Page 1 F150B FL150B SERVICE MANUAL 6BM-28197-5L-11...
Page 2: Important Information
Yamaha equipment. It has been written to suit the needs of persons who have the Bronze Technical Certificate of YTA (Yamaha Technical Academy) marine or the equivalent basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or ser- vice to the equipment could render it unsafe or unfit for use.
Page 3 Contents General information INFO Specification SPEC TECH Technical features and description Rigging information GING TRBL Troubleshooting SHTG Electrical system ELEC Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT Maintenance Index Appendix...
Page 5: Table Of Contents
INFO General information Safety while working ............0-1 Rotating part ................0-1 Hot part ..................0-1 Electric shock ................0-1 Propeller ..................0-1 Handling of gasoline ..............0-1 Ventilation .................. 0-1 Self-protection ................0-2 Working with crane ..............0-2 Handling of burner ..............0-2 Part, lubricant, and sealant ............
Page 6: Safety While Working
INFO General information Safety while working Handling of gasoline • Gasoline is highly flammable. Keep gaso- To prevent an accident or injury and to line and all flammable products away from ensure quality service, follow the safety pro- heat, sparks, and open flames. cedures provided below.
Page 7: Self-Protection
• Use a wire rope of adequate strength, and and sealants or those recommended by lift up the outboard motor with the three Yamaha, when servicing or repairing the out- point suspension. board motor. • If the outboard motor does not have three...
Page 8: Special Service Tool
INFO General information Special service tool Disassembly and assembly Use the recommended special service tools • Use compressed air to remove dust and dirt to work safety, and to protect parts from dam- during disassembly. age. • Apply engine oil to the contact surfaces of moving parts before assembly.
Page 9: How To Use This Manual Manual Format
Safety while working / How to use this manual How to use this manual How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. •...
Page 10: Abbreviation
Idle Speed Control Measurement Neutral Pressure Control Valve PORT Port side Power Trim and Tilt Reverse Research Octane Number Society of Automotive Engineers STBD Starboard side Switch Top Dead Center Throttle Position Sensor Upside Water in Fuel YDIS Yamaha Diagnostic System...
Page 11: Sealant And Locking Agent
Sealant and locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication point. Symbol Name Application Yamaha 4-stroke motor oil Lubricant Gear oil Lubricant Water resistant grease Lubricant (Yamaha grease A) Molybdenum disulfide grease...
Page 12 INFO General information Symbol Name Application LOCTITE 242 (blue) Sealant LOCTITE 572 (white) Sealant...
Page 13: Special Service Tool
Sealant and locking agent / Special service tool Special service tool Special service tool For all markets except for U.S.A. and Canada Special tools with Yamaha parts number (90890-*****) are distributed by Parts Division. Drilling plate Peak voltage adapter B 90890-06783 90890-03172 YDIS (CD-ROM, Ver.
Page 14 INFO General information Test harness (2 pins) Leakage tester 90890-06792 90890-06840 Test harness (3 pins) Test harness (3-pins) 90890-06791 90890-06793 Vacuum/pressure pump gauge set Vacuum gauge 90890-06756 90890-03159 Test harness (2 pins) Digital tachometer 90890-06867 90890-06760 Fuel pressure gauge Compression gauge 90890-06786 90890-03160...
Page 15 Special service tool Compression gauge extension Valve guide remover/installer 90890-06563 90890-06801 Flywheel holder Valve guide installer 90890-06522 90890-06810 Flywheel puller Valve guide reamer 90890-06521 90890-06804 Valve spring compressor Valve lapper 90890-04019 90890-04101 Valve spring compressor attachment Valve seat cutter holder 90890-06320 90890-06316 0-10...
Page 16 INFO General information Valve seat cutter Gear puller 90890-06817, 90890-06326, 90890-06816, 90890-06540 90890-06325, 90890-06324 Piston ring compressor Oil filter wrench 90890-05158 90890-06830 Shift rod push arm Needle bearing attachment 90890-06052 90890-06654, 90890-06611, 90890-06653, 90890-06610, 90890-06612 Ring nut wrench 4 90890-06512 Driver rod L3 90890-06652 Ring nut wrench extension...
Page 17 Special service tool Bearing housing puller claw L Driver rod SS 90890-06502 90890-06604 Stopper guide plate Bearing depth plate 90890-06501 90890-06603 Center bolt Bearing inner race attachment 90890-06504 90890-06640 Stopper guide stand Drive shaft holder 6 90890-06538 90890-06520 Bearing puller assembly Pinion nut holder 90890-06535 90890-06715...
Page 18 INFO General information Needle bearing attachment Driver rod LS 90890-06608, 90890-06607 90890-06606 Ball bearing attachment Backlash indicator 90890-06636, 90890-06633 90890-06706 Driver rod LL Magnet base plate 90890-06605 90890-07003 Bearing outer race attachment Dial gauge set 90890-06619 90890-01252 Bearing outer race puller assembly Magnet base B 90890-06523 90890-06844...
Page 19 Special service tool Pinion height gauge Bearing inner race attachment 90890-06671 90890-06660 Slide hammer handle Up relief fitting 90890-06531 90890-06773/06838 Puller head Hydraulic pressure gauge 90890-06514 90890-06776/06800 Ring nut wrench Down relief fitting 90890-06578 90890-06774 Ball bearing attachment Trim & tilt wrench 90890-06629 90890-06587 0-14...
Page 20 SPEC Specification Model features ................1-1 General feature ................. 1-1 Model designation ..............1-2 Serial number ................1-2 Model data ................... 1-3 Dimension and Weight .............. 1-3 Performance ................1-3 Power unit ................. 1-3 Lower unit .................. 1-4 Bracket unit ................1-4 Fuel and oil requirement ............
Page 21 Special tightening torque ............1-18 Fuel system ................1-18 Power unit ................1-18 Lower unit (regular rotation model) ......... 1-19 Lower unit (counter rotation model) ......... 1-20 Bracket unit ................1-20 PTT unit ................... 1-20 General tightening torque ............. 1-21...
Page 22: Model Features
SPEC Specification Model features General feature F150B and FL150B Overall Features; • Light weight and compact, 4-stroke, L4, DOHC, 16-valve, 2670 cm (162.9 cu. in) engine • Easy startability and drivability • Low noise, low emission, low fuel consumption Power unit •...
Page 23: Model Designation
X: UL (25 in) Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket. YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON Model name Approved model code Transom height Serial number...
Page 24: Model Data
SPEC Specification Model data Dimension and Weight Model Item Unit F150B FL150B Overall length mm (in) 862 (33.9) Overall width mm (in) 512 (20.2) Overall height mm (in) 1842 (72.5) Boat transom height mm (in) 635 (25.0) Weight (with aluminum propel- kg (lb) 227.0 (500.4)
Page 25: Lower Unit
Model data Lower unit Model Item Unit F150B FL150B Gear shift positions F–N–R Gear ratio 2.00 (28/14) Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction (rear view) Clockwise Counter clockwise Propeller mark...
Page 26: Battery Requirement
SPEC Specification Battery requirement Model Item Unit F150B FL150B Minimum cold cranking amps CCA/EN Minimum rated capacity 20HR/IEC PTT requirement Model Item Unit F150B FL150B ATF Dexron ΙΙ Fluid type L (US qt, Fluid type quantity 0.7 (0.7, 0.6) Imp qt)
Page 27: Electrical Technical Data
Model data / Electrical technical data Electrical technical data Electrical technical data Ignition timing control system Model Item Unit F150B FL150B Spark plug mm (in) 1.0–1.1 (0.039–0.043) Spark plug wire Resistance at 20 °C (68 °F) kΩ 4.6–10.9 kΩ 3.3–8.0 kΩ...
Page 28: Fuel Injection Control System
SPEC Specification Model Item Unit F150B FL150B Air pressure sensor Input voltage 4.75–5.25 Output voltage at –20.0 kPa (–0.20 kgf/ 3.21 , –2.9 psi) at –46.7 kPa (–0.467 kgf/ 2.16 , –6.8 psi) Engine temperature sensor Resistance (*1) at 20 °C (68 °F) kΩ...
Page 29: Engine Speed Control System
Electrical technical data Engine speed control system Model Item Unit F150B FL150B Oil pressure sensor Input voltage 4.75–5.25 Output voltage (*1) at 450.0 kPa (4.50 kgf/ , 65.3 psi) and 60 °C (140 °F) with SL 10W-30 engine oil and at 700 r/...
Page 30: Charging System
SPEC Specification Charging system Model Item Unit F150B FL150B Lighting coil Output peak voltage at cranking (unloaded) 11.0 at 1500 r/min (unloaded) 50.0 at 3500 r/min (unloaded) 110.0 Resistance (*1) Ω at 20 °C (68 °F) 0.2–0.3 Fuse Rectifier Regulator...
Page 31: Gauge / Sensor
Electrical technical data Gauge / sensor Model Item Unit F150B FL150B Hour meter Input voltage 11.2 Water pressure sensor Input voltage 4.75–5.25 Output voltage at 392.0 kPa (3.92 kgf/ , 56.8 psi) at 784.0 kPa (7.84 kgf/ , 113.7 psi)
Page 32: Fuel System Technical Data
SPEC Specification Fuel system technical data Fuel system Model Item Unit F150B FL150B Fuel filter assembly Holding pressure kPa (kgf/ Positive pressure 200.0 (2.00, 29.0) , psi) kPa (kgf/ Negative pressure 80.0 (0.80, 11.6) , psi) Fuel pump Holding pressure...
Page 33: Power Unit Technical Data
Fuel system technical data / Power unit technical data Power unit technical data Power unit technical data Power unit Model Item Unit F150B FL150B Cylinder Minimum compression pres- kPa (kgf/ 880.0 (8.80, 127.6) sure (*1) , psi) Engine oil Oil pressure (*2) at 60 °C (140 °F) with SL...
Page 34 SPEC Specification Model Item Unit F150B FL150B Valve lifter Outside diameter mm (in) 32.982–32.997 (1.2985–1.2991) Camshaft Cam lobe height Intake mm (in) 45.300–45.400 (1.7835–1.7874) Exhaust mm (in) 44.350–44.450 (1.7461–1.7500) Cam lobe width Intake mm (in) 35.950–36.050 (1.4154–1.4193) Exhaust mm (in) 35.950–36.050 (1.4154–1.4193)
Page 35: Crankcase Assembly
Power unit technical data Crankcase assembly Model Item Unit F150B FL150B Cylinder Bore mm (in) 94.000–94.017 (3.7008–3.7014) Piston Diameter mm (in) 93.921–93.941 (3.6977–3.6985) Measuring point mm (in) 14.0 (0.55) Piston clearance (*1) mm (in) 0.075–0.080 (0.0030–0.0031) Ring groove (Top) mm (in) 1.23–1.25 (0.0484–0.0492)
Page 36 SPEC Specification Model Item Unit F150B FL150B Crankcase Crankshaft journal oil clear- mm (in) 0.021–0.050 (0.0008–0.0020) ance Thermostat Valve opening temperature at 0.05 mm (0.0020 in) °C (°F) 58.0–62.0 (136.4–143.6) Fully open temperature °C (°F) 70.0 (158.0) Fully open stroke at 70.0 °C (158.0 °F)
Page 37: Lower Unit Technical Data
Power unit technical data / Lower unit technical data Lower unit technical data Lower unit technical data Lower unit assembly (regular rotation model) Model Item Unit F150B Lower unit kPa (kgf/ , psi) Holding pressure 68.6 (0.686, 9.9) Pinion-to-forward gear...
Page 38: Bracket Unit Technical Data
SPEC Specification Bracket unit technical data PTT system Model Item Unit F150B FL150B Hydraulic pressure MPa (kgf/ Down (*1) 5.9–8.8 (59.0–88.0, 855.5–1276.0) , psi) MPa (kgf/ Up (*1) 9.8–11.8 (98.0–118.0, 1421.0–1711.0) , psi) Motor brush Standard length mm (in) 9.8 (0.39)
Page 39: Special Tightening Torque
Bracket unit technical data / Special tightening torque Special tightening torque Special tightening torque Fuel system Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Canister bracket bolt Fuel pump cover screw Fuel pump assembly bolt Filter cup —...
Page 40: Lower Unit (Regular Rotation Model)
SPEC Specification Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Thermoswitch — 17.0 Exhaust cover plug 40.6 Exhaust cover bolt Engine temperature sensor — 11.1 Cylinder block plug 17.0 Engine hanger bolt Oil pressure sensor — 13.3 Oil filter —...
Page 41: Lower Unit (Counter Rotation Model)
Special tightening torque Lower unit (counter rotation model) Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Gear oil check screw — Gear oil drain screw — Lower case mounting bolt 34.7 Trim tab bolt 31.0 Propeller nut —...
Page 42: General Tightening Torque
SPEC Specification Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Manual valve — 0.35 2.58 Tilt cylinder end screw — 12.8 94.4 Tilt piston nut — 70.8 Trim cylinder end screw — 14.0 103.3 Filter plug — General tightening torque This chart specifies tightening torques for standard fasteners with a standard ISO...
Page 43 TECH Technical features and description Electronic control system ............2-1 Engine ECM component ............2-2 Sensor, switch and actuator ............2-4 Electronic fuel injection control system ........2-5 Ignition timing control system ..........2-10 Engine speed control system ..........2-13 Idle speed control ..............
Page 44: Technical Features And Description
F150B has fail-safe functions. In the event of a failure related to each sensor and actuator, the fail- safe function works to continue the control using the reference values set by engine ECM, or stop the engine.
Page 45: Engine Ecm Component
Electronic control system Engine ECM component Pulser coil Thermoswitch Ignition coil Oil pressure sensor Engine ECM Air temperature sensor Hour meter...
Page 46 TECH Technical features and description Air pressure sensor ISC valve Engine temperature sensor Throttle body High-pressure fuel pump Fuel injector...
Page 47: Sensor, Switch And Actuator
Electronic control system Sensor, switch and actuator Calculates the command values, and controls the fuel injection, Engine ECM ignition timing, and the engine speed based on the signals sent by each sensors. For detecting the engine speed. For detecting the crankshaft angle and the position of the pistons. Pulser coil For identifying each group of cylinders (#1 and #4, #2 and #3).
Page 48: Electronic Fuel Injection Control System
Technical features and description Electronic fuel injection control system F150B uses electronic fuel injection control system to control the fuel injection timing and the amount of injected fuel. The fuel injection amount (example: duration of fuel injector energization) is controlled to assure the appropriate air/fuel ratio based on the intake air flow rate calculated from intake pressure and engine speed, responding to every engine operating condition represented by the signals from each sensor.
Page 49 Electronic control system Circuit diagram Pulser coil #1 Pulser coil #1 Pulser coil #2 Pulser coil #2 Fuel injector #1 Fuel injector #1 Fuel injector #2 Fuel injector #2 Fuel injector #3 Fuel injector #3 Air pressure sensor Air pressure sensor Fuel injector #4 Fuel injector #4 Ground...
Page 50 TECH Technical features and description System chart After running through the fuel filter, the fuel is sent to the vapor separator by the fuel pump attached to the cylinder head cover and driven by the camshaft. Then, the fuel is pressurized by the electric fuel pump within the vapor separator, runs through the pressure regulator to the fuel rail, and injected into the combustion chamber through the fuel injector.
Page 51 Electronic control system Fuel injection control Synchronous Simultaneous The fuel injection timing control applicable to the start-up mode injection injection for a after the cylinder identification is completed by the pulser coil. group of Fuel injectors are turned on simultaneously for each cylinder cylinders at group (#1 and 4, #2 and 3), synchronized at the crankshaft engine start-...
Page 52 TECH Technical features and description Normal group injection Cylinder 1 Compression Combustion Exhaust Intake Compression Cylinder 3 Intake Compression Combustion Exhaust Intake Cylinder 4 Exhaust Intake Compression Combustion Exhaust Cylinder 2 Combustion Exhaust Intake Compression Combustion BTDC70° BTDC10° BTDC70° BTDC10° BTDC70°...
Page 53: Ignition Timing Control System
Electronic control system Ignition timing control system F150B uses ignition timing control system to control the ignition timing and the duration of ignition coil energization. High output power, improved fuel economy, and low exhaust emissions are attained by properly controlling the ignition timing and the duration of ignition coil energization in response to every engine operating conditions, based on the signals from each sensor and the map data.
Page 54 TECH Technical features and description Block diagram Crankshaft angle, Engine speed Pulser coil Throttle valve opening Neutral position Neutral switch Ignition signal Intake air pressure Ignition coil #1 and #4 Air pressure sensor Engine Intake air temperature Air temperature sensor Ignition signal Ignition coil #2 and #3 Engine temperature...
Page 55 Electronic control system Circuit diagram Pulser coil #1 Pulser coil #2 Air pressure sensor Ground Engine temperature sensor Ignition coil #1 and #4 Air temperature sensor Engine Ignition coil #2 and #3 Shift cut switch Engine shut-off switch Neutral switch YDIS Main switch Rectifier...
Page 56: Engine Speed Control System
TECH Technical features and description Engine speed control system Engine speed control system on F150B reduces the engine speed in case of overheat and low oil pressure to prevent possible engine damages. Control Description Engine condition Name Overheat Detects the...
Page 57 Electronic control system For the shift cutout control, fuel injection is shut off in the cylinder order #1, #4, and #3 at 2.5-second intervals when the engine is running at 2000 r/min or more. Fuel injection to the #2 cylinder is not shut off.
Page 58 TECH Technical features and description Circuit diagram Pulser coil #1 Fuel injector #1 Pulser coil #2 Fuel injector #2 Fuel injector #3 Fuel injector #4 Ignition coil #1, 4 Air pressure sensor Ignition coil #2, 3 Oil pressure sensor Ground Oil pressure lamp Engine temperature sensor Over heat lamp...
Page 59: Idle Speed Control
Electronic control system Idle speed control Engine ECM controls the amount of intake air into the engine at idle by driving the ISC stepper motor based on the signals from each sensor to regulate the area of the passage bypassing the main pipe where the throttle valve is installed.
Page 60: Fail-Safe Control
TECH Technical features and description Fail-safe control If the electrical components malfunction, the engine ECM controls the ignition and fuel injection as shown in the table. Trouble Malfunction Criterion Ignition control Fuel injection control code components Pulser coil No signal received during four Fixed to BTDC 10°...
Page 61: Power Unit System
Power unit system Power unit system Outline of system F150B is equipped with L 4, 4-stroke engine. The offset crank shaft is used, in which the crankshaft centerline is offset by 10.0 mm (0.39 in) from the cylinder centerline. The long intake manifold made from plastic is used for higher intake efficiency to obtain higher out- put power.
Page 62 TECH Technical features and description Cylinder head cover The blowby gas separator is used to obtain low emissions and is built into the cylinder head cover to obtain a compact design. The gas and oil flow is shown below. Blowby gas Intake silencer Blowby gas separator (integrated with cylinder head cover)
Page 63 Power unit system Connecting rod The connecting rod and connecting rod cap are manufactured as a single piece. Then, they are split using impact force. Only use the connecting rods and connecting rod caps in their original combina- tions, do not interchange them. Connecting rod Connecting rod cap 2-20...
Page 64 TECH Technical features and description Offset crankshaft The crankshaft centerline is offset by 10.0 mm (0.39 in) from the centerline of the cylinder bore. The offset positioning results in the disagreement of crankshaft TDC with piston TDC, and allows the dif- ferent duration of compression stroke from that of combustion stroke.
Page 65: Lubrication System
Power unit system / Lubrication system Lubrication system Lubrication system The lubrication oil flow diagram is as follows. Crankcase Cylinder head Cylinder sleeve Piston Crank pin Camshaft Camshaft journal Intake and exhaust valve Crankshaft main journal Main passage Oil filter Oil pressure sensor Oil filter bracket Relief valve...
Page 66 TECH Technical features and description Engine oil flow Oil pan Oil strainer Oil pump Oil filter Oil pressure sensor Relief valve 2-23...
Page 67: Cooling System
Lubrication system / Cooling system Cooling system Cooling system The fresh cooling water is taken into the front of the trim tab and supplied to the exhaust passage of the lower case to cool the exhaust gas. Cooling water also flows around the muffler to cool the upper case and reduce exhaust noise. Thermostat Cylinder block Cylinder head...
Page 68 TECH Technical features and description Cooling water flow Water inlet Water pump Oil pan Exhaust guide Exhaust cover Thermostat 2-25...
Page 69 Cooling system Cooling water flow Flushing hose (exhaust cover-to-garden hose adapter) Cooling water hose (exhaust cover-to-fuel cooler) Cooling water hose (fuel cooler-to-cooling water pilot hole) Speedometer hose Exhaust cover Fuel cooler Pilot hole (on the bottom cowling) 2-26...
Page 70: Intake And Exhaust System
TECH Technical features and description Intake and exhaust system The intake and exhaust air flow diagram. Intake air flow Throttle body Exhaust gas flow Intake manifold Exhaust cover Exhaust guide Exhaust manifold Muffler Propeller Intake silencer 2-27...
Page 71: Idle Exhaust System
Intake and exhaust system Idle exhaust system The exhaust gas runs out through the idle exhaust port at idle engine speed. The labyrinth structure is used to reduce the exhaust noise. Exhaust gas flow Labyrinth structure 2-28...
Page 72: Ptt Unit
TECH Technical features and description PTT unit Trim-up and tilt-up function When the PTT switch is pressed to “UP,” the PTT motor operates the gear pump and fluid pressure is generated. As a result, the fluid pressure pushes the up-shuttle piston, enters the trim cylinder and tilt cylinder lower chambers through the up-main valve, and then pushes the trim ram and tilt ram upward.
Page 73: Trim Ram Retraction Function
PTT unit Trim ram retraction function When the outboard motor is tilted up and held in place with the tilt stop lever and the PTT switch is pressed to “DN,” the trim ram will be retracted. Although the gear pump attempts to draw fluid from the tilt cylinder and trim cylinder lower cham- bers, after the PTT switch has been pressed, fluid cannot be drawn from the tilt cylinder lower cham- ber because the tilt ram is secured in place by the tilt stop lever.
Page 74: Trim-Down And Tilt-Down Function
TECH Technical features and description Trim-down and tilt-down function When the PTT switch is pressed to “DN,” the power trim and tilt motor operates the gear pump and fluid pressure is generated. As a result, the fluid pressure pushes the down-shuttle piston, enters the tilt cylinder upper chamber through the down-main valve, and then pushes the tilt ram down- ward.
Page 75: Stationary Condition
PTT unit Stationary condition When the PTT switch is not pressed, the gear pump will not pump the fluid, the up-main valve and the down-main valve will remain closed, and the PTT unit in the system remains constant. This will allow the tilt ram and the trim ram to maintain their positions until the PTT fluid flows through the system again.
Page 76 GING Rigging information Outboard motor installation ........... 3-1 Dimensions ................. 3-2 Exterior ..................3-2 Clamp bracket ................3-3 Crate top cover pictograph description ......3-4 Uncrate procedure ..............3-5 Outboard motor mount ............3-6 Mounting the rigging grommet ..........3-8 Rigging grommet description .............
Page 77 Rigging recommendations ........... 3-25 Extension length recommendation of battery cable ....3-25 Propeller selection ..............3-26 Propeller size ................3-26 Selection .................. 3-26...
Page 78: Rigging Information
• Improper mounting of the outboard motor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. Consult your dealer or a Yamaha trained per- son experienced in proper rigging should mount the motor.
Page 79: Dimensions
Outboard motor installation / Dimensions Dimensions Dimensions Exterior mm (in) 629 (24.8) 1148 (45.2) 164 (6.5) 698 (27.5) 75 (3.0) 162(6.4) 43 (1.7) 646 (25.4) (*1) The distance between the center of PORT outboard motor and the center of STBD outboard motor. (*2) Transom height...
Page 80: Clamp Bracket
GING Rigging information Clamp bracket mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 82 (3.2) 13 (0.5) 13 (0.5) 125.4 (4.9) 125.4 (4.9)
Page 81: Crate Top Cover Pictograph Description
Dimensions / Crate top cover pictograph description Crate top cover pictograph description Crate top cover pictograph description The following pictographs are important signs to handle the crate. Read the notice and understand what pictographs mean to avoid a damage to the product when handling, transporting and/or keeping the crate.
Page 82: Uncrate Procedure
GING Rigging information Uncrate procedure 1. Check for any shipping damage. 2. Remove the top cover. 3. Remove all bolts from the bottom plate, and remove the frame. NOTICE: Be careful not to cause any damage to the outboard motor. 4.
Page 83: Outboard Motor Mount
Uncrate procedure / Outboard motor mount Outboard motor mount Outboard motor mount Proper mounting of the outboard motor will mean better performance, maximum reliabil- ity, and maximum customer satisfaction. This chapter contains the specifications neces- sary for the outboard motor mounting, and may vary slightly depending on application.
Page 84 GING Rigging information Mount twin outboard motors so the dis- TIP: tance from the center line of each outboard This mounting height information is for refer- motor to the centerline of the boat transom ence only. It is impossible to provide com- are equal on both sides.
Page 85: Mounting The Rigging Grommet
Outboard motor mount / Mounting the rigging grommet Mounting the rigging grommet Mounting the rigging grommet Rigging grommet description Main wiring harness Water temperature lead (option) Boat transom Mounting bolt Water pressure hose (option) thickness (D) Isolator lead (option) M12 × 115 mm 55–65 mm Battery cable Gauge harness...
Page 86 GING Rigging information 2. Remove the bolts c, and then remove the retaining plate b. 7. Align the mark a on the bushing h with the mark b on the plate i. 3. Fully screw in the cable joint d to the shift cable e.
Page 87: Installing The Throttle Cable
Mounting the rigging grommet 2. Open the clamp c of the throttle cable holder d. 10. Install the cable joint d to the pin c, and secure it with the clip k. TIP: TIP: Throttle cable position is adjustable by using Pull the inner cable to avoid the free play the throttle cable holder d.
Page 88: Installing The Isolator Lead (Option)
GING Rigging information 5. Adjust the cable joint a to the pin c of throttle cam. WARNING! The throttle cable joint must be screwed in a minimum 8.0 mm (0.31 in). Locknut h: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 9. Check the throttle cable for proper operation.
Page 89: Installing The Water Temperature Sensor (Option)
Mounting the rigging grommet 2. Remove the yellow tape b to make the 2. Connect the gauge harness b to the coupler a. wires loose. 3. Install the coupler a to the bracket a. 3. Remove the each caps, and then connect the couplers c and d.
Page 90 GING Rigging information 2. Install the extension hose d to the nipple c, and then fasten it with the plastic tie 7. Install the speed sensor j onto the speed sensor adapter i, and then tighten the speed sensor to the specified torque.
Page 91: Installing The Water Pressure Sensor (Option For 6Y8 Multifunction Meter)
Mounting the rigging grommet Adapter c: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 3. Install the water pressure sensor d onto the adapter c, and then tighten the water pressure sensor d to the specified torque. 10. Install the rubber seal in the area c of the rigging grommet.
Page 92: Installing The Rigging Grommet
GING Rigging information 2. Connect the main wiring harness coupler a, and then secure the main wiring harness coupler a with the holder c. TIP: Make sure that the rubber seal is installed securely. Installing the rigging grommet 1. Install each harness in the relevant posi- 6.
Page 93: Installing The Fuel Flow Sensor
Mounting the rigging grommet / Installing the fuel flow sensor / Remote control box and switch panel installation Installing the fuel flow sensor Installing the fuel flow sensor Remote control box and switch panel installation 1. Install the fuel joints a to the fuel flow sensor b.
Page 94: Installing The Battery
GING Rigging information Installing the battery • Improper battery connections or cable size selection may result in a fire. • When installing an isolator lead to the positive battery terminal or battery switch, over-cur- rent protection in compliance with ABYC (E-11) must be provided. If battery connections are reversed, thorough charging system testing is required, replace damaged components.
Page 95 Installing the battery Outboard Outboard motor motor STBD PORT Isolator lead Black Black Battery cable Black Isolator lead Outboard motor Isolator lead Isolator lead Battery switch Black Black ON/OFF Battery cable Isolator lead Outboard Outboard motor motor STBD PORT Isolator lead Battery switch Battery switch ON/OFF...
Page 96: Battery Wiring With House (Accessory) Battery
GING Rigging information Battery wiring with house (accessory) battery • When only one battery is used for one engine, connect the positive battery cable and the isolator lead to the positive battery terminal. If the isolator lead is left unconnected, acci- dental contact of the isolator lead with the negative terminal of the battery can cause a short circuit which may result in a fire.
Page 97 Installing the battery Outboard motor Isolator lead Black Black Battery cable House battery Isolator lead Outboard Outboard motor motor STBD PORT Isolator lead Battery switch Battery switch ON/OFF Black Black ON/OFF ON/OFF Black Black Battery cable House battery Isolator lead Outboard Outboard STBD...
Page 98 GING Rigging information 3-21...
Page 99: System Diagram
System diagram 3-22...
Page 100 GING Rigging information 3-23...
Page 101 System diagram 3-24...
Page 102 GING Rigging information Rigging recommendations Extension length recommendation of battery cable Exceeding the recommended extension length of battery cable may cause poor electrical system performance or damage. To extend the length of battery cables, follow the requirements in the tables for your battery capacity, cable size, and ambient temperature.
Page 103: Propeller Selection
Rigging recommendations / Propeller selection Propeller selection Propeller selection Selection When the engine speed is at the full throttle The performance of a boat and outboard operating range (4500–5500 r/min), the ideal motor will be critically affected by the size propeller for the boat is one that provides and type of propeller you choose.
Page 104 GING Rigging information Counter rotation model Propeller size (in) Material 14 × 19 - ML Aluminum 14 1/2 × 17 - ML 13 3/4 × 17 - ML1 13 3/4 × 19 - ML1 13 3/4 × 21 - ML 13 3/8 ×...
Page 105 TRBL SHTG Troubleshooting YDIS ....................4-1 Feature ..................4-1 Hardware requirement ............... 4-1 Function ..................4-2 YDIS kit ..................4-3 Connecting the communication cable to the outboard motor ..4-3 Troubleshooting the power unit ..........4-4 Troubleshooting procedure ............4-4 Troubleshooting the power unit using the YDIS ......
Page 106: Troubleshooting
TRBL SHTG Troubleshooting YDIS This manual contains the model-specific information. See “YDIS Instruction Manual” for detailed information. Feature The newly developed YDIS provides quicker detection and analysis of engine malfunctions. By connecting your computer to the engine ECM of an outboard motor using the communication cable, this software can be used to display sensor data and data stored in the engine ECM on the computer’s monitor.
Page 107: Function
YDIS Function • Diagnosis Displays each part name, and the engine ECM trouble codes and status when the engine start switch is turned to “ON.” This allows you to quickly specify malfunctioning parts. The trouble codes displayed are the same as those described. See “Trouble code and checking step” (4-6). •...
Page 108: Ydis Kit
TRBL SHTG Troubleshooting • Record of engine oil exchange This function can record the history of engine oil exchange. YDIS kit Item Q’ty CD-ROM (software + instruction manual) Adapter Communication cable YDIS (CD-ROM, Ver. 1.30) a: 60V-WS853-04 YDIS (KIT) a, b, c: 60V-85300-04 Connecting the communication cable to the outboard motor YDIS coupler (gray)
Page 109: Troubleshooting The Power Unit Troubleshooting Procedure
YDIS / Troubleshooting the power unit Troubleshooting the power unit Troubleshooting the power unit Troubleshooting procedure 1. Before troubleshooting the outboard motor, make sure that fresh fuel of the specified type has been used. 2. Check that all electrical connections are tight and from corrosion, and that the battery is fully charged to 12 V.
Page 110 TRBL SHTG Troubleshooting Trouble code table O: Indicate —: Not applicable Diagnosis Diagnosis Diagnostic Code code output record Item test lead code (YDIS Ver. (YDIS Ver. output 1.30) 1.30) Normal — — Pulser coil malfunction Engine temp sensor malfunction (Engine temperature sensor mal- function) Throttle position sensor malfunction Battery voltage malfunction...
Page 111 Troubleshooting the power unit...
Page 112 TRBL SHTG Troubleshooting...
Page 113 Troubleshooting the power unit...
Page 114 TRBL SHTG Troubleshooting...
Page 115: Trouble Code And Checking Step
Troubleshooting the power unit Troubleshooting the power unit 4. If a trouble code is detected, see “Trouble code and checking step” (4-6). using the diagnostic flash indicator 1. Connect the special service tool a. TIP: When more than one trouble code is detected, the Diagnostic flash indicator B flashes in the pattern of the lowest trouble code.
Page 116 TRBL SHTG Troubleshooting 4-11...
Page 117 Troubleshooting the power unit 4-12...
Page 118 TRBL SHTG Troubleshooting 4-13...
Page 119 Troubleshooting the power unit 4-14...
Page 120 TRBL SHTG Troubleshooting 4-15...
Page 121 Troubleshooting the power unit 4-16...
Page 122 TRBL SHTG Troubleshooting 4-17...
Page 123 Troubleshooting the power unit 4-18...
Page 124 ELEC Electrical system Electrical components ............. 5-1 Port view ..................5-1 Junction box assembly .............. 5-2 Aft view ..................5-3 Bow view ................... 5-4 Top view ..................5-5 Wiring harness routing ............5-6 Port view ..................5-6 Junction box assembly .............. 5-7 Aft view ..................
Page 125 Checking the Rectifier Regulator ..........5-27 Ignition units and components ........... 5-28 Checking the ignition spark ............. 5-28 Checking the spark plug wire ..........5-28 Checking the ignition coil ............5-29 Checking the pulser coil ............5-30 Checking the air temperature sensor ........5-31 Checking the air pressure sensor ..........
Page 126: Electrical System
ELEC Electrical system Electrical components Port view Engine ECM Starter motor Thermoswitch Rectifier Regulator Ignition coil Speed sensor coupler Water pressure sensor coupler Oil pressure sensor Fuse holder...
Page 127: Junction Box Assembly
Electrical components Junction box assembly Engine ECM Fuse (50 A) (engine battery) PTT relay Air temperature sensor Starter relay Diode (connect to the PTT relay) Flash indicator connector Fuse (30 A) (starter relay) Fuse (30 A) (20 A) (spare) Fuse (20 A) (engine start switch, PTT switch) Fuse (20 A) (engine ECM, ISC, fuel injector, high-pressure fuel pump, ignition coil, YDIS) Fuse (50 A) (house battery)
Page 128: Aft View
ELEC Electrical system Aft view Spark plug wire High-pressure fuel pump coupler Fuel injector Shift cut switch coupler Neutral switch coupler...
Page 129: Bow View
Electrical components Bow view Hour meter Main harness coupler YDIS coupler Water detection switch (in fuel filter)
Page 130: Top View
ELEC Electrical system Top view Air pressure sensor Joint connector Engine temperature sensor Lighting coil (stator assembly) Pulser coil...
Page 131: Wiring Harness Routing
Electrical components / Wiring harness routing Wiring harness routing Wiring harness routing Port view Blowby hose Install the ignition coil lead and speed sensor Wiring harness lead. Run the pulser coil lead under the breather hose and the wiring harness. Run the oil pressure sensor lead behind the Rectifier Regulator coupler.
Page 132: Junction Box Assembly
ELEC Electrical system Junction box assembly Starter motor lead Fasten the wiring harness, Rectifier Regulator Power supply lead lead , and the power supply lead with a Rectifier Regulator lead plastic tie. PTT motor lead Install the starter motor lead , PTT motor Isolator lead lead...
Page 133: Aft View
Wiring harness routing Aft view Run the fuel injector lead back side the fuel rail. Install the clamp to the spark plug wires #1 and #2. Install the clamp to the spark plug wires #2 and #4. Install the clamp to the spark plug wires #3 and #4.
Page 134: Top View
ELEC Electrical system Top view Cooling water pilot hose Install the pulser coil coupler to the junction Engine temperature sensor lead Junction box Run the wiring harness up side the cooling water pilot hose Run the wiring harness in the bottom cowling groove.
Page 135: Bottom Cowling
Wiring harness routing Bottom cowling Shift cut switch PTT switch lead Neutral switch PTT switch Regular rotation model 6Y8 Multifunction Meter communication cou- Counter rotation model pler Install the PTT motor lead and isolator lead Gauge harness coupler with the clamp. Isolator coupler Align the positioning tape on the flushing hose 6Y8 Multifunction Meter communication lead...
Page 136: Circuit Diagram
ELEC Electrical system Circuit diagram TIP: The circled numbers in the illustration indicate the engine ECM terminal numbers. Pulser coil #1 Fuel injector #1 Fuel injector #2 Pulser coil #2 Fuel injector #3 Fuel injector #4 Air pressure sensor Oil pressure sensor Ignition coil #1, 4 Water pressure sensor Ignition coil #2, 3...
Page 137: Ecm Coupler Layout
Circuit diagram / ECM coupler layout ECM coupler layout ECM coupler layout 1 2 3 4 5 6 7 8 9 10111213141516171819202122 23242526272829303132333435363738394041424344 Connecting part Color Connecting part Color Battery power source Red/Yellow 6Y8 Multifunction White Meter Neutral switch Blue/Green Remote control Green Ground...
Page 138: Checking The Electrical Component
When checking the peak voltage, do not touch any of the connections of the digital Checking by use of the digital tester tester probes. The electrical technical data apply to the measurements taken by the Yamaha recom- mendation tester. 5-13...
Page 139: Engine Control Units And Components
Checking the electrical component / Engine control units and components Engine control units and components The resistance shown is the value taken before the engine start. It may change depending on the environmental conditions and the ambient temperature. Input voltage changes depending on the bat- tery voltage.
Page 140: Checking The Engine Ecm Circuit
ELEC Electrical system 4. Turn the engine start switch to “ON,” and then measure the input voltage between terminals f and g. 3. Measure the input voltage at the engine ECM coupler terminal 16 and ground. Main relay input voltage: Terminal f–Terminal g 12.0 V (battery voltage) 5.
Page 141: Checking The Tps
Engine control units and components 9. Connect the engine ECM coupler a, and then install the junction box cover. Checking the TPS 1. Connect the YDIS to display “Throttle position sensor.” Engine ECM input voltage (reference data): 2. Start the engine and warm up, and then Terminal 13–Ground turn it off.
Page 142: Checking The Isc
ELEC Electrical system 4. Remove the TPS, and then measure the output voltages of the TPS when the sen- sor free position c to fully turned posi- tion d. 8. Check the wiring harness for continuity. TPS output voltage (reference data): Free position c Full turn position d 0.298 V...
Page 143 Engine control units and components 3. Disconnect the ISC coupler a. 4. Turn the engine start switch to “ON,” and then measure the ISC input voltage at the ISC coupler terminal and ground. Wiring harness continuity: Terminal 1–Terminal 20 Terminal 2–Terminal c Terminal 3–Terminal 18 Terminal 4–Terminal 21 Terminal 5–Terminal c...
Page 144: Checking The Oil Pressure Sensor
ELEC Electrical system Checking the oil pressure sensor 1. Disconnect the oil pressure sensor cou- pler a, and then connect the test har- ness (3 pins) a. P/W B 6. Check the wiring harness for continuity. Test harness (3 pins) a: 90890-06869 2.
Page 145 Engine control units and components Hour meter input voltage (reference data): Yellow (Y)–Black (B) 11.2 V 6. Check the wiring harness for continuity. 3. Turn the engine start switch to “OFF.” 4. Disconnect the 10-pin main harness cou- pler b. Wiring harness continuity: a Terminal 1–b Terminal 3 a Terminal 1–c Terminal 13...
Page 146: Checking The Water Pressure Sensor (Option)
ELEC Electrical system Checking the water pressure sensor Water pressure sensor output voltage: (option) Blue/White (L/W)–Black (B) 1. Disconnect the water pressure sensor 2.5 V at 392.0 kPa coupler a. (3.92 kgf/cm , 56.8 psi) 4.5 V at 784.0 kPa 2.
Page 147: Checking The Speed Sensor (Option)
Engine control units and components Checking the speed sensor (option) Speed sensor output voltage: 1. Disconnect the speed sensor coupler a. Blue (L)–Black (B) 2.5 V at 392.0 kPa 2. Turn the engine start switch to “ON,” and (3.92 kgf/cm , 56.8 psi) then measure the input voltage at the 4.5 V at 784.0 kPa...
Page 148: Fuel Control Units And Components
ELEC Electrical system Fuel control units and components Checking the water detection switch 1. Disconnect the water detection switch coupler a. 2. Turn the engine start switch to “ON,” and then measure the input voltage at the water detection switch coupler. Terminal Float position...
Page 149: Checking The Fuel Injector
Fuel control units and components 8. Connect the engine ECM coupler e, and Fuel injector resistance (reference data): then install junction box cover. 14.0–15.0 Ω at 20 °C (68 °F) 9. Install the filter cup assembly. See “Fuel 6. Remove the junction box cover and the filter”...
Page 150: Checking The High-Pressure Fuel Pump
ELEC Electrical system 4. Turn the engine start switch to “OFF.” Wiring harness continuity: Fuel injector #1 5. Measure the resistance of the high-pres- Terminal 1–Terminal c sure fuel pump motor. Terminal 2–Terminal 40 Fuel injector #2 Terminal 1–Terminal c Terminal 2–Terminal 39 Fuel injector #3 Terminal 1–Terminal c...
Page 151: Charging Units And Components
Fuel control units and components / Charging units and components Charging units and components Charging units and components Checking the lighting coil (stator assembly) 1. Disconnect the lighting coil coupler a, and then connect the test harness (3 pins) a. Test harness (3 pins) a: 90890-06847 2.
Page 152: Checking The Rectifier Regulator
ELEC Electrical system Checking the Rectifier Regulator If the battery cables are connected in reverse, the Rectifier Regulator can be damaged. 1. Disconnect the Rectifier Regulator cou- pler a, and then connect the test har- ness (3 pins) a. Test harness (3 pins) a: 90890-06846 2.
Page 153: Ignition Units And Components
Charging units and components / Ignition units and components Ignition units and components Ignition units and components Rectifier Regulator continuity (testing diode mode): Checking the ignition spark Tester probe Display value 1. Remove the spark plug wire cover. – (reference data) 2.
Page 154: Checking The Ignition Coil
ELEC Electrical system Spark plug wire resistance: Ignition coil output peak voltage: #1: 4.6–10.9 kΩ #1, 4 #2: 3.3–8.0 kΩ Black/Orange (B/O)–Ground #3: 3.8–9.3 kΩ #2, 3 #4: 4.2–10.0 kΩ Black/White (B/W)–Ground at 20 °C (68 °F) Loaded r/min Cranking 1500 3500 4.
Page 155: Checking The Pulser Coil
Ignition units and components Wiring harness continuity: Pulser coil output peak voltage: White/Red (W/R)–Black (B) Ignition coil #1, 4 White/Black (W/B)–Black (B) Terminal 1–Terminal 22 Terminal 2–Terminal c Unloaded Loaded r/min Ignition coil #2, 3 Cranking 1500 3500 Terminal 1–Terminal 44 DC V 21.0 39.0...
Page 156: Checking The Air Temperature Sensor
ELEC Electrical system 4. Remove the junction box cover, and then disconnect the engine ECM coupler b. 3. Check that the difference between the ambient temperature and the displayed intake temperature is within ± 5 °C (±9 °F). TIP: • Check the air temperature sensor when the 5.
Page 157: Checking The Air Pressure Sensor
Ignition units and components 11. Connect the engine ECM coupler b, and then install the junction box cover. 12. Install the air temperature sensor, and then connect the air temperature sensor coupler a. Checking the air pressure sensor 1. Disconnect the air pressure sensor cou- pler a.
Page 158: Checking The Engine Temperature Sensor
ELEC Electrical system 4. Connect the special service tool a and test harness (3 pins) b. Vacuum/pressure pump gauge set a: 90890-06756 Test harness (3 pins) b: 90890-06869 5. Apply negative pressure to the air pres- sure sensor slowly, and then measure the output voltage.
Page 159: Checking The Thermoswitch
Ignition units and components B B/Y Engine temperature sensor input voltage: Black/Yellow (B/Y)–Black (B) 4.75–5.25 V 9. Check the wiring harness for continuity. 3. Turn the engine start switch to “OFF.” 4. Remove the engine temperature sensor. 5. Place the engine temperature sensor in a container of water and slowly heat the water.
Page 160 ELEC Electrical system 2. Turn the engine start switch to “ON,” and then measure the input voltage at the thermoswitch connectors. Temperature Time No continuity Continuity Thermoswitch continuity temperature: e: 84–90 °C (183–194 °F) f: 68–82 °C (154–180 °F) Thermoswitch input voltage: 7.
Page 161: Checking The Shift Cut Switch
Ignition units and components Wiring harness continuity: Shift cut switch resistance: 4.465–4.935 kΩ at b position Pink (P)–Terminal 37 0 Ω at c position at 20 °C (68 °F) Black (B)–Terminal 8 6. Remove the junction box cover, and then 10.
Page 162: Checking The Neutral Switch
ELEC Electrical system Checking the neutral switch 1. Disconnect the neutral switch coupler a. 2. Turn the engine start switch to “ON,” and then measure the input voltage. 7. Check the wiring harness for continuity. Neutral switch input voltage: Blue/Green (L/G)–Black (B) 4.75–5.25 V 3.
Page 163: Starting Units And Components
Ignition units and components / Starting units and components Starting units and components Starting units and components START Checking the starter relay 1. Remove the junction box cover. 2. Measure the input voltage between the starter relay terminal a and ground. 704 remote control 703 remote control Terminal...
Page 164: Checking The Engine Start Switch
ELEC Electrical system Terminal Battery lead Connect Disconnect 5. Install the starter relay, and then connect the starter relay leads. 6. Install the junction box cover. 704 remote control Checking the engine start switch 703 remote control 1. Disconnect the engine start switch cou- Terminal Lever pler.
Page 165 Starting units and components / Starter motor Starter motor Starter motor Part name Q’ty Remarks Stator Armature Brush holder assembly Brush spring Brush assembly Starting motor gear assembly Washer set Bracket M4 × 15 mm Screw M6 × 117 mm Bolt M6 ×...
Page 166 ELEC Electrical system Part name Q’ty Remarks Pinion shaft Planetary gear Plate Starter motor pinion Pinion stopper set Rubber seal Lever assembly Gasket Not reusable Magnet switch Washer 5-41...
Page 167: Starter Motor
Starter motor Removing the starter motor 2. Connect the negative battery cable to the starter motor body c. 1. Remove the junction box cover. 3. Connect the positive battery cable to the 2. Remove the starter motor from the power starter motor lead (Brown/White) d, and unit.
Page 168: Disassembling The Starter Motor
ELEC Electrical system 4. Remove the bolts g, and then disassem- 2. Check for smooth operation. Turn the pin- ion counterclockwise to check that it ble the starter motor. operates smoothly and turn it clockwise to check that it locks in place. Disassembling the starter motor 1.
Page 169: Checking The Starter Motor
Starter motor 8. Remove the plate o, and then remove Checking the starter motor the armature l from the brush holder 1. Check the commutator. Clean with assembly m. 600–grit sandpaper and compressed air if dirty. 2. Measure the commutator diameter a. Replace the armature if below specifica- tion.
Page 170: Checking The Brush
ELEC Electrical system 4. Check armature continuity. Replace the armature if out of specifica- tions. Brush standard length f: 15.5 mm (0.61 in) Wear limit g: 9.5 mm (0.37 in) Armature continuity: Assembling the starter motor Do not allow grease or oil to contact the Checking the brush commutator of the armature.
Page 171 Starter motor TIP: Make sure that the clutch assembly j does not come out from the pinion shaft k. TIP: 7. Install the pinion shaft assembly m, lever Align the holes a and b in the plate with the n, rubber seal o, planetary gears p, holes a and b in the bracket e.
Page 172: Installing The Starter Motor
ELEC Electrical system 8. Assemble the starter motor. Installing the starter motor 1. Install the starter motor to the power unit. See “Starter motor” (7-12). 2. Install the junction box cover. 9. Install the spring s, pinion t, pinion stopper u and clip v. 10.
Page 173: Ptt System
Starter motor / PTT system PTT system PTT system PTT relay continuity: Checking the PTT relay 1. Remove the junction box cover 2. Measure the input voltage between the PTT relay terminal a and terminal b. 6. Connect the positive battery lead to the terminal e, and the negative battery lead to the terminal b, and then check the PTT relay for continuity.
Page 174: Checking The Ptt Switch (On Bottom Cowling)
ELEC Electrical system 7. Connect the positive battery lead to the PTT switch input voltage: terminal f, and the negative battery lead Red (R)–Ground to the terminal b, and then check the 12.0 V (battery voltage) PTT relay for continuity. Replace the PTT relay if out of specification.
Page 175: Checking The Trim Sensor
PTT system Wiring harness continuity: Trim sensor resistance (reference data): 238.8–378.8 Ω at b a Terminal 1–e Terminal 1 9.0–11.0 Ω at c (setting resistance) a Terminal 2–e Terminal 2 a Terminal 3–Terminal c 4. Disconnect the gauge harness coupler 7.
Page 176 FUEL Fuel system Hose routing ................6-1 Fuel hose and blowby hose ............6-1 Vapor gas hose ................. 6-2 Cooling water hose ..............6-3 Fuel line ..................6-4 Reducing the fuel pressure ............6-4 Measuring the fuel pressure ............6-4 Checking the pressure regulator ..........
Page 177 Fuel injector ................6-25 Checking the fuel rail ............... 6-26 Installing the fuel injector ............6-26 Intake manifold ................ 6-27 Checking the intake manifold ..........6-28 Checking the air pressure sensor ..........6-28 Checking the ISC ..............6-28 Installing the intake manifold ........... 6-28 Vapor separator ...............
Page 178: Fuel System
FUEL Fuel system Hose routing Fuel hose and blowby hose Fuel hose (primer pump-to-fuel filter) Blowby hose (cylinder head cover-to-intake Fuel hose (fuel filter-to-joint) silencer) Fuel hose (joint-to-fuel pump) Fuel hose (joint-to-fuel pump) Primer pump Fuel hose (fuel pump-to-joint) Fuel filter Fuel hose (fuel pump-to-joint) Fuel pump Fuel hose (joint-to-filter)
Page 179: Vapor Gas Hose
Hose routing Vapor gas hose Vapor gas hose (vapor separator-to-joint) Vapor separator Vapor gas hose (vapor separator-to-joint) Joint Vapor gas hose (joint-to-filter) Filter Vapor gas hose (filter-to-canister tank port) Canister Vapor gas hose (canister purge port-to-joint) Filter Vapor gas hose (joint-to-joint) Pressure regulator Vapor gas hose (canister atmospheric port-to- filter)
Page 180: Cooling Water Hose
FUEL Fuel system Cooling water hose Cooling water hose (exhaust cover-to-fuel cooler) Cooling water pilot hose (fuel cooler-to-cooling water pilot hole) Flushing hose (exhaust cover-to-flushing hose adapter) Fuel cooler Cooling water pilot hole (on the bottom cowl- ing)
Page 181: Fuel Line
Hose routing / Fuel line Fuel line Fuel line Fuel pressure gauge b: Reducing the fuel pressure 90890-06786 4. Turn the engine start switch to “ON,” and Always reduce the fuel pressure in the then measure the fuel pressure within 3 high-pressure fuel line before servicing seconds.
Page 182: Checking The Pressure Regulator
FUEL Fuel system Checking the pressure regulator 1. To connect the special service tool a, see “Measuring the fuel pressure” (6-4) step 1–step 3. 2. Disconnect the pressure regulator hose b, and then connect the special service tool c to the pressure regulator d. Fuel pressure gauge a: 90890-06786 Vacuum/pressure pump gauge set c: 90890-06756...
Page 183: Canister
Fuel line / Canister Canister Canister 10 N m (1.0 kgf m, 7.4 ft lb) Part name Q’ty Remarks Hose Plastic tie Not reusable Joint Hose Clamp Hose M6 × 16 mm Bolt Filter Bracket Canister M6 × 42 mm Bolt Grommet Collar...
Page 184: Checking The Canister
FUEL Fuel system 3. Tighten the fuel pump assembly bolt d Checking the canister to the specified torque. 1. Check the canister. Replace the canister if cracked. 2. Connect the special service tool a to the atmospheric port a and cover the other ports b with fingers.
Page 185: Fuel Pump
Canister / Fuel pump Fuel pump Fuel pump 4 N m (0.4 kgf m, 3.0 ft lb) 10 N m (1.0 kgf m, 7.4 ft lb) 10 N m (1.0 kgf m, 7.4 ft lb) Part name Q’ty Remarks M6 × 35 mm Screw Cover Fuel pump body 2...
Page 186 FUEL Fuel system 4 N m (0.4 kgf m, 3.0 ft lb) 10 N m (1.0 kgf m, 7.4 ft lb) 10 N m (1.0 kgf m, 7.4 ft lb) Part name Q’ty Remarks O-ring Not reusable Hose Hose...
Page 187: Checking The Fuel Pump
Fuel pump Checking the fuel pump 1. Connect the special service tool a to the fuel pump inlet a. 2. Cover the fuel pump outlet b with a fin- ger, and then apply the specified positive pressure. Check that there is no air leak- age.
Page 188: Checking The Diaphragm And Valve
FUEL Fuel system 3. While holding the fuel pump body 1 a in place, insert a flathead screwdriver into the hole c in the plunger e and rotate it 90°. Assembling the fuel pump Before assemble the fuel pump, clean the parts and soak the valves and diaphragm in gasoline to obtain prompt operation of the 4.
Page 189: Checking The Primer Pump
Fuel pump 4. Install the pin e. Fuel pump screw f: 4 N·m (0.4 kgf·m, 3.0 ft·lb) TIP: Make sure to align the projections a, b, and 5. While holding the fuel pump body 1 Checking the primer pump assembly a in place, insert a flathead 1.
Page 190: Fuel Filter
FUEL Fuel system Fuel filter 5 N m (0.5 kgf m, 3.7 ft lb) Part name Q’ty Remarks Damper Joint Plastic tie Not reusable Hose Hose M6 × 30 mm Bolt M6 × 14 mm Bolt Collar Grommet Bracket Hose Fuel filter assembly O-ring Not reusable...
Page 191: Checking The Fuel Filter Assembly
Fuel filter Checking the fuel filter assembly 1. Connect the vacuum/pressure pump gauge a to the fuel inlet a. 2. Cover the fuel outlet b with a finger, and then apply the specified positive pres- sure. Replace the O-ring, fuel cup assembly, or fuel filter assembly if the specified pressure cannot be maintained for at least 15 seconds.
Page 192 FUEL Fuel system 7. Check the fuel cup assembly c. Clean with straight gasoline if there are foreign substance replace cracked. NOTICE: When cleaning the fuel cup assembly c, make sure not to remove the clip e and float f, otherwise the water detection switch may be dam- aged.
Page 193: Intake Silencer
Fuel filter / Intake silencer Intake silencer Intake silencer 6 N m (0.6 kgf m, 4.4 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) Part name Q’ty Remarks Intake silencer assembly O-ring Not reusable Collar Collar Grommet ×...
Page 194 FUEL Fuel system Throttle link Part name Q’ty Remarks × Bolt 35 mm Collar Wave washer Throttle cam Roller × Bolt 25 mm Collar Throttle lever 1 Washer Spring Throttle link rod Throttle lever 2 6-17...
Page 195: Throttle Link
Throttle link Checking the throttle link 1. Check the throttle lever 1, roller and throt- tle cam. Replace if cracked or worn. 2. Check the throttle lever 2, and throttle link rod. Replace if cracked or worn. 3. Check the spring. Replace if fatigued or deformed.
Page 196: Adjusting The Throttle Link
FUEL Fuel system Adjusting the throttle link 1. Contact the stopper a on the throttle lever 2 a to the fully closed stopper b on the cylinder block, and then adjust the throttle link joint assembly b so that the specified clearance c is obtained.
Page 197: Throttle Body
Throttle link / Throttle body Throttle body Throttle body 13 N m (1.3 kgf m, 9.6 ft lb) Part name Q’ty Remarks Throttle link joint 1 Throttle link joint 2 Bracket × Bolt 16 mm × Bolt 20 mm × Bolt 70 mm Throttle body assembly...
Page 198: Checking The Tps
FUEL Fuel system Checking the TPS 1. Check the TPS exterior. Replace if cracked. 2. Check the TPS electrical performance. See “Checking the TPS” (5-16). Adjusting the TPS When adjusting the TPS, the output voltage can also be measured using the “Engine monitor”...
Page 199: Installing The Throttle Body Assembly
Throttle body Installing the throttle body assembly Adjusting the TPS (when 1. Install the throttle link joint assembly a. disassembling or replacing the throttle body) When adjusting the TPS, the output voltage can also be measured using the “Engine monitor” of the YDIS. To connect and operate the YDIS, see the YDIS (Ver.
Page 200: Synchronizing The Throttle Valve
FUEL Fuel system 7. Loosen the TPS screws d and adjust the position of the TPS e to get the specified output voltage. TPS output voltage: Pink (P)–Black (B) 0.70 ± 0.02 V O P B 12. Operate the throttle valves several times and make sure that the TPS output volt- age is within specification.
Page 201 Throttle body TIP: • To increase the vacuum pressure, turn the synchronizing screw e in direction a. • To decrease the vacuum pressure, turn the synchronizing screw e in direction b. Example: Check results: Cylinder 49.0 48.0 47.0 46.0 (mmHg) (370.0) (360.0) (350.0)
Page 202: Fuel Injector
FUEL Fuel system Fuel injector 13 N m (1.3 kgf m, 9.6 ft lb) 10 mm (0.39 in) 5 N m (0.5 kgf m, 3.7 ft lb) 12 mm (0.47 in) 13 N m (1.3 kgf m, 9.6 ft lb) Part name Q’ty Remarks...
Page 203: Checking The Fuel Rail
Fuel injector Checking the fuel rail 1. Check the fuel rail. Replace the fuel rail if cracked or deformed. 2. Check the fuel injector electrical perfor- mance. See “Checking the fuel injector” (5-24). Installing the fuel injector 1. Install a new O-ring set a and a new rubber seal b to the fuel injector c.
Page 204: Intake Manifold
FUEL Fuel system Intake manifold 5N m (0.5 kgf m, 3.7 ft lb) Part name Q’ty Remarks Gasket Not reusable O-ring Not reusable Holder Filter Air pressure sensor × Screw 15 mm × Screw 15 mm Intake manifold Gasket Not reusable ×...
Page 205: Checking The Intake Manifold
Intake manifold Checking the intake manifold 1. Check the intake manifold. Replace the intake manifold if cracked or deformed. Checking the air pressure sensor 1. Check the air pressure sensor exterior. Replace if cracked. 2. Check the air pressure sensor electrical performance.
Page 206: Vapor Separator
FUEL Fuel system Vapor separator 5 N m (0.5 kgf m, 3.7 ft lb) 2 N m (0.2 kgf m, 1.5 ft lb) 2 N m (0.2 kgf m, 1.5 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) Part name Q’ty Remarks...
Page 207 Vapor separator 5 N m (0.5 kgf m, 3.7 ft lb) 2 N m (0.2 kgf m, 1.5 ft lb) 2 N m (0.2 kgf m, 1.5 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) Part name Q’ty Remarks Hose...
Page 208 FUEL Fuel system 5 N m (0.5 kgf m, 3.7 ft lb) 2 N m (0.2 kgf m, 1.5 ft lb) 2 N m (0.2 kgf m, 1.5 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) Part name Q’ty Remarks Needle valve assembly...
Page 209: Draining The Fuel
Vapor separator Draining the fuel 1. Drain the remained gasoline in the vapor separator with a drain pan. Loosen the drain screw a, and then remove the cap b. Push in the air valve with a screw- driver. 2. Remove the needle valve assembly and other components.
Page 210: Assembling The Vapor Separator
FUEL Fuel system 2. Check the needle valve. Replace needle valve assembly if bent or worn. 3. Check the float. Replace if there is deteri- oration. 4. Check the filter. Clean if there is dirt or residue. Assembling the vapor separator 1.
Page 211 Vapor separator — MEMO — 6-34...
Page 212 POWR Power unit Power unit (check and adjustment) ........7-1 Checking the compression pressure ......... 7-1 Checking the oil pressure ............7-2 Checking the valve clearance ........... 7-2 Adjusting the valve clearance ............ 7-3 Flywheel magnet ................ 7-5 Removing the flywheel magnet ..........7-6 Installing the flywheel magnet ...........
Page 213 Cylinder head ................7-36 Removing the cylinder head ............ 7-38 Checking the valve lifter ............7-38 Checking the cylinder head ............. 7-38 Checking the valve spring ............7-39 Checking the valve ..............7-39 Checking the valve guide ............7-40 Replacing the valve guide ............7-40 Checking the valve seat ............
Page 214: Power Unit
POWR Power unit Power unit (check and adjustment) Checking the compression pressure 1. Start the engine and warm up until the engine idle speed is stable at 650–750 r/ min, and then turn it off. 2. Remove the clip from the engine shut-off switch.
Page 215: Checking The Oil Pressure
Power unit (check and adjustment) 3. Disconnect the fuel hoses a and vapor Checking the oil pressure gas hoses b, and then remove the 1. Connect a computer to the outboard canister c and fuel pumps d. motor and use the YDIS. To connect and operate the YDIS, see the YDIS (Ver.
Page 216: Adjusting The Valve Clearance
POWR Power unit 9. Measure the intake valve clearance for cylinders #3 and #4, and exhaust valve clearance for cylinders #2 and #4. Adjust if out of specification. 6. Measure each valve clearance e and f Adjusting the valve clearance according to step 7–step 9.
Page 217 Power unit (check and adjustment) 8. Install the necessary valve shim into the valve lifter. 9. Install the camshafts, driven sprockets, and timing belt. See “Installing the timing belt, driven sprocket, and camshaft” (7- 30). 10. Install the stator assembly (lighting coil). 11.
Page 218 POWR Power unit Flywheel magnet 270 N m (27.0 kgf m, 199.1 ft lb) Part name Q’ty Remarks Width across flats: 36 mm Washer Base assembly M6 × 30 mm Screw Stator assembly (lighting coil) Pulser coil Holder Bracket M6 × 35 mm Bolt Holder Collar...
Page 219: Flywheel Magnet
Flywheel magnet Removing the flywheel magnet 1. Loosen the flywheel magnet nut. NOTICE: Apply force in the direction of the arrows to prevent the flywheel holder a from slipping off easily. Flywheel holder a: 90890-06522 2. Remove the flywheel magnet. NOTICE: To prevent damage to the TIP: engine or tools, screw in the flywheel...
Page 220: Wiring Harness
POWR Power unit Wiring harness Part name Q’ty Remarks Wiring harness M6 × 20 mm Bolt Wiring harness M6 × 12 mm Bolt Washer M8 × 16 mm Bolt Wiring harness...
Page 221: Removing The Wiring Harness
Wiring harness 9. Disconnect the TPS coupler k, ISC Removing the wiring harness coupler m, air pressure sensor coupler 1. Remove the flywheel magnet cover. n, and engine temperature sensor coupler p, and then remove the wiring 2. Remove the flywheel magnet. See harness from the brackets b.
Page 222: Installing The Wiring Harness
POWR Power unit 13. Remove fuse box, then disconnect the fuse box couplers u, v, and connector w. Installing the wiring harness To install all of the wiring harnesses, see “Wiring harness routing” (5-6). 14. Disconnect the oil pressure sensor 1.
Page 223 Wiring harness 4. Install the bracket a, and then connect the oil pressure sensor coupler f, thermoswitch connectors g and ignition coil couplers h. 8. Connect the hour meter coupler s. 5. Connect the fuse box couplers k, m, and connector n, and then install the fuse box.
Page 224 POWR Power unit 11. Connect the all fuel injector couplers. 12. Connect the shift cut switch coupler A and neutral switch coupler B. 13. Connect the PTT switch coupler D, trim sensor coupler gauge harness coupler F, and water detection switch coupler G, and then install the gauge harness coupler F to the bracket.
Page 225 Wiring harness / Starter motor Starter motor Starter motor 4 N m (0.4 kgf m, 3.0 ft lb) 7 N m (0.7 kgf m, 5.2 ft lb) 29 N m (2.9 kgf m, 21.4 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) Part name Q’ty Remarks...
Page 226: Starter Motor
POWR Power unit 4 N m (0.4 kgf m, 3.0 ft lb) 7 N m (0.7 kgf m, 5.2 ft lb) 29 N m (2.9 kgf m, 21.4 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) Part name Q’ty Remarks Terminal...
Page 227: Fuse Box
Starter motor / Fuse box Fuse box Fuse box Part name Q’ty Remarks Fuse box assembly Fuse 50 A M5 × 10 mm Screw Fuse 20 A Relay Fuse 30 A M5 × 20 mm Screw Cover Gasket Fuse puller Fuse 20 A, Spare Fuse...
Page 228: Junction Box
POWR Power unit Junction box 4 N m (0.4 kgf m, 3.0 ft lb) Part name Q’ty Remarks M6 × 28 mm Bolt Holder Collar Grommet Bracket Holder Hour meter M5 × 16 mm Screw Collar Grommet Junction box Collar Grommet M6 ×...
Page 229 Junction box 4 N m (0.4 kgf m, 3.0 ft lb) Part name Q’ty Remarks ø6 × 19 mm Screw Cover M6 × 10 mm Bolt M6 × 20 mm Bolt PTT relay ø6 × 19 mm Screw Holder Starter relay Holder Grommet Air temperature sensor...
Page 230: Timing Belt
POWR Power unit Timing belt 7 N m (0.7 kgf m, 5.2 ft lb) 39 N m (3.9 kgf m, 28.8 ft lb) Part name Q’ty Remarks Timing belt Timing belt tensioner Plate Washer M6 × 10 mm Screw Plate Drive sprocket M5 ×...
Page 231: Replacing The Timing Belt
Timing belt Replacing the timing belt 5. Disconnect the stator assembly coupler e and pulser coil coupler f, and then remove the blowby hose a and stator • Do not turn the flywheel magnet coun- assembly (lighting coil) b. terclockwise, otherwise the water pump impeller may be damaged.
Page 232: Power Unit Assembly
POWR Power unit TIP: Leave the pin inserted into the hole k of the timing belt tensioner until the timing belt is installed again. 9. Remove the timing belt from the driven sprockets, and then from the drive sprocket. 12. Adjust the timing belt to the specified installation height m.
Page 233 Timing belt / Power unit assembly Power unit assembly Power unit assembly 4 N m (0.4 kgf m, 3.0 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 20 N m (2.0 kgf m, 14.8 ft lb) 42 N m (4.2 kgf m, 31.0 ft lb) 42 N m (4.2 kgf m, 31.0 ft lb) Part name Q’ty...
Page 234 POWR Power unit 4 N m (0.4 kgf m, 3.0 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 20 N m (2.0 kgf m, 14.8 ft lb) 42 N m (4.2 kgf m, 31.0 ft lb) 42 N m (4.2 kgf m, 31.0 ft lb) Part name Q’ty Remarks...
Page 235: Removing The Power Unit
Power unit assembly 5. Disconnect the fuel hose d. Removing the power unit Make sure to reduce the fuel pressure before removing the power unit. See “Reducing the fuel pressure” (6-4). It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency.
Page 236: Installing The Power Unit
POWR Power unit 13. Remove the power unit by removing the bolts k, l and m. 10. Disconnect the flushing hose h. Installing the power unit 1. Clean the power unit mating surface, and install the dowels a and a new gasket 2.
Page 237 Power unit assembly Bolt (M8) c: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Bolt (M10) d and e: 42 N·m (4.2 kgf·m, 31.0 ft·lb) 3. Install the apron f, and then tightening the bolts g to the specified torque. 6. Connect the flushing hose i. 7.
Page 238 POWR Power unit 9. Connect the fuel hose l. 10. Connect the PTT motor leads d, and then install the junction box cover. PTT motor lead bolt m: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 11. Connect the battery leads n. 12.
Page 239 Power unit assembly / Camshaft Camshaft Camshaft 2 N m (0.2 kgf m, 1.5 ft lb) 60 N m (6.0 kgf m, 44.3 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 17 N m (1.7 kgf m, 12.5 ft lb) Part name Q’ty Remarks...
Page 240 POWR Power unit 2 N m (0.2 kgf m, 1.5 ft lb) 60 N m (6.0 kgf m, 44.3 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 17 N m (1.7 kgf m, 12.5 ft lb) Part name Q’ty Remarks Camshaft (EX)
Page 241: Camshaft
Camshaft Removing the timing belt, driven sprocket, and camshaft Check the valve clearances before removing the parts. • Do not turn the crankshaft counterclock- wise, otherwise the water pump impeller may be damaged. • Do not turn the crankshaft or the driven sprockets when the timing belt is not installed.
Page 242: Checking The Timing Belt And Sprocket
POWR Power unit Checking the camshaft 1. Measure the cam lobe height a and width b. Replace the camshaft if out of specification. Cam lobe height a: Intake: 45.300–45.400 mm (1.7835–1.7874 in) Exhaust: Checking the timing belt and 44.350–44.450 mm (1.7461–1.7500 in) sprocket Cam lobe width b: 1.
Page 243: Installing The Timing Belt, Driven Sprocket, And Camshaft
Camshaft 3. Measure the camshaft journal diameter c and cylinder head journal inside diameter d. Replace the camshaft, cylinder head assembly, or both if out of specifications. 63P EX 63P IN 3. Install the camshafts so that the dowels b are facing inward and that they are Camshaft journal diameter c: aligned with the mating surface of the 24.960–24.980 mm...
Page 244 POWR Power unit 5. Tighten the camshaft cap bolts to the specified torques in 2 stages and in the sequence numbers (a, b, · · ·). Apply engine oil to the camshaft caps and camshaft cap bolts before installation. Driven sprocket bolt d: 60 N·m (6.0 kgf·m, 44.3 ft·lb) 8.
Page 245: Exhaust Cover
Camshaft / Exhaust cover Exhaust cover Exhaust cover 6 N m (0.6 kgf m, 4.4 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 23 N m (2.3 kgf m, 17.0 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 55 N m (5.5 kgf m, 40.6 ft lb) Part name...
Page 246 POWR Power unit 6 N m (0.6 kgf m, 4.4 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 23 N m (2.3 kgf m, 17.0 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 55 N m (5.5 kgf m, 40.6 ft lb) Part name Q’ty...
Page 247: Removing The Exhaust Cover
Exhaust cover Removing the exhaust cover 1. Remove the cover a and thermostat b. Installing the PCV Install a new gasket a and the PCV b, and 2. Remove the exhaust cover bolts in the then tighten the bolts. sequence numbers (a, b, · · ·). Installing the exhaust cover 1.
Page 248 POWR Power unit 3. Install the thermoswitch e. Bolt d: 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 7-35...
Page 249 Exhaust cover / Cylinder head Cylinder head Cylinder head 14 N m (1.4 kgf m, 10.3 ft lb) 28 N m (2.8 kgf m, 20.7 ft lb) 15 16 13 14 25 N m (2.5 kgf m, 18.4 ft lb) 19 N m (1.9 kgf m, 14.0 ft lb) 37 N m (3.7 kgf m, 27.3 ft lb) Part name...
Page 250 POWR Power unit 14 N m (1.4 kgf m, 10.3 ft lb) 28 N m (2.8 kgf m, 20.7 ft lb) 15 16 13 14 25 N m (2.5 kgf m, 18.4 ft lb) 19 N m (1.9 kgf m, 14.0 ft lb) 37 N m (3.7 kgf m, 27.3 ft lb) Part name Q’ty...
Page 251: Cylinder Head
Cylinder head Removing the cylinder head Checking the valve lifter 1. Remove the valve lifters from the cylinder 1. Check the valve lifters. Replace if dam- head. aged, scratched, or worn. 2. Remove the cylinder head bolts in the 2. Measure the valve lifter outside diameter. sequence numbers ·...
Page 252: Checking The Valve Spring
POWR Power unit Valve margin thickness a: Cylinder head warpage limit: 0.1 mm (0.0039 in) Intake: 0.70 mm (0.0276 in) Checking the valve spring Exhaust: 1. Measure the valve spring free length a. 1.00 mm (0.0394 in) Replace if out of specification. 3.
Page 253: Checking The Valve Guide
Cylinder head 2. Install a new valve guide c using the Checking the valve guide special service tool b from the camshaft Before checking the valve guides, make sure side until the valve guide installer d that the valve stem diameter is within specifi- contacts the cylinder head.
Page 254: Checking The Valve Seat
POWR Power unit 4. Measure the valve guide inside diameter. Valve guide inside diameter: 5.504–5.522 mm (0.2167–0.2174 in) Checking the valve seat 1. Eliminate carbon deposits from the valves. 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seats.
Page 255 Cylinder head 2. Cut the surface of the valve seat with a 45° cutter by turning the cutter clockwise until the valve seat face has become smooth. NOTICE: Do not over cut the valve seat. Make sure to turn the cutter evenly downward at a pressure of 40–50 N (4.0–5.0 kgf, 8.8–11.0 lbf) to prevent chatter marks.
Page 256: Assembling The Cylinder Head
POWR Power unit 8. If the valve seat contact area is too narrow and situated near the top edge of the valve face, use a 30° cutter to cut the top edge of the valve seat, and then use a 45° cutter to center the area and set its width.
Page 257: Installing The Cylinder Head
Cylinder head TIP: The valve spring can be installed in any direction. 3. Compress the valve spring, and then install the valve cotters g. Cylinder head bolt a–j (M10): 1st: 19 N·m (1.9 kgf·m, 14.0 ft·lb) 2nd: 37 N·m (3.7 kgf·m, 27.3 ft·lb) 4.
Page 258: Cylinder Block
POWR Power unit Cylinder block 23 N m (2.3 kgf m, 17.0 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 15 N m (1.5 kgf m, 11.1 ft lb) 12 13 17 18...
Page 259 Cylinder block 4 N m (0.4 kgf m, 3.0 ft lb) 23 N m (2.3 kgf m, 17.0 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 15 N m (1.5 kgf m, 11.1 ft lb) 12 13 17 18 18 N m (1.8 kgf m, 13.3 ft lb)
Page 260 POWR Power unit 23 N m (2.3 kgf m, 17.0 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 15 N m (1.5 kgf m, 11.1 ft lb) 12 13 17 18 18 N m (1.8 kgf m, 13.3 ft lb)
Page 261: Removing The Oil Pump Assembly
Cylinder block Removing the oil pump assembly Removing the crankcase cover 1. Remove the oil pump a. 1. Remove the crankcase cover a bolts in the sequence numbers (a, b, · · ·). Removing the oil filter bracket 1. Remove the oil filter a using a 72.5 mm Disassembling the oil pump (2.9 in) oil filter wrench b, and then assembly...
Page 262: Assembling The Oil Pump Assembly
POWR Power unit Assembling the oil pump assembly General pipe e: 1. Install a new oil seal into the oil pump a = 45.0 mm (1.77 in) cover. 4. Install a new oil seal f and the gasket g, and then tighten the screws h to the specified torque.
Page 263: Installing The Crankcase Cover
Cylinder block 1. Install the new O-rings a and oil pump 2. Install the crankcase cover a onto the b by aligning the oil pump gear with the crankcase, and then tighten the bolts b and c to the specified torques in 2 crankshaft.
Page 264: Installing The Anode (Cylinder Block)
POWR Power unit 3. Install the oil filter, and then tighten it to the specified torque using a 72.5 mm (2.9 in) oil filter wrench c. Apply a thin coat of engine oil to the O-ring of a new oil filter before installation. Oil filter wrench c: 90890-06830 Oil filter:...
Page 265: Crankcase
Cylinder block / Crankcase Crankcase Crankcase 30 N m(3.0 kgf m, 22.1 ft lb) 14 N m(1.4 kgf m, 10.3 ft lb) 26 N m(2.6 kgf m, 19.2 ft lb) 30 N m(3.0 kgf m, 22.1 ft lb) 23 N m(2.3 kgf m, 17.0 ft lb) 43 N m(4.3 kgf m, 31.7 ft lb) Part name Q’ty...
Page 266: Disassembling The Cylinder Block
POWR Power unit Disassembling the cylinder block 1. Remove the crankcase bolts in the sequence numbers (a, b, · · ·). 4. Remove the crankshaft. 5. Remove the collar d. TIP: Do not remove the plugs a from the crank- case.
Page 267: Checking The Piston Diameter
Crankcase Checking the piston diameter 1. Measure the piston outside diameter at the specified measuring point. Replace if out of specification. Piston ring dimensions: Top ring a: B:1.17–1.19 mm (0.0461–0.0469 in) T:2.80–3.00 mm (0.1102–0.1181 in) Second ring b: Piston diameter a: B:1.17–1.19 mm (0.0461–0.0469 in) 93.921–93.941 mm (3.6977–3.6985 in) Measuring point b:...
Page 268: Checking The Piston Ring Groove
POWR Power unit Piston ring end gap a: Piston ring side clearance: Top ring a: Top ring: 0.15–0.30 mm (0.0059–0.0118 in) 0.04–0.08 mm (0.0016–0.0031 in) Second ring b: Second ring: 0.30–0.45 mm (0.0118–0.0177 in) 0.03–0.07 mm (0.0012–0.0028 in) Oil ring c: Oil ring: 0.15–0.60 mm (0.0059–0.0236 in) 0.04–0.13 mm (0.0016–0.0051 in)
Page 269: Checking The Crankpin Oil Clearance
Crankcase TIP: Install the connecting rod bearings in their original positions. 3. Put a piece of Plastigauge (PG-1) onto the crankpin, parallel to the crankshaft. Crankshaft journal diameter a: 51.980–52.000 mm (2.0465–2.0472 in) Crankpin diameter b: 49.980–50.000 mm (1.9677–1.9685 in) Crankpin width c: 22.00–22.10 mm (0.8661–0.8701 in) TIP:...
Page 270: Selecting The Connecting Rod Bearing
POWR Power unit 5. Tighten the connecting rod bolts to the specified torques in 3 stages. In the 3rd stage, make a mark b on the connecting rod cap bolts, connecting rod caps, and then tighten the bolts 90° from the mark. Crankpin oil clearance (reference data): 0.027–0.052 mm (0.0011–0.0020 in) Selecting the connecting rod bearing...
Page 271: Checking The Crankshaft Journal Oil Clearance
Crankcase Upper bearing Lower bearing color color Green Green Green Blue Blue Blue Blue Example: If the connecting rod big end inside diameter a is “35” and the crankpin mark b is “81,” and then select the bearing colors in “g.” Checking the crankshaft journal oil 4.
Page 272 POWR Power unit TIP: Do not put the Plastigauge (PG-1) over the oil hole in the crankshaft journals. 5. Install the remaining half of the main bearings into the crankcase. TIP: Install the main bearings in their original posi- tions. 6.
Page 273: Selecting The Main Bearing
Crankcase 3. Select the suitable color c for the main bearing from the table. Crankshaft main journal oil clearance: 0.021–0.050 mm (0.0008–0.0020 in) Cylinder block mark b TIP: 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 When loosening the main bearing bolts and crankcase bolts, loosen them in the opposite order used for tightening.
Page 274: Assembling The Cylinder Block
POWR Power unit Assembling the cylinder block 1. Install the collar a by striking it with a plastic hammer. TIP: Install the connecting rod bearings in their original positions. 2. Install the oil rings b, 2nd ring c, and top ring d onto each pistons. 6.
Page 275 Crankcase 8. Install the lower main bearings l into the 10. Install the piston with the “UP” mark on main bearing cap m. the piston crown facing towards the flywheel magnet. Apply engine oil to the side of the pistons and piston rings before installation.
Page 276 POWR Power unit TIP: • After tightening the connecting rod cap bolts, check that the crankshaft rotates smoothly. • Make sure that the mark c of the connect- ing rod faces towards the flywheel magnet side of the crankshaft. 12. Install the lower main bearings o and new O-ring p into the crankcase.
Page 277 LOWR Lower unit Lower unit (regular rotation model) ........8-1 Removing the lower unit ............8-3 Water pump and shift rod (regular rotation model) ..8-4 Removing the water pump and shift rod ........8-6 Disassembling the water pump housing ........8-6 Checking the water pump and shift rod ........
Page 278 LOWR Shimming ................8-31 Shim location ................8-32 Selecting the pinion shim (T3) ..........8-33 Pinion shim (T3) selection table ..........8-36 Measuring the forward gear backlash ........8-38 Adjusting the forward gear shim thickness (T1) ...... 8-39 Forward gear shim (T1) selection chart ........8-41 Measuring the reverse gear backlash ........
Page 279 Shimming (counter rotation model) ........8-65 Shimming workflow ..............8-65 Shimming check sheet ............8-66 Measuring the forward and reverse gear backlash before disassembly ................8-68 Shimming ................8-71 Shim location ................8-72 Selecting the pinion shim (T3) ..........8-73 Pinion shim (T3) selection table ..........
Page 280 LOWR Lower unit Lower unit (regular rotation model) 42 N m (4.2 kgf m, 31.0 ft lb) 54 N m (5.4 kgf m, 39.8 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb)
Page 281 Lower unit (regular rotation model) 42 N m (4.2 kgf m, 31.0 ft lb) 54 N m (5.4 kgf m, 39.8 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb)
Page 282: Lower Unit
LOWR Lower unit Removing the lower unit • Make sure to disconnect the battery cables from the battery and the clip from the engine shut-off switch. • When removing the lower unit with the power unit installed, make sure to sus- pend the outboard motor.
Page 283 Lower unit (regular rotation model) / Water pump and shift rod (regular rotation model) Water pump and shift rod (regular rotation model) Water pump and shift rod (regular rotation model) Part name Q’ty Remarks M6 × 20 mm Bolt Oil seal Not reusable Oil seal housing O-ring...
Page 284 LOWR Lower unit Part name Q’ty Remarks Cover Seal O-ring Not reusable Insert cartridge O-ring Not reusable Collar Spacer Washer Wave washer...
Page 285: Water Pump And Shift Rod (Regular Rotation Model)
Water pump and shift rod (regular rotation model) Removing the water pump and shift 1. Install the lower unit onto a repair stand. 2. Remove the water pump housing a, impeller b, and Woodruff key c. 3. Remove the outer plate cartridge d and gasket e.
Page 286: Checking The Water Pump And Shift Rod
LOWR Lower unit Checking the water pump and shift 1. Check the water pump housing. Replace if deformation. TIP: If the engine overheated, the inside of the water pump housing may be deformed, therefore make sure to remove the insert car- tridge when checking the housing.
Page 287: Propeller Shaft Housing (Regular Rotation Model)
Water pump and shift rod (regular rotation model) / Propeller shaft housing (regular rotation model) Propeller shaft housing (regular rotation model) Propeller shaft housing (regular rotation model) 143 N m (14.3 kgf m, 105.5 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) Part name Q’ty Remarks...
Page 288 LOWR Lower unit 143 N m (14.3 kgf m, 105.5 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) Part name Q’ty Remarks Ball bearing Not reusable Ring nut Claw washer Oil seal Not reusable Needle bearing Not reusable Propeller shaft housing O-ring Not reusable...
Page 289: Removing The Propeller Shaft Housing Assembly
Propeller shaft housing (regular rotation model) Removing the propeller shaft housing assembly 1. Fold one tooth of the claw washer that is bent toward the propeller. 2. Loosen the ring nut. Bearing housing puller claw L e: 90890-06502 Stopper guide plate f: 90890-06501 Center bolt g: 90890-06504 TIP: Be careful not to lose the key h.
Page 290: Disassembling The Propeller Shaft Housing Assembly
LOWR Lower unit Disassembling the propeller shaft housing assembly 1. Remove the reverse gear a and thrust washer b. Needle bearing attachment j: 90890-06653 Driver rod L3 k: 90890-06652 Checking the propeller shaft housing Bearing separator c: 90890-06534 1. Check the propeller shaft housing. Stopper guide plate d: 90890-06501 Replace if cracked or damaged.
Page 291: Assembling The Propeller Shaft Housing Assembly
Propeller shaft housing (regular rotation model) Do not reuse the bearing, always replace it with a new one. 1. Install the needle bearing a into the pro- peller shaft housing b to the specified depth a. 2. Align the hole a in the dog clutch g with the hole b in the propeller shaft.
Page 292 LOWR Lower unit 2. Apply grease to new oil seals f, and 4. Heat the installation area of the ball bearing in the propeller shaft housing l then install them into the propeller shaft housing to the specified depth d. with a gas torch, and then install the reverse gear assembly m.
Page 293 Propeller shaft housing (regular rotation model) / Drive shaft and lower case (regular rotation model) Drive shaft and lower case (regular rotation model) Drive shaft and lower case (regular rotation model) 94 N m (9.4 kgf m, 69.3 ft lb) Part name Q’ty Remarks...
Page 294 LOWR Lower unit 94 N m (9.4 kgf m, 69.3 ft lb) Part name Q’ty Remarks Pinion nut 8-15...
Page 295: Drive Shaft And Lower Case (Regular Rotation Model)
Drive shaft and lower case (regular rotation model) Removing the drive shaft Needle bearing attachment c: 1. Remove the pinion nut. 90890-06610 Driver rod L3 d: 90890-06652 Disassembling the forward gear 1. Remove the taper roller bearing a. Drive shaft holder 6 a: 90890-06520 Bearing separator b: 90890-06534 Pinion nut holder b: 90890-06715 Needle bearing attachment c:...
Page 296: Checking The Pinion And Forward Gear
LOWR Lower unit 2. Remove the needle bearing a. Checking the pinion and forward gear 1. Check the pinion and forward gear. Replace if cracked or worn. Checking the drive shaft 1. Check the drive shaft. Replace if dam- aged or worn. 2.
Page 297: Assembling The Forward Gear
Drive shaft and lower case (regular rotation model) 2. Heat the installation area of the taper 4. Install the rollers into the needle bearing roller bearing outer race in the lower case outer race, and install the special service tool into the needle bearing assembly e, with a gas torch, and then install the outer race b.
Page 298: Assembling The Drive Shaft Housing
LOWR Lower unit 1. Install the needle bearing a into the 1. Install new needle bearings into the for- ward gear to the specified depth. drive shaft housing to the specified depth Needle bearing attachment a: Needle bearing attachment b: 90890-06612 Driver rod SS b: 901890-06604 90890-06610...
Page 299: Installing The Drive Shaft
Drive shaft and lower case (regular rotation model) 5. Tighten the pinion nut to the specified TIP: torque. Install an oil seal halfway into the drive shaft housing, and then install the other oil seal. Installing the drive shaft Do not reuse the bearing, always replace it with a new one.
Page 300: Installing The Shift Rod
LOWR Lower unit 4. Install the original shim(s) (T2) g, the 7. Bend one claw toward the propeller and propeller shaft housing assembly e, and the other 3 claws toward the gear. key h. Installing the shift rod 1. Make sure that the gear shift is in the N TIP: position, and then install the shift rod Do not reuse a shim if it is any deformed or...
Page 301: Installing The Water Pump
Drive shaft and lower case (regular rotation model) Installing the water pump TIP: 1. Install the dowels a, a new gasket b, The spacer h and collar i should fit and the outer plate cartridge c. together firmly. 5. When installing the pump housing and a new O-ring j, apply grease to the inside of the insert cartridge, and then turn the drive shaft clockwise while pushing down...
Page 302: Installing The Lower Unit
LOWR Lower unit 2. Apply the specified pressure to check Shift rod push arm a: 90890-06052 that the pressure is maintained in the lower unit for at least 10 seconds. 3. Install the dowels b into the lower unit NOTICE: Do not over pressurize the and extension.
Page 303 Drive shaft and lower case (regular rotation model) 6. Install the propeller f and propeller nut g. Place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque. Recommended gear oil: Hypoid gear oil API: GL-4...
Page 304: Shimming (Regular Rotation Model)
LOWR Lower unit Shimming (regular rotation model) Shimming workflow Remove the water pump assembly. Measure the backlash before disassembly. Within Shimming is not required. specification? Disassemble the lower unit. Select the pinion shims (T3). Assemble the lower unit. Measure the backlash. Adjust the forward gear shim Within thickness (T1) and reverse...
Page 305: Shimming Check Sheet
Shimming (regular rotation model) Shimming check sheet Checking the external appearance The deviation of the lower case dimension from standard. Serial number Remarks Measuring the pinion height (mm) Measurements Measurement point a Measurement point b Measurement point c Measurement point d Average Truncated average (M) Measuring the forward gear backlash...
Page 306 LOWR Lower unit Adjusting the forward gear shim thickness (T1) Measure the thickness of each forward gear shim (T1) in 2 places. (mm) Number of shim(s) Subtotal 0.10 0.12 0.15 0.18 0.30 0.40 0.50 Total Adjusting the reverse gear shim thickness (T2) Measure the thickness of each reverse gear shim (T2) in 2 places.
Page 307: Measuring The Forward And Reverse Gear Backlash Before Disassembly
Shimming (regular rotation model) Measuring the forward and reverse gear backlash before disassembly 1. Install the lower unit onto a repair stand. 2. Remove the water pump assembly. See “Removing the water pump and shift rod” (8-6). 3. Set the gear shift to the N position. Center bolt (shimming) d: 5 N·m (0.5 kgf·m,3.7 ft·lb) 8.
Page 308 LOWR Lower unit 10. Set the spring g on the outer plate cartridge, and then install the handle h so stopper that spring is compressed approximately a from its free length. Backlash indicator i: 90890-06706 Magnet base plate j: 90890-07003 Dial gauge set k: 90890-01252 Magnet base B l: 90890-06844 Spring g: 90501-450A2...
Page 309 Shimming (regular rotation model) Example: TIP: (mm) • The resistance of the spring increases the force required to turn the drive shaft. There- Measurement 0.60 0.61 0.57 fore, to obtain correct measurements, con- point d sider the spring resistance force when Measurement 0.51 0.53...
Page 310: Shimming
LOWR Lower unit 20. Check that the reverse gear backlash average is within specification. Reverse gear backlash: 0.33–0.74 mm (0.0130–0.0291 in) TIP: Adjust the shim thicknesses if the reverse gear backlash is out of specification. 21. Remove the special service tools, and then install the water pump assembly.
Page 311: Shim Location
Shimming (regular rotation model) Shim location 8-32...
Page 312: Selecting The Pinion Shim (T3)
LOWR Lower unit Selecting the pinion shim (T3) TIP: • Spray anti-rust lubricant on the bearing • Do not install the shim(s) (T3) or O-ring. before installation. Do not apply gear oil to Make sure to check the thrust bearing outer the parts.
Page 313 Shimming (regular rotation model) 4. Check the gap between the pinion and the special service tool. NOTICE: When tightening the pinion nut, check that the drive shaft rotates smoothly. Also, make sure that there is a gap between the pinion and the special service tool.
Page 314 LOWR Lower unit Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm Example: (M) = 0.24 (P) = –3 (T3) = 0.95 mm from the “pinion shim (T3) selection table.” Pinion height TIP: measurement (M) • Measure the gap at 4 points: c, d, e, and 0.23 0.24 0.25...
Page 315: Pinion Shim (T3) Selection Table
Shimming (regular rotation model) Pinion shim (T3) selection table (mm) 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 1.32 1.32 1.32 1.30 1.30 1.28 1.28 1.25 1.25 1.25 1.22 1.22 1.22 1.20 1.20 1.32 1.32 1.30...
Page 316 LOWR Lower unit (mm) 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95...
Page 317: Measuring The Forward Gear Backlash
Shimming (regular rotation model) Measuring the forward gear backlash TIP: • Spray anti-rust lubricant on the gear and Turn the drive shaft 10 times or more to seat bearings before installation. Do not apply the thrust bearing. gear oil to the parts. Otherwise, correct measurements cannot be obtained.
Page 318: Adjusting The Forward Gear Shim Thickness (T1)
LOWR Lower unit Pinion nut: 94 N·m (9.4 kgf·m, 69.3 ft·lb) 8. Check that the drive shaft rotates smoothly. If the drive shaft does not rotate smoothly, reduce the shim(s) (T1) thickness by 0.1 mm, and then check that the rotation of the shaft again. 9.
Page 319: Forward Gear Shim (T1) Selection Chart
Shimming (regular rotation model) 2. Measure the thickness of each original • The values for the shim thickness adjust- shim(s) (T1) in 2 places. ments specified in the selection chart are intended to achieve the median value within TIP: the range for the specified forward or Do not reuse a shim if it is deformed or reverse gear backlash.
Page 320 LOWR Lower unit 8-41...
Page 321 Shimming (regular rotation model) 8-42...
Page 322: Measuring The Reverse Gear Backlash
LOWR Lower unit Measuring the reverse gear backlash 0.20 1. Install the shim(s) (T2) and propeller shaft housing assembly. See “Measuring the forward gear backlash” (8-38) step 9–step 13. –0.20 2. Measure the reverse gear backlash. See “Measuring the forward and reverse gear –0.40 backlash before disassembly”...
Page 323 Shimming (regular rotation model) 4. Calculate the new reverse gear shim thickness (T2) as same way in the example. Calculation formula: New reverse gear shim thickness (T2) = Cur- rent reverse gear shim thickness + Shim thickness adjustment Example: If the current reverse gear shim thickness is 0.62 mm and the shim thickness adjustment is –0.20 mm, then (T2) = 0.62 mm + (–0.20) mm...
Page 324 LOWR Lower unit 8-45...
Page 325 Shimming (regular rotation model) 8-46...
Page 326: Lower Unit (Counter Rotation Model)
LOWR Lower unit Lower unit (counter rotation model) 42 N m (4.2 kgf m, 31.0 ft lb) 54 N m (5.4 kgf m, 39.8 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb)
Page 327 Lower unit (counter rotation model) 42 N m (4.2 kgf m, 31.0 ft lb) 54 N m (5.4 kgf m, 39.8 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb)
Page 328: Removing The Lower Unit
LOWR Lower unit Removing the lower unit • Make sure to disconnect the battery cables from the battery and the clip from the engine shut-off switch. • When removing the lower unit with the power unit installed, make sure to sus- pend the outboard motor.
Page 329: Water Pump And Shift Rod (Counter Rotation Model)
Lower unit (counter rotation model) / Water pump and shift rod (counter rotation model) Water pump and shift rod (counter rotation model) Water pump and shift rod (counter rotation model) 14 15 Part name Q’ty Remarks M6 × 20 mm Bolt Oil seal Not reusable...
Page 330 LOWR Lower unit 14 15 Part name Q’ty Remarks Cover Seal O-ring Not reusable Insert cartridge O-ring Not reusable Collar Spacer Washer Wave washer 8-51...
Page 331: Removing The Water Pump And Shift Rod
Water pump and shift rod (counter rotation model) Removing the water pump and shift See “Removing the water pump and shift rod” (8-6) step 1–step 4. 1. Remove the oil seal housing a and shift rod assembly b. Disassembling the water pump housing See “Disassembling the water pump hous- ing”...
Page 332: Propeller Shaft Housing (Counter Rotation Model)
LOWR Lower unit Propeller shaft housing (counter rotation model) 143 N m (14.3 kgf m, 105.5 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) Part name Q’ty Remarks Self-locking nut Water inlet cover (STBD) Shift rod joint Ball Shift slider Ball...
Page 333 Propeller shaft housing (counter rotation model) 143 N m (14.3 kgf m, 105.5 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) Part name Q’ty Remarks Shim (T4) — Ring nut Claw washer Oil seal Not reusable Needle bearing Not reusable Propeller shaft housing O-ring...
Page 334: Removing The Propeller Shaft Housing Assembly
LOWR Lower unit Removing the propeller shaft housing assembly 1. Fold one tooth of the claw washer that is bent toward the propeller. 2. Loosen the ring nut. Slide hammer e: 90890-06531 Puller head f: 90890-06514 TIP: Be careful not to lose the key g. Disassembling the propeller shaft housing assembly 1.
Page 335: Checking The Propeller Shaft Housing
Propeller shaft housing (counter rotation model) 2. Remove the forward gear j, thrust washer k, bearing outer race l, taper roller bearing m, thrust bearing n, and shim(s) (T4) o. 5. Remove the needle bearing s. Bearing separator p: (commercially available) 3.
Page 336: Assembling The Propeller Shaft Housing Assembly
LOWR Lower unit 4. After installing the taper roller bearing Propeller shaft runout limit: and bearing outer race, check that the 0.02 mm (0.008 in) propeller shaft rotates smoothly. 3. Check the dog clutch, shift rod joint, and 5. Install the thrust washer f, forward gear slider.
Page 337 Propeller shaft housing (counter rotation model) TIP: Install the dog clutch h with the “F” mark d facing toward the forward gear. 9. Install the cross pin o, and then install the spring p. 8-58...
Page 338: Drive Shaft And Lower Case (Counter Rotation Model)
LOWR Lower unit Drive shaft and lower case (counter rotation model) 94 N m (9.4 kgf m, 69.3 ft lb) Part name Q’ty Remarks Thrust bearing Shim (T3) — O-ring Not reusable Needle bearing Not reusable M8 × 25 mm Bolt Oil seal Not reusable...
Page 339 Drive shaft and lower case (counter rotation model) 94 N m (9.4 kgf m, 69.3 ft lb) Part name Q’ty Remarks Pinion Pinion nut 8-60...
Page 340: Removing The Drive Shaft
LOWR Lower unit Removing the drive shaft See “Removing the drive shaft” (8-16) step 1 and step 2. 1. Pull out the reverse gear assembly. Disassembling the drive shaft housing See “Disassembling the drive shaft housing” (8-16). Disassembling the reverse gear Ball bearing attachment b: 90890-06636 1.
Page 341: Checking The Pinion And Reverse Gear
Drive shaft and lower case (counter rotation model) Checking the pinion and reverse TIP: gear Do not reuse a shim if it is any deformed or 1. Check the pinion and reverse gear. scratched. Replace if cracked or worn. 3. While holding the special service tool c, Checking the drive shaft strike the tool to check that the roller See “Checking the drive shaft”...
Page 342: Assembling The Reverse Gear
LOWR Lower unit Assembling the reverse gear Assembling the drive shaft housing See “Assembling the drive shaft housing” (8- 63). Do not reuse the bearing, always replace it with a new one. Installing the drive shaft 1. Install the reverse gear assembly into the 1.
Page 343: Installing The Shift Rod
Drive shaft and lower case (counter rotation model) Installing the shift rod 1. Make sure that the gear shift is in the N position, and then install the shift rod assembly a. 2. Make sure that the drive shaft and the propeller shaft are moving properly when the gear is shifted into F position and into R position.
Page 344: Shimming (Counter Rotation Model)
LOWR Lower unit Shimming (counter rotation model) Shimming workflow Remove the water pump assembly. Measure the backlash and propeller shaft free play before disassembly. Within Shimming is not required. specification? Disassemble the lower unit. Select the pinion shims (T3) and propeller shaft shim (T4). Assemble the lower unit.
Page 345: Shimming Check Sheet
Shimming (counter rotation model) Shimming check sheet Checking the external appearance The deviation of the lower case dimension from standard. Serial number Remarks Measuring the propeller shaft free play (mm) Measurements Free play Measuring the pinion height (mm) Measurements Measurement point a Measurement point b Measurement point c Measurement point d...
Page 346 LOWR Lower unit Measuring the reverse gear backlash (mm) Measurements Before disassembly After disassembly Measurement point a Measurement point b Measurement point c Measurement point d Average Truncated average (BL1) Adjusting the forward gear shim thickness (T2) Measure the thickness of each forward gear shim (T2) in 2 places. (mm) Number of shim(s) Subtotal...
Page 347: Measuring The Forward And Reverse Gear Backlash Before Disassembly
Shimming (counter rotation model) Measuring the forward and reverse gear backlash before disassembly Two pieces of washers (90201-26M00) are required to measure the reverse gear back- lash for the shim adjustment on the counter rotation model. Please prepare the washers before starting the shimming procedure.
Page 348 LOWR Lower unit 9. Set the spring g on the outer plate cartridge, and then install the handle h so stopper that spring is compressed approximately a from its free length. Backlash indicator i: 90890-06706 Magnet base plate j: 90890-07003 Dial gauge set k: 90890-01252 Magnet base B l: 90890-06844 Spring g: 90501-450A2...
Page 349 Shimming (counter rotation model) Example: TIP: (mm) • The resistance of the spring increases the force required to turn the drive shaft. There- Measurement 0.24 0.23 0.22 fore, to obtain correct measurements, con- point d sider the spring resistance force when Measurement 0.25 0.25...
Page 350: Shimming
LOWR Lower unit Washer m: 90201-26M00 Ring nut wrench extension p: 90890-06513 18. Install the original shim(s) (T2) p, Ring nut wrench 4 q: 90890-06512 propeller shaft housing assembly q, and key r. Ring nut (shimming): 70 N·m (7.0 kgf·m, 51.6 ft·lb) 21.
Page 351: Shim Location
Shimming (counter rotation model) Shim location 8-72...
Page 352: Selecting The Pinion Shim (T3)
LOWR Lower unit Selecting the pinion shim (T3) Available shim thicknesses: See “Selecting the pinion shim (T3)” (8-33). 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm Pinion shim (T3) selection table See “Pinion shim (T3) selection table” (8-36). TIP: No shim (T4) adjustment is required if the Selecting the propeller shaft shim measurement falls within specification.
Page 353 Shimming (counter rotation model) 6. Heat the installation area of the taper roller bearing outer race in the propeller shaft housing with a gas torch, and then install the propeller shaft e and forward gear assembly f. NOTICE: When heating the propeller shaft housing, heat the entire installation...
Page 354: Propeller Shaft Shim (T4) Selection Table
LOWR Lower unit Propeller shaft shim (T4) selection table (*1) Shim adjustment is unnecessary where is no number. (mm) 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 –0.28 –0.25 –0.25 –0.22 –0.20 –0.18 –0.15 –0.15 –0.12 0.18 0.20 0.22 0.24 0.26 0.28...
Page 355: Measuring The Forward Gear Backlash
Shimming (counter rotation model) Measuring the forward gear backlash 3. Install the claw washer. Check that the position a is set in place properly. • Spray anti-rust lubricant on the gear and bearings before installation. Do not apply gear oil to the parts. Otherwise, correct measurements cannot be obtained.
Page 356: Forward Gear Shim (T2) Selection Chart
LOWR Lower unit 2. Measure the thickness of each original • The values for the shim thickness adjust- shim(s) (T2) in 2 places. ments specified in the selection chart are intended to achieve the median value within TIP: the range for the specified forward or Do not reuse a shim if it is deformed or reverse gear backlash.
Page 357 Shimming (counter rotation model) 8-78...
Page 358 LOWR Lower unit 8-79...
Page 359: Measuring The Reverse Gear Backlash
Shimming (counter rotation model) Measuring the reverse gear backlash 5. Install the pinion and pinion nut, and then tighten the pinion nut temporarily. • Spray anti-rust lubricant on the gear and bearings before installation. Do not apply TIP: gear oil to the parts. Otherwise, correct When installing the pinion, lift up the drive measurements cannot be obtained.
Page 360: Adjusting The Reverse Gear Shim Thickness (T1)
LOWR Lower unit 8. Check that the drive shaft rotates smoothly. If the drive shaft does not rotate smoothly, reduce the shim(s) (T1) thickness by 0.1 mm, and then check that the rotation of the shaft again. 9. Install the shim(s) (T2) g determined in “Adjusting forward gear...
Page 361: Reverse Gear Shim (T1) Selection Chart
Shimming (counter rotation model) 2. Measure the thickness of each original • The values for the shim thickness adjust- shim(s) (T1) in 2 places. ments specified in the selection chart are intended to achieve the median value within TIP: the range for the specified forward or Do not reuse a shim if it is deformed or reverse gear backlash.
Page 362 LOWR Lower unit 8-83...
Page 363 Shimming (counter rotation model) 8-84...
Page 364 BRKT Bracket unit Shift rod and shift bracket ............9-1 Removing the shift rod and shift bracket ........9-3 Disassembling the shift bracket ..........9-3 Assembling the shift bracket ............. 9-3 Installing the shift rod and shift bracket ........9-5 PTT switch and cowling lock lever ........
Page 365 PTT unit ..................9-32 Removing the PTT unit ............9-33 Checking the hydraulic pressure ..........9-34 Bleeding the PTT unit .............. 9-36 Installing the PTT unit .............. 9-36 PTT motor .................. 9-39 Removing the reservoir ............9-41 Removing the PTT motor ............9-41 Disassembling the PTT motor ..........
Page 366: Bracket Unit
BRKT Bracket unit Shift rod and shift bracket 2.5 N m (0.25 kgf m, 1.84 ft lb) 2.5 N m (0.25 kgf m, 1.84 ft lb) 1 N m (0.1 kgf m, 0.7 ft lb) 19 N m (1.9 kgf m, 14.0 ft lb) 18 N m(1.8 kgf m, 13.3 ft lb) Part name Q’ty...
Page 367 Shift rod and shift bracket 2.5 N m (0.25 kgf m, 1.84 ft lb) 2.5 N m (0.25 kgf m, 1.84 ft lb) 1 N m (0.1 kgf m, 0.7 ft lb) 19 N m (1.9 kgf m, 14.0 ft lb) 18 N m(1.8 kgf m, 13.3 ft lb) Part name Q’ty...
Page 368: Removing The Shift Rod And Shift Bracket
BRKT Bracket unit Removing the shift rod and shift bracket 1. Remove the shift bracket assembly a. 2. Remove the neutral switch b. For checking neutral switch, “Checking the neutral switch” (5-37). 2. Remove the shift lever b and shift rod assembly c.
Page 369 Shift rod and shift bracket Screw b: 2.5 N·m (0.25 kgf·m, 1.84 ft·lb) 2. Install the neutral switch c, and then tighten the screws d to the specified torque. Shift bracket bolt g: 19 N·m (1.9 kgf·m, 14.0 ft·lb) Screw d: 6.
Page 370: Installing The Shift Rod And Shift Bracket
BRKT Bracket unit 5. Install the shift bracket assembly h, and Installing the shift rod and shift then install the bushing i and clip j to bracket the shift lever f. 1. Install the bushing a, and then install the circlip b.
Page 371 Shift rod and shift bracket / PTT switch and cowling lock lever PTT switch and cowling lock lever PTT switch and cowling lock lever 3 N m (0.3 kgf m, 2.2 ft lb) Part name Q’ty Remarks Gasket PTT switch M6 ×...
Page 372 BRKT Bracket unit 3 N m (0.3 kgf m, 2.2 ft lb) Part name Q’ty Remarks Hook Grommet Hose Plastic tie Not reusable Hose joint Hose joint Gasket Adapter ø6 × 19 mm Screw Clamp Counter rotation model...
Page 373: Ptt Switch And Cowling Lock Lever
PTT switch and cowling lock lever Removing the PTT switch 1. Remove the holder a, and then remove the PTT switch b. For checking the PTT switch, see “Checking the PTT switch (on bottom cowling)” (5-49). STBD Removing the flushing hose 1.
Page 374: Installing The Flushing Hose
BRKT Bracket unit Installing the flushing hose 1. Pass the flushing hose a, trim sensor lead a, and PTT motor leads b through the grommet b, and then fasten them with plastic ties c around the grommet 3. Apply grease into the housing d until grease comes out from the cowling lock lever bushing.
Page 375: Bottom Cowling
PTT switch and cowling lock lever / Bottom cowling Bottom cowling Bottom cowling Part name Q’ty Remarks M6 × 20 mm Bolt Holder Bracket Bracket Bracket Clamp Holder Grommet Collar Rubber seal Water outlet Grommet M8 × 35 mm Bolt Grommet Collar Rubber seal...
Page 376 BRKT Bracket unit Part name Q’ty Remarks Bottom cowling Grommet 9-11...
Page 377 Bottom cowling / Upper case and mounts Upper case and mounts Upper case and mounts 54 N m (5.4 kgf m, 39.8 ft lb) 72 N m (7.2 kgf m, 53.1 ft lb) 72 N m (7.2 kgf m, 53.1 ft lb) Part name Q’ty Remarks...
Page 378 BRKT Bracket unit 54 N m (5.4 kgf m, 39.8 ft lb) 72 N m (7.2 kgf m, 53.1 ft lb) 72 N m (7.2 kgf m, 53.1 ft lb) Part name Q’ty Remarks M10 × 45 mm Bolt Washer M14 ×...
Page 379: Upper Case And Mounts
Upper case and mounts 2. Install the upper mount bracket c, and Removing the upper case then tighten the upper mount bracket 1. Drain the remained engine oil. See “Dis- bolts d temporarily. assembling the upper case” (9-17) step 2. Disconnect the ground lead a and adapter b.
Page 380 BRKT Bracket unit 9. Connect the ground lead o. 5. Install the upper and lower mounting bolts into the bracket assembly i simul- 10. Pass the speedometer hose p through taneously. the steering arm q, and then connect it 6. Install the washers j, upper mounting to the speedometer hose adapter r.
Page 381: Upper Case
Upper case and mounts / Upper case Upper case Upper case 20 N m (2.0 kgf m, 14.8 ft lb) 42 N m (4.2 kgf m, 31.0 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 27 N m (2.7 kgf m, 19.9 ft lb) Part name Q’ty Remarks...
Page 382: Disassembling The Upper Case
BRKT Bracket unit Disassembling the upper case Checking the drive shaft bushing 1. Remove the drain bolt a. 1. Check the bushing. Replace if cracked or worn. Assembling the upper case 1. Install the bushing a, and then install the circlip b.
Page 383 Upper case Baffle plate screw g: 4 N·m (0.4 kgf·m, 3.0 ft·lb) Oil pan assembly bolt (M8) m: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Oil pan assembly bolt (M10) n: 42 N·m (4.2 kgf·m, 31.0 ft·lb) 7. Install a new gasket o and the drain bolt p, and then tighten it to the specified torque.
Page 384: Oil Pan And Exhaust Manifold
BRKT Bracket unit Oil pan and exhaust manifold 20 N m (2.0 kgf m, 14.8 ft lb) 20 N m (2.0 kgf m, 14.8 ft lb) 20 N m (2.0 kgf m, 14.8 ft lb) 11 N m (1.1 kgf m, 8.1 ft lb) Part name Q’ty Remarks...
Page 385 Oil pan and exhaust manifold 20 N m (2.0 kgf m, 14.8 ft lb) 20 N m (2.0 kgf m, 14.8 ft lb) 20 N m (2.0 kgf m, 14.8 ft lb) 11 N m (1.1 kgf m, 8.1 ft lb) Part name Q’ty Remarks...
Page 386: Disassembling The Oil Pan And Exhaust Manifold
BRKT Bracket unit Disassembling the oil pan and 2. Check the exhaust guide, exhaust mani- fold, and muffler. Replace the exhaust exhaust manifold guide, exhaust manifold, and muffler if 1. Remove the muffler a, plate b, and then cracked or if there is corrosion. remove the exhaust manifold c.
Page 387 Oil pan and exhaust manifold 5. Install the rubber seal l and cooling water pipe m. 6. Install the dowels n, new gaskets o, and the plate p, and then install the muf- fler assembly q. 7. Tighten the muffler assembly bolts r to the specified torque.
Page 388: Steering Arm
BRKT Bracket unit Steering arm Part name Q’ty Remarks Steering arm Washer Bushing O-ring Not reusable Bushing Steering yoke Circlip Grommet 9-23...
Page 389: Removing The Steering Arm
Steering arm Removing the steering arm 1. Remove the circlip a, and then remove the steering yoke b by striking it with a copper hammer. 4. Install the steering yoke i, making sure it is facing the same direction as the steering arm (aligning a with b).
Page 390 BRKT Bracket unit 5. Hold the steering arm c, and then strike the steering yoke i with a copper hammer until the groove c for installing the circlip is visible. 6. Install the circlip j. 7. Apply grease into the grease nipple k until it comes out from both the upper and lower bushings d.
Page 391: Clamp Bracket And Swivel Bracket
Steering arm / Clamp bracket and swivel bracket Clamp bracket and swivel bracket Clamp bracket and swivel bracket 3 N m(0.3 kgf m, 2.2 ft lb) 15 N m(1.5 kgf m, 11.1 ft lb) 3 N m(0.3 kgf m, 2.2 ft lb) 27 28 Part name Q’ty...
Page 392 BRKT Bracket unit 3 N m(0.3 kgf m, 2.2 ft lb) 15 N m(1.5 kgf m, 11.1 ft lb) 3 N m(0.3 kgf m, 2.2 ft lb) 27 28 Part name Q’ty Remarks Washer Anode Plate M6 × 30 mm Bolt Ground lead Bushing...
Page 393 Clamp bracket and swivel bracket 3 N m(0.3 kgf m, 2.2 ft lb) 15 N m(1.5 kgf m, 11.1 ft lb) 3 N m(0.3 kgf m, 2.2 ft lb) 27 28 Part name Q’ty Remarks M6 × 15 mm Screw Trim sensor 9-28...
Page 394: Removing The Clamp Bracket
BRKT Bracket unit Removing the clamp bracket 1. Remove the PTT unit. See “Removing the PTT unit” (9-33). 2. Remove the plastic tie a. 9. Remove the spring l, hook m, and pins 3. Remove the anode b. 4. Remove the trim sensor cam c. 5.
Page 395 Clamp bracket and swivel bracket 5. Install through tube Distance a: temporarily tighten the self-locking nut 30.3–30.6 mm (1.19–1.20 in) 2. Install the bushings a, collar b, distance 6. Install the anode l. collar assembly c, and tilt stop levers d, 7.
Page 396: Adjusting The Trim Sensor Cam
BRKT Bracket unit 10. Apply grease into the grease nipples until TIP: grease comes out from the bushings c. • To decrease the resistance, turn the trim sensor cam in direction c. • To increase the resistance, turn the trim sensor cam in direction d.
Page 397: Ptt Unit
Clamp bracket and swivel bracket / PTT unit PTT unit PTT unit 39 N m (3.9 kgf m, 28.8 ft lb) Part name Q’ty Remarks Shaft Circlip Bushing PTT unit Ground lead M6 × 10 mm Bolt M10 × 30 mm Bolt Washer Shaft...
Page 398: Removing The Ptt Unit
BRKT Bracket unit Removing the PTT unit • After tilting up the swivel bracket, make sure to support it with the tilt stop lever. Otherwise, the swivel bracket could sud- denly lower if the PTT unit should lose fluid pressure. •...
Page 399: Checking The Hydraulic Pressure
PTT unit 4. Install the reservoir cap a, and then tighten it to the specified torque. Reservoir cap a: 0.7 N·m (0.07 kgf·m, 0.5 ft·lb) 5. Remove the circlip b, and then remove the manual valve c. 6. Install the special service tools d and e. Checking the hydraulic pressure Check the hydraulic pressure.
Page 400 BRKT Bracket unit Battery Hydraulic pressure gauge e: PTT motor lead terminal 90890-06776/06800 Black (B) Down relief fitting f: 90890-06774 Down – Black/White (B/W) TIP: 8. Reverse the PTT motor leads between Quickly change the special service tools the battery terminals to fully extend the before any fluid flows out of the hole.
Page 401: Bleeding The Ptt Unit
PTT unit 5. Reverse the PTT motor leads between Battery PTT motor lead the battery terminals to fully extend the terminal PTT rams. Black/White (B/W) – Black (B) 13. Remove the special service tools, and then install the manual valve and circlip. Manual valve: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) TIP:...
Page 402 BRKT Bracket unit 1. Connect the PTT motor leads a to the battery terminals to retract the PTT rams. Battery PTT motor lead terminal Black (B) Down – Black/White (B/W) 2. Fully tilt the swivel bracket up, and then support it with the tilt stop lever a. Bolt f: 39 N·m (3.9 kgf·m, 28.7 ft·lb) 7.
Page 403 PTT unit 9. Insert the shaft g from the port side and install the circlip h. 10. Connect the ground lead i. 11. Fasten the PTT motor lead a and trim sensor lead with new plastic ties j. 9-38...
Page 404: Ptt Motor
BRKT Bracket unit PTT motor 5 N m (0.5 kgf m, 3.7 ft lb) 0.7 N m (0.07 kgf m, 0.5 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) Part name Q’ty Remarks M6 × 14 mm Bolt Reservoir O-ring...
Page 405 PTT motor 5 N m (0.5 kgf m, 3.7 ft lb) 0.7 N m (0.07 kgf m, 0.5 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) Part name Q’ty Remarks Brush 1 Spring M4 × 15 mm Screw Oil seal Not reusable...
Page 406: Removing The Reservoir
BRKT Bracket unit 2. Remove the PTT motor screws c, and Removing the reservoir then remove stator NOTICE: Hold the end of the armature • Make sure that the PTT rams are fully shaft with a pair of pliers, and then extended when removing the reservoir, remove the armature together with the otherwise fluid can spurt out from the...
Page 407: Checking The Ptt Motor
PTT motor Digital circuit tester: 90890-03174 Armature continuity: Checking the brush 1. Measure the length of each brush. Checking the PTT motor Replace the brushes if below specifica- 1. Check the commutator. Clean with 600 tion. grit sandpaper and compressed air if dirty. Motor brush standard length: 2.
Page 408: Assembling The Ptt Motor
BRKT Bracket unit 3. Check the motor base and bearing. Replace the PTT motor assembly if the motor base is cracked or damaged, or if the bearing is pitted or if there is rumbling. Assembling the PTT motor • Do not reuse the oil seal and O-rings, always replace them with new ones.
Page 409: Installing The Reservoir
PTT motor Installing the reservoir 1. Install a new O-ring a and the reservoir b, and then tighten the reservoir mount- ing bolts c to the specified torque. 2. Install a new O-ring d and the reservoir cap e, and then tighten the reservoir cap e to the specified torque.
Page 410: Ptt Gear Pump
BRKT Bracket unit PTT gear pump 6 N m (0.6 kgf m, 4.4 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 3.5 N m (0.35 kgf m, 2.58 ft lb) Part name Q’ty Remarks...
Page 411 PTT gear pump 6 N m (0.6 kgf m, 4.4 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 3.5 N m (0.35 kgf m, 2.58 ft lb) Part name Q’ty Remarks Manual valve...
Page 412: Disassembling The Gear Pump Assembly
BRKT Bracket unit 6. Remove the spring p, absorber valve pin Disassembling the gear pump q, ball r, and up-relief valve seat s and assembly O-ring t. 1. Remove the PTT motor assembly. See “Removing the PTT motor” (9-41). 2. Remove the bolts a and b, and then remove the gear pump assembly c.
Page 413: Assembling The Gear Pump Assembly
PTT gear pump 2. Check the down-relief valve b. Clean if 2. Install new O-rings f onto the main valves g, and then install the main there is dirt or residue. valves. 3. Check the main valves c and shuttle pistons d.
Page 414 BRKT Bracket unit 5. Install the gear pump cover l, and then Manual valve s: tighten the gear pump cover bolts m 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) temporarily. 11. Install the valve pin u and new O-rings 12. Install the valve seat assembly w, and O- rings x.
Page 415: Ptt Cylinder
PTT gear pump / PTT cylinder PTT cylinder PTT cylinder 128 N m (12.8 kgf m, 94.4 ft lb) 140 N m (14.0 kgf m, 103.3 ft lb) 96 N m (9.6 kgf m, 70.8 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) Part name Q’ty Remarks...
Page 416 BRKT Bracket unit 128 N m (12.8 kgf m, 94.4 ft lb) 140 N m (14.0 kgf m, 103.3 ft lb) 96 N m (9.6 kgf m, 70.8 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) Part name Q’ty Remarks Plug...
Page 417: Removing The Tilt Ram And Trim Ram
PTT cylinder Removing the tilt ram and trim ram 8. Install the trim ram assemblies, and then tighten the trim cylinder end screws temporarily. Make sure that the PTT rams are fully 9. Cover the tilt cylinder opening with a rag extended before removing the tilt cylinder e, and then blow compressed air through end screw otherwise fluid can spurt out...
Page 418: Checking The Tilt Cylinder And Trim Cylinder
BRKT Bracket unit 2. Remove the nut a, and then remove the tilt piston absorber valves b. Checking the valve 1. Check the tilt piston absorber valves a. Checking the tilt cylinder and trim Clean if there is dirt or residue. cylinder 1.
Page 419: Assembling The Trim Ram
PTT cylinder 2. Install the tilt cylinder end screw d and tilt piston e to the tilt ram f. 3. Install new O-rings g and h to the tilt piston e. Tilt piston nut m: 96 N·m (9.6 kgf·m, 70.8 ft·lb) Assembling the trim ram 1.
Page 420: Installing The Trim Ram
BRKT Bracket unit 2. Install a new seal d, new dust seal e, and new O-ring f to the trim cylinder end screw g. 3. Install the trim cylinder end screws g. 5. Fill the PTT body with the recommended fluid to the correct level b through holes c, d, and e.
Page 421: Installing The Tilt Ram
PTT cylinder Trim cylinder end screw e: 140 N·m (14.0 kgf·m, 103.3 ft·lb) 7. Install gear pump. “Assembling the gear pump assembly” (9-48). 8. Install the PTT reservoir. See “Installing the reservoir” (9-44). Installing the tilt ram Trim and tilt wrench b: 90890-06587 1.
Page 422 Maintenance Outline ..................10-1 Predelivery check ..............10-4 Checking the battery ............... 10-4 Checking the cooling water pilot hole ........10-4 Checking the engine oil level ........... 10-5 Checking the engine start switch and engine shut-off switch .............. 10-5 Checking the fuel system ............10-5 Checking the gear oil level ............
Page 423 Replacing the timing belt ............10-16 Checking the thermostat ............10-16 Adjusting the throttle link and throttle cable ......10-16 Checking the top cowling ............10-17 Checking the valve clearance ..........10-17 Checking the water pump ............10-17...
Page 424 • If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and qual- ity. Any parts of inferior quality may cause malfunction, and the resulting loss of control could endanger the operator and passengers.
Page 425 Outline Maintenance interval chart 1 Initial Every Refer Item Actions 20 hours 100 hours 300 hours 500 hours to page (3 months) (1 years) (3 years) (5 years) Anode(s) (external) Check/replace 10-9 Anode(s) (cylinder head) Check/replace 10-9 Anodes(s) (exhaust cover, Replace 10-9 cylinder block)
Page 426 Check 10-10 Wiring harness connec- Check/replace — tions/wiring coupler con- nections Yamaha meter/gauge Check (*1) — : Not applicable (*1): See “6Y8 Multifunction Meter set up manual” for the check of 6Y8 Multifunction Meter. Maintenance interval chart 2 Every Refer...
Page 427: Predelivery Check
Outline / Predelivery check Predelivery check Predelivery check To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the battery Battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic.
Page 428 Maintenance Checking the engine oil level Checking the engine start switch and 1. Put the outboard motor in an upright engine shut-off switch position (not tilted). NOTICE: If the 1. Check that the engine starts when the motor is not level, the oil level indi- engine start switch is turned to “START.”...
Page 429 Predelivery check Checking the gear shift and throttle operation 1. Check that the gear shift operates smoothly when the remote control lever is shifted from N to F or R. 2. Check that the throttle operates smoothly when the remote control lever is shifted from F or R to the fully open position a.
Page 430 Maintenance Checking the PTT system 1. Check that the outboard motor tilts up and down smoothly when operating the PTT unit. 2. Check that there is no abnormal noise produced when the outboard motor is tilted up or down. 3. Check that there is no interference with wires or hoses when the tilted-up Checking the steering system outboard motor is steered.
Page 431 Predelivery check TIP: TIP: The test run is part of the break-in operation. When using the flushing device (flushing hose joint adapter), flush the cooling water passages without starting the engine. Break-in Run the engine under load (in gear with a propeller installed) for 10 hours as follows.
Page 432 Maintenance General Periodic Maintenance Checking the anode Do not oil, grease, or paint the anodes or the trim tab, otherwise they will be ineffec- tive. 1. Check the anodes and trim tab. Clean the anodes or trim tab if there are scales, grease, or oil.
Page 433 650–750 r/ min. 2. Check the engine idle speed using the Yamaha genuine tachometer (on-board meter) or using the YDIS. To connect and operate the YDIS, see the YDIS (Ver. 1.30 or later) Instruction Manual.
Page 434 Maintenance 5. Remove the oil filler cap a. Pull out the 9. Insert the dipstick b and remove it again. dipstick b and use the oil changer c to Make sure to completely insert the extract the oil completely. dipstick into the dipstick guide, otherwise the oil level measurement will be incorrect.
Page 435 General Periodic Maintenance 4. Install the oil filter, and then tighten it to Checking the fuel joint and fuel the specified torque using a 72.5 mm hoses (fuel joint-to-fuel injector) (2.9 in) oil filter wrench a. 1. Remove the spark plug wire cover. 2.
Page 436 Maintenance 2. Place a drain pan a under the gear oil drain hole. 3. Remove the gear oil drain screw b and gasket c. NOTICE: If there is an excessive quantity of metal particles on the magnetic gear oil drain screw b, this can indicate lower unit problem.
Page 437 General Periodic Maintenance TIP: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the area. 3. Apply corrosion resistant grease to the area. 10-14...
Page 438 Maintenance Checking the PCV 1. Check the PCV. See “Checking the PCV” (7-34). Checking the PTT fluid level 1. Check the PTT fluid level. See “Checking the hydraulic pressure” (9-34). Checking the PTT operation 1. Tilt the outboard motor to the fully up and fully down positions a few times and Checking the spark plug check the entire trim range for smooth...
Page 439 General Periodic Maintenance 5. Measure the thermostat valve opening a 5. Install spark plugs, tighten temporarily, and then tighten to the at the specified water temperatures. specified torque using a spark plug Replace thermostat wrench. specification. Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb) Checking the timing belt 1.
Page 440 Maintenance 3. Contact the stopper a on the throttle lever 2 d to the fully closed stopper b on the cylinder block and then adjust the throttle link joint assembly e so that the specified clearance c is obtained. TIP: •...
Page 441 Index Index Bleeding the PTT unit ....... 9-36 Bottom cowling ........ 5-10, 9-10 Abbreviation ..........0-5 Bow view ............ 5-4 Adjusting the forward gear shim Bracket unit........1-4, 1-20 thickness (T1) .........8-39 Bracket unit technical data ....... 1-17 Adjusting the forward gear shim Break-in ............
Page 442 Index Checking the fuel pump ......6-10 Checking the PTT switch Checking the fuel rail ........6-26 (on bottom cowling) ........ 5-49 Checking the fuel system......10-5 Checking the PTT system ......10-7 Checking the gear oil level.....10-6, 10-12 Checking the pulser coil ......5-30 Checking the gear pump......9-47 Checking the Rectifier Regulator ....
Page 443 Index Flywheel magnet ........7-5 Forward gear shim (T1) selection chart ..8-41 Dimension and Weight........1-3 Forward gear shim (T2) selection chart ..8-78 Dimensions ..........3-2 Fuel and oil requirement......1-4 Disassembling the cylinder block....7-53 Fuel control units and components... 5-23 Disassembling the drive shaft Fuel filter...........
Page 444 Index Installing the fuel injector ......6-26 Lower unit assembly Installing the gauge harness .....3-11 (regular rotation model) ......1-16 Installing the intake manifold.....6-28 Lower unit technical data......1-16 Installing the isolator lead (option) ....3-11 Lubricating the outboard motor....10-13 Installing the lower unit ....8-23, 8-64 Lubrication system........
Page 445 Index PTT cylinder..........9-50 Sealant and locking agent ......0-6 PTT gear pump .........9-45 Selecting the connecting rod bearing ..7-57 PTT motor ..........9-39 Selecting the main bearing ....... 7-60 PTT requirement .........1-5 Selecting the pinion shim (T3) ..8-33, 8-73 PTT switch and cowling lock lever ....9-6 Selecting the propeller shaft shim (T4) ..
Page 446 Index Upper case..........9-16 Upper case and mounts......9-12 Vapor gas hose...........6-2 Vapor separator ........6-29 Ventilation ...........0-1 Water pump and shift rod (counter rotation model) .............8-50 Water pump and shift rod (regular rotation model) ............8-4 When the outboard hits something in the water ............2-32 Wiring harness ..........7-7 Wiring harness routing ........5-6...
Page 447 Appendix Wiring diagram ................A-2 How to use the wiring diagram ..........A-2 Fuel unit ..................A-3 Ignition unit ................A-5 Charging unit and starting unit ..........A-7...
Page 448 — MEMO —...
Page 449: Wiring Diagram
Wiring diagram How to use the wiring diagram Composition of the wiring diagrams The wiring diagram consists of three categories. Fuel unit, Ignition unit, Charging and starting unit. Legend symbols in the wiring diagrams Double colors wire No wire connector A wire is not included in the selected wiring unit.
Page 450 Fuel unit Fuse (50A) (engine battery) Fuse (50A) (house battery) Fuse (20A) (engine ECM, ISC, fuel injector, high-pressure fuel pump, ignition coil, YDIS) Fuse (20A) (engine start switch, PTT switch) Fuse (30A) (starter motor relay) Main relay To 10-pin main harness To gauge TIP: Depending on the outboard motor, the location of the coupler terminal may be changed as indicated...
Page 452 YAMAHA MOTOR CO., LTD. Printed in China Jul. 2008 – 0.6 × 1 ABE (E_4)
Page 453 Fuel unit Br Y W R B Fuse box Starter motor START PTT relay PULL (*1) (*1) Engine start switch 1 23 Pu/G Joint connector 22 44 Engine ECM Pu/B Pu/R Pu/Y Fuel injector Water detection switch High-pressure fuel pump...
Page 454 Ignition unit Fuse (50A) (engine battery) Fuse (50A) (house battery) Fuse (20A) (engine ECM, ISC, fuel injector, high-pressure fuel pump, ignition coil, YDIS) Fuse (20A) (engine start switch, PTT switch) Fuse (30A) (starter motor relay) Main relay To 10-pin main harness To gauge TIP: Depending on the outboard motor, the location of the coupler terminal may be changed...
Page 455: Ignition Unit
Ignition unit Fuse box W R B Starter motor START PTT relay (*1) PULL (*1) Engine start switch 1 23 22 44 Joint connector Engine ECM Thermoswitch Neutral switch Pulser coil Air pressure Air temperature Water pressure Oil pressure sensor sensor sensor (option) Engine...
Page 456 Charging unit and starting unit Fuse (50A) (engine battery) Fuse (50A) (house battery) Fuse (20A) (engine ECM, ISC, fuel injector, high-pressure fuel pump, ignition coil, YDIS) Fuse (20A) (engine start switch, PTT switch) Fuse (30A) (starter motor relay) Main relay Diode (connect to the PTT relay) To 10-pin main harness To gauge...
Page 457 Charging unit and starting unit (*1) Rectifier Regulator Starter assembly Br Y W R B Fuse box START AC 1 AC 1 AC 1 Engine start PULL switch (*1) 1 23 22 44 Engine ECM PTT relay Starter YDIS coupler relay Hour meter PTT switch...

This manual is also suitable for:

Fl150b

Yamaha F150B Service Manual

Gen Info General Information 0

Safety While Working

How to Use this Manual Manual Format

Sealant and Locking Agent

Special Service Tool

Spec Specification 1

Model Features

Model Data

Electrical Technical Data

Fuel System Technical Data

Power Unit Technical Data

Lower Unit Technical Data

Bracket Unit Technical Data

Special Tightening Torque

General Tightening Torque

Tech Fea Technical Features and Description 2

Technical Features and Description

Electronic Control System

Power Unit System

Lubrication System

Cooling System

Intake and Exhaust System

PTT Unit

Rig Ging Rigging Information 3

Rigging Information

Outboard Motor Installation

Dimensions

Crate Top Cover Pictograph Description

Uncrate Procedure

Outboard Motor Mount

Mounting the Rigging Grommet

Remote Control Box and Switch Panel Installation

Installing the Fuel Flow Sensor

Installing the Battery

System Diagram

Trbl Shtg Troubleshooting 4

Ydis

Troubleshooting

Troubleshooting the Power Unit Troubleshooting Procedure

Elec Electrical System 5

Electrical System

Electrical Components

Wiring Harness Routing

Circuit Diagram

ECM Coupler Layout

Checking the Electrical Component

Engine Control Units and Components

Fuel Control Units and Components

Charging Units and Components

Ignition Units and Components

Starting Units and Components

Starter Motor

PTT System

Fuel Fuel System 6

Fuel System

Hose Routing

Fuel Line

Canister

Fuel Pump

Fuel Filter

Intake Silencer

Throttle Link

Throttle Body

Fuel Injector

Intake Manifold

Vapor Separator

Powr Power Unit 7

Power Unit (Check and Adjustment)

Power Unit

Flywheel Magnet

Wiring Harness

Starter Motor

Fuse Box

Junction Box

Timing Belt

Power Unit Assembly

Camshaft

Exhaust Cover

Cylinder Head