TOHATSU BFT250A Service Manual
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TOHATSU BFT250A Service Manual

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Table of Contents

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See also: Owner's Manual
BFT 250A
OB No.61ZX210
14-01 NB

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Summary of Contents for TOHATSU BFT250A

  • Page 1 BFT 250A OB No.61ZX210 14-01 NB...
  • Page 2 Introduction Before reading this manual This service manual provides information that is needed for inspection, service and repair of applicable outboard motors. For our customers' safe and comfortable use of the products for long term, it is essential to maintain the performance and quality of the outboard motors. To ensure this, the maintenance and service have to be done properly by service technicians with fundamental knowledge and skills.
  • Page 3 Introduction Avant de lire le présent manuel Le présent manuel d’entretien fournit les informations nécessaires au contrôle, à l’utilisation et à la réparation des moteurs hors-bords concernés. Pour une utilisation de nos produits par nos clients, à long terme, en toute sécurité...
  • Page 4 Introducción Antes de leer este manual Este manual de servicio brinda la información que se requiere para la inspección, el servicio y la reparación de los correspondientes motores fuera de borda. Para que nuestros clientes puedan utilizar los productos durante largo tiempo de forma segura y cómoda, resulta fundamental mantener el desempeño y la calidad de los motores fuera de borda.
  • Page 5 Einführung Vor dem Durchlesen dieses Handbuchs Dieses Service-Handbuch enthält die Information, die zur Inspektion, Service und Reparatur der jeweiligen Außenbordmotoren benötigt wird. Zur Sicherheit unserer Kunden und für eine komfortable, langfristige Benutzung der Produkte ist es unumgänglich, die Leistung und Qualität der Außenbordmotoren instand zu halten.
  • Page 6 dummyhead dummyhead How to use this manual A Few Words About Safety How to use this manual SERVICE INFORMATION The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage this Honda product or create an unsafe condition.

  • Page 7: Table Of Contents

    dummyhead dummyhead CONTENTS GENERAL INFORMATION SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING FUEL SYSTEM ENGINE COVER/COVER LOCK CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM OTHER ELECTRICAL COOLING SYSTEM LUBRICATION SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD CYLINDER BLOCK GEAR CASE (STANDARD ROTATION) GEAR CASE (COUNTER ROTATION) MOUNT TRIM/TILT CONTROLS...
  • Page 8 dummyhead dummyhead How to use this manual INTRODUCTION This manual covers the service and repair procedures for the Honda BF250A outboard motor. All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at anytime without notice.
  • Page 9 dummyhead dummyhead How to use this manual SERVICE RULES • Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product. •...
  • Page 10 dummyhead dummyhead How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbreviated Full term term Alternator American Petroleum Institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center Automatic Transmission Fluid Attachment Battery...

  • Page 11: General Information

    dummytext 1. GENERAL INFORMATION SERIAL NUMBER LOCATION ·····················1-2 DIMENSIONAL DRAWING ··························· 1-4 SPECIFICATIONS ·········································1-2...

  • Page 12: Specifications

    dummyhead dummyhead GENERAL INFORMATION SERIAL NUMBER LOCATION GENERAL INFORMATION The engine serial number is stamped on the alternator bracket and the product identification number is located on the right stern bracket. Always specify these numbers when inquiring about the engine or when ordering parts in order to obtain the correct parts for the outboard motor being serviced.

  • Page 13: Lower Unit

    dummyhead dummyhead GENERAL INFORMATION ENGINE Model BF250A Description code BEBJJ Type 4-stroke, O.H.C., 6-cylinder Displacement 3,583 cm (218.6 cu in) Bore x stroke 89.0 x 96.0 mm (3.50 x 3.78 in) Rated power (*1) 186.4 kW (250 PS) Maximum torque 320 N·m (32.6 kgf·m, 236 lbf·ft) Compression ratio 10.0:1...
  • Page 14 dummyhead dummyhead GENERAL INFORMATION DIMENSIONAL DRAWING Transom LA type 1,760 mm (69.3 in) 508 mm (20.0 in) XA and XCA types 1,887 mm (74.3 in) 635 mm (25.0 in) XXA and XXCA types 2,014 mm (79.3 in) 762 mm (30.0 in) 920 mm (36.2 in) 625 mm (24.6 in)
  • Page 15 dummyhead dummyhead GENERAL INFORMATION 482 mm (19.0 in) 30° 482 mm 30° (19.0 in) 629.5 mm (24.8 in) 75.8 mm 1,015 mm (3.0 in) 93.7 mm (3.7 in) (40.0 in) 12° 68°...
  • Page 16 dummyhead dummyhead GENERAL INFORMATION Propeller shaft Φ4 mm (Φ0.2 in) 7 mm (0.3 in) 28.5 mm 57.0 – 58.0 mm (1.12 in) (2.24 – 2.28 in) 56.5 mm (2.22 in) 151 mm (5.9 in)

  • Page 17: Service Information

    dummytext 2. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················2-2 LUBRICATION & SEAL POINT ·················· 2-15 ENGINE & FRAME TORQUE VALUES ········2-4 CABLE/HARNESS ROUTING ···················· 2-19 STANDARD TORQUE VALUES ···················2-7 TUBE ROUTING ········································· 2-34 TOOLS···························································2-8...

  • Page 18: Maintenance

    dummyhead dummyhead SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION ENGINE Unit: mm (in) Part Item Standard Service limit Engine Idle speed (in neutral) 650 ± 50 min (rpm) – Trolling speed 650 ± 50 min (rpm) – Cylinder compression 1,450 – 1,690 kPa (15 – 17 kgf/cm –...
  • Page 19 dummyhead dummyhead SERVICE INFORMATION Part Item Standard Service limit Crankshaft Journal O.D. Main 71.976 – 72.000 (2.8337 – 2.8346) – 55.976 – 57.000 (2.2038 – 2.2441) – Journal taper (Main/Pin) 0.005 (0.0002) Max. 0.010 (0.0004) Journal roundness (Main/Pin) 0.005 (0.0002) Max. 0.010 (0.0004) Crankshaft runout 0.025 (0.0010) Max.
  • Page 20 dummyhead dummyhead SERVICE INFORMATION Part Item Standard Service limit EMT sensor Resistance 40°C/104°F 1.0 – 1.3 kΩ – 100°C/212°F 0.1 – 0.2 kΩ – VTEC spool Resistance 14.25 – 15.75 Ω – solenoid valve IAC valve Resistance 8.7 – 10.5 Ω –...
  • Page 21 dummyhead dummyhead SERVICE INFORMATION Thread Dia. and pitch Torque values Item Remarks mm (in) N·m kgf·m lbf·ft Oil filter cartridge M20 x 1.5 Oil pressure sealing bolt M22 x 1.5 Oil drain plug M12 x 1.5 Throttle body bolt M8 x 1.25 Mount case bolt M10 x 1.25 See page 13-8...
  • Page 22 dummyhead dummyhead SERVICE INFORMATION GEAR CASE Thread Dia. and pitch Torque values Item Remarks mm (in) N·m kgf·m lbf·ft Gear case bolt M10 x 1.25 (LA, XA and XCA types) Gear case self-lock nut M10 x 1.25 (XXA and XXCA types) Gear case self-lock nut M12 x 1.25 Gear case stud bolt...

  • Page 23: Standard Torque Values

    dummyhead dummyhead SERVICE INFORMATION OTHERS Thread Dia. and pitch Torque values Item Remarks mm (in) N·m kgf·m lbf·ft Neutral switch nut M20 x 1.0 0.25 Grease fitting M6 x 1.0 0.31 Starter motor B terminal nut M8 x 1.25 Alternator terminal B terminal nut M6 x 1.0 0.82 Oil filter holder bolt...

  • Page 24: Special Tools

    dummyhead dummyhead SERVICE INFORMATION TOOLS COMMERCIALLY AVAILABLE TOOLS ORDERING INFORMATION These tools are distinguished by the words (Commercially available). They are not available through the American Honda Parts Development. Most commercially available tools shown in this Shop Manual can be ordered through the Honda Marine Tool and Equipment Program by calling (888) 424-6857.
  • Page 25 dummyhead dummyhead SERVICE INFORMATION Attachment, 32 x 42 mm Attachment, 30 x 37 mm Taper bearing installer attachment, 070PD-ZY3A100 070PD-ZY6A200 90 mm 070PF-ZY3A100 SCS service connector Float level gauge Fuel pressure gauge, 0 – 100 psi 070PZ-ZY30100 07401-0010000 07406-004000B Remover weight Valve guide driver, 5.35 x 9.7 mm Attachment, 32 x 35 mm 07936-371020A or 07936-3710200...
  • Page 26 dummyhead dummyhead SERVICE INFORMATION Driver, 22 mm I.D. Attachment, 17 mm I.D. Attachment, 50 mm 07746-0020100 07746-0020300 07APF-ZY3A100 Attachment, 25 mm I.D. Puller adapter Pilot, 20 mm 07746-0030200 07APF-ZY3A200 07746-0040500 Pilot, 35 mm Pilot, 30 mm Pilot, 25 mm 07746-0040800 07746-0040700 07746-0040600 Pilot, 14 mm...
  • Page 27 dummyhead dummyhead SERVICE INFORMATION Valve spring compressor Lock nut wrench, 36 x 47.8 mm Remover handle 07757-0010000 07916-MB00002 07936-3710100 Bearing driver attachment, Oil seal driver attachment, 28 x 35 mm Bearing driver attachment, 64 x 72 mm 44 x 49.5 mm 07945-4150200 07946-SB20000 07945-3330300...
  • Page 28 dummyhead dummyhead SERVICE INFORMATION Air quick connector Oil pressure adapter, 22 x 1.5 mm Pin type spanner, 128 mm 07AAZ-P8AA100 07APJ-ZY3A101 070PA-ZX20100 Valve guide reamer, 5.5 mm Holder handle Pilot, 28 mm 07HAH-PJ7A100 07JAB-001020A 07JAD-PH80400 Installer shaft, 15 x 370 mm Oil seal driver, 65 mm Belt tension gauge 07VMF-KZ30200...
  • Page 29 dummyhead dummyhead SERVICE INFORMATION Pin wrench, 6 mm Pin wrench, 4 mm Vertical shaft holder 07SPA-ZW1010A 07SPA-ZW1020A 07SPB-ZW10200 Backlash indicator tool Oil pressure gauge joint A Oil pressure gauge joint B 07SPJ-ZW0030B 07SPJ-ZW1010A 07SPJ-ZW1020A Air adapter VTEC air stopper Oil seal driver attachment, 80 x 96 mm 070AJ-0010101 070AJ-0030100 07ZAD-PNA0100...
  • Page 30 dummyhead dummyhead SERVICE INFORMATION Valve adjustment wrench, 10 mm Engine hanger Attachment, 27.5 x 44 mm 07908-5900000 VSB02C000021 07948-9540000 2-14...
  • Page 31 dummyhead dummyhead SERVICE INFORMATION LUBRICATION & SEAL POINT ENGINE Material Location Remarks Engine oil Oil filter holder threads Oil filter cartridge O-ring Lost motion Valve stem seal internal circumference Valve adjusting screw threads Oil pipe joint O-ring Oil control orifice O-ring Oil strainer O-ring Oil pump rotor chamber 30 cc...
  • Page 32 dummyhead dummyhead SERVICE INFORMATION Material Location Remarks Industrial parts cleaner Each oil seal and water seal outer surface solution (mixture of the Threebond ® 2720C and water in a ratio of 1:9) Marine grease (water resistant Each oil seal and water seal lip urea based grease) Water tube grommet entire circumference Exhaust manifold/water jacket cover O-ring...
  • Page 33 dummyhead dummyhead SERVICE INFORMATION STERN BRACKET MOUNT Material Location Remarks Marine grease (water resistant Lower cylinder collar outer surface urea based grease) Lower cylinder bushing inner and outer surface Mount frame shaft and spline Thrust washer (34 mm) Swivel case liner circumference Oil seal (39.5 x 52 x 6 mm) lip and outer surface Swivel case shaft sliding part Swivel case tilting shaft sliding part...
  • Page 34 dummyhead dummyhead SERVICE INFORMATION OTHERS Material Location Remarks Marine grease (water resistant Drain plug rubber lip urea based grease) Alternator front bearing outer surface Alternator rear bearing inner surface Throttle cam ® Loctite PRISM 403 Water joint cap nut seating surface 2-18...
  • Page 35 dummyhead dummyhead SERVICE INFORMATION CABLE/HARNESS ROUTING STARTER CABLE 1 (+) TERMINAL ACG CABLE TERMINAL POWER TILT RELAY WIRE TERMINAL TACH PULSE 2P CONNECTOR EMT SENSOR 2 2P CONNECTOR EMT SENSOR 1 2P CONNECTOR HO2S ALTERNATOR 4P CONNECTOR 4P CONNECTOR SWITCH PANEL WIRE HARNESS 14P CONNECTOR POWER TILT MOTOR...
  • Page 36 dummyhead dummyhead SERVICE INFORMATION FUSE/RELAY JUNCTION BOX FUSE/RELAY JUNCTION BOX 8P CONNECTOR 23P CONNECTOR ACG CABLE TACH PULSE 2P CONNECTOR ALTERNATOR INTERFACE 4P CONNECTOR 6P CONNECTOR SWITCH PANEL WIRE HARNESS 14P CONNECTOR POWER TILT RELAY WIRE TERMINAL DLC 4P STARTER CABLE 1 (+) FUSE/RELAY JUNCTION BOX INDICATOR PANEL 10P CONNECTOR...
  • Page 37 dummyhead dummyhead SERVICE INFORMATION ACG CABLE POWER TILT RELAY CABLE RED TAPE GREEN TAPE YELLOW TAPE STARTER CABLE 1 (+) GREEN YELLOW MAIN WIRE HARNESS GROUND TERMINALS STOPPER MAIN WIRE HARNESS POWER TILT RELAY GROUND TERMINALS GROUND TERMINALS STOPPER STARTER CABLE GROUND (BATTERY GROUND TERMINAL) 2-21...
  • Page 38 dummyhead dummyhead SERVICE INFORMATION INDICATOR PANEL SWITCH PANEL WIRE HARNESS WIRE HARNESS NMEA INTERFACE WIRE (Optional part) STARTER CABLE 1 (+) STARTER CABLE (–) NMEA INTERFACE WIRE (Optional part) NMEA INTERFACE WIRE (Optional part) STARTER CABLE (–) STARTER CABLE 1 (+) SHIFT CONTROL CABLE THROTTLE CONTROL CABLE...
  • Page 39 dummyhead dummyhead SERVICE INFORMATION AIR FLOW CLAMP Install the air flow clamp as shown. AIR FLOW CLAMP TP SENSOR 3P CONNECTOR EMT SENSOR 1 2P CONNECTOR IAC VALVE 2P CONNECTOR MAIN WIRE HARNESS ECM 36P CONNECTOR B (Black) ECM 36P CONNECTOR A (Gray) TP SENSOR 3P CONNECTOR...
  • Page 40 dummyhead dummyhead SERVICE INFORMATION ALTERNATOR B TERMINAL COVER COVER ACG CABLE TERMINAL STARTER CABLE 1 (+) TERMINAL POWER TILT RELAY WIRE TERMINAL IAC VALVE 2P CONNECTOR TP SENSOR 3P CONNECTOR JOINT CONNECTOR 1 Install the joint connector 1 as shown. After installation, check the main wire harness for twisting.
  • Page 41 dummyhead dummyhead SERVICE INFORMATION CKP SENSOR 2P CONNECTOR Align the stay with the center of grommet. Cruising direction GROMMET 90° STAY HARNESS BAND CLIP VTEC SOLENOID VALVE 1P CONNECTOR ECM BRACKET HARNESS BAND CLIP POWER TILT SWITCH 3P CONNECTOR VTEC SOLENOID VALVE 1P CONNECTOR POWER TILT SWITCH WIRE Install the power tilt switch wire from the outside...
  • Page 42 dummyhead dummyhead SERVICE INFORMATION IAT SENSOR 2P CONNECTOR MAP SENSOR 3P CONNECTOR HARNESS BAND CLIP EMT SENSOR 2 2P CONNECTOR No.4 DIRECT IGNITION COIL 3P CONNECTOR No.5 DIRECT IGNITION COIL 3P CONNECTOR No.6 DIRECT IGNITION COIL 3P CONNECTOR WATER LEVEL SENSOR 2P CONNECTOR 2-26...
  • Page 43 dummyhead dummyhead SERVICE INFORMATION POWER TILT MOTOR 2P CONNECTOR WIRE POWER TILT RELAY HO2S 4P CONNECTOR 2P CONNECTOR POWER TILT RELAY GROUND TERMINALS CABLE POWER TILT MOTOR 2P CONNECTOR/ POWER TILT RELAY 1P CONNECTOR WIRE POWER TILT RELAY CASE POWER TILT MOTOR POWER TILT RELAY 2P CONNECTOR 1P CONNECTOR...
  • Page 44 dummyhead dummyhead SERVICE INFORMATION THROTTLE CABLE B THROTTLE CABLE A THROTTLE CABLE B THROTTLE CABLE A 2-28...
  • Page 45 dummyhead dummyhead SERVICE INFORMATION POWER TILT RELAY 1P CONNECTOR POWER TILT RELAY POWER TILT RELAY GROUND TERMINALS CABLE MAIN WIRE HARNESS WIRE HARNESS CLIP POWER TILT RELAY GROUND TERMINALS CABLE POWER TILT MAIN WIRE RELAY CABLE HARNESS POWER TILT MOTOR 2P CONNECTOR STARTER CABLE 2 (+) POWER TILT RELAY CABLE STARTER MOTOR B TERMINAL NUT (8 mm)
  • Page 46 dummyhead dummyhead SERVICE INFORMATION WIRE BAND (Cut off the surplus band L. ENGINE UNDER COVER leaving approximately 5 mm (0.2 in)) UNDER CASE Align the white tape end with GROMMET the under case grommet end. TRIM ANGLE SENSOR WIRE POWER TILT MOTOR WIRE L.
  • Page 47 dummyhead dummyhead SERVICE INFORMATION TRIM ANGLE SENSOR WIRE Check the wire for slack. POWER TILT MOTOR WIRE Check the wire for twisting. SWIVEL CASE R. STERN BRACKET TRIM ANGLE SENSOR POWER TILT MOTOR 2-31...
  • Page 48 dummyhead dummyhead SERVICE INFORMATION L. TIMING BELT BACK COVER CMP SENSOR 1 CMP SENSOR 2 4P CONNECTOR HARNESS BAND CLIP (Cut off the surplus band leaving approximately 10 mm (0.4 in)) IAT SENSOR 2P CONNECTOR No.1 FUEL INJECTOR 2P CONNECTOR No.4 FUEL INJECTOR 2P CONNECTOR WIRE HARNESS CLIP...
  • Page 49 dummyhead dummyhead SERVICE INFORMATION MAIN WIRE HARNESS to SWITCH IAB CONTROL SOLENOID No.1 FUEL INJECTOR WIRE 6P CONNECTOR VALVE 2P CONNECTOR 2P CONNECTOR CMP SENSOR 1 CMP SENSOR 2 4P CONNECTOR EBT SENSOR 2P CONNECTOR No.4 FUEL INJECTOR 2P CONNECTOR HARNESS BAND CLIP WIRE HARNESS CLIP WIRE HARNESS CLIP...
  • Page 50 dummyhead dummyhead SERVICE INFORMATION TUBE ROUTING R. WATER RELIEF TUBE Install the longer side of the water relief tube into the 77 mm (3.0 in) thermostat. Install the shorter side of the water relief tube into the exhaust manifold. THERMOSTA The tubes have a paint mark T SIDE for the installation direction.
  • Page 51 dummyhead dummyhead SERVICE INFORMATION L. WATER RELIEF TUBE Install the longer side of the water relief tube into the 77 mm (3.0 in) thermostat. Install the shorter side of the water relief tube into the exhaust manifold. THERMOSTAT The tubes have a paint mark SIDE for the installation direction.
  • Page 52 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE (3.5 x 540 mm) FUEL TUBE (3.5 x 590 mm) PRESSURE REGULATOR RETURN HOSE A AIR VENT TUBE AIR VENT TUBE A FUEL HOSE A V TUBE (3.5 x 6.5 x 600 mm) FUEL TUBE C WATER OUTLET TUBE FUEL TUBE E PRESSURE REGULATOR...
  • Page 53 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE (3.5 x 130 mm) FUEL TUBE (3.5 x 600 mm) FUEL TUBE (3.5 x 50 mm) FUEL JOINT HOSE CHECK VALVE FUEL TUBE D IAB CONTROL DIAPHRAGM FUEL PIPE FUEL TUBE G CHECK VALVE FUEL TUBE (3.5 x 40 mm) 2-37...
  • Page 54 dummyhead dummyhead SERVICE INFORMATION TUBE CLAMP D10.7 TUBE CLIP B12 TUBE CLAMP D10.5 TUBE CLIP B12 TUBE CLIP B8 TUBE CLAMP D10.5 HOSE CLIP TUBE CLAMP D32.5 TUBE CLAMP D10.5 120° TUBE CLIP D12.0 Cruising direction 2-38...
  • Page 55 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE (3.5 x 540 mm) BREATHER TUBE C BREATHER TUBE B AIR VENT TUBE BREATHER TUBE A WIRE CLIP FUEL TUBE (3.5 x 130 mm) CHECK VALVE CLAMP FUEL HOSE A CHECK VALVE TUBE WHITE WHITE PAINTED CHECK VALVE...
  • Page 56 dummyhead dummyhead SERVICE INFORMATION BREATHER TUBE B BREATHER TUBE C WIRE CLIP A FUEL TUBE (3.5 x 130 mm) BREATHER TUBE A AIR VENT TUBE FUEL TUBE CHECK VALVE TUBE (3.5 x 50 mm) FUEL HOSE A WIRE HARNESS CLIP AIR VENT TUBE PRESSURE REGULATOR...
  • Page 57 dummyhead dummyhead SERVICE INFORMATION TUBE CLIP B8 TUBE CLIP B12 TUBE CLAMP D32.5 FUEL TUBE D WATER SEPARATOR/WATER LEVEL SENSOR CYLINDER HEAD COVER OIL RETURN HOSE TUBE CLIP B8 WATER TUBE CLAMP D10.5 OUTLET TUBE TUBE CLAMP D10.5 WATER INLET TUBE WATER INLET TUBE WATER OUTLET...
  • Page 58 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE (3.5 x 540 mm) FUEL TUBE (3.5 x 590 mm) FUEL TUBE (3.5 x 130 mm) FUEL TUBE (3.5 x 600 mm) PRESSURE REGULATOR RETURN HOSE A TUBE CLAMP D10.7 FUEL TUBE (3.5 x 50 mm) PRESSURE REGULATOR RETURN HOSE A AIR VENT TUBE...
  • Page 59 dummytext 3. MAINTENANCE MAINTENANCE SCHEDULE························3-2 LUBRICATION ············································ 3-25 WATER SEPARATOR INSPECTION ········· 3-27 TOOLS···························································3-3 ENGINE OIL LEVEL INSPECTION/OIL FUEL FILTER (LOW PRESSURE SIDE) CHANGE························································3-4 INSPECTION/REPLACEMENT ·················· 3-27 ENGINE OIL FILTER REPLACEMENT ········3-6 FUEL FILTER (HIGH PRESSURE SIDE) INSPECTION/REPLACEMENT ·················· 3-29 GEAR CASE OIL CHANGE ··························3-7 FUEL LINE INSPECTION/ REPLACEMENT ·········································...

  • Page 60: Maintenance Schedule

    dummyhead dummyhead MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE Item REGULAR SERVICE PERIOD (2) Perform at every indicated month or operating hour interval, whichever comes first. Refer Every Every Every First Every 6 year page Each After month months years years or 20 or 100 hrs.

  • Page 61: Tools

    dummyhead dummyhead MAINTENANCE Item REGULAR SERVICE PERIOD (2) Perform at every indicated month or operating hour interval, whichever comes first. Refer Every Every Every First Every 6 year page Each After month months years years or 20 or 100 hrs. hrs.

  • Page 62: Engine Oil Level Inspection/Oil

    dummyhead dummyhead MAINTENANCE ENGINE OIL LEVEL INSPECTION/OIL CHANGE OIL LEVEL INSPECTION Start the engine, let it warm up to the normal operating UPPER temperature, and stop the engine. LIMIT Place the outboard motor in the vertical position (with the engine level), and remove the engine cover. Remove the dipstick [1], and wipe it clean with a shop towel.
  • Page 63 dummyhead dummyhead MAINTENANCE OIL CHANGE Used engine oil contains substances that have been identified as carcinogenic. If repeatedly left in contact with the skin for prolonged periods, it may cause skin cancer. Wash your hands thoroughly with soap and water as soon as possible after contact with used engine oil.

  • Page 64: Engine Oil Filter Replacement

    dummyhead dummyhead MAINTENANCE ENGINE OIL FILTER REPLACEMENT Remove the engine cover. Drain the engine oil as described in the oil change procedure (page 3-5). Place a shop towel under the oil filter [1] to absorb any spilled oil, and then attach the special tool to the oil filter and remove it.

  • Page 65: Gear Case Oil Change

    dummyhead dummyhead MAINTENANCE GEAR CASE OIL CHANGE Place the outboard motor on a level surface and position the outboard motor vertically (with the engine level). Tilt the outboard motor up slightly until the drain hole is at its lowest point. Remove the oil drain plug bolt [1] and oil check bolt [2], then check for metal particles on the magnet end.

  • Page 66: Timing Belt Inspection

    dummyhead dummyhead MAINTENANCE TIMING BELT INSPECTION INSPECTION Remove the timing belt cover (page 14-6). Check the timing belt [1] for wear and damage. Replace the timing belt if it is worn or damaged. Check the timing belt and the related parts for oil and grease.

  • Page 67: Alternator Belt Inspection

    dummyhead dummyhead MAINTENANCE Rotate the crankshaft pulley [1] counterclockwise by six teeth of the timing belt driven pulley gear, and then turn the crankshaft pulley clockwise by three teeth of the timing belt driven pulley gear. If the crankshaft pulley was turned more than three teeth of the timing belt driven pulley gear, turn the crankshaft pulley clockwise to bring the No.
  • Page 68 dummyhead dummyhead MAINTENANCE BELT TENSION INSPECTION USING BELT TENSION GAUGE Set the special tool at the center between the alternator belt pulley [1] and the crankshaft pulley [2], and measure the belt tension. TOOL: Belt tension gauge [3] 07TGG-001000A or 07JGG-001010A BELT TENSION: New belt*1 880 –...

  • Page 69: Throttle Linkage Inspection

    dummyhead dummyhead MAINTENANCE THROTTLE LINKAGE INSPECTION/ ADJUSTMENT STANDARD INSPECTION/ ADJUSTMENT 1. Remove the engine cover. OPEN SIDE: 2. Check the throttle cable length of the sections 10.0 mm (0.39 in) shown at the throttle cam [1] open side and the close side respectively.
  • Page 70 dummyhead dummyhead MAINTENANCE 7. Check whether the throttle arm [1] is in contact with the full open position stopper [2]. If it is not, adjust the throttle arm (page 3-13). • Make sure the shift control cable is adjusted properly (page 20-10).
  • Page 71 dummyhead dummyhead MAINTENANCE THROTTLE ARM ADJUSTMENT If the throttle arm does not fully open Slide the lock plate [1] backward and remove the throttle control cable [2] from the throttle arm [3]. Move the remote control lever to the full throttle position.
  • Page 72 dummyhead dummyhead MAINTENANCE Move the remote control lever [1] to the "F" (Forward) full open position. Check whether the throttle arm is in contact with the full "N" open position stopper as shown on page 3-12. (NEUTRAL) Move the remote control lever to the "N" (Neutral) "F"...

  • Page 73: Valve Clearance

    dummyhead dummyhead MAINTENANCE VALVE CLEARANCE • Valve clearance inspection and adjustment must be performed with the engine cold. 1. Remove the following: – Cylinder head cover (page 14-19) – Timing belt covers (page 14-6) 2. Manually turn the crankshaft pulley [1] clockwise, and align the No.
  • Page 74 dummyhead dummyhead MAINTENANCE 4. If adjustment is necessary, loosen the valve adjusting lock nut [1] using the special tool, and adjust the intake and exhaust valve clearance by turning the valve adjusting screw [2] right or left. TOOL: Valve adjustment wrench, 07908-5900000 10 mm [3] No.

  • Page 75: Spark Plug Inspection

    dummyhead dummyhead MAINTENANCE 5. After adjustment, secure the adjusting screw [1] and loosely tighten the lock nut [2]. 6. Recheck the valve clearances using a feeler gauge [3], and tighten the valve adjusting lock nut to the specified torque. TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft) 7.
  • Page 76 dummyhead dummyhead MAINTENANCE Clean any dirt from around the spark plug bases. Use a spark plug wrench [1] and remove the spark plugs. If the spark plug is dirty, clean the spark plug using a Standard: Standard: spark plug cleaner. Visually inspect the spark plug.

  • Page 77: Propeller And Cotter Pin

    dummyhead dummyhead MAINTENANCE PROPELLER AND COTTER PIN INSPECTION Check the propeller [1] for bends or damage. Make sure the split pin [2] ends are bent as shown to lock the castle nut [3]. Replace the propeller or split pin, if necessary: –...
  • Page 78 dummyhead dummyhead MAINTENANCE STERN BRACKET Check the anode [1] for excessive wear or corrosion. Replace the anode with a new one if it is corroded excessively (page 19-6). Check the continuity between the anode [1] and stern bracket or power trim/tilt. Remove the corrosion as it prevents continuity.
  • Page 79 dummyhead dummyhead MAINTENANCE EXHAUST MANIFOLD Remove the exhaust manifold (page 5-95). Check the anode [1] for excessive wear or corrosion. If the anode is worn to less than 2/3 of its original length, replace it with a new one. Check the continuity between the anode [1] and exhaust manifold.
  • Page 80 dummyhead dummyhead MAINTENANCE Check the continuity between the anode [1] and cylinder block. Remove the corrosion as it prevents continuity. Perform continuity inspection between the anode metal surface without corrosion and the bare aluminum surface of the cylinder block. If there is no continuity, remove the anode metal (page 15-4) and remove the corrosion of the following parts using sandpaper.
  • Page 81 dummyhead dummyhead MAINTENANCE USING A COMMERCIALLY AVAILABLE DIGITAL MULTIMETER Install a commercially available digital multimeter with an inductive pickup (Fluke 88) [1]. Connect the inductive pickup to the No.1 ignition coil primary wire [2] with the "SPARK PLUG" side toward the spark plug as shown.
  • Page 82 dummyhead dummyhead MAINTENANCE Wait until the engine speed stabilizes, and then check the idle speed. If the idle speed is outside the specification, adjust by turning the idle adjusting screw [1] in or out. BASE IDLE SPEED (AT NEUTRAL): 570 ± 30 min (rpm) (with IAC valve connector disconnected) After adjustment, stop the engine and apply Nippon...

  • Page 83: Lubrication

    dummyhead dummyhead MAINTENANCE LUBRICATION Apply marine grease to the following parts: THROTTLE ARM SHIFT SLIDER COLLAR SIDE LOCK CABLE END LINK ROD GREASE FITTING THROTTLE CAM CLICK SPRING THRUST RECEIVER ROLLER GREASE FITTING THRUST RECEIVER SLIDING SURFACES SHIFT LINK ROD TILTING SHAFT GREASE FITTING PROPELLER SHAFT...
  • Page 84 dummyhead dummyhead MAINTENANCE SWIVEL CASE GREASE FITTING FRONT LOCK GREASE FITTING COVER LOCK BOLT CABLE END LOCK LEVER ATTACHING AREA SHAFT PIVOT SWIVEL CASE GREASE FITTING CABLE END SIDE LOCK VERTICAL SHAFT GREASE FITTING SHIFT ROD A UPPER BEARING BUSHINGS/PINS 3-26...

  • Page 85: Water Separator Inspection

    dummyhead dummyhead MAINTENANCE WATER SEPARATOR INSPECTION Remove the L. engine under cover (page 6-4). Check the water separator [1] for water accumulation or sediment. If water or sediment is found, or the warning buzzer sounds, disassemble and clean the water separator (page 5-93).
  • Page 86 dummyhead dummyhead MAINTENANCE REPLACEMENT Clamp fuel tubes A [1] and B [2] with hose clips, and then disconnect fuel tubes A and C from the strainer. Release the power tilt switch wire [3] from the harness clip [4]. Remove the two bolts [5] and fuel strainer [6] with the strainer bracket [7].

  • Page 87: Fuel Filter (High Pressure Side) Inspection/Replacement

    dummyhead dummyhead MAINTENANCE FUEL FILTER (HIGH PRESSURE SIDE) INSPECTION/REPLACEMENT Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. •...

  • Page 88: Fuel Line Inspection

    dummyhead dummyhead MAINTENANCE FUEL LINE INSPECTION/ REPLACEMENT Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Check the fuel line, fuel hose, and the fuel tubes for damage, fuel...

  • Page 89: Battery And Cable Connection

    dummyhead dummyhead MAINTENANCE BATTERY AND CABLE CONNECTION A battery can explode if you do not follow the proper procedure, causing serious injury to anyone nearby. Follow all procedures carefully and keep sparks and open flames away from the battery. The battery contains sulfuric acid electrolyte, which is highly corrosive and poisonous.

  • Page 90: Water Passage Cleaning

    dummyhead dummyhead MAINTENANCE WATER PASSAGE CLEANING Flush the cooling system as follows. Do not run the motor when flushing with a garden hose or the motor may be damaged. For safety, remove the emergency stop switch clip so the engine cannot be started while you are standing near the propeller.

  • Page 91: Emergency Stop Switch

    dummyhead dummyhead MAINTENANCE EMERGENCY STOP SWITCH INSPECTION Make sure that the clip [1] is set at the emergency stop switch. Start the engine and idle the engine in neutral. The engine should stop when the clip is removed. If it does not, replace the emergency stop switch. Set the clip [1] to the emergency stop switch.
  • Page 92 dummyhead dummyhead MEMO...

  • Page 93: Troubleshooting

    dummytext 4. TROUBLESHOOTING BEFORE TROUBLESHOOTING···················4-2 ALERT SYSTEM/WARNING SYSTEM TROUBLESHOOTING ································ 4-18 ENGINE TROUBLESHOOTING····················4-2 FRAME TROUBLESHOOTING ·················· 4-25 FUSE/ELECTRIC POWER LINE TROUBLESHOOTING·································4-15...
  • Page 94 dummyhead dummyhead TROUBLESHOOTING BEFORE TROUBLESHOOTING TROUBLESHOOTING • Use a known-good battery for troubleshooting. • Disconnect the boat equipment (electrical loads) • Check that the connectors are connected securely. • Check for sufficient fresh fuel in the fuel tank. • Check that the emergency stop switch clip is set securely. •...
  • Page 95 dummyhead dummyhead TROUBLESHOOTING 6. Spark Plug Inspection Remove and inspect spark plugs. Is the spark plug wet? – • Incorrect spark plug heat range • Incorrect spark plug gap • Restriction or blockage between the cooling fan cover and cylinder head •...
  • Page 96 dummyhead dummyhead TROUBLESHOOTING ENGINE STARTS BUT STALLS SOON 1. Alert system inspection Turn the combination switch ON. Check the warning buzzer sound. Does the warning buzzer sound twice and then keep sounding? – Perform alert system/warning system troubleshooting (page 4-18). –...
  • Page 97 dummyhead dummyhead TROUBLESHOOTING 7. Pressure regulator inspection Check the fuel pressure and record it (page 5-111). Disconnect the pressure regulator vacuum tube. Check the fuel pressure. Is the fuel pressure higher with the vacuum tube disconnected? – GO TO STEP 8. –...
  • Page 98 dummyhead dummyhead TROUBLESHOOTING 4. Pressure regulator inspection Inspect the fuel pressure and record it (page 5-111). Disconnect the pressure regulator vacuum tube. Inspect the fuel pressure. Is the fuel pressure higher with the vacuum tube disconnected? – GO TO STEP 5. –...
  • Page 99 dummyhead dummyhead TROUBLESHOOTING 5. Alternator F line inspection Inspect the alternator F line (page 4-9). Is the alternator F line normal? – Replace the ECM with a new one and recheck. – Replace the alternator with a new one and recheck. ENGINE SPEED IS HIGHER THAN THE SPECIFIED TROLLING SPEED AFTER WARMING UP 1.
  • Page 100 dummyhead dummyhead TROUBLESHOOTING 2. Engine idle speed inspection Check the idle speed (page 3-22). Is the idle speed normal? – Improperly adjusted idle adjusting screw. – GO TO STEP 3. 3. Pressure regulator inspection Inspect the fuel pressure and record it (page 5-111). Disconnect the pressure regulator vacuum tube.
  • Page 101 dummyhead dummyhead TROUBLESHOOTING ENGINE SPEED IS HIGHER (750 min (rpm)) THAN THE SPECIFIED IDLE SPEED WITH NORMAL ELECTRICAL LOAD AFTER WARMING UP FUSE/RELAY JUNCTION BOX No.4 No.5 FUSE FUSE (30A) (10A) MAIN RELAY No.1 No.10 FUSE FUSE (150A) (10A) BATTERY (12V) OPTION COMBINATION...
  • Page 102 dummyhead dummyhead TROUBLESHOOTING ENGINE SPEED IS NOT STABLE DURING IDLE AND TROLLING 1. Alert system inspection Turn the combination switch ON. Check the warning buzzer sound. Does the warning buzzer sound twice and then keep sounding? – Perform alert system/warning system troubleshooting (page 4-18). –...
  • Page 103 dummyhead dummyhead TROUBLESHOOTING 8. Fuel injector inspection Inspect the fuel injector (page 5-116). Is the fuel injector normal? – GO TO STEP 9. – • Repair the open or short circuit fuel injector wire • Faulty fuel injector 9. IAC valve inspection Replace the IAC valve with a new one and start the engine.
  • Page 104 dummyhead dummyhead TROUBLESHOOTING 6. Neutral switch inspection Inspect the neutral switch (page 9-20). Is the neutral switch normal? – GO TO STEP 7. – Replace the neutral switch with a new one and recheck. 7. Fuel injector inspection Inspect the fuel injector (page 5-116). Is the fuel injector normal? –...
  • Page 105 dummyhead dummyhead TROUBLESHOOTING 5. IAB control solenoid valve inspection Check operation of the IAB control solenoid valve (page 5-118). Is the IAB system operating correctly? – GO TO STEP 6. – Faulty IAB control solenoid valve 6. VTEC system inspection Inspect the following VTEC system: –...
  • Page 106 dummyhead dummyhead TROUBLESHOOTING ENGINE SPEED DOES NOT DECREASE 1. Throttle cable inspection Inspect the throttle cable (page 3-11). Is the throttle cable adjustment correct? – GO TO STEP 2. – Improper throttle cable adjustment (page 3-11). 2. Throttle body inspection Check the throttle shaft of the throttle body.
  • Page 107 dummyhead dummyhead TROUBLESHOOTING FUSE/ELECTRIC POWER LINE TROUBLESHOOTING FUSE CONNECTION TABLE Fuse No. Amps. Component(s) or Circuit(s) Protected 150 A Alternator (Output terminal) ECM (Power supply), Fuel injector, Alternator, DLC, O sensor heater, IAB control solenoid valve, 30 A Direct ignition coil, Relay (Included in the junction box: Main relay, Starter relay, Fuel pump relay) Alternator (Input terminal), Combination switch, Power tilt relay, Warning buzzer, Oil indicator 10 A light, Overheat indicator light, MIL, Alternator indicator light, tachometer, Trim meter, Hour meter,...
  • Page 108 dummyhead dummyhead TROUBLESHOOTING FUSE LOAD CHART To ALTERNATOR (DETECTION TERMINAL) POWER W/Bl TILT SWITCH W/Bl POWER TRIM/ TILT SWITCH To POWER TILT RELAY W/Bl To POWER TILT RELAY W/Bl COMBINATION SWITCH COMBINATION SWITCH Bl/R W/Bl Bl/Y Bl/W Bl/Y W/Bl W/Bl Bl/W To WARNING BUZZER (OP) Bl/Y...
  • Page 109 dummyhead dummyhead TROUBLESHOOTING MIL AND WARNING BUZZER DOES NOT OPERATE 1. Fuse inspection Turn the combination switch OFF. Check for blown No.4, No.5, and No.9 fuses. Is the fuse blown? – Replace the blown fuse and check for short in the main wire harness or incorrect load by referring to the fuse load chart (page 4-16).
  • Page 110 dummyhead dummyhead TROUBLESHOOTING 4. Main relay inspection Inspect the main relay (page 10-11). Is the main relay normal? – GO TO STEP 5. – Replace the main relay with a new one and recheck. 5. Fuse/relay junction box inspection Inspect the main relay circuit into the fuse/relay junction box (page 10-13).
  • Page 111 dummyhead dummyhead TROUBLESHOOTING FUNCTION TEST USING THE HDS 1. Fuse inspection Turn the combination switch OFF. Check the No.10 fuse in the fuse/relay junction box. Is the fuse blown? – Replace the blown fuse and check for short in the main wire harness or incorrect load by referring to the fuse load chart (page 4-16).
  • Page 112 dummyhead dummyhead TROUBLESHOOTING FUNCTION TEST WITHOUT USING THE HDS 1. Fuse inspection Turn the combination switch OFF. Check the No.10 fuse in the fuse/relay junction box. Is the fuse blown? – Replace the blown fuse and check for short in the main wire harness or incorrect load by referring to the fuse load chart (page 4-16).
  • Page 113 dummyhead dummyhead TROUBLESHOOTING 5. MIL inspection Turn the combination switch OFF. ECM CONNECTOR A Short the No.3 terminal (Red/Blue) of the ECM MAIN WIRE HARNESS SIDE connector A main wire harness side 36P connector to engine ground using a jumper wire. Turn the combination switch ON.
  • Page 114 dummyhead dummyhead TROUBLESHOOTING WARNING BUZZER SOUNDS CONTINUOUSLY • The warning buzzer can sound when the starter motor speed is extremely low, but the alert system/warning system is normal if the buzzer stops sounding after starting the engine. THE OVERHEAT INDICATOR LIGHT COMES ON OR BLINKS 1.
  • Page 115 dummyhead dummyhead TROUBLESHOOTING THE OVERHEAT INDICATOR LIGHT GOES OFF AND OIL INDICATOR LIGHT GOES OFF OR BLINKS 1. MIL inspection Check to see if the MIL stays on. Does the MIL stay ON? – Perform PGM-FI troubleshooting (page 5-6) – GO TO STEP 2. 2.
  • Page 116 dummyhead dummyhead TROUBLESHOOTING THE OVERHEAT INDICATOR LIGHT GOES OFF AND OIL INDICATOR LIGHT COMES ON 1. Overheat indicator light and oil indicator light inspection Check the overheat indicator light and oil indicator light as follows: – Using the HDS (page 4-19) –...
  • Page 117 dummyhead dummyhead TROUBLESHOOTING FRAME TROUBLESHOOTING HARD TO SHIFT 1. Control cable inspection Check the remote control cable (engine side) for corrosion. Is the control cable normal? – GO TO STEP 2. – Replace the remote control cable. 2. Shift control cable adjustment Adjust the shift control cable (page 20-3).
  • Page 118 dummyhead dummyhead TROUBLESHOOTING 3. Oil leak inspection Check for oil leakage from the power trim/tilt. Is there oil leakage? – Replace the O-ring and oil seal at the leaking point (if the manual valve O-ring or piston rod A (cylinder cap) oil seal is leaking, replace it as an assembly). –...
  • Page 119 dummyhead dummyhead TROUBLESHOOTING POWER TRIM/TILT MOTOR DOES NOT OPERATE 1. Power trim/tilt motor inspection Connect the battery to the power tilt motor and check whether the motor operates. Does the motor turn? – GO TO STEP 2. – GO TO STEP 4. 2.
  • Page 120 dummyhead dummyhead TROUBLESHOOTING POWER TRIM/TILT QUICK REFERENCE CHART Symptom Pressure check Check/repair method Check point Does not Does not Does not hold Lower chamber Upper chamber tilt up tilt down hydraulic hydraulic Lowers Extends pressure lower pressure lower than spec or than spec or pressure drops.
  • Page 121 dummyhead dummyhead TROUBLESHOOTING [15] UPPER CHAMBER SPOOL VALVE [1] MOTOR [10] PUMP [11] DOWN RELIEF VALVE [13] LOWER CHAMBER SPOOL VALVE [12] LOWER CHAMBER CHECK VALVE [2] MANUAL VALVE [14] UPPER CHAMBER CHECK VALVE PISTON ROD A ASSEMBLY [8] DUST SEAL/O-RING [1] MOTOR [9] OIL PUMP ASSEMBLY...
  • Page 122 dummyhead dummyhead MEMO...
  • Page 123 dummytext 5. FUEL SYSTEM TOOLS······································································ 5-2 IAB CONTROL SOLENOID VALVE REMOVAL/ INSTALLATION····················································5-102 SERVICE PRECAUTIONS ······································· 5-3 CMP SENSOR REMOVAL/INSTALLATION········5-103 SYSTEM LOCATION ··············································· 5-9 EOP SWITCH (HIGH PRESSURE SIDE) REMOVAL/ INSTALLATION····················································5-103 PIPING CONNECTIONS ········································ 5-10 EOP SWITCH (LOW PRESSURE SIDE) REMOVAL/ CIRCUIT DIAGRAM ···············································...

  • Page 124: Tools

    dummyhead dummyhead FUEL SYSTEM TOOLS FUEL SYSTEM LIST SCS service connector Float level gauge Fuel pressure gauge, 0 – 100 psi 070PZ-ZY30100 07401-0010000 07406-004000B Test probe 07ZAJ-RDJA110...

  • Page 125: Service Precautions

    dummyhead dummyhead FUEL SYSTEM SERVICE PRECAUTIONS GENERAL TROUBLESHOOTING Before troubleshooting • First, check the MIL [1]. • Be sure to turn the combination switch OFF before disconnecting and connecting the connectors. • Clear the DTCs and reset the ECM after inspection. –...
  • Page 126 dummyhead dummyhead FUEL SYSTEM Replace the O-rings (7.47 x 3.6 mm) [1] and seal rings (7.45 x 3.61 mm) [2] with new ones when the fuel line is removed/installed or replaced. • Apply the recommended engine oil to the O-rings and seal rings before installing the fuel injector [3].
  • Page 127 dummyhead dummyhead FUEL SYSTEM SYSTEM DESCRIPTION SELF-DIAGNOSIS SYSTEM The ECM has a self-diagnosis function that memorizes the failure code and turns the MIL ON when it detects an abnormality with the input/output system. FAIL-SAFE FUNCTION The PGM-FI system is provided with a fail-safe function to provide minimum running capability even when there is trouble in the system.
  • Page 128 dummyhead dummyhead FUEL SYSTEM DTC READOUT Turn the combination switch ON; the MIL [1] will stay on for a few seconds, then go off. Start the engine and check the MIL. • If the engine will not start, turn the starter motor for more than 10 seconds and check the MIL.
  • Page 129 dummyhead dummyhead FUEL SYSTEM READING DTC WITH THE HDS • The HDS can readout the DTC, freeze data, current data, and other ECM condition. How to connect the HDS Turn the combination switch to OFF. Remove the dummy connector [1] from the DLC [2]. Connect the HDS [3] to the DLC.
  • Page 130 dummyhead dummyhead FUEL SYSTEM INSPECTION AT ECM CONNECTOR • Always clean around and keep any foreign material away from connector before disconnecting it. • A faulty PGM-FI system is often related to poorly connected or corroded terminals. Check those connections before proceeding. •...

  • Page 131: System Location

    dummyhead dummyhead FUEL SYSTEM SYSTEM LOCATION [12] [18] [19] [10] [11] [13] [14] [15] [17] [16] [20] CMP 1 sensor [12] IAB control solenoid valve CMP 2 sensor [13] HO2S MAP sensor [14] EMT sensor 2 IAT sensor [15] Water separator/water level sensor TP sensor [16] IAC valve...

  • Page 132: Piping Connections

    dummyhead dummyhead FUEL SYSTEM PIPING CONNECTIONS [21] [19] [23] [22] [11] [10] [20] [13] [14] [12] [15] [16] [17] [18] Vapor separator [13] EMT sensor 1 Fuel strainer (High pressure side) [14] EMT sensor 2 Fuel pump (High pressure side) [15] Knock sensor Air vent strainer...

  • Page 133: Circuit Diagram

    dummyhead dummyhead FUEL SYSTEM CIRCUIT DIAGRAM No.4 (30A) Bl/Y FUSE/RELAY JUNCTION BOX No.11 (15A) No.8 (10A) Y/Bl No.9 (15A) Y/Bl MAIN RELAY No.10 (10A) Y/Bl No.5 (10A) COMBINATION FUEL PUMP RELAY SWITCH Bu/R STARTER RELAY BATTERY To NEXT PAGE To STARTER MOTOR W/Bl FUEL PUMP (HIGH PRESSURE SIDE)
  • Page 134 dummyhead dummyhead FUEL SYSTEM From PREVIOUS From PREVIOUS From PREVIOUS PAGE PAGE PAGE EBT SENSOR EACVP Bl/Y IAC VALVE IAT SENSOR EACVM Y/Bl HO2S EMT SENSOR 1 Bl/Y R/Bl TOH1 EMT SENSOR 2 O2HT W/Bl TOH2 VTEC SOLENOID VALVE KNOCK SENSOR IAB CONTROL VALVE R/Bu CONTROL/DISPLAY SECTION...

  • Page 135: Ecm Terminal Arrangement

    dummyhead dummyhead FUEL SYSTEM ECM TERMINAL ARRANGEMENT ECM CONNECTOR A (GRAY) ECM side connector (viewed from the terminal side) Termina Terminal mark Name Content/Signal l No. – – – ACGLP Alternator indicator lamp Alternator indicator lamp output WARNL MIL output TDC2P CMP 2 sensor (+) CMP 2 sensor (+) input...
  • Page 136 dummyhead dummyhead FUEL SYSTEM ECM CONNECTOR B (BLACK) ECM side connector (viewed from the terminal side) Termina Terminal mark Name Content/Signal l No. CAN1H NMEA CAN HI NMEA CAN HI output CAN 12V NMEA 12 V power source NMEA 12 V power input CAN GND NMEA ground NMEA ground...

  • Page 137: Dtc Troubleshooting

    dummyhead dummyhead FUEL SYSTEM DTC TROUBLESHOOTING DTC INDEX Ref. Detected component Probable cause page MIL does not • Loose or poor contact of the come ON/blink connector • Faulty indicator light 0 or does not • Open circuit in MIL wire 4-17 communicate •...
  • Page 138 dummyhead dummyhead FUEL SYSTEM Ref. Detected component Probable cause page CMP 1 sensor (no pulse) • Loose or poor contact of the connector • Open or short circuit in CMP 1 5-30 sensor wire • Faulty CMP 1 sensor CMP 1 sensor (abnormal pulse) •...
  • Page 139 dummyhead dummyhead FUEL SYSTEM Ref. Detected component Probable cause page ECT sensor 3 (EMT sensor 2) • Loose or poor contact of the (voltage too low) connector • Short circuit in EMT sensor 2 5-42 141-1 wire • Faulty EMT sensor 2 ECT sensor 3 (EMT sensor 2) •...
  • Page 140 dummyhead dummyhead FUEL SYSTEM MIL IS ON BUT DTC IS 0 OR DOES NOT COMMUNICATE TP SENSOR MAP SENSOR No.5 No.9 No.10 FUSE/RELAY FUSE FUSE FUSE JUNCTION BOX (10A) (15A) (10A) R/Bl Br/Y WARNL R/Bu R/Bl W/Bl Y/Bl Y/Bl Y/Bl K-LINE TRMA Y/Bu...
  • Page 141 dummyhead dummyhead FUEL SYSTEM 3. MIL ON line short circuit inspection Turn the combination switch OFF. Disconnect ECM connector A Turn the combination switch ON and check the MIL. Does the MIL go OFF? – GO TO STEP 4. – Repair short in the main wire harness between the ECM and the MIL.
  • Page 142 dummyhead dummyhead FUEL SYSTEM 8. Trim angle sensor power line short circuit inspection 1 Turn the combination switch OFF. Disconnect the trim angle sensor 3P connector Turn the combination switch ON and check the MIL. Does the MIL go OFF? –...
  • Page 143 dummyhead dummyhead FUEL SYSTEM DTC 1-4 (ABNORMAL HO2S) HO2S Bl/Y Bl/Y Bl: Black Br: Brown JOINT Y: Yellow O: Orange CONNECTOR 1 Bu: Blue Lb: Light blue G: Green Lg: Light green R: Red P: Pink W: White Gr: Gray 1.
  • Page 144 dummyhead dummyhead FUEL SYSTEM 3. Fuel supply system inspection Measure the fuel pressure (page 5-110). Is the fuel pressure normal? – Repair open or short in the main wire harness between the ECM and HO2S. If the main wire harness is correct, replace the ECM with a new one, and recheck.
  • Page 145 dummyhead dummyhead FUEL SYSTEM 2. MAP sensor signal line short circuit inspection Turn the combination switch OFF and disconnect the MAP sensor 3P connector MAP SENSOR 3P CONNECTOR Turn the combination switch ON. MAIN WIRE HARNESS SIDE Measure the voltage between the MAP sensor 3P connector main wire harness side No.2 (White/Red) terminal and engine ground.
  • Page 146 dummyhead dummyhead FUEL SYSTEM 3. MAP sensor signal/GND line open circuit inspection Measure the voltage between the MAP sensor 3P connector main wire harness side No.2 MAP SENSOR 3P CONNECTOR (White/Red) terminal and No.3 (Green) terminal. MAIN WIRE HARNESS SIDE Is the measurement within 4.75 –...
  • Page 147 dummyhead dummyhead FUEL SYSTEM 2. CKP sensor inspection Turn the combination switch OFF. Inspect the CKP sensor (page 5-123). Is the CKP sensor correct? – Repair the open or short circuit in the CKP sensor harness between the CKP sensor and ECM.
  • Page 148 dummyhead dummyhead FUEL SYSTEM DTC 6-1, 6-2 (ECT SENSOR 1 (EBT SENSOR) VOLTAGE IS TOO LOW OR TOO HIGH) ECT SENSOR 1 (EBT SENSOR) Bl: Black Br: Brown Y: Yellow O: Orange JOINT CONNECTOR 1 Bu: Blue Lb: Light blue G: Green Lg: Light green R: Red...
  • Page 149 dummyhead dummyhead FUEL SYSTEM DTC 6-2 (ECT SENSOR 1 (EBT SENSOR) VOLTAGE IS TOO HIGH) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the EBT sensor 2P connector ECM connector A , ECM connector B switch wire 6P connector and then reconnect them.
  • Page 150 dummyhead dummyhead FUEL SYSTEM DTC 7-1, 7-2 (TP SENSOR VOLTAGE IS TOO LOW OR TOO HIGH) R/Bl TP SENSOR VCC2 R/Bl Bl: Black Br: Brown Y: Yellow O: Orange JOINT CONNECTOR 1 Bu: Blue Lb: Light blue G: Green Lg: Light green R: Red P: Pink W: White...
  • Page 151 dummyhead dummyhead FUEL SYSTEM 3. TP sensor signal line short circuit inspection Turn the combination switch OFF. Disconnect ECM connector A Check for continuity between the TP sensor 3P connector main wire harness side No.2 (Red/ Black) terminal and engine ground. Is there continuity? –...
  • Page 152 dummyhead dummyhead FUEL SYSTEM DTC 8-1, 8-2 (NO CMP 1 SENSOR PULSE OR ABNORMAL SENSOR PULSE) CMP 1 SENSOR TDC1P TDC1M Bl: Black Br: Brown Y: Yellow O: Orange Bu: Blue Lb: Light blue G: Green Lg: Light green R: Red P: Pink W: White Gr: Gray...
  • Page 153 dummyhead dummyhead FUEL SYSTEM DTC 8-2 (ABNORMAL CMP 1 SENSOR PULSE) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the CMP sensor 4P connector ECM connector A and then reconnect them. Clear the DTC (page 5-6). • Continue the procedure if the DTC does not clear.
  • Page 154 dummyhead dummyhead FUEL SYSTEM DTC 10-1, 10-2 (IAT SENSOR VOLTAGE IS TOO LOW OR TOO HIGH) IAT SENSOR Bl: Black Br: Brown Y: Yellow O: Orange Bu: Blue Lb: Light blue G: Green Lg: Light green JOINT CONNECTOR 1 R: Red P: Pink W: White Gr: Gray...
  • Page 155 dummyhead dummyhead FUEL SYSTEM DTC 10-2 (IAT SENSOR VOLTAGE IS TOO HIGH) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the IAT sensor 2P connector ECM connector A , ECM connector B joint connector 1 and then reconnect them. Clear the DTC (page 5-6).
  • Page 156 dummyhead dummyhead FUEL SYSTEM DTC 14-1 (ABNORMAL IAC VALVE) VALVE EACVP EACVM Bl: Black Br: Brown Y: Yellow O: Orange Bu: Blue Lb: Light blue G: Green Lg: Light green R: Red P: Pink W: White Gr: Gray 1. Symptom reproduction test Turn the combination switch OFF.
  • Page 157 dummyhead dummyhead FUEL SYSTEM DTC 21-1 (ABNORMAL OUTPUT OF VTEC SPOOL SOLENOID VALVE) VTEC SPOOL SOLENOID 12 V VALVE Bl: Black Br: Brown Y: Yellow O: Orange Bu: Blue Lb: Light blue G: Green Lg: Light green R: Red P: Pink W: White Gr: Gray 1.
  • Page 158 dummyhead dummyhead FUEL SYSTEM DTC 23-1 (ABNORMAL OUTPUT OF KNOCK SENSOR) KNOCK SENSOR R/Bu R/Bu R/Bu R/Bu Bl: Black Br: Brown Y: Yellow O: Orange Bu: Blue Lb: Light blue G: Green Lg: Light green R: Red P: Pink W: White Gr: Gray 1.
  • Page 159 dummyhead dummyhead FUEL SYSTEM 3. Knock sensor inspection Replace the knock sensor with a new one and perform the knock sensor symptom reproduction test. Does the DTC 23-1 appear? – Replace the ECM with a new one and recheck. – Faulty original knock sensor. End of inspection.
  • Page 160 dummyhead dummyhead FUEL SYSTEM 2. HO2S heater inspection Turn the combination switch OFF. Inspect the HO2S heater (page 5-126). Is the HO2S heater correct? – Repair open in the main wire harness between the No.10 fuse and the HO2S or between the HO2S and ECM.
  • Page 161 dummyhead dummyhead FUEL SYSTEM 2. CMP sensor inspection Turn the combination switch OFF. Inspect the CMP 2 sensor (page 5-124). Is the CMP sensor correct? – Repair the open or short circuit in the CMP 2 sensor harness between the CMP 2 sensor and ECM.
  • Page 162 dummyhead dummyhead FUEL SYSTEM DTC 140-1, 140-2 (ECT SENSOR 2 (EMT SENSOR 1) VOLTAGE IS TOO LOW OR TOO HIGH) ECT SENSOR (EMT SENSOR 1) TOH1 R/Bl R/Bl Bl: Black Br: Brown Y: Yellow O: Orange Bu: Blue Lb: Light blue G: Green Lg: Light green R: Red...
  • Page 163 dummyhead dummyhead FUEL SYSTEM DTC 140-2 (ECT SENSOR 2 (EMT SENSOR 1) VOLTAGE IS TOO HIGH) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the EMT sensor 1 2P connector ECM connector A , ECM connector B joint connector 1 and then reconnect them.
  • Page 164 dummyhead dummyhead FUEL SYSTEM DTC 141-1, 141-2 (ECT SENSOR 3 (EMT SENSOR 2) VOLTAGE IS TOO LOW OR TOO HIGH) ECT SENSOR 3 (EMT SENSOR 2) TOH2 Bl: Black Br: Brown Y: Yellow O: Orange Bu: Blue Lb: Light blue G: Green Lg: Light green JOINT CONNECTOR 1...
  • Page 165 dummyhead dummyhead FUEL SYSTEM DTC 141-2 (ECT SENSOR 3 (EMT SENSOR 2) VOLTAGE IS TOO HIGH) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the EMT sensor 2 2P connector ECM connector A , ECM connector B joint connector 1 and then reconnect them.
  • Page 166 dummyhead dummyhead FUEL SYSTEM DTC 142-1 (ABNORMAL EOP SWITCH (HIGH PRESSURE SIDE)) JOINT CONNECTOR 1 SWITCH (HIGH) 12 V OPSH Bl: Black Br: Brown Y: Yellow O: Orange Bu: Blue Lb: Light blue G: Green Lg: Light green R: Red P: Pink W: White Gr: Gray...

  • Page 167: Mil Troubleshooting

    dummyhead dummyhead FUEL SYSTEM MIL TROUBLESHOOTING MIL INDEX Ref. Detected component Probable cause No. of page Condition blinks Detected • Loose or poor contact of the component connector • Faulty indicator light MIL does • Open circuit in MIL wire 4-16 not blink •...
  • Page 168 dummyhead dummyhead FUEL SYSTEM Ref. Detected component Probable cause No. of page Condition blinks Blink VTEC spool solenoid valve • Loose or poor contact of the connector • Open and short circuit in VTEC 5-58 spool solenoid valve wire • Faulty VTEC spool solenoid valve Blink Knock sensor...
  • Page 169 dummyhead dummyhead FUEL SYSTEM MIL ON BUT DOES NOT BLINK OR INDICATE DTC CODE TP SENSOR MAP SENSOR No.5 No.9 No.10 FUSE/RELAY FUSE FUSE FUSE JUNCTION BOX (10A) (15A) (10A) R/Bl Br/Y WARNL R/Bu R/Bl W/Bl Y/Bl Y/Bl Y/Bl K-LINE TRMA Y/Bu Y/Bl...
  • Page 170 dummyhead dummyhead FUEL SYSTEM 3. MAP sensor power line short circuit inspection 1 Turn the combination switch OFF. Connect ECM connector disconnect the MAP sensor 3P connector Turn the combination switch ON and check the MIL. Does the MIL go OFF? –...
  • Page 171 dummyhead dummyhead FUEL SYSTEM 8. Trim angle sensor power line short circuit inspection 2 Measure the voltage between the trim angle sensor 3P connector main wire harness side No.3 (Brown/White) terminal and engine ground. TRIM ANGLE SENSOR 3P CONNECTOR MAIN WIRE HARNESS SIDE Is the measurement within 4.75 –...
  • Page 172 dummyhead dummyhead FUEL SYSTEM 2. HO2S inspection Turn the combination switch OFF and disconnect the HO2S 4P connector Inspect the HO2S (page 5-126). Is the HO2S correct? – GO TO STEP 3. – Replace the HO2S with a new one and recheck.
  • Page 173 dummyhead dummyhead FUEL SYSTEM 2. MAP sensor power line open circuit inspection Turn the combination switch OFF and disconnect the MAP sensor 3P connector MAP SENSOR 3P CONNECTOR Turn the combination switch ON. MAIN WIRE HARNESS SIDE Measure the voltage between the MAP sensor 3P connector main wire harness side No.1 (Brown/Yellow) terminal and engine ground.
  • Page 174 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 4 TIMES (CKP SENSOR) SENSOR CRKP CRKM Bl: Black Br: Brown Y: Yellow O: Orange Bu: Blue Lb: Light blue G: Green Lg: Light green R: Red P: Pink W: White Gr: Gray 1. Symptom reproduction test Turn the combination switch OFF.
  • Page 175 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 6 TIMES (EBT SENSOR) SENSOR Bl: Black Br: Brown Y: Yellow O: Orange Bu: Blue Lb: Light blue JOINT CONNECTOR 1 G: Green Lg: Light green R: Red P: Pink W: White Gr: Gray 1.
  • Page 176 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 7 TIMES (TP SENSOR) R/Bl TP SENSOR VCC2 R/Bl Bl: Black Br: Brown Y: Yellow O: Orange JOINT CONNECTOR 1 Bu: Blue Lb: Light blue G: Green Lg: Light green R: Red P: Pink W: White Gr: Gray 1.
  • Page 177 dummyhead dummyhead FUEL SYSTEM 3. TP sensor signal line open/short circuit inspection Turn the combination switch OFF. Disconnect the ECM connector A Check for an open or short in the wire between the TP sensor 3P connector main wire harness side No.2 (Red/Black) terminal and ECM connector main wire harness side No.7 (Red/Black) terminal.
  • Page 178 dummyhead dummyhead FUEL SYSTEM 2. CMP 1 sensor installation inspection Turn the combination switch OFF. Inspect the CMP 1 sensor installation (page 5-103). Is the CMP sensor installed correctly? – GO TO STEP 3. – Install the CMP 1 sensor correctly and recheck.
  • Page 179 dummyhead dummyhead FUEL SYSTEM 2. IAT sensor signal/GND line open/short circuit inspection Turn the combination switch OFF and disconnect the IAT sensor 2P connector IAT SENSOR 2P CONNECTOR Turn the combination switch ON. MAIN WIRE HARNESS SIDE Measure the voltage between the IAT sensor 2P connector main wire harness side No.1 (Red/ Yellow) terminal and No.2 (Green) terminal.
  • Page 180 dummyhead dummyhead FUEL SYSTEM 2. IAC valve inspection Turn the combination switch OFF and disconnect the IAC valve 2P connector Inspect the IAC valve (page 5-125). Is the IAC valve correct? – Repair open or short in the main wire harness between the ECM and IAC valve.
  • Page 181 dummyhead dummyhead FUEL SYSTEM 2. VTEC spool solenoid valve inspection Turn the combination switch OFF and disconnect the VTEC spool solenoid valve 1P connector Inspect the VTEC spool solenoid valve (page 5- 125). Is the VTEC spool solenoid valve correct? –...
  • Page 182 dummyhead dummyhead FUEL SYSTEM 2. Knock sensor line open or short circuit inspection Turn the combination switch OFF. Disconnect the knock sensor 1P connector and ECM connector B Check for continuity through the Knock sensor wire. Is the knock sensor line correct? –...
  • Page 183 dummyhead dummyhead FUEL SYSTEM 2. EMT sensor 1 signal /GND line open circuit inspection Turn the combination switch OFF and disconnect the EMT sensor 1 2P connector EMT SENSOR 1 2P CONNECTOR Turn the combination switch ON. MAIN WIRE HARNESS SIDE Measure the voltage between the EMT sensor 1 2P connector main wire harness side No.1 (Red/...
  • Page 184 dummyhead dummyhead FUEL SYSTEM 2. EMT sensor 2 signal /GND line open circuit inspection Turn the combination switch OFF and disconnect the EMT sensor 2 2P connector EMT SENSOR 2 2P CONNECTOR Turn the combination switch ON. MAIN WIRE HARNESS SIDE Measure the voltage between the EMT sensor 2 2P connector main wire harness side No.1 (Red)
  • Page 185 dummyhead dummyhead FUEL SYSTEM 2. EOP switch (High pressure side) line open circuit inspection Turn the combination switch OFF and disconnect the EOP switch (High pressure side) 2P connector EOP SWITCH (High pressure side) Turn the combination switch ON. 2P CONNECTOR MAIN WIRE HARNESS SIDE Measure the voltage between the EOP switch (High OPSH pressure side) 2P connector...
  • Page 186 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 41 TIMES (4 LONG BLINKS AND ONE SHORT BLINK) HO2S HEATER HO2S HEATER O2HT W/Bl W/Bl Y/Bl Y/Bl FUSE/RELAY JUNCTION BOX No.10 Bl: Black Br: Brown FUSE Y: Yellow O: Orange (10 A) Bu: Blue Lb: Light blue G: Green Lg: Light green...
  • Page 187 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 58 TIMES (5 LONG BLINKS AND 8 SHORT BLINKS) CMP 2 SENSOR SENSOR 2 TDC2P TDC2M Bl: Black Br: Brown Y: Yellow O: Orange Bu: Blue Lb: Light blue G: Green Lg: Light green R: Red P: Pink W: White...

  • Page 188: Fuel Pressure Relieving

    dummyhead dummyhead FUEL SYSTEM FUEL PRESSURE RELIEVING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. •...
  • Page 189 dummyhead dummyhead FUEL SYSTEM FUEL PUMP (LOW PRESSURE SIDE) REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Remove the intake manifold (page 5-72).
  • Page 190 dummyhead dummyhead FUEL SYSTEM COOLING FAN COVER REMOVAL/ INSTALLATION REMOVAL • Do not disassemble the cooling fan cover assembly. WASHER (6 mm) (2) BOLT/WASHER (6 x 25 mm) (2) BOLT (6 x 60 mm) (2) HOSE CLAMP AIR FLOW CLAMP SCREW GROMMET (4) COOLING FAN COVER Assy.

  • Page 191: Installation

    dummyhead dummyhead FUEL SYSTEM INSTALLATION Connect the air flow tube [1] to the throttle body [2] securely while pushing the main harness [3] down. • Take care that the main harness is not damaged by the air flow clamp [4]. Install and tighten the two bolt/washers (6 x 25 mm) [2] and two bolts (6 x 60 mm) [3].
  • Page 192 dummyhead dummyhead FUEL SYSTEM Put the throttle cable A [1] first, then put the throttle cable B [2] into the slit [3] of the cooling fan cover and hold them to the cable guides [4] of the cooling fan cover as shown. 5-70...
  • Page 193 dummyhead dummyhead FUEL SYSTEM THROTTLE BODY REMOVAL/ INSTALLATION/CLEANING REMOVAL/INSTALLATION Remove the cooling fan cover (page 5-68). • When assembling, route the throttle cables and crankcase breather hose properly (page 2-19). • After assembly, adjust the throttle cables (page 3-11). IAT SENSOR 2P CONNECTOR CRANKCASE BREATHER HOSE THROTTLE CABLE B INTAKE MANIFOLD...

  • Page 194: Cleaning

    dummyhead dummyhead FUEL SYSTEM CLEANING Wipe off carbon or any other dirt or stain with soft dry THROTTLE BODY shop towels sprayed with carburetor cleaner, and clean the throttle valve and bore. The inside of the throttle body is coated with molybdenum.
  • Page 195 dummyhead dummyhead FUEL SYSTEM Loosen the air flow clamp screw [1]. Release the cover locking cable [1] from the clamp [2]. Remove the bolt (8 x 35 mm) [3], washer (8 mm) [4], and bolt (6 x 12 mm) [5]. [3]/[4] Release the fuel pipe [1] from the clamps [2].
  • Page 196 dummyhead dummyhead FUEL SYSTEM Remove the ten bolts (6 x 22 mm) [1] and intake manifold upper cover [2]. Remove the seven bolts (8 x 50 mm) [1], bolt (6 x 32 mm) [2], two nuts (8 mm) [3], and intake manifold [4]. •...
  • Page 197 dummyhead dummyhead FUEL SYSTEM EXPLODED VIEW GASKET INTAKE MANIFOLD SPACER BOLT (6 x 12 mm) (2) ENGINE COVER BRACKET BOLT (8 x 50 mm) (7) WASHER (8 mm) (2) BOLT (8 x 35 mm) (2) BOLT (6 x 22 mm) (10) INTAKE MANIFOLD INTAKE MANIFOLD GASKET NUT (8 mm) (2)
  • Page 198 dummyhead dummyhead FUEL SYSTEM INSTALLATION Install a new intake manifold gasket [1] and the intake manifold spacer [2] to the stud bolts [3]. Install the intake manifold [1] to the studs and cooling fan cover grommet; do not turn the grommet inside out. Be sure not to pinch the vacuum tube and fuel tube.
  • Page 199 dummyhead dummyhead FUEL SYSTEM Connect the vacuum tube [1] to the IAB control diaphragm [2]. Install the engine cover bracket [1] and washer (8 mm) [2], and then tighten the bolt (8 x 35 mm) [3] and bolt (6 x 12 mm) [4] securely. Install the fuel pipe [5] to the clamps [6].

  • Page 200: Fuel Injectors/Fuel Pressure Regulator

    dummyhead dummyhead FUEL SYSTEM Connect the IAC valve 2P connector [1] and TP sensor 3P connector [2]. Connect the throttle cables [1] to the throttle cam [2]. Connect the pressure regulator vacuum hose [3] to the intake manifold [4]. Connect the MAP sensor 3P connector [5] and clamp it to the harness clip [6].
  • Page 201 dummyhead dummyhead FUEL SYSTEM Disconnect the fuel return hose [1] and vacuum hose [2] from the pressure regulator [3]. Remove the bolt (6 x 25 mm) [1] and disconnect fuel hose A [2]. Disconnect the fuel pipe joint [3], and then remove the O-rings [4].
  • Page 202 dummyhead dummyhead FUEL SYSTEM Remove the bolt (6 x 14 mm) [1] and release harness clip A [2] from the fuel pipe [3]. Remove the two bolts (6 x 35 mm) [4]. Remove the fuel pipe from the injector base by pulling the fuel joint hose [5] from the air vent hose [6] on the back side of the vapor separator.
  • Page 203 dummyhead dummyhead FUEL SYSTEM Remove the bolts (6 x 10 mm) [1] and injector clips A [2] from the fuel pipes [3]. Remove all injectors [4] from the fuel pipes. Remove the O-ring [5] and seal ring [6]. Remove the two bolts (6 x 14 mm) [1] and pressure regulator [2].
  • Page 204 dummyhead dummyhead FUEL SYSTEM EXPLODED VIEW FUEL HOSE A BOLT (6 x 25 mm) O-RING (3) O-RING (7.8 x 1.9 mm) (2) BOLT (6 x 14 mm) RETURN HOSE BOLT (6 x 35 mm) (2) VACUUM HOSE R. FUEL PIPE PRESSURE REGULATOR BOLT (6 x 14 mm) (2) BOLT...
  • Page 205 dummyhead dummyhead FUEL SYSTEM INSTALLATION Replace the O-ring with a new one [1] and install the pressure regulator [2]. Install the pressure regulator to the L. fuel pipe [3] with two bolts [4]. Coat a new seal ring (7.45 x 3.61 mm) [1] and a new O- ring (7.47 x 3.6 mm) [2] with engine oil, and install them to the injector [3].
  • Page 206 dummyhead dummyhead FUEL SYSTEM Coat two O-rings [1] with engine oil and install them to the fuel pipe joint [2], and then install the fuel joint hose [3] to the fuel pipe [4] and tighten the bolt (6 x 25 mm) [5].
  • Page 207 dummyhead dummyhead FUEL SYSTEM Install the fuel pipe [1] to the injector bases and tighten the two bolts (6 x 35 mm) [2]. Set harness clip A [3] and tighten the bolt (6 x 14 mm) [4]. Coat new O-rings [5] with engine oil and install them to the fuel pipe joint [6], and then install the fuel joint hose [7] to the fuel pipe and tighten the bolt (6 x 25 mm) [8].

  • Page 208: Fuel Pump (High Pressure Side)/Vapor Separator Removal/Installation

    dummyhead dummyhead FUEL SYSTEM Connect the fuel return hose [1] and vacuum hose [2] to the pressure regulator [3]. Connect the 2P connectors [1] to the fuel injectors. Clamp the main harness [2] to the tube clip [3]. Install the intake manifold (page 5-76). FUEL PUMP (HIGH PRESSURE SIDE)/ VAPOR SEPARATOR REMOVAL/ INSTALLATION...
  • Page 209 dummyhead dummyhead FUEL SYSTEM Release the wire harness from the clamp [1] of the fuel pump. Disconnect the fuel pump (high pressure side) 2P connector [2] and release the connector from the connector holder of the fuel pump. Disconnect the vacuum tubes [1] from the vacuum tank of the vapor separator.
  • Page 210 dummyhead dummyhead FUEL SYSTEM Disconnect the air vent tube [1] from the check valve [2]. Disconnect the fuel tube E [1] from the vapor separator [2]. Remove the two bolts (8 x 35 mm) [3] and bolt/washer (8 x 35 mm) [4]. Before disconnecting the air vent tube [1], mark the air vent hose and hose joint of the vapor separator for proper position [2].
  • Page 211 dummyhead dummyhead FUEL SYSTEM EXPLODED VIEW AIR VENT TUBE WATER OUTLET TUBE FUEL TUBE C WATER INLET TUBE MARK FUEL PUMP (HIGH PRESSURE SIDE)/ VAPOR SEPARATOR FUEL TUBE E TUBE CLIP B12 TUBE CLAMP D10.5 (2) BOLT (8 x 35 mm) (2) TUBE CLAMP D10.7 VACUUM TUBES...
  • Page 212 dummyhead dummyhead FUEL SYSTEM INSTALLATION Connect the water inlet tube [1] and water outlet tube [2] to the vapor separator [3]. Connect the air vent tube [4] in its original position as marked during disconnection [5]. Connect the air vent tube [1] to the joint pipe [2]. Install the vapor separator [1] and loosely tighten the two bolts (8 x 35 mm) [2] and bolt/washer (8 x 35 mm) [3].
  • Page 213 dummyhead dummyhead FUEL SYSTEM Apply engine oil to new O-ring [1]. Install the O-ring to the slit of fuel pipe joint [2]. Connect fuel hose A [3] to the vapor separator. Install and tighten the bolt (6 x 25 mm) [4]. Connect the vacuum tubes [1] to the vacuum tank [2] (the fuel tube with the check valve connects to the lower side of the vacuum tank joint.)

  • Page 214: Air Vent Strainer/Air Vent Tube Removal

    dummyhead dummyhead FUEL SYSTEM AIR VENT STRAINER/AIR VENT TUBE REMOVAL/INSTALLATION Remove the fuel pump (High pressure side)/vapor separator (page 5-86). • If there is a crack or deterioration, replace the tube. • When assembly, route the tube properly (page 2-34). CHECK VALVE JOINT PIPE AIR VENT TUBE...

  • Page 215: Water Separator/Water Level Sensor Removal/Installation/Cleaning

    dummyhead dummyhead FUEL SYSTEM WATER SEPARATOR/WATER LEVEL SENSOR REMOVAL/INSTALLATION/ CLEANING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. REMOVAL Turn the combination switch OFF, and disconnect the battery negative (–) cable, then the battery positive (+)
  • Page 216 dummyhead dummyhead FUEL SYSTEM Turn the separator cover [1] and position the fuel tube inlet joint [2] with the “I” mark [3] on the suspension in the range [4] as shown. Tighten the three separator cover screw/washers (5 x 12 mm) [5] to the specified torque. TORQUE: 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) INSTALLATION Install the water separator [1] to the bracket [2].

  • Page 217: Exhaust Manifold Removal

    dummyhead dummyhead FUEL SYSTEM EXHAUST MANIFOLD REMOVAL/ INSTALLATION REMOVAL Remove the following: – HO2S 4P connector (L. side only: page 10-6) – engine cover bracket (page 6-9) WATER RELIEF TUBE TUBE CLAMP (D29.0) EMT SENSOR 2P CONNECTOR BOLT (8 x 40 mm) (4) BOLT (8 x 60 mm) (4) WATER RETURN...
  • Page 218 dummyhead dummyhead FUEL SYSTEM INSTALLATION Apply marine grease to a new O-ring [1] and install it to the exhaust manifold [2]. Install the exhaust manifold [1] into the exhaust guide water seal. Do not turn the grommet inside out. Set a new gasket [2] to the exhaust manifold and loosely tighten the bolt (8 x 60 mm) [3] to the lower corner of the exhaust manifold.

  • Page 219: Exhaust Manifold Anode Removal

    dummyhead dummyhead FUEL SYSTEM Connect the water return tube [1] and water tube [2] to the exhaust manifold. Connect the water relief tube [1] to the exhaust manifold [2]. Connect the EMT sensor 2P connector [3]. Install the following: – HO2S 4P connector (L. side only: page 10-6) –...

  • Page 220: Installation

    dummyhead dummyhead FUEL SYSTEM MAP SENSOR REMOVAL/ INSTALLATION Remove the engine cover. Disconnect the MAP sensor 3P connector [1]. Remove the bolt (5 x 18 mm) [2], MAP sensor [3], and wire band stay [4]. Replace the O-ring with new one [5] and coat it with engine oil.

  • Page 221: Iac Valve Removal/Installation

    dummyhead dummyhead FUEL SYSTEM IAC VALVE REMOVAL/INSTALLATION Remove the engine cover. Disconnect the IAC valve 2P connector [1]. Remove the two bolts (6 x 22 mm) [2] and remove the IAC valve [3]. Install a new gasket [4] and IAC valve to the throttle body spacer and tighten the two bolts.

  • Page 222: Ho2S Removal/Installation

    dummyhead dummyhead FUEL SYSTEM HO2S REMOVAL/INSTALLATION REMOVAL Remove the power tilt relay case (page 10-6). Remove the HO2S [1] from the left exhaust manifold using a 14 mm crowfoot wrench, commercially available tool (ANM14) [2]. INSTALLATION Install the HO2S [1] to the left exhaust manifold and tighten it using a 14 mm crowfoot wrench, commercially available tool (ANM14) [2] to the specified torque.

  • Page 223: Vtec Solenoid Valve Removal

    dummyhead dummyhead FUEL SYSTEM VTEC SOLENOID VALVE REMOVAL/ INSTALLATION Remove the following: – Cooling fan cover (page 5-68) – ECM (page 10-5) Release the VTEC solenoid valve 1P connector [1] from the connector holder of the ECM bracket [2] and disconnect it.

  • Page 224: Ckp Sensor Removal/Installation

    dummyhead dummyhead FUEL SYSTEM CKP SENSOR REMOVAL/ INSTALLATION Disconnect the battery negative (–) terminal from the [11] battery. Remove the following: – ECM (page 10-5) – Timing belt drive pulley and timing belt (page 14-6) Remove the bolt (6 x 14 mm) [1] and stay [2]. Disconnect the CKP sensor 2P connector [3] and release the connector from the connector holder of the ECM bracket [4].

  • Page 225: Cmp Sensor Removal/Installation

    dummyhead dummyhead FUEL SYSTEM CMP SENSOR REMOVAL/ INSTALLATION Remove the following: – Throttle body (page 5-71). – Left timing belt back cover (page 14-6) Release the CMP sensor 4P connector [1] from the connector holder of the connector bracket [2] and disconnect it.

  • Page 226: Eop Switch (Low Pressure Side) Removal

    dummyhead dummyhead FUEL SYSTEM EOP SWITCH (LOW PRESSURE SIDE) REMOVAL/INSTALLATION Remove the cylinder head (page 14-22). Disconnect the 1P connector [1] and remove the EOP switch (Low pressure side) [2]. Clean the oil pressure switch threads and apply liquid ® sealant (Threebond #1215,...

  • Page 227: Installation

    dummyhead dummyhead FUEL SYSTEM EBT SENSOR REMOVAL/ INSTALLATION Remove the cylinder head (page 14-22). Disconnect the 2P connector [1] and remove the EBT sensor [2]. Replace the O-ring with a new one [3] and coat it with engine oil. Apply liquid sealant (Threebond ®...

  • Page 228: Fuel Pump (High Pressure Side)/Fuel Filter Disassembly/Assembly

    dummyhead dummyhead FUEL SYSTEM FUEL PUMP (HIGH PRESSURE SIDE)/ FUEL FILTER DISASSEMBLY/ ASSEMBLY DISASSEMBLY Remove the fuel pump (high pressure side)/vapor separator (page 5-86). PRESSURE REGULATOR HARNESS HOLDER SCREW (4 x 10 mm) RETURN HOSE B 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) PUMP COVER SCREW/ TUBE CLAMP (D10.7) WASHER (5 x 15 mm) [4]...
  • Page 229 dummyhead dummyhead FUEL SYSTEM ASSEMBLY Install a new O-ring [1] to the insulator A [2]. Install the ring [3] to the insulator A and install them to the fuel pump unit [4]. Install the fuel pump Assy. to the fuel pump case [5] securely.
  • Page 230 dummyhead dummyhead FUEL SYSTEM Install the fuel pump cover [1] with the connector holder [2]. Install the harness holder clips [3] to the connector holder as shown. Install and tighten the four screw/washers (5 x 15 mm) [4] to the specified torque. TORQUE: 3.4 N·m (0.35 kgf·m, 25 lbf·ft) Set the harness holder [1] and washer (4 mm) [2], and tighten the harness holder screw (4 x 10 mm) [3].

  • Page 231: Vapor Separator Disassembly

    dummyhead dummyhead FUEL SYSTEM VAPOR SEPARATOR DISASSEMBLY/ ASSEMBLY Remove the fuel pump (High pressure side) (page 5- 106). COVER SCREW/WASHER (5 x 15 mm) (6) 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) VAPOR VAPOR SEPARATOR SEPARATOR GROMMET (2) COLLAR (2) COVER BRACKET B BOLT (6 x 16 m) (2) 12 N·m (1.2 kgf·m, 9 lbf·ft) FLOAT VALVE...

  • Page 232: Fuel Pressure Measurement

    dummyhead dummyhead FUEL SYSTEM FUEL PRESSURE MEASUREMENT Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Relieve the fuel pressure (page 5-66).

  • Page 233: Fuel Pressure Regulator

    dummyhead dummyhead FUEL SYSTEM FUEL PRESSURE REGULATOR INSPECTION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Relieve the fuel pressure (page 5-66).

  • Page 234: Fuel Pump (Low Pressure Side)

    dummyhead dummyhead FUEL SYSTEM If the fuel pressure does not rise, connect the vacuum tube to the pressure regulator. Pinch the pressure regulator return hose [1] that goes from the pressure regulator to the vapor separator 2 or 3 times lightly, and measure the fuel pressure again.

  • Page 235: Fuel Pump (High Pressure Side)

    dummyhead dummyhead FUEL SYSTEM FUEL PUMP (HIGH PRESSURE SIDE) INSPECTION DISCHARGE VOLUME INSPECTION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. •...
  • Page 236 dummyhead dummyhead FUEL SYSTEM CIRCUIT INSPECTION No.8 FUSE No.4 FUSE No.5 FUSE (10A) (30A) (10A) FUSE/RELAY JUNCTION BOX MAIN RELAY FUEL PUMP RELAY FLR1 FLR2 Bl/Y Bu/R W/Bl BATTERY OPTION GND6 Bl/Y Bl/Y Bu/R COMBINATION Bl/Y SWITCH Bl/Y Bl/Y Bl/Y LOAD W/Bl W/Bl...

  • Page 237: Vapor Separator Inspection

    dummyhead dummyhead FUEL SYSTEM 3. Fuel pump relay, main relay Inspection Turn the combination switch OFF. Inspect the fuel pump relay (page 10-11). Inspect the main relay (page 10-11). Is the fuel pump relay normal? – GO TO STEP 4. –...

  • Page 238: Fuel Injector Inspection

    dummyhead dummyhead FUEL SYSTEM FLOAT HEIGHT The float valve and the float must be installed on the cover properly. Place the cover as shown and measure the distance between the float and cover (i.e. float height) at the tip of the float. TOOL: Float level gauge [1] 07401-0010000...

  • Page 239: Throttle Body Inspection

    dummyhead dummyhead FUEL SYSTEM 2. Fuel injector signal line open/short circuit Inspection Turn the combination switch OFF. Disconnect the ECM connector B Check for open or short circuit between each fuel injector 2P connector main wire harness side No.1 terminal and ECM connector B main wire harness side terminal.

  • Page 240: Iab Control Solenoid Valve

    dummyhead dummyhead FUEL SYSTEM IAB CONTROL SOLENOID VALVE INSPECTION CIRCUIT INSPECTION Y/Bl IAB CONTROL SOLENOID VALVE No.10 FUSE (10 A) Y/Bl FUSE/RELAY JUNCTION BOX Bl: Black Br: Brown Y: Yellow O: Orange Bu: Blue Lb: Light blue G: Green Lg: Light green R: Red P: Pink W: White...
  • Page 241 dummyhead dummyhead FUEL SYSTEM SOLENOID VALVE INSPECTION Remove the IAB control solenoid valve (page 5-102). Measure the resistance between the IAB control solenoid valve [1] terminals. Resistance: 37 – 44 Ω If the resistance is out of specification, replace the IAB control solenoid valve.

  • Page 242: Eop Switch (High Pressure Side)

    dummyhead dummyhead FUEL SYSTEM VALVE OPERATION INSPECTION • Do not adjust the stop screw. It was preset at the factory. Check the IAB control valve [1] for smooth movement. Check the IAB valve shaft for binding or sticking. Check that there is no clearance between the stop screw and the fully closed position stopper when the IAB control valve is fully closed.

  • Page 243: Eop Switch (Low Pressure Side)

    dummyhead dummyhead FUEL SYSTEM SWITCH INSPECTION Disconnect the 2P connector [1] from the EOP switch (High pressure side) [2]. Check for continuity between the EOP switch (High pressure side) terminals. • If there is continuity, the EOP switch is OK. •...

  • Page 244: Ebt/Emt Sensor Inspection

    dummyhead dummyhead FUEL SYSTEM SWITCH INSPECTION Disconnect the 1P connector [1] from the EOP switch (Low pressure side) [2]. Check for continuity between the EOP switch (low pressure side) terminal and engine ground. • If there is continuity, the switch wire harness is OK. •...

  • Page 245: Ckp Sensor Inspection

    dummyhead dummyhead FUEL SYSTEM CKP SENSOR INSPECTION Remove the ECM (page 10-5). Disconnect the CKP sensor 2P connector [1]. Measure the resistance between the CKP sensor 2P connector sensor side No. 1 (Blue) and No.2 (White) terminals. Resistance:1,850 – 2,450 Ω CRKP CRKM (Blue)

  • Page 246: Water Level Sensor Inspection

    dummyhead dummyhead FUEL SYSTEM CMP 2 SENSOR PEAK VOLTAGE Remove the throttle body (page 5-71). Disconnect the CMP sensor 4P connector [1]. Measure the resistance between the CMP sensor 4P connector sensor side No. 3 (Yellow) and No.4 (Black) terminals. Resistance:1,850 –...

  • Page 247: Vtec Spool Solenoid Valve

    dummyhead dummyhead FUEL SYSTEM VTEC SPOOL SOLENOID VALVE INSPECTION SOLENOID VALVE INSPECTION • When checking the operation of the VTEC system, perform VTEC system inspection (page 14-37). Remove the ECM (page 10-5). Disconnect the VTEC solenoid valve 1P connector [1]. Measure the resistance between the 1P connector terminal and body ground.

  • Page 248: Ho2S Inspection

    dummyhead dummyhead FUEL SYSTEM HO2S INSPECTION SYSTEM INSPECTION OPERATION TEST 1. HO2S operation test 1 Turn the combination switch OFF and disconnect the HO2S 4P connector HO2S 4P CONNECTOR SENSOR SIDE Connect the battery positive (+) cable to the sensor side No.4 (White) terminal and the battery negative cable (–) to the sensor side No.3 (White) terminal of the HO2S 4P connector respectively.

  • Page 249: Intake Manifold Stud Bolt

    dummyhead dummyhead FUEL SYSTEM INTAKE MANIFOLD STUD BOLT REPLACEMENT Remove the intake manifold (page 5-72). Thread two nuts onto the stud [1] and tighten them together, and use a wrench on them to turn the stud bolt out. 28 mm (1.1 in) Install new stud bolts into the injector base using the double nut procedure above and tighten them.
  • Page 250 dummyhead dummyhead MEMO...

  • Page 251: Engine Cover/Cover Lock

    dummytext 6. ENGINE COVER/COVER LOCK COMPONENT LOCATION ····························6-2 DAMPER HOOK REMOVAL/ INSTALLATION ·········································· 6-12 FRONT SEPARATE COVER REMOVAL/ INSTALLATION·············································6-3 SIDE COVER BRACKET DISASSEMBLY/ ASSEMBLY ················································· 6-12 L./R. ENGINE UNDER COVER REMOVAL/ INSTALLATION·············································6-3 FRONT COVER BRACKET DISASSEMBLY/ ASSEMBLY ················································· 6-13 COVER LOCKING CABLE REMOVAL/ INSTALLATION·············································6-6 DAMPER HOOK DISASSEMBLY/ ASSEMBLY ·················································...

  • Page 252: Component Location

    dummyhead dummyhead ENGINE COVER/COVER LOCK COMPONENT LOCATION ENGINE COVER/COVER LOCK 10 N·m (1.0 kgf·m, 7 lbf·ft)

  • Page 253: Front Separate Cover Removal

    dummyhead dummyhead ENGINE COVER/COVER LOCK FRONT SEPARATE COVER REMOVAL/ INSTALLATION Remove the engine cover. Remove the two bolt/washers (6 x 25 mm) [1], special bolt (6 x 17 mm) [2], two special bolts (6 x 37 mm) [3], and remove the front separate cover [4]. Install the front separate cover by sliding the tab [5] into the engine under cover.
  • Page 254 dummyhead dummyhead ENGINE COVER/COVER LOCK Remove the under cover cap [1] and special bolt [2]. Remove the eight special bolts [3] from the R. engine under cover [4] and remove it halfway. Disconnect the water check tube [5] from the water check grommet [6].
  • Page 255 dummyhead dummyhead ENGINE COVER/COVER LOCK Remove the rivet screw [1] from the L. engine under cover. Remove the under cover cap [1] and special bolt [2]. Remove the plug maintenance cover special bolt [3] and plug maintenance cover [4]. Remove the nine special bolts [5] from the L. engine under cover [6] and remove it halfway.

  • Page 256: Installation

    dummyhead dummyhead ENGINE COVER/COVER LOCK COVER LOCKING CABLE REMOVAL/ INSTALLATION REMOVAL Remove the L./R. engine under cover (page 6-3). Loosen the washer side nut [1] of the cover locking cable A [2], and then disconnect the cable from the R. lock arm [3].
  • Page 257 dummyhead dummyhead ENGINE COVER/COVER LOCK Apply marine grease to the front lock arm [1] cable end insertion part. Insert the cable end (A side) [2] of cover locking cable B [3] into the front lock arm. Install cover locking cable B so that the cable aligns with the groove of the front cover bracket [4], and tighten the washer side nut [5] to the specified torque.
  • Page 258 dummyhead dummyhead ENGINE COVER/COVER LOCK Apply marine grease to the R. lock arm [1] cable end insertion part. Insert the cable end (A side) [2] of cover locking cable A into the R. lock arm. Install cover locking cable A so that the cable aligns with the groove of the R.

  • Page 259: Installation

    dummyhead dummyhead ENGINE COVER/COVER LOCK ENGINE COVER BRACKET REMOVAL/ INSTALLATION Remove the cover locking cable (page 6-6). FUEL PIPE CLAMP BOLT (6 x 12 mm) (6) REAR COVER BRACKET A REAR COVER BRACKET B L. COVER BRACKET BOLT (6 x 12 mm) (2) CABLE CLAMP BOLT (8 x 35 mm) (2) WASHER (8 mm) (4)

  • Page 260: Installation

    dummyhead dummyhead ENGINE COVER/COVER LOCK POWER TILT SWITCH REMOVAL/ INSTALLATION Remove the R. engine under cover (page 6-3). Release the hooks [1] of the power tilt switch [2] from the holder [3] and R. engine under cover [4] as shown. Remove the power tilt switch.
  • Page 261 dummyhead dummyhead ENGINE COVER/COVER LOCK Remove the bolt (6 x 14 mm) [1] and cable holder [2], and release the starter cables from the front cover bracket groove. Remove the four bolts (8 x 22 mm) [3] and the front cover bracket [4].

  • Page 262: Damper Hook Removal

    dummyhead dummyhead ENGINE COVER/COVER LOCK DAMPER HOOK REMOVAL/ INSTALLATION ENGINE COVER SCREW (4 x 10 mm) (2) COVER BOLT (6 x 20 mm) (4) SOCKET BOLT (6 x 16 mm) (4) COLLAR (6.5 x 9 x 3 mm) (8) DAMPER HOOK (4) SIDE COVER BRACKET DISASSEMBLY/ASSEMBLY •...
  • Page 263 dummyhead dummyhead ENGINE COVER/COVER LOCK FRONT COVER BRACKET DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the front cover bracket (page 6-10). Remove the four bolts (6 x 20 mm) [1] and front lock [2] from the front cover bracket [3]. Remove the E-ring [1] and washer (8 mm) [2] from the front lock shaft [3].
  • Page 264 dummyhead dummyhead ENGINE COVER/COVER LOCK FRONT LOCK DISASSEMBLY/ASSEMBLY Remove the front lock (page 6-13). Remove the E-ring [1] and washer [2] from the front lock assembly [3]. Release the cover lock spring [4] from the striker holder [5] hole, then remove the striker holder and cover lock spring.

  • Page 265: Assembly

    dummyhead dummyhead ENGINE COVER/COVER LOCK Install the front lock [1] and four bolts (6 x 20 mm) [2] to the front cover bracket [3]. Install the front cover bracket (page 6-10). DAMPER HOOK DISASSEMBLY/ ASSEMBLY Remove the damper hook (page 6-12). Disassemble the following: –...

  • Page 266: Damper Hook Adjustment

    dummyhead dummyhead ENGINE COVER/COVER LOCK DAMPER HOOK ADJUSTMENT Adjust height of the damper [1] hook to be 18.0 – 19.0 mm (0.71 – 0.75 in) by tightening the nuts, and adjust for an even clearance between the engine cover and the undercover.

  • Page 267: Charging System

    dummytext 7. CHARGING SYSTEM SYSTEM LOCATION·····································7-2 ALTERNATOR REMOVAL/ INSTALLATION ············································ 7-5 SYSTEM DIAGRAM ······································7-2 ALTERNATOR DISASSEMBLY/ ASSEMBLY ··················································· 7-6 TOOLS···························································7-3 ALTERNATOR INSPECTION ····················· 7-15 CHARGING SYSTEM TROUBLESHOOTING···································7-4...

  • Page 268: System Location

    dummyhead dummyhead CHARGING SYSTEM SYSTEM LOCATION CHARGING SYSTEM ALTERNATOR FUSE/RELAY JUNCTION BOX SYSTEM DIAGRAM FUSE/RELAY JUNCTION BOX No.4 No.5 FUSE FUSE (30A) (10A) MAIN RELAY No.1 No.10 FUSE FUSE (150A) (10A) BATTERY (12V) OPTION COMBINATION SWITCH Bl/Y Bl/Y LOAD Y/Bl W/Bl W/Bl ALTERNATOR...

  • Page 269: Tools

    dummyhead dummyhead CHARGING SYSTEM TOOLS LIST Driver Attachment, 52 x 55 mm Pilot, 17 mm 07749-0010000 07746-0010400 07746-0040400 Driver, 22 mm I.D. Attachment, 17 mm I.D. Attachment, 25 mm I.D. 07746-0020100 07746-0020300 07746-0030200...
  • Page 270 dummyhead dummyhead CHARGING SYSTEM CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. Battery test Remove the battery. Check the battery condition using the commercially available battery tester. Is the battery in good condition? – GO TO STEP 2. – Faulty battery. 2.

  • Page 271: Alternator Removal

    dummyhead dummyhead CHARGING SYSTEM ALTERNATOR REMOVAL/ INSTALLATION REMOVAL Disconnect the battery negative (–) cable. Remove the cooling fan cover (page 5-68). Disconnect the 4P connector [1] from the alternator. Remove the alternator B terminal nut [2] and ACG cable [3] from the alternator B terminal [4]. Loosen the alternator bolt [1] and nut [2].

  • Page 272: Alternator Disassembly

    dummyhead dummyhead CHARGING SYSTEM Install the alternator belt [1] to the alternator and adjust the belt tension by turning the special adjuster bolt [2]. Adjust the belt tension (page 3-9). After adjusting the belt tension, tighten the alternator bolt [3], then the alternator nut [4] to the specified torque.
  • Page 273 dummyhead dummyhead CHARGING SYSTEM Remove the nut [1] from the alternator B terminal and remove the insulator bushing [2]. Remove the three nuts [3], screw (5 x 8 mm) [4], and plate [5]. Remove the rear end cover [1]. Remove the brush holder insulator [2]. Remove the two screws (4 x 6 mm) [3] and the brush holder [4].
  • Page 274 dummyhead dummyhead CHARGING SYSTEM Remove the four screw/washers (4 x 7 mm) [1], rectifier [2], and seal ring [3]. Remove the four nuts [1], insulators [2], and the rear housing [3]. Remove the washer [4]. Remove the rotor [1] from the stator (drive end housing) [2].
  • Page 275 dummyhead dummyhead CHARGING SYSTEM Remove the rear bearing [1] and bearing cover [2] from the rotor using a commercially available bearing puller [3]. Install a commercially available bearing puller with care not to damage the rotor shaft. Remove the four screws (4.5 x 19 mm) [1] and bearing retainer [2].
  • Page 276 dummyhead dummyhead CHARGING SYSTEM EXPLODED VIEW SCREW (4.5 x 19 mm) (4) ROTOR REAR BEARING BEARING RETAINER STATOR FRONT BEARING (DRIVE END HOUSING) WASHER ALTERNATOR PULLEY BEARING COVER STUD BOLT (4) SCREW/WASHER (4 x 25 mm) (2) SCREW (4 x 6 mm) (2) IC REGULATOR PULLEY LOCK NUT RECTIFIER...
  • Page 277 dummyhead dummyhead CHARGING SYSTEM ASSEMBLY If the front bearing is removed, replace with a new bearing [1]. Apply grease to a new bearing outer surface. Install a new front bearing in the stator (drive end housing) using the special tool as shown. TOOLS: Driver [2] 07749-0010000...
  • Page 278 dummyhead dummyhead CHARGING SYSTEM If the rear bearing is removed, replace a new bearing [1]. Apply grease to a new bearing inner surface. Install a new rear bearing on the rotor shaft [2] using the special tool as shown. TOOLS: Driver, 22 mm I.D.
  • Page 279 dummyhead dummyhead CHARGING SYSTEM Install the washer [1] onto the rotor shaft [2]. • When installing the rear cover housing, be sure that the washer is positioned within the bearing circumference. Install the rear housing [3] to the stator by aligning the holes [4] of the rear housing with the terminals [5] of the stator.
  • Page 280 dummyhead dummyhead CHARGING SYSTEM Install the brush holder [1] as shown and tighten the two screws (4 x 6 mm) [2]. Install the brush holder insulator [3]. • Take care not to damage the rotor shaft slip rings with the brush holder during installation. Install the rear end cover [4].

  • Page 281: Alternator Inspection

    dummyhead dummyhead CHARGING SYSTEM ALTERNATOR INSPECTION BRUSH HOLDER ASSEMBLY Measure the brush length. If the measurement is less than the service limit, replace the brush holder assembly. STANDARD: 10.5 mm (0.41 in) SERVICE LIMIT: 9.0 mm (0.35 in) RECTIFIER ASSEMBLY •...
  • Page 282 dummyhead dummyhead CHARGING SYSTEM ROTOR Check to be sure that there is continuity between the slip rings [1]. Check to see that there is no continuity between a slip ring and the rotor [2], and between a slip ring and the rotor shaft [3].

  • Page 283: Ignition System

    dummytext 8. IGNITION SYSTEM SYSTEM LOCATION·····································8-2 IGNITION SYSTEM TROUBLESHOOTING ·································· 8-3 SYSTEM DIAGRAM ······································8-2 SPARK TEST ················································ 8-4...
  • Page 284 dummyhead dummyhead IGNITION SYSTEM SYSTEM LOCATION IGNITION SYSTEM CKP SENSOR FUSE/RELAY JUNCTION BOX DIRECT IGNITION COIL SYSTEM DIAGRAM FUSE/RELAY JUNCTION BOX DIRECT IGNITION DIRECT IGNITION DIRECT IGNITION No.4 No.5 COIL 5 COIL 1 COIL 3 FUSE FUSE (30A) (10A) MAIN RELAY Black Brown...
  • Page 285 dummyhead dummyhead IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING NO SPARK(S) 1. MIL inspection Turn the combination switch ON and check that the MIL stays ON. Does the MIL stay ON? – PGM-FI troubleshooting (page 5-6) – GO TO STEP 2. 2. Emergency stop switch clip inspection Check the emergency stop switch clip.
  • Page 286 dummyhead dummyhead IGNITION SYSTEM 7. Timing belt driven pulley inspection Check for proper installation of the timing belt driven pulley. Is the timing belt driven pulley installed correctly? – GO TO STEP 8. – Correct the timing belt driven pulley installation 8.
  • Page 287 dummytext 9. STARTING SYSTEM SYSTEM LOCATION·····································9-2 NEUTRAL SWITCH REMOVAL/ INSTALLATION ············································ 9-6 SYSTEM DIAGRAM ······································9-2 STARTER MOTOR DISASSEMBLY/ ASSEMBLY ··················································· 9-6 STARTING SYSTEM TROUBLESHOOTING···································9-3 STARTER MOTOR INSPECTION ·············· 9-16 STARTER MOTOR REMOVAL/ INSTALLATION·············································9-5 NEUTRAL SWITCH INSPECTION ············· 9-20...

  • Page 288: System Location

    dummyhead dummyhead STARTING SYSTEM SYSTEM LOCATION STARTING SYSTEM MAIN RELAY NEUTRAL SWITCH STARTER MOTOR FUSE/RELAY JUNCTION BOX SYSTEM DIAGRAM FUSE/RELAY JUNCTION BOX No.4 No.5 FUSE FUSE (30A) (10A) STARTER RELAY OPTION COMBINATION SWITCH Bl/W Bl/W W/Bl W/Bl W/Bl Bl/W Bl/W Bl/W Bl/W BATTERY...
  • Page 289 dummyhead dummyhead STARTING SYSTEM STARTING SYSTEM TROUBLESHOOTING STARTER MOTOR DOES NOT TURN 1. Standard inspection Check the following: – Battery condition – Burned No. 4 (30 A) fuse – Burned No. 5 (10 A) fuse Are the above items in good condition? –...
  • Page 290 dummyhead dummyhead STARTING SYSTEM 5. Starter relay coil line open circuit inspection Disconnect the neutral switch 2P connector Turn the combination switch to the START position. NEUTRAL SWITCH 2P CONNECTOR Measure the voltage at the neutral switch 2P MAIN WIRE HARNESS SIDE connector main wire harness side No.2 (Blue) terminal and No.1 (Black) terminal.

  • Page 291: Starter Motor Removal

    dummyhead dummyhead STARTING SYSTEM STARTER MOTOR REMOVAL/ INSTALLATION Disconnect the battery negative (–) terminal, then the positive (+) terminal from the battery. Remove the engine cover. Remove the three bolt/washers (6 x 27 mm) [1] and release the power tilt relay case [2] from cylinder block. Disconnect the L.

  • Page 292: Neutral Switch Removal

    dummyhead dummyhead STARTING SYSTEM NEUTRAL SWITCH REMOVAL/ INSTALLATION Remove the electric parts case (page 10-4). Remove the bolt (6 x 14 mm) [1] and neutral switch bracket [2] from the crankcase. Remove the neutral switch plate [3] and neutral switch [4] from the bracket by removing the neutral switch nut (20 mm) [5].
  • Page 293 dummyhead dummyhead STARTING SYSTEM Remove the two screws (6 x 22 mm) [1] and the two O- rings [2]. Remove the starter magnetic switch [3], spring [4], and the plunger [5]. Remove the two bolt screws [1] and remove the yoke/ rear bracket [2].
  • Page 294 dummyhead dummyhead STARTING SYSTEM Remove the two screws (5 x 8 mm) [1] and rear bracket [2]. Remove the brush holder [1] from the armature [2]. Remove the steel ball [1] and three planetary gears [2]. Remove the packing [1].
  • Page 295 dummyhead dummyhead STARTING SYSTEM Remove the overrunning clutch [1] from the front bracket [2]. Remove the clutch fork [3] from the overrunning clutch. Secure the gear shaft [1] by placing a wood block [2] under the gear shaft assembly. Secure the gear shaft assembly, being careful that the internal gear does not contact the wood block.
  • Page 296 dummyhead dummyhead STARTING SYSTEM Remove the clip [1] and plate [2]. Remove the brush sets [1] and four brush springs [2]. 9-10...
  • Page 297 dummyhead dummyhead STARTING SYSTEM EXPLODED VIEW • After assembling the starter motor, apply a sufficient amount of water resisting sealant (Sumitomo 3M Padding Sealer #8533 or equivalent) to the mating sections of each part (page 9-16). BRUSH SPRING (4) REAR BRACKET BRUSH HOLDER CLIP FRONT BRACKET...
  • Page 298 dummyhead dummyhead STARTING SYSTEM ASSEMBLY Install the brushes [1] and four brush springs [2] on the brush holder [3]. Install the plate [1] on the brush holder. Secure the plate with the clip [2]. Apply grease to the internal gear [1], inner wall of the overrunning clutch [2], gear shaft [3] sliding surface, and the surface of a new gear shaft stopper [4].
  • Page 299 dummyhead dummyhead STARTING SYSTEM Apply grease to the sliding surface of the clutch fork [1]. Set the clutch fork in the indicated position of the overrunning clutch groove [2] as shown. Install the overrunning clutch [1] assembly on the front bracket [2].
  • Page 300 dummyhead dummyhead STARTING SYSTEM Install the brush holder [1] on the armature [2]. Apply grease to the armature shaft. Install the rear bracket [1] as shown. Apply the water resisting sealant (Sumitomo 3M Padding Sealer #8533 or equivalent) to the seat of each screw [2].
  • Page 301 dummyhead dummyhead STARTING SYSTEM Install the plate [1] and packing [2] on the front bracket [3]. Install the yoke/rear bracket assembly [4]. • Install by aligning the projection [5] on the yoke with the cutout [6] in the front bracket. Apply water resisting sealant (Sumitomo 3M Padding Sealer #8533 or equivalent) to the seat of each bolt [7].

  • Page 302: Starter Motor Inspection

    dummyhead dummyhead STARTING SYSTEM WATER RESISTING SEALANT APPLICATION POINTS After the assembling the starter motor, apply a sufficient amount of water-resisting sealant (Sumitomo 3M Padding Sealer #8533 or equivalent) to the mating surfaces as shown. – Packing/front bracket mating section [1] –...
  • Page 303 dummyhead dummyhead STARTING SYSTEM INSULATION DEPTH Measure the mica depth [1]. If the grooves are clogged or mica depth is less than the service limit, recut the grooves using a hacksaw blade or a small file. STANDARD: 0.40 – 0.50 mm (0.016 – 0.020 in) SERVICE LIMIT: 0.20 mm (0.008 in) ARMATURE Check the armature and shaft gear for wear and...
  • Page 304 dummyhead dummyhead STARTING SYSTEM Measure commutator [1] runout using a dial gauge [2]. SERVICE LIMIT: 0.10 mm (0.004 in) If the measurement is more than the service limit, replace the armature with a new one. Check for continuity between each segment. If an open circuit exists between any two segments, replace the armature.
  • Page 305 dummyhead dummyhead STARTING SYSTEM Check for continuity between the commutator and armature shaft. If there is continuity, replace the armature. Place the armature in an armature tester (commercially available). Hold a hacksaw blade close to the armature core. If the blade is attracted to the core or vibrates when the core is turned, the armature is shorted.

  • Page 306: Neutral Switch Inspection

    dummyhead dummyhead STARTING SYSTEM NEUTRAL SWITCH INSPECTION INSPECTION Remove the fuse/relay junction box (page 10-3). Disconnect the neutral switch 2P connector [1] and release the connector from the connector holder. Attach the tester leads to the two terminals at the neutral switch.

  • Page 307: Other Electrical

    dummytext 10. OTHER ELECTRICAL SYSTEM LOCATION···································10-2 SWITCH PANEL INDICATOR WIRE HARNESSES REMOVAL/ INSTALLATION ·········································· 10-8 FUSE RELAY JUNCTION BOX REMOVAL/ INSTALLATION···········································10-3 RELAY REMOVAL/INSTALLATION ········ 10-10 ELECTRIC PARTS CASE REMOVAL/ INSTALLATION···········································10-4 MAIN/STARTER RELAY INSPECTION ··· 10-11 ECM REMOVAL/INSTALLATION···············10-5 FUEL PUMP RELAY INSPECTION ·········· 10-11 ECM BRACKET REMOVAL/ FUSE/RELAY JUNCTION BOX INSTALLATION···········································10-5...

  • Page 308: System Location

    dummyhead dummyhead OTHER ELECTRICAL SYSTEM LOCATION OTHER ELECTRICAL POWER TILT RELAY FUSE/RELAY JUNCTION BOX 10-2...
  • Page 309 dummyhead dummyhead OTHER ELECTRICAL FUSE RELAY JUNCTION BOX REMOVAL/INSTALLATION REMOVAL Disconnect the battery negative (–) cable, then the positive (+) cable from the battery. Remove the engine cover. Remove the following: – Fuse/relay junction box terminal bolts (6 x 22 mm) [1] (three) –...

  • Page 310: Installation

    dummyhead dummyhead OTHER ELECTRICAL ELECTRIC PARTS CASE REMOVAL/ INSTALLATION Remove the fuse/relay junction box (page 10-3). Remove the DLC [1], tach pulse 2P connector [2] and interface 6P connector [3] from the electric parts case [4]. Disconnect the switch panel wire harness 14P connector [5], indicator wire harness 6P connector [6] and neutral switch 2P connector [7].

  • Page 311: Installation

    dummyhead dummyhead OTHER ELECTRICAL ECM REMOVAL/INSTALLATION Disconnect the battery negative (–) cable, then the positive (+) cable from the battery. Remove the engine cover. Remove the two bolts (6 x 20 mm) [1] and the ECM [2]. Disconnect the ECM connector A [3] and B [4]. Installation is in the reverse order of removal.

  • Page 312: Installation

    dummyhead dummyhead OTHER ELECTRICAL POWER TILT RELAY/POWER TILT RELAY CASE REMOVAL/ INSTALLATION Disconnect the battery negative (–) cable, then the positive (+) cable from the battery. Remove the engine cover. Remove the bolt (6 x 12 mm) [1], power tilt relay ground terminal [2] and two wire harness clips [3].
  • Page 313 dummyhead dummyhead OTHER ELECTRICAL Remove the two power tilt relay mounting bolt/washers (6 x 25 mm) [1], harness band clip [2] and power tilt relay [3]. Remove the two collars [4] and two grommets [5] from the power tilt relay. Remove the following parts from the power tilt relay case [6]: –...

  • Page 314: Switch Panel Indicator Wire

    dummyhead dummyhead OTHER ELECTRICAL SWITCH PANEL INDICATOR WIRE HARNESSES REMOVAL/ INSTALLATION REMOVAL Remove the following: – Front separate cover (page 6-3) – Shift control cable pivot (page 20-3) – Throttle control cable pivot (page 20-6) Loosen the screw and remove the grommet band [1], then remove the under case grommet A [2].
  • Page 315 dummyhead dummyhead OTHER ELECTRICAL INSTALLATION • Be careful not to press the fuel tube A with the under case grommet A. Connect the switch panel wire harness connector 14P connector [1] and indicator panel wire harness 6P connector [2], and then attach them to the connector holders.

  • Page 316: Relay Removal/Installation

    dummyhead dummyhead OTHER ELECTRICAL Install the under case grommet A [1] to the groove [2] of the front cover bracket as shown. Install the remote control cable plate [3] to the groove [4] of the front cover bracket and tighten the bolt (6 x 16 mm) [5].

  • Page 317: Main/Starter Relay Inspection

    dummyhead dummyhead OTHER ELECTRICAL MAIN/STARTER RELAY INSPECTION Remove the relay from the fuse/relay junction box (page 10-10). Connect the ohmmeter to the relay terminal C [1] and terminal D [2]. Connect the battery positive (+) cable to the relay terminal A [3] and battery negative (–) cable to terminal B [4].

  • Page 318: Fuse/Relay Junction Box

    dummyhead dummyhead OTHER ELECTRICAL FUSE/RELAY JUNCTION BOX INSPECTION BLOCK FUSE INSPECTION Disconnect the battery negative (–) cable, then the positive (+) cable from the battery. Remove the engine cover. Open the fuse/relay junction box cover [1]. Remove the two block fuse screw/washers [2] and No.1 fuse [3] from fuse/relay junction box and check for continuity.
  • Page 319 dummyhead dummyhead OTHER ELECTRICAL BLADE FUSE INSPECTION Remove the fuses from fuse/relay junction box and check for blown fuses. If the fuses are normal, install the fuses to fuse/relay junction box and check for continuity between the terminals in each connectors as shown in the table. There should be continuity at all times.

  • Page 320: Power Tilt Relay Inspection

    dummyhead dummyhead OTHER ELECTRICAL Check terminals No.9 fuse (15 A) No.8 terminal and fuse/relay junction box 23P connector No.2 (INJ 6) terminal No.9 fuse (15 A) No.8 terminal and fuse/relay junction box 8P connector No.6 (IGP 1) terminal No.9 fuse (15 A) No.8 terminal and fuse/relay junction box 8P connector No.7 (IGP 2) terminal No.10 fuse (10 A) No.11 terminal and main relay No.28 terminal No.10 fuse (10 A) No.12 terminal and fuse/relay junction box 8P connector...

  • Page 321: Trim Angle Sensor Inspection

    dummyhead dummyhead OTHER ELECTRICAL Connect a battery as shown. There must be continuity/ no continuity between the terminals shown. • Use a known-good battery for the test. Positive (+) battery terminal connected to Light green terminal: Between Green and Black No continuity Between Blue and Black Continuity...
  • Page 322 dummyhead dummyhead MEMO...

  • Page 323: Cooling System

    dummytext 11. COOLING SYSTEM COMPONENT LOCATION ··························11-2 WATER PUMP REMOVAL/ INSTALLATION ·········································· 11-9 TOOLS·························································11-3 CYLINDER SLEEVE WATER JACKET ANODE REMOVAL/INSTALLATION ····················· 11-15 WATER LINE DESCRIPTION ·····················11-4 RELIEF VALVE DISASSEMBLY/ THERMOSTAT REMOVAL/ ASSEMBLY ··············································· 11-17 INSTALLATION···········································11-5 FLUSH VALVE DISASSEMBLY/ WATER JACKET REMOVAL/ ASSEMBLY ···············································...

  • Page 324: Component Location

    dummyhead dummyhead COOLING SYSTEM COMPONENT LOCATION COOLING SYSTEM 20 N·m (2.0 kgf·m, 15 lbf·ft) 11-2...

  • Page 325: Tools

    dummyhead dummyhead COOLING SYSTEM TOOLS LIST Attachment, 42 x 47 mm Driver 07746-0010300 07749-0010000 11-3...

  • Page 326: Water Line Description

    dummyhead dummyhead COOLING SYSTEM WATER LINE DESCRIPTION INLET WATER LINE THERMOSTAT EXHAUST MANIFOLD OUTLET WATER LINE RELIEF VALVE CYLINDER SLEEVE WATER JACKET THERMOSTAT CYLINDER HEAD EXHAUST EXHAUST MANIFOLD MANIFOLD WATER JACKET RELIEF VALVE MOUNT CASE VAPOR SEPARATOR OVERFLOW CASE FLUSH VALVE EXTENSION CASE WATER TUBE WATER PUMP...

  • Page 327: Thermostat Removal

    dummyhead dummyhead COOLING SYSTEM THERMOSTAT REMOVAL/ INSTALLATION R. SIDE Remove the cooling fan cover (page 5-68). Remove the water relief tube [1] and two tube clamps D29.0 [2] from the thermostat cover [3] and R. exhaust manifold [4]. Remove the bolt (6 x 35 mm) [5], two bolts (6 x 60 mm) [6], thermostat cover and thermostat [7] from the engine.

  • Page 328: Water Jacket Removal

    dummyhead dummyhead COOLING SYSTEM WATER JACKET REMOVAL/ INSTALLATION REMOVAL Remove the engine assembly (page 13-4). Remove the following: – Bolts (8 x 100 mm) [1] (two) – Bolts (8 x 30 mm) [2] (four) – Bolts (6 x 121 mm) [3] (six) –...
  • Page 329 dummyhead dummyhead COOLING SYSTEM INSTALLATION Apply a bead (Φ1.5 – 2.0 mm (0.06 – 0.08 in)) of liquid gasket (Threebond ® #1211, Hondabond Hondabond 4, or equivalent) to the exhaust guide seal B [1] installation section of the exhaust guide [2] as shown.
  • Page 330 dummyhead dummyhead COOLING SYSTEM Install new cover packings [1] to the L./R. water jacket covers [2]. Install the water jacket cover to the engine mount case [3]. Install and tighten the following: – Bolts (8 x 100 mm) [4] (two) –...

  • Page 331: Water Pump Removal

    dummyhead dummyhead COOLING SYSTEM WATER PUMP REMOVAL/ INSTALLATION REMOVAL Remove the following: Standard rotation type – Propeller (page 16-6) – Gear case (page 16-8) Counter rotation type – Propeller (page 17-5) – Gear case (page 17-7) Remove the water tube seal ring [1] from the impeller housing [2].
  • Page 332 dummyhead dummyhead COOLING SYSTEM Remove the bolt (6 x 16 mm) [1] and water pump housing [2]. Remove the water pump housing O-ring [3], O-ring (65.4 x 2.4 mm) [4] and two dowel pins [5]. Remove the gear case grommet [6] and rubber setting plate [7] from the gear case.
  • Page 333 dummyhead dummyhead COOLING SYSTEM EXPLODED VIEW IMPELLER HOUSING BOLT/WASHER IMPELLER HOUSING (8 x 60 mm) (4) WATER TUBE SEAL RING DOWEL PIN (2) 20 N·m (2.0 kgf·m, 15 lbf·ft) BOLT (6 x 16 mm) DISTANCE COLLAR (4) WATER PUMP HOUSING WATER PUMP O-RING PUMP LINER WATER SEAL...
  • Page 334 dummyhead dummyhead COOLING SYSTEM INSTALLATION Apply soapy water to the outer circumference of the WATER SEAL new water seals (26 x 42 x 7 mm) [1] and marine INSTALLATION grease to the water seals mating surface. DIRECTION Drive the water seals one by one into the water pump housing using the special tools.
  • Page 335 dummyhead dummyhead COOLING SYSTEM Install a new impeller gasket [1] and impeller cover [2]. Apply marine grease to the pump liner [1] inner surface. Install the pump liner in the impeller housing [2] by aligning the two projections [3] on the pump liner with the two grooves [4] in the impeller housing.
  • Page 336 dummyhead dummyhead COOLING SYSTEM Set the special key [1] to the groove [2] in the vertical shaft [3]. Install the pump impeller [4], aligning the key groove [5] in the pump impeller with the special key. Set the impeller housing [6] on the vertical shaft. Install the impeller housing while turning the vertical shaft clockwise.

  • Page 337: Cylinder Sleeve Water Jacket Anode Removal/Installation

    dummyhead dummyhead COOLING SYSTEM CYLINDER SLEEVE WATER JACKET ANODE REMOVAL/INSTALLATION Remove the exhaust manifold (page 5-95). Remove the sealing bolt [1] and washer [2] from the cylinder block. Remove corrosion and sealing tape from the sealing bolt. • Use a soft resin brush or shop towel to clean the surface.
  • Page 338 dummyhead dummyhead COOLING SYSTEM Install a new sealing washer [1] to the sealing bolt [2]. Cover the sealing bolt threads with sealing tape. Starting from the top, wrap it counterclockwise 1-1/4 to 1-1/2 turn as shown [3]. • Do not use sealant, as it may protrude between anode metal cylinder...

  • Page 339: Relief Valve Disassembly

    dummyhead dummyhead COOLING SYSTEM RELIEF VALVE DISASSEMBLY/ ASSEMBLY Remove the engine cover bracket (page 6-9). Disconnect the water outlet tube [1] from the right relief valve and remove the tube clamp D10.5 [2]. Remove the following: – Bolts (6 x 32 mm) [3] (two) –...

  • Page 340: Flush Valve Disassembly

    dummyhead dummyhead COOLING SYSTEM FLUSH VALVE DISASSEMBLY/ ASSEMBLY Remove the L. engine under cover (page 6-4). Disconnect the flush valve tube [1] and remove the tube clip 65 [2] and tube clip B12.5 [3]. Disconnect the water joint tube [4] and remove the tube clip B12.5 [5].

  • Page 341: Thermostat Inspection

    dummyhead dummyhead COOLING SYSTEM THERMOSTAT INSPECTION Remove the thermostat (page 11-5). Immerse the thermostat [1] in water. Heat the water and observe the operation of the thermostat as the water temperature increases. Measure the water temperature when the thermostat starts opening. Don't let the thermometer [2] or the thermostat touch the container;...
  • Page 342 dummyhead dummyhead MEMO...

  • Page 343: Lubrication System

    dummytext 12. LUBRICATION SYSTEM COMPONENT LOCATION ··························12-2 OIL CASE/EXHAUST PIPE/WATER TUBE REMOVAL/INSTALLATION ······················· 12-6 LUBRICATION SYSTEM DIAGRAM ··········12-3 OIL PUMP REMOVAL/INSTALLATION ····· 12-9 TOOLS·························································12-4 OIL PUMP DISASSEMBLY/ ASSEMBLY ··············································· 12-10 OIL FILLER EXTENSION REMOVAL/ INSTALLATION···········································12-5 OIL PRESSURE TEST ······························ 12-12 OIL LEVEL GAUGE COVER REMOVAL/ INSTALLATION···········································12-5 OIL PUMP INSPECTION ··························...

  • Page 344: Component Location

    dummyhead dummyhead LUBRICATION SYSTEM COMPONENT LOCATION LUBRICATION SYSTEM 10 N·m (1.0 kgf·m, 7 lbf·ft) 12-2...

  • Page 345: Lubrication System Diagram

    dummyhead dummyhead LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM VTEC SPOOL SOLENOID VALVE EOP SWITCH (LOW PRESSURE SIDE) INTAKE ROCKER ARM EOP SWITCH (HIGH PRESSURE SIDE) EXHAUST ROCKER ARM CRANKSHAFT PISTON MAIN JOURNAL CONNECTING ROD JOURNAL OIL FILTER OIL JET INTAKE ROCKER ARM SHAFT CAMSHAFT RELIEF VALVE...

  • Page 346: Tools

    dummyhead dummyhead LUBRICATION SYSTEM TOOLS LIST Driver Oil seal driver attachment, 72 mm Oil seal driver, 44.5 mm 07749-0010000 07947-6340201 07947-SB00100 Oil pressure adapter, 22 x 1.5 mm 07APJ-ZY3A101 12-4...

  • Page 347: Oil Filler Extension Removal

    dummyhead dummyhead LUBRICATION SYSTEM OIL FILLER EXTENSION REMOVAL/ INSTALLATION Remove the two bolts (6 x 22 mm) [1] and the oil filler extension [2]. Apply liquid gasket (Threebond ® #1141H, Hondabond HT, Hondabond 4, or equivalent) to the shaded part shown.
  • Page 348 dummyhead dummyhead LUBRICATION SYSTEM OIL CASE/EXHAUST PIPE/WATER TUBE REMOVAL/INSTALLATION REMOVAL Drain the engine oil (page 3-4). Remove the extension case: – Standard rotation type (page 16-11) – Counter rotation type (page 17-9) Remove the six bolts (8 x 28 mm) [1], six washers (8 mm) [2], two exhaust pipes [3], and two exhaust pipe gaskets [4].
  • Page 349 dummyhead dummyhead LUBRICATION SYSTEM EXPLODED VIEW OIL LEVEL GAUGE O-RING (20.6 x 2.7 mm) OIL STRAINER OIL STRAINER BOLT (6 x 18 mm) (4) 10 N·m (1.0 kgf·m, 7 lbf·ft) OIL CASE GASKET WATER TUBE OIL CASE GROMMET OIL DRAIN PLUG 23 N·m (2.3 kgf·m, 17 lbf·ft) EXHAUST PIPE GASKET (2)
  • Page 350 dummyhead dummyhead LUBRICATION SYSTEM INSTALLATION • Do not fill the engine with oil, or start the engine within 15 minutes after oil case installation. Apply engine oil to a new O-ring [1], and install it to the Upper area: oil strainer [2]. Apply a bead [Φ1.0 mm (0.04 in)] of the liquid gasket ®...

  • Page 351: Oil Pump Removal/Installation

    dummyhead dummyhead LUBRICATION SYSTEM OIL PUMP REMOVAL/INSTALLATION REMOVAL Remove the engine (page 13-4). Remove the bolt (6 x 16 mm) [1] and washer (6 mm) [2] from the shift arm [3]. Release the shift arm from shift shaft B [4]. Remove the E-ring [5], washer (14 mm) [6], and shift shaft B.
  • Page 352 dummyhead dummyhead LUBRICATION SYSTEM OIL PUMP DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the oil pump (page 12-9). OIL SEAL (31 x 46 x 7 mm) OIL PUMP COVER SCREW (6 x 16 mm) (8) 7.0 N·m (0.71 kgf·m, 5.2 lbf·ft) OIL PUMP COVER OIL PUMP RELIEF DOWEL PIN (5 x 8 mm) (2) SEALING BOLT (18 mm)

  • Page 353: Assembly

    dummyhead dummyhead LUBRICATION SYSTEM ASSEMBLY ® Apply liquid sealant (Threebond #1216 or equivalent) to the threads of the two sealing bolts [1]. • To prevent leaks, do not install the parts if 5 minutes or more have elapsed since applying the liquid gasket.

  • Page 354: Oil Pressure Test

    dummyhead dummyhead LUBRICATION SYSTEM Using the special tools or hydraulic press, install each oil seal to the position shown. • Press-fit the oil seal (46 x 60 x 9 mm) [1] to the position 23.2 – 23.8 mm (0.24 – 0.27 in) [2] from the body end to the oil seal face.

  • Page 355: Oil Pump Inspection

    dummyhead dummyhead LUBRICATION SYSTEM Make sure the oil pressure adapter O-ring [1] is in good condition. Install and tighten the oil pressure adapter [2] to the specified torque. TOOL: Oil pressure adapter, 22 x 1.5 mm 07APJ-ZY3A101 TORQUE: 9 N·m (0.9 kgf·m, 6.6 lbf·ft) •...
  • Page 356 dummyhead dummyhead LUBRICATION SYSTEM OUTER ROTOR-TO-PUMP BODY CLEARANCE Measure the outer rotor-to-pump body clearance. STANDARD: 0.10 – 0.18 mm (0.004 – 0.007 in) SERVICE LIMIT: 0.20 mm (0.008 in) OUTER ROTOR-TO-OIL PUMP BODY SIDE CLEARANCE Measure the outer rotor-to-oil pump body side clearance.

  • Page 357: Engine Removal/Installation

    dummytext 13. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ··························13-2 ENGINE REMOVAL ···································· 13-4 TOOL ···························································13-3 ENGINE INSTALLATION···························· 13-6 13-1...

  • Page 358: Component Location

    dummyhead dummyhead ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ENGINE REMOVAL/INSTALLATION 44 N·m (4.5 kgf·m, 32 lbf·ft) 75 N·m (7.6 kgf·m, 55 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 75 N·m (7.6 kgf·m, 55 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 13-2...
  • Page 359 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION TOOL LIST Engine hanger VSB02C000021 13-3...

  • Page 360: Engine Removal

    dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Disconnect the battery negative (–) cable, then positive (+) cable from the battery.

  • Page 361: Tool

    dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Disconnect the water tubes [1] from the exhaust manifolds. Disconnect the cylinder head cover oil return hoses [1] and air vent tube [2]. Attach the engine chains [1] to the engine hanger [2]. TOOL: Engine hanger [3] VSB02C000021 Remove the cap [1], two mount case flange nuts [2], two flange bolts (10 x 55 mm) [3], and two flange bolts...

  • Page 362: Engine Installation

    dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Remove the following bolts from the under side of the engine mounting case [1]. • bolts (10 x 60 mm) (two) • bolt (10 x 85 mm) (one) • bolt/washer (12 x 65 mm) (one) • bolt/washers (12 x 120 mm) (two) •...
  • Page 363 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Turn shift shaft A [1] so that the cutout [2] is positioned Viewing from the lower side as shown. (This position shows shift shaft A is in the of the mounting case. neutral position.) Cruising direction Install shift shaft A [1], washer [2] and shift shaft B [3] by aligning the punch mark [4] on shift shaft A with the punch mark [5] on shift shaft B.
  • Page 364 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Set the dowel pin (10 x 16 mm) [1] and dowel pin (14 x 15 mm) [2] to the mount case. Install a new mount case gasket [3]. Slowly install the engine assembly on the engine mount case [4].
  • Page 365 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Apply engine oil to a new O-ring (59.4 x 3.1 mm) [1], and install it to the starter motor [2]. Install the starter motor, but do not tighten the starter motor bolts. Tighten the bolts and nuts to the upper side of the engine assembly in the numbered order to the specified torque.
  • Page 366 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Apply marine grease to the seal holder [1] O-ring groove and bearing part. Apply marine grease to a new O-ring (26.9 x 2.4 mm) [2], and install it to the seal holder. Install the seal holder on shift shaft B [3] so that shift shaft B does not tilt on the mount case.
  • Page 367 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Connect the cylinder head cover oil return hoses [1] and air vent tube [2]. Connect the water tubes [1] to the exhaust manifolds. Connect fuel tube G [1] to the fuel pump (low pressure side) [2]. Install fuel tube G to the hose clip [3].
  • Page 368 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Install the starter cable (–) [1] and bolt (8 x 18 mm) [2]. Install the following parts: – Oil case/Exhaust pipe/Water tube (page 12-8) – Fuel pump (High pressure side)/Vapor separator (page 5-90) – Water separator (page 5-94) –...
  • Page 369 dummytext 14. CYLINDER HEAD COMPONENT LOCATION ··························14-2 CYLINDER HEAD DISASSEMBLY/ ASSEMBLY ··············································· 14-25 TOOLS·························································14-4 ROCKER ARMS/SHAFTS DISASSEMBLY/ ASSEMBLY ··············································· 14-31 TIMING BELT DRIVE/DRIVEN PULLEY REMOVAL/INSTALLATION························14-6 CYLINDER COMPRESSION TEST ·········· 14-33 CYLINDER HEAD COVER REMOVAL/ INSTALLATION·········································14-19 CYLINDER HEAD INSPECTION ·············· 14-33 CYLINDER HEAD REMOVAL/ VALVE GUIDE REPLACEMENT ··············...

  • Page 370: Component Location

    dummyhead dummyhead CYLINDER HEAD COMPONENT LOCATION CYLINDER HEAD 83 N·m (8.5 kgf·m, 61 lbf·ft) 90 N·m (9.2 kgf·m, 66 lbf·ft) 90 N·m (9.2 kgf·m, 66 lbf·ft) 245 N·m (25.0 kgf·m, 181 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 14-2...
  • Page 371 dummyhead dummyhead CYLINDER HEAD 39.2 N·m (4.0 kgf·m, 29 lbf·ft)+ 50°+ 53° 14-3...

  • Page 372: Tools

    dummyhead dummyhead CYLINDER HEAD TOOLS LIST Air supply Air adapter VTEC air stopper 07AAJ-PNAA100 070AJ-0010101 070AJ-0030100 Valve guide reamer, 5.5 mm Valve guide driver, 5.35 x 9.7 mm Attachment, 52 x 55 mm 07HAH-PJ7A100 07742-0010100 07746-0010400 Driver Valve spring compressor Holder handle 07749-0010000 07757-0010000...
  • Page 373 dummyhead dummyhead CYLINDER HEAD Air supply attachment 07VAJ-P8A010A 14-5...

  • Page 374: Timing Belt Drive/Driven Pulley Removal/Installation

    dummyhead dummyhead CYLINDER HEAD TIMING BELT DRIVE/DRIVEN PULLEY REMOVAL/INSTALLATION REMOVAL Disconnect the battery negative (–) cable. Make sure the remote control lever is in "N" (neutral) position. Remove the following: – Engine cover – Cooling fan cover (page 5-68) Remove the four bolts (6 x 16 mm) [1] and cooling fan [2].
  • Page 375 dummyhead dummyhead CYLINDER HEAD Turn the crankshaft pulley [1] clockwise so that the groove [2] of the crankshaft pulley lines up with the pointer [3]. Make sure both the right side and left side timing belt RIGHT SIDE: driven pulley NO. 1 TDC marks [1] align with the timing belt back cover pointers [2].
  • Page 376 dummyhead dummyhead CYLINDER HEAD Loosen the crankshaft pulley bolt [1] using the special tools as shown. • Do not use an impact wrench. Remove the bolt- washer while holding the crankshaft pulley with the special tool. • Do not turn the crankshaft counterclockwise. TOOLS: Holder attachment, 50 mm [2] 070PB-0010100...
  • Page 377 dummyhead dummyhead CYLINDER HEAD Disconnect the CMP sensor 4P connector [1]. Using the special tool as shown, loosen the timing belt driven pulley bolt [1]. TOOL: Lock nut wrench, 56 mm [2] 07LPA-ZV30200 Remove the timing belt driven pulley bolt [1], timing belt driven pulley [2], and key [3] from the camshaft.
  • Page 378 dummyhead dummyhead CYLINDER HEAD Remove the timing belt tensioner bolt [1] and timing belt tensioner pulley [2] and return spring [3]. Remove the two caps [1] and idler pulley bolts [2], and then remove the idler pulleys [3]. 14-10...
  • Page 379 dummyhead dummyhead CYLINDER HEAD EXPLODED VIEW Degrease, clean and/or lubricate the parts marked with according DEGREASING/CLEANING/ LUBRICATION instructions. Do not lubricate any part unless instructed to do so on page 14-14. TIMING BELT TIMING BELT COVER (2) COVER BOLT (4) TIMING BELT IDLER PULLEY A BOLT 83 N·m (8.5 kgf·m, 61 lbf·ft) BOLT (6 x 16 mm) (4)
  • Page 380 dummyhead dummyhead CYLINDER HEAD INSTALLATION Install the timing belt tensioner pulley [1] and loosely tighten the timing belt tensioner bolt [2]. Install the return spring [3] as shown. Push the tensioner pulley in the direction shown [4], and then tighten the tensioner bolt. Install idler pulley A [1] and tighten the idler pulley A bolt [2] to the specified torque.
  • Page 381 dummyhead dummyhead CYLINDER HEAD Install the timing belt back cover [1] to the cylinder head and tighten the two special bolts (8 x 29 mm) [2]. Install the timing belt driven pulley [3] and special key [4] to the camshaft by aligning the key groove [5] of the driven pulley with the key groove [6] of the camshaft.

  • Page 382: Cylinder Block

    dummyhead dummyhead CYLINDER HEAD Be sure to degrease, clean, or lubricate the following parts before installation. : WIPE WITH SHOP TOWEL : DEGREASE Crankshaft pulley bolt [1] : LUBRICATE WITH OIL • Degrease the entire surface of the bolt-washer (especially the washer and the crankshaft pulley mating surface) with a clean shop towel.
  • Page 383 dummyhead dummyhead CYLINDER HEAD Install the timing belt drive pulley [1] by aligning the pin [2] of the pulley with the long hole [3] of the timing guide plate [4]. Align the key groove [5] of the crankshaft with the key groove [6] of the drive pulley, and install the key [7].
  • Page 384 dummyhead dummyhead CYLINDER HEAD Clean the timing belt pulleys and the upper and lower LEFT SIDE: covers. Set the timing belt driven pulleys to No. 1 TDC by aligning the TDC marks [1] on the timing belt driven pulleys with the pointers [2] on the timing belt back cover.
  • Page 385 dummyhead dummyhead CYLINDER HEAD Clean any oil off the inside face of the crankshaft pulley [1], and apply lubricant to the crankshaft pulley bolt [2] (page 14-14). Install the crankshaft pulley by aligning the key groove of the crankshaft [3] and key groove of the pulley. Install and tighten the crankshaft pulley bolt to the specified torque using the special tools.
  • Page 386 dummyhead dummyhead CYLINDER HEAD Make sure the No. 1 piston TDC marks [1] on both RIGHT SIDE: timing belt driven pulleys and the pointers [2] on the timing belt covers are aligned when the groove of the crankshaft pulley lines up with the pointer on the crankcase.

  • Page 387: Cylinder Head Cover Removal

    dummyhead dummyhead CYLINDER HEAD Install the cooling fan [1] and four bolts (6 x 16 mm) [2]. Install the following: – Cooling fan cover (page 5-69) – Engine cover CYLINDER HEAD COVER REMOVAL/ INSTALLATION REMOVAL Disconnect the battery negative (–) cable. Shift the remote control lever in the N (neutral) position.
  • Page 388 dummyhead dummyhead CYLINDER HEAD Disconnect the cylinder head cover oil return hose [1]. Remove the eight bolts (6 x 35 mm) [1] and cylinder head cover [2]. INSTALLATION Check the cylinder head cover gasket [1] and spark plug tube seal [2], and replace them if necessary. Install the spark plug tube seal to the cylinder head cover [3] in the direction as shown, until its upper surface is 0.7 –...
  • Page 389 dummyhead dummyhead CYLINDER HEAD Apply engine oil to the spark plug tube [1]. Clean the cylinder head mating surfaces with a shop towel or equivalent material. Install the cylinder head cover by aligning the spark plug tube seal with the spark plug tube. Tighten the eight bolts (6 x 35 mm) in the numbered order in two steps.

  • Page 390: Cylinder Head Removal

    dummyhead dummyhead CYLINDER HEAD CYLINDER HEAD REMOVAL/ INSTALLATION REMOVAL • Remove the cylinder head assembly while the engine is cold to prevent warpage. • Take care not to damage the cylinder head and cylinder block mating surfaces. Set the timing belt driven pulley at top dead center of the compression stroke of the No.1 cylinder before removal/installation of the cylinder head assembly (page 14-6).
  • Page 391 dummyhead dummyhead CYLINDER HEAD EXPLODED VIEW CYLINDER HEAD BOLT/WASHER (12 x 163 mm) (16) 39.2 N·m (4.0 kgf·m, 29 lbf·ft) + 50°+ 53° DOWEL PIN (16 x 22 mm) (4) CYLINDER HEAD GASKET CYLINDER HEAD OIL CONTROL ORIFICE (2) O-RING (2) CYLINDER HEAD GASKET CYLINDER HEAD 14-23...
  • Page 392 dummyhead dummyhead CYLINDER HEAD INSTALLATION Set the crankshaft drive pulley at top dead center of the compression stroke of the No.1 cylinder before installation of the cylinder head assembly (page 14-6). Clean the cylinder head and cylinder block mating surfaces. Clean the oil control orifice [1] and oil passage using pressurized air.

  • Page 393: Cylinder Head Disassembly

    dummyhead dummyhead CYLINDER HEAD CYLINDER HEAD DISASSEMBLY/ ASSEMBLY DISASSEMBLY Remove the following: – Cylinder head (page 14-22) – Timing belt back cover (page 14-6) Remove the four nuts [1], injector base [2], gasket [3], and the two dowel pins [4]. Loosen the twelve valve adjusting lock nuts [1] and twelve adjusting screws [2].
  • Page 394 dummyhead dummyhead CYLINDER HEAD Select a suitable tool [1] that matches the diameter of the valve spring retainer. Attach the tool to the retainer and lightly tap on the tool to separate the valve keepers and the retainer. • Tap at right angles to each valve stem head. Take care not to bend the valves.
  • Page 395 dummyhead dummyhead CYLINDER HEAD EXPLODED VIEW Apply oil to the following parts when reassembling. Engine oil: • Lost motion (full face) • Exhaust rocker arm shaft bolt (threaded part and seat) • Valve stem seal (internal circumference) • Valve adjusting screw (threaded part) •...

  • Page 396: Assembly

    dummyhead dummyhead CYLINDER HEAD ASSEMBLY Install the valve stem seals. SPRING (WHITE) SPRING (BLACK) Note that valve stem seal A (intake side) and B (exhaust side) are different. Do not confuse them. INTAKE STEM INTAKE STEM SEAL B SEAL A Install the valve spring seat.
  • Page 397 dummyhead dummyhead CYLINDER HEAD Lightly tap the end of each valve stem [1] two or three times with a plastic hammer to ensure proper seating of the valve and valve keepers. Tap the valve stem only along its axis so you do not bend the stem.
  • Page 398 dummyhead dummyhead CYLINDER HEAD Set the rocker arm assembly in place, and loosely install the bolts. Make sure that the rocker arms are properly positioned on the valve stems. Apply engine oil to the threaded section and the seating surface of exhaust rocker arm shaft bolts, and tighten the bolts in the numbered order in two or three steps to the standard torque.
  • Page 399 dummyhead dummyhead CYLINDER HEAD ROCKER ARMS/SHAFTS DISASSEMBLY/ASSEMBLY • Identify parts as they are removed so they can be reinstalled in their original locations. • Inspect the rocker arm shafts and rocker arms (page 14-33). • Rocker arms must be installed in the same positions if reused.
  • Page 400 dummyhead dummyhead CYLINDER HEAD RIGHT BANK INTAKE ROCKER ARM ASSEMBLY INTAKE ROCKER ARM SHAFT SPRING EXHAUST ROCKER EXHAUST ROCKER ARM B ARM A EXHAUST ROCKER ARM SHAFT Letter A is stamped Letter B is stamped on rocker arm. on rocker arm. 14-32...

  • Page 401: Cylinder Compression Test

    dummyhead dummyhead CYLINDER HEAD CYLINDER COMPRESSION TEST Set the remote control lever in the "N" (neutral) position. Remove the engine cover and disconnect the ECM connector A [1] and B [2]. Remove the spark plugs (page 3-17). Install a compression gauge (EEPV303A: commercially available) [1] in the No.1 plug hole.
  • Page 402 dummyhead dummyhead CYLINDER HEAD VALVE FACE/STEM O.D. Inspect each valve face [1] for pitting, wear, or irregularities. Inspect each valve stem for bending or abnormal stem wear. Replace the valve if necessary. Measure and record each valve stem O.D. STANDARD: IN: 5.485 –...
  • Page 403 dummyhead dummyhead CYLINDER HEAD VALVE STEM-TO-VALVE GUIDE CLEARANCE Subtract each valve stem O.D. from the corresponding valve guide I.D. STANDARD: IN: 0.020 – 0.045 mm (0.0008 – 0.0018 in) EX: 0.055 – 0.080 mm (0.0022 – 0.0032 in) SERVICE LIMIT: IN: 0.080 mm (0.0032 in) EX: 0.120 mm (0.0047 in) If the stem-to-guide clearance exceeds the service limit,...
  • Page 404 dummyhead dummyhead CYLINDER HEAD ROCKER ARM SHAFT O.D. Measure and record the rocker arm shaft O.D. STANDARD: IN/EX: 19.972 – 19.993 mm (0.7863 – 0.7871 in) Replace the rocker arm shaft if its O.D. is smaller than the service limit. ROCKER ARM I.D.
  • Page 405 dummyhead dummyhead CYLINDER HEAD VTEC ROCKER ARM TEST Remove the cylinder head covers (page 14-19). Set the No. 1 piston at TDC (page 14-6). Push on the intake mid rocker arm of the No.1 cylinder [1]. The mid rocker arm should move independently of the primary rocker arm [2] and secondary rocker arm [3].
  • Page 406 dummyhead dummyhead CYLINDER HEAD Make sure that the intake primary rocker arm [1] and intake secondary rocker arm [2] are mechanically connected by the piston and that the mid rocker arm [3] does not move when pushed manually. If any intake mid rocker arm moves independently of the primary and secondary rocker arms, replace the rocker arms as a set.
  • Page 407 dummyhead dummyhead CYLINDER HEAD CAM LOBE HEIGHT Wipe the camshaft clean, then inspect the lift ramps. TIMING BELT Replace the camshaft if any lobes are pitted, scored or excessively worn. LEFT BANK Measure cam lobe height. STANDARD: IN/PRI: 34.88 – 34.98 mm (1.3732 – 1.3772 in) IN/MID: 36.227 –...
  • Page 408 dummyhead dummyhead CYLINDER HEAD CAMSHAFT JOURNAL I.D. Measure the I.D. of each camshaft journal. STANDARD: 43.000 – 43.024 mm (1.6929 – 1.6939 in) CAMSHAFT OIL CLEARANCE Zero the gauge to the camshaft journal O.D. Clean the camshaft bearing surfaces in the cylinder head.
  • Page 409 dummyhead dummyhead CYLINDER HEAD CAMSHAFT RUNOUT Measure the camshaft runout. STANDARD: 0.030 mm (0.0012 in) Max. SERVICE LIMIT: 0.040 mm (0.0016 in) Camshaft runout is half of maximum gauge reading. CYLINDER HEAD WARPAGE Remove carbon deposits from combustion chamber. MEASUREMENT POINTS Clean off any gasket material from the cylinder head surface.

  • Page 410: Valve Guide Replacement

    dummyhead dummyhead CYLINDER HEAD CYLINDER HEAD BOLT/WASHER Measure the bolt O.D. at the two points as shown. STANDARD: 11.3 mm (0.44 in) 75 mm (3.0 in) 40 mm (1.6 in) Replace the cylinder head bolt/washer if its O.D. is smaller than the service limit. Measure the O.D.
  • Page 411 dummyhead dummyhead CYLINDER HEAD Install new valve guides [1] from the valve spring side of the cylinder head. Remove new valve guides from the refrigerator one at a time as you install them, in order to keep them chilled. TOOL: Valve guide driver, 5.35 x 9.7 mm [2] 07742-0010100 Drive each valve guide to the specified height, measured from the top of the valve guide to the cylinder...

  • Page 412: Valve Seat Reconditioning

    dummyhead dummyhead CYLINDER HEAD VALVE SEAT RECONDITIONING Thoroughly clean the combustion chambers and valve seats to remove carbon deposits. Apply a light coat of Prussian Blue compound or erasable felt-tipped marker ink to the valve faces [1]. Insert the valves, and then lift them and snap them closed against their seats several times.
  • Page 413 dummyhead dummyhead CYLINDER HEAD Measure the valve set width. STANDARD: 1.25 – 1.55 mm (0.049 – 0.061 in) SERVICE LIMIT: 2.0 mm (0.08 in) Make a light pass with the 45° cutter to remove any possible burrs at the edges of the seat. After resurfacing the seats, inspect for even valve seating.
  • Page 414 dummyhead dummyhead MEMO...
  • Page 415 dummytext 15. CYLINDER BLOCK COMPONENT LOCATION ··························15-2 CRANKCASE COVER/CRANKSHAFT/PISTON DISASSEMBLY/ASSEMBLY ······················ 15-7 TOOLS·························································15-3 FLYWHEEL INSPECTION ························ 15-26 CYLINDER BLOCK ANODE REMOVAL/ INSTALLATION···········································15-4 CRANKSHAFT/PISTON/CYLINDER BLOCK INSPECTION············································· 15-27 FLYWHEEL REMOVAL/INSTALLATION ···15-4 BEARING SELECTION····························· 15-36 15-1...

  • Page 416: Component Location

    dummyhead dummyhead CYLINDER BLOCK COMPONENT LOCATION CYLINDER BLOCK 29 N·m (3.0 kgf·m, 21 lbf·ft) + 58° 118 N·m (12.0 kgf·m, 87 lbf·ft) 16 N·m (1.6 kgf·m, 12 lbf·ft) 20 N·m (2.0 kgf·m, 15 lbf·ft) + 90° 32 N·m (3.3 kgf·m, 24 lbf·ft) 49 N·m (5.0 kgf·m, 36 lbf·ft) 15-2...

  • Page 417: Tools

    dummyhead dummyhead CYLINDER BLOCK TOOLS LIST Ring gear holder Oil seal driver attachment, 80 x 96 mm Oil seal driver, 66 mm 070PB-ZY3A100 07ZAD-PNA0100 07947-3710200 Driver 07749-0010000 15-3...

  • Page 418: Cylinder Block Anode Removal

    dummyhead dummyhead CYLINDER BLOCK CYLINDER BLOCK ANODE REMOVAL/ INSTALLATION Remove the oil pump (page 12-9). Remove the two screws (5 x 16 mm) [1] and two anode metals [2]. Installation is in the reverse order of removal. FLYWHEEL REMOVAL/INSTALLATION REMOVAL Remove the oil pump (page 12-9).
  • Page 419 dummyhead dummyhead CYLINDER BLOCK EXPLODED VIEW Remove oil from the mating surface between the crankshaft and the flywheel, and the mating surface between the flywheel and the flywheel boss, using a degreasing cleaning agent before installing the flywheel and the flywheel boss. CRANKSHAFT (Degrease) FLYWHEEL (Degrease) DOWEL PIN (14 x 15 mm)
  • Page 420 dummyhead dummyhead CYLINDER BLOCK INSTALLATION Clean the mating surfaces between the crankshaft and the flywheel [1] with a degreasing cleaning agent, and set the flywheel on the crankshaft. Apply engine oil to the seat and the threaded part of the flywheel bolts [2].
  • Page 421 dummyhead dummyhead CYLINDER BLOCK CRANKCASE COVER/CRANKSHAFT/ PISTON DISASSEMBLY/ASSEMBLY CRANKCASE COVER/CRANKSHAFT DISASSEMBLY Remove the following parts: – Engine assembly (page 13-4) – Cylinder head (page 14-22) – Oil filter (page 3-6) – Thermostat (page 11-5) – ECM bracket (page 10-5) – Power tilt relay case (page 10-6) –...
  • Page 422 dummyhead dummyhead CYLINDER BLOCK Remove the three timing belt tensioner base bolts (10 x 40 mm) [1], bolt (6 x 22 mm) [2], timing belt tensioner base [3], and O-ring [4]. Remove the dowel pin [5]. Remove the two bolts (8 x 25 mm) [1] and engine hanger plate [2].
  • Page 423 dummyhead dummyhead CYLINDER BLOCK Remove the two bolts (8 x 50 mm) [1], bolt (8 x 75 mm) [10] [11] [2], VTEC spool valve [3], and VTEC spool valve filter [4]. Remove the seven bolts (6 x 35 mm) [5], crankcase upper cover [6], oil hole gasket [7], oil pipe joint [8] and two dowel pins [9].
  • Page 424 dummyhead dummyhead CYLINDER BLOCK Remove the piston assembly [1] by pushing on the connecting rod. CORRECT • To avoid mix up during reassembly, mark each piston/connecting rod assembly with its cylinder number. • Before removing the piston assembly, remove the carbon deposits from the cylinder.
  • Page 425 dummyhead dummyhead CYLINDER BLOCK Remove the five side bolts (10 x 60 mm) [1], two side bolts (10 x 80 mm) [2], side bolt (10 x 109 mm) [3], eight bearing cap bolts [4], four bearing caps [5], four lower main bearings [6], and eight dowel pins [7].
  • Page 426 dummyhead dummyhead CYLINDER BLOCK Apply engine oil to the piston pin clip [1] and turn them in the ring grooves until the end gaps are lined up with the cutouts [2] in the piston pin holes. • Do not damage the piston pin clip installation groove.
  • Page 427 dummyhead dummyhead CYLINDER BLOCK EXPLODED VIEW BEARING CAP BOLT/WASHER (11 x 105 mm) (8) 29 N·m (3.0 kgf·m, 21 lbf·ft) + 58° BEARING CAP (4) DOWEL PIN (8) LOWER MAIN BEARING (4) CRANKSHAFT UPPER MAIN BEARING (4) SIDE BOLT/WASHER (10 x 80 mm) 49 N·m (5.0 kgf·m, 36 lbf·ft) SIDE BOLT/WASHER THRUST WASHER (2)
  • Page 428 dummyhead dummyhead CYLINDER BLOCK PISTON RING PISTON PIN (6) PISTON PIN CLIP (12) PISTON (6) CONNECTING ROD (6) CYLINDER BLOCK DOWEL PIN (2) CONNECTING ROD BEARING (12) CONNECTING ROD BEARING CAP (6) CONNECTING ROD BOLT (12) 20 N·m (2.0 kgf·m, 15 lbf·ft) + 90° 15-14...
  • Page 429 dummyhead dummyhead CYLINDER BLOCK PISTON ASSEMBLY Install a new piston pin clip [1] on one side only. • Wear eye protection as the piston pin clips can pop out during installation. • Make sure the piston pin clip does not align with the cutout in the piston pin bore.
  • Page 430 dummyhead dummyhead CYLINDER BLOCK Install the piston rings in the ring grooves of the piston [1] with the marks on the top ring [2] and the second ring [3] facing up. • Clean the ring grooves thoroughly before installing the piston rings. •...
  • Page 431 dummyhead dummyhead CYLINDER BLOCK Stagger the piston ring end gaps as shown (top ring [1], second ring [2], side rail (top side) [3], spacer [4], and side rail (skirt side) [5]). • Do not align with the piston pin, and avoid the direction that makes a right angle with the piston pin.
  • Page 432 dummyhead dummyhead CYLINDER BLOCK Clean the mating surfaces between the upper main bearing [1] and cylinder block [2] with a degreasing cleaning agent. Apply molybdenum disulfide oil to the crankshaft mating surface of the upper main bearing. Install the four upper main bearings onto the cylinder block by aligning the tab [3] of the main bearing with the groove [4] of the cylinder block.
  • Page 433 dummyhead dummyhead CYLINDER BLOCK Clean the mating surfaces between the lower main JOURNAL POSITION bearing [1] and bearing cap [2] with a degreasing cleaning agent. Apply molybdenum disulfide oil to the crankshaft mating surface of the lower main bearing. Install the four lower main bearings onto the four bearing caps by aligning the tab [3] of the main bearing with groove [4] of the bearing caps.
  • Page 434 dummyhead dummyhead CYLINDER BLOCK Install the piston [1] with the arrow mark [2] facing the timing belt side of the engine. Using a piston ring compressor (RC40C: commercially available) [3], position the piston in the cylinder block, and tap it in using the wooden handle of a hammer.
  • Page 435 dummyhead dummyhead CYLINDER BLOCK Tighten the eight bearing cap bolts [1] in the numbered sequence shown. Tighten them to the specified torque, then tighten them to an additional 58°. TORQUE: 29 N·m (3.0 kgf·m, 21 lbf·ft) + 58° Tighten the five (10 x 60 mm), (10 x 109 mm), and two (10 x 80 mm) side bolts [2] in the numbered sequence shown.
  • Page 436 dummyhead dummyhead CYLINDER BLOCK Install a new O-ring (26.2 x 2.4 mm) [1], two dowel pins [2] and oil seal case [3] to the cylinder block. Tighten the eight bolts (6 x 22 mm) [4]. Apply marine grease to a new oil seal [1] lips. Drive in the oil seal into the crankcase upper cover [2] using the special tool.
  • Page 437 dummyhead dummyhead CYLINDER BLOCK Coat new O-ring (18.3 x 3.5 mm) [1] and O-ring (16.3 x 3.5 mm) [2] with engine oil and install them to the oil pipe joint [3]. Install the oil pipe joint to the cylinder block. Install a new oil hole gasket [4], two dowel pins [5] and the crankcase upper cover [6] to the cylinder block with the seven bolts (6 x 35 mm) [7].
  • Page 438 dummyhead dummyhead CYLINDER BLOCK Install a new O-ring (25 x 2.4 mm) [1], two dowel pins [2] and the crankcase [3] to the cylinder block [4]. [12] Loosely tighten the fifteen bolts (6 x 32 mm) [5], two [10] bolts (6 x 37 mm) [6], and two bolts (6 x 55 mm) [7] in the positions shown.
  • Page 439 dummyhead dummyhead CYLINDER BLOCK Install the dowel pin [1]. Align the dowel pin position, and install a new O-ring [2] and timing belt tensioner base [3]. Install and tighten the three timing belt tensioner base bolts (10 x 40 mm) [4] to the specified torque. TORQUE: 45 N·m (4.6 kgf·m, 33 lbf·ft) Install and tighten the bolt (6 x 22 mm) [5].

  • Page 440: Flywheel Inspection

    dummyhead dummyhead CYLINDER BLOCK Position the harness clamp [1] against the stopper [2] of the cylinder block, then install and tighten the bolt (6 x 14 mm) [3]. Install the following parts: – Flywheel (page 15-6) – EOP switch (High pressure side) (page 5-103) –...
  • Page 441 dummyhead dummyhead CYLINDER BLOCK CRANKSHAFT/PISTON/CYLINDER BLOCK INSPECTION PISTON SKIRT O.D. Measure and record the piston O.D. at a point 11.5 mm (0.45 in) from the bottom, and 90° to the piston pin bore. O.D. STANDARD: 88.974 – 88.984 mm (3.5029 – 3.5033 in) SERVICE LIMIT: 88.964 mm (3.5025 in) 11.5 mm...
  • Page 442 dummyhead dummyhead CYLINDER BLOCK PISTON-TO-CYLINDER CLEARANCE Subtract each piston skirt O.D. from the corresponding cylinder sleeve I.D. STANDARD: 0.016 – 0.041 mm (0.0006 – 0.0016 in) SERVICE LIMIT: 0.080 mm (0.0032 in) PISTON RING THICKNESS Check the piston ring and oil ring for damage. Always replace the oil ring spacer and side rails as a set.
  • Page 443 dummyhead dummyhead CYLINDER BLOCK PISTON RING END GAP Measure the piston ring end gap 15 – 20 mm (0.6 – 0.8 in) from the cylinder bottom. Before measurement, be sure to set the ring in the PISTON cylinder squarely using the piston. RING STANDARD: 0.20 –...
  • Page 444 dummyhead dummyhead CYLINDER BLOCK PISTON PIN-TO-PIN BORE CLEARANCE Set the cylinder gauge at the piston pin O.D., and set the gauge needle at zero "0". Set the cylinder gauge in the piston pin hole, and measure the piston pin-to-pin bore clearance. STANDARD: –0.005 –...
  • Page 445 dummyhead dummyhead CYLINDER BLOCK CRANKSHAFT MAIN JOURNAL O.D. Measure the crankshaft main journal [1] O.D. STANDARD: 71.976 – 72.000 mm (2.8337 – 2.8346 in) CRANKPIN O.D. Measure the crankpin [1] O.D. STANDARD: 55.976 – 57.000 mm (2.2038 – 2.2441 in) CRANKSHAFT JOURNAL ROUNDNESS (MAIN/CRANKPIN JOURNALS)
  • Page 446 dummyhead dummyhead CYLINDER BLOCK CRANKSHAFT AXIAL CLEARANCE Measure the crankshaft axial clearance. STANDARD: 0.10 – 0.35 mm (0.004 – 0.014 in) SERVICE LIMIT: 0.45 mm (0.018 in) If the measurement exceeds the service limit, check the thrust washers and the thrust surface of the crankshaft. Replace the thrust washers with new ones, and recheck.
  • Page 447 dummyhead dummyhead CYLINDER BLOCK CYLINDER HEAD SURFACE WARPAGE Take care not to damage (scores, scratches, etc.) the MEASUREMENT POINTS mating surface with the gasket. Measure the surface warpage using a straight edge [1] and a feeler gauge [2] as shown. STANDARD: 0.07 mm (0.003 in) Max.
  • Page 448 dummyhead dummyhead CYLINDER BLOCK CRANKSHAFT MAIN BEARING OIL CLEARANCE To check main bearing-to-journal oil clearance, remove the bearing caps, crankshaft, and main bearings (page 15-7). Clean each main journal and main bearings with a clean shop towel. Check each main journal, thrust washer contact surface, main bearing for scoring, scratches or damage.
  • Page 449 dummyhead dummyhead CYLINDER BLOCK CONNECTING ROD BEARING OIL CLEARANCE To check connecting rod bearing-to-crankpin oil clearance, remove the connecting rod bearing caps, crankshaft, and connecting rod bearings (page 15-7). Clean each crankpin, connecting rod bearing cap, and connecting rod bearing with a clean shop towel. Check each crankpin and connecting rod bearing for scoring, scratches or damage.

  • Page 450: Bearing Selection

    dummyhead dummyhead CYLINDER BLOCK BEARING SELECTION CRANKSHAFT MAIN BEARING • When replacing the main bearing, check the crankshaft main journal code number and the cylinder block I.D. code letter or number, and select the correct bearing by referring to the bearing selection table.
  • Page 451 dummyhead dummyhead CYLINDER BLOCK Select the correct bearing by referring to the cylinder block I.D. code letter or number and the crankshaft main journal code number. Crankshaft main bearing selection table Cylinder block I.D. code number or Crankshaft letter main journal A or I B or II C or III...
  • Page 452 dummyhead dummyhead CYLINDER BLOCK CONNECTING ROD BEARING • When replacing the connecting rod bearing, check the crankpin code letter and the connecting rod code number, and select the correct bearing by referring to the bearing selection table. • If the code letters and/or numbers are not clear, clean the areas with a cleaning solvent and check again.
  • Page 453 dummyhead dummyhead CYLINDER BLOCK Select the correct bearing by referring to the crankpin code letter and the connecting rod code number. Connecting rod bearing selection table Connecting rod code number Crankpin 1 or I 2 or II 3 or III 4 or IIII code letter Bearing I.D.
  • Page 454 dummyhead dummyhead MEMO...

  • Page 455: Gear Case (Standard Rotation)

    dummytext 16. GEAR CASE (STANDARD ROTATION) COMPONENT LOCATION ··························16-2 PROPELLER SHAFT HOLDER DISASSEMBLY/ASSEMBLY ···················· 16-32 TOOLS·························································16-3 VERTICAL SHAFT DISASSEMBLY/ ASSEMBLY ··············································· 16-32 PROPELLER REMOVAL/ INSTALLATION···········································16-6 SHIM SELECTION ···································· 16-35 ANODE METAL/WATER SCREEN REMOVAL/ INSTALLATION···········································16-7 BACKLASH INSPECTION························ 16-41 GEAR CASE/EXTENSION SEPARATOR (XXA PROPELLER SHAFT THRUST CLEARANCE type) REMOVAL/INSTALLATION ··············16-8 INSPECTION·············································...

  • Page 456: Component Location

    dummyhead dummyhead GEAR CASE (STANDARD ROTATION) COMPONENT LOCATION GEAR CASE (STANDARD ROTATION) 4.5 N·m (0.46 kgf·m, 3.3 lbf·ft) 20 N·m (2.0 kgf·m, 15 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft) 37 N·m (3.8 kgf·m, 27 lbf·ft) 1 N·m (0.1 kgf·m, 0.7 lbf·ft) MAX.
  • Page 457 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) TOOLS LIST Driver, 480 mm Bearing race puller Prop shaft holder 070GD-001A100 070PC-ZY3A101 Attachment, 32 x 42 mm Taper bearing installer attachment, Attachment, 37 x 40 mm 070PD-ZY3A100 90 mm 07746-0010200 070PF-ZY3A100 Pilot, 25 mm Pilot, 28 mm Fork seal driver attachment, 27.2 mm 07746-0040600...
  • Page 458 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Remover weight Bearing driver attachment, Oil seal driver attachment, 28 x 35 mm 07936-371020A or 07936-3710200 44 x 49.5 mm 07945-4150200 07945-3330300 Bearing driver attachment, 64 x 72 mm Oil seal driver, 44.5 mm Driver, 280 mm 07946-SB20000 07947-SB00100...
  • Page 459 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Backlash inspection tool set Pilot, 30 mm Attachment, 27.5 x 44 mm 070PJ-ZX20200 07746-0040700 07948-9540000 16-5...
  • Page 460 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) PROPELLER REMOVAL/ INSTALLATION SPLIT PIN (4.0 mm) Be sure to use a Honda genuine part (stainless steel). Bend the pin ends as shown to secure the nut. SPLIT PIN (4.0 mm) 3-BLADE PROPELLER (Optional part) PROPELLER THRUST WASHER Install the thrust washer in the direction as shown.
  • Page 461 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) ANODE METAL/WATER SCREEN REMOVAL/INSTALLATION ANODE METAL (2) BOLT (6 x 55 mm) WATER SCREEN SCREW (5 x 55 mm) 1 N·m (0.1 kgf·m, 0.7 lbf·ft) SELF-LOCKING NUT (6 mm) O-RING GEAR OIL CHECK BOLT 6.5 N·m (0.66 kgf·m, 4.8 lbf·ft) O-RING GEAR OIL DRAIN PLUG BOLT...
  • Page 462 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) GEAR CASE/EXTENSION SEPARATOR (XXA type) REMOVAL/INSTALLATION REMOVAL Set the remote control lever in the "N" (Neutral) position. Tilt up the motor to the uppermost position. Remove the bolt/washer (10 x 32 mm) [1], and trim tab [2].
  • Page 463 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) INSTALLATION Set the remote control lever in the "N" (Neutral) position. Check that the cutout [1] of the spline faces the cruising direction [2] (this position is "N" (Neutral)). If the cutout of the spline is not in the direction shown, protect the spline with a shop towel [3] and turn the shift rod [4] right or left with a wrench until the cutout faces toward the specified direction.
  • Page 464 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Install the trim tab [1] by aligning the " " marks [2]. (single motor type) Install the gear case cover [3]. (dual motor type) Install and tighten the bolt/washer (10 x 32 mm) [4]. After installing the gear case, adjust the shift control cable (page 20-3).
  • Page 465 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) EXTENSION CASE REMOVAL/ INSTALLATION REMOVAL Remove the following: – L./R. Engine under cover (page 6-3) – Gear case (page 16-8) [18] – Extension separator (XXA type: page 16-8) Remove the lower mounting cover screw/washer (6 x 40 mm) [1], six special bolts (6 x 17 mm) [2] and L./R.
  • Page 466 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) EXPLODED VIEW GROUND TERMINAL BOLT (6 x 12 mm) MOUNT CASE SEAL RUBBER BOLT (14 x 180 mm) (2) LOWER MOUNT STOPPER (2) LOWER MOUNT NUT (14 mm) (2) 103 N·m (10.5 kgf·m, 76 lbf·ft) DOWEL PIN (2) WASHER (14 mm) (2) DRAIN PLUG RUBBER...
  • Page 467 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) INSTALLATION Apply marine grease to the extension case grommet [1] inner surface and install it to the extension case [2]. Install the drain plug rubber [3], two dowel pins [4] and two special bolts (6 x 12 mm) [5] to the extension case. Install the two rubbers [1] to the two lower mount [15] housings [2].
  • Page 468 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) SHIFT ROD REMOVAL/INSTALLATION REMOVAL Remove the water pump (page 11-9). Wrap a shop towel [1] around the shift rod spline, and use pliers to turn the shift rod [2] in the direction shown (cutout of the shift rod spline [3] is toward the left side of the cruising direction [4]).
  • Page 469 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Remove the shift rod spring [1], washer [2], and E-ring [3] from the shift rod [4]. EXPLODED VIEW SHIFT ROD HOLDER WATER SEAL (12 x 21 x 6 mm) (2) O-RING SHIFT ROD SPRING WASHER (12 mm) E-RING (10 mm) SHIFT ROD...
  • Page 470 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) INSTALLATION Install the E-ring [1], washer [2], and shift rod spring [3] on the shift rod [4]. • Do not reuse the E-ring if it is deformed or deteriorated. • Check that the E-ring is set in the groove in the shift rod securely.
  • Page 471 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Apply marine grease to the lips and soapy water to the outer circumference of the new water seals (12 x 21 x 6 mm) [1]. With the lips facing up, drive the water seals (12 x 21 x 6 mm) into the shift rod holder [2].
  • Page 472 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) PROPELLER SHAFT HOLDER REMOVAL/INSTALLATION Drain the gear case oil (page 3-7). Remove the following: – Propeller (page 16-6) – Gear case (page 16-8) – Extension separator (XXA type: page 16-8) – Shift rod (page 16-14) Remove the two bolts (12 x 45 mm) [1], two washers (12 mm) [2].
  • Page 473 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) SHIFT SLIDER/PROPELLER SHAFT REMOVAL/INSTALLATION SHIFT SLIDER REMOVAL Remove the propeller shaft holder (page 16-18). Remove the cross pin ring [1] and the shifter pin [2], and then remove the clutch shifter [3]. Remove the shift slider [1] and the two steel balls (#7) [2] from the propeller shaft [3].

  • Page 474: Tools

    dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Remove the shift plate [1] from the shift slider [2], and then remove the two shift springs [3] and the two steel balls (#12) [4]. • Take care not to let the shift springs and the steel balls pop out of the shift slider during removal of the shift plate.
  • Page 475 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Remove the two water seals (30 x 45 x 7 mm) [1] from the propeller shaft holder [2] using a commercially available oil seal remover. EXPLODED VIEW STEEL BALL (#12) (2) STEEL BALL (#7) (2) SHIFT PLATE SHIFT SPRING (2) SHIFT...
  • Page 476 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) PROPELLER SHAFT INSTALLATION Apply soapy water to the outer circumference and <Water seal installation direction> marine grease to the mating surfaces of new water seals (30 x 45 x 7 mm) [1]. Drive the water seals one by one into the propeller shaft holder [2] using the special tool.
  • Page 477 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Apply gear oil to the threads and seating surface of the bearing holder [1]. Position the bearing holder on the propeller shaft. Loosely tighten the bearing holder by hand against the propeller shaft holder [2]. Attach the fixing tool or special tool [3] (page 16-20), on the propeller shaft holder and secure with two bolts [4].
  • Page 478 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) With the groove [1] on the clutch shifter [2] toward the forward bevel gear, assemble the clutch shifter on the propeller shaft while aligning the shifter pin installation hole [3] with the long hole [4] in the propeller shaft. •...
  • Page 479 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Push the shift slider [1] into the propeller shaft [2] slowly, and set the steel balls (#7) [3] in the positions shown. • Note that the shift rod cannot be installed unless the shift slider is on the reverse side. Set the shift slider on the reverse side securely.
  • Page 480 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Set a commercially available universal bearing puller [1] between the taper bearing (inner race) and the forward bevel gear. Drive the taper bearing (60 x 100 x 30 mm) (inner race) out of the forward bevel gear using the special tools and a hydraulic press as shown.
  • Page 481 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) EXPLODED VIEW Engine side LOCK NUT (68 mm) 132 N·m (13.5 kgf·m, 97 lbf·ft) VERTICAL SHAFT OIL SLINGER FORWARD BEVEL GEAR GEAR CASE TAPER ROLLER BEARING (60 x 100 x 30 mm) FORWARD BEVEL GEAR SHIM PINION GEAR PINION GEAR NUT 196 N·m (20.0 kgf·m, 145 lbf·ft)
  • Page 482 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) INSTALLATION Install the forward bevel gear shim [1] on the gear case. • When the gear case, forward bevel gear, or the taper bearing have been replaced with new ones, perform shim adjustment and select the appropriate shim accordingly (page 16-35).
  • Page 483 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Wipe the tapered part [1] of the vertical shaft [2] and pinion gear [3] with a shop towel and degreasing cleaning solvent. Apply gear oil to the threads and seating surface of the pinion gear nut [4]. Install the vertical shaft and pinion gear on the gear case, then loosely tighten the pinion gear nut.
  • Page 484 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) BEARING HOLDER DISASSEMBLY/ ASSEMBLY DISASSEMBLY Attach a commercially available universal bearing puller [1] between the bearing holder [2] and the reverse bevel gear [3]. Remove the reverse bevel gear/bearing [4] from the bearing holder using the special tools and hydraulic press as shown.
  • Page 485 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) ASSEMBLY Install the reverse bevel gear shim [1] on the bearing holder [2]. • When the gear case, reverse bevel gear or bearing is replaced with a new one, perform shim adjustment and select the appropriate shim accordingly (page 16-35).
  • Page 486 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) PROPELLER SHAFT HOLDER DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the needle bearing (32 x 42 x 30 mm) [1] from the propeller shaft holder [2] using the special tools and hydraulic press. TOOLS: Driver, 280 mm [3] 07949-3710001 Oil seal driver attachment, 28 x 35 mm [4]...
  • Page 487 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Check the taper roller bearing for abnormal sound and play. Replace the inner race and outer race as a set if necessary. Set a commercially available universal bearing puller [1] on the taper roller bearing [inner race], and install the vertical shaft [2] on the hydraulic press with the flywheel [1] JAW, OTC1123 boss installation side facing up.
  • Page 488 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) ASSEMBLY Set the pinion gear [1] on the vertical shaft [2], and loosely tighten the pinion gear nut [3] by hand. Apply gear oil to the inner surface of the taper roller bearing inner races, rollers, and the inner surface of the outer race.
  • Page 489 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) SHIM SELECTION SHIM POSITION • Use shims to adjust the position of each gear so that they engage properly. Perform shim adjustment if the backlash of a gear is outside the specification or after replacing the gear case, vertical shaft, propeller shaft, or bearing with a new one.
  • Page 490 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) PINION GEAR SHIM Remove the taper roller bearing (32 x 66 x 49 mm) if it is mounted on the vertical shaft [1] (page 16-32). Clean the tapered surfaces [1] of the vertical shaft [2] and pinion gear [3] thoroughly using a shop towel and degreasing cleaning agent.
  • Page 491 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Measure the height (E’’) of the taper roller bearing MEASUREMENT E’’: (outer race [1]) using a regular vernier caliper [2], and record it. Calculate the length from the inner race end to the outer race end (E) by determining the gap between the measurements E’...
  • Page 492 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Remove the trim tab from the gear case (page 16-8). Cross reference the engagement mark [1] located on the trim tab installation part of the gear case [2] and the tolerance calculated in the previous step, and refer to the pinion gear shim selection table to determine the required thickness of the shim (Sp).
  • Page 493 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) HOW TO SELECT SHIM COMBINATION To obtain 0.90 mm (0.035 in) of shim thickness, combine one gear shim A, one gear shim C, and one gear shim D, or combine four gear shim A and one gear shim D.
  • Page 494 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) REVERSE BEVEL GEAR SHIM Measure the bearing height (H) of a new ball bearing (55 x 100 x 21 mm) [1] using a regular vernier caliper [2] as shown, and record the measurement. Calculate the tolerance using the measurement H obtained in the previous step and the following formula.
  • Page 495 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) THRUST SHIM Remove the trim tab from the gear case (page 16-8). Cross reference the engagement mark [1] located on the trim tab installation part of the gear case [2] and refer to the shim selection table to determine the required thickness of the shim (St).
  • Page 496 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Turn the vertical shaft [1] five to ten turns clockwise to fit the taper bearing. Retighten the puller bolt to the specified torque. TORQUE: 5 N·m (0.51 kgf·m, 3.7 lbf·ft) Repeat the procedure several times. Set the special tools as shown.
  • Page 497 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) REVERSE BEVEL GEAR BACKLASH Backlash adjustment must be made after adjustment of each gear shim (page 16-35). Install the following parts except the water pump. – Vertical shaft/forward bevel gear (page 16-28) – Propeller shaft holder (page 16-18) –...
  • Page 498 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) PROPELLER SHAFT THRUST CLEARANCE INSPECTION Adjust the propeller shaft thrust clearance after inspection of the backlash. Install the following parts except the water pump. – Vertical shaft/forward bevel gear (page 16-28) – Propeller shaft holder (page 16-18) –...
  • Page 499 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) GEAR CASE PRESSURE INSPECTION • Perform the gear case pressure check and check for pressure leakage after disassembling reassembling the gear case. • In principle, the pressure check should be made on the gear case before filling it with gear oil and before installing it on the outboard motor.
  • Page 500 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) While applying the specified air pressure to the gear case, turn the vertical shaft [1] five or six turns clockwise. • Be sure to turn the vertical shaft clockwise, or damage to the water pump impeller can occur. While applying the specified air pressure to the gear case, turn the propeller shaft [1] right and left two or three turns.
  • Page 501 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) PROPELLER SHAFT INSPECTION PROPELLER SHAFT O.D. Measure the O.D. of the propeller shaft where the bearings ride. STANDARD: At bevel gear [1]: 27.974 – 27.983 mm (1.1013 – 1.1017 in) At needle bearing [2]: 32.007 –...
  • Page 502 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) VERTICAL SHAFT RUNOUT Support each journal with V-blocks as shown. 125.5 mm 26 mm Set the dial indicator and measure the vertical shaft (4.9 in) (1.0 in) runout while turning the shaft. STANDARD: LA type 0.30 mm (0.012 in) or below XA type 0.35 mm (0.014 in) or below...
  • Page 503 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) EXTENSION SEPARATOR STUD BOLT REPLACEMENT (XXA type) Remove the extension separator (page 16-8). Thread two nuts onto the stud bolt (12 x 170 mm) [1] and six stud bolts (10 x 170 mm) [2], and tighten them together.
  • Page 504 dummyhead dummyhead GEAR CASE (STANDARD ROTATION) Apply gear oil to the outer circumference of a new needle bearing [1]. Install the needle bearing (30.5 x 47 x 37 mm) in the gear case [2] using the special tools, until it is fully seated.

  • Page 505: Gear Case (Counter Rotation)

    dummytext 17. GEAR CASE (COUNTER ROTATION) COMPONENT LOCATION ··························17-2 REVERSE BEVEL GEAR NEEDLE BEARING (28 x 39 x 30 mm) REPLACEMENT········· 17-30 TOOLS·························································17-3 PROPELLER SHAFT HOLDER DISASSEMBLY/ASSEMBLY ···················· 17-30 PROPELLER REMOVAL/ INSTALLATION···········································17-5 VERTICAL SHAFT DISASSEMBLY/ ASSEMBLY ··············································· 17-31 ANODE METAL/WATER SCREEN REMOVAL/ INSTALLATION···········································17-6 SHIM SELECTION ····································...
  • Page 506 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) COMPONENT LOCATION GEAR CASE (COUNTER ROTATION) 4.5 N·m (0.46 kgf·m, 3.3 lbf·ft) 20 N·m (2.0 kgf·m, 15 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft) 37 N·m (3.8 kgf·m, 27 lbf·ft) 1 N·m (0.1 kgf·m, 0.7 lbf·ft) MAX.
  • Page 507 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) TOOLS LIST Driver Bearing race puller Prop shaft holder 07749-0010000 070PC-ZY3A101 Attachment, 32 x 42 mm Taper bearing installer attachment, Oil seal driver attachment, 42 x 47 mm 070PD-ZY3A100 90 mm 07947-ZV00100 070PF-ZY3A100 Attachment, 37 x 40 mm Oil seal driver attachment, 28 x 35 mm Lock nut wrench, 36 x 47.8 mm 07746-0010200...
  • Page 508 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Oil seal driver, 44.5 mm Driver, 280 mm Pilot, 28 mm 07947-SB00100 07949-3710001 07JAD-PH80400 Pilot, 32 x 50 mm Vertical shaft holder Backlash indicator tool 07MAD-PR90200 07SPB-ZW10200 07SPJ-ZW0030B Installer shaft, 15 x 370 mm Pin type spanner, 128 mm Puller jaws, 25 mm 07VMF-KZ30200...

  • Page 509: Propeller Removal

    dummyhead dummyhead GEAR CASE (COUNTER ROTATION) PROPELLER REMOVAL/ INSTALLATION SPLIT PIN (4.0 mm) Be sure to use a Honda genuine part (stainless steel). Bend the pin ends as shown to secure the nut. SPLIT PIN (4.0 mm) 3-BLADE PROPELLER (Optional part) PROPELLER THRUST WASHER Install the thrust washer in the direction as shown.
  • Page 510 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) ANODE METAL/WATER SCREEN REMOVAL/INSTALLATION ANODE METAL (2) BOLT (6 x 55 mm) WATER SCREEN SCREW (5 x 55 mm) 1 N·m (0.1 kgf·m, 0.7 lbf·ft) SELF-LOCKING NUT (6 mm) O-RING GEAR OIL CHECK BOLT 6.5 N·m (0.66 kgf·m, 4.8 lbf·ft) O-RING SELF-LOCKING NUT (5 mm)
  • Page 511 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) GEAR CASE/EXTENSION SEPARATOR (XXCA type) REMOVAL/INSTALLATION REMOVAL Set the remote control lever in the "N" (Neutral) position. Tilt up the motor to the uppermost position. Remove the bolt/washer (10 x 32 mm) [1], and gear case cover [2].
  • Page 512 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Tilt up the motor to the uppermost position. Install the two dowel pins [1] to the extension separator [2]. (XXCA type) Install the two dowel pins [3] to the gear case [4]. Install the shift rod A [5] by aligning the cutout [6] of the shift rod A spline with the projection [7] of the spline of shift shaft A [8].

  • Page 513: Mount

    dummyhead dummyhead GEAR CASE (COUNTER ROTATION) VERTICAL SHAFT BUSHING REMOVAL/INSTALLATION Remove the gear case (page 17-7). Remove the extension separator (XXCA type: page 17- Remove the internal circlip [1], washer (30 mm) [2], and vertical shaft bushing [3]. Inspect the vertical shaft bushing I.D. (page 17-45). Replace the vertical shaft bushing if necessary.
  • Page 514 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Remove the drain plug rubber [1], two dowel pins [2], extension case grommet [3] and two special bolts (6 x 12 mm) [4] from the extension case. 17-10...
  • Page 515 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) EXPLODED VIEW GROUND TERMINAL BOLT (6 x 12 mm) MOUNT CASE SEAL RUBBER BOLT (14 x 180 mm) (2) LOWER MOUNT STOPPER (2) LOWER MOUNT NUT (14 mm) (2) 103 N·m (10.5 kgf·m, 76 lbf·ft) DOWEL PIN (2) WASHER (14 mm) (2) DRAIN PLUG RUBBER...

  • Page 516: Gear Case/Extension Separator (Xxa Type) Removal/Installation

    dummyhead dummyhead GEAR CASE (COUNTER ROTATION) INSTALLATION Apply marine grease to the extension case grommet [1] inner surface and install it to the extension case [2]. Install the drain plug rubber [3], two dowel pins [4] and two special bolts (6 x 12 mm) [5] to the extension case. Install the two rubbers [1] to the two lower mount [15] housings [2].
  • Page 517 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) SHIFT ROD REMOVAL/INSTALLATION REMOVAL Remove the water pump (page 11-9). Wrap a shop towel [1] around the shift rod spline, and use pliers to turn the shift rod [2] in the direction shown (Cutout of the shift rod spindle [3] is toward the right side of the cruising direction [4]).
  • Page 518 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Remove the shift rod spring [1], washer [2], and E-ring [3] from the shift rod [4]. EXPLODED VIEW WATER SEAL (12 x 21 x 6 mm) [2] SHIFT ROD HOLDER SHIFT HOLDER O-RING SHIFT ROD SPRING WASHER (12 mm) E-RING (10 mm) SHIFT ROD...
  • Page 519 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) INSTALLATION Install the E-ring [1], washer [2], and shift rod spring [3] on the shift rod [4]. • Do not reuse the E-ring if it is deformed or deteriorated. • Check that the E-ring is set in the groove in the shift rod securely.
  • Page 520 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Apply marine grease to the lips and soapy water to the outer circumference of the new water seals (12 x 21 x 6 mm) [1]. With the lips facing up, drive the water seals (12 x 21 x 6 mm) into the shift rod holder [2].
  • Page 521 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) PROPELLER SHAFT HOLDER REMOVAL/INSTALLATION Drain the gear case oil (page 3-7). Remove the following: – Propeller (page 17-5) – Gear case (page 17-7) – Extension separator (XXCA types: page 17-7) – Shift rod (page 17-13) Remove the two bolts (12 x 45 mm) [1], two washers (12 mm) [2].
  • Page 522 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) SHIFT SLIDER/PROPELLER SHAFT REMOVAL/INSTALLATION SHIFT SLIDER REMOVAL Remove the propeller shaft holder (page 17-17) Remove the cross pin ring [1] and the shifter pin [2], and then remove the clutch shifter [3]. Remove the shift slider [1] and the two steel balls (#7) [2] from the propeller shaft [3].
  • Page 523 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Remove the shift plate [1] from the shift slider [2], and then remove the two shift springs [3] and the two steel balls (#12) [4]. • Take care not to let the shift springs and the steel balls pop out of the shift slider during removal of the shift plate.
  • Page 524 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Remove the two water seals (30 x 45 x 7 mm) [1] from the propeller shaft holder [2] using a commercially available oil seal remover. EXPLODED VIEW STEEL BALL (#7) (2) SHIFT SPRING CROSS PIN RING SHIFT PLATE ROLLER SHIFT SLIDER...
  • Page 525 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) PROPELLER SHAFT INSTALLATION Apply soapy water to the outer circumference of new <Water seal installation direction> water seals (30 x 45 x 7 mm) [1]. Drive the water seals one by one into the propeller shaft holder [2] using the special tool.
  • Page 526 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Apply gear oil to the thrust bearing F [1] and install it to the propeller shaft [2]. Install the propeller shaft on the propeller shaft holder [3]. Apply gear oil to the thrust bearing (50 x 72 x 4.5 mm) [4] and install it to the propeller shaft.
  • Page 527 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) BEARING HOLDER INSTALLATION Apply gear oil to the threads and seating surface of the bearing holder [1]. Position the bearing holder on the propeller shaft. Loosely tighten the bearing holder by hand against the propeller shaft holder [2].
  • Page 528 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) With the groove [1] on the clutch shifter [2] toward the forward bevel gear, assemble the clutch shifter on the propeller shaft while aligning the shifter pin installation hole [3] with the long hole [4] in the propeller shaft. •...

  • Page 529: Installation

    dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Push the shift slider [1] into the propeller shaft [2] slowly, and set the steel balls (#7) [3] in the positions shown. • Note that the shift rod cannot be installed unless the shift slider is on the forward side. Set the shift slider on the forward side securely.
  • Page 530 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Replace the puller jaws [1] of the special tools as shown. TOOLS: Bearing race puller [2] 070PC-ZY3A101 Puller jaws, 25 mm [3] 07WPC-ZW50100 Remove the reverse bevel gear [1] using the special tools as shown. TOOLS: Bearing race puller [2] 070PC-ZY3A101...
  • Page 531 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) EXPLODED VIEW LOCK NUT Engine side 132 N·m (13.5 kgf·m, 97 lbf·ft) VERTICAL SHAFT OIL SLINGER REVERSE BEVEL GEAR GEAR CASE BEARING (55 x 100 x 21 mm) REVERSE BEVEL GEAR SHIM PINION GEAR PINION GEAR NUT (18 mm) 196 N·m (20.0 kgf·m, 145 lbf·ft) NEEDLE BEARING...

  • Page 532: Installation

    dummyhead dummyhead GEAR CASE (COUNTER ROTATION) INSTALLATION Apply gear oil to the circumference of a new ball bearing [1]. Place a wood block [2] under the reverse bevel gear [3]. Drive the ball bearing (55 x 100 x 21 mm) into the reverse bevel gear using the special tool and a hydraulic press as shown.
  • Page 533 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Wipe the tapered part [1] of the vertical shaft [2] and pinion gear [3] with a shop towel and degreasing cleaning solvent. Apply gear oil to the threads and seating surface of the pinion gear nut [4]. Install the vertical shaft and pinion gear on the gear case, then loosely tighten the pinion gear nut.

  • Page 534: Assembly

    dummyhead dummyhead GEAR CASE (COUNTER ROTATION) REVERSE BEVEL GEAR NEEDLE BEARING (28 x 39 x 30 mm) REPLACEMENT Remove the reverse bevel gear (page 17-25). Drive out the needle bearing (28 x 39 x 30 mm). Place a wood block [1] under the reverse bevel gear [2]. Apply gear oil to the outer circumference of a new needle bearing [3].

  • Page 535: Vertical Shaft Disassembly

    dummyhead dummyhead GEAR CASE (COUNTER ROTATION) VERTICAL SHAFT DISASSEMBLY/ ASSEMBLY DISASSEMBLY Remove the oil slinger [1] from the vertical shaft [2] by expanding the cut in the oil slinger with a screwdriver. Check the taper roller bearing for abnormal sound and play.
  • Page 536 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) EXPLODED VIEW TAPER ROLLER BEARING (32 x 66 x 49 mm) (INNER RACE) VERTICAL SHAFT TAPER ROLLER BEARING (32 x 66 x 49 mm) (OUTER RACE) TAPER ROLLER BEARING (32 x 66 x 49 mm) (INNER RACE) PINION GEAR SHIM OIL SLINGER ASSEMBLY...
  • Page 537 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Apply gear oil to the taper roller bearing insertion part of the vertical shaft [1]. Set the vertical shaft on the hydraulic press with the pinion gear [2] side facing up as shown. Install the taper roller bearing (32 x 66 x 49 mm) [3] on the vertical shaft using the hydraulic press.

  • Page 538: Shim Selection

    dummyhead dummyhead GEAR CASE (COUNTER ROTATION) SHIM SELECTION SHIM POSITION • Use shims to adjust the position of each gear so that they engage properly. Perform shim adjustment if the backlash of a gear is outside the specification or after replacing the gear case, vertical shaft, or bearing with a new one.
  • Page 539 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) PINION GEAR SHIM Remove the taper roller bearing (32 x 66 x 49 mm) if it is mounted on the vertical shaft [1] (page 17-31). Clean the tapered surfaces [1] of the vertical shaft [2] and pinion gear [3] thoroughly using a shop towel and degreasing cleaning agent.
  • Page 540 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Measure the height (E’’) of the taper roller bearing (outer race [1]) using a regular vernier caliper [2], and record it. Calculate the length from the inner race end to the outer race end (E) by determining the gap between the measurements E’...
  • Page 541 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Remove the gear case cover from the gear case (page 17-7). Cross reference the engagement mark [1] located on the trim tab installation part of the gear case [2] and the tolerance calculated in the previous step, and refer to the pinion gear shim selection table to determine the required thickness of the shim (Sp).
  • Page 542 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) HOW TO SELECT SHIM COMBINATION To obtain 0.90 mm (0.035 in) of shim thickness, combine one gear shim A, one gear shim C, and one gear shim D, or combine four gear shim A and one gear shim D.
  • Page 543 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Remove the gear case cover from the gear case (page 17-7). Cross reference the engagement mark [1] located on the gear case cover installation part of the gear case [2] and the tolerance, and refer to the reverse bevel gear shim selection table to determine the required thickness of the shim (Sr).

  • Page 544: Backlash Inspection

    dummyhead dummyhead GEAR CASE (COUNTER ROTATION) BACKLASH INSPECTION FORWARD BEVEL GEAR BACKLASH Backlash adjustment must be made after adjustment of each gear shim (page 17-34). Install the following parts except the water pump. – Vertical shaft/forward bevel gear (page 17-28) –...
  • Page 545 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) REVERSE BEVEL GEAR BACKLASH Backlash adjustment must be made after adjustment of each gear shim (page 17-34). Install the following parts except the water pump. – Vertical shaft/forward bevel gear (page 17-28) – Propeller shaft holder (page 17-17) –...
  • Page 546 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) GEAR CASE PRESSURE INSPECTION • Perform the gear case pressure check and check for pressure leakage after disassembling reassembling the gear case. • In principle, the pressure check should be made on the gear case before filling it with gear oil and before installing it on the outboard motor.

  • Page 547: Clutch Shifter Inspection

    dummyhead dummyhead GEAR CASE (COUNTER ROTATION) While applying the specified air pressure to the gear case, turn the vertical shaft [1] five or six turns clockwise. • Be sure to turn the vertical shaft clockwise, or damage to the water pump impeller can occur. While applying the specified air pressure to the gear case, turn the propeller shaft [1] right and left two or three turns.

  • Page 548: Propeller Shaft Inspection

    dummyhead dummyhead GEAR CASE (COUNTER ROTATION) PROPELLER SHAFT INSPECTION PROPELLER SHAFT O.D. Measure the O.D. of the propeller shaft where the bearings ride. STANDARD: At bevel gear [1]: 27.974 – 27.983 mm (1.1013 – 1.1017 in) At needle bearing [2]: 32.007 –...

  • Page 549: Vertical Shaft Bush Inspection

    dummyhead dummyhead GEAR CASE (COUNTER ROTATION) VERTICAL SHAFT RUNOUT Support each journal with V-blocks as shown. 125.5 mm 26 mm Set the dial indicator and measure the vertical shaft (4.9 in) (1.0 in) runout while turning the shaft. STANDARD: XCA type 0.35 mm (0.014 in) or below XXCA type...

  • Page 550: Extension Separator Stud Bolt

    dummyhead dummyhead GEAR CASE (COUNTER ROTATION) EXTENSION SEPARATOR STUD BOLT REPLACEMENT (XXCA type) Remove the extension separator (page 17-7). Thread two nuts onto the stud bolt (12 x 170 mm) [1] and six stud bolts (10 x 170 mm) [2], and tighten them together.
  • Page 551 dummyhead dummyhead GEAR CASE (COUNTER ROTATION) Apply gear oil to the outer circumference of a new needle bearing [1]. Install the needle bearing (30.5 x 47 x 37 mm) in the gear case [2] using the special tools, until it is fully seated.
  • Page 552 dummyhead dummyhead MEMO...
  • Page 553 dummytext 18. MOUNT COMPONENT LOCATION ··························18-2 MOUNT CASE REMOVAL/ INSTALLATION ·········································· 18-4 TOOLS·························································18-3 MOUNT CASE DISASSEMBLY/ ASSEMBLY ················································· 18-5 18-1...
  • Page 554 dummyhead dummyhead MOUNT COMPONENT LOCATION MOUNT 83 N·m (8.5 kgf·m, 61 lbf·ft) 18-2...
  • Page 555 dummyhead dummyhead MOUNT TOOLS LIST Attachment, 32 x 35 mm Attachment, 24 x 26 mm Pilot, 20 mm 07746-0010100 07746-0010700 07746-0040500 Pilot, 22 mm Pilot, 14 mm Driver 07746-0041000 07746-0041200 07749-0010000 18-3...
  • Page 556 dummyhead dummyhead MOUNT MOUNT CASE REMOVAL/ INSTALLATION Remove the engine (page 13-4). Remove the seven bolts (6 x 20 mm) [1], mount rubber cover [2] and mount rubber cover seal [3]. Hold the two bolts (12 x 200 mm) [4] and remove the two upper rubber mount nuts [5].
  • Page 557 dummyhead dummyhead MOUNT MOUNT CASE DISASSEMBLY/ ASSEMBLY DISASSEMBLY Remove the mount case (page 18-4). Remove the oil pump rubber [1] from the mount case. Remove the two water seals (22 x 35 x 7 mm) [2] from the mount case. Remove the three bolts (10 x 32 mm) [1], three washers (10 mm) [2], and mount rubber holder [3].
  • Page 558 dummyhead dummyhead MOUNT Remove the C-ring [1], E-ring [2], washer (14 mm) [3], water seal (14 x 26 x 8 mm) [4], and shift shaft A [5] from the mount case [6]. Remove the needle bearing (20 x 28 x 13 mm) [1] from the mount case.
  • Page 559 dummyhead dummyhead MOUNT EXPLODED VIEW BOLT (10 x 32 mm) (3) OIL PUMP RUBBER WASHER (10 mm) (3) WATER SEAL (22 x 35 x 7 mm) (2) MOUNT RUBBER HOLDER SHIFT SHAFT A MOUNT RUBBER (2) INNER RING RUBBER SPACER (2) NEEDLE BEARING (20 x 28 x 13 mm) UPPER MOUNT STOPPER...
  • Page 560 dummyhead dummyhead MOUNT ASSEMBLY Apply marine grease lips outer <WATER SEAL circumference of a new shift shaft A water seal [1]. INSTALLATION DIRECTION> Turn the mount case over and install the shift shaft A water seal into the mount case using the special tools as shown, noting the installation direction.
  • Page 561 dummyhead dummyhead MOUNT Apply marine grease to the water seal contact surface and spline of the shift shaft A [1]. Install the washer (14 mm) [2], E-ring [3], C-ring [4], and shift shaft A to the mount case [5]. Install the under cover seal A [1], two mount rubbers [2], two rubber spacers [3], two upper mount stopper washers [4], and two bolts (12 x 200 mm) [5] into the mount case.
  • Page 562 dummyhead dummyhead MOUNT Apply engine oil to a new oil pump rubber [1]. Install the oil pump rubber to the mount case. Note the installation direction of the oil pump rubber. Install the mount case (page 18-4). 18-10...

  • Page 563: Trim/Tilt

    dummytext 19. TRIM/TILT COMPONENT LOCATION ··························19-2 POWER TRIM/TILT DISASSEMBLY/ ASSEMBLY ··············································· 19-19 ATF LINE DESCRIPTION ···························19-3 POWER TILT MOTOR DISASSEMBLY/ ASSEMBLY ··············································· 19-36 TOOLS·························································19-5 POWER TILT MOTOR INSPECTION ······· 19-41 POWER TRIM/TILT/SWIVEL CASE REMOVAL/ INSTALLATION···········································19-6 POWER TILT SWITCH INSPECTION ······ 19-43 SWIVEL CASE/MOUNT FRAME DISASSEMBLY/ASSEMBLY ····················19-11 19-1...
  • Page 564 dummyhead dummyhead TRIM/TILT COMPONENT LOCATION TRIM/TILT 34 N·m (3.5 kgf·m, 25 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 19-2...

  • Page 565: Atf Line Description

    dummyhead dummyhead TRIM/TILT ATF LINE DESCRIPTION Trim/tilt up: DOWN RELIEF VALVE PISTON ROD A POWER TILT MOTOR PUMP Discharge Charge LOWER CHAMBER SPOOL VALVE OIL TANK PISTON ROD B MANUAL VALVE LOWER CHAMBER CHECK VALVE UPPER CHAMBER SPOOL VALVE UPPER CHAMBER CHECK VALVE 19-3...
  • Page 566 dummyhead dummyhead TRIM/TILT Trim/tilt down: DOWN RELIEF VALVE POWER TILT MOTOR PISTON ROD A PUMP Discharge Charge LOWER CHAMBER SPOOL VALVE OIL TANK MANUAL PISTON ROD B VALVE LOWER CHAMBER CHECK VALVE UPPER CHAMBER SPOOL VALVE UPPER CHAMBER CHECK VALVE 19-4...
  • Page 567 dummyhead dummyhead TRIM/TILT TOOLS LIST Lower mount puller adapter Pressure gauge, 0 – 5,000 psi Pin wrench, 6 mm 07APB-ZY3A200 07KPJ-VD6020B 07SPA-ZW1010A Pin wrench, 4 mm Attachment, 30 x 37 mm Attachment, 50 mm 07SPA-ZW1020A 070PD-ZY6A200 07APF-ZY3A100 Puller adapter Assembly shaft Oil pressure gauge joint A 07APF-ZY3A200 07APF-ZY3A300...
  • Page 568 dummyhead dummyhead TRIM/TILT POWER TRIM/TILT/SWIVEL CASE REMOVAL/INSTALLATION REMOVAL Remove the mount case (page 18-4) and swivel case/ stern bracket from the boat. Loosen the manual valve [1] fully and set the swivel case to the uppermost position. After raising the swivel case to the uppermost position, secure it in the position with the tilt stopper and tighten the manual valve to the specified torque.
  • Page 569 dummyhead dummyhead TRIM/TILT Remove the self-locking nut (25 x 2.0 mm) [1], washer (25 mm) [2], self-locking nut (7/8-14 UNF) [3], washer (7/8 in) [4], and tilting shaft [5]. Remove the self-locking nut (10 mm) [6], washer (10 mm) [7], and bolt (10 x 235 mm) [8]. [10] Remove the R.
  • Page 570 dummyhead dummyhead TRIM/TILT Store the power trim/tilt assembly [1] vertically with the upper cylinder bushing section [2] facing up after Storage removal. Never store the power trim/tilt with the motor position: facing up or with the lower cylinder bushing section [3] facing up.
  • Page 571 dummyhead dummyhead TRIM/TILT INSTALLATION Apply marine grease to the upper cylinder bushings [1] inner and outer surfaces, upper cylinder pin [2] outer surface. Install the two upper cylinder bushings to the power trim/tilt piston rod A [3]. install the power trim/tilt piston rod A to the swivel case [4].
  • Page 572 dummyhead dummyhead TRIM/TILT Apply marine grease to the swivel case bushings [1] inner and outer surfaces, wave washer (26 mm) [2], tilting shaft [3] bearing part and threads and swivel case [13] [14] [4] tilting shaft sliding part. Install the two swivel case bushings, two wave washers (26 mm), and tilting shaft to the swivel case.

  • Page 573: Swivel Case/Mount Frame Disassembly/Assembly

    dummyhead dummyhead TRIM/TILT Install the anode [1], ground terminal [2] and two bolts (6 x 23 mm) [4]. If the manual valve [1] is tightened, loosen it fully. Raise the swivel case a little, unlock the tilt stopper, and lower the swivel case to the lowermost position. TORQUE: 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) Install the swivel case/stern bracket to the boat.
  • Page 574 dummyhead dummyhead TRIM/TILT Mark the mount frame [1] so that punch mark [2] aligns with the " " mark [3] on the lower mount center housing [4]. Pull the lower mount center housing from the mount frame using an 8-inch 2-jaw puller (commercially available) [5] and special tools.
  • Page 575 dummyhead dummyhead TRIM/TILT Remove the mount frame [1] from the swivel case [2]. Remove the wave washer (40 mm) [3], oil seal (39.5 x 52 x 6 mm) [4], two swivel case liners [5], and thrust washer (34 mm) [6] from the swivel case. Remove the six grease fittings [1] from the swivel case.
  • Page 576 dummyhead dummyhead TRIM/TILT Remove the spring pins using a commercially available pin punch [1]. Remove the two tilt stoppers [1], two tilt arm bushings [2] and the tilting bracket [3]. Check the tilt arm bushing for wear and damage. Replace if necessary. Remove the bolt (6 x 14 mm) [4], click spring [5] and assist spring [6].
  • Page 577 dummyhead dummyhead TRIM/TILT EXPLODED VIEW TILT ARM BUSHING ([2) THRUST RECEIVER BUSHING B (2) TILT STOPPER (2) MOUNT FRAME GREASE FITTING [6] 3.0 N·m (0.31 kgf·m, 2.2 lbf·ft) SWIVEL CASE SPRING PIN (3.0 x 20 mm) (2) TILTING BRACKET WASHER (12 mm) (2) BOLT (6 x 14 mm) CLICK...
  • Page 578 dummyhead dummyhead TRIM/TILT ASSEMBLY Install the assist spring [1], click spring [2], and bolt (6 x 14 mm) [3], and tighten it. Apply marine grease to the click spring roller. Apply marine grease to the tilt stopper [4] shaft, tilt arm bushing [5] inner and outer surface and tilting bracket [6] cam part.
  • Page 579 dummyhead dummyhead TRIM/TILT Apply marine grease to the circumference of the swivel case liner [1], swivel case [2] thrust receiver part and shaft sliding part. Install the swivel case liner by aligning the projection [3] on the swivel case liner with the groove [4] in the swivel case.
  • Page 580 dummyhead dummyhead TRIM/TILT Install the lower mount center housing [1] on the mount frame using the special tools as shown. TOOLS: Attachment, 30 x 37 mm [2] 070PD-ZY6A200 Assembly shaft [3] 07APF-ZY3A300 Attachment, 50 mm [4] 07APF-ZY3A100 To ease assembly, apply grease or lubricating oil to the threads, nuts and washers of the threaded rods before drawing the parts together.

  • Page 581: Power Trim/Tilt Disassembly

    dummyhead dummyhead TRIM/TILT Position the ground cable [1] against the stopper [2] of the lower mount center housing [3], and then install and tighten the screw (6 x 8 mm) [4]. Install the swivel case (page 19-9). POWER TRIM/TILT DISASSEMBLY/ ASSEMBLY DISASSEMBLY •...
  • Page 582 dummyhead dummyhead TRIM/TILT Remove the three oil tank mounting bolt/washers (6 x 8 mm) [1] and oil tank [2] from the cylinder. Remove the O-ring [3] from the cylinder. Drain the residual ATF in the oil tank. Remove the four power tilt motor mounting bolt/ washers (6 x 34 mm) [1] and power tilt motor [2] from the pump.
  • Page 583 dummyhead dummyhead TRIM/TILT Remove socket bolts A (8 x 84 mm) [1], two socket bolts B (8 x 23 mm) [2], and the pump [3]. Remove the five O-rings [4] and orifice collar [5] from the cylinder. Remove the reservoir valve [6], pin [7], and steel ball [8] from the cylinder.
  • Page 584 dummyhead dummyhead TRIM/TILT Remove the rod guide [1] and piston rod B [2] from the trim cylinder slowly. Remove the rod guide from piston rod B. Drain the ATF from the trim cylinders. Remove the O-ring [1] and backup ring [2] from piston rod B [3].
  • Page 585 dummyhead dummyhead TRIM/TILT Hold the cylinder with a vise (page 19-21). Make sure that the piston rod A [1] is in the fully extended position. Set the special tool on the cylinder cap [2] as shown, and remove the piston rod A. TOOL: Pin wrench, 6 mm [3] 07SPA-ZW1010A...
  • Page 586 dummyhead dummyhead TRIM/TILT EXPLODED VIEW PISTON ROD A CYLINDER CAP 208 N·m (21.2 kgf·m, 153 lbf·ft) POWER TILT MOTOR FREE PISTON BACKUP RING POWER TILT MOTOR MOUNTING BOLT/WASHER (4) O-RING (2) 4.9 N·m (0.50 kgf·m, 3.6 lbf·ft) O-RING OIL TANK MOUNTING BOLT/ WASHER (6 x 8 mm) (3) 4.9 N·m (0.50 kgf·m, 3.6 lbf·ft) OIL TANK CAP...
  • Page 587 dummyhead dummyhead TRIM/TILT ASSEMBLY • Do not reuse O-rings and oil seals. • Do not use a shop towel or equivalent cloth, and do not wear gloves during this operation. • Do not reuse the drained ATF. • When operation is made by holding the cylinder in a vise, do not tighten the vise excessively.
  • Page 588 dummyhead dummyhead TRIM/TILT Apply ATF to a new O-ring [1] and Install it on the bottom (i.e. nut side) of the piston rod A [2]. Apply ATF to a new O-ring [1] and Install it on the cylinder cap [3] of the piston rod A. With the piston rod A fully extended, install the piston rod A slowly in the piston rod chamber of the cylinder [4].
  • Page 589 dummyhead dummyhead TRIM/TILT Apply ATF to a new oil seal [1]. Holding the oil seal in the shape of a "U" with your fingers, install it in the lower groove in the rod guide [2], taking care not to damage the oil seal. Apply ATF to a new dust seal [3].
  • Page 590 dummyhead dummyhead TRIM/TILT Using the special tool, tighten the left and right rod guides [1] to the specified torque. TOOL: Pin wrench, 4 mm [2] 07SPA-ZW1020A TORQUE: 140 N·m (14.3 kgf·m, 103 lbf·ft) Apply ATF to the manual valve O-rings [1]. Install the manual valve [2] to the pump [3] and tighten it to the specified torque.
  • Page 591 dummyhead dummyhead TRIM/TILT Install the filter B [1] and drive joint [2] on the pump [3]. After installation, check filter B for bubbles. Remove the bubbles with the oil bottle [1] or an equivalent tool if necessary. Be sure to remove the air bubbles, or it will cause air in the system.
  • Page 592 dummyhead dummyhead TRIM/TILT Install the power tilt motor [1] on the pump by aligning the projection [2] on the motor with the cutout in the drive joint [3]. Set the motor wire of the power tilt motor facing toward the manual valve side. Tighten the four power tilt motor mounting bolt/washers [4] to the specified torque.

  • Page 593: Air Bleeding

    dummyhead dummyhead TRIM/TILT AIR BLEEDING • Bleed air from the unit whenever the power trim/tilt is assembled. • Perform the following procedure to bleed air: 1. Bleed air without mounting the unit on the outboard motor. 2. Check hydraulic pressure (page 19-33). 3.
  • Page 594 dummyhead dummyhead TRIM/TILT 7. With the rods extended fully, operate the power tilt motor to extend the each rod until relief valve opens again. Operate the power tilt motor to compress the each rod and be sure that the rods compress (page 19-31).
  • Page 595 dummyhead dummyhead TRIM/TILT 4. Lower the outboard motor slowly to the lowermost position by loosening the manual valve [1]. 5. Tighten the manual valve to the specified torque. TORQUE: 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) 6. Hold the outboard motor in the lowermost position for five minutes.
  • Page 596 dummyhead dummyhead TRIM/TILT Remove the oil tank cap [1] and check wether the ATF is at the upper limit of the filler port [2]. Operate the power tilt motor to compress the each rod (page 19-31) fully. Operate the power tilt motor to extend the each rod (page 19-31) fully again, and read the pressure gauge to measure the lower chamber hydraulic pressure.
  • Page 597 dummyhead dummyhead TRIM/TILT Remove the oil tank cap [1] and check wether the ATF is at the upper limit of the filler port [2]. Operate the power tilt motor to compress the each rod (page 19-31) fully, and read the pressure gauge to measure the upper chamber hydraulic pressure.

  • Page 598: Power Tilt Motor Disassembly

    dummyhead dummyhead TRIM/TILT POWER TILT MOTOR DISASSEMBLY/ ASSEMBLY DISASSEMBLY Untape the corrugated teflon tube [1], and pull the tube to the opposite side of the wire holder. Remove the wire holder screw (stainless steel screw: 4 x 16 mm) [2]. Pull out the wire holder [3] and the two grommets [4] from the yoke [5], and move them to the tube side.
  • Page 599 dummyhead dummyhead TRIM/TILT Pull the brushes [1] from the brush holders and remove the two brush springs [2]. Disconnect the motor wire (Blue wire) terminal [3] from the breaker [4] while holding the breaker with a screwdriver. • Do not disconnect the Blue wire terminal without holding the breaker, or it can cause damage to the breaker.
  • Page 600 dummyhead dummyhead TRIM/TILT EXPLODED VIEW WIRE HOLDER SCREW (STAINLESS STEEL: 4 x 16 mm) 1.4 N·m (0.14 kgf·m, 1.0 lbf·ft) YOKE ARMATURE BLUE WIRE SCREW (4 x 10 mm) (2) GREEN WIRE BRUSH HOLDER B BRUSH HOLDER A BREAKER Do not touch the bimetal part. BRUSH BRUSH SPRING (2) O-RING...
  • Page 601 dummyhead dummyhead TRIM/TILT ASSEMBLY Apply grease to the oil seal lips. Apply grease to a new O-ring [1] and install it to the front bracket groove [2]. Set the brush holder A [3] and brush terminal [4] above the motor wire (Green wire) terminal [5] and loosely [11] tighten the screw (4 x 10 mm) [6].
  • Page 602 dummyhead dummyhead TRIM/TILT Make sure that there is no washer, etc. on the magnet in the yoke [1]. Wrap the armature shaft [2] with a shop towel [3] or equivalent material, and hold the shaft with pliers [4]. Pulling the two motor wires [5] of the yoke side slowly, install the armature/front bracket [6] on the yoke.

  • Page 603: Power Tilt Motor Inspection

    dummyhead dummyhead TRIM/TILT POWER TILT MOTOR INSPECTION OPERATION INSPECTION Connect the battery [1] to the power tilt motor 2P connector terminals [2] and check that the motor turns. Connect the battery in reverse and check that the motor turns in the opposite direction. Connect the battery, being very careful not to cause a short-circuit.
  • Page 604 dummyhead dummyhead TRIM/TILT MICA DEPTH Check the grooves of the commutator and measure the mica depth [1]. SERVICE LIMIT: 0.50 mm (0.020 in) If the grooves are clogged or mica depth is less than the service limit, recut the grooves using a hacksaw blade or a small file.

  • Page 605: Power Tilt Switch Inspection

    dummyhead dummyhead TRIM/TILT Place the armature on an armature tester (commercially available.) Hold a hacksaw blade close to the armature core. If the blade is attracted to the core or vibrates when the core is turned, the armature is shorted. Replace the armature.
  • Page 606 dummyhead dummyhead MEMO...

  • Page 607: Controls

    dummytext 20. CONTROLS COMPONENT LOCATION ··························20-2 SHIFT ARM/LINK ROD REMOVAL/ INSTALLATION ·········································· 20-9 SHIFT CONTROL CABLE REMOVAL/ INSTALLATION···········································20-3 SHIFT CONTROL CABLE INSPECTION/ ADJUSTMENT ·········································· 20-10 THROTTLE CONTROL CABLE REMOVAL/ INSTALLATION···········································20-6 SHIFT SHAFT ALIGNMENT ····················· 20-12 THROTTLE ARM/SHIFT LINK BRACKET REMOVAL/INSTALLATION························20-7 20-1...
  • Page 608 dummyhead dummyhead CONTROLS COMPONENT LOCATION CONTROLS 20-2...
  • Page 609 dummyhead dummyhead CONTROLS SHIFT CONTROL CABLE REMOVAL/ INSTALLATION REMOVAL Remove the front separate cover (page 6-3). Slide the lock plate [1] backward and remove the shift control cable [2] from the link rod [3]. INSTALLATION • Before installing the cable to the outboard motor, check the following.
  • Page 610 dummyhead dummyhead CONTROLS 4. Move the remote control lever fully to the "R" (Reverse) side [1]. Return the lever to the "N" (Neutral) position [2] slowly. 5. With the lever returned to the "N" (Neutral) position, mark a mark on the cable outer seal end of the inner cable (Mark (B) [3]).
  • Page 611 dummyhead dummyhead CONTROLS 9. With the shift control cable [1] in the condition described in step 7, connect the shift control cable to the link rod [2] while loosen the adjusting nut [3] and turning the shift pivot [4] so the shift pivot sets on the link rod smoothly.

  • Page 612: Throttle Control Cable

    dummyhead dummyhead CONTROLS THROTTLE CONTROL CABLE REMOVAL/INSTALLATION REMOVAL Remove the front separate cover (page 6-3). Slide the lock plate [1] backward and remove throttle control cable [2] from the throttle arm [3]. INSTALLATION Before installing the cable to the outboard motor, check that the cable is connected to the remote control box side properly.
  • Page 613 dummyhead dummyhead CONTROLS THROTTLE ARM/SHIFT LINK BRACKET REMOVAL/INSTALLATION REMOVAL Remove the following: – R. engine under cover (page 6-3) – Shift control cable (page 20-3) – Throttle control cable (page 20-6) Disconnect the throttle cables [1]. Remove the bolt (6 x 12 mm) [2], washer (6 mm) [3], and throttle arm [4].
  • Page 614 dummyhead dummyhead CONTROLS INSTALLATION Apply marine grease to the link rod insertion part and throttle arm insertion part of the shift link bracket [1]. Install the tube clamp [2] to the shift link bracket. Install the shift link bracket by aligning the groove [3] of the shift link bracket with the link rod [4], and then install and tighten the three bolt/washers (6 x 12 mm) [5].
  • Page 615 dummyhead dummyhead CONTROLS SHIFT ARM/LINK ROD REMOVAL/ INSTALLATION REMOVAL Move the remote control lever to the "N" (Neutral) position. Remove the following: – Electric parts case (page 10-4) – Shift control cable (page 20-3) Remove the bolt (6 X 14 mm) [1], click spring [2], and assist spring [3] Remove the snap pin [4] and washer (6 mm) [5] from the shift arm [6].
  • Page 616 dummyhead dummyhead CONTROLS INSTALLATION Apply marine grease to the click spring roller. Install the assist spring [1] and click spring [2] to the crankcase. Loosely tighten the bolt (6 x 14 mm) [3]. After adjusting the shift control cable, tighten the bolt. Apply marine grease to the link rod insertion part and click part of the shift arm.
  • Page 617 dummyhead dummyhead CONTROLS Move the link rod [1] forward [2] lightly until it stops at the end of the freeplay; mark indicator A [3] on the shift link bracket [4] as shown. Move the link rod until it stops at the end of the freeplay; mark indicator B [5] on the shift link bracket as shown.
  • Page 618 dummyhead dummyhead CONTROLS SHIFT SHAFT ALIGNMENT When shift shafts A and B are not properly aligned, it may be possible to start the engine in either forward or reverse gear. Always make sure the shafts are properly aligned. After reassembly and before starting the engine: •...
  • Page 619 dummyhead dummyhead CONTROLS Verify the gear case is in the neutral position by rotating the propeller shaft [1] by hand and checking for free, quiet rotation. Use gloves to protect your hands. If the gear case is not in the neutral position, temporarily lower shift shaft B [2] until it engages with shift shaft A.
  • Page 620 dummyhead dummyhead CONTROLS Apply marine grease to the seal holder [1] O-ring groove and bearing part. Install a new O-ring [2] to the seal holder and apply marine grease to it. Install the seal holder on shift shaft B [3] so that shift shaft B does not tilt on the mount case.

  • Page 621: Technical Features

    dummytext 21. TECHNICAL FEATURES SHIFT EFFORT REDUCTION SYSTEM ·····21-2 CHARGE OUTPUT ENHANCEMENT WHEN IDLING························································· 21-4 21-1...
  • Page 622 dummyhead dummyhead TECHNICAL FEATURES SHIFT EFFORT REDUCTION SYSTEM TECHNICAL FEATURES GENERAL The effort when shifting the control lever (throttle valve) from the half-open position to the neutral is reduced by retarding the ignition timing by the ECM. The ECM starts computation to retard the ignition timing to reduce shift effort when the engine speed is above the prescribed level, Executes shift effort the throttle is fully closed, and the gear is engaged.
  • Page 623 dummyhead dummyhead TECHNICAL FEATURES The crankshaft speed variations are transmitted to the clutch shifter dog, which is in mesh with the forward/reverse bevel gear, via the vertical shaft and the pinion gear. The torque variations occurring in the clutch shifter dog reduce the shift effort. From CRANKSHAFT SHAFT ROD VERTICAL SHAFT...
  • Page 624 dummyhead dummyhead TECHNICAL FEATURES CHARGE OUTPUT ENHANCEMENT WHEN IDLING GENERAL Detecting electrical loads in the outboard motor when idling, the engine idle speed is enhanced when the electrical loads are high to increase charging capacity to allow for use of more electrical power in the outboard motor. (Only when in neutral) CONSTRUCTION AND FEATURES The ECM detects ACGF output (ACGF load condition output) from the alternator and computes current electrical loads in the outboard motor.

  • Page 625: Wiring Diagrams

    dummytext 22. WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & SYSTEM WIRING DIAGRAM ····················· 22-6 RELATED INFORMATION··························22-2 CONNECTOR GENERAL LAYOUT WIRING DIAGRAM······································22-5 DRAWING ··················································· 22-7 22-1...
  • Page 626 dummyhead dummyhead WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION WIRING DIAGRAMS The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained in this section. HOW TO READ CONNECTOR DRAWINGS Connector drawings show the terminal arrangement, terminal No., number of pins, and the shape of terminal (male or female).
  • Page 627 dummyhead dummyhead WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM SYMBOL OF TERMINAL It shows the shape of each terminal to identify whether it is a male or female terminal. TERMINAL No. TP SENSOR MAP SENSOR W/Bl W/Bl No. 3 No.
  • Page 628 dummyhead dummyhead WIRING DIAGRAMS 22-4...
  • Page 629 WIRING DIAGRAM WIRING DIAGRAMS DIRECT IGNITION DIRECT IGNITION DIRECT IGNITION OPTION TACHOMETER TRIM METER FUEL FUEL FUEL VOLT HOUR COIL 2 COIL 6 COIL 4 INJECTOR 1 INJECTOR 3 INJECTOR 5 METER METER FUEL FUEL FUEL INJECTOR 2 INJECTOR 4 INJECTOR 6 DIRECT IGNITION DIRECT IGNITION...
  • Page 630 SYSTEM WIRING DIAGRAM No.4 (30A) FUSE/RELAY JUNCTION BOX No.11 (15A) No.8 (10A) AIR VENT STRAINER COMBINATION SWITCH No.9 (15A) MAIN RELAY No.10 (10A) FUEL STRAINER LOAD (High pressure side) No.5 (10A) FUEL PUMP RELAY FUEL PUMP (High pressure side) IGP1 BATTERY IGP2 FLR1...
  • Page 631 CONNECTOR GENERAL LAYOUT DRAWING Terminal Wire color ALTERNATOR B TERMINAL number Terminal Wire color number Power tilt W/Bl switch side VTEC SOLENOID VALVE 1P CONNECTOR Main wire harness side Terminal Wire color number Terminal Wire color Terminal Wire color Terminal Wire color Terminal Wire color...
  • Page 632 POWER TILT RELAY 2P CONNECTOR IAT SENSOR 2P CONNECTOR Terminal Wire color Terminal Wire color Terminal Wire color number number POWER TILT RELAY 1P CONNECTOR number HO2S 4P CONNECTOR Main wire Main wire harness side MAP SENSOR 3P CONNECTOR harness side Power tilt relay cable side POWER TILT MOTOR 2P CONNECTOR...
  • Page 633 MAIN WIRE HARNESS Terminal Wire color Terminal Wire color Terminal Wire color STARTER CABLE 1 (+) TERMINAL number number number W/Bl – GND1 Bl/Y POWER TILT RELAY WIRE TERMINAL Y/Bl G/Bl Y/Bl GND2 W/Bl ACG CABLE TERMINAL Y/Bu Bu/R GND3 Main wire Y/Bl G/Bl...
  • Page 634 Terminal Wire color Terminal Wire color number Terminal Wire color number number Y/Bl No.4 FUEL INJECTOR 2P CONNECTOR Y/Bl Main wire Main wire Main wire harness side harness side harness side No.1 FUEL INJECTOR 2P CONNECTOR No.5 FUEL INJECTOR 2P CONNECTOR No.2 FUEL INJECTOR 2P CONNECTOR Terminal Wire color...
  • Page 635 INDEX dummytext INDEX AIR VENT STRAINER/AIR VENT TUBE REMOVAL/ DIMENSIONAL DRAWING············································· 1-4 INSTALLATION·····························································5-92 DTC TROUBLESHOOTING ········································· 5-15 ALERT SYSTEM/WARNING SYSTEM EBT SENSOR REMOVAL/INSTALLATION ··············· 5-105 TROUBLESHOOTING ··················································4-18 EBT/EMT SENSOR INSPECTION ····························· 5-122 ALTERNATOR BELT INSPECTION ·······························3-9 ECM BRACKET REMOVAL/INSTALLATION··············· 10-5 ALTERNATOR DISASSEMBLY/ASSEMBLY ·················7-6 ECM REMOVAL/INSTALLATION·································...
  • Page 636 dummytext INDEX FUSE RELAY JUNCTION BOX REMOVAL/ POWER TILT SWITCH INSPECTION························ 19-43 INSTALLATION ···························································· 10-3 POWER TILT SWITCH REMOVAL/INSTALLATION···· 6-10 FUSE/ELECTRIC POWER LINE POWER TRIM/TILT DISASSEMBLY/ASSEMBLY ····· 19-19 TROUBLESHOOTING ················································· 4-15 POWER TRIM/TILT INSPECTION ······························· 3-33 FUSE/RELAY JUNCTION BOX INSPECTION ·········· 10-12 POWER TRIM/TILT/SWIVEL CASE REMOVAL/ GEAR CASE NEEDLE BEARING REPLACEMENT INSTALLATION ····························································...
  • Page 637 dummytext INDEX FUEL SYSTEM···························································5-9 UNDER COVER SEAL B REPLACEMENT·················· 6-16 IGNITION SYSTEM ····················································8-2 VALVE CLEARANCE ··················································· 3-15 OTHER ELECTRICAL ··············································10-2 VALVE GUIDE REPLACEMENT································ 14-42 STARTING SYSTEM··················································9-2 VALVE SEAT RECONDITIONING ····························· 14-44 SYSTEM WIRING DIAGRAM ·······································22-6 VAPOR SEPARATOR DISASSEMBLY/ THERMOSTAT INSPECTION ····································11-19 ASSEMBLY ································································...
  • Page 638 Copyright © 2014 Tohatsu Corporation. All rights reserved. No part of this manual may be reproduced or transmitted in any form or by any means without the express written permission of Tohatsu Corporation.
  • Page 639 BFT 250A OB No.61ZX210 14-01 NB Printed in Japan...

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