Yamaha 9.9C, Service Manual

Page 1: ...15C SERVICE MANUAL 63V 28197 1F 11 LIT 18616 02 59 9 9C ...

Page 2: ... and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Important information Particularly important information is distinguished in this manual by the following notations Q The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED w Failure to follow WARNING instructions could result in severe injury or death to...

Page 3: ...Model name 9 9C 15C USA and 9 9CMH 15CMH CANADA name Indication 9 9 15 ...

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Page 9: ...Model Approved Staring World wide USA model code serial No 9 9FMH 9 9CMH 682K S 1009214 15FMH 15CMH 684K S 1019178 ...

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Page 17: ... Twin Total 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 1 Control system Tiller handle Starting system Manual starter Enrichment system Choke valve Ignition control system CDI Ignition timing Degree ATDC 5 0 BTDC 30 0 Maximum generator output V W 12 80 12 40 80 Spark plug NGK B7HS 10 Cooling system Water Exhaust system Propeller boss Lubricatio...

Page 18: ...e 8 0 12 0 16 0 20 0 Tilt up angle Degree 67 0 Steering angle Degree 45 0 45 0 Drive unit Gear shift positions F N R Gear ratio 2 08 27 13 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear view Clockwise Propeller ID mark J ...

Page 19: ...ension B mm in 1 98 2 00 0 0780 0 0787 Dimension T mm in 2 40 2 60 0 0945 0 1024 End gap mm in 0 15 0 35 0 0059 0 0138 Side clearance mm in 0 02 0 06 0 0008 0 0024 2nd ring Barrel Dimension B mm in 1 96 1 98 0 0772 0 0780 Dimension T mm in 2 40 2 60 0 0945 0 1024 End gap mm in 0 15 0 35 0 0059 0 0138 Side clearance mm in 0 04 0 08 0 0016 0 0032 Reed valve Valve stopper height mm in 0 6 0 7 0 02 0 ...

Page 20: ... height mm in 12 5 15 5 0 49 0 61 Valve seat size mm in 1 2 0 05 Main jet M J 110 Main nozzle M N mm in 3 0 0 12 Main air jet M A J 120 Pilot jet P J 48 Pilot air jet P A J 75 LOWER UNIT Item Unit Model 9 9C 15C Gear backlash Pinion forward mm in 0 19 0 86 0 0075 0 0339 Pinion reverse mm in 0 95 1 65 0 0374 0 0650 Pinion shims mm 1 13 1 2 Forward shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Reverse...

Page 21: ...nition coil resistance Primary coil B W B Ω 0 05 0 07 Secondary coil B W spark plug wire kΩ 1 6 2 5 Pulser coil resistance B W B Ω 352 00 528 00 Charge coil resistance Br L Ω 248 00 372 00 CDI Unit output peak voltage B O B B W B Cranking load V 120 0 1 500 r min load V 210 0 3 500 r min load V 170 0 Lighting system Lighting voltage minimum 3 000 V 11 5 maximum 5 500 V 14 0 17 5 Lighting coil resi...

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Page 24: ...d carburetor models Inspection adjustment 1 1 Anode s external Inspection replacement 1 1 Anode s internal Inspection replacement 1 Cooling water passages Cleaning 1 1 Propeller and cotter pin Inspection replacement 1 1 Throttle link throttle cable throttle pick up timing Inspection adjustment 1 Shift link shift cable Inspection adjustment 1 Thermostat Inspection 1 Water pump Inspection 1 Cowling ...

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Page 29: ...3 6 CONTROL SYSTEM LOWER UNIT INSP ADJ ...

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Page 35: ...4 1 CARBURETOR REMOVAL FUEL ...

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Page 37: ...4 3 CARBURETOR REMOVAL FUEL ...

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Page 39: ...4 5 CARBURETOR FUEL ...

Page 40: ...king 1 6 Screw 1 7 Arm pin 1 8 Float 1 9 Clip 1 10 Needle valve 1 11 Cap 1 12 Pilot jet 1 13 Main jet 1 14 Main nozzle 1 15 Screw with washer 4 4 x 10 mm 16 Plate 1 17 Packing 1 18 Stopping screw 1 19 Spring 1 20 Carburetor body 1 FUEL PUMP DISASSEMBLY Follow the left Step for removal 1 Screw with washer 4 2 Pump cover 1 3 Diaphragm 1 4 Pump body 1 5 Screw 2 6 Seat valve 2 7 Nut 2 8 Diaphragm 1 9 ...

Page 41: ...sassembling the carburetor make sure to note number of times the pilot screw is turned out from the seated position to its set position 8 Do not use steelwire for cleaning the jets as this may enlarge the jet diameters and seri ously affect performance ...

Page 42: ...CARBURETOR FUEL Carburetor assembly NOTE Before assembling the carburetor make sure to turn the pilot screw the same number of times as noted before disassembly from the seated position to its set position ...

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Page 46: ...5 2 POWER UNIT REMOVAL POWR ...

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Page 75: ...6 1 LOWER UNIT REMOVAL LOWR ...

Page 76: ...6 2 LOWER UNIT REMOVAL LOWR ...

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Page 84: ...6 10 DRIVE SHAFT FORWARD GEAR AND SHIFT ROD LOWR ...

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Page 100: ...7 1 STEERING HANDLE AND SHIFT LEVER BRKT ...

Page 101: ...7 2 STEERING HANDLE AND SHIFT LEVER BRKT ...

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Page 105: ...7 6 UPPER CASE AND EXHAUST MANIFOLD BRKT ...

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Page 108: ...7 9 CRAMP BRACKET BRKT ...

Page 109: ...7 10 CRAMP BRACKET BRKT ...

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Page 112: ...ELEC ...

Page 113: ...8 1 ELECTRICAL COMPONENTS ELEC ...

Page 114: ...8 2 ELECTRICAL COMPONENTS ELEC ...

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Page 117: ...8 5 IGNITION SYSTEM ELEC ...

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Page 122: ...8 10 IGNITION SYSTEM ELEC ...

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Page 124: ...8 12 STARTING SYSTEM ELEC ...

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Page 135: ...Printed in USA YAMAHAMOTOR CORPORATION USA ...