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Yamaha Z200N Service Manual

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Z200N, LZ200N

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Summary of Contents for Yamaha Z200N

Page 1 Z200N, LZ200N...
Page 2 PREFACE...
Page 3 HOW TO USE THIS MANUAL MANUAL FORMAT MODEL INDICATION ILLUSTRATIONS CROSS REFERENCES...
Page 4 IMPORTANT INFORMATION...
Page 5: How To Use This Manual
HOW TO USE THIS MANUAL...
Page 6 SYMBOLS...
Page 7 CONTEXT...
Page 8: Chapter 1. General Information
CHAPTER 1. GENERAL INFORMATION...
Page 9 IDENTIFICATION SERIAL NUMBER STARTING SERIAL NUMBERS...
Page 10 SAFETY WHILE WORKING FIRE PREVENTION VENTILATION SELF-PROTECTION OILS, GREASES AND SEALING FLUIDS...
Page 11: Good Working Practices
GOOD WORKING PRACTICES...
Page 12: Disassembly And Assembly
DISASSEMBLY AND ASSEMBLY...
Page 13 SPECIAL TOOLS MEASURING...
Page 16: Removing And Installing
REMOVING AND INSTALLING...
Page 19: Chapter 2. Specifications
CHAPTER 2. SPECIFICATIONS...
Page 20: General Specifications
GENERAL SPECIFICATIONS...
Page 22 MAINTENANCE SPECIFICATIONS POWER UNIT...
Page 24 LOWER UNIT ELECTRICAL...
Page 28 DIMENSIONS...
Page 30 TIGHTENING TORQUES SPECIFIED TORQUES...
Page 32: General Torques
GENERAL TORQUES...
Page 33: Chapter 3. Periodic Inspections And Adjustments
CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS...
Page 35: Maintenance Interval Chart
MAINTENANCE INTERVAL CHART...
Page 37 TOP COWLING CHECKING THE TOP COWLING FIT FUEL SYSTEM CHECKING THE FUEL LINE...
Page 38: Checking The Fuel Filter
CHECKING THE FUEL FILTER...
Page 39 MEASURING THE FUEL PRESSURE (MEDIUM-PRESSURE FUEL LINE) CHECKING THE FUEL PRESSURE (MECHANICAL FUEL PUMP)
Page 40 CHECKING THE MECHANICAL FUEL PUMP OIL LEVEL CHANGING THE MECHANICAL FUEL PUMP OIL...
Page 41 CONTROL SYSTEM SYNCHRONIZING THE THROTTLE VALVES...
Page 42: Adjusting The Throttle Position Sensor
ADJUSTING THE THROTTLE POSITION SENSOR...
Page 43: Adjusting The Engine Idling Speed
ADJUSTING THE ENGINE IDLING SPEED...
Page 44 ADJUSTING THE REMOTE. CONTROL SHIFT CABLE ADJUSTING THE REMOTE CONTROL THROTTLE CABLE...
Page 45: Checking The Drive Belt
CHECKING THE DRIVE BELT...
Page 46 ADJUSTING THE CRANK POSITION SENSOR COOLING SYSTEM CHECKING THE COOLING WATER DISCHARGE OIL INJECTION SYSTEM CHECKING THE OIL STRAINER...
Page 47 SYNCHRONIZING THE OIL PUMP...
Page 48 AIR BLEEDING THE OIL INJECTION SYSTEM CHECKING THE ELECTRIC OIL PUMP...
Page 49 POWER TRIM AND TILT SYSTEM CHECKING THE POWER TRIM AND TILT FLUID LEVEL...
Page 50 ADJUSTING THE TRIM SENSOR CAM LOWER UNIT CHECKING THE GEAR OIL LEVEL...
Page 51: Changing And Checking The Gear Oil
CHANGING AND CHECKING THE GEAR OIL...
Page 52 CHECKING THE LOWER UNIT (FOR AIR LEAKS) GENERAL CHECKING THE ANODES...
Page 53: Checking The Battery
CHECKING THE BATTERY...
Page 54: Checking The Spark Plugs
CHECKING THE SPARK PLUGS...
Page 56: Lubrication Points
LUBRICATION POINTS...
Page 57: Chapter 4. Fuel System
CHAPTER 4. FUEL SYSTEM...
Page 59 FLYWHEEL MAGNET ASSEMBLY COVER REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY COVER...
Page 60 MEDIUM-PRESSURE FUEL LINE REMOVING/INSTALLING THE MEDIUM-PRESSURE FUEL LINE...
Page 63 REDUCING THE FUEL PRESSURE (MEDIUM-PRESSURE FUEL LINE)
Page 64 DISCONNECTING THE FUEL HOSE JOINT CHECKING THE PRESSURE REGULATOR...
Page 65 VAPOR SEPARATOR REMOVING/INSTALLING THE VAPOR SEPARATOR...
Page 67 REMOVING THE HOSE CLAMPS INSTALLING THE HOSE CLAMPS...
Page 68: Disassembling/Assembling The Vapor Separator
DISASSEMBLING/ASSEMBLING THE VAPOR SEPARATOR...
Page 70 REMOVING THE ELECTRIC FUEL PUMP FILTER INSTALLING THE ELECTRIC FUEL PUMP FILTER...
Page 71: Removing/Installing The Pressure Regulator
REMOVING/INSTALLING THE PRESSURE REGULATOR...
Page 73 ELECTRIC FUEL PUMP DISASSEMBLING/ASSEMBLING THE ELECTRIC FUEL PUMP...
Page 76 THROTTLE CONTROL LEVER CAM REMOVING/INSTALLING THE THROTTLE CONTROL LEVER CAM...
Page 77 THROTTLE POSITION SENSOR AND AIR TEMPERATURE SENSOR REMOVING/INSTALLING THE THROTTLE POSITION SENSOR AND AIR TEMPERATURE SENSOR...
Page 79: Installing The Throttle Position Sensor
INSTALLING THE THROTTLE POSITION SENSOR...
Page 80 DRIVE BELT REMOVING/INSTALLING THE DRIVE BELT...
Page 82 REMOVING THE DRIVE SPROCKET REMOVING THE DRIVEN SPROCKET INSTALLING THE DRIVEN SPROCKET...
Page 83 INSTALLING THE DRIVE SPROCKET INSTALLING THE DRIVE BELT...
Page 84 INJECTOR DRIVER REMOVING/INSTALLING THE INJECTOR DRIVER...
Page 86 REMOVING THE INJECTOR DRIVER COUPLER...
Page 87 DISASSEMBLING/ASSEMBLING THE INJECTOR DRIVER...
Page 88 HIGH-PRESSURE FUEL LINE ASSEMBLY REMOVING/INSTALLING THE HIGH-PRESSURE FUEL LINE ASSEMBLY...
Page 91 DISASSEMBLING/ASSEMBLING THE HIGH-PRESSURE FUEL LINE ASSEMBLY...
Page 94 REMOVING THE HOSE CLAMPS INSTALLING THE HOSE CLAMPS...
Page 95 MECHANICAL FUEL PUMP DISASSEMBLING/ASSEMBLING THE MECHANICAL FUEL PUMP BODY...
Page 98 DISASSEMBLING/ASSEMBLING THE MECHANICAL FUEL PUMP ASSEMBLY...
Page 101 LOW-PRESSURE FUEL LINE REMOVING/INSTALLING THE LOW-PRESSURE FUEL LINE...
Page 102: Disassembling/Assembling The Low-Pressure Fuel Line
DISASSEMBLING/ASSEMBLING THE LOW-PRESSURE FUEL LINE...
Page 103: Checking The Check Valve
CHECKING THE CHECK VALVE...
Page 104 FUEL FILTER DISASSEMBLING/ASSEMBLING THE FUEL FILTER...
Page 106 FUEL PUMP DISASSEMBLING/ASSEMBLING THE FUEL PUMP...
Page 108: Checking The Fuel Pumps
CHECKING THE FUEL PUMPS...
Page 109 OIL INJECTION SYSTEM REMOVING/INSTALLING THE OIL INJECTION SYSTEM...
Page 111 DISASSEMBLING/ASSEMBLING THE OIL INJECTION SYSTEM...
Page 113 CHECKING THE CHECK VALVE...
Page 114 OIL TANK DISASSEMBLING/ASSEMBLING THE OIL TANK...
Page 115: Chapter 5. Power Unit
CHAPTER 5. POWER UNIT...
Page 117 FLYWHEEL MAGNET ASSEMBLY REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY...
Page 118: Removing The Flywheel Magnet Assembly
REMOVING THE FLYWHEEL MAGNET ASSEMBLY...
Page 119: Installing The Flywheel Magnet Assembly
INSTALLING THE FLYWHEEL MAGNET ASSEMBLY...
Page 120 POWER UNIT DISCONNECTING/CONNECTING THE LEADS...
Page 122: Disconnecting/Connecting The Hoses
DISCONNECTING/CONNECTING THE HOSES...
Page 123 REMOVING/INSTALLING THE EXHAUST EXPANSION CHAMBER...
Page 125 INSTALLING THE APRON...
Page 126: Removing/Installing The Power Unit
REMOVING/INSTALLING THE POWER UNIT...
Page 127 SUSPENDING THE POWER UNIT INSTALLING THE POWER UNIT...
Page 128 STATOR ASSEMBLY REMOVING/INSTALLING THE STATOR ASSEMBLY...
Page 130 CONTROL UNIT REMOVING/INSTALLING THE CONTROL UNIT ASSEMBLY...
Page 132 FUSE HOLDER REMOVING/INSTALLING THE FUSE HOLDER...
Page 133 DISASSEMBLING/ASSEMBLING THE FUSE HOLDER...
Page 134 JUNCTION BOX ASSEMBLY REMOVING/INSTALLING THE JUNCTION BOX ASSEMBLY...
Page 137: Disassembling/Assembling The Junction Box Assembly
DISASSEMBLING/ASSEMBLING THE JUNCTION BOX ASSEMBLY...
Page 139 WIRE HARNESSES REMOVING/INSTALLING THE MAIN WIRE HARNESS...
Page 141 REMOVING/INSTALLING THE SUB WIRE HARNESS...
Page 142 REMOVING/INSTALLING THE INJECTOR WIRE HARNESS...
Page 144 STARTER MOTOR REMOVING/INSTALLING THE STARTER MOTOR...
Page 145 OXYGEN DENSITY SENSOR REMOVING/INSTALLING THE OXYGEN DENSITY SENSOR...
Page 147 INSTALLING THE OXYGEN DENSITY SENSOR...
Page 148 REED VALVES REMOVING/INSTALLING THE REED VALVES...
Page 150 CHECKING THE REED VALVE ASSEMBLY...
Page 151 EXTERNAL FITTINGS REMOVING/INSTALLING THE EXTERNAL FITTINGS...
Page 154 CYLINDER HEAD COVERS REMOVING/INSTALLING THE CYLINDER HEAD COVERS...
Page 156 CHECKING THE THERMOSTATS...
Page 157 CYLINDER HEADS REMOVING/INSTALLING THE CYLINDER HEADS...
Page 159: Checking The Cylinder Heads
CHECKING THE CYLINDER HEADS...
Page 160 EXHAUST COVERS REMOVING/INSTALLING THE EXHAUST COVERS...
Page 162: Checking The Pressure Control Valve
CHECKING THE PRESSURE CONTROL VALVE...
Page 163 CRANKCASE REMOVING/INSTALLING THE CRANKCASE...
Page 165 ASSEMBLING THE OIL SEAL HOUSING INSTALLING THE CRANKCASE...
Page 166 CYLINDER BODY ASSEMBLY DISASSEMBLING/ASSEMBLING THE CYLINDER BODY ASSEMBLY...
Page 169 DISASSEMBLING/ASSEMBLING THE PISTON AND CONNECTING ROD ASSEMBLIES...
Page 170 DISASSEMBLING/ASSEMBLING THE CRANKSHAFT ASSEMBLY...
Page 171 DISASSEMBLING THE UPPER BEARING HOUSING REMOVING THE BEARING AND OIL PUMP DRIVE GEAR...
Page 172: Checking The Cylinder Body
CHECKING THE CYLINDER BODY...
Page 173 CHECKING THE PISTONS CALCULATING THE PISTON-TO-CYLINDER CLEARANCE...
Page 174 CHECKING THE PISTON PINS AND SMALL-END BEARINGS CHECKING THE PISTON RINGS...
Page 175 CHECKING THE OIL PUMP DRIVEN GEAR...
Page 176 CHECKING THE LABYRINTH RINGS CHECKING THE CRANKSHAFT...
Page 177 INSTALLING THE OIL PUMP DRIVE GEAR INSTALLING THE BEARING INSTALLING THE PISTON RINGS AND PISTON...
Page 178 ASSEMBLING THE UPPER BEARING HOUSING...
Page 179 INSTALLING THE CRANKSHAFT ASSEMBLY INSTALLING THE PISTON AND CONNECTING ROD ASSEMBLIES...
Page 180: Chapter 6. Lower Unit
CHAPTER 6. LOWER UNIT...
Page 184 LOWER UNIT (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE LOWER UNIT...
Page 186 REMOVING THE PROPELLER REMOVING THE TRIM TAB CHECKING THE PROPELLER...
Page 187: Installing The Propeller
INSTALLING THE PROPELLER...
Page 188 WATER PUMP (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE WATER PUMP...
Page 190 CHECKING THE IMPELLER HOUSING CHECKING THE IMPELLER AND IMPELLER HOUSING CUP CHECKING THE WOODRUFF KEY INSTALLING THE IMPELLER AND IMPELLER HOUSING...
Page 192 SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY...
Page 193 REMOVING THE SHIFT ROD ASSEMBLY...
Page 194 PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY...
Page 196 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING...
Page 197: Disassembling/Assembling The Propeller Shaft Assembly
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY...
Page 198 REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY DISASSEMBLING THE PROPELLER SHAFT HOUSING...
Page 199 CHECKING THE REVERSE GEAR CHECKING THE BEARINGS CHECKING THE PROPELLER SHAFT HOUSING...
Page 200 CHECKING THE DOG CLUTCH CHECKING THE PROPELLER SHAFT ASSEMBLING THE PROPELLER SHAFT HOUSING...
Page 201: Installing The Propeller Shaft Housing Assembly
INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY...
Page 202 DRIVE SHAFT (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE DRIVE SHAFT...
Page 204 REMOVING THE PINION DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY DISASSEMBLING THE FORWARD GEAR ASSEMBLY...
Page 205 CHECKING THE PINION CHECKING THE DRIVE SHAFT CHECKING THE DRIVE SHAFT HOUSING CHECKING THE BEARINGS ASSEMBLING THE FORWARD GEAR ASSEMBLY...
Page 206 ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY...
Page 207: Installing The Pinion
INSTALLING THE PINION...
Page 208 LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS) DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY...
Page 209 DISASSEMBLING THE LOWER CASE ASSEMBLY CHECKING THE DRIVE SHAFT SLEEVE CHECKING THE NEEDLE BEARING ASSEMBLING THE LOWER CASE ASSEMBLY...
Page 211 LOWER UNIT (COUNTER ROTATION MODELS) REMOVING/INSTALLING THE LOWER UNIT...
Page 213 REMOVING THE PROPELLER REMOVING THE TRIM TAB CHECKING THE PROPELLER...
Page 214 INSTALLING THE PROPELLER...
Page 215 WATER PUMP (COUNTER ROTATION MODELS) REMOVING/INSTALLING THE WATER PUMP...
Page 217 CHECKING THE IMPELLER HOUSING CHECKING THE IMPELLER AND IMPELLER HOUSING CUP CHECKING THE WOODRUFF KEY INSTALLING THE IMPELLER AND IMPELLER HOUSING...
Page 219 SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS) REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY...
Page 220 REMOVING THE SHIFT ROD ASSEMBLY...
Page 221 PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS) REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY...
Page 222: Disassembling/Assembling The Propeller Shaft Housing Assembly
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY...
Page 224 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY...
Page 225 REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY REMOVING THE PROPELLER SHAFT ASSEMBLY...
Page 226 DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY DISASSEMBLING THE FORWARD GEAR ASSEMBLY CHECKING THE FORWARD GEAR CHECKING THE BEARINGS CHECKING THE PROPELLER SHAFT HOUSING...
Page 227 CHECKING THE DOG CLUTCH CHECKING THE PROPELLER SHAFT ASSEMBLING THE PROPELLER SHAFT HOUSING...
Page 228 INSTALLING THE PROPELLER SHAFT ASSEMBLY INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY...
Page 229 DRIVE SHAFT (COUNTER ROTATION MODELS) REMOVING/INSTALLING THE DRIVE SHAFT...
Page 231 REMOVING THE PINION REMOVING THE REVERSE GEAR DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY DISASSEMBLING THE REVERSE GEAR ASSEMBLY...
Page 232 CHECKING THE PINION CHECKING THE DRIVE SHAFT CHECKING THE DRIVE SHAFT HOUSING CHECKING THE BEARINGS...
Page 233 ASSEMBLING THE REVERSE GEAR ASSEMBLY ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY...
Page 234 INSTALLING THE REVERSE GEAR INSTALLING THE PINION...
Page 235 LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS) DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY...
Page 236 DISASSEMBLING THE LOWER CASE ASSEMBLY CHECKING THE DRIVE SHAFT SLEEVE CHECKING THE NEEDLE BEARING ASSEMBLING THE LOWER CASE ASSEMBLY...
Page 238 SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)
Page 239: Selecting The Pinion Shims
SELECTING THE PINION SHIMS...
Page 241: Selecting The Forward Gear Shims
SELECTING THE FORWARD GEAR SHIMS...
Page 243: Selecting The Reverse Gear Shims
SELECTING THE REVERSE GEAR SHIMS...
Page 245 SHIMMING (REGULAR ROTATION MODELS) (FOR WORLDWIDE)
Page 246 SELECTING THE PINION SHIMS...
Page 248 SELECTING THE FORWARD GEAR SHIMS...
Page 249 SELECTING THE REVERSE GEAR SHIMS...
Page 251 BACKLASH (REGULAR ROTATION MODELS) MEASURING THE FORWARD GEAR BACKLASH...
Page 253: Measuring The Reverse Gear Backlash
MEASURING THE REVERSE GEAR BACKLASH...
Page 255 SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)
Page 256 SELECTING THE PINION SHIMS...
Page 258 SELECTING THE REVERSE GEAR SHIMS...
Page 259 SELECTING THE FORWARD GEAR SHIMS...
Page 261: Selecting The Propeller Shaft Shims
SELECTING THE PROPELLER SHAFT SHIMS...
Page 262 SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE)
Page 263 SELECTING THE PINION SHIMS...
Page 265 SELECTING THE REVERSE GEAR SHIMS...
Page 266 SELECTING THE FORWARD GEAR SHIMS...
Page 268 SELECTING THE PROPELLER SHAFT SHIMS...
Page 269 BACKLASH (COUNTER ROTATION MODELS) MEASURING THE FORWARD GEAR BACKLASH...
Page 270 MEASURING THE REVERSE GEAR BACKLASH...
Page 273: Chapter 7. Bracket Unit
CHAPTER 7. BRACKET UNIT...
Page 275 BOTTOM COWLING REMOVING/INSTAING THE BOTTOM COWLING...
Page 277 DISASSEMBLING/ASSEMBLING THE BOTTOM COWLING...
Page 280 SHIFT ROD ASSEMBLY DISASSEMBLING/ASSEMBLING THE SHIFT ROD ASSEMBLY...
Page 281 UPPER CASE ASSEMBLY REMOVING/INSTALLING THE UPPER CASE ASSEMBLY...
Page 283: Disassembling/Assembling The Upper Case Assembly
DISASSEMBLING/ASSEMBLING THE UPPER CASE ASSEMBLY...
Page 285 EXHAUST MANIFOLD ASSEMBLY DISASSEMBLING/ASSEMBLING THE EXHAUST MANIFOLD ASSEMBLY...
Page 287 CLAMP BRACKETS REMOVING/INSTALLING THE CLAMP BRACKETS...
Page 289 STEERING ARM REMOVING/INSTALLING THE STEERING ARM...
Page 290 SWIVEL BRACKET ASSEMBLY DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET ASSEMBLY...
Page 292 POWER TRIM AND TILT UNIT REMOVING/INSTALLING THE POWER TRIM AND TILT UNIT...
Page 294 REMOVING THE POWER TRIM AND TILT UNIT BLEEDING THE POWER TRIM AND TILT UNIT (ON OUTBOARD)
Page 296 RESERVOIR AND POWER TRIM AND TILT MOTOR REMOVING/INSTALLING THE RESERVOIR AND POWER TRIM AND TILT MOTOR...
Page 297 CHECKING THE RESERVOIR CHECKING THE GEAR PUMP HOUSING FILTER...
Page 298: Installing The Power Trim And Tilt Motor
INSTALLING THE POWER TRIM AND TILT MOTOR...
Page 299 FILLING THE RESERVOIR BLEEDING THE POWER TRIM AND TILT UNIT...
Page 301 MEASURING THE HYDRAULIC PRESSURE...
Page 304 TILT RAM ASSEMBLY AND GEAR PUMP UNIT REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND GEAR PUMP UNIT...
Page 306 REMOVING THE TILT RAM END SCREW REMOVING THE GEAR PUMP UNIT DISASSEMBLING THE GEAR PUMP UNIT...
Page 307 CHECKING THE TILT RAM CHECKING THE GEAR PUMP UNIT...
Page 308 ASSEMBLING THE GEAR PUMP UNIT...
Page 309 INSTALLING THE GEAR PUMP UNIT INSTALLING THE TILT RAM ASSEMBLY...
Page 311 TRIM RAM ASSEMBLIES AND FREE PISTON REMOVING/INSTALLING THE TRIM RAM ASSEMBLIES AND FREE PISTON...
Page 312 REMOVING THE TRIM RAM END SCREWS REMOVING THE FREE PISTON...
Page 313 CHECKING THE TRIM RAMS CHECKING THE FREE PISTON CHECKING THE TRIM RAM CYLINDERS INSTALLING THE FREE PISTON...
Page 314: Installing The Trim Rams
INSTALLING THE TRIM RAMS...
Page 316: Chapter 8. Electrical Systems
CHAPTER 8. ELECTRICAL SYSTEMS...
Page 319: Electrical Components
ELECTRICAL COMPONENTS ( P o r t v i e w )
Page 320 (Starboard view)
Page 321 (Junction box assembly)
Page 322 ( A f t v i e w )
Page 323 (Top view)
Page 324: Wire Harness
WIRE HARNESS...
Page 327 ELECTRICAL COMPONENTS ANALYSIS DIGITAL CIRCUIT TESTER MEASURING THE PEAK VOLTAGE PEAK VOLTAGE ADAPTOR...
Page 328: Measuring A Low Resistance
MEASURING A LOW RESISTANCE...
Page 329: Ignition System
IGNITION SYSTEM...
Page 330: Checking The Ignition Spark Gap
CHECKING THE IGNITION SPARK GAP...
Page 331 CHECKING THE BATTERY CHECKING THE FUSES CHECKING THE FUSE HOLDER...
Page 332 MEASURING THE CONTROL UNIT OUTPUT PEAK VOLTAGE...
Page 333: Measuring The Pulser Coil Output Peak Voltage
MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE...
Page 334: Checking The Spark Plug Caps
CHECKING THE SPARK PLUG CAPS...
Page 335: Ignition Control System
IGNITION CONTROL SYSTEM...
Page 336 CHECKING THE BATTERY CHECKING THE FUSES CHECKING THE FUSE HOLDER MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE MEASURING THE CRANK POSITION SENSOR OUTPUT PEAK VOLTAGE...
Page 337 MEASURING THE ENGINE COOLING WATER TEMPERATURE SENSOR RESISTANCE CHECKING THE THERMO SWITCH CONTINUITY...
Page 338 CHECKING THE OIL LEVEL SENSOR CONTINUITY MEASURING THE THROTTLE POSITION SENSOR OUTPUT VOLTAGE...
Page 339: Checking The Shift Position Switch
CHECKING THE SHIFT POSITION SWITCH...
Page 340: Fuel Control System
FUEL CONTROL SYSTEM...
Page 342 CHECKING THE BATTERY CHECKING THE FUSES CHECKING THE FUSE HOLDER MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE MEASURING THE CRANK POSITION SENSOR OUTPUT PEAK VOLTAGE MEASURING THE THROTTLE POSITION SENSOR OUTPUT VOLTAGE MEASURING THE ENGINE COOLING WATER TEMPERATURE SENSOR RESISTANCE CHECKING THE ELECTRICAL OIL PUMP...
Page 343 CHECKING THE OXYGEN DENSITY SENSOR...
Page 344 CHECKING THE ATMOSPHERIC PRESSURE SENSOR...
Page 345: Checking The Intake Air Temperature Sensor
CHECKING THE INTAKE AIR TEMPERATURE SENSOR...
Page 346: Checking The Fuel Injectors
CHECKING THE FUEL INJECTORS...
Page 347 CHECKING THE FUEL PRESSURE SENSOR...
Page 348: Checking The Water Detection Switch
CHECKING THE WATER DETECTION SWITCH...
Page 349: Starting System
STARTING SYSTEM...
Page 350 CHECKING THE BATTERY CHECKING THE FUSES CHECKING THE FUSE HOLDER CHECKING THE WIRE HARNESS CONTINUITY CHECKING THE WIRE CONNECTIONS CHECKING THE STARTER RELAY...
Page 351 STARTER MOTOR DISASSEMBLING/ASSEMBLING THE STARTER MOTOR...
Page 355 REMOVING THE STARTER MOTOR PINION CHECKING THE STARTER MOTOR PINION CHECKING THE ARMATURE...
Page 356 MEASURING THE BRUSHES...
Page 357: Checking The Magnetic Switch Relay
CHECKING THE MAGNETIC SWITCH RELAY...
Page 359: Charging System
CHARGING SYSTEM...
Page 360 CHECKING THE BATTERY CHECKING THE FUSES CHECKING THE FUSE HOLDER MEASURING THE RECTIFIER/REGULATOR OUTPUT PEAK VOLTAGE...
Page 361 MEASURING THE LIGHTING COIL OUTPUT PEAK VOLTAGE...
Page 362: Oil Feed Pump Control System
OIL FEED PUMP CONTROL SYSTEM...
Page 363 CHECKING THE BATTERY CHECKING THE FUSES CHECKING THE FUSE HOLDER CHECKING THE OIL LEVEL SENSOR/SWITCH CONTINUITY...
Page 364 CHECKING THE EMERGENCY SWITCH CHECKING THE OIL PUMP (SUB-OIL TANK)
Page 365: Power Trim And Tilt System
POWER TRIM AND TILT SYSTEM...
Page 366 CHECKING THE BATTERY CHECKING THE FUSES CHECKING THE FUSE HOLDER CHECKING THE POWER TRIM AND TILT RELAY...
Page 367 CHECKING THE TRAILER SWITCH CONTINUITY MEASURING THE TRIM SENSOR RESISTANCE...
Page 368 POWER TRIM AND TILT MOTOR DISASSEMBLING/ASSEMBLING THE POWER TRIM AND TILT MOTOR...
Page 370 REMOVING THE STATOR REMOVING THE BRUSH CHECKING THE BRUSH...
Page 371: Checking The Armature
CHECKING THE ARMATURE...
Page 372 INSTALLING THE BRUSH INSTALLING THE ARMATURE INSTALLING THE STATOR...
Page 373: Chapter 9. Trouble Analysis
CHAPTER 9. TROUBLE ANALYSIS...
Page 374 TROUBLE ANALYSIS TROUBLE ANALYSIS CHART...
Page 378 SELF-DIAGNOSIS DIAGNOSIS CODE INDICATION DIAGNOSIS THE ELECTRONIC CONTROL SYSTEM...
Page 380 TROUBLE SHOOTING FOR HIGH-PRESSURE DIRECT INJECTION...
Page 383: Wiring Diagram
WIRING DIAGRAM...

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