Yamaha 9.9C User manual

15C
SERVICE MANUAL
63V-28197-1F-11
LIT-18616-02-59
9.9C

NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs 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 detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications 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:
QThe 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 the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
cC
A 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/15C
SERVICE MANUAL
©2003 by by Yamaha Motor Corporation, USA
1st Edition, December 2003
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-59
Chapter1 03.11.14 20:04 Page 1

Model name 9.9C 15C
USA and 9.9CMH 15CMH
CANADA name
Indication 9.9 15
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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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2-1
GENERAL SPECIFICATIONS
SPEC
GENERAL SPECIFICATIONS
Item Unit Model
9.9C 15C
Dimensions
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/min
Full throttle operating range r/min 4,500-5,500
Maximum 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/min
Idle speed r/min 700–800
Power unit
Engine type 2-stroke, 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
Lubrication system Pre-mixed fuel and oil (100:1)
Fuel and oil
Fuel type Regular gasoline
Engine oil 2-stroke outboard motor oil
Engine oil grade
NMMA-certified TC-W3
Gear oil type Hypoid gear oil
Gear oil grade (*2) API GL-4
SAE 90
Gear 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 SPECIFICATIONS
SPEC
Item Unit Model
9.9C 15C
Bracket unit
Tilt angle Degree 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
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2-3
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Unit Model
9.9C 15C
Cylinder head
Warpage limit mm (in) 0.10 (0.0039)
Cylinder
Bore size mm (in) 56.000–56.020 (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)
Piston
Piston diameter (D) mm (in) 55.940–55.985 (2.2024–2.2041)
Measuring point (H) mm (in) 10.0 (0.39)
Piston-to-cylinder clearance mm (in) 0.035–0.040 (0.0014–0.0016)
Wear limit 0.09
Piston pin boss bore mm (in) 14.004–14.015 (0.5513–0.5518)
Piston pin
Outside diameter mm (in) 13.996–14.000 (0.5510–0.5512)
Piston rings
Top ring Keystone
Dimension 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 (0.02–0.03) 5.9–6.1 (0.23–0.24)
Valve vending limit mm (in) 0.200 (0.0079)
Connecting rod
Small end inside diameter mm (in) 18.000–18.011 (0.7087–0.7091)
Big end inside diameter mm (in) 28.039–28.052 (1.1039–1.1044)
Crankshaft
Crank width (A) mm (in) 46.90–46.95 (1.85–1.85)
(B) mm (in) 25.90–26.10 (1.02–1.03)
Runout limit (D) mm (in) 0.03 (0.0012)
Big end side clearance (E) mm (in) 0.300–0.800 (0.0118–0.0315)
Maximum small end axial play
(F) mm (in) 2.0 (0.08)
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2-4
MAINTENANCE SPECIFICATIONS
SPEC
Item Unit Model
9.9C 15C
Thermostat
Opening temperature °C (°F) 48.0–52.0 (118.40–125.60)
Fully open temperature °C (°F) 60.0 (140.00)
Valve open lower limit mm (in) 3.0 (0.12)
Carburetor
ID mark 63V10
Float 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 shims mm 0.1, 0.2, 0.3, 0.4, 0.5
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