TOHATSU BFT115A Service Manual
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TOHATSU BFT115A Service Manual

4 stroke
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Table of Contents

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See also: Owner's Manual
BFT 115A
OB No.62ZX100
14-01 NB

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Summary of Contents for TOHATSU BFT115A

  • Page 1 BFT 115A OB No.62ZX100 14-01 NB...
  • Page 2 Introduction Before reading this manual This service manual provides information that is needed for inspection, service and repair of applicable outboard motors. For our customers' safe and comfortable use of the products for long term, it is essential to maintain the performance and quality of the outboard motors. To ensure this, the maintenance and service have to be done properly by service technicians with fundamental knowledge and skills.
  • Page 3 Introduction Avant de lire le présent manuel Le présent manuel d’entretien fournit les informations nécessaires au contrôle, à l’utilisation et à la réparation des moteurs hors-bords concernés. Pour une utilisation de nos produits par nos clients, à long terme, en toute sécurité...
  • Page 4 Introducción Antes de leer este manual Este manual de servicio brinda la información que se requiere para la inspección, el servicio y la reparación de los correspondientes motores fuera de borda. Para que nuestros clientes puedan utilizar los productos durante largo tiempo de forma segura y cómoda, resulta fundamental mantener el desempeño y la calidad de los motores fuera de borda.
  • Page 5 Einführung Vor dem Durchlesen dieses Handbuchs Dieses Service-Handbuch enthält die Information, die zur Inspektion, Service und Reparatur der jeweiligen Außenbordmotoren benötigt wird. Zur Sicherheit unserer Kunden und für eine komfortable, langfristige Benutzung der Produkte ist es unumgänglich, die Leistung und Qualität der Außenbordmotoren instand zu halten.
  • Page 6 How to use this manual A Few Words About Safety How to use this manual SERVICE INFORMATION The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage this Honda product or create an unsafe condition.

  • Page 7: Table Of Contents

    How to use this manual GENERAL INFORMATION SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING FUEL SYSTEM ENGINE COVER/COVER LOCK CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM OTHER ELECTRICAL COOLING SYSTEM LUBRICATION SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD CYLINDER BLOCK GEAR CASE (STANDARD ROTATION) GEAR CASE (COUNTER ROTATION) MOUNT TRIM/TILT CONTROLS...
  • Page 8 How to use this manual INTRODUCTION This manual covers the service and repair procedures for the Honda BF115D outboard motor. All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at anytime without notice.
  • Page 9 How to use this manual SERVICE RULES • Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product. •...
  • Page 10 How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbreviated Full term term Alternator Air Fuel Ratio American Petroleum Institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center Automatic Transmission Fluid Attachment Battery...

  • Page 11: General Information

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

  • Page 12: Specifications

    GENERAL INFORMATION SERIAL NUMBER LOCATION GENERAL INFORMATION 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 13: Lower Unit

    GENERAL INFORMATION ENGINE Model BF115D Description code BEBHJ Type 4-stroke, D.O.H.C., 4 cylinder Displacement 2,354 cm (143.6 cu in) Bore × stroke 87.0 × 99.0 mm (3.43 × 3.90 in) Rated power 84.6 kW (115 PS) at 5,250 min (rpm) Maximum torque 194 N·m (19.8 kgf·m, 143 lbf·ft) Compression ratio...
  • Page 14 GENERAL INFORMATION DIMENSIONAL DRAWING Transom LU, LD and LC types 1,665 mm (65.6 in) 508 mm (20.0 in) XU, XD, XC and XCD types 1,790 mm (70.5 in) 635 mm (25.0 in) 845 mm (33.3 in) 580 mm (22.8 in) 12°...
  • Page 15 GENERAL INFORMATION 539 mm (21.2 in) 76 mm (3.0 in) 679 mm (26.7 in) 83.7 mm 68° (3.30 in) 12° 615 mm (24.2 in) LU, LD and LC types: 1,024 mm (40.3 in) XU, XD, XC and XCD types: 1,144 mm (45.0 in)
  • Page 16 GENERAL INFORMATION Propeller shaft Φ4 (Φ0.16) 7 mm (0.3 in) 57.5 ± 0.5 mm 56.5 mm 28.5 mm (2.26 ± 0.02 in) (2.22 in) (1.12 in) 151 mm (5.9 in)

  • Page 17: Service Information

    2. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················2-2 LUBRICATION & SEAL POINT ·················· 2-14 ENGINE & FRAME TORQUE VALUES ········2-4 CABLE/HARNESS ROUTING ···················· 2-17 STANDARD TORQUE VALUES ···················2-7 TUBE ROUTING ········································· 2-35 TOOLS···························································2-8...
  • Page 18 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 ± 50 min (rpm) – Cylinder compression 1,230 – 1,630 kPa 930 (9.5, 135) (12.6 –...
  • Page 19 SERVICE INFORMATION Part Item Standard Service limit Connecting rods Difference between upper and lower 0 – 0.10 (0 – 0.004) – parts of connecting rod bolt O.D. Small end I.D. 21.970 – 21.976 (0.8650 – 0.8652) – Small end-to-piston pin clearance 0.005 –...
  • Page 20 SERVICE INFORMATION Part Item Standard Service limit Thermostat Begin to Cylinder head side 48 – 52 °C (118 °F – 126 °F) – open Cylinder block side 58 – 62 °C (136 °F – 144 °F) – Fully open Cylinder head side 60 °C (140 °F) –...
  • Page 21 SERVICE INFORMATION Torque values Thread Dia. (mm) and Item pitch (length) N·m kgf·m lbf·ft Crankshaft pulley bolt M16 x 1.5 25.5 Balancer chain guide bolt M6 x 1.0 Cam chain tensioner arm pivot bolt M8 x 1.25 Chain case bolt M6 x 1.0 Balancer driven sprocket M10 x 1.25...
  • Page 22 SERVICE INFORMATION GEAR CASE Torque values Thread Dia. (mm) and Item pitch (length) N·m kgf·m lbf·ft Pinion gear nut M18 x 1.0 14.5 Oil level check bolt M8 x 1.25 Drain plug bolt M8 x 1.25 Bearing holder (XCD type) M100 x 2.0 19.5 Impeller housing bolt...

  • Page 23: Standard Torque Values

    SERVICE INFORMATION OTHERS Torque values Thread Dia. (mm) and Item pitch (length) N·m kgf·m lbf·ft Neutral switch nut M20 x 1.0 0.25 Grease fitting M6 x 1.0 0.31 Starter motor B terminal nut M8 x 1.25 Alternator B terminal nut M6 x 1.0 0.82 No1.

  • Page 24: Special Tools

    SERVICE INFORMATION TOOLS SPECIAL TOOLS Driver, 480 mm Oil pressure gauge attachment Trim cap wrench, 4 mm 070GD-0010100 070MJ-0010101 070PA-0010100 Ring gear holder Bearing race puller Taper bearing driver attachment 070PB-ZY60100 070PC-ZY30100 070PD-ZY60100 Attachment, 30 x 37 mm Taper bearing installer attachment Gauge adapter, 100 mm 070PD-ZY60200 070PF-ZY60100...
  • Page 25 SERVICE INFORMATION Fuel pressure gauge Oil pressure gauge set Remover weight 07406-0040004 07506-3000001 07741-0010201 Valve guide driver, 5.35 x 9.7 Pin driver 6.0 Attachment, 32 x 35 mm 07742-0010100 07744-0010500 07746-0010100 Attachment, 37 x 40 mm Attachment, 42 x 47 mm Attachment, 52 x 55 mm 07746-0010200 07746-0010300...
  • Page 26 SERVICE INFORMATION Pilot, 20 mm Pilot, 25 mm Pilot, 35 mm 07746-0040500 07746-0040600 07746-0040800 Driver Valve spring compressor Valve spring compressor 07749-0010000 07757-0010000 attachment 07757-PJ10100 Valve seat cutter, 45° 35 mm [IN] Valve seat cutter, 45° 33 mm [EX] Valve seat cutter, 32° 38.5 mm [IN] 07780-0010400 07780-0010800 07780-0012400...
  • Page 27 SERVICE INFORMATION Bearing separator attachment, 18 mm Remover handle Bearing remover, 30 mm 07931-4630100 07936-3710100 07936-8890300 Bearing driver attachment, Bearing driver attachment, 28 x 30 mm Oil seal driver, 72 mm 44 x 49.5 mm 07946-1870100 07947-6340201 07945-3330300 Oil seal driver, 44.5 mm Oil seal driver attachment, 21 mm Oil seal driver attachment, 07947-SB00100...
  • Page 28 SERVICE INFORMATION Oil filter wrench, 65 mm Valve guide reamer, 5.5 mm Socket wrench, 19 x 90 mm 07HAA-PJ70101 07HAH-PJ70100 07JAA-001020A Holder handle oil seal driver, 65 mm Belt tension gauge 07JAB-001020B 07JAD-PL90100 07JGG-0010101 Holder attachment, 50 mm, offset Attachment, 52 x 55 mm Stem seal driver 07MAB-PY30100 07NAD-P200100...
  • Page 29 SERVICE INFORMATION Oil pressure gauge joint B Installer shaft, 15 x 370 mm Pin spanner wrench, 110 mm 07SPJ-ZW10200 07VMF-KZ30200 07WAA-S1G0100 Puller jaws, 25 mm Backlash indicator tool Oil seal driver attachment, 80 x 96 mm 07WPC-ZW50100 07SPJ-ZW0030Z 07ZAD-PNA0100 Test probe Bearing remover attachment, 37 mm Pressure tester S-34 07ZAJ-RDJA110...
  • Page 30 SERVICE INFORMATION LUBRICATION & SEAL POINT ENGINE Location Material Remarks Main bearing bolt threads and seating surface Engine oil Oil filter holder threads (Oil filter flange side) Oil filter cartridge O-ring Camshaft holder bolt threads and seating surface Cylinder head bolt threads and seating surface Crankshaft pulley bolt threads and seating surface CMP pulse plate bolt threads and seating surface Valve stem seal inner surface...
  • Page 31 SERVICE INFORMATION Location Material Remarks Each oil seal and water seal lip Use marine grease (water resistant urea based Water tube grommet inner and outer surface grease) Exhaust manifold O-ring Exhaust guide seal part Cylinder head sealing bolt Locking agent (Threebond® 1322 or equivalent) Spark plug tube seal lip Soapy water...
  • Page 32 SERVICE INFORMATION LINKAGE Location Material Remarks Shift rod A spline Use marine grease (water resistant urea based Shift shaft A water seal (14 x 26 x 8 mm) lip and outer sur- grease) face Shift shaft A water seal contact surface and spline Shift shaft B water seal contact surface Seal holder O-ring (25 x 2.4 mm) Seal holder O-ring groove and bearing part...
  • Page 33 SERVICE INFORMATION CABLE/HARNESS ROUTING VIEWED FROM THE UPPER RIGHT REAR SIDE: HARNESS BAND CLIP HARNESS BAND CLIP After securing the cables and harnesses with the harness band clips, cut the end of Clamp the main wire harness and the ECT sensor 3 the harness band clips so that the projected wire as shown.
  • Page 34 SERVICE INFORMATION VIEWED FROM THE RIGHT SIDE: ALTERNATOR B TERMINAL Install the terminal by tightening the nut, and then set the cover securely. COVER Connect the cable to the alternator B terminal as shown. 60° A/F SENSOR 4P CONNECTOR HARNESS BAND CLIP ALTERNATOR 4P CONNECTOR HARNESS...
  • Page 35 SERVICE INFORMATION VIEWED FROM THE UPPER RIGHT SIDE: HARNESS BAND CLIP Clamp the main wire harness as shown. OUTSIDE MAIN WIRE HARNESS MAIN WIRE HARNESS A/F SENSOR 4P CONNECTOR ECT SENSOR 2 HARNESS BAND CLIP 2P CONNECTOR ECT SENSOR 4 2P CONNECTOR CKP SENSOR 3P CONNECTOR MAIN WIRE HARNESS...
  • Page 36 SERVICE INFORMATION VIEWED FROM THE RIGHT SIDE: CKP SENSOR 3P TACHOMETER MAIN WIRE HARNESS CONNECTOR PULSE CHECK 2P CONNECTOR HARNESS DLC 4P BAND CLIP NMEA 2000 6P CONNECTOR FUSE/RELAY JUNCTION BOX 10P CONNECTOR HARNESS BAND CLIP FUSE/RELAY ECM 36P JUNCTION BOX CONNECTOR A 23P CONNECTOR (Gray)
  • Page 37 SERVICE INFORMATION VIEWED FROM THE RIGHT SIDE TACHOMETER PULSE CHECK 2P CONNECTOR DLC 4P HARNESS BAND CLIPS NMEA 2000 6P CONNECTOR MAIN WIRE FUSE/RELAY HARNESS JUNCTION BOX 10P CONNECTOR HARNESS BAND CLIP HARNESS OFFSET BAND ECT SENSOR 1 2P CONNECTOR EOP SENSOR HARNESS 3P CONNECTOR...

  • Page 38: Starter Motor

    SERVICE INFORMATION FUSE/RELAY JUNCTION BOX: ALTERNATOR FUSE CABLE TERMINAL STARTER CABLE (+) 2 TERMINAL GREEN TAPE YELLOW TAPE RED TAPE STARTER CABLE (+) 1 TERMINAL STARTER MOTOR STARTER CABLE (+) 2 TERMINAL 90 ° C001 STARTER S TERMINAL Connect the starter cable (+) 2 terminal STARTER CABLE (+) and the starter cable (+) terminal so that they are at a right angle to the vertical...
  • Page 39 SERVICE INFORMATION VIEWED FROM THE RIGHT FRONT SIDE HARNESS BAND CLIP HARNESS BAND CLIP Clamp the starter cable (+) 2 and power Clamp the starter cable (+) 1, starter cable (+) 2 and starter cable (+). trim/tilt switch wire. STARTER CABLE (+) 1 POWER TRIM/TILT (To fuse/relay junction box) SWITCH WIRE...
  • Page 40 SERVICE INFORMATION CABLE GROMMET: REMOTE CONTROL REMOTE CONTROL CABLE (SHIFT SIDE) CABLE (THROTTLE SIDE) INDICATOR WIRE HARNESS CABLE GROMMET SWITCH PANEL CABLE STARTER CABLES FUEL TUBE A Viewed from the front side: 2-24...
  • Page 41 SERVICE INFORMATION VIEWED FROM THE FRONT SIDE: GND4 POWER TRIM/TILT RELAY GROUND NEUTRAL SWITCH CABLE TERMINAL 2P CONNECTOR (NOTE 2) GND3 HARNESS FRAME GROUND POWER TRIM/TILT BAND CLIP TERMINAL RELAY 3P CONNECTOR (NOTE 1) GND2 TP SENSOR 3P FRAME GROUND CONNECTOR TERMINAL (NOTE 1)
  • Page 42 SERVICE INFORMATION VIEWED FROM THE FRONT SIDE: HARNESS BAND CLIPS HARNESS BAND CLIP REMOTE CONTROL CABLE MAIN WIRE (THROTTLE SIDE) HARNESS REMOTE CONTROL CABLE (SHIFT SIDE) COVER LOCK CABLE A REMOTE CONTROL CABLE (THROTTLE SIDE) SWITCH PANEL CABLE REMOTE CONTROL CABLE (SHIFT SIDE) INDICATOR WIRE HARNESS REMOTE CONTROL...
  • Page 43 SERVICE INFORMATION VIEWED FROM THE FRONT SIDE: FRAME GROUND CABLE TERMINALS GND4 Connect the Black, Blue, Green/Red and the Green/White · POWER TRIM/TILT RELAY wires to the upper frame ground terminal. GROUND CABLE TERMINAL · Connect the Black/White, Blue, Green/Black and Green wires to the lower frame ground terminal.
  • Page 44 SERVICE INFORMATION VIEWED FROM THE LEFT FRONT SIDE: HARNESS CLIP HARNESS Clamp the taped part of the TP SENSOR 3P BAND CLIP water level sensor wire and CONNECTOR WATER LEVEL main wire harness. SENSOR 2P CONNECTOR MAIN WIRE HARNESS HARNESS BAND CLIP WATER LEVEL SENSOR WIRE...
  • Page 45 SERVICE INFORMATION VIEWED FROM THE LEFT FRONT SIDE: HARNESS BAND CLIP IAC VALVE 2P CONNECTOR IAT SENSOR 2P CONNECTOR HARNESS BAND CLIP HARNESS JOINT JOINT BAND CLIP CONNECTOR 1 CONNECTOR 2 Clamp the main wire harness and joint connector wire as shown.
  • Page 46 SERVICE INFORMATION VIEWED FROM THE UPPER LEFT REAR SIDE: MAIN WIRE HARNESS HARNESS BAND CLIP HARNESS BAND CLIPS JOINT CONNECTORS HARNESS HOSE CLAMP Set the joint connector to the connector holder. BAND CLIPS Set the main wire harness in the smaller clamp and pressure regulator return hose JOINT in the larger clamp.
  • Page 47 SERVICE INFORMATION VIEWED FROM THE LEFT REAR SIDE: HARNESS MAIN WIRE HARNESS BAND CLIP HOSE CLAMP (NOTE 1) No.1 IGNITION COIL 3P CONNECTOR No.1 FUEL INJECTOR 2P CONNECTOR No.2 IGNITION COIL 3P CONNECTOR KNOCK SENSOR 1P CONNECTOR No.3 IGNITION COIL 3P CONNECTOR No.2 FUEL INJECTOR 2P...
  • Page 48 SERVICE INFORMATION VIEWED FROM THE LOWER LEFT SIDE: HOSE CLAMP · Set the fuel hose (High pressure side) in the clamp of the larger diameter side and the main wire harness in the smaller diameter side. · Clamp the fuel hose (High pressure side) to the left-hand side of the marked point.
  • Page 49 SERVICE INFORMATION VIEWED FROM THE LOWER LEFT SIDE: HARNESS BAND CLIP Clamp the main wire harness and knock sensor wire. MAIN WIRE KNOCK SENSOR HARNESS CLIP HARNESS 1P CONNECTOR (NOTE 1) HOSE CLAMP (NOTE 2) KNOCK SENSOR WIRE Viewed from the upper side: CABLE CLIP SPIRAL TUBE Wind the spiral tube around the power...
  • Page 50 SERVICE INFORMATION SWIVEL CASE: CLIP CLIP Clamp the spiral tube as shown. Align the tape end of the power SPIRAL TUBE trim/tilt motor wire harness with the clip end. TAPE END TRIM ANGLE SENSOR WIRE POWER TRIM/TILT MOTOR WIRE CLIP END Viewed from the cylinder Viewed from the lower side: Viewed from the left side:...
  • Page 51 SERVICE INFORMATION TUBE ROUTING VIEWED FROM THE RIGHT SIDE: WATER RELIEF TUBE A WATER RELIEF · Install at approximately right TUBE CLAMP D10.5 TUBE A angles to the horizontal line. Install the tube clamp as shown. · After installation, check the tube for twist, bend, etc.
  • Page 52 SERVICE INFORMATION VIEWED FROM THE UPPER RIGHT SIDE: TUBE CLAMP D25.0 Install the tube clamp with the lugs facing in the direction shown. WATER RELIEF TUBE A WATER RELIEF TUBE A Viewed from the cylinder head side TUBE CLAMP D10.5 (NOTE 1) TUBE CLAMP D10.5 FUEL TUBE JOINT...
  • Page 53 SERVICE INFORMATION VIEWED FROM THE LOWER RIGHT SIDE: TUBE CLAMP TUBE CLAMP D10.5 D10.5 TUBE (7 x 40 mm) TUBE (7 x 160 mm) WATER RELIEF TUBE TUBE CLAMP TUBE CLAMPS D10.5 D10.5 T-JOINT TUBE CLAMP D10.5 TUBE (7 x 200 mm) TUBE CLAMP TUBE CLIP B1 TUBE (8 x 300 mm)
  • Page 54 SERVICE INFORMATION VIEWED FROM THE LOWER LEFT SIDE: FUEL TUBE C HOSE CLAMP (NOTE 1) TUBE CLIP B12 FUEL HOSE (HIGH TUBE CLIP B12 PRESSURE SIDE) FUEL TUBE E FUEL TUBE TUBE CLIP B12 HOLDER FUEL TUBE CLIP WATER TUBE F (14 mm) FUEL TUBE A WATER TUBE G...
  • Page 55 SERVICE INFORMATION VIEWED FROM THE UPPER LEFT SIDE: PRESSURE REGULATOR CONTROL TUBE Clamp the pressure regulator control tube, aligning the marked part on the tube with the end of the tube clip (3.5 mm). PRESSURE REGULATOR TUBE CLIP CONTROL TUBE (3.5 mm) FUEL TUBE CLAMP Set breather tube in the larger...
  • Page 56 SERVICE INFORMATION VIEWED FROM THE LEFT REAR SIDE: FUEL TUBE CLIP (14 mm) TUBE CLAMP BREATHER Install aligning the end of the fuel tube clip (14 D17.0 TUBE mm) with the white mark on the air vent tube. (12 x 740 mm) WATER RELIEF AIR VENT TUBE A...
  • Page 57 SERVICE INFORMATION VIEWED FROM THE LEFT REAR SIDE: BREATHER AIR VENT PRESSURE REGULATOR AIR VENT TUBE TUBE A RETURN HOSE TUBE D (12 x 740 mm) TUBE CLAMP D10.7 HOSE CLAMP Set fuel tube E in the larger diameter side of CHECK the clamp and water tube VALVE...
  • Page 58 MEMO...

  • Page 59: Maintenance

    3. MAINTENANCE MAINTENANCE SCHEDULE························3-2 WATER SEPARATOR INSPECTION ········· 3-24 TOOLS···························································3-3 FUEL STRAINER (LOW PRESSURE SIDE) INSPECTION/REPLACEMENT ·················· 3-24 ENGINE OIL LEVEL INSPECTION/OIL CHANGE························································3-4 FUEL STRAINER (HIGH PRESSURE SIDE) INSPECTION/REPLACEMENT ·················· 3-26 ENGINE OIL FILTER REPLACEMENT ········3-6 THERMOSTAT INSPECTION ····················· 3-26 GEAR CASE OIL CHANGE ··························3-7 FUEL LINE INSPECTION/ REPLACEMENT ·········································...

  • Page 60: Maintenance Schedule

    MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE Item REGULAR SERVICE PERIOD (2) Perform at every indicated month or operating hour interval, whichever comes first. Refer to Every 6 page First Every Every 2 months Each use After use month or year or years or or 100 20 hrs.
  • Page 61 MAINTENANCE TOOLS LIST Oil filter wrench, 65 mm Belt tension gauge 07HAA-PJ70101 07JGG-0010101...
  • Page 62 MAINTENANCE ENGINE OIL LEVEL INSPECTION/OIL CHANGE OIL LEVEL INSPECTION Start the engine, let it warm up to the normal operating temperature, and stop the engine. UPPER LIMIT Place the outboard motor in the vertical position (with the engine level), and remove the engine cover. Remove the dipstick (1), and wipe it clean with a shop towel.
  • Page 63 MAINTENANCE OIL CHANGE Used engine oil contains substances that have been identified as carcinogenic. If repeatedly left in contact with the skin for pro- longed periods, it may cause skin cancer. Wash your hands thoroughly with soap and water as soon as possible after contact with used engine oil.
  • Page 64 MAINTENANCE ENGINE OIL FILTER REPLACEMENT Remove the engine cover. Drain the engine oil as described in the oil change procedure (page 3-5). Place a shop towel under the oil filter (1) to absorb any spilled oil, and then attach the special tool to the oil filter and remove it.

  • Page 65: Gear Case Oil Change

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

  • Page 66: Alternator Belt Inspection

    MAINTENANCE ALTERNATOR BELT INSPECTION BELT INSPECTION Remove the following: – Engine cover – Silencer duct (page 5-82) Check the alternator belt (1) for wear and damage. Replace the belt if it is worn or damaged (page 7-5). Check the alternator belt and the related parts for oil contamination, etc.
  • Page 67 MAINTENANCE BELT DEFLECTION INSPECTION Measure the belt deflection by pushing the alternator BELT DEFLECTION belt at the center between the alternator belt pulley (1) When pushed with 98 N and crankshaft pulley (2) with 98 N (10 kgf, 22 lbf) of (10 kgf, 22 lbf) of force.
  • Page 68 MAINTENANCE 2. Check whether the throttle arm (1) is in contact with the full open position stopper (2). Perform the adjustment (page 3-11) if the throttle arm is not in contact with the stopper. 3. With the throttle arm in contact with the full open position stopper, measure the clearance between the throttle cam (1) of the throttle body assembly and full open position stopper (2).
  • Page 69 MAINTENANCE SYMPTOM ADJUSTMENT If the throttle arm does not fully open Slide the lock plate (1) backward and remove the throttle control cable (2) from the throttle arm (3). Loosen the shift pivot lock nut (1). Adjust the shift pivot (2) so it can be installed over the throttle arm (3) easily.
  • Page 70 MAINTENANCE Move the remote control lever (1) to the "F" (Forward) full open position (2). Check whether the throttle linkage satisfies the conditions on step 2, 3 and 4 on page 3-10. Move the remote control lever to the "N" (Neutral) (3) “F”...
  • Page 71 MAINTENANCE IDLE SPEED INSPECTION/ ADJUSTMENT INSPECTION Check the following before starting the idle speed inspection. • Spark plug inspection (page 3-17) • MIL must be OFF. Turn the combination switch OFF. Place the outboard motor vertically (with the engine level to the ground), and set the remote control lever in the "N"...
  • Page 72 MAINTENANCE ADJUSTMENT 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 (2). The MIL (3) should come ON and the warning buzzer should sound (intermittent sound: long beep). Wait until the engine speed stabilizes, and then check the idle speed.
  • Page 73 MAINTENANCE VALVE CLEARANCE INSPECTION/ ADJUSTMENT • Valve clearance inspection and adjustment must be performed with the engine cold 1. Remove the following: – Silencer duct (page 5-82) – Cylinder head cover (page 14-6) 2. Manually turn the crankshaft pulley (1) clockwise, and align the cutout (2) of the crankshaft pulley with the index mark (3) of the chain case.
  • Page 74 MAINTENANCE 5. If adjustment is necessary, loosen the valve adjusting lock nut (1), and adjust the intake and exhaust valve clearance by turning the valve adjusting screw (2) right or left. 6. After adjustment, secure the adjusting screw and loosely tighten the lock nut. 7.

  • Page 75: Spark Plug Inspection

    MAINTENANCE SPARK PLUG INSPECTION Remove the engine cover. Remove the two mud guard clips (1) from the upper side of under cover grommet (2). Detach the upper side of the under cover grommet. Remove the two bolts (1) and plug hole coil cover (2). Remove the socket bolts (1) and pull out each ignition coil (2) from the corresponding spark plug.
  • Page 76 MAINTENANCE If the spark plug is dirty, clean the spark plug using a 1.00 – 1.10 mm (0.039 – 0.043 in) spark plug cleaner. Visually inspect the spark plugs. Discard the plugs if the insulators (1) are cracked, chipped, or fouled. Measure the plug gap between the center electrode (2) and side electrode (3) with a wire-type feeler gauge.
  • Page 77 MAINTENANCE PROPELLER AND COTTER PIN INSPECTION Check the propeller (1) for bending or damage and replace if necessary. – Standard rotation type (page 16-6) – Counter rotation type (page 17-6) Make sure the split pin (2) ends are bent as shown to lock the nut (3) and replace if necessary.
  • Page 78 MAINTENANCE Remove the trim tab. – Standard rotation type (page 16-8) – Counter rotation type (page 17-8) Remove the corrosion as it prevents the continuity. Perform continuity inspection between the anode metal (1) surface without corrosion and the bare aluminum surface of the gear case trim tab installation area (2).
  • Page 79 MAINTENANCE ANODE METAL INSPECTION (INSIDE ENGINE) EXHAUST MANIFOLD Remove the engine cover. Remove the four bolts (1) and two exhaust manifold covers (2). Check the anode metal (1) for excessive wear or corrosion and replace if necessary. If the anode metal is worn to less than 2/3 of its original length, replace it with a new one.
  • Page 80 MAINTENANCE LUBRICATION Apply marine grease to the following parts: THROTTLE ROD/LINK TILT BRACKET THROTTLE LINK/ PIVOT/PLATE ENGINE COVER BRACKET TILTING SHAFT PTT THRUST RECEIVER PROPELLER SHAFT SWIVEL CASE COVER LOCK BOLT 3-22...
  • Page 81 MAINTENANCE THROTTLE ARM/ SHIFT ARM/ PIVOT PLATE/ ENGINE COVER LOCK ENGINE COVER ENGINE COVER LOCK LEVER/ NEUTRAL SWITCH/ CABLE (FRONT) LOCK CABLE OPEN SHAFT CLICK ARM ROLLER ENGINE COVER LOCK TILT LOCK LEVER CABLE (RIGHT SIDE) LOWER CYLINDER UPPER CYLINDER TILTING SHAFT THREADS SWIVEL SHAFT BUSHING/COLLAR...
  • Page 82 MAINTENANCE WATER SEPARATOR INSPECTION Remove the engine cover. Check the water separator (1) for water accumulation or sediment. If water or sediment is found, or the water filled alert buzzer sounds, remove the water separator and perform the inspection (page 5-138). Install the engine cover.
  • Page 83 MAINTENANCE Remove the three screws (1), plate (2), strainer cup (3) and O-ring (4) from the strainer body (5). Clean the water or sediment in the cup, and if necessary, replace the strainer (6). Install a new O-ring. Install the strainer body and plate to the strainer cup, then tighten the three screws to the specified torque.
  • Page 84 MAINTENANCE FUEL STRAINER (HIGH PRESSURE SIDE) INSPECTION/REPLACEMENT Gasoline is highly flammable and explosive. You can be burned or seriously injured when han- dling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. •...
  • Page 85 MAINTENANCE FUEL LINE INSPECTION/ REPLACEMENT Gasoline is highly flammable and explosive. You can be burned or seriously injured when han- dling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Check the fuel line, fuel hose and fuel tubes for damage, fuel leakage,...
  • Page 86 MAINTENANCE BATTERY AND CABLE CONNECTION A battery can explode if you do not follow the proper procedure, causing serious injury to anyone near- Follow all procedures carefully and keep sparks and open flames away from the battery. The battery contains sulfuric acid (electrical) which is highly corrosive and poisonous.
  • Page 87 MAINTENANCE WATER PASSAGE CLEANING • Do not run the motor when flushing with a garden hose or the motor may be damaged. • For safety, remove the emergency stop switch clip so the engine cannot be started while you are standing near the propeller.
  • Page 88 MAINTENANCE WATER PUMP INSPECTION Place the outboard motor in a test tank or connect an external water supply to the water inlet. Start the engine and idle the engine in neutral. Water should flow from the cooling system inspection hole (1) while the engine is running. If water does not flow while the engine is running, inspect the water pump (page 11-7).
  • Page 89 MAINTENANCE EACH OPERATION PART INSPECTION Check each component for proper operation. – Check the steering component for smooth operation without excessive play when fully turned to right and left. – Check the shift control cable/throttle control cable for smooth operation without excessive play. ENGINE CONDITION INSPECTION Start the engine and idle the engine in neutral.
  • Page 90 MEMO...

  • Page 91: Troubleshooting

    4. TROUBLESHOOTING BEFORE TROUBLESHOOTING···················4-2 ALERT SYSTEM/WARNING SYSTEM TROUBLESHOOTING ································ 4-17 ENGINE TROUBLESHOOTING····················4-2 FRAME TROUBLESHOOTING ·················· 4-24 FUSE/ELECTRIC POWER LINE TROUBLESHOOTING·································4-13...
  • Page 92 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 93 TROUBLESHOOTING 6. Spark Test Perform the spark test with each ignition coil (page 8-4). Is there normal spark? – GO TO STEP 7. – Perform ignition system troubleshooting (page 8-3). 7. Cylinder Compression Check the cylinder compression (page 14-44). Is the compression normal? –...
  • Page 94 TROUBLESHOOTING ENGINE STARTS BUT STALLS SOON 1. Alert system inspection Turn the combination switch ON. Check the warning buzzer sound. Does the warning buzzer sound twice and then keep sounding? – Perform alert system/warning system troubleshooting (page 4-17). – GO TO STEP 2. 2.
  • Page 95 TROUBLESHOOTING 7. Pressure regulator inspection Check the fuel pressure and record it (page 5-129). Disconnect the pressure regulator control tube. Check the fuel pressure. Is the fuel pressure higher with the control tube disconnected? – GO TO STEP 8. – Faulty pressure regulator 8.
  • Page 96 TROUBLESHOOTING ENGINE SOMETIMES MISFIRES OR TENDS TO STALL 1. Spark Plug Inspection Remove and inspect the spark plugs. Is the spark plug wet? – • Incorrect spark plug heat range • Incorrect spark plug gap • Restriction or blockage between the silencer case and cylinder head •...
  • Page 97 TROUBLESHOOTING ENGINE DOES NOT RUN SMOOTHLY ENGINE IDLE SPEED IS HIGHER THAN SPECIFIED AFTER WARMING UP 1. Alert system inspection Turn the combination switch ON. Check the warning buzzer sound. Does the warning buzzer sound twice and then keep sounding? –...
  • Page 98 TROUBLESHOOTING 4. Pressure regulator inspection Check the fuel pressure and record it (page 5-129). Disconnect the pressure regulator control tube. Check the fuel pressure. Is the fuel pressure higher with the control tube disconnected? – GO TO STEP 5. – Faulty pressure regulator 5.
  • Page 99 TROUBLESHOOTING ENGINE SPEED IS UNSTABLE DURING IDLE AND TROLLING 1. Alert system inspection Turn the combination switch ON. Check the warning buzzer sound. Does the warning buzzer sound twice and then keep sounding? – Perform alert system/warning system troubleshooting (page 4-17). –...
  • Page 100 TROUBLESHOOTING 8. Fuel injector inspection Inspect the fuel injector (page 5-134). Is the fuel injector normal? – GO TO STEP 9. – • Repair the open or short circuit fuel injector wire • Faulty fuel injector 9. IAC valve inspection Replace the IAC valve with a new one and start the engine.
  • Page 101 TROUBLESHOOTING 6. Fuel injector inspection Inspect the fuel injector (page 5-134). Is the fuel injector normal? – Replace the ECM with a new one and recheck. – • Repair the open or short circuit fuel injector wire • Faulty fuel injector 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.
  • Page 102 TROUBLESHOOTING ENGINE SPEED INCREASES EXCESSIVELY 1. Propeller inspection Check the propeller for bend or damage. Is the propeller normal? – 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 installed correctly? –...
  • Page 103 TROUBLESHOOTING FUSE/ELECTRIC POWER LINE TROUBLESHOOTING FUSE BOX CONNECTION TABLE Fuse No. Amps. Component (s) or Circuit (s) Protected 100 A Alternator (Charging terminal) 30 A A/F sensor heater relay 30 A ECM (Power supply), Fuel injectors, CKP sensor, CMP sensor, Alternator, DLC, Di- rect ignition coils, Main relay, Starter relay, A/F sensor heater relay, Fuel pump relay 10 A Alternator, Power trim/tilt switch, Combination switch, Main relay, Starter relay,...
  • Page 104 TROUBLESHOOTING FUSE LOAD CHART To ALTERNATOR W/Bl POWER TRIM/TILT SWITCH W/Bl POWER TRIM/TILT SWITCH To POWER TRIM/TILT RELAY W/Bl W/Bl To POWER TRIM/TILT RELAY COMBINATION SWITCH COMBINATION SWITCH Bl/R W/Bl Bl/Y Bl/W Bl/Y W/Bl W/Bl Bl/W To BUZZER (OP) To INDICATOR (OP) Bl/R To TACHOMETER (OP) START...
  • Page 105 TROUBLESHOOTING MIL AND WARNING BUZZER DOES NOT OPERATE 1. Fuse inspection Turn the combination switch OFF. Check for blown No.4, No.5, and No.9 fuses. Is the fuse blown? – Replace the blown fuse and check for short in the main wire harness or incorrect load by referring to the fuse load chart (page 4-14).
  • Page 106 TROUBLESHOOTING 4. Main relay inspection Inspect the main relay (page 10-13). Is the main relay normal? – GO TO STEP 5. – Replace the main relay with a new one and recheck. 5. Fuse/relay junction box inspection Inspect the maine relay circuit into the fuse/relay junction box (page 10-16).
  • Page 107 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 108 TROUBLESHOOTING FUNCTION TEST USING THE HDS 1. Fuse inspection Turn the combination switch OFF. Check the No.10 fuse in the fuse/relay junction box. Is the fuse blown? – Replace the blown fuse and check for short in the main wire harness or incorrect load by referring to the fuse load chart (page 4-14).
  • Page 109 TROUBLESHOOTING FUNCTION TEST WITHOUT USING THE HDS 1. Fuse inspection Turn the combination switch OFF. Check the No.10 fuse in the fuse/relay junction box. Is the fuse blown? – Replace the blown fuse and check for short in the main wire harness or incorrect load by referring to the fuse load chart (page 4-14).
  • Page 110 TROUBLESHOOTING 5. MIL inspection Turn the combination switch OFF. Short the No.3 terminal (Red/Blue) of the ECM ECM CONNECTOR A connector A main wire harness side MAIN WIRE HARNESS SIDE connector to engine ground using a jumper wire. Turn the combination switch ON. Does the MIL come ON? –...
  • Page 111 TROUBLESHOOTING WARNING BUZZER SOUNDS CONTINUOUSLY • The warning buzzer can sound when the starter motor speed is extremely low, but the alert system/warning system is normal if the buzzer stops sounding after starting the engine. THE OVERHEAT INDICATOR LIGHT COMES ON OR BLINKS 1.
  • Page 112 TROUBLESHOOTING THE OVERHEAT INDICATOR LIGHT GOES OFF AND OIL INDICATOR LIGHT GOES OFF OR BLINKS 1. MIL inspection Check to see if the MIL stays on. Does the MIL stay ON? – Perform PGM-FI troubleshooting (page 5-6). – GO TO STEP 2. 2.
  • Page 113 TROUBLESHOOTING WARNING BUZZER SOUNDS INTERMITTENTLY (LONG BEEP) 1. MIL inspection Check to see if the MIL stays on. Does the MIL stay ON? – Perform PGM-FI troubleshooting (page 5-6). – GO TO STEP 2. 2. Alternator indicator light inspection Check to see if the alternator indicator light stays on. Does the alternator indicator light stay ON? –...
  • Page 114 TROUBLESHOOTING FRAME TROUBLESHOOTING HARD TO SHIFT 1. Shift control cable inspection Check the shift control cable for corrosion. Is the control cable normal? – GO TO STEP 2. – Replace the shift control cable. 2. Shift control cable adjustment Adjust the shift control cable (page 20-16). Check the shift control lever of the remote control box for proper operation.
  • Page 115 TROUBLESHOOTING 3. Oil leak inspection Check for oil leakage from the power trim/tilt. Is there oil leakage? – Replace the O-ring and oil seal at the leaking point (when the manual valve O-ring or piston rod (cylinder cap) oil seal is leaking, replace it as an assembly). –...
  • Page 116 TROUBLESHOOTING POWER TRIM/TILT MOTOR DOES NOT OPERATE 1. Power trim/tilt motor inspection Connect the battery to the power tilt motor and check whether the motor operates (page 19-48). Does the motor turn? – GO TO STEP 2. – GO TO STEP 4. 2.
  • Page 117 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 pres- hydraulic pres- Lowers Extends sure lower than sure lower than specification or specification or pressure drops.
  • Page 118 TROUBLESHOOTING (14) LOWER CHAMBER (10) PUMP SPOOL VALVE (11) UP RELIEF VALVE (16) UPPER CHAMBER SPOOL VALVE (15) UPPER CHAMBER CHECK VALVE (12) DOWN RELIEF VALVE (2) MANUAL VALVE (13) LOWER CHAMBER PISTON ROD CHECK VALVE ASSEMBLY (8) DUST SEAL/O-RING (1) MOTOR (9) OIL PUMP...

  • Page 119: Fuel System

    5. FUEL SYSTEM ECT SENSOR 1 REMOVAL/INSTALLATION ··········· 5-116 TOOLS············································································5-2 ECT SENSOR 2 REMOVAL/INSTALLATION ··········· 5-117 SERVICE PRECAUTIONS ·············································5-3 ECT SENSOR 3 REMOVAL/INSTALLATION ··········· 5-117 SYSTEM LOCATION······················································5-9 ECT SENSOR 4 REMOVAL/INSTALLATION ··········· 5-118 CIRCUIT DIAGRAM ·····················································5-10 CKP SENSOR REMOVAL/INSTALLATION·············· 5-118 PIPING CONNECTIONS ··············································5-12 CMP SENSOR REMOVAL/INSTALLATION ·············...
  • Page 120 FUEL SYSTEM TOOLS FUEL SYSTEM LIST Float level gauge Fuel pressure gauge Sensor socket wrench, 22 x 150 mm 07401-0010000 07406-0040004 07906-PD10000 SCS service check connector Test probe 070PZ-ZY30100 07ZAJ-RDJA110...
  • Page 121 FUEL SYSTEM SERVICE PRECAUTIONS 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 HDS: page 5-6) –...
  • Page 122 FUEL SYSTEM Replace the O-ring (7.47 × 3.6 mm) (1) and O-ring (7.45 × 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 123 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 124 FUEL SYSTEM DTC READOUT Turn the combination switch ON; the MIL will stay on for a few seconds, then go off. Start the engine and check the MIL (1). • If the engine will not start, turn the starter motor for more than 10 seconds and check the MIL.
  • Page 125 FUEL SYSTEM READING DTC WITH THE HDS • The HDS can readout the DTC, freeze data, current data, and other ECM conditions. Turn the combination switch OFF. With Dr. H shown: Remove the dummy connector (1) from the DLC (2). Connect the HDS (3) to the DLC.
  • Page 126 FUEL SYSTEM INSPECTION AT ECM CONNECTOR • Always clean around and keep any foreign material away from the ECM connector before disconnecting • A faulty PGM-FI system is often related to poorly connected or corroded terminals. Check those connections before proceeding. •...
  • Page 127 FUEL SYSTEM SYSTEM LOCATION (11) (12) (10) (13) (14) (20) (15) (19) (16) (18) (17) IAT sensor (11) ECT sensor 1 ECT sensor 2 (12) CKP sensor Injector (13) Alternator Knock sensor (14) Fuse/relay junction box Fuel pump (15) IAC valve (16) Neutral switch Water separator/water level sensor...

  • Page 128: Circuit Diagram

    FUEL SYSTEM CIRCUIT DIAGRAM FUEL PUMP FUSE/RELAY JUNCTION BOX (HIGH PRESSURE SIDE) FUEL PUMP RELAY No.8 (10 A) A/F SENSOR HEATER RELAY No.3 (30 A) No.4 (30 A) No.10 (10 A) To next page No.11 (15 A) MAIN RELAY No.9 (15 A) BATTERY No.5 (10 A) To next...
  • Page 129 FUEL SYSTEM From previous page OPTION REMOTE CONTROL BOX BUZZER To IC regulator (Alternator) ACGL BUZZ EACVP WARNL IAC VALVE ALTERNATOR INDICATOR LIGHT EACVM ACGLP OVERHEAT INDICATOR LIGHT KNOCK SENSOR OIL INDICATOR LIGHT EMERGENCY EMS1 STOP SWITCH EMS2 From previous page FUEL CONSUMPTION...
  • Page 130 FUEL SYSTEM PIPING CONNECTIONS CHECK VALVE VAPOR FILTER FUEL STRAINER (HIGH PRESSURE SIDE) To mounting case VAPOR FUEL SEPARATOR PUMP (HIGH PRESSURE SIDE) FUEL FUEL FUEL INJECTOR 4 INJECTOR 3 INJECTOR 2 PRESSURE REGULATOR FUEL STRAINER WATER (LOW PRESSURE SEPARATOR SIDE) WATER LEVEL...
  • Page 131 FUEL SYSTEM ECM TERMINAL ARRANGEMENT ECM CONNECTOR A (GRAY) ECM side connector (viewed from the terminal side) Termi- Terminal mark Name Content/Signal nal No. ACGLP Alternator indicator light Alternator indicator light signal output LAFR A/F sensor heater relay A/F sensor heater relay driver WARNL MIL output TACHO...
  • Page 132 FUEL SYSTEM ECM CONNECTOR B (BLACK) ECM side connector (viewed from the terminal side) Termi- Terminal mark Name Content/Signal nal No. NET-H NMEA 2000 CAN HI NMEA 2000 CAN HI output NET-S NMEA 2000 12V power source NMEA 2000 12V power input NET-C NMEA 2000 ground NMEA 2000 ground...
  • Page 133 FUEL SYSTEM DTC TROUBLESHOOTING DTC INDEX Detected component Probable cause Ref. page 0 or does MIL does not • Loose or poor contact of the connec- 4-15 not com- come ON/ municate blink • Faulty indicator light • Open circuit in MIL wire •...
  • Page 134 FUEL SYSTEM Detected component Probable cause Ref. page TP sensor (voltage too low) • Loose or poor contact of the connec- 5-29 • Open or short circuit in TP sensor wire (THL) • Open circuit in TP sensor wire (VCC2) •...
  • Page 135 FUEL SYSTEM Detected component Probable cause Ref. page 41-3 A/F sensor heater • Loose or poor contact of the connec- 5-40 (abnormal high current or low current) • Open or short circuit in A/F sensor heater wire (LAFR) • Open circuit in A/F sensor heater wire (AFHT+) •...
  • Page 136 FUEL SYSTEM Detected component Probable cause Ref. page 141-2 ECT sensor 3 (voltage too • Loose or poor contact of the connec- 5-50 high) • Open circuit in ECT sensor 3 wire (TOH2) • Open circuit in ECT sensor 3 wire (SG2) •...
  • Page 137 FUEL SYSTEM MIL IS ON BUT DTC IS 0 OR DOES NOT COMMUNICATE TP SENSOR MAP SENSOR No. 9 Black Brown FUSE No. 5 No. 10 Yellow Orange (15 A) FUSE FUSE (10 A) (10 A) Blue Light blue Green Light green Pink Br/W...
  • Page 138 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 Light green wire. (Light green) 3.
  • Page 139 FUEL SYSTEM 6. TP sensor power line short circuit inspection 1 Turn the combination switch OFF. Disconnect the TP sensor 3P connector Turn the combination switch ON and check the MIL. Does the MIL go OFF? – Replace the TP sensor. –...
  • Page 140 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 5-6). • Continue the procedure if the DTC does not clear. Start the engine and recheck the DTC using the HDS.
  • Page 141 FUEL SYSTEM 2. MAP sensor signal line short circuit inspection Turn the combination switch OFF and disconnect the MAP sensor 3P connector MAP SENSOR 3P CONNECTOR Turn the combination switch ON. MAIN WIRE HARNESS SIDE Measure the voltage between the MAP sensor 3P connector main wire harness side No.2 (White/Red) terminal and engine ground.
  • Page 142 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 143 FUEL SYSTEM DTC 4-1, 4-2 (NO CKP SENSOR PULSE OR ABNORMAL CKP SENSOR PULSE) No. 9 FUSE (15 A) CKP SENSOR Y/Bl G/Bl G/Bl GND2 Black Brown JOINT Yellow Orange Blue Light blue CONNECTOR 1 Green Light green Pink White Gray DTC 4-1 (NO CKP SENSOR PULSE) 1.
  • Page 144 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 MAIN WIRE HARNESS SIDE terminal and No.2 (Green/Black) terminal. Is the measurement within 4.75 –...
  • Page 145 FUEL SYSTEM DTC 6-1, 6-2 (ECT SENSOR 1 VOLTAGE IS TOO LOW OR TOO HIGH) ECT SENSOR 1 Black Brown Yellow Orange Blue Light blue Green Light green Pink JOINT White Gray CONNECTOR 2 DTC 6-1 (ECT SENSOR 1 VOLTAGE IS TOO LOW) 1.
  • Page 146 FUEL SYSTEM DTC 6-2 (ECT SENSOR 1 VOLTAGE IS TOO HIGH) • When the DTC code 6-2, 7-2, 10-2, 22-2, 140-2, 141-2, and 143-2 are indicated at the same time, the ground line (SG2) is open. 1. Symptom reproduction test Turn the combination switch OFF.
  • Page 147 FUEL SYSTEM DTC 7-1, 7-2 (TP SENSOR VOLTAGE IS TOO LOW OR TOO HIGH) R/Bl SENSOR Br/W VCC2 Br/W R/Bl Black Brown Yellow Orange Blue Light blue Green Light green JOINT Pink CONNECTOR 2 White Gray DTC 7-1 (TP SENSOR VOLTAGE IS TOO LOW) •...
  • Page 148 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 149 FUEL SYSTEM DTC 8-1, 8-2 (NO CMP SENSOR PULSE OR ABNORMAL CMP SENSOR PULSE) No. 9 FUSE (15 A) CMP SENSOR Y/Bl G/Bl G/Bl G/Bl Black Brown Yellow Orange Blue Light blue Green Light green Pink JOINT White Gray GND2 CONNECTOR 1 DTC 8-1 (NO CMP SENSOR PULSE) 1.
  • Page 150 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 151 FUEL SYSTEM DTC 10-1, 10-2 (IAT SENSOR VOLTAGE IS TOO LOW OR TOO HIGH) IAT SENSOR JOINT Black Brown Yellow Orange CONNECTOR 2 Blue Light blue Green Light green Pink White Gray DTC 10-1 (IAT SENSOR VOLTAGE IS TOO LOW) 1.
  • Page 152 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, 141-2, and 143-2 are indicated at the same time, the ground line (SG2) is open. 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the IAT sensor 2P connector ECM connector A , ECM connector B...
  • Page 153 FUEL SYSTEM DTC 14-1 (ABNORMAL IAC VALVE CURRENT) 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 154 FUEL SYSTEM DTC 22-1, 22-2 (EOP SENSOR VOLTAGE TOO LOW OR TOO HIGH) POIL SENSOR Br/W VCC2 Br/W Black Brown Yellow Orange JOINT Blue Light blue CONNECTOR 2 Green Light green Pink White Gray DTC 22-1 (EOP SENSOR VOLTAGE IS TOO LOW) •...
  • Page 155 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 EOP SENSOR 3P CONNECTOR (Brown/White) terminal and engine ground. MAIN WIRE HARNESS SIDE Is the measurement within 4.75 – 5.25 V? –...
  • Page 156 FUEL SYSTEM 3. EOP sensor signal/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 No.3 (Green/Red) MAIN WIRE HARNESS SIDE terminal. Is the measurement within 4.75 – 5.25 V? –...
  • Page 157 FUEL SYSTEM DTC 23-1 (ABNORMAL KNOCK SENSOR DETECTION) KNOCK SENSOR R/Bu R/Bu Black Brown Yellow Orange Blue Light blue Green Light green Pink White Gray 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the knock sensor 1P connector and ECM connector B , and then reconnect them.
  • Page 158 FUEL SYSTEM DTC 41-3, 41-4 (ABNORMAL A/F SENSOR HEATER CURRENT) FUSE/RELAY JUNCTION BOX LAFR No. 3 No. 4 No. 5 FUSE FUSE FUSE AFHT+ (30 A) (30 A) (10 A) AFHT Bl/W MAIN BI/Y SENSOR RELAY HEATER RELAY Bl/Y W/Bl W/BI BATTERY W/BI...
  • Page 159 FUEL SYSTEM 2. Fuse inspection Turn the combination switch OFF. Check for blown No.3 fuse. 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 4-14).
  • Page 160 FUEL SYSTEM DTC 41-4 (ABNORMAL CURRENT) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the A/F sensor 4P connector fuse/relay junction box 23P connector , fuse/ relay junction box 10P connector , and ECM connector A , and then reconnect them. Clear the DTC (page 5-6).
  • Page 161 FUEL SYSTEM 6. A/F sensor line short circuit inspection Disconnect the ECM connector A Check continuity between following terminals. – A/F sensor 4P connector main wire harness side No.1 (Black/yellow) terminal and ECM connector A main wire harness side No.18 (Black/White) terminal –...
  • Page 162 FUEL SYSTEM DTC 48-5, 48-6, 48-7 (ABNORMAL A/F SENSOR CURRENT) FROM FUSE/RELAY JUNCTION BOX A/F SENSOR AFHT Bl/W Bl/W Bl/Y Bl/Y W/Bl W/Bl Black Brown Yellow Orange Blue Light blue Green Light green Pink White Gray DTC 48-5 (OPEN CIRCUIT IN A/F SENSOR WIRE (AFV/AFC)) 1.
  • Page 163 FUEL SYSTEM 2. A/F sensor line open circuit inspection Turn the combination switch OFF. Disconnect the A/F sensor 4P connector ECM connector A Check for open circuit between the A/F sensor 4P connector main wire harness side No.1 (Black/Yellow) terminal and ECM connector A main wire harness side No.27 (Black/Yellow) terminal.
  • Page 164 FUEL SYSTEM DTC 48-7 (SHORT CIRCUIT IN A/F SENSOR (AFC)) 1. Symptom reproduction test Turn the combination switch OFF. Clear the DTC (page 5-6). • Continue the procedure if the DTC does not clear. Start the engine and let it run at 3,000 min (rpm) for 5 minutes or more under no load until the engine temperature is over 85 °C (185 °F).
  • Page 165 FUEL SYSTEM DTC 140-1, 140-2 (ECT SENSOR 2 VOLTAGE IS TOO LOW OR TOO HIGH) ECT SENSOR 2 TOH1 R/Bl R/Bl Black Brown Yellow Orange Blue Light blue JOINT Green Light green Pink CONNECTOR 2 White Gray DTC 140-1 (ECT SENSOR 2 VOLTAGE IS TOO LOW) 1.
  • Page 166 FUEL SYSTEM DTC 140-2 (ECT SENSOR 2 VOLTAGE IS TOO HIGH) • When the DTC code 6-2, 7-2, 10-2, 22-2, 140-2, 141-2, and 143-2 are indicated at the same time, the ground line (SG2) is open. 1. Symptom reproduction test Turn the combination switch OFF.
  • Page 167 FUEL SYSTEM DTC 141-1, 141-2 (ECT SENSOR 3 VOLTAGE IS TOO LOW OR TOO HIGH) ECT SENSOR 3 TOH2 JOINT Black Brown CONNECTOR 2 Yellow Orange Blue Light blue Green Light green Pink White Gray DTC 141-1 (ECT SENSOR 3 VOLTAGE IS TOO LOW) 1.
  • Page 168 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, 141-2, and 143-2 are indicated at the same time, the ground line (SG2) is open. 1. Symptom reproduction test Turn the combination switch OFF.
  • Page 169 FUEL SYSTEM DTC 143-1, 143-2 (ECT SENSOR 4 VOLTAGE IS TOO LOW OR TOO HIGH) ECT SENSOR 4 TOH3 Black Brown Yellow Orange Blue Light blue JOINT Green Light green CONNECTOR 2 Pink White Gray DTC 143-1 (ECT SENSOR 4 VOLTAGE IS TOO LOW) 1.
  • Page 170 FUEL SYSTEM DTC 143-2 (ECT SENSOR 4 VOLTAGE IS TOO HIGH) • When the DTC code 6-2, 7-2, 10-2, 22-2, 140-2, 141-2, and 143-2 are indicated at the same time, the ground line (SG2) is open. 1. Symptom reproduction test Turn the combination switch OFF.
  • Page 171 FUEL SYSTEM MIL TROUBLESHOOTING MIL INDEX Detected component Probable cause Ref. page No. of Condition blinks MIL does Detected • Loose or poor contact of the connec- 4-15 not blink component • Faulty indicator light • Open circuit in MIL wire •...
  • Page 172 FUEL SYSTEM Detected component Probable cause Ref. page No. of Condition blinks Blink Knock sensor • Loose or poor contact of the connec- 5-70 (abnormal detection) • Open and short circuit in knock sen- sor wire • Faulty knock sensor Blink ECT sensor 2 •...
  • Page 173 FUEL SYSTEM MIL TURNS ON BUT DOES NOT BLINK WITH SCS SERVICE CHECK CONNECTOR CONNECTED Black Brown TP SENSOR MAP SENSOR No. 9 Yellow Orange FUSE No. 5 No. 10 (15 A) FUSE FUSE Blue Light blue (10 A) (10 A) Green Light green Pink...
  • Page 174 FUEL SYSTEM 2. MIL ON line short circuit inspection Turn the combination switch OFF. Disconnect the ECM connector A Turn the combination switch ON and check the MIL. Does the MIL go OFF? – GO TO STEP 3. – Repair short in the main wire harness between the ECM and the MIL.
  • Page 175 FUEL SYSTEM 7. Trim angle sensor power line short circuit inspection 1 Turn the combination switch OFF. Disconnect the trim angle sensor 3P connector Turn the combination switch ON and check the MIL. Does the MIL go OFF? – Replace the trim angle sensor. –...
  • Page 176 FUEL SYSTEM MIL BLINKS 3 (MAP SENSOR) SENSOR Br/Y VCC1 Br/Y Black Brown Yellow Orange Blue Light blue Green Light green Pink White Gray 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the MAP sensor 3P connector ECM connector A , and ECM connector B , and then reconnect them.
  • Page 177 FUEL SYSTEM 3. MAP sensor signal open or short circuit/GND line open circuit inspection Measure the voltage between the MAP sensor 3P connector main wire harness side No.2 MAP SENSOR 3P CONNECTOR (White/Red) terminal No.3 (Green/Red) MAIN WIRE HARNESS SIDE terminal.
  • Page 178 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 MAIN WIRE HARNESS SIDE Turn the combination switch ON. Measure the voltage between the CKP sensor 3P connector main wire harness side No.3 (Yellow/Black) terminal and engine ground.
  • Page 179 FUEL SYSTEM MIL BLINKS 6 (ECT SENSOR 1) ECT SENSOR 1 Black Brown Yellow Orange Blue Light blue Green Light green Pink JOINT White Gray CONNECTOR 2 • When the MIL blinks 6, 7, 10, 22, 24, 25, and 27 at the same time, the ground line (SG2) is open.
  • Page 180 FUEL SYSTEM MIL BLINKS 7 (TP SENSOR) R/Bl SENSOR Br/W VCC2 Br/W R/Bl Black Brown Yellow Orange Blue Light blue Green Light green JOINT Pink CONNECTOR 2 White Gray • When the MIL blinks 6, 7, 10, 22, 24, 25, and 27 at the same time, the ground line (SG2) is open.
  • Page 181 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 and short 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 182 FUEL SYSTEM MIL BLINKS 8 (CMP SENSOR) No. 9 FUSE (15 A) CMP SENSOR Y/Bl G/Bl G/Bl G/Bl Black Brown Yellow Orange Blue Light blue Green Light green Pink JOINT White Gray GND2 CONNECTOR 1 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the CMP sensor 3P connector ECM connector A , and joint connector 1...
  • Page 183 FUEL SYSTEM 3. CMP sensor signal line open or short circuit/ GND line open circuit inspection Measure the voltage between the CMP sensor 3P CMP SENSOR 3P CONNECTOR connector main wire harness side No.1 MAIN WIRE HARNESS SIDE (Green) terminal and No.2 (Green/Black) terminal. Is the measurement within 4.75 –...
  • Page 184 FUEL SYSTEM MIL BLINKS 10 (ONE LONG BLINK AND NO SHORT BLINK) IAT SENSOR IAT SENSOR JOINT Black Brown Yellow Orange CONNECTOR 2 Blue Light blue Green Light green Pink White Gray • When the MIL blinks 6, 7, 10, 22, 24, 25, and 27 at the same time, the ground line (SG2) is open.
  • Page 185 FUEL SYSTEM MIL BLINKS 14 (ONE LONG BLINK AND 4 SHORT BLINKS) IAC VALVE 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 186 FUEL SYSTEM MIL BLINKS 22 (2 LONG BLINKS AND 2 SHORT BLINKS) EOP SENSOR POIL SENSOR Br/W VCC2 Br/W Black Brown Yellow Orange JOINT Blue Light blue CONNECTOR 2 Green Light green Pink White Gray • When the MIL blinks 6, 7, 10, 22, 24, 25, and 27 at the same time, the ground line (SG2) is open.
  • Page 187 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 No.3 (Green/Red) MAIN WIRE HARNESS SIDE terminal.
  • Page 188 FUEL SYSTEM MIL BLINKS 23 (2 LONG BLINKS AND 3 SHORT BLINKS) KNOCK SENSOR KNOCK SENSOR R/Bu R/Bu Black Brown Yellow Orange Blue Light blue Green Light green Pink White Gray 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the knock sensor 1P connector and ECM connector B , and then reconnect...
  • Page 189 FUEL SYSTEM MIL BLINKS 24 (2 LONG BLINKS AND 4 SHORT BLINKS) ECT SENSOR 2 ECT SENSOR 2 TOH1 R/Bl R/Bl Black Brown Yellow Orange Blue Light blue JOINT Green Light green Pink CONNECTOR 2 White Gray • When the MIL blinks 6, 7, 10, 22, 24, 25, and 27 at the same time, the ground line (SG2) is open.
  • Page 190 FUEL SYSTEM MIL BLINKS 25 (2 LONG BLINKS AND 5 SHORT BLINKS) ECT SENSOR 3 ECT SENSOR 3 TOH2 JOINT Black Brown CONNECTOR 2 Yellow Orange Blue Light blue Green Light green Pink White Gray • When the MIL blinks 6, 7, 10, 22, 24, 25, and 27 at the same time, the ground line (SG2) is open.
  • Page 191 FUEL SYSTEM MIL BLINKS 27 (2 LONG BLINKS AND 7 SHORT BLINKS) ECT SENSOR 4 ECT SENSOR 4 TOH3 Black Brown Yellow Orange Blue Light blue JOINT Green Light green CONNECTOR 2 Pink White Gray • When the MIL blinks 6, 7, 10, 22, 24, 25, and 27 at the same time, the ground line (SG2) is open.
  • Page 192 FUEL SYSTEM MIL BLINKS 41 (4 LONG BLINKS AND ONE SHORT BLINK) A/F SENSOR HEATER FUSE/RELAY JUNCTION BOX LAFR No. 3 No. 4 No. 5 FUSE FUSE FUSE AFHT+ (30 A) (30 A) (10 A) AFHT Bl/W MAIN BI/Y SENSOR RELAY HEATER RELAY...
  • Page 193 FUEL SYSTEM 2. Fuse inspection Turn the combination switch OFF. Check for blown No.3 fuse. 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 4-14).
  • Page 194 FUEL SYSTEM 6. A/F sensor line short circuit inspection Disconnect the ECM connector A Check continuity between following terminals. – A/F sensor 4P connector main wire harness side No.1 (Black/yellow) terminal and ECM connector A main wire harness side No.18 (Black/White) terminal –...
  • Page 195 FUEL SYSTEM MIL BLINKS 48 (4 LONG BLINKS AND 8 SHORT BLINKS) A/F SENSOR FROM FUSE/RELAY JUNCTION BOX A/F SENSOR AFHT Bl/W Bl/W Bl/Y Bl/Y W/Bl W/Bl Black Brown Yellow Orange Blue Light blue Green Light green Pink White Gray 1.
  • Page 196 FUEL SYSTEM 2. A/F sensor line open or short circuit inspection Turn the combination switch OFF. Disconnect the A/F sensor 4P connector ECM connector A Check for open or short circuit between the A/F sensor 4P connector main wire harness side No.1 (Black/Yellow) terminal and ECM connector A main wire harness side No.27 (Black/Yellow) terminal.
  • Page 197 FUEL SYSTEM FUEL PRESSURE RELIEVING Gasoline is highly flammable and explosive. You can be burned or seriously injured when han- dling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. • Disconnect the battery cable from the battery negative (–) terminal before relieving the fuel pressure.
  • Page 198 FUEL SYSTEM FUEL PUMP (LOW PRESSURE SIDE) REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when han- dling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. REMOVAL Remove the L.
  • Page 199 FUEL SYSTEM INSTALLATION Apply engine oil to a new O-ring (1) and install it to the fuel pump (2). Position the fuel pump marks (3) as shown, then install and tighten the bolts (4) to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) (1)/(2) Connect the fuel tube B (1) and fuel tube D (2) to the fuel pump (3).
  • Page 200 FUEL SYSTEM SILENCER DUCT REMOVAL/ INSTALLATION Remove the engine cover. Release the pressure regulator control tube (1) from the two tube clips (2). Release the harness band clip (3) of the main wire harness from the silencer duct (4). Release the breather tube (5) from the silencer duct groove (6) and clamp (7).
  • Page 201 FUEL SYSTEM SILENCER CASE REMOVAL/ INSTALLATION REMOVAL Remove the engine cover. Disconnect the IAT sensor 2P connector (1) and release the harness band clip (2) from the silencer case (3). Loosen the air flow clamp screw (4). Disconnect the crankcase breather tube from the silencer case. SILENCER CASE BOLT (6 ×...
  • Page 202 FUEL SYSTEM INSTALLATION Connect the air flow tube (1) to the throttle body (2) and set the wire harness (3) into the groove (4) in the left lower side of silencer case (5). Install and tighten the three bolts (6). •...
  • Page 203 FUEL SYSTEM THROTTLE BODY REMOVAL/ INSTALLATION/CLEANING REMOVAL Remove the silencer case (page 5-83). Disconnect the MAP sensor 3P connector (1) and release the harness band clip (2). Release the water level sensor 2P connector (1) from the sensor wire bracket (2). Disconnect the TP sensor 3P connector (3) and release the harness band clip (4) from the sensor wire bracket.
  • Page 204 FUEL SYSTEM CLEANING Wipe off carbon or any other dirt or stain with soft dry shop towels sprayed with carburetor cleaner, and clean the throttle valve and bore. • The inside of the throttle body is coated with molybdenum. Do not wipe the molybdenum coated area (1) of throttle valve.
  • Page 205 FUEL SYSTEM Connect the MAP sensor 3P connector (1) and install the harness band clip (2). Connect the TP sensor 3P connector (1) and install the harness band clip (2) to the sensor wire bracket (3). Install the water level sensor 2P connector (4) to the sensor wire bracket.
  • Page 206 FUEL SYSTEM Disconnect the IAC valve 2P connector (1). Remove the three bolts (8 × 35 mm) (1), two bolts (8 × 35 mm) (2), two nuts (3) and intake manifold (4). • If the stud bolt (5) became loose during intake manifold removal, tighten them so that the stud bolt height above the injector base surface is as specified.
  • Page 207 FUEL SYSTEM EXPLODED VIEW INTAKE MANIFOLD PACKING (4) COLLAR GROMMET (2) GROOVE IAC VALVE PACKING INTAKE MANIFOLD IAC VALVE BOLT (8 × 45 mm) (2) 22 N·m (2.2 kgf·m, 16 lbf·ft) 5-89...
  • Page 208 FUEL SYSTEM INSTALLATION Install the four new intake manifold packings (1) to the intake manifold (2) by aligning the tabs (3) of the packings with the grooves (4) of the intake manifold. Install the intake manifold to the engine. • Take care not to pinch the pressure regulator return hose (5) and air vent tube (6) with the upper side of intake manifold.
  • Page 209 FUEL SYSTEM Connect the pressure regulator control tube (1) to the intake manifold joint (2). Install the L. side cover bracket (1) and tighten the two bolts (2). Install the following: – Throttle body (page 5-85) – L. engine under cover (page 6-4) FUEL INJECTORS/FUEL PRESSURE REGULATOR REMOVAL/ INSTALLATION...
  • Page 210 FUEL SYSTEM Release the clips (1) of the main wire harness from the clip brackets (2). Disconnect the four fuel injector 2P connectors (3). Remove the hose clamp (4). Remove the regulator cap (1). Disconnect the pressure regulator control tube (2) and pressure regulator return tube (3) from the pressure regulator (4).
  • Page 211 FUEL SYSTEM Release the fuel tube B (1) and air vent tube (2) from the four 14 mm tube clips (3). Remove the two nuts (4) and fuel line (5). 5-93...
  • Page 212 FUEL SYSTEM EXPLODED VIEW REGULATOR PRESSURE REGULATOR PRESSURE REGULATOR HARNESS BAND CONTROL TUBE RETURN TUBE PRESSURE REGULATOR BOLT (6 × 10 mm) (4) 27 N·m (2.8 kgf·m, 20 lbf·ft) O-RING (7.8 × 1.9 mm) (4) JOINT PIPE TUBE CLAMP D10.7 TUBE CLIP (14 mm) (4) NUT (2) FUEL PIPE BOLT (2)
  • Page 213 FUEL SYSTEM INSTALLATION Apply engine oil to the new O-ring (7.47 × 3.6 mm) (1) and O-ring (7.45 × 3.61 mm) (2) and install them into the grooves of the fuel injector (3). • Be sure to install the O-rings in their correct locations.
  • Page 214 FUEL SYSTEM Apply engine oil to two new O-rings (1) and install them to the joint pipe (2). Insert the joint pipe until it is seated on the fuel line (3). Install the fuel hose (4) to the fuel line and tighten the bolt (5).
  • Page 215 FUEL SYSTEM Connect the four fuel injector 2P connectors (1). Install the main wire harness clips (2) to the clip brackets (3). Secure the pressure regulator return hose (4) and main wire harness (5) with the hose clamp (6). Install the L. side cover bracket (1) and tighten the two bolts (2).
  • Page 216 FUEL SYSTEM INJECTOR BASE REMOVAL/ INSTALLATION Remove the intake manifold (page 5-87). Remove the fuel line assembly (page 5-91). Installation is in the reverse order or removal. Tighten the five bolts (8 × 25 mm) and two nuts (8 mm) to the specified torque in the numbered order in two or three steps.
  • Page 217 FUEL SYSTEM WATER SEPARATOR/WATER LEVEL SENSOR REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when han- dling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. REMOVAL Remove the L.
  • Page 218 FUEL SYSTEM INSTALLATION Install the suspension (1) to the water separator (2) and align the screw (3) of the water separator body (4) on the fuel tube A (5) side with the center line (6) of the suspension as shown. (11) Install the water separator to the fuel strainer stay (7).
  • Page 219 FUEL SYSTEM FUEL PUMP (HIGH PRESSURE SIDE)/ VAPOR SEPARATOR REMOVAL/ INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when han- dling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. •...
  • Page 220 FUEL SYSTEM Remove the bolt (1) and fuel hose (2). Remove the joint pipe (3) and two O-rings (4). Release the hose clip (1) from the fuel hose (2) and disconnect the air vent tube E (3) and pressure regulator return hose (4) from the vapor separator (5). Disconnect the fuel tube B (1) (from the low pressure side fuel pump) from the vapor separator.
  • Page 221 FUEL SYSTEM Remove the two bolts (8 × 35 mm) (1), bolt (8 × 30 mm) (2) and vapor separator (3) by releasing the fuel hose (high pressure side) (4) from the hose clip (5). INSTALLATION Install the vapor separator (1) to the engine by installing the fuel hose (high pressure side) (2) to the hose clip (3).
  • Page 222 FUEL SYSTEM Connect the fuel tube B (1) to the vapor separator. Connect the pressure regulator return hose (1) to the vapor separator (2). Connect the air vent tube E (3) to the vapor separator, then clamp the air vent tube E and fuel hose (4) with the hose clip (5).
  • Page 223 FUEL SYSTEM Check the tubes that they are connected correctly (page 2-35). After checking the hose connection, tighten the two bolts (8 × 35 mm) (1) and bolt (8 × 30 mm) (2) to the specified torque. TORQUE: 26 N·m (2.7 kgf·m, 19 lbf·ft) Install the L.
  • Page 224 FUEL SYSTEM AIR VENT STRAINER/AIR VENT TUBE REMOVAL/INSTALLATION Remove the intake manifold (page 5-87). • Check the tubes for deterioration or cracks and replace if necessary. • After installation, check the tube clamps for correct installation (page 2-35). Installation is in the reverse order of removal. BREATHER TUBE T-JOINT AIR VENT TUBE D...
  • Page 225 FUEL SYSTEM EXHAUST MANIFOLD REMOVAL/ INSTALLATION REMOVAL Remove the following: – L./R. side cover bracket (page 6-18) Disconnect the following water tubes: – Water relief tube A (1) – Water relief tube B (2) – Tube (7 × 90 mm) (3) –...
  • Page 226 FUEL SYSTEM Disconnect the ECT sensor 3 (2P) connector (1). Remove the three bolts (1), oil pass cover (2), gasket (3) and filter (4). Remove the two bolts (10 × 75 mm) (1), three bolts (10 × 45 mm) (2), exhaust manifold (3) and exhaust manifold gasket (4).
  • Page 227 FUEL SYSTEM EXPLODED VIEW BOLT (6 × 14 mm) (3) GASKET ECT SENSOR 3 2P FILTER CONNECTOR OIL PASS COVER BOLT (6 × 52 mm) (3) BOLT (10 × 45 mm) (3) 39 N·m (4.0 kgf·m, 29 lbf·ft) BOLT (10 × 75 mm) 39 N·m (4.0 kgf·m, 29 lbf·ft) EXHAUST MANIFOLD EXHAUST GUIDE...
  • Page 228 FUEL SYSTEM INSTALLATION Apply marine grease exhaust manifold installation area of the exhaust guide. Apply marine grease to new O-ring (76.4 × 3.1 mm) (1) and O-ring (79.8 × 3.1 mm) (2) and install them to the exhaust manifold (3). Set the exhaust manifold (1) on the exhaust guide (2).
  • Page 229 FUEL SYSTEM Install the filter (1), new gasket (2) and oil pass cover (3), then tighten the three bolts (4). Connect the ECT sensor 3 (2P) connector (1). Install the connector bracket (1) and tighten the three bolts (2). Connect the A/F sensor 4P connector (3) and install it to the connector bracket.
  • Page 230 FUEL SYSTEM Connect the following water tubes: – Water relief tube A (1) – Water relief tube B (2) – Tube (7 × 90 mm) (3) – Tube (7 × 75 mm) (4) – Tube (7 × 120 mm) (5) –...
  • Page 231 FUEL SYSTEM MAP SENSOR REMOVAL/ INSTALLATION Remove the silencer case (page 5-83). Disconnect the MAP sensor 3P connector (1). Remove the screw (2), harness clamp holder (3) and MAP sensor (4). Remove the O-ring (1). Apply engine oil to a new O-ring and install it to the MAP sensor.
  • Page 232 FUEL SYSTEM IAC VALVE REMOVAL/INSTALLATION Remove the engine cover. Disconnect the IAC valve 2P connector (1). Remove the two bolts (2) and IAC valve (3). Remove the IAC valve packing (1). Install a new IAC valve packing. Install the IAC valve (1) to the intake manifold and tighten the bolts (2) to the specified torque in the numbered order in two or three steps.
  • Page 233 FUEL SYSTEM A/F SENSOR REMOVAL/ INSTALLATION REMOVAL Remove the engine cover. Disconnect the A/F sensor 4P connector (1) and remove it from the connector bracket (2). Remove the four harness band clips (3) from the connector bracket. Remove the three bolts (4) and connector bracket. Remove the A/F sensor (1) from the exhaust manifold (2), using a special tool.
  • Page 234 FUEL SYSTEM INSTALLATION Install the A/F sensor (1) to the exhaust manifold (2). Tighten the A/F sensor to the specified torque using a special tool. TOOL: Sensor socket wrench, 07906-PD10000 22 x 150 mm (3) TORQUE: 42 N·m (4.3 kgf·m, 31 lbf·ft) Install the connector bracket (1) and tighten the three bolts (2).
  • Page 235 FUEL SYSTEM ECT SENSOR 2 REMOVAL/ INSTALLATION Remove the engine cover. Disconnect the ECT sensor 2 (2P) connector (1). Remove the ECT sensor 2 (2). Remove the O-ring (1). Apply engine oil to a new O-ring and install it to the ECT sensor 2 (2).
  • Page 236 FUEL SYSTEM ECT SENSOR 4 REMOVAL/ INSTALLATION Remove the engine cover. Disconnect the ECT sensor 4 (2P) connector (1). Remove the ECT sensor 4 (2). Remove the O-ring (1). Apply engine oil to a new O-ring and install it to the ECT sensor 4 (2).
  • Page 237 FUEL SYSTEM CMP SENSOR REMOVAL/ INSTALLATION Remove the following: – L. engine under cover (page 6-4) – R. engine under cover (page 6-10) Disconnect the CMP sensor 3P connector (1). Remove the bolt (2), CMP sensor (3) and O-ring (4). Apply engine oil to a new O-ring and install it to CMP sensor.
  • Page 238 FUEL SYSTEM SILENCER DUCT DISASSEMBLY/ ASSEMBLY Remove the silencer duct (page 5-82). CLAMP (18.5 mm) SCREW (5 × 20 mm) (8) SILENCER DUCT A SILENCER DUCT B GROMMET (4) COLLAR (4) TUBE CLIP (3.5 mm) 5-120...
  • Page 239 FUEL SYSTEM SILENCER CASE DISASSEMBLY/ ASSEMBLY Remove the silencer case (page 5-83). SILENCER DUCT COLLAR (3) GROMMET SILENCER DUCT GROMMET SPRING GROMMET (3) SILENCER CASE SENSOR GROMMET AIR FLOW TUBE SPRING AIR FLOW TUBE IAT SENSOR AIR FLOW TUBE CLAMP VINYL TUBE 5-121...
  • Page 240 FUEL SYSTEM THROTTLE BODY DISASSEMBLY/ ASSEMBLY Remove the throttle body (page 5-85). SET PLATE SCREW (5 × 18 mm) 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) MAP SENSOR O-RING O-RING THROTTLE BODY IDLE ADJUST SCREW HARNESS CLIP BRACKET E BOLT (6 × 12 mm) STOPPER PIN 5-122...
  • Page 241 FUEL SYSTEM WATER SEPARATOR DISASSEMBLY/ CLEANING/ASSEMBLY Remove the water separator (page 5-99). Remove the three screws (1), set plate (2), water separator cup (3) and O-ring (4) from the water separator body (5). Remove the baffle plate (6) from the water separator body.
  • Page 242 FUEL SYSTEM FUEL PUMP (HIGH PRESSURE SIDE)/ FUEL STRAINER DISASSEMBLY/ ASSEMBLY DISASSEMBLY Remove the fuel pump (high pressure side)/vapor separator (page 5-101). SCREW (5 mm) (2) SCREW (4 mm) 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) WASHER (4 mm) FUEL STRAINER (HIGH PRESSURE SIDE)
  • Page 243 FUEL SYSTEM ASSEMBLY Install a new O-ring (1) and collar (2) to the fuel pump (3). Install a new O-ring (4) to the pump holder (5). Install the following parts to the fuel pump case (6). – Pump holder – Fuel pump –...
  • Page 244 FUEL SYSTEM Install a new O-ring (1) to the fuel pump case (2). Connect the Blue/Yellow terminal (3) to the fuel pump positive (+) terminal (4). Connect the Black terminal (5) to the fuel pump negative (-) terminal (6). Install the pump cover (1) and connector bracket (2). Install and tighten the four screws (3) to the specified torque.
  • Page 245 FUEL SYSTEM VAPOR SEPARATOR DISASSEMBLY/ ASSEMBLY Remove the fuel pump (high pressure side) (page 5-101). VAPOR SEPARATOR COVER SCREW (6) 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) COVER FLOAT PACKING BOLT (6 × 16 mm) (2) FLOAT VALVE 12 N·m (1.2 kgf·m, 9 lbf·ft) FLOAT PIN COLLAR (2) SCREW (2)
  • Page 246 FUEL SYSTEM FUEL PRESSURE MEASUREMENT Gasoline is highly flammable and explosive. You can be burned or seriously injured when han- dling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Relieve the fuel pressure (page 5-79). Remove the service check bolt and set the special tool in the threaded bolt hole.
  • Page 247 FUEL SYSTEM FUEL PRESSURE REGULATOR INSPECTION Gasoline is highly flammable and explosive. You can be burned or seriously injured when han- dling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Relieve the fuel pressure (page 5-79).
  • Page 248 FUEL SYSTEM FUEL PUMP (LOW PRESSURE SIDE) INSPECTION Remove the fuel pump (low pressure side) (page 5-80). 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 249 FUEL SYSTEM CIRCUIT INSPECTION FUSE/RELAY JUNCTION BOX 12 12 No. 8 No. 4 No. 5 FLR1 FUSE FUSE FUSE (10 A) (30 A) (10 A) FLR2 FUEL MAIN PUMP RELAY RELAY Bu/R Bl/Y W/Bl BATTERY GND3 JOINT CONNECTOR 1 Bl/Y W/Bl Bl/W Bl/W...
  • Page 250 FUEL SYSTEM 2. Fuel pump power/ground line open circuit inspection Turn the combination switch OFF and disconnect FUEL PUMP (HIGH PRESSURE SIDE) the fuel pump (High pressure side) 2P connector 2P CONNECTOR MAIN WIRE HARNESS SIDE Turn the combination switch ON. Measure the battery voltage between the fuel pump (High pressure side) 2P connector main wire...
  • Page 251 FUEL SYSTEM VAPOR SEPARATOR INSPECTION FLOAT VALVE Disassemble the vapor separator (page 5-127). 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 252 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 253 FUEL SYSTEM CIRCUIT INSPECTION FUSE/RELAY JUNCTION BOX No. 5 No. 4 FUSE FUSE (10 A) (30 A) INJ4 MAIN RELAY INJ3 No. 9 INJ2 FUSE (15 A) INJ1 Y/Bl Y/Bl Y/Bl Y/Bl Bl/Y W/Bl BATTERY Y/Bl Y/Bl Y/Bl Y/Bl W/Bl Bl/Y GND1 OPTION...
  • Page 254 FUEL SYSTEM 2. Fuel injector signal line open or short circuit Inspection Turn the combination switch OFF. Disconnect the ECM connector B Check for open or short circuit between each fuel injector 2P connector main wire harness side No.1 terminal and ECM connector B main wire harness side terminal.
  • Page 255 FUEL SYSTEM ECT SENSOR 1/2/3/4 INSPECTION Remove the following: – ECT sensor 1 (page 5-116) – ECT sensor 2 (page 5-117) – ECT sensor 3 (page 5-117) – ECT sensor 4 (page 5-118) 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 256 FUEL SYSTEM WATER LEVEL SENSOR INSPECTION Remove the water separator (page 5-99). Check that the float (1) of the water level sensor moves up and down smoothly with the separator cup removed. Check for continuity between the water level sensor 2P connector (2) terminals in each float position.
  • Page 257 FUEL SYSTEM A/F SENSOR HEATER INSPECTION Turn the combination switch OFF. Disconnect the A/F sensor 4P connector (1). Measure the resistance between the No.3 (Black) and No.4 (Black) terminals of the A/F sensor. Resistance: 0.86 – 1.10 Ω (at 20 °C/68 °F) If the resistance is not as specified, replace the A/F sensor.
  • Page 258 MEMO...

  • Page 259: Engine Cover/Cover Lock

    6. ENGINE COVER/COVER LOCK COMPONENT LOCATION ····························6-2 HOOK BRACKET REMOVAL/ INSTALLATION ·········································· 6-20 FRONT SEPARATE COVER REMOVAL/ INSTALLATION·············································6-3 ENGINE COVER AIR GUIDE REMOVAL/ INSTALLATION ·········································· 6-20 L. ENGINE UNDER COVER REMOVAL/ INSTALLATION·············································6-4 SIDE COVER BRACKET DISASSEMBLY/ ASSEMBLY ················································· 6-21 R. ENGINE UNDER COVER REMOVAL/ INSTALLATION···········································6-10 UNDER COVER FRONT BRACKET DISASSEMBLY/ASSEMBLY ······················...
  • Page 260 ENGINE COVER/COVER LOCK COMPONENT LOCATION ENGINE COVER/COVER LOCK 10 N·m (1.0 kgf·m, 7 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 4.5 N·m (0.46 kgf·m, 3.3 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft)
  • Page 261 ENGINE COVER/COVER LOCK FRONT SEPARATE COVER REMOVAL/ INSTALLATION REMOVAL Remove the engine cover. Loosen the under case grommet band (1) and remove it from the under case grommet (2). Remove the special bolt (6 x 17 mm) (3), three screws (6 x 25 mm) (4), three collars (5) and front separate cover (6).
  • Page 262 ENGINE COVER/COVER LOCK Install the three collars (1), then loosely install the three screws (6 x 25 mm) (2) and special bolt (6 x 17 mm) (3). • Be sure that the special bolt flange is positioned in the case bolt hole. Tighten the screws and special bolt in the numbered order in several steps.
  • Page 263 ENGINE COVER/COVER LOCK Remove the three screws (6 x 25 mm) (1), collars (2), and six special bolts (6 x 17 mm) (3) from the L. engine under cover (4). (1)/(2) Release the L. engine under cover (1) from the boss (2) of the L.
  • Page 264 ENGINE COVER/COVER LOCK INSTALLATION Install the water check grommet (1) from the outside of the L. engine under cover. Connect the hose (2) to the water check grommet. Install the L. engine under cover (1) by aligning its lower side (2) with the extension case (3). Install the hole (1) of the L.
  • Page 265 ENGINE COVER/COVER LOCK Check that the cover lock cable A (1) is positioned on the L. engine under cover (2) as shown. Install the tab (1) of the front side (swivel case side) of L. engine under cover (2) into the grooves (3) of the R. engine under cover (4).
  • Page 266 ENGINE COVER/COVER LOCK Install the tabs (1) of the rear side (cylinder head cover side) of L. engine under cover (2) into the grooves (3) of the R. engine under cover (4). • Be sure that all tabs and grooves are completely aligned with each other.
  • Page 267 ENGINE COVER/COVER LOCK Check that the harness clips (1) and harness tapes (2) of the power tilt motor wire (3) are aligned. Position the clips while aligning their edges with the L. engine under cover projections (4), then install and tighten the two rivet screws (5).
  • Page 268 ENGINE COVER/COVER LOCK R. ENGINE UNDER COVER REMOVAL/ INSTALLATION REMOVAL Remove the front separate cover (page 6-3). Disconnect the flush plug cap (1) from the R. engine under cover. Release the wire harness clip (1) and remove the power tilt switch 3P connector (2) from the electric parts case (3).
  • Page 269 ENGINE COVER/COVER LOCK Release the R. engine under cover (1) from the boss (2) of the R. side cover bracket (3). Remove the R. engine under cover (1). Remove the nut (2) and water joint cap (3). INSTALLATION Apply locking agent (Loctite® PRISM 403 or equivalent) to the seating surface of the nut (1).
  • Page 270 ENGINE COVER/COVER LOCK Position the power tilt switch wire on the upper side of the R. engine under cover and pull the hose with the flush plug cap out of the R. engine under cover. Install the R. engine under cover (1) by aligning its lower side (2) with the extension case (3).
  • Page 271 ENGINE COVER/COVER LOCK Check that the cover lock cable B (1) is positioned under the R. engine under cover (2) as shown. Install the tabs (1) of the rear side (cylinder head cover side) of L. engine under cover (2) into the grooves (3) of the R.
  • Page 272 ENGINE COVER/COVER LOCK Install the under cover grommet (1) onto the idle exhaust port (2). Install the four under cover grommet bosses (3) into the engine under cover holes (4) securely. Set the six mud guard clips (5) by aligning the clip holes of under cover grommet and engine under covers.
  • Page 273 ENGINE COVER/COVER LOCK COVER LOCK CABLE REMOVAL/ INSTALLATION REMOVAL Remove the following: – Engine cover – Front separate cover (page 6-3) – L. engine under cover (page 6-4) – R. engine under cover (page 6-10) Remove the vinyl tube (1) and fuel tube (2) from the under cover front bracket (3).
  • Page 274 ENGINE COVER/COVER LOCK Insert the inner cable end of cover lock cable A (1) into the front lock arm (2). Install cover lock cable A to the under cover front bracket (3), and tighten the washer side lock nut (4) to the specified torque.
  • Page 275 ENGINE COVER/COVER LOCK Insert the inner cable end of cover lock cable B (1) into the L. side lock (2). Install cover lock cable B to the L. side cover bracket (3), and tighten the washer side lock nut (4) to the specified torque.
  • Page 276 ENGINE COVER/COVER LOCK SIDE COVER BRACKET REMOVAL/ INSTALLATION L. SIDE COVER BRACKET Remove the cover lock cable A and B (page 6-15). Remove the two flange bolts (1) and L. side cover bracket (2). Installation is in the reverse order of removal. R.
  • Page 277 ENGINE COVER/COVER LOCK Remove the trim angle sensor 3P connector (1) and power tilt motor 2P connector (2) from the connector bracket A. Disconnect the trim angle sensor 3P connector and power tilt motor 2P connector. Release the under case grommet C (1) from the under cover front bracket (2) toward out side as shown.
  • Page 278 ENGINE COVER/COVER LOCK HOOK BRACKET REMOVAL/ INSTALLATION SOCKET BOLT (6×16 mm) 10 N·m (1.0 kgf·m, 7 lbf·ft) ENGINE COVER SOCKET BOLT (6×20 mm) (5) 10 N·m (1.0 kgf·m, 7 lbf·ft) HOOK BRACKET ASSEMBLY (3) COLLAR (11) ENGINE COVER AIR GUIDE REMOVAL/ INSTALLATION Remove the right and left hook bracket assembly (page 6-20).
  • Page 279 ENGINE COVER/COVER LOCK Clean the mating surfaces of the engine cover and engine cover air guide. Apply sealant (SHINETSU-SILICONE KE45 equivalent) to the specified area (1) of the engine cover air guide. Installation is in the reverse order of removal. SIDE COVER BRACKET DISASSEMBLY/ASSEMBLY L.
  • Page 280 ENGINE COVER/COVER LOCK R. SIDE COVER BRACKET Remove the R. side cover bracket (page 6-18). Remove the E-ring (1) and washer (2) from the side lock (3). Remove the side lock from the R. side cover bracket (4) by pulling down the side lock, while releasing the cover lock hook spring (5) from the R.
  • Page 281 ENGINE COVER/COVER LOCK Remove the E-ring (1) from the cover open shaft (2). Compress the lock lever return spring (3) by sliding the cover lock bushing B (4), then slightly lean the shaft as shown, so the shaft head (5) does not come in contact with the under cover front bracket (6).
  • Page 282 ENGINE COVER/COVER LOCK ASSEMBLY Install the bracket cap (1). (10) Apply marine grease to the shaft area of the front lock (2) and cover lock bushing (3) whole surface. Apply marine grease to the cover lock hook spring (4) whole surface and install it into the front lock hole (5). Turn the front lock as shown, then slightly lean the front lock and install it into the under cover front bracket (6).
  • Page 283 ENGINE COVER/COVER LOCK Apply marine grease to the whole surfaces of the washer (10 mm) (1), two wave washers (2), two cover lock bushings A (3) and lock front shaft (4) sliding surface of under cover front bracket (5). Set the two cover lock bushings A, washer (10 mm) and two wave washers to the cover lock lever (6) and install it to the under cover front bracket.
  • Page 284 ENGINE COVER/COVER LOCK HOOK BRACKET ADJUSTMENT Turn the nut (1) and adjust the hook bracket (2) height until the clearance between the engine under cover and engine cover is 17.5 – 18.5 mm (0.69 – 0.73 in). 17.5 – 18.5 mm (0.69 –...
  • Page 285 ENGINE COVER/COVER LOCK UNDER COVER SEAL B REPLACEMENT Remove the extension case (1). – Standard rotation type (page 16-12) – Counter rotation type (page 17-12) Remove the under cover seal B (2). Clean the seal installation surface of extension case. Apply adhesive (Threebond®...
  • Page 286 MEMO...

  • Page 287: Charging System

    7. CHARGING SYSTEM SYSTEM LOCATION·····································7-2 ALTERNATOR REMOVAL/ INSTALLATION ············································ 7-5 SYSTEM DIAGRAM ······································7-2 ALTERNATOR BRACKET REMOVAL/ INSTALLATION ············································ 7-7 TOOLS···························································7-3 ALTERNATOR DISASSEMBLY/ CHARGING SYSTEM ASSEMBLY ··················································· 7-8 TROUBLESHOOTING···································7-4 ALTERNATOR INSPECTION ····················· 7-20...
  • Page 288 CHARGING SYSTEM SYSTEM LOCATION CHARGING SYSTEM FUSE/RELAY JUNCTION BOX ALTERNATOR MAIN RELAY FUSE (10A) FUSE (30A) FUSE (100A) SYSTEM DIAGRAM FUSE/RELAY JUNCTION BOX No.4 No.5 No.1 FUSE FUSE Black Brown FUSE (30 A) (10 A) (100 A) Yellow Orange MAIN Blue Light blue RELAY...
  • Page 289 CHARGING SYSTEM TOOLS LIST Attachment, 37 x 40 mm Attachment, 52 x 55 mm Attachment, 24 x 26 mm 07746-0010200 07746-0010400 07746-0010700 Driver, 22 mm I.D. Attachment, 15 mm I.D. Pilot, 15 mm 07746-0020100 07746-0020200 07746-0040300 Driver 07749-0010000...
  • Page 290 CHARGING SYSTEM CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. Battery test Remove the battery. Check the battery condition using the commercially available battery tester. Is the battery in good condition? – GO TO STEP 2. – Faulty battery 2.
  • Page 291 CHARGING SYSTEM ALTERNATOR REMOVAL/ INSTALLATION REMOVAL Disconnect the battery negative (–) cable. Remove the silencer duct (page 5-82). Disconnect the 4P connector (1) from the alternator. Remove the nut (2) and alternator fuse cable (3) from the alternator B terminal (4). Loosen the bolt (1) and nut (2).
  • Page 292 CHARGING SYSTEM Install the alternator belt (1) to the crankshaft pulley (2), then alternator pulley (3). Adjust the belt tension by turning the special adjuster bolt (4) (page 3-9). • Do not turn the crankshaft pulley counterclockwise. After adjusting the belt tension, tighten the nut (5) first, then the bolt (6) to the specified torque.
  • Page 293 CHARGING SYSTEM ALTERNATOR BRACKET REMOVAL/ INSTALLATION Remove the flange bolt (6 × 16 mm) (1) and alternator stay (2). Remove the special adjuster bolt (3) and tensioner bolt (4). Remove the four bolts (8 × 28 mm) (5) and alternator bracket (6).
  • Page 294 CHARGING SYSTEM ALTERNATOR DISASSEMBLY/ ASSEMBLY DISASSEMBLY Remove the lock nut (1) and alternator pulley (2) using the two offset wrenches (10 mm (3) and 22 mm (4)) as shown. Remove the nut (1) and insulator bushing (2) from the alternator B terminal. Remove the three rear end cover bolts (3) and rear end cover (4).
  • Page 295 CHARGING SYSTEM Remove the screw (4 x 8 mm) (1), screw (4 x 6 mm) (2), and brush holder (3). Remove the brush holder insulator (4) from the brush holder. Remove the two screws (4 x 25 mm) (1), screw (4 x 6 mm) (2) and IC regulator (3).
  • Page 296 CHARGING SYSTEM Remove the four screws (1). Straighten the four wires (2) as shown and remove the rectifier (3). • Replace the stator with a new one, if the wires are broken around the rectifier holes. Remove the two nuts (1), two rear housing bolts (2) and rear housing (3).
  • Page 297 CHARGING SYSTEM Remove the rotor (1) from the stator (drive end frame) (2). Remove the bearing cover (3) from the rotor shaft (4). Before removing the rear bearing (1), check the bearing for abnormal play and replace if necessary. Remove the rear bearing from the rotor using a commercially available bearing puller (2).
  • Page 298 CHARGING SYSTEM Remove the four screws (1) and bearing retainer plate (2). Remove the two stud bolts (3) from the stator (4). Before removing the front bearing (1), check the bearing for abnormal play and replace if necessary. Support the stator housing in a vise, and drive out the front bearing using the special tools.
  • Page 299 CHARGING SYSTEM EXPLODED VIEW NUT (6 mm) INSULATOR BUSHING SCREW (4 × 6 mm) (6) SCREW (4 × 25 mm) (2) SCREW (4 × 8 mm) BRUSH HOLDER INSULATOR REAR END COVER RECTIFIER BRUSH HOLDER IC REGULATOR ROTOR REAR END COVER BOLT (3) REAR BEARING WAVE WASHER REAR HOUSING...
  • Page 300 CHARGING SYSTEM ASSEMBLY If the front bearing is removed, replace with a new bearing (1). Apply grease to the outer circumference of the bearing. Install a new front bearing in the stator (drive end frame) using the special tool as shown. TOOLS: Driver (2) 07749-0010000...
  • Page 301 CHARGING SYSTEM If the rear bearing (1) is removed, replace it with a new one. Install the washer (2) to the rotor shaft (3). Apply grease to the inner surface of new bearing and install it to the rotor shaft. Attach the special tool to the front bearing (1) side of the rotor shaft (2), then set the rotor to a hydraulic press.
  • Page 302 CHARGING SYSTEM Clean the grease or oil from the slip ring (1) of the rotor using a shop towel. Install the rotor (2) to the stator (drive end frame) (3). Install the bearing cover (4) onto the rotor shaft. Apply grease to the outer circumference of the rear bearing (1).
  • Page 303 CHARGING SYSTEM Install the rectifier (1) and bend the wires (2) toward the rectifier and around the screw holes as shown. Install and tighten the four screws (3). • Replace the stator with a new one, if the wires are broken around the rectifier holes.
  • Page 304 CHARGING SYSTEM Tighten the two screws (4 × 25 mm) (1), screw (4 × 6 mm) (2) and screw (4 × 8 mm) (3) while slightly pushing the brush of IC regulator/brush holder (4) against the slip ring (5) of the rotor shaft. Tighten the screw (4 ×...
  • Page 305 CHARGING SYSTEM Install the alternator pulley (1) and hold the rotor shaft (2) using a 10 mm wrench (3), then tighten the alternator pulley lock nut (4) using a 22 mm torque wrench (5). TORQUE: 110 N·m (11.2 kgf·m, 81 lbf·ft) 7-19...
  • Page 306 CHARGING SYSTEM ALTERNATOR INSPECTION BRUSH HOLDER ASSEMBLY Measure the brush length. STANDARD: 10.5 mm (0.41 in) SERVICE LIMIT: 8.4 mm (0.33 in) If the measurement is less than the service limit, replace the brush holder assembly. RECTIFIER ASSEMBLY • Inspect the rectifier by removing it from the stator. Check for continuity between the B terminal (1) and respective P terminals (P1, P2, P3, and P4), and between the E terminal (2) and respective P terminals...
  • Page 307 CHARGING SYSTEM ROTOR Check that there is continuity between the slip rings (1). Check that there is no continuity between a slip ring and rotor (2), and between a slip ring and rotor shaft (3). Replace the rotor if it is abnormal. Measure the slip ring O.D.
  • Page 308 MEMO...

  • Page 309: Ignition System

    8. IGNITION SYSTEM SYSTEM LOCATION·····································8-2 IGNITION SYSTEM TROUBLESHOOTING ·································· 8-3 SYSTEM DIAGRAM ······································8-2 SPARK TEST ················································ 8-4...
  • Page 310 IGNITION SYSTEM SYSTEM LOCATION IGNITION SYSTEM CKP SENSOR FUSE/RELAY JUNCTION BOX MAIN RELAY FUSE (10 A) FUSE (15 A) DIRECT IGNITION COIL FUSE (30 A) SYSTEM DIAGRAM FUSE/RELAY JUNCTION BOX No.4 No.5 DIRECT IGNITION COIL 1 DIRECT IGNITION COIL 3 Black Brown FUSE...
  • Page 311 IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING NO SPARK (S) 1. MIL inspection Turn the combination switch ON and check that the MIL stays ON. Does the MIL stay ON? – PGM-FI troubleshooting (page 5-6). – GO TO STEP 2. 2. Emergency stop switch clip inspection Check the emergency stop switch clip.
  • Page 312 IGNITION SYSTEM 7. Emergency stop switch signal line short circuit inspection Disconnect the ECM connector A and B Disconnect the switch panel cable 14P connector Check for continuity between the ECM connector B main wire harness side No.30 (Black/Red) terminal, No.31 (Black/Red) terminal and engine ground. Is there continuity? –...

  • Page 313: Starting System

    9. STARTING SYSTEM SYSTEM LOCATION·····································9-2 STARTER MOTOR REMOVAL/ INSTALLATION ············································ 9-5 SYSTEM DIAGRAM ······································9-2 STARTER MOTOR DISASSEMBLY/ ASSEMBLY ··················································· 9-6 STARTING SYSTEM TROUBLESHOOTING···································9-3 STARTER MOTOR INSPECTION ·············· 9-15...
  • Page 314 STARTING SYSTEM SYSTEM LOCATION STARTING SYSTEM FUSE/RELAY JUNCTION BOX STARTER RELAY FUSE (30 A) FUSE (10 A) NEUTRAL SWITCH STARTER MOTOR SYSTEM DIAGRAM FUSE/RELAY JUNCTION BOX No.4 No.5 FUSE FUSE (30 A) (10 A) STARTER RELAY OPTION COMBINATION SWITCH Bl/W Bl/W W/Bl W/Bl...
  • Page 315 STARTING SYSTEM STARTING SYSTEM TROUBLESHOOTING STARTER MOTOR DOES NOT TURN 1. Standard inspection Check the following: – Battery condition – Burned No.4 (30 A) fuse Are the above items in good condition? – GO TO STEP 2. – Replace or repair the malfunctioning part (s). 2.
  • Page 316 STARTING SYSTEM 5. Starter relay switch coil line open circuit inspection Disconnect the neutral switch 2P connector NEUTRAL SWITCH 2P CONNECTOR Turn the combination switch to the START position. MAIN WIRE HARNESS SIDE Measure the voltage at the neutral switch 2P connector main wire harness side No.2 (Black/yellow) terminal and No.1 (Black) terminal.
  • Page 317 STARTING SYSTEM STARTER MOTOR REMOVAL/ INSTALLATION Disconnect the battery negative (–) terminal. Remove the electric parts case (page 10-5). Disconnect starter motor S terminal (1) from the starter solenoid (2). Remove the two nuts (3), alternator fuse cable (4), washer (5) and starter cable (6) from the starter solenoid.
  • Page 318 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) and two O-rings (2). Remove the starter solenoid (3), spring (4) and plunger (5).
  • Page 319 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 320 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 321 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 Remove the brush sets (4) and four brush springs (5).
  • Page 322 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 9-14). CLIP BRUSH SET PLATE REAR BRACKET BRUSH HOLDER SCREW (5×8 mm) (2) 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft)
  • Page 323 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 324 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 325 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). Install and tighten the two screws to the specified torque.
  • Page 326 STARTING SYSTEM Install the spring (1) and plunger (2) to the starter solenoid (3), then assemble the plunger and clutch fork (4) as shown. Apply engine oil to new O-rings (5) and install them onto the screws (6). Install and tighten the two screws to the specified torque.
  • Page 327 STARTING SYSTEM STARTER MOTOR INSPECTION BRUSH LENGTH Measure the brush length. 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). STANDARD: 0.40 –...
  • Page 328 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: 0.1 mm (0.004 in) If the measurement is more than the service limit, replace the armature with a new one.
  • Page 329 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 330 STARTING SYSTEM Turn the gear shaft assembly (1) by holding the overrunning clutch (2). The gear shaft assembly should turn only clockwise. If the clutch turns freely in both directions or if it does not turn at all, replace the overrunning clutch. Check the pinion gear teeth for wear and damage and replace if necessary.

  • Page 331: Other Electrical

    10. OTHER ELECTRICAL SYSTEM LOCATION···································10-2 RELAY REMOVAL/INSTALLATION ········ 10-13 FUSE/RELAY JUNCTION BOX REMOVAL/ MAIN/STARTER/A/F SENSOR INSTALLATION···········································10-3 HEATER RELAY INSPECTION ················ 10-13 ECM REMOVAL/INSTALLATION···············10-4 FUEL PUMP RELAY INSPECTION ·········· 10-14 ELECTRIC PARTS CASE REMOVAL/ FUSE/RELAY JUNCTION BOX INSTALLATION···········································10-5 INSPECTION············································· 10-14 SWITCH PANEL CABLE/INDICATOR WIRE POWER TILT RELAY INSPECTION ········...

  • Page 332: System Location

    OTHER ELECTRICAL SYSTEM LOCATION OTHER ELECTRICAL FUSE/RELAY JUNCTION BOX NEUTRAL SWITCH POWER TILT RELAY TRIM ANGLE SENSOR 10-2...

  • Page 333: Fuse/Relay Junction Box Removal

    OTHER ELECTRICAL FUSE/RELAY JUNCTION BOX REMOVAL/INSTALLATION Disconnect the battery negative (–) cable, then the positive (+) cable from the battery. Remove the engine cover. 10P CONNECTOR FUSE/RELAY JUNCTION BOX BOLT (6 x 20 mm) (4) 5 N·m (0.51 kgf·m, 3.7 lbf·ft) BOLT (6 x 12 mm) (3) 8P CONNECTOR MAIN WIRE...

  • Page 334: Ecm Removal/Installation

    OTHER ELECTRICAL ECM REMOVAL/INSTALLATION Disconnect the battery negative (–) cable, then the positive (+) cable from the battery. Remove the engine cover. ECM CONNECTOR A ECM CONNECTOR B BOLT (2) 5 N·m (0.51 kgf·m, 3.7 lbf·ft) 10-4...

  • Page 335: Electric Parts Case Removal

    OTHER ELECTRICAL ELECTRIC PARTS CASE REMOVAL/ INSTALLATION Remove the following: – Fuse/relay junction box (page 10-3) – ECM (page 10-4) ALTERNATOR 4P CONNECTOR ALTERNATOR B TERMINAL CKP SENSOR 3P CONNECTOR NUT (6 mm) TACHOMETER PULSE CHECK 2P CONNECTOR DLC 4P ECT SENSOR 1 2P CONNECTOR EOP SENSOR...

  • Page 336: Switch Panel Cable/Indicator Wire Harness Removal/Installation

    OTHER ELECTRICAL SWITCH PANEL CABLE/INDICATOR WIRE HARNESS REMOVAL/ INSTALLATION REMOVAL Disconnect the battery negative (–) cable, then the positive (+) cable from the battery. Remove the following: – Front separate cover (page 6-3) – Shift control cable pivot (page 20-3) –...
  • Page 337 OTHER ELECTRICAL INSTALLATION • Be careful not to press the fuel tube A with the remote control cable grommet. Connect the 14P connector (1) of the switch panel cable and 6P connector (2) of the indicator wire harness, then install them to the neutral switch bracket (3).
  • Page 338 OTHER ELECTRICAL Install the remote control cable grommet (1) while aligning the front under cover bracket (2) end surface. Install the remote control cable plate (3) to the groove (4) of the front under cover bracket, then tighten the bolt (5).

  • Page 339: Starter Cable Removal

    OTHER ELECTRICAL STARTER CABLE REMOVAL/ INSTALLATION REMOVAL Disconnect the battery negative (–) cable, then the positive (+) cable from the battery. Remove the following: – Under cover front bracket (page 6-18) – Switch panel cable/indicator wire harness (page 10- Remove the two bolts (1) and starter cables (+) (2) from the fuse/relay junction box (3).
  • Page 340 OTHER ELECTRICAL INSTALLATION Connect the starter cable (+) 1P connector (1) and install it to the connector bracket A (2). Install the harness band clip (3) to the neutral switch bracket (4). Install the harness band clip (1) to the cable bracket B (2).

  • Page 341: Power Tilt Relay/Connector

    OTHER ELECTRICAL POWER TILT RELAY/CONNECTOR BRACKET A REMOVAL/INSTALLATION Disconnect the battery negative (–) cable, then the positive (+) cable from the battery. Remove the following: – Under cover front bracket (page 6-18) – Switch panel cable/indicator wire harness (page 10- Disconnect the fuel tube A (1) from the drain tube holders (2).
  • Page 342 OTHER ELECTRICAL Remove the bolt (6 x 12 mm) (1) and ground terminal (2) of the power tilt relay. Remove the four bolts (6 x 14 mm) (3). Remove the connector bracket A (4), power tilt relay (5) and relay bracket (6) as a set. Remove the two wire clips (7) from the relay bracket.

  • Page 343: Relay Removal/Installation

    OTHER ELECTRICAL RELAY REMOVAL/INSTALLATION Disconnect the battery negative (–) cable, then the positive (+) cable from the battery. Remove the engine cover and fuse/relay junction box cover. Remove the following: – Main relay (1) – Starter relay (2) – A/F sensor heater relay (3) –...

  • Page 344: Fuel Pump Relay Inspection

    OTHER ELECTRICAL FUEL PUMP RELAY INSPECTION Remove the fuel pump relay from the fuse/relay junction box (page 10-13). Connect the ohmmeter to the fuel pump relay terminal C (1) and terminal D (2). Connect the battery positive (+) cable to the fuel pump relay terminal A (3) and battery negative (–) cable to terminal B (4).
  • Page 345 OTHER ELECTRICAL Check for continuity between the terminal and terminal of fuse/relay junction box. If the fuse is normal but there is no continuity between the terminals, replace the fuse/relay junction box with a new one. 10-15...
  • Page 346 OTHER ELECTRICAL BLADE FUSE INSPECTION Remove the fuses from fuse/relay junction box and check for blown fuses. If the fuses are normal, install the fuses to fuse/relay junction box and check for continuity between the terminals in each connectors as shown in the table. FUSE/RELAY JUNCTION BOX No.8 No.3...

  • Page 347: Power Tilt Relay Inspection

    OTHER ELECTRICAL Check terminals No.9 fuse No.8 terminal and fuse/relay junction box 23P connector No.3 terminal No.9 fuse No.8 terminal and fuse/relay junction box 23P connector No.7 terminal No.10 fuse No.11 terminal and main relay No.28 terminal No.10 fuse No.12 terminal and fuse/relay junction box 23P connector No.10 terminal No.10 fuse No.12 terminal and fuse/relay junction box 23P connector No.11 terminal...

  • Page 348: Trim Angle Sensor Inspection

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

  • Page 349: Neutral Switch Inspection

    OTHER ELECTRICAL NEUTRAL SWITCH INSPECTION Remove the front separate cover (page 6-3). Remove the switch panel cable 14P connector (1) and indicator wire harness 6P connector (2) from the neutral switch bracket (3), then disconnect them. Remove the neutral switch 2P connector (1) from the connector bracket A and disconnect it.
  • Page 350 MEMO...

  • Page 351: Cooling System

    11. COOLING SYSTEM COMPONENT LOCATION ··························11-2 WATER PUMP REMOVAL/ INSTALLATION ·········································· 11-7 TOOLS·························································11-3 RELIEF VALVE DISASSEMBLY/ ASSEMBLY ··············································· 11-13 WATER LINE DESCRIPTION ·····················11-4 FLUSH VALVE DISASSEMBLY/ THERMOSTAT REMOVAL/ ASSEMBLY ··············································· 11-14 INSTALLATION···········································11-5 THERMOSTAT INSPECTION ··················· 11-15 WATER RELIEF TUBE REMOVAL/ INSTALLATION···········································11-6 11-1...
  • Page 352 COOLING SYSTEM COMPONENT LOCATION COOLING SYSTEM 11-2...
  • Page 353 COOLING SYSTEM TOOLS LIST Attachment, 32 x 35 mm Driver 07746-0010100 07749-0010000 11-3...
  • Page 354 COOLING SYSTEM WATER LINE DESCRIPTION THERMOSTAT (CYLINDER HEAD SIDE) : 50 °C/122 °F CYLINDER HEAD THERMOSTAT (CYLINDER BLOCK SIDE) : 60 °C/140 °F EXHAUST MANIFOLD CYLINDER BLOCK OIL FILTER FLANGE VAPOR SEPARATOR Inlet water Outlet water INSPECTION HOLE RELIEF VALVE WATER TUBE WATER PUMP WATER SCREEN...
  • Page 355 COOLING SYSTEM THERMOSTAT REMOVAL/INSTALLATION Remove the engine cover. Disconnect the water relief tube A (1) from the thermostat cover (2). Remove the following: – Three bolts (6 x 22 mm) (3) – Thermostat cover – Two thermostats (4) – Thermostat cover packing (5) –...
  • Page 356 COOLING SYSTEM WATER RELIEF TUBE REMOVAL/INSTALLATION Remove the following: – Engine cover – L. engine under cover (page 6-4) – R. engine under cover (page 6-10) Disconnect the water relief tube A (1) from the thermostat cover (2). Remove the water tube clamp (3) from the water relief tube A and main wire harness (4). Disconnect the tube (7 x 90 mm) (5), tube (7 x 120 mm) (6) and water tube E (7) from the engine side.
  • Page 357 COOLING SYSTEM WATER PUMP REMOVAL/ INSTALLATION REMOVAL Remove the following: – Propeller – Standard rotation type (page 16-6) – Counter rotation type (page 17-6) – Gear case – Standard rotation type (page 16-8) – Counter rotation type (page 17-8) Remove the water tube seal ring (1) from the impeller housing (2) Remove the four bolts (8 x 60 mm) (3), four distance collars (4), and impeller housing.
  • Page 358 COOLING SYSTEM Remove the two bolts (1) and water seal housing (2) Remove the O-ring (58.5 x 3.5 mm) (3) from the water seal housing. Remove the water seal (23 x 36 x 6 mm) (1) and water seal (23 x 36 x 8 mm) (2) using a commercially available oil seal remover.
  • Page 359 COOLING SYSTEM EXPLODED VIEW BOLT (8 x 40 mm) (4) 20 N·m (2.0 kgf·m, 15 lbf·ft) WATER TUBE SEAL RING IMPELLER HOUSING DISTANCE COLLAR (4) BOLT (6 x 20 mm) (2) WATER PUMP O-RING WATER PUMP HOUSING PUMP LINER PUMP IMPELLER O-RING (58.5 x 3.5 mm) WATER SEAL (23 x 36 x 8 mm)
  • Page 360 COOLING SYSTEM INSTALLATION Apply soapy water to the circumference of the new WATER SEAL INSTALL DIRECTION: water seals and marine grease to the water seals mating surface. Drive the water seal (23 x 36 x 8 mm) (1) and water seal (23 x 36 x 6 mm) (2) into the water pump housing (3) using the special tools.
  • Page 361 COOLING SYSTEM Install the rubber setting plate (1) and gear case grommet (2) to the gear case (3). Install the two dowel pins (4), a new impeller gasket (5) and impeller cover (6). Apply marine grease to the pump liner (1) inner surface. Install the pump liner into the impeller housing (2) by aligning the two projections (3) on the pump liner with the two grooves (4) in the impeller housing.
  • Page 362 COOLING SYSTEM Set the special key (1) to the groove (2) in the vertical shaft (3). Install the pump impeller (4) by aligning the key groove (5) in the pump impeller with the special key. Install the impeller housing (6) while turning the vertical shaft clockwise.
  • Page 363 COOLING SYSTEM RELIEF VALVE DISASSEMBLY/ ASSEMBLY Remove the R. engine under cover (page 6-10). Remove the following: – Bolt (6 x 22 mm) (1) – Water relief tube C (2) – Relief valve (3) – Relief valve cover O-ring (4) –...
  • Page 364 COOLING SYSTEM FLUSH VALVE DISASSEMBLY/ ASSEMBLY Remove the following: – L. engine under cover (page 6-4) – R. engine under cover (page 6-10) Remove the following: – Two tube clamps D10.5 (1) – Tube (7 x 200 mm) (2) – Flush valve spring (3) –...
  • Page 365 COOLING SYSTEM THERMOSTAT INSPECTION Remove the thermostat (page 11-5). Immerse the thermostat (1) in water. Heat the water and observe the operation of the thermostat as the water temperature increases. Measure the water temperature when the thermostat starts opening. Don't let the thermometer (2) or the thermostat touch the container;...
  • Page 366 MEMO...

  • Page 367: Lubrication System

    12. LUBRICATION SYSTEM COMPONENT LOCATION ··························12-2 OIL PUMP REMOVAL/ INSTALLATION ·········································· 12-9 LUBRICATION SYSTEM DIAGRAM ··········12-3 OIL PUMP DISASSEMBLY/ ASSEMBLY ··············································· 12-10 TOOLS·························································12-4 OIL PRESSURE TEST ······························ 12-13 OIL FILTER FLANGE REMOVAL/ INSTALLATION···········································12-5 OIL PUMP INSPECTION ·························· 12-14 OIL CASE/WATER TUBE REMOVAL/ INSTALLATION···········································12-6 12-1...
  • Page 368 LUBRICATION SYSTEM COMPONENT LOCATION LUBRICATION SYSTEM 10 N·m (1.0 kgf·m, 7 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 12-2...
  • Page 369 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM EXHAUST ROCKER ARM EXHAUST ROCKER SHAFT EXHAUST CAM SHAFT INTAKE CAM SHAFT INTAKE ROCKER SHAFT OIL PASS COVER INTAKE ROCKER PISTON CAM CHAIN JET 2 OIL JET CAM CHAIN JET 1 CRANKSHAFT CAM CHAIN TENSIONER EOP SENSOR BALANCER CHAIN JET REAR BALANCER SHAFT...
  • Page 370 LUBRICATION SYSTEM TOOLS LIST Oil pressure gauge attachment Pressure gauge attachment Oil pressure gauge set 070MJ-0010101 07406-0030000 07506-3000001 Driver Oil seal driver, 44.5 mm Oil seal driver, 72 mm 07749-0010000 07947-SB00100 07947-6340201 12-4...
  • Page 371 LUBRICATION SYSTEM OIL FILTER FLANGE REMOVAL/INSTALLATION Remove the following: – Electric parts case (page 10-5) – Remove the oil filter (page 3-6) Installation is in the reverse order of removal. WATER TUBE E TUBE CLAMP D10.5 (2) BOLT (6 × 25 mm) (4) OIL FILTER FLANGE O-RING (22.5 ×...
  • Page 372 LUBRICATION SYSTEM OIL CASE/WATER TUBE REMOVAL/ INSTALLATION REMOVAL Drain the engine oil (page 3-5). Remove the following: – Gear case – Standard rotation type (page 16-8) – Counter rotation type (page 17-8) – Extension case – Standard rotation type (page 16-12) –...
  • Page 373 LUBRICATION SYSTEM EXPLODED VIEW OIL LEVEL PIPE BOLT (6 × 12 mm) O-RING (11.5 × 3.5 mm) OIL CASE GASKET OIL LEVEL GAUGE OIL STRAINER BOLT (6 × 18 mm) (2) DOWEL PIN (2) OIL CASE O-RING (20.6 × 2.6 mm) DRAIN PLUG WASHER BOLT (10 ×...
  • Page 374 LUBRICATION SYSTEM INSTALLATION Apply engine oil to a new O-ring (1), and install it to the Lower area: Upper area: oil strainer (2). Apply 1.0 – 5.0 mm (0.04 – 0.20 in) bead of liquid sealant (ThreeBond® #1211 or equivalent) to the upper and lower area of a new oil case gasket (3) as shown.
  • Page 375 LUBRICATION SYSTEM OIL PUMP REMOVAL/INSTALLATION Remove the engine (page 13-3). DOWEL PIN (14 × 20 mm) OIL PUMP BODY GASKET OIL PUMP BODY DOWEL PIN (10 × 16 mm) BOLT (8 × 32 mm) (5) 12-9...
  • Page 376 LUBRICATION SYSTEM OIL PUMP DISASSEMBLY/ASSEMBLY DISASSEMBLY SCREW (6 × 16 mm) (9) 7 N·m (0.71 kgf·m, 5.2 lbf·ft) OIL SEAL (31 × 46 × 7 mm) OIL PUMP COVER INNER ROTOR DOWEL PIN (5 × 8 mm) (2) OUTER ROTOR OIL PUMP BODY ThreeBond #1216 or equivalent...
  • Page 377 LUBRICATION SYSTEM ASSEMBLY Apply liquid sealant (Threebond® 1216 or equivalent) to the threads of the two sealing bolts (1). • To prevent leaks, do not install the parts if 5 minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the old residue.
  • Page 378 LUBRICATION SYSTEM Install the two dowel pins (1) to the oil pump body. Install the oil pump cover (2) and tighten the nine screws (3) to the specified torque. TORQUE: 7 N·m (0.71 kgf·m, 5.2 lbf·ft) After assembly, check that the rotors rotate smoothly. Install the oil seal (46 ×...
  • Page 379 LUBRICATION SYSTEM OIL PRESSURE TEST Remove the oil filter (page 3-6). 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 attachment (3)
  • Page 380 LUBRICATION SYSTEM OIL PUMP INSPECTION OIL PUMP BODY I.D. Measure the oil pump body I.D. STANDARD: 84.000 – 84.030 mm (3.3071 – 3.3083 in) OIL PUMP BODY DEPTH Measure the oil pump body depth. STANDARD: 12.520 – 12.550 mm (0.4929 – 0.4941 in) OUTER ROTOR HEIGHT Measure the outer rotor height.
  • Page 381 LUBRICATION SYSTEM INNER ROTOR-TO-OUTER ROTOR CLEARANCE Measure the inner rotor-to-outer rotor clearance. STANDARD: 0.04 – 0.16 mm (0.002 – 0.006 in) SERVICE LIMIT: 0.20 mm (0.008 in) Replace the inner rotor and outer rotor as a set (page 12-10) if the measurement exceeds the service limit. OUTER ROTOR-TO-PUMP BODY CLEARANCE Measure the outer rotor-to-pump body clearance.
  • Page 382 MEMO...
  • Page 383 13. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ··························13-2 ENGINE INSTALLATION···························· 13-6 ENGINE REMOVAL ····································13-3 13-1...
  • Page 384 ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ENGINE REMOVAL/INSTALLATION 26 N·m (2.7 kgf·m, 19 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 26 N·m (2.7 kgf·m, 19 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 26 N·m (2.7 kgf·m, 19 lbf·ft) 13-2...

  • Page 385: Engine Removal/Installation

    ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Gasoline is highly flammable and explosive. You can be burned or seriously injured when han- dling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Disconnect the negative (–) and positive (+) cables from the battery.
  • Page 386 ENGINE REMOVAL/INSTALLATION Remove the four bolts (8 × 30 mm) (1) that secure the exhaust guide from the under side of the mounting case. Viewed from the under side of the mounting case: Remove the following fasteners: • Two cap nuts (1) •...
  • Page 387 ENGINE REMOVAL/INSTALLATION Remove the following bolts from the under side of the Viewed from the under side of mounting case (1). the mounting case: • Bolt (8 × 100 mm) (2) (6)/(7) • Bolt (10 × 80 mm) (3) • Two bolts (10 × 110 mm) (4) •...

  • Page 388: Engine Installation

    ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION Apply marine grease to the shift shaft B (1) installation area of mounting case. Set the shift shaft washer (2) under the shift shaft B. Install the shift shaft B by aligning its punch mark (3) with the punch mark (4) on shift shaft A (5).
  • Page 389 ENGINE REMOVAL/INSTALLATION Install the dowel pin (10 × 16 mm) (1), dowel pin (14 × 20 mm) (2) and new mounting case gasket (3) to the mounting case (4). Apply engine oil to a new oil pump rubber (1) and install it to the mounting case.
  • Page 390 ENGINE REMOVAL/INSTALLATION Tighten the four exhaust guide bolts (1) from the under side of the mounting case in the numbered order in two or three steps to the specified torque. TORQUE: 26 N·m (2.7 kgf·m, 19 lbf·ft) Install the three washers (12 mm) (1) to the two bolts (12 ×...
  • Page 391 ENGINE REMOVAL/INSTALLATION Connect the air vent tube (1) and oil tube (2) to the mounting case. Install the following: – Starter motor (page 9-5) – Water relief tube (page 11-6) – Seal holder (page 20-12) – Shift link bracket (page 20-7) –...
  • Page 392 MEMO...

  • Page 393: Cylinder Head

    14. CYLINDER HEAD COMPONENT LOCATION ··························14-2 ROCKER ARM DISASSEMBLY/ ASSEMBLY ··············································· 14-38 TOOLS·························································14-4 CYLINDER HEAD DISASSEMBLY/ ASSEMBLY ··············································· 14-39 CYLINDER HEAD COVER REMOVAL/ INSTALLATION···········································14-6 CYLINDER COMPRESSION TEST ·········· 14-44 CRANKSHAFT PULLEY/CAM CHAIN REMOVAL/INSTALLATION······················14-11 CYLINDER HEAD INSPECTION ·············· 14-45 CAMSHAFT/ROCKER ARM REMOVAL/ VALVE GUIDE REPLACEMENT ··············...
  • Page 394 CYLINDER HEAD COMPONENT LOCATION CYLINDER HEAD 250 N·m (25.5 kgf·m, 184 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)
  • Page 395 CYLINDER HEAD 12 N·m (1.2 kgf·m, 9 lbf·ft) REUSED BOLT: 40 N·m (4.1 kgf·m, 30 lbf·ft) + 90°+ 90° NEW BOLT: 40 N·m (4.1 kgf·m, 30 lbf·ft) + 90°+ 90°+ 98° 45 N·m (4.6 kgf·m, 33 lbf·ft) 115 N·m (11.7 kgf·m, 85 lbf·ft) 72 N·m (7.3 kgf·m, 53 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)
  • Page 396 CYLINDER HEAD TOOLS LIST Valve guide driver 5.35×9.7 Attachment 52 × 55 mm Driver 07742-0010100 07746-0010400 07749-0010000 Valve spring compressor Valve spring compressor attachment Valve seat cutter, 45° 35 mm [IN] 07757-0010000 07757-PJ10100 07780-0010400 Valve seat cutter, 45° 33 mm [EX] Valve seat cutter, 32°...
  • Page 397 CYLINDER HEAD Valve guide reamer, 5.525 mm Socket wrench 19 × 90 Holder handle 07HAH-PJ70100 07JAA-001020A 07JAB-001020B Holder attachment, 50 mm, offset Stem seal driver 07MAB-PY30100 07PAD-0010000 14-5...
  • Page 398 CYLINDER HEAD CYLINDER HEAD COVER REMOVAL/ INSTALLATION REMOVAL Disconnect the battery negative (–) cable. Shift the remote control lever in the N (neutral) position. Remove the following: – L. engine under cover (page 6-4) – R. engine under cover (page 6-10) –...
  • Page 399 CYLINDER HEAD Disconnect the mount case side oil tube (1). Move the water relief tube A (1) from the cylinder head cover boss (2) to the exhaust manifold side. Remove the six nuts (1), six cylinder head cover washers (2) and cylinder head cover (3). 14-7...
  • Page 400 CYLINDER HEAD INSTALLATION Check the cylinder head cover packing (1) and spark plug tube seal (2) for oil leaks, deterioration or damage, and replace them if necessary. Install the cylinder head cover packing and spark plug tube seal to the cylinder head cover (3). Clean the cylinder head mating surfaces with a shop towel or equivalent material.
  • Page 401 CYLINDER HEAD Apply soapy water to the lips (1) of the spark plug tube seal (2). Install the cylinder head cover (3) to the cylinder head by aligning the spark plug tube (4) with the spark plug tube seal. • Be careful not to damage the spark plug tube seal and do not allow the seal lip to turn inside out.
  • Page 402 CYLINDER HEAD Connect the fuel tube B (1) and fuel tube D (2) to the fuel pump (low pressure side). Connect the oil tube (1). • Be sure that the oil tube is connected to the mount case securely. Connect the crankcase breather tube (1). Set the main wire harness (2) to the cylinder head cover bosses (3).
  • Page 403 CYLINDER HEAD Connect the CMP sensor 3P connector and install the harness band clip (2) to the clip bracket F (3). Install the R. side cover bracket (1) and tighten the bolts (2). Install the following: – Direct ignition coils (page 3-17) –...
  • Page 404 CYLINDER HEAD Remove the A/F sensor 4P connector (1) from the harness clip bracket C (2) and disconnect it. Remove the harness band clip (3) from the harness clip bracket C. Remove the three bolts (4) and harness clip bracket C. Remove the two bolts (1) and harness clip bracket B (2).
  • Page 405 CYLINDER HEAD Disconnect the CKP sensor 3P connector (1). Loosen the crankshaft pulley bolt (1) using the special tools as shown. • Do not use an impact wrench. Remove the bolt while holding the crankshaft pulley with the special tool. •...
  • Page 406 CYLINDER HEAD Remove the following bolts from the chain case. • Three bolts (6 × 25 mm) (1) • Ten bolts (6 × 28 mm) (2) • Two bolts (6 × 31 mm) (3) • Bolt (SH) (6 × 38 mm) (4) •...
  • Page 407 CYLINDER HEAD Remove the tensioner pivot bolt (1) and cam chain tensioner arm (2). Remove the three bolts (3) and cam chain guide (4). Remove the two bolts (1) and cam chain guide B (2). Remove the crank pulser plate (1) from the crankshaft (2).
  • Page 408 CYLINDER HEAD EXPLODED VIEW • Check for oil leaks from the crankshaft oil seal and replace if necessary. HARNESS CLIP BRACKET B BOLTS (10 × 43 mm) BOLT (SH) (6 × 38 mm) 39 N·m (4.0 kgf·m, 29 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) BOLTS (6 ×...
  • Page 409 CYLINDER HEAD INSTALLATION Align the crankshaft sprocket mark (1) with the pointer (2) on the cylinder block. Install the cam chain guide (1), then install and tighten the three bolts (2) to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Install the cam chain tensioner arm (3), then install and tighten the tensioner pivot bolt (4) to the specified torque.
  • Page 410 CYLINDER HEAD Hold the hexagonal parts of the intake camshaft (1) and INTAKE SIDE: EXHAUST SIDE: exhaust camshaft (2) with a wrench or equivalent tool, then align the intake cam sprocket mark (3) and exhaust cam sprocket mark (4) as shown. At this position, the No.
  • Page 411 CYLINDER HEAD Wipe off the oil and clean the crankshaft (1) outer surface using a shop towel. Install the crank pulser plate (2) with the "OUT-SIDE" mark (3) facing out. Install the cam chain guide B (1) and tighten the two bolts (2) to the specified torque.
  • Page 412 CYLINDER HEAD Apply soapy water to a new crankshaft oil seal (43 × 58 × 7 mm) (1) outer surface. Drive in the oil seal until it is fully seated on the cam chain case (2) using the special tools. TOOLS: Driver (3) 07749-0010000...
  • Page 413 CYLINDER HEAD Clean the cylinder block, cylinder head and chain case 2.0 - 3.0 mm mating surface. (0.08 - 0.12 in) Apply 2.0 – 3.0 mm (0.08 – 0.12 in) bead of liquid More than 2.5 mm (0.10 in) sealant (Threebond® 1280B or equivalent) to the specified area of chain case (1).
  • Page 414 CYLINDER HEAD Set the chain case (1) against the crankcase side (2) and install it to the cylinder block (3). Loosely install the two bolts (6 × 31 mm) (4). Loosely install the other bolts and tighten them to the specified torque in two or three steps.
  • Page 415 CYLINDER HEAD Be sure to degrease, clean, or lubricate the following : Wipe off with a clean shop towel. parts before installation. × : Degrease Crankshaft pulley bolt (1) : Apply engine oil. • Degrease the entire surface of the bolt-washer (especially the washer and crankshaft pulley mating surface) with a clean shop towel.
  • Page 416 CYLINDER HEAD Connect the CKP sensor 3P connector (1). Set the main wire harness (1) between the tabs (2). Install the harness clip bracket B (3) and tighten the two bolts (4). 14-24...
  • Page 417 CYLINDER HEAD Install the four harness band clips (1) to the harness clip bracket C (2). Set the harness clip bracket C and tighten the three bolts (3). Connect the A/F sensor 4P connector (4) and install it to the harness clip bracket C. Install the following: –...
  • Page 418 CYLINDER HEAD CAMSHAFT/ROCKER ARM REMOVAL/ INSTALLATION REMOVAL Disconnect the battery negative (–) cable. Make sure the remote control lever is in "N" (neutral) position. Turn the crankshaft and set the No. 1 piston at top dead center of compression stroke (page 3-15). Remove the crankshaft pulley/cam chain (page 14-11).
  • Page 419 CYLINDER HEAD Hold the hexagonal part of intake camshaft (1) with a wrench (2) or equivalent tool. Remove the VTC flange bolt (3), intake camshaft sprocket (4) and dowel pin (5). Hold the hexagonal part of intake camshaft (1) with a wrench (2) or equivalent tool.
  • Page 420 CYLINDER HEAD Hold the hexagonal part of exhaust camshaft (1) with a wrench (2) or equivalent tool. Remove the bolt (3), exhaust camshaft sprocket (4) and dowel pin (5). Hold the hexagonal part of exhaust camshaft (1) with a wrench (2) or equivalent tool. Remove the sealing bolt (3) and CMP pulse plate (4).
  • Page 421 CYLINDER HEAD Loosen the twenty-one camshaft holder bolts (1) in the numbered sequence in two or three steps. Remove the following: – Twenty-one bolts (1) – Five camshaft holders (2) – Intake camshaft (3) – Exhaust camshaft (4) – Ten dowel pins (5) Install the four bolts (1) in the positions as shown and remove the rocker arm assembly (2) from the cylinder head.
  • Page 422 CYLINDER HEAD EXPLODED VIEW DOWEL PINS (10 × 16 mm) (10) FLANGE BOLT (12 × 47 mm) 115 N·m (11.7 kgf·m, 85 lbf·ft) INTAKE CAMSHAFT ROCKER ARM SPROCKET ASSEMBLY BOLT (10 × 32 mm) 72 N·m (7.3 kgf·m, 53 lbf·ft) EXHAUST CAMSHAFT SPROCKET DOWEL PINS (4.2 ×...
  • Page 423 CYLINDER HEAD INSTALLATION Completely degrease the No. 5 rocker shaft holder (1) mating surface with cylinder head, using a degreasing agent. Apply 2.0 – 3.0 mm (0.08 – 0.12 in) bead of liquid sealant (Threebond® 1280B or equivalent) to the specified area (2) of No.
  • Page 424 CYLINDER HEAD Check that the dowel pins (1) of intake camshaft (2) and exhaust camshaft (3) are positioned as shown. Tighten the bolts (1) to the specified torque in the numbered sequence in two or three steps. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) : Two bolts (6 ×...
  • Page 425 CYLINDER HEAD Hold the hexagonal part of exhaust camshaft (1) with a wrench or equivalent tool. Install the exhaust camshaft sprocket (2) by aligning its groove (3) with the dowel pin (4) of the exhaust camshaft. Apply engine oil to the threads and seating surface of the bolt and tighten it to the specified torque.
  • Page 426 CYLINDER HEAD Apply engine oil to new O-rings (1) and install them to the CMP sensor (2) and CMP hole plug (3). Install the CMP sensor and CMP hole plug to the No.5 rocker shaft holder (4) and tighten the two bolts (5). Connect the CMP sensor 3P connector (1) and install the harness band clip (2) to the clip bracket F (3).
  • Page 427 CYLINDER HEAD CYLINDER HEAD REMOVAL/ INSTALLATION REMOVAL • Remove the cylinder head when the engine is cold. • Be careful not to damage the gasket mating surfaces of cylinder head and cylinder block. Turn the crankshaft and set the No. 1 piston at top dead center of compression stroke (page 3-15).
  • Page 428 CYLINDER HEAD EXPLODED VIEW DOWEL PINS (14 × 20 mm) (2) CYLINDER HEAD GASKET CYLINDER HEAD CYLINDER HEAD BOLT (11 × 155 mm) (10) REUSED BOLT: 40 N·m (4.1 kgf·m, 30 lbf·ft) + 90°+ 90° NEW BOLT: 40 N·m (4.1 kgf·m, 30 lbf·ft) + 90°+ 90°+ 98° 14-36...
  • Page 429 CYLINDER HEAD INSTALLATION Turn the crankshaft and set the No. 1 piston at top dead center of compression stroke (page 3-15). Clean the cylinder head and cylinder block mating surfaces. Install the two dowel pins (1) to the cylinder block. Install a new cylinder head gasket (2) with its tab (3) positioned as shown.
  • Page 430 CYLINDER HEAD ROCKER ARM DISASSEMBLY/ ASSEMBLY • Identify parts before they are removed so they can be reinstalled in their original locations. • Check the rocker arm contacting surface of camshaft for wear or damage. Apply molybdenum disulfide oil to the intake and exhaust rocker shaft whole surfaces. EXHAUST INTAKE ROCKER ARM...
  • Page 431 CYLINDER HEAD CYLINDER HEAD DISASSEMBLY/ ASSEMBLY DISASSEMBLY Remove the cylinder head (page 14-35). Use an appropriate tool (1) that matches the diameter of the valve spring retainer. Attach the tool to the retainer and lightly tap the tool with a plastic hammer (2) to separate the valve keepers from the retainer.
  • Page 432 CYLINDER HEAD Remove the valve spring retainer (1), valve spring (2), valve (3), valve stem seal (4) and valve spring seat (5). Check the valve heads for chipping and excessive carbon deposits. Clean or replace the valves if necessary. • Identify each part so they can be reinstalled in their original locations.
  • Page 433 CYLINDER HEAD EXPLODED VIEW Apply oil to the following parts during assembly. Engine oil: • Valve stem seals (inner surface) Molybdenum disulfide oil: • Valve stem (sliding surface) EXHAUST VALVE SPRING VALVE KEEPERS STEM SEAL B SPRING RETAINERS VALVE SPRING Apply liquid sealant to the threads SEAT ( Threebond®...
  • Page 434 CYLINDER HEAD ASSEMBLY Note that valve stem seal A (intake side) (1) and B (exhaust side) (2) are different. Do not confuse them. SPRING (BLACK) SPRING (WHITE) Install the valve spring seat. Apply engine oil to the new valve stem seal (1) inner surface.
  • Page 435 CYLINDER HEAD Using an appropriate tool (1), lightly tap the end of each valve stem (2) two or three times with a plastic hammer to ensure proper seating of the valve and valve keepers. • Tap the valve stem only along its axis so you do not bend the stem.
  • Page 436 CYLINDER HEAD CYLINDER COMPRESSION TEST Set the remote control lever in the "N" (neutral) position. Remove the emergency stop switch clip. Remove the No. 1 spark plug (page 3-17). Install a compression gauge (commercially available) (1) in the No.1 plug hole. Disconnect the throttle control cable (1) from the throttle arm (2).
  • Page 437 CYLINDER HEAD CYLINDER HEAD INSPECTION VALVE SPRING FREE LENGTH Measure the free length of the valve springs. STANDARD: IN: 49.64 mm (1.954 in) EX: 49.64 mm (1.954 in) VALVE FACE/STEM O.D. Inspect each valve face (1) for pitting, wear, or irregularities.
  • Page 438 CYLINDER HEAD VALVE STEM-TO-VALVE GUIDE CLEARANCE Subtract each valve stem O.D. from the corresponding valve guide I.D. STANDARD: IN: 0.030 – 0.055 mm (0.0012 – 0.0022 in) EX: 0.055 – 0.080 mm (0.0022 – 0.0031 in) SERVICE LIMIT: IN: 0.080 mm (0.0031 in) EX: 0.110 mm (0.0043 in) If the stem-to-guide clearance exceeds the service limit, determine if the new guide with standard dimensions...
  • Page 439 CYLINDER HEAD ROCKER SHAFT O.D. Measure and record the rocker shaft O.D. at each rocker arm sliding area. STANDARD: IN/EX: 16.983 – 16.994 mm (0.6686 – 0.6691 in) Replace the rocker shaft if its O.D. is smaller than the service limit (page 14-38). ROCKER ARM I.D.
  • Page 440 CYLINDER HEAD CAM LOBE HEIGHT Wipe the camshaft clean, then inspect the cam lobes INTAKE and journals for damage. CAM CHAIN CAMSHAFT Clean the bearing and check the bearing for damage. Measure cam lobe height. STANDARD: 32.626 – 32.931 mm (1.2845 – 1.2965 in) 33.927 –...
  • Page 441 CYLINDER HEAD CAMSHAFT JOURNAL I.D. Install each journal onto the cylinder head and tighten them to the specified torque. Measure the I.D. of each camshaft journal. STANDARD: 29.000 – 29.024 mm (1.1417 – 1.1427 in) CAMSHAFT OIL CLEARANCE Clean off any oil from the camshafts, camshaft holders and rocker shaft holders.
  • Page 442 CYLINDER HEAD CAMSHAFT AXIAL CLEARANCE Install the rocker shaft holders, camshafts and camshaft (2) (facing up) holders and tighten the bolts to the specified torque (page 14-31). Put the camshaft (1) at top dead center of the compression stroke of the No. 1 piston (with the dowel pin (2) facing up) and set a dial indicator (3).
  • Page 443 CYLINDER HEAD CAMSHAFT RUNOUT Place V blocks (1) or equivalent under the journal at both ends of the camshaft. Set a dial indicator and measure the camshaft runout by turning the camshaft. STANDARD: 0.030 mm (0.0012 in) Max SERVICE LIMIT: 0.040 mm (0.0016 in) Replace the camshaft if the measurement exceeds the service limit (page 14-26).
  • Page 444 CYLINDER HEAD CYLINDER HEAD BOLT (11 × 155 mm) Measure the bolt O.D. at the two points as shown. 50 mm 45 mm STANDARD: 10.6 mm (0.417 in) Replace the cylinder head bolt if its O.D. is smaller than the service limit. Measure the O.D.
  • Page 445 CYLINDER HEAD Install new valve guides (1) from the valve spring side of the cylinder head. Drive each valve guide to the specified height, measured from the top of the valve guide to the cylinder head as shown. TOOL: Valve guide driver, 5.35 × 9.7 (2) 07742-0010100 Valve guide installation height: IN: 15.20 –...
  • Page 446 CYLINDER HEAD VALVE SEAT RECONDITIONING Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coat of Prussian Blue to each valve seats. Tap the valve against the valve seat several times without rotating the valve, to check for proper valve seat contact using a commercially available valve lapper (1).
  • Page 447 CYLINDER HEAD Using 32° cutter, remove the top edge of the existing valve seat material. OLD SEAT WIDTH 32° Using 60° cutter, remove the bottom edge of the old seat. OLD SEAT WIDTH 60° Use 45° cutter and cut the seat to the proper width. STANDARD: 1.25 –...
  • Page 448 CYLINDER HEAD After cutting the seat, apply lapping compound to the valve face and lap the valve using a commercially available valve lapper (1). • Excessive lapping pressure may deform or damage the seat. • Change the angle of lapping tool frequently to prevent uneven seat wear.

  • Page 449: Cylinder Block

    15. CYLINDER BLOCK COMPONENT LOCATION ··························15-2 BALANCER CASE DISASSEMBLY/ ASSEMBLY ··············································· 15-30 TOOLS·························································15-4 FLYWHEEL INSPECTION ························ 15-32 FLYWHEEL REMOVAL/INSTALLATION ···15-5 CRANKSHAFT/PISTON/CYLINDER BLOCK INSPECTION ······························· 15-32 CRANKCASE/BALANCER REMOVAL/ INSTALLATION···········································15-8 BEARING SELECTION····························· 15-43 CYLINDER BLOCK/CRANKSHAFT/ PISTON DISASSEMBLY/ASSEMBLY······15-15 15-1...

  • Page 450: Component Location

    CYLINDER BLOCK COMPONENT LOCATION CYLINDER BLOCK 12 N·m (1.2 kgf·m, 9 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 45 N·m (4.6 kgf·m, 33 lbf·ft) 118 N·m (12.0 kgf·m, 87 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) 45 N·m (4.6 kgf·m, 33 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 15-2...
  • Page 451 CYLINDER BLOCK 20 N·m (2.0 kgf·m, 15 lbf·ft) + 90° 30 N·m (3.1 kgf·m, 22 lbf·ft) + 56° 26 N·m (2.7 kgf·m, 19 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 128 N·m (13.1 kgf·m, 94 lbf·ft) 16 N·m (1.6 kgf·m, 12 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 15-3...

  • Page 452: Tools

    CYLINDER BLOCK TOOLS LIST Pin driver, 6.0 Driver Ring gear holder 07744-0010500 07749-0010000 070PB-ZY60100 Oil seal driver attachment, 80 × 96 mm 07ZAD-PNA0100 15-4...

  • Page 453: Flywheel Removal/Installation

    CYLINDER BLOCK FLYWHEEL REMOVAL/INSTALLATION REMOVAL Remove the oil pump (page 12-9). Set the special tool (1) on the starter motor mounting position and tighten the suitable bolts (2) and nuts (3). TOOL: Ring gear holder (1) 070PB-ZY60100 Remove the eight special bolts (4) and flywheel boss (5).

  • Page 454: Cylinder Block/Crankshaft/ Piston Disassembly/Assembly

    CYLINDER BLOCK EXPLODED VIEW CRANKSHAFT (Degrease) DOWEL PIN (14 x 20 mm) FLYWHEEL FLYWHEEL BOSS (Degrease) (Degrease) DOWEL PIN (10 x 16 mm) BOLT (12 mm) (8) 118 N·m (12.0 kgf·m, 87 lbf·ft) SPECIAL BOLT (8 mm) (8) 32 N·m (3.3 kgf·m, 24 lbf·ft) 15-6...
  • Page 455 CYLINDER BLOCK INSTALLATION Clean the mating surfaces between the crankshaft (1) and flywheel (2) with a degreasing cleaning agent, then set the flywheel on the crankshaft. Apply engine oil to the threads and seating surfaces of the eight bolts (12 mm) (3). Hand tighten the eight bolts.
  • Page 456 CYLINDER BLOCK CRANKCASE/BALANCER REMOVAL/ INSTALLATION REMOVAL Remove the following: – Main wire harness – Intake manifold (page 5-87) – Crankshaft pulley/cam chain (page 14-11) – Flywheel (page 15-5) – Fuel strainer (page 3-24) – Water separator (page 5-99) Remove the fifteen bolts (6×25 mm) (1) from the crankcase (2).
  • Page 457 CYLINDER BLOCK Remove the two chain guide bolts (1) and balancer chain guide (2). Remove the three bolts (6 × 14 mm) (3) and balancer chain tensioner (4). Remove the bolt (10 × 30 mm) (5), crankshaft sprocket (6), driven sprocket (7) and balancer chain (8). Remove the two bolts (10 ×...
  • Page 458 CYLINDER BLOCK EXPLODED VIEW BOLT (6 × 25 mm) (15) 12 N·m (1.2 kgf·m, 9 lbf·ft) CRANKCASE BOLT (6 × 14 mm) CABLE BRACKET O-RING BOLT (8 × 50 mm) OIL CAP 22 N·m (2.2 kgf·m, 16 lbf·ft) BOLT (8 × 20 mm) (2) BOLT (10 ×...
  • Page 459 CYLINDER BLOCK INSTALLATION Install the dowel pin (18 × 13 mm) (1), dowel pin (12 × 16 mm) (2) and balancer case assembly (3) to the cylinder block. Apply engine oil to the threads and seating surface of the bolts and tighten them to the specified torque. TORQUE: 45 N·m (4.6 kgf·m, 33 lbf·ft) : TWO BOLTS (10 ×...

  • Page 460: Balancer Case Disassembly

    CYLINDER BLOCK Align the rear balancer shaft boss (1) with the index mark (2) of balancer case. Hold the rear balancer shaft (3) by inserting a special tool (4) into the shaft through the maintenance hole (5). TOOL: Pin driver 6.0 (4) 07744-0010500 Install the balancer chain to the crankshaft sprocket by aligning its color plate (one place) (1) with the index...
  • Page 461 CYLINDER BLOCK Install the balancer chain guide (1) to the cylinder block (2) and tighten the two chain guide bolts (3) to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Push the balancer chain tensioner (1) against the balancer chain (2) and install it to the rear balancer holder (3).
  • Page 462 CYLINDER BLOCK Install the crankshaft pulley/cam chain (page 14-17). Clean the crankcase and lower block mating surfaces 2.0 - 3.0 mm thoroughly with degreasing agent. (0.08 - 0.12 in) Apply 2.0 – 3.0 mm (0.08 – 0.12 in) bead of liquid sealant (Threebond®...
  • Page 463 CYLINDER BLOCK CYLINDER BLOCK/CRANKSHAFT/ PISTON DISASSEMBLY/ASSEMBLY CYLINDER BLOCK/CRANKSHAFT DISASSEMBLY Remove the following: – Cylinder head (page 14-35) – Crankcase/balancer (page 15-8) – Oil filter flange (page 12-5) – Knock sensor (page 5-119) – EOP sensor (page 5-119) – ECT sensor 1 (page 5-116) –...
  • Page 464 CYLINDER BLOCK Remove the following parts from the cylinder block (1): – Lower block (2) – Oil seal (3) – Dowel pin (18 × 22 mm) (4) – Ten dowel pins (13 × 14 mm) (5) Remove the five lower main bearings (1) from the lower block.
  • Page 465 CYLINDER BLOCK Remove the connecting rod bolts (1) and connecting rod caps (2) of each cylinder. • Store the removed parts separately for each cylinder. Remove the connecting rod bearings (3) and dowel pins (4) of each cylinder. Remove the crankshaft (1) and two thrust washers (2), taking care not to damage the journal.
  • Page 466 CYLINDER BLOCK Remove the connecting rod bearing (1) from the connecting rod (2). • Check the connecting rod bearing for damage (scores, scratches, etc.) and replace it with a new one if necessary. PISTON DISASSEMBLY Remove the piston ring (1) using a piston ring expander (commercially available) (2).
  • Page 467 CYLINDER BLOCK Wearing heavy gloves, heat the piston and connecting rod assembly to approximately 70 °C (158 °F), and then remove the piston pin (1). Check the piston parts (page 15-32). 15-19...
  • Page 468 CYLINDER BLOCK EXPLODED VIEW BOLT (8 × 35 mm) (10) 26 N·m (2.7 kgf·m, 19 lbf·ft) LOWER MAIN BEARING (5) BOLT (8 × 50 mm) (4) 26 N·m (2.7 kgf·m, 19 lbf·ft) BOLT(11 × 95 mm) (10) OIL SEAL 30 N·m (3.1 kgf·m, 22 lbf·ft) + 56° (80 ×...
  • Page 469 CYLINDER BLOCK TOP RING (4) SECOND RING (4) PISTON PIN CLIP (8) PISTON RINGS SIDE RAIL (8) SPACER (4) PISTON (4) CONNECTING ROD (4) PISTON PIN (4) DOWEL PIN (10 × 12 mm) (8) CONNECTING ROD BEARING (8) CONNECTIN ROD CAP (4) CONNECTING ROD BOLT (8) 20 N·m (2.0 kgf·m, 15 lbf·ft) + 90°...
  • Page 470 CYLINDER BLOCK PISTON ASSEMBLY Install the piston pin clip (1) on one side only. • Wear eye protection as the piston pin clips can pop out during installation. • Make sure the piston pin clip does not align with the cutout in the piston pin bore.
  • Page 471 CYLINDER BLOCK Install the piston rings in the ring grooves of the piston (1) with the marks on the top ring (2) and second ring (3) facing up. • Clean the ring grooves thoroughly before installing the piston rings. • Install the piston rings with care not to break the piston rings.
  • Page 472 CYLINDER BLOCK Stagger the piston ring end gaps as shown (top ring) (1), second ring (2), side rail (top side) (3), spacer (4), and side rail (skirt side) (5). Do not align with the piston pin, and avoid the direction that makes a right angle with the piston pin.
  • Page 473 CYLINDER BLOCK Apply molybdenum disulfide oil to the connecting rod bearing surface (1). Install the connecting rod bearing to the connecting rod by aligning the tab (2) of the connecting rod bearing with the groove (3) of the connecting rod. Apply molybdenum disulfide oil to the piston (1) outer surface, piston rings, oil rings and cylinder sleeve inner surface.
  • Page 474 CYLINDER BLOCK Install the connecting rod bearing (1) to the connecting rod (2) by aligning the tab (3) of the connecting rod bearing with the groove (4) of the connecting rod. Apply molybdenum disulfide oil to the connecting rod bearing surface. Apply molybdenum disulfide oil to the crankshaft main journal, crank pin, thrust washer contacting surfaces.
  • Page 475 CYLINDER BLOCK Install the connecting rod bearing (1) to the connecting rod cap (2) by aligning the tab (3) of the connecting rod bearing with the groove (4) of the connecting rod cap. Install the two dowel pins (5). Apply molybdenum disulfide oil to the connecting rod bearing surface.
  • Page 476 CYLINDER BLOCK Clean the crankcase (1) and lower block (2) mating surfaces thoroughly with degreasing agent. Apply 2.0 – 3.0 mm (0.08 – 0.12 in) bead of liquid sealant (Threebond® 1280B or equivalent) to the indicated area of lower block mating surface. •...
  • Page 477 CYLINDER BLOCK Apply engine oil to the threads and seating surface of the ten bolts (8 × 35 mm) (1) and four bolts (8 × 50 mm) (2), then install them. Tighten the ten bolts in the numbered sequence shown. Tighten them in two or three steps to the specified torque.
  • Page 478 CYLINDER BLOCK BALANCER CASE DISASSEMBLY/ ASSEMBLY DISASSEMBLY Remove the balancer case (page 15-8). BOLT (6 × 32 mm) (3) 12 N·m (1.2 kgf·m, 9 lbf·ft) BOLT (8 × 55 mm) (3) 28 N·m (2.9 kgf·m, 21 lbf·ft) BOLT (6 × 25 mm) (2) 12 N·m (1.2 kgf·m, 9 lbf·ft) REAR BALANCER HOLDER REAR BALANCER SHAFT...
  • Page 479 CYLINDER BLOCK ASSEMBLY Install the four balancer shaft bearings (1) to the front balancer holder (2) and rear balancer holder (3) by aligning the tab (4) of the bearing with the groove (5) of the holders. Apply molybdenum disulfide oil to the balancer shaft journal surface.

  • Page 480: Flywheel Inspection

    CYLINDER BLOCK FLYWHEEL INSPECTION Inspect the ring gear (1) of the flywheel (2) for wear or damage. If it is worn or damaged, inspect the starter motor pinion gear (page 9-15). CRANKSHAFT/PISTON/CYLINDER BLOCK INSPECTION PISTON SKIRT O.D. Check the piston outer surface for damage (scores, scratches, etc.), warpage and cracks.
  • Page 481 CYLINDER BLOCK CYLINDER SLEEVE I.D. Check the cylinder sleeve inner surface for damage (scores, scratches, etc.). Measure and record the cylinder I.D. at three levels in both X and Y axis. Take the maximum reading to determine the cylinder wear. Note the identification codes (1) as shown.
  • Page 482 CYLINDER BLOCK PISTON RING GROOVE WIDTH Measure the piston ring groove width. STANDARD: TOP: 1.230 – 1.240 mm (0.0484 – 0.0488 in) SECOND: 1.240 – 1.250 mm (0.0488 – 0.0492 in) OIL: 2.005 – 2.025 mm (0.0789 – 0.0797 in) SERVICE LIMIT: SECOND TOP:...
  • Page 483 CYLINDER BLOCK PISTON PIN BORE I.D. Measure the piston pin bore I.D.at the both sides of the piston. Take the largest measurement to determine the piston pin bore I.D. STANDARD: 21.960 – 21.963 mm (0.8646 – 0.8647 in) PISTON PIN O.D. Check the piston pin outer surface for damage.
  • Page 484 CYLINDER BLOCK CONNECTING ROD SMALL END-TO- PISTON PIN CLEARANCE Subtract each piston pin O.D. from the corresponding connecting rod small end I.D. STANDARD: 0.005 – 0.015 mm (0.0002 – 0.0006 in) SERVICE LIMIT: 0.020 mm (0.0008 in) CONNECTING ROD BIG END AXIAL CLEARANCE Measure the connecting rod big end axial clearance.
  • Page 485 CYLINDER BLOCK CRANKSHAFT MAIN JOURNAL O.D. Measure the crankshaft main journal O.D. STANDARD: No. 1, 2, 4, 5 (1): 54.984 – 55.008 mm (2.1647 – 2.1657 in) No. 3 (2): 54.976 – 55.000 mm (2.1644 – 2.1654 in) CRANK PIN O.D. Measure the crank pin (1) O.D.
  • Page 486 CYLINDER BLOCK CRANKSHAFT AXIAL CLEARANCE Measure the crankshaft axial clearance. STANDARD: 0.10 – 0.35 mm (0.004 – 0.014 in) SERVICE LIMIT: 0.45 mm (0.018 in) If the measurement exceeds the service limit, check the thrust washers and the thrust surface of the cylinder block.
  • Page 487 CYLINDER BLOCK CRANKSHAFT RUNOUT Install the No.1 main bearing (1) and No.5 main bearing (2) to the cylinder block (3). Install the crankshaft (4) to the cylinder block. Measure the crankshaft runout. STANDARD: 0.030 mm (0.0012 in) Max SERVICE LIMIT: 0.040 mm (0.0016 in) 15-39...
  • Page 488 CYLINDER BLOCK MATING SURFACE WITH CYLINDER HEAD WARPAGE Take care not to damage (scores, scratches, etc.) the MEASUREMENT POINTS mating surface with the gasket. Measure the surface warpage using a straight edge (1) and a feeler gauge (2) as shown. STANDARD: 0.07 mm (0.003 in) Max SERVICE LIMIT:...
  • Page 489 CYLINDER BLOCK CRANKSHAFT MAIN BEARING OIL CLEARANCE To check main bearing-to-journal oil clearance, remove the lower block, crankshaft, and main bearings (page 15-15). Clean each main journal and main bearings and check for wear or damage. Install the main bearings, crankshaft and lower block to the cylinder block, and tighten the bolts to the specified torque (page 15-24).
  • Page 490 CYLINDER BLOCK CONNECTING ROD BEARING OIL CLEARANCE To check connecting rod bearing-to-crank pin oil clearance, remove the connecting rod bearing caps, crankshaft, and connecting rod bearings (page 15-15). Clean each crank pin and connecting rod bearing and check for wear or damage. Set the crankshaft to the cylinder block, install the connecting rod caps and tighten the connecting rod bolts to the specified torque (page 15-24).

  • Page 491: Bearing Selection

    CYLINDER BLOCK BEARING SELECTION 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 letters and/or numbers are not clear, clean the areas with a cleaning solvent and check again.
  • Page 492 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 1 or I 2 or II 3 or III 4 or IIII code letter Bearing I.D.
  • Page 493 CYLINDER BLOCK CRANKSHAFT MAIN BEARING • When replacing the main bearing, check the crankshaft main journal code number and the cylinder block I.D. code letter or number, and select the correct bearing by referring to the bearing selection table. • If the code letter and/or number is not clear, clean the area with a cleaning solvent and check again.
  • Page 494 CYLINDER BLOCK Select the correct bearing by referring to the cylinder block I.D. code letter or number and the crankshaft main journal code number. Crankshaft main bearing selection table Cylinder block I.D. code number or letter Crankshaft main journal code 1 or A or I 2 or B or II 3 or C or III...
  • Page 495 16. GEAR CASE (STANDARD ROTATION) COMPONENT LOCATION ··························16-2 VERTICAL SHAFT REMOVAL/ INSTALLATION ········································ 16-29 TOOLS·························································16-3 PROPELLER SHAFT HOLDER DISASSEMBLY/ASSEMBLY ···················· 16-34 PROPELLER REMOVAL/ INSTALLATION···········································16-6 VERTICAL SHAFT DISASSEMBLY/ ASSEMBLY ··············································· 16-35 ANODE METAL/WATER SCREEN REMOVAL/INSTALLATION························16-7 SHIM SELECTION ···································· 16-38 GEAR CASE REMOVAL/ INSTALLATION···········································16-8 BACKLASH INSPECTION························...
  • Page 496 GEAR CASE (STANDARD ROTATION) COMPONENT LOCATION GEAR CASE (STANDARD ROTATION) 34 N·m (3.5 kgf·m, 25 lbf·ft) 83 N·m (8.5 kgf·m, 61 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 1 N·m (0.1 kgf·m, 0.7 lbf·ft) MAX. TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft) 16-2...
  • Page 497 GEAR CASE (STANDARD ROTATION) TOOLS LIST Driver, 480 mm Bearing race puller Attachment, 30 x 37 mm 070GD-0010100 070PC-ZY30100 070PD-ZY60200 Taper bearing installer attachment Gauge adapter, 100 mm Remover weight 070PF-ZY60100 070PJ-ZY30100 07741-0010201 Attachment, 42 x 47 mm Attachment, 62 x 68 mm Pilot, 25 mm 07746-0010300 07746-0010500...
  • Page 498 GEAR CASE (STANDARD ROTATION) Remover handle Bearing remover, 30 mm Bearing driver attachment, 07936-3710100 07936-8890300 44 x 49.5 mm 07945-3330300 Oil seal driver, 44.5 mm Oil seal driver attachment, 21 mm Oil seal driver attachment, 07947-SB00100 07947-ZV00100 27.5 x 44 mm 07948-9540000 Driver, 280 mm Driver shaft, B...
  • Page 499 GEAR CASE (STANDARD ROTATION) Puller bolt Backlash indicator tool Installer shaft, 15 x 370 mm 07SPC-ZW0011Z 07SPJ-ZW0030Z 07VMF-KZ30200 Backlash indicator attachment Bearing remover attachment, 37 mm Pressure tester S-34 07WPK-ZW50100 07ZMD-MBW0200 07APJ-001A100 Adapter 07APJ-001A300 16-5...
  • Page 500 GEAR CASE (STANDARD ROTATION) PROPELLER REMOVAL/ INSTALLATION SPLIT PIN (4.0 mm) Be sure to use a Honda genuine part (stainless steel). Bend the pin ends as shown to secure the nut. SPLIT PIN (4.0 mm) PROPELLER THRUST WASHER Install the propeller thrust washer in the direction as shown.
  • Page 501 GEAR CASE (STANDARD ROTATION) ANODE METAL/WATER SCREEN REMOVAL/INSTALLATION ANODE METAL (2) BOLT (6 x 50 mm) WATER SCREEN (2) SCREW (5 x 50 mm) 1 N·m (0.1 kgf·m, 0.7 lbf·ft) SELF-LOCKING NUT (6 mm) SELF-LOCKING NUT (5 mm) 16-7...
  • Page 502 GEAR CASE (STANDARD ROTATION) GEAR CASE REMOVAL/INSTALLATION REMOVAL Set the remote control lever in the "N" (Neutral) position. Tilt up the motor to the uppermost position. Remove the bolt (10 × 32 mm) (1) and trim tab (2). Remove the seven bolts (10 × 40 mm) (3) while supporting the gear case (4).
  • Page 503 GEAR CASE (STANDARD ROTATION) INSTALLATION Set the remote control lever in the "N" (Neutral) position. Check that the cutout (1) of the shift rod (2) spline faces the cruising direction (3) (this position is "N" (Neutral)). If the cutout of the spline is not in the cruising direction, protect the spline with a shop towel (4) and turn the shift rod right or left with a wrench until the cutout faces toward the cruising direction.
  • Page 504 GEAR CASE (STANDARD ROTATION) Apply marine grease to the vertical shaft (1) spline area and water tube seal ling (2). (3): XC/XD/XU types only: Apply marine grease to the vertical shaft bushing (3) inner surface. (XC, XD and XU types only) Install the two dowel pins (4) to the gear case (5).
  • Page 505 GEAR CASE (STANDARD ROTATION) VERTICAL SHAFT BUSHING REMOVAL/INSTALLATION (XC, XD and XU type only) Remove the gear case (page 16-8). Remove the internal circlip (1), washer (2) and vertical shaft bushing (3). Inspect the vertical shaft bushing (page 16-50) and replace if necessary.
  • Page 506 GEAR CASE (STANDARD ROTATION) EXTENSION CASE REMOVAL/ INSTALLATION REMOVAL Remove the following: – L. engine under cover (page 6-4) – R. engine under cover (page 6-10) – Gear case (page 16-8) Remove the three bolts (8 × 30 mm) (1) and lower mount housing (2).
  • Page 507 GEAR CASE (STANDARD ROTATION) EXPLODED VIEW EXTENSION CASE GROMMET BOLT (12 × 225 mm) (2) LOWER MOUNT COLLAR (2) LOWER RUBBER MOUNT (2) BOLT (6 × 12 mm) GROUND TERMINAL DOWEL PIN (6 × 10 mm) (2) WASHER (12 mm) (4) SELF-LOCKING NUT LOWER MOUNT (12 mm) (2)
  • Page 508 GEAR CASE (STANDARD ROTATION) INSTALLATION Apply marine grease to the extension case grommet (1) inner surface and install it to the extension case (2) as shown. Install the two dowel pins (3) to the extension case. Clean the mating surfaces of the extension case (1) and oil case using a degreasing agent.
  • Page 509 GEAR CASE (STANDARD ROTATION) Install the lower rubber mount (1) and lower mount collar (2) while holding the extension case. • Install the lower mount collar with the smaller diameter side toward the lower rubber mount. • Install the lower rubber mount with the "OUT" mark toward out.
  • Page 510 GEAR CASE (STANDARD ROTATION) Remove the bolt (1) and washer (2). Remove the shift rod holder (3) and shift rod (4). Remove the two water seals (1) and O-ring (2) from the shift rod holder (3). Remove the shift rod spring (1), washer (2) and E-ring (3) from the shift rod (4).
  • Page 511 GEAR CASE (STANDARD ROTATION) EXPLODED VIEW SHIFT ROD HOLDER WATER SEAL (12 x 21 x 6 mm) (2) O-RING (55.6 x 3.5 mm) WASHER (12 mm) SHIFT ROD SPRING E-RING (10 mm) END NIPPLE SHIFT ROD WIRE BAND (2) SPEED SENSOR TUBE B SENSOR NIPPLE 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
  • Page 512 GEAR CASE (STANDARD ROTATION) INSTALLATION Install the E-ring (1), washer (2), and shift rod spring (3) onto the shift rod (4). • Do not reuse the E-ring if it is deformed or deteriorated. • Check that the E-ring is set in the groove in the shift rod securely.
  • Page 513 GEAR CASE (STANDARD ROTATION) Apply marine grease to the mating surfaces and soapy water to the circumference of the new water seals (1). Drive the water seals into the shift rod holder (2) using the special tools in the correct direction as shown. TOOL: Driver (3) 07749-0010000...
  • Page 514 GEAR CASE (STANDARD ROTATION) Install the shift rod holder (1) into the gear case by aligning the projection (2) of the shift rod holder with the recess (3) of the gear case. Install the washer (4) and tighten the bolt (5). After installation, check that the cutout (6) in the shift rod splines is in the cruising direction (7).
  • Page 515 GEAR CASE (STANDARD ROTATION) PROPELLER SHAFT HOLDER REMOVAL/INSTALLATION Remove the following: – Propeller (page 16-6) – Gear case (page 16-8) – Shift rod (page 16-15) Remove the two bolts (1) and two washers (2). Insert a screwdriver or equivalent tool into the recess (3) in the propeller shaft holder (4) and remove the propeller shaft holder from the gear case (5).
  • Page 516 GEAR CASE (STANDARD ROTATION) SHIFT SLIDER/BEARING HOLDER/ PROPELLER SHAFT REMOVAL/ INSTALLATION SHIFT SLIDER REMOVAL Remove the propeller shaft holder (page 16-21). Remove the cross pin ring (1), shifter pin (2) and clutch shifter (3). Remove the shift slider (1) and two steel balls (#7) (2) from the propeller shaft (3), being careful not to lose the steel balls.
  • Page 517 GEAR CASE (STANDARD ROTATION) Remove the shift plate (1) from the shift slider (2), then remove the two shift springs (3) and two steel balls (#9) (4). • Take care not to let the shift springs and steel balls (#9) pop out of the shift slider during removal of the shift plate.
  • Page 518 GEAR CASE (STANDARD ROTATION) Remove the two water seals (1) from the propeller shaft holder (2) using a commercially available oil seal remover. Set a commercially available universal bearing puller (1) between the reverse bevel gear (2) and bearing (3). Remove the bearing from the reverse bevel gear using the special tools and hydraulic press.
  • Page 519 GEAR CASE (STANDARD ROTATION) EXPLODED VIEW SHIFT SLIDER SHIFT SPRING (2) CROSS PIN RING STEEL BALL (#9) (2) ROLLER SHIFT SHIFTER PIN PLATE CLUTCH SHIFTER CIRCLIP (14 mm) STEEL BALL (#7) (2) REVERSE BEVEL GEAR PROPELLER SHAFT RADIAL BALL BEARING (50 x 90 x 20 mm) THRUST BEARING...
  • Page 520 GEAR CASE (STANDARD ROTATION) PROPELLER SHAFT INSTALLATION Apply gear oil to the circumference of a new bearing (1). Install the bearing to the reverse bevel gear (2) using the special tools and hydraulic press. TOOLS: Driver (3) 07749-0010000 Attachment, 62 × 68 mm (4) 07746-0010500 Pilot, 35 mm (5) 07746-0040800...
  • Page 521 GEAR CASE (STANDARD ROTATION) Apply gear oil to the circumference of the thrust bearing (1). Soak the propeller shaft holder (2) in a container filled with oil with its reverse bevel gear installation side (3) facing down as shown. Heat the oil to 80 – 90°C (176 – 194°F). •...
  • Page 522 GEAR CASE (STANDARD ROTATION) Set the two steel balls (#7) (1) in the steel ball installation holes of the shift slider (2), and push the shift slider slowly into the propeller shaft (3). • Push the shift slider into the propeller shaft with care not to allow the steel balls (#7) to pop out.
  • Page 523 GEAR CASE (STANDARD ROTATION) Install the cross pin ring (1) onto the clutch shifter (2). • Check that the coils of the cross pin ring do not overlap with each other. Check that the steel balls (#7) (1) are positioned in the groove (2) of the propeller shaft (3) as shown.
  • Page 524 GEAR CASE (STANDARD ROTATION) Remove the forward bevel gear/taper bearing (1). Remove the eighteen needle bearing rollers (2). Set a commercially available universal bearing puller (1) between the taper bearing (inner race) and forward bevel gear. Remove the taper bearing (inner race) from the forward bevel gear using the special tools and hydraulic press.

  • Page 525: Gear Case (Standard Rotation)

    GEAR CASE (STANDARD ROTATION) EXPLODED VIEW LOCK NUT (64 mm) Engine side: 123 N·m (12.5 kgf·m, 91 lbf·ft) VERTICAL SHAFT FORWARD BEVEL GEAR GEAR CASE NEEDLE BEARING (OUTER RING) TAPER BEARING (50 x 90 x 28 mm) PINION GEAR PINION GEAR NUT 142 N·m (14.5 kgf·m, 105 lbf·ft) NEEDLE BEARING...
  • Page 526 GEAR CASE (STANDARD ROTATION) INSTALLATION • When the gear case or the taper bearing have been replaced with new ones, perform shim adjustment and select the appropriate shim accordingly (page 16-38). Soak the gear case (1) in a container (2) filled with oil with its bearing installation side facing down as shown.
  • Page 527 GEAR CASE (STANDARD ROTATION) Apply marine grease to the needle bearing rollers (1) and install them into the needle bearing outer ring (2). Install the forward bevel gear/taper bearing (3). Install the vertical shaft (1) into the gear case (2). Apply gear oil to the threads and seating surface of the lock nut (3).
  • Page 528 GEAR CASE (STANDARD ROTATION) Wipe the tapered part (1) of the vertical shaft (2) and pinion gear (3) with a shop towel and degreasing cleaning solvent. Attach the special tool to the end (flywheel boss installation side) of the vertical shaft as shown. TOOL: Vertical shaft holder (4) 07SPB-ZW10200...
  • Page 529 GEAR CASE (STANDARD ROTATION) ASSEMBLY Apply gear oil to the outer circumference of a new needle bearing (30 x 37 x 26 mm) (1). Install the needle bearing into the propeller shaft holder (2) until the specified depth, using the special tools and hydraulic press.
  • Page 530 GEAR CASE (STANDARD ROTATION) Check the taper roller bearing for abnormal sound and play. Replace the inner race and outer race as a set if necessary. Set a commercially available universal bearing puller (1) under the taper roller bearing (inner race) (2) and set the vertical shaft (3) on the hydraulic press with the flywheel boss installation side facing up.
  • Page 531 GEAR CASE (STANDARD ROTATION) ASSEMBLY Set the pinion gear (1) onto the vertical shaft (2), and loosely tighten the pinion gear nut (3) by hand. Apply gear oil to the inner wall of the taper roller bearing inner races (4), rollers and outer circumference of the outer race (5).

  • Page 532: Gear Case (Counter Rotation)

    GEAR CASE (STANDARD ROTATION) 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, gear or bearing with a new one.
  • Page 533 GEAR CASE (STANDARD ROTATION) PINION GEAR SHIM Clean the tapered surfaces (1) of the vertical shaft (2) and pinion gear (3) thoroughly using a shop towel and degreasing cleaning agent. Install the pinion gear onto the vertical shaft. Tighten the pinion gear nut (4) to the specified torque using the special tool.
  • Page 534 GEAR CASE (STANDARD ROTATION) Hold the vertical shaft (1) upright with the pinion gear facing up. Set a commercially available depth gauge (2) in the groove (3) of the pinion gear side special tool (4) as shown. Measure the length (D) from the pinion gear end to the end of the vertical shaft flange and record the measurement.
  • Page 535 GEAR CASE (STANDARD ROTATION) Measure the height (E’’) of the taper roller bearing outer MEASUREMENT E ’’ : race (1) using a depth gauge (2) or vernier caliper (3), and record it. Calculate the length from the inner race end to the outer race end (E) by determining the gap between the measurements E’...
  • Page 536 GEAR CASE (STANDARD ROTATION) Remove the trim tab (page 16-8). Record the engagement mark (1) located on the trim tab installation part of the gear case (2). Cross reference the engagement mark and tolerance calculated in the previous step, and refer to the pinion gear shim selection table to determine the required thickness of the shim (Sp).
  • Page 537 GEAR CASE (STANDARD ROTATION) HOW TO READ SHIM SELECTION TABLE When the engagement mark on the gear case housing is C and tolerance is -0.05 mm (-0.002 in), the shim selection table shows that the required shim thickness is 0.55 mm (0.022 in). (See the table shown below). Pinion gear shim selection table Unit: mm Calculation value...
  • Page 538 GEAR CASE (STANDARD ROTATION) Remove the trim tab (page 16-8). Record the engagement mark (1) located on the trim tab installation part of the gear case (2). Cross reference the engagement mark and tolerance calculated in the previous step, and refer to the forward bevel gear shim selection table to determine the required thickness of the shim (Sf).
  • Page 539 GEAR CASE (STANDARD ROTATION) BACKLASH INSPECTION FORWARD BEVEL GEAR BACKLASH Backlash adjustment must be made after adjustment of each gear shim (page 16-38). Install the following parts except the water pump. – Vertical shaft (page 16-29) – Propeller shaft holder (page 16-21) –...
  • Page 540 GEAR CASE (STANDARD ROTATION) Obtain the forward bevel gear backlash using the dial indicator runout and the following formula. Formula: Backlash = Dial gauge runout ÷ 0.86 Example: When dial gauge runout is 0.175 mm (0.0069 in), Backlash = 0.175 mm (0.0069 in) ÷ 0.86 = 0.20 mm (0.008 in) STANDARD VALUE: 0.10 –...
  • Page 541 GEAR CASE (STANDARD ROTATION) GEAR CASE PRESSURE INSPECTION • Perform the gear case pressure check and check for pressure leakage after disassembling reassembling the gear case. • In principle, the pressure check should be made on the gear case before filling it with gear oil and before installing it on the outboard motor.
  • Page 542 GEAR CASE (STANDARD ROTATION) While applying the specified air pressure to the gear case, turn the vertical shaft (1) five or six turns clockwise. Be sure to turn the vertical shaft clockwise, or damage to the water pump impeller can occur. While applying the specified air pressure to the gear case, turn the propeller shaft (1) right and left two or three turns.
  • Page 543 GEAR CASE (STANDARD ROTATION) PROPELLER SHAFT INSPECTION PROPELLER SHAFT O.D. Measure the O.D. of the propeller shaft at the forward bevel gear area (1) and needle bearing area (2). STANDARD: At forward bevel gear: 24.987 – 25.000 mm (0.9837 – 0.9843 in) At needle bearing: 30.007 –...
  • Page 544 GEAR CASE (STANDARD ROTATION) VERTICAL SHAFT RUNOUT Support each journal with V-blocks as shown. *1:557 mm (21.9 in) Set the dial indicator and measure the vertical shaft 124 mm runout while turning the shaft. *2:684 mm (26.9 in) (4.9 in) STANDARD: 0.30 mm (0.012 in) or below *1:350 mm (13.8 in)
  • Page 545 GEAR CASE (STANDARD ROTATION) Apply gear oil to the outer circumference of a new needle bearing (28.575 x 44.45 x 31.75 mm) (1). Install the needle bearing into the gear case (2) using the special tools. • Install the needle bearing with the stamped side facing down (facing the special tool side).
  • Page 546 MEMO...
  • Page 547 17. GEAR CASE (COUNTER ROTATION) COMPONENT LOCATION ··························17-2 BEARING HOLDER DISASSEMBLY/ ASSEMBLY ··············································· 17-34 TOOLS·························································17-3 PROPELLER SHAFT HOLDER DISASSEMBLY/ASSEMBLY ···················· 17-36 PROPELLER REMOVAL/ INSTALLATION···········································17-6 VERTICAL SHAFT DISASSEMBLY/ ASSEMBLY ··············································· 17-37 ANODE METAL/WATER SCREEN REMOVAL/INSTALLATION························17-7 SHIM SELECTION ···································· 17-40 GEAR CASE REMOVAL/ INSTALLATION···········································17-8 BACKLASH INSPECTION························...
  • Page 548 GEAR CASE (COUNTER ROTATION) COMPONENT LOCATION GEAR CASE (COUNTER ROTATION) 34 N·m (3.5 kgf·m, 25 lbf·ft) 83 N·m (8.5 kgf·m, 61 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 1 N·m (0.1 kgf·m, 0.7 lbf·ft) MAX. TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft) 17-2...
  • Page 549 GEAR CASE (COUNTER ROTATION) TOOLS LIST Bearing race puller Taper bearing driver attachment Attachment, 30 x 37 mm 070PC-ZY30100 070PD-ZY60100 070PD-ZY60200 Taper bearing installer attachment Gauge adapter, 100 mm Remover weight 070PF-ZY60100 070PJ-ZY30100 07741-0010201 Attachment, 52 × 55 mm Attachment, 62 x 68 mm Pilot, 25 mm 07746-0010400 07746-0010500...
  • Page 550 GEAR CASE (COUNTER ROTATION) Remover handle Bearing remover, 30 mm Bearing driver attachment, 07936-3710100 07936-8890300 44 x 49.5 mm 07945-3330300 Oil seal driver, 44.5 mm Oil seal driver attachment, 21 mm Oil seal driver attachment, 07947-SB00100 07947-ZV00100 27.5 x 44 mm 07948-9540000 Driver, 280 mm Driver shaft, B...
  • Page 551 GEAR CASE (COUNTER ROTATION) Puller bolt Backlash indicator tool Installer shaft, 15 x 370 mm 07SPC-ZW0011Z 07SPJ-ZW0030Z 07VMF-KZ30200 Pin spanner wrench, 110 mm Puller jaws, 25 mm Backlash indicator attachment 07WAA-S1G0100 07WPC-ZW50100 07WPK-ZW50100 Bearing remover attachment, 37 mm Pressure tester S-34 Adapter 07ZMD-MBW0200 07APJ-001A100...
  • Page 552 GEAR CASE (COUNTER ROTATION) PROPELLER REMOVAL/ INSTALLATION SPLIT PIN (4.0 mm) Be sure to use a Honda genuine part (stainless steel). Bend the pin ends as shown to secure the nut. SPLIT PIN (4.0 mm) PROPELLER THRUST WASHER Install the propeller thrust washer in the direction as shown.
  • Page 553 GEAR CASE (COUNTER ROTATION) ANODE METAL/WATER SCREEN REMOVAL/INSTALLATION ANODE METAL (2) BOLT (6 x 50 mm) WATER SCREEN (2) SCREW (5 x 50 mm) 1 N·m (0.1 kgf·m, 0.7 lbf·ft) SELF-LOCKING NUT (6 mm) SELF-LOCKING NUT (5 mm) 17-7...
  • Page 554 GEAR CASE (COUNTER ROTATION) GEAR CASE REMOVAL/INSTALLATION REMOVAL Set the remote control lever in the "N" (Neutral) position. Tilt up the motor to the uppermost position. Remove the bolt (10 × 32 mm) (1) and gear case cover (2). Remove the seven bolts (10 × 40 mm) (3) while supporting the gear case (4).
  • Page 555 GEAR CASE (COUNTER ROTATION) INSTALLATION Set the remote control lever in the "N" (Neutral) position. Check that the cutout (1) of the shift rod (2) spline faces the cruising direction (3) (this position is "N" (Neutral)). If the cutout of the spline is not in the cruising direction, protect the spline with a shop towel (4) and turn the shift rod right or left with a wrench until the cutout faces toward the cruising direction.
  • Page 556 GEAR CASE (COUNTER ROTATION) Apply marine grease to the vertical shaft (1) spline area, vertical shaft bushing (2) inner surface and water tube seal ling (3). Install the two dowel pins (4) to the gear case (5). Install the gear case by aligning the spline cutout (6) of the shift rod (7) with the spline projection (8) of the shift rod A (9).
  • Page 557 GEAR CASE (COUNTER ROTATION) VERTICAL SHAFT BUSHING REMOVAL/INSTALLATION Remove the gear case (page 17-8). Remove the internal circlip (1), washer (2) and vertical shaft bushing (3). Inspect the vertical shaft bushing (page 17-54) and replace if necessary. Install the vertical shaft bushing to the extension case (4) with its groove (5) facing up.
  • Page 558 GEAR CASE (COUNTER ROTATION) EXTENSION CASE REMOVAL/ INSTALLATION REMOVAL Remove the following: – L. engine under cover (page 6-4) – R. engine under cover (page 6-10) – Gear case (page 17-8) Remove the three bolts (8 × 30 mm) (1) and lower mount housing (2).
  • Page 559 GEAR CASE (COUNTER ROTATION) EXPLODED VIEW EXTENSION CASE GROMMET BOLT (12 × 225 mm) (2) LOWER MOUNT COLLAR (2) LOWER RUBBER MOUNT (2) BOLT (6 × 12 mm) GROUND TERMINAL WASHER (12 mm) (4) DOWEL PIN (6 × 10 mm) (2) LOWER MOUNT HOUSING (2) SELF-LOCKING NUT...
  • Page 560 GEAR CASE (COUNTER ROTATION) INSTALLATION Apply marine grease to the extension case grommet (1) inner surface and install it to the extension case (2) as shown. Install the two dowel pins (3) to the extension case. Clean the mating surfaces of the extension case (1) and 10 - 15 mm oil case using a degreasing agent.
  • Page 561 GEAR CASE (COUNTER ROTATION) Install the lower rubber mount (1) and lower mount collar (2) while holding the extension case. • Install the lower mount collar with the smaller diameter side toward the lower rubber mount. • Install the lower rubber mount with the "OUT" mark toward out.
  • Page 562 GEAR CASE (COUNTER ROTATION) Remove the bolt (1) and washer (2). Remove the shift rod holder (3) and shift rod (4). Remove the two water seals (1) and O-ring (2) from the shift rod holder (3). Remove the shift rod spring (1), washer (2) and E-ring (3) from the shift rod (4).
  • Page 563 GEAR CASE (COUNTER ROTATION) EXPLODED VIEW SHIFT ROD HOLDER WATER SEAL (12 x 21 x 6 mm) (2) O-RING (55.6 x 3.5 mm) WASHER (12 mm) SHIFT ROD SPRING E-RING (10 mm) END NIPPLE SHIFT ROD WIRE BAND (2) SPEED SENSOR TUBE B SENSOR NIPPLE 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
  • Page 564 GEAR CASE (COUNTER ROTATION) INSTALLATION Install the E-ring (1), washer (2), and shift rod spring (3) onto the shift rod (4). • Do not reuse the E-ring if it is deformed or deteriorated. • Check that the E-ring is set in the groove in the shift rod securely.
  • Page 565 GEAR CASE (COUNTER ROTATION) Apply marine grease to the mating surfaces and soapy water to the circumference of the new water seals (1). Drive the water seals into the shift rod holder (2) using the special tools in the correct direction as shown. TOOL: Driver (3) 07749-0010000...
  • Page 566 GEAR CASE (COUNTER ROTATION) Install the shift rod holder (1) into the gear case by aligning the projection (2) of the shift rod holder with the recess (3) of the gear case. Install the washer (4) and tighten the bolt (5). After installation, check that the cutout (6) in the shift rod splines is in the cruising direction (7).
  • Page 567 GEAR CASE (COUNTER ROTATION) PROPELLER SHAFT HOLDER REMOVAL/INSTALLATION Remove the following: – Propeller (page 17-6) – Gear case (page 17-8) – Shift rod (page 17-15) Remove the two bolts (1) and two washers (2). Insert a screwdriver or equivalent tool into the recess (3) in the propeller shaft holder (4) and remove the propeller shaft holder from the gear case (5).
  • Page 568 GEAR CASE (COUNTER ROTATION) SHIFT SLIDER/BEARING HOLDER/ PROPELLER SHAFT REMOVAL/ INSTALLATION SHIFT SLIDER REMOVAL Remove the propeller shaft holder (page 17-21). Remove the cross pin ring (1), shifter pin (2) and clutch shifter (3). Remove the shift slider (1) and two steel balls (#7) (2) from the propeller shaft (3), being careful not to lose the steel balls.
  • Page 569 GEAR CASE (COUNTER ROTATION) Remove the shift plate (1) from the shift slider (2), then remove the two shift springs (3) and two steel balls (#9) (4). • Take care not to let the shift springs and steel balls (#9) pop out of the shift slider during removal of the shift plate.
  • Page 570 GEAR CASE (COUNTER ROTATION) Remove the two water seals (1) from the propeller shaft holder (2) using a commercially available oil seal remover. EXPLODED VIEW SHIFT SLIDER SHIFT SPRING (2) ROLLER CROSS PIN RING SHIFTER PIN CLUTCH SHIFTER SHIFT PLATE STEEL BALL (#9) (2) CIRCLIP (14 mm)
  • Page 571 GEAR CASE (COUNTER ROTATION) PROPELLER SHAFT INSTALLATION Apply soapy water to the outer circumference and marine grease to the mating surfaces of new water seals (1). <Water seal installation direction> Install the water seals into the propeller shaft holder (2) in the direction as shown, using the special tool.
  • Page 572 GEAR CASE (COUNTER ROTATION) Install the propeller shaft (1) into the propeller shaft holder (2). • Check that there is a groove (3) on the propeller shaft. If there is no groove, this propeller shaft is for standard rotation type. Install the thrust bearing washer (4) with its chamfered side (5) facing the propeller shaft holder side.
  • Page 573 GEAR CASE (COUNTER ROTATION) SHIFT SLIDER INSTALLATION Install a shift spring (1), two steel balls (#9) (2), the other shift spring and shift plate (3) into the shift slider (4) in this order. Install the roller (5) by aligning the hole in the shift slider with the hole in the shift plate, then install the circlip (6).
  • Page 574 GEAR CASE (COUNTER ROTATION) Install the shifter pin (1) while aligning the hole (2) of the clutch shifter (3) with the hole (4) of the shift slider (5). Install the cross pin ring (1) onto the clutch shifter (2). • Check that the coils of the cross pin ring do not overlap with each other.
  • Page 575 GEAR CASE (COUNTER ROTATION) Remove the lock nut (1) using the special tool. TOOL: Lock nut wrench, 36 × 47.8 mm (2) 07916-MB00002 Remove the vertical shaft (3). • Be careful not to drop the needle bearing (rollers) when removing the vertical shaft. Remove the eighteen needle bearing rollers (1).
  • Page 576 GEAR CASE (COUNTER ROTATION) If the ball bearing (1) remains in the gear case side, remove it using the bearing race puller (2) with the replaced puller jaws (3) used in previous step and the following special tools. TOOLS: Remover handle (4) 07936-3710100 Remover weight (5) 07741-0010201...
  • Page 577 GEAR CASE (COUNTER ROTATION) EXPLODED VIEW LOCK NUT (64 mm) Engine side: 123 N·m (12.5 kgf·m, 91 lbf·ft) VERTICAL SHAFT REVERSE BEVEL GEAR GEAR CASE RADIAL BALL BEARING NEEDLE BEARING (50 x 90 x 20 mm) OUTER RING PINION GEAR PINION GEAR NUT 142 N·m (14.5 kgf·m, 105 lbf·ft) NEEDLE BEARING...
  • Page 578 GEAR CASE (COUNTER ROTATION) INSTALLATION Apply gear oil to the circumference of a new ball bearing (1). Place a wood block (2) under the reverse bevel gear (3). Drive the ball bearing to the reverse bevel gear using the special tool and a hydraulic press as shown. TOOL: Oil seal driver, 65 mm (4) 07JAD-PL90100...
  • Page 579 GEAR CASE (COUNTER ROTATION) Apply marine grease to the needle bearing rollers (1) and install them into the needle bearing outer ring (2). Install the vertical shaft (1) into the gear case (2). • Be careful not to drop the needle bearing rollers. Apply gear oil to the threads and seating surface of the lock nut (3).
  • Page 580 GEAR CASE (COUNTER ROTATION) Wipe the tapered part (1) of the vertical shaft (2) and pinion gear (3) with a shop towel and degreasing cleaning solvent. Attach the special tool to the end (flywheel boss installation side) of the vertical shaft as shown. TOOL: Vertical shaft holder (4) 07SPB-ZW10200...
  • Page 581 GEAR CASE (COUNTER ROTATION) Remove the taper bearing (outer race) (1) using the special tools and hydraulic press. TOOLS: Driver (2) 07749-0010000 Taper bearing driver 070PD-ZY60100 attachment (3) Remove the forward bevel gear shim (4) from the bearing holder (5). EXPLODED VIEW TAPER BEARING (50 ×...
  • Page 582 GEAR CASE (COUNTER ROTATION) Install the taper bearing (outer race) (1) into the bearing holder (2) using the special tools and a hydraulic press as shown. TOOLS: Driver (3) 07749-0010000 Taper bearing installer attachment (4) 070PF-ZY60100 Place a wood block (1) under the forward bevel gear (2).
  • Page 583 GEAR CASE (COUNTER ROTATION) ASSEMBLY Apply gear oil to the outer circumference of a new needle bearing (30 x 37 x 26 mm) (1). Install the needle bearing into the propeller shaft holder (2) until the specified depth, using the special tools and hydraulic press.
  • Page 584 GEAR CASE (COUNTER ROTATION) Check the taper roller bearing for abnormal sound and play. Replace the inner race and outer race as a set if necessary. Set a commercially available universal bearing puller (1) under the taper roller bearing (inner race) (2) and set the vertical shaft (3) on the hydraulic press with the flywheel boss installation side facing up.
  • Page 585 GEAR CASE (COUNTER ROTATION) ASSEMBLY Set the pinion gear (1) onto the vertical shaft (2), and loosely tighten the pinion gear nut (3) by hand. Apply gear oil to the inner wall of the taper roller bearing inner races (4), rollers and outer circumference of the outer race (5).
  • Page 586 GEAR CASE (COUNTER ROTATION) 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, gear or bearing with a new one.
  • Page 587 GEAR CASE (COUNTER ROTATION) PINION GEAR SHIM Clean the tapered surfaces (1) of the vertical shaft (2) and pinion gear (3) thoroughly using a shop towel and degreasing cleaning agent. Install the pinion gear onto the vertical shaft. Tighten the pinion gear nut (4) to the specified torque using the special tool.
  • Page 588 GEAR CASE (COUNTER ROTATION) Hold the vertical shaft (1) upright with the pinion gear facing up. Set a commercially available depth gauge (2) in the groove (3) of the pinion gear side special tool (4) as shown. Measure the length (D) from the pinion gear end to the end of the vertical shaft flange and record the measurement.
  • Page 589 GEAR CASE (COUNTER ROTATION) Measure the height (E’’) of the taper roller bearing outer MEASUREMENT E ’’ : race (1) using a depth gauge (2) or vernier caliper (3), and record it. Calculate the length from the inner race end to the outer race end (E) by determining the gap between the measurements E’...
  • Page 590 GEAR CASE (COUNTER ROTATION) Cross reference the engagement mark and tolerance calculated in the previous step, and refer to the pinion gear shim selection table to determine the required thickness of the shim (Sp). Pinion gear shim selection table Unit: mm Calculation value -0.31 -0.25...
  • Page 591 GEAR CASE (COUNTER ROTATION) FORWARD BEVEL GEAR SHIM Assemble the outer race (1) and inner race (2) of a new taper bearing (50 × 90 × 28 mm), and turn the outer race two or three turns to seat the bearing. If using a depth gauge (3), measure the bearing height (F) from the outer race end to the inner race end as shown, and record the measurement.
  • Page 592 GEAR CASE (COUNTER ROTATION) Forward bevel gear shim type table Shim type Thickness Shim A 0.10 mm Shim B 0.15 mm Shim C 0.30 mm Shim D 0.50 mm After shim selection, inspect the propeller shaft thrust clearance (page 17-51). REVERSE BEVEL GEAR SHIM Measure the bearing height (H) of a new ball bearing (1) using a depth gauge (2) or vernier caliper (3) as...
  • Page 593 GEAR CASE (COUNTER ROTATION) Reverse bevel gear shim type table Shim type Thickness Shim A 0.10 mm Shim B 0.15 mm Shim C 0.30 mm Shim D 0.50 mm PROPELLER SHAFT THRUST SHIM Assemble the outer race (1) and inner race (2) of a new taper bearing (50 ×...
  • Page 594 GEAR CASE (COUNTER ROTATION) Propeller shaft thrust shim selection table (Counter rotation type) Unit: mm Calculation value +0.05 +0.10 – – – +0.05 +0.10 +0.15 Bearing height 28.00 – 28.05 0.75 0.70 0.65 28.05 – 28.10 0.70 0.65 0.60 Refer to page 17-44 for information on how to read the shim selection table and shim combination.
  • Page 595 GEAR CASE (COUNTER ROTATION) Attach the special tool to the vertical shaft (1) as shown, adjust the dial indicator (2) so its needle is at the line "2" of the backlash indicator tool. TOOLS: Backlash indicator tool (3) 07SPJ-ZW0030Z 90° 90°...
  • Page 596 GEAR CASE (COUNTER ROTATION) REVERSE BEVEL GEAR BACKLASH Backlash adjustment must be made after adjustment of each gear shim (page 17-40). Install the following parts except the water pump. – Vertical shaft (page 17-32) – Propeller shaft holder (page 17-21) –...
  • Page 597 GEAR CASE (COUNTER ROTATION) THRUST CLEARANCE INSPECTION • Always inspect the propeller shaft thrust clearance when adjusting the backlash. • Always adjust the propeller shaft thrust clearance when forward bevel gear shim is replaced with new ones. Check that the bearing holder is securely tightened to the specified torque on the propeller shaft holder (1) (page 17-25).
  • Page 598 GEAR CASE (COUNTER ROTATION) While applying the specified air pressure to the gear case, move the shift rod (1) right and left five or six times using pliers. • Wrap a shop towel (2) around the shift rod spline to move the shift rod with pliers.
  • Page 599 GEAR CASE (COUNTER ROTATION) CLUTCH SHIFTER INSPECTION Check the clutch parts (1) on the forward and reverse sides for wear and damage. PROPELLER SHAFT INSPECTION PROPELLER SHAFT O.D. Measure the O.D. of the propeller shaft at the reverse bevel gear area (1) and needle bearing area (2). STANDARD: At reverse bevel gear: 24.987 –...
  • Page 600 GEAR CASE (COUNTER ROTATION) VERTICAL SHAFT INSPECTION VERTICAL SHAFT O.D. Measure the O.D. of the vertical shaft at the needle bearing area (1). 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 601 GEAR CASE (COUNTER ROTATION) GEAR CASE BEARING REPLACEMENT NEEDLE BEARING Set the special tools on the needle bearing (28.575 x 44.45 x 31.75 mm) (1), and place a shop towel (2) or equivalent material under the needle bearing as shown. TOOLS: Driver, 280 mm (3) 07949-3710001...
  • Page 602 MEMO...

  • Page 603: Mount

    18. MOUNT COMPONENT LOCATION ··························18-2 MOUNTING CASE REMOVAL/ INSTALLATION ·········································· 18-4 TOOLS·························································18-3 MOUNTING CASE DISASSEMBLY/ ASSEMBLY ················································· 18-5 18-1...
  • Page 604 MOUNT COMPONENT LOCATION MOUNT 83 N·m (8.5 kgf·m, 61 lbf·ft) 18-2...
  • Page 605 MOUNT TOOLS LIST Attachment, 32 × 35 mm Attachment, 24 × 26 mm Pilot, 20 mm 07746-0010100 07746-0010700 07746-0040500 Attachment, 28 × 30 mm Driver 07946-1870100 07749-0010000 18-3...
  • Page 606 MOUNT MOUNTING CASE REMOVAL/ INSTALLATION Place the outboard motor on a level surface so it is in the vertical position. Remove the engine (page 13-3). Swivel the outboard motor right and left, then remove the two nuts (1). Remove the mounting case (1) from the mounting frame (2).
  • Page 607 MOUNT MOUNTING CASE DISASSEMBLY/ ASSEMBLY DISASSEMBLY Remove the mounting case (page 18-4). Remove the E-ring (1), washer (2), water seal (3) and shift shaft A (4) from the mounting case (5). Remove the six bolts (1). Remove the upper mount holder (2) and upper mount holder gasket (3).
  • Page 608 MOUNT Apply heat around the needle bearing (1) installation area of the mounting case, and remove the needle bearing from the mounting case. 18-6...
  • Page 609 MOUNT EXPLODED VIEW WATER SEAL (22 × 35 × 7 mm) (2) BOLT (8 × 35 mm) (6) SHIFT SHAFT B UPPER MOUNT HOLDER SHIFT SHAFT A UPPER MOUNT HOLDER GASKET UPPER MOUNT RUBBER INNER RING BOLT NEEDLE BEARING (6 × 25 mm) (3) (20 ×...
  • Page 610 MOUNT ASSEMBLY Apply engine oil to the outer circumference of a new needle bearing (1). Install the needle bearing in the mounting case using the special tools as shown. TOOLS: Driver (2) 07749-0010000 Attachment, 28 × 30 mm (3) 07946-1870100 Pilot, 20 mm (4) 07746-0040500 Apply marine grease to the outer circumference of a...
  • Page 611 MOUNT Apply marine grease to the circumference of two new water seals (22 × 35 × 7 mm) (1). Install the water seals in the mounting case using the special tools as shown, noting the installation direction. TOOL: Driver (2) 07749-0010000 Attachment, 32 ×...
  • Page 612 MOUNT Install the upper rubber mount (1) to the mounting case (2) with its "UP" mark (3) facing up. Install the two stud bolts (4) with its longer thread side facing the upper rubber mount. Long Short Upper rubber mount side Install a new upper mount holder gasket (1) and upper mount holder (2) with their cutouts (3) positioned as shown, and tighten the six bolts (4).

  • Page 613: Trim/Tilt

    19. TRIM/TILT COMPONENT LOCATION ··························19-2 POWER TRIM/TILT DISASSEMBLY/ ASSEMBLY ··············································· 19-25 TOOLS·························································19-3 POWER TILT MOTOR DISASSEMBLY/ ASSEMBLY ··············································· 19-43 POWER TRIM/TILT/SWIVEL CASE/STERN BRACKET REMOVAL/INSTALLATION ·····19-4 POWER TILT MOTOR INSPECTION ······· 19-48 SWIVEL CASE/MOUNT FRAME DISASSEMBLY/ASSEMBLY ····················19-16 POWER TILT SWITCH INSPECTION ······ 19-50 19-1...
  • Page 614 TRIM/TILT COMPONENT LOCATION TRIM/TILT 34 N·m (3.5 kgf·m, 25 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 19-2...
  • Page 615 TRIM/TILT TOOLS LIST Attachment, 52 × 55 mm Driver, 40 mm I.D. Driver 07746-0010400 07746-0030100 07749-0010000 Bearing separator attachment, 18 mm Pin wrench, 6 × 35 mm Trim cap wrench, 4 mm 07931-4630100 07SPA-ZW10101 070PA-0010100 Oil pressure gauge joint A Oil pressure gauge joint B (Upper chamber side) (Lower chamber side)
  • Page 616 TRIM/TILT POWER TRIM/TILT/SWIVEL CASE/ STERN BRACKET REMOVAL/ INSTALLATION REMOVAL Remove the following: – Engine cover – Switch panel cable/indicator wire (page 10-6) – L. engine under cover (page 6-4) – R. engine under cover (page 6-10) – Gear case – Standard rotation type (page 16-8) –...
  • Page 617 TRIM/TILT Turn the outboard motor right and left, then remove the two self-locking nuts (1). Check that the engine and mount case mating surfaces are level to the ground. Holding the outboard motor, remove the stern bracket/ swivel case assembly (1) from the outboard motor. If it is hard to remove the stern bracket/swivel case assembly, adjust the engine position by raising and lowering the outboard motor slowly with the hoist.
  • Page 618 TRIM/TILT Loosen the manual valve (1) fully and set the swivel case in the uppermost position, using the tilt stopper. Tighten the manual valve to the specified torque with the swivel case in the uppermost position. TORQUE: 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) Tighten Loosen Open the wire harness clip (1) and release the trim...
  • Page 619 TRIM/TILT Remove the two bolts (1), screw (2), ground cable (3) and anode metal (4). Remove the self-locking nut (1), washer (2) and bolt (3). Remove the two E-rings (1) from the upper cylinder pin (2). Remove the upper cylinder pin and pull off the piston rod (3) of the power trim/tilt from the swivel case (4).
  • Page 620 TRIM/TILT Loosen the self-locking nut (25 × 2.0 mm) (1) or self- locking nut (7/8-14 UNF) (2). While holding the power trim/tilt (1) by hand, spread the L./R. stern bracket (2)/(3) and remove the lower cylinder collar (4). Pull out the wire and tube from the L. stern bracket hole and remove the power trim/tilt.
  • Page 621 TRIM/TILT Remove the self-locking nut (25 × 2.0 mm) (1) or the self-locking nut (7/8-14 UNF) (2) from the tilting shaft (3). Remove the tilting shaft, L./R. stern bracket (4)/(5), two wave washers (6) and swivel case (7). Remove the two swivel case bushings (8). Remove the O-ring (9) from the inside of the tilting shaft.
  • Page 622 TRIM/TILT EXPLODED VIEW SWIVEL CASE SWIVEL CASE BUSHING (2) UPPER CYLINDER PIN E-RING (15 mm) (2) SELF-LOCKING NUT (7/8-14 UNF) 34 N·m (3.5 kgf·m, 25 lbf·ft) WAVE WASHER (26 mm) (2) BOLT TILTING SHAFT TRIM (6 × 20 mm) (2) ANGLE O-RING SELF-LOCKING NUT...
  • Page 623 TRIM/TILT INSTALLATION • Check that the piston rod of the power trim/tilt is in the fully extended position. Install the wire harness clip (1) to the L. stern bracket (2). Apply marine grease inner wall circumference of new swivel case bushings (3) and install them to the swivel case (4).
  • Page 624 TRIM/TILT Tighten the self-locking nut (25 × 2.0 mm) (1) or self- locking nut (7/8-14 UNF) (2) to the specified torque. TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) Tighten the self-locking nut (25 × 2.0 mm) or self- locking nut (7/8-14 UNF) of the other side to the specified torque.
  • Page 625 TRIM/TILT Install the spiral tube (1) around the trim angle sensor wire (2) and power/tilt motor wire (3). Align the taped end (4) of the power/tilt motor wire with the end of the motor wire bushing (5) and install. Clamp the trim angle sensor wire and power/tilt motor wire with the wire harness clip (6).
  • Page 626 TRIM/TILT Inspect the anode metal (1) for corrosion and replace if necessary. Install the anode metal and ground cable (2) and tighten the two bolts (3). Set the ground cable in the specified angle as shown, and tighten the screw (4). 90°...
  • Page 627 TRIM/TILT Install the lower rubber mount. – Standard rotation type (page 16-14) – Counter rotation type (page 17-14) Remove the chains (1) from the three engine hangers (2). Route the connectors (1) into the hole (2) of the under cover front bracket (3). Check that the taped end (4) of the power/tilt motor wire (5) are aligned with the end of the under case grommet C (6).
  • Page 628 TRIM/TILT SWIVEL CASE/MOUNT FRAME DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the swivel case/stern bracket (page 19-4). Remove the screw (1) and ground cable (2). Remove the external circlip (3). Before disassembling the lower mount center housing (1), put a mark (2) on the mount frame (3) so it is aligned with the “...
  • Page 629 TRIM/TILT Apply heat to the lower mount center housing (1), using a commercially available heat gun (2) or equivalent. Overheating the lower mount center housing may cause damage to the painted surfaces. Remove the lower mount center housing by using the special tool with a commercially available bearing puller (3).
  • Page 630 TRIM/TILT Remove the oil seal (1). Remove the two swivel case liners (2) from the swivel case (3). Remove the three grease fittings (1) from the swivel case (2). Remove the two self-locking nuts (3), two washers (4) and two thrust receivers (5) from the swivel case. 19-18...
  • Page 631 TRIM/TILT Remove the bolt (1), click spring (2) and click assist spring (3). Drive out the spring pin (4) from the tilting bracket, using a commercially available pin driver (5). Remove the spring pin on the other side in the same manner.
  • Page 632 TRIM/TILT EXPLODED VIEW BOLT (6 × 14 mm) SPRING PIN CLICK ASSIST SPRING (2.5 × 20 mm) (2) TILTING BRACKET SWIVEL CASE LINER CLICK SPRING TILT STOPPER (2) MOUNT FRAME SELF-LOCKING NUT (10 mm) (2) 39 N·m (4.0 kgf·m, 29 lbf·ft) TILT ARM BUSHING (2) THRUST RECEIVER...
  • Page 633 TRIM/TILT ASSEMBLY Install the click assist spring (1) and click spring (2), then tighten the bolt (3). Apply marine grease to the click spring roller surface. Apply marine grease to the two tilt stoppers (4) and tilt arm bushings (5). Install the tilt arm bushings and tilt stoppers to the swivel case (6).
  • Page 634 TRIM/TILT Apply marine grease to the swivel case liner (1) whole surface. Install the two swivel case liners into the swivel case (2) by aligning its tabs (3) with the case grooves (4). Apply marine grease to the lips and circumference of a new oil seal (5).
  • Page 635 TRIM/TILT Apply grease to the splines of the lower mount center housing (1). Install the lower mount center housing on the mount frame (2) by aligning its “ ” mark (3) with the mark (4) on the mount frame that had been made during disassembly.
  • Page 636 TRIM/TILT Check that the mount frame turns smoothly and that the external circlip can be installed. If the circlip can be installed but the mount frame does not turn smoothly, perform the following procedure. Set the special tool and a commercially available bearing puller (1) to the lower mount center housing (2).
  • Page 637 TRIM/TILT POWER TRIM/TILT DISASSEMBLY/ ASSEMBLY DISASSEMBLY • Do not overtighten the cylinder when holding the power trim/tilt with a vise. Do not hold the cylinder with a vise except the specified area (page 19-27). • Do not disassemble the pump assembly. If it is faulty, replace it as an assembly.
  • Page 638 TRIM/TILT Remove the four bolts (1) and power tilt motor (2). Remove the O-ring (1) from the power tilt motor (2). Remove the drive joint (1) and filter B (2) from the pump assembly (3). Check the mesh of the filter B for blockage and tear. If it is torn, replace it with a new one.
  • Page 639 TRIM/TILT Remove the internal circlip (1) and manual valve (2) from the pump assembly (3). Check the manual valve for wear or damage and replace it if necessary. Hold the cylinder (1) in a vise (2) with shop towel or soft jaws as shown.
  • Page 640 TRIM/TILT Remove the O-ring (1) from the rod guide (2). Remove the dust seal (3) using a sharp-end screwdriver (4) or equivalent tool. Remove the oil seal (5) from the rod guide in the same manner. • Be careful not to damage the oil seal installation surface of the rod guide.
  • Page 641 TRIM/TILT Remove the piston rod (1) from the cylinder (2). Remove the two O-rings (3) from the cylinder cap/ piston rod (4). Remove the free piston (1), backup ring (2) and O-ring (3) from the cylinder (4). Check the sliding surface of the free piston and backup ring surface for wear or damage, replace it if necessary.
  • Page 642 TRIM/TILT EXPLODED VIEW PISTON ROD CYLINDER CAP 208 N·m (21.2 kgf·m, 153 lbf·ft) POWER TILT MOTOR O-RING (2) BOLT (4) FREE PISTON 4.9 N·m (0.50 kgf·m, 3.6 lbf·ft) BACKUP RING O-RING OIL TANK O-RING RESERVOIR VALVE BOLT (3) STEEL 4.9 N·m (0.50 kgf·m, BALL DRIVE JOINT 3.6 lbf·ft)
  • Page 643 TRIM/TILT INSTALLATION • Do not reuse O-rings and oil seals. • Do not use a shop towel or equivalent cloth, and do not wear gloves during this operation. • Do not reuse the drained ATF. • When operation is made by holding the cylinder in a vise, do not tighten the vise excessively.
  • Page 644 TRIM/TILT Apply ATF to a new O-ring (1) and Install it on the bottom of the piston rod (2). Apply ATF to a new O-ring (3) and Install it on the cylinder cap (4). With the piston rod fully extended, install the piston rod slowly into the cylinder (5).
  • Page 645 TRIM/TILT Apply ATF to a new oil seal (1). Holding the oil seal in the shape of a "U" with your fingers, install it in the lower groove in the rod guide (2), taking care not to damage the oil seal. Apply ATF to a new dust seal (3).
  • Page 646 TRIM/TILT Using the special tool and a torque wrench (1), tighten the left and right rod guides (2) to the specified torque as shown. TOOL: Pin wrench, 4 mm (3) 070PA-0010100 TORQUE: 140 N·m (14.3 kgf·m, 103 lbf·ft) To tighten the rod guide with the pin wrench, 4 mm, read the torque as follows.
  • Page 647 TRIM/TILT Fill the pump (1) fully with fresh ATF using an oil bottle (2) or equivalent by pouring the ATF into the holes (3) alternately, removing the air inside the pump until it is completely filled up. Check the filter B (1) for dust or tear in the mesh. Install the filter B and drive joint (2) on the pump (3).
  • Page 648 TRIM/TILT Install the power tilt motor (1) on the pump by aligning the projection (2) on the motor with the cutout (3) in the drive joint with the motor wire (4) facing toward the manual valve side. Install and tighten the four bolts (1) to the specified torque.

  • Page 649: Air Bleeding

    TRIM/TILT AIR BLEEDING • Bleed air from the unit whenever the power trim/tilt is assembled. • Perform the following procedure to bleed air: 1. Bleed air without mounting the unit on the outboard motor. 2. Check hydraulic pressure (page 19-39). 3.
  • Page 650 TRIM/TILT 8. With the rods extended fully, push the "UP" side of the power tilt switch (1) until relief valve opens again. Push the "DN" side of the power tilt switch, and be sure that the rods compress. If the rods extend and compress fully, go to the hydraulic pressure check (page 19-39).
  • Page 651 TRIM/TILT HYDRAULIC PRESSURE CHECK After bleeding air from the power trim/tilt without installing on the outboard motor and checking each rod for proper compression, perform the following operation in the same manner as bleeding air without installing on the outboard motor. –...
  • Page 652 TRIM/TILT Remove the oil tank cap (1) and check if the ATF is at the upper limit of the filler port (2). Push the "DN" side of the power tilt switch (3) to compress each rod fully. Push the "UP" side of the power tilt switch to extend each rod fully again, and read the pressure gauge (4) to measure the lower chamber hydraulic pressure.
  • Page 653 TRIM/TILT Remove the oil tank cap (1) and check if the ATF is at the upper limit of the filler port (2). Push the "DN" side of the power tilt switch (3) to compress each rod fully, and read the pressure gauge (4) to measure the upper chamber hydraulic pressure.
  • Page 654 TRIM/TILT Air bleeding with the power trim/tilt on the outboard motor • Perform the following procedure after bleeding air without mounting the power trim/tilt on the outboard motor and after checking the hydraulic pressure. 1. Install the power trim/tilt on the outboard motor securely.
  • Page 655 TRIM/TILT POWER TILT MOTOR DISASSEMBLY/ ASSEMBLY DISASSEMBLY Untape the corrugated tube (1), and pull the tube to the connector side. Remove the screw (2). Pull out the wire holder (3) and the two grommets (4) from the yoke (5), and move them to the tube side. Pull out the grommets with care not to damage them.
  • Page 656 TRIM/TILT Pull the brushes (1) from the brush holder A (2) and B (3). Disconnect the motor wire (Blue wire) terminal (4) from the breaker (5) 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 657 TRIM/TILT EXPLODED VIEW SCREW (STAINLESS STEEL: 4 x 16 mm) 1.4 N·m (0.14 kgf·m, 1.0 lbf·ft) CORRUGATED TUBE YOKE ARMATURE BLUE WIRE SCREW (4 x 10 mm) (2) GREEN WIRE BRUSH HOLDER B BRUSH HOLDER A BRUSH BREAKER Do not touch the bimetal part. BRUSH SPRING (2) O-RING FRONT BRACKET...
  • Page 658 TRIM/TILT ASSEMBLY Apply marine grease to the oil seal lips. Apply marine grease to a new O-ring (1) and install it to the front bracket (2) groove. (10) (11) Set the brush holder A (3) and motor wire (Green wire) terminal (4), then install the brush terminal (5) and loosely tighten the screw (6).
  • Page 659 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 660 TRIM/TILT POWER TILT MOTOR INSPECTION OPERATION INSPECTION Connect a battery (1) to the 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 661 TRIM/TILT MICA DEPTH Check the grooves of the commutator and measure the mica depth. SERVICE LIMIT: 0.50 mm (0.020 in) (1) If the grooves are clogged or mica depth is less than the service limit, recut the grooves using a hacksaw blade or a small file.
  • Page 662 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 663: Controls

    20. CONTROLS COMPONENT LOCATION ··························20-2 SEAL HOLDER REMOVAL/ INSTALLATION ········································ 20-12 SHIFT CONTROL CABLE REMOVAL/ INSTALLATION···········································20-3 SHIFT LINK BRACKET DISASSEMBLY/ASSEMBLY ···················· 20-15 THROTTLE CONTROL CABLE REMOVAL/INSTALLATION························20-6 SHIFT CONTROL CABLE INSPECTION/ADJUSTMENT ··················· 20-16 SHIFT LINK BRACKET REMOVAL/ INSTALLATION···········································20-7 SHIFT SHAFT B ALIGNMENT ················· 20-18 SHIFT ARM/NEUTRAL SWITCH REMOVAL/INSTALLATION························20-8 20-1...
  • Page 664 CONTROLS COMPONENT LOCATION CONTROLS 20-2...
  • Page 665 CONTROLS SHIFT CONTROL CABLE REMOVAL/ INSTALLATION REMOVAL Remove the front separate cover (page 6-3). Remove the shift control cable (1) by sliding the lock plate (2) of the shift pivot (3) as shown. Loosen the shift pivot lock nut (4) and remove the shift pivot.
  • Page 666 CONTROLS 4. Move the remote control lever fully to the "R" (Reverse) side (1). Return the lever to the "N" (Neutral) position (2) slowly. 5. With the lever returned to the "N" (Neutral) position, draw Mark (B) (3) on the inner cable (4) at the end of cable outer seal (5).
  • Page 667 CONTROLS 9. With the shift control cable (1) in the condition described in step 7, connect the shift pivot (2) to the shift link pin (3) while turning the shift pivot so that the shift pivot sets on the shift pin smoothly. Take care not to move mark (C) and outer seal end out of alignment.

  • Page 668: Throttle Control Cable

    CONTROLS THROTTLE CONTROL CABLE REMOVAL/INSTALLATION REMOVAL Remove the front separate cover (page 6-3). Remove the shift control cable (1) by sliding the lock plate (2) of the shift pivot (3) as shown. Loosen the shift pivot lock nut (4) and remove the shift pivot from the throttle control cable.
  • Page 669 CONTROLS SHIFT LINK BRACKET REMOVAL/ INSTALLATION Remove the following: – Front separate cover (page 6-3) – Shift control cable (page 20-3) – Throttle control cable (page 20-6) – Switch panel cable/indicator wire harness (page 10-6) Remove the linkage pivot (1) of the throttle rod (2) from the throttle plate (3). Remove the two bolts (4).
  • Page 670 CONTROLS SHIFT ARM/NEUTRAL SWITCH REMOVAL/INSTALLATION REMOVAL Move the remote control lever to the "N" (Neutral) position. Remove the shift link bracket (page 20-7). Remove the snap pin (1) and washer (2) from the shift arm (3). Pull the click arm (1) as shown direction and hold it, then remove the shift arm (2) from the shift shaft B (3).
  • Page 671 CONTROLS Remove the nut (1) and neutral switch (2) from the neutral switch bracket (3). Remove the following: – Bolt (1) – Washer (2) – Click arm (3) – Click spring (4) – Click arm bushing (5) Check the click arm for wear or damage; replace it if necessary.
  • Page 672 CONTROLS INSTALLATION Apply marine grease to a new click arm bushing (1) inner surface and install it to the click arm (2). (11) Apply marine grease to the shaft area (3) of the seal holder and roller area (4) of the click arm. (10) Install the click spring (5) to the click arm by aligning the hook A (6) of the click spring with the groove (7) of the...
  • Page 673 CONTROLS Pull the click arm (1) as shown direction and hold it, then install the neutral switch bracket by aligning the hole (2) with the projection (3) on the seal holder. Install and tighten the bolt (4). Install the fuel tube A (5) to the fuel tube holder (6). Apply marine grease to the link pin inserting area and roller contact area of the shift arm (1).
  • Page 674 CONTROLS SEAL HOLDER REMOVAL/ INSTALLATION REMOVAL Remove the following: – Shift arm/neutral switch (page 20-8) – R. engine under cover (page 6-10) Remove the bolt (6 x 14 mm) (1) and cable bracket A (2). Remove the starter cables (3) from the cable bracket A. Remove the two bolts (6 x 20 mm) (4) and seal holder (5).
  • Page 675 CONTROLS EXPLODED VIEW OIL SEAL BOLT (6 x 20 mm) (2) SEAL HOLDER O-RING (25 x 2.4 mm) SHIFT SHAFT B BOLT (6 x 14 mm) CABLE BRACKET A INSTALLATION Apply marine grease to a new O-ring (1) outer surface. Apply marine grease to the O-ring installation area of the seal holder (2) and shift shaft B bearing area.
  • Page 676 CONTROLS Install the cable bracket A (1) to the seal holder (2) and tighten the bolt (6 x 14 mm) (3). Attach a piece of tape (4) around the flange area of shift shaft B (5) as shown. Apply marine grease to the oil seal lips (6) of the seal holder.
  • Page 677 CONTROLS SHIFT LINK BRACKET DISASSEMBLY/ ASSEMBLY Remove the shift link bracket (page 20-7). Installation is in the reverse order of removal. THROTTLE PLATE LINK PIN THROTTLE LINK E-RING (4 mm) (2) BUSHING A (2) THROTTLE ARM (Mating surface with throttle link) SHIFT LINK BRACKET WASHER (6 mm)
  • Page 678 CONTROLS SHIFT CONTROL CABLE INSPECTION/ ADJUSTMENT INSPECTION Remove the front separate cover (page 6-3). Move the remote control lever to the "N" (Neutral) position. Make sure that the roller (1) of the click arm is in the groove (2) of the shift arm. Make sure that the neutral switch tip area (3) is pushing the click arm flat area (4).
  • Page 679 CONTROLS ADJUSTMENT Move the remote control lever to the "N" (Neutral) position. Loosen the lock nut (1) of the remote control cable (shift side) and remove the shift pivot (2) from the shift link pin (3). Make sure that the roller (4) of the click arm is in the groove (5) of the shift arm.
  • Page 680 CONTROLS SHIFT SHAFT B ALIGNMENT Remove the following: – Seal holder (page 20-12) – Gear case – Standard rotation type (page 16-8) – Counter rotation type (page 17-8) Turn the shift shaft B (1) clockwise until the shift shaft A (2) touches the stopper (3) in the mounting case as shown.

  • Page 681: Technical Features

    21. TECHNICAL FEATURES OIL PRESSURE ALERT SYSTEM··············21-2 21-1...
  • Page 682 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 683 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 684 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 685: Wiring Diagrams

    22. WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & SYSTEM DIAGRAM ···································· 22-6 RELATED INFORMATION··························22-2 CONNECTOR GENERAL LAYOUT WIRING DIAGRAMS ···································22-5 DRAWING ··················································· 22-7 22-1...
  • Page 686 WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION WIRING DIAGRAMS The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained in this section. HOW TO READ CONNECTOR DRAWINGS Connector drawings show the terminal arrangement, terminal No., number of pins, and the shape of terminal (male or female). Both the male and female connectors are shown for the common connectors, while only the main wire harness side connectors are shown for the dedicated connectors.
  • Page 687 WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM SYMBOL OF TERMINAL It shows the shape of each terminal to identify whether it is a male or female terminal. TERMINAL No. TP SENSOR MAP SENSOR No. 9 Black Brown FUSE No. 5 No.
  • Page 688 MEMO...
  • Page 689 WIRING DIAGRAMS WIRING DIAGRAMS/SYSTEM DIAGRAM FUSE/RELAY JUNCTION BOX OPTION COMBINATION SWITCH No. 4 TACHOMETER TRIM METER BLACK BROWN No. 8 No. 3 No. 5 BAT LOAD ST (30 A) (10 A) (30 A) (10 A) VOLT HOUR COLOR Bl/R W/Bl Bl/Y Bl/W YELLOW ORANGE...
  • Page 690 SYSTEM DIAGRAM FUSE/RELAY JUNCTION BOX No.4 (30A) No.11 (15A) : Low pressure fuel line No.8 (10A) No.3 (30A) No.9 (15A) : High pressure fuel line MAIN RELAY No.10 (10A) CHECK LOAD VALVE No.5 (10A) FUEL PUMP RELAY COMBINATION SWITCH (OPTION) VAPOR FILTER STARTER RELAY...
  • Page 691 CONNECTOR GENERAL LAYOUT DRAWING Terminal Wire color Terminal Wire color Terminal Wire color Terminal Wire color Terminal Wire color Terminal Wire color number number number number number number – R/Bl CKP SENSOR 3P G/Bl W/Bl CONNECTOR TACHOMETER Y/Bl W/Bu Main wire PULSE CHECK 2P Main wire Main wire...
  • Page 692 Battery negative ( – ) cable terminal Terminal Wire color Terminal Wire color Terminal Wire color number number number NEUTRAL SWITCH GND1 W/BI 2P CONNECTOR BI/Y Main wire FRAME GROUND Terminal Wire color POWER TRM/TILT Y/Bu harness side TERMINAL number Ground cable tarminals RELAY 3P CONNECTOR Terminal...
  • Page 693 Terminal Wire color Terminal Wire color number number BI/W Y/BI Main wire harness side No.1 IGNITION COIL Main wire harness side 3P CONNECTOR Terminal Wire color No.1 FUEL number INJECTOR 2P BI/W Terminal Wire color CONNECTOR number Bu/R Bu/Bl No.2 IGNITION COIL Main wire BI/W harness side...
  • Page 694 MEMO...

  • Page 695: Index

    INDEX INDEX A/F SENSOR HEATER INSPECTION························5-139 ECM REMOVAL/INSTALLATION································· 10-4 A/F SENSOR REMOVAL/INSTALLATION ·················5-115 ECM TERMINAL ARRANGEMENT······························ 5-13 AIR VENT STRAINER/AIR VENT TUBE REMOVAL/ ECT SENSOR 1/2/3/4 INSPECTION ························· 5-137 INSTALLATION···························································5-106 ECT SENSOR 1 REMOVAL/INSTALLATION ············ 5-116 ALERT SYSTEM/WARNING SYSTEM ECT SENSOR 2 REMOVAL/INSTALLATION ············ 5-117 TROUBLESHOOTING ··················································4-17 ECT SENSOR 3 REMOVAL/INSTALLATION ············...
  • Page 696 INDEX GEAR CASE REMOVAL/INSTALLATION R. ENGINE UNDER COVER REMOVAL/ GEAR CASE (COUNTER ROTATION) ··················· 17-8 INSTALLATION ···························································· 6-10 GEAR CASE (STANDARD ROTATION) ················· 16-8 RELAY REMOVAL/INSTALLATION ··························· 10-13 HOOK BRACKET ADJUSTMENT································ 6-26 RELIEF VALVE DISASSEMBLY/ASSEMBLY ············ 11-13 HOOK BRACKET DISASSEMBLY/ASSEMBLY ·········· 6-25 ROCKER ARM DISASSEMBLY/ASSEMBLY·············...
  • Page 697 INDEX THROTTLE CONTROL CABLE REMOVAL/ VERTICAL SHAFT BUSHING INSPECTION INSTALLATION·····························································20-6 GEAR CASE (COUNTER ROTATION) ················· 17-54 THROTTLE LINKAGE INSPECTION/ADJUSTMENT ····3-9 GEAR CASE (STANDARD ROTATION) ··············· 16-50 THRUST CLEARANCE INSPECTION VERTICAL SHAFT BUSHING REMOVAL/ GEAR CASE (COUNTER ROTATION) ··················17-51 INSTALLATION TOOLS GEAR CASE (COUNTER ROTATION) ·················...
  • Page 698 Copyright © 2014 Tohatsu Corporation. All rights reserved. No part of this manual may be reproduced or transmitted in any form or by any means without the express written permission of Tohatsu Corporation.
  • Page 699 BFT 115A OB No.62ZX100 14-01 NB Printed in Japan...

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