Yamaha F80BETL Service Manual
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Yamaha F80BETL Service Manual

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F80B
F100D
SERVICE MANUAL
6D9-28197-3G-11

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Summary of Contents for Yamaha F80BETL

  • Page 1 F80B F100D SERVICE MANUAL 6D9-28197-3G-11...
  • Page 2 NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
  • Page 3 Contents General information INFO Specifications SPEC Periodic checks and adjustments Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT – Electrical systems ELEC Troubleshooting TRBL SHTG Index...

  • Page 5: Table Of Contents

    INFO General information How to use this manual ................. 1-1 Manual format.................... 1-1 Symbols..................... 1-2 Safety while working..................1-3 Fire prevention................... 1-3 Ventilation....................1-3 Self-protection ................... 1-3 Parts, lubricants, and sealants ..............1-3 Good working practices ................1-4 Disassembly and assembly ............... 1-4 Identification....................1-5 Applicable model ..................1-5 Serial number ....................

  • Page 6: How To Use This Manual

    INFO General information 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 information below as a guide for effective and quality service. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list.

  • Page 7: Symbols

    7 Apply Yamaha 4-stroke motor oil A Apply corrosion resistant grease 8 Apply gear oil (Yamaha grease D) 9 Apply water resistant grease (Yamaha grease A) B Apply low temperature resistant grease 0 Apply molybdenum disulfide grease (Yamaha grease C)

  • Page 8: Safety While Working

    Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the out- board motor. Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous.

  • Page 9: Good Working Practices

    Safety while working 6. Keep a supply of clean, lint-free cloths for Disassembly and assembly wiping up spills, etc. 1. Use compressed air to remove dust and dirt during disassembly. Good working practices Special service tools 2. Apply engine oil to the contact surfaces Use the recommended special service tools of moving parts before assembly.

  • Page 10: Identification

    INFO General information Identification Propeller selection Applicable model The performance of a boat and outboard motor will be critically affected by the size This manual covers the following model. and type of propeller you choose. Propellers Applicable model greatly affect boat speed, acceleration, engine life, fuel economy, and even boating F80BET, F100DET and steering capabilities.

  • Page 11: Selection

    Identification / Propeller selection / Predelivery checks Selection When the engine speed is at the full throttle operating range (5,000–6,000 r/min), the ideal propeller for the boat is one that pro- vides maximum performance in relation to boat speed and fuel consumption. Propeller size (in) Material 12 5/8 ×...

  • Page 12: Checking The Gear Oil Level

    INFO General information Checking the gear oil level NOTE: 1. Check the gear oil level. The optimum mounting height is affected by the combination of the boat and the outboard motor. To determine the optimum mounting height, test run the outboard motor at differ- ent heights.

  • Page 13: Checking The Steering System

    Predelivery checks S69J3370 S69J1210 WARNING Checking the power trim and tilt system The shift/throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) 1. Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit.

  • Page 14: Checking The Cooling Water Pilot Hole

    INFO General information 3. Check that the engine turns off when the Break-in engine stop lanyard is pulled from the During the test run, perform the break-in engine stop lanyard switch. operation in the following three stages. 1. One hour a at 2,000 r/min or at approxi- mately half throttle 2.
  • Page 15 SPEC Specifications General specifications................... 2-1 Maintenance specification ................2-3 Power unit....................2-3 Lower unit ....................2-6 Electrical ....................2-6 Dimensions....................2-9 Tightening torques..................2-11 Specified torques..................2-11 General torques..................2-13 6D93G11...

  • Page 16: Specifications

    SPEC Specifications General specifications Model Item Unit F80BET F100DET Dimension Overall length mm (in) 817 (32.2) Overall width mm (in) 479 (18.9) Overall height mm (in) 1,582 (62.3) mm (in) 1,710 (67.3) Boat transom height mm (in) 508 (20.0) mm (in) 635 (25.0) Weight (with aluminum propeller)
  • Page 17 General specifications Model Item Unit F80BET F100DET Fuel and oil Fuel type Regular unleaded gasoline (*1) Fuel minimum rating Engine oil 4-stroke motor oil Engine oil grade SE, SF, SG, SH, or SJ 10W-30 or 10W-40 Engine oil quantity (without oil filter replacement) L (US qt, 4.3 (4.55, 3.78) Imp qt)

  • Page 18: Maintenance Specification

    SPEC Specifications Maintenance specification Power unit Model Item Unit F80BET F100DET Power unit Minimum compression 860 (8.6, 124.7) (*1) pressure (kgf/cm , psi) (*2) Oil pressure 510 (5.1, 74.0) at engine idle speed (kgf/cm , psi) Cylinder head Warpage limit mm (in) 0.1 (0.0039) (lines indicate straightedge...
  • Page 19 Maintenance specification Model Item Unit F80BET F100DET Oil ring Dimension B mm (in) 2.38–2.48 (0.0937–0.0976) Dimension T mm (in) 2.40 (0.0945) End gap mm (in) 0.20–0.70 (0.0079–0.0276) Side clearance mm (in) 0.03–0.15 (0.0012–0.0059) Camshafts Intake (A) mm (in) 36.48–36.58 (1.4362–1.4402) Exhaust (A) mm (in) 36.90–37.06 (1.4528–1.4591)
  • Page 20 SPEC Specifications Model Item Unit F80BET F100DET Valve lifters Valve lifter outside diameter mm (in) 27.965–27.980 (1.1010–1.1016) Valve lifter-to-cylinder head mm (in) 0.020–0.056 (0.0008–0.0022) clearance Valve shims Valve shim thickness mm (in) 2.0–3.3 (0.08–0.13) (in 0.025 mm increments) Connecting rods Big end inside diameter mm (in) 47.025–47.045 (1.8514–1.8522)

  • Page 21: Lower Unit

    Maintenance specification Model Item Unit F80BET F100DET Oil pump Discharge L (US gal, 5.9 (1.559, 1.298) at 1,000 r/min at 97–103 °C (207–217 °F) Imp gal)/min with 10W-30 engine oil Pressure 118.0 (1.18, 17.1) at 1,000 r/min at 97–103 °C (207–217 °F) (kgf/cm , psi) with 10W-30 engine oil...
  • Page 22 SPEC Specifications Model Item Unit F80BET F100DET ECM output peak voltage (B/R, B/W – Ground) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Pulser coil output peak voltage (W/R, W/B – B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) 18.2 at 3,500 r/min (loaded)
  • Page 23 Maintenance specification Model Item Unit F80BET F100DET Charging system Fuse Stator coil output peak voltage (W – W) at cranking (unloaded) 12.4 at 1,500 r/min (unloaded) 45.3 at 3,500 r/min (unloaded) 98.3 Stator coil resistance (W – W) at 20 °C (68 °F) 0.24–0.36 Ω...

  • Page 24: Dimensions

    SPEC Specifications Dimensions Exterior mm (in) L : 998 (39.3) 527 (20.7) X: 1,115 (43.9) 171 (6.73) 651 (25.6) 62 (2.4) 164 (6.5) 12˚ 28 (1.1) 574 (22.6) S6D82010 6D93G11...
  • Page 25 Maintenance specification Clamp bracket mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 80 (3.1) 13 (0.5) 13 (0.5) 125.4 (4.9) 125.4 (4.9) S6D82020 2-10 6D93G11...
  • Page 26 SPEC Specifications Tightening torques Specified torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel system Fuel filter cup — Fuel pump mounting bolt Fuel pump screw Sensor assembly screw 0.37 Idle speed control screw 0.37 Fuel rail mounting bolt Throttle body mounting bolt Fuel cooler screw Float chamber screw...
  • Page 27 Tightening torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb 10.3 20.7 Cylinder head bolt 11.1 22.1 90° Spark plug — 18.4 Cylinder block plug 17.0 Oil filter joint — 36.1 Oil filter — 13.3 Exhaust cover bolt Anode screw Exhaust cover plug 40.6...
  • Page 28 SPEC Specifications Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Exhaust manifold bolt Steering arm stud bolt 14.8 Self-locking nut — 11.1 Trim sensor cam screw Power trim and tilt unit Reservoir cap — PTT motor bolt Gear pump bolt Gear pump housing bolt Relief valve cap bolt...
  • Page 29 Periodic checks and adjustments Special service tools ..................3-1 Maintenance interval chart................3-2 Top cowling ....................3-3 Checking the top cowling................3-3 Fuel system ....................3-3 Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) ....3-3 Checking the fuel filter ................3-3 Power unit.......................

  • Page 30: Special Service Tools

    Periodic checks and adjustments Special service tools Digital tachometer 90890-06760 Leakage tester 90890-06840 Oil filter wrench 64 90890-01426 6D93G11...

  • Page 31: Maintenance Interval Chart

    Special service tools / Maintenance interval chart Maintenance interval chart Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Initial Every Refer to Item Remarks 10 hours 50 hours 100 hours 200 hours...

  • Page 32: Top Cowling

    Periodic checks and adjustments Top cowling 2. Check the low-pressure fuel hose con- nections and fuel joint for leaks. Replace Checking the top cowling if necessary. Also, check the fuel filter 1, 1. Check the fitting by pushing the cowling fuel pump 2, strainer 3, and fuel cooler with both hands.

  • Page 33: Power Unit

    Top cowling / Fuel system / Power unit Power unit Checking the engine oil 1. Place the outboard motor in an upright position. 2. Remove the oil dipstick, wipe it clean, and then insert it back into the dipstick hole. 3.

  • Page 34: Replacing The Oil Filter

    Periodic checks and adjustments 2. Remove the oil dipstick and oil filler cap 7. Turn the engine off, and then check the oil level and correct it if necessary. Replacing the oil filter 1. Extract the engine oil with an oil changer or drain it.

  • Page 35: Checking The Timing Belt

    Power unit 2. While turning the flywheel magnet clock- wise, check the interior a and the exte- rior b of the timing belt for cracks, damage, or wear. Replace if necessary. S6D83070 NOTE: For replacement procedures, see Chapter 5, “Replacing the timing belt.” S6D83060 Oil filter: Checking the spark plugs...

  • Page 36: Checking The Thermostat

    Periodic checks and adjustments 5. Check the spark plug gap a. Adjust if out of specification. Specified spark plug: LFR5A-11 (NGK) Spark plug gap a: 1.0–1.1 mm (0.039–0.043 in) S6D83080 6. Install the spark plugs, tighten them fin- 3. Suspend the thermostat in a container of ger tight, then to the specified torque water.

  • Page 37: Checking The Cooling Water Passage

    Power unit / Control system Water Valve lift a temperature 0.05 mm 58–62 °C (0.0020 in) (136–144 °F) (valve begins to lift) above more than 70 °C (158 °F) 4.3 mm (0.17 in) 6. Install the thermostat and cover. Control system 7.
  • Page 38 Periodic checks and adjustments 3. Loosen the locknut 1, remove the clip 2, and then disconnect the throttle cable joint 3. 4. Loosen the locknut 4, and then discon- nect the throttle link rod joint 5 from the ball joint of the throttle body. S6D83110 8.

  • Page 39: Checking The Gear Shift Operation

    Control system 5. Align the alignment mark a on the bush- ing and alignment mark b on the bracket. S69J3370 WARNING The throttle cable joint must be screwed S6D81040 in a minimum of 8.0 mm (0.31 in) c. 6. Install the clip 4. 12.

  • Page 40: Bracket Unit

    Periodic checks and adjustments Bracket unit Checking the power trim and tilt operation 1. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation. Check the power trim and tilt fluid level if necessary. S6D83150 WARNING After tilting up the outboard motor, be...

  • Page 41: Lower Unit

    Bracket unit / Lower unit Lower unit Checking the gear oil level 1. Fully tilt the outboard motor down. 2. Remove the check screw 1, and then check the gear oil level in the lower case. 3. Check the oil for metal and discoloration, S60C3540 and its viscosity.

  • Page 42: Checking The Lower Unit For Air Leakage

    Periodic checks and adjustments 4. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible. Leakage tester: 90890-06840 2.

  • Page 43: General

    Lower unit / General General NOTE: Checking the anodes If it is necessary to disassemble the outboard 1. Check the anodes and trim tab for motor to check an anode, refer to the applica- scales, grease, or oil. Clean if necessary. ble disassembly procedure in this manual.

  • Page 44: Lubricating The Outboard Motor

    Periodic checks and adjustments 2. Check the specific gravity of the electro- Lubricating the outboard motor lyte. Fully charge the battery if out of 1. Apply water resistant grease to the areas specification. shown. WARNING Battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic.
  • Page 45 General S60C3710 NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the area shown. S6D83190 3. Apply corrosion resistant grease to the area shown. 3-16 6D93G11...
  • Page 46 Periodic checks and adjustments — MEMO — 3-17 6D93G11...
  • Page 47 FUEL Fuel system Special service tools ..................4-1 Hose routing ....................4-2 Fuel and blowby hoses................4-2 Fuel filter and fuel pump ................4-3 Checking the fuel pump................4-5 Disassembling the fuel pump ..............4-5 Checking the diaphragm and valves ............4-6 Assembling the fuel pump ................. 4-6 Intake manifold....................

  • Page 48: Fuel System

    FUEL Fuel system Special service tools Vacuum/pressure pump gauge set 90890-06756 Fuel pressure gauge 90890-06786 Fuel pressure gauge adapter B 90890-06942 6D93G11...

  • Page 49: Hose Routing

    Special service tools / Hose routing Hose routing Fuel and blowby hoses 1 Blowby hose 2 Fuel hose (primary pump-to-fuel filter) 3 Fuel hose (fuel filter-to-fuel pump) 4 Fuel hose (fuel pump-to-strainer) 5 Fuel hose (strainer-to-vapor separator) 6 High-pressure fuel hose (vapor separator-to-fuel rail) 7 Fuel hose (pressure regulator-to-fuel cooler) 8 Fuel hose (fuel cooler-to-vapor separator) 9 Canister hose (vapor separator-to-canister)

  • Page 50: Fuel Filter And Fuel Pump

    FUEL Fuel system Fuel filter and fuel pump · · · 10 N m (1.0 kgf m, 7.4 ft · · · m (0.3 kgf m, 2.2 ft S6D84020 Part name Q’ty Remarks Fuel filter assembly O-ring Not reusable Fuel filter element O-ring Not reusable Float...
  • Page 51 Fuel filter and fuel pump · · · m (0.4 kgf m, 3.0 ft S6D84030 Part name Q’ty Remarks Screw ø6 × 35 mm Cover Gasket Not reusable Fuel pump body 2 assembly Diaphragm Spring Fuel pump body 1 Spring Plunger 6D93G11...

  • Page 52: Checking The Fuel Pump

    FUEL Fuel system Checking the fuel pump 6. Apply the specified positive pressure and check that there is no air leakage. Disas- 1. Place a drain pan under the fuel hose semble the fuel pump if necessary. connections, and then disconnect the fuel hoses from the fuel pump.

  • Page 53: Checking The Diaphragm And Valves

    Fuel filter and fuel pump 3. Slowly let up on the plunger and dia- phragm, and then remove them. Checking the diaphragm and valves 1. Check the diaphragm for tears and the valves for cracks. Replace if necessary. Assembling the fuel pump NOTE: Clean the parts and soak the valves and the diaphragm in gasoline before assembly to...

  • Page 54: Intake Manifold

    FUEL Fuel system Intake manifold S6D94010 Part name Q’ty Remarks Intake silencer F80BET Bolt M6 × 80 mm Bushing Collar Intake manifold assembly Bolt M8 × 30 mm Collar Bolt M8 × 100 mm Spacer Bolt M6 × 45 mm Collar Holder Gasket...
  • Page 55 Intake manifold · · · 3.7 N m (0.37 kgf m, 2.7 ft · · · m (0.8 kgf m, 5.9 ft · · · m (0.8 kgf m, 5.9 ft S6D84050 Part name Q’ty Remarks Intake manifold Sensor assembly Screw ø5 ×...

  • Page 56: Checking The Throttle Position Sensor

    • If the throttle position sensor output voltage is out of specification, reinstall the throttle position sensor. • Measure the throttle position sensor output voltage using the Yamaha Diagnostic Sys- tem. • Do not turn the throttle stop screw a. Throttle position sensor output voltage at engine idle speed: 0.8–1.2 V...
  • Page 57 Intake manifold / Vapor separator Vapor separator S6D84070 Part name Q’ty Remarks Vapor separator Bolt M6 × 30 mm Grommet Collar Fuel hose Fuel inlet hose Hose Joint Hose Hose Hose Hose Clamp Clamp Quick connector Clamp Not reusable Plastic tie Not reusable 4-10 6D93G11...
  • Page 58 FUEL Fuel system · · · m (0.3 kgf m, 2.2 ft · · · 1.5 N m (0.15 kgf m, 1.1 ft · · · m (0.3 kgf m, 2.2 ft · · · m (0.4 kgf m, 3.0 ft S6D84080 Part name Q’ty...

  • Page 59: Vapor Separator

    Vapor separator · · · m (0.5 kgf m, 3.7 ft · · · 10 N m (1.0 kgf m, 7.4 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft ·...

  • Page 60: Reducing The Fuel Pressure

    FUEL Fuel system Reducing the fuel pressure CAUTION: 1. Remove the cap 1. • Do not rotate the quick connector tab 1 2. Cover the pressure check valve a of the past the stopper position a, otherwise it vapor separator with a rag, and then could be damaged.

  • Page 61: Checking The Pressure Regulator

    Vapor separator Fuel pressure (reference data): 230 kPa (2.3 kgf/cm , 33.4 psi) WARNING • Before measuring the fuel pressure, make sure that the drain screw is tight- ened securely. • Do not loosen the drain screw while S6D84190 measuring the fuel pressure. Loosening WARNING the drain screw can cause fuel to spray out creating a fire hazard.

  • Page 62: Draining The Fuel

    FUEL Fuel system 4. Disconnect the pressure regulator hose, WARNING and then connect the special service tools to the pressure regulator. • Before measuring the fuel pressure, make sure that the drain screw is tight- ened securely. • Do not loosen the drain screw while measuring the fuel pressure.

  • Page 63: Removing The Fuel Hose Clamp

    Vapor separator S6D84100 WARNING WARNING Reduce the fuel pressure before loosen- Do not reuse the fuel hose clamp, always ing the vapor separator drain screw, or replace it with a new one. pressurized fuel will spray out and may result in serious injury. Disassembling the vapor separator 1.

  • Page 64: Assembling The Vapor Separator

    FUEL Fuel system 2. Check the float for deterioration. Replace if necessary. 3. Check the filter for dirt or residue. Clean if necessary. Assembling the vapor separator 1. Install the needle valve, float, and float pin, and then check the float for smooth S6C14200 operation.
  • Page 65 Vapor separator Float height d: 35.0 ± 1.0 mm (1.38 ± 0.04 in) NOTE: When adjusting the float height, do not bend the lever e. 4-18 6D93G11...

  • Page 66: Canister

    FUEL Fuel system Canister S6D84150 Part name Q’ty Remarks Bolt M6 × 16 mm Bracket Canister Bolt M6 × 28 mm Grommet Bracket Collar Hose Hose Hose Filter Hose Clamp Bolt M6 × 10 mm Holder Bolt M6 × 16 mm Bracket 4-19 6D93G11...

  • Page 67: Checking The Canister

    Canister Checking the canister 1. Check the canister for cracks. Replace if necessary. 2. Connect the special service tool to the atmospheric port 1 and cover the other ports, each with a finger. S6D84160 3. Apply the specified positive pressure and check that there is no air leakage.
  • Page 68 POWR Power unit Special service tools ..................5-1 Power unit....................... 5-3 Checking the compression pressure ............5-3 Checking the oil pressure ................5-3 Checking the valve clearance..............5-10 Replacing the timing belt .................5-13 Removing the power unit.................5-16 Removing the timing belt and sprockets..........5-17 Checking the timing belt and sprockets...........5-18 Installing the sprockets and timing belt............5-18 Throttle link....................
  • Page 69 Cylinder block ....................5-40 Disassembling the cylinder block ............5-41 Checking the piston diameter ..............5-41 Checking the cylinder bore ..............5-42 Checking the piston clearance ..............5-42 Checking the piston rings ................5-42 Checking the piston ring grooves ............5-43 Checking the piston ring side clearance..........5-43 Checking the connecting rod big end side clearance ......5-43 Checking the crankshaft ................5-44 Checking the crankpin oil clearance............
  • Page 70 POWR Power unit Special service tools Compression gauge Valve spring compressor 90890-03160 90890-04019 Compression gauge extension M14 Valve spring compressor attachment 90890-06563 90890-06320 Flywheel holder Valve guide remover/installer 5.9 90890-06522 90890-04064 Flywheel puller Valve guide reamer 6.0 90890-06521 90890-04066 Crankshaft holder 20 Valve seat cutter holder 90890-06552 90890-06553...

  • Page 71: Special Service Tools

    Special service tools Valve seat cutter 90890-06312, 90890-06315, 90890-06324, 90890-06326, 90890-06328, 90890-06555 Piston slider 90890-06530 Oil filter wrench 64 90890-01426 6D93G11...

  • Page 72: Power Unit

    POWR Power unit Power unit NOTE: Checking the compression pressure • If the compression pressure increases, 1. Start the engine, warm it up for 5 min- check the pistons and piston rings for wear. utes, and then turn it off. Replace if necessary.
  • Page 73 Power unit · · · 42 N m (4.2 kgf m, 31.0 ft · · · 42 N m (4.2 kgf m, 31.0 ft · · · m (0.4 kgf m, 3.0 ft S6D85010 Part name Q’ty Remarks Damper Grommet Grommet Flywheel magnet cover Power unit...
  • Page 74 POWR Power unit · · · 215 N m (21.5 kgf m, 158.6 ft S6D85020 Part name Q’ty Remarks Washer Flywheel magnet Screw ø4 × 10 mm Screw ø6 × 30 mm Stator coil Bolt M6 × 30 mm Stator assembly Collar Bolt M6 ×...
  • Page 75 Power unit · · · 265 N m (26.5 kgf m, 195.5 ft · · · 60 N m (6.0 kgf m, 44.3 ft · · · 39 N m (3.9 kgf m, 28.8 ft S6D85030 Part name Q’ty Remarks Timing belt Bolt M10 ×...
  • Page 76 POWR Power unit · · · 29 N m (2.9 kgf m, 21.4 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft ·...
  • Page 77 Power unit · · · 29 N m (2.9 kgf m, 21.4 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft ·...
  • Page 78 POWR Power unit m (0.8 kgf m, 5.9 ft • • • S1280B 17 N m (1.7 kgf m, 12.5 ft • • • · · · m (0.2 kgf m, 1.5 ft S1280B m (0.8 kgf m, 5.9 ft •...

  • Page 79: Checking The Valve Clearance

    Power unit Checking the valve clearance CAUTION: • Do not turn the flywheel magnet coun- terclockwise, otherwise the valve sys- tem may be damaged. • Do not remove the ignition timing pointer. • Do not turn the flywheel magnet or the driven sprockets when the timing belt is not installed.
  • Page 80 POWR Power unit 4. Install the driven sprockets 0, timing belt Valve clearance (cold): 9, and spring 8, and then tighten the Intake e: tensioner bolt. 0.20 ± 0.03 mm (0.008 ± 0.001 in) Exhaust f: 0.34 ± 0.03 mm (0.013 ± 0.001 in) 6.
  • Page 81 Power unit 19. Check that the “TDC” mark a on the fly- 11. Remove the valve shim C from the valve lifter D using a thin screwdriver. wheel magnet is aligned with the pointer b, and that “ ” marks c and d on the driven sprockets are aligned.

  • Page 82: Replacing The Timing Belt

    POWR Power unit Replacing the timing belt CAUTION: • Do not turn the drive sprocket counter- clockwise, otherwise the valve system may be damaged. • Do not remove the ignition timing pointer. • Do not turn the drive sprocket or the driven sprockets when the timing belt is not installed.
  • Page 83 Power unit 9. Check that “ ” marks c and d on the driven sprockets are aligned. S6D85220 6. Disconnect the cooling water hose 3 S6D85240 and remove the bracket 4. 7. Remove the spring 5 and timing belt tensioner 6, and then remove the timing belt 7 from the driven sprockets, then from the drive sprocket.
  • Page 84 POWR Power unit 10. Install a new timing belt 8 onto the drive 13. Install the spring A. sprocket with its part number in the upright position, and then install the belt onto the driven sprockets in a counter- clockwise direction. S6D85260 14.

  • Page 85: Removing The Power Unit

    Power unit 18. Install the stator assembly and Woodruff 5. Disconnect the fuel hose and shift posi- key. tion switch coupler. 19. Install the flywheel magnet. 6. Disconnect the cooling water pilot hose, canister hose, and flushing hose. 7. Remove the oil dipstick. 8.

  • Page 86: Removing The Timing Belt And Sprockets

    POWR Power unit Removing the timing belt and NOTE: sprockets • Use a deep socket 2 for this procedure. • Do not turn the camshaft when loosening CAUTION: the drive sprocket nut. • Do not turn the drive sprocket counter- clockwise, otherwise the valve system may be damaged.

  • Page 87: Checking The Timing Belt And Sprockets

    Power unit S6D85740 NOTE: • Apply engine oil to the driven sprocket bolts before installation. • Do not turn the camshafts when tightening the driven sprocket bolts. S6D85380 Flywheel holder: 90890-06522 Checking the timing belt and sprockets Driven sprocket bolt 2: 1.
  • Page 88 POWR Power unit 3. Install the retaining plate 3, Woodruff 6. Tighten the drive sprocket nut 6 to the key 4, drive sprocket 5, and nut 6, and specified torque. then tighten the nut. S6D85410 NOTE: Use a deep socket 7 for this procedure. Crankshaft holder 20 8: 90890-06552 Drive sprocket nut 6:...

  • Page 89: Throttle Link

    Power unit / Throttle link Throttle link S6D84140 Part name Q’ty Remarks Throttle cam Bolt M6 × 35 mm Collar Wave washer Washer Spring Washer Throttle lever Bolt M6 × 25 mm Collar Throttle link rod Throttle link rod joint Bracket Bolt M6 ×...

  • Page 90: Ecm

    POWR Power unit S6D85050 Part name Q’ty Remarks Wiring harness Bracket Bolt M6 × 15 mm Bolt M6 × 12 mm Bracket Bracket Bracket Bolt M6 × 20 mm Collar Grommet Bolt M6 × 30 mm Rectifier Regulator Bolt M6 × 25 mm Bolt M6 ×...

  • Page 91: Junction Box

    ECM / Junction box Junction box · · · m (0.3 kgf m, 2.2 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.3 kgf m, 2.2 ft · · · m (0.4 kgf m, 3.0 ft ·...
  • Page 92 POWR Power unit · · · m (0.3 kgf m, 2.2 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.3 kgf m, 2.2 ft · · · m (0.4 kgf m, 3.0 ft · ·...

  • Page 93: Cylinder Head

    Junction box / Cylinder head Cylinder head 15 N m (1.5 kgf m, 11.1 ft • • • 30 N m (3.0 kgf m, 22.1 ft • • • 90˚ 25 N m (2.5 kgf m, 18.4 ft • • •...
  • Page 94 POWR Power unit 15 N m (1.5 kgf m, 11.1 ft • • • 30 N m (3.0 kgf m, 22.1 ft • • • 90˚ 25 N m (2.5 kgf m, 18.4 ft • • • · · · 14 N m (1.4 kgf m, 10.3 ft...

  • Page 95: Removing The Cylinder Head

    Cylinder head Removing the cylinder head NOTE: 1. Remove the cylinder head cover. Do not mix the valve train parts. Keep them organized in their proper groups. 2. Remove camshaft caps 1 and 2 in the sequence shown. 5. Remove the cylinder head bolts in the sequence shown.

  • Page 96: Checking The Valve Lifters

    POWR Power unit 6. Remove the intake and exhaust valves. Valve spring free length a: 53.20 mm (2.0945 in) 2. Measure the valve spring tilt b. Replace if above specification. Valve spring tilt limit b: 2.6 mm (0.10 in) NOTE: Checking the valves Be sure to keep the valves, springs, and 1.

  • Page 97: Checking The Valve Guides

    Cylinder head S60C5450 Valve stem diameter b: Valve guide inside diameter a: Intake: Intake and exhaust: 5.975–5.990 mm 6.000–6.018 mm (0.2352–0.2358 in) (0.2362–0.2369 in) Exhaust: 5.960–5.975 mm 2. Calculate the valve stem-to-valve guide (0.2346–0.2352 in) clearance as follows. Replace the valve guide if out of specification.

  • Page 98: Checking The Valve Seat

    POWR Power unit 2. Install the new valve guide 2 by striking 4. Measure the valve guide inside diameter. the special tool from the camshaft side to Valve guide inside diameter: the specified position a. Intake and exhaust: 6.000–6.018 mm (0.2362–0.2369 in) Checking the valve seat 1.

  • Page 99: Refacing The Valve Seat

    Cylinder head S63P5240 Valve seat contact width a: 1.20–1.60 mm (0.0472–0.0630 in) Refacing the valve seat 1. Reface the valve seat with the valve seat a Slag or rough surface cutters. CAUTION: Do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pres- sure of 40–50 N (4–5 kgf, 8.8–11 lbf) to prevent chatter marks.
  • Page 100 POWR Power unit 4. Use a 60° cutter to adjust the contact 7. If the valve seat contact area is too nar- width of the bottom edge of the valve row and situated near the top edge of the seat. valve face, use a 30°...

  • Page 101: Checking The Camshafts

    Cylinder head CAUTION: Do not get the lapping compound on the valve stem and valve guide. 10. After every lapping procedure, be sure to clean off any remaining lapping com- pound from the cylinder head and the valve. S6D85450 11. Check the valve seat contact area of the Camshaft runout limit: valve again.

  • Page 102: Installing The Valves

    POWR Power unit 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in the directions shown. Replace if above specification. S6D85470 NOTE: The valve spring can be installed in any direction. S6D85460 Valve spring compressor 6: 90890-04019 Cylinder head warpage limit: Valve spring compressor attachment...

  • Page 103: Installing The Cylinder Head

    Cylinder head 90˚ S6D85480 S60C5680 CAUTION: 4. Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters Do not reuse the cylinder head gasket, securely. always replace it with a new one. NOTE: • Apply engine oil to the cylinder head bolts before installation.
  • Page 104 POWR Power unit 3. Install the valve shims and valve lifters. 6. Install the camshaft caps in their proper positions as shown with the stamped NOTE: numbers upside down. • Apply engine oil to the valve shims and valve lifters before installation. 7.
  • Page 105 Cylinder head S1280B S6D85520 Cylinder head cover bolt: 1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb) 2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb) 9. Install the sprockets and timing belt. NOTE: For sprocket and timing belt installation pro- cedures, see “Installing the sprockets and timing belt.”...

  • Page 106: Exhaust Cover

    POWR Power unit Exhaust cover · · · 49 N m (4.9 kgf m, 36.1 ft · · · 18 N m (1.8 kgf m, 13.3 ft 23 N m (2.3 kgf m, 17.0 ft • • • · · ·...
  • Page 107 Exhaust cover · · · 49 N m (4.9 kgf m, 36.1 ft · · · 18 N m (1.8 kgf m, 13.3 ft 23 N m (2.3 kgf m, 17.0 ft • • • · · · 55 N m (5.5 kgf m, 40.6 ft ·...

  • Page 108: Removing The Exhaust Cover

    POWR Power unit Removing the exhaust cover Installing the exhaust cover 1. Remove the exhaust cover bolts in the 1. Install a new gasket and the exhaust sequence shown. cover. 2. Install the bolts, and then tighten them to the specified torques in two stages and in the sequence shown.

  • Page 109: Cylinder Block

    Exhaust cover / Cylinder block Cylinder block 19 N m (1.9 kgf m, 14.0 ft • • • 60˚ S518 · · · 14 N m (1.4 kgf m, 10.3 ft · · · 28 N m (2.8 kgf m, 20.7 ft 18 N m (1.8 kgf m, 13.3 ft...

  • Page 110: Disassembling The Cylinder Block

    POWR Power unit Disassembling the cylinder block 1. Place a rag under the oil filter, and then remove the filter using the oil filter wrench. NOTE: Be sure to clean up any oil spills. Oil filter wrench 64: 90890-01426 NOTE: •...

  • Page 111: Checking The Cylinder Bore

    Cylinder block Checking the cylinder bore Piston clearance: 1. Measure the cylinder bore (D –D ) at 0.070–0.080 mm measuring points a, b, and c, and in (0.0028–0.0031 in) direction d (D ), which is parallel to the crankshaft, and direction e (D Checking the piston rings ), which is at a right angle to the crankshaft.

  • Page 112: Checking The Piston Ring Grooves

    POWR Power unit 3. Check the piston ring end gap d at the Piston ring groove: specified measuring point. Replace if out Top ring a: of specification. 1.23–1.25 mm (0.048–0.049 in) Second ring b: 1.52–1.54 mm (0.060–0.061 in) Oil ring c: 2.51–2.53 mm (0.099–0.100 in) Checking the piston ring side clearance...

  • Page 113: Checking The Crankshaft

    Cylinder block Crankshaft journal diameter a: 47.985–48.000 mm (1.8892–1.8898 in) Crankpin diameter b: 43.982–44.000 mm (1.7316–1.7323 in) Crankpin width c: 21.00–21.07 mm (0.8268–0.8295 in) 2. Measure the crankshaft runout. Replace the crankshaft if above specification. Connecting rod big end side clearance a: 0.14–0.28 mm (0.0055–0.0110 in) Checking the crankshaft...
  • Page 114 POWR Power unit 2. Install the upper bearing into the con- necting rod 1 and the lower bearing into the connecting rod cap 2. S60C5960 S60C5A10 NOTE: Install the bearings in their original positions. NOTE: Make sure that the large, flat side a on the connecting rod faces towards the flywheel 3.

  • Page 115: Selecting The Connecting Rod Bearing

    Cylinder block 6. Remove the connecting rod cap and 3. Check the crankpin mark on the crank- shaft 1. measure the width of the compressed Plastigauge (PG-1) on each crankpin. Replace the connecting rod bearing if out of specification. (#1) (#2) (#3) Crankpin oil clearance:...

  • Page 116: Checking The Crankshaft Journal Oil Clearance

    POWR Power unit 5. Select the suitable color b for the con- Checking the crankshaft journal oil necting rod bearing from the table below clearance according to the calculated values. 1. Clean the bearings, the crankshaft jour- nals, the bearing portions of the crank- case, and the cylinder block.

  • Page 117: Selecting The Main Bearing

    Cylinder block 5. Install the remaining half of the bearings 8. Remove the crankcase, and then mea- into the crankcase. sure the width of the compressed Plasti- gauge (PG-1) each crankshaft 6. Install the crankcase onto the cylinder journal. Replace the main bearing if out block and apply engine oil onto the of specification.
  • Page 118 POWR Power unit 2. Check the crankshaft journal mark on the crankshaft 1 and the cylinder block mark on the cylinder block 2. (#1) (#2) (#3) (#4) (#5) S6D85720 Main bearing selection table (20 °C [68 °F]) S60C5A40 Cylinder block Bearing journal inside Bearing...

  • Page 119: Assembling The Power Unit

    Cylinder block Assembling the power unit NOTE: 1. Install the oil ring 1, second ring 2, and Install the bearings in their original positions. top ring 3 onto the pistons with the “T” marks a on the piston rings facing upward.
  • Page 120 POWR Power unit 6. Set the crankshaft 8 and oil seals 9 and NOTE: 0 into the cylinder block as shown. • Make sure that the large, flat side c of the connecting rod faces towards the flywheel magnet side of the crankshaft. •...

  • Page 121: Installing The Power Unit

    Cylinder block Installing the power unit 1. Clean the power unit mating surface, and install the dowels 1 and a new gasket 2. Install the power unit 3 by installing bolts 4 and 5, then tightening them to the specified torques in two stages and in the sequence shown.
  • Page 122 POWR Power unit 6. Connect the fuel hose and shift position switch coupler. 7. Connect the PTT motor leads and PTT switch coupler, and then install the junc- tion box cover. PTT motor lead bolt: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8.
  • Page 123 LOWR Lower unit Special service tools ..................6-1 Lower unit ....................... 6-4 Removing the lower unit ................6-8 Removing the water pump and shift rod............ 6-9 Disassembling the oil seal housing ............6-9 Checking the water pump and shift rod .............6-9 Propeller shaft housing ................6-10 Removing the propeller shaft housing assembly........

  • Page 124: Special Service Tools

    LOWR Lower unit Special service tools Ring nut wrench 3 Bearing separator 90890-06511 90890-06534 Ring nut wrench extension Stopper guide stand 90890-06513 90890-06538 Bearing housing puller claw L Bearing puller assembly 90890-06502 90890-06535 Stopper guide plate Needle bearing attachment 90890-06501 90890-06607, 90890-06611, 90890-06612, 90890-06614 Center bolt...
  • Page 125 Special service tools Driver rod SS Drive shaft holder 5 90890-06604 90890-06519 Bearing depth plate Pinion nut holder 90890-06603 New: 90890-06715 Current: 90890-06505 Driver rod LS 90890-06606 Bearing outer race puller assembly 90890-06523 Ball bearing attachment 90890-06655 Driver rod SL 90890-06602 Bearing inner race attachment 90890-06639, 90890-06643, 90890-06661...
  • Page 126 LOWR Lower unit Driver rod LL Backlash indicator 90890-06605 90890-06706 Shift rod push arm Magnet base plate 90890-06052 90890-07003 Pinion height gauge Dial gauge set 90890-06710 90890-01252 Digital caliper Magnetic base B 90890-06704 90890-06844 Shimming plate 90890-06701 6D93G11...

  • Page 127: Lower Unit

    Special service tools / Lower unit Lower unit Part name Q’ty Remarks Lower unit Hose Check screw Gasket Not reusable Dowel Bolt M10 × 40 mm/L-transom model Drain screw Grommet Bolt M10 × 45 mm Bolt M8 × 60 mm/L-transom model Spacer Propeller Washer...
  • Page 128 LOWR Lower unit Part name Q’ty Remarks Dowel X-transom model Extension X-transom model Stud bolt M10 × 180 mm/X-transom model Washer X-transom model Spring washer X-transom model X-transom model Bolt M8 × 190 mm/X-transom model 6D93G11...
  • Page 129 Lower unit Part name Q’ty Remarks Bolt M6 × 16 mm O-ring Not reusable Oil seal Not reusable Oil seal housing O-ring Not reusable Circlip Shift rod Woodruff key Screw ø4 × 12 mm Bolt M8 × 75 mm Cover Bolt M8 ×...
  • Page 130 LOWR Lower unit Part name Q’ty Remarks Gasket Not reusable Outer plate cartridge Gasket Not reusable Oil seal housing O-ring Not reusable Gasket Not reusable Oil seal Not reusable 6D93G11...

  • Page 131: Removing The Lower Unit

    Lower unit Removing the lower unit 1. Drain the gear oil. 2. Set the gear shift to the neutral position, S6D86020 and place a block of wood between the 5. Loosen the bolts (nuts), and then remove anti-cavitation plate and propeller to keep the lower unit from the upper case.

  • Page 132: Removing The Water Pump And Shift Rod

    LOWR Lower unit Removing the water pump and shift Checking the water pump and shift 1. Remove the water pump housing and 1. Check the water pump housing for defor- impeller. mation. Replace if necessary. 2. Remove the Woodruff key. 2.

  • Page 133: Propeller Shaft Housing

    Lower unit / Propeller shaft housing Propeller shaft housing Part name Q’ty Remarks Slider Shift plunger Cross pin Dog clutch Spring Propeller shaft Washer Reverse gear Thrust washer Ball bearing Not reusable O-ring Not reusable Propeller shaft housing Straight key Needle bearing Oil seal Not reusable...

  • Page 134: Removing The Propeller Shaft Housing Assembly

    LOWR Lower unit Removing the propeller shaft Disassembling the propeller shaft housing assembly assembly 1. Straighten the claw washer tabs a, and 1. Remove the spring 1, and then remove then remove the ring nut and claw the cross pin 2, dog clutch 3, slider and washer.

  • Page 135: Checking The Propeller Shaft Housing

    Propeller shaft housing CAUTION: Do not reuse the bearing, always replace it with a new one. Stopper guide plate 5: 90890-06501 Stopper guide stand 6: 90890-06538 Bearing puller assembly 7: S6D56510 90890-06535 Runout limit: 0.02 mm (0.0008 in) 3. Remove the oil seals and needle bear- ing.

  • Page 136: Assembling The Propeller Shaft Housing

    LOWR Lower unit Assembling the propeller shaft Ball bearing attachment 4: housing 90890-06655 1. Install the needle bearing into the propel- Driver rod LS 5: 90890-06606 ler shaft housing to the specified depth. Depth d: 5.0 ± 0.5 mm (0.20 ± 0.02 in) 3.
  • Page 137 Propeller shaft housing Bearing inner race attachment 0: 90890-06661 6-14 6D93G11...

  • Page 138: Drive Shaft And Lower Case

    LOWR Lower unit Drive shaft and lower case Part name Q’ty Remarks Drive shaft Taper roller bearing Not reusable Pinion shim — Sleeve Hose Plastic tie Not reusable Joint Cooling water inlet cover Screw ø5 × 40 mm Seal Plate Forward gear shim —...
  • Page 139 Drive shaft and lower case Part name Q’ty Remarks Pinion Lower case 6-16 6D93G11...

  • Page 140: Removing The Drive Shaft

    LOWR Lower unit Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear. CAUTION: Do not reuse the bearing, always replace it with a new one. S68S6360J Drive shaft holder 5 1: 90890-06519 Pinion nut holder 2: Bearing separator 1: 90890-06534 New: 90890-06715...

  • Page 141: Checking The Pinion And Forward Gear

    Drive shaft and lower case Checking the pinion and forward NOTE: gear Install the claws as shown. 1. Check the teeth of the pinion, and the teeth and dogs of the forward gear for cracks or wear. Replace if necessary. Bearing outer race puller assembly 1: Checking the bearings...

  • Page 142: Assembling The Lower Case

    LOWR Lower unit Assembling the lower case CAUTION: 1. Install the needle bearing into the lower Add or remove shim(s), if necessary, if case to the specified depth. replacing the taper roller bearing or lower case. NOTE: • Apply the gear oil to the inside and outside of the sleeve before installation.

  • Page 143: Assembling The Drive Shaft

    Drive shaft and lower case Bearing inner race attachment 1: 90890-06643 Installing the drive shaft 1. Install the forward gear, then the drive shaft assembly, pinion, and pinion nut, and then tighten the nut to the specified torque. Needle bearing attachment 1: 90890-06607 2.

  • Page 144: Installing The Water Pump And Shift Rod

    LOWR Lower unit 3. Install the propeller shaft housing assem- bly 4 into the lower case, and then install the straight key 5, claw washer 6, and ring nut 7. 4. Tighten the ring nut to the specified torque. S60C6430 NOTE: Install the shift rod assembly into the lower case, turn it counterclockwise 90°...

  • Page 145: Installing The Lower Unit

    Drive shaft and lower case 3. Install a new O-ring 5 onto the oil seal housing 6. 4. Install a new gasket 7, the oil seal hous- ing 6, a new gasket 8, the outer plate cartridge 9, and a new gasket 0. S6D86150 S1104J NOTE:...
  • Page 146 LOWR Lower unit 2. Align the alignment mark a on the bush- ing with the alignment mark b on the bracket. S6D81040 È X-transom model Lower case mounting bolt (nut): 39 N·m (3.9 kgf·m, 28.8 ft·lb) 5. Install the trim tab 2 to its original posi- tion, and then connect the speedometer Shift rod push arm: 90890-06052 hose 3.
  • Page 147 Drive shaft and lower case 6. Install the propeller and propeller nut, 7. Fill the gear oil to the correct level. and then tighten the nut finger tight. Place a block of wood between the anti- cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque.

  • Page 148: Shimming

    LOWR Lower unit Shimming 6-25 6D93G11...

  • Page 149: Selecting The Pinion Shims

    Shimming Shimming Pinion nut: NOTE: 93 N·m (9.3 kgf·m, 68.6 ft·lb) • Shimming is not required when assembling the original lower case and inner parts. 3. Measure the distance (M) between the • Shimming is required when assembling the special service tool and the pinion as original inner parts and a new lower case.

  • Page 150: Selecting The Forward Gear Shims

    LOWR Lower unit 4. Calculate the pinion shim thickness (T3) Example: as shown in the examples below. If “T3” is “0.55 mm”, then the pinion shim is 0.58 mm. If “T3” is “0.64 mm”, then the pinion shim is 0.65 mm. Selecting the forward gear shims 1.

  • Page 151: Backlash

    Shimming / Backlash Example: If “T1” is “0.47 mm”, then the forward gear shim is 0.45 mm. If “T1” is “0.50 mm”, then the forward gear shim is 0.48 mm. Backlash Measuring the forward gear backlash 1. Remove the water pump assembly. S68S6260 NOTE: NOTE:...
  • Page 152 LOWR Lower unit 3. Install the special service tool so that it Backlash indicator 4: 90890-06706 pushes against the propeller shaft. Magnet base plate 5: 90890-07003 Dial gauge set 6: 90890-01252 Magnetic base B 7: 90890-06844 5. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction.
  • Page 153 Backlash — MEMO — 6-30 6D93G11...
  • Page 154 BRKT Bracket unit Special service tools ..................7-1 Shift rod ......................7-2 Bottom cowling ....................7-3 Upper case...................... 7-6 Removing the upper case................7-12 Disassembling the oil pump..............7-12 Checking the oil pump ................7-12 Assembling the oil pump .................7-12 Disassembling the upper case ..............7-13 Checking the drive shaft bushing ............
  • Page 155 Tilt cylinder and trim cylinder ..............7-35 Disassembling the trim cylinder...............7-38 Disassembling the tilt cylinder ..............7-38 Checking the tilt cylinder and trim cylinder ..........7-39 Checking the valves ................7-39 Assembling the tilt cylinder ..............7-39 Assembling the power trim and tilt unit............7-41 Bleeding the power trim and tilt unit ............

  • Page 156: Special Service Tools

    BRKT Bracket unit Special service tools Bearing outer race attachment Cylinder-end screw wrench 90890-06625, 90890-06628 New: 90890-06568 Current: 90890-06544 Driver rod LL 90890-06605 Driver rod L3 90890-06652 Driver rod LS 90890-06606 Ball bearing attachment 90890-06638 Needle bearing attachment 90890-06612, 90890-06653 6D93G11...

  • Page 157: Shift Rod

    Special service tools / Shift rod Shift rod · · · 18 N m (1.8 kgf m, 13.3 ft · · · m (0.1 kgf m, 0.7 ft S6D87010 Part name Q’ty Remarks Bolt Spring Ball Washer Bushing Bolt M6 × 25 mm Bracket Shift rod Screw...

  • Page 158: Bottom Cowling

    BRKT Bracket unit Bottom cowling 36 37 · · · m (0.2 kgf m, 1.5 ft S6D87020 Part name Q’ty Remarks Bolt M6 × 16 mm Washer Lever Washer Bushing Bolt M6 × 30 mm Base Lever Spring Bolt M6 × 20 mm Hook Cooling water outlet Canister outlet...
  • Page 159 Bottom cowling 36 37 · · · m (0.2 kgf m, 1.5 ft S6D87020 Part name Q’ty Remarks Bottom cowling Grommet Collar Bolt M6 × 20 mm Holder Bolt M6 × 20 mm Bracket Bolt M6 × 25 mm Plate Power trim and tilt switch Grommet Grommet...
  • Page 160 BRKT Bracket unit 36 37 · · · m (0.2 kgf m, 1.5 ft S6D87020 Part name Q’ty Remarks Adapter Gasket Joint Joint Plastic tie Not reusable Hose Bolt M6 × 20 mm Bolt M6 × 25 mm Retaining plate Bolt M6 ×...
  • Page 161 Bottom cowling / Upper case Upper case · · · 10 N m (1.0 kgf m, 7.4 ft · · · 51 N m (5.1 kgf m, 37.6 ft · · · m (0.3 kgf m, 2.2 ft S6D87030 Part name Q’ty Remarks Oil seal...
  • Page 162 BRKT Bracket unit m (0.4 kgf m, 3.0 ft • • • WR-No.2 WR-No.2 WR-No.2 · · · m (0.4 kgf m, 3.0 ft S6D97010 Part name Q’ty Remarks Oil seal Not reusable Screw ø6 × 10 mm Gasket Not reusable O-ring Not reusable Shaft...
  • Page 163 Upper case · · · m (0.4 kgf m, 3.0 ft · · · 20 N m (2.0 kgf m, 14.8 ft · · · 28 N m (2.8 kgf m, 20.7 ft WR-No.2 · · · 27 N m (2.7 kgf m, 20.0 ft 22 23 S6D97020...

  • Page 164: Upper Case

    BRKT Bracket unit · · · m (0.4 kgf m, 3.0 ft · · · 20 N m (2.0 kgf m, 14.8 ft · · · 28 N m (2.8 kgf m, 20.7 ft WR-No.2 · · · 27 N m (2.7 kgf m, 20.0 ft 22 23...
  • Page 165 Upper case · · · 10 N m (1.0 kgf m, 7.4 ft · · · 11 N m (1.1 kgf m, 8.1 ft S6D87060 Part name Q’ty Remarks Exhaust guide Gasket Not reusable Dowel Gasket Not reusable Oil strainer Collar Bolt M6 ×...
  • Page 166 BRKT Bracket unit · · · 10 N m (1.0 kgf m, 7.4 ft · · · 11 N m (1.1 kgf m, 8.1 ft S6D87060 Part name Q’ty Remarks Muffler Bolt M6 × 50 mm Grommet Spacer Pipe 7-11 6D93G11...

  • Page 167: Removing The Upper Case

    Upper case Removing the upper case Checking the oil pump 1. Place a drain pan under the drain hole, 1. Check the gear teeth for cracks or wear and then remove the drain bolt 1 and let and the oil pump case for scratches. the oil drain completely.

  • Page 168: Disassembling The Upper Case

    BRKT Bracket unit 3. Install new oil seals into the oil seal hous- ing. S6D87140 Ball bearing attachment 1: S6D97030 WR-No.2 90890-06638 Needle bearing attachment 4: Driver rod LL 2: 90890-06605 90890-06612 Driver rod LS 2: 90890-06606 Checking the drive shaft bushing 1.

  • Page 169: Checking The Oil Strainer

    Upper case Checking the oil strainer 1. Check the oil strainer for dirt or residue. Clean if necessary. Assembling the oil pan 1. Install a new gasket onto the exhaust guide 1. 2. Install a new gasket and the oil strainer 2 onto the exhaust guide, and then tighten the bolts to the specified torque.

  • Page 170: Assembling The Upper Case

    BRKT Bracket unit Assembling the upper case 2. Install the bolts 3, and then tighten them to the specified torque. 1. Install the drive shaft bushing into the upper case, and then install the circlip. WR-No.2 S6D97050 Needle bearing attachment 1: 90890-06653 S6D87590 Driver rod L3 2: 90890-06652...
  • Page 171 Upper case 7. Install the oil pump assembly 9 and the bolts 0, and then tighten them to the specified torque. S6D87210 NOTE: When installing the oil pump assembly onto the upper case, pour a small amount of engine oil into the oil inlet or oil outlet of the oil pump assembly.

  • Page 172: Steering Arm

    BRKT Bracket unit Steering arm · · · 20 N m (2.0 kgf m, 14.8 ft S6D87220 Part name Q’ty Remarks Steering hook Stud bolt M10 × 40 mm Steering arm Washer Bushing O-ring Not reusable Bushing Washer Steering yoke Damper Circlip 7-17...

  • Page 173: Removing The Steering Arm

    Steering arm Removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer. S6D87250 4. Install the steering yoke 0 to the steer- ing arm 5 by aligning the center a of the yoke with the center b of the steer- ing arm.

  • Page 174: Clamp Brackets And Swivel Bracket

    BRKT Bracket unit Clamp brackets and swivel bracket · · · m (0.2 kgf m, 1.5 ft · · · 15 N m (1.5 kgf m, 11.1 ft S6D87490 Part name Q’ty Remarks Swivel bracket Clamp bracket Clamp bracket Self-locking nut Screw ø6 ×...
  • Page 175 Clamp brackets and swivel bracket 4 16 · · · m (0.3 kgf m, 2.2 ft S6D87500 Part name Q’ty Remarks Swivel bracket Tilt stop lever Bushing a: 30.3–30.6 mm (1.19–1.20 in) Distance collar Hook Bolt M6 × 10 mm Spring Tilt stop lever Trim sensor...

  • Page 176: Removing The Clamp Brackets

    BRKT Bracket unit Removing the clamp brackets NOTE: 1. Remove the power trim and tilt unit. For Adjust the trim sensor after installing the removal procedure, see “Removing the power trim and tilt unit. power trim and tilt unit.” 2. Remove the anode 1. 2.
  • Page 177 Clamp brackets and swivel bracket S60X7160 Trim sensor setting resistance: Pink (P) – Black (B) 10 ± 1 Ω at 20 °C (68 °F) Trim sensor cam screw 1: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 4. Fully tilt the outboard motor up, and then support it with the tilt stop lever 3.
  • Page 178 BRKT Bracket unit Power trim and tilt unit 13 14 13 14 S6D87270 Part name Q’ty Remarks Power trim and tilt unit Circlip Shaft Circlip Shaft Bushing Bushing Ground lead Bolt M6 × 10 mm Bushing Bushing Collar Holder Bolt M6 ×...

  • Page 179: Removing The Power Trim And Tilt Unit

    Power trim and tilt unit Removing the power trim and tilt unit 4. Remove the circlips 6, then the lower mounting shaft 7. 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. 5.

  • Page 180: Power Trim And Tilt Motor

    BRKT Bracket unit Power trim and tilt motor · · · m (0.4 kgf m, 3.0 ft 13 14 · · · m (0.7 kgf m, 5.2 ft S6D87290 Part name Q’ty Remarks Power trim and tilt motor Bolt M6 × 20 mm O-ring Not reusable Joint...
  • Page 181 Power trim and tilt motor · · · m (0.4 kgf m, 3.0 ft 13 14 · · · m (0.7 kgf m, 5.2 ft S6D87290 Part name Q’ty Remarks Circuit breaker Spring PTT motor base Oil seal Not reusable Plate Screw ø4 ×...

  • Page 182: Disassembling The Power Trim And Tilt Motor

    BRKT Bracket unit Disassembling the power trim and 3. Remove the armature from the PTT motor base. tilt motor 1. Remove the power trim and tilt motor, O- CAUTION: ring, and joint from the power trim and tilt Do not allow grease or oil to contact the unit.
  • Page 183 Power trim and tilt motor 5. Check the circuit breaker for continuity. Replace if there is no continuity. Commutator diameter wear limit: 21.0 mm (0.83 in) 6. Measure the brush length. Replace if below specification. 3. Measure the commutator undercut a. Replace the armature if below specifica- tion.

  • Page 184: Assembling The Power Trim And Tilt Motor

    BRKT Bracket unit Assembling the power trim and tilt motor 1. Install a new oil seal 1 and the bushing 2 into the motor base 3 as shown. NOTE: Place a clean cloth over the end of the arma- ture shaft, hold it with a pair of pliers, and then carefully slide the stator over the arma- ture.

  • Page 185: Gear Pump

    Power trim and tilt motor / Gear pump Gear pump · · · · · · · · · m (0.5 kgf m, 3.7 ft m (0.5 kgf m, 3.7 ft m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft ·...
  • Page 186 BRKT Bracket unit · · · · · · · · · m (0.5 kgf m, 3.7 ft m (0.5 kgf m, 3.7 ft m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft · ·...
  • Page 187 Gear pump · · · · · · m (0.2 kgf m, 1.5 ft m (0.4 kgf m, 3.0 ft S6D87550 Part name Q’ty Remarks Manual release spring Ball Bracket Bolt M3 × 5 mm Bolt M5 × 6 mm Washer O-ring Not reusable...

  • Page 188: Disassembling The Gear Pump

    BRKT Bracket unit Disassembling the gear pump 1. Remove the manual valve, then the gear pump and filters. S6C17600 Checking the gear pump 1. Clean all the pistons and balls, and then S6D87370 check them for damage or wear. Replace 2.
  • Page 189 Gear pump Lever bolt (M3) B, C: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 9. Install the up-relief valve seat D and down-relief valve seat E. 10. Install the relief valve seat caps F by installing bolts G and H, then tightening S6C17620 them to the specified torques.

  • Page 190: Tilt Cylinder And Trim Cylinder

    BRKT Bracket unit Tilt cylinder and trim cylinder · · · 90 N m (9.0 kgf m, 66.4 ft · · · · · · 85 N m (8.5 kgf m, 62.7 ft 80 N m (8.0 kgf m, 59.0 ft S6D87390 Part name Q’ty...
  • Page 191 Tilt cylinder and trim cylinder · · · 90 N m (9.0 kgf m, 66.4 ft · · · · · · 85 N m (8.5 kgf m, 62.7 ft 80 N m (8.0 kgf m, 59.0 ft S6D87390 Part name Q’ty Remarks Valve...
  • Page 192 BRKT Bracket unit · · · 90 N m (9.0 kgf m, 66.4 ft · · · · · · 85 N m (8.5 kgf m, 62.7 ft 80 N m (8.0 kgf m, 59.0 ft S6D87390 Part name Q’ty Remarks Free piston Circlip...

  • Page 193: Disassembling The Trim Cylinder

    Tilt cylinder and trim cylinder Disassembling the trim cylinder 1. Hold the power trim and tilt unit 1 in a vise using aluminum plates a on both sides. NOTE: Place the tilt cylinder in the vise horizontally. 2. Loosen the tilt cylinder end screw 2, and 2.

  • Page 194: Checking The Tilt Cylinder And Trim Cylinder

    BRKT Bracket unit 4. Remove the bolt 3, then the tilt piston 2. Check the operation of the absorber valve and check for dirt or residue. Clean if necessary. Assembling the tilt cylinder 1. Install a new O-ring, the backup ring, and a new dust seal 1 into the trim cylinder end screw 2.
  • Page 195 Tilt cylinder and trim cylinder 6. Install the new O-rings 9 and 0, and backup ring A onto the trim piston B. 7. Install the balls C, valves D, and springs E into the trim piston, and then install the washer F and trim piston to the tilt cylin- der G.

  • Page 196: Assembling The Power Trim And Tilt Unit

    BRKT Bracket unit 15. Install the tilt cylinder end screw 8, and then tighten it to the specified torque. Assembling the power trim and tilt unit 1. Hold the trim cylinder in a vise using alu- minum plates on both sides. 2.
  • Page 197 Tilt cylinder and trim cylinder S6D87450 NOTE: Recommended power trim and tilt Apply grease to the balls from falling out of fluid: the cylinder installation. ATF Dexron II 5. Install a new O-ring, the joint, and the 8. Install the trim cylinder end screw 8, and power trim and tilt motor 5 by installing then tighten it to the specified torque.

  • Page 198: Bleeding The Power Trim And Tilt Unit

    BRKT Bracket unit 10. Install the reservoir cap 9. 4. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole. Recommended power trim and tilt fluid: ATF Dexron II 5. Install the reservoir cap, and then tighten it to the specified torque.

  • Page 199: Installing The Power Trim And Tilt Unit

    Tilt cylinder and trim cylinder CAUTION: After tilting the outboard motor up, be sure to support it with the tilt stop lever. 2. Install the collars and bushings. 3. Lift the power trim and tilt unit up, and then install the upper mounting shaft 2. 4.

  • Page 200: Power Trim And Tilt Electrical System

    BRKT Bracket unit 2. Fully tilt the outboard motor up, and then NOTE: release it to let it lower by its own weight If the fluid is at the correct level, the fluid four to five times. should overflow out of the filler hole when the reservoir cap is removed.

  • Page 201: Checking The Power Trim And Tilt Switch

    Tilt cylinder and trim cylinder / Power trim and tilt electrical system Power trim and tilt relay continuity Sky blue (Sb) – Black (B) Continuity Light green (Lg) – Black (B) Terminal 1 – Terminal 4 Continuity Terminal 2 – Terminal 4 Terminal 1 –...

  • Page 202: Checking The Trim Sensor

    BRKT Bracket unit Checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification. NOTE: Turn the lever 1 and measure the resistance as it gradually changes. Trim sensor resistance: Pink (P) – Black (B) 238.8–378.8 Ω at 20 °C (68 °F) a 9–11 Ω...
  • Page 203 – ELEC Electrical systems Special service tools ..................8-1 Checking the electrical components............8-2 Measuring the peak voltage ..............8-2 Measuring the lower resistance..............8-2 Electrical components................... 8-3 Port view....................8-3 Starboard view................... 8-4 Bow view ....................8-5 Top view ....................8-6 Ignition and ignition control system ............8-7 Checking the ignition spark ...............

  • Page 204: Electrical Systems

    – ELEC Electrical systems Special service tools Ignition tester Test harness (6 pins) 90890-06756 90890-06848 Digital circuit tester Vacuum/pressure pump gauge set 90890-03174 90890-06756 Peak voltage adapter B 90890-03172 Test harness (2 pins) 90890-06792 Test harness (3 pins) 90890-06791 6D93G11...

  • Page 205: Checking The Electrical Components

    Special service tools / Checking the electrical components Checking the electrical Measuring the lower resistance When measuring a resistance of 10 Ω or less components with the digital circuit tester, the correct mea- Measuring the peak voltage surement cannot be obtained due to the internal resistance of the tester.

  • Page 206: Electrical Components

    – ELEC Electrical systems Electrical components Port view S6D88010 1 Idle speed control 7 Throttle position sensor 2 Sensor assembly (intake air temperature and intake air pressure) 3 Pulser coil 4 Oil pressure switch 5 Fuel injector 6 Electric fuel pump 6D93G11...

  • Page 207: Starboard View

    Electrical components Starboard view S6D88020 1 Ignition coil 2 Cooling water temperature sensor 3 Starter motor 4 Junction box 5 Spark plug 6D93G11...

  • Page 208: Bow View

    – ELEC Electrical systems Bow view S6D88030 1 ECM 9 Fuse (20A) 2 Sensor assembly (ECM, ignition coil, electric fuel pump, and fuel (intake air temperature and intake air injector) pressure) 0 Fuse (20A) 3 Idle speed control (main switch and power trim and tilt switch) 4 Throttle position sensor A Fuse (20 A) 5 Rectifier Regulator...

  • Page 209: Top View

    Electrical components Top view S6D88040 1 Fuel injection 2 Shift position switch 3 Sensor assembly (intake air temperature and intake air pressure) 4 Idle speed control 5 Stator coil 6 Power trim and tilt switch 7 Starter motor 6D93G11...

  • Page 210: Ignition And Ignition Control System

    NOTE: system The ignition spark can also be checked using Checking the ignition spark the “Stationary test” of the Yamaha Diagnos- 1. Remove the spark plug wire cover. tic System. 2. Disconnect the spark plug caps from the Checking the spark plug wires spark plugs.

  • Page 211: Checking The Ecm

    Ignition and ignition control system 3. Measure the pulser coil output peak volt- Ignition coil resistance: age. Replace the stator assembly if Primary coil: below specification. Red (R) – Black/white (B/W) 1.53–2.07 Ω at 20 °C (68 °F) Secondary coil: 12.495–16.905 kΩ...

  • Page 212: Checking The Cooling Water Temperature Sensor

    Electrical systems 2. Connect a computer to the outboard Checking the oil pressure switch motor and use the Yamaha Diagnostic 1. Check the oil pressure switch for continu- System to display the intake air tempera- ity. Replace if there is no continuity.

  • Page 213: Checking The Main And Fuel Pump Relay (Main Control)

    NOTE: relay terminal 4 or 5. Replace if there is Check the operation of the fuel injectors continuity. using the “Stationary test” of the Yamaha Diagnostic System. Checking the electric fuel pump 1. Turn the engine start switch to ON.

  • Page 214: Checking The Main And Fuel Pump Relay (Fuel Control)

    – ELEC Electrical systems 2. Listen for the operating sound of the 6. Check that there is no continuity between electric fuel pump 1. Check the fuel sys- the relay terminals 2 and 3 after dis- tem if there is no sound. connecting a battery terminal from the relay terminal 2 or 4.
  • Page 215 Fuel control system / Starting system S60V8265 8-12 6D93G11...

  • Page 216: Starter Motor

    – ELEC Electrical systems Starter motor S63P8050 Part name Q’ty Remarks Clip Pinion stopper Starter motor pinion Spring Bolt M6 × 35 mm Housing Bearing Clutch assembly E-clip Not reusable Washer Bracket Pinion shaft Planetary gear Outer gear Plate Armature Stator 8-13 6D93G11...
  • Page 217 Starter motor S63P8050 Part name Q’ty Remarks Brush assembly Brush spring Brush holder Plate Washer Bracket Screw ø4 × 15 mm Bolt M6 × 120 mm Rubber seal Shift lever Spring Magnet switch assembly Washer 8-14 6D93G11...

  • Page 218: Disassembling The Starter Motor

    – ELEC Electrical systems Disassembling the starter motor 2. Measure commutator diameter. Replace the armature if below specifica- 1. Slide the pinion stopper 1 down as tion. shown, and then remove the clip 2. NOTE: Commutator diameter wear limit: Remove the clip with a thin screwdriver. 28.0 mm (1.10 in) 3.

  • Page 219: Checking The Brushes

    Starter motor / Charging system 3. Connect the negative battery lead to the starter motor body. Armature continuity Commutator segments b Continuity Br/W Segment – No continuity Armature core c Segment – No continuity Armature shaft d Checking the brushes 1.

  • Page 220: Checking The Rectifier Regulator

    – ELEC Electrical systems 3. Measure the stator coil output peak volt- age. Replace the stator coil if below specification. S6D88150 Digital circuit tester: 90890-03174 Test harness (6 pins): 90890-06848 S6D88140 Digital circuit tester: 90890-03174 Rectifier Regulator output peak Peak voltage adapter B: voltage: 90890-03172 Red (R) –...
  • Page 221 TRBL SHTG Troubleshooting Special service tools ..................9-1 Yamaha Diagnostic System ................9-2 Introduction....................9-2 Power unit....................... 9-5 Bracket unit ....................9-13 Electrical systems..................9-17 Self-diagnosis....................9-18 Diagnosing the electronic control system ..........9-18 6D93G11...

  • Page 222: Trbl Shtg

    TRBL SHTG Troubleshooting Special service tools Yamaha Diagnostic System 60V-85300-02 YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL Yamaha Diagnostic System 60V-WS853-02 Diagnostic flash indicator B 90890-06865 6D93G11...
  • Page 223 Yamaha Diagnostic System Introduction Features The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of an outboard motor using the communication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor.
  • Page 224 • Windows XP is a multiuser operating system, therefore, be sure to end this program if the login user is changed. • The USB adapter cannot be used with Windows 95. For operating instructions of the Yamaha Diagnostic System, refer to the “Yamaha Diagnostic Sys- tem Instruction Manual.” 6D93G11...

  • Page 225: Yamaha Diagnostic System

    Yamaha Diagnostic System Connecting the communication cable to the outboard motor Bow view 3-pin communication coupler S6D89010 6D93G11...

  • Page 226: Power Unit

    TRBL SHTG Troubleshooting NOTE: • Check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V. • To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter.
  • Page 227 Power unit Is there Replace the fuse. continuity? Check the wiring harnesses for continuity. Is there Replace the wiring harnesses. continuity? Listen for the operation sound of the starter relay. Can the operation sound Replace the starter relay. be heard? Check the starter motor opera- tion.
  • Page 228 TRBL SHTG Troubleshooting Symptom: Engine cranks, but will not start (engine stop lanyard switch is operating nor- mally). • Check the ignition system. • Check the fuel system. • Check the compression pressure of the power unit. WARNING Check that the spark plugs pro- •...
  • Page 229 Power unit Check the main and fuel pump Wet spark plugs? relay for continuity. (8-11) Is there Replace the main Start the engine using dried or continuity? and fuel pump relay. new spark plugs. Check the fuel system. Check the compression pres- Does the engine sure of the combustion chamber.
  • Page 230 Check the pressure regulator. Within injector resistance. (4-14) specification? (8-10) Within Check the fuel system using the specification? Yamaha Diagnostic System. Good operating Replace the fuel Replace the pressure regulator. injector. condition? Check the fuel system using the Yamaha Diagnostic System. 6D93G11...
  • Page 231 Power unit Ignition system WARNING Check the ignition spark using • Do not touch any of the connections of the ignition tester. (8-7) the ignition tester leads. • Do not let sparks leak out of the removed spark plug caps. •...
  • Page 232 The engine turns off when the throttle is opened quickly. Acceleration is tardy and the engine is likely to stop at any moment. • Check the engine using the diagnostic flash indicator or the Yamaha Diagnostic System. Symptom: Engine can run, but engine speed will not increase.
  • Page 233 Check the oil pump for debris or specification? oil leaks. Check the oil Debris or leaks? passage. Check the oil pressure switch. Clean or replace the defective (8-9) parts. Good condition? Replace the oil pressure switch. Check the engine using the Yamaha Diagnostic System. 9-12 6D93G11...

  • Page 234: Bracket Unit

    TRBL SHTG Troubleshooting Bracket unit Symptom: Power trim and tilt unit does not operate. Listen for the operation sound of the power trim and tilt relay. Can the Check the voltage between each terminal of the PTT relay operation sound coupler when pushing the power trim and tilt switch.
  • Page 235 Bracket unit Is it closed? Close the valve. Check the power trim and tilt fluid level. At specified Add fluid to the correct level. level? Disassemble the power trim and tilt unit, and then check the filter for debris or dirt. Stuck foreign substance or Clean or replace the filters.
  • Page 236 TRBL SHTG Troubleshooting Symptom: Power trim and tilt unit does not hold the outboard motor up. Check that the manual valve is closed. Is it closed? Close the valve. Check the power trim and tilt fluid level. At specified Add fluid to the correct level. level? Disassemble the power trim and tilt unit, and then check the fil-...
  • Page 237 Bracket unit Symptom: Shift mechanism of the forward gear and reverse gear does not operate properly. Check the shift cable operation. Good operating Check the shift cables and links condition? of the remote control box. Check the operation of the shift rod.

  • Page 238: Electrical Systems

    TRBL SHTG Troubleshooting Electrical systems Symptom: Battery becomes weaker quickly. • Check the charging system. Measure the output peak voltage of the stator coil. Within Replace the stator coil. specification? Measure the Rectifier Regulator output peak voltage. Within Replace the Rectifier Regulator. specification? Replace the battery, and then check the voltage of all electri-...

  • Page 239: Self-Diagnosis

    Electrical systems / Self-diagnosis Self-diagnosis Diagnosing the electronic control system 1. Connect the special service tool to the outboard motor as shown. • Trouble code indication Example: The illustration indicates code number 23. a: Light on, 0.33 second b: Light off, 4.95 seconds c: Light off, 0.33 second d: Light off, 1.65 seconds S6D89030...
  • Page 240 TRBL SHTG Troubleshooting 4. If a flash pattern listed in the diagnostic code chart is displayed, check the mal- functioning part according to the flash pattern. NOTE: When more than one problem is detected, the light of the special service tool flashes in the pattern of the lowest numbered problem.
  • Page 241 Index Checking the connecting rod big end side clearance ..........5-43 Adjusting the float ........4-17 Checking the cooling water passage..3-8 Adjusting the throttle link and Checking the cooling water pilot hole ..1-9 throttle cable ..........3-8 Checking the cooling water temperature Adjusting the trim sensor ......7-21 sensor............
  • Page 242 Index Checking the piston clearance....5-42 Checking the piston diameter ....5-41 Diagnosing the electronic control Checking the piston ring grooves....5-43 system ............ 9-18 Checking the piston ring side clearance ...5-43 Dimensions..........2-9 Checking the piston rings......5-42 Disassembling the cylinder block ..... 5-41 Checking the power trim and Disassembling the drive shaft....
  • Page 243 Index Propeller shaft housing......6-10 Propeller size..........1-5 Hose routing..........4-2 How to use this manual.......1-1 Reducing the fuel pressure....... 4-13 Refacing the valve seat ......5-30 Identification..........1-5 Removing the clamp brackets ....7-21 Ignition and ignition control system.....8-7 Removing the cylinder head ..... 5-26 Installing the clamp brackets.....7-21 Removing the drive shaft......
  • Page 244 Index Upper case..........7-6 Vapor separator ........4-10 Ventilation ...........1-3 Yamaha Diagnostic System......9-2 6D93G11...
  • Page 245 Index — MEMO — 6D93G11...
  • Page 246 Wiring diagram F80BET, F100DET 1 Ignition coil Color code 2 Spark plug : Black 3 Power trim and tilt switch (tiller handle) : Brown (optional) : Green 4 Power trim and tilt switch (bottom cowling) : Blue 5 Battery : Light green 6 Cooling water temperature sensor : Orange 7 Starter motor...
  • Page 248 YAMAHA MOTOR CO., LTD. Printed in the Netherlands Nov. 2004 – 1.2 × 1 CR...
  • Page 249 F80BET, F100DET 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Br/W...

This manual is also suitable for:

F100dF80betF100detF80b

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