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General| Engine Type | 2-Stroke |
|---|---|
| Fuel Induction System | Carburetor |
| Starting System | Manual |
| Ignition System | CDI |
| Displacement | 496 cc |
| Max. Output | 30 hp |
| Gear Ratio | 2.08:1 |
| Fuel Tank Capacity | External tank |
Provides information on model and serial numbers for identifying the outboard motor.
Details essential safety precautions for handling gasoline, ventilation, self-protection, and proper lubricants.
Lists and illustrates special tools recommended by Yamaha for accurate assembly and tune-up.
Lists various measuring instruments like tachometers, vacuum testers, and gauges.
Lists special tools required for removing and installing various engine components.
Provides overall specifications including dimensions, weight, performance, and power unit details for various models.
Details specific maintenance data for the engine, including cylinder, piston, crankshaft, and electrical components.
Lists the physical dimensions of the outboard motor and bracket in millimeters and inches.
Specifies the correct torque values for tightening standard fasteners according to ISO thread pitch.
Covers checks and tasks performed before the unit is delivered to the customer.
Illustrates the electrical wiring diagram and connector assignments for specific models.
Details scheduled maintenance tasks performed at regular intervals.
Provides a chart detailing maintenance intervals based on operating hours or time.
Instructions for inspecting and replacing the anode to prevent corrosion.
Safety precautions and inspection procedures for the battery, including fluid level and specific gravity.
Shows an exploded view of the fuel system components for identification.
Provides safety warnings and steps for removing the fuel line.
Details procedures for cleaning and inspecting the fuel filter and fuel joints.
Outlines the steps for installing the fuel system, noting connection points and hose routing.
Presents an exploded view of the carburetor components for identification.
Provides safety warnings and steps for removing and disassembling the carburetor.
Details inspection procedures for carburetor body, needle valve, pilot screw, collar, float, and fuel pump.
Step-by-step instructions for assembling the carburetor components.
Shows an exploded view of the oil injection system components for identification.
Steps for draining oil and removing the carburetor and oil injection system.
Procedures for cleaning and inspecting the oil tank, oil level gauge, and oil hoses.
Steps for connecting oil hoses, installing the oil pump, assembling the oil tank, and connecting delivery hoses.
Provides an exploded view of the power unit components for identification.
Details general cleaning and tool preparation before engine removal and disassembly.
Instructions for removing electrical, fuel system, and control components before power unit removal.
Step-by-step instructions for disassembling the power unit components, including cylinder head, intake manifold, and crankcase.
Details procedures for inspecting various power unit components.
Procedures for cleaning and inspecting the cylinder head for warping.
Steps for cleaning and inspecting the cylinder block for cracks, scratches, and bore diameter.
Instructions for cleaning and inspecting the piston, including diameter and clearance measurements.
Procedures for inspecting piston ring clearance and end gap.
Cleaning and inspection steps for the piston pin and small end bearings.
Inspection of the crankshaft for deflection and connecting rod side clearance.
Inspection of the reed valve for warping and cracks, and measurement of valve stopper height.
Cleaning and inspection of the thermostat, including checking valve opening temperature.
Cleaning and inspection of crank main bearings for surface defects and proper operation.
Visual inspection of drive gear teeth for damage.
Visual inspection of driven gear teeth for damage.
Provides step-by-step instructions for reassembling and adjusting power unit components.
Details the process of assembling various power unit parts and components.
Instructions for installing bearings, oil seals, O-rings, and the oil pump drive gear.
Steps for installing piston rings and aligning end gaps.
Instructions for installing gaskets, cylinder head cover, exhaust cover, and thermostat.
Provides an exploded view of the lower unit components for identification.
Steps to prepare for lower unit removal, including removing propeller, spacer, and draining gear oil.
Instructions for disconnecting the shift rod and removing the lower unit assembly.
Step-by-step instructions for disassembling lower unit parts like water pump housing, gears, and shafts.
Details procedures for inspecting various lower unit components.
Cleaning and inspection of the gear case for cracks, corrosion, or distortion.
Cleaning and inspection of the bearing housing for damage or corrosion.
Inspection of the claw washer for cracks.
Cleaning and inspection of the ring-nut for thread damage or cracks.
Inspection of the water pump housing for twisting or scratches.
Visual inspection of the impeller for wear, cracks, distortion, or burning.
Cleaning and inspection of the oil-seal housing for cracks or corrosion.
Inspection of gear teeth and dogs for cracks, peeling, or distortion.
Inspection of bearings for pitting, scratching, rumbling, and replacement if necessary.
Inspection of the clutch dog and mating gear for wear or damage.
Inspection of shafts for grooved wear, bearings, oil seals, and spline wear.
Inspection of the drive shaft sleeve for wear or cracks.
Inspection of shift plunger and shift-rod boot for wear or damage.
Refers to Chapter 3 for periodic inspection of these components.
Provides step-by-step instructions for reassembling and adjusting lower unit components.
Details the process of assembling various lower unit parts and components.
Instructions for selecting shims for the forward gear based on measurements.
Guidance on selecting shims for the pinion gear using specified tools and calculations.
Steps for installing the thrust washer, bearing, and propeller shaft housing.
Instructions for selecting shims for the reverse gear using measurements and calculations.
Describes procedures for measuring gear backlash using dial gauges.
Procedure to measure backlash of the forward gear using dial gauges and indicators.
Procedure to measure backlash of the reverse gear using dial gauges and indicators.
Steps for installing the water pump housing, impeller, and oil seals.
Procedure for checking the lower unit for leaks using a pressure tester.
Final installation steps for the lower unit, including propeller, trim tab, and gear oil.
Covers the removal, installation, and exploded view of the steering handle assembly.
Details the removal, installation, and exploded view of the bottom cowling.
Covers the removal, installation, and exploded view of the upper case assembly.
Covers the removal, installation, and exploded view of the steering bracket.
Covers the components, removal, installation, and service points of the PTT unit.
Details the removal, installation, and exploded view of the clamp bracket for non-PTT models.
Details the removal, installation, and exploded view of the clamp bracket for PTT models.
Covers the removal, installation, and exploded view of the swivel bracket.
Covers the exploded diagram, removal, installation, service points, and air bleeding of the tilt rod assembly.
Details procedures for removing the tilt rod, tilt piston, and performing air bleeding.
Instructions for loosening the tilt cylinder end screw and removing the tilt rod.
Cautionary advice on removing the tilt piston assembly only when replacing the oil seal.
Lists electrical components with numerical references for specific outboard motor models.
Shows the wiring diagram and color codes for connecting electrical components.
Procedures for removing and installing the flywheel magneto assembly.
Steps for removing the recoil starter or flywheel cover and starter pulley.
Details diagnostic procedures for electrical system components.
Procedures for inspecting electrical components using testers and adapters.
Instructions for using a digital circuit tester for electrical checks.
Guidelines for checking peak voltage, noting factors affecting it and potential issues.
Information on using the peak voltage adaptor with a digital circuit tester.
Covers spark plug inspection and ignition system adjustments.
Safety warnings and steps for checking and adjusting the spark plug gap.
Details inspection procedures for pulser coil, thermo switch, and oil level gauge.
Refers to the Ignition System section for pulser coil inspection.
Procedures for measuring thermo switch continuity and temperature.
Instructions for checking the continuity of the oil level gauge.
Covers battery, fuse, wire harness, starter relay, starter switch, neutral switch, and fuel enrichment valve checks.
Refers to General section for battery checks.
Instructions for checking fuse continuity and rating.
Checks for wire harness continuity and proper connections.
Check for proper connections of wires.
Procedures for checking starter relay condition and continuity.
Details peak voltage measurements for the rectifier and lighting coil.
Instructions for measuring peak voltage of the rectifier and lighting coil.
Covers inspection and troubleshooting of the PTT motor, relays, and sensors.
Instructions for checking PTT motor operation and continuity.
Procedure for measuring trim sensor resistance.
Notes on preliminary checks before consulting the trouble analysis chart.
A chart correlating trouble modes with check elements and reference chapters.
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