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FT8DMH
Yamaha FT8DMH Service Manual
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5-2
MANUAL ST
AR
TER
INST
ALLING
THE DUST COVER
GROMMET
Insta
ll:
Dust cover grommet
NOTE:
Set the gro
m
met so that
the lar
ge flange
diameter is
at the bot
tom and i
nstall t
o the
dust cover
.
ADJUSTING THE ST
ART
-IN-GEAR
PROTECTION DEVICE
Adjust:
Start-in-
gear protection device
Refer to “ADJUSTING
THE ST
ART
-
IN-GEAR PROTECTION DEVICE” on
page 3-8.
70
72
Table of Contents
How to Use this Manual
3
Table of Contents
3
How to Use this Manual
5
Periodic Check and Adjustment
6
Specifications
6
Table of Contents
7
Chapter 1
9
Identification
9
Serial Number
9
Starting Serial Numbers
9
Safety While Working
10
Fire Prevention
10
Ventilation
10
Self-Protection
10
Oils, Greases and Sealing Fluids
10
Good Working Practices
11
Disassembly and Assembly
12
Special Tools
13
Measuring
13
Removing and Installing
15
Chapter 2 Specifications
17
General Specifications (F6Amh/F6Mh)
18
General Specifications (F8Cmh/F8Mh)
20
Maintenance Specifications
22
Power Unit
22
Lower Unit
25
Electrical
26
Outboard Dimensions
28
Bracket Dimensions
30
Tightening Torques
31
Specified Torques
31
General Torques
33
Chapter 3 Periodic Check and Adjustment
34
Maintenance Interval Chart
35
Top Cowling
36
Checking the Water Drain Hole
36
Checking the Top Cowling Fit
36
Fuel System
37
Checking the Fuel Line
37
Control System
38
Adjusting the Shift Control Cable
38
Adjusting the Throttle Control Cables
39
Adjusting the Throttle Axle Link
40
Adjusting the Engine Idling Speed
41
Adjusting the Start-In-Gear Protection Device
42
Power Unit
43
Checking the Engine Oil Level
43
Replacing the Engine Oil
43
Adjusting the Valve Clearance
44
Measuring the Compression Pressure
46
Checking the Ignition Timing
47
Checking the Timing Belt
48
Cooling System
48
Checking the Cooling Water Discharge
48
Lower Unit
49
Checking the Gear Oil Level
49
Changing and Checking the Gear Oil Level
49
Checking the Lower Unit (for Air Leaks)
50
General
51
Checking the Anode
51
Checking the Battery
51
Checking the Spark Plugs
52
Lubrication Points
54
Chapter 4 Fuel System
56
Checking the Fuel Filter
58
Checking the Fuel Joint
58
Fuel Joint, Fuel Filter and Fuel Pump
58
Fuel Pump
58
Installing the Fuel Filter
58
Fuel Pump
59
Disassembling/Assembling the Fuel Pump
59
Checking the Fuel Pump
60
Assembling the Fuel Pump
60
Intake System
61
Removing/Installing the Intake System
61
Installing the Intake Manifold
63
Carburetor
64
Disassembling/Assembling the Carburetor
64
Disassembling the Carburetor
66
Checking the Carburetor
66
Assembling the Carburetor
67
Chapter 5 Power Unit
68
Manual Starter
70
Removing/Installing the Manual Starter
70
Adjusting the Start-In-Gear Protection Device
71
Installing the Dust Cover Grommet
71
Disassembling/Assembling the Manual Starter
72
Disassembling the Manual Starter
74
Assembling the Manual Starter
75
Checking the Manual Starter
75
Flywheel Rotor
78
Removing/Installing the Flywheel Rotor
78
Removing the Flywheel Rotor
79
Installing the Flywheel Rotor
80
Power Unit
81
Disconnecting/Connecting the Electrical Leads
81
Disconnecting/Connecting the Cables and Hose
82
Adjusting the Throttle Control Cable(S)
83
Removing/Installing the Power Unit
84
Installing the Power Unit
85
Removing/Installing the Throttle Link and Right Side Electrical Components
86
Removing/Installing the Left Side Electrical Components 1 (One Lighting Coil Model)
88
Removing/Installing the Left Side Electrical Components 2 (One Lighting Coil Model)
89
Removing/Installing the Left Side Electrical Components 1(Two Lighting Coils Model)
90
Removing/Installing the Left Side Electrical Components 2(Two Lighting Coils Model)
91
Thermostat, Timing Belt and Gears
92
Removing/Installing the Thermostat, Timing Belt and Gears
92
Removing the Timing Belt
94
Removing the Drive Gear
94
Removing the Driven Gear
94
Checking the Thermostat
95
Checking the Timing Belt
95
Installing the Driven Gear
95
Installing the Drive Gear
96
Installing the Timing Belt
97
Adjusting the Valve Clearance
97
Anode and Exhaust Cover
99
Checking the Anode
99
Installing the Exhaust Cover
99
Cylinder Head and Oil Pump
100
Removing/Installing the Cylinder Head and Oil Pump
100
Checking the Spark Plug
102
Installing the Oil Pump
102
Installing the Cylinder Head
102
Installing the Cylinder Head Cover
103
Disassembling/Assembling the Oil Pump
104
Checking the Oil Pump
105
Assembling the Oil Pump
105
Camshaft and Valves
106
Removing/Installing the Camshaft and Valves
106
Removing the Valve
108
Checking the Valve and Valve Guide
108
Checking the Valve Spring
109
Checking the Rocker Arm Rocker Arm Shaft
110
Checking the Camshaft
110
Checking the Cylinder Head
111
Replacing the Valve Guide
111
Refacing the Valve Seat
112
Installing the Valve
114
Installing the Camshaft Oil Seal
114
Crankshaft, Piston and Cylinder Body
115
Removing/Installing the Crankshaft, Piston and Cylinder Body
115
Disassembling/Assembling the Piston and Connecting Rod
116
Checking the Cylinder Body
117
Checking the Piston
117
Calculating the Piston-To-Cylinder Clearance
118
Checking the Piston Pin
118
Checking the Piston Ring
119
Checking the Crankshaft
119
Checking the Crankshaft-Plain Bearing Oil Clearance
120
Checking the Crankshaft-Connecting Rod Oil Clearance
122
Installing the Piston Ring
124
Installing the Connecting Rod
124
Installing the Piston and Connecting Rod
125
Installing the Oil Seal
125
Installing the Crankcase
125
Chapter 6 Lower Unit
126
Checking the Anode
130
Checking the Propeller
130
Installing the Lower Unit
130
Removing the Propeller
130
Installing the Propeller
131
Removing/Installing the Water Pump
132
Checking the Water Pump Housing, Cartridge Insert and Impeller
133
Propeller Shaft Housing and Propeller Shaft
134
Removing/Installing the Propeller Shaft Housing Assembly and Propeller Shaft Assembly
134
Installing the Propeller Shaft Housing Assembly
135
Disassembling/Assembling the Propeller Shaft Assembly
136
Checking the Dog Clutch
137
Checking the Propeller Shaft
137
Assembling the Propeller Shaft Assembly
137
Disassembling/Assembling the Propeller Shaft Housing Assembly
138
Disassembling the Propeller Shaft Housing Assembly
139
Checking the Reverse Gear
139
Checking the Ball Bearing
139
Checking the Propeller Shaft Housing
140
Assembling the Propeller Shaft Housing Assembly
140
Drive Shaft and Forward Gear
142
Removing/Installing the Drive Shaft and Forward Gear
142
Removing the Ball Bearing
143
Checking the Pinion
143
Checking the Drive Shaft
143
Checking the Forward Gear
143
Checking the Ball Bearing
143
Installing the Ball Bearing
144
Bearing Housing, Shift Cam and Lower Case
145
Removing/Installing the Bearing Housing, Shift Cam and Lower Case
145
Removing the Solid Bushing
146
Disassembling the Bearing Housing
146
Checking the Coller
146
Checking the Shift Cam
146
Checking the Lower Case
146
Assembling the Bearing Housing
147
Installing the Solid Bushing
148
Backlash
149
Measuring the Forward Gear Backlash
149
Measuring the Reverse Gear Backlash
150
Chapter 7 Bracket Unit
152
Bracket Unit
152
Removing/Installing the Steering Handle
153
Installing the Steering Handle
155
Adjusting the Throttle Control Cables
155
Adjusting the Shift Cable
155
Disassembling/Assembling the Steering Handle
156
Assembling the Steering Handle
158
Removing/Installing the Shift Lever
159
Removing/Installing the Bottom Cowling
161
Removing/Installing the Upper Case
163
Installing the Lower Mount
164
Disassembling/Assembling the Upper Case
165
Installing the Oil Seal
167
Installing the Muffler
167
Swivel and Steering Bracket
168
Removing/Installing the Swivel and Steering Bracket
168
Steering Friction
169
Disassembling/Assembling the Steering Friction
169
Assembling the Steering Friction
170
Removing/Installing the Clamp Bracket
171
Installing the Clamp Bracket Plate
173
Chapter 8 Electrical System
176
Electrical System
176
Electrical Components
177
(One Lighting Coil Model)
177
Top View and Left Side View
177
Details of the Wiring Harness Connection
178
(Two Lighting Coils Model)
179
Top View, Front View and Left Side View
179
Details of the Wiring Harness Connection
180
Electrical Components Analysis
181
Digital Circuit Tester
181
Measuring the Peak Voltage
181
Peak Voltage Adaptor
181
Measuring a Low Resistance
182
Ignition System
183
Checking the Spark Plugs
184
Checking the Ignition Spark Gap
184
Checking the Spark Plug Caps and Ignition Coil
184
Checking the Charge Coil
186
Checking the Pulser Coil
186
Checking the CDI Unit
187
Ignition Control System
188
Checking the Engine Stop Switch
189
Checking the Pulser Coil
189
Checking the Oil Pressure Switch
190
Checking Emergency Signal Light
190
Charging System
191
(One Lighting Coil Model)
191
(Two Lighting Coils Model)
192
Checking the Battery
193
Checking the Lighting Coil
193
Checking the Rectifier and Rectifier/Regulator
194
Trouble Analysis
195
Manual Format
204
All of the Procedures in this Manual Are Organised in a Sequential, Step-By-Step Format. the Information Has Been Compiled to Provide the Mechanic with an Easy to Read, Handly
204
Reference that Contains Comprehensive Explanations of All Disassembly, Repair, Assembly, and Inspection Operations
204
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
204
Bearings Pitting/Scratches
204
To Assist You in Finding Your Way through this Manual, the Section Title and Major Heading Is Given at the Top of Every Page
204
Model Indication
204
Multiple Models Are Referred to in this Manual and Their Model Indications Are Noted as Follows
204
USA and Canada Name
204
The Illustrations Within this Service Manual Represent All of the Designated Models
204
General Information
208
Identification
211
Serial Number
211
Starting Serial Numbers
211
Special Tools
212
Removal and Installation
212
General Specifications (T8Ph/T8Mh/Ft8Dmh)
214
General Specifications (Ft8Dep/T8Pr, Ft8De/T8Er)
215
Maintenance Specifications
217
Power Unit
217
Lower Unit
220
Electrical
221
Outboard Dimensions (T8Ph/T8Mh/Ft8Dmh)
223
Outboard Dimensions (Ft8Dep/T8Pr, Ft8De/T8Er)
225
Bracket Dimension (Ft8Dmh/T8Mh, Ft8De/T8Er)
227
Bracket Dimension (Ft8Dep/T8Pr/T8Ph)
228
Maintenance Interval Chart
232
Power Unit
233
Adjusting the Valve Clearance
233
General
234
Checking the Anode
234
Lower Unit
235
Removing/Installing the Lower Unit
235
Power Tilt System
234
Checking the Power Tilt (Pt) Fluid Level
234
Water Pump
237
Removing/Installing the Water Pump
237
Checking the Impeller Housing
238
Checking the Impeller and Impeller Housing Cup
238
Installing the Impeller Housing Cup
238
Propeller Shaft Housing and Propeller Shaft
239
Removing/Installing the Propeller Shaft Housing Ass'yand Propeller Shaft Ass'y
239
Removing the Propeller Shaft Housing Ass'y
240
Propeller Shaft Ass'y
241
Disassembling/Assembling the Propeller Shaft Ass'y
241
Checking the Dog Clutch
242
Checking the Propeller Shaft
242
Propeller Shaft Housing Ass'y
243
Disassembling/Assembling the Propeller Shaft Housing Ass'y
243
Disassembling the Propeller Shaft Housing Ass'y
244
Checking the Gears
244
Checking the Bearing
245
Checking the Propeller Shaft Housing
245
Assembling Propeller Shaft Housing Ass'y
245
Drive Shaft, Forward Gear, Shift Rod and Oil Seal Housing
247
Removing/Installing the Drive Shaft, Forward Gear and Shaft Rod
247
Removing the Pinion and Forward Gear
249
Disassembling the Oil Seal Housing Ass'y
249
Installing the Sleeve
249
Disassembling the Lower Case
250
Checking the Pinion and Forward Gear
251
Checking the Drive Shaft
251
Checking the Shift Cam
251
Checking the Bearing
251
Checking the Sleeve
251
Checking the Lower Case
251
Assembling the Lower Case
251
Assembling the Oil Seal Housing Ass'y
252
Assembling the Forward Gear
252
Shimming (for Usa and Canada)
253
Selecting the Pinion Shims
253
Shimming (Except for Usa and Canada)
254
Selecting the Pinion Shims
254
Selecting the Forward Gear Shims
255
Selecting the Reverse Gear Shims
256
Backlash Measurement
257
Measuring the Forward Gear Backlash
257
Measuring the Reverse Gear Backlash
258
Upper Case
260
Disassembling/Assembling the Upper Case
260
Steering Friction
262
Disassembling/Assembling the Steering Friction
262
Power Tilt (Pt) Unit
263
Disassembling/Assembling the Valves and Pump 1
263
Installing the Relief Valve
265
Disassembling/Assembling the Pt Motor
266
Removing the Armature
267
Checking the Pt Motor
267
Checking the Pt Motor Assembly
269
Installing the Oil Seal
269
Disassembling/Assembling the Power Tilt (Pt) Cylinder
272
Disassembling the Power Tilt (Pt) Cylinder
274
Assembling the Power Tilt (Pt) Cylinder
275
Removing/Installing the Power Tilt (Pt) Unit
279
Starter Motor
281
Disassembling/Assembling the Starter Motor
281
Removing the Pinion
283
Checking the Pinion
283
Checking the Armature
283
Checking the Brush Holder
284
Power Tilt (Pt) System
285
Power Tilt (Pt) System (T8Pr/Ft8Dep)
285
Power Tilt (Pt) System (T8Ph)
286
Checking the Pt Switch
287
Checking the Pt Relay
287
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Yamaha FT8DMH Specifications
General
Brand
Yamaha
Model
FT8DMH
Category
Outboard Motor
Language
English
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