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9.9F, 15F
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NOTICE
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HOW TO USE THIS MANUALMANUAL FORMATMODEL INDICATIONTHE
ILLUSTRATIONSREFERENCES
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WARNINGS, CAUTIONS AND NOTES
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HOW TO READ DESCRIPTIONS
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SYMBOLS
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INDEX
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CHAPTER 1. GENERAL INFORMATION
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IDENTIFICATIONSERIAL NUMBERSTARTING SERIAL NUMBER
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SAFETY WHILE WORKINGFIRE
PREVENTIONVENTILATIONSELF-PROTECTIONOILS, GREASES AND SEALING
FLUIDS
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GOOD WORKING PRACTICES
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DISASSEMBLY AND ASSEMBLY
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SPECIAL TOOLSMEASURING
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REMOVAL AND INSTALLATION
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CHAPTER 2. SPECIFICATIONS
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GENERAL SPECIFICATIONS
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MAINTENANCE SPECIFICATIONSENGINE
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LOWERELECTRICALDIMENSION
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TIGHTENING TORQUESPECIFIED TORQUEGENERAL TORQUE
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CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT
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MAINTENANCE INTERVAL CHART
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PERIODIC SERVICEFUEL SYSTEMFuel lineCONTROL SYSTEMIgnition
timing adjustment
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Throttle link adjustment
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Start-in-gear protection adjustmentIdle speed adjustment
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LOWER UNITGear oil
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Lower unit leakage checkGENERALAnode
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Battery
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Spark plug
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Greasing point
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CHAPTER 4. FUEL SYSTEM
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FUEL JOINT AND FUEL FILTEREXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHARTSERVICE POINTSFuel joint
inspectionFuel filter inspection
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CARBURETOR REMOVALEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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CARBURETOREXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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SERVICE POINTSCarburetor inspectionFuel pump inspection
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Carburetor assembly
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CHAPTER 5. POWER UNIT
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POWER UNIT REMOVALEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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RECOIL STARTEREXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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SERVICE POINTSSheave drum removalSpiral spring removalStarter
stopping plunger inspectionDrive pawl and spring inspectionBushing
inspection
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Sheave drum inspectionSpiral spring inspectionStarter rope
inspectionRecoil starter checking
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FLYWHEEL MAGNETO AND MAGNETO BASEEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHARTSERVICE POINTSFlywheel magneto
removal
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ELECTRICAL UNITEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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CONTROL UNITEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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REED VALVEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART
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SERVICE POINTSReed valve inspection
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CYLINDER HEAD, THERMOSTAT AND EXHAUST COVEREXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHARTSERVICE POINTSCylinder head
inspection
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Thermostat inspection
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CRANKCASE AND CYLINDER BODYEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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SERVICE POINTSCylinder body inspection
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Piston to cylinder clearanceCylinder body and crankcase
installation
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CRANK SHAFT AND PISTONEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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SERVICE POINTSBearing removalPiston inspectionPiston pin and
small end bearing inspection
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Piston ring inspection
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Crankshaft inspection
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Piston and piston ring installationCrankshaft and piston
installation
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CHAPTER 6. LOWER UNIT
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LOWER UNIT REMOVALEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHARTSERVICE POINTSPropeller
inspection
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WATER PUMPEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHARTSERVICE POINTSWater pump housing
inspectionImpeller and insert cartridge inspection
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PROPELLER SHAFT AND REVERSE GEAREXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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SERVICE POINTSPropeller shaft housing removalPropeller shaft
housing disassembly
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Reverse gear inspectionBearing inspectionPropeller shaft housing
inspectionDog clutch inspectionPropeller shaft inspectionPropeller
shaft housing assembly
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DRIVE SHAFT, FORWARD GEAR AND SHIFT RODEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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SERVICE POINTSPinion nut removal and installationForward gear
disassemblyBearing housing disassembly and assemblyLowercase
disassembly
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Pinion and forward gear inspectionDrive shaft inspectionShift
cam inspectionBearing inspectionSleeve inspection
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Lower case inspectionLower case assembly
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Drive shaft oil seal housing assemblyForward gear assembly
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SHIMMINGEXPLODED DIAGRAM
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SHIM SELECTION (FOR USA AND CANADA)Pinion gear shim
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SHIM SELECTION (EXCEPT FOR USA AND CANADA)Pinion gear shim
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Forward gear shim
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Reverse gear shim
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BACKLASH MEASUREMENTForward gear
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Reverse gear
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CHAPTER 7. BRACKET UNIT
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STEERING HANDLE AND SHIFT LEVEREXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART AND SHIFT LEVER
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SERVICE POINTSControl cable inspectionBushing inspectionFriction
piece inspectionSteering handle inspectionThrottle shaft
inspection
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BOTTOM COWLINGEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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UPPER CASE AND EXHAUST MANIFOLDEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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SERVICE POINTSRubber mount inspectionMount bolt inspection
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CLAMP BRACKETEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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STEERING AND SWIVEL BRACKETEXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHART
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CHAPTER 8. ELECTRICAL UNIT
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ELECTRICAL COMPONENTSMANUAL STARTER MODEL
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ELECTRICAL STARTER MODEL
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REMOTE CONTROL MODEL
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ELECTRICAL ANALYSISINSPECTIONPeak voltage measurement
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IGNITION SYSTEMWIRING DIAGRAM
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IGNITION SPARK GAP
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CDI SYSTEM PEAK VOLTAGE
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SPARK PLUG
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SPARK PLUG CAP
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ENGINE STOP SWITCHMAIN SWITCH
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STARTING SYSTEMWIRING DIAGRAM
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BATTERYFUSEWIRING HARNESSWIRING CONNECTIONENGINE STOP SWITCHMAIN
SWITCHSTARTER SWITCHNEUTRAL SWITCH
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STARTER RELAY
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STARTER MOTOREXPLODED DIAGRAM
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REMOVAL AND INSTALLATION CHARTSERVICE POINTSPinion removal
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Pinion inspectionArmature inspection
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Brush holder inspectionCover inspection
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CHARGING SYSTEMWIRING DIAGRAM
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CHARGING SYSTEM PEAK VOLTAGEFUSEBATTERY
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CHAPTER 9. TROUBLE ANALYSIS
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TROUBLE ANALYSISTROUBLE ANALYSIS CHART
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9.9F, 15FNOTICEHOW TO USE THIS MANUALMANUAL FORMATMODEL
INDICATIONTHE ILLUSTRATIONSREFERENCESWARNINGS, CAUTIONS AND
NOTESHOW TO READ DESCRIPTIONSSYMBOLS
INDEXCHAPTER 1. GENERAL INFORMATIONIDENTIFICATIONSERIAL
NUMBERSTARTING SERIAL NUMBER
SAFETY WHILE WORKINGFIRE
PREVENTIONVENTILATIONSELF-PROTECTIONOILS, GREASES AND SEALING
FLUIDSGOOD WORKING PRACTICESDISASSEMBLY AND ASSEMBLY
SPECIAL TOOLSMEASURINGREMOVAL AND INSTALLATION
CHAPTER 2. SPECIFICATIONSGENERAL SPECIFICATIONSMAINTENANCE
SPECIFICATIONSENGINELOWERELECTRICALDIMENSION
TIGHTENING TORQUESPECIFIED TORQUEGENERAL TORQUE
CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENTMAINTENANCE
INTERVAL CHARTPERIODIC SERVICEFUEL SYSTEMFuel line
CONTROL SYSTEMIgnition timing adjustmentThrottle link
adjustmentStart-in-gear protection adjustmentIdle speed
adjustment
LOWER UNITGear oilLower unit leakage check
GENERALAnodeBatterySpark plugGreasing point
CHAPTER 4. FUEL SYSTEMFUEL JOINT AND FUEL FILTEREXPLODED
DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE POINTSFuel joint
inspectionFuel filter inspection
CARBURETOR REMOVALEXPLODED DIAGRAMREMOVAL AND INSTALLATION
CHART
CARBURETOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE
POINTSCarburetor inspectionFuel pump inspectionCarburetor
assembly
CHAPTER 5. POWER UNITPOWER UNIT REMOVALEXPLODED DIAGRAMREMOVAL
AND INSTALLATION CHART
RECOIL STARTEREXPLODED DIAGRAMREMOVAL AND INSTALLATION
CHARTSERVICE POINTSSheave drum removalSpiral spring removalStarter
stopping plunger inspectionDrive pawl and spring inspectionBushing
inspectionSheave drum inspectionSpiral spring inspectionStarter
rope inspectionRecoil starter checking
FLYWHEEL MAGNETO AND MAGNETO BASEEXPLODED DIAGRAMREMOVAL AND
INSTALLATION CHARTSERVICE POINTSFlywheel magneto removal
ELECTRICAL UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION
CHART
CONTROL UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART
REED VALVEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE
POINTSReed valve inspection
CYLINDER HEAD, THERMOSTAT AND EXHAUST COVEREXPLODED
DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE POINTSCylinder head
inspectionThermostat inspection
CRANKCASE AND CYLINDER BODYEXPLODED DIAGRAMREMOVAL AND
INSTALLATION CHARTSERVICE POINTSCylinder body inspectionPiston to
cylinder clearanceCylinder body and crankcase installation
CRANK SHAFT AND PISTONEXPLODED DIAGRAMREMOVAL AND INSTALLATION
CHARTSERVICE POINTSBearing removalPiston inspectionPiston pin and
small end bearing inspectionPiston ring inspectionCrankshaft
inspectionPiston and piston ring installationCrankshaft and piston
installation
CHAPTER 6. LOWER UNITLOWER UNIT REMOVALEXPLODED DIAGRAMREMOVAL
AND INSTALLATION CHARTSERVICE POINTSPropeller inspection
WATER PUMPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE
POINTSWater pump housing inspectionImpeller and insert cartridge
inspection
PROPELLER SHAFT AND REVERSE GEAREXPLODED DIAGRAMREMOVAL AND
INSTALLATION CHARTSERVICE POINTSPropeller shaft housing
removalPropeller shaft housing disassemblyReverse gear
inspectionBearing inspectionPropeller shaft housing inspectionDog
clutch inspectionPropeller shaft inspectionPropeller shaft housing
assembly
DRIVE SHAFT, FORWARD GEAR AND SHIFT RODEXPLODED DIAGRAMREMOVAL
AND INSTALLATION CHARTSERVICE POINTSPinion nut removal and
installationForward gear disassemblyBearing housing disassembly and
assemblyLowercase disassemblyPinion and forward gear
inspectionDrive shaft inspectionShift cam inspectionBearing
inspectionSleeve inspectionLower case inspectionLower case
assemblyDrive shaft oil seal housing assemblyForward gear
assembly
SHIMMINGEXPLODED DIAGRAMSHIM SELECTION (FOR USA AND
CANADA)Pinion gear shim
SHIM SELECTION (EXCEPT FOR USA AND CANADA)Pinion gear
shimForward gear shimReverse gear shim
BACKLASH MEASUREMENTForward gearReverse gear
CHAPTER 7. BRACKET UNITSTEERING HANDLE AND SHIFT LEVEREXPLODED
DIAGRAMREMOVAL AND INSTALLATION CHART AND SHIFT LEVERSERVICE
POINTSControl cable inspectionBushing inspectionFriction piece
inspectionSteering handle inspectionThrottle shaft inspection
BOTTOM COWLINGEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART
UPPER CASE AND EXHAUST MANIFOLDEXPLODED DIAGRAMREMOVAL AND
INSTALLATION CHARTSERVICE POINTSRubber mount inspectionMount bolt
inspection
CLAMP BRACKETEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART
STEERING AND SWIVEL BRACKETEXPLODED DIAGRAMREMOVAL AND
INSTALLATION CHART
CHAPTER 8. ELECTRICAL UNITELECTRICAL COMPONENTSMANUAL STARTER
MODELELECTRICAL STARTER MODELREMOTE CONTROL MODEL
ELECTRICAL ANALYSISINSPECTIONPeak voltage measurement
IGNITION SYSTEMWIRING DIAGRAMIGNITION SPARK GAPCDI SYSTEM PEAK
VOLTAGESPARK PLUGSPARK PLUG CAPENGINE STOP SWITCHMAIN SWITCH
STARTING SYSTEMWIRING DIAGRAMBATTERYFUSEWIRING HARNESSWIRING
CONNECTIONENGINE STOP SWITCHMAIN SWITCHSTARTER SWITCHNEUTRAL
SWITCHSTARTER RELAY
STARTER MOTOREXPLODED DIAGRAMREMOVAL AND INSTALLATION
CHARTSERVICE POINTSPinion removalPinion inspectionArmature
inspectionBrush holder inspectionCover inspection
CHARGING SYSTEMWIRING DIAGRAMCHARGING SYSTEM PEAK
VOLTAGEFUSEBATTERY
CHAPTER 9. TROUBLE ANALYSISTROUBLE ANALYSISTROUBLE ANALYSIS
CHART
