9.9MHC (63V3) 15MHC (63W3) 9.9FMH 04 (63V3) 15FMH 04 (63W3)

Transcription

1 9.9MHC (63V3) 15MHC (63W3) 9.9FMH 04 (63V3) MH 04 (63W3) 1C63V-100E1 ( 2C63V-100E1 )

2 FOREWORD This Parts Catalogue is related to the parts for the model(s) on the cover page. When you are ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers and part names correctly. 1. Modifications or additions which have been made after the issue of the Parts Catalogue will be announced in the Parts News. It is advisable that you make the necessary corrections to the Parts Catalogue according to the Parts News. 6. The asterisk (*) before a reference number indicates modified items after the first edition. 7. Applicable Serial No. Engine Serial No. 2. Abbreviations The following abbreviations are used in this Parts Catalogue. UR Use specified parts number. UN Use as many as needed. AP Alternate Parts LM Locally Made (Parts need to be ordered locally) F# Frame No. (Applicable machine No.) O/S Over Size 3. The number of components for assembly Parts, which are to be supplied in an assembly, are listed with a dot (.) in front of the part name as shown below. The numeral appearing to the right of each component part indicates the quantity of parts for each assembly unit. PART DESCRIPTION Q TY 2F FRONT FLASHER LIGHT ASSY BULB (6V 18W) 1 4. Applicable colours of graphics are represented in the as shown below. PART DESCRIPTION Q TY 2N X5 FUEL TANK COMP. 2 MXR 3J GRAPHIC, FUEL TANK 1 FOR MXR 5. Note that the illustrations for reference in finding parts numbers are not to be used for assembling. When assembling, please use the applicable service manual. 8. Applicable Engine Starting Serial No. Model Serial No. Model Serial No K K F 682K K Applicable Colour Code Abbreviation Colour Name Colour Code DBNM2 DARK BLUISH GRAY METALLIC 2 004D 10. Quantity Column Information Column No. Name Of Q ty Column Applicable Model 1 9.9MHC, 9.9FMH 2 15MHC, MH A2

3 CONTENTS TOP COWLING... A4 CYLINDER & CRANKCASE... A5 CRANKSHAFT & PISTON... A6 INTAKE... B1 CARBURETOR... B2 FUEL 1... B4 FUEL 2... B5 STARTER... B6 GENERATOR... C1 ELECTRICAL... C2 BOTTOM COWLING... C3 STEERING... C4 CONTROL... C6 REMO-CON ATTACHMENT... D1 BRACKET 1... D2 BRACKET 2... D4 UPPER CASING... D6 LOWER CASING & DRIVE 1... D7 LOWER CASING & DRIVE 2... E3 FUEL TANK... E5 REPAIR KIT 1... E6 REPAIR KIT 2... E7 INDEX NUMERICAL INDEX... G1 A3

4 FIG. 1 TOP COWLING PART DESCRIPTION 1 63V D TOP COWLING ASSY 1 63W D TOP COWLING ASSY V SEAL G HOOK M04.RIVET L HOLDER, CLAMP BAND M04.RIVET V D.MOLDING, AIR DUCT BOLT, WITH WASHER V W GRAPHIC SET V GRAPHIC, FRONT 1 63W GRAPHIC, FRONT V GRAPHIC, REAR 1 63W GRAPHIC, REAR 1 A4

5 FIG. 2 CYLINDER & CRANKCASE PART DESCRIPTION 1 63V W S CRANK CYLINDER ASSY V S CRANKCASE ASSY PIPE, JOINT PIPE, JOINT M08 HOSE (L220) M08 HOSE (L220) CLIP ANODE SCREW, FLAT HEAD PIN, DOWEL M07 BOLT, WITH WASHER V S INNER COVER, EXHAUST V A0 GASKET, EXHAUST INNER COVER V S OUTER COVER, EXHAUST NIPPLE, HOSE HOSE (L300) MA4 BOLT, WITH WASHER E S HEAD, CYLINDER V A1 GASKET, CYLINDER HEAD M05 BOLT, FLANGE S COVER, THERMOSTAT E THERMOSTAT M03 WASHER, PLATE A1 GASKET, COVER MA2 BOLT, WITH WASHER PLUG, SPARK (NGK B7HS-10) 2 2 FOR USA PLUG, SPARK (NGK BR7HS-10) 2 2 FOR CAN,OCE A5

6 FIG. 3 CRANKSHAFT & PISTON PART DESCRIPTION 1 63V HOUSING, OIL SEAL M16 O-RING OIL SEAL M48 OIL SEAL OIL SEAL BOLT WASHER V CRANKSHAFT ASSY V CRANK FOR OCE 10 63V CRANK FOR OCE 11 63V CRANK FOR OCE 12 63V CRANK FOR OCE U7.BEARING V SEAL, LABYRINTH FOR OCE PIN, CRANK FOR OCE ROD, CONNECTING 2 2 FOR OCE V5.BEARING 2 2 FOR OCE M23.WASHER 4 4 FOR OCE PIN, SPRING 1 1 FOR OCE CIRCLIP 1 1 FOR OCE 21 6E PISTON (STD) 2 2 6E PISTON (0.25MM O/S) 2 2 AP 6E PISTON (0.50MM O/S) 2 2 AP PISTON RING SET (STD) PISTON RING SET (0.25MM O/S) 2 2 AP PISTON RING SET (0.50MM O/S) 2 2 AP PIN, PISTON 2 2 A6

7 FIG. 3 CRANKSHAFT & PISTON PART DESCRIPTION PIN, DOWEL WASHER, PLATE CIRCLIP M00 OIL SEAL V SPACER M29 WASHER, PLATE 1 1 A7

8 FIG. 4 INTAKE PART DESCRIPTION 1 63V REED VALVE ASSY 1 FOR USA,OCE 63V REED VALVE ASSY 1 FOR CAN 63W REED VALVE ASSY W REED SET BOLT WASHER V LEVER, CHOKE PIN, SPRING V JOINT, CHOKE LEVER V ROD, CHOKE V SILENCER ASSY, INTAKE M15 COLLAR M25 GROMMET M86 O-RING M94 BOLT, WITH WASHER H KNOB, CHOKE V ROD, CHOKE GROMMET J GROMMET V LEVER, CHOKE JOINT, CHOKE LEVER M09 WASHER, PLATE M03 SCREW, TAPPING 1 1 B1

9 FIG. 5 CARBURETOR PART DESCRIPTION 1 63V CARBURETOR ASSY FOR USA,CAN 63V CARBURETOR ASSY FOR OCE SCREW, PILOT SPRING V PLATE V GASKET SCREW, PAN HEAD V JET (#48) RUBBER CAP V SCREW, STOP SPRING, COMPRESSION V GASKET, FLOAT CHAMBER V BODY, FLOAT CHAMBER V JET, NEEDLE JET, MAIN (#110) SCREW, WITH WASHER W GASKET G SCREW, DRAIN V FLOAT G VALVE, NEEDLE PIN, FLOAT CLIP H PIN, FLOAT ARM SCREW, PAN HEAD SCREW, BIND NUT SCREW, WITH WASHER 4 4 B2

10 FIG. 5 CARBURETOR PART DESCRIPTION 27 6G COVER V DIAPHRAGM G BODY G DIAPHRAGM G GASKET, FUEL PUMP L VALVE, CHECK SCREW, PAN HEAD N0 1432A 00.PLUG 1 1 FOR 63V B3

11 FIG. 6 FUEL 1 PART DESCRIPTION 1 6G FUEL PIPE JOINT COMP BOLT WASHER N FILTER ASSY N ELEMENT, FILTER N CUP, FILTER O-RING NUT M00 HOSE (L180) CLIP BRACKET, FILTER BOLT V PLATE H 2819R 31 TAG, WARNING W TOOL KIT 1 1 AP B4

12 FIG. 7 FUEL 2 PART DESCRIPTION 1 6Y FUEL PIPE COMP AP FOR USA 2 6E FUEL PIPE JOINT COMP O-RING Y FUEL PIPE JOINT COMP O-RING M01.HOSE (L2050) E BAND M00.HOSE (L850) Y PRIMER PUMP ASSY 1 1 B5

13 FIG. 8 STARTER PART DESCRIPTION 1 63V STARTER ASSY 1 1 WITH SAFETY DEVICE 2 63V CASE, STARTER V GUIDE, ROPE M05.COLLAR V DRUM, SHEAVE V PAWL, DRIVE V SPRING, STARTER V BUSH V PLATE, DRIVE V SPRING, DRIVE PAWL V SPRING V SPRING, RETURN V CIRCLIP V BOLT V COLLAR V SCREW *.WIRE, STARTER (L:1800MM) 1 1 *1 18 6G HANDLE, STARTER G COVER V STOPPER V PLUNGER, STARTER STOP V SPRING, RETURN V WASHER, FLAT PIN, COTTER V SEAL, RUBBER BOLT WASHER 3 3 B6

14 FIG. 8 STARTER PART DESCRIPTION 28 6A MARK A MARK FOR CAN B7

15 FIG. 9 GENERATOR PART DESCRIPTION 1 63V ROTOR ASSY 1 1 FOR USA,OCE 63V ROTOR ASSY (WITH RING GEAR) 1 1 FOR CAN 2 63V COIL, PULSER V COIL, CHARGE V COIL, LIGHTING V RETAINER, MAGNETO BASE M53 COLLAR M68 BOLT, FLANGE M24 COLLAR M69 BOLT, FLANGE KEY, WOODRUFF NUT WASHER, PLATE 1 1 C1

16 FIG. 10 ELECTRICAL PART DESCRIPTION 1 63V C.D.I. UNIT ASSY BOLT WASHER M11 CLAMP M61 CLAMP V IGNITION COIL ASSY BOLT WASHER GROMMET PLUG CAP ASSY 2 2 FOR USA 6E PLUG CAP ASSY 2 2 FOR CAN,OCE M02 CLAMP BOLT WASHER WIRE, EARTH LEAD BOLT WASHER P CONCENT 1 1 FOR OCE C2

17 FIG. 11 BOTTOM COWLING PART DESCRIPTION 1 63V D COWLING, BOTTOM GROMMET 1 1 FOR USA,CAN GROMMET V GROMMET GROMMET G GROMMET M19 GROMMET V D LEVER, CLAMP E LEVER, CLAMP M45 BUSH WASHER, WAVE WASHER, PLATE BOLT NUT BOLT WASHER COLLAR M31 GROMMET V RUBBER, SEAL H NIPPLE, HOSE M57 CLAMP E MARK FOR USA 6E MARK FOR CAN,OCE C3

18 FIG. 12 STEERING PART DESCRIPTION 1 63V D HANDLE, STEERING M97 BUSH M21 WASHER, WAVE M55 WASHER, PLATE M96 BUSH G COVER, HANDLE STEERING BOLT, STUD NUT, SELF-LOCKING G BOLT, FRICTION ADJUSTING G FRICTION, STEERING HANDLE GRIP PIN, COTTER GRIP, STEERING HANDLE H INDICATOR, THROTTLE M09 RIVET G RUBBER, HANDLE M13 SCREW WASHER, PLATE SPRING, COMPRESSION BUSH G LEVER, THROTTLE E STAY SCREW, PAN HEAD L THROTTLE CABLE ASSY V HANDLE, GEAR SHIFT M05 BOLT, WITH WASHER M86 COLLAR M18 WASHER, WAVE 1 1 C4

19 FIG. 12 STEERING PART DESCRIPTION 28 6E INDICATOR, SHIFT V LINK, SHIFT ROD WASHER, PLATE CLIP W ENGINE STOP SWITCH ASSY STOPPER Y 00.CAP E LABEL, CAUTION E LABEL, CAUTION FOR CAN C5

20 FIG. 13 CONTROL PART DESCRIPTION 1 63V STAY, THROTTLE WIRE CAP M50 COLLAR BOLT, FLANGE BOLT WASHER V LEVER, MAGNETO CONTROL SCREW, PAN HEAD NUT, HEXAGON M16 SPRING, COMPRESSION CAP V JOINT, LINK H JOINT, LINK NUT CLIP V WASHER, LOCK V LEVER, FREE ACCEL V LINK, ACCEL JOINT, CHOKE LEVER V PULLEY M37 SPRING, TORSION M38 SPRING, TORSION V ARM, SHIFT ROD V LEVER, SHIFT ROD M25 SCREW, WITH WASHER V LEVER, SHIFT ROD M25 SCREW, WITH WASHER 1 1 C6

21 FIG. 13 CONTROL PART DESCRIPTION BOLT WASHER V SPRING V BUSHING, SHIFT ROD LEVER M25 SCREW, WITH WASHER V ROD, SHIFT NUT NUT V ARM M06 COLLAR M39 SPRING, TORSION BOLT WASHER L LINK JOINT, CHOKE LEVER V CABLE COMP., STARTER STOP M16.GROMMET 1 1 C7

22 FIG. 14 REMO-CON ATTACHMENT PART DESCRIPTION 1 63V REMOTE CONT. ATTACHMENT ASSY. 1 1 AP 2 63V BRACKET, REMOTE CONTROL CLAMP, CABLE PIN, SPRING BOLT WASHER NUT, HEXAGON CABLE END, REMOTE CONTROL CLIP M12.WASHER, PLATE V LEVER, THROTTLE CONTROL BUSH M04.WASHER, WAVE M02.WASHER, PLATE V ROD M06.WASHER, PLATE PIN, COTTER V THROTTLE LEVER, CONTROL NUT, FLANGE V LEVER, SHIFTCONTROL M25.SCREW, WITH WASHER BUSH V HOOK, STEERING 1 1 AP BOLT 1 1 AP WASHER 1 1 AP NUT, SELF-LOCKING 1 1 AP D1

23 FIG. 15 BRACKET 1 PART DESCRIPTION 1 63V D BRACKET, CLAMP V D BRACKET, CLAMP M WIRE, LEAD SCREW, PAN HEAD SCREW, PAN HEAD E HANDLE, TRANSOM CLAMP M01 PIN E SCREW, TRANSOM CLAMP PAD, TRANSOM CLAMP W BOLT, CLAMP BRACKET M54 WASHER, PLATE M94 BUSH M69 BUSH V D CARRYING HANDLE V HOOK M65 O-RING M75 COLLAR WASHER, WAVE SCREW, PAN HEAD NUT, FLANGE J PLATE, CLAMP BRACKET NUT, SELF-LOCKING M13 COLLAR M29 BOLT WASHER NUT TILT ROD ASSY 1 1 D2

24 FIG. 15 BRACKET 1 PART DESCRIPTION PLATE, TILT LOCK PIN, SPRING M07 SPRING, CONICAL V D BRACKET, SWIVEL M TILT LEVER ASSY COVER V SHAFT, STOPPER M60 WASHER, PLATE M07 COLLAR M95 BUSH M RECEIVER ASSY M00 SPRING, TENSION V LEVER, TILT SCREW, PAN HEAD CIRCLIP V PLATE, TILT LOCK M41 SPRING, TORSION R PLATE, TILT LOCK R SHAFT, TILT LOCK M03 CIRCLIP V SHAFT, REVERSE LOCK CIRCLIP R ROD, TILT LOCK V SPRING, REVERSE LOCK V LEVER, TILT STOP M84 BOLT V LABEL (SPARK,IGNITION) 1 1 FOR CAN D3

25 FIG. 16 BRACKET 2 PART DESCRIPTION M03 NIPPLE, GREASE V PLATE, FRICTION SEAL, DAMPER M07 BOLT, FLANGE V WIRE, LEAD V D BRACKET, STEERING WASHER F BUSHING, PIVOT SHAFT BUSH M94 O-RING M60 BUSH M54 BOLT, STUD V B MOUNT DAMPER, UPPER SIDE V PLATE NUT COLLAR V DAMPER, WATER SEAL V A0 GASKET, UPPER CASING BOLT WASHER V D HOUSING, LOWER MOUNT RUBBER V MOUNT DAMPER, LOWER FRONT MOUNT DAMPER, LOWER SIDE BOLT WASHER BOLT WASHER 2 2 D4

26 FIG. 16 BRACKET 2 PART DESCRIPTION M28 NUT 4 4 D5

27 FIG. 17 UPPER CASING PART DESCRIPTION 1 63V D CASING, UPPER 1 1 S 63V D CASING, UPPER 1 L 2 63V PLATE, SEAL DAMPER M06 SCREW, PAN HEAD PIN, DOWEL V A1 GASKET, UPPER CASING BOLT WASHER F B MANIFOLD, EXT V GASKET, EXHAUST MANIFOLD V A1 GASKET, EXHAUST MANIFOLD BOLT WASHER BUSHING, DRIVE SHAFT 1 L CIRCLIP 1 L D6

28 FIG. 18 LOWER CASING & DRIVE 1 PART DESCRIPTION 1 63V D LOWER UNIT ASSY 1 1 S 63V D LOWER UNIT ASSY 1 L 2 63V D CASING, LOWER V8 BEARING V SLEEVE, DRIVE SHAFT BEARING E SHIM (T:1.13MM) 1 1 UR 6E SHIM (T:1.20MM) 1 1 UR BEARING SHIM (T:0.10MM) 1 1 UR SHIM (T:0.12MM) 1 1 UR SHIM (T:0.15MM) 1 1 UR SHIM (T:0.18MM) 1 1 UR SHIM (T:0.30MM) 1 1 UR SHIM (T:0.40MM) 1 1 UR SHIM (T:0.50MM) 1 1 UR PLUG, STRAIGHT SCREW GASKET V WATER PUMP HOUSING COMP V INSERT, CARTRIDGE DAMPER, WATER SEAL V IMPELLER V KEY, WOODRUFF O-RING V OUTER PLATE, CARTRIDGE M07 PIN, DOWEL BOLT 4 4 D7

29 FIG. 18 LOWER CASING & DRIVE 1 PART DESCRIPTION 20 63V PLATE V B HOUSING, BEARING BUSH, SOLID OIL SEAL V A0 PACKING, LOWER CASING ME6 O-RING BOLT V SHIFT CAM ASSY 1 1 S 63V SHIFT CAM ASSY 1 L 28 63V DRIVE SHAFT ASSY 1 1 S 63V DRIVE SHAFT ASSY 1 L 29 63V PINION M06 NUT E GEAR E GEAR SHIM (T:0.10MM) 1 1 UR SHIM (T:0.30MM) 1 1 UR SHIM (T:0.50MM) 1 1 UR WASHER, PLATE SHAFT, PROPELLER PLUNGER, SHIFT CLUTCH, DOG PIN, STRAIGHT RING, CROSS PIN M06 SPRING, COMPRESSION D CAP, LOWER CASING BEARING (B6005) 1 1 E1

30 FIG. 18 LOWER CASING & DRIVE 1 PART DESCRIPTION U2 BEARING OIL SEAL M09 O-RING M80 O-RING BOLT WASHER 2 2 E2

31 FIG. 19 LOWER CASING & DRIVE 2 PART DESCRIPTION 1 63V DAMPER, WATER SEAL V RUBBER, WATER SEAL V TUBE, WATER 1 1 S 63V TUBE, WATER 1 L M07 PIN, DOWEL BOLT WASHER G COVER, WATER INLET V COVER, WATER INLET M04 SCREW, COUNTERSUNK NUT, SELF-LOCKING N ANODE BOLT, FLANGE WASHER, INTERNAL TOOTH V DAMPER, SEAL E SPACER M01 WASHER, PLATE M01 NUT, CASTLE PIN, COTTER EL PROPELLER (3X9-1/4"X12"-J) 1 1 UR EL PROPELLER (3X9-1/4"X10-1/2"-J) 1 1 UR EL PROPELLER (3X9-1/4"X9"-J) 1 1 UR EL PROPELLER (3X9-1/4"X8"-J) 1 1 UR EL PROPELLER (3X9-1/2"X6-1/2"-J) 1 1 UR EL PROPELLER (3X9-1/4"X9-3/4"-J) 1 1 UR 63V EL PROPELLER (3X9-1/4"X11"-J) 1 1 UR 63V EL PROPELLER (3X9-1/4"X9"-J) 1 1 UR E3

32 FIG. 19 LOWER CASING & DRIVE 2 PART DESCRIPTION W EL PROPELLER (3X9-3/4"X8"-J) 1 1 UR 683 W EL PROPELLER (3X9-3/4"X6-1/2"-J) 1 1 UR 21 6E RING, DEFLECTOR M07.NUT, CASTLE M02.WASHER, PLATE V TUBE, WATER 1 L 25 63V GROMMET, WATER TUBE 1 1 L 26 63V GROMMET, WATER TUBE 2 1 L E4

33 FIG. 20 FUEL TANK PART DESCRIPTION 1 6YJ FUEL TANK ASSY 1 1 AP FOR CAN 6YJ FUEL TANK ASSY (24L) 1 1 AP FOR OCE 2 6YJ CAP ASSY Y FUEL METER ASSY 1 1 WITH INDICATOR SCREW, PAN HEAD Y SEAL Y GASKET, FUEL METER YJ STRAINER Y FUEL PIPE COMP AP FOR CAN 61J FUEL PIPE COMP AP FOR OCE M06.HOSE (L2050) Y PRIMER PUMP ASSY 1 1 FOR 6Y J PRIMER PUMP ASSY 1 1 FOR 61J M05.HOSE (L850) BAND FOR 6Y BAND FOR 61J G FUEL PIPE JOINT COMP O-RING Y FUEL PIPE JOINT COMP O-RING 1 1 E5

34 FIG. 21 REPAIR KIT 1 PART DESCRIPTION 1 63V W POWER HEAD GASKET KIT V A0.GASKET, EXHAUST INNER COVER V A1.GASKET, CYLINDER HEAD A1.GASKET, COVER M16.O-RING OIL SEAL OIL SEAL M48.OIL SEAL M00.OIL SEAL V SPACER M29.WASHER, PLATE V W CARBURETOR REPAIR KIT SCREW, PILOT V GASKET V GASKET, FLOAT CHAMBER SCREW, WITH WASHER W GASKET V FLOAT G VALVE, NEEDLE PIN, FLOAT CLIP H PIN, FLOAT ARM 1 1 E6

35 FIG. 22 REPAIR KIT 2 PART DESCRIPTION 1 63V W LOWER UNIT GASKET KIT V A1.GASKET, UPPER CASING V GASKET, EXHAUST MANIFOLD V A1.GASKET, EXHAUST MANIFOLD GASKET O-RING V OUTER PLATE, CARTRIDGE OIL SEAL V A0.PACKING, LOWER CASING ME6.O-RING OIL SEAL M09.O-RING M80.O-RING V DAMPER, WATER SEAL V RUBBER, WATER SEAL V W WATER PUMP REPAIR KIT DAMPER, WATER SEAL BOLT V INSERT, CARTRIDGE V IMPELLER V OUTER PLATE, CARTRIDGE V KEY, WOODRUFF V W0078 0A CHROME PUMP KIT V INSERT, CARTRIDGE V OUTER PLATE, CARTRIDGE V IMPELLER 1 1 E7

36 NUMERICAL INDEX PART PART PART PART PART PART 6E S V A V V V V V V V E E E E S A V W V V V V N0 1432A W V V V V G H V V V V V G V S V V V V V V V V V V V V L V V G V V V V V G V V V V YJ YJ YJ Y Y G G E Y Y J Y Y Y E J Y Y V V G G L G G N N N YJ L H 2819R V S V A V S F B V A V V V H V V V V V V H J V V V V V D G G G H G V E G V V D V F V D W D V D V L G V W V W V D V V V D G E E V D E V D V D J E E W V V V D M R V R R M V V V V V V V V V V V V V V E V V V V V V V V V V V V V V V V V H V B V V D V V D V D V A V A V G V N V D V D V D V A V B D V V V V V E E G1

37 NUMERICAL INDEX PART PART PART PART PART PART 6E E EL V EL EL V EL EL EL EL EL E E V V V V V V M E V W Y A A E E V V V V V V V V W V W W V W V W V W0078 0A V W S V W W W EL W EL M M M M M M M M M MA MA M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M ME M M M M M M U V V U M M M G2

38 NUMERICAL INDEX PART PART PART PART PART PART G3

39 9.9MHC/15MHC 9.9FMH/MH PARTS CATALOGUE 2003 by Yamaha Motor Co., Ltd. 1st edition, April 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.