1984-1993 Yamaha 6HP-8HP 2-Stroke Outboard Repair Manual

1984 - 1993 OUTBOARD SERVICE MANUAL Model : 6LH, 6LJ, 6MSHP, 6MSHQ, 6MSHR, 6SD, 6SF, 6SG, 6SH, 6SJ, 8LD, 8LJ, 8LK, 8LN, 8MLHP, 8MLHQ, 8MLHR, 8MSHP, 8MSHQ, 8MSHR, 8SD, 8SF, 8SG, 8SH, 8SJ, 8SK, 8SN 6G1281972100 *6G1281972100*

8NSERVICEMANUAL ©1986 by Yamaha Motor Corp., USA 1st Edition - April 1983 2nd Printing - March 1986 - JEM D-172 All rights reserved.Any reprintingor unauthorized use withoutthe written permissionof Yamaha Motor Corporation, U.S.A., is expresslyprohibited. PRINTED IN U.S.A. P/N LIT-18616-00-03

NOTICE This manual has been written by the Yamaha Motor Company primarily for use by Yamaha dealersand their qualified mechanics.It is not possibleto put an entire mechanic'seducation into one manual, so it isassumedthat persons using this manual to perform maintenance and repairs on Yamaha outboard motors have a basic understandingof the mechanical con- cepts and procedures inherent to outboard motorrepair technology. Without such know- ledge, attempted repairs or service to this model may render it unfit for use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changesin specificationsor procedureswill be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. Particularly important information is dis- tinguished in this manual by the following notations: NOTE: A NOTE provides key information to make procedures easier or clearer. A CAUTION indicates special procedures that must be followed to avoid damage to the outboard motor, WARNING: A WARNING indicates special procedures that must be followedto avoid injury to an outboard motor operator or person inspect- ing or repairing an outboard motor. OVERSEAS SERVICE OVERSEAS OPERATIONS YAMAHA MOTOR CO., LTD.

8N EXTERNAL VIEW

GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS FUEL SYSTEM AN D CARBURETION POWER HEAD OVERHAU L LOWER UNIT OVERHAU L _ELECTRICAL o. RECOIL STARTER .. ¢,P APPENDICES _".

GENERAL INFORMATION OUTBOARD MOTOR IDENTI FICATION Engineserial number SPECIAL TOOLS The engine serial number is stamped on .the plate attached to the cylinder body. The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help pre- vent damage caused by the use of improper tools or improvised techniques. For Tune-up 1. Compression gauge P/N. YU-33223 Model and serialnumber The model and serial number plate is attached _ r-w/:, to the port clamp bracket. L_ 2. Timing light P/N. YU-33277 This timing light is used for checking the ignition timing. 1-1

3. Tachometer For engine service P/N. YU-08036 1. Flywheel magneto holder P/N. YB-06139 This tachometer is used for checking This tool is used for removing and tigh- the engine speed, tening the flywheel securing nut. 2. Flywheel magneto puller P/N. YU-33270 This tool is used for removing the flywheel. 3, Dial gauge set 1 P/N. YU-01256 3. P/N. YU-01037 (14mm hole addaptor) (Stand) 2. P/N. YU-03097 4. P/N. YU-01038 (Gauge) (Bolt) / [__ ® This dial gauge set is used for determing the gear shim. 1-2

For lower unit service 4. Attachment 1. Handle P/N. YB-06022 P/N. YB-6071 Attachment P/N. YB-06016 P/N. YB-06021 YB6071 YB-06016 YB-06021 __) _ _ This tool is used for installing the bushing. (Use handle P/N. YB-6071 ) ' 5. Handle A Theses tools are used when installing P/N. YB-06027 the oil seal. Handle B 2. Attachment P/N. YB-06028 P/No YB-06016 Rot driver P/N. YB-06229 YB.06027 YB-06028 YB-06229 This tool is used for installing the bearing. (use handle P/N. YB-6071) These tools are used for removing the 3. Driver head bushing. P/N. YB-06167 6. Attachment P/N. YB-6025 This tool is used for installing the taper This tool is used for installing the bush- roller bearing outer race. (Use handle P/N. YB-6071 ) ing and oil seal. (Use handle P/N.YB-6071) 1-3

7, Bushing installer assembly 2. Ignition coil tester P/N. YB-06029 P/N. YU-33261 This tool is used for installing the bushing. 8. Dial gauge stand P/N. YB-7003 SEALING AGENTS AND LUBRICANTS Backlash indicator rod P/N. YB-6265 Sealingagents 1. Yamaha Bond No.4 P/N. ACC-11001-30-00 YB-6265 Lubricants 1 } 1. Water resistant grease (Yamaha all- purpose grease, P/N LUB- GREAS-13-00) 2. Yamaha gear case lube, P/N LUB- GEAR L-11-00 These tools are used for measuring the backlash for the forward/reverse gear. For electrical components 1. Yamaha pocket tester P/N. YU-03112 1-4

COOLING SYSTEM This outboard motor employs an open-cir- cuit, direct cooling-system. As a preventive measure against over-cooling the engine, a thermostat is used, which controls the engine operating temperature properly. Cooling water flow Upper casing I i xhau, 00e , rbl 1 C_,,oderhead "1 Thermostat (OPEN) [ 'Thermostat l I Cylinder head(Upper) 1 ' 1 t Cylinder head (Lower) ] I Exhaust cover (Lower) ] [ Exhaust cover (Upper) ,J I Cylinder body (Right) ] [ Cylinder body (Left) I ] Cylinder body (Upper) I 1 Cylinder body (Left) '1 "l Pilot water J I Cylinder body (Rightl i [ Uppercasing l [ Water tube 1 [ Water pump J Cooling water inlet ] 1-5

1984-1993 Yamaha 6HP-8HP 2-Stroke Outboard Repair Manual

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