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Yamaha F90D Service Manual

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F90D
SERVICE MANUAL
*LIT186160286*
LIT-18616-02-86
6D8-28197-1G-11

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Summary of Contents for Yamaha F90D

  • Page 1 F90D SERVICE MANUAL *LIT186160286* LIT-18616-02-86 6D8-28197-1G-11...

  • Page 2: Important Information

    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.
  • Page 3 Contents General information INFO Specifications SPEC Periodic checks and adjustments Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT – Electrical systems ELEC Troubleshooting TRBL SHTG Index...

  • Page 4: Table Of Contents

    INFO General information How to use this manual ................. 1-1 Manual format.................... 1-1 Symbols..................... 1-2 Safety while working..................1-3 Fire prevention................... 1-3 Ventilation....................1-3 Self-protection ................... 1-3 Parts, lubricants, and sealants ..............1-3 Good working practices ................1-4 Disassembly and assembly ............... 1-4 Identification....................1-5 Applicable model ..................1-5 Serial number ....................

  • Page 5: How To Use This Manual

    INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list.

  • Page 6: Periodic Checks And Adjustments

    7 Apply Yamaha 4-stroke motor oil A Apply corrosion resistant grease 8 Apply gear oil (Yamaha grease D) 9 Apply water resistant grease (Yamaha grease A) B Apply low temperature resistant grease 0 Apply molybdenum disulfide grease (Yamaha grease C)

  • Page 7: Safety While Working

    Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the out- board motor. Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous.

  • Page 8: Good Working Practices

    Safety while working Disassembly and assembly 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. 1. Use compressed air to remove dust and dirt during disassembly. Good working practices Special service tools 2. Apply engine oil to the contact surfaces Use the recommended special service tools of moving parts before assembly.

  • Page 9: Identification

    INFO General information Identification Propeller selection Applicable model The performance of a boat and outboard motor will be critically affected by the size This manual covers the following model. and type of propeller you choose. Propellers Applicable model greatly affect boat speed, acceleration, engine life, fuel economy, and even boating F90TR and steering capabilities.

  • Page 10: Selection

    Identification / Propeller selection / Predelivery checks Selection When the engine speed is at the full throttle operating range (5,000–6,000 r/min), the ideal propeller for the boat is one that pro- vides maximum performance in relation to boat speed and fuel consumption. Propeller size (in) Material 12 5/8 ×...

  • Page 11: Checking The Gear Oil Level

    INFO General information Checking the gear oil level NOTE: 1. Check the gear oil level. The optimum mounting height is affected by the combination of the boat and the outboard motor. To determine the optimum mounting height, test run the outboard motor at differ- ent heights.

  • Page 12: Checking The Steering System

    Predelivery checks S69J1210 S69J3370 WARNING Checking the power trim and tilt system The shift/throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) 1. Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit.

  • Page 13: Checking The Cooling Water Pilot Hole

    INFO General information 3. Check that the engine turns off when the Break-in engine stop lanyard is pulled from the During the test run, perform the break-in engine stop lanyard switch. operation in the following three stages. 1. One hour a at 2,000 r/min or at approxi- mately half throttle 2.
  • Page 14 SPEC Specifications General specifications................... 2-1 Maintenance specification ................2-3 Power unit....................2-3 Lower unit ....................2-6 Electrical ....................2-6 Dimensions....................2-9 Tightening torques..................2-11 Specified torques..................2-11 General torques..................2-13 6D81G11...

  • Page 15: General Specifications

    SPEC Specifications General specifications Model Item Unit F90TR Dimension Overall length mm (in) 817 (32.2) Overall width mm (in) 479 (18.9) Overall height mm (in) 1,582 (62.3) mm (in) 1,710 (67.3) Boat transom height mm (in) 508 (20.0) mm (in) 635 (25.0) Weight (without propeller)
  • Page 16 General specifications Model Item Unit F90TR Fuel and oil Fuel type Regular unleaded gasoline (*1) Fuel minimum rating Engine oil 4-stroke motor oil Engine oil grade SE, SF, SG, SH, or SJ 10W-30 or 10W-40 Engine oil quantity (without oil filter replacement) L (US qt, 4.3 (4.55, 3.78) Imp qt)

  • Page 17: Specifications

    SPEC Specifications Maintenance specification Power unit Model Item Unit F90TR Power unit Minimum compression 860 (8.6, 124.7) (*1) pressure (kgf/cm , psi) (*2) Oil pressure 510 (5.1, 74.0) at engine idle speed (kgf/cm , psi) Cylinder head Warpage limit mm (in) 0.1 (0.0039) (lines indicate straightedge position)
  • Page 18 Maintenance specification Model Item Unit F90TR Oil ring Dimension B mm (in) 2.38–2.48 (0.0937–0.0976) Dimension T mm (in) 2.40 (0.0945) End gap mm (in) 0.20–0.70 (0.0079–0.0276) Side clearance mm (in) 0.03–0.15 (0.0012–0.0059) Camshafts Intake (A) mm (in) 36.48–36.58 (1.4362–1.4402) Exhaust (A) mm (in) 36.90–37.06 (1.4528–1.4591) Intake (B)
  • Page 19 SPEC Specifications Model Item Unit F90TR Valve lifters Valve lifter outside diameter mm (in) 27.965–27.980 (1.1010–1.1016) Valve lifter-to-cylinder head mm (in) 0.020–0.056 (0.0008–0.0022) clearance Valve shims Valve shim thickness mm (in) 2.0–3.3 (0.08–0.13) (in 0.025 mm increments) Connecting rods Big end inside diameter mm (in) 47.025–47.045 (1.8514–1.8522) Big end side clearance...

  • Page 20: Lower Unit

    Maintenance specification Model Item Unit F90TR Oil pump Discharge L (US gal, 5.9 (1.559, 1.298) at 1,000 r/min at 97–103 °C (207–217 °F) Imp gal)/min with 10W-30 engine oil Pressure 118.0 (1.18, 17.1) at 1,000 r/min at 97–103 °C (207–217 °F) (kgf/cm , psi) with 10W-30 engine oil...
  • Page 21 SPEC Specifications Model Item Unit F90TR ECM output peak voltage (B/R, B/W – Ground) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Pulser coil output peak voltage (W/R, W/B – B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) 18.2 at 3,500 r/min (loaded)
  • Page 22 Maintenance specification Model Item Unit F90TR Charging system Fuse Stator coil output peak voltage (W – W) at cranking (unloaded) 12.4 at 1,500 r/min (unloaded) 45.3 at 3,500 r/min (unloaded) 98.3 Stator coil resistance (W – W) Ω at 20 °C (68 °F) 0.24–0.36 Rectifier Regulator output peak voltage...

  • Page 23: Dimensions

    SPEC Specifications Dimensions Exterior mm (in) L : 998 (39.3) 527 (20.7) X: 1,115 (43.9) 171 (6.73) 651 (25.6) 62 (2.4) 164 (6.5) 12˚ 28 (1.1) 574 (22.6) S6D82010 6D81G11...
  • Page 24 Maintenance specification Clamp bracket mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 80 (3.1) 13 (0.5) 13 (0.5) 125.4 (4.9) 125.4 (4.9) S6D82020 2-10 6D81G11...

  • Page 25: Tightening Torques

    SPEC Specifications Tightening torques Specified torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel system Fuel filter cup — Fuel pump mounting bolt Fuel pump screw Sensor assembly screw 0.37 Idle speed control screw 0.37 Fuel rail mounting bolt Throttle body mounting bolt Fuel cooler screw Float chamber screw...
  • Page 26 Tightening torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb 10.3 20.7 Cylinder head bolt 11.1 22.1 90° Spark plug — 18.4 Cylinder block plug 17.0 Oil filter joint — 36.1 Oil filter — 13.3 Exhaust cover bolt Anode screw Exhaust cover plug 40.6...

  • Page 27: General Torques

    SPEC Specifications Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Steering arm stud bolt 14.8 Self-locking nut — 11.1 Trim sensor cam screw Power trim and tilt unit Reservoir cap — PTT motor bolt Gear pump bolt Gear pump housing bolt Relief valve cap bolt Lever bolt...
  • Page 28 Periodic checks and adjustments Special service tools ..................3-1 Maintenance interval chart................3-2 Top cowling ....................3-3 Checking the top cowling................3-3 Fuel system ....................3-3 Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) ....3-3 Checking the fuel filter ................3-3 Power unit.......................

  • Page 29: Chk Adj

    Periodic checks and adjustments Special service tools Digital tachometer YU-39951-B Battery powered timing light YM-33277-A Pressure/vacuum tester YB-35956-A Oil filter wrench YU-38411 6D81G11...

  • Page 30: Maintenance Interval Chart

    Special service tools / Maintenance interval chart Maintenance interval chart Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Initial Every Refer to Item Remarks 10 hours 50 hours 100 hours 200 hours...

  • Page 31: Top Cowling

    Periodic checks and adjustments Top cowling 2. Check the low-pressure fuel hose con- nections and fuel joint for leaks. Replace Checking the top cowling if necessary. Also, check the fuel filter 1, 1. Check the fitting by pushing the cowling fuel pump 2, strainer 3, and fuel cooler with both hands.

  • Page 32: Power Unit

    Top cowling / Fuel system / Power unit Power unit Checking the engine oil 1. Place the outboard motor in an upright position. 2. Remove the oil dipstick, wipe it clean, and then insert it back into the dipstick hole. 3.

  • Page 33: Replacing The Oil Filter

    Periodic checks and adjustments 2. Remove the oil dipstick and oil filler cap 7. Turn the engine off, and then check the oil level and correct it if necessary. Replacing the oil filter 1. Extract the engine oil with an oil changer or drain it.

  • Page 34: Checking The Timing Belt

    Power unit 2. While turning the flywheel magnet clock- wise, check the interior a and the exte- rior b of the timing belt for cracks, damage, or wear. Replace if necessary. S6D83070 NOTE: For replacement procedures, see Chapter 5, “Replacing the timing belt.” S6D83060 Oil filter: Checking the spark plugs...

  • Page 35: Checking The Thermostat

    Periodic checks and adjustments 5. Check the spark plug gap a. Adjust if out of specification. Specified spark plug: LFR5A-11 (NGK) Spark plug gap a: 1.0–1.1 mm (0.039–0.043 in) S6D83080 6. Install the spark plugs, tighten them fin- 3. Suspend the thermostat in a container of ger tight, then to the specified torque water.

  • Page 36: Checking The Cooling Water Passage

    Power unit / Control system Water Valve lift a temperature 0.05 mm 58–62 °C (0.0020 in) (136–144 °F) (valve begins to lift) above more than 70 °C (158 °F) 4.3 mm (0.17 in) 6. Install the thermostat and cover. Control system 7.
  • Page 37 Periodic checks and adjustments 3. Loosen the locknut 1, remove the clip 2, and then disconnect the throttle cable joint 3. 4. Loosen the locknut 4, and then discon- nect the throttle link rod joint 5 from the ball joint of the throttle body. S6D83110 8.

  • Page 38: Checking The Gear Shift Operation

    Control system 5. Align the alignment mark a on the bush- ing and alignment mark b on the bracket. S69J3370 WARNING The throttle cable joint must be screwed S6D81040 in a minimum of 8.0 mm (0.31 in) c. 6. Install the clip 4. 12.

  • Page 39: Bracket Unit

    Periodic checks and adjustments Bracket unit Checking the power trim and tilt operation 1. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation. Check the power trim and tilt fluid level if necessary. S6D83150 WARNING After tilting up the outboard motor, be...

  • Page 40: Lower Unit

    Bracket unit / Lower unit Lower unit Checking the gear oil level 1. Fully tilt the outboard motor down. 2. Remove the check screw 1, and then check the gear oil level in the lower case. 3. Check the oil for metal and discoloration, S60C3540 and its viscosity.

  • Page 41: Checking The Lower Unit For Air Leakage

    Periodic checks and adjustments 4. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible. Pressure/vacuum tester: YB-35956-A 2.

  • Page 42: General

    Lower unit / General General NOTE: Checking the anodes If it is necessary to disassemble the outboard 1. Check the anodes and trim tab for motor to check an anode, refer to the applica- scales, grease, or oil. Clean if necessary. ble disassembly procedure in this manual.

  • Page 43: Lubricating The Outboard Motor

    Periodic checks and adjustments 2. Check the specific gravity of the electro- Lubricating the outboard motor lyte. Fully charge the battery if out of 1. Apply water resistant grease to the areas specification. shown. WARNING Battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic.
  • Page 44 General S60C3710 NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the area shown. S6D83190 3. Apply corrosion resistant grease to the area shown. 3-16 6D81G11...
  • Page 45 FUEL Fuel system Special service tools ..................4-1 Hose routing ....................4-2 Fuel and blowby hoses................4-2 Fuel filter and fuel pump ................4-3 Checking the fuel pump................4-5 Disassembling the fuel pump ..............4-5 Checking the diaphragm and valves ............4-6 Assembling the fuel pump ................. 4-6 Intake manifold....................

  • Page 46: Fuel System

    FUEL Fuel system Special service tools Pressure/vacuum tester YB-35956-A Fuel pressure gauge YB-06766 Fuel pressure gauge adapter B YB-06942 6D81G11...

  • Page 47: Hose Routing

    Special service tools / Hose routing Hose routing Fuel and blowby hoses 1 Blowby hose 2 Fuel hose (primary pump-to-fuel filter) 3 Fuel hose (fuel filter-to-fuel pump) 4 Fuel hose (fuel pump-to-strainer) 5 Fuel hose (strainer-to-vapor separator) 6 High-pressure fuel hose (vapor separator-to-fuel rail) 7 Fuel hose (pressure regulator-to-fuel cooler) 8 Fuel hose (fuel cooler-to-vapor separator) 9 Canister hose (vapor separator-to-canister)

  • Page 48: Fuel Filter And Fuel Pump

    FUEL Fuel system Fuel filter and fuel pump · · · 10 N m (1.0 kgf m, 7.4 ft · · · m (0.3 kgf m, 2.2 ft S6D84020 Part name Q’ty Remarks Fuel filter assembly O-ring Not reusable Fuel filter element O-ring Not reusable Float...
  • Page 49 Fuel filter and fuel pump · · · m (0.4 kgf m, 3.0 ft S6D84030 Part name Q’ty Remarks ø6 × 35 mm Screw Cover Gasket Not reusable Fuel pump body 2 assembly Diaphragm Spring Fuel pump body 1 Spring Plunger 6D81G11...

  • Page 50: Checking The Fuel Pump

    FUEL Fuel system Checking the fuel pump 6. Apply the specified positive pressure and check that there is no air leakage. Disas- 1. Place a drain pan under the fuel hose semble the fuel pump if necessary. connections, and then disconnect the fuel hoses from the fuel pump.

  • Page 51: Checking The Diaphragm And Valves

    Fuel filter and fuel pump 3. Slowly let up on the plunger and dia- phragm, and then remove them. Checking the diaphragm and valves 1. Check the diaphragm for tears and the valves for cracks. Replace if necessary. Assembling the fuel pump NOTE: Clean the parts and soak the valves and the diaphragm in gasoline before assembly to...

  • Page 52: Intake Manifold

    FUEL Fuel system Intake manifold S6D84040 Part name Q’ty Remarks Intake silencer M6 × 80 mm Bolt Bushing Collar Intake manifold assembly M8 × 30 mm Bolt Collar M8 × 100 mm Bolt Spacer M6 × 45 mm Bolt Collar Holder Gasket Not reusable...
  • Page 53 Intake manifold · · · 3.7 N m (0.37 kgf m, 2.7 ft · · · m (0.8 kgf m, 5.9 ft · · · m (0.8 kgf m, 5.9 ft S6D84050 Part name Q’ty Remarks Intake manifold Sensor assembly ø5 ×...

  • Page 54: Checking The Throttle Position Sensor

    • If the throttle position sensor output voltage is out of specification, reinstall the throttle position sensor. • Measure the throttle position sensor output voltage using the Yamaha Diagnostic Sys- tem. • Do not turn the throttle stop screw a. Throttle position sensor output voltage at engine idle speed: 0.8–1.2 V...
  • Page 55 Intake manifold / Vapor separator Vapor separator S6D84070 Part name Q’ty Remarks Vapor separator M6 × 30 mm Bolt Grommet Collar Fuel hose Fuel inlet hose Hose Joint Hose Hose Hose Hose Clamp Clamp Quick connector Clamp Not reusable Plastic tie Not reusable 4-10 6D81G11...
  • Page 56 FUEL Fuel system · · · m (0.3 kgf m, 2.2 ft · · · 1.5 N m (0.15 kgf m, 1.1 ft · · · m (0.3 kgf m, 2.2 ft · · · m (0.4 kgf m, 3.0 ft S6D84080 Part name Q’ty...

  • Page 57: Vapor Separator

    Vapor separator · · · m (0.5 kgf m, 3.7 ft · · · 10 N m (1.0 kgf m, 7.4 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft ·...

  • Page 58: Reducing The Fuel Pressure

    FUEL Fuel system Reducing the fuel pressure CAUTION: 1. Remove the cap 1. • Do not rotate the quick connector tab 1 2. Cover the pressure check valve a of the past the stopper position a, otherwise it vapor separator with a rag, and then could be damaged.

  • Page 59: Checking The Pressure Regulator

    Vapor separator Fuel pressure (reference data): 230 kPa (2.3 kgf/cm , 33.4 psi) Checking the pressure regulator 1. Disconnect the quick connector from the fuel rail. NOTE: Before disconnecting the quick connector, S6D84110 release the fuel pressure. WARNING • When connecting the fuel pressure 2.

  • Page 60: Draining The Fuel

    FUEL Fuel system 6. Check that the fuel pressure reduces WARNING when vacuum pressure is applied to the pressure regulator. If the fuel pressure Reduce the fuel pressure before loosen- does not reduce, replace the pressure ing the vapor separator drain screw, or regulator.

  • Page 61: Checking The Vapor Separator

    Vapor separator S6C14220 S6C14210 NOTE: NOTE: Remove the float pin in the direction of the • Do not reuse the float pin, always replace it arrow a shown. with a new one. • Install the float pin in the direction of the arrow a shown.

  • Page 62: Adjusting The Float

    FUEL Fuel system 3. Check the float height d as shown. Adjust the float height if out of specifica- tion. Float height d: 35.0 ± 1.0 mm (1.38 ± 0.04 in) S6C14200 NOTE: NOTE: • The float should be resting on the needle When adjusting the float height, do not bend valve, but not compressing it.

  • Page 63: Canister

    Vapor separator / Canister Canister S6D84150 Part name Q’ty Remarks M6 × 16 mm Bolt Bracket Canister M6 × 28 mm Bolt Grommet Bracket Collar Hose Hose Hose Filter Hose Clamp M6 × 10 mm Bolt Holder M6 × 16 mm Bolt Bracket 4-18...

  • Page 64: Checking The Canister

    FUEL Fuel system Checking the canister 1. Check the canister for cracks. Replace if necessary. 2. Connect the special service tool to the atmospheric port 1 and cover the other ports, each with a finger. S6D84160 3. Apply the specified positive pressure and check that there is no air leakage.
  • Page 65 POWR Power unit Special service tools ..................5-1 Power unit....................... 5-3 Checking the compression pressure ............5-3 Checking the oil pressure ................5-3 Checking the valve clearance..............5-10 Replacing the timing belt .................5-13 Removing the power unit.................5-16 Removing the timing belt and sprockets..........5-17 Checking the timing belt and sprockets...........5-18 Installing the sprockets and timing belt............5-18 Throttle link....................
  • Page 66 Cylinder block ....................5-39 Disassembling the cylinder block ............5-40 Checking the piston diameter ..............5-40 Checking the cylinder bore ..............5-41 Checking the piston clearance ..............5-41 Checking the piston rings ................5-41 Checking the piston ring grooves ............5-42 Checking the piston ring side clearance..........5-42 Checking the connecting rod big end side clearance ......5-43 Checking the crankshaft ................5-43 Checking the crankpin oil clearance............

  • Page 67: Power Unit

    POWR Power unit Special service tools Compression gauge Valve spring compressor YU-33223 YM-01253 Valve spring compressor attachment YB-06320 Compression gauge extension YB-06563 Valve guide remover/installer YM-04064-A Flywheel magnet holder YB-06139 Valve guide reamer YM-04066 Universal puller YB-06117 Neway valve seat kit YB-91044 Crankshaft holder YB-06552...
  • Page 68 Special service tools Oil filter wrench YU-38411 6D81G11...

  • Page 69: Power Unit

    POWR Power unit Power unit NOTE: Checking the compression pressure • If the compression pressure increases, 1. Start the engine, warm it up for 5 min- check the pistons and piston rings for wear. utes, and then turn it off. Replace if necessary.
  • Page 70 Power unit · · · 42 N m (4.2 kgf m, 31.0 ft · · · 42 N m (4.2 kgf m, 31.0 ft · · · m (0.4 kgf m, 3.0 ft S6D85010 Part name Q’ty Remarks Damper Grommet Grommet Flywheel magnet cover Power unit...
  • Page 71 POWR Power unit · · · 215 N m (21.5 kgf m, 158.6 ft S6D85020 Part name Q’ty Remarks Washer Flywheel magnet ø4 × 10 mm Screw ø6 × 30 mm Screw Stator coil M6 × 30 mm Bolt Stator assembly Collar M6 ×...
  • Page 72 Power unit · · · 265 N m (26.5 kgf m, 195.5 ft · · · 60 N m (6.0 kgf m, 44.3 ft · · · 39 N m (3.9 kgf m, 28.8 ft S6D85030 Part name Q’ty Remarks Timing belt M10 ×...
  • Page 73 POWR Power unit · · · 29 N m (2.9 kgf m, 21.4 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft ·...
  • Page 74 Power unit · · · 29 N m (2.9 kgf m, 21.4 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft ·...
  • Page 75 POWR Power unit m (0.8 kgf m, 5.9 ft • • • S1280B 17 N m (1.7 kgf m, 12.5 ft • • • · · · m (0.2 kgf m, 1.5 ft S1280B m (0.8 kgf m, 5.9 ft •...

  • Page 76: Checking The Valve Clearance

    Power unit Checking the valve clearance CAUTION: • Do not turn the flywheel magnet coun- terclockwise, otherwise the valve sys- tem may be damaged. • Do not remove the ignition timing pointer. • Do not turn the flywheel magnet or the driven sprockets when the timing belt is not installed.
  • Page 77 POWR Power unit 4. Install the driven sprockets 0, timing belt 9, and spring 8, and then tighten the Valve clearance (cold): Intake e: tensioner bolt. 0.20 ± 0.03 mm (0.008 ± 0.001 in) Exhaust f: 0.34 ± 0.03 mm (0.013 ± 0.001 in) 6.
  • Page 78 Power unit 11. Remove the valve shim C from the valve 19. Check that the “TDC” mark a on the fly- lifter D using a thin screwdriver. wheel magnet is aligned with the pointer b, and that “ ” marks c and d on the driven sprockets are aligned.

  • Page 79: Replacing The Timing Belt

    POWR Power unit Replacing the timing belt CAUTION: • Do not turn the drive sprocket counter- clockwise, otherwise the valve system may be damaged. • Do not remove the ignition timing pointer. • Do not turn the drive sprocket or the driven sprockets when the timing belt is not installed.
  • Page 80 Power unit 9. Check that “ ” marks c and d on the driven sprockets are aligned. S6D85220 6. Disconnect the cooling water hose 3 S6D85240 and remove the bracket 4. 7. Remove the spring 5 and timing belt tensioner 6, and then remove the timing belt 7 from the driven sprockets, then from the drive sprocket.
  • Page 81 POWR Power unit 10. Install a new timing belt 8 onto the drive 13. Install the spring A. sprocket with its part number in the upright position, and then install the belt onto the driven sprockets by turning it counterclockwise. S6D85260 14.

  • Page 82: Removing The Power Unit

    Power unit 18. Install the stator assembly and Woodruff 4. Disconnect the throttle cable and shift key. cable. 19. Install the flywheel magnet. 5. Disconnect the fuel hose and shift posi- tion switch coupler. 6. Disconnect the cooling water pilot hose, canister hose, and flushing hose.

  • Page 83: Removing The Timing Belt And Sprockets

    POWR Power unit Removing the timing belt and NOTE: sprockets • Use a deep socket 2 for this procedure. • Do not turn the camshaft when loosening CAUTION: the drive sprocket nut. • Do not turn the drive sprocket counter- clockwise, otherwise the valve system may be damaged.

  • Page 84: Checking The Timing Belt And Sprockets

    Power unit S6D85390 NOTE: • Apply engine oil to the driven sprocket bolts before installation. • Do not turn the camshafts when tightening the driven sprocket bolts. S6D85380 Flywheel magnet holder: YB-06139 Checking the timing belt and sprockets Driven sprocket bolt 2: 1.
  • Page 85 POWR Power unit 3. Install the retaining plate 3, Woodruff 6. Tighten the drive sprocket nut 6 to the key 4, drive sprocket 5, and nut 6, and specified torque. then tighten the nut. S6D85410 NOTE: Use a deep socket 7 for this procedure. Crankshaft holder 8: YB-06552 Drive sprocket nut 6: S60C5240...

  • Page 86: Throttle Link

    Power unit / Throttle link Throttle link S6D84140 Part name Q’ty Remarks Throttle cam M6 × 35 mm Bolt Collar Wave washer Washer Spring Washer Throttle lever M6 × 25 mm Bolt Collar Throttle link rod Throttle link rod joint Bracket M6 ×...

  • Page 87: Ecm

    POWR Power unit S6D85050 Part name Q’ty Remarks Wiring harness Bracket M6 × 15 mm Bolt M6 × 12 mm Bolt Bracket Bracket Bracket M6 × 20 mm Bolt Collar Grommet M6 × 30 mm Bolt Rectifier Regulator M6 × 25 mm Bolt M6 ×...

  • Page 88: Junction Box

    ECM / Junction box Junction box · · · m (0.4 kgf m, 3.0 ft · · · m (0.3 kgf m, 2.2 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.4 kgf m, 3.0 ft S6D85060 Part name Q’ty...
  • Page 89 POWR Power unit · · · m (0.4 kgf m, 3.0 ft · · · m (0.3 kgf m, 2.2 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.4 kgf m, 3.0 ft S6D85060 Part name Q’ty Remarks...

  • Page 90: Cylinder Head

    Junction box / Cylinder head Cylinder head 15 N m (1.5 kgf m, 11.1 ft • • • 30 N m (3.0 kgf m, 22.1 ft • • • 90˚ 25 N m (2.5 kgf m, 18.4 ft • • •...
  • Page 91 POWR Power unit 15 N m (1.5 kgf m, 11.1 ft • • • 30 N m (3.0 kgf m, 22.1 ft • • • 90˚ 25 N m (2.5 kgf m, 18.4 ft • • • · · · 14 N m (1.4 kgf m, 10.3 ft...

  • Page 92: Removing The Cylinder Head

    Cylinder head Removing the cylinder head NOTE: 1. Remove the cylinder head cover. Do not mix the valve train parts. Keep them organized in their proper groups. 2. Remove camshaft caps 1 and 2 in the sequence shown. 5. Remove the cylinder head bolts in the sequence shown.

  • Page 93: Checking The Valve Lifters

    POWR Power unit 6. Remove the intake and exhaust valves. Valve spring free length a: 53.20 mm (2.0945 in) 2. Measure the valve spring tilt b. Replace if above specification. Valve spring tilt limit b: 2.6 mm (0.10 in) NOTE: Checking the valves Be sure to keep the valves, springs, and 1.

  • Page 94: Checking The Valve Guides

    Cylinder head S60C5450 Valve stem diameter b: Valve guide inside diameter a: Intake: Intake and exhaust: 5.975–5.990 mm 6.000–6.018 mm (0.2352–0.2358 in) (0.2362–0.2369 in) Exhaust: 5.960–5.975 mm 2. Calculate the valve stem-to-valve guide (0.2346–0.2352 in) clearance as follows. Replace the valve guide if out of specification.

  • Page 95: Checking The Valve Seat

    POWR Power unit 2. Install the new valve guide 2 by striking 4. Measure the valve guide inside diameter. the special tool from the camshaft side to Valve guide inside diameter: the specified position a. Intake and exhaust: 6.000–6.018 mm (0.2362–0.2369 in) Checking the valve seat 1.

  • Page 96: Refacing The Valve Seat

    Cylinder head a Slag or rough surface CAUTION: Do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pres- Valve seat contact width a: sure of 40–50 N (4–5 kgf, 8.8–11 lbf) to prevent chatter marks.

  • Page 97: Checking The Camshafts

    POWR Power unit 5. Use a 45° cutter to adjust the contact 8. If the valve seat contact area is too nar- width of the valve seat to specification. row and situated near the bottom edge of the valve face, use a 60° cutter to cut the bottom edge of the valve seat.

  • Page 98: Checking The Cylinder Head

    Cylinder head S69J5970 Cam lobe a: Camshaft journal diameter c: Intake: 24.960–24.980 mm 36.48–36.58 mm (0.9827–0.9835 in) Camshaft cap inside diameter d: (1.4362–1.4402 in) Exhaust: 25.000–25.021 mm 36.90–37.06 mm (0.9843–0.9851 in) (1.4528–1.4591 in) Cam lobe b: Checking the cylinder head Intake: 1.

  • Page 99: Installing The Valves

    POWR Power unit Installing the valves 3. Compress the valve spring, and then install the valve cotters 8 using a thin 1. Install a new valve seal 1 onto the valve screwdriver with a small amount of guide. grease applied to it. S60C5660 2.
  • Page 100 Cylinder head NOTE: • Apply engine oil to the valve shims and valve lifters before installation. • Install the valve shims and valve lifters in their original positions. 4. Install the camshaft (intake) 1 and cam- shaft (exhaust) 2 with the new oil seals S1280B 90˚...
  • Page 101 POWR Power unit 6. Install the camshaft caps in the proper position as shown and with the stamped numbers facing upside down. S1280B 7. Tighten the camshaft cap bolts to the specified torques in two stages and in the sequence shown. S6D85520 Cylinder head cover bolt: 1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb)

  • Page 102: Exhaust Cover

    Cylinder head / Exhaust cover Exhaust cover · · · 49 N m (4.9 kgf m, 36.1 ft · · · 18 N m (1.8 kgf m, 13.3 ft 23 N m (2.3 kgf m, 17.0 ft • • • ·...
  • Page 103 POWR Power unit · · · 49 N m (4.9 kgf m, 36.1 ft · · · 18 N m (1.8 kgf m, 13.3 ft 23 N m (2.3 kgf m, 17.0 ft • • • · · · 55 N m (5.5 kgf m, 40.6 ft ·...

  • Page 104: Removing The Exhaust Cover

    Exhaust cover Removing the exhaust cover Installing the exhaust cover 1. Remove the exhaust cover bolts in the 1. Install a new gasket and the exhaust sequence shown. cover. 2. Install the bolts, and then tighten them to the specified torques in two stages and in the sequence shown.

  • Page 105: Cylinder Block

    POWR Power unit Cylinder block 19 N m (1.9 kgf m, 14.0 ft • • • 60˚ S518 · · · 14 N m (1.4 kgf m, 10.3 ft · · · 28 N m (2.8 kgf m, 20.7 ft 18 N m (1.8 kgf m, 13.3 ft...

  • Page 106: Disassembling The Cylinder Block

    Cylinder block Disassembling the cylinder block 1. Place a rag under the oil filter, and then remove the filter using the oil filter wrench. NOTE: Be sure to clean up any oil spills. Oil filter wrench: YU-38411 NOTE: • Be sure to keep the bearings in the order as 2.

  • Page 107: Checking The Cylinder Bore

    POWR Power unit Checking the cylinder bore Piston clearance: 1. Measure the cylinder bore (D –D ) at 0.070–0.080 mm measuring points a, b, and c, and in (0.0028–0.0031 in) direction d (D ), which is parallel to the crankshaft, and direction e (D Checking the piston rings ), which is at a right angle to the crankshaft.

  • Page 108: Checking The Piston Ring Grooves

    Cylinder block Checking the piston ring side clearance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. S63P5730 Piston ring end gap d: Top ring: Piston ring side clearance: 0.15–0.30 mm Top ring a: (0.0059–0.0118 in)

  • Page 109: Checking The Connecting Rod Big End Side Clearance

    POWR Power unit Checking the connecting rod big end Crankshaft journal diameter a: side clearance 47.985–48.000 mm 1. Measure the connecting rod big end side (1.8892–1.8898 in) clearance a. Replace the connecting Crankpin diameter b: rod or crankshaft or both if out of specifi- 43.982–44.000 mm cation.
  • Page 110 Cylinder block S60C5960 NOTE: Install the bearings in their original positions. S60C5A10 3. Put a piece of Plastigauge (PG-1) onto NOTE: the crankpin, parallel to the crankshaft. Make sure that the large, flat side a on the connecting rod faces towards the flywheel magnet side of the crankshaft.

  • Page 111: Selecting The Connecting Rod Bearing

    POWR Power unit 6. Remove the connecting rod cap and 3. Check the crankpin mark on the crank- shaft 1. measure the width of the compressed Plastigauge (PG-1) on each crankpin. Replace the connecting rod bearing if out of specification. (#1) (#2) (#3)

  • Page 112: Checking The Crankshaft Journal Oil Clearance

    Cylinder block Connecting rod bearing selection table (20 °C [68 °F]) Connecting rod big end inside Upper Lower diameters – bearing bearing crankpin diameters (mm) 3.025–3.027 Yellow Yellow 3.028–3.034 Yellow Green* 3.035–3.041 Green Green 3.042–3.049 Green Blue* S60C5910 3.050–3.057 Blue Blue 3.058–3.063 Blue...

  • Page 113: Selecting The Main Bearing

    POWR Power unit 7. Tighten the crankcase bolts to the speci- fied torques in two stages and in the sequence shown. Crankshaft journal oil clearance: 0.024–0.044 mm 60˚ (0.0009–0.0017 in) Selecting the main bearing 1. When replacing the main bearing, select the suitable bearing as follows.
  • Page 114 Cylinder block NOTE: CAUTION: Cylinder block journal inside diameters (#1– • The (*) mark indicates that the colors of #5) and crankshaft journal diameters (#1–#5) the upper and lower bearings are differ- can be determined by the stamped value as ent.

  • Page 115: Assembling The Power Unit

    POWR Power unit Assembling the power unit NOTE: 1. Install the oil ring 1, second ring 2, and Install the bearings in their original positions. top ring 3 onto the pistons with the “T” marks a on the piston rings facing upward.
  • Page 116 Cylinder block 6. Set the crankshaft 8 and oil seals 9 and NOTE: 0 into the cylinder block as shown. • Make sure that the large, flat side c of the connecting rod faces towards the flywheel magnet side of the crankshaft. •...

  • Page 117: Installing The Power Unit

    POWR Power unit 11. Tighten the crankcase bolts to the speci- 13. Install all parts removed during disas- fied torques in two stages and in the sembly. sequence shown. Installing the power unit 1. Clean the power unit mating surface, and install the dowels 1 and a new gasket 2.
  • Page 118 Cylinder block 5. Connect the flushing hose, cooling water pilot hose, and canister hose. 6. Connect the fuel hose and shift position switch coupler. 7. Connect the PTT motor leads and PTT switch coupler, and then install the junc- tion box cover. PTT motor lead bolt: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8.
  • Page 119 LOWR Lower unit Special service tools ..................6-1 Lower unit ....................... 6-4 Removing the lower unit ................6-8 Removing the water pump and shift rod............ 6-9 Disassembling the oil seal housing ............6-9 Checking the water pump and shift rod .............6-9 Propeller shaft housing ................6-10 Removing the propeller shaft housing assembly........

  • Page 120: Lower Unit

    LOWR Lower unit Special service tools Gland nut wrench Bearing housing needle bearing remover YB-34447 YB-06112, YB-06153 Bearing housing puller Driver handle (large) YB-06207 YB-06071 Universal puller Propeller shaft oil seal installer YB-06117 YB-06269 Slide hammer Drive shaft needle bearing depth stop YB-06096 YB-34473 Bearing puller legs...
  • Page 121 Special service tools Drive shaft holder Shift rod push arm YB-06151 YB-06052 Drive shaft needle bearing remover and Pinion shim selecting tool installer YB-34432-9, YB-34432-10A, YB-06155 YB-34432-11A, YB-34432-17 Drive shaft seal installer Forward gear shim selecting tool YB-06244 YB-34446-1, YB-34446-3, YB-34446-5, YB-34446-7 Forward gear bearing cup installer YB-06276-B...

  • Page 122: Lower Unit

    LOWR Lower unit Dial indicator gauge YU-03097 Magnetic base stand YU-A8438 6D81G11...
  • Page 123 Special service tools / Lower unit Lower unit Part name Q’ty Remarks Lower unit Hose Check screw Gasket Not reusable Dowel M10 × 40 mm/L-transom model Bolt Drain screw Grommet M10 × 45 mm Bolt M8 × 60 mm/L-transom model Bolt Spacer Propeller...
  • Page 124 LOWR Lower unit Part name Q’ty Remarks Dowel X-transom model Extension X-transom model M10 × 180 mm/X-transom model Stud bolt Washer X-transom model Spring washer X-transom model X-transom model M8 × 190 mm/X-transom model Bolt 6D81G11...
  • Page 125 Lower unit Part name Q’ty Remarks M6 × 16 mm Bolt O-ring Not reusable Oil seal Not reusable Oil seal housing O-ring Not reusable Circlip Shift rod Woodruff key ø4 × 12 mm Screw M8 × 75 mm Bolt Cover M8 ×...
  • Page 126 LOWR Lower unit Part name Q’ty Remarks Gasket Not reusable Outer plate cartridge Gasket Not reusable Oil seal housing O-ring Not reusable Gasket Not reusable Oil seal Not reusable 6D81G11...

  • Page 127: Removing The Lower Unit

    Lower unit Removing the lower unit 1. Drain the gear oil. 2. Set the gear shift to the neutral position, S6D86020 and place a block of wood between the 5. Loosen the bolts (nuts), and then remove anti-cavitation plate and propeller to keep the lower unit from the upper case.

  • Page 128: Removing The Water Pump And Shift Rod

    LOWR Lower unit Removing the water pump and shift Checking the water pump and shift 1. Remove the water pump housing and 1. Check the water pump housing for defor- impeller. mation. Replace if necessary. 2. Remove the Woodruff key. 2.

  • Page 129: Propeller Shaft Housing

    Lower unit / Propeller shaft housing Propeller shaft housing Part name Q’ty Remarks Slider Shift plunger Dog clutch Spring Propeller shaft Shim 0.3 mm Washer Reverse gear Thrust washer Ball bearing Not reusable O-ring Not reusable Propeller shaft housing Straight key Needle bearing Oil seal Not reusable...

  • Page 130: Removing The Propeller Shaft Housing Assembly

    LOWR Lower unit Removing the propeller shaft Disassembling the propeller shaft housing assembly assembly 1. Remove the spring 1, and then remove 1. Straighten the claw washer tabs a, and the cross pin 2, dog clutch 3, slider and then remove the ring nut and claw washer.

  • Page 131: Checking The Propeller Shaft Housing

    Propeller shaft housing Slide hammer 2: YB-06096 Runout limit: 0.02 mm (0.0008 in) Bearing puller legs 3: YB-06523 3. Remove the oil seals and needle bear- 3. Check the dog clutch and slider for ing. cracks or wear. Replace if necessary. Assembling the propeller shaft assembly 1.

  • Page 132: Assembling The Propeller Shaft Housing

    LOWR Lower unit Assembling the propeller shaft Propeller shaft oil seal installer 3: housing YB-06269 1. Install the needle bearing into the propel- Driver handle (large) 4: YB-06071 ler shaft housing to the specified depth. Depth c: 5.0 ± 0.5 mm (0.20 ± 0.02 in) 3.
  • Page 133 Propeller shaft housing Bearing outer race attachment 9: YB-06109 6-14 6D81G11...

  • Page 134: Drive Shaft And Lower Case

    LOWR Lower unit Drive shaft and lower case Part name Q’ty Remarks Drive shaft Taper roller bearing Not reusable Pinion shim — Sleeve Hose Plastic tie Not reusable Joint Cooling water inlet cover ø5 × 40 mm Screw Seal Plate Forward gear shim —...
  • Page 135 Drive shaft and lower case Part name Q’ty Remarks Pinion Lower case 6-16 6D81G11...

  • Page 136: Removing The Drive Shaft

    LOWR Lower unit Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear. CAUTION: Do not reuse the bearing, always replace it with a new one. S68S6150 Drive shaft holder 1: YB-06151 Bearing splitter plate 1: (commercially available) Disassembling the drive shaft...

  • Page 137: Checking The Pinion And Forward Gear

    Drive shaft and lower case Checking the bearings NOTE: 1. Check the bearings for pitting or rum- Install the claws as shown. bling. Replace if necessary. Checking the drive shaft Slide hammer 1: YB-06096 1. Check the drive shaft for bends or wear. Bearing puller legs 2: YB-06523 Replace if necessary.

  • Page 138: Assembling The Lower Case

    LOWR Lower unit Assembling the lower case CAUTION: 1. Install the needle bearing into the lower Add or remove shim(s), if necessary, if case to the specified depth. replacing the taper roller bearing or lower case. NOTE: • Apply the gear oil to the inside and outside of the sleeve before installation.

  • Page 139: Assembling The Drive Shaft

    Drive shaft and lower case General pipe 1: a = 33 mm (1.30 in) b = 28 mm (1.10 in) Installing the drive shaft 1. Install the forward gear, then the drive shaft assembly, pinion, and pinion nut, and then tighten the nut to the specified torque.

  • Page 140: Installing The Water Pump And Shift Rod

    LOWR Lower unit 3. Install the shim 4 and propeller shaft housing assembly 5 into the lower case, and then install the straight key 6, claw washer 7, and ring nut 8. 4. Tighten the ring nut to the specified torque.

  • Page 141: Installing The Lower Unit

    Drive shaft and lower case 3. Install a new O-ring 5 onto the oil seal housing 6. 4. Install a new gasket 7, the oil seal hous- ing 6, a new gasket 8, the outer plate cartridge 9, and a new gasket 0. S6D86150 S1104J NOTE:...
  • Page 142 LOWR Lower unit 2. Align the alignment mark a on the bush- ing with the alignment mark b on the bracket. S6D81040 È X-transom model Lower case mounting bolt (nut): 39 N·m (3.9 kgf·m, 28.8 ft·lb) 5. Install the trim tab 2 to its original posi- tion, and then connect the speedometer Shift rod push arm: YB-06052 hose 3.
  • Page 143 Drive shaft and lower case 6. Install the propeller and propeller nut, 7. Fill the gear oil to the correct level. and then tighten the nut finger tight. Place a block of wood between the anti- cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque.

  • Page 144: Shimming

    LOWR Lower unit Shimming 6-25 6D81G11...

  • Page 145: Selecting The Pinion Shims

    Shimming Shimming NOTE: Tighten the clamp bolts another 1/4 of a turn NOTE: after they contact the clamp 2. • Shimming is not required when assembling the original lower case and inner parts. • Shimming is required when assembling the 4.

  • Page 146: Selecting The Forward Gear Shims

    LOWR Lower unit 5. Measure the clearance (M) between the shim selecting tool and the pinion as shown. S68S6260 NOTE: “F” is the deviation of the lower case dimen- sion from standard. The “F” mark a is stamped on the trim tab mounting surface of NOTE: Measure the pinion at three points to find the the lower case in 0.01 mm units.

  • Page 147: Backlash

    Shimming / Backlash Backlash NOTE: Measuring the forward gear backlash Tighten the nut four turns after it contacts the 1. Remove the water pump assembly. spring. NOTE: Do not remove the oil seal housing in this Forward gear shim selecting tool: procedure.
  • Page 148 LOWR Lower unit 4. Install the backlash indicator onto the Available shim thicknesses: drive shaft (20 mm [0.79 in] in diameter), 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and then the dial gauge onto the lower unit. 0.50 mm 7. Remove the special service tools, and then install the water pump assembly.
  • Page 149 BRKT Bracket unit Special service tools ..................7-1 Shift rod ......................7-2 Bottom cowling ....................7-3 Upper case...................... 7-6 Removing the upper case................7-12 Disassembling the oil pump..............7-12 Checking the oil pump ................7-12 Assembling the oil pump .................7-12 Disassembling the upper case ..............7-13 Checking the drive shaft bushing ............
  • Page 150 Tilt cylinder and trim cylinder ..............7-35 Disassembling the trim cylinder...............7-38 Disassembling the tilt cylinder ..............7-38 Checking the tilt cylinder and trim cylinder ..........7-39 Checking the valves ................7-39 Assembling the tilt cylinder ..............7-39 Assembling the power trim and tilt unit............7-41 Bleeding the power trim and tilt unit ............

  • Page 151: Bracket Unit

    BRKT Bracket unit Special service tools Bearing installer Drive shaft needle bearing installer and YB-41446 remover Bearing cup installer YB-06196 YB-06167 Trim cylinder wrench Driver handle (large) YB-06175-2B YB-06071 Driver handle (small) YB-06229 Roller bearing installer/remover YB-06432 Oil seal installer YB-06023 6D81G11...

  • Page 152: Shift Rod

    Special service tools / Shift rod Shift rod · · · 18 N m (1.8 kgf m, 13.3 ft · · · m (0.1 kgf m, 0.7 ft S6D87010 Part name Q’ty Remarks Bolt Spring Ball Washer Bushing M6 × 25 mm Bolt Bracket Shift rod...

  • Page 153: Bottom Cowling

    BRKT Bracket unit Bottom cowling 36 37 · · · m (0.2 kgf m, 1.5 ft S6D87020 Part name Q’ty Remarks M6 × 16 mm Bolt Washer Lever Washer Bushing M6 × 30 mm Bolt Base Lever Spring M6 × 20 mm Bolt Hook Cooling water outlet...
  • Page 154 Bottom cowling 36 37 · · · m (0.2 kgf m, 1.5 ft S6D87020 Part name Q’ty Remarks Bottom cowling Grommet Collar M6 × 20 mm Bolt Holder M6 × 20 mm Bolt Bracket M6 × 25 mm Bolt Plate Power trim and tilt switch Grommet Grommet...
  • Page 155 BRKT Bracket unit 36 37 · · · m (0.2 kgf m, 1.5 ft S6D87020 Part name Q’ty Remarks Adapter Gasket Joint Joint Plastic tie Not reusable Hose M6 × 20 mm Bolt M6 × 25 mm Bolt Retaining plate M6 ×...

  • Page 156: Upper Case

    Bottom cowling / Upper case Upper case · · · 10 N m (1.0 kgf m, 7.4 ft · · · 51 N m (5.1 kgf m, 37.6 ft · · · m (0.3 kgf m, 2.2 ft S6D87030 Part name Q’ty Remarks Oil seal...
  • Page 157 BRKT Bracket unit m (0.4 kgf m, 3.0 ft • • • WR-No.1 WR-No.1 WR-No.1 · · · m (0.4 kgf m, 3.0 ft S6D87040 Part name Q’ty Remarks Oil seal Not reusable ø6 × 10 mm Screw Gasket Not reusable O-ring Not reusable Shaft...
  • Page 158 Upper case · · · 20 N m (2.0 kgf m, 14.8 ft · · · 28 N m (2.8 kgf m, 20.7 ft WR-No.1 · · · 27 N m (2.7 kgf m, 20.0 ft 22 23 S6D87050 Part name Q’ty Remarks M8 ×...
  • Page 159 BRKT Bracket unit · · · 20 N m (2.0 kgf m, 14.8 ft · · · 28 N m (2.8 kgf m, 20.7 ft WR-No.1 · · · 27 N m (2.7 kgf m, 20.0 ft 22 23 S6D87050 Part name Q’ty Remarks...
  • Page 160 Upper case · · · 10 N m (1.0 kgf m, 7.4 ft · · · 11 N m (1.1 kgf m, 8.1 ft S6D87060 Part name Q’ty Remarks Exhaust guide Gasket Not reusable Dowel Gasket Not reusable Oil strainer Collar M6 ×...
  • Page 161 BRKT Bracket unit · · · 10 N m (1.0 kgf m, 7.4 ft · · · 11 N m (1.1 kgf m, 8.1 ft S6D87060 Part name Q’ty Remarks Muffler M6 × 50 mm Bolt Grommet Spacer Pipe 7-11 6D81G11...

  • Page 162: Removing The Upper Case

    Upper case Removing the upper case Checking the oil pump 1. Place a drain pan under the drain hole, 1. Check the gear teeth for cracks or wear and then remove the drain bolt 1 and let and the oil pump case for scratches. the oil drain completely.

  • Page 163: Disassembling The Upper Case

    BRKT Bracket unit 3. Install new oil seals into the oil seal hous- ing. S6D87140 Oil seal installer 1: YB-06023 S6D87120 WR-No.1 Driver handle (small) 2: YB-06229 Roller bearing installer/remover 4: YB-06432 Checking the drive shaft bushing Driver handle (large) 2: YB-06071 1.

  • Page 164: Checking The Oil Strainer

    Upper case Checking the oil strainer 1. Check the oil strainer for dirt or residue. Clean if necessary. Assembling the oil pan 1. Install a new gasket onto the exhaust guide 1. 2. Install a new gasket and the oil strainer 2 onto the exhaust guide, and then tighten the bolts to the specified torque.

  • Page 165: Assembling The Upper Case

    BRKT Bracket unit Assembling the upper case Installing the upper case 1. Install the upper mount 1 and bolts 2 1. Install the drive shaft bushing into the upper case, and then install the circlip. into the upper case. 2. Install the bolts 3, and then tighten them to the specified torque.
  • Page 166 Upper case NOTE: Before tightening the lower mounting nut, be sure to connect the ground lead to the lower mounting bolt. 6. Install the mount covers 8. 7. Install the oil pump assembly 9 and the bolts 0, and then tighten them to the specified torque.

  • Page 167: Steering Arm

    BRKT Bracket unit Steering arm · · · 20 N m (2.0 kgf m, 14.8 ft S6D87220 Part name Q’ty Remarks Steering hook M10 × 40 mm Stud bolt Steering arm Washer Bushing O-ring Not reusable Bushing Washer Steering yoke Damper Circlip 7-17...

  • Page 168: Removing The Steering Arm

    Steering arm Removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer. S6D87250 4. Install the steering yoke 0 to the steer- ing arm 5 by aligning the center a of the yoke with the center b of the steer- ing arm.

  • Page 169: Clamp Brackets And Swivel Bracket

    BRKT Bracket unit Clamp brackets and swivel bracket · · · m (0.2 kgf m, 1.5 ft · · · 15 N m (1.5 kgf m, 11.1 ft S6D87490 Part name Q’ty Remarks Swivel bracket Clamp bracket Clamp bracket Self-locking nut ø6 ×...
  • Page 170 Clamp brackets and swivel bracket 4 16 · · · m (0.3 kgf m, 2.2 ft S6D87500 Part name Q’ty Remarks Swivel bracket Tilt stop lever Bushing a: 30.3–30.6 mm (1.19–1.20 in) Distance collar Hook M6 × 10 mm Bolt Spring Tilt stop lever Trim sensor...

  • Page 171: Removing The Clamp Brackets

    BRKT Bracket unit Removing the clamp brackets NOTE: 1. Remove the power trim and tilt unit. For Adjust the trim sensor after installing the removal procedure, see “Removing the power trim and tilt unit. power trim and tilt unit.” 2. Remove the anode 1. 2.
  • Page 172 Clamp brackets and swivel bracket S63P7250 Trim sensor setting resistance: Pink (P) – Black (B) 10 ± 1 Ω at 20 °C (68 °F) Trim sensor cam screw 1: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 4. Fully tilt the outboard motor up, and then support it with the tilt stop lever 3.

  • Page 173: Power Trim And Tilt Unit

    BRKT Bracket unit Power trim and tilt unit 13 14 13 14 S6D87270 Part name Q’ty Remarks Power trim and tilt unit Circlip Shaft Circlip Shaft Bushing Bushing Ground lead M6 × 10 mm Bolt Bushing Bushing Collar Holder M6 × 10 mm Bolt 7-23 6D81G11...

  • Page 174: Removing The Power Trim And Tilt Unit

    Power trim and tilt unit 4. Remove the circlips 6, then the lower Removing the power trim and tilt unit mounting shaft 7. 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. 5.

  • Page 175: Power Trim And Tilt Motor

    BRKT Bracket unit Power trim and tilt motor · · · m (0.4 kgf m, 3.0 ft 13 14 · · · m (0.7 kgf m, 5.2 ft S6D87290 Part name Q’ty Remarks Power trim and tilt motor M6 × 20 mm Bolt O-ring Not reusable...
  • Page 176 Power trim and tilt motor · · · m (0.4 kgf m, 3.0 ft 13 14 · · · m (0.7 kgf m, 5.2 ft S6D87290 Part name Q’ty Remarks Circuit breaker Spring PTT motor base Oil seal Not reusable Plate ø4 ×...

  • Page 177: Disassembling The Power Trim And Tilt Motor

    BRKT Bracket unit Disassembling the power trim and 3. Remove the armature from the PTT motor base. tilt motor 1. Remove the power trim and tilt motor, O- CAUTION: ring, and joint from the power trim and tilt Do not allow grease or oil to contact the unit.
  • Page 178 Power trim and tilt motor 5. Check the circuit breaker for continuity. Replace if there is no continuity. Commutator diameter wear limit: 21.0 mm (0.83 in) 6. Measure the brush length. Replace if 3. Measure the commutator undercut a. below specification. Replace the armature if below specifica- tion.

  • Page 179: Assembling The Power Trim And Tilt Motor

    BRKT Bracket unit Assembling the power trim and tilt motor 1. Install a new oil seal 1 and the bushing 2 into the motor base 3 as shown. NOTE: Place a clean cloth over the end of the arma- ture shaft, hold it with a pair of pliers, and then carefully slide the stator over the arma- ture.

  • Page 180: Gear Pump

    Power trim and tilt motor / Gear pump Gear pump · · · · · · · · · m (0.5 kgf m, 3.7 ft m (0.5 kgf m, 3.7 ft m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft ·...
  • Page 181 BRKT Bracket unit · · · · · · · · · m (0.5 kgf m, 3.7 ft m (0.5 kgf m, 3.7 ft m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft · ·...
  • Page 182 Gear pump · · · · · · m (0.2 kgf m, 1.5 ft m (0.4 kgf m, 3.0 ft S6D87550 Part name Q’ty Remarks Manual release spring Ball Bracket M3 × 5 mm Bolt M5 × 6 mm Bolt Washer O-ring Not reusable...

  • Page 183: Disassembling The Gear Pump

    BRKT Bracket unit Disassembling the gear pump 1. Remove the manual valve, then the gear pump and filters. S6C17600 Checking the gear pump 1. Clean all the pistons and balls, and then S6D87370 check them for damage or wear. Replace 2.
  • Page 184 Gear pump Lever bolt (M3) B, C: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 9. Install the up-relief valve seat D and down-relief valve seat E. 10. Install the relief valve seat caps F by installing bolts G and H, then tightening S6C17620 them to the specified torques.

  • Page 185: Tilt Cylinder And Trim Cylinder

    BRKT Bracket unit Tilt cylinder and trim cylinder · · · 90 N m (9.0 kgf m, 66.4 ft · · · · · · 85 N m (8.5 kgf m, 62.7 ft 80 N m (8.0 kgf m, 59.0 ft S6D87390 Part name Q’ty...
  • Page 186 Tilt cylinder and trim cylinder · · · 90 N m (9.0 kgf m, 66.4 ft · · · · · · 85 N m (8.5 kgf m, 62.7 ft 80 N m (8.0 kgf m, 59.0 ft S6D87390 Part name Q’ty Remarks Valve...
  • Page 187 BRKT Bracket unit · · · 90 N m (9.0 kgf m, 66.4 ft · · · · · · 85 N m (8.5 kgf m, 62.7 ft 80 N m (8.0 kgf m, 59.0 ft S6D87390 Part name Q’ty Remarks Free piston Circlip...

  • Page 188: Disassembling The Trim Cylinder

    Tilt cylinder and trim cylinder Disassembling the trim cylinder 1. Hold the power trim and tilt unit 1 in a vise using aluminum plates a on both sides. NOTE: Place the tilt cylinder in the vise horizontally. 2. Loosen the tilt cylinder end screw 2, and 2.

  • Page 189: Checking The Tilt Cylinder And Trim Cylinder

    BRKT Bracket unit 4. Remove the bolt 3, then the tilt piston 2. Check the operation of the absorber valve and check for dirt or residue. Clean if necessary. Assembling the tilt cylinder 1. Install a new O-ring, the backup ring, and a new dust seal 1 into the trim cylinder end screw 2.
  • Page 190 Tilt cylinder and trim cylinder 6. Install the new O-rings 9 and 0, and backup ring A onto the trim piston B. 7. Install the balls C, valves D, and springs E into the trim piston, and then install the washer F and trim piston to the tilt cylin- der G.

  • Page 191: Assembling The Power Trim And Tilt Unit

    BRKT Bracket unit 15. Install the tilt cylinder end screw 8, and then tighten it to the specified torque. Assembling the power trim and tilt unit 1. Hold the trim cylinder in a vise using alu- minum plates on both sides. 2.
  • Page 192 Tilt cylinder and trim cylinder S6D87450 NOTE: Recommended power trim and tilt Apply grease to the balls from falling out of fluid: the cylinder installation. ATF Dexron II 5. Install a new O-ring, the joint, and the 8. Install the trim cylinder end screw 8, and power trim and tilt motor 5 by installing then tighten it to the specified torque.

  • Page 193: Bleeding The Power Trim And Tilt Unit

    BRKT Bracket unit Bleeding the power trim and tilt unit 6. Connect the PTT motor leads to the bat- 1. Tighten the manual valve 1 by turning it tery terminals to fully retract the tilt ram. clockwise. Battery PTT motor lead terminal Light green (Lg) Down...

  • Page 194: Installing The Power Trim And Tilt Unit

    Tilt cylinder and trim cylinder NOTE: • Repeat this procedure so that the ram goes up and down four or five times (be sure to wait a few seconds before switching the leads). • If the ram does not move up and down eas- ily, push and pull on the ram to assist oper- ation.

  • Page 195: Power Trim And Tilt Electrical System

    BRKT Bracket unit 6. Support the outboard motor with the tilt NOTE: stop lever 1. Repeat this procedure until the fluid remains at the correct level. Reservoir cap: 7 N·m (0.7 kgf·m, 5.2 ft·lb) Power trim and tilt electrical system S60C7975 Checking the fuse 1.

  • Page 196: Checking The Power Trim And Tilt Switch

    Tilt cylinder and trim cylinder / Power trim and tilt electrical system 3. Connect the light green (Lg) lead to the positive battery terminal and the black (B) lead to the negative battery terminal as shown. 4. Check for continuity between terminals 2 and 3.
  • Page 197 – ELEC Electrical systems Special service tools ..................8-1 Checking the electrical components............8-2 Measuring the peak voltage ..............8-2 Measuring the lower resistance..............8-2 Electrical components................... 8-3 Port view....................8-3 Starboard view................... 8-4 Bow view ....................8-5 Top view ....................8-6 Ignition and ignition control system ............8-7 Checking the ignition spark ...............

  • Page 198: Electrical Systems

    – ELEC Electrical systems Special service tools Spark checker Test harness (6 pins) YM-34487 YB-06848 Digital multimeter Pressure/vacuum tester YU-34899-A YB-35956-A Peak volt meter adapter YU-39991 Test harness (2 pins) YB-06792 Test harness (3 pins) YB-06791 6D81G11...

  • Page 199: Checking The Electrical Components

    Special service tools / Checking the electrical components Checking the electrical Measuring the lower resistance When measuring a resistance of 10 Ω or less components with the digital circuit tester, the correct mea- Measuring the peak voltage surement cannot be obtained due to the internal resistance of the tester.

  • Page 200: Electrical Components

    – ELEC Electrical systems Electrical components Port view S6D88010 1 Idle speed control 7 Throttle position sensor 2 Sensor assembly (intake air temperature and intake air pressure) 3 Pulser coil 4 Oil pressure switch 5 Fuel injector 6 Electric fuel pump 6D81G11...

  • Page 201: Starboard View

    Electrical components Starboard view S6D88020 1 Ignition coil 2 Cooling water temperature sensor 3 Starter motor 4 Junction box 5 Spark plug 6D81G11...

  • Page 202: Bow View

    – ELEC Electrical systems Bow view S6D88030 1 ECM 9 Fuse (20A) 2 Sensor assembly (ECM, ignition coil, electric fuel pump, and fuel (intake air temperature and intake air injector) 0 Fuse (20A) pressure) 3 Idle speed control (main switch and power trim and tilt switch) 4 Throttle position sensor A Fuse (20 A) 5 Rectifier Regulator...

  • Page 203: Top View

    Electrical components Top view S6D88040 1 Fuel injection 2 Shift position switch 3 Sensor assembly (intake air temperature and intake air pressure) 4 Idle speed control 5 Stator coil 6 Power trim and tilt switch 7 Starter motor 6D81G11...

  • Page 204: Ignition And Ignition Control System

    NOTE: system The ignition spark can also be checked using Checking the ignition spark the “Stationary test” of the Yamaha Diagnos- 1. Remove the spark plug wire cover. tic System. 2. Disconnect the spark plug caps from the Checking the spark plug wires spark plugs.

  • Page 205: Checking The Ecm

    Ignition and ignition control system 3. Measure the pulser coil output peak volt- Ignition coil resistance: age. Replace the stator assembly if Primary coil: below specification. Red (R) – Black/white (B/W) 1.53–2.07 Ω at 20 °C (68 °F) Secondary coil: 12.495–16.905 kΩ...

  • Page 206: Checking The Cooling Water Temperature Sensor

    Electrical systems 2. Connect a computer to the outboard Checking the oil pressure switch motor and use the Yamaha Diagnostic 1. Check the oil pressure switch for continu- System to display the intake air tempera- ity. Replace if there is no continuity.

  • Page 207: Checking The Main And Fuel Pump Relay (Main Control)

    NOTE: relay terminal 4 or 5. Replace if there is Check the operation of the fuel injectors continuity. using the “Stationary test” of the Yamaha Diagnostic System. Checking the electric fuel pump 1. Turn the engine start switch to ON.

  • Page 208: Checking The Main And Fuel Pump Relay (Fuel Control)

    – ELEC Electrical systems 2. Listen for the operating sound of the 6. Check that there is no continuity between electric fuel pump 1. Check the fuel sys- the relay terminals 2 and 3 after dis- tem if there is no sound. connecting a battery terminal from the relay terminal 2 or 4.
  • Page 209 Fuel control system / Starting system S60V8265 8-12 6D81G11...

  • Page 210: Starter Motor

    – ELEC Electrical systems Starter motor S63P8050 Part name Q’ty Remarks Clip Pinion stopper Starter motor pinion Spring M6 × 35 mm Bolt Housing Bearing Clutch assembly E-clip Not reusable Washer Bracket Pinion shaft Planetary gear Outer gear Plate Armature Stator 8-13 6D81G11...
  • Page 211 Starter motor S63P8050 Part name Q’ty Remarks Brush assembly Brush spring Brush holder Plate Washer Bracket ø4 × 15 mm Screw M6 × 120 mm Bolt Rubber seal Shift lever Spring Magnet switch assembly Washer 8-14 6D81G11...

  • Page 212: Disassembling The Starter Motor

    – ELEC Electrical systems Disassembling the starter motor 2. Measure commutator diameter. 1. Slide the pinion stopper 1 down as Replace the armature if below specifica- shown, and then remove the clip 2. tion. NOTE: Commutator diameter wear limit: Remove the clip with a thin screwdriver. 28.0 mm (1.10 in) 3.

  • Page 213: Checking The Brushes

    Starter motor / Charging system 3. Connect the negative battery lead to the starter motor body. Armature continuity Commutator segments b Continuity Segment – No continuity Armature core c Segment – No continuity Armature shaft d Checking the brushes 1. Measure the brush length. Replace the S6D88130 brush assembly if below specification.

  • Page 214: Checking The Rectifier Regulator

    – ELEC Electrical systems 3. Measure the stator coil output peak volt- age. Replace the stator coil if below specification. S6D88150 Digital multimeter: YU-34899-A Test harness (6 pins): YB-06848 S6D88140 Digital multimeter: YU-34899-A Rectifier Regulator output peak Peak volt meter adapter: YU-39991 voltage: Test harness (6 pins): YB-06848 Red (R) –...
  • Page 215 TRBL SHTG Troubleshooting Special service tools ..................9-1 Yamaha Diagnostic System ................9-2 Introduction....................9-2 Power unit....................... 9-5 Bracket unit ....................9-13 Electrical systems..................9-17 Self-diagnosis....................9-18 Diagnosing the electronic control system ..........9-18 6D81G11...

  • Page 216: Trbl Shtg

    TRBL SHTG Troubleshooting Special service tools Yamaha Diagnostic System 60V-85300-02 YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL Yamaha Diagnostic System 60V-WS853-02 Diagnostic test lead YB-06795 6D81G11...
  • Page 217 Yamaha Diagnostic System Introduction Features The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of an outboard motor using the communication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor.
  • Page 218 • Windows XP is a multiuser operating system, therefore, be sure to end this program if the login user is changed. • The USB adapter cannot be used with Windows 95. For operating instructions of the Yamaha Diagnostic System, refer to the “Yamaha Diagnostic Sys- tem Instruction Manual.” 6D81G11...
  • Page 219 Yamaha Diagnostic System Connecting the communication cable to the outboard motor Bow view 3-pin communication coupler S6D89010 6D81G11...

  • Page 220: Power Unit

    TRBL SHTG Troubleshooting NOTE: • Check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V. • To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter.
  • Page 221 Power unit Is there Replace the fuse. continuity? Check the wiring harnesses for continuity. Is there Replace the wiring harnesses. continuity? Listen for the operation sound of the starter relay. Can the oper- ation sound Replace the starter relay. be heard? Check the starter motor opera- tion.
  • Page 222 TRBL SHTG Troubleshooting Symptom: Engine cranks, but will not start (engine stop lanyard switch is operating nor- mally). • Check the ignition system. • Check the fuel system. • Check the compression pressure of the power unit. WARNING Check that the spark plugs pro- •...
  • Page 223 Power unit Does the Check the compression pres- engine start? sure of the combustion chamber. Within specification? Check the condition of the spark Failure in starting operation plugs again. Check the valve Wet spark plugs? Failure in starting operation clearance. Adjust the valve Within Check the fuel system.
  • Page 224 Check the fuel Within Check the pressure regulator. injector resistance. specification? Check the fuel system using the Within Yamaha Diagnostic System. specification? Replace the fuel Good operat- Replace the pressure regulator. injector. ing condition? Check the fuel system using the Yamaha Diagnostic System.
  • Page 225 Check the ignition system out- Good spark? put peak voltage. Check the ignition Within Replace the spark plug. system using the specification? Yamaha Diagnostic System. Check the ignition coils resis- tance. Check the ignition Within Replace the ignition coil. system using the...
  • Page 226 The engine turns off when the throttle is opened quickly. Acceleration is tardy and the engine is likely to stop at any moment. • Check the engine using the diagnostic flash indicator or the Yamaha Diagnostic System. Symptom: Engine can run, but engine speed will not increase.
  • Page 227 Check the oil pump for debris or specification? oil leaks. Check the oil Debris or leaks? passage. Clean or replace the defective Check the oil pressure switch. parts. Good condition? Replace the oil pressure switch. Check the engine using the Yamaha Diagnostic System. 9-12 6D81G11...

  • Page 228: Bracket Unit

    TRBL SHTG Troubleshooting Bracket unit Symptom: Power trim and tilt unit does not operate. Listen for the operation sound of the power trim and tilt relay. Can the oper- Check the voltage between each terminal of the PTT relay ation sound coupler when pushing the power trim and tilt switch.
  • Page 229 Bracket unit Is it closed? Close the valve. Check the power trim and tilt fluid level. At specified Add fluid to the correct level. level? Disassemble the power trim and tilt unit, and then check the filter for debris or dirt. Stuck foreign substance or Clean or replace the filters.
  • Page 230 TRBL SHTG Troubleshooting Symptom: Power trim and tilt unit does not hold the outboard motor up. Check that the manual valve is closed. Is it closed? Close the valve. Check the power trim and tilt fluid level. At specified Add fluid to the correct level. level? Disassemble the power trim and tilt unit, and then check the...
  • Page 231 Bracket unit Symptom: Shift mechanism of the forward gear and reverse gear does not operate properly. Check the shift cable operation. Good operat- Check the shift cables and links ing condition? of the remote control box. Check the operation of the shift rod.

  • Page 232: Electrical Systems

    TRBL SHTG Troubleshooting Electrical systems Symptom: Battery becomes weaker quickly. • Check the charging system. Measure the output peak voltage of the stator coil. Within Replace the stator coil. specification? Measure the Rectifier Regulator output peak voltage. Within Replace the Rectifier Regulator. specification? Replace the battery, and then check the voltage of all electri-...

  • Page 233: Self-Diagnosis

    Electrical systems / Self-diagnosis Self-diagnosis Diagnosing the electronic control system 1. Connect the special service tool to the outboard motor as shown. • Trouble code indication Example: The illustration indicates code number 23. a: Light on, 0.33 second b: Light off, 4.95 seconds c: Light off, 0.33 second d: Light off, 1.65 seconds S6D89020...
  • Page 234 TRBL SHTG Troubleshooting 4. If a flash pattern listed in the diagnostic code chart is displayed, check the mal- functioning part according to the flash pattern. NOTE: When more than one problem is detected, the light of the special service tool flashes in the pattern of the lowest numbered problem.
  • Page 235 Index Checking the cooling water pilot hole ..1-9 Checking the cooling water temperature Adjusting the float ........4-17 sensor............8-9 Adjusting the throttle link and Checking the crankpin oil clearance..5-43 throttle cable ..........3-8 Checking the crankshaft ......5-43 Adjusting the trim sensor ......7-21 Checking the crankshaft journal oil After test run ..........1-9 clearance ..........
  • Page 236 Index Checking the piston ring side clearance ...5-42 Disassembling the drive shaft....6-17 Checking the piston rings......5-41 Disassembling the forward gear ....6-17 Checking the power trim and tilt fluid Disassembling the fuel pump ..... 4-5 level............3-11 Disassembling the gear pump ....7-33 Checking the power trim and tilt motor ..7-27 Disassembling the lower case ....
  • Page 237 Index Identification..........1-5 Reducing the fuel pressure....... 4-13 Ignition and ignition control system.....8-7 Refacing the valve seat ......5-30 Installing the clamp brackets.....7-21 Removing the clamp brackets ....7-21 Installing the cylinder head .......5-33 Removing the cylinder head ..... 5-26 Installing the drive shaft ......6-20 Removing the drive shaft......
  • Page 238 Index Upper case..........7-6 Vapor separator ........4-10 Ventilation ...........1-3 Yamaha Diagnostic System......9-2 6D81G11...
  • Page 239 F90TR 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Pu/R...
  • Page 240 Wiring diagram F90TR 1 Ignition coil Color code 2 Spark plug : Black 3 Power trim and tilt switch (tiller handle) : Brown (optional) : Green 4 Power trim and tilt switch (bottom cowling) : Blue 5 Battery : Light green 6 Cooling water temperature sensor : Orange 7 Starter motor...
  • Page 241 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Jul. 2004 –...

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F90tr

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