Yamaha 250GETO Service Manual
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Yamaha 250GETO Service Manual

Yamaha 250GETO Service Manual

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250G
L250G
SERVICE MANUAL
6
6S3-28197-5H-11

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Summary of Contents for Yamaha 250GETO

  • Page 1 250G L250G SERVICE MANUAL 6S3-28197-5H-11...

  • Page 2: Important Information

    NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.

  • Page 3: Table Of Contents

    Contents General information INFO Specification SPEC Periodic check and adjustment Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT Electrical system ELEC Troubleshooting TRBL SHTG Index...
  • Page 5 INFO General information How to use this manual ................1-1 Manual format ..................1-1 Symbol ..................... 1-2 Safety while working ................... 1-3 Fire prevention ..................1-3 Ventilation ....................1-3 Self-protection ..................1-3 Parts, lubricant, and sealant ..............1-3 Good working practice ................1-4 Disassembly and assembly ..............

  • Page 6: How To Use This Manual

    INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 9 Parts are shown and detailed in an exploded diagram and are listed in the components list (see in the figure below for an example page).

  • Page 7: Specification

    7 Apply Yamaha 2-stroke outboard motor oil q Apply corrosion resistant grease 8 Apply gear oil (Yamaha grease D) 9 Apply water resistant grease (Yamaha grease A) w Apply low temperature resistant grease 0 Apply molybdenum disulfide grease (Yamaha grease C)

  • Page 8: Safety While Working

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

  • Page 9: Good Working Practice

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

  • Page 10: Identification

    Applicable model 250GETO, L250GETO 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 6B410020 1 Model name 2 Approved model code...

  • Page 11: Special Service Tool

    Identification/Special service tool Special service tool Digital tachometer Compression gauge 90890-06760 90890-03160 Leakage tester Flywheel holder 90890-06840 90890-06522 Vacuum/pressure pump gauge set Flywheel puller 90890-06756 90890-06521 Digital caliper Piston slider ø85 90890-06704 90890-06530 Needle bearing attachment Timing light 90890-06608, 90890-06610, 90890-06653 90890-03141 90890-06654, 90890-06611 6S35H11...
  • Page 12 INFO General information Pressure pin B Driver rod L3 90890-02390 90890-06652 Support Driver rod LS 90890-02394 90890-06606 Pinion nut holder Bearing separator 90890-06715 90890-06534 Dial gauge set Gear puller 90890-01252 90890-06540 Ring nut wrench extension Cylinder gauge 90890-06513 90890-06759 6S35H11...
  • Page 13 Special service tool Puller head Stopper guide stand 90890-06514 90890-06538 Drive shaft holder 6 Stopper guide plate 90890-06520 90890-06501 Bearing depth plate Bearing housing puller claw L 90890-06603 90890-06502 Center bolt Driver rod SS 90890-06504 90890-06604 Driver rod LL Bearing puller assembly 90890-06605 90890-06535 6S35H11...
  • Page 14 INFO General information Ball bearing attachment Bearing outer race puller assembly 90890-06635, 90890-06655, 90890-06656 90890-06523 90890-06657 Outer race puller claw B Shimming plate 90890-06533 90890-06701 Shift rod push arm Slide hammer handle 90890-06052 90890-06531 Bearing outer race attachment Pinion height gauge 90890-06622, 90890-06624, 90890-06626 90890-06710 90890-06628, 90890-06658...
  • Page 15 Special service tool Backlash indicator Ring nut wrench 4 90890-06706 90890-06510 Ignition tester Magnet base plate 90890-06754 90890-07003 Digital circuit tester Cylinder-end screw wrench 90890-03174 90890-06568 PTT piston vice attachment Peak voltage adaptor B 90890-03172 90890-06572 Ring nut wrench Diagnostic flash indicator B 90890-06578 90890-06865 6S35H11...
  • Page 16 INFO General information PTT oil pressure gauge assembly Test harness (4 pins) 90890-06580 90890-06871 Tilt rod wrench Test harness (6 pins) 90890-06569 90890-06872 Test harness (3 pins) 90890-06857 Test harness (2 pins) 90890-06867 Test harness (3 pins) 90890-06870 1-11 6S35H11...

  • Page 17: Feature And Benefit

    Special service tool/Feature and benefit Feature and benefit Power unit Piston An aluminum piston with heat treatment is used to obtain durability and reliability. Molybdenum coating is given to the skirt of piston to obtain more lubrication and reduce friction. 1st or 2nd oversized piston in available for overhaul service.
  • Page 18 INFO General information Cylinder sleeve The slit of exhaust port is removed and smoother curved exhaust port is used on, which can pre- vent the piston rings from scuffing with lesser fuel. 250A 250G Exhaust slit Sleeve Cylinder body The shallow water jacket is designed to increase the rigidity of cylinder body. Wider rib is used to obtain rigid cylinder body.
  • Page 19 Feature and benefit Engine mount bolt A fully thread bolt coated with a sealing agent has been used for mounting the engine. This gives a sealing function to the bolt, which will prevent the bolt from sticking by saltwater enter- ing into the bolt hole for crystallizing and corroding.

  • Page 20: Bracket/Upper Case

    INFO General information Bracket/upper case Ptt unit The components of clamp bracket and PTT unit are the same as 250A. Tilt cylinder PTT specifications PTT ID mark 61A-25 Tilt stroke 147 mm, 5.8 in Impact relief valve 20.6 MPa, 210 kgf/cm , 2,988 psi Trim stroke 99 mm, 3.9 in Fluid...

  • Page 21: Lower Unit

    Feature and benefit Lower unit Oil passage The oil passages have been added to the drive shaft at pinion end and the lower case between gear housing and shifter room to increase the gear oil fluidity, so that the lubrication ability has increased. Drive shaft oil passage Lower case oil passage 6S35H11...
  • Page 22 INFO General information Exhaust passage components A hard anodic oxide coating has been given to the exhaust passage's components to obtain corro- sion-resistance. The effected components are as follows, • Exhaust pipe 61A-41132-20 • Muffler 61A-14711-30 Example; Muffler Mark M is stamped to recognize Hard anodic oxide coated components 1-17...
  • Page 23 Feature and benefit Forward gear thrust bearing The forward gear bearing is newly designed to receive the thrust force from propeller at the outer race, which can obtain durability and reliability. Compared with the taper roller bearing, this structure can remove the thrust load from the taper rollers of bearing.

  • Page 24: Fuel System

    INFO General information Fuel system Premixing system New auto lube system (auto oil blend system) is used to obtain simple structure. The oil is supplied to the fuel line via the mechanical oil pump, and obtained simple oil hose deliv- ery layout.
  • Page 25 Feature and benefit 2) Oil indicator control This engine has the oil warning indicators. When the key switch is turned to ON, all indicators light for 3 seconds to check the bulbs. The indicators on tachometer show the oil level condition as below. For 30 seconds after Over 30 seconds after switch ON...
  • Page 26 INFO General information Cooling system The cooling water flow diagram is as follows. Cylinder head Thermostat Cylinder body Exhaust outer cover Upper case Exhaust guide Rectifier/Regulator Flushing device Lower case Water pump Pilot hole Propeller boss Cooling water inlet Sea, River, Lake Cooling water flow chart NOTE: The cylinder head gasket has been newly designed for 250G.
  • Page 27 Feature and benefit Electrical system Hour meter Hour meter has been built in the engine for easier management of service interval. The meter shows the elapsed engine operation hours after the engine was manufactured. Hour is counted by the signal of crank position sensor, and kept even if the engine is turned off. When the key switch is turned on, all of segments light for 2 seconds to check the display.
  • Page 28 INFO General information Ignition control The micro-computer controls the ignition timing due to the throttle valve angle and engine RPM at every 0.01 seconds. When starting the engine, the ignition timing is fixed to BTDC7. If the engine condition is in an emergency, the ignition is controlled to misfire. 1) Warm-up control When starting a cold engine, the ignition timing range is controlled by the engine temperature as below.

  • Page 29: Propeller Selection

    Feature and benefit/Propeller selection Propeller selection The performance of a boat and outboard Select the propeller which is not exceed motor will be critically affected by the size and 5,500 r/min. Otherwise can not obtain the type of propeller you choose. Propellers correct engine performance, it becames greatly affect boat speed, acceleration, could result engine damaged.

  • Page 30: Predelivery Check

    INFO General information Checking the engine oil level Predelivery check 1. Check the engine oil level. To make the delivery process smooth and efficient, the predelivery checks should be 2. Fill in the engine oil into the remote oil completed as explained below. tank, turn the engine start swich to “ON”...

  • Page 31: Checking The Outboard Motor Mounting Height

    Predelivery check Checking the outboard motor 2. Check that the control lever 1 is in its mounting height fully closed position, and check that the 1. Check that the anti-cavitation plate is center of the throttle cam roller 2 aligned aligned with the bottom of the boat.

  • Page 32: Checking The Steering System

    INFO General information Checking the steering system Checking the PTT system 1. Check that the steering operates smooth- 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 tilt- ed up or down.

  • Page 33: Checking The Cooling Water Pilot Hole

    Predelivery check Break-in 4. Check that the engine turns off when the During the test run, perform the break-in lock plate of engine stop lanyard is pulled operation in the following 5 stages. from the engine stop lanyard switch. 1. 10 minutes a at the lowest possible speed.

  • Page 34: After Test Run

    INFO General information After test run 1. Check for water in the gear oil. 2. Check for fuel leakage in the cowling. 3. Flush the cooling water passage with fresh water using the flushing kit 1 and with the engine running at idle. 6S310070 Be sure to supply sufficient water when flushing the cooling water passage, other-...
  • Page 35 SPEC Specification General specification ..................2-1 Maintenance specification ................2-3 Power unit....................2-3 Lower unit ....................2-5 Electrical ....................2-5 Dimension ....................2-9 Tightening torque ..................2-11 Specified torque ..................2-11 General torque..................2-13 6S35H11...

  • Page 36: Specification

    SPEC Specification General specification Model Item Unit 250GET L250GET Dimension Overall length mm (in) 854 (33.6) Overall width mm (in) 562 (22.1) Overall height mm (in) 1,785 (70.3) mm (in) 1.912 (75.3) Boat transom height mm (in) 635 (25.0) mm (in) 762 (30.0) Weight (with stainless propeller)
  • Page 37 General specification Model Item Unit 250GET L250GET Fuel and oil Fuel type Regular unleaded gasoline RON (*1) Engine oil 2-stroke outboard motor oil Engine oil grade NMMA-certified TC-W3 Engine oil tank capacity Oil tank L (US gt, 1.2 (1.27, 1.06) Imp gt) Remote oil tank L (US gt,...

  • Page 38: Maintenance Specification

    SPEC Specification Maintenance specification Power unit Model Item Unit 250GET L250GET Power unit Minimum compression pressure (*1) (kgf/cm , psi) (4.3, 61) Cylinder head Warpage limit mm (in) 0.10 (0.0039) (lines indicate straightedge position) Cylinders Bore size mm (in) 90.000–90.020 (3.5433–3.5441) Pistons Piston diameter (D) mm (in)
  • Page 39 Maintenance specification Model Item Unit 250GET L250GET Piston rings Top ring Dimension B mm (in) 1.970–1.990 (0.0776–0.0783) Dimension T mm (in) 2.700–2.900 (0.1063–0.1142) End gap mm (in) 0.30–0.50 (0.0118–0.0197) Side clearance mm (in) 0.02–0.06 (0.0008–0.0024) Oversize outside diameter mm (in) 90.25 (3.5531) mm (in) 90.50 (3.5630)

  • Page 40: Lower Unit

    SPEC Specification Model Item Unit 250GET L250GET Carburetor ID mark 6S300 Main jet (M.J.) 158 [SU, PU, PM] 164 [SM, PL] 162 [SL] Main nozzle (M.N.) mm (in) 4.5 (0.18) Pilot jet (P.J.) 74 [SU], 78 [PU], 80 [SM, SL], 84 [PM, PL] Pilot air jet (P.A.J.) 50 [SU, PU]...
  • Page 41 Maintenance specification Model Item Unit 250GET L250GET Spark plug gap mm (in) 0.9–1.0 (0.035–0.039) Ignition coil resistance Ω Primary coil (B/W–B) 0.18–0.24 at 20°C (68°F) Secondary coil (B/W–spark plug wire) kΩ 2.72–3.68 at 20°C (68°F) Spark plug cap resistance kΩ 4.0–6.0 CDI unit output peak voltage (B/W–B)
  • Page 42 SPEC Specification Model Item Unit 250GET L250GET Charge coil output peak voltage (R–Br) at Cranking (unloaded) at Cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) (B/R–L) at Cranking (unloaded) at Cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Charge coil resistance at 20°C (68°F) Ω...
  • Page 43 Maintenance specification Model Item Unit 250GET L250GET PTT system Trim sensor Ω Trim sensor resistance 9–11 at 20°C (68°F) (P–B) Ω Resistance 248–388 at 20°C (68°F) (P–B) ATF Dexron 2 Fluid type Motor type 61A02 Output 0.38 Brushes Standard length mm (in) 12.0 (0.47) Wear limit...

  • Page 44: Dimension

    SPEC Specification Dimension Exterior mm (in) 1,155(45.5) 631 (24.8) 1,271(50.0) 185 (7.3) 556 (22.3) 181 (7.1) 74.0 (2.9) 6S32001M 6S35H11...
  • Page 45 Maintenance specification Clamp bracket mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 79 (3.1) 13 (0.5) 13 (0.5) 101.5 (4.0) 101.5 (4.0) 125.4 (4.9) 125.4 (4.9) 6S32002M 6S35H11 2-10...

  • Page 46: Tightening Torque

    SPEC Specification Tightening torque Specified torque Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel system Intake silencer screw — Throttle sensor screw — Hour meter cover screw — Oil pump bolt Power unit Power unit bolt 18.4 Apron bolt Flywheel magnet nut...
  • Page 47 Tightening torque Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Lower unit (regular rotation model) Check screw — Drain screw — Lower case mount bolt 34.7 Water pump housing bolt 13.3 Shift rod cover bolt Trim tab bolt 31.0 Propeller shaft housing bolt 22.1...

  • Page 48: General Torque

    SPEC Specification Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb PTT unit PTT motor mount bolt Reservoir tank mount bolt Reservoir cap — Main valve — Manual valve — Pipe joint — 11.1 Gear pump screw — Gear pump bolt Tilt ram —...
  • Page 49 Periodic check and adjustment Maintenance interval chart ................3-1 Top cowling ....................3-2 Checking the top cowling ................. 3-2 Fuel system ....................3-2 Checking the fuel joint and fuel hose (fuel joint-to-carburetor) ....3-2 Checking the fuel filter ................3-2 Power unit .....................

  • Page 50: Periodic Check And Adjustment

    Check / charge 3-14 Cooling water passages Clean Cowling clamp Check Fuel filter (can be dis- Check / clean assembled) Fuel system Check Fuel tank (Yamaha por- Check / clean — table tank) Gear oil Change 3-12 Lubrication points Lubricate 3-14...

  • Page 51: Top Cowling

    Maintenance interval chart/Top cowling/Fuel system Top cowling Fuel system Checking the top cowling Checking the fuel joint and fuel 1. Check the fitting by pushing the cowling hose (fuel joint-to-carburetor) with both hands. Adjust the fittings if nec- 1. Check the fuel hose connections and fuel essary.

  • Page 52: Power Unit

    Periodic check and adjustment Power unit 4. Check the spark plug gap a. Adjust if out of specification. Checking the engine oil level 1. Place the outboard motor in an upright position. 2. Check the engine oil level. 3. Make sure the oil level is between the upper 1 and lower 2 level marks.

  • Page 53: Checking The Cooling Water Passage

    Power unit Checking the cooling water passage 3. Place a thermometer in the water and 1. Check the cooling water inlet cover 1, slowly heat the water. screw 2 and cooling water inlet for clog- ging. Clean the water inlet cover and cooling water inlet if necessary.

  • Page 54: Control System

    Periodic check and adjustment Control system 4. Loosen the throttle lever tightening screw 4 to clockwise on the upper and lower Synchronizing the carburetor carburetors. 1. Remove the throttle cable and intake silencer. NOTE: 2. Loosen the throttle lever tightening screw The screw 4 is left hand thread.

  • Page 55: Checking The Throttle Sensor

    Control system 7. Align the mark 5 on the accelerator cam 2. Remove the throttle link rod 2 from the with the center of the roller 6 on the mid- upper carburetor. dle carburetor and tighten the throttle lever tightening screw 1. 6S330260 3.

  • Page 56: Checking The Engine Idle Speed

    Periodic check and adjustment Checking the engine idle speed 4. If the specified engine idle speed cannot be obtained, adjust the pilot screws. NOTE: Before cheking the engine idle speed, the NOTE: pilot screws should be properly adjusted. When adjust the pilot screws, adjust it in the all of cylinders.

  • Page 57: Adjusting The Throttle Cable

    Control system Adjusting the throttle cable NOTE: The throttle cable joint must be screwed in Before adjusting the throttle cable, the throttle a minimum of 8.0 mm (0.31 in) a. stop screw should be properly adjusted. NOTE: 1. Loosen the locknut 1, remove the clip 2 Pull the throttle cable towards the engine to and then remove the throttle cable joint remove any free play in the cable before...

  • Page 58: Checking The Gear Shift Operation

    Periodic check and adjustment Checking the gear shift operation 6. Install the shift cable joint 3, install the 1. Check that the gear shift operates clip 2, and then tighten the locknut 1. smoothly when shifting it from neutral to forward or reverse.

  • Page 59: Checking The Choke Solenoid

    Control system/Bracket Bracket 3. Check that the ATDC 4° scale a on the flywheel magnet is aligned with the point- Checking the PTT operation er b on the timing plate. 1. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation.

  • Page 60: Lower Unit

    Periodic check and adjustment Checking the PTT fluid level 3. If necessary, add sufficient fluid of the 1. Fully tilt the outboard motor up, and then recommended type until it overflows out support it with the tilt stop lever 1. of the filler hole.

  • Page 61: Changing The Gear Oil

    Bracket/Lower unit Changing the gear oil 1. Tilt the outboard motor so that the gear oil drain screw at the lowest point possi- ble. 2. Place a drain pan under the drain screw 1, remove the drain screw, then the check screw 2 and let the oil drain com- pletely.

  • Page 62: Checking The Lower Unit For Air Leakage

    Periodic check and adjustment Checking the lower unit for air leak- Do not over pressurize the lower unit, oth- erwise the oil seals may be damaged. 1. Remove the check screw 1, and then install the special service tool. 6S330140 6G430430 Leakage tester: 90890-06840 2.

  • Page 63: Checking The Battery

    Lower unit/General Checking the battery NOTE: 9 Batteries vary per manufacturer. The proce- 1. Check the battery electrolyte level. If the dures mentioned in this manual may not level is at or below the minimum level mark a, add distilled water until the level always apply, therefore, consult the instruc- tion manual of the battery.
  • Page 64 Periodic check and adjustment 2. Apply low temperature resistant grease to the area shown. 6S330060 6G430540 3. Apply corrosion resistant grease to the area shown. 6S330070 6S330100 6S330080 6S330090 NOTE: Apply grease to the grease nipple until it flows from the bushings a. 3-15 6S35H11...
  • Page 65 FUEL Fuel system Hose routing ....................4-1 Fuel hose and breather hose ..............4-1 Fuel line ......................4-3 Carburetor ..................... 4-6 Disassembling the carburetor ..............4-10 Checking the carburetor ................ 4-10 Assembling the carburetor ..............4-11 Adjusting the throttle sensor ..............4-12 Fuel pump ....................

  • Page 66: Fuel System

    FUEL Fuel system Hose routing Fuel hose and breather hose 6S34001A 1 Fuel hose (fuel tank-to-fuel filter) 2 Fuel hose (fuel filter-to-fuel pumps) 3 Fuel hose (fuel pumps-to-carburetors) 4 Oil hose (remote oil tank-to-engine oil tank) 5 Oil hose (engine oil tank-to-oil injection pump) 6 Oil hose (oil injection pump-to-fuel hose) 6S35H11...
  • Page 67 Hose routing PORT 6S34001B 1 Breather hose (upper-to-lower) 2 Breather hose (manifold-to-cylinder body #2) 3 Breather hose (manifold-to-cylinder body #4) 4 Breather hose (manifold-to-cylinder body #6) 5 Breather hose (manifold-to-cylinder body #1) 6 Breather hose (manifold-to-cylinder body #3) 7 Breather hose (manifold-to-cylinder body #5) 8 Breather hose (manifold-to-intake silencer) 6S35H11...

  • Page 68: Fuel Line

    FUEL Fuel system Fuel line 6S34020E Part name Q’ty Remarks M6 × 16 mm Bolt Fuel filter assembly Lock tie Not reusable Fuel hose Fuel hose Fuel hose Oil hose Fuel hose Fuel hose Fuel pump assembly Gasket Not reusable Fuel hose Fuel hose Fuel hose...
  • Page 69 Fuel line 6S34020E Part name Q’ty Remarks M6 × 50 mm Bolt Holder Hose 6S35H11...
  • Page 70 FUEL Fuel system 6S34040E Part name Q’ty Remarks M6 × 16 mm Bolt Washer Holder M6 × 14 mm Bolt Bracket Fuel filter assembly O-ring Not reusable O-ring Not reusable Fuel filter element Spring Float Fuel filter cup O-ring Not reusable 6S35H11...
  • Page 71 Fuel line/Carburetor Carburetror 3 N·m (0.3 kgf·m, 2.2 ft·lb) 6S34050E Part name Q’ty Remarks ø6 × 55 mm Screw Intake silencer Hose Hose Gasket Not reusable Upper carburetor assembly Middle carburetor assembly Lower carburetor assembly Link rod Joint Gasket Not reusable M6 ×...
  • Page 72 FUEL Fuel system 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 6S34060E Part name Q’ty Remarks Plug Gasket Screw Plate Pilot screw...

  • Page 73: Carburetor

    Carburetor 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 6S34060E Part name Q’ty Remarks Gasket Main jet Float chamber Plug Gasket Pilot jet...
  • Page 74 FUEL Fuel system 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 6S34060E Part name Q’ty Remarks ø5 × 10 mm Screw Throttle sensor Joint...

  • Page 75: Disassembling The Carburetor

    Carburetor Disassembling the carburetor 4. Check the pilot screw and needle valve for bends or wear. Replace the pilot NOTE: screw and needle valve if necessary. 9 Before disassembling the carburetors, make sure to note the number of times the pilot screw is turned out from the seated position to its set position.

  • Page 76: Assembling The Carburetor

    FUEL Fuel system Assembling the carburetor 6. Install the pilot screw, and then turn in 1. Install the gaskets 1, plugs 2, pilot air until it is lightly seated, and then turn out jets 3, and air bleed plugs 4 onto the by the specified number of turns.

  • Page 77: Adjusting The Throttle Sensor

    Carburetor Adjusting the throttle sensor 5. Turn the engine start switch to ON. 1. Remove the hour meter cover 1 and intake silencer cover. 6. Loosen the throttle sensor screws. 7. Adjust the position of the throttle sensor until the specified output voltage is obtained.

  • Page 78: Fuel Pump

    FUEL Fuel system Fuel pump 6G44030E Part name Q’ty Remarks Base Gasket Not reusable Diaphragm Body assembly ø5 × 28 mm Screw Washer Check valve Body Gasket Not reusable Diaphragm Collar O-ring Not reusable Cover Plate Spring ø5 × 35 mm Screw 4-13 6S35H11...

  • Page 79: Checking The Fuel Pump

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

  • Page 80: Assembling The Fuel Pump

    FUEL Fuel system Assembling the fuel pump NOTE: NOTE: Clean the parts and soak the valves and the Make sure that the gaskets and diaphragms diaphragms in gasoline before assembly to are kept in place through the assembly obtain prompt operation of the fuel pumps process.

  • Page 81: Oil Injection System

    Fuel pump/Oil injection system Oil injection system 3 N·m (0.3 kgf·m, 2.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 6S34110E Part name Q’ty Remarks Oil level sensor Oil filter Washer Oil tank Air vent hose Emergency switch Collar Grommet Lock tie Not reusable Water trap M6 ×...
  • Page 82 FUEL Fuel system 3 N·m (0.3 kgf·m, 2.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 6S34110E Part name Q’ty Remarks Oil pump link rod M6 × 20 mm Bolt Oil pump O-ring Not reusable Cover ø5 × 20 mm Screw 4-17 6S35H11...

  • Page 83: Checking The Check Valve

    Oil injection system Checking the check valve Assembling the oil tank 1. Install the washer 1, oil filter 2, and oil 1. Connect the special service tool to the level sensor 3 into the oil tank 4. check valve. 2. Apply positive pressure to the check valve port.

  • Page 84: Bleeding The Oil Pump

    FUEL Fuel system Bleeding the oil pump 4. When there are no air bubbles left, tight- en the air bleed screw. 5. Disconnect the oil pump link rod joint 2 9 Make sure that the engine oil is filled in from the oil pump lever.
  • Page 85 Oil injection system 10. Connect the oil pump link rod 4 to the oil pump lever. Check the oil pump lever clearance a between the oil pump lever and stopper. 6S340030 Oil pump lever clearance a: 1 mm (0.039 in) 11.

  • Page 86: Powr

    POWR Power unit Power unit ..................... 5-1 Checking the compression pressure ............5-1 Removing the power unit ..............5-11 Removing the flywheel magnet ............. 5-12 Removing the flywheel magnet ............. 5-12 Removing the electrical component ............5-13 Intake manifold ................... 5-15 Removing the intake manifold ...............
  • Page 87 Checking the piston pin ................. 5-33 Checking the connecting rod small end axial play ........ 5-34 Checking the connecting rod big end side clearance ......5-34 Checking the crankshaft ................ 5-34 Assembling the crankshaft ..............5-35 Assembling the crankshaft roller bearing ..........5-36 Assembling the oil seal housing ............

  • Page 88: Power Unit

    POWR Power unit Power unit 5. If the compression pressure is below specification and the compression pres- Checking the compression pressure sure for each cylinder is unbalanced, add 1. Start the engine, warm it up for 5 min- a small amount of engine oil to the cylin- utes, and then turn it off.
  • Page 89 Power unit 25 N·m (2.5 kgf·m, 18.4 ft·lb) 25 N·m (2.5 kgf·m, 18.4 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 6S35010E Part name Q’ty Remarks Grommet Flywheel cover Dowel Gasket Not reusable M6 × 20 mm Bolt M6 × 16 mm Bolt Retaining plate Grommet...
  • Page 90 POWR Power unit 200 N·m (20 kgf·m, 148 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 6S35020E 3 N·m (0.3 kgf·m, 2.2 ft·lb) Part name Q’ty Remarks Flywheel magnet Washer M6 × 35 mm Bolt Stator assembly M6 × 20 mm Bolt ø5 ×...
  • Page 91 Power unit 200 N·m (20 kgf·m, 148 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 6S35020E 3 N·m (0.3 kgf·m, 2.2 ft·lb) Part name Q’ty Remarks M6 × 16 mm Bolt Hour meter ø5 × 20 mm Screw M6 × 30 mm Bolt Grommet Clamp...
  • Page 92 POWR Power unit 18 N·m (1.8 kgf·m, 13.3 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 6S35030E Part name Q’ty Remarks Control lever M8 × 40 mm Bolt Wave washer Collar Throttle link rod Lock nut...
  • Page 93 Power unit 18 N·m (1.8 kgf·m, 13.3 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 6S35030E Part name Q’ty Remarks Lever Spring Washer Bracket M6 × 20 mm Bolt Stay Lock nut ø6 ×...
  • Page 94 POWR Power unit 18 N·m (1.8 kgf·m, 13.3 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 6S35040E Part name Q’ty Remarks M8 × 45 mm Bolt M8 × 35 mm Bolt M8 ×...
  • Page 95 Power unit 6S35050E Part name Q’ty Remarks Case Grommet M6 × 28 mm Bolt Collar M6 × 20 mm Bolt M6 × 14 mm Bolt Ignition coil Plug cap Ground lead M6 × 16 mm Bolt Plate Wire harness Holder M6 ×...
  • Page 96 POWR Power unit 6S35060E Part name Q’ty Remarks PTT relay Clamp M6 × 30 mm Bolt Wireharness Ground lead Starter relay Holder ø5 × 12 mm Screw Stay Fuse Spare fuse Positive battery lead Fuse holder Fuse M6 × 14 mm Bolt Joint connector Rectifier Regulator...
  • Page 97 Power unit 6S35060E Part name Q’ty Remarks M6 × 30 mm Bolt Clamp Clip Hose Grommet Collar Case 6S35H11 5-10...

  • Page 98: Removing The Power Unit

    POWR Power unit Removing the power unit 4. Set the remote control lever in the neutral position, and then disconnect the shift NOTE: cable 9, throttle cable 0. It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency.

  • Page 99: Removing The Flywheel Magnet

    Power unit NOTE: 9. Remove the apron r. Make an alignment mark a at the installation point of the timing plate, and then remove the timing plate 1. 2. Loosen the flywheel magnet nut. 6S350280 6F650200 10. Remove the power unit by removing the bolts t and y.

  • Page 100: Removing The Electrical Component

    POWR Power unit 3. Remove the stator assembly 3 pulser coil assembly 4 and crank position sen- To prevent damage to the engine or tools, sor 5. screw in the flywheel puller set bolts evenly and completely so that the fly- wheel puller is parallel to the flywheel magnet.
  • Page 101 Power unit 5. Remove the starter relay 7, the PTT relay assembly 8, and rectifier regulator 9 onto the power unit. 6S350525 6. Disconnect the ignition coil leads, and then remove the CDI unit 0 and case q. 6S350420 6S35H11 5-14...

  • Page 102: Intake Manifold

    POWR Power unit Intake manifold 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 12mm (0.47in) (0.27in) (0.27in) (0.27in) 6S35070E Part name Q’ty Remarks Intake manifold Reed valve assembly Gasket Not reusable Reed valve set Gasket Not reusable...
  • Page 103 Intake manifold 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 12mm (0.47in) (0.27in) (0.27in) (0.27in) 6S35070E Part name Q’ty Remarks M6 × 20 mm Bolt Bracket Hose Hose 6S35H11 5-16...

  • Page 104: Removing The Intake Manifold

    POWR Power unit Removing the intake manifold Checking the reed valve 1. Check the reed valves for bends a. 1. Remove the carburetor assemblies and the fuel hoses. Replace the reed valves if above specifi- cation. 2. Disconnect the hoses 1. S60V5530 6S350730 Valve bend limit a:...
  • Page 105 Intake manifold/Exhaust cover Exhaust cover 10 N·m (1.0 kgf·m, 7.4 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 6S35080E Part name Q’ty Remarks M6 ×...
  • Page 106 POWR Power unit 10 N·m (1.0 kgf·m, 7.4 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 6S35080E Part name Q’ty Remarks Lock tie Not reusable Hose 5-19...

  • Page 107: Exhaust Cover

    Exhaust cover Removing the exhaust cover Checking the PCV 1. Remove the exhaust cover bolts in the 1. Remove the pressure control valve. sequence shown. 2. Check the pressure control valve for wear or deformation. Replace the control valve if necessary. 3.

  • Page 108: Cylinder Head

    POWR Power unit Cylinder head 25 N·m (2.5 kgf·m, 18.4 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 6S35090E Part name Q’ty Remarks Gasket Not reusable Cylinder head...

  • Page 109: Removing The Cylinder Head

    Cylinder head Removing the cylinder head 1. Remove the spark plugs. 2. Remove the cylinder head cover bolts in the sequence shown. PORT STBD 6S350230 Do not scratch or damage the mating sur- faces of the cylinder head and cylinder block. NOTE: Insert a flat-head screw driver between the pry tabs to pry off the cylinder heads.

  • Page 110: Crankcase

    POWR Power unit Crankcase 20 N·m (2.0 kgf·m, 14.8 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 12mm (0.27in) (0.47in) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 100 N·m (10 kgf·m, 73.8 ft·lb) 6S35100E Part name Q’ty Remarks Crankcase...
  • Page 111 Crankcase 20 N·m (2.0 kgf·m, 14.8 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 12mm (0.27in) (0.47in) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 100 N·m (10 kgf·m, 73.8 ft·lb) 6S35100E Part name Q’ty Remarks Oil seal Not reusable M6 ×...
  • Page 112 POWR Power unit 23 N·m (2.3 kgf·m, 17.0 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 36 N·m (3.6 kgf·m, 26.6 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 36 N·m (3.6 kgf·m, 26.6 ft·lb) 6S35110E Part name Q’ty Remarks...
  • Page 113 Crankcase 23 N·m (2.3 kgf·m, 17.0 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 36 N·m (3.6 kgf·m, 26.6 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 36 N·m (3.6 kgf·m, 26.6 ft·lb) 6S35110E Part name Q’ty Remarks Plug...
  • Page 114 POWR Power unit 6S35120E Part name Q’ty Remarks Connecting rod Piston (Starboard side) Washer Needle bearing Clip Not reusable Piston pin Piston ring set Piston (Port side) 5-27 6S35H11...

  • Page 115: Removing The Crankcase

    Crankcase Removing the crankcase Specified bolts a :M8 × 60 mm 1. Remove the crankshaft balancer nut. Thread size b : 25 mm or more 3. Remove the oil seal housing bolts. S60V5640 S60V5690 Apply force in the direction arrows shown, 4.

  • Page 116: Disassembling The Oil Seal Housing

    POWR Power unit Disassembling the oil seal housing Removing the piston, connecting 1. Remove the circlip from oil seal housing. rod assembly and crankshaft assembly 1. Remove the connecting rod bolts and the connecting rod caps, and then remove the piston with connecting rod. 6S350130 2.

  • Page 117: Disassembling The Piston And Connecting Rod Assembly

    Crankcase Checking the bearing 2. Remove the crankshaft assembly. 1. Check the bearings for pitting or rum- bling. Disassembling the crankshaft 1. Remove the seal rings 1. S60V5730 S60V5750 3. Remove the roller bearing 1 and main NOTE: bearing 2. To remove the seal rings 1, widen the seal ring end gap a, and then remove the ring from the groove and remove the crankpin b.

  • Page 118: Checking The Oil Pump Driven Gear And The Oil Pump Drive Gear

    POWR Power unit Checking the oil pump driven gear 3. Remove the circlip 4, and then remove and the oil pump drive gear the lower ball bearing. 1. Check the oil pump driven gear and the oil pump drive gear for cracks, damage, or wear.

  • Page 119: Checking The Cylinder Bore

    Crankcase Checking the cylinder bore Checking the piston ring 1. Measure the cylinder bore (D —D ) at 1. Check the piston ring dimensions of B measuring points a, b, and c, and in and T. Replace the piston and piston direction d (D ), which is parallel rings as a set if out of specification.

  • Page 120: Checking The Piston Ring Side Clearance

    POWR Power unit Checking the piston pin boss bore 2. Level the piston rings 1 in a cylinder with 1. Measure the piston pin boss bore. a piston crown. Replace the piston if out of specification. 3. Check the piston ring end gap a at the specified measuring point b.

  • Page 121: Checking The Connecting Rod Small End Axial Play

    Crankcase Checking the connecting rod small Checking the crankshaft 1. Measure the crankshaft journal diameter end axial play a and crankpin diameter b. Replace the 1. Measure the connecting rod small end crankshaft if out of specification. axial play. Replace the bearing and con- necting rod if above specification.

  • Page 122: Assembling The Crankshaft

    POWR Power unit 2. Install the lower ball bearing 4, then the 2. Measure the crankshaft runout. Replace the crankshaft if above specification. circlip. S60V5940 6S350100 Crankshaft runout limit c: 0.02 mm (0.0008 in) Do not reuse the ball bearing, always replace it with a new one.

  • Page 123: Assembling The Crankshaft Roller Bearing

    Crankcase NOTE: Install the upper ball bearing with the projec- tion c facing toward the wave side of crank- shaft. General pipe 6: d = 45 mm (1.77 in) e = 100 mm (3.93 in) Support 3: S60V5980 90890-02394 Bearing outer race attachment 1: 4.

  • Page 124: Assembling The Piston And Connecting Rod Assembly

    1. Set the crankshaft in the cylinder block. 6S350330 NOTE: 9 Face the embossed “YAMAHA” mark a on the connecting rod in the same direction as the “UP” mark b on the piston. 9 Always use new piston pin clips.
  • Page 125 Crankcase NOTE: NOTE: 9 Fit dowels 1 on the cylinder block into the 9 Apply engine oil to the pistons and piston dowel holes 2 in the main bearings. rings before installation. 9 Align the projection 3 and the projection 4 9 Be sure to install the piston and connecting of the roller bearing with the groove in the rod assemblies into the corresponding...
  • Page 126 POWR Power unit 4. Install the oil seal housing onto the cylin- 7. Install the crankcase onto the cylinder der block. block, and then tighten the crankcase bolts to the specified torques in two stages and in the sequence shown. S60V5B00 NOTE: Install the oil seal housing with the arrow...
  • Page 127 Crankcase 9. Install the crankshaft balancer, and then tighten the crankshaft balancer nut to the specified torque. 6S350240 S60V5B50 NOTE: Apply LOCTITE 572 to the exhaust cover bolts before installation. Apply force to the direction of the arrows shown, to prevent the flywheel holder Exhaust cover bolt: from slipping off easily 1st: 5 N·m (0.5 kgf·m, 3.7 ft·lb)
  • Page 128 POWR Power unit 12. Install the new gaskets r and the cylin- 13. Install the thermoswitche u onto the der heads t, and then tighten the cylin- cylinder head i. der head bolts y to the specified torques in two stages and in the sequence shown.
  • Page 129 Crankcase NOTE: Apply LOCTITE 572 to the cylinder head cover bolts before installation. Cylinder head cover bolt: 1st: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 2nd: 11 N·m (1.1 kgf·m, 8.1 ft·lb) 15. Install the spark plugs temporary tight d, then to the specified torque e with a spark plug wrench.
  • Page 130 POWR Power unit 18. Install the starter motor g, crank position 20. Install the starter relay z, the PTT relay sensor h, pulser coil assembly j and assembly x, and rectifier regulator c stator coil k onto the power unit. onto the power unit.

  • Page 131: Installing The Power Unit

    Crankcase 22. Install the carburetor assemblies b and choke solenoid n onto the power unit. 6S350065 Power unit bolt 4,5: 6S350380 25 N·m (2.5 kgf·m, 18.4 ft·lb) Installing the power unit 3. Install the apron 6. 1. Clean the power unit matching surface, and install the dowels 1 and a new gas- ket 2.
  • Page 132 POWR Power unit 4. Connect the cooling water pilot hose 7 10. Install the Woodruff key and flywheel and ground lead 8. magnet. 11. Tighten the flywheel magnet nut to the specified torque. 6S350035 5. Connect the fuel hose and oil hose. 6.

  • Page 133: Adjusting The Timing Plate

    Crankcase NOTE: 13. Install the retaining plate r. 9 Align the marks a on the timing plate o, which you made during disassembly. 9 For adjustment procedures, following “Adjusting the timing plate” steps. 16. Install the all removed parts. Adjusting the timing plate NOTE: 6S350015 Remove the all spark plugs and lock plate...
  • Page 134 POWR Power unit 4. As look at the dial gauge, slightly turn the flywheel counterclockwise to the speci- fied position. 6S330360 Cylinder #1 piston stroke (BTDC): 2.76 mm (0.108 in) 5. Align the timing plate with the flywheel at and install the timing plate 2. BTDC 19 °...
  • Page 135 — MEMO — 6S35H11 5-48...

  • Page 136: Lowr

    LOWR Lower unit Lower unit (regular rotation model) .............6-1 Removing the lower unit ................6-4 Removing the water pump and shift rod ...........6-5 Checking the water pump and shift rod.............6-5 Propeller shaft housing (regular rotation model) ........6-6 Removing the propeller shaft housing assembly........6-8 Disassembling the propeller shaft assembly ..........6-8 Disassembling the propeller shaft housing..........6-8 Checking the propeller shaft housing ............6-9...
  • Page 137 Lower unit (counter rotation model) ............6-30 Removing the lower unit ................6-33 Removing the water pump and shift rod ..........6-34 Checking the water pump and shift rod...........6-34 Propeller shaft housing (counter rotation model) ........6-35 Removing the propeller shaft housing assembly........6-37 Disassembling the propeller shaft assembly 1 ........6-37 Disassembling the propeller shaft assembly 2 ........6-37 Disassembling the forward gear ..............6-39 Checking the propeller shaft housing ............6-39...

  • Page 138: Lower Unit

    LOWR Lower unit Lower unit (regular rotation model) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 9 N·m (0.9 kgf·m, 6.6 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) 6S36010E Part name Q’ty...
  • Page 139 Lower unit (regular rotation model) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 6S36020E Part name Q’ty Remarks Shift rod Oil seal Not reusable Cover O-ring Not reusable Spring Circlip M6 × 20 mm Bolt Seal Woodruff key M8 ×...
  • Page 140 LOWR Lower unit 18 N·m (1.8 kgf·m, 13.3 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 6S36020E Part name Q’ty Remarks Outer plate cartridge Gasket Not reusable Dowel Dowel 6S35H11...

  • Page 141: Removing The Lower Unit

    Lower unit (regular rotation model) Removing the lower unit 3. Mark the trim tab 1 at the area shown, 1. Drain the gear oil. For draining proce- and then remove it. dures, see Chapter 3, “Changing the gear oil.” 4. Loosen the bolts 2, and then remove the lower unit from the upper case.

  • Page 142: Removing The Water Pump And Shift Rod

    LOWR Lower unit Removing the water pump and shift Checking the water pump and shift 1. Remove the water pump housing 1 and 1. Check the water pump housing. Replace impeller 2. if there is deformation. 2. Remove the woodruff key 3. 2.
  • Page 143 Lower unit (regular rotation model)/Propeller shaft housing (regular rotation model) Propeller shaft housing (regular rotation model) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 6S36030E Part name Q’ty...
  • Page 144 LOWR Lower unit 18 N·m (1.8 kgf·m, 13.3 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 6S36030E Part name Q’ty Remarks Oil seal Not reusable Ring M8 × 20 mm Bolt Cooling water inlet cover Screw...

  • Page 145: Propeller Shaft Housing (Regular Rotation Model)

    Propeller shaft housing (regular rotation model) Removing the propeller shaft hous- Disassembling the propeller shaft ing assembly assembly 1. Remove the bolts 1, ring 2 and bolts 3. 1. Remove the spring 1, and then remove the cross pin 2, shift rod joint 3, shift plunger 4, balls 5, shift slider 6, and dog clutch 7.

  • Page 146: Checking The Propeller Shaft Housing

    LOWR Lower unit 2. Remove the ball bearing from reverse 2. Check the teeth and dogs of the reverse gear, and then remove the reverse gear gear. Replace if cracked or worn. shims. 3. Check the bearings. Replace if pitted or if there is rumbling.

  • Page 147: Assembling The Propeller Shaft Housing

    Propeller shaft housing (regular rotation model) Assembling the propeller shaft Depth d: housing 4.75–5.25 mm (0.187–0.207 in) 1. Install the needle bearing into the pro- peller shaft housing to the specified 3. Install the new ball bearing into the pro- peller shaft housing using a press.
  • Page 148 LOWR Lower unit 4. Install the reverse gear 7 and original shim(s) 8 into the propeller shaft hous- ing using a press. S6S16050 NOTE: 9 Be sure to select the reverse gear shim(s) if replacing the propeller shaft housing, lower case, or ball bearing.
  • Page 149 Propeller shaft housing/Drive shaft and lower case (regular rotation model) Drive shaft and lower case (regular rotation model) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 142 N·m (14.2 kgf·m, 104.7 ft·lb) 6S36040E Part name Q’ty Remarks Drive shaft Cover Oil seal Not reusable M8 ×...
  • Page 150 LOWR Lower unit 18 N·m (1.8 kgf·m, 13.3 ft·lb) 142 N·m (14.2 kgf·m, 104.7 ft·lb) 6S36040E Part name Q’ty Remarks Needle bearing Not reusable Forward gear 6-13 6S35H11...

  • Page 151: Drive Shaft And Lower Case (Regular Rotation Model)

    Drive shaft and lower case (regular rotation model) Removing the drive shaft Disassembling the drive shaft 1. Loosen the pinion nut. housing 1. Remove the cover, oil seals, and needle bearing. 6F660190 S6P26070E Drive shaft holder 6 1: 90890-06520 Needle bearing attachment 1: Pinion nut holder 2: 90890-06610 90890-06715...

  • Page 152: Disassembling The Lower Case

    LOWR Lower unit 2. Remove the needle bearings from the 2. Remove the roller bearing outer race and forward gear using a chisel. shim(s). 6G460100 6F660235 Bearing outer race puller assembly 3: 90890-06523 Outer race puller claw B 4: Do not reuse the bearing, always replace 90890-06533 it with a new one.

  • Page 153: Checking The Lower Case

    Drive shaft and lower case (regular rotation model) Checking the lower case Ball bearing attachment 3: 1. Check the skeg and torpedo. Replace the 90890-06655 lower case if cracked or damaged. Bearing outer race puller assembly 4: Assembling the lower case 90890-06523 1.

  • Page 154: Assembling The Drive Shaft Housing

    LOWR Lower unit Assembling the drive shaft housing Installing the drive shaft 1. Install the needle bearing into the drive 1. Install the forward gear into the lower shaft housing to the specified depth. case. 2. Install the thrust bearing 1 and original shim(s) 2 onto the drive shaft 3.

  • Page 155: Installing The Propeller Shaft Housing

    Drive shaft and lower case (regular rotation model) 6F660310 6S360110 NOTE: Drive shaft holder 6 7: Face the shift plunger connect part to 90890-06520 upward. Pinion nut holder 8: 90890-06715 4. Install the propeller shaft housing assem- bly into the lower case, and then tighten Pinion nut: the bolts 4 to the specified torque.

  • Page 156: Installing The Water Pump And Shift Rod

    LOWR Lower unit Installing the water pump and shift 2. Install a new gasket 4, the outer plate cartridge 5, and dowels 6. 1. Install the shift rod assembly 1 and seal 6S360128 3. Install the Woodruff key 7 into the drive 6S360127 shaft.

  • Page 157: Installing The Lower Unit

    Drive shaft and lower case (regular rotation model) NOTE: 5. Install the new O-ring 9 and insert car- 9 When installing the pump housing, apply tridge 0 into the pump housing q. grease to the inside of the housing, and then turn the drive shaft clockwise while pushing down the pump housing.
  • Page 158 LOWR Lower unit 6. Install the grommet 5. 2. Set the gear shift to the neutral position at the lower unit. Make sure that the shift 7. Install the propeller and propeller nut 6, rod is in the neutral position using a spe- cial service tool.
  • Page 159 Drive shaft and lower case (regular rotation model) Propeller nut 6: 54 N·m (5.4 kgf·m, 39.8 ft·lb) 8. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible.

  • Page 160: Shimming (Regular Rotation Model)

    LOWR Lower unit Shimming (regular rotation model) 6S36050EA 6-23 6S35H11...

  • Page 161: Shimming

    Shimming (regular rotation model) Shimming 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. NOTE: 9 Shimming is not required when assembling Pinion nut: the original lower case and inner parts. 142 N·m (14.2 kgf·m, 104.7 ft·lb) 9 Shimming is required when assembling the 3.

  • Page 162: Selecting The Forward Gear Shim

    LOWR Lower unit 5. Calculate the pinion shim thickness (T3) Example: as shown in the examples below. If “T3” is 0.70 mm, then the pinion shim is 0.68 mm. If “T3” is 0.74 mm, then the pinion shim is 0.72 mm. Selecting the forward gear shim 1.

  • Page 163: Selecting The Reverse Gear Shim

    Shimming (regular rotation model) 2. Calculate the forward gear shim thick- Available shim thicknesses: ness (T1) as shown in the examples 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and below. 0.50 mm Example: If “T1” is 0.45 mm, then the forward gear shim is 0.42 mm.

  • Page 164: Backlash (Regular Rotation Model)

    LOWR Lower unit 2. Calculate the reverse gear shim thick- If “M2” is 19.92 mm and “R” is (+ 3) and “A” is ness (T2) as shown in the examples (– 5), then below. T2 = 21.00 – (+ 3)/100 – (– 5)/100 –...
  • Page 165 Shimming (regular rotation model)/Backlash (regular rotation model) 3. Install the special service tools so that it 5. Set the lower unit upside down. pushes against the propeller shaft. 6S360190 NOTE: Install the dial gauge so that the plunger a NOTE: contacts the mark b on the backlash indica- While turning the drive shaft clockwise 5-6 times to contact the gear evenly it tightens...
  • Page 166 LOWR Lower unit 8. Remove the special service tools from 10. Slowly turn the drive shaft clockwise and the propeller shaft. counterclockwise, and measure the backlash when the drive shaft stops in 9. Apply a load to the reverse gear by each direction.
  • Page 167 Backlash (regular rotation model)/Lower unit (counter rotation model) Lower unit (counter rotation model) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 9 N·m (0.9 kgf·m, 6.6 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) 6S36050E Part name...
  • Page 168 LOWR Lower unit 18 N·m (1.8 kgf·m, 13.3 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 6S36070E Part name Q’ty Remarks Shift rod Oil seal Not reusable Cover O-ring Not reusable Spring Circlip M6 × 20 mm Bolt Seal Woodruff key M8 ×...
  • Page 169 Lower unit (counter rotation model) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 6S36070E Part name Q’ty Remarks Outer plate cartridge Gasket Not reusable Dowel Dowel 6S35H11 6-32...

  • Page 170: Removing The Lower Unit

    LOWR Lower unit Removing the lower unit 3. Mark the trim tab 1 at the area shown, 1. Drain the gear oil. For draining proce- and then remove it. dures, see Chapter 3, “Changing the gear oil.” 4. Loosen the bolts 2, and then remove the lower unit from the upper case.

  • Page 171: Removing The Water Pump And Shift Rod

    Lower unit (counter rotation model) Removing the water pump and shift Checking the water pump and shift 1. Remove the water pump housing 1 and 1. Check the water pump housing. Replace impeller 2. if there is deformation. 2. Remove the woodruff key 3. 2.

  • Page 172: Propeller Shaft Housing (Counter Rotation Model)

    LOWR Lower unit Propeller shaft housing (counter rotation model) 108 N·m (10.8 kgf·m, 79.7 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 6S36080E Part name Q’ty Remarks...
  • Page 173 Propeller shaft housing (counter rotation model) 108 N·m (10.8 kgf·m, 79.7 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 6S36080E Part name Q’ty Remarks Propeller shaft shim —...

  • Page 174: Removing The Propeller Shaft Housing Assembly

    LOWR Lower unit Removing the propeller shaft hous- Disassembling the propeller shaft ing assembly assembly 1 1. Remove the bolts 1, ring 2 and bolts 3. 1. Remove the spring 1, and then remove the cross pin 2, shift rod joint 3, shift plunger 4, balls 5, shift slider 6, and dog clutch 7.
  • Page 175 Propeller shaft housing (counter rotation model) 4. Remove the bearing outer race 8, taper 2. Install the propeller shaft housing assem- roller bearing 9, thrust bearing 0, and bly in the reverse direction into the lower propeller shaft shim(s) q using a press. case.

  • Page 176: Disassembling The Forward Gear

    LOWR Lower unit Checking the propeller shaft 6. Remove the oil seals and needle bearing. 1. Check the each propeller shaft. Replace if bent or worm the spline. 2. Measure the propeller shaft runout. S60V6720 Needle bearing attachment y: 6S360310 90890-06611 Driver rod L3 u: 90890-06652 Runout limit: 0.02 mm (0.0008 in)

  • Page 177: Assembling The Propeller Shaft Housing

    Propeller shaft housing (counter rotation model) 2. Install the new bushing 4 into the for- 2. Install the needle bearing into the pro- ward gear 5. peller shaft housing to the specified depth. 6S360340 S6P26050E Needle bearing attachment 6: NOTE: 90890-06653 9 Install the needle bearing with the manufac- Driver rod LS 7: 90890-06606...
  • Page 178 LOWR Lower unit 4. Install the original shim(s) 6 and thrust 6. Install the propeller shaft housing assem- bearing 7 with the propeller shaft 2 into bly in the reverse direction into the lower the propeller shaft housing. case. 6S360255 6S360360 NOTE: NOTE:...
  • Page 179 Propeller shaft housing (counter rotation model) Assembling the propeller shaft 8. Install the original shim(s) t, forward gear y, and dog clutch u using a press. assembly 1 1. Install the dog clutch 1, shift plunger 2, ball 3, slider 4 and shift rod joint 5, into the propeller shaft 6, and then install the cross pin 7 and spring 8.

  • Page 180: Drive Shaft And Lower Case (Counter Rotation Model)

    LOWR Lower unit Drive shaft and lower case (counter rotation model) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 142 N·m (14.2 kgf·m, 104.7 ft·lb) 6S36090E Part name Q’ty Remarks Drive shaft Cover Oil seal Not reusable M8 × 25 mm Bolt Drive shaft housing Needle bearing O-ring...
  • Page 181 Drive shaft and lower case (counter rotation model) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 142 N·m (14.2 kgf·m, 104.7 ft·lb) 6S36090E Part name Q’ty Remarks Needle bearing Reverse gear Washer Needle bearing 6S35H11 6-44...

  • Page 182: Removing The Drive Shaft

    LOWR Lower unit Removing the drive shaft Disassembling the drive shaft 1. Loosen the pinion nut. housing 1. Remove the cover, oil seals, and needle bearing. 6F660190 S6P26070E Drive shaft holder 6 1: 90890-06520 Needle bearing attachment 1: Pinion nut holder 2: 90890-06610 90890-06715 Driver rod L3 2: 90890-06652...

  • Page 183: Disassembling The Lower Case

    Drive shaft and lower case (counter rotation model) Disassembling the lower case 3. Remove the needle bearing from the 1. Remove the needle bearing. retainer. S6P26070E S69J6470 NOTE: Needle bearing attachment 5: Since the diameter of the passage in the 90890-06654 lower case and the diameter of the special Driver rod L3 6: 90890-06652...

  • Page 184: Checking The Lower Case

    LOWR Lower unit Checking the lower case 3. Install the needle bearing into the lower 1. Check the skeg and torpedo. Replace the case. lower case if cracked or damaged. Assembling the lower case 1. Install the needle bearing into the retain- er to the specified depth.

  • Page 185: Assembling The Drive Shaft Housing

    Drive shaft and lower case (counter rotation model) Assembling the drive shaft housing Installing the drive shaft 1. Install the thrust bearing 1 and reverse 1. Install the needle bearing into the drive gear 2 into the lower case. shaft housing to the specified depth. S6P26800E 6S360410 Needle bearing attachment 1:...

  • Page 186: Installing The Propeller Shaft Housing

    LOWR Lower unit 3. Install the drive shaft 5 into the lower 4. Install the drive shaft housing q, and case. Then install the pinion 6, washer then tighten the drive shaft housing bolt 7 and pinion nut 8, and then tighten the nut 8 to the specified torque.

  • Page 187: Installing The Water Pump And Shift Rod

    Drive shaft and lower case (counter rotation model) NOTE: 4. Install the propeller shaft housing bolts 9 Check the gear shift to the neutral position, 4, and then tighten the bolts to the spec- when installing the shift rod. ified torque. 9 After assembling the lower unit, check that the shift rod operates smoothly, and check 5.

  • Page 188: Installing The Lower Unit

    LOWR Lower unit NOTE: 5. Install the new O-ring 9 and insert car- 9 When installing the pump housing, apply tridge 0 into the pump housing q. grease to the inside of the housing, and then turn the drive shaft clockwise while pushing down the pump housing.
  • Page 189 Drive shaft and lower case (counter rotation model) 2. Set the gear shift to the neutral position Lower case mount bolt 2: at the lower unit. Make sure that the shift 47 N·m (4.7 kgf·m, 34.7 ft·lb) rod is in the neutral position using a spe- Trim tab bolt 4: cial service tool.
  • Page 190 LOWR Lower unit NOTE: If the grooves in the propeller nut 6 do not align with the cotter pin hole, tighten the nut until they are aligned. Propeller nut 6: 54 N·m (5.4 kgf·m, 39.8 ft·lb) 8. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible.

  • Page 191: Shimming (Counter Rotation Model)

    Drive shaft and lower case (counter rotation model)/Shimming (counter rotation model) Shimming (counter rotation model) M6-10 6S36060EL 6S35H11 6-54...

  • Page 192: Shimming

    LOWR Lower unit Shimming 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. NOTE: 9 Shimming is not required when assembling Pinion nut: the original lower case and inner parts. 142 N·m (14.2 kgf·m, 104.7 ft·lb) 9 Shimming is required when assembling the 3.

  • Page 193: Selecting The Reverse Gear Shim

    Shimming (counter rotation model) 5. Calculate the pinion shim thickness (T3) Example: as shown in the examples below. If “T3” is 0.70 mm, then the pinion shim is 0.68 mm. If “T3” is 0.74 mm, then the pinion shim is 0.72 mm.
  • Page 194 LOWR Lower unit 2. Calculate the reverse gear shim thick- Available shim thicknesses: ness (T1) as shown in the examples 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and below. 0.50 mm Example: If “T1” is 0.45 mm, then the reverse gear shim is 0.42 mm.

  • Page 195: Selecting The Forward Gear Shim

    Shimming (counter rotation model) Selecting the forward gear shim 2. Calculate the forward gear shim thick- 1. Turn the taper roller bearing outer race 1 ness (T2) as shown in the examples 2 or 3 times to seat the rollers, and then below.

  • Page 196: Selecting The Propeller Shaft Shim

    LOWR Lower unit If “M5” is 21.95 mm and “M6” is 16.78 mm and “R” is (– 1) and “A” is (+ 2), then T2 = 6.50 + (– 1)/100 – (+ 2)/100 – 21.95 + 16.78 mm = 6.50 – 0.01 – 0.02 – 21.95 + 16.78 mm = 1.30 mm 3.
  • Page 197 Shimming (counter rotation model) 3. Calculate the propeller shaft shim thick- 4. Round the numerals for the propeller ness (T4) as shown in the examples shaft shim(s) (T4) as follows. below. Calculated numeral Rounded numeral at 1/100th place 1, 2 3, 4, 5 6, 7, 8 9, 10...

  • Page 198: Backlash (Counter Rotation Model)

    LOWR Lower unit 7. Install the shim(s) 6, thrust bearing 4, propeller shaft 5, taper roller bearing 7 and claw washer 8, and then tighten the ring nut 9 to the specified torque. 69D60035 Shift rod push arm: 90890-06052 6S360490 3.
  • Page 199 Shimming (counter rotation model)/Backlash (counter rotation model) 4. Install the backlash indicator onto the 7. Add or remove shim(s) if out of specifica- drive shaft (22.4 mm [0.88 in] in diame- tion. ter), then the dial gauge onto the lower Forward gear unit.
  • Page 200 LOWR Lower unit 11. Turn the shift rod to the neutral position 15. Add or remove shim(s) if out of specifica- d with the shift rod push arm. tion. Reverse gear 12. Turn the drive shaft counterclockwise Shim thickness backlash approximately 30°.
  • Page 201 — MEMO — 6S35H11 6-64...

  • Page 202: Bracket Unit

    BRKT Bracket unit Bottom cowling ....................7-1 Upper case, steering arm ................7-5 Disassembling the upper case ..............7-9 Checking the upper case.................7-10 Assembling the upper case ..............7-10 Removing the steering arm ..............7-14 Installing the steering arm ...............7-14 Installing the upper case................7-15 Clamp bracket and swivel bracket .............7-16 Removing the PTT unit................7-18 Removing the clamp bracket ..............7-18 Installing the clamp bracket ..............7-19...
  • Page 203 Tilt cylinder and trim cylinder..............7-38 Disassembling the tilt cylinder and trim cylinder ........7-40 Checking the tilt cylinder and trim cylinder ..........7-41 Checking the valve ..................7-42 Assembling the tilt ram ................7-42 Assembling the trim ram................7-43 Installing the tilt cylinder ................7-43 Installing the trim ram ................7-43 Installing the PTT motor ................7-44 Installing the reservoir ................7-45 Installing the tilt ram.................7-45...

  • Page 204: Bottom Cowling

    BRKT Bracket unit Bottom cowling 5 N·m (0.5 kgf·m, 3.7 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 6S37010E Part name Q’ty Remarks M8 × 45 mm Bolt M8 × 45 mm Bolt Washer Grommet Collar Seal Ground lead Hose Cooling water pilot hole Grommet PTT motor lead Trim sensor coupler...
  • Page 205 Bottom cowling 5 N·m (0.5 kgf·m, 3.7 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 6S37010E Part name Q’ty Remarks Bottom cowling M6 × 30 mm Bolt M6 × 12 mm Bolt Spring Stay Washer Bushing Seal Grease nipple Bracket Shift rod Cotter pin Grommet Plate...
  • Page 206 BRKT Bracket unit 8 N·m (0.8 kgf·m, 5.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 6S37020E Part name Q’ty Remarks Clamp M6 × 20 mm Bolt Plate M8 ×...
  • Page 207 Bottom cowling 8 N·m (0.8 kgf·m, 5.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 6S37020E Part name Q’ty Remarks Clamp lever Holder Spring hook Hook Hook...

  • Page 208: Upper Case, Steering Arm

    BRKT Bracket unit Upper case, steering arm 72 N·m (7.2 kgf·m, 53.1 ft·lb) 72 N·m (7.2 kgf·m, 53.1 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 6S37030E Part name Q’ty Remarks Upper case assembly Cover Ground lead M6 × 10 mm Bolt M6 ×...
  • Page 209 Upper case, steering arm 18 N·m (1.8 kgf·m, 13.3 ft·lb) å 6S37045E Part name Q’ty Remarks Upper case Dowel Upper mount Washer Rubber washer Washer M14 × 190 mm Bolt Bracket Muffler assembly Rubber seal Not reusable Mount housing Ground lead Washer Rubber washer Lower mount...
  • Page 210 BRKT Bracket unit 18 N·m (1.8 kgf·m, 13.3 ft·lb) å 6S37045E Part name Q’ty Remarks M8 × 30 mm Bolt Extension U-transom M6 × 35 mm Bolt M10 × 45 mm Bolt M14 × 205 mm Bolt Circlip Bushing Grommet Rubber seal Not reusable 6S35H11...
  • Page 211 Upper case, steering arm 18 N·m (1.8 kgf·m, 13.3 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) S60V7050 Part name Q’ty Remarks Muffler Exhaust manifold Gasket Not reusable Lower exhaust guide Gasket Not reusable Upper exhaust guide Flushing hose Lock tie Not reusable...

  • Page 212: Disassembling The Upper Case

    BRKT Bracket unit Disassembling the upper case 3. Remove the exhaust manifold 7. 1. Remove the muffler assembly 1 and rubber seal 2 from the upper case 3. S60V7140 å 4. Remove the lower exhaust guide 8 from the upper exhaust guide 9. S60V7120 å...

  • Page 213: Checking The Upper Case

    Upper case, steering arm Checking the upper case 2. Install a new gasket 3, the lower exhaust 1. Check the rubber dampers. Replace if guide 4, and bolts 5, and then tighten deterioration or cracks. the bolts to the specified torque. 2.
  • Page 214 BRKT Bracket unit 4. Install the rubber damper 9 and clip 0 7. Install the muffler assembly t during onto the muffler q. inserting the tip of the cooling water pipe w into the joint hole a of the upper case. 5.
  • Page 215 Upper case, steering arm 10. Install the bracket o, and then tighten the bolts p. S60V7230 NOTE: First tighten the center located, when tighten the bolts a. 11. Install the lower mounts a and mount housings s. S60V7240 6S370017 6S35H11 7-12...
  • Page 216 BRKT Bracket unit 6S37040E Part name Q’ty Remarks Steering arm Washer Bushing Bracket assembly O-ring Not reusable Bushing Steering yoke Circlip Damper 7-13 6S35H11...

  • Page 217: Removing The Steering Arm

    Upper case, steering arm Removing the steering arm Installing the steering arm 1. Remove the circlip 1. 1. Install the washer 1 and bushing 2 onto the steering arm 3. 2. Place the swivel bracket 4 in an upright position, and then install the steering arm onto the swivel bracket assembly S69J7075 2.

  • Page 218: Installing The Upper Case

    BRKT Bracket unit Installing the upper case 4. Install the steering yoke 9 to the steer- 1. Install the upper and lower mount bolts ing arm 3 by aligning the center a of the into the bracket assembly 1 simultane- yoke with the center b of the steering ously.
  • Page 219 Upper case, steering arm/Clamp bracket and swivel bracket Clamp bracket and swivel bracket 3 N·m (0.3 kgf·m, 2.2 ft·lb) 22 N·m (2.2 kgf·m, 16.2 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 36 N·m (3.6 kgf·m, 26.6 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6S37050E Part name Q’ty...
  • Page 220 BRKT Bracket unit 3 N·m (0.3 kgf·m, 2.2 ft·lb) 22 N·m (2.2 kgf·m, 16.2 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 36 N·m (3.6 kgf·m, 26.6 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6S37050E Part name Q’ty Remarks M6 × 10 mm Bolt Spring Spring holder...

  • Page 221: Clamp Bracket And Swivel Bracket

    Clamp bracket and swivel bracket Removing the PTT unit 5. Remove the circlip 7, and then remove 1. Fully tilt the outboard motor up, and then the shaft 8. support it with the tilt stop lever 1. 6. Remove the PTT unit 9. S60V3310 9 After tilting up the outboard motor, be sure to support it with the tilt stop lever.

  • Page 222: Installing The Clamp Bracket

    BRKT Bracket unit Installing the clamp bracket 1. Install the tilt stop levers and spring onto the swivel bracket assembly. 2. Install the trim sensor 1 onto the star- board clamp bracket. 6S370370 Do not pinch the trim sensor pin 9 when down the swivel bracket.

  • Page 223: Adjusting The Trim Sensor

    Clamp bracket and swivel bracket 2. Install the PTT unit mount bolts 2 onto 8. Inject grease into all grease nipples until grease comes out from the bushings a. both clamp brackets together with the PTT unit 3, and then tighten them. 3.
  • Page 224 BRKT Bracket unit 2. Loosen the screws 2. 3. Adjust the position of the trim sensor, and then tighten the screws 2 temporary. NOTE: 9 To decrease the resistance, turn the trim sensor in direction a. 9 To increase the resistance, turn the trim sensor in direction b.

  • Page 225: Ptt Unit

    Clamp bracket and swivel bracket/PTT unit PTT unit 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 11 N·m (1.1 kgf·m,8.1 ft·lb) 6S37060E Part name...
  • Page 226 BRKT Bracket unit 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 11 N·m (1.1 kgf·m,8.1 ft·lb) 6S37060E Part name Q’ty...

  • Page 227: Checking The Hydraulic Pressure

    PTT unit Checking the hydraulic pressure Battery Rams PTT motor lead 1. Check the hydraulic pressure. Check the terminal internal parts if out of specification. Light green (Lg) Down Sky blue (Sb) 2. Fully extend the PTT rams. 3. Loosen the pipe joints 1, and then Hydraulic pressure (down): remove the pipe joint a.
  • Page 228 BRKT Bracket unit 10. Loosen the pipe joints 3, and then Hydraulic pressure (up): remove the pipe joint b. 11.3 – 13.3 MPa (113 – 133 kgf/cm 11. Install the special service tools as shown. 13. Reverse the PTT motor leads between the battery terminals to fully retract the rams.
  • Page 229 PTT unit 17. Place the PTT unit in an upright position. 18. Remove the reservoir cap 4, and then check the fluid level in the reservoir. Make sure that the trim and tilt rams are fully extended when removing the reser- voir cap, otherwise fluid can spurt out from the unit due to internal pressure.

  • Page 230: Ptt Motor

    BRKT Bracket unit PTT motor 6S37080E Part name Q’ty Remarks Frame M5 × 100 mm Bolt O-ring Not reusable Brush holder assembly Spring Brush ø4 × 10 mm Screw Stator assembly Wave washer Bearing Armature O-ring PTT motor base Oil seal Not reusable 7-27 6S35H11...

  • Page 231: Disassembling The Ptt Motor

    PTT motor Disassembling the PTT motor 3. Remove the stator 2 and O-ring 3. 1. Remove the PTT motor, O-ring, and joint from the PTT unit. 9 Make sure that the trim and tilt rams are fully extended when removing the PTT motor, otherwise fluid can spurt out from the unit due to internal pressure.

  • Page 232: Checking The Ptt Motor

    BRKT Bracket unit Checking the PTT motor Motor commutator standard 1. Check the commutator. Clean with 600– undercut b: grit sandpaper and compressed air if 1.8 mm (0.07 in) dirty. Wear limit: 1.2 mm (0.05 in) 4. Check the armature for continuity. Replace if out of specifications.

  • Page 233: Assembling The Ptt Motor

    PTT motor 5. Push the brushes 8 into the holders, and 6. Check the base. Replace if cracked or then install the armature 9. damaged. 7. Check the bearing and oil seal. Replace if damaged or worn. Assembling the PTT motor 1.

  • Page 234: Gear Pump

    BRKT Bracket unit Gear pump 2 N·m (0.2 kgf·m, 1.5 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6S37070E Part name Q’ty Remarks Gear housing 1 Ball ø4 × 30 mm Screw Gear pump filter Drive gear Gear housing 2 M5 × 12 mm Bolt O-ring Not reusable...
  • Page 235 Gear pump · · · m (0.4 kgf m, 3.0 ft · · · m (0.4 kgf m, 3.0 ft S60V7110 Part name Q’ty Remarks Trim down plate Seal ø5 × 10 mm Screw Trim down spring Main valve seal ø5 ×...

  • Page 236: Disassembling The Gear Pump

    BRKT Bracket unit Disassembling the gear pump and 4. Separate the gear pump housing 2 8 main valve from the gear pump as shown. 1. Remove the manual valve 1 and gear pump 2. 6S370240 NOTE: Upside down the gear pump housing, and then remove the gear pump housing 2 8.

  • Page 237: Checking The Main Valve

    Gear pump Checking the gear pump housing 3. Remove the springs 6 pins 7,washers 1. Check the inside of the gear pump hous- 8, valve seats 9, valve seals 0, balls q, relief valve seat w, O-ring e and fil- ing.

  • Page 238: Assembling The Relief Valve

    BRKT Bracket unit Assembling the relief valve 4. Install the relief valve plate q by install 1. Install the relief valve filter 1 and new O- ing the screws w, then tighten them to ring 2 into the PTT body. the specified torque.

  • Page 239: Assembling The Gear Pump

    Gear pump Assembling the gear pump 4. Install the new O-rings, piston 8, main 1. Install the drive gear 1 and driven gear valves 9 and valve support 0. 2 and balls 3 into the gear housing 1 4, and then install the gear housing 2 5. 6S370270 2.
  • Page 240 BRKT Bracket unit 6. Install the new O-rings r, joint t ,gear pump filter y, and then install the new O- ring u, valve seat i, new O-ring o, ball p, manual valve assembly a and circlip 6S370315 Gear pump screw e: 2 N·m (0.2 kgf·m, 1.5 ft·lb) Manual valve a: 2 N·m (0.2 kgf·m, 1.5 ft·lb)
  • Page 241 Gear pump/Tilt cylinder and trim cylinder Tilt cylinder and trim cylinder 55 N·m (5.5 kgf·m, 40.6 ft·lb) 90 N·m (9.0 kgf·m, 66.4 ft·lb) 160 N·m (16.0 kgf·m, 118 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 6S37090E Part name Q’ty Remarks Circlip Dust seal Not reusable...
  • Page 242 BRKT Bracket unit 55 N·m (5.5 kgf·m, 40.6 ft·lb) 90 N·m (9.0 kgf·m, 66.4 ft·lb) 160 N·m (16.0 kgf·m, 118 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 6S37090E Part name Q’ty Remarks O-ring Not reusable Backup ring O-ring Not reusable Spring Adapter Tilt piston...

  • Page 243: Tilt Cylinder And Trim Cylinder

    Tilt cylinder and trim cylinder Disassembling the tilt cylinder and trim cylinder Never look into the tilt cylinder opening 1. Remove the tilt cylinder from PTT unit. when removing the free piston. The free piston and PTT fluid can be forcefully 2.

  • Page 244: Checking The Tilt Cylinder And Trim Cylinder

    BRKT Bracket unit Checking the tilt cylinder and trim 10. Hold the PTT body 6 in a vice using alu- minum plates a on both sides. cylinder 1. Check the PTT body 1 and tilt cylinder 2. Replace if cracked or if there is corro- sion.

  • Page 245: Checking The Valve

    Tilt cylinder and trim cylinder Checking the valve 4. Tighten the tilt ram 9 to the specified 1. Check the tilt piston absorber valves 1. torque. Clean if there is dirt or residue. S6P27560 Assembling the tilt ram S69J7310 PTT piston vice attachment 0: Do not use a rag when assembling the 90890-06572 PTT unit as dust and particles on the PTT...

  • Page 246: Assembling The Trim Ram

    BRKT Bracket unit Assembling the trim ram Installing the tilt cylinder 1. Install the new O-ring 1, backup ring 2, 1. Install the new O-ring 1 to the free pis- spring 3, adapter 4, and circlip 5 to the ton 2. trim piston 6.

  • Page 247: Installing The Ptt Motor

    Tilt cylinder and trim cylinder 1. Hold the PTT body 1 in a vice using alu- Cylinder-end screw wrench: minum plates a on both sides. 90890-06568 Trim cylinder end screw 2: 160 N·m (16 kgf·m, 118 ft·lb) Installing the PTT motor 1.

  • Page 248: Installing The Reservoir

    BRKT Bracket unit 4. Install the new O-ring 2 and PTT motor 2. Fill the PTT fluid into the reservoir tank, 3, and then tighten the bolts 4 to the and then install the new O-ring 4 and reservoir cap 5, and then tighten it to the specified torque.

  • Page 249: Bleeding The Ptt Unit

    Tilt cylinder and trim cylinder 3. Install the tilt piston assembly into the tilt 4. If fluid is below the correct level, add fluid cylinder, and then tighten the tilt cylinder of the recommended type. end screw 1 to the specified torque. 5.

  • Page 250: Bleeding The Ptt Unit (Built-In)

    BRKT Bracket unit 5. Remove the reservoir cap 1, and then 8. Check the fluid level when the rams are fully extended. If the fluid level is low, add check the fluid level in the reservoir. sufficient fluid, and then repeat step 7. Bleeding the PTT unit (built-in) 1.

  • Page 251: Ptt Electrical System

    Tilt cylinder and trim cylinder/PTT electrical system PTT electrical system 3. Connect the digital circuit tester between PTT relay terminals 1 and 3. Checking the fuse 1. Check the fuse (80A) for continuity. 4. Connect the light green (Lg) lead to the Replace if there is no continuity.

  • Page 252: Checking The Ptt Switch

    BRKT Bracket unit Checking the PTT switch 1. Check the PTT switch for continuity. Replace if out of specification. Lead color Switch Sky blue Red (R) Light green position (Sb) (Lg) Free Down Checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification.

  • Page 253: Elec

    ELEC Electrical system Checking the electrical component .............8-1 Measuring the peak voltage ..............8-1 Electrical component ..................8-2 Port view ....................8-2 Starboard view...................8-3 Junction box....................8-4 Aft view ......................8-6 Top view.....................8-7 Ignition and ignition control system ............8-8 Checking the ignition spark gap ..............8-8 Checking the spark plug cap ..............8-8 Checking the ignition coil................8-9 Checking the CDI unit................8-9...

  • Page 254: Electrical System

    ELEC Electrical system Checking the electrical NOTE: 9 Before measuring the peak voltage, check component all wiring for proper connection and corro- Measuring the peak voltage sion, and check that the battery is fully To check the electrical components or mea- charged.

  • Page 255: Electrical Component

    Checking the electrical component/Electrical component Electrical component Port view å ∫ ç ∂ © ƒ ´ 6S380010 1 Throttle sensor å To pulser coil. ∫ To oil feed pump (wiring harness). 2 Hour meter ç To CDI unit (wiring harness). 3 Spark plug ∂...

  • Page 256: Starboard View

    ELEC Electrical system Starboard view 6S380020 1 Spark plug cap 0 Shift cut switch coupler 2 Spark plug 3 Engine temperature sensor 4 Crank position sensor 5 Pulse coil assembly 6 Stator assembly 7 Starter motor 8 Choke solenoid 9 Shift cut switch 6S35H11...

  • Page 257: Junction Box

    Electrical component Junction box å Section A ´ Section B ç ∫ Section C © ˙ ∂ ˆ ∆ ƒ 6S380040 1 Rectifier Regulator å To stator assembly. ∫ To crank position sensor. 2 PTT relay ç To engine temperature sensor. 3 Fuse holder (80A) ∂...
  • Page 258 ELEC Electrical system å Section A ´ Section B ç ∫ Section C © ˙ ∂ ˆ ∆ ƒ 6S380040 ˙ Do not out the leads from slot of the box. Section B ˆ Clamp with battery lead and PTT relay lead. Wiring for fuse holder, engine temperature sen- ∆...

  • Page 259: Aft View

    Electrical component Aft view ç å ∫ ∂ ´ ´ BOTTOM 6S380050 1 Ignition coil #1 å To locate the charge coil coupler. ∫ To locate the coupler to center of the CDI unit 2 Ignition coil #2 3 Ignition coil #3 case, and then bend the harness and clamp 4 Ignition coil #4 them after install the tube.

  • Page 260: Top View

    ELEC Electrical system Top view 6S380030 1 Spark plug q Crank position sensor 2 Thermoswitch w Engine temperature sensor 3 Ignition coil #1 4 Ignition coil #2 5 Oil level gauge 6 Emergency switch 7 Throttle sensor 8 Pulser coil assembly 9 Stator assembly 0 Starter motor 6S35H11...

  • Page 261: Ignition And Ignition Control System

    Electrical component/Ignition and ignition control system Ignition and ignition control Checking the spark plug cap 1. Remove the CDI unit cover, and then system remove the ignition coils. Checking the ignition spark gap 1. Disconnect the spark plug caps from the 2.

  • Page 262: Checking The Ignition Coil

    ELEC Electrical system Checking the ignition coil Checking the CDI unit 1. Remove the CDI unit cover, and then 1. Remove the CDI unit cover. remove the ignition coils. 2. Connect the digital circuit tester with 2. Disconnect the ignition coil connectors. peak voltage adaptor B to the ignition coil lead and the ground.

  • Page 263: Checking The Pulser Coil

    Ignition and ignition control system Checking the pulser coil 4. Disconnect the pulser coil coupler. 1. Remove the hour meter cover. 5. Connect the digital circuit tester to the 2. Connect the test harness to the pulser pulser coil coupler (pulser coil side). coil.

  • Page 264: Checking The Crank Position Sensor

    ELEC Electrical system Checking the crank position sensor 1. Remove the junction box cover. 2. Connect the test harness to the crank position sensor. 3. Measure the crank position sensor output peak voltage. Replace the crank position sensor if less than specification. 6S380105 Crank position sensor resistance (reference data):...

  • Page 265: Checking The Crank Position Sensor Air Gap

    Ignition and ignition control system Checking the crank position sensor 4. Measure the input voltage at the engine air gap temperature sensor coupler (engine tem- 1. Remove the flywheel magnet cover. perature sensor side). Check the wiring harness if less than specification. 2.

  • Page 266: Checking The Charge Coil

    ELEC Electrical system Checking the charge coil 7. Remove the engine temperature sensor. 1. Remove the CDI unit cover. 8. Place the engine temperature sensor in a 2. Connect the test harness to the charge container of water and slowly heat the coil.

  • Page 267: Checking The Thermoswitch

    Ignition and ignition control system 6. Measure the charge coil resistance. Thermoswitch continuity Replace the stator assembly if out of temperature: specification. Pink (P) – Black (B) ON e: 84.0 – 90.0 °C (183 – 194°F) OFF f: 60.0 – 74.0 °C (140 –...

  • Page 268: Starting System

    ELEC Electrical system Starting system 5. Check the continuity at the shift cut switch coupler a to CDI unit coupler b Checking the fuse (wiring harness side). Replace the wiring 1. Check the fuse for continuity. Replace harness if no continuity. the fuse if there is no continuity.

  • Page 269: Checking The Engine Stop Lanyard Switch

    Ignition and ignition control system/Starting system Checking the engine stop lanyard Checking the starter relay 1. Remove the starter relay 1. switch 1. Check the engine stop lanyard switch for continuity. Replace if there is no continu- ity. 6S380180 2. Connect the digital circuit tester leads to the starter relay terminals.

  • Page 270: Starter Motor

    ELEC Electrical system Starter motor 9 N·m (0.9 kgf·m, 6.6 ft·lb) 6S38010E Part name Q’ty Remarks M8 × 25 mm Bolt Starting motor bracket Retainer Starter motor pinion Front bracket Washer — Armature Stator Spring Brush holder Washer Washer Washer Rear bracket Screw M6 ×...

  • Page 271: Removing The Starter Motor Pinion

    Starter motor Removing the starter motor pinion Checking the armature 1. Slide the pinion stopper 1 down using 1. Check the commutator for dirt. Clean with the box wrench, and then remove the 600– grit sandpaper and compressed air clips 2. if necessary.

  • Page 272: Checking The Brush

    ELEC Electrical system 4. Check the armature for continuity. 2. Check the brush holder assembly for Replace the armature if out of specifica- continuity. Replace the brush holder if out tions. of specifications. 6G480270 Brush continuity: 6G480256 Brush 1 – Brush 2 No continuity Checking the starter motor operation Armature continuity...

  • Page 273: Charging System

    Starter motor/Charging system Charging system Checking the lighting coil 1. Remove the junction box cover. 2. Connect the test harness to the lighting coil. 3. Measure the lighting coil output peak voltage. Replace the stator assembly if 6S380225 less than specification. Lighting coil resistance (reference data): Green(G) 1 or 2 –...
  • Page 274 ELEC Electrical system Rectifier Regulator output peak voltage: Rectifier Regulator continuity Red (R) – Ground or Red/white (R/W) – Ground Tester lead Unloaded r/min 1,500 3,500 DC V 4. Check the Rectifier Regulator for continu- ity. Replace if out of specification. 0.42 –...

  • Page 275: Checking The Hour Meter

    Charging system/Oil feed control system Checking the hour meter å 1. Remove the hour meter cover. 2. Disconnect the hour meter coupler. 3. Connect the positive battery lead to the yellow (Y) terminal 1. 4. Connect the negative battery lead to the S60V8330 black (B) terminal 2.

  • Page 276: Checking The Emergency Switch

    ELEC Electrical system Checking the emergency switch Checking the oil pump 1. Remove the emergency switch from the (remote oil tank) engine oil tank. 1. Connect the positive battery lead to the brown (Br) lead. 2. Disconnect the emergency switch con- nector from the wiring harness.

  • Page 277: Shtg

    TRBL TRBL SHTG SHTG Troubleshooting Troubleshooting the power unit ..............9-1 Troubleshooting the power unit using the diagnostic flash indicator..9-1 Troubleshooting the power unit (trouble code not available).....9-2 Troubleshooting the PTT unit ..............9-7 Troubleshooting the lower unit..............9-8 6S35H11...

  • Page 278: Trbl Shtg

    NOTE: 9 When checking the diagnostic cord, to start the engine. 9 The diagnostic signal code is the same among Yamaha outboard motors. 6S390020 9 The diagnosis flash indicator lights for 3 9 Trouble code indication seconds after the engine start switch is Example: The illustration indicates code turned on.
  • Page 279 Troubleshooting the power unit Troubleshooting the power unit (trouble code not available) The trouble shooting when a trouble code is not available consists of the following 4 items. Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause 1: The content considered as the trouble factors of symptom 2.
  • Page 280 TRBL SHTG Troubleshooting Symptom 1: Engine will not start (engine cranks) Refer Symptom 2 Cause 1 Cause 2 Checking step page Deterioration or dirty — — Replace the new fuel. — fuel Fuel line Check the fuel line. Fuel supplied to the malfunction carburetor improperly Fuel pump...
  • Page 281 Trouble shooting the power unit Refer Symptom 2 Cause 1 Cause 2 Checking step page Measure the pulser coil Pulser coil out- output peak voltage 8-10 and resistance. put peak volt- Pulser coil malfunction age less than Change the pulser coil specifications and check the ignition Spark plug does...
  • Page 282 TRBL SHTG Troubleshooting Refer Symptom 2 Cause 1 Cause 2 Checking step page Fuel not sup- Float height Disassemble and Carburetor malfunction 4-10 plied properly improperly check the carburetor. Spark plug gap Check the spark plug Spark plug malfunction improperly gap and condition.
  • Page 283 Troubleshooting the power unit Symptom 1: Limited engine speed (below 2,000 r/min) Refer Symptom 2 Cause 1 Cause 2 Checking step page Clogged cooling water Check the cooling — inlet water inlet. Check the impeller. Water pump 6-34 impeller Check the Woodruff malfunction 9Buzzer comes key.
  • Page 284 TRBL SHTG Troubleshooting Troubleshooting the PTT unit Symptom 1: PTT unit does not operate Refer Symptom 2 Cause 1 Cause 2 Checking step page PTT switch malfunction — Check the PTT switch. 7-49 Short, open, or loose PTT relay does Check the wiring har- connection of the —...
  • Page 285 Troubleshooting the power unit Symptom 1: PTT unit does not hold the outboard motor up Refer Symptom 2 Cause 1 Cause 2 Checking step page Manual valve Check the manual Manual valve opened — malfunction valve. Insufficient PTT fluid — 3-11 Add sufficient fluid.
  • Page 286 Index Checking the bearings ......5-30 Checking the brush........8-19 Adjusting the throttle cable ...... 3-8 Checking the carburetor ......4-10 Adjusting the throttle sensor ....4-12 Checking the CDI unit........8-9 Adjusting the timing plate ...... 5-46 Checking the charge coil ......8-13 Adjusting the trim sensor ......7-20 Checking the check valve .......4-18 Aft view ............8-6...
  • Page 287 Checking the lower case ....6-16, 6-47 Checking the lower unit for air leakage . 3-13 Dimension ..........2-9 Checking the main valve ......7-34 Disassembling the carburetor ....4-10 Checking the oil filter ......4-18 Disassembling the crankshaft ....5-30 Checking the oil level sensor....8-22 Disassembling the drive shaft housing Checking the oil pump (remote oil tank)..8-23 ............6-14, 6-45...
  • Page 288 Index Propeller shaft housing (counter rotation model) ............6-35 Hose routing ..........4-1 Propeller shaft housing (regular rotation How to use this manual ......1-1 model) ............6-6 Propeller size ......... 1-24 PTT motor ..........7-27 Identification ..........1-5 PTT unit ...........7-22 Ignition and ignition control system ...8-8 Installing the clamp bracket .....7-19 Installing the drive shaft....6-17, 6-48 Removing the clamp bracket ....7-18...
  • Page 289 Test run ..........1-28 Tightening torque ........2-11 Top cowling ..........3-2 Top view.............8-7 Troubleshooting the lower unit....9-8 Troubleshooting the power unit ....9-1 Troubleshooting the power unit (trouble code not available) .....9-2 Troubleshooting the power unit using the diagnostic flash indicator ......9-1 Troubleshooting the PTT unit ....9-7 Upper case, steering arm ......7-5 Ventilation ..........
  • Page 290 WIRING DIAGRAM 250G, L250G 1 Throttle sensor Color code 2 PTT switch : Black 3 Oil level sensor (engine oil tank) B/Br : Black/brown 4 Emergency switch B/G : Black/green 5 Thermoswitch B/R : Black/red 6 Spark plug B/W : Black/white 7 Ignition coil B/Y : Black/yellow 8 CDI unit...
  • Page 292 YAMAHA MOTOR CO., LTD. Printed in Japan Aug. 2005 – 1.4 × 1 ! (E_2) Printed on recycled paper...
  • Page 293 250G, L250G W/Br W/Br 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35 36 37 3839 40 41 42 1 2 3...

This manual is also suitable for:

L250geto

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