HIDEA HDF6 Service Manual

HIDEA
+'F6
SERVICE MANUAL
7-3-
1
Preface
This manual has been prepared by +LGHD primarily for use by +LGHD dealers and their trained
mechanics when performing maintenance procedures and repairs to +LGHD equipment. It has
been written to suit the needs of persons who have the equivalent basic understanding of the
mechanical andelectrical concepts and procedures inherent in the work, for without such
knowledge attemptedrepairs or service to the equipment could render it unsafe or unfit for use.
Because +LGHD 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 +LGHD dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual. Also, up-to-date parts information is available on web. Additional information and up-to-date
information on +LGHD products and services are available on +LGHD Service Portal.
Important information
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
A WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
A NOTICE indicates special precautions that must be taken to avoid damages to the out-
board motor or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
)+'
SERVICE MANUAL
©201by +,'($3RZHU0DFKLQHU\
Co., Ltd.All rights reserved.
Any reprinting or unauthorized use
without the written permission of
+,'($3RZHU0DFKLQHU\Co.,
Ltd. is expressly prohibited.
2
Contents
GEN
General information INFO
Specification SPEC
TECH
Technical features and description FEA
RIG
Rigging information GING
TRBL
Troubleshooting SHTG
Electrical system ELEC
Fuel system FUEL
Power unit POWR
Lower unit LOWR
Bracket unit BRKT
Maintenance MNT
Index
Appendix
3
4
GEN
INFO
General information 0
Safety while working

Rotating part
Hot part
Electric shock
Propeller
Handling of gasoline
Ventilation
Self-protection
Working with crane
Part, lubricant, and sealant
Handling of sealant
Special service tool
Tightening torque .
Non-reusable part
Disassembly and assembly
How to use this manual

Manual format
Abbreviation
Lubricant, sealant, and thread locking agent

Symbol
5
GEN
INFO General information
Safety while working Handling of gasoline
To prevent an accident or injury and to pro- • Gasoline is highly flammable. Keep gaso-
vide quality service, observe the following line and all flammable products away from
safety procedures. heat, sparks, and open flames.
• Gasoline is poisonous and can cause injury
Rotating part or death. Handle gasoline with care. Never
• Hands, feet, hair, jewelry, clothing, personal siphon gasoline by mouth. If you swallow
flotation device straps, and so on, can some gasoline, inhale a lot of gasoline
become entangled with internal rotating vapor, or get some gasoline in your eyes,
parts of the engine, resulting in serious see your doctor immediately. If gasoline
injury or death. spills on your skin, wash with soap and
• Keep the top cowling installed whenever water. If gasoline spills on your clothing,
possible. Do not remove or install the top change your clothes.
cowling when the engine is running.
• Only operate the engine with the top cowl-
ing removed according to the specific
instructions in the manual. Keep hands,
feet, hair, jewelry, clothing, personal flota-
tion device straps, and so on, away from
any exposed moving parts.
Hot part
During and after operation, engine parts are
hot enough to cause burns. Do not touch any Ventilation
parts under the top cowling until the engine • Gasoline vapor and exhaust gas are
has cooled. heavier than air and extremely poisonous. If
gasoline vapor or exhaust gas is inhaled in
Electric shock large quantities, it may cause loss of con-
Do not touch any electrical parts while start- sciousness and death within a short time.
ing or operating the engine. Otherwise, shock • When test running an engine indoors (for
or electrocution could result. example, in a water tank) make sure to do
so where adequate ventilation can be main-
Propeller tained.
Do not hold the propeller with your hands
when loosening or tightening the propeller
nut.
6
Self-protection Part, lubricant, and sealant
• Protect your eyes by wearing safety Use only genuine +LGHD parts, lubricants,
glasses or safety goggles during all opera- and sealants, or those recommended by
tions involving drilling and grinding, or when +LGHD, when servicing or repairing the out-
using an air compressor. board motor.
• Protect your hands and feet by wearing pro-
tective gloves and safety shoes when nec-
essary.
Handling of sealant
• Wear protective gloves to protect your skin,
when using the sealants.
Working with crane • See the material safety data sheet issued
• Outboard motors weighing 18.0 kg (39.7 lb) by the manufacturer. Some of the sealants
and over must be carried by a crane. may be harmful to human health.
• Use the wire ropes of adequate strength,
and lift up the outboard motor using the
three point suspension.
• If the outboard motor does not have three
or more points to be suspended, support it
using additional ropes or the like so that the
outboard motor can be lifted and carried in
a stable manner.

Use the recommended special service tools
to work safely, and to protect parts from dam-
age.
7
GEN
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
in the center and moving outward.
Non-reusable part
Always use new gaskets, seals, O-rings, cot-
ter pins, and so on, when installing or assem-
bling parts.
Disassembly and assembly

• Use compressed air to remove dust and dirt
during disassembly.
• Apply engine oil to the contact surfaces of
moving parts before assembly.
• Install bearings so that the bearing identifi-

cation mark is facing in the direction indi-
cated in the installation procedure. In
addition, make sure to lubricate the bear-
ings 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 normally
after assembly.
8
Safety while working / 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 following information as a guide for effective and quality service.
• Parts are shown and detailed in an exploded diagram and are listed in the component list (see a
in the following figure for an example page).
• The component list consists of part names and quantities, as well as bolt and screw dimensions
(see b in the following figure).
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication points (see c in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see d in the following fig-
ure), and in the related detailed instructions. Some torque specifications are listed in stages as
torque figures or angles in degrees.
• Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see e in the following figure for an example page).
TIP:
For troubleshooting procedures, see Chapter 4, “Troubleshooting.”
c d a
LOWR
Lower unit
Lower unit
16 N·m (1.6 kgf·m, 11.8 ft·lb)
9 N·m (0.9 kgf·m, 6.6 ft·lb)
9 N·m (0.9 kgf·m, 6.6 ft·lb)
8
1 2 11N·m (1.1 kgf·m, 8.1 ft·lb)
3 7
6
5
6 8 LOWR
Lower unit
4 4. Apply the specified pressure to check
1 9 TIP: that the pressure is maintained in the
A 22 23 While turning the drive shaft clockwise, push lower unit for at least 10 seconds.
11 down on the water pump housing and install
14 NOTICE: Do not over pressurize the
21 water pump housing. lower unit. Otherwise, the oil seals
23 could be damaged.
10 8. Install the plates m and rubber seal n.
11
n
12
13
14
17 15
16
20 6 m d
m
18
19 19 9 N·m (0.9 kgf·m, 6.6 ft·lb)
11N·m (1.1 kgf·m, 8.1 ft·lb)

A L-transom model Leakage tester d
15N·m (1.5 kgf·m, 11.1 ft·lb)
Holding pressure:
No. Par t name Q’ty R em a r k s 98.0 kPa (0.98 kgf/cm 2, 14.2 psi)
1 Cover 2
2 Shift joint bolt 1 Checking the lower unit for air 5. If the specified pressure cannot be
3 Joint 1 leakage maintained, check the drive shaft,
4 Joint 1 1. Install new gaskets a, the drain screw b propeller shaft, and rubber seal for bends
5 Check screw 1 and the flushing screw c. or damage, and check the shift rod
6 Gasket 3 rubber seal for damage or wear.
7 Flushing screw 1 2. Tighten the drain screw b and flushing
8 Dowel 2 screw c to the specified torque. Assembling the extension (L-
9 Cotter pin 1 transom model)
10 Propeller nut 1 1. Install the bushing a and circlip b.
a
11 Washer 1 c
12 Propeller 1
d c
13 Spacer 1 a b
c
14 Lower case mounting bolt 2
15 Lock washer 1 a
16 Bolt 1 b
17 Anode 1 d
Drain screw b: a
8-1 9 N·m (0.9 kgf·m, 6.6 ft·lb)
Flushing screw c:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
3. Install the special service tool d.

Driver rod L3 c
Needle bearing attachment d
b
e 8-15
A
9
GEN
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
____ _____
BTDC Before Top Dead Center
CCA Cold Cranking Ampere
CDI Capacitor Discharge Ignition
____ _____
F Forward
IEC International Electrotechnical Commission
N Neutral
OHV Overhead Valve
PORT Port side
R Reverse
RON Research Octane Number
STBD Starboard side
TDC Top Dead Center
10
How to use this manual / Lubricant, sealant, and thread locking agent
Lubricant, sealant, and thread locking agent
Symbol
Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication
points.
Symbol Name Application
+LGHD 4-stroke motor oil Lubricant
Gear oil Lubricant
Water resistant grease Lubricant

(+LGHa grease A)
Molybdenum disulfide grease Lubricant
Corrosion resistant grease Lubricant

(+LGHa grease D)
ThreeBond Lubricant
Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent
and the application points.
Symbol Name Application
ThreeBond Thread locking agent
ThreeBond Thread locking agent
Gasket Maker Sealant
LOCTITE Sealant
11
GEN
Digital circuit tester Pilot screw driver
Peak voltage adapter B Compression gauge
Ignition tester (spark gap tester) Digital tachometer
Vacuum/pressure pump gauge set Timing light
Leakage tester Flywheel holder
12
Flywheel puller Valve spring compressor attachment
Driver rod L3 Valve guide remover/installer
Needle bearing attachment Valve guide reamer
Needle bearing attachment Valve lapper
Valve spring compressor Valve seat cutter holder
13
GEN
Valve seat cutter Valve seat cutter
60°
Valve seat cutter Needle bearing attachment

45°
Valve seat cutter Driver rod LL

60°
Valve seat cutter Ball bearing attachment

30°
Valve seat cutter Driver rod LS

45°
14
Ball bearing attachment Bearing outer race attachment
Piston slider Bushing installer center bolt
Stopper guide plate Bushing attachment
Stopper guide stand Bushing attachmeQW
Bearing puller assembly
15
GEN
— MEMO —
16
SPEC
Specification
Model feature
General feature
Model designation
Serial number
Model data
Dimension and weight
Performance
Power unit
Lower unit
Bracket unit
Fuel and oil requirement
Electrical technical data

Ignition timing control system
Charging system
Fuel system technical data

Fuel system
Power unit technical data

Power unit
Manual starter
Cylinder head assembly
Crankcase assembly
Lower unit technical data

Lower unit assembly
Specified tightening torque

Fuel system
Power unit
Lower unit
Bracket unit
General tightening torque
17
SPEC
Specification
Model feature
General feature
F6 Overall feature
• 4-stroke, 1-cylinder, OHV, 2-valve, 139.0 cm3 (8.5 cu. in) engine
a Power unit
• Compact OHV engine b
a
• Blowby gas reburning system
• Trochoid type oil pump lubrication
• Decompression starter
• Fuel line with a primer pump
• Dual fuel line
• Recoil manual starter
b Electrical c
• Ignition timing control by CDI unit
• CDI unit with the integrated ignition coil
• Charging system
c Bracket unit d
• Manual tilt
• Reverse lock system
• Balanced carrying handle
d Lower unit
• Under water exhaust system
18
Model feature
Model designation
F +S
a b c d
a Model description F: 4-stroke regular rotation

b Model name :
c H: Tiller handle
d Transom height S: S (VKRUW
L: L (ORQJ)
Serial number Approved Starting

The outboard motor serial number is indi- Model name
mode code serial No.
cated on a label affixed to the port clamp
bracket. HDF6
d a
HI DE A
b c
+,'($ INDUSTRIE
PRODUCT ASSEMBLED IN &+,1$
a6HULDOQXPEHU
bApproved model code
c1RPLQDO3RZHU
d0DVV
19
SPEC
Specification
Model data
Dimension and weight
Model
Item Unit
+'F6
Overall length mm (in) 750.0 (29.5)
Overall width mm (in) 403.0 (15.9)
Overall height
S mm (in) 1040.0 (40.9)
L mm (in) 1168.0 (46.0)
Boat transom height
S mm (in) 440.0 (17.3)
L mm (in) 568.0 (22.4)
Weight (with propeller)
S kg (lb) 27.0 (59.5)
L kg (lb) 28.0 (61.7)
Performance
Model
Item Unit
+'F
Maximum output
At 5000 r/min kW (HP)
At 5500 r/min kW (HP) 3.7 (5.0)
Full throttle operating range r/min 4500–5500
Engine idle speed r/min 1450–1550
Power unit
Model
Item Unit
+'F6
Type 4-stroke
Cylinder quantity 1
Total displacement cm³ (cu. in) 139.0 (8.5)
Bore stroke mm (in) 62.0 46.0 (2.4 1.8)
Compression ratio 8.90 : 1
Control system Tiller handle
Starting system Manual
Fuel system Carburetor
Ignition control system CDI
Advance type Microcomputer
Starting enrichment Choke valve
Spark plug CR6HSB (NGK)
Cooling system Water
Exhaust system Under water
Lubrication system Wet sump
20
Model data
Lower unit
Model
Item Unit
+'F
Gear shift positions F-N-R
Gear ratio 2.08 (27/13)
Reduction gear type Straight bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction (rear view) Clockwise
Propeller mark BA
Bracket unit
Model
Item Unit
+'F
Trim angle
At 12º boat transom Degree 4 to 20
Tilt-up angle Degree 64
Steering angle Degree 90 + 90
Trim and tilt system Manual
Fuel and oil requirement

Model
Item Unit
+'F
Fuel type Regular unleaded gasoline
Fuel minimum rating RON
4-stroke motor oil with combinations of the
Engine oil
following oil classifications
Engine oil grade (*1) SE, SF, SG, SH, SJ, SL
5W-30, 10W-30, 10W-40
Total engine oil quantity (oil pan L
0.6
capacity)
Gear oil type
Gear oil grade (*2)
L
Gear oil quantity
If the recommended engine oil grades are not available, use engine oil with anFODVVLILFDWLRQ RI6+6-RU
6/
21
SPEC
Specification
Ignition timing control system
Model
Item Unit
+')
Spark plug
Cap resistance (*1)
At 20 °C (68 °F) k\ 5.0
Gap mm (in) 0.6–0.7 (0.024–0.028)
Ignition timing
At 1500 r/min Degree BTDC 7–9
CDI unit
Air gap mm (in) 0.4–0.6 (0.016–0.024)
(*1)The figures are for reference only.
Charging system
Model
Item Unit
H')
Lighting coil
Output peak voltage
At cranking (unloaded) V 20.0
At 1500 r/min (unloaded) V 30.1
At 3500 r/min (unloaded) V 64.3
Resistance (*1)
At 20 °C (68 °F) \ 0.771–0.869
Rectifier Regulator
Output peak voltage
At 1500 r/min (loaded) V 13.0
At 3500 r/min (loaded) V 13.0
(*1) The figures are for reference only.
Fuel system technical data

Fuel system
Model
Item Unit
+'F6
Fuel joint
Holding pressure
kPa (kgf/
Positive pressure 50.0 (0.50, 7.3)
cm2, psi)
Fuel strainer
Holding pressure
kPa (kgf/
cm2, psi)
Primer pump
Holding pressure
kPa (kgf/
cm2, psi)
22
Electrical technical data / Fuel system technical data / Power unit technical data
Model
Item Unit
+'F6
Carburetor
Float height (*1) mm (in) 10.0 (0.4)
Valve seat size mm (in) 0.8 (0.03)
Main jet (MJ) # 60 # 70 # 75
Main nozzle mm (in) 1.6 (0.06) 2.0 (0.08) 2.4 (0.09)
Pilot jet (PJ) # 35 #42
Pilot air jet (PAJ) # 105 # 110
Adjustable pilot screw (PS) turns out 1 3/8 ± 3/4 2 1/8 ± 3/4 2 1/4 ± 3/4
Fuel pump
Holding pressure
kPa (kgf/
Inlet positive pressure 50.0 (0.50, 7.3)
cm2, psi)
kPa (kgf/
Outlet positive pressure 50.0 (0.50, 7.3)
cm2, psi)

Power unit
Model
Item Unit
+'F6
Cylinder
Minimum compression pres- kPa (kgf/
700.0 (7.00, 101.5)
sure (*1) cm2, psi)
Thermostat
Valve opening temperature °C (°F) 58–62 (136–144)
Fully open temperature °C (°F) 70 (158)
Fully open stroke mm (in) 3.0 (0.12)
(*1) Measuring conditions: Ambient temperature 20 °C (68 °F), wide open throttle, with spark plug
removed from cylinder.
When pulling the starter handle to crank the engine, the compression pressure may vary
depending on the speed at which the starter handle is pulled. The figures are for reference only.
Manual starter
Model
Item Unit
+'F6
Starter rope
Length (*1) mm (in) 1800.0 (70.9)
Extended length mm (in) 1430.0–1570.0 (56.3–61.8)
23
SPEC
Specification
Cylinder head assembly
Model
Item Unit
+'F6
Valve
Clearance
Intake and exhaust mm (in) 0.08–0.12 (0.003–0.005)
Margin thickness
Intake mm (in) 0.800–1.200 (0.0315–0.0472)
Exhaust mm (in) 1.100–1.500 (0.0433–0.0591)
Runout (*1)
Intake mm (in) 0.050 (0.0020)
Exhaust mm (in) 0.030 (0.0012)
Seat contact width
Cylinder head
Warpage limit 0.10 (0.0039)
Push rod
Runout
Intake and exhaust mm (in) 0.5 (0.02)
Valve spring
Free length mm (in) 27.6 (1.09)
Tilt limit mm (in) 1.0 (0.04)
Valve stem
Diameter
Intake mm (in) 5.475–5.490 (0.2156–0.2161)
Exhaust mm (in) 5.460–5.475 (0.2150–0.2156)
Runout (*1)
Intake mm (in) 0.050 (0.0020)
Exhaust mm (in) 0.030 (0.0012)
Valve guide
Inside diameter
Clearance
Intake mm (in) 0.010–0.037 (0.0004–0.0015)
Exhaust mm (in) 0.025–0.052 (0.0010–0.0020)
Installation height mm (in) 8.2–9.1 (0.32–0.36)
Cam shaft
Cam lobe height
Intake mm (in) 32.037–32.137 (1.2613–1.2652)
Exhaust mm (in) 32.038–32.138 (1.2613–1.2653)
Cam lobe width
Fuel pump cam diameter (*1) mm (in) 19.600 (0.7717)
Journal diameter mm (in) 14.965–14.990 (0.5892–0.5902)
Runout mm (in) 0.030 (0.0012)
24
Crankcase assembly
Model
Item Unit
+'F6
Crankcase
Crankshaft journal inside
mm (in) 25.020–25.041 (0.9850–0.9859)
diameter
Camshaft journal inside
mm (in) 15.000–15.018 (0.5906–0.5913)
diameter
Oil pump
Rotor housing inside diame-
mm (in) 23.130–23.160 (0.9106–0.9118)
ter
Outer rotor diameter mm (in) 22.980–23.000 (0.9047–0.9055)
Outer rotor height mm (in) 9.950–9.980 (0.3917–0.3929)
Inner rotor height mm (in) 9.950–9.980 (0.3917–0.3929)
Piston
Diameter mm (in) 61.950–61.965 (2.4390–2.4396)
Measuring point mm (in) 1.0 (0.04)
Oversize diameter
1st mm (in) 62.200–62.215 (2.4488–2.4494)
2nd mm (in) 62.450–62.465 (2.4587–2.4592)
Piston clearance mm (in) 0.035–0.065 (0.0014–0.0026)
Ring groove (Top) mm (in) 1.210–1.230 (0.0476–0.0484)
Ring groove (2nd) mm (in) 1.210–1.230 (0.0476–0.0484)
Ring groove (Oil) mm (in) 2.010–2.030 (0.0791–0.0799)
Pin boss inside diameter mm (in) 15.004–15.015 (0.5907–0.5911)
Pin outside diameter mm (in) 14.995–15.000 (0.5904–0.5906)
Cylinder
Bore mm (in) 62.000–62.015 (2.4409–2.4415)
Piston ring
End gap measuring point
mm (in) 60.0 (2.36)
(*1)
Top ring
Type Barrel
Dimension height (B) mm (in) 1.170–1.190 (0.0461–0.0469)
Dimension width (T) mm (in) 2.500–2.700 (0.0984–0.1063)
End gap (*1) mm (in) 0.110–0.210 (0.0043–0.0083)
Side clearance mm (in) 0.020–0.060 (0.0008–0.0024)
2nd ring
Type Taper
Dimension width (T) mm (in) 2.600–2.800 (0.1024–0.1102)
End gap (*1) mm (in) 0.260–0.410 (0.0102–0.0161)
Oil ring
Dimension width (T) (*1) mm (in) 2.550–2.850 (0.1004–0.1122)
End gap (*1) mm (in) 0.200–0.700 (0.0079–0.0276)
25
SPEC
Specification
Model
Item Unit
+'F6
Connecting rod
Small end inside diameter mm (in) 15.015–15.029 (0.5911–0.5917)
Big end inside diameter mm (in) 28.000–28.015 (1.1024–1.1030)
Oil clearance mm (in) 0.016–0.046 (0.0006–0.0018)
Crankshaft
Runout mm (in) 0.020 (0.0008)
Journal diameter (cylinder
mm (in) 24.980–24.993 (0.9835–0.9840)
block side)
Journal diameter (crankcase
mm (in) 24.982–24.994 (0.9835–0.9840)
side)
Crankpin diameter mm (in) 27.969–27.984 (1.1011–1.1017)
Crankpin width mm (in) 21.000–21.100 (0.8268–0.8307)
Valve lifter
Outside diameter mm (in) 7.965–7.980 (0.3136–0.3142)

Lower unit assembly
Model
Item Unit
+'F6
Lower unit
.Pa (kgf/
Holding pressure 98.0 (0.98, 14.2)
cm2, psi)
Propeller shaft
Runout mm (in) 0.02 (0.001)
Drive shaft
Runout mm (in) 0.4 (0.02)
26
Power unit technical data / Lower unit technical data / Specified tightening torque
Fuel system
Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Choke cable nut — 4 0.4 3.0
Choke holder bolt M5 4 0.4 3.0
Fuel cock screw M6 7 0.7 5.2
Intake manifold bolt M6 12 1.2 8.9
Throttle cable locknut — 4 0.4 3.0
Throttle link screw M4 1.5 0.15 1.11
Fuel pump valve screw M3 0.5 0.05 0.37
Fuel pump screw M4 2 0.2 1.5
Fuel pump bolt M6 7 0.7 5.2
Power unit
Tightening torques
N·m kgf·m ft·lb
CDI unit bolt M6 10 1.0 7.4
Valve adjusting locknut — 10 1.0 7.4
Drive plate screw — 7 0.7 5.2
Start-in-gear protection cable locknut — 2 0.2 1.5
Flywheel magnet nut — 60 6.0 44.3
Engine shut-off switch nut — 2 0.2 1.5
Power unit mounting bolt M6 12 1.2 8.9
1st 5 0.5 3.7
Crankcase bolt M6
2nd 11 1.1 8.1
Blind plug M8 20 2.0 14.8
Pivot bolt — 10 1.0 7.4
1st 13 1.3 9.6
Cylinder head bolt M8
2nd 28 2.8 20.7
Thermostat cover anode screw M5 2 0.2 1.5
Spark plug — 13 1.3 9.6
1st 6 0.6 4.4
Connecting rod cap bolt M7
2nd 12 1.2 8.9
Breather plate screw M5 8 0.8 5.9
Lower unit
Tightening torques
N·m kgf·m ft·lb
Drain screw — 9 0.9 6.6
Flushing screw — 9 0.9 6.6
Lower case mounting bolt (S-transom model) M6 11 1.1 8.1
Lower case mounting bolt (L-transom model) M6 15 1.5 11.1
Shift joint bolt M6 16 1.6 11.8
Check screw — 9 0.9 6.6
27
SPEC
Specification
Bracket unit
Tightening torques
N·m kgf·m ft·lb
Throttle rod screw M5 4 0.4 3.0
Throttle grip screw M5 4 0.4 3.0
Tiller handle mounting bolt M8 28 2.8 20.7
Carrying handle bolt M8 19 1.9 14.0
Start-in-gear protection cable locknut — 4 0.4 3.0
Primer pump holder bolt M6 11 1.1 8.1
Shift lever bolt M8 19 1.9 14.0
Shift link bolt M5 3.5 0.35 2.58
Grease nipple — 3 0.3 2.2
Self-locking nut — 15 1.5 11.1
General tightening torque

This chart indicates the tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifications
for special components and assemblies are
provided in the applicable sections of this
manual. To prevent warpage, tighten multi-
fastener assemblies in a crisscross fashion
and progressive stages until the specified
torque is reached. Unless otherwise indi-
cated, torque specifications require clean,
dry threads.
Components should be at room temperature.
Width General torque
Screw
across specifications
size (B)
flats (A) N·m kgf·m ft·lb
8 mm M5 5 0.5 3.7
10 mm M6 8 0.8 5.9
12 mm M8 18 1.8 13.3
14 mm M10 36 3.6 26.6
17 mm M12 43 4.3 31.7
28
TECH
FEA
Technical features and description
Engine control system

Outline
CDI unit
Ignition timing control
Ignition cut-off control
Power unit system

Outline
Automatic decompressor
Blowby gas reburning system
Lighting coil
Fuel system
Outline
Carburetor
Built-in primer pump
Lubrication system
Outline
Oil pump and engine oil flow
Tilt system
Outline
Reverse lock system
Lubrication diagram
Cooling flow diagram
Intake and exhaust flow diagram
29
TECH
FEA Technical features and description
Engine control systemOutline
The F6 adopt the CDI ignition system consisting of the CDI unit and the flywheel magnet.
The CDI unit has a compact design with an integrated ignition coil.
There are two types of ignition control systems. One is ignition timing control at normal operation,
and the other one is ignition cut-off control during engine cranking and when over-revving.
aCDI unit
bFlywheel magnet
30
CDI unit
When the permanent magnet a on the flywheel magnet a passes in front of the CDI unit b, the
exciter coil b in the CDI unit b induces an electric current c to produce a crank signal d that will
be transmitted to the ignition control circuit e. The electric current that has been induced by the
exciter coil b is also sent to charge the capacitor f.
When the ignition control circuit e transmits an ignition signal g, the capacitor f will discharge and
produce current h in the primary coil k, and induce a high voltage m in the secondary coil n to
ignite the spark plug c.
The CDI unit b ignites the spark plug c once per crankshaft rotation.
c f
k n c
a b
h m
a
d g
e
Ignition timing control

The CDI unit ignites the spark plug at the ignition timings that are programmed based on each
engine speed.
The engine speed will be calculated based on the crank signals that are input into the ignition con-
trol circuit.
31
TECH
Ignition cut-off control
There are two types of ignition cut-off control. One is a system to cut off the ignition during engine
cranking without outputting ignition signals a from ignition control circuit b when the engine speed
is 150 r/min or lower. The other one is a system to stop ignition to prevent damage to the engine
when over-revving. While this control system is activated, the ignition control circuit b keeps output-
ting ignition signals a without charging the capacitor c.
Ignition control during engine cranking Engine speed control
150 r/min or less 5900 r/min or more
a
b
a
b
A Ignition control during engine cranking

B Engine speed control
32
Engine control system / Power unit system
Power unit system
Outline
The +'F6 feature an OHV engine with a newly designed cylinder head and cylinder block. The
decompressor is built into the camshaft to facilitate engine cranking with a manual starter.
In addition, a blowby gas reburning system is incorporated to reduce the amount of oil contained in
the blowby gases.
The flywheel magnet, lighting coil, and Rectifier Regulator are available as optional accessories,
and these will enable battery charging.
g
f
b a
a Valve lifter g Flywheel magnet (optional)

b Push rod h Intake silencer
c Rocker arm
d Valve a Decompression actuator
e Rectifier Regulator (optional)
f Lighting coil (optional)
33
TECH
To facilitate engine cranking, the decompression actuator forcefully opens the exhaust valve on the
compression stroke to release compression pressure during engine cranking and prevent pressure
in the cylinder from increasing. As the cranking speed increases, the decompression actuator will
move in the direction of a due to the centrifugal force and the exhaust valve will return to normal
operation.
Decompression actuator
A Compression pressure
34
Power unit system
Blowby gas reburning system
A blowby gas reburning system is adopted to be respectful with the environment.
To reburn the blowby gases, this engine separates oil from the blowby gases in two labyrinths.
First, oil is separated from the blowby gases in the cylinder block labyrinth, and then in the intake
silencer labyrinth.
The oil separated from the blowby gases flows back to the crankcase, and the blowby gases sepa-
rated from the oil are sucked into the combustion chamber.
A
B
C
a Cylinder block labyrinth

b Intake silencer labyrinth
A Blowby gas
B Engine oil
C Air
35
TECH
Lighting coil
The F6 can be equipped with a flywheel magnet, lighting coil, and Rectifier Regulator,available as
optional accessories, to enable battery charging.
The electrical current generating capacity is 6A when the engine speed is at 6000 r/min.
a
b
e
f
aLighting coil
bRectifier Regulator
cFuse
dBattery
eSwitch
fElectrical component
36
Power unit system / Fuel system
Fuel system
Outline
This engine is equipped with a simply-designed and reliable butterfly-type carburetor. A built-in
primer pump is also provided in order to ease engine starting when the float chamber is empty, or
when operating the engine after it has been stored for a long time.
a Primer pump
b Carburetor
37
TECH
Carburetor
Idle and low speed operation
When the engine is running at idle or at low speed, negative pressure generated in the pilot passage
a will be increased.
Air is drawn into the pilot passage through the pilot air jet b to be mixed with the fuel that is also
sucked into the passage through the pilot jet a. This air and fuel mixture is supplied to the engine
through the pilot hole c. The pilot screw b controls the amount of air and fuel mixture that will be
supplied to the engine.
When running at low speed, the air and fuel mixture is supplied to the engine through the pilot hole
c and through the bypass holes d.
c
b
b
a c
b
d
b
C
D
E
A Idle operation
B Low speed operation
C Air
D Fuel
E Air and fuel mixture
38
Fuel system
Medium speed operation
When running at medium speed, the air that has entered through the main bore a flows faster,
causing negative pressure to increase in the main bore a.
When the negative pressure in the main bore a increases, the fuel is sucked from the main jet a to
be mixed with the air that has entered from the main air jet b through the emulsion tube c, and
then drawn into the main nozzle b.
The fuel drawn into the main nozzle b is mixed with the air in the venturi, producing air and fuel mix-
ture that will be supplied to the engine.
The air and fuel mixture is simultaneously supplied to the engine through the pilot hole d and the
bypass holes e.
b
e
A
b B
c
a C
A Air
B Fuel
C Air and fuel mixture
39
TECH
High speed operation
When running at high speed, the throttle valve opening is near the fully open position, and the neg-
ative pressure generated in the main bore a becomes even higher. Consequently, a larger amount
of air and fuel mixture is drawn from the main nozzle a to be supplied to the engine.
At high speed operation, as the negative pressure in the main bore a becomes higher than the neg-
ative pressure in the pilot passage b, fuel is not drawn through the pilot jet c.
A
a B
C
A Air
B Fuel
C Air and fuel mixture
40
Fuel system
Built-in primer pump
This engine is equipped with a built-in primer pump in order to ease engine starting when the float
chamber is empty, or when operating the engine after it has been stored for a long time.
The built-in primer pump sends fuel directly to the float chamber in the carburetor without operating
the mechanical fuel pump.
A
A Fuel passage (mechanical fuel pump)

B Fuel passage (built-in primer pump)
41
TECH
Lubrication system
Outline
For the first time in a single-cylinder engine, a trochoid type oil pump has been adopted in order to
improve lubrication performance.
The oil hole in the crankshaft allows oil to lubricate the crankpin and connecting rod.

The oil pump is driven by the camshaft.
The oil that has been pumped out by the oil pump flows into the camshaft, and it is then sent to the
upper part of the engine to lubricate the crankshaft journal bearing.
After that, the oil flows down to the crankshaft, and then it is splashed by the rotational force of the
crankshaft to lubricate all parts of the engine.
There is an oil hole in the crankshaft.
The oil entered through the oil hole will flow down to the crankpin to lubricate the crankpin and con-
necting rod.
a c
b
A
B
a Oil pump a Oil hole

b Camshaft b Crankpin
c Crankshaft journal bearing
d Crankshaft A Engine oil flow
B Splashing oil
42
Lubrication system / Tilt system
Tilt system
Outline
The incorporated reverse lock system prevents the outboard motor from tilting up when the shift
position is in reverse and the throttle is applied.
Reverse lock system

In this system, the tilt up function will be automatically locked when shifted in reverse. When the shift
lever a is moved to the reverse position, the rod b, which was pushing up the reverse lock c,
moves down. Then, due to the return spring d force, the reverse lock c is forced to move in the
direction a to prevent the outboard motor from tilting up.
The reverse lock system does not operate when the outboard motor is tilted up.
c
b
43
TECH
Lubrication diagram
Crankshaft
Crankshaft
journal bearing
Camshaft
Oil pump
Oil strainer
Cylinder head Crankshaft Crankpin
Crankshaft
Camshaft
journal bearing
Piston
Cylinder block
Cylinder bore
Valve lifter Camshaft
Oil pump
Oil strainer
A
Crank case B
A Engine oil flow

B Splashing oil
44
Lubrication diagram / Cooling flow diagram
Cooling flow diagram
Thermostat
Upper case
Cooling water hose
Thermostat Cooling water hose
Water pump Cylinder head

Upper case
Cylinder block
Upper case Lower case
Water pump
Cooling water inlet

Cooling water inlet
Water
A
B
A Cooling water flow

B Pilot water
45
TECH
Intake and exhaust flow diagram
Carburetor
Intake manifold
Intake silencer
A
B
A Intake air flow

B Exhaust gas flow
46
RIG
GING
Rigging information
Outboard motor installation
Dimension
Exterior +'F6
Clamp bracket
Uncrating procedure
Outboard motor mounting

Installing the charging system
Installing the battery
Rigging recommendations
Battery requirement
Propeller selection
Propeller size
Selection
47
RIG
GING Rigging information
• Overpowering a boat could cause severe instability. Do not mount an outboard motor with
more horsepower than the maximum rating on the capacity plate of the boat. If the boat
does not have a capacity plate, consult the boat manufacturer.
• Improper mounting of the outboard motor could result in hazardous conditions, such as
poor handling, loss of control, or fire hazards. Consult your dealer or have a +,GHD-
trained person experienced in proper rigging mount the outboard motor.
Too much weight on the transom could change the center of gravity, buoyancy, operating
balance, or performance of the boat, which could cause loss of control or swamping. Con-
sult the boat manufacturer for the maximum engine weight allowable on the transom, which
is different from the overall boat capacity. Overloading the transom with an outboard motor
that is too heavy could also damage the hull, transom, deck, or helm area, as well as the out-
board motor and other equipment.
48
Outboard motor installation / Dimension
Dimension
Exterior +'F6
mm (in)
325 (12.8)
°
90
153 (6.1)
222 (8.8) 181 (7.2)
425 (16.8)
130 (5.2) 409 (16.2)

341 (13.5)
S: 635 (25.0)
383 (15.1) L: 753 (29.0)
134 (5.3)
63 (2.5)
503 (19.9)
430 (17.0)
395 (15.6)
191 (7.6)
0.6 (0.02)
39 (1.6)
S: 435 (17.2)
L: 562 (22.2)
(*1)
S: 644 (25.4)
L: 771 (30.4)
S: 555 (21.9)
L: 637 (25.1)
S: 71
L: 93 (2.8)
(3.7)
°
69
12°
104 (4.1)
259 (10.2)
(*1) Transom height
49
RIG
Clamp bracket
mm (in)
83 (3.3) 83 (3.3)
55 (2.2) 55 (2.2)
48 (1.9)
136 (5.4)
22 (0.9)
60 (2.4)
50
Uncrating
Dimension / Uncrating procedure / Outboard motorprocedure
mounting
Uncrating procedure
TIP:
1. Check the crate for any shipping dam-
Place the outboard motor on the boat or on a
age.
stand so that the clamp bracket is in the tilt-
2. Open the top cover. up position for easy mounting.
3. Remove the wrapping, and then check Outboard motor mounting

the outboard motor for concealed
Proper mounting of the outboard motor will
damage.
provide better performance, maximum reli-
ability, and highest customer satisfaction.
4. Pass the lifting rope around the carrying
This chapter contains the specifications nec-
handle. NOTICE: Do not use a lifting
essary to mount the outboard motor, and may
harness to lift up the outboard motor.
vary slightly depending on applications.
5. Tension the lifting rope. When mounting the outboard motor, make
sure that there is sufficient clearance for the
outboard motor to fully move to port and star-
board, as well as fully tilt up. See
“Dimension”.
1. Place the outboard motor on the vertical

centerline of the boat transom. Check
that distance a is equal to distance b
and that distance c is equal to distance
d.
6. Lift up the outboard motor carefully so A C/L

that the carrying handle is facing up.
a b
c d
B C/L
7. Place the outboard motor on the boat or

on a stand.
a b
c d
A Hull without strakes

B Hull with strakes
C/L: Centerline of transom
51
RIG
2. Adjust the position of the outboard motor
so that the height of the anti-cavitation
plate e is between the bottom of the
boat and a maximum of 25.0 mm (1.0 in)
f below it.
e
7. Remove the bolt e, and then install the
TIP: Rectifier Regulator f using the included
This mounting height information is for refer- bolts g.
ence only. It is impossible to provide com-
plete instructions for every possible boat and
outboard motor combination.
3. Tighten the clamp screws. e
Installing the charging system

f
1. Drain any remaining fuel from the fuel g
tank.
8. Remove the grommet h, and then route
2. Remove the manual starter. See the leads i.
“Removing the manual starter”.
9. Install the holder j using the fuel joint
3. Remove the flywheel magnet. See bolt k, and then fasten the leads using
“Removing the flywheel magnet”. the holder j.
4. Slide the clamp a down, and then 10. Connect the connector a of leads i.
disconnect the fuel hose b.
k
5. Remove the fuel tank c.
j
c i
a
a j
h
6. Install the lighting coil d.
52
11. Install the bracket l to the bottom
cowling using the self-tapping bolt m,
and then install the fuse box n.
n
d q
l TIP:
m
Check that the lighting coil leads d do not
interfere with the flywheel magnet.
12. Connect the Rectifier Regulator
connectors of Green (G) leads and Red
15. Install the included flywheel magnet
(R) lead.
(optional). See “Installing the flywheel
magnet”.
16. Connect the hose b, and then fasten it

G using the clamp a.
17. Install the fuel tank c.
c
R
a
13. Remove the bolt o, and then install the
Rectifier Regulator ground lead b, fuse
ground lead c, and bracket p using the b
removed bolt o.
18. Install the manual starter. See “Installing

p o the manual starter”.
b Improper battery connections or cable

size selection may result in a fire.
c
14. Install the holder q, and then fasten the

leads using the holder q.
If battery connections are reversed, check

the electrical system and replace any
damaged components.
53
RIG
Rigging recommendations Full throttle operating range:
Battery requirement F6C: 4500–5500 r/min
Make sure that the size of the battery cable
terminals is appropriate for the size of the
battery terminals. Propeller size (in) Material
To prevent the battery cable terminal connec- 7 1/2 8 - BA
tions from corroding, solder each battery 7 1/4 6 1/2 - BA (*1) Aluminum
cable terminal to the battery cable. 7 1/4 8 1/4 - BA (*2)
Ambient temperature above 0 °C (32 °F) (*1)F6C only
Unit Minimum capacity
CCA/EN 347.0 Amps
20HR/IEC 40.0 Ah
Propeller selection
The performance of a boat and outboard
motor will be critically affected by the size
and type of propeller that is used. 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 outboard motor.
Propeller size
The size of the propeller is indicated on a
propeller blade.
a b c
aPropeller diameter
bPropeller pitch
cPropeller type
Selection
When the engine speed is at the full throttle
operating range, the ideal propeller for the
boat is one that provides maximum perfor-
mance in relation to boat speed and fuel con-
sumption.
54
TRBL
SHTG
Troubleshooting
Outboard motor troubleshooting

Troubleshooting procedure
Troubleshooting the power unit
Troubleshooting the lower unit
55
TRBL
SHTG Troubleshooting
1. Before troubleshooting the outboard motor, make sure that fresh fuel of the specified type has
been used.
2. Make sure that all electrical connections are secure and free from corrosion.
3. If the outboard motor is equipped with the charging system,check that the battery is fully
charged.

Troubleshooting consists of the following 3 items:
Symptom 1: Specific trouble conditions
Symptom 2: Trouble conditions of an area or individual part
Cause: Trouble causes of symptom 2
— : Not applicable
Symptom 1: Engine does not crank.
Symptom 2 Cause Checking step
Starter handle cannot be Gear shift not in the N position Set the gear shift to the N position.
pulled Start-in-gear protection cable Adjust the start-in-gear protection cable.
not adjusted properly
Manual starter malfunction Disassemble and check the manual
starter.
Decompressor malfunction Check the camshaft.
Stuck piston or crankshaft Disassemble and check the power unit.
Stuck drive shaft Disassemble and check the lower unit.
Starter handle can be Manual starter malfunction Disassemble and check the manual
pulled, but the engine starter.
does not crank Damaged flywheel magnet Check the flywheel magnet Woodruff
Woodruff key key.
Symptom 1: Engine will not start (engine cranks).
Spark plug does not — Check the ignition spark.

spark Spark plug malfunction Check the spark plug.
Spark plug cap malfunction Check the spark plug cap.
Engine shut-off switch malfunc- Check the engine shut-off switch.
tion
Fuel not supplied Fuel cock closed Set the fuel cock to the proper position.
Clogged fuel strainer Check the fuel strainer for clog or dirt.
Fuel leakage Check the fuel line for fuel leakage.
Fuel pump malfunction Check the fuel pump for fuel leakage.
Check the diaphragm for tears.
Check the camshaft for wear.
Carburetor malfunction Disassemble and clean the carburetor.
56
Compression pressure Compression leakage Measure the compression pressure.

is low Check the valve for bends or stuck.
Check the decompressor for proper
operation.
Check the piston and piston ring for
damage.
Check the cylinder for damage.
Improper valve timing Check the valve timing.
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, limited engine
speed, or engine stalls.
Fuel not supplied — Check that the air vent screw is open.
Throttle valve does not Carburetor malfunction Check the throttle valve for proper move-
move properly ment.
Throttle link and throttle cable Adjust the throttle link and throttle cable.
not installed properly
Spark is weak — Check the CDI unit air gap.
Improper fuel and air Choke valve does not operate Check the choke valve operation.
amount supplied properly
Carburetor malfunction Adjust the pilot screw.
Disassemble and clean the carburetor.
Air leakage (carburetor to cylin- Check the O-ring and gaskets of the car-
der head) buretor and intake manifold.
Symptom 1: High engine idle speed.
Improper fuel and air Carburetor malfunction Adjust the pilot screw.
amount supplied Disassemble and clean the carburetor.
Throttle link and throttle cable Adjust the throttle link and throttle cable.
not installed properly
Symptom 1: Engine overheats.
Cooling water not dis- Clogged cooling water inlet Check the cooling water inlet.
charged from the cooling Water pump impeller malfunc- Check the impeller.
water pilot hole tion Check the pin.
Water leakage from the water Check the insert cartridge.
pump housing Check the outer plate cartridge.
Check the water pump housing.
Leak or clogged cooling water Check the water pipe for damage and
passage proper installation.
Check the cooling water passage.
— Thermostat malfunction Check the thermostat.
57
TRBL
SHTG Troubleshooting
Symptom 1: Improper oil lubrication.
Oil cannot be seen Low engine oil level Check the oil level.
through the oil lubrica- Check for engine oil leakage.
tion check window
Check the valve stem seal and valve.
Check the piston ring.
Insufficient oil lubrication Check the oil pump.
Check the oil strainer.
Check the oil passage.
Symptom 1: Discharged battery
Battery performance decrease Check the battery capacity and specific

gravity.
Short, open, or loose connec- Check the battery cable and terminals
tion in charging circuit for proper connections.
Lighting coil malfunction Measure the lighting coil output peak
— voltage.
Measure the lighting coil resistance.
Rectifier Regulator malfunction Measure the Rectifier Regulator output
peak voltage.
Check the Rectifier Regulator for conti-
nuity.

Troubleshooting consists of the following 3 items:
Symptom 1: Specific trouble conditions
Symptom 2: Trouble conditions of an area or individual part
Cause: Trouble causes of symptom 2
Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate prop-
erly.
Shift rod malfunction Check the shift rod joint.

Shift mechanism malfunction Check the shift rod for wear.
(lower unit) Check the dog clutch.
—
Check the forward gear, reverse gear,
and pinion for damage or wear.
58
ELEC
Electrical system
Electrical component and wiring harness routing

Port
Top
Checking the electrical component

Measuring the peak voltage
Using the digital tester
Charging unit and component

Checking the lighting coil
Checking the Rectifier Regulator
Ignition unit and component

Checking the ignition spark
Checking the spark plug cap
Checking the engine shut-off switch
59
ELEC
Electrical system
Port
A B
d f e d c
aEngine shut-off switch lead (Black) A Install the holder horizontally, and then
bSpark plug cap fasten the spark plug wire using the
cSpark plug holder.
dGround lead (Black) B Point the end of plastic tie inward (engine
eCDI unit lead (Black) side), and then cut the end.
fRectifier Regulator
60
Top
B
d c b
aEngine shut-off switch A Fold the holders inward so that the leads
bCDI unit do not come out from the holders.
cFuse (20 A) B Check that the ground lead does not inter-
dLighting coil fere with the bolt or washer.
61
ELEC
Electrical system
Checking the electrical
TIP:
component • Before measuring the peak voltage, check
Measuring the peak voltage all wiring harness for corrosion. Also, make
sure that the wiring harness is connected
properly and that the battery is fully
When measuring the peak voltage, do not charged.
touch any of the connections of the digital • Use peak voltage adapter B with the rec-
tester probes. ommended digital circuit tester.
• Connect the positive pin of peak voltage
adapter B to the positive terminal of the dig-
ital circuit tester, and the negative pin to the
When measuring the peak voltage
negative terminal.
between the terminals of an electrical
• When measuring the peak voltage, set the
component using the digital tester, make
digital circuit tester to the DC voltage
sure that the leads do not contact any
mode.
metal parts. Otherwise, the electrical com-
ponent may short-circuit and be dam-
aged. Using the digital tester
The electrical technical data apply to the
To check the electrical components or mea- measurements taken using the +LGHD-rec-
sure the peak voltage, use the special ser- ommended tester.
vice tools. A malfunctioning electrical The resistance values shown are the values
component can be checked easily by mea- taken before the engine is started. The actual
resistance may vary depending on the envi-
suring the peak voltage. The specified engine
ronmental conditions and ambient tempera-
speed when measuring the peak voltage is
ture.
affected by many factors, such as fouled
spark plugs or a weak battery. If one of these
factors is present, the peak voltage cannot be
measured properly.
DC V
Digital circuit tester

Peak voltage adapter B
62
Checking the electrical component / Charging unit and component
Charging unit and component 2. Measure the Rectifier Regulator output
Checking the lighting coil peak voltage.
R R
1. Remove the holder a, and then discon- R
nect the lighting coil connectors a.
G G a
Rectifier Regulator peak voltage:

a a Red (R)–Ground
Loaded
r/min
2. Measure the lighting coil output peak 1500 3500
voltage. DC V 13.0 13.0
Lighting coil output peak voltage:
Green (G)–Green (G) TIP:
Unloaded Do not use peak voltage adapter B when
r/min measuring the Rectifier Regulator output
Cranking 1500 3500
peak voltage.
DC V 20.0 30.1 64.3
3. Disconnect the Rectifier Regulator

TIP: connectors a, b, c, and Rectifier
To prevent the engine from starting when Regulator ground lead d.
cranking it, remove the clip from the engine
shut-off switch.
a
3. Measure the lighting coil resistance.
Lighting coil resistance (reference data):

0.771–0.869 \ at 20 °C (68 °F)
4. Connect the lighting coil connectors, and

b
then fasten the lighting coil leads using c d
the holder a.
4. Check the Rectifier Regulator for
Checking the Rectifier Regulator continuity. Replace if out of specification.
If the battery cables are connected in

reverse, the Rectifier Regulator can be b
damaged.
c
1. Remove the holder a.

d
63
ELEC
Electrical system
3. Crank the engine and check for a spark.
a WARNING! Do not touch any of the
connections of the special service
b
tool.
c
OK
Rectifier Regulator continuity

(testing diode mode):
a
Tester probe Display value
(reference data)
Ignition tester (spark gap tester) a
b OL
a c OL
d OL 4. Disconnect the special service tool a,
a 0.384 V and then connect the spark plug cap.
b c 0.938 V Checking the spark plug cap

d 0.649 V 1. Remove the spark plug cap from the
a 0.384 V spark plug wire by turning the cap coun-
c b 0.938 V terclockwise.
d 0.654 V
a 0.716 V
d b 0.384 V
c 0.384 V
OL: Indicates an overload
TIP:
Make sure to set the tester measurement
range to the diode mode.
2. Measure the spark plug cap resistance.
5. Connect the Rectifier Regulator

connectors a, b, c, and Rectifier
Regulator ground lead d.
6. Fasten the Rectifier Regulator leads

using the holder a.
Ignition unit and component

Checking the ignition spark
1. Disconnect the spark plug cap from the
Spark plug cap resistance
spark plug.
(reference data):
5.0 k\ at 20 °C (68 °F)
2. Connect the spark plug cap to the special
service tool a.
64
Charging unit and component / Ignition unit and component
3. Install the spark plug cap to the spark
plug wire by turning the spark plug cap
clockwise.

1. Disconnect the engine shut-off switch
connector a.
2. Check the engine shut-off switch for

continuity.
b
a
Terminal
Switch position
b c
Clip installed
Clip removed C C
Button pushed C C
3. Connect the engine shut-off switch

connector a.
65
ELEC
Electrical system
— MEMO —
66
FUEL
Fuel system
Hose routing
Fuel hose
Blowby hose, oil return hose, and cooling water hose
Fuel tank
Removing the fuel tank
Removing the primer pump
Checking the fuel tank
Checking the fuel joint
Checking the fuel strainer (tank side)
Checking the fuel strainer
Checking the primer pump
Installing the primer pump
Installing the fuel tank
Intake silencer
Removing the throttle cable and throttle link
Removing the carburetor
Installing the carburetor
Installing the throttle cable and throttle link
Adjusting the throttle cable and throttle link
Carburetor
Disassembling the carburetor
Checking the carburetor
Assembling the carburetor
Fuel pump
Removing the fuel pump
Checking the fuel pump
Disassembling the fuel pump
Checking the diaphragm and valve
Assembling the fuel pump
Installing the fuel pump
67
FUEL
Fuel system
Hose routing
Fuel hose
h
e
g
d
d
c f b
c b a
a Fuel hose (fuel tank to fuel cock)

b Fuel hose (fuel cock to fuel strainer) a Fuel tank
c Fuel hose (fuel strainer to joint) b Fuel cock
d Fuel hose (joint to fuel pump) c Fuel strainer
e Fuel hose (fuel pump to carburetor) d Joint
f Fuel hose (joint to primer pump) e Fuel pump
g Fuel hose (primer pump to carburetor) f Carburetor
h Fuel hose (fuel joint to fuel cock) g Primer pump
h Fuel joint
68
Hose routing
Blowby hose, oil return hose, and cooling water hose
a Blowby hose (cylinder block to intake

silencer)
b Oil return hose (intake silencer to crank-
case)
c Cooling water hose (thermostat cover to
crankcase)
a Intake silencer
69
FUEL
Fuel system
Fuel tank
4 N·m (0.4 kgf·m, 3.0 ft·lb)
1
2 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4
5
3 6
7
8
9
10 9
11 17 10
18 11
20 16
11 19 11
11
27 12
30 27 28
13
11 21
31 27
22 11 14
11 26 11 15
29 23 11
25
11
24
7 N·m (0.7 kgf·m, 5.2 ft·lb)
No. Part name Q’ty Remarks

1 Choke holder bolt 1
2 Holder 1
3 Grommet 1
4 Fuel cap 1
5 Rubber seal 1
6 Fuel strainer 1
7 Fuel tank 1
8 Bolt 1
9 Grommet 2
10 Collar 2
11 Clamp 11
12 Hose 1
13 Fuel cock 1
14 Fuel cock screw 1
15 Hose 1
16 Holder 1
17 Fuel joint 1
70
Fuel tank
4 N·m (0.4 kgf·m, 3.0 ft·lb)

1
2 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4
5
3 6
7
8
9
10 9
11 17 10
18 11
20 16
11 19 11
11
27 12
30 27 28
13
11 21
31 27
22 11 14
11 26 11 15
29 23 11
25
11
24
7 N·m (0.7 kgf·m, 5.2 ft·lb)

18 Rubber seal 1
19 Choke cable nut 1
20 Holder 1
21 Choke cable 1
22 Fuel strainer 1
23 Hose 1
24 Hose 1
25 Holder 1
26 Hose 1
27 Plastic tie 3 /PUSFVTBCMF
28 Joint 1
29 Primer pump 1
30 Hose 1
31 Hose 1
71
FUEL
Fuel system
Cover the fuel components using a rag to
prevent fuel from spilling out.
1. Drain the fuel from the fuel tank.
2. Remove the manual starter. See f

3. Disconnect the fuel hose a, and then

remove the fuel tank b.
7. Remove the fuel hoses a, c, and d.
b c
a
4. Disconnect the fuel hoses c and d.
8. Remove the cap g, and then remove the
fuel joint h.
d
c
5. Remove the fuel cock screw e. g
Removing the primer pump

1. Remove the holder a, and then remove

the choke cable b.
a
b
e
6. Remove the fuel cock f.
72
Fuel tank
2. Disconnect the fuel hoses c and d. Checking the fuel joint
1. Check the fuel joint. Replace if cracked or
3. Remove the primer pump e. damaged.
2. Connect the special service tool a to the

fuel joint outlet a.
c 3. Apply the specified positive pressure.

Replace the fuel joint if the specified
pressure cannot be maintained for at
least 10 seconds.
e d
a
a
0 50
Vacuum/pressure pump gauge set a

4. Remove the holder f, fuel strainer g,
fuel hose c, and primer pump e.
Specified positive pressure:
50.0 kPa (0.50 kgf/cm2, 7.3 psi)
Checking the fuel strainer (tank side)

1. Check the fuel strainer. Clean it using
f g straight gasoline if there is foreign mate-
rial.
c
e 1. Check the fuel strainer. Replace if
cracked or damaged.
5. Remove the fuel hoses d, h, and i.
h fuel inlet a.
3. Block the fuel outlet b using a rubber

plug b, and then apply the specified
d
positive pressure. Replace the fuel
strainer if the specified pressure cannot
be maintained for at least 15 seconds.
i

1. Check the fuel tank. Replace if cracked
or damaged.
73
FUEL
Fuel system
d b
b b a
a c
Leakage tester a 2. Install the clamps f and g temporarily

onto the fuel hoses a, b, c, and h,
Specified positive pressure: and then connect the fuel hose to the fuel
200.0 kPa (2.00 kgf/cm2, 29.0 psi) strainer i and primer pump j.
Checking the primer pump 3. Fasten the fuel hose b, c and h using
the clamps f.
primer pump inlet a.
4. Install the holder k.
2. Block the fuel outlet b using a rubber g
plug b.
f g
3. Apply the specified positive pressure. a
b f
Replace the primer pump if the specified k i
pressure cannot be maintained for at
least 30 seconds. h
j
f c
b b 5. Install the primer pump j to the holders

a
l.
6. Connect the fuel hose a, and then

fasten it using the clamp g.
a j a
Leakage tester a

166.7 kPa (1.667 kgf/cm2, 24.2 psi)
g
Installing the primer pump
1. Connect the fuel hoses a, b, and c to l
the joint d, and then fasten them using
7. Connect the fuel hose h, and then
the plastic ties e.
fasten it using the clamp g.
74
Fuel tank
Installing the fuel tank
1. Install the fuel joint a.
a
8. Pass the choke cable m through the hole
in the bottom cowling, and then tighten
the choke cable nut n to the specified 2. Install the clamps b and c temporarily
torque. onto the fuel hoses d, e, and f, and
then connect the hoses to the fuel cock
g.
3. Fasten the fuel hoses using the clamps

b, and then install the holder h.
h d
c
n m f
b
Choke cable nut n:

4 N·m (0.4 kgf·m, 3.0 ft·lb) c c
9. Insert the cable end a into the hole of e g

choke lever.
4. Install the fuel cock g.
10. Place the outer tube end b of choke
cable m so that it contacts the stopper
c, and then install the holder n.
11. Tighten the choke holder bolt o to the

specified torque.
g
o o
a
5. Tighten the fuel cock screw i to the

specified torque.
c n m
b
Choke holder bolt o:

4 N·m (0.4 kgf·m, 3.0 ft·lb)
75
FUEL
Fuel system
Fuel cock screw i:

7 N·m (0.7 kgf·m, 5.2 ft·lb)
6. Connect the hoses d and f, and then

fasten them using the clamps c.
c
d
f
7. Connect the hose e, and then fasten it

using the clamp c.
8. Insert the protrusion a of the fuel tank j

into the grommet k.
a
c
k
e

the manual starter”.
76
Fuel tank / Intake silencer
Intake silencer
12 N·m (1.2 kgf·m, 8.9 ft·lb)

3
1 4
12 2
5
9
6
8
13 7
10
14
23
15 11
14
22
21 16
21
9
20
20 17
18
9
19

1 Hose 1
2 Hose 1
3 Bolt 1
4 Washer 1
5 Collar 1
6 Throttle cam 1
7 Lever 1
8 Holder 1
9 Clamp 3
10 Gasket 1 /PUSFVTBCMF
11 Throttle link rod 1
12 Intake manifold bolt 2
13 Intake manifold 1
15 Spacer 1
16 Cap 1
17 Hose 1
77
FUEL
Fuel system
12 N·m (1.2 kgf·m, 8.9 ft·lb)

3
1 4
12 2
5
9
6
8
13 7
10
14
23
15 11
14
22
21 16
21
9
20
20 17
18
9
19

18 Carburetor assembly 1
19 Cap 1
20 Bolt 2
21 Washer 2
22 Intake silencer 1
23 O-ring 1 /PUSFVTBCMF
78
Intake silencer
Removing the throttle cable and
throttle link
1. Loosen the screw a, and then remove
the cap b and throttle link rod c.
2. Remove the throttle cables d.

d c
3. Disconnect the fuel hose d and oil return

b hose e.
e
c a
3. Remove the washer e, collar f, throttle

cam g, lever h and holder i.
e d
f
4. RemoveWKHLQWDNH silencer f, O-ring g,
g carburetor h, gaskets i BOE spacer j.
i
h 5. Remove the fuel hose k.
g
i
j
i
1. Remove the blowby hose a. f
a
k
2. Remove the intake manifold b and

gasket c.
79
FUEL
Fuel system
Installing the carburetor 5. Install a new gasket k and the intake
manifold i, and then tighten the intake
manifold bolt l to the specified torque.
Do not reuse an O-ring or gasket, always
replace it with a new one. l
1. Install the clamps a and b temporarily

onto the fuel hose c.
2. Connect the fuel hose c, and then k

fasten it using the clamp a.
i l
3. Install new gaskets d, the spacer e, the
carburetor f, a new O-ring g, and the Intake manifold bolt l:
intake silencer h to the intake manifold 12 N·m (1.2 kgf·m, 8.9 ft·lb)
i.
6. Install the blowby hose m.
i
m
g
d
h
Installing the throttle cable and
a throttle link
c 1. Install the lever a, throttle cam b, collar
c, washer d, and holder e.
b
f
d
4. Connect the oil return hose j and fuel
hose c, and then fasten the fuel hose c
using the clamp b.
e b
j
a
b
c
2. Turn the throttle grip to the fully closed
position.
80
Intake silencer
3. Install the shorter cable f to the section
a a b
a of the bracket g. c
4. Install the throttle cable h, and then

tighten the locknuts b to the specified
torque.
h c
b
a
4. Adjust the length of cable d so that there

is no clearance between the cable end d
and the section e of the throttle cam b.
g
b
a f b
Throttle cable locknut b:

4 N·m (0.4 kgf·m, 3.0 ft·lb)
d
5. Install the throttle link rod i and cap j,
and then tighten the throttle link screw k e
to the specified torque. d
j k 5. Check that the section b on the throttle

i cam contacts stopper c when the
throttle grip is in the fully open position,
and that the section b contacts stopper
f when the throttle grip is in the fully
closed position.
Throttle link screw k:

1.5 N·m (0.15 kgf·m, 1.11 ft·lb)
Adjusting the throttle cable and

throttle link
1. Loosen the locknuts a. c
f b
2. Turn the throttle grip to the fully open 6. Tighten the throttle cable locknuts a to
position. the specified torque.
3. Adjust the length of cable a so that the

stopper b of the throttle cam b contacts
section c of the bracket c.
81
FUEL
Fuel system
Throttle cable locknut a:

4 N·m (0.4 kgf·m, 3.0 ft·lb)
7. Loosen the throttle link screw e.
8. Turn the throttle grip to the fully open

position.
9. While pulling the lever g, tighten the

throttle link screw e to the specified
torque.
e g
Throttle link screw e:

1.5 N·m (0.15 kgf·m, 1.11 ft·lb)
10. Check that the throttle link is in the fully

open and fully closed positions when
turning the throttle grip to the fully open
and fully closed positions.
82
Intake silencer / Carburetor
Carburetor
1.5 N·m (0.15 kgf·m, 1.11 ft·lb) 3 A 6 B 20
5
1 2 4
19 12 11 9
15
14
18 13
17
16
10 10

1 Throttle stop screw 1
2 Spring 1
3 Throttle link screw 1
4 Spring 1
6 Pilot screw 1
7 Pilot jet 1
9 Float chamber 1
10 Screw 2
12 Drain screw 1
13 Pin 1
14 Spring 1
15 Main nozzle 1
16 Main jet 1
17 Float 1
83
FUEL
Fuel system
1.5 N·m (0.15 kgf·m, 1.11 ft·lb) 3 6

5
1 2 4
19 12 11 9
15
14
18 13
17
16
10 10

18 Clip 1
19 Needle valve 1
84
Carburetor
Disassembling the carburetor i
1. Remove the drain screw a.
2. Remove the float chamber b and gasket

c. j
c
b
6. Remove the pilot jet k and pilot screw
l.
m
l
a
3. Remove the spring d, and then remove

the pin e.
k
Pilot screw driver m

e
Checking the carburetor
1. Check that the throttle valve operates
d smoothly.
2. Check the air and fuel passages. Clean

4. Remove the float f, needle valve g, the carburetor body if there is dirt or
and clip h. foreign material.
f 3. Blow compressed air into all passages

h g and jets. WARNING! When using
compressed air, wear safety glasses
or safety goggles. Otherwise, eye
injury could result from flying debris
or liquid.
4. Check the main jet, pilot air jet, and main

nozzle. Clean if there is dirt or residue.
5. Remove the main jet i and main nozzle NOTICE: Do not use steel wire to
j. clean the jets. Otherwise, the jet
diameters could be enlarged, which
could seriously affect performance.
85
FUEL
Fuel system
5. Check the needle valve. Replace if
deformed or worn.
a g
Position a: 1.0 mm (0.04 in)
6. Check the float. Replace if cracked or 5. Measure the float height b. Adjust the
deformed. float height by bending the tab c if out of
specification.
Assembling the carburetor 45°
Do not reuse an O-ring or gasket, always e

replace it with a new one. c
1. Install the main nozzle a and main jet b.

b b
Float height b (reference data):

10.0 mm (0.4 in)
2. Install the needle valve c, clip d, and TIP:

float e. When measuring the float height b hold the
carburetor body at angle of 45° so that there
3. Install the float pin f to the specified is no load on the needle valve spring.
installation position a.
4. Install the spring g. 6. Install a new gasket h, the float chamber

i, a new O-ring j, and the drain screw
k.
e
d c
86
Carburetor
h
i
k j
7. Install the pilot jet l, the spring m, a

new O-ring n, and the pilot screw o.
n p
m
Pilot screw driver p
8. Turn the pilot screw o in until it is lightly

seated, and then turn it out the specified
number of turns.
Pilot screw setting:

+'F6: 1 3/8 ± 3/4 turns out
87
FUEL
Fuel system
Fuel pump
2 N·m (0.2 kgf·m, 1.5 ft·lb)
0.5 N·m (0.05 kgf·m, 0.37 ft·lb)
2 3 5
2
6
5
6
7
4
2 9 9
1 2
8
10
11
12
16
15
9
14 13
9
15
7 N·m (0.7 kgf·m, 5.2 ft·lb)

1 Fuel pump 1
2 Fuel pump screw 4
3 Cover 1
4 Diaphragm 1 /PUSFVTBCMF
5 Fuel pump valve screw 2
6 Valve 2
7 Fuel pump body 2 1
8 Plunger 1
9 Nut 4
10 Spring 1
11 Fuel pump body 1 1
12 Spring 1
13 Pin 1
14 Diaphragm 1 /PUSFVTBCMF
15 Fuel pump bolt 2
88
Fuel pump
Removing the fuel pump a
1. Remove the fuel pump a and O-ring b.
a a
b
b
0 50
b Specified positive pressure:

50.0 kPa (0.50 kgf/cm2, 7.3 psi)
Checking the fuel pump
1. Connect the special service tool a to the Disassembling the fuel pump
fuel pump inlet a. 1. Remove the cover a, diaphragm b, and
fuel pump body 2 c.
2. Block the fuel pump outlet b using the
rubber plug b, and then apply the
specified positive pressure. Check that a
there is no air leakage.
b
a b c
b
a
2. Align the slot a in the fuel pump body 1
0 50
d with the hole b in the plunger e by
turning the plunger e.
e b
Vacuum/pressure pump gauge set a a
d

50.0 kPa (0.50 kgf/cm2, 7.3 psi)

fuel pump outlet b.
4. Block the fuel pump inlet a using the 3. Remove the pin f by pushing the
rubber plug b, and then apply the plunger and diaphragm.
specified positive pressure. Check that
there is no air leakage.
89
FUEL
Fuel system
a
b b
a
4. Remove the diaphragm g, spring h, Fuel pump valve screw b:

plunger e, and spring i. 0.5 N·m (0.05 kgf·m, 0.37 ft·lb)
2. Install the springs c and d, plunger e,

i e
and diaphragm f.
g
h
d e
f
c
5. Remove the valves j.
3. Align the hole a in the plunger e with

j the hole b in the diaphragm f by
pushing the plunger and diaphragm.
j
4. Install the pin g.
e a
Checking the diaphragm and valve
b
1. Check the diaphragm. Replace if torn. f
2. Check the valve. Replace if deformed or

worn.

Before assembling the fuel pump, clean the
parts and soak the valves and diaphragm in g
gasoline to obtain proper operation of the fuel
pump.
5. Turn the plunger so that the protrusions
1. Install the valves a, and then tighten the c in the diaphragm f fit into the slots d
fuel pump valve screws b to the speci- in the fuel pump body 1 h.
fied torque.
90
Fuel pump
d c
f
h
d
c
6. Install the fuel pump body 2 i, a new

diaphragm j, and the cover k, and then
tighten the fuel pump screws l to the
specified torque.
j i
l
Fuel pump screw l:

2 N·m (0.2 kgf·m, 1.5 ft·lb)
Installing the fuel pump

1. Install a new O-ring a and the fuel pump
b, and then tighten the fuel pump bolts
c to the specified torque.
b
a
Fuel pump bolt c:

7 N·m (0.7 kgf·m, 5.2 ft·lb)
91
POWR
Power unit
Power unit (check and adjustment)

Checking the compression pressure
Checking the ignition timing
Checking the CDI unit air gap
Adjusting the CDI unit air gap
Checking the valve clearance
Adjusting the valve clearance
Manual starter
Removing the manual starter
Disassembling the manual starter
Checking the manual starter
Checking the spiral spring
Assembling the manual starter
Installing the manual starter
Adjusting the start-in-gear protection cable
Measuring the starter rope
Power unit assembly

Removing the power unit
Installing the power unit
Flywheel magnet
Removing the flywheel magnet
Installing the flywheel magnet
Crankcase
Removing the oil pump
Removing the oil seal housing
Removing the crankcase
Checking the crankcase
Checking the rotor assembly
Checking the oil strainer
Checking the oil seal housing
Installing the crankcase
Installing the oil pump
Installing the oil seal housing
Cylinder head
Removing the cylinder head
Disassembling the cylinder head
Checking the cylinder head
Checking the rocker arm
Checking the push rod
Checking the valve spring
Checking the valve
Checking the valve guide
92
Replacing the valve guide
Checking the valve seat
Refacing the valve seat
Checking the spark plug
Checking the thermostat cover anode
Checking the thermostat
Assembling the cylinder head
Installing the cylinder head
Cylinder block
Disassembling the cylinder block
Checking the piston diameter
Checking the cylinder bore
Checking the piston ring
Checking the piston ring end gap
Checking the piston ring groove
Checking the piston ring side clearance
Checking the piston pin boss inside diameter
Checking the piston pin diameter
Checking the connecting rod small end inside diameter and
big end inside diameter
Checking the crankshaft
Checking the connecting rod oil clearance
Checking the cylinder block
Checking the camshaft
Checking the valve lifter
Assembling the cylinder block
93
POWR
Power unit
Power unit (check and 9. Connect the spark plug cap.
adjustment)
Checking the compression pressure
1. Install the special service tools a and b
1. Start the engine, warm it up for 5 min-
to the spark plug wire a.
utes, and then stop it.
2. Start the engine and warm it up until the
2. Remove the clip from the engine shut-off
idle speed stabilizes at 1450–1550 r/min.
switch.
3. Check that the pointer b on the manual
3. Disconnect the spark plug cap, and then
starter is aligned with the specified
remove the spark plug. NOTICE: Before
ignition timing mark on the flywheel
removing the spark plug, remove any
magnet.
dirt or dust in the spark plug well that
may fall into the cylinder.
4. Install the special service tool a.
b
a b
Compression gauge
5. Fully open the throttle.

a
6. Pull the starter handle quickly several
times to crank until the reading on the Digital tachometer
compression gauge stabilizes, and then Timing light
measure the compression pressure.
Ignition timing: BTDC 7–9° at 1500 r/min
Minimum compression pressure
(reference data):
700.0 kPa (7.00 kgf/cm2, 101.5 psi) TIP:
at 20 °C (68 °F) Set the digital tachometer to the 2-cycle 1-
cylinder mode because this engine ignites
the spark plug once per crankshaft rotation.
TIP:
When pulling the starter handle to crank the
engine, the compression pressure may vary Checking the CDI unit air gap
depending on the speed at which the starter
handle is pulled.
Do not turn the flywheel magnet counter-
7. Remove the special service tool. clockwise. Otherwise, the water pump
impeller could be damaged.
8. Install the spark plug. See step 4 in
“Installing the cylinder head”.
94
1. Remove the manual starter. See
2. Turn the flywheel magnet clockwise to

align the permanent magnet a with the a
protrusions b on the CDI unit.
3. Measure the CDI unit air gap c.
b
c
CDI unit bolt a:
a 10 N·m (1.0 kgf·m, 7.4 ft·lb)
4. Measure the CDI unit air gap.

Measure the valve clearances when the
engine is cold.
CDI unit air gap c:
0.4–0.6 mm (0.016–0.024 in)
Adjusting the CDI unit air gap clockwise. Otherwise, the water pump
Do not turn the flywheel magnet counter- 1. Remove the clip from the engine shut-off
clockwise. Otherwise, the water pump switch.
2. Remove the engine shut-off switch lead
1. Turn the flywheel magnet clockwise to a, ground leads a and b from the
align the permanent magnet a with the holders c and d.
protrusions b on the CDI unit.
2. Loosen the CDI unit bolts a, and then c

adjust the CDI unit air gap c.
a
b
c a
b
a
d
a
3. Loosen the bolts e in the order a, b,
and so on, and then remove the cylinder
head cover f and gasket g.
CDI unit air gap c:

0.4–0.6 mm (0.016–0.024 in)
3. Tighten the CDI unit bolts a to the

specified torque.
95
POWR
Power unit
Valve clearance:
e Intake d and exhaust e:
0.08–0.12 mm (0.003–0.005 in)
b
c 6. Install a new gasket h, the cylinder head
e
cover f, the holders c, d, i, and
d ground lead b, and then tighten the bolts
a e in the order a, b, and so on.
NOTICE: Do not reuse a gasket,
always replace it with a new one.
f c b
f
d
g e
h i e
e
4. Slowly pull the starter handle to align the e
TDC mark b on the flywheel magnet and
the pointer c of the manual starter.
a
d
b
c
e
c b
e
7. Install the ground leads a, b and

engine shut-off switch lead a to the
holders c and d.
TIP:
Make sure that the rocker arms are not push-
ing the intake and exhaust valves.
c
5. Measure the intake and exhaust valve a

clearances d and e.
b a
d Adjusting the valve clearance

Adjust the valve clearances when the engine
e is cold.
96
TIP:
Do not turn the flywheel magnet counter- • To decrease the valve clearance, turn the
clockwise. Otherwise, the water pump rocker arm pivot in direction c.
impeller could be damaged. • To increase the valve clearance, turn the
rocker arm pivot in direction d.
1. Align the TDC mark a on the flywheel
magnet and the pointer b of the manual 3. Tighten the valve adjusting locknut a to
starter. the specified torque, and then check the
valve clearances.
b
b
b
a
2. Loosen the valve adjusting locknut a,
and then turn the rocker arm pivot b until Valve adjusting locknut a:
the specified valve clearance is obtained. 10 N·m (1.0 kgf·m, 7.4 ft·lb)
a b
a
b
b
a c
a
Valve clearance:
Intake and exhaust:
0.08–0.12 mm (0.003–0.005 in)
97
POWR
Power unit
Manual starter
6
7
8
5
9
10
5
4
18
17
3
2
1 19
11
12 12
13
13
14
15
7 N·m (0.7 kgf·m, 5.2 ft·lb) 16

1 Cap 1
2 Starter handle 1
3 Rubber seal 1
4 Starter rope 1 1800.0mm (70.9in) (reference data)
5 Bolt 2
6 Guide 1
7 Bolt 1
8 Starter plunger 1
9 Spring 1
10 Cover 1
11 Sheave drum 1
12 Spring 2
13 Drive pawl 2
14 Clip 1
15 Drive plate 1
16 Drive plate screw 1
17 E-clip 1
98
Manual starter
6
7
8
5
9
10
5
4
18
17
3
2
1 19
11
12 12
13
13
14
15
7 N·m (0.7 kgf·m, 5.2 ft·lb) 16

18 Plate 1
19 Spiral spring 1
99
POWR
Power unit
Removing the manual starter 4. Remove the sheave drum d and plate
1. Disconnect the start-in-gear protection i.
cable a.
i
2. Remove the manual starter b.
a
b
d
5. Remove the spiral spring j. WARNING!

The spiral spring can pop out. Cover
the spiral spring with rags when
Disassembling the manual starter removing it.
1. Align the protrusion a on the starter
plunger a and the mark b on the man-
ual starter b.
2. While holding the starter rope c, turn the

sheave dram d 3–4 turns clockwise.
c j
b
6. Remove the starter rope c, E-clip k,
a starter plunger a, starter plunger spring
a l, and guide m.
m
d b a
l
3. Remove the drive plate e, drive pawls
f, and drive pawl springs g, and then
remove the clip h from the drive plate e. c
e k
Checking the manual starter

f h
1. Check the guide, drive pawls, drive plate,
f plate, and starter plunger. Replace if
cracked or damaged.
g
2. Check the clip, drive pawl springs, E-clip,
g
and starter plunger spring. Replace if
bent, cracked, or damaged.
100
Manual starter
3. Check the sheave drum. Replace if
cracked or damaged. e
4. Check the starter handle. Replace if

cracked or damaged.
5. Check the starter rope. Replace if

b
damaged.
Starter rope length (reference data):

1800.0 mm (70.9 in)
Checking the spiral spring a

1. Check the spiral spring a. Replace if c
bent, cracked, or damaged.
TIP:
Make sure to leave c 12.0 mm (0.47 in) or
more at the end a of the starter rope.
5. Wind the starter rope e twice around the

sheave drum f counterclockwise, and
then fit the starter rope e into the slot d.
a
f d
Assembling the manual starter

1. Install the guide a.
2. Install the starter plunger b and starter

plunger spring c, and then install the E-
clip d. e
a
b
c 6. Hook the end e of the spiral spring g
onto the section f of the sheave drum
b f, and then install the spiral spring g
into the sheave drum f. WARNING! The
spiral spring can pop out. Cover the
spiral spring with rags when installing
d c
it.
g
3. Route the starter rope e. e
f g
4. Tie a knot in both ends a and b of the
starter rope e.
7. Install the plate h.
101
POWR
Power unit
8. Install the sheave drum f with the
n
protrusion g on the starter plunger b m
and the mark h of the manual starter i
aligned. p p
m l
n
9. Turn the sheave drum f to hook the end
k of the spiral spring g onto the section
l
m in the manual starter i.
k
b
f g k k
g
n
h
n
m i
p n
k h k
10. Install the drive pawl springs j and drive k

pawls k.
p
k m
j
Drive plate screw n:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
13. Align the protrusion g on the starter

plunger b and the mark h on the
manual starter i.
11. Install the clip l to the drive plate m.
14. While holding the starter rope e, turn the
12. Install the drive plate m by aligning the sheave dram f 3 turns counterclock-
protrusion n on the drive pawls k and wise.
the slots p in the drive plate m, and then
tighten the drive plate screw n to the 15. Remove the starter rope e from the slot
specified torque. d, and then let the sheave drum f turn
slowly so that the starter rope e is
wound around the sheave drum f.
d
i
b
g
f h
102
Manual starter
16. Align the protrusion g on the starter 3. Tighten the start-in-gear protection cable
plunger b and the mark h on the locknut a to the specified torque.
manual starter i.
a
b
17. Pull the starter handle o several times to
check that the sheave drum turns b
smoothly and to check the starter rope e c
for slack.
a
b
i
b Start-in-gear protection cable locknut a:

2 N·m (0.2 kgf·m, 1.5 ft·lb)
g
e o 4. Move the shift lever to the F or R position.
h
5. Check that the starter handle cannot be
Installing the manual starter pulled.
1. Install the manual starter a.
Measuring the starter rope
2. Connect the start-in-gear protection 1. Pull the starter handle a to extend the
cable b. starter rope b completely, and then
measure the starter rope extended
b length a.
a
b
Adjusting the start-in-gear
protection cable
Starter rope extended length a:
1430.0–1570.0 mm (56.3–61.8 in)
Make sure to remove the clip from the
engine shut-off switch before checking
the start-in-gear protection.
1. Move the shift lever to the N position.
2. Loosen the start-in-gear protection cable

locknut a, and then align the protrusion
b on the starter plunger a and the mark
c on the manual starter b.
103
POWR
Power unit
Power unit assembly
2 N·m (0.2 kgf ·m, 1.5 ft·lb) 6
1 5
7
3 8
2 4 9
1 6
5
5
12 10
6
13
11
15
14
15
13
14
12 N·m (1.2 kgf·m, 8.9 ft·lb)

15
16 12 N·m (1.2 kgf·m, 8.9 ft·lb)
13 13

1 Dowel 2
3 Engine shut-off switch nut 1
4 Engine shut-off switch 1
5 Plastic tie 4
6 Bolt 4
7 Holder 1
8 Bracket 1
9 CDI unit coupler 1
10 Ground lead 1
11 Power unit assembly 1
12 Plate 1
13 Bolt 5
14 Power unit mounting bolt 4
15 Power unit mounting bolt 5
16 Cover 1
104
Power unit assembly
Removing the power unit 8. Disconnect the CDI unit coupler a, CDI
Cover the fuel components using a rag to unit ground lead b, engine shut-off
prevent fuel from spilling out. switch ground lead c, and ground lead
j.

a
clockwise. Otherwise, the water pump
b c
1. Drain the engine oil. See step 4 in
j
“Changing the engine oil”.
2. Drain the fuel. j
3. Removemanualstarter. See 9. Remove the plastic tie k.

4. Remove the fuel tank. See step 3 in

“Removing the fuel tank”.
5. Remove the holder a, and then

disconnect the choke cable b.
k
6. Disconnect the throttle cables c.
c 10. Loosen the screw l, and then remove

the cap m and throttle link rod n.
11. Remove the holder o, throttle cam p,

and bracket q, and then remove the
a engine shut-off switch lead d and
ground lead j from the holders r, s,
b
and t.
7. Slide the clamp d away from the r p q l

carburetor e, slide the clamp f away m
o
from the fuel pump g, and then n
disconnect the fuel hoses h and i.
d s
e j
g
h
t
d i 12. Remove the cover u and plate v.

f
105
POWR
Power unit
Flywheel magnet nut z:

60 N·m (6.0 kgf·m, 44.3 ft·lb)
v 15. Install the special service tool A, and

then suspend the power unit.
NOTICE: To prevent damage to the
engine or tool, screw in the puller set
bolts evenly and completely so that
u the flywheel puller is parallel to the
flywheel magnet.
13. Remove the starter pulley w. NOTICE:

Apply force in the direction of the
arrow to prevent the flywheel holder
x from slipping off easily. A
w
x
Flywheel puller A
16. Loosen the power unit mounting bolts B

and C in the order a, b, and so on, and
Flywheel holder x then remove the power unit assembly.
14. Install the washer y, flywheel magnet PORT

nut z, and then tighten the flywheel C
magnet nut z to the specified torque. c
h
NOTICE: Apply force in the direction d i
of the arrow to prevent the flywheel B B
holder x from slipping off easily. a
z STBD
y C
f B
g e
B b
x
Flywheel holder x
106
Power unit assembly
1. Install the engine shut-off switch a, and
then tighten the engine shut-off switch
nut b to the specified torque.
2. Route the engine shut-off switch lead a

and ground lead c.
a
B b
B
B
C a
B B
c
TIP:
Lift up the power unit using the crane,
because the gasket on power unit is firmly Engine shut-off switch nut b:
adhered to the upper case. 2 N·m (0.2 kgf·m, 1.5 ft·lb)
3. Install the special service tool. See steps

17. Loosen the engine shut-off switch nut D, 13–15 in “Removing the power unit”
and then remove the engine shut-off
switch E and ground lead j from the
bottom cowling. 4. Clean the power unit mating surface, and
then install the dowels d and a new
gasket e. NOTICE: Do not reuse a
gasket, always replace it with a new
D one.
5. Install the power unit, and then tighten

the power unit mounting bolts f and g
to the specified torque in the order a, b,
and so on.

clockwise. Otherwise, the water pump
107
POWR
Power unit
e
f
d
Flywheel holder i
g
8. Install the starter pulley j and washer
d
k, and then tighten the flywheel magnet
g
nut h to the specified torque. NOTICE:
f Apply force in the direction of the
f
g f arrow to prevent the flywheel holder
f
i from slipping off easily.
PORT j
g
g
b h
f a
f f
i
k
i
STBD
g
f Flywheel holder i
d
c e Flywheel magnet nut h:
f h
60 N·m (6.0 kgf·m, 44.3 ft·lb)
9. Install the plate l and cover m.
Power unit mounting bolt f and g:

12 N·m (1.2 kgf·m, 8.9 ft·lb)
l
6. Remove the special service tool.
7. Loosen the flywheel magnet nut h.

NOTICE: Apply force in the direction
m
of the arrow to prevent the flywheel
holder i from slipping off easily.
108
Power unit assembly
10. Connect the CDI unit coupler b, CDI unit
ground lead c, engine shut-off switch a
ground lead d, and ground lead c. z
b
c d c
c
c d
z
d
e
c c
c
11. Install the engine shut-off switch lead a c
z
and ground lead c to the holders n, o,
z y
and p.
12. Install the bracket q, lever r, throttle

cam s, collar t, washer u, and holder 15. Connect the fuel hoses A and B, and
v. then fasten them using the clamps C.
13. Install the throttle link rod w and cap x.

A
n
v q u
x
t C B
w s C
o
a r
c 16. Connect the throttle cables D, and then

adjust the throttle cables D. See steps
p 2–9 in “Adjusting the throttle cable and
throttle link”.
17. Connect the choke cable E, and then

14. Fasten the engine shut-off switch lead a, install the holder F. See steps 9 and 10
CDI unit ground lead c, CDI unit lead e, in “Installing the primer pump”.
engine shut-off switch ground lead d,
and ground leads c and y using the 18. Tighten the choke holder bolt G to the
plastic ties z. specified torque.
109
POWR
Power unit
D
G
Choke holder bolt G:

4 N·m (0.4 kgf·m, 3.0 ft·lb)
19. Install the fuel tank. See step 8 in

“Installing the fuel tank”.

the manual starter”.
110
Power unit assembly / Flywheel magnet
Flywheel magnet
1
60 N·m (6.0 kgf·m, 44.3 ft·lb) 2

3
10 N·m (1.0 kgf·m, 7.4 ft·lb)
8 4
7 5
9 10

1 Flywheel magnet nut 1
2 Washer 1
3 Starter pulley 1
4 Flywheel magnet 1
5 Woodruff key 1
6 Spark plug cap 1
7 CDI unit 1
8 CDI unit bolt 2
9 Bolt 1
10 Holder 1
111
POWR
Power unit
Removing the flywheel magnet Installing the flywheel magnet
1. Remove the holder a. 1. Install the Woodruff key a, flywheel
magnet b, starter pulley c, and washer
2. Disconnect the spark plug cap b, and d, and then tighten the flywheel magnet
then remove the CDI unit c. nut e to the specified torque. NOTICE:
c Apply force in the direction of the
f from slipping off easily.
e b
d b
b
a
3. Remove the starter pulley d. NOTICE:

Apply force in the direction of the a
c
a
e from slipping off easily.
e
e
Flywheel holder e f
4. Remove the flywheel magnet f and

Woodruff key. NOTICE: To prevent Flywheel holder f
damage to the engine or tool, screw in
the puller set bolts evenly and Flywheel magnet nut e:
completely so that the flywheel puller 60 N·m (6.0 kgf·m, 44.3 ft·lb)
is parallel to the flywheel magnet.
TIP:
g Make sure to remove any grease from the
tapered portion a of the crankshaft and the
inner surface b of the flywheel magnet b.
2. Install the CDI unit g, and then tighten

the CDI unit bolts h to the specified
torque.
f
3. Connect the spark plug cap i, and then
Flywheel puller g install the holder j.
112
Flywheel magnet
h g
i
j
CDI unit bolt h:

10 N·m (1.0 kgf·m, 7.4 ft·lb)
4. Adjust the CDI unit air gap. See

“Adjusting the CDI unit air gap”.
113
POWR
Power unit
Crankcase
4
1
2
15
5
6
3
6
11 12 14 16
12
7 13
8 11
23
9
22 10
11
19
21
20 11
19
11 11
19 17
18 11
a 5 N·m (0.5 kgf·m, 3.7 ft·lb)
b 11 N·m (1.1 kgf·m, 8.1 ft·lb)
11 11
20 N·m (2.0 kgf·m, 14.8 ft·lb)

1 Oil seal 1 /PUSFVTBCMF
4 Rotor assembly 1
5 Plate 1
6 Screw 2
8 Oil strainer 1
9 Spring 1
10 Cover 1
11 Crankcase bolt 10
12 Dowel 2
14 Crankcase 1
15 Holder 1
16 Hose 1
114
Crankcase
4
1
2
15
5
6
3
6 13
11 12 14 16
12
7
8 11
23
9
22 10
11
19
21
20 11
19
11 11
19 17
18 11
a 5 N·m (0.5 kgf·m, 3.7 ft·lb)
b 11 N·m (1.1 kgf·m, 8.1 ft·lb)
11 11
20 N·m (2.0 kgf·m, 14.8 ft·lb)

18 Blind plug 1
19 Bolt 3
20 Drain bolt 1
22 Bolt 1
23 Oil seal housing 1
115
POWR
Power unit
Removing the oil pump Removing the oil seal housing
1. Remove the drain bolt a and gasket b, 1. Remove the oil seal housing a.
and then drain the remaining engine oil.
b
a
2. Remove the O-ring b and oil seals c

2. Remove the cover c, gasket d, spring and d.
e, and oil strainer f.
b
c
d
d c
e
Removing the crankcase
f 1. Remove the cooling water hose a.
a
3. Remove the plate g, and then remove
the rotor assembly h.
g
h
2. Remove the blind plug b and gasket c.
c
b
TIP:
Keep the rotor assembly h in the same
direction as originally installed.
116
Crankcase
3. Loosen the crankcase bolts d in the a b
order a, b, and so on, and then remove
the crankcase e, gasket f, and dowels
g.
f d
j e
g
d
Crankshaft journal inside diameter a:

25.020–25.041 mm
c
(0.9850–0.9859 in)
b Camshaft journal inside diameter b:
h 15.000–15.018 mm
i a (0.5906–0.5913 in)
4. Measure the rotor housing inside

d diameter c.
c
Rotor housing inside diameter c:

23.130–23.160 mm
(0.9106–0.9118 in)

1. Check the rotor assembly. Replace if
cracked or worn.
1. Check the crankcase. Replace if cor- 2. Measure the rotor assembly dimensions
roded or cracked. a, b, and c.
2. Measure the crankshaft journal inside a

diameter a.
3. Measure the camshaft journal inside

diameter b. b
117
POWR
Power unit
Outer rotor diameter a:

22.980–23.000 mm e g
a f
(0.9047–0.9055 in)
Outer rotor height b: d d
9.950–9.980 mm (0.3917–0.3929 in)
Inner rotor height c:
9.950–9.980 mm (0.3917–0.3929 in)
h
Checking the oil strainer
1. Check the oil strainer. Clean if there is i
dirt or residue. c
b j
Checking the oil seal housing
1. Check the oil seal housing. Replace if
cracked or damaged. Crankcase bolt d:
1st: 5 N·m (0.5 kgf·m, 3.7 ft·lb)
Installing the crankcase 2nd: 11 N·m (1.1 kgf·m, 8.1 ft·lb)
3. Install a new gasket e, and then tighten

the blind plug f to the specified torque.
Do not reuse a gasket, always replace it
with a new one.
1. Install the dowels a and a new gasket

b.
2. Install the crankcase c, and then tighten e

the crankcase bolts d to the specified f
torques in 2 stages and in the order a,
b, and so on.
d Blind plug f:
20 N·m (2.0 kgf·m, 14.8 ft·lb)
4. Install the cooling water hose g.

c
g
118
Crankcase
Installing the oil pump
Driver rod L3 b
Needle bearing attachment c

with a new one. 2. Install the oil seal d.
1. Install the rotor assembly a and plate b.

b
TIP: e d
Install the rotor assembly in the same direc-
tion as when it was removed.
2. Install the oil strainer c, the spring d, a

new gasket e, and the cover f.
3. Install a new gasket g and the drain bolt Driver rod L3 b

h. Needle bearing attachment e
h
b
3. Install a new O-ring f to the oil seal
housing g, and then install the oil seal
f housing g.
g a
e
g
d
f
c
Installing the oil seal housing
Do not reuse an oil seal or O-ring, always

replace it with a new one.
1. Install new oil seals a.
b
c
119
POWR
Power unit
Cylinder head
2
1 2 N·m (0.2 kgf·m, 1.5 ft·lb)
9
2
10
3
8
11
4
12
5 13
6 8
7 14
24
29
30
12
15
28 16 12
13 12
10 N·m (1.0 kgf·m, 7.4 ft·lb)
26 24 17
26 25 16 18
24 23
18
25 22
17
27 24 23 19
22 21
10 N·m (1.0 kgf·m, 7.4 ft·lb)
31 21
20 a 13 N·m (1.3 kgf·m, 9.6 ft·lb)
13 N·m (1.3 kgf·m, 9.6 ft·lb)
b 28 N·m (2.8 kgf·m, 20.7 ft·lb)

2 Bolt 3
3 Thermostat cover 1
4 Thermostat 1
5 Anode 1
6 Thermostat cover anode screw 1
8 Push rod 2
10 Holder 1
11 Ground lead 1
12 Bolt 5
13 Holder 2
14 Cylinder head cover 1
15 Push rod guide 1
16 Pivot bolt 2
17 Rocker arm 2
120
Cylinder head
2
1 2 N·m (0.2 kgf·m, 1.5 ft·lb)
9
2
10
3
8
11
4
12
5 13
6 8
7 14
24
29
30
12
15
28 16 12
13 12
10 N·m (1.0 kgf·m, 7.4 ft·lb)
26 24 17
26 25 16 18
24 23
18
25 22
17
27 24 23 19
22 21
10 N·m (1.0 kgf·m, 7.4 ft·lb)
31 21
20 a 13 N·m (1.3 kgf·m, 9.6 ft·lb)
13 N·m (1.3 kgf·m, 9.6 ft·lb)
b 28 N·m (2.8 kgf·m, 20.7 ft·lb)

18 Rocker arm pivot 2
19 Valve adjusting locknut 2
20 Valve cotter 2
21 Valve spring retainer 2
22 Valve spring 2
23 Spring seat 2
24 Cylinder head bolt 4
25 Valve seal 2 /PUSFVTBCMF
26 Valve guide 2
27 Spark plug 1
28 Cylinder head 1
29 Intake valve 1
30 Exhaust valve 1
31 Dowel 2
121
POWR
Power unit
Removing the cylinder head 4. Loosen the cylinder head bolts l in the
1. Remove the spark plug a, thermostat order a, b, and so on, and then remove
cover b, gasket c, thermostat d, and the cylinder head m, gasket n, and push
thermostat cover anode e. rods o. NOTICE: Do not scratch or
damage the mating surfaces of the
a
cylinder head and cylinder block.
d
d b a
l
e
c c
b
2. Loosen the bolts f in the order a, b,
and so on, and then remove the cylinder
head cover g and gasket h.
b m
d
o
f
n
e
a c l
l
l
g
f Disassembling the cylinder head
1. Remove the push rod guide a.
h a
f
3. Loosen the valve adjusting locknuts i,

and then remove the rocker arm pivots j
and rocker arms k.
k
2. Remove the intake and exhaust valves.
j
i
i
k
j
122
Cylinder head
Valve spring compressor b Cylinder head warpage limit:

0.10 mm (0.0039 in)
Valve spring compressor attachment c
1. Check the rocker arms. Replace if
TIP: cracked, damaged, or worn.
Make sure to keep the parts in the order of
removal.
Checking the push rod
1. Measure the push rod runout.
3. Remove the valve seals d.
d
d
Push rod runout: 0.5 mm (0.02 in)

Checking the cylinder head Checking the valve spring
1. Remove carbon deposits from the com- 1. Measure the valve spring free length a.
bustion chamber, and then check the cyl-
inder head for corrosion or scratches.
2. Check the cylinder head warpage in 6

directions. Replace the cylinder head
assembly if above specification.
123
POWR
Power unit
3. Measure the valve stem diameter b.
Replace if out of specification.
Valve spring free length a:

27.6 mm (1.09 in)
Valve stem diameter b:
2. Measure the valve spring tilt b. Replace Intake:
if above specification. 5.475–5.490 mm (0.2156–0.2161 in)
Exhaust:
b 5.460–5.475 mm (0.2150–0.2156 in)
4. Measure the valve stem runout.
Valve spring tilt limit b: 1.0 mm (0.04 in)
Checking the valve

1. Check the valve face. Replace the valve
if pitted or worn. Valve stem runout (reference data):
Intake: 0.050 mm (0.0020 in)
2. Measure the valve margin thickness a. Exhaust: 0.030 mm (0.0012 in)
a Checking the valve guide
Before checking the valve guide, make sure
to check the valve.
1. Measure the valve guide inside diameter

a. Replace if out of specification.
Valve margin thickness a: a

Intake:
0.800–1.200 mm (0.0315–0.0472 in)
Exhaust:
1.100–1.500 mm (0.0433–0.0591 in)
124
Cylinder head
Valve guide inside diameter a: Valve guide remover/installer b

Intake and exhaust:
5.500–5.512 mm (0.2165–0.2170 in)
Valve guide installation height a:
2. Calculate the valve guide clearance. 8.2–9.1 mm (0.32–0.36 in)
Replace the valve guide if out of
specification. 3. Insert the special service tool d into the
valve guide c, and then ream the valve
Valve guide clearance:
guide.
Intake:
0.010–0.037 mm (0.0004–0.0015 in)
d
Exhaust:
0.025–0.052 mm (0.0010–0.0020 in)
Replacing the valve guide c

After replacing the valve guide, check the
valve seat contact area.
1. Remove the valve guide a from the com-

bustion chamber side using the special
service tool b. Valve guide reamer d
TIP:
b
• Turn the valve guide reamer clockwise to
ream the valve guide.
a • Do not turn the valve guide reamer counter-
clockwise when removing it.
• Make sure to clean the valve guide after
reaming it.
4. Measure the valve guide inside diameter.

Valve guide remover/installer b
Valve guide inside diameter:
Intake and exhaust:
2. Install a new valve guide c from the 5.500–5.512 mm (0.2165–0.2170 in)
rocker arm side to the specified
installation height a using the special Checking the valve seat
service tool b. 1. Remove carbon deposits from the valves.
2. Apply a thin, even layer of Mechanic's

blueing dye (Dykem) onto the valve seat.
b
3. Press the valve lightly against the valve
a seat using the special service tool a.
125
POWR
Power unit
Refacing the valve seat
a
After every lapping procedure, make sure
to clean off any remaining lapping com-
pound from the cylinder head and valves.
1. Reface the valve seat using valve seat

cutters.
Valve lapper a
4. Measure the valve seat contact width a

where the blueing dye is adhered to the 30˚ 45˚ 60˚
valve face. Reface the valve seat if the
valve is not seated properly or if the valve
seat contact width is out of specification.
Check the valve guide if the valve seat
contact width is uneven.
Valve seat cutter holder

Intake:
Valve seat cutter 30°
a
Exhaust:
2. Cut the surface of the valve seat using a

45° cutter by turning the cutter clockwise
until the valve seat face has become
smooth. NOTICE: Do not over cut the
valve seat. To prevent chatter marks,
make sure to turn the cutter evenly
using a downward force of 40–50 N
(4.0–5.0 kgf, 8.8–11.0 lbf).
Valve seat contact width a

Intake and exhaust:
0.6–0.8 mm (0.02–0.03 in)
126
Cylinder head
45˚
b
a c
45˚
b Previous contact width

a Slag or rough surface
c Specified contact width
3. Adjust the top edge of the valve seat
6. Check the valve seat contact area of the
contact width using a 30° cutter.
valve. See “Checking the valve seat”
30˚
Example:
b
• If the valve seat contact area is too wide
and situated in the center of the valve face,
cut the top edge of the valve seat using a
30° cutter, and then cut the bottom edge
using a 60° cutter to center the area and set
its width.
b Previous contact width 30˚

b
4. Adjust the bottom edge of the valve seat
contact width using a 60° cutter.
b
60˚
60˚ • If the valve seat contact area is too narrow

and situated near the top edge of the valve
face, cut the top edge of the valve seat
b Previous contact width using a 30° cutter to center the area, and
then set its width using a 45° cutter.
5. Adjust the valve seat contact width to
specification using a 45° cutter. 30˚
b
127
POWR
Power unit
• If the valve seat contact area is too narrow
and situated near the bottom edge of the
valve face, cut the bottom edge of the valve a
seat using a 60° cutter to center the area,
and then set its width using a 45° cutter.
2. Check the spark plug. Replace if the

electrodes are eroded, there is carbon or
60˚ other deposits.
3. Check the spark plug gap b. Replace if

b Previous contact width out of specification.
7. After refacing the contact width of the

valve seat to specification, apply a thin,
b
even layer of lapping compound onto the
valve seat, and then lap the valve using
the special service tool a. NOTICE: Do
not get the lapping compound on the
valve stem and valve guide.
a Specified spark plug: CR6HSB (NGK)

Spark plug gap b:
0.6–0.7 mm (0.024–0.028 in)
Checking the thermostat cover

anode
1. Check the anode. Replace if eroded.
Clean if there is grease, oil, or scales.
Valve lapper a
NOTICE: Do not apply grease, oil, or
8. Recheck the valve seat contact area of paint to the anode.
the valve. See “Checking the valve
seat”.
Checking the thermostat
1. Suspend the thermostat in a container of
Checking the spark plug water.
1. Clean the electrodes a using a spark
2. Place a thermometer in the water and
plug cleaner.
slowly heat the water.
128
Cylinder head
2. Install the valve b, spring seat c, valve
spring d, and valve spring retainer e in
this order, and then install the special
service tools f and g.
e
f
d
c
g
3. Measure the thermostat valve opening a
at the specified water temperatures.
Valve spring compressor f

Water
Valve opening a
temperature Valve spring compressor attachment g
58–62 °C
Starts opening
(136–144 °F)
3. Compress the valve spring, and then
above 70 °C
3.0 mm (0.12 in) or above install the valve cotter h.
(158 °F)

h
Do not reuse a gasket or oil seal, always

1. Install a new valve seal a.

h
129
POWR
Power unit
4. Tap the valve spring retainer lightly using
a plastic hammer to seat the valve cotter a
securely.
c
d a
b
d
d
5. Install the push rod guide i, and then
tighten the pivot bolts j to the specified
torque. a
d
j
j d
i b
Cylinder head bolt d:

1st: 13 N·m (1.3 kgf·m, 9.6 ft·lb)
Pivot bolt j: 2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
10 N·m (1.0 kgf·m, 7.4 ft·lb)
2. Install the thermostat cover anode e to
the thermostat cover f, and then tighten
Installing the cylinder head
the thermostat cover anode screw g to
the specified torque.
Do not reuse a gasket, always replace it 3. Install the thermostat h, a new gasket
with a new one. i, the thermostat cover f, and then
connect the ground lead j.
1. Install the dowels a, a new gasket b,
and the cylinder head c, and then 4. Install the spark plug k, and then tighten
tighten the cylinder head bolts d to the it to the specified torque.
specified torques in 2 stages and in the k
order a, b, and so on.
h f
ge
i
j
130
Cylinder head
Thermostat cover anode screw g: s

2 N·m (0.2 kgf·m, 1.5 ft·lb) v
Spark plug k:
13 N·m (1.3 kgf·m, 9.6 ft·lb)
t
5. Check that the mark a on the crankshaft t
u
l is aligned with the hole b on the r
camshaft m. v
j
l a
d
b
v
m e
a
c
6. Install the push rods n and rocker arms
o, and then screw in the rocker arm
pivots p and valve adjusting locknuts q.
o
n
p
p
q
o
7. Install the crankcase. See “Installing the

crankcase”
8. Adjust the valve clearance. See steps 2

and 3 in “Adjusting the valve
clearance”.
9. Install a new gasket r, the cylinder head

cover s, and the clamps t, u, and then
connect the ground lead j.
10. Tighten the bolts v in the order a, b,

and so on.
131
POWR
Power unit
Cylinder block
1
17
a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
16 b 12 N·m (1.2 kgf·m, 8.9 ft·lb)
15
5
6
3 7
12
11 8
13
5
11 9
10
14 8 N·m (0.8 kgf·m, 5.9 ft·lb)

2 Cylinder block 1
3 Connecting rod assembly 1
4 Connecting rod bolt 2
5 Clip 2 /PUSFVTBCMF
6 Piston pin 1
7 Piston 1
8 Piston ring set 1
9 Plate 1
10 Breather plate screw 2
11 Valve lifter 2
12 Camshaft 1
13 Crankshaft 1
14 Washer 1
15 Ball bearing 1 /PUSFVTBCMF
17 Dipstick 1
132
Cylinder block
Disassembling the cylinder block
1. Remove the dipstick a. i
j
2. Remove the camshaft b, valve lifters c, h
and plate d.
c d
a
b Driver rod L3
Needle bearing attachment j
6. Remove the clips k, and then remove

3. Remove the connecting rod cap a, and the piston pin l and connecting rod c.
then remove the connecting rod and
piston assembly b. k
a c
b
4. Remove the washer e, crankshaft f, k

and oil seal g.
e Checking the piston diameter
1. Measure the piston diameter a at the
specified measuring point b.
f
b a
5. Remove the ball bearing h.
133
POWR
Power unit
Piston diameter a:
a b
61.950–61.965 mm B B
(2.4390–2.4396 in) T T
Measuring point b:
1.0 mm (0.04 in) up from the bottom
of the piston skirt c
B
Oversize piston diameter:
Oversize 1st:
62.200–62.215 mm T
(2.4488–2.4494 in)
Oversize 2nd: Piston ring dimensions:
62.450–62.465 mm Top ring a:
(2.4587–2.4592 in) B: 1.170–1.190 mm (0.0461–0.0469 in)
T: 2.500–2.700 mm (0.0984–0.1063 in)
Checking the cylinder bore 2nd ring b:
1. Measure the cylinder bore (D1–D6) at B: 1.170–1.190 mm (0.0461–0.0469 in)
measuring points a, b, and c, and in T: 2.600–2.800 mm (0.1024–0.1102 in)
direction d (D1, D3, D5), which is paral- Oil ring c:
lel to the crankshaft, and in direction e B: 1.850–2.000 mm (0.0728–0.0787 in)
(D2, D4, D6), which is at a right angle to T: 2.550–2.850 mm (0.1004–0.1122 in)
the crankshaft. (reference data)
Checking the piston ring end gap

a 1. Level the piston ring a in the cylinder
b D2 D1 d with a piston crown at the specified mea-
c
suring point a.
D4 D3 e
2. Measure the piston ring end gap b.
D6 D5
a 5.0 mm (0.20 in)

b 28.0 mm (1.10 in)
c 50.0 mm (1.97 in)
a b
Cylinder bore (D1–D6):
62.000–62.015 mm
(2.4409–2.4415 in)
Measuring point a (reference data):
Checking the piston ring 60.0 mm (2.36 in)
1. Measure the piston ring dimensions B Piston ring end gap b (reference data):
and T. Top ring:
0.110–0.210 mm (0.0043–0.0083 in)
2nd ring:
0.260–0.410 mm (0.0102–0.0161 in)
Oil ring:
0.200–0.700 mm (0.0079–0.0276 in)
134
Cylinder block
Checking the piston ring groove
1. Measure the piston ring grooves. a
b
c
Piston pin boss inside diameter a:
15.004–15.015 mm
Piston ring groove: (0.5907–0.5911 in)
Top ring a:
1.210–1.230 mm (0.0476–0.0484 in) TIP:
2nd ring b: Do not measure it at the groove b.
1.210–1.230 mm (0.0476–0.0484 in)
Oil ring c:
Checking the piston pin diameter
2.010–2.030 mm (0.0791–0.0799 in)
1. Measure the piston pin outside diameter
a.
Checking the piston ring side
clearance a
1. Measure the piston ring side clearance.
Piston pin outside diameter a:

14.995–15.000 mm
(0.5904–0.5906 in)
Piston ring side clearance:
Top ring a: Checking the connecting rod small
0.020–0.060 mm (0.0008–0.0024 in)
end inside diameter and big end
2nd ring b:
inside diameter
0.020–0.060 mm (0.0008–0.0024 in)
1. Install the connecting rod cap a by align-
Oil ring c:
ing the mark b on the connecting rod c
0.010–0.180 mm (0.0004–0.0071 in)
and the mark d on the connecting rod
Checking the piston pin boss inside cap a, and then tighten the connecting
diameter rod cap bolts a to the specified torques
in 2 stages.
1. Measure the piston pin boss inside diam-
eter a.
2. Measure the connecting rod small end
inside diameter e and the big end inside
diameter f.
135
POWR
Power unit
b Crankshaft journal diameter (cylinder block

f d side) b:
e 24.980–24.993 mm
(0.9835–0.9840 in)
Crankshaft journal diameter (crankcase
side) c:
24.982–24.994 mm
c a
(0.9835–0.9840 in)
a
Crankpin diameter d:
27.969–27.984 mm
Connecting rod small end inside diameter (1.1011–1.1017 in)
e: Crankpin width e:
15.015–15.029 mm 21.000–21.100 mm
(0.5911–0.5917 in) (0.8268–0.8307 in)
Connecting rod big end inside diameter f:
28.000–28.015 mm 3. Measure the crankshaft runout.
(1.1024–1.1030 in)
Connecting rod cap bolt a:

1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)

1. Check the crankshaft gear a. Replace
the crankshaft if damaged or worn.
2. Measure the crankshaft journal diameter

Crankshaft runout: 0.020 mm (0.0008 in)
b and c, crankpin diameter d, and
crankpin width e. Checking the connecting rod oil
c clearance
a 1. Clean the connecting rod, connecting rod
cap, and crankpin.
b
2. Place a piece of Plastigauge (PG-1) onto
the crankpin a, parallel to the
crankshaft.
e
a
136
Cylinder block
TIP: Connecting rod oil clearance:

Do not place the Plastigauge (PG-1) over the 0.016–0.046 mm (0.0006–0.0018 in)
oil hole in the crankpin of the crankshaft.
1. Check the cylinder block. Replace if cor-
3. Install the connecting rod cap b by
roded or cracked.
aligning the mark c on the connecting
rod d and the mark e on the connecting
2. Measure the camshaft journal inside
rod cap b, and then tighten the
diameter a.
connecting rod cap bolts a to the
specified torques in 2 stages. a
a
c Camshaft journal inside diameter a:

15.000–15.018 mm
(0.5906–0.5913 in)
d
Checking the camshaft
1. Check the camshaft gear. Replace the
Connecting rod cap bolt a: camshaft if damaged or worn.
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 2. Check the decompression actuator.
Replace the camshaft if the
TIP: decompression actuator does not
Do not turn the connecting rod until the con- operate smoothly.
necting rod oil clearance measurement has
been completed.
4. Remove the connecting rod cap, and

then measure the width of the
compressed Plastigauge (PG-1) on the
crankpin.
3. Measure the cam lobe height a, cam

lobe width b, and fuel pump cam
diameter c.
137
POWR
Power unit
a
c
Cam lobe height a: Camshaft runout: 0.030 mm (0.0012 in)

Intake:
32.037–32.137 mm Checking the valve lifter
(1.2613–1.2652 in) 1. Check the valve lifter. Replace if dam-
Exhaust: aged or worn.
32.038–32.138 mm
(1.2613–1.2653 in) 2. Measure the valve lifter outside diameter
Cam lobe width b: a.
Intake and exhaust:
a
26.950–27.050 mm
(1.0610–1.0650 in)
Fuel pump cam diameter c:
19.600 mm (0.7717 in)
(reference data)
4. Measure the camshaft journal diameter

d.
d d
Valve lifter outside diameter a:
7.965–7.980 mm (0.3136–0.3142 in)
Do not reuse an O-ring or oil seal, piston

pin clip, or bearing, always replace it with
a new one.
Camshaft journal diameter d:
14.965–14.990 mm 1. Install a new ball bearing a.
(0.5892–0.5902 in)
b
5. Measure the camshaft runout.
138
Cylinder block
Driver rod LL b
k
Ball bearing attachment c a
2. Install a new oil seal d.

b c
e
f
d j
d k
Driver rod LS e TIP:

Ball bearing attachment f • Face the mark b on the con-
necting rod a in the same direction as the
“UP” mark c on the piston crown.
3. Install the crankshaft g and washer h. • Do not align the clip end with the groove d
in the piston pin boss.
h
5. Install the oil rings e, 2nd ring f, and
top ring g.
6. Offset the piston ring end gaps. NOTICE:

Do not scratch the pistons or break
the piston rings.
g
e h
#5
#4
f
#3
g
#2
4. Assemble the piston i, connecting rod #1 #1
a, piston pin j, and clips k. #4 10˚
#3
10˚ h
#5
#2
139
POWR
Power unit
TIP: TIP:
• Make sure that the “N” marks h of the 2nd Make sure that the crankshaft turns smoothly.
ring f and the top ring g are facing
upward. 9. Install the valve lifters n.
• Make sure that the piston rings move
smoothly. 10. Align the mark p on the crankshaft o
with the mark r on the camshaft p, and
7. Install the piston with the “UP” mark c then install the camshaft p.
on the piston crown facing toward the
flywheel magnet. 11. Install a new O-ring q to the dipstick r,
and then screw in the dipstick r.
12. Install the plate s, and then tighten the

l breather plate screws t to the specified
c
torque.
n t
s
q
Piston slider l r
p
8. Install the connecting rod cap k by
aligning the mark m on the connecting
rod a and the mark n on the connecting
rod cap k, and then tighten the
o p
connecting rod cap bolts m to the
specified torques in 2 stages.
m p
n
Breather plate screw t:
8 N·m (0.8 kgf·m, 5.9 ft·lb)
a
k m
Connecting rod cap bolt m:

1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
140
LOWR
Lower unit
Lower unit
Removing the lower unit (S-transom model) .
Removing the lower unit (L-transom model) .
Disassembling the extension (L-transom model)
Checking the propeller
Checking the lower unit anode
Water pump and shift rod

Removing the water pump and shift rod
Checking the water pump
Checking the shift rod
Propeller shaft housing

Removing the propeller shaft housing assembly
Disassembling the propeller shaft assembly
Disassembling the propeller shaft housing assembly
Checking the propeller shaft
Checking the dog clutch
Checking the propeller shaft housing
Checking the reverse gear
Assembling the propeller shaft assembly
Assembling the propeller shaft housing assembly
Drive shaft and lower case

Removing the drive shaft
Disassembling the lower case
Checking the pinion
Checking the forward gear
Checking the drive shaft
Checking the lower case
Assembling the lower cas
Installing the drive shaft
Installing the propeller shaft housing assembly
(S-transom model)
Installing the propeller shaft housing assembly
(L-transom model)
Installing the water pump and shift rod
Checking the lower unit for air leakage
Assembling the extension (L-transom model)
Installing the lower unit (S-transom model)
Installing the lower unit (L-transom model)
141
LOWR
Lower unit
Lower unit
1ÂP NJIÂPIWÂOE
9 N·m (0.9 kgf·m, 6.6 ft·lb)
9 N·m (0.9 kgf·m, 6.6 ft·lb)
8
1 2 11N·m (1.1 kgf·m, 8.1 ft·lb)
3 7
6
5
6 8
4
1 9
A 22 23
11
14
21
23
10
11
12
13
14
17 15
16
20 6
18
19 19 9 N·m (0.9 kgf·m, 6.6 ft·lb)
11N·m (1.1 kgf·m, 8.1 ft·lb)

A L-transom model 15N·m (1.5 kgf·m, 11.1 ft·lb)

1 Cover 2
2 Shift joint bolt 1
3 Joint 1
4 Joint 1
5 Check screw 1
7 Flushing screw 1
8 Dowel 2
9 Cotter pin 1 /PUSFVTBCMF
10 Propeller nut 1
11 Washer 1
12 Propeller 1
13 Spacer 1
15 Lock washer 1
16 Bolt 1
17 Anode 1
142
Lower unit
1ÂP NJIÂPIWÂOE
9 N·m (0.9 kgf·m, 6.6 ft·lb)
9 N·m (0.9 kgf·m, 6.6 ft·lb)
8
1 2 11N·m (1.1 kgf·m, 8.1 ft·lb)
3 7
6
5
6 8
4
1 9
A 22 23
11
14
21
23
10
11
12
13
14
17 15
16
20 6
18
19 19 9 N·m (0.9 kgf·m, 6.6 ft·lb)
11N·m (1.1 kgf·m, 8.1 ft·lb)

A L-transom model 15N·m (1.5 kgf·m, 11.1 ft·lb)

18 Drain screw 1
20 Extension 1
21 Bushing 1
22 Circlip 1
23 Dowel 2
143
LOWR
Lower unit
Removing the lower unit (S-transom 7. Remove the lower unit d.
model)
8. Remove the anode e and flushing screw
f.
• Make sure to remove the clip from the
engine shut-off switch.
• When removing the lower unit with the
power unit installed, make sure to sus-
d
pend the outboard motor. If the outboard
motor is not suspended, it can fall sud- f
denly and result in severe injuries.
• Do not hold the propeller with your
hands when loosening or tightening the
propeller nut.
1. Drain the gear oil. See steps 1–4 in

“Changing the gear oil”.
e
2. Remove the cotter pin.
3. Set the gear shift to the N position.
4. Place a block of wood between the anti- Removing the lower unit (L-transom
cavitation plate and the propeller to keep model)
the propeller from turning, and then
remove the propeller nut and propeller.
• Make sure to remove the clip from the
• When removing the lower unit with the
motor is not suspended, it can fall sud-
propeller nut.
5. Set the gear shift to the R position.
See steps 1–6 in “Removing the lower unit
6. Remove the covers a, and then remove
(S-transom model)”.
the joints b and c.
1. Remove the lower unit a and extension
b.
a 2. Remove the anode c and flushing screw

c d.
b
a
144
Lower unit
Disassembling the extension (L-

transom model)
1. Remove the circlip a, and then remove
the bushing b.
e d
e
b
b
a
Stopper guide plate c

Stopper guide stand d
Bearing puller assembly e

1. Check the propeller blades and splines.
Replace the propeller if cracked, dam-
aged, or worn.
Checking the lower unit anode

1. Check the anode. Replace if eroded.
Clean if there is grease, oil, or scales.
NOTICE: Do not apply grease, oil, or
paint to the anode.
145
LOWR
Lower unit
1
3
1
16
4
2
7 13 15
8
11
9
10 14
12

1 Bolt 4
2 Plate 2
3 Rubber seal 1
4 Water pump housing 1
5 Insert cartridge 1
6 Impeller 1
8 Outer plate cartridge 1
9 Rubber seal 1
10 Bolt 1
11 Dowel 2
12 Housing 1
13 Shift rod 1
14 Pin 1
15 Pin 1
146
Removing the water pump and shift
rod TIP:
If the engine overheated, check the water
1. Remove the rubber seal a, plates b,
pump housing for deformation.
water pump housing c, insert cartridge
d, and impeller e.
2. Check the impeller, insert cartridge, and
2. Remove the gasket f, pin g and outer outer plate cartridge. Replace if cracked
plate cartridge h. or worn.
a 3. Check the pin and pin hole in the drive

shaft. Replace if deformed or worn.
b
b Checking the shift rod
1. Check the shift rod. Replace if deformed
or worn.
c
3. Remove the housing i, shift rod j,

rubber seal k, gasket l, and pin m.

1. Check the water pump housing. Replace
if cracked or deformed.
147
LOWR
Lower unit
11
10
4
9
8 9 11
2 7
1 6

1 Shift plunger 1
2 Spring 1
3 Dog clutch 1
4 Propeller shaft 1
5 Washer 2
6 Reverse gear 1
7 Ball bearing 1
10 Propeller shaft housing 1
11 Bolt 2
148
Removing the propeller shaft
housing assembly b
1. Remove the bolts a, and then remove
the propeller shaft housing assembly b.
a
b
a
2. Remove the ball bearing c.
d
TIP:
Insert flat-head screwdrivers between the
propeller shaft housing assembly b and the
lower case to remove the propeller shaft e
housing assembly.
c f
Disassembling the propeller shaft

Stopper guide plate d
assembly
Stopper guide stand e
1. Remove the shift plunger a.
Bearing puller assembly f
2. Push the spring b, and then remove the 3. Remove the oil seals g and O-ring h.
dog clutch c.
3. Remove the spring b.

g
a h
Checking the propeller shaft

b 1. Check the propeller shaft. Replace if
c damaged or worn.
2. Measure the propeller shaft runout.
Disassembling the propeller shaft

housing assembly
1. Remove the washers a and reverse
gear b.
149
LOWR
Lower unit
Assembling the propeller shaft
housing assembly
Do not reuse a bearing, oil seal, or O-ring,

1. Install new oil seals a.
Propeller shaft runout:

0.02 mm (0.001 in) b
Checking the dog clutch c

1. Check the dog clutch, shift plunger, and
spring. Replace if cracked or worn.
a
1. Check the propeller shaft housing.
Replace if cracked or damaged. Driver rod L3 b
Needle bearing attachment c
1. Check the teeth and dogs of the reverse
gear. Replace if cracked or worn. TIP:
Install an oil seal halfway into the propeller
Assembling the propeller shaft shaft housing, and then install the other oil
assembly seal.
1. Install the spring a into the hole in the
propeller shaft b. 2. Install a new ball bearing d.
2. Push the spring a, and then install the 3. Install a new O-ring e.
dog clutch c.
a
f
g
e
d
a
c
b Driver rod LS f
Bearing outer race attachment g
TIP:
Face the identification mark a on the ball
bearing toward the reverse gear.
150
Propeller shaft housing / Drive shaft and lower case
4
1
11
2
10
5 6

1 Drive shaft 1
2 Clip 1 /PUSFVTBCMF
4 Bushing 1 /PUSFVTBCMF
5 Lower case 1
7 Washer 1
8 Pinion 1
9 E-clip 1
10 Ball bearing 1 /PUSFVTBCMF
11 Forward gear 1
151
LOWR
Lower unit
1. Remove the E-clip a, and then remove
the drive shaft b and pinion c. e
2. Remove the clip d.
3. Remove the forward gear e.
3. Remove the bushing f.
b e
d
c f
a
Disassembling the lower case 4. Remove the bushing g.

1. Remove the ball bearing a.
b
b
c
c
d g
i
a
Stopper guide plate b
Stopper guide plate b Stopper guide stand c
Stopper guide stand c Bushing installer center bolt h
Bearing puller assembly d Bushing attachment i
2. Remove the oil seals e.

Checking the pinion
1. Check the teeth of the pinion. Replace if
cracked or worn.

1. Check the teeth and dogs of the forward
gear. Replace if cracked or worn.
152
Checking the drive shaft
1. Check the drive shaft. Replace if dam- d
aged or worn.
c e
2. Measure the drive shaft runout.
Driver rod L3 d
Bushing attachment e
3. Install new oil seals f to the specified

depth a.
Drive shaft runout: 0.4 mm (0.02 in)
a
Checking the lower case d
1. Check the lower case. Replace if cracked
or damaged. g
Assembling the lower case
f
Do not reuse a bearing, bushing, or oil
seal, always replace it with a new one. Driver rod L3 d
Needle bearing attachment g
1. Install a new bushing a.
Depth a: 1.0 mm (0.04 in)
b 4. Install the ball bearing h.

a b b
i
a
j
h
Bushing installer center bolt b Driver rod LS i

Bearing outer race attachment j
2. Install a new bushing c.
153
LOWR
Lower unit
TIP:
Face the identification mark b on the ball a
bearing toward the forward gear. b
Installing the drive shaft c

e
1. Install the forward gear a.
d
2. Install a new clip b to the drive shaft c.
NOTICE: Do not reuse a clip, always
replace it with a new one. 2. Install the propeller shaft housing
assembly f.
c
b
f
Installing the propeller shaft housing

assembly (L-transom model)
1. Install the reverse gear a, washers b,
3. Install the washer d, pinion e, and drive
drive shaft c, and shift plunger d to the
shaft c, and then install the E-clip f.
propeller shaft housing e.
c
f d a
d b
e
c
e
d
2. Install the lower case mounting bolt f

into the hole in the rear of the lower case
g, and then install the propeller shaft
housing assembly h.
Installing the propeller shaft housing
assembly (S-transom model)
1. Install the reverse gear a, washers b,
drive shaft c, and shift plunger d to the
propeller shaft housing e.
154
4. Install the outer plate cartridge g, a new
f
gasket h, and then install the pin i.
g
h
g
h
i
Installing the water pump and shift
rod
5. Align the slot b in the impeller j with
the pin i, and then install the impeller.
with a new one.
b
1. Install the pin a to the shift rod b.
2. Install the rubber seal c to the housing j i

d, and then install the shift rod b.
3. Install the dowels e, a new gasket f,

and the housing d.
6. Align the protrusion c on the insert
cartridge k with the groove d in the
c a water pump housing l, and then install
d the insert cartridge.
a a
b
c
d
a e k
l
7. Install the water pump housing assembly.

NOTICE: Do not turn the drive shaft
counterclockwise. Otherwise, the
water pump impeller could be
damaged.
a: 1.0 mm (0.04 in)
155
LOWR
Lower unit
4. Apply the specified pressure to check
TIP: that the pressure is maintained in the
While turning the drive shaft clockwise, push lower unit for at least 10 seconds.
down on the water pump housing and install NOTICE: Do not over pressurize the
water pump housing. lower unit. Otherwise, the oil seals
could be damaged.
8. Install the plates m and rubber seal n.
n
m d
m
Leakage tester d
Holding pressure:
98.0 kPa (0.98 kgf/cm2, 14.2 psi)
Checking the lower unit for air 5. If the specified pressure cannot be
leakage maintained, check the drive shaft,
1. Install new gaskets a, the drain screw b propeller shaft, and rubber seal for bends
and the flushing screw c. or damage, and check the shift rod
rubber seal for damage or wear.
2. Tighten the drain screw b and flushing
screw c to the specified torque. Assembling the extension (L-
transom model)
1. Install the bushing a and circlip b.
a
c
d c
a b
c
a
b
d
Drain screw b: a
9 N·m (0.9 kgf·m, 6.6 ft·lb)
Flushing screw c:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
3. Install the special service tool d.

Driver rod L3 c
1HHGle bearing attachment d
156
Installing the lower unit (S-transom e
model)
a
• Make sure to remove the clip from the f
a
propeller nut.
• When installing the lower unit with the b
motor is not suspended, it can fall sud- c
d
1. Move the shift lever to the R position.

c
2. Set the gear shift to the R position.
F Lower case mounting bolt c:
N 11 N·m (1.1 kgf·m, 8.1 ft·lb)
R
TIP:
Make sure that the cooling water pipe e is
inserted securely into the rubber seal f.
6. Install the joints g and h, and then

tighten the shift joint bolt i to the
specified torque.
3. Install the dowels a.
7. Install the covers j.
4. Install the lower unit b to the upper case,
and then tighten the lower case mounting
bolts c to the specified torque.
j
5. Install the anode d.
i
h
g
j
Shift joint bolt i:

1 N·m (1. kgf·m, ft·lb)
9. Install the spacer k, propeller l, washer

m, and propeller nut n.
157
LOWR
Lower unit
Installing the lower unit (L-transom
model)
m • Make sure to remove the clip from the

n engine shut-off switch.
k l propeller nut.
• When installing the lower unit with the
motor is not suspended, it can fall sud-
10. Place a block of wood between the anti-
cavitation plate and the propeller to keep See steps 1 and 2 in “Installing the lower unit
the propeller from turning, and then (S-transom model)”.
tighten the propeller nut.
1. Install the dowels a and extension b.
11. Install a new cotter pin o. NOTICE: Do
not reuse a cotter pin, always replace 2. Install the lower unit c to the upper case,
it with a new one. and then tighten the lower case mounting
bolts d to the specified torque.
3. Install the anode e.
o a f
o
b
a
12. Fill the lower unit with gear oil up to the

proper level. See steps 5–8 in “Changing c
the gear oil”. a
d
Lower case mounting bolt d:

1ÂP NJIÂPIWÂOE )
158
TIP:
Make sure that the cooling water pipe f is
inserted securely into the rubber seal g.
See steps 6–12 in “Installing the lower unit

(S-transom model)”.
159
LOWR
Lower unit
— MEMO —
160
BRKT
Bracket unit
Tiller handle
Disassembling the tiller handle
Assembling the tiller handle
Bottom cowling
Disassembling the bottom cowling
Assembling the bottom cowling
Upper case and shift lever

Removing the shift lever
Removing the upper case .
Checking the upper case
Installing the upper case
Installing the shift lever
Clamp bracket .
Disassembling the clamp bracket
Assembling the clamp bracket
161
BRKT
Bracket unit
Tiller handle
4 N·m (0.4 kgf·m, 3.0 ft·lb)
1
12
28 N·m (2.8 kgf·m, 20.7 ft·lb)
2
5 9 13
10
3 9
11
6
4 7
8
3
14
15
24 16
17
18
19
20
21
20
23
22
4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)

1 Holder 1
2 Holder 1
3 Throttle cable 2
4 Holder 2
5 Tiller handle mounting bolt 1
6 Plate 1
7 Bushing 1
8 Washer 1
9 Washer 2
10 Wave washer 1
11 Bushing 1
12 Throttle friction adjuster 1
13 Tiller handle 1
14 Throttle rod 1
15 Plate 1
16 Throttle rod screw 2
17 Friction piece 1
162
Tiller handle
4 N·m (0.4 kgf·m, 3.0 ft·lb)

1
12
28 N·m (2.8 kgf·m, 20.7 ft·lb)
2
5 9 13
10
3 9
11
6
4 7
8
3
14
15
24 16
17
18
19
20
21
20
23
22
4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)

19 Bushing 1
20 Washer 2
21 Spring 1
22 Throttle grip 1
23 Throttle grip screw 1
24 Bushing 1
163
BRKT
Bracket unit
Disassembling the tiller handle 5. Remove the cotter pin p and throttle
1. Remove the holders a, b, and c. friction adjuster q.
c m
b o
n p
2. Remove the plate d and tiller handle q

assembly e.
l
6. Remove the plate r, friction piece s,

throttle cables t, and throttle rod u.
d
u r
s t
3. Remove the bushings f, g, washers h,
i, and wave washer j, and then
remove the bushing k.
f Assembling the tiller handle

1. Pass the throttle cables a through the
h holes in the tiller handle b.
k
i
a
g
j a
4. Remove the throttle grip l, washers m, 2. Install the cable into the throttle rod c.
spring n, and bushing o.
164
Tiller handle
k
c
i
j
h
3. Install the friction piece d onto the g

throttle rod c, and then install the plate
e. l
4. Tighten the throttle rod screws f to the

Throttle grip screw m:
specified torque.
4 N·m (0.4 kgf·m, 3.0 ft·lb)
c f
7. Install the bushing n, and then install the
e washers o, wave washer p, bushing q,
washer r, and bushing s.
d s
r
Throttle rod screw f:

n
4 N·m (0.4 kgf·m, 3.0 ft·lb) o
p
5. Install the throttle friction adjuster g, and o
q
then install a new cotter pin h.
NOTICE: Do not reuse a cotter pin,
6. Install the bushing i, washers j, spring 8. Install the tiller handle assembly t and
k, throttle grip l, and then tighten the plate u, and then tighten the tiller handle
throttle grip screw m to the specified mounting bolt v to the specified torque.
torque.
165
BRKT
Bracket unit
Tiller handle mounting bolt v:

28 N·m (2.8 kgf·m, 20.7 ft·lb)
9. Install the holders w, x, and y.

y
x
166
Tiller handle / Bottom cowling
Bottom cowling
11 N·m (1.1 kgf·m, 8.1 ft·lb)
2 N·m (0.2 kgf·m, 1.5 ft·lb) 10
5
2 5
6 9
1 4 11
8 9
2 7
5 12
6 7
3
6 12
13
14
15
20
18
16
18 17
19 18
4 N·m (0.4 kgf·m, 3.0 ft·lb)
16
19 N·m (1.9 kgf·m, 14.0 ft·lb)

1 Start-in-gear protection cable 1
2 Primer pump holder bolt 2
3 Holder 1
4 Holder 1
5 Bolt 4
6 Grommet 4
7 Nut 2
8 Bolt 1
9 Pin 2
10 Cowling lock lever 1
11 Bracket 1
12 Clip 2
13 Bracket 1
14 Bottom cowling 1
15 Grommet 1
16 Carrying handle bolt 2
17 Carrying handle 1
167
BRKT
Bracket unit
11 N·m (1.1 kgf·m, 8.1 ft·lb)

2 N·m (0.2 kgf·m, 1.5 ft·lb) 10
5
2 5
6 9
1 4 11
8 9
2 7
5 12
6 7
3
6 12
13
14
15
20
18
16
18 17
19 18
4 N·m (0.4 kgf·m, 3.0 ft·lb)
16
19 N·m (1.9 kgf·m, 14.0 ft·lb)

18 Collar 4
19 Cap 1
20 Grommet 1
168
Bottom cowling
Disassembling the bottom cowling
1. Remove the start-in-gear protection d c
cable a and holders b and c. d b
e
b c
a e
a f
g
g
Carrying handle bolt g:

19 N·m (1.9 kgf·m, 14.0 ft·lb)
2. Remove the carrying handle d. 3. Install the start-in-gear protection cable

h and holders i and j.
3. Remove the clips e, pins f, cowling
lock lever g, and brackets h and i. 4. Tighten the start-in-gear protection cable
locknut a and primer pump holder bolts
f g k to the specified torque.
h
f
k
e k
j
h
i e d
Assembling the bottom cowling

1. Install the brackets a, b, cowling lock
lever c, pins d, and clips e. Start-in-gear protection cable locknut a:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
2. Install the carrying handle f, and then Primer pump holder bolt k:
tighten the carrying handle bolts g to the 11 N·m (1.1 kgf·m, 8.1 ft·lb)
specified torque.
169
BRKT
Bracket unit
6 11 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
19 N·m (1.9 kgf·m, 14.0 ft·lb)
12 13
7 18
14 16 17
8
15
5 18
31
9
10
1 30
2 19
4 18
32
3 25
3 N·m (0.3 kgf·m, 2.2 ft·lb) 20
24 24
29
18
23
26 28
21
27 26 22

1 Cap 1
2 Shift lever bolt 1
3 Shift lever 1
4 Shift rod 1
5 Pipe 1
6 Rubber seal 1
7 Shift link lever 1
9 Ball 1
10 Spring 1
11 Shift link bolt 1
12 Bracket 1
13 Washer 1
15 Upper case 1
16 Damper 1
17 Cover 1
170
6 11 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

19 N·m (1.9 kgf·m, 14.0 ft·lb)
12 13
7 18
14 16 17
8
15
5 18
31
9
10
1 30
2 19
4 18
32
3 25
3 N·m (0.3 kgf·m, 2.2 ft·lb) 20
24 24
29
18
23
26 28
21
27 26 22

18 Bolt 6
19 Steering friction adjuster 1
20 Spring 1
21 Bushing 1
22 Bushing 1
23 Bushing 1
24 Bushing 2
25 Spring 1
26 Bolt 2
27 Reverse lock 1
28 Grommet 1
29 Friction piece 1
31 Collar 1
32 Grease nipple 1
171
BRKT
Bracket unit
Removing the shift lever
1. Remove the shift lever a, collar b, and a
bracket c.
2. Remove the ball d and spring e.
c
b
d 2. Move the plate a up, and then tilt the

e
outboard motor up.
a
3. Remove the cap f, shift lever a, and O-

rings g.
3. Remove the reverse lock b and springs

f c and d.
g
a d
c
4. Remove the cotter pin h, washer i, and
shift rod j.
j i b
h
4. Remove the upper case e.

Removing the upper case
1. Remove the water pipe a.
172
e
n
b p
p
d m
o
c
5. Remove the steering friction adjuster f, Bushing installer center bolt n

and then remove the cover g and friction Bushing attachment o
piece h.
f Pipe p (reference):
h b: 12.0 mm (0.5 in)
c: 16.0 mm (0.7 in)
d: 37.0 mm (1.5 in)
g
Checking the upper case
1. Check the upper case. Replace if
cracked or eroded.
6. Remove the bushings i, j, k, and l. Installing the upper case

1. Install a new bushing a. NOTICE: Do
not reuse a bushing, always replace it
with a new one.
b
c
k a
l l
i
j
a
Driver rod L3 b
7. Remove the bushing m. Needle bearing attachment c
2. Install the bushings d and e.
173
BRKT
Bracket unit
d
l
3. Install the bushings f and g.
g
7. Tilt the outboard motor up.
8. Install the springs m, n and reverse lock

o.
f
m
n
4. Install the friction piece h to the upper
case i.
5. Install the cover j, and then install the

steering friction adjuster k.
k o
h
j
i
9. Install the rubber seal p to the water
pipe q, and then install the water pipe
q.
j p
k
q
h i
6. Install the upper case l.
174
Installing the shift lever l
k
Do not reuse a cotter pin or O-ring, always
i
h
1. Install the shift rod a, the washer b, and
a new cotter pin c. e
j
b
Shift link bolt l:
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
a c
c
2. Install new O-rings d and the shift lever

e.
3. Tighten the shift lever bolt f to the

specified torque, and then install the cap
g.
g f
Shift lever bolt f:

19 N·m (1.9 kgf·m, 14.0 ft·lb)
4. Install the spring h, ball i, collar j,

bracket k, and shift lever e.
5. Tighten the shift link bolt l to the

specified torque.
175
BRKT
Bracket unit
Clamp bracket
15 N·m (1.5 kgf·m, 11.1 ft·lb)
1
5
2
8
6 9
3
4
7
6
14 10
18
15
16 23
17 19
15
19
22 11
21
14
13
20
17
16 12

1 Self-locking nut 1
2 Plate 1
3 Nut 1
4 Washer 1
5 Clamp bracket (STBD) 1
6 Washer 2
7 Collar 1
8 Swivel bracket 1
9 Bolt 1
10 Clamp bracket (PORT) 1
11 Bolt 1
12 Tilt pin 1
13 Spring 1
14 Clamp pad 2
15 Clamp screw 2
16 Pin 2
17 Clamp handle 2
176
Clamp bracket
15 N·m (1.5 kgf·m, 11.1 ft·lb)
1
5
2
8
6 9
3
4
7
6
14 10
18
15
16 23
17 19
15
19
22 11
21
14
13
20
17
16 12

18 Spring 1
19 Bushing 2
20 Plate 1
21 Bolt 2
22 Cover 1
23 Tilt lock lever 1
177
BRKT
Bracket unit
Disassembling the clamp bracket
1. Remove the tilt pin a. d
c
b
2. Remove the self-locking nut b and nut
c. e
3. Remove the plate d, clamp bracket

(STBD) e, washers f, swivel bracket
g, collar h, and clamp bracket (PORT) b
a
i.
3. Hook the sections a of the spring a
e
b onto the tilt lock lever c, and then fit the
g section b into the slot in the plate e.
d f
c
c h
a
f
e
i a b
a
4. Install the bolts f and g into the clamp

4. Remove the plate j, cover k, bushings bracket (PORT) h.
l, tilt lock lever m, and spring n.
5. Install the washers i, swivel bracket j,
k
m collar k, clamp bracket (STBD) l onto
j the bolts f and g.
l
6. Install the plate m, self-locking nut n,
washer o, nut p, and tilt pin q.
7. Tighten the self-locking nut n to the

l specified torque.
n

1. Place the spring a.
2. Install the bushings b, tilt lock lever c,

cover d, and plate e.
178
Clamp bracket
l
n
m j
i
p o k
i
h
f
q
g
Self-locking nut n:
15 N·m (1.5 kgf·m, 11.1 ft·lb)
179
BRKT
Bracket unit
— MEMO —
180
MNT
Maintenance
Outline
Maintenance interval chart
Predelivery check
Checking the battery
Checking the cooling water pilot hole
Checking the engine oil level
Checking the fuel system
Checking the gear oil level
Checking the gear shift and throttle operation
Checking the outboard motor mounting height
Checking the steering system
Checking the throttle cable
Checking the tilt system
Starting the engine
Test run
Break-in
After test run
General periodic maintenance

Checking the anode
Checking the cooling water passage
Checking the engine idle speed
Changing the engine oil
Checking the fuel joint and fuel hoses
(fuel joint to carburetor)
Changing the gear oil .
Lubricating the outboard motor
Checking the thermostat .
Adjusting the throttle link rod and throttle cable .
Checking the top cowling
181
MNT
Maintenance
Outline
• To obtain long product life, +LGHD strongly recommends that the specified periodic checks and
maintenance be performed according to the maintenance interval chart.
• If replacement parts are necessary, use only genuine +LGHD parts of equivalent design and qual-
ity. Any parts of inferior quality may cause a malfunction, and the resulting loss of control could
endanger the operator and passengers. +LGHD genuine parts and accessories are available
from +,'($ dealers.
• The service intervals provided in the Maintenance Chart are based upon “typical” operating condi-
tions that include speed variations, sufficient time for engine warm up and cool-down, medium to
light load, and an average cruising speed in the 3000 to 4000 r/min range. If your normal operating
conditions are more intensive, more frequent servicing will be required, especially the engine oil
and gear oil changes. Examples of the intensive operation will be: wide-open-throttle, trolling, or
idling operation for extended periods of time, carrying heavy loads, and frequent starting and stop-
ping or shifting. In most cases, the frequent maintenance pays off in increased engine life and
greater owner satisfaction.
• The maintenance cycle on these charts assumes usage of 100 hours per year and regular flush-
ing of the cooling water passages. Adjust the maintenance frequency when operating the engine
under adverse conditions, such as extended trolling.
• Disassembly or repairs may be necessary depending on the outcome of maintenance checks.
• Expendable or consumable parts and lubricants will lose their effectiveness over time and through
normal usage regardless of the warranty period.
• When operating the outboard motor in salt water, or in muddy, turbid (cloudy), or acidic water, flush
the engine using clean water after each use.
Maintenance interval chart

Initial Every
Item Actions 20 hours 100 hours 300 hours 500 hours
(3 months) (1 year) (3 years) (5 years)
Anode (external) Check/replace U
Anode (thermostat cover) Check/replace U
Battery (electrolyte level, Check/charge/replace U U
terminal)
Cooling water leakage Check U U
Cowling lock lever Check U
Engine starting condition/ Check U U
noise
Engine idle speed/noise Check U U
Engine oil Replace U U
Engine shut-off switch Check/replace U U
Fuel strainer Check/replace U U
Fuel hose Check/replace U U
Fuel pump Check/replace U
Fuel/oil leakage Check U U
Gear oil Replace U U
Greasing points Lubricate U U
Impeller/ Check/replace U
water pump housing
182
Outline
Initial Every
Item Actions 20 hours 100 hours 300 hours 500 hours
(3 months) (1 year) (3 years) (5 years)
Impeller/ Replace U
water pump housing
Pilot water Check U U
Propeller/propeller nut/ Check/replace U U
cotter pin
Shift link Check/replace U U
Spark plug Check/replace U

Spark plug cap Check/replace U U
Throttle link/ Check/adjust/replace U U
throttle cable
Thermostat Check/replace U
Valve clearance Check/adjust U
Water inlet Check U U

Wiring harness Check/replace U U
connections/wiring
coupler connections
Fuel tank (built-in tank) Check U
Every
Item Actions
1000 hours
Upper case Check/replace U
TIP:
When using lead high-sulfur gasoline, checking the valve clearance may be required more fre-
quently than every 500 hours.
183
MNT
Maintenance
Predelivery check
To make the delivery process smooth and
efficient, complete the predelivery checks as
a
explained in the following procedures.
Battery electrolyte is dangerous; it con-

tains sulfuric acid, which is poisonous 2. Check the specific gravity of the
and highly caustic. Always follow these electrolyte. Fully charge the battery if
preventive measures: below specification.
• Avoid bodily contact with electrolyte as Recommended battery capacity:
it can cause severe burns or permanent 9$
eye injury. Electrolyte specific gravity:
• Wear protective eye gear when handling
1.280 at 20 °C (68 °F)
or working near batteries.
Antidote (EXTERNAL):
• SKIN - Wash with water.
• EYES - Flush with water for 15 minutes TIP:
and get immediate medical attention. • Batteries vary depending on the manufac-
Antidote (INTERNAL): turer. The procedures mentioned in this
• Drink large quantities of water or milk manual may not always apply. Therefore,
followed with milk of magnesia, beaten see the instruction manual of the battery.
egg, or vegetable oil. Get immediate • Disconnect the negative battery cable first,
medical attention. and then the positive battery cable.
Batteries produce explosive, hydrogen
gas. Always follow these preventive mea- Checking the cooling water pilot hole
sures: 1. Start the engine, and then check that
• Charge batteries in a well-ventilated cooling water is discharged from the
area. cooling water pilot hole.
• Keep batteries away from fire, sparks, or
open flames (for example, welding
equipment and lighted cigarettes).
• DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
1. Check the battery electrolyte level. If the

level is at or below the minimum level
mark a, add distilled water until the level Checking the engine oil level
is between the maximum and minimum 1. Place the outboard motor in an upright
level marks. position. NOTICE: If the outboard
motor is not level, the oil level indi-
cated on the dipstick may not be accu-
rate.
184
Predelivery check
2. Start the engine and warm it up for 5–10 Checking the fuel system
minutes. 1. Check that the fuel hoses are securely
connected. See “Fuel hose”.
3. Stop the engine and leave it off for 5–10 NOTICE: This is a 4-stroke engine.
minutes. Never use premixed fuel or 2-stroke
outboard motor oil.
4. Remove the top cowling.
5. Remove the dipstick and wipe it clean
1. Place the outboard motor in an upright
using a rag.
position.
6. Screw in the dipstick completely for
2. Remove the check screw a, and then
accurate measurement and remove it.
check the gear oil level in the lower case.
7. Check the oil level using the dipstick to
make sure the level falls at the center TIP:
between the upper level a and the lower If the oil is at the proper level, a small amount
level b. Add oil if it is below the lower of oil should flow out of the check hole.
level b, or extract to the center level if it
is above the upper level a. 3. Install a new gasket b and the check
a screw a, and then tighten the check
screw a to the specified torque.
NOTICE: Do not reuse a gasket,
a
b
b
a

1. Check that the engine turns off when the
clip is pulled from the engine shut-off
switch.
Check screw a:
2. Check that the engine turns off when the 9 N·m (0.9 kgf·m, 6.6 ft·lb)
engine shut-off switch is pushed.
Checking the gear shift and throttle
operation
Do not overtighten the friction adjuster. If

there is too much resistance, it could be
difficult to move the throttle grip, which
could result in an accident.
1. Check that the gear shift operates

smoothly when the shift lever is moved
from the N to the F or R position.
185
MNT
Maintenance
2. Check that the throttle operates smoothly
when the throttle grip is turned from the b
fully closed position to the fully open
position.
Checking the outboard motor a

mounting height
1. Check that the anti-cavitation plate a is
between the bottom of the boat b and a
maximum of 25.0 mm (1.0 in) c below it.
If the mounting height is too high, cavita-
TIP:
tion will occur and propulsion will
• To increase the friction, move the steering
decrease. Besides, the engine speed will
friction adjuster in direction a.
increase abnormally and cause the
• To decrease the friction, move the steering
engine to overheat. If the mounting
friction adjuster in direction b.
height is too low, water resistance will
increase, which will decrease engine effi-
ciency and performance. 2. Check that the steering operates
smoothly.
3. Check that there is no interference with

wires or hoses when steering the
outboard motor. (When equipped with
the optional parts)
c Checking the throttle cable

1. Turn the throttle grip to the fully closed
b
a position.
TIP: 2. Check that the stopper a on the throttle

The optimum mounting height depends on cam a contacts the stopper b on the
the combination of the boat and outboard bracket b.
motor. To determine the optimum mounting
height, test run the outboard motor at differ- 3. Turn the throttle grip to the fully open
ent heights. position.
4. Check that the stopper a on the throttle

2. Check that the clamp brackets are cam a contacts the stopper c on the
secured using the clamp screws. bracket b.
Checking the steering system b a

1. Check the steering friction for proper
adjustment.
c
b a
186
Predelivery check
Checking the tilt system
2. Fully tilt up the outboard motor, and then

check that the outboard motor tilts up
smoothly and automatically locks in a,
b, c, d positions when it is tilted up.
a
3. Move the shift lever to the F or R position.
4. Check that the starter handle cannot be

a
pulled.
b
c Test run
d
1. Start the engine, and then check that the
3. Check that there is no interference with gear shift operates smoothly.
hoses or leads when the tilted-up
outboard motor is steered. (When 2. Warm up the engine, and then check the
equipped with the optional parts) engine idle speed.
4. Slightly tilt the outboard motor up and 3. Operate the engine at trolling speed.
move the tilt lock lever to the release
4. Operate the outboard motor according to
position, and then fully tilt outboard motor
the break-in procedure.
down. Check that the outboard motor tilts
down smoothly.
5. Check that the outboard motor does not
tilt up when the shift lever is moved to the
R position and that water does not flow in
over the transom.
TIP:
The test run is part of the break-in operation.
Break-in
Operate the engine under load (in gear with a
5. Check that the outboard motor does not propeller installed) for 10 hours as follows:
tilt up when the shift lever is moved to the
1. For the 1st hour a of operation:
R position.
Operate the engine at varying speeds up
Starting the engine to 2000 r/min or approximately 1/2 throt-
Engine starting procedure differs depending tle.
on the conditions.
2. For the 2nd hour b of operation:
1. Move the shift lever to the N position. Operate the engine at 3000 r/min or at
approximately 3/4 throttle.
2. Check that the engine starts when the
starter handle a is pulled.
187
MNT
Maintenance
3. For the remaining 8 hours c of 1. Check the anodes. See “Checking the
operation: thermostat cover anode”, and
Operate the engine at any engine speed. “Checking the lower unit anode”.
However, do not operate the engine at
full throttle for more than 5 minutes at a Checking the battery
time.
1. Check the battery. See “Checking the
4. After the 1st 10 hours of operation: battery”.
Operate the engine normally.
Checking the cooling water passage

1. Check the water inlets a. Clean if
a b c clogged.
A 0 1 2 10 a
A Hour
After test run

1. Check for water in the gear oil.
2. Place the lower unit in water, and then
2. Check for fuel leakage in the cowling. start the engine.
3. Flush the cooling water passages using 3. Check for water flow at the cooling water
fresh water. NOTICE: Do not perform pilot hole. If there is no water flow, check
this procedure on land while the the cooling water passage inside the
engine is running. Otherwise, the outboard motor.
water pump could be damaged and
the engine could be severely damaged
due to overheating.
TIP:
When using the flushing device (flushing
hose joint adapter), flush the cooling water
passages without starting the engine.

Checking the anode Checking the engine idle speed
1. Install the special service tool a to spark
plug wire a.
Do not apply grease, oil, or paint to the
anodes. Otherwise, the anodes become
ineffective.
188
Predelivery check / General periodic maintenance
Changing the engine oil
The engine oil should be extracted using an
a oil changer.
a
Change the engine oil after the first 20

hours of operation or 3 months, and every
100 hours or at 1-year intervals thereafter.

Digital tachometer a position. NOTICE: If the outboard
motor is not level, the oil level indi-
TIP: cated on the dipstick may not be accu-
Set the digital tachometer to the 2-cycle 1- rate.
cylinder mode because this engine ignites
the spark plug once per crankshaft rotation. 2. Start the engine and warm it up for 5–10
minutes.
2. Start the engine and warm it up for 5–10 3. Stop the engine and leave it off for 5–10
minutes. minutes.
3. Check the engine idle speed. Adjust if out 4. Remove the dipstick a, and then extract
of specification. the oil completely using the oil changer
b.
4. Turn the throttle stop screw b in
directions b or c until the specified a
engine idle speed is obtained.
c b
Engine idle speed: 1450–1550 r/min

5. Fill the engine with the specified amount
TIP: of the recommended engine oil through
• To increase the engine idle speed, turn the the oil filler hole. Screw in the dipstick a.
throttle stop screw b in direction b. NOTICE: Overfilling the oil could
• To decrease the engine idle speed, turn the cause leakage or damage. If the oil
throttle stop screw b in direction c. level is above the upper level mark,
extract until the level meets the
5. Rev the engine a few times. specified level.
6. Stop the engine, and then remove the

special service tool.
189
MNT
Maintenance
Checking the fuel joint and fuel
Recommended engine oil:
hoses (fuel joint to carburetor)
4-stroke motor oil
1. Check the fuel joint and fuel hose
con-nections. See “Fuel hose”.
Replacement engine oil quantity:
0.6 L
1. Check the fuel strainer. See “Checking
the fuel strainer”.
6. Leave the outboard motor off for 5–10 Changing the gear oil
minutes.
7. Remove the dipstick a and wipe it clean Do not reuse a gasket, always replace it
using a rag. with a new one.
8. Fully screw the dipstick a all the way in,

and then remove it.
position.
9. Check the oil level using the dipstick to
2. Place a drain pan a under the gear oil
make sure that the level falls between the
drain hole.
upper level a and lower level b.
a 3. Remove the drain screw b and gasket
c.
4. Remove the check screw d and the

a gasket e and let the oil drain completely.
b NOTICE: Check the used oil after it
has been drained. If the oil is milky,
water is getting into the lower case
which can cause gear damage.
10. Screw in the dipstick.
11. Start the engine, and then check that the

oil can be seen through the oil check hole e
d
and that there is no oil leakage. NOTICE:
If the oil cannot be seen through the c
oil check hole or if there is oil leakage,
b
stop the engine and find the cause.
a
1. Check the engine oil level. See
“Check-ing the engine oil level”.
Checking the engine shut-off switch 5. Insert the gear oil tube into the drain
1. Check the engine shut-off switch. See hole, and then slowly fill the lower case
“Checkingtheengine VKXWRII VZLWFK with gear oil until oil flows out of the
check hole and no air bubbles are visible.
190
6. Install a new gasket f and the check Lubricating the outboard motor
screw d. 1. Apply water resistant grease to the spec-
ified areas.
f
d
Oil quantity:
0.1 L
7. Remove the gear oil tube, and then

install a new gasket g and the drain
screw b.
g
b
8. Tighten the check screw d and drain

screw b to the specified torque.
Check screw d:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
Drain screw b:
9 N·m (0.9 kgf·m, 6.6 ft·lb)

1. Check the gear oil level. See “Checking
the gear oil level”.

1. Check the ignition timing. See “Checking
the ignition timing”.
191
MNT
Maintenance
Adjusting the throttle link rod and
throttle cable
1. Adjust the throttle link rod. See “Adjusting
the throttle cable and throttle link”.
Checking the top cowling

1. Check the fitting by pushing the top cowl-
ing. Adjust if there is free play.
2. Loosen the bolts a.
2. Apply corrosion resistant grease to the 3. Move the hook b up or down slightly to
specified area. adjust its position.
b
a
b

TIP:
1. Check the propeller. See “Checking the
• To loosen the fitting, move the hook in
propeller”.
direction a.
• To tighten the fitting, move the hook in
direction b.
1. Check the spark plug. See “Checking the
spark plug”.
4. Tighten the bolts a.
1. Check the spark plug cap. See “Checking 5. Recheck the fitting. Replace the cowling
the spark plug cap”. seal if the free play cannot be adjusted.
Checking the thermostat Checking the valve clearance

1. Check the thermostat. See “Checking the 1. Check the valve clearance. See
thermostat”. “Check-ing the valve clearance”.
192
1. Check the water pump housing and
impeller. See “Checking the water
pump”.
193
Index
A. Checking the connecting rod oil

clearance
Abbreviation Checking the connecting rod small end inside
Adjusting the CDI unit air gap diameter and big end inside diameter
Adjusting the start-in-gear protection Checking the cooling water passage
cable
Checking the cooling water pilot hole3
Adjusting the throttle cable and
throttle link
Adjusting the throttle link rod
and throttle cable Checking the cylinder bore
Adjusting the valve clearance
Checking the cylinder head
After test run Checking the diaphragm and valve
Assembling the bottom cowling Checking the dog clutch
Assembling the carburetor Checking the drive shaft
Checking the electrical componenW
Checking the engine idle speed
Assembling the extension Checking the engine shut-off VZLWFK
(L-transom model)
Assembling the lower case Checking the fuel joint
Assembling the manual starter Checking the fuel joint and fuel hoses (fuel joint
Assembling the propeller shaft assembly to carburetor)
Assembling the propeller shaft housing Checking the fuel pump
assembly
Assembling the tiller handle Checking the fuel strainer (tank side)
Checking the fuel system
B. Checking the gear oil level
Battery requirement Checking the gear shift and throttle
Blowby gas reburning system operation
Blowby hose, oil return hose, and cooling Checking the ignition spark
water hose Checking the ignition timingChecking
Bottom cowling the lighting coil
Bracket unit Checking the lower case
Break-in Checking the lower unit anode
Built-in primer pump Checking the lower unit for air leakage
Checking the manual starteUChecking
the oil seal housingChecking the oil
C. strainer
Carburetor Checking the outboard motor mounting
CDI unit
Changing the engine oil height
Changing the gear oil Checking the pinion
Charging system Checking the piston diameter
Charging unit and component Checking the piston pin boss inside
Checking the anode diameter
Checking the battery Checking the piston pin diameter
Checking the camshaft Checking the piston ring
Checking the carburetor Checking the piston ring end gap
Checking the CDI unit air gap Checking the piston ring groove
Checking the compression pressure Checking the piston ring side clearance
Checking the primer pump
194
Index
Checking the propeller shaft Drive shaft and lower case
Checking the push rod E.
Checking the Rectifier Regulator
Electric shock
Electrical component and wiring harness
routing
Checking the shift rod
Exterior +')
Checking the spiral spring
Checking the steering system F.
Checking the thermostat Flywheel magnet
Checking the thermostat cover anode Fuel and oil requirement
Checking the throttle cableChecking Fuel hose
the tilt system Fuel pump
Checking the top cowling Fuel system
Checking the upper case Fuel system technical data
Checking the valve Fuel tank
Checking the valve guide G.
Checking the valve lifter
Checking the valve seat General feature
Checking the valve spring General periodic maintenance
Checking the water pump General tightening torque
Clamp bracket
Cooling flow diagram H.
Crankcase Handling of gasoline
Crankcase assembly Handling of sealant
Cylinder block High speed operation
Cylinder head Hose routing
Cylinder head assembly Hot part
D. I.
Dimension Idle and low speed operation
Dimension and weight Ignition cut-off control
Disassembling the bottom cowling Ignition timing control
Disassembling the carburetor Ignition timing control system
Disassembling the clamp bracket Ignition unit and component
Disassembling the cylinder block Installing the battery
Disassembling the cylinder head Installing the carburetor
Disassembling the extension (L-transom Installing the charging system
model) Installing the crankcase
Disassembling the fuel pump Installing the cylinder head
Disassembling the lower case Installing the drive shaft
Disassembling the manual starter Installing the flywheel magnet
Disassembling the propeller shaft Installing the fuel pump
assembly Installing the fuel tank
Disassembling the propeller shaft housing Installing the lower unit
assembly
Disassembling the tiller handle
Disassembly and assembly (L-transom model)
195
Index
Installing the lower unit P.
(S-transom model)
Part, lubricant, and sealant
Installing the manual starter
Installing the oil pump Performance
Installing the oil seal housing Port
Power unit
Installing the primer pump Power unit (check and adjustment)
Installing the propeller shaft housing assembly Power unit assembly
(L-transom model Power unit system
Installing the propeller shaft housing assembly Power unit technical data
(S-transom model) Predelivery check
Propeller
Installing the shift lever
Installing the throttle cable and Propeller selection
throttle link Propeller shaft housing
Propeller size
Installing the upper case
Installing the water pump and shift rod
Intake and exhaust flow diagram R.
Intake silencer Refacing the valve seat
L. Removing the crankcase
Lighting coil Removing the cylinder head
Lower unit
Lower unit assembly Removing the flywheel
Removing the fuel pump
Lubricant, sealant, and thread locking
Removing the lower unit
(L-transom model)
agent
Removing the lower unit
Lubricating the outboard motor
(S-transom model)
Lubrication diagram
Removing the manual starter
Lubrication system
Removing the oil pump
Removing the oil seal housing
M. Removing the power unit
Maintenance interval chart Removing the primer pump
Manual format Removing the propeller shaft housing
Manual starter assembly
Measuring the peak voltage Removing the shift lever
Measuring the starter rope Removing the throttle cable and
Medium speed operation throttle link
Model data Removing the upper case
Model designation Removing the water pump and shift rod
Model feature Replacing the valve guide
Reverse lock system
N. Rigging recommendations
Rotating part
Non-reusable part
O. S.
Selection
Self-protection
Serial number
Outline
196
Index
Starting the engine
Symbol
T.
Test run
Tightening torque
Tiller handle
Tilt system
Top
U.
Uncrating procedure
Using the digital tester
V.
Ventilation
W.
Working with crane
197
Index
— MEMO —
198
Appendix
Wiring diagram
How to use the wiring diagram
+'F6
199
Wiring diagram
How to use the wiring diagram
Legend symbols in the wiring diagrams
a b
a No wire connector
b Optional parts
Color Code
B : Black
G : Green
R : Red
W : White
+')
aFuse (20A) (Battery)
Engine shut-off
switch
W B
Clip installed
Clip removed
Pushed
W
B
a
W R R
B
R
G
CDI unit G
B
Lighting coil Rectifier Regulator

B
200
201
0DUFK. 201
(%_&)
202

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HIDEA

Electrical system ELEC

Fuel system FUEL

Power unit POWR

Lower unit LOWR

Bracket unit BRKT

Safety while working

How to use this manual

Lubricant, sealant, and thread locking agent

Special service tool

Special service tool

Disassembly and assembly

• Install bearings so that the bearing identifi-

11N·m (1.1 kgf·m, 8.1 ft·lb)

3. Install the special service tool d.

Gear oil Lubricant

Water resistant grease Lubricant

Molybdenum disulfide grease Lubricant

Corrosion resistant grease Lubricant

ThreeBond Thread locking agent

Gasket Maker Sealant

Digital circuit tester Pilot screw driver

Peak voltage adapter B Compression gauge

Ignition tester (spark gap tester) Digital tachometer

Vacuum/pressure pump gauge set Timing light

Leakage tester Flywheel holder

Driver rod L3 Valve guide remover/installer

Needle bearing attachment Valve guide reamer

Needle bearing attachment Valve lapper

Valve spring compressor Valve seat cutter holder

Valve seat cutter Needle bearing attachment

Valve seat cutter Driver rod LL

Valve seat cutter Ball bearing attachment

Valve seat cutter Driver rod LS

Piston slider Bushing installer center bolt

Stopper guide plate Bushing attachment

Stopper guide stand Bushing attachmeQW

Bearing puller assembly

Electrical technical data

Fuel system technical data

Power unit technical data

Lower unit technical data

Specified tightening torque

General tightening torque

a Model description F: 4-stroke regular rotation

Serial number Approved Starting

Fuel and oil requirement

Fuel system technical data

Power unit technical data

Lower unit technical data

General tightening torque

Engine control system

Power unit system

Cooling flow diagram

Intake and exhaust flow diagram

Ignition timing control

A Ignition control during engine cranking

a Valve lifter g Flywheel magnet (optional)

a Cylinder block labyrinth