 45 N m 4 5 kgf m 33 2 ft lb 7 44 Bracket unit 5 Install a new O ring and the backup ring 40 onto the tilt piston 6 Install the balls on absorber valve pins 02 and springs 43 as shown 7 Install the plate 44 washer and bolt to the tilt piston and then tighten the bolt to the specified torque S6AG7310 Tilt piston bolt 69 7 N m 0 7 kgf m 5 2 ft lb 8 Install a new O ring to the cylinder liner 48 and then install the cylinder liner into the tilt cylinder 9 S6AG 7320 9 Install the power tilt gear pump power tilt motor assembly and reservoir cap to the tilt cylinder 7 45 NOTE Er To install the power tilt motor assembly and gear pump assembly see Assembling the gear pump 7 39 10 Fill the tilt cylinder with the recommended fluid to about 60 x Recommended power tilt fluid ATF Dexron II 11 Install the backup ring 27 and a new O ring to the free piston and then install the free piston into the tilt cylinder dg S6AG731 1 12 Place the tilt cylinder end screw at the bottom of the tilt ram 13 Install the tilt piston assembly into the tilt cylinder 7 O D SEIT fe S6AG7330 6AG3 11 14 Tighten the tilt cylinder end screw to the Specified torque S6AG7225 Tilt cylinder end screw
186. t the flushing hose cooling water hose and fuel hose S6AG5D00 4 Remove the junction box cover and then remove the plastic ties and clamps 5 Disconnect the engine stop lanyard switch lead W Remove the bolt and engine stop lanyard switch lead B terminal Disconnect the engine start Switch leads R and Br 40 Manual tilt model Tiller handle model Remove the terminal nuts op and then disconnect the power tilt motor leads 02 and power tilt relay leads 43 Disconnect the power tilt switch coupler and power tilt switch leads R 45 Power tilt model 5 27 de SHY RES AER A gt S6AG5D03 Ole Z a 20 SE E W R O 7 ZN NA ch d Q KORN D SE de J ND PS S6AG5D04 KE aen JE S6AG5D06 Manual tilt model Tiller handle model P ower tilt model 6 Remove the junction box bracket 9 Manual tilt model Remove the power tilt relay 47 Power tilt model 6AG3 11 Power unit 7 Remove the warning indicator assembly and bracket 49 S6AG5D09 8 Disconnect the throttle cables from the throttle cam Tiller handle model Disconnect the cable joint from the throt tle cam Remote control model 9 Remove the bolts and then remove the shift rod cam Gm e S wal ba DL SLL MEGA Kap d L EST X pm NS S IZ 60 rep Jah DI gees RO Ve S6AG5D10 Tiller handle model Remote control model
187. t the power bobbin connec tors 3 Measure the power bobbin resistance Replace the stator coil assembly if out of Specification Power bobbin resistance reference data Blue L Blue L 0 77 1 04 Q at 20 C 68 F 4 Connect the power bobbin connectors Charging system electric starter model Checking the lighting coil 1 Disconnect the lighting coil connectors 2 Measure the lighting coil output peak voltage Replace the stator coil assembly if below specification 6AG3 11 Engine electric control system Charging system electric starter model S6AG8260 NOTE gt e To prevent the engine from starting when cranking It be sure to disconnect both Spark plug caps e Do not remove the clip from the engine stop lanyard switch Lighting coil output peak voltage Green G Green G Unloaded Unleaded mn 3 Measure the lighting coil resistance Replace the stator coil assembly if out of Specification Lighting coil resistance reference data Green G Green G 0 31 0 43 Q at 20 C 68 F 4 Connect the lighting coil connectors 6AG3 11 Checking the Rectifier Regulator CAUTION If the battery cables are connected in reverse the Rectifier Regulator can be damaged 1 Measure the Rectifier Regulator 07 out put peak voltage Check the Rectifier R egulator for continuity if the output peak voltage is below specification S6AG8270 NOTE e
188. tall the plunger and diaphragm into fuel pump body 1 and then install the pin to the plunger S6AG 4140 S6AG 4150 NOTE SE e Align the pin installation holes with the Slot in fuel pump body 1 and then install the pin while pushing the plunger and diaphragm completely inward e Turn fuel pump body 1 until the pin is 90 from the slots in fuel pump body 1 e Make sure that the projections on the diaphragm fit correctly into fuel pump body 1 2 Assemble the fuel pump as shown 6AG3 11 Fuel pump S6AG 4160 NOTE e Moisten the inside of the fuel pump with gasoline to ensure a good seal e Make sure that the diaphragms are kept in place through the assembly process e After disassembling and assembling the fuel pump check it for air leaks See Checking the fuel pump 4 6 6AG3J 11 4 8 ory Fuel system Carburetor unit S6AG4010 Ko Paname Joy Remarks Intake silencer Blowby hose Carburetor assembly Gasket S pacer Grommet Bolt Bolt O ring Plastic tie Throttle link rod Clamp Not reusable M6 x 100 mm WO COnN AD UB WYN ke Not reusable 1 1 1 2 1 1 2 1 1 1 1 1 4 9 6AG3 11 Carburetor unit Carburetor S6AG 4050 Remarks Screw Screw Retainer Prime Start O ring Screw Cover Gasket Throttle stop screw S pring Pin O ring S pring Screw Protector Carburetor body Float chamber 4 x 5 mm 4 x 10
189. te control model NOTE SE s The shift lever cannot be operated unless the throttle grip is in the fully closed posi tion Tiller handle model s The resistance of the throttle grip tiller han dle model or remote control lever remote control model can be adjusted using the throttle friction adjuster Q 3 Check that the shift lever cannot be set to the forward or reverse position when the grip is not in the fully closed position Tiller handle model S6AG1125 6AG3J1 1 4 Set the shift lever to the forward or reverse position and then check that the starter handle cannot be pulled If the starter rope can be pulled out normally adjust the start in gear protection cable Manual starter model S6AG1145 NOTE a To adjust the start in gear protection cable see Checking the start in gear protection manual starter model 3 11 Checking the steering system 1 Check the steering friction for proper adjustment Tiller handle model S6AG1100 NOTE SSS e To increase the friction move the steering lock lever in direction e To decrease the friction move the steering lock lever in direction 2 Check that the steering operates smoothly 6AG3J11 Predelivery check 56611060 S6AG1110 Tiller handle model Remote control model 3 Check that there is no interference with leads cables or hoses when the out board motor is steered es d General information Checking
190. ter modell Checking the gear ol Checking the gear oil level Checking the gear Dump eee Checking the gear shift and throttle operation sse eee eee eee Checking the gear shift operation remote control model Checking the gear shift operation tiller handle modell Checking the ignition Coil esere Checking the ignition epark eee eee Checking the ignition timing seeren Checking the lighting Coil seeren Checking the lower case Checking the lower unit for air leakage Checking the neutral switch remote control model Checking the neutral switch tiller handle model with electric SAET EEE Checking the oil pressure eseese Checking the oil pressure Switch seess Checking the oil DUMP sese eee eee eee Checking the oil strainer see ee eee eee Checking the outboard motor MOUNN NEON ae Checking the pinion and forward gear Checking the piston clearance eee eee Checking the piston diameter sss eee Checking the piston pin boss bore Checking the piston pin diameter Checking the piston ng Checking the piston ring end gap Checking the piston ring groove 66 Checking the piston ring side clearance 5 Checking the power bobbin TON PAME Sta Lasser Checking the power tilt fluid level Checking the power tilt motor sss eee eee Checking the power tilt relay Checking the po
191. that the shifting mechanism works properly and smoothly S6AG6371 Installing the water pump 1 Install the dowels 1 and outer plate car tridge Lower unit 2 Install the Woodruff key and impeller 4 to the drive shaft ar TE NOTE When installing the impeller onto the drive shaft align the groove in the impeller with the Woodruff key 3 Install the insert cartridge and a new O ring into the pump housing S6AG6570 NOTE Align the insert cartridge projection with the hole in the pump housing 4 Install the water pump housing assembly into the lower case and then install the rubber seal S6AG 6400 CAUTION Do not turn the drive shaft counterclock wise otherwise the water pump impeller may be damaged NOTE EE e Apply grease to the inside of the water pump housing e While turning the drive shaft clockwise push down on the water pump housing and install it e Align the projection on the rubber seal with the hole in the pump housing 5 Tighten the water pump housing bolts and outer plate cartridge bolts o to the Specified torque Water pump housing bolt 18 N m 1 8 kgf m 13 3 ft lb Outer plate cartridge bolt 49 18 N m 1 8 kgf m 13 3 ft lb Installing the lower unit 1 Setthe shift lever to the neutral position Tiller handle model Set the remote control lever to the neu tral position Remote control model
192. the armature if below specifica tion 569J8410 S6AG8470 Brush holder assembly continuity Commutator standard undercut 0 8 mm 0 03 in Wear limit 0 2 mm 0 01 in Checking points Brush Terminal Brush Brush Brush Terminal 2 Measure the length of each brush Replace if below specification 4 Check the armature for continuity Replace the armature If out of specifica tion S6AG 8460 i ol Armature continuity Checking points 569J8430 Commutator segments Segment Armature core Brush standard length 12 5 mm 0 49 in Wear limit 9 0 mm 0 35 in Checking the brush holder and brush 1 Check the brush holder assembly for continuity Replace if out of specification 6AG 3 11 8 16 ELEC 7 ELEC W s Electrical system Assembling the starter motor CAUTION Do not allow grease or oil to contact the commutator of the armature 1 Install the brush holder assembly into the bracket and then tighten the screws Q 2 Install the O ring spacer washer 6 and spring washer and then tighten the nut to the specified torque S6AG8490 S6AG 8480 S6AG8500 Starter motor terminal nut 0 4 N m 0 04 kgf m 0 30 ft lb NOTE e Align the projections on the stator with groove on the bracket and 3 Install the washer and armature into the bracket groove o
193. 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 NOTE o e Before measuring the peak voltage check all wiring for proper connection and corro sion and check that the battery is fully charged e Use the peak voltage adapter B with the recommended digital circuit tester e Connect the positive pin of peak voltage adapter B to the positive terminal of the dig ital tester and the negative pin to the nega tive terminal e When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode Tz Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 6AG3 11 Checking the electrical component Starter motor electric starter model Starter motor electric starter model 20 4 N m 0 04 kgf m 0 30 ft Ib S6AG8380 No Parname oy Remarks 1 Clip 1 2 Pinion stopper 1 3 Spring 1 4 Pinion stopper set 1 5 Pinion 1 6 Cover 1 7 O ring 2 8 Washer 1 t 1 0 mm 9 Shim 10 Washer 1 t 2 0 mm 11 Armature 1 12 Washer 1 t 0 25 mm 13 Stator 1 14 Brush holder assembly 1 15 Brush spring 2 16 Brush 1 1 17 Brush 2 assembly 1 6AG 3 11 8 12 sc 7 ELEC a Electrical system 27 Spring washer 28 Nut 0 4 N m 0 04 kgf m 0 30 ft Ib S6AG8380
194. ting the forward gear shim 1 Turn the taper roller bearing outer race 07 2 or 3 times to seat the rollers and then measure the bearing height M2 as shown gt I Tr aA S6AG6470J NOTE e Select the shim thickness T1 by using the specified measurement s and the calcula tion formula e Measure the bearing outer race at 4 points to find the height average vz Digital caliper 90890 06704 Shimming plate 90890 06701 2 Calculate the forward gear shim thick ness Calculation formula Forward gear shim thickness T1 16 60 M2 3 Select the forward gear shim s T1 as follows 6AG3J11 at 1 100th place Li H gt 8 Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Example If T1 is 0 23 mm then the forward gear shim is 0 22 mm If T1 is 0 30 mm then the forward gear shim is 0 28 mm Selecting the reverse gear shim 1 Remove the reverse gear and reverse gear shim s from the propeller shaft housing 2 Measure the propeller shaft housing height M3 as shown S6AG6480 6AG3 11 Shimming 10 mm 0 39 in S6AG6490 M3 M3 10 mm NOTE Measure the propeller shaft housing at 4 points to find the height average Z Digital caliper 90890 06704 Shimming plate 90890 06701 6 22 Lower unit 3 Turn the ball bearing 2 or 3 times and then measure the height from the ball bearing M4 as sh
195. tput KW 0 60 Cranking time limit Second 30 Stator motor clearance mm in 0 05 0 25 0 002 0 010 Wear limit mm in 0 6 0 02 Brushes Standard length i 12 5 0 49 Wear limit i 9 0 0 35 Commutator Standard diameter i 30 0 1 18 Wear limit 29 0 1 14 Standard undercut 0 8 0 03 Wear limit 0 2 0 01 Pinion stopper height 26 5 28 5 1 04 1 12 C1 Ambient temperature 24 C 75 F with no power supplied The figures are for reference only 2 The figures are for reference only lt lt lt lt lt lt 6AG3J11 2 22 SPEC naan Specification Charging system Fuse Lighting coil output peak voltage G G at cranking unloaded at 1 500 r min unloaded at 3 500 r min unloaded Lighting coil resistance G G at 20 C 68 F 0 31 0 43 Rectifier Regulator output peak voltage R B at 1 500 r min unloaded at 3 500 r min unloaded Power tilt motor Output Brushes Standard length Wear limit Commutator Standard diameter Wear limit Standard undercut Wear limit C1 The figures are for reference only 2 23 GAG3J11 Dimension Exterior 15M 15EB 20M 6AG3J11 xr O gt SS 341 13 4 598 23 5 Maintenance specification 45 Se OO kb CH Tr CN Si CO kb 4 CH b es SS or Oo Nr Oo Ne Tr 959 22 0 S 730 28 7 381 15 0 L 847 33 3 219 8 6 mm in S6AG2010 2 24 SPEC Specification Exterior 20EBT 32
196. ugh tube from the port side NOTE When installing the through tube hook tilt lock rod 1 onto the tilt lock lever 4 Install the self locking nut onto the through tube and then tighten it to the Specified torque S elf locking nut 19 N m 1 9 kgf m 14 0 ft lb 5 Install the tilt stopper plates and tilt Stopper plate bolts to the swivel bracket and then tighten the bolts to the Specified torque Tilt stopper plate bolt 8 N m 0 8 kgf m 5 9 ft lb 6 Install the collar and clamp bracket bolt 42 and then tighten the clamp bracket nut 43 7 Install the tilt pin 49 8 Apply grease to all grease nipples until it comes out from the areas S6AG 7843 NOTE To check the tilt operation see Checking the tilt system manual tilt model 1 17 7 24 Bracket unit Clamp bracket and swivel bracket power tilt model 16 0 go 13 19 N m 1 9 kgf m 14 0 ft Ib 24 N m 2 4 kgf m 17 7 ft Ib 6 Heels 13 A 24 N m 2 4 kgf m 17 7 ft Ib pls 8N m 8 N m 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib S6AG7760 No Part name Remarks 1 Cap 2 2 Self locking nut 2 3 Through tube 1 4 Hanger 1 5 Swivel bracket 1 6 Clamp bracket 1 STBD 7 Clamp bracket 1 PORT 8 Shaft 1 9 Collar 1 10 E clip 1 11 Collar 2 12 Stopper 2 13 Nut 2 14 Washer 2 15 Bolt 1 16 Plug 14 L L
197. urn the drive shaft clockwise and ee counterclockwise and measure the back lash when the drive shaft stops in each wz Stopper guide plate 90890 06501 direction d gjen GEN puller claw S NOTE l e Pull the drive shaft downward and then Center bolt 90890 06504 unii e Measure the backlash at 4 points to find the Center bolt average 2 N m 0 2 kgf m 1 5 ft lb Forward gear backlash 6 Turn the lower unit upside down 0 18 0 87 mm 0 0071 0 0343 in 7 Install the backlash indicator onto the EK drive shaft 13 mm 0 51 in in diameter 9 Adjust the current shim thickness l t e and then install the dial gauge forward gear backlash is out of specifica tion Forward gear rn Shim thickness Less than To be decreased by 0 18 mm 0 0071 in 0 53 M x 0 43 More than To be increased by 0 87 mm 0 0343 in M 0 53 x 0 43 M Measurement Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 10 Remove the special service tools from the propeller shaft S6AG6530 6AG 3 11 6 24 Lower unit 11 Install the propeller washer and nut without installing the spacer oO S6AG6540 12 Tighten the propeller nut to the specified torque Propeller nut 2 N m 0 2 kgf m 1 5 ft lb 13 Turn the lower unit upside down 14 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in
198. ushing 2 a new O ring and the plate onto the swivel bracket BNO A Sg 7 18 Bracket unit 4 Apply grease to the grease nipple on the swivel bracket until it comes out from the upper bushing S6AG7740 NOTE To assemble the clamp brackets see Install ing the clamp bracket 7 24 or Installing the clamp bracket 7 28 Installing the upper case 1 Install the upper case assembly to the clamp bracket 2 Install the plate and upper mounting nuts Q and then tighten the upper mounting nuts to the specified torque 3 Install the rubber dampers small large and front and then install the mount housings 6 and ground lead ter minal using the mount housing bolts and and the mount housing nuts dO NOTE o e Be sure to remove any oil from the mount housing bolts and e Install the ground lead terminal so that it is within the range shown 4 Tighten the mount housing nuts 0 to the Specified torques in 3 stages and in the sequence shown NOTE _ ___ Tighten the mount housing nuts evenly and in the following order 1H2 H3H41 5 Install the ground lead terminal on to the swivel bracket 7 19 6 Install the ground lead terminal 42 to the upper case as shown S6AG 7680 Upper mounting nut 40 N m 4 0 kgf m 29 5 ft lb Mount housing nut 49 lst 15 N m 1 5 kgf m 11 1 ft lb 2nd 28 N m 2 8 kgf m 20
199. ver clockwise so that it contacts the carbure tor body as shown 4 Turn the free accel lever clockwise until it contacts the throttle cam 5 Tighten the throttle link stopper screw 07 6 Turn the throttle grip tiller handle model or remote control lever remote control model to the fully open and fully closed positions and check that the throttle cam Operates smoothly NOTE o After adjusting the throttle link adjust the engine idle speed See Checking the engine idle speed 3 11 Checking the gear shift operation tiller handle model 1 Check that the gear shift operates smoothly when the shift lever is shifted from the neutral position to forward or reverse Adjust the shift rod adjusting nut if necessary 6AG3J11 Control system Checking the gear shift operation S remote control model TE 1 Check that the gear shift operates smoothly when the remote control lever is shifted from neutral position to forward or reverse Adjust the shift cable length and shift rod adjusting nut if necessary 2 Set the remote control lever to the neu tral position 3 Loosen the locknut remove the clip and then disconnect the shift cable joint N Sr FT S6AG3471 pe NOTE To adjust the shift rod adjusting nut 07 see Ce Installing the lower unit 6 17 S6AG 3400 2 Turn the throttle grip to the fully closed 4 Adjust the position of the shift cable joint position
200. wards the engine to remove any free play in the cable before adjusting the position of the throttle cable joint D Connect the throttle cable joint install the clip and then tighten the locknut 2 3 8 CHK Q ADJ Periodic check and adjustment 7 Set the remote control lever to the fully open and fully closed positions and check that the fully open stopper and fully closed stopper on the throttle cam contact the throttle cam bracket as shown S6AG 3370 Fully open position Fully closed position 8 Connect the throttle link rod to the free accel lever NOTE After adjusting the throttle cables adjust the throttle link Tiller handle model After adjusting the throttle cable adjust the throttle link Remote control model Adjusting the throttle link 1 Loosen the throttle link stopper screw oy eg 46 op den e oN 2 O UG gt ER S6AG 3350 3 9 2 Turn the throttle grip tiller handle model or remote control lever remote control model to the fully open position and hold it In place Check that the fully open stop per on the throttle cam contacts the throttle cam bracket NOTE Sa If the fully open stopper does not contact the throttle cam bracket adjust the throttle cable s See Adjusting the throttle cable tiller handle model 3 7 or Adjusting the throttle cable remote control model 3 8 3 Turn the carburetor throttle le
201. wer tilt switch Checking the power tilt system power tilt model arioso Checking the Prime Start Checking the propeler AAA Checking the propeller chatt Checking the propeller shaft housing Checking the puleercoil eee eee Checking the Rectifier Regulator Checking the rocker arm and rocker arm RE EE Checking the shift rod AAA 6 13 Checking the spark olug eee e 3 5 Checking the spark plug Cap 8 22 Checking the starter motor sees eee 8 15 Checking the starter motor operation 8 14 Checking the starter motor pinion 8 14 Checking the starter relay electric starter modell 8 21 Checking the start in gear protection manual starter modell 3 11 Checking the steering operation tiller handle modell 3 13 Checking the steering system see 1 16 Checking the thermostat 3 6 Checking the thermoswlitch sss eee 8 25 Checking the tilt cylinder and piston 7 43 Checking the tilt operation manual tilt modell 3 13 Checking the tilt operation power tilt modell sss esse eee eee 3 13 Checking the tilt system manual tilt modell 1 17 Checking the timing Delt 3 5 Checking the timing belt and sprocket 5 31 Checking the top Cowlmg eee eee e 3 2 Checking the Valve eee eee eee eee 5 39 Checking the valve cdearance sees eee 5 2 Checking the valve guide seisseen 5 39 Checking the valve seal eee 7 38 Checking the valve seat
202. wer tilt switch Check the power tilt 7 49 malfunction Switch Short open or Check the wiring WD loose connection of harness continuity the wiring harness Power tilt relay mal Check the powertilt 7 48 function relay Disassemble and check the power tilt motor Power tilt motor Manual valve left Manual valve mal Check the manual operates butthe tilt open function valve ram does not Insufficient power Add sufficient fluid extend tilt fluid Power tilt fluid leak Check the power tilt age unit for leakage Clogged filter Disassemble and Clogged fluid pas check the power tilt Sages unit P ower tilt motor malfunction Power tilt motor Short open or Check the wiring does not operate loose connection in harness continuity power tilt motor cir cuit Malfunction of the power tilt unit inter nal parts WD See the wiring diagram 9 7 6AG3 11 Troubleshooting the outboard motor Symptom 1 Power tilt unit does not hold the outboard motor up Symptom 2 Cause 2 Checking step Manual valve left Manual valve mal Check the manual open function valve Insufficient power Add sufficient fluid tilt fluid Power tilt fluid leak Check the power tilt age unit for leakage Disassemble and check the power tilt unit Clogged fluid pas sages Malfunction of the power tilt unit inter nal parts 6AG 3 11 9 8 TRBL P SHTG Troubleshooting Troubleshooting the lower unit Symptom 1 Shift mec
203. worn Check the Woodruff key and the keyway in the drive shaft Replace if worn or deformed 6AG3 11 Lower unit Propeller shaft housing Propeller shaft housing BN mi 0 8 kgf m 5 9 ft Ib S6AG6070 Partname Shift plunger Dog clutch Cross pin Cross pin ring S pring Washer Reverse gear O ring Reverse gear shim Ball bearing Needle bearing O ring Bolt Propeller shaft housing Oil seal Propeller shaft OO N DD UB WN bm KA k k KA KA k b KA Not reusable Not reusable Not reusable Not reusable M6 x 20 mm Not reusable G KM a KM a Pe 6AG 3 11 6 6 Lower unit Removing the propeller shaft housing assembly 1 Remove the bolts from the propeller shaft housing 2 Remove the propeller shaft housing and then remove the propeller shaft Ae Ca f Gu S6AG6080 Stopper guide plate 90890 06501 Center bolt 90890 06504 Bearing housing puller claw S 90890 06564 Disassembling the propeller shaft assembly 1 Remove the shift plunger O from the propeller shaft 2 Remove the cross pin ring and then remove the cross pin and dog clutch 4 3 Pull out the spring from the propeller Shaft S S6AG6090 6 7 Disassembling the propeller shaft housing assembly 1 Remove the reverse gear and shim s S6AG6100 De S6AG6110 CAUTION Do not reuse the bearing always r
204. y bolt 8 N m 0 8 kgf m 5 9 ft lb 6AG3 11 12 Tighten the flywheel magnet nut to the Specified torque a 3 A LC Z fs an 1 7 S6AG5G40 AA WARNING Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily Flywheel holder 90890 06522 Flywheel magnet nut do 108 N m 10 8 kgf m 79 7 ft lb 13 Install all parts removed during disas sembly 6AG3 11 Power unit check and adjustment 5 6 Manual starter manual starter model S6AG 5500 No Part name Remarks 1 Cover 1 2 Sheave drum 1 3 Drive pawl 1 4 Spiral spring 1 5 Drive plate 1 6 Drive pawl spring 1 1 7 Spring 1 8 Drive pawl spring 2 1 9 E clip 1 10 Screw 1 5 x 20 mm 11 Spring 1 12 Starter plunger 1 13 Cover 1 14 Drain hose 1 15 Screw 2 4x 16 mm 16 Packing 1 1 17 Starter handle 5 7 6AG3J 11 Manual starter manual starter model 21 NR Pa 11 wh Ke CH p Cee SS a S6AG 5500 Part name i Remarks Cap Starter rope 1 800 mm 70 9 in Start in gear protection cable Bolt M6 x 20 mm S pring Driven sprocket cover 6AG 3 11 5 8 Disassembling the manual starter 1 Remove the drive plate and drive pawl Spring 1 S6AG5510 WARNING The sheave drum can pop out Hold the sheave drum with your hand and then remove the drive plate 2 Remove the sheave drum

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