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EH63/EH64/EH65/EH72

SERVICE MANUAL

Products Co., Ltd.

1st Edition, February 2019

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Powered

Products Co., Ltd.

is expressly prohibited.

Main Page

Table of Contents8
General Information13
Machine Identification13
Serial Number13
Dimensions14
Dimension Chart for P.t.o14
Top16
Mounting Base16
Left Side17
Front17
Rear18
Important Information19
Preparation for Removal and Disassembly19
Caution on Service19
Notes on Service19
All Replacement Parts20
Gaskets, Oil Seals, and O-Rings20
Bearings and Oil Seals21
Basic Service Information21
Electrical System21
Special Tools and Testers25
Periodic Checks and Adjustments27
Introduction27
Maintenance Intervals Chart27
Periodic Maintenance/Lubrication Intervals27
Periodic Maintenance29
Spark Plugs30
Fuel Leakage30
Fuel Filter30
Engine Oil Leakage31
Engine Oil Level31
Replacing the Engine Oil32
Oil Cooler (Eh72A/Eh72B/Eh72K)34
Air Filter Element34
Muffler36
Breather Hose37
Cylinder Head Decarbonization37
Adjusting the Valve Clearance38
Engine Speed (Eh63K/Eh64A/ Eh64K/Eh65A/Eh65B)40
Engine Speed (Eh72A/Eh72B/Eh72K)42
Fittings and Fasteners44
Engine45
Engine Inspection45
Measuring the Compression Pressure45
Air Filter47
Eh63K/Eh64A/Eh64K/Eh65A/Eh65B47
Eh72A/Eh72B/Eh72K48
Muffler49
Eh63K/Eh72B/Eh72K49
Eh64K50
Eh65B51
Eh65A/Eh72A52
Installing the Muffler53
Oil Cooler and Oil Filter54
Removing the Oil Cooler (Eh72A/Eh72B/Eh72K)55
Checking the Oil Cooler (Eh72A/Eh72B/Eh72K)55
Installing the Oil Cooler (Eh72A/Eh72B/Eh72K)55
Rectifier/Regulator57
Case and Fan58
Removing the Case and Fan59
Checking the Case and Fan59
Installing the Case and Fan60
Cylinder Covers61
Cylinder Cover 1 and Cylinder Cover 261
Cylinder Cover 362
Tci Units, Flywheel and Stator Coil Assembly63
Tci Units63
Flywheel and Stator Coil Assembly64
Removing the Flywheel and Stator Coil Assembly65
Checking the Flywheel and Stator Coil Assembly66
Installing the Flywheel and Stator Coil Assembly66
Installing the Tci Units67
Engine Switch and Oil Warning Light (Equipped Models Only)69
Cylinder Head Covers, Cylinder Heads70
Cylinder Head #170
Cylinder Head #273
Checking the Rocker Arms76
Removing the Cylinder Heads76
Checking the Cylinder Heads76
Installing the Cylinder Head Assemblies77
Valves78
Cylinder Head #178
Cylinder Head #279
Removing the Valves and Valve Springs80
Checking the Valves and Valve Springs80
Checking the Valve Seats82
Valve Lapping83
Installing the Valves and Valve Springs84
Oil Pump85
Disassembling the Oil Pump86
Checking the Oil Pump86
Assembling the Oil Pump86
Pistons, Camshaft, Crankcase, and Crankshaft88
Crankcase Cover88
Camshaft89
Pistons and Crankshaft90
Crankcase91
Checking the Relief Valve92
Assembling the Relief Valve92
Checking the Oil Pump Strainer92
Assembling the Oil Pump Strainer92
Removing the Flyweight Shaft Assembly and Governor Fork92
Disassembling the Flyweight Shaft Assembly93
Checking the Flyweight Shaft Assembly93
Assembling the Flyweight Shaft Assembly94
Installing the Flyweight Shaft Assembly and Governor Fork94
Removing the Camshaft and Valve Lifters95
Checking the Camshaft95
Checking the Valve Lifters97
Installing the Valve Lifters and Camshaft97
Checking the Crankcase Cover97
Installing the Crankcase Cover98
Checking the Cylinders and Pistons98
Checking the Crankcase100
Checking the Piston Pins100
Checking the Piston Rings101
Checking the Crankshaft102
Checking the Connecting Rods Oil Clearance102
Installing the Pistons and Piston Rings103
Installing the Crankshaft104
Selecting the Crankshaft Shim106
Fuel109
Fuel Pump109
Eh63K/Eh64A/Eh64K/Eh65A/Eh65B109
Eh72A/Eh72B/Eh72K110
Checking the Fuel Pump111
Carburetor Assembly112
Removing the Carburetor (Eh63K/Eh64A/Eh64K/Eh65A/Eh65B)112
Disassembling the Carburetor (Eh64A/Eh65B)113
Disassembling the Carburetor (Eh63K/Eh64K/Eh65A)115
Removing the Carburetor (Eh72A/Eh72B/Eh72K)117
Disassembling the Carburetor (Eh72A/Eh72B/Eh72K)118
Removing the Carburetor Assembly119
Checking the Carburetor119
Installing the Carburetor Assembly120
Adjusting the Governor121
Intake Manifold122
Eh63K/Eh64A/Eh64K/Eh65A/Eh65B122
Eh72A/Eh72B/Eh72K123
Removing the Intake Manifold124
Checking the Intake Manifold124
Installing the Intake Manifold124
Electrical126
Circuit Diagram126
Electrical Components128
Checking the Switch Continuity130
Checking the Oil Pressure Switch130
Checking the Ignition Spark Gap131
Checking the Air Gap132
Checking the Ignition Coil (Tci Unit, Primary) Resistance132
Checking the Ignition Coil (Tci Unit, Secondary) Resistance132
Checking the Engine Switch (Equipped Models Only)133
Checking the Starter Motor Operation133
Checking the Wire Harness134
Electric Starting System135
Removing the Starter Motor135
Charging System136
Checking the Stator Coil Assembly136
Checking the Rectifier/Regulator136
Troubleshooting139
Engine Does Not Start139
Electric Starting System140
Engine Starts but Stalls140
Engine Speed Does Not Increase141
Engine Speed Is Uneven142
The Battery (Option) Is Not Charged142
Governor Operation143
Specifications145
General Specifications145
Maintenance Specifications147
Engine147
Electrical151
Tightening Torques154
General Torque Specifications154
Lubrication Points and Type of Lubricants155
Wire Routing Diagram156
Fuel Pump and Fuel Hose (Eh63K)156
Fuel Pump and Fuel Hose (Eh64A)157
Fuel Pump and Fuel Hose (Eh64K, Except for Kor)158
Fuel Pump and Fuel Hose (Eh64K, for Kor)159
Fuel Pump and Fuel Hose (Eh65A)160
Fuel Pump and Fuel Hose (Eh65B)161
Fuel Pump and Fuel Hose (Eh72A)162
Fuel Pump and Fuel Hose (Eh72B, for Sea/Eh72K, for Chn)163
Fuel Pump and Fuel Hose (Eh72K, Except for Chn)164
Air Filter, Carburetor and Fuel Hose (Eh63K/Eh64A/Eh64K, Except for Kor)165
Air Filter, Carburetor and Fuel Hose (Eh64K, for Kor/Eh65A/Eh65B)166
Air Filter, Carburetor and Fuel Hose (Eh72A/Eh72B/Eh72K)167
Carburetor and Intake Manifold (Eh64A/Eh64K, Except for Kor)168
Carburetor and Intake Manifold (Eh64K, for Kor/Eh65A/Eh65B)169
Carburetor and Intake Manifold (Eh72A/Eh72B/Eh72K)170
Tci Unit (Eh63K)171
Tci Unit (Eh64A)172
Tci Unit (Eh64K, Except for Kor)173
Tci Unit (Eh64K, for Kor)174
Tci Unit (Eh65A)175
Tci Unit (Eh65B)176
Tci Unit (Eh72A)177
Tci Unit (Eh72B, for Sea/Eh72K, for Chn)178
Tci Unit (Eh72K, Except for Chn)179
Rectifier/Regulator and Starter Motor (Eh63K)180
Rectifier/Regulator and Starter Motor (Eh64A)181
Rectifier/Regulator and Starter Motor (Eh64K, Except for Kor)182
Rectifier/Regulator and Starter Motor (Eh64K, for Kor)183
Rectifier/Regulator and Starter Motor (Eh65A)184
Rectifier/Regulator and Starter Motor (Eh65B)185
Rectifier/Regulator and Starter Motor (Eh72A)186
Rectifier/Regulator and Starter Motor (Eh72B, for Sea/Eh72K, for Chn)187
Rectifier/Regulator and Starter Motor (Eh72K, Except for Chn)188

Yamaha EH63 - Page 3

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