Yamaha F225F Service Manual
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Yamaha F225F Service Manual

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Table of Contents

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F(L)225F
F(L)250D
F(L)300B
SERVICE MANUAL
6CE-28197-3N-11

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Summary of Contents for Yamaha F225F

  • Page 1 F(L)225F F(L)250D F(L)300B SERVICE MANUAL 6CE-28197-3N-11...
  • Page 2 Preface This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have the Bronze Technical Certificate of the YTA...

  • Page 3: Table Of Contents

    Contents General information INFO Specification SPEC TECH Technical features and description Rigging information GING TRBL Troubleshooting SHTG Electrical system ELEC Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT Maintenance Index Appendix...

  • Page 5: General Information

    INFO General information Safety while working ............ 0-1 Rotating part ................0-1 Hot part ..................0-1 Electric shock ................0-1 Propeller ..................0-1 Handling of gasoline ..............0-1 Ventilation .................. 0-1 Self-protection ................0-2 Working with crane ..............0-2 Handling of gas torch ..............0-2 Part, lubricant, and sealant ............

  • Page 6: Safety While Working

    INFO General information Safety while working Handling of gasoline • Gasoline is highly flammable. Keep gaso- To prevent an accident or injury and to pro- line and all flammable products away from vide quality service, observe the following heat, sparks, and open flames. safety procedures.

  • Page 7: Self-Protection

    Yamaha, when servicing or repairing the out- • If the outboard motor does not have three board motor. or more points to be suspended, support it...

  • Page 8: Handling Of Sealant

    INFO General information Handling of sealant Non-reusable part • Wear protective gloves to protect your skin, Always use new gaskets, seals, O-rings, cot- when using the sealants. ter pins, and so on, when installing or assem- • See the material safety data sheet issued bling parts.

  • Page 9: How To Use This Manual

    How to use this manual Safety while working / How to use this manual How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the following information as a guide for effective and quality service. •...

  • Page 10: Abbreviation

    INFO General information Abbreviation The following abbreviations are used in this service manual. Abbreviation Description ABYC American Boat and Yacht Council American Petroleum Institute ATDC After Top Dead Center Automatic Transmission Fluid American Wire Gauge BTDC Before Top Dead Center Check Engine Cold Cranking Ampere Down side...
  • Page 11 How to use this manual Abbreviation Description Up side Variable Camshaft Timing Water in Fuel Y-COP Yamaha Customer Outboard Protection YDIS Yamaha Diagnostic System...

  • Page 12: Lubricant, Sealant, And Thread Locking Agent

    Lubricant, sealant, and thread locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points. Symbol Name Application Yamaha 4-stroke motor oil Lubricant Gear oil Lubricant Water resistant grease Lubricant (Yamaha grease A)
  • Page 13 Lubricant, sealant, and thread locking agent Symbol Name Application ThreeBond 1386B Sealant ThreeBond 1530D Sealant LOCTITE 210 (red) Thread locking agent LOCTITE 242 (blue) Thread locking agent LOCTITE 271 (red) Thread locking agent LOCTITE 572 (white) Sealant Silicone sealant Sealant...

  • Page 14: Special Service Tool

    INFO General information Special service tool For all markets except U.S.A. and Canada Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division. Engine lifting eye Peak voltage adapter B 90890-06820 90890-03172 Drilling plate Test harness (3 pins)
  • Page 15 Special service tool Ignition tester (spark gap tester) Leakage tester 90890-06754 90890-06840 Test harness (2 pins) Compression gauge 90890-06867 90890-03160 Test harness (3 pins) Compression gauge extension 90890-06791 90890-06563 Fuel pressure gauge adapter Balance hanger 90890-06842 90890-06822 Fuel pressure gauge Rotor holder 90890-06786 90890-01235...
  • Page 16 INFO General information Sheave holder Valve lapper 90890-01701 90890-04101 Valve spring compressor Valve seat cutter holder 90890-04019 90890-06316 Valve spring compressor attachment Valve seat cutter 30° 90890-06320 90890-06331 Valve guide remover/installer Valve seat cutter 45° 90890-06801 90890-06332 Valve guide reamer Valve seat cutter 60°...
  • Page 17 Special service tool Valve seat cutter 30° Needle bearing attachment 90890-06327 90890-06612 Valve seat cutter 45° Bearing inner race attachment 90890-06325 90890-06640 Valve seat cutter 60° Piston ring compressor 90890-06324 90890-05158 Oil filter wrench Needle bearing attachment 90890-06830 90890-06653 Driver rod L3 Shift rod socket 90890-06652 90890-06679...
  • Page 18 INFO General information Needle bearing attachment Center bolt 90890-06614 90890-06504 Ring nut wrench extension Ball bearing attachment 90890-06513 90890-06634 Ring nut wrench 6 Needle bearing attachment 90890-06677 90890-06611 Bearing housing puller claw L Bearing inner race attachment 90890-06502 90890-06661 Stopper guide plate Driver rod LL 90890-06501 90890-06605...
  • Page 19 Special service tool Bearing outer race attachment Needle bearing attachment 90890-06623 90890-06680 Bearing inner race attachment Ball bearing attachment 90890-06640 90890-06655 Drive shaft ring nut wrench Bearing outer race puller assembly 90890-06674 90890-06523 Drive shaft holder 6 Bearing outer race attachment 90890-06520 90890-06628 Pinion nut holder...
  • Page 20 INFO General information Magnet base plate Slide hammer 90890-07003 90890-06531 Dial gauge set Puller head 90890-01252 90890-06514 Magnet base B Needle bearing attachment 90890-06844 90890-06607 Pinion shimming gauge Ring nut wrench 90890-06675 90890-06578 Pinion shimming gauge rod Bearing puller assembly 90890-06676 90890-06535 0-15...
  • Page 21 Special service tool PTT oil pressure gauge assembly 90890-06580 Cylinder-end screw wrench 90890-06568 PTT piston vice attachment 90890-06572 Tilt rod wrench 90890-06569 0-16...

  • Page 22: Specification

    SPEC Specification Model feature ..............1-1 General feature ................. 1-1 Model designation ..............1-2 Serial number ................1-2 Model data ................. 1-3 Dimension and weight ............... 1-3 Performance ................1-3 Power unit ................. 1-4 Lower unit .................. 1-5 Bracket unit ................1-5 Fuel and oil requirement ............
  • Page 23 Lower unit (regular rotation model) ......... 1-27 Lower unit (counter rotation model) ......... 1-28 Bracket unit ................1-28 PTT unit ................... 1-29 General tightening torque ..........1-30...

  • Page 24: Model Feature

    SPEC Specification Model feature General feature F(L)225F, F(L)250D, and F(L)300B overall feature • Newly developed 60° V6, DOHC, 24-valve, 4-stroke 4169.0 cm (254.4 cu. in) engine • Low exhaust emissions conform to EU regulations • All models can use Digital network control •...

  • Page 25: Model Designation

    F225FET 1000001– bracket. FL225FET 1000001– F250DET 1000001– FL250DET 1000001– F300BET 1000001– FL300BET 1000001– YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON a Model name b Approved model code c Transom height d Serial number e Model year code...

  • Page 26: Model Data

    SPEC Specification Model data Dimension and weight Model Item Unit F225FET FL225FET F250DET FL250DET Overall length mm (in) 958.0 (37.7) Overall width mm (in) 634.0 (25.0) Overall height mm (in) 1890.0 (74.4) 2017.0 mm (in) — 2017.0 (79.4) (79.4) Boat transom height mm (in) 643 (25.3) 770.0...

  • Page 27: Power Unit

    Model data Model Item Unit F300BET FL300BET Maximum fuel consumption L (US gal, At 5500 r/min 97.0 (25.6, 21.3) Imp gal)/hr Engine idle speed r/min 650–750 Power unit Model Item Unit F225FET FL225FET F250DET FL250DET Type 4-stroke, DOHC Cylinder quantity Total displacement (cu.

  • Page 28: Lower Unit

    SPEC Specification Lower unit Model Item Unit F225FET FL225FET F250DET FL250DET Gear shift positions F–N–R Gear ratio 1.75 (21/12) Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Clock- Counter Clock- Counter Propeller direction (rear view) wise clockwise wise...

  • Page 29: Fuel And Oil Requirement

    Model data Fuel and oil requirement Model Item Unit F225FET FL225FET F250DET FL250DET Fuel type Regular unleaded gasoline Minimum fuel octane number 4-stroke motor oil with combination of the fol- Engine oil lowing SAE and API oil classifications SE, SF, SG, SH, SJ, SL Engine oil grade (*1) 5W-30, 10W-30, 10W-40 Total engine oil quantity (oil pan...

  • Page 30: Battery Requirement

    SPEC Specification Battery requirement Model Item Unit F225FET FL225FET F250DET FL250DET Minimum cold cranking amps CCA/EN 640.0 Minimum rated capacity 20HR/IEC 80.0 Model Item Unit F300BET FL300BET Minimum cold cranking amps CCA/EN 640.0 Minimum rated capacity 20HR/IEC 80.0 PTT fluid requirement Model Item Unit...

  • Page 31: Electrical System Technical Data

    Electrical system technical data Model data / Electrical system technical data Electrical system technical data Ignition timing control system Model Item Unit F225FET FL225FET F250DET FL250DET Spark plug mm (in) 1.0–1.1 (0.039–0.043) Cam position sensor Input voltage 12.0 Ignition coil Input voltage 12.0 Pulser coil...
  • Page 32 SPEC Specification Model Item Unit F300BET FL300BET Spark plug mm (in) 1.0–1.1 (0.039–0.043) Cam position sensor Input voltage 12.0 Ignition coil Input voltage 12.0 Pulser coil Air gap mm (in) 0.4–1.1 (0.016–0.043) Output peak voltage At cranking (unloaded) At cranking (loaded) At 1500 r/min (loaded) 23.9 At 3500 r/min (loaded)

  • Page 33: Fuel Injection Control System

    Electrical system technical data Fuel injection control system Model Item Unit F225FET FL225FET F250DET FL250DET Fuel line Pressure (*1) Within 5 seconds after kPa (kgf/ engine start switch turned 330.0 (3.30, 47.9) , psi) to ON kPa (kgf/ At 700 r/min 280.0 (2.80, 40.6) , psi) Water detection switch...

  • Page 34: Engine Speed Control System

    SPEC Specification Model Item Unit F300BET FL300BET Low-pressure fuel pump Input voltage 12.0 Resistance (*1) Ω At 20 °C (68 °F) 0.5–4.0 High-pressure fuel pump Input voltage 12.0 Resistance (*1) Ω At 20 °C (68 °F) 0.2–3.0 Vapor shut-off valve Input voltage 12.0 Resistance...

  • Page 35: Vct System

    Electrical system technical data Model Item Unit F300BET FL300BET Output voltage (*1) With throttle valve fully closed TPS1 0.37–0.63 TPS2 2.5–3.5 Throttle valve opening angle (*1) With throttle valve fully degree closed Input voltage 4.75–5.25 Output voltage 0.2–1.5 2.412–2.588 3.5–4.8 Input voltage 4.75–5.25 Oil pressure sensor...

  • Page 36: Shift Actuator

    SPEC Specification Shift actuator Model Item Unit F225FET FL225FET F250DET FL250DET Shift actuator Rod stroke (*1) mm (in) 78.2 (3.08) mm (in) 59.2 (2.33) mm (in) 41.1 (1.62) Motor resistance (*1) Ω At 20 °C (68 °F) (*1) The figures are for reference only. Model Item Unit...

  • Page 37: Charging System

    Electrical system technical data Charging system Model Item Unit F225FET FL225FET F250DET FL250DET Lighting coil Output peak voltage At cranking (unloaded) At 1500 r/min (unloaded) 38.0 At 3500 r/min (unloaded) 83.2 Resistance (*1) Ω At 20 °C (68 °F) 0.1056–0.1584 Fuse Rectifier Regulator Output peak voltage...

  • Page 38: Gauge/Sensor

    SPEC Specification Model Item Unit F225FET FL225FET F250DET FL250DET Brush Standard length mm (in) 15.5 (0.61) Wear limit mm (in) 9.5 (0.37) Model Item Unit F300BET FL300BET Y-COP Input voltage 12.0 Starter motor Type Sliding gear Output 1.70 Cranking time limit second Commutator Standard diameter...
  • Page 39 Electrical system technical data Model Item Unit F300BET FL300BET Water pressure sensor Input voltage 4.75–5.25 Output voltage (*1) At 392.0 kPa (3.92 kgf/cm 56.8 psi) At 784.0 kPa (7.84 kgf/cm 113.7 psi) Speed sensor Input voltage 4.75–5.25 Output voltage (*1) At 392.0 kPa (3.92 kgf/cm 56.8 psi) At 784.0 kPa (7.84 kgf/cm...

  • Page 40: Fuel System Technical Data

    SPEC Specification Fuel system technical data Fuel system Model Item Unit F225FET FL225FET F250DET FL250DET Fuel filter assembly Holding pressure kPa (kgf/ Positive pressure 200.0 (2.00, 29.0) , psi) kPa (kgf/ Negative pressure 80.0 (0.80, 11.6) , psi) Canister Holding pressure kPa (kgf/ Positive pressure 19.6 (0.196, 2.8)

  • Page 41: Power Unit Technical Data

    Power unit technical data Fuel system technical data / Power unit technical data Power unit technical data Power unit Model Item Unit F225FET FL225FET F250DET FL250DET Compression pressure kPa (kgf/ Minimum (*1) 700.0 (7.00, 101.5) , psi) Engine oil Oil pressure (*2) At 60 °C (140 °F) with SL kPa (kgf/ 10W-30 engine oil and at...

  • Page 42: Cylinder Head Assembly

    SPEC Specification Model Item Unit F300BET FL300BET Thermostat Valve opening temperature °C (°F) 50.0–54.0 (122.0–129.0) Fully open temperature °C (°F) 62.0 (144.0) Fully open stroke mm (in) 4.3 (0.17) Replacement engine oil quan- tity (at periodic maintenance) L (US qt, Without oil filter replacement 6.0 (6.34, 5.28) Imp qt)
  • Page 43 Power unit technical data Model Item Unit F225FET FL225FET F250DET FL250DET Valve stem Diameter Intake mm (in) 5.477–5.492 (0.2156–0.2162) Exhaust mm (in) 5.464–5.479 (0.2151–0.2157) Runout Intake and exhaust mm (in) 0.01 (0.0004) Valve guide Inside diameter Intake and exhaust mm (in) 5.504–5.522 (0.2167–0.2174) Valve guide clearance Intake...

  • Page 44: Crankcase Assembly

    SPEC Specification Model Item Unit F300BET FL300BET Valve stem Diameter Intake mm (in) 5.477–5.492 (0.2156–0.2162) Exhaust mm (in) 5.464–5.479 (0.2151–0.2157) Runout Intake and exhaust mm (in) 0.01 (0.0004) Valve guide Inside diameter Intake and exhaust mm (in) 5.504–5.522 (0.2167–0.2174) Valve guide clearance Intake mm (in) 0.012–0.045 (0.0005–0.0018)
  • Page 45 Power unit technical data Model Item Unit F225FET FL225FET F250DET FL250DET Connecting rod Small end inside diameter mm (in) 22.010–22.024 (0.8665–0.8671) Big end inside diameter mm (in) 55.990–56.010 (2.2043–2.2051) Big end side clearance mm (in) 0.140–0.310 (0.0055–0.0122) Oil clearance (*1) mm (in) 0.025–0.050 (0.0010–0.0020) Crankshaft...
  • Page 46 SPEC Specification Model Item Unit F300BET FL300BET Connecting rod Small end inside diameter mm (in) 22.010–22.024 (0.8665–0.8671) Big end inside diameter mm (in) 55.990–56.010 (2.2043–2.2051) Big end side clearance mm (in) 0.140–0.310 (0.0055–0.0122) Oil clearance (*1) mm (in) 0.025–0.050 (0.0010–0.0020) Crankshaft Journal diameter mm (in)

  • Page 47: Lower Unit Technical Data

    Lower unit technical data Power unit technical data / Lower unit technical data Lower unit technical data Lower unit assembly (regular rotation model) Model Item Unit F225F F250D F300B Lower unit kPa (kgf/ Holding pressure 68.6 (0.686, 9.9) , psi)

  • Page 48: Bracket Unit Technical Data

    SPEC Specification Bracket unit technical data PTT system Model Item Unit F225FET FL225FET F250DET FL250DET Hydraulic pressure MPa (kgf/ Down 6.7–8.7 (67.0–87.0, 971.5–1261.5) , psi) MPa (kgf/ 13.0–15.0 (130.0–150.0, 1885.0–2175.0) , psi) Motor commutator Standard diameter mm (in) 23.0 (0.91) Wear limit mm (in) 22.0 (0.87)

  • Page 49: Specified Tightening Torque

    Specified tightening torque Bracket unit technical data / Specified tightening torque Specified tightening torque Specified tightening torques are provided for specific nuts, bolts, and screws. When tightening these fasteners, follow the tightening torque specifications indicated throughout the manual to meet the design aims of the outboard motor.

  • Page 50: Lower Unit (Regular Rotation Model)

    SPEC Specification Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Rectifier Regulator cover bolt 18.4 Starter motor bracket bolt Starter motor bolt 22.1 Engine ECM bolt Shift actuator bolt 14.0 Timing belt tensioner bolt — 28.8 Pulley bolt 28.8 Camshaft cap bolts 12.5...

  • Page 51: Lower Unit (Counter Rotation Model)

    Specified tightening torque Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Trim tab bolt 31.0 Propeller nut — 39.8 Lower case mounting bolt (X-transom model) 34.7 Lower case stud bolt (U-transom model) — 17.0 Lower case mounting nut (U-transom model) —...

  • Page 52: Ptt Unit

    SPEC Specification Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Muffler bolt 14.8 Plate screw Self-locking nut — 17.0 Grease nipple — Trim sensor screw PTT unit Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Reservoir mounting bolt 14.0...

  • Page 53: General Tightening Torque

    General tightening torque Specified tightening torque / General tightening torque General tightening torque This chart indicates the tightening torques for standard fasteners with a standard ISO thread pitch. General torque Width Screw specifications across size (B) flats (A) N·m kgf·m ft·lb 8 mm 10 mm...
  • Page 54 SPEC Specification — MEMO — 1-31...

  • Page 55: Tech Fea

    TECH Technical features and description Electronic control system ..........2-1 Engine ECM component ............2-2 Sensor, switch, and actuator ............. 2-3 Electronic fuel injection control ..........2-5 Ignition timing control ..............2-8 VCT control ................2-10 Knock control ................2-11 Engine speed control ...............

  • Page 56: Technical Features And Description

    TECH Technical features and description Electronic control system This model uses an electronic fuel injection control, ignition timing control, knock control, engine speed control, Digital Electronic Control, electronic shift control, ETV control, and fail-safe control. The engine ECM performs these controls based on data received from each sensor and switch. The engine ECM is equipped with a self-diagnosis function.

  • Page 57: Engine Ecm Component

    Electronic control system Engine ECM component a ETV n SPS b Air pressure sensor o Shift actuator c Air temperature sensor p OCV (STBD) d Pulser coil q Thermoswitch (STBD) e Engine temperature sensor r Cam position sensor (STBD IN) f Vapor shut-off valve s Oil pressure sensor g Thermoswitch (PORT)

  • Page 58: Sensor, Switch, And Actuator

    TECH Technical features and description Sensor, switch, and actuator Engine ECM Determines the engine operating conditions according to the input signals from the sensors which are installed at various locations on the engine, and sends output signals to operate the actuators to perform the various control functions.
  • Page 59 Electronic control system Low-pressure fuel Sends the fuel from the fuel tank to the vapor separator. pump...

  • Page 60: Electronic Fuel Injection Control

    TECH Technical features and description Electronic fuel injection control In electronic fuel injection control, the engine ECM determines the fuel injection timing and fuel injection amount according to the signals from the sensors and performs the appropriate fuel injec- tion. The fuel injection amount is controlled by the fuel injector actuation time. There are 2 types of fuel injection timing control: synchronous fuel injection and asynchronous fuel injection.
  • Page 61 Electronic control system Synchronous fuel injection Synchronous fuel injection is fuel injection that occurs using a fixed timing, which is synchronized with the crankshaft angle set by the engine ECM according to the signals from the pulser coil. Fuel injection Fuel injection timing Fuel injection amount Condition...
  • Page 62 TECH Technical features and description Asynchronous fuel injection Asynchronous fuel injection is fuel injection that occurs using the timing determined necessary by the engine ECM according to the signals from the sensors, not synchronized with the crankshaft angle set by the engine ECM. At engine start-up or during acceleration, if the changes in the signals from the TPS or air pressure sensor exceed a predetermined level, fuel injection is performed simul- taneously for all of the cylinders.

  • Page 63: Ignition Timing Control

    Electronic control system Ignition timing control In ignition timing control, the engine ECM uses signals from the sensors to assess engine operating conditions and determines the basic ignition timing and ignition coil energization time. The engine ECM also applies various restrictions and compensations to determine the actual ignition timing. The ignition timing is also controlled according to the knock control.
  • Page 64 TECH Technical features and description Basic ignition timing The basic ignition timing is divided into 3 types: engine starting ignition timing, idling basic ignition timing, and normal basic ignition timing. Basic ignition timing Criteria Ignition cylinder Engine starting ignition timing Engine is starting (less than All cylinders simultaneously (BTDC 10°)

  • Page 65: Vct Control

    Electronic control system VCT control In VCT control, the engine ECM determines the appropriate intake valve opening timing according to the signals from the sensors. According to the engine operating conditions, the OCVs are oper- ated and the VCT assemblies are advanced, retarded, or maintained in the current position to con- trol the intake valve opening timing.

  • Page 66: Knock Control

    TECH Technical features and description Knock control In knock control, the engine ECM receives the knock signal from the knock sensor which is installed on the cylinder block between the cylinder banks. The engine ECM retards the ignition timing and decreases the engine speed according to the amount of knocking to protect the engine from dam- age.

  • Page 67: Engine Speed Control

    Electronic control system Engine speed control In engine speed control, the engine ECM decreases the engine speed to protect the engine from damage. Pulser coil Air pressure sensor Cam position sensor (PORT EX) Fuel injector Cam position sensor (PORT IN) Cam position sensor (STBD IN) Ignition coil...
  • Page 68 TECH Technical features and description Skip-firing control Criteria Description ETV is locked in Controls the Over 1501 r/min Firing and fuel injection will be an open position. engine speed skipped for all of the cylinders. when it has been 1399–1500 r/min Firing and fuel injection will be determined that skipped for cylinders #1, #2, #3, #5,...

  • Page 69: Etv Control

    Electronic control system ETV control In ETV control, the engine ECM determines the appropriate throttle valve opening according to the signals from the sensors, and controls the throttle valve. The engine ECM is equipped with a learn- ing function that records all of the compensations made by the control to the throttle valve opening for the operating conditions up to that point.

  • Page 70: Electronic Shift Control System

    TECH Technical features and description Electronic shift control system The electronic shift control system operates the shift actuator based on the Digital Electronic Control communication data transmitted by the Digital Electronic Control ECM. Pulser coil Shift actuator Cam position sensor (PORT EX) Fuel injector Cam position sensor...

  • Page 71: Fail-Safe Control

    Electronic control system Fail-safe control In fail-safe control, the engine ECM enters the fail-safe mode when an electrical component mal- functions. The fail-safe control system records the trouble codes according to the engine trouble conditions. Trouble Item gauge Trouble conditions to be detected code display Pulser coil...
  • Page 72 TECH Technical features and description Trouble Item gauge Trouble conditions to be detected code display 146, 147, Open or short circuit in the SPS circuit, and shift 148, 149, actuator does not operate. 150, 153, 154, 155 156, 157 Extension Communication error between the engine ECM and wiring harness Digital Electronic Control...

  • Page 73: Charging System

    Electronic control system Charging system This model features a high output charging system that provides up to 70 A. This charging system also functions as a battery isolator that will charge a house (accessory) bat- tery. The engine ECM senses the voltage of the main battery and house (accessory) battery based on the signals from the Rectifier Regulator.

  • Page 74: Digital Network Control

    TECH Technical features and description Digital network control This model features the newly developed 6Y9 Digital Electronic Control that includes the Digital Electronic Control ECM. Mutual authentication is performed between the Digital Electronic Control ECM and the engine ECM. The Digital Electronic Control system operates only when the mutual authentication has suc- ceeded.
  • Page 75 Electronic control system Digital Electronic Control component A Single type (6X6) g Alert indicator B Twin type (6X6) h Engine selector switch C Triple type (6X6) i Engine start switch D Single type (6X7) j Main switch k 6Y9 Multifunction Color Gauge a Control lever l Engine start/stop button (single type) b PTT switch...

  • Page 76: Sensor, Switch

    TECH Technical features and description Sensor, switch Digital Electronic Control Converts actions on the control lever related to the gearshift and the throttle opening or closing into electrical signals and transmits the signals to the engine ECM. Receives digital signals transmitted from the engine ECM. Performs mutual authentication with the engine ECM to perform various controls.

  • Page 77: Y-Cop

    Y-COP Electronic control system / Y-COP Y-COP Y-COP consists of a transmitter and a receiver. The receiver transmits an authorization ID to the Digital Electronic Control ECM. If an authorization ID is not received or if the transmitted authoriza- tion ID does not match the registered ID in the Digital Electronic Control ECM, the receiver cannot perform data communication with the Digital Electronic Control ECM.

  • Page 78: Power Unit System

    TECH Technical features and description Power unit system This model is equipped with a newly developed V6, 4-stroke engine that has 60° cylinder banks. The cylinder heads feature plastic cylinder head covers, shimless valve lifters, and exhaust covers that are integrated into the cylinder heads. The cylinder block features a crankcase equipped with an oil cooler, a crankshaft with an integrated drive sprocket, and sleeveless cylinders.

  • Page 79: Shimless Valve Lifter

    Power unit system Shimless valve lifter Newly designed valve lifters a have been adopted in place of the valve shims previously used b. The valve lifters are available in different thicknesses a. Therefore, the valve clearance b can be adjusted by replacing the current valve lifter with a new valve lifter of the appropriate thickness. A Previous V6 model B New V6 model Sleeveless cylinder...

  • Page 80: Oil Cooler

    TECH Technical features and description Oil cooler The oil coolers a are incorporated into the crankcase b and oil filter bracket c to improve the cool- ing performance. Engine oil that has lubricated the engine is cooled in the oil cooler in the crank- case b, and returned to the oil pan.

  • Page 81: Fuel System

    Fuel system Power unit system / Fuel system Fuel system Fuel diagram Vapor shut-off valve Pressure regulator Fuel rail Fuel injector Fuel rail Fuel injector Vapor separator High-pressure fuel pump Fuel cooler Low-pressure fuel pump Fuel filter (with water Primer pump separator and water detection switch) Canister...
  • Page 82 TECH Technical features and description Primer pump Boat fuel filter (optional) Boat fuel tank Fuel filter (with water separator and water detection switch) Check valve Atmosphere Low-pressure fuel pump Check valve Atmosphere Check valve Filter Canister Vapor shut-off valve Surge tank Float chamber High-pressure Vapor...

  • Page 83: Lubrication System

    Lubrication system Fuel system / Lubrication system Lubrication system Lubrication diagram VCT assembly VCT assembly Oil pressure sensor Oil filter Relief valve Oil pump Strainer Oil pan Piston Camshaft oil passage assembly Crankpin (connecting rod big end) Cylinder head oil passage Camshaft journal Crankshaft main journal...

  • Page 84: Cooling System

    TECH Technical features and description Cooling system The PCV has been removed to simplify the structure of the cooling system. The crankcase, vapor separator, and Rectifier Regulator are cooled using the cooling water. Cooling diagram Thermostat Rectifier Regulator Fuel cooler Oil cooler Exhaust guide Upper case...
  • Page 85 Cooling system Thermostat (PORT) Thermostat (STBD) Rectifier Regulator Cylinder block (PORT) Cylinder block (STBD) Cylinder head (PORT) Cylinder head (STBD) Cooling water outlet Fuel cooler Cylinder block Oil cooler (crankcase) Oil cooler (oil filter Exhaust guide Exhaust guide bracket) Oil pan Oil pan Water pump Upper case...

  • Page 86: Intake And Exhaust System

    TECH Technical features and description Intake and exhaust system Intake and exhaust diagram Throttle body Intake manifold Surge tank Cylinder head Intake manifold Exhaust guide Idle silencer Exhaust manifold Muffler Propeller A Intake air flow B Exhaust gas flow 2-31...

  • Page 87: Lower Unit

    Lower unit Intake and exhaust system / Lower unit Lower unit Double taper roller bearing A double taper roller bearing a is used to receive the thrust load of the pinion and stabilize the axial free play of the drive shaft b. The drive shaft b is secured in the lower case using a ring nut c. As a result, the axial free play is removed and the pinion position is secured.

  • Page 88: Propeller

    TECH Technical features and description Propeller The newly designed propeller is a standard feature of this model. When shifting gears, this propeller absorbs much of the resulting force and noise using the damper a movement for smooth operation. The damper a is replaceable. When shifting gears, the protrusions a on the dedicated spacer b transmit the rotational force of the propeller shaft directly to the propeller c.
  • Page 89 Lower unit — MEMO — 2-34...

  • Page 90: Rig Ging

    GING Rigging information Outboard motor installation ..........3-1 Dimension ................3-2 Exterior: F(L)225F, F(L)250D, F(L)300B ........3-2 Clamp bracket ................3-3 Crate top cover pictograph description ......3-4 Uncrating procedure ............3-5 Outboard motor mounting ..........3-6 Rigging grommet mounting ..........3-8 Rigging grommet description .............
  • Page 91 Rigging recommendation ..........3-30 Extension length recommendation of battery cable ....3-30 Propeller selection ............3-32 Propeller size ................3-32 Selection .................. 3-32...

  • Page 92: Rigging Information

    • Improper mounting of the outboard motor could result in hazardous conditions, such as poor handling, loss of control, or fire hazards. Consult your dealer or have a Yamaha- trained person experienced in proper rigging mount the outboard motor.

  • Page 93: Dimension

    Dimension Outboard motor installation / Dimension Dimension Exterior: F(L)225F, F(L)250D, F(L)300B mm (in) X:1155 (45.5) 639 (25.2) U:1272 (50.1) 230 (9.1) 728 (28.7) X:239 (9.4) 75 (3.0) U:241 (9.5) 240 (19.5) X:53 (2.1) U:59 (2.3) 673 (26.5) (*1) Distance between the outboard motors in twin or triple installation (*2) Transom height...

  • Page 94: Clamp Bracket

    GING Rigging information Clamp bracket mm (in) 180 (7.1) 180 (7.1) 79 (3.1) 163.5 (6.4) 163.5 (6.4) 13 (0.5) 125.4 (4.9) 125.4 (4.9)

  • Page 95: Crate Top Cover Pictograph Description

    Crate top cover pictograph description Dimension / Crate top cover pictograph description Crate top cover pictograph description The following pictographs are important when handling the crate. Read the notice and understand what each pictograph means to prevent damage to the outboard motor when handling, transporting, and storing the crate.

  • Page 96: Uncrating Procedure

    GING Rigging information Uncrating procedure 1. Check the crate for shipping damage. 2. Remove the top cover. 3. Remove all of the bolts from the bottom plate, and then remove the frame. NOTICE: Be careful not to damage the outboard motor. 4.

  • Page 97: Outboard Motor Mounting

    Outboard motor mounting Uncrating procedure / Outboard motor mounting Outboard motor mounting Proper mounting of the outboard motor pro- vides better performance, maximum reliabil- ity, and the highest customer satisfaction. This chapter contains the specifications nec- essary to mount the outboard motor, and may vary slightly depending on applications.
  • Page 98 GING Rigging information TIP: TIP: • Make sure that the distance g is equal to This mounting height information is for refer- distance h. ence only. It is impossible to provide com- • If the boat has a V shape hull, the center plete instructions for every possible boat and outboard motor should have longer transom outboard motor combination.

  • Page 99: Rigging Grommet Mounting

    Rigging grommet mounting Outboard motor mounting / Rigging grommet mounting 5. Apply sealant to the mounting holes and secure the outboard motor using the included mounting bolts small washers c, large washers d, and nuts e. NOTICE: Make sure that there is no clearance between the surfaces of the boat transom and the clamp brackets.

  • Page 100: Installing The Battery Cable

    GING Rigging information 3. Route the extension wiring harness Installing the rigging grommet through the bottom cowling. 1. Route each harness through the proper hole in the rigging grommet. See “Rig- 4. Connect the extension wiring harness ging grommet description” (3-8). coupler b, and then fasten the main wiring harness coupler a using the 2.

  • Page 101: Optional Equipment

    Optional equipment Rigging grommet mounting / Optional equipment 2. Install a new gasket c and the adapter Optional equipment d, and then tighten the adapter d to the Installing the isolator lead specified torque. NOTICE: Do 1. Remove the cap a. reuse a gasket, always replace it with a new one.

  • Page 102: Installing The Speed Sensor

    GING Rigging information 3. Remove the speed sensor coupler b 6. Connect the water pressure sensor coupler b, and then fasten the water from the engine ECM bracket d, and pressure sensor harness a using the then remove the cap c. holder h.

  • Page 103: Installing The Digital Electronic Control Box And Switch Panel

    Installing the Digital Electronic Control box and switch panel Installing Y-COP (optional in non-European markets) Installing Y-COP (optional in non-European markets) See the Yamaha Security System Y-COP installation manual. • Install the receiver so that the UP mark is facing up.
  • Page 104 GING Rigging information 2. Push the unlock button a of the transmitter. The buzzer of the receiver will sound 2 short beeps. A 6Y9 Multifunction Color Gauge B 6Y8 Multifunction Meter TIP: 3. Turn the engine start switch to ON. The •...
  • Page 105 Installing Y-COP (optional in non-European markets) A 6Y9 Multifunction Color Gauge B 6Y8 Multifunction Meter TIP: • If the outboard motor is equipped with the 6Y9 Multifunction Color Gauge, Y-COP mark c will not be displayed when the engine start switch is turned to ON. •...

  • Page 106: Battery Installation

    GING Rigging information Battery installation • Make sure to connect the battery properly and select the proper cable sizes. Otherwise, a fire could result. • When installing an isolator lead to the positive battery terminal or battery switch, over-cur- rent protection in compliance with ABYC (E-11) must be provided. Do not reverse the battery connections.
  • Page 107 Battery installation STBD PORT Outboard Outboard motor motor Isolator lead Red Black Black Black Outboard motor Isolator lead Black Battery switch ON/OFF STBD PORT Outboard Outboard motor motor Isolator lead Isolator lead Black Black ON/OFF ON/OFF Battery switch Battery switch Black 3-16...

  • Page 108: Battery Wiring With House (Accessory) Battery

    GING Rigging information STBD PORT Outboard Outboard motor motor Battery switch Battery switch Navigation systems Boat systems Black Black ON/OFF ON/OFF Black Black Black Battery wiring with house (accessory) battery • When only one battery is used for one engine, connect the positive battery cable and isola- tor lead to the positive battery terminal.
  • Page 109 Battery installation Outboard motor Isolator lead Battery switch Battery switch ON/OFF Black House battery Outboard motor Isolator lead Black Black House battery Outboard motor Isolator lead Black Battery switch Black House battery 3-18...
  • Page 110 GING Rigging information STBD PORT Outboard Outboard motor motor Isolator lead Isolator lead Black Black Battery switch Battery switch ON/OFF ON/OFF Black Black Battery switch House battery STBD PORT Outboard Outboard motor motor Isolator lead Isolator lead Black Battery switch Black Battery switch ON/OFF...
  • Page 111 Battery installation STBD PORT Outboard Outboard motor motor Isolator lead Isolator lead Black Black Battery switch Battery switch House battery Black Black STBD PORT Outboard Outboard motor motor Isolator lead Isolator lead Battery switch Battery switch Black ON/OFF ON/OFF ON/OFF Black Black Black...

  • Page 112: Digital Network System Diagram

    GING Rigging information Digital network system diagram This outboard motor uses simple cabling of the digital network system of the Digital Electronic Con- trol, 6Y8 Multifunction Meter, and 6Y9 Multifunction Color Gauge, making rigging simple and easy. The diagram (Digital network system diagram) shown here is a sample digital network system dia- gram using the 6Y9 system.
  • Page 113 Digital network system diagram NMEA 0183 CANCEL MENU (*1) (*3) (*2) 3-22...

  • Page 114: Twin Outboard Motor Application

    GING Rigging information Twin outboard motor application (*1) The extension wiring harness is available in 5 lengths types: 6.1 m (20.0 ft), 7.0 m (23.0 ft), 8.0 m (26.2 ft), 10.0 m (32.8 ft), and 12.0 m (39.4 ft). Select the one that fits the boat length. (*2) Connect to the all engine start/stop button (optional).
  • Page 115 Digital network system diagram NMEA 0183 CANCEL MENU (*2) (*3) (*1) (*1) 3-24...
  • Page 116 GING Rigging information CANCEL MENU 3-25...

  • Page 117: Triple Outboard Motor Application

    Digital network system diagram Triple outboard motor application (*1) The extension wiring harness is available in 5 lengths types: 6.1 m (20.0 ft), 7.0 m (23.0 ft), 8.0 m (26.2 ft), 10.0 m (32.8 ft), and 12.0 m (39.4 ft). Select the one that fits the boat length. (*2) Connect to the all engine start/stop button (optional).
  • Page 118 GING Rigging information NMEA 0183 CANCEL MENU (*2) f (*3) (*1) (*1) (*1) 3-27...
  • Page 119 Digital network system diagram CANCEL MENU 3-28...

  • Page 120: Digital Electronic Control System Reset

    GING Rigging information Digital Electronic Control system reset A Digital Electronic Control system reset is required after the replacement of the Digital Electronic Control ECM or the engine ECM. 1. Connect the YDIS to display “Remote Control System Reset.” To connect and operate the YDIS, see the YDIS (Ver.
  • Page 121 Rigging recommendation Digital Electronic Control system reset / Rigging recommendation Rigging recommendation Extension length recommendation of battery cable Do not exceed the recommended extension length for the battery cable. Otherwise, the elec- trical system could be damaged or operate improperly. To extend the length of battery cables, follow the requirements in the tables for battery capacity, cable size, and ambient temperature.
  • Page 122 GING Rigging information Ambient temperature –15 °C (5 °F) Battery requirements Cable specifications Number of Maximum total extension length batteries in (Positive battery cable + Negative battery cable) Minimum Unit parallel capacity 20 mm 30 mm 50 mm 60 mm (AWG4) (AWG2) (AWG1/0)
  • Page 123 Propeller selection Rigging recommendation / Propeller selection Propeller selection The propeller sizes listed in the propeller list indicate the following information: The size and type of propeller that is used will affect the performance of a boat and out- board motor critically. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities.
  • Page 124 GING Rigging information Regular rotation model Propeller size Material 3 X 14 1/2 X 19 T (*1) 3 X 15 X 17 T (*1) 3 X 14 3/4 X 23 T 3 X 15 3/4 X 13 T 3 X 15 3/4 X 15 T 3 X 15 1/2 X 17 T Stainless 3 X 15 1/4 X 19 T...

  • Page 125: Trbl Shtg

    TRBL SHTG Troubleshooting YDIS ..................4-1 Feature ..................4-1 Hardware requirement ............... 4-1 Function ..................4-2 Connecting the communication cable to the outboard motor ..4-4 Troubleshooting the power unit ........4-5 Troubleshooting procedure ............4-5 Troubleshooting the power unit using the YDIS ......4-5 Trouble code and checking step ..........

  • Page 126: Troubleshooting

    TRBL SHTG Troubleshooting YDIS This manual contains model-specific information. See the YDIS instruction manual for detailed infor- mation. Feature The newly developed YDIS provides quicker detection and analysis of the engine malfunctions. By connecting your computer to the engine ECM of an outboard motor using the communication cable, this software can be used to display sensor data and data stored in the engine ECM on the computer monitor.

  • Page 127: Function

    YDIS Function • Diagnosis Displays each part name and the engine ECM trouble codes and status when the engine start switch is turned to ON. This enables you to find the malfunctioning parts. The trouble codes dis- played are the same as those described in this chapter. See “Trouble code and checking step” (4-8). •...
  • Page 128 TRBL SHTG Troubleshooting • Active test The test can be performed while the engine is running and the gear shift is set to the N position. It is not possible to perform the test while the boat is moving. Drop cylinder (#1–#6) •...

  • Page 129: Connecting The Communication Cable To The Outboard Motor

    YDIS Connecting the communication cable to the outboard motor a YDIS coupler (gray) YDIS (CD-ROM, Ver. 1.33) a: 60V-WS853-06 YDIS USB adapter and cable b: 60V-WS850-00...

  • Page 130: Troubleshooting The Power Unit

    TRBL SHTG Troubleshooting Troubleshooting the power unit Troubleshooting procedure 1. Before troubleshooting the outboard motor, check that fresh fuel of the specified type has been used. 2. Check that all electrical connections are secure and free from corrosion, and that the battery is fully charged.
  • Page 131 Troubleshooting the power unit Trouble code table O: Indicated —: Not indicated YDIS diagno- Code No. Item YDIS diagnosis sis record Pulser coil malfunction Engine temp sensor malfunction (Engine temperature sensor malfunction) Knock sensor malfunction Battery voltage malfunction Intake temp sensor malfunction (Air temperature sensor malfunction) Cam position sensor (EXH) malfunction Water in fuel...
  • Page 132 TRBL SHTG Troubleshooting YDIS diagno- Code No. Item YDIS diagnosis sis record 160,161, Remote control system malfunction 162,163, (Digital Electronic Control) 164,165, 166,167, 168,169, 170,171, 172,173, 174,175, 176,177, 178,179, 180,181, 183,184, 186,187 The trouble codes 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 183, 184, and 186 are applicable only to the dual station model.
  • Page 133 Troubleshooting the power unit...
  • Page 134 TRBL SHTG Troubleshooting...
  • Page 135 Troubleshooting the power unit 4-10...
  • Page 136 TRBL SHTG Troubleshooting 4-11...
  • Page 137 Troubleshooting the power unit 4-12...
  • Page 138 TRBL SHTG Troubleshooting 4-13...
  • Page 139 Troubleshooting the power unit 4-14...
  • Page 140 TRBL SHTG Troubleshooting 4-15...
  • Page 141 Troubleshooting the power unit 4-16...
  • Page 142 TRBL SHTG Troubleshooting 4-17...
  • Page 143 Troubleshooting the power unit 4-18...
  • Page 144 TRBL SHTG Troubleshooting 4-19...
  • Page 145 Troubleshooting the power unit 4-20...
  • Page 146 TRBL SHTG Troubleshooting 4-21...
  • Page 147 Troubleshooting the power unit 4-22...
  • Page 148 TRBL SHTG Troubleshooting 4-23...
  • Page 149 Troubleshooting the power unit 4-24...
  • Page 150 TRBL SHTG Troubleshooting 4-25...
  • Page 151 Troubleshooting the power unit 4-26...
  • Page 152 TRBL SHTG Troubleshooting 4-27...
  • Page 153 Troubleshooting the power unit 4-28...

  • Page 154: Troubleshooting The Power Unit (Trouble Code Not Detected)

    TRBL SHTG Troubleshooting Troubleshooting the power unit (trouble code not detected) Troubleshooting consists of the following 3 items: Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause: Trouble causes of symptom 2 — : Not applicable Symptom 1: Engine does not crank.
  • Page 155 Troubleshooting the power unit Symptom 1: Engine will not start (engine cranks). Symptom 2 Cause Checking step page Engine ECM does not Main relay malfunction Check the main relay. 5-22 operate Blown fuse Check the fuse. Short, open, or loose connec- Check for wiring continuity between the 5-23 tion in engine ECM circuit...
  • Page 156 TRBL SHTG Troubleshooting Symptom 2 Cause Checking step page Fuel not supplied (all — Measure the fuel pressure. cylinders) Pinched or kinked fuel hose Check the fuel hose. Fuel leakage Check the fuel line for leakage. Clogged fuel filter element Check the fuel filter element for dirt and 6-12 obstructions.
  • Page 157 Troubleshooting the power unit Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited engine speed. Symptom 2 Cause Checking step page Spark plug does not Spark plug malfunction Check the ignition spark. 5-45 spark (some cylinders) Check the spark plug. 7-48 Short, open, or loose connec- Measure the ignition coil input voltage.
  • Page 158 TRBL SHTG Troubleshooting Symptom 1: High engine idle speed. Symptom 2 Cause Checking step page Air leakage (throttle valve–cyl- Check the gaskets of the intake mani- 6-14 — inder head) folds, surge tank, and throttle body. 6-20 Symptom 1: Engine stalls, unstable engine idle speed, or poor acceleration. Symptom 2 Cause Checking step...
  • Page 159 Troubleshooting the power unit Symptom 1: Limited engine speed (below 2000–3000 r/min). Symptom 2 Cause Checking step page Buzzer comes on Thermoswitch malfunction Measure the thermoswitch input voltage. 5-51 Overheat alert Check the thermoswitch for continuity. 5-51 indicator comes on Check for continuity between the ther- 5-51 moswitch and the engine ECM.

  • Page 160: Troubleshooting The Ptt Unit

    TRBL SHTG Troubleshooting Troubleshooting the PTT unit Troubleshooting consists of the following 3 items: Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause: Trouble causes of symptom 2 — : Not applicable Symptom 1: PTT unit does not operate. Symptom 2 Cause Checking step...

  • Page 161: Troubleshooting The Lower Unit

    Troubleshooting the power unit Troubleshooting the lower unit Troubleshooting consists of the following 3 items: Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause: Trouble causes of symptom 2 — : Not applicable Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate prop- erly.
  • Page 162 ELEC Electrical system Electrical component ............5-1 Port .................... 5-1 Starboard ................... 5-2 Fuse holder ................5-3 Rear ................... 5-5 Front ..................5-6 Top .................... 5-7 Bottom cowling ................5-8 Wiring harness routing ............. 5-9 Port .................... 5-9 Starboard ................. 5-10 Rear ..................
  • Page 163 Checking the vapor shut-off valve ........... 5-39 Charging unit and component ........5-40 Checking the lighting coil (stator assembly) ......5-40 Checking the Rectifier Regulator ..........5-42 Ignition unit and component .......... 5-45 Checking the ignition spark ............. 5-45 Checking the ignition coil ............5-46 Checking the pulser coil ............

  • Page 164: Electrical System

    ELEC Electrical system Electrical component Port a ETV (TPS) b Vapor shut-off valve c Thermoswitch (PORT) d OCV (PORT) e Fuel injector f High-pressure fuel pump g Low-pressure fuel pump...

  • Page 165: Starboard

    Electrical component Starboard a OCV (STBD) b Thermoswitch (STBD) c Fuse holder d PTT relay e Rectifier Regulator f Oil pressure sensor g Fuel injector...

  • Page 166: Fuse Holder

    ELEC Electrical system Fuse holder a Fuse (100 A) (engine battery) f Fuse (30 A) (ignition coil, VCT, fuel injec- b Fuse (20 A) (engine start switch, PTT tor, and engine ECM) g Main relay switch, and Digital Electronic Control h Fuse (30 A) (starter relay) ECM) c Fuse (100 A) (house [accessory] battery)
  • Page 167 Electrical component m Starter relay n Fuse (10 A) (low-pressure fuel pump)

  • Page 168: Rear

    ELEC Electrical system Rear a Engine ECM b Ignition coil c Knock sensor d Speed sensor coupler (optional) e Joint connector 3 f Diode g Joint connector 2 h Water pressure sensor coupler...

  • Page 169: Front

    Electrical component Front a Starter motor b YDIS coupler c Water detection switch (in fuel cup assem- bly)

  • Page 170: Top

    ELEC Electrical system a Cam position sensor (STBD IN) i Engine temperature sensor b Joint connector 4 j Pulser coil c Joint connector 1 k Air temperature sensor d Cam position sensor (PORT EX) l Air pressure sensor e Condenser m Lighting coil (stator assembly) f Condenser g Condenser...

  • Page 171: Bottom Cowling

    Electrical component Bottom cowling A Regular rotation model a PTT switch B Counter rotation model b SPS c Shift actuator d Water detection switch coupler e Trim sensor coupler f Extension wiring harness...

  • Page 172: Wiring Harness Routing

    ELEC Electrical system Wiring harness routing Port A Install the pulser coil coupler to the wiring the holders. D Install the holders to the intake manifold harness guide. B Install the holder to the intake manifold, so that the catch of each holder is facing and then fasten the thermoswitch connec- up, and then fasten the main wiring har- tors using the holder.

  • Page 173: Starboard

    Wiring harness routing Starboard A Install the holders to the intake manifold, a Wiring harness b Ground lead and then fasten the main wiring harness c Thermoswitch lead using the holder. B Fasten the main wiring harness, ther- d PTT ground lead e Lighting coil lead moswitch connectors, and cooling water f Power supply lead...
  • Page 174 ELEC Electrical system C Install the holder to the bracket, and then F Install the holders to the intake manifold, fasten the Rectifier Regulator lead and and then fasten the PTT motor lead using isolator lead using the holder. the holder. D Fit the section of the PTT motor lead G Install the terminal of the ground lead with marked with white tape into the slot in the...
  • Page 175 Wiring harness routing J Install the Rectifier Regulator ground lead terminal and PTT relay ground lead termi- nal so that they contact the stopper. 5-12...

  • Page 176: Rear

    ELEC Electrical system Rear C Fasten the grommet of the main wiring a Ignition coil lead b Vapor gas hose harness using the holder. D Fasten the main wiring harness and igni- A Install the holder on the main wiring har- tion coil lead using the holder.

  • Page 177: Front

    Wiring harness routing Front A Fasten the PTT relay lead using the holder. B Align the starter motor lead with the arrow mark on the terminal. 5-14...

  • Page 178: Top

    ELEC Electrical system A Install the holders to the wiring harness guide, and then fasten the main wiring harness using the holders. B Fasten the low-pressure fuel pump lead and air pressure sensor lead using the holder. C Route the lighting coil leads under the holder.

  • Page 179: Bottom Cowling

    Wiring harness routing Bottom cowling A Regular rotation model a Flushing hose B Counter rotation model b SPS lead c Trim sensor lead d Speedometer hose e PTT motor lead f PTT switch lead g Vapor gas hose 5-16...

  • Page 180: Circuit Diagram

    ELEC Electrical system Circuit diagram TIP: The circled numbers in the illustration indicate the engine ECM terminal numbers. Fuel injector #1 Fuel injector #1 Pulser coil Pulser coil Fuel injector #2 Fuel injector #2 Fuel injector #3 Fuel injector #3 Fuel injector #4 Fuel injector #4 Fuel injector #5...
  • Page 181 Circuit diagram OCV (STBD) Water pressure sensor Water pressure sensor OCV (PORT) Speed sensor Speed sensor Vapor shut-off valve Vapor shut-off valve Trim sensor Trim sensor Fuel pump relay High-pressure High-pressure Air temperature sensor High-pressure Air temperature sensor (high-pressure) fuel pump fuel pump fuel pump relay Engine temperature sensor...

  • Page 182: Ecm Coupler Layout

    ELEC Electrical system ECM coupler layout 61 62 63 64 65 66 67 27 28 29 30 31 32 33 34 35 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 68 69 70 71 72 73 36 37 38 39 40 41 42 43 104 105 106 107...
  • Page 183 ECM coupler layout 61 62 63 64 65 66 67 27 28 29 30 31 32 33 34 35 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 68 69 70 71 72 73 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 104 105...

  • Page 184: Checking The Electrical Component

    ELEC Electrical system Checking the electrical component When measuring peak voltage Using the YDIS between the terminals of an electrical When checking the ETV, TPS, OCV, ignition component using the digital tester, make spark, high-pressure fuel pump, fuel injector, sure that the leads do not contact any or each sensor, use the YDIS.

  • Page 185: Using The Digital Tester

    The electrical technical data apply to the lead to the terminal b, and then check measurements taken using the Yamaha rec- for continuity between the terminals c ommended tester. and d. Replace the relay if there is no The resistance values shown are the values continuity.

  • Page 186: Checking The Engine Ecm Circuit

    ELEC Electrical system Wiring harness continuity: Terminal 41–Ground Terminal 42–Ground Terminal 86–Ground Terminal 99–Ground 3. Measure the input voltage between the engine ECM coupler terminal 37 and ground. Main relay input voltage: Terminal e–Terminal g 12.0 V (battery voltage) 5. Turn the engine start switch to OFF. 6.

  • Page 187: Checking The Etv And Tps

    Engine control unit and component 8. Check the wiring harness for continuity. 1. Connect the YDIS to display “Throttle position sensor (main),” “Throttle valve opening,” and “Throttle position sensor (sub).” 2. Start the engine, warm it up for 5–10 minutes, and then stop it. 3.

  • Page 188: Checking The Etv Motor Relay

    ELEC Electrical system 6. Turn the engine start switch to ON, and then measure the TPS input voltage at the ETV coupler. Check the wiring harness if out of specification. See “Checking the ETV (TPS) circuit” (5-25). ETV motor relay input voltage: Terminal a–Ground 12.0 V (battery voltage) 4.

  • Page 189: Checking The Sps

    Engine control unit and component 7. Check the wiring harness for continuity. 3. Check the wiring harness for continuity. Wiring harness continuity: Terminal 61–Terminal 1 Terminal 111–Terminal 12 117 116 Terminal 120–Terminal 5 Terminal 95–Ground Terminal 103–Ground 8. Connect the engine ECM couplers a and b.

  • Page 190: Checking The Shift Actuator Relay

    ELEC Electrical system 2. Check the shift actuator relay. See SPS output voltage: “Checking the main relay” (5-22). 0.2–1.5 V 2.412–2.588 V 3. Measure the input voltage between the terminal a and ground. 3.5–4.8 V 3. Turn the engine start switch to OFF, and then disconnect the SPS coupler a.

  • Page 191: Checking The Sps And Shift Actuator Circuit

    Engine control unit and component Checking the SPS and shift actuator circuit 1. Disconnect the engine ECM couplers a and b. 2. Disconnect the SPS coupler c. 3. Remove the intake manifold (PORT), and then disconnect the shift actuator motor coupler d.

  • Page 192: Checking The Cam Position Sensor

    ELEC Electrical system 9. Connect the engine ECM couplers a Wiring harness continuity: and b. a Terminal 32–d Terminal 2 a Terminal 34–d Terminal 1 10. Connect the fuse holder couplers e and b Terminal 63–c Terminal 2 f, and then install the fuse holder a. b Terminal 75–c Terminal 4 b Terminal 78–c Terminal 1 11.
  • Page 193 Engine control unit and component Cam position sensor input voltage: Red/Yellow (R/Y)–Black (B) 12 V 12.0 V (battery voltage) White/Black (W/B)–Black (B) (STBD IN) White/Green (W/G)–Black (B) (PORT IN) White/Blue (W/L)–Black (B) (PORT EX) 4.75–5.25 V 3. Turn the engine start switch to OFF. 4.
  • Page 194 ELEC Electrical system 18. Check the wiring harness for continuity. Cam position sensor output voltage: White/Black (W/B)–Black (B) (STBD IN) White/Green (W/G)–Black (B) (PORT IN) White/Blue (W/L)–Black (B) (PORT EX) Position Voltage g, k More than 4.8 Less than 1.0 TIP: Using analog circuit tester is recommended.

  • Page 195: Checking The Ocv

    Engine control unit and component Wiring harness continuity STBD (testing diode mode): Tester probe Display value (refer- ence data) m Terminal a Terminal 0.512 V a Terminal m Terminal m Terminal b Terminal 0.529 V PORT b Terminal m Terminal m Terminal c Terminal 0.512 V...

  • Page 196: Checking The Oil Pressure Sensor

    ELEC Electrical system 9. Disconnect the battery leads. 10. Remove the intake manifold (STBD). 11. Remove the fuse holder a, and then Wiring harness continuity: disconnect the fuse holder coupler c. a Terminal 1–d Terminal 49 a Terminal 2–c Terminal 18 b Terminal 1–d Terminal 50 b Terminal 2–c Terminal 18 14.

  • Page 197: Fuel Control Unit And Component

    Fuel control unit and component Engine control unit and component / Fuel control unit and component Oil pressure sensor input voltage: Orange (O)–Black (B) 4.75 V–5.25 V 3. Remove the oil pressure sensor, and then connect the pressure pump a and special service tool b.

  • Page 198: Checking The Fuel Injector

    ELEC Electrical system Water detection switch input voltage: Blue/White (L/W)–Black (B) 4.75–5.25 V 3. Turn the engine start switch to OFF, and then remove the filter cup assembly. 4. Check that the float a move smoothly. 5. Check the water detection switch for continuity when the float a is in positions 7.
  • Page 199 Fuel control unit and component STBD 8. Disconnect the engine ECM coupler c. PORT Fuel injector input voltage: Red/Yellow (R/Y)–Ground 9. Check the wiring harness for continuity. 12.0 V (battery voltage) 4. Turn the engine start switch to OFF. 5. Measure the fuel injector resistance. Fuel injector resistance (reference data): 11.5–12.5 Ω...

  • Page 200: Checking The Low-Pressure Fuel Pump And High-Pressure Fuel Pump

    ELEC Electrical system Wiring harness continuity: Injector #1 Terminal 1–Terminal 18 Terminal 2–Terminal 87 Injector #2 Terminal 1–Terminal 18 Terminal 2–Terminal 88 Injector #3 Terminal 1–Terminal 18 Terminal 2–Terminal 96 Low-pressure fuel pump input voltage: Injector #4 Red/Yellow (R/Y)–Ground Terminal 1–Terminal 18 12.0 V (battery voltage) Terminal 2–Terminal 97 Injector #5...

  • Page 201: Checking The High-Pressure Fuel Pump Relay

    Fuel control unit and component Low-pressure fuel pump a resistance Wiring harness continuity: (reference data): a Terminal 1–c Terminal 7 0.5–4.0 Ω at 20 °C (68 °F) a Terminal 2–e Terminal 56 High-pressure fuel pump b resistance b Terminal 1–c Terminal 1 (reference data): b Terminal 2–Ground 0.2–3.0 Ω...

  • Page 202: Checking The Vapor Shut-Off Valve

    ELEC Electrical system 3. Turn the engine start switch to ON, and 2. Turn the engine start switch to ON, and then measure the input voltage between then measure the input voltage between the terminal a and ground, and the the vapor shut-off valve coupler terminal terminal b and ground.

  • Page 203: Charging Unit And Component

    Charging unit and component Fuel control unit and component / Charging unit and component 6. Remove the special service tool a. 7. Measure the resistance between the vapor shut-off valve terminals. Wiring harness continuity: Vapor shut-off valve resistance: 30.0–34.0 Ω at 20 °C (68 °F) Terminal 1–Terminal 73 Terminal 2–Terminal 19 8.
  • Page 204 ELEC Electrical system TIP: When measuring the lighting coil output peak voltage under the cranking (unloaded) condi- tion, remove the clip from the engine shut-off switch to prevent the engine from starting. 6. Remove the intake manifold (STBD). 7. Disconnect the special service tools a and b.

  • Page 205: Checking The Rectifier Regulator

    Charging unit and component Checking the Rectifier Regulator Do not connect the battery cables in reverse. Otherwise, the Rectifier Regula- tor could be damaged. 1. Remove the fuse cover a. 2. Measure the Rectifier Regulator output peak voltage. 5. Remove the fuse holder, and then remove the Rectifier Regulator couplers g, h, and k.
  • Page 206 ELEC Electrical system Rectifier Regulator continuity (testing diode mode): Tester probe Display value (reference data) Rectifier Regulator continuity (testing diode mode): Tester probe Display value (reference data) 0.000 V 0.000 V 0.447 V 0.441 V 0.447 V OL: Indicates an overload 5-43...
  • Page 207 Charging unit and component Rectifier Regulator continuity Rectifier Regulator continuity (testing diode mode): (testing diode mode): Tester probe Tester probe Display value Display value (reference data) (reference data) 0.446 V 0.447 V 0.446 V 0.445 V 0.445 V 0.446 V 0.447 V 0.446 V 0.445 V...

  • Page 208: Ignition Unit And Component

    ELEC Electrical system Rectifier Regulator continuity (testing diode mode): Tester probe Display value 2 1 2 (reference data) Wiring harness continuity: Terminal 1–Terminal 118 Terminal 2–Terminal 85 0.809 V 9. Connect the Rectifier Regulator couplers 0.807 V and ground lead, and then install the fuse 0.809 V holder.

  • Page 209: Checking The Ignition Coil

    Ignition unit and component Charging unit and component / Ignition unit and component Ignition tester (spark gap tester) a: 90890-06754 4. Disconnect the special service tool a. 5. Install the ignition coils. Checking the ignition coil 1. Disconnect the ignition coil couplers a. 2.

  • Page 210: Checking The Pulser Coil

    ELEC Electrical system 3. Measure the pulser coil output peak Wiring harness continuity: voltage. Ignition coil #1 Terminal 1–Terminal 106 Terminal 2–Ground Terminal 3–Terminal 18 Ignition coil #2 Terminal 1–Terminal 98 Terminal 2–Ground Terminal 3–Terminal 18 Ignition coil #3 Terminal 1–Terminal 110 Terminal 2–Ground Terminal 3–Terminal 18 Ignition coil #4...

  • Page 211: Checking The Air Temperature Sensor

    Ignition unit and component TIP: • Check the air temperature sensor when the engine is cold. • When checking the air temperature sensor, remove the top cowling and do not start the engine. 4. Disconnect the air temperature sensor coupler a. 7.

  • Page 212: Checking The Air Pressure Sensor

    ELEC Electrical system Air temperature sensor resistance (reference data): 2.21–2.69 kΩ at 20 °C (68 °F) 0.32 kΩ at 80 °C (176 °F) 10. Disconnect the engine ECM coupler b. Air pressure sensor input voltage: Orange (O)–Black (B) 4.75–5.25 V 4.

  • Page 213: Checking The Engine Temperature Sensor

    Ignition unit and component Checking the engine temperature Air pressure sensor output voltage sensor (reference data): 1. Disconnect the engine temperature sen- Pink/Green (P/G)–Black (B) sor coupler a. 3.21 V at –20.0 kPa (–0.20 kgf/cm , –2.9 psi) 2. Turn the engine start switch to ON, and 2.16 V at –46.7 kPa then measure the input voltage at the (–0.467 kgf/cm...

  • Page 214: Checking The Thermoswitch

    ELEC Electrical system PORT 8. Check the wiring harness for continuity. Thermoswitch input voltage: Pink (P)–Black (B) 4.75–5.25 V 3. Turn the engine start switch to OFF. 4. Remove the thermoswitches. 5. Place the thermoswitches in a container of water and heat the water slowly. Wiring harness continuity: Terminal 1–Terminal 64 Terminal 2–Terminal 77...

  • Page 215: Checking The Knock Sensor

    Ignition unit and component 7. Disconnect the engine ECM coupler k. Knock sensor resistance: 8. Check the wiring harness for continuity. 504.0–616.0 kΩ at 20 °C (68 °F) 3. Disconnect the engine ECM coupler b. Wiring harness continuity: Pink (P)–Terminal 71 4.

  • Page 216: Starting Unit And Component

    ELEC Electrical system START Starter relay input voltage: Terminal a–Ground 12.0 V (battery voltage) 4. Connect the tester probes between the terminals b and c, and then turn the engine start switch to START and measure the input voltage. A Engine start switch B Main switch Terminal Switch...

  • Page 217: Checking The Engine Start/Stop Button

    Starting unit and component Ignition unit and component / Starting unit and component START Terminal Switch position Engine start/stop button continuity: START Button pushed in: (*1) A : Terminal a–Terminal b A Engine start switch B : Terminal c–Terminal d B Main switch C : Terminal e–Terminal f D : Terminal g–Terminal h...
  • Page 218 ELEC Electrical system Y-COP input voltage: Red (R)–Ground 12.0 V (battery voltage) 2. Connect the Y-COP coupler a. 5-55...

  • Page 219: Starter Motor

    Starter motor Starting unit and component / Starter motor Starter motor Part name Q’ty Remarks Brush spring Brush assembly Brush holder assembly Washer set Starting motor gear assembly Bracket Screw 16 mm Bolt 127 mm Planetary gear Outer gear Plate Stator Armature Pinion assembly...
  • Page 220 ELEC Electrical system Part name Q’ty Remarks Bracket assembly Pinion shaft Cover Bolt 35 mm Lever assembly Seal set Magnet switch Washer 5-57...

  • Page 221: Removing The Starter Motor

    Starter motor Removing the starter motor Checking the magnet switch 1. Connect the tester probes to the magnet switch terminals a and b. Before removing the starter motor, make 2. Connect the negative battery cable a sure to disconnect the negative battery to the starter motor body.

  • Page 222: Disassembling The Starter Motor

    ELEC Electrical system 4. Remove the rubber seal c, lever d, and 2. Turn the pinion counterclockwise to pinion shaft assembly e. check that it operates smoothly and turn it clockwise to check that it locks in place. Disassembling the starter motor 1.

  • Page 223: Checking The Armature (Starter Motor)

    Starter motor 7. Remove the E-clip m, and then remove the shim n, brackets h, gasket i, and shim p. Checking the armature (starter motor) 1. Check the commutator. Clean using 8. Remove the stator j. 600-grit sandpaper and compressed air if dirty.

  • Page 224: Checking The Brush Holder

    ELEC Electrical system Brush holder assembly continuity: 2. Measure the length f of each brush. Replace the brush assembly if below specification. Commutator standard undercut b: 0.5–0.8 mm (0.02–0.03 in) Wear limit: 0.2 mm (0.01 in) 4. Check armature continuity. Replace if out of specification.
  • Page 225 Starter motor 3. Install the armature a along with the 5. Install the pinion assembly h, pinion brush holder assembly b to the bracket stopper m, and clip n. c, and then install the stator d. 6. Install the pinion shaft assembly p, the lever r, and a new rubber seal s.

  • Page 226: Installing The Starter Motor

    ELEC Electrical system 2. Install the intake manifold (STBD). See “Installing the intake manifold” (6-16). 6Y9 Multifunction Color Gauge sensor Checking the water pressure sensor (optional) 1. Disconnect the water pressure sensor coupler a. 2. Turn the engine start switch to ON, and then measure the input voltage at the water pressure sensor coupler.

  • Page 227: Checking The Speed Sensor (Optional)

    6Y9 Multifunction Color Gauge sensor Starter motor / 6Y9 Multifunction Color Gauge sensor 8. Install the water pressure sensor, and Pressure pump a: then connect the water pressure sensor (commercially available) coupler a. Test harness (3 pins) b: 90890-06869 9. Connect the engine ECM couplers b and c.

  • Page 228: Outboard Motor And Digital Electronic Control Connection

    ELEC Electrical system 3 2 1 Wiring harness continuity: Terminal 1–Terminal 79 Terminal 2–Terminal 77 Terminal 3–Terminal 66 Pressure pump a: 8. Install the speed sensor, and then (commercially available) connect the speed sensor coupler a. Test harness (3 pins) b: 90890-06869 9.

  • Page 229: Ptt Electrical System

    6Y9 Multifunction Color Gauge sensor / PTT electrical system Outboard motor and Digital Electronic Control connection / PTT electrical system Outboard motor and Digital Electronic Control connection / PTT electrical system 2. Disconnect the engine ECM couplers b Wiring harness continuity: and c.
  • Page 230 ELEC Electrical system 7. Connect the positive battery lead to the connector g, connect the negative battery lead to the connector f, and then check the PTT relay for continuity. Replace if out of specification. PTT relay input voltage: Red (R)–Ground 12.0 V (battery voltage) 4.

  • Page 231: Checking The Ptt Switch (Bottom Cowling)

    PTT electrical system 10. Remove the fuse holder b, and then 16. Install the intake manifold (STBD). See disconnect the fuse holder coupler k. “Installing the intake manifold” (6-16). 17. Connect the engine ECM coupler m. Checking the PTT switch (bottom cowling) 1.

  • Page 232: Checking The Trim Sensor

    ELEC Electrical system Terminal Wiring harness continuity: Switch position Terminal 1–Terminal 54 Terminal 2–Terminal 16 Terminal 3–Terminal 45 Free 8. Connect the fuse holder coupler e, and then install the fuse holder a. 4. Remove the intake manifold (STBD). 9. Install the intake manifold (STBD). See 5.
  • Page 233 PTT electrical system 3. Disconnect the engine ECM couplers e and f. 4. Check the wiring harness for continuity. Wiring harness continuity: Terminal 1–Terminal 77 Terminal 2–Terminal 27 5. Connect the engine ECM couplers e and f. 6. Install the trim sensor, and then connect trim sensor coupler...
  • Page 234 FUEL Fuel system Hose routing ..............6-1 Fuel hose and blowby hose ............6-1 Vapor gas hose ................. 6-2 Cooling water hose ..............6-4 Fuel system ............... 6-6 Reducing the fuel pressure ............6-6 Disconnecting the quick connector ..........6-6 Measuring the fuel pressure ............
  • Page 235 Vapor separator ............... 6-33 Draining the fuel ..............6-35 Removing the vapor separator ..........6-35 Checking the vapor shut-off valve ........... 6-36 Installing the vapor separator ..........6-36 Vapor separator and high-pressure fuel pump .... 6-37 Disassembling the vapor separator ......... 6-39 Checking the high-pressure fuel pump ........

  • Page 236: Fuel System

    FUEL Fuel system Hose routing Fuel hose and blowby hose a Fuel hose (joint to fuel filter assembly) a Primer pump b Fuel hose (fuel filter assembly to joint) b Joint c Fuel hose (joint to low-pressure fuel c Fuel filter assembly d Joint pump) d Fuel hose (low-pressure fuel pump to...

  • Page 237: Vapor Gas Hose

    Hose routing Vapor gas hose a Vapor gas hose (vapor separator to canis- h Vapor gas hose (check valve to bottom ter tank port) cowling) b Vapor gas hose (canister purge port to i Vapor gas hose (atmosphere to check joint) valve) c Vapor gas hose (joint to vapor shut-off...
  • Page 238 FUEL Fuel system a Vapor separator b Joint c Canister d Joint e Vapor shut-off valve f Check valve g Pressure regulator h Air pressure sensor...

  • Page 239: Cooling Water Hose

    Hose routing Cooling water hose a Cooling water hose (cylinder block to oil g Cooling water hose (thermostat cover cooler) [STBD] to joint) b Cooling water hose (cylinder block to fuel h Cooling water hose (joint to Rectifier Reg- cooler) ulator) c Cooling water pilot hose (fuel cooler to oil i Cooling water hose (Rectifier Regulator to...

  • Page 240: Fuel System

    FUEL Fuel system m Cooling water hose (joint to joint) a Oil cooler n Cooling water hose (joint to cylinder block b Fuel cooler (vapor separator) c Rectifier Regulator [PORT]) d Cooling water outlet (on the bottom cowl- o Cooling water hose (joint to cylinder block [STBD]) ing) p Cooling water hose (thermostat cover...

  • Page 241: Reducing The Fuel Pressure

    Fuel system Hose routing / Fuel system Fuel system Disconnecting the quick connector Reducing the fuel pressure Before disconnecting the quick connec- tor, reduce the fuel pressure. Otherwise, Before servicing the high-pressure fuel pressurized fuel could spray out. line or vapor separator, make sure to reduce the fuel pressure in the fuel line.

  • Page 242: Measuring The Fuel Pressure

    FUEL Fuel system TIP: • After disconnecting the quick connector a, be careful not to lose the retainer c. • Cover the quick connector and fuel rail with a plastic bag to prevent damage and to pro- tect them from dirt. Measuring the fuel pressure 1.

  • Page 243: Checking The Pressure Regulator

    Fuel system 9. Disconnect the special service tools a Vacuum/pressure pump gauge set b: WARNING! Before 90890-06756 disconnecting the special service tools, cover the end of the hose using 5. Block the end of the pressure regulator a clean and dry rag. Also, make sure hose a using a rubber plug.
  • Page 244 FUEL Fuel system Fuel filter assembly 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks Joint Clamp Hose Holder Cover M6 × 16 mm Bolt Holder Bracket M6 × 25 mm Bolt Grommet Collar Plastic tie Fuel filter assembly O-ring Fuel filter element Fuel cup assembly...

  • Page 245: Fuel Filter Assembly

    Fuel filter assembly 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks Float 6-10...

  • Page 246: Removing The Fuel Filter Assembly

    FUEL Fuel system Removing the fuel filter assembly Cover the fuel components using a rag to prevent fuel from spilling out. 1. Disconnect the water detection switch coupler a. Checking the fuel filter assembly 1. Connect the special service tool a to the 2.

  • Page 247: Disassembling The Fuel Filter Assembly

    Fuel filter assembly 4. Block the fuel inlet a using a rubber plug Checking the fuel cup assembly b, and then apply the specified negative 1. Check the fuel cup assembly. Clean pressure. Replace the O-ring, fuel cup using straight gasoline if there is foreign assembly, or fuel filter assembly if the material replace...
  • Page 248 FUEL Fuel system 2. Connect the fuel hoses c and d, and then fasten them using the plastic ties e. 3. Install the cover f. 4. Connect the water detection switch coupler a. 6-13...

  • Page 249: Intake Manifold

    Intake manifold Fuel filter assembly / Intake manifold Intake manifold 7 N·m (0.7 kgf·m, 5.2 ft·lb) 24 N·m (2.4 kgf·m, 17.7 ft·lb) 24 N·m (2.4 kgf·m, 17.7 ft·lb) 10 11 11 N·m (1.1 kgf·m, 8.1 ft·lb) 11 N·m (1.1 kgf·m, 8.1 ft·lb) Part name Q’ty Remarks...

  • Page 250: Removing The Intake Silencer

    FUEL Fuel system Removing the intake silencer Removing the intake manifold 1. Remove the caps a, and then remove 1. Disconnect the air temperature sensor coupler a. the PTT motor leads a. 2. Remove the PTT motor leads a from the holder b.

  • Page 251: Checking The Intake Manifold

    Intake manifold PORT STBD 5. Remove the main wiring harness e from Checking the intake manifold the holders e. 1. Check the intake manifolds. Replace if cracked or deformed. Installing the intake manifold Do not reuse a gasket, always replace it with a new one.
  • Page 252 FUEL Fuel system 4. Tighten the intake manifold bolts e to PORT the specified torque in 2 stages and in the order a, b, and so on. PORT STBD Intake manifold bolt e (M6): 1st: 11 N·m (1.1 kgf·m, 8.1 ft·lb) STBD 2nd: 11 N·m (1.1 kgf·m, 8.1 ft·lb) TIP:...

  • Page 253: Installing The Intake Silencer

    Intake manifold 10. Route the PTT motor leads g through PORT the guide, and then fasten them using the holder l. 11. Install the drain hose m to the intake 7. Fasten the fuel injector lead e and manifold. thermoswitch lead f using the holders STBD Installing the intake silencer 1.
  • Page 254 FUEL Fuel system 3. Install the blowby hose f. 4. Connect the air temperature sensor coupler a. 6-19...
  • Page 255 Throttle body Intake manifold / Throttle body Throttle body 11 N·m (1.1 kgf·m, 8.1 ft·lb) 14 21 Part name Q’ty Remarks M8 × 60 mm Bolt Holder Grommet Bracket Holder Bracket M6 × 20 mm Bolt Air pressure sensor Hose Throttle body Gasket Surge tank...
  • Page 256 FUEL Fuel system 11 N·m (1.1 kgf·m, 8.1 ft·lb) 14 21 Part name Q’ty Remarks Bracket Bracket Bracket M6 × 16 mm Bolt Bracket Holder Hose Hose 6-21...

  • Page 257: Throttle Body

    Throttle body Removing the throttle body and surge tank 1. Disconnect the air pressure sensor cou- pler a and ETV coupler b. 2. Remove the YDIS coupler c and low- pressure fuel pump coupler d. 7. Remove the vapor gas hoses g and h from the holder i, and then remove the bracket j.

  • Page 258: Checking The Etv

    FUEL Fuel system 2. Install the surge tank d. 10. Remove the air pressure sensor hose n, pressure regulator hose e, and vapor gas hose f. 3. Install the brackets e and f, and then tighten the surge tank bracket bolts g to Checking the ETV the specified torque.
  • Page 259 Throttle body 7. Fasten the cooling water hose n using the holder o. 8. Connect the air pressure sensor hose c, and then install the air pressure sensor 5. Connect the pressure regulator hose b and vapor gas hose a. 9.

  • Page 260: Canister

    FUEL Fuel system Canister Part name Q’ty Remarks Hose Check valve Hose Joint Hose Hose Bolt Grommet Collar Bracket Bracket M6 × 15 mm Bolt Canister Hose 6-25...

  • Page 261: Removing The Canister

    Canister Removing the canister 1. Disconnect the vapor gas hoses a, b and c. Checking the canister 1. Check the canister. Replace if cracked. 2. Connect the special service tool a to the 2. Remove the vapor gas hose a from the atmospheric port a and block the other holders d.

  • Page 262: Installing The Canister

    FUEL Fuel system 2. Connect the vapor gas hoses b, c, d, 2. Apply positive pressure and check that e, and f to the joint g and check air comes out of the opposite end of the valves h. canister check valve.
  • Page 263 Canister 6-28...

  • Page 264: Low-Pressure Fuel Pump

    FUEL Fuel system Low-pressure fuel pump 5 N·m (0.5 kgf·m, 3.7 ft·lb) 12 mm 9 mm 12 mm (0.47 in) (0.35 in) (0.47 in) 12 mm (0.47 in) Part name Q’ty Remarks Hose Holder Plastic tie Hose Clamp Joint Bushing Low-pressure fuel pump Holder Clamp...

  • Page 265: Removing The Low-Pressure Fuel Pump

    Low-pressure fuel pump Removing the low-pressure fuel 4. Remove holder then disconnect the fuel hoses h and i. pump Cover the fuel components using a rag to prevent fuel from spilling out. 1. Remove the vapor gas hoses a and b from the holder c.

  • Page 266: Installing The Low-Pressure Fuel Pump

    FUEL Fuel system 6. Install the fuel hose h to the holders i and j. Leakage tester a: 90890-06840 7. Install the clamp k temporarily onto the Specified positive pressure: fuel hose l. 170.0 kPa (1.70 kgf/cm , 24.7 psi) Installing the low-pressure fuel 8.
  • Page 267 Low-pressure fuel pump 11. Fasten the vapor gas hoses p and q using the holder r. 6-32...
  • Page 268 FUEL Fuel system Vapor separator Part name Q’ty Remarks Hose Joint Joint Hose Hose Holder Holder Clamp Hose M6 × 35 mm Bolt Collar Grommet Vapor separator assembly Clamp Hose Plastic tie M6 × 15 mm Bolt 6-33...

  • Page 269: Vapor Separator

    Vapor separator Part name Q’ty Remarks Vapor shut-off valve Bracket Hose Holder 6-34...

  • Page 270: Draining The Fuel

    FUEL Fuel system 2. Disconnect the vapor gas hoses a, b, Draining the fuel and c, cooling water hose d, and fuel 1. Remove the intake manifold (PORT). hose e. 2. Disconnect the fuel hose a from the vapor separator assembly b. 3.

  • Page 271: Checking The Vapor Shut-Off Valve

    Vapor separator 5. Remove the cooling water hose d and 4. Install the vapor separator assembly g. fuel hose j. Checking the vapor shut-off valve 1. Check the vapor shut-off valve exterior. Replace if cracked. 2. Check the electrical performance of the vapor shut-off valve.
  • Page 272 FUEL Fuel system Vapor separator and high-pressure fuel pump 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty...
  • Page 273 Vapor separator and high-pressure fuel pump 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty...

  • Page 274: Disassembling The Vapor Separator

    FUEL Fuel system 5. Remove the cover k, gasket l, high- Disassembling the vapor separator pressure fuel pump m, and grommet n. 1. Remove the drain screw a and drain hose b. 2. Remove the fuel cooler cover c and gasket d.

  • Page 275: Checking The High-Pressure Fuel Pump

    Vapor separator and high-pressure fuel pump Checking the high-pressure fuel 2. Apply positive pressure and check that air comes out of the opposite end b of pump the check valve. Replace the check valve 1. Check the electrical performance of the if no air comes out.
  • Page 276 FUEL Fuel system 5. Install a new gasket m and the cover n, and then tighten the float chamber cover screws o to the specified torque. Needle valve assembly screw b: 2 N·m (0.2 kgf·m, 1.5 ft·lb) Float pin screw e: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 3.
  • Page 277 Vapor separator and high-pressure fuel pump Cover bolt t: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 7. Install the pressure regulator u and holder v, and then tighten the pressure regulator screw w to the specified torque. 8. Install a new gasket x and the fuel cooler cover y, and then tighten the fuel cooler cover screws z to the specified torque.

  • Page 278: Fuel Injector

    FUEL Fuel system Fuel injector Part name Q’ty Remarks M6 × 25 mm Bolt Quick connector Fuel rail (PORT) Holder Fuel injector O-ring set Fuel rail (STBD) Clamp Hose Joint Hose Hose 6-43...

  • Page 279: Removing The Fuel Injector

    Fuel injector Removing the fuel injector PORT Cover the fuel components using a rag to prevent fuel from spilling out. 1. Disconnect the quick connectors. See steps 2 and 3 in “Disconnecting the quick connector” (6-6). 2. Remove the fuel hoses a, b, and c. STBD 5.
  • Page 280 FUEL Fuel system 1. Install new O-rings a and b to fuel STBD injector c. 5. Install the fuel hoses e, f, and g, and then connect the quick connectors. 2. Install the fuel injectors c onto the fuel rail a, and then install the holders b. 6.
  • Page 281 POWR Power unit Power unit (check and adjustment) ......... 7-1 Checking the compression pressure ......... 7-1 Checking the oil pressure ............7-1 Checking the pulser coil air gap ..........7-1 Checking the valve clearance ........... 7-2 Adjusting the valve clearance ............ 7-4 Power unit assembly ............
  • Page 282 POWR Installing the timing belt ............7-39 Camshaft ................7-42 Removing the driven sprocket and camshaft ......7-45 Checking the sprocket ............. 7-47 Checking the valve lifter ............7-47 Checking the camshaft ............7-47 Checking the spark plug ............7-48 Installing the camshaft and driven sprocket ......
  • Page 283 Checking the cylinder bore ............7-78 Checking the piston ring ............7-78 Checking the piston ring end gap ..........7-79 Checking the piston ring groove ..........7-79 Checking the piston ring side clearance ........7-79 Checking the piston pin boss inside diameter ......7-79 Checking the piston pin diameter ..........

  • Page 284: Power Unit

    POWR Power unit Power unit (check and 10. Install the ignition coils. adjustment) 11. Connect the fuel injector couplers. Checking the compression pressure 1. Start the engine, warm it up for 5–10 min- Checking the oil pressure utes, and then stop it. 1.

  • Page 285: Checking The Valve Clearance

    Power unit (check and adjustment) 7. Turn the flywheel magnet c clockwise Checking the valve clearance until the dowel hole e in the flywheel Measure the valve clearances when the magnet c is aligned between the VCT engine is cold. assembly (STBD) d and driven sprocket (STBD) e.
  • Page 286 POWR Power unit 14. Install the cylinder head covers. 15. Install the timing belt guide (STBD), and then adjust timing belt guide clearance. See step 8 in “Installing the timing belt” (7-39). 16. Install the engine ECM bracket and engine ECM. PORT STBD 17.

  • Page 287: Adjusting The Valve Clearance

    Power unit (check and adjustment) Adjusting the valve clearance 9. Remove the VCT assemblies, driven sprockets, camshafts. Adjust the valve clearances when the engine “Removing the driven sprocket and is cold. camshaft” (7-45). 1. Reduce the fuel pressure. See “Reducing the fuel pressure”...
  • Page 288 POWR Power unit 16. Install pulser coil stator assembly. See steps 1–3 in “Installing the flywheel magnet” (7-15). 17. Install the flywheel magnet. See step 5 in “Installing the flywheel magnet” (7-15). 18. Check the pulser coil air gap. See steps 2 and 3 in “Checking the pulser coil air gap”...
  • Page 289 Power unit assembly Power unit (check and adjustment) / Power unit assembly Power unit assembly 3 N·m (0.3 kgf·m, 2.2 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) Part name Q’ty Remarks...
  • Page 290 POWR Power unit 3 N·m (0.3 kgf·m, 2.2 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) Part name Q’ty Remarks Collar Grommet Grommet Bolt 15 mm Idle silencer...

  • Page 291: Removing The Power Unit

    Power unit assembly Removing the power unit 1. Remove the plastic tie a, and then remove the rigging tube retainer b. 6. Remove the plastic tie h, and then disconnect the extension wiring harness coupler c. 2. Remove the grommet holder c, and then remove the rigging grommet d.
  • Page 292 POWR Power unit 11. Disconnect the cooling water hose o. 15. Remove the aprons r, s, rubber seal t, idle silencer u, and grommet v. 12. Disconnect the vapor gas hose p. 16. Install the special service tools w and x. 17.

  • Page 293: Installing The Power Unit

    Power unit assembly Engine lifting eye w: 90890-06820 Engine lifting eye c: 90890-06820 Balance hanger x: 90890-06822 Balance hanger d: 90890-06822 Installing the power unit Power unit mounting bolts g and h: 1. Clean the power unit mating surface, and 1st: 42 N·m (4.2 kgf·m, 31.0 ft·lb) then install the dowels a and a new gas- 2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb)
  • Page 294 POWR Power unit 10. Connect the cooling water hose r. Apron screw n: 3 N·m (0.3 kgf·m, 2.2 ft·lb) 7. Connect the trim sensor coupler a. 11. Install the brackets s and t, and then tighten the surge tank bracket bolts u to the specified torque.
  • Page 295 Power unit assembly 13. Connect the PTT switch coupler b, and PTT motor lead bolt A: then install it to the bracket x. 4 N·m (0.4 kgf·m, 3.0 ft·lb) 18. Install the shift lever C, and then install 14. Connect the SPS coupler c, and then the clip D.
  • Page 296 POWR Power unit 21. Install the tube retainer H, and then fasten it using the plastic tie I. 7-13...
  • Page 297 Flywheel magnet Power unit assembly / Flywheel magnet Flywheel magnet 4 N·m (0.4 kgf·m, 3.0 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 90° Part name Q’ty Remarks Bolt 35 mm Stator assembly Base assembly Dowel Bracket Plastic tie Pulser coil bolt 20 mm Pulser coil Flywheel magnet bolt...

  • Page 298: Flywheel Magnet

    POWR Power unit Removing the flywheel magnet Installing the flywheel magnet 1. Loosen the flywheel magnet bolts a in the order a, b, and so on, and then remove the flywheel magnet and dowel. Do not reuse a flywheel magnet bolt, NOTICE: Apply force in the direction always replace it with a new one.
  • Page 299 Flywheel magnet 90° Rotor holder h: 90890-01235 Flywheel magnet bolt g: 1st: 40 N·m (4.0 kgf·m, 29.5 ft·lb) 2nd: 90° TIP: In the second tightening stage for the fly- wheel magnet bolts g, mark the bolts and flywheel magnet with identification marks e, and then tighten the bolts 90°...
  • Page 300 POWR Power unit Wiring harness Part name Q’ty Remarks Wiring harness Wiring harness guide Bolt 20 mm Holder Holder Holder Holder Holder Plastic tie 7-17...

  • Page 301: Wiring Harness

    Wiring harness Removing the wiring harness 1. Disconnect the ignition coil couplers a, engine ECM couplers b, and knock sen- sor coupler c. 2. Remove the speed sensor coupler d, joint connector e, and water pressure sensor coupler f. 3. Remove the wiring harness a from the holders b.
  • Page 302 POWR Power unit PORT STBD 13. Disconnect the PTT relay coupler B. 12. Remove the fuse box d, and then disconnect the fuse holder couplers t 14. Disconnect Rectifier Regulator and u, Rectifier Regulator couplers v, coupler D. w, and x, power source coupler y, and isolator coupler A.

  • Page 303: Installing The Wiring Harness

    Wiring harness 17. Remove the starter motor lead J. Installing the wiring harness 1. Install the wiring harness guide a. 18. Remove the holders L from the wiring harness guide e, and then remove the main wiring harness. 2. Install the main wiring harness, and then install the holders a to the wiring harness guide a.
  • Page 304 POWR Power unit 3. Install the starter motor lead b, and then tighten the starter motor lead screw b to the specified torque. 8. Connect the fuse holder couplers k and m, Rectifier Regulator couplers n, p, and r, power source coupler s, and Starter motor lead screw b: isolator coupler t.
  • Page 305 Wiring harness PORT STBD 13. Install the holders D to the wiring harness guide. 14. Fasten the wiring harness e using the holders f and g. STBD 15. Install the condensers E. 16. Connect the cam position sensor coupler 12. Connect the OCV couplers w, cam (PORT EX) F.
  • Page 306 POWR Power unit 20. Connect the ignition coil couplers L, engine ECM couplers M, and knock sensor coupler N. 7-23...
  • Page 307 Fuse box Wiring harness / Fuse box Fuse box 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty Remarks Fuse box assembly Cover Cover Fuse puller Relay Screw 10 mm Fuse 100 A, spare is included. Fuse 10 A, spare is included. Fuse 20 A, spare is included.

  • Page 308: Junction Box

    POWR Power unit Junction box 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 25 N·m (2.5 kgf·m, 18.4 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks...
  • Page 309 Junction box 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 25 N·m (2.5 kgf·m, 18.4 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks Cover...
  • Page 310 POWR Power unit 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 25 N·m (2.5 kgf·m, 18.4 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks Bracket...

  • Page 311: Removing The Rectifier Regulator

    Junction box Removing the Rectifier Regulator 1. Remove the ground lead a. 2. Disconnect the cooling water hoses b and c. 3. Remove the power source lead a and 3. Remove the Rectifier Regulator a. isolator lead b. 4. Remove the terminal c and junction box 4.

  • Page 312: Installing The Rectifier Regulator

    POWR Power unit Installing the Rectifier Regulator 1. Install a new gasket a and the cover b, and then tighten the Rectifier Regulator cover bolts c to the specified torques in 2 stages. NOTICE: Do not reuse a gas- ket, always replace it with a new one. Terminal bolt c: 25 N·m (2.5 kgf·m, 18.4 ft·lb) Rectifier Regulator cover bolts c:...
  • Page 313 Starter motor Junction box / Starter motor Starter motor 25 N·m (2.5 kgf·m, 18.4 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) Part name Q’ty Remarks Bracket Starter motor bracket bolt 35 mm Dowel Bracket...

  • Page 314: Starter Motor

    POWR Power unit Removing the starter motor Starter motor bracket bolt (M6) d: 1. Remove the starter motor a. 12 N·m (1.2 kgf·m, 8.9 ft·lb) Starter motor bracket bolt (M8) e: 2. Remove the brackets b and c. 25 N·m (2.5 kgf·m, 18.4 ft·lb) Starter motor bolt g: 30 N·m (3.0 kgf·m, 22.1 ft·lb) Installing the starter motor...
  • Page 315 Engine ECM Starter motor / Engine ECM Engine ECM 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Engine ECM Engine ECM bolt 20 mm Bolt 30 mm Grommet Collar Holder Holder Bracket 7-32...

  • Page 316: Engine Ecm

    POWR Power unit Removing the engine ECM 1. Remove the engine ECM a and bracket Installing the engine ECM 1. Install the bracket a and engine ECM b, and then tighten the engine ECM bolts c to the specified torque. Engine ECM bolt c: 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7-33...
  • Page 317 Shift actuator Engine ECM / Shift actuator Shift actuator 19 N·m (1.9 kgf·m, 14.0 ft·lb) Part name Q’ty Remarks Shift actuator Bracket Bushing Shift link assembly Bolt 25 mm Bushing Washer Clip Shift actuator bolt 55 mm 7-34...

  • Page 318: Shift Actuator

    POWR Power unit Removing the shift actuator Assembling the shift actuator assembly assembly 1. Remove the shift actuator a. 1. Install the shift link assembly a, bushing b, bushing c, pin d, washer e, and clip f. 2. Remove the bracket b. Installing the shift actuator assembly 1.
  • Page 319 Shift actuator Shift actuator bolts d: 19 N·m (1.9 kgf·m, 14.0 ft·lb) 7-36...
  • Page 320 POWR Power unit Timing belt 39 N·m (3.9 kgf·m, 28.8 ft·lb) 39 N·m (3.9 kgf·m, 28.8 ft·lb) 39 N·m (3.9 kgf·m, 28.8 ft·lb) Part name Q’ty Remarks Timing belt Timing belt tensioner Pulley bolt 55 mm Washer Pulley Collar Bolt 14 mm Guide Guide...

  • Page 321: Timing Belt

    Timing belt Removing the timing belt When the timing belt is not installed, do not turn the crankshaft or driven sprock- ets. Otherwise, the pistons and valves or intake and exhaust valves could collide with each other and be damaged. 1.

  • Page 322: Checking The Timing Belt

    POWR Power unit Timing belt tensioner bolt a: 39 N·m (3.9 kgf·m, 28.8 ft·lb) Pulley bolt d: 39 N·m (3.9 kgf·m, 28.8 ft·lb) 2. Install the timing belt e onto the crankshaft so that the part number b is in the upright position and the belt position mark c is aligned with the small “...
  • Page 323 Timing belt 3. Install the timing belt onto the VCT assemblies and driven sprockets by aligning the belt position marks d, e, f, and g with the “ ” marks in the order listed. TIP: • When turning the timing belt tensioner, apply a force of 15 N·m (1.5 kgf·m, 11.1 ft·lb) or less.
  • Page 324 POWR Power unit 8. Adjust the timing belt guide clearance s. Timing belt guide clearance s: 0.5–1.5 mm (0.02–0.06 in) 7-41...
  • Page 325 Camshaft Timing belt / Camshaft Camshaft 32 N·m (3.2 kgf·m, 23.6 ft·lb) 60 N·m (6.0 kgf·m, 44.3 ft·lb) 60 N·m (6.0 kgf·m, 44.3 ft·lb) 27 28 28 N·m (2.8 kgf·m, 20.7 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) Part name...
  • Page 326 POWR Power unit 32 N·m (3.2 kgf·m, 23.6 ft·lb) 60 N·m (6.0 kgf·m, 44.3 ft·lb) 60 N·m (6.0 kgf·m, 44.3 ft·lb) 27 28 28 N·m (2.8 kgf·m, 20.7 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) Part name...

  • Page 327: Camshaft

    Camshaft 32 N·m (3.2 kgf·m, 23.6 ft·lb) 60 N·m (6.0 kgf·m, 44.3 ft·lb) 60 N·m (6.0 kgf·m, 44.3 ft·lb) 27 28 28 N·m (2.8 kgf·m, 20.7 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) Part name Q’ty...

  • Page 328: Removing The Driven Sprocket And Camshaft

    POWR Power unit Removing the driven sprocket and camshaft When the timing belt is not installed, do not turn the crankshaft or camshafts. Oth- erwise, the pistons and valves or intake and exhaust valves could collide with 60° each other and be damaged. 3.
  • Page 329 Camshaft 5. Secure the intake camshaft using a wrench, and then remove the VCT assemblies e and f. NOTICE: When removing the VCT bolt, do not secure the VCT assembly. Otherwise, the VCT assembly could be damaged. When removing the VCT assembly, do not turn the intake camshaft.

  • Page 330: Checking The Sprocket

    POWR Power unit Checking the camshaft 1. Check the edge and face of the flange on the camshafts (PORT) and intake cam- shaft (STBD) that is used for the cam position sensor. Replace the camshaft if damaged, rough, or scratched. TIP: •...

  • Page 331: Checking The Spark Plug

    Camshaft 3. Measure the camshaft runout. 2. Check the spark plug. Replace if the Camshaft runout: 0.030 mm (0.0012 in) electrodes are eroded, or there is carbon or other deposits. 4. Measure the camshaft journal diameter c and camshaft journal inside diameter 3.
  • Page 332 POWR Power unit 1. Check that the large “ ” mark a on the 4. Install the camshafts e, f, g, and h in the proper positions and new oil seals i. crankshaft is aligned with the mating sur- face of the crankcase and cylinder block. P-IN P-EX 2.
  • Page 333 Camshaft STBD STBD PORT 60° 60° 7. Install the camshaft caps j, k, and l in their proper positions that stamped numbers are upside down. 8. Install the camshaft cap bolts m and n. Camshaft cap bolts m and n: 1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb) 2nd: 17 N·m (1.7 kgf·m, 12.5 ft·lb) 10.
  • Page 334 POWR Power unit 12. Secure the exhaust camshaft using a wrench, and then tighten the driven sprocket bolts p to the specified torque. NOTICE: When tightening the bolt, do turn exhaust camshaft. Otherwise, the intake and exhaust valves could collide with each other and be damaged.
  • Page 335 Camshaft 19. Turn crankshaft clockwise 60° gradually until the large “ ” mark k on the crankshaft is aligned with the rib m on the cylinder block. NOTICE: Do not turn the crankshaft clockwise more than 60°. Otherwise, the pistons and valves could collide with each other and be damaged.

  • Page 336: Cylinder Head

    POWR Power unit Cylinder head 7 N·m (0.7 kgf·m, 5.2 ft·lb) 29 28 20 21 14 N·m (1.4 kgf·m, 10.3 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) 14 N·m (1.4 kgf·m, 10.3 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) 56 N·m (5.6 kgf·m, 41.3 ft·lb) 39 N·m (3.9 kgf·m, 28.8 ft·lb) 180°...
  • Page 337 Cylinder head 7 N·m (0.7 kgf·m, 5.2 ft·lb) 29 28 20 21 14 N·m (1.4 kgf·m, 10.3 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) 14 N·m (1.4 kgf·m, 10.3 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) 56 N·m (5.6 kgf·m, 41.3 ft·lb) 39 N·m (3.9 kgf·m, 28.8 ft·lb) 180°...

  • Page 338: Removing The Cylinder Head

    POWR Power unit Removing the cylinder head 1. Remove the OCVs a and filters a. 2. Remove the cylinder heads b and gaskets c. NOTICE: Be careful not to scratch damage mating surfaces of the cylinder head and cylinder block. Valve spring compressor e: 90890-04019 Valve spring compressor attachment f: 90890-06320...

  • Page 339: Checking The Cylinder Head Bolt

    Cylinder head Valve spring free length a: 48.1 mm (1.89 in) 2. Measure the valve spring tilt b. Replace if above specification. Cylinder head warpage limit: 0.10 mm (0.0039 in) Checking the cylinder head bolt 1. Measure the diameters a and b of the cylinder head bolt at the specified mea- suring points c and d.

  • Page 340: Checking The Valve Guide

    POWR Power unit 3. Measure the valve stem diameter b. Valve guide inside diameter a: Replace if out of specification. Intake and exhaust: 5.504–5.522 mm (0.2167–0.2174 in) 2. Calculate the valve guide clearance. Replace the valve guide if out of specification.

  • Page 341: Checking The Valve Seat

    Cylinder head Valve guide remover/installer b: 90890-06801 Valve guide installation height a: 11.300–11.700 mm (0.4449–0.4606 in) 3. Insert the special service tool d into the valve guide c, and then ream the valve guide. Valve lapper a: 90890-04101 4. Measure the valve seat contact width a where the blueing dye adhered to the valve face.

  • Page 342: Refacing The Valve Seat

    POWR Power unit Refacing the valve seat 45˚ After every lapping procedure, make sure to clean off any remaining lapping com- pound from the cylinder head and valves. 1. Reface the valve seat using the special service tools. a Slag or rough surface 3.

  • Page 343: Checking The Cylinder Head Anode

    Cylinder head • If the valve seat contact area is too narrow and situated near the bottom edge of the valve face, cut the bottom edge of the valve seat using a 60° cutter to center the area, and then set its width using a 45° cutter. 45˚...
  • Page 344 POWR Power unit 4. Tap the valve spring retainer lightly using a plastic hammer to seat the valve cotters h securely. 2. Install the valve b, valve spring seat c, valve spring d, and valve spring retainer e in this order, and then install the special service tools f and g.

  • Page 345: Installing The Cylinder Head

    Cylinder head Installing the cylinder head 90˚ PORT STBD (T55) 90˚ Do not reuse a filter, gasket, or O-ring, always replace it with a new one. 1. Install new filters a and the OCVs a, and then tighten the OCV bolts b to the specified torque.
  • Page 346 POWR Power unit Oil cooler and oil pump assembly 49 N·m (4.9 kgf·m, 36.1 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) Part name...
  • Page 347 Oil cooler and oil pump assembly 49 N·m (4.9 kgf·m, 36.1 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) Part name...
  • Page 348 POWR Power unit 49 N·m (4.9 kgf·m, 36.1 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) Part name Q’ty...

  • Page 349: Oil Cooler And Oil Pump Assembly

    Oil cooler and oil pump assembly Removing the oil filter bracket 1. Remove the oil filter a. Oil filter wrench b: 90890-06830 2. Remove the oil pressure sensor c, O- ring d, and oil filter union bolt e. 3. Remove the cover f, gasket g, oil filter bracket h, and gasket i.

  • Page 350: Checking The Oil Pump Assembly

    POWR Power unit Driver rod L3 b: 90890-06652 Needle bearing attachment c: 90890-06612 Checking the oil pump assembly TIP: 1. Check the inner surface of the oil pump Install an oil seal halfway into the oil pump housing. Replace the oil pump assembly housing, and then install the other oil seal.

  • Page 351: Installing The Oil Pump Assembly

    Oil cooler and oil pump assembly Installing the oil cooler Do not reuse a gasket, always replace it with a new one. 1. Install the anodes a. 2. Install a new gasket b, the oil cooler c, a new gasket d, and the cover e, and then tighten the oil cooler bolts f to the specified torques in 2 stages and in the order a, b, and so on.

  • Page 352: Installing The Oil Filter Bracket

    POWR Power unit Installing the oil filter bracket Do not reuse a gasket or O-ring, always replace it with a new one. 1. Install a new gasket a, the oil filter bracket b, a new gasket c, the cover d, and the holder e, and then tighten the oil filter bracket bolts f and g to the speci- Oil filter union bolt h:...

  • Page 353: Cylinder Block Sensor And Switch

    Cylinder block sensor and switch Oil cooler and oil pump assembly / Cylinder block sensor and switch Cylinder block sensor and switch 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 14 N·m (1.4 kgf·m, 10.3 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 32 N·m (3.2 kgf·m, 23.6 ft·lb)
  • Page 354 POWR Power unit 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 14 N·m (1.4 kgf·m, 10.3 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 32 N·m (3.2 kgf·m, 23.6 ft·lb) Part name Q’ty Remarks Joint...

  • Page 355: Removing The Pulley Bracket

    Cylinder block sensor and switch 3. Remove the thermoswitches f. Removing the pulley bracket 1. Remove the bracket a. Removing the knock sensor 1. Remove the bracket a. 2. Remove the knock sensor b. Checking the thermostat 1. Suspend the thermostat in a container of water.

  • Page 356: Installing The Thermostat

    POWR Power unit Installing the thermostat Do not reuse a gasket, always replace it with a new one. 1. Install the thermoswitches a. 2. Install new gaskets b and the thermostat housings c, and then tighten the thermostat housing bolts d to the specified torque.
  • Page 357 Cylinder block sensor and switch Timing belt pulley bracket bolt b: 1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb) 2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb) 7-74...
  • Page 358 POWR Power unit Cylinder block 55 N·m (5.5 kgf·m, 40.6 ft·lb) 90° 55 N·m (5.5 kgf·m, 40.6 ft·lb) 90° 40 N·m (4.0 kgf·m, 29.5 ft·lb) 14 N·m (1.4 kgf·m, 10.3 ft·lb) 90° 28 N·m (2.8 kgf·m, 20.7 ft·lb) Part name Q’ty Remarks Cylinder block...
  • Page 359 Cylinder block 55 N·m (5.5 kgf·m, 40.6 ft·lb) 90° 55 N·m (5.5 kgf·m, 40.6 ft·lb) 90° 40 N·m (4.0 kgf·m, 29.5 ft·lb) 14 N·m (1.4 kgf·m, 10.3 ft·lb) 90° 28 N·m (2.8 kgf·m, 20.7 ft·lb) Part name Q’ty Remarks Connecting rod bolt 42 mm Crankpin bearing Collar...

  • Page 360: Disassembling The Cylinder Block

    POWR Power unit Disassembling the cylinder block TIP: 1. Remove the crankcase a. • To prevent mixing the pistons, connecting rods, and connecting rod caps, mark each with an identification number b of the cor- responding cylinder. • Mark each connecting rod and connecting rod cap with mark c on the side facing toward the flywheel magnet end of the crankshaft.

  • Page 361: Checking The Piston Diameter

    Cylinder block Bearing splitter plate i: Piston diameter a: (commercially available) 95.945–95.960 mm Gear puller j: (commercially available) (3.7774–3.7779 in) General cylindrical tool k: Measuring point b: d = 19 mm (0.7 in) 13.500 mm (0.5315 in) up from the e = 90 mm (3.5 in) bottom of the piston skirt 5.

  • Page 362: Checking The Piston Ring End Gap

    POWR Power unit Piston ring dimension: Top ring a: B: 1.200 mm (0.0472 in) T: 2.800–3.000 mm (0.1102–0.1181 in) 2nd ring b: B: 1.170–1.190 mm (0.0461–0.0469 in) T: 3.800–4.000 mm (0.1496–0.1575 in) Oil ring c: B: 2.400–2.470 mm (0.0945–0.0972 in) T: 2.350–2.750 mm (0.0925–0.1083 in) Piston ring groove: Top ring a:...

  • Page 363: Checking The Piston Pin Diameter

    Cylinder block 90˚ Connecting rod small end inside diameter a: 22.010–22.024 mm (0.8665–0.8671 in) Connecting rod big end inside diameter b: Piston pin boss inside diameter a: 55.990–56.010 mm 22.011–22.018 mm (2.2043–2.2051 in) (0.8666–0.8668 in) Connecting rod bolt a: TIP: 1st: 40 N·m (4.0 kgf·m, 29.5 ft·lb) When measuring the piston pin boss inside 2nd: 90°...

  • Page 364: Checking The Crankshaft

    POWR Power unit Crankshaft journal diameter a: 72.976–72.996 mm (2.8731–2.8739 in) Crankpin diameter b: 52.980–53.000 mm (2.0858–2.0866 in) Crankpin width c: 21.000–21.100 mm (0.8268–0.8307 in) 2. Measure the crankshaft runout. Connecting rod big end side clearance a: 0.140–0.310 mm (0.0055–0.0122 in) Checking the crankshaft Crankshaft runout: 0.030 mm (0.0012 in) 1.

  • Page 365: Checking The Crankpin Oil Clearance

    Cylinder block Checking the crankpin oil clearance 1. Clean the crankpin bearings, connecting rod, connecting rod cap, and crankpin. 2. Install the crankpin bearings a into the connecting rod a and connecting rod cap b. TIP: Install the crankpin bearings in the original TIP: positions.

  • Page 366: Selecting The Crankpin Bearing

    POWR Power unit Example: TIP: Connecting rod big In the second tightening stage for the con- end inside diameter Number in table necting rod bolts b, mark the connecting rod bolts and the connecting rod cap with identifi- 56.005 mm cation marks e, and then tighten the bolts 90°...
  • Page 367 Cylinder block Example: If the connecting rod big end inside diameter a is “05” h and the crankpin mark b is “81” k, select the bearing colors in “g.” The upper bearing color is blue and the lower bearing color is green. 90 91 04 05 06 07 7-84...

  • Page 368: Crankpin Bearing Selection Table

    POWR Power unit Crankpin bearing selection table 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 a Connecting rod big end inside diameter b Crankpin mark 7-85...

  • Page 369: Checking The Crankshaft Journal Oil Clearance

    Cylinder block Checking the crankshaft journal oil TIP: clearance Install the crankshaft journal bearings in the After checking the crankshaft journal oil original positions. clearance, check the crankcase bolts. See “Checking the crankcase bolt” (7-81). 6. Install the crankcase d, and then tighten the crankcase bolts e and f to the 1.

  • Page 370: Selecting The Crankshaft Journal Bearing

    POWR Power unit Crankcase bolts e and f a–p (M10): 1st: 55 N·m (5.5 kgf·m, 40.6 ft·lb) 2nd: 90° Crankcase bolt g q–F (M8): 1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb) 2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb) TIP: • Do not turn the crankshaft until the crank- shaft journal oil clearance measurement has been completed.
  • Page 371 Cylinder block Upper bearing Lower bearing color color Purple Purple Purple Yellow Yellow Yellow Yellow Green Green Green Green Brown Brown Brown Example: If the crankshaft journal mark a is “77” r and the cylinder block mark b is “17” s, select the bearing colors in “p.”...

  • Page 372: Crankshaft Journal Bearing Selection Table

    POWR Power unit Crankshaft journal bearing selection table 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 a Crankshaft journal mark b Cylinder block mark 7-89...

  • Page 373: Checking The Cylinder Block Anode

    Cylinder block Checking the cylinder block anode TIP: 1. Check the anodes. Replace if eroded. • Face the mark b on the connecting rod a Clean if there is grease, oil, or scales. in the same direction as the mark c on the NOTICE: Do not apply grease, oil, or piston crown.
  • Page 374 POWR Power unit TIP: Install the crankpin bearings in the original positions. 6. Install the crankshaft journal bearings f. Piston ring compressor k: 90890-05158 9. Install the connecting rod caps m to the TIP: connecting rods, and then tighten new Install the crankshaft journal bearings f in bolts l to the specified torques in 2 the original positions.
  • Page 375 Cylinder block TIP: • Make sure that the marks p on the con- necting rod and connecting rod cap m face toward the flywheel magnet end of the crankshaft. • In the second tightening stage for the con- necting rod bolts l, mark the connecting rod bolts and the connecting rod cap with identification marks r, and then tighten the bolts 90°...
  • Page 376 LOWR Lower unit Lower unit (regular rotation model, X-transom model) ....8-1 Removing the lower unit ............8-3 Disassembling the propeller ............8-3 Checking the propeller .............. 8-3 Checking the lower unit anode ..........8-4 Assembling the propeller ............8-4 Lower unit (regular rotation model, U-transom model) ....
  • Page 377 Checking the lower case ............8-25 Assembling the drive shaft ............8-25 Assembling the forward gear ........... 8-27 Assembling the lower case ............8-27 Assembling the oil seal housing ..........8-28 Installing the forward gear ............8-28 Installing the drive shaft ............8-28 Installing the propeller shaft housing assembly .......
  • Page 378 LOWR Disassembling the water pump housing ........8-70 Checking the water pump and shift rod ........8-70 Assembling the water pump housing ........8-70 Propeller shaft housing (counter rotation model) ..8-71 Removing the propeller shaft housing assembly ..... 8-73 Disassembling the propeller shaft housing assembly .....
  • Page 379 Measuring the forward gear backlash ........8-91 Adjusting the forward gear shim (T2) thickness ...... 8-91 Forward gear shim (T2) selection chart ........8-93 Measuring the reverse gear backlash ........8-95 Adjusting the reverse gear shim (T1) thickness ...... 8-95 Reverse gear shim (T1) selection table ........
  • Page 380 LOWR Lower unit Lower unit (regular rotation model, X-transom model) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 54 N·m (5.4 kgf·m, 39.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name...
  • Page 381 Lower unit (regular rotation model, X-transom model) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 54 N·m (5.4 kgf·m, 39.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty...

  • Page 382: Removing The Lower Unit

    LOWR Lower unit Removing the lower unit • Make sure to disconnect the battery cables from the battery, and remove the clip from the engine shut-off switch. • When removing the lower unit with the power unit installed, make sure to sus- pend the outboard motor.

  • Page 383: Checking The Lower Unit Anode

    Lower unit (regular rotation model, X-transom model) Checking the lower unit anode Installation height c (reference data): 1. Check the trim tab. Replace if eroded. 4.0 mm (0.158 in) Clean if there is grease, oil, or scales. NOTICE: Do not apply grease, oil, or TIP: paint to the trim tab.

  • Page 384: Lower Unit

    LOWR Lower unit TIP: The damper a will be in the proper position (the damper a is in contact with the spacer f) after the propeller nut e has been tight- ened to the specified torque. Therefore, when installing the propeller to the outboard motor, make sure to tighten the propeller nut e to the specified torque.

  • Page 385: (Regular Rotation Model, U-Transom Model)

    Lower unit (regular rotation model, X-transom model) / Lower unit (regular rotation model, U-transom model) Lower unit (regular rotation model, U-transom model) Lower unit (regular rotation model, U-transom model) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 54 N·m (5.4 kgf·m, 39.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb)
  • Page 386 LOWR Lower unit 42 N·m (4.2 kgf·m, 31.0 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 54 N·m (5.4 kgf·m, 39.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name...

  • Page 387: Removing The Lower Unit

    Lower unit (regular rotation model, U-transom model) Removing the lower unit TIP: When disassembling the lower unit, measure the backlash before disassembly. See “Mea- • Make sure to disconnect the battery suring the forward gear backlash and reverse cables from the battery, and remove the gear backlash before disassembly”...
  • Page 388 LOWR Lower unit Water pump and shift rod (regular rotation model) Part name Q’ty Remarks Shift rod E-clip O-ring Plate Oil seal Bolt 25 mm Cover Seal plate Woodruff key Dowel Impeller Outer plate cartridge Gasket Rubber seal Plate O-ring Insert cartridge...
  • Page 389 Water pump and shift rod (regular rotation model) Part name Q’ty Remarks O-ring Water pump housing Bolt 45 mm Oil seal Cover Seal 8-10...

  • Page 390: Removing The Water Pump And Shift Rod

    LOWR Lower unit Removing the water pump and shift Shift rod socket l: 90890-06679 1. Remove the water pump housing a, 5. Remove the plate m, oil seal n, O-ring dowels b, O-ring c, impeller d, and o, and shift rod p. Woodruff key e.

  • Page 391: Checking The Water Pump And Shift Rod

    Water pump and shift rod (regular rotation model) 3. Remove the cover e and seal f. 2. Install new oil seals c to the specified depth a. Checking the water pump and shift 1. Check the water pump housing. Replace if deformed.
  • Page 392 LOWR Lower unit TIP: Fit the protrusions b on the insert cartridge h into the slots c in the water pump housing 8-13...
  • Page 393 Water pump and shift rod (regular rotation model) / Propeller shaft housing (regular rotation model) Propeller shaft housing (regular rotation model) Propeller shaft housing (regular rotation model) 10 12 11 13 1 N·m (0.1 kgf·m, 0.7 ft·lb) 155 N·m (15.5 kgf·m, 114.3 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) Part name Q’ty...
  • Page 394 LOWR Lower unit 10 12 11 13 1 N·m (0.1 kgf·m, 0.7 ft·lb) 155 N·m (15.5 kgf·m, 114.3 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) Part name Q’ty Remarks O-ring Washer Propeller shaft shim (T4) — Taper roller bearing Propeller shaft housing Rubber seal Needle bearing Oil seal...

  • Page 395: Removing The Propeller Shaft Housing Assembly

    Propeller shaft housing (regular rotation model) Removing the propeller shaft housing assembly 1. Remove the water pipe a and rubber seals b. Ring nut wrench extension d: 90890-06513 Ring nut wrench 6 e: 90890-06677 5. Remove the propeller shaft housing ring nut f and claw washer g.

  • Page 396: Disassembling The Propeller Shaft Assembly

    LOWR Lower unit TIP: When removing the slider d, make sure that the balls e do not fall out of position. Disassembling the reverse gear 1. Remove the ball bearing a and thrust washer b. 8. Remove the taper roller bearing b, propeller shaft shims n, washer o, and reverse gear assembly c.

  • Page 397: Checking The Propeller Shaft

    Propeller shaft housing (regular rotation model) Propeller shaft runout: 0.02 mm (0.0008 in) Checking the dog clutch 1. Check the dog clutch, shift plunger, cross Driver rod L3 d: 90890-06652 pin, spring, balls, and slider. Replace if Needle bearing attachment e: cracked or worn.

  • Page 398: Assembling The Reverse Gear

    LOWR Lower unit TIP: When installing the slider c, make sure that the balls b do not fall out of position. 2. Install the dog clutch d so that the hole a in the dog clutch d and the hole b in the propeller shaft are aligned with the hole c in the slider c.
  • Page 399 Propeller shaft housing (regular rotation model) 2. While holding the special service tool b, strike the tool to check that the taper roller bearing outer race a is installed properly. Bearing inner race attachment h: 90890-06640 Depth d: 5.8–6.2 mm (0.228–0.244 in) Driver rod LL b: 90890-06605 Bearing outer race attachment c: TIP:...
  • Page 400 LOWR Lower unit Drive shaft and lower case (regular rotation model) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 177 N·m (17.7 kgf·m, 130.5 ft·lb) 15 20 143 N·m (14.3 kgf·m, 105.5 ft·lb) Part name Q’ty Remarks Drive shaft Pinion shim (T3) —...

  • Page 401: Drive Shaft And Lower Case (Regular Rotation Model)

    Drive shaft and lower case (regular rotation model) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 177 N·m (17.7 kgf·m, 130.5 ft·lb) 15 20 143 N·m (14.3 kgf·m, 105.5 ft·lb) Part name Q’ty Remarks Forward gear shim (T1) Thrust bearing Circlip Washer Taper roller bearing Forward gear Needle bearing...

  • Page 402: Removing The Drive Shaft

    LOWR Lower unit Removing the drive shaft Drive shaft holder 6 g: 90890-06520 1. Remove the oil seal housing a. Pinion nut holder h: 90890-06715 Removing the forward gear 1. Remove the forward gear a, thrust bear- ing b, forward gear shim c, and adapter 2.

  • Page 403: Disassembling The Forward Gear

    Drive shaft and lower case (regular rotation model) Disassembling the forward gear • Use heat-resistant gloves. Otherwise, burns could result. • To prevent fires, remove any flammable substances, such as gasoline and oil, around the working area. • Keep good ventilation while working. 2.

  • Page 404: Disassembling The Lower Case

    LOWR Lower unit Disassembling the lower case TIP: • Before removing the needle bearing, make sure to remove the forward gear assembly. • Use heat-resistant gloves. Otherwise, • Before installing the special service tool, burns could result. make sure that the rollers are installed in •...
  • Page 405 Drive shaft and lower case (regular rotation model) Press load (bearing): 18 N (1800 kgf) 4. Turn the taper roller bearing 10 turns or more to seat the bearing. 5. Install the claw washer c, and then tighten the drive shaft nut d temporarily. Bearing inner race attachment a: 90890-06640 Press load (bearing): 18...

  • Page 406: Assembling The Forward Gear

    LOWR Lower unit 8. Hold the taper roller bearing outer race, and then measure the motive torque of the drive shaft. Drive shaft motive torque: 0.27–1.94 N·m (0.03–0.20 kgf·m, 0.20–1.43 ft·lb) 9. Bend the tab h on the claw washer c to secure the drive shaft nut d.

  • Page 407: Assembling The Oil Seal Housing

    Drive shaft and lower case (regular rotation model) Installing the forward gear TIP: 1. Install the adapter a, original forward • The needle bearing contains 24 rollers. gear shim b, thrust bearing c, and for- • Face the bearing identification mark a on ward gear d.

  • Page 408: Installing The Propeller Shaft Housing Assembly

    LOWR Lower unit 0.045 m Drive shaft ring nut wrench k: 90890-06674 Torque wrench setting value = 177 N·m ÷ (A + 0.045) Drive shaft holder 6 g: 90890-06520 Pinion nut holder h: 90890-06715 • 177 N·m (17.7 kgf·m, 130.5 ft·lb): Speci- fied tightening torque for the drive shaft Pinion nut f: ring nut...
  • Page 409 Drive shaft and lower case (regular rotation model) 1. Install the reverse gear a, the washer b, the original propeller shaft shims c, and a new taper roller bearing a. TIP: Make sure to fit the protrusion b on the pro- peller shaft housing into the slot c in the 2.

  • Page 410: Installing The Shift Rod

    LOWR Lower unit 1. Install a new O-ring a and a new oil seal b to the plate c. 8. Install the dowels m, cover n, and then tighten the cover bolts o to the specified 2. Install the plate c to the shift rod d. torque.

  • Page 411: Checking The Lower Unit For Air Leakage

    Drive shaft and lower case (regular rotation model) 1. Install the plate a, rubber seal b, and seal plate c. 2. Install the dowels d, a new gasket e, the outer plate cartridge f, the cover g, and the Woodruff key h. TIP: While turning the drive shaft clockwise, push the water pump housing down to install it.

  • Page 412: Installing The Lower Unit (X-Transom Model)

    LOWR Lower unit 4. Install the lower unit d, and then tighten Installing the lower unit (X-transom the lower case mounting bolts e and f model) to the specified torque. NOTICE: Make sure to align the splines on the lower unit shift rod with the splines on the •...

  • Page 413: Installing The Lower Unit (U-Transom Model)

    Drive shaft and lower case (regular rotation model) 7. Place a block of wood between the anti- Installing the lower unit (U-transom cavitation plate and the propeller to model) prevent the propeller from turning, and then tighten the propeller nut m to the specified torque.
  • Page 414 LOWR Lower unit Lower case mounting nut i: 47 N·m (4.7 kgf·m, 34.7 ft·lb) Lower case mounting bolt j and k: 47 N·m (4.7 kgf·m, 34.7 ft·lb) 5. Install the trim tab and propeller. See steps 5–8 in “Installing the lower unit (X- transom model)”...

  • Page 415: Shimming (Regular Rotation Model)

    Drive shaft and lower case (regular rotation model) / Shimming (regular rotation model) Shimming (regular rotation model) Shimming (regular rotation model) Shimming workflow Remove the water pump assembly and cover. Measure the backlash before disassembly. Within specification? Shimming is not required. Disassemble the lower unit.

  • Page 416: Shimming Check Sheet

    LOWR Lower unit Shimming check sheet Lower case deviation Serial number Remarks Pinion height (mm) Measurements Measuring point #1 Measuring point #2 Measuring point #3 Measuring point #4 Average Round-down average Forward gear backlash (mm) Measurements Before disassembly After disassembly Measuring point #1 Measuring point #2 Measuring point #3...
  • Page 417 Shimming (regular rotation model) Forward gear shim (T1) thickness measurement in 2 places (mm) Number of shim(s) Subtotal 2.00 2.03 2.06 2.09 2.12 2.15 Total Reverse gear shim (T2) thickness measurement in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15 0.18...

  • Page 418: Measuring The Forward Gear Backlash And Reverse Gear Backlash Before Disassembly

    LOWR Lower unit Measuring the forward gear backlash and reverse gear backlash before disassembly 1. Remove the water pump assembly, cover, and outer plate cartridge. See steps 1–3 in “Removing the water pump and shift rod” (8-11). 2. Set the gear shift to the N position. Backlash indicator e: 90890-06836 Magnet base plate f: 90890-07003 Dial gauge set g: 90890-01252...
  • Page 419 Shimming (regular rotation model) Shift rod socket a: 90890-06679 12. While turning the shift rod toward the R position using the specified torque, turn the drive shaft slowly clockwise and TIP: counterclockwise measure • Measure the backlash at 4 points: a, b, backlash between where the drive shaft c, and d, turning the drive shaft 180°...
  • Page 420 LOWR Lower unit 14. Check that the reverse gear backlash average is within specification. Reverse gear backlash: 0.15–0.88 mm (0.0059–0.0346 in) TIP: Adjust the shim thicknesses if the reverse gear backlash is out of specification. 15. Remove the special service tools, and then install the outer plate cartridge, cover, and water pump assembly.

  • Page 421: Shimming

    Shimming (regular rotation model) Shimming • Before selecting the forward gear shim (T1) and reverse gear shims (T2), make sure to select the pinion shims (T3). • When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do not apply gear oil, grease, or sealant to the parts.

  • Page 422: Selecting The Pinion Shim (T3)

    LOWR Lower unit Selecting the pinion shim (T3) • Spray anti-rust lubricant on the gears and bearings before installation. Do not apply gear oil to the parts. Otherwise, correct measurements cannot be obtained. • Keep the parts free of foreign material, such as dirt and lint.
  • Page 423 Shimming (regular rotation model) TIP: • Measure the distance at 4 points: d, e, f, 0.51 0.52 0.53 0.54 0.55 and g, turning the drive shaft 90° clock- 0.54 wise after each measurement. 0.55 • Write down the measurement data in the 0.56 shimming check sheet.
  • Page 424 LOWR Lower unit 9. Calculate the new pinion shim (T3) thickness. Calculation formula: New pinion shim (T3) thickness = Current pinion shim thickness + Shim thickness adjustment Example: Use the following formula when the shim thickness adjustment value is positive. Current pinion shim thickness = 0.70 mm Shim thickness adjustment = 0.18 mm New pinion shim (T3) thickness...

  • Page 425: Calculated Value (B) Table

    Shimming (regular rotation model) Calculated value (B) table (mm) –011 –010 –009 –008 –007 –006 –005 –004 –003 –002 –001 0.64 0.65 0.66 0.67 0.68 0.69 0.70 0.71 0.72 0.73 0.74 0.75 0.64 0.65 0.66 0.67 0.68 0.69 0.70 0.71 0.72 0.73 0.74...

  • Page 426: Pinion Shim (T3) Selection Table

    LOWR Lower unit Pinion shim (T3) selection table The shim thickness does not have to be adjusted for the gray-colored cell. (mm) 0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.54 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20...
  • Page 427 Shimming (regular rotation model) (mm) 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.46 0.47 0.48 0.49 0.50 0.54 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07 0.55 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07 0.56 +0.17 +0.16 +0.15 +0.14...
  • Page 428 LOWR Lower unit (mm) 0.51 0.52 0.53 0.54 0.55 0.56 0.57 0.58 0.59 0.60 0.61 0.62 0.54 –0.07 –0.08 0.55 –0.07 0.56 0.57 0.58 +0.07 0.59 +0.08 +0.07 0.60 +0.09 +0.08 +0.07 0.61 +0.10 +0.09 +0.08 +0.07 0.62 +0.11 +0.10 +0.09 +0.08 +0.07...
  • Page 429 Shimming (regular rotation model) (mm) 0.63 0.64 0.65 0.66 0.67 0.68 0.69 0.70 0.71 0.72 0.73 0.74 0.54 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20 0.55 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19...
  • Page 430 LOWR Lower unit (mm) 0.75 0.76 0.77 0.78 0.79 0.80 0.81 0.82 0.83 0.84 0.85 0.86 0.54 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29 –0.30 –0.31 –0.32 0.55 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29 –0.30 –0.31 0.56...
  • Page 431 Shimming (regular rotation model) (mm) 0.87 0.88 0.89 0.90 0.91 0.92 0.93 0.94 0.95 0.96 0.97 0.98 0.54 –0.33 –0.34 –0.35 –0.36 –0.37 –0.38 –0.39 –0.40 –0.41 –0.42 –0.43 –0.44 0.55 –0.32 –0.33 –0.34 –0.35 –0.36 –0.37 –0.38 –0.39 –0.40 –0.41 –0.42 –0.43...
  • Page 432 LOWR Lower unit (mm) 0.99 1.00 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 0.54 –0.45 –0.46 –0.47 –0.48 –0.49 –0.50 –0.51 –0.52 –0.53 –0.54 0.55 –0.44 –0.45 –0.46 –0.47 –0.48 –0.49 –0.50 –0.51 –0.52 –0.53 0.56 –0.43 –0.44 –0.45 –0.46 –0.47 –0.48...

  • Page 433: Measuring The Forward Gear Backlash

    Shimming (regular rotation model) Measuring the forward gear backlash Adjusting the forward gear shim (T1) • Spray anti-rust lubricant on the gears and thickness bearings before installation. Do not apply 1. Remove the propeller shaft housing gear oil to the parts. Otherwise, correct assembly and propeller shaft assembly.
  • Page 434 LOWR Lower unit Available shim thicknesses: 2.00, 2.03, 2.06, 2.09, 2.12, 2.15 mm TIP: • The gray-colored cells on the selection table indicate the range where the shim adjustment is unnecessary. Shimming is not required if the obtained forward gear shim thickness is indicated by the gray-col- ored cells.

  • Page 435: Forward Gear Shim (T1) Selection Table

    Shimming (regular rotation model) Forward gear shim (T1) selection table (mm) 0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 2.00 2.03 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.06 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.09 2.00...

  • Page 436: Measuring The Reverse Gear Backlash

    LOWR Lower unit Measuring the reverse gear backlash TIP: • Spray anti-rust lubricant on the gears and Do not reuse a shim if deformed or bearings before installation. Do not apply scratched. gear oil to the parts. Otherwise, correct measurements cannot be obtained. 3.
  • Page 437 Shimming (regular rotation model) TIP: TIP: • If the shim thickness adjustment value is • Use up to 3 shims to obtain the required positive, the current shim thickness must be shim thickness. increased by that amount and, if the value •...
  • Page 438 LOWR Lower unit 8-59...
  • Page 439 Shimming (regular rotation model) 8-60...

  • Page 440: Selecting The Propeller Shaft Shim (T4)

    LOWR Lower unit Selecting the propeller shaft shim (T4) 1. Install the original propeller shaft shims, propeller shaft assembly, and propeller shaft housing assembly. See steps 1–6 in “Installing the propeller shaft housing assembly” (8-29). TIP: • If the original shims are missing, install new Propeller shaft motive torque: shims with a combined thickness of 0.44–1.32 N·m (0.04–0.13 kgf·m,...
  • Page 441 Shimming (regular rotation model) / Lower unit (counter rotation model, X-transom model) Lower unit (counter rotation model, X-transom model) Lower unit (counter rotation model, X-transom model) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 54 N·m (5.4 kgf·m, 39.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb)
  • Page 442 LOWR Lower unit 42 N·m (4.2 kgf·m, 31.0 ft·lb) 54 N·m (5.4 kgf·m, 39.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty Remarks...

  • Page 443: Removing The Lower Unit

    Lower unit (counter rotation model, X-transom model) Removing the lower unit 1. Drain the gear oil. See steps 1–6 in “Changing the gear oil” (10-10). 2. Remove the propeller, trim tab, and lower unit. See steps 2–5 in “Removing the lower unit”...

  • Page 444: Lower Unit

    LOWR Lower unit Lower unit (counter rotation model, U-transom model) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 54 N·m (5.4 kgf·m, 39.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb)
  • Page 445 Lower unit (counter rotation model, U-transom model) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 54 N·m (5.4 kgf·m, 39.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb)

  • Page 446: Removing The Lower Unit

    LOWR Lower unit Removing the lower unit 1. Drain the gear oil. See steps 1–6 in “Changing the gear oil” (10-10). 2. Remove the propeller and trim tab. See steps 2–5 in “Removing the lower unit” (8-3). 3. Remove the extension and lower unit. See steps 3 and 4 in “Removing the lower unit”...

  • Page 447: Water Pump And Shift Rod (Counter Rotation Model)

    Lower unit (counter rotation model, U-transom model) / Water pump and shift rod (counter rotation model) Water pump and shift rod (counter rotation model) Water pump and shift rod (counter rotation model) Part name Q’ty Remarks Shift rod E-clip O-ring Plate Oil seal Bolt...
  • Page 448 LOWR Lower unit Part name Q’ty Remarks O-ring Water pump housing Bolt 45 mm Oil seal Cover Seal 8-69...

  • Page 449: Removing The Water Pump And Shift Rod

    Water pump and shift rod (counter rotation model) Removing the water pump and shift 1. Remove the water pump. See steps 1–4 in “Removing the water pump and shift rod” (8-11). 2. Remove the plate a, oil seal b, O-ring c, and shift rod d.

  • Page 450: Propeller Shaft Housing (Counter Rotation Model)

    LOWR Lower unit Propeller shaft housing (counter rotation model) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 10 12 11 17 1 N·m (0.1 kgf·m, 0.7 ft·lb) 155 N·m (15.5 kgf·m, 114.3 ft·lb) Part name Q’ty Remarks Self-locking nut Water inlet cover (STBD) Water pipe Rubber seal Water inlet cover screw...
  • Page 451 Propeller shaft housing (counter rotation model) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 10 12 11 17 1 N·m (0.1 kgf·m, 0.7 ft·lb) 155 N·m (15.5 kgf·m, 114.3 ft·lb) Part name Q’ty Remarks O-ring Thrust bearing Propeller shaft shim (T4) — Propeller shaft housing Rubber seal Needle bearing...

  • Page 452: Removing The Propeller Shaft Housing Assembly

    LOWR Lower unit Removing the propeller shaft 3. Heat the installation area of the taper roller bearing outer race in the propeller housing assembly shaft housing c using a gas torch, and 1. Remove the water pipe, cover, propeller then remove the forward gear d. shaft housing ring nut, and claw washer.

  • Page 453: Checking The Propeller Shaft

    Propeller shaft housing (counter rotation model) Assembling the propeller shaft housing assembly and forward gear • Use heat-resistant gloves. Otherwise, burns could result. • To prevent fires, remove any flammable substances, such as gasoline and oil, around the working area. •...
  • Page 454 LOWR Lower unit 4. Heat the installation area of the taper roller bearing outer race b in the propeller shaft housing using a gas torch, and then install the taper roller bearing outer race b. NOTICE: When heating the propeller shaft housing, heat the entire installation area...

  • Page 455: Drive Shaft And Lower Case (Counter Rotation Model)

    Propeller shaft housing (counter rotation model) / Drive shaft and lower case (counter rotation model) Drive shaft and lower case (counter rotation model) Drive shaft and lower case (counter rotation model) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 177 N·m (17.7 kgf·m, 130.5 ft·lb) 143 N·m (14.3 kgf·m, 105.5 ft·lb) Part name Q’ty...
  • Page 456 LOWR Lower unit 40 N·m (4.0 kgf·m, 29.5 ft·lb) 177 N·m (17.7 kgf·m, 130.5 ft·lb) 143 N·m (14.3 kgf·m, 105.5 ft·lb) Part name Q’ty Remarks Reverse gear shim (T1) Thrust bearing Circlip Needle bearing Reverse gear Needle bearing Pinion Washer Pinion nut 8-77...

  • Page 457: Removing The Drive Shaft

    Drive shaft and lower case (counter rotation model) Removing the drive shaft See “Removing the drive shaft” (8-23). Removing the reverse gear 1. Remove the reverse gear a, thrust bear- ing b, reverse gear shim c, and adapter Driver rod L3 c: 90890-06652 Needle bearing attachment d: 90890-06653 3.

  • Page 458: Assembling The Lower Case

    LOWR Lower unit Needle bearing attachment b: 90890-06653 Driver rod L3 c: 90890-06652 Installation depth a: TIP: 9.2–9.6 mm (0.36–0.38 in) Make sure to fit the dowel e into the slot a in the lower case. TIP: Face the bearing identification mark b on the Installing the drive shaft needle bearing a up.

  • Page 459: Installing The Shift Rod

    Drive shaft and lower case (counter rotation model) 3. Install the claw washer, ring nut, cover, Installing the lower unit (U-transom and water pipe. See steps 4, 5, and 7–9 model) in “Installing the propeller shaft housing 1. Check that the shift rod is in the N posi- assembly”...

  • Page 460: Shimming (Counter Rotation Model)

    LOWR Lower unit Shimming (counter rotation model) Shimming workflow Remove the water pump assembly and cover. Measure the backlash before disassembly. Within specification? Shimming is not required. Disassemble the lower unit. Select the pinion shims (T3) and propeller shaft shims (T4). Assemble the lower unit.

  • Page 461: Shimming Check Sheet

    Shimming (counter rotation model) Shimming check sheet Lower case deviation Serial number Remarks Pinion height (mm) Measurements Measuring point #1 Measuring point #2 Measuring point #3 Measuring point #4 Average Round-down average Forward gear backlash (mm) Measurements Before disassembly After disassembly Measuring point #1 Measuring point #2 Measuring point #3...
  • Page 462 LOWR Lower unit Forward gear shim (T2) thickness measurement in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15 0.18 0.30 0.40 0.50 Total Reverse gear shim (T1) thickness measurement in 2 places (mm) Number of shim(s) Subtotal 2.00 2.03 2.06 2.09...

  • Page 463: Measuring The Forward Gear Backlash And Reverse Gear Backlash Before Disassembly

    Shimming (counter rotation model) Measuring the forward gear backlash and reverse gear backlash before disassembly 1. Remove the water pump assembly, cover, and outer plate cartridge. See steps 1–3 in “Removing the water pump and shift rod” (8-11). 2. Set the gear shift to the N position. Backlash indicator e: 90890-06836 Magnet base plate f: 90890-07003 Dial gauge set g: 90890-01252...
  • Page 464 LOWR Lower unit 12. Apply a load to the reverse gear by installing the propeller j, spacer k, and washer l (without the spacer m). 13. Tighten the propeller nut n to the TIP: specified torque. • Measure the backlash at 4 points: a, b, c, and d, turning the drive shaft 180°...
  • Page 465 Shimming (counter rotation model) Cover bolt o: 8 N·m (0.8 kgf·m, 5.9 ft·lb) Specified torque: 15 N·m (1.5 kgf·m, 11.1 ft·lb) TIP: • Do not turn the drive shaft using too much force. Otherwise, the reverse gear will turn, leading to incorrect measurements. •...

  • Page 466: Shimming

    LOWR Lower unit Shimming • Before selecting the forward gear shim (T2) and reverse gear shims (T1), make sure to select the pinion shims (T3). • When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do not apply gear oil, grease, or sealant to the parts.

  • Page 467: Selecting The Pinion Shim (T3)

    Shimming (counter rotation model) Selecting the pinion shim (T3) Dial gauge set a: 90890-01252 See “Selecting the pinion shim (T3)” (8-43). Magnetic base B b: 90890-06844 Calculated value (B) table Propeller shaft free play: See “Calculated value (B) table” (8-46). 0.25–0.35 mm (0.0098–0.0138 in) Pinion shim (T3) selection table 6.
  • Page 468 LOWR Lower unit 9. Remove the special service tools, and TIP: then install the determined propeller • If the shim thickness adjustment value is shaft shims. positive, the current shim thickness must be increased by that amount and, if the value is negative, the current shim thickness must be decreased by that amount.

  • Page 469: Propeller Shaft Shim (T4) Selection Table

    Shimming (counter rotation model) Propeller shaft shim (T4) selection table The shim thickness does not have to be adjusted for the gray-colored cell. (mm) –0.3 –0.2 –0.1 +0.1 +0.2 +0.3 +0.4 +0.5 +0.6 +0.7 +0.8 +0.9 +1.0 +1.1 +1.2 +1.3 +1.4 +1.5 +1.6...

  • Page 470: Measuring The Forward Gear Backlash

    LOWR Lower unit Measuring the forward gear backlash 2. Measure the thickness of each original forward gear shim in 2 places. • Spray anti-rust lubricant on the gears and bearings before installation. Do not apply gear oil to the parts. Otherwise, correct TIP: measurements cannot be obtained.
  • Page 471 Shimming (counter rotation model) TIP: TIP: • If the shim thickness adjustment value is • Use up to 3 shims to obtain the required positive, the current shim thickness must be shim thickness. increased by that amount and, if the value •...
  • Page 472 LOWR Lower unit 8-93...
  • Page 473 Shimming (counter rotation model) 8-94...

  • Page 474: Measuring The Reverse Gear Backlash

    LOWR Lower unit Measuring the reverse gear backlash Adjusting the reverse gear shim (T1) thickness • Spray anti-rust lubricant on the gears and bearings before installation. Do not apply 1. Remove the propeller shaft housing gear oil to the parts. Otherwise, correct assembly.
  • Page 475 Shimming (counter rotation model) Example: Backlash measurement (BL1) = 0.49 mm a Current reverse gear shim thickness = 2.06 mm b Use the determined shim thickness of 2.03 mm instead of the current shim thickness. (mm) 0.47 0.48 0.49 2.00 2.03 2.06 2.03...

  • Page 476: Reverse Gear Shim (T1) Selection Table

    LOWR Lower unit Reverse gear shim (T1) selection table (mm) 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.46 2.00 2.03 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.06 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.09 2.00 2.00...
  • Page 477 Shimming (counter rotation model) — MEMO — 8-98...
  • Page 478 BRKT Bracket unit Shift rod and SPS .............. 9-1 Removing the shift rod and SPS ..........9-2 Installing the shift rod and SPS ..........9-2 Cowling lock lever ............. 9-3 Removing the cowling lock lever ..........9-5 Removing the flushing hose ............9-5 Installing the flushing hose ............
  • Page 479 PTT motor ................ 9-38 Removing the reservoir ............9-40 Removing the PTT motor ............9-40 Disassembling the PTT motor ..........9-40 Checking the armature (PTT motor) ........9-41 Checking the brush ..............9-41 Assembling the PTT motor ............9-42 Installing the reservoir ............. 9-43 Installing the PTT motor ............
  • Page 480 BRKT Bracket unit Shift rod and SPS Part name Q’ty Remarks Bolt 25 mm Clip Bushing Washer Circlip Shift rod Shift lever Bushing Bracket Dowel Grommet...
  • Page 481 Shift rod and SPS Removing the shift rod and SPS 1. Remove the clip a, shift lever b, SPS c, bushing d, and washer e. 2. Remove the shift rod f, bushings g, 4. Fit the protrusion a on the SPS i into bracket h, and grommet i.
  • Page 482 BRKT Bracket unit Cowling lock lever 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks Hose Plastic tie Joint Joint Gasket Adapter Grommet Guide Holder Bracket Bolt 12 mm Plastic tie Flushing hose adapter screw ø6 20 mm Bracket Water outlet Hook Bushing...
  • Page 483 Cowling lock lever 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks Washer Wave washer Lever Bolt 12 mm Spring Cowling lock lever (STBD) Lever Clamp Cowling lock lever (PORT) Grommet Cowling lock lever (front) Bracket Holder...
  • Page 484 BRKT Bracket unit 3. Remove the plastic ties j, and then Removing the cowling lock lever remove the grommet k, flushing hose 1. Remove the spring a, and then remove i, trim sensor lead a, and PTT motor the hook b. lead b.
  • Page 485 Cowling lock lever 5. Install the flushing hose adapter f, and then tighten the flushing hose adapter screws g to the specified torque. 6. Route the flushing hose a through the joint h, install it to the hose joint i, and then fasten the flushing hose a using the plastic tie j.
  • Page 486 BRKT Bracket unit PTT switch and bottom cowling Counter rotation model Part name Q’ty Remarks Gasket Cover PTT switch Bolt 12 mm Holder Grommet Bracket Grommet Bolt 35 mm Collar Rubber seal Grommet Bolt 16 mm Grommet Bracket Rubber seal Drain hose...
  • Page 487 PTT switch and bottom cowling Counter rotation model Part name Q’ty Remarks Drain hose Bolt 16 mm Drain box Rubber seal Drain box O-ring Dipstick Dipstick guide Bottom cowling...
  • Page 488 BRKT Bracket unit A Regular rotation model Removing the PTT switch B Counter rotation model 1. Remove the holder a, and then remove the PTT switch b and gasket c. STBD PORT A Regular rotation model B Counter rotation model Installing the PTT switch 1.
  • Page 489 Upper case and mount PTT switch and bottom cowling / Upper case and mount Upper case and mount 55 N·m (5.5 kgf·m, 40.6 ft·lb) 10 12 13 55 N·m (5.5 kgf·m, 40.6 ft·lb) 72 N·m (7.2 kgf·m, 53.1 ft·lb) 72 N·m (7.2 kgf·m, 53.1 ft·lb) Part name Q’ty Remarks...
  • Page 490 BRKT Bracket unit 55 N·m (5.5 kgf·m, 40.6 ft·lb) 10 12 13 55 N·m (5.5 kgf·m, 40.6 ft·lb) 72 N·m (7.2 kgf·m, 53.1 ft·lb) 72 N·m (7.2 kgf·m, 53.1 ft·lb) Part name Q’ty Remarks Bolt 10 mm Ground lead Hose Adapter Plastic tie Washer...
  • Page 491 Upper case and mount Removing the upper case 6. Remove the upper mount bracket bolts e, upper mount bracket h, damper i, 1. Drain the remaining engine oil. upper mounts j, plates k, stopper l, 2. Disconnect the ground lead a and collars m, plate n, and upper mounting speedometer hose b, and then remove bolts o.
  • Page 492 BRKT Bracket unit 3. Install the washers j and lower mounts k and l to the lower mounting bolts m. 4. Install the lower mount brackets n, and then tighten the lower mount bracket Upper mounting nut p: bolts o temporarily. 72 N·m (7.2 kgf·m, 53.1 ft·lb) Lower mounting nut s: 72 N·m (7.2 kgf·m, 53.1 ft·lb)
  • Page 493 Upper case and mount Lower mount bracket bolt o: 55 N·m (5.5 kgf·m, 40.6 ft·lb) 9-14...
  • Page 494 BRKT Bracket unit Upper case 42 N·m (4.2 kgf·m, 31.0 ft·lb) 27 N·m (2.7 kgf·m, 19.9 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) Part name Q’ty Remarks Bolt 14 mm Drain bolt 12 mm Gasket Cover Damper...
  • Page 495 Upper case Disassembling the upper case 1. Remove the drain bolt a, gasket b, cover c, and damper d. 2. Remove the anodes e. Bearing puller assembly l: 90890-06535 3. Remove the oil pan assembly a and Stopper guide plate m: 90890-06501 dowels f.
  • Page 496 BRKT Bracket unit Needle bearing attachment b: 90890-06611 Driver rod L3 c: 90890-06652 2. Install the circlip d. 3. Install the rubber seal e into the upper case. Upper case bolt j (M10): 42 N·m (4.2 kgf·m, 31.0 ft·lb) Upper case bolt k (M8): 20 N·m (2.0 kgf·m, 14.8 ft·lb) Anode screw m: 4 N·m (0.4 kgf·m, 3.0 ft·lb)
  • Page 497 Oil pan and exhaust manifold Upper case / Oil pan and exhaust manifold Oil pan and exhaust manifold 12 N·m (1.2 kgf·m, 8.9 ft·lb) 17 20 20 N·m (2.0 kgf·m, 14.8 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) Part name Q’ty Remarks...
  • Page 498 BRKT Bracket unit 12 N·m (1.2 kgf·m, 8.9 ft·lb) 17 20 20 N·m (2.0 kgf·m, 14.8 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) Part name Q’ty Remarks Muffler Water pipe Rubber seal 9-19...
  • Page 499 Oil pan and exhaust manifold Disassembling the oil pan and 2. Check exhaust guide, exhaust manifold, muffler. Replace exhaust manifold corroded or cracked. 1. Remove the water pipe a, rubber seal b, muffler c, gasket d, plate e, and 3. Check the oil pan. Replace if corroded or gasket f.
  • Page 500 BRKT Bracket unit 4. Install a new gasket h, the exhaust manifold i, and a new rubber seal j, and then tighten the exhaust manifold bolts k temporarily. Muffler bolt q: 5. Tighten the exhaust manifold bolts k to 20 N·m (2.0 kgf·m, 14.8 ft·lb) the specified torque, and then tighten the oil pan bolts g to the specified torque.
  • Page 501 Steering arm Oil pan and exhaust manifold / Steering arm Steering arm Part name Q’ty Remarks Steering arm Washer Bushing O-ring Bushing Steering yoke Circlip 9-22...
  • Page 502 BRKT Bracket unit Removing the steering arm 1. Remove the circlip a. 2. Remove the steering yoke b. Installing the steering arm 1. Install the bushing a and washer b, and then install the steering arm c. 2. Install the bushing d, a new O-ring e, the bushing f, and the washer g.
  • Page 503 Steering arm 4. Hold the steering arm c, and then strike the steering yoke h using a copper hammer until the groove for installing the circlip is visible. 5. Install the circlip i. 6. Inject grease into the grease nipple on the swivel bracket.
  • Page 504 BRKT Bracket unit Clamp bracket and swivel bracket 4 N·m (0.4 kgf·m, 3.0 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 23 25 23 Part name Q’ty Remarks Clamp bracket (STBD) Grease nipple Self-locking nut Holder...
  • Page 505 Clamp bracket and swivel bracket 4 N·m (0.4 kgf·m, 3.0 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 23 25 23 Part name Q’ty Remarks Friction plate Trim stopper Ground lead Friction plate Collar...
  • Page 506 BRKT Bracket unit Removing the clamp bracket 1. Remove the PTT unit. See “Removing the PTT unit” (9-32). 2. Remove the anode a. 3. Remove the ground leads b and c. 4. Remove the self-locking nut d and through tube e, and then disassemble the clamp brackets f and g.
  • Page 507 Clamp bracket and swivel bracket 2. Install the bushings a, collar b, distance 5. Install the plates j and k, and then collar assembly b, and tilt stop levers d tighten the plate screw l to the specified and e. torque.
  • Page 508 BRKT Bracket unit Adjusting the trim sensor After tilting the swivel bracket up, make sure to support it using the tilt stop lever. Otherwise, the swivel bracket could sud- denly lower. 1. Fully tilt the swivel bracket up, and then support it using the tilt stop lever a.
  • Page 509 Clamp bracket and swivel bracket Digital circuit tester: 90890-03174 Trim sensor setting resistance (reference data): Terminal c –Terminal d 9.0–11.0 Ω 6. Fully tilt the swivel bracket up, and then support it using the tilt stop lever. 7. Tighten the trim sensor screws b to the specified torque.
  • Page 510 BRKT Bracket unit PTT unit Part name Q’ty Remarks Shaft Circlip Plastic tie Bolt 14 mm Holder Bushing PTT unit Bolt 45 mm Bolt 10 mm 9-31...
  • Page 511 PTT unit Removing the PTT unit When removing the PTT unit with the power unit installed, make sure to sus- pend the outboard motor. 1. Fully tilt the swivel bracket up, and then support it using the tilt stop lever a. 5.
  • Page 512 BRKT Bracket unit Checking the hydraulic pressure Check the hydraulic pressure. Check the internal parts if out of specification. Before removing the reservoir cap, make sure that the PTT rams are fully extended. Otherwise, fluid could be expelled force- fully from the PTT unit due to internal pressure.
  • Page 513 PTT unit 15. Connect the PTT motor leads to the battery terminals to fully extend the trim rams, and then measure the hydraulic pressure when the reading on the pressure gauge stabilizes. Battery PTT motor lead terminal Sky blue (Sb) Light green (Lg) 10.
  • Page 514 BRKT Bracket unit Manual valve a: Battery PTT motor lead terminal 2 N·m (0.2 kgf·m, 1.5 ft·lb) Light green (Lg) 3. Check the fluid level. See steps 3–5 in Down Sky blue (Sb) “Checking the hydraulic pressure” (9-33). 17. Remove the special service tool c. 4.
  • Page 515 PTT unit 6. Check the fluid level when the PTT rams are fully extended. If the fluid level is low, add sufficient fluid, and then repeat steps 4 and 5. Installing the PTT unit • After tilting the swivel bracket up, make sure to support it using the tilt stop lever.
  • Page 516 BRKT Bracket unit 7. Connect the ground lead f. 8. Fasten the PTT motor lead a and trim sensor lead b using the plastic ties g, and then install the holder h. 9-37...
  • Page 517 PTT motor PTT unit / PTT motor PTT motor 7 N·m (0.7 kgf·m, 5.2 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) Part name Q’ty Remarks Spacer Filter Sheet O-ring Reservoir cap O-ring Reservoir Reservoir mounting bolt 20 mm Joint O-ring...
  • Page 518 BRKT Bracket unit 7 N·m (0.7 kgf·m, 5.2 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) Part name Q’ty Remarks O-ring Spring Brush Motor base assembly Oil seal 9-39...
  • Page 519 PTT motor Removing the reservoir Disassembling the PTT motor 1. Remove the stator a, and then remove the armature b. NOTICE: Secure the end of the armature shaft using a pair Before removing the reservoir, make sure of pliers, and then remove the arma- that the PTT rams are fully extended.
  • Page 520 BRKT Bracket unit TIP: Before removing the bearing, measure and write down the bearing depth a. 4. Remove the bearing g. Motor commutator standard diameter: 23.0 mm (0.91 in) Wear limit: 22.0 mm (0.87 in) 3. Measure the commutator undercut b. Bearing splitter f: (commercially available) Bolt h (commercially available):...
  • Page 521 PTT motor 1. Install a new oil seal a. Motor brush standard length a: 2. Install the brushes b and springs c. 11.5 mm (0.45 in) Wear limit b: 4.5 mm (0.18 in) 2. Check the motor base assembly for continuity.
  • Page 522 BRKT Bracket unit Installing the reservoir Do not reuse an O-ring, always replace it Depth b (reference data): with a new one. 0.95 mm (0.04 in) 1. Install the spacer a, filter b, and sheet 5. Push the brushes b into the holders, and then install the armature f.
  • Page 523 PTT motor TIP: Align the protrusion b on the armature shaft with the slot c in the joint. 2. Fill the gear pump housing with the recommended fluid to the proper level a. Recommended PTT fluid: ATF DEXRON II 3. Turn the joint a using a screwdriver to remove any air between the pump gear teeth.
  • Page 524 BRKT Bracket unit PTT gear pump 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty Remarks Gear pump bolt 40 mm Plate Filter Seal Valve lock screw Spring Valve pin Valve seal Spring...
  • Page 525 PTT gear pump 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty Remarks Up-main valve Ball Relief valve seat O-ring Ball Manual release plate Filter Ball Valve pin Spring Spacer O-ring...
  • Page 526 BRKT Bracket unit 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty Remarks O-ring Spacer Filter O-ring Manual valve Circlip 9-47...
  • Page 527 PTT gear pump 4. Remove the bracket k, and then remove Disassembling the gear pump the filter l, spacers m, springs n, valve housing pins o, and balls p and q. 1. Remove the manual valve a, and then remove the gear pump assembly b. 2.
  • Page 528 BRKT Bracket unit 4. Check the main valves f and g. Clean if there is dirt or residue. 4. Install the balls g, the valve pins h, the springs i, the spacers j, and new O- rings k. 5. Install the balls l and manual release plate m.
  • Page 529 PTT gear pump 10. Install the ball v, valve support pin u, and spring w, and then install the valve lock screw x. Gear pump bolt F: 7 N·m (0.7 kgf·m, 5.2 ft·lb) Manual valve H: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 15.
  • Page 530 BRKT Bracket unit PTT cylinder 160 N·m (16.0 kgf·m, 118.0 ft·lb) 90 N·m (9.0 kgf·m, 66.4 ft·lb) 65 N·m (6.5 kgf·m, 47.9 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty...
  • Page 531 PTT cylinder 160 N·m (16.0 kgf·m, 118.0 ft·lb) 90 N·m (9.0 kgf·m, 66.4 ft·lb) 65 N·m (6.5 kgf·m, 47.9 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks...
  • Page 532 BRKT Bracket unit Removing the tilt ram 5. Cover the tilt cylinder opening with a rag i, and then blow compressed air through the hole a to remove the free piston j. WARNING! When removing Before removing the tilt cylinder, make the free piston, never look into the tilt sure that the PTT rams are fully extended.
  • Page 533 PTT cylinder Checking the tilt cylinder and PTT body 1. Check the PTT body a and tilt cylinder a. Replace if corroded or cracked. 2. Check the inner surfaces of the PTT body a and tilt cylinder a. Replace if scratched.
  • Page 534 BRKT Bracket unit Assembling the tilt ram • When assembling the PTT unit, do not PTT piston vice attachment i: use a rag. Otherwise, dust and particles 90890-06572 could get on the PTT unit components, Tilt rod wrench j: 90890-06569 causing poor performance.
  • Page 535 PTT cylinder 1. Install a new O-ring a to the free piston Assembling the trim ram 2. Push the free piston b into the tilt • When assembling the PTT unit, do not cylinder c until it bottoms out. use a rag. Otherwise, dust and particles could get on the PTT unit components, 3.
  • Page 536 BRKT Bracket unit 2. Install the trim ram assemblies, and then tighten the trim cylinder end screws a to the specified torque. 4. Install the tilt piston assembly into the tilt cylinder, and then tighten the tilt cylinder end screw a to the specified torque. Cylinder-end screw wrench b: 90890-06568 Trim cylinder end screw a:...
  • Page 537 PTT cylinder — MEMO — 9-58...
  • Page 538 Maintenance Outline ................10-1 Maintenance interval chart 1 ........... 10-1 Maintenance interval chart 2 ........... 10-2 Predelivery check ............10-3 Checking the battery ............... 10-3 Checking the cooling water pilot hole ........10-3 Checking the engine oil level ........... 10-4 Checking the communication between the engine and the Digital Electronic Control ...........
  • Page 539 Checking the top cowling ............10-14 Checking the valve clearance ..........10-14 Checking the water pump ............10-14...
  • Page 540 • If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and qual- ity. Any parts of inferior quality may cause a malfunction, and the resulting loss of control could endanger the operator and passengers.
  • Page 541 Wiring harness Check/Replace — connections/Lead coupler connections Yamaha meter/Gauge Check — — :Not applicable TIP: When using lead high-sulfur gasoline, checking the valve clearance may be required more fre- quently than every 500 hours. Maintenance interval chart 2...
  • Page 542 Maintenance Predelivery check To make the delivery process smooth and efficient, complete the predelivery checks as explained in the following procedures. Checking the battery Battery electrolyte is dangerous; it con- tains sulfuric acid, which is poisonous 2. Check specific gravity and highly caustic.
  • Page 543 Predelivery check Checking the engine oil level 1. Place the outboard motor in an upright position. NOTICE: If outboard motor is not level, the oil level indi- cated on the dipstick may not be cor- rect. 2. Start the engine and warm it up for 5–10 minutes.
  • Page 544 Maintenance Checking the engine start switch and engine shut-off switch (single outboard motor application) 1. Check that the engine starts when the engine start switch a is turned to START. 2. Check that the engine stops when the engine start switch a is turned to OFF. 3.
  • Page 545 Predelivery check Checking the PTT system Check screw a: 9 N·m (0.9 kgf·m, 6.6 ft·lb) 1. Check that the outboard motor tilts up and down smoothly when the PTT switch Checking the gear shift and throttle is pushed. operation 1. Check that the gear shift operates 2.
  • Page 546 Maintenance Break-in TIP: Operate the engine under load (in gear with a When using the flushing device (flushing propeller installed) for 10 hours as follows: hose joint adapter), flush the cooling water passages without starting the engine. 1. For the first hour a of operation: Operate the engine at varying speeds up to 2000 r/min or approximately 1/2 throt- General periodic maintenance...
  • Page 547 1. Start the engine and warm it up for 5–10 minutes. 2. Check the engine idle speed using the Yamaha genuine tachometer (on-board meter) or the YDIS. To connect and operate the YDIS, see the “YDIS (Ver. 1.33 or later) instruction manual.”...
  • Page 548 Maintenance 10. Check that the oil level indicated on the dipstick b is between the upper mark a and the lower mark b. 11. Start the engine and check that the oil pressure alert indicator does not come on. Also, check that there is no oil leakage.
  • Page 549 General periodic maintenance 3. Install a new oil filter b, and then tighten Checking the engine start/stop it to the specified torque. button and engine shut-off switch (twin or triple outboard motor application) 1. Check the engine start/stop button and engine shut-off switch.
  • Page 550 Maintenance 4. Remove the drain screw b and gasket c. NOTICE: If there is a significant amount of metal particles on the magnetic drain screw, the lower unit may have a problem. 5. Remove the check screw d and gasket e and let the oil drain completely.
  • Page 551 General periodic maintenance Water inlet cover bolt h: 2 N·m (0.2 kgf·m, 1.5 ft·lb) Checking the gear oil level 1. Check the gear oil level. See “Checking the gear oil level” (10-5). Replacing the OCV filter 1. Remove the OCV assemblies. 2.
  • Page 552 Maintenance 2. Remove the reservoir cap b and O-ring 2. Apply low temperature resistant grease c, and then check the fluid level in the to the specified lubrication points. reservoir. WARNING! Before removing the reservoir cap, make sure that the rams fully extended.
  • Page 553 General periodic maintenance Checking the PTT operation 1. Fully tilt the outboard motor up and down a few times and check that the outboard motor tilts up and down smoothly. Check the PTT fluid level if the tilt operation is not smooth.
  • Page 554 Index Index Bottom cowling ........5-8, 5-16 Bracket unit........1-5, 1-28 Abbreviation ..........0-5 Bracket unit technical data ....... 1-25 Active test ...........4-3 Break-in ............ 10-7 Adjusting the forward gear shim (T1) thickness ..........8-54 Adjusting the reverse gear shim (T1) Calculated value (B) table ....8-46, 8-88 thickness ..........8-95 Camshaft ..........
  • Page 555 Index Checking the engine idle speed....10-8 Checking the main wiring harness.... 5-65 Checking the engine oil level ...10-4, 10-9 Checking the OCV........5-32 Checking the engine shut-off switch ..5-52 Checking the oil cooler ......7-67 Checking the engine start switch and Checking the oil cooler anode ....
  • Page 556 Index Checking the top cowling ......10-14 Disassembling the lower case ..8-25, 8-78 Checking the trim sensor ......5-69 Disassembling the oil pan and exhaust Checking the valve......7-56, 9-54 manifold ..........9-20 Checking the valve clearance ..7-2, 10-14 Disassembling the oil pump assembly ..7-66 Checking the valve guide......7-57 Disassembling the oil seal Checking the valve lifter......7-47...
  • Page 557 Index Installing the canister........ 6-27 Installing the clamp bracket ...... 9-27 Fail-safe control ........2-16 Installing the cowling lock lever ....9-6 Feature............4-1 Installing the cylinder head ....... 7-62 Flywheel magnet........7-14 Installing the Digital Electronic Control box and Forward gear shim (T1) selection table ..8-56 switch panel..........
  • Page 558 Index Installing Y-COP (optional in non-European Model designation ........1-2 markets) ..........3-12 Model features..........1-1 Intake and exhaust diagram......2-31 Intake and exhaust system .......2-31 Intake manifold..........6-14 Non-reusable part........0-3 Junction box..........7-25 Oil cooler ..........2-25 Oil cooler and oil pump assembly..... 7-63 Oil pan and exhaust manifold ....
  • Page 559 Index Reducing the fuel pressure ......6-6 Reverse gear shim (T1) selection Refacing the valve seat......7-59 table............8-97 Registering the receiver ID to the ECM ..3-12 Reverse gear shim (T2) selection chart..8-59 Removing the canister ......6-26 Rigging grommet description ...... 3-8 Rigging grommet mounting ......
  • Page 560 Index Trouble code table ........4-6 Troubleshooting procedure ......4-5 Troubleshooting the lower unit....4-36 Troubleshooting the power unit....4-5 Troubleshooting the power unit (trouble code not detected) ...........4-29 Troubleshooting the power unit using the YDIS............4-5 Troubleshooting the PTT unit....4-35 Twin outboard motor application....3-23 Uncrating procedure ........3-5 Upper case..........9-15 Upper case and mount......9-10...
  • Page 561 Appendix Wiring diagram ..............A-2 How to use the wiring diagram ..........A-2 Engine control unit ..............A-3 Fuel unit ..................A-5 Ignition unit ................A-7 Charging unit and starting unit ..........A-9 PTT unit .................. A-11...
  • Page 562 — MEMO —...
  • Page 563 Wiring diagram How to use the wiring diagram Composition of the wiring diagrams The wiring diagram consists of five categories. The engine control unit, fuel unit, ignition unit, charg- ing unit and starting unit, and PTT unit. Legend symbols in the wiring diagrams a Double colors wire b No wire connector c A wire is not included in the selected wiring unit.
  • Page 564 Engine control unit a Fuse (30 A) (starter relay) b Fuse (15 A) (high-pressure fuel pump) c Fuse (10 A) (ETV) d Fuse (15 A) (shift actuator) e Fuse (30 A) (ignition coil, VCT, fuel injector, engine ECM) f Fuse (10 A) (low-pressure fuel pump) g Fuse (20 A) (engine start switch, PTT switch, Digital Electronic Control ECM, high-pressure fuel pump) h Fuse (100 A) (engine battery)
  • Page 566 YAMAHA MOTOR CO., LTD. May 2010 – ** × 1 ABE (E_1)
  • Page 567 Engine control unit Br Y W R B START Fuse box Battery PULL House (accessory) Engine start switch battery 27 36 44 52 35 43 51 60 61 68 74 80 Joint connector 1 67 73 79 86 87 96 104 112 Joint connector 2 Engine ECM 95 103 111 120...
  • Page 568 Fuel unit a Fuse (30 A) (starter relay) b Fuse (15 A) (high-pressure fuel pump) c Fuse (10 A) (ETV) d Fuse (15 A) (shift actuator) e Fuse (30 A) (ignition coil, VCT, fuel injector, engine ECM) f Fuse (10 A) (low-pressure fuel pump) g Fuse (20 A) (engine start switch, PTT switch, Digital Electronic Control ECM, high-pressure fuel pump) h Fuse (100 A) (engine battery)
  • Page 569 Fuel unit Br Y W R B START Fuse box Battery PULL House (accessory) battery Engine start switch 27 36 44 52 35 43 51 60 Joint connector 1 61 68 74 80 67 73 79 86 Joint connector 2 Pu/R Pu/B 87 96 104 112...
  • Page 570 Ignition unit a Fuse (30 A) (starter relay) b Fuse (15 A) (high-pressure fuel pump) c Fuse (10 A) (ETV) d Fuse (15 A) (shift actuator) e Fuse (30 A) (ignition coil, VCT, fuel injector, engine ECM) f Fuse (10 A) (low-pressure fuel pump) g Fuse (20 A) (engine start switch, PTT switch, Digital Electronic Control ECM, high-pressure fuel pump) h Fuse (100 A) (engine battery)
  • Page 571 Ignition unit Br Y W R B START Fuse box Battery 27 36 44 52 PULL House (accessory) battery Engine start switch Joint connector 1 35 43 51 60 61 68 74 80 Joint connector 2 67 73 79 86 Engine ECM 87 96 104 112 B/Br...
  • Page 572 Charging unit and starting unit a Fuse (30 A) (starter relay) b Fuse (15 A) (high-pressure fuel pump) c Fuse (10 A) (ETV) d Fuse (15 A) (shift actuator) e Fuse (30 A) (ignition coil, VCT, fuel injector, engine ECM) f Fuse (10 A) (low-pressure fuel pump) g Fuse (20 A) (engine start switch, PTT switch, Digital Electronic Control ECM, high-pressure fuel pump)
  • Page 573 Charging unit and starting unit Br Y W R B START PULL Engine start switch 27 36 44 52 35 43 51 60 61 68 74 80 Starter motor Battery 67 73 79 86 House (accessory) Rectifier 87 96 104 112 battery Regulator AC 1...
  • Page 574 PTT unit a Fuse (30 A) (starter relay) b Fuse (15 A) (high-pressure fuel pump) c Fuse (10 A) (ETV) d Fuse (15 A) (shift actuator) e Fuse (30 A) (ignition coil, VCT, fuel injector, engine ECM) f Fuse (10 A) (low-pressure fuel pump) g Fuse (20 A) (engine start switch, PTT switch, Digital Electronic Control ECM, high-pressure fuel pump) h Fuse (100 A) (engine battery)
  • Page 575 PTT unit Br Y W R B START Battery PULL House (accessory) battery Engine start switch 27 36 44 52 35 43 51 60 Joint connector 1 61 68 74 80 67 73 79 86 87 96 104 112 Joint connector 4 Engine ECM 95 103 111 120 PTT relay...
  • Page 576 A-13...

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