Page 1 WORLDWIDE Z200N LZ200N USA, CANADA Z200Y LZ200Y SERVICE MANUAL 290369 68F-28197-Z9-A1...
Page 2 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 HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explanations of all disassembly, repair, assembly, and check operations.
Page 4 IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.
Page 5 HOW TO USE THIS MANUAL 1 The main points regarding removing/installing and disassembling/assembling procedures are shown in the exploded views. 2 The numbers in the exploded views indicate the required sequence of the procedure and should be observed accordingly. 3 Symbols are used in the exploded views to indicate important aspects of the procedure. A list of meanings for these symbols is provided on the following page.
Page 6: General Information
Symbol F to H in an exploded diagram indicate the grade of lubricant and the loca- tion of the lubrication point. F Apply Yamaha 2-stroke outboard motor oil (TC-W3) G Apply water resistant grease (Yamaha grease A, Yamaha marine grease)
Page 7: Table Of Contents
CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTIONS AND ADJUSTMENTS INSP FUEL SYSTEM FUEL POWER UNIT POWR LOWER UNIT LOWR BRACKET UNIT BRKT – ELECTRICAL SYSTEMS ELEC TROUBLE ANALYSIS TRBL ANLS...
Page 9 INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION .................... 1-1 SERIAL NUMBER ..................1-1 STARTING SERIAL NUMBERS ............... 1-1 SAFETY WHILE WORKING ................1-2 FIRE PREVENTION ................... 1-2 VENTILATION................... 1-2 SELF-PROTECTION.................. 1-2 OILS, GREASES AND SEALING FLUIDS..........1-2 GOOD WORKING PRACTICES ..............1-3 DISASSEMBLY AND ASSEMBLY ............
Page 10: Identification
IDENTIFICATION INFO IDENTIFICATION SERIAL NUMBER The outboard motor’s serial number is stamped on a label which is attached to the port side of the clamp bracket. NOTE: If the serial number label is removed, “VOID” marks will be appear on the label. 1 Model name 2 Approved model code 3 Transom height...
Page 11: Safety While Working
SAFETY WHILE WORKING INFO SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be fol- lowed Yamaha dealers their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline and keep it away from heat, sparks and open flames.
Page 12: Good Working Practices
SAFETY WHILE WORKING INFO Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practices, any risk is minimized. A summary of the most important precau- tions is as follows: 1.
Page 13: Disassembly And Assembly
SAFETY WHILE WORKING INFO 3. Non-reusable items Always use new gaskets, packings, O- rings, split-pins, circlips, etc., on reas- sembly. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed air when disassembling. 2. Oil the contact surfaces of moving parts before assembly. 3.
Page 14: Special Tools
SPECIAL TOOLS INFO SPECIAL TOOLS Using the correct special tools recom- mended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvising and using improper tools can damage the equipment. NOTE: • For USA and Canada, use part numbers that start with “J-”, “YB-”, “YM-”, “YS-”,...
Page 15 SPECIAL TOOLS INFO A Magnetic base P/N. YU-34481 90890-06705 B Magnetic base attaching plate P/N. YB-07003 90890-07003 C Backlash indicator P/N. YB-06265 90890-06706 D Dial gauge set P/N. YU-03097 90890-01252 E Hydraulic pressure gauge P/N. 90890-06776 F Up-relief valve attachment P/N.
Page 16 SPECIAL TOOLS INFO L Diagnostic unit Check the engine condition by using a personal computer when it is connected to the Electronic Control Unit (ECU). Diagnosis: Indicates the name of a failed part. Diagnosis record: Displays the name of the part whose diag- nosis is detected, along with the engine running total hours.
Page 17: Removing And Installing
SPECIAL TOOLS INFO REMOVING AND INSTALLING 1 Flywheel magnet assembly holder P/N. YB-06139 ........ a 90890-06522 ......b 2 Universal puller P/N. YB-06117 ........ a 90890-06521 ......b 3 Bearing/oil seal attachment P/N. YB-06205 ........ a 90890-06663 ......b 4 Piston ring compressor P/N.
Page 18 SPECIAL TOOLS INFO B Propeller shaft housing puller P/N. YB-06207 ........ a 90890-06502 ......b C Center bolt P/N. 90890-06504 D Slide hammer P/N. YB-06096 90890-06531 E Drive shaft holder P/N. YB-06201 90890-06520 F Pinion nut holder P/N. 90890-06505 G Pinion nut holder attachment P/N.
Page 19 SPECIAL TOOLS INFO S Bearing/oil seal attachment P/N. 90890-06637 T Bearing/oil seal attachment P/N. 90890-06659, 90890-06660, 90890-06661, 90890-06662 U Slide hammer attachment P/N. YB-06335 90890-06514 V End screw wrench P/N. YB-06548 90890-06548 W End screw wrench P/N. YB-06175-1A X Universal holder P/N.
Page 21 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 MAINTENANCE SPECIFICATIONS..............2-3 POWER UNIT.................... 2-3 LOWER UNIT.................... 2-5 ELECTRICAL ..................... 2-5 DIMENSIONS ................... 2-9 TIGHTENING TORQUES ................2-11 SPECIFIED TORQUES ................2-11 GENERAL TORQUES ................2-13...
Page 22: Spec
SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — DIMENSION Overall length mm (in) 792 (31.2) Overall width mm (in) 554 (21.8) Overall height mm (in) 1,782 (70.2) Boat transom height mm (in) 635 (25.0) WEIGHT (with aluminum propeller)
Page 23 SPEC GENERAL SPECIFICATIONS Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — FUEL AND OIL Fuel type Unleaded regular gasoline Fuel rating *PON Engine oil type 2-stroke outboard engine oil Engine oil grade TC-W3 Engine oil capacity (engine oil tank) L (US qt, lmp qt) 0.9 (0.95, 0.79) (sub-oil tank)
Page 24: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS POWER UNIT Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — CYLINDER HEADS Warpage limit mm (in) 0.1 (0.004) (lines indicate straightedge position) CYLINDERS Bore size mm (in) 90.00 - 90.02 (3.543 - 3.544) Wear limit mm (in) 90.1 (3.55)
Page 25 SPEC MAINTENANCE SPECIFICATIONS Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — CONNECTING RODS Small-end axial play mm (in) 2.0 (0.08) limit (F) Big-end side mm (in) 0.12 - 0.26 (0.005 - 0.010) clearance (E) OIL INJECTION PUMP ID mark 68F00 Bleeding...
Page 26: Lower Unit
SPEC MAINTENANCE SPECIFICATIONS LOWER UNIT Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — GEAR BACKLASH Pinion - forward gear mm (in) 0.25 - 0.46 0.21 - 0.43 (0.010 - 0.018) (0.008 - 0.017) Pinion - reverse gear mm (in) 0.74 - 1.29 0.97 - 1.29...
Page 27 SPEC MAINTENANCE SPECIFICATIONS Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — IGNITION CONTROL SYSTEM Crank position sensor (G/L) 1.0 ± 0.5 (0.04 ± 0.02) Crank-position-sensor-to- mm (in) flywheel gap Output peak voltage lower limit @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min...
Page 28 SPEC MAINTENANCE SPECIFICATIONS Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — Fuel pressure sensor Output voltage (P – B) 2.8 - 3.2 Water detection switch Float position a “ON” mm (in) STARTER MOTOR Type Sliding gear Output Cranking time limit Second Brushes...
Page 29 SPEC MAINTENANCE SPECIFICATIONS Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — OIL FEED PUMP CONTROL SYSTEM Oil level sensor (engine oil tank) Float position a mm (in) 3 - 6 (0.12 - 0.24) “OFF” Float position b mm (in) 33 - 36 (1.30 - 1.42) “ON”...
Page 30: Dimensions
SPEC MAINTENANCE SPECIFICATIONS DIMENSIONS Symbol Models Worldwide Z200NETO LZ200NETO Unit Z200TR LZ200TR Canada Z200TR — mm (in) 613 (24.1) mm (in) 180 (7.1) mm (in) 646 (25.4) mm (in) 69 (2.7) mm (in) 1,150 (45.3) mm (in) 574 (22.6) mm (in) 1,074 (42.3) mm (in) 708 (27.9)
Page 31 SPEC MAINTENANCE SPECIFICATIONS Symbol Models Worldwide Z200NETO LZ200NETO Unit Z200TR LZ200TR Canada Z200TR — mm (in) 125.4 (4.9) mm (in) 254 (10.0) mm (in) 163.5 (6.4) mm (in) 50.8 (2.0) mm (in) 180 (7.1) mm (in) 367 (14.4) mm (in) 18.5 (0.7) mm (in) 82 (3.2)
Page 32: Tightening Torques
SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torques Part to be tightened Thread size m•kgf ft•lb POWER UNIT Intake silencer Electric oil pump Fuel injection unit Atmospheric pressure sensor Electric oil pump bracket Throttle position sensor Intake air temperature sensor Drive belt tensioner Mechanical fuel pump Fuel rail...
Page 33 SPEC TIGHTENING TORQUES Tightening torques Part to be tightened Thread size m•kgf ft•lb Crankcase Connecting rod LOWER UNIT Propeller Lower unit Ring nut — 14.5 Pinion nut Gear oil drain screw — Gear oil level check screw — BRACKET UNIT Flushing hose Shift rod detent mechanism screw —...
Page 34: General Torques
SPEC TIGHTENING TORQUES GENERAL TORQUES General torque This chart specifies tightening torques for specifications Nut (A) Bolt (B) standard fasteners with a standard ISO m•kgf ft•lb thread pitch. Tightening torque specifica- 8 mm tions for special components or assemblies 10 mm are provided in applicable sections of this 12 mm manual.
Page 36 INSP CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS MAINTENANCE INTERVAL CHART .............. 3-1 TOP COWLING ....................3-3 CHECKING THE TOP COWLING FIT ............3-3 FUEL SYSTEM ....................3-3 CHECKING THE FUEL LINE ..............3-3 CHECKING THE FUEL FILTER ..............3-4 MEASURING THE FUEL PRESSURE (MEDIUM-PRESSURE FUEL LINE)............
Page 37 INSP GENERAL ...................... 3-18 CHECKING THE ANODES..............3-18 CHECKING THE BATTERY..............3-19 CHECKING THE SPARK PLUGS............3-20 LUBRICATION POINTS................3-22...
Page 38: Maintenance Interval Chart
INSP MAINTENANCE INTERVAL CHART MAINTENANCE INTERVAL CHART Use the following chart as a guide to general maintenance intervals. Dependant on operating conditions, adjust the maintenance intervals accordingly. Initial Every Refer to Item Remarks 10 hours 50 hours 100 hours 200 hours page (Break-in) (3 months)
Page 39 INSP MAINTENANCE INTERVAL CHART Initial Every Refer to Item Remarks 10 hours 50 hours 100 hours 200 hours page (Break-in) (3 months) (6 months) (1 year) GENERAL Anodes Check/replace 3-18 Battery Check/charge (every month) 3-19 Spark plugs Clean/adjust/ 3-20 replace Wiring and connectors Adjust/reconnect —...
Page 40: Top Cowling
INSP TOP COWLING/FUEL SYSTEM TOP COWLING CHECKING THE TOP COWLING FIT 1. Check: • Top cowling fitting Loose/unlatched → Adjust the top cowling hook. 3010 2. Adjust: • Top cowling hook position Adjustment steps (1) Loosen the bolts 1 approximately 1/4 of a turn.
Page 41: Checking The Fuel Filter
INSP FUEL SYSTEM 2. Check: • High-pressure fuel line Cracks/damage/leaks → Replace. Refer to “HIGH-PRESSURE FUEL LINE ASSEMBLY” on page 4-30. 3026 3. Check: • Plastic locking ties Loosen → Retighten or replace. 4. Check: • Low-pressure fuel line Cracks/damage/leaks → Replace. Refer “LOW-PRESSURE FUEL...
Page 42: Measuring The Fuel Pressure (Medium-Pressure Fuel Line)
INSP FUEL SYSTEM MEASURING THE FUEL PRESSURE (MEDIUM-PRESSURE FUEL LINE) Measure: • Fuel pressure (medium-pressure fuel line) Out of specification → Check the medium-pressure fuel line. Fuel pressure (medium-pressure fuel line) 280 - 360 kPa (2.8 - 3.6 kgf/cm , 39.8 - 51.2 psi) Measuring steps (1) Install the fuel pressure gauge onto the pressure check valve.
Page 43: Checking The Mechanical Fuel Pump Oil Level
INSP FUEL SYSTEM CHECKING THE MECHANICAL FUEL PUMP OIL LEVEL Check: • Mechanical fuel pump oil level Level is low → Add to the proper level. Recommended gear oil GEAR CASE LUBE (USA) or Hypoid gear oil SAE 90 Checking steps (1) Remove the gear oil level check screw 1 and check the oil level.
Page 44: Control System
INSP CONTROL SYSTEM CONTROL SYSTEM SYNCHRONIZING THE THROTTLE VALVES 1. Check: • Throttle valve synchronization Uneven opening → Adjust. Checking steps (1) Remove the intake silencer 1. (2) Disconnect the throttle lever rod 2 and oil pump link rod. (3) Turn the throttle stop screw 3 until it does not touch the stopper.
Page 45: Adjusting The Throttle Position Sensor
INSP CONTROL SYSTEM ADJUSTING THE THROTTLE POSITION SENSOR 1. Measure: • Throttle position sensor output voltage (with the throttle valves fully closed) Out of specification → Adjust. Throttle position sensor output voltage (pink (P) – orange (O)) 0.50 ± 0.02 V NOTE: •...
Page 46: Adjusting The Engine Idling Speed
INSP CONTROL SYSTEM ADJUSTING THE ENGINE IDLING SPEED 1. Measure: • Engine idling speed Out of specification → Adjust. Engine idling speed 700 ± 30 r/min 3082 Measuring steps (1) Start the engine and allow it to warm up for a few minutes. (2) Install the tachometer onto the spark plug lead of cylinder #1.
Page 47: Adjusting The Remote Control Shift Cable
INSP CONTROL SYSTEM ADJUSTING THE REMOTE CONTROL SHIFT CABLE 1. Check: • Shift operation Incorrect → Adjust. 2. Adjust: • Remote control shift cable length Adjustment steps (1) Loosen the locknut 1. (2) Remove the clip 2. (3) Disconnect the shift cable joint 3. (4) Set the remote control lever to the neutral position.
Page 48: Checking The Drive Belt
INSP CONTROL SYSTEM 2. Adjust: • Remote control throttle cable length Adjustment steps (1) Loosen the locknut 1 and stopper screw 2. (2) Loosen the locknut 3. (3) Remove the clip 4. (4) Disconnect the throttle cable joint 5. (5) Set the remote control lever to the fully closed position.
Page 49: Adjusting The Crank Position Sensor
CONTROL SYSTEM/COOLING SYSTEM/ INSP OIL INJECTION SYSTEM ADJUSTING THE CRANK POSITION SENSOR 1. Measure: • Crank position sensor-to-flywheel magnet assembly clearance a Out of specification → Adjust. Crank position sensor-to-flywheel magnet assembly clearance 3136 1.0 ± 0.5 mm (0.04 ± 0.02 in) 2.
Page 50: Synchronizing The Oil Pump
INSP OIL INJECTION SYSTEM SYNCHRONIZING THE OIL PUMP 1. Check: • Oil pump lever position Incorrect → Adjust. NOTE: Make sure the oil pump lever 1 touches the stopper a (fully closed position) when the throttle valves are closed. 3150 2.
Page 51: Air Bleeding The Oil Injection System
INSP OIL INJECTION SYSTEM AIR BLEEDING THE OIL INJECTION SYSTEM CAUTION: • DO NOT USE GASOLINE MIXED WITH OIL (PREMIX). • USE UNLEADED STRAIGHT GASOLINE ONLY. Bleed: • Air bubbles (from the oil injection system) Bleeding steps (1) Fill the oil tank with the engine oil. Recommended engine oil Engine oil type 2-stroke outboard engine oil...
Page 52: Power Trim And Tilt System
INSP POWER TRIM AND TILT SYSTEM POWER TRIM AND TILT SYSTEM CHECKING THE POWER TRIM AND TILT FLUID LEVEL Check: • Power trim and tilt fluid level Level is low → Add power trim and tilt fluid to the proper level. Recommended power trim and tilt fluid ATF Dexron II...
Page 53: Insp Adj
INSP POWER TRIM AND TILT SYSTEM/LOWER UNIT ADJUSTING THE TRIM SENSOR CAM 1. Measure: • Trim sensor setting resistance Out of specification → Adjust. Trim sensor setting resistance Pink (P) – Black (B) 80 ± 12 Ω at 20 ˚C (68 ˚F) Measuring steps (1) Fully tilt the outboard down.
Page 54: Changing And Checking The Gear Oil
INSP LOWER UNIT CHANGING AND CHECKING THE GEAR OIL 1. Check: • Gear oil Milky oil → Replace the oil seal. Slag oil → Check the gears, bearings, and clutch dog. Checking steps (1) Tilt up the outboard slightly. (2) Place a container under the gear oil drain screw 1.
Page 55: Checking The Lower Unit (For Air Leaks)
INSP LOWER UNIT/GENERAL CHECKING THE LOWER UNIT (FOR AIR LEAKS) Check: • Lower unit holding pressure Pressure drops → Check the seals and components. Lower unit holding pressure 100 kPa (1.0 kg/cm , 14.2 psi) Checking steps CAUTION: Do not overpressurize the lower unit. Excessive pressure may damage the oil seals.
Page 56: Checking The Battery
INSP GENERAL CHECKING THE BATTERY WARNING Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poi- sonous and highly caustic. Always follow these preventive measures: • Avoid bodily contact with electrolytic fluid as it can cause severe burns or per- manent eye injury.
Page 57: Checking The Spark Plugs
INSP GENERAL Check: • Electrolyte level Below the minimum level mark → Add distilled water to the proper level. • Electrolyte specific gravity Less than specification → Recharge the battery. Electrolyte specific gravity 1.280 at 20˚C (68˚F) CHECKING THE SPARK PLUGS 1.
Page 58 INSP GENERAL 3. Measure: • Spark plug gap a Out of specification → Regap. Spark plug gap 1.0 - 1.1 mm (0.039 - 0.043 in) 3270 4. Tighten: • Spark plugs Spark plug 25 Nm (2.5 m • kgf, 18 ft • lb) NOTE: •...
Page 59: Lubrication Points
INSP GENERAL LUBRICATION POINTS Apply: • Yamaha marine grease (for USA and Canada) • Yamaha grease A (for worldwide) 3290 3300 3310 3320 3330 3-22...
Page 60: Fuel
FUEL CHAPTER 4 FUEL SYSTEM FLYWHEEL MAGNET ASSEMBLY COVER........... 4-1 REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY COVER................. 4-1 MEDIUM-PRESSURE FUEL LINE ..............4-2 REMOVING/INSTALLING THE MEDIUM-PRESSURE FUEL LINE..4-2 REDUCING THE FUEL PRESSURE (MEDIUM-PRESSURE FUEL LINE)............4-5 DISCONNECTING THE FUEL HOSE JOINT..........4-6 CHECKING THE PRESSURE REGULATOR..........
Page 61 FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY..........4-30 REMOVING/INSTALLING THE HIGH-PRESSURE FUEL LINE ASSEMBLY.................... 4-30 DISASSEMBLING/ASSEMBLING THE HIGH-PRESSURE FUEL LINE ASSEMBLY................... 4-33 REMOVING THE HOSE CLAMPS............4-36 INSTALLING THE HOSE CLAMPS ............4-36 MECHANICAL FUEL PUMP ................. 4-37 DISASSEMBLING/ASSEMBLING THE MECHANICAL FUEL PUMP BODY..................
Page 62: Flywheel Magnet Assembly Cover
FUEL FLYWHEEL MAGNET ASSEMBLY COVER FLYWHEEL MAGNET ASSEMBLY COVER REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY COVER 4005 Order Job/Part Q’ty Remarks Flywheel magnet assembly cover Grommet For installation, reverse the removal procedure.
Page 63: Medium-Pressure Fuel Line
FUEL MEDIUM-PRESSURE FUEL LINE MEDIUM-PRESSURE FUEL LINE REMOVING/INSTALLING THE MEDIUM-PRESSURE FUEL LINE 20 19 kgf, 7.2 ft 10 Nm (1.0 m • • 6 × 60 mm kgf, 2.2 ft 3 Nm (0.3 m • • 6 × 12 mm 6 ×...
Page 64 FUEL MEDIUM-PRESSURE FUEL LINE 20 19 kgf, 7.2 ft 10 Nm (1.0 m • • 6 × 60 mm kgf, 2.2 ft 3 Nm (0.3 m • • 6 × 12 mm 6 × 45 mm kgf, 5.8 ft 8 Nm (0.8 m 4010 •...
Page 65 FUEL MEDIUM-PRESSURE FUEL LINE 20 19 kgf, 7.2 ft 10 Nm (1.0 m • • 6 × 60 mm kgf, 2.2 ft 3 Nm (0.3 m • • 6 × 12 mm 6 × 45 mm kgf, 5.8 ft 8 Nm (0.8 m 4010 •...
Page 66: Reducing The Fuel Pressure (Medium-Pressure Fuel Line)
FUEL MEDIUM-PRESSURE FUEL LINE REDUCING THE FUEL PRESSURE (MEDIUM-PRESSURE FUEL LINE) WARNING Always reduce the fuel pressure in the medium-pressure fuel line before servicing the line or the vapor separator. If the fuel pressure is not released, pressurized fuel may spray out. 1.
Page 67: Disconnecting The Fuel Hose Joint
FUEL MEDIUM-PRESSURE FUEL LINE DISCONNECTING THE FUEL HOSE JOINT Disconnect: • Fuel hose joint 1 NOTE: Disconnect from the fuel strainer 2 the fuel hose with the collar a slid to the end b of the joint. 4063 CHECKING THE PRESSURE REGULATOR Check: •...
Page 68: Vapor Separator
FUEL VAPOR SEPARATOR VAPOR SEPARATOR REMOVING/INSTALLING THE VAPOR SEPARATOR 4 × 10 mm 6 × 35 mm 4090 Order Job/Part Q’ty Remarks Atmospheric pressure sensor Refer to “MEDIUM-PRESSURE FUEL coupler, electric oil pump LINE” on page 4-2. coupler, fuel inlet hose, fuel Before performing the following return hoses, electric oil pump procedure, reduce the fuel pressure...
Page 69 FUEL VAPOR SEPARATOR 4 × 10 mm 6 × 35 mm 4090 Order Job/Part Q’ty Remarks Small washer Vapor separator Collar Grommet Hose clamp Not reusable Fuel strainer Fuel hose Screw Fuel hose joint holder For installation, reverse the removal procedure.
Page 70: Removing The Hose Clamps
FUEL VAPOR SEPARATOR REMOVING THE HOSE CLAMPS Remove: • Hose clamps NOTE: Remove the hose clamps by cutting its joint. 4070 CAUTION: The fuel hose will be damaged if a hose clamps are removed without cutting the joint. INSTALLING THE HOSE CLAMPS Install: •...
Page 71: Disassembling/Assembling The Vapor Separator
FUEL VAPOR SEPARATOR DISASSEMBLING/ASSEMBLING THE VAPOR SEPARATOR 4 × 14 mm 4 Nm (0.4 m kgf, 2.9 ft • • 6 × 20 mm kgf, 5.8 ft 8 Nm (0.8 m • • 6 × 20 mm 4110 Order Job/Part Q’ty Remarks Screw...
Page 72 FUEL VAPOR SEPARATOR 4 × 14 mm 4 Nm (0.4 m kgf, 2.9 ft • • 6 × 20 mm kgf, 5.8 ft 8 Nm (0.8 m • • 6 × 20 mm 4110 Order Job/Part Q’ty Remarks O-ring Float chamber Electric fuel pump filter Rubber damper holder Rubber damper...
Page 73: Removing The Electric Fuel Pump Filter
FUEL VAPOR SEPARATOR REMOVING THE ELECTRIC FUEL PUMP FILTER Remove: • Electric fuel pump filter NOTE: To remove the electric fuel pump filter, turn it clockwise. 4120 INSTALLING THE ELECTRIC FUEL PUMP FILTER Install: • Rubber damper 1 • Rubber damper holder 2 •...
Page 74: Removing/Installing The Pressure Regulator
FUEL VAPOR SEPARATOR REMOVING/INSTALLING THE PRESSURE REGULATOR 6 × 14 mm 4100 Order Job/Part Q’ty Remarks Float chamber Refer to “DISASSEMBLING/ASSEMBLING THE VAPOR SEPARATOR” on page 4-10. Hose (vapor separator and pressure regulator- to-throttle body) Screw Pressure regulator O-ring Continued on next page. 4-13...
Page 75 FUEL VAPOR SEPARATOR 6 × 14 mm 4100 Order Job/Part Q’ty Remarks Filter Fuel return joint O-ring O-ring For installation, reverse the removal procedure. 4-14...
Page 76: Electric Fuel Pump
FUEL ELECTRIC FUEL PUMP ELECTRIC FUEL PUMP DISASSEMBLING/ASSEMBLING THE ELECTRIC FUEL PUMP 4150 Order Job/Part Q’ty Remarks Terminal cover Positive electric fuel pump (red lead) terminal cap Negative electric fuel pump (blue lead) terminal cap (M4) a = 7 mm Spring washer (M5) b = 8 mm Spring washer...
Page 77 FUEL ELECTRIC FUEL PUMP 4150 Order Job/Part Q’ty Remarks Negative electric fuel pump terminal O-ring Collar O-ring Electric fuel pump guide plate Electric fuel pump Coupler holder Terminal assembly Continued on next page. 4-16...
Page 78 FUEL ELECTRIC FUEL PUMP 4150 Order Job/Part Q’ty Remarks O-ring Insulator O-ring Screw Float pin Float Clip Needle valve For assembly, reverse the disassembly procedure. 4-17...
Page 79: Throttle Control Lever Cam
FUEL THROTTLE CONTROL LEVER CAM THROTTLE CONTROL LEVER CAM REMOVING/INSTALLING THE THROTTLE CONTROL LEVER CAM 4170 Order Job/Part Q’ty Remarks Throttle link rod Refer to “MEDIUM-PRESSURE FUEL LINE” on page 4-2. Throttle link Bolt Collar Wave washer Throttle control lever cam Washer For installation, reverse the removal procedure.
Page 80: Throttle Position Sensor And Air Temperature Sensor
THROTTLE POSITION SENSOR AND FUEL AIR TEMPERATURE SENSOR THROTTLE POSITION SENSOR AND AIR TEMPERATURE SENSOR REMOVING/INSTALLING THE THROTTLE POSITION SENSOR AND AIR TEMPERATURE SENSOR 4180 Order Job/Part Q’ty Remarks Screw Throttle position sensor Screw Washer Throttle position sensor bracket Collar Grommet Throttle position sensor cam Spring...
Page 81 THROTTLE POSITION SENSOR AND FUEL AIR TEMPERATURE SENSOR 4180 Order Job/Part Q’ty Remarks Washer Grommet Bolt Intake air temperature sensor bracket Bolt Engine hanger For installation, reverse the removal procedure. 4-20...
Page 82: Installing The Throttle Position Sensor
THROTTLE POSITION SENSOR AND FUEL AIR TEMPERATURE SENSOR INSTALLING THE THROTTLE POSITION SENSOR NOTE: During installation, make sure the throttle position sensor is properly adjusted. Install: • Throttle position sensor Refer to “ADJUSTING THE THROTTLE POSITION SENSOR” on page 3-8. 4-21...
Page 83: Drive Belt
FUEL DRIVE BELT DRIVE BELT REMOVING/INSTALLING THE DRIVE BELT kgf, 29 ft 40 Nm (4.0 m • • 10 × 45 mm 8 × 45 mm 2.0 mm (0.08 in) 8 × 12 mm 8 × 25 mm 4300 Order Job/Part Q’ty Remarks...
Page 84 FUEL DRIVE BELT kgf, 29 ft 40 Nm (4.0 m • • 10 × 45 mm 8 × 45 mm 2.0 mm (0.08 in) 8 × 12 mm 8 × 25 mm 4300 Order Job/Part Q’ty Remarks Tensioner bracket Bolt Drive sprocket plate Drive sprocket Dowel pin...
Page 85: Removing The Drive Sprocket
FUEL DRIVE BELT CAUTION: Do not loosen or tighten the drive sprocket bolt and driven sprocket nut when the drive belt is installed. REMOVING THE DRIVE SPROCKET 4310 Remove: • Drive sprocket Universal holder YU-01235 / 90890-01235 REMOVING THE DRIVEN SPROCKET Remove: •...
Page 86: Installing The Drive Sprocket
FUEL DRIVE BELT INSTALLING THE DRIVE SPROCKET 4310 Install: • Drive sprocket Universal holder YU-01235 / 90890-01235 INSTALLING THE DRIVE BELT Install: • Drive belt CAUTION: • Never forcefully twist, turn inside out, or bend the drive belt. • Do not let oil or grease get onto the drive 4330 belt.
Page 87: Injector Driver
FUEL INJECTOR DRIVER INJECTOR DRIVER REMOVING/INSTALLING THE INJECTOR DRIVER 6 × 12 mm 6 × 12 mm 6 × 35 mm 4340 Order Job/Part Q’ty Remarks Flywheel magnet assembly cover Refer to “FLYWHEEL MAGNET ASSEMBLY COVER” on page 4-1. Fuel rail cover Spark plug cap Ignition coil coupler Bolt...
Page 88 FUEL INJECTOR DRIVER 6 × 12 mm 6 × 12 mm 6 × 35 mm 4340 Order Job/Part Q’ty Remarks Upper wire harness holder Wire harness cover Bolt Injector driver assembly Injector driver coupler For installation, reverse the removal procedure. 4-27...
Page 89: Removing The Injector Driver Coupler
FUEL INJECTOR DRIVER REMOVING THE INJECTOR DRIVER COUPLER Remove: • Injector driver coupler NOTE: • Disconnect the injector driver coupler by pressing on the release plate part a and pressing up the lock plate b using both 4355 thumbs unit it stops. •...
Page 90: Disassembling/Assembling The Injector Driver
FUEL INJECTOR DRIVER DISASSEMBLING/ASSEMBLING THE INJECTOR DRIVER 5 × 20 mm 6 × 20 mm 4350 Order Job/Part Q’ty Remarks Bolt Injector driver Bolt Ignition coil Collar Collar Grommet Injector driver case For assembly, reverse the disassembly procedure. 4-29...
Page 91: High-Pressure Fuel Line Assembly
FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY HIGH-PRESSURE FUEL LINE ASSEMBLY REMOVING/INSTALLING THE HIGH-PRESSURE FUEL LINE ASSEMBLY 6 × 14 mm kgf, 17 ft 23 Nm (2.3 m • • 8 × 70 mm kgf, 17 ft 23 Nm (2.3 m • •...
Page 92 FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY 6 × 14 mm kgf, 17 ft 23 Nm (2.3 m • • 8 × 70 mm kgf, 17 ft 23 Nm (2.3 m • • 8 × 55 mm kgf, 19 ft 26 Nm (2.6m •...
Page 93 FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY 6 × 14 mm kgf, 17 ft 23 Nm (2.3 m • • 8 × 70 mm kgf, 17 ft 23 Nm (2.3 m • • 8 × 55 mm kgf, 19 ft 26 Nm (2.6m •...
Page 94: Disassembling/Assembling The High-Pressure Fuel Line Assembly
FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY DISASSEMBLING/ASSEMBLING THE HIGH-PRESSURE FUEL LINE ASSEMBLY 5 × 12 mm 8 × 45 mm 8 × 40 mm 6 × 16 mm 4370 Order Job/Part Q’ty Remarks Fuel injector holder Fuel injector Seal ring (thin) Not reusable O-ring Not reusable...
Page 95 FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY 5 × 12 mm 8 × 45 mm 8 × 40 mm 6 × 16 mm 4370 Order Job/Part Q’ty Remarks Fuel rail Seal ring (thin) Not reusable O-ring Not reusable Seal ring (thick) Not reusable Bolt Washer Collar...
Page 96 FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY 5 × 12 mm 8 × 45 mm 8 × 40 mm 6 × 16 mm 4370 Order Job/Part Q’ty Remarks Fuel feed hose joint Center fuel rail Screw Fuel feed hose guide O-ring Not reusable O-ring Not reusable Hose clamp...
Page 97: Removing The Hose Clamps
FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY REMOVING THE HOSE CLAMPS Remove: • Hose clamp NOTE: Remove the hose clamp by cutting its joint. CAUTION: 4070 The fuel hose will be damaged if a hose clamp is removed without cutting the joint. INSTALLING THE HOSE CLAMPS Install: •...
Page 98: Mechanical Fuel Pump
FUEL MECHANICAL FUEL PUMP MECHANICAL FUEL PUMP DISASSEMBLING/ASSEMBLING THE MECHANICAL FUEL PUMP BODY 6 × 35 mm 8 × 35 mm 8 × 30 mm 4380 6 × 16 mm Order Job/Part Q’ty Remarks Gear oil Refer to “CHANGING THE MECHANICAL FUEL PUMP OIL”...
Page 99 FUEL MECHANICAL FUEL PUMP 6 × 35 mm 8 × 35 mm 8 × 30 mm 4380 6 × 16 mm Order Job/Part Q’ty Remarks Mechanical fuel pump assembly Mechanical fuel pump body Joint plate O-ring Not reusable Bolt Mechanical fuel pump body cover Camshaft O-ring...
Page 100 FUEL MECHANICAL FUEL PUMP 6 × 35 mm 8 × 35 mm 8 × 30 mm 4380 6 × 16 mm Order Job/Part Q’ty Remarks Bolt Washer Collar Mechanical fuel pump regulator Bolt Washer Fuel return hose joint O-ring Not reusable For assembly, reverse the disassembly procedure.
Page 101: Disassembling/Assembling The Mechanical Fuel Pump Assembly
FUEL MECHANICAL FUEL PUMP DISASSEMBLING/ASSEMBLING THE MECHANICAL FUEL PUMP ASSEMBLY 6 × 45 mm 8 × 20 mm 8 × 45 mm 4390 Order Job/Part Q’ty Remarks Bolt Washer Fuel pressure sensor plate Fuel pressure sensor O-ring Not reusable Seal ring Not reusable Clip Fuel return hose...
Page 102 FUEL MECHANICAL FUEL PUMP 6 × 45 mm 8 × 20 mm 8 × 45 mm 4390 Order Job/Part Q’ty Remarks Fuel return hose (hose joint-to-mechanical fuel pump) Hose joint Bolt Bolt Washer Mechanical fuel pump cover Fuel return hose adaptor O-ring Not reusable O-ring...
Page 103 FUEL MECHANICAL FUEL PUMP 6 × 45 mm 8 × 20 mm 8 × 45 mm 4390 Order Job/Part Q’ty Remarks Outlet valve Mechanical fuel pump joint O-ring Not reusable Seal ring (thin) Not reusable O-ring Not reusable Seal ring (thick) Not reusable Mechanical fuel pump For assembly, reverse the disassembly...
Page 104: Low-Pressure Fuel Line
FUEL LOW-PRESSURE FUEL LINE LOW-PRESSURE FUEL LINE REMOVING/INSTALLING THE LOW-PRESSURE FUEL LINE 4190 Order Job/Part Q’ty Remarks Vapor separator Refer to “VAPOR SEPARATOR” on page 4-7. Bolt Bracket Bolt Holder Water detection switch coupler Bolt Bolt Gasket Not reusable Low-pressure fuel line For installation, reverse the removal procedure.
Page 105: Disassembling/Assembling The Low-Pressure Fuel Line
FUEL LOW-PRESSURE FUEL LINE DISASSEMBLING/ASSEMBLING THE LOW-PRESSURE FUEL LINE 4200 Order Job/Part Q’ty Remarks Plastic locking tie Not reusable Fuel hose (hose joint-to-fuel filter) Fuel filter Fuel hose (check valve-to-fuel filter) Check valve Fuel hose assembly (check valve-to-fuel pump) Fuel pump Fuel hose assembly (fuel pump-to-vapor separator) For assembly, reverse the disassembly...
Page 106: Checking The Check Valve
FUEL LOW-PRESSURE FUEL LINE CHECKING THE CHECK VALVE Check: • Check valve operation Damage/reverse air flow → Replace. Checking steps NOTE: Do not overpressurize the check valve. Excessive pressure may cause air to leak out. (1) Install the Mity vac onto the check valve as shown.
Page 107: Fuel Filter
FUEL FUEL FILTER FUEL FILTER DISASSEMBLING/ASSEMBLING THE FUEL FILTER 8 Nm (0.8 m kgf, 5.8 ft • • 6 × 16 mm 6 × 14 mm 4210 Order Job/Part Q’ty Remarks Bolt Washer Fuel filter nut holder Fuel filter nut Fuel filter cup/water detection switch assembly O-ring...
Page 108 FUEL FUEL FILTER 8 Nm (0.8 m kgf, 5.8 ft • • 6 × 16 mm 6 × 14 mm 4210 Order Job/Part Q’ty Remarks O-ring Spring Bolt Fuel filter bracket Collar Grommet Fuel filter cap For assembly, reverse the disassembly procedure.
Page 109: Fuel Pump
FUEL FUEL PUMP FUEL PUMP DISASSEMBLING/ASSEMBLING THE FUEL PUMP 4220 Order Job/Part Q’ty Remarks Screw Diaphragm body Diaphragm Gasket Not reusable Fuel pump base Gasket Not reusable Diaphragm Continued on next page. 4-48...
Page 110 FUEL FUEL PUMP 4220 Order Job/Part Q’ty Remarks Spring seat Spring Screw Fuel pump valve Fuel pump body For assembly, reverse the disassembly procedure. 4-49...
Page 111: Checking The Fuel Pumps
FUEL FUEL PUMP CHECKING THE FUEL PUMPS 1. Check: • Diaphragm • Fuel pump valves Damage → Replace. 2. Check: • Fuel pumps Reverse air flow → Replace. Checking steps NOTE: Do not overpressurize the fuel pump. Excessive pressure may cause air to leak out.
Page 112: Oil Injection System
FUEL OIL INJECTION SYSTEM OIL INJECTION SYSTEM REMOVING/INSTALLING THE OIL INJECTION SYSTEM 4250 Order Job/Part Q’ty Remarks Electric oil pump hose, electric Refer to “MEDIUM-PRESSURE FUEL oil pump coupler and electric oil LINE” on page 4-2. pump assembly Junction box assembly Refer to “JUNCTION BOX ASSEMBLY”...
Page 113 FUEL OIL INJECTION SYSTEM 4250 Order Job/Part Q’ty Remarks Emergency switch connector Clip Plastic washer Oil pump link rod Bolt O-ring Bolt Clamp Oil injection system assembly For installation, reverse the removal procedure. 4-52...
Page 114: Disassembling/Assembling The Oil Injection System
FUEL OIL INJECTION SYSTEM DISASSEMBLING/ASSEMBLING THE OIL INJECTION SYSTEM 4260 Order Job/Part Q’ty Remarks Oil tank air vent hose (oil tank-to-intake silencer) Plastic locking tie Not reusable Oil hose (sub oil tank-to-oil tank) Oil hose (oil tank-to-oil pump) Oil tank assembly Oil hose joint Clip Oil hose...
Page 115 FUEL OIL INJECTION SYSTEM 4260 Order Job/Part Q’ty Remarks Check valve Electric oil pump Metal clamp Electric oil pump hose (electric oil pump-to-vapor separator) Check valve Oil feed hose (oil pump-to-crankcase) Oil pump For assembly, reverse the disassembly procedure. 4-54...
Page 116: Checking The Check Valve
FUEL OIL INJECTION SYSTEM CHECKING THE CHECK VALVE Check: • Check valve operation Damage/reverse air flow → Replace. Checking steps NOTE: Do not overpressurize the check valve. Excessive pressure may cause air to leak out. (1) Install the Mity vac onto the check valve as shown.
Page 117: Oil Tank
FUEL OIL TANK OIL TANK DISASSEMBLING/ASSEMBLING THE OIL TANK 4270 Order Job/Part Q’ty Remarks Oil level sensor Oil strainer Washer Oil tank Cap nut Emergency switch Collar Grommet For assembly, reverse the disassembly procedure. 4-56...
Page 118: Powr
POWR CHAPTER 5 POWER UNIT FLYWHEEL MAGNET ASSEMBLY ..............5-1 REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY ..5-1 REMOVING THE FLYWHEEL MAGNET ASSEMBLY ......5-2 INSTALLING THE FLYWHEEL MAGNET ASSEMBLY ......5-3 POWER UNIT ....................5-4 DISCONNECTING/CONNECTING THE LEADS ........5-4 DISCONNECTING/CONNECTING THE HOSES........
Page 119 POWR REED VALVES ....................5-32 REMOVING/INSTALLING THE REED VALVES........5-32 CHECKING THE REED VALVE ASSEMBLY .......... 5-34 EXTERNAL FITTINGS................... 5-35 REMOVING/INSTALLING THE EXTERNAL FITTINGS......5-35 CYLINDER HEAD COVERS ................5-38 REMOVING/INSTALLING THE CYLINDER HEAD COVERS....5-38 CHECKING THE THERMOSTATS............5-40 CYLINDER HEADS..................
Page 120 POWR FLYWHEEL MAGNET ASSEMBLY FLYWHEEL MAGNET ASSEMBLY REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY 5010 Order Job/Part Q’ty Remarks Drive sprocket Refer to “DRIVE BELT” on page 4-22. Bolt Drive sprocket bracket Flywheel magnet assembly nut Washer Flywheel magnet assembly Woodruff key For installation, reverse the removal procedure.
Page 121: Flywheel Magnet Assembly
POWR FLYWHEEL MAGNET ASSEMBLY REMOVING THE FLYWHEEL MAGNET Å ASSEMBLY Remove: • Flywheel magnet assembly Removing steps (1) Remove the flywheel magnet assem- bly nut. 5020 Flywheel magnet assembly holder ı YB-06139 / 90890-06522 Å For USA and Canada ı For worldwide NOTE: The major load should be applied in the direction of the arrows.
Page 122: Installing The Flywheel Magnet Assembly
POWR FLYWHEEL MAGNET ASSEMBLY INSTALLING THE FLYWHEEL Å MAGNET ASSEMBLY Install: • Flywheel magnet assembly nut Flywheel magnet assembly holder YB-06139 / 90890-06522 5060 Å For USA and Canada ı For worldwide ı NOTE: The major load should be applied in the direction of the arrows.
Page 123: Power Unit
POWR POWER UNIT POWER UNIT DISCONNECTING/CONNECTING THE LEADS 5080 Order Job/Part Q’ty Remarks Battery leads 1 (from the battery) Remote control shift and throttle rods and cables 2 Bolt Negative battery lead Positive battery lead Screw Junction box cover Continued on next page.
Page 124 POWR POWER UNIT 5080 Order Job/Part Q’ty Remarks Bolt Power trim and tilt lead (blue) Power trim and tilt lead (green) Trim sensor coupler and connector Shift position switch coupler Clip Shift rod lever bushing For installation, reverse the removal procedure.
Page 125: Disconnecting/Connecting The Hoses
POWR POWER UNIT DISCONNECTING/CONNECTING THE HOSES 5090 Order Job/Part Q’ty Remarks Plastic locking tie Not reusable Oil hose (oil tank-to-sub-oil tank) Pilot water hose (pilot water outlet-to-rectifier/regulator) Fuel hose (fuel filter-to-hose joint) Bolt Cable guide Trailer switch coupler Bolt Shift rod assembly For installation, reverse the removal procedure.
Page 126: Removing/Installing The Exhaust Expansion Chamber
POWR POWER UNIT REMOVING/INSTALLING THE EXHAUST EXPANSION CHAMBER 5095 Order Job/Part Q’ty Remarks Screw Bolt Bolt Apron Collar Hose joint Rubber seal Bolt Continued on next page.
Page 127 POWR POWER UNIT 5095 Order Job/Part Q’ty Remarks Exhaust expansion chamber Exhaust expansion chamber hose Rubber seal Rubber seal Clip Cooling water hose (exhaust manifold-to-power unit) For installation, reverse the removal procedure.
Page 128: Installing The Apron
POWR POWER UNIT INSTALLING THE APRON 1. Install: • Hose joint NOTE: First insert the hose joint 1 in the exhaust expansion chamber hose 2, and then insert the apron securely in the hose joint. 5096 2. Install: • Apron CAUTION: Make sure not to get the flushing hose 1 caught between the mating surfaces a of...
Page 129: Removing/Installing The Power Unit
POWR POWER UNIT REMOVING/INSTALLING THE POWER UNIT 5100 Order Job/Part Q’ty Remarks Bolt Bolt Power unit Gasket Not reusable Dowel pin For installation, reverse the removal procedure. 5-10...
Page 130: Suspending The Power Unit
POWR POWER UNIT SUSPENDING THE POWER UNIT CAUTION: Make sure to use engine hangers in three different areas when suspending the power unit as shown. If the engine hangers are not used correctly the power unit will not be balanced, which could result in serious 5105 injury or death.
Page 131: Stator Assembly
POWR STATOR ASSEMBLY STATOR ASSEMBLY REMOVING/INSTALLING THE STATOR ASSEMBLY 5110 Order Job/Part Q’ty Remarks Flywheel magnet assembly Refer to “FLYWHEEL MAGNET ASSEMBLY” on page 5-1. Plastic locking tie Not reusable Crank position sensor coupler Screw Crank position sensor Refer to “ADJUSTING THE CRANK POSITION SENSOR”...
Page 132 POWR STATOR ASSEMBLY 5110 Order Job/Part Q’ty Remarks Bolt Stator assembly holder Stator assembly Pulser coil coupler Screw Pulser coil assembly For installation, reverse the removal procedure. 5-13...
Page 133: Control Unit
POWR CONTROL UNIT CONTROL UNIT REMOVING/INSTALLING THE CONTROL UNIT ASSEMBLY 5120 Order Job/Part Q’ty Remarks High-pressure fuel line assembly Refer to “HIGH-PRESSURE FUEL LINE ASSEMBLY” on page 4-30. Bolt Control unit coupler guide Control unit coupler Bolt Control unit case Continued on next page.
Page 134 POWR CONTROL UNIT 5120 Order Job/Part Q’ty Remarks Collar Collar Grommet Bolt Control unit For installation, reverse the removal procedure. 5-15...
Page 135: Fuse Holder
POWR FUSE HOLDER FUSE HOLDER REMOVING/INSTALLING THE FUSE HOLDER 5130 Order Job/Part Q’ty Remarks Junction box cover Refer to “POWER UNIT” on page 5-4. Fuel holder cover Screw Grommet holder Grommet Screw Fuse holder assembly Fuse holder coupler Plastic locking tie Not reusable For installation, reverse the removal procedure.
Page 136: Disassembling/Assembling The Fuse Holder
POWR FUSE HOLDER DISASSEMBLING/ASSEMBLING THE FUSE HOLDER 3 × 10 mm 5 × 10 mm 5135 Order Job/Part Q’ty Remarks Fuse (20A) Fuse (30A) Screw Fuse (80A) Screw Fuse holder Terminal (big) Terminal (small) Driver relay Main relay Terminal plate For assembly, reverse the disassembly procedure.
Page 137: Junction Box Assembly
POWR JUNCTION BOX ASSEMBLY JUNCTION BOX ASSEMBLY REMOVING/INSTALLING THE JUNCTION BOX ASSEMBLY 9 Nm (0.9 m • kgf, 6.5 ft • Ib) 5140 Order Job/Part Q’ty Remarks Pilot water hose Refer to “POWER UNIT” on page 5-4. Fuse holder coupler Refer to “FUSE HOLDER”...
Page 138 POWR JUNCTION BOX ASSEMBLY 5150 Order Job/Part Q’ty Remarks Power trim and tilt lead (green) Power trim and tilt lead (blue) Lighting coil coupler Oxygen density sensor coupler (blue) Starter motor lead Starter relay connector Power trim and tilt relay coupler Fuse holder coupler Continued on next page.
Page 139 POWR JUNCTION BOX ASSEMBLY 5150 Order Job/Part Q’ty Remarks Fuse holder connector Bolt Ground lead Bolt Ground lead Ground lead plate Bolt Junction box assembly For installation, reverse the removal procedure. 5-20...
Page 140: Disassembling/Assembling The Junction Box Assembly
POWR JUNCTION BOX ASSEMBLY DISASSEMBLING/ASSEMBLING THE JUNCTION BOX ASSEMBLY 5160 Order Job/Part Q’ty Remarks Screw Starter relay holder Starter relay Bolt Power trim and tilt relay Bolt Rectifier/regulator Bolt Rectifier/regulator cover Gasket Not reusable Clip Continued on next page. 5-21...
Page 141 POWR JUNCTION BOX ASSEMBLY 5160 Order Job/Part Q’ty Remarks Cooling water hose (rectifier/regulator-to-exhaust outer cover) Cooling water hose (rectifier/regulator-to-pilot water outlet) Clamp Clamp Fuse holder cover hook Collar Collar Grommet Junction box For assembly, reverse the disassembly procedure. 5-22...
Page 142: Wire Harnesses
POWR WIRE HARNESSES WIRE HARNESSES REMOVING/INSTALLING THE MAIN WIRE HARNESS ⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄ 6 × 12 mm 5170 Order Job/Part Q’ty Remarks Oil level sensor coupler 1 and Refer to “OIL INJECTION SYSTEM” on emergency switch connector 2 page 4-51. Remote control cables Trim sensor connector 3, shift Refer to “POWER UNIT”...
Page 143 POWR WIRE HARNESSES ⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄ 6 × 12 mm 5170 Order Job/Part Q’ty Remarks Thermo switch connector Bolt Ground lead For installation, reverse the removal procedure. 5-24...
Page 144: Removing/Installing The Sub Wire Harness
POWR WIRE HARNESSES REMOVING/INSTALLING THE SUB WIRE HARNESS 5175 Order Job/Part Q’ty Remarks Throttle position sensor coupler Refer to “MEDIUM-PRESSURE FUEL 1, atmospheric pressure sensor LINE” on page 4-2. coupler 2 and intake air temperature sensor coupler 3 Fuel pressure sensor coupler 4 Refer to “HIGH-PRESSURE FUEL LINE ASSEMBLY”...
Page 145: Removing/Installing The Injector Wire Harness
POWR WIRE HARNESSES REMOVING/INSTALLING THE INJECTOR WIRE HARNESS ⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄⁄⁄ 6 × 12 mm 5180 Order Job/Part Q’ty Remarks Electric oil pump coupler 1 and Refer to “MEDIUM-PRESSURE FUEL electric fuel pump connectors 2 LINE” on page 4-2. Ignition coil couplers 3 and Refer to “INJECTOR DRIVER”...
Page 146 POWR WIRE HARNESSES ⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄⁄⁄ 6 × 12 mm 5180 Order Job/Part Q’ty Remarks Oxygen density sensor coupler Refer to “JUNCTION BOX ASSEMBLY” (blue) 9, fuse holder coupler 0 on page 5-18. and fuse holder connector A Bolt Ground lead For installation, reverse the removal...
Page 147: Starter Motor
POWR STARTER MOTOR STARTER MOTOR REMOVING/INSTALLING THE STARTER MOTOR 5190 Order Job/Part Q’ty Remarks Positive battery lead Refer to “POWER UNIT” on page 5-4. Power trim and tilt lead (red) and Refer to “JUNCTION BOX ASSEMBLY” starter motor lead on page 5-18. Bolt Starter motor For installation, reverse the removal...
Page 148: Oxygen Density Sensor
POWR OXYGEN DENSITY SENSOR OXYGEN DENSITY SENSOR REMOVING/INSTALLING THE OXYGEN DENSITY SENSOR 5200 Order Job/Part Q’ty Remarks Plastic locking tie Not reusable Rubber cap Bolt Oxygen density sensor cover Bolt Bolt Bolt Continued on next page. 5-29...
Page 149 POWR OXYGEN DENSITY SENSOR 5200 Order Job/Part Q’ty Remarks Oxygen density sensor assembly Gasket set Not reusable Oxygen density sensor bracket Oxygen density sensor Refer to “CHECKING THE OXYGEN DENSITY SENSOR” on page 8-25. Oxygen density sensor joint For installation, reverse the removal procedure.
Page 150: Installing The Oxygen Density Sensor
POWR OXYGEN DENSITY SENSOR INSTALLING THE OXYGEN DENSITY SENSOR Install: • Bolts 1 2 3 Bolt 14 Nm (1.4 m • kgf, 10 ft • lb) 5205 NOTE: Make sure to tighten bolts 1, 2, and 3 to the specified torque, in numerical order. 5-31...
Page 151 POWR REED VALVES REED VALVES REMOVING/INSTALLING THE REED VALVES 5210 Order Job/Part Q’ty Remarks Fuel injection unit Refer to “MEDIUM-PRESSURE FUEL LINE” on page 4-2. Recirculation hose Bolt Gasket Not reusable Intake manifold Screw Gasket Not reusable Reed valve assembly Continued on next page.
Page 152 POWR REED VALVES 5210 Order Job/Part Q’ty Remarks Screw Reed valve stopper Metal reed Reed valve seat For installation, reverse the removal procedure. 5-33...
Page 153: Reed Valves
POWR REED VALVES CHECKING THE REED VALVE ASSEMBLY 1. Check: • Reed valve Cracks/damage → Replace. 2. Measure: • Warpage limit a Out of specification → Replace. Warpage limit 0.2 mm (0.008 in) 5220 3. Measure: • Reed valve stopper height a Out of specification →...
Page 154: External Fittings
POWR EXTERNAL FITTINGS EXTERNAL FITTINGS REMOVING/INSTALLING THE EXTERNAL FITTINGS 5240 Order Job/Part Q’ty Remarks Fuel injection unit Refer to “MEDIUM-PRESSURE FUEL LINE” on page 4-2. High-pressure fuel line assembly Refer to “HIGH-PRESSURE FUEL LINE ASSEMBLY” on page 4-30. Low-pressure fuel line Refer to “LOW-PRESSURE FUEL LINE”...
Page 155 POWR EXTERNAL FITTINGS 5240 Order Job/Part Q’ty Remarks Starter motor Refer to “STARTER MOTOR” on page 5-28. Bolt Collar Wave washer Throttle control lever Throttle control rod Washer Screw Shift position switch holder Shift position switch Continued on next page. 5-36...
Page 156 POWR EXTERNAL FITTINGS 5245 Order Job/Part Q’ty Remarks Bolt Stopper screw assembly Shift rod lever bracket Bolt High-pressure fuel line assembly bracket Collar Hose clamp Recirculation hose Bolt Ground lead For installation, reverse the removal procedure. 5-37...
Page 157: Cylinder Head Covers
POWR CYLINDER HEAD COVERS CYLINDER HEAD COVERS REMOVING/INSTALLING THE CYLINDER HEAD COVERS 5 Nm (0.5 m • kgf, 3.6 ft • Ib) 2nd 11 Nm (1.1 m • kgf, 8.0 ft • Ib) 6 × 40 mm kgf, 18 ft 25 Nm (2.5 m •...
Page 158 POWR CYLINDER HEAD COVERS 5 Nm (0.5 m • kgf, 3.6 ft • Ib) 2nd 11 Nm (1.1 m • kgf, 8.0 ft • Ib) 6 × 40 mm kgf, 18 ft 25 Nm (2.5 m • • 5 Nm (0.5 m • kgf, 3.6 ft • Ib) 2nd 11 Nm (1.1 m •...
Page 159: Checking The Thermostats
POWR CYLINDER HEAD COVERS CHECKING THE THERMOSTATS 1. Check: • Thermostat Damage/valve does not open → Replace. 2. Measure: • Thermostat opening temperature • Valve lift a 5260 Out of specification → Replace. Water temperature Valve lift Below 48 - 52 ˚C 0 mm (118 - 126 ˚F) (0 in)
Page 160: Cylinder Heads
POWR CYLINDER HEADS CYLINDER HEADS REMOVING/INSTALLING THE CYLINDER HEADS 6 × 20 mm 5 × 12 mm 6 × 20 mm 15 Nm (1.5 m • kgf, 11 ft • Ib) 2nd 30 Nm (3.0 m • kgf, 22 ft • Ib) 8 ×...
Page 161 POWR CYLINDER HEADS 6 × 20 mm 5 × 12 mm 6 × 20 mm 15 Nm (1.5 m • kgf, 11 ft • Ib) 2nd 30 Nm (3.0 m • kgf, 22 ft • Ib) 8 × 60 mm 4 ×...
Page 162: Checking The Cylinder Heads
POWR CYLINDER HEADS CHECKING THE CYLINDER HEADS 1. Check: • Combustion chamber Carbon deposits → Clean. • Water jacket Mineral deposits/rust→ Clean. CAUTION: 5265 Do not scratch the contacting surfaces of the cylinder head and cylinder head cover. 2. Measure: •...
Page 163: Exhaust Covers
POWR EXHAUST COVERS EXHAUST COVERS REMOVING/INSTALLING THE EXHAUST COVERS 6 × 20 mm 4 Nm (0.4 m • kgf, 2.9 ft • Ib) 2nd 8 Nm (0.8 m • kgf, 5.8 ft • Ib) 6 × 30 mm 4 Nm (0.4 m • kgf, 2.9 ft • Ib) 2nd 8 Nm (0.8 m •...
Page 164 POWR EXHAUST COVERS 6 × 20 mm 4 Nm (0.4 m • kgf, 2.9 ft • Ib) 2nd 8 Nm (0.8 m • kgf, 5.8 ft • Ib) 6 × 30 mm 4 Nm (0.4 m • kgf, 2.9 ft • Ib) 2nd 8 Nm (0.8 m •...
Page 165: Checking The Pressure Control Valve
POWR EXHAUST COVERS CHECKING THE PRESSURE CONTROL VALVE Check: • Pressure control valve seat 1 • Pressure control valve 2 • Pressure control valve cover 3 Cracks/damage → Replace any defec- tive parts. 5310 • Spring 4 Damage/wear → Replace. 5-46...
Page 166: Crankcase
POWR CRANKCASE CRANKCASE REMOVING/INSTALLING THE CRANKCASE 5320 Order Job/Part Q’ty Remarks Flywheel magnet assembly Refer to “FLYWHEEL MAGNET ASSEMBLY” on page 5-1. Power unit Refer to “POWER UNIT” on page 5-4. Pulser coil assembly Refer to “STATOR ASSEMBLY” on page 5-12. Intake manifold Refer to “REED VALVES”...
Page 167 POWR CRANKCASE 5320 Order Job/Part Q’ty Remarks Bolt Bolt Crankcase Oil seal housing O-ring Oil seal Dowel pin For installation, reverse the removal procedure. 5-48...
Page 168: Assembling The Oil Seal Housing
POWR CRANKCASE ASSEMBLING THE OIL SEAL Å HOUSING Install: • Oil seal Bearing/oil seal attachment ..1 YB-06195 / 90890-06637 90890-06631 Driver rod ........2 5330 YB-06071 / 90890-06606 ı Å For USA and Canada ı For worldwide 5340 INSTALLING THE CRANKCASE Apply: ®...
Page 169: Cylinder Body Assembly
POWR CYLINDER BODY ASSEMBLY CYLINDER BODY ASSEMBLY DISASSEMBLING/ASSEMBLING THE CYLINDER BODY ASSEMBLY 5360 Order Job/Part Q’ty Remarks Cylinder heads Refer to “CYLINDER HEAD COVERS” on page 5-38. Crankcase Refer to “CRANKCASE” on page 5-47. Upper bearing housing Oil seal O-ring Needle bearing Connecting rod bolt Connecting rod cap...
Page 170 POWR CYLINDER BODY ASSEMBLY 5360 Order Job/Part Q’ty Remarks Big-end bearing Piston/connecting rod assembly Crankshaft assembly Clip Main journal bearing Screw Anode Bolt Lead holder Continued on next page. *: Loosen 5-51...
Page 171 POWR CYLINDER BODY ASSEMBLY 5360 Order Job/Part Q’ty Remarks Cylinder cover Gasket Not reusable Bolt Damper bracket Oil pump driven gear Cylinder body For assembly, reverse the disassembly procedure. *: Loosen 5-52...
Page 172: Disassembling/Assembling The Piston And Connecting Rod Assemblies
POWR CYLINDER BODY ASSEMBLY DISASSEMBLING/ASSEMBLING THE PISTON AND CONNECTING ROD ASSEMBLIES 5370 Order Job/Part Q’ty Remarks Piston pin clip Not reusable Piston pin Piston Washer Small-end bearing Top piston ring 2nd piston ring Connecting rod For assembly, reverse the disassembly procedure.
Page 173: Disassembling/Assembling The Crankshaft Assembly
POWR CYLINDER BODY ASSEMBLY DISASSEMBLING/ASSEMBLING THE CRANKSHAFT ASSEMBLY 5600 Order Job/Part Q’ty Remarks Labyrinth ring Circlip Ball bearing Oil pump drive gear Crankshaft For assembly, reverse the disassembly procedure. 5-54...
Page 174: Disassembling The Upper Bearing Housing
POWR CYLINDER BODY ASSEMBLY DISASSEMBLING THE UPPER Å BEARING HOUSING Remove: • Needle bearing Needle bearing attachment..1 YB-06205 / 90890-06663 Driver rod ........2 90890-06606 5390 Å For USA and Canada ı ı For worldwide 5400 REMOVING THE BEARING AND OIL PUMP DRIVE GEAR Remove: •...
Page 175: Checking The Cylinder Body
POWR CYLINDER BODY ASSEMBLY CHECKING THE CYLINDER BODY 1. Check: • Cylinder sleeves Cracks/score marks → Replace. • Cylinder body water jacket Mineral deposits/rust → Clean. CAUTION: Do not scratch the contacting surfaces of the crankcase and cylinder head. 2. Check: •...
Page 176: Checking The Pistons
POWR CYLINDER BODY ASSEMBLY CHECKING THE PISTONS Measure: • Piston diameter (with a micrometer) Out of specification → Replace. Measuring Piston diameter point “H” 5440 10 mm 89.845 - 89.869 mm Standard (0.4 in) (3.5372 - 3.5381 in) Oversize piston diameter 1st oversize* 90.11 mm (3.548 in) 2nd oversize...
Page 177: Checking The Piston Pins And Small-End Bearings
POWR CYLINDER BODY ASSEMBLY CHECKING THE PISTON PINS AND SMALL-END BEARINGS 1. Check: • Piston pin • Small-end bearing Heat discoloration → Replace. Damage/scratches → Replace. 2. Measure: • Piston pin diameter (with a micrometer) Out of specification → Replace. Piston pin diameter 23.065 - 23.070 mm (0.9081 - 0.9083 in)
Page 178: Checking The Oil Pump Driven Gear
POWR CYLINDER BODY ASSEMBLY 1. Measure: • Piston ring end gap a (with a thickness gauge) Out of specification → Replace. Piston ring end gap 0.30 - 0.40 mm (0.012 - 0.016 in) Piston ring end gap limit 0.60 mm (0.024 in) Measuring point “H”...
Page 179: Checking The Labyrinth Rings
POWR CYLINDER BODY ASSEMBLY CHECKING THE LABYRINTH RINGS 1. Check: • Labyrinth ring 1 Cracks/damage/wear → Replace. 2. Measure: • Labyrinth ring wear a or b + c Out of specification → Replace. Labyrinth ring wear limit 5620 0.10 mm (0.004 in) CHECKING THE CRANKSHAFT 1.
Page 180: Installing The Oil Pump Drive Gear
POWR CYLINDER BODY ASSEMBLY INSTALLING THE OIL PUMP DRIVE GEAR Install: • Oil pump drive gear Bearing separator ..... 1 YB-06219 / 90890-06534 Bearing/oil seal attachment ..2 90890-06661 5660 90890-06622 INSTALLING THE BEARING Install: • Bearing Bearing separator ..... 1 YB-06219 / 90890-06534 Bearing/oil seal attachment ..
Page 181: Assembling The Upper Bearing Housing
The washers must be installed with their convex sides facing towards the piston. NOTE: The embossed YAMAHA mark a on the connecting rod must face the same direc- tion as the “UP” mark on the piston. ASSEMBLING THE UPPER BEARING HOUSING 1.
Page 182: Installing The Crankshaft Assembly
POWR CYLINDER BODY ASSEMBLY INSTALLING THE CRANKSHAFT ASSEMBLY Install: • Cylinder body • Crankshaft assembly NOTE: • Align the crankshaft labyrinth ring end gaps with their respective locating pins. • Install the bearing locating pins into the cylinder body. 5570 INSTALLING THE PISTON AND CONNECTING ROD ASSEMBLIES Install:...
Page 184: Lowr
LOWR CHAPTER 6 LOWER UNIT LOWER UNIT (REGULAR ROTATION MODELS) ......... 6-1 REMOVING/INSTALLING THE LOWER UNIT ........6-1 REMOVING THE PROPELLER ..............6-3 REMOVING THE TRIM TAB..............6-3 CHECKING THE PROPELLER..............6-3 INSTALLING THE PROPELLER..............6-4 WATER PUMP (REGULAR ROTATION MODELS)........6-5 REMOVING/INSTALLING THE WATER PUMP........
Page 185 DRIVE SHAFT (REGULAR ROTATION MODELS)........6-19 REMOVING/INSTALLING THE DRIVE SHAFT........6-19 REMOVING THE PINION ............... 6-21 DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ... 6-21 DISASSEMBLING THE FORWARD GEAR ASSEMBLY ....... 6-21 CHECKING THE PINION ................ 6-22 CHECKING THE DRIVE SHAFT.............. 6-22 CHECKING THE DRIVE SHAFT HOUSING ...........
Page 186 LOWR PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS).............. 6-38 REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY.................... 6-38 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY................6-39 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY.................... 6-41 REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY.... 6-42 REMOVING THE PROPELLER SHAFT ASSEMBLY......6-42 DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY....................
Page 187 LOWR SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA) ................6-55 SELECTING THE PINION SHIMS ............6-56 SELECTING THE FORWARD GEAR SHIMS ......... 6-58 SELECTING THE REVERSE GEAR SHIMS..........6-60 SHIMMING (REGULAR ROTATION MODELS) (FOR WORLDWIDE) ..6-62 SELECTING THE PINION SHIMS ............6-63 SELECTING THE FORWARD GEAR SHIMS .........
Page 188 LOWR LOWER UNIT (REGULAR ROTATION MODELS) LOWER UNIT (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE LOWER UNIT 6010 Order Job/Part Q’ty Remarks Speedometer hose Cotter pin Propeller nut Washer Washer Propeller Spacer Continued on next page.
Page 189 LOWR LOWER UNIT (REGULAR ROTATION MODELS) 6010 Order Job/Part Q’ty Remarks Bolt Trim tab Bolt Bolt Lower unit Dowel pin Exhaust seal For installation, reverse the removal procedure.
Page 190: Lower Unit (Regular Rotation Models)
LOWR LOWER UNIT (REGULAR ROTATION MODELS) REMOVING THE PROPELLER Remove: • Propeller nut WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries 6016 and the lanyard engine stop switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning.
Page 191: Installing The Propeller
LOWR LOWER UNIT (REGULAR ROTATION MODELS) INSTALLING THE PROPELLER Install: • Propeller nut Propeller nut 55 Nm (5.5 m • kgf, 40 ft • lb) WARNING 6017 Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries and the lanyard engine stop switch.
Page 192 LOWR WATER PUMP (REGULAR ROTATION MODELS) WATER PUMP (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE WATER PUMP 6020 Order Job/Part Q’ty Remarks Lower unit Refer to “LOWER UNIT (REGULAR ROTATION MODELS)” on page 6-1. Bolt Plate washer Impeller housing Impeller housing cup Grommet Spacer Collar...
Page 193 LOWR WATER PUMP (REGULAR ROTATION MODELS) 6020 Order Job/Part Q’ty Remarks Spacer Washer Wave washer Impeller Woodruff key Impeller plate Gasket Not reusable Dowel pin For installation, reverse the removal procedure.
Page 194: Water Pump (Regular Rotation Models)
LOWR WATER PUMP (REGULAR ROTATION MODELS) CHECKING THE IMPELLER HOUSING Check: • Impeller housing Cracks/damage → Replace. CHECKING THE IMPELLER AND IMPELLER HOUSING CUP Check: • Impeller • Impeller housing cup Cracks/damage → Replace any defec- tive parts. CHECKING THE WOODRUFF KEY Check: •...
Page 195 LOWR WATER PUMP (REGULAR ROTATION MODELS) 2. Install: • O-ring 1 • Impeller housing cup 2 • Impeller housing 3 • O-ring 4 NOTE: • When installing the impeller housing cup, align its projection with the hole in the 6030 impeller housing.
Page 196: Shift Rod Assembly (Regular Rotation Models)
SHIFT ROD ASSEMBLY LOWR (REGULAR ROTATION MODELS) SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY 6035 Order Job/Part Q’ty Remarks Impeller plate Refer to “WATER PUMP (REGULAR ROTATION MODELS)” on page 6-5. Bolt (with plate washer) Shift rod assembly Oil seal housing Oil seal Spring...
Page 197: Removing The Shift Rod Assembly
SHIFT ROD ASSEMBLY LOWR (REGULAR ROTATION MODELS) REMOVING THE SHIFT ROD ASSEMBLY Remove: • Shift rod assembly NOTE: Remove the shift rod assembly when the shift rod is in the neutral position. 6-10...
Page 198: Propeller Shaft Housing Assembly (Regular Rotation Models)
PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6040 Order Job/Part Q’ty Remarks Gear oil Refer to “CHANGING AND CHECKING THE GEAR OIL” on page 3-17. Shift rod assembly Refer to “SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS)”...
Page 199 PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) 6040 Order Job/Part Q’ty Remarks Reverse gear shim Propeller shaft assembly Washer Propeller shaft housing For installation, reverse the removal procedure. *: As required 6-12...
Page 200: Disassembling/Assembling The Propeller Shaft Housing
PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING 6045 Order Job/Part Q’ty Remarks O-ring Reverse gear Thrust washer Ball bearing Oil seal Needle bearing Propeller shaft housing For assembly, reverse the disassembly procedure. 6-13...
Page 201 PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY 6100 Order Job/Part Q’ty Remarks Spring Dog clutch Shift rod joint Shift rod joint slider Ball Spring Ball Propeller shaft For assembly, reverse the disassembly procedure. 6-14...
Page 202 PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY 1. Straighten: • Claw washer tabs 2. Remove: • Ring nut • Claw washer Ring nut wrench ....... 1 6050 YB-34447 / 90890-06512 Ring nut wrench extension ..2 Å...
Page 203: Checking The Reverse Gear
PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) 2. Remove: Å • Ball bearing Slide hammer......1 YB-06096 Guide plate........ 2 90890-06501 Guide plate stand ..... 3 90890-06538 Bearing puller......4 6070 90890-06535 Small universal claws ....5 ı 90890-06536 Å...
Page 204: Checking The Dog Clutch
PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) CHECKING THE DOG CLUTCH Check: • Dog clutch Damage/wear → Replace. CHECKING THE PROPELLER SHAFT Check: • Propeller shaft Damage/wear → Replace. ASSEMBLING THE PROPELLER Å SHAFT HOUSING 1. Install: • Needle bearing Needle bearing installation position a 24.75 - 25.25 mm...
Page 205: Installing The Propeller Shaft Housing Assembly
PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY Install: • Reverse gear shim(s) • Propeller shaft housing assembly • Straight key • Claw washer • Ring nut 6095 Ring nut wrench ....... 1 YB-34447 / 90890-06512 Ring nut wrench extension ..
Page 206: Drive Shaft (Regular Rotation Models)
LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) DRIVE SHAFT (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE DRIVE SHAFT 6105 Order Job/Part Q’ty Remarks Propeller shaft housing assembly Refer to “PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)” on page 6-11. Pinion nut Pinion Bolt Drive shaft housing assembly Pinion shim Thrust bearing...
Page 207 LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) 6105 Order Job/Part Q’ty Remarks Forward gear assembly O-ring Oil seal cover Oil seal Needle bearing Drive shaft housing Tapered roller bearing Not reusable Needle bearing Forward gear For installation, reverse the removal procedure. 6-20...
Page 208: Removing The Pinion
LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) REMOVING THE PINION Remove: • Pinion nut • Pinion Drive shaft holder ..... 1 YB-06201 / 90890-06520 Pinion nut holder ...... 2 90890-06505 6110 Pinion nut holder attachment . 3 90890-06508 DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY Remove: •...
Page 209: Checking The Pinion
LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) CHECKING THE PINION Check: • Teeth Damage/wear → Replace. CHECKING THE DRIVE SHAFT Check: • Drive shaft Damage/wear → Replace. CHECKING THE DRIVE SHAFT HOUSING Check: • Drive shaft housing Cracks/damage → Replace. CHECKING THE BEARINGS Check: •...
Page 210: Assembling The Drive Shaft Housing Assembly
LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) 2. Install: • Tapered roller bearing Bearing/oil seal attachment 90890-06659 6155 ASSEMBLING THE DRIVE SHAFT Å HOUSING ASSEMBLY 1. Install: • Needle bearing Position a 5.75 - 6.25 mm (0.226 - 0.246 in) Bearing/oil seal attachment ..1 6125 YB-06196 / 90890-06610 Driver rod ........
Page 211: Installing The Pinion
LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) INSTALLING THE PINION Install: • Pinion • Pinion nut Drive shaft holder ..... 1 YB-06201 / 90890-06520 Pinion nut holder ...... 2 90890-06505 Pinion nut holder attachment . 3 6111 90890-06508 Pinion nut 95 Nm (9.5 m • kgf, 68 ft • lb) 6-24...
Page 212: Lower Case Assembly (Regular Rotation Models)
LOWER CASE ASSEMBLY LOWR (REGULAR ROTATION MODELS) LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS) DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY 6160 Order Job/Part Q’ty Remarks Forward gear Refer to “DRIVE SHAFT (REGULAR ROTATION MODELS)” on page 6-19. Drive shaft sleeve Needle bearing Tapered roller bearing outer race Forward gear shim Water seal...
Page 213: Disassembling The Lower Case Assembly
LOWER CASE ASSEMBLY LOWR (REGULAR ROTATION MODELS) DISASSEMBLING THE LOWER CASE ASSEMBLY 1. Remove: • Needle bearing Bearing/oil seal attachment ..1 YB-06194 / 90890-06636 Driver rod ........2 YB-06071 / 90890-06605 6165 2. Remove: Å • Tapered roller bearing outer race •...
Page 214 LOWER CASE ASSEMBLY LOWR (REGULAR ROTATION MODELS) 2. Install: • Needle bearing Bearing/oil seal attachment ..1 YB-06246 / 90890-06636 Bearing puller......2 YB-06029 / 90890-06523 Needle bearing installation plate ........... 3 YB-06247 6180 6-27...
Page 215: Lower Unit (Counter Rotation Models)
LOWR LOWER UNIT (COUNTER ROTATION MODELS) LOWER UNIT (COUNTER ROTATION MODELS) REMOVING/INSTALLING THE LOWER UNIT 6011 Order Job/Part Q’ty Remarks Cotter pin Propeller nut Washer Washer Propeller Spacer Continued on next page. 6-28...
Page 216 LOWR LOWER UNIT (COUNTER ROTATION MODELS) 6011 Order Job/Part Q’ty Remarks Bolt Trim tab Bolt Bolt Lower unit Dowel pin Exhaust seal For installation, reverse the removal procedure. 6-29...
Page 217: Removing The Propeller
LOWR LOWER UNIT (COUNTER ROTATION MODELS) REMOVING THE PROPELLER Remove: • Propeller nut WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries 6018 and the lanyard engine stop switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning.
Page 218: Installing The Propeller
LOWR LOWER UNIT (COUNTER ROTATION MODELS) INSTALLING THE PROPELLER Install: • Propeller nut Propeller nut 55 Nm (5.5 m • kgf, 40 ft • lb) WARNING 6019 Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries and the lanyard engine stop switch.
Page 219: Water Pump (Counter Rotation Models)
LOWR WATER PUMP (COUNTER ROTATION MODELS) WATER PUMP (COUNTER ROTATION MODELS) REMOVING/INSTALLING THE WATER PUMP 6022 Order Job/Part Q’ty Remarks Lower unit Refer to “LOWER UNIT (COUNTER ROTATION MODELS)” on page 6-28. Bolt Plate washer Impeller housing Impeller housing cup Grommet Spacer Collar...
Page 220 LOWR WATER PUMP (COUNTER ROTATION MODELS) 6022 Order Job/Part Q’ty Remarks Spacer Washer Wave washer Impeller Woodruff key Impeller plate Gasket Not reusable Dowel pin For installation, reverse the removal procedure. 6-33...
Page 221: Checking The Impeller Housing
LOWR WATER PUMP (COUNTER ROTATION MODELS) CHECKING THE IMPELLER HOUSING Check: • Impeller housing Cracks/damage → Replace. CHECKING THE IMPELLER AND IMPELLER HOUSING CUP Check: • Impeller • Impeller housing cup Cracks/damage → Replace any defec- tive parts. CHECKING THE WOODRUFF KEY Check: •...
Page 222 LOWR WATER PUMP (COUNTER ROTATION MODELS) 2. Install: • O-ring 1 • Impeller housing cup 2 • Impeller housing 3 • O-ring 4 NOTE: • When installing the impeller housing cup, align its projection with the hole in the 6030 impeller housing.
Page 223: Shift Rod Assembly (Counter Rotation Models)
SHIFT ROD ASSEMBLY LOWR (COUNTER ROTATION MODELS) SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS) REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY 6195 Order Job/Part Q’ty Remarks Impeller plate Refer to “WATER PUMP (COUNTER ROTATION MODELS)” on page 6-32. Bolt (with plate washer) Shift rod assembly Oil seal housing Oil seal Spring...
Page 224: Removing The Shift Rod Assembly
SHIFT ROD ASSEMBLY LOWR (COUNTER ROTATION MODELS) REMOVING THE SHIFT ROD ASSEMBLY Remove: • Shift rod assembly NOTE: Remove the shift rod assembly when the shift rod is in the neutral position. 6-37...
Page 225: Propeller Shaft Housing Assembly (Counter Rotation Models)
PROPELLER SHAFT HOUSING ASSEMBLY LOWR (COUNTER ROTATION MODELS) PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS) REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6200 Order Job/Part Q’ty Remarks Gear oil Refer to “CHANGING AND CHECKING THE GEAR OIL” on page 3-17. Shift rod assembly Refer to “SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS)”...
Page 226: Disassembling/Assembling The Propeller Shaft Housing Assembly
PROPELLER SHAFT HOUSING ASSEMBLY LOWR (COUNTER ROTATION MODELS) DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6205 Order Job/Part Q’ty Remarks O-ring Spring Dog clutch Forward gear assembly Propeller shaft assembly Thrust bearing Propeller shaft shim Continued on next page. *: As required 6-39...
Page 227 PROPELLER SHAFT HOUSING ASSEMBLY LOWR (COUNTER ROTATION MODELS) 6205 Order Job/Part Q’ty Remarks Oil seal Needle bearing Propeller shaft housing Forward gear Thrust washer Tapered roller bearing outer race Tapered roller bearing Not reusable For assembly, reverse the disassembly procedure. 6-40...
Page 228: Disassembling/Assembling The Propeller Shaft Assembly
PROPELLER SHAFT HOUSING ASSEMBLY LOWR (COUNTER ROTATION MODELS) DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY 6235 Order Job/Part Q’ty Remarks Shift rod joint Shift rod joint slider Ball Spring Ball Propeller shaft For assembly, reverse the disassembly procedure. 6-41...
Page 229: Removing The Propeller Shaft Housing Assembly
PROPELLER SHAFT HOUSING ASSEMBLY LOWR (COUNTER ROTATION MODELS) REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY 1. Straighten: • Claw washer tabs 2. Remove: • Ring nut • Claw washer Ring nut wrench ....... 1 6050 YB-34447 / 90890-06512 Ring nut wrench extension ..2 90890-06513 3.
Page 230: Disassembling The Propeller Shaft Housing Assembly
PROPELLER SHAFT HOUSING ASSEMBLY LOWR (COUNTER ROTATION MODELS) DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY Remove: • Oil seals • Needle bearing Bearing/oil seal attachment ..1 YB-06196 / 90890-06653 Driver rod ........2 6225 YB-06071 / 90890-06652 DISASSEMBLING THE FORWARD GEAR ASSEMBLY Remove: •...
Page 231: Checking The Dog Clutch
PROPELLER SHAFT HOUSING ASSEMBLY LOWR (COUNTER ROTATION MODELS) CHECKING THE DOG CLUTCH Check: • Dog clutch Damage/wear → Replace. CHECKING THE PROPELLER SHAFT Check: • Propeller shaft Damage/wear → Replace. ASSEMBLING THE PROPELLER Å SHAFT HOUSING 1. Install: • Needle bearing Needle bearing installation position a 24.75 - 25.25 mm...
Page 232: Installing The Propeller Shaft Assembly
PROPELLER SHAFT HOUSING ASSEMBLY LOWR (COUNTER ROTATION MODELS) INSTALLING THE PROPELLER SHAFT ASSEMBLY Install: • Forward gear assembly • Propeller shaft assembly 6233 INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY Install: • Forward gear shim(s) • Propeller shaft housing assembly • Straight key •...
Page 233: Drive Shaft (Counter Rotation Models)
LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) DRIVE SHAFT (COUNTER ROTATION MODELS) REMOVING/INSTALLING THE DRIVE SHAFT 6240 Order Job/Part Q’ty Remarks Propeller shaft housing assembly Refer to “PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)” on page 6-38. Pinion nut Pinion Bolt Drive shaft housing assembly Pinion shim Thrust bearing...
Page 234 LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) 6240 Order Job/Part Q’ty Remarks Reverse gear assembly Thrust bearing O-ring Oil seal cover Oil seal Needle bearing Drive shaft housing Roller bearing inner race Needle bearing Reverse gear For installation, reverse the removal procedure.
Page 235: Removing The Pinion
LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) REMOVING THE PINION Remove: • Pinion nut • Pinion Drive shaft holder ..... 1 YB-06201 / 90890-06520 Pinion nut holder ...... 2 90890-06505 6110 Pinion nut holder attachment . 3 90890-06508 Å REMOVING THE REVERSE GEAR Remove: •...
Page 236: Checking The Pinion
LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) 2. Remove: Å • Needle bearings Slide hammer......1 YB-06096 Guide plate........ 2 90890-06501 Guide plate stand ..... 3 90890-06538 Bearing puller......4 6145 90890-06535 Small universal claws ....5 ı 90890-06536 Å For USA and Canada ı...
Page 237: Assembling The Reverse Gear Assembly
LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) ASSEMBLING THE REVERSE GEAR ASSEMBLY 1. Install: • Needle bearings Needle bearing installation position a 21.0 - 21.4 mm (0.827 - 0.843 in) Needle bearing installation 6150 position b 4.5 - 4.9 mm (0.177 - 0.193 in) Bearing/oil seal attachment ..
Page 238: Installing The Reverse Gear
LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) 2. Install: • Oil seals Oil seal installation position a 0.25 - 0.75 mm (0.010 - 0.030 in) Bearing/oil seal attachment ..1 YB-06195 / 90890-06633 Driver rod ........2 6130 YB-06071 / 90890-06652 INSTALLING THE REVERSE GEAR Install: •...
Page 239: Lower Case Assembly (Counter Rotation Models)
LOWER CASE ASSEMBLY LOWR (COUNTER ROTATION MODELS) LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS) DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY 6290 Order Job/Part Q’ty Remarks Reverse gear Refer to “DRIVE SHAFT (COUNTER ROTATION MODELS)” on page 6-46. Drive shaft sleeve Needle bearing Needle bearing outer case Roller bearing Reverse gear shim...
Page 240: Disassembling The Lower Case Assembly
LOWER CASE ASSEMBLY LOWR (COUNTER ROTATION MODELS) DISASSEMBLING THE LOWER CASE ASSEMBLY 1. Remove: • Needle bearing outer race Bearing/oil seal attachment ..1 YB-06194 / 90890-06636 Driver rod ........2 YB-06071 / 90890-06605 6313 2. Remove: Å • Roller bearing •...
Page 241 LOWER CASE ASSEMBLY LOWR (COUNTER ROTATION MODELS) 2. Install: • Needle bearing outer race Bearing/oil seal attachment ..1 YB-06246 / 90890-06636 Bearing puller......2 YB-06029 / 90890-06523 Needle bearing installation plate ........... 3 YB-06247 6314 6-54...
Page 242: Shimming (Regular Rotation Models) (For Usa And Canada)
SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA) NOTE: • There is no need to select shims when reassembling with the original case and inner parts. • Shim calculations are required when reas- sembling with the original inner parts and a new case (the difference between the original inner parts and the new case).
Page 243: Selecting The Pinion Shims
SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) SELECTING THE PINION SHIMS NOTE: Find the shim thickness (T3) by selecting shims until the specified value (M0) is obtained with the special tool. 6505 1. Measure: • Specified measurement (M) Out of specified value (M0) →...
Page 244 SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) (2) Install the pinion height gauge, drive shaft, thrust bearing 1, and shim(s) 2. Pinion height gauge YB-34432-7, -11 NOTE: If the original shim(s) is unavailable, start with a 0.50-mm shim. 6515 (3) Install the pinion and pinion nut.
Page 245: Selecting The Forward Gear Shims
SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) SELECTING THE FORWARD GEAR SHIMS NOTE: Find the shim thickness (T1) by selecting shims until the specified value (M0) is obtained with the special tool. 6525 1. Measure: • Specified measurement (M) Out of specified value (M0) →...
Page 246 SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) (2) Install the shimming gauge, bearing 1, and shim(s) 2. Shimming gauge YB-34446-1, -3, -4, -8 NOTE: If the original shim(s) is unavailable, start with a 0.50-mm shim. (3) Measure the specified measurement (M).
Page 247: Selecting The Reverse Gear Shims
SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) SELECTING THE REVERSE GEAR SHIMS NOTE: Find the shim thickness (T2) by selecting shims until the specified value (M0) is obtained with the special tool. 6545 1. Measure: • Specified measurement (M) Out of specified value (M0) →...
Page 248 SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) (2) Install the shimming gauge, bearing, thrust washer, reverse gear, and shim(s). Shimming gauge YB-34468-1 NOTE: • If the original shim(s) is unavailable, start 6555 with a 0.50-mm shim. • Turn the reverse gear assembly a few times until the gear and bearing are hori- zontal.
Page 249: Shimming (Regular Rotation Models) (For Worldwide)
SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR WORLDWIDE) SHIMMING (REGULAR ROTATION MODELS) (FOR WORLDWIDE) NOTE: • There is no need to select shims when reassembling with the original case and inner parts. • Shim calculations are required when reas- sembling with the original inner parts and a new case (the difference between the original inner parts and the new case).
Page 250: Selecting The Pinion Shims
SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR WORLDWIDE) SELECTING THE PINION SHIMS NOTE: Select the shim thickness (T3) by using the specified measurement(s) and the calcula- tion formula. Select: • Shim thickness (T3) 6575 Selecting steps (1) Measure (M3). Digital caliper 90890-06704 NOTE: Install the bearing housing 1, thrust bear-...
Page 251 SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR WORLDWIDE) (5) Calculate the pinion shim thickness (T3). Pinion shim thickness (T3) = 80.0 + P/100 – M3 – M4 NOTE: • “P” is the deviation of the lower case dimension from standard. It is stamped 6590 on the trim tab mounting surface of the lower case in 0.01-mm units.
Page 252: Selecting The Forward Gear Shims
SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR WORLDWIDE) SELECTING THE FORWARD GEAR SHIMS NOTE: Select the shim thickness (T1) by using the specified measurement(s) and the calcula- tion formula. Select: 6595 • Shim thickness (T1) Selecting steps (1) Measure (M1). Shimming plate ......1 90890-06701 Digital caliper ......
Page 253: Selecting The Reverse Gear Shims
SHIMMING (REGULAR ROTATION MODELS) (FOR LOWR WORLDWIDE) Example: If M1 is “28.10 mm” and F is “+5”, then T1 = 28.6 + (+5)/100 – 28.10 mm = 28.6 + 0.05 – 28.10 mm = 0.55 mm (3) Select the forward gear shim(s) (T1). Calculated numeral Rounded at 1/100th place...
Page 254 SHIMMING (REGULAR ROTATION MODELS) (FOR LOWR WORLDWIDE) (2) Calculate the reverse gear shim thick- ness (T2). Reverse gear shim thickness (T2) = M2 – 29.0 – R/100 NOTE: • “R” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units.
Page 255: Backlash (Regular Rotation Models)
LOWR BACKLASH (REGULAR ROTATION MODELS) BACKLASH (REGULAR ROTATION MODELS) NOTE: • Do not install the water pump compo- nents when measuring the backlash. • Measure both the forward and reverse gear backlashes. • If both the forward and reverse gear back- lashes are larger than specification, the pinion may be too high.
Page 256 LOWR BACKLASH (REGULAR ROTATION MODELS) (3) Install the backlash indicator onto the drive shaft (on the 22.4 mm (0.88 in) diameter portion of the drive shaft). Backlash indicator ....5 YB-06265 / 90890-06706 (4) Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indi- 6655...
Page 257: Measuring The Reverse Gear Backlash
LOWR BACKLASH (REGULAR ROTATION MODELS) MEASURING THE REVERSE GEAR BACKLASH 1. Measure: • Reverse gear backlash Out of specification → Adjust. Reverse gear backlash 0.74 - 1.29 mm (0.029 - 0.051 in) Measuring steps (1) Set the shift rod into the neutral posi- tion.
Page 258 LOWR BACKLASH (REGULAR ROTATION MODELS) (6) Slowly turn the drive shaft clockwise and counterclockwise. When the drive shaft stops in each direction, measure the backlash. 2. Adjust: • Reverse gear shim Remove or add shim(s). Reverse gear Shim thickness backlash Less than To be increased by (1.02 –...
Page 259: Shimming (Counter Rotation Models) (For Usa And Canada)
SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR USA AND CANADA) SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA) NOTE: • There is no need to select shims when reassembling with the original case and inner parts. • Shim calculations are required when reas- sembling with the original inner parts and a new case (the difference between the original inner parts and the new case).
Page 260: Selecting The Pinion Shims
SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR USA AND CANADA) SELECTING THE PINION SHIMS NOTE: Find the shim thickness (T3) by selecting shims until the specified measurement (M) is obtained with the special tool. 6505 1. Measure: • Specified measurement (M) Out of specified value (M0) →...
Page 261 SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR USA AND CANADA) (2) Install the pinion height gauge, drive shaft, thrust bearing 1, and shim(s) 2. Pinion height gauge YB-34432-7, -11 NOTE: If the original shim(s) is unavailable, start with a 0.50-mm shim. 6515 (3) Install the pinion and pinion nut.
Page 262: Selecting The Reverse Gear Shims
SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR USA AND CANADA) SELECTING THE REVERSE GEAR SHIMS NOTE: Find the shim thickness (T1) by selecting shims until the specified value (M0) is obtained with the special tool. 6525 1. Measure: • Specified measurement (M) Out of specified value (M0) →...
Page 263: Selecting The Forward Gear Shims
SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR USA AND CANADA) (2) Install the roller bearing 1, thrust bearing 2, and shim(s) 3. NOTE: If the original shim(s) is unavailable, start with a 0.50-mm shim. (3) Measure the specified measurement (M). 6540 2.
Page 264 SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR USA AND CANADA) Measuring steps (1) Calculate the specified value (M0). NOTE: • “R” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units.
Page 265: Selecting The Propeller Shaft Shims
SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR USA AND CANADA) 2. Adjust: • Shim thickness (T2) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as pos- sible.
Page 266: Shimming (Counter Rotation Models) (For Worldwide)
SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR WORLDWIDE) SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE) NOTE: • There is no need to select shims when reassembling with the original case and inner parts. • Shim calculations are required when reas- sembling with the original inner parts and a new case (the difference between the original inner parts and the new case).
Page 267: Selecting The Pinion Shims
SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR WORLDWIDE) SELECTING THE PINION SHIMS NOTE: Select the shim thickness (T3) by using the specified measurement(s) and the calcula- tion formula. Select: • Shim thickness (T3) 6575 Selecting steps (1) Measure (M3). Digital caliper 90890-06704 NOTE: Install the bearing housing 1, thrust bear-...
Page 268 SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR WORLDWIDE) (5) Calculate the pinion shim thickness (T3). Pinion shim thickness (T3) = 80.0 + P/100 – M3 – M4 NOTE: • “P” is the deviation of the lower case dimension from standard. It is stamped 6590 on the trim tab mounting surface of the lower case in 0.01-mm units.
Page 269: Selecting The Reverse Gear Shims
SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR WORLDWIDE) SELECTING THE REVERSE GEAR SHIMS NOTE: Select the shim thickness (T1) by using the specified measurement(s) and the calcula- tion formula. Select: 6595 • Shim thickness (T1) Selecting steps (1) Measure (M1). Digital caliper 90890-06704 NOTE: •...
Page 270: Selecting The Forward Gear Shims
SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR WORLDWIDE) Example: If M1 is “28.10 mm” and F is “+5”, then T1 = 29.1 + (+5)/100 – 28.10 mm = 29.1 + 0.05 – 28.10 mm = 1.05 mm (3) Select the reverse gear shim(s). Calculated numeral Rounded at 1/100th place...
Page 271 SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR WORLDWIDE) (2) Calculate the forward gear shim thick- ness (T2). Forward gear shim thickness (T2) = M2 – 29.5 – R/100 NOTE: • “R” is the deviation of the lower case dimension from standard. It is stamped 6625 on the trim tab mounting surface of the lower case in 0.01-mm units.
Page 272: Selecting The Propeller Shaft Shims
SHIMMING (COUNTER ROTATION MODELS) LOWR (FOR WORLDWIDE) SELECTING THE PROPELLER SHAFT SHIMS NOTE: Find the shim thickness (T4) by selecting shims until the specified measurement is obtained with the special tool. 6630 1. Install: • Shim(s) 1 • Thrust bearing 2 •...
Page 273: Backlash (Counter Rotation Models)
LOWR BACKLASH (COUNTER ROTATION MODELS) BACKLASH (COUNTER ROTATION MODELS) NOTE: • Do not install the water pump compo- nents when measuring the backlash. • Measure both the forward and reverse gear backlashes. • If both the forward and reverse gear back- lashes are larger than specification, the pinion may be too high.
Page 274: Measuring The Reverse Gear Backlash
LOWR BACKLASH (COUNTER ROTATION MODELS) (3) Install the backlash indicator onto the drive shaft (on the 22.4 mm (0.88 in) diameter portion of the drive shaft). Backlash indicator ....5 YB-06265 / 90890-06706 (4) Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indi- 6655...
Page 275 LOWR BACKLASH (COUNTER ROTATION MODELS) Measuring steps (1) Set the shift rod into the neutral posi- tion. Shift rod wrench YB-06052 / 90890-06052 6645 (2) Load the reverse gear by installing the propeller without the spacer 1 and then tighten the propeller nut. Propeller nut 5 Nm (0.5 m •...
Page 276 LOWR BACKLASH (COUNTER ROTATION MODELS) (8) Turn the shift rod into the neutral posi- tion with the shift rod wrench. (9) Turn the drive shaft counterclockwise approximately 30˚ more. 6720 (10) Turn the shift rod into the reverse posi- tion with the shift rod wrench. (11) Slowly turn the drive shaft clockwise and counterclockwise.
Page 278: Brkt
BRKT CHAPTER 7 BRACKET UNIT BOTTOM COWLING..................7-1 REMOVING/INSTA ING THE BOTTOM COWLING ........ 7-1 DISASSEMBLING/ASSEMBLING THE BOTTOM COWLING ....7-3 SHIFT ROD ASSEMBLY ................. 7-6 DISASSEMBLING/ASSEMBLING THE SHIFT ROD ASSEMBLY... 7-6 UPPER CASE ASSEMBLY................7-7 REMOVING/INSTALLING THE UPPER CASE ASSEMBLY ....7-7 DISASSEMBLING/ASSEMBLING THE UPPER CASE ASSEMBLY ..
Page 279 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT........7-30 REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND GEAR PUMP UNIT ................7-30 REMOVING THE TILT RAM END SCREW ..........7-32 REMOVING THE GEAR PUMP UNIT ............ 7-32 DISASSEMBLING THE GEAR PUMP UNIT .......... 7-32 CHECKING THE TILT RAM ..............
Page 280 BRKT BOTTOM COWLING BOTTOM COWLING REMOVING/INSTA ING THE BOTTOM COWLING 7010 Order Job/Part Q’ty Remarks Power unit Refer to “POWER UNIT” on page 5-4. Shift rod assembly Bolt Holder Bolt Bracket Battery lead Hose guide Continued on next page.
Page 281 BRKT BOTTOM COWLING 7010 Order Job/Part Q’ty Remarks Power trim and tilt lead Trim sensor lead Bolt Ground lead Speedometer hose Flushing hose Bottom cowling For installation, reverse the removal procedure.
Page 282 BRKT BOTTOM COWLING DISASSEMBLING/ASSEMBLING THE BOTTOM COWLING 7030 Order Job/Part Q’ty Remarks Bolt Lower spring holder Spring Bolt Upper spring holder Wave washer Bushing Clamp lever Bolt Continued on next page.
Page 283 BRKT BOTTOM COWLING 7030 Order Job/Part Q’ty Remarks Clamp plate Pilot water outlet Wire harness clamp Bolt Cable holder Grommet Collar Grommet Collar Continued on next page.
Page 284 BRKT BOTTOM COWLING 7035 Order Job/Part Q’ty Remarks Bolt Trailer switch holder Trailer switch Bolt Ground lead Silencer cover Gasket Not reusable Bottom cowling For assembly, reverse the disassembly procedure.
Page 285 BRKT SHIFT ROD ASSEMBLY SHIFT ROD ASSEMBLY DISASSEMBLING/ASSEMBLING THE SHIFT ROD ASSEMBLY 7040 Order Job/Part Q’ty Remarks Screw Spring Ball Clip Shift rod lever Rubber seal Circlip Shift rod bracket Bushing Shift rod For assembly, reverse the disassembly procedure.
Page 286 BRKT UPPER CASE ASSEMBLY UPPER CASE ASSEMBLY REMOVING/INSTALLING THE UPPER CASE ASSEMBLY 7050 Order Job/Part Q’ty Remarks Lower unit Refer to “LOWER UNIT (REGULAR ROTATION MODELS)” on page 6-1. Bottom cowling Refer to “BOTTOM COWLING” on page 7-1. Bolt Ground lead (upper case-to-swivel bracket) Bolt Lower mount cover...
Page 287 BRKT UPPER CASE ASSEMBLY 7050 Order Job/Part Q’ty Remarks O-ring Self-locking nut Upper case assembly Rubber seal For installation, reverse the removal procedure.
Page 288 BRKT UPPER CASE ASSEMBLY DISASSEMBLING/ASSEMBLING THE UPPER CASE ASSEMBLY 7060 Order Job/Part Q’ty Remarks Bolt Upper mount bracket Upper mount Bolt Bolt Lower mount bracket Lower mount Ground lead Bolt Bolt Continued on next page.
Page 289 BRKT UPPER CASE ASSEMBLY 7060 Order Job/Part Q’ty Remarks Bolt Muffler assembly Rubber seal Muffler Rubber seal Rubber seal Upper case Dowel pin Circlip Bushing For assembly, reverse the disassembly procedure. 7-10...
Page 290 BRKT EXHAUST MANIFOLD ASSEMBLY EXHAUST MANIFOLD ASSEMBLY DISASSEMBLING/ASSEMBLING THE EXHAUST MANIFOLD ASSEMBLY 7070 Order Job/Part Q’ty Remarks Bolt Muffler Gasket Not reusable Water tube Water seal Bolt Exhaust manifold Gasket Not reusable Continued on next page. 7-11...
Page 291 BRKT EXHAUST MANIFOLD ASSEMBLY 7070 Order Job/Part Q’ty Remarks Bolt Lower exhaust manifold guide Gasket Not reusable Upper exhaust manifold guide Plastic locking tie Salt water models Not reusable Flushing hose Salt water models For assembly, reverse the disassembly procedure. 7-12...
Page 292 BRKT CLAMP BRACKETS CLAMP BRACKETS REMOVING/INSTALLING THE CLAMP BRACKETS 7080 Order Job/Part Q’ty Remarks Upper case assembly Refer to “UPPER CASE ASSEMBLY” on page 7-7. Rubber cap Grease nipple Ground lead Bolt Ground lead Anode bracket Anode Trim sensor Refer to “ADJUSTING THE TRIM SENSOR CAM”...
Page 293 BRKT CLAMP BRACKETS 7080 Order Job/Part Q’ty Remarks Self-locking nut Bolt Clamp bracket bolt Starboard clamp bracket Port clamp bracket Bushing Swivel bracket assembly For installation, reverse the removal procedure. 7-14...
Page 294 BRKT STEERING ARM STEERING ARM REMOVING/INSTALLING THE STEERING ARM 7090 Order Job/Part Q’ty Remarks Upper case assembly Refer to “UPPER CASE ASSEMBLY” on page 7-7. Circlip Steering arm yoke Washer Washer O-ring Steering arm Washer Bushing Swivel bracket assembly For installation, reverse the removal procedure.
Page 295 BRKT SWIVEL BRACKET ASSEMBLY SWIVEL BRACKET ASSEMBLY DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET ASSEMBLY 7100 Order Job/Part Q’ty Remarks Steering arm Refer to “STEERING ARM” on page 7-15. Trim stopper Bolt Spring holder Spring Continued on next page. 7-16...
Page 296 BRKT SWIVEL BRACKET ASSEMBLY 7100 Order Job/Part Q’ty Remarks Starboard tilt stop lever Port tilt stop lever Bushing Bushing Tilt stop lever joint assembly For assembly, reverse the disassembly procedure. 7-17...
Page 297 BRKT POWER TRIM AND TILT UNIT POWER TRIM AND TILT UNIT REMOVING/INSTALLING THE POWER TRIM AND TILT UNIT 7110 Order Job/Part Q’ty Remarks Tilt up the outboard Plastic locking tie Not reusable Power trim and tilt lead Bolt Ground lead Circlip Upper mounting pin Continued on next page.
Page 298 BRKT POWER TRIM AND TILT UNIT 7110 Order Job/Part Q’ty Remarks Bolt Washer Lower mounting pin Power trim and tilt unit Collar For installation, reverse the removal procedure. 7-19...
Page 299 BRKT POWER TRIM AND TILT UNIT REMOVING THE POWER TRIM AND TILT UNIT WARNING After tilting up the outboard, be sure to support it with the tilt stop levers. Otherwise, the outboard could suddenly lower if the power trim and tilt unit should lose fluid pressure.
Page 300 BRKT POWER TRIM AND TILT UNIT (3) Tilt up the outboard fully, then release it, and let it lower by its own weight. (4) Tighten the manual valve by turning it clockwise. (5) Let the power trim and tilt fluid settle for about 5 minutes.
Page 301 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR RESERVOIR AND POWER TRIM AND TILT MOTOR REMOVING/INSTALLING THE RESERVOIR AND POWER TRIM AND TILT MOTOR 7160 Order Job/Part Q’ty Remarks Power trim and tilt unit Refer to “POWER TRIM AND TILT UNIT” on page 7-18.
Page 302 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR WARNING • To prevent the hydraulic fluid from spurt- ing out due to internal pressure, the out- board should be kept fully tilted up (the tilt rod at full length). • After removing the power trim and tilt motor or reservoir, do not push the tilt ram down.
Page 303 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR INSTALLING THE POWER TRIM AND TILT MOTOR 1. Install: • Gear pump housing filter 1 • Drive pin 2 2. Fill: • Gear pump housing Recommended power trim and 7170 tilt fluid ATF Dexron II NOTE: Add power trim and tilt fluid until it reaches...
Page 304 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR FILLING THE RESERVOIR WARNING To prevent the hydraulic fluid from spurt- ing out due to internal pressure, the tilt ram should be kept at full length. 1. Fill: • Reservoir Recommended power trim and tilt fluid ATF Dexron II 2.
Page 305 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR B. If step A was unsuccessful, connect the leads on the battery terminals and fully compress the tilt ram assembly by hand. C. If step B was unsuccessful, loosen the manual valve, compress the trim and tilt ram assemblies fully by hand, and then tighten the manual valve.
Page 306 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR MEASURING THE HYDRAULIC PRESSURE Check: • Hydraulic pressure Out of specification → Repair. Hydraulic pressure (with the power trim and tilt ram assemblies fully extended) 9.8 - 11.8 MPa (100 - 120 kg/cm (with the power trim and tilt ram assemblies fully compressed) 5.9 - 8.8 MPa (60 - 90 kg/cm...
Page 307 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR (4) Connect the leads on the battery termi- nals in the down position until the power trim and tilt ram assemblies are fully compressed. 7210 (5) Connect the leads on the battery termi- nals in the up position until the power trim and tilt ram assemblies are fully extended.
Page 308 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR (10) After measuring the hydraulic pres- sure, connect the leads on the battery terminals in the up position until the power trim and tilt ram assemblies are fully extended. (11) Remove the special tools. (12) Install the manual valve and circlip.
Page 309 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT TILT RAM ASSEMBLY AND GEAR PUMP UNIT REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND GEAR PUMP UNIT 7290 Order Job/Part Q’ty Remarks Reservoir and power trim and tilt Refer to “RESERVOIR AND POWER TRIM motor AND TILT MOTOR”...
Page 310 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT 7290 Order Job/Part Q’ty Remarks Check valve assembly Bolt Gear pump Shuttle valve Check valve Up-relief valve assembly Down-relief valve assembly For installation, reverse the removal procedure. 7-31...
Page 311 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT REMOVING THE TILT RAM END SCREW Loosen: • Tilt ram end screw End screw wrench YB-06548 / 90890-06548 7300 NOTE: Hold the power trim and tilt unit in a vise using aluminum plates on both sides. REMOVING THE GEAR PUMP UNIT Remove: •...
Page 312 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT 2. Remove: • Check valves 1 and 2 NOTE: To remove the check valves, cover the gear pump housing with a clean cloth and then blow compressed air through holes a and b. 7330 CHECKING THE TILT RAM Check:...
Page 313 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT ASSEMBLING THE GEAR PUMP UNIT CAUTION: Install all components in their original direction and position for proper assembly and operation. 1. Install: • Balls (3.18 mm/0.125 in) 1 • Shuttle valves 2 NOTE: Apply grease to the balls to prevent them from falling out of the gear pump.
Page 314 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT INSTALLING THE GEAR PUMP UNIT 1. Install: • O-rings 1 • Ball 2 • Pin 3 • Check valve 4 • Check valve assembly 5 NOTE: 7380 When installing the check valve assembly, make sure the pin is on the tilt ram cylinder side as shown.
Page 315 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT 2. Fill: • Gear pump housing Recommended power trim and tilt fluid ATF Dexron II NOTE: Add power trim and tilt fluid through the 7410 hole a until the fluid level is to the top of the gear pump unit.
Page 316 BRKT TRIM RAM ASSEMBLIES AND FREE PISTON TRIM RAM ASSEMBLIES AND FREE PISTON REMOVING/INSTALLING THE TRIM RAM ASSEMBLIES AND FREE PISTON 7440 Order Job/Part Q’ty Remarks Tilt ram assembly and gear Refer to “TILT RAM ASSEMBLY AND pump unit GEAR PUMP UNIT” on page 7-30. Trim ram end screw Trim ram O-ring...
Page 317 BRKT TRIM RAM ASSEMBLIES AND FREE PISTON REMOVING THE TRIM RAM END Å ı SCREWS Loosen: • Trim ram end screws End screw wrench YB-06175-1A / 90890-06548 Å For USA and Canada 7450 ı For worldwide NOTE: Hold the power trim and tilt unit in a vise using aluminum plates on both sides.
Page 318 BRKT TRIM RAM ASSEMBLIES AND FREE PISTON CHECKING THE TRIM RAMS Check: • Trim rams Excessive scratches → Replace. Bends/excessive corrosion → Replace. Rust → Polish. (with 400 - 600 grit sandpaper) CHECKING THE FREE PISTON Check: • Free piston Excessive scratches →...
Page 319 BRKT TRIM RAM ASSEMBLIES AND FREE PISTON 2. Install: • Piston ring 1 • O-ring 2 • Free piston 3 NOTE: Push the free piston into the tilt ram cylin- der until it bottoms out. 7490 INSTALLING THE TRIM RAMS WARNING Do not push the trim rams down while installing them into the trim ram cylinders.
Page 320 BRKT TRIM RAM ASSEMBLIES AND FREE PISTON 3. Install: • Trim ram assemblies 1 NOTE: Place each trim ram end screw at the bot- tom of each trim ram and install them into the trim ram cylinders. 7520 4. Tighten: Å...
Page 321 – ELEC CHAPTER 8 ELECTRICAL SYSTEMS ELECTRICAL COMPONENTS................. 8-1 (Port view) ....................8-1 (Starboard view) ..................8-2 (Junction box assembly)................. 8-3 (Aft view) ....................8-4 (Top view)....................8-5 WIRE HARNESS ..................... 8-6 ELECTRICAL COMPONENTS ANALYSIS ............. 8-9 DIGITAL CIRCUIT TESTER............... 8-9 MEASURING THE PEAK VOLTAGE............
Page 322: Elec
– ELEC FUEL CONTROL SYSTEM................8-22 CHECKING THE BATTERY..............8-24 CHECKING THE FUSES ................. 8-24 CHECKING THE FUSE HOLDER ............8-24 MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE....8-24 MEASURING THE CRANK POSITION SENSOR OUTPUT PEAK VOLTAGE....................8-24 MEASURING THE THROTTLE POSITION SENSOR OUTPUT VOLTAGE....................
Page 323 – ELEC OIL FEED PUMP CONTROL SYSTEM ............8-44 CHECKING THE BATTERY..............8-45 CHECKING THE FUSES ................. 8-45 CHECKING THE FUSE HOLDER ............8-45 CHECKING THE OIL LEVEL SENSOR/SWITCH CONTINUITY..... 8-45 CHECKING THE EMERGENCY SWITCH ..........8-46 CHECKING THE OIL PUMP (SUB-OIL TANK)........8-46 POWER TRIM AND TILT SYSTEM ..............
Page 324 – ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS (Port view) 8010 1 Throttle position sensor 0 Water detection switch 2 Electric fuel pump connectors A Trailer switch coupler (3P) 3 Emergency switch B Oil level sensor coupler (6P) 4 Oil level sensor C Electric oil pump 5 Thermo switch D Atmospheric pressure sensor...
Page 325 – ELEC ELECTRICAL COMPONENTS (Starboard view) 8020 1 Thermo switch 2 Oxygen density sensor coupler (2P) 3 Oxygen density sensor 4 Crank position sensor coupler (2P) 5 Starter motor 6 Fuse holder 7 Junction box assembly 8 Thermo switch connectors...
Page 326 – ELEC ELECTRICAL COMPONENTS (Junction box assembly) Å ı Ç Ó ‰ Ï Ì Ì Ç Î 8030 1 Thermo switch connectors B Fuse (30A) 2 Oxygen density sensor coupler (2P) C Rectifier/regulator 3 Power trim and tilt relay coupler (2P) Å...
Page 327 – ELEC ELECTRICAL COMPONENTS (Aft view) 8040 1 Control unit 2 Control unit couplers (26P, 26P, 34P) 3 Ignition coils 4 Ignition coil couplers (2P) 5 Injector driver couplers (26P) 6 Injector driver...
Page 328 – ELEC ELECTRICAL COMPONENTS (Top view) 8050 1 Remote control coupler (10P) 0 Fuel pressure sensor 2 Shift position switch A Oil level sensor 3 Oxygen density sensor B Electric fuel pump connectors 4 Shift position switch coupler (2P) C Trailer switch 5 Crank position sensor D Electric fuel pump 6 Thermo switches...
Page 329 – ELEC WIRE HARNESS WIRE HARNESS ⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄ 88 E L/G G L/W L/R B B B B P P L/W B/R L/R L/R L/Y Y/R B R W/R R R R Y/R L/G L/R 8060 Connect to: 8 Fuse holder : Black : White...
Page 330 – ELEC WIRE HARNESS 7 2 3 8 W/Y W/G W/Br O P B W/Y W/R W/Br W/G W/B 8070 Connect to: 5 Atmospheric pressure : Black W/B : White/black 1 Personal computer sensor : Green W/Br : White/brown 2 Intake air temperature 6 Pulser coil : Gray W/G : White/green...
Page 331 – ELEC WIRE HARNESS ⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄⁄⁄⁄⁄⁄⁄ Pu/W Pu/L Pu/G Pu/Y 3 3 3 9 8 3 3 3 0 Pu/B Pu/R L B/Y B/O B/L W/R W/Y W/L Pu/Y Pu/R O/Y O/R R/Y L/Y R/L R R B/Br B/G W/B W/G W/Br W/Br R/W...
Page 332 – ELEC ELECTRICAL COMPONENTS ANALYSIS ELECTRICAL COMPONENTS ANALYSIS DIGITAL CIRCUIT TESTER Digital tester J-39299 / 90890-06752 NOTE: 8090 “ ” indicates a continuity of electric- ity which means a closed circuit at the respective switch position. MEASURING THE PEAK VOLTAGE NOTE: •...
Page 333 – ELEC ELECTRICAL COMPONENTS ANALYSIS NOTE: • When measuring the peak voltage, set the selector to the DC voltage mode. • Make sure the peak voltage adaptor leads are properly installed in the digital tester. • Make sure the positive pin (the “+” mark facing up as shown) on the peak voltage adaptor is installed into the positive termi- 8120...
Page 334 – ELEC IGNITION SYSTEM IGNITION SYSTEM 8190 Å To remote control 1 Pulser coil B/W : Black/white W/R : White/red 2 Fuse holder : Black/yellow W/Y : White/yellow 3 Fuse (20A) : Black : Blue/yellow 4 Main relay : Red : Red/blue 5 Fuse (80A) : White...
Page 335 – ELEC IGNITION SYSTEM CHECKING THE IGNITION SPARK GAP WARNING • Do not touch any of the connections of the spark gap tester lead wires. • Do not let sparks leak out of the removed spark plug cap. • Keep flammable gas or liquids away, 8200 since this test can produce sparks.
Page 336 – ELEC IGNITION SYSTEM CHECKING THE BATTERY Refer to “CHECKING THE BATTERY” on page 3-19. CHECKING THE FUSES Check: • Fuse continuity No continuity → Replace. • Fuse rating Out of specification → Replace. Fuse rating 1: 12 V - 80 A 2: 12 V - 30 A 3: 12 V - 20 A 8195...
Page 337 – ELEC IGNITION SYSTEM 2. Check: • Driver relay continuity No continuity → Replace the fuse holder. Checking steps (1) Remove the fuse 1. (2) Connect the tester and battery as shown. Positive digital tester probe → Fuse holder terminal 2 Negative digital tester probe →...
Page 338 – ELEC IGNITION SYSTEM Measure: • Control unit output peak voltage Below specification → Replace the control unit. (B/W) Control unit output peak voltage Black/white (B/W) – Red/yellow (R/Y) Black/green (B/G) – Red/yellow (R/Y) Black/brown (B/Br) – Red/yellow (R/Y) Black/orange (B/O) – Red/yellow (R/Y) Black/yellow (B/Y) –...
Page 339 – ELEC IGNITION SYSTEM CHECKING THE SPARK PLUG CAPS 1. Check: • Spark plug cap Loose connection → Tighten. Cracks/damage → Replace. Replacement steps (1) To remove the spark plug cap turn it counterclockwise. 8280 (2) To install the spark plug cap turn it clockwise until it is tight.
Page 340 – ELEC IGNITION CONTROL SYSTEM IGNITION CONTROL SYSTEM 8300 1 Pulser coil 0 Throttle position : Black : Red/blue 2 Crank position sensor sensor : Orange W/B : White/black : Pink W/Br : White/brown 3 Fuse holder A Engine cooling water : Red W/G : White/green 4 Fuse (20A)
Page 341 – ELEC IGNITION CONTROL SYSTEM CHECKING THE BATTERY Refer to “CHECKING THE BATTERY” on page 3-19. CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-13. CHECKING THE FUSE HOLDER Refer “CHECKING FUSE HOLDER” on page 8-13. MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE Refer to “MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE”...
Page 342 – ELEC IGNITION CONTROL SYSTEM MEASURING THE ENGINE COOLING WATER TEMPERATURE SENSOR RESISTANCE Measure: • Engine cooling water temperature sensor resistance Out of specification → Replace. Engine cooling water temperature sensor resistance Black/yellow (B/Y) – Black/yellow (B/Y) 5 ˚C (41 ˚F): 128 k Ω 20 ˚C (68 ˚F): 54 - 69 k Ω...
Page 343 – ELEC IGNITION CONTROL SYSTEM CHECKING THE OIL LEVEL SENSOR CONTINUITY Refer to “CHECKING THE OIL LEVEL SENSOR/SWITCH CONTINUITY” on page 8-45. MEASURING THE THROTTLE POSITION SENSOR OUTPUT VOLTAGE Measure: • Throttle position sensor output volt- Out of specification → Check the con- trol unit.
Page 344 – ELEC IGNITION CONTROL SYSTEM CHECKING THE SHIFT POSITION SWITCH 1. Check: • Shift position switch continuity Out of specification → Replace. Lead color Switch Blue/yellow (L/Y) – position Black (B) 8345 Home No continuity Continuity 2. Check: • Shift position switch Does not return to the home position →...
Page 345 – ELEC FUEL CONTROL SYSTEM FUEL CONTROL SYSTEM 8390 1 Pulser coil 0 Control unit F Water detection switch 2 Crank position sensor A Fuel pressure G Electric fuel pump 3 Oxygen density sensor B Throttle position sensor H Injector driver 4 Fuse holder C Engine cooling water I Fuel injectors...
Page 346 – ELEC FUEL CONTROL SYSTEM 8390 : Black : Blue/red Pu/B : Purple/black W/B : White/black : Gray L/W : Blue/white Pu/G : Purple/green W/Br : White/brown : Blue : Blue/yellow Pu/L : Purple/blue W/G : White/green : Orange : Orange/black Pu/R : Purple/red W/L : White/blue : Pink...
Page 347 – ELEC FUEL CONTROL SYSTEM CHECKING THE BATTERY Refer to “CHECKING THE BATTERY” on page 3-19. CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-13. CHECKING THE FUSE HOLDER Refer “CHECKING FUSE HOLDER” on page 8-13. MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE Refer to “MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE”...
Page 348 – ELEC FUEL CONTROL SYSTEM CHECKING THE OXYGEN DENSITY SENSOR 1. Measure: • Oxygen density sensor heater resis- tance Out of specification → Replace. Oxygen density sensor heater resistance Red/white (R/W) – Black (B) 2 - 100 Ω 2. Measure: •...
Page 349 – ELEC FUEL CONTROL SYSTEM (2) Remove any oil from the oxygen den- sity sensor with acetone or a similar solvent and allow the sensor to thor- oughly dry. (3) Heat the front end of the oxygen den- sity sensor 1 with a gas torch 2 (in the center of its blue flame a) for 10 - 15 seconds.
Page 350 – ELEC FUEL CONTROL SYSTEM Measuring steps (1) Connect the test harness between the atmospheric pressure sensor and the wire harness as shown. Test harness (3-pin) YB-06769 / 90890-06769 (2) Turn the engine start switch to the on position. (3) Measure the atmospheric pressure sensor output voltage.
Page 351 – ELEC FUEL CONTROL SYSTEM CHECKING THE FUEL INJECTORS 1. Check: • Fuel injector operating sound No sound (no fuel is being sprayed) → Check the electric fuel pump. Checking steps (1) Start the engine. (2) Fully close the throttle valves. (3) Attach the screwdriver 1 onto the fuel injector body and check if all of the fuel injectors have a solenoid valve operat-...
Page 352 – ELEC FUEL CONTROL SYSTEM 3. Measure: • Injector driver output peak voltage Correct → Replace the electric fuel pump. Out of specification → Replace the injector driver. Injector driver output peak voltage Orange/red (O/R) – Purple/red (Pu/R) Orange/black (O/B) – Purple/black (Pu/B) Orange/yellow (O/Y) –...
Page 353 – ELEC FUEL CONTROL SYSTEM CHECKING THE WATER DETECTION SWITCH Check: • Water detection switch continuity Out of specification → Replace. Lead color Float Blue/white position Black (B) (L/W) 8490 8-30...
Page 354 – ELEC STARTING SYSTEM STARTING SYSTEM 8500 1 Battery : Black 2 Fuse holder : Brown 3 Fuse (20A) : Red 4 Fuse (80A) Br/W : Brown/white 5 Fuse (30A) 6 Starter relay 7 Starter motor Å To remote control 8-31...
Page 355 – ELEC STARTING SYSTEM CHECKING THE BATTERY Refer to “CHECKING THE BATTERY” on page 3-19. CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-13. CHECKING THE FUSE HOLDER Refer “CHECKING FUSE HOLDER” on page 8-13. CHECKING THE WIRE HARNESS CONTINUITY Check: •...
Page 356 – ELEC STARTER MOTOR STARTER MOTOR DISASSEMBLING/ASSEMBLING THE STARTER MOTOR 6 × 50 mm 4 × 20 mm 4 × 15 mm 6 × 120 mm 8530 Order Job/Part Q’ty Remarks Starter motor Refer to “STARTER MOTOR” on page 5-28. Brush terminal Bolt Magnetic switch relay...
Page 357 – ELEC STARTER MOTOR 6 × 50 mm 4 × 20 mm 4 × 15 mm 6 × 120 mm 8530 Order Job/Part Q’ty Remarks Dust seal Diaphragm Spring Clip Starter motor pinion stopper Starter motor pinion Spring Bolt Lower bracket Continued on next page.
Page 358 – ELEC STARTER MOTOR 6 × 50 mm 4 × 20 mm 4 × 15 mm 6 × 120 mm 8530 Order Job/Part Q’ty Remarks Stator Armature Starter motor bracket Brush assembly Screw Brush holder assembly Thrust plate Thrust washer Planetary gear seat cover Continued on next page.
Page 359 – ELEC STARTER MOTOR 6 × 50 mm 4 × 20 mm 4 × 15 mm 6 × 120 mm 8530 Order Job/Part Q’ty Remarks Outer ring gear Planetary gear Starter motor clutch Shift lever assembly Circlip Starter motor pinion shaft Planetary gear seat Thrust washer Shield bearing...
Page 360 – ELEC STARTER MOTOR REMOVING THE STARTER MOTOR PINION Remove: • Clip 1 NOTE: Slide the pinion stopper 2 down as shown and then remove the clip. 8540 CHECKING THE STARTER MOTOR PINION 1. Check: • Starter motor pinion teeth Damage/wear →...
Page 361 – ELEC STARTER MOTOR 3. Check: • Commutator undercut Dirt/foreign matter → Clean. (with compressed air) 8580 4. Measure: • Commutator undercut a Out of specification → Replace the armature. Commutator undercut limit 0.2 mm (0.01 in) 8590 5. Check: •...
Page 362 – ELEC STARTER MOTOR 2. Check: • Brush assembly continuity Out of specification → Replace the brush assembly. Brush assembly continuity Brush 1 – Brush 2 Brush 3 – Brush 4 8620 Continuity Brush (3, 4) – Brush assembly holder 5 Brush 1 –...
Page 363 – ELEC STARTER MOTOR (5) Check that there is continuity between the magnetic switch relay terminals. (6) Check that there is no continuity after the Br/W lead is removed. NOTE: The starter motor pinion should be pushed out while the magnetic switch is on. (7) Install the terminal to the magnetic switch relay.
Page 364 – ELEC CHARGING SYSTEM CHARGING SYSTEM 8630 1 Lighting coil : Black 2 Rectifier/regulator : Green 3 Fuse holder : Red 4 Fuses (80A) 5 Battery 8-41...
Page 365 – ELEC CHARGING SYSTEM CHECKING THE BATTERY Refer to “CHECKING THE BATTERY” on page 3-19. CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-13. CHECKING THE FUSE HOLDER Refer “CHECKING FUSE HOLDER” on page 8-13. MEASURING THE RECTIFIER/ REGULATOR OUTPUT PEAK VOLTAGE Measure:...
Page 366 – ELEC CHARGING SYSTEM MEASURING THE LIGHTING COIL OUTPUT PEAK VOLTAGE Measure: • Lighting coil output peak voltage Below specification → Replace the lighting coil. Lighting coil output peak voltage Green (G) – Green (G) Circuit Loaded r/min Cranking 1,500 3,500 Test harness (1-pin) YB-06788 / 90890-06788...
Page 367 – ELEC OIL FEED PUMP CONTROL SYSTEM OIL FEED PUMP CONTROL SYSTEM 8680 Å To remote control 1 Battery : Green/red ı To oil level meter 2 Fuse holder : Blue/green 3 Fuse (20A) : Blue/red 4 Fuse (80A) : Black L/W : Blue/white 5 Control unit : Brown...
Page 368 – ELEC OIL FEED PUMP CONTROL SYSTEM CHECKING THE BATTERY Refer to “CHECKING THE BATTERY” on page 3-19. CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-13. CHECKING THE FUSE HOLDER Refer “CHECKING FUSE HOLDER” on page 8-13. CHECKING THE OIL LEVEL SENSOR/ SWITCH CONTINUITY Check:...
Page 369 – ELEC OIL FEED PUMP CONTROL SYSTEM CHECKING THE EMERGENCY SWITCH 1. Check: • Emergency switch continuity Out of specification → Replace. Lead color Switch position Blue (L) – Black (B) 8710 Home a No continuity On b Continuity 2. Check: •...
Page 370 – ELEC POWER TRIM AND TILT SYSTEM POWER TRIM AND TILT SYSTEM 8730 Å To remote control 1 Battery : Orange ı To trim meter 2 Fuse holder : Pink Ç To control unit 3 Fuse (20A) : Red 4 Fuse (80A) : Sky blue 5 Power trim and tilt relay : Black...
Page 371 – ELEC POWER TRIM AND TILT SYSTEM CHECKING THE BATTERY Refer to “CHECKING THE BATTERY” on page 3-19. CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-13. CHECKING THE FUSE HOLDER Refer “CHECKING FUSE HOLDER” on page 8-13. CHECKING THE POWER TRIM AND TILT RELAY 1.
Page 372 – ELEC POWER TRIM AND TILT SYSTEM (4) Connect the digital tester between power trim and tilt relay terminals + and 2. (5) Connect a 12-V battery as shown. Sky blue (Sb) lead → Positive terminal Black (B) lead → Negative terminal (6) Check that there is continuity between the power trim and tilt relay terminals.
Page 373 – ELEC POWER TRIM AND TILT MOTOR POWER TRIM AND TILT MOTOR DISASSEMBLING/ASSEMBLING THE POWER TRIM AND TILT MOTOR 8800 Order Job/Part Q’ty Remarks Power trim and tilt motor Refer to “RESERVOIR AND POWER TRIM AND TILT MOTOR” on page 7-22. Screw Lead holder Screw...
Page 374 – ELEC POWER TRIM AND TILT MOTOR 8800 Order Job/Part Q’ty Remarks Brush holder Brush Spring Lower cover Oil seal Bearing For assembly, reverse the disassembly procedure. 8-51...
Page 375 – ELEC POWER TRIM AND TILT MOTOR REMOVING THE STATOR Remove: • Stator 1 CAUTION: • Keep the power trim and tilt motor leads inside the stator. • Do not allow grease or oil to contact the 8810 commutator. NOTE: •...
Page 376 – ELEC POWER TRIM AND TILT MOTOR 2. Check • Brush continuity No continuity → Replace. CAUTION: Do not touch the bimetal a; touching it may affect the operation of the breaker. 8850 CHECKING THE ARMATURE 1. Measure: • Commutator diameter a Out of specification →...
Page 377 – ELEC POWER TRIM AND TILT MOTOR INSTALLING THE BRUSH Install: • Brushes 1 • Brush holders 2 • Power trim and tilt motor leads 3 • Screw 4 CAUTION: 8900 Do not touch the bimetal; touching it may affect the operation of the breaker. INSTALLING THE ARMATURE Install: •...
Page 379 TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS ..................9-1 TROUBLE ANALYSIS CHART ..............9-1 SELF-DIAGNOSIS................... 9-5 DIAGNOSIS CODE INDICATION ............. 9-5 DIAGNOSIS THE ELECTRONIC CONTROL SYSTEM ......9-5 TROUBLE SHOOTING FOR HIGH-PRESSURE DIRECT INJECTION ... 9-7...
Page 380 TRBL TROUBLE ANALYSIS ANLS TROUBLE ANALYSIS NOTE: The following items should be checked before the “TROUBLE ANALYSIS CHART” is con- sulted. 1. The battery is properly charged and its specified gravity is within specification. 2. There are no incorrect wiring connections. 3.
Page 381: Trbl Anls
TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter Cylinder head gaskets Seal Cylinder block Crankcase Piston rings Pistons Bearings Thermostats Water passages LOWER UNIT Neutral position Dog clutch Gears Water inlets Water pump Propeller shaft(s) Shift rod joint Shift cam Shift shaft Lower case...
Page 382 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter ELECTRICAL Ignition system • Pulser coils • Control unit • Ignition coils • Spark plugs Ignition/fuel control system • Lanyard switch — • Main relay • Driver relay •...
Page 383 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter Oil feed pump control system • Oil level sensor (engine oil tank) • Oil level switch (sub-oil tank) Power trim and tilt system • Trailer switch • Power trim and tilt relay •...
Page 384 TRBL SELF-DIAGNOSIS ANLS SELF-DIAGNOSIS DIAGNOSIS CODE INDICATION 1. Normal condition (no defective part or irregular process- ing is found) Single flash is given every 5 seconds. a : Light on, 0.3 second b : Light off, 5 seconds 2. Trouble code indication Example: The illustration indicates code number 23.
Page 385 TRBL SELF-DIAGNOSIS ANLS NOTE: When more than one problem is detected, the diagnostic indicator’s light flashes in the pattern of the lowest numbered problem. After that problem is corrected, the light flashes in the pattern of the next lowest numbered problem. This continues until all of the problems are detected and corrected.
Page 386 TROUBLE SHOOTING FOR HIGH-PRESSURE TRBL DIRECT INJECTION ANLS TROUBLE SHOOTING FOR HIGH-PRESSURE DIRECT INJECTION Items Symptoms 1. Poor starting/ 1. No firing. The starter motor cranks the engine, but no firing is Engine will generated in the cylinder. not start 2.
Page 387 TROUBLE SHOOTING FOR HIGH-PRESSURE TRBL DIRECT INJECTION ANLS Items Symptoms 2. Erratic idling 1. The engine speed is not constant when idling. speed 2. The engine stalls when the throttle lever is pulled back. 3. The engine stalls when the throttle lever is opened or during outboard operation.
Page 388 TROUBLE SHOOTING FOR HIGH-PRESSURE TRBL DIRECT INJECTION ANLS Items Symptoms 3. Erratic engine 1. The engine is started, but will not run smoothly. The engine speed speed drops during acceleration. 1. Check the medium/high-pressure fuel lines. 1) Check for fuel line leaks 2) Check the fuel pressure Fuel pressure is (vapor separator and...
Page 389 WIRING DIAGRAM COLOR CODE Black Blue/yellow Z200NETO, LZ200NETO/ Z200TR, LZ200TR Brown Orange/black Green Orange/green Orange/blue Gray Blue Orange/red W/B W/Y H Lighting G Pulser coil Light green Orange/white coil Orange Orange/yellow Pink Pu/B Purple/black Pu/G : Purple/green W/Br Sky blue Pu/L Purple/blue W/Br...
Page 390 COLOR CODE Black Blue/yellow Brown Orange/black Green Orange/green Gray Orange/blue Blue Orange/red Light green Orange/white R/Y R/Y Pu/R Pu/Y Pu/L Pu/B Orange Orange/yellow O/R O/Y O/L Pu/G Pink Pu/B Purple/black Pu/G : Purple/green Pu/W Sky blue Pu/L Purple/blue White Pu/R Purple/red Yellow Pu/W...
Page 392 YAMAHA MOTOR CO., LTD. Printed in Japan Oct. 1999 – 0.6 × 1 CR (Z200NETO, LZ200NETO) Printed on recycled paper...

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Lz200n Z200y Lz200y

Yamaha Z200N Service Manual

Table of Contents

Specifications

Insp Adj

Chapter 4 Fuel System

Chapter 5 Power Unit

Chapter 6 Lower Unit

Propeller Shaft Housing Assembly (Regular Rotation Models)

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