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278 Pgs + 1 f/o F100X SERVICE MANUAL 1111111111111111111111111111111111111111111111111111111111111111111111 LIT-18616-01-96 NOTICE This manual has been prepared by the Yamaha Motor Company Ltd. primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because the Yamaha Motor Company, Ltd. has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. A10001-0' F100X SERVICE MANUAL ©1998 Yamaha Motor Co., Ltd. 1st Edition, August 1998 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means including photocopying and recording without the written permission of the copyright holder. Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature. Printed in USA LIT-1861 6-01-96 HOW TO USE THIS MANUAL CD MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/scratches -7 Replace. To assist you in finding your way through this manual, the section title and major heading is given at the top of every page. ILLUSTRATIONS The illustrations within this service manual represent all of the designated models. CROSS REFERENCES The cross references have been kept to a minimum. Cross references will direct you to the appropriate section or chapter. IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. ffi The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! A. WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. A NOTE provides key information to make procedures easier or clearer. HOW TO USE THIS MANUAL G) To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. ® Numbers are given in the order of the jobs in the exploded diagram. @ Symbols indicate parts to be lubricated or replaced (see "SYMBOLS"). @ A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. Example: 0-ring size 39.5 x 2.5 mm: Inside diameter (D) x Ring diameter (d) d ® Dimension figures and the number of parts, are provided for fasteners that require a tight ening torque. Example: Bolt or screw size x 25 mm M10 (D) x 25 mm (L) ® Jobs requiring more information (such as special tools and technical data) are described sequentially. lOWER UNIT REMOVAl. followthe left·seep· for removal Cot1erp1n .. PrQfMIIIernut""..' PrQfMIIIer Coll•r"""""' Adjutttngnut Loweruni1 oo.r.\pll'l Driw«[email protected]:. YIH0>20--.......... ttact.ment loll .... irman.ri Q): YB-06022190190-015&35 t.lns..ll: • 00\.t. ... Oil.... pRitlon: ®: 12.S..13.0ntrn co.a..o.s11n1&. 5.5 .. &.0 mm 10.22 .. 0.241nl [email protected]: y....... _ ... buring .n.mm.m Col .... lnstaller1(i): v.....,,_....,. CD CD ® @ G) ® ® (j) ® i1[ ® @ @ © @ @ @ @ 1 m @ @ @) ® @ @ 1 1 a a 271 242 ® ® 1 1 a a 572 A50001-1-4 SYMBOLS Symbols G) to ® are designed as thumbtabs to indicate the content of a chapter. CD General information ® Specifications @ Periodic inspection and adjustment G) Fuel system ® Power unit ® Lower unit (j) Bracket unit ® Electrical systems ® Trouble analysis [email protected]) [email protected] indicate specific data: @ Special tool @ Specified liquid © Specified engine speed @ Specified torque @ Specified measurement @ Specified electrical value [Resistance (Q), Voltage (V), Electric current (A)J Symbol @ to @) in an exploded diagram indicate the grade of lubricant and the location of the lubrication point: @Apply Yamaha 4-stroke outboard motor oil @ Apply water resistant grease (Yamaha grease A. Yamaha marine grease) @Apply molybdenum disulfide grease Symbols @) to ® in an exploded diagram indicate the grade of the sealing or locking agent and the location of the application point: @) Apply Gasket Maker® ® Apply Yamabond #4 (Yamaha bond number 4) @ Apply LOCTITE® No. 271 (Red LOCTITE) @ Apply LOCTITE® No. 242 (Blue LOCTITE) ® Apply LOCTITE® No. 572 ® Apply silicon sealant CD AJ0000-0 INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT ELECTRICAL SYSTEMS TROUBLE ANALYSIS GEN INFO SPEC INSP ADJ FUEL POWR LOWR BRKT D ELEC ? • TRBL ANLS ;r CHAPTER 1 GENERAL INFORMATION IDENTIFICATION ............................................................................................. 1-1 SERIAL NUMBER ..................................................................................... 1-1 STARTING SERIAL NUMBERS ............................................................... 1-1 SAFETY WHILE WORKING 1-2 ............................................................................ FIRE PREVENTION 1-2 ................................................................................... VENTILATION ........................................................................................... 1-2 SELF-PROTECTION .................................................................................. 1-2 OILS, GREASES AND SEALING FLUIDS 1-2 ................................................ GOOD WORKING PRACTICES ................................................................ 1-3 DISASSEMBLY AND ASSEMBLY 1-4 ........................................................... SPECIAL TOOLS 1-5 ............................................................................................. MEASURING ............................................................................................ 1-5 REMOVAL AND INSTALLATION ............................................................ 1-6 ' IDENTIFICATION A60000-1" IDENTIFICATION SERIAL NUMBER The outboard motor's serial number is stamped on a label which is attached to the port side of the clamp bracket. If the serial number label is removed, "VOID" marks will be appear on the label. CD Model name ® Approval model code @ Transom height @) Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as follows: Model name Approval model code Starting serial numberWorldwide USA/ CANADA F100AET F100TR 67F L: 300101 -X: 700101 1-2 SAFETY WHILE WORKING SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline and keep it away from heat, sparks and open flames. VENTILATION Gasoline (petrol) vapor is heavier than air and is deadly if inhaled in large quantities. Engine exhaust gases are harmful to breathe. When test-running an engine indoors, maintain good ventilation. SELF-PROTECTION Protect your eyes with suitable safety glasses or safety goggles, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves or protective shoes if appropriate to the work you are doing. OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha. ...... SAFETY WHILE WORKING CD Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practices, any risk is minimized. A summary of the most important precautions is as follows: 1. While working, maintain good standards of personal and industrial hygiene. 2. Clothing which has become contaminated with lubricants should be changed as soon as practicable, and laundered before further use. 3. Avoid skin contact with lubricants; do not, for example, place a soiled wipingrag in your pocket. 4. Hands and any other part of the body which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with hot water and soap as soon as practicable. 5. To protect the skin, the application of a suitable barrier cream to the hands before working, is recommended. 6. A supply of clean lint-free cloths should be available for wiping purposes. GOOD WORKING PRACTICES 1. The right tools Use the recommended special tools to protect parts from damage. Use the right tool in the right manner -do not improvise. 2. Tightening torque Follow the tightening torque instructions. When tightening bolts, nuts and screws, tighten the large sizes first, and tighten inner-positioned fixings before outer-positioned ones. SAFETY WHILE WORKING CD 3. Non-reusable items Always use new gaskets, packings, 0rings, split-pins, circlips, etc., on reassembly. DISASSEMBL V AND ASSEMBL V 1. Clean parts with compressed air when disassembling. 2. Oil the contact surfaces of moving parts before assembly. 3. After assembly, check that moving parts operate normally. 4. Install bearings with the manufacturer's markings on the side exposed to view, and liberally oil the bearings. 5. When installing oil seals, apply a light coating of water-resistant grease to the outside diameter. GEN .. INFO -y SPECIAL TOOLS AB0000-0• SPECIAL TOOLS Using the correct special tools, recommended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvising and using improper tools can damage the equipment. r @@ ®® ® GEN • INFO -y ® SPECIAL TOOLS 9. Shimming gauge P/N. YB-34468-3 10. Backlash indicator P/N. YB-06265 90890-06706 11. Base plate P/N. YB-07003 12. Flexible stand P/N. YU-34481 90890-06705 13. Dial gauge P/N. YU-3097 90890-01252 REMOVAL AND INSTALLATION 1. Oil filter wrench P/N. YU-38411 90890-01426 2. Flywheel holder P/N. YB-06139 90890-06522 3. Universal puller P/N. YB-061 17 ................................ @ 90890-06521 ........................... (b) 4. Valve spring compressor P/N. YM-01 253 90890-04019 5. Valve spring compressor adapter (fl,l22 mm) P/N. YB-06554 90890-06554 6. Valve seat cutter set P/N. YM-91043-C [email protected] .............. 90890-06803 ........................... (b) 7. Valve seat cutter holder (fl.l6 mm) P/N. YB-06553 90890-06553 8. Valve seat cutter P/N. YB-06555 (45°-30 mm) YB-06556 (90°-30 mm) 90890-06555 (45° -30 mm) 90890-06556 (90°-30 mm) .. SPECIAL TOOLS CD @ ® ® ® 9. Valve guide remover (ji'j6 mm) P/N. YM-4064-A 90890-04064 10. Valve guide reamer (ji'j6 mm) P/N. YM-04066 90890-04066 11 . Crankshaft holder P/N. YB-06552 90890-06552 12. Ring nut wrench P/N. YB-34447 90890-06511 13. Extension P/N. 90890-06513 14. Bearing housing puller P/N. YB-06207 ................................ @ 90890-06502 .......................... ---a / Service points Follow the left "Step" for removal. Remove it up side down with 5, 6 and 7 Outer Inner TILT ROD ASSV. EXPLODED DIAGRAM 7------(!) 12 x45mm 85 Nm (8.5 m •kg, 61 ft •lb) Step Procedure/Part name 11 Bolt 12 Shim 13 Plate 14 Pin 15 Pin 16 Spring 17 Plunger 18 Ball 19 Tilt piston 20 Ball 21 0-ring Q'ty 1 1 1 2 4 4 4 4 1 1 1 27 0--___..:0---a / Service points Face it upward when removing. TILT ROD ASSY. CD EXPLODED DIAGRAM 7 -----0 20--0\ .. I!....-___.r 21 .... 19-':::1 o--14 13-@@--12 12 x 45 mm 85 Nm (8.5 m okg, 61 ft olb) Step Procedure/Part name 22 Inner cylinder end screw 23 0-ring 24 Backup ring 25 0-ring 26 Outer cylinder end screw 27 0-ring 28 Dust seal 29 Backup ring 30 0-ring 31 Tilt rod O'ty 1 1 1 1 1 1 1 1 1 1 27 30--__..:0--a / Service points Reverse the disassembly steps for installation. TILT ROD ASSVSERVICE POINTS .A WARNING • To prevent the PTT fluid from spurting out due to internal pressure, the outboard should be kept fully tilted up (the tilt rod at full length). • After removing the tilt motor or oil reservoir, do not push the tilt rod down. This may cause hydraulic fluid to spurt out from the port. Do not wipe hydraulic system components with rags, paper, tissues, etc., because their fibers may enter the hydraulic system and cause malfunctions. Tilt rod assy. and inner cylinder removal 1. Remove: • Outer cylinder end screw • Inner cylinder end screw Tilt cylinder wrench: VB-06175-28/90890-06544 Cylinder end screw inspection 1. Inspection: • Cylinder end screw • 0-ring • Backup ring • Dust seal Damage --7 Replace. TilT ROD ASSV. Tilt rod assy. and inner cylinder installation 1. Tighten: • Inner cylinder end screw • Outer cylinder end screw Tilt cylinder wrench: VB-06175-28/90890-06544 Tilt cylinder end screw: .... 80 Nm (8.0 m •kg, 58 ft •lb) Trim cylinder end screw: 90 Nm (9.0 m •kg, 65 ft •lb) PUMP HOUSING PUMP HOUSING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name O'ty PUMP HOUSING DISASSEMBL V PTT unit 1 Circlip 1 2 Manual valve screw 1 3 0-ring 1 4 Circlip 1 5 Spring 1 6 Plunger 1 7 Ball 1 Service points Follow the left "Step" for removal. Refer to "POWER TRIM AND TILT (PTT) UNIT". PUMP HOUSING EXPLODED DIAGRAM 13 16 22 24 9 10 11 12 13 14 18 .. 20 .. 21 Procedure/P Manual val art name 0 . ve seat -rmg End screw 0-ring Filter Relief valve 0-ring 0-ring Valve seat Spring Valve seat h . ousmg 1 1 Service p EXPLODED DIAGRAM PUMP HOUSING 21 22 23 24 25 26 Procedure/P 0-ring art name Filter 0-ring M .am valve assy 0-ring · 0-ring Shuttle piston 0-ring ..everse the di mstallation. sassembly steps for GEAR PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q'ty Service points GEAR PUMP REMOVAL Follow the left "Step" for removal. PTI motor Refer to "PTI MOTOR, PUMP HOUSING, AND TILT CYLINDER". 1 Joint 1 2 Bolt 3 3 Gear pump assy. 1 4 Filter 2 5 0-ring 2 6 0-ring 2 7 Spring 1 6x35 mm 6Nm (0.6m •kg, 4.3 ft •lb) 2 3 4 ..::-{j "'o J 1/l EXPLODED DIAGRAM 6 x 35 mm 6 Nm (0.6 m o kg, 4.3 ft olb) Step Procedure/Part name Q'ty Service points 8 Valve support pin 1 9 Valve seat 1 10 Relief valve seat 1 11 0-ring 1 12 Filter 1 13 Cap screw 1 14 Spring 1 15 Plunger 1 16 Ball 1 Reverse the removal steps for installation. PITMOTOR EXPLODED DIAGRAM 12 11 REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q'ty Service points PIT MOTOR DISASSEMBL V Follow the left "Step" for removal. 1 Screw 3 2 Yoke assy. 1 3 0-ring 1 4 Screw 1 5 Armature assy. 1 6 Screw 3 7 Brush 2 8 Spring 2 EXPLODED DIAGRAM 12 11 Step Procedure/Part name O'ty Service points 9 Circuit breaker assy. 1 10 Brush holder plate 1 11 Oil seal 1 12 PTT motor base 1 Reverse the disassembly steps for installation. SERVICE POINTS Motor inspection 1. Inspect: • Commutator Dirt .. Clean with 600 grit sandpaper. 2. Inspect: • Segment undercut Obstruction .. Clean. Remove all metal particles with compressed air. 3. Measure: • Armature coil continuity Out of specification .. Replace. .. Armature coil continuity Commutator segments Continuity Segment -laminations No continuity Segment -shaft No continuity 4. Inspect: • PTI motor base Cracks/damage .. Replace. 5. Inspect: • Stator bushing • PTI motor base bushing Cracks/damage .. Replace. 6. Inspect: • PTI motor base oil seal Damage/wear .. Replace. PTT motor assembly 1. Check: • PTI motor operation Incorrect operation .. Repair. .. PTT motor operation Blue (+), Green (-) Motor turns clockwise Green (+), Blue (-) Motor turns counterclockwise PIT UNIT SERVICE POINTS PTT fluid filling 1. Fill: • Reservoir Recommended PTT fluid: ATF Dexron II Fully extend the tilt rod when filling the reservoir with the fluid. 2. Install: • Reservoir plug .. Reservoir plug: .... 7.0 Nm (0.7 m •kg, 5.2 ft · lb) Air bleeding 1. Bleed: • PTT unit Bleeding steps: • Close the manual valve by turning it clockwise. • Set the PTT unit upright. • Connect the PTT motor leads to the battery. """"---.... '" ' ' tl't I ,\., ) l -r yi L(G) Tilt rod PTT motor lead Battery terminal Up Blue (±) Green 8 • Remove the reservoir plug and make sure the PTT fluid is up to the brim of the reservoir plug hole. If the PTT fluid is below the brim of the reservoir plug hole, add fluid until it is to the proper level. • Install the reservoir plug. • Connect the PTT motor leads to the battery. PTT motor Battery Tilt rod lead terminal Green (±) Down Blue 8 • Reverse the PTT motor leads between the battery terminals when the tilt rod fully extends and then reverse them again when it fully compresses. Repeat this procedure so the tilt rod goes up and down several times. • Check the fluid level again, add fluid if necessary, and then extend and compress the tilt rod several times as explained above. • Repeat these steps until the fluid remains at the proper level. 2. Check: • PTT unit operation Rough operation --7 Bleed. CHAPTER 8 ELECTRICAL SYSTEMS ELECTRICAL COMPONENTS ......................................................................... 8-1 (Starboard view) ...................................................................................... 8-1 (Port view) ................................................................................................ 8-2 (Front view) .............................................................................................. 8'-3 (Rear view) ............................................................................................... 8-4 WIRE HARNESS .............................................................................................. 8-5 ELECTRICAL ANALYSIS ................................................................................. 8-6 INSPECTION 8-6 ............................................................................................. Digital circuit tester ........................................................................... 8-6 Peak voltage measurement .............................................................. 8-6 Peak voltage adaptor ........................................................................ 8-6 Test harness ....................................................................................... 8-7 IGNITION SYSTEM ......................................................................................... 8-8 IGNITION SPARK GAP ............................................................................. 8-9 IGNITION SYSTEM PEAK VOLTAGE 8-10 .................................................... SPARK PLUGS ....................................................................................... 8-12 SPARK PLUG LEAD ASSY ..................................................................... 8-12 IGNITION CONTROL SYSTEM .................................................................... 8-13 PICK-UP COILS 8-14 ....................................................................................... ENGINE TEMPERATURE SENSOR ....................................................... 8-14 OIL PRESSURE SWITCH ........................................................................ 8-1 4 THROTTLE POSITION SENSOR (TPS) 8-15 .................................................. STARTING SYSTEM ..................................................................................... 8-16 BATTERY ................................................................................................ 8-17 FUSES 8-17 ..................................................................................................... WIRE HARNESS ..................................................................................... 8-17 WIRE CONNECTIONS 8-17 ............................................................................ STARTER RELAY .................................................................................... 8-17 STARTER MOTOR ........................................................................................ 8-18 EXPLODED DIAGRAM ........................................................................... 8-18 REMOVAL AND INSTALLATION CHART .............................................8-18 SERVICE POINTS ................................................................................... 8-22 Pinion gear removal 8-22 ........................................................................ Pinion gear inspection .................................................................... 8-22 Armature inspection ....................................................................... 8-22 Brush holder inspection .................................................................. 8-23 RELAY (MAGNETIC SWITCH) ............................................................... 8-24 CHARGING SYSTEM 8-25.................................................................................... CHARGING SYSTEM PEAK VOLTAGE 8-26 ................................................. FUSES 8-26 ..................................................................................................... BATTERY ................................................................................................ 8-26 ENRICHMENT CONTROL SYSTEM ............................................................. 8-27 BATTERY ................................................................................................ 8-28 FUSES 8-28 ..................................................................................................... LIGHTING COIL ...................................................................................... 8-28 RECTIFIER/REGULATOR ........................................................................ 8-28 ELECTROTHERMAL VALVE .................................................................. 8-28 POWER TRIM AND TILT (PTT) CONTROL SYSTEM .................................. 8-29 FUSES 8-30 ..................................................................................................... BATTERY ................................................................................................ 8-30 PTT MOTOR ........................................................................................... 8-30 PTT RELAYS 8-30 ........................................................................................... TRAILER SWITCH 8-31 ................................................................................... TRIM SENSOR ........................................................................................ 8-31 ELEC ElECTRICAlCOMPONENTS ELECTRICAL COMPONENTS (Starboard view) CD Ignition coils Br :Brown @ Starter motor G :Green @ Relay (magnetic switch) Gy :Gray @Fuse L :Blue ® Engine temperature sensor Lg : Light green Sb :Sky blue ELEC 0ELECTRICAL COMPONENTS (Port view) CD Throttle position sensor (TPS) ® Oil pressure switch @ Electrothermal valve ELEC ELECTRICALCOMPONENTS (Front view) CD CDI unit 8 :Black ® Rectifier/regulator 8r :Brown @ Starter relay G :Green @ PTT relays L :Blue Lg : Light green Sb :Sky blue 8/W : Black/White I ELEC ELECTRICALCOMPONENTS (Rear view) CD Spark plug ® Spark plug lead ELEC WIRE HARNESS WIRE HARNESS [9© .. C8) o0o00 00 000 @ @ (j)..IR @ a Connect to: CD Ground lead ® Throttle position sensor {TPS) @ CDI unit @ Rectifier/regulator ® Trailer switch ® Choke solenoid (j) Starter relay @ PTT relays ® Remote control @) Warning lamp @ Engine temperature sensor @ Oil pressure switch B :Black Br :Brown Lg0 : Light green :Orange P :Pink R :Red Sb :Sky blue Y :Yellow P/W : Pink/White ELEc ELECTRICAL ANALvs•sELECTRICALANALVSIS INSPECTION Digital circuit tester Throughout this chapter the digital circuit tester's part number has been omitted. Refer to the following part number. Digital circuit tester: J-39299/90890-06752 " 0---0 " indicates a continuity of electricity; i.e., a closed circuit at the respective switch position. Peak voltage measurement • When checking the condition of the ignition system it is vital to know the peak voltage. • Cranking speed is dependant on many factors (e.g., fouled or weak spark plugs, a weak battery). If one of these is defected, the peak voltage will be lower than specification. elf the peak voltage measurement is not within specification the engine will not operate properly. • A low peak voltage will also cause components to prematurely wear . Peak voltage adaptor • Throughout this chapter the peak voltage adaptor's part number has been omitted. Refer to the following part number. • The peak voltage adaptor should be used with the digital circuit tester. Peak voltage adaptor: VU-39991/90890-03169 I ELEC 0ELECTRICALANALYSIS 1 2 3 • When measuring the peak voltage, connect the peak voltage adaptor to the digital tester and switch the selector to the • Make sure that the positive pin (the "+" mark facing up as shown) on the adaptor is installed into the positive terminal of the tester. • The test harness is needed for the following tests. DC voltage mode. • Make sure that the properly installed tester. in adaptor the digital leads cirare cuit .. Voltage measurement [§] Peak voltage measurement Test harness YB90890Pin Usage 1 06443 06757 3 Throttle position sensor (TPS) 2 38832 06772 6 Pick-up coil 3 06770 06770 3 Charge coil Checking steps: • Disconnect the coupler connections. • Connect the test harness between the couplers. • Connect the tester terminals to the terminals which are being checked. • Run the engine and observe the measurement. ELEC IGNITION SYSTEM IGNITION SYSTEM @ @ CD ITJ ;;- (j)@] p 0 p 0 w R w B CD Spark plugs ® Ignition coils @ Throttle position sensor (TPS) @ Pick-up coils ® 1 OP coupler ® CDI unit (J) Lighting coil @ Rectifier/regulator ® Battery @) Fuse (30A) B/W :Black/White W/B :White/Black W/R :White/Red B :Black 0 :Orange R :Red W :White B/0 : Black/Orange ELEC IGNITION SYSTEM IGNITION SPARK GAP A WARNING • When checking the spark gap, do not touch any of the connections of the spark gap tester lead wires. • When performing the spark gap test, take special care not to let sparks leak out of the removed spark plug cap. • When performing the spark gap check, keep flammable gas or liquids away, since this test can produce sparks. 1. Check: • Ignition spark gap Below specification ---7 Continue to check the CDI unit output. Spark gap: 11 mm (0.4 in) Checking steps: • Remove the spark plugs from the engine. • Connect the spark plug cap to the spark gap tester. • Set the spark gap length on the adjusting knob. r Spark gap tester: VM-34487/90890-06754 • Crank the engine and observe the ignition system spark through the discharge window. [A] For USA and CANADA ill] For worldwide ELEC []IGNITION SYSTEM CC>IGNITION SYSTEM PEAK VOLTAGE A WARNING When checking the CDI unit do not touch any of the connections of the digital tester lead wires. • If there is no spark, or the spark is weak, continue with the ignition system test. elf a good spark is obtained, the problem is not with the ignition system, but possibly with the spark plug(-s) or another component. 1. Measure: • CDI unit output peak voltage Above specification .. Replace the ignition coil. Below specification .. Measure the lighting coil output peak voltage. Repeat this check two times. CDI unit output peak voltage: Black/White (B/W) -Black (B): Black/Orange (B/0) -Black (B): 107 Vat 400 r/min (cranking) 110 Vat 1,500 r/min 111 Vat 3,500 r/min 8/W -8 for cylinders #2 and #3. 8/0 -8 for cylinders #1 and #4. ELEC 0 SYSTEM 2. Measure: • Lighting coil output peak voltage Below specification .. Replace the lighting coil. Above specification .. Measure the CDI unit output peak voltage. Lighting coil output peak voltage: White (W) -White (W): 7.1 Vat 400 r/min (cranking) 15 Vat 1,500 r/min 18 Vat 3,500 r/min 3. Measure: • Pick-up coil output peak voltage Above specification .. Replace the CDI unit. Below specification .. Replace the pick-up coil. Pick-up coil output peak voltage: White/Red (W/R) -Black (B): White/Black (W /B) -Black (B): 4.5 Vat 400 r/min (cranking) 10 Vat 1,500 r/min 16 V at 3,500 r/min ELEC SYSTEM CD 4. Measure: • Rectifier output peak voltage Excessively below specification -7 Check the lighting coil output peak voltage. Rectifier output peak voltage: Red (R) -Black (B) 14 Vat 1,500 r/min 18 V at 3,500 r/min SPARK PLUGS Refer to "GENERAL" in chapter 3. SPARK PLUG LEAD ASSV. 1. Inspect: • Spark plug cap • Spark plug lead Cracks/damage -7 Replace. 2. Measure: • Spark plug lead assy. resistance Out of specification -7 Replace. Spark plug lead assy. resistance: #1 : 4.5 -10.7 kQ #2: 3.3 -8.0 kO #3: 3.7 -8.9 kQ #4: 4.3 -10.2 kQ Remove the spark plug lead assy. from the ignition coil. ELEC 0IGNITIONCONTROLSYSTEMIGNITION CONTROL SYSTEM CD B P/W B/Y @ CD CDI unit B :Black ® Engine temperature sensor 0 :Orange @ Oil pressure switch P : Pink @ Pick-up coils W :White ® Throttle position sensor (TPS) B!Y : Black/Yellow ® Lighting coil P/W : Pink/White (J) Rectifier/regulator W/B :White/Black @ Battery W/R :White/Red ® Fuse (30A) ELEC 0IGNITION CONTROL SYSTEM PICK-UP COILS Refer to "IGNITION SYSTEM". ENGINE TEMPERATURE SENSOR 1. Measure: • Output voltage (at the specified temperature) Out of specification ---) Replace. Engine temperature sensor resistance: -2o ·c (-4 "F): 15.5 k.Qo ·c (32 "F): 5.79 k.Q20 ·c (68 "F): 2.45 kn 40 ·c (104 "F): 1.5o k.Q OIL PRESSURE SWITCH 1. Measure: • Oil pressure switch continuity Out of specification ---) Replace. r Mity Vac: VB-35956/90890-06756 Oil pressure switch continuity pressure: 15 kPa (0.15 kg/cm2, 2.13 psi) and below ELEC IGNITIONCONTROlSYSTEM CD THROTTLE POSITION SENSOR (TPS) 1. Check: • TPS input voltage (at idling speed) Out of specification -7 Check the CDI unit. TPS input voltage (R -0): 5 ± 0.25 v 2. Check: • TPS output voltage (at idle speed) Out of specification -7 Adjust the TPS position. Output voltage (P -0): 0.7 ± 0.02 v Checking steps: • Connect the test harness. • Connect the tester leads to the test harness (P -0). • Start the engine, allow it to warm up for several minutes. • Measure the voltage at engine idling speed. • While slowly opening and closing the throttle valves, check if the voltage changes gradually. Set the digital tester to the manual range. In the auto range the voltage changes cannot be accurately measured. 3. Adjust: • TPS position Adjustment steps: • Start the engine at idling speed. • Move the throttle control lever until it contacts the fully-closed stopper. Refer to "Carburetor pickup timing check and adjustment" in chapter 3. • Loosen the screws. • Adjust the position of the TPS until the specified voltage is obtained. • Tighten the bolts. ELECSTARTING SYSTEM CD Fuse ® 1 OP coupler Br B R B :Black Br :Brown R Br @ Starter relay R :Red G) Battery ® Relay (magnetic switch) ® Starter motor ELEC 0STARTINGSYSTEM BATTERY Refer to "GENERAL" in chapter 3. FUSES 1. Check: • Fuse continuity No continuity ----7 Replace. • Fuse rating Out of specification ----7 Replace. Fuse rating: 20 A (main fuse) 30 A (starter fuse) WIRE HARNESS 1. Check: • Wire harness continuity No continuity ----7 Replace. WIRE CONNECTIONS 1. Check: • Wire connections Poor connections ----7 Properly connect. STARTER RELAY 1. Check: • Starter relay Faulty ----7 Replace. Checking steps: • Connect the tester leads between the starter relay terminals as shown. • Connect the brown lead terminal to the positive battery terminal. • Connect the black lead terminal to the negative battery terminal. • Check that there is continuity between the starter relay terminals. • Check that there is no continuity after the brown or black lead is removed. ELEc sTARTER MOTOR STARTER MOTOR EXPLODED DIAGRAM 17 11 14 12 32g l 4x20mm .... ;N 2931422..23.. 24 REMOVAL AND INSTALLATION CHART Step Procedure/Part name O'ty Service points STARTER MOTOR Follow the left "Step" for removal. DISASSEMBLY Starter motor Refer to "IGNITION COILS AND STARTER MOTOR" in chapter 5. 1 Nut 1 2 Bolt 2 3 Spring 1 4 Screw 1 5 Dust seal 1 6 Dust seal cover 1 sTARTER MOTOR CD EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 15 1"-18.. 17 11 14 12 6x 120 mm Procedure/Part name Dust seal Relay (magnetic switch) Bolt Screw Yoke assy. Rear cover Thrust washer Plate Brush holder assy. 7.. <.>--21 O'ty Service points 1 1 2 2 1 1 1 1 1 ELEC STARTER MOTOR EXPLODED DIAGRAM Step 16 17 18 19 20 21 22 23 24 ..-18.. 17 11 • 15 14 12 Procedure/Part name Brush assy. Armature Center bracket plate Outer ring gear Planetary gear Pinion shaft E-ring Thrust washer Center bracket · " --21 8 Q'ty Service points 1 1 1 1 3 1 1 1 1 ELEC STARTER MOTOR EXPLODED DIAGRAM Step 25 26 27 28 29 30 31 32 1"-18.. 17 11 15 14 12 6 x 120 mm Procedure/Part name Pinion gear clip Pinion gear stopper Pinion gear Spring Clutch assy. Bearing Shift lever Housing 7.. <.> --21 O'ty Service points 1 1 1 1 1 1 1 1 Reverse the disassembly steps for installation. ELEC STARTER MOTOR SERVICE POINTS Pinion gear removal 1. Remove: • Pinion gear clip G) Remove the clip with a thin screwdriver. Pinion gear inspection 1. Inspect: • Pinion gear teeth Damage/wear .. Replace the pinion gear. 2. Check: • Clutch assy. movement Incorrect .. Replace. Rotate the pinon gear clockwise to check that it moves freely. Also, rotate the pinion gear counterclockwise to make sure that it locks. Armature inspection 1. Inspect: • Commutator Dirt .. Clean with 600 grit sandpaper. 2. Measure: • Commutator diameter Out of specification .. Replace. Commutator diameter limit: 28.0 mm (1.10 in) ELEC 0STARTER MOTOR 3. Measure: • Commutator undercut ® Out of specification .. Replace. Commutator undercut limit: 0.2 mm (0.01 in) 8-23 4. Check: • Armature coil continuity Out of specification .. Replace. .. Armature coil continuity: Commutator segments Continuity Segment -Armature core Discontinuity Segment -Armature shaft Discontinuity Brush holder inspection 1. Measure: • Brush length @ Out of specification .. Replace. Brush length limit: 9.5 mm (0.37 in) 2. Check: • Brush holder continuity Out of specification .. Replace. Brush holder continuity: Brush CD -Brush ® Discontinuity RELA V (MAGNETIC SWITCH) 1. Check: • Relay (magnetic switch) condition No continuity .. Replace. Checking steps: • Connect the tester leads between the relay (magnetic switch) terminals as shown. • Connect the starter motor body to the negative battery terminal. • Connect the Black/white (8/W) lead to the positive battery terminal. • Check that there is continuity between the relay (magnetic switch) terminals. • Check that there is no continuity after the B/W lead is removed. The pinion gear should be pushed out while the magnet switch is ON. CHARGING SYSTEM G/W CD CD Lighting coil B :Black ® Rectifier/regulator G :Green @Fuse R :Red @ Battery W :White G/W :Green/White ELEC CHARGING SYSTEM CD CHARGING SYSTEM PEAK VOLTAGE 1. Measure: • Lighting coil output peak voltage • Rectifier output peak voltage Referto "IGNITION SYSTEM". FUSES Refer to "STARTING SYSTEM". BATTERY Refer to "GENERAL" in chapter 3. ELEC ENRICHMENTCONTROLSYSTEM ENRICHMENT CONTROL SYSTEM ® ® .. B/YG/W B G/W B R R B ;-© LL L B 30..A) .. R G/W w w w CD G G (j) ® B/Y B CD Lighting coil ® Rectifier/regulator @Fuse @) Battery @ CDI unit ® Electrothermal valve (j) 10P coupler @ Engine temperature sensor B G L R W G/W BN :Black :Green :Blue :Red :White :Green/White : BlackNellow ELEC ENRICHMENT CONTROL SYSTEM BATTERY Refer to "GENERAL" in chapter 3. FUSES Refer to "STARTING SYSTEM". LIGHTING COIL Refer to "IGNITION SYSTEM". RECTIFIER/REGULATOR Refer to "IGNITION SYSTEM". ELECTROTHERMAL VALVE 1. Check: • Electrothermal valve operation Faulty .. Replace. Checking steps: • Connect a 12-V battery to the electrothermal valve. • Check that the plunger pushes out from the holder. L G L Lg G Sb o Sb g R 8 8 @ UP FREE Sb @ R000Sb Lg0Gy 8 0 @ p Gy POWERTRIMAND TILT (PTTJCONTROL SYSTEM CD POWERTRIM AND TILT (PTT) CONTROL SYSTEM CD PTI motor B :Black ® PTI relays G :Green @ Trailer switch @ 1 OP coupler Gy L :Gray :Blue ® Fuses (20A, 30A) ® Battery Lg0 : Light green :Orange (j) Trim sensor P :Pink @ 4P coupler R :Red Sb :Sky blue ELEC POWERTRIMANDTILT(PTT)CONTROLSYSTEM CD FUSES Refer to "STARTING SYSTEM". BATTERY Refer to "GENERAL" in chapter 3. PTT MOTOR Refer to "POWER TRIM AND TILT (PTT) UNIT" in chapter 7. PTT RELAYS 1. Check: • PTT relay condition Incorrect -----7 Replace. Checking steps: • Connect the tester leads between the PTT relay terminals as shown. • Connect the Black (B) lead to the negative battery terminal. • Connect the Sky blue (Sb) or Light green (Lg) lead on each relay to the positive battery terminal. • Check that there is continuity between the PTT relay terminals. • Check that there is no continuity after the (Sb)/(Lg) lead is removed. ELEC []POWER TRIMAND TILT (PTT) CONTROL SYSTEM CD TRAILER SWITCH 1. Check: • Trailer switch continuity Out of specification .. Replace. .. Switch position Lead color Sky blue (Sb) Red (R) Light green (Lg) Up Free Down TRIM SENSOR 1. Measure: • Trim sensor resistance Out of specification .. Replace. Trim sensor resistance: Pink (P) -Black (B) 582 -873 Q at 20 OC (68 OF) Orange (0) -Black (B) 800 -1,200 Qat 20 OC (68 OF) Turn the trim sensor lever and measure the resistance as it gradually changes. ? CHAPTER 9 TROUBLE ANAL VSIS TROUBLE ANALYSIS ..................................................................................... 9-1 TROUBLE ANALYSIS CHART ................................................................. 9-1 TROUBLEANALVSIS CDTROUBLEANALVSIS The following items should be checked before the "Trouble analysis" chart is consulted. 1. The battery is properly charged and its specified gravity is within specification. 2. The battery terminals. 3. There are no incorrect wiring connections. 4. Wiring connections are properly secured and are not rusty. 5. The lockplate is attached to the engine stop lanyard switch. 6. The shift position is in neutral. 7. Fuel is reaching the carburetor(s). 8. All fluids are at the specified levels. 9. The rigging and engine settings are correct. 10.The engine is free from any "Hull problem". TROUBLE ANALVSIS CHART Trouble mode w.. za: 0w t= t9a... t9 _J .. uCJ) .. z _J _Jz CJ) 0 .. t9 z >-t9 _J a: CJ) t9 a: z 0:: a:_J z _J z I a: .. a: CJ) CJ) 0 C!J a:t9 ::::> t9 0 w 0 0 .. a: w 0z 0 z 0 0 > 0 0 <( 0:: 0 w a: w a... _J 0 _J _J a... I !:!:: a... 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Check elements Relative part FUEL SYSTEM Fuel hose Fuel joint Fuel filter Fuel pump Carburetors POWER UNIT Spark plug(s) Piston(s) and piston ring(s) Valve(s) and valve seat(s) Valve clearance adjusting shim(s) Camshaft(s) Timing belt Oil pump Oil filter Oil pressure switch Engine temperature sensor Thermostat Reference Chapter 4 4 4 4 4 3 5 4 3 5 4 6 3 8 8 5 TROUBlE ANAl VSIS CD Trouble mode Check elements w<( za: 0w .. (!)I-a_ za: 0 (!)<( w I-a:I-u (!) 0 .. <(CJ) z w z zI-a: B t.!J I Reference 0 <( :::> (!) _I z u Relative part CJ) 2 CJ) z _I _I (!) >-Chapter z (!) _I 0 .. z z _I a: CJ) (!) a: I z a: a:_I <( 0 w z w i= -a: :?; a: CJ) CJ) 0 t.!J a:(!) :::> (!) 0 w 0 0 .. a: w 0z 0 z 0 0 > 0 0 <( a: 0 w a: w a_ _I 0 _I _I a_ I !E a_ 0 0 0 0 Cylinder head 5 0 0 0 0 Cylinder body 5 LOWER UNIT 0 Shift rod and lever 6 0 0 Clutch 6 0 0 Reduction gear(s) 6 0 Sliding shifter 6 0 Water pump 6 0 0 Lower case 6 0 Propeller 6 BRACKET UNIT 0 Swivel bracket 7 0 Mounting rubber(s) 7 PTT unit 0 Main valve 7 0 Relief valve(s) 7 0 Absorber valve(s) 7 0 Manual valve 7 0 Gear pump unit 7 0 Cylinder and pump housing 7 0 PTT relay 8 0 PTT motor 7 ELECTRICAL 0 0 0 Ignition coil(s) 8 Starter motor 0 8 Electrothermal valve 0 8 0 0 0 0 CDI unit 0 0 Lighting coil 8 0 Rectifier/regulator 8 0 Starter relay 8 0 Fuse 8 YAMAHA YAMAHA MOTOR CO., LTD. Printed in USA Aug. 1998 x 1.5 CR 1861 6-01-96 IF1 00X) Marine Outboards F80X, F1 00X SUPPLEMENTARY SERVICE MANUAL II 11 1111 LIT-1 861 6-01 -96 67F-281 97 -ZB-1 X PREFACE This Supplementary Service Manual has been prepared to introduce the modification and additional information for the F80X, F100X. For complete service information and procedures, it is necessary to add the following manual with the corresponding sections in this Supplementary Service Manual. F100X SERVICE MANUAL: LIT-18616-01-96 A1 0001-0* F80X, F100X SUPPLEMENTARY SERVICE MANUAL ©1999 Yamaha Motor Co., Ltd. 1st Edition, January 1999 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means including photocopying and recording without the written permission of the copyright holder. Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature. Printed in USA LIT -18616-01 -96 HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/scratches -7 Replace. To assist you in finding your way through this manual, the section title and major heading is given at the top of every page. ILLUSTRATIONS The illustrations within this service manual represent all of the designated models. CROSS REFERENCES The cross references have been kept to a minimum. Cross references will direct you to the appropriate section or chapter. IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. ffi The Safety Alert Symbol means ATIENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! A WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. A NOTE provides key information to make procedures easier or clearer. HOW TO USE THIS MANUAL CD To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. ® Numbers are given in the order of the jobs in the exploded diagram. @ Symbols indicate parts to be lubricated or replaced (see "SYMBOLS"). G) A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. Example: 0-ring size 39.5 x 2.5 mm: Inside diameter (D) x Ring diameter (d) d ® Dimension figures and the number of parts, are provided for fasteners that require a tight ening torque. Example: Bolt or screw size x 25 mm M10 (D) x 25 mm (l) ..L-----1 ® Jobs requiring more information (such as special tools and technical data) are described sequentially. *' loweR uNIT lOWER UNIT EXPLODED DIAGRAM Procedure/Part name a·ry ServiCe po•nts LOWER UNIT REMOVAL Follow the lefC •step" lor removal Coner p1!'1 ..Propeller IIIII Spacer Propeller Coll1r locknut Adjust•ng nut LDwer un•t Dow.lp•n Reverse th41 removal steps for •nstallat•on *' PROPEUER SHAFT Assv. SERVICE POINTS Propelw """" auy. removal lwtth U.. pi"Dppler tMft ho'*Sing ...1 l. Re-rnow.: •Propellershaftnsv (wilt! tiW pr(lpelllrf shaft housing IU'f.) YB-GI62'l4 Apply LOCTITE® No. 572 @ Apply silicon sealant GENERAL INFORMATION IDENTIFICATION ............................................................................................... 1 SERIAL NUMBER 1 ........................................................................................ STARTING SERIAL NUMBERS .................................................................. 1 SPECIFICATIONS GENERAL SPECIFICATIONS ............................................................................. 2 MAINTENANCE SPECIFICATIONS ................................................................... 4 ENGINE ........................................................................................................ 4 LOWER......................................................................................................... 7 ELECTRICAL ................................................................................................ 8 DIMENSIONS ................................................................................................... 10 TIGHTENING TORQUES 11 ................................................................................. BRACKET UNIT STEERING HANDLE (OPTION) ....................................................................... 13 EXPLODED DIAGRAM .............................................................................. 13 REMOVAL AND INSTALLATION CHART 13 ................................................ ELECTRICAL SYSTEMS IGNITION SYSTEM .......................................................................................... 24 ENGINE STOP SWITCH (OPTION) 25 ........................................................... STARTING SYSTEM ........................................................................................ 26 NEUTRAL SWITCH (OPTION) .................................................................. 27 APPENDIX FUEL PUMPS 4-3 .................................................................................................. EXPLODED DIAGRAM ............................................................................. 4-3 REMOVAL AND INSTALLATION CHART 4-3 ............................................... STATOR COIL ASSEMBLY ............................................................................ 5-9 EXPLODED DIAGRAM ............................................................................. 5-9 REMOVAL AND INSTALLATION CHART 5-9 ............................................... VALVES......................................................................................................... 5-29 Valve seat inspection ...................................................................... 5-29 WIRING DIAGRAM GEN IDENTIFICATION INFO A60000-1* IDENTIFICATION SERIAL NUMBER The outboard motor's serial number is stamped on a label which is attached to the port side of the clamp bracket. If the serial number label is removed, "VOID" marks will be appear on the label. G) Model name ® Approval model code @ Transom height @ Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as follows: Model name Worldwide USA/ CANADA Approval model code Starting serial number F80AET F80TR 67G l: 300101 -X: 700101 - F1 00AET F1 00TR 67F l: 300101 -X: 700101 - tJ"II' GENERALsPECIFicATioNs GENERAL SPECIFICATIONS Item Unit F80 Model F100 DIMENSION Overall length mm (in) 817 (32.2) Overall width mm (in) 479 (18.9) Overall height (L) mm (in) 1,582 (62.3) (X) mm (in) 1,710 (67.3) WEIGHT (L) kg (lb) 166 (366) (X) kg (lb) 169 (373) PERFORMANCE Maximum output (ISO) kW (hp) @ 58.8 (80) 73.6 (100) 5,500 r/min Full throttle operating range r/min 5,000 -6,000 Maximum fuel consumption L (US gal, Imp gal)/hr @ 6,000 r/min 27 (7.13, 5.94) 31 (8.19, 6.82) POWER UNIT Type In-line, 4 stroke, DOHC, 16 valves Number of cylinders 4 Displacement cm3 (cu. in) 1,596 (97 .39) Bore x stroke mm (in) 79.0 X 81.4 (3.11 X 3.20) Compression ratio 9.6:1 Minimum compression kPa (kgf/cm2, psi) 950 (9.5, 135) pressure Number of carburetors 4 Control system Remote control Starting system Electric motor Ignition control system CDI (Microcomputer) Lighting coil Stator Lighting coil output V-A@ 1,000 r/min 12 -12 V-A@ 6,000 r/min 12 -20 Starting enrichment PrimeStart Spark plug model LFR5A-1 1 (NGK) X 4 (manufacturer) x quantity Spark plug gap mm (in) 1.1 (0.043) Exhaust system Propeller boss Lubrication system Wet sump Lubrication oil pressure at 65 OC ( 149 "F), with kPa (kgf/cm2, psi) 320 (3.2, 45.5) 10W-30 engine oil @ 850 r/min CD Model Item Unit F80 F100 FUEL AND OIL Fuel type Unleaded regular gasoline Fuel rating PON * 86 RON * 91 Engine oil type 4-stroke motor oil Engine oil grade API SE, SF, SG, SH SAE 10W-30, 10W-40 Total quantity With oil filter cm3 (US oz, Imp oz) 4,700 (159, 165) Without oil filter cm3 (US oz, Imp oz) 4,500 ( 152, 158) Gear oil type Hypoid gear oil Gear oil grade API GL-4 SAE 90 Total quantity cm3 (US oz, Imp oz) 670 (22.6, 23.6) BRACKET Trim angle Tilt-up angle Steering angle DRIVE UNIT Gear positions Gear ratio Gear type Propeller direction (rear view) Propeller drive system Propeller mark -4-16 Degree 70 Degree 35 + 35 F-N-R 2.31 (30:13) Spiral bevel gear Clockwise Spline K ELECTRICAL Battery capacity Ah (kC) 70 -100 (252 -360) Minimum cold-cranking A 380 performance * PON: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2 RON: Research Octane Number MAINTENANcEsPEciFicATioNsMAINTENANCESPECIFICATIONS ENGINE Item CYLINDER HEAD Warpage limit Camshaft journal inside diameter Valve lifter hole inside diameter CYLINDERS Bore Standard Taper limit Out-of-round limit Unit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) CAMSHAFTS Intake (A) Exhaust (A) QA Intake and exhaust (B) Valve lift 8 mm (in) mm (in) mm (in) Intake Exhaust Camshaft journal diameter Camshaft journal oil clearance Maximum camshaft runout VALVES Face angle Intake Exhaust Valve clearance (cold) Intake Exhaust Head diameter (A) Intake Exhaust Face width (B) Intake Exhaust Seat width (C) Intake Exhaust Margin thickness (D) Intake Exhaust mm (in) mm (in) mm (in) mm (in) mm (in) Degree Degree mm (in) mm (in) bz mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) Model F80 F100 0.1 (0.004) 25.000 -25.021 (0.984 -0.985) 28.000 -28.021 (1.102 -1.103) 79.000 -79.020 (3.1 10 -3.1 11) 0.08 (0.003) 0.08 (0.003) 37.22 -37.38 (1 .465 -1.472) 36.90 -37.06 (1.453 -1.459) 29.92 -30.08 (1.178 -1.184) 6.94 (0.273) 6.58 (0.259) 24.96 -24.98 (0.9827 -0.9835) 0.020 -0.061 (0.0008 -0.0024) 0.1 (0.004) 120, 91, 110 140, 91, 110 0.20 ± 0.03 (0.008 ± 0.001) 0.34 ± 0.03 (0.013 ± 0.001 ) 29.00 -29.20 (1.142 -1.150) 24.00 -24.20 (0.945 -0.953) 2.00 -2.43 (0.079 -0.096) 2.28 -2.71 (0.090 -0.107) 1.58 -1.94 (0.062 -0.076) 1.80 -2.02 (0.071 -0.080) 0.45 -0.65 (0.018 -0.026) 0.65 -0.85 (0.026 -0.033) MAINTENANCESPECIFICATIONS CD Model Item Unit F80 F100 Stem diameter Intake Exhaust Guide inside diameter Intake and exhaust Stem-to-guide clearance Intake Exhaust Stem runout limit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) 5.975 -5.990 (0.2352 -0.2358) 5.960 -5.975 (0.2346 -0.2352) 6.005 -6.018 (0.2364 -0.2369) 0.015 -0.043 (0.0006 -0.0017) 0.030 -0.058 (0.0012 -0.0023) 0.03 (0.001) VALVE SPRINGS Free length mm (in) 53.20 (2.094) Minimum free length mm (in) 52.25 (2.057) Tilt limit mm (in) 2.6 (0.10) VALVE LIFTERS Valve lifter outside diameter mm (in) 27.965-27.980 (1.1010-1.1016) Valve-lifter-to-cylinder-head mm (in) 0.020 -0.056 (0.0008 -0.0022) clearance VALVE PADS Valve pad thickness mm (in) 2.000 -3.300 (0.0787 -0.1299) (in 0.025 mm increments) PISTONS Piston-to-cylinder clearance mm (in) Measuring point (D) mm (in) m Measuring point (H) mm (in) Pin boss inside o mm (in) diameter Oversize piston diameter mm (in) 0.070 -0.080 (0.0028 -0.0031) 78.928 -78.949 (3.1 07 4 -3.1 082) 13 (0.51) 18.008 -18.015 (0.7090 -0.7093) 79.25 (3.120) PISTON PINS Outside diameter mm (in) 17.997 -18.000 (0.7085 -0.7087) PISTON RINGS Top ring Dimension B mm (in) 1.17 -1.19 (0.046 -0.04 7) Dimension T mm (in) 2.89 -2.91 (0.114 -0.1 15) End gap mm (in) 0.15 -0.30 (0.006 -0.012) Side clearance mm (in) 0.02 -0.08 (0.001 -0.003) 2nd ring Dimension B mm (in) 1.47 -1.49 (0.058 -0.059) Dimension T mm (in) 3.00 -3.20 (0.1 18 -0.126) End gap mm (in) 0.70 -0.90 (0.028 -0.035) Side clearance mm (in) 0.03 -0.07 (0.001 -0.003) Oil ring Dimension B ..Jsmm (in) 2.38 -2.48 (0.094 -0.098) Dimension T mm (in) 2.40 (0.094) End gap mm (in) 0.20 -0. 70 (0.008 -0.028) Side clearance mm (in) 0.03 -0.15 (0.001 -0.006) sPEc MAINTENANcEsPECIFICATioNs CD Model Item Unit F80 F100 CONNECTING RODS Small-end inside diameter mm (in) 17.965 -17.985 (0.7073 -0.7081) Big-end inside diameter mm (in) 47.025 -47.035 (1.8514 -1.8518) Big-end oil clearance mm (in) 0.023 -0.035 (0.0009 -0.0014) Big-end bearing thickness Yellow mm (in) 1.499 -1.506 (0.0590 -0.0593) Green mm (in) 1.506 -1.513 (0.0593 -0.0596) Blue mm (in) 1.513 -1.520 (0.0596 -0.0598) Red mm (in) 1.520 -1.527 (0.0598 -0.0601 ) CRANKSHAFT Crankshaft journal Diameter mm (in) 47.985 -48.000 (1 .8892 -1.8898) Minimum diameter mm (in) 47.972 ( 1.8887) Crankshaft pin Diameter mm (in) 43.982 -44.000 (1.7316 -1.7323) Minimum diameter mm (in) 43.971 ( 1.731 1) Runout limit mm (in) 0.03 (0.001 ) CRANKCASE Crankcase main journal inside diameter Crankshaft journal oil clearance Upper crankcase main journal bearing thickness Green Blue Red Lower crankcase main journal bearing thickness Yellow Green Blue Red No. 3 main journal bearing thickness Green Blue Red mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) 54.023 -54.042 (2.1269 -2.1276) 0.024 -0.044 (0.0009 -0.0017) 2.992 -2.999 (0.1178 -0.1181) 2.999 -3.006 (0.1181 -0.1183) 3.006 -3.013 (0.1183 -0.1186) 3.010-3.017 (0.1185-0.1188) 3.017 -3.024 (0.1188 -0.1191) 3.024 -3.031 (0.1191 -0.1193) 3.031 -3.038 (0.1193-0.1196) 2.992 -2.999 (0.1178 -0.1181) 2.999 -3.006 (0.1181 -0.1183) 3.006 -3.013 (0.1183 -0.1186) THERMOSTAT Valve opening temperature oc rF) 60 (140) Full-open temperature oc rF) 70 (158) Minimum valve lift mm (in) 3.0 (0.12) MAINTENANcEsPECIFICATIONs Item Unit Model F80 F100 FUEL PUMP Discharge L (US gal, Imp gal)/ hr @ 3,000 r/min 65 (17.16, 14.3) Maximum pressure kPa (kgf/cm2, psi) 49 (0.49, 6.97) Plunger stroke mm (in) 5.85 -9.05 (0.23 -0.36) OIL PUMP Discharge at 100 ·c (212 ·F), with 10W-30 engine oil L (US gal, Imp gal) /min @ 1,000 r/min 5.9 (1.56, 1.30) Pressure kPa (kgf/cm2, psi) 118 (1.18, 16.78) Relief valve opening pressure kPa (kgf/cm2, psi) 490 (4.90, 69.69) CARBURETOR ID mark Worldwide, CANADA 67GOO 67FOO USA 67G10 67F10 Main jet # 112 128 Main air jet # 115 75 Pilot jet # Pilot air jet # 85 - Mid-range jet # Pilot screw Turns out 2-1/2 ± 1/2 2 ± 1/2 Float height mm (in) 14 (0.55) Engine idling speed r/min 850 -950 PTT UNIT Fluid type A TF, Dexron II Relief pressure Up operation MPa (kgf/cm2, psi) 18.0 (180, 2,560) Down operation MPa (kgf/cm2, psi) 2.0 (20, 284) Trim piston relief valve opening MPa (kgf/cm2, psi) 9.5 (95, 1,351) pressure Tilt piston relief valve opening MPa (kgf/cm2, psi) 31 .0 (310, 4,409) pressure Ram stroke Trim operation mm (in) 45 (1 .77) Tilt operation mm (in) 110 (4.33) LOWER Item Unit Model F80 F100 GEAR BACKLASH Forward gear Adjusting shim thickness mm (in) mm 0.13 -0.46 (0.005 -0.018) 0.1 0, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 MAINTENANcEsPECIFICATioNs CD ELECTRICAL Model Item Unit F80 F100 IGNITION SYSTEM Ignition firing order Cylinders #1 .. #3 .. #4 .. #2 Ignition timing Degree 5° ATDC -25° BTDC Lighting coil output peak voltage (W -W) at 400 r/min (cranking) v 7.1 at 1,500 r/min v 15 at 3,500 r/min v 18 Lighting coil resistance (W -W) n@20 oc (68 OF) 0.32 -0.48 Pick-up coil output peak voltage (W/B-B, W/R-B) at 400 r/min (cranking) v at 1,500 r/min v 10 at 3,500 r/min v 16 Pick-up coil resistance n@20 oc (68 OF) 445 -545 (W/B-B, W/R -B) COl unit output peak voltage (B/W-B, B/0-B) at 400 r/min (cranking) v 107 at 1,500 r/min v 110 at 3,500 r/min v 111 Spark plug lead assy. resistance Cylinder #1 lead kQ@20 oc (68 OF) 4.5 -10.7 Cylinder #2 lead kQ@20 oc (68 OF) 3.3 -8.0 Cylinder #3 lead kQ@20 oc (68 OF) 3.7 -8.9 Cylinder #4 lead kQ@20 oc (68 OF) 4.3 -10.2 Ignition coil resistance Primary n @ 20 oc (68 OF) 0.078 -0.106 Secondary kQ@20 oc (68 OF) 3.5 -4.7 IGNITION CONTROL SYSTEM Oil pressure switch (on/off) kPa (kg/cm2, psi) 15 (0.1 5, 2.13) Engine temperature sensor resistance at -20 OC ( -4 OF) kQ 15.5 at 0 OC (32 OF) kQ 5.79 at 20 OC (68 OF) kQ 2.45 at 40 OC (104 OF) kQ 1.50 at 60 OC (140 OF) kQ 0.59 CHARGING SYSTEM Rectifier/regulator output peak voltage (R -B) at 1,500 r/min v 14 at 3,500 r/min v 18 -8 sPEc MAINTENANcEsPECIFICATIONs CD Model Item Unit F80 F100 ENRICHMENT CONTROL SYSTEM Electrothermal valve heater Q at 20 OC (68 OF) 20 resistance STARTER MOTOR Type Sliding gear Model (manufacturer) 51 14-828 (HITACHI) Weight kg (lb) 3.5 (7.7) Output kW -V 1.4-12 Rating Second 30 Reduction gear ratio 7.85 (102:13) Brush Length mm (in) 15.5 (0.61) Minimum length mm (in) 9.5 (0.37) Commutator Diameter mm (in) 29.0 (1.14) Minimum diameter mm (in) 28.0 (1.10) Undercut mm (in) 0.5 (0.02) Undercut limit mm (in) 0.2 (0.01) -' 0 I 479 (1 8.9) 1582 (62.3) 662 (26.0) L: 920 (36.2) X: 1 ,047 (41.2) L: 540 (21.3) 190 (7.5) 191 (7.5) X: 667 (26.3) --1 ,/',rv ..... 1\) ' '!' I' co I \ ' I I\, ,I ' c 3 -tn3 s: ., -= m m 1667 (65.6) 2. 2 n rJ) 2 s: m 2 02 rJ) .j::. rv ..... c:;:; (J1 .59 8 TIGHTENINGTORQUES TIGHTENING TORQUES Part to be tightened Thread size Nm m •kg ft . lb Tightening torques POWER UNIT Breather cover bolt M4 Camshaft cap bolt 1st M7 2nd Camshaft pulley bolt M10 M6 Connecting rod bolt 1st M8 2nd Crankcase bolt 1st M8 2nd Crankcase journal bolt 1st M10 2 8 17 60 4 8 14 28 19 0.2 0.8 1.7 6.0 0.4 0.8 Turn 90° 1.4 2.8 1.9 Turn 60° (*11 27 1.4 5.8 12 43 5.8 10 20 14 1st 14 1.4 10 CDI unit cover screw 2.9 2nd (1.5 mm pitch) Crankshaft pulley nut M40 265 192 M8 Cylinder head 2nd 28 2.8 20 1st 15 1.5 11 Cylinder head bolt 2nd M10 33 3.3 (1.5 mm pitch) 3rd Turn 90° (*21 Cylinder head cover bolt M6 8 0.8 5.8 1st 6 0.6 Outer exhaust cover bolt M6 2nd 12 1.2 8.7 Flywheel magneto nut M24 190 19 137 Fuel pump bracket bolt M7 17 1.7 12 Oil filter -18 1.8 13 Oil filter plug (cylinder block) M20 50 5.0 36 Spark plug M14 2.5 18 Spark plug cap cover hexagon bolt M6 4 0.4 2.9 - Throttle link ball joint 4 0.4 2.9 Timing belt tensioner bolt M10 4.0 29 Timing plate screw M6 4 0.4 2.9 LOWER UNIT - Cooling water inlet screw 5 0.5 3.6 Lower unit mounting bolt/nut M10 40 4.0 29 Pinion gear nut M16 95 9.5 68 Propeller nut M16 35 3.5 25 Ring nut M101 .5 100 10 72 BRACKET Apron mounting screw -4 0.4 2.9 Exhaust guide mounting bolt M8 20 2.0 14 Exhaust manifold mounting bolt M6 10 1.0 7.2 Grease nipple -3 0.3 2.2 Lower rubber mounting nut M12 52 5.2 38 Part to be tightened Thread size Tightening torques Nm m •kg ft . lb Oil drain bolt M14 27 2.7 20 Oil pump cover screw -4 0.4 2.9 Oil pump mounting bolt M6 10 1.0 7.2 Oil strainer mounting bolt M6 10 1.0 7.2 Power unit mounting bolt M10 42 4.2 30 Shift rod friction cap bolt -18 1.8 13 Sub-exhaust guide mounting screw -4 0.4 2.9 Tapping bolt M6 10 1.0 7.2 Through tube nut M22 15 1.5 11 Upper rubber mounting nut M12 52 5.2 38 PTT UNIT Blind plug PT 1/8 12 1.2 8.7 Inner cylinder end cap -80 8.0 58 Main valve -11 1.1 8.0 - Manual valve 2 0.2 1.4 - Manual valve seat 4 0.4 2.9 PTT motor mounting hexagon bolt -7 0.7 5.1 PTT reservoir housing hexagon bolt -6 0.6 4.3 PTT reservoir mounting hexagon bolt -6 0.6 4.3 PTT reservoir unit mounting hexagon bolt -9 0.9 6.5 - PTT reservoir plug 7 0.7 - Outer cylinder end cap 90 9.0 - Tilt piston hexagon bolt 85 8.5 61 ELECTRICAL Oil pressure switch PT 1/8 8 0.8 5.8 Oil pressure switch wiring nut -2 0.2 1.4 Starter motor battery terminal bolt/nut M8 9 0.9 6.5 Throttle position sensor (TPS) screw -4 0.4 2.9 Water pressure sensor braided plug M14 23 2.3 17 Torque value (for reference only) ( *1l 50 Nm (5.0 m •kg, 36 ft •lb)(*2l 70 Nm (7.0 m •kg, 51 ft •lb) STEXPLODED DIAGRAM EERING HANDLE (OPTION) 8 x 30 mm 1.---® 13 Nm(1.3m•kg,9.4ft•lb) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q'ty Service points STEERING FRICTION REMOVAL Follow the left "Step" for removal. 1 Nut 1 2 Washer 1 3 Bolt 1 4 Nut 1 5 Link rod 1 6 Washer 2 7 Wing nut 1 8 Bolt 1 9 Friction rod 1 10 Friction piece 1 Reverse the removal steps for installation. 11' TEERINGHANDLEIOPIONJ EXPLODED DIAGRAM 6 x 25 mm 12 REMOVAL AND INSTALLATION CHART Step Procedure/Part name O'ty Service points STEERING HANDLE REMOVAL Follow the left "Step" for removal. 1 Bolt 2 2 Fitting plate 1 3 Clip 2 4 Throttle cable 1 5 Bolt 1 6 Cable clamp 1 7 Shift cable 1 8 Bolt 1 9 Plate 1 STEERINGHANDLE (OPTION) EXPLODED DIAGRAM 6x 25 mm 12 Step Procedure/Part name Q'ty Service points 10 Bolt 1 11 Clamp 1 12 Main switch leads 5 13 Trailer/PTT switch coupler 1 14 Junction box cover 1 15 Extension, wire harness 1 16 Nut 2 17 Steering handle assembly 1 Reverse the removal steps for installation. STEERING HANDLE(OPTION) CD EXPLODED DIAGRAM 4 Nm (0.4 m ·kg, 2.9 ft •lb) 19 572 18 Nm (1.8 m •kg, 13 ft •lb) 2 10 6 x 20 mm 3 6 x 40 mm 14 6 x 25 mm 5 Nm (0.5 m •kg, 3.7 ft •lb) 6 x 16 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name O'ty Service points STEERING HANDLE Follow the left "Step" for disassembly. DISASSEMBLY Steering handle assembly 1 Engine stop switch leads 2 2 Bolt 1 3 Bolt 1 4 Nut 1 5 Screw 1 6 Cover 1 7 Main switch assembly 1 .. STEERINGHANDLE(OPTION) EXPLODED DIAGRAM 4 Nm (0.4 m •kg, 2.9 ft •lb) 19 10 6 x 20 mm 3 6x40 mm 6 x 25 mm 14 5 Nm (0.5 m •kg, 3.7 ft •lb) 6 x 16 mm Step Procedure/Part name O'ty Service points 8 Holder 9 Screw 10 Throttle grip 11 Washer 12 Spring 13 Bushing 14 Screw 15 Screw 16 Cover 17 Screw 18 Power trim and tilt switch 1 1 1 1 1 1 5 2 1 2 1 STEERINGHANDL(OPION) EXPLODED DIAGRAM 4 Nm (0.4 m •kg, 2.9 ft •lb) 19 Step 19 20 21 22 23 24 25 26 10 14 6x 16 mm 17 Procedure/Part name Nut Engine stop lanyard switch Screw Shift lever cover Bolt Shift lever Bushing Steering handle sub assembly 2 6 x 20 mm 3 6 x 40 mm 6 x 25 mm 5 Nm (0.5 m •kg, 3.7 ft •lb) Q'ty Service points 1 1 2 1 1 1 1 1 Reverse the disassembly steps for assembly. STEERINGHANDLE(OPTION) EXPLODED DIAGRAM 6 x 20 mm 10 x 80 mm 38 Nm (3.8 m •kg, 27.5 ft •lb) REMOVAL AND INSTALLATION CHART Step Procedure/Part name O'ty Service points STEERING HANDLE SUB Follow the left "Step" for disassembly. ASSEMBLY DISASSEMBLY 1 Clip 1 2 Cable clamp 1 3 Throttle cable 1 Shorter cable 4 Bolt 1 5 Shift cable bracket 1 6 Cotter pin 1 7 Friction adjusting knob 1 8 Bolt 1 9 Bolt 2 10 Throttle shaft 1 STEERING HANDLE (OPTION) EXPLODED DIAGRAM 6x 20 mm 10 x 80 mm 38 Nm (3.8 m •kg, 27.5 ft •lb) Step Procedure/Part name Q'ty Service points 11 Friction piece 1 12 Frame 1 13 Clip 1 14 Shift cable 1 Longer cable 15 Throttle arm shaft 1 16 Throttle arm 1 17 Screw 2 18 Spring housing 1 19 Roller 1 20 Actuator 1 21 Spring 1 22 Shift arm 1 iii' STEERING HANDLE(OPTION) EXPLODED DIAGRAM Step Procedure/Part name O'ty Service points 23 Bushing 1 24 Nut 1 25 Washer 1 26 Bolt 1 27 Washer 1 28 Wave washer 1 29 Collar 1 30 Bracket 1 31 Washer 1 32 Bushing 2 33 Steering handle 1 Reverse the disassembly steps for assembly. 11' STEERINGHANDlE(OPTION) EXPLODED DIAGRAM 1 6 x 14 mm 4 Nm (0.4 m •kg, 2.9 ft •lb) 11 REMOVAL AND INSTALLATION CHART Step Procedure/Part name O'ty Service points NEUTRAL SWITCH REMOVAL Follow the left "Step" for removal. Junction box cover Refer to "STEERING HANDLE REMOVAL". 1 Neutral switch lead 2 2 Screw 3 3 CDI unit cover 1 4 Throttle position sensor (TPS) 1 coupler 5 Link rod 1 6 Bolt 2 CD EXPLODED DIAGRAM 4 Nm (0.4 m •kg, 2.9 ft •lb) 11 Step Procedure/Part name Q'ty Service points 7 Throttle control lever unit 1 assembly 8 Plastic locking tie 1 9 Bolt 3 10 Bolt 8 11 Intake silencer 1 12 Bolt 2 13 Neutral switch 1 14 Damper plate 1 15 Stay 1 Reverse the removal steps for installation. IGNITION SYSTEM IGNITION SYSTEM B& @ BJ_ @ OFFONSTART w B B w CD Spark plugs CV Ignition coils @ Throttle position sensor (TPS) @ Pick-up coils ® 10P coupler ® CDI unit (]) Lighting coil @ Rectifier/regulator ® Battery @) Fuse (30A) @ Main switch (on Tiller handle) @ Engine stop switch (on Tiller handle) B/W : Black/White W/B :White/Black W/R :White/Red B :Black Br :Brown 0 :Orange R : Red W :White Y :Yellow B/0 : Black/Orange I ELEC IGNITION SYSTEM CD ENGINE STOP SWITCH (OPTION) 1. Check: • Continuity No continuity ---7 Replace. .. Lead color White Black Remove the lock plate G) Install the lock lever ® Push the button @ STARTING SYSTEM CD ® Br Br oooo oo Br B W ® Y R OFF ON B R @) CD Fuse B :Black ® 1 OP coupler Br :Brown @ Starter relay @) Battery R W :Red :White @ Relay (magnetic switch) Y :Yellow @ Starter motor (j) Neutral switch @ Main switch sTARTINGsvsTEM NEUTRAL SWITCH (OPTION) 1. Check: • Continuity No continuity ---7 Replace. .. Switch Lead color position Brown Brown ® Home position (Q) Depressed APPENDIX F100 has been modified some specifications. Please replace following pages in F100 service manual (P/N. 67F-28197-Z8-11 (LIT-18616-0196), 67F-28197-Z8-C1 and 67F-28197-L 1). ....:............GRAM ALLATION CHART Service FUEL PUMP RE..OVAL 1 Plastic loc mg k. t1e 4 2 Clip 4 2 4 Fuel hose (fuel pump, ..IN) 2 Bolt 4 Fuel pump 2 0-ring 2 Reverse the re moval steps for installation. 3 Fuel hose (fuel p ump· OUT) STATOCOILASSEMBLV STATORCOILASSEMBLY EXPLODED DIAGRAM 6 x 30 mm 5 2 1 ..-__ ----.. -- /"'-.:: t,' ' ..... : - 1----- REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q'ty Service points STATOR COIL ASSEMBLY Follow the left "Step" for removal. REMOVAL Flywheel magneto Refer to "FLYWHEEL MAGNETO". 1 Screw 3 2 CDI unit cover 1 3 Lighting coil coupler 1 4 Screw 1 5 Bolt 3 6 Stator coil assembly 1 • Install the new valve guide to the specified position (from the top of the valve guide bore as shown) ® with the valve guide remover/installer. Valve guide position: 11.5 mm (0.45 in) installing the valve guide, bore the valve guide with the valve guide Valve guide reamer: YM-04066/90890-04066 • Heat the cylinder head in an oven to 200 ·c (392 ·F) to ease valve guide removal and installation, and to maintain the correct interference fit. • Before installing the valve guide, mark its installation position (b) as shown. 1. Measure: • Valve seat width ® Out of specification .. Reface the valve seat. Valve seat width: IN: 1.58 -1.94 mm (0.062 -0.076 in) EX: 1.80 -2.02 mm (0.07 1 -0.080 in) 2. Reface: • Valve seat IIIIIAI.. -To prevent chatter marks, turn the valve seat cutter while an even, downward pressure (4 -5 kg). Valve seat inspection COLORCODE B :Black :Yellow • 0 y WIRING DIAGRAM $ Br :Brown e B/0 : Black/orange & & G :Green B(W : Blackr'white() ()() B{Y : Blec](JYel!ow.fjt Gy : Gray :::t:$ L :Blue G!R : Green/Red G{IN : Greentwhlte P/B :Pink/black Lg :Light green 0 :Orange 8 8 p:Pink R :Red Sb : Slcy blue ()W:White 0 () () P(W : Pinkr'whlte W/B : White/Black W/A : White/red @> ..park plug _ : , ,.,,.,,_.._,__,.,,_,..,.,,.,.,,.,,_,.,,.,,.,,__,.,,.,,..,_,__,.,,.,,_,.,,.,B/W••-._.,"'([:]