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The Yamaha outboard motor service manual downloads for the above listed models describes the service procedures for the complete engine. Follow the Maintenance Schedule recommendations to ensure that the motor is in peak operating condition and the emission levels are within the standards set by the your states/county Resources Board. Performing the scheduled maintenance is very important. It compensates for the initial wear that occurs during the life of the outboard motor.
 
All chapters in the Yamaha service manuals apply to the whole engine and illustrates procedures for removal & installation of components that are in detailed step-by-step fashion.
 
Most all service manual chapters start with an assembly or system illustration, diagrams, exploded parts view, quality pictures, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to the troubleshooting page for a list of causes and effects to determine the problem at the end of the manual.

1984-1994 Yamaha Outboard Service Manual/WorkShop Manual Application: 2 hp 1 cyl. (43cc) 2-stroke 1984 1994, 3 hp 1 cyl. (70cc) 2-stroke 1989, 3 hp 1 cyl. (70cc) 2-stroke 1990 1994, 4 hp 1 cyl. (83cc) 2-stroke 1984 1994, 5 hp 1 cyl. (103cc) 2-stroke 1984 1994, 6 hp 2 cyl. (165cc) 2-stroke 1986 1994, 8 hp 2 cyl. (165cc) 2-stroke 1984 1994, 9.9 hp 2 cyl. (246cc) 2-stroke 1984 1994, 9.9 hp 2 cyl. (232cc) 4-stroke 1984 1994, 15 hp 2 cyl. (246cc) 2-stroke 1984 1994, 25 hp 2 cyl. (395cc) 2-stroke 1988 1994, 25 hp 2 cyl. (430cc) 2-stroke 1990 1994, 25 hp 2 cyl. (496cc) 2-stroke 1984 1994, 28 Jet 3 cyl. (698cc) 2-stroke 1990 1994, 30 hp 2 cyl. (496cc) 2-stroke 1984 1994, 30 hp 3 cyl. (496cc) 2-stroke 1987 1994, 35 Jet 3 cyl. (698cc) 2-stroke 1987 1994, 40 hp 2 cyl. (592cc) 2-stroke 1989 1994, 40 hp 3 cyl. (698cc) 2-stroke 1984 1994, 50 hp 3 cyl. (698cc) 2-stroke 1984 1994, 50 hp 3 cyl. (849cc) 2-stroke 1994 1994, 55 hp 2 cyl. (760cc) 2-stroke 1989 1994, 60 hp 3 cyl. (849cc) 2-stroke 1991 1992 1993 1994, 65 Jet 3 cyl. (1140cc) 2-stroke 1987 1994, 70 hp 3 cyl. (849cc) 2-stroke 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994, 75 hp 3 cyl. (1140cc) 2-stroke 1994, 80 hp 3 cyl. (1140cc) 2-stroke 1994, 80 Jet V4 (1730cc) 2-stroke 1987 1994, 85 hp 3 cyl. (1140cc) 2-stroke 1989 1994, 90 hp 3 cyl. (1140cc) 2-stroke 1984 1994, 115 hp V4 (1730cc) 2-stroke 1984 1994, 130 hp V4 (1730cc) 2-stroke 1988 1994, 140 hp V4 (1730cc) 2-stroke 1984 1994, 140 Jet V6 (2596cc) 2-stroke 1987 1994, 150 hp V6 (2596cc) 2-stroke 1984 1994, 175 hp V6 (2596cc) 2-stroke 1984 1994, 200 hp V6 (2596cc) 2-stroke 1984 1994, 220 hp V6 (2596cc) 2-stroke 1984 1985 1986 1987, 225 hp 76 deg. V6 (3130cc) 2-stroke 1994, 225 hp 90 deg. V6 (2596cc) 2-stroke 1987 1988 1989 1990 1991 1992 1993 1994, 250 hp V6 (3130cc) 2-stroke 1990 1994

LIT-18616-01-24 Service Manual Application: Yamaha Ouboard 9.9HP (9.9-HP) 4-stroke engines. Model Names: T9.9T (T9.9-T), F9.9T (F9.9T), T9.9MH (T9.9-MH), F9.9AM (F9.9-AM), F9.9AEM (FT9.9-AEM), T9.9ER (T9.9-ER), F9.9AE (F9.9-AE), F9.9MH (F9.9-MH), F9.9BM (F9.9-BM), T9.9EH (T9.9-EH), F9.9BEM (F9.9-BEM), F9.9BE (F9.9-BE).

LIT-18616-01-28 Service Repair Manual Application: 1995, 1996, 1997 (95, 96, 97) Yamaha Marine Outboard E48T (E48-T) C55T (C55-T) 48HP & 55HP 2-Stroke. Item Model Names: E48T, C55T, E48C, E48MH, E55C, 55BM, C55ER, 55BE, 55BEM, C55TR, 55BET.

LIT-18616-01-35 Service Manual Application: 1996-1997 Yamaha F8, T9.9, F9.9 8HP (8-hp) & 9.9Hp (9.9-hp) 4-stroke engines. Exact Models Covered (Covers All 1996-1997 Models World Wide): F8B (F8-B), F9.9A (F9.9-A), F9.9B (F9.9-B), T9.9U (T9.9-U), F9.9U (F9.9-U), F8BM (F8-BM), F8BEM (F8-BEM), F8BE (F8-BE), T9.9MH (T9.9-MH), T9.9AM (T9.9-AM), FT9.9AMH (FT-9.9-AMH), T9.9EH (T9.9-EH), F9.9AEM (FT9.9-AEM), T9.9ER (T9.9-ER), FT9.9AE (FT9.9-AE), F9.9MH (F9.9-MH), F9.9BM (F9.9-BM), F9.9EH (F9.9-EH), F9.9BEM (F9.9-BEM), F9.9BE (F9.9-BE).

LIT-18616-01-29 Service Repair Manual Application: 1996, 1997 (96, 97) E60, E60H 60HP (60-HP) Yamaha Marine Outboard 2-Stroke. Item Model Names: E60, E60H, E60HM, E60HE, E60HEM, E60MH, E60EH. Covers USA, Canada and wold wide models.

LIT-18616-01-73 Service Repair Manual Application: 1997 97' Yamaha Marine Outboard 75HP (75HP) 2-Stroke. Item Model Names: E75V, E-75-V, E75-V, E-75V 75AM, 75AEM, 75AE, 75AET, 85AEM, 85AE, 85AET, E75B, E60J, E75MH. Covers USA, Canada and wold wide models.

LIT-18616-01-66 Service Repair Manual Application: 1997-1998 Yamaha Marine Outboard 20HP (20-HP) & 25HP 25-HP) 10V, 25V, 25V2 2-Stroke Engines. Model Names 20DM (20-DM), 20DMO (20-DMO), 20DEM (20-DEM), 20DEMO (20-DEMO), 20DERO (20-DERO), 20MH (20-MH), 20MH2 (20-MH2), 20EH (20-EH), 20EH2 (20-EH2), 25DM (25-DM), 25NMO (25-NMO), 25NEMO (25-NEMO), 25NE (25-NE), 25NEO (25-NEO), 25NERO (25-NERO), 25MH (25-MH), 25MH2 (25-MH2), 25EH (25-EH), 25ER (25-ER).

LIT-18616-01-81 Service Repair Manual Application: 1998-1999 98-99 40HP (40-HP) & 50HP (50-HP) 40W 50W Yamaha Marine Outboard 2-Stroke Item Model Names: 40-W, 50-W, 40VMH, 40VMHD, 40VMHO, 40VMO, 40VWH, 40VE, 40VEO, 40VEHTO, 40VET, C40MH, 40MH, C40ER, 40ER, P40TH, C40TR, 40VETO, 50HMHO, 50HMHD, 50HMO, 50HMDO, 50HWHD, 50HEDO, 50HET, 50HETO, 40TR, 50ER, C50TR, 50TR Covers USA, Canada and wold wide models.

LIT-18616-F1-50 & LIT-18616-02-12 Service Repair Manual Application: 1998-2005 Yamaha Marine Outboard 15HP (15-HP) 4-Stroke Engines F15W (F15-W), F15Z (F15-Z) 1998, 1999, 2000, 2001, 2002, 2003, 2004 & 2005. This manual covers all 15HP 4-Stroke models world wide including USA CANADA. USA & CANADA MODELS: F15MHW (F15-MHW), F15EHW (F15-EHW), F15AMH (F15-AMH), F15AEH (F15-AEH), F15AEP (F15-AEP), F15AEHP (F15-AEHP), F15PR (F15-PR), F15PH (F15-PH), F15AEP (F15-AEP), F15AEHP (F15-AEHP). WOLD WIDE MODELS: F15AMH (F15-AMH), F15AEH (F15-AEH), F15AE (F15-AE).

LIT-18616-01-83 Service Manual Application: 1998-2006 Yamaha F8, T9.9, F9.9 8HP (8-hp) & 9.9Hp (9.9-hp) 4-stroke engines for 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 & 2006. Model Name: T9.9W (T9.9-W), F9.9W (F9.9-W), F8BMH (F8-BMH), F8BEH (F8-BEH), F8BE (F8-BE), T9.9MH (T9.9-MH) FT9.9AMH (FT-9.9-AMH), T9.9EH (T9.9-EH), FT9.9AEH (FT9.9-AEH), T9.9ER (T9.9-ER), FT9.9AE (FT9.9-AE), F9.9MH (F9.9-MH), F9.9BMH (F9.9-BMH), F9.9EH (F9.9-EH), F9.9BEH (F9.9-BEH), F9.9BE (F9.9-BE).

LIT-18616-01-79 Service Repair Manual Application: 1998-2005 Yamaha Marine Outboard 4HP (4-HP) 4-Stroke Engines F4X (F4-X, F-4X) 1999, 2000, 2001, 2002, 2003, 2004 & 2005. This manual covers all 4HP 4-Stroke models world wide including F4MSHX, F4MLHX, F4AMH, USA CANADA.

LIT-18616-01-94 Service Repair Manual Application: 1999-2000 99-00 25HP (25-HP) & 30HP (30-HP) 25X, 25-X, 30X, 30-X, 25J, 25-J, 30D, 30-D Yamaha Marine Outboard 2-Stroke. Model Names: 25JMH, 25MH3, 30DMH, 25JMHO, 30DMHO, 30MH, 25JEHO, 25EH3, 30DWH, 25JEO, 25JETO, 25TR3, 30DEHO, 30EH, 30DMO, 30DE, 30DEO, 30ER, 30DET, 30DETO, 30TR Covers USA, Canada and wold wide models.

LIT-18616-01-96 Service Repair Manual Application: 1999, 2000, 2001, 2002 99, 00, 01, 02 100HP (100-HP) F100X, F100-X, F-100X Yamaha Marine Outboard 4-Stroke. Model Names: F100TR, F100-TR, F-100TR, F100AET, F-100AET, F100-AET Covers USA, Canada and woldwide models.

LIT-18616-02-16 Service Repair Manual Application: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 00, 01, 02, 03, 04, 05, 06 Yamaha Marine Outboard 40HP (40-HP) F40B (F-40B-F40-B) 4-Stroke Engines. Model name F40BMHD, F40BWHD, F40BED, F40BET, USA and Canada name F40MH, F40ER, F40TR.

LIT-18616-02-19 Service Repair Manual Application: 2001, 2002, 2003, 2004, 2005, 2006, 01, 02, 03, 04, 05, 06, Yamaha Marine Outboard 6HP & 8HP (F6Z F8Z) 4-Stroke Engines. Model Name: F6AMH, F8CMH, F6MH, F8MH (F6-AMH, F6-MH, F8-AMH, F8-MH).

ALL 250HP 2003-2006 MODELS Service Repair Manual Application: 2003, 2004, 2005, 2006 Yamaha Marine Outboard 250HP (250-HP) 2-Stroke & 4-Stroke Engines. LIT-18616-02-78 -  2004-2005 Z250C & LZ250C LZ250TR 2-STROKE ENGINE. LIT-18616-02-43 - 2003-2005 Z250B & LZ250B MODEL NAME Z250TR/LZ250TR 2-STROKE ENGINE. LIT-18616-02-97 - 2005-2006 F250 & LF250 F250TR/LF250TR 4-STROKE ENGINE. 

LIT-18616-02-54 Service Repair Manual Application: 2004, 2005, 2006 Yamaha Marine Outboard 2.5HP (2.5-HP) F2.5C (F2.5-C, F 2.5C) F2.5MH 4-Stroke Engines.

LIT-1816-02-59 Service Repair Manual Application: 2004, 2005, 2006 Yamaha Marine Outboard 9.9HP & 15HP (9.9-HP 15-HP) 2-Stroke Engines. Model name 9.9CMH & 15CMH ( 9.9 & 15 CMH).

LIT-18616-02-61 Service Repair Manual Application: 2004-2006 Yamaha Marine Outboard 25HP (25-HP) 4-Stroke Engines F25C, T25C (F-25C F25-C T25-C T-25C) F25MH, F25EH, F25ER, F25TR, T25TR.

LIT-18616-02-65 Service Repair Manual Application: 2004-2006 Yamaha Marine Outboard 40HP (40-HP) & 50HP (50-HP) 4-Stroke Engines. Exact model name 40VETO 50HETO, Both USA and CANADA models covered 40TR 50TR / 40C-50C.

LIT-18616-02-66 Service Repair Manual Application: 2004 2005 2006 Yamaha Marine Outboard 70HP (70-HP) 2-Stroke Engines. Model name 70BETO, USA and Canada name 70TR 70C (70-C).

LIT-18616-02-66 Service Repair Manual Application: 2004 2005 2006 Yamaha Marine Outboard 90HP (90-HP) 2-Stroke Engines. Model name 90AETO, USA and Canada name 90TR 90C (90-C).

LIT-18616-02-72 Service Repair Manual Application: 2004-2005-2006 Yamaha Marine Outboard 130HP & 115HP (115C 130C) 2-Stroke Engines. Model Name: 115CETO (115-CETO), 130BETO (130-BETO) 115TR, 130TR.

LIT-18616-02-51 Service Repair Manual Application: 2004, 2005, 2006 Yamaha Marine Outboard 150HP (150-HP) F150C & LF150C (LF-F-150C-F150-C) 4-Stroke Engines. Model name F150TR, LF150TR (F-LF-150-TR)

LIT-18616-02-71 Service Repair Manual Application: 2004, 2005, 2006 Yamaha Marine Outboard 115HP (115-HP) 4-Stroke Engines. Model name F115AET LF115AET, USA and Canada name F115TR LF115TR.

LIT-18616-02-73 Service Repair Manual Application: 2004-2005-2006 Yamaha Marine Outboard 150 HP (150HP) 150C & V150C 2-Stroke Engines. Model Name: 150FETO, 150GETO.

LIT-18616-02-66 Service Repair Manual Application: 2004 2005 2006 Yamaha Marine Outboard 60HP (60-HP) 2-Stroke Engines. Model name 60FETO USA and Canada name 60TR, 60C (60-C).

LIT-18616-02-76 Service Repair Manual Application: 2004-2006 Yamaha Marine Outboard F200C, LF200C, F225C, LF225C 200HP (200-HP) & 225HP (225-HP) V6 4-Stroke Engines.

LIT-18616-02-85 Service Repair Manual Application: 2005-2006 Yamaha Marine Outboard 50HP & 60HP (50-HP, 60-HP) 4-Stroke Engines F50D T50D F60D T60D (F-50-D, T-50-D, F60-D, T60-D).

LIT-18616-02-86 Service Repair Manual Application: 2005-2006 05-06' Yamaha Marine Outboard F90D 90HP 4-Stroke Engines. Model Name F90TR


RELATED YAMAHA OUTBOARD ENGINE SPCIFICATIONS (SPECS) SEARCHES:

PERFORMANCE
Horsepower:
Model Wide Open Throttle (WOT) rpm
Range
115 hp (85.8 Kw) @ 5500 rpm
5000 - 6000
OUTBOARD
WEIGHT
Electric
115 EFI ELPT 386 lb (175 kg)
FUEL
Recommended Gasoline Automotive Unleaded
with a Minimum Pump Posted
Octane Rating of 87
OIL
Oil Filter
Oil Filter Wrench
Engine Oil Capacity
Engine Oil
+20
+40
+60
+80
F° C°
0
+100
–7
+4
+16
+27
–18
+38
SAE
10W-30
SAE
25W-40
p/n 35-822626A2
p/n 91-802653Q1
Either 5 Quarts or 5 Liters
SAE 10W-30 viscosity oil is recommended
for use in all temperatures.
SAE 25W-40 viscosity oil may be used
at temperatures above 40° F (4° C).
Use  4-Cycle Marine
Oil with the proper viscosity for the
expected temperature in your area (see
range thermometer on left). If not available,
use a premium quality 4-cycle engine
oil certified to meet or exceed any
one of the following American Petroleum
Institute (API) service classifications
SH, SG, SF, CF-4, CE, CD, CDll.

IGNITION
SYSTEM
Readings taken @
68°F (20°C).
Type
Spark Plug:
Type
Gap
Hex Size
Torque
Hole Size
Firing Order
Ignition Timing:
@ Idle (750 rpm) in Neutral
@ WOT (6000 rpm)
Stator Coil Output - Peak Voltage:
@ 400 rpm (Cranking)
@ 750 rpm (Idle)
@ 1500 rpm
@ 3500 rpm
Stator Coil Resistance
Crank Position Sensor - Peak Voltage:
@ 400 rpm (Cranking)
@ 750 rpm (Idle)
@ 1500 rpm
@ 3500 rpm
Crank Position Sensor Resistance
ECM (Coil Primary) - Peak Voltage:
@ 400 rpm (Cranking)
@ 750 rpm (Idle)
@ 1500 rpm
@ 3500 rpm
Ignition Coil Resistance
Primary
Secondary (Between Boots)
Coil for Cylinders 1 & 4
Coil for Cylinders 2 & 3
Engine Protection Controls:
Engine Speed Limiter
Spark Cut-Out to Cylinders
#1 or #4
#1 and #4
#1, #4, and #2 or #3
#1, #2, #3, and #4
Overheat/Low Oil Pressure Engine
Speed Control (Spark Cut-Out to
Cylinders #1 and #4).
Water Temperature Sensor:
Warning Horn/rpm Reduction.
Reset Temperature and Closed
Throttle.
Engine Oil Pressure Switch:
Warning Horn/rpm Reduction
Microcomputer-ECM
NGK LFR6A-11
0.039 - 0.043 in. (1.0 - 1.1 mm)
5/8 in. (16 mm)
18 lb-ft (25 Nm)
14 mm
1-3-4-2
4° A.T.D.C
20° B.T.D.C
10 - 18 V
16 - 24 V
16 - 24 V
16 - 24 V
0.2 - 0.8 W
3.0 -6.3 V
9 - 16 V
18 - 28 V
35 - 55 V
445 - 565 W
180 - 320 V
180 - 235 V
230 -290 V
280 - 340 V
1.8 - 2.6 W
18.97 - 35.23 kW
18.55 - 34.45 kW
6200 rpm
6250 rpm
6350 rpm
6450 rpm
Gradually Lowers to 2000 rpm
194°F (90°C)
167°F (75°C)
Continuity Below 21.78 psi (150 kPa)

IGNITION
SYSTEM
Readings taken @
68°F (20°C).
Reset Pressure and Closed
Throttle.
Engine Water Temperature Sensor
Resistance:
@ 41°F (5°C)
@ 68°F (20°C)
@ 212°F (100°C)
Throttle Position Sensor (TPS):
Input Voltage @ Idle (750 rpm)
Output Voltage@ Idle (750 rpm)
No Continuity Above 21.78 psi (150 kPa)
4.62 kW
2.44 kW
0.19 kW
5.0 ± 0.25 V
0.718 - 0.746 V
CHARGING
SYSTEM
Readings taken @
68°F (20°C).
Alternator Type:
Alternator Output
Stator Coil - Peak Voltage:
@ 400 rpm (Cranking)
@ 750 rpm (Idle)
@ 1500 rpm
@ 3500 rpm
Stator Coil Resistance
Rectifier/Regulator Output - Peak
Voltage:
@ 750 rpm (Idle)
@ 1500 rpm
@ 3500 rpm
Quicksilver Tachometer Setting
Three Phase Stator Coil (12 Pole)
12.0 V; 25 Amps. (300 Watts)
(Rectified/Regulated)
10 - 18 V
16 - 24 V
16 - 24 V
16 - 24 V
0.2 - 0.8 W
12.5 - 15.5 V
13.0 - 16.0 V
13.0 - 16.0 V
“6P” or “4”
STARTING
SYSTEM
Electric Start:
Starter Type
Model/Manufacturer
Output
Rating
Reduction Gear Ratio
Brush:
Length
Minimum Length
Commutator:
Diameter
Minimum Diameter
Undercut
Undercut Limit
Ampere Draw Under:
(Load)
(No Load)
Sliding Gear
S114-838A/Hitachi
1.4 kW - 12 V
30 Seconds
7.85 (102:13)
0.610 in. (15.5 mm)
0.374 in. (9.5 mm)
1.113 in. (29.0 mm)
1.100 in. (28.0 mm)
0.020 in. (0.5 mm)
0.008 in. (0.2 mm)
165 Amps
80 Amps
BATTERY
Battery Rating
Minimum Requirement
For operation below 32° F (0° C)
Ampere-Hours (Ah)
465 Marine Cranking Amps (MCA)
or 350 Cold Cranking Amps (CCA)
1000 Marine Cranking Amps (MCA) or
775 Cold Cranking Amps (CCA)
70 - 100
FUEL
SYSTEM
Fuel Pump Type
Fuel Pump:
Discharge (@ 3000 rpm)
Pressure (Maximum)
Plunger Stroke
Fuel Tank Capacity
External (Plunger/Diaphragm)
17 gph (65 L/h)
7 psi (49 kPa)
0.23 - 0.36 in. (5.85 - 9.05 mm)
Accessory

FUEL INJECTION
Fuel Injection System
Idle rpm (In Neutral) Warm
Idle rpm (In Forward Gear) Warm
Fuel Pressure @ 1500rpm
Batch (1 & 4) - (2 & 3)
750 ± 50 rpm
700 ± 50 rpm
41-44 psi (283-304 kPa)
CYLINDER
BLOCK
Type
Displacement
Number of Cylinders
In–Line, 4 Stroke – DOHC, 16 Valves
106.2 cid (1,741 cc)
4
STROKE Length 3.496 in. (88.8 mm)
CYLINDER
BORE
Diameter
Standard
Oversize-0.010 in. (0.25 mm)
Taper/Out of Round Maximum
Bore Type
3.110 - 3.111 in. (79.000 - 79.020 mm)
3.120 - 3.121 in. (79.250 - 79.270 mm)
0.003 in. (0.08 mm)
Cast Iron
PISTON
Piston Type
Measure Point (H)
O.D. at Skirt (H)
Standard (D)
Oversize-0.010 in. (0.25 mm)
Pin Boss Inside Diameter
H
D
Aluminum
0.51 in. (13 mm)
3.1074 - 3.1082 in. (78.928 - 78.949 mm)
3.1174 - 3.1182 in. (79.178 - 79.199 mm)
0.7090 - 0.7093 in. (18.008 - 18.015 mm)
PISTON
CLEARANCE
Piston to Cylinder Clearance 0.0028 - .0031 in. (0.070 - 0.080 mm)
RINGS
Top Ring
Dimension “B”
Dimension “T”
End Gap (Installed)
Side Clearance
Middle Ring
Dimension “B”
Dimension “T”
End Gap (Installed)
Side Clearance
Bottom (Oil Ring)
Dimension “B”
Dimension “T”
End Gap (Installed)
Side Clearance
T
B
T
B
T
B
0.046 - 0.047 in. (1.17 - 1.19 mm)
0.114 - 0.115 in. (2.89 - 2.91 mm)
0.006 - 0.012 in. (0.15 - 0.30 mm)
0.001 - 0.003 in. (0.03 - 0.08 mm)
0.058 - 0.059 in. (1.47 - 1.49 mm)
0.118 - 0.126 in. (3.00 - 3.20 mm)
0.028 - 0.035 in. (0.70 - 0.90 mm)
0.001 - 0.003 in. (0.03 - 0.08 mm)
0.094 - 0.098 in. (2.38 - 2.48 mm)
0.094 in. (2.40 mm)
0.008 - 0.028 in. (0.20 - 0.70 mm)
0.001 - 0.006 in. (0.03 - 0.15 mm)
COMPRESSION
RATIO
Compression Ratio
Cylinder Compression (Minimum)
9.7:1
138 psi (950 kPa)
PISTON PIN Piston Pin Outside Diameter 0.7085 - 0.7087 in. (17.997 - 18.000 mm)

CONNECTING
ROD
Small End Inside Diameter
Big End Inside Diameter
Oil Clearance (Big End)
Big End Bearing Thickness
Yellow
Green
Blue
Red
0.7073 - 0.7081 in. (17.965 - 17.985 mm)
1.7726 - 1.7734 in. (45.025 - 45.045 mm)
0.0010 - 0.0012 in. (0.025 - 0.031 mm)
0.0591 - 0.0594 in. (1.502 -1.508 mm)
0.0594 - 0.0596 in. (1.508 - 1.514 mm)
0.0596 - 0.0598 in. (1.514 - 1.520 mm)
0.0598 - 0.0601 in. (1.520 - 1.526 mm)
CRANKSHAFT
Crankshaft Journal
Diameter
Minimum Diameter
Crankshaft Pin
Diameter
Minimum Diameter
Crankshaft Run-out
1.8891 - 1.8898 in.
(47.984 - 48.000 mm)
1.8887 in. (47.972 mm)
1.6535 - 1.6528 in.
(42.000 - 41.982 mm)
1.7311 in. (43.971 mm)
0.001 in. (0.03 mm)
CRANKCASE
Crankcase Main Journal Inside
Diameter
Crankshaft Journal Oil Clearance
Upper Crankcase Main Journal
Bearing Thickness
Green
Blue
Red
Lower Crankcase Main Journal
Bearing Thickness
Yellow
Green
Blue
Red
No. 3 Main Journal Bearing Thickness
Green
Blue
Red
2.1269 - 2.1276 in.
(54.023 - 54.042 mm)
0.0009 - 0.0017 in. (0.024 - 0.044 mm)
0.1178 - 0.1181 in. (2.992 - 2.999 mm)
0.1181 - 0.1183 in. (2.999 - 3.006 mm)
0.1183 - 0.1186 in. (3.006 - 3.013 mm)
0.1185 -0.1188 in. (3.010 - 3.017 mm)
0.1188 - 0.1191 in. (3.017- 3.024 mm)
0.1191 - 0.1193 in. (3.024 - 3.031 mm)
0.1193 - 0.1196 in. (3.031 - 3.038 mm)
0.1178 - 0.1181 in. (2.992 - 2.999 mm)
0.1181 - 0.1183 in. (2.999 - 3.006 mm)
0.1183 - 0.1186 in. (3.006 - 3.013 mm)

CAMSHAFT
Camshaft Dimensions
Intake “A”
Exhaust “A”
Intake “B”
Exhaust “B”
Valve Lift
Intake
Exhaust
Run-out Limit
Camshaft Bearing Diameter “a”
Camshaft Bearing Oil Clearance
A
B
A
1.465 - 1.472 in. (37.22 - 37.38 mm)
1.453 - 1.459 in. (36.90 - 37.06 mm)
1.178 - 1.184 in. (29.92 - 30.08 mm)
1.178 - 1.184 in. (29.92 - 30.08 mm)
0.287 in. (7.30 mm)
0.275 in. (6.98 mm)
0.004 in. (0.1 mm)
0.9827 - 0.9835 in. (24.96 - 24.98 mm)
0.0008-0.0024 in.(0.020-0.061 mm)
VALVE SPRING
Free Length “a”
Minimum Free Length
Tilt Limit “b”
2.094 in. (53.20 mm)
2.057 in. (52.25 mm)
Less than 0.10 in. (2.6 mm)
CYLINDER HEAD
Warp Limit
Camshaft Bearing Inside Diameter
Valve Lifter Bore Inside Diameter
0.004 in. (0.1 mm)
0.984 - 0.985 in. (25.000 - 25.021 mm)
1.102 - 1.103 in. (28.000 - 28.021 mm)
VALVES
Valve/Valve Seat/Valve Guides:
Valve Clearance (cold)
Intake
Exhaust
Valve Face Angle
Intake
Exhaust
Valve Dimensions:
“A” Head Diameter
Intake
Exhaust
“B” Face Width
Intake
Exhaust
“C” Seat Width
Intake
Exhaust
“D” Margin Thickness
Intake
Exhaust
Stem Outside Diameter
Intake
Exhaust
Guide Inside Diameter
Intake
Exhaust
Stem To Guide Clearance
Intake
Exhaust
Stem Run-out Limit (max.)
0.007 - 0.009 in. (0.17 - 0.23 mm)
0.012 - 0.014 in. (0.31 - 0.37 mm)
120°, 91°, 110°
140°, 91°, 110°
1.142 - 1.150 in. (29.00 - 29.20 mm)
0.945 - 0.953 in. (24.00 - 24.20 mm)
0.078 - 0.094 in. (1.98 - 2.40 mm)
0.089 - 0.106 in. (2.26 - 2.69 mm)
0.062 - 0.076 in. (1.58 - 1.94 mm)
0.071 - 0.080 in. (1.80 - 2.02 mm)
0.031 - 0.047 in. (0.80 - 1.20 mm)
0.039 - 0.055 in. (1.00 - 1.40 mm)
0.2352 - 0.2358 in. (5.975 - 5.990 mm)
0.2346 - 0.2352 in. (5.960 - 5.975 mm)
0.2364 - 0.2369 in. (6.005 - 6.018 mm)
0.2364 - 0.2369 in. (6.005 - 6.018 mm)
0.0006 - 0.0017 in. (0.015 - 0.043 mm)
0.0012 - 0.0023 in. (0.030 - 0.058 mm)
0.001 in. (0.03 mm)
“A”
“B”
“C”
“D”
Valve Dimensions
Head Diameter Face Width Seat Width Margin Thickness
VALVE LIFTERS
Valve Lifter Outside diameter
Valve Lifter to Lifter Bore Clearance
1.1010 - 1.1016 in.
(27.965 - 27.980 mm)
0.0008 - 0.0022 in. (0.020 -0.056 mm)
VALVE SHIM Valve shim Thickness
(in 0.025 mm increments)
0.0787 - 0.1299 in. (2.000 - 3.300 mm)
THERMOSTAT
Valve Opening Temperature
Full Open Temperature
Valve Lift (Minimum)
122° F (50° C)
140° F (60° C)
0.17 in. (4.3 mm)

LUBRICATION
SYSTEM
Pump Type
Oil Pump Drive
Discharge at 212°F (100°C) with
10W-30 Oil at 1000 rpm
Engine Oil Pressure (Warm Engine)
@ 750 rpm
Engine Oil Pan Capacity
Relief Valve Opening Pressure
Oil Pump:
Non-Serviceable
Trochoid with Relief Valve
Drive shaft Spline
1.56 gph (5.9 L/h)
50.75 psi (350 kPa)
Either 5 Qts. or 5 Liters
71 psi (490 kPa)
MID-SECTION
Recommended Transom Height:
Short Shaft
Long Shaft
Steering Pivot Range
Full Tilt Up Angle
Allowable Transom Thickness (Max)
20 in. (51 cm)
25 in. (64 cm)
60°
71°
3 in. (76.2 mm)
GEAR HOUSING
BIGFOOT
(2.07:1)
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Pinion Gear Locating Tool
Flat Number
Disc Number
Forward Gear Backlash
Backlash Indicating Tool
Mark Number
Water Pressure
@ 1000 rpm
@ 6000 rpm (WOT)
2.07:1
24 fl oz (710 mL)
Premium Gear Lubricant
29 Spiral/Bevel
14 Spiral/Bevel
0.025 in. (0.64 mm)
91-12349A2
#2
#3
0.015-0.022 in. (0.38-0.55 mm)
91-19660--1
#1
5 psi (34.5 kPa)
20.5 psi (141.5 kPa)

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