228

CHAPTER FIVE

75

77 INTAKE MANIFOLD AND REED HOUSING (2 HP MODEL)

76
1. 2. 3. 4. 5. Intake manifold/reed housing Reed valve Reed stop Lockwasher Screw

78 INTAKE MANIFOLD AND REED HOUSING (3 HP MODEL)

REED HOUSING/INTAKE MANIFOLD Inspect the reed valves upon removal for bent, cracked or missing sections (Figure 75, typical). Measure the reed tip opening (A, Figure 76) and reed stop opening (B) during inspection and after installing new components. If the measurement(s) are incorrect, replace the reed valve and/or reed stop. Reed valve specifications are in Table 2.
1. 2. 3. 4. 5. Intake manifold/adapter/reed housing Reed valve Reed stop Lockwasher Screw

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229

79 INTAKE MANIFOLD AND REED HOUSING (4 AND 5 HP MODELS)

81 INTAKE MANIFOLD AND REED HOUSING (9.9 AND 15 HP MODELS)

1. 2. 3. 4. 5.

Intake manifold/reed housing Reed valve Reed stop Lockwasher Screw

1. 2. 3. 4.

Screw and lockwasher Reed stop Reed valve Intake manifold/reed housing

80

INTAKE MANIFOLD AND REED HOUSING (6 AND 8 HP MODELS)

Reed housing and intake manifold designs vary by model. Refer to Figures 77-84 during the removal, disassembly and installation procedures. Removal 1. Remove the carburetor as described in this chapter. 2. On oil injected models, disconnect the oil lines from the intake manifold fittings. 3. Remove the fasteners, then carefully pry the intake manifold, reed housing and plates from the crankcase cover. Remove and discard any gaskets. 4. Inspect the reeds for defects, then measure the reed tip and reed stop openings as described in this section. Remove the reed valves and stops only if they must be replaced. Remove them as follows: a. On 20-90 hp models, remove the screws, then carefully pull the reed assemblies from the intake manifold. b. Remove the screws, reed stops and reed valves from the engine. 5. Use a suitable solvent to thoroughly clean all components. Dry the components with compressed air. Clean all residual Loctite from the reed screw and screw openings.

1. 2. 3. 4. 5. 6. 7. 8. 9.

Bolt Intake manifold Gasket Reed housing Gasket Reed stop Reed valve Screw Carburetor mounting gasket

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CHAPTER FIVE

82

INTAKE MANIFOLD AND REED HOUSING (20 HP, 25 HP AND 30 HP MODELS)

20 and 25 hp two-cylinder models

1. 2. 3. 4. 5. 6. 7. 8.

Screws Reed stops Reed valves Reed valve assemblies Screw and lockwashers Screw and washer Intake manifold Gasket

25 and 30 hp three-cylinder models

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231

83 INTAKE MANIFOLD AND REED HOUSING (28 JET, 35 JET, 40 HP AND 50 HP)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Screw Reed stop Reed valve Reed body Gasket Plate Gasket Bolt Oil inlet fittings Intake manifold

Inspection 1. Inspect the reed valves for cracked, chipped or missing petals. Replace all reeds in the engine if any are faulty. The conditions contributing to reed failure may have affected other reed valves. Remove the cylinder head and inspect the piston and cylinder head if any petals are missing. Refer to Chapter Eight for cylinder head removal and installation procedures.

2. Inspect the reed contact surface for worn or irregular surfaces. Replace the reed body, intake manifold or reed mounting plate if these are any defects. 3. Inspect the screw opening for damaged or missing threads. The threads may be damaged during screw removal. Replace the component if the threads are damaged. 4. Inspect the reed stop for cracked or damaged surfaces and replace as needed.

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CHAPTER FIVE

84 INTAKE MANIFOLD AND REED HOUSING (60-90 HP MODELS)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Screw Lockwasher Reed stop Reed valve Reed body Reed valve assembly Screw and washer Gasket Plate Gasket Intake manifold Bolt and washer

5. Use feeler gauges to measure the reed tip opening at the points indicated (A, Figure 76). If the reed tip opening exceeds the specification in Table 2, replace the reed valves. 6. Use a depth micrometer to measure the distance from the tip of the reed valve to the reed stop surface (B, Figure 76). If the measurement is not within the reed stop opening specification in Table 2, replace the reed stop. Installation Refer to Figures 77-84 during the assembly and installation procedures.

1. Install the reed valve and reed stop onto the reed mounting surface. Center the reed petals over the openings. 2. Apply Loctite 242 to the threads of the reed and reed stop mounting screws, then thread the screws into the intake manifold, reed plate or reed body. Check for properly centered reed petals, then tighten the screws to the specification in Table 1. 3. On 20-90 hp models, install new gaskets, then fit the reed valve assemblies onto the plate and intake manifold. Apply Loctite 242 to the threads, then hand-thread the reed assembly screws into the reed assemblies, plate and intake manifold. Tighten the screws evenly to the specification in Table 1.

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233

85

RECIRCULATION SYSTEM (4 AND 5 HP MODELS)

88

RECIRCULATION SYSTEM (65 JET AND 75-90 HP MODELS)

1. Hose: 120 mm (4.72 in.) 2. Hose: 100 mm (3.94 in.) 3. Hose: 70 mm (2.76 in.)

86

RECIRCULATION SYSTEM (28 JET, 45 JET, 40 HP AND 50 HP MODELS)

4. Install a new gasket, then install the intake manifold/reed housing assembly onto the intake manifold. 5. Apply Loctite 242 to the threads, then hand-thread the intake manifold bolts into the power head. Tighten the bolts in two steps to the specification in Table 1. Use a crossing pattern or the cast in torque sequence numbering on the intake manifold. 6. On oil injected models, connect the oil lines to the intake manifold fittings. 7. Install the carburetor(s) and silencer cover as described in this chapter. 8. On oil injected models, bleed air from the oil injection system as described in Chapter Twelve. RECIRCULATION SYSTEM Faulty hoses in the recirculation system result in oil and fuel leaks, hard starting, and rough idling. Inspect the recirculation hoses for tears, leaks or deterioration. Replace all of the recirculation hoses if any are faulty. The condition that contributed to failure of one hose is probably affecting the others. Only use the hose available from a Yamaha outboard dealership. An automotive vacuum hose is not suitable for the application. To prevent hose kinking and blocked passages, never cut hoses longer or shorter than the original. Note the hoses routing and connection points before removing them. Most models use a single hose or short sections of hose that are easy to route. Always route the hose to the fitting from which it was removed. For models with multiple hose connection points, refer to Figures 85-88.

87

RECIRCULATION SYSTEM (60 AND 70 HP MODELS)