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Pike 9,9 - English

1. S6AU8002 a H model short Pulser coil b H model long Warning indicator Engine shut off switch lead Lighting coils Oil pressure switch Spark plug Rectifier Regulator Charge coil CDI unit 8 3 6AU3K11 Electrical component and wiring harness routing Route the oil pressure switch lead in the direction shown Fit the oil pressure switch lead into the groove in the driven sprocket cover Bend the side of the junction box outward as shown To tiller handle Route the warning indicator lead under the shift cable k 9 0 a gt 6AU3K11 8 4 Erec ELEC m Electrical system H model with electric starter
2. S6AU 8064 a E model Warning indicator Engine shut off switch Engine start button E model Engine shut off switch lead 8 15 6AU3K11 Electrical component and wiring harness routing A Route the engine shut off switch lead under the throttle cables B Route the engine shut off switch lead as shown making sure that the lead does not contact the throttle shaft C Fasten the engine start button lead at the white tape with a plastic tie Install the plastic tie as shown E model D Align the blue tape on the engine start button lead with the grommet in the bottom cowling Position the Slack in the engine start button lead toward the tiller handle E model 6AU3K11 8 16 ELEC ELEC m Electrical system H model long S6AU8065 a E model Warning indicator Engine shut off switch Engine start button 8 17 6AU3K11 Electrical component and wiring harness routing
3. S6AU8003 a MT model CDI unit b PT model Neutral switch Fuse 10 A Lighting coils PT relay PT model Oil pressure switch Warning indicator Spark plug Pulser coil Rectifier Regulator Engine shut off switch lead Starter motor Engine start button lead Charge coil Battery cable 8 5 6AU3K11 Electrical component and wiring harness routing PT switch lead PT model Install the terminal plate making sure that it contacts the PT relay PT model Route the lighting coil lead to the outside of the crankcase pin Route the oil pressure switch lead in the direction shown Fit the oil pressure switch lead into the groove in the driven sprocket cover Bend the side of the junction box outward as shown Route the battery cable under the bracket Route the warning indicator lead under the shift cable Fasten the PT motor lead with the holder making sure that there is no slack in the lead PT model E el mme Ez 6AU3K11 8 6 evec ELEC m Electrical system R model S6AU8004C Lighting coils PT relay PT model Oil pres
4. S6AU8005 Pulser coil PT relay lead R Fuse 10 A E model Starter motor E model Starter relay E model Neutral switch E model PT relay PT model PT motor leads Sb Lg PT relay leads Sb Lg Negative battery cable 8 9 6AU3K11 Electrical component and wiring harness routing gt Pass the PT motor leads Sb Lg and PT relay leads Sb Lg through the caps and then connect the leads to the terminals and cover the connections with the caps Be sure to pass leads of the same color through the caps and connect them to the same terminal PT model Jo Fasten the PT relay leads Sb Lg R PT model PT motor lead PT model and wiring harness connector R to the bracket with a plastic tie 0 Install the terminals of the negative battery cable and PT relay lead R PT model using the bolt as shown 6AU3K11 8 10 evec ELEC si Electrical system Port view M model with 1 lighting coil Pulser coil Rectifier Ignition coil Spark plugs Rectifier connector R Pulser coil connectors pulser coil to CDI unit W R B Rectifier connectors Rectifier to CDI unit G G 8 11 S6AU8062 Charge coil connectors charge coil to CDI unit L Br Ignition coil connectors ignition coil to CDI unit O B Oil pressu
5. A Route the engine shut off switch lead under the throttle cables B Route the engine shut off switch lead along the tiller handle bracket so that it does not contact the throttle shaft and then route it and the throttle cables through the corrugated tube C Fasten the engine start button lead at the white tape with a plastic tie Install the plastic tie as shown E model D Align the blue tape on the engine start button lead with the grommet in the bottom cowling Position the Slack in the engine start button lead toward the tiller handle E model 6AU3K11 8 18 evec ELEC Re 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 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 NO
6. Bottom cowling Remarks Grommet Collar Rubber seal Water outlet Grommet Grommet Grommet Screw Bracket Fuel joint Bracket Bolt Cable guide Adapter Bolt Nut Bracket 6AU3K11 OD E EE EE NE STE EE H model R model 6 x 20 mm H model H model M6 x 10 mm H model H model M6 x 12 mm R model R model R model 7 16 Bracket unit Upper case and steering arm a Oo 120 N m 2 0 kgf m 14 8 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 12 N m 1 2 kgf m 8 9 ft Ib LAN m 1 4 kgf m 10 3 ft Ib EE S6AU7016 P art name Remarks LO ON AU P GA A KE 7 17 Steering arm L transom model S transom model Washer Bushing 1 Bushing 2 O ring Plate Grease nipple Water seal rubber Water pipe Hose Nut Plate Upper case assembly Rubber damper Mount housing Nut Rubber damper Not reusable L transom model S transom model L transom model S transom model PRNNPFP k A k k k k k k k k k H 6AU3K11 Upper case and steering arm 7 N m 0 7 kgf m 5 2 ft Ib 12 N m 1 2 kgf m 8 9 ft Ib LAN m 1 4 kgf m 10 3 ft Ib Partname Remarks 20 N m 2 0 kgf m 14 8 ft Ib S6AU7016 Bolt M6 x 55 mm Ground lead Bolt Screw ob 7 mm 6AU3K11 M6 x 85 mm 7 18 Bracket unit S6AU7017 Remarks a Oo LO O
7. S6AU8063 Fuse 10 A E model Rectifier Regulator connector Rectifier Pulser coil Regulator to fuse and engine start button R Starter motor E model Rectifier Regulator connector Rectifier Rectifier Regulator Regulator to PT switch R Spark plugs Pulser coil connectors pulser coil to CDI unit Ignition coil W R B Starter relay E model Rectifier Regulator connectors Rectifier PT relay PT model Regulator to CDI unit G G W Rectifier Regulator connector G 8 13 6AU3K11 Electrical component and wiring harness routing Charge coil connectors charge coil to CDI unit L Br Oil pressure switch connector oil pressure switch to CDI unit P Warning indicator connectors warning indicator to CDI unit Y R P Engine shut off switch connector engine shut off switch to CDI unit Y Emergency circuit connector CDI unit to CDI unit W A 35 mm 1 38 in B 15 mm 0 59 in ICT 55 mm 2 17 in D Fasten the charge coil lead and lighting coil lead with a plastic tie as shown so that they are not pinched when the flywheel magnet and ignition coil bracket are installed E Fasten the Rectifier Regulator lead to the starter motor bracket with plastic ties before installing the starter motor Cut off the excess end of each plastic tie 6AU3K11 8 14 Erec ELEC ai Electrical system H model short
8. S6AU5160 NOTE Do not get any sealant on the main bearings 10 Install the crankcase onto the cylinder block and then tighten the crankcase bolts to the specified torques in 2 stages and in the sequence shown D S6AU5150 NOTE EDER Apply engine oil to the threads of the crank case bolts before installation Crankcase bolt 1st 15 N m 1 5 kgf m 11 1 ftlb 2nd 30 N m 3 0 kgf m 22 1 ft lb 5 50 11 Install the relief valve and tighten it to the specified torque S6AU5162 NOTE sn mnd Apply a thin coat of engine oil to the O ring of the relief valve before installation Relief valve g 8 N m 0 8 kgf m 5 9 ft lb 12 Install a new gasket the thermostat and the thermostat cover Thermostat cover bolt 8 N m 0 8 kgf m 5 9 ft lb 13 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 U Gg S6AU5163 Exhaust cover bolt Ist 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 5 51 2 Install the dowels a new gasket and the power unit and then tighten the mounting bolts to the specified torque CAUTION Do not reuse the gasket always replace it with a new one S6AU5164 P
9. S6AU1040 NOTE Make sure that the cooling water hoses are securely connected and that the flushing hose joint adapter for Europe is not loose or damaged 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 varying speeds up to 2 000 r min or approximately half throttle then for another hour increase engine speed as much as necessary to put the boat on plane but avoid full throttle operation 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 ee The test run is part of the break in operation Break in Run the engine under load in gear with a propeller installed for 10 hours as follows 1 For the ist hour of operation Run the engine at varying speeds up to 2 000 r min or approximately half throttle 2 For the 2nd hour of operation Increase engine speed as much as nec essary to put the boat on plane but avoid full throttle operation then back off on the throttle while keeping the boat at a planing speed 3 Remaining 8 hours Run the engine at any speed However avoid operating at full throttle for more than 5 minutes at a time 4 After the 1st 10 hours Operate the engine normally 69J1
10. E S6AU6113 CAUTION Do not reuse the bearing always replace it with a new one NOTE SE Fit the hooks of the puller claw into the slots in the lower case Z Stopper guide plate D 90890 06501 Bearing puller assembly 90890 06535 6 32 Lower unit 2 Remove the needle bearing from the lower case S6AU6114 CAUTION Do not reuse the bearing always replace it with a new one Cz 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 2 mia Sa S6AU6115 6 33 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 Assembling the lower case 1 Install a new taper roller bearing outer race OD S6AU6117 C Driver rod LL 90890 06605 Bearing outer race attachment 90890 06625 2 Install a new needle bearing
11. S6AU5103 6AU3K11 Cylinder head 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 EEE To check the valve seat contact area see Checking the valve seat 5 31 Checking the rocker arm and rocker arm shaft 1 Check the rocker arms rocker arm shaft and contact surface of each rocker arm Replace if worn 2 Measure the rocker arm inside diameter and rocker arm shaft outside diameter Replace if out of specification S6AU5104 Rocker arm inside diameter 13 000 13 018 mm 0 5118 0 5125 in Rocker arm shaft outside diameter 12 941 12 951 mm 0 5095 0 5099 in 5 34 Checking the camshaft 1 Measure the cam lobe Replace if out of specification D S69J5950 Cam lobe Intake and exhaust 23 45 23 55 mm 0 9232 0 9272 in Cam lobe Intake and exhaust 19 95 20 05 mm 0 7854 0 7894 in 2 Measure the camshaft runout Replace if above specification S6AU 5106 AS Camshaft runout limit 0 03 mm 0 0012 in 3 Measure the camshaft journal diameter and the cylinder head journal inside diameter Replace the camshaft cylin der head or both if out of specification 5 35 S6AU5107 Camshaft journal diamete
12. S6AU5128 4 Remove the crankcase bolts in the sequence shown S6AU5129 5 Remove the crankcase 5 41 I re T S6AU5177 NOTE TL Insert a flathead screwdriver between the tabs of the crankcase and the cylinder block to separate them 6 Remove the connecting rod caps and then remove the connecting rod and pis ton assemblies S6AU5178 7 Remove the crankshaft main bearings and oil seals NOTE EE EEE Be sure to keep the main bearings in the order as they were removed 8 Remove the piston pin clips and pis ton pin and then remove the piston 6AU3K11 NOTE To avoid interchanging the pistons connect ing rods and connecting rod caps mark each with an identification number of the corresponding cylinder and be sure to keep them in the order as they were removed 9 Remove the piston rings Checking the piston diameter 1 Measure the piston diameter at the spec ified measuring point Replace if out of specification S6AG5850 Piston diameter 55 950 55 965 mm 2 2028 2 2033 in Measuring point 1 5 mm 0 06 in up from the bottom of the piston skirt Oversize piston diameter Oversize 1st 56 200 56 215 mm 2 2126 2 2132 in Oversize 2nd 56 450 56 465 mm 2 2224 2 2230 in 6AU3K11 Cylinder block Checking the cylinder bore 1 Measure the cylinder
13. 4 Install a new O ring and the stator on to the PT motor base and then tighten the screws 9 S6AU 7076 PT motor assembly bolt gg 5 N m 0 5 kgf m 3 7 ft lb S6AU7075 NOTE __ gt Align the rounded section of the stator with the rounded section of the PT motor base 5 Install a new O ring the pin the manual valve 5 and a new O ring to the PT motor assembly 6 Install a new gasket and the PT motor assembly to the tilt cylinder and then tighten the PT motor assembly bolts to the specified torque 6AU3K11 7 40 Bracket unit PT gear pump O O a 30 vil LU Sam WW Dee wu Teo oJ Oo O SN m 0 5 kgf m 3 7 ft Ib S6AU7077 Part name 4 Remarks Not reusable O ring Manual valve Pin Spring Manual release pin Spring Valve pin Valve seal Spring Bolt Filter Spring Absorber valve pin Ball Gear pump housing Drive gear Pin Length 14 6 mm 0 57 in Length 18 3 mm 0 72 in M5 x 25 mm Nere NNN HO PNN HN k k k HR 7 41 6AU3K11 PT gear pump O O a 30 vil LU Sam WW Dee MN Teo y O O 5 N m 0 5 kgf m 3 7 ft Ib S6AU7077 Part name i Remarks Driven gear E clip Main valve seal O ring Shuttle piston 1 Down main valve O ring Valve seat Main valve Spring Spacer F ilter Shuttle piston 2 Spring Up main valve O ring Ba
14. Remove the dowels from the lower case H lt e S6AU6007 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 N SA Check the impeller insert cartridge and outer plate cartridge Replace if cracked or worn Check the Woodruff key and the keyway in the drive shaft Replace if worn or deformed 6AU3K11 Lower unit Propeller shaft housing Propeller shaft housing S6AU6008 No Remarks 1 2 3 4 5 6 7 8 Partname lt Cross pin Dog clutch Cross pin ring Shift plunger Spring Propeller shaft Washer Reverse gear Reverse gear shim Ball bearing O ring O ring Propeller shaft housing Bolt Bushing Oil seal LA ki ke kb kb ki om Not reusable Not reusable Not reusable M6 x 16 mm Not reusable Not reusable NPNP PPR 6AU3K11 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 assembly S6AU6009 NOTE e Insert flat head screwdrivers between the propeller shaft housing assembly and the lower case to pry the assembly loose e If the propeller shaft housing
15. 1 14 Checking the battery Eimod lii ssh than den 1 14 Connecting the throttle cable and shift cable R model 1 14 Checking the gear shift and throttle operation 1 15 Checking the steering system ENNEN 1 16 Checking the tilt system MT model 1 17 Checking the PT system PT model 1 17 Checking the engine start button or switch and engine shut off switch 1 17 Checking the cooling water pilot hole 1 19 TEST EE 1 19 BGA HIT eege TR osama daa antag genee 1 19 After TSS EE 1 19 Precaution when transporting or storing the outboard motor 1 20 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 e 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 The component list consists of part names and quantities as well as bolt and screw dimensions see in the figure below e Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point see 3 in the figure below Tightening torque specifications are provided in the exploded diagrams see in the figure below for an example and in the related detailed instructions Some torque specifications are listed in stages as torque figure
16. 4 14 LH Power unit Power unit check and adjustment ss sssssssssssunsssunnnnunnnnnnnnnnnnnnnnunnnnnnnnnnnnnn nna 5 1 Checking the compression pressure ENEE 5 1 Checking the valve clearance a nana anaa aana anana anna 5 1 Replacing the timing ag iere Ee Ne s 5 3 Manual starter M model 5 6 Disassembling the manual starter 5 8 Checking the manual starter 5 8 Assembling the manual EE 5 9 Power UNE isa seacenvancanndscninicersdrctvasdensastuvanveavedvavacssssarnaeearaavsavaviaiseuactavaatersdicates 5 12 Power unit SSE E 5 12 Ignition coil CDI unit and Rectifier M modell 5 14 Ignition coil CDI unit and Rectifier Regulator E modell 5 15 Throttle cam and oil pressure switch anane a nana anana ena aen 5 17 Retenuen ee tere 5 18 Timing belt and SHPO C KOE EN 5 19 Removing the timing belt and Sprocket ANN 5 21 Checking the timing belt and eprocket AA 5 22 Installing the sprocket and timing belt ssrrnaaanarrrnnnavrrrnnennvvrrnnnnnnrrnssrrnnnr 5 22 Cylinder Nedd E 5 25 Removing the cylinder head nesuuausbensnnvmusvitneninkfjeinten 5 28 Disassembling the cylinder head 5 28 Checking the Cylinder heat nn ne Re 5 29 Checking the valve spring 5 29 UE negen VAN Ja 5 30 Checking the valve guide VV 5 30 Replacing the valve UI 5 31 Checking the valve seat 5 31 Refacing the valve S at der Eed EENS 5 32 Checking the rocker arm and rocker arm Shaft AA 5 34 Checking the camshaft
17. J S6AU1032 Checking the PT system PT model 1 Check that the outboard motor tilts up and down smoothly when operating the PT switch L S6AU1033 A H model B R 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 Checking the engine start button or switch and engine shut off switch 1 Check that the engine starts when the engine start button is pushed H model Check that the engine starts when the engine start switch is turned to START R model 6AU3K11 S6AU1035 A H model B R model 2 Check that the engine turns off when the engine shut off switch is pushed H model Check that the engine turns off when the engine start switch is turned to OFF R model S6AU1047 a T A S6AU1036 6AU3K1 1 Predelivery check S6AU1035 A H model short B H model long C R model 3 Check that the engine turns off when the clip is pulled from the engine shut off switch S6AU1048 fg I gt S6AU1038 69J1220 A H model short B H model long C R model an General information Checking the cooling water pilot hole 1 Place the lower unit in water and then start the engine 2 Check for water flow at the cooling water pilot hole
18. Brush Brush Brush Q Terminal 4 Check the armature for continuity Replace the armature if out of specifica tion 2 Measure the length of each brush Replace if below specification S6AU8017 Armature continuity S69J8430 Checking points Continuity Commutator segments Yes Segment Armature core No Segment Armature shaft No 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 6AU3K11 8 24 evec E ELEC ze 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 2 Install the O ring spacer washer and spring washer and then tighten the nut to the specified torque S6AU8020 Starter motor terminal nut 0 4 N m 0 04 kgf m 0 30 ft lb 3 Install the washer and armature into the bracket 4 Install the stator on washer shim s washer and cover and then tighten the bolts 49 8 25 S6AU8021 S6AU8022 NOTE gt e Install the stator so that the line mark is toward the bracket Align the projections on the stator with the groove in t
19. S L i 1 187 46 7 1 255 49 4 Transom height 552 21 7 620 24 4 Boat transom height S L i 508 20 0 X i 635 25 0 Weight with aluminum propeller S For Europe For Oceania L For Europe 49 1 108 For Oceania 49 1 108 X 50 2 111 2 1 6AU3K11 Item Unit General specification Performance Maximum output Full throttle operating range Maximum fuel consumption Engine idle speed kW HP r min L US gal Imp gal hr r min 7 3 9 9 at 5 500 r min 5 000 6 000 3 9 1 0 0 9 at 6 000 r min 1 050 50 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 Maximum generator output Spark plug Cooling system Exhaust system Lubrication system cm cu in mm in 4 stroke L 2 212 12 9 56 0 x 43 0 2 20 x 1 69 9 4 Tiller handle Manual Remote control Electric Carburetor Choke valve CDI micro computer Micro computer BTDC 53 12 80 12 6 0 BR6HS 10 NGK Water Propeller boss Wet sump Fuel and oil Fuel type Engine oil type Engine oil grade Engine oil quantity Gear oil type Gear oil grade Gear oil quantity API SAE L US at Imp qt API SAE cm US oz Im
20. e Before installing the lower unit make sure that the locknut is removed from the shift rod e When installing the lower unit make sure that the water pipe is inserted securely into the rubber seal Lower case mounting bolt 18 N m 1 8 kgf m 13 3 ftlb 4 Install the locknut and then screw the adjusting nut onto the shift rod 6AU3K11 NG S6AU6059 ZX Screwed in length 8 0 9 0 mm 0 31 0 35 in 5 Tighten the locknut NOTE TT After connecting the shift rod check that the gear shift operates properly 6 Install the anode and cooling water inlet covers and then tighten the anode bolt to the specified torque es A 572 S6AU6138 Anode bolt 8 N m 0 8 kgf m 5 9 ft lb 7 Install the propeller and propeller nut 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 6AU3K11 Drive shaft and lower case high thrust model S6AU6139 A WARNING e Do not hold the propeller with your hands when loosening or tightening it lt Be sure to disconnect the battery cables from the battery and remove the clip from the engine shut off switch E model NOTE eebe If the holes in the propeller nut do not align with the cotter pin hole tighten the nut until they are aligned Propeller nut 21 Nm 2 1 kgf m 15 5 ft lb 8 Fill the lower
21. 3 N m 0 3 kgf m 2 2 ft Ib SW Part name Remarks a Oo o On Un P DI NN Hm Shift lever Screw Bolt Washer Wave washer Bushing Shift lever cam E clip Holder Bolt Holder Shift cable Throttle cable Throttle friction adjuster Cotter pin Friction piece Engine shut off switch 96 x 10 mm M8 x 30 mm M6 x 16 mm A k k k M k k P k k k N k k RUH 6AU3K11 7 6 Bracket unit sa 3 N m 0 3 kgf m 2 2 ft Ib SW P art name Remarks Tiller handle Plate Bolt Spring Screw Grip Washer Spring Washer Bushing Throttle shaft Plate Plastic tie PT switch Bracket Screw Screw M6 x 20 mm 95 x 20 mm PT model PT model 6 x 16 mm PT model 6 x 16 mm PT model GA FA k k NHH k k k k k k k kA k k ob 7 7 6AU3K11 Removing the tiller handle 1 Disconnect the engine shut off switch leads engine start button leads E model and PT switch leads PT model 2 Remove the manual starter M model Remove the PT relay PT relay bracket PT model starter relay and starter relay bracket E model NOTE 0 To remove the parts see Electrical compo nent and wiring harness routing 8 1 3 Remove the nut and disconnect the shift cable S6AU7003 4 Disconnect the throttle cables from the throttle cam S6AU7004 5 Remove the tiller handle NOTE JE See the
22. M model Remove the driven sprocket cover and flywheel magnet cover E model 2 Disconnect the spark plug caps and remove the spark plugs 3 Remove the fuel hoses fuel pump blowby hose and cylinder head cover S6AU5003 4 Turn the flywheel magnet clockwise and align the TA mark on the driven sprocket with the A mark on the thermostat cover 6AU3K11 S6AU5004 5 Measure the intake and exhaust valve Clearances for cylinder 1 Adjust if out of specification S6AU5005 NOTE Note the measurement data Valve clearance Intake 0 15 0 20 mm 0 006 0 008 in Exhaust 0 20 0 25 mm 0 008 0 010 in 6 Loosen the rocker arm locknut and then turn the adjusting screw until the specified valve clearance is obtained 6AU3K11 Power unit check and adjustment NOTE ee e To decrease the valve clearance turn the adjusting screw in direction e To increase the valve clearance turn the adjusting screw in direction Lt Tappet adjusting tool 90890 01311 7 Tighten the rocker arm locknut to the Specified torque Rocker arm locknut 7 N m 0 7 kgfm 5 2 ft lb 8 Turn the flywheel magnet an additional 360 clockwise and align the 2 A mark on the driven sprocket with the A mark on the thermostat cover S6AU5007 9 Repeat steps 5 7 for cylinder 2 10 Install al
23. Measuring the forward and reverse gear backlash rrrrnnrvrrnnrnvrnrrrrnnnnnr 6 17 6AU3K11 Lower unit high thrust model ns 6 21 Removing the lower unit 6 24 Removing the water DUMP is tice thine teh ute nia dee 6 25 Checking the water PUMP Lende 6 25 Propeller shaft housing high thrust model 6 26 Removing the propeller shaft housing assembly aana nani 6 27 Disassembling the propeller shaft assembly 6 27 Disassembling the propeller shaft housing as sembhy 6 27 Checking the propeller shaft housing 6 28 Checking the propeller shaft nanang 6 28 Assembling the propeller shaft assembly 6 28 Assembling the propeller shaft housing 6 29 Drive shaft and lower case high thrust model ss 6 31 Removing the drive shaft drive shaft housing and shiftrod 6 32 Disassembling the drive shaft housing 6 32 Disassembling the lower case 6 32 Checking the pinion and forward ge r uses 6 33 Checking the DEBI DEE 6 33 Checking the drive Shaft rss inter nnstiesanninennes 6 33 CHECKING the shift TO re nn annee 6 33 Checking the lower case 0 atueiesiedn an eneeteerieaeaieet 6 33 Assembling the lower EE 6 33 Assembling the drive Shaft housing 6 34 Installing the shift rod drive shaft housing and drive haft 6 35 Installing the propeller Shaft housing 6 35 Installing the water pm cares ne Se A en tu eee 6 36 Installing the lower UNG soos cree cota
24. S6AU5078 S6AU5079 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 hk a S68V5775 Valve spring free length 27 6 mm 1 0866 in 2 Measure the valve spring tilt amp Replace if above specification 6AU3K11 69J5730 ZX Valve spring tilt limit 1 0 mm 0 039 in Checking the valve 1 Check the valve face Replace the valve if pitted or worn 2 Measure the valve margin thickness Gi Replace the valve if out of specification S69J5740 Valve margin thickness Intake 0 7 mm 0 028 in Exhaust 1 0 mm 0 039 in 3 Measure the valve stem diameter Replace the valve if out of specification S69J5750 6AU3K11 Cylinder head Valve stem diameter Intake 5 475 490 mm 0 2156 0 2161 in Exhaust 5 460 475 mm 0 2150 0 2156 in 4 Measure the valve stem runout Replace the valve if above specification S69J5760 Valve stem runout limit 0 01 mm 0 0004 in Checking the valve guide NOTE SE Before checking a valve guide make sure that the valve stem diameter is within specifi cation 1 Measure the valve guide inside diameter S6AU5085 Valve guide inside diameter amp Intake and exhaust 5 500 5 512 mm 0 2165 0 2170 in 5 30 2 Calculate the valve
25. but the engine does not crank Stuck piston Seizure or rust Piston lock due to water in the com bustion chamber Disassemble and check the power unit Stuck drive shaft Buildup of foreign material on the Spline of drive shaft and bushing Malfunction of the lower unit internal parts Disassemble and check the lower unit Starter motor mal function Disassemble and check the starter motor Damaged flywheel magnet Woodruff key Symptom 1 Engine does not start engine cranks Symptom 2 Cause 1 Check the flywheel magnet Woodruff key Checking step Spark plug does not spark Spark plug malfunc tion Check the spark plug Spark plug cap mal function Check the spark plug cap Ignition coil mal function Check the ignition coil Engine shut off switch malfunction Check the engine shut off switch Charge coil mal function Check the charge coil Pulser coil malfunc tion Check the pulser coil Short or open con nection in ignition circuit Check the wiring harness continuity CDI unit malfunc tion WD See the wiring diagram 9 3 Check the CDI unit Troubleshooting the outboard motor Symptom 2 Cause 1 Cause 2 Checking step Fuel not supplied Pinched or kinked fuel hose Check the fuel hoses and fuel hose joint Clogged fuel filter Replac
26. sus ch dtiniendeticee tar eae diet EE 5 35 Assembling the cylinder Nea EE 5 35 Installing the cylinder headers 5 37 CHECKING the oil PUMP Lassa aaa ren han antaa ga naa 5 37 6AU3K11 Cylinder DIOCkK nissan nantes euer kueedegeg etc 5 39 Disassembling the cylinder block 5 41 CHECKING the piston diameter Wiad Met te tes 5 42 Checking the Cylinder bore uk 5 42 Checking the piston Eleng 5 42 Checking the piston ring ss 5 43 Checking the piston ring end gap Lvnmednuvavvmeeneireiepemeieasenerbet 5 43 CHECKING the piston ring grOOVe La rihanna nets 5 43 Checking the piston ring side clearance 5 44 Checking the piston pin boss bore um mtnemngvis dis usamet 5 44 Checking the piston pin diameter 5 44 Checking the connecting rod small end inside diameter and big end inside diameter 5 44 Checking the connecting rod big end side clearance mrsrnnnrnrrnrrvrrnrrnnenn 5 45 Checking the crankshaft aan nanang 5 45 Checking the crankpin oil clearance eeeeseseteeseeeeseeesseeeseeveeeessesestanenee 5 45 Checking the crankshaft journal oil clearance mnsnvrvrvvrrrvvvrvrrrrrrrevrernen 5 46 Selecting the crankshaft main bearing usarnasvnnrnrannenanvennnransrennsrsnnesnnrene 5 48 Assembling the cylinder block 3 23 soahaniesntelirennmes magasine 5 48 Installing the power VD since sean nt hee gege bgeeeec 5 51 6AU3K11 Power unit check and adjust
27. throttle cables are fitted securely into the holes in the pivot section of the tiller handle as shown 8 Install the tiller handle assembly to the tiller handle bracket and then tighten the nuts to the specified torque Tiller handle assembly nut 10 N m 1 0 kgf m 7 4 ft lb Tiller handle assembly self locking nut 22 Nem 2 2 kgf m 16 2 ft lb 9 Install the tiller handle assembly to the steering bracket and then tighten the nuts to the specified torque Tiller handle bracket nut 36 N m 3 6 kgf m 26 6 ft lb 10 Connect the throttle cables to the throttle cam NOTE e To adjust the throttle cables see Adjusting the throttle cable H model 3 7 e When adjusting the throttle cables make sure that the ends of the outer cables are not pulled out of the holes in the pivot section of the tiller handle 6AU3K11 Tiller handle long 11 Connect the engine shut off switch leads engine start button leads E model and PT switch leads PT model 6AU3K11 7 10 Bracket unit Friction plate H model S6AU 7009 a Oo LO OO JO Un BUN KE Part name i Remarks Steering lock shaft Bracket Collar Bolt Washer Steering lock lever Friction piece Short M5 x 14 mm Friction plate Collar Steering lock washer Self locking nut Bolt Washer Bolt Long M5 x 20 mm N ON k k A k HN H
28. with the holes in the water pump housing 5 Tighten the water pump housing bolts and to the specified torque Water pump housing bolt and 18 N m 1 8 kgf m 13 3 ft lb Installing the lower unit 1 Set the shift lever to the R position H model Set the remote control lever to the R position R model 6AU3K11 2 Setthe shift rod to the R position 3 Install the lower unit to the upper case and then tighten the lower case mounting bolts to the specified torque KT e S6AU6058 NOTE 0 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 e When installing the lower unit make sure that the water pipe is inserted securely into the rubber seal Lower case mounting bolt 18 N m 1 8 kgf m 13 3 ftlb 4 Install the locknut and then screw the adjusting nut onto the shift rod 6AU3K11 Drive shaft and lower case Screwed in length 8 0 9 0 mm 0 31 0 35 in 5 Tighten the locknut NOTE TT After connecting the shift rod check that the gear shift operates properly 6 Install the anode and cooling water inlet covers and then tighten the anode bolt to the specified torque 572 S6AU6060 Anode bolt 8 N m 0 8 kgf m 5 9 ft lb 6 16 Lower unit 7 Install the propeller an
29. AT mark on the driven sprocket with the a mark on the thermostat cover NOTE 0 Check that the notch in the drive sprocket and the A mark on the cylinder block are aligned 3 Remove the timing belt from the driven sprocket and then remove it from the drive sprocket CAUTION Unless directed to do so in the following instructions do not turn the drive sprocket or driven sprocket when the tim ing beltis not installed Otherwise the pis tons and valves will collide with each other and be damaged 4 Align the notch in the drive sprocket with the mating surface of the crank case and cylinder block by turning the crankshaft clockwise approximately 90 gradually N S6AU5057 5 Hold the driven sprocket using the spe cial service tool and then remove the driven sprocket bolt EE D foe PONY seausos9 6AU3K11 NOTE SE Make sure that the driven sprocket does not turn when loosening the driven sprocket bolt Flywheel holder 90890 06522 6 Remove the driven sprocket and Woo druff key 7 Install the power unit to the special ser vice tool as shown and then remove the drive sprocket nut NOTE on 3 Use a deep 30 mm socket to loosen the drive sprocket nut Shaft holder 90890 06561 8 Remove the lock washer retaining plate drive sprocket and Woodruff
30. Checking the tilt operation PT model 3 13 Checking the tilt system MT model 1 17 D Checking the timing belt ee 3 5 Checking the timing belt and sprocket 5 22 Checking the top COWIING eee 3 3 Checking the valve secsec 5 30 Checking the valve cearance 5 1 Checking the valve guide 110111 5 30 Checking the valve seal 7 44 Checking the valve seat 5 31 Checking the valve Spring 00 5 29 Checking the warning indicator assembly versie Ta aa a eege degt eeh 8 35 Checking the water pUMp ceee 6 5 6 25 Clamp bracket and swivel bracket MT modeloen ien a i aga aba 7 26 Clamp bracket and swivel bracket PE modela a aaa aka naa ang aa rain ak A 7 31 Connecting the throttle cable and shift cable R model 1 14 Control system 3 7 Cylinder block 5 39 Cylinder head nassen 5 25 DIMENSION eet aaa aa aa aab AEN 2 12 Disassembling the carburetor 4 11 Disassembling the cylinder block 5 41 Disassembling the cylinder head 5 28 Disassembling the drive shaft NOUSING EE 6 11 6 32 Disassembling the friction plate 01 7 12 Disassembling the fuel pump 0111 4 5 Disassembling the gear pump se 7 44 Disassembling the lower case 6 11 6 32 Disassembling the manual starter 5 8 Disassembling the propeller shaft assembly uo cescessscccsssseessseeesssseeseees 6 7 6 27 Disassembling the pro
31. SA ie ri une Dress 6 37 Shimming high thrust Model ss 6 39 SUMING sn deu ee tn TE a EN ag E ag Kan 6 40 Selecting the pinion SANE Lae 6 40 Selecting the forward gear ehm 6 40 Selecting the reverse gear shim sasae aane a anana n aaa anane nean 6 41 Backlash high thrust model 6 42 Measuring the forward and reverse gear backlash A 6 42 6AU3K11 Lower unit Lower unit 17 N m 1 7 kgf m 12 5 ft Ib Gel 8 N m 0 8 kgf m 5 9 ft Ib Se 18 N m 1 8 kgf m 13 3 ft Ib E SE n 2 N m 0 2 kgf m 1 5 ft Ib No Part name Remarks lt S6AU6001 6 1 1 2 3 4 5 6 7 8 9 Adjusting nut Locknut Dowel Rubber seal Check screw Gasket Cooling water inlet cover Cooling water inlet cover Nut Screw Drain screw Lower case Bolt Anode Special washer Bolt Spacer Not reusable Short Long 95 x 16 mm M8 x 35 mm Not reusable M6 x 16 mm A k k k P k k MH k NN k k NN RR 6AU3K11 Lower unit 17 N m 1 7 kgf m 12 5 ft Ib MJ 8 N m 0 8 kgf m 5 9 ft Ib Ma2 N m 0 2 kgf m 1 5 ft Ib Mal 18 N m 1 8 kgf m 13 3 ft Ib JON m 0 9 kgf m 6 6 ft Ib S6AU6001 Part name Remarks Propeller Washer Propeller nut Cotter pin Not reusable 6AU3K11 6 2 Lower unit S6AU6002 Part name i Remarks Bolt Plate Rubber seal Water pump housing Insert c
32. case NOTE Install the drive shaft sleeve with the hole facing forward 3 Install the shift rod a new gasket 4 and the drive shaft housing assembly NOTE Make sure that the projection on the gas ket is toward the port side 4 Install the drive shaft original pinion shim s roller bearing pinion and pinion nut to the drive shaft 6 35 NOTE TT lt When installing the pinion lift up the drive Shaft slightly and align the pinion and shaft Splines e Be sure to select the pinion shim s if replacing the pinion roller bearing or lower case To select the shim see Shimming high thrust model 6 39 5 Tighten the pinion nut to the specified torque S6AU6127 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 2 Install the washer and propeller shaft housing assembly into the lower case and then tighten the bolts to the speci fied torque 6AU3K11 Drive shaft and lower case high thrust model S6AU6129 Propeller shaft housing bolt 8 N m 0 8 kgf m 5 9 ft lb 3 Check that the shifting mechanism works properly and smoothly Installing the water pump 1 Install the dowels and outer plate car tridge S6AG6380 2 Install the Woodruff key and impeller to the driv
33. case bolt M8 18 1 8 Shift rod grommet plate bolt M6 8 0 8 Self locking nut 19 1 9 Tilt stopper plate bolt MT model 8 0 8 Anode bolt PT model M6 8 0 8 Stopper nut PT model 24 2 4 Ground lead bolt PT model M6 8 0 8 PT unit mounting shaft bolt PT model M8 1 8 Grease nipple 0 3 PT unit PT model PT motor assembly bolt 0 5 Reservoir cap 0 5 Gear housing bolt 0 5 Tilt cylinder end screw 4 5 Tiltram 4 5 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 specified torque is reached Unless otherwise specified torque specifications require clean dry threads Components should be at room temperature S69J2150 General torque specifications N m kgfm ftlb 5 0 5 3 7 8 0 8 5 9 18 18 133 36 3 6 26 6 43 4 3 31 7 2 21 6AU3K11 Periodic check and adjustment Maintenance interval chart ss 3 1 Top CO WAG E 3 3 Checking the top COWNNG Ae sent danses tetes 3 3 Fuel System eege 3 3 Checking the fuel joint and fuel hose fuel joint to carburetor sce 3 3 Checking the fuel filter EE 3 3 Hefe 3 4 Power UM ritssrteei
34. exploded diagram for disassembly 7 6 Installing the tiller handle 1 Assemble the tiller handle 6AU3K11 Tiller handle long NOTE EE See the exploded diagram for assembly 7 6 2 Install the shift lever cam and cam Springs S6AU7122 3 Install the throttle friction adjuster and then install the cotter pin S6AU7005 7 8 Bracket unit 4 Install the engine shut off switch to the tiller handle and then tighten the nut to the specified torque Pass the engine shut off switch lead through a hole in the pivot section of the tiller han dle 5 Install the PT switch to the bracket and then tighten the bracket screws to the specified torque PT model 6 Install the PT switch to the tiller handle and then tighten the PT switch screws d and to the specified torque PT model S6AU7006 NOTE Tighten the screws o and then tighten the screw 2 Engine shut off switch nut 2 N m 0 2 kgf m 1 5 ft lb PT switch bracket screw 0 4N m 0 4 kgf m 3 0 ft lb PT switch screw d and 6 N m 0 6 kgf m 4 4 ft lb 7 Connect the throttle cable ends to the throttle pulley 7 9 S6AU7007 NOTE e When routing the engine shut off switch lead make sure that it does not contact the throttle shaft in the area lt Make sure that the ends of the outer
35. fuel filter Replace the fuel fil ter Fuel pump malfunc tion Disassemble and check the fuel pump Carburetor malfunc tion WD See the wiring diagram 9 5 Throttle stop screw not adjusted cor rectly Adjust the throttle stop screw Pilot screw not adjusted correctly Adjust the pilot screw Malfunction of the carburetor internal parts Disassemble and check the carbure tor Symptom 2 Cause 1 Troubleshooting the outboard motor Cause 2 Checking step Low compression pressure Valve clearance not adjusted correctly Adjust the valve clearance Damaged cylinder head gasket Damaged valve Scratched piston or cylinder Damaged or worn piston ring Disassemble and check the cylinder head and power unit Throttle valve does not fully open Throttle control sys tem malfunction Throttle cable s not adjusted correctly Check and adjust the throttle cable s Throttle link rod not adjusted correctly Check and adjust the throttle link rod Air leakage into intake manifold carburetor to cylin der head Symptom 1 High engine idle speed Symptom 2 Cause 1 Damaged gaskets spacer and intake manifold carbure tor to cylinder head Cause 2 Check the gaskets spacer and intake manifold carbure tor to cylinder head Checking step Engine speed does not decrease whe
36. holes in the pivot section of the tiller handle as shown 5 Install the tiller handle assembly to the tiller handle bracket and then tighten the nut to the specified torque Ve Tiller handle assembly nut 22 N m 2 2 kgf m 16 2 ft lb 6 Install the tiller handle assembly to the steering bracket and then tighten the nuts to the specified torque Tiller handle bracket nut 36 N m 3 6 kgf m 26 6 ft lb 7 Connect the throttle cables to the throttle cam NOTE e To adjust the throttle cables see Adjusting the throttle cable H model 3 7 e When adjusting the throttle cables make sure that the ends of the outer cables are not pulled out of the holes in the pivot section of the tiller handle 8 Connect the engine shut off switch leads and engine start button lead E model 6AU3K11 Tiller handle short 7 4 Bracket unit Tiller handle long Ma 22N m 2 2 kgf m 16 2 ft Ib Fe 10 N m 1 0 kgf m 7 4 ft Ib 2186 N m 3 6 kgf m 26 6 ft Ib S6AU7001 Part name Remarks Throttle cable Nut Shift cable Nut Self locking nut Nut Plate Bushing Plug Engine start button Tiller handle bracket Stud bolt Bushing Washer Wave washer Bushing Tiller handle assembly a Oo o A um P W N Ha OD lt M model E model eeN b k NR k k k k k k 4 k k N 7 5 6AU3K11 Tiller handle long sa
37. into the lower case to the specified depth S6AU6119 6AU3K11 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 special service tool Z Driver rod SL 90890 06602 Bearing depth plate 90890 06603 Needle bearing attachment 90890 06617 AS Installation depth 189 3 189 8 mm 7 45 7 47 in Assembling the drive shaft housing 1 Install the bushing into the drive shaft housing pall to d Q S6AU6123 NOTE Align a groove in the bushing with the hole in the drive shaft housing CL 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 6AU3K11 Drive shaft and lower case high thrust model S6AU6125 NOTE eeh Install an oil seal halfway into the drive shaft housing and then install the other oil seal Ko Driver rod L3 90890 06652 Needle bearing attachment 90890 06613 Installation depth 7 0 8 0 mm 0 28 0 31 in 6 34 Lower unit 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
38. its viscosity 6AU3K11 Top cowling Fuel system Power unit PN ja O KO S6AU1018 NOTE SE e If the oil appears milky or dirty check for and repair the cause and then change the oil lt 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 S6AU 3008 3 4 CHK Q ADJ Periodic check and adjustment 3 Place a drain pan under the drain hole and then remove the engine oil drain bolt and let the oil drain completely S6AU3009 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 into the oil dipstick hole 4 Install the engine oil drain bolt and then tighten it to the specified torque Engine oil drain bolt 24 N m 2 4 kgf m 17 7 ftlb 5 Pour the specified amount of the recom mended engine oil into the oil filler hole Recommended engine oil 4 stroke motor oil API SE SF SG SH SJ orSL SAE 5W 30 10W 30 or 10W 40 Engine oil quantity 0 8 L 0 85 US qt 0 70 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 lev
39. 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 6AU3K11 Timing belt and sprocket Installing the sprocket and timing belt CAUTION Unless directed to do so in the following instructions do not turn the crankshaft or camshaft when the timing belt is not installed Otherwise the pistons and valves will collide with each other and be damaged 1 Align the keyway in the crankshaft with the mating surface of the crank case and cylinder block S6AU5061 2 Install the Woodruff key drive sprocket retaining plate and lock washer and then install the drive sprocket nut temporarily meal 5 22 3 Install the power unit to the special ser vice tool and then tighten the drive sprocket nut to the specified torque NOTE Use a deep 30 mm socket to tighten the drive sprocket nut Shaft holder 90890 06561 Drive sprocket nut 36 N m 3 6 kgf m 26 6 ft lb 4 Bend the lock washer along a flat side of the nut ENG S6AU5179 5 Install the washer Woodruff key driven sprocket 49 and washer and then install the driven sprocket bolt temporarily 5 23 S6AU5064 6 Hold the driven sprocket using the spe cial service tool and then tighten
40. level is between and Recommended engine oil 4 stroke motor oil API SE SF SG SH Sy or SL SAE 5W 30 10W 30 or 10W 40 Engine oil quantity 0 8 L 0 85 US qt 0 70 Imp at Checking the gear oil level 1 Check the gear oil level Fr S6AU1043 S6AU1019 Except for high thrust model For high thrust model ol gt 6AU3K1 1 Predelivery check NOTE EE If the oil is at the correct level a small amount of oil should overflow out of the check hole when the gear oil check screw is removed Checking the battery E model 1 Check the battery capacity electrolyte level and specific gravity of the electro lyte Recommended battery capacity CCA EN 347 0 A 20HR 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 Connecting the throttle cable and shift cable R model NOTE SE To adjust the throttle cable and shift cable see Adjusting the throttle cable R model 3 8 or Checking the gear shift operation R model 3 10 1 Set the remote control lever to the N position and the throttle lever to the fully closed position aa General information 2 Turn the throttle cam counterclock wise until the fully closed stopper on the cam contacts the fully closed stopper on the throttle cable bracket and hold it in that position Conn
41. m 1 2 kgf m 8 9 ft Ib S6AU4017 Part name Remarks Carburetor assembly Gasket Spacer Bolt Bolt Intake manifold Gasket Cooling water hose Flushing hose Dowel lt Not reusable M6 x 35 mm M6 x 25 mm Not reusable For Europe N A kA k kA N k N H 6AU3K11 4 8 el H Fuel system Carburetor S6AU4018 No Partname Q ty Remarks 1 Screw 3 g4 x 10 mm 2 Cover 1 3 Gasket 1 4 Plug 1 5 Carburetor body 1 6 Throttle stop screw 1 g4 x 20mm 7 Spring 1 8 Boot 1 9 Plunger rod 1 10 Pilot screw 1 For Europe 11 Pilot screw 1 For Oceania 12 O ring 1 13 Main nozzle 1 14 Plug 1 15 Pilotjet 1 16 Main jet 1 17 Float pin 1 4 9 6AU3K11 Carburetor unit S6AU4018 Part name Remarks lt Gasket Needle valve Float Float chamber assembly Screw Plunger rod guide O ring Plunger Spring Circlip Ball Float chamber Drain screw Gasket Screw Not reusable 93 x 6 mm Not reusable Not reusable g4 x 10 mm ND k k k k k k RPP k k k k Ka 6AU3K11 4 10 ue D Fuel system Removing the carburetor 1 Disconnect the fuel hose and blowby hose SE EAN ET p S6AU4020 2 Disconnect the throttle link rod and choke rod 3 Disconnect the choke solenoid coupler R model NOTE The choke solenoid coupler is located under the junction bo
42. manual valve O ring and pin 7 37 5 6 S6AU7062 Remove the stator and O ring from the PT motor base 49 S6AU 7063 Remove the armature plate screw d and then remove the armature assembly Og L S6AU 7064 6AU3K11 NOTE e Push the brushes apart and then remove the armature assembly lt Do not remove the bearing from the arma ture assembly 7 Remove the brush holder screws brushes 4 brush springs and oil seal from the PT motor base o S6AG7125 Checking the PT motor 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty S6AU 7066 2 Measure the commutator diameter Replace the armature if below specifica tion S6AU7067 6AU3K11 PT motor 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 amp 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 mm S6AG7087 Armature continuity Checking point Continuity Commutator segments Yes Segment Armature core No Segment Armature shaft No 5 Check the bearing Replace the
43. model Remove the driven sprocket cover and flywheel magnet cover E model 2 Disconnect the cooling water hose 3 Remove the thermostat cover and thermostat 6AU3K11 Power unit S6AU3015 CAUTION Do not reuse the gasket always replace it with a new one 4 Suspend the thermostat in a container of water 5 Place a thermometer in the water and Slowly heat the water S69J5E40 3 6 AD AD Periodic check and adjustment 6 Measure the thermostatvalve opening at the specified water temperatures Replace the thermostat if out of specifi cation S6AL3100 Water temperature Valve opening 0 05 mm 0 0020 in valve begins to open Above More than 70 158 F 3 0 mm 0 12 in 58 62 C 136 144 F 7 Install a new gasket the thermostat and the thermostat cover and then tighten the thermostat cover bolts to the speci fied torque Thermostat cover bolt 8 N m 0 8 kgf m 5 9 ft lb Checking the cooling water passage 1 Check the cooling water inlet covers and cooling water inlets Clean if clogged S6D53130 2 Place the lower unit in water and then start the engine 3 7 3 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 S6AU3020 Control system Adjusting the throttle cable H model 1 Disconnect the throttl
44. ower unit mounting bolt 21 Nm 2 1 kgf m 15 5 ft lb 3 Install the apron dipstick and choke rod 4 Connect the throttle cables onto the throttle cam and then adjust the cables H model Connect the throttle cable joint onto the throttle cam and then adjust the throttle cable R model NOTE ee To adjust the throttle cable s see Adjusting the throttle cable H model 3 7 or Adjust ing the throttle cable R model 3 8 5 Connect the flushing hose for Europe cooling water hoses and fuel hose 6AU3K11 VEE nr sc EE LA Na S6AU5172 6 Connectthe engine shut off switch leads oil pressure warning indicator leads and engine start button leads H model Connect the 10 pin main harness to the power unit R model NOTE To connect the leads see Electrical compo nent and wiring harness routing 8 1 7 Install the PT relay and connect the PT relay lead PT switch coupler and PT Switch lead PT model 8 Connect the battery cables battery lead and starter motor lead E model 9 Install the manual starter and driven Sprocket cover and then connect the start in gear protection cable M model Install the flywheel magnet cover and driven sprocket cover E model NOTE To connect the start in gear protection cable see Checking the start in gear protection M model 3 11 6AU3K11 Cylinder block 5 52 Lower unit Lower UN Aa is
45. remover installer 90890 06801 A Valve guide reamer 90890 06804 ZN Valve seat cutter holder 90890 06316 6AU3K11 Special service tool S Valve seat cutter O 90890 06312 90890 06315 90890 06328 90890 06813 90890 06814 90890 06815 gt Driver rod L3 90890 06652 Needle bearing attachment 90890 06613 90890 06614 90890 06616 90890 06653 d Piston slider 90890 06843 7 Stopper guide plate 90890 06501 an General information Bearing puller assembly Ball bearing attachment 90890 06535 90890 06634 Stopper guide stand Bushing attachment 90890 06538 90890 06650 Bushing attachment Driver rod LL 90890 06649 90890 06605 Needle bearing attachment Bushing installer center bolt 90890 06617 90890 06601 Driver rod LS Bearing housing puller claw S 90890 06606 90890 06564 1 9 6AU3K1 1 Center bolt 90890 06504 Backlash indicator 90890 06706 gt Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base B 90890 06844 6AU3K1 1 Special service tool 2 Ball bearing attachment 90890 06632 S Bearing outer race attachment 90890 06625 Driver rod SL 90890 06602 Bearing depth plate 90890 06603 Digital caliper 90890 06704 aa General information Shimming plate Ignition tester 90890 06701 90890 06754 Needle bearing attachment 90890 06615 Power tilt wrench 90890 06560 Digital circuit tester 908
46. replace Pilot water Check Throttle link throttle cable throttle pick up timing Check adjust replace Thermostat Check replace Timing belt Check replace Valve clearance Check adjust Water inlet TU Check and if defective replace 3 1 Check 6AU3K11 Item Remarks Initial Maintenance interval chart Every 20 hours 3 months 100 hours 300 hours 1 year 3 years 500 hours 5 years Refer to page Main switch stop switch choke switch Check replace O O 8 26 8 27 8 33 Wire harness connections wire coupler connections Check replace O O 8 1 Selva Fuel tank NOTE Check clean e When 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 500 hours Item Remarks Every 1 000 hours Refer to page Exhaust guide exhaust manifold Check replace O 7 22 Timing belt 6AU3K11 Replace O 5 3 3 2 AD AD Periodic check and adjustment Top cowling Checking the top cowling 1 Check the fitting by pushing the cowling with both hands Adjust if necessary S6AU3001 2 Loosen the bolts 3 Move the hook up or down slightly to adj
47. rollers and then measure the bearing height M2 as shown Calculated number ik S6AG 6470 NOTE e Ed 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 CZ Digital caliper 90890 06704 Shimming plate 90890 06701 2 Calculate the forward gear shim thick ness Calculation formula Forward gear shim thickness T1 16 50 M2 6 40 Lower unit 3 Select the forward gear shim s T1 as follows Shim thickness Calculated number mm 0 00 0 10 0 11 0 20 0 10 0 21 0 30 0 20 0 31 0 40 0 30 0 41 0 50 0 40 Available shim thicknesses 0 10 0 20 0 30 and 0 40 mm Example If T1 is 0 23 mm then the forward gear shim thickness is 0 20 mm If T1 is 0 30 mm then the forward gear shim thickness is 0 20 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 6 41 S6AG 6490 M3 M3 10 mm NOTE eeben Measure the propeller shaft housing at 4 points to find the height average 2 Digital caliper 90890 06704 Shimming plate 90890 06701 3 Turn the ball bearing 2 or 3 times
48. the crankcase S6AU5152 NOTE ee The stamped mark is for the main bear ings of crankshaft journal 1 and the stamped mark is for the main bearings of crankshaft journal 2 2 Select the suitable bearing color for the main bearings from the table Stamped marks and Bearing color Blue Black Brown 6AU3K11 Cylinder block Assembling the cylinder block 1 Assemble the piston connecting rod piston pin and piston pin clips A S6AU5153 CAUTION Do not reuse the piston pin clips always replace them with new ones NOTE SE e Before assembly make sure that the identi fication numbers made on the piston and connecting rod during removal are the same lt Face the A mark on the connecting rod in the same direction as the UP mark on the piston 5 48 2 Install the oil ring 2nd ring and top ring onto each piston NOTE Make sure that the N marks of the 2nd ring and the top ring are facing upward 3 Offset the piston ring end gaps as shown L D J sonusiss CAUTION Do not scratch the pistons or break the piston rings NOTE se 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 S6AU5156 5 49 NOTE EE Appl
49. the float position shown opposite its pivoting side Float height 20 0 21 0 mm 0 79 0 83 in Assembling the carburetor 1 Install the pilot jet main jet main nozzle and plug to the carburetor body as shown 6AU3K11 Carburetor unit 2 Install the needle valve float and float pin as shown and then check the float for smooth operation 4 S S6AU4028 NOTE Install the float pin in the direction of the arrow mark on the carburetor body 4 12 el H Fuel system 3 Install the pilot screw turn it in until it is lightly seated and then turn it out the specified number of turns gt fr Be LA 6 S6AU4030 For Europe For Oceania LA B K Pilot screw adjusting tool for Europe 90890 03154 AS Pilot screw setting 1 5 8 turns out Installing the carburetor 1 Install new gaskets the spacer Q the carburetor assembly Q and the intake silencer using the bolts NOTE Install the spacer with the chamfered side facing toward the intake manifold 2 Connect the choke solenoid coupler R model 3 Connect the throttle link rod to the car buretor throttle lever and the choke rod to the carburetor choke lever 4 13 S6AU4031 NOTE SS e To adjust the throttle link rod see Adjust ing the throttle link 3 9 e Place the choke solenoid coupler under the jun
50. the oil pump 5 37 e Before installing the oil pump assembly be sure to fill it with a small amount of engine oil through the oil passages DQ 5 37 Oil pump assembly bolt 8 N m 0 8 kgf m 5 9 ft lb Installing the cylinder head 1 Install a new gasket the dowels and the cylinder head and then tighten the bolts to the specified torques in the sequence shown S6AU5121 CAUTION Do not reuse the cylinder head gasket always replace it with a new one NOTE aa Apply engine oil to the cylinder head bolts before installation e Tighten the bolts to the specified torques in 2 stages Cylinder head bolt M8 1st 15 N m 1 5 kgf m 11 1 ftlb 2nd 29 Nem 2 9 kgf m 21 4 ft lb Cylinder head bolt M6 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 Nem 1 2 kgf m 8 9 ft lb Checking the oil pump 1 Remove the oil pump screws and dis assemble the oil pump 6AU3K11 Cylinder head S6AU5122 2 Check the inner surface of the oil pump housing Replace the oil pump assembly if scratched 3 Assemble the oil pump and then tighten the oil pump screws to the specified torque ID es EC JO 9 9 S6AU5125 NOTE meer e The punch mark on the outer rotor faces towards the oil pump cover e The punch mark on the inner rotor faces towards
51. the operation 7 Fully extend the tilt ram 8 Remove the reservoir cap and then check the fluid level in the reservoir WARNING Make sure that the tilt ram is fully extended when removing the reservoir cap otherwise fluid can spurt out from the unit due to internal pressure 6AU3K11 NOTE 0 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 lt If the fluid is below the correct level add the recommended PT fluid AC Recommended PT fluid ATF Dexron II 9 Install the reservoir cap and then tighten it to the specified torque NOTE EE 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 PT electrical system Checking the fuse 1 Check the fuse for continuity Replace if there is no continuity NOTE ee ee e For the location of the fuse see Electrical component and wiring harness routing 8 1 e To check the fuse see Checking the fuse E model 8 26 Checking the PT relay 1 Check the PT relay for continuity Replace if out of specification 6AU3K11 PT cylinder PT electrical system S6AU7106 Black B Green G Q Black B Blue L Black B Sky blue Sb Black B Light
52. the out board motor 869J1040 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 aa 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 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 hy
53. to the front of stopper 1 8 Apply grease to all grease nipples until it comes out from the areas S6AU7059 6AU3K11 Clamp bracket and swivel bracket PT model PT motor PT motor 5 N m 0 5 kgf m 3 7 ft Ib S6AU7060 Part name No 1 2 3 4 5 6 7 8 Remarks lt Screw 4 x 10 mm Stator O ring Armature Screw Brush Brush Screw Brush spring Bolt PT motor base Gasket Oil seal O ring O ring Manual valve Reservoir cap Not reusable 4 x 8 mm Long lead Short lead 4 x 10 mm M5 x 25 mm Not reusable Not reusable Not reusable Not reusable A k k k k k k P N N k k k k H k ND 6AU3K11 7 36 Bracket unit Disassembling the PT motor 1 Remove the PT unit from the bracket NOTE EE To remove the PT unit see Removing the PT unit 7 33 Fully extend the tilt ram and then open the manual valve by turning it counter clockwise S6AG7335 WARNING Make sure that the tilt ram is fully extended before removing the PT motor otherwise fluid can spurt out from the unit due to internal pressure NOTE To prevent the internal PT unit parts from fall ing out lay the PT unit on its side so that the PT motor is in an upright position before removing it Remove the PT motor base bolts and then remove the PT motor assembly and gasket from the tilt cylinder Remove the
54. unit 6 15 6 37 Installing the power unt 5 51 Installing the propeller shaft NOUSING E 6 14 6 35 Installing the PT unit cece 7 34 Installing the shift rod drive shaft housing and drive shaft 6 13 6 35 Installing the sprocket and timing belt 5 22 Installing the starter motor secr 8 26 Installing the steering am 7 23 Installing the tiller handle 7 3 7 8 Installing the upper case 7 24 Installing the water pump 6 15 6 36 6AU3K11 Index L LOWORUNIbassisicies aise lites 2 8 3 14 6 1 Lower unit high thrust model 6 21 Lubricating the outboard motor 3 17 M Maintenance interval chart 3 1 Maintenance specification 0014441 2 4 Manual format 1 1 Manual starter M model 5 6 Measuring the forward and reverse gear backlash eee 6 17 6 42 Measuring the peak voltage 8 19 Models den ee et eatin 1 6 P Part lubricant and sealant 000464 1 4 Bort view saisine alert 8 11 Power unit 2 4 3 4 5 12 Power unit check and adjustment 5 1 Power unit assembly sesane aennen ai 5 12 Precaution when transporting or Storing the outboard motor 1 20 Predelivery check 1 13 Propeller selection 1 12 Propeller shaft housing 6 6 Propeller shaft housing high thrust model 6 26 Propeller size 1 12 PT cylinder A naga Lawang 7 47 PT elec
55. unit with gear oil to the cor rect level Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Gear oil quantity 370 cm 12 51 US os 13 05 Imp 02 6 38 Lower unit Shimming high thrust model ON HH UV T3 M1 INNA NAD MA T2 maju Lu S6AU6141 6 39 6AU3K11 Shimming NOTE SE 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 roller bearing S6AU6142 NOTE EE e Select the shim thickness T3 by using the Specified measurement s and the calcula tion formula lt Measure the roller bearing at 4 points to find the thickness average Digital caliper 90890 06704 2 Calculate the pinion shim thickness Calculation formula Pinion shim thickness T3 6 05 Ml 3 Select the pinion shim s T3 as follows 6AU3K11 Shimming high thrust model Shim thickness mm 1 14 1 20 1 13 1 21 1 30 1 20 Available shim thicknesses 1 13 and 1 20 mm Selecting the forward gear shim 1 Turn the taper roller bearing outer race 2 or 3 times to seat the
56. 0 7 0 03 86 2 0 0 08 40 1 5 8 1 050 50 6AU3K11 Item Maintenance specification Fuel pump Fuel pump holding pressure Fuel inlet positive pressure Fuel inlet negative pressure Fuel outlet positive pressure Fuel joint holding pressure Positive pressure Fuel filter assembly holding pressure Positive pressure Lower unit Item kPa kgf cm psi kPa kgf cm psi kPa kgf cm psi kPa kgf cm psi kPa kgf cm psi Unit 200 2 0 29 0 Lower unit Holding pressure Gear backlash Pinion to forward gear Pinion to reverse gear Pinion shims Forward gear shims Reverse gear shims kPa kgf cm psi 0 50 2 27 0 0197 0 0894 0 50 2 27 0 0197 0 0894 1 9 2 0 2 1 2 2 0 10 0 12 0 15 0 18 0 30 0 1 100 1 0 14 0 76 2 30 0 0299 0 0906 0 76 2 30 0 0299 0 0906 1 13 1 20 0 1 0 2 0 3 0 4 0 1 0 2 0 3 Propeller shaft Runout limit 1 Figures obtained using the special service tools 6AU3K1 1 0 05 0 0020 0 02 0 0008 2 8 SPEC ee Specification Drive shaft Runout limit Electrical Item 0 5 0 0197 Ignition and ignition control system Spark plug gap Spark plug cap resistance Ignition coil resistance Primary coil O B at 20 C 68 F Secondary coil
57. 023 A Fully open position B Fully closed position 7 Connect the throttle link rod to the free accel lever NOTE After adjusting the throttle cables adjust the throttle link Adjusting the throttle cable R model 1 Disconnect the throttle link rod from the free accel lever 2 Loosen the locknut remove the clip and then disconnect the throttle cable joint S6AU3024 3 Set the remote control lever to the N position 4 Check that the fully closed stopper on the throttle cam contacts the throttle cable bracket 3 8 CHK Q ADJ Periodic check and adjustment 5 Adjust the position of the throttle cable joint until its hole is aligned with the set pin on the throttle cam D AVE DE S6AG1090 WARNING The throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in NOTE as Pull the throttle cable towards the engine to remove any free play in the cable before adjusting the position of the throttle cable joint 6 Connect the throttle cable joint install the clip and then tighten the locknut 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 cable bracket as shown S6AU3060 3 9 S6AU3026 A Fully open position B Fully closed position 8 Connectthe thr
58. 028 S6AU3063 H model short H model long gt 6AU3K11 S6AU3029 NOTE se To adjust the shift rod adjusting nut see Installing the lower unit 6 15 or Installing the lower unit 6 37 Checking the gear shift operation R model 1 Check that the gear shift operates smoothly when the remote control lever is shifted from the N position to the F position or R position Adjust the shift cable length and shift rod adjusting nut if necessary 2 Set the remote control lever to the N position 3 Loosen the locknut remove the clip and then disconnect the shift cable joint SY H EE US E N E FO ae 3 10 AD AD Periodic check and adjustment 4 Adjust the position of the shift cable joint until its hole is aligned with the set pin on the shift rod lever joint D RER S6AG3130 WARNING The shift cable joint must be screwed in a minimum of 8 0 mm 0 31 in 5 Connect the shift cable joint install the clip and then tighten the locknut 6 Adjust the shift rod adjusting nut E S 4 S6AU3033 NOTE rs To adjust the shift rod adjusting nut see Installing the lower unit 6 15 or Installing the lower unit 6 37 7 Check the gear shift for smooth opera tion Checking the start in gear protection M model CAUTION Be sure to remove the clip from the engine shut off switch be
59. 039 Cylinder Bore size 2 5 56 000 56 015 2 2047 2 2053 6AU3K11 Item Maintenance specification Piston Piston diameter D pall Measuring point H ht Piston clearance Piston pin boss bore Oversize piston diameter 1st 2nd Piston ring groove Top ring 2nd ring Oil ring 55 950 55 965 2 2028 2 2033 1 5 0 06 0 035 0 065 0 0014 0 0026 14 004 14 015 0 5513 0 5518 56 200 56 215 2 2126 2 2132 56 450 56 465 2 2224 2 2230 1 23 1 25 0 0484 0 0492 1 52 1 54 0 0598 0 0606 2 51 2 53 0 0988 0 0996 Piston pin Outside diameter 13 996 14 000 0 5510 0 5512 Piston ring Top ring Dimension B Dimension T End gap Side clearance 2nd ring Dimension B Dimension T End gap Side clearance Oil ring Dimension B Dimension T End gap Side clearance Barrel 1 17 1 19 0 0461 0 0469 1 95 2 15 0 0768 0 0846 0 15 0 30 0 0059 0 0118 0 04 0 08 0 0016 0 0031 Plain 1 47 1 49 0 0579 0 0587 2 40 2 60 0 0945 0 1024 0 30 0 45 0 0118 0 0177 0 03 0 07 0 0012 0 0028 2 35 2 50 0 0925 0 0984 2 30 2 60 0 0906 0 1024 0 20 0 70 0 0079 0 0276 0 01 0 18 0 0004 0 0071 Connecting rod Small end inside diameter Big end inside diameter Big end side clearance Crankpin oil clearance 14 015 14 029 0 5518 0 5523 27 030 27 042 1 0642 1 0646 0 05 0 22 0 0020 0 0087 0 021 0 045 0 0008 0 0018 Crankshaft Cr
60. 11 NOP RP RPP RPP PPP RPP RP FPN 95 x 11 mm 7 2 Bracket unit Removing the tiller handle 1 Disconnect the engine shut off switch leads and engine start button leads E model NOTE s vr To disconnect the leads see Electrical com ponent and wiring harness routing 8 1 2 Disconnect the throttle cables from the throttle cam gt sl he lt IN I EE S6AU7117 3 Remove the tiller handle NOTE Le See the exploded diagram for disassembly 7 2 Installing the tiller handle 1 Assemble the tiller handle NOTE ee See the exploded diagram for assembly 7 2 2 Install the throttle friction adjuster and then install the cotter pin S6AU7118 7 3 3 Install the engine shut off switch to the tiller handle and then tighten the nut to the specified torque Pass the engine shut off switch lead through a hole in the pivot section of the tiller han dle S6AU7120 NOTE E Route the engine shut off switch lead as shown making sure to fit it securely into the notch in the tiller handle Engine shut off switch nut 2 N m 0 2 kgf m 1 5 ft lb 4 Connect the throttle cable ends to the throttle pulley S6AU7121 6AU3K11 NOTE Make sure that the ends of the outer throt tle cables are fitted securely into the
61. 2 Remove the bushing from the lower case 6AU3K11 S6AU6158 CAUTION Do not reuse the bushing always replace it with a new one Cz Driver rod L3 90890 06652 Bushing attachment 4 90890 06650 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 2 Eee S6AU6037 AS Drive shaft runout limit 1 0 mm 0 0394 in 6AU3K11 Drive shaft and lower case 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 Assembling the lower case 1 Install the original forward gear shim s and a new ball bearing S6AU6039 NOTE SE Install the ball bearing with the manufacture identification mark facing toward the forward gear Driver rod LL 90890 06605 Ball bearing attachment 90890 06634 6 12 Lower unit 2 Install a new bushing into the lower case Ce QE H S Install the bushing until its flange is in tight conta
62. 240 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 6AU3K11 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 EE When using the flushing device flushing hose joint adapter for Europe flush the cooling water passages without starting the engine Precaution when transporting or storing the outboard motor 1 When transporting or storing the out board motor while removed from a boat keep the outboard motor in the attitude shown or use an outboard motor stand S6AU 1042 6AU3K1 1 Predelivery check 1 20 aa General information MEMO 1 21 6AU3K11 Specification General PECIFIC GUO EE 2 1 Maintenance specification ssssnsmmnnnnnnnnnnnnnnnnes 2 4 Power e E 2 4 PUG SVSIGM E 2 7 Lower EE 2 8 Electrical E 2 9 PRIMO MSIOM REE anaE aaan paaa etine iaa 2 12 Tightening TON UN 2 19 Specified TONG EE 2 19 General TOP UE 2 21 6AU3K1 1 SPEC ae Specification General specification Item Dimension Overall length For Europe i 573 22 6 For Oceania i 573 22 6 Overall width For Europe i 335 13 2 For Oceania i 335 13 2 Overall height
63. 4 Wind the starter rope twice around the sheave drum in the direction of the arrow shown S6AU5031 NOTE After winding the starter rope D around the sheave drum install the starter rope in the notch 5 Install the spiral spring into the manual starter cover 6AU3K11 S6AU5032 NOTE Hook the end of the spiral spring onto the cut out in the manual starter cover 6 Install the sheave drum into the man ual starter cover zm NG 3 SUE SE gt TK SE NS TT ss a ib NE SL JD ge KY 4 ODS A TE NOTE e When installing the sheave drum set the Spiral spring by turning the sheave drum lt Hook the end of the spiral spring onto the cut out in the sheave drum 7 Install drive pawl spring 1 the drive plate and the screw S6AU5034 Drive plate screw 5 N m 0 5 kgf m 3 7 ft lb 6AU3K11 Manual starter M model 8 Turn the sheave drum 4 turns in the direction of the arrow shown S6AU5035 NOTE a S Hold the starter plunger while turning the sheave drum as shown 9 Remove the starter rope from the notch and then fit it into the groove in the sheave drum NOTE 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 the starter handle several times to check t
64. 560 3 Drain the PT fluid 4 Remove the tilt cylinder and free pis ton from the cylinder S6AG7250 7 49 5 Hold the tilt piston in a vise using alu minum plates on both sides and then remove the tilt piston and tilt cylinder end screw from the tilt ram N S6AU7091 6 Remove the absorber valve from the tilt piston poecesess S6AU7090 Checking the tilt cylinder and piston 1 Check the tilt cylinder o Replace if cracked or scratched 2 Check the tilt piston free piston and backup rings and Replace if cracked or scratched 3 Check the tilt cylinder end screw dust seal and backup ring Replace if cracked or scratched 6AU3K11 4 Check the tilt ram Polish with 400 600 grit sandpaper if there is light rust or replace if bent or excessively corroded 0 gt S6AU 7092 5 Check the absorber valve Clean if there is dirt or residue S6AU7093 Assembling the tilt cylinder CAUTION lt Do not use a rag when assembling the PT unit as dust and particles on the PT unit components can lead to poor per formance e Do not reuse the dust seal and O rings always replace them with new ones 6AU3K11 PT cylinder NOTE TT Lubricate the parts with ATF Dexron II during assembly 1 Install a new dust seal new O rings and and the backup ring into the tilt cylinder end screw S6
65. 6 30 Lower unit Drive shaft and lower case high thrust model S6AU6105 Part name Remarks L transom model X transom model Not reusable a Oo LO OO JO Un P GA A KE Shift rod Gasket Drive shaft sleeve Needle bearing O ring Oil seal Bushing Drive shaft housing Drive shaft Pinion shim Roller bearing Pinion Pinion nut Taper roller bearing Forward gear shim Forward gear Not reusable Not reusable Not reusable PRPRPNP k k k kb L transom model X transom model PPP Pp Not reusable 6 31 6AU3K11 Removing the drive shaft drive shaft housing and shift rod 1 Remove the pinion nut S6AU6106 2 Remove the pinion pinion shim s and roller bearing 3 Remove the drive shaft and then remove the drive shaft housing assembly gas ket and shift rod S6AU6107 CAUTION Be sure to remove the drive shaft before removing the drive shaft housing assem bly from the lower case 4 Remove the drive shaft sleeve 5 Pull out the forward gear Disassembling the drive shaft housing 1 Remove the oil seals and bushing 6AU3K11 Drive shaft and lower case high thrust model S6AU6109 CZ Driver rod L3 90890 06652 Bushing attachment 90890 06649 Disassembling the lower case 1 Remove the taper roller bearing outer race and forward gear shim s M Y Oy K
66. 75 mm R model R model Starter motor lead Bolt Bolt 10 pin coupler harness Throttle cable Apron Screw Nut 6 x 30 mm KA A k k RP OO A H 5 13 6AU3K11 Ignition coil CDI unit and Rectifier M model ha 8 N m 0 8 kgf m 5 9 ft Ib 3 5 N gt m 0 35 kgf m 2 6 ft Ib Power unit 14 8 N m 0 8 kgf m 5 9 ft Ib S6AU5176 No Partname Q ty 1 Bolt 2 M5 x 10 mm 2 Pulser coil 1 3 CDI unit 1 4 Bolt 2 M6 x 20 mm 5 Junction box 1 6 Screw 2 4 x 11 mm 7 Spark plug 2 8 Bolt 1 M6 x 12 mm 9 Bolt 2 M8 x 12 mm 10 Bracket 1 11 Rectifier 1 12 Screw 1 95 x 25 mm 13 Ignition coil 1 14 Bolt 2 M6x25mm 6AU3K11 5 14 Ignition coil CDI unit and Rectifier Regulator E model PS 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib S6AU5040 No Part name Q ty Remarks 1 Bolt 2 M5 x 10 mm 2 Pulser coil 1 3 Fuse holder assembly 1 4 Fuse holder bracket 1 5 CDI unit 1 6 Bolt 2 M6 x 20 mm 7 Junction box 1 8 Screw 2 4 x 11 mm 9 Starter motor lead 1 10 Nut 1 11 Washer 1 12 Bolt 2 M8 x 25 mm 13 Starter motor 1 14 Spark plug 2 15 Starter motor bracket 1 16 Holder 1 17 Bolt 1 M6x12mm 5 15 6AU3K11 Pl 8 N m 0 8 kgf m 5 9 ft Ib Part name Power unit x 8 N m 0 8 kgf m 5 9 ft Ib
67. 8 018 0 7087 0 7094 diameter A Camshaft Intake and i 23 45 23 55 0 9232 0 9272 exhaust A Intake and i 19 95 20 05 0 7854 0 7894 exhaust B Camshaft journal diameter C i 17 975 17 991 0 7077 0 7083 Camshaft runout limit i 0 03 0 0012 Rocker arm shaft Outside diameter i 12 941 12 951 0 5095 0 5099 1 Measuring conditions Ambient temperature 20 C 68 F wide open throttle with spark plugs removed from all cylinders The figures are for reference only 6AU3K1 1 2 4 SPEC BEZ Specification Item Rocker arm Inside diameter 13 000 13 018 0 5118 0 5125 Valve Valve clearance cold Intake Exhaust Head diameter A Intake Exhaust FK Face width B Intake and exhaust Margin thickness D Intake Exhaust Stem diameter AD Intake and exhaust SN Seat contact width C K Intake Exhaust Stem runout limit Guide inside diameter Intake and exhaust Stem to guide clearance Intake Exhaust Guide height 0 15 0 20 0 006 0 008 0 20 0 25 0 008 0 010 23 9 24 1 0 94 0 95 21 9 22 1 0 86 0 87 1 84 2 26 0 0724 0 0890 0 6 0 8 0 024 0 031 0 7 0 028 1 0 0 039 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 8 05 0 25 0 32 0 01 Valve spring Free length Tilt limit 27 6 1 0866 1 0 0
68. 90 03174 Peak voltage adapter B 90890 03172 1 11 6AU3K11 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 and on the side of the propel ler boss 00x Ai S69W1040 000x0 0 NW S69W1050 Propeller diameter in inches Propeller pitch in inches Propeller type propeller mark 6AU3K1 1 Special service tool Propeller selection Selection When the engine speed is at the full throttle operating range 5 000 6 000 r min the ideal propeller for the boat is one that pro vides maximum performance in relation to boat speed and fuel consumption Model Propeller size in Material 81 2x61 2 N 81 2x71 2 N 81 2x8 N 9 9 81 2x81 2 N 81 2x91 4 N 9x5 N 9x7 N Aluminum aa General information Predelivery check To make the delivery process smooth and efficient the predelivery checks should be completed as explaine
69. 90890 06501 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 3 Remove the oil seals and needle bear ing 6AU3K11 S6AU6094 CAUTION Do not reuse the bearing always replace it with a new one CZ Driver rod L3 90890 06652 A Needle bearing attachment 90890 06616 Checking the propeller shaft housing 1 Clean the propeller shaft housing and then check it Replace if cracked or dam aged 2 Check the teeth and dogs of the reverse gear Replace the reverse gear if cracked or worn ee the propeller shaft Check the propeller shaft Replace if damaged or worn 2 Measure the propeller shaft runout Replace if above specification 2 S6AU6095 6AU3K11 Propeller shaft housing high thrust model Propeller shaft runout limit 0 02 mm 0 0008 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 es Install the dog clutch with the F mark facing toward the forward gear 3 Install the shift plunger S6AU6096 NARA S6AU6097 6 28 Lower unit Assembling the propeller shaft housing 1 Install a new needle bearing into the pro peller shaft housing to the specified de
70. AG 7300 ee 2 Install the tilt cylinder end screw to the tilt ram 3 Install the ball pin spring and dowel to the tiltram Q Nas TD CL gt e E N EO 271 PS 5 S6AU7116 7 50 7 Bracket unit 4 Install the tilt piston S6AU7115 NOTE Tighten the tilt piston temporarily and then check that the spring is visible through the oil hole in the piston when the tilt ram assem bly is upright 5 Hold the tilt piston in a vise using alu minum plates on both sides and then tighten the tilt ram to the specified torque S6AU 7095 Tiltram 45 N m 4 5 kgf m 33 2 ft lb 6 Install a new O ring and the backup ring onto the tilt piston 7 51 S6AU7096 7 Install a new O ring to the tilt cylinder and then install the tilt cylinder into the cylinder S6AU7097 8 Install the PT gear pump PT motor assembly and reservoir cap to the tilt cylinder NOTE EE To install the PT motor assembly and gear pump assembly see Assembling the gear pump 7 45 9 Fill the cylinder with the recommended PT fluid to about 60 AC Recommended PT fluid ATF Dexron II 10 Install the backup ring and a new O ring to the free piston and then install the free piston into the cylinder 6AU3K11 S6AU7098 11 Place the tilt cylinder end screw at the bottom of the tilt ram 12 Install the tilt ram assembly into
71. CED S6AU7041 7 S6AU 7039 Disassembling the swivel bracket 1 Unhook the spring from the tilt support bar Remove the E clips from the tilt lever shaft and then pull out the shaft and remove the tilt lever 6AU3K11 7 28 Bracket unit 3 Remove the springs 4 Remove the E clip from pin 2 and then pull out the pin 5 Remove the E clip from pin 1 and then pull out the pin and remove the col lars tilt lock rod 2 tilt lock plate 1 and tilt lock plate 2 S6AU7042 Assembling the swivel bracket 1 Assemble tilt lock plate 2 tilt lock plate 1 the collars tilt lock rod 2 and pin 1 and then install the E clip ss NOTE After installing the E clip turn itto make sure that it is installed securely or r 2 Pass pin 2 through the swivel bracket and tilt lock plate 2 and then install the E clip Hook the springs onto tilt lock plate 1 and then hook them onto the holes in the swivel bracket 7 29 S6AU7044 NOTE EE After installing the E clip turn it to make sure that itis installed securely 3 Install the stopper shaft and tilt sup port bar to the swivel bracket and then install the E clip 4 Hook tilt lock rod 2 the spring and tilt lock rod 1 49 onto the tilt lever 5 Install the tilt lever shaft into the swivel bracket op making sure to pass the shaf
72. ELEC ES Electrical system 3 Check the engine start button 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 Continuity Free No Pushed Yes 4 Connect the connectors of the engine start button Checking the engine start switch R 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 L S6AU8027 8 27 Engine start switch input voltage reference data Red R Ground 12 V battery voltage 3 Set the remote control lever to the N 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 PUSH OFF START PUSH S6AU8028 Lead color Red Yellow Brown S witch R Br position OH O O O 5 Connect the 10 pin main harness cou pler Checking the neutral switch H model with electric starter 1 Disconnect the neutral switch connec tors 6AU3K11 Starting system 2 Push the engine start button a
73. N N FH k EA M8 x 16 mm 7 11 6AU3K11 Disassembling the friction plate 1 Remove the friction plate bolts and and then remove the friction plate assembly from the swivel bracket S6AG7A90 NOTE 0 Before removing the friction plate bolts turn the outboard motor all the way to port or starboard 2 Disassemble the friction plate assembly NOTE ee See the exploded diagram for disassembly 7 11 Assembling the friction plate 1 Turn the steering lock shaft until it is flush with the end of the nut on the bracket a S6AG7B00 6AU3K11 Friction plate H model O O S6AG7B01 O NOTE ee 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 EE e See the exploded diagram for assembly 7 11 e Face the 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 12 Bracket unit 3 Install the friction plate assembly onto the swivel bracket and tighten the friction plate bolts and temporarily NOTE Before installing the friction plate bolts turn the outboard motor all the way to port or starboard S6AU7013 4 Tighten the friction plate bolts and to t
74. O On Un BUN KE Part name Q lt Bolt M6x14mm Exhaust manifold Upper case Plate Grommet Bolt Bolt Bolt Upper mount Bolt Washer Exhaust guide Oil seal Gasket Grommet Oil strainer Baffle plate L transom model S transom model Not reusable Not reusable A k k k HAHA k k MB N P k k k k k ND 7 19 6AU3K11 Upper case and steering arm S6AU7017 Part name Remarks lt Dowel Oil pan Rubber seal Screw Grommet Plate Gasket Drain bolt Bolt 95 x 7 mm Not reusable M8 x 30 mm KA k k k k k k FPN 6AU3K11 7 20 Bracket unit Removing the upper case NOTE e Drain the engine oil before removing the upper case assembly lt 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 water pipe 4 Remove the upper mounting nuts and then remove the upper case assembly S6AU7018 Disassembling the upper case 1 Remove the engine oil drain bolt and grommet 2 Remove the upper mount from the upper case assembly 3 Remove the oil pan assembly from the upper case 7 21 S6AU7019 4 Remove the oil pan from the exhaust guide baffle plate and gasket 5 Remo
75. OL Bac O Nyre Ces 5 K aly oi S6AU5073 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 S6AU5074 NOTE Nn To disassemble check and assemble the oil pump see Checking the oil pump 5 37 2 Pull out the rocker arm shaft and then remove the springs collars and and rocker arms 6AU3K11 Cylinder head S6AU5075 NOTE EE e Loosen the locknuts and adjusting screws to ease the tension on the rocker arm shaft before pulling it out e Be sure to keep the parts in the order as they were removed 3 Remove the camshaft and oil seal S6AU5076 5 28 4 Remove the intake and exhaust valves JH 9 S6AU5077 NOTE Be sure to keep the valves springs and other parts in the order as they were removed CZ Valve spring compressor i 90890 04019 Valve spring compressor attachment 90890 06320 Checking the cylinder head 1 Eliminate carbon deposits from the com bustion chambers and check for deterio ration 2 Check the cylinder head warpage using a straightedge and thickness gauge in the directions shown Replace the cyl inder head assembly if above specifica tion 5 29
76. Pike 9 9 SERVICE MANUAL Marine 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 easier or cle
77. S6AU5040 Remarks Bolt Bolt Rectifier Regulator Bolt Ignition coil Bolt 6AU3K11 M8 x 55 mm M8 x 40 mm M6 x 12 mm M6 x 25 mm 5 16 Throttle cam and oil pressure switch 8 N m 0 8 kgf m 5 9 ft Ib FT 8 N m 0 8 kgf m 5 9ft Ib IJAN m 0 2 kgf m 1 5 ft Ib S6AU5045 Part name Remarks Oil pressure switch Oil pressure switch lead Throttle cable bracket Throttle cable Throttle cam Free accel lever Clip Collar Washer Bolt Bolt Throttle cable Clip a O o A Ou P WW N ta OD lt H model M6 x 45 mm M6 x 12 mm R model R model A k k k k k M M k M k k ob 5 17 6AU3K11 Power unit Removing the power unit 1 Disconnect the startin gear protection cable and then remove the driven Sprocket cover and manual starter M NOTE To disconnect the leads see Electrical com ponent and wiring harness routing 8 1 model Remove the driven sprocket cover and 5 Disconnect the flushing hose for flywheel magnet cover E model Europe cooling water hoses and fuel hose 2 Disconnect the battery cables battery lead and starter motor lead E model D p 2 SE KA S6AU5046 6 Disconnect the throttle cables from the throttle cam H model Disconnect the throttle cable joint from the throttle cam R model S6AU5047 7 Remove the choke rod dipstick and apron
78. SCrew secsec 4 13 Adjusting the throttle cable H model 3 7 Adjusting the throttle cable R model 3 8 Adjusting the throttle link 3 9 After test POL dee Aiba ead 1 19 Assembling the carburetor ee 4 12 Assembling the cylinder block 5 48 Assembling the cylinder head 5 35 Assembling the drive shaft NOUS ING WEE 6 13 6 34 Assembling the friction plate 7 12 Assembling the fuel pump 4 6 Assembling the gear pump eee 7 45 Assembling the lower case 6 12 6 33 Assembling the manual starter 5 9 Assembling the propeller shaft ASSOMDIY E 6 8 6 28 Assembling the propeller shaft NOUSING RE 6 9 6 29 Assembling the PT motor 7 39 Assembling the starter mofor 8 25 Assembling the swivel bracket 7 29 Assembling the tilt cylinder esce 7 50 Assembling the upper case 7 22 BaCklaS his rata aana ENG nine dr 6 17 Backlash high thrust model 1 6 42 Bleeding the PT unt 7 52 Bottom Cowlmg anane n anana a anane 7 14 BOW VIEW sarsa aas aa naa ga aga Na dang a aa ay ken agak 8 9 Bracket unt 3 12 Breakin saat aan aa NG Aa NG a NGE a ayake 1 19 Carburetor is attenante 4 9 Carburetor unit 4 7 Changing the engine oil 3 4 Changing the gear oil 3 14 Charging system E model eee 8 36 Checking the anode ane nei 3 16 Checking the battery 3 16 Checking the battery E model 1 14 Ch
79. Starter motor E model Lasserre 8 20 Starting system sssenenanenana nean na nen anen 8 26 Symbol es feel NA aa ees 1 2 T EE erster dE L ebeeEnLigeegeteg Eer 1 19 Throttle cam and oil pressure switch 5 17 Tightening torque eerren 2 19 Tiller handle long 7 5 Tiller handle short 7 1 Timing belt and eprocket anana 5 19 TODGOWIMGY saras eran egen raaa aaa ai aaa 3 3 TOP VIEW aksa aaa anggan NG ngan a a Wa Ta eins 8 1 Troubleshooting table format 9 1 Troubleshooting the lower unit 9 8 Troubleshooting the outboard motor 9 1 Troubleshooting the power unit 9 1 Troubleshooting the PT unit PT model 9 7 U D Upper case and steering arm 7 17 V Ventilation jessica ie tnt 1 4 6AU3K11 Index MEMO 6AU3K11 i 5 Wiring diagram Pike 9 9M CDI unit Pulser coil Lighting coil 1 coil Lighting coil 2 coils Charge coil Oil pressure switch Rectifier Rectifier Regulator Ignition coil Spark plug Fuse 10 A Battery Engine shut off switch Oil pressure waming indicator Optional Color code B Black Br Brown G Green L Blue O Orange P Pink R Red W White Y Yellow G W Green white W R White red Y R _ Yellow red Wiring diagram FT9 9GE FT9 9GEP CDI unit Choke solenoid Pulser coil Lighting coil Charge coil Oil pressure switch Starter mo
80. TE SE 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 GA Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 6AU3K11 Checking the electrical component Starter motor E model Starter motor E model 0 4 N m 0 04 kgf m 0 30 ft Ib S6AU8008 Part name Remarks Not reusable a CO LO OO JO Un P GA A k Clip Pinion stopper Spring Pinion stopper set Pinion Cover O ring Washer Shim Washer Armature Washer Stator Brush holder assembly Brush spring Screw Brush 2 assembly Not reusable t 1 0 mm kN k M A PB t 2 0 mm t 0 25 mm 4 x 8 mm PNNP RPP bk 6AU3K11 8 20 Erec ELEC m Electrical system Part name 0 4 N m 0 04 kgf m 0 30 ft Ib S6AU8008 Remarks Brush 1 Spacer Bracket O ring Washer Bolt O ring Spacer Washer Spring washer Nut 8 21 NN H HN N N EH FH ob M5 x 120 mm 6AU3K11 Removing the starter motor 1 Remove the starter
81. Tighten the connecting rod cap bolts to the specified torques in 2 stages Connecting rod cap bolt 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 11 N m 1 1 kgf m 8 1 ft lb 5 44 2 Measure the connecting rod small end inside diameter and big end inside diameter Replace the connecting rod if out of specification S6AU5139 Connecting rod small end inside diameter 14 015 14 029 mm 0 5518 0 5523 in Connecting rod big end inside diameter 27 030 27 042 mm 1 0642 1 0646 in Checking the connecting rod big end side clearance 1 Measure the connecting rod big end side clearance S6AU5140 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 diame ters crankpin diameters and crankpin widths Replace the crank shaft if out of specification 5 45 S6AU5141 S6AU5142 Crankshaft journal diameter 30 002 30 014 mm 1 0582 1 0586 in Crankpin diameter 26 997 27 009 mm 1 0629 1 0633 in Crankpin width 21 000 21 070 mm 0 8268 0 8295 in 2 Measure the crankshaft runout Replace if above specification S6AU5143 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 6AU3K11 2 Puta piece of Plastigauge PG 1 onto t
82. Use a commercially available vacuum pres Sure pump gauge and meter that can be pressurized up to 200 kPa 2 0 kgf cm 29 0 psi Specified positive pressure 200 kPa 2 0 kgf cm 29 0 psi 4 4 el D Fuel system Checking the fuel joint 1 Check the fuel joint Replace if cracked or damaged 2 Connect the special service tool to the fuel joint outlet 3 Apply the specified positive pressure Replace the fuel joint if the specified pressure cannot be maintained for at least 10 seconds S6AU4004 K Vacuum pressure pump gauge set i 90890 06756 AS Specified positive pressure 50 kPa 0 5 kgf cm 7 3 psi Disassembling the fuel pump 1 Disassemble the fuel pump as shown S6AU4010 2 Remove the pin from the plunger and then disassemble fuel pump body 1 4 5 S6AU401 1 S6AU4012 NOTE _ e Push the plunger and diaphragm com pletely inward and then turn fuel pump body 1 approximately 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 S6AU4013 6AU3K11 Assembling the fuel pump NOTE Clean the parts and soak the valves and the diaphragms in gasoline before assembly 1 Install the plunger and diaphragm into f
83. air 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 6AU3K11 Bracket unit Lower unit Recommended gear oil Hypoid gear oil API GL 4 SAE 90 4 Install a new gasket and the gear oil check screw D 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 S6AU3044 A Except for high thrust model B For high thrust model 3 14 AD AD Periodic check and adjustment 3 Check the oil for metal and discoloration and its viscosity Check the internal parts of the lower case if necessary 4 Insert a gear oil tube or gear oil pump into the drain hole and slowly fill with gear oil until oil flows out of the check hole and no air bubbles are visible S6AU3045 Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Gear oil quantity Except for high thrust model 150 cm 5 07 US oz 5 29 Imp oz For high thrust model 370 cm 12 51 US oz 13 05 Imp 02 5 Install new gaskets and the gear oil check screw quickly install the gear oil drain screw and then tighten them to the specified torq
84. and then measure the height from the ball bearing M4 as shown S6AG6500 6AU3K11 Shimming high thrust model Backlash high thrust model Y o mm 0 39 in S6AG6510 M4 M4 10 mm NOTE een e Select the shim thickness T2 by using the Specified measurement s and the calcula tion formula lt 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 58 05 M3 M4 5 Select the reverse gear shim s T2 as follows Calculated number va 0 00 0 10 0 11 0 20 0 1 0 21 0 30 0 2 0 31 0 32 03 Available shim thicknesses 0 1 0 2 and 0 3 mm 6AU3K11 Backlash high thrust model Measuring the forward and reverse gear backlash NOTE TT 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 Set the shift rod to the N position at the lower unit S6AU6130 3 Turn the lower unit so that the propeller shaft is facing down 4 Install the special service tools 6 42 Lower unit 5 Tighten the center bolt to the specified torque while turning the drive shaft S6AU6152 Z Center bolt D 90890 06504 I Stop
85. and then remove the mounting 3 Disconnect the PT switch coupler PT bolts switch lead R and PT relay lead G L and remove the PT relay PT 8 Remove the power unit gasket model and dowels o d J S6AU5048 4 Disconnect the engine shut off switch leads oil pressure warning indicator leads and engine start button leads H model Disconnect the 10 pin main harness from the power unit R model S6AU5052 6AU3K11 5 18 Timing belt and sprocket 98 N m 9 8 kgf m 72 3 ft Ib 12 N m 1 2 kgf m 8 9 ft Ib amp 19 e LE Ee S6AU5053 Part name Remarks Width across flats 22 mm a CO LO ON On Un P GA A KE Nut Washer Flywheel magnet Bolt Charge coil Timing belt Nut Lock washer Retaining plate Drive sprocket Woodruff key Woodruff key Bolt Lighting coil Bolt Washer Driven sprocket M6x25 mm Width across flats 30 mm M6 x 30 mm M6 x 14 mm A k kA 4 P k k k k HE HN k k kb 5 19 6AU3K11 Timing belt and sprocket 98 N m 9 8 kgf m 72 3 ft Ib 12 N m 1 2 kgf m 8 9 ft Ib S6AU5053 No Part name i Remarks 18 Washer 19 Woodruff key 6AU3K11 5 20 Removing the timing belt and sprocket 1 Remove the flywheel magnet charge coil and lighting coil s NOTE See Replacing the timing belt 5 3 2 Align the 1
86. ankshaft journal diameter Crankpin diameter Crankpin width Crankshaft runout limit 1 The figures are for reference only 6AU3K1 1 30 002 30 014 1 0582 1 0586 26 997 27 009 1 0629 1 0633 21 000 21 070 0 8268 0 8295 0 05 0 0020 2 6 SE ve ifi i Specification Item Crankcase Crankshaft journal oil clearance Upper and lower crankcase main journal bearing thickness A Blue B Black C Brown mm in mm in mm in 0 006 0 034 0 0002 0 0013 1 502 1 506 0 0591 0 0593 1 498 1 502 0 0590 0 0591 1 494 1 498 0 0588 0 0590 Oil pump Type Relief valve opening pressure kPa kgf cm psi Trochoid 390 450 3 90 4 50 56 6 65 3 Thermostat Opening temperature at 0 05 mm 0 0020 in Fully open temperature Valve open lower limit C F C F 58 62 136 144 70 158 3 0 0 12 Manual starter Starter rope length Starter rope pulling length 1 The figures are for reference only Fuel system mm in mm in 1 900 74 8 1 400 1 600 55 12 62 99 Carburetor ID mark For Europe For Oceania Float height Valve seat size Main jet M J For Europe For Oceania Main nozzle M N Pilot jet P J Pilot screw P S For Europe For Oceania Engine idle speed 2 7 mm in turns out turns out r min 6AU20 6AU50 6AU00 6AU30 20 0 21 0 0 79 0 83
87. arer Contents muh General information z Specification 00 U m O GA Periodic check and adjustment TH A gt Oo G Fuel system As TI C m m ie D O1 VW O Lower unit Q D Bracket unit n Electrical system ee 4 malo SE 0 JJ U Troubleshooting Oo L 0 SST 6AU3K1 1 General information How to use this TUTE 1 1 Manual f rmat eu aaa Kan pa sanan an Rene ES SE 1 1 SYMBOL EE EE EE a A t 1 2 Abbreviatibnh EE 1 3 Sealant and locking agent table AEN 1 3 Safety while working eminente mineedsiekknee 1 4 Fire EEA RE degedlekge geed Age sien 1 4 Ventilation BEE 1 4 SPENN E 1 4 Part lubricant and eealant sanese en area nen ee en anane ea naen nenen arena ene n eee 1 4 Good working bel ien de EE 1 5 Disassembly and assembly 1 5 e Oe EE 1 6 lee EE 1 6 Serial tu E EEN 1 6 Special service tool 2 scores este ects eee etree nn saines 1 7 Propeller Selen 1 12 Propeller SIZ genee nn nt math aa a S San 1 12 E e EE 1 12 Predelivery CHECK Sasniarinaniniannitaimnnininernnnmmminninl 1 13 Checking the outboard motor mounting height 1 13 Removing the intake silencer protective covering saaaaaaaaaaaa aane 1 13 Checking the fuel system EE 1 13 Checking the engine oil level a nean anana aana a nana anae 1 13 Checking the gear oil level
88. armature if damaged 7 38 Bracket unit Checking the brush holder and brush 1 Check the brush holder assembly for continuity Replace the PT motor base if out of specification GDS S6AG7090 NOTE ee The brush holder and circuit breaker cannot be removed from the PT motor base assem bly if either part is damaged replace the PT motor base PT motor base continuity Checking point Terminal G Terminal L For all terminal combinations not listed above Continuity Yes No 2 Measure the length of each brush Replace the brushes if below specifica tion S69J8430 7 39 Motor brush standard length 6 0 mm 0 24 in Wear limit 3 0 mm 0 12 in Assembling the PT motor CAUTION e Do not reuse the oil seal and O ring always replace them with new ones lt Do not allow grease or oil to contact the commutator of the armature 1 Install a new oil seal into the PT motor base as shown S6AU 7072 Driver rod L3 90890 06652 Needle bearing attachment 90890 06615 2 Install the brush springs brush short lead brush long lead and brush holder screws to the PT motor base as shown S6AU 7073 Brush lead length gt 6AU3K11 3 Push the brushes into the holders and then install the armature assembly and tighten the armature plate screw 9 S6AU 7074
89. artridge Impeller O ring Bolt Dowel Outer plate cartridge Woodruff key M8 x 45 mm Not reusable M8 x 25 mm No 1 2 3 4 5 6 7 8 9 10 11 eeN b A k k kA k kA A 6 3 6AU3K11 Removing the lower unit 1 Drain the gear oil S6AU6003 2 Setthe gear shift to the N position place a block of wood between the anti cavita tion plate and propeller to keep the pro peller from turning and then remove the propeller nut and propeller S6AU6004 WARNING e Do not hold the propeller with your hands when loosening or tightening it lt Be sure to disconnect the battery cables from the battery and remove the clip from the engine shut off switch E model 3 Loosen the locknut while holding the adjusting nut and then turn the adjust ing nut to disconnect the shift rod NOTE NN Set the gear shift to the R position before dis connecting the shift rod 6AU3K11 Lower unit 4 Remove the locknut NOTE a 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 6 Remove the anode and cooling water inlet covers 6 4 Lower unit Removing the water pump 1 Remove the water pump housing and impeller Remove the Woodruff key from the drive shaft and then remove the outer plate cartridge
90. assembly to the tilt cylinder and then tighten the PT motor assembly bolts to the specified torque 6AU3K11 PT gear pump S6AU7114 PT motor assembly bolt 5 N m 0 5 kgf m 3 7 ft lb 6AU3K11 7 46 Bracket unit PT cylinder FT 45 N m 4 5 kof m 33 2 ft Ib Da5 N m 0 5 kgf m 3 7 ft Ib S6AU7087 a Oo o SI On Un BUN Hm Partname Remarks Tilt ram assembly Tilt ram Dust seal Tilt cylinder end screw O ring Backup ring O ring Absorber valve Ball Pin Spring Dowel Tilt piston O ring Backup ring Free piston Backup ring lt Not reusable Not reusable Not reusable Not reusable RPP FP RP PRP RP PR PR PR EH FH 7 47 6AU3K11 PT cylinder EN m m E K X in E un D E m m E X L E un 5 N m 0 5 kgf m 3 7 ft Ib S6AU7087 2 2 wn gt 2 w Le Not reusable Not reusable Part name Tilt cylinder Cylinder Reservoir cap 19 21 22 7 48 6AU3K11 Bracket unit Disassembling the tilt cylinder 1 Hold the cylinder in a vise using alumi num 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 06
91. assembly is stuck to the lower case use the special ser vice tools See Backlash 6 17 Disassembling the propeller shaft assembly 1 Remove the shift plunger from the propeller shaft 2 Remove the cross pin ring and then remove the cross pin and dog clutch 3 Pull out the spring from the propeller shaft S6AU6011 6 7 Disassembling the propeller shaft housing assembly 1 Remove the reverse gear and shim s S6AU6012 2 Remove the ball bearing S6AU6014 CAUTION Do not reuse the bearing always replace it with a new one Lt Stopper guide plate 90890 06501 A Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 3 Remove the oil seals and bushing 6AU3K11 S6AU6016 CAUTION Do not reuse the bushing always replace it with a new one CZ Driver rod L3 90890 06652 Bushing attachment 90890 06649 Checking the propeller shaft housing 1 Clean the propeller shaft housing and then check it Replace if cracked or dam aged 2 Check the teeth and dogs of the reverse gear Replace the reverse gear if cracked or worn ee the propeller shaft Check the propeller shaft Replace if damaged or worn 2 Measure the propeller shaft runout Replace if above specification S6AG6130 6AU3K11 Propeller shaft housing Propeller shaft runout limit 0 05 mm 0 0020 in 3 Check the dog
92. 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 to the crankshaft 69J5B70 Cylinder bore D D 56 000 56 015 mm 2 2047 2 2053 in Checking the piston clearance 1 Check the piston clearances if replacing the piston piston ring set cylinder block or all parts NOTE NGNE 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 5 42 Checking the piston ring 1 Measure the piston ring dimensions B and T Replace the piston ring set if out of specification CE Er ui S6AU5133 Piston ring dimensions Top ring B 1 17 1 19 mm 0 0461 0 0469 in T 1 95 2 15 mm 0 0768 0 0846 in 2nd ring B 1 47 1 49 mm 0 0579 0 0587 in T 2 40 2 60 mm 0 0945 0 1024 in Oil ring B 2 35 2 50 mm 0 0925 0 0984 in T 2 30 2 60 mm 0 0906 0 1024 in Checking the piston ring end gap 1 Level the piston ring in the cylinder with a piston crown at the specified mea suring point 2 Measure the piston ring end gap 5 43 S6AU5134 NOTE The figures are for reference only Depend ing on how the parts are assembled the actual measurements may not be
93. ce of the flywheel magnet lt Apply engine oil to the threads of the fly wheel magnet nut GG and upper and lower surfaces of the washer before installa tion 12 Tighten the flywheel magnet nut to the specified torque 5 5 S6AG5G40 WARNING Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily Flywheel holder 90890 06522 Charge coil bolt 12 N m 1 2 kgf m 8 9 ft lb Flywheel magnet nut 98 N m 9 8 kgf m 72 3 ft lb 13 Install all parts removed during disas sembly 6AU3K11 Power unit check and adjustment Manual starter M model Manual starter M model S6AU5024 Part name Remarks Start in gear protection cable Bolt Spring Starter plunger Spring Cover Fuse puller Cap Starter handle Starter rope Damper Spiral spring Sheave drum assembly E clip Sheave drum Drive pawl Drive pawl spring 2 a Oo o SI On Un P DI NN Hm 1 900 mm 74 8 in reference data PPP RPP PPP PRP RPP k H k ON k 6AU3K11 5 6 pour E Power unit S6AU5024 Part name Spring Drive pawl spring 1 Drive plate Screw 5 7 6AU3K11 Manual starter M model Disassembling the manual starter 5 Remove the starter rope and E clip 1 While holding the starter rope turn the and then remove the drive pawl drive sheave drum in the direction of the pawl spring 2 and spr
94. 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 S6AU6018 S S6AU6019 6 8 Lower unit Assembling the propeller shaft housing 1 Install a new bushing into the propeller shaft housing to the specified depth S6AU6021 Cz Driver rod L3 90890 06652 Needle bearing attachment 90890 06617 2 Apply grease to new oil seals and then install them into the propeller shaft hous ing to the specified depth NOTE n Install an oil seal halfway into the propeller shaft housing and then install the other oil seal Cz Driver rod L3 90890 06652 Needle bearing attachment 90890 06614 6 9 Installation depth amp 3 0 3 5 mm 0 12 0 14 in 3 Install a new ball bearing into the propel ler shaft housing S6AU6025 NOTE Install the ball bearing with the manufacture identification mark facing toward the reverse gear 22 Driver rod LS 90890 06606 Ball bearing attachment 90890 06634 4 Install the reverse gear and original shim s into the propeller shaft housing S6AU6026 NOTE After instal
95. ct with the lower case an S6AU6041 Bushing installer center bolt 90890 06601 Needle bearing attachment 90890 06616 Assembling the drive shaft housing 1 Install the bushing into the drive shaft housing A d 1 S6AU6045 ee K Driver rod L3 90890 06652 A Bushing attachment 90890 06650 6 13 2 Apply grease to new oil seals and then install them into the drive shaft housing to the specified depth S6AU6047 NOTE Install an oil seal halfway into the drive shaft housing and then install the other oil seal Ko Driver rod L3 90890 06652 Needle bearing attachment 90890 06614 Installation depth 6 0 5 mm 0 24 0 26 in Installing the shift rod drive shaft housing and drive shaft 1 Install the forward gear into the lower case 2 Install the drive shaft sleeve Q into the lower case 3 Install the shift rod a new gasket and the drive shaft housing assembly NOTE I I Make sure that the projection on the gas ket is toward the starboard side 4 Install the drive shaft thrust washer pinion and E clip to the drive shaft 6AU3K11 O S6AU6048 NOTE When installing the pinion lift up the drive shaft slightly and align the pinion and shaft Splines Installing the propeller shaft housing 1 Install the propeller shaft assembly into th
96. ction box after connecting it 4 Adjust the engine idle speed NOTE SE If the carburetor has been disassembled and assembled adjust the pilot screw and then adjust the engine idle speed See Adjusting the pilot screw 4 13 Adjusting the pilot screw 1 Adjust the throttle stop screw NOTE Se 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 1 2 1 3 4 turns to tighten it temporarily 2 Start the engine and warm it up 3 Attach the special service tool to spark plug wire 1 Digital tachometer 90890 06760 6AU3K11 4 Turn the pilot screw in direction until it is lightly seated and then turn it in direction the specified number of turns _ 56AU4032 For Europe For Oceania gt KZ Pilot screw adjusting tool for d Europe 90890 03154 2 Pilot screw setting 1 5 8 turns out 5 Turn the throttle stop screw in direc tion or until the specified engine idle speed is obtained 6AU3K11 Carburetor unit NOTE eee 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
97. cutter to adjust the contact width of the bottom edge of the valve seat 5 33 Q XY S6AG5 70 Previous contact width 5 Use a 45 cutter to adjust the contact width of the valve seat to specification S6AG5 80J Previous contact width Specified contact width 6 Check the valve seat contact area of the valve NOTE To check the valve seat contact area see Checking the valve seat 5 31 7 Ifthe 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 ke S6AG5 30 O Previous contact width 6AU3K11 8 If the valve seat contact area is too nar row and situated near the top 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 WI Ag Sy X S6AG5 40 O 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 S6AG5 50 O 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
98. d below Checking the outboard motor mounting height 1 Check that the anti cavitation plate is between the bottom of the boat and a maximum of 25 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 S6D51030 NOTE 0 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 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 that the fuel hoses are securely connected and that the fuel tank is full with fuel S6AU1017 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 6AU3K11 S6AU1018 NOTE If the engine oil is below the minimum level mark Q add sufficient oil until the
99. d propeller nut 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 S6AU6061 A WARNING e Do not hold the propeller with your hands when loosening or tightening it Be sure to disconnect the battery cables from the battery and remove the clip from the engine shut off switch E model NOTE ee If the grooves in the propeller nut do not align with the cotter pin hole tighten the nut until they are aligned Na Propeller nut 17 N m 1 7 kgf m 12 5 ftlb 8 Fill the lower unit with gear oil to the cor rect level 6 17 Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Gear oil quantity 150 cm 5 07 US oz 5 29 Imp oz Backlash Measuring the forward and reverse gear backlash NOTE ma NK Remove the water pump assembly before measuring the backlash 1 Install the lower unit onto a repair stand 2 Set the shift rod to the N position at the lower unit 3 Install the special service tools 4 Tighten the center bolt to the specified torque while turning the drive shaft 6AU3K11 Drive shaft and lower case Backlash KA Center bolt D 90890 06504 A Stopper guide plate 90890 06501 Bearing housing puller claw S 90890 06564 Center bolt 2 N m 0 2 kgfm 1 5 ft lb 5 Turn the lower unit upside down 6 Install the backlash indicator onto the dr
100. da tr te Na cre mnt terne teen dant den Ge 6 1 Rule le eeneg nr or er dt na 6 4 Removing the water pump 6 5 Checking the water PUND EE 6 5 Propeller shaft ROUSING uge gsegcreueeseueek uueudeeEeeegEekeugEkCeeuEECRdEESEEESSEAEEE VEER 6 6 Removing the propeller shaft housing assembly aana nane 6 7 Disassembling the propeller shaft assembly sssanenenanen anana aana an ee 6 7 Disassembling the propeller shaft housing assembly 6 7 Checking the propeller Shaft housing 6 8 Checking the propeller Share 6 8 Assembling the propeller shaft assembly 6 8 Assembling the propeller shaft housing 6 9 Drive shaft and lower Case cine 6 10 Removing the drive shaft drive shaft housing and shiftrod 6 11 Disassembling the drive Shaft housing 6 11 Disassembling the lower CaSe Etude ay cst yonder 6 11 Checking the pinion and forward gear nen aae aaa eee n ena anane 6 12 Checking the DE aNNG isa nana nement 6 12 Checking the Gh es EE 6 12 Checking the SHIM FOC iesevvetineiitiedyerstecesovenadbiaurnderessehadaaneverendhs 6 12 CHECKING the lower EE 6 12 Assembling the lower case 6 12 Assembling the drive shaft housing eaaa aee a anna anana Naane 6 13 Installing the shift rod drive shaft housing and drive schaft 6 13 Installing the propeller Shaft housing 6 14 Installing the water pump 6 15 Installing the lower UNI sert Ste nr ner nt tn PS A RTE 6 15 GET E him ne men fete net rater mr tt Laure ane 6 17
101. djust the start in gear protection cable M model S6AU1045 S6AU1026 H model short H model long gt 6AU3K11 Predelivery check NOTE SE To adjust the start in gear protection cable see Checking the start in gear protection M model 3 11 Checking the steering system 1 Check the steering friction for proper adjustment H model S6AU1027 NOTE 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 A H model B R model an General information 3 Check that there is no interference with leads cables or hoses when the out board motor is steered Checking the tilt system MT model 1 Set the tilt lock lever 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 il S6AU1030 S6AU1031 2 Check that there is no interference with leads cables or hoses when the tilted up outboard motor is steered 3 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 SE
102. e link rod from the free accel lever 2 Loosen the locknuts and and then turn the adjusting nuts and to loosen the throttle cables and S6AU 3021 3 Turn the throttle grip to the fully open position and hold it in place 4 Turn the adjusting nut so that the fully open stopper on the throttle cam con tacts the throttle cable bracket as shown and then tighten the locknut 6AU3K11 Power unit Control system NOTE Be careful not to pull the outer cables too much towards the power unit as they could be pulled out of the holes in the pivot section of the tiller handle If the outer cables are pulled out of the tiller handle see Installing the tiller handle 7 3 or Installing the tiller handle 7 8 5 Turn the adjusting nut to remove the Slack in the throttle cable and then tighten the locknut LI O SO IT 7 S6AU3022 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 the throttle cable bracket as shown Repeat steps 2 5 if necessary had GO 3 S6AU3059 6AU3K11 S6AU3
103. e lower case S6AU6050 2 Install the washer and propeller shaft housing assembly into the lower case and then tighten the bolts to the speci fied torque 6AU3K11 Drive shaft and lower case NOTE S6AU6157 Install the propeller shaft housing assembly with the arrow mark facing upward Propeller shaft housing bolt 8 N m 0 8 kgf m 5 9 ft lb 3 Check that the shifting mechanism works properly and smoothly 6 14 Lower unit Installing the water pump 1 Install the dowels and outer plate car tridge S6AU6053 2 Install the Woodruff key and impeller to the drive shaft S6AG 6390 NOTE EEE When installing the impeller amp 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 water pump housing S6AG6570 6 15 NOTE TT TL Align the insert cartridge projection with the hole in the water pump housing 4 Install the water pump housing assembly into the lower case and then install the rubber seal at 572 S6AU6056 CAUTION Do not turn the drive shaft counterclock wise otherwise the water pump impeller may be damaged NOTE EE 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 projections on the rubber seal
104. e pinion teeth Replace the pin ion if cracked or worn 2 Check the pinion for smooth operation NOTE eg Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place Disassembling the starter motor 1 Slide the pinion stopper down as shown and then remove the clip pin ion stopper and spring S6AU8010 8 22 ELEC ELEC ES Electrical system 2 Turn the pinion clockwise and then remove the pinion S6AU8011 3 Remove the cover stator armature O P S6AU8013 and washer Checking the starter motor 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty S6AG8440 2 Measure the commutator diameter Replace the armature if below specifica S6AU8012 tion 4 Remove the nuts spring washers washer Spacer and screws and then remove the brush holder assembly from the bracket 49 S6AG8450 Commutator standard diameter 30 0 mm 1 18 in Wear limit 29 0 mm 1 14 in 8 23 6AU3K11 Starter motor E model 3 Measure the commutator undercut Replace the armature if below specifica tion 69J8410 S6AG8470 Commutator standard undercut 0 5 0 8 mm 0 02 0 03 in Wear limit 0 2 mm 0 01 in Brush holder assembly continuity Checking points Continuity Brush Terminal Yes
105. e shaft 6AU3K11 S6AG6390 NOTE I 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 water pump housing S6AG6570 NOTE eege Align the insert cartridge projection with the hole in the water pump housing 6 36 Lower unit 4 Install the water pump housing assembly into the lower case and then install the rubber seal eg S6AU6134 CAUTION Do not turn the drive shaft counterclock wise otherwise the water pump impeller may be damaged NOTE 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 Align the projections on the rubber seal with the holes in the water pump housing 5 Tighten the water pump housing bolts and to the specified torque Water pump housing bolt and og 18 N m 1 8 kgf m 13 3 ftlb Installing the lower unit 1 Set the shift lever to the R position H model Set the remote control lever to the R position R model 2 Setthe shift rod to the R position 6 37 3 Install the lower unit to the upper case and then tighten the lower case mounting bolts to the specified torque S6AU6136 NOTE e Before installing the lower unit to the upper case install the dowels into the lower case
106. e the fuel fil ter Fuel pump malfunc tion Disassemble and check the fuel pump Carburetor malfunc tion Malfunction of the carburetor internal parts Disassemble and check the carbure tor Low compression pressure 6AU3K11 Valve clearance not adjusted correctly Adjust the valve clearance Damaged cylinder head gasket Damaged valve Valve stuck to valve guide Scratched piston or cylinder Damaged or worn piston ring Disassemble and check the cylinder head and power unit 9 4 TRBL 1 SHTG e Troubleshooting Symptom 1 Unstable engine idle speed poor acceleration poor performance limited engine speed or engine stalls Symptom 2 Cause 1 Cause 2 Checking step Intermittent spark Spark plug malfunc tion Check the spark plug Spark plug cap mal function Check the spark plug cap Ignition coil mal function Check the ignition coil Engine shut off switch malfunction Check the engine shut off switch Charge coil mal function Check the charge coil Pulser coil malfunc tion Check the pulser coil Short or open con nection in ignition circuit Check the wiring harness continuity CDI unit malfunc tion Check the CDI unit Incorrect fuel and air amount supplied Pinched or kinked fuel hose Check the fuel hoses and fuel hose joint Clogged
107. ecking the bearing 11 6 12 6 33 Checking the brush holder and lt 7 39 8 24 Checking the camshaft nei 5 35 Checking the Carburebor seran arai 4 11 Checking the CDI unit 8 34 Checking the charge co 8 32 6AU3K11 Index Checking the choke solenoid R model 8 36 Checking the compression pressure 5 1 Checking the connecting rod big end side Cl ATANCEs EE 5 45 Checking the connecting rod small end inside diameter and big end inside EI 5 44 Checking the cooling water passage 3 7 Checking the cooling water pilot hole 1 19 Checking the crankpin oil clearance 5 45 Checking the crankehaft eee 5 45 Checking the crankshaft journal oil CICAFANCE e scie eegend eege detente 5 46 Checking the cylinder bore essee 5 42 Checking the cylinder heat 5 29 Checking the diaphragm and valve 4 5 Checking the drive shaft 6 12 6 33 Checking the electrical component 8 19 Checking the engine idle speed 3 11 Checking the engine oil 3 4 Checking the engine oil level 1 13 Checking the engine shut off switch H rel CIE 8 33 Checking the engine shut off switch due CIE 8 33 Checking the engine start button H model with electric starten 8 26 Checking the engine start button or switch and engine shut off switch 1 17 Checking the engine start switch R modelist srania 8 27 Checkin
108. ect the throt tle cable to the throttle cam and then install the clip S6AU1020 NOTE 0 Pull the throttle cable toward the engine to remove any free play in the cable before con necting the throttle cable joint 3 Check that the shift lever is in the N position as shown Connect the shift cable to the shift lever and then install the clip S6AU1022 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 H model Check that the throttle operates smoothly when the remote control lever is shifted from the F position or R position to the fully open position R model 2 Check that the gear shift operates smoothly when the shift lever or remote control lever is shifted from the N position to the F position or R position Eo S6AU1044 x A D S6AU1023 6AU3K11 S6AU1024 A H model short B H model long C R model The resistance of the throttle grip H model or remote control lever R model can be adjusted using the throttle friction adjuster D 3 Set the shift lever to the F position or R position and then check that the starter handle cannot be pulled If the starter rope can be pulled out normally a
109. ed measurement Specified oil or fluid Specified electrical value Specified engine speed resistance voltage electric current Specified tightening torque Symbols to in an exploded diagram or illustration indicate the grade of lubricant and the lubri cation point Apply 4 stroke motor oil Apply corrosion resistant grease Apply gear oil Apply water resistant grease a Applv low temperature resistant grease Apply molybdenum disulfide grease Apply injector grease Symbols to in an exploded diagram or illustration indicate the type of sealant or locking agent and the application point Apply Gasket Maker Apply LOCTITE 242 blue Apply ThreeBond 1104J Apply LOCTITE 572 Apply LOCTITE 271 red Apply silicone sealant 6AU3K1 1 4 2 aa General information Abbreviation The following abbreviations are used in this service manual Abbreviation API American Petroleum Institute BOW Bow end BTDC Before Top Dead Center CCA Cold Cranking Ampere CDI Capacitor Discharge Ignition E model Electric starter model EN European Norm European standard EX Exhaust F position Forward position H model Tiller handle model International Electrotechnical Commission IN Intake M model Manual starter model MT Manual tilt N position Neutral position PORT Port side PT Power tilt R model Remote control model R position Reverse position SAE Society of Automotive Engineers Starboard side Wiring Diagra
110. el 3 5 Checking the timing belt CAUTION Do not turn the flywheel magnet counter clockwise otherwise the water pump impeller may be damaged 1 Remove the driven sprocket cover and manual starter M model Remove the driven sprocket cover and flywheel magnet cover E model N 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 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 with a spark plug cleaner or wire brush S69J3190 6AU3K11 3 Check the spark plug Replace if the electrodes are eroded or there is exces sive carbon or other deposits or if the gasket is damaged 4 Check the spark plug gap Adjust the Spark plug gap if out of specification om i d S69J3200 NOTE Perform steps 2 4 for each spark plug Specified spark plug BR6HS 10 NGK S park plug gap 0 9 1 0 mm 0 035 0 039 in 5 Install the spark plugs tighten them tem porarily and then tighten them to the specified torque using a spark plug wrench Sp Spark plug 24 N m 2 4 kgf m 17 7 ft lb 6 Connect the spark plug caps Checking the thermostat 1 Remove the driven sprocket cover and manual starter M
111. er Disassemble and check the power unit Stuck drive shaft Buildup of foreign material on the spline of drive shaft and bushing Malfunction of the lower unit internal parts Disassemble and check the lower unit Symptom 2 Cause 1 Troubleshooting the outboard motor Cause 2 Checking step Starter rope operates but the engine does not crank Symptom 1 Engine does not crank E model Symptom 2 Manual starter mal function Disassemble and check the manual starter Damaged flywheel magnet Woodruff key Cause 1 Cause 2 Check the flywheel magnet Woodruff key Checking step Starter motor does not operate Shift lever or remote control lever not in the N position Setthe shift lever or remote control lever to the N position Blown fuse Check the fuse Engine start button or engine start switch malfunction Check the engine Start button or engine start switch Neutral switch mal function Check the neutral Switch Starter relay mal function Check the starter relay Short or open con nection in starter motor circuit Check the wiring harness continuity Starter motor mal function WD See the wiring diagram 6AU3K11 Disassemble and check the starter motor SHTG 6 Troubleshooting Symptom 2 Cause 1 Cause 2 Checking step Starter motor oper ates
112. er plate Wave washer Swivel bracket Clamp bracket Spring Tilt pin Bolt Grease nipple lt L transom model S transom model PORT M6 x 155 mm BR k A b P A BH Bb RP RN 6AU3K11 7 26 Bracket unit S6AU7038 a Oo o SI On Un BUN Hm Remarks Partname Tilt lever shaft Tilt lock lever Tilt lock rod 1 Tilt support bar Stopper shaft Tilt lever E clip Spring Swivel bracket Tilt lock rod 2 Pin1 Tilt lock plate 2 Pin2 Spring E clip Tilt lock plate 1 Collar gt L transom model S transom model Qty 1 1 1 1 1 1 4 1 1 1 1 1 1 2 1 1 2 7 27 6AU3K11 Clamp bracket and swivel bracket MT model Removing the clamp bracket 1 Remove the tilt pin clamp bracket nut and clamp bracket bolt 2 Remove the tilt stopper plate bolts Swivel bracket side 3 Remove the self locking nuts and plate 4 Remove the through tube tilt lock lever and collar and then disas NOTE TT semble the clamp brackets Unhook tilt lock rod 2 from the tilt lever when removing the lever NOTE NN Unhook tilt lock rod 1 from the tilt lock lever when removing the lever 2 Remove the E clip from the stopper 7 TT shaft and then pull out the shaft and remove the tilt support bar 5 Remove the tilt stopper plate bolts on clamp bracket side and tilt stopper plates gt
113. f each bearing into the slots in the cylinder block 4 Put a piece of Plastigauge PG 1 on each crankshaft journal parallel to the crankshaft S6D55870 NOTE Be sure not to put the Plastigauge PG 1 over the oil hole in each crankshaft journal 5 Install the remaining half of the main bearings into the crankcase NOTE e Install the main bearings in their original positions e Insert the projection of each bearing into the slots in the crankcase 5 47 6 Install the crankcase onto the cylinder block NOTE Ee 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 S6AU5150 NOTE EE Do not turn the crankshaft until the crankshaft journal oil clearance measurement has been completed Crankcase bolt 1st 15 N m 1 5 kgf m 11 1 ftlb 2nd 30 N m 3 0 kgf m 22 1 ft lb 8 Gently remove the crankcase and then measure the width of the compressed Plastigauge PG 1 on each crankshaft journal Replace the main bearings if out of specification S6D55880 6AU3K11 NOTE When loosening the crankcase bolts loosen them in the opposite order used for tighten ing Crankshaft journal oil clearance reference data 0 006 0 034 mm 0 0002 0 0013 in Selecting the crankshaft main bearing 1 Check the stamped marks and on
114. fore checking the start in gear protection 3 11 1 Setthe shift lever to the F position or R 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 N position and loosen the locknut Align the cable end with the mark on the manual Starter cover by turning the adjusting nut 3 Tighten the locknut S6AU3034 Checking the engine idle speed 1 Start the engine and warm it up 2 Attach the special service tool to spark plug wire 1 and then check the engine idle speed Adjust if out of specifi cation S6AU 3035 6AU3K11 Digital tachometer 90890 06760 Engine idle speed 1 050 50 r min 3 Turn the throttle stop screw in direc tion or until the specified engine idle speed is obtained As SS E S lt S6AU3036 NOTE To increase the engine idle speed turn the throttle stop screw in direction To decrease the engine idle speed turn the throttle stop screw 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 Startthe engine and warm it up 2 Attach the special service tool to spark plug wire 1 S6AU 3037 6AU3K11 Con
115. ft lb 7 Install the tilt pin 8 Apply grease to all grease nipples until it comes out from the areas S6AU 7048 NOTE EE ee To check the tilt operation see Checking the tilt system MT model 1 17 7 30 Bracket unit Clamp bracket and swivel bracket PT model 19 N m 1 9 kgf m 14 0 ft Ib 24 N m 2 4 kgf m 17 7 ft Ib 3 N m 0 3 kgf m 2 2 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib S6AU7049 P art name Remarks a Oo ON On Un BUN Hm Cap Self locking nut Plate Nut Washer Clamp bracket Bolt Washer Collar Shaft Collar Collar Stopper 1 Swivel bracket E clip Clamp bracket Through tube Not reusable PORT kA k k k k MA k k NNN HN FA HO NN 7 31 6AU3K11 Clamp bracket and swivel bracket PT model 19 N m 1 9 kgf m 14 0 ft Ib 24 N m 2 4 kgf m 17 7 ft Ib x 3 N m 0 3 kgf m 2 2 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib S6AU7049 P art name i Remarks Stopper 2 Bolt Anode Shaft Grease nipple Ground lead Bolt Collar PT unit Collar Plastic tie Collar A k k k 4 N A k k HEN H 6AU3K11 7 32 Bracket unit Removing the PT unit 1 Fully tilt the outboard motor up and then Support it with the tilt stop lever S6AG7771 After tilting up the outboard motor be sure to supp
116. g the exhaust manifold oil pan and exhaust guide seeen 7 22 Checking the filter 7 44 Checking the fuel filter 3 3 4 4 Checking the fuel joint 4 5 Checking the fuel joint and fuel hose fuel joint to carburetor eere 3 3 Checking the fuel pump 4 4 Checking the fuel System cecce 1 13 Checking eise 7 54 Checking the fuse E model 8 26 Checking the gear oil 3 14 Checking the gear oil level 1 14 Checking the gear PUMP eerrnrvrrrrrrrrnrrn 7 44 Checking the gear shift and throttle operatio N s slesi ine rini i EES 1 15 Checking the gear shift operation H model nanas gan ag aan aaa E ds 3 10 Checking the gear shift operation RMmodel sa asia aaa aana nie ga a nus 3 10 Checking the ignition coll 8 31 Checking the ignition Spark 11 8 30 i 1 Index Checking the ignition timing 3 12 Checking the lighting coil niki 8 36 Checking the lower case 6 12 6 33 Checking the lower unit for air leakage 3 15 Checking the manual starter 5 8 Checking the neutral switch H model with electric starter a c 8 27 Checking the neutral switch R model 8 28 Checking the oil pressure switch 8 34 Checking the oil PUMP eee 5 37 Checking the oil strainer oo eee 7 22 Checking the outboard motor mounting height 1 13 Checking the pinion and forward 0 akinesia anti 6 12 6 33 Checking the piston clearance nnsrarvnen 5 42 Checking the pi
117. g the ln ue EE 7 8 Friction plate H model ccistsssndensdcatesisaetescisavanssansaceiedeiandcsstanacaterslusanas 7 11 Disassembling the friction TEE 7 12 Assembling the friction plate 7 12 e un Bt TU e BEN 7 14 Upper case and Steering arm 7 17 Removing the upper case 7 21 Disassembling the Upper EE 7 21 Checking the exhaust manifold oil pan and ekhaustguide_ 7 22 Checking the olebraImget goe sees naissant aana Anan Naane 7 22 Assembling the upper EE 7 22 Removing the steering arm 7 23 Installing the steering arm sasae aane eaaa ene ba an inde 7 23 Installing the upper Case asasi aee eaaa aana aana aaa Nn Anna 7 24 Clamp bracket and swivel bracket MT model 7 26 Removing the clamp bracketsss sise entnemensensse 7 28 Disassembling the swivel bracket NNN 7 28 Assembling the swivel bracket eea anna aane anane nne nean 7 29 Installing the clamp ee EE 7 30 Clamp bracket and swivel bracket PT model 7 31 Removing the PT UNIES SR nn A re dns 7 33 Removing the clamp bracket sisi 7 33 Installing the Clamp bracket EE 7 34 Installing He PT unik sasasi danene ani Gae ENENGE E NA KN i Ga ea wi 7 34 PT MOtOr EE 7 36 Disassembling the PT MOLOTEEE Gene naar Geirs 7 37 Checking the PT NON ss 7 38 Checking the brush holder and brush 7 39 Assembling the Ae EE 7 39 6AU3K11 PT gear PUMp sannnnnnnnnnnnnnnnnnnnnnnnnnvnnvnnnnnnnnnnvnnnnnnnnnnnnnn
118. giene 1 Use compressed air to remove dust and dirt during disassembly Apply oil or fluid 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 6AU3K11 Identification Model This manual covers the following models Applicable model Pike 9 9 Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket S6AG1010 KZ D S6AL1D00 Model name Approved model code Transom height Serial number 6AU3K1 1 Safety while working Identification 1 6 an General information Special service tool Digital tachometer 90890 06760 Timing light 90890 03141 Leakage tester 90890 06840 Vacuum pressure pump gauge set 90890 06756 Pilot screw adjusting tool 90890 03154 Compression gauge 90890 03160 Tappet adjusting tool 90890 01311 Flywheel holder 90890 06522 Flywheel puller 90890 06521 Shaft holder 90890 06561 6AU3K11 Valve spring compressor 90890 04019 Ke Valve spring compressor attachment 90890 06320 WA Valve guide
119. green Lg Red R Green G Red R Blue L Continuity No continuity 7 54 Bracket unit 2 Connect the positive battery lead to the light green Lg lead and the negative battery lead to the black B terminal PT relay continuity as shown and then check the PT relay Red R Blue lo Continuity for continuity Replace the PT relay if out of specification Red R Green G Continuity Red R Blue L Green G Blue L No continuity 1 Red R Green G Green G Blue L amp No continuity Checking the PT switch Check the PT switch for continuity Replace if out of specification Switch position he S6AG7890 Lead color Skyblue Sb Red R Free 3 Connect the positive battery lead to the sky blue Sb lead and the negative Up battery lead to the black B terminal as shown and then check the PT relay for continuity Replace the PT relay if out of specification S6AU7108 7 55 Down 6AU3K11 6AU3K11 Electrical system Electrical component and wiring harness routing sssm 8 1 TSOP IW ee eebe EE 8 1 e 8 9 Pee 8 11 Checking the electrical component 8 19 Measuring Me peak voltage E 8 19 Starter motor E model 8 20 Removing the starter MOON ciexvisaivts sux co
120. hat the sheave drum turns smoothly and to check the starter rope for slack Repeat steps 4 9 if necessary SIT S6AU5036 NOTE Hold the starter plunger while pulling the starter handle 5 10 11 Install the manual starter onto the power unit and then connect the start in gear protection cable NOTE y 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 M model 3 11 12 Pull the starter handle to extend the Starter rope completely and then mea sure the starter rope length S6AU5037 AS Starter rope pulling length 1 400 1 600 mm 55 12 62 99 in 5 11 6AU3K11 Manual starter M model Power unit Power unit Power unit assembly 211 18 N m 1 8 kgf m 13 3 ft Ib S6AU5038 Part name Remarks M model E model Manual starter Flywheel magnet cover Driven sprocket cover Oil dipstick Throttle cable Choke rod Power unit Bolt Negative battery cable Bolt Gasket Dowel Start in gear protection cable Cooling water hose Cooling water hose Flushing hose Fuel hose M6 x 12 mm E model M8 x 16 mm E model Not reusable M model For Europe A k k k k A k k k k k PNR k k ok 6AU3K11 5 12 S6AU5038 Part name Remarks E model M6 x 10 mm E model M8 x
121. he bracket and the groove in the cover 5 Install the pinion spring and pinion stopper 49 6 Slide the pinion stopper down and then install a new clip 6AU3K11 T 0 S6AG8510 NOTE e Install the pinion stopper in the direction shown lt Check the starter motor operation again after assembling it Installing the starter motor 1 Install the starter motor to the power unit 2 Connect the wiring harness to the starter motor and then fasten the wiring har ness NOTE PEN Ng To connect the wiring harness to the starter motor see Electrical component and wiring harness routing 8 1 Starting system Checking the fuse E model 1 Check the fuse for continuity Replace if there is no continuity S6AU8024 NOTE For the location of the fuse see Electrical component and wiring harness routing 8 1 6AU3K11 Starter motor E model Starting system Checking the engine start button H 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 et H e eg p Ke S6AU8025 Engine start button input voltage reference data Red R Ground 12 V battery voltage 8 26 evec
122. he carburetor vag 4 11 Assembling the Carburetor ase sen anana aaa a eaaa anna nne aana anana 4 12 Installing the carburetoruuasannaussaarmmesidmneinsrvntsnnensdnnk 4 13 Adjusting the pilot SCE TE 4 13 6AU3K11 e Fuel system Hose routing Fuel hose blowby hose and cooling water hose Cooling water hose thermostat cover to cylinder block Blowby hose cylinder head cover to intake silencer Fuel hose fuel joint to fuel filter assembly Flushing hose flushing hose adapter to intake manifold for Europe Cooling water hose exhaust cover to exhaust Cooling water hose intake manifold to cooling water pilot hole Fuel hose fuel filter assembly to fuel pump 4 1 S6AU4001 Fuel hose fuel pump to carburetor assembly 6AU3K11 Hose routing Fuel pump fuel filter and fuel joint Fuel pump fuel filter and fuel joint el 8 N m 0 8 kgf m 5 9 ft Ib S6AU4005 Part name Remarks Fuel pump Bolt O ring Clamp Fuel hose Fuel hose Fuel filter Fuel hose Plastic tie Seal Fuel joint Bolt M6 x 30 mm Not reusable A k k k M k k H UN H NN KR No 1 2 3 4 5 6 7 8 9 10 11 12 6AU3K11 4 2 el H Fuel system 0 5 N m 0 05 kgf m 0 37 ft Ib PS2 N m 0 2 kgf m 1 5 ft Ib S6AU4006 Partname Remarks a CO A eum P GH Ha O lt Screw 4 x 30 mm Cover Diaphragm Screw Check valve Fue
123. he crankpin parallel to the crankshaft S6AU5144 NOTE ee 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 to the crank pin S6AU5145 NOTE SS Make sure that the a marks of the con necting rod face towards the flywheel magnet end A of the crankshaft 4 Tighten the connecting rod cap bolts to the specified torques in 2 stages 6AU3K11 Cylinder block S6AU5146 NOTE SE Do not turn the connecting rod until the crankpin oil clearance measurement has been completed Connecting rod cap bolt 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 11 N m 1 1 kgf m 8 1 ft lb 5 Remove the connecting rod cap and measure the width of the compressed Plastigauge PG 1 on the crankpin Check the connecting rods and crank shaft if out of specification and replace the defective parts S6AU5147 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 5 46 2 Place the cylinder block upside down on a bench 3 Install half of the main bearings and the crankshaft into the cylinder block S6D55860 NOTE E RR e Install the main bearings in their original positions lt Insert the projection o
124. he specified torques Friction plate bolt M8 18 N m 1 8 kgf m 13 3 ftlb 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 7 13 NOTE To check and adjust the friction plate see Checking the steering operation H model 3 12 Friction self locking nut 6 N m 0 6 kgf m 4 4 ft lb 6AU3K11 Bottom cowling a Oo Partname Friction plate H model Bottom cowling o SI On Un P DI NN Hm Flushing hose Grommet Grommet Grommet Shift lever Bolt O ring Bolt Retaining plate Grommet Grommet Holder Holder Bolt Bracket Start in gear protection cable Shift rod lever 6AU3K11 A k M OI A k k RP PNP RP RPP k k k For Europe For Oceania PT model M5x16mm M6x25 mm H model R model PT model M6x25 mm M model 7 14 Bracket unit Partname Remarks Bolt Bracket Clip Bolt Bracket Spring Shift rod Grommet Bolt Bolt Bracket Bracket Starter relay Cooling water hose Bolt Cowling lock lever Bolt M6 x 20 mm M6 x 20 mm PT model PT model M6 x 20 mm E model M6 x 12 mm E model E model E model E model M6 x 35 mm O EE Ee Ee M6x12mm 7 15 6AU3K11 Part name
125. hed ve lt u Clip removed Yes CSS D KO EE WS N lt GR CL GA 9 3 Connect the engine shut off switch con AN Se V nector and terminal TI ENA i by e sW 4 H 4 Checking the engine shut off switch R model 1 Disconnect the 10 pin main harness cou pler 2 Turn the engine start switch to ON and then check the engine shut off switch for continuity at the 10 pin main harness S6AU8040 coupler remote control box end Check the wiring harness or replace the engine 2 Check the engine shut off switch for shut off switch if out of specification continuity between the engine shut off switch connector and terminal engine shut off switch end Replace if out of Specification OFF S6AU8042 Engine shut off switch continuity White W Black B Switch position Continuity Clip installed No Clip removed Yes S6AG8150 3 Turn the engine start switch to OFF 4 Connect the 10 pin main harness cou pler 8 33 6AU3K11 Ignition and ignition control system Engine electric control system Engine electric control system Checking the CDI unit 1 Measure the CDI unit M output peak voltage Replace if below specification S6AU8043 NOTE SE 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 shut off
126. hin even layer of Mechanic s blueing dye Dykem onto the valve seat Valve seat contact width Intake and exhaust 3 Press the valve lightly against the valve 0 6 0 8 mm 0 024 0 031 in seat with a valve lapper as shown Refacing the valve seat 1 Reface the valve seat with the valve seat cutters S6AU5089 DNT 4 Measure the valve seat contact width where the blueing dye is adhered to the ea 5050 valve face Reface the valve seat if the valve is not seated properly or if the valve A Valve seat cutter holder seat contact width is out of specification 7 90890 06316 Check the valve guide if the valve seat Valve seat cutter contact is uneven 30 intake 90890 06328 30 exhaust 90890 06815 45 intake 90890 06312 45 exhaust 90890 06814 60 intake 90890 06315 4 60 exhaust 90890 06813 ES E 6AU3K11 5 32 S68V5720 2 Cut the surface of the valve seat with a 45 cutter by turning the cutter clockwise until the valve seat face has become smooth S6AU5095 S6AG5 20 Slag or rough surface CAUTION Do not over cut the valve seat Be sure to turn the cutter evenly downward ata pres sure of 40 50 N 4 5 kgf 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 307 je Ne SCH S6AG5 60 O Previous contact width 4 Use a 60
127. hrust model S6AU6086 Remarks a CO CDJ On Un P DI FA Hm Part name lt Cross pin Dog clutch Cross pin ring Shift plunger Spring Propeller shaft Washer Reverse gear Reverse gear shim Ball bearing O ring O ring Propeller shaft housing Bolt Needle bearing Oil seal LA ki ke kb kb ki om Not reusable Not reusable Not reusable M6 x 25 mm Not reusable Not reusable NPNP PPR 6AU3K11 6 26 Lower unit Removing the propeller shaft housing assembly 1 Remove the bolts from the propeller shaft housing 2 Remove the propeller shaft housing assembly S6AU6009 NOTE e Insert flat head screwdrivers between the propeller shaft housing assembly and the lower case to pry the assembly loose e If the propeller shaft housing assembly is stuck to the lower case use the special ser vice tools See Backlash high thrust model 6 42 Disassembling the propeller shaft assembly 1 Remove the shift plunger from the propeller shaft 2 Remove the cross pin ring and then remove the cross pin and dog clutch 3 Pull out the spring from the propeller shaft S6AU6089 6 27 Disassembling the propeller shaft housing assembly 1 Remove the reverse gear and shim s S6AU6090 2 CAUTION Do not reuse the bearing always replace it with a new one GC Stopper guide plate D
128. hted 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 manual of the battery e Disconnect the negative battery cable first then the positive battery cable AS Electrolyte specific gravity 1 280 at 20 C 68 F Lubricating the outboard motor 1 Apply water resistant grease to the areas shown 3 17 S6AG 3440 S6AU3056 H model NOTE echt Apply grease until it flows from the bushings 2 Apply low temperature resistant grease to the areas shown 6AU3K11 General 3 Apply corrosion resistant grease to the area shown S6D53300 6AU3K11 3 18 CHK ADJ 3 19 Q Periodic check and adjustment MEMO 6AU3K11 Fuel system HOS FOUUING EEN 4 1 Fuel hose blowby hose and cooling water hose eran a nean ei 4 1 Fuel pump fuel filter and fuel joint ss 4 2 Checking the fuel UML int nn nn 4 4 Checking the fuel filter 4 Sn entr Din kranser 4 4 Checkingthe fueljolht gaga nes ARS OR A a 4 5 Disassembling the fuel pump VV 4 5 Checking the diaphragm and valve ist honda tnt les 4 5 Assembling the fuel pump ss 4 6 Carburetor Unit sasana dagan gasangan nn menu dee 4 7 CAB EE 4 9 Removing the e E EE 4 11 Disassembling the Carburetor un 4 11 Checking t
129. ing from the arrow shown until there is no tension in sheave drum the spiral spring 2 Remove the drive plate and drive pawl spring 1 S6AU5027 Checking the manual starter 100 1 Check the drive pawl E clip starter plunger and drive plate Replace if cracked or damaged 2 Check the springs Replace if bent cracked or damaged 3 Remove the sheave drum S6AG5550 S6AU5026 4 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 6AU3K11 5 8 3 Check the sheave drum Replace if cracked or damaged 4 Check the spiral spring Replace if cracked bent or damaged S6AG5540 5 Check the starter handle Replace if cracked or damaged 6 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 1 900 mm 74 8 in e Be sure to use a genuine Selva starter rope Assembling the manual starter 1 Install the starter rope into the sheave drum 2 Install the drive pawl starter plunger drive pawl spring 2 spring and E clip 3 Install the starter handle 5 9 S6AU5030 NOTE e Tie a knot at the end of the starter rope as shown in the illustration lt Be sure to leave 12 20 mm 0 47 0 79 in at the end of the starter rope
130. ition and ignition control system Pulser coil resistance reference data Charge coil output peak voltage Brown Br Blue L Unloaded Loaded Cranking 1 500 140 160 180 White red W R Black B 240 360 Q at 20 C 68 F 4 Connect the pulser coil connectors Checking the charge coil 2 Disconnect the charge coil connectors 1 Measure the charge coil output peak voltage Replace the stator coil assembly if below specification 3 Measure the charge coil resistance Replace if out of specification Charge coil resistance reference data Brown Br Blue L 232 348 Q at 20 68 F 4 Connectthe charge coil connectors S6AU8039 NOTE 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 shut off 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 6AU3K11 8 32 ELEC ELEC RW Electrical system Checking the engine shut off switch H model Engine shut off switch continuity 1 Disconnect the engine shut off switch White W Black B connector and terminal Switch position Continuity Clip installed No Engine stop button pus
131. ity at the specified pressures Replace if out of specification S6AG8130 8 35 NOTE Slowly operate the special service tool Vacuum pressure pump gauge set 90890 06756 Oil pressure switch continuity Oil pressure switch Ground Oil pressure More than 14 7 kPa 0 147 kgf cm2 2 132 psi Less than 14 7kPa 0 147 kgf cm2 2 132 psi Continuity No NOTE SS gag Apply pressure to the oil pressure switch gradually The oil pressure switch is operat ing correctly if the digital tester indication changes from continuity to no continuity in the range of 14 7 4 9 kPa 0 147 0 049 kgf cm 2 132 0 711 psi 8 Install the oil pressure switch and then connect the oil pressure switch connec tor Checking the warning indicator assembly 1 Disconnect the oil pressure switch con nector and then ground the pink P lead wiring harness end 2 Start the engine increase the engine speed to approximately 2 000 r min and check that the oil pressure warning indi cator comes on 3 Push the engine stop button H model Turn the engine start switch to OFF R model 4 Connect the oil pressure switch lead ter minal 5 Disconnect the warning indicator assem bly coupler 6AU3K11 Engine electric control system Charging system E model 6 Connect the yellow red Y R lead to the positive penlight battery terminal 1 5 V and connect the pink P lead to the neg ati
132. ive shaft 11 8 mm 0 46 in in diame ter and then install the dial gauge 6AU3K11 S6AU6076 NOTE gt Install the dial gauge so that the plunger tip is aligned with the mark on the back lash indicator UL Backlash indicator 90890 06706 G Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base B 90890 06844 7 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction NOTE are o e Pull the drive shaft downward and then turn it e Measure the backlash at 4 points to find the average AS Forward gear backlash 0 50 2 27 mm 0 0197 0 0894 in 6 18 Lower unit 8 Adjust the current shim thickness if the forward gear backlash is out of specifica tion Forward gear backlash Less than 0 50 mm 0 0197 in 1 39 M x 0 40 More than To be increased by 2 27 mm 0 0894 in M 1 39 x 0 40 Shim thickness To be decreased by M Measurement Available shim thicknesses 0 10 0 12 0 15 0 18 and 0 30 mm 9 Remove the special service tools from the propeller shaft 10 Install the propeller washer and propel ler nut without installing the spacer S6AU6077 11 Tighten the propeller nut to the specified torque Propeller nut 2 N m 0 2 kgf m 1 5 ft lb 12 Slowly turn the drive shaft clockwise and counterclockwise and measure the back la
133. k mechanism of the lever 3 13 S6AG3220 Checking the PT fluid level 1 Fully tilt the outboard motor up and then Support it with the tilt stop lever 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 PT unit should lose fluid pressure 2 Remove the reservoir cap and then check the fluid level in the reservoir S6AG 3230 NOTE R 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 AC Recommended PT fluid ATF Dexron II 6AU3K11 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 MD and then check the gear oil level in the lower case Also check the oil for discoloration and its viscosity A e S6AU3061 S6AU3043 Except for high thrust model For high thrust model LA IB NOTE a e H 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 e If the oil appears milky or dirty check for and rep
134. kgf m 21 4 ft Ib NG 6N mi0 6kgi m 4 4 ft Ib 12N m 1 2 kgf m 8 9 ft Ib S6AU5071 Remarks a Oo LO OO On Un BUN KE Part name lt Plug O ring Anode Screw Cylinder head assembly Gasket Dowel Bolt Bolt Bolt Screw Plate Gasket Gasket Cylinder head cover Bolt Oil filler cap Not reusable 95 x 24 mm Not reusable M6 x 70 mm M8 x 74 mm M8 x 60 mm 4 x 10 mm Not reusable Not reusable M6 x 20 mm kA P k k k k Un M BRUN k k k k kb 5 25 6AU3K11 Cylinder head 7 N m 0 7 kgf m 5 2 ft Ib Pl 8 N m 0 8 kgf m 5 9 ft Ib S6AU5072 P art name Remarks Not reusable a Oo OANA Un P DI FA Hm Oil seal Cylinder head Intake valve Exhaust valve Camshaft Gasket Oil pump assembly Bolt Locknut Adjusting screw Valve cotter Valve spring retainer Valve spring Valve seal Valve spring seat Valve guide Collar Not reusable M6 x 30 mm Not reusable Not reusable w aA SS PS P PS SS Ota k k N NR FE 6AU3K11 5 26 he 8 N m 0 8 kgf m 5 9 ft Ib S6AU5072 P art name Remarks Rocker arm Spring Collar Shaft 5 27 6AU3K11 Removing the cylinder head 1 Remove the cylinder head cover 2 Remove the cylinder head bolts in the sequence shown cofs SL ZC E Gg N
135. l 9 7 Troubleshooting the lower unit 9 8 6AU3K11 TRBL D SHTG e Troubleshooting Troubleshooting the outboard motor NOTE Before troubleshooting the outboard motor lt Make sure that fresh fuel of the specified type has been used lt Make sure that the battery is fully charged lt 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 Content considered as the trouble causes of symptom 2 Cause 2 Content considered as the trouble causes of cause 1 Troubleshooting the power unit Symptom 1 Engine does not crank M model Symptom 2 Cause 1 Cause 2 Checking step Starter rope does not operate 9 1 Shift lever notin the N position Set the shift lever to the N position Start in gear pro tection cable not adjusted correctly Adjust the start in gear protection cable Manual starter mal function Disassemble and check the manual Starter Stuck piston Seizure or rust Piston lock due to water in the com bustion chamb
136. l parts removed during removal 5 2 Replacing the timing belt CAUTION 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 21 and Installing the sprocket and timing belt 5 22 1 Disconnect the spark plug caps and remove the spark plugs 2 Disconnect the cooling water hose from the thermostat cover 3 Remove the flywheel magnet nut S6AG5G30 WARNING Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily 5 3 NOTE __ _ Use a 22 mm socket to loosen the flywheel magnet nut Flywheel holder 90890 06522 4 Remove the flywheel magnet and Woo druff key S63P5280 S63P5290 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 ee 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 charge coil 6AU3K11 lt lt L ih 4 gr k SS S de 5 6 Align the 1 A mark on the driven sprocket with the A mark on the thermostat cover S6AU5017 NOTE SE Check tha
137. l pump body 2 Diaphragm Spring Fuel pump body 1 Nut Spring Plunger Pin Not reusable 93 x5 mm 4 1 1 2 2 1 1 1 1 4 1 1 1 4 3 6AU3K11 Checking the fuel pump 1 Connect the special service tool to the fuel pump inlet 2 Cover the fuel pump outlet with your fin ger and then apply the specified positive pressure Check that there is no air leak age S6AU4007 Vacuum pressure pump gauge set 4 90890 06756 ZX Specified positive pressure 50 kPa 0 5 kgf cm 7 3 psi 3 Apply the specified negative pressure and check that there is no air leakage S6AU4008 ZX 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 6AU3K11 Fuel pump fuel filter and fuel joint S6AU4009 Specified positive pressure 50 kPa 0 5 kgf cm 7 3 psi Checking the fuel filter NOTE To check the fuel filter see Checking 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 pres sure Replace the fuel filter if the speci fied pressure cannot be maintained for at least 10 seconds e sg A VA ei S6AU4003 NOTE
138. lay from a battery terminal Check that there is no continuity between the starter relay terminals Replace if there is continuity S6AU8033 8 Install the starter relay and then connect the battery cables starter relay connec tor and starter relay leads Ignition and ignition control system Checking the ignition spark 1 Disconnect the spark plug caps from the Spark plugs NOTE To prevent the engine from starting when cranking it be sure to disconnect both spark plug caps 2 Connectthe 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 6AU3K11 AA WARNING e Do not touch any of the connections of the special service tool lt Be sure to install the special service tool to the spark plug cap so that sparks do not leak out lt Keep flammable gas or liquids away since this test can produce sparks NOTE ee 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 SE S6AG8030 8 30 ELEC ELEC E Electrical system 2 Measure the spark plug cap resistance Checking the pulser coil Replace if out of specification 1 Measure the pulser coil output peak voltage Replace if below
139. ler nut to the specified torque Propeller nut 2 N m 0 2 kgf m 1 5 ft lb 13 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction S6AU6156 NOTE e Pull the drive shaft downward and then turn it e Measure the backlash at 4 points to find the average 6AU3K11 Backlash high thrust model Reverse gear backlash 0 76 2 30 mm 0 0299 0 0906 in 14 Adjust the current shim thickness if the reverse gear backlash is out of specifica tion Reverse gear backlash Less than 0 76 mm 0 0299 in 1 53 M x 0 39 More than To be increased by 2 30 mm 0 0906 in M 1 53 x 0 39 Shim thickness To be decreased by M Measurement Available shim thicknesses 0 1 0 2 and 0 3 mm 15 Turn the lower unit upright 16 Remove the special service tools and propeller and then install the water pump assembly NOTE EE To install the water pump assembly see Installing the water pump 6 36 17 Fill the lower unit with gear oil to the cor rect level 6 44 Bracket unit Tiller handle sShort ssssssusssnusnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nanna 7 1 Removing the tiller handle ce ess net nn eat nr ee tte tue at 7 3 Installing the tiller handle 7 3 Tiller h ndle ongji nuuusuuviunsalsemenuiedriemvssint numnnsiidiie 7 5 Removing the tiller handle 7 8 Installin
140. ling the reverse gear and shim s check that the gear rotates smoothly 6AU3K11 Propeller shaft housing Drive shaft and lower case Drive shaft and lower case S6AU6027 Part name Remarks L transom model S transom model Not reusable No 1 2 3 4 5 6 7 8 Shiftrod Gasket Drive shaft sleeve O ring Oil seal Bushing Drive shaft housing Drive shaft Clip Thrust washer Pinion E clip Bushing Forward gear shim Ball bearing Forward gear Not reusable Not reusable L transom model S transom model A k k k k k k k A k k k kb Not reusable Not reusable Ech 6AU3K11 6 10 Lower unit Removing the drive shaft drive shaft housing and shift rod 1 Remove the E clip pinion and thrust washer S6AU6028 2 Remove the drive shaft drive shaft hous ing assembly gasket and shift rod S6AU6029 3 Remove the drive shaft sleeve 4 Pull out the forward gear Disassembling the drive shaft housing 1 Remove the oil seals and bushing S6AU6031 CZ Driver rod L3 90890 06652 Bushing attachment 90890 06650 Disassembling the lower case 1 Remove the ball bearing and forward gear shim s S6AU6035 CAUTION Do not reuse the bearing always replace it with a new one CZ Stopper guide plate D 90890 06501 A Bearing puller assembly 90890 06535
141. ll Not reusable Not reusable Not reusable N Ne Ne MA FA FA NNN k RON NN F 6AU3K11 7 42 Bracket unit NW NW Part name 5SN m 0 5 kgf m 3 7 ft Ib Remarks S6AU7077 Spring Dowel Reservoir cap O ring 7 43 Not reusable 6AU3K11 Disassembling the gear pump 1 Remove the manual valve filter manual release pins valve seals and balls 2 Remove the gear pump housing shut tle piston 1 and shuttle piston 2 S6AU7079 3 Remove the down main valve up main valve balls om dowels drive gear 49 and driven gear Seegen S r 1 S6AU 7080 6AU3K11 PT gear pump 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 e A Pi a Cag re be 7 00 Ze SG sv Wi Sa De Ni Bi K 7 er LRS ASS ef be e ha 6 s f 09 s N a s Ne Ta KHN p sv See NG gt Ke O H Pi D a K p D CAM Bs K ser p s Be 2 Ee s Da SC a CN ka P S Bessi AN s e s sy A gt Le S6AG7185 Nae 2 Check the main valves Replace if damaged va SENG gt Se r S lt is S Na 7 3 x
142. ls Cieurastenivivedesdeusitacerspusicianextiacnnsels 8 22 Checking the starter motor operation nara ee aaa eaaa ene a eea 8 22 Checking the starter motor PINON DEE 8 22 Disassembling the starter motor aee aaa eaaa anaa anna naa anane 8 22 Checking the starter MORON Kasa 8 23 Checking the brush holder and bmueh re ena nenen nana nane 8 24 Assembling the starter MOOR Luanda 8 25 Installing the Starter motor 8 26 Starting System EE 8 26 Checking the fuse E model 8 26 Checking the engine start button H model with electric stater 8 26 Checking the engine start switch R modell 8 27 Checking the neutral switch H model with electric starter 8 27 Checking the neutral switch R model 8 28 Checking the starter relay E model 8 29 Ignition and ignition control system nissan 8 30 Checking the ignition Sparks sense te ne am lee 8 30 Checking the spark plug Cap 8 30 Checking the ignition TOAN caches Ook aaa 8 31 Checking the pulser COW seven fn et na 8 31 Checking the charge coil nansssessavnordmsarmorirenesmuap me nie 8 32 Checking the engine shut off switch H modell 8 33 Checking the engine shut off switch R modell 8 33 Engine electric control System 8 34 Ch cking the Di UM se 8 34 Checking the oil pressure Switch sas anni une Eeer e 8 34 Checking the warning indicator assembly 8 35 Checking the choke solenoid R model 8 36 Charging system E model sise 8 36 Checking the lighting Colis ist Rena
143. m Sealant and locking agent table The following table contains sealants locking agents and lubricants used in this service manual that are not listed on page 1 2 Symbol Application Bl LOCTITE 518 Sealant Henkel ThreeBond 1207B Sealant ThreeBond ME 1 Antirust lubricant 1 3 6AU3K11 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 S69J1010 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 69J1020 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 6AU3K1 1 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
144. ment Checking the compression pressure 1 Start the engine warm it up and then turn it off 2 Remove the clip from the engine shut off Switch 3 Disconnect the spark plug caps remove the spark plugs and then install the spe cial service tool into a spark plug hole S6AU5001 CAUTION Before removing the spark plugs remove any dirt or dust in the spark plug wells that may fall into the cylinders US Compression gauge 90890 03160 4 Fully open the throttle and fully push in the choke knob 5 Crank the engine until the reading on the compression gauge stabilizes and then measure the compression pressure Minimum compression pressure reference data 630 kPa 6 3 kgf cm 91 4 psi M model 700 kPa 7 0 kgf cm2 101 5 psi E model 5 1 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 and then measure the pressure again NOTE e 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 valve clearance NOTE SE Measure the valve clearances when the engine is cold 1 Remove the driven sprocket cover and manual starter
145. motor from the power unit NOTE ad 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 Ignition coil CDI unit and Rectifier Regulator E model 5 15 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 S6AU8009 6AU3K11 Starter motor E model AA 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 lt 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 assembling 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 th
146. n throttle control lever is in fully closed position Carburetor malfunc tion Throttle stop screw not adjusted cor rectly Adjust the throttle stop screw Pilot screw not adjusted correctly Adjust the pilot Screw Malfunction of the carburetor internal parts Disassemble and check the carbure tor Throttle control lever does not return to fully closed position 6AU3K11 Throttle control system malfunction Throttle cable s not adjusted correctly Check and adjust the throttle cable s Throttle link rod not adjusted correctly Check and adjust the throttle link rod Throttle cam not installed correctly Check the throttle cam 9 6 TRBL D SHTG Troubleshooting Symptom 1 Limited engine speed below 2 000 r min Symptom 2 Cause 1 Checking step Buzzer comes on R model e Oil pressure warning indicator comes on Insufficient engine oil Add sufficient oil Engine oil pressure decrease Oil pump malfunc tion Check the oil pump Clogged oil strainer Check the oil strainer Clogged oil pas sages Check the engine oil passages power unit and oil pump Oil pressure switch malfunction Troubleshooting the PT unit PT model Symptom 1 PT unit does not operate Symptom 2 PT motor does not operate Cause 1 Blown fuse Cause 2 Check the oil pres sure switch Checking s
147. n 8 36 CHECKING ne RETTE EE 8 37 Checking the Rectifier R QUi tOr nement 8 39 ELEC ELEC RS Electrical system Electrical component and wiring harness routing Top view H model with 1 lighting coil S6AU8001 a H model short Rectifier b H model long Charge coil CDI unit Lighting coil Pulser coil Oil pressure switch Warning indicator Spark plug Lighting coil leads G G Ignition coil Engine shut off switch lead 8 1 6AU3K11 Electrical component and wiring harness routing Route the oil pressure switch lead in the direction shown Fit the oil pressure switch lead into the groove in the driven sprocket cover Bend the side of the junction box inward as shown To tiller handle Route the warning indicator lead under the shift cable Fit the lighting coil lead into the holder before installing the lighting coil and holder F fm 2 0 b gt 6AU3K11 8 2 evec ELEC Ke Electrical system H model with 2 lighting coils
148. nd shift cable joint malfunc tion R model Check and adjust the shift cable and shift cable joint R model Remote control box malfunction R model Check the remote control box R model Shift rod cam mal function Check the shift link rod Detent malfunction Check the shift rod cam Shift rod operation malfunction Shift rod not con nected correctly Check the connec tion of the shift rod Shift rod not adjusted correctly Adjust the shift rod Shift mechanism malfunction in lower unit Disassemble and check the lower unit 9 8 TRBL D SHTG e Troubleshooting Symptom 1 Cooling water does not discharge from the cooling water pilot hole Symptom 2 Cause 1 Checking step 9 9 Clogged cooling water inlet Check the cooling water inlets Clogged cooling water passages Incorrectly con nected cooling water hose Check the cooling water passages Damaged water pipe or incorrect installation Check the water pipe and its installa tion Water pump mal function Damaged water pump impeller Check the impeller Check the Woo druff key Water leakage from water pump hous ing Check the water pump housing Check the insert cartridge Check the outer plate cartridge 6AU3K11 A C Abbreviation eu anaa aga aa pina ah aga aaa 1 3 Adjusting the pilot
149. nd 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 Continuity engine start button and wiring harness if below specification Pushed enn position Free F position or R position Yes No 4 Connect the connectors of the neutral switch Checking the neutral switch R model NOTE Be sure to check the engine start switch for continuity before checking the neutral switch 1 Set the remote control lever to the N position 2 Turn the engine start switch to START SPE and then check the neutral switch for continuity at the 10 pin main harness Neutral switch input voltage coupler remote control box end 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 S6AG 8220 6AU3K11 8 28 evec ELEC EH Electrical system 3 Set the remote control lever to the F posi tion or R position and then check the neutral switch for continuity Check the Push the engine start button and then measure the input voltage between the Starter relay connector neutral switch end and the ground Check the engine start button neutral switch wiring ha
150. nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 7 41 Disassembling the gear pump anana nana aana anana nana n nane 7 44 Checking the gear pUMp Le 7 44 Checking the valve Seal muurrmmmsvrrvrvnrvvrrirerrennrrrererrorrressvrrressenn 7 44 CNECKING NG MENS 7 44 Assembling the gear pump 7 45 PT CYL OP geste eege ege eegene Eege 7 47 Disassembling the tilt cylinder uk 7 49 Checking the tilt cylinder and piston EE 7 49 Assembling the tilt cvlmder ken 7 50 Bleeding the P T Tt 7 52 PT electrical system BE 7 54 CHGEKING the TUS Cine ater cee eae Grr oa il i eo ag ana ERR 7 54 Checking the ER 7 54 CHECKING UTEP rn EE A RENE 7 55 6AU3K11 Bracket unit Tiller handle short 22 N m 2 2 kgf m 16 2 ft Ib 36 N m 3 6 kgf m 26 6 ft Ib S6AU7111 Part name Remarks a Oo o A um P WW N Ha OD lt Throttle cable Nut Nut Plate Bushing Plug Engine start button Tiller handle bracket Stud bolt Bushing Washer Wave washer Bushing Tiller handle assembly M model E model FPRPNNBFPNPFPRFPRPRPRFPHENN 7 1 6AU3K11 Part name a Oo Q lt Tiller handle short hse 2 N m 0 2 kgf m 1 5 ft Ib S6AU7112 Remarks Throttle cable Tiller handle Throttle friction adjuster Cotter pin Friction piece Engine shut off switch Screw Grip Washer Spring Washer Bushing Throttle shaft Plate Screw CDJ On Un P DI NN Hm 6AU3K
151. nstall the plate and upper mounting nuts and then tighten the upper mounting nuts to the specified torque 3 Install the ground lead terminal to the upper case as shown 4 Install the rubber dampers and front and then install the mount hous ings and ground lead terminal using the mount housing bolts amp and and the mount housing nuts 9 6AU3K11 Upper case and steering arm NOTE SE Install the ground lead terminal so that it is within the range 30 shown 5 Tighten the mount housing nuts to the specified torques in 3 stages and in the sequence shown NOTE a Tighten the mount housing nuts evenly and in the following order 4 2H 3H 4 6 Install the ground lead terminal on to the swivel bracket 7 Install the water pipe S6AU 7036 7 24 Bracket unit Upper mounting nut 20 N m 2 0 kgf m 14 8 ftlb Mount housing nut 49 1st 7 Nem 0 7 kgf m 5 2 ft lb 2nd 12 Nem 1 2 kgf m 8 9 ft lb 3rd 14 N m 1 4 kgf m 10 3 ft lb Grease nipple 3 N m 0 3 kgf m 2 2 ft lb 7 25 6AU3K11 Upper case and steering arm Clamp bracket and swivel bracket MT model Clamp bracket and swivel bracket MT model Be 13 SN Ke 242 Ma3 N m 0 3 kgf m 2 2 ft Ib S6AU 7037 Remarks a Oo o SI On Un P DI NN Hm Part name Self locking nut Plate Through tube Nut Clamp bracket Collar Tilt lock lever Bushing Bolt Tilt stopp
152. o Ht MO H Ge 2 7 o BIR 4 5 w D 356 14 1 S6AU2006 6AU3K11 Maintenance specification Exterior mim in EZE O 122 X EG 8 82 0g2 1 A HI amp es vt GE Ai ae A 85 iS al 3 O wo ie OO oo d xl oO i S 4 JI e 2 Bet 3 gt bi ire 7 es J 9 A e z oO a n H el SS qos Sige A aan V RS 7 5 rt TRL Fr ES a CH S t i gt Te is NG EX ei X VZ NPE 25 N a h Ty A 2 D tros I Ne ze IO LU 623 L gl 902 871 eze va 029 X Z9 8 Lz 299 7 DEI 012 E89 E 29 ZEG X 8 0 61 Fte 798 7 S6AU2009 2 16 6AU3K1 1 Maintenance specification Clamp bracket 70 5 2 8 70 5 2 8 187 5 7 4 48 1 9 67 2 7 L 32 1 3 6AU3K11 2 18 SE ve ifi i Specification Tightening torque Specified torque Tightening torques kof m ft lb Part to be tightened Thread size Fuel system Fuel joint bolt M6 0 8 5 9 Fuel pump screw M4 0 2 1 5 Fuel pump valve screw M3 0 05 Power unit Drive plate screw M model M5 0 5 Power unit mounting bolt M8 2 1 Apron screw M6 Ignition coil bolt M6 0 8 Ignition coil bracket bolt 1 lighting coil M8 1 8 Rectifier screw 1 lighting coil M5 Rectifier Regulator bolt 2 ligh
153. oil 1 coil resistance at 20 C 68 F Lighting coil 2 coils output peak voltage G W G at cranking unloaded at 1 500 r min unloaded at 3 500 r min unloaded Lighting coil 2 coils resistance G W G at 20 C 68 F G G 1 The figures are for reference only 6AU3K1 1 0 24 0 36 0 61 0 91 2 10 SPEC BEZ Specification Item Rectifier output peak voltage R Ground at 1 500 r min unloaded at 3 500 r min unloaded Rectifier Regulator output peak voltage R Ground at 1 500 r min loaded at 3 500 r min loaded PT motor Output Brushes Standard length Wear limit Commutator Standard diameter Wear limit Standard undercut Wear limit 2 11 6AU3K11 Maintenance specification Dimension Exterior mim in A y pr on N gt BES a3 o a N LO h 497 19 6 d S 708 27 9 274 10 8 L 825 32 5 121 4 8 431 17 0 66 2 6 I I Ea T Say e lt Q Q ol e b 7 o B o 8 Ur e Na 7 Pcs el ar se 8 amp an s y IN n ES ee ols z yp r y Oh S 27 Se Se A 198 H Ss Gg SE 65 NI re 8 18 0 7 el AC L 27 1 1 oa LO si AE 5 Ga S Su A Se tS e
154. oil 2 coils output peak voltage Green White G W Green G Unloaded Cranking 1 500 3 500 16 1 33 3 79 1 3 Measure the lighting coil resistance Replace if out of specification S6AU8053 Lighting coil 1 coil resistance reference data Green G Green G 0 24 0 36 Q at 20 C 68 F Lighting coil 2 coils resistance reference data Green White G W Green G 0 61 0 91 Q at 20 C 68 F 4 Connect the lighting coil connectors Checking the Rectifier 1 Measure the Rectifier output peak voltage Check the Rectifier for continuity if the output peak voltage is below speci fication S6AU8059 Lighting coil 1 coil Lighting coil 2 coils gt NOTE 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 shut off switch 8 37 6AU3K11 Charging system E model o B S6AU8055 a S6AU8054 NOTE S6S18360 e Do not use peak voltage adapter B when measuring the Rectifier output peak volt NOTE S age Be sure to set the measurement range and display the mark by pushing the SHIFT switch when checking the Rectifier continuity e Be sure to check the lighting coil before measuring the Rectifier output peak volt age Rec
155. ort it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the PT unit should lose fluid pressure NOTE If the PT unit does not operate open the manual valve by turning it counterclockwise and then tilt the outboard motor up manually 2 Remove the plastic tie from the clamp bracket and then pull out the PT motor lead S6AG7770 3 Remove the bolt amp and ground lead from the PT unit 4 Remove the bolts washers collars and 49 and shaft 5 Remove the E clip shaft and collar and then remove the upper end of the tilt rod from the swivel bracket 7 33 6 Remove the PT unit and then remove the collar g S6AU7052 Removing the clamp bracket 1 Remove the ground lead terminal self locking nuts and through tube and then remove the clamp brackets S6AU7053 NOTE nM Be sure to remove the ground lead terminal before removing the self locking nuts 6AU3K11 Clamp bracket and swivel bracket PT model Installing the clamp bracket 1 Tighten the self locking nut completely Self locking nut onto the shorter threaded end of the 19 N m 1 9 kgf m 14 0 ft lb through tube Ground lead bolt 8 N m 0 8 kgf m 5 9 ft lb Anode bolt 8 N m 0 8 kgf m 5 9 ft lb Stopper nut 24 N m 2 4 kgf m 17 7 ft lb Installing the PT unit 1 Fully tilt the outboard motor up and then S
156. ot oil grease or paint the anodes otherwise they will be ineffective manual S6AU3048 Checking the battery 1 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 S6AG 3280 569 3620 2 Check the specific gravity of the electro lyte Fully charge the battery if below specification 25 S6AU3052 A PT model B Except for high thrust model C For high thrust model 6AU3K11 3 16 AD AD Periodic check and adjustment WARNING Battery electrolyte is dangerous it con tains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures lt Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury lt Wear protective eye gear when handling or working near batteries Antidote EXTERNAL lt SKIN Wash with water lt 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 lt Charge batteries in a well ventilated area lt Keep batteries away from fire sparks or open flames e g welding equipment lig
157. ottle link rod to the free accel lever NOTE After adjusting the throttle cable adjust the throttle link Adjusting the throttle link 1 Loosen the throttle link stopper screw S6AU3027 2 Turn the throttle grip H model or remote control lever R model to the fully open position and hold it in place Check that the fully open stopper on the throttle cam contacts the throttle cable bracket NOTE ne er If the fully open stopper does not contact the throttle cable bracket adjust the throt tle cable s See Adjusting the throttle cable H model 3 7 or Adjusting the throttle cable R model 3 8 3 Turn the carburetor throttle lever clockwise so that it contacts the carbure tor body as shown 6AU3K11 Control system 4 Turn the free accel lever counterclock wise until it contacts the throttle cam 5 Tighten the throttle link stopper screw 6 Turn the throttle grip H model or remote control lever R model to the fully open and fully closed positions and check that the throttle cam operates smoothly NOTE SE After adjusting the throttle link adjust the engine idle speed See Checking the engine idle speed 3 11 Checking the gear shift operation H model 1 Check that the gear shift operates smoothly when the shift lever is shifted from the N position to the F position or R position Adjust the shift rod adjusting nut if necessary S6AU3
158. p oz Regular unleaded gasoline 4 stroke motor oil SE SF SG SH SJ or SL 5W 30 10W 30 or 10W 40 0 8 0 85 0 70 Hypoid gear oil GL 4 90 370 12 51 13 05 1 If the recommended engine oil grades are not available use engine oil with an API classification of SH Su or SL and an SAE classification of 15W 40 20W 40 or 20W 50 2 Meeting both API and SAE requirements 6AU3K1 1 2 2 SPEC BEE Specification Item Unit Bracket unit Trim angle at 12 boat transom Tilt up angle Steering angle Degree Degree Degree 0 0 4 0 8 0 12 0 71 74 38 38 PT system Fluid type ATF Dexron II Drive unit Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction rear view Propeller mark F N R 2 08 27 13 Straight bevel gear 2 92 38 13 Spiral bevel gear Dog clutch Spline Clockwise R Electrical Battery minimum capacity CCA EN 20HR IEC Electrolyte specific gravity at 20 C 68 F 2 3 6AU3K11 General specification Maintenance specification Maintenance specification Power unit Item Unit Power unit Minimum compression kPa 630 63 91 4 700 7 0 101 5 pressure kgf cm psi Cylinder head Warpage limit mm in 0 10 0 0039 lines indicate straightedge position Cylinder head journal inside i 18 000 1
159. peller shaft housing assembly 6 7 6 27 Disassembling the PT motor 7 37 Disassembling the starter motor 8 22 Disassembling the swivel bracket 7 28 Disassembling the tilt cylinder s s 7 49 Disassembling the upper case 7 21 Disassembly and assembly 1 5 Draining the fuel 3 4 Drive shaft and lower case cee 6 10 Drive shaft and lower case high thrust modell 6 31 6AU3K11 E D Electrical sasapan naa ENEE REEL a a 2 9 Electrical component and wiring harness FOULING sisa aseran eran n eaaa 8 1 Engine electric control System 8 34 F D Fire prevention 1 4 Friction plate H model 7 11 Fuel hose blowby hose and cooling Water Moses 4 1 Fuel pump fuel filter and fuel joint 4 2 Fuel system 2 7 3 3 G EC 3 16 General specification 2 1 General torque cecene 2 21 Good working practice cece teers 1 5 H HOSE routing 4 1 How to use this manual 1 1 l identificato Nanin re aa 1 6 Ignition and ignition control system 8 30 Ignition coil CDI unit and Rectifier UC Brel OG 5 14 Ignition coil CDI unit and Rectifier Regulator E model 5 15 Installing the Carburetor eseese 4 13 Installing the clamp bracket 7 30 7 34 Installing the cylinder head 0 5 37 Installing the lower
160. per guide plate 90890 06501 Bearing housing puller claw S 90890 06564 V2 Center bolt 2 N m 0 2 kgfm 1 5 ft lb 6 Turn the lower unit upside down 7 Install the backlash indicator onto the drive shaft 12 8 mm 0 50 in in diame ter and then install the dial gauge S6AU6154 6 43 NOTE SE Install the dial gauge so that the plunger tip is aligned with the mark on the back lash indicator YO Backlash indicator 90890 06706 Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base B 90890 06844 8 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction NOTE __ e Pull the drive shaft downward and then turn it e Measure the backlash at 4 points to find the average Forward gear backlash 0 76 2 30 mm 0 0299 0 0906 in 9 Adjust the current shim thickness if the forward gear backlash is out of specifica tion Forward gear backlash Less than Shim thickness To be decreased by 0 76 mm 0 0299 in 1 53 M x 0 39 More than To be increased by 2 30 mm 0 0906 in M 1 53 x 0 39 M Measurement Available shim thicknesses 0 10 0 20 0 30 and 0 40 mm 10 Remove the special service tools from the propeller shaft 6AU3K11 11 Install the propeller spacer and nut without installing the spacer S6AU6155 12 Tighten the propel
161. pth S6AU6099 NOTE Install the needle bearing with the manufac ture identification mark facing toward the oil Seals propeller side Cz Driver rod L3 90890 06652 Needle bearing attachment 90890 06616 AS Installation depth 0 0 25 mm 0 0 01 in 2 Apply grease to new oil seals and then install them into the propeller shaft hous ing to the specified depth 6 29 S6AU6101 NOTE a Install an oil seal halfway into the propeller shaft housing and then install the other oil Seal Cz Driver rod L3 90890 06652 Needle bearing attachment 90890 06613 AS Installation depth 4 5 5 0 mm 0 18 0 20 in 3 Install a new ball bearing into the propel ler shaft housing S6AU6103 NOTE TU Install the ball bearing with the manufacture identification mark facing toward the reverse gear 6AU3K11 Propeller shaft housing high thrust model Cz Driver rod LS 90890 06606 Ball bearing attachment 90890 06632 4 Install the reverse gear and original shim s into the propeller shaft housing S6AU6104 NOTE ee lt 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 high thrust model 6 39 e After installing the reverse gear and shim s check that the gear rotates smoothly 6AU3K11
162. r 17 975 17 991 mm 0 7077 0 7083 in Cylinder head journal inside diameter 18 000 18 018 mm 0 7087 0 7094 in Assembling the cylinder head 1 Install a new valve seal onto the valve guide 2 Install the valve valve spring seat valve spring and valve spring retainer in the sequence shown and then attach the special service tools 6AU3K11 Cylinder head 4 Install a new oil seal 0 SEA Driver rod L3 90890 06652 S6AU5110 d Needle bearing attachment 90890 06653 Valve spring compressor 90890 04019 5 Install the camshaft in the direction Valve spring compressor shown attachment 90890 06320 3 Compress the valve spring and then install the valve cotter yg LI Zeg 6 Align the keyway in the camshaft with the a mark on the cylinder head as S6AU5111 shown GT NY ET S6AU5113 S6AU5117 NOTE e Make sure that the valve cotter is fitted securely into the groove in the valve 6AU3K11 5 36 7 Install the rocker arms springs and collars and into the cylinder head and then install the rocker arm shaft 8 Install the oil pump assembly by aligning the slot in the oil pump drive shaft with the camshaft pin S6AU5120 NOTE e To disassemble check and assemble the oil pump see Checking
163. r ness and ground lead if below specifica tion H model Turn the engine start switch to START and then measure the input voltage between the starter relay connector neu tral switch end and the ground Check the engine start switch neutral switch in the remote control box wiring harness and ground lead if below specification R model wiring harness or replace the neutral Switch if out of specification Brown Br Remote control lever position N position 0O F position or R position 4 Turn the engine start switch to OFF 5 Connect the 10 pin main harness cou pler S6AU8032 Checking the starter relay E model 1 Disconnect the starter relay connec Starter relay input voltage tor reference data Brown Br Ground 12 V battery voltage 2 Setthe shift lever or remote control lever to the N position 4 Disconnect the battery cables and then remove the starter relay 5 Connect the digital circuit tester leads to the starter relay terminals 8 29 6AU3K11 Starting system Ignition and ignition control system 6 Connect the brown Br lead of the Starter relay to the positive battery termi nal and connect the black B lead to the negative battery terminal Check for con tinuity between the starter relay termi nals Replace if there is no continuity 7 Disconnect the brown Br or black B lead of the starter re
164. r nut 17 1 7 12 5 Propeller nut high thrust model 21 2 1 15 5 Cooling water inlet cover screw M5 2 0 2 1 5 Anode bolt M6 8 0 8 5 9 Water pump housing bolt M8 18 1 8 13 3 Propeller shaft housing bolt M6 8 0 8 5 9 Pinion nut high thrust model 25 2 5 18 4 Bracket unit Shift lever bolt H model short R model M5 3 0 3 2 2 Shift lever bolt H model long M8 18 1 8 13 3 Shift lever screw H model long M6 3 0 3 2 2 Tiller handle bracket nut H model 36 3 6 26 6 Tiller handle assembly nut H model short 22 22 16 2 Tiller handle assembly nut H model long 10 1 0 7 4 Tiller handle assembly self locking nut H 22 22 16 2 model long Throttle grip screw H model M5 3 0 3 2 2 PT switch screw PT model M6 6 0 6 4 4 PT switch bracket screw PT model M6 4 0 4 3 0 Engine shut off switch nut H model 2 0 2 1 5 Friction plate assembly bolt H model M5 7 0 7 5 2 Friction plate bolt H model M5 7 0 7 5 2 Friction plate bolt H model M8 18 1 8 13 3 Friction self locking nut H model 6 0 6 4 4 Flushing hose adapter screw M6 2 0 2 1 5 Cowling lock lever bolt M6 8 0 8 5 9 Upper mounting nut 20 2 0 14 8 Let 7 0 7 5 2 Mount housing nut 2nd 12 1 2 8 9 3rd 14 1 4 10 3 6AU3K11 2 20 SPEC BEZ Specification Part to be tightened Thread size Tightening torques N m kgf m Upper mount bolt M6 11 1 1 Engine oil drain bolt 24 2 4 Oil pan bolt M8 21 2 1 Exhaust manifold bolt M6 11 1 1 Upper
165. re switch connector oil pressure switch to CDI unit P Warning indicator connectors warning indicator to CDI unit Y R P 6AU3K11 Electrical component and wiring harness routing Engine shut off switch connector engine shut off switch to CDI unit Y Emergency circuit connector CDI unit to CDI unit W 15 mm 0 59 in 55 mm 2 17 in 35 mm 1 38 in Fasten the charge coil lead and lighting coil lead with a plastic tie as shown so that they are not pinched when the flywheel magnet and ignition coil bracket are installed ieee 6AU3K11 8 12 ELEC ELEC m Electrical system M model and E model with 2 lighting coils
166. s or angles in degrees Separate procedures and illustrations are used to explain the details of removal checking and installation where necessary see in the figure below for an example page NOTE For troubleshooting procedures see Chapter 9 Troubleshooting LOWR t e Lower unit Lower unit regular rotation model i 22 19 2154 N m 5 4 kgt m 39 8 ft 1b j 20 21 H ABN i AD gt 18 142 N m 4 2 kgf m 31 0 Ib Mimer 4 i gt IN 7 A A Le Drive shaft and lower case regular rotation model TEE Ka N e GES Removing the drive shaft Luc GPT 24 pl k i F MG i 1 Remove the pinion nut 25 8 BE pi i f wk 2 47 N m 47 kgf m 34 7 ft Ib t S a qn AIEN m 0 9 kgf m 6 6 tt Ib S6ALGANG nam GAN OOOO o Do not reuse the bearing always replace Vag Drive shaft holder 6 90890 06520 it with a new one Pinion nut holder 90890 06715 24 2 Remove the drive shaft drive shaft hous E Bearing separator D 90890 06534 ing pinion thrust bearing spring and a7N m 4 7 kot m 34 71 Bian m 10 9 kgf m 6 611 E washer AJAT N m 4 7 kgf m 347 11 18 Disassembling the lower case 1 Remove the needie bearing from the lower case 3 Pull out the forward gear Part name ne Remarks Lower unit Piate Rubber seal Check
167. screw Gasket Bolt Drain screw Grommet Bott Disassembiing the drive shaft housing 1 Remove the cover oil seals and needle bearing Not reusable M10 x 45 mm X transom model Sen we M10 x 45 mm Bolt Spacer Propeller Spacer Washer Cotter pin Propeller nut Trim tab M10 x 70 mm X transom model Not reusable SG Sad SE E 1 1 SALAT gt SGALSS9N ar Driver rod L3 90890 06652 Es Needle bearing attachment 2 90890 06610 Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press 6AL3J11 s6M 6249 NOTE Since the diameter of the passage in the lower case and the diameter of the special service tool are both 40 mm 1 57 in the special service tool may not fit into the lower case In that case use a special ser vice tool with a smaller diameter Be sure to remove the forward gear before removing the needle bearing 2 Ball bearing attachment Va 90890 06655 Driver rod LL 90890 06605 6AU3K11 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 EE a H A Specification Power unit Electrical system SPEC POWR ELEC Troubleshooting Periodic check and adjustment Lower unit CHK Special service tool Specifi
168. sh when the drive shaft stops in each direction 6 19 S6AU6078 NOTE EE e Pull the drive shaft downward and then turn it e Measure the backlash at 4 points to find the average Reverse gear backlash 0 50 2 27 mm 0 0197 0 0894 in 13 Adjust the current shim thickness if the reverse gear backlash is out of specifica tion Reverse gear backlash Less than Shim thickness To be decreased by 0 50 mm 0 0197 in 1 39 M x 0 40 More than To be increased by 2 27 mm 0 0894 in M 1 39 x 0 40 M Measurement Available shim thicknesses 0 1 mm 14 Turn the lower unit upright 15 Remove the special service tools and propeller and then install the water pump assembly 6AU3K11 NOTE To install the water pump assembly see Installing the water pump 6 15 16 Fill the lower unit with gear oil to the cor rect level 6AU3K11 Backlash 6 20 Lower unit Lower unit high thrust model Aal 9 N m 0 9 kgf m 6 6 ft Ib hse 8 N m 0 8 kgf m 5 9 ft Ib 2N m 0 2 kgf m 1 5 ft Ib S6AU6079 Part name j Remarks a CO LO ON On Un P GA A Hm Adjusting nut Locknut Dowel Rubber seal Check screw Gasket Cooling water inlet cover Cooling water inlet cover Nut Screw Drain screw Lower case Bolt Anode Special washer Bolt Spacer Not reusable g5 x 20 mm M8 x 30 mm L transom model Not reusable M6
169. 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 Charge coil output peak voltage Br L at cranking unloaded at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Charge coil resistance Br L 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 1 The figures are for reference only 2 9 0 9 1 0 0 035 0 039 4 0 6 0 0 26 0 35 240 360 232 348 6AU3K11 Maintenance specification ltem Unit Oil pressure switch Specified oil pressure kPa kgf cm psi 14 7 0 147 2 132 Fuel control system Choke solenoid resistance L B at 20 C 68 F 4 0 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 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 5 0 8 0 02 0 03 0 2 0 01 52 2 05 Charging system Fuse Lighting coil 1 coil output peak voltage G G at cranking unloaded at 1 500 r min unloaded at 3 500 r min unloaded Lighting c
170. specification De S6AG 8040 ET S park plug cap resistance reference data 4 0 6 0 kQ Checking the ignition coil 1 Disconnect the ignition coil connectors 2 Remove the spark plug caps from the l spark plug wires by turning the caps S6AU8038 counterclockwise NOTE EE 3 Measure the ignition coil resistance e To prevent the engine from starting when Replace if out of specification cranking it be sure to disconnect both Spark plug caps Do not remove the clip from the engine shut off switch If measuring the output peak voltage under the unloaded conditions disconnect the 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 S6AG 8050 Ignition coil resistance reference data Primary coil Orange 0 Black B Pulser coil output peak voltage White red W R Black B Unloaded Loaded Cranking 1 500 3 500 7 0 35 7 0 10 5 0 26 0 35 Q at 20 C 68 F Secondary coil Spark plug wire Spark plug wire 6 8 10 2 kQ at 20 68 F 2 Disconnectthe pulser coil connectors 4 Install the spark plug caps to the spark plug wires by turning the caps clockwise and then connect the ignition coil con nectors 3 Measure the pulser coil resistance Replace if out of specification 8 31 6AU3K11 Ign
171. stem to valve guide clearance as follows Replace the valve guide if out of specification 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 com bustion chamber side S6AU5086 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 S6AU5087 5 31 NOTE ee Apply engine oil to the surface of a new valve guide before installation CZ Valve guide remover installer 90890 06801 Valve guide height Intake and exhaust 8 05 0 25 mm 0 32 0 01 in 4 Insert the special service tool into the valve guide and then ream the valve guide S6AU5088 NOTE 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 Do not turn the reamer counterclockwise when removing it 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 6AU3K11 Cylinder head 2 Apply a t
172. ston diameter 5 42 Checking the piston pin boss bore 5 44 Checking the piston pin diameter 5 44 Checking the piston ring eee 5 43 Checking the piston ring end gap 5 43 Checking the piston ring groove 5 43 Checking the piston ring side Eee if sg rene trames 5 44 Checking the propeller cee 3 15 Checking the propeller shaft 6 8 6 28 Checking the propeller shaft ell WEE 6 8 6 28 Checking the PT fluid level es 3 13 Checking the PT motor ane 7 38 Checking the PT relay 7 54 Checking the PT switch 0ianenaraneei 7 55 Checking the PT system PT model 1 17 Checking the pulser co 8 31 Checking the Rechter 8 37 Checking the Rectifier Regulator 8 39 Checking the rocker arm and rocker atmi EE 5 34 Checking the shift mod 6 12 6 33 Checking the spark plug 0 eee 3 5 Checking the spark plug cap 8 30 Checking the starter motor 8 23 Checking the starter motor operation 8 22 Checking the starter motor pinion 8 22 Checking the starter relay E model 8 29 Checking the start in gear protection M model sense scsi aana DANA redd 3 11 Checking the steering operation HMOE nies teense ees dE ebe 3 12 Checking the steering system 1 16 Checking the thermostat 3 6 Checking the tilt cylinder and piston 7 49 Checking the tilt operation MT model 3 13
173. sure switch Pulser coil Choke solenoid Warning indicator Spark plug Battery cable Rectifier Regulator 10 pin main harness Starter motor Charge coil CDI unit Fuse 10 A 8 7 6AU3K11 Electrical component and wiring harness routing Install the terminal plate making sure that it contacts the PT relay PT model Route the lighting coil lead to the outside of the crankcase pin Route the oil pressure switch lead in the direction shown Fit the oil pressure switch lead into the groove in the driven sprocket cover Bend the side of the junction box outward as shown Fasten the PT motor lead with the holder making sure that there is no slack in the lead PT model Flo 0 b gt 6AU3K11 8 8 ELEC ELEC We Electrical system Bow view
174. switch 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 Be sure to check the charge coil and pulser coil before measuring the CDI unit output peak voltage CDI unit output peak voltage reference data Orange 0 Black B Loaded Cranking 1 500 140 170 Checking the oil pressure switch 1 Disconnect the oil pressure switch OM connector 6AU3K11 2 Start 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 S6AU8047 Oil pressure switch input voltage reference data Pink P Ground 10 12 V 3 Push the engine stop button H model Turn the engine start switch to OFF R model 8 34 evec ELEC E Electrical system 4 Check the oil pressure switch for con tinuity when the engine is stopped and when itis running Check the oil pressure and oil pressure switch if out of specifica tion lt gt SC QU S6AU8048 Oil pressure switch continuity Oil pressure switch Ground Continuity Engine condition Stopped Yes Running No 5 Remove the oil pressure switch 6 Connect the special service tool to the oil pressure switch 7 Check the oil pressure switch for continu
175. t through the tilt support bar and tilt lever 49 and then install the E clips 49 6 Hook the spring onto the tilt support bar S6AG7A20 6AU3K11 NOTE 0 e See the exploded diagram for the installa tion directions of the spring and tilt lock rod 1 7 27 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 clamp bracket side to the clamp brackets and then tighten the bolts to the specified torque Tilt stopper plate bolt 8 N m 0 8 kgf m 5 9 ft lb 212 S6AU7046 2 Tighten the self locking nut completely onto the shorter threaded end of the through tube S6AG7801 6AU3K11 Clamp bracket and swivel bracket MT model 3 Assemble the clamp brackets amp and swivel bracket and then install the collar clamp bracket bolt and through tube o from the port side NOTE do ene When installing the through tube hook tilt lock rod 1 onto the tilt lock lever 4 Install the self locking nut op onto the through tube and then tighten it to the specified torque Self locking nut 19 N m 1 9 kgf m 14 0 ft lb 5 Tighten the clamp bracket nut 6 Install the tilt stopper plates and tilt stopper plate bolts 3 swivel bracket side 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
176. t the notch in the drive sprocket and the A mark on the cylinder block are aligned 7 Remove the timing belt from the driven sprocket and then remove it from the drive sprocket 6AU3K11 Power unit check and adjustment CAUTION Unless directed to do so in the following instructions do not turn the drive sprocket or driven sprocket when the tim ing beltis 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 ee Before installing the timing belt make sure that the notch on the drive sprocket and the mark on the driven sprocket are aligned with the marks on the cylinder block and thermo stat cover 5 4 9 Turn the drive sprocket clockwise 2 turns and then check that the parts are aligned at the areas and as shown 10 Install the charge coil and tighten the charge coil bolts amp to the specified torque 11 Install the Woodruff key and then install the flywheel magnet NOTE 0 e Be sure to remove any grease from the tapered portion of the crankshaft and the inner surfa
177. tep Check the fuse PT switch malfunc tion PT relay malfunc tion Check the PT switch Check the PT relay Short or open con nection in PT motor circuit Check the wiring harness continuity PT motor malfunc tion Disassemble and check the PT motor PT motor operates but the tilt ram does not extend Manual valve left open Manual valve mal function Check the manual valve Insufficient PT fluid Add sufficient fluid PT fluid leakage Check the PT unit for leakage Clogged filter Clogged fluid pas sages Malfunction of the PT unit internal parts WD See the wiring diagram 9 7 Disassemble and check the PT unit 6AU3K11 Troubleshooting the outboard motor Symptom 1 PT unit does not hold the outboard motor up Symptom 2 Cause 1 Cause 2 Checking step Manual valve left open Manual valve mal function Check the manual valve Insufficient PT fluid Add sufficient fluid PT fluid leakage Check the PT unit for leakage Air in PT fluid Bleed the PT unit Clogged fluid pas sages Malfunction of the PT unit internal parts Troubleshooting the lower unit Symptom 1 Shift mechanism of the forward gear and reverse gear does not operate properly Symptom 2 Cause 1 Cause 2 Disassemble and check the PT unit Checking step 6AU3K11 Shift cable a
178. the driven sprocket bolt to the specified torque NOTE e Make sure that the driven sprocket does not turn when tightening the driven sprocket bolt Flywheel holder 90890 06522 Driven sprocket bolt 12 N m 1 2 kgf m 8 9 ftlb Align the 1 A mark on the driven sprocket with the A mark on the thermostat cover S6AU5067 6AU3K11 Timing belt and sprocket 8 Align the notch in the drive sprocket with the A mark on the cylinder block by turning the crankshaft counter clockwise approximately 90 gradually O 11 Install the charge coil lighting coil s and 3 Yj flywheel magnet CT S6AU5068 NOTE SE 9 Install the timing belt onto the drive See Replacing the timing belt 5 3 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 lt Do not get oil or grease on the timing belt 10 Turn the drive sprocket clockwise 2 turns and then check that the parts are aligned at the areas and as shown 6AU3K11 5 24 Cylinder head ot 18 N m 1 8 kgf m 13 3 ft Ib S 8N m 0 8 kgf m 5 9 ft Ib hx 2 N m 0 2 kgf m 1 5 ft Ib 15N m 1 5 kgf m 11 1 ft bb 29N m 2 9
179. the cylin der S6AU7099 13 Tighten the tilt cylinder end screw to the specified torque 6AU3K11 PT cylinder S6AU 7100 Tilt cylinder end screw 45 N m 4 5 kgf m 33 2 ft lb Bleeding the PT unit NOTE SEN Make sure that the tilt ram is fully extended 1 Place the PT unit in an upright position 2 Turn the manual valve clockwise 90 to close it S6AG7341 7 52 Bracket unit 3 Remove the reservoir cap and then check the fluid level in the reservoir 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 PT fluid AC Recommended PT 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 5 Connect the PT motor leads to the bat tery terminals to fully retract the tilt ram S6AG7380 7 53 Battery terminal Green G 0 Blue L PT motor lead 6 Reverse the PT motor leads between the battery terminals to fully extend the tilt ram S6AG7370 PT motor lead terminal Blue L Green G NOTE n e Repeat steps 5 6 to fully extend and retract the tilt ram 4 to 5 times e If the tilt ram does not move up and down easily push and pull on the ram to assist
180. the oil pump housing Oil pump screw 5 N m 0 5 kgf m 3 7 ft lb 6AU3K11 5 38 Cylinder block 6 N m 0 6 kgf m 4 4 ft Ib 12 N m 1 2 kgf m 8 9 ft Ib D 8 N m 0 8 kgf m 5 9 ft Ib el 8 N m 0 8 kgf m 5 9 ft Ib Ny 6N m 0 6 kgf m 4 4 ft Ib S 11N m 1 1 kgf m 8 1 ft Ib a Oo Partname lt S6AU5126 Remarks Bolt Crankcase Bolt Connecting rod Oil seal Crankshaft Main bearing Oil seal Dowel Bolt Exhaust cover Gasket Bolt Thermostat cover Thermostat Gasket Cylinder block LO ON ADU BUN Hm 5 39 kA k k k NRBR k Un M k P k ERNA RK OD M8 x65 mm M7 x 35 mm Not reusable Not reusable M6 x 25 mm Not reusable M6 x 20 mm Not reusable 6AU3K11 6 N m 0 6 kgf m 4 4 ft Ib 12 N m 1 2 kgf m 8 9 ft Ib 6N m 0 6 kgf m 4 4 ft Ib VO 11N m 1 1 kgf m 8 1 ft Ib Part name Cylinder block el 8 N m 0 8 kgf m 5 9 ft Ib S6AU5126 Remarks O ring Relief valve Clip Piston pin Piston Piston ring set 6AU3K11 Not reusable Not reusable 5 40 Disassembling the cylinder block 1 Remove the exhaust cover bolts in the sequence shown and then remove the exhaust cover 4 S6AU5127 2 Remove the thermostat cover thermo Stat and gasket 3 Remove the relief valve
181. the outboard MOON wisi sccasecdedecvssconeatysd dveeisteinedsernvventeconbuts 3 17 6AU3K11 CHK ADJ Maintenance interval chart Use the following chart as a guideline for general maintenance Adjust the maintenance intervals according to the operating conditions of the outboard motor Item Remarks Q Periodic check and adjustment Initial E very 20 hours 3 months 100 hours 1 year 300 hours 3 years 500 hours 5 years Refer to page Anode s external Check replace O 3 16 Anode s cylinder head thermostat cover Check replace O 3 16 Battery Check charge replace O 3 16 Cooling water leakage Check replace 3 7 Cowling clamp Check 3 3 Engine starting condition noise Check Engine idle speed noise Check Engine oil Replace Engine oil filter built into oil pan Check clean replace Fuel filter Replace Fuel pump Check replace Fuel oil leakage Check Fuel pipe Check replace Fuel pipe Replace Gear oil Replace Greasing points Lubricate Impeller water pump housing Check replace Impeller water pump housing Replace PT unit Check P ropeller propeller nut cotter pin Check replace Shift link shift cable Check adjust replace S park plug s Check adjust replace S park plug caps spark plug wires Check
182. tifier output peak voltage Red R Ground Rectifier continuity testing diode Testerlead Display value V Conti Unloaded 1 500 3 500 reference data nuity 13 19 GO RO 0 416 Yes GO BO OL No 2 Disconnect the Rectifier connector and GO GO OL No terminal GO RO 0 415 3 Check the Rectifier for continuity GO BO OL No Replace if out of specification GO GO OL No B R 0 849 NOTE gt 2 The voltage values given in the table are for BO G 0 487 reference only If voltage is produced there BO GO 0 492 is continuity and if there is an overload RO BO OL there is no continuity Refer to the table to RO GO OL determine if there should or should not be continuity and replace the Rectifier if out of RO GO OL specification OL Indicates an overload 6AU3K11 8 38 Erec ELEC Ps Electrical system Checking the Rectifier Regulator 1 Measure the Rectifier Regulator out put peak voltage Check the Rectifier Regulator for continuity if the output peak voltage is below specification S6AU8060 NOTE e Measure the Rectifier Regulator output peak voltage with the connector R dis connected lt Do not use peak voltage adapter B when measuring the Rectifier Regulator output peak voltage e Be sure to check the lighting coil before meas
183. ting coils M6 0 8 S park plug 2 4 Pulser coil bolt M5 0 5 CDI unit bolt Starter motor bolt E model Negative battery cable bolt E model Charge coil bolt Starter motor lead nut E model Starter motor terminal nut E model Starter relay lead bolt E model Starter motor bracket bolt E model Oil pressure switch Oil pressure switch lead bolt Throttle cam bolt Throttle cable bracket bolt Flywheel magnet nut Drive sprocket nut Driven sprocket bolt Intake manifold bolt Cylinder head cover bolt Blowby plate screw Cylinder head bolt Anode plug Rocker arm locknut Oil pump assembly bolt Oil pump screw 2 19 6AU3K11 Tightening torque Tightening torques Part to be tightened Thread size Kan kgf m St Anode screw M5 2 0 2 1 5 Thermostat cover bolt M6 8 0 8 5 9 Relief valve 8 0 8 5 9 1st 6 0 6 4 4 Exhaust cover bolt ond M6 12 12 89 1st 15 1 5 11 1 Crankcase bolt ond M8 30 30 21 1st 6 0 6 4 4 Connecting rod cap bolt ond M7 11 11 31 Lower unit Gear oil drain screw 9 0 9 6 6 Gear oil check screw 9 0 9 6 6 Lower case mounting bolt M8 18 1 8 13 3 Lower case mounting nut X transom model 18 1 8 13 3 Propelle
184. tor Rectifier Regulator Ignition coil Spark plug PT motor PT model PT relay PT model dd Fuse 10 A Battery Starter relay Oil pressure waming indicator To remote control box PT model Al B 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 G W Green white W R White red Y R Yellow red Pike 9 9 M CT y ri be HIM SoH TTTTT nom Pike 9 9E q T I i a 1 d 1 1 1 1 T i 1 ret eT 1 1 f EE 1
185. trical system ccecce 7 54 PT QG APF PUMP dasanan da Aan kaa eag entrees 7 41 PT MOO rss ng ANANE Nn KANG Kae rares sa 7 36 R Refacing the valve seat 5 32 Removing the carburetor cesses 4 11 Removing the clamp bracket 7 28 7 33 Removing the cylinder head 5 28 Removing the drive shaft drive shaft housing and shift rod 6 11 6 32 Removing the intake silencer protective COVENIN Ga Atari enden 1 13 Removing the lower unit 6 4 6 24 Removing the power unit 5 18 Removing the propeller shaft housing assembhy 6 7 6 27 Removing the PT unit 7 33 Removing the starter MOtOT eree 8 22 Removing the steering arm ee 7 23 Removing the tiller handle 7 3 7 8 Removing the timing belt and sprocket 5 21 1 3 Index Removing the upper case 7 21 Removing the water pump 6 5 6 25 Replacing the timing belt eee 5 3 Replacing the valve guide 5 31 5 D Safety while working eessen 1 4 Sealant and locking agenttable 1 3 Selecting the crankshaft main bearing 5 48 Selecting the forward gear shim 6 40 Selecting the pinion shim ee 6 40 Selecting the reverse gear Shim 6 41 Ee EE 1 12 Self protection 1 4 Serial number 1 6 Shimming akasa Na AN a etteetteeteeeeees 6 40 Shimming high thrust model 6 39 Special service tool 1 7 Specified torque seeren 2 19
186. trol system Bracket unit 3 Check that the pointer is aligned with the 5 mark on the flywheel magnet as shown a eee se ee EN _ ANL Bee S6AU3038 Ignition timing at 1 050 r min BTDC 53 Bracket unit Checking the steering operation H 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 S6AU3039 3 12 AD AD Periodic check and adjustment 2 Adjust the self locking nut until the steering operation is proper S6AG3430 Checking the tilt operation MT 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 MT model 1 17 Checking the tilt operation PT model 1 Fully tilt the outboard motor up and down a few times and check the entire tilt range for smooth operation Check the PT fluid level if necessary NOTE End e To check the PT fluid level see Checking the PT fluid level 3 13 e Be sure to listen to the winding sound of the PT motor for smooth operation 2 Fully tilt the outboard motor up and then support it with the tilt stop lever to check the loc
187. ttery and remove the clip from the engine shut off switch E model 3 Loosen the locknut while holding the adjusting nut and then turn the adjust ing nut to disconnect the shift rod NOTE NN Set the gear shift to the R position before dis connecting the shift rod 6AU3K11 Lower unit high thrust model 4 Remove the locknut NOTE a 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 6 Remove the anode and cooling water inlet covers S6AU6084 6 24 Lower unit Removing the water pump 1 Remove the water pump housing and impeller 2 Remove the Woodruff key from the drive shaft and then remove the outer plate cartridge 3 Remove the dowels from the lower case S6AU6085 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 2 Check the impeller insert cartridge and outer plate cartridge Replace if cracked or worn 3 Check the Woodruff key and the keyway in the drive shaft Replace if worn or deformed 6 25 6AU3K11 Lower unit high thrust model Propeller shaft housing high thrust model Propeller shaft housing high t
188. ue Gear oil check screw Q and drain screw MD 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 D and then install the special service tool 3 15 S6AU3047 2 Apply the specified pressure and check that the pressure is maintained in the lower unit for at least 10 seconds CAUTION Do not overpressurize the lower unit oth erwise the oil seals can be damaged NOTE a 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 cm 14 psi 3 If the 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 6AU3K11 Lower unit General General Checking the anode 1 Check the anodes Clean the anodes if there are scales grease or oil 2 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 CAUTION Do n
189. uel pump body 1 and then install the pin to the plunger S6AU4014 S6AU4015 NOTE be 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 lt Turn fuel pump body 1 until the pin is 90 from the slot in the body lt Make sure that the projections on the diaphragm fit correctly into fuel pump body 1 2 Assemble the fuel pump as shown 6AU3K11 Fuel pump fuel filter and fuel joint S6AU4016 NOTE EE 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 4 4 6 ory Fuel system Carburetor unit NG MO 6N m 0 6 kgf m 4 4 ft Ib 12 N m 1 2 kgf m 8 9 ft Ib S6AU4017 Part name Remarks lt Plastic tie O ring Bolt Holder Choke solenoid Choke knob Choke knob guide Blowby hose Fuel hose Clamp Bolt Collar Intake silencer O ring Choke rod Throttle link rod Screw R model M6x12mm R model M6 x 85 mm Not reusable A k k k k A b k k k k k HN N RN 4x 6 mm 4 7 6AU3K11 Carburetor unit NG MO 6N m 0 6 kgf m 4 4 ft Ib 12 N
190. upper mount bolts to the specified torque S6AU7031 NOTE Apply sealant 1104 to the mating surface 7 23 Upper case bolt 18 N m 1 8 kgf m 13 3 ft lb Upper mount bolt 11 N m 1 1 kgf m 8 1 ft lb 7 Install the grommet and engine oil drain bolt and then tighten the drain bolt to the specified torque Engine oil drain bolt 24 N m 2 4 kgf m 17 7 ft lb Removing the steering arm 1 Remove the steering arm from the swivel bracket by pulling the arm off the bracket ROZ AS JAR ESN p U d K ko DP dei 00 S6AU7032 NOTE Ms To disassemble the clamp brackets see Removing the clamp bracket 7 28 or Removing the clamp bracket 7 33 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 bushing 2 a new O ring and the plate onto the swivel bracket 6AU3K11 sr or S6AU7033 4 Apply grease to the grease nipple on the swivel bracket until it comes out from the upper bushing IDI NS S6AG7740 NOTE To assemble the clamp brackets see Install ing the clamp bracket 7 30 or Installing the clamp bracket 7 34 Installing the upper case 1 Install the upper case assembly to the clamp bracket 2 I
191. upport it with the tilt stop lever 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 S6AU7056 4 Install the ground lead terminals to the brackets using the bolt and bolts A WARNING After tilting the outboard motor up be 5 Install stopper 1 stopper 2 49 and the Geier PP SPP sure to support it with the tilt stop lever stopper nuts S6AU7055 NOTE gt Install the anode with the projection facing towards the bow 6AU3K11 7 34 Bracket unit 2 Install the collar onto the PT unit 3 Install the PT unit collars and shaft and washers onto the clamp brackets and then tighten the bolts to the specified torque 4 Install the collars and upper end of the tilt ram shaft op and E clip to the swivel bracket 5 Install the ground lead terminal to the PT unit A S6AU7113 NOTE Install the ground lead as shown PT unit mounting shaft bolt 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 7 35 6 Pass the PT motor lead through the hole in the clamp bracket STBD 7 Fasten the PT motor lead to the clamp bracket with a plastic tie TON S6AU 7058 NOTE Route the PT motor lead
192. uring the Rectifier Regulator output peak voltage Rectifier Regulator output peak voltage Red R Ground Loaded 1 500 3 500 13 13 2 Disconnect the Rectifier Regulator con nector and terminal 3 Check the Rectifier Regulator for conti nuity Replace if out of specification 8 39 NOTE SE The voltage values given in the table are for reference only If voltage is produced there is continuity and if there is an overload there is no continuity Refer to the table to determine if there should or should not be continuity and replace the Rectifier Regulator if out of specification S6AU8061 56518360 NOTE SE Be sure to set the measurement range and display the mark by pushing the SHIFT switch when checking the Rectifier Regulator continuity 6AU3K11 Charging system E model Rectifier Regulator continuity testing diode Tester lead Display value V reference data GW RO 0 364 GWOI BO 0 741 GWO D 1 117 GO RO 0 444 GO B OL GO GW OL BO RO BO GW B GO RO BO RO JGWO RO G OL Indicates an overload 6AU3K11 8 40 Erec ELEC Ke Electrical system MEMO 8 41 6AU3K11 TRBL Troubleshooting Troubleshooting the outboard motor sise 9 1 Troubleshooting Beete LEE 9 1 Troubleshooting the power unit 9 1 Troubleshooting the PT unit PT mode
193. ust 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 3 3 S6AU 3003 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 Replace if there is leakage or deterioration A Se r S6AU3004 Checking the fuel filter 1 Check the fuel filter Replace if there is residue or if itis cracked or damaged 6AU3K11 S6AU3005 CAUTION When replacing the fuel filter the arrow mark must face toward the fuel pump NOTE Be sure not to spill any fuel when removing the fuel filter 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 AT ir NEVA LES GS 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 Remove the oil dipstick again to check the oil level and to check the oil for dis coloration and
194. ve terminal and then check that the warning indicator comes on Replace the warning indicator assembly if it does not come on Y R LED dE ER S6AU8051 CAUTION e Only use a penlight battery 1 5 V when checking the LED Other batteries e g alkaline batteries or high voltage batter ies will damage the diode Do not apply more than 1 7 V to the leads when checking the LED NOTE A feature of an LED is that it only allows cur rent to flow in one direction Checking the choke solenoid R model 1 Push the engine start switch at the ON or START position and then check the operation of the choke solenoid Check the choke solenoid resistance if it does not operate ON PUSH OFF START PUSH S6AU8052 2 Disconnect the choke solenoid coupler 6AU3K11 3 Measure the choke solenoid resis tance Replace if out of specification S6AU8058 Choke solenoid resistance reference data Blue L Black B 4 0 Q at 20 C 68 F 4 Connect the choke solenoid coupler Charging system E model Checking the lighting coil Disconnect the lighting coil connectors 8 36 Erec ELEC ae Electrical system 2 Measure the lighting coil output peak voltage Replace if below specification Lighting coil 1 coil output peak voltage Green G Green G Unloaded Cranking 1 500 6 1 14 6 Lighting c
195. ve the oil strainer from the exhaust guide 6 Remove the oil seal from the exhaust guide S6AU 7023 7 Remove the exhaust manifold from the upper case 6AU3K11 S6AU7022 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 Clean the removed parts before checking them Checking the oil strainer 1 Check the oil strainer Clean if there is dirt or residue Assembling the upper case 1 Install the exhaust manifold to the upper case and then tighten the exhaust manifold bolts to the specified torque S6AU7028 6AU3K11 Upper case and steering arm Exhaust manifold bolt 11 N m 1 1 kgf m 8 1 ft lb 2 Install a new oil seal into the exhaust guide S6AU7025 Z Driver rod L3 90890 06652 __ Needle bearing attachment 90890 06614 3 Install the oil strainer the dowels and a new gasket 49 onto the exhaust guide S6AU7026 7 22 Bracket unit 4 Install the baffle plate and rubber seal to the oil pan and then tighten the oil pan bolts to the specified torque S6AU7027 Oil pan bolt 21 N m 2 1 kgf m 15 5 ftlb 5 Install the dowels and oil pan assem bly 49 and then tighten the upper case bolts to the specified torque 6 Install the upper mount and then tighten the
196. ventinatesstenrocursietuavacudvacuedsadueet deruntetekeens ean 3 4 Checking the engine OI sn hemansanisatemenuntensanennedinntansenst 3 4 Changing the engine ER 3 4 Checking the timing b lier 3 5 Checking the spark DIG EE 3 5 Checking the thermostat estnneatenmemienensenedtemenenngannrin 3 6 Checking the cooling water passage 3 7 Control system sessisasuncacstececdenchedncnsvencasacwssdeasauseweneadevaneddeanuetenadteuatducavasedunbene 3 7 Adjusting the throttle cable H model 3 7 Adjusting the throttle cable R model ENNEN 3 8 Adjusting the throttle EE 3 9 Checking the gear shift operation H modell 3 10 Checking the gear shift operation R model 3 10 Checking the start in gear protection M modell 3 11 Checking the engine idle speed sasaia ane aaa a nean nana nana n aana nanang 3 11 Checking the ignition timing 3 12 Br cket unit EN 3 12 Checking the steering operation H modell 3 12 Checking the tilt operation MT model anae aana n aane nenen aaa 3 13 Checking the tilt operation PT modell 3 13 Checking the PT fluid NOV EE 3 13 WG TO E 3 14 Checking the gear diese hs te Pat are ee re dard 3 14 Changing the gear OIhasssssessssnnsenrentennntennnninsenirntendienrnreinu 3 14 Checking the lower unit for air leakage AAA 3 15 Checking the propeller aana anana anana nana anang 3 15 EE TEE 3 16 Checking the Spa enges sean enter 3 16 Checking Ne batten EE 3 16 Lubricating
197. within the specified ranges Piston ring end gap reference data Top ring 0 15 0 30 mm 0 0059 0 0118 in 2nd ring 0 30 0 45 mm 0 0118 0 0177 in Oil ring 0 20 0 70 mm 0 0079 0 0276 in Measuring point reference data 10 mm 0 4 in Checking the piston ring groove 1 Measure the piston ring grooves Replace the piston if out of specification 6AU3K11 S6AU5135 Piston ring groove Top ring 1 23 1 25 mm 0 0484 0 0492 in 2nd ring 1 52 1 54 mm 0 0598 0 0606 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 S6AU5136 Piston ring side clearance Top ring 0 04 0 08 mm 0 0016 0 0031 in 2nd ring 0 03 0 07 mm 0 0012 0 0028 in Oil ring 0 01 0 18 mm 0 0004 0 0071 in 6AU3K11 Cylinder block Checking the piston pin boss bore 1 Measure the piston pin boss bore Replace the piston if out of specification S6AU5137 Piston pin boss bore 14 004 14 015 mm 0 5513 0 5518 in Checking the piston pin diameter 1 Measure the piston pin diameter Replace if out of specification S69J5C30 Piston pin diameter 13 996 14 000 mm 0 5510 0 5512 in Checking the connecting rod small end inside diameter and big end inside diameter 1
198. x 4 Remove the bolts and then remove the intake silencer and carburetor assembly S6AU4021 Disassembling the carburetor NOTE EE See the exploded diagram for disassembly 4 9 1 Remove the float pin float and needle valve 4 11 S S6AU4035 NOTE Remove the float pin in the direction of the arrow shown which is opposite to the arrow mark on the carburetor body 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 S6AU4022 WARNING Wear appropriate protective eye gear dur ing the cleaning process to prevent any eye injury by the blown off debris or liq uid 3 Check the main jet pilot jet and main nozzle Clean if there is dirt or residue CAUTION Do not use steel wire clean the jets other wise the jet diameters may be enlarged which may seriously affect performance 6AU3K11 4 Check the pilot screw and needle valve Replace if worn or deformed S6AG 4200 5 Check the float Replace if cracked or deformed 6 Measure the float height Replace the float or needle valve if out of specifica tion S6AU4024 NOTE lt When measuring the float height hold the carburetor body at a 45 angle as shown so that there is no load on the nee dle valve spring lt Take measurements at
199. x x ES OS OG PCB e Go S6AG7180 3 Check the manual valve and spring Replace if damaged Checking the filter 1 Check the gear pump filters Clean if there is dirt or residue NOTE SE See the exploded diagram for the filter instal lation positions 7 41 7 44 Bracket unit Assembling the gear pump CAUTION Do not use a rag when assembling the PT unit as dust and particles on the PT unit components can lead to poor per formance Do not reuse the O rings always replace them with new ones NOTE SE Lubricate the parts with ATF Dexron II during assembly 1 Install the drive gear driven gear balls dowels and main valves to the tilt cylinder 2 Install shuttle piston 1 and shuttle pis ton 2 to the gear pump housing and then install the housing to the tilt cyl inder 3 Install the gear housing bolts and then tighten the bolts to the specified torque S6AU7084 7 45 Wu Wu e CG 04 S6AU 7085 NOTE Be sure to install shuttle piston 1 and shut tle piston 2 in the correct positions the pis ton shapes are different Gear housing bolt 5 N m 0 5 kgf m 3 7 ft lb 4 Install the balls valve seals man ual release pins 3 spring and filter to the gear pump housing S6AU7086 5 Install the manual valve and a new O ring to the PT motor base 6 Install a new gasket and the PT motor
200. x 30 mm A k k k P k k MH k N k k NN FH kb 6 21 6AU3K11 Lower unit high thrust model Aal 9 N m 0 9 kgf m 6 6 ft Ib hse 8 N m 0 8 kgf m 5 9 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib S6AU6079 Part name j Remarks Clip Washer Propeller Spacer Propeller Deflector Washer Propeller nut Cotter pin Stud bolt Rubber seal Dowel Extension Washer Nut Not reusable gt Q X transom model X transom model X transom model X transom model X transom model X transom model E P k 4 k P k k k k k kA k k ok 6AU3K11 6 22 Lower unit he 18 N m 1 8 kgf m 13 3 ft Ib S6AU6080 P art name Remarks O lt Bolt Plate Rubber seal Water pump housing Insert cartridge Impeller O ring Bolt Dowel Outer plate cartridge Woodruff key M8 x 45 mm Not reusable M8 x 25 mm No 1 2 3 4 5 6 7 8 9 10 11 eeN b A k k k k kA BR 6 23 6AU3K11 Removing the lower unit 1 Drain the gear oil S6AU6081 2 Set the gear shift to the N position place a block of wood between the anti cavita tion plate and propeller to keep the pro peller from turning and then remove the propeller nut and propeller S6AU6004 WARNING e Do not hold the propeller with your hands when loosening or tightening it lt Be sure to disconnect the battery cables from the ba
201. y engine oil to the side of each piston and the piston rings before installation Piston slider 90890 06843 5 Install half of the main bearings into the cylinder block 9 S6AU5157 NOTE SE 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 and oil seals and into the cylinder block as shown S6AU5158 NOTE SEN Apply engine oil to the inside of each oil seal before installation 6AU3K11 7 Install the connecting rod caps to the connecting rods and then tighten the connecting rod cap bolts to the specified torques in 2 stages al INE S6AU5159 NOTE D e Make sure that the a marks on the connecting rod cap face towards the fly wheel magnet end A of the crankshaft 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 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 11 N m 1 1 kgf m 8 1 ftlb 8 Install the remaining half of the main bearings into the crankcase NOTE aa oe td e Install the main bearings in their original positions Insert the projection of each bearing into the slots in the crankcase 9 Apply sealant to the mating surface of the crankcase 6AU3K11 Cylinder block 518

Pike 9,9 - English

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