TOHATSU 200 Series Service Manual
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TOHATSU 200 Series Service Manual

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BFT
200/225A
OB No.62ZY300Z
14-01 NB

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  • Page 1 200/225A OB No.62ZY300Z 14-01 NB...
  • Page 2 Introduction Before reading this manual   This service manual provides information that is needed for inspection, service and repair of  applicable outboard motors. For our customers' safe and comfortable use of the products for  long term, it is essential to maintain the performance and quality of the outboard motors. To  ensure  this,  the  maintenance  and  service  have  to  be  done  properly  by  service  technicians  with  fundamental  knowledge  and  skills.  This  manual  is  utilized  so  that  our  customers  can  always use their outboard motor with full satisfaction. As  this  document  contains  information  from  the  Honda  Motor's  Service  Manual,  the  document contains information about models that are not sold by our company. Additionally, ...
  • Page 3 Introduction Avant de lire le présent manuel Le présent manuel d’entretien fournit les informations nécessaires au contrôle, à l’utilisation et à la réparation des moteurs hors-bords concernés. Pour une utilisation de nos produits par nos clients, à long terme, en toute sécurité...
  • Page 4 Introducción Antes de leer este manual Este manual de servicio brinda la información que se requiere para la inspección, el servicio y la reparación de los correspondientes motores fuera de borda. Para que nuestros clientes puedan utilizar los productos durante largo tiempo de forma segura y cómoda, resulta fundamental mantener el desempeño y la calidad de los motores fuera de borda.
  • Page 5 Einführung Vor dem Durchlesen dieses Handbuchs Dieses Service-Handbuch enthält die Information, die zur Inspektion, Service und Reparatur der jeweiligen Außenbordmotoren benötigt wird. Zur Sicherheit unserer Kunden und für eine komfortable, langfristige Benutzung der Produkte ist es unumgänglich, die Leistung und Qualität der Außenbordmotoren instand zu halten.
  • Page 6 How to use this manual A Few Words About Safety How to use this manual SERVICE INFORMATION The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage this Honda product or create an unsafe condition.
  • Page 7 How to use this manual INTRODUCTION This supplement covers the construction, function, and GENERAL INFORMATION servicing procedures of the Honda BF175AK3/200AK3/ 225AK3 outboard motor. SERVICE INFORMATION For service information that is not covered in this supplement, please refer to the BF175AK1/200AK1/ MAINTENANCE 225AK1 (62ZY300) base shop manual.
  • Page 8 MEMO...
  • Page 9 dummytext 1. GENERAL INFORMATION SPECIFICATIONS ·········································1-2...
  • Page 10 dummyhead dummyhead GENERAL INFORMATION SPECIFICATIONS GENERAL INFORMATION TYPE DESCRIPTION It may be necessary to refer to this chart for reference purposes when reading this manual. Model BF175AK3 Type XD/XT/XU XXD/XXT Shaft Length type Counter Rotation – Remote control Power Trim/Tilt Tachometer Trim meter XL: Extra long, XXL: Extra-extra long...
  • Page 11 dummyhead dummyhead GENERAL INFORMATION DIMENSIONS AND WEIGHTS Model BF175AK3 Description code BAJJ Type XD/XT/XU XXD/XXT Overall length 920 mm (36.2 in) Overall width 625 mm (24.6 in) Overall height 1,797 mm (70.7 in) 1,924 mm (75.7 in) Dry weight (*1) 270 kg (595 lbs) 275 kg (606 lbs) Operating weight...
  • Page 12 dummyhead dummyhead GENERAL INFORMATION FRAME Model BF175AK3 Type XD/XT/XU XXD/XXT Transom height (*1) 635 mm (25.0 in) 762 mm (30.0 in) Tilting angle (*1) 68° Tilting stage Stageless Trim angle (*1) – 4° to 16° Swivel angle 30° right and left *1: Transom angle is at 12°.
  • Page 13 dummyhead dummyhead GENERAL INFORMATION ENGINE Model BF175AK3 BF200AK3 BF225AK3 Description code BEAJJ BEAEJ BEAGJ Type 4-stroke, O.H.C., 6-cylinder Displacement 3,471 cm (211.7 cu in) Bore x stroke 89.0 x 93.0 mm (3.50 x 3.66 in) Rated power (*1) 128.7 kW (175 PS) 147.1 kW (200 PS) 165.5 kW (225 PS) Maximum torque...
  • Page 14 dummyhead dummyhead MEMO...
  • Page 15 dummytext 2. SERVICE INFORMATION ENGINE & FRAME TORQUE VALUES ········2-2 TUBE ROUTING ········································· 2-18 CABLE/HARNESS ROUTING·······················2-3...
  • Page 16 dummyhead dummyhead SERVICE INFORMATION ENGINE & FRAME TORQUE VALUES SERVICE INFORMATION OTHERS Thread Dia. and pitch Torque values Item Remarks mm (in) N·m kgf·m lbf·ft Power tilt relay mounting bolt/ M6 x 1.0 0.51 washer Fuse/relay junction box terminal bolt M6 x 1.0 0.87 Fuse/relay junction box mounting...
  • Page 17 dummyhead dummyhead SERVICE INFORMATION CABLE/HARNESS ROUTING STARTER CABLE 1 (+) TERMINAL ACG CABLE TERMINAL POWER TILT RELAY WIRE TERMINAL TACHO PULSE 2P CONNECTOR EMT SENSOR 2 2P CONNECTOR EMT SENSOR 1 2P CONNECTOR HO2S ALTERNATOR 4P CONNECTOR 4P CONNECTOR (Except XT, XCT, XXT, XXCT types) SWITCH PANEL WIRE HARNESS...
  • Page 18 dummyhead dummyhead SERVICE INFORMATION FUSE/RELAY JUNCTION BOX FUSE/RELAY JUNCTION BOX 8P CONNECTOR 23P CONNECTOR ACG CABLE TACHO PULSE 2P CONNECTOR ALTERNATOR INTERFACE 4P CONNECTOR 6P CONNECTOR SWITCH PANEL WIRE HARNESS 14P CONNECTOR POWER TILT RELAY WIRE TERMINAL DLC 4P STARTER CABLE 1 (+) FUSE/RELAY JUNCTION BOX INDICATOR PANEL 10P CONNECTOR...
  • Page 19 dummyhead dummyhead SERVICE INFORMATION ACG CABLE POWER TILT RELAY CABLE RED TAPE GREEN TAPE YELLOW TAPE STARTER CABLE 1 (+) GREEN YELLOW MAIN WIRE HARNESS GROUND TERMINALS STOPPER MAIN WIRE HARNESS POWER TILT RELAY GROUND TERMINALS GROUND TERMINALS STOPPER STARTER CABLE GROUND (BATTERY GROUND TERMINAL)
  • Page 20 dummyhead dummyhead SERVICE INFORMATION INDICATOR PANEL SWITCH PANEL WIRE HARNESS WIRE HARNESS NMEA INTERFACE WIRE (Optional part) STARTER CABLE 1 (+) STARTER CABLE (–) NMEA INTERFACE WIRE (Optional part) NMEA INTERFACE WIRE (Optional part) STARTER CABLE (–) STARTER CABLE 1 (+) SHIFT CONTROL CABLE THROTTLE CONTROL CABLE...
  • Page 21 dummyhead dummyhead SERVICE INFORMATION AIR FLOW CLAMP Install the air flow clamp as shown. AIR FLOW CLAMP TP SENSOR 3P CONNECTOR EMT SENSOR 1 2P CONNECTOR IAC VALVE 2P CONNECTOR MAIN WIRE HARNESS ECM 36P CONNECTOR B (Black) ECM 36P CONNECTOR A (Gray) TP SENSOR 3P CONNECTOR...
  • Page 22 dummyhead dummyhead SERVICE INFORMATION ALTERNATOR B TERMINAL COVER COVER ACG CABLE TERMINAL STARTER CABLE 1 (+) TERMINAL POWER TILT RELAY WIRE TERMINAL IAC VALVE 2P CONNECTOR TP SENSOR 3P CONNECTOR JOINT CONNECTOR 1 Install the joint connector 1 as shown. After installation, check the main wire harness for twist.
  • Page 23 dummyhead dummyhead SERVICE INFORMATION CKP SENSOR 2P CONNECTOR Align the stay with the center of grommet. Cruising direction GROMMET 90° STAY HARNESS BAND CLIP VTEC SOLENOID VALVE 1P CONNECTOR (BF225 only) ECM BRACKET HARNESS BAND CLIP POWER TILT SWITCH 3P CONNECTOR VTEC SOLENOID VALVE 1P CONNECTOR (BF225 only)
  • Page 24 dummyhead dummyhead SERVICE INFORMATION IAT SENSOR 2P CONNECTOR MAP SENSOR 3P CONNECTOR HARNESS BAND CLIP EMT SENSOR 2 2P CONNECTOR No.4 DIRECT IGNITION COIL 3P CONNECTOR No.5 DIRECT IGNITION COIL 3P CONNECTOR No.6 DIRECT IGNITION COIL 3P CONNECTOR WATER LEVEL SENSOR 2P CONNECTOR 2-10...
  • Page 25 dummyhead dummyhead SERVICE INFORMATION POWER TILT MOTOR 2P CONNECTOR WIRE HO2S 4P CONNECTOR POWER TILT RELAY (Except XT, XCT, XXT, 2P CONNECTOR XXCT types) POWER TILT RELAY GROUND TERMINALS CABLE POWER TILT MOTOR 2P CONNECTOR/ POWER TILT RELAY 1P CONNECTOR WIRE POWER TILT RELAY CASE POWER TILT MOTOR POWER TILT RELAY...
  • Page 26 dummyhead dummyhead SERVICE INFORMATION THROTTLE CABLE B THROTTLE CABLE A THROTTLE CABLE B THROTTLE CABLE A 2-12...
  • Page 27 dummyhead dummyhead SERVICE INFORMATION POWER TILT RELAY 1P CONNECTOR POWER TILT RELAY POWER TILT RELAY GROUND TERMINALS CABLE MAIN WIRE HARNESS WIRE HARNESS CLIP POWER TILT RELAY GROUND TERMINALS CABLE POWER TILT MAIN WIRE RELAY CABLE HARNESS POWER TILT MOTOR 2P CONNECTOR STARTER CABLE 2 (+) POWER TILT RELAY CABLE STARTER MOTOR B...
  • Page 28 dummyhead dummyhead SERVICE INFORMATION WIRE BAND (Cut off the surplus band L. ENGINE UNDER COVER remaining it about 5 mm (0.2 in)) UNDER CASE Align the white tape end with GROMMET the under case grommet end. TRIM ANGLE SENSOR WIRE POWER TILT MOTOR WIRE L.
  • Page 29 dummyhead dummyhead SERVICE INFORMATION TRIM ANGLE SENSOR WIRE Check the wire for slack. POWER TILT MOTOR WIRE Check the wire for twist. SWIVEL CASE R. STERN BRACKET TRIM ANGLE SENSOR POWER TILT MOTOR 2-15...
  • Page 30 dummyhead dummyhead SERVICE INFORMATION L. TIMING BELT BACK COVER CMP SENSOR 1 CMP SENSOR 2 4P CONNECTOR HARNESS BAND CLIP (Cut off the surplus band remaining it about 10 mm (0.4 in)) IAT SENSOR 2P CONNECTOR No.1 FUEL INJECTOR 2P CONNECTOR No.4 FUEL INJECTOR 2P CONNECTOR WIRE HARNESS CLIP...
  • Page 31 dummyhead dummyhead SERVICE INFORMATION MAIN WIRE HARNESS to SWITCH IAB CONTROL SOLENOID No.1 FUEL INJECTOR WIRE 6P CONNECTOR VALVE 2P CONNECTOR 2P CONNECTOR CMP SENSOR 1 CMP SENSOR 2 4P CONNECTOR EBT SENSOR 2P CONNECTOR No.4 FUEL INJECTOR 2P CONNECTOR HARNESS BAND CLIP WIRE HARNESS CLIP WIRE HARNESS CLIP...
  • Page 32 dummyhead dummyhead SERVICE INFORMATION TUBE ROUTING R. WATER RELIEF TUBE Install the longer side of the water relief tube into the 77 mm (3.0 in) thermostat. Install the shorter side of the water relief tube into the exhaust manifold. THERMOSTAT The tubes have a paint mark SIDE for the installation direction.
  • Page 33 dummyhead dummyhead SERVICE INFORMATION L. WATER RELIEF TUBE Install the longer side of the water relief tube into the 77 mm (3.0 in) thermostat. Install the shorter side of the water relief tube into the exhaust manifold. THERMOSTAT The tubes have a paint mark SIDE for the installation direction.
  • Page 34 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE (3.5 x 540 mm) FUEL TUBE (3.5 x 590 mm) PRESSURE REGULATOR RETURN HOSE A AIR VENT TUBE FUEL HOSE A AIR VENT TUBE A V TUBE (3.5 x 6.5 x 600 mm) FUEL TUBE C WATER OUTLET TUBE FUEL TUBE E PRESSURE REGULATOR...
  • Page 35 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE (3.5 x 130 mm) FUEL TUBE (3.5 x 600 mm) FUEL TUBE (3.5 x 50 mm) FUEL JOINT HOSE CHECK VALVE FUEL TUBE D IAB CONTROL DIAPHRAGM FUEL PIPE FUEL TUBE G CHECK VALVE FUEL TUBE (3.5 x 40 mm) 2-21...
  • Page 36 dummyhead dummyhead SERVICE INFORMATION TUBE CLAMP D10.7 TUBE CLIP B12 TUBE CLAMP D10.5 TUBE CLIP B12 TUBE CLIP B8 TUBE CLAMP D10.5 HOSE CLIP TUBE CLAMP D32.5 TUBE CLAMP D10.5 120° TUBE CLIP D12.0 Cruising direction 2-22...
  • Page 37 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE (3.5 x 540 mm) BREATHER TUBE C BREATHER TUBE B AIR VENT TUBE BREATHER TUBE A WIRE CLIP FUEL TUBE (3.5 x 130 mm) CHECK VALVE CLAMP FUEL HOSE A CHECK VALVE TUBE WHITE WHITE PAINTED CHECK VALVE...
  • Page 38 dummyhead dummyhead SERVICE INFORMATION BREATHER TUBE B BREATHER TUBE C WIRE CLIP A FUEL TUBE (3.5 x 130 mm) BREATHER TUBE A AIR VENT TUBE FUEL TUBE CHECK VALVE TUBE (3.5 x 50 mm) FUEL HOSE A AIR VENT TUBE WIRE HARNESS CLIP PRESSURE...
  • Page 39 dummyhead dummyhead SERVICE INFORMATION TUBE CLIP B8 TUBE CLIP B12 TUBE CLAMP D32.5 FUEL TUBE D WATER SEPARATOR/WATER LEVEL SENSOR CYLINDER HEAD COVER OIL RETURN HOSE TUBE CLIP WATER TUBE CLAMP D10.5 OUTLET TUBE TUBE CLAMP D10.5 WATER INLET TUBE WATER INLET TUBE WATER OUTLET...
  • Page 40 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE (3.5 x 540 mm) FUEL TUBE (3.5 x 590 mm) FUEL TUBE (3.5 x 130 mm) FUEL TUBE (3.5 x 600 mm) PRESSURE REGULATOR RETURN HOSE A TUBE CLAMP D10.7 FUEL TUBE (3.5 x 50 mm) PRESSURE REGULATOR AIR VENT TUBE RETURN HOSE A...

  • Page 41: Table Of Contents

    dummytext 3. MAINTENANCE MAINTENANCE SCHEDULE························3-2 WATER SEPARATOR INSPECTION ··········· 3-6 SPARK PLUG INSPECTION·························3-4 FUEL FILTER (LOW PRESSURE SIDE) INSPECTION/REPLACEMENT ···················· 3-6 IDLE SPEED INSPECTION/ ADJUSTMENT···············································3-5 FUEL LINE INSPECTION/ REPLACEMENT ··········································· 3-8...

  • Page 42: Maintenance Schedule

    dummyhead dummyhead MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE (*) Refer to page of base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). Item REGULAR SERVICE PERIOD (2) Perform at every indicated month or operating hour interval, whichever comes first. Refer Every Every Every First Every mont year Each After...
  • Page 43 dummyhead dummyhead MAINTENANCE Item REGULAR SERVICE PERIOD (2) Perform at every indicated month or operating hour interval, whichever comes first. Refer Every Every Every First Every mont year page Each After mont years years h or hs or 1,200 hrs. hrs.

  • Page 44: Spark Plug Inspection

    dummyhead dummyhead MAINTENANCE SPARK PLUG INSPECTION Remove the engine cover. Remove the plug maintenance cover (page 6-5). Disconnect the 3P connector [1] from the direct ignition coil [2]. Remove the bolt/washers [3], collar [4] and direct ignition coils. Take care not to an impact or drop the direct ignition coils.

  • Page 45: Idle Speed Inspection

    dummyhead dummyhead MAINTENANCE IDLE SPEED INSPECTION/ ADJUSTMENT INSPECTION Check the following before starting the idle speed inspection. – Battery must be in good condition – Boat equipment (electrical loads) must be removed – Spark plug inspection (page 3-4) – MIL must be OFF Place the outboard motor vertically (with the engine level to the ground), and set the remote control lever in the "N"...

  • Page 46: Water Separator Inspection

    dummyhead dummyhead MAINTENANCE WATER SEPARATOR INSPECTION Remove the L. engine under cover (page 6-5). Check the water separator [1] for water accumulation or sediment. If water or sediment is found, or the warning buzzer sounds, disassemble and clean the water separator (page 5-50).
  • Page 47 dummyhead dummyhead MAINTENANCE REPLACEMENT Clamp fuel tubes A [1] and B [2] with hose clips, and then disconnect fuel tubes A and C from the strainer. Release the power tilt switch wire [3] from the harness clip [4]. Remove the two bolts [5] and fuel strainer [6] with the strainer bracket [7].

  • Page 48: Fuel Line Inspection

    dummyhead dummyhead MAINTENANCE FUEL LINE INSPECTION/ REPLACEMENT Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Refer page base...
  • Page 49 dummytext 4. TROUBLESHOOTING BEFORE TROUBLESHOOTING···················4-2 FUSE/ELECTRIC POWER LINE TROUBLESHOOTING ·································· 4-3 ENGINE TROUBLESHOOTING····················4-2 ALERT SYSTEM/WARNING SYSTEM TROUBLESHOOTING ·································· 4-5...
  • Page 50 dummyhead dummyhead TROUBLESHOOTING BEFORE TROUBLESHOOTING TROUBLESHOOTING • Use a known-good battery for troubleshooting. • Remove the boat equipment (electrical loads) • Check that the connectors are connected securely. • Check for sufficient fresh fuel in the fuel tank. • Check that the emergency stop switch clip is set securely. •...
  • Page 51 dummyhead dummyhead TROUBLESHOOTING FUSE/ELECTRIC POWER LINE TROUBLESHOOTING FUSE CONNECTION TABLE Fuse No. Amps. Component(s) or Circuit(s) Protected 150 A Alternator (Output terminal) ECM (Power supply), Fuel injector, Alternator, DLC, O sensor heater (Except XT, XCT, XXT, 30 A XXCT types), IAB control solenoid valve, Direct ignition coil, Relay (Included in the junction box: Main relay, Starter relay, Fuel pump relay) Alternator (Input terminal), Combination switch, Power tilt relay, Warning buzzer, Oil indicator light, 10 A...
  • Page 52 dummyhead dummyhead TROUBLESHOOTING FUSE LOAD CHART To ALTERNATOR (DETECTION TERMINAL) POWER W/Bl TILT SWITCH W/Bl POWER TRIM/ TILT SWITCH To POWER TILT RELAY W/Bl To POWER TILT RELAY W/Bl COMBINATION SWITCH COMBINATION SWITCH Bl/R W/Bl Bl/Y Bl/W Bl/Y W/Bl W/Bl Bl/W To WARNING BUZZER (OP) Bl/Y...
  • Page 53 dummyhead dummyhead TROUBLESHOOTING ALERT SYSTEM/WARNING SYSTEM TROUBLESHOOTING FUNCTION TEST USING THE HDS 1. Fuse inspection Turn the combination switch OFF. Check the No.10 fuse in the fuse/relay junction box. Is the fuse blown? – Replace the blown fuse and check for short in the main wire harness or incorrect load by referring to the fuse load chart (page 4-4).
  • Page 54 dummyhead dummyhead TROUBLESHOOTING FUNCTION TEST WITHOUT USING THE HDS 1. Fuse inspection Turn the combination switch OFF. Check the No.10 fuse in the fuse/relay junction box. Is the fuse blown? – Replace the blown fuse and check for short in the main wire harness or incorrect load by referring to the fuse load chart (page 4-4).
  • Page 55 dummyhead dummyhead TROUBLESHOOTING 5. MIL inspection Turn the combination switch OFF. ECM CONNECTOR A Short the No.3 terminal (Red/Blue) of the ECM MAIN WIRE HARNESS SIDE connector A main wire harness side 36P connector to engine ground using a jumper wire. Turn the combination switch ON.
  • Page 56 dummyhead dummyhead TROUBLESHOOTING WARNING BUZZER SOUNDS CONTINUOUSLY THE OVERHEAT INDICATOR LIGHT GOES OFF AND OIL INDICATOR LIGHT GOES OFF OR BLINKS (*) Refer to page of base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). 1. MIL inspection Check to see if the MIL stays on. Does the MIL stay ON? –...
  • Page 57 dummytext 5. FUEL SYSTEM SERVICE PRECAUTIONS ····························5-2 HO2S REMOVAL/INSTALLATION (Except XT, XCT, XXT, XXCT types) ····························· 5-52 ECM TERMINAL ARRANGEMENT ··············5-4 FUEL PUMP (HIGH PRESSURE SIDE)/FUEL FILTER DISASSEMBLY/ASSEMBLY ········ 5-53 DTC TROUBLESHOOTING ··························5-6 FUEL PUMP (HIGH PRESSURE SIDE) MIL TROUBLESHOOTING ·························5-30 INSPECTION···············································...

  • Page 58: Service Precautions

    dummyhead dummyhead FUEL SYSTEM SERVICE PRECAUTIONS FUEL SYSTEM CLEARING DTC How to clear the DTC with HDS Connect the HDS to the DLC (page 5-3). Clear the DTC with the HDS while the engine is stopped. To clear the DTC without the HDS, refer to the following procedure.
  • Page 59 dummyhead dummyhead FUEL SYSTEM READING DTC WITH THE HDS • The HDS can readout the DTC, freeze data, current data, and other ECM condition. Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). How to connect the HDS Turn the combination switch to OFF. Remove the dummy connector [1] from the DLC [2].

  • Page 60: Ecm Terminal Arrangement

    dummyhead dummyhead FUEL SYSTEM ECM TERMINAL ARRANGEMENT ECM CONNECTOR A (GRAY) ECM side connector (viewed from the terminal side) Terminal No. Terminal mark Name Content/Signal – – – ACGLP Alternator indicator lamp Alternator indicator lamp output WARNL MIL output TDC2P CMP 2 sensor (+) CMP 2 sensor (+) input TDC2M...
  • Page 61 dummyhead dummyhead FUEL SYSTEM ECM CONNECTOR B (BLACK) ECM side connector (viewed from the terminal side) Terminal No. Terminal mark Name Content/Signal CAN1H NMEA CAN HI NMEA CAN HI output CAN 12V NMEA 12 V power source NMEA 12 V power input CAN GND NMEA ground NMEA ground...
  • Page 62 dummyhead dummyhead FUEL SYSTEM DTC TROUBLESHOOTING DTC INDEX Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). Ref. Detected component Probable cause page MIL does not • Loose or poor contact of the come ON/blink connector • Faulty indicator light 0 or does not •...
  • Page 63 dummyhead dummyhead FUEL SYSTEM Ref. Detected component Probable cause page CMP 1 sensor (no pulse) • Loose or poor contact of the connector • Open or short circuit in CMP 1 5-18 sensor wire • Faulty CMP 1 sensor CMP 1 sensor (abnormal pulse) •...
  • Page 64 dummyhead dummyhead FUEL SYSTEM MIL IS ON BUT DTC IS 0 OR DOES NOT COMMUNICATE 1. DLC power/GND line open circuit inspection Turn the combination switch OFF and disconnect the HDS. Turn the combination switch ON. Measure the voltage at the DLC No.3 (Yellow/Black) terminal and No.2 (Black) terminal.
  • Page 65 dummyhead dummyhead FUEL SYSTEM 5. MAP sensor power line short circuit inspection 2 Measure the voltage between the MAP sensor 3P connector main wire harness side No.1 MAP SENSOR 3P CONNECTOR (Brown/Yellow) terminal and engine ground. MAIN WIRE HARNESS SIDE Is the measurement within 4.75 –...
  • Page 66 dummyhead dummyhead FUEL SYSTEM 9. Trim angle sensor power line short circuit inspection 2 Measure the voltage between the trim angle sensor 3P connector main wire harness side No.3 (Brown/White) terminal and engine ground. TRIM ANGLE SENSOR 3P CONNECTOR Is the measurement within 4.75 – 5.25 V? MAIN WIRE HARNESS SIDE –...
  • Page 67 dummyhead dummyhead FUEL SYSTEM DTC 3-1, 3-2 (MAP SENSOR VOLTAGE TOO LOW OR TOO HIGH) DTC 3-1 (MAP SENSOR VOLTAGE IS TOO LOW) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the MAP sensor 3P connector ECM connector A , ECM connector B and then reconnect them.
  • Page 68 dummyhead dummyhead FUEL SYSTEM 2. MAP sensor power line open circuit inspection Turn the combination switch OFF and disconnect the MAP sensor 3P connector MAP SENSOR 3P CONNECTOR Turn the combination switch ON. MAIN WIRE HARNESS SIDE Measure the voltage between the MAP sensor 3P connector main wire harness side No.1 (Brown/Yellow) terminal and engine ground.
  • Page 69 dummyhead dummyhead FUEL SYSTEM DTC 4-1, 4-2 (NO CKP SENSOR PULSE OR ABNORMAL CKP SENSOR PULSE) Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). DTC 4-1 (NO CKP SENSOR PULSE) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the CKP sensor 2P connector ECM connector A and then reconnect them.
  • Page 70 dummyhead dummyhead FUEL SYSTEM 3. CKP sensor inspection Replace the CKP sensor and connect the CKP sensor 2P connector Start the engine and check the DTC using the HDS. Does the DTC 4-2 appear? – Replace the ECM with a new one and recheck.
  • Page 71 dummyhead dummyhead FUEL SYSTEM DTC 6-2 (ECT SENSOR 1 (EBT SENSOR) VOLTAGE IS TOO HIGH) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the EBT sensor 2P connector ECM connector A , ECM connector B switch wire 6P connector and then reconnect them.
  • Page 72 dummyhead dummyhead FUEL SYSTEM DTC 7-1, 7-2 (TP SENSOR VOLTAGE IS TOO LOW OR TOO HIGH) DTC 7-1 (TP SENSOR VOLTAGE IS TOO LOW) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the TP sensor 3P connector ECM connector A , ECM connector B joint connector 1 and then reconnect them.
  • Page 73 dummyhead dummyhead FUEL SYSTEM DTC 7-2 (TP SENSOR VOLTAGE IS TOO HIGH) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the TP sensor 3P connector ECM connector A , ECM connector B joint connector 1 and then reconnect them. Clear the DTC (page 5-2).
  • Page 74 dummyhead dummyhead FUEL SYSTEM DTC 8-1, 8-2 (NO CMP 1 SENSOR PULSE OR ABNORMAL SENSOR PULSE) Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). DTC 8-1 (NO CMP 1 SENSOR PULSE) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the CMP sensor 4P connector ECM connector A and then reconnect them.
  • Page 75 dummyhead dummyhead FUEL SYSTEM 3. CMP 1 sensor inspection Replace the CMP sensor and connect the CMP sensor 4P connector Start the engine and check the DTC using the HDS. Does the DTC 8-2 appear? – Replace the ECM with a new one and recheck.
  • Page 76 dummyhead dummyhead FUEL SYSTEM DTC 10-2 (IAT SENSOR VOLTAGE IS TOO HIGH) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the IAT sensor 2P connector ECM connector A , ECM connector B joint connector 1 and then reconnect them. Clear the DTC (page 5-2).
  • Page 77 dummyhead dummyhead FUEL SYSTEM DTC 14-1 (ABNORMAL IAC VALVE) Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the IAC valve 2P connector , ECM connector B and then reconnect them. Clear the DTC (page 5-2). •...
  • Page 78 dummyhead dummyhead FUEL SYSTEM DTC 21-1 (ABNORMAL OUTPUT OF VTEC SPOOL SOLENOID VALVE) (BF225 only) Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the VTEC spool solenoid valve 1P connector , ECM connector B and then reconnect them.
  • Page 79 dummyhead dummyhead FUEL SYSTEM DTC 23-1 (ABNORMAL OUTPUT OF KNOCK SENSOR) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the knock sensor 1P connector ECM connector B , switch wire 6P connector and then reconnect them. Clear the DTC (page 5-2). •...
  • Page 80 dummyhead dummyhead FUEL SYSTEM DTC 41-2 (ABNORMAL HO2S HEATER) (Except XT, XCT, XXT, XXCT types) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the HO2S 4P connector , ECM connector A , junction box 23P connector and then reconnect them. Clear the DTC (page 5-2).
  • Page 81 dummyhead dummyhead FUEL SYSTEM 2. CMP sensor inspection Turn the combination switch OFF. Inspect the CMP 2 sensor (page 5-131*). Is the CMP sensor correct? – Repair the open or short circuit in the CMP 2 sensor harness between the CMP 2 sensor and ECM.
  • Page 82 dummyhead dummyhead FUEL SYSTEM DTC 140-1, 140-2 (ECT SENSOR 2 (EMT SENSOR 1) VOLTAGE IS TOO LOW OR TOO HIGH) DTC 140-1 (ECT SENSOR 2 (EMT SENSOR 1) VOLTAGE IS TOO LOW) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the EMT sensor 1 2P connector ECM connector A , ECM connector B...
  • Page 83 dummyhead dummyhead FUEL SYSTEM 2. EMT sensor 1 signal /GND line open circuit inspection Turn the combination switch OFF and disconnect the EMT sensor 1 2P connector EMT SENSOR 1 2P CONNECTOR MAIN WIRE HARNESS SIDE Turn the combination switch ON. Measure the voltage between the EMT sensor 1 2P connector main wire harness side No.1 (Red/...
  • Page 84 dummyhead dummyhead FUEL SYSTEM DTC 141-2 (ECT SENSOR 3 (EMT SENSOR 2) VOLTAGE IS TOO HIGH) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the EMT sensor 2 2P connector ECM connector A , ECM connector B joint connector 1 and then reconnect them.
  • Page 85 dummyhead dummyhead FUEL SYSTEM DTC 142-1 (ABNORMAL EOP SWITCH (HIGH PRESSURE SIDE)) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the EOP switch (High pressure side) 2P connector , ECM connector B , switch wire 6P connector , joint connector 1 and then reconnect them.

  • Page 86: Mil Troubleshooting

    dummyhead dummyhead FUEL SYSTEM MIL TROUBLESHOOTING MIL INDEX Ref. No. of Detected component Probable cause Condition page blinks Detected • Loose or poor contact of the component connector • Faulty indicator light MIL does • Open circuit in MIL wire not blink •...
  • Page 87 dummyhead dummyhead FUEL SYSTEM Ref. Detected component Probable cause No. of page Condition blinks Blink VTEC spool solenoid valve • Loose or poor contact of the connector • Open and short circuit in VTEC (BF225 5-42 spool solenoid valve wire only) •...
  • Page 88 dummyhead dummyhead FUEL SYSTEM MIL ON BUT DOES NOT BLINK OR INDICATE DTC CODE 1. DLC short circuit inspection Turn the combination switch OFF. Disconnect the dummy connector from the DLC Check for continuity between the DLC No.4 (Light green) terminal and engine ground. Is the measurement within 4.75 –...
  • Page 89 dummyhead dummyhead FUEL SYSTEM 5. TP sensor power line short circuit inspection 1 Turn the combination switch OFF. Disconnect the TP sensor 3P connector Turn the combination switch ON and check the MIL. Does the MIL go OFF? – Replace the TP sensor. –...
  • Page 90 dummyhead dummyhead FUEL SYSTEM MIL BLINKS ONCE (HO2S) (Except XT, XCT, XXT, XXCT types) Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the HO2S 4P connector , ECM connector A , ECM connector B , joint connector 1 and then reconnect them.
  • Page 91 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 3 TIMES (MAP SENSOR) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the MAP sensor 3P connector ECM connector A , ECM connector B and then reconnect them. Reset the ECM (page 5-2). Turn the combination switch ON and check the number of blinks of the MIL.
  • Page 92 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 4 TIMES (CKP SENSOR) Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the CKP sensor 2P connector ECM connector A and then reconnect them. Reset the ECM (page 5-2). Start the engine.
  • Page 93 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 6 TIMES (EBT SENSOR) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the EBT sensor 2P connector ECM connector A , ECM connector B switch wire 6P connector , joint connector 1 and then reconnect them.
  • Page 94 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 7 TIMES (TP SENSOR) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the TP sensor 3P connector ECM connector A , ECM connector B joint connector 1 and then reconnect them. Reset the DTC (page 5-2). Turn the combination switch ON and check the number of blinks of the MIL.
  • Page 95 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 8 TIMES (CMP 1 SENSOR) Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the CMP sensor 4P connector ECM connector A and then reconnect them. Reset the ECM (page 5-2).
  • Page 96 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 10 TIMES (ONE LONG BLINK AND NO SHORT BLINKS) IAT SENSOR 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the IAT sensor 2P connector ECM connector A , ECM connector B joint connector 1 and then reconnect them.
  • Page 97 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 14 TIMES (ONE LONG BLINK AND 4 SHORT BLINKS) IAC VALVE Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the IAC valve 2P connector , ECM connector B and then reconnect them.
  • Page 98 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 21 TIMES (2 LONG BLINKS AND ONE SHORT BLINK) VTEC SPOOL SOLENOID VALVE (BF225 only) Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the VTEC spool solenoid valve 1P connector , ECM connector B and then...
  • Page 99 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 23 TIMES (2 LONG BLINKS AND 3 SHORT BLINKS) KNOCK SENSOR 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the knock sensor 1P connector ECM connector B , switch wire 6P connector and then reconnect them.
  • Page 100 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 24 TIMES (2 LONG BLINKS AND 4 SHORT BLINKS) EMT SENSOR 1 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the EMT sensor 1 2P connector ECM connector A , ECM connector B joint connector 1 and then reconnect them.
  • Page 101 dummyhead dummyhead FUEL SYSTEM 2. EMT sensor 2 signal /GND line open circuit inspection Turn the combination switch OFF and disconnect the EMT sensor 2 2P connector EMT SENSOR 2 2P CONNECTOR Turn the combination switch ON. MAIN WIRE HARNESS SIDE Measure the voltage between the EMT sensor 2 2P connector main wire harness side No.1 (Red)
  • Page 102 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 41 TIMES (4 LONG BLINKS AND ONE SHORT BLINK) HO2S HEATER (Except XT, XCT, XXT, XXCT types) 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the HO2S 4P connector , ECM connector A , junction box 23P connector and then reconnect them.
  • Page 103 dummyhead dummyhead FUEL SYSTEM MIL BLINKS 58 TIMES (5 LONG BLINKS AND 8 SHORT BLINKS) CMP 2 SENSOR Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). 1. Symptom reproduction test Turn the combination switch OFF. Disconnect the CMP sensor 4P connector ECM connector A and then reconnect them.

  • Page 104: Fuel Pump (Low Pressure Side) Removal/Installation

    dummyhead dummyhead FUEL SYSTEM FUEL PUMP (LOW PRESSURE SIDE) REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Refer page base...

  • Page 105: Fuel Pump (High Pressure Side)/Vapor Separator Removal

    dummyhead dummyhead FUEL SYSTEM FUEL PUMP (HIGH PRESSURE SIDE)/ VAPOR SEPARATOR REMOVAL/ INSTALLATION EXPLODED VIEW AIR VENT TUBE WATER OUTLET TUBE WATER INLET TUBE FUEL TUBE C MARK FUEL PUMP (HIGH PRESSURE SIDE)/ VAPOR SEPARATOR FUEL TUBE E TUBE CLIP B12 TUBE CLAMP D10.5 (2) BOLT (8 x 35 mm) (2)

  • Page 106: Water Separator/Water Level

    dummyhead dummyhead FUEL SYSTEM WATER SEPARATOR/WATER LEVEL SENSOR REMOVAL/INSTALLATION/ CLEANING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. REMOVAL Turn the combination switch OFF, and disconnect the battery negative (–) cable, then the battery positive (+)
  • Page 107 dummyhead dummyhead FUEL SYSTEM Turn the separator cover [1] and position the fuel tube inlet joint [2] of the separator cover with the “I” mark [3] on the suspension so the "I" mark is located on the range [4] as shown. Tighten the three separator cover screw/washers (5 x 12 mm) [5] to the specified torque.

  • Page 108: Ho2S Removal/Installation

    dummyhead dummyhead FUEL SYSTEM HO2S REMOVAL/INSTALLATION (Except XT, XCT, XXT, XXCT types) REMOVAL Remove the power tilt relay case (page 10-8). Remove the HO2S [1] from the left exhaust manifold using a commercially available tool (ANM14) [2]. INSTALLATION Install the HO2S [1] to the left exhaust manifold and tighten it using a commercially available tool (ANM14) [2] to the specified torque.

  • Page 109: Fuel Pump (High Pressure Side)/Fuel Filter Disassembly/Assembly

    dummyhead dummyhead FUEL SYSTEM FUEL PUMP (HIGH PRESSURE SIDE)/ FUEL FILTER DISASSEMBLY/ ASSEMBLY DISASSEMBLY Remove the fuel pump (high pressure side)/vapor separator (page 5-49). PRESSURE REGULATOR HARNESS HOLDER SCREW (4 x 10 mm) RETURN HOSE B 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) PUMP COVER SCREW/ TUBE CLAMP (D10.7) WASHER (5 x 15 mm) [4]...
  • Page 110 dummyhead dummyhead FUEL SYSTEM ASSEMBLY Install a new O-ring [1] to the insulator A [2]. Install the ring [3] to the insulator A and install them to the fuel pump unit [4]. Install the fuel pump Assy. to the fuel pump case [5] securely.
  • Page 111 dummyhead dummyhead FUEL SYSTEM Install the fuel pump cover [1] with the connector holder [2]. Install the harness holder clips [3] to the connector holder as shown. Install and tighten the four screw/washers (5 x 15 mm) [4] to the specified torque. TORQUE: 3.4 N·m (0.35 kgf·m, 25 lbf·ft) Set the harness holder [1], washer (4 mm) [2] and tighten the harness holder screw (4 x 10 mm) [3].

  • Page 112: Inspection

    dummyhead dummyhead FUEL SYSTEM FUEL PUMP (HIGH PRESSURE SIDE) INSPECTION CIRCUIT INSPECTION 1. No.8 Fuse (10 A) inspection Turn the combination switch OFF. Check for blown No.8 fuse. Is the fuse blown? – Replace the blown fuse and check for short in the main wire harness or incorrect load by referring to the fuse load chart (page 4-4).

  • Page 113: Fuel Injector Inspection

    dummyhead dummyhead FUEL SYSTEM 5. Fuel pump relay line Inspection Install the fuel pump relay and fuse/relay junction box. ECM CONNECTOR A Disconnect the ECM connector A MAIN WIRE HARNESS SIDE Turn the combination switch ON. FLR 1 FLR 2 Measure the voltage as follows: (Light green) (Light green)

  • Page 114: Iab Control Solenoid Valve

    dummyhead dummyhead FUEL SYSTEM FUEL INJECTOR INSPECTION Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). Remove the intake manifold (page 5-75*). Turn the combination switch OFF and disconnect the fuel injector connectors. Measure the resistance between the fuel injector terminals [1]. Resistance:11 –...

  • Page 115: Eop Switch (High Pressure Side)

    dummyhead dummyhead FUEL SYSTEM EOP SWITCH (HIGH PRESSURE SIDE) INSPECTION SWITCH WIRE HARNESS INSPECTION Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). Remove the cylinder head (page 14-23*). Disconnect the switch wire 6P connector [1] from the main wire harness. Check for continuity between the No.1 (Yellow/Red) and No.5 (Green) terminals of the switch wire 6P connector.

  • Page 116: Ho2S Inspection

    dummyhead dummyhead FUEL SYSTEM HO2S INSPECTION (Except XT, XCT, XXT, XXCT types) SYSTEM INSPECTION OPERATION TEST 1. HO2S operation test 1 Turn the combination switch OFF and disconnect the HO2S 4P connector HO2S 4P CONNECTOR SENSOR SIDE Connect the battery positive (+) cable to the sensor side No.4 (White) terminal and the battery negative cable (–) to the sensor side No.3 (White) terminal of the HO2S 4P connector respectively.
  • Page 117 dummytext 6. ENGINE COVER/COVER LOCK COMPONENT LOCATION ····························6-2 L./R. ENGINE UNDER COVER REMOVAL/ INSTALLATION ············································ 6-3...
  • Page 118 dummyhead dummyhead ENGINE COVER/COVER LOCK COMPONENT LOCATION ENGINE COVER/COVER LOCK 10 N·m (1.0 kgf·m, 7 lbf·ft)
  • Page 119 dummyhead dummyhead ENGINE COVER/COVER LOCK L./R. ENGINE UNDER COVER REMOVAL/INSTALLATION R. ENGINE UNDER COVER Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). Remove the front separate cover (page 6-4*). Disconnect the flush plug cap [1] from the R. engine under cover. Disconnect the power tilt switch 3P connector [1], and release the wire from the harness clips [2].
  • Page 120 dummyhead dummyhead ENGINE COVER/COVER LOCK Remove the under cover cap [1] and special bolt [2]. Remove the eight special bolts [3] from the R. engine under cover [4] and remove it halfway. Disconnect the water check tube [5] from the water check grommet [6].
  • Page 121 dummyhead dummyhead ENGINE COVER/COVER LOCK L. ENGINE UNDER COVER Remove the engine cover. Disconnect the power tilt motor 2P connector [1] and the trim angle sensor 3P connector [2]. Open the harness clips [3] and release the power tilt motor wire and the trim angle sensor wire. Remove the rivet screw [1] from the L.
  • Page 122 dummyhead dummyhead ENGINE COVER/COVER LOCK Remove the under cover cap [1] and special bolt [2]. Remove the plug maintenance cover special bolt [3] and plug maintenance cover [4]. Remove the nine special bolts [5] from the L. engine under cover [6] and remove it halfway. Release the under case grommet [7] from the L.
  • Page 123 dummytext 7. CHARGING SYSTEM CHARGING SYSTEM TROUBLESHOOTING···································7-2...
  • Page 124 dummyhead dummyhead CHARGING SYSTEM CHARGING SYSTEM TROUBLESHOOTING CHARGING SYSTEM BATTERY IS DAMAGED OR WEAK (*) Refer to page of base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). 1. Battery test Remove the battery. Check the battery condition using the commercially available battery tester. Is the battery in good condition? –...
  • Page 125 dummytext 8. IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING···································8-2...
  • Page 126 dummyhead dummyhead IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING IGNITION SYSTEM NO SPARK(S) 1. MIL inspection Turn the combination switch ON and check that the MIL stays ON. Does the MIL stay ON? – PGM-FI troubleshooting (page 5-8) – GO TO STEP 2. 2.
  • Page 127 dummyhead dummyhead IGNITION SYSTEM 7. Timing belt driven pulley inspection Check for proper installation of the timing belt driven pulley. Is the timing belt driven pulley installed correctly? – GO TO STEP 8. – Correct the timing belt driven pulley installation 8.
  • Page 128 dummyhead dummyhead MEMO...
  • Page 129 dummytext 9. STARTING SYSTEM STARTING SYSTEM NEUTRAL SWITCH REMOVAL/ TROUBLESHOOTING···································9-2 INSTALLATION ············································ 9-5 STARTER MOTOR REMOVAL/ NEUTRAL SWITCH INSPECTION ··············· 9-5 INSTALLATION·············································9-4...

  • Page 130: Troubleshooting

    dummyhead dummyhead STARTING SYSTEM STARTING SYSTEM TROUBLESHOOTING STARTING SYSTEM STARTER MOTOR DOES NOT TURN 1. Standard inspection Check the following: – Battery condition – Burned No. 4 (30 A) fuse – Burned No. 5 (10 A) fuse Are the above items in good condition? –...
  • Page 131 dummyhead dummyhead STARTING SYSTEM 5. Starter relay coil line open circuit inspection Disconnect the neutral switch 2P connector Turn the combination switch to the START position. NEUTRAL SWITCH 2P CONNECTOR Measure the voltage at the neutral switch 2P MAIN WIRE HARNESS SIDE connector main wire harness side No.2 (Blue) terminal and No.1 (Black) terminal.

  • Page 132: Installation

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

  • Page 133: Neutral Switch Inspection

    dummyhead dummyhead STARTING SYSTEM NEUTRAL SWITCH REMOVAL/ INSTALLATION Remove the electric parts case (page 10-7). Remove the bolt (6 x 14 mm) [1] and neutral switch bracket [2] from the crankcase. Remove the neutral switch plate [3] and neutral switch [4] from the bracket by removing the neutral switch nut (20 mm) [5].
  • Page 134 dummyhead dummyhead MEMO...
  • Page 135 dummytext 10. OTHER ELECTRICAL FUSE RELAY JUNCTION BOX REMOVAL/ FUEL PUMP RELAY INSPECTION ············ 10-7 INSTALLATION···········································10-2 ELECTRIC PARTS CASE REMOVAL/ SWITCH PANEL INDICATOR WIRE INSTALLATION ·········································· 10-7 HARNESSES REMOVAL/ INSTALLATION···········································10-3 POWER TILT RELAY/POWER TILT RELAY CASE REMOVAL/INSTALLATION ············ 10-8 RELAY REMOVAL/INSTALLATION···········10-6 FUSE/RELAY JUNCTION BOX MAIN/STARTER RELAY INSPECTION······10-6 INSPECTION·············································...
  • Page 136 dummyhead dummyhead OTHER ELECTRICAL FUSE RELAY JUNCTION BOX OTHER ELECTRICAL REMOVAL/INSTALLATION REMOVAL Disconnect the battery negative (–) cable, then the positive (+) cable from the battery. Remove the engine cover. Remove the following: – Fuse/relay junction box terminal bolts (6 x 22 mm) [1] (three) –...

  • Page 137: Installation

    dummyhead dummyhead OTHER ELECTRICAL SWITCH PANEL INDICATOR WIRE HARNESSES REMOVAL/ INSTALLATION Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). REMOVAL Remove the following: – Front separate cover (page 6-4*) – Shift control cable pivot (page 20-3*) – Throttle control cable pivot (page 20-6*) Loosen the screw and remove the grommet band [1], then remove the under case grommet A [2].

  • Page 138: Installation

    dummyhead dummyhead OTHER ELECTRICAL INSTALLATION • Be careful not to press the fuel tube A with the under case grommet A. Connect the switch panel wire harness connector 14P connector [1] and indicator panel wire harness 6P connector [2], and then attach them to the connector holders.
  • Page 139 dummyhead dummyhead OTHER ELECTRICAL Install the under case grommet A [1] to the groove [2] of the front cover bracket as shown. Install the remote control cable plate [3] to the groove [4] of the front cover bracket and tighten the bolt (6 x 16 mm) [5].

  • Page 140: Relay Removal/Installation

    dummyhead dummyhead OTHER ELECTRICAL RELAY REMOVAL/INSTALLATION Disconnect the battery negative (–) cable, then the positive (+) cable from the battery. Remove the engine cover. Open the fuse/relay junction box cover [1]. Remove the following: – Main relay [2] – Starter relay [3] –...

  • Page 141: Fuel Pump Relay Inspection

    dummyhead dummyhead OTHER ELECTRICAL FUEL PUMP RELAY INSPECTION Remove the fuel pump relay from the fuse/relay junction box (page 10-6). Connect the ohmmeter to the fuel pump relay terminal C [1] and terminal D [2]. Connect the battery positive (+) cable to the fuel pump relay terminal A [3] and battery negative (–) cable to terminal B [4].

  • Page 142: Installation

    dummyhead dummyhead OTHER ELECTRICAL Remove the following parts from the electric parts case [1]: – Connector holder mounting bolts (6 x 10 mm) [2] (five) – Connector holders [3] (five) – Collars [4] (four) – Grommets [5] (four) – Wire harness clip [6] –...
  • Page 143 dummyhead dummyhead OTHER ELECTRICAL Remove the three bolt/washers (6 x 27 mm) [1], wire harness clip [2] and two harness band clips [3]. Remove the two power tilt relay mounting bolt/washers (6 x 25 mm) [1], harness band clip [2] and power tilt relay [3].

  • Page 144: Fuse/Relay Junction Box

    dummyhead dummyhead OTHER ELECTRICAL FUSE/RELAY JUNCTION BOX INSPECTION BLOCK FUSE INSPECTION Disconnect the battery negative (–) cable, then the positive (+) cable from the battery. Remove the engine cover. Open the fuse/relay junction box cover [1]. Remove the two block fuse screw/washers [2] and No.1 fuse [3] from fuse/relay junction box and check for continuity.
  • Page 145 dummyhead dummyhead OTHER ELECTRICAL BLADE FUSE INSPECTION Remove the fuses from fuse/relay junction box and check for blown fuses. If the fuses are normal, install the fuses to fuse/relay junction box and check for continuity between the terminals in each connectors as shown in the table. There should be continuity at all times.
  • Page 146 dummyhead dummyhead OTHER ELECTRICAL Check terminals No.9 fuse (15 A) No.8 terminal and fuse/relay junction box 23P connector No.2 (INJ 6) terminal No.9 fuse (15 A) No.8 terminal and fuse/relay junction box 8P connector No.6 (IGP 1) terminal No.9 fuse (15 A) No.8 terminal and fuse/relay junction box 8P connector No.7 (IGP 2) terminal No.10 fuse (10 A) No.11 terminal and main relay No.28 terminal No.10 fuse (10 A) No.12 terminal and fuse/relay junction box 8P connector...
  • Page 147 dummytext 13. ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL ····································13-2 ENGINE INSTALLATION···························· 13-4 13-1...
  • Page 148 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL ENGINE REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Refer page base...
  • Page 149 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Disconnect the water tubes [1] from the exhaust manifolds. Disconnect the cylinder head cover oil return hoses [1] and air vent tube [2]. Attach the engine chains [1] to the engine hanger [2]. Remove the cap [1], two mount case flange nuts [2], two flange bolts (10 x 55 mm) [3], and two flange bolts (12 x 95 mm) [4] from the engine assembly.
  • Page 150 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Remove the following bolts from the under side of the engine mounting case [1]. • bolts (10 x 60 mm) (two) • bolt (10 x 85 mm) (one) • bolt/washer (12 x 65 mm) (one) • bolt/washers (12 x 120 mm) (two) •...
  • Page 151 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Turn shift shaft A [1] so that the cutout [2] is positioned Viewing from the lower side as shown. (This position shows shift shaft A is in the of the mounting case. neutral position.) Cruising direction Install shift shaft A [1], washer [2] and shift shaft B [3] by aligning the punch mark [4] on shift shaft A with the punch mark [5] on shift shaft B.
  • Page 152 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Set the dowel pin (10 x 16 mm) [1] and dowel pin (14 x 15 mm) [2] to the mount case. Install a new mount case gasket [3]. Slowly install the engine assembly on the engine mount case [4].
  • Page 153 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Apply engine oil to a new O-ring (59.4 x 3.1 mm) [1], and install it to the starter motor [2]. Install the starter motor, but do not tighten the starter motor bolts. Tighten the bolts and nuts to the upper side of the engine assembly in the numbered order to the specified torque.
  • Page 154 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Apply marine grease to the seal holder [1] O-ring groove and bearing part. Apply marine grease to a new O-ring (26.9 x 2.4 mm) [2], and install it to the seal holder. Install the seal holder on shift shaft B [3] so that shift shaft B does not tilt on the mount case.
  • Page 155 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Connect the water tubes [1] to the exhaust manifolds. Connect the fuel tube G [1] to the fuel pump (low pressure side) [2]. Install the fuel tube G to the hose clip [3]. Connect the fuel tube A [1] and B [2] to the fuel strainer [3].
  • Page 156 dummyhead dummyhead MEMO...
  • Page 157 dummytext 15. CYLINDER BLOCK CRANKCASE COVER/CRANKSHAFT/PISTON DISASSEMBLY/ASSEMBLY ······················15-2 15-1...
  • Page 158 dummyhead dummyhead CYLINDER BLOCK CRANKCASE COVER/CRANKSHAFT/ CYLINDER BLOCK PISTON DISASSEMBLY/ASSEMBLY CRANKCASE COVER/CRANKSHAFT DISASSEMBLY Refer page base shop manual (BF175AK1·200AK1·225AK1: 62ZY300). Remove the following parts: – Engine assembly (page 13-2) – Cylinder head (page 14-22*) – Oil filter (page 3-6*) – Thermostat (page 11-5*) –...
  • Page 159 dummyhead dummyhead CYLINDER BLOCK Remove the three timing belt tensioner base bolts (10 x 40 mm) [1], bolt (6 x 22 mm) [2], timing belt tensioner base [3], and O-ring [4]. Remove the dowel pin [5]. Remove the two bolts (8 x 20 mm) [1] and engine hanger plate [2].
  • Page 160 dummyhead dummyhead CYLINDER BLOCK Remove the two bolts (8 x 50 mm) [1], bolt (8 x 75 mm) [10] [11] [2], VTEC spool valve [3], and VTEC spool valve filter [4]. Remove the seven bolts (6 x 35 mm) [5], crankcase upper cover [6], oil hole gasket [7], oil pipe joint [8] and two dowel pins [9].
  • Page 161 dummyhead dummyhead CYLINDER BLOCK Remove the piston assembly [1] by pushing on the connecting rod. CORRECT • To avoid mix up during reassembly, mark each piston/connecting rod assembly with its cylinder number. • Before removing the piston assembly, remove the carbon deposits from the cylinder.
  • Page 162 dummyhead dummyhead CYLINDER BLOCK Remove the five side bolts (10 x 60 mm) [1], two side bolts (10 x 80 mm) [2], side bolt (10 x 109 mm) [3], eight bearing cap bolts [4], four bearing caps [5], four lower main bearings [6], and eight dowel pins [7].
  • Page 163 dummyhead dummyhead CYLINDER BLOCK Apply molybdenum disulfide oil and install the two thrust washers [1] in the No.3 journal so that the grooves [2] are facing out. Clean the mating surfaces between the lower main JOURNAL POSITION bearing [1] and bearing cap [2] with a degreasing cleaning agent.
  • Page 164 dummyhead dummyhead CYLINDER BLOCK Clean the mating surfaces between the connecting rod bearing [1] and connecting rod [2] with a degreasing cleaning agent. Apply molybdenum disulfide oil to the crankshaft mating surface of the connecting rod bearing. Install the connecting rod bearing to the connecting rod by aligning the tab [3] of the connecting rod bearing with the groove [4] of the connecting rod.
  • Page 165 dummyhead dummyhead CYLINDER BLOCK Clean the mating surfaces between the connecting rod [1] and connecting rod bearing cap [2]. • Be careful not to damage the mating surface between the connecting rod and connecting rod bearing cap. Replace the connecting rod and connecting rod bearing cap as a set, if damaged.
  • Page 166 dummyhead dummyhead CYLINDER BLOCK Apply marine grease to a new oil seal [1] lips. Drive in the oil seal into the oil seal case [2] using the special tools. TOOLS: Driver [3] 07749-0010000 Oil seal driver attachment, 80 x 96 mm [4] 07ZAD-PNA0100 Wipe the oil off the mating surface of the cylinder block and oil seal case.
  • Page 167 dummyhead dummyhead CYLINDER BLOCK Wipe the oil off the mating surface of the cylinder block and the crankcase upper cover. Before installing the crankcase upper cover, apply a 1.5 ® -3.0 mm bead of liquid gasket (Threebond #1280B or equivalent) to the shaded part as shown. •...
  • Page 168 dummyhead dummyhead CYLINDER BLOCK Install a new O-ring (25 x 2.4 mm) [1], two dowel pins [2] and the crankcase [3] to the cylinder block [4]. [12] Loosely tighten the fifteen bolts (6 x 32 mm) [5], two [10] bolts (6 x 37 mm) [6], and two bolts (6 x 55 mm) [7] in the positions shown.
  • Page 169 dummyhead dummyhead CYLINDER BLOCK Install the dowel pin [1]. Align the dowel pin position, and install a new O-ring [2] and timing belt tensioner base [3]. Install and tighten the three timing belt tensioner base bolts (10 x 40 mm) [4] to the specified torque. TORQUE: 45 N·m (4.6 kgf·m, 33 lbf·ft) Install and tighten the bolt (6 x 22 mm) [5].
  • Page 170 dummyhead dummyhead CYLINDER BLOCK Position the harness clamp [1] against the stopper [2] of the cylinder block, then install and tighten the bolt (6 x 14 mm) [3]. Install the following parts: – Flywheel (page 15-6*) – EOP switch (High pressure side) (page 5-107*) –...
  • Page 171 dummytext 21. TECHNICAL FEATURES SHIFT EFFORT REDUCTION SYSTEM ·····21-2 CRACKING CONNECTING ROD ··············· 21-5 CHARGE OUTPUT ENHANCEMENT WHEN IDLING ·························································21-4 21-1...
  • Page 172 dummyhead dummyhead TECHNICAL FEATURES SHIFT EFFORT REDUCTION SYSTEM TECHNICAL FEATURES GENERAL The effort when shifting the control lever (throttle valve) from the half-open position to the neutral is reduced by retarding the ignition timing by the ECM. The ECM starts computation to retard the ignition timing to reduce shift effort when the engine speed is above the prescribed level, Executes shift effort the throttle is fully closed, and the gear is in engagement.
  • Page 173 dummyhead dummyhead TECHNICAL FEATURES The crankshaft speed variations are transmitted to the clutch shifter dog, which is in mesh with the forward/reverse bevel gear, via the vertical shaft and the pinion gear. The torque variations occurring in the clutch shifter dog reduce the shift effort. From CRANKSHAFT SHAFT ROD VERTICAL SHAFT...
  • Page 174 dummyhead dummyhead TECHNICAL FEATURES CHARGE OUTPUT ENHANCEMENT WHEN IDLING GENERAL Detecting electrical loads in the outboard motor when idling, the engine idle speed is enhanced when the electrical loads are high to increase charging capacity to allow for use of more electrical power in the outboard motor. (Only when neutral) CONSTRUCTION AND FEATURES The ECM detects ACGF output (ACGF load condition output) from the alternator and computes current electrical loads in the outboard motor.
  • Page 175 dummyhead dummyhead TECHNICAL FEATURES CRACKING CONNECTING ROD This engine provides cracking connecting rods to utilize productivity improvement and to trim weight. The cracking connecting rod is split from the single- piece connecting rod assembly into connecting rod and bearing cap. Since the connecting rod and bearing cap have complex mating surfaces to hold them each other, the dowel pin is not required when assembling connecting...
  • Page 176 dummyhead dummyhead MEMO...
  • Page 177 dummytext 22. WIRING DIAGRAMS WIRING DIAGRAM······································22-5 CONNECTOR GENERAL LAYOUT DRAWING ··················································· 22-7 SYSTEM WIRING DIAGRAM······················22-6 22-1...
  • Page 178 WIRING DIAGRAM WIRING DIAGRAMS DIRECT IGNITION DIRECT IGNITION DIRECT IGNITION OPTION TACHOMETER TRIM METER FUEL FUEL FUEL VOLT HOUR COIL 2 COIL 6 COIL 4 INJECTOR 1 INJECTOR 3 INJECTOR 5 METER METER FUEL FUEL FUEL DIRECT IGNITION DIRECT IGNITION DIRECT IGNITION INJECTOR 2 INJECTOR 4...
  • Page 179 SYSTEM WIRING DIAGRAM No.4 (30A) FUSE/RELAY JUNCTION BOX No.11 (15A) No.8 (10A) AIR VENT STRAINER COMBINATION SWITCH No.9 (15A) MAIN RELAY No.10 (10A) FUEL STRAINER LOAD (High pressure side) No.5 (10A) FUEL PUMP RELAY FUEL PUMP (High pressure side) IGP1 BATTERY IGP2 FLR1...
  • Page 180 CONNECTOR GENERAL LAYOUT DRAWING Terminal Wire color ALTERNATOR B TERMINAL number Terminal Wire color number Power tilt W/Bl switch side VTEC SOLENOID VALVE 1P CONNECTOR Main wire harness side (BF225 only) Terminal Wire color Terminal Wire color number Terminal Wire color Terminal Wire color Terminal...
  • Page 181 POWER TILT RELAY 2P CONNECTOR IAT SENSOR 2P CONNECTOR Terminal Wire color Terminal Wire color Terminal Wire color number number number POWER TILT RELAY 1P CONNECTOR HO2S 4P CONNECTOR Main wire (Except XT, XCT, XXT, XXCT types) Main wire harness side MAP SENSOR 3P CONNECTOR harness side Power tilt relay...
  • Page 182 MAIN WIRE HARNESS Terminal Wire color Terminal Wire color Terminal Wire color STARTER CABLE 1 (+) TERMINAL number number number W/Bl – GND1 Bl/Y Y/Bl POWER TILT RELAY WIRE TERMINAL G/Bl Y/Bl GND2 W/Bl ACG CABLE TERMINAL Y/Bu Bu/R GND3 Main wire Y/Bl G/Bl...
  • Page 183 Terminal Wire color Terminal Wire color number number Terminal Wire color number Y/Bl No.4 FUEL INJECTOR 2P CONNECTOR Y/Bl Main wire Main wire Main wire harness side harness side harness side No.1 FUEL INJECTOR 2P CONNECTOR No.5 FUEL INJECTOR 2P CONNECTOR No.2 FUEL INJECTOR 2P CONNECTOR Terminal Wire color...
  • Page 184 INDEX dummytext INDEX ALERT SYSTEM/WARNING SYSTEM FUSE RELAY JUNCTION BOX REMOVAL/ TROUBLESHOOTING ····················································4-5 INSTALLATION ···························································· 10-2 BEFORE TROUBLESHOOTING ····································4-2 FUSE/ELECTRIC POWER LINE CABLE/HARNESS ROUTING ········································2-3 TROUBLESHOOTING···················································· 4-3 CHARGE OUTPUT ENHANCEMENT WHEN FUSE/RELAY JUNCTION BOX INSPECTION··········· 10-10 IDLING ··········································································21-4 HO2S INSPECTION CHARGING SYSTEM TROUBLESHOOTING················7-2 (Except XT, XCT, XXT, XXCT types) ···························...
  • Page 185 Copyright © 2014 Tohatsu Corporation. All rights reserved. No part of this manual may be reproduced or transmitted in any form or by any means without the express written permission of Tohatsu Corporation.
  • Page 186 200/225A OB No.62ZY300Z 14-01 NB Printed in Japan...

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