9.9c, 15c service manual

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  • 15C

    SERVICE MANUAL

    63V-28197-1F-11LIT-18616-02-59

    9.9C

  • NOTICE

    This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trainedmechanics when performing maintenance procedures and repairs to Yamaha equipment. It hasbeen written to suit the needs of persons who have a basic understanding of the mechanical andelectrical concepts and procedures inherent in the work, for without such knowledge attemptedrepairs or service to the equipment could render it unsafe or unfit for use.

    Because Yamaha has a policy of continuously improving its products, models may differ in detailfrom the descriptions and illustrations given in this publication. Use only the latest edition of thismanual. Authorized Yamaha dealers are notified periodically of modifications and significantchanges in specifications and procedures, and these are incorporated in successive editions of thismanual.

    Important informationParticularly important information is distinguished in this manual by the following notations:

    Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

    wFailure to follow WARNING instructions could result in severe injury or death to the machineoperator, a bystander, or a person inspecting or repairing the outboard motor.

    cCA CAUTION indicates special precautions that must be taken to avoid damage to the out-board motor.

    NOTE:A NOTE provides key information to make procedures easier or clearer.

    9.9C/15CSERVICE MANUAL

    2003 by by Yamaha Motor Corporation, USA1st Edition, December 2003

    All rights reserved.Any reprinting or unauthorized usewithout the written permission ofYamaha Motor Corporation, USA

    is expressly prohibited.Printed in USALIT-18616-02-59

    Chapter1 03.11.14 20:04 Page 1

  • Model name 9.9C 15C

    USA and9.9CMH 15CMH

    CANADA name

    Indication 9.9 15

    Chapter1 03.11.14 20:04 Page 2

  • Model Approved Staring

    World wide USA model code serial No.

    9.9FMH 9.9CMH 682K S:1009214

    15FMH 15CMH 684K S:1019178

    Chapter1 03.11.26 13:54 Page 3

  • 2-1

    GENERAL SPECIFICATIONSSPEC

    GENERAL SPECIFICATIONS

    Item UnitModel

    9.9C 15CDimensions

    Overall length mm (in) 873 (34.4)Overall width mm (in) 332 (13.1)Overall height mm (in) 1,040 (40.9)

    Transom height mm (in) 440 (17.3)Boat transom height mm (in) 381 (15.0)Dry weight

    kg (lb) (*1) 36.0 (79)Performance

    Maximum output kW (hp) 7.3 (9.9) 11.0 (15)

    @ 5,000 r/minFull throttle operating range r/min 4,500-5,500Maximum fuel consumption L (US gal,lmp gal)/hr 5.1 (1.3, 1.1) @ 5,500 r/min 7.3 (1.9, 1.6) @ 5,500 r/minIdle speed r/min 700800

    Power unitEngine type 2-stroke, TwinTotal displacement cm3 (cu. in) 446.0 (15.01)Bore x stroke mm (in) 56.0 50.0 (2.20 1.97)Compression ratio 6.80 :1Control system Tiller handleStarting system Manual starterEnrichment system Choke valveIgnition control system CDIIgnition timing Degree ATDC 5.0BTDC 30.0Maximum generator output V-W 1280 1240/80Spark plug (NGK) B7HS-10Cooling system WaterExhaust system Propeller bossLubrication system Pre-mixed fuel and oil (100:1)

    Fuel and oilFuel type Regular gasolineEngine oil 2-stroke outboard motor oilEngine oil grade NMMA-certified TC-W3Gear oil type Hypoid gear oilGear oil grade (*2) API GL-4

    SAE 90Gear oil quantity cm3 (US oz, 250.0 (8.45, 8.82)

    lmp oz)

    (*1) With Aluminum propeller(*2) Meeting both API and SAE requirements

    Chapter2 03.11.14 20:06 Page 1

  • 2-2

    GENERAL SPECIFICATIONSSPEC

    Item UnitModel

    9.9C 15CBracket unit

    Tilt angle Degree 8.0, 12.0, 16.0, 20.0Tilt-up angle Degree 67.0Steering angle Degree 45.0 + 45.0

    Drive unitGear shift positions F-N-RGear ratio 2.08 (27/13)Reduction gear type Spiral bevel gearClutch type Dog clutchPropeller shaft type SplinePropeller direction (rear view) ClockwisePropeller ID mark J

    Chapter2 03.11.14 20:06 Page 2

  • 2-3

    MAINTENANCE SPECIFICATIONSSPEC

    MAINTENANCE SPECIFICATIONSENGINE

    Item UnitModel

    9.9C 15CCylinder head

    Warpage limit mm (in) 0.10 (0.0039)Cylinder

    Bore size mm (in) 56.00056.020 (2.2047-2.2055)Wear limit mm (in) 56.1 (2.21)Taper limit mm (in) 0.08 (0.0032)Out-of-round limit mm (in) 0.05 (0.0020)

    PistonPiston diameter (D) mm (in) 55.94055.985 (2.20242.2041)Measuring point (H) mm (in) 10.0 (0.39)

    Piston-to-cylinder clearance mm (in) 0.0350.040 (0.00140.0016)Wear limit 0.09Piston pin boss bore mm (in) 14.00414.015 (0.55130.5518)

    Piston pinOutside diameter mm (in) 13.99614.000 (0.55100.5512)

    Piston ringsTop ring Keystone

    Dimension B mm (in) 1.982.00 (0.07800.0787)Dimension T mm (in) 2.402.60 (0.09450.1024)End gap mm (in) 0.150.35 (0.00590.0138)Side clearance mm (in) 0.020.06 (0.00080.0024)

    2nd ring BarrelDimension B mm (in) 1.961.98 (0.07720.0780)Dimension T mm (in) 2.402.60 (0.09450.1024)End gap mm (in) 0.150.35 (0.00590.0138)Side clearance mm (in) 0.040.08 (0.00160.0032)

    Reed valveValve stopper height mm (in) 0.60.7 (0.020.03) 5.96.1 (0.230.24)Valve vending limit mm (in) 0.200 (0.0079)Connecting rod

    Small end inside diameter mm (in) 18.00018.011 (0.70870.7091)Big end inside diameter mm (in) 28.03928.052 (1.10391.1044)

    CrankshaftCrank width (A) mm (in) 46.9046.95 (1.851.85)

    (B) mm (in) 25.9026.10 (1.021.03)

    Runout limit (D) mm (in) 0.03 (0.0012)Big end side clearance (E) mm (in) 0.3000.800 (0.01180.0315)Maximum small end axial play (F) mm (in) 2.0 (0.08)

    Chapter2 03.11.14 20:06 Page 3

  • 2-4

    MAINTENANCE SPECIFICATIONSSPEC

    Item UnitModel

    9.9C 15CThermostat

    Opening temperature C (F) 48.052.0 (118.40125.60)Fully open temperature C (F) 60.0 (140.00)Valve open lower limit mm (in) 3.0 (0.12)

    CarburetorID mark 63V10Float height mm (in) 12.515.5 (0.490.61)Valve seat size mm (in) 1.2 (0.05)Main jet (M.J.) #110Main nozzle (M.N.) mm (in) 3.0 (0.12)Main air jet (M.A.J.) #120Pilot jet (P.J.) #48Pilot air jet (P.A.J.) #75

    LOWER UNIT

    Item UnitModel

    9.9C 15CGear backlash

    Pinion forward mm (in) 0.190.86 (0.00750.0339)Pinion reverse mm (in) 0.951.65 (0.03740.0650)Pinion shims mm 1.13, 1.2Forward shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50Reverse shims mm 0.1, 0.2, 0.3, 0.4, 0.5

    Chapter2 03.11.14 20:06 Page 4

  • 2-5

    MAINTENANCE SPECIFICATIONSSPECELCTRICAL

    Item UnitModel

    9.9C 15CIgnition system

    Ignition timing (full retarded) Degree A.T.D.C. 4.06.0(full advanced) Degree B.T.D.C. 29.031.0

    Piston position (full retarded) Degree A.T.D.C. 0.1(full advanced) Degree B.T.D.C. 4.04.4 (B.T.D.C. 0.160.18)

    Spark plug gap mm (in) 0.91.0 (0.0350.039 )Ignition coil resistancePrimary coil (B/WB) 0.050.07Secondary coil(B/Wspark plug wire) k 1.62.5Pulser coil resistance (B/WB) 352.00528.00Charge coil resistance (BrL) 248.00372.00CDI Unit output peak voltage(B/OB, B/WB)@ Cranking (load) V 120.0@ 1,500 r/min (load) V 210.0@ 3,500 r/min (load) V 170.0

    Lighting systemLighting voltage(minimum) @3,000 V 11.5(maximum) @5,500 V 14.017.5Lighting coil resistance (GG) 0.160.24

    DIMENSIONSmm (in)

    Symbol UnitModel

    9.9C 15CH4 :S mm (in) 440.0 (17.32)C1 mm (in) 30.0 (1.18)C2 mm (in) 56.0 (2.20)

    Chapter2 03.11.26 13:55 Page 5

  • 3-1

    MAINTENANCE INTERVAL CHARTINSPADJ

    10 hours 50 hours 100 hours 200 hours(1 month) (3 months) (6 months) (1 year)

    Spark plug(s) Cleaning / adjustment /replacement 1 1 1

    Greasing points Greasing 1Gear oil Change 1 1Fuel system Inspection 1 1 1Fuel filter (can bedisassembled) Inspection / cleaning 1 1 1

    Fuel tank (Yamahaportable tank) Inspection / cleaning 1

    Idling speed (carburetormodels) Inspection / adjustment 1 1

    Anode(s) (external) Inspection / replacement 1 1Anode(s) (internal) Inspection / replacement 1Cooling water passages Cleaning 1 1Propeller and cotter pin Inspection / replacement 1 1Throttle link / throttle cable/ throttle pick-up timing Inspection / adjustment 1

    Shift link / shift cable Inspection / adjustment 1Thermostat Inspection 1Water pump Inspection 1Cowling clamp Inspection 1

    Item ActionsInitial Every

    NOTE:When operating in salt water, turbid or muddy water, the engine should be flushed with clean waterafter each use.

    Chapter3 03.11.14 20:06 Page 1

  • 3-6

    CONTROL SYSTEM/LOWER UNITINSPADJ

    Chapter3 03.11.14 20:06 Page 2

  • 4-1

    CARBURETOR REMOVALFUEL

    Chapter4 03.11.14 20:07 Page 1

  • 4-3

    CARBURETOR REMOVALFUEL

    Chapter4 03.11.14 20:08 Page 2

  • 4-5

    CARBURETORFUEL

    Chapter4 03.11.26 13:57 Page 3

  • 4-6

    CARBURETORFUEL

    Step Procedure/Part name Qty Service pointsCARBURETOR DISASSEMBLY Follow the left Step for removal.Carburetor assembly Refer to the CARBURETOR REMOVAL

    section in chapter 4.1 Drain screw 12 Washer 13 Screw (with washer) 4 4 x 14 mm4 Float chamber 15 Float chamber packing 16 Screw 17 Arm pin 18 Float 19 Clip 1

    10 Needle valve 111 Cap 112 Pilot jet 113 Main jet 114 Main nozzle 115 Screw (with washer) 4 4 x 10 mm16 Plate 117 Packing 118 Stopping screw 119 Spring 120 Carburetor body 1

    FUEL PUMP DISASSEMBLY Follow the left Step for removal.1 Screw (with washer) 42 Pump cover 13 Diaphragm 14 Pump body 15 Screw 26 Seat valve 27 Nut 28 Diaphragm 19 Diaphragm gasket 1

    Reverse the removal steps for installation.

    REMOVAL AND INSTALLATION CHART

    Chapter4 03.11.26 13:57 Page 4

  • 4-7

    CARBURETORFUEL

    SERVICE POINTSNOTE:8 Before disassembling the carburetor, make

    sure to note number of times the pilot screwis turned out from the seated position to itsset position.