Page 1 BFT 75A BFT 90A BFT 75A BFT 90A OB No.62ZY950US OB No.62ZY950US 14-01 NB 14-01 NB Printed in Japan BFT75-90AUS_Cover_140207.indd 1 14/02/07 10:56...
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 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 4: Table Of Contents
dummyhead dummyhead CONTENTS SPECIFICATIONS SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING FUEL SYSTEM ENGINE COVER CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM OTHER ELECTRICAL COOLING SYSTEM LUBRICATION SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD CYLINDER BLOCK GEAR CASE MOUNT TRIM/TILT CONTROLS TECHNICAL FEATURES WIRING DIAGRAMS INDEX...
Page 5: Specifications
dummyhead dummyhead How to use this manual INTRODUCTION This manual covers the service and repair procedures for the Honda BF75DK3/BF80A/BF90DK4/BF100A outboard motors. 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 6 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 7 dummyhead dummyhead How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbreviated term Full term Ambient Air Temperature Alternator American Petroleum Institute Assy. Assembly ATDC After Top Dead Center Automatic Transmission Fluid Attachment Battery...
Page 8 dummyhead dummyhead How to use this manual HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION 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 9 dummyhead dummyhead How to use this manual 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. CONNECTOR/TERMINAL No. Indicates the ground. Every connector and terminal has a number to help the users find the location and shape of (Circled GND followed with No.
Page 10 dummytext 1. SPECIFICATIONS SERIAL NUMBER LOCATION ················· 1-2 DIMENSIONAL DRAWING ······················ 1-7 SPECIFICATIONS·································· 1-2...
Page 11 dummyhead dummyhead SPECIFICATIONS SERIAL NUMBER LOCATION SPECIFICATIONS The engine serial number is stamped on the right side of cylinder block 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 12 dummyhead dummyhead SPECIFICATIONS Model BF90DK4 Description code BBCJ Type LHTD LRTL LRTD XRTL XRTD Overall length 904 mm 746 mm (35.6 in) (29.4 in) Overall width 646 mm 449 mm (25.4 in) (17.7 in) Overall height 1,566 mm 1,693 mm (61.7 in) (66.7 in) Dry weight (*1)
Page 13 dummyhead dummyhead SPECIFICATIONS FRAME Model BF75DK3 BF80A Type LHGX LRTA LRTC LRTX LHTD LRTL LRTD XRTL Transom height (*1) 537 mm 664 mm (21.1 in) (26.1 in) Tilting angle (*1) 68° Tilting stage Stageless Trim angle (*1) – 4° to 16° Swivel angle 30°...
Page 14 dummyhead dummyhead SPECIFICATIONS Model BF100A Type LHTD LRTL LRTD XRTL XRTD Transom height (*1) 537 mm 664 mm (21.1 in) (26.1 in) Tilting angle (*1) 68° Tilting stage Stageless Trim angle (*1) – 4° to 16° Swivel angle 30° right and left Shaft length type Remote control box Long tiller handle...
Page 15: Lower Unit
dummyhead dummyhead SPECIFICATIONS LRTA/XRTA/LRTC/XRTC type Model BF75DK3 BF80A BF90DK4 BF100A Description code BEBAJ BEBLJ BEBCJ BEBMJ Type 4-stroke, S.O.H.C., 4 cylinder Displacement 1,496 cm (91.3 cu in) Bore x stroke 73.0 x 89.4 mm (2.87 x 3.52 in) Rated power 55.2 kW (75 PS) 58.8 kW (80 PS) 66.2 kW (90 PS)
Page 16 dummyhead dummyhead SPECIFICATIONS DIMENSIONAL DRAWING REMOTE CONTROL TYPE Unit: mm (in) 746 (29.4) 449 (17.7) 76.2 (3.0) 48.4 (1.91) 12°...
Page 17 dummyhead dummyhead SPECIFICATIONS LONG TILLER HANDLE TYPE Unit: mm (in) 1,407 (55.4) 904 (35.6) 153 (6.0) 746 (29.4) 449 (17.7) 76.2 (3.0) 12°...
Page 18 dummyhead dummyhead SPECIFICATIONS Propeller shaft Ø4 (Ø0.2) 7 mm (0.3 in) 57.5 ± 0.5 mm 28.5 mm 60 mm (1.12 in) (2.26 ± 0.02 in) (2.36 in) 154.5 mm (6.1 in)
Page 19 dummyhead dummyhead MEMO...
Page 20: Service Information
dummytext 2. SERVICE INFORMATION MAINTENANCE STANDARDS ················· 2-2 TOOLS ·············································· 2-12 ENGINE & FRAME TORQUE VALUES ······ 2-4 CABLE/HARNESS ROUTING ················ 2-18 STANDARD TORQUE VALUES ··············· 2-7 TUBE ROUTING ·································· 2-43 LUBRICATION & SEAL POINT ················ 2-8...
Page 21: Maintenance
dummyhead dummyhead SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION ENGINE Unit: mm (in) Part Item Standard Service limit Engine Idle speed (in neutral) 750 ± 50 min (rpm) – Trolling speed 650 – 1,000 min (rpm) – Cylinder compression 1.45 – 1.65 MPa 0.93 MPa (14.8 –...
Page 22 dummyhead dummyhead SERVICE INFORMATION Unit: mm (in) Part Item Standard Service limit Connecting Small end I.D. 17.964 – 17.977 (0.7072 – 0.7078) – rods Small end-to-piston pin clearance 0.019 – 0.036 (0.0007 – 0.0014) – Big end axial clearance 0.15 – 0.35 (0.006 – 0.014) 0.40 (0.016) Connecting rod big end oil clearance 0.020 –...
Page 23 dummyhead dummyhead SERVICE INFORMATION FRAME Unit: mm (in) Part Item Standard Service limit Propeller shaft Shaft O.D. At forward bevel gear 24.987 – 25.000 (0.9837 – 0.9843) 24.966 (0.9829) bearing At needle 30.007 – 30.020 (1.1814 – 1.1819) 29.986 (1.1805) bearing Runout 0.02 (0.001) or below...
Page 24 dummyhead dummyhead SERVICE INFORMATION Thread Dia. and pitch Torque values Item Remarks mm (in) N·m kgf·m lbf·ft Flywheel bolt M12 x 1.0 10.5 Apply engine oil to the threads and seating surface. Alternator rotor bolt M14 x 1.5 – – –...
Page 25 dummyhead dummyhead SERVICE INFORMATION STERN BRACKET Thread Dia. and pitch Torque values Item Remarks mm (in) N·m kgf·m lbf·ft Stern bracket self lock nut M25 x 2.0 Stern bracket self lock nut 7/18-14UNF Grease fitting M6 x 1.0 0.31 POWER TRIM/TILT (Except LHGX type) Thread Dia.
Page 26: 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 0.26 Starter motor B terminal nut M8 x 1.25 PGM-FI/Main relay bolt M6 x 1.0 0.51 Connector bracket C bolt M6 x 1.0 0.51...
Page 27 dummyhead dummyhead SERVICE INFORMATION LUBRICATION & SEAL POINT ENGINE Material Location Remarks Engine oil Crankcase mount bolt threads and seating surface Oil filter holder threads (Cylinder block side) Cylinder head bolt threads and seating surface Alternator rotor bolt threads and seating surface Connecting rod bolt threads and seating surface Lost motion whole surface (BF90D/BF100A only) Locker shaft bolt threads and seating surface...
Page 28 dummyhead dummyhead SERVICE INFORMATION FRAME GEAR CASE Material Location Remarks Use marine grease Vertical shaft engine side spline (water resistant urea based Vertical shaft water seal (23 x 36 x 6 mm) lip and between grease) seals Vertical shaft bushing inner surface (XRT type) Water pump liner inner surface Water pump O-ring Water pump housing O-ring...
Page 29 dummyhead dummyhead SERVICE INFORMATION LINKAGE Material Location Remarks Use marine grease Shift rod A spline (water resistant urea based Shift shaft A oil seal (14 x 26 x 6 mm) lip grease) Shift shaft A oil seal contact surface and bearing part Shift shaft B water seal contact surface and bearing part O-ring (27 x 2 mm) Seal holder O-ring groove and bearing part and water seal...
Page 30 dummyhead dummyhead SERVICE INFORMATION TILLER HANDLE Material Location Remarks Use marine grease Steering friction rod seating area (water resistant urea based Tiller handle shift frame side and upper surface grease) Throttle rod sliding surface Tiller handle shift arm pin spring outer surface Shift arm pin outer surface Shift gear bushing outer surface Shift gear teeth and roller contact area and steel ball...
Page 31: 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 32 dummyhead dummyhead SERVICE INFORMATION Threaded shaft SCS short connector Bearing driver attachment, 30 X 37 mm 07APF-ZY3A300 070PZ-ZY30100 070PD-ZY6A200 Float level gauge Fuel pressure gauge, 0 – 100 psi Driver, 40 mm I.D. 07401-0010000 07406-004000B 07746-0030100 Oil pressure gauge attachment Stem seal driver Remover weight 070MJ-0010101...
Page 33 dummyhead dummyhead SERVICE INFORMATION Attachment, 42 X 47 mm Attachment, 52 X 55 mm Attachment, 22 X 24 mm 07746-0010300 07746-0010400 07746-0010800 Puller adapter Attachment, 24 X 26 mm Pilot, 10 mm 07APF-ZY3A200 07746-0010700 07746-0040100 Pilot, 14 mm Pilot, 17 mm Pilot, 25 mm 07746-0041200 07746-0040400...
Page 34 dummyhead dummyhead SERVICE INFORMATION Driver Valve spring compressor Lock nut wrench, 30/64 mm 07749-0010000 07757-0010000 07916-MB00002 Bearing remover, 30 mm Remover handle MT.assembly holder 07936-8890300 07936-3710100 07KPF-VD60100 Bearing driver attachment, 37 mm Oil seal driver Driver handle, 15 x 280 mm 07ZMD-MBW0200 07947-SB04100 07949-3710001...
Page 35 dummyhead dummyhead SERVICE INFORMATION Air pressure regulator Disassembly tool, B Pulley holder attachment, hex 50 mm 07AAJ-PNAA101 07964-MB00200 070PB-0010100 or 07NAB-001040A Trim cap wrench, 4 mm Pin wrench, 6 mm Vertical shaft holder 070PA-001A100 07SPA-ZW1010A 07SPB-ZW10200 Gauge joint A (Upper chamber) Gauge joint B (Lower chamber) VTEC air stopper 07SPJ-ZW1010A...
Page 36 dummyhead dummyhead SERVICE INFORMATION Piston pin pilot Insert adjuster Pilot collar 18 070AF-PWC0110 070AF-PWC0120 070AF-PWC0130 Backlash indicator tool 07SPJ-ZW0030B 2-17...
Page 37 dummyhead dummyhead SERVICE INFORMATION CABLE/HARNESS ROUTING AIR FLOW BAND Tighten the air flow band bolt so that the band inside dimension is as shown. IAT SENSOR 2P 6 – 8 mm CONNECTOR IAT SENSOR (0.24 – 0.31 in) MAP SENSOR 3P CONNECTOR HARNESS MAP SENSOR...
Page 38 dummyhead dummyhead SERVICE INFORMATION WIRE CLAMP • Install the pump harness into the WIRE CLAMPER upper side of the clamp, and set the REMOTE CONTROL CABLE clamp so that the opening is facing Set the pump harness or TILLER HANDLE 14P the crankcase side.
Page 39 dummyhead dummyhead SERVICE INFORMATION TP SENSOR 3P CONNECTOR TP SENSOR MAIN HARNESS HARNESS BAND POWER TILT RELAY 3P Set into the clamps of SILENCER CASE CONNECTOR the silencer case (Except LHGX type) properly. HARNESS BAND CLIP WATER LEVEL SENSOR 2P CONNECTOR HARNESS BAND CLIP...
Page 40 dummyhead dummyhead SERVICE INFORMATION HARNESS BAND CLIP REMOTE CONTROL CABLE or TILLER HANDLE 14P CONNECTOR MAIN HARNESS INDICATOR LIGHT 6P CONNECTOR HARNESS BAND CLIP HARNESS BAND CLIP Clamp the remote control cable harness or tiller handle cable harness, and indicator light harness.
Page 41 dummyhead dummyhead SERVICE INFORMATION LOCATING BAND LOCATING BAND Set the water level sensor wire so the Set the water level sensor wire so locating band is above the harness clip the locating band is above clip C. RELAY as shown. BRACKET WATER LEVEL SENSOR 2P...
Page 42 dummyhead dummyhead SERVICE INFORMATION FUEL PUMP (HIGH) HARNESS 2P CONNECTOR BAND CLIP POWER TILT RELAY WIRE CLAMPER 3P CONNECTOR (Except LHGX type) Set the pump harness REMOTE CONTROL CABLE above the power tilt MAIN HARNESS or TILLER HANDLE 14P relay 3P connector wire CONNECTOR (Except LHGX type).
Page 43 dummyhead dummyhead SERVICE INFORMATION WIRE CLAMP PUMP HARNESS HARNESS BAND MAIN HARNESS WATER LEVEL SENSOR 2P CONNECTOR REMOTE CONTROL CABLE GROMMET HARNESS BAND CLIP TRIM ANGLE SENSOR 3P CONNECTOR (Except LHGX type) SPIRAL TUBE (12 X 14.6 mm) (Except LHGX type) WATER LEVEL SENSOR/WATER UNDER COVER...
Page 44 dummyhead dummyhead SERVICE INFORMATION THROTTLE CABLE SHIFT CABLE INDICATOR LIGHT REMOTE CONTROL CABLE HARNESS HARNESS or TILLER HANDLE HARNESS STARTER CABLE REMOTE CONTROL CABLE FUEL TUBE A GROMMET <Front view with the grommet installed into the outboard motor> FUEL TUBE A STARTER CABLE WHITE TAPE Install the starter cable by...
Page 45 dummyhead dummyhead SERVICE INFORMATION EOP SENSOR CKP SENSOR 3P EOP SENSOR 3P CONNECTOR CONNECTOR HARNESS CKP SENSOR BAND CLIPS HARNESS CLIP BRACKET A HARNESS CLIP BRACKET C IAC VALVE 2P MAIN CONNECTOR HARNESS HO2S 4P CONNECTOR IAC VALVE HARNESS BAND CLIPS 2-26...
Page 46 dummyhead dummyhead SERVICE INFORMATION CKP SENSOR 3P IAT SENSOR 2P CONNECTOR CONNECTOR HARNESS BAND CLIPS MAIN HARNESS CKP SENSOR IAC VALVE 2P CONNECTOR HARNESS BAND CLIPS IAC VALVE HARNESS BAND CLIPS HARNESS BAND CLIPS KNOCK SENSOR (BF90D/BF100A only) KNOCK SENSOR 1P CONNECTOR (BF90D/BF100A only) 2-27...
Page 47 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE CLAMP A • Set with fuel tube D positioned in front of the main harness. • Set with the openings facing the fuel line side. • Set by aligning the upper edge with the paint mark on fuel tube D. FUEL TUBE D MAIN HARNESS FUEL TUBE C...
Page 48 dummyhead dummyhead SERVICE INFORMATION HARNESS BAND CLIP KNOCK SENSOR (BF90D/BF100A only) HARNESS BAND KNOCK SENSOR 1P CLIP CONNECTOR EBT SENSOR (BF90D/BF100A only) No.2 FUEL INJECTOR 2P CONNECTOR No.3 FUEL INJECTOR 2P CONNECTOR HARNESS BAND CLIP No.4 FUEL INJECTOR 2P CONNECTOR VTEC SOLENOID (BF90D/BF100A only) HARNESS BAND...
Page 49 dummyhead dummyhead SERVICE INFORMATION VTEC SOLENOID MAIN HARNESS (BF90D/BF100A only) HARNESS BAND CLIP HARNESS BAND (BF90D/BF100A only) CLIP HARNESS CLIP VTEC SOLENOID 1P CONNECTOR (BF90D/BF100A only) HARNESS CMP SENSOR MAIN HARNESS CMP SENSOR STRAP (30 mm) 3P CONNECTOR 2-30...
Page 50 dummyhead dummyhead SERVICE INFORMATION ALTERNATOR MAIN HARNESS HARNESS BAND STATOR CLIP HARNESS CLIP BRACKET E HARNESS CLIP BRACKET C STATOR HARNESS JOINT CONNECTOR 1 HARNESS BAND HO2S 4P CLIP CONNECTOR JOINT CONNECTOR 2 2-31...
Page 51 dummyhead dummyhead SERVICE INFORMATION HO2S WIRE JOINT JOINT CONNECTOR 2 CONNECTOR 1 The protector tube must HARNESS BAND contact the HO2S wire. CLIP No.1 IGNITION COIL 3P CONNECTOR No.1 IGNITION COIL HO2S No.2 IGNITION COIL 3P CONNECTOR STATOR 3P CONNECTOR No.2 IGNITION COIL REGULATOR/ RECTIFIER...
Page 52 dummyhead dummyhead SERVICE INFORMATION ECM 36P CONNECTOR B (Black) ELECTRONIC HARNESS HO2S 4P PARTS CASE ECM 36P BAND CLIP CONNECTOR CONNECTOR A (Gray) CLAMP STATOR HARNESS HO2S WIRE The protector tube must contact the HARNESS HO2S wire. BAND CLIP HO2S STATOR WIRE ENGINE SPEED CHECK Set into the clamp...
Page 53 dummyhead dummyhead SERVICE INFORMATION HARNESS BAND CLIP CLAMP HARNESS STATOR HARNESS BAND CLIP MAIN HARNESS HARNESS BAND CLIP GROUND CABLE PGM-FI/MAIN RELAY PGM-FI/MAIN RELAY 6P CONNECTOR PGM-FI/MAIN RELAY FUSE BOX 5P WHITE WIRE CONNECTOR WIRE HARNESS CLIP HARNESS BAND CLIP CLAMP PGM-FI/MAIN RELAY 5P CONNECTOR...
Page 54 dummyhead dummyhead SERVICE INFORMATION HARNESS GROUND BAND CLIP CABLE PGM-FI/MAIN RELAY 6P CONNECTOR WIRE WIRE HARNESS CLIP Clamp the PGM-FI/main PGM-FI/MAIN relay 5P connector wire. RELAY CLAMP Clamp the PGM-FI/main relay white wire. FUSE CABLE PGM-FI/MAIN RELAY WHITE WIRE PGM-FI/MAIN RELAY 5P CONNECTOR WIRE PGM-FI/MAIN RELAY 5P CONNECTOR...
Page 55 dummyhead dummyhead SERVICE INFORMATION GROUND CABLE • Install with the Black and Blue terminal onto the upper side, and the Black terminals onto the lower side. • Tighten the bolt while pushing the ground terminal against the lug on the cylinder block.
Page 56 dummyhead dummyhead SERVICE INFORMATION PGM-FI/MAIN RELAY WHITE WIRE STARTER FUSE CABLE CABLE (+) MAIN HARNESS POWER TRIM/ STARTER MOTOR Set into the clamps TILT SWITCH 3P of the silencer case CLAMPS CONNECTOR properly. (Except LHGX NMEA 2000 6P type) CONNECTOR POWER TRIM/ TILT SWITCH (Except LHGX...
Page 57 dummyhead dummyhead SERVICE INFORMATION LEAD WIRE (137 mm) Tighten the screw while pushing the terminal against the lug of the lower mount center housing. LEAD WIRE (137 mm) UNDER COVER LOWER MOUNT GROMMET C CENTER HOUSING (Except LHGX type) CLIP (14 mm) (Except LHGX type) SPIRAL TUBE (12 X 14.6 mm)
Page 58 dummyhead dummyhead SERVICE INFORMATION POWER TRIM/TILT LEAD WIRE • Route between the lugs of the anode metal. • Install so that the angle is 90° as shown at the power trim/tilt side. 90° ANODE METAL SPIRAL TUBE (12 X 14.6 mm) (Except LHGX type) TRIM ANGLE WIRE...
Page 59 dummyhead dummyhead SERVICE INFORMATION TILLER HANDLE TYPE: REMOTE CONTROL CABLE (SHIFT CABLE) POWER TRIM/ HARNESS TILT SWITCH BAND (Except LHGX (Except LHGX type) type) POWER TRIM/ TILT SWITCH WARNING WIRE BUZZER (Except LHGX type) REMOTE CONTROL CABLE (THROTTLE TUBE (40 mm) HARNESS BAND CABLE) (Except LHGX...
Page 60 dummyhead dummyhead SERVICE INFORMATION <When the steering friction rod is installed on the right side> STEERING STEERING BRACKET FRICTION SHAFT STEERING FRICTION ROD STEERING FRICTION BLOCK <When the steering friction rod is installed on the left side> STEERING FRICTION SHAFT STEERING BRACKET STEERING FRICTION ROD...
Page 61 dummyhead dummyhead SERVICE INFORMATION REMOTE CONTROL TYPE: POWER TRIM/TILT SWITCH INDICATOR LIGHT POWER TRIM/TILT SWITCH WIRE WARNING BUZZER WIRE HARNESS CLIP TIE-WRAP BAND COMBINATION SWITCH EMERGENCY STOP SWITCH POWER TRIM/TILT SWITCH WIRE REMOTE CONTROL CABLE B REMOTE CONTROL POWER TRIM/TILT W/Bl W/Bl CABLE B...
Page 62 dummyhead dummyhead SERVICE INFORMATION TUBE ROUTING PRESSURE REGULATOR CONTROL TUBE VINYL TUBE PRESSURE REGULATOR (5 X 9 X 240 mm) RETURN HOSE TUBE CLIP B12 TUBE CLAMP D TUBE CLIP D10.7 FUEL TUBE A FUEL TUBE B GROMMET FUEL HOSE FUEL TUBE A HOSE GROMMET WATER LEVEL SENSOR/...
Page 63 dummyhead dummyhead SERVICE INFORMATION GROMMET GUIDE Install by aligning the groove with the guide of the under cover front bracket. FUEL TUBE A UNDER COVER FRONT BRACKET “→” MARK WATER LEVEL SENSOR/ FUEL TUBE A WATER SEPARATOR FUEL TUBE B •...
Page 64 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE B FUEL TUBE B PROTECTOR TUBE PROTECTOR TUBE FUEL HOSE HOSE CLIP • Set onto fuel tube B between the protector tubes. • Install with the opening facing the engine side. • Set the fuel hose into the underside of the hose clip.
Page 65 dummyhead dummyhead SERVICE INFORMATION WIRE CLAMP • Install the pump harness into the upper side of the clamp, and set the clamp so that the opening is facing the crankcase side. • Install the pressure regulator return hose into the lower side of the clamp, and set the clamp so the opening is facing the crankcase side.
Page 66 dummyhead dummyhead SERVICE INFORMATION HARNESS CLIP BREATHER PIPE BRACKET A TUBE CLIP B12 Install with the clip ends FUEL TUBE JOINT facing up. BREATHER TUBE B FUEL TUBE C FUEL TUBE CLAMP B Install with the clip ends facing as shown. BREATHER TUBE A HARNESS...
Page 67 dummyhead dummyhead SERVICE INFORMATION TUBE CLIP B12 Install with the clip ends TUBE CLIP B12 facing up. TUBE CLAMP Install with the clip ends 7.5 - 11.5 facing up. TUBE (7.3 X 90 mm) FUEL FUEL TUBE D FUEL STRAINER MAIN TUBE C (LOW)
Page 68 dummyhead dummyhead SERVICE INFORMATION CHECK VALVE Install with the CHECK VALVE arrow facing down. TUBE A CHECK VALVE FUEL TUBE C TUBE B T-JOINT TUBE CLAMP 7.5 - 11.5 AIR VENT TUBE B CLAMP FUEL TUBE D VAPOR SEPARATOR COVER FUEL TUBE CLAMP B AIR VENT TUBE A...
Page 69 dummyhead dummyhead SERVICE INFORMATION TUBE CLAMP 7.5 - 11.5 Install fuel tube C into the large clamp, and check valve tube B into the small clamp with the openings of the clamp facing the cylinder block side. CHECK VALVE FUEL STRAINER TUBE B (LOW) FUEL...
Page 70 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE CLAMP B Install with the opening facing the fuel line side. FUEL TUBE AIR VENT BRACKET TUBE B AIR VENT STRAINER FUEL TUBE CLAMP B AIR VENT TUBE C AIR VENT TUBE A PAINT MARK FUEL TUBE CLAMP B PAINT MARKS Install with the opening...
Page 71 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE CLAMP B FUEL TUBE Install with the opening CLAMP A facing out. PAINT HOSE CLIP FUEL TUBE D MARK FUEL TUBE C AIR VENT TUBE C FUEL LINE AIR VENT TUBE A FUEL HOSE TUBE CLIP TUBE CLIP B10...
Page 72 dummyhead dummyhead SERVICE INFORMATION WATER JACKET COVER TUBE CLIP 65 Install with the clip ends facing down. WATER TUBE A Connect so the tube end TUBE CLIP B10 is pushed against the lug of the water jacket cover. Install with the clip ends facing the cylinder block side.
Page 73 dummyhead dummyhead SERVICE INFORMATION CYLINDER HEAD COVER AIR VENT TUBE C TUBE CLAMP FUEL HOSE D29.0 FUEL TUBE CLAMP B FUEL TUBE C CLAMP WATER TUBE A TUBE CLIP 65 TUBE WATER TUBE B OIL TUBE CLIP B10 Set into the clamp of •...
Page 74 dummyhead dummyhead SERVICE INFORMATION WATER CHECK TUBE Install into the clamp of the idle exhaust port. TUBE CLIP B10 WATER TUBE B TUBE CLIP B10 IDLE EXHAUST PORT 2-55...
Page 75 dummyhead dummyhead SERVICE INFORMATION BREATHER PIPE BREATHER TUBE C ALTERNATOR Set into the alternator Set into the alternator COVER cover clamp. cover clamps. FUEL TUBE CLAMP B ALTERNATOR BREATHER FUEL TUBE BREATHER ALTERNATOR COVER CLAMPS TUBE A JOINT TUBE B COVER CLAMP BREATHER PIPE ALTERNATOR...
Page 76 dummyhead dummyhead SERVICE INFORMATION TUBE CLIP B1 (13 mm) TUBE CLIP D10.5 TUBE (7 X 110 mm) TUBE CLIP D10.5 TUBE (8 X 300 mm) 2-57...
Page 77 dummyhead dummyhead MEMO...
Page 78 dummytext 3. MAINTENANCE MAINTENANCE SCHEDULE ··················· 3-2 LUBRICATION ···································· 3-22 ENGINE OIL LEVEL CHECK/OIL WATER SEPARATOR CHECK··············· 3-25 CHANGE ·············································· 3-4 FUEL STRAINER (LOW PRESSURE SIDE) ENGINE OIL FILTER CHANGE ················ 3-5 INSPECTION/CLEANING ······················ 3-25 GEAR CASE OIL CHANGE ····················· 3-6 FUEL FILTER (HIGH PRESSURE SIDE) INSPECTION/REPLACEMENT···············...
Page 79: 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 First Every 6 Every 2 Every 3 to page Every Each After month months years years year or or 20 or 100...
Page 80: Operating Hour Notification System
dummyhead dummyhead MAINTENANCE 1. Lubricate more frequently when used in salt water. 2. For professional commercial use, log hours of operation to determine proper maintenance intervals. 3. When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. 4.
Page 81: Engine Oil Level Check/Oil
dummyhead dummyhead MAINTENANCE ENGINE OIL LEVEL CHECK/OIL CHANGE OIL LEVEL INSPECTION Place the outboard motor in the vertical position (with the engine level), and remove the engine cover. Start the engine, let it warm up to the normal operating temperature, and stop the engine. Remove the dipstick [1] and wipe it clean with a shop towel.
Page 82: Engine Oil Filter Change
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 83: Gear Case Oil Change
dummyhead dummyhead MAINTENANCE Apply clean engine oil to the O-ring [1] and threads [2] of a new oil filter. Clean the filter mounting base, and coat the stud with clean engine oil. • Use only a Honda Genuine oil filter or a filter of equivalent quality specified for your model.
Page 84 dummyhead dummyhead MAINTENANCE ADDING Place the outboard motor on a level surface and position the outboard motor vertically (with the engine level). Remove the oil check bolt [1] and oil drain plug bolt [2], and then check for metal particles on the magnet end [3].
Page 85 dummyhead dummyhead MAINTENANCE 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 check bolt [1], oil drain plug bolt [2], and drain the old oil.
Page 86: Throttle Control Cable/Throttle Link Check/Adjustment
dummyhead dummyhead MAINTENANCE THROTTLE CONTROL CABLE/ THROTTLE LINK CHECK/ ADJUSTMENT CHECK Remote control type: Remote control type: Set the control lever [1] in the forward full open position. "N" (Neutral) • If it is hard to set the control lever in the "F" (Forward) or "R"...
Page 87 dummyhead dummyhead MAINTENANCE 1. With the control lever or throttle grip in the full open position, check that the throttle arm [1] is in contact with the full open stopper [2] of the shift link bracket [3]. 2. Holding the control lever or throttle grip in the position of step 1, check the clearance between the throttle cam [4] and the stopper (full open side) [5] of the throttle body.
Page 88 dummyhead dummyhead MAINTENANCE ADJUSTMENT THROTTLE ARM NOT IN FULL OPEN POSITION 1. Loosen the shift pivot lock nut [1] of the remote control cable (throttle side) [2] and remove the shift pivot [3] from the throttle arm link pin [4]. 2.
Page 89: Valve Clearance Check
dummyhead dummyhead MAINTENANCE THROTTLE ARM NOT IN FULL OPEN POSITION OR THE THROTTLE CAM NOT IN FULL OPEN POSITION 1. Remove the following: – Under cover (page 19-23) – Grip rubber and grip pipe (page 19-27) 2. Loosen the lock nut [1] of the tiller handle side throttle cable pivot [2] and turn the throttle cable pivot so that the throttle arm is in the full open position or the throttle cam is in the full open...
Page 90 dummyhead dummyhead MAINTENANCE 4. With the No.1 piston at top dead center of its compression stroke as described in step 3, check the intake and exhaust valve clearance on the No.1 cylinder by inserting a feeler gauge [1] between the intake/exhaust side rocker arm valve adjusting screw [2] and the valve stem end [3].
Page 91 dummyhead dummyhead MAINTENANCE 10.After adjusting the intake and exhaust valve No.3 Piston at top dead center of clearances of the No.1 cylinder, turn the alternator compression stroke: rotor clockwise by increments of 180° and bring the piston of each cylinder at the top dead center of its compression stroke.
Page 92: Spark Plug Check/Replacement
dummyhead dummyhead MAINTENANCE SPARK PLUG CHECK/REPLACEMENT REMOVAL Remove the engine cover. Remove the bolt [1] and plug maintenance cover [2]. Disconnect the ignition coil 3P connector [1]. Remove the bolts [2] and ignition coils [3]. Take care not to an impact or drop the ignition coils. Replace the ignition coil if dropped.
Page 93 dummyhead dummyhead MAINTENANCE CHECK Visually inspect the spark plug. Replace the plug if it is Standard: heavily fouled or the insulator [1] is cracked or chipped. Check the following and replace if necessary. – Insulator and sealing washer [2] for damage –...
Page 94: Pin Check
dummyhead dummyhead MAINTENANCE PROPELLER AND SPLIT PIN CHECK Check the propeller [1] for bending 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. ANODE METAL CHECK (OUTER SIDE) GEAR CASE Check the anode metal [1] for excessive wear or...
Page 95 dummyhead dummyhead MAINTENANCE Remove the trim tab (page 16-4). Check the continuity between the anode [1] and gear case trim tab installation area [2]. Remove any corrosion; it prevents continuity. Perform continuity inspection between the anode metal surface without corrosion and the bare aluminum surface of the gear case trim tab installation area.
Page 96: Anode Metal Check (Inner Side)
dummyhead dummyhead MAINTENANCE ANODE METAL CHECK (INNER SIDE) CYLINDER SLEEVE WATER JACKET Remove the cylinder head water jacket anode (page 11-4). Check the anode [1] for excessive wear or corrosion. If the anode is worn to less than 2/3 of its original length, replace the screw, anode metal, sealing bolt with new ones as a set.
Page 97: Idle Speed Check/Adjustment
dummyhead dummyhead MAINTENANCE IDLE SPEED CHECK/ADJUSTMENT INSPECTION Check the following before starting the idle speed inspection. – Battery must be in good condition – Boat equipment (electrical loads) must be removed – Spark plug inspection (page 3-15) – MIL must be OFF Place the outboard motor vertically (with the engine level to the ground), and set the remote control lever in the "N"...
Page 98 dummyhead dummyhead MAINTENANCE ADJUSTMENT Remove the propeller and set the outboard motor gear case in a test tank filled with water. Start the engine. Disconnect the 2P connector [1] from the IAC valve. The MIL [2] should come ON and the warning buzzer should sound (intermittent sound: long beep).
Page 99: Lubrication
dummyhead dummyhead MAINTENANCE LUBRICATION [1] Detent spring roller [1] Throttle arm pivot and sliding part [2] Throttle plate pivot and sliding part [3] Shift slide pivot sliding part [4] Link pin [5] Shift link pin [6] Throttle arm link pin [1] Tiller handle [1] Tiller handle [1] Vertical shaft...
Page 100 dummyhead dummyhead MAINTENANCE [1] Mount frame [1] Throttle rod hole in the throttle body Engine oil [1] Tilting shaft threads [1] Detent spring roller [2] Tilting shaft cam [1] Grease fitting (Tilting shaft outer surface) [1] Grease fitting Gear oil (Tilting shaft outer surface) [1] Gear case 3-23...
Page 101 dummyhead dummyhead MAINTENANCE [1] Tilting stopper bearing [1] Upper cylinder bushing, pin [1] Power trim/tilt (Except LHGX type) [1] Thrust receiver (Except LHGX type) [1] Lower cylinder bushing color 3-24...
Page 102: Water Separator Check
dummyhead dummyhead MAINTENANCE WATER SEPARATOR CHECK 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. Remove the engine cover.
Page 103 dummyhead dummyhead MAINTENANCE REPLACEMENT Place a shop towel under the fuel tubes. Clamp fuel tube C [1] and fuel tube [2] securely with a commercially available tube clip [1]. Remove the fuel strainer [1] and strainer suspension [2] from harness clip bracket B [3]. Disconnect fuel tube C [4] and fuel tube [5].
Page 104 dummyhead dummyhead MAINTENANCE Set the strainer suspension [1] on a new fuel strainer [2] with the projection [3] up. Install the strainer suspension by aligning the suction side joint base [4] of the fuel strainer with the "I" mark [5] on the strainer suspension. Fuel strainer view from the front: Install the fuel strainer [1] in harness band clip bracket B [2].
Page 105: 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 106: Fuel Tank/Filter Cleaning
dummyhead dummyhead MAINTENANCE FUEL TANK/FILTER 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. Remove the four screws [1] and fuel tank filter [2]. Clean the fuel tank with solvent, and allow the fuel tank to dry thoroughly.
Page 107: Fuel Line Check/Replacement
dummyhead dummyhead MAINTENANCE FUEL LINE CHECK/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 leakage,...
Page 108: Nuts, Bolts, Fasteners
dummyhead dummyhead MAINTENANCE NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values (page 2-4). Check that all safety clips, hose clamps, and cable stays are in place and properly secured. CRANKCASE BREATHER CHECK Remove the engine cover.
Page 109: Power Trim/Tilt Check
dummyhead dummyhead MAINTENANCE POWER TRIM/TILT CHECK Set the swivel case to the uppermost position. Make sure that the power trim/tilt has no ATF leaks. If the ATF leaks, replace or repair the faulty part(s) (page 18-41). SHIFT CONTROL CABLE CHECK/ ADJUSTMENT CABLE CHECK Remove the following:...
Page 110 dummyhead dummyhead MAINTENANCE CONTROL ADJUSTMENT 1. Move the control lever to the "N" (Neutral) position. 2. Loosen the shift pivot lock nut [1] of the remote control cable (shift side) [2] and remove the shift pivot [3] from the shift link pin [4]. 3.
Page 111 dummyhead dummyhead MAINTENANCE 8. Align mark (C) [1] made in step 7 with the end of the cable outer seal. 9. Check that the detent spring roller sits in the groove in the shift arm. 10.Move the tip [1] of the shift link pin lightly to the right and left.
Page 112 dummyhead dummyhead MAINTENANCE 13.Move the control lever from the "F" (Forward) to the “N” (Neutral) position. If the gear does not shift to neutral, disconnect the shift control cable from the shift link pin. Move the inner cable toward the mark Adjustment range (A) [1] and repeat the procedure from step 9.
Page 113 dummyhead dummyhead MEMO...
Page 114 dummytext 4. TROUBLESHOOTING BEFORE TROUBLESHOOTING ··············· 4-2 ALERT SYSTEM/WARNING SYSTEM TROUBLESHOOTING ·························· 4-16 ENGINE TROUBLESHOOTING ················ 4-2 FRAME TROUBLESHOOTING··············· 4-23 FUSE/ELECTRIC POWER LINE TROUBLESHOOTING ·························· 4-12...
Page 115: Before Troubleshooting
dummyhead dummyhead TROUBLESHOOTING BEFORE TROUBLESHOOTING TROUBLESHOOTING • Use a known-good battery for troubleshooting. • 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 116 dummyhead dummyhead TROUBLESHOOTING 5. Fuel Pump (High pressure side) Inspection You should hear the pump hum when the combination switch is turned "ON". Is the hum heard? – GO TO STEP 6. – Perform fuel pump system (High pressure side) inspection (page 5-99). 6.
Page 117 dummyhead dummyhead TROUBLESHOOTING 11. IAC valve inspection Replace the IAC valve with a new one and start the engine. Engine starts? – Faulty original IAC valve. – Replace the ECM with a new one and recheck. ENGINE STARTS BUT STALLS SOON 1.
Page 118 dummyhead dummyhead TROUBLESHOOTING 6. Pressure regulator inspection Check the fuel pressure and record it (page 5-97) Disconnect the pressure regulator vacuum tube. Check the fuel pressure. Is the fuel pressure higher with the vacuum tube disconnected? – GO TO STEP 7. –...
Page 119 dummyhead dummyhead TROUBLESHOOTING ENGINE DOES NOT RUN SMOOTHLY OR THE ENGINE STALLS DURING DECELERATION 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 stop? –...
Page 120 dummyhead dummyhead TROUBLESHOOTING 7. Neutral switch inspection Inspect the neutral switch (page 9-22) Is the neutral switch normal? – GO TO STEP 8. – Faulty original neutral switch. 8. Fuel injector inspection Inspect the fuel injector (page 5-103) Is the fuel injector normal? –...
Page 121 dummyhead dummyhead TROUBLESHOOTING 4. IAC valve inspection Replace the IAC valve with a new one and start the engine. Is the idle speed normal? – Faulty original IAC valve. – Replace the ECM with a new one and recheck. ENGINE SPEED IS LOWER THAN THE SPECIFIED IDLE SPEED OR TROLLING SPEED AFTER WARMING UP 1.
Page 122 dummyhead dummyhead TROUBLESHOOTING 3. Fuel Flow Inspection Inspect the fuel flow (page 5-99) Is the fuel flow within specification? – GO TO STEP 4. – • Clogged or damaged fuel tube • Clogged fuel strainer (Low pressure side) • Clogged water separator •...
Page 123 dummyhead dummyhead TROUBLESHOOTING ENGINE SPEED DOES NOT STABILIZE WHEN RUNNING AT HIGH SPEED AND ENGINE SPEED IS NOT AS HIGH AS IT USED TO BE WHEN RUNNING WITH THE THROTTLE FULLY OPEN 1. Throttle link and throttle cable inspection Inspect the throttle cable (page 3-9). Is the throttle link and throttle cable adjustment correct? –...
Page 124 dummyhead dummyhead TROUBLESHOOTING ENGINE SPEED INCREASES EXCESSIVELY 1. Propeller inspection Check the propeller. Is the propeller correct? – GO TO STEP 2. – • Propeller mismatched • Faulty propeller 2. Outboard motor installation inspection Inspect the outboard motor installation (Transom height/tilt angle). Is the outboard motor installation correct? –...
Page 125 dummyhead dummyhead TROUBLESHOOTING FUSE/ELECTRIC POWER LINE TROUBLESHOOTING FUSE BOX CONNECTION TABLE Fuse No. Amps. Component (s) or Circuit (s) Protected – 70 A Regulator/Rectifier 10 A Fuel pump (High pressure) 10 A Power tilt relay, Combination switch, PGM-FI/Main relay, Oil indicator light, Overheat indicator light, MIL, Alternator indicator, Warning buzzer, Tachometer, Trim meter, Hour meter, Volt meter, 15 A...
Page 126 dummyhead dummyhead TROUBLESHOOTING FUSE LOAD CHART To REGULATOR/RECTIFIER (OUTPUT TERMINAL) POWER TRIM/TILT FUSE SWITCH (70 A) (OUTBOARD MOTOR To POWER TILT RELAY SIDE) To POWER TILT RELAY POWER TRIM/TILT SWITCH (REMOTE CONTROL BOX/ W/Bl W/Bl TILLER HANDLE SIDE) To ECM (EMS) Bl/R FUSE (10 A)
Page 127 dummyhead dummyhead TROUBLESHOOTING MIL AND WARNING BUZZER DOES NOT OPERATE 1. Fuse inspection Turn the combination switch OFF. Check for blown No.2, No.6, and No.5 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 4-13) –...
Page 128 dummyhead dummyhead TROUBLESHOOTING 4. No.6 fuse line inspection Turn the combination switch OFF. PGM-FI/MAIN RELAY 4P CONNECTOR Disconnect PGM-FI/main relay 5P connector MAIN WIRE HARNESS SIDE Turn the combination switch ON. Measure the voltage between the PGM-FI/main relay 5P connector main wire harness side No.5 (White) terminal and engine ground.
Page 129 dummyhead dummyhead TROUBLESHOOTING ALERT SYSTEM/WARNING SYSTEM TROUBLESHOOTING • Perform the MIL initial check before starting the engine. 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. When the warning buzzer keeps sounding after MIL initial check, refer to the following symptom chart and perform the necessary troubleshooting.
Page 130 dummyhead dummyhead TROUBLESHOOTING FUNCTION TEST USING THE Dr.H 1. Buzzer inspection Turn the combination switch OFF and connect the Dr.H. Test the warning buzzer using the Dr.H. Does the buzzer sound? – GO TO STEP 2. – • Inspect the warning buzzer •...
Page 131 dummyhead dummyhead TROUBLESHOOTING FUNCTION TEST WITHOUT USING THE Dr.H 1. Indicator light/buzzer short circuit inspection Turn the combination switch OFF and disconnect the ECM connector A and B Turn the combination switch ON. Does the warning buzzer sound and/or indicator come ON? –...
Page 132 dummyhead dummyhead TROUBLESHOOTING 5. Overheat indicator light inspection Turn the combination switch OFF. ECM CONNECTOR A Short the No.32 terminal (Red) 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 133 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. AND THE OVERHEAT INDICATOR LIGHT COMES ON OR BLINKS 1.
Page 134 dummyhead dummyhead TROUBLESHOOTING AND 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 5-16) –...
Page 135 dummyhead dummyhead TROUBLESHOOTING 7. EOP sensor inspection Replace the EOP sensor (page 5-84). Check the oil indicator light and buzzer. Does the oil indicator light come ON and the buzzer stop sounding? – Faulty original EOP sensor. – Replace the ECM with a new one and recheck. AND THE OVERHEAT INDICATOR LIGHT GOES OFF AND OIL INDICATOR LIGHT COMES ON 1.
Page 136: Frame Troubleshooting
dummyhead dummyhead TROUBLESHOOTING WARNING BUZZER SOUNDS INTERMITTENTLY (SHORT BEEP) 1. Water separator/fuel strainer (low pressure side) inspection Turn the combination switch OFF. Check the water separator and the fuel strainer (low pressure side). Is there water in the cup? – Remove the water and clean the cup of the water separator and fuel strainer. –...
Page 137 dummyhead dummyhead TROUBLESHOOTING POWER TRIM/TILT DOES NOT MOVE 1. power tilt motor inspection Turn the combination switch ON. Operate the power trim/tilt switch and check the power tilt motor sound. Do you hear the motor sound? – GO TO STEP 2. –...
Page 138 dummyhead dummyhead TROUBLESHOOTING POWER TRIM/TILT DOES NOT HOLD POSITION 1. Manual valve inspection Check the manual valve tightness. Is the manual valve tight? – GO TO STEP 2. – Tighten the manual valve to the specified torque: 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) 2.
Page 139 dummyhead dummyhead TROUBLESHOOTING 4. Overheat inspection Check the motor for overheating. Is the motor overheated? – Cool down the motor. – GO TO STEP 5. 5. Power tilt motor continuity inspection Check for continuity at the motor (page 18-46). Is there continuity? –...
Page 140 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 141 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 [14] UPPER CHAMBER CHECK VALVE PISTON ROD A ASSEMBLY [8] DUST SEAL/O-RING [1] MOTOR [9] OIL...
Page 142: Fuel System
dummytext 5. FUEL SYSTEM ECT SENSOR 2 REMOVAL/INSTALLATION ··· 5-85 SERVICE PRECAUTIONS ····························· 5-2 ECT SENSOR 3 REMOVAL/INSTALLATION ··· 5-85 PIPING CONNECTIONS································ 5-7 AIR VENT STRAINER/CHECK VALVE CIRCUIT DIAGRAM······································ 5-8 REMOVAL/INSTALLATION ·························· 5-86 SYSTEM LOCATION ···································5-10 WATER SEPARATOR REMOVAL/ INSTALLATION·········································· 5-87 ECM TERMINAL ARRANGEMENT ················5-11 WATER SEPARATOR DISASSEMBLY/ DTC TROUBLESHOOTING ··························5-13...
Page 143: Service Precautions
dummyhead dummyhead FUEL SYSTEM SERVICE PRECAUTIONS FUEL SYSTEM GENERAL TROUBLESHOOTING Before troubleshooting • First, check the MIL. • Be sure to turn the combination switch OFF before disconnecting and connecting the connectors. • Clear the DTCs after inspection. – DTC (with the Dr.H: page 5-5) –...
Page 144 dummyhead dummyhead FUEL SYSTEM Replace the O-ring (7.47 x 3.6 mm) [1] and O-ring (7.45 x 3.61 mm) [2] with new ones when the fuel line is removed/installed or replaced. • Install the O-rings in their proper locations. • Apply engine oil to the O-rings before installation. •...
Page 145 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 146: Engine Cover
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 147 dummyhead dummyhead FUEL SYSTEM READING DTC WITH THE Dr.H • The Dr.H can readout the DTC and other engine conditions. • Refer to the Instruction Manual for the Dr. H how to use. Turn the combination switch to OFF. Remove the dummy connector [1] from the DLC [2]. Connect the Dr.H [3] to the DLC.
Page 148: Piping Connections
dummyhead dummyhead FUEL SYSTEM FINAL PROCEDURE (AFTER TROUBLESHOOTING) Clear the DTCs. • DTC (with the Dr.H: page 5-5) • MIL (without the Dr.H: page 5-5) Disconnect the SCS service check connector or Dr.H from the DLC and connect the dummy connector. PIPING CONNECTIONS [15] [14]...
Page 149: Circuit Diagram
dummyhead dummyhead FUEL SYSTEM CIRCUIT DIAGRAM REGULATOR/ ALTERNATOR RECTIFIER FUSE PGM-FI/MAIN RELAY (70 A) No.6 FUSE (30 A) FUSE (10 A) No.2 FUSE (10 A) FUSE (15 A) MAIN FUSE (15 A) N0.1 FUSE (10 A) COMBINATION SWITCH BATTERY To STARTER MOTOR FUEL PUMP IGP1 IGP2...
Page 150 dummyhead dummyhead FUEL SYSTEM NEUTRAL NEUTRAL SWITCH SWITCH H02S NTSW O2HT TRIM ANGLE SENSOR WARNING VCC3 BUZZER BUZZ TRIM METER TRMA ALTERNATOR ACGLP 12 V EMERGENCY PGM-FI 12 V STOP SWITCH WARNL EMS1 EMS2 OVERHEAT A11 K-LINE TLUP TACHOMETER TLDN DOWN TACHO TROLLING...
Page 151: System Location
dummyhead dummyhead FUEL SYSTEM SYSTEM LOCATION [12] [11] [14] [15] [13] [16] [10] [17] [22] [21] [18] [19] [20] IAC valve [12] MAP sensor IAT sensor [13] HO2S Alternator stator [14] ECT sensor 2 CKP sensor [15] EOP sensor [16] PGM-FI/main relay Injector [17]...
Page 152: Ecm Terminal Arrangement
dummyhead dummyhead FUEL SYSTEM ECM TERMINAL ARRANGEMENT ECM CONNECTOR A (GRAY) ECM side connector (viewed from the terminal side) Terminal No. Terminal mark Name Content/Signal – – – ACGLP Alternator indicator light Alternator indicator light output WARNL MIL output TACHO Tachometer Tachometer pulse output –...
Page 153 dummyhead dummyhead FUEL SYSTEM ECM CONNECTOR B (BLACK) ECM side connector (viewed from the terminal side) Terminal No. Terminal mark Name Content/Signal CAN 1H NMEA 2000 CAN HI NMEA 2000 CAN HI output CAN 12V NMEA 2000 12V power source NMEA 2000 12V power input CAN GND NMEA 2000 ground...
Page 154: Dtc Troubleshooting
dummyhead dummyhead FUEL SYSTEM DTC TROUBLESHOOTING DTC INDEX Detected component Probable cause Ref. page MIL does not • Loose or poor contact of the 4-17 come ON/ connector blink • Faulty indicator light 0 or does not • Open circuit in MIL wire communicate •...
Page 155 dummyhead dummyhead FUEL SYSTEM Detected component Probable cause Ref. page TP sensor (voltage too high) • Loose or poor contact of the 5-28 connector • Open circuit in TP sensor wire (SG2) • Faulty TP sensor CMP sensor (no pulse) •...
Page 156 dummyhead dummyhead FUEL SYSTEM Detected component Probable cause Ref. page 140-1 ECT sensor 2 (voltage too low) • Loose or poor contact of the 5-39 connector • Short circuit in ECT sensor 2 wire (TOH1) • Faulty ECT sensor 2 140-2 ECT sensor 2 (voltage too high) •...
Page 157 dummyhead dummyhead FUEL SYSTEM MIL IS ON BUT DTC IS 0 OR DOES NOT COMMUNICATE TP SENSOR MAP SENSOR No.2 No.4 FUSE FUSE FUSE (15 A) (10 A) (10 A) R/Bl Br/Y WARNL R/Bu R/Bl 12 V W/Bl K-LINE TRMA Y/Bu Y/Bl REMOTE CONTROL type...
Page 158 dummyhead dummyhead FUEL SYSTEM 2. DLC signal line short circuit inspection Measure the voltage between the DLC No.4 (Light green) terminal and engine ground. Is the measurement within 4.75 – 5.25 V? – GO TO STEP 3. – Repair short in the main wire harness between the ECM and the DLC.
Page 159 dummyhead dummyhead FUEL SYSTEM 7. TP sensor power line short circuit inspection 2 Measure the voltage between the TP sensor 3P connector main wire harness side No.1 (Blue) TP SENSOR 3P CONNECTOR terminal and engine ground. MAIN WIRE HARNESS SIDE Is the measurement within 4.75 –...
Page 160 dummyhead dummyhead FUEL SYSTEM DTC 0-2, 0-5, 0-8 (INTERNAL FAILURE OF ECM) 1. Reproduction test Turn the combination switch ON and wait for more than one second. Clear the DTC (page 5-5). • Continue the procedure if the DTC does not clear.
Page 161 dummyhead dummyhead FUEL SYSTEM 2. HO2S inspection Turn the combination switch OFF and disconnect the HO2S 4P connector Inspect the HO2S (page 5-108). Is the HO2S correct? – GO TO STEP 3. – Replace the HO2S with a new one and recheck.
Page 162 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 MAIN WIRE HARNESS SIDE Turn the combination switch ON. Measure the voltage between the MAP sensor 3P connector main wire harness side No.2 (White/Red) terminal and engine ground.
Page 163 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 164 dummyhead dummyhead FUEL SYSTEM DTC 4-1, 4-2 (NO CKP SENSOR PULSE OR ABNORMAL CKP SENSOR PULSE) BLACK BROWN YELLOW ORANGE LIGHT BLUE BLUE No.5 GREEN LIGHT GREEN FUSE PINK (15 A) WHITE GRAY CKP SENSOR JOINT CONNCTOR 1 Y/Bl G/Bl GND5 DTC 4-1 (NO CKP SENSOR PULSE) 1.
Page 165 dummyhead dummyhead FUEL SYSTEM 2. CKP sensor power line open circuit inspection Turn the combination switch OFF and disconnect the CKP sensor 3P connector CKP SENSOR 3P CONNECTOR Turn the combination switch ON. MAIN WIRE HARNESS SIDE Measure the voltage between the CKP sensor 3P connector main wire harness side No.3 (Yellow/Black) terminal and engine ground.
Page 166 dummyhead dummyhead FUEL SYSTEM DTC 6-1, 6-2 (EBT SENSOR VOLTAGE IS TOO LOW OR TOO HIGH) SENSOR BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE JOINT CONNCTOR 2 GREEN LIGHT GREEN PINK WHITE GRAY DTC 6-1 (EBT SENSOR VOLTAGE IS TOO LOW) 1.
Page 167 dummyhead dummyhead FUEL SYSTEM DTC 6-2 (EBT SENSOR VOLTAGE IS TOO HIGH) • When the DTC code 6-2, 7-2, 10-2, 22-2, 140-2, and 141-2 are indicated at the same time, the ground line (SG2) is open. 1. Symptom reproduction test Turn the combination switch OFF.
Page 168 dummyhead dummyhead FUEL SYSTEM DTC 7-1, 7-2 (TP SENSOR VOLTAGE IS TOO LOW OR TOO HIGH) R/Bl SENSOR VCC2 R/Bl BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE JOINT GREEN LIGHT GREEN CONNECTOR 2 PINK WHITE GRAY DTC 7-1 (TP SENSOR VOLTAGE IS TOO LOW) •...
Page 169 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 170 dummyhead dummyhead FUEL SYSTEM DTC 8-1, 8-2 (NO CMP SENSOR PULSE OR ABNORMAL CMP SENSOR PULSE) BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE No.5 GREEN LIGHT GREEN FUSE PINK (15 A) WHITE GRAY SENSOR JOINT CONNECTOR 1 G/Bl GND5 DTC 8-1 (NO CMP SENSOR PULSE) 1.
Page 171 dummyhead dummyhead FUEL SYSTEM 2. CMP sensor power line open circuit inspection Turn the combination switch OFF and disconnect the CMP sensor 3P connector CMP SENSOR 3P CONNECTOR MAIN WIRE HARNESS SIDE Turn the combination switch ON. Measure the voltage between the CMP sensor 3P connector main wire harness side No.3 (Yellow/Black) terminal and engine ground.
Page 172 dummyhead dummyhead FUEL SYSTEM DTC 10-1, 10-2 (IAT SENSOR VOLTAGE IS TOO LOW OR TOO HIGH) SENSOR BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE GREEN LIGHT GREEN JOINT CONNECTOR 2 PINK WHITE GRAY DTC 10-1 (IAT SENSOR VOLTAGE IS TOO LOW) 1.
Page 173 dummyhead dummyhead FUEL SYSTEM DTC 10-2 (IAT SENSOR VOLTAGE IS TOO HIGH) • When the DTC code 6-2, 7-2, 10-2, 22-2, 140-2, and 141-2 are indicated at the same time, the ground line (SG2) is open. 1. Symptom reproduction test Turn the combination switch OFF.
Page 174 dummyhead dummyhead FUEL SYSTEM DTC 14-1 (IAC VALVE CONTROL FAILURE) VALVE EACVP EACVM BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE GREEN LIGHT GREEN PINK WHITE GRAY 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the IAC valve 2P connector ECM connector B , and then reconnect them.
Page 175 dummyhead dummyhead FUEL SYSTEM DTC 21-1 (VTEC SOLENOID VALVE FAILURE) VTEC SOLENOID 12 V VALVE BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE GREEN LIGHT GREEN PINK WHITE GRAY 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the VTEC solenoid valve 1P connector , ECM connector B and then reconnect them.
Page 176 dummyhead dummyhead FUEL SYSTEM DTC 22-1, 22-2 (EOP SENSOR VOLTAGE TOO LOW OR TOO HIGH) POIL SENSOR VCC2 BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE GREEN LIGHT GREEN PINK JOINT CONNECTOR 2 WHITE GRAY DTC 22-1 (EOP SENSOR VOLTAGE IS TOO LOW) •...
Page 177 dummyhead dummyhead FUEL SYSTEM 3. EOP sensor power line open circuit inspection Measure the voltage between the EOP sensor 3P connector main wire harness side No.1 (Blue) EOP SENSOR 3P CONNECTOR terminal and engine ground. MAIN WIRE HARNESS SIDE Is the measurement within 4.75 – 5.25 V? –...
Page 178 dummyhead dummyhead FUEL SYSTEM 3. EOP sensor signal/GND line open circuit inspection Measure the voltage between the EOP sensor 3P EOP SENSOR 3P CONNECTOR connector main wire harness side No.2 MAIN WIRE HARNESS SIDE (Yellow/Red) terminal and No.3 (Green) terminal. Is the measurement within 4.75 –...
Page 179 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 open and short circuit between the knock sensor 1P connector main wire harness side No.1 (Red/Blue) terminal and ECM connector B No.29 (Red/Blue) terminal.
Page 180 dummyhead dummyhead FUEL SYSTEM – Temporary failure (code does reappear) 2. HO2S heater inspection Turn the combination switch OFF. Inspect the HO2S heater (page 5-108). Is the HO2S heater normal? – Repair open in the main wire harness between the No.4 fuse and the HO2S or between the HO2S and ECM.
Page 181 dummyhead dummyhead FUEL SYSTEM 2. ECT sensor 2 signal line short circuit inspection Turn the combination switch OFF and disconnect ECT SENSOR 2 (2P) CONNECTOR the ECT sensor 2 (2P) connector MAIN WIRE HARNESS SIDE Turn the combination switch ON. Measure the voltage between the ECT sensor 2 (2P) connector main wire harness side No.1...
Page 182 dummyhead dummyhead FUEL SYSTEM DTC 141-1, 141-2 (ECT SENSOR 3 VOLTAGE IS TOO LOW OR TOO HIGH) SENSOR 3 TOH2 BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE GREEN LIGHT GREEN JOINT CONNECTOR 2 PINK WHITE GRAY DTC 141-1 (ECT SENSOR 3 VOLTAGE IS TOO LOW) 1.
Page 183 dummyhead dummyhead FUEL SYSTEM DTC 141-2 (ECT SENSOR 3 VOLTAGE IS TOO HIGH) • When the DTC code 6-2, 7-2, 10-2, 22-2, 140-2, and 141-2 are indicated at the same time, the ground line (SG2) is open. 1. Symptom reproduction test Turn the combination switch OFF.
Page 184: Mil Troubleshooting
dummyhead dummyhead FUEL SYSTEM MIL TROUBLESHOOTING MIL INDEX Detected component Probable cause Ref. page No. of blinks Condition MIL does not Detected • Loose or poor contact of the 4-18 blink component connector • Faulty indicator light • Open circuit in MIL wire •...
Page 185 dummyhead dummyhead FUEL SYSTEM Detected component Probable cause Ref. page No. of blinks Condition Blink VTEC solenoid valve • Loose or poor contact of the 5-60 (BF90D/ (failure) connector 100A only) • Open and short circuit in VTEC solenoid valve wire •...
Page 186 dummyhead dummyhead FUEL SYSTEM MIL TURNS ON BUT DOES NOT BLINK WITH SCS SERVICE CHECK CONNECTOR CONNECTED TP SENSOR MAP SENSOR No.2 No.4 FUSE FUSE FUSE (15 A) (10 A) (10 A) R/Bl Br/Y WARNL R/Bu R/Bl 12 V W/Bl K-LINE TRMA Y/Bu...
Page 187 dummyhead dummyhead FUEL SYSTEM 1. DLC signal line short circuit inspection Turn the combination switch OFF and remove the SCS service check connector [1] from DLC Turn the combination switch ON. Measure the voltage between the DLC No.4 (Light green) terminal and engine ground. Is the measurement within 4.75 –...
Page 188 dummyhead dummyhead FUEL SYSTEM 4. MAP sensor power line short circuit inspection 2 Measure the voltage between the MAP sensor 3P connector main wire harness side No.1 MAP SENSOR 3P CONNECTOR (Brown/Yellow) terminal and engine ground. MAIN WIRE HARNESS SIDE Is the measurement within 4.75 –...
Page 189 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 TRIM ANGLE SENSOR 3P CONNECTOR (Brown/White) terminal and engine ground. MAIN WIRE HARNESS SIDE Is the measurement within 4.75 –...
Page 190 dummyhead dummyhead FUEL SYSTEM 2. HO2S inspection Turn the combination switch OFF. Inspect the HO2S (page 5-108). Is the HO2S correct? – GO TO STEP 3. – Replace the HO2S with a new one and recheck. 3. Fuel supply system inspection Measure the fuel pressure (page 5-97).
Page 191 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 MAIN WIRE HARNESS SIDE Turn the combination switch ON. Measure the voltage between the MAP sensor 3P connector main wire harness side No.1 (Brown/Yellow) terminal and engine ground.
Page 192 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 4 (CKP SENSOR) BLACK BROWN ORANGE YELLOW No.5 BLUE LIGHT BLUE FUSE GREEN LIGHT GREEN PINK (15 A) WHITE GRAY CKP SENSOR JOINT CONNCTOR 1 Y/Bl G/Bl GND5 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the CKP sensor 3P connector ECM connector A , and joint connector 1...
Page 193 dummyhead dummyhead FUEL SYSTEM 3. CKP sensor signal line open or short circuit/ GND line open circuit inspection Measure the voltage between the CKP sensor 3P connector main wire harness side No.1 (Blue) CKP SENSOR 3P CONNECTOR terminal and No.2 (Green/Black) terminal. MAIN WIRE HARNESS SIDE Is the measurement within 4.75 –...
Page 194 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 6 (EBT SENSOR) SENSOR BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE GREEN LIGHT GREEN PINK JOINT CONNCTOR 2 WHITE GRAY • When the MIL blinks 6, 7, 10, 22, 24, and 25 at the same time, the ground line (SG2) is open.
Page 195 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 7 (TP SENSOR) R/Bl SENSOR VCC2 R/Bl BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE GREEN LIGHT GREEN JOINT PINK WHITE GRAY CONNECTOR 2 • When the MIL blinks 6, 7, 10, 22, 24, and 25 at the same time, the ground line (SG2) is open.
Page 196 dummyhead dummyhead FUEL SYSTEM 3. TP sensor signal line open or short circuit inspection Turn the combination switch OFF. Disconnect the ECM connector A Check for open circuit between the TP sensor 3P connector main wire harness side No.2 (Red/ Black) terminal and ECM connector A main wire harness side No.8 (Red/Black) terminal.
Page 197 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 8 (CMP SENSOR) BLACK BROWN YELLOW ORANGE No.5 BLUE LIGHT BLUE FUSE GREEN LIGHT GREEN (15 A) PINK WHITE GRAY SENSOR JOINT CONNECTOR 1 G/Bl GND2 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the CMP sensor 3P connector ECM connector A , and joint connector 1...
Page 198 dummyhead dummyhead FUEL SYSTEM 3. CMP sensor signal line open or short circuit/ GND line open circuit inspection Measure the voltage between the CMP sensor 3P connector main wire harness side No.1 CMP SENSOR 3P CONNECTOR (Green) terminal and No.2 (Green/Black) terminal. MAIN WIRE HARNESS SIDE Is the measurement within 4.75 –...
Page 199 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 10 (ONE LONG BLINK AND NO SHORT BLINK) IAT SENSOR SENSOR BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE GREEN LIGHT GREEN PINK JOINT CONNECTOR 2 WHITE GRAY • When the MIL blinks 6, 7, 10, 22, 24, and 25 at the same time, the ground line (SG2) is open.
Page 200 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 14 (ONE LONG BLINK AND 4 SHORT BLINKS) IAC VALVE BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE GREEN LIGHT GREEN PINK WHITE GRAY VALVE EACVP EACVM 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the IAC valve 2P connector , ECM connector B...
Page 201: Solenoid Valve
dummyhead dummyhead FUEL SYSTEM MIL BLINKS 21 TIMES (2 LONG BLINKS AND ONE SHORT BLINK) VTEC SOLENOID VALVE BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE GREEN LIGHT GREEN PINK WHITE GRAY VTEC SOLENOID 12 V VALVE 1. Symptom reproduction test Turn the combination switch OFF.
Page 202 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 22 (2 LONG BLINKS AND 2 SHORT BLINKS) EOP SENSOR POIL SENSOR VCC2 Br/W BLACK BROWN YELLOW ORANGE LIGHT BLUE BLUE GREEN LIGHT GREEN PINK JOINT CONNECTOR 2 WHITE GRAY • When the MIL blinks 6, 7, 10, 22, 24, and 25 at the same time, the ground line (SG2) is open.
Page 203 dummyhead dummyhead FUEL SYSTEM 3. EOP sensor signal line open or short circuit/ GND line open circuit inspection Measure the voltage between the EOP sensor 3P connector main wire harness side No.2 EOP SENSOR 3P CONNECTOR (Yellow/Red) terminal and No.3 (Green) terminal. MAIN WIRE HARNESS SIDE Is the measurement within 4.75 –...
Page 204 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 open and short circuit between the knock sensor 1P connector main wire harness side No.1 (Red/Blue) terminal and ECM connector B No.29 (Red/Blue) terminal.
Page 205 dummyhead dummyhead FUEL SYSTEM 2. ECT sensor 2 signal line open or short circuit/ GND line open circuit inspection Turn the combination switch OFF and disconnect the ECT sensor 2 (2P) connector ECT SENSOR 2 (2P) CONNECTOR MAIN WIRE HARNESS SIDE Turn the combination switch ON.
Page 206 dummyhead dummyhead FUEL SYSTEM 2. ECT sensor 3 signal line open or short circuit/ GND line open circuit inspection Turn the combination switch OFF and disconnect the ECT sensor 3 (2P) connector ECT SENSOR 3 (2P) CONNECTOR MAIN WIRE HARNESS SIDE Turn the combination switch ON.
Page 207: Fuel Pressure Relieving
dummyhead dummyhead FUEL SYSTEM 2. HO2S sensor heater inspection Turn the combination switch OFF. Inspect the HO2S heater (page 5-108). Is the HO2S heater normal? – Repair open in the main wire harness between the ECM and HO2S. If main wire harness is correct, replace the ECM with a new one and recheck.
Page 208: Fuel Pump (Low Pressure Side) Removal/Installation
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 engine cover.
Page 209 dummyhead dummyhead FUEL SYSTEM Remove the two bolt/washers [1] and remove the silencer case [2]. INSTALLATION Set the air flow band [1] on the silencer grommet [2], and connect the silencer grommet into the throttle body until it stops. Tighten the two bolt/washers [3] securely. Tighten the air flow band to the dimension shown or tighten it to the specified torque.
Page 210: Intake Manifold Removal
dummyhead dummyhead FUEL SYSTEM INTAKE MANIFOLD REMOVAL/ INSTALLATION REMOVAL Remove the following: – Engine cover – Silencer case (page 5-67) Disconnect the MAP sensor 3P connector [1] and remove the harness band clip [2]. Disconnect the TP sensor 3P connector [1]. Remove the throttle rod [1].
Page 211 dummyhead dummyhead FUEL SYSTEM Disconnect the IAC valve 2P connector [1], and EOP sensor 3P connector [2]. Remove the two harness band clips [3]. Remove the three harness band clips [1] from the intake manifold. Release tube D [1] from the clamp of the intake manifold.
Page 212 dummyhead dummyhead FUEL SYSTEM INSTALLATION Install the new intake manifold gasket [1] on the intake manifold. • Align the projection [2] of the gasket with the groove [3] in the intake manifold. Set the intake manifold [1] on the engine. Install the three bolts [2], two bolt/washers [3], and the two nuts [4], and tighten them in the numbered sequence shown in two or three steps.
Page 213 dummyhead dummyhead FUEL SYSTEM Install the three harness band clips [1] in the positions shown. Set the pressure regulator control tube [1] and the vinyl tube [2] to the intake manifold. Connect the TP sensor 3P connector [1]. Connect the MAP sensor 3P connector [1], and install the harness band clip [2] on the set plate.
Page 214: Fuel Injectors Removal
dummyhead dummyhead FUEL SYSTEM FUEL INJECTORS 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. REMOVAL Disconnect the battery cable from the battery negative (–) terminal.
Page 215 dummyhead dummyhead FUEL SYSTEM Remove the two nuts [1], and remove the fuel line [2] and two collars [3]. Remove the following parts from the fuel line [1]: – Two injector clips [2] – Four bolts [3] – Four fuel injectors [4] –...
Page 216 dummyhead dummyhead FUEL SYSTEM INSTALLATION • Install the fuel injector as a set of 2. Apply thin coat of engine oil to a new O-ring (7.47 x 3.6 mm) [1], and install one on each injector [2]. Set a new O-ring (7.45 x 3.61 mm) [3] to the each fuel injector.
Page 217: Fuel Pump (High Pressure Side)/Vapor Separator Removal/Installation
dummyhead dummyhead FUEL SYSTEM Connect the 2P connectors [1] to the corresponding injectors. Install the three harness band clips [2]. Install the following: – L. engine under cover (page 6-7) – Engine cover FUEL PUMP (HIGH PRESSURE SIDE)/ VAPOR SEPARATOR REMOVAL/ INSTALLATION Gasoline is highly flammable and explosive.
Page 218 dummyhead dummyhead FUEL SYSTEM Release the water level sensor 2P connector [1] and the trim angle sensor 3P connector [2] from the relay bracket and remove the harness band clip [3] from the relay bracket. Remove the hose clip [4] from the fuel hose and fuel tube B.
Page 219 dummyhead dummyhead FUEL SYSTEM Release the fuel hose [1] from three fuel tube clamps [2]. Remove the bolt [1], and disconnect the fuel hose [2] from the fuel line. Remove the fuel pipe joint [3], and remove the two O- rings [4].
Page 220 dummyhead dummyhead FUEL SYSTEM INSTALLATION Connect the fuel pump (high pressure side) 2P connector [1]. Connect the fuel pump (high pressure side) 2P connector to the relay bracket, and secure the pump harness to the cord clamp [2]. Install the vapor separator, and tighten the three bolt/ washers [1] securely.
Page 221 dummyhead dummyhead FUEL SYSTEM Connect water tube A [1] and B [2] into the water jacket cover until they stop, and install the tube clip and tube clip B 10. Set fuel tube B [1] to the two fuel tube clamp Bs [2] by attaching the ends of the protector tubes to the fuel tube clamp Bs.
Page 222: Map Sensor Removal/Installation
dummyhead dummyhead FUEL SYSTEM Connect the pressure regulator control tube [1] and the vinyl tube [2] to the intake manifold. Set the pressure regulator control tube to the fuel tube clamp D [3]. Install the following: – L. engine under cover (page 6-7) –...
Page 223: Iac Valve Removal/Installation
dummyhead dummyhead FUEL SYSTEM IAC VALVE REMOVAL/INSTALLATION Remove engine cover. Loosen the three bolts, two nuts, two bolt/washers, and air flow band of the intake manifold (page 5-69). Disconnect the IAC valve 2P connector [1] from the IAC valve [2]. Remove the two bolts [3] and remove the IAC valve by slightly shifting the intake manifold.
Page 224: Ckp Sensor Removal/Installation
dummyhead dummyhead FUEL SYSTEM Remove the three bolts [1] and remove harness clip bracket D [2], VTEC solenoid valve [3], gasket [4], and the filter [5]. • Check the filter. If it is restricted, replace the engine oil and oil filter. Install a new gasket and filter on the VTEC solenoid valve.
Page 225: Eop Sensor Removal/Installation
dummyhead dummyhead FUEL SYSTEM EOP SENSOR REMOVAL/ INSTALLATION Remove the intake manifold (page 5-69). Disconnect the EOP sensor 3P connector [1] from the EOP sensor [2]. Apply engine oil to a new O-ring [3] and install on the cylinder block. Install the EOP sensor and tighten to the specified torque.
Page 226: Ect Sensor 2 Removal/Installation
dummyhead dummyhead FUEL SYSTEM ECT SENSOR 2 REMOVAL/ INSTALLATION Remove engine cover. Disconnect the ECT sensor 2 (2P) connector [1] from ECT sensor 2 [2]. Remove ECT sensor 2. Apply engine oil to a new O-ring [3] and install on ECT sensor 2.
Page 227: Air Vent Strainer/Check Valve Removal/Installation
dummyhead dummyhead FUEL SYSTEM AIR VENT STRAINER/CHECK VALVE REMOVAL/INSTALLATION Remove the intake manifold (page 5-69). • Check each tube for deterioration or cracks and replace the tubes if necessary. • After assembly, check that the tube clamps are set securely (page 2-43). O-RING HARNESS CLIP BOLT...
Page 228: Water Separator Removal
dummyhead dummyhead FUEL SYSTEM WATER SEPARATOR REMOVAL/ INSTALLATION REMOVAL • Before removing the water separator, place a shop towel under each tube and water separator, clamp the two fuel tubes with commercially available tube clamps, and then disconnect the fuel tubes. Clamp fuel tube A [1] and fuel tube B [2] securely with the two commercially available tube clamps [3].
Page 229 dummyhead dummyhead FUEL SYSTEM INSTALLATION • Check each tube for deterioration or cracks, and replace if necessary. Set the suspension [1] on the water separator cup [2] with the projection [3] up. Install the suspension so that the flat part on the backside [4] of the suspension is in line with the mark (suction side) [5] of the joint.
Page 230: Water Separator Disassembly
dummyhead dummyhead FUEL SYSTEM Connect fuel tube A [1] to the mark (suction side) [2] of the joint of the water separator. Connect fuel tube B [3] to the mark (discharge side) [4] of the joint of the water separator, aligning the "I" mark [5] on fuel tube B with the mark on the water separator.
Page 231: Assembly
dummyhead dummyhead FUEL SYSTEM SILENCER CASE DISASSEMBLY/ASSEMBLY SENSOR GROMMET ASSEMBLY: Install the sensor grommet in the direction shown. COLLAR (2) SILENCER CASE GROMMET (2) IAT SENSOR AIR FLOW BAND SILENCER GROMMET ASSEMBLY: Install the silencer grommet so the projection on the silencer grommet sits between the two projections on the VINYL TUBE (4 x 7 x 190 mm) silencer case.
Page 232: Fuel Pump (High Pressure Side)/Vapor Separator Disassembly/Assembly
dummyhead dummyhead FUEL SYSTEM FUEL PUMP (HIGH PRESSURE SIDE)/VAPOR SEPARATOR DISASSEMBLY/ASSEMBLY COMPONENTS LOCATION Remove the fuel pump (high pressure side) and vapor separator (page 5-76). PRESSURE REGULATOR PRESSURE REGULATOR CONTROL TUBE O-RING BOLT (6 x 14 mm) (2) SCREW-WASHER (5 mm) (3) 11.8 N·m (1.2 kgf·m, 9 lbf·ft) CORD CLAMP 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft)
Page 233 dummyhead dummyhead FUEL SYSTEM SCREW-WASHER (5 mm) (6) 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) VAPOR SEPARATOR COVER FLOAT VALVE O-RING FLOAT PIN FLOAT SCREW (2) 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) GASKET FUEL TUBE CLAMP B VAPOR SEPARATOR BODY WATER JACKET COVER SCREW-WASHER (4 mm) (5) 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) 5-92...
Page 234 dummyhead dummyhead FUEL SYSTEM FUEL PUMP ASSEMBLY Install new O-rings [1] on the vapor separator body. Install the pump case [2] with care not to allow the O- rings to come out of position. Set the bracket [3] on the bolt [4]. TORQUE: 11.8 N·m (1.2 kgf·m, 9 lbf·ft) Install tube clamp B [5] and grommet [6] on the bracket.
Page 235 dummyhead dummyhead FUEL SYSTEM Install the pump harness [1] on the pump cover [2], and install the screw [3] and washer [4]. Tighten the screw to the specified torque. TORQUE: 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) Set each wire in the respective recess [1] in the holder, and set the Blue/Yellow terminal [2] and Black terminal [3] in the positions shown.
Page 236 dummyhead dummyhead FUEL SYSTEM Install a new O-ring [1] on the pump case. Connect the Blue/Yellow wire [2] and Black wire [3] from the pump harness to the fuel pump. • Connect the Blue/Yellow wire terminal to the positive (+) terminal [4] of the pump, and the Black wire terminal to the negative (-) terminal [5] of the pump securely.
Page 237: Fuel Tank/Fuel Tank Tube Disassembly/Assembly
dummyhead dummyhead FUEL SYSTEM FUEL TANK/FUEL TANK TUBE DISASSEMBLY/ASSEMBLY 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. DISASSEMBLY TUBE CLIP BANDS (12.5 mm)
Page 238: 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 239: 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. Check that the pressure regulator control tube [1] is not bent, disconnected, or damaged.
Page 240: Fuel Pump (Low Pressure Side)
dummyhead dummyhead FUEL SYSTEM FUEL PUMP (LOW PRESSURE SIDE) INSPECTION Remove the fuel pump (low pressure side) (page 5-67). Push the fuel pump plunger [1] and make sure the plunger moves smoothly. If the plunger is stiff, replace the fuel pump (low pressure side).
Page 241 dummyhead dummyhead FUEL SYSTEM CIRCUIT INSPECTION PGM-FI/MAIN RELAY FUEL PUMP FUSE FUSE FUSE (10 A) (30 A) (10 A) FLR1 FLR2 REMOTE CONTROL TYPE: W/Bl BATTERY LOAD Bl/Y COMBINATION SWITCH GND6 GND4 Bl/Y W/Bl TILLER HANDLE TYPE: JOINT CONNECTOR 1 JOINT CONNECTOR 2 GND2 W/Bl...
Page 242 dummyhead dummyhead FUEL SYSTEM 3. Pump harness inspection Turn the combination switch OFF and disconnect the PGM-FI/main relay 6P connector Check for continuity between the PGM-FI/main relay 6P connector main wire harness side No.3 (Blue/Red) terminal and fuel pump (high pressure side) 2P connector main wire FUEL PUMP 1...
Page 243: Vapor Separator Inspection
dummyhead dummyhead FUEL SYSTEM VAPOR SEPARATOR INSPECTION FLOAT VALVE Disassemble the vapor separator (page 5-91). If gasoline overflows from the vapor separator, perform the following check. Remove the float valve [1] from the float. Check the float valve tip and valve seat [2] for wear and damage.
Page 244: Fuel Injector Inspection
dummyhead dummyhead FUEL SYSTEM FUEL INJECTOR INSPECTION OPERATION INSPECTION • If engine does not start, refer to "ENGINE DOES NOT START" (page 4-2). Start the engine and let it idle. Confirm the fuel injector operates with a sounding rod or stethoscope [1]. If the fuel injector does not operate, check the following: –...
Page 245 dummyhead dummyhead FUEL SYSTEM CIRCUIT INSPECTION FUEL FUEL FUEL FUEL INJECTOR 4 INJECTOR 3 INJECTOR 2 INJECTOR 1 No.5 FUSE (15 A) INJ4 INJ3 INJ2 INJ1 BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE GREEN LIGHT GREEN JOINT CONNECTOR 1 PINK WHITE GRAY 1.
Page 246: Throttle Body Inspection
dummyhead dummyhead FUEL SYSTEM THROTTLE BODY INSPECTION INSPECTION Remove the following: – Engine cover – Silencer case (page 5-67) Check that the throttle valve turns smoothly when the throttle cam is turned. Check that there is no looseness on the throttle valve shaft when turning the throttle lever.
Page 247: Ebt Sensor/Ect Sensor 2/3
dummyhead dummyhead FUEL SYSTEM EBT SENSOR/ECT SENSOR 2/3 INSPECTION Remove the following: – EBT sensor (page 5-84) – ECT sensor 2 (page 5-85) – ECT sensor 3 (page 5-85) Heat the coolant with an electric heating element. Suspend the sensor [1] in heated coolant and check the continuity through the sensor as the coolant heats up.
Page 248: Vtec Solenoid Valve Inspection (Bf90D/Bf100A Only)
dummyhead dummyhead FUEL SYSTEM VTEC SOLENOID VALVE INSPECTION (BF90D/BF100A ONLY) Remove the following: – Engine cover – L. engine under cover (page 6-5). Disconnect the VTEC solenoid valve 1P connector [1]. Measure the resistance between the VTEC solenoid valve 1P connector terminal and body ground. Resistance: 14 - 16 Ω...
Page 249: Ho2S Inspection
dummyhead dummyhead FUEL SYSTEM HO2S INSPECTION SYSTEM INSPECTION 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 250 dummytext 6. ENGINE COVER COMPONENT LOCATION ······················· 6-2 UNDER COVER FRONT BRACKET REMOVAL/INSTALLATION ··················· 6-12 ENGINE COVER REMOVAL/ INSTALLATION ····································· 6-3 UNDER COVER REAR BRACKET REMOVAL/ INSTALLATION··································· 6-15 FRONT SEPARATE COVER REMOVAL/ INSTALLATION ····································· 6-4 UNDER COVER FRONT BRACKET DISASSEMBLY/ASSEMBLY·················· 6-17 L./R.
Page 251: Component Location
dummyhead dummyhead ENGINE COVER COMPONENT LOCATION ENGINE COVER 10 N·m (1.0 kgf·m, 7 lbf·ft) 5 N·m (0.51 kgf·m, 3.7 lbf·ft) 5 N·m (0.51 kgf·m, 3.7 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 5 N·m (0.51 kgf·m, 3.7 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft)
Page 252: Engine Cover Removal
dummyhead dummyhead ENGINE COVER ENGINE COVER REMOVAL/ INSTALLATION REMOVAL Unlock the locks on the front and rear sides of the engine cover and remove the engine cover. ENGINE COVER ENGINE COVER SEAL INSTALLATION ® Apply glue (LOCTITE 460 or equivalent) to the engine cover seal [1] at the points shown.
Page 253: Front Separate Cover Removal
dummyhead dummyhead ENGINE COVER FRONT SEPARATE COVER REMOVAL/INSTALLATION REMOVAL Remove the engine cover. Remove the bolt [1], special bolt (6 x 17 mm) [2], special bolt (6 x 37 mm) [3] and, front separate cover [4]. INSTALLATION Install the front separate cover [1] on the outboard motor and loosely tighten the bolt [2], special bolt (6 x 17 mm) [3], and special bolt (6 x 37 mm) [4].
Page 254 dummyhead dummyhead ENGINE COVER L./R. ENGINE UNDER COVER REMOVAL/INSTALLATION REMOVAL Remove the following: – Engine cover – Front separate cover (page 6-4) Remove the flush plug cap [1] from the water joint cap [2] of the R. engine under cover. Disconnect the power trim/tilt switch 3P connector [1].
Page 255 dummyhead dummyhead ENGINE COVER Remove the six bolt/washers [1], five special bolts [2], and rear bracket bolt [3] from the L./R. engine under covers. Remove the L. engine under cover [1] and R. engine under cover [2] from the engine side stoppers [3].
Page 256: Installation
dummyhead dummyhead ENGINE COVER Remove the L. engine under cover [1] and R. engine under cover [2] from the outboard motor. INSTALLATION Align the L. engine under cover installation groove [1] with the under cover seal A [2] of the mount case as shown, and install the L.
Page 257 dummyhead dummyhead ENGINE COVER Install the L. engine under cover [1] on the engine side stoppers [2]. Pull out the power trim/tilt switch wire through the top of the R. engine under cover. Align the R. engine under cover installation groove [1] with the under cover seal A [2] of the mount case as shown, and install the R.
Page 258 dummyhead dummyhead ENGINE COVER Install the L./R. engine under covers, aligning the projection [1] on the front side (swivel case side) of the L. engine under cover with the recess [2] in the R. engine under cover as shown. • Do not allow the R. engine under cover to interfere with the tube (8 x 300 mm) of the mount case or with the oil drain part of the oil case during installation.
Page 259 dummyhead dummyhead ENGINE COVER Loosely tighten the six bolt/washers [1] and five special bolts [2] to the L./R. engine under covers. Loosely tighten the rear bracket bolt [3] to the under cover rear bracket. • Be sure that the shoulders on the special bolts go into the holes on the L./R. engine under covers. Tighten the bolts to the specified torque in the numbered order as shown.
Page 260 dummyhead dummyhead ENGINE COVER Connect the power trim/tilt switch 3P connector [1]. Tighten the flush plug cap [1] against the water joint cap [2] of the R. engine under cover. Install the following: – Front separate cover (page 6-4) – Engine cover ENGINE SIDE STOPPER REMOVAL/INSTALLATION REMOVAL Remove the L./R.
Page 261: Under Cover Front Bracket Removal/Installation
dummyhead dummyhead ENGINE COVER INSTALLATION Install the following: – Grommet [1] – Collar [2] – Seat side rubber [3] Install the engine side stopper [4] and loosely tighten the bolt/washer [5]. Set the fuel hose from fuel tube clamp B [6]. Set air vent tube C to fuel tube clamp B [7].
Page 262 dummyhead dummyhead ENGINE COVER Remove the bolt/washers [1] and pull the under cover front bracket [2] toward you. Disconnect the trim angle sensor 3P connector [1] and the power tilt motor 2P connector [2]. Remove under case grommet C [1] from the under cover front bracket [2].
Page 263 dummyhead dummyhead ENGINE COVER INSTALLATION Set the under cover front bracket [1] on the outboard motor. Pass the wires [1] through the hole [2] in the under cover front bracket. Check that the end of the taped parts [1] of the power tilt motor wire align with the end of under case grommet C [2], and install under case grommet C [3] on the under cover front bracket [4].
Page 264 dummyhead dummyhead ENGINE COVER Install the bolt/washer (6 x 95 mm) [1], bolt/washers (6 x 27 mm) [2], and tighten them. Install the vinyl tube [1] into the under cover front bracket [2]. Install the following: – Remote control cable grommet (page 19-5) –...
Page 265 dummyhead dummyhead ENGINE COVER Remove the two bolts [1], two washers [2], and two distance collars [3]. Remove the under cover rear bracket [4] from the outboard motor. INSTALLATION Install the under cover rear bracket [1] and two distance collars [2] on the outboard motor. Install the two bolts [3] and two washers [4] and tighten the bolts.
Page 266: Under Cover Front Bracket Disassembly/Assembly
dummyhead dummyhead ENGINE COVER Insert the idle exhaust port [1] into the mount case [2] until the upper and lower lips [3] of the idle exhaust port sit on the mount case securely and the upper lip [4] is level to the mount case as shown. Install the following: –...
Page 267: Assembly
dummyhead dummyhead ENGINE COVER R. ENGINE UNDER COVER DISASSEMBLY/ASSEMBLY Remove the L./R. engine under cover (page 6-5). Remove the nut [1] and water joint cap [2]. Remove the switch stay [3] and power trim/tilt switch [4]. Install the water joint cap on the R. engine under cover [5]. Apply locking agent to the seating surface of the nut and tighten it to the specified torque.
Page 268 dummytext 7. CHARGING SYSTEM SYSTEM LOCATION ······························ 7-2 ALTERNATOR COVER··························· 7-5 SYSTEM DIAGRAM ······························· 7-2 ALTERNATOR REMOVAL/ INSTALLATION····································· 7-6 CHARGING SYSTEM TROUBLESHOOTING ···························· 7-3 ALTERNATOR INSPECTION ················· 7-13 COMPONENT LOCATION ······················· 7-4 REGULATOR/RECTIFIER INSPECTION ·· 7-13...
Page 269: System Location
dummyhead dummyhead CHARGING SYSTEM SYSTEM LOCATION CHARGING SYSTEM ALTERNATOR REGULATOR/RECTIFIER SYSTEM DIAGRAM ALTERNATOR ALTERNATOR FUSE 70 A FUSE ACGLP (10 A) REMOTE CONTROL TYPE: REGULATOR/ INDICATOR LIGHT COMBINATION RECTIFIER (ALTERNATOR WARNING LIGHT) SWITCH BATTERY LOAD BAT ACGLP BAT W/Bu W/Bu Bl/Y Bl/Y W/Bl...
Page 270: Troubleshooting
dummyhead dummyhead CHARGING SYSTEM CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. Battery test Remove the battery. Check the battery condition using a commercially available battery tester. Is the battery in good condition? – GO TO STEP 2. – Faulty battery. 2.
Page 271: Component Location
dummyhead dummyhead CHARGING SYSTEM COMPONENT LOCATION Tighten the bolt in 3 steps: 1. Torque to 187 N·m (19.1 kgf·m, 138 lbf·ft) to seat the alternator rotor, and then loosen the bolt. 2. Torque to 37 N·m (3.8 kgf·m, 27 lbf·ft). 3.
Page 272: Alternator Cover
dummyhead dummyhead CHARGING SYSTEM ALTERNATOR COVER Remove the engine cover. ALTERNATOR COVER INSTALLATION: BOLT (6 X 25 mm) After installing the alternator cover, set the breather tube on the hooks of the alternator cover. WASHER (6 mm) HOOKS ALTERNATOR COVER GROMMET CASE COLLAR HOOKS BREATHER TUBE C...
Page 273: Alternator Removal
dummyhead dummyhead CHARGING SYSTEM ALTERNATOR REMOVAL/ INSTALLATION REMOVAL Remove the following: – Engine cover – Alternator cover (page 7-5) Disconnect the CKP sensor 3P connector. Remove the bolt [1] and CKP sensor [2] from the chain case [3]. Remove the O-ring [4] from the CKP sensor. Loosen the bolt/washer using the pulley holder attachment and the holder handle (special tools) as shown.
Page 274 dummyhead dummyhead CHARGING SYSTEM Remove the two bolts [1] and ECM. Remove the harness band clip [1] from the electronic parts case. Remove the harness band clip [1] from the electronic parts case. Release the stator harness [2] from the electronic parts case clamp and disconnect the stator 3P connector [3].
Page 275 dummyhead dummyhead CHARGING SYSTEM Release the stator harness [1] through the gap between the electronic parts case [2] case and main wire harness [3]. Remove the bolt [1] and harness clip bracket E [2]. Release the stator harness [3] from the electric parts [4] and chain case [5].
Page 276 dummyhead dummyhead CHARGING SYSTEM EXPLODED VIEW BOLT/WASHER (14 X 36 mm) ALTERNATOR ROTOR Tighten the bolt in 3 steps: BOLT (6 X 14 mm) 1. Torque to 187 N·m (19.1 kgf·m, HARNESS 138 lbf·ft) to seat the alternator rotor, BAND CLIP E and then loosen the bolt.
Page 277 dummyhead dummyhead CHARGING SYSTEM Set the stator harness [1] on the chain case [2] and electronic parts case [3] as shown. Install harness clip bracket E [4] and tighten the bolt [5]. Route the stator harness [1] through the gap between the electronic parts case [2] and main wire harness [3] as shown.
Page 278 dummyhead dummyhead CHARGING SYSTEM Set the main wire harness band clip [1] on the electronic parts case. Install the ECM [1] and two bolts [2]. Tighten the bolts to the specified torque. TORQUE: 5 N·m (0.51 kgf·m, 3.7 lbf·ft) Install harness clip bracket C [1] and two bolts [2] to the chain case [3].
Page 279 dummyhead dummyhead CHARGING SYSTEM Install the alternator rotor [1] on the crankshaft, and loosely tighten the bolt/washer [2]. • Note that the alternator rotor has very strong magnetic force. Hold the alternator rotor [3] by the pulley during installation and removal and do not hold it by the rotor pulser plate [4] so you don’t pinch your fingers with the rotor.
Page 280: Alternator Inspection
dummyhead dummyhead CHARGING SYSTEM ALTERNATOR INSPECTION ALTERNATOR ROTOR Check the pulser plate for deformation and damage. Replace the pulser plate with a new one if necessary. ALTERNATOR STATOR Measure the resistance between the following terminals. Between No.1 and No.2 terminals Between No.1 and No.3 terminals 0.09 –...
Page 281 dummyhead dummyhead MEMO...
Page 282: Ignition System
dummytext 8. IGNITION SYSTEM SYSTEM LOCATION ······························ 8-2 IGNITION SYSTEM TROUBLESHOOTING ···························· 8-3 SYSTEM DIAGRAM ······························· 8-2...
Page 283 dummyhead dummyhead IGNITION SYSTEM SYSTEM LOCATION IGNITION SYSTEM CKP SENSOR PGM-FI MAIN RELAY IGNITION COIL SYSTEM DIAGRAM IGNITION COIL NO.1 IGNITION COIL NO.3 FUSE (30 A) FUSE (15 A) W/Bl FUSE FUSE (10 A) (15 A) W/Bl BATTERY SPARK SPARK PLUG PLUG PGM-FI/...
Page 284 dummyhead dummyhead IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING 1. MIL inspection 1 Turn the combination switch ON and check the MIL. Does the MIL stay on for a few seconds, and then go off? – GO TO STEP 3. – GO TO STEP 2. 2.
Page 285 dummyhead dummyhead IGNITION SYSTEM 8. Ignition coil power/ground line open circuit inspection Turn the combination switch OFF. IGNITION COIL 3P CONNECTOR Disconnect the ignition coil 3P connector. MAIN WIRE HARNESS SIDE Turn the combination switch ON. Measure the voltage between the ignition coil 3P connector main wire harness side No.3 (Yellow/ IGP 1/2/3/4 Black) terminal and No.2 (Black) terminal.
Page 286 dummytext 9. STARTING SYSTEM SYSTEM LOCATION ······························ 9-2 FLYWHEEL REMOVAL/INSTALLATION···· 9-8 SYSTEM DIAGRAM ······························· 9-2 STARTER MOTOR DISASSEMBLY/ ASSEMBLY ········································ 9-10 STARTING SYSTEM TROUBLESHOOTING ···························· 9-3 STARTER MOTOR INSPECTION ··········· 9-19 STARTER MOTOR REMOVAL/ FLYWHEEL INSPECTION ····················· 9-22 INSTALLATION ····································· 9-5 NEUTRAL SWITCH INSPECTION···········...
Page 287: System Location
dummyhead dummyhead STARTING SYSTEM SYSTEM LOCATION STARTING SYSTEM PGM-FI/MAIN RELAY STARTER MOTOR NEUTRAL SWITCH SYSTEM DIAGRAM BLACK BROWN YELLOW ORANGE PGM-FI/MAIN RELAY BLUE LIGHT BLUE GREEN LIGHT GREEN PINK WHITE GRAY FUSE FUSE (10 A) (30 A) STARTER MOTOR BATTERY GND2 TILLER HANDLE TYPE: REMOTE CONTROL TYPE:...
Page 288: Troubleshooting
dummyhead dummyhead STARTING SYSTEM STARTING SYSTEM TROUBLESHOOTING STARTER MOTOR DOES NOT TURN 1. Standard inspection Check the following: – Battery condition – Blown No. 2 (10 A) fuse – Blown No. 6 (30 A) fuse Are the above items in good condition? –...
Page 289 dummyhead dummyhead STARTING SYSTEM 5. Shift control cable inspection Control lever is in the "N" (Neutral) position. Tip [1] of the neutral switch is set in the detent assisted spring [2] securely and the detent spring roller [3] is set in the groove [4] in the shift arm. Shift cable adjustment correct? –...
Page 290: Starter Motor Removal
dummyhead dummyhead STARTING SYSTEM STARTER MOTOR TURNS SLOWLY • Low battery voltage • Poorly connected battery terminal cable • Poorly connected starter motor cable • Faulty starter motor • Poorly connected battery ground cable • Incorrect engine oil viscosity STARTER MOTOR TURNS, BUT ENGINE DOES NOT TURN •...
Page 291 dummyhead dummyhead STARTING SYSTEM Remove the bolts [1] and starter motor [2]. Remove the O-ring [1] from the starter motor [2]. INSTALLATION Install a new O-ring [1] to the starter motor [2]. Install the bolts [1] and tighten them to the specified torque.
Page 292 dummyhead dummyhead STARTING SYSTEM Set the PGM-FI/Main relay white wire [1] and the fuse cable [2] in the recess [3] in the electronic parts case. Set the starter cable (+) [1] on the B terminal [2] of the starter motor [3]. Install and tighten the nut [4] to the specified torque while adjusting the clearance between the starter cable (+) and the starter motor to 10 –...
Page 293: Flywheel Removal/Installation
dummyhead dummyhead STARTING SYSTEM FLYWHEEL REMOVAL/INSTALLATION REMOVAL Remove the engine (page 13-3). Remove the starter motor (page 9-5). Set the special tool on the mounting flange of the starter motor. TOOL Ring gear holder [1] 070PB-ZY9A100 Insert the starter motor mounting bolt (10 x 75 mm) [2] that has been tightening the starter motor into the bolt hole, and secure the special tool by tightening the starter mounting bolt (10 x 35 mm) [3].
Page 294 dummyhead dummyhead STARTING SYSTEM INSTALLATION Clean the crankshaft and flywheel mating surfaces Apply engine oil to the threads and seating surface of the bolts. Install the flywheel [2] on the crankshaft [3] and loosely tighten the six bolts. Set the special tool on the mounting flange of the starter motor.
Page 295: Starter Motor Disassembly
dummyhead dummyhead STARTING SYSTEM STARTER MOTOR DISASSEMBLY/ ASSEMBLY DISASSEMBLY Remove the nut [1] by pulling off the terminal cover [2] and disconnect the motor wire [3] from the M terminal [4]. Remove the two screws [1]. Remove the starter solenoid [2], spring [3], and plunger [4].
Page 296 dummyhead dummyhead STARTING SYSTEM Remove the yoke [1] from the armature/rear bracket assembly [2]. Remove the two screws [1] and rear bracket [2] from the armature [3]. Remove the brush holder [1] from the armature [2]. Remove the steel ball [1] and three planetary gears [2] from the front bracket [3].
Page 297 dummyhead dummyhead STARTING SYSTEM Remove the packing [1] from the front bracket [2]. Remove the overrunning clutch [1] and clutch fork [2] from the front bracket [3]. Secure the gear shaft [1] by placing a wood block [2] under the gear shaft assembly, taking care not to touch the internal gear [3].
Page 298 dummyhead dummyhead STARTING SYSTEM Remove the gear shaft stopper [1], internal gear [2], and overrunning clutch [3] from the gear shaft [4]. Remove the clip [1] and plate [2] from the brush holder [3]. Remove the brush sets [4] and four brush springs [5]. 9-13...
Page 299 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 9-18). CLIP BRUSH SET PLATE REAR BRACKET BRUSH HOLDER BRUSH SPRING (4) SCREW (5 x 8 mm) (2)
Page 300: Assembly
dummyhead dummyhead STARTING SYSTEM ASSEMBLY Set the four brush springs [1] and brush sets [2] into the brush holder [3]. Install the plate [4] on the brush holder and secure it with the clip [5]. Apply grease to the internal gear [1], inner wall of the overrunning clutch [2], gear shaft [3] outer surface, and whole surface of the gear shaft stopper [4].
Page 301 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 302 dummyhead dummyhead STARTING SYSTEM Install the brush holder [1] onto the armature [2]. Apply grease to the armature shaft. Install the rear bracket [3]. Apply water resisting sealant (Sumitomo 3M Padding Sealer #8533 or equivalent) to the seating surface of each screw [4].
Page 303 dummyhead dummyhead STARTING SYSTEM Install the spring [1] and plunger [2] to the starter solenoid [3], then assemble the plunger and clutch fork [4] as shown. Install and tighten the two screws [5]. Connect the motor wire [6] to the M terminal [7] and tighten the nut [8].
Page 304: Starter Motor Inspection
dummyhead dummyhead STARTING SYSTEM STARTER MOTOR INSPECTION BRUSH LENGTH Measure the brush length [1]. If brush length is less than the service limit, replace the brushes as a set. STANDARD: 12.3 mm (0.48 in) SERVICE LIMIT: 7.0 mm (0.28 in) MICA DEPTH Measure the mica depth [1].
Page 305 dummyhead dummyhead STARTING SYSTEM Measure the commutator [1] O.D. STANDARD: 29.4 mm (1.16 in) SERVICE LIMIT: 28.8 mm (1.13 in) If the measurement is less than the service limit, replace the armature with a new one. 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.
Page 306 dummyhead dummyhead STARTING SYSTEM Check for continuity between the commutator and armature coil core. If continuity exists, replace the armature. 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).
Page 307: Flywheel Inspection
dummyhead dummyhead STARTING SYSTEM STARTER SOLENOID Check for continuity between the S terminal and front bracket. If there is no continuity, replace the starter solenoid. Check for continuity between the S terminal and M terminal. If there is no continuity, replace the starter solenoid. FLYWHEEL INSPECTION Check the ring gear [1] for wear and damage.
Page 308: Other Electrical
dummytext 10. OTHER ELECTRICAL SYSTEM LOCATION ···························· 10-2 PGM-FI/MAIN RELAY INSPECTION······· 10-13 ECM, PGM-FI/MAIN RELAY REMOVAL/ FUSE BOX INSPECTION ····················· 10-14 INSTALLATION ··································· 10-3 70 A FUSE BOX/FUSE INSPECTION ····· 10-14 REGULATOR/RECTIFIER/FUSE BOX/70 A FUSE BOX REMOVAL/INSTALLATION··· 10-4 POWER TILT RELAY INSPECTION ······· 10-15 STARTER CABLE/FUSE CABLE POWER TRIM/TILT SWITCH INSPECTION REMOVAL/INSTALLATION ···················...
Page 309: System Location
dummyhead dummyhead OTHER ELECTRICAL SYSTEM LOCATION OTHER ELECTRICAL PGM-FI/MAIN RELAY 70 A FUSE BOX FUSE BOX POWER TILT RELAY 10-2...
Page 310 dummyhead dummyhead OTHER ELECTRICAL ECM, PGM-FI/MAIN RELAY REMOVAL/INSTALLATION Remove the following: – Battery (-) cable – Engine cover – R. engine under cover (page 6-5) ELECTRONIC PARTS COLLAR (4) CASE GROMMET (4) ELECTRONIC PARTS CASE BOLT/WASHER (6 X 27 mm) (4) STATOR HARNESS SENSOR 2 HARNESS CLIP...
Page 311: Regulator/Rectifier/Fuse Box/70 Afuse Box Removal/Installation
dummyhead dummyhead OTHER ELECTRICAL Set the ground terminals with the Blue and black terminals [1] on the upper side, and the Black terminals [2] on the lower side as shown. Tighten the two bolts [3] while pushing the ground terminals against the projections [4] on the cylinder block as shown.
Page 312 dummyhead dummyhead OTHER ELECTRICAL Insert a screwdriver or equivalent tool [1] into the locking lug [2] on the fuse box [3] and unlock. With the lock unlocked, pull the fuse box toward you. Remove the fuse box from the fuse box bracket [4]. Remove the power trim/tilt switch 3P connector [1] and the two harness band clips [2] from the fuse box bracket [3].
Page 313: Starter Cable/Fuse Cable Removal/Installation
dummyhead dummyhead OTHER ELECTRICAL STARTER CABLE/FUSE CABLE REMOVAL/INSTALLATION REMOVAL Remove the following: – Battery (+) cable and (-) cable – Engine cover – R./L. engine under cover (page 6-5) – Under cover front bracket (page 6-12) – Fuse box bracket (page 10-5) Remove the harness band clip [1] from the neutral switch bracket [2].
Page 314 dummyhead dummyhead OTHER ELECTRICAL Release the starter cable (+) [1], starter cable (-) [2], and fuse cable [3] from the starter cable holder [4]. Remove the harness band clip [1] from the electronic parts case [2] and release the fuse cable [3]. Remove the 70 A fuse box cover [1].
Page 315 dummyhead dummyhead OTHER ELECTRICAL Remove the ECM (page 10-3) Release the fuse box 5P connector [1] from the ECM bracket [2] and disconnect the 5P connector. Open the wire harness clip [3], and remove the fuse cable [4]. EXPLODED VIEW FUSE CABLE TERMINAL COVER NEUTRAL SWITCH...
Page 316 dummyhead dummyhead OTHER ELECTRICAL Set the fuse cable [1] and install the bolt [2]. Tighten the bolt. Install the 70 A fuse box cover [3]. Install the harness band clip [1] to the electronic parts case [2]. Set the fuse cable [3] to the groove [4] of the electronic parts case.
Page 317 dummyhead dummyhead OTHER ELECTRICAL Set the starter cable (+) [1] on the B terminal [2] of the starter motor [3]. Install and tighten the nut [4] to the specified torque while adjusting the clearance between the starter cable (+) and the starter motor to 10 – 20 mm (0.4 – 0.8 in) as shown.
Page 318: Power Tilt Relay/Relay Bracket Removal/Installation
dummyhead dummyhead OTHER ELECTRICAL POWER TILT RELAY/RELAY BRACKET REMOVAL/INSTALLATION Remove the following: – Battery cable (-) – Engine cover – R./L. Engine under cover (page 6-5) – Under cover front bracket (page 6-12) – Silencer case (page 5-67) – Water separator (page 5-87) CODE CLAMPER FUEL PUMP 2P MAIN WIRE HARNESS...
Page 319 dummyhead dummyhead OTHER ELECTRICAL HARNESS BRACKET CLIP GROMMET (4) COLLAR (4) RELAY BRACKET CLIP C BOLT/WASHER (6 x 28 mm) (4) NUT (20 mm) 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft) NEUTRAL SWITCH BRACKET POWER TILT BOLT (6 x 12 mm) BOLT (6 x 14 mm) RELAY COLLAR (2) NEUTRAL...
Page 320: Pgm-Fi/Main Relay Inspection
dummyhead dummyhead OTHER ELECTRICAL PGM-FI/MAIN RELAY INSPECTION • Check the battery condition before starting the inspection. • Do not connect the battery for more than 30 seconds. Wait for one minute or more before connecting the battery again. MAIN RELAY CIRCUIT INSPECTION Connect the 6P connector PGM-FI/main relay side No.2 (Black/yellow) terminal to the battery (+) terminal using a jumper wire.
Page 321: Fuse Box Inspection
dummyhead dummyhead OTHER ELECTRICAL FUSE BOX INSPECTION • Disconnect the battery cable at the negative (-) FUSE BOX cable before the inspection. Remove the fuses and check for blown fuses. If the fuses are normal, install them in the fuse box and check for continuity between the terminals shown below.
Page 322: Power Tilt Relay Inspection
dummyhead dummyhead OTHER ELECTRICAL POWER TILT RELAY INSPECTION • Remove the power tilt relay before inspection. Check for continuity between the following terminals. Between Green and Black Continuity Between Blue and Black Continuity POWER TILT RELAY Between Green and White No continuity Between Blue and White No continuity...
Page 323: Power Trim/Tilt Switch Inspection (Outboard Motor Side)
dummyhead dummyhead OTHER ELECTRICAL POWER TRIM/TILT SWITCH INSPECTION (OUTBOARD MOTOR SIDE) Remove the engine cover. Disconnect the power trim/tilt switch 3P connector [1]. Attach the tester lead to each terminal and check for continuity. When the switch is pushed "UP" or "DN", there should be continuity between the terminals marked with a circle in the table below.
Page 324: Cooling System
dummytext 11. COOLING SYSTEM COMPONENT LOCATION ····················· 11-2 RELIEF VALVE REMOVAL/ INSTALLATION·································· 11-11 WATER LINE DESCRIPTION················· 11-3 FLUSH VALVE DISASSEMBLY/ ASSEMBLY ······································· 11-12 THERMOSTAT/WATER JACKET COVER REMOVAL/INSTALLATION ··················· 11-4 THERMOSTAT INSPECTION················ 11-12 WATER PUMP REMOVAL/ INSTALLATION ··································· 11-6 11-1...
Page 325: Component Location
dummyhead dummyhead COOLING SYSTEM COMPONENT LOCATION COOLING SYSTEM 19.7 N·m (2.0 kgf·m, 15 lbf·ft) 11-2...
Page 326: Water Line Description
dummyhead dummyhead COOLING SYSTEM WATER LINE DESCRIPTION THERMOSTAT (50 °C) THERMOSTAT (60 °C) CYLINDER BLOCK WATER JACKET ANODE VAPOR SEPARATOR REGULATOR/ RECTIFIER RELIEF VALVE CYLINDER HEAD WATER JACKET WATER CHECK HOLE FLUSH VALVE MOUNT CASE/GEAR CASE WATER TUBE WATER PUMP WATER SCREEN 11-3...
Page 327: Thermostat/Water Jacket Cover Removal/Installation
dummyhead dummyhead COOLING SYSTEM THERMOSTAT/WATER JACKET COVER REMOVAL/INSTALLATION REMOVAL Remove the following parts. – Engine cover – R. engine under (page 6-5) – Fuse box (70 A)/regulator/rectifier (page 10-4) Release the harness band clip from harness clip bracket C and release the HO2S 4P connector (page 5- 82).
Page 328 dummyhead dummyhead COOLING SYSTEM INSTALLATION • There are two types of the thermostats; one for the cylinder head and the other for the cylinder block. Do not confuse them on assembly. Install the two anode metals [1] on the cylinder head, and tighten the two screws [2] securely. Install the new water jacket cover gasket [3] and the water jacket cover [4] on the cylinder head, and loosely tighten the twelve bolts [5].
Page 329: Water Pump Removal
dummyhead dummyhead COOLING SYSTEM Set the three harness straps [1] and the harness band clips [2] on the water jacket cover. Connector the ignition coil 3P connectors [3], ECT sensor 3 (2P) connector [4], and CMP sensor 3P connector [5]. Connect the HO2S 4P connector and set the harness band clip to harness clip bracket C (page 5-82).
Page 330 dummyhead dummyhead COOLING SYSTEM Remove the impeller cover [1] and the impeller gasket [2]. Remove the water pump housing [1] and water pump gasket [2]. Remove the water pump housing O-ring [3] and two dowel pins [4]. Remove the gear case grommet [5] and rubber setting plate [6] from the gear case.
Page 331 dummyhead dummyhead COOLING SYSTEM EXPLODED VIEW WATER TUBE SEAL RING BOLT (8 x 55 mm) (4) IMPELLER HOUSING 19.7 N·m (2.0 kgf·m, 15 lbf·ft) DOWEL PIN (6 x 10 mm) (2) WASHER (8 mm) (4) WATER PUMP DISTANCE COLLAR (4) HOUSING WATER PUMP O-RING WATER PUMP...
Page 332: Installation
dummyhead dummyhead COOLING SYSTEM INSTALLATION Apply soapy water to the outer circumference of the WATER SEAL new water seals (23 x 36 x 6 mm) [1]. INSTALLATION Drive the water seals (23 x 36 x 6 mm) one by one into DIRECTION: the water pump housing using the special tools.
Page 333 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 334 dummyhead dummyhead COOLING SYSTEM Install the four distance collars [1] on the impeller housing and tighten the four impeller housing bolts [2] and washers [3] to the specified torque. TORQUE: 19.7 N·m (2.0 kgf·m, 15 lbf·ft) Apply marine grease to the inner wall of the water tube seal ring [4].
Page 335: Thermostat Inspection
dummyhead dummyhead COOLING SYSTEM FLUSH VALVE DISASSEMBLY/ASSEMBLY Remove the engine under cover (page 6-5). TUBE (7 X 110 mm) TUBE CLAMP (D 10.5) (2) INSTALLATION: Check the tube (7 X 110 mm) for deterioration and cracks. Replace if necessary. FLUSH VALVE SPRING (Apply grease to the part where the water mouth...
Page 336: Lubrication System
dummytext 12. LUBRICATION SYSTEM COMPONENT LOCATION ····················· 12-2 OIL PUMP REMOVAL/INSTALLATION···· 12-7 LUBRICATION SYSTEM DIAGRAM········ 12-3 OIL PUMP DISASSEMBLY/ASSEMBLY ·· 12-8 STARTING PROCEDURE AFTER OIL PRESSURE CHECK ······················ 12-10 INSTALLING MAJOR ASSEMBLIES······· 12-4 OIL PUMP INSPECTION ······················ 12-10 OIL CASE REMOVAL/INSTALLATION ···· 12-5 12-1...
Page 337: Component Location
dummyhead dummyhead LUBRICATION SYSTEM COMPONENT LOCATION LUBRICATION SYSTEM 23 N·m (2.3 kgf·m, 17 lbf·ft) 21.5 N·m (2.2 kgf·m, 16 lbf·ft) 12-2...
Page 338: Lubrication System Diagram
dummyhead dummyhead LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAM CHAIN JET 1 CAM CHAIN JET 2 CAMSHAFT PISTON ROCKER SHAFT EOP SENSOR CRANKSHAFT EXHAUST ROCKER ARM INTAKE ROCKER ARM OIL FILTER OIL PUMP RELIEF VALVE VTEC SOLENOID VALVE OIL STRAINER OIL CASE 12-3...
Page 339: Starting Procedure After Installing Major Assemblies
dummyhead dummyhead LUBRICATION SYSTEM STARTING PROCEDURE AFTER INSTALLING MAJOR ASSEMBLIES Perform the starting procedure after installing the following major assemblies. – Engine removal/installation – Cylinder head removal/installation – Oil case removal/installation Inspect the following and adjust if necessary: – Shift control cable (page 3-32). –...
Page 340: Oil Case Removal/Installation
dummyhead dummyhead LUBRICATION SYSTEM OIL CASE REMOVAL/INSTALLATION REMOVAL Remove the extension case/lower rubber mount (page 16-9). BOLT (6 x 12 mm) OIL LEVEL PIPE O-RING OIL LEVEL GAUGE OIL CASE GASKET DOWEL PIN (6 x 10 mm) (2) O-RING BOLT (6 x 16 mm) (3) OIL STRAINER OIL CASE OIL DRAIN PLUG BOLT...
Page 341 dummyhead dummyhead LUBRICATION SYSTEM INSTALLATION Apply engine oil to a new O-ring [1], and install it to the oil strainer [2]. Install the oil strainer on the mount case, and tighten the three bolts [3] securely. Clean the oil case/mount case mating surfaces and both sides of a new oil case gasket [1] thoroughly using a shop towel and degreasing cleaning solvent.
Page 342: Oil Pump Removal/Installation
dummyhead dummyhead LUBRICATION SYSTEM Tighten five bolts (8 x 100 mm) and eleven bolts (8 x 35 mm) to the specified torque in the numbered sequence shown in two or three steps. TORQUE: 21.5 N·m (2.2 kgf·m, 16 lbf·ft) Tightening point Part name 1 - 5 bolt (8 x 100 mm)
Page 343: Oil Pump Disassembly/Assembly
dummyhead dummyhead LUBRICATION SYSTEM Install a new O-ring [1] on the oil pump [2]. Install the oil pump on the cylinder head by aligning the oil pump shaft [3] with the socket of the cam pulser plate bolt [4]. Tighten the two bolts (8 x 60 mm) [1] and two bolts (8 x 40 mm) [2] securely.
Page 344 dummyhead dummyhead LUBRICATION SYSTEM ASSEMBLY Check the relief valve [1] surface for scores, scratches and other damage. Apply engine oil to the relief valve and the relief valve spring [2]. Install the following parts to the oil pump [3]. – Relief valve –...
Page 345: Oil Pressure Check
dummyhead dummyhead LUBRICATION SYSTEM OIL PRESSURE CHECK Remove the oil filter (page 3-5). Check the condition of the O-ring [1] of the special tool and install it to the oil filter flange [2]. Tighten the special tool to the specified torque. TOOL: Oil pressure gauge 070MJ-0010101...
Page 346 dummyhead dummyhead LUBRICATION SYSTEM OIL PUMP BODY DEPTH Measure the oil pump body depth. STANDARD: 18.04 – 18.07 mm (0.710 – 0.711 in) If the measurement exceeds the standard limit, replace the oil pump body. OUTER ROTOR HEIGHT Measure the outer rotor height. STANDARD: 17.98 –...
Page 347 dummyhead dummyhead LUBRICATION SYSTEM OUTER ROTOR-TO-OIL PUMP BODY SIDE CLEARANCE Measure the outer rotor-to-oil pump body side clearance. STANDARD: 0.04 – 0.09 mm (0.002 – 0.004 in) SERVICE LIMIT: 0.12 mm (0.005 in) If the measurement exceeds the service limit, replace the outer rotor and the oil pump body with the new ones as a set.
Page 348 dummytext 13. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ····················· 13-2 ENGINE INSTALLATION ······················ 13-8 ENGINE REMOVAL ····························· 13-3 13-1...
Page 349 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ENGINE REMOVAL/INSTALLATION 27 N·m (2.8 kgf·m, 20 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 13-2...
Page 350 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. Remove the following: –...
Page 351 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Open the hose grommet [1] and release the fuel hose [2]. Release fuel tube B [3] from the two fuel tube clamp Bs [4]. Release fuel tube C from the tube clamp [5]. Disconnect air vent tube A [1] and fuel tube D [2] from the vapor separator.
Page 352 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Release the fuel pump cord [1] from the cord clamper [2] and disconnect the fuel pump 2P connector [3]. Remove the vapor separator. Remove the regulator/rectifier and fuse box bracket (page 10-4). Remove the bolt [1] from the starter motor [2]. Disconnect the oil tube [1] from the mount case [2].
Page 353 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Remove the six bolts (8 X 45 mm) [1], bolt (8 X 35 mm), and two cap nuts [3] from the outboard motor. 13-6...
Page 354 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Remove the seven bolts (8 X 100 mm) [1] and three bolts (8 X 120 mm) [2] from the underside of the mount case [3]. Pull the engine [4] up slowly, and remove it from the mount case.
Page 355: Engine Installation
dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION Clean the engine /mount case mating surfaces and Φ1.0 – 6.0 mm both sides of a new mount case gasket [1] thoroughly (0.04 – 0.24 in) using a shop towel and degreasing cleaning solvent. Apply a bead [Φ1.0 –...
Page 356 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Tighten each bolt and nut to the specified torque in the numbered order in two or three steps. TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft) • Do not confuse the bolts on installation. Tightening Part name point 1 –...
Page 357 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Loosen the bolt (10 X 35 mm) [1] and install the bolt (10 X 75 mm) [2]. Tighten the bolt (10 X 35 mm) and the bolt (10 X 75 mm) to the specified torque. TORQUE: 44 N·m (4.5 kgf·m, 33 lbf·ft) Install the regulator/rectifier and fuse box bracket (page 10-4).
Page 358 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Connect air vent tube C [1] to the mount case joint. Connect water tube A [2] and water tube B [3] to the vapor separator. Set fuel tube B [1] to the fuel tube clamp Bs [2] by attaching the ends of the protector tubes to the fuel tube clamp Bs.
Page 359 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Connect the pressure regulator control tube [1] to the intake manifold [2] and set the tube in tube clamp D [3]. Connect the vinyl tube [4] to the intake manifold. Apply engine oil to new O-rings [5] and install them on the fuel pipe joint [6].
Page 360 dummytext 14. CYLINDER HEAD COMPONENT LOCATION ····················· 14-2 ROCKER ARMS/SHAFT DISASSEMBLY/ ASSEMBLY ······································· 14-30 CHAIN CASE/CAM CHAIN REMOVAL/ INSTALLATION ··································· 14-4 CYLINDER COMPRESSION TEST········· 14-32 CYLINDER HEAD COVER REMOVAL/ CYLINDER HEAD INSPECTION ············ 14-32 INSTALLATION ··································14-15 VALVE GUIDE REPLACEMENT············ 14-40 CYLINDER HEAD REMOVAL/ INSTALLATION ··································14-19 VALVE SEAT RECONDITIONING··········...
Page 361: Component Location
dummyhead dummyhead CYLINDER HEAD COMPONENT LOCATION CYLINDER HEAD 22 N·m (2.2 kgf·m, 16 lbf·ft) 61 N·m (6.2 kgf·m, 45 lbf·ft) 14-2...
Page 362 dummyhead dummyhead CYLINDER HEAD 18 N·m (1.8 kgf·m, 13 lbf·ft) 29 N·m (3.0 kgf·m, 21 lbf·ft) + 130° 14-3...
Page 363: Chain Case/Cam Chain Removal
dummyhead dummyhead CYLINDER HEAD CHAIN CASE/CAM CHAIN REMOVAL/ INSTALLATION • Keep the magnetic parts away from the cam chain. REMOVAL Disconnect the battery negative (–) cable. Make sure the remote control lever is in "N" (neutral) position. Remove the following: –...
Page 364 dummyhead dummyhead CYLINDER HEAD Remove the bolt/washer [1] from the electronic parts case. Remove the bolt/washer [1] from the silencer case. Remove the ten bolts (6 x 28 mm) [1], three bolts (6 x 22 mm) [2], bolt (6 x 40 mm) [3], and two special bolts (6 x 31 mm) [4] from the chain case.
Page 365 dummyhead dummyhead CYLINDER HEAD Remove the oil seal [1] from chain case. Insert a screwdriver into the cam chain tensioner slider [1] as shown, and remove the bolt [2] while holding the cam chain tensioner slider. Remove the bolt [1], and remove the cam chain tensioner slider [2].
Page 366 dummyhead dummyhead CYLINDER HEAD Remove the bolt [1], oil pipe [2], and O-ring [3]. Remove the cam chain [4]. Loosen the bolt/washer [1] while holding the camshaft with a 30 mm open end wrench as shown. Remove the bolt/washer [1], and remove the cam chain driven sprocket [2] from the camshaft.
Page 367 dummyhead dummyhead CYLINDER HEAD EXPLODED VIEW HARNESS CLIP BRACKET C BREATHER PIPE TUBE JOINT BREATHER TUBE C BREATHER TUBE B BOLT (6 x 14 mm) (2) BOLT (6 x 40 mm) BOLT BOLT (6 x 28 mm) (10) (6 x 22 mm) (3) BOLT (6 x 14 mm) SPECIAL BOLT...
Page 368 dummyhead dummyhead CYLINDER HEAD INSTALLATION Clean the cam drive sprocket [1] seat and the crankshaft [2] in the part where it contacts the sprocket seat thoroughly with the degreasing clean agent. Install the special key [3] in the key groove [4] in the crankshaft.
Page 369 dummyhead dummyhead CYLINDER HEAD Tighten the bolt/washer [1] to the specified torque while holding the camshaft with a 30 mm open end wrench as shown. TORQUE: 61 N·m (6.2 kgf·m, 45 lbf·ft) Align the cooler plate (1 place) [1] of the cam chain [2] with the punch mark [3] on the cam chain drive sprocket as shown, and install the cam chain on the drive sprocket.
Page 370 dummyhead dummyhead CYLINDER HEAD Apply engine oil to a new O-ring [1], and install it on the oil pipe [2]. Install the oil pipe and tighten the bolt [3] securely. Install the cam chain guide [1], and tighten the two bolts [2] securely.
Page 371: Cylinder Block
dummyhead dummyhead CYLINDER HEAD Apply soapy water to the outer surface of a new oil seal [1]. Install the oil seal in the chain case using the special tool. Install the oil seal in the position shown. TOOL: Driver [2] 07749-0010000 Attachment, 52 x 55 mm [3] 07746-0010400...
Page 372 dummyhead dummyhead CYLINDER HEAD Install the two alternator cover grommets [1] on the chain case. First, loosely tighten the two special bolts [2] on the chain case to correctly position it. Then, loosely tighten the ten bolts (6 x 28 mm) [3], three bolts (6 x 22 mm) [4], and the bolt (6 x 40 mm) [5] on the chain case.
Page 373 dummyhead dummyhead CYLINDER HEAD Tighten the bolt/washer [1] on the electronic parts case securely. Tighten the bolt/washer [1] on the silencer case securely. Set connector bracket A [1] on the chain case, and tighten the bolt [2] securely. Set harness clip bracket A [1] on the chain case, and tighten the bolt [2] securely.
Page 374: Cylinder Head Cover Removal
dummyhead dummyhead CYLINDER HEAD Set harness clip bracket B [1] on the chain case, and tighten the two bolts [2] securely. Install the tube joint [3] on fuel tube clamp B, and install the fuel strainer (low pressure side) [4] on harness clip bracket B.
Page 375 dummyhead dummyhead CYLINDER HEAD Disconnect breather tube [1] from the cylinder head cover [2]. Remove the nine bolts [3], and remove the cylinder head cover. • Oil leaks out when the cylinder head cover is removed. Catch the leaking oil with a shop towel and a suitable container, and wipe up any spilled oil.
Page 376 dummyhead dummyhead CYLINDER HEAD Connect the oil tube to the cylinder head cover by aligning the projection [1] on the oil tube with the projection [2] on the cylinder head cover. Set the tube clamp D29.0 with the lug [3] in the position shown.
Page 377 dummyhead dummyhead CYLINDER HEAD Tighten the nine bolts securely in the numbered sequence shown in two or three steps. Connect the oil tube [1] to the mount case [2] securely. Install the following parts: – Under cover rear bracket (page 6-16) –...
Page 378: 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. Remove the following: –...
Page 379 dummyhead dummyhead CYLINDER HEAD Remove the cylinder head [1] from the cylinder block. Remove the cylinder head gasket [2] and two dowel pins [3] from the cylinder block. INSTALLATION • Make sure there are no foreign objects between the gasket and cylinder head and cylinder block. •...
Page 380 dummyhead dummyhead CYLINDER HEAD Clean the cylinder head [1] and the cylinder block mounting surfaces. Install the two dowel pins [2] on the cylinder block. Install a new cylinder head gasket [3] on the cylinder block by setting the projection of the cylinder head gasket in the position shown.
Page 381: Cylinder Head Assembly
dummyhead dummyhead CYLINDER HEAD CYLINDER HEAD ASSEMBLY/DISASSEMBLY DISASSEMBLY • Mark the removed parts (e.g. valves, springs, and other related parts) and store them securely, grouping them by intake side and exhaust side for each cylinder. Install each part in the original position on the assembly.
Page 382 dummyhead dummyhead CYLINDER HEAD Check whether the fuel pump lifter [1] is in contact with the camshaft [2]. If it is, push the fuel pump lifter in toward the cylinder head side. Remove the cam pulser plate bolt [1] from the camshaft [2], and remove the cam pulser plate [3].
Page 383 dummyhead dummyhead CYLINDER HEAD Use a socket [1] that matches the diameter of the valve spring retainer. Attach the socket to the retainer, and lightly tap on the socket to separate the valve keepers from the retainer. • Tap straight down on each valve stem head. Take care not to bend the valve.
Page 384 dummyhead dummyhead CYLINDER HEAD EXPLODED VIEW ROCKER SHAFT BOLT (5) 29 N·m (3.0 kgf·m, 21 lbf·ft) CAMSHAFT LOST MOTION SPRING (4) CAM PULSER PLATE ROCKER SHAFT ASSEMBLY CAM PULSER PLATE BOLT 34 N·m (3.5 kgf·m, 25 lbf·ft) DOWEL PIN (7 x 12 mm) FUEL PUMP LIFTER INTAKE VALVE SPRING (8)
Page 385: Assembly
dummyhead dummyhead CYLINDER HEAD ASSEMBLY Apply molybdenum disulfide oil to the valve stem sliding surface, and insert the valve [1] into the valve guide. Check that the valve moves up and down smoothly. • Do not confuse the intake valve and the exhaust valve on assembly.
Page 386 dummyhead dummyhead CYLINDER HEAD Install the valve spring [1] and valve spring retainer [2]. • Do not confuse the intake valve spring and the PAINT exhaust valve spring. IDENTIFICATION: The intake side can be identified by the blue paint on the spring.
Page 387 dummyhead dummyhead CYLINDER HEAD Tap on the valve stem head [1] lightly with a plastic hammer [2] two or three times, and set the valve stem and valve keepers in the proper position securely. • Tap straight down on each valve stem head. Take care not to bend the valve.
Page 388 dummyhead dummyhead CYLINDER HEAD Apply engine oil to the four lost motion springs [1] and install them in the cylinder head assembly. Set the dowel pin [2] in the cylinder head assembly and install the rocker shaft assembly [3] on the cylinder head assembly.
Page 389 dummyhead dummyhead CYLINDER HEAD ROCKER ARMS/SHAFT DISASSEMBLY/ASSEMBLY BF75D/80A • Remove or install the rocker arm assembly from the cam chain side to disassemble or assemble the rocker shaft assembly. • Note the location of each part before disassembly. Do not confuse the parts. Install the parts in their original positions.
Page 390 dummyhead dummyhead CYLINDER HEAD BF90D/100A • Remove or install the rocker arm assembly from the cam chain side to disassemble or assemble the rocker shaft assembly. • Note the location of each part before disassembly. Do not confuse the parts. Install the parts in their original positions.
Page 391: Cylinder Compression Test
dummyhead dummyhead CYLINDER HEAD CYLINDER COMPRESSION TEST Set the remote control lever in the "N" (neutral) position. Remove the emergency stop switch clip. Disconnect all the injector 2P connectors. Disconnect the ignition coil 3P connector of each cylinder, and remove the spark plugs (page 3-15). Disconnect the remote control cable from the throttle arm (page 19-8).
Page 392 dummyhead dummyhead CYLINDER HEAD VALVE LENGTH/VALVE O.D. Measure the overall length and the O.D. of the valve. Overall length STANDARD: IN: 118.55 – 119.15 mm (4.667 – 4.691 in) EX: 117.25 – 117.85 mm (4.616 – 4.640 in) Valve O.D. STANDARD: IN: 27.85 –...
Page 393 dummyhead dummyhead CYLINDER HEAD VALVE SEAT WIDTH 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. Insert the valves, and then lift them and snap them closed against their seats several times.
Page 394 dummyhead dummyhead CYLINDER HEAD ROCKER ARM I.D. Measure and record each rocker arm I.D. STANDARD: IN/EX: 20.012 – 20.030 mm (0.7879 – 0.7886 in) Replace the rocker arm shaft if its O.D. is smaller than the standard (page 14-30). ROCKER ARM SHAFT-TO-ROCKER ARM CLEARANCE Subtract each rocker arm shaft O.D.
Page 395 dummyhead dummyhead CYLINDER HEAD • Use the special tool under the following conditions: – At cylinder head assembly – If the engine power drops at high speed but the cause cannot be determined. Install the cylinder head cover (page 14-16). Start the engine and let it warm up five minutes.
Page 396 dummyhead dummyhead CYLINDER HEAD VTEC ROCKER ARM INSPECTION (BF90D/BF100A only) Disassemble the rocker arm assembly parts: – Primary rocker arm [1] – Rocker arm piston [2] – Piston stopper [3] – Return spring [4] – Retainer [5] – Secondary rocker arm [6] •...
Page 397 dummyhead dummyhead CYLINDER HEAD CAMSHAFT JOURNAL I.D. Measure the I.D. of each camshaft journal. STANDARD: 41.995 – 42.019 mm (1.6533 – 1.6543 in) CAMSHAFT OIL CLEARANCE Calculate the difference between the camshaft journal O.D. and the cylinder head journal I.D. STANDARD: 0.045 –...
Page 398 dummyhead dummyhead CYLINDER HEAD CAMSHAFT RUNOUT Place V blocks or equivalent under the journal at both ends of the camshaft. Install the dial indicator on the camshaft, and measure the camshaft runout by turning the camshaft. STANDARD: 0.03 mm (0.001 in) max. SERVICE LIMIT: 0.04 mm (0.002 in) If the measurement exceeds the service limit, replace the camshaft with a new one.
Page 399: Valve Guide Replacement
dummyhead dummyhead CYLINDER HEAD VALVE GUIDE REPLACEMENT Chill the replacement new valve guides in a freezer for about an hour. Use a hot plate or oven to heat the cylinder evenly to 150°C (302°F). Check the temperature with a temperature indicating stick (available at a welding supply store) or equivalent.
Page 400: Valve Seat Reconditioning
dummyhead dummyhead CYLINDER HEAD Thoroughly clean the cylinder head to remove any cutting residue. Check the valve guide bore; it should be straight, round and centered in the valve guide. insert the valve and check operation. If the valve does not operate smoothly, the guide may have been bent during installation.
Page 401 dummyhead dummyhead CYLINDER HEAD Use the 30° – 32° and 60° cutters to narrow and adjust OLD SEAT the valve seat so that it contacts the middle of the valve CONTACT TOO HIGH WIDTH face. The 30° – 32° cutter removes material from the top edge.
Page 402: Cylinder Block
dummytext 15. CYLINDER BLOCK COMPONENT LOCATION ····················· 15-2 CRANKSHAFT/PISTON/CYLINDER BLOCK INSPECTION ·························· 15-18 CRANKCASE/CRANKSHAFT/CYLINDER BLOCK/PISTON DISASSEMBLY/ BEARING SELECTION ························ 15-25 ASSEMBLY ········································ 15-3 15-1...
Page 403 dummyhead dummyhead CYLINDER BLOCK COMPONENT LOCATION CYLINDER BLOCK 10 N·m (1.0 kgf·m, 7 lbf·ft) + 90° 24 N·m (2.4 kgf·m, 18 lbf·ft) + 40° 49 N·m (5.0 kgf·m, 36 lbf·ft) 15-2...
Page 404 dummyhead dummyhead CYLINDER BLOCK CRANKCASE/CRANKSHAFT/ CYLINDER BLOCK/PISTON DISASSEMBLY/ASSEMBLY CRANKCASE/CRANKSHAFT/ CYLINDER BLOCK DISASSEMBLY Store the removed parts (e.g. bearings, connecting rods, rod caps, bolts) securely, grouping them for each cylinder. Move the shift to the "N" (Neutral) position. Remove the engine from the outboard motor (page 13- Remove the following parts.
Page 405 dummyhead dummyhead CYLINDER BLOCK Remove the ten bolts [1] from the crankcase. Loosen the ten bolt/washers [1] in the numbered order shown in two or three steps. Remove the ten bolt/washers from the crankcase. Insert a screwdriver into the recesses in the crankcase and separate the crankcase a little at a time.
Page 406 dummyhead dummyhead CYLINDER BLOCK Remove the crankcase [1] and oil seal [2] from the cylinder block [3]. Check the lower main bearings [1] for damage (scores, scratches, etc.) before removing them. Replace the lower main bearings if necessary. Remove the five lower main bearings from the crankcase.
Page 407 dummyhead dummyhead CYLINDER BLOCK Remove the crankshaft [1] from the cylinder block, bearing careful not to damage the journals. Remove the two thrust washers [2] from the cylinder block. Check the thrust washers for damage (scores, scratches, etc.), and replace if necessary. Check the upper main bearings [3] for damage (scores, scratches, etc.) before removing them.
Page 408 dummyhead dummyhead CYLINDER BLOCK PISTON DISASSEMBLY Before removing the connecting rod bearing, check it for damage (scores, scratches, etc.) and replace if necessary. Remove the connecting rod bearing and the piston rings from the piston assembly. Check the piston rings for damage and replace if necessary.
Page 409 dummyhead dummyhead CYLINDER BLOCK Install the insert adjuster (special tool) [1] on the insert pin [2]. Adjust dimension A to 45 mm (1.8 in) by turning the insert adjuster. DIMENSION A 45 mm (1.8 in) TOOLS: Piston pin tool set 07PAF-0010000 Insert adjuster 070AF-PWC0120...
Page 410 dummyhead dummyhead CYLINDER BLOCK EXPLODED VIEW TOP RING PISTON RING SECOND RING SIDE RAIL (TOP SIDE) OIL RING PISTON SIDE RAIL PISTON PIN (SKIRT SIDE) CONNECTING CONNECTING ROD BEARING (2) CONNECTING ROD CAP CONNECTING ROD BOLT (2) 10 N·m (1.0 kgf·m, 7 lbf·ft) + 90° 15-9...
Page 411 dummyhead dummyhead CYLINDER BLOCK PISTON ASSEMBLY • Use the same special tools as those used during DIMENSION A disassembly (page 15-7). 45 mm (1.8 in) Install the insert adjuster (special tool) [1] on the insert pin [2]. Adjust dimension A of the insert adjuster to 45 mm (1.8 in) by turning the insert adjuster.
Page 412 dummyhead dummyhead CYLINDER BLOCK Install the top ring [1] and the second ring [2] in the ring grooves in the piston with the maker marks facing up. Install the oil ring [3] in the ring groove, aligning the retaining tab [4] of the side rail (top side) [5] with the positioning groove [6] in the ring groove.
Page 413 dummyhead dummyhead CYLINDER BLOCK CRANK CASE/CRANK SHAFT EXPLODED VIEW CONNECTING ROD BOLT (8) BOLT BOLT/WASHER (10 x 105 mm) (10) 10 N·m (1.0 kgf·m, 7 lbf·ft) + 90° (6 x 32 mm) (12) 24 N·m (2.4 kgf·m, 18 lbf·ft) + 40° CONNECTING ROD CAP (4) CONNECTING ROD BEARING (8)
Page 414 dummyhead dummyhead CYLINDER BLOCK CRANKCASE/CRANKSHAFT/ CYLINDER BLOCK ASSEMBLY Set the dowel pin [1] in the cylinder block by lightly tapping on the dowel pin with a plastic hammer as shown. • Tap lightly at right angles to the cylinder block. Take care not to deform the dowel pin.
Page 415 dummyhead dummyhead CYLINDER BLOCK Install the upper main bearings [1] on the cylinder block, aligning the projection [2] on each upper main bearing with the concave [3] in the cylinder block. Apply molybdenum disulfide oil to the crankshaft main journal, crank pin and the thrust washer mating surface. Put the No.2 and No.3 pistons at bottom dead center of their stroke.
Page 416 dummyhead dummyhead CYLINDER BLOCK Install the thrust washers [1] on the cylinder block No.4 journal. • Install the thrust washers with the grooved side [2] toward the crankshaft. Install the lower main bearing [1] on the crank case, aligning the projection [2] on the lower main bearing with the concave [3] in the crankcase.
Page 417 dummyhead dummyhead CYLINDER BLOCK Apply engine oil to the threads and seat of the bolt/ washers [1]. Loosely tighten the ten bolt/washers on the crankcase, and tighten them to the specified torque in two or three steps in the numbered sequence shown. After tightening to the specified torque, tighten the bolt/ washers additionally by 40°...
Page 418 dummyhead dummyhead CYLINDER BLOCK Apply soapy water to the outer surface of a oil seal [1]. Using the special tools as shown, install the oil seal on the cylinder block assembly as shown. Drive in the oil seal so its upper side is 1.0 to 2.0 mm (0.04 to 0.08 in) deep from the surface.
Page 419 dummyhead dummyhead CYLINDER BLOCK CRANKSHAFT/PISTON/CYLINDER BLOCK INSPECTION PISTON SKIRT O.D. Check the piston outer surface for damage (scores, scratches, etc.). Check the piston for warpage and cracks. Measure and record the piston O.D. [1] at 13 mm (0.5 in) [2] from the bottom and perpendicular to the piston pin bore.
Page 420 dummyhead dummyhead CYLINDER BLOCK PISTON RING THICKNESS Check the piston ring for damage (scores, scratches, etc.). Measure the piston ring thickness. STANDARD: 0.970 – 0.985 mm (0.0382 – 0.0388 in) SECOND 1.175 – 1.190 mm (0.0463 – 0.0469 in) The oil rings are the combination rings. Replace the side rails and the spacer as a set when either the top or second ring needs replacement.
Page 421 dummyhead dummyhead CYLINDER BLOCK PISTON RING END GAP Use the piston to push the piston ring [1] into the cylinder sleeve and position it horizontally at 15 to 20 mm (0.6 to 0.8 in) from the bottom of the cylinder. Measure the piston end gap [2].
Page 422 dummyhead dummyhead CYLINDER BLOCK CONNECTING ROD SMALL END-TO- PISTON PIN CLEARANCE Measure the connecting rod small end I.D. STANDARD: 17.964 – 17.977 mm (0.7072 – 0.7078 in) Calculate the gap between the piston pin O.D. and the connecting rod small end I.D. STANDARD: 0.019 –...
Page 423 dummyhead dummyhead CYLINDER BLOCK CRANK PIN JOURNAL O.D. Measure the crank pin journal [1] O.D. STANDARD: 39.976 – 40.000 mm (1.5739 – 1.5748 in) CRANKSHAFT JOURNAL (MAIN, PIN) ROUNDNESS Measure the crankshaft main journal O.D. and the Measure the roundness at the crank pin O.D.
Page 424 dummyhead dummyhead CYLINDER BLOCK CRANKSHAFT RUNOUT Install the No.1 upper main bearing [1] and the No.5 upper main bearing [2] on the cylinder block [3]. Install the crankshaft [4] on the cylinder block. Set the dial indicator [5] on the crankshaft as shown. Measure crankshaft runout...
Page 425 dummyhead dummyhead CYLINDER BLOCK Remove the crankcase. Measure the compressed width of the plastigauge [1] using the scale [2] printed on the bag of the plastigauge. • Take the widest width on the plastigauge. STANDARD: 0.018 – 0.036 mm (0.0007 – 0.0014 in) SERVICE LIMIT: 0.050 mm (0.0020 in) If the measurement exceeds the service limit, replace...
Page 426 dummyhead dummyhead CYLINDER BLOCK CYLINDER BLOCK WARPAGE Take care not to damage (scores, scratches, etc.) the mating surface with the cylinder head gasket. Measure the surface warpage using a straight edge and a feeler gauge as shown STANDARD: 0.07 mm (0.003 in) max. SERVICE LIMIT: 0.10 mm (0.004 in) If the measurement exceeds the service limit, replace...
Page 427 dummyhead dummyhead CYLINDER BLOCK Check each cylinder block I.D. code letter [1] in the position shown, and record it. • The cylinder block I.D. code letters are for the No.1 and the subsequent number journals when viewed from the left side. Cylinder block I.D.: 54 mm (2.1 in) Code Tolerance...
Page 428 dummyhead dummyhead CYLINDER BLOCK CONNECTING ROD BEARING When replacing the connecting rod bearing, check the crank pin code letter and the connecting rod code number, and select the correct bearing by referring to the bearing selection table. • If the code letter and/or number is not clear, clean the area with a cleaning solvent and check again.
Page 429 dummyhead dummyhead CYLINDER BLOCK Select the correct bearing by referring to the crank pin code letter and the connecting rod code number. Connecting rod bearing selection table: Connecting rod code number Crank pin code letter Bearing identification color Pink Yellow Green Pink Yellow...
Page 430: Gear Case
dummytext 16. GEAR CASE COMPONENT LOCATION ····················· 16-2 VERTICAL SHAFT/FORWARD BEVEL GEAR REMOVAL/INSTALLATION ········ 16-25 PROPELLER REMOVAL/ INSTALLATION ··································· 16-3 PROPELLER SHAFT HOLDER DISASSEMBLY/ASSEMBLY················· 16-30 ANODE METAL/WATER SCREEN REMOVAL/INSTALLATION ··················· 16-4 VERTICAL SHAFT DISASSEMBLY/ ASSEMBLY ······································· 16-33 GEAR CASE/EXTENSION SEPARATOR (XRT TYPE ONLY) REMOVAL/ SHIM SELECTION ······························...
Page 431: Component Location
dummyhead dummyhead GEAR CASE COMPONENT LOCATION GEAR CASE 34 N·m (3.5 kgf·m, 25 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 83 N·m (8.5 kgf·m, 61 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 1 N·m (0.10 kgf·m, 0.7 lbf·ft) MAX. TORQUE: 44.1 N·m (4.5 kgf·m, 33 lbf·ft) 16-2...
Page 432: Installation
dummyhead dummyhead GEAR CASE PROPELLER REMOVAL/INSTALLATION 3-BLADE PROPELLER (Optional part) SPLIT PIN (4.0 mm) INSTALLATION: 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) (Spline and threads) PROPELLER THRUST WASHER INSTALLATION: Install the thrust washer in the direction as...
Page 433: Anode Metal/Water Screen Removal/Installation
dummyhead dummyhead GEAR CASE ANODE METAL/WATER SCREEN REMOVAL/INSTALLATION GEAR OIL CHECK BOLT 6.5 N·m (0.66 kgf·m, 4.8 lbf·ft) ANODE METAL (2) GEAR CASE GROMMET O-RING BOLT (6 x 35 mm) BOLT (8 x 25 mm) WASHER (8 mm) R. WATER SCREEN SCREW (5 x 55 mm) 1.0 N·m (0.10 kgf·m, 0.7 lbf·ft)
Page 434: Gear Case/Extension Separator
dummyhead dummyhead GEAR CASE GEAR CASE/EXTENSION SEPARATOR (XRT TYPE ONLY) REMOVAL/INSTALLATION REMOVAL Remove the propeller (page 16-3). Move the shift to the "N" (Neutral) position. Tilt up the outboard motor to the uppermost position. Pull the tilt stopper down to secure the outboard motor. Remove the socket bolt [1], gear case cover B [2], and distance collar [3].
Page 435 dummyhead dummyhead GEAR CASE EXPLODED VIEW CIRCLIP (40 mm) STUD BOLT (Spline) (10 x 202 mm) WASHER (26 mm) SHIFT ROD A VERTICAL SHAFT BUSHING DOWEL PIN (2) STUD BOLT (10 x 164 mm) (4) (Shift rod spline) DOWEL PIN (2) (Water tube seal ring inner surface) XRT type only...
Page 436: Installation
dummyhead dummyhead GEAR CASE INSTALLATION Move the shift to the “N” (Neutral) position. Check that the shift rod [1] in the gear case is in the “N” (Neutral) position. • Check whether the cutout [2] of the shift rod spline faces in the direction shown.
Page 437 dummyhead dummyhead GEAR CASE Apply marine grease to the vertical shaft spline [1] and shift rod spline [2]. Apply marine grease to the water tube insertion part [3] and water tube seal ring inner surface [4]. Install the vertical shaft bushing with the groove toward the extension separator.
Page 438: Extension Case/Lower Rubber Removal/Installation
dummyhead dummyhead GEAR CASE EXTENSION CASE/LOWER RUBBER REMOVAL/INSTALLATION REMOVAL/INSTALLATION Remove the following: – Engine cover – R./L. engine under cover (page 6-5) – Gear case/Extension case (XRT type only)(page 16- Tilt up the outboard motor and hold it in position by hooking the engine hanger chain on each of the two engine hangers.
Page 439 dummyhead dummyhead GEAR CASE Remove the bolt [1], water tube plate [2], water tube [3], and the water tube grommet [4]. EXPLODED VIEW WATER TUBE (Inner surface) WATER TUBE GROMMET BOLT (12 x 186 mm) (2) PLATE UNDER COVER RUBBER LID CLIP (7 mm) DOWEL PIN (6 x 10 mm) (2)
Page 440: Installation
dummyhead dummyhead GEAR CASE INSTALLATION Tilt up the outboard motor and hold it in position by hooking the engine hanger chain on each of the two engine hangers. Apply marine grease to the inner surface of the water tube grommet [1], and install it on the water tube [2]. Connect the water tube to the oil case, noting the installation direction as shown.
Page 441 dummyhead dummyhead GEAR CASE While pushing the lead wire [1] against the projection [2] on the lower mount center housing as shown, tighten the screw [3]. Clean the extension case /oil case mating surfaces [1] thoroughly using a shop towel and degreasing cleaning solvent.
Page 442 dummyhead dummyhead GEAR CASE Apply marine grease to the water tube end [1]. Install the extension case [2] on the outboard motor, aligning the water tube with the extension case grommet [3]. Tighten the eight bolts [4]. Install the lower mount collar [1], lower rubber mount [2], and the lower mount stopper [3] on the extension case [4].
Page 443 dummyhead dummyhead GEAR CASE Attach the lead wire [1] to the extension case [2], and tighten the bolt [3]. Install the lower mount housing [4] on the extension case, and tighten the three bolt/washers [5]. Remove the engine hangar chain from the engine hangers, and lower the outboard motor to the lowermost position.
Page 444 dummyhead dummyhead GEAR CASE Remove the shift rod spring [1], washer [2], and E-ring [3]. Remove the two water seals [1]. Remove the O-ring [2]. EXPLODED VIEW SHIFT ROD HOLDER WATER SEAL (12 x 21 x 6 mm) (2) O-RING WASHER (12 mm) E-RING (10 mm) SHIFT ROD SPRING...
Page 445 dummyhead dummyhead GEAR CASE INSTALLATION Apply soapy water to the outer circumference of new water seals [1]. Drive the water seals one by one into the shift rod holder [2] using the special tool. Note the installation direction of the water seals. Be sure to apply marine grease to the water seal mating surfaces before installation.
Page 446 dummyhead dummyhead GEAR CASE Insert the shift rod [1] into the gear case, aligning the cam of the shift rod with the "A" point [2] of the gear case as shown. Install the shift rod on the shift slider [3], aligning the cam of the shift rod with the grooves in the shift slider.
Page 447: Propeller Shaft Holder Removal/Installation
dummyhead dummyhead GEAR CASE PROPELLER SHAFT HOLDER REMOVAL/INSTALLATION Remove the following: – Propeller (page 16-3) – Gear case (page 16-5) – Water pump (page 11-6) – Shift rod (page 16-14) Remove the two bolt/washers. Insert the screwdriver or equivalent tool into the recess [1] in the propeller shaft holder [2], and remove the propeller shaft holder from the gear case.
Page 448: Shift Slider/Propeller Shaft Removal/Installation
dummyhead dummyhead GEAR CASE SHIFT SLIDER/PROPELLER SHAFT REMOVAL/INSTALLATION REMOVAL Remove the shift shaft holder (page 16-18). Remove the propeller shaft [1], two ball bearings [2], and O-ring [3] from the propeller shaft holder [4]. Remove the two water seals [5] from the propeller shaft holder.
Page 449 dummyhead dummyhead GEAR CASE Remove the circlip [1] from the shift slider [2]. Remove the roller [1] from the shift slider [2] using a commercially available pin driver [3]. • Take care not to let the shift springs and the steel balls pop out of the shift slider during removal of the roller.
Page 450 dummyhead dummyhead GEAR CASE EXPLODED VIEW SHIFT SPRING (2) STEEL BALL (#11) (2) STEEL BALL (#7) (2) SHIFT PLATE ROLLER CROSS PIN RING SHIFT SLIDER PROPELLER SHAFT SHIFTER PIN CLUTCH SHIFTER CIRCLIP BALL BEARING (2) O-RING (94 x 4.1 mm) PROPELLER SHAFT HOLDER WATER SEAL (30 x 45 x 7 mm) (2)
Page 451 dummyhead dummyhead GEAR CASE INSTALLATION Set a wood block [1] under the reverse bevel gear [2]. <Water seal installation direction> Apply soapy water to the outer circumference of new water seals [3]. Drive the water seals one by one into the propeller shaft holder using the special tool.
Page 452 dummyhead dummyhead GEAR CASE With the "F" mark [1] on the clutch shifter toward the forward bevel gear (i.e. toward front), assemble the clutch shifter with the propeller shaft while aligning the Reverse bevel shifter pin installation hole [2] with the long slot [3] in the gear side: propeller shaft.
Page 453 dummyhead dummyhead GEAR CASE 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 454: Vertical Shaft/Forward Bevel Gear Removal/Installation
dummyhead dummyhead GEAR CASE VERTICAL SHAFT/FORWARD BEVEL GEAR REMOVAL/INSTALLATION REMOVAL Remove the following: – Propeller (page 16-3) – Gear case (page 16-5) – Water pump (page 11-6) – Shift rod (page 16-14) – Propeller shaft holder (page 16-18) Attach the special tool to the vertical shaft end (Flywheel installation side) [1].
Page 455 dummyhead dummyhead GEAR CASE Set a commercially available universal bearing puller [1] between the taper bearing (inner race) and forward bevel gear. Drive the taper bearing (inner race) out of the forward bevel gear using the special tools and a hydraulic press as shown.
Page 456 dummyhead dummyhead GEAR CASE EXPLODED VIEW (Threads and LOCK NUT (64 mm) seating surface) 123 N·m (12.5 kgf·m, 91 lbf·ft) VERTICAL SHAFT TAPER ROLLER BEARING (30 x 62 x 40 mm) OIL SLINGER FORWARD BEVEL GEAR GEAR CASE TAPER BEARING (50 x 82 x 21.5 mm) FORWARD BEVEL GEAR SHIM (Threads and...
Page 457 dummyhead dummyhead GEAR CASE INSTALLATION Install a new shim [1] on the gear case [2]. • 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 16-40).
Page 458 dummyhead dummyhead GEAR CASE Apply gear oil to the threads and seating surface of the lock nut [1]. Tighten the lock nut to the specified torque using the special tool as shown. TOOL: Lock nut wrench, 30/64 mm [2] 07916-MB00002 TORQUE: 123 N·m (12.5 kgf·m, 91 lbf·ft) •...
Page 459: Propeller Shaft Holder Disassembly/Assembly
dummyhead dummyhead GEAR CASE PROPELLER SHAFT HOLDER DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the needle bearing [1] from the propeller shaft holder [2] using the special tool as shown. TOOLS: Bearing remover, 30 mm [3] 07936-8890300 Remover handle [4] 07936-3710100 Remover weight [5] 07936-371020A Remove the reverse bevel gear/bearing [1] from the propeller shaft holder [2] using the special tools and a...
Page 460 dummyhead dummyhead GEAR CASE Attach a commercially available universal bearing puller [1] between the reverse bevel gear and the reverse bearing. Remove the ball bearing from the reverse bevel gear using the special tools and hydraulic press as shown. TOOLS: Driver [2] 07749-0010000 Attachment, 37 x 40 mm [3]...
Page 461 dummyhead dummyhead GEAR CASE ASSEMBLY Apply gear oil to the circumference of a new ball bearing [1]. Set a wood block [2] under the reverse bevel gear [3]. Drive the ball bearing into the reverse bevel gear using the special tool and a hydraulic press as shown. TOOL: Driver, 40 mm I.D.
Page 462: Vertical Shaft Disassembly
dummyhead dummyhead GEAR CASE Set a wood block [1] under the reverse bevel gear [2]. Apply gear oil to the circumference of a new needle bearing [3]. Drive the needle bearing into the propeller shaft holder [4] using the special tools and a hydraulic press as shown.
Page 463 dummyhead dummyhead GEAR CASE 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) [2], and install the vertical shaft [3] on the hydraulic press with the flywheel boss installation side facing up.
Page 464 dummyhead dummyhead GEAR CASE 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 wall of new taper roller bearing inner races [4], roller and the circumference of new outer race [5].
Page 465: Shim Selection
dummyhead dummyhead GEAR CASE SHIM SELECTION • 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 466 dummyhead dummyhead GEAR CASE PINION GEAR SHIM Remove the taper roller bearing (30 x 62 x 40 mm) if it is mounted on the vertical shaft [1] (page 16-33). Clean the tapered surface [2] of the vertical shaft and the tapered surface of the pinion gear [3] thoroughly using a shop towel and degreasing cleaning agent.
Page 467 dummyhead dummyhead GEAR CASE Lift the outer race [1], remove the inner race, and Distance D’’: replace the outer race on the gauge adapter special tool [2]. Measure the height of the outer race (Distance D’’) [3] and record it. Calculate the length from the inner race end to the outer race end (D) by determining the gap between the measurements D’...
Page 468 dummyhead dummyhead GEAR CASE Pinion gear shim selection table Unit: mm Calculation value -0.31 -0.25 -0.20 -0.15 -0.10 -0.05 – – – – – – – -0.25 -0.20 -0.15 -0.10 -0.05 +0.05 1.00 0.95 0.90 0.85 0.80 0.75 0.70 0.95 0.90 0.85 0.80...
Page 469 dummyhead dummyhead GEAR CASE FORWARD BEVEL GEAR SHIM If you have a gauge adapter special tool, place the disc that is included with that tool on a flat surface. Make sure the side marked with the tool number is on the bottom and the smooth side is up.
Page 470: Backlash Inspection
dummyhead dummyhead GEAR CASE Select the shims from the forward bevel gear shims of different thickness to obtain the required thickness (Sf) by combining the shims. Shim type table Shim type Thickness Shim A 0.10 mm Shim B 0.15 mm Shim C 0.30 mm Shim D...
Page 471 dummyhead dummyhead GEAR CASE Attach the special tool to the vertical shaft [1] as shown, and adjust the dial gauge [2] so its needle is at line "1" of the special tool (backlash indicator tool). TOOL: Backlash indicator tool [3] 07SPJ-ZW0030B 90°...
Page 472 dummyhead dummyhead GEAR CASE While watching pressure tester gauge [1], apply the specified air pressure to the gear case by pumping the handle slowly. Do not apply excessive air pressure. AIR PRESSURE: 0.029 MPa (0.3 kgf/cm , 4.3 psi) While applying the specified air pressure to the gear case, move the shift rod [1] right and left five or six times using pliers.
Page 473: Propeller Shaft Inspection
dummyhead dummyhead GEAR CASE If the air pressure drops, place the gear case in a container filled with a water. Apply the specified air pressure to the gear case again, move the shift rod, vertical shaft and the propeller shaft, and locate the point where the air is leaking.
Page 474: Vertical Shaft Inspection
dummyhead dummyhead GEAR CASE VERTICAL SHAFT INSPECTION VERTICAL SHAFT O.D. (At needle bearing) Measure the O.D. of the vertical shaft where the needle bearing [1] rides. STANDARD: 28.566 – 28.575 mm (1.1246 – 1.1250 in) SERVICE LIMIT: 28.545 mm (1.1238 in) If the measurement is less than the service limit, replace the vertical shaft with a new one.
Page 475: Gear Case Needle Bearing
dummyhead dummyhead GEAR CASE GEAR CASE NEEDLE BEARING REPLACEMENT Remove the vertical shaft (page 16-25) Set the special tools on the needle bearing [1], and place a shop towel [2] or equivalent material under the needle bearing as shown. TOOLS: Driver handle, 15 x 280 mm [3] 07949-3710001 Bearing driver attachment,...
Page 476 dummytext 17. MOUNT MOUNT CASE REMOVAL/ MOUNT CASE ASSEMBLY/ INSTALLATION ··································· 17-2 DISASSEMBLY ··································· 17-3 17-1...
Page 477 dummyhead dummyhead MOUNT MOUNT CASE REMOVAL/ MOUNT INSTALLATION Remove the engine from the mount case (page 13-3). UPPER RUBBER MOUNT (2) INSTALLATION: Mounting direction as shown. LONG SHORT BOLT (8 x 25 mm) (8) UPPER MOUNT STOPPER RUBBER (2) NUT (12 mm) (2) UPPER MOUNT 83 N·m (8.5 kgf·m, 61 lbf·ft) STOPPER (2)
Page 478 dummyhead dummyhead MOUNT MOUNT CASE ASSEMBLY/ DISASSEMBLY EXPLODED VIEW Remove the mount case (page 17-2). SIDE WASHER (14 mm) SHIFT SHAFT ASSEMBLY E-RING (12 mm) SHIFT SHAFT WASHER FLANGE BUSHING WATER SEAL (14 x 16 x 22.5 mm) (22 x 35 x 7 mm) (2) OIL SEAL (14 x 26 x 6 mm) WASHER (14 mm)
Page 479 dummyhead dummyhead MOUNT FLANGE BUSHING (14 x 16 x 22.5 mm) INSTALLATION Set a thick wood block [1] under the oil seal (14 x 26 x 6 mm) installation part [2] of the mount case as shown. Apply engine oil to the circumference of a new flange bushing [3].
Page 480 dummyhead dummyhead MOUNT SHIFT SHAFT INSTALLATION Apply marine grease to the shift shaft assembly installation part [1] in the mount case. Set the shift shaft washer [2] on the mount case. Install shift shaft A [3] and shift shaft B [4] of the shift shaft assembly in the mount case in this sequence.
Page 481 dummyhead dummyhead MEMO...
Page 482: Trim/Tilt
dummytext 18. TRIM/TILT COMPONENT LOCATION ····················· 18-2 POWER TRIM/TILT DISASSEMBLY/ ASSEMBLY ······································· 18-23 ATF LINE DESCRIPTION ······················ 18-4 POWER TILT MOTOR DISASSEMBLY/ ASSEMBLY ······································· 18-41 POWER TRIM/TILT/SWIVEL CASE REMOVAL/INSTALLATION (EXCEPT LHGX TYPE) ························· 18-6 POWER TILT MOTOR INSPECTION ······ 18-46 SWIVEL CASE/MOUNT FRAME GAS ASSISTED DAMPER/SWIVEL DISASSEMBLY/ASSEMBLY·················18-15...
Page 483: Component Location
dummyhead dummyhead TRIM/TILT COMPONENT LOCATION TRIM/TILT Except LHGX type: 34 N·m (3.5 kgf·m, 25 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 18-2...
Page 484 dummyhead dummyhead TRIM/TILT LHGX type only: 34 N·m (3.5 kgf·m, 25 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 18-3...
Page 485: 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 18-4...
Page 486 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 18-5...
Page 487: Power Trim/Tilt/Swivel Case
dummyhead dummyhead TRIM/TILT POWER TRIM/TILT/SWIVEL CASE REMOVAL/INSTALLATION (EXCEPT LHGX TYPE) REMOVAL Remove the following – Engine (page 13-3) – Mount (page 17-2) Connect the battery positive (+) cable to the Green terminal [1] of the power tilt motor 2P connector [2] and the battery negative (-) cable to the Blue terminal [3].
Page 488 dummyhead dummyhead TRIM/TILT Remove the screws [1] and ground wire [2]. Remove the two bolts [3], ground wire, and the anode metal [4] from the stern brackets. • Check the anode metal for corrosion. If it is corroded excessively, replace with a new one. Remove the two E-rings [1] from the upper cylinder pin [2].
Page 489 dummyhead dummyhead TRIM/TILT While pushing the L./R. stern brackets lightly against the swivel case, remove the self-locking nut [1], washer [2], and bolt [3] from the R. stern bracket. While holding the power trim/tilt [1] with your hand, remove the locking nut (25 X 2.0 mm) [2] from the tilting shaft [3].
Page 490 dummyhead dummyhead TRIM/TILT Remove the self-locking nut (7/8-14 UNF) [1] from the tilting shaft [2]. Remove the swivel case [3] from the tilting shaft, and then remove the wave washer (26 mm) [4] and the tilting shaft from the R. stern bracket [5]. Check the swivel case bushings [6] mounted on the swivel case.
Page 491 dummyhead dummyhead TRIM/TILT EXPLODED VIEW SWIVEL CASE SWIVEL CASE BUSHING (2) UPPER CYLINDER PIN TILTING SHAFT E-RING (15 mm) (2) TILTING BOLT UPPER CYLINDER BUSHING (2) SELF-LOCKING NUT (7/8-14 UNF) 34 N·m (3.5 kgf·m, 25 lbf·ft) BOLT TRIM (6 X 20 mm) (2) ANGLE WAVE WASHER O-RING...
Page 492 dummyhead dummyhead TRIM/TILT INSTALLATION • Check that the piston rod of the power trim/tilt is extended fully. Apply marine grease to the inner wall and outer surface of the swivel case bushings [1] and install them on the swivel case [2]. Apply marine grease to the circumference of a new O- ring [3], and install it in the groove [4] in the tilting shaft [5] securely.
Page 493 dummyhead dummyhead TRIM/TILT While pushing the L./R. stern brackets lightly toward the swivel case side, install the bolt [1] and the washer [2], and loosely tighten the self-locking nut (10 mm) [3]. Install the trim angle sensor [1] and tighten the two bolts [2].
Page 494 dummyhead dummyhead TRIM/TILT Pass the trim angle sensor wire [1] and the power tilt motor wire [2] through the motor wire bushing [3] in the positions shown. Install the motor wire bushing in the L. stern bracket, aligning the projection [4] on the motor wire bushing with the concave [5] in the L.
Page 495 dummyhead dummyhead TRIM/TILT Set the lead wire [1] between the projections [2] on the anode metal [3], and install them with the two bolts [4]. Tighten the bolts. • Before installation, check the anode metal for corrosion and replace it with a new one if necessary. Set the lead wire as shown and install the screw [5].
Page 496: Swivel Case/Mount Frame Disassembly/Assembly
dummyhead dummyhead TRIM/TILT SWIVEL CASE/MOUNT FRAME DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the swivel case/stern bracket (page 18-6). Remove the external circlip [1] from the swivel shaft. Mark [1] the mount frame [2] so that it aligns with the " " mark [3] on the lower mount center housing [4]. Warm up the lower mount center housing [1] and mount frame [2] using a heat gun (ETB1600: commercially available) [3].
Page 497 dummyhead dummyhead TRIM/TILT Remove the mount frame [1], washer [2], and the wave washer [3] from the swivel case [4]. Remove the oil seal [1] from the swivel case [2]. Check the swivel case liners [3] mounted on the swivel case and replace them with new ones if they are worn, damaged, or deformed.
Page 498 dummyhead dummyhead TRIM/TILT Remove the three grease fittings [1] from the swivel case [2]. Remove the two self-locking nuts [3], washers [4], and thrust receivers [5]. Remove the bolt [1], detent spring [2], and detent assisted spring [3]. Using a commercially available pin driver (2.5 mm) [4], drive out the spring pin (2.5 X 20 mm) [5] up to the position where if does not interfere with the swivel case.
Page 499 dummyhead dummyhead TRIM/TILT EXPLODED VIEW BOLT (6 X 14 mm) DETENT ASSIST SWIVEL CASE SPRING SPRING PIN LINER (2) (2.5 X 20 mm) (2) DETENT SPRING TILTING BRACKET TILT STOPPER (2) MOUNT FRAME SELF-LOCKING NUT (10 mm) (2) TILT ARM BUSHING (2) THRUST RECEIVER (2) WASHER...
Page 500 dummyhead dummyhead TRIM/TILT ASSEMBLY Install the detent assist spring [1], detent spring [2], and bolt [3]; tighten the bolt. Apply marine grease to the detent spring roller. Apply marine grease to the circumference of the tilt stoppers [4] and tilt arm bushings [5]. Apply marine grease to the tilting bracket cam [6].
Page 501 dummyhead dummyhead TRIM/TILT Apply marine grease to the circumference of the swivel case liners [1]. Install the swivel case liners by aligning the projection [2] on each swivel case liner with the recess [3] in the swivel case. Apply marine grease to the circumference of a new oil seal [1].
Page 502 dummyhead dummyhead TRIM/TILT Apply marine grease to the circumference of the thrust washer [1] and install it to the mount frame [2]. Apply marine grease to the circumference of the mount frame shaft and install the mount frame on the swivel case [3].
Page 503 dummyhead dummyhead TRIM/TILT Set the nut [1], washer [2], and bearing driver attachment, 30 X 37 mm [3] on the threaded shaft [4] Mount frame side: (special tool). TOOLS: Threaded shaft 07APF-ZY3A300 Bearing driver attachment, 070PD-ZY6A200 30 x 37 mm Install the threaded shaft (special tool) on the mount frame as shown.
Page 504: Power Trim/Tilt Disassembly
dummyhead dummyhead TRIM/TILT If the mount frame turns smoothly and the circlip can be installed in the groove, install the external circlip [1] in the designated position and apply marine grease to the part A [2] shown. Install the swivel case/stern bracket (page 18-11). POWER TRIM/TILT DISASSEMBLY/ ASSEMBLY DISASSEMBLY...
Page 505 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 from 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 506 dummyhead dummyhead TRIM/TILT Remove socket bolt 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 [6]. Remove the reservoir valve [7] from the cylinder. •...
Page 507 dummyhead dummyhead TRIM/TILT Remove the rod guide [1] and piston rod B [2] from the trim cylinder slowly. • Do not push piston rod B into the trim cylinder chamber during removal. Remove the rod guide from piston rod B. Drain the ATF from the trim cylinders.
Page 508 dummyhead dummyhead TRIM/TILT Hold the cylinder with a vise (page 18-25). Make sure that piston rod A [1] is in the fully extended position. Set the special tool on the cylinder cap [2] as shown, and remove piston rod A. TOOL: Pin wrench, 6 mm [3] 07SPA-ZW1010A...
Page 509 dummyhead dummyhead TRIM/TILT EXPLODED VIEW PISTON ROD A CYLINDER CAP 207.5 N·m (21.2 kgf·m, 153 lbf·ft) POWER TILT MOTOR O-RING (3.5 X 41.7 mm) BACKUP RING FREE PISTON POWER TILT MOTOR O-RING (2) MOUNTING BOLT/WASHER (4) (3.5 X 38.7 mm) 4.9 N·m (0.50 kgf·m, 3.6 lbf·ft) O-RING (1.9 X 11 mm)
Page 510 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 holding the cylinder in a vise, do not tighten the vise excessively.
Page 511 dummyhead dummyhead TRIM/TILT Apply ATF to a new O-ring [1] and Install it on the bottom (i.e. nut side) of piston rod A [2]. Apply ATF to a new O-ring [3] and Install it on the cylinder cap [4] of piston rod A. Apply marine grease to the cylinder cap threads.
Page 512 dummyhead dummyhead TRIM/TILT Apply ATF to a new O-ring [1] and new backup ring [2], and install them on piston rod B [3]. • Install the backup ring on piston rod B with care not to break it. Apply ATF to a new oil seal [1]. Holding the oil seal in the shape of a "U"...
Page 513 dummyhead dummyhead TRIM/TILT Apply marine grease to the rod guide threads [1]. Install the rod guide on piston rod B [2]. Extend piston rod B fully and hold it in that position. Set one piston rod B in the left cylinder chamber and one in the right cylinder chamber.
Page 514 dummyhead dummyhead TRIM/TILT Apply ATF to five new O-rings [1] and orifice collar [2]. Install the reservoir valve [3] into the cylinder [4]. Pump side: Cylinder side: • Note the installation direction of the reservoir valve. • Take care not to let the pin and steel ball come out of the reservoir valve.
Page 515 dummyhead dummyhead TRIM/TILT After installation, check filter B for bubbles. Remove the bubbles with an oil bottle [1] or an equivalent tool if necessary. Be sure to remove the air bubbles, or they will cause air in the system. After removing the air bubbles, fill the pump fully with ATF again.
Page 516 dummyhead dummyhead TRIM/TILT Apply ATF to a new O-ring [1] and install it on the cylinder. Install the oil tank [2] on the cylinder and tighten the three oil tank mounting bolt/washers [3] to the specified torque. TORQUE: 4.9 N·m (0.50 kgf·m, 3.6 lbf·ft) Remove the oil tank cap [1].
Page 517: 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 18-38). 3.
Page 518 dummyhead dummyhead TRIM/TILT 7. With the rods extended fully, operate the power tilt motor to extend each rod until the relief valve opens again. Operate the power tilt motor to compress each rod and be sure that the rods compress (page 18-38).
Page 519 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. Tighten Loosen 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 520 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 18-36) fully. Operate the power tilt motor to extend each rod (page 18-36) fully again, and read the pressure gauge [1] to measure the lower chamber hydraulic pressure.
Page 521 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 18-36) fully, and read the pressure gauge [1] to measure the upper chamber hydraulic pressure.
Page 522: 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 523 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 524 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 525 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 brush holder A [3] and brush terminal [4] above the motor wire (Green wire) terminal [5] and loosely tighten [11] the screw (4 x 10 mm) [6].
Page 526 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 527: 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 528 dummyhead dummyhead TRIM/TILT MICA DEPTH Check the grooves of the commutator and measure the mica depth [1]. SERVICE LIMIT: 0.5 mm (0.02 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 529: Gas Assisted Damper/Swivel Case/Stern Bracket Removal
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 530 dummyhead dummyhead TRIM/TILT Remove the two E-rings [1], and upper cylinder pin [2]. Remove the self-locking nut [1] from the tilting shaft. While holding the gas assisted damper [2], remove the L. stern bracket [3] and wave washer [4]. Remove the gas assisted damper and wave washers [5]. Remove the lower cylinder collar [6] and spacers [7].
Page 531 dummyhead dummyhead TRIM/TILT Remove the self-locking nut (7/8-14 UNF) [1] from the tilting shaft [2]. Remove the swivel case [3] from the tilting shaft. Remove the wave washer [4] and tilting shaft from the R. stern bracket [5]. • Check the bushings [6] mounted on the swivel case and replace the them with new ones if they are worn, damaged, or deformed.
Page 532 dummyhead dummyhead TRIM/TILT DISPOSAL The gas assisted damper assembly is filled with the high pressured gas. Observe the following instructions. • Never heat the gas assisted damper, as it can explode. • Never disassemble the gas assisted damper, as it is filled with high pressured nitrogen gas. •...
Page 533 dummyhead dummyhead TRIM/TILT EXPLODED VIEW SCREW (6 x 8 mm) LEAD WIRE (137 mm) SWIVEL CASE SWIVEL CASE BUSHING (2) WAVE WASHER (26 mm) (4) UPPER CYLINDER PIN TILTING SHAFT E-RING (15 mm) (2) TILTING CAP SELF-LOCKING NUT (7/8-14 UNF mm) NUT (6 mm) 34 N·m (3.5 kgf·m, 25 lbf·ft) O-RING...
Page 534: Installation
dummyhead dummyhead TRIM/TILT INSTALLATION Apply marine grease to the inner wall and outer surface of the swivel case bushings [1] and install them on the swivel case [2]. Apply marine grease to the circumference of the new O- ring [3], and install it in the groove [4] in the tilting shaft [5] securely.
Page 535 dummyhead dummyhead TRIM/TILT Install the E-ring [1] in the upper cylinder pin [2]. Apply marine grease to the outer surface of the upper cylinder pin. Apply marine grease to the outer surface of the lower cylinder collar [3], and install it in the gas assisted damper [4].
Page 536 dummyhead dummyhead TRIM/TILT While pushing the L./R. stern brackets lightly toward the swivel case side, install the bolt [1] and the washer [2], and loosely tighten the self-locking nut (10 mm) [3]. Tighten the self-locking nut (25 x 2.0 mm) [4] to the specified torque so that the tilting shaft end is flush with the nut end.
Page 537 dummyhead dummyhead TRIM/TILT Install the adjusting bolt [1] and the washer [2], and tighten the self-locking nut [3]. 18-56...
Page 538: Controls
dummytext 19. CONTROLS COMPONENT LOCATION ····················· 19-2 STEERING FRICTION SHAFT/ROD REMOVAL/INSTALLATION ( TILLER HANDLE TYPE) ······················ 19-20 REMOTE CONTROL CABLE/GROMMET REMOVAL/INSTALLATION ··················· 19-3 TILLER HANDLE REMOVAL/ INSTALLATION·································· 19-21 SHIFT LINK BRACKET/NEUTRAL SWITCH REMOVAL/INSTALLATION ······ 19-8 TILLER HANDLE DISASSEMBLY/ ASSEMBLY ······································· 19-23 SEAL HOLDER REMOVAL/ INSTALLATION ··································19-12 COMBINATION SWITCH INSPECTION ··...
Page 539: Component Location
dummyhead dummyhead CONTROLS COMPONENT LOCATION CONTROLS 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft) 19-2...
Page 540: Remote Control Cable/Grommet Removal/Installation
dummyhead dummyhead CONTROLS REMOTE CONTROL CABLE/GROMMET REMOVAL/INSTALLATION REMOVAL Remove the following part, – Engine cover – Front separate cover (page 6-4) Loosen the under case grommet band [1] and remove it from the remote control cable grommet [2]. Remove the remote control cable (shift side) shift pivot [1] from the shift link pin [2].
Page 541 dummyhead dummyhead CONTROLS COMPONENTS DRAWING BOLT REMOTE CONTROL CABLE (6 x 16 mm) (2) (THROTTLE SIDE) REMOTE CONTROL CABLE COVER REMOTE CONTROL CABLE (SHIFT SIDE) REMOTE CONTROL CABLE GROMMET SHIFT PIVOT/ LOCK PLATE CONNECTOR CONNECTOR UNDER CASE GROMMET BAND HARNESS BAND CLIP REMOTE CONTROL CABLE PLATE...
Page 542 dummyhead dummyhead CONTROLS INSTALLATION Set the starter cable [1] on the front bracket [2]. • Align the tape end [3] on he starter cable with the end of the front bracket. Remote control type: Route the starter cable [1], fuel tube [2], 14P connector wire harness [3], and 6P connector wire harness [4] through the cable grommet [5].
Page 543 dummyhead dummyhead CONTROLS Long tiller handle type: Route the starter cable [1], fuel tube [2], and 14P/6P connector wire harness [3] through the cable grommet [4]. • Align the tape [5] on the 14P/6P connector wire harness with the end of the cable grommet. Install the cable grommet [1] in the groove in the front bracket [2], aligning the flat part [3] of the front bracket with the flat part [4] of the cable grommet.
Page 544 dummyhead dummyhead CONTROLS Connect the 14P connector [1] and 6P connector [2] to the engine side connectors [3] and secure the connectors to the connector holders [4]. Install the remote control cable plate [5] and tighten the bolt [6]. Secure the 14P connector wire harness [7] and 6P connector wire harness [8] with the new harness band clip [9] and install it to the remote control cable plate.
Page 545: Shift Link Bracket/Neutral Switch Removal/Installation
dummyhead dummyhead CONTROLS Check that each cable and tube is set in the holes in the cable grommet securely. Secure the cable grommet [1] with the grommet band [2]. Adjust the following parts. – Throttle control cable(page 3-9) – Shift control cable Install the following parts.
Page 546 dummyhead dummyhead CONTROLS Remove the snap pin [1] and remove the shift arm [2] from the sift shaft. • Remove the snap pin with care not to move the shift arm out of the “N” (Neutral) position. Release the neutral switch 2P connector [1] from the neutral switch bracket [2] and disconnect the connector.
Page 547 dummyhead dummyhead CONTROLS REMOVAL SNAP PIN SHIFT ARM THROTTLE ROD CLIP A NEUTRAL SWITCH BRACKET NUT (20 mm) 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft) BOLT (6 x 14 mm) BOLT (6 x 18 mm) (2) SHIFT LINK BRACKET BOLT (6 x 20 mm) (2) STARTER CABLE HOLDER 19-10...
Page 548 dummyhead dummyhead CONTROLS INSTALLATION Set the neutral switch [1] on the neutral switch bracket [2] and tighten the nut [3] to the specified torque. TORQUE: 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft) Set clip A [4] on the neutral switch wire and install clip A on the neutral switch bracket.
Page 549: Seal Holder Removal
dummyhead dummyhead CONTROLS Apply marine grease to the following part. – Circumference of the link pin of the shift link bracket – Throttle plate (linkage pivot installation part) – linkage pivot (throttle rod) Install the shift link bracket [1], aligning the link pin [2] with the long hole in the shift arm [3] and secure the shift link bracket by tightening the two bolts [4].
Page 550: Shift Link Bracket Disassembly
dummyhead dummyhead CONTROLS SHIFT LINK BRACKET DISASSEMBLY/ ASSEMBLY Remove the shift link bracket (page 19-8). THROTTLE PLATE (SLIDING SURFACE) E-RING (4 mm) (3) INSTALLATION (WASHER MATING SURFACE) (MOUNTING DIRECTION: (SEAT) PORTION) CHAMFER BUSHING A (2) (MATING SURFACE) SHIFT PIVOT PLATE (THROTTLE LINK THROTTLE ARM MATING SURFACE/...
Page 551: Steering Rod Removal/Installation (Remote Control Type)
dummyhead dummyhead CONTROLS SEAL HOLDER WATER SEAL REPLACEMENT Remove the seal holder (page 19-12). Remove the water seal (14 X 26 X 6 mm) [1] from the seal holder [2] using the commercially available oil seal remover. Apply soapy water to the circumference of a new water seal (14 X 26 X 6 mm), and install it on the seal holder.
Page 552 dummyhead dummyhead CONTROLS REMOTE CONTROL BOX DISASSEMBLY/ASSEMBLY REMOTE CONTROL CABLE SHIFT PIVOT (2) INSTALLATION: Screw in the shift pivot 8 mm (0.3 in) or more onto the threaded end of the cable. 8 mm (0.3 in) REMOTE CONTROL BOX COVER C LOCK NUT (10-32 UNF) (2) LOCK PIN (6 mm) (2)
Page 553 dummyhead dummyhead CONTROLS ELECTRIC COMPONENTS EMERGENCY STOP SWITCH WARNING BUZZER COMBINATION SWITCH SCREW (5 X 8 mm) (2) POWER TRIM/TILT SWITCH WIRE 0.7 N·m (0.07 kgf·m, 0.5 lbf·ft) INSTALLATION: Route the power trim/tilt switch wire and POWER TILT set the power tilt cord clamp as shown. CORD CLAMP POWER TRIM/ TILT SWITCH...
Page 554 dummyhead dummyhead CONTROLS SLIDING PLATE SCREW (5 X 10 mm) LINK JOINT WASHER (5 mm) BRACKET E-CLIP (4 mm) NUT (5 mm) FAST IDLE SPRING E-CLIP (7 mm) 4.9 N·m (0.50 kgf·m, 3.6 lbf·ft) WASHER (6 mm) (2) WASHER (8 mm) BOLT (5 X 16 mm) FAST IDLE WHEEL...
Page 555: Remote Control Box
dummyhead dummyhead CONTROLS REMOTE CONTROL LEVER/CONTROL WHEEL BOLT (8 X 35 mm) SCREW (5 X 10 mm) NUT (6 mm) 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft) 23.5 N·m (2.4 kgf·m, 17 lbf·ft) WASHER (5 mm) WASHER (4 mm) (2) (Journal/hole) CONTROL WHEEL NEUTRAL SWITCH SPACER...
Page 556: Remote Control Lever
dummyhead dummyhead CONTROLS REMOTE CONTROL LEVER NEUTRAL RELEASE REMOTE CONTROL LEVER LEVER SPRING SCREW (5 X 10 mm) 4.9 N·m (0.50 kgf·m, 3.6 lbf·ft) LEVER SETTING REMOTE CONTROL PLATE LEVER GRIP SCREW (5 X 12 mm) POWER TRIM/TILT 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft) SWITCH REMOTE CONTROL LEVER...
Page 557: Steering Friction Shaft/Rod Removal/Installation
dummyhead dummyhead CONTROLS STEERING FRICTION SHAFT/ROD REMOVAL/INSTALLATION (TILLER HANDLE TYPE) O-RING STEERING FRICTION ROD STEERING FRICTION BLOCK WASHER (8 mm) STEERING SELF-LOCKING FRICTION SHAFT NUT (6 mm) NUT (8 mm) (2) SPLIT PIN FRICTION BOLT (2.0 mm) POSITION VARIATIONS OF STEERING FRICTION ROD •...
Page 558 dummyhead dummyhead CONTROLS TILLER HANDLE REMOVAL/INSTALLATION REMOVAL Remove the control cables (page 19-3). Remove the two self-locking nuts [1] and two washers [2]. Remove the two bolts [1] and two washers [2] from the steering bracket [3], and remove the tiller handle [4] and friction rod [5].
Page 559: Installation
dummyhead dummyhead CONTROLS INSTALLATION Set the steering bracket [1] of the tiller handle [2] on the mount frame [3] and install the two washers [4] and two bolts [5]. loosely tighten the bolts. Apply marine grease to the seating area (at two places) of the steering friction rod [6]. Install the steering friction rod on the steering bracket and the steering friction shaft as shown.
Page 560 dummyhead dummyhead CONTROLS TILLER HANDLE DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the tiller handle (page 19-21). Remove the six screws [1] and under cover [2]. Remove the grommet [1] from the tiller handle. Remove the two E-rings [2] from each of the two remote control cables [3], and disconnect the remote control cables from the throttle arm and the shift frame.
Page 561 dummyhead dummyhead CONTROLS Remove the harness band clip [1] that clamps the cord tube (40 mm) [2] from the connector bracket [3] as shown. Remove the switch clip [1] from the emergency stop switch [2]. Remove the nut [3] from the emergency stop switch, and push the emergency stop switch into the housing.
Page 562 dummyhead dummyhead CONTROLS Remove the bolt [1] from the connector bracket [2], and remove the harness and the connector bracket as a set from the tiller handle. Remove the harness band clip [3], which clamps tube A [4], from the connector bracket. Remove the warning buzzer [5] from the housing.
Page 563 dummyhead dummyhead CONTROLS Open the harness band clip [1] that clamps tube A [2]. Disconnect all the combination switch connectors [3]. Disconnect the two warning buzzer connectors [4]. Disconnect all the indicator light connectors [1]. Remove the indicator light [2] from the tiller handle by pushing the retaining tabs [3] on the right and left sides to the indicator light as shown.
Page 564 dummyhead dummyhead CONTROLS Remove the bolt [1] and height adjust block [2]. Remove the nut (small) [3] that tightens the steering bracket. Remove the bolt [4], nut (large) [5], wave washer [6], distance collar [7], and washer (12 mm small) [8]. Remove the steering bracket [9] and washer (12 mm large) [10].
Page 565 dummyhead dummyhead CONTROLS Loosen the throttle friction grip [1] of the grip pipe [2], and turn the grip pipe clockwise to remove it from the tiller handle. Remove the throttle friction grip [1], throttle friction pad, [2] and the throttle friction block [3] from the grip pipe [4].
Page 566 dummyhead dummyhead CONTROLS Remove the cap [1]. Loosen the socket bolt [2] by approximately 10 mm (0.4 in). Remove the shift lever [3] from the tiller handle by lightly tapping the bolt head with a plastic hammer. Remove the socket bolt and the washer [4] from the shift lever, and remove the lever stopper [5] and the shift lever from the tiller handle.
Page 567 dummyhead dummyhead CONTROLS Remove the throttle cable pin [1] from the throttle cable pivot [2]. Loosen the nut [3] of the throttle cable pivot, and remove the throttle cable pivot, nut, and rod grommet [4] from the throttle rod [5]. Remove the two screws [1] and remove the lock plate [2].
Page 568 dummyhead dummyhead CONTROLS EXPLODED VIEW UNDER COVER/CABLE/STEERING BRACKET SCREW (5 x 12 mm) (6) 2.4 N·m (0.24 kgf·m, 1.8 lbf·ft) REMOTE CONTROL CABLE (THROTTLE SIDE) UNDER COVER REMOTE CONTROL BOLT/WASHER (6 X 12 mm) (2) CABLE (SHIFT SIDE) 7 N·m (0.71 kgf·m, 5.2 lbf·ft) STEERING BRACKET CABLE BRACKET E-RING (4 mm) (2)
Page 569 dummyhead dummyhead CONTROLS ELECTRIC PARTS HARNESS BAND EMERGENCY CLIP (3) TUBE B STOP SWITCH POWER TRIM/TILT SWITCH WIRE (Except LHGX type) GROMMET INDICATOR WARNING LIGHT WIRES BUZZER WIRE COMBINATION SWITCH BOLT (6 X 12 mm) 7 N·m (0.71 kgf·m, 5.2 lbf·ft) TUBE A CORD TUBE SWITCH CLIP...
Page 570 dummyhead dummyhead CONTROLS POWER TRIM/TILT SWITCH/THROTTLE SCREW (5 X 10 mm) (2) (Except LHGX TYPE) WIRE COVER (Except LHGX TYPE) SWITCH HARNESS BAND (2) HOLDER (Except LHGX TYPE) BOLT (5 X 8 mm) 4.5 N·m (0.46 kgf·m, 3.3 lbf·ft) SWITCH HOLE GROMMET (LHGX TYPE ONLY) WASHER POWER TRIM/TILT SWITCH...
Page 571 dummyhead dummyhead CONTROLS SHIFT LEVER/SHIFT GEAR BOLT (5 X 12 mm) (3) 4.5 N·m (0.46 kgf·m, 3.3 lbf·ft) WASHER (5 mm) (3) THROTTLE ARM THROTTLE ROD WASHER GUIDE PLATE (10 mm) (2) STEEL BALL E-RING (9 mm) ROD GROMMET NUT (5 mm) 1.3 N·m (0.13 kgf·m, 1.0 lbf·ft) SCREW (5 X 14 mm) (2) BOLT/WASHER...
Page 572: Assembly
dummyhead dummyhead CONTROLS ASSEMBLY Install the lock plate [1] on the spring guide [2]. Install and tighten the two screws [3]. Apply marine grease to the outer surface of the spring [4], shift arm pin [5], and the roller [6]. Install the shift arm pin and spring on the spring guide by noting the shift arm pin installation direction as shown.
Page 573 dummyhead dummyhead CONTROLS Set the steel ball [1] in the position as shown. Apply marine grease to the pin of the throttle arm [2]. Apply marine grease to the throttle rod [3] at position as shown. Set the two washers [4] and the throttle rod on the throttle arm, and install the E-ring [5] securely as shown. Apply marine grease to the pivot points of the throttle arm.
Page 574 dummyhead dummyhead CONTROLS Apply marine grease to the indicated position of the housing [1] and to the outer surface of the bushing [2], and then install the bushing on the housing. Apply marine grease to the new O-ring [3] and install it on the shift lever [4].
Page 575 dummyhead dummyhead CONTROLS Apply marine grease to the grip pipe installation part of the tiller handle. Install the throttle friction block [1] on the tiller handle by aligning the wide projection [2] on the tiller handle with the wide recess [3] in the friction block. Apply marine grease to the outer surface of the throttle cable pin [1].
Page 576 dummyhead dummyhead CONTROLS Install and tighten the bolt [1] to the specified torque. TORQUE: 7 N·m (0.71 kgf·m, 5.2 lbf·ft) Check that the grip pipe is tightened securely by turning it clockwise fully (full close position), and tighten the throttle friction grip securely. Install the grip rubber [2] on the grip pipe with the "...
Page 577 dummyhead dummyhead CONTROLS Apply marine grease to the side and outer surface of the steering handle bushings [1] and to the inner wall of the housing. Install the steering handle bushings on the tiller handle. Apply marine grease to the washer (large) [2]. Set the washer (large) in the position shown, and install the steering bracket [3] on the tiller handle.
Page 578 dummyhead dummyhead CONTROLS Connect the connectors to the indicator light connectors [1], combination switch connectors [2], and warning buzzer connectors [3]. Set tube A [4] over the connectors that were just connected, and clamp tube A at the connectors securely using a new harness band clip [5].
Page 579 dummyhead dummyhead CONTROLS Install the combination switch [1] on the tiller handle [2], aligning the cutout [3] in the combination switch with the flat part [4] in the switch installation part of the tiller handle as shown. Install the emergency stop switch [5] on the tiller handle, aligning the cutout [6] in the emergency stop switch with the flat part [7] in the switch installation part of the tiller handle as shown.
Page 580 dummyhead dummyhead CONTROLS Install the warning buzzer [1] in the housing. Route the warning buzzer wire [2] between the projections [3] in the housing as shown. • Operate the throttle arm and check that it does not interfere with the warning buzzer wire. Install the nut [1] on the combination switch and tighten the nut to the specified torque.
Page 581 dummyhead dummyhead CONTROLS Apply thread locking agent (LOCTITE® 242 or equivalent) to the threads of the two bolt/washers [1]. Install the cable bracket [2] and clamp bracket [3], and tighten the two bolt/washers to the specified torque. TORQUE: 7 N·m (0.71 kgf·m, 5.2 lbf·ft) Set the shift side remote control cable [4] in the handle cable installation hole in the grommet [5], and set the throttle side remote control cable [6] in the handle cable...
Page 582: Combination Switch Inspection
dummyhead dummyhead CONTROLS Clean the housing and under cover mating surfaces thoroughly using a shop towel and degreasing cleaning 20 mm solvent. (0.8 in) Apply liquid gasket (ThreeBond® #1216E or equivalent) to the housing in the areas shown. 9 mm (0.4 in) Install the under cover [1] and six screws [2] and tighten them to the specified torque.
Page 583: Warning Buzzer Inspection
dummyhead dummyhead CONTROLS WARNING BUZZER INSPECTION • Use a known-good battery for the test. Connect the Black/Yellow terminal of the warning buzzer to the positive (+) terminal of the 12 V battery and the Yellow/Green terminal to the negative (–) terminal of the battery.
Page 584: Indicator Light Inspection
dummyhead dummyhead CONTROLS INDICATOR LIGHT INSPECTION • Use a known-good battery for the test. Route the indicator light wires as shown. Connect switch A [1] and switch B [2], which are connected to the battery negative (–) terminal, to the Black and Yellow terminals.
Page 585: Power Trim/Tilt Switch Inspection (Remote Control/ Tiller Handle Side)
dummyhead dummyhead CONTROLS POWER TRIM/TILT SWITCH INSPECTION (REMOTE CONTROL/ TILLER HANDLE SIDE) Check for continuity between the terminals with the <Remote control type> switch in each position. Light green White/Black Light White/ Light blue Light blue green Black NORMAL DOWN : Continuity <Tiller handle type>...
Page 586: Technical Features
dummytext 20. TECHNICAL FEATURES OIL PRESSURE ALERT SYSTEM ·········· 20-2 COMPACT & HIGH POWER ALTERNATOR + DIRECT WATER-COOLED REGULATOR/ RECTIFIER ········································· 20-6 CAM CHAIN TENSION ADJUSTMENT SYSTEM & LUBRICATION MECHANISM ······································ 20-5 LOW SPEED SIDE INTAKE ROCKER ARM STRUCTURE (BF90D/BF100A ONLY)····· 20-7 20-1...
Page 587 dummyhead dummyhead TECHNICAL FEATURES OIL PRESSURE ALERT SYSTEM TECHNICAL FEATURES SYSTEM DESCRIPTION This model utilizes an oil pressure alert system with the EOP sensor, which detects the oil pressure linearly, instead of a conventional system that uses two EOP switches (high pressure side/low pressure side). This system enables more accurate control of pressure alert, depending on the engine speed and engine temperature, which realizes an enhanced reliability of the whole system.
Page 588 dummyhead dummyhead TECHNICAL FEATURES EOP SENSOR A conventional EOP switch is an ON/OFF pressure switch, which includes a mechanical contact, that turns ON when the oil pressure is below a specified value and turns OFF when the pressure is above a specified value. The EOP sensor includes a piezoelectric device which converts the electronic signals into voltage, which ranges from 0 to 5 V, and transmits to the ECM.
Page 589 dummyhead dummyhead TECHNICAL FEATURES ABNORMAL OIL PRESSURE DETECTION In a conventional system, the ECM uses two EOP switches (low/high pressure) in order to detect an abnormal oil pressure according to the operating condition that varies with the engine speed and engine temperature. On this newly introduced oil pressure alert system, the ECM detects linear change of oil pressure by the EOP sensor, constantly compares the constantly changing detected value with the normal value depending on engine speed and temperature, in order to find an abnormal oil pressure.
Page 590 dummyhead dummyhead TECHNICAL FEATURES CAM CHAIN TENSION ADJUSTMENT SYSTEM & LUBRICATION MECHANISM OUTLINE The BF75D/BF80A/BF90D/BF100A are equipped with a cam chain tensioner and a cam chain tensioner slider to constantly maintain the cam chain tension at the proper level. The oil injected from the oil pipe drips down from the ribs located in the chain case, then lubricates the cam chain driven sprocket, cam chain drive sprocket, cam chain, cam chain tensioner, and the cam chain tensioner slider.
Page 591 dummyhead dummyhead TECHNICAL FEATURES COMPACT & HIGH POWER ALTERNATOR + DIRECT WATER- COOLED REGULATOR/RECTIFIER OUTLINE The BF75D/BF80A/BF90D/BF100A are each equipped with an alternator that uses a permanent magnet. By adoption of this type of alternator, the number of parts could be reduced significantly, compared to the existing models equipped with the self-exciting alternator, and high output power is achieved as well.
Page 592 dummyhead dummyhead TECHNICAL FEATURES LOW SPEED SIDE INTAKE ROCKER ARM STRUCTURE (BF90D/BF100A ONLY) STRUCTURE AND FEATURES The low speed side (low lift side) intake rocker arm was changed to the integral fork end type, which contributed to reduction in the number of parts.
Page 593 dummyhead dummyhead MEMO...
Page 594: Wiring Diagrams
dummytext 21. WIRING DIAGRAMS WIRING DIAGRAMS SYSTEM DIAGRAM ····························· 21-5 (REMOTE CONTROL TYPE)·················· 21-3 CONNECTOR GENERAL WIRING DIAGRAMS LAYOUT DRAWING ····························· 21-6 (TILLER HANDLE TYPE) ······················ 21-4 21-1...
Page 595 dummytext WIRING DIAGRAMS (REMOTE CONTROL TYPE) WIRING DIAGRAMS FUSE BOX FUEL PUMP EQUIPPED TYPE OPTIONAL PART MAIN FUEL FUEL FUEL FUEL ALTERNATOR TACHO METER TRIM METER ALTERNATOR IGNITION COIL #4 IGNITION COIL #3 IGNITION COIL #2 IGNITION COIL #1 COMBINATION SWITCH INJECTOR #4 INJECTOR #3 INJECTOR #2...
Page 596 dummytext WIRING DIAGRAMS (TILLER HANDLE TYPE) FUSE BOX FUEL PUMP OPTIONAL PART MAIN FUEL FUEL FUEL FUEL ALTERNATOR TACHO METER TRIM METER ALTERNATOR IGNITION COIL #4 IGNITION COIL #3 IGNITION COIL #2 IGNITION COIL #1 INJECTOR #4 INJECTOR #3 INJECTOR #2 INJECTOR #1 W/Bu ACGLP...
Page 597 dummytext SYSTEM DIAGRAM CHECK VALVE REGULATOR/ IG2 IG1 RECTIFIER PGM-FI/MAIN RELAY BF90D/BF100A Only AIR VENT STRAINER ALTERNATOR MAIN PRESSURE REGULATOR COMBINATION VAPOR SWITCH SEPARATOR STARTER IGP1 FUEL MOTOR IGP2 STRAINER FLR1 (HIGH) FLR2 BATTERY FUEL PUMP NTSW (HIGH) VCC3 NEUTRAL SWITCH TRIM ANGLE...
Page 598 dummytext CONNECTOR GENERAL LAYOUT DRAWING Terminal Wire color Terminal Wire color number number JOINT JOINT W/Bu CONNECTOR 1 CONNECTOR 2 Main wire harness side Main wire harness side STATOR 3P Y/Bl CONNECTOR No.1 IGNITION COIL 3P CONNECTOR Terminal Wire color Terminal Wire color number...
Page 599 dummytext ECM 36P ECM 36P CONNECTOR B (Black) CONNECTOR A (Gray) Terminal Wire color Terminal Wire color HO2S 4P number number ENGINE SPEED CHECK CONNECTOR Bl/Y 2P CONNECTOR (Blue) W/Bl W/Bl Main wire harness side Main wire harness side Y/Bl Terminal Wire color Terminal...
Page 600 dummytext GROUND Terminal Wire color CABLE number FUSE BOX GROUND W/Bu 5P CONNECTOR CABLE GROUND CABLE W/Bl Main wire harness side GROUND CABLE Terminal Wire color number W/Bu Main relay side W/Bl PGM-FI/MAIN RELAY 6P CONNECTOR Terminal Wire color number PGM-FI/MAIN RELAY 5P CONNECTOR NMEA 2000 6P...
Page 601 dummytext Terminal Wire color number REMOTE CONTROL CABLE or TILLER HANDLE 14P Y/Bl CONNECTOR IAT SENSOR 2P W/Bu CONNECTOR INDICATOR LIGHT Main wire harness side R/Bu 6P CONNECTOR MAP SENSOR 3P Terminal Wire color number CONNECTOR Br/Y EXCEPT LHGX TYPE Main wire harness side Terminal Wire color...
Page 602 dummytext EOP SENSOR 3P CKP SENSOR 3P CONNECTOR CONNECTOR FUEL PUMP (HIGH) Terminal Wire color 2P CONNECTOR number Terminal Wire color number POWER TILT RELAY Terminal Wire color 3P CONNECTOR Main wire harness side number FUSE CABLE 1P No.1 FUEL (Except LHGX type) Fuse cable side CONNECTOR...
Page 603 dummytext REMOTE CONTROL TYPE (Side mount remote control box) [Equipped type only] WIRING DIAGRAM: POWER TRIM/TILT REMOTE CONTROL CABLE B SWITCH REMOTE INDICATOR INDICATOR LIGHT Terminal Wire color Terminal Wire color TACHO METER TRIM METER CONTROL LIGHT number number Terminal Wire color CABLE B number...
Page 604 dummytext • Connectors are viewed from the terminal side TACHO METER METER HARNESS A Terminal Wire color Terminal Wire color (Equipped type only) (Equipped type only) number number Terminal Wire color Terminal Wire color Terminal Wire color Terminal Wire color W/Bl Y/Bl number...
Page 605 dummytext TILLER HANDLE TYPE [Equipped type only] WIRING DIAGRAM: POWER TRIM/TILT Connectors in 40 mm cord tube: HANDLE CABLE 40 mm CORD SWITCH Terminal Wire color TUBE (EQUIPPED TYPE ONLY) number Terminal Wire color Terminal Wire color number number W/Bu W/Bl R/Bu W/Bu...
Page 606 dummytext • Connectors are viewed from the terminal side Terminal Wire color Terminal Wire color number number Terminal Wire color W/Bl Bl/W number Bl/Y Bl/R Y/Bl Y/Bu G/Bl Meter harness A side Main wire harness side Except LHGX Type Terminal Wire color Terminal Wire color...
Page 607 INDEX dummytext INDEX 70 A FUSE BOX/FUSE INSPECTION ··················· 10-14 ENGINE SIDE STOPPER REMOVAL/ Numerics AIR VENT STRAINER/CHECK VALVE REMOVAL/ INSTALLATION ·············································· 6-11 INSTALLATION··············································· 5-86 ENGINE TROUBLESHOOTING ·······························4-2 ALERT SYSTEM/WARNING SYSTEM EOP SENSOR REMOVAL/INSTALLATION ·············· 5-84 TROUBLESHOOTING······································ 4-16 EXTENSION CASE/LOWER RUBBER REMOVAL/ ALTERNATOR COVER ··········································7-5 INSTALLATION ··············································...
Page 608 dummytext INDEX MOUNT CASE REMOVAL/INSTALLATION ············· 17-2 STARTER MOTOR INSPECTION ···························9-19 NEUTRAL SWITCH INSPECTION ························· 9-22 STARTER MOTOR REMOVAL/INSTALLATION ········· 9-5 NUTS, BOLTS, FASTENERS································ 3-31 STARTING PROCEDURE AFTER INSTALLING OIL CASE REMOVAL/INSTALLATION···················· 12-5 MAJOR ASSEMBLIES ······································12-4 OIL PRESSURE ALERT SYSTEM ························· 20-2 STARTING SYSTEM TROUBLESHOOTING··············...
Page 609 BFT 75A BFT 90A BFT 75A BFT 90A OB No.62ZY950US OB No.62ZY950US 14-01 NB 14-01 NB Printed in Japan BFT75-90AUS_Cover_140207.indd 1 14/02/07 10:56...

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Bft 90a

TOHATSU BFT75A Service Manual

Table of Contents

3. Maintenance

4. Troubleshooting

5. Fuel System

6. Engine Cover

7. Charging System

9. Starting System

10. Other Electrical

11. Cooling System

12. Lubrication System

14. Cylinder Head

16. Gear Case

18. Trim/Tilt

19. Controls

Quick Links

Chapters

Troubleshooting

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Summary of Contents for TOHATSU BFT75A