Page 1 Worldwide: (6BT) (6BG) USA, CAN, AUS, and NZL: (6BT) (6BG) 6BG-28197-ZX-11 LIT-18616-03-84...
Page 2 Preface This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have the Bronze Technical Certificate of the YTA...
Page 3: Table Of Contents
Contents General information Specification Technical feature and description Rigging information Troubleshooting Electrical system Fuel system Power unit Lower unit Bracket unit Maintenance Appendix...
Page 4: General Information
General information Model information .............. 0-1 Applicable model ................ 0-1 Model name designation ............0-1 General feature ................0-3 Important safety and service information......0-4 Rotating parts ................0-4 Hot parts..................0-4 Electric shock ................0-4 Propeller ..................0-4 Handling of gasoline..............0-4 Ventilation...................
Page 5: Model Information
Model information Model information Applicable model This manual applies to the following models. Worldwide Model name Approved model code Starting serial No. F30BEHD 6BTK 1000001– F30BET F40FEHD F40FED 6BGK 1000001– F40FET USA, CAN, AUS, and NZL Model name Approved model code Starting serial No.
Page 6 Model information USA, CAN, AUS, and NZL F 40 L E H A Model category F: 4-stroke Horsepower 30/40 S: 15 in Motor transom height L: 20 in Blank: PTT and E-start Starting method/PTT E: Electric start Blank: Remote control Control method H: Tiller handle Generation...
Page 7: General Feature
Model information General feature • Electronic fuel injected, 4-stroke, L3, SOHC, 6-valve, 747 cm³ (45.6 cu. in) engine • Low exhaust emissions conform to EU1, US EPA, CARB 3-STAR, and JBIA regulations. • Low fuel evaporative/permeation emissions conform to US EPA regulation. a.
Page 8: Important Safety And Service Information
Important safety and service information Important safety and service in- Handling of gasoline • Gasoline is highly flammable. Keep gasoline formation and all flammable products away from heat, To prevent an accident or injury and to provide sparks, and open flames. quality service, observe the following informa- •...
Page 9: Lifting Outboard Motors
Yamaha • Use a wire cable lifting harness of adequate parts, lubricants, or sealants will not be cov- strength to lift up the outboard motor in a sta- ered by warranty.
Page 10: Special Service Tools
Important safety and service information Special service tools For safety and to help protect parts from dam- age, use the recommended special service tools. • During disassembly, cover all openings, such as intake and exhaust ports, to prevent foreign materials from entering the engine. Foreign materials could cause severe inter- nal damage when the engine is started.
Page 11: How To Use This Manual
How to use this manual How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the following information as a guide for effective and quality service. •...
Page 12: Conditions When Testing And Adjusting
The following abbreviations are used in this service manual. Abbreviation Description Electronic Control Module Idle Speed Control Power Trim and Tilt Throttle Position Sensor Vapor Separator Tank Y-COP Yamaha Customer Outboard Protection YDIS Yamaha Diagnostic System Color code Black Light green Sky blue Brown Orange...
Page 13: Specified Tightening Torque
Specified tightening torque Specified tightening torque Specified tightening torques are provided for specific nuts, bolts, and screws. Specified tightening torque specifications are provided in the exploded diagrams and in the related working instructions. When tightening these fasteners, follow the tightening torque specifications and procedures indicated throughout the manual to meet the design aims of the outboard motor.
Page 14: Symbol
Lubricant YAMALUBE outboard gear oil or Yamalube Ma- Lubricant rine Gearcase Lube Water resistant grease Lubricant (Yamaha grease A or Yamalube Marine Grease) Low temperature resistant grease (Yamaha grease C or Yamalube Molybdenum Lubricant Disulfide grease) Corrosion resistant grease Lubricant...
Page 15 Symbol Symbol Name Application ThreeBond 1377B Thread locking agent ThreeBond 1901 Lubricant LOCTITE 242 (blue) Thread locking agent LOCTITE 271 (red) Thread locking agent LOCTITE 572 (white) Sealant 0-11...
Page 16: Special Service Tool
Special service tool Special service tool Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division. Special service tools with USA and Canada tool numbers (YB/YM/YS/YU–*****) are distributed by K&L Supply Co. Some of the special service tools are only available from the Marine Service Division.
Page 17 Special service tool Valve spring compres- Valve guide remover/ Valve guide installer Valve guide reamer sor attachment installer 90890-06810 90890-06804 90890-06320 90890-06801 Valve lapper Valve seat cutter hold- Valve seat cutter 30 Valve seat cutter 45 90890-04101 90890-06326 90890-06312 90890-06316 Valve seat cutter 60...
Page 18 Special service tool Drive shaft holder 3 Pinion nut holder Bearing inner race at- Driver rod LL 90890-06517 90890-06715 tachment 90890-06605 90890-06641 Bearing outer race at- Driver rod SL Bearing depth plate Bearing outer race at- tachment 90890-06602 90890-06603 tachment 90890-06622 90890-06627 Bearing inner race at-...
Page 19 Special service tool US SST No. YDIS2 Hardware Kit Digital multimeter Peak volt adapter Test harness FWY–6 LIT-YDIS2-01-KT YU-34899-A YU-39991 YB-06872 Pressure/vacuum tes- Test harness (3 pins) Test harness Spark checker YB-06870 FW13613–2 YM-34487 YB-35956-B YB-06887 Test harness Test harness (3 pins) Test harness (2 pins) Fuel pressure gauge SM6195043...
Page 20 Special service tool Driver handle (large) Driveshaft bearing in- Oil filter wrench Piston ring compressor YB-06071 staller YB-01426 YM-08037 YB-06110 Slide hammer Bearing puller legs Needle bearing attach- Bearing housing bear- YB-06096 YB-06523 ment ing/oil seal installer YB-06112 YB-06111 Oil seal installer Bearing inner race at- Bearing cup installer Driveshaft holder...
Page 21 Special service tool Shift rod socket Bearing housing puller Backlash indicator rod Backlash adjustment YB-06681 YB-06207 YB-06265 plate YB-07003 Dial indicator gauge Magnetic base stand Pinion height gauge Reverse gear bearing YU-03097 YU-A8438 YB-06668 remover YB-41707 Pinion gear bushing in- Driveshaft needle Trim cylinder wrench staller...
Page 22: Specification
Specification Specification data .............. 1-1 External dimensions ............1-1 Clamp bracket dimensions ..........1-9...
Page 23 Specification data Specification data For specification data, see Appendix, “Specification” (A-1). External dimensions TIP: The dimension values may include reference values.
Page 24 External dimensions F30BEHD, F30EHA mm (in) 779 (30.7) 342 (13.5) 923 (36.3) 235 (9.3) 583 (23.0) 178 (7.0) 65 (2.6) 29 (1.1) 522 (20.6) *1. Motor transom height *2. Fully tilt-up angle (Not tilt support angle)
Page 25 External dimensions F30HA mm (in) 779 (30.7) 345 (13.6) 925 (36.4) 235 (9.3) 583 (23.0) 177 (7.0) 65 (2.6) 29 (1.1) 522 (20.6) *1. Motor transom height *2. Fully tilt-up angle (Not tilt support angle)
Page 26 External dimensions F30BET, F30A S: 817 (32.2) L: 924 (36.4) 345 (13.6) 134 (5.3) 583 (23.0) 65 (2.6) 158 (6.2) S: 0 (0) L: 29 (1.1) 522 (20.6) *1. Motor transom height *2. Fully tilt-up angle (Not tilt support angle)
Page 27 External dimensions F40FEHD, F40EHA mm (in) 779 (30.7) S: 816 (32.1) 342 (13.5) L: 923 (36.3) 235 (9.3) 583 (23.0) 178 (7.0) 65 (2.6) S: 0 (0) L: 29 (1.1) 522 (20.6) *1. Motor transom height *2. Fully tilt-up angle (Not tilt support angle)
Page 28 External dimensions F40HA mm (in) 779 (30.7) 345 (13.6) 925 (36.4) 235 (9.3) 583 (23.0) 177 (7.0) 65 (2.6) 29 (1.1) 522 (20.6) *1. Motor transom height *2. Fully tilt-up angle (Not tilt support angle)
Page 29 External dimensions F40FED mm (in) S: 816 (32.1) L: 923 (36.3) 342 (13.5) 134 (5.3) 583 (23.0) 65 (2.6) 158 (6.2) S: 0 (0) L: 29 (1.1) 522 (20.6) *1. Motor transom height *2. Fully tilt-up angle (Not tilt support angle)
Page 30 External dimensions F40FET, F40A mm (in) S: 817 (32.2) L: 924 (36.4) 345 (13.6) 134 (5.3) 583 (23.0) 65 (2.6) 158 (6.2) S: 0 (0) L: 29 (1.1) 522 (20.6) *1. Motor transom height *2. Fully tilt-up angle (Not tilt support angle)
Page 31 Clamp bracket dimensions Clamp bracket dimensions TIP: The dimension values may include reference values. mm (in) 180 (7.1) 180 (7.1) 69 (2.7) 163.5 (6.4) 163.5 (6.4) 13 (0.5) 13 (0.5) 125.9 (5.0) 125.9 (5.0)
Page 32: Technical Feature And Description
Technical feature and description Electronic control system ..........2-1 Electrical components ..............2-3 Fail-safe..................2-5 Engine ECM ................ 2-7 Intake silencer ..............2-7 Fuel system ................ 2-8 Fuel diagram ................2-8 Lubrication system ............2-10 Lubrication diagram..............2-10 Cooling system ..............2-12 Cooling diagram ...............
Page 33: Electronic Control System
Electronic control system Electronic control system This model uses an electronic fuel injection control, ignition timing control, engine speed control, ISC valve control, and fail-safe control. The engine ECM performs these controls based on signals received from each sensor and switch. The engine ECM is equipped with a self-diagnosis function which can be used to check trouble codes on the YDIS.
Page 34 Electronic control system 1. Pulser coil 2. Oil pressure switch 3. Thermo sensor 4. Shift position switch 5. Water detection switch 6. Water pressure sensor *1 7. Speed sensor *1 8. Ignition coil 9. Fuel injector 10. Vapor shut-off valve 11.
Page 35: Electrical Components
Electronic control system Electrical components...
Page 36 Electronic control system Part name Function Detects the engine speed. Pulser coil Detects the crankshaft angle and piston positions. Thermo sensor Detects water temperature. Ignition coil Produces high voltage to ignite a spark plug. Oil pressure switch Detects oil pressure decrease. Determines the engine operating conditions based on the input Engine ECM signals from the sensors which are installed at various locations...
Page 37: Fail-Safe
Electronic control system Fail-safe In the fail-safe control, the engine ECM enters the fail-safe control mode when an electrical component malfunctions. The fail-safe control system records the trouble codes according to the engine trouble conditions. Trouble Trouble conditions to be detect- Item Control and operation code...
Page 38 Electronic control system Trouble Trouble conditions to be detect- Item Control and operation code Cooling water temperature is 40 C (104 F) or less, and en- Over cooling ECM does not control. gine speed is 3000 r/min or more for 2 minutes or more. Open or short circuit in the Y- The engine starts, but the en- COP circuit.
Page 39: Engine Ecm
Engine ECM Engine ECM The F30B engine ECM has been newly developed based on the F40F engine. The approved model codes “a” identify each engine ECM. EC1302 8125 Model name Approved model code “a” F30B F40F Intake silencer The intake silencer comes in shapes suitable for the intake air volume of each model. A.
Page 40: Fuel System
Fuel system Fuel system Fuel diagram 16. Vapor shut-off valve 10. Pressure regulator 5. Fuel strainer 4. Low-pressure fuel pump 2. Primer pump 6. Vapor separator 3. Fuel filter 15. Fuel cooler 12. Fuel injector 11. Fuel rail...
Page 41 Fuel system 16. Vapor shut-off valve 6. Vapor separator 10. Pressure 17. Intake silencer 18. Intake manifold regulator 284kPa (2.84kgf/cm 41.2 psi) 11. Fuel rail 15. Fuel 9. High-pressure cooler fuel pump Fuel injector Fuel injector Fuel injector 8. Filter 13.
Page 42: Lubrication System
Lubrication system Lubrication system Lubrication diagram 6. Oil pressure switch 3. Oil pump 4. Oil filter 1. Oil pan 2. Oil strainer 10. Sleeve 14. Intake and exhaust valves 9. Piston 13. Rocker arm 8. Crankshaft pin 12. Rocker arm shaft 7.
Page 43 Lubrication system 1. Oil pan 2. Oil strainer 3. Oil pump 4. Oil filter 5. Main gallery 6. Oil pressure switch 7. Crankshaft journal 8. Crankshaft pin 9. Piston 10. Sleeve 11. Camshaft journal 12. Rocker arm shaft 13. Rocker arm 14.
Page 44: Cooling System
Cooling system Cooling system Cooling diagram 10. Thermostat 8. Fuel cooler 11. Exaust guide 15. Trim tab water inlet 3. Water pump 2. Water inlet 2-12...
Page 45 Cooling system 8. Fuel cooler 9. Cooling water pilot hole 11. Exhaust guide 7. Exhaust cover 10. Thermostat 12. Upper case 4. Exhaust port 6. Cylinder head 5. Cylinder block 13. Lower case 3. Water pump 15. Trim tab 2. Water inlet water inlet 14.
Page 46: Intake And Exhaust System
Intake and exhaust system Intake and exhaust system Intake and exhaust diagram 1. Intake silencer 2. Throttle body 3. Intake manifold 8. Idle exhaust hole 4. Exhaust guide 5. Exhaust manifold 6. Muffler 7. Propeller boss 1. Intake silencer 2. Throttle body 3.
Page 47: Hose Routing
Hose routing Hose routing Fuel hose 1. Fuel joint to joint 2. Joint to fuel filter 3. Fuel filter to fuel pump 4. Fuel pump to strainer 5. Strainer to vapor separator 6. Pressure regulator to fuel cooler 7. Fuel cooler to vapor separator 8.
Page 48: Vapor Gas Hose And Blowby Hose
Hose routing Vapor gas hose and blowby hose 1. Vapor separator to joint 2. Vapor separator to joint 3. Joint to vapor shut-off valve 4. Vapor shut-off valve to throttle body 5. Cylinder head cover to intake silencer 2-16...
Page 49: Cooling Water Hose
Hose routing Cooling water hose 1. Exhaust cover to joint 2. Joint to fuel cooler 3. Fuel cooler to fuel cooler 4. Fuel cooler to joint 5. Joint to joint 6. Joint to exhaust guide 7. Joint to cooling water pilot hole 8.
Page 50: Rigging Information
Rigging information Important reminder on rigging.......... 3-1 Outboard motor mounting instructions ........3-1 Crate handling ..............3-2 Crate top cover pictograph description........3-2 Uncrating ................3-3 Uncrating procedure..............3-3 Rigging grommet mounting ..........3-5 Rigging grommet description............3-5 Installing the battery cable............3-5 Installing the shift cable and throttle cable .........
Page 51: Important Reminder On Rigging
Important reminder on rigging Important reminder on rigging Outboard motor mounting instructions • Overpowering a boat could cause severe instability. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer.
Page 52: Crate Handling
Crate handling Crate handling Crate top cover pictograph description The following pictographs are important when handling the crate. Read the notice and understand what each pictograph means to prevent damage to the outboard motor when handling, transporting, and storing the crate. IMPORTANT This unit delivered to carrier in a good condition.
Page 53: Uncrating
Uncrating Uncrating g. Install the shackles “1” to the engine hang- ers “2”, and then install the lifting harness- Uncrating procedure es “3” to the shackles “1”. Wear gloves to avoid injury from sharp steel edges while uncrating. 1. Uncrate: •...
Page 54 Uncrating Lift up the outboard motor carefully along m. For the procedure of outboard motor with the bottom frame “1”. mounting on boat, see “Rigging Guide” (6YR-2819Y-**). n. Remove the lifting harness and shackles, Make sure that the lifting harnesses do not and then install the fiywheel magneto cov- damage any parts of the outboard motor.
Page 55: Rigging Grommet Mounting
Rigging grommet mounting Rigging grommet mounting Installing the battery cable 1. Install: Rigging grommet description • Battery cable Pass all the rigging components through the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ proper holes in the rigging grommet. a. Remove the plastic tie “1”, and then re- move the main wire harness coupler “a”.
Page 56: Installing The Shift Cable And Throttle Cable
Rigging grommet mounting Installing the shift cable and throttle b. Move the remote control lever to the N po- sition. cable c. Align the pin “1” with the mark “a” on the shift bracket “2”. Always perform the cable adjustment in ad- vance, following the procedures in the in- struction accompanied with remote control box.
Page 57 Rigging grommet mounting h. Tighten the shift cable locknut “4” from its Pull the inner cable “3” using the force of fully seated position to the specified angle. 15 N (1.5 kgf, 3.4 lbf) to remove any free play in the cable. m.
Page 58: Installing The Main Wire Harness
Rigging grommet mounting 3. Check: • Shift cable operation • Throttle cable operation Improper  Repeat from step 2. 4. Install: • Grommet “1” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Installing the 6Y8 multifunction meter harness (pigtail bus wire) 1. Remove the cap “1”. 2. Route the pigtail bus wire “2” through the bottom cowling.
Page 59: Installing The Conventional Gauge (6Y5/6Y7) Harness
Tiller handle Installing the conventional gauge (6Y5/6Y7) harness 1. Install: • Gauge harness ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the cap “1”. b. Route the gauge harness “2” through the bottom cowling. See “Bottom cowling (re- mote control model)” (5-9). Grommet holder bolt “5” c.
Page 60 Tiller handle c. Install the tiller handle assembly “3” to the h. Remove the cap “1”. steering arm “4”, and then tighten the tiller Route the trolling switch harness “2” handle nuts “5” to the specified torque. through the bottom cowling, and then con- d.
Page 61: Battery Installation
Battery installation Battery installation 2. Check: • Steering friction TIP: Make sure to connect the battery properly Make sure that the hoses, harnesses, leads, and select the proper cable sizes. Other- and cables do no interfere with the steering wise, a fire could result. friction plate assembly.
Page 62: Propeller Selection
Propeller selection Propeller selection With the engine speed at full throttle operating range and under a maximum boat load, the engine speed should be within the upper half of the full throttle operating speed range. Full throttle operating range 5000–6000 r/min Blade Dia.
Page 63: Troubleshooting
Troubleshooting YDIS ..................4-1 Connecting the communication cable ........4-1 Outboard motor troubleshooting........4-3 Troubleshooting procedure ............4-3 Troubleshooting the power unit using the YDIS ......4-3 Trouble code and checking step ..........4-5 Troubleshooting procedure (trouble code not detected) .... 4-7 Troubleshooting the power unit ..........
Page 64: Ydis
YDIS YDIS The Yamaha Diagnostic System uses precision fault diagnosis to offer better serviceability at a time when there is increasing demand for service tools for electronically controlled products. It provides quick, reliable, safe, and reasonable service, and is intended to obtain customer satisfaction. The Ya- maha Diagnostic System features updated software and expanded tool functions that allow it to re- spond to new models and technologies, maintaining compatibility with regulations.
Page 65 YDIS K-Line a. YDIS coupler 2. Adapter cap 4. K-Line harness 1. Adapter interface 3. USB cable 1. Adapter interface 2. Adapter cap 3. USB cable 4. K-Line harness a. YDIS coupler (gray)
Page 66: Outboard Motor Troubleshooting
Outboard motor troubleshooting Outboard motor troubleshooting Troubleshooting procedure 1. Before troubleshooting the outboard motor, check that fresh fuel of the specified type has been used. 2. Check that all electrical connections are secure and free from corrosion, and that the battery is fully charged.
Page 67 Outboard motor troubleshooting Trouble code table ✔: Indicated —: Not indicated YDIS diagnosis Code No. Item YDIS diagnosis record ✔ ✔ Thermo sensor ✔ ✔ ✔ ✔ Battery voltage ✔ ✔ Air temperature sensor ✔ ✔ Water in fuel filter ✔...
Page 68: Trouble Code And Checking Step
Outboard motor troubleshooting Trouble code and checking step —: Not applicable Trou- Item (Condition) Symptom Checking steps page code Measure the thermo sensor in- “Check Engine” is displayed. 5-32 put voltage. High engine idle speed Thermo sensor Degraded acceleration perfor- Measure the thermo sensor re- 5-32 (Out of specifi-...
Page 69 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code Check the gear shift operation. 10-4 Measure the shift position 5-32 switch input voltage. Shift position “Check Engine” is displayed. Check the shift position switch switch (Irregu- 5-32 Engine operates normally. for continuity.
Page 70: Troubleshooting Procedure (Trouble Code Not Detected)
Outboard motor troubleshooting Troubleshooting procedure (trouble code not detected) Troubleshooting consists of the following 5 items: Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause: Trouble causes of symptom 2 Checking steps: Method for checking See page: Reference page —: Not applicable Troubleshooting the power unit...
Page 71 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Measure the pulser coil output peak 5-30 voltage. Pulser coil malfunction Checking the pulser coil air gap. Measure the pulser coil resistance. 5-30 Spark plug does not Check the engine ECM output peak produce a spark (all Engine ECM malfunction 5-29...
Page 72 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Check the ISC valve for sticking. 5-20 Intake air passage malfunc- — Check the intake manifold and throt- tion 6-12 tle body for air leakage. Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited en- gine speed.
Page 73 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Check the valve timing. 7-16 Improper valve timing Check the timing belt. 7-15 Measure the valve clearance. Check the rocker arm for damage. 7-39 Compression pres- Check the camshaft for damage. 7-40 sure is low Check the valve and valve seat for...
Page 74 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Check the engine oil level. 10-15 Check for engine oil leakage. 2-10 Insufficient engine oil Check the valve seals and valves. 7-30 Check the piston rings. 7-52 Buzzer comes on, oil Check the oil pressure switch.
Page 75: Troubleshooting The Ptt Unit
Outboard motor troubleshooting Symptom 1: Y-COP lock and unlock function, but there is no answer-back (beep). Symptom 2 Cause Checking steps page Buzzer malfunction Check the buzzer. — — Measure the buzzer input voltage. — Short, open, or loose con- nection of the wire harness Check the Y-COP circuit.
Page 76: Troubleshooting The Lower Unit
Outboard motor troubleshooting Symptom 1: PTT unit does not hold the outboard motor up. Symptom 2 Cause Checking steps page Manual valve open Check the manual valve. 9-27 Insufficient PTT fluid Add sufficient PTT fluid. 10-20 PTT fluid leakage Check for PTT fluid leakage. 10-20 PTT fluid pressure Disassemble and check the PTT...
Page 77: Electrical System
Electrical system Electrical component and wire harness routing ..... 5-1 Port..................... 5-1 Starboard..................5-3 Front ................... 5-5 Rear.................... 5-6 Top ..................... 5-7 Bottom cowling (tiller handle model) .......... 5-8 Bottom cowling (remote control model)........5-9 Tiller handle (tiller handle model) ..........5-11 ECM circuit diagram ............
Page 78 Electrical system Ignition unit and component ........... 5-28 Checking the ignition spark ............5-28 Checking the engine ECM............5-29 Checking the ignition coil............5-29 Checking the spark plug cap ............ 5-30 Checking the pulser coil ............5-30 Checking the intake air temperature sensor......5-31 Checking the intake air pressure sensor ........
Page 79: Electrical Component And Wire Harness Routing
Electrical component and wire harness routing Electrical component and wire harness routing Port...
Page 80 Electrical component and wire harness routing 1. Engine ECM 2. Fuse (20 A) (engine start switch, PTT switch) 3. Fuse (30 A) (main relay) 4. Fuse (20 A) (starter relay) 5. Lighting coil lead 6. Wire harness 7. Ignition coil 8.
Page 81: Starboard
Electrical component and wire harness routing Starboard...
Page 82 Electrical component and wire harness routing 1. Fuel hose 2. Blowby hose 3. Wire harness 4. Vapor gas hose 5. Throttle body lead 6. Throttle body 7. High-pressure fuel pump 8. Fuel injector 9. Vapor shut-off valve lead A. Install the injector leads #1 and #2 into the positions “a”, and then install the wire harness into the positions “b”.
Page 83: Front
Electrical component and wire harness routing Front 1. Positive battery cable 10. Starter relay lead (brown) 2. Negative battery cable 11. 10-pin coupler 3. PTT relay A. Install the negative battery cable “2” into 4. PTT motor lead (blue) the slots of the bracket. 5.
Page 84: Rear
Electrical component and wire harness routing Rear 1. Water detection switch 2. Water detection switch lead 3. Speed sensor (optional) 4. Fuel hose A. Wind the water detection switch lead se- curing it with a clamp.
Page 85: Top
Electrical component and wire harness routing 1. Vapor shut-off valve 9. High-pressure fuel pump lead 2. Spark plug 10. Wire harness 3. Thermo sensor 4. Pulser coil 5. Lighting coil (stator assembly) 6. Starter motor 7. Blowby hose 8. Vapor gas hose...
Page 86: Bottom Cowling (Tiller Handle Model)
Electrical component and wire harness routing Bottom cowling (tiller handle model) 1. Shift position switch 9. Speedometer hose 2. Water pressure sensor coupler 10. PTT motor lead (PTT model) 3. Shift position switch coupler 11. Trolling switch lead 4. Trolling switch coupler 12.
Page 87: Bottom Cowling (Remote Control Model)
Electrical component and wire harness routing Bottom cowling (remote control model)
Page 88 Electrical component and wire harness routing 1. Shift position switch 2. PTT switch (PTT model) 3. PTT switch coupler (PTT model) 4. Water pressure sensor coupler 5. Shift position switch coupler 6. Trolling switch coupler 7. Alert indicator coupler 8. 6Y8 multifunction meter communication coupler 9.
Page 89: Tiller Handle (Tiller Handle Model)
Electrical component and wire harness routing Tiller handle (tiller handle model) 5-11...
Page 90 Electrical component and wire harness routing 1. Engine start switch coupler 2. Extension wire harness 3. Alert indicator harness 4. Grommet 5. Engine start switch 6. Engine shut-off switch 7. Alert buzzer 8. Neutral switch 9. PTT switch (F30HA, F40HA) 10.
Page 91: Ecm Circuit Diagram
ECM circuit diagram ECM circuit diagram : Indicate a connection between the symbols. The circled numbers in the illustration indicate the engine ECM terminal numbers. < INPUT > < OUTPUT > 1. Pulser coil 21. Fuel injector #1 22. Fuel injector #2 2.
Page 92 ECM circuit diagram 1. Pulser coil 2. TPS 3. Intake air pressure sensor 4. Speed sensor 5. Water pressure sensor 6. Trim sensor 7. Thermo sensor 8. Intake air temperature sensor 9. Oil pressure switch 10. Engine shut-off switch 11. Trolling switch (UP) 12.
Page 93: Ecm Coupler Layout
ECM coupler layout ECM coupler layout 434241403938373635 525150494847464544 3433323130292827262524232221201918 Connecting part Color Connecting part Color Trim sensor Pink — — Oil pressure switch Pink/White — — Trolling switch (UP) Orange/White 6Y8 network White Shift position switch Blue/Green 6Y8 network White Tachometer (remote —...
Page 94: Checking The Electrical Component
Checking the electrical component Checking the electrical compo- To check the electrical components or mea- sure the peak voltage, use the special service nent tools. A malfunctioning electrical component Using the YDIS can be checked easily by measuring the peak When checking the TPS, ISC valve, high-pres- voltage.
Page 95: Using The Digital Tester
Measure the input voltage between the ter- minal and ground. Using the digital tester The electrical technical data applies to the measurements taken using the Yamaha rec- ommended tester. The resistance values shown are the values taken before the engine is started. The actual resistance may vary depending on the environ- mental conditions and ambient temperature.
Page 96: Checking The Engine Ecm Circuit
Engine control unit and component Connect the positive battery lead to the connector “a”, and the negative battery lead to the connector “b”, and then check for continuity between the connectors “c” and “d”. Replace the relay if out of specifi- cation.
Page 97: Checking The Tps
Engine control unit and component 2. Check: 4. Measure: • Engine ECM ground circuit continuity • Engine ECM input voltage Out of specification  Replace the wire Out of specification  Check the wire har- harness. ness for continuity. Engine ECM input voltage 12 V Terminal 36–Ground ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 98: Checking The Isc Valve
Engine control unit and component c. Turn the engine start switch to ON, and ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Start the engine, and then check that the then measure the TPS output voltage engine speed increases using the YDIS when the remote control lever is at the fully “Active test”.
Page 99: Checking The Alert Indicator (Tiller Handle Model)
Engine control unit and component c. Apply positive pressure to the oil pressure switch “1” slowly, and then check that con- Do not apply a voltage higher than 1.7 V tinuity is lost in the range of the working when checking the LED. pressure.
Page 100: Checking The Alert Buzzer
Fuel control unit and component Checking the alert buzzer 2. Check: • Trolling switch continuity 1. Check: Out of specification  Replace. • Alert buzzer continuity Out of specification  Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the alert buzzer. b. Connect the battery leads to the alert buzzer connectors, and check that the alert buzzer comes on.
Page 101: Checking The Fuel Injector
Fuel control unit and component d. Connect the water detection switch cou- Checking the fuel injector pler. 1. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Fuel injector operation (using the YDIS “Stationary test”) 2. Check: No operating sound  Check the fuel in- • Water detection switch continuity jector input voltage.
Page 102: Checking The High-Pressure Fuel Pump
Fuel control unit and component 3. Measure: • Fuel injector resistance Out of specification  Replace. Resistance (reference data) 12.00  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the fuel injector couplers. b. Measure the fuel injector resistance. c. Turn the engine start switch to OFF. d.
Page 103: Checking The Vapor Shut-Off Valve
Fuel control unit and component Checking the vapor shut-off valve 1. Measure: Connect the battery leads to the vapor • Vapor shut-off valve input voltage shut-off valve terminals for only a few sec- Out of specification  Check the wire har- onds.
Page 104: Charging Unit And Component
Charging unit and component Charging unit and component Checking the lighting coil (stator as- sembly) 1. Measure: • Lighting coil output peak voltage Out of specification  Measure the light- ing coil resistance. Lighting coil output peak voltage (reference data) Green (G)–Green (G) Unloaded r/min...
Page 105: Checking The Rectifier/Regulator
Charging unit and component Checking the rectifier/regulator Test harness FW13613–2 “1” 90890-06887 Do not connect the battery cables in re- Test harness FW13613–2 “1” verse. Otherwise, the rectifier/regulator YB-06887 could be damaged. c. Disconnect the special service tool. 1. Measure: d.
Page 106: Ignition Unit And Component
Ignition unit and component Ignition unit and component Rectifier/regulator continuity Checking the ignition spark (testing diode mode) 1. Check: Tester probe Display value • Ignition spark (reference data) (–) No spark  Check ignition system circuit. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the spark plug.
Page 107: Checking The Engine Ecm
Ignition unit and component Checking the engine ECM Test harness SM6195043 1. Measure: 90890-06861 • Engine ECM output peak voltage Out of specification  Checking the pulser Test harness SM6195043 YB-06861 coil. Engine ECM output peak voltage d. Disconnect the special service tool. (reference data) #1: Black/Orange (B/Or)–Black (B) e.
Page 108: Checking The Spark Plug Cap
Ignition unit and component Checking the spark plug cap Checking the pulser coil 1. Measure: 1. Measure: • Spark plug cap resistance • Pulser coil output peak voltage Out of specification  Replace. Out of specification  Measure the pulser coil resistance.
Page 109: Checking The Intake Air Temperature Sensor
Ignition unit and component g. Start the engine, and then measure the b. Connect the YDIS to display “Intake air peak voltage at the specified engine temperature”. speed. c. Check that the difference between the am- bient temperature and the displayed intake air temperature is within ...
Page 110: Checking The Thermo Sensor
Ignition unit and component Checking the thermo sensor 1. Measure: • Thermo sensor input voltage Out of specification  Check the wire har- ness for continuity. Input voltage Black/Yellow (B/Y)–Black (B) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ d. Install the thermo sensor. See “Installing a. Disconnect the thermo sensor coupler “a”. the thermo sensor”...
Page 111: Checking The Engine Shut-Off Switch
Ignition unit and component 2. Check: 2. ON • Shift position switch continuity 1. OFF 3. START Out of specification  Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the shift position switch. b. Check the shift position switch for continu- ity. 1. OFF 2.
Page 112: Starting Unit And Component
Starting unit and component Starting unit and component 3. Check: • Starter relay operation Checking the starter relay Out of specification  Replace. 1. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Starter relay input voltage a. Connect the positive battery lead to the re- Out of specification ...
Page 113: Checking The Engine Start Switch
Starting unit and component Checking the engine start switch 1. Check: • Engine start switch continuity Out of specification  Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the main wire harness coupler or switch panel coupler. b. Check the engine start switch for continui- 2.
Page 114: Starter Motor
Starter motor Starter motor 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Planetary gear Screw M5  7 mm Pinion stopper set Lead Pinion shaft Screw set Outer gear Cover screw: M6  25 Clutch assembly Bracket screw: M5 ...
Page 115: Removing The Starter Motor
Starter motor Removing the starter motor 2. Remove: • Cap • Pinion stopper Before removing the starter motor, make • Clip sure to disconnect the negative battery ter- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Push the pinion stopper “1” down, and minal. then remove the clip “2”. 1.
Page 116: Checking The Armature (Starter Motor)
Starter motor Checking the armature (starter motor) Standard commutator undercut 1. Check: 0.5 mm (0.02 in) • Commutator Dirty  Clean using 600-grit sandpaper Wear limit 0.2 mm (0.01 in) and compressed air. 4. Check: • Armature continuity Out of specification  Replace the arma- ture.
Page 117: Assembling The Starter Motor
Starter motor 2. Measure: • Brush length Below specification  Replace the brush. a. Standard brush length ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Wear limit 3. Install: Standard brush length • Brush holder assembly 12.3 mm (0.48 in) • Bracket Wear limit • Bracket screw 5.5 mm (0.22 in) •...
Page 118 Starter motor 4. Assemble: 6. Install: • Clutch assembly “1” • Pinion shaft assembly “1” • Outer gear “2” • Lever “2” • Pinion shaft “3” • Planetary gear “3” • Rubber seal “4” 5. Install: • Pinion stopper “1” 7.
Page 119: Installing The Starter Motor
Starter motor 8. Install: • Cap “1” • Magnet switch “2” • Starter motor lead “3” • Starter motor lead screw “4” Stator motor lead screw 3.0N·m (0.30 kgf·m, 2.2 lb·ft) Installing the starter motor 1. Install: • Starter motor See “Installing the starter motor”...
Page 120: 6Y8 Multifunction Meters Sensor
6Y8 Multifunction Meters sensor 6Y8 Multifunction Meters sensor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the water pressure sensor, and Checking the water pressure sensor then connect the pressure pump “1” and 1. Measure: special service tool “2”. • Water pressure sensor input voltage Out of specification ...
Page 121: Checking The Speed Sensor
6Y8 Multifunction Meters sensor Checking the speed sensor c. Apply positive pressure to the speed sen- sor slowly, and then measure the output 1. Measure: voltage. • Speed sensor input voltage Out of specification  Check the wire har- ness for continuity. Input voltage Orange (Or)–Black (B) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 122: Ptt System
PTT system PTT system Checking the PTT relay 1. Measure: • PTT relay input voltage G/W G Out of specification  Check the wire har- ness for continuity. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the caps. b. Measure the input voltage between the PTT relay terminal “a”...
Page 123: Checking The Ptt Switch (On Bottom Cowling)
PTT system Connect the positive battery lead to the terminal “a”, and the negative battery lead to the terminal “b”, and then check the PTT relay for continuity. G/W G c. Connect the PTT switch coupler. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • PTT switch continuity Out of specification ...
Page 124: Checking The Ptt Switch (Tiller Handle Model)
PTT system Checking the PTT switch (tiller handle PTT switch continuity model) Terminal Switch po- 1. Measure: sition “a” “b” “c” • PTT switch input voltage Out of specification  Check the wire har- ness for continuity. Free Input voltage 12 V c.
Page 125 PTT system c. Turn the trim sensor lever “1” from the free position “a” to the setting position “b”, and then measure the resistance as it gradual- ly changes. d. Install the trim sensor, and then connect the trim sensor coupler. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 126: Fuel System
Fuel system Fuel system ................ 6-1 Reducing the fuel pressure ............6-1 Disconnecting the quick connector..........6-1 Measuring the fuel pressure............6-1 Checking the pressure regulator ..........6-3 Fuel filter ................6-4 Removing the fuel filter assembly ..........6-5 Checking the fuel filter assembly..........6-5 Checking the fuel filter element ..........
Page 127 Fuel system Fuel cooler ................ 6-20 Vapor separator and high-pressure fuel pump ..... 6-21 Checking the fuel strainer............6-22 Checking the vapor separator ..........6-22 Adjusting the float height ............6-22 Assembling the vapor separator..........6-23 Fuel injector ..............6-25 Removing the fuel injector............
Page 128: Reducing The Fuel Pressure
Fuel system Fuel system Disconnecting the quick connector Reducing the fuel pressure Before disconnecting the quick connector, reduce the fuel pressure. Otherwise, pres- Before servicing the high-pressure fuel line surized fuel could spray out. or vapor separator, make sure to reduce the fuel pressure in the fuel line.
Page 129 Fuel system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Reduce the fuel pressure. See “Reducing the fuel pressure” (6-1). b. Disconnect the quick connector from the fuel rail. See “Disconnecting the quick con- nector” (6-1). c. Connect the special service tool “1” to the quick connector and the fuel rail. A.
Page 130: Checking The Pressure Regulator
Fuel system k. Disconnect the special service tool. Before disconnecting the special service tools, cover the end of the hose using a clean and dry rag. Connect the quick connector to the fuel rail. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Checking the pressure regulator 1. Reduce the fuel pressure. See “Reducing the fuel pressure”...
Page 131: Fuel Filter
Fuel filter Fuel filter 5 N·m (0.5 kgf·m, 3.7 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Cover Bracket Clip Hose Plastic tie Hose Fuel filter assembly Fuel cup assembly O-ring Fuel filter element Clip Float Clamp Joint Hose Bolt M6 ...
Page 132: Removing The Fuel Filter Assembly
Fuel filter Removing the fuel filter assembly d. Block the fuel inlet “b” using a rubber plug “2”, and then apply the specified negative Cover the fuel components using a rag to pre- pressure. Replace the O-ring, fuel cup as- vent fuel from spilling out.
Page 133: Checking The Primer Pump
Fuel filter Checking the primer pump ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the special service tool “1” to the 1. Check: fuel joint outlet “a”. • No air leakage Air leakage  Replace. b. Apply the specified positive pressure. Re- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ place the fuel joint if the specified pressure a.
Page 134: Installing The Fuel Filter Assembly
Fuel filter Installing the fuel filter assembly 1. Install: • Fuel joint • Fuel filter assembly • Clamp • Hose • Plastic tie...
Page 135: Fuel Pump Assembly
Fuel pump assembly Fuel pump assembly 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) Part name Q’ty Remarks Bolt M6  30 mm Fuel pump assembly O-ring Screw M5  43 mm Washer Cover Diaphragm Fuel pump body Plunger Spring Diaphragm Spring Fuel pump body...
Page 136: Checking The Fuel Pump Assembly
Fuel pump assembly Checking the fuel pump assembly Fuel inlet holding pressure (nega- 1. Check: tive pressure) • No air leakage Air leakage  Disassemble and check the 30.0 kPa (0.30 kgf/cm², 4.4 psi) fuel pump. See “Disassembling the fuel d.
Page 137: Checking The Diaphragm And Valve
Fuel pump assembly b. Remove the pin “1” by pressing the plung- Assembling the fuel pump er and diaphragm. Before assembling the fuel pump, clean the parts and soak the valves and diaphragm in gasoline to obtain prompt operation of the fuel pump.
Page 138: Installing The Fuel Pump Assembly
Fuel pump assembly d. Turn the plunger “1” so that both the dia- phragm tab “a” and the groove “b” face to- ward the same direction. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: • Fuel pump body “1” • Diaphragm “2” • Fuel pump cover “3” •...
Page 139: Intake Silencer, Intake Manifold And Throttle Body
Intake silencer, intake manifold and throttle body Intake silencer, intake manifold and throttle body Part name Q’ty Remarks Plastic tie Cover Bolt M6  12 mm Intake silencer O-ring Bolt M8  40 mm Bolt M6  35 mm Intake manifold Gasket Bolt M6 ...
Page 140: Checking The Throttle Body
Intake silencer, intake manifold and throttle body Checking the throttle body 1. Check: • Throttle body exterior Cracked  Replace. 2. Check: • Throttle valve movement Not smooth  Clean. Checking the intake manifold 1. Check: • Intake manifold Cracked/deformed  Replace. Checking the vapor shut-off valve 1.
Page 141: Throttle Link Rod
Throttle link rod Throttle link rod Part name Q’ty Remarks Throttle link rod Bolt M6  45 mm Collar Wave washer Throttle cam Bolt M6  35 mm Throttle control lever Collar Spring Cotter pin Throttle cam roller 6-14...
Page 142: Installing The Throttle Link
Throttle link rod Installing the throttle link d. Install the throttle cam assembly “1”. 1. Install: • Throttle link rod ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the roller “1”, a new cotter pin “2”, the spring “3”, the collar “4”, and the bolt “5”.
Page 143 Throttle link rod b. Check that the protrusion “a” on the throttle lever “1” and the protrusion “b” on the shift bracket “2” are aligned. c. Turn the throttle cam until it contacts the roller “3” slightly. d. Adjust the throttle link rod length so that its end “a”...
Page 144: Vapor Separator
Vapor separator Vapor separator Part name Q’ty Remarks Part name Q’ty Remarks Bolt M6  20 mm Bolt M6  30 mm Cover Collar Collar Grommet Grommet Fuse puller Hose Holder Holder Holder Hose Vapor shut-off valve Bolt M6  16 mm Bracket Bolt M6 ...
Page 145: Draining The Fuel
Vapor separator Draining the fuel 2. Disconnect: • Quick connector 1. Drain: • Blowby hose • Fuel • Vapor gas hose ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • High-pressure fuel pump coupler a. Loosen the drain screw “1”. • Cooling water hoses 3. Remove: • Vapor separator assembly Installing the vapor separator 1.
Page 146 Vapor separator b. Connect the cooling water hoses “1” and “2”. c. Connect the vapor gas hoses “1” and “2”, and then install the holder “3”. d. Connect the quick connector “1”, and then install the holder “2” aligning it with the white tape “3”...
Page 147: Fuel Cooler
Fuel cooler Fuel cooler 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Clamp Hose Hose Joint Clip Hose Hose Hose Strainer Joint Holder Holder Clamp Clamp Hose Quick connector Plastic tie Hose Hose...
Page 148: Vapor Separator And High-Pressure Fuel Pump
Vapor separator and high-pressure fuel pump Vapor separator and high-pressure fuel pump 5 N·m (0.5 kgf·m, 3.7 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 1.5 N·m (0.15 kgf·m, 1.1 lb·ft) Part name Q’ty...
Page 149: Checking The Fuel Strainer
Vapor separator and high-pressure fuel pump Checking the fuel strainer 2. Check: • Float 1. Check: Deteriorated  Replace. • No air leakage Air leakage  Replace. 3. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Filter a. Connect the leakage tester “1” to the fuel Dirt or residue ...
Page 150: Assembling The Vapor Separator
Vapor separator and high-pressure fuel pump 2. Adjust: Assembling the vapor separator • Float height “a” 1. Assemble: • Float height “b” • Vapor separator ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Bend portions “1” of the float to adjust the a. Install the plates “1” and “2”, and then tight- float height to specification “a”.
Page 151 Vapor separator and high-pressure fuel pump c. Install the filter “1”. Float chamber cover screw “4” 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) Connect the lead “a”. g. Install the pressure regulator “1”, the pres- sure regulator bolts “2”, new O-rings “3”, d.
Page 152: Fuel Injector
Fuel injector Fuel injector Part name Q’ty Remarks Bolt M6  40 mm Fuel rail Holder Fuel injector O-ring set 2 pcs/set 6-25...
Page 153: Removing The Fuel Injector
Fuel injector Removing the fuel injector Fuel injection volume Cover the fuel components using a rag to pre- 71–83 cm³ (90 cc)/30 sec vent fuel from spilling out. Test fuel Dry sorbent (viscosity: 1.2  0.03 1. Reduce: • Fuel pressure mm²/s, specific gravity: 0.774 [15 C]) See “Reducing the fuel pressure”...
Page 154: Power Unit
Power unit Power unit (check and adjustment)........7-1 Checking the compression pressure .......... 7-1 Checking the oil pressure............7-1 Checking the pulser coil air gap ..........7-2 Adjusting the pulser coil air gap ..........7-2 Checking the valve clearance ............ 7-2 Adjusting the valve clearance.............
Page 155 Power unit Replacing the valve guide ............7-34 Checking the valve seat ............7-36 Refacing the valve seat ............7-36 Checking the rocker arm and rocker arm shaft ......7-39 Checking the camshaft............. 7-40 Checking the spark plug............7-40 Checking the cylinder head anode ........... 7-41 Assembling the cylinder head ..........
Page 156: Power Unit (Check And Adjustment)
Power unit (check and adjustment) Power unit (check and adjust- g. Crank the engine until the reading on the compression gauge stabilizes, and then ment) measure the compression pressure. Checking the compression pressure 1. Check: h. Remove the special service tools. •...
Page 157: Checking The Pulser Coil Air Gap
Power unit (check and adjustment) d. Measure the oil pressure. TIP: • Use a pressure gauge with an adapter that has a 1/8 pitch thread. • The actual oil pressure may vary depending on the temperature and engine oil viscosity. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 158 Power unit (check and adjustment) 1. Check: e. Turn the flywheel magneto clockwise and • Valve clearance align the “1△” mark “a” on the driven Out of specification  Adjust. See “Adjust- sprocket “1” with the “△” mark “b” on the ing the valve clearance”...
Page 159 Power unit (check and adjustment) g. Measure the intake and exhaust valve k. Measure the intake and exhaust valve clearances of the specified cylinder. clearances of the applicable cylinder. ✔ ✔ — — — — ✔ ✔ — — — —...
Page 160: Adjusting The Valve Clearance
Power unit (check and adjustment) p. Install the fuel filter assembly “5”, the fuel Adjusting the valve clearance hoses “6”, and the blowby hose “7”. Adjust the valve clearances when the engine is cold. Do not turn the flywheel magneto counter- clockwise.
Page 161: Power Unit Assembly
Power unit assembly Power unit assembly 21 N·m (2.1 kgf·m, 15 lb·ft) 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 21 N·m (2.1 kgf·m, 15 lb·ft) Part name Q’ty Remarks Bolt M6  20 mm Grommet holder Grommet Cable guide Rigging grommet Dipstick Bolt M6 ...
Page 162: Removing The Power Unit
Power unit assembly Removing the power unit e. Remove the cover “4”. Cover the fuel components using a rag to pre- vent fuel from spilling out. 1. Remove: • Power unit assembly ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the grommet holder “1”, grommet “2”, and rigging grommet “3”.
Page 163 Power unit assembly Remove the each harness from the n. Disconnect the cooling water hoses “1”. clamps “1”. o. Remove the dipstick “1”. k. Remove the water pressure sensor har- ness “a” from the clamp “1”. p. Remove the clip “1”, and then remove the shift rod lever “2”...
Page 164: Installing The Power Unit
Power unit assembly Remove the apron “1”. b. Install the power unit with the power unit mounting bolts “2”. c. Tighten the power unit mounting bolts “2” to the specified torques in 2 stages and in the order [1],[2], and so on. s.
Page 165 Power unit assembly d. Install the apron “1” and apron bolts “2”, g. Install the dipstick “1”. and then tighten the apron screws “3” to the specified torque. h. Connect the cooling water hoses “1”. Apron screw “3” 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) e.
Page 166 Power unit assembly k. Install the water pressure sensor harness “a” to the clamp “1”. Connect the trolling switch coupler “a” and alert indicator coupler “b” (tiller handle model). PTT motor lead bolt “5” 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) m.
Page 167 Power unit assembly v. Install the shift cable and throttle cable. See “Installing the shift cable and throttle cable (remote control model)” (3-14). ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7-12...
Page 168: Flywheel Magneto And Timing Belt
Flywheel magneto and timing belt Flywheel magneto and timing belt 160 N·m (16 kgf·m, 118 lb·ft) 38 N·m (3.8 kgf·m, 28 lb·ft) 150 N·m (15 kgf·m, 111 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Bolt M10  35 mm Nut Width across flats: 30 mm Washer...
Page 169: Removing The Flywheel Magneto
Flywheel magneto and timing belt Removing the flywheel magneto Flywheel holder “2” 1. Turn the flywheel magneto clockwise to 90890-06522 align the “1△” mark “a” on the driven Flywheel magneto holder “2” sprocket “1” with the “△” mark “b” on the YB-06139 cylinder head.
Page 170: Removing The Timing Belt And Sprocket
Flywheel magneto and timing belt Removing the timing belt and sprock- Crankshaft holder 16 “2” 90890-06355 Crankshaft holder “2” YW-06355 When the timing belt is not installed, do not turn the crankshaft or driven sprocket. Oth- erwise, the pistons and valves could collide 3.
Page 171: Installing The Sprocket And Timing Belt
Flywheel magneto and timing belt Installing the sprocket and timing belt 3. Install: • Woodruff key “1” • Drive sprocket “2” When the timing belt is not installed, do not • Retaining plate “3” turn the crankshaft or driven sprocket. Oth- •...
Page 172: Installing The Stator Assembly
Flywheel magneto and timing belt Installing the stator assembly Drive sprocket nut “1” 1. Install: 150 N·m (15 kgf·m, 111 lb·ft) • Base assembly “1” • Stator assembly “2” 5. Install: • Stator assembly bolt “3” • Timing belt • Stator assembly coupler “4” •...
Page 173: Installing The Flywheel Magneto
Flywheel magneto and timing belt Installing the flywheel magneto 1. Install: • Woodruff key “1” (to the crankshaft) • Flywheel magneto “2” TIP: Make sure to remove any grease from the ta- pered portion of the crankshaft “a” and the fly- wheel magneto “b”.
Page 174: Engine Ecm, Rectifier/Regulator, And Ignition Coil
Engine ECM, rectifier/regulator, and ignition coil Engine ECM, rectifier/regulator, and ignition coil Part name Q’ty Remarks Bolt M6  25 mm Engine ECM Rectifier/regulator Spark plug cap Ignition coil Grommet Plate Clamp Plate 7-19...
Page 175 Wire harness Wire harness 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Bolt M6  16 mm 20 A, spare is Fuse included.
Page 176: Wire Harness
Wire harness Installing the wire harness YDIS coupler screw “6” 1. Install: 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) • Clamp “1” • PTT relay coupler “a” 2. Install: • Fuse holder “2” • Bracket “1” • Clamp “3” • Terminal “2” •...
Page 177 Wire harness 3. Install: Starter relay lead bolt “2” • Main relay “1” 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) • Main relay screw “2” • Main relay coupler “a” 6. Install: • PTT relay “1” • PTT relay coupler “a” •...
Page 178 Wire harness 7-23...
Page 179 Starter motor Starter motor 30 N·m (3.0 kgf·m, 22 lb·ft) 9 N·m (0.9 kgf·m, 6.6 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Part name Q’ty Remarks Bolt M6  25 mm Bolt M6  20 mm Bracket Clip Bushing Washer Shift rod lever Spring washer Bolt M6 ...
Page 180: Starter Motor
Starter motor Installing the starter motor 1. Install: • Starter motor lead “1” • Starter motor lead nut “2” • Starter motor lead bolt “3” • Starter motor “4” • Starter motor bolt “5” Starter motor lead nut “2” 9 N·m (0.9 kgf·m, 6.6 lb·ft) Starter motor lead bolt “3”...
Page 181 Cylinder head Cylinder head 6 N·m (0.6 kgf·m, 4.4 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) 17 N·m (1.7 kgf·m, 13 lb·ft) 34 N·m (3.4 kgf·m, 25 lb·ft) 90° Part name Q’ty Remarks Bolt M6  45 mm Oil pump assembly Gasket Bolt M6 ...
Page 182: Cylinder Head
Cylinder head Removing the cylinder head 1. Remove: • Oil pump assembly “1” [10] [11] [12] 4. Remove: • Cylinder head bolt “1” • Cylinder head bolt “2” • Cylinder head “3” 2. Remove: • Cylinder head cover “1” Do not scratch or damage the mating sur- faces of the cylinder head and cylinder block.
Page 183: Checking The Cylinder Head Bolt
Cylinder head Checking the cylinder head bolt 2. Install: • Dowel pin 1. Measure: • Cylinder head bolt (M9) diameter • Cylinder head gasket Out of specification  Replace. • Cylinder head ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the diameters “a” and “b” of the 3.
Page 184 Cylinder head 4. Install: 6. Install: • Gasket “1” • Gasket “1” • Plate “2” • Oil pump assembly “2” • Cylinder head cover “3” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a new gasket “1”, the oil pump as- sembly “2”, and the oil pump bolts, aligning the slot in the oil pump drive shaft “a”...
Page 185: Camshaft And Valve
Camshaft and valve Camshaft and valve 18 N·m (1.8 kgf·m, 13 lb·ft) 14 13 17 16 19 19 11 10 18 N·m (1.8 kgf·m, 13 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 18 N·m (1.8 kgf·m, 13 lb·ft) 14 N·m (1.4 kgf·m, 10 lb·ft) Part name Q’ty Remarks...
Page 186: Disassembling The Cylinder Head
Camshaft and valve Disassembling the cylinder head 3. Remove: • Rocker arm shaft bolt “1” 1. Remove: • Washer “2” • Cylinder head anode “1” • Stopper “3” • Spark plug “2” • Tensioner “4” • Engine hanger “3” • Washer “5” •...
Page 187: Checking The Cylinder Head
Camshaft and valve 5. Remove: Checking the cylinder head • Valve cotter 1. Check: • Retainer • Cylinder head Damage/scratches  Replace. • Valve spring • Valve spring seat • Cylinder head warpage Out of specification  Replace. • Intake valve •...
Page 188: Checking The Valve Spring
Camshaft and valve Checking the valve spring Checking the valve 1. Measure: 1. Check: • Free length “a” • Valve face Below specification  Replace. Pitted/worn  Replace. 2. Measure: • Margin thickness “a” Out of specification  Replace. Free length IN 39.85 mm (1.57 in) Limit 37.86 mm (1.49 in)
Page 189: Checking The Valve Guide
Camshaft and valve 4. Measure: 2. Calculate: • Stem runout • Valve stem to valve guide clearance Above specification  Replace. Out of specification  Replace the valve and valve guide. Valve stem to valve guide clear- ance = valve guide inside diameter –...
Page 190 Camshaft and valve 2. Install: 3. Ream: • Valve guide “1” • Valve guide ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ TIP: a. Install a new valve guide “1” to the speci- • To ream the valve guide, turn the valve guide fied installation height “a” from the cam- reamer clockwise.
Page 191: Checking The Valve Seat
Camshaft and valve Checking the valve seat 1. Measure: • Contact width “a” Not seated properly/out of specification  Reface. Uneven  Check the valve guide. Valve lapper “1” 90890-04101 Valve lapping tool “1” YM-A8998 d. Measure the valve seat contact width “a” where the blue layout fluid is adhered to the valve face.
Page 192 Camshaft and valve A. Worldwide B. USA and Canada Valve seat cutter holder 90890-06316 Intake: Valve seat cutter 30 90890-06326 Valve seat cutter 45 90890-06312 A. Worldwide Valve seat cutter 60 B. USA and Canada 90890-06323 Exhaust: 45° Valve seat cutter 30 90890-06328 Valve seat cutter 45...
Page 193 Camshaft and valve • If the valve seat contact area is too nar- a. Previous contact width row and situated near the top edge of the d. Adjust the valve seat contact width to valve face, cut the top edge of the valve specification using a 45...
Page 194: Checking The Rocker Arm And Rocker Arm Shaft
Camshaft and valve After refacing the valve seat to the speci- Checking the rocker arm and rocker fied contact width, apply a thin, even layer arm shaft of lapping compound onto the valve seat, 1. Check: and then lap the valve using the special •...
Page 195: Checking The Camshaft
Camshaft and valve Checking the camshaft 3. Measure: • Camshaft journal diameters “a”, “b”, and 1. Measure: “c” and cylinder head journal inside diame- • Lobe height “a” Below specification  Replace. ters “d” Out of specification  Replace. Cam lobe height IN 30.737–30.837 (1.2101–...
Page 196: Checking The Cylinder Head Anode
Camshaft and valve 2. Check: 2. Install: • Spark plug • Intake valve Electrodes are eroded, edges of elec- • Exhaust valve trodes are rounded, insulator is damaged, • Valve spring seat or there is carbon or other deposits.  Re- •...
Page 197 Camshaft and valve b. Compress the valve spring, and then in- 3. Install: stall the valve cotters “1”. • Oil seal “1” c. Tap the valve spring retainer lightly using a plastic hammer to seat the valve cotters “1” securely. TIP: Make sure that both valve cotters “1”...
Page 198 Camshaft and valve 4. Install: • Camshaft “1” • Gasket “2” • Camshaft retaining bolt “3” c. Tighten the rocker arm shaft bolts “1” grad- 5. Install: ually to the specified torque and in the or- • Rocker arm der [1], [2], and so on. •...
Page 199: Exhaust Cover
Exhaust cover Exhaust cover 23 N·m (2.3 kgf·m, 17 lb·ft) 9 N·m (0.9 kgf·m, 6.6 lb·ft) 6 N·m (0.6 kgf·m, 4.4 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) 56 N·m (5.6 kgf·m, 41 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 40 N·m (4.0 kgf·m, 30 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 18 N·m (1.8 kgf·m, 13 lb·ft)
Page 200: Removing The Exhaust Cover
Exhaust cover Removing the exhaust cover 4. Remove: • Exhaust cover bolt “1” 1. Remove: • Thermostat cover “2” • Bracket “1” • Thermostat “3” • Exhaust cover “4” 2. Remove: • Exhaust cover plug “1” • Exhaust cover plug “2” •...
Page 201: Checking The Exhaust Cover Anode
Exhaust cover 2. Remove: c. Measure the thermostat valve opening “a” • Oil filter union bolt “1” at the specified water temperatures. Checking the exhaust cover anode Water tempera- Valve opening “a” ture 1. Check: • Anode 58–62 C Starts opening Eroded (1/2 or more) ...
Page 202: Installing The Thermo Sensor
Exhaust cover 2. Install: Installing the thermo sensor • Oil filter “1” 1. Install: • Gasket “1” • Thermo sensor “2” Oil filter wrench “2” 90890-01426 Oil filter wrench “2” Thermo sensor “2” YB-01426 23 N·m (2.3 kgf·m, 17 lb·ft) Installing the exhaust cover Oil filter “1”...
Page 203 Exhaust cover 2. Tighten: Exhaust cover anode screw “3” • Exhaust cover bolt “1” 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) TIP: Exhaust cover anode plug “4” Tighten the exhaust cover bolts “1” to the spec- 18 N·m (1.8 kgf·m, 13 lb·ft) ified torques in 2 stages and in the order [1], [2], Exhaust cover plug (M14) “6”...
Page 204: Cylinder Block
Cylinder block Cylinder block 15 N·m (1.5 kgf·m, 11 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) 6 N·m (0.6 kgf·m, 4.4 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) 6 N·m (0.6 kgf·m, 4.4 lb·ft) 17 N·m (1.7 kgf·m, 13 lb·ft) Part name Q’ty Remarks...
Page 205: Disassembling The Cylinder Block
Cylinder block Disassembling the cylinder block 3. Remove: • Connecting rod bolt “1” 1. Loosen: • Connecting rod cap “2” • Crankcase bolt “1” • Piston assembly “3” • Crankcase bolt “2” TIP: TIP: • Make sure to keep the crankshaft pin bear- Loosen the crankcase bolts in the order [1], [2], ings in their original groups.
Page 206: Checking The Piston Diameter
Cylinder block 5. Remove: Piston • Piston pin clip “1” • Piston pin “2” Diameter • Connecting rod “3” 64.950–64.965 (2.5571– 2.5577 in) Limit 64.910 mm (2.5555 in) 1st oversize diameter 65.200–65.215 (2.5669– 2.5675 in) 2nd oversize diameter 65.450–65.465 (2.5768– 2.5774 in) Measuring point 5.0 mm (0.20 in)
Page 207: Checking The Piston Clearance
Cylinder block Checking the piston clearance Piston ring dimensions 1. Measure: Top ring • Piston diameter Height (B) See “Checking the piston diameter” (7-51). 1.170–1.190 (0.0461– • Cylinder bore 0.0469 in) See “Checking the cylinder bore” (7-51). Width (T) 2. Calculate: 2.300–2.500 (0.0906–...
Page 208: Checking The Piston Ring Groove
Cylinder block b. Measure the piston ring end gap “b”. Checking the piston ring side clear- ance 1. Measure: • Piston ring side clearance Above specification  Check the piston ring grooves and piston ring. See “Checking the piston ring groove” (7- 53) and “Checking the piston ring”...
Page 209: Checking The Piston Pin Boss Inside Diameter
Cylinder block Checking the piston pin boss inside diameter 1. Measure: • Piston pin boss inside diameter “a” Above specification  Replace. TIP: When measuring the piston pin boss inside di- ameter, do not measure it at the ring groove “b” or oil groove “c”.
Page 210: Checking The Connecting Rod Big End Side Clearance
Cylinder block b. Measure the connecting rod small end in- side diameter “a” and big end inside diam- eter “b”. Connecting rod bolt “1” 1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft) 2nd: 17 N·m (1.7 kgf·m, 13 lb·ft) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Checking the connecting rod big end Journal diameter 42.984–43.000 (1.6923–...
Page 211: Checking The Big End Oil Clearance
Cylinder block Checking the big end oil clearance 1. Measure: • Big end oil clearance Out of specification  Replace crankshaft pin bearing. See “Selecting the crankshaft pin bearing” (7-57). Big end oil clearance 0.016–0.040 (0.0006– 0.0016 in) d. Install the connecting rod “1” and connect- Limit ing rod cap “2”...
Page 212: Selecting The Crankshaft Pin Bearing
Cylinder block Remove the connecting rod cap, and then measure the width of the compressed Plastigauge (PG-1) on the crankshaft pin. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Selecting the crankshaft pin bearing When replacing the crankshaft pin bearing, se- lect the bearing as follows: 1. Select: •...
Page 213: Checking The Journal Oil Clearance
Cylinder block Checking the journal oil clearance 1. Measure: • Journal oil clearance Out of specification  Replace crankshaft journal bearing. See “Selecting the crankshaft journal bear- ing” (7-59). Journal oil clearance 0.012–0.036 (0.0005– 0.0014 in) e. Install the crankshaft journal bearings into Limit the crankcase.
Page 214: Selecting The Crankshaft Journal Bearing
Cylinder block b. Check the mark “a” on the crank web and the mark “b” on the cylinder block. c. Select the suitable colors “c” for the crank- shaft journal bearing. [13] [14] [10] [11] [12] J3 J4 [16] [15] Crankcase bolt (M8) “2”...
Page 215: Assembling The Cylinder Block
Cylinder block • Oil ring Crankshaft journal bearing selection table at • 2nd ring 20 C (68 F) • Top ring Cylinder ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Crankshaft journal Bearing col- block mark a. Install the oil rings “1”, 2nd ring “2”, and top mark “a”...
Page 216 Cylinder block 3. Install: A. Worldwide • Crankshaft pin bearing “1” (into the con- B. USA and Canada necting rod “2” and connecting rod cap “3”) Piston slider “1” TIP: 90890-06529 • Install the crankshaft pin bearings in the orig- Piston ring compressor “2”...
Page 217 Cylinder block TIP: Distance “c” • Make sure that the protrusions “a” on the con- 14.2–14.8 mm (0.56–0.58 in) necting rod and connecting rod caps “1” are Distance “d” facing toward the flywheel magneto end of 95.4–96.0 mm (3.76–3.78 in) the crankshaft.
Page 218 Cylinder block b. Apply a thin, even layer of sealant onto the mating surface of the crankcase. TIP: • Install the crankshaft journal bearings “1” into [13] the crankcase in the same positions as the [14] crankshaft journal bearings in the cylinder block.
Page 219: Lower Unit
Lower unit Lower unit ................8-1 Removing the lower unit............. 8-2 Checking the propeller ............... 8-2 Checking the lower unit anode ........... 8-2 Water pump ................ 8-3 Checking the water pump............8-4 Propeller shaft housing ............. 8-5 Removing the propeller shaft housing assembly......8-6 Disassembling the propeller shaft assembly ......
Page 220 Lower unit Shimming ................8-24 Shimming workflow ..............8-24 Shimming check sheet ............. 8-25 Measuring the forward gear backlash and reverse gear backlash before disassembly ......8-27 Shimming procedure ..............8-31 Shim location................8-31 Selecting the pinion shim (T3)..........8-32 Measuring the forward gear backlash ........
Page 221: Lower Unit
Lower unit Lower unit 35 N·m (3.5 kgf·m, 26 lb·ft) 40 N·m (4.0 kgf·m, 30 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Cotter pin Dowel pin Propeller nut Lower unit Washer...
Page 222: Removing The Lower Unit
Lower unit Removing the lower unit 4. Remove: • Trim tab bolt • Trim tab • Make sure to disconnect the battery ca- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Mark the trim tab “1” and lower case with bles from the battery, and remove the clip an identification mark “a”, and then remove from the engine shut-off switch.
Page 223: Water Pump
Water pump Water pump Part name Q’ty Remarks Bolt M8  30 mm Cover Seal Water pump housing Insert cartridge Impeller O-ring Impeller key Outer plate cartridge Gasket Rubber seal Plate Dowel pin...
Page 224: Checking The Water Pump
Water pump Checking the water pump 1. Check: • Water pump housing Deformed  Replace. TIP: If the engine overheats, the inside of the water pump housing may be deformed. Therefore, make sure to remove the insert car- tridge when checking the water pump housing. 2.
Page 225 Propeller shaft housing Propeller shaft housing 16 N·m (1.6 kgf·m, 12 lb·ft) Part name Q’ty Remarks Bolt M8  25 mm Propeller shaft housing Propeller shaft Shift plunger Spring Cross pin Dog clutch Slider Spring O-ring O-ring Washer Reverse gear Reverse gear shim —...
Page 226: Propeller Shaft Housing
Propeller shaft housing Removing the propeller shaft housing Disassembling the propeller shaft assembly housing assembly 1. Remove: 1. Remove: • Bolt “1” • Reverse gear “1” • Propeller shaft housing assembly “2” • Reverse gear shim(s) (T2) “2” TIP: Insert flat-head screwdrivers between the pro- peller shaft housing assembly “2”...
Page 227 Propeller shaft housing 2. Remove: 3. Remove: • Ball bearing “1” • Oil seal “1” • Needle bearing “2” A. Worldwide B. USA and Canada The ball bearing remains installed in the propeller shaft housing A. Worldwide Stopper guide plate “2” B.
Page 228: Checking The Propeller Shaft
Propeller shaft housing Checking the propeller shaft Assembling the propeller shaft as- 1. Check: sembly • Propeller shaft 1. Install: Damaged/worn  Replace. • Dog clutch “1” • Propeller shaft “2” 2. Measure: • Spring (in the slider) “3” • Propeller shaft runout •...
Page 229: Assembling The Propeller Shaft Housing Assembly
Propeller shaft housing 3. Check: Driver rod L3 “2” • Dog clutch operates smoothly 90890-06652 Needle bearing attachment “3” 90890-06614 Driver handle (large) “4” YB-06071 Bearing housing bearing/oil seal installer “5” YB-06111 Installation depth “b” Assembling the propeller shaft hous- 3.0–3.5 mm (0.118–0.138 in) ing assembly 1.
Page 230 Propeller shaft housing Driver rod L3 “2” 90890-06652 Needle bearing attachment “3” 90890-06614 Driver handle (large) “4” YB-06071 Oil seal installer “5” YB-06168 Installation depth “a” Needle bearing attachment “2” 4.0–4.5 mm (0.157–0.177 in) 90890-06608 Bearing cup installer “2” 3. Install: YB-06167 •...
Page 231 Drive shaft and lower case Drive shaft and lower case 74 N·m (7.4 kgf·m, 55 lb·ft) 1.0 N·m (0.10 kgf·m, 0.73 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Cover Sleeve Oil seal housing as- Needle bearing sembly Forward gear Oil seal housing Taper roller bearing O-ring...
Page 232: Drive Shaft And Lower Case
Drive shaft and lower case Removing the drive shaft 1. Loosen: • Pinion nut “1” A. Worldwide B. USA and Canada Bearing inner race attachment “3” 90890-06641 Bearing splitter plate “4” YB-06219 Drive shaft holder 3 “2” Disassembling the forward gear 90890-06517 1.
Page 233: Disassembling The Lower Case
Drive shaft and lower case Driver rod L3 “2” Needle bearing attachment “2” 90890-06652 90890-06614 Needle bearing attachment “3” Driver rod L3 “3” 90890-06614 90890-06652 Bearing separator “4” Driveshaft needle bearing remov- 90890-06534 er and installer “4” YB-06063 Roller bearing installer/remover “5”...
Page 234: Checking The Shift Rod
Drive shaft and lower case 3. Remove: Checking the shift rod • Taper roller bearing outer race “1” 1. Check: • Shim(s) (T3) “2” • Shift rod Bent/worn  Replace. • Drive shaft sleeve “3” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Heat the area of the lower case where the Checking the pinion tapered roller bearing outer race is to be 1.
Page 235: Assembling The Forward Gear
Drive shaft and lower case Assembling the forward gear b. Heat the area of the lower case where the tapered roller bearing outer race is to be in- 1. Install: stalled using a gas torch, and then install a • Tapered roller bearing inner race “1” new tapered roller bearing outer race “2”.
Page 236 Drive shaft and lower case A. Worldwide B. USA and Canada Driver rod LL “1” 90890-06605 Bearing outer race attachment “2” 90890-06622 Driver handle (large) “3” YB-06071 Forward gear outer race installer A. Worldwide “4” B. USA and Canada YB-41446 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 237 Drive shaft and lower case 3. Install: 4. Install: • Drive shaft sleeve “1” • Taper roller bearing outer race • Shim(s) (T3) “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. While holding the special service tool “1”, • Taper roller bearing outer race “3” strike the tool to check that the taper roller ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 238: Assembling The Drive Shaft
Drive shaft and lower case 5. Install: Assembling the oil seal housing • Water inlet cover (STBD) “1” 1. Install: • Water inlet cover (PORT) “2” • Oil seal “1” • Nut “3” • Water inlet cover screw “4” TIP: After installing the water inlet covers, make sure that there is no rattling.
Page 239: Installing The Shift Rod, Drive Shaft, And Oil Seal Housing
Drive shaft and lower case Installing the shift rod, drive shaft, and oil seal housing 1. Install: • O-ring “1” (to the plate) • Oil seal “2” (to the plate) • E-clip “3” • Plate “4” • O-ring “5” • Shift rod “6” 5.
Page 240: Installing The Propeller Shaft Housing Assembly
Drive shaft and lower case 7. Install: 3. Tighten: • Washer “1” • Propeller shaft housing bolt “1” • Oil seal housing assembly “2” • Cover “3” Propeller shaft housing bolt “1” 16 N·m (1.6 kgf·m, 12 lb·ft) Installing the water pump 1.
Page 241: Checking The Lower Unit For Air Leakage
Drive shaft and lower case 2. Install: TIP: • Impeller key “1” When installing the water pump housing, apply • Impeller “2” grease to the inside of the insert cartridge, and ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ then turn the drive shaft clockwise while push- a.
Page 242: Installing The Lower Unit
Drive shaft and lower case b. Apply the specified pressure. Check that 2. Set the gear shift to the N position. the pressure is maintained in the lower unit for 10 seconds or more. Do not overpressurize the lower unit. Oth- erwise, the oil seals could be damaged.
Page 243 Drive shaft and lower case 4. Install: 5. Install: • Spacer“1” • Cotter pin “1” • Propeller “2” TIP: • Washer “3” If the slots in the propeller nut “2” are not • Washer “4” • Propeller nut “5” aligned with the cotter pin hole, tighten the pro- peller nut until they are aligned.
Page 244: Shimming
Shimming Shimming Shimming workflow 1. Remove the water pump assembly. 2. Measure the backlash before disassembly. 4. YES 3. Within specification? 5. Shimming is not required. 6. NO 7. Disassemble the lower unit. 8. Select the pinion shims (T3). 9. Assemble the lower unit. 10.
Page 245: Shimming Check Sheet
Shimming Shimming check sheet Lower case deviation Serial number Remarks Pinion height Measurements (mm) Measuring point “a” Measuring point “b” Measuring point “c” Measuring point “d” Average Round-down average Forward gear backlash Measurements (mm) Before disassembly After disassembly Measuring point “a” Measuring point “b”...
Page 246 Shimming Forward gear shim (T1) thickness measurement in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15 0.18 0.30 0.40 0.50 Total Reverse gear shim (T2) thickness measurement in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15 0.18 0.30 0.40...
Page 247: Measuring The Forward Gear Backlash And Reverse Gear Backlash Before Disassembly
Shimming Measuring the forward gear backlash b. Set up the special service tools “1”, “2”, and “3”, and then tighten the center bolt “3” and reverse gear backlash before dis- temporarily. assembly 1. Install: • Lower unit (onto a repair stand) 2.
Page 248 Backlash indicator “1” 90890-06706 Backlash indicator rod “1” YB-06265 Handle holder “3” EU0-23814-30 (2 required) *1 *1. Order from Yamaha Parts Distribution Center. A. Worldwide B. USA and Canada Handle stopper nut “4” (shimming) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Center bolt “1”...
Page 249 Shimming TIP: Magnet base plate “1” • Measure the backlash at 4 points: “a”, “b”, “c”, 90890-07003 and “d”, turning the drive shaft 180 clockwise Backlash adjustment plate “1” after each measurement. YB-07003 • Write down the measurement data in the Dial gauge set “2”...
Page 250 Shimming p. Apply a load to the reverse gear by install- ing the propeller “1”, washer “2”, washer “3”, and propeller nut “4” (without installing the spacer “5”). q. Tighten the propeller nut “4” to the speci- fied torque. Propeller nut “4” (shimming) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Repeat steps k–m to measure the reverse gear backlash.
Page 251: Shimming Procedure
Shimming Shimming procedure • Before selecting the forward gear shim (T1) and reverse gear shims (T2), make sure to select the pin- ion shims (T3). • When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do not apply gear oil, grease, or sealant to the parts.
Page 252: Selecting The Pinion Shim (T3)
Shimming Selecting the pinion shim (T3) • Spray anti-rust lubricant on the bearing be- When tightening the pinion nut, check that fore installation. Do not apply gear oil to the the drive shaft turns smoothly. parts. Otherwise, correct measurements cannot be obtained. d.
Page 253 Shimming Recheck the gap “a” between the pinion Drive shaft holder 3 “1” “1” and the special service tool “2”. 90890-06517 TIP: Driveshaft holder “1” If there is no gap, the shim(s) (T3) may not YB-06079 have been removed. Pinion nut “2” 74 N·m (7.4 kgf·m, 55 lb·ft) g.
Page 254: Measuring The Forward Gear Backlash
Shimming Determine the distance average, and then (T3) = 0.60 mm from the “Pinion shim (T3) round down the average to 2 decimal plac- selection table”. Pinion height mea- surement (M) Example: 0.18 0.19 0.20 (mm)  –2 Measurement point “a” 0.20 Stamped value ...
Page 255: Adjusting The Forward Gear Shim Thickness (T1)
Shimming 4. Measure: TIP: • Forward gear backlash • If the shim thickness adjustment value is pos- See step 3 in “Measuring the forward gear itive, increase the current shim thickness by backlash and reverse gear backlash be- that amount and, if the value is negative, de- fore disassembly”...
Page 256: Measuring The Reverse Gear Backlash
Shimming b. Calculate the new forward gear shim (T1) Measuring the reverse gear backlash thickness. • Spray anti-rust lubricant on the gears and bearings before installation. Do not apply TIP: gear oil to the parts. Otherwise, correct mea- • Use the lowest number of shims to obtain the surements cannot be obtained.
Page 257 Shimming 3. Select: –0.10 • Reverse gear shim (T2) –0.20 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ –0.30 a. Determine the reverse gear shim (T2) –0.40 thickness adjustment using the “Reverse –0.50 gear shim (T2) selection chart” according –0.60 to the backlash measurement (BL2) from –0.70 “Measuring the reverse gear backlash”.
Page 258 Shimming Available shim thicknesses Reverse shims 0.10/0.12/0.15/0.18/0.30/0.40/ 0.50 mm ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: • Determined reverse gear shim (T2) • Propeller shaft housing assembly 8-38...
Page 259: Bracket Unit
Bracket unit Friction plate (tiller handle model) ........9-1 Installing the friction plate............9-2 Tiller handle (tiller handle model) ........9-3 Assembling the tiller handle ............9-5 Electrical component (tiller handle) ......... 9-8 Assembling the electrical component......... 9-9 Shift rod and shift bracket..........9-10 Bottom cowling ..............
Page 260 Bracket unit Hydro tilt ................9-24 Removing the hydro tilt assembly ..........9-25 Checking the hydro tilt.............. 9-25 Checking the hydro tilt anode........... 9-25 Installing the hydro tilt assembly ..........9-25 PTT unit ................9-26 Removing the PTT unit............. 9-27 Bleeding the PTT unit...............
Page 261 Friction plate (tiller handle model) Friction plate (tiller handle model) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft) 40 N·m (4.0 kgf·m, 30 lb·ft) 6 N·m (0.6 kgf·m, 4.4 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft) Part name Q’ty Remarks...
Page 262: Friction Plate (Tiller Handle Model)
Friction plate (tiller handle model) Installing the friction plate 3. Move the steering lock lever “1” to the maximum. 1. Install: • Steering lock shaft “1” • Steering lock lever “2” • Washer “3” • Bracket “4” TIP: Face the “TOP” mark on the steering lock lever “2”...
Page 263 Tiller handle (tiller handle model) Tiller handle (tiller handle model) 35 36 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 10 4 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Screw M6 ...
Page 264 Tiller handle (tiller handle model) 35 36 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 10 4 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Part name Q’ty Remarks Washer Plate Collar Retainer Spring Bushing Grease nipple A. PTT model B.
Page 265: Tiller Handle (Tiller Handle Model)
Tiller handle (tiller handle model) Assembling the tiller handle 1. Assemble: • Tiller handle ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Pass the throttle shaft “1” through the fric- tion piece “2” and tiller handle “3”. b. Install the bushing “4”, retainers “5”, and spring “6”. Align the marks “a”...
Page 266 Tiller handle (tiller handle model) h. Face the section “a” of the plate “1” toward Throttle grip screw “2” the throttle friction adjuster “2”. 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Align the slot “b” in the bushing “3” with the PTT switch screw “5”...
Page 267 Tiller handle (tiller handle model) q. Connect the connectors “a” of the PTT switch Red (R) lead, Sky blue (Sb) lead, and Light green (Lg) lead (PTT model). Connect the connectors “a” of the neutral switch Brown (Br) leads, and then install Grease nipple “2”...
Page 268 Electrical component (tiller handle) Electrical component (tiller handle) 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Part name Q’ty Remarks Cover Clamp Screw M6  20 mm Plate Alert indicator Grommet Gasket Bolt M6 ...
Page 269: Electrical Component (Tiller Handle)
Electrical component (tiller handle) Assembling the electrical component g. Align the white tapes “a” on the extension wire harness “1” and alert indicator har- 1. Assemble: ness “2” with the inner end of the grommet • Electrical component “3”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
Page 270: Shift Rod And Shift Bracket
Shift rod and shift bracket Shift rod and shift bracket 18 N·m (1.8 kgf·m, 13 lb·ft) Part name Q’ty Remarks Shift rod detent bolt M12  23 mm Spring Ball Cotter pin Washer Bushing Bracket Bolt M5  14 mm Bushing Shift rod Grommet...
Page 271: Bottom Cowling
Bottom cowling Bottom cowling 5 N·m (0.5 kgf·m, 3.7 lb·ft) 37 36 Part name Q’ty Remarks Part name Q’ty Remarks Bolt M6  30 mm Water outlet Bolt M6  20 mm Grommet Collar Bracket Rubber seal Clamp Plastic tie Bracket Hose Clamp...
Page 272 Bottom cowling 5 N·m (0.5 kgf·m, 3.7 lb·ft) 37 36 Part name Q’ty Remarks Cover PTT switch Grommet Grommet Collar Grommet Bottom cowling A. PTT model 9-12...
Page 273 Upper case assembly and mount Upper case assembly and mount 24 N·m (2.4 kgf·m, 18 lb·ft) 16 15 14 Part name Q’ty Remarks Bolt M6  7 mm Ground lead Self-locking nut Washer Bolt M8  30 mm Bolt M8  175 mm Upper mount Plate Bolt M8 ...
Page 274: Upper Case Assembly And Mount
Upper case assembly and mount Removing the upper case TIP: 1. Drain: Tighten the lower mount cover bolts temporar- • Engine oil ily. 2. Remove: • Upper case assembly TIP: Before removing the upper case assembly, loosen the upper mount bolts “1” and lower mount cover bolts (PORT and STBD) “2”.
Page 275: Upper Case
Upper case Upper case 21 N·m (2.1 kgf·m, 15 lb·ft) 21 N·m (2.1 kgf·m, 15 lb·ft) 27 N·m (2.7 kgf·m, 20 lb·ft) 27 N·m (2.7 kgf·m, 20 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Clip Dowel pin Hose A.
Page 276: Disassembling The Upper Case
Upper case Disassembling the upper case Assembling the upper case 1. Remove: 1. Install: • Circlip “1” • Drive shaft bushing “1” • Drive shaft bushing “2” • Circlip “2” A. Worldwide B. USA and Canada Driver rod L3 “3” 90890-06652 Driver handle (large) “3”...
Page 277 Upper case 2. Install: • Plug gasket • Plug • Guide • Baffle plate • Cooling water pipe rubber seal • Cooling water pipe • Muffler rubber seal • Dowel pin • Muffler rubber seal • Upper case assembly • Upper case bolt •...
Page 278 Oil pan and exhaust guide Oil pan and exhaust guide 11 N·m (1.1 kgf·m, 8.1 lb·ft) 24 23 22 Part name Q’ty Remarks Part name Q’ty Remarks Bolt M6  25 mm Gasket Bolt M5  12 mm Muffler Bolt M6  20 mm Gasket Plate Plate...
Page 279: Oil Pan And Exhaust Guide
Oil pan and exhaust guide Checking the oil pan and exhaust guide 1. Clean: • Removed parts 2. Check: • Exhaust guide • Exhaust manifold • Muffler • Oil pan Corroded/cracked  Replace. A. Worldwide B. USA and Canada Checking the oil strainer 1.
Page 280 Oil pan and exhaust guide 2. Install: 4. Tighten: • Exhaust manifold bolt • Exhaust guide gasket • Oil pan bolt • Relief valve gasket • Relief valve cover Exhaust manifold bolt • Oil strainer 11 N·m (1.1 kgf·m, 8.1 lb·ft) •...
Page 281: Steering Arm
Steering arm Steering arm 20 N·m (2.0 kgf·m, 15 lb·ft) Part name Q’ty Remarks Circlip Steering yoke Bushing O-ring Bushing Self-locking nut Washer Steering hook Stud bolt Steering arm Washer Bushing A. Remote control model 9-21...
Page 282: Removing The Steering Arm
Steering arm Removing the steering arm 1. Remove: • Circlip “1” • Steering yoke “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the steering yoke “2” by striking it using a copper hammer. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: Installing the steering arm • Circlip “1” 1. Install: •...
Page 283 Steering arm 3. Inject: • Grease TIP: Inject grease into the grease nipple “1” until it comes out from both the upper and lower bushings “a”. 9-23...
Page 284: Hydro Tilt
Hydro tilt Hydro tilt Part name Q’ty Remarks Bolt M8  15 mm Washer Shaft Collar Collar Bushing E-clip Shaft Bushing Bushing Hydro tilt assembly Screw M6  25 mm Anode Bolt M6  10 mm Tilt lock lever 9-24...
Page 285: Removing The Hydro Tilt Assembly
Hydro tilt Removing the hydro tilt assembly Installing the hydro tilt assembly 1. Install: • Anode When removing the hydro tilt assembly • Bushing (to the hydro tilt, clamp bracket, with the power unit installed, make sure to and swivel bracket) suspend the outboard motor.
Page 286: Ptt Unit
PTT unit PTT unit Part name Q’ty Remarks Plastic tie Corrugated tube Plastic tie Bolt M6  10 mm Bolt M8  15 mm Washer Shaft Bushing Bushing E-clip Shaft PTT unit Bushing Bushing 9-26...
Page 287: Removing The Ptt Unit
PTT unit Removing the PTT unit Manual valve “1” 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) When removing the PTT unit with the power unit installed, make sure to suspend the c. Remove the reservoir cap “1”, and then outboard motor. check the fluid level.
Page 288: Installing The Ptt Unit
PTT unit Connect the battery jumper leads to the Remove the reservoir cap, and then check PTT motor lead “1” to fully retract the trim the fluid level. and tilt ram. TIP: TIP: If the fluid is below the proper level, add the If the trim and tilt ram does not move down eas- recommended PTT fluid.
Page 289 PTT unit 3. Install: • Plastic tie ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Fasten the PTT motor lead “1” and the speedometer hose “2” at the white tape “a” with a new plastic tie “3”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: • Corrugated tube • Plastic tie ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 290 Clamp bracket and swivel bracket Clamp bracket and swivel bracket 22 N·m (2.2 kgf·m, 16 lb·ft) 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Screw M6  15 mm Stopper knob Trim sensor Stopper shaft Bolt M6 ...
Page 291: Clamp Bracket And Swivel Bracket
Clamp bracket and swivel bracket Checking the clamp bracket anode 2. Inject: • Grease 1. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Anode Eroded (1/2 or more)  Replace. a. Inject grease into the grease nipples until There is grease, oil, or scales.  Clean. grease comes out from the bushings “a”.
Page 292 Clamp bracket and swivel bracket Setting resistance 9–11  (F30A, F30BET, F30HA, F40A, F40FET, F40HA) Terminal “c”–Terminal “d” d. Tighten the screw “1” so that the gap “a” between the ends of the trim sensor cam is within specification. Trim sensor cam end gap “a” 16.0–19.0 mm (0.63–0.75 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 293: Ptt Motor
PTT motor PTT motor 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 9 10 7 N·m (0.7 kgf·m, 5.2 lb·ft) 10 11 Part name Q’ty Remarks PTT motor assembly Screw M4  12 mm Stator O-ring Armature Screw M4  16 mm PTT motor lead Brush Brush assembly...
Page 294: Removing The Ptt Motor
PTT motor Removing the PTT motor Before removing the reservoir cap, make sure that the trim and tilt ram is fully ex- tended. Otherwise, fluid could be expelled forcefully from the PTT unit due to internal pressure. 1. Drain: Checking the armature (PTT motor) •...
Page 295: Checking The Brush
PTT motor 3. Measure: Checking the brush • Commutator undercut “a” 1. Measure: Below specification  Replace the arma- • Brush length Below specification  Replace the brush. ture. a. Standard brush length Standard commutator undercut b. Wear limit 1.50 mm (0.0591 in) (F30A, F30BET, F30HA, F40A,...
Page 296: Assembling The Ptt Motor
PTT motor Assembling the PTT motor 3. Install: • Armature ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Push the brushes “1” into the brush holder, Do not apply grease or oil to the commuta- and then install the armature “2”. tor of the armature. 1. Install: •...
Page 297: Installing The Ptt Motor
PTT motor Installing the PTT motor 1. Install: • Joint • Spring • O-ring (to the motor base) • PTT motor assembly • PTT motor mounting bolt • O-ring (to the reservoir cap) • Reservoir cap PTT motor mounting bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Reservoir cap 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Page 298: Ptt Gear Pump
PTT gear pump PTT gear pump 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 11 N·m (1.1 kgf·m, 8.1 lb·ft) 9 N·m (0.9 kgf·m, 6.6 lb·ft) 6 N·m (0.6 kgf·m, 4.4 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks...
Page 299 PTT gear pump 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 11 N·m (1.1 kgf·m, 8.1 lb·ft) 9 N·m (0.9 kgf·m, 6.6 lb·ft) 6 N·m (0.6 kgf·m, 4.4 lb·ft) Part name Q’ty Remarks Spring Lock screw 9-39...
Page 300: Checking The Gear Pump
PTT gear pump Checking the gear pump 1. Check: • Gear pump shaft It does not rotate smoothly  Replace the gear pump assembly. Checking the gear pump housing 1. Check: • Gear pump housing Corrosion/cracks  Replace the gear pump assembly.
Page 301: Ptt Cylinder
PTT cylinder PTT cylinder 61 N·m (6.1 kgf·m, 45 lb·ft ) 90 N·m (9.0 kgf·m, 66 lb·ft ) Part name Q’ty Remarks Trim and tilt ram as- sembly Dust seal O-ring O-ring O-ring Free piston assembly O-ring Cylinder 9-41...
Page 302: Removing The Trim And Tilt Ram Assembly
PTT cylinder Removing the trim and tilt ram assem- 4. Remove: • Free piston ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. Loosen: a. Cover the tilt cylinder using a rag “1”, and • Trim cylinder end screw “1” then blow compressed air through the hole “a”...
Page 303: Checking The Absorber Valve
PTT cylinder Checking the absorber valve 1. Check: • Absorber valve Dirt/residue  Clean. Assembling the trim and tilt ram as- sembly 1. Install: • Dust seal “1” • O-ring “2” • O-ring “3” Tilt piston bolt “1” 61 N·m (6.1 kgf·m, 45 lb·ft) Installing the trim and tilt ram assem- 1.
Page 304 PTT cylinder 3. Install: 5. Tighten: • Trim cylinder end screw “1” • O-ring “1” • Free piston “2” 4. Install: • Trim and tilt ram assembly ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place the tilt cylinder end screw “1” at the bottom of the trim and tilt ram. b.
Page 305: Maintenance
Maintenance Outline ................10-1 Maintenance interval chart 1 ............ 10-1 Maintenance interval chart 2 ............ 10-3 Predelivery check............. 10-4 Checking the engine oil level............ 10-7 Checking the battery ..............10-7 Checking the cooling water pilot hole........10-8 Checking the gear oil level ............10-8 Checking the outboard motor mounting height ......
Page 306: Outline
• If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and quality. Any parts of inferior quality may cause a malfunction, and the resulting loss of control could endanger the operator and passengers.
Page 307 Outline Initial Every Item Actions 20 hours 100 hours 300 hours 500 hours (3 months) (1 year) (3 years) (5 years) Engine oil filter (car- ●/○ Replacement tridge) Fuel filter (can be disas- Inspection or replace- ●/○ ●/○ sembled) ment as necessary ●...
Page 308: Maintenance Interval Chart 2
○ ○ tions/wire coupler con- ment as necessary nections (Yamaha) ○ ○ Inspection Meter/gauge Fuel tank (Yamaha por- Inspection and cleaning ○ table tank) as necessary *1. Cylinder head *2. Exhaust cover, exhaust guide Maintenance interval chart 2 Every Item...
Page 309: Predelivery Check
Predelivery check Predelivery check To make the delivery process smooth and efficient, complete the predelivery checks as explained in the following procedures. Item Procedures Check the oil level using the dipstick. Engine oil level 10-7 Oil is not at the proper level  Add or extract engine oil. Check the battery electrolyte level.
Page 310 Predelivery check Item Procedures Check the PTT unit operation. Not smooth  Check the PTT fluid level and PTT motor electric 10-9 current when the relief valve operate. Check that there is no abnormal noise produced when the out- PTT unit board motor is tilted up or down.
Page 311 Predelivery check Item Procedures Start the engine, and then check that the gear shift operates prop- — erly. Warm up the engine, and then check the engine idle speed. 10-14 Out of specification  Perform the troubleshooting procedures. Operate the boat at trolling speed. —...
Page 312: Checking The Engine Oil Level
Predelivery check Checking the engine oil level Checking the battery Make sure that the engine is filled with en- Battery electrolyte is dangerous; it con- gine oil before operating the outboard mo- tains sulfuric acid, which is poisonous and tor for the first time. Otherwise, the engine highly caustic.
Page 313: Checking The Cooling Water Pilot Hole
Predelivery check 2. Check: • Specific gravity of the electrolyte Below specification  Fully charge the battery. TIP: • Batteries vary depending on the manufactur- er. The procedures mentioned in this manual may not always apply. Therefore, see the in- struction manual of the battery.
Page 314: Checking The Outboard Motor Mounting Height
Predelivery check Checking the outboard motor mount- Checking the power trim and tilt unit ing height 1. Check: • Power trim and tilt unit 1. Check: Abnormal noise  Check the PTT unit. • Outboard motor mounting height Interference  Check the hose and wire Improper ...
Page 315 Predelivery check b. Check that the outboard motor does not tilt up or down when the tilt lock lever “1” is in the lock position “a”. c. Fully tilt the outboard motor up, and then support it using the tilt support knob “1”. Check that the tilt support knob locks in place properly.
Page 316: General Periodic Maintenance
General periodic maintenance General periodic maintenance Item Procedures 7-41 7-46 Check the anodes. Eroded (1/2 or more worn out)  Replace. Anodes 9-19 Adhered grease, oil, paint, or scales  Clean. 9-25 9-31 Check the battery electrolyte level. Below the minimum level mark  Add distilled water. Battery 10-7 Check the specific gravity of the electrolyte.
Page 317 General periodic maintenance Item Procedures Check the fuel filter element. Dirt/residue  Replace. Water accumulated  Drain. Checking the fuel cup assembly. Foreign material  Clean. Fuel filter Cracked  Replace. Checking the fuel inlet or fuel outlet holding pressure. Out of specification ...
Page 318 Check the wire harness coupler and lead coupler connections. — Lead (Yamaha) Check the meter/gauge display. — Meter/gauge Check the fuel tank Cracked/damage  Replace. Fuel tank (Yamaha — Leaking  Check the related parts. portable tank) Dirt/residue  Clean. 10-13...
Page 319: Checking The Engine Idle Speed/Noise
General periodic maintenance Checking the engine idle speed/noise 1. Check: • Engine idling speed Out of specification  Perform the trouble- shooting procedures. See “Troubleshoot- ing procedure” (4-3). ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the engine idle speed using the YDIS. See the YDIS (Ver. 2.33 or later) in- struction manual.
Page 320: Changing The Engine Oil By Removing The Drain Bolt
General periodic maintenance 3. Drain: Engine oil quantity (without oil fil- • Engine oil ter replacement) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filler cap “1”. 1.5 L (1.59 US qt, 1.32 Imp.qt) b. Leave the outboard motor off for 5–10 min- utes.
Page 321 General periodic maintenance 1. Warm up: Drain bolt “2” • Engine 27 N·m (2.7 kgf·m, 20 lb·ft) See step 1 in “Changing the engine oil us- ing an oil changer” (10-14). 5. Fill: 2. Remove: • Recommended engine oil • Top cowling ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 322: Replacing The Oil Filter
General periodic maintenance Start the engine and check that the oil pressure alert indicator does not come on. Also, check that there is no oil leakage. If the oil pressure alert indicator comes on or if there is oil leakage, stop the engine and find the cause.
Page 323: Changing The Gear Oil
General periodic maintenance b. Install the oil filler cap and dipstick, and e. After the gear oil has been drained, check then start the engine and warm it up for 5– the used oil. Pressure test the lower case 10 minutes. and inspect the oil seal for damage if the oil is milky.
Page 324: Checking The Gear Oil Level
General periodic maintenance Gear oil quantity 0.430 L (0.455 US qt, 0.378 Imp.qt) Oil level plug “2” 7 N·m (0.7 kgf·m, 5.2 lb·ft) d. Remove the gear oil pump, and then install a new gasket “1” and the drain screw “2”. TIP: Before installing the magnetic drain screw, make sure to remove all metal particles.
Page 325: Greasing The Clamp Bracket Bolt (Through Tube)
General periodic maintenance b. Apply low temperature resistant grease to the specified lubrication point. c. Apply corrosion resistant grease to the specified lubrication point. 4. Assemble the hydraulic steering cylinder or steering cable to the through tube. Checking the PTT fluid level Never get under the outboard motor while it is tilted.
Page 326: Checking The Cowling Lock Lever
General periodic maintenance b. Remove the reservoir cap “1” and O-ring Checking the cowling lock lever “2”, and then check the fluid level in the 1. Check: reservoir. • Top cowling fitting Looseness/ratting  Adjust. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Before removing the reservoir cap, make a.
Page 327 Appendix Specification ...............A-1 Wiring diagram ..............A-14 How to use the wiring diagram ..........A-14 Engine control unit, fuel unit, and ignition unit......A-15 Charging unit, starting unit, and PTT unit......... A-16 Control unit ................A-17 Shim selection table and chart ........A-18 Pinion shim (T3) selection table ..........
Page 328: Specification
Specification Model data Dimension and weight F30BEHD F30BET F40FEHD F40FET Model F30HA F40FED F40HA F30EHA F30A F40EHA F40A Overall length 1362 mm (53.6 in) 698 mm (27.5 in) 1362 mm (53.6 in) 698 mm (27.5 in) Overall width 384 mm (15.1 in) 1228 mm (48.3 in) 1228 mm (48.3 in) Overall height S...
Page 329 F30BEHD F30BET F40FEHD F40FET Model F30HA F40FED F40HA F30EHA F30A F40EHA F40A Starting carburetion sys- Fuel injection Ignition system Advance type Microcomputer Maximum generator out- 17 A Maximum charging 13 A capacity Spark plug (NGK) DPR6EB-9 Firing order 1-2-3 Steering system Tiller handle Remote steering Tiller handle...
Page 330 F30BEHD F30BET F40FEHD F40FET Model F30HA F40FED F40HA F30EHA F30A F40EHA F40A Min. research octane number (RON) Min. pump octane num- 86 (F40EHA, F40FE- 86 (F30EHA) 86 (F30A) — 86 (F40A) ber (PON) HD_*EC2) YAMALUBE 4 or 4- YAMALUBE 4 or 4- YAMALUBE 4 or 4- YAMALUBE 4 or 4- stroke outboard motor...
Page 331 F30BEHD F30BET F40FEHD F40FET Model F30HA F40FED F40HA F30EHA F30A F40EHA F40A 1.64 m (5.4 ft) 1.64 m (5.4 ft) 1.64 m (5.4 ft) 1.64 m (5.4 ft) (F30BEHD) (F40FEHD) Battery cable length 2.24 m (7.3 ft) (F30BET) 1.64 m (5.4 ft) 2.24 m (7.3 ft) (F40FET) 2.24 m (7.3 ft)
Page 332 F30BEHD F30BET F40FEHD F40FET Model F30HA F40FED F40HA F30EHA F30A F40EHA F40A Ignition timing ATDC7.0  ATDC8.0  Idle speed (in neutral) BTDC20.0  Rated speed Intake air pressure sensor Input voltage Thermo sensor Resistance at 20 C (68 2.49 k F) Resistance at 60 C (140 0.589 k...
Page 333 Engine speed control system F30BEHD F30BET F40FEHD F40FET Model F30HA F40FED F40HA F30EHA F30A F40EHA F40A Throttle valve opening angle at throttle valve 0.10  fully closed (reference data) Throttle valve opening angle at throttle valve 75.3  fully open (reference data) Input voltage Oil pressure switch...
Page 334 Starting system F30BEHD F30BET F40FEHD F40FET Model F30HA F40FED F40HA F30EHA F30A F40EHA F40A Starter motor Type Sliding gear Output 0.90 kW Cranking time limit 30 sec Standard brush length 12.3 mm (0.48 in) Wear limit 5.5 mm (0.22 in) Standard commutator 29.4 mm (1.16 in) diameter...
Page 335 Fuel system technical data Fuel system F30BEHD F30BET F40FEHD F40FET Model F30HA F40FED F40HA F30EHA F30A F40EHA F40A Fuel line Fuel pressure at engine start switch to “ON” 280 kPa (2.8 kgf/cm², 40.6 psi) within 3 seconds Fuel pressure at engine 230 kPa (2.3 kgf/cm², 33.4 psi) idle speed Primer pump...
Page 336 F30BEHD F30BET F40FEHD F40FET Model F30HA F40FED F40HA F30EHA F30A F40EHA F40A Engine oil Engine oil pressure at idle speed (reference 230.0 kPa (2.30 kgf/cm², 33.4 psi) data) Engine oil pressure at 3000 r/min (reference 480.0 kPa (4.80 kgf/cm², 69.6 psi) data) * For the checking method, see “Checking the oil pressure”...
Page 337 F30BEHD F30BET F40FEHD F40FET Model F30HA F40FED F40HA F30EHA F30A F40EHA F40A Valve stem Diameter IN 5.475–5.490 mm (0.2156–0.2161 in) Limit 5.445 mm (0.2144 in) Diameter EX 5.460–5.475 mm (0.2150–0.2156 in) Limit 5.430 mm (0.2138 in) Runout limit IN 0.01 mm (0.0004 in) Runout limit EX 0.01 mm (0.0004 in) Valve guide...
Page 338 F30BEHD F30BET F40FEHD F40FET Model F30HA F40FED F40HA F30EHA F30A F40EHA F40A 1st oversize diameter 65.200–65.215 mm (2.5669–2.5675 in) 2nd oversize diameter 65.450–65.465 mm (2.5768–2.5774 in) Measuring point 5.0 mm (0.20 in) Piston clearance 0.035–0.065 mm (0.0014–0.0026 in) Limit 0.115 mm (0.0045 in) Ring groove (Top) 1.21–1.23 mm (0.0476–0.0484 in) Ring groove (2nd)
Page 339 F30BEHD F30BET F40FEHD F40FET Model F30HA F40FED F40HA F30EHA F30A F40EHA F40A Connecting rod Small end inside diame- 15.985–15.998 mm (0.6293–0.6298 in) Big end inside diameter 36.000–36.024 mm (1.4173–1.4183 in) Big end side clearance 0.050–0.220 mm (0.0020–0.0087 in) Limit 0.27 mm (0.0106 in) Big end oil clearance 0.016–0.040 mm (0.0006–0.0016 in) Limit...
Page 340 Bracket unit technical data PTT system F30BEHD F30BET F40FEHD F40FET Model F30HA F40FED F40HA F30EHA F30A F40EHA F40A Hydraulic pressure — 5.40 Mpa (54.0 kgf/cm², 783.0 psi) — 5.40 Mpa (54.0 kgf/cm², 783.0 psi) Down — 2.00 Mpa (20.0 kgf/cm², 290.0 psi) —...
Page 341: Wiring Diagram
Wiring diagram Wiring diagram How to use the wiring diagram Composition of the wiring diagrams The wiring diagram consists of three categories; “Engine control unit, fuel unit, and ignition unit”, “Charging unit, starting unit, and PTT unit”, and “Control unit”. Legend symbols in the wiring diagrams Double colors wire Not used (vacant)
Page 342 Jul. 2018 ABE...
Page 343 Engine control unit, fuel unit, and ignition unit 1. Engine ECM 2. Thermo sensor 3. Pulser coil 4. Oil pressure switch 5. Ignition coil 6. Water detection switch 14. Starter motor 7. Shift position switch 18. Battery 17. PTT relay 16.
Page 344 Charging unit, starting unit, and PTT unit 1. Engine ECM 2. Speed sensor 3. Water pressure sensor 4. PTT motor 11. Stator assembly 9. Starter motor 5. PTT switch 6. Trim sensor 7. Joint connector 1 8. Joint connector 2 15.
Page 345: Control Unit
Control unit 1. 703 side mount remote control 2. Engine start switch 3. Engine shut-off switch 1. 703 side mount remote control 14. Switch panel (6R5-82570-06) 4. PTT switch 2. Engine start switch 4. PTT switch 2. Engine start switch 3.
Page 346: Shim Selection Table And Chart
Shim selection table and chart Pinion shim (T3) selection table (mm) 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36...
Page 347: Forward Gear Shim (T1) Selection Chart
Forward gear shim (T1) selection chart 1.10 1.00 0.90 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 –0.10 –0.20 –0.30 –0.40 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 A (1/100 mm) 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 –0.23 –0.20 –0.17 –0.15 –0.12 –0.09 –0.07 –0.04 –0.01 0.01 0.04 0.07 0.09 0.12 0.15 0.17 0.20 0.23 0.25 0.28 0.31 0.33 0.36 0.39 0.41 0.44 0.47 0.49 0.52 0.55 0.57 0.60 0.63 0.65 0.68 0.71 0.73 0.76 0.79 0.81 0.84...
Page 348 Worldwide: (6BT) (6BG) USA, CAN, AUS, and NZL: (6BT) (6BG) 6BG-28197-ZX-11 LIT-18616-03-84 Jul. 2018 ABE...

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