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Outboard Motor
55DEHD
Yamaha 55DEHD User Manual
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PO
WR
5-
6885J11
P
ower unit
25 N
·
m (2.5 kgf
·
m, 18.4 ft
·
lb)
15 N
·
m (1.5 kgf
·
m, 11.1 ft
·
lb)
30 N
·
m (3.0 kgf
·
m, 22.1 ft
·
lb)
6885090E
Cylinder head,
exhaust co
ver
5-15
No
.
P
ar
t name
Q
’
ty
Remarks
1
Bolt
4
M6
×
35 mm
2
Holder
1
3
Ther
mostat co
ver
1
4
Spring
1
5
PCV
1
6
Ther
mostat
1
7
Gasket
1
8
Grommet
1
9
Spark plug
3
10
Bolt
18
M6
×
25 mm
11
Ground lead
1
12
Cylinder head cov
er
1
13
Bolt
14
M8
×
60 mm
14
Gasket
1
15
Ther
mos
witch
1
16
Cylinder head
1
17
Gasket
1
Not reusable
Not reusable
Not reusable
6885J11_05 07.9.26 15:44 Page 18
101
103
Table of Contents
1 General Information
3
Important Information
2
Table of Contents
3
General Information
5
How to Use this Manual
6
Manual Format
6
Specification
7
Symbol
7
Abbreviation
8
Safety While Working
9
Fire Prevention
9
Ventilation
9
Self-Protection
9
Part, Lubricant, and Sealant
9
Good Working Practice
10
Disassembly and Assembly
10
Identification
11
Model
11
Serial Number
11
Special Service Tool
12
Propeller Selection
18
Propeller Size
18
Selection
18
Predelivery Check
18
Checking the Fuel System
18
Checking the Gear Oil
19
Checking the Battery
19
Checking the Outboard Motor Mounting Height
19
Checking the Remote Control Cable (ED, ET)
19
Checking the Steering System
20
Checking the PTT System (ET)
20
Checking the Gear Shift and Throttle Operation
21
Checking the Engine Start Switch and Engine Stop Lanyard Switch
21
Checking the Cooling Water Pilot Hole
22
Test Run
22
Break-In
22
After Test Run
23
Spec Specification
25
General Specification
26
Specification
26
Maintenance Specification
30
Power Unit (55D, 75A Models)
30
Lower Unit (55D, 75A Models)
32
Electrical (55D, 75A Models)
32
Power Unit (85A Models)
35
Lower Unit (85A Models)
37
Dimension
40
Tightening Torque
44
Specified Torque
44
General Torque
46
Chk Adj Periodic Check and Adjustment
47
Default Chapter
47
Periodic Check and Adjustment
47
Maintenance Interval Chart
48
Fuel System
49
Top Cowling
49
Checking the Top Cowling
49
Checking the Fuel Joint and Fuel Hose (Fuel Tank-To-Carburetor)
49
Power Unit
50
Checking the Fuel Filter
50
Checking the Spark Plug
50
Checking the Thermostat
50
Checking the Cooling Water Passage
51
Control System
52
Synchronizing the Carburetor
52
Checking the Control Link Position
53
Adjusting the Throttle Cable
54
Checking the Engine Idle Speed
55
Checking the Ignition Timing
56
Checking the Timing Plate
57
Checking the Ignition Timing Stopper
58
Checking the Gear Shift Operation
60
Checking the Neutral Switch Operation (EHD)
61
Checking the Choke Solenoid Position (ED, ET)
61
Bracket
62
Checking the PTT Operation (ET)
62
Checking the PTT Fluid Level (ET)
62
Checking the Tilt Operation (EHD, ED)
63
Lower Unit
64
Checking the Tilt Pin
64
Checking the Gear Oil Level
64
Changing the Gear Oil
64
Checking the Lower Unit for Air Leakage
65
Checking the Propeller
66
General
66
Checking the Anode
66
Checking the Battery
66
Lubricating the Outboard Motor
67
Fuel Fuel System
69
Fuel System
70
Hose Routing
70
Fuel Line
72
Fuel Pump
74
Checking the Primer Pump
75
Checking the Fuel Joint
75
Checking the Fuel Pump
76
Disassembling the Fuel Pump
76
Assembling the Fuel Pump
77
Carburetor
78
Disassembling the Carburetor
82
Checking the Carburetor
82
Checking the Float Height
82
Assembling the Carburetor
83
Powr Power Unit
86
Power Unit
88
Checking the Compression Pressure
88
Removing the Power Unit
96
Removing the Flywheel Magnet
98
Removing the Electrical Component
98
Removing the Control Lever and Throttle Cam
99
Intake Manifold
101
Removing the Reed Valve Assembly
101
Checking the Reed Valve
101
Cylinder Head, Exhaust Cover
102
Removing the Cylinder Head
105
Checking the Cylinder Head
106
Removing the Exhaust Cover
106
Checking the Exhaust Cover
107
Checking the PCV
107
Crankcase
108
Removing the Crankcase
111
Removing the Piston, Connecting Rod Assembly and Crankshaft Assembly
111
Checking the Cylinder Block
112
Disassembling the Piston and Connecting Rod Assembly
112
Checking the Bearing
112
Checking the Piston Pin
112
Disassembling the Crankshaft
113
Checking the Cylinder Bore
113
Checking the Piston Diameter
114
Checking the Piston Ring Side Clearance
114
Checking the Piston Pin Boss Bore
114
Checking the Piston Ring
114
Checking the Crankshaft
115
Checking the Connecting Rod Big End Side Clearance
115
Checking the Connecting Rod Small End Axial Play
116
Disassembling the Upper Bearing
116
Assembling the Upper Bearing
116
Assembling the Crankshaft
117
Assembling the Piston and Connecting Rod Assembly
117
Disassembling the Oil Seal Housing
118
Checking the Oil Seal Housing
118
Assembling the Oil Seal Housing
118
Assembling the Power Unit
119
Installing the Electrical Component
123
Install the Control Lever and Throttle Cam
125
Installing the Power Unit
125
Lowr Lower Unit
129
Lower Unit
130
Removing the Lower Unit
133
Removing the Water Pump
134
Checking the Water Pump
135
Disassembling the Oil Seal Housing
135
Assembling the Oil Seal Housing
135
Propeller Shaft Housing
136
Removing the Propeller Shaft Housing Assembly
137
Disassembling the Propeller Shaft Assembly
137
Disassembling the Propeller Shaft Housing
138
Checking the Propeller Shaft Housing
139
Checking the Reverse Gear
139
Checking the Propeller Shaft
139
Assembling the Propeller Shaft Housing
139
Assembling the Propeller Shaft Assembly
141
Drive Shaft and Lower Case
142
Removing the Drive Shaft
143
Removing the Shift Rod
143
Disassembling the Drive Shaft
143
Disassembling the Forward Gear
144
Disassembling the Lower Case
144
Checking the Pinion and Forward Gear
145
Checking the Drive Shaft
145
Checking the Lower Case
145
Assembling the Forward Gear
145
Assembling the Drive Shaft
145
Assembling the Lower Case
146
Installing the Shift Rod
147
Installing the Drive Shaft
147
Installing the Oil Seal Housing
148
Installing the Propeller Shaft Housing
148
Installing the Water Pump
149
Installing the Lower Unit
151
Shimming
154
Selecting the Pinion Shim
155
Selecting the Forward Gear Shim
156
Selecting the Reverse Gear Shim
157
Backlash
158
Measuring the Forward and Reverse Gear Backlash
158
Brkt Bracket Unit
162
Default Chapter
162
Bracket Unit
162
Tiller Handle 2
166
Assembling the Tiller Handle (EHD)
166
Checking the Throttle Cable and Shift Cable (EHD)
166
Lubricating the Throttle Gear (EHD)
167
Bottom Cowling
168
Upper Case, Steering Arm
171
Disassembling the Upper Case
174
Checking the Upper Case
174
Assembling the Upper Case
174
Removing the Steering Arm
178
Checking the Steering Arm
178
Installing the Steering Arm
178
Installing the Upper Case
180
Clamp Bracket and Swivel Bracket
183
Removing the Clamp Bracket (EHD, ED)
185
Checking the Shock Absorber
186
Disassembling the Swivel Bracket (EHD, ED)
186
Checking the Swivel Bracket
186
Assembling the Swivel Bracket (EHD, ED)
187
Assembling the Clamp Bracket (EHD, ED)
187
Removing the PTT Unit (ET)
193
Removing the Clamp Bracket (ET)
194
Disassembling the Swivel Bracket (ET)
194
Checking the Swivel Bracket (ET)
194
Assembling the Swivel Bracket (ET)
195
Installing the Clamp Bracket (ET)
195
Installing the PTT Unit (ET)
195
Adjusting the Trim Sensor Cam (ET)
196
PTT Unit
198
Checking the Hydraulic Pressure
200
PTT Motor
204
Disassembling the PTT Motor
205
Checking the PTT Motor
206
Assembling the PTT Motor
207
Gear Pump
211
Disassembling the Gear Pump, down Relief Valve and Main Valve
211
Disassembling the Relief Valve and Manual Valve
212
Checking the Gear Pump
212
Checking the Main Valve
212
Checking the Manual Valve
213
Checking the Gear Housing
213
Checking the Reservoir
213
Checking the Filter
213
Checking Relief Valve
213
Assembling the Relief Valve and Manual Valve
213
Assembling the Gear Pump
215
Tilt Cylinder and Trim Cylinder
216
Disassembling the Tilt Cylinder and Trim Cylinder
218
Checking the Tilt Cylinder and Trim Cylinder
220
Checking the Valve
220
Assembling the Tilt Ram
221
Assembling the Trim Ram
222
Installing the Tilt Cylinder
222
Installing the Trim Ram
223
Installing the PTT Motor
223
Installing the Reservoir
224
Installing the Tilt Ram
224
Bleeding the PTT Unit
225
Bleeding the PTT Unit (Built-In)
226
PTT Electrical System
227
Checking the Fuse
227
Checking the PTT Relay
227
Checking the Trim Sensor
228
Elec Electrical System
229
Default Chapter
229
Elec
229
Electrical System
230
Checking the Electrical Component
230
Measuring the Peak Voltage
230
Electrical Component
231
Starboard View
231
Ignition and Ignition Control System
233
Checking the Ignition Spark Gap
233
Checking the Spark Plug Cap (with Resister Type)
233
Checking the Spark Plug Cap
233
Checking the Ignition Coil
234
Checking the CDI Unit
235
Checking the Pulser Coil
236
Checking the Charge Coil
236
Checking the Thermoswitch
237
Checking the Warning Indicator (EHD)
238
Starting System
238
Checking the Fuse
238
Checking the Engine Start Switch
238
Checking the Engine Stop Lanyard Switch
239
Checking the Starter Relay
240
Checking the Neutral Switch Continuity (EHD)
240
Measuring the Choke Solenoid Resistance (ED, ET)
240
Starter Motor
243
Removing the Starter Motor Pinion
243
Checking the Starter Motor Pinion
243
Checking the Armature
243
Checking the Brush
244
Installing the Starter Motor Pinion
245
Checking the Starter Motor Operation
245
Charging System
245
Checking the Lighting Coil
245
Checking the Rectifier Regulator
246
Trbl Shtg
247
Contents
248
Fuel
251
Troubleshooting the Ptt Unit
254
Shtg
256
Lowr
262
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Yamaha 55DEHD Specifications
General
Brand
Yamaha
Model
55DEHD
Category
Outboard Motor
Language
English
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