Page 1 PREFACE CONTENTS This manual covers the construction, function and SPECIFICATIONS serving procedures for the Honda BF135A•BF150A outboard motors. SERVICE INFORMATION All information contained in this manual is based on the latest product information available at the time of MAINTENANCE printing. We reserve the right to make changes at anytime without notice.
Page 2: Table Of Contents
INDEX 1. SPECIFICATIONS ............1-1 3. MAINTENANCE ............3-1 1. SPECIFICATIONS ..........1-1 1. MAINTENANCE SCHEDULE ........ 3-1 2. DIMENSIONAL DRAWINGS........1-4 2. ENGINE OIL............3-2 3. OIL FILTER .............. 3-3 2. SERVICE INFORMATION ..........2-1 4. GEAR CASE OIL ............ 3-4 5.
Page 3 12. SILENCER CASE/THROTTLE BODY/ EOP SWITCH (HIGH PRESSURE SIDE) TROUBLESHOOTING ······································ 5-54 INTAKE MANIFOLD .......... 5-128 ECT SENSOR 4 TROUBLESHOOTING ··········· 5-55 13. FUEL INJECTOR/PRESSURE REGULATOR..5-136 7. TROUBLESHOOTING WITHOUT 14. FUEL PUMP (LOW PRESSURE SIDE) ....5-142 HDS TESTER ............5-57 15.
Page 4 11. OIL PUMP/FLYWHEEL ..........11-1 16. STEERING ROD/REMOTE CONTROL BOX .... 16-1 1. EOP SWITCH/OIL FILTER FLANGE ....11-2 1. STEERING ROD............ 16-1 2. OIL PUMP ............11-6 2. REMOTE CONTROL BOX (OPTIONAL 3. FLYWHEEL............11-12 PART) ..............16-2 3. CONTROL PANEL (OPTIONAL PART) ....16-7 12.
Page 5 Abbreviations Alternator Air Fuel Ratio American Petroleum Institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center Automatic Transmission Fluid Attachment Battery Bottom Dead Center BTDC Before Top Dead Center BARO Barometric Pressure Crankshaft Position Comp. Complete Camshaft Position Cylinder Data Link Connector Engine Coolant Temperature Engine Control Module...
Page 6: Specifications
1.SPECIFICATIONS 1. SPECIFICATIONS 2. DIMENSIONAL DRAWINGS 1. SPECIFICATIONS • DIMENSIONS AND WEIGHTS Model BF135A Description code BARJ BASJ BARJ BASJ Types Overall length 845 mm (33.3 in) Overall width 580 mm (22.8 in) Overall height 1,665 mm (65.6 in) 1,790 mm (70.5 in)
Page 7 • TYPES OF Honda BF135A•BF150A OUTBOARD MOTORS It may be necessary to refer to this chart for reference purposes when reading this manual. Model BF135A•BF150A Types Shaft length type Remote control ○ ○ ○ ○ ○ ○ ○ Control panel ○...
Page 8 • ENGINE Model BF135A BF150A Description code BEARJ BEANJ Type 4-stroke, D.O.H.C., 4-cylinder 4-stroke, D.O.H.C., VTEC, 4-cylinder Displacement 2,354 cm (143.6 cu-in) Bore x stroke 87 x 99 mm (3.4 x 3.9 in) Rated power (Full throttle range) 100.7 kW (135 HP) 111.9 kW (150 HP)
Page 9: Dimensional Drawings
2. DIMENSIONAL DRAWINGS [ ]: Extra-long shaft type 580 mm 845 mm (33.3 in) (22.8 in) 12°...
Page 10 • PROPELLER SHAFT ø4 (ø0.2) 7 mm (0.3 in) 56.5 mm 28.5 mm 57.5 ± 0.5 mm (1.12 in) (2.26 ± 0.02 in) (2.22 in) 151 mm (5.9 in)
Page 11: Service Information
2. SERVICE INFORMATION 1. THE IMPORTANCE OF PROPER SERVICING 7. TORQUE VALUES 2. IMPORTANT SAFETY PRECAUTIONS 8. SPECIAL TOOLS 3. SERVICE RULES 9. TROUBLESHOOTING 4. SYMBOLS USED IN THIS MANUAL 10. CABLE/HARNESS ROUTING 5. SERIAL NUMBER LOCATIONS 11. TUBE ROUTING 6.
Page 12: Service Rules
3. SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may damage the unit. 2. Use the special tools designed for the product. 3. Install new gaskets, O-rings, etc. when reassembling.
Page 13: Maintenance Standards
6. MAINTENANCE STANDARDS • ENGINE Unit: mm (in) Parts Item Standard Service limit Engine Idle speed (in neutral) 750 ± 50 min –1 (rpm) – Trolling speed 650 ± 50 min –1 (rpm) – Cylinder compression 1,532 – 1,728 [kPa (kgf/cm , psi) at 200 min –1 (rpm)]...
Page 14 Unit: mm (in) Parts Item Standard Service limit Pistons Ring groove width 1.23 – 1.24 (0.0484 – 0.0488) 1.25 (0.0492) Second 1.24 – 1.25 (0.0488 – 0.0492) 1.25 (0.0492) 2.005 – 2.025 (0.0789 – 0.0797) 2.05 (0.081) Piston pins Pin O.D. 21.961 –...
Page 15 Unit: mm (in) Parts Item Standard Service limit Camshaft Camshaft axial clearance 0.05 – 0.20 (0.002 – 0.008) 0.4 (0.02) Camshaft runout 0.03 (0.001) Max. 0.4 (0.02) Journal O.D. No. 1 28.955 – 28.970 (1.1400 – 1.1405) – No. 2 – No. 5 28.925 –...
Page 16 • FRAME Unit: mm (in) Parts Item Standard Service limit Propeller Shaft O.D. At forward bevel gear 24.987 – 25.000 (0.9837 – 0.9843) 24.966 (0.9829) shaft (LC, LD, XC and XD types) At reverse bevel gear 24.987 – 25.000 (0.9837 – 0.9843) 24.966 (0.9829) (LCD, XCC and XCD types) At needle bearing...
Page 17: Torque Values
7. TORQUE VALUES Torque value Thread dia. (mm) Item N . m kgf . m lbf . ft and pitch (length) • ENGINE Lower block bolt (*1) M11 x 1.5 M8 x 1.25 Crankcase bolt M6 x 1.0 Oil case bolt M10 x 1.25 Lower block orifice M10 x 1.0...
Page 18 Torque value Thread dia. (mm) Item N . m kgf . m lbf . ft and pitch (length) • ENGINE Mounting case bolt M12 x 1.25 M10 x 1.25 M8 x 1.25 Mounting case nut M10 x 1.25 Plug hole coil bolt M6 x 1.0 Flywheel boss bolt M8 x 1.25...
Page 19 Torque value Thread dia. (mm) Item N . m kgf . m lbf . ft and pitch (length) • STERN BRACKET 7/8-14 UNF self-locking nut 7/8-14 UNF 25 x 2.0 mm self-locking nut M25 x 2.0 10 mm self-locking nut M10 x 1.25 •...
Page 20: Special Tools
8. SPECIAL TOOLS • Special tools applicable to the parts except gear case Tool name Tool number Application Ring gear holder 070PB-ZY60100 Flywheel boss, flywheel removal/installation SCS service check connector 070PZ-ZY30100 ECU troubleshooting, idling adjustment Test harness 070PZ-ZY60100 ECU troubleshooting Float level gauge 07401-0010000 Vapor separator float level inspection...
Page 21 Tool name Tool number Application 44 Pin wrench, 6 mm 07SPA-ZW10100 Piston rod comp. removal/installation 45 Pin wrench, 4 mm 07SPA-ZW10200 Rod guide comp. removal/installation 46 Oil pressure gauge joint A 07SPJ-ZW10100 Power trim/tilt assembly blow pressure inspection 47 Oil pressure gauge joint B 07SPJ-ZW10200 48 Oil seal driver attachment, 96 07ZAD-PNA0100...
Page 22 • Special tools applicable to all types of gear case Tool name Tool number Application Outer driver attachment, 30 x 37 070PD-ZY60200 30 x 37 x 26 mm needle bearing installation Gauge adapter, 110 mm 070PJ-ZY30100 Vertical shaft pinion gear shim adjustment Attachment, 32 x 35 mm 07746-0010100 23 x 36 x 6 mm water seal installation...
Page 23 • Special tools applicable to LCD, XCC and XCD types of gear case Tool name Tool number Application 40 Pilot, 35 mm 07746-0040800 Forward bevel gear removal 41 Attachment, 27.2 07747-0010300 Forward bevel gear removal 42 Driver 07749-0010000 Driver for 38, 39, 40 and 41 43 Oil seal driver, 65 mm 07JAD-PL90100 50 x 90 x 20 mm radial ball bearing...
Page 24: Troubleshooting
BF135A•BF150A 9. TROUBLESHOOTING a. ENGINE • HARD STARTING • Use a known-good battery for troubleshooting. Turn the ignition switch ON. Check whether Perform ignition (power) system trouble- Does not come ON. the MIL comes ON for 2 seconds. shooting (P. 2-20).
Page 25: Cylinder Compression Test
BF135A•BF150A • CYLINDER COMPRESSION TEST THROTTLE ARM 1) Move the remote control lever to the “N” (Neutral) position. 2) Remove the clip of the emergency stop switch. 3) Remove the engine cover and disconnect the fuel injector connectors of each cylinder.
Page 26: Engine Does Not Run Smoothly
BF135A•BF150A • ENGINE DOES NOT RUN SMOOTHLY • Perform “g. ALERT SYSTEM” (P. 2-32) troubleshooting when the warning buzzer sounds. Perform the following troubleshooting when the warning buzzer does not sound but the engine does not run smoothly. Engine starts, but stalls Faulty spark plug.
Page 27 BF135A•BF150A Engine speed does not Throttle link and/or cable misadjust- Adjust the throttle link and/or cable increase. (P. 3-26). Propeller mismatched. Replace with the correct propeller. High pressure fuel strainer clogged. Replace the (high pressure) fuel strainer (P. 3-18). Low pressure fuel strainer clogged.
Page 28 BF135A•BF150A Engine starts, but stalls Throttle link and/or cable misadjust- Adjust the throttle link and/or cable soon. Idle speed is not (P. 3-26). stable or stalls. Throttle shaft not move smoothly. Check the throttle body and clean if necessary (P. 5-95).
Page 29 BF135A•BF150A Engine sometimes mis- Water in the fuel. • Check for water in the low pres- fires or stalls. sure fuel strainer. Replace if nec- essary (P. 3-15). • Check for water in the water sep- arator and drain if necessary (P.
Page 30: Ignition (Power) System
BF135A•BF150A b. IGNITION (POWER) SYSTEM • ENGINE DOES NOT START Turn the ignition switch ON. Check Does not whether the warning buzzer sounds sound. twice. Check for blown No. 3 (10A), No. 7 Replace the blown fuse(s). (30A) and the No. 4 (15A) fuses.
Page 31: Fuse Load Chart
BF135A•BF150A • FUSE LOAD CHART To ALTERNATOR (DETECTION W/Bl TERMINAL) POWER TILT SWITCH To POWER TRIM/TILT RELAY To POWER TRIM/TILT RELAY POWER TRIM/ TILT SWITCH To ECM Bl/R No. 3 (10A) FUSE To BUZZER Bl/Y W/Bl Bl/Y To INDICATOR LIGHT...
Page 32: Fuse Box Connection Table
BF135A•BF150A • FUSE BOX CONNECTION TABLE Fuse No. Fuse capacity Connect to A/F sensor heater High pressure side fuel pump Power trim/tilt relay, Alternator (detection terminal), Ignition switch, PGM-FI main relay, Warning buzzer, Indicator light (oil, overheat), Meters ECM, Fuel injector, CMP sensor, CKP sensor...
Page 33: Engine Does Not Start
BF135A•BF150A c. STARTING SYSTEM • ENGINE DOES NOT START • Before starting troubleshooting, check each wire for connection and correct as necessary. Check whether the remote control Move the remote control lever in the Not in “N” (Neutral) lever is in the “N” (Neutral) position.
Page 34 BF135A•BF150A From P. 2-23 (A) From P. 2-23 (B) Check the ignition switch (P . 16-9). Replace the ignition switch. Is the ignition switch in good condi- tion? Replace the starter motor with a new Repair or replace the wire har- one and recheck.
Page 35: Ignition System
BF135A•BF150A d. IGNITION SYSTEM • ENGINE IS HARD TO START * Before troubleshooting, turn the ignition switch ON and check whether the MIL comes ON for 2 seconds and the warn- ing buzzer sounds twice intermittently. If the MIL does not come ON or the warning buzzer does not sound, perform power system troubleshooting (P. 2-20).
Page 36 BF135A•BF150A From P. 2-25 Check the CKP sensor connector. Connect the CKP sensor connector properly Is the connector connected securely? and recheck. Check for open circuit in the ignition coil’s Replace or repair the wire harness. (Open cir- power line.
Page 37 BF135A•BF150A From P. 2-26 Check for short circuit in the ignition coil’s Replace or repair the wire harness (Short cir- signal line. cuit in the wire harness between the ignition coil and the ECM). 1 Turn the ignition switch OFF. Check for continuity between the No.
Page 38: Fuel System
BF135A•BF150A e. FUEL SYSTEM • ENGINE IS HARD TO START • When the gasoline is flowing out of the vapor separator, check the vapor separator (P. 5-112 thru. 5-120). Turn the ignition switch ON and check the fuel pump operation.
Page 39 BF135A•BF150A From P. 2-28 (A) From P. 2-28 (B) Check for open circuit in the fuel Replace or repair the wire har- pump power line. ness (Open circuit in the fuel pump power line). 1 Disconnect the main relay 2P connector.
Page 40: Charging System
BF135A•BF150A f. CHARGING SYSTEM • BATTERY UNDER CHARGED Is the alternator belt tension correct Adjust the alternator belt tension (P. 3-29). (Inspection: P. 3-29)? Start the engine and let it idle to warm up. Replace the battery. Measure the voltage between the battery terminals when the engine speed is 3,000 (rpm).
Page 41 BF135A•BF150A • ALTERNATOR INDICATOR LINE INSPECTION Turn the ignition switch ON. Start the engine. End of inspection (Good) Does the alternator indicator Does the alternator indicator lightcome ON? light go OFF? Check for short circuit in the L Replace or repair the wire har- line.
Page 42: Alert System
BF135A•BF150A g. ALERT SYSTEM • OIL ALERT SYSTEM When the oil pressure switch (low pressure side) detects low oil pressure, the ECM receives the signal from the oil pres- sure switch and decreases the engine speed gradually to 1,800 min (rpm).
Page 43: Continuously
BF135A•BF150A • WARNING BUZZER SOUNDS CONTINUOUSLY Check the indicator light. Is the overheat indicator light To P. 2-36 NO (OFF) Is the oil indicator light OFF? Check the oil indicator light. Replace the oil indicator light. (ON) Is the oil indicator light normal? Check the warning buzzer.
Page 44 BF135A•BF150A From P. 2-33 Start the engine. Snap the engine (4,000 min Normal (End of inspection) Is the oil indicator light ON with /rpm or above under no load) the engine idling? and check the oil indicator and warning buzzer.
Page 45: Oil Pressure Inspection
BF135A•BF150A From P. 2-34 Check the oil pressure. Perform the following checks Is the oil pressure within the and repair or replace as nec- specification? essary. • Clogged oil strainer • Clogged oil filter • Faulty oil pump • Clogged oil passage Replace the oil pressure switch Oil pressure switch is faulty.
Page 46 BF135A•BF150A From P. 2-33 Stop the engine and check the Clean the water screen. water screen. Is the water screen clogged? Start the engine and check the • Check the water pump and water check port with the engine replace if necessary.
Page 47: Intermittent Prolonged Sound Of Warning Buzzer Keeps Sounding
BF135A•BF150A • INTERMITTENT PROLONGED SOUND OF WARNING BUZZER KEEPS SOUNDING Is the MIL ON? Perform MIL troubleshooting (P. 5-18 or 5-61). Is the alternator indicator light Check for open in the indicator Replace or repair the wire har- light power line.
Page 48: Intermittent Short Sound Of Warning Buzzer Keeps Sounding
BF135A•BF150A • INTERMITTENT SHORT SOUND OF WARNING BUZZER KEEPS SOUNDING Stop the engine. Check the water separa- Drain the water from the water separator tor and the low pressure fuel strainer. and/or the low pressure fuel strainer (P. 3-15). Is the water accumulated in the water sep-...
Page 49: Shift Mechanism
BF135A•BF150A h. SHIFT MECHANISM Shift lever does not move. Shift cable corroded or stuck with Replace: P. 15-3 salt. Shift cable misadjusted. Adjust: P. 3-25 Shift arm damaged. Replace: P. 17-11 Shift detent arm damaged. Replace: P. 17-12 Shift rod and shift rod A bent or Replace: P.
Page 50: Power Trim/Tilt Assembly
BF135A•BF150A i. POWER TRIM/TILT ASSEMBLY • POWER TRIM/TILT ASSEMBLY DOES NOT MOVE Check the motor sound. Does not sound Perform troubleshooting “POWER TRIM/TILT MOTOR DOES NOT TURN” (P. 2- 42). Sounds Check the manual valve for looseness. Tighten the manual valve securely.
Page 51 BF135A•BF150A • POWER TRIM/TILT ASSEMBLY DOES NOT HOLD Check the manual valve for tightness. Loose Tighten the manual valve securely. Tight Check for oil leakage from the power Leaking Replace the O-ring and oil seal of the leaking trim/tilt assembly.
Page 52 BF135A•BF150A • POWER TRIM/TILT MOTOR DOES NOT TURN Connect the 12V battery directly to the motor terminals and check whether the motor turns. Does not turn. Turns Check for open circuit in the motor Replace the front bracket. Open wire.
Page 53: Check Point
BF135A•BF150A • POWER TRIM/TILT ASSEMBLY QUICK REFERENCE CHART Symptom Pressure check Lower chamber Upper chamber Does Does hydraulic pres- hydraulic pres- Check point Check/repair method not tilt Does not hold sure lower than sure lower than tilt up down (See page 2-44) spec.
Page 54 BF135A•BF150A • CHECK POINTS LOWER CHAMBER SPOOL VALVE PUMP UP RELIEF VALVE UPPER CHAMBER SPOOL VALVE DOWN RELIEF VALVE UPPER CHAMBER CHECK VALVE LOWER CHAMBER MANUAL VALVE CHECK VALVE DUST SEAL/O-RING PISTON ROD ASSEMBLY MOTOR OIL (ATF) SHOCK RELIEF VALVE...
Page 55: Cable/Harness Routing
10. CABLE/HARNESS ROUTING After securing the cables and harnesses with the harness band clips, cut the end of the harness band clips so that the projected length is 5 – 10 mm (0.2 – 0.4 in) as shown. HARNESS BAND CLIP 5 –...
Page 56 [1] HARNESS BAND CLIP Clamp the main wire harness and the ECT sensor 3 wire as shown. [1]-1 ECT (ENGINE COOLANT TEMPERATURE) SENSOR 3 WIRE [1]-2 ECT (ENGINE ECT (ENGINE ENGINE SIDE COOLANT COOLANT TEMPERATURE) TEMPERATURE) SENSOR 4 SENSOR 4 2P CONNECTOR A/F (AIR FUEL RATIO) SENSOR 4P CONNECTOR...
Page 57 [3] HARNESS BAND CLIP Clamp the VTEC solenoid valve wire [BF150A only] and the A/F sensor wire as shown. [3]-1 A/F (AIR FUEL RATIO) SENSOR 4P CONNECTOR [3]-2 INSIDE [3]-3 VTEC SOLENOID VALVE WIRE [BF150A only] ECT (ENGINE COOLANT TEMPERATURE [2] A/F (AIR FUEL RATIO) SENSOR 4 MAIN WIRE...
Page 58 [2] ALTERNATOR FUSE CABLE (WHITE CABLE) ALTERNATOR 4P CONNECTOR MAIN WIRE HARNESS ECT (ENGINE COOLANT TEMPERATURE) SENSOR 1 ECT (ENGINE COOLANT TEMPERATURE) SENSOR 1 2P CONNECTOR EOP (ENGINE OIL PRESSURE) SWITCH [8] HARNESS BAND CLIP (HIGH PRESSURE Clamp the alternator SIDE) 2P CONNECTOR fuse cable and the main wire harness as...
Page 59 [5] ALTERNATOR FUSE BOX B TERMINAL Install the alternator fuse box B terminal at 30° from the horizontal line as shown. [5]-1 ALTERNATOR FUSE BOX B TERMINAL [3] ALTERNATOR FUSE BOX (90A) [2] FUSE BOX 30° [1] HARNESS BAND CLIP [4] WIRE HARNESS CLIP Clamp the alternator...
Page 60 [1] HARNESS BAND CLIP [2] ALTERNATOR FUSE BOX (90A) [16] PGM-FI MAIN RELAY STARTER CABLE [15] ALTERNATOR FUSE CABLE (WHITE CABLE) [14] STARTER CABLE 3P CONNECTOR MAIN WIRE HARNESS [13] PGM-FI MAIN RELAY CONNECTOR WIRE ALTERNATOR FUSE CABLE [12] HARNESS BAND CLIPS [11] PGM-FI MAIN RELAY...
Page 61 [1] POWER TILT SWITCH HARNESS BAND 3P CONNECTOR CLIPS [4] STARTER CABLE [10] PGM-FI MAIN RELAY CONNECTOR HARNESS BAND CLIP POWER TILT [4] STARTER CABLE SWITCH WIRE [5] HARNESS CLIP [8] WIRE HARNESS CLIP Clamp the alternator fuse cable, PGM-FI main relay [6] STARTER CABLE wire and the power tilt switch 3P CONNECTOR...
Page 62 [4] CLIP A [3] HARNESS BAND CLIP POWER TILT Clamp the alternator STARTER Clamp the starter SWITCH fuse cable. CABLE cable. 3P CONNECTOR ALTERNATOR [10] FUSE CABLE POWER TILT SWITCH [6] CABLE BRACKET A POSITIVE (+) STARTER CABLE Clamp the alternator fuse cable STARTER and the starter cable as shown.
Page 63 <REMOTE CONTROL CABLE GROMMET viewed from outer side of the outboard motor> REMOTE CONTROL CABLE REMOTE CONTROL CABLE (Throttle side) (Shift side) REMOTE CONTROL INDICATOR LIGHT CABLE WIRE SPEED SENSOR TUBE A [5] BATTERY ISOLATOR (Optional part) [7] STARTER CABLE [6] FUEL TUBE A [10] WHIT TAPE FRONT BRACKET...
Page 64 [8] TP (THROTTLE POSITION) POWER TILT RELAY SENSOR 3P CONNECTOR 3P CONNECTOR REMOTE CONTROL CABLE 14P CONNECTOR [9] TP (THROTTLE [3] HARNESS POSITION) BAND CLIP [5] MAIN WIRE [3] HARNESS BAND HARNESS SENSOR HARNESS CLIP BAND CLIP [10] [2] REMOTE CONTROL WATER LEVEL SPEED CABLE (Throttle side)
Page 65 [1] FRAME GROUND TERMINALS • Connect the black, blue, green/red and the green/white wires to the upper frame ground terminal, and the green, blue, black/white and the green/black wires to the lower frame ground terminal. • Install by pushing the frame ground terminals against the corresponding projections on the crankcase.
Page 66 [2] TP (THROTTLE [1] TP (THROTTLE POSITION) HARNESS BAND POSITION) [4] POWER TILT RELAY SENSOR CLIP SENSOR 3P CONNECTOR 3P CONNECTOR [6] HARNESS CLIP WATER LEVEL Clamp the main wire [19] MAIN WIRE SENSOR harness 3P CONNECTOR HARNESS water level sensor wire at its taped part.
Page 67 [1] POWER TILT RELAY GROUND TERMINAL [4] WIRE HARNESS CLIP Install pushing ground Clamp the power tilt relay 3P terminal against the projection on the crankcase. connector, 2P connector and POWER TILT HARNESS BAND the 1P connector wires as RELAY CLIP shown.
Page 68 [3] HARNESS BAND CLIP [6] WIRE BAND Clamp the main wire harness, BARO Clamp the main wire harness, BARO sensor wire and the IAB control valve wire sensor wire and the IAB control valve as shown. wire as shown. [3]-2 [6]-2 [6]-1 ENGINE MAIN WIRE...
Page 69 [2] HARNESS BAND CLIP Clamp the main wire harness, joint connector 1 wire and the joint connector 2 wire as shown. [2]-2 ENGINE SIDE [2]-3 [2]-1 JOINT JOINT CONNECTOR 1 CONNECTOR 2 WIRE WIRE [2]-4 MAIN WIRE PRESSURE HARNESS REGULATOR RETURN HOSE MAIN WIRE MAIN WIRE HARNESS...
Page 70 [2] MAIN WIRE [1] HARNESS BAND CLIP HARNESS No.1 IGNITION COIL [4] ECT (ENGINE COOLANT TEMPERATURE [17] SENSOR 3 No.1 FUEL INJECTOR 2P CONNECTOR 2P CONNECTOR No.1 IGNITION COIL 3P CONNECTOR MAIN WIRE HARNESS No.2 IGNITION COIL [16] No.2 IGNITION COIL No.2 FUEL INJECTOR 3P CONNECTOR 2P CONNECTOR...
Page 71 [2] HOSE CLAMP • Set the fuel hose (high pressure side) in the clamp of the larger diameter side and the main wire harness in the smaller diameter side. • Clamp the fuel hose (high pressure side) at the left-hand side to the marked point.
Page 72 [5] HARNESS BAND CLIP Clamp main wire harness and the knock sensor wire. [5]-1 KNOCK SENSOR WIRE [3] HARNESS CLIP Clamp the main wire harness and the water level sensor [5]-2 MAIN WIRE wire at the taped part. HARNESS [2] WATER LEVEL SENSOR WIRE [4] MAIN WIRE KNOCK SENSOR...
Page 73 [1] 14 mm CLIPS • Clamp the power tilt motor wire, trim [1]-1 SPEED SENSOR [1]-3 angle sensor wire and the speed sensor [1]-1 SPEED SENSOR TUBE A POWER tube A. TUBE A TILT • Install the 14 mm clip aligning the tape MOTOR [1]-4 PROJECTIONS end of the power tilt motor wire with the...
Page 74 • Side-mount remote control EMERGENCY IGNITION WARNING SOLENOID SWITCH STOP SWITCH SWITCH BUZZER [7] POWER TRIM/TILT INDICATOR SWITCH LIGHT POWER TRIM/TILT SWITCH WIRE [5] REMOTE CONTROL CABLE B SOLENOID SWITCH IGNITION SWITCH EMERGENCY STOP SWITCH [5] REMOTE CONTROL WARNING CABLE B BUZZER POWER REMOTE...
Page 75 • Control panel INDICATOR LIGHT [OIL PRESSURE LIGHT/ OVERHEAT LIGHT] [4] WARNING BUZZER IGNITION SWITCH WIRE HARNESS BAND EMERGENCY STOP SWITCH SWITCH PANEL HARNESS CONNECTION: P. 16-8 2-65...
Page 76: Tube Routing
11. TUBE ROUTING [1] WATER RELIEF TUBE A • Install at approximately right angles horizontal line. • After installation, check the tube for twist, bend, etc. [1]-2 7 x 120 mm TUBE WATER RELIEF [1]-1 Approx. 90° TUBE A TUBE CLAMP D10.5 [13] 7 x 90 mm TUBE [12] WATER TUBE CLAMP INSTALLATION: P.
Page 77 [2] TUBE CLAMP D25.0 Install the tube clamp with the lugs facing in the direction shown. [2]-1 WATER RELIEF TUBE A [2]-2 <Cylinder head cover viewed from the front> WATER RELIEF TUBE A TUBE CLAMP D10.5 7 x 90 mm TUBE TUBE CLAMP D10.5 FUEL TUBE JOINT [6] TUBE CLAMP D10.5...
Page 78 [2] TUBE CLAMP D10.5 [1] TUBE CLAMPS D10.5 7 x 160 mm TUBE [2] TUBE CLAMP D10.5 WATER RELIEF TUBE C [6] 7 x 40 mm TUBE [1] TUBE CLAMPS D10.5 [5] T-JOINT TUBE CLAMP D10.5 7 x 200 mm TUBE 12 mm TUBE CLIP B1 [9] 8 x 300 mm TUBE [2] TUBE CLAMP D10.5...
Page 79 [1] 4 x 7 x 160 mm VINYL TUBE FUEL TUBE A SPEED SENSOR TUBE A UNDERCASE GROMMET C [3] SPEED SENSOR TUBE A [2] FUEL TUBE A 4 x 7 x 160 mm VINYL TUBE Insert into the hole in the under cover front bracket securely.
Page 80 [1] WATER SEPARATOR with WATER LEVEL [2] TUBE CLIP B12 SENSOR FUEL TUBE C TUBE CLIP B12 FUEL TUBE HOLDER [4] FUEL TUBE A [5] 14 mm FUEL TUBE CLIP 14 mm FUEL TUBE FUEL TUBE HOLDER [4] FUEL TUBE A CLIP 2-70...
Page 81 [1] PRESSURE REGULATOR CONTROL TUBE Connect pressure regulator control tube aligning the marked part [5] FUEL TUBE CLAMP on the tube with the end of the 3.5 mm tube clamp. Set the breather tube in the clamp of [1]-2 the larger diameter side and the [1]-1 3.5 mm pressure regulator control tube in the...
Page 82 WATER RELIEF TUBE A INSTALLATION: P. 2-66 [4] 14 mm FUEL TUBE CLIP Install aligning the end of the 14 mm fuel TUBE CLAMP tube clip with the end of the white mark [1] BREATHER TUBE D17.0 on the air vent tube. [4]-1 AIR VENT TUBE A...
Page 83 [2] HOSE CLAMP [5] SENSOR HOSE CLIP Set the fuel tube E in FUEL HOSE Clamp the fuel hose (HIGH the clamp of the larger TUBE (high pressure side) diameter side and the PRESSURE AIR VENT CLIP and the fuel tube B. SIDE) 7 x 400 mm tube in the TUBE A...
Page 84 [4] HOSE CLAMP Set the air vent tube B in the clamp of the larger diameter side and the pressure regulator [6] TUBE CLIP return hose in the smaller AIR VENT diameter side. Clamp the air vent tube [3] VAPOR TUBE B E and the fuel hose CHAMBER...
Page 85 WATER SEPARATOR with WATER LEVEL SENSOR 4 x 7 x 160 mm VINYL TUBE FUEL STRAINER INSTALLATION: MAIN WIRE P. 2-69 HARNESS [8] HOSE CLAMP TUBE CLIP INSTALLATION: P. 2-61 FUEL TUBE C SPEED SENSOR TUBE A FUEL HOSE (HIGH PRESSURE SIDE) [10]...
Page 86 [3] SPEED SENSOR TUBE PLATE Install the speed sensor tube plate [3]-1 so that the distance between the SPEED SENSOR end of the plate and the end of the TUBE B speed sensor tube B is 15 – 20 mm (0.6 –...
Page 87: Lubrication
12. LUBRICATION Apply oil or marine grease to the following parts. (Marine grease) ① ② ① ③ ④ ② ⑤ ⑥ ① THROTTLE PLATE ① DETENT ARM ROLLER ② THROTTLE ARM ② NEUTRAL SWITCH ③ THROTTLE ARM LINK PIN ④ SHIFT SLIDE PIVOT/SHIFT PIVOT PLATE ⑤...
Page 88 ② (Marine grease) ② THROTTLE BODY ① ① ① COVER LOCK CABLE A/B CABLE END ③ ② L. SIDE LOCK ① FRONT ROCK CABLE ② FRONT ROCK ③ COVER OPEN SHAFT ② ① ① ② ① DETENT SPRING ROLLER ① TILTING SHAFT ②...
Page 89 COVER LOCK BOLTS ① ② ② ① UPPER CYLINDER BUSHING/ TILT STOPPER BEARING ② SLIDING SURFACE OF THRUST RECEIVER SWIVEL CASE LOWER CYLINDER BUSHINGS/ COLLAR/WAVE WASHERS 2-79...
Page 90: Maintenance
3. MAINTENANCE 1. MAINTENANCE SCHEDULE 9. WATER SEPARATOR with WATER 2. ENGINE OIL LEVEL SENSOR 3. OIL FILTER 10. IDLING 4. GEAR CASE OIL 11. SHIFT CONTROL CABLE 5. SPARK PLUGS 12. THROTTLE CONTROL CABLE/ 6. VALVE CLEARANCE THROTTLE LINK 7.
Page 91: Engine Oil
2. ENGINE OIL [1] DIPSTICK Oil Level Inspection: UPPER Check the engine oil level with the engine stopped and the LIMIT outboard motor in the vertical position. 1) Remove the engine cover. 2) Remove the dipstick and wipe it clean. LOWER LIMIT 3) Insert the dipstick all the way in the oil level pipe, then pull...
Page 92: Oil Filter
4) Clean the filter mounting base, and coat the seal of the new oil filter with clean engine oil. • Use only a genuine Honda oil filter or a filter of equivalent quality specified for you model. Using the wrong Honda filter, or a not-Honda filter which is not of equivalent quality, may cause engine damage.
Page 93: Gear Case Oil
4. GEAR CASE OIL Inspection: 1) Place the outboard motor on a level surface and position it vertically. 2) Remove the oil level bolt and check whether the gear case oil flows out of the gear case. If it flows out, be sure to catch the oil in a suitable container.
Page 94 Replacement: [1] OIL LEVEL BOLT 1) Place the outboard motor on a level surface and tilt up the outboard motor. 2) Remove the oil level bolt and the oil drain bolt, and drain the old oil. Replace the O-rings on assembly. If there is water in the oil, the water will flow out first when the oil drain bolt is removed, or the oil will be a milky color.
Page 95: Spark Plugs
5. SPARK PLUGS SCREWDRIVER Removal: 1) Remove the engine cover (P. 4-2). [2] SLOT 2) Set a screwdriver in the slot in the two mud guard clips at the top of the under cover grommet, and raise the mud guard clips. Remove the two mud guard clips.
Page 96 5) Remove the 6 x 25 mm socket bolts and remove each ignition coil from the corresponding spark plug. No.1 IGNITION COIL Pull out each ignition coil halfway. 6) Disconnect the ignition coil 3P connector from each ignition coil. No.2 IGNITION Remove each ignition coils.
Page 97 Inspection/Cleaning: 1) Visually inspect the spark plugs. Discard the plugs if the SEALING insulators are cracked or chipped. WASHER 1.0 – 1.1 mm 2) Remove carbon or other deposits with a plug cleaner. (0.039 – 0.043 in) NOTICE Do not spray the cleaner more than 20 seconds. 3) Measure the plug gap with a wire-type feeler gauge.
Page 98: Valve Clearance
6. VALVE CLEARANCE Inspection/Adjustment: UNDER COVER GROMMET • Valve clearance inspection and adjustment must be performed with the engine cold. 1) Remove the engine cover (P. 4-2). 2) Move the remote control lever to the “N” (Neutral) position. 3) Set a screwdriver in the slot in the six mud guard clips, and raise the mud guard clips (P.
Page 99 8) Clamp the fuel tube B and D with the commercially [1] TUBE CLIP [2] FUEL TUBE B available tube clips as shown, and disconnect the fuel tube (Commercially B and D from the fuel pump (low pressure side). available) WARNING Gasoline is highly flammable and explosive.
Page 100 11) Remove the six 6 mm hex. cap nuts and the six head cover washers, and remove the cylinder head cover. [1] CYLINDER HEAD COVER HEAD COVER WASHER (6) 6 mm HEX. CAP NUT (6) 12) Release the pressure regulator control tube from the two 3.5 mm tube clips of the silencer duct assembly. Remove the harness band clip, that clamps the main wire harness, from the silencer duct assembly.
Page 101 14) Remove the four 6 x 25 mm flange bolts and the four 6 mm washers, and remove the silencer duct assembly. SILENCER DUCT ASSEMBLY 6 x 25 (4) 6 mm WASHER (4) 15) Attach the wrench to the 16 x 49 mm washer bolt on the [2] 16 x 49 mm crankshaft pulley as shown.
Page 102 17) Holding the cutout in the crankshaft pulley aligned with the “ ” mark on the chain case, check that the “ ” mark on [2] “ ” MARKS EXHAUST INTAKE the intake camshaft sprocket is in alignment with the CAMSHAFT CAMSHAFT “...
Page 103 24) After adjusting the intake and exhaust valve clearances of [1] No.3 PISTON AT TOP DEAD CENTER OF the No.1 cylinder, turn the crankshaft pulley clockwise by COMPRESSION STROKE: increments of 180° and bring the piston of each cylinder at the top dead center of its compression stroke.
Page 104: Fuel Strainer (Low Pressure Side)
25) After adjusting the valve clearances on each cylinder, install the silencer duct assembly on the silencer case. SILENCER 6 x 25 (4) DUCT 26) Set the four 6 x 25 mm flange bolts and the four 6 mm ASSEMBLY washers, then tighten the four 6 x 25 mm flange bolts securely.
Page 105 Removal: [1] FUEL TUBE E WARNING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. TUBE CLIPS • Handle fuel only outdoors. (Commercially • Wipe up spills immediately. available) 1) Clamp the fuel tube C and E securely with the two [3] FUEL TUBE C...
Page 106 4) Install the strainer suspension on the fuel strainer cup so that its projections are at the fuel strainer body side. [1] FUEL STRAINER BODY 5) Install the fuel strainer (low pressure side) on the fuel [2] PROJECTIONS strainer stay securely. [3] FUEL STRAINER STAY [4] STRAINER...
Page 107: Fuel Strainer (High Pressure Side)
8. FUEL STRAINER (HIGH PRESSURE SIDE) • Disconnect the battery cable from the battery negative (-) terminal before relieving the fuel pressure. • Replace the sealing washers when the service check bolt is loosened or removed. • Catch the draining gasoline from the filter to avoid contaminating the engine parts with the gasoline.
Page 108: Water Separator With Water Level Sensor
9. WATER SEPARATOR with WATER LEVEL SENSOR WATER SEPARATOR WARNING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Inspection: [1] CONNECTOR [2] HARNESS...
Page 109 Disassembly: 1) Remove the three 5 x 12 mm screws from the water 5 x 12 mm separator body, then remove the plate and the water SCREW (3) separator cup. 2) Clean the water separator cup. Replace the fuel strainer with a new one if it is contaminated.
Page 110 3) Install the strainer suspension on the water separator cup [1] WATER SEPARATOR so that its projections are at the water separator body side. BODY 4) Install the water separator with water level sensor on the fuel strainer stay securely. PROJECTIONS [4] FUEL STRAINER STRAINER...
Page 111: Idling
3) Remove the electric part cover. [1] ENGINE SPEED CHECK CONNECTOR [Blue 2P connector] 4) Install the commercially available digital tachometer (KOWA: KEK-8-MT600) or the HDS (Honda Diagnostic System). How to connect the digital tachometer (KOWA: KEK-8- MT600): 1) Disconnect the engine speed check connector (Blue connector: 2P connector).
Page 112 2P connector, to the digital tachometer. PIN JACK [2] DIGITAL TACHOMETER (KOWA: KEK-8-MT600) How to connect the HDS (Honda Diagnostic System): [1] DATA LINK CONNECTORS (DLC) 1) Disconnect the data link connectors (Red connector: 4P [RED: 4P CONNECTOR] connector).
Page 113: Shift Control Cable
11. SHIFT CONTROL CABLE [1] FLAT PART OF [2] NEUTRAL SWITCH DETENT ARM Inspection: 1) Remove the engine cover (P. 4-2). Remove the front separate cover (P. 4-7). 2) Move the remote control lever to the “N” (Neutral) position. Check that the detent arm roller sets in the groove in the shift arm as shown.
Page 114 Adjustment: [1] SHIFT PIVOT [2] LOCK NUT 1) Move the remote control lever to the “N” (Neutral) position. 2) Loosen the shift pivot lock nut of the remote control cable (shift side) and detach the shift pivot from the shift link pin. 3) Check that the detent arm roller sets in the groove in the shift arm.
Page 115: Throttle Control Cable/ Throttle Link
12. THROTTLE CONTROL CABLE/ [4] “N” (NEUTRAL) THROTTLE LINK [3] “F” (FORWARD) Inspection: REMOTE CONTROL 1) Remove the engine cover (P. 4-2). LEVER Remove the front separate cover (P. 4-7). 2) Move the remote control lever to the “F” (Forward) full FULL open position.
Page 116 Adjustment: [1] LINK PIN THROTTLE <Throttle arm not in full open position> 1) Loosen the shift pivot lock nut of the remote control cable (throttle side), and remove the shift pivot from the throttle arm link pin. SHIFT 2) Screw in the shift pivot a little until the throttle arm contacts PIVOT the full open stopper, and temporarily install the shift pivot [3] LOCK NUT...
Page 117: Remote Control Lever Friction
Check item: [1] 5 x 16 mm HEX. BOLT <Side-mount remote control type only> 1) Remove the remote control box cover B and C (P. 16-2). 2) Move the remote control lever to the full open position and be sure that the link joint arm is in contact with the 5 x 16 mm hex.
Page 118 a. Best tension check using belt tension gauge: 1) Set the special tool at the center between the alternator belt pulleys, and measure the belt tension. TOOL: Belt tension gauge 07JGG-0010101 BELT TENSION GAUGE 329 – 490 N 07JGG-0010101 Used belt (40 –...
Page 119 3) Remove the alternator belt by removing it from the alternator pulley first, then from the crankshaft pulley. ALTERNATOR BELT • Do not contaminate the alternator belt with oil or grease. • Do not bend the alternator belt. Store the belt by hanging it on the wall.
Page 120: Engine Cover/Cover Lock
4. ENGINE COVER/COVER LOCK 1. ENGINE COVER 4. UNDER COVER FRONT BRACKET/ L./R. SIDE COVER BRACKETS 2. FRONT SEPARATE COVER 3. L./R. ENGINE UNDER COVERS 4.5 N . m (0.45 kgf . m, 3.3 lbf . ft) 4.5 N . m (0.45 kgf . m, 3.3 lbf .
Page 121: Engine Cover
1. ENGINE COVER a. REMOVAL/INSTALLATION Remove the engine cover by pulling the cover lock lever toward you. b. DISASSEMBLY/ASSEMBLY [1] ENGINE COVER [2] ENGINE COVER SEAL ASSEMBLY: Install the engine cover seal in the direction shown. [2]-1 [2]-2 INSIDE OUTSIDE COVER LOCK LEVER c.
Page 122 d. HOOK BRACKET DISASSEMBLY/ASSEMBLY COVER LOCK FRONT SIDE: BOLT [5] HOOK DAMPER 6.5 x 10 x 11.5 mm [6] 12 mm WASHER DISTANCE COLLAR (3) 6 x 20 mm SOCKET BOLT [7] LOCK ADJUSTING SPRING [8] HOOK BRACKET 6 x 16 mm SOCKET BOLT [9] 6 mm WASHER [10] 6 mm HEX.
Page 123 e. HOOK BRACKET ASSEMBLY COVER LOCK 1) Apply grease to the cover lock bolt installation part of the BOLT hook bracket. 2) Install the lock adjusting spring, 12 mm washer and the hook damper on the hook bracket. HOOK DAMPER 3) Apply grease to the flanged part of the cover lock bolt.
Page 124 g. ADJUSTMENT • HOOK BRACKET 1) Install the engine cover on the outboard motor and lock it securely. 2) Measure the clearance between the engine cover and the L./R. engine under covers. • Measure the clearance at the three points, i.e. at the front and at the rear right and left sides.
Page 125 h. ENGINE COVER DISASSEMBLY Remove the hook bracket assembly (P. 4-2). ENGINE COVER AIR GUIDE 4 x 10 mm SELF- TAPPING SCREW (8) [3] ENGINE COVER i. ENGINE COVER ASSEMBLY 1) Clean the engine cover and engine cover air guide mating surfaces.
Page 126: Front Separate Cover
2. FRONT SEPARATE COVER a. REMOVAL 1) Remove the engine cover (P. 4-2). 2) Loosen the undercase grommet band and remove it from the remote control cable grommet. 3) Remove the 6 x 17 mm special bolt and the three 6 x 25 mm screws, then detach the front separate cover. 4) Remove the front separate cover.
Page 127 3) Loosely tighten the three 6 x 25 mm screws and one 6 x 17 mm special bolt. 6 x 17 mm SPECIAL • Check that the special bolt is not on the case but it is BOLT 6 x 25 mm tightened properly.
Page 128: L./R. Engine Under Covers
3. L./R. ENGINE UNDER COVERS a. REMOVAL Remove the following parts. – Engine cover (P. 4-2) – Front separate cover (P. 4-7) – Electric part cover (P. 3-22) 1) Remove the flush plug cap from the R. engine under cover. FLUSH PLUG 2) Open the wire harness clip.
Page 129 6) Loosen the two 5 x 10 mm rivet screws and remove the two 14 mm clips. [1] 14 mm CLIP (2) 5 x 10 mm RIVET SCREW (2) 7) Remove the three 6 x 25 mm screws and the eleven 6 x 17 mm special bolts from the L./R. engine under covers. L.
Page 130 9) Open the L. engine under cover and disconnect the 7 x 400 mm tube from the water check grommet. 7 x 400 mm TUBE WATER CHECK GROMMET 10) Detach the R. engine under cover from the projection of the [1] PROJECTION R.
Page 131 b. R. ENGINE UNDER COVER DISASSEMBLY [1] 16 mm HEX. NUT POWER TILT SWITCH STAY POWER TILT SWITCH STAY GROMMET [2] WATER JOINT [3] R. ENGINE UNDER COVER [4] POWER TILT SWITCH c. INSPECTION [1] UP (Up) • POWER TILT SWITCH Check for continuity between the terminals with the switch in each position.
Page 132 d. COMPONENTS DRAWING [3] 14 mm CLIP (2) 6 x 25 mm SCREWS L. ENGINE 4.5 N . m (0.45 kgf . m, POWER TILT SWITCH UNDER 3.3 lbf . ft) 3P CONNECTOR 7 x 400 mm TUBE COVER FLUSH PLUG CAP [7] 6 x 17 mm SPECIAL BOLT (11) [13]...
Page 133 e. R. ENGINE UNDER COVER ASSEMBLY 1) Position the water joint cap on the R. engine under cover and tighten the 16 mm hex. nut securely. Note the installation direction of the water joint cap. 2) Position the power tilt switch on the power tilt switch grommet with the “UP” mark on the power tilt switch facing 3) Install the power tilt switch on the R.
Page 134 4) Install the L. engine under cover aligning the hole in the L. [1] L. ENGINE UNDER [2] PROJECTION engine under cover with the projection on the L. side cover COVER bracket. HOLE L. SIDE COVER BRACKET 5) Check that the cover lock cable A is set on the L. engine under cover as shown.
Page 135 8) Align the projections at the front side (i.e. swivel case side) of the L. engine under cover with the recess in the R. engine [1] RECESS under cover as shown. R. ENGINE UNDER COVER PROJECTIONS L. ENGINE UNDER COVER 9) With the R.
Page 136 11) Install the L./R. engine under covers aligning the projection on the rear (i.e. cylinder head cover side) of the L. engine [1] L. ENGINE UNDER under cover with the recess in the R. engine under cover. COVER Install the L./R. engine under covers, too, aligning the projections at the upper part of the L.
Page 137 14) Check that the end of each 14 mm clip aligns with the end [2] 5 x 10 mm of the taped part of the power tilt motor wire as shown. RIVET POWER TILT SCREW (2) MOTOR WIRE 15) Tighten the two 5 x 10 mm rivet screws securely while pushing the end of the two 14 mm clips against the corresponding projection on the L.
Page 138 19) Push in the head of the mud guard clips in the numbered [1] LIP on the reverse side sequence securely. of the grommet. 20) Check that the lip on the reverse side of the under cover grommet is set on the engine under cover. ⑤...
Page 139: Under Cover Front Bracket/ L./R. Side Cover Brackets
4. UNDER COVER FRONT BRACKET/ [2] COVER LOCK 4 x 7 x 160 mm CABLE A L./R. SIDE COVER BRACKETS VINYL TUBE LOCK Remove the following pars. – Engine cover (P. 4-2) – Front separate cover (P. 4-7) – L./R. engine under cover (P. 4-9) –...
Page 140 5) Remove the two 8 x 30 mm hex. bolts and the two 8 mm washers, then remove the under cover front bracket. UNDER COVER FRONT BRACKET [2] 8 mm WASHER (2) [3] 8 x 30 mm HEX. BOLT (2) DISASSEMBLY: 1) Remove the 6 mm E-ring and the 8 mm washer from the lock front shaft.
Page 141 3) Remove the 6 mm E-ring from the cover open shaft. COVER OPEN UNDER Remove the cover lock bushing B in a manner of bringing SHAFT COVER it to the lock lever return spring side. FRONT BRACKET With the return spring compressed with the bushing B, hold the cover open shaft at a slightly inclined angle.
Page 142 COMPONENTS DRAWING: 6 mm E-RING (3) [4] 8 mm WASHER (3) UNDER COVER FRONT BRACKET LOCK FRONT SHAFT COVER LOCK BUSHING A (3) [15] COVER LOCK BUSHING B [14] LOCK LEVER RETURN SPRING [13] COVER OPEN SHAFT [12] 10 mm WASHER [11] 10 mm WAVE...
Page 143 b. L. SIDE COVER BRACKET COVER LOCK REMOVAL: CABLE A 1) Loosen the lock nuts on the cover lock cable A and B, and COVER LOCK disconnect the cover lock cable A and B from the side lock. CABLE B [2] LOCK NUT [4] SIDE LOCK [2] LOCK NUT...
Page 144 DISASSEMBLY: [2] 6 mm E-RING 1) Remove the 6 mm E-ring and the 8 mm washer from the side lock. 8 mm WASHER 2) Lower the side lock and detach the hook of the cover lock COVER LOCK hook spring from the hole in the L. side cover bracket. BUSHING A (2) Remove the side lock from the L.
Page 145 c. R. SIDE COVER BRACKET REMOVAL: 1) Loosen the lock nut on the cover lock cable B, and [1] LOCK NUT disconnect the cover lock cable B from the side lock. [2] SIDE LOCK [3] COVER LOCK CABLE B 2) Remove the two 6 x 22 mm flange bolts and remove the R. side cover bracket.
Page 146 DISASSEMBLY: [3] COVER LOCK 6 mm E-RING 1) Remove the 6 mm E-ring and the 8 mm washer from the BUSHING A (2) side lock. 2) Lower the side lock and detach the hook of the cover lock hook spring from the hole in the R. side cover bracket. 8 mm WASHER Remove the side lock from the R.
Page 147 d. R. SIDE COVER BRACKET/L. SIDE COVER [2] 6 mm E-RING [3] COVER LOCK BRACKET/UNDER COVER FRONT BRACKET BUSHING A (2) ASSEMBLY 8 mm WASHER R. SIDE COVER BRACKET: 1) Apply marine grease to the outer surface of the cover lock bushing As, and install them on the R.
Page 148 UNDER COVER FRONT BRACKET: [2] 6 mm E-RING 8 mm WASHER 1) Install the bracket cap. [1] COVER LOCK BUSHING A 2) Apply marine grease to the front lock shaft and the outer surface of the cover lock bushing. (MARINE GREASE) 3) Apply marine grease to the outer surface of the cover lock hook spring.
Page 149 12) Apply marine grease to the outer surface of the 10 mm washer, two 10 mm wave washers and the cover lock bushing A and to the inner wall of the lock front shaft hole in the under cover front bracket. 13) Install the two cover lock bushing As, 10 mm washer and the two 10 mm wave washers on the cover lock lever as shown.
Page 150 3) Install the under cover front bracket securely with the two 8 x 30 mm hex. bolts and the two 8 mm washers. UNDER COVER FRONT BRACKET 8 mm WASHER (2) 8 x 30 mm HEX. BOLT (2) 4) Pass the tube and the wires through the hole in the under [2] WIRES cover front bracket.
Page 151 6) Check that the taped ends of the power tilt motor wire and trim angle sensor wire are in alignment with the end of the Wires and tube must not undercase grommet C. Install the undercase grommet C on interfere with the lock lever. the under cover front bracket so they engage securely in FRONT the groove of the undercase grommet C.
Page 152 10) Adjust the length between the other end of the cable outer and the end of the nut of the cover lock cable A so that it is 13 mm (0.5 in) as shown. 11) Holding the nut in the position described in step 10, 13 mm (0.5 in) position the inner cable end of the cover lock cable A on the side lock and position the cable A nut on the L.
Page 153 16) Adjust the length between the other end of the cable outer and the end of the nut of the cover lock cable B so that it is 13 mm (0.5 in) as shown. 17) Holding the nut in the position described in step 16, 13 mm position the inner cable end of the cover lock cable B on the (0.5 in)
Page 154: Programmed-Fuel Injection
5. PROGRAMMED FUEL INJECTION BF135A•BF150A 1. SERVICE PRECAUTIONS 15. FUEL STRAINER (LOW PRESSURE SIDE)/ WATER SEPARATOR 2. CIRCUIT DIAGRAM 16. EOP (ENGINE OIL PRESSURE) SWITCH 3. VACUUM CONNECTIONS (HIGH PRESSURE SIDE) 4. PARTS LOCATION/ECM TERMINAL LAYOUT 17. EOP (ENGINE OIL PRESSURE) SWITCH 5.
Page 155: Service Precautions
BF135A•BF150A 1. SERVICE PRECAUTIONS • Apply the recommended engine oil to the O-rings before installation. Avoid using the vegetable oil and the alco- • PGM-FI (PROGRAMMED FUEL INJECTION) holic grease. TROUBLESHOOTING • First, check the MIL of the indicator. O-RING •...
Page 156: Circuit Diagram
BF135A•BF150A 2. CIRCUIT DIAGRAM To STARTER MOTOR BATTERY ECT (ENGINE COOLANT TEMPERATURE) SENSOR 3 IGNITION SWITCH ECT (ENGINE COOLANT TEMPERATURE) SENSOR 2 PGM-FI MAIN RELAY IAT (INTAKE AIR TEMPERATURE) SENSOR INJECTOR ECT (ENGINE COOLANT TEMPERATURE) SENSOR 1 IGNITION COIL TP (THROTTLE POSITION) SENSOR...
Page 157 BF135A•BF150A A/F (AIR FUEL RATIO) SENSOR TACHOMETER PULSE CHECK CONNECTOR A/F (AIR FUEL RATIO) SENSOR RELAY TACHOMETER (OPTION) IAB (INTAKE AIR BYPASS) CONTROL VALVE DATA LINK CONNECTOR FUEL GAUGE EMERGENCY STOP SWITCH BUZZER TRIM METER (OPTION) TRIM ANGLE SENSOR ACG INDICATOR LIGHT...
Page 158: Vacuum Connections
BF135A•BF150A 3. VACUUM CONNECTIONS To MOUNT CASE VAPOR SEPARATOR IAB (INTAKE AIR BYPASS) CONTROL SOLENOID VALVE FUEL PUMP DIAPHRAGM HIGH PRESSURE SIDE FUEL FILTER INJECTOR VAPOR FILTER WATER SEPARATOR SILENCER CASE FUEL STRAINER TP (THROTTLE POSITION) SENSOR BREATHER CHAMBER MAP (MANIFOLD ABSOLUTE PRESSURE)
Page 159: Parts Location/Ecm Terminal Layout
BF135A•BF150A 4. PARTS LOCATION/ECM TERMINAL LAYOUT IAT (INTAKE AIR TEMPERATURE) SENSOR KNOCK SENSOR BARO (BAROMETRIC PRESSURE) SENSOR FUEL PUMP (HIGH PRESSURE SIDE) ECT (ENGINE COOLANT TEMPERATURE) SENSOR 2 WATER LEVEL SENSOR INJECTOR TP (THROTTLE POSITION) SENSOR IAB (INTAKE AIR BYPASS) CONTROL SOLENOID...
Page 160 BF135A•BF150A A/F (AIR FUEL RATIO) SENSOR PGM-FI MAIN RELAY VTEC SOLENOID VALVE EOP (ENGINE OIL PRESSURE) SWITCH (HIGH PRESSURE SIDE) ECT (ENGINE COOLANT TEMPERATURE) SENSOR 4 EOP (ENGINE OIL PRESSURE) SWITCH CKP (CRANKSHAFT POSITION) SENSOR (LOW PRESSURE SIDE) ECT (ENGINE COOLANT TEMPERATURE) SENSOR 1...
Page 161 BF135A•BF150A • ECM TERMINAL LAYOUT ECM CONNECTOR A HARNESS SIDE CONNECTOR VIEWED FROM THE TERMINAL SIDE Terminal Wire Terminal Name Content/Signal color mark Logic ground 2 (Common with B17) Sensor ground 2 Not used W/Bl AFV1 A/F sensor (V) Power source for the A/F sensor...
Page 162 BF135A•BF150A ECM CONNECTOR B HARNESS SIDE CONNECTOR VIEWED FROM THE TERMINAL SIDE Terminal Wire Terminal Name Content/Signal color mark Not used CMP sensor CMP sensor signal CKP sensor CKP sensor signal Br/Y VCC1 Sensor power 1 Power for sensor (5V) MAP sensor Detects vacuum at the intake manifold.
Page 163 BF135A•BF150A ECM CONNECTOR C HARNESS SIDE CONNECTOR VIEWED FROM THE TERMINAL SIDE Terminal Wire Terminal Name Content/Signal color mark Y/Bl IGP1 ECM main power 1 (Common with C5) At ignition switch ON: Battery voltage Power ground 1 (Common with C6)
Page 164: Troubleshooting
BF135A•BF150A 5. TROUBLESHOOTING 3. Perform the troubleshooting by referring to the “Trou- bleshooting Guide by DTC” (P. 5-15) or “Troubleshoot- The ECM (Engine Control Module) has the self-diagnosis ing Guide by No. of Blinks” (P. 5-59). function which memorizes the failure code and turns the...
Page 165 BF135A•BF150A • QUICK REFERENCE CHART OF TROUBLESHOOTING BY SYSTEM When the MIL does not come ON but the engine becomes faulty, refer to the following troubleshooting chart and check the parts in the numbered order shown on the chart. Idle Control System...
Page 166: Troubleshooting With Hds Tester
BF135A•BF150A 6. TROUBLESHOOTING WITH HDS • WHEN USING HDS POCKET TESTER DURING CRUISING TESTER 1. Remove the engine cover and the electric part cover (Section 4). • DTC (DIAGNOSTIC TROUBLE CODE) CHECK 2. Remove the cap from the under cover front bracket.
Page 167 BF135A•BF150A 5. Secure the extension wire as shown with the band. • TO CLEAR DTC EXTENSION WIRE 1. Remove the engine cover and the electric part cover. OF TESTER 2. Connect the HDS pocket tester to the data link con- nector (DLC).
Page 168: Troubleshooting Guide By Dtc
BF135A•BF150A a. TROUBLESHOOTING GUIDE BY DTC PGM-FI MIL Detected unit Probable problem part Ref. page – MIL does not • Open circuit in MIL wire 5-18 come ON/blinks • Blown MIL bulb 0-2, • Open circuit in ECM ground wire or...
Page 169 BF135A•BF150A PGM-FI MIL Detected unit Probable problem part Ref. page 10-1 MIL comes ON IAT sensor (Voltage too low) • Short circuit in IAT sensor wire 5-38 • Faulty IAT sensor • Faulty ECM 10-2 MIL comes ON IAT sensor (Voltage too high) •...
Page 170 BF135A•BF150A PGM-FI MIL Detected unit Probable problem part Ref. page 140-1 MIL comes ON ECT sensor 2 (Voltage too low) • Short circuit in ECT sensor 2 wire 5-51 • Faulty ECT sensor 2 • Faulty ECM 140-2 MIL comes ON ECT sensor 2 (Voltage too high) •...
Page 171: Troubleshooting
BF135A•BF150A b. TROUBLESHOOTING 2. Main power line check -1. Disconnect the remote control harness 14P connector. • MIL Does Not Come ON -2. Measure the voltage between the No. 3 (White/Black) terminal of the main harness side 14P connector and 1.
Page 172 BF135A•BF150A 3. IGP power line check 4. ECM power line check -1. Turn the ignition switch OFF. Disconnect the PGM-FI -1. Turn the ignition switch OFF and disconnect the fuse main relay 6P connector. box 3P connector. -2. Turn the ignition switch ON. Measure the voltage -2.
Page 173 BF135A•BF150A 5. MIL power line check 6. Alternator indicator light check -1. Turn the ignition switch OFF and disconnect the fuse -1. Turn the ignition switch ON and check the alternator box 3P connector. indicator light. -2. Turn the ignition switch ON. Measure the voltage between the No.
Page 174: Mil Comes On But Dtc Code Does Not
BF135A•BF150A 8. Function test • MIL Comes ON but DTC Code -1. Turn the ignition switch OFF and connect the HDS Does Not Appear pocket tester. -2. Turn the ignition switch ON and perform the function 1. ECM power line check test.
Page 175 BF135A•BF150A -3. Turn the ignition switch OFF and disconnect the ECM Is there the continuity? connector B. YES – Perform “3. DTC recheck”. -4. Check for the continuity between the No. 3 (Light NO – Repair open in the main harness.
Page 176: Alert System Initial Operation Is
BF135A•BF150A • Alert System Initial Operation Is 2. Buzzer line check -1. Turn the ignition switch OFF and disconnect the Faulty Yellow/Green terminal from the buzzer. -2. Connect the Yellow/Green terminal of the buzzer to the 1. Function test Black terminal with a jumper wire to short.
Page 177 BF135A•BF150A 3. MIL line check -5. Check for continuity between the No. 4 (Yellow/ Black) terminal and the No. 6 (Red/Blue) terminal of the MIL -1. Turn the ignition switch OFF and disconnect the MIL 6P connector. 6P connector. -2. Turn the ignition switch ON. Measure the voltage between the No.
Page 178 BF135A•BF150A 4. Overheat indicator line check -3. Turn the ignition switch OFF and connect the indicator light Yellow terminal. -1. Turn the ignition switch OFF. Disconnect the Red ter- -4. Disconnect the remote control harness 14P connector. minal of the indicator light and connect the Black ter- -5.
Page 179: Neutral Switch Malfunction
BF135A•BF150A • Neutral Switch Malfunction -4. Disconnect the ECM connector B. -5. Check for the continuity between the No. 13 • Before following test, perform the neutral position check. (Black/Blue) terminal of the ECM harness side con- nector B and the No. 1 (Black/Blue) terminal of the Engine speed does not increase in gears (BF150A only).
Page 180: Tachometer Malfunction
Do the tachometer and tester readings agree? YES – Normal (Temporary problem has been removed.) NO – Perform “2. Tachometer power line check”. TACHO *Tolerance of genuine Honda tachometer: (GRAY) At 2,000 rpm:±160 rpm VIEWED FROM THE At 4,000 rpm:+200 rpm TERMINAL SIDE –150 rpm...
Page 181: Ecm Troubleshooting
BF135A•BF150A • ECM Troubleshooting • MAP Sensor Troubleshooting DTC 0-2, 0-5, 0-8: Inside of ECM is faulty DTC 3-1: MAP sensor voltage is low 1. Symptom reproduction test 1. Symptom reproduction test -1. Connect the HDS pocket tester. -1. Connect the HDS pocket tester and clear the DTC -2.
Page 182 BF135A•BF150A DTC 3-2: MAP sensor voltage is high Is there the continuity? YES – Perform “4. MAP sensor ground line open cir- 1. Symptom reproduction test cuit check”. -1. Connect the HDS pocket tester and clear the DTC NO – Repair open in the wire between the MAP once.
Page 183: Ckp Sensor Troubleshooting
BF135A•BF150A 6. MAP sensor signal line open circuit check • CKP Sensor Troubleshooting -1. Turn the ignition switch OFF and disconnect the ECM DTC 4-1: No CKP pulse connector B. 1. Symptom reproduction test -2. Check for the continuity between the No. 2 (White/Red) terminal of the MAP sensor harness side 3P connec- -1.
Page 184 BF135A•BF150A 3. CKP sensor power line open circuit check 5. CKP sensor signal line short circuit check -1. Turn the ignition switch ON and measure the voltage -1. Turn the ignition switch OFF. Check for continuity between the No. 1 (Yellow/Black) terminal of the CKP between the No.
Page 185 BF135A•BF150A 7. CKP sensor check DTC 4-2: CKP pulse is abnormal -1. Connect the HDS pocket tester and clear the DTC 1. Symptom reproduction test once. -1. Connect the HDS pocket tester and clear the DTC -2. Start the engine and let it run at idling under no load.
Page 186: Ect Sensor 1 Troubleshooting
BF135A•BF150A • ECT Sensor 1 Troubleshooting DTC 6-2: ECT sensor 1 voltage is high 1. Symptom reproduction test DTC 6-1: ECT sensor 1 voltage is low -1. Connect the HDS pocket tester and clear the DTC 1. Symptom reproduction test once.
Page 187: Tp Sensor Troubleshooting
BF135A•BF150A • TP Sensor Troubleshooting Is the measurement 4.30 – 5.25V? YES – Repair open in the sensor ground line. DTC 7-1: TP sensor voltage is low NO – Repair open in the wire between the ECM 1. Symptom reproduction test and the ECT sensor 1.
Page 188 BF135A•BF150A DTC 7-2: TP sensor voltage is high 3. TP sensor power line open circuit check -1. Turn the ignition switch ON. Measure the voltage 1. Symptom reproduction test between the No. 3 (Brown/White) terminal of the TP -1. Connect the HDS pocket tester and clear the DTC sensor harness side 3P connector and the engine once.
Page 189: Cmp Sensor Troubleshooting
BF135A•BF150A 5. TP sensor check • CMP Sensor Troubleshooting -1. Turn the ignition switch OFF and connect the TP sen- DTC 8-1: No CMP sensor pulse sor 3P connector. 1. Symptom reproduction test -2. Measure the TP sensor voltage using the HDS pocket tester.
Page 190 BF135A•BF150A 3. CMP sensor power line open circuit check DTC 8-2: CMP sensor pulse is abnormal -1. Turn the ignition switch ON. Measure the voltage 1. Symptom reproduction test between the No. 1 (Yellow/Black) terminal of the CMP -1. Connect the HDS pocket tester and clear the DTC sensor harness side 3P connector and the engine once.
Page 191: Iat Sensor Troubleshooting
BF135A•BF150A • IAT Sensor Troubleshooting DTC 10-2: IAT sensor voltage is high 1. Symptom reproduction test DTC 10-1: IAT sensor voltage is low -1. Connect the HDS pocket tester and clear the DTC 1. Symptom reproduction test once. If the DTC can not be cleared, go on the trou- -1.
Page 192: Baro Sensor Troubleshooting
BF135A•BF150A • BARO Sensor Troubleshooting Is there the continuity? YES – Perform “4. IAT sensor check”. DTC 13-1: BARO sensor voltage is low NO – Repair open in the wire between the IAT sen- sor and the engine ground. 1. Symptom reproduction test -1.
Page 193 BF135A•BF150A DTC 13-2: BARO sensor voltage is high Is the measured voltage 4.75 – 5.25V? YES – Repair open in the wire between the BARO 1. Symptom reproduction test sensor and the engine ground. -1. Connect the HDS pocket tester and clear the DTC NO –...
Page 194: Iac Valve Troubleshooting
BF135A•BF150A • IAC Valve Troubleshooting -2. Check for the continuity between the IAC valve No. 2 terminal and the body ground. DTC 14-1: IAC valve current is abnormal IAC VALVE SIDE 2P 1. Symptom reproduction test CONNECTOR -1. Connect the HDS pocket tester and clear the DTC once.
Page 195: Vtec Solenoid Valve
BF135A•BF150A 5. IAC valve line short circuit check • VTEC Solenoid Valve Troubleshooting -1. Check for the continuity between the No. 26 DTC 21-1: VTEC solenoid valve output is abnormal (Green/White) terminal of the ECM connector B and 1. Symptom reproduction test the engine ground, and between the No.
Page 196: Knock Sensor Troubleshooting
BF135A•BF150A 3. VTEC signal line short circuit check • Knock Sensor Troubleshooting -1. Disconnect the ECM connector A. DTC 23-1: Knock sensor detects failure -2. Check for the continuity between the No. 20 1. Symptom reproduction test (Green/Yellow) terminal of the ECM connector A and the body ground.
Page 197: Shooting
BF135A•BF150A 3. Knock sensor signal line short circuit test • A/F Heater Troubleshooting -1. Check for the continuity between the No. 15 (Red/Blue) DTC 41-3: A/F heater is abnormal terminal of the ECM connector A and the body ground. 1. Symptom reproduction test -1.
Page 198 BF135A•BF150A -9. Check for the continuity between the No. 3 (White) ter- Is there the battery voltage? minal of the A/F heater relay harness side 4P connec- YES – Go to the step 5. tor and the No. 3 (White) terminal of the A/F sensor NO –...
Page 199 BF135A•BF150A 4. Heater line short circuit check DTC 41-4: A/F sensor heater is abnormal -1. Turn the ignition switch OFF and disconnect the ECM 1. Symptom reproduction test connector C. -1. Connect the HDS pocket tester and clear the DTC -2.
Page 200 BF135A•BF150A -9. Check for the continuity between the No. 3 (White) ter- Is there the battery voltage? minal of the A/F heater relay harness side 4P connec- YES – Go to the step 5. tor and the No. 3 (White) terminal of the A/F sensor NO –...
Page 201 BF135A•BF150A 4. Heater line short circuit check -3. Check for the continuity between the No. 3 (Black/ White) terminal of the ECM connector C and the -1. Turn the ignition switch OFF and disconnect the ECM respective terminals of the No. 1 (White/Black) and the connector C.
Page 202: A/F Sensor Troubleshooting
BF135A•BF150A • A/F Sensor Troubleshooting -3. Check for the continuity between the No. 2 (Black/Yellow) terminal of the A/F sensor harness side DTC 48-5: A/F sensor current is abnormal 4P connector and the No. 14 (Black/Yellow) terminal of the ECM connector A.
Page 203 BF135A•BF150A DTC 48-6: A/F sensor V current is abnormal DTC 48-7: A/F sensor C current is abnormal 1. Symptom reproduction test 1. Symptom reproduction test -1. Connect the HDS pocket tester and clear the DTC -1. Connect the HDS pocket tester and clear the DTC once.
Page 204: Ect Sensor 2 Troubleshooting
BF135A•BF150A • ECT Sensor 2 Troubleshooting DTC 140-2: ECT sensor 2 voltage is high 1. Symptom reproduction test DTC 140-1: ECT sensor 2 voltage is low -1. Connect the HDS pocket tester and clear the DTC 1. Symptom reproduction test once.
Page 205: Ect Sensor 3 Troubleshooting
BF135A•BF150A 3. ECT sensor 2 ground line open circuit check • ECT Sensor 3 Troubleshooting -1. Connect the ECM connector B. DTC 141-1: ECT sensor 3 voltage is low -2. Check for the continuity between the No. 1 (Green/ 1. Symptom reproduction test Red) terminal of the ECT sensor 2 harness side 2P connector and the body ground.
Page 206 BF135A•BF150A DTC 141-2: ECT sensor 3 voltage is high 3. ECT sensor 3 ground line open circuit check -1. Connect the ECM connector B. 1. Symptom reproduction test -2. Check for continuity between the No. 1 (Green/Red) -1. Connect the HDS pocket tester and clear the DTC terminal of the ECT sensor 3 harness side 2P con- once.
Page 207: Eop Switch (High Pressure Side)
BF135A•BF150A • EOP switch (High pressure side) 3. EOP switch signal line short circuit check -1. Turn the ignition switch OFF. Disconnect the EOP Troubleshooting switch 2P connector and the ECM connector A. DTC 142-1: EOP switch signal is abnormal -2.
Page 208: Ect Sensor 4 Troubleshooting
BF135A•BF150A 5. EOP switch check • ECT Sensor 4 Troubleshooting -1. Turn the ignition switch OFF and connect all the con- DTC 143-1: ECT sensor 4 voltage is low nectors. 1. Symptom reproduction test -2. Turn the ignition switch ON and check the EOP switch using the HDS pocket tester.
Page 209 BF135A•BF150A DTC 143-2: ECT sensor 4 voltage is high 3. ECT sensor 4 ground line open circuit check -1. Connect the ECM connector B. 1. Symptom reproduction test -2. Check for the continuity between the No. 1 -1. Connect the HDS pocket tester and clear the DTC (Green/Red) terminal of the ECT sensor 4 harness once.
Page 210: Troubleshooting Without Hds Tester
BF135A•BF150A 7. TROUBLESHOOTING WITHOUT • ECM Reset Procedure HDS TESTER 1. Turn the ignition switch OFF. • Check of Number of Blinks of MIL 2. Short-circuit the 4P (Red) data link connector located inside the electric part cover using the special tool 1.
Page 211 BF135A•BF150A • Final Procedure (After Troubleshooting) • Connecting Test Harness 1. Disconnect the SCS short connector from the data link Use the test harness (special tool) and a commercially connector. available digital circuit tester for troubleshooting. Disconnect the test harness sensor connector if the •...
Page 212: Troubleshooting Guide
BF135A•BF150A a. TROUBLESHOOTING GUIDE Detected unit Probable problem part Ref. page No. of blinks • Open circuit in MIL wire 5-61 MIL does • Blown MIL bulb not come • Open circuit or poor grounding of ECM ground wire • Faulty ECM Stays ON •...
Page 213 BF135A•BF150A Detected unit Probable problem part Ref. page No. of blinks ECT sensor 2 (Low voltage) • Open or short circuit in the ECT sensor 2 wire 5-84 • Faulty ECT sensor 2 • Faulty ECM ECT sensor 3 (Low voltage) •...
Page 214: Troubleshooting
BF135A•BF150A b. TROUBLESHOOTING 2. Main power supply line check -1. Disconnect the remote control harness 14P connector. • MIL Does Not Come On -2. Measure the voltage between the No. 3 (White/ Black) terminal of the main harness side 14P connector and 1.
Page 215: Faulty
BF135A•BF150A 3. IGP power supply line check 4. ECM power supply line check -1. Turn the ignition switch OFF and disconnect the PGM- -1. Turn the ignition switch OFF and disconnect the fuse FI main relay 6P connector. box 3P connector.
Page 216 BF135A•BF150A 5. MIL power supply line check 6. Alternator indicator light check -1. Turn the ignition switch OFF and disconnect the fuse -1. Turn the ignition switch ON and check the alternator box 3P connector. indicator light. -2. Turn the ignition switch ON. Measure the voltage between the No.
Page 217 BF135A•BF150A • MIL ON but MIL Does Not Blink -6. Connect the SCS short connector to the data link con- nector to short-circuit. With SCS Circuit Shorted -7. Measure the voltage between the test harness B-16 terminal (+) and A-1 (–) terminal, and between the B- 1.
Page 218 BF135A•BF150A 3. Sensor check -9. With the ECU connector A disconnected, check for the continuity between the test harness A-12 terminal and -1. Turn the ignition switch ON. the engine ground. -2. Disconnect the MAP sensor 3P connector and check the MIL.
Page 219 BF135A•BF150A • Alert System Initial Operation Is Faulty -3. Turn the ignition switch OFF and disconnect the Yellow/Green terminal from the buzzer. 1. Wire harness short-circuit check -4. Connect the Yellow/Green terminal of the buzzer to the Black terminal with a jumper wire to short-circuit.
Page 220 BF135A•BF150A 3. Overheat indicator line check 4. Oil pressure indicator line check -1. Connect the test harness B-31 terminal to the engine -1. Connect the test harness B-32 terminal to the engine ground to short-circuit. ground to short-circuit. -2. Turn the ignition switch ON and check that the over- -2.
Page 221 BF135A•BF150A 5. MIL line check 6. Alternator indicator line check -1. Disconnect the ECM connector B and connect the test -1. Turn the ignition switch OFF and disconnect the alter- harness B-25 terminal to the engine ground to short- nator 4P connector.
Page 222 BF135A•BF150A -3. Check for the continuity between the No. 1 (Brown) ter- 9. EOP switch (high pressure side) line check minal of the water separator water level sensor har- -1. Disconnect the high pressure side EOP switch 2P con- ness side connector and the test harness A-19 termi- nector.
Page 223: Neutral Switch Malfunction
BF135A•BF150A • Neutral Switch Malfunction • Tachometer Malfunction Engine speed does not increase in gear (BF150A only) Tachometer does not function so that it corre- sponds to the engine speed. Perform neutral switch inspection (P. 17-13) and neutral position adjustment (P. 3-25) before troubleshooting.
Page 224: Map Sensor Troubleshooting
BF135A•BF150A • MAP Sensor Troubleshooting 3. MAP sensor signal line open circuit check -1. Connect the ECM connector A. MIL blinks 3 times. -2. Turn the ignition switch ON. 1. Symptom reproduction test -3. Measure the voltage between the No. 2 (White/Red) terminal of the MAP sensor harness side 3P connec- -1.
Page 225: Ckp Sensor Troubleshooting
BF135A•BF150A 5. MAP sensor ground line open circuit check • CKP Sensor Troubleshooting -1. Check for the continuity between the No. 1 (Green/ MIL blinks 4 times. Red) terminal of the MAP sensor harness side 3P con- 1. Symptom reproduction test nector and the body ground.
Page 226 BF135A•BF150A 6. CKP sensor check Is the measured voltage 4.75 – 5.25V? YES – Perform "4. CKP sensor signal line short cir- -1. Reset the ECM. cuit check". -2. Start the engine and let it run at idling under no load.
Page 227: Ect Sensor 1 Troubleshooting
BF135A•BF150A • ECT Sensor 1 Troubleshooting 3. ECT sensor 1 line short circuit check -1. Turn the ignition switch OFF and disconnect the ECM MIL comes ON 6 times. connector B. 1. Symptom reproduction test -2. Check for the continuity between the No. 2 (Red/White) terminal of the ECT sensor 1 harness side 2P con- -1.
Page 228: Tp Sensor Troubleshooting
BF135A•BF150A 5. ECT sensor 1 check • TP Sensor Troubleshooting -1. Turn the ignition switch OFF and disconnect the 2P MIL blinks 7 times. connector of the ECT sensor 1. 1. Symptom reproduction test -2. Measure the resistance between the No. 1 and the No.
Page 229 BF135A•BF150A 3. TP sensor signal line open circuit check 5. TP sensor ground line open circuit check -1. Turn the ignition switch OFF and disconnect the TP -1. Turn the ignition switch OFF and disconnect the TP sensor connector. sensor 3P connector.
Page 230: Cmp Sensor Troubleshooting
BF135A•BF150A • CMP Sensor Troubleshooting Is the voltage 4.75 – 5.25V? YES – Perform "4. CMP sensor signal line short cir- MIL blinks 8 times. cuit check". 1. Symptom reproduction test NO – Repair open in the wire between the CMP sensor and the ECM.
Page 231: Iat Sensor Troubleshooting
BF135A•BF150A 6. CMP sensor check • IAT Sensor Troubleshooting -1. Reset the ECM. MIL blinks 10 times. -2. Start the engine and let it run at idling under no load. 1. Symptom reproduction check Check the MIL. -1. Reset the ECM.
Page 232 BF135A•BF150A 3. IAT sensor signal line short circuit check 5. IAT sensor check -1. Turn the ignition switch OFF and disconnect the ECM -1. Turn the ignition switch OFF and disconnect the IAT connector B. sensor 2P connector. -2. Check for the continuity between the No. 2 (Red/ -2.
Page 233: Baro Sensor Troubleshooting
BF135A•BF150A • BARO Sensor Troubleshooting 3. BARO sensor signal line open circuit check -1. Turn the ignition switch ON. Measure the voltage MIL blinks 13 times. between the No. 2 (White/Blue) terminal of the BARO 1. Symptom reproduction test sensor harness side 3P connector and the body ground.
Page 234: Iac Valve Troubleshooting
BF135A•BF150A 5. BARO sensor ground line open circuit check • IAC Valve Troubleshooting -1. Turn the ignition switch ON. Measure the voltage MIL blinks 14 times between the No. 1 (Green/Red) terminal of the BARO 1. Symptom reproduction test sensor harness side 3P connector and the engine ground.
Page 235: Vtec Solenoid Valve Trouble
BF135A•BF150A -2. Check for the continuity between the IAC valve No. 2 • VTEC Solenoid Valve Troubleshooting terminal and the body ground. MIL blinks 21 times IAC VALVE SIDE 1. Spool solenoid valve check 2P CONNECTOR -1. Turn the ignition switch OFF and disconnect the spool solenoid valve connector.
Page 236: Knock Sensor Troubleshooting
BF135A•BF150A 3. VTEC signal line open circuit check • KNOCK Sensor Troubleshooting -1. Check for the continuity between the spool solenoid MIL blinks 23 times valve harness side connector terminal and A-20 termi- 1. Symptom reproduction test nal of the test harness.
Page 237: Ect Sensor 2 Troubleshooting
BF135A•BF150A 3. Knock sensor signal line short circuit check • ECT Sensor 2 Troubleshooting -1. Check for the continuity between the test harness A-15 MIL blinks 24 times terminal and the engine ground. 1. Symptom reproduction test -1. Reset the ECM.
Page 238 BF135A•BF150A 3. ECT sensor 2 ground line short circuit check 5. ECT sensor 2 check -1. Turn the ignition switch OFF. Disconnect the ECT sen- -1. Turn the ignition switch OFF and disconnect the 2P sor 2 connector and the ECM connector B.
Page 239: Ect Sensor 3 Troubleshooting
BF135A•BF150A • ECT Sensor 3 Troubleshooting 3. ECT sensor 3 signal line short circuit check -1. Turn the ignition switch OFF. Disconnect the ECT sen- MIL blinks 25 times sor 3 connector and the ECM connector B. 1. Symptom reproduction test -2.
Page 240: Eop Switch (High Pressure Side)
BF135A•BF150A 5. ECT sensor 3 check • EOP switch (High Pressure Side) -1. Turn the ignition switch OFF and disconnect the ECT Troubleshooting sensor 3 2P connector. -2. Measure the resistance between the No.1 and No.2 MIL blinks 26 times terminals of the ECT sensor 3 side 2P connector.
Page 241 BF135A•BF150A 3. EOP switch signal line short circuit check 5. EOP switch check -1. Turn the ignition switch OFF. Disconnect the EOP -1. Turn the ignition switch OFF and connect each con- switch 2P connector and the ECM connector A.
Page 242: Ect Sensor 4 Troubleshooting
BF135A•BF150A • ECT Sensor 4 Troubleshooting 3. ECT sensor 4 signal line short circuit check -1. Turn the ignition switch OFF. Disconnect the ECT sen- MIL blinks 27 times sor 4 connector and the ECM connector B. 1. Symptom reproduction test -2.
Page 243: A/F Sensor Heater Trouble
BF135A•BF150A 5. ECT sensor 4 check • A/F Sensor Heater Troubleshooting -1. Turn the ignition switch OFF and disconnect the ECT MIL blinks 41 times sensor 4 2P connector. 1. Symptom reproduction test -2. Measure the voltage between the No.1 and No.2 ter- minals of the ECT sensor 4 side 2P connector.
Page 244 BF135A•BF150A 4. A/F heater check Is there the battery voltage? YES – Go to the step 6. -1. Turn the ignition witch OFF and disconnect the A/F NO – Blown No.1 (30A) fuse, or repair open in the sensor 4P connector.
Page 245: A/F Sensor Troubleshooting
BF135A•BF150A 6. Heater line open circuit check • A/F Sensor Troubleshooting -1. Connect the No.3 (Black/White) and the No.4 (White) MIL blinks 48 times terminals of the A/F sensor harness side 4P connector 1. Symptom reproduction test respectively to the engine ground with the jumper wires.
Page 246: Idle Control System
BF135A•BF150A 3. A/F sensor line short circuit check 8. IDLE CONTROL SYSTEM -1. Turn the ignition switch OFF. Disconnect the A/F sen- sor connector and the ECM connector A. • Troubleshooting -2. Check for the continuity between the test harness A-4 When the MIL does not come ON but an engine failure of terminal and the engine ground.
Page 247: Adjustment
BF135A•BF150A • Idle Adjusting Screw Adjustment 6) Adjust the idle speed by turning the adjusting screw. • If adjustment cannot be made, check each vacuum Check the following before adjustment. tube for disconnection and collapse, then check and • Idle speed inspection (P. 3-22) clean the throttle body (P.
Page 248: Throttle Body Inspection
• Do not spray the carburetor cleaner directly to the throttle body. • Use the genuine Honda carburetor cleaner. 3) Apply the engine oil to the new IAC valve gasket and • Do not wipe the throttle valve where is coated with install it.
Page 249: Fuel Supply System
BF135A•BF150A 9. FUEL SUPPLY SYSTEM High pressure fuel supply system • Troubleshooting • Hard to start When the MIL does not come ON but an engine failure of 1. Fuel line (high pressure side) (P. 5-104) either of the following symptoms occurs at the engine start 2.
Page 250: Pgm-Fi Main Relay Harness
BF135A•BF150A • PGM-FI Main Relay Harness Inspection 5. Turn the ignition switch ON. Measure the voltage between the No.2 (Black/Yellow) terminal of the PGM- Check with test harness: FI main relay harness side 6P connector and the 1. Turn the ignition switch OFF and disconnect each con- engine ground.
Page 251 BF135A•BF150A Check without test harness: Is there the continuity? YES – Go to the step 8. 1. Turn the ignition switch OFF and disconnect each con- NO – Blown No.4 (15A) fuse, or open in the wire nector from the PGM-FI main relay.
Page 252 BF135A•BF150A 8. Check for the continuity between the terminals of the Is there the battery voltage? fuse box harness side 6P connector and ECM con- YES – Go to the step 6. nectors A and B: NO – Blown No.3 (10A) fuse, or faulty ignition...
Page 253: Injector Harness Inspection
BF135A•BF150A • Injector Harness Inspection Is there the continuity? YES – Repair open in the wire between the ECM Check with test harness: and the injector 1. Turn the ignition switch OFF and disconnect each 2P NO – Go to the step 5.
Page 254 BF135A•BF150A Check without test harness: Is there the continuity? YES – Repair open in the wire between the ECM 1. Turn the ignition switch OFF and disconnect the 2P and the injector. connector from the respective injectors. NO – Go to the step 5.
Page 255: How To Relieve Fuel Pressure
BF135A•BF150A • How To Relive Fuel Pressure SHOP TOWEL Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately.
Page 256 BF135A•BF150A 3) Disconnect the pressure regulator control tube from the PRESSURE REGULATOR pressure regulator, and clamp the vacuum tube. CONTROL TUBE TUBE CLAMP (Commercially available) 4) Remove the propeller. Set the outboard motor gear case in a test tank filled with water. Start the engine and measure the fuel pressure at idling.
Page 257: Fuel Line Inspection
BF135A•BF150A • Fuel Line Inspection Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. 1) Check the fuel pipe, fuel hose, pressure regulator return hose and the fuel tube for damage, gasoline leakage, rust and other abnormalities.
Page 258: Fuel Injector Inspection
BF135A•BF150A • Fuel Injector Inspection When the engine is hard to start: 1) Disconnect the fuel injector connector and measure the resistance between the terminals. 2) If the fuel injector is normal, check the following • No.7 (10A) fuse • No.4 (15A) fuse •...
Page 259: Pressure Regulator Inspection
BF135A•BF150A • Pressure Regulator Inspection Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. • If the fuel pressure is lower than the specified standard pres- sure, check the high pressure side fuel pump (P.
Page 260: Fuel Pump (High Pressure Side)
BF135A•BF150A • Fuel Pump (High pressure side) Inspection FUEL PUMP 2P CONNECTOR Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors.
Page 261 BF135A•BF150A • Discharge Volume Check PRESSURE REGULATOR Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately.
Page 262: Iab (Intake Air Bypass) Control
BF135A•BF150A 10. IAB (Intale Air Bypass) 3. IAB control valve check -1. Connect the vacuum tubes. CONTROL SYSTEM -2. Disconnect the IAB control valve 2P connector while running the engine at idling. • IAB Control Valve Inspection -3. Check the vacuum tube located above the IAB control valve for vacuum.
Page 263: Inspection
BF135A•BF150A 6. Signal line open circuit check • Shutter Valve Diaphragm Inspection -1. Turn the ignition switch OFF and disconnect the IAB control valve 2P connector. NOTICE -2. Turn the ignition switch ON. Measure the voltage between the No.1 (Yellow/Black) terminal of the IAB •...
Page 264: Vapor Separator/Fuel Pump (High Pressure Side)
BF135A•BF150A 11. VAPOR SEPARATOR/FUEL PUMP (HIGH PRESSURE SIDE) a. REMOVAL Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. [2] HARNESS [3] FUEL PUMP 2P •...
Page 265 BF135A•BF150A 8) Disconnect the fuel tube B from the low pressure side fuel pump. [1] FUEL TUBE B 9) Disconnect the water tube from the crankcase. [1] WATER TUBE 10) Remove the two 8 x 35 mm flange bolts, two 8 mm wash- ers, and one 8 x 30 mm flange bolt.
Page 266 BF135A•BF150A b. DISASSEMBLY 1) Disconnect the 4.5 x 55 mm fuel tube. 2) Remove the 8 x 35 mm flange bolt and the 8 mm washer. Remove the vapor separator stay. 3) Remove the collar and the vapor separator grommet.
Page 267 BF135A•BF150A 7) Remove the four 5 mm screw-washers. Remove the con- nector bracket and pump cover. 8) Remove the O-ring from the pump cover and discard it. Replace the O-ring with a new one on assembly. 9) Remove the pump holder.
Page 268 BF135A•BF150A 11) Remove the O-ring and the seal ring. [2] INSULATOR [3] PLATE Replace the O-ring with a new one on assembly. O-RING Do not reuse. 12) Remove the plate and the insulator. 13) Remove the high pressure side fuel pump, pump holder and the O-ring.
Page 269 BF135A•BF150A 15) Remove the eight 5 mm screw-washers and the eight 6 mm washers. Remove the water jacket cover and the cover gas- ket. Replace the cover gasket with a new one on assembly. COVER GASKET Do not reuse. 5 mm COLLAR (8)
Page 270 BF135A•BF150A c. INSPECTION FLOAT HEIGHT • Check the float height by installing the float properly. 1) Place the vapor separator cover as shown. Measure the distance between the float and vapor separator cover (i.e. float height). • Set the special tool at right angles to the float chamber mating surface and measure at the highest position of the float.
Page 271 BF135A•BF150A d. ASSEMBLY • Vapor Separator Chamber 5 mm SCREW-WASHER (6) 3.4 N m (0.35 kgf m, 2.5 lbf • • • VAPOR SEPARATOR COVER GASKET COVER Do not reuse. 6 x 16 (2) 12 N m (1.2 kgf m, 9 lbf •...
Page 272 BF135A•BF150A 1) Install the float valve and float pin to the float. [1] SCREW (2) FLOAT PIN 2) Set the float assembly on the vapor separator cover and tighten the two screws to the specified torque. FLOAT TORQUE: 2.1 N m (0.21 kgf...
Page 273 BF135A•BF150A 8) Apply a thin coat of the engine oil to a new cover gasket and install it on the water jacket cover. COVER GASKET Do not reuse. 9) Set the eight collars on the water jacket cover and install the WATER JACKET water jacket cover on the vapor separator chamber.
Page 274 BF135A•BF150A • Fuel Pump (High Pressure Side) 4 mm SCREW 4 mm WASHER 5 mm SCREW-WASHER (4) 3.4 N·m (0.35 kgf·m, 2.4 lbf·ft) PUMP HARNESS ASSEMBLY FUEL HOSE FUEL STRAINER [10] (HIGH PRESSURE (HIGH PRESSURE SIDE) CONNECTOR SIDE) BRACKET PUMP COVER...
Page 275 BF135A•BF150A 1) Apply a thin coat of the engine oil to the new O-rings and set them on the vapor separator chamber. O-RING (2) Do not reuse. 2) Install the pump case with care not to allow the O-rings to come out of position.
Page 276 BF135A•BF150A 7) Install the pump harness assembly on the pump cover, and [1] 4 mm SCREW [2] 4 mm WASHER secure the pump harness assembly with the 4 mm screw. TORQUE: 2.1 N • m (0.21 kgf • m, 1.5 lbf •...
Page 277 BF135A•BF150A 14) Tighten the four 5 mm screw-washers securely. [1] 5 mm SCREW-WASHER (4) • Install the connector bracket in the position shown and 3.4 N·m (0.35 kgf·m, 2.4 lbf·ft) secure with the two 5 mm screw-washers. CONNECTOR TORQUE: 3.4 N m (0.35 kgf...
Page 278 BF135A•BF150A e. INSTALLATION VAPOR VAPOR 1) Install the vapor separator grommet and the collar on the SEPARATOR SEPARATOR fuel pump case. STAY GROMMET COLLAR 2) Loosely tighten the vapor separator stay with the 8 mm washer and the 8 x 35 mm flange bolt.
Page 279 BF135A•BF150A 7) Connect the 7.3 x 350 mm water tube to the cylinder block [1] TUBE CLIP and secure it with the tube clip. [2] 7.3 x 350 mm WATER TUBE 8) Connect the fuel tube B to the vapor separator and secure it [1] TUBE CLIP B12 with the tube clip B12.
Page 280 BF135A•BF150A 14) Connect the fuel pump 2P connector and set the connector on the connector bracket. HARNESS FUEL PUMP 2P BAND CLIP CONNECTOR 15) Install the harness band clip on the connector bracket in the CLAMPS position shown in the drawing.
Page 281: Silencer Case/Throttle Body/Intake Manifold
BF135A•BF150A 12. SILENCER CASE/THROTTLE [1] HARNESS BAND CLIP BODY/INTAKE MANIFOLD a. SILENCER CASE REMOVAL 1) Remove the engine cover. 2) Disconnect the IAT sensor 2P connector and remove the harness band clip from the silencer case. [3] IAT SENSOR 2P...
Page 282 BF135A•BF150A b. THROTTLE BODY/INTAKE MANIFOLD MAP SENSOR 3P REMOVAL CONNECTOR 1) Remove the silencer case (P . 5-128). 2) Disconnect the MAP sensor 3P connector and remove the harness band clip. HARNESS BAND CLIP 3) Remove the water level sensor connector from the the har- ness clip bracket E.
Page 283 BF135A•BF150A 9) Disconnect the pressure regulator vacuum tube from the intake manifold joint. PRESSURE REGULATOR VACUUM TUBE INTAKE MANIFOLD JOINT 10) Remove the two 8 x 55 mm flange bolts and remove the L. side cover bracket. L. SIDE COVER BRACKET •...
Page 284 BF135A•BF150A c. INTAKE MANIFOLD DISASSEMBLY/ASSEMBLY [2] SOLENOID VALVE TUBE ASSEMBLY: Connect the solenoid valve tube to the top of the intake air cut-off solenoid valve, and the diaphragm tube to the lower joint of the intake air cut-off solenoid valve.
Page 285 BF135A•BF150A d. THROTTLE BODY DISASSEMBLY/REASSEMBLY [1] MAP SENSOR ASSEMBLY: Apply the engine oil to the new O-ring and install it on the MAP 5 x 18 mm SCREW sensor. Install aligning the cutout in the set plate with the lib of the sensor as shown.
Page 286 BF135A•BF150A 3) Set the five 8 x 35 mm flange bolts, two 8 mm washers and [1] 8 mm FLANGE NUT (2) the two 8 mm flange nuts. 4) Tighten the 8 x 35 mm flange bolts and the 8 mm flange nuts in the numbered sequence in two or three steps to the specified torque.
Page 287 BF135A•BF150A 9) Connect the vacuum tube to the pressure regulator. PRESSURE REGULATOR VACUUM TUBE INTAKE MANIFOLD JOINT 10) Install the L. side cover bracket assembly and tighten the two 8 x 55 mm flange bolts securely. L. SIDE COVER BRACKET...
Page 288 BF135A•BF150A f. SILENCER CASE INSTALLATION [2] CRANKCASE BREATHER TUBE [1] SILENCER CASE 1) Install the silencer case and tighten the three 6 x 25 mm flange bolts and the three 6 mm washers. 6 x 25 (3) • Check that the wire harnesses are not pinched.
Page 289: Fuel Injector/Pressure Regulator
BF135A•BF150A 13. FUEL INJECTOR/PRESSURE REGULATOR a. FUEL LINE ASSEMBLY REMOVAL Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately.
Page 290 BF135A•BF150A 7) Disconnect the pressure regulator control tube and the pres- [2] PRESSURE REGULATOR sure regulator return hose from the pressure regulator. TUBE CLAMP CONTROL TUBE D10.7 8) Remove the pressure regulator. Remove the joint pipe and PRESSURE the O-rings.
Page 291 BF135A•BF150A b. FUEL TUBE ASSEMBLY DISASSEMBLY/ASSEMBLY • Replace the O-rings with the new ones and apply the engine oil to the new O-rings before installation. 7.85 x 3.53 mm O-RING (4) 6 x 10 (4) INJECTOR CLIP (4) Do not reuse.
Page 292 BF135A•BF150A c. INJECTOR BASE REMOVAL/INSTALLATION 1) Remove the fuel injectors (P . 5-136). 2) Remove the silencer case (P . 5-128) and remove the intake manifold (P . 5-129). 3) Remove the five 8 x 25 mm flange bolts and the two 8 mm flange nuts, then remove the injector base and the injector base gasket.
Page 293 BF135A•BF150A d. FUEL TUBE ASSEMBLY INSTALLATION AIR VENT TUBE 1) Apply the engine oil to the O-rings on the injectors. Install the fuel line assembly and tighten the 8 mm flange nuts securely. STUD BOLT (2) • Replace the O-rings on assembly.
Page 294 BF135A•BF150A 8) Apply the engine oil to the O-rings and install them on the joint pipe. [1] COLLAR 9) Install the joint pipe on the fuel line. 10) Connect the fuel hose (high pressure side) and tighten the 6 x 25 mm flange bolt securely.
Page 295: Fuel Pump (Low Pressure Side)
BF135A•BF150A 14. FUEL PUMP (LOW PRESSURE SIDE) L. SIDE COVER BRACKET Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately.
Page 296 BF135A•BF150A c. INSTALLATION FUEL TUBE B TUBE CLIP B11 (2) SENSOR HOSE CLIP [4] 33.2 x 2.4 mm O-RING Do not reuse. [9] FUEL TUBE E 6 x 27 (2) [8] TUBE JOINT 12 N·m (1.2 kgf·m, 9 lbf·ft) [5] FUEL PUMP...
Page 297: Fuel Strainer (Low Pressure Side)/Water Separator
BF135A•BF150A 15. FUEL STRAINER (LOW PRESSURE SIDE)/WATER SEPARATOR Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately.
Page 298 BF135A•BF150A b. DISASSEMBLY/REASSEMBLY • WATER SEPARATOR WATER SEPARATOR BODY WATER SEPARATOR CUP/ WATER LEVEL SWITCH INSPECTION: P. 3-20 SET PLATE BAFFLE PLATE O-RING 5 x 12 mm SCREW (3) • FUEL STRAINER (LOW PRESSURE SIDE) FUEL STRAINER BODY FUEL STRAINER...
Page 299: Eop (Engine Oil Pressure) Switch (High Pressure Side)
BF135A•BF150A 16. EOP (ENGINE OIL PRESSURE) SWITCH (HIGH PRESSURE SIDE) a. INSPECTION 1) Disconnect the high pressure side EOP switch 2P connec- tor. 2) Check for the continuity between the switch side 2P connec- tor terminals. EOP SWITCH 2P • The high pressure side EOP switch is normal if there is CONNECTOR continuity.
Page 300: Ect (Engine Coolant Temperature) Sensor 1
BF135A•BF150A b. REPLACEMENT 1) Disconnect the low pressure side EOP switch terminal. 2) Remove the EOP switch. 3) Clean the EOP switch installation section in the crankcase. ® 4) Apply the liquid gasket (ThreeBond #1215 or equivalent) to the indicated area of the threads of the new EOP switch.
Page 301: Ect (Engine Coolant Temperature) Sensor 2, 3, 4
BF135A•BF150A 19. ECT (ENGINE COOLANT [2] O-RING ECT SENSOR 2 TEMPERATURE) SENSOR 2, 3, 4 Do not reuse. 2P CONNECTOR a. REPLACEMENT 1) Disconnect the ECT sensor 2P connector. 2) Remove the ECT sensor and the O-ring. • Replace the O-ring with a new one on assembly.
Page 302: Baro (Barometric Pressure) Sensor
BF135A•BF150A 20. BARO (BAROMETRIC PRESSURE) 5 x 18 mm BARO SENSOR SENSOR WASHER BOLT 3P CONNECTOR a. REPLACEMENT 1) Disconnect the BARO sensor 3P connector. 2) Remove the 5 x 18 mm washer bolt and remove the BARO BARO sensor.
Page 303: Ckp (Crankshaft Position) Sensor
BF135A•BF150A 23. CKP (CRANKSHAFT POSITION) [1] O-RING SENSOR Do not reuse. a. REPLACEMENT 1) Remove the silencer case (P . 5-128). 2) Disconnect the CKP sensor 3P connector. 3) Remove the 6 x 16 mm flange bolt, and remove the CKP [2] CKP SENSOR sensor and the O-ring.
Page 304: Vapor Chamber/Check Valve
BF135A•BF150A 25. VAPOR CHAMBER/CHECK VALVE a. DISASSEMBLY/ASSEMBLY 1) Remove the intake manifold (P . 5-129). [4] CHECK VALVE ASSEMBLY: Install with the " " mark toward the vacuum tube C side. CRANKCASE VACUUM TUBE D [4]-1 BREATHER TUBE VACUUM TUBE C...
Page 305: Exhaust Manifold
• 7 x 120 mm tube • Water tube E WATER TUBE E [6] WATER RELIEF TUBE B 3) BF135A: Disconnect the A/F sensor connector and remove 6 x 14 (3) the connector from the harness band clip bracket. CONNECTOR BRACKET...
Page 306 6) Disconnect the ECT sensor 3 connector. ECT SENSOR 3 CONNECTOR 7) Remove the 6 x 55 mm flange bolts and remove the valve assembly (BF135A) or the VTEC solenoid valve assembly (BF150A). VTEC SOLENOID VALVE ASSEMBLY (BF150A) 6 x 55 (3) VALVE ASSEMBLY (BF135A) 8) Remove the 6 x 22 mm flange bolts and remove the R.
Page 307 BF135A•BF150A 9) Remove the two 10 x 75 mm flange bolts and the three 10 x [1] GASKET 45 mm flange bolts. Remove the exhaust manifold and the Do not reuse. exhaust manifold gasket. • Replace the gasket on assembly.
Page 308 BF135A•BF150A c. INSTALLATION 6 x 14 (3) CONNECTOR BRACKET 6 x 55 (3) VTEC SOLENOID VALVE ASSEMBLY 10 x 45 (3) 10 x 75 (2) [6] GASKET Do not reuse. EXHAUST MANIFOLD [3] 76.4 x 3.1 mm [4] 79.9 x 3.1 mm...
Page 309 BF135A•BF150A 5) Tighten the two 10 x 75 mm flange bolts and the three 10 x 45 mm flange bolts to the specified torque in the numbered sequence in two or three steps. 10 x 45 (3) TORQUE: 39 N •...
Page 310 BF135A•BF150A 8) Install the VTEC spool valve assembly (BF150A) or valve assembly (BF135A) and tighten the 6 x 55 mm flange bolts [1] FILTER securely. • Do not allow the gasket and filter to come out of position. [2] GASKET...
Page 311 BF135A•BF150A 12) Connect the following water hoses. • Water relief tube A/B WATER RELIEF TUBE A • 7 x 90 mm tube • 7 x 75 mm tube 7 x 120 mm TUBE • 7 x 120 mm tube • Water tube E...
Page 312: Alternator
6. ALTERNATOR 1. SILENCER DUCT 2. ALTERNATOR 110 N . m (11.2 kgf . m, 81 lbf . ft) 26 N . m (2.7 kgf . m, 20 lbf . ft) 44 N . m (4.5 kgf . m, 33 lbf . ft) 8 N .
Page 313: Silencer Duct
1. SILENCER DUCT [2] SILENCER DUCT ASSEMBLY a. REMOVAL 18.5 mm CLAMP 1) Remove the engine cover (P. 4-2). PRESSURE BREATHER REGULATOR TUBE Release the pressure regulator control tube from the two CONTROL 3.5 mm tube clips of the silencer duct assembly. TUBE Remove the harness band clip, that secures the main wire harness, from the silencer duct assembly.
Page 314 b. DISASSEMBLY Remove the eight 5 x 12 mm self-tapping screws and remove the silencer duct A. c. COMPONENTS DRAWING [2] 18.5 mm CLAMP 5 x 12 mm SELF-TAPPING SCREW (8) [3] SILENCER DUCT A 6 x 25 (4) [4] SILENCER DUCT B [11] 6 mm WASHER (4) DUCT GROMMET (4)
Page 315 e. INSTALLATION SILENCER DUCT 6 x 25 (4) 1) Install the silencer duct assembly on the silencer case. 6 mm ASSEMBLY WASHER (4) 2) Set the four 6 mm washers and the four 6 x 25 mm flange bolts, then tighten the four 6 x 25 mm flange bolts securely. 3) Set the breather tube in the 18.5 mm clamp and the guide of the silencer duct assembly.
Page 316: Alternator
2. ALTERNATOR a. ALTERNATOR ASSEMBLY INSPECTION (With the alternator assembly mounted on the outboard motor) NOTICE Do not disconnect the battery terminals while the alternator is running. • Alternator assembly inspection must be made with the assembly mounted on the outboard motor. •...
Page 317 b. REMOVAL [1] ALTERNATOR 4P CONNECTOR Remove the following pars. – Engine cover (P. 4-2) – Silencer duct (P. 6-2) 1) Disconnect the battery negative (-) cable from the battery negative terminal. Disconnect the alternator 4P connector. Disconnect the alternator fuse cable from the alternator assembly.
Page 318 5) Remove the 10 x 80 mm flange bolt. Pull the alternator assembly toward you. Remove the 8 mm flange nut and remove the alternator assembly from the tensioner bolt. [1] ALTERNATOR ASSEMBLY 8 mm FLANGE 10 x 80 [3] TENSIONER BOLT c.
Page 319 d. ALTERNATOR ASSEMBLY/ALTERNATOR BRACKET COMPONENTS DRAWING ALTERNATOR BELT 8 mm FLANGE NUT 10 x 80 26 N . m (2.7 kgf . m, 44 N . m (4.5 kgf . m, CRANKSHAFT 20 lbf . ft) 33 lbf . ft) PULLEY [3] ALTERNATOR ASSEMBLY...
Page 320 e. ALTERNATOR ASSEMBLY DISASSEMBLY PULLEY 22 mm OFFSET 1) Loosen the pulley lock nut using a 22 mm offset wrench LOCK WRENCH and a 10 mm offset wrench. 2) Remove the pulley lock nut and the alternator pulley. 10 mm OFFSET WRENCH PULLEY LOCK ALTERNATOR...
Page 321 5) Remove the two 4 x 6 mm screws from the brush holder assembly and remove the brush holder assembly. BRUSH HOLDER INSULATOR Remove the brush holder insulator from the brush holder assembly. 4 x 6 mm SCREW (2) BRUSH HOLDER ASSEMBLY 6) Remove the two 4 x 25 mm screw-washers and the 4 x 6...
Page 322 7) Remove the four 4 x 6 mm screws from the rectifier assembly. [1] WIRE (Straighten.) 8) Straighten the four wires as shown and remove the rectifier assembly. NOTICE Replace the stator with a new one if a wire broke near the small hole in the rectifier assembly.
Page 323 11) Remove the rotor from the stator (drive end housing). Remove the bearing cover from the rotor shaft. BEARING COVER STATOR [DRIVE END HOUSING] [3] ROTOR 12) Check the rear bearing for abnormal sound and play before removal. Replace the rear bearing with a new one if there is abnormal sound or play.
Page 324 14) Remove the four screws and the retainer plate. [2] SCREW (4) Remove the two stud bolts from the stator [drive end housing]. RETAINER PLATE STATOR [DRIVE END HOUSING] STUD BOLT (2) 15) Check the front bearing for abnormal sound or play before removal.
Page 325 f. INSPECTION (Unit inspection) • BRUSH HOLDER ASSEMBLY Measure the brush length. If the measurement is less than the service limit, replace the brush holder assembly. STANDARD SERVICE LIMIT 10.5 mm (0.41 in) 8.4 mm (0.33 in) • RECTIFIER ASSEMBLY [1] E (GROUND) •...
Page 326 • STATOR [DRIVE END HOUSING] [1] WIRES Inspect the stator by removing it from the outboard motor. [1] WIRES 1) Check to see that there is continuity between the wires. 2) Check to see that there is no continuity between each wire and the stator core.
Page 327 g. COMPONENTS DRAWING [1] 6 mm HEX. NUT INSULATOR BUSHING 4 x 25 mm SCREW- WASHER (2) 4 x 6 mm SCREW (7) [5] BRUSH HOLDER [23] INSULATOR RECTIFIER ASSEMBLY [6] REAR END COVER BOLT (3) [25] BRUSH REAR END HOLDER COVER [24] IC REGULATOR...
Page 328 h. ALTERNATOR ASSEMBLY ASSEMBLY 1) Tighten the two stud bolts on the stator. 2) Apply grease to the outer surface of a new front bearing. DRIVER 07749-0010000 Drive the front bearing into the stator using the special tools as shown. TOOLS: Driver 07749-0010000...
Page 329 4) Position a washer on the rotor shaft. REAR Apply grease to the inner wall of the new rear bearing and BEARING install it on the rotor shaft. WASHER ROTOR SHAFT 5) Attach the special tool to the front bearing side of the rotor shaft, and position the rotor on the hydraulic press.
Page 330 7) Check the rotor slip rings for contamination with grease. If it is contaminated with grease, wipe it off thoroughly with BEARING COVER a clean cloth. Install the rotor on the stator [drive end housing]. SLIP RINGS Install a bearing cover on the rotor shaft. STATOR [DRIVE END HOUSING]...
Page 331 10) Pass the four wires through the four holes at the projection on the reverse side of the rectifier assembly. WIRE (Bend along 11) Bend each wire to the rectifier assembly side. the hole.) Bend each wire along the respective screw holes. 12) Tighten the four 4 x 6 mm screws securely.
Page 332 15) Tighten the two 4 x 25 mm screw-washers and the two 4 x [1] 4 x 6 mm SCREW (2) 6 mm screws securely while pushing the brush of the IC 4 x 25 mm SCREW- regulator/brush holder assembly, assembled in step 14, WASHER (2) lightly against the rotor shaft slip rings.
Page 333 18) Position the alternator pulley on the rotor shaft and tighten the pulley lock nut. ALTERNATOR PULLEY LOCK 19) Tighten the pulley lock nut to the specified torque using a PULLEY 10 mm offset wrench and a torque wrench. TORQUE: 110 N . m (11.2 kgf . m, 81 lbf . ft) TORQUE WRENCH [3] PULLEY LOCK...
Page 334 j. INSTALLATION 1) Position the alternator assembly over the tensioner bolt and loosely tighten the 8 mm flange nut. 2) Position the alternator assembly between the projections of the alternator bracket and loosely tighten the 10 x 80 mm flange bolt. [1] ALTERNATOR 10 x 80 ASSEMBLY...
Page 335 4) Tighten the special adjusting bolt. [1] 8 mm FLANGE Inspect and adjust the alternator belt (P. 3-29). 10 x 80 5) After adjustment, tighten the 8 mm flange nut and 10 x 80 mm flange bolt in this order to the specified torque. TORQUE: 8 mm flange nut: 26 N .
Page 336: Engine Removal/Installation
7. ENGINE REMOVAL/INSTALLATION 1. REMOVAL 2. INSTALLATION 26 N . m (2.7 kgf . m, 44 N . m (4.5 kgf . m, 20 lbf . ft) 33 lbf . ft) 44 N . m (4.5 kgf . m, 33 lbf . ft) 64 N .
Page 337: Removal
1. REMOVAL Remove the following pars. ENGINE HANGER (3) – Engine cover (P. 4-2). – L./R. engine under covers (P. 4-9). – Under cover front bracket/L./R. side cover brackets (P. 4-20). – Vapor separator (P. 5-111). – Gear case assembly (P. 14-3 and 42). 1) Hook the hoist hooks on the three engine hangers and secure the engine not to fall down.
Page 338 5) Remove the four 8 x 30 mm flange bolts that secure the exhaust guide from the underside of the mounting case. 6) Disconnect the water relief tube C from the relief valve cover (P. 8-6). EXHAUST GUIDE 8 x 30 (4) 7) Remove the two 10 mm cap nuts and the 10 x 70 mm flange 10 x 70 bolt from the engine assembly.
Page 339 9) Remove the following bolts and washers from the underside of the mounting case. • 8 x 100 mm flange bolt (1) • 10 x 80 mm flange bolt (1) • 10 x 110 mm flange bolts (2) • 12 x 70 mm hex. bolt (1) •...
Page 340 COMPONENTS DRAWING 8 x 55 (2) 26 N . m (2.7 kgf . m, ENGINE ASSEMBLY 10 mm CAP NUT (2) 20 lbf . ft) 10 x 70 44 N . m (4.5 kgf . m, 33 lbf . ft) 44 N .
Page 341: Installation
2. INSTALLATION SHIFT SHAFT B 1) Align the punch mark on the shift shaft A with the punch mark on the shift shaft B before installing the engine assembly. [2] ALIGNMENT MARKS NOTICE • Be sure to align the punch marks securely before installing the engine assembly.
Page 342 8) Lower the engine assembly slowly onto the mounting case while aliging the exhaust manifold of the engine assembly EXHAUST with the exhaust guide. MANIFOLD 9) Connect the water relief tube B and the 7 x 40 mm tube, disconnected in step 2, to the exhaut guide (P. 8-7, 9). NOTICE Lower the engine assembly onto the mounting case slowly while holding the engine vertically.
Page 343 12) Loosely tighten the bolts and nuts at the designated places 8 x 55 12 x 83 from the top of the engine assembly. Tighten the bolts and nuts to the specified torque in the numbered sequence in two or three steps. TORQUE: 12 x 83 mm flange bolt: 64 N .
Page 344: Thermostat/Relief Valve/Flush Valve
8. THERMOSTAT/RELIEF VALVE/ FLUSH VALVE 1. THERMOSTAT 3. FLUSH VALVE 2. WATER RELIEF TUBE/RELIEF VALVE 12 N . m (1.2 kgf . m, 9 lbf . ft) 12 N . m (1.2 kgf . m, 9 lbf . ft)
Page 345: Thermostat
1. THERMOSTAT a. DISASSEMBLY 1) Remove the engine cover (P. 4-2). 2) Disconnect the water relief tube A from the thermostat cover. Do not reuse the thermostat cover O-ring. Replace it with a new one on reassembly. 3) Remove the thermostat. 4) Disconnect the 2P connectors from the ECT sensor 2 and 4, and remove the ECT sensor 2 and 4.
Page 346 b. INSPECTION • THERMOSTAT THERMOMETER 1) Immerse the thermostat in water. 2) Heat the water and observe the operation of the thermostat as the water temperature increases. 3) Measure the water temperature when the thermostat starts to open. THERMOSTAT • Don't let the thermometer or the thermostat touch the container;...
Page 347 d. ASSEMBLY 1) Check the thermostats for the identification mark and install each of them in the proper position (P. 8-3). Install the thermostat for the cylinder head in the ECT sensor 2 installation hole side, and install the thermostat for the cylinder block in the ECTsensor 4 installation hole side.
Page 348: Water Relief Tube/Relief Valve
2. WATER RELIEF TUBE/RELIEF VALVE Remove the following parts. – Engine cover (P. 4-2) – L./R. engine under covers (P. 4-9) a. REMOVAL OF WATER RELIEF TUBE ASSEMBLY 1) Disconnect the water relief tube A from the thermostat cover. Remove the water tube clamp from the water relief tube A and the main wire harness. 2) Disconnect the 7 x 90 mm tube, 7 x 120 mm tube and the water tube E from the engine side.
Page 349 c. WATER RELIEF TUBE C/RELIEF VALVE DISASSEMBLY 1) Disconnect the 7 x 160 mm tube, 7 x 40 mm tube and the water relief tube C from the engine side. 2) Disconnect each tube from the T-joint. 3) Remove the two 6 x 22 mm flange bolts and remove the relief valve cover and the relief valve. Do not reuse the relief valve cover O-ring.
Page 350 e. WATER RELIEF TUBE C/RELIEF VALVE [1] RELIEF VALVE COVER SIDE ASSEMBLY NOTICE Check the tubes for deterioration and cracks before assembly. RELIEF VALVE Replace if necessary. 1) Install the relief valve on the mount case noting the installation direction as shown. 2) Set a new relief valve cover O-ring on the relief valve cover, and install the relief valve cover with the two 6 x 22 mm flange bolts.
Page 351 f. ASSEMBLY OF WATER RELIEF TUBE ASSEMBLY WATER RELIEF NOTICE TUBE A SIDE Check the tubes for deterioration and cracks before assembly. Replace if necessary. 1) Note the connection position of each tube to the 4-way joint as shown. 4-WAY JOINT 2) Connect the water relief tube B to the 4-way joint so that its installation angle is approximately 33˚...
Page 352 6) Connect the 7 x 75 mm tube and the water tube E to the 4-way joint. 7) Connect the 7 x 75 mm tube to the fuel tube joint. 8) Connect the 7 x 90 mm tube and the 7 x 120 mm tube to the fuel tube joint. 9) Connect the 7 x 120 mm tube with the lugs of the tube clamp D10.5s toward down.
Page 353: Flush Valve
3. FLUSH VALVE a. DISASSEMBLY Remove the following parts. – Engine cover (P. 4-2) – L./R. engine under cover (P. 4-9) 1) Disconnect the 7 x 200 mm tube from the mount case. 2) Disconnect the 8 x 300 mm tube from the flush valve cover. Remove the water seal, water hose joint A and the flush plug cap from the 8 x 300 mm tube.
Page 354 b. INSPECTION • FLUSH VALVE Check the flush valve gasket for deterioration and cracks, and replace the flush valve if necessary. FLUSH VALVE GASKET c. ASSEMBLY FLUSH VALVE COVER SIDE NOTICE Check each tube for deterioration and cracks before assembly. Replace the tubes if necessary.
Page 355: Crankshaft Pulley/Cam Chain
9. CRANKSHAFT PULLEY/CAM CHAIN 1. DISASSEMBLY 2. ASSEMBLY 245 N . m (25.0 kgf . m, 181 lbf . ft) 12 N . m (1.2 kgf . m, 9 lbf . ft) 12 N . m (1.2 kgf . m, 9 lbf . ft) 12 N .
Page 356: Disassembly
1. DISASSEMBLY 6 x 14 (3) HARNESS CLIP BRACKET C Remove the following parts. – Engine cover (P. 4-2) – L./R. engine under cover (P. 4-9) – Silencer duct (P. 6-2) – Alternator belt (P. 3-29) – Thermostat (P. 8-2) –...
Page 357 6) Disconnect the CKP sensor 3P connector from the CKP [1] CKP SENSOR sensor. 3P CONNECTOR [2] CKP SENSOR 7) Loosen the 16 x 49 mm bolt-washer using the special tools as shown. [2] HANDLE PULLEY HOLDER TOOLS: 07JAB-001020B ATTACHMENT, Handle 07JAB-001020B HEX 50 mm...
Page 358 9) Remove all bolts securing the chain case. 10 x 43 (3) • 10 x 43 mm flange bolts (3) 6 x 37 (SH BOLT) • 6 x 38 mm (SH) flange bolt (1) 6 x 28 (10) • 6 x 28 mm flange bolts (10) •...
Page 359 12) Remove the two 6 x 30 mm flange bolts and remove the 6 x 30 (2) cam chain tensioner while pushing the cam chain tensioner arm toward the cam chain (direction of arrow). [1] CAM CHAIN TENSIONER CAM CHAIN TENSIONER ARM 13) Remove the tensioner pivot bolt and the cam chain tensioner arm.
Page 360 16) Remove the crank pulser plate from the crankshaft. [1] CRANKSHAFT CRANK PULSER PLATE 17) Remove the cam chain. NOTICE Keep the cam chin away from any magnetic parts and devices after removal. CAM CHAIN...
Page 361 CHAIN CASE DISASSEMBLY: 1) Check the 43 x 58 x 7 mm oil seal for cut and other damage and replace if necessary. Remove the 43 x 58 x 7 mm oil seal using a commercially available oil seal remover. Replace the 43 x 58 x 7 mm oil seal with a new one on assembly.
Page 362 COMPONENTS DRAWING: [2] 16 x 49 mm BOLT-WASHER 245 N . m (25.0 kgf . m, 181 lbf . ft) [3] CRANKSHAFT PULLEY [1] 6 x 38 (SH BOLT) 12 N . m (1.2 kgf . m, 9 lbf . ft) 10 x 43 (3) 6 x 28 (10) 12 N .
Page 363: Assembly
2. ASSEMBLY [1] <Oil seal installation direction> CHAIN CASE ASSEMBLY: [2] (Apply grease 1) Apply soapy water to the outer surface of a new 43 x 58 x to the lip.) 7 mm oil seal. Using the special tools, drive in the 43 x 58 x 7 mm oil seal until it seats on the chain case as shown.
Page 364 4) Install the chain case by tightening the three 6 x 14 mm flange bolts to the specified torque. TORQUE: 12 N . m (1.2 kgf . m, 9 lbf . ft) 5) Position a new 15 x 1.9 mm O-ring on the CKP sensor and apply engine oil to the O-ring. Install the CKP sensor by tightening the 6 x 16 mm flange bolt securely.
Page 365 CAM CHAIN/CRANKSHAFT PULLEY ASSEMBLY: [1] CRANKSHAFT [2] “ ” MARKS SPROCKET NOTICE Keep the cam chain away from any magnetic parts and devices. 1) Align the “ ” mark on the crankshaft sprocket with the “ ” mark on the cylinder block. [3] CYLINDER BLOCK 2) Install the cam chain guide and tighten the three 6 x 20 mm flange bolts to the specified torque.
Page 366 4) Install the cam chain aligning the color plate (one) with the [1] CAM CHAIN “ ” mark (or punch mark) on the crankshaft sprocket as shown. [3] COLLAR PLATE [2] “ ” MARK (1 place) (or punch mark) 5) Holding the hexagonal part of both the intake and exhaust [1] <INTAKE SIDE>...
Page 367 8) Pushing the cam chain tensioner arm toward the cam chain, install the cam chain tensioner by aligning the 6 x 30 (2) [1] 1.5 mm PIN cutouts of the cam chain tensioner with the recess in the cam chain tensioner arm. Tighten the two 6 x 30 mm flange bolts to the specified torque.
Page 368 10) Install the cam chain guide B and tighten the two 8 x 110 mm flange bolts to the specified torque. TORQUE: 22 N . m (2.2 kgf . m, 16 lbf . ft) 8 x 110 (2) [1] CAM CHAIN GUIDE B 11) Install the new chain case gasket on the chain case.
Page 369 12) Install the new chain case O-ring on the chain case. CHAIN CASE O-RING [2] CHAIN CASE 13) Remove the old liquid gasket, oil and the contamination from the cylinder block/cylinder head and chain case Apply bar [2.5 mm mating surfaces. (0.10 in) thick] of the liquid gasket...
Page 370 15) Install the chain case on the cylinder block aligning the end of the chain case at the crankcase side. 10 x 43 (3) 6 x 38 6 x 28 (10) (SH BOLT) 16) Loosely tighten the two 6 x 31 mm special bolts in the positions shown.
Page 371 18) Wipe up oil thoroughly from the threaded part of the : [1] Wipe up contamination. crankshaft where the 16 x 49 mm bolt-washer is tightened, : [2] Apply engine oil. and from the crankshaft pulley and the 16 x 49 mm bolt- : [3] Degrease with degreasing cleaning agent.
Page 372 22) Tighten the 16 x 49 mm bolt-washer to the specified torque using the special tools as shown. [1] HANDLE 07JAB-001020B TOOLS: Handle 07JAB-001020B Pulley holder attachment, HEX 50 mm 07JAB-0010400 Socket wrench, 19 mm 07JAA-001020A TORQUE: 245 N . m (25.0 kgf . m, 181 lbf . ft) [2] SOCKET WRENCH, 19 mm [3] PULLEY HOLDER...
Page 373 24) Position the main wire harness in the recesses of the chain case. 8 x 20 (2) [1] ENGINE HANGER B 25) Tighten the engine hanger B with the two 8 x 20 mm flange bolts. MAIN WIRE HARNESS RECESSES OF CHAIN CASE 26) Position the three harness band clips on the harness clip bracket C.
Page 374: Cylinder Head/Valves
10. CYLINDER HEAD/VALVE 1. CYLINDER HEAD COVER REMOVAL 8. VALVE GUIDE REPLACEMENT 2. CYLINDER HEAD COVER 9. VALVE SEAT RECONDITIONING DISASSEMBLY 10. CLYLINDER HEAD ASSEMBLY 3. CAMSHAFT/ROCKER ARM ASSEMBLY DISASSEMBLY 11. CYLINDER HEAD ASSEMBLY 4. CAMSHAFT/ROCKER ARM INSTALLATION INSPECTION 12. CAMSHAFT/ROCKER ARM 5.
Page 375: Cylinder Head Cover Removal
1. CYLINDER HEAD COVER REMOVAL Remove the following parts. – Engine cover (P. 4-2) – L./R. engine under covers (P. 4-9) – Ignition coil/spark plug (P. 3-6) 1) Disconnect the breather tube and the main wire harness from the cylinder head cover. MAIN WIRE BREATHER HARNESS...
Page 376 4) Disconnect the oil tube from the mounting case. OIL TUBE MOUNTING CASE 5) Move the water relief tube A from your side of the projection on the cylinder head cover to the other side. WATER RELIEF TUBE A PROJECTION CYLINDER HEAD COVER...
Page 377: Cylinder Head Cover Disassembly
2. CYLINDER HEAD COVER DISASSEMBLY HEAD COVER GASKET INSPECTION: Check for damage and deterioration. Replace if necessary. CYLINDER HEAD COVER HEAD COVER WASHER (6) 6 mm HEX. CAP NUT (6) 12 N . m (1.2 kgf . m, 9 lbf . ft) PHC COVER [11] SPARK PLUG TUBE SEAL (4)
Page 378: Camshaft/Rocker Arm Disassembly
3. CAMSHAFT/ROCKER ARM DISASSEMBLY Remove the following parts. – Engine cover (P. 4-2) – L./R. engine under covers (P. 4-9) – Ignition coil/spark plug (P. 3-6) – Cylinder head cover (P. 10- 2) 1) Move the remote control lever to the “N” (Neutral) position.
Page 379 7) Using a hex. wrench, loosen the 14 mm sealing bolt that tightens the camshaft collar. CAMSHAFT COLLAR 14 mm SEALING BOLT 8) Remove the VTC flange bolt from the intake camshaft sprocket. Remove the intake camshaft sprocket from the INTAKE CAMSHAFT intake camshaft.
Page 380 10) Using a hex. wrench, loosen the 14 mm sealing bolt that tightens the CMP pulse plate. CMP PULSE PLATE 14 mm SEALING BOLT 11) Remove the 10 x 32 mm flange bolt from the exhaust camshaft sprocket, then remove the exhaust camshaft 10 x 32 EXHAUST sprocket from the exhaust camshaft.
Page 381 13) Loosen the camshaft holder bolts in the numbered sequence in two or three steps. 14) Remove the following bolts. • Head cover bolts (6) • 8 x 110 mm flange bolts (2) • 8 x 90 mm flange bolts (12) •...
Page 382 16) Remove the 14 mm sealing bolts from the intake/exhaust [1] EXHAUST camshafts, then remove the camshaft collar and the CMP CAMSHAFT pulse plate. PULSE PLATE [3] CAMSHAFT COLLAR INTAKE 14 mm SEALING CAMSHAFT BOLT (2) 17) Insert the bolts into the rocker shaft holders and remove the rocker arm assembly from the cylinder head assembly.
Page 383 COMPONENTS DRAWING VTC FLANGE BOLT 10 x 16 mm 113 N . m (11.5 kgf . m, 83 lbf . ft) DOWEL PIN (10) [4] INTAKE CAMSHAFT SPROCKET ROCKER ARM 10 x 32 ASSEMBLY 72 N . m (7.3 kgf . m, 53 lbf .
Page 384 DISASSEMBLY OF ROCKER ARM ASSEMBLY BF150A: NOTICE • Note the location of each part before disassembly. Do not confuse the parts and install them in their original positions. • Check the camshaft contact surface of each rocker arm for wear or damage. •...
Page 385 BF135A: NOTICE • Note the location of each part before disassembly. Do not confuse the parts and install them in their original positions. • Check the camshaft contact surface of each rocker arm for wear or damage. • Insert the bolts in the rocker shaft holders before removing or installing the rocker arm assembly from/on the cylinder head.
Page 386: Camshaft/Rocker Arm Inspection
4. CAMSHAFT/ROCKER ARM [1] INTAKE CAMSHAFT: <BF150A> <BF135A> INSPECTION [2] PRI [3] MID [4] SEC [4] SEC [2] PRI • CAM HEIGHT Clean the camshaft and check the cam surface for wear and damage. STANDARD SERVICE LIMIT [5] CAM CHAIN [5] CAM CHAIN 32.626 –...
Page 387 • CAMSHAFT OIL CLEARANCE 1) Clean the camshaft and check the journals for wear and damage. 2) Clean the rocker shaft holder bearings and the camshaft PLASTIGAUGE holder bearings. Install the rocker shaft holders and the camshaft on the cylinder head assembly. 3) Set a plastigauge on each journal as shown.
Page 388 • CAMSHAFT AXIAL CLEARANCE 1) Install the rocker shaft holder, camshaft and the camshaft holder, and tighten the bolts to the specified torque (P. 10- 35). 2) Put the camshaft at the top dead center of the compression stroke of the No.1 piston (with the dowel pin at your side). Install the dial indicator.
Page 389 • ROCKER ARM I.D. STANDARD SERVICE LIMIT 17.019 – 17.035 mm (0.6700 – 0.6707 in) 17.012 – 17.039 mm (0.6698 – 0.6708 in) • ROCKER ARM-TO-ROCKER SHAFT CLEARANCE STANDARD SERVICE LIMIT 0.025 – 0.052 mm 0.08 mm (0.0010 – 0.0020 in) (0.003 in) 0.018 –...
Page 390 NOTICE • Check that the following conditions are met before using the air supply (special tool). The following conditions are essential for use of the air supply, as the specified air pressure of 290 kPa (3.0 kgf/cm , 43 psi) must be maintained AIR SUPPLY at the gauge of the tool.
Page 391 Note to remove the rubber band after installation. 2) If the pistons do not move smoothly, replace the rocker arm BF135A: as an assembly. ROCKER ARM 3) Apply the engine oil to the rocker arm pistons on assembly.
Page 392: Cylinder Head Assembly Removal
5. CYLINDER HEAD ASSEMBLY REMOVAL ② ① NOTICE • Removal of the cylinder head assembly must be made when the engine is cold (38˚C or below). • Take care not to damage (scores or scratches) the gasket mating surfaces with the cylinder head and the cylinder ⑥...
Page 393: Cylinder Head Assembly Disassembly
6. CYLINDER HEAD ASSEMBLY [1] PLASTIC HAMMER DISASSEMBLY SOCKET NOTICE Mark each removed parts and store them securely classifying them into the groups of the intake side and the exhaust side of each cylinder. Install each part in the original position on assembly.
Page 394 4) Remove the valve keeper from the groove in the valve stem. VALVE KEEPER (2) 5) Remove the remaining valve keepers. 6) Remove the valve spring retainer, valve spring, valve, valve spring seat and the valve stem seal. Check the valve for chipping and excessive carbon deposits.
Page 395 COMPONENTS DRAWING 14 x 20 mm DOWEL PIN (2) CYLINDER HEAD GASKET VTC HOLE PLUG 6 x 20 [19] CYLINDER HEAD VTC FILTER [18] EXHAUST VALVE GUIDE (8) VTC STRAINER VALVE STEM SEAL B (8) EXHAUST VALVE SPRING (8) 6 x 20 (2) [17] INTAKE VALVE (8) [16]...
Page 396: Cylinder Head Assembly Inspection
7. CYLINDER HEAD ASSEMBLY INSPECTION • VALVE SPRING FREE LENGTH Measure the free length of the valve springs. STANDARD SERVICE LIMIT 49.64 mm IN/EX (1.954 in) • VALVE FACE/VALVE STEM O.D. <Valve face> Inspect each valve face for pitting or wear irregularities. Inspect each valve face for even seat.
Page 397 • VALVE STEM-TO-VALVE GUIDE CLEARANCE STANDARD SERVICE LIMIT 0.030 – 0.055 mm 0.08 mm (0.0012 – 0.0022 in) (0.003 in) 0.055 – 0.080 mm 0.11 mm (0.0022 – 0.0031 in) (0.004 in) If the stem-to-guide clearance exceeds the service limit, replace the valve and the valve guide as a set (P.
Page 398 • CYLINDER HEAD WARPAGE 1) Remove the carbon deposits from the combustion MEASUREMENT POINT chamber. Clean off any gasket material from the cylinder head surface. 2) Check the spark plug holes and valve areas for cracks. 3) Check the cylinder head for warpage using a straight edge and a feeler gauge.
Page 399: Valve Guide Replacement
8. VALVE GUIDE REPLACEMENT 1) Chill the replacement valve guides in the freezer section of VALVE GUIDE a refrigerator for about an hour. DRIVER, 5.5 mm 07742-0010100 2) Drive the valve guide out of the combustion chamber side using a special tools. TOOL: Valve guide driver, 5.5 mm 07742-0010100...
Page 400 4) Thoroughly clean the cylinder head to remove any cutting residue. 5) Check the valve guide bore; it should be straight, round and centered in the valve guide, insert the valve and check operation. If the valve does not operate smoothly, the guide may have been bent during installation.
Page 401: Valve Seat Reconditioning
9. VALVE SEAT RECONDITIONING 1) Thoroughly clean the combustion chambers and valve seats to remove carbon deposits. Apply a light coat of Prussian Blue compound or erasable felt-tipped marker ink to the valve faces. 2) Insert the valves, and then lift them and snap them closed against their seats several times.
Page 402 • VALVE SEAT WIDTH STANDARD SERVICE LIMIT 1.25 – 1.55 mm 2.0 mm IN/EX (0.049 – 0.061 in) (0.08 in) 5) Make a light pass with the 45˚ cutter to remove any possible 1.25 – 1.55 mm burrs at the edges of the seat. (0.049 –...
Page 403: Cylinder Head Assembly Assembly
10. CYLINDER HEAD ASSEMBLY ASSEMBLY VALVE SPRING 1) Apply molybdenum disulfide oil to the valve stem sliding SEAT surface and insert the valve into the valve guide. Check that the valve moves up and down smoothly. NOTICE MOLYBDENUM DISULFIDE OIL Do not confuse the intake valve and the exhaust valve on assembly.
Page 404 4) Install the valve spring and the valve spring retainer. VALVE SPRING NOTICE Do not confuse the intake valve spring and the exhaust valve spring. <Identification> The intake side can be identified with the pink paint on the VALVE SPRING RETAINER spring.
Page 405: Cylinder Head Assembly Installation
11. CYLINDER HEAD ASSEMBLY PROJECTION INSTALLATION CYLINDER HEAD NOTICE GASKET • Do not let any foreign material enter the gap between the gasket, cylinder head and the cylinder block. • Take care not to damage (scores, scratches, etc.) the cylinder head and the cylinder block at the mating surface with the gasket.
Page 406 5) Apply engine oil to the threads and the washer seat of the ten 11 x 155 mm bolt-washers, and loosely tighten them on the cylinder head assembly. 11 x 155 mm BOLT-WASHER (10) 6) Tighten the 11 x 155 mm bolt-washers to the specified torque in the numbered sequence in two or three steps.
Page 407: Camshaft/Rocker Arm Assembly
12. CAMSHAFT/ROCKER ARM Apply a bead ASSEMBLY of the liquid gasket. 1) Degrease the cylinder head mating surface of the No.5 rocker shaft holder with the degreasing cleaning agent. 2) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in)] of the liquid gasket (ThreeBond #1280B or equivalent) to the indicated ®...
Page 408 6) Apply molybdenum disulfide oil to the journals and cam surfaces of the camshafts. 7) Install the intake/exhaust camshafts, ten dowel pins, camshaft holders and the cam chain guide B. NOTICE Install the camshafts with the No.1 piston at the top dead center of the compression stroke (i.e.
Page 409 10) Secure the hex. part of the exhaust camshaft with a wrench or equivalent tool. EXHAUST CAMSHAFT 11) Install the exhaust camshaft sprocket on the exhaust camshaft by aligning the concave in the exhaust camshaft EXHAUST CAMSHAFT sprocket with the dowel pin on the exhaust camshaft. SPROCKET CONCAVE Tighten the 10 x 32 mm flange bolt on the exhaust camshaft...
Page 410 13) Install the intake camshaft sprocket on the intake camshaft by aligning the concave in the intake camshaft sprocket INTAKE CAMSHAFT CONCAVE with the dowel pin on the intake camshaft. SPROCKET INTAKE Tighten the VTEC flange bolt on the intake camshaft to the CAMSHAFT specified torque.
Page 411: Cylinder Head Cover Assembly
13. CYLINDER HEAD COVER [1] <Spark plug tube seal installation direction> ASSEMBLY 1) Install the spark plug tube seals on the cylinder head cover noting the installation direction of the seal. SPARK PLUG TUBE SEAL (4) CYLINDER HEAD COVER 2) Clean the groove of the cylinder head cover and clean the head cover gasket.
Page 412 4) Connect the oil tube to the cylinder head cover by aligning the projection on the oil tube with the projection on the cylinder head cover. Check that the oil tube is inserted in the cylinder head cover CYLINDER HEAD securely.
Page 413: Cylinder Head Cover Installation
14. CYLINDER HEAD COVER INSTALLATION 1) Thoroughly clean the cylinder head/cylinder head cover mating surfaces using a degreasing cleaning agent. 2) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in)] of the liquid gasket (ThreeBond #1280B or equivalent) to the cylinder Apply a bead ®...
Page 414 7) Tighten the 6 mm hex. cap nuts to the specified torque in the numbered sequence in two or three steps. TORQUE: 12 N . m (1.2 kgf . m, 9 lbf . ft) ③ ④ ① ② ⑤ ⑥ 8) Move the water relief tube A from the other side of the projection on the cylinder head cover to your side.
Page 415 10) Connect the oil tube to the mounting case. After connection, check that the oil tube is inserted in the mounting case securely. OIL TUBE MOUNTING CASE 11) Install the R. side cover bracket assembly on the engine assembly and tighten the two 6 x 22 mm flange bolts. R.
Page 416: Oil Pump/Flywheel
11. OIL PUMP/FLYWHEEL 1. EOP SWITCH/OIL FILTER 2. OIL PUMP FLANGE 3. FLYWHEEL 12 N . m (1.2 kgf . m, 9 lbf . ft) 8 N . m (0.8 kgf . m, 5.8 lbf . ft) 12 N . m (1.2 kgf . m, 9 lbf . ft) 22 N .
Page 417: Eop Switch/Oil Filter Flange
1. EOP SWITCH/OIL FILTER FLANGE a. DISASSEMBLY Remove the following parts. – Engine cover (P. 4-2) – L./R. engine under covers (P. 4-9) 1) Drain the engine oil (P. 3-2) and remove the oil filter using the special tool as shown. TOOL: Oil filter wrench 07HAA-PJ70101...
Page 418 b. INSPECTION Check for continuity between the terminal and body. If there is no continuity, replace the EOP switch c. ASSEMBLY 1) Apply engine oil to a new 13 x 1.5 mm O-ring and install it on the ECT sensor. 2) Tighten the ECT sensor to the specified torque and connect the ECT sensor 2P connector.
Page 419 5) Apply engine oil to a new 22.5 x 24 mm O-ring and install it on the oil filter flange. 6) Install the oil filter flange and tighten the 6 x 20 mm flange bolt and the four 6 x 25 mm flange bolts securely. 7) Connect the water tube E and the 7 x 160 mm tube to the oil filter flange, and clamp the tube with the tube clamp D10.5 securely.
Page 420 10) Then, tighten it to the specified torque using the same special tool as that used during disassembly. TOOL: Oil filter wrench 07HAA-PJ70101 TORQUE: 12 N . m (1.2 kgf . m, 9 lbf . ft) OIL FILTER WRENCH 07HAA-PJ70101 11) Before installing the EOP switch (low pressure side), clean the switch and apply the liquid gasket (ThreeBond ®...
Page 421: Oil Pump
2. OIL PUMP a. REMOVAL 1) Remove the engine from the outboard motor (P. 7-2). 2) Remove the five 8 x 32 mm flange bolts. Remove the oil pump body assembly, oil pump body gasket, 14 x 20 mm dowel pin and the 10 x 16 mm dowel pin. Replace the oil pump body gasket with a new one on assembly.
Page 422 b. DISASSEMBLY 6 x 16 mm FLAT SCREW (9) 31 x 46 x 7 mm OIL SEAL INSPECTION: • Check the oil seal lip for breakage or other damage. Replace if necessary. • Do not reuse. Replace on assembly. OIL PUMP COVER [11] INNER ROTOR 5 x 8 mm DOWEL PIN (2)
Page 423 c. INSPECTION • OIL PUMP BODY I.D. STANDARD SERVICE LIMIT 84.000 – 84.030 mm (3.3071 – 3.3083 in) • OIL PUMP BODY DEPTH STANDARD SERVICE LIMIT 9.520 – 9.550 mm (0.3748 – 0.3760 in) • OUTER ROTOR HEIGHT STANDARD SERVICE LIMIT 9.480 –...
Page 424 • INNER ROTOR-TO-OUTER ROTOR CLEARANCE STANDARD SERVICE LIMIT 0.04 – 0.16 mm 0.20 mm (0.002 – 0.006 in) (0.008 in) • OUTER ROTOR-TO-PUMP BODY CLEARANCE STANDARD SERVICE LIMIT 0.02 – 0.07 mm 0.12 mm (0.001 – 0.003 in) (0.005 in) •...
Page 425 d. ASSEMBLY 1) Apply thread locking agent to the threads of the 18 mm OIL PUMP BODY sealing bolt. 2) Check the relief valve surface for scores, scratches and other damage. Apply engine oil to the relief valve and the relief valve spring.
Page 426 6) Apply soapy water to the outer surface of each new oil seal. 7) Using the special tools, drive the 46 x 60 x 9 mm oil seal into the oil pump body and the 31 x 46 x 7 mm oil seal into the oil pump cover so they set in the respective position of the dimensions shown.
Page 427 3. FLYWHEEL a. REMOVAL 1) Remove the engine from the outboard motor (P. 7-2). 2) Remove the oil pump body assembly (P. 11-6). 3) Set the special tool on the starter motor mounting part and temporarily tighten the special tool using the 10 mm bolts, 10 mm washers and the 10 mm nuts.
Page 428 b. COMPONENTS DRAWING 14 x 20 mm DOWEL PIN FLYWHEEL 12 mm BOLT (8) 118 N . m (12.0 kgf . m, 87 lbf . ft) FLYWHEEL BOSS 10 x 16 mm DOWEL PIN 8 mm SPECIAL BOLT (8) 32 N . m (3.3 kgf . m, 24 lbf . ft) 8 x 32 (5) OIL PUMP BODY GASKET...
Page 429 c. INSPECTION Check the ring gear for wear and damage. If it is worn or FLYWHEEL damaged, check the starter motor pinion gear. RING GEAR d. INSTALLATION 1) Clean the crankshaft and flywheel mating surfaces thoroughly with the degreasing cleaning agent. ⑦...
Page 430: Crankcase/Balancer
12. CRANKCASE/BALANCER 1. CRANKCASE/BALANCER CASE 4. BALANCER CASE ASSEMBLY ASSEMBLY REMOVAL ASSEMBLY 2. BALANCER CASE ASSEMBLY 5. CRANKCASE/BALANCER CASE DISASSEMBLY ASSEMBLY INSTALLATION 3. INSPECTION 12 N . m (1.2 kgf . m, 9 lbf . ft) 44 N . m (4.5 kgf . m, 33 lbf . ft) 22 N .
Page 431: Crankcase/Balancer Case Assembly Removal
1. CRANKCASE/BALANCER CASE 6 x 25 (15) ASSEMBLY REMOVAL Remove the following parts. – Engine cover (P. 4-2) – L./R. engine under covers (P. 4-9) – Silencer case (P. 5-128) – Throttle body/intake manifold (P. 5-129) – Silencer duct (P. 6-2) –...
Page 432 7) Remove the two chain guide bolts and remove the balancer chain guide. Remove the three 6 x 14 mm flange bolts and remove the 6 x 14 (3) balancer chain tensioner. 8) Hold the rear balancer shaft by inserting the special tool into the maintenance hole in the front balancer.
Page 433 COMPONENTS DRAWING 6 x 25 (15) 12 N . m (1.2 kgf . m, 9 lbf . ft) 6 x 14 CABLE BRACKET B CRANKCASE [16] 26 x 2.7 mm O-RING Do not reuse. [15] OIL CAP 10 x 105 (2) 44 N .
Page 434: Balancer Case Assembly Disassembly
2. BALANCER CASE ASSEMBLY DISASSEMBLY 8 x 55 (3) 6 x 32 (3) 27 N . m (2.8 kgf . m, 20 lbf . ft) 12 N . m (1.2 kgf . m, 9 lbf . ft) 6 x 25 (2) 12 N .
Page 435: Inspection
3. INSPECTION • BALANCER SHAFT JOURNAL O.D. Measure the O.D. of the balancer shaft No.1 journal. STANDARD SERVICE LIMIT 19.938 – 19.950 mm 19.92 mm Front (0.7850 – 0.7854 in) (0.784 in) 23.938 – 23.950 mm 23.92 mm Rear (0.9424 – 0.9429 in) (0.942 in) If the measurement exceeds the service limit, replace the balancer shaft.
Page 436: Balancer Case Assembly Assembly
4. BALANCER CASE ASSEMBLY BALANCER SHAFT PROJECTION ASSEMBLY BEARING 1) Install the four balancer shaft bearings on the front/rear balancer holders by aligning the projection on each balancer shaft bearing with the concave at the corresponding bearing installation part of the front/rear CONCAVE balancer shaft.
Page 437: Crankcase/Balancer Case Assembly Installation
5. CRANKCASE/BALANCER CASE 10 x 105 (2) 8 x 50 ASSEMBLY INSTALLATION 8 x 75 1) Apply engine oil to the threads and seat of each bolt. BALANCER CASE 2) Install the balancer case assembly and the two dowel pins ASSEMBLY on the lower block and tighten the bolts to the specified torque.
Page 438 4) Align the alignment mark on the front balancer holder with the projection on the rear balancer shaft. REAR BALANCER PROJECTION ALIGNMENT SHAFT MARK 5) Hold the rear balancer shaft by inserting the special tool [2] MAINTENANCE into the maintenance hole in the front balancer. HOLE PIN DRIVER, 6.0 mm TOOL:...
Page 439 8) Install the driven sprocket together with the balancer chain [3] PROJECTION [2] CONCAVE on the rear balancer shaft by aligning the concave in the driven sprocket with the projection on the rear balancer shaft. 10 x 30 mm TORQUE: 44 N . m (4.5 kgf . m, 33 lbf . ft) BOLT-WASHER After installation, remove the special tool from the balancer case assembly.
Page 440 After replacing the balancer chain tensioner with new one: 11) Install the set clip, that came together with the new balancer chain tensioner, on the balancer chain tensioner. BALANCER CHAIN TENSIONER SET CLIP 12) Install the balancer chain tensioner assembled in step 10 on the rear balancer holder and tighten the three 6 x 14 mm BALANCER CHAIN flange bolts.
Page 441 16) Apply engine oil to the threads and seat of the 6 x 25 mm 6 x 25 (18) flange bolts 17) Install the two dowel pins and crankcase on the lower block and loosely tighten the 6 x 25 mm flange bolts. CRANKCASE [2] 13 x 20 mm DOWEL PIN (2)
Page 442: Cylinder Block/Crankshaft/Pistons
13. CYLINDER BLOCK/CRANKSHAFT/ PISTON 1. DISASSEMBLY 3. BEARING SELECTION 2. INSPECTION 4. ASSEMBLY 26 N . m (2.7 kgf . m, 20 lbf . ft) 20 N . m (2.0 kgf . m, 14 lbf . ft) + 90˚ 29 N . m (3.0 kgf . m, 26 N .
Page 443: Disassembly
1. DISASSEMBLY a. LOWER BLOCK/CRANKSHAFT/CYLINDER ① ② BLOCK Remove the following parts. ⑥ ⑤ – Engine cover (P. 4-2) – L./R. engine under covers (P. 4-9) – Cylinder head assembly (P. 10-19) ⑩ ⑨ – Engine assembly (P. 7-2) – Oil pump (P. 11-6) ⑭...
Page 444 6) Remove the lower block, 80 x 98 x 10 mm oil seal and the [2] 80 x 98 x 10 mm eleven dowel pins from the cylinder block. LOWER BLOCK OIL SEAL Replace the oil seal on assembly. 13 x 14 mm DOWEL PIN (10) 18 x 22 mm DOWEL PIN...
Page 445 12) Remove the crankshaft from the cylinder block with care not to damage (scores, scratches, etc.) the journals. CRANKSHAFT Remove the two thrust washers. 13) Before removing the upper main bearings, check each UPPER MAIN bearing for damage (scores, scratches, etc.) and replace if BEARING (5) necessary.
Page 446 b. PISTON ASSEMBLY 1) Remove the connecting rod bearing and the piston ring CONNECTING PISTON RING from the piston assembly. ROD BEARING NOTICE • Do not apply excessive force to the piston ring as it can break the piston ring. Handle the piston ring with care. •...
Page 447 c. COMPONENTS DRAWING 8 x 50 (4) 8 x 35 (10) 26 N . m (2.7 kgf . m, 20 lbf . ft) 26 N . m (2.7 kgf . m, 20 lbf . ft) LOWER MAIN BEARING (5) 11 x 95 mm BOLT-WASHER (10) 29 N .
Page 448 TOP RING [14] PISTON RING SECOND RING PISTON PIN [13] CLIP (2) SIDE RAIL (2) PISTON [12] OIL RING [11] SPACER CONNECTING ROD [10] PISTON PIN 10 x 12 mm DOWEL PIN (2) CONNECTING ROD BEARING (2) CONNECTING ROD CAP CONNECTING ROD BOLT (2) 20 N .
Page 449: Inspection
2. INSPECTION • PISTON SKIRT O.D. O.D. 1) Check the piston outer surface for damage (scores, scratches, etc.). Check the piston for warpage and cracks. 11 mm (0.4 in) 2) Measure and record the piston O.D. at a point 11 mm from the bottom, and 90˚...
Page 450 • PISTON RING THICKNESS 1) Check the piston ring for damage (scores, scratches, etc.). 2) Measure the piston ring thickness. STANDARD SERVICE LIMIT 1.170 – 1.185 mm (0.0461 – 0.0467 in) 1.175 – 1.190 mm SECOND (0.0463 – 0.0469 in) The oil rings are the combination rings.
Page 451 • PISTON PIN BORE I.D. STANDARD SERVICE LIMIT 21.960 – 21.963 mm (0.8646 – 0.8647 in) • PISTON PIN O.D. STANDARD SERVICE LIMIT 21.961 – 21.965 mm 21.953 mm (0.8646 – 0.8648 in) (0.8643 in) • PISTON PIN-TO-PIN BORE CLEARANCE 1) Set the cylinder gauge at the piston pin O.D.
Page 452 • CONNECTING ROD BIG END AXIAL CLEARANCE STANDARD SERVICE LIMIT 0.15 – 0.35 mm 0.4 mm (0.006 – 0.014 in) (0.02 in) • CRANKSHAFT MAIN JOURNAL O.D. NO.2 MAIN NO.4 MAIN STANDARD SERVICE LIMIT JOURNAL JOURNAL 54.984 – 54.992 mm No.1, 2, 4, 5, (2.1647 –...
Page 453 • CRANKSHAFT AXIAL CLEARANCE Install the dial indicator as shown. Measure the crankshaft axial play by moving the crankshaft back and forth with a screwdriver. STANDARD SERVICE LIMIT 0.10 – 0.35 mm 0.45 mm (0.004 – 0.014 in) (0.018 in) If the measurement exceeds the service limit, check the thrust washer and the cylinder block thrust surface.
Page 454 • CYLINDER HEAD SURFACE WARPAGE 1) Take care not to damage (score, scratches, etc.) the mating surface with the gasket. 2) Measure the surface warpage using a straight edge and a feeler gauge as shown. STANDARD SERVICE LIMIT 0.07 mm (0.003 in) Max. 0.10 mm (0.004 in) •...
Page 455 • CRANKSHAFT MAIN BEARING OIL CLEARANCE 1) Clean the crankshaft main journals and the main bearings. PLASTIGAUGE Check the journals and the bearings for damage and wear. 2) Install the upper main bearings and the crankshaft on the cylinder block. Install the lower main bearings and the lower block and tighten the bolts to the specified torque (P.
Page 456: Bearing Selection
3. BEARING SELECTION a. CONNECTING ROD BEARING NOTICE • When replacing the connecting rod bearing, check the crank pin code letter and the connecting rod code number, and select the correct bearing by referring to the bearing selection table. • If the code letters and/or numbers are not clear, clean the areas with a cleaning solvent and check again.
Page 457 Connecting rod bearing selection table: Connecting rod code number Crank pin 1 or l 2 or ll 3 or lll 4 or llll code letter Bearing identification color Pink/ Pink Yellow Yellow Yellow/ Pink Yellow Green Green Green/ Yellow Green Brown Brown Brown/...
Page 458 b. CRANKSHAFT MAIN BEARING NOTICE • When replacing the main bearing, check the crankshaft main journal code number and the cylinder block I.D. code letter or number, and select the correct bearing by referring to the bearing selection table. • If the code letter and/or number is not clear, clean the area with a cleaning solvent and check again.
Page 459 Crankshaft main bearing selection table: Cylinder block I.D. code letter or number Crankshaft main journal 1 or A or l 2 or B or ll 3 or C or lll 4 or D or llll code number Bearing identification color Pink/ Pink Yellow...
Page 460: Assembly
4. ASSEMBLY a. PISTON ASSEMBLY 1) Install the piston pin clip only on one side of the piston. NOTICE Take care not to let the piston pin clip jump out of position. PISTON PIN CLIP 2) Warm up the piston to approximately 70˚C (158˚F). CAUTION Take care not to get your hand, etc.
Page 461 6) Install the piston rings in the ring grooves in the piston with the marker marks on the top ring and the second ring TOP RING facing up. Install the side rail (top side) by aligning the lug of the side SECOND RING rail (top side) with the positioning groove in the ring groove.
Page 462 b. LOWER BLOCK/CRANKSHAFT/CYLINDER BLOCK 1) Apply molybdenum disulfide oil to the piston skirt and the inner wall of the cylinder sleeve. 2) Using the handle of a hammer, drive the piston slowly into [2] MOLYBDENUM “ ” MARK the cylinder block with the “ ”...
Page 463 6) Install the upper main bearings on the cylinder block [1] PROJECTION aligning the projection on the upper main bearing with the UPPER MAIN concave in the cylinder block. BEARING 7) Apply molybdenum disulfide oil to the crankshaft main journal, crank pin and the thrust washer mating surfaces. 8) Put the No.2 and No.3 pistons at the bottom dead center of their stroke.
Page 464 11) Apply engine oil to the threads and seat of the connecting rod bolts. CONNECTING ROD Install the connecting rod cap assembly on the connecting CAP ASSEMBLY rod and tighten the two connecting rod bolts to the CONNECTING specified torque. ROD BOLT (2) After tightening to the specified torque, tighten the bolts to an additional 90˚.
Page 465 15) Clean the cylinder block and lower block mating surfaces thoroughly with the degreasing cleaning agent. Apply a bead of 16) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in.)] of the liquid liquid gasket. gasket (ThreeBond ® #1280B or equivalent) to the indicated area of the cylinder block.
Page 466 18) Apply engine oil to the threads and the seating face of the washer of the 11 x 95 mm bolt-washers. 19) Loosely tighten the ten 11 x 95 mm bolt-washers on the lower block, then tighten the bolt-washers in the numbered sequence in two or three steps to the specified torque.
Page 467 22) Apply soapy water to the outer surface of the new 80 x 98 x 10 mm oil seal. Apply engine oil to the oil seal lip. 23) Using the special tools as shown, install the 80 x 98 x 10 OIL SEAL DRIVER mm oil seal on the crankshaft.
Page 468: Propeller/Gear Case/Extension Case/Oil Case
14. PROPELLER/GEAR CASE/EXTENSION CASE/OIL CASE 1. PROPELLER 12. PROPELLER SHAFT HOLDER 2. GEAR CASE ASSEMBLY [*1] ASSEMBLY [*2] 3. WATER PUMP/SHIFT ROD [*1] 13. PROPELLER SHAFT/PROPELLER 4. PROPELLER SHAFT HOLDER SHAFT HOLDER [*2] ASSEMBLY [*1] 14. VERTICAL SHAFT/BEVEL GEAR [*2] 5.
Page 469: Propeller
1. PROPELLER a. REMOVAL/INSTALLATION 18 mm CASTLE NUT INSTALLATION: TORQUE: 1 N . m (0.1 kgf . m, 0.7 lbf . ft) If the split pin cannot be set by tightening to the specified torque, tighten the castle nut additionally until the split pin can be set. MAX.
Page 470: Gear Case Assembly [*1]
2. GEAR CASE ASSEMBLY [*1] SPEED SENSOR TUBE B a. REMOVAL 1) Place the remote control lever in the “N” (Neutral) position. 2) Tilt up the outboard motor to the uppermost position. 3) Disconnect the speed sensor tube B and the speed sensor tube C.
Page 471 7) Remove the shift rod A from the shift shaft A. SHIFT ROD A SHIFT SHAFT A b. COMPONENTS DRAWING SHIFT ROD A VERTICAL SHAFT 6 x 10 mm DOWEL PIN (2) 10 mm WASHER (7) GEAR CASE ASSEMBLY 10 x 40 mm HEX. BOLT (7) 34 N .
Page 472 c. INSTALLATION 1) Place the remote control lever in the “N” (Neutral) position. CUTOUT 2) Check that the shift rod of the gear case is in the “N” (Neutral) position. To check: Check whether the cutout of the shift rod spline faces in the SHIFT ROD direction shown.
Page 473 7) Apply grease to the vertical shaft spline and the shift rod spline. VERTICAL Apply grease to the water tube insertion part and to the SHAFT WATER TUBE inner wall of the water tube seal ring of the impeller housing. WATER TUBE Apply grease to the inner wall of the vertical shaft bushing SEAL RING...
Page 474: Water Pump/Shift Rod [*1]
3. WATER PUMP/SHIFT ROD [*1] WATER TUBE 8 x 40 mm SEAL RING a. DISASSEMBLY HEX. BOLT (4) Remove the following parts. – Propeller (P. 14-2) IMPELLER 8 mm – Gear case assembly (P. 14-3) HOUSING WASHER (4) 1) Remove the speed sensor tube C. VERTICAL 2) Remove the water tube seal ring from the impeller housing.
Page 475 6) Check the pump impeller for cracks, wear or damage from overheating, and replace if necessary. 7) Remove the pump impeller, pump liner and the water pump O-ring from the impeller housing. Replace the O-ring with a new one on assembly. IMPELLER HOUSING PUMP LINER...
Page 476 12) Remove the 6 x 12 mm hex. bolt and the pivot washer. Remove the shift rod holder and the shift rod assembly. SHIFT ROD HOLDER SHIFT ROD ASSEMBLY 6 x 12 mm HEX. BOLT PIVOT WASHER 13) Remove the shift rod spring, 12 mm washer and the 10 mm E-ring from the shift rod.
Page 477 b. COMPONENTS DRAWING 8 x 40 mm HEX. BOLT (4) WATER TUBE SEAL RING 19.7 N . m (2.0 kgf . m, 14 lbf . ft) 8 mm IMPELLER HOUSING WASHER (4) DISTANCE COLLAR (4) 6 x 20 (2) WATER PUMP O-RING [16] WATER SEAL...
Page 478 12 x 21 x 6 mm WATER SEAL (2) SHIFT ROD HOLDER [15] 55.6 x 3.5 mm O-RING [14] SHIFT ROD SPRING [13] 12 mm WASHER [12] 10 mm E-RING [11] [10] GEAR CASE SHIFT ROD TUBE JOINT GROMMET SPEED SENSOR TUBE C SENSOR NIPPLE 6 x 12 mm...
Page 479 c. ASSEMBLY [1] <Water seal installation 1) Apply soapy water to the circumference of the 12 x 21 x 6 direction> mm water seals. 2) Drive the 12 x 21 x 6 mm water seals one by one in the shift rod holder using the special tools.
Page 480 5) Install the shift rod by aligning the shift cam of the shift rod [2] No mark in the shift [1] CUTOUT with the groove in the shift slider so that the cutout of the rod end. shift rod spline faces in the cruising direction. NOTICE •...
Page 481 8) Apply soapy water to the circumference of the 23 x 36 x 6 [1] 23 x 36 x 6 mm [2] <Water seal installation mm water seals. WATER SEALS direction> 9) Drive the 23 x 36 x 6 mm water seals one by one in the water seal housing using the special tools.
Page 482 13) Apply grease to the inner wall of the water pump liner. [2] WOODRUFF KEY Install the pump impeller in the water pump liner with the INSTALLATION GROOVE woodruff key installation groove facing up and the pump (Apply grease [2] WOODRUFF KEY impeller fins in the direction shown.
Page 483 17) Install the woodruff key in the groove in the vertical shaft. Align the groove in the pump impeller with the woodruff key and install the impeller housing by turning it clockwise. WOODRUFF KEY NOTICE • Turn the impeller housing clockwise when it is turned with the pump impeller mounted.
Page 484: Propeller Shaft Holder Assembly [*1]
4. PROPELLER SHAFT HOLDER ASSEMBLY [*1] [2] PROPELLER SHAFT HOLDER ASSEMBLY a. REMOVAL/INSTALLATION Remove the following parts. – Propeller (P. 14-2) – Gear case assembly (P. 14-3) – Water pump/shift rod (P. 14-7) 1) Remove the two 10 mm washers and the two 10 x 40 mm RECESS flange bolts.
Page 485: Propeller Shaft/Propeller Shaft Holder [*1]
5. PROPELLER SHAFT/PROPELLER 8 x 47 mm CLUTCH SHAFT HOLDER [*1] SHIFTER PIN SHIFTER a. DISASSEMBLY Remove the following parts. – Propeller (P. 14-2) – Gear case assembly (P. 14-3) – Water pump/shift rod (P. 14-7) – Propeller shaft holder assembly (P. 14-17) 1) Remove the cross pin ring and the 8 x 47 mm shifter pin, then remove the clutch shifter.
Page 486 4) Remove the 3 x 12.8 mm roller from the shift slider assembly using a commercially available pin driver. 3 x 12.8 mm ROLLER SHIFT SLIDER ASSEMBLY 5) Remove the shift plate from the shift slider, then remove the two shift springs and the two #9 steel balls. #9 STEEL BALLS NOTICE Take care not to let the shift springs and the #9 steel balls...
Page 487 7) Before removing the bearing, check the bearing for abnormal sound and play. Replace if necessary. 8) Install a commercially available universal bearing puller DRIVER between the reverse bevel gear and the bearing. ATTACHMENT, 27.2 07749-0010000 07747-0010300 9) Remove the bearing from the reverse bevel gear using the special tools as shown.
Page 488 14) Check the needle bearing for abnormal sound and play before removal. Replace the needle bearing if necessary. REMOVER WEIGHT 15) Remove the needle bearing from the propeller shaft holder 07741-0010201 using the special tools as shown. REMOVER HANDLE Replace the needle bearing with a new one on assembly. 07936-3710100 TOOLS: Remover weight...
Page 489 c. COMPONENTS DRAWING 14 mm CIRCLIP 3 x 12.8 mm ROLLER CROSS PIN RING SHIFT SPRING (2) 8 x 47 mm SHIFT SHIFTER PIN SLIDER [10] SHIFT PLATE CLUTCH SHIFTER #9 STEEL BALLS #7 STEEL BALL (2) [19] PROPELLER SHAFT [11] REVERSE BEVEL GEAR...
Page 490 d. ASSEMBLY 1) Apply gear oil to the circumference of the new needle bearing. ATTACHMENT, OUTER DRIVER 62 x 68 mm 2) Install the needle bearing on the propeller shaft holder ATTACHMENT, 07746-0010500 using the special tools and the hydraulic press. 30 x 37 070PD-ZY60200 TOOLS:...
Page 491 6) Apply gear oil to the circumference of the new bearing. 7) Install the bearing on the revere bevel gear using the special tools and the hydraulic press. ATTACHMENT, DRIVER 62 x 68 mm 07749-0010000 TOOLS: 07746-0010500 Driver 07749-0010000 Attachment, 62 x 68 mm 07746-0010500 Pilot, 35 mm 07746-0040800...
Page 492 14) Install the shift spring, two #9 steel balls, shift spring and the shift plate in this order in the shift slider. 3 x 12.8 mm SHIFT SPRINGS ROLLER 15) Install the 3 x 12.8 mm roller while aligning the hole in the shift slider with the hole in the shift plate, then install the 14 mm circlip.
Page 493 18) Install the 8 x 47 mm shifter pin while aligning the hole in the clutch shifter with the hole in the shift slider. 8 x 47 mm SHIFTER PIN HOLE IN SHIFT SLIDER SHIFT SLIDER CLUTCH SHIFTER HOLE IN CLUTCH SHIFTER 19) Install the cross pin ring on the clutch shifter.
Page 494: Vertical Shaft/Bevel Gear [*1]
6. VERTICAL SHAFT/BEVEL GEAR [*1] VERTICAL SHAFT a. DISASSEMBLY Remove the following parts. – Propeller (P. 14-2) – Gear case assembly (P. 14-3) – Water pump/shift rod (P. 14-7) – Propeller shaft holder assembly (P. 14-17) 1) Attach the special tool to the end (crankshaft installation side) of the vertical shaft.
Page 495 10) Check the taper bearing (outer race) for damage before removing it. Replace together with the inner race as a set if FORWARD necessary. BEVEL BEARING RACE REMOVER GEAR SHIM PULLER WEIGHT 11) Remove the taper bearing (outer race) using the special 070PC-ZY3A100 07741-0010201 tools as shown.
Page 496 18) Check the needle bearing (outer race) in the gear case for damage before removing it. Replace the needle bearing (outer race) if necessary. 19) Attach the special tools to the needle bearing (outer race) and place a shop towel or equivalent material under the DRIVER HANDLE, needle bearing (outer race) as shown.
Page 497 c. COMPONENTS DRAWING VERTICAL SHAFT 64 mm LOCK NUT 123 N . m (12.5 kgf . m, 90 lbf . ft) 30 x 62 x 40 mm TAPER ROLLER BEARING (INNER RACE) 30 x 62 x 40 mm TAPER ROLLER BEARING (OUTER RACE) 30 x 62 x 40 mm...
Page 498 d. ASSEMBLY NOTICE DRIVER OIL SEAL DRIVER, Measure the bearing height from the end of the taper bearing 07749-0010000 52 x 55 mm outer race to the end of the inner race and record the 07NAD-P200100 or measurement before installing the 50 x 90 x 28 mm taper 07NAD-P20A100 bearing on the forward bevel gear (P.
Page 499 11) Position the vertical shaft on the hydraulic press with the pinion gear side facing up. PINION GEAR 12) Install the taper roller bearing on the vertical shaft using the hydraulic press. VERTICAL NOTICE PINION SHAFT • Check that the ends of the special tool are set on the taper GEAR roller bearing inner race and on the hydraulic press table securely.
Page 500 16) Install the needle bearing in the gear case using the special tools. TOOLS: SHAFT INSTALLER, Shaft installer, 15 x 370 mm 07VMF-KZ30200 15 x 370 mm Attachment, 78 x 90 mm 07GAD-SD40101 ATTACHMENT, 07VMF-KZ30200 Oil seal driver attachment, 27.5 x 44 mm 07948-9540000 78 x 90 mm 07GAD-SD40101...
Page 501 20) Wipe the tapered part of the vertical shaft and pinion gear with a shop towel and a degreasing cleaning solvent. VERTICAL SHAFT 21) Attach the special tool to the end (crankshaft installation side) of the vertical shaft as shown. TOOL: Vertical shaft holder 07SPB-ZW10200...
Page 502: Shim Selection [*1]
7. SHIM SELECTION [*1] PINION GEAR NOTICE VERTICAL Adjust the shim thickness after replacing the gear case, vertical SHAFT shaft, bearing, taper bearing and the taper roller bearing. a. PINION GEAR SHIM Remove the taper roller bearing if it is mounted on the vertical shaft (P.
Page 503 6) Hold the vertical shaft upright (with the pinion gear toward up) and secure the vertical shaft. DEPTH GAUGE (Commercially 7) Set the commercially available depth gauge at the gauge available) adapter of the pinion gear side as shown. Measure the vertical shaft length (distance D) and record it.
Page 504 11) Calculate the gap (distance E) between the outer race and inner race using the measurements obtained in step 9 and 10 and the following formula. Formula: Bearing height – Outer race height = Gap (distance E) Example: When, bearing height from the outer race end to the inner race end is 34.9 mm (1.37 in), And, outer race height is 29.7 mm (1.17 in): 34.9 –...
Page 505 • Pinion gear shim selection table [3] Unit: mm (in) [2] Calculation value +0.41 (+0.0161) +0.35 (+0.014) +0.30 (+0.0118) +0.25 (+0.010) +0.20 (+0.008) +0.15 (+0.006) +0.10 (+0.004) – – – – – – – +0.35 (+0.014) +0.30 (+0.0118) +0.25 (+0.010) +0.20 (+0.008) +0.15 (+0.006) +0.10 (+0.004) +0.05 (+0.002) 0.30 (0.0118) 0.35 (0.014) 0.40 (0.0157)
Page 506 b. FORWARD BEVEL GEAR SHIM 1) Assemble the outer race and the inner race of the new 50 x OUTER RACE 90 x 28 mm taper bearing, and turn the outer race two or three turns. 2) Measure the bearing height (distance F) from the outer race INNER RACE end to the inner race end as shown, and record the measurement.
Page 507: Shim Position [*1]
8. SHIM POSITION [*1] 30 x 62 x 40 mm TAPER ROLLER BEARING (INNER RACE) [11] 30 x 62 x 40 mm TAPER ROLLER BEARING (OUTER RACE) [10] PINION GEAR SHIM SELECTION: P. 14-35 VERTICAL SHAFT PINION GEAR PINION GEAR NUT 142 N .
Page 508: Backlash Adjustment [*1]
9. BACKLASH ADJUSTMENT [*1] a. FORWARD BEVEL GEAR BACKLASH PULLER BOLT Backlash adjustment must be made after adjustment of each 07SPC-ZW0011Z gear shim (P. 14-35). Install the parts except the water pump in the gear case (P. 14- 12, 17 and 31). 1) Hold the propeller shaft securely with the special tool as shown, and tighten the puller bolt to the specified torque.
Page 509: Gear Case Assembly [*2]
10. GEAR CASE ASSEMBLY [*2] SPEED SENSOR TUBE B a. REMOVAL 1) Place the remote control lever in the “N” (Neutral) position. 2) Tilt up the outboard motor to the uppermost position. 3) Disconnect the speed sensor tube B and the speed sensor tube C.
Page 510 7) Remove the shift rod A from the shift shaft A. SHIFT ROD A SHIFT SHAFT A b. COMPONENTS DRAWING SHIFT ROD A VERTICAL SHAFT 6 x 10 mm DOWEL PIN (2) 10 mm WASHER (7) GEAR CASE 10 x 40 mm HEX. BOLT (7) ASSEMBLY 34 N .
Page 511 c. INSTALLATION 1) Place the remote control lever in the “N” (Neutral) position. CUTOUT 2) Check that the shift rod of the gear case is in the “N” (Neutral) position. To check: Check whether the cutout of the shift rod spline faces in the SHIFT ROD direction shown.
Page 512 7) Apply grease to the vertical shaft spline and the shift rod spline. VERTICAL Apply grease to the water tube insertion part and to the SHAFT WATER TUBE inner wall of the water tube seal ring of the impeller housing. Apply grease to the inner wall of the vertical shaft bushing WATER TUBE SEAL RING...
Page 513: Water Pump/Shift Rod [*2]
11. WATER PUMP/SHIFT ROD [*2] WATER TUBE 8 x 40 mm SEAL RING a. DISASSEMBLY HEX. BOLT (4) Remove the following parts. – Propeller (P. 14-2) IMPELLER 8 mm – Gear case assembly (P. 14-42) HOUSING WASHER (4) 1) Remove the speed sensor tube C. VERTICAL 2) Remove the water tube seal ring from the impeller housing.
Page 514 6) Check the pump impeller for cracks, wear or damage from overheating, and replace if necessary. 7) Remove the pump impeller, pump liner and the water pump O-ring from the impeller housing. Replace the O-ring with a new one on assembly. IMPELLER PUMP LINER HOUSING...
Page 515 12) Remove the 6 x 12 mm hex. bolt and the pivot washer. Remove the shift rod holder and the shift rod assembly. SHIFT ROD HOLDER SHIFT ROD ASSEMBLY 6 x 12 mm HEX. BOLT PIVOT WASHER 13) Remove the shift rod spring, 12 mm washer and the 10 mm E-ring from the shift rod.
Page 516 b. COMPONENTS DRAWING WATER TUBE 8 x 40 mm HEX. BOLT (4) SEAL RING 19.7 N . m (2.0 kgf . m, 14 lbf . ft) 8 mm IMPELLER HOUSING WASHER (4) DISTANCE COLLAR (4) 6 x 20 (2) WATER PUMP O-RING [16] WATER SEAL...
Page 517 12 x 21 x 6 mm WATER SEAL (2) SHIFT ROD HOLDER [15] 55.6 x 3.5 mm O-RING [14] SHIFT ROD SPRING [13] 12 mm WASHER [12] 10 mm E-RING [11] [10] GEAR CASE SHIFT ROD TUBE JOINT GROMMET SPEED SENSOR TUBE C SENSOR NIPPLE 6 x 12 mm...
Page 518 c. ASSEMBLY [1] <Water seal 1) Apply soapy water to the circumference of the 12 x 21 x 6 installation direction> mm water seals. 2) Drive the 12 x 21 x 6 mm water seals one by one in the shift rod holder using the special tools.
Page 519 5) Install the shift rod by aligning the shift cam of the shift rod [2] Mark in the shift [1] CUTOUT with the groove in the shift slider so that the cutout of the rod end. shift rod spline faces in the cruising direction. NOTICE •...
Page 520 8) Apply soapy water to the circumference of the 23 x 36 x 6 [1] 23 x 36 x 6 mm [2] <Water seal installation mm water seals. WATER SEALS direction> 9) Drive the 23 x 36 x 6 mm water seals one by one in the water seal housing using the special tools.
Page 521 13) Apply grease to the inner wall of the water pump liner. [2] WOODRUFF KEY Install the pump impeller in the water pump liner with the INSTALLATION GROOVE woodruff key installation groove facing up and the pump (Apply grease [2] WOODRUFF KEY impeller fins in the direction shown.
Page 522 17) Install the woodruff key in the groove in the vertical shaft. Align the groove in the pump impeller with the woodruff key and install the impeller housing by turning it clockwise. WOODRUFF KEY NOTICE • Turn the impeller housing clockwise when it is turned with the pump impeller mounted.
Page 523: Propeller Shaft Holder Assembly [*2]
12. PROPELLER SHAFT HOLDER ASSEMBLY [*2] [2] PROPELLER SHAFT HOLDER a. REMOVAL/INSTALLATION ASSEMBLY Remove the following parts. – Propeller (P. 14-2) – Gear case assembly (P. 14-42) – Water pump/shift rod (P. 14-46) 1) Remove the two 10 mm washers and the two 10 x 40 mm RECESSE flange bolts.
Page 524: Propeller Shaft/Propeller Shaft Holder [*2]
13. PROPELLER SHAFT/PROPELLER 8 x 47 mm SHAFT HOLDER [*2] CLUTCH SHIFTER SHIFTER PIN a. DISASSEMBLY Remove the following parts. – Propeller (P. 14-2) – Gear case assembly (P. 14-42) – Water pump/shift rod (P. 14-46) – Propeller shaft holder assembly (P. 14-56) 1) Remove the cross pin ring and the 8 x 47 mm shifter pin, then remove the clutch shifter.
Page 525 4) Remove the 3 x 12.8 mm roller from the shift slider assembly using a commercially available pin driver. 3 x 12.8 mm ROLLER SHIFT SLIDER ASSEMBLY 5) Remove the shift plate from the shift slider, then remove the two shift springs and the two #9 steel balls. NOTICE Take care not to let the shift springs and the #9 steel balls #9 STEEL BALLS...
Page 526 7) Position the propeller shaft holder assembly on the fixing tool and secure the holder assembly with the bolt. 8) Hold the fixing tool with a vise. PIN SPANNER WRENCH, 110 mm 9) Loosen the bearing holder using the special tool as shown. 07WAA-S1G0100 TOOL: Pin spanner wrench, 110 mm...
Page 527 14) Before removing the taper bearing (outer race), check the outer race for damage. Replace the inner race and the outer race as a set if necessary. TAPER BEARING DRIVER DRIVER 07749-0010000 15) Remove the taper bearing (outer race) from the bearing ATTACHMENT holder using the special tools and the hydraulic press.
Page 528 22) Check the needle bearing for abnormal sound and play before removal. Replace the needle bearing if necessary. 23) Remove the needle bearing from the propeller shaft using REMOVER WEIGHT the special tools as shown. REMOVER HANDLE 07741-0010201 07936-3710100 Replace the needle bearing with a new one on assembly. TOOLS: Remover weight 07741-0010201...
Page 529 c. COMPONENTS DRAWING 14 mm CIRCLIP 3 x 12.8 mm [4] CROSS ROLLER [10] PIN RING SHIFT SPRING (2) 8 x 47 mm SHIFT SHIFTER PIN SLIDER CLUTCH [11] SHIFTER SHIFT PLATE FORWARD BEVEL GEAR #9 STEEL BALLS [12] #7 STEEL BALL (2) FORWARD BEVEL GEAR SHIM [13]...
Page 530 d. ASSEMBLY 1) Apply gear oil to the circumference of the new needle bearing. ATTACHMENT, 2) Install the needle bearing on the propeller shaft holder OUTER DRIVER 62 x 68 mm using the special tools and the hydraulic press. ATTACHMENT, 07746-0010500 30 x 37 070PD-ZY60200...
Page 531 6) Apply gear oil to the circumference of the new 105 x 3.1 mm O-ring and install it on the propeller shaft holder. 7) Install the new thrust shim on the propeller shaft holder. THRUST BEARING 8) Install the thrust bearing washer with the chamfered side CHAMFER toward the thrust shim.
Page 532 15) Place the wood block under the forward bevel geaar. 16) Place the bearing holder assembly on the forward bevel gear. ATTACHMENT, DRIVER 62 x 68 mm 17) Apply gear oil to the inner wall of the taper bearing inner 07749-0010000 07746-0010500 race and position it in the forward bevel gear.
Page 533 23) Install the shift spring, two #9 steel balls, shift spring and the shift plate in this order in the shift slider. 3 x 12.8 mm SHIFT SPRINGS ROLLER 24) Install the 3 x 12.8 mm roller aligning the hole in the shift slider with the hole in the shift plate, then install the 14 mm SHIFT circlip.
Page 534 27) Install the 8 x 47 mm shifter pin while aligning the hole in the clutch shifter with the hole in the shift slider. 8 x 47 mm SHIFTER PIN HOLE IN SHIFT SLIDER SHIFT SLIDER HOLE IN CLUTCH CLUTCH SHIFTER SHIFTER 28) Install the cross pin ring on the clutch shifter.
Page 535: Vertical Shaft/Bevel Gear [*2]
14. VERTICAL SHAFT/BEVEL GEAR [*2] VERTICAL SHAFT a. DISASSEMBLY Remove the following pars. – Propeller (P. 14-2) – Gear case assembly (P. 14-42) – Water pump/shift rod (P. 14-46) – Propeller shaft holder assembly (P. 14-56) 1) Attach the special tool to the end (crankshaft installation side) of the vertical shaft.
Page 536 6) Check the needle bearing for abnormal sound and play. Replace the roller and the outer race as a set if necessary. 7) Remove the needle bearing (roller). NEEDLED BEARING (ROLLER) 8) Replace the puller jaws of the special tool as shown. TOOLS: Bearing race puller 070PC-ZY3A100...
Page 537 10) Check the bearing for abnormal noise and play before removal. Replace if necessary. 50 x 90 x 20 mm RADIAL BALL REMOVER BEARING RACE 11) Remove the 50 x 90 x 20 mm radial ball bearing using the BEARING WEIGHT PULLER special tools as shown.
Page 538 18) Check the needle bearing (outer race) for damage before removal. Replace if necessary. 19) Position the special tools on the needle bearing (outer race) and the shop towel under the needle bearing (outer race) as shown. DRIVER HANDLE, 15 x 280 mm 07949-3710001 TOOLS: BEARING DRIVER...
Page 539 c. COMPONENTS DRAWING VERTICAL SHAFT 64 mm LOCK NUT 123 N . m (12.5 kgf . m, 90 lbf . ft) 30 x 62 x 40 mm TAPER ROLLER BEARING (INNER RACE) 30 x 62 x 40 mm TAPER ROLLER BEARING (OUTER RACE) 30 x 62 x 40 mm...
Page 540 d. ASSEMBLY 1) Apply gear oil to the circumference of the new bearing. OIL SEAL DRIVER, 2) Place a wood block under the reverse bevel gear. 65 mm 50 x 90 x 20 mm 07JAD-PL90100 or 3) Install the bearing on the reverse bevel gear using the RADIAL BALL 07JAD-PL9A100 special tool and the hydraulic press.
Page 541 7) Position the pinion gear on the vertical shaft and loosely tighten the pinion gear nut by hand. 8) Apply gear oil to the inner wall of the inner race, roller and VERTICAL the circumference of the outer race of the taper roller SHAFT bearings.
Page 542 13) Install the oil slinger on the vertical shaft aligning the [2] PROJECTION projection on the inside of the oil slinger with the recess of the pinion gear installation side of the vertical shaft. VERTICAL SHAFT CONCAVE OIL SLINGER 14) Attach the special tool to the new needle bearing as shown. Install the needle bearing with the stamped side of the needle bearing (outer race) toward the special tool.
Page 543 17) Install the vertical shaft assembly with care not to let the needle bearing roller come out of position. LOCK NUT WRENCH, 18) Apply gear oil to the threads and seat of the 64 mm lock 30/64 mm nut, and tighten the lock nut using the special tool. 07916-MB00002 TOOL: Lock nut wrench, 30/64 mm...
Page 544: Shim Selection [*2]
15. SHIM SELECTION [*2] PINION GEAR NUT NOTICE Adjust the shim thickness after replacing the gear case, vertical VERTICAL shaft, bearing, taper bearing and the taper roller bearing. SHAFT a. PINION GEAR SHIM Remove the 30 x 62 x 40 mm taper roller bearing if it is mounted on the vertical shaft (P.
Page 545 6) Hold the vertical shaft upright (with the pinion gear toward up) and secure the vertical shaft. DEPTH GAUGE (Commercially available) 7) Set the commercially available depth gauge at the gauge adapter of the pinion gear side as shown. Measure the vertical shaft length (distance D) and record it.
Page 546 11) Calculate the gap (distance E) between the outer race and inner race using the measurements obtained in step 9 and 10 and the following formula. Formula: Bearing height – Outer race height = Gap (distance E) Example: When, bearing height from the outer race end to the inner race end is 34.9 mm (1.37 in), And, outer race height is 29.7 mm (1.17 in): 34.9 –...
Page 547 • Pinion gear shim selection table [3] Unit: mm (in) [2] Calculation value +0.41 (+0.0161) +0.35 (+0.014) +0.30 (+0.0118) +0.25 (+0.010) +0.20 (+0.008) +0.15 (+0.006) +0.10 (+0.004) – – – – – – – +0.35 (+0.014) +0.30 (+0.0118) +0.25 (+0.010) +0.20 (+0.008) +0.15 (+0.006) +0.10 (+0.004) +0.05 (+0.002) 0.30 (0.0118) 0.35 (0.014) 0.40 (0.0157)
Page 548 b. FORWARD BEVEL GEAR SHIM 1) Assemble the outer race and the inner race of the 50 x 90 x OUTER RACE 28 mm taper bearing, and turn the outer race two or three turns. 2) Measure the bearing height (distance F) from the outer race INNER RACE end to the inner race end as shown, and record the measurement.
Page 549 c. REVERSE BEVEL GEAR SHIM 1) Measure the bearing height (distance H) of the new 50 x 90 x 20 mm radial ball bearing as shown, and record the measurement. 2) Determine the calculation value using the bearing height (distance H) and the following formula. Formula: Bearing height (distance H) –...
Page 550 d. THRUST SHIM 1) Assemble the outer race and inner race of the 50 x 90 x 28 OUTER RACE mm taper bearing, and turn the outer race two or three turns. 2) Measure the bearing height (distance F) from the outer race INNER RACE end to the inner race end as shown, and record the measurement.
Page 551: Shim Position [*2]
16. SHIM POSITION [*2] 30 x 62 x 40 mm TAPER ROLLER BEARING (INNER RACE) [14] 30 x 62 x 40 mm TAPER ROLLER BEARING (OUTER RACE) [13] PINION GEAR SHIM SELECTION: P. 14-77 [12] VERTICAL SHAFT [11] PINION GEAR [10] PINION GEAR NUT 142 N .
Page 552: Backlash Adjustment [*2]
17. BACKLASH ADJUSTMENT [*2] a. FORWARD BEVEL GEAR BACKLASH PULLER BOLT Backlash adjustment must be made after adjustment of each 07SPC-ZW0011Z gear shim (P. 14-77). Install the parts except the water pump in the gear case (P. 14- 51, 56 and 73). 1) Hold the propeller shaft securely with the special tool as shown, and tighten the puller bolt to the specified torque.
Page 553 b. REVERSE BEVEL GEAR BACKLASH 1) Turn the vertical shaft five to ten turns clockwise for snug seat of the bevel gear taper roller bearing. 2) Using the wrench, turn the shift rod in the direction shown with the arrow and fix the propeller shaft. NOTICE If it is hard to fix the propeller shaft, turn the propeller shaft to change the phase of the shaft and fix it.
Page 554 c. THRUST CLEARANCE ADJUSTMENT Adjust the thrust clearance after replacement of the forward DIAL INDICATOR bevel gear shim. 1) Check that the bearing holder assembly is securely tightened to the specified torque on the propeller shaft holder (P. 14-65). Check that the clutch shifter and the shift slider are not installed (P.
Page 555: Anode Metal/Water Screen
18. ANODE METAL/WATER SCREEN a. REMOVAL/INSTALLATION Anode metal/water screen removal/installation can be made with the gear case mounted on the outboard motor. ANODE METAL (2) 5.5 x 1.5 mm O-RING 5 x 50 mm OVAL SCREW INSPECTION: Do not reuse. Replace the anode metal if 1 N .
Page 556 19. EXTENSION CASE/LOWER LOWER MOUNT RUBBER MOUNT HOUSING 6 x 12 a. DISASSEMBY Remove the following parts. – Engine cover (P. 4-2) – L./R. engine under cover (P. 4-9) – Gear case assembly (P. 14-3 and 42) 1) Tilt up the outboard motor and hold it in the position by GROUND hooking the hoist hook on each of the three engine CABLE...
Page 557 9) Remove the 6 x 12 mm flange bolt, and remove the water tube setting plate, water tube and the water tube grommet. WATER TUBE GROMMET WATER TUBE SETTING PLATE 6 x 12 WATER TUBE b. COMPONENTS DRAWING 12 x 225 mm HEX. BOLT (2) 83 N .
Page 558 c. ASSEMBLY 1) Apply grease to the circumference of the water tube grommet and install it on the water tube. 2) Connect the water tube to the oil case noting the installation direction as shown. PROJECTION 3) Install the water tube set plate aligning the stopper hole of the water tube set plate with the projection on the oil case, and then tighten the 6 x 12 mm flange bolt.
Page 559 6) Clean the extension case and oil case mating surfaces with a degreasing cleaning solvent and a shop towel. EXTENSION CASE 7) Apply sealant to the entire sealing surface of the oil case side of the extension case (ThreeBond ® #5222B or equivalent).
Page 560 10) Install the lower mount collar and the lower rubber mount on the extension case. NOTICE 12 x 225 mm HEX. BOLT • Install the lower mount collar with the smaller diameter side toward the lower rubber mount. • Install the lower rubber mount with the “OUT” mark toward out.
Page 561: Extension Case/Lower Rubber Mount
20. OIL CASE a. REMOVAL Remove the following parts. – Engine cover (P. 4-2) – L./R. engine under cover (P. 4-9) – Gear case assembly (P. 14-3 and 42) – Extension case/lower rubber mount (P. 14-89) 1) Drain the engine oil from the oil case (P. 3-2). 2) Remove the sixteen 10 x 40 mm flange bolts and remove the oil case from the mount case.
Page 562 b. INSTALLATION 1) Clean the oil case and mount case mating surfaces and the both sides of the oil pan gasket with a cleaning solvent and a shop towel. OIL PAN GASKET 2) Apply bead [ø1.0 – 5.0 mm (ø0.04 – 0.20 in)] of the liquid gasket (ThreeBond ®...
Page 563: Oil Case
5) Apply the engine oil to the threads and seat of the sixteen 10 x 40 mm flange bolts. Install the two dowel pins and the oil case on the mount OIL LEVEL GAUGE case, then loosely tighten the sixteen 10 x 40 mm flange 6 x 12 bolts.
Page 564: Mounting Case/Stern Bracket/Swivel Case/Power Trim/Tilt Assembly
15. MOUNTING CASE/STERN BRACKET/SWIVEL CASE/POWER TRIM/TILT ASSEMBLY 1. MOUNTING CASE 4. POWER TRIM/TILT ASSEMBLY 2. STERN BRACKET/SWIVEL CASE 5. AIR BLEEDING REMOVAL/INSTALLATION 6. BLOW PRESSURE INSPECTION 3. STERN BRACKET/SWIVEL 7. POWER TILT MOTOR ASSEMBLY CASE/POWER TRIM/TILT ASSEMBLY 83 N . m (8.5 kgf . m, 61 lbf .
Page 565: Mounting Case
1. MOUNTING CASE a. REMOVAL Remove the following parts. – Engine cover (P. 4-2) – L./R. engine under covers (P. 4-9) – Under cover front bracket (P. 4-20) – Water relief tube C (P. 8-6) – Engine assembly (P. 7-2) Remove the two 12 mm self-locking nuts and remove the mounting case assembly.
Page 566 b. MOUNTING CASE DISASSEMBLY 1) Remove the under cover seal A and the mounting case rubber seal from the mounting case. Remove the shift shaft B and the shift shaft washer. 2) Remove the three 6 x 25 mm flange bolts and remove the idle exhaust port and the idle exhaust port gasket. Replace the gasket with a new one on assembly.
Page 567 c. 20 x 28 x 13 mm NEEDLE BEARING REMOVAL [1] 20 x 28 x 13 mm NEEDLE BEARING 1) Remove all parts from the mounting case. 2) Warm up the 20 x 28 x 13 mm needle bearing of the mounting case and remove the needle bearing.
Page 568 2) Install the new upper mount holder gasket and the upper mount holder on the upper rubber mount with the cutouts 8 x 35 (6) in the upper mount holder gasket and in the upper mount holder toward the opposite side from the water seal installation part.
Page 569 5) Apply grease to the circumference and the mating surfaces [1] <Water seal of the two new 22 x 35 x 7 mm water seals. installation direction> 6) Install the 22 x 35 x 7 mm water seals one by one in the mounting case using the special tools as shown.
Page 570 11) Apply grease to the shift shaft A installation part in the mounting case. [1] SHIFT SHAFT A 12) Set the shift shaft A on the mounting case and install the 14 mm washer and the 12 mm E-ring on the shift shaft A. [2] 14 mm WASHER [3] 12 mm...
Page 571 15) Clean the mounting case/idle exhaust port mating surfaces [2] LIQUID GASKET and the both sides of the idle exhaust port gasket (Apply to both sides.) thoroughly with a degreasing cleaning solvent and shop towel. LIQUID GASKET APPLICATION 16) Apply a bead [ø1.0 – 5.0 mm (ø0.04 –0.20 in)] of the liquid AREA gasket (ThreeBond ®...
Page 572 f. INSTALLATION 1) Set the mounting case assembly on the mount frame and tighten the two 12 mm self-locking nut to the specified torque. TORQUE: 83 N . m (8.5 kgf . m, 61 lbf . ft) 2) Remove the following parts. –...
Page 573: Stern Bracket/Swivel Case Removal/Installation
2. STERN BRACKET/SWIVEL CASE [2] TRIM ANGLE [1] POWER TILT MOTOR SENSOR 2P CONNECTOR REMOVAL/INSTALLATION 3P CONNECTOR a. REMOVAL Remove the following parts. – Engine cover (P. 4-2) – L./R. engine under covers (P. 4-9) – Gear case assembly (P. 14-3 and 42) –...
Page 574 5) Swing the outboard motor right and left and remove the two 12 mm self-locking nuts. 6) Check that the engine assembly/mounting case mating surfaces are level to the ground. Holding the outboard motor with the hoist, remove the stern bracket/swivel case assembly mounted on the outboard motor stand from the outboard motor.
Page 575 b. INSTALLATION 1) Lift up the outboard motor until the 12 x 145 mm stud bolts are flush with the holes in the mount frame of the stern bracket/swivel case assembly. 2) Holding the outboard motor with the hoist, move the stern bracket/swivel case assembly, that are attached to the outboard motor stand, slowly toward the outboard motor.
Page 576 5) Pass the tube and wires through the hole in the under cover [1] UNDER COVER front bracket. WIRES FRONT BRACKET TUBE Check that the taped ends of the power tilt motor wire and trim angle sensor wire are in alignment with the end of the undercase grommet C.
Page 577: Stern Bracket/Swivel Case/ Power Trim/Tilt Assembly
3. STERN BRACKET/SWIVEL CASE/ POWER TRIM/TILT ASSEMBLY a. STERN BRACKET/SWIVEL CASE/POWER TRIM/ TILT ASSEMBLY REMOVAL Remove the following parts. – Engine cover (P. 4-2) – L./R. engine under covers (P. 4-9) – Gear case assembly (P. 14-3 and 42) – Stern bracket/swivel case (P. 15-10) 1) Loosen the manual valve fully and set the swivel case assembly in the uppermost position.
Page 578 4) Open the two wire bands that secure the speed sensor tube [1] SPEED SENSOR A and B and disconnect the speed sensor tube A and B TUBE A from the joint A. Replace the wire bands with the new ones on assembly. Check the speed sensor tube A for deterioration and cracks.
Page 579 7) Remove the speed sensor tube plates that secure the speed sensor tube B. Remove the speed sensor tube B. [1] SPEED SENSOR Check the speed sensor tube B for deterioration and cracks. TUBE B Replace if necessary. [2] 6 x 8 mm SCREW (2) [3] SPEED SENSOR TUBE PLATE (2)
Page 580 9) Remove the 15 mm E-ring from the upper cylinder pin. Remove the upper cylinder pin and the piston rod of the power trim/tilt assembly from the swivel case assembly. Check the upper cylinder bushing mounted on the piston rod of the power trim/tilt assembly. If it is damaged, replace with a new one.
Page 581 12) Remove the tilting bolt cap and loosen the 25 x 2.0 mm self- locking nut or the 7/8-14 UNF self-locking nut. [1] TILTING BOLT 13) Holding the power trim/tilt assembly with the hands, extend the L./R. stern brackets to the right and left and remove the lower cylinder collar and the two 32 mm wave washers.
Page 582 16) Remove the 25 x 2.0 mm self-locking nut or 7/8-14 UNF self-locking nut from the tilting shaft. Replace the 25 x 2.0 mm self-locking nut or 7/8-14 UNF self-locking nut with a new one on assembly. 17) Remove the tilting shaft and remove the L./R. stern brackets, two 26 mm wave washers and the swivel case assembly. Check the swivel case bushing that is mounted on the swivel case assembly.
Page 583 c. COMPONENTS DRAWING [1] TILTING BOLT [16] SPEED SENSOR TUBE PLATE (2) [15] 6 x 8 mm SCREW (2) SPEED SENSOR TUBE B [14] WIRE HARNESS CLIP [3] 10 mm [13] WASHER SPEED SENSOR TUBE A [12] WIRE BAND (2) [11] JOINT A 10 mm SELF-LOCKING [10] SPEED SENSOR...
Page 584 15 mm E-RING (2) [2] SWIVEL CASE [4] SWIVEL CASE ASSEMBLY BUSHING (2) [1] UPPER CYLINDER 7/8-14 UNF SELF- TILTING LOCKING NUT SHAFT 34 N . m (3.5 kgf . m, 25 lbf . ft) [19] 6 x 20 mm HEX.
Page 585 d. SWIVEL CASE ASSEMBLY DISASSEMBLY 1) Remove the 6 x 8 mm screw and the ground cable. [1] 6 x 8 mm SCREW Remove the 39 mm external circlip. 39 mm EXTERNAL GROUND CIRCLIP CABLE 2) Put a mark on the mount frame so it aligns with the [1] “...
Page 586 4) Remove the mount frame and the 34 mm thrust washer from the swivel case. MOUNT FRAME Remove the 40 mm wave washer. SWIVEL CASE 34 mm THRUST WASHER 40 mm WAVE WASHER 5) Check the 39.5 x 52 x 6 mm oil seal lip for cut and replace if necessary before removing the oil seal.
Page 587 7) Remove the three grease fittings from the swivel case. [2] SWIVEL CASE 8) Remove the two 10 mm self-locking nuts and the two 10 [3] 10 mm mm washers, then remove the two thrust receivers. SELF- LOCKING NUT (2) [1] GREASE FITTING (3) [4] 10 mm...
Page 588 e. COMPONENTS DRAWING [2] 6 x 14 mm HEX. BOLT DETENT ASSISTED SPRING [1] DETENT SWIVEL CASE SPRING LINER (2) [5] 2.5 x 20 mm SPRING PIN (2) [6] TILTING [21] BRACKET GREASE FITTING (3) 3 N . m (0.3 kgf . m, 2.2 lbf .
Page 589 f. SWIVEL CASE ASSEMBLY ASSEMBLY [2] PROJECTION 2.5 mm PIN 1) Apply grease to the circumference of the new tilt stopper DRIVER bushings and install them on the swivel case. (Commercially available) 2) Install the two tilt stoppers and the tilting bracket on the swivel case.
Page 590 8) Apply grease to the outer surface of the swivel case liner. [3] PROJECTION [4] SWIVEL CASE Install the swivel case liner aligning the projection on the LINER swivel case liner with the concave in the swivel case. SWIVEL CASE 9) Apply grease the circumference of the new 39.5 x 52 x 6 mm oil seal and install it in the bottom of the swivel case.
Page 591 12) Apply grease to the spline of the lower mount center housing. [2] MOUNT [1] “ ” MARK FRAME Install the lower mount center housing on the mount frame aligning the “ ” mark on the lower center housing with the mark on the mount frame that had been put during disassembly.
Page 592 15) Remove the swivel case assembly and the special tool from [1] 39 mm EXTERNAL the hydraulic press. CIRCLIP PART “A” 16) Check that the mount frame turns smoothly. Check that the 39 mm external circlip sets in position smoothly. <Mount frame turns smoothly and circlip can be installed>...
Page 593 g. STERN BRACKET/SWIVEL CASE/POWER TRIM/ [2] SWIVEL CASE TILT ASSEMBLY INSTALLATION SWIVEL ASSEMBLY CASE • Check that the piston rod of the power trim/tilt assembly is in BUSHING the fully extended position. TILTING SHAFT 1) Apply grease to the inner wall and circumference of the new swivel case bushings.
Page 594 10) Tighten the 25 x 2.0 mm self-locking nut or the 7/8-14 UNF self-locking nut to the specified torque. TILTING BOLT CAP TORQUE: 34 N . m (3.5 kgf . m, 25 lbf . ft) Tighten the 25 x 2.0 mm self-locking nut or the 7/8-14 UNF self-locking nut of the other side to the specified torque.
Page 595 13) Check that the corrugated tube on the power tilt motor wire [1] CORRUGATED TUBE stands erect as shown. (It must stand erect.) [2] POWER TILT MOTOR WIRE 14) Clamp the speed sensor tube B with the two speed sensor [3] SPEED SENSOR tube plates and loosely tighten the two 6 x 8 mm screws.
Page 596 18) Wind the spiral tube around the trim angle sensor wire, power tilt motor wire and the speed sensor tube A. SPIRAL TUBE 19) Align the taped end of the power tilt motor wire with the end of the motor wire bushing and install. Clamp the trim angle sensor wire, power tilt motor wire and the speed sensor tube A with the wire harness clip.
Page 597 22) Apply grease to the inner wall and circumference of the new upper cylinder bushings and install them on the piston rod of the power trim/tilt assembly. 23) Apply grease to the circumference of the upper cylinder pin. 24) Align the hole in the piston rod with the hole in the swivel case assembly and insert the upper cylinder pin into the swivel case assembly.
Page 598 26) Check the anode metal for corrosion and replace with a new one if necessary. Tighten the anode metal with the two 6 x 25 mm hex. bolts securely. 6 mm WASHER (2) [1] ANODE 6 x 25 mm METAL HEX.
Page 599: Power Trim/Tilt Assembly
4. POWER TRIM/TILT ASSEMBLY a. REMOVAL Remove the stern bracket, swivel case and the power trim/tilt assembly (P. 15-14). b. DISASSEMBLY • Do not reuse the O-rings. • Do not try to disassemble the pump assembly. Replace the pump assembly as an assembly if it is faulty. •...
Page 600 4) Remove the four hex. bolts and remove the power tilt [1] HEX. BOLT (4) motor assembly from the pump assembly. Drain the Automatic Transmission Fluid (ATF) from the pump assembly. [2] POWER TILT MOTOR ASSEMBLY PUMP ASSEMBLY 5) Remove the O-ring from the power tilt motor assembly. [1] O-RING Replace the O-ring with a new one on assembly.
Page 601 8) Remove the internal circlip and remove the manual valve [3] PUMP ASSEMBLY from the pump assembly. [1] INTERNAL Check the manual valve and the O-ring for deterioration, CIRCLIP wear and damage. Replace them if necessary. Replace the manual valve with a new one on assembly. MANUAL VALVE 9) Set the cylinder comp.
Page 602 14) Remove the O-ring from the rod guide comp. [1] DUST SEAL Replace the O-ring with a new one on assembly. 15) Insert a sharp-end screwdriver into the gap between the OIL SEAL dust seal and the rod guide comp. Raise the dust seal and remove it from the rod guide comp.
Page 603 21) Remove the piston rod comp. from the cylinder comp. CYLINDER COMP. PISTON ROD 22) Remove the O-rings from the cylinder cap and the piston COMP. rod comp. Replace the O-rings with the new ones on assembly. CYLINDER O-RINGS 23) Remove the free piston from the cylinder comp. [1] FREE PISTON Check the sliding surface of the free piston for wear and...
Page 604 d. COMPONENTS DRAWING PISTON ROD COMP. [5] CYLINDER CAP 162 N . m (16.5kgf . m, 119 lbf . ft) POWER TILT MOTOR ASSEMBLY [6] FREE PISTON [1] HEX. BOLT (4) 5 N . m (0.5 kgf . m, O-RINGS [7] BACKUP RING 3.6 lbf .
Page 605 COMP. 2) Pour approximately 30 cm (1.0 fl oz.) of the Automatic Transmission Fluid (ATF) in the piston rod chamber of the cylinder comp. [1] VICE Genuine Honda Automatic Transmission Fluid (ATF) Recommended oil DEXRON ® or equivalent. 3) Apply Automatic Transmission Fluid (ATF) to the new O- [1] FREE PISTON ring and the backup ring.
Page 606 5) After installing the free piston, pour the fresh Automatic Transmission Fluid (ATF) slowly up to the top of the piston [1] Pour slowly rod chamber of the cylinder comp. up to the top of the piston rod chamber. 6) Apply Automatic Transmission Fluid (ATF) to the new O- [1] CYLINDER ring and install it on the piston rod comp.
Page 607 11) Apply Automatic Transmission Fluid (ATF) to the new O- ring and the backup ring and install them on the piston rod [1] PISTON comp. ROD B • Install the backup ring on the free piston with care not to break it.
Page 608 18) Holding the piston rod B in place, loosely tighten the rod guide comp. on the cylinder comp. ROD GUIDE COMP. • Do not install the piston rod Bs by pushing them into respective trim cylinders. 19) Using the special tool, tighten the left and right rod guide comps.
Page 609 26) Check the filter B for blockage and damage. Replace the filter B if it is damaged. DRIVE JOINT Blow air through the filter B if it is clogged. Clean the filter B carefully to avoid damage. FILTER B Install the filter B and the drive joint on the pump assembly. PUMP ASSEMBLY 27) After installation, check the filter B for bubbles.
Page 610 31) Set the four hex. bolts on the power tilt motor assembly [1] HEX. BOLT (4) and tighten the bolts to the specified torque. TORQUE: 5 N . m (0.5 kgf . m, 3.6 lbf . ft) POWER TILT MOTOR ASSEMBLY [3] PUMP ASSEMBLY...
Page 611: Air Bleeding
5. AIR BLEEDING <Power trim/tilt assembly not mounted on the outboard motor> • Bleed air from the unit whenever the power trim/tilt assembly is disassembled. • Be sure to perform air bleeding in the following order. Air bleeding without mounting the unit on the outboard motor;...
Page 612 <When the rods do not compress fully> 1) With the rods extended fully, push the “UP” side of the power tilt switch until the unit blows again. Push the “DN” side of the power tilt switch, and be sure that the rods compress.
Page 613: Blow Pressure Inspection
3) Lower the outboard motor slowly to the lowermost [1] MANUAL VALVE position by loosening the manual valve. 4) Tighten the manual valve securely. 5) Hold the outboard motor in the lowermost position for five minutes. 6) Then, push the “UP” side of the power tilt switch and raise the outboard motor to the uppermost position.
Page 614 4) Remove the oil tank cap. Check that Automatic Transmission Fluid (ATF) is at the upper limit of the filler port (P. 15-47). 5) Push the “DN” side of the power tilt switch to compress each rod fully. 6) Push the “UP” side of the power tilt switch to extend each rod fully again.
Page 615 4) Remove the oil tank cap. Check that Automatic Transmission Fluid (ATF) is at the upper limit of the filler port (P. 15-47). 5) Push the “DN” side of the power tilt switch to compress each rod fully. Read the pressure gauge to measure the upper chamber blow pressure.
Page 616: Power Tilt Motor Assembly
7. POWER TILT MOTOR ASSEMBLY [1] CORRUGATED [2] 4 x 16 mm SCREW TUBE (Stainless steel) a. DISASSEMBLY 1) Untape the corrugated tube and pull the tube to the connector side. WIRE HOLDER 2) Remove the 4 x 16 mm screw. Pull out the wire holder and YOKE the two grommets from the yoke assembly and move them ASSEMBLY...
Page 617 b. COMPONENTS DRAWING 4 x 16 mm SCREW (Stainless steel) CORRUGATED TUBE 1.4 N . m (0.14 kgf . m, 1.0 lbf . ft) [1] ARMATURE YOKE ASSEMBLY MOTOR WIRE (Blue wire) [14] MOTOR WIRE (Green wire) 4 x 10 mm SCREW (2) [13] BRUSH ASSEMBLY BREAKER ASSEMBLY...
Page 618 c. INSPECTION • BRUSH LENGTH Measure the brush length. If the brush length is less than the service limit, replace the front bracket assembly. STANDARD SERVICE LIMIT 9.8 mm (0.39 in) 4.8 mm (0.19 in) • BREAKER ASSEMBLY [2] ARMATURE 1) Install the armature on the front bracket assembly.
Page 619 • SHORT CIRCUIT TEST – CORE-TO-COMMUTATOR Check for continuity between the commutator and armature coil core. If continuity exists, replace the armature. • SHORT CIRCUIT TEST – SHAFT-TO-COMMUTATOR Check for continuity between the commutator and armature shaft. If there is continuity, replace the armature. •...
Page 620 d. ASSEMBLY • When the front bracket assembly is replaced with the new one, remove the 4 x 10 mm screw that secures the brush BRUSH ASSEMBLY holder B. FRONT BRACKET BRUSH 1) Install the new O-ring and the oil seal on the front bracket ASSEMBLY SPRINGS assembly (P.
Page 621 8) Install the two grommets and the wire holder on the yoke assembly. [2] 4 x 16 mm SCREW CORRUGATED (Stainless steel) TUBE Tighten the 4 x 16 mm screw (stainless steel screw) to the specified torque. Take care not to overtighten it. TORQUE: 1.4 N .
Page 622: Steering Rod/Remote Control Box
16. STEERING ROD/REMOTE CONTROL 1. STEERING ROD 3. CONTROL PANEL (OPTIONAL PART) 2. REMOTE CONTROL BOX 4. INSPECTION (OPTIONAL PART) 1. STEERING ROD a. REMOVAL/INSTALLATION 3/8-24 UNF BOLT 22 N . m (2.2 kgf . m, 16 lbf . ft) TILTING BOLT CAP STEERING CABLE STEERING ROD COLLAR...
Page 623: Remote Control Box (Optional Part)
2. REMOTE CONTROL BOX (OPTIONAL PART) a. DISASSEMBLY/ASSEMBLY • REMOTE CONTROL CABLE SHIFT PIVOT (2) INSTALLATION: Screw in the shift pivot 8 mm or more onto the threaded end of the cable. [1]-1 8 mm or more [10] 5 x 25 mm SELF- 10-32 UNF REMOTE CONTROL TAPPING SCREW (7)
Page 624 • ELECTRIC COMPONENTS EMERGENCY STOP SWITCH INSPECTION: P. 16-9 WARNING BUZZER INSPECTION: P. 16-10 IGNITION SWITCH [11] INSPECTION: P. 16-9 5 x 8 mm SELF- TAPPING SCREW (2) [10] POWER TILT CORD CLAMP SPARE EMERGENCY STOP SWITCH CLIP 16 mm HEX. NUT 1.5 N .
Page 625 • SLIDING PLATE 7 mm E-CLIP 5 x 10 mm 5 mm WASHER SCREW 4 mm E-CLIP 8 mm WASHER FAST IDLE WHEEL 6 mm WASHER (2) 5 mm HEX. NUT [10] FAST IDLE SPRING 5 x 16 mm HEX. BOLT [25] 13 x 13 mm FAST IDLE [11]...
Page 626 • REMOTE CONTROL LEVER ASSEMBLY/CONTROL WHEEL 6 mm HEX. NUT 5 x 10 mm SELF-TAPPING SCREW 8 x 35 mm HEX. BOLT 4 mm WASHER (2) 5 mm WASHER 8 mm WASHER NEUTRAL SWITCH SPACER [21] CONTROL WHEEL FRICTION ADJUSTING BOLT [20] 28 mm WASHER THROTTLE...
Page 627 • REMOTE CONTROL LEVER REMOTE CONTROL NEUTRAL 5 x 10 mm SCREW LEVER SPRING RELEASE LEVER REMOTE CONTROL LEVER GRIP LEVER SETTING PLATE [10] 5 x 12 mm SELF- TAPPING SCREW [11] POWER TRIM/TILT SWITCH REMOTE CONTROL INSPECTION: P. 16-10 LEVER WIRE HARNESS CLIP 5 x 12 mm...
Page 628: Control Panel (Optional Part)
3. CONTROL PANEL (OPTIONAL PART) a. DISASSEMBLY/ASSEMBLY SWITCH PANEL HARNESS INDICATOR LIGHT IGNITION SWITCH CONNECTION: P. 16-8 [MIL/ALTERNATOR INSPECTION: P. 16-9 INDICATOR LIGHT] INSPECTION: P. 16-9 SWITCH PANEL WIRE HARNESS CABLE BAND BUZZER BRACKET [18] CONTROL PANEL [17] 22 mm NUT 4.9 N .
Page 629 b. SWITCH PANEL HARNESS CONNECTION: Connect the switch panel harnesses to the respective switches as shown. To SWITCH To POWER PANEL CABLE TRIM/TILT To EMERGENCY SWITCH STOP SWITCH To METER HARNESS SWITCH PANEL HARNESS SIDE CONTROL PANEL SIDE [10] INDICATOR IGNITION LIGHT SWITCH...
Page 630: Inspection
4. INSPECTION Bl/W Bl/R • IGNITION SWITCH Check for continuity between the terminals with the switch in Bl/Y each position. Wire W/Bl Position (Bl) (Bl/R) (W/Bl) (Bl/Y) (Bl/W) OFF (Stop) ON (Run) START (Start) : Continuity Bl: Black R: Red W: White Y: Yellow •...
Page 631 • WARNING BUZZER NOTICE Use a known-good battery. Connect the black/yellow terminal of the warning buzzer to the battery positive (+) terminal, and the yellow/green terminal to the battery negative (–) terminal as shown. Check that the buzzer sounds this time. 12 V •...
Page 632: Cables/Shift Link Bracket/Shift Arm/Neutral Switch
17. CABLES/SHIFT LINK BRACKET/SHIFT ARM/NEUTRAL SWITCH 1. REMOTE CONTROL CABLE/ 2. SHIFT LINK BRACKET/NEUTRAL GROMMET SWITCH 3. SEAL HOLDER 2.5 N . m (0.25 kgf . m, 1.8 lbf . ft) 17-1...
Page 633: Remote Control Cable/Grommet
1. REMOTE CONTROL CABLE/GROMMET a. REMOVAL Remove the following parts. – Engine cover (P. 4-2) – Front separate cover (P. 4-7). 1) Remove the remote control cable (shift side) shift pivot from the shift arm shift link pin. 2) Remove the remote control cable (throttle side) shift pivot from the throttle arm link pin. 3) Remove the remote control cables (shift and throttle sides) from the remote control cable plate and the remote control cable grommet.
Page 634 5) Remove the 6 x 16 mm hex. bolt and the 6 mm washer from the remote control cable plate, then remove the remote control cable plate. Release the starter cable from the cable bracket A and remove the remote control cable grommet from the under cover front bracket.
Page 635 b. COMPONENTS DRAWING SHIFT PIVOT (2) LOCK NUT (2) REMOTE CONTROL CABLE (Throttle side) REMOTE CONTROL CABLE [17] (Shift side) 6 x 16 mm HEX. BOLT [16] 6 mm WASHER [15] REMOTE CONTROL CABLE PLATE SPEED [14] SENSOR REMOTE CONTROL TUBE A CABLE GROMMET REMOTE...
Page 636 c. INSTALLATION UNDER COVER 1) Set the indicator light wire and the remote control cable in FRONT BRACKET the specified positions in the remote control cable WHITE TAPE grommet. Be sure that the tie wires on the indicator light wire and the remote control cable are set against the remote control cable grommet.
Page 637 4) Install the remote control cable plate on the flat surface of the remote control cable grommet by aligning the projection on the remote control cable plate with the groove in the under cover front bracket. Take care not to move the alignments described in step 1 and 2 this time.
Page 638 6) Install the lock nut and the shift pivot on each of the remote control cables. Align the groove in each of the remote control cables (shift and throttle sides) with the cutouts in the remote control cable plate, and install the remote control cables on the remote control cable plate. Fasten the undercase grommet band securely (P.
Page 639 4) Move the remove control lever fully to the “R” (Reverse) [2] “N” (NEUTRAL) position, then return it slowly to the “N” (Neutral) position. “R” (REVERSE) 5) With the remote control lever in the position described in step 4, mark (B) at the end of the cable outer seal of the inner cable.
Page 640 9) With the remote control cable (shift side) in the position described in step 7 (i.e. the mark (C) aligns with the cable REMOTE CONTROL CABLE outer seal end), adjust the shift side remote control cable (Shift side) length by turning the shift pivot so that the shift pivot sets on the shift link pin smoothly.
Page 641 e. REMOTE CONTROL CABLE (THROTTLE SIDE) INSTALLATION 1) Apply marine grease to the link pin and the mounting part of the link pin on the shift pivot. LINK PIN 2) Set the remote control cable (throttle side) shift pivot on the [2] (MARINE throttle arm link pin.
Page 642: Shift Link Bracket/Neutral Switch
2. SHIFT LINK BRACKET/NEUTRAL SWITCH a. REMOVAL Remove the following parts. – Engine cover (P. 4-2) – Front separate cover (P. 4-7) – L./R. engine under cover (P. 4-9) – Remote control cable/grommet (P. 17-2) 1) Remove the throttle rod linkage pivot from the throttle plate. 2) Remove the two 6 x 18 mm flange bolts from the shift link bracket assembly.
Page 643 4) Remove the shift arm from the shift shaft B while pulling the detent arm to your side. SHIFT ARM DETENT SHIFT SHAFT B Pull to your side. 5) Remove the 6 x 14 mm flange bolt from the neutral switch 6 x 14 bracket while pulling the detent arm toward you, then (Pull in the direction...
Page 644 11) Remove the 20 mm hex. nut from the neutral switch, then remove the neutral switch from the neutral switch bracket. 20 mm HEX. NUT NEUTRAL SWITCH BRACKET NEUTRAL SWITCH 12) Remove the 6 x 12 mm flange bolt from the detent arm, then remove the 6 mm washer, detent arm and the detent 6 x 12 spring.
Page 645 c. COMPONENTS DRAWING THROTTLE ROD 6 x 18 (2) [18] 12 mm SNAP RING [17] 12 mm WASHER SHIFT LINK BRACKET ASSEMBLY CONNECTOR BRACKET A [16] SHIFT ARM FUEL TUBE A FUEL TUBE HOLDER 6 x 14 6 x 12 [15] 6 mm WASHER CLIP A...
Page 646 d. DISASSEMBLY OF SHIFT LINK BRACKET ASSEMBLY 1) Remove the throttle link. 2) Remove the throttle arm and remove the link pin. 3) Remove the shift link pin, link pin, shift slide pivot and the shift pivot plate. 4) Remove the throttle plate. 5) Check the two bushing As from the shift link bracket.
Page 647 e. ASSEMBLY OF SHIFT LINK BRACKET ASSEMBLY 1) Apply marine grease to the outer surface of the two bushing As and the inner wall at the mounting part of the bushing A in the link bracket. Install the two bushing As in the shift link bracket. 2) Apply marine grease to the outer surface of the throttle plate shaft.
Page 648 f. INSTALLATION 6 x 12 1) Apply marine grease to the inner wall of a new detent arm bushing. Set the detent arm bushing on the detent arm. 2) Apply marine grease to the seal holder shaft. 6 mm WASHER Apply marine grease to the roller area of the detent arm.
Page 649 6) Clamp the neutral switch wire with the clip A and set the clip A on the neutral switch bracket. NEUTRAL SWITCH 2P CONNECTOR CONNECTOR 7) Connect the neutral switch 2P connector and set the neutral BRACKET A switch 2P connector on the connector bracket A. FUEL TUBE HOLDER 8) Set the fuel tube holder on the connector bracket A.
Page 650 13) Set the 12 mm washer on the shift shaft B and secure with the 12 mm snap ring. 12 mm SNAP RING 12 mm WASHER SHIFT ARM [Set in the “N” (Neutral) position.] 14) Apply marine grease to the outer surface of the link pin of the shift link bracket and to the long hole in the shift arm. Set the link pin aligning with the long hole in the shift arm.
Page 651: Seal Holder
3. SEAL HOLDER 6 x 20 (2) a. REMOVAL SEAL HOLDER Remove the following pars. – Engine cover (P. 4-2) – Front separate cover (P. 4-7) – R. engine under cover (P. 4-9) – Remote control cable/bracket (P. 17-2) – Shift link bracket/neutral switch (P. 17-11) 1) Remove the 6 x 14 mm flange bolt from the cable bracket A, and remove the cable bracket A.
Page 652 c. COMPONENTS DRAWING 12 x 26 x 7 mm OIL SEAL 6 x 20 (2) SEAL HOLDER SHIFT SHAFT B 25 x 2.4 mm O-RING ALTERNATOR FUSE CABLE CABLE BRACKET A STARTER CABLE 6 x 14 17-21...
Page 653 d. SHIFT SHAFT B CORRECTION [1] STOPPER STOPPER Correct the shift shaft B with the seal holder removed. Correct the shift shaft B only when the shift shaft B is raised or when it is disengaged from the shift shaft A in the mounting case.
Page 654 e. ASSEMBLY 12 x 26 x 7 mm 1) Apply marine grease to a new 25 x 2.4 mm O-ring. OIL SEAL Apply soapy water to the outer surface of the 12 x 26 x 7 (Apply soapy mm oil seal. water to the outer surface.) Apply marine grease to the mounting part of the O-ring on...
Page 655: Electrical Equipment
18. ELECTRICAL EQUIPMENT 1. STARTER MOTOR 4. POWER TILT RELAY/CONNECTOR 2. STARTER CABLE BRACKET A 3. ECM/PGM-FI MAIN RELAY/FUSE BOX 1. STARTER MOTOR a. REMOVAL 1) Disconnect the negative (–) cable from the battery negative terminal. 2) Disconnect the main relay (White) terminal from the magnetic switch. 3) Move the terminal cover aside and remove the 8 mm washer-nuts and the 8 mm washer.
Page 656 b. DISASSEMBLY [1] 8 mm WASHER-NUT 1) Move the terminal cover aside. Remove the 8 mm washer- nut and disconnect the motor wire from the S terminal. MOTOR WIRE S TERMINAL [4] STARTER MAGNETIC SWITCH 2) Remove the 6 x 22 mm washer screws and the O-rings. [1] STARTER MAGNETIC Remove the magnetic switch, spring and the plunger.
Page 657 5) Remove the yoke from the armature/rear bracket assembly. ARMATURE/REAR BRACKET ASSEMBLY YOKE 6) Remove the two 5 x 8 mm screws and remove the rear bracket. 5 x 8 mm SCREW (2) REAR BRACKET 7) Remove the brush holder. BRUSH HOLDER 8) Remove the steel ball and planetary gear.
Page 658 9) Remove the gasket. GASKET 10) Remove the overrunning clutch. CLUTCH FORK 11) Remove the clutch fork. OVERRUNNING CLUTCH • OVERRUNNING CLUTCH DISASSEMBLY [1] PIPE 1) Secure the gear shaft by placing a wood block under the [I.D.: approx. 11mm (0.4 in), gear shaft assembly.
Page 659 5) Remove the gear shaft and the gear shaft stopper. Remove [1] GEAR SHAFT STOPPER the internal gear and the overrunning clutch. ONE-WAY CLUTCH INTERNAL GEAR GEAR SHAFT • BRUSH HOLDER DISASSEMBLY 1) Remove the clip and the plate. PLATE 2) Remove the brush sets and the brush springs.
Page 660 • MICA DEPTH Measure the mica depth. If the grooves are clogged or mica depth is less than the service limit, recut the grooves using a hacksaw blade or a small file. STANDARD SERVICE LIMIT 0.4 – 0.5 mm 0.2 mm (0.016 –...
Page 661 • ARMATURE Check the armature and shaft gear for wear and damage. • ARMATURE SHORT-CIRCUIT TEST Place the armature in an armature tester (commercially available). Hold a hacksaw blade close to the armature core. If the blade is attracted to the core or vibrates when the core is turned, the armature is shorted.
Page 662 • SHORT-CIRCUIT TEST — CORE-TO- COMMUTATOR Check for continuity between the commutator and armature coil core. If continuity exists, replace the armature. • SHORT-CIRCUIT TEST — SHAFT-TO-ARMATURE Check for continuity between the armature and armature shaft. If there is continuity, replace the armature. •...
Page 663 • MAGNETIC SWITCH [1] S TERMINAL After assembly, check for continuity between the S terminal and the yoke (ground). Check for continuity between the S terminal and the M terminal. d. ASSEMBLY M TERMINAL NOTICE After assembling the starter motor, apply sufficient amount of the water resisting sealant (Sumitomo 3M Padding Sealer #8533 or equivalent) to the mating sections of each part (P.
Page 664 • OVERRUNNING CLUTCH ASSEMBLY [1] GEAR SHAFT STOPPER 1) Apply grease to the internal gear, inner wall of the overrunning clutch, gear shaft sliding surface and the ONE-WAY surface of the gear shaft stopper. CLUTCH 2) Assemble the overrunning clutch, gear shaft and the gear shaft stopper with the internal gear.
Page 665 • FRONT BRACKET ASSEMBLY 1) Apply grease to the sliding surface of the clutch fork. 2) Set the clutch fork in the indicated position of the overrunning clutch. OVERRUNNING CLUTCH CLUTCH FORK 3) Install the overrunning clutch assembly on the front [3] OVERRUNNING bracket.
Page 666 • REAR BRACKET/YOKE ASSEMBLY 1) Install the brush holder on the armature. 5 x 8 mm SCREW (2) 2.5 N . m (0.25 kgf . m, 1.8 lbf . ft) 2) Apply grease to the armature shaft and install the gear bracket as shown.
Page 667 8) Apply the engine oil to the new O-rings and install the O- [1] 8 mm WASHER-NUT rings on the 6 x 22 mm screws. 9) Install the plunger, spring and the starter magnetic switch. STARTER MAGNETIC • Assemble the plunger and the clutch fork as shown. SWITCH 10) Tighten the 6 x 22 mm screws to the specified torque.
Page 668 e. INSTALLATION 1) Apply the engine oil to the new O-ring. 2) Set the two 10 x 90 mm flange bolts on the starter motor, and install both the starter motor and the two 10 x 90 mm flange bolts on the engine. 3) Tighten the two 10 x 90 mm flange bolts to the specified torque.
Page 669: Starter Cable
2. STARTER CABLE a. REMOVAL Remove the following parts. – Engine cover (P. 4-2) – Front separate cover (P. 4-7) STARTER CABLE 1P NOTICE CONNECTOR (W WIRE) Disconnect the starter cable from the battery before disconnecting and connecting the starter cable. 1) Release the starter cable from the two harness clips.
Page 670 7) Release the starter cable from the cable bracket A. CABLE BRACKET A STARTER CABLE b. COMPONENTS LOCATION ALTERNATOR FUSE CABLE 8 mm WASHER-NUT (2) 11 N . m (1.1 kgf . m, 8 lbf . ft) STARTER CABLE [13] 1P CONNECTOR 8 mm WASHER (W WIRE)
Page 671 c. INSTALLATION 1) Secure the alternator fuse cable and the starter cable with the cable bracket A as shown. CABLE BRACKET A STARTER CABLE STARTER CABLE ALTERNATOR FUSE CABLE CABLE BRACKET A 2) Tighten the 8 x 18 mm flange bolt to the specified torque [1] CABLE BRACKET B while pushing the negative (–) starter cable against the STARTER...
Page 672 5) Install the positive (+) starter cable on the magnetic switch [1] 8 mm WASHER- B terminal at right angles to the vertical center line of the TERMINAL COVER magnetic switch as shown. Tighten the 8 mm washer-nut to the specified torque. [6] ALTERNATOR FUSE CABLE TORQUE: 11 N .
Page 673: Ecm/Pgm-Fi Main Relay/Fuse Box
3. ECM/PGM-FI MAIN RELAY/FUSE BOX a. ELECTRIC PART COVER/ECM REMOVAL/INSTALLATON Remove the following parts. – Engine cover (P. 4-2) – R. engine under cover (P. 4-9) On installation, position each connector and harness in the proper position (P. 2-48). ELECTRIC ECM CONNECTOR PART COVER C (6P CONNECTOR)
Page 674 b. PGM-FI MAIN RELAY/CONNECTOR BRACKET B REMOVAL/INSTALLATION Remove the following parts. – Engine cover (P. 4-2) – R. engine under cover (P. 4-9) – Electric part cover/ECM (P. 18-19) Disconnect the PGM-FI main relay connector wire and the alternator fuse cable from the starter motor. On installation, position each connector and harness in the proper position (P.
Page 675 c. FUSE BOX/ALLTERNATOR FUSE BOX (90A) REMOVAL/INSTALLATION Remove the following parts. – Engine cover (P. 4-2) – R. engine under cover (P. 4-9) – Electric part cover/ECM (P. 18-19) – PGM-FI main relay/connector bracket B (P. 18-20) On installation, position each connector and harness in the proper position (P. 2-48 through P. 2-51). ALTERNATOR FUSE 6 mm WASHER-NUT (2) BOX B TERMINAL...
Page 676 COLLAR (4) CASE GROMMET (4) [11] 6 mm WASHER (4) 6 x 25 (4) [10] FUSE BOX BRACKET CONNECTOR HOLDER CLIP B 6 x 10 5 N . m (0.5 kgf . m, 3.6 lbf . ft) FUSE BOX COVER [3] CONNECTOR BRACKET C FUSE BOX...
Page 677 • FUSE BOX 1) Insert a screwdriver or equivalent tool into the locking lugs on the top and underside of the fuse box, and unlock. 2) With the lock unlocked, pull the fuse box toward you and remove the fuse box from the fuse box bracket. •...
Page 678 d. INSPECTION NOTICE • Use a known-good battery. • Do not connect the battery for more than 30 seconds. Wait for one minute or more before connecting the battery again. • PGM-FI MAIN RELAY 1) Connect the battery positive (+) terminal to the Black/Yellow terminal of the PGM-FI main relay 6P connector and the battery negative (–) terminal to the Black terminal.
Page 679 • LAF RRELAY Connect the battery positive (+) terminal to the LAF relay No.3 terminal and the battery negative (–) terminal to the No.4 LAF RELAY terminal. There must be continuity between the No.1 and No.2 terminal of the LAF relay. CONNECTOR VIEWED FROM THE FRONT SIDE No.
Page 680 • FUSE BOX/FUSE ALTERNATOR NOTICE TERMINAL FUSE BOX Disconnect the positive (+) and negative (–) starter cables from the battery before inspection and replacement of the fuse box/fuse. 1) Remove the fuses from the fuse box and check for blown fuse.
Page 681: Power Tilt Relay/Connector Bracket A
4. POWER TILT RELAY/CONNECTOR BRACKET A a. REMOVAL/INSTALLATION Remove the following parts. – Engine cover (P 4-2) – L./R. engine under covers (P. 4-9) – Under cover front bracket (P. 4-20) Remove each connector from the connector bracket A, then remove the connector bracket A and the power tilt relay. On installation, position the connectors and harnesses in the proper position (P.
Page 682 WIRE HARNESS CLIP INSTALLATION: FRAME GROUND 6 x 12 (2) Clamp the power tilt INSTALLATION: P. 18-29 relay ground cable. RELAY BRACKET 6 x 14 (4) [12] WIRE HARNESS CLIP POWER TILT RELAY 6 x 12 GROUND CABLE WIRE HARNESS CLIP INSTALLATION: P.
Page 683 • FRAME GROUND INSTALLATION: Tighten the 6 x 12 mm flange bolts while pushing each ground FRAME GROUND terminal against the projection on the crankcase as shown. TERMINAL POWER TILT RELAY PROJECTIONS • POWER TILT RELAY GROUND CABLE GROUND TERMINAL INSTALLATION: 1) Connect the Black, Blue, Green/White wire side of the ground terminal to the upper connection, and the Green,...
Page 684 NOTICE Use a known-good battery. 2) Connect the wires as shown, and check for continuity between the following terminals. • Connecting positive (+) battery terminal to Light green terminal: Green to Black terminals No continuity Blue to Black terminals Continuity Green to White terminals Continuity Blue to White terminals...
Page 685: Operation
19. OPERATION 1. DOHC (SWING ARM TYPE) + VTEC 4. AIR/FUEL RATIO O FEEDBACK 2. CHAIN DRIVE CAM DRIVE SYSTEM CONTROL BY A/F SENSOR 3. INDEPENDENT CYLINDER HEAD/ CYLINDER BLOCK COOLING SYSTEM 1. DOHC (SWING ARM TYPE) + VTEC STRUCTURE AND FEATURES VTEC (BF150A only) •...
Page 686: Chain Drive Cam Drive System
2. CHAIN DRIVE CAM DRIVE SYSTEM STRUCTURE AND FEATURES The intake/exhaust cam drive method was changed from the existing cogged belt drive to the silent chain drive type. The chain tensioner was changed to the hydraulic type to make it maintenance free. Structure: As the basic structure of this chain drive cam drive system, the balancer is laid out in front of the crankshaft and the drive valve system is laid out behind the crankshaft.
Page 687: Independent Cylinder Head/Cylinder Block Cooling System
3. INDEPENDENT CYLINDER HEAD/CYLINDER BLOCK COOLING SYSTEM STRUCTURE AND FEATURES The cylinder head and cylinder block cooling passages are laid out independently from each other, each of which is equipped with the thermostat to control the cooling water temperature of each passage. Structure: •...
Page 688: Air/Fuel Ratio O
4. AIR/FUEL RATIO O FEEDBACK CONTROL BY A/F SENSOR Receiving the current value signal from the A/F (Air Fuel Ratio) sensor, the ECM controls the fuel injection duration (fuel amount) so that the engine’s suction air fuel mixture is at or near the target air/fuel ratio determined by the main CPU. MAP SENSOR DECISION OF BASIC DECISION OF TARGET...
Page 689 BF135A•BF150A Side Mount Remote Control Type...
Page 690 Top Mount Remote Control Type/Panel Mount Remote Control Type 20-2...
Page 691 BF135A•BF150A PGM-FI System Diagram VAPOR SEPARATOR FUEL PUMP (HIGH PRESSURE SIDE) FUEL STRAINER (HIGH PRESSURE SIDE) VAPOR FILTER BATTERY IGNITION SWITCH STARTER MOTOR NEUTRAL SWITCH TRIM METER (OPTION) TRIM ANGLE SENSOR A/F HEATER RELAY PGM-FI MAIN RELAY CMP SENSOR ACG WARNING LIGHT...
Page 692 Specifications 6 - 10 Service Information 11 - 89 Maintenance 90 - 119 Engine cover/Cover Lock 120 - 153 Programmed Fuel Injection 154 - 311 Alternator 312 - 335 Engine removal/Installation 336 - 343 Thermostat/Relief valve/Flush valve 344 - 354 Crankshaft pulley/Cam chain 355 - 373 Cylinder head/Valves...

This manual is also suitable for:

Marine bf150a

Honda BF135A Manual

Specifications

Service Information

Maintenance

Engine Cover/Cover Lock

Programmed-Fuel Injection

Alternator

Engine Removal/Installation

Thermostat/Relief Valve/Flush Valve

Crankshaft Pulley/Cam Chain

Cylinder Head/Valves

Oil Pump/Flywheel

Crankcase/Balancer

Cylinder Block/Crankshaft/Pistons

Propeller/Gear Case/Extension Case/Oil Case

Mounting Case/Stern Bracket/Swivel Case/Power Trim/Tilt Assembly

Steering Rod/Remote Control Box

Cables/Shift Link Bracket/Shift Arm/Neutral Switch

Electrical Equipment

Operation

Quick Links

Troubleshooting

Related Manuals for Honda BF135A

Summary of Contents for Honda BF135A