SELVA MARINE Kingfish 25 Service Manual
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SELVA MARINE Kingfish 25 Service Manual

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Kingfish 25
SERVICE MANUAL

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Summary of Contents for SELVA MARINE Kingfish 25

  • Page 1 Kingfish 25 SERVICE MANUAL...
  • Page 2 Preface This manual has been prepared by Selva primarily for use by Selva dealers and their trained mechanics when performing maintenance procedures and repairs to Selva equipment. It has been written to suit the needs of persons who have basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
  • Page 3 Contents General information INFO Specification SPEC TECH Technical features and description Rigging information GING TRBL Troubleshooting SHTG Electrical system ELEC Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT Maintenance Index Appendix...

  • Page 5: Table Of Contents

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

  • Page 6: Safety While Working

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

  • Page 7: Self-Protection

    Safety while working Self-protection Handling of gas torch • Protect your eyes by wearing safety • Improper handling of a gas torch may result glasses or safety goggles during all opera- in burns. For information on the proper han- tions involving drilling and grinding, or when dling of the gas torch, see the operation using an air compressor.

  • Page 8: Special Service Tool

    INFO General information Special service tool Disassembly and assembly Use the recommended special service tools • Use compressed air to remove dust and dirt to work safely, and to protect parts from dam- during disassembly. age. • Apply engine oil to the contact surfaces of moving parts before assembly.

  • Page 9: How To Use This Manual

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

  • Page 10: Abbreviation

    INFO General information Abbreviation The following abbreviations are used in this service manual. Abbreviation Description American Petroleum Institute ATDC After Top Dead Center BTDC Before Top Dead Center Cold Cranking Ampere Capacitor Discharge Ignition Centerline European Norm (European standard) Exhaust Forward International Electrotechnical Commission Intake...

  • Page 11: Lubricant, Sealant, And Thread Locking Agent

    How to use this manual / Lubricant, sealant, and thread locking agent Lubricant, sealant, and thread locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points. Symbol Name Application 4-stroke motor oil Lubricant Gear oil Lubricant...

  • Page 12: Special Service Tool

    INFO General information Symbol Name Application LOCTITE 242 (blue) Thread locking agent LOCTITE 572 (white) Sealant Silicone sealant Sealant Special service tool For all markets except U.S.A. and Canada Special service tools with Selva part numbers (90890-*****) are distributed by the Parts Division. Drilling plate Ignition tester (spark gap tester) 90890-06783...
  • Page 13 Lubricant, sealant, and thread locking agent / Special service tool Test harness (2 pins) Flywheel puller 90890-06887 90890-06521 Vacuum/pressure pump gauge set Crankshaft holder 90890-06756 90890-06355 Pilot screw driver (for Europe) Valve spring compressor 90890-06673 90890-04019 Compression gauge Valve spring compressor attachment 90890-03160 90890-06320 Flywheel holder...
  • Page 14 INFO General information Valve guide reamer Valve seat cutter 60° 90890-06804 90890-06324 Valve lapper Valve seat cutter 30° 90890-04101 90890-06328 Valve seat cutter holder Valve seat cutter 45° 90890-06316 90890-06312 Valve seat cutter 30° Valve seat cutter 60° 90890-06327 90890-06315 Valve seat cutter 45°...
  • Page 15 Special service tool Bearing outer race attachment Bearing puller assembly 90890-06626 90890-06535 Oil filter wrench Stopper guide stand 90890-01426 90890-06538 Piston slider Needle bearing attachment 90890-06529 90890-06615 Stopper guide plate Driver rod L3 90890-06501 90890-06652 Bearing separator Needle bearing attachment 90890-06534 90890-06611 0-10...
  • Page 16 INFO General information Bearing inner race attachment Needle bearing attachment 90890-06640 90890-06616 Bearing outer race attachment Driver rod SL 90890-06628 90890-06602 Drive shaft holder 3 Bearing depth plate 90890-06517 90890-06603 Ball bearing attachment Driver rod LL 90890-06637 90890-06605 Bearing inner race attachment Bearing outer race attachment 90890-06643 90890-06625...
  • Page 17 Special service tool Bearing inner race attachment Center bolt 90890-06645 90890-06504 Bearing inner race attachment Bearing housing puller claw S 90890-06644 90890-06564 Pinion height gauge Backlash indicator 90890-06710 90890-06706 Pinion height gauge plate B Pinion height gauge 90890-06712 90890-06668 Shimming plate Dial gauge set 90890-06701 90890-01252...
  • Page 18 INFO General information Magnet base B Ball bearing attachment 90890-06844 90890-06633 Magnet base plate Bearing inner race attachment 90890-07003 90890-06641 Needle bearing attachment Needle bearing attachment 90890-06614 90890-06612 Driver rod SS Bearing outer race attachment 90890-06604 90890-06622 Bearing inner race attachment Bearing outer race attachment 90890-06639 90890-06627...
  • Page 19 Special service tool Ball bearing attachment Digital tachometer 90890-06634 90890-06760 Bushing installer center bolt 90890-06601 Needle bearing attachment 90890-06613 Needle bearing attachment 90890-06617 Cylinder-end screw wrench 90890-06568 0-14...
  • Page 20 INFO General information — MEMO — 0-15...
  • Page 21 SPEC Specification Model features ................1-1 General feature ................1-1 Model designation ..............1-2 Serial number ................1-2 Model data ..................1-3 Dimension and Weight ............... 1-3 Performance................1-3 Power unit .................. 1-4 Bracket unit ................1-5 Lower unit................... 1-5 Fuel and oil requirement.............

  • Page 22: Model Features

    Model features Model designation F 25 D E H T L F :4-stroke regular rotation Model description FT :4-stroke regular rotation (high thrust) Model name 25: 25 Product generation A: A and up M: Manual starter E: Electric starter Functions H: Tiller handle T: Power trim and tilt S: S (15 in)

  • Page 23: Model Data

    SPEC Specification Model data Dimension and Weight Model Item Unit Overall length mm (in) 1181.0 (46.5) Overall width mm (in) 412.0 (16.2) Overall height mm (in) 1157.0 (45.6) — mm (in) 1284.0 (50.6) Boat transom height mm (in) 381.0 (15.0) —...

  • Page 24: Power Unit

    Model data Model Item Unit E.ST. E.ST.PT. Maximum output at 5500 r/min kW (HP) 19.3 (25) Full throttle operating range r/min 5000–6000 Maximum fuel consumption L (US gal, at 5500 r/min 9.2 (2.4, 2.0) Imp gal)/hr Engine idle speed r/min 925–1025 Power unit Model...

  • Page 25: Bracket Unit

    SPEC Specification Model Item Unit E.ST. E.ST.PT. Exhaust system Propeller boss Lubrication system Wet sump Bracket unit Model Item Unit Trim angle (at 12° boat transom) Degree –4, 0, 8, 12 –3 to 16 Tilt-up angle Degree Steering angle Degree 42 + 42 Trim and tilt system Manual...

  • Page 26: Fuel And Oil Requirement

    Model data Fuel and oil requirement Model Item Unit Fuel type Regular unleaded gasoline 4-stroke motor oil with combinations of the Engine oil following SAE and API oil classifications Engine oil grade (*1) SE, SF, SG, SH, SJ, SL 5W-30, 10W-30, 10W-40 Total engine oil quantity L (US qt, 1.7 (1.80, 1.50)

  • Page 27: Battery Requirement

    SPEC Specification Battery requirement Model Item Unit Minimum cold cranking amps CCA/EN 347.0 Minimum rated capacity 20HR/IEC 40.0 Model Item Unit E.ST. E.ST.PT. Minimum cold cranking amps CCA/EN 347.0 Minimum rated capacity 20HR/IEC 40.0 PTT requirement Model Item Unit Fluid type —...
  • Page 28 Model data / Electrical technical data Model Item Unit Pulser coil Air gap mm (in) 0.8 (0.031) Resistance (*1) Ω at 20 °C (68 °F) 152.0–228.0 Output peak voltage at cranking (unloaded) at cranking (loaded) at 1500 r/min (loaded) at 3500 r/min (loaded) Neutral switch Input voltage (*1) 12.0...

  • Page 29: Engine Speed Control System

    SPEC Specification Model Item Unit E.ST. E.ST.PT. Pulser coil Air gap mm (in) 0.8 (0.031) Resistance (*1) Ω at 20 °C (68 °F) 152.0–228.0 Output peak voltage at cranking (unloaded) at cranking (loaded) at 1500 r/min (loaded) at 3500 r/min (loaded) Neutral switch Input voltage (*1) 12.0...

  • Page 30: Charging System

    Electrical technical data Model Item Unit E.ST. E.ST.PT. Oil pressure switch Working pressure (kgf/cm 29.4–58.8 (0.294–0.588, 4.3–8.5) psi) Prime Start Ω Resistance (*1) 20.0 Power bobbin Output peak voltage at cranking (loaded) 10.6 at 1500 r/min (loaded) 25.1 at 3500 r/min (loaded) 59.1 (*1) The figures are for reference only.

  • Page 31: Starting System

    SPEC Specification Model Item Unit E.ST. E.ST.PT. Rectifier Regulator Output peak voltage at 1500 r/min (loaded) 13.0 at 3500 r/min (loaded) 13.0 (*1) The figures are for reference only. Starting system Model Item Unit Starter motor Type — Sliding gear Output —...
  • Page 32 Electrical technical data / Fuel system technical data Model Item Unit Fuel filter assembly Holding pressure Positive pressure (kgf/cm 200.0 (2.00, 29.0) psi) Fuel pump Holding pressure Inlet positive pressure (kgf/cm 50.0 (0.50, 7.3) psi) Inlet negative pressure (kgf/cm 30.0 (0.30, 4.4) psi) Outlet positive pressure (kgf/cm...

  • Page 33: Power Unit Technical Data

    SPEC Specification Model Item Unit E.ST. E.ST.PT. Fuel pump Holding pressure Inlet positive pressure (kgf/cm 50.0 (0.50, 7.3) psi) Inlet negative pressure (kgf/cm 30.0 (0.30, 4.4) psi) Outlet positive pressure (kgf/cm 50.0 (0.50, 7.3) psi) Carburetor 14.0 ± 2.0 (0.55 ± 0.08) Float height mm (in) Valve seat size...

  • Page 34: Manual Starter

    Fuel system technical data / Power unit technical data Model Item Unit E.ST. E.ST.PT. Cylinder Minimum compression (kgf/cm 870.0 (8.70, 126.2) pressure (*1) psi) Engine oil Oil pressure (*2) at 60 °C (140 °F) with SL 10W-30 engine oil and at (kgf/cm 250.0 (2.50, 36.3) 950 r/min...
  • Page 35 SPEC Specification Model Item Unit Valve spring Free length mm (in) 39.9 (1.57) Tilt mm (in) 1.7 (0.07) Camshaft Cam lobe height Intake mm (in) 30.839–30.939 (1.2141–1.2181) Exhaust mm (in) 30.937–31.037 (1.2180–1.2219) Cam lobe width Intake and exhaust mm (in) 25.950–26.050 (1.0217–1.0256) Journal diameter #1 mm (in)
  • Page 36 Power unit technical data Model Item Unit E.ST. E.ST.PT. Valve guide Inside diameter Intake and exhaust mm (in) 5.500–5.512 (0.2165–0.2170) Stem-to-guide clearance Intake mm (in) 0.010–0.037 (0.0004–0.0015) Exhaust mm (in) 0.025–0.052 (0.0010–0.0020) Installation position mm (in) 16.3–16.7 (0.64–0.66) Valve spring Free length mm (in) 39.9 (1.57)

  • Page 37: Crankcase Assembly

    SPEC Specification Crankcase assembly Model Item Unit Cylinder Bore mm (in) 65.000–65.015 (2.5591–2.5596) Piston Diameter mm (in) 64.950–64.965 (2.5571–2.5577) Measuring point mm (in) 5.0 (0.20) Piston clearance mm (in) 0.035–0.065 (0.0014–0.0026) Ring groove (Top) mm (in) 1.210–1.230 (0.0476–0.0484) Ring groove (2nd) mm (in) 1.510–1.530 (0.0594–0.0602) Ring groove (Oil)
  • Page 38 Power unit technical data Model Item Unit Crankcase Crankshaft journal oil mm (in) 0.012–0.036 (0.0005–0.0014) clearance Model Item Unit E.ST. E.ST.PT. Cylinder Bore mm (in) 65.000–65.015 (2.5591–2.5596) Piston Diameter mm (in) 64.950–64.965 (2.5571–2.5577) Measuring point mm (in) 5.0 (0.20) Piston clearance mm (in) 0.035–0.065 (0.0014–0.0026) Ring groove (Top)

  • Page 39: Lower Unit Technical Data

    SPEC Specification Model Item Unit E.ST. E.ST.PT. Crankshaft Journal diameter mm (in) 42.986–43.000 (1.6924–1.6929) Crankpin diameter mm (in) 32.993–33.000 (1.2989–1.2992) Runout mm (in) 0.035 (0.0014) Crankpin width mm (in) 21.000–21.070 (0.8268–0.8295) Crankcase Crankshaft journal oil mm (in) 0.012–0.036 (0.0005–0.0014) clearance (*1) The figures are for reference only.

  • Page 40: Bracket Unit Technical Data

    Power unit technical data / Lower unit technical data / Bracket unit technical data Model Item Unit E.ST. E.ST.PT. 0.10, 0.12, 0.7, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 0.15, 0.18, Pinion shim (T3) 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, Forward gear shim (T1) 1.0, 1.1, 1.2, 1.3, 1.4 0.30, 0.40,...

  • Page 41: Special Tightening Torque

    SPEC Specification Special tightening torque Rigging information Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Shift cable locknut — Throttle cable locknut — Fuel system Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Fuel filter cup —...

  • Page 42: Lower Unit

    Special tightening torque Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Exhaust cover bolt Thermostat cover bolt Balancer piston nut — 15.7 115.8 Connecting rod bolt 12.5 11.1 Crankcase bolt 22.1 Crankcase bolt Crankcase cover bolt Lower unit Tightening torques Part to be tightened Screw size...

  • Page 43: Ptt Unit

    SPEC Specification Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb 15.5 Upper case bolt 15.5 Baffle plate screw (high thrust model) Upper case plug (high thrust model) — 12.5 Engine oil drain bolt — 19.9 Exhaust manifold bolt Exhaust manifold bolt (high thrust model) Stud bolt —...

  • Page 44: General Tightening Torque

    Special tightening torque / General tightening torque General tightening torque This chart indicates the tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components and assemblies are provided in the applicable sections of this manual.
  • Page 45 SPEC Specification — MEMO — 1-25...
  • Page 46 TECH Technical features and description Engine control system .............. 2-1 Outline ..................2-1 Ignition control system ............. 2-3 Ignition timing control ..............2-3 Basic ignition timing control............2-4 Starting ignition timing control ............ 2-4 Acceleration ignition timing control..........2-5 Cold and warm engine ignition timing control......2-6 Engine speed control..............

  • Page 47: Tech Fea

    TECH Technical features and description Engine control system Outline The CDI unit controls the ignition timing according to the input signals for the engine speed, engine speed changes, engine cooling water temperature, and oil pressure. If the engine speed exceeds 6200 r/min, the ignition is cut off so that the engine speed does not increase too high.
  • Page 48 Engine control system 1 CDI unit 2 Pulser coil 3 Ignition coil 4 Thermo sensor 5 Oil pressure switch...

  • Page 49: Ignition Control System

    TECH Technical features and description Ignition control system Ignition timing control The CDI unit determines the optimum ignition timing and sends the electric current to the primary coil of the ignition coil according to the signals from the pulser coil, thermo sensor, and oil pressure switch.

  • Page 50: Basic Ignition Timing Control

    Ignition control system Basic ignition timing control The ignition signals are output for the ignition timing that has been programmed according to the engine speed. Normally, the ignition timing is controlled so that it is between BTDC 6 degrees and BTDC 26 degrees.

  • Page 51: Acceleration Ignition Timing Control

    TECH Technical features and description Acceleration ignition timing control When the engine is accelerated rapidly, the ignition timing is changed as shown in the following graph. Control-starting condition Control time Ignition timing Changes from line 1 to line 2 Rapid acceleration 1 second in the graph.

  • Page 52: Cold And Warm Engine Ignition Timing Control

    Ignition control system Cold and warm engine ignition timing control The ignition timing is corrected as shown in the following graph according to the engine cooling water temperature. Control-starting condition Corrected ignition timing –20 °C (–4 °F) or more and 10 °C (50 °F) or BTDC 5 degrees less More than 10 °C (50 °F) and less than 30 °C...

  • Page 53: Engine Speed Control

    TECH Technical features and description Engine speed control When the engine speed is more than the upper limit or when overheating or low oil pressure is detected, the engine speed is controlled to prevent damage to the engine. Engine speed control during over-revving When the engine speed is 6200 r/min or more, control is performed by cutting off the power to the ignition coil (ignition by the spark plug is stopped).

  • Page 54: Power Unit

    Ignition control system / Power unit Power unit Outline These models feature a newly designed SOHC, in-line, 2-cylinder engine that uses the basic layout of the engine from the Moray 25. Like the Moray 25, the engine is equipped with a balancer 1 to decrease engine vibration and, for man- ual starter models, a camshaft 2 that includes a decompression device for easy starting.

  • Page 55: Balancer

    TECH Technical features and description Balancer The balancer 1, which is installed in the opposite direction of the pistons, decreases the engine vibration by canceling out the primary vibrations produced by the reciprocating motion of the pis- tons. Automatic decompression device (manual starter model) When the starter rope is pulled, the decompression actuator 1 for each exhaust valve retards the closing timing of the valve to reduce the pressure in the cylinder and decrease the force that is nec- essary to pull the rope.

  • Page 56: Lubrication System

    Power unit / Lubrication system Lubrication system System diagram Oil pressure switch Oil pump Oil filter Oil strainer È Intake and exhaust Sleeve Main gallery valves Oil pressure switch Rocker arm Oil filter Piston Relief valve Oil pump Crank pin Rocker arm shaft Oil strainer Crankshaft journal...

  • Page 57: Cooling System

    TECH Technical features and description Cooling system System diagram Thermostat Exhaust guide Oil pan È Water pump Cooling water inlet É Cooling water outlet Thermostat Exhaust guide Exhaust cover Upper case Cylinder head Exhaust port Lower case Cylinder block Water pump Trim tab water inlet Propeller boss È...

  • Page 58: Intake And Exhaust System

    Cooling system / Intake and exhaust system Intake and exhaust system System diagram Intake silencer Carburetor Intake manifold Exhaust manifold Propeller boss È É È Intake air flow É Exhaust gas flow 2-12...

  • Page 59: Carburetor

    TECH Technical features and description Carburetor Prime Start system The Prime Start system adjusts the amount of fuel that is sent to the carburetor according to the time that the power to the power bobbin is turned on. When the engine is started, the Prime Start plunger 1 is fully retracted and the fuel enrichment valve 2 is fully open to enrich the air and fuel mixture during engine starting and warm up.

  • Page 60: Acceleration Pump

    Carburetor Acceleration pump The acceleration pump increase the amount of the fuel that is sent to the combustion chambers dur- ing acceleration. When the throttle grip or remote control lever is operated, the throttle valve opens and the acceleration pump rod 1 is operated by the force of a spring 2. The acceleration pump is operated only when the throttle lever moves from the fully closed position to the half-open position.

  • Page 61: Ptt Unit

    TECH Technical features and description PTT unit Outline The PTT unit consists of the motor unit, the gear pump unit, the valve unit, and the cylinder unit. The main valve 1, which is a component of the valve unit, consists of the up valve a, the down valve b, and the shuttle piston c.

  • Page 62: Tilt Up Operation

    PTT unit Tilt up operation When the up side of the PTT switch is pushed, fluid pressure created by the gear pump 2 causes PTT fluid to flow into the up side of the shuttle piston c and pushes the up valve a, causing it to open.

  • Page 63: Tilt Down Operation

    TECH Technical features and description Tilt down operation When the down side of the PTT switch is pushed, fluid pressure created by the gear pump 2 causes PTT fluid to flow into the down side of the shuttle piston c and pushes the down valve b, causing it to open.

  • Page 64: Operation During Malfunctions

    PTT unit Operation during malfunctions When the fluid pressure in the PTT cylinder is more than the specified limit, the protection valves (absorber valve pins) 5 and 6 will open to force the fluid out of the cylinder and to return it to the reservoir and prevent damage to the cylinder.
  • Page 65 TECH Technical features and description — MEMO — 2-19...
  • Page 66 Rigging information Outboard motor installation ............ 3-1 Dimensions .................. 3-2 Exterior Kingfish 25 STD ............3-2 Exterior Kingfish 25 E.ST............3-4 Exterior Kingfish 25 E.ST.PT............3-5 Clamp bracket (manual tilt model)..........3-7 Clamp bracket (PTT model) ............3-8 Crate top cover pictograph description .......

  • Page 67: Rig Ging

    GING Rigging information Outboard motor installation • Overpowering a boat could cause severe instability. Do not mount an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer. •...

  • Page 68: Dimensions

    Outboard motor installation / Dimensions Dimensions Exterior King sh 25 (version STD) mm (in) S: 761 (30.0) 580 (22.8) L: 880 (34.6) 378 (14.9) 601 (23.7) 189 (7.4) 65 (2.6) S: 15 (0.6) L: 6 (0.2) 433 (17.0) (*1) Transom height...

  • Page 69: Exterior Kingfish 25 E.st

    Dimensions Exterior King sh 25 E.ST. mm (in) S: 761 (30.0) 378 (14.9) L: 880 (34.6) 123 (4.8) 601 (23.7) 65 (2.6) 147 (5.8) S: 15 (0.6) L: 6 (0.2) 433 (17.0) (*1) Transom height...

  • Page 70: Exterior Kingfish 25 E.st.pt

    GING Rigging information Exterior King sh 25 E.ST.PT. mm (in) 353 (13.9) 875 (34.4) 123 (4.8) 601 (23.7) 65 (2.6) 158 (6.2) 14 (0.6) 433 (17.0) (*1) Transom height...

  • Page 71: Clamp Bracket (Manual Tilt Model)

    GING Rigging information Clamp bracket (manual tilt model) mm (in) 150 (5.9) 150 (5.9) 140 (5.5) 140 (5.5) 37 (1.5) 10.5 (0.4) 70 (2.8)

  • Page 72: Clamp Bracket (Ptt Model)

    Dimensions Clamp bracket (PTT model) mm (in) 180 (7.1) 180 (7.1) 69 (2.7) 163.5 (6.4) 163.5 (6.4) 13 (0.5) 13 (0.5) 125.9 (5.0) 125.9 (5.0)

  • Page 73: Crate Top Cover Pictograph Description

    GING Rigging information Crate top cover pictograph description The following pictographs are important when handling the crate. Read the notice and understand what each pictograph means to prevent damage to the outboard motor when handling, transporting, and storing the crate. IMPORTANT HANDLE WITH CARE This unit delivered to carrier in a good condition.

  • Page 74: Uncrate Procedure

    Crate top cover pictograph description / Uncrate procedure Uncrate procedure TIP: 1. Check the crate for shipping damage. Place a rag a between the manual starter (manual starter model) or flywheel magnet 2. Remove the top cover. cover (electric starter model) and the lifting harness.

  • Page 75: Mounting The Outboard Motor

    GING Rigging information Mounting the outboard motor Proper mounting of the outboard motor will provide better performance, maximum reli- ability, and highest customer satisfaction. This chapter contains the specifications nec- essary to mount the outboard motor, and may vary slightly depending on applications. When mounting the outboard motor, make sure that there is sufficient clearance for the outboard motor to fully move to port and star-...
  • Page 76 Mounting the outboard motor C/L: Centerline of transom Boat transom Mounting bolt Drilling plate 1: 90890-06783 thickness (D) M10 × 100 mm (3.94 in) 55–65 mm Mounting hole diameter k: M12 × 105 mm (2.17–2.56 in) 10.5 mm (0.4 in) (4.13 in) 13.0 mm (0.5 in) 5.

  • Page 77: Mounting The Rigging Grommet

    GING Rigging information Mounting the rigging grommet Rigging grommet description 4. Fully screw in the shift cable joint 5 to the shift cable 3. a Battery cable b Extension wiring harness c Analog tachometer (optional) Installing the shift cable and throttle cable (remote control model) Always perform the cable adjustment in advance, following the procedures in the...
  • Page 78 Mounting the rigging grommet 9. Adjust the shift cable joint 5, and then 13. Check that the throttle cam 0 contacts install the shift cable joint 5 to the pin f. the stopper A. WARNING! The shift cable joint must 14.

  • Page 79: Installing The Wiring Harness (Remote Control Model)

    GING Rigging information 17. Install the grommet 1 and grommet 6. Install the rigging grommet 1 and grom- holder D. met holder 7. Installing the wiring harness (remote Installing the remote control box and control model) tachometer (remote control model) 1.

  • Page 80: Propeller Selection

    Mounting the rigging grommet / Installing the battery / Rigging recommendations / Propeller selection Propeller selection Selection When the engine speed is at the full throttle The performance of a boat and outboard operating range, the ideal propeller for the motor will be critically affected by the size boat is one that provides maximum perfor- and type of propeller that is used.
  • Page 81 GING Rigging information — MEMO — 3-17...
  • Page 82 TRBL SHTG Troubleshooting Troubleshooting the outboard motor ........4-1 Troubleshooting procedure ............4-1 Troubleshooting the power unit ..........4-2 Troubleshooting the PTT unit ............. 4-9 Troubleshooting the lower unit ..........4-10...
  • Page 83 TRBL SHTG Troubleshooting Troubleshooting the outboard motor Troubleshooting procedure 1. Before troubleshooting the outboard motor, make sure that fresh fuel of the specified type has been used. 2. Make sure that all electrical connections are secure and free from corrosion, and that the bat- tery is fully charged.
  • Page 84 Troubleshooting the outboard motor...
  • Page 85 TRBL SHTG Troubleshooting...
  • Page 86 Troubleshooting the outboard motor...
  • Page 87 TRBL SHTG Troubleshooting...
  • Page 88 Troubleshooting the outboard motor...
  • Page 89 TRBL SHTG Troubleshooting...
  • Page 90 Troubleshooting the outboard motor...
  • Page 91 TRBL SHTG Troubleshooting...
  • Page 92 Troubleshooting the outboard motor 4-10...
  • Page 93 ELEC Electrical system Electrical component and wiring harness routing .... 5-1 Port view..................5-1 Starboard view ................5-4 Front view................... 5-5 Top view ..................5-7 Tiller handle................5-8 Circuit diagram ................5-9 CDI unit coupler layout ............. 5-9 Checking the electrical component ........
  • Page 94 Checking the brush ..............5-25 Assembling the starter motor ........... 5-25 Installing the starter motor............5-27 Charging unit and components ..........5-27 Checking the lighting coil............5-27 Checking the Rectifier Regulator (electric starter model)..5-28 PTT electrical system .............. 5-29 Checking the PTT relay............

  • Page 95: Electrical System

    ELEC Electrical system Electrical component and wiring harness routing Port view Ë Ì Ê É È 1 Starter motor (electric starter model) 7 Negative battery cable (electric starter 2 Oil pressure switch model) 3 Rectifier Regulator (electric starter model) 8 Starter relay ground lead (electric starter 4 Ignition coil model) 5 Engine shut-off switch ground lead (tiller...
  • Page 96 Electrical component and wiring harness routing Ë Ì Ê É È È Route the Prime Start lead and wiring har- C Lighting coil lead (electric starter model) D Rectifier Regulator lead (electric starter ness to the inside of the battery cable. model) (Electric starter model) É...
  • Page 97 ELEC Electrical system Ë Ì Ê É È Ê Connect the engine shut-off switch ground lead (tiller handle model) and main wiring harness ground lead that have white tape. Ë Connect the negative battery cable. (Elec- tric starter model) Ì Connect the starter relay ground lead (electric starter model) and main wiring harness ground lead.

  • Page 98: Starboard View

    Electrical component and wiring harness routing Starboard view È 1 Prime Start 2 PTT relay (PTT model) È Fasten the Prime Start lead using the holders.

  • Page 99: Front View

    ELEC Electrical system Front view È Ê Ë É Ê Ë Í Ì 1 CDI unit 7 Neutral switch lead (tiller handle model 2 Fuse (20 A) (electric starter model) with electric starter) 3 Fuse (30 A) (electric starter model) 8 Prime Start lead 4 Starter relay (electric starter model) 9 PTT motor lead (PTT model)
  • Page 100 Electrical component and wiring harness routing È Ê Ë É Ê Ë Í Ì Ë Connect the battery lead and wiring har- C 10-pin main wiring harness (remote control model) ness lead. (PTT model) Ì Fold the PTT motor lead and place the D Starter relay lead (electric starter model) E Engine start button lead (tiller handle slack in the lead in the bottom cowling.

  • Page 101: Top View

    ELEC Electrical system Top view È È Route charge coil lead, lighting coil lead, 1 Thermo sensor 2 Pulser coil and Prime Start lead along the groove in 3 Stator assembly the base. 4 Charge coil lead 5 Lighting coil lead 6 Thermo sensor lead 7 Main wiring harness...

  • Page 102: Tiller Handle

    Electrical component and wiring harness routing Tiller handle È È Fit the protrusion on the bracket into the 1 Engine start button (electric starter model) (for Oceania) third indentation in the corrugated tube. 2 Engine shut-off switch (PTT model) (for Oceania) 3 Battery cable (electric starter model) (for Oceania) 4 Alert indicator...

  • Page 103: Circuit Diagram

    ELEC Electrical system Circuit diagram TIP: The circled numbers in the illustration indicate the CDI unit terminal numbers. Ignition coil Engine shut-off switch Pulser coil Overheat alert indicator Charge coil CDI unit Thermo sensor Oil pressure alert indicator Tachometer Oil pressure switch Alert buzzer Ground Battery...

  • Page 104: Checking The Electrical Component

    Circuit diagram / CDI unit coupler layout / Checking the electrical component / Ignition unit and components Checking the electrical TIP: component • Before measuring the peak voltage, check Measuring the peak voltage all wiring harness for corrosion. Also, make sure that the wiring harness is connected properly and that the battery is fully When measuring the peak voltage, do not...

  • Page 105: Checking The Spark Plug Cap

    ELEC Electrical system Ignition tester (spark gap tester) 1: 90890-06754 TIP: Repeat steps 2–4 for each spark plug cap. 3. Crank the engine and check for a spark. If there is no spark, check the ignition system. WARNING! Do not touch any of the connections of the special ser- Spark plug cap resistance vice tool.

  • Page 106: Checking The Pulser Coil

    Ignition unit and components Checking the pulser coil 4. Connect the pulser coil connectors. 1. Measure the pulser coil output peak volt- Checking the charge coil age. 1. Disconnect the charge coil coupler a, and then connect the special service tool 2.

  • Page 107: Checking The Cdi Unit

    ELEC Electrical system 3. Disconnect the special service tool cou- TIP: pler b. • When measuring the output peak voltage under the cranking condition, disconnect 4. Measure the charge coil resistance. the all spark plug caps from the spark plugs to prevent the engine from starting.

  • Page 108: Checking The Oil Pressure Switch

    Ignition unit and components 2. Start the engine, and then measure the Thermo sensor input voltage oil pressure switch 1 input voltage. (reference data): Black/Yellow (B/Y)–Black (B) 4.75–5.25 V 4. Stop the engine. 5. Remove the special service tool 1, and then remove the thermo sensor 2.

  • Page 109: Checking The Alert Indicator

    ELEC Electrical system 3. Connect the alert indicator coupler to the Leakage tester 2: 90890-06840 battery terminals (1.5 V), and then check that the overheat alert indicator comes Working pressure: 29.4–58.8 kPa (0.294–0.588 kgf/cm , 4.3–8.5 psi) 7. Install the oil pressure switch, and then connect the oil pressure switch connec- tor.

  • Page 110: Checking The Engine Start Button (Tiller Handle Model With Electric Starter)

    Ignition unit and components Power bobbin output peak voltage: Blue (L)–Blue (L) Loaded r/min Cranking 1500 3500 DC V 10.6 25.1 59.1 TIP: • When measuring the output peak voltage under the cranking condition, remove the clip from the engine shut-off switch to pre- vent the engine from starting.

  • Page 111: Checking The Engine Start Switch (Remote Control Model)

    ELEC Electrical system Checking the engine start switch Engine start switch continuity: (remote control model) Terminal Switch 1. Disconnect the 10-pin main wiring har- position ness coupler. 2. Measure the engine start switch input START voltage at the 10-pin main wiring harness coupler a.

  • Page 112: Checking The Engine Shut-Off Switch (Remote Control Model)

    Ignition unit and components / Starting unit and components Starting unit and components Engine shut-off switch continuity: Checking the fuse (electric starter Terminal model) Switch position 1. Check the fuse for continuity. Clip installed c Engine shut-off switch pushed d Clip removed e 3.

  • Page 113: Checking The Neutral Switch (Tiller Handle Model With Electric Starter)

    ELEC Electrical system Starter relay input voltage (reference data): Brown (Br)–Ground 12.0 V (battery voltage) 3. Disconnect the starter relay ground lead b, and then remove the starter relay. NOTICE: Always disconnect the nega- tive battery terminal before discon- necting the starter relay terminals. 4.

  • Page 114: Checking The Neutral Switch (Remote Control Model)

    Starting unit and components Checking the neutral switch (remote control model) Before checking the neutral switch, make sure to check the engine start switch. 1. Move the remote control lever to the N position. 2. Disconnect the 10-pin main wiring har- ness coupler.
  • Page 115 ELEC Electrical system Starter motor Part name Q’ty Remarks Armature Brush holder assembly Bracket M5 × 105 mm Bolt M6 × 25 mm, cover screw Screw set M5 × 8 mm, bracket screw Bracket Starter motor gear assembly Pinion shaft Planetary gear Pinion stopper set Clutch assembly...

  • Page 116: Starter Motor

    Starter motor Removing the starter motor 3. Connect a lead 2 to the magnet switch terminal b. 1. Remove the starter motor from the power unit. See “Starter motor” (7-32). 4. Connect the positive battery cable 3 to the lead 2, and then check the magnet Checking the starter motor operation switch continuity between the terminals 1.
  • Page 117 ELEC Electrical system 2. Remove the bracket 2. 6. Remove the armature 4 from the brush holder assembly 5. 3. Disassemble the starter motor. 7. Remove the lever 7 and pinion shaft assembly 8. 8. Remove the rubber seal a and planetary gear 9.

  • Page 118: Checking The Armature (Starter Motor)

    Starter motor Checking the armature (starter motor) 1. Check the commutator. Clean with 600– grit sandpaper and compressed air if 9. Remove the cap b. dirty. 10. Push the pinion stopper c down using a pipe 0, and then remove the clip d. 2.

  • Page 119: Checking The Brush

    ELEC Electrical system 3. Measure the commutator undercut b. Replace the armature if below specifica- tion. Commutator standard undercut b: 0.5 mm (0.02 in) Brush holder assembly continuity: Wear limit: 0.2 mm (0.01 in) 4. Check armature continuity. Replace if out of specification. 2.
  • Page 120 Starter motor 4. Install the clip c into the pinion shaft groove. 5. Install the clip c into the groove in the stopper b by tapping the pinion shaft 7. 2. Install the armature 1 together with the brush holder assembly 2 to the bracket 3, and then install the stator 4.

  • Page 121: Installing The Starter Motor

    ELEC Electrical system Charging unit and components Checking the lighting coil 1. Remove manual starter. “Removing the manual starter” (7-7). (Manual starter model) Remove the flywheel magnet cover. (Electric starter model) 2. Disconnect the lighting coil coupler a, and then connect the special service tool 3.

  • Page 122: Checking The Rectifier Regulator (Electric Starter Model)

    Starter motor / Charging unit and components TIP: • When measuring the output peak voltage under the cranking condition, remove the clip from the engine shut-off switch to pre- vent the engine from starting. • When measuring the output peak voltage under the unloaded condition, disconnect the special service tool coupler b.

  • Page 123: Ptt Electrical System

    ELEC Electrical system TIP: Make sure to set the measurement range g, and display the mark h by pushing the “SHIFT” switch when checking the Rectifier Regulator continuity. 7. Connect the Rectifier Regulator couplers, and then install the flywheel magnet cover.

  • Page 124: Checking The Ptt Switch

    Charging unit and components / PTT electrical system 6. Connect the positive battery lead to the terminal f, connect the negative battery lead to the terminal b, and then check the PTT relay for continuity. Replace if G/W G out of specification. G/W G Test harness (2 pins) 1: 90890-06867 PTT relay continuity:...
  • Page 125 ELEC Electrical system 3. Check the PTT switch for continuity. Replace if out of specification. Wiring harness continuity: a Terminal 1–e Terminal 1 Terminal a Terminal 2–e Terminal 2 Switch a Terminal 3–Terminal f position 7. Install the fuse 1. Free Down 8.
  • Page 126 FUEL Fuel system Hose routing ................6-1 Fuel hose, blowby hose, and cooling water hose....... 6-1 Fuel filter assembly ..............6-2 Checking the fuel joint ..............6-4 Checking the fuel filter assembly..........6-4 Checking the fuel filter element ..........6-4 Fuel pump ..................

  • Page 127: Fuel System

    FUEL Fuel system Hose routing Fuel hose, blowby hose, and cooling water hose 1 Fuel hose (fuel joint to fuel filter assembly) 8 Flushing hose 2 Fuel hose (fuel filter assembly to fuel (flushing hose adapter to joint) 9 Blowby hose pump assembly) 3 Fuel hose (fuel pump assembly to (cylinder head cover to intake silencer)
  • Page 128 Hose routing / Fuel filter assembly Fuel filter assembly · · · 2.5 N m (0.25 kgf m, 1.84 ft Part name Q’ty Remarks M6 × 25 mm Bolt Fuel joint Seal M6 × 20 mm Bolt Holder Tiller handle model Holder Holder Clamp...
  • Page 129 FUEL Fuel system · · · 2.5 N m (0.25 kgf m, 1.84 ft Part name Q’ty Remarks Clamp Holder Tube Hose Hose...

  • Page 130: Checking The Fuel Joint

    Fuel filter assembly Checking the fuel joint 1. Check the fuel joint 1. Replace if cracked or damaged. 2. Connect the special service tool 2 to the fuel joint outlet a. 3. Apply the specified positive pressure. Replace the fuel joint if the specified pressure cannot be maintained for at least 10 seconds.
  • Page 131 FUEL Fuel system Fuel pump · · · m (0.3 kgf m, 2.2 ft Part name Q’ty Remarks Fuel pump assembly M5 × 43 mm Screw Cover Diaphragm Not reusable Fuel pump body 2 Diaphragm Spring Plug Plastic tie Not reusable M6 ×...

  • Page 132: Fuel Pump

    Fuel pump Checking the fuel pump 1. Connect the special service tool 1 to the fuel pump inlet a. 2. Block the fuel pump outlets b using rub- ber plugs 2, and then apply the speci- fied positive pressure. Check that there is no air leakage.

  • Page 133: Checking The Diaphragm And Valve

    FUEL Fuel system 2. Align the hole a in the diaphragm 1 with 4. Remove the plunger 5, springs 7 and the hole b in the plunger 4 by pushing 8, and diaphragm 9. the plunger and diaphragm. 3. Install the pin 5. Checking the diaphragm and valve 1.
  • Page 134 Fuel pump 5. Install fuel pump body 2 7, a new dia- phragm 8, and the cover 9, and then tighten the screws 0 to the specified torque. Fuel pump cover screw 0: 3 N·m (0.3 kgf·m, 2.2 ft·lb)

  • Page 135: Intake Silencer

    FUEL Fuel system Intake silencer Part name Q’ty Remarks M6 × 100 mm Bolt Intake silencer O-ring Not reusable Throttle link rod Carburetor Gasket Not reusable Joint M6 × 55 mm Bolt Holder M6 × 16 mm Bolt Intake manifold Gasket Not reusable Blowby hose...

  • Page 136: Carburetor

    Intake silencer / Carburetor Carburetor Part name Q’ty Remarks Hose M4 × 10 mm Screw Holder Cover Gasket Not reusable Throttle stop screw Spring Needle valve Pilot jet Plug Gasket Not reusable Drain screw Main nozzle Main jet M4 × 8 mm Screw Cover Prime Start...
  • Page 137 FUEL Fuel system Part name Q’ty Remarks Retainer Boot Clamp Plunger rod Spring O-ring Not reusable Pilot screw For Europe Pilot screw For Oceania Gasket Not reusable M3 × 6 mm Screw Plunger Spring Float Float pin M4 × 8 mm Screw Float chamber M4 ×...

  • Page 138: Removing The Carburetor

    Carburetor Removing the carburetor Checking the carburetor 1. Disconnect the fuel hose 1 and blowby 1. Check that the throttle valve operates hose 2. smoothly. 2. Check the air and fuel passages and jets. Clean the carburetor body if there is dirt or foreign material.

  • Page 139: Checking The Prime Start

    FUEL Fuel system Prime Start plunger length a after battery leads are connected (reference data): 5 minutes: 14.2 mm (0.56 in) 10 minutes: 14.9 mm (0.59 in) at 23 °C (73 °F) Assembling the carburetor Do not reuse a gasket or O-ring, always replace it with a new one.

  • Page 140: Installing The Carburetor

    Carburetor 3. Install the spring 9, a new O-ring 0, and the pilot screw A, turn the pilot screw in until it is lightly seated, and then turn it out the specified number of turns. É È È For Europe É...
  • Page 141 FUEL Fuel system Throttle link, throttle cam, and shift cam (tiller handle model) Part name Q’ty Remarks Throttle link rod Holder M6 × 55 mm Bolt Washer Free accelerator lever Collar Throttle cam Spring M6 × 14 mm Bolt Bracket Clip Washer Roller...

  • Page 142: Throttle Link, Throttle Cam, And Shift Cam (Tiller Handle Model)

    Throttle link, throttle cam, and shift cam (tiller handle model) Removing the throttle link, throttle cam, and shift cam 1. Remove the throttle link rod 1. 2. Remove the throttle cam assembly 2. Installing the throttle link, throttle cam, and shift cam 1.

  • Page 143: Adjusting The Throttle Link Rod

    FUEL Fuel system 5. Install the throttle link rod E. 4. Tighten the throttle link stop screw 1. TIP: Hook the end a of the spring 8 onto the tab b on the bracket 1. Adjusting the throttle link rod 1.
  • Page 144 Throttle link, throttle cam, and shift cam (tiller handle model) / Throttle link, throttle cam, and shift cam (remote control model) Throttle link, throttle cam, and shift cam (remote control model) Part name Q’ty Remarks M6 × 65 mm Bolt Washer Collar Throttle link rod...

  • Page 145: Throttle Link, Throttle Cam, And Shift Cam (Remote Control Model)

    FUEL Fuel system Removing the throttle link, throttle cam, and shift cam 1. Remove the throttle link rod 1. 2. Remove the throttle cam assembly 2 with the bracket 3. Installing the throttle link, throttle cam, and shift cam 1. Install the collar 1, shift cam 2, and washer 3.

  • Page 146: Adjusting The Throttle Link Rod

    Throttle link, throttle cam, and shift cam (remote control model) 3. Turn the carburetor throttle lever c TIP: clockwise so that it contacts the stopper Insert the end a of the spring C into the hole b in the bracket D. 4.
  • Page 147 POWR Power unit Power unit (check and adjustment) ........7-1 Checking the compression pressure .......... 7-1 Checking the oil pressure............7-1 Checking the pulser coil air gap ..........7-1 Adjusting the pulser coil air gap ..........7-2 Checking the valve clearance ............ 7-2 Adjusting the valve clearance.............
  • Page 148 Checking the valve ..............7-40 Checking the valve guide ............7-41 Replacing the valve guide ............7-41 Checking the valve seat ............7-42 Refacing the valve seat ............7-43 Checking the rocker arm and rocker arm shaft ......7-44 Checking the camshaft............. 7-45 Checking the spark plug............

  • Page 149: Power Unit

    POWR Power unit Power unit (check and 8. Install the spark plugs, and then connect the spark plug caps. adjustment) Checking the compression pressure Checking the oil pressure 1. Start the engine, warm it up for 5 min- 1. Remove the oil pressure switch, and then utes, and then stop it.

  • Page 150: Adjusting The Pulser Coil Air Gap

    Power unit (check and adjustment) 2. Turn the flywheel magnet 1 clockwise to Checking the valve clearance align a protrusion a on the flywheel Measure the valve clearances when the magnet with the protrusion b on the engine is cold. pulser coil 2.

  • Page 151: Adjusting The Valve Clearance

    POWR Power unit 7. Turn the flywheel magnet 360° clockwise and align the “4” mark e on the driven sprocket 8 with the “ ” mark b on the cylinder head. 6. Measure the intake and exhaust valve clearances c and d for cylinder #1. Adjust if out of specification.
  • Page 152 Power unit (check and adjustment) TIP: • To decrease the valve clearance, turn the adjusting screw 2 in direction a. • To increase the valve clearance, turn the adjusting screw 2 in direction b. 2. Tighten the locknut 1 to the specified torque, and then measure the valve clearances.

  • Page 153: Manual Starter

    POWR Power unit Manual starter · · · 1.5 N m (0.15 kgf m, 1.11 ft · · · 3.4 N m (0.34 kgf m, 2.51 ft · · · 5.4 N m (0.54 kgf m, 3.98 ft Part name Q’ty Remarks Starter handle...
  • Page 154 Manual starter · · · 1.5 N m (0.15 kgf m, 1.11 ft · · · 3.4 N m (0.34 kgf m, 2.51 ft · · · 5.4 N m (0.54 kgf m, 3.98 ft Part name Q’ty Remarks Drive pawl Drive pawl spring 2 Spring Drive pawl spring 1...

  • Page 155: Removing The Manual Starter

    POWR Power unit 4. Remove the sheave drum 3. Removing the manual starter 1. Disconnect the start-in-gear protection cable 1. 5. Remove the spiral spring 7. WARNING! The spiral spring 7 can pop out. Cover the spiral spring with rags 2.

  • Page 156: Checking The Manual Starter

    Manual starter TIP: When replacing the starter rope with a new one, make sure that the length is approxi- mately 2100.0 mm (82.7 in). Checking the spiral spring 1. Check the spiral spring. Replace if bent, cracked, or damaged. Checking the manual starter 1.
  • Page 157 POWR Power unit 5. Install the spiral spring C. WARNING! The spiral spring can pop out. Cover the spiral spring with rags when installing it. TIP: Hook the end e of the spiral spring C onto the protrusion f on the manual starter cover Sheave drum screw 9: 6.

  • Page 158: Installing The Manual Starter

    Manual starter Cover screw I: 1.5 N·m (0.15 kgf·m, 1.1 ft·lb) 11. Pull the starter handle A several times to check that the sheave drum turns Drive plate screw G: smoothly and to check the starter rope 5.4 N·m (0.54 kgf·m, 3.98 ft·lb) for slack.

  • Page 159: Adjusting The Start-In-Gear Protection Cable

    POWR Power unit Adjusting the start-in-gear protection cable Make sure to remove the clip from the engine shut-off switch before checking the start-in-gear protection. 1. Move the shift lever to the N position. 2. Loosen the locknut 1, and then align the cable end a with the mark b on the Starter rope extended length a: manual starter cover by turning the...
  • Page 160 Manual starter / Power unit assembly Power unit assembly · · · m (0.3 kgf m, 2.2 ft · · · m (0.2 kgf m, 1.5 ft 1901 · · · 21 N m (2.1 kgf m, 15.5 ft · ·...
  • Page 161 POWR Power unit · · · m (0.3 kgf m, 2.2 ft · · · m (0.2 kgf m, 1.5 ft 1901 · · · 21 N m (2.1 kgf m, 15.5 ft · · · 21 N m (2.1 kgf m, 15.5 ft Part name Q’ty...

  • Page 162: Power Unit Assembly

    Power unit assembly Removing the power unit (remote 5. Disconnect the battery cables 0 and bat- tery lead c, and then unfasten the nega- control model) tive battery cable from the holder A. 1. Remove the grommet holder 1, and then remove the rigging grommet 2 and grommet 3.
  • Page 163 POWR Power unit 10. Disconnect the PTT switch coupler h. 14. Remove the oil dipstick M, apron N, and driven sprocket cover O. (PTT model) 11. Remove the shift link bolts G. 15. Install the shackle P onto the engine hanger on the cylinder head.

  • Page 164: Removing The Power Unit (Tiller Handle Model)

    Power unit assembly 3. Disconnect the start-in-gear protection cable. See step 1 in “Removing the man- ual starter” (7-7). 4. Disconnect the battery cables, battery lead, and battery lead connector. (Elec- tric starter model) See steps 5 and 6 in “Removing the power unit (remote con- trol model)”...

  • Page 165: Installing The Power Unit (Remote Control Model)

    POWR Power unit 11. Remove the power unit. See steps 11–17 STBD in “Removing the power unit (remote control model)” (7-14). Front Installing the power unit (remote control model) Make sure to install the shift rod and shift link onto the bottom cowling before installing the power unit.
  • Page 166 Power unit assembly 5. Connect the fuel hose 9, and then slide the clamp 0 up. 9. Connect the alert indicator coupler b. 6. Connect the cooling water hose A to the exhaust cover, and then install the holder B to the bracket C. 10.
  • Page 167 POWR Power unit 14. Connect the battery cables L and bat- tery lead f, and then fasten the negative battery cable and ground leads using the holder M. 17. Connect the shift cable P, throttle cable Q, and shift link rod R, and then install the clips S.

  • Page 168: Installing The Power Unit (Tiller Handle Model)

    Power unit assembly Installing the power unit (tiller 7. Connect the PTT motor leads. (PTT model) See steps 10–12 in “Installing the handle model) power unit (remote control model)” (7- Make sure to install the shift rod and shift link 17).

  • Page 169: Flywheel Magnet And Timing Belt

    POWR Power unit Flywheel magnet and timing belt · · · 157 N m (15.7 kgf m, 115.8 ft · · · m (0.4 kgf m, 3.0 ft · · · 38 N m (3.8 kgf m, 28.0 ft · ·...
  • Page 170 Flywheel magnet and timing belt · · · 157 N m (15.7 kgf m, 115.8 ft · · · m (0.4 kgf m, 3.0 ft · · · 38 N m (3.8 kgf m, 28.0 ft · · · 150 N m (15.0 kgf m, 110.6 ft Part name...

  • Page 171: Removing The Flywheel Magnet

    POWR Power unit 4. Remove the pulser coil 3, and then Removing the flywheel magnet remove the stator assembly 4 and base Do not turn the flywheel magnet counter- clockwise. Otherwise, the water pump impeller could be damaged. 1. Remove the manual starter and driven sprocket cover.

  • Page 172: Checking The Timing Belt And Sprocket

    Flywheel magnet and timing belt 3. Remove the timing belt 3 from the driven sprocket, and then remove it from the drive sprocket. 4. Loosen the bolt 4, and then remove the driven sprocket 1. Crankshaft holder 9: 90890-06355 Checking the timing belt and sprocket 1.
  • Page 173 POWR Power unit 3. Align the notch a in the drive sprocket 2 with the protrusion b on the cylinder block. 4. Align the “1” mark c on the driven sprocket 7 with the “ ” mark d on the Crankshaft holder 5: 90890-06355 cylinder head.

  • Page 174: Installing The Flywheel Magnet

    Flywheel magnet and timing belt Flywheel holder 8: 90890-06522 Flywheel magnet nut 7: 157 N·m (15.7 kgf·m, 115.8 ft·lb) Installing the flywheel magnet 1. Install the base 1 and stator assembly TIP: 2, and then install the pulser coil 3. Make sure to remove any grease from the tapered portion a of the crankshaft and the inner surface b of the flywheel magnet 5.

  • Page 175: Wiring Harness And Cdi Unit

    POWR Power unit Wiring harness and CDI unit È Tiller handle model with electric starter É Manual starter model · · · m (0.5 kgf m, 3.7 ft Ê Remote control model Ë Electric starter model Ì PTT model Ë Ë...
  • Page 176 Wiring harness and CDI unit È Tiller handle model with electric starter É Manual starter model · · · m (0.5 kgf m, 3.7 ft Ê Remote control model Ë Electric starter model Ì PTT model Ë Ë Ì Ê Ì...

  • Page 177: Removing The Wiring Harness

    POWR Power unit 6. Remove the alert indicator coupler e Removing the wiring harness from the bracket. 1. Remove the caps a, and then discon- nect the wiring harness 1 and PTT relay 7. Disconnect the wiring harness ground coupler b. (PTT model) lead f.

  • Page 178: Installing The Wiring Harness

    Wiring harness and CDI unit 3. Fasten the main wiring harness using the holders 1 and 2. 4. Connect the Rectifier Regulator coupler d. (Electric starter model) 5. Connect the thermo sensor coupler e and oil pressure switch connector f. 13.
  • Page 179 POWR Power unit 11. Connect the wiring harness ground lead É m. (PTT model) 12. Install the alert indicator coupler n to the bracket. 13. Install the neutral switch 8. (Tiller handle model with electric starter) È È Tiller handle model with electric starter É...
  • Page 180 Wiring harness and CDI unit / Starter motor Starter motor · · · 29 N m (2.9 kgf m, 21.4 ft Part name Q’ty Remarks Holder Bracket Holder M6 × 16 mm Bolt Holder Electric starter model Fuse puller Electric starter model Ignition coil M6 ×...

  • Page 181: Starter Motor

    POWR Power unit · · · 29 N m (2.9 kgf m, 21.4 ft Part name Q’ty Remarks Starter motor Electric starter model M6 × 20 mm Bolt Bracket 7-33...

  • Page 182: Cylinder Head

    Starter motor / Cylinder head Cylinder head · · · 12 N m (1.2 kgf m, 8.9 ft · · · 23 N m (2.3 kgf m, 17.0 ft 90˚ 1377B · · · m (0.6 kgf m, 4.4 ft ·...

  • Page 183: Removing The Cylinder Head

    POWR Power unit Removing the cylinder head 1. Remove the oil pump assembly 1 and gasket 2. 2. Remove the cylinder head cover 3 and gasket 4. Installing the cylinder head Do not reuse a gasket, always replace it with a new one. 1.
  • Page 184 Cylinder head 4. Install a new gasket 7 and the oil pump assembly 8 by aligning the slot in the oil pump drive shaft b with the camshaft pin c. NOTICE: Before installing the oil pump assembly 8, make sure to fill it with engine oil through the oil pas- sages d.

  • Page 185: Camshaft And Valve

    POWR Power unit Camshaft and valve · · · 14 N m (1.4 kgf m, 10.3 ft · · · m (0.2 kgf m, 1.5 ft · · · 18 N m (1.8 kgf m, 13.3 ft · · · 17 N m (1.7 kgf m, 12.5 ft...
  • Page 186 Camshaft and valve · · · 14 N m (1.4 kgf m, 10.3 ft · · · m (0.2 kgf m, 1.5 ft · · · 18 N m (1.8 kgf m, 13.3 ft · · · 17 N m (1.7 kgf m, 12.5 ft ·...

  • Page 187: Disassembling The Cylinder Head

    POWR Power unit Disassembling the cylinder head TIP: 1. Remove the engine hanger 1, bracket Make sure to keep the parts in the order as 2, spark plugs 3, and anodes 4. they were removed. 3. Remove the retaining bolt B and gasket C, and then remove the camshaft D and oil seal E.

  • Page 188: Checking The Cylinder Head

    Camshaft and valve TIP: Valve spring free length a: Make sure to keep the parts in the order as 39.9 mm (1.57 in) they were removed. 2. Measure the valve spring tilt b. Replace if above specification. Checking the cylinder head 1.

  • Page 189: Checking The Valve Guide

    POWR Power unit Valve guide inside diameter a: Intake and exhaust: 5.500–5.512 mm (0.2165–0.2170 in) 2. Calculate the valve-stem-to-valve-guide clearance as follows. Replace the valve guide if out of specification. Valve-stem-to-valve-guide clearance = valve guide inside diameter – valve stem diameter: Valve stem diameter b: Intake: Intake:...

  • Page 190: Checking The Valve Seat

    Camshaft and valve 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat. 3. Press the valve lightly against the valve seat using the special service tool 1. Valve guide remover/installer 2: 90890-06801 Valve guide installation position a: 16.3–16.7 mm (0.64–0.66 in) Valve lapper 1: 90890-04101 4.

  • Page 191: Refacing The Valve Seat

    POWR Power unit Valve seat contact width a: Intake and exhaust: 1.200–1.600 mm (0.0472–0.0630 in) Refacing the valve seat After every lapping procedure, make sure to clean off any remaining lapping com- pound from the cylinder head and valves. 45˚ 1.

  • Page 192: Checking The Rocker Arm And Rocker Arm Shaft

    Camshaft and valve b Previous contact width 5. Adjust the valve seat contact width to specification using a 45° cutter. • If the valve seat contact area is too narrow and situated near the bottom edge of the valve face, cut the bottom edge of the valve seat using a 60°...

  • Page 193: Checking The Camshaft

    POWR Power unit Camshaft runout: 0.030 mm (0.0012 in) 3. Measure the camshaft journal diameters c and d, and the cylinder head journal inside diameters e. Rocker arm inside diameter b: 16.000–16.018 mm (0.6299–0.6306 in) Rocker arm shaft diameter c: 15.971–15.991 mm (0.6288–0.6296 in) Checking the camshaft Camshaft journal diameter c:...

  • Page 194: Checking The Cylinder Head Anode

    Camshaft and valve 2. Check the spark plug. Replace if the 2. Install the valve 2, valve spring seat 3, valve spring 4, and valve spring retainer electrodes are eroded, there is carbon or 5 in this order, and then attach the spe- other deposits.
  • Page 195 POWR Power unit Driver rod LS 0: 90890-06606 Bearing outer race attachment A: 90890-06626 6. Install the camshaft B, and then install a new gasket C and tighten the retaining bolt D. 4. Tap the valve spring retainer lightly using a plastic hammer to seat the valve cot- ters 8 securely.
  • Page 196 Camshaft and valve Rocker arm shaft bolt K: 18 N·m (1.8 kgf·m, 13.3 ft·lb) 9. Install new O-rings L and the cylinder head anodes M to the cylinder head anode plugs N, and then tighten the screws O to the specified torque. 10.

  • Page 197: Exhaust Cover

    POWR Power unit Exhaust cover · · · 23 N m (2.3 kgf m, 17.0 ft · · · m (0.8 kgf m, 5.9 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.6 kgf m, 4.4 ft ·...
  • Page 198 Exhaust cover · · · 23 N m (2.3 kgf m, 17.0 ft · · · m (0.8 kgf m, 5.9 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.6 kgf m, 4.4 ft ·...

  • Page 199: Removing The Exhaust Cover

    POWR Power unit Removing the exhaust cover Removing the oil pressure switch 1. Remove the exhaust cover plugs 1 and 1. Remove the oil pressure switch 1. 2, exhaust cover anode 3, and gaskets 4 and 5. Removing the oil filter 1.

  • Page 200: Checking The Thermostat

    Exhaust cover Checking the thermostat Oil filter union bolt 1: 1. Suspend the thermostat in a container of 40 N·m (4.0 kgf·m, 29.5 ft·lb) water. 2. Install the oil filter 2, and then tighten it 2. Place a thermometer in the water and to the specified torque.

  • Page 201: Installing The Exhaust Cover

    POWR Power unit Exhaust cover and thermostat cover bolt 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 2. Install a new O-ring 8 and the exhaust cover anode 9 to the anode plug 0, and then tighten the screw A to the specified torque.

  • Page 202: Cylinder Block

    Exhaust cover / Cylinder block Cylinder block · · · 157 N m (15.7 kgf m, 115.8 ft 21 22 · · · 12 N m (1.2 kgf m, 8.9 ft · · · · · · · · · 15 N m (1.5 kgf m, 11.1 ft...
  • Page 203 POWR Power unit · · · 157 N m (15.7 kgf m, 115.8 ft 21 22 · · · 12 N m (1.2 kgf m, 8.9 ft · · · · · · · · · 15 N m (1.5 kgf m, 11.1 ft m (0.6 kgf m, 4.4 ft...

  • Page 204: Disassembling The Cylinder Block

    Cylinder block 4. Remove the connecting rod caps a, and Disassembling the cylinder block then remove the crankpin bearings 5, 1. Remove the crankcase cover 1 and connecting rods, and piston assemblies gasket 2. 2. Remove the balancer piston 3. TIP: •...

  • Page 205: Checking The Piston Diameter

    POWR Power unit 6. Remove the piston pin clips B and pis- Checking the cylinder bore ton pin C, and then remove the connect- 1. Measure the cylinder bore (D –D ) at ing rod c. measuring points a, b, and c, and in direction d (D ), which is parallel to the crankshaft, and in direction e (D...

  • Page 206: Checking The Piston Ring End Gap

    Cylinder block Checking the piston ring end gap Piston ring groove: 1. Level the piston ring 1 in the cylinder Top ring a: with a piston crown at the specified mea- 1.210–1.230 mm (0.0476–0.0484 in) suring point a. 2nd ring b: 2.

  • Page 207: Checking The Piston Pin Diameter

    POWR Power unit Piston pin boss inside diameter a: Connecting rod small end inside diameter a: 15.974–15.985 mm (0.6289–0.6293 in) 15.985–15.998 mm (0.6293–0.6298 in) Connecting rod big end inside TIP: diameter b: When measuring the piston boss inside 36.000–36.024 mm (1.4173–1.4183 in) diameter, do not measure it at the ring groove b.

  • Page 208: Checking The Crankpin Oil Clearance

    Cylinder block Crankshaft journal diameter a: 42.986–43.000 mm (1.6924–1.6929 in) Crankpin diameter b: 32.993–33.000 mm (1.2989–1.2992 in) Crankpin width c: 21.000–21.070 mm (0.8268–0.8295 in) 2. Measure the crankshaft runout. TIP: Do not place the Plastigauge (PG-1) over the oil hole in the crankpin of the crankshaft. 4.

  • Page 209: Selecting The Crankpin Bearing

    POWR Power unit TIP: • Make sure that the protrusions f on the connecting rod a and connecting rod cap b face towards the flywheel magnet end of the crankshaft. • Do not turn the connecting rod until the crankpin oil clearance measurement has been completed.
  • Page 210 Cylinder block TIP: Do not place the Plastigauge (PG-1) over the oil hole in each crankshaft journal. 5. Install the crankshaft journal bearings Crankcase bolt 5 1–6 (M8): into the crankcase. 1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb) TIP: Crankcase bolt 6 7–B (M6): Install the crankshaft journal bearings in the...

  • Page 211: Selecting The Crankshaft Journal Bearing

    POWR Power unit Assembling the cylinder block TIP: When loosening the crankcase bolts, loosen them in the opposite order used for tighten- Do not reuse an oil seal or piston pin clip, ing. always replace it with a new one. 1.
  • Page 212 Cylinder block 6. Install the crankshaft journal bearings 6. TIP: Install the crankshaft journal bearings 6 in the original positions. 4. Install the crankpin bearings 4 into the connecting rod a and connecting rod 7. Install the balancer rod 7 and new oil cap k.
  • Page 213 POWR Power unit TIP: • Install the crankshaft journal bearings B in the original positions. • Do not apply any sealant on the crankshaft journal bearings. 11. Install the crankcase C, and then tighten the bolts D to the specified torques in 2 stages and in the order 1, 2, and so on.
  • Page 214 Cylinder block Crankcase bolt D 1–6 (M8): 1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb) Crankcase bolt E 7–B (M6): 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) TIP: Make sure...
  • Page 215 POWR Power unit — MEMO — 7-67...
  • Page 216 LOWR Lower unit Lower unit ..................8-1 Removing the lower unit............. 8-3 Checking the propeller ............... 8-3 Checking the lower unit anode ........... 8-3 Water pump .................. 8-4 Removing the water pump ............8-6 Checking the water pump............8-6 Propeller shaft housing ............
  • Page 217 LOWR Shimming ..................8-24 Shim location................8-24 Shimming ................. 8-25 Selecting the pinion shim ............8-25 Selecting the forward gear shim..........8-26 Selecting the reverse gear shim..........8-27 Measuring the forward and reverse gear backlash ....8-28 Lower unit (high thrust model) ..........
  • Page 218 Shimming (high thrust model) ..........8-52 Shimming workflow ..............8-52 Shimming check sheet ............. 8-53 Measuring the forward and reverse gear backlash before disassembly ........... 8-55 Shimming ................. 8-57 Shim location................8-57 Selecting the pinion shim (T3)..........8-58 Pinion shim (T3) selection table ..........8-61 Measuring the forward gear backlash ........

  • Page 219: Lower Unit

    LOWR Lower unit Lower unit · · · 1901 34 N m (3.4 kgf m, 25.1 ft · · · m (0.9 kgf m, 6.6 ft · · · m (0.9 kgf m, 6.6 ft · · · 37 N m (3.7 kgf m, 27.3 ft Part name...
  • Page 220 Lower unit · · · 1901 34 N m (3.4 kgf m, 25.1 ft · · · m (0.9 kgf m, 6.6 ft · · · m (0.9 kgf m, 6.6 ft · · · 37 N m (3.7 kgf m, 27.3 ft Part name Q’ty...

  • Page 221: Removing The Lower Unit

    LOWR Lower unit 7. Make an alignment mark a on the trim Removing the lower unit tab 4 and lower case, and then remove the trim tab 4. • Make sure to disconnect the battery cables from the battery, and remove the 8.
  • Page 222 Lower unit / Water pump Water pump Part name Q’ty Remarks O-ring Not reusable L-transom model Not reusable S-transom model Water tube L-transom model O-ring Not reusable S-transom model Water tube S-transom model M6 × 40 mm Bolt Extension plate L-transom model Rubber seal Water pump housing...
  • Page 223 LOWR Lower unit Part name Q’ty Remarks Dowel Rubber seal Plate...

  • Page 224: Water Pump

    Water pump Removing the water pump 1. Remove the extension plate 1 (L-tran- som model), water tube 2, water pump housing 3, insert cartridge 4, O-ring 5, and impeller 6. 2. Remove the Woodruff key 7, and then remove the outer plate cartridge 8. 3.

  • Page 225: Propeller Shaft Housing

    LOWR Lower unit Propeller shaft housing · · · 11 N m (1.1 kgf m, 8.1 ft 15 13 Part name Q’ty Remarks Shift plunger Cross pin Dog clutch Spring Spring Propeller shaft Washer Reverse gear Reverse gear shim — O-ring Not reusable Ball bearing...

  • Page 226: Removing The Propeller Shaft Housing Assembly

    Propeller shaft housing Removing the propeller shaft housing assembly 1. Remove the propeller shaft housing assembly 1. TIP: Stopper guide plate 2: 90890-06501 • Insert flat-head screwdrivers between the Bearing puller assembly 3: 90890-06535 propeller shaft housing assembly 1 and Bearing separator 4: 90890-06534 the lower case to remove the propeller Stopper guide stand 5: 90890-06538...

  • Page 227: Checking The Propeller Shaft

    LOWR Lower unit Assembling the propeller shaft assembly 1. Align the hole a in the dog clutch 1 with the hole b in the propeller shaft 2. 2. Install the spring 3. Needle bearing attachment 8: 90890-06615 TIP: Driver rod L3 9: 90890-06652 Install the dog clutch 1 with the “F”...
  • Page 228 Propeller shaft housing TIP: Install an oil seal halfway into the propeller shaft housing, and then install the other oil seal. 3. Install the original reverse gear shims 6 and a new ball bearing 7. Needle bearing attachment 2: 90890-06615 Driver rod L3 3: 90890-06652 Depth a: 31.0–31.5 mm (1.220–1.240 in) TIP:...
  • Page 229 LOWR Lower unit 8-11...
  • Page 230 Propeller shaft housing / Drive shaft and lower case Drive shaft and lower case 1104J · · · 50 N m (5.0 kgf m, 36.9 ft · · · m (0.1 kgf m, 0.7 ft Part name Q’ty Remarks Taper roller bearing Not reusable Pinion shim —...
  • Page 231 LOWR Lower unit 1104J · · · 50 N m (5.0 kgf m, 36.9 ft · · · m (0.1 kgf m, 0.7 ft Part name Q’ty Remarks O-ring Not reusable Rubber seal Plate M6 × 25 mm Bolt Oil seal Not reusable Oil seal housing Gasket...

  • Page 232: Drive Shaft And Lower Case

    Drive shaft and lower case Removing the drive shaft, oil seal housing, and shift rod 1. Loosen the pinion nut, and then remove the drive shaft assembly 1 and pinion 2. Remove the oil seals 2. Drive shaft holder 3 3: 90890-06517 2.

  • Page 233: Disassembling The Lower Case

    LOWR Lower unit 3. Heat the installation area of the taper roller bearing outer race 4 in the lower case using a gas torch, and then remove the taper roller bearing outer race and forward gear shims 5. NOTICE: When heating the lower case, heat the entire installation area evenly.

  • Page 234: Checking The Shift Rod

    Drive shaft and lower case Drive shaft runout: 0.5 mm (0.0197 in) Checking the lower case 1. Check the lower case. Replace if cracked TIP: or damaged. • Before removing the taper roller bearing outer race 6, place some cushioning mate- Assembling the lower case rial under the lower case to catch the outer race when it falls out.
  • Page 235 LOWR Lower unit TIP: Driver rod SL 6: 90890-06602 Do not reuse a shim if deformed or Bearing depth plate 7: 90890-06603 scratched. Needle bearing attachment 8: 90890-06615 3. While holding the special service tool 3, strike the tool to check that the taper Depth a: 185.0–186.0 mm (7.28–7.32 in) roller bearing outer race is installed prop- erly.

  • Page 236: Assembling The Forward Gear

    Drive shaft and lower case Water inlet cover screw: 1 N·m (0.1 kgf·m, 0.7 ft·lb) Assembling the forward gear Do not reuse a bearing, always replace it with a new one. 1. Install a new taper roller bearing 1. TIP: •...

  • Page 237: Installing The Shift Rod, Oil Seal Housing, And Drive Shaft

    LOWR Lower unit 1. Install new oil seals 1 to the specified depth a. Driver rod LS 2: 90890-06606 Ball bearing attachment 3: 2. Install the forward gear assembly. 90890-06637 3. Install the drive shaft assembly 5 and Depth a: 5.5–6.0 mm (0.22–0.24 in) pinion 6, and then tighten the nut to the specified torque.

  • Page 238: Installing The Water Pump

    Drive shaft and lower case 3. Install the Woodruff key 5. 4. Align the slot a in the impeller 6 with the Woodruff key 5, and then install the impeller 6. 2. Install the propeller shaft housing assem- bly 3, and then tighten the bolts 4 to the specified torque.

  • Page 239: Checking The Lower Unit For Air Leakage

    LOWR Lower unit Leakage tester 2: 90890-06840 2. Apply the specified pressure to check that the pressure is maintained in the TIP: lower unit for at least 10 seconds. While turning the drive shaft clockwise, push NOTICE: Do not over pressurize the down on the water pump housing and install lower unit.
  • Page 240 Drive shaft and lower case TIP: The adjusting nut 5 must be screwed in 8.0 mm (0.31 in) a or more. 6. Install a new special washer 9, the anode 0, and the trim tab A. 3. Install the dowels 1. 4.
  • Page 241 LOWR Lower unit Propeller nut F: 34 N·m (3.4 kgf·m, 25.1 ft·lb) 8. Install a new cotter pin G. TIP: If the grooves in the propeller nut F do not align with the cotter pin hole, tighten the pro- peller nut until they are aligned. 9.

  • Page 242: Shimming

    Drive shaft and lower case / Shimming Shimming Shim location 42.5 24.0 24.0 8-24...

  • Page 243: Shimming

    LOWR Lower unit Shimming • Shimming is not required if the backlash is within specification. • Shimming is required when assembling the original inner parts and a new lower case. • Shimming is required when replacing the pinion, forward gear, reverse gear, bear- ings, shaft, or propeller shaft housing.

  • Page 244: Selecting The Forward Gear Shim

    Shimming Example: 2. Measure the bearing height (M1) at 4 If (M3) is 28.30 mm and “P” is (+5), then points, and then calculate the average. (T3) = 28.30 – 27.00 – (+5)/100 mm = 28.30 – 27.00 – 0.05 mm = 1.25 mm If (M3) is 28.43 mm and “P”...

  • Page 245: Selecting The Reverse Gear Shim

    LOWR Lower unit 1. Heat the installation area of the reverse TIP: gear ball bearing 1 in the propeller shaft “F” is the deviation of the lower case dimen- housing 2 using a gas torch, and then sion from standard. The “F” mark a is install the ball bearing.

  • Page 246: Measuring The Forward And Reverse Gear Backlash

    Shimming Example: If (T2) is 1.05 mm, then the reverse gear shim is 1.0 mm. If (T2) is 1.19 mm, then the reverse gear shim is 1.1 mm. Measuring the forward and reverse gear backlash 1. Remove the water pump assembly and outer plate cartridge.

  • Page 247: Lower Unit (High Thrust Model)

    LOWR Lower unit 6. Tighten the center bolt 2 to the specified torque while holding the drive shaft to prevent it from turning. Handle stopper 6: EU0-23814-30 Handle stopper nut a (shimming): 2 N·m (0.2 kgf·m, 1.5 ft·lb) 11. Install the special service tools 7, 8, and 9, and then install the special ser- Center bolt 2 (shimming): vice tool 0 to apply a load.
  • Page 248 Shimming 14. Determine the backlash average, and then round down the average to the 1/100 place. Example: (mm) Measuring point b 0.51 Measuring point c 0.53 Measuring point d 0.54 Measuring point e 0.52 Average 0.5250 Round-down average (BL1) 0.52 15.
  • Page 249 LOWR Lower unit Propeller nut E (shimming): 10 N·m (1.0 kgf·m, 7.4 ft·lb) 19. Repeat steps 7–12 to measure the reverse gear backlash. 20. Check that the reverse gear backlash average is within specification. Reverse gear backlash: 0.92–1.65 mm (0.0362–0.0650 in) TIP: Adjust the shim thicknesses if the reverse gear backlash is out of specification.
  • Page 250 Shimming / Lower unit (high thrust model) Lower unit (high thrust model) · · · 34 N m (3.4 kgf m, 25.1 ft 1901 · · · 39 N m (3.9 kgf m, 28.8 ft 1104J · · · m (0.9 kgf m, 6.6 ft ·...
  • Page 251 LOWR Lower unit · · · 34 N m (3.4 kgf m, 25.1 ft 1901 · · · 39 N m (3.9 kgf m, 28.8 ft 1104J · · · m (0.9 kgf m, 6.6 ft · · · · ·...

  • Page 252: Removing The Lower Unit

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

  • Page 253: Checking The Propeller

    LOWR Lower unit Checking the propeller See “Checking the propeller” (8-3). Checking the lower unit anode 1. Check the anode and trim tab. Replace if eroded. Clean if there is grease, oil, or scales. NOTICE: Do not apply grease, oil, or paint to the anode and trim tab. 8-35...
  • Page 254 Lower unit (high thrust model) / Water pump (high thrust model) Water pump (high thrust model) Part name Q’ty Remarks Cover Seal M8 × 30 mm Bolt Water pump housing Insert cartridge Impeller O-ring Not reusable Dowel Outer plate cartridge Gasket Not reusable Woodruff key...

  • Page 255: Water Pump (High Thrust Model)

    LOWR Lower unit Removing the water pump 1. Remove the water pump housing 1, insert cartridge 2, impeller 3, O-ring 4, and Woodruff key 5. 2. Remove the outer plate cartridge 6 and gasket 7. 3. Remove the rubber seal 8 and plate 9. Checking the water pump See “Checking the water pump”...

  • Page 256: Propeller Shaft Housing (High Thrust Model)

    Water pump (high thrust model) / Propeller shaft housing (high thrust model) Propeller shaft housing (high thrust model) · · · 16 N m (1.6 kgf m, 11.8 ft 13 16 Part name Q’ty Remarks Shift plunger Cross pin Dog clutch Spring Spring Propeller shaft...

  • Page 257: Removing The Propeller Shaft Housing Assembly

    LOWR Lower unit Removing the propeller shaft Stopper guide plate 3: 90890-06501 housing assembly Bearing separator 4: 90890-06534 1. Remove the propeller shaft housing Bearing puller assembly 5: 90890-06535 assembly 1. Stopper guide stand 6: 90890-06538 2. Remove the ball bearing 7. TIP: •...

  • Page 258: Checking The Dog Clutch

    Propeller shaft housing (high thrust model) Checking the dog clutch See “Checking the dog clutch” (8-9). Checking the propeller shaft housing See “Checking the propeller shaft housing” (8-9). Checking the reverse gear See “Checking the reverse gear” (8-9). Assembling the propeller shaft Driver rod LS 6: 90890-06606 assembly Ball bearing attachment 7: 90890-06637...
  • Page 259 LOWR Lower unit Ball bearing attachment B: 90890-06633 5. Install new O-rings C and D. 8-41...
  • Page 260 Propeller shaft housing (high thrust model) / Drive shaft and lower case (high thrust model) Drive shaft and lower case (high thrust model) · · · 50 N m (5.0 kgf m, 36.9 ft · · · m (0.1 kgf m, 0.7 ft Part name Q’ty...
  • Page 261 LOWR Lower unit · · · 50 N m (5.0 kgf m, 36.9 ft · · · m (0.1 kgf m, 0.7 ft Part name Q’ty Remarks Forward gear Taper roller bearing Not reusable Forward gear shim — M5 × 25 mm Screw Water inlet cover (PORT) Water inlet cover (STBD)

  • Page 262: Drive Shaft And Lower Case (High Thrust Model)

    Drive shaft and lower case (high thrust model) Removing the oil seal housing, drive shaft, and shift rod 1. Remove the cover 1, oil seal housing assembly 2, and washer 3. 2. Remove the O-ring 4, plate 5, O-ring 6, washer 7, and shift rod 8. Disassembling the drive shaft 1.

  • Page 263: Disassembling The Lower Case

    LOWR Lower unit Disassembling the lower case 2. Measure the drive shaft runout. Replace if above specification. • Use heat-resistant gloves. Otherwise, burns could result. • To prevent fires, remove any flammable substances, such as gasoline and oil, around the working area. •...
  • Page 264 Drive shaft and lower case (high thrust model) 4. Heat the installation area of the taper Driver rod LL 1: 90890-06605 roller bearing outer race in the lower Bearing outer race attachment 3: case using a gas torch, and then install 90890-06622 the sleeve 8, the original pinion shims 9, and a new taper roller bearing outer...

  • Page 265: Assembling The Forward Gear

    LOWR Lower unit TIP: Bearing inner race attachment 2: If a high-pitched metallic sound is produced 90890-06644 when the special service tool is struck, the taper roller bearing outer race 0 is installed Assembling the oil seal housing properly. Do not reuse an oil seal or O-ring, always 6.

  • Page 266: Installing The Propeller Shaft Housing Assembly

    Drive shaft and lower case (high thrust model) Installing the propeller shaft housing assembly 1. Install the washer 1 and propeller shaft assembly 2. Drive shaft holder 3 5: 90890-06517 2. Install the propeller shaft housing assem- bly 3, and then tighten the bolts 4 to the specified torque.

  • Page 267: Checking The Lower Unit For Air Leakage

    LOWR Lower unit Checking the lower unit for air Installing the lower unit leakage 1. Remove the gear oil check screw 1, and • Make sure to disconnect the battery then install the special service tool 2. cables from the battery, and remove the See step 1 in “Checking the lower unit for clip from the engine shut-off switch.
  • Page 268 Drive shaft and lower case (high thrust model) 8. Install the anode D and trim tab E. Extension nut 4: 39 N·m (3.9 kgf·m, 28.8 ft·lb) 4. Install the dowels 5. 5. Install the lower unit to the upper case, and then tighten the bolts 6 to the speci- fied torque.
  • Page 269 LOWR Lower unit TIP: If the grooves in the propeller nut J do not align with the cotter pin hole, tighten the nut until they are aligned. 11. Fill the lower unit with gear oil up to the proper level. See steps 5–9 in “Changing the gear oil”...

  • Page 270: Shimming (High Thrust Model)

    Drive shaft and lower case (high thrust model) / Shimming (high thrust model) Shimming (high thrust model) Shimming workflow Remove the water pump assembly. Measure the backlash before disassembly. Within specification? Shimming is not required. Disassemble the lower unit. Select the pinion shims (T3). Assemble the lower unit.

  • Page 271: Shimming Check Sheet

    LOWR Lower unit Shimming check sheet Lower case deviation Serial number Remarks Pinion height (mm) Measurements Measuring point #1 Measuring point #2 Measuring point #3 Measuring point #4 Average Round-down average Forward gear backlash (mm) Measurements Before disassembly After disassembly Measuring point #1 Measuring point #2 Measuring point #3...
  • Page 272 Shimming (high thrust model) Forward gear shim thickness (T1) measurement in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15 0.18 0.30 0.40 0.50 Total Reverse gear shim thickness (T2) measurement in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15...

  • Page 273: Measuring The Forward And Reverse Gear Backlash Before Disassembly

    LOWR Lower unit Measuring the forward and reverse 7. Turn the drive shaft 180° clockwise and measure the backlash again. gear backlash before disassembly 1. Remove the water pump assembly and outer plate cartridge. See “Removing the water pump” (8-37). 2.
  • Page 274 Shimming (high thrust model) 15. Remove the special service tools, and TIP: then install the outer plate cartridge and Adjust the shim thicknesses if the forward water pump assembly. See “Installing the gear backlash is out of specification. water pump” (8-49). 10.

  • Page 275: Shimming

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

  • Page 276: Selecting The Pinion Shim (T3)

    Shimming (high thrust model) 3. Check the gap d between the special Selecting the pinion shim (T3) service tool 1 and the pinion 2. • Spray anti-rust lubricant on the bearing NOTICE: When tightening the nut 3, before installation. Do not apply gear oil to check that the drive shaft turns the parts.
  • Page 277 LOWR Lower unit 6. Place the pinion facing upward and hold 10. Measure the gap between the special service tool 1 and the pinion 2. When it in the upright position. measuring the gap, insert the end of the 7. Turn the drive shaft 10 times or more to thickness gauge straight into the gap at seat the taper roller bearing.
  • Page 278 Shimming (high thrust model) Example: (M) = 0.11 “P” = –2 P – 2 (T3) = 0.52 mm from the “Pinion shim (T3) selection table”. Pinion height measurement (M) 0.10 0.11 0.12 Stamped –1 value on the –2 0.52 lower case “P” –3 TIP: The “P”...

  • Page 279: Pinion Shim (T3) Selection Table

    LOWR Lower unit Pinion shim (T3) selection table (mm) È 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.30 0.32 0.32 0.35 0.35 0.35 0.38 0.38 0.38 0.40 0.40 0.42 0.32 0.32 0.35 0.35 0.35 0.38 0.38 0.38 0.40...
  • Page 280 Shimming (high thrust model) (mm) È 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.58...

  • Page 281: Measuring The Forward Gear Backlash

    LOWR Lower unit Measuring the forward gear backlash Forward gear backlash: • Spray anti-rust lubricant on the gear and 0.22–0.69 mm (0.0087–0.0272 in) bearings before installation. Do not apply gear oil to the parts. Otherwise, correct Adjusting the forward gear shim measurements cannot be obtained.
  • Page 282 Shimming (high thrust model) TIP: TIP: • If the shim thickness adjustment value is • Use the fewest number of shims to obtain positive, the current shim thickness must the required shim thickness. be increased by that amount and, if the •...
  • Page 283 LOWR Lower unit 8-65...

  • Page 284: Measuring The Reverse Gear Backlash

    Shimming (high thrust model) Measuring the reverse gear backlash TIP: • Spray anti-rust lubricant on the gear and Do not reuse a shim if deformed or bearings before installation. Do not apply scratched. gear oil to the parts. Otherwise, correct measurements cannot be obtained.
  • Page 285 LOWR Lower unit TIP: TIP: • If the shim thickness adjustment value is • Use the fewest number of shims to achieve positive, the current shim thickness must the required shim thickness. be increased by that amount and, if the •...
  • Page 286 Shimming (high thrust model) 8-68...
  • Page 287 LOWR Lower unit 8-69...
  • Page 288 BRKT Bracket unit Tiller handle ................. 9-1 Disassembling the tiller handle........... 9-4 Assembling the tiller handle ............9-5 Adjusting the throttle cable (tiller handle model) ......9-6 Steering friction (tiller handle model) ........9-8 Disassembling the steering friction..........9-9 Assembling the steering friction ..........9-9 Shift link and shift rod .............
  • Page 289 BRKT Oil pan and exhaust manifold (high thrust model) ..9-36 Disassembling the oil pan and exhaust manifold ..... 9-38 Checking the oil pan and exhaust manifold......9-39 Checking the oil strainer............9-39 Checking the exhaust guide anode .......... 9-39 Assembling the oil pan and exhaust manifold ......
  • Page 290 PTT cylinder ................9-73 Disassembling the PTT cylinder..........9-74 Checking the PTT cylinder and piston........9-74 Assembling the PTT cylinder............ 9-75 Bleeding the PTT unit............... 9-76...

  • Page 291: Bracket Unit

    BRKT Bracket unit Tiller handle 18 19 · · · 37 N m (3.7 kgf m, 27.3 ft · · · 3.5 N m (0.35 kgf m, 2.58 ft · · · 2.5 N m (0.25 kgf m, 1.84 ft ·...
  • Page 292 Tiller handle 18 19 · · · 37 N m (3.7 kgf m, 27.3 ft · · · 3.5 N m (0.35 kgf m, 2.58 ft · · · 2.5 N m (0.25 kgf m, 1.84 ft · · · m (0.4 kgf m, 3.0 ft Part name...
  • Page 293 BRKT Bracket unit 18 19 · · · 37 N m (3.7 kgf m, 27.3 ft · · · 3.5 N m (0.35 kgf m, 2.58 ft · · · 2.5 N m (0.25 kgf m, 1.84 ft · · ·...

  • Page 294: Disassembling The Tiller Handle

    Tiller handle Disassembling the tiller handle 1. Remove the cover 1 and grommet 2. 2. Remove the shift link rod 3, shift lever 4, and holder 5. 6. Remove the washers A, spring B, and bushing C. 3. Remove the cover 6, and then remove the tiller handle assembly 7.

  • Page 295: Assembling The Tiller Handle

    BRKT Bracket unit 5. Route the throttle cables 8, engine shut- off switch lead b, and PTT switch lead c (PTT model) through the protector 9. Assembling the tiller handle 1. Install the PTT switch 1, and then tighten the screws 2 and 3 to the speci- fied torque (PTT model).

  • Page 296: Adjusting The Throttle Cable (Tiller Handle Model)

    Tiller handle 10. Install the throttle friction adjuster G, and then install a new cotter pin H. TIP: • When routing the engine shut-off switch 11. Install the bushing I, washers J, wave lead b and PTT switch lead c (PTT washers K, and tiller handle assembly model), make sure that it is not pinched by the plate 7 and that there is no slack in the...
  • Page 297 BRKT Bracket unit 6. Turn the throttle grip to the fully open and fully closed positions and check that the fully open stopper a and fully closed stopper c on the throttle cam 8 contact the stopper b on the bracket 9. È...

  • Page 298: Steering Friction (Tiller Handle Model)

    Tiller handle / Steering friction (tiller handle model) Steering friction (tiller handle model) · · · m (0.3 kgf m, 2.2 ft · · · m (0.4 kgf m, 3.0 ft Part name Q’ty Remarks Steering friction assembly Steering lock shaft Steering lock lever Washer Friction piece...

  • Page 299: Disassembling The Steering Friction

    BRKT Bracket unit Disassembling the steering friction TIP: 1. Remove the bolts 1. Make sure that the portion a of the steering lock shaft 1 with complete threads around 2. Remove the self-locking nut 2, bolt 3, the shaft does not protrude past the portion and steering lock shaft 4, and then dis- b of the steering arm 2.
  • Page 300 Steering friction (tiller handle model) Friction plate bolt 0: 4 N·m (0.4 kgf·m, 3.0 ft·lb) Self-locking nut A: 4 N·m (0.4 kgf·m, 3.0 ft·lb) TIP: To check and adjust the steering friction, see “Checking the steering system (tiller handle model)” (10-6). 9-10...
  • Page 301 BRKT Bracket unit Shift link and shift rod 4–8 mm (0.16–0.31 in) Part name Q’ty Remarks Clip Washer Shift link rod Lever Lever Bracket Shift rod lever Stopper Shift rod 9-11...

  • Page 302: Bottom Cowling

    Shift link and shift rod / Bottom cowling Bottom cowling · · · m (0.4 kgf m, 3.0 ft · · · m (0.5 kgf m, 3.7 ft 19 21 27 28 Part name Q’ty Remarks Alert indicator Gasket M6 × 20 mm Bolt Holder Tiller handle model with electric starter, for...
  • Page 303 BRKT Bracket unit · · · m (0.4 kgf m, 3.0 ft · · · m (0.5 kgf m, 3.7 ft 19 21 27 28 Part name Q’ty Remarks Joint Hose M6 × 30 mm Bolt ø6 × 20 mm Screw Grommet Hook...
  • Page 304 Bottom cowling · · · m (0.4 kgf m, 3.0 ft · · · m (0.5 kgf m, 3.7 ft 19 21 27 28 Part name Q’ty Remarks Gasket PTT switch PTT model Bottom cowling Grommet Collar Rubber seal Water outlet Grommet Engine start button Tiller handle model with electric starter, for...

  • Page 305: Upper Case And Mounts (S-Transom, For Europe)

    BRKT Bracket unit Upper case and mounts (S-transom, for Europe) · · · 24 N m (2.4 kgf m, 17.7 ft · · · 26 N m (2.6 kgf m, 19.2 ft 1322 1322 · · · m (0.3 kgf m, 2.2 ft ·...
  • Page 306 Upper case and mounts (S-transom, for Europe) · · · 24 N m (2.4 kgf m, 17.7 ft · · · 26 N m (2.6 kgf m, 19.2 ft 1322 1322 · · · m (0.3 kgf m, 2.2 ft ·...

  • Page 307: Removing The Upper Case

    BRKT Bracket unit Removing the upper case 1. Drain the remaining engine oil. 2. Disconnect the ground lead 1. 3. Remove lower mount housing 2 2. 6. Remove lower mount housing 1 0, and then remove the lower mount covers A, 4.
  • Page 308 Upper case and mounts (S-transom, for Europe) 7. Install the washers E, and then tighten the self-locking nuts F to the specified torque. 8. Install lower mount housing 2 G, and then tighten the bolts H to the specified torques in 2 stages in the order 1, 2, and so on.

  • Page 309: Upper Case And Mounts (L-Transom)

    BRKT Bracket unit Upper case and mounts (L-transom) · · · 26 N m (2.6 kgf m, 19.2 ft · · · 24 N m (2.4 kgf m, 17.7 ft · · · 54 N m (5.4 kgf m, 39.8 ft ·...

  • Page 310: Removing The Upper Case

    Upper case and mounts (L-transom) Removing the upper case 1. Drain the remaining engine oil. 2. Remove the lower mount housings 1, and then remove the rubber dampers 2 and 3. 3. Remove the ground lead 4. Installing the upper case 1.
  • Page 311 BRKT Bracket unit Self-locking nut 8: 24 N·m (2.4 kgf·m, 17.7 ft·lb) Grease nipple 0: 3 N·m (0.3 kgf·m, 2.2 ft·lb) 6. Install the rubber dampers A and B, and then install the lower mount housings C and ground lead D. 7.

  • Page 312: Upper Case And Mounts (High Thrust Model)

    Upper case and mounts (L-transom) / Upper case and mounts (high thrust model) Upper case and mounts (high thrust model) · · · 24 N m (2.4 kgf m, 17.7 ft · · · m (0.3 kgf m, 2.2 ft 8 7 6 Part name Q’ty...
  • Page 313 BRKT Bracket unit · · · 24 N m (2.4 kgf m, 17.7 ft · · · m (0.3 kgf m, 2.2 ft 8 7 6 Part name Q’ty Remarks Washer Ground lead M8 × 20 mm, for Oceania Bolt Lower mount cover For Oceania 9-23...

  • Page 314: Removing The Upper Case

    Upper case and mounts (high thrust model) Removing the upper case 7. Remove the washers B, bolts C, wash- ers D, rubber washers E, and washers 1. Drain the remaining engine oil. F, from the lower mounts G, and then 2.
  • Page 315 BRKT Bracket unit 4. Install the lower mount assemblies B and lower mount housings C, and then tighten the bolts D temporarily. 5. Install the upper case assembly E to the bracket assembly F, and then tighten the nuts G and nuts H to the specified torque.

  • Page 316: Upper Case

    Upper case and mounts (high thrust model) / Upper case Upper case · · · m (0.2 kgf m, 1.5 ft · · · 27 N m (2.7 kgf m, 19.9 ft · · · 21 N m (2.1 kgf m, 15.5 ft ·...

  • Page 317: Disassembling The Upper Case

    BRKT Bracket unit Disassembling the upper case 1. Remove the oil pan assembly 1 and dowels 2. 2. Remove the drain bolt 3, gasket 4, and damper 5. Baffle plate screw 3: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2. Install the damper 4 and a new gasket 5, and then tighten the drain bolt 6 to the specified torque.

  • Page 318: Upper Case (High Thrust Model)

    Upper case / Upper case (high thrust model) Upper case (high thrust model) · · · · · · 21 N m (2.1 kgf m, 15.5 ft m (0.3 kgf m, 2.2 ft · · · 21 N m (2.1 kgf m, 15.5 ft 15 16 ·...
  • Page 319 BRKT Bracket unit · · · · · · 21 N m (2.1 kgf m, 15.5 ft m (0.3 kgf m, 2.2 ft · · · 21 N m (2.1 kgf m, 15.5 ft 15 16 · · · 27 N m (2.7 kgf m, 19.9 ft ·...

  • Page 320: Disassembling The Upper Case

    Upper case (high thrust model) Disassembling the upper case 1. Remove the engine oil drain bolt 1. 2. Remove the oil pan assembly 2 and dowels 3. 3. Remove the rubber seals 4 and 5 and damper 6. Stopper guide plate B: 90890-06501 Bushing installer center bolt C: 90890-06601 Checking the drive shaft bushing...
  • Page 321 BRKT Bracket unit 3. Install the guide 6 and baffle plate 7, and then tighten the screws 8 to the specified torque. Upper case bolt A: 1st: 21 N·m (2.1 kgf·m, 15.5 ft·lb) 2nd: 21 N·m (2.1 kgf·m, 15.5 ft·lb) TIP: Make sure to fit the tip of the water pipe B Baffle plate screw 8:...

  • Page 322: Oil Pan And Exhaust Manifold

    Upper case (high thrust model) / Oil pan and exhaust manifold Oil pan and exhaust manifold 5 4 3 · · · 10 N m (1.0 kgf m, 7.4 ft Part name Q’ty Remarks Oil seal Not reusable Exhaust guide M6 ×...
  • Page 323 BRKT Bracket unit 5 4 3 · · · 10 N m (1.0 kgf m, 7.4 ft Part name Q’ty Remarks Dowel Oil pan M6 × 25 mm Bolt Gasket Not reusable Exhaust manifold M6 × 50 mm Bolt 9-33...

  • Page 324: Disassembling The Oil Pan And Exhaust Manifold

    Oil pan and exhaust manifold Disassembling the oil pan and exhaust manifold 1. Remove the exhaust manifold 1 and gasket 2. 5. Remove the oil seal B. 2. Remove the oil pan 3, dowels 4, cool- ing water pipe 5, and gasket 6. Checking the oil pan and exhaust manifold 1.
  • Page 325 BRKT Bracket unit Needle bearing attachment 3: 90890-06613 Driver rod L3 4: 90890-06652 5. Install a new gasket E and the exhaust Depth a: 0.5–1.0 mm (0.02–0.04 in) manifold F, and then tighten the bolts G temporarily. 2. Install the rubber seal 5 and new gas- kets 6 and 7 onto the exhaust guide 2.
  • Page 326 Oil pan and exhaust manifold / Oil pan and exhaust manifold (high thrust model) Oil pan and exhaust manifold (high thrust model) · · 11 N m (1.1 kgf m, 8.1 ft • 16 17 18 20 Part name Q’ty Remarks Gasket Not reusable...
  • Page 327 BRKT Bracket unit · · 11 N m (1.1 kgf m, 8.1 ft • 16 17 18 20 Part name Q’ty Remarks Cover M5 × 12 mm Bolt M6 × 20 mm Bolt Gasket Not reusable Exhaust manifold M6 × 50 mm Bolt Rubber seal Not reusable...

  • Page 328: Disassembling The Oil Pan And Exhaust Manifold

    Oil pan and exhaust manifold (high thrust model) Disassembling the oil pan and exhaust manifold 1. Remove the muffler 1, gaskets 2, and plate 3. 4. Remove the oil strainer A, cover B, and gaskets C and D. 2. Remove the rubber seal 4, exhaust manifold 5, and gasket 6.

  • Page 329: Checking The Oil Pan And Exhaust Manifold

    BRKT Bracket unit Checking the oil pan and exhaust manifold 1. Clean the removed parts. 4. Install the gasket 6, pipe 7, dowels 8, 2. Check the muffler, exhaust manifold, and and oil pan 9, and then tighten the bolts exhaust guide.
  • Page 330 Oil pan and exhaust manifold (high thrust model) Exhaust manifold bolt D: 11 N·m (1.1 kgf·m, 8.1 ft·lb) 7. Install new gaskets E, the plate F, and the muffler G, and then tighten the muf- fler bolts H. 8. Install the anode I. 9-40...

  • Page 331: Steering Arm

    BRKT Bracket unit Steering arm · · · 37 N m (3.7 kgf m, 27.3 ft · · · 3.9 N m (0.39 kgf m, 2.88 ft · · · 20 N m (2.0 kgf m, 14.8 ft Part name Q’ty Remarks Remote control model...

  • Page 332: Removing The Steering Arm

    Steering arm Removing the steering arm 1. Remove the rubber seal 1. 2. Remove the steering arm 2, and then remove the washer 3, bushing 4, and friction piece 5. 3. Remove the bushing 6, O-ring 7, and bushing 8. Friction piece bolt 9: 3.9 N·m (0.39 kgf·m, 2.88 ft·lb) 4.

  • Page 333: Steering Arm (High Thrust Model)

    BRKT Bracket unit Steering arm (high thrust model) · · · 3.9 N m (0.39 kgf m, 2.88 ft · · · 37 N m (3.7 kgf m, 27.3 ft · · · 20 N m (2.0 kgf m, 14.8 ft Part name Q’ty Remarks...

  • Page 334: Removing The Steering Arm

    Steering arm (high thrust model) Removing the steering arm Installing the steering arm 1. Remove the circlip 1, and then remove the steering yoke 2 by striking it using a Do not reuse an O-ring or rubber seal, copper hammer. always replace it with a new one.
  • Page 335 BRKT Bracket unit È É È For Europe É For Oceania 5. Hold the steering arm 6, and then strike the steering yoke B using a copper ham- mer until the groove for installing the cir- clip is visible. 6. Install the circlip C. 7.

  • Page 336: Clamp Bracket (Manual Tilt Model)

    Steering arm (high thrust model) / Clamp bracket (manual tilt model) Clamp bracket (manual tilt model) · · · 24 N m (2.4 kgf m, 17.7 ft · · · 45 N m (4.5 kgf m, 33.2 ft · · ·...
  • Page 337 BRKT Bracket unit · · · 24 N m (2.4 kgf m, 17.7 ft · · · 45 N m (4.5 kgf m, 33.2 ft · · · m (0.3 kgf m, 2.2 ft Part name Q’ty Remarks M8 × 255 mm Bolt Ground lead Collar...

  • Page 338: Removing The Clamp Bracket

    Clamp bracket (manual tilt model) Removing the clamp bracket 1. Remove the ground lead 1. 2. Remove the tilt pin 2 and bolt 3. 3. Remove the E-clips 4, and then remove Installing the clamp bracket the tilt stopper plate pins 5 and 6. 1.
  • Page 339 BRKT Bracket unit 7. Install the bushings F and G, collar H, and tilt stopper plate pins I and J to the swivel bracket 9, and then install the E- clips K. Tilt stopper plate nut 6: 24 N·m (2.4 kgf·m, 17.7 ft·lb) 3.
  • Page 340 Clamp bracket (manual tilt model) / Swivel bracket (manual tilt model) Swivel bracket (manual tilt model) · · · m (0.4 kgf m, 3.0 ft Part name Q’ty Remarks Tilt lock lever Bushing Swivel bracket Bushing Cotter pin Not reusable Spring Collar Tilt lock plate (PORT)
  • Page 341 BRKT Bracket unit · · · m (0.4 kgf m, 3.0 ft Part name Q’ty Remarks Tilt lever M5 × 5 mm Screw Tilt lock rod Collar 9-51...

  • Page 342: Disassembling The Swivel Bracket

    Swivel bracket (manual tilt model) Disassembling the swivel bracket 5. Remove the cotter pin 0, and then remove the pin A and collar B. 1. Unhook the spring 1. 2. Remove the E-clip 2, and then remove the pin 3. 6.
  • Page 343 BRKT Bracket unit 3. Hook the springs A onto the tilt lock arm Tilt lever screw H: 3, and then fit the end of the springs into 4 N·m (0.4 kgf·m, 3.0 ft·lb) the holes a in the swivel bracket 8. 7.

  • Page 344: Clamp Bracket And Swivel Bracket (Ptt Model)

    Swivel bracket (manual tilt model) / Clamp bracket and swivel bracket (PTT model) Clamp bracket and swivel bracket (PTT model) · · · 45 N m (4.5 kgf m, 33.2 ft · · · m (0.3 kgf m, 2.2 ft ·...
  • Page 345 BRKT Bracket unit · · · 45 N m (4.5 kgf m, 33.2 ft · · · m (0.3 kgf m, 2.2 ft · · · 36 N m (3.6 kgf m, 26.6 ft · · · m (0.3 kgf m, 2.2 ft Part name Q’ty...

  • Page 346: Removing The Clamp Bracket

    Clamp bracket and swivel bracket (PTT model) Removing the clamp bracket 1. Remove the PTT unit. See “Removing the PTT unit” (9-59). 2. Remove the stoppers 1. 3. Disconnect the ground leads 2, 3, and Checking the clamp bracket anode (high thrust model) 1.
  • Page 347 BRKT Bracket unit 4. Tighten the self-locking nut A to the 7. Inject grease into the grease nipples on specified torque, and then install the the swivel bracket. See “Lubricating the caps B. outboard motor” (10-14). Self-locking nut A: 45 N·m (4.5 kgf·m, 33.2 ft·lb) 5.

  • Page 348: Ptt Unit

    Clamp bracket and swivel bracket (PTT model) / PTT unit PTT unit Part name Q’ty Remarks E-clip Shaft Bushing Plastic tie Not reusable Bushing PTT unit Anode Except high thrust model M6 × 25 mm, except high thrust model Bolt M6 ×...

  • Page 349: Removing The Ptt Unit

    BRKT Bracket unit Removing the PTT unit When removing the PTT unit with the power unit installed, make sure to sus- pend the outboard motor. 1. Tilt the swivel bracket to the fully up posi- tion, and then support it with the stopper knob 1.
  • Page 350 PTT unit 4. Install the anode 9 (except high thrust model) and ground lead terminals 0 and A to the PTT unit. 5. Pass the PTT motor lead B through the hole a in the clamp bracket C, and then fasten the PTT motor lead B to the clamp bracket C using the plastic tie D.

  • Page 351: Ptt Motor

    BRKT Bracket unit PTT motor · · · m (0.2 kgf m, 1.5 ft · · · m (0.1 kgf m, 0.7 ft · · · m (0.7 kgf m, 5.2 ft · · · m (0.7 kgf m, 5.2 ft 18 19 Part name Q’ty...
  • Page 352 PTT motor · · · m (0.2 kgf m, 1.5 ft · · · m (0.1 kgf m, 0.7 ft · · · m (0.7 kgf m, 5.2 ft · · · m (0.7 kgf m, 5.2 ft 18 19 Part name Q’ty Remarks...

  • Page 353: Removing The Ptt Motor

    BRKT Bracket unit 2. Remove the armature assembly 2. Removing the PTT motor Make sure that the tilt ram is fully extended before removing the PTT motor. Otherwise, fluid can spurt out from the unit due to internal pressure. 1. Fully extend the tilt ram, and then open the manual valve 1 by turning it clock- wise.

  • Page 354: Checking The Brush

    PTT motor 2. Measure the commutator diameter a. Armature continuity: Replace the armature assembly if below specification. 5. Check the bearing. Replace the armature assembly if damaged. Checking the brush 1. Measure the length of each brush. Replace if below specification. PTT motor commutator standard diameter: 16.3 mm (0.64 in) Wear limit: 14.9 mm (0.59 in)

  • Page 355: Installing The Ptt Motor

    BRKT Bracket unit 2. Install the PTT motor lead 4, springs 5, Installing the PTT motor circuit breaker 6, brush holder 7, and brushes 8 and 9, and then tighten the Do not reuse an O-ring, always replace it screws 0 to the specified torque. with a new one.

  • Page 356: Ptt Gear Pump

    PTT motor / PTT gear pump PTT gear pump · · · · · · 11 N m (1.1 kgf m, 8.1 ft m (0.4 kgf m, 3.0 ft · · · m (0.3 kgf m, 2.2 ft 24 23 22 21 20 21 22 ·...
  • Page 357 BRKT Bracket unit · · · · · · 11 N m (1.1 kgf m, 8.1 ft m (0.4 kgf m, 3.0 ft · · · m (0.3 kgf m, 2.2 ft 24 23 22 21 20 21 22 · ·...
  • Page 358 PTT gear pump · · · · · · 11 N m (1.1 kgf m, 8.1 ft m (0.4 kgf m, 3.0 ft · · · m (0.3 kgf m, 2.2 ft 24 23 22 21 20 21 22 · ·...

  • Page 359: Disassembling The Gear Pump Housing

    BRKT Bracket unit Disassembling the gear pump housing 1. Remove the gear pump housing 2. Remove the balls 2 , absorber valve pins E and shuttle 6. Remove the main valves piston F 3. Remove the gear pump assembly 4. Remove the spring 6 , valve pin 7 , valve seal 8 G , spring 7.

  • Page 360: Checking The Gear Pump

    2. Check the main valves and shuttle pis- ton. Replace if damaged. 3. Check the valve support pin, relief valve, valve seal, and spring. Replace if dam- aged. 4. Check the manual valve and spring. Replace if damaged. Checking the lter 1.
  • Page 361 BRKT Bracket unit 4. Install the relief valve 3, valve seat 8, 7. Install the shuttle piston E, and then and spring 9, and then tighten the valve tighten the main valves C to the speci- lock screw 7 to the specified torque. fied torque.
  • Page 362 PTT gear pump Gear pump bolt T: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 12. Install new O-rings U and V, the filter W, the springs X, the absorber valve pins Y, the balls Z, new O-rings [, and the gear pump housing \, and then tighten the bolts ] to the specified torque.
  • Page 363 BRKT Bracket unit PTT cylinder · · · 61 N m (6.1 kgf m, 45.0 ft · · · 90 N m (9.0 kgf m, 66.4 ft Part name Q’ty Remarks Tilt ram assembly Dust seal Not reusable O-ring Not reusable O-ring Not reusable Backup ring...
  • Page 364 PTT cylinder Disassembling the PTT cylinder 1. Loosen the tilt cylinder end screw a, and then remove the tilt ram assembly 1. Cylinder-end screw wrench 2: 5. Remove the absorber valves d. 90890-06568 2. Drain the PTT fluid. 3. Cover the PTT cylinder opening with a rag 3, and then blow compressed air through the hole b to remove the free piston 4.
  • Page 365 BRKT Bracket unit 4. Install the balls f, absorber valve pins g, springs h, and balls k. 5. Install the washer m, and then tighten the tilt piston bolt n to the specified torque. Assembling the PTT cylinder Lubricate the parts with ATF Dexron II during assembly.
  • Page 366 PTT cylinder 11. Tighten the tilt cylinder end screw c to Recommended PTT fluid: ATF Dexron II the specified torque. 8. Install a new O-ring 5 to the free piston 6, and then install the free piston 6 into the cylinder 7. Cylinder-end screw wrench 8: 90890-06568 9.
  • Page 367 BRKT Bracket unit 3. Remove the reservoir cap 2, and then check the fluid level in the reservoir. Battery PTT motor lead terminal Green (G) Down Blue (L) 6. Reverse the PTT motor lead connections between the battery terminals to fully extend the tilt ram.
  • Page 368 PTT cylinder 7. Repeat steps 5–6 in to fully extend and retract the tilt ram 4 to 5 times. 8. Fully extend the tilt ram. 9. Remove the reservoir cap, and then check the fluid level in the reservoir. WARNING! Make sure that the tilt ram is fully extended when removing the reservoir cap.
  • Page 369 Maintenance Outline ..................10-1 Maintenance interval chart ............10-1 Predelivery check ..............10-3 Checking the battery ..............10-3 Checking the cooling water pilot hole........10-3 Checking the engine oil level............ 10-4 Checking the engine start button or switch and engine shut-off switch............10-4 Checking the fuel system ............
  • Page 370 Adjusting the throttle link rod and throttle cable ..... 10-15 Checking the top cowling ............10-15 Checking the valve clearance ..........10-16 Checking the water pump............10-16...

  • Page 371: Outline

    Maintenance Outline • To obtain long product life, Selva strongly recommends that the specified periodic checks and maintenance be performed according to the maintenance interval chart. • If replacement parts are necessary, use only genuine Selva parts of equivalent design and quality.
  • Page 372 Outline Initial Every Item Actions 20 hours 100 hours 300 hours 500 hours page (3 months) (1 year) (3 years) (5 years) Fuel pump Check/replace Fuel/oil leakage Check Gear oil Replace 10-12 Greasing points Lubricate 10-14 Impeller/water pump Check/replace housing Impeller/water pump Replace housing...

  • Page 373: Predelivery Check

    Maintenance Predelivery check To make the delivery process smooth and efficient, complete the predelivery checks as explained in the following procedures. Checking the battery Battery electrolyte is dangerous; it con- tains sulfuric acid, which is poisonous and highly caustic. Always follow these 2.

  • Page 374: Checking The Engine Oil Level

    Predelivery check Checking the engine oil level È 1. Put the outboard motor in an upright position. NOTICE: If the motor is not level, the oil level indicated on the dip- stick may not be accurate. 2. Start the engine and warm it up for 5–10 minutes.

  • Page 375: Checking The Fuel System

    Maintenance Checking the gear oil level É START 1. Put the outboard motor in an upright position. 2. Remove the check screw 1, and then check the gear oil level. È Tiller handle model É Remote control model 3. Check that the engine stops when the clip is pulled from the engine shut-off switch.

  • Page 376: Checking The Outboard Motor Mounting Height

    Predelivery check 2. Check that the throttle operates smoothly Checking the PTT system (PTT when the throttle grip is turned from the model) fully closed position to the fully open 1. Check that the outboard motor tilts up position. (Tiller handle model) and down smoothly when operating the Check that the throttle operates smoothly PTT switch.

  • Page 377: Checking The Throttle Cable And Shift Cable

    Maintenance É È Tiller handle model TIP: É Remote control model • Tighten or loosen the friction adjusting nut with the steering lock lever in the position 3. Check that the shift link lever 2 is in the N position. (Remote control model) •...

  • Page 378: Test Run

    Predelivery check 3. Move the tilt lock lever 1 to the lock position b, slightly tilt the outboard motor FAST up, and then fully tilt it down. Check that the outboard motor tilts down smoothly START and automatically locks in the fully tilted down position.

  • Page 379: Break-In

    Maintenance Break-in TIP: Operate the engine under load (in gear with a When using the flushing device (flushing propeller installed) for 10 hours as follows: hose joint adapter), flush the cooling water 1. For the 1st hour a of operation: passages without starting the engine.

  • Page 380: Checking The Engine Idle Speed

    Predelivery check / General periodic maintenance 4. Install the water inlet covers 1 and trim Digital tachometer 1: 90890-06760 tab 2 (high thrust model), and then tighten the inlet cover screw 3 to the Engine idle speed: 925–1025 r/min specified torque. 4.

  • Page 381: Checking The Engine Oil Level

    Maintenance 1. Place the outboard motor in an upright Recommended engine oil: position. NOTICE: If the outboard 4-stroke motor oil with combinations of motor is not level, the oil level indi- the following SAE and API oil classifica- cated on the dipstick may not be tions: accurate.

  • Page 382: Replacing The Oil Filter

    General periodic maintenance Replacing the oil filter Recommended engine oil: 1. Extract the engine oil using an oil 4-stroke motor oil with combinations of changer. See steps 1–4 in “Changing the the following SAE and API oil classifica- engine oil” (10-10). tions: API: SE, SF, SG, SH, SJ, SL 2.

  • Page 383: Checking The Gear Oil Level

    Maintenance 3. Remove the drain screw 2 and gasket 3. NOTICE: If there is an excessive quantity of metal particles on the mag- netic gear oil drain screw 2, this can indicate lower unit problem. 4. Remove the check screw 4 and gasket 5 and let the oil drain completely.

  • Page 384: Lubricating The Outboard Motor

    General periodic maintenance Lubricating the outboard motor 3. Apply corrosion resistant grease to the specified area. 1. Apply water resistant grease to the spec- ified areas. È É È É Checking the propeller 1. Check the propeller. See “Checking the propeller”...

  • Page 385: Checking The Ptt Operation

    Maintenance 2. Remove the reservoir cap 2 and O-ring 3, and then check the fluid level in the reservoir. WARNING! Make sure that the PTT ram is fully extended when removing the reservoir cap. 3. Check the PTT unit for fluid leakage. Adjusting the shift cable 1.

  • Page 386: Checking The Valve Clearance

    General periodic maintenance 2. Loosen the nuts 1. 3. Move the hook 2 up or down slightly to adjust its position. TIP: • To loosen the fitting, move the hook 2 in direction a. • To tighten the fitting, move the hook 2 in direction b.
  • Page 387 Index Break-in ............ 10-9 Abbreviation ..........0-5 Acceleration ignition timing control .....2-5 Camshaft and valve........7-37 Acceleration pump ........2-14 Carburetor ........2-13 6-10 Adjusting the forward CDI unit coupler layout ....... 5-9 gear shim thickness (T1)......8-63 Changing the engine oil......10-10 Adjusting the pulser coil air gap ....7-2 Changing the gear oil ......
  • Page 388 Index Checking the engine Checking the piston ring start button or switch and side clearance ........7-58 engine shut-off switch ....10-4 10-12 Checking the Prime Start....5-15 6-13 Checking the engine start switch Checking the propeller... 8-3 8-35 10-14 (remote control model)......5-17 Checking the propeller shaft....8-9 8-39 Checking the exhaust cover......7-51...
  • Page 389 Index Cold and warm engine ignition Engine speed control system ..... 1-9 timing control..........2-6 Exhaust cover........... 7-49 Exterior Kingfish 25 E.ST......3-4 Cooling system .........2-11 Exterior Kingfish 25 ........3-5 Crankcase assembly.........1-17 Exterior Kingfish 25 E.ST.PT....... 3-2 Crate top cover pictograph description ..3-9 Cylinder block ...........7-54...
  • Page 390 Index Installing the propeller shaft housing assembly ......8-19 8-48 Non-reusable part........0-3 Installing the PTT motor......9-65 Installing the PTT unit .......9-59 Installing the remote control box and Oil pan and exhaust manifold ....9-32 tachometer (remote control model)..3-15 Oil pan and exhaust manifold Installing the shift cable and (high thrust model)........
  • Page 391 Index Removing the power unit Steering arm (high thrust model) ....9-43 (remote control model)......7-14 Steering friction (tiller handle model) ..9-8 Removing the power unit Swivel bracket (manual tilt model) .... 9-50 (tiller handle model) ........7-16 Symbol............0-6 Removing the propeller System diagram.....
  • Page 392 Appendix Wiring diagram ................A-1 How to use the wiring diagram ........... A-1...
  • Page 393 Wiring diagram How to use the wiring diagram Legend symbols in the wiring diagrams 1 Double colors wire. 2 No wire connector. Color Code : Black : Brown : Green : Blue : Light green : Orange : Pink : Red : Sky blue : White B/R : Black/Red...
  • Page 396 Kingfish 25 Starter motor È Starter relay Battery Charge coil Power bobbin Lighting coil Rectifier Regulator PTT relay Fuse (30A) Pulser coil CDI unit Fuse (20A) Thermo sensor pressure switch Alert indicator Ignition coil PTT motor Spark plug Engine Shut-off switch...
  • Page 397 Color Code : Black : Brown : Green : Blue : Light green : Orange : Pink : Red : Sky blue : White B/R : Black/Red B/Y : Black/Yellow Br/W : Brown/White G/R : Green/Red P/B : Pink/Black P/W : Pink/White W/R : White/Red Y/B : Yellow/Black Y/R : Yellow/Red...
  • Page 398 Kingfish 25 E.PT. / E.ST.PT. Starter motor Starter relay Battery Charge coil Power bobbin Lighting coil Rectifier Regulator È PTT relay Fuse (30A) Pulser coil CDI unit Fuse (20A) Thermo sensor pressure switch Alert indicator Ignition coil PTT motor Spark plug Sb R É...

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