2004 Yamaha Marine 160 Outboard Motor 6V, 8V Service Manual (P/N LIT-18616-01-64)
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Yamaha Models Covered & Key Technical Specifications
Models: 6CM, 6CEM, 8CM, 8CEM
Sub-models / Variants: 6MH, 8MH
Model Years: 2004
Serial Numbers: 6CM/6MH (S: 003802–, L: 303150–), 6CEM (S: 100101–, L: 400101–), 8CM/8MH (S: 008601–, L: 305566–), 8CEM (UL: 700101–, S: 100101–, L: 100101–)
Technical Data:
- Engine type: 2-stroke, 2-cylinder
- Displacement: 165 cm³ (10.07 cu. in.)
- Bore × Stroke: 50 mm × 42 mm
- Compression ratio: 7.00
- Ignition timing (Full advanced): B.T.D.C. 35° ± 1°
- Spark plug gap: 0.9–1.0 mm (0.035–0.039 in)
- Gear oil capacity: 160 cm³ (5.41 US oz)
- Fuel octane rating: Min. 86 P.O.N.
- Idle speed: 900 ± 50 rpm
Yamaha Manual Features & Content Preview
- Covers 2004 Yamaha Marine 160, 6V, and 8V outboard motor variants, including the 6CM, 6CEM, 8CM, 8CEM, 6MH, and 8MH models.
- Official Yamaha publication (P/N LIT-18616-01-64, July 1996 first edition).
- Contains 47 exploded-view diagrams and 15 torque-specification tables to support professional workshop repair reference.
Engine and Fuel System Documentation
The 2004 Yamaha Marine 160 service manual documents the precise technical requirements for the 165cc 2-stroke powerhead. Technicians will find complete specification data. This covers everything from piston-to-cylinder clearances to flywheel magneto assembly settings. Always verify that workspaces are adequately ventilated and standard shop safety protocols are active before beginning teardown procedures. Detailed chapters break down the fuel system structure. The manual provides clear component identification for the 6V and 8V engine series. You also get specific reference values for carburetor float adjustment, pilot screw settings, and the fuel pump diaphragm. Assembly data is clearly listed. The crankcase bolt torque is 11 Nm, while the final stage cylinder head bolt torque requires 8 Nm.
Lower Unit and Electrical References
Lower unit specifications feature critical measurement data to maintain factory tolerances. You will find exact gear backlash measurements and pinion shim selections. Maintenance tolerances for the shift shaft and water pump housing are fully documented. For electrical systems, the text outlines essential diagnostic baselines. These include stator coil resistance values, required ignition timing, and fuse ratings for the 6CEM and 8CEM electric-start configurations. Proper fluid replacement is also covered. The 160 cm³ gear oil capacity for these 2-stroke outboards is explicitly stated. This 100-page OEM publication serves as a highly efficient repair index for professional mechanics. It focuses strictly on factory technical data and system layouts rather than generic DIY tutorials.
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