Yamaha SX150C Service Manual
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Yamaha SX150C Service Manual

Yamaha SX150C Service Manual

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*LIT186160280*
LIT-18616-02-80
SX150C
VX150C
DX150C
SX200C
SERVICE MANUAL
67H-28197-1F-11

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Summary of Contents for Yamaha SX150C

  • Page 1 SX150C VX150C DX150C SX200C SERVICE MANUAL *LIT186160280* LIT-18616-02-80 67H-28197-1F-11...
  • Page 2 A20000-1 NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equip- ment. It has been written to suit the needs of persons who have a basic understanding of the...
  • Page 3 HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
  • Page 4 IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.
  • Page 5 HOW TO USE THIS MANUAL 1 The main points regarding removing/installing and disassembling/assembling procedures are shown in the exploded views. 2 The numbers in the exploded views indicate the required sequence of the procedure and should be observed accordingly. 3 Symbols are used in the exploded views to indicate important aspects of the procedure. A list of meanings for these symbols is provided on the following page.

  • Page 6: General Information

    Symbol F to H in an exploded diagram indicate the grade of lubricant and the loca- tion of the lubrication point. F Apply Yamaha 2-stroke outboard motor oil (TC-W3) G Apply water resistant grease (Yamaha grease A, Yamaha marine grease)

  • Page 7: Table Of Contents

    CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTIONS AND ADJUSTMENTS INSP FUEL SYSTEM FUEL POWER UNIT POWR LOWER UNIT LOWR BRACKET UNIT BRKT – ELECTRICAL SYSTEMS ELEC TROUBLE ANALYSIS TRBL ANLS...
  • Page 8 INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION..................... 1-1 SERIAL NUMBER ..................1-1 STARTING SERIAL NUMBERS ............... 1-1 SAFETY WHILE WORKING ................1-2 FIRE PREVENTION ................... 1-2 VENTILATION................... 1-2 SELF-PROTECTION.................. 1-2 OILS, GREASES AND SEALING FLUIDS..........1-2 GOOD WORKING PRACTICES ..............1-3 DISASSEMBLY AND ASSEMBLY ............

  • Page 9: Identification

    IDENTIFICATION INFO IDENTIFICATION SERIAL NUMBER The outboard motor serial number is stamped on a label attached to the port clamp bracket. 1 Model name 2 Approved model code 3 Transom height 4 Serial number S67H1010 1020 STARTING SERIAL NUMBERS The starting serial number blocks are as fol- lows: Approved Starting serial...

  • Page 10: Safety While Working

    SAFETY WHILE WORKING INFO SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be fol- lowed Yamaha dealers their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline and keep it away from heat, sparks and open flames.

  • Page 11: Good Working Practices

    SAFETY WHILE WORKING INFO Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practices, any risk is minimized. A summary of the most important precau- tions is as follows: 1.

  • Page 12: Disassembly And Assembly

    SAFETY WHILE WORKING INFO 3. Non-reusable items Always use new gaskets, packings, O- rings, split-pins, circlips, etc., on reas- sembly. 1080 DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed air when disassembling. 2. Oil the contact surfaces of moving parts before assembly.

  • Page 13: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS Using the correct special tools recom- mended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvising and using improper tools can damage the equipment. NOTE: • For U.S.A. and Canada, use part numbers that start with “J-”, “YB-”, “YM-”, “YU-”...
  • Page 14 SPECIAL TOOLS INFO B Up-relief valve attachment P/N. 90890-06773 Down-relief valve attachment P/N. 90890-06774 C Digital tester P/N. J-39299 90890-06752 D Peak voltage adapter P/N. YU-39991 ........ a 90890-03169 ......b E Spark gap tester P/N. YM-34487 ....... a 90890-06754 ......b F Diagnostic indicator P/N.

  • Page 15: Removing And Installing

    SPECIAL TOOLS INFO REMOVING AND INSTALLING 1 Flywheel magnet assembly holder P/N. YB-06139 ........ a 90890-06522 ......b 2 Universal puller P/N. YB-06117 ........ a 90890-06521 ......b 3 Bearing/oil seal attachment P/N. YB-06196 ........ a 90890-06610, 90890-06637 ..b 4 Driver rod P/N.
  • Page 16 SPECIAL TOOLS INFO A Bearing puller P/N. 90890-06535 B Bearing/oil seal attachment P/N. 90890-06659, 90890-06661, 90890-06662 C Ring nut wrench P/N. YB-34447 90890-06512 D Ring nut wrench extension P/N. YB-06513 90890-06513 E Propeller shaft housing puller P/N. YB-06207 ........ a YB-06502 ........
  • Page 17 SPECIAL TOOLS INFO P Ring nut wrench P/N. YB-42223 Q Bearing/oil seal attachment P/N. YB-42225 R Bearing/oil seal attachment P/N. YB-42227 S Bearing/oil seal attachment P/N. YB-42229 90890-06607 T Pinion nut holder P/N. YB-42224 U End screw wrench P/N. YB-06548 90890-06548 V End screw wrench P/N.
  • Page 18 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 MAINTENANCE SPECIFICATIONS..............2-3 POWER UNIT.................... 2-3 LOWER UNIT.................... 2-5 ELECTRICAL ..................... 2-5 DIMENSIONS ................... 2-9 TIGHTENING TORQUES ................2-12 SPECIFIED TORQUES ................2-12 GENERAL TORQUES ................2-14...

  • Page 19: Fuel System

    SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Item Unit SX150TR VX150TR DX150TR SX200TR DIMENSION Overall length mm (in) 823 (32.4) 896 (35.3) 823 (32.4) Overall width mm (in) 577 (22.7) Overall height mm (in) — 1,637 (64.4) 1,573 (61.9) — mm (in) 1,742 (68.6) —...
  • Page 20 SPEC GENERAL SPECIFICATIONS Model Item Unit SX150TR VX150TR DX150TR SX200TR FUEL AND OIL Fuel type Unleaded regular gasoline (*1) Fuel rating Engine oil type 2-stroke outboard motor oil Engine oil grade TC-W3 Engine oil capacity (engine oil tank) L (US qt, 0.9 (0.95, 0.79) lmp qt) (sub-oil tank)

  • Page 21: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS POWER UNIT Model Item Unit SX150TR VX150TR DX150TR SX200TR CYLINDER HEADS Warpage limit mm (in) 0.1 (0.004) (lines indicate straightedge position) CYLINDERS Bore size mm (in) 90.00 - 90.02 (3.543 - 3.544) Wear limit mm (in) 90.1 (3.55) Taper limit mm (in)
  • Page 22 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit SX150TR VX150TR DX150TR SX200TR CONNECTING RODS Small-end axial play mm (in) 2.0 (0.08) limit (F) Big-end side mm (in) 0.12 - 0.26 (0.005 - 0.010) clearance (E) OIL INJECTION PUMP ID mark 6R400 67H00 20.4 ±...

  • Page 23: Spec

    SPEC MAINTENANCE SPECIFICATIONS LOWER UNIT Model Item Unit SX150TR VX150TR DX150TR SX200TR GEAR BACKLASH Pinion - forward gear mm (in) 0.25 - 0.46 0.71 - 1.01 0.19 - 0.59 0.25 - 0.46 (0.010 - 0.018) (0.028 - 0.040) (0.007 - 0.023) (0.010 - 0.018) Pinion - reverse gear mm (in)
  • Page 24 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit SX150TR VX150TR DX150TR SX200TR Pulser coil (W/R, W/Y, W/G, W/B, W/L, W/Br – B) Output peak voltage lower limit @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min IGNITION CONTROL SYSTEM Crank position sensor (G/W –...
  • Page 25 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit SX150TR VX150TR DX150TR SX200TR STARTING SYSTEM Fuse 1 Fuse 2 STARTER MOTOR Type Bendix Output Rating Second Brushes Standard length mm (in) 17.0 (0.67) Wear limit mm (in) 10.0 (0.39) Commutator Standard diameter mm (in) 33.0 (1.30) Wear limit mm (in)
  • Page 26 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit SX150TR VX150TR DX150TR SX200TR POWER TRIM AND TILT SYSTEM Trim sensor Ω Resistance (P – B) 9 - 378.6 POWER TRIM AND TILT MOTOR Fluid type ATF Dexron II Brushes Standard length mm (in) 9.8 (0.39) Wear limit mm (in)

  • Page 27: Dimensions

    SPEC MAINTENANCE SPECIFICATIONS DIMENSIONS EXTERIOR (SX150, VX150, SX200) mm (in) L: 1,036 (40.8) 587 (23.1) X: 1,152 (45.4) 179 (7.0) 550 (21.7) 74 (2.9) 159 (6.3) L: 41 (1.6) X: 50 (2.0) 647 (25.5)
  • Page 28 SPEC MAINTENANCE SPECIFICATIONS EXTERIOR (DX150) mm (in) 587 ( 23.1) 1,033 (40.7) 179 (7.0) 557 (21.9) 74 (2.9) 159 (6.3) 59 (2.3) 717 (28.2) 2-10...
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS CLAMP BRACKET mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 82 (3.2) 13 (0.5) 13 (0.5) 125.4 (4.9) 125.4 (4.9) 2-11...

  • Page 30: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torques Part to be tightened Thread size m•kgf ft•lb POWER UNIT Intake silencer Fuel injection unit Fuel filter nut holder Fuel filter bracket Oil pump Flywheel magnet assembly Negative battery lead Positive battery lead Power unit mount Emergency switch —...
  • Page 31 SPEC TIGHTENING TORQUES Tightening torques Part to be tightened Thread size m•kgf ft•lb Connecting rod LOWER UNIT Propeller Rear propeller (for DX150) Forward propeller (for DX150) Lower unit Ring nut — 14.5 Pinion nut Gear oil drain screw — Gear oil level check screw —...

  • Page 32: General Torques

    SPEC TIGHTENING TORQUES GENERAL TORQUES General torque This chart specifies tightening torques for specifications Nut (A) Bolt (B) standard fasteners with a standard ISO m•kgf ft•lb thread pitch. Tightening torque specifica- 8 mm tions for special components or assemblies 10 mm are provided in applicable sections of this 12 mm manual.
  • Page 33 INSP CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS MAINTENANCE INTERVAL CHART .............. 3-1 TOP COWLING....................3-2 INSPECTING THE TOP COWLING FIT ............ 3-2 FUEL SYSTEM ....................3-2 INSPECTING THE FUEL LINE..............3-2 INSPECTING THE FUEL FILTER .............. 3-3 MEASURING THE FUEL PRESSURE (HIGH-PRESSURE FUEL LINE) ...............

  • Page 34: Insp Adj

    INSP MAINTENANCE INTERVAL CHART MAINTENANCE INTERVAL CHART Use the following chart as a guide to general maintenance intervals. Dependant on operating conditions, adjust the maintenance intervals accordingly. Initial Every Refer to Item Remarks 10 hours 50 hours 100 hours 200 hours page (Break-in) (3 months)

  • Page 35: Top Cowling

    INSP TOP COWLING/FUEL SYSTEM TOP COWLING INSPECTING THE TOP COWLING FIT 1. Inspect: • Top cowling fitting Loose/unlatched → Adjust the top cowling hook. 3010 2. Adjust: • Top cowling hook position Adjustment steps (1) Loosen the bolts 1 approximately 1/4 of a turn.

  • Page 36: Inspecting The Fuel Filter

    INSP FUEL SYSTEM 2. Inspect: • Plastic locking tie Loosen → Retighten or replace. 3. Inspect: • Low-pressure fuel line Cracks/damage/leaks → Replace. Refer “LOW-PRESSURE FUEL LINE” on page 4-21. 3030 INSPECTING THE FUEL FILTER Inspect: • Fuel filter element •...

  • Page 37: Control System

    INSP CONTROL SYSTEM CONTROL SYSTEM SYNCHRONIZING THE THROTTLE VALVES 1. Inspect: • Throttle valve synchronization Uneven opening → Adjust. Inspecting steps (1) Remove the intake silencer 1. (2) Disconnect the throttle lever rod 2. (3) Turn the throttle stop screw 3 until it does not touch the stopper.

  • Page 38: Adjusting The Engine Idling Speed

    INSP CONTROL SYSTEM ADJUSTING THE ENGINE IDLING SPEED 1. Measure: • Engine idling speed Out of specification → Adjust. Engine idling speed 730 ± 30 r/min Measuring steps (1) Start the engine and allow it to warm up for a few minutes. (2) Install the tachometer onto the spark plug lead of cylinder #1.

  • Page 39: Adjusting The Throttle Position Sensor

    INSP CONTROL SYSTEM (4) Tighten the pickup adjustment screw 1 while pressing down on the throttle control lever cam roller 2. NOTE: Turn the pickup adjustment screw 1 coun- terclockwise to tighten it. 3081 ADJUSTING THE THROTTLE POSITION SENSOR 1. Measure: •...

  • Page 40: Adjusting The Remote Control Shift Cable

    INSP CONTROL SYSTEM 2. Adjust: • Throttle position sensor Adjustment steps 3100 (1) Loosen the screws 2. (2) Adjust the position of the throttle posi- tion sensor until the specified output voltage is obtained. Throttle position sensor output voltage (pink (P) – orange (O)) 0.50 ±...

  • Page 41: Adjusting The Remote Control Throttle Cable

    INSP CONTROL SYSTEM ADJUSTING THE REMOTE CONTROL THROTTLE CABLE NOTE: Before adjusting the remote control throttle cable, be sure to adjust the throttle valves’ opening and engine idling speed. 1. Inspect: • Throttle operation Incorrect → Adjust. NOTE: Make sure the throttle valves are fully closed when the remote control lever is fully closed position.

  • Page 42: Cooling System

    INSP COOLING SYSTEM/OIL INJECTION SYSTEM COOLING SYSTEM INSPECTING THE COOLING WATER DISCHARGE Inspect: • Cooling water discharge No discharge → Clean and inspect the cooling water passage. 3140 Inspecting steps (1) Place the lower unit in water. (2) Start the engine. (3) Check that water flows from the cool- ing water outlet.

  • Page 43: Air Bleeding The Oil Injection System

    INSP OIL INJECTION SYSTEM AIR BLEEDING THE OIL INJECTION SYSTEM Bleed: • Air bubbles (from the oil injection system) Bleeding steps (1) Fill the fuel tank with the fuel/oil mix- ture (50:1). Recommended fuel Fuel type Unleaded regular gasoline Fuel rating PON: 86 RON: 91 Recommended engine oil...

  • Page 44: Measuring The Oil Pump Discharge

    INSP OIL INJECTION SYSTEM MEASURING THE OIL PUMP DISCHARGE Measure: • Oil pump discharge Out of specification → Check all of the oil pump components and replace any defective parts. Engine oil discharge (3 minutes) 150J, 150L, D150N/ SX150, VX150, DX150 20.4 ±...
  • Page 45 INSP OIL INJECTION SYSTEM Measuring steps (1) Fill the fuel tank with the fuel/oil mix- ture (50:1) and fill the oil tank with engine oil. Recommended fuel Fuel type Unleaded regular gasoline Fuel rating PON: 86 RON: 91 Recommended engine oil Engine oil type 2-stroke outboard motor oil Engine oil grade...

  • Page 46: Power Trim And Tilt System

    INSP POWER TRIM AND TILT SYSTEM POWER TRIM AND TILT SYSTEM3 INSPECTING THE POWER TRIM AND TILT FLUID LEVEL Inspect: • Power trim and tilt fluid level Level is low → Add power trim and tilt fluid to the proper level. Recommended power trim and tilt fluid ATF Dexron II...

  • Page 47: Lower Unit

    INSP LOWER UNIT LOWER UNIT INSPECTING THE GEAR OIL LEVEL Inspect: • Gear oil level Level is low → Add gear oil to the proper level. CHANGING AND INSPECTING THE GEAR OIL 1. Inspect: • Gear oil Milky oil → Replace the oil seal. Slag oil →...

  • Page 48: Inspecting The Lower Unit (For Air Leaks)

    INSP LOWER UNIT Filling steps (1) Place the outboard in an upright posi- tion. (2) Insert the gear oil tube into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible.

  • Page 49: General

    INSP GENERAL GENERAL INSPECTING THE ANODES Inspect: • Anodes 1 • Trim tab 2 (except for D150N/DX150) Scales → Clean. Grease/oil → Clean. Excessive wear → Replace. CAUTION: Do not oil, grease or paint the anode, or it will not operate properly. INSPECTING THE BATTERY WARNING Battery electrolytic fluid is dangerous;...

  • Page 50: Inspecting The Spark Plugs

    INSP GENERAL NOTE: • Batteries vary among manufacturers. Therefore, the following procedures may not always apply. Consult your battery manufacturer’s instructions. • First, disconnect the negative lead, then the positive lead. Inspect: • Electrolyte level Below the minimum level mark → Add distilled water to the proper level.
  • Page 51 INSP GENERAL 3. Measure: • Spark plug gap a Out of specification → Regap. Spark plug gap 0.9 - 1.0 mm (0.035 - 0.039 in) 3270 4. Tighten: • Spark plug Spark plug 25 Nm (2.5 m • kgf, 18 ft • lb) NOTE: •...

  • Page 52: Lubrication Points

    INSP GENERAL LUBRICATION POINTS Apply: • Water resistant grease 3290 3300 3310 3320 3330 3-19...

  • Page 53: Fuel

    FUEL CHAPTER 4 FUEL SYSTEM HIGH-PRESSURE FUEL LINE................. 4-1 REMOVING/INSTALLING THE HIGH-PRESSURE FUEL LINE ....4-1 REDUCING THE FUEL PRESSURE (HIGH-PRESSURE FUEL LINE) ............... 4-3 INSPECTING THE PRESSURE REGULATOR.......... 4-4 FUEL INJECTORS ................... 4-5 REMOVING/INSTALLING THE FUEL INJECTORS ......... 4-5 DISASSEMBLING/ASSEMBLING THE FUEL INJECTORS ....
  • Page 54 FUEL FUEL PUMP....................4-24 DISASSEMBLING/ASSEMBLING THE FUEL PUMP ......4-24 INSPECTING THE CHECK VALVE ............4-26 INSPECTING THE FUEL PUMPS............4-26 OIL INJECTION SYSTEM ................4-28 REMOVING/INSTALLING THE OIL INJECTION SYSTEM ....4-28 DISASSEMBLING/ASSEMBLING THE OIL INJECTION SYSTEM..4-30 OIL TANK ...................... 4-31 DISASSEMBLING/ASSEMBLING THE OIL TANK........
  • Page 55 FUEL HIGH-PRESSURE FUEL LINE HIGH-PRESSURE FUEL LINE REMOVING/INSTALLING THE HIGH-PRESSURE FUEL LINE 4010 Order Job/Part Q’ty Remarks Screw Intake silencer Suction hose (intake silencer-to-throttle body) Oil tank air vent hose (intake silencer-to-oil tank) Throttle link rod Oil pump link rod Throttle position sensor coupler Fuel injector coupler High-pressure fuel pump resistor...
  • Page 56 FUEL HIGH-PRESSURE FUEL LINE 4010 Order Job/Part Q’ty Remarks Main relay connector Plastic locking tie Not reusable Fuel inlet hose (fuel pump-to-vapor separator) Oil inlet hose (oil pump-to-vapor separator) Bolt (with washer) Gasket Not reusable Fuel injection unit For installation, reverse the removal procedure.

  • Page 57: High-Pressure Fuel Line

    FUEL HIGH-PRESSURE FUEL LINE REDUCING THE FUEL PRESSURE (HIGH-PRESSURE FUEL LINE) WARNING Always reduce the fuel pressure in the high-pressure fuel line before servicing the line or the vapor separator. If the fuel pres- sure is not released, pressurized fuel may spray out.

  • Page 58: Inspecting The Pressure Regulator

    FUEL HIGH-PRESSURE FUEL LINE INSPECTING THE PRESSURE REGULATOR Inspect: • Pressure regulator Faulty → Replace the pressure regula- tor. Inspecting steps (1) Install the fuel pressure gauge onto the pressure check valve and then install the Mity vac onto the pressure regula- tor vacuum hose.

  • Page 59: Fuel Injectors

    FUEL FUEL INJECTORS FUEL INJECTORS REMOVING/INSTALLING THE FUEL INJECTORS 4020 Order Job/Part Q’ty Remarks Intake silencer Refer to “HIGH-PRESSURE FUEL LINE” on page 4-1. Before performing the following procedure, reduce the fuel pressure (high-pressure fuel line). Plastic locking tie Not reusable Bolt Washer Fuel rail...

  • Page 60: Disassembling/Assembling The Fuel Injectors

    FUEL FUEL INJECTORS DISASSEMBLING/ASSEMBLING THE FUEL INJECTORS 4030 Order Job/Part Q’ty Remarks Rubber seal Rubber damper O-ring Filter For assembly, reverse the disassembly procedure.

  • Page 61: Inspecting The Filters

    FUEL FUEL INJECTORS INSPECTING THE FILTERS Check: • Filter Damage/tears → Replace. Contaminants → Clean. 4040...

  • Page 62: Fuel Hoses

    FUEL FUEL HOSES FUEL HOSES REMOVING/INSTALLING THE FUEL HOSES 4050 Order Job/Part Q’ty Remarks Intake silencer Refer to “HIGH-PRESSURE FUEL LINE” on page 4-1. Before performing the following procedure, reduce the fuel pressure (high-pressure fuel line). Hose clamp Not reusable Fuel hose (fuel pump-to-fuel rail) Fuel hose...

  • Page 63: Removing The Hose Clamps

    FUEL FUEL HOSES REMOVING THE HOSE CLAMPS Remove: • Hose clamp NOTE: Remove the hose clamp by cutting its joint. CAUTION: 4070 The fuel hose will be damaged if a hose clamp is removed without cutting the joint. INSTALLING THE HOSE CLAMPS Install: •...

  • Page 64: Vapor Separator

    FUEL VAPOR SEPARATOR VAPOR SEPARATOR REMOVING/INSTALLING THE VAPOR SEPARATOR 4 × 14 mm 6 × 30 mm 4090 Order Job/Part Q’ty Remarks Fuel hoses Refer to “FUEL HOSES” on page 4-8. High-pressure fuel pump connector Bolt Large washer Small washer Collar Grommet Screw...

  • Page 65: Removing/Installing The Pressure Regulator

    FUEL VAPOR SEPARATOR REMOVING/INSTALLING THE PRESSURE REGULATOR 4 × 14 mm 6 × 14 mm 4100 Order Job/Part Q’ty Remarks Screw Pressure check valve holder Hose (vapor separator and pressure regulator- to-throttle body) Screw Pressure regulator O-ring Continued on next page. 4-11...
  • Page 66 FUEL VAPOR SEPARATOR 4 × 14 mm 6 × 14 mm 4100 Order Job/Part Q’ty Remarks Filter Fuel return joint O-ring O-ring For installation, reverse the removal procedure. 4-12...

  • Page 67: Disassembling/Assembling The Vapor Separator

    FUEL VAPOR SEPARATOR DISASSEMBLING/ASSEMBLING THE VAPOR SEPARATOR 4 × 14 mm 4110 Order Job/Part Q’ty Remarks Drain screw 4.8 × 1.9 mm O-ring Screw O-ring Float chamber High-pressure fuel pump filter Rubber damper holder Rubber damper Vapor separator body For assembly, reverse the disassembly procedure.

  • Page 68: Removing The High-Pressure Fuel Pump Filter

    FUEL VAPOR SEPARATOR REMOVING THE HIGH-PRESSURE FUEL PUMP FILTER Remove: • High-pressure fuel pump filter NOTE: To remove the high-pressure fuel pump fil- ter, turn it clockwise. 4120 INSTALLING THE HIGH-PRESSURE FUEL PUMP FILTER Install: • Rubber damper 1 • Rubber damper holder 2 •...

  • Page 69: High-Pressure Fuel Pump

    FUEL HIGH-PRESSURE FUEL PUMP HIGH-PRESSURE FUEL PUMP DISASSEMBLING/ASSEMBLING THE HIGH-PRESSURE FUEL PUMP 4150 Order Job/Part Q’ty Remarks Positive high-pressure fuel pump (red lead) terminal cap Negative high-pressure fuel (blue lead) pump terminal cap (M4) a = 7 mm Spring washer (M5) b = 8 mm Spring washer Positive high-pressure fuel pump...
  • Page 70 FUEL HIGH-PRESSURE FUEL PUMP 4150 Order Job/Part Q’ty Remarks Negative high-pressure fuel pump terminal 4.5 × 1.5 mm O-ring Washer (white) Collar 45.7 × 3.5 mm O-ring High-pressure fuel pump guide plate High-pressure fuel pump Insulator Continued on next page. 4-16...
  • Page 71 FUEL HIGH-PRESSURE FUEL PUMP 4150 Order Job/Part Q’ty Remarks 8 × 1.3 mm O-ring Screw Float pin Float Clip Needle valve For assembly, reverse the disassembly procedure. 4-17...

  • Page 72: Throttle Control Lever Cam

    FUEL THROTTLE CONTROL LEVER CAM THROTTLE CONTROL LEVER CAM REMOVING/INSTALLING THE THROTTLE CONTROL LEVER CAM 4170 Order Job/Part Q’ty Remarks Throttle link Bolt (with washer) Wave washer Collar Throttle control lever cam For installation, reverse the removal procedure. 4-18...

  • Page 73: Throttle Position Sensor

    FUEL THROTTLE POSITION SENSOR THROTTLE POSITION SENSOR REMOVING/INSTALLING THE THROTTLE POSITION SENSOR 4180 Order Job/Part Q’ty Remarks Screw Throttle position sensor Screw Washer Throttle position sensor bracket Collar Grommet Spacer Spring For installation, reverse the removal procedure. 4-19...

  • Page 74: Installing The Throttle Position Sensor

    FUEL THROTTLE POSITION SENSOR INSTALLING THE THROTTLE POSITION SENSOR NOTE: During installation, make sure the throttle position sensor is properly adjusted. Install: • Throttle position sensor Refer to “ADJUSTING THE THROTTLE POSITION SENSOR” on page 3-6. 4-20...

  • Page 75: Low-Pressure Fuel Line

    FUEL LOW-PRESSURE FUEL LINE LOW-PRESSURE FUEL LINE REMOVING/INSTALLING THE LOW-PRESSURE FUEL LINE 4190 Order Job/Part Q’ty Remarks Bolt Bracket Bolt Holder Bolt (with washer) Plastic locking tie Not reusable Bolt (with washer) Gasket Not reusable Low-pressure fuel line For installation, reverse the removal procedure.

  • Page 76: Disassembling/Assembling The Low-Pressure Fuel Line

    FUEL LOW-PRESSURE FUEL LINE DISASSEMBLING/ASSEMBLING THE LOW-PRESSURE FUEL LINE 4200 Order Job/Part Q’ty Remarks Plastic locking tie Not reusable Fuel hose (hose joint-to-fuel filter) Fuel filter Fuel hose (check valve-to-fuel filter) Check valve Fuel hose assembly (check valve-to-fuel pump) Fuel pump Fuel hose assembly (fuel pump-to-vapor separator) For assembly, reverse the disassembly...

  • Page 77: Fuel Filter

    FUEL FUEL FILTER FUEL FILTER DISASSEMBLING/ASSEMBLING THE FUEL FILTER 4210 Order Job/Part Q’ty Remarks Bolt Fuel filter nut holder Fuel filter nut Fuel filter cup O-ring Fuel filter element Spring O-ring Bolt Fuel filter bracket Fuel filter cap For assembly, reverse the disassembly procedure.
  • Page 78 FUEL FUEL PUMP FUEL PUMP DISASSEMBLING/ASSEMBLING THE FUEL PUMP 4220 Order Job/Part Q’ty Remarks Screw Diaphragm body Diaphragm Gasket Not reusable Fuel pump base Gasket Not reusable Diaphragm Continued on next page. 4-24...
  • Page 79 FUEL FUEL PUMP 4220 Order Job/Part Q’ty Remarks Spring seat Spring Screw Fuel pump valve Fuel pump body For assembly, reverse the disassembly procedure. 4-25...

  • Page 80: Fuel Pump

    FUEL FUEL PUMP INSPECTING THE CHECK VALVE Inspect: • Check valve operation Damage/reverse air flow → Replace. Inspecting steps NOTE: Do not overpressurize the check valve. Excessive pressure may cause air to leak out. (1) Install the Mity vac onto the check valve as shown.
  • Page 81 FUEL FUEL PUMP Inspecting steps NOTE: Do not overpressurize the fuel pump. Excessive pressure may cause air to leak out. (1) Install the Mity vac onto the fuel pump as shown. Mity vac YB-35956 / 90890-06756 (2) Apply the specified pressure with the Mity vac.

  • Page 82: Oil Injection System

    FUEL OIL INJECTION SYSTEM OIL INJECTION SYSTEM REMOVING/INSTALLING THE OIL INJECTION SYSTEM 4250 Order Job/Part Q’ty Remarks Bolt Bracket Bolt Holder Oil level sensor coupler Clip Washer Oil pump link rod Plastic locking tie Not reusable Oil hose (oil hose assembly joint-to-vapor separator) Continued on next page.
  • Page 83 FUEL OIL INJECTION SYSTEM 4250 Order Job/Part Q’ty Remarks Bolt O-ring Bolt Clamp Oil tank assembly Collar Grommet For installation, reverse the removal procedure. 4-29...

  • Page 84: Disassembling/Assembling The Oil Injection System

    FUEL OIL INJECTION SYSTEM DISASSEMBLING/ASSEMBLING THE OIL INJECTION SYSTEM 4260 Order Job/Part Q’ty Remarks Oil tank air vent hose (oil tank-to-intake silencer) Plastic locking tie Not reusable Oil hose (sub oil tank-to-oil tank) Oil hose (oil tank-to-oil pump) Oil tank assembly Metal clamp Oil hose assembly (oil pump-to-vapor separator)

  • Page 85: Oil Tank

    FUEL OIL TANK OIL TANK DISASSEMBLING/ASSEMBLING THE OIL TANK 4270 Order Job/Part Q’ty Remarks Oil level sensor Oil strainer Washer Oil tank For assembly, reverse the disassembly procedure. 4-31...

  • Page 86: Powr

    POWR CHAPTER 5 POWER UNIT FLYWHEEL MAGNET ASSEMBLY ..............5-1 REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY ....................5-1 REMOVING THE FLYWHEEL MAGNET ASSEMBLY ......5-2 INSTALLING THE FLYWHEEL MAGNET ASSEMBLY ......5-3 POWER UNIT ....................5-4 DISCONNECTING/CONNECTING THE LEADS ........5-4 DISCONNECTING/CONNECTING THE HOSES........
  • Page 87 POWR EXTERNAL FITTINGS................... 5-29 REMOVING/INSTALLING THE EXTERNAL FITTINGS ......5-29 CYLINDER HEADS ..................5-31 REMOVING/INSTALLING THE CYLINDER HEADS ......5-31 INSPECTING THE THERMOSTATS ............5-33 INSPECTING THE CYLINDER HEADS........... 5-33 EXHAUST COVERS ..................5-35 REMOVING/INSTALLING THE EXHAUST COVERS ......5-35 INSPECTING THE PRESSURE CONTROL VALVE........
  • Page 88 POWR FLYWHEEL MAGNET ASSEMBLY FLYWHEEL MAGNET ASSEMBLY REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY kgf, 137 ft 190 Nm (19m • • 5010 Order Job/Part Q’ty Remarks Flywheel magnet assembly cover Flywheel magnet assembly nut Washer Flywheel magnet assembly Woodruff key For installation, reverse the removal procedure.
  • Page 89 POWR FLYWHEEL MAGNET ASSEMBLY REMOVING THE FLYWHEEL MAGNET Å ASSEMBLY Remove: • Flywheel magnet assembly Removing steps (1) Remove the flywheel magnet assem- bly nut. 5020 Flywheel magnet assembly holder ı YB-06139 / 90890-06522 Å For USA and Canada ı Except for USA and Canada NOTE: The major load should be applied in the direction of the arrows.
  • Page 90 POWR FLYWHEEL MAGNET ASSEMBLY INSTALLING THE FLYWHEEL Å MAGNET ASSEMBLY Install: • Flywheel magnet assembly nut Flywheel magnet assembly holder YB-06139 / 90890-06522 5060 Å For USA and Canada ı Except for USA and Canada ı NOTE: The major load should be applied in the direction of the arrows.
  • Page 91 POWR POWER UNIT POWER UNIT DISCONNECTING/CONNECTING THE LEADS 5080 Order Job/Part Q’ty Remarks Battery leads (from the battery) Remote control shift and throttle rods and cables Bolt Negative battery lead Positive battery lead Junction box cover Power trim and tilt lead (blue) Power trim and tilt lead (green)
  • Page 92 POWR POWER UNIT DISCONNECTING/CONNECTING THE HOSES 6 × 20 mm 6 × 20 mm 6 × 12 mm 5090 Order Job/Part Q’ty Remarks Screw CDI unit cover Pilot water hose Bolt Ground lead Plastic locking tie Not reusable Cooling water hose Bolt Cable guide Continued on next page.
  • Page 93 POWR POWER UNIT 6 × 20 mm 6 × 20 mm 6 × 12 mm 5090 Order Job/Part Q’ty Remarks Trailer switch coupler Fuel hose (check valve-to-fuel filter) Oil hose (sub oil tank-to-oil tank) For installation, reverse the removal procedure.
  • Page 94 POWR POWER UNIT REMOVING/INSTALLING THE POWER UNIT 6 × 20 mm 8 × 30 mm 6 × 16 mm 8 × 135 mm kgf, 15 ft 21 Nm (2.1 m • • 8 × 30 mm 6 × 16 mm kgf, 15 ft 21 Nm (2.1 m •...
  • Page 95 POWR POWER UNIT 6 × 20 mm 8 × 30 mm 6 × 16 mm 8 × 135 mm kgf, 15 ft 21 Nm (2.1 m • • 8 × 30 mm 6 × 16 mm kgf, 15 ft 21 Nm (2.1 m •...
  • Page 96 POWR STATOR ASSEMBLY STATOR ASSEMBLY REMOVING/INSTALLING THE STATOR ASSEMBLY 5110 Order Job/Part Q’ty Remarks Flywheel magnet assembly Refer to “FLYWHEEL MAGNET ASSEMBLY” on page 5-1. Crank position sensor coupler Screw Crank position sensor Lighting coil coupler Charge coil coupler Bolt Stator assembly holder Stator assembly Continued on next page.
  • Page 97 POWR STATOR ASSEMBLY 5110 Order Job/Part Q’ty Remarks Pulser coil coupler Bolt Ground lead Screw Pulser coil assembly For installation, reverse the removal procedure. 5-10...
  • Page 98 POWR CDI UNIT CDI UNIT REMOVING/INSTALLING THE CDI UNIT ASSEMBLY 5120 Order Job/Part Q’ty Remarks CDI unit cover Refer to “DISCONNECTING/ CONNECTING THE HOSES” on page 5-5. Bolt Ground lead Bolt CDI unit coupler guide CDI unit coupler Emergency switch connector Fuel injector coupler High-pressure fuel pump resistor coupler...
  • Page 99 POWR CDI UNIT 5120 Order Job/Part Q’ty Remarks Oxygen density sensor coupler (black coupler) Bolt Bolt Ground lead Spark plug cap Bolt CDI unit assembly For installation, reverse the removal procedure. 5-12...
  • Page 100 POWR CDI UNIT REMOVING/INSTALLING THE CDI UNIT kgf, 2.9 ft 4 Nm (0.4 m • • 6 × 20 mm 6 × 12 mm 6 × 12 mm 6 × 25 mm 5130 Order Job/Part Q’ty Remarks Bolt Ground lead Ground lead Ignition coil connector Bolt...
  • Page 101 POWR CDI UNIT kgf, 2.9 ft 4 Nm (0.4 m • • 6 × 20 mm 6 × 12 mm 6 × 12 mm 6 × 25 mm 5130 Order Job/Part Q’ty Remarks Emergency switch cap Emergency switch CDI unit case For assembly, reverse the disassembly procedure.
  • Page 102 POWR HIGH-PRESSURE FUEL PUMP RESISTOR HIGH-PRESSURE FUEL PUMP RESISTOR REMOVING/INSTALLING THE HIGH-PRESSURE FUEL PUMP RESISTOR 4160 Order Job/Part Q’ty Remarks High-pressure fuel pump resistor coupler Bolt (with washer) High-pressure fuel pump resistor assembly Collar Screw (with washer) Continued on next page. 5-15...
  • Page 103 POWR HIGH-PRESSURE FUEL PUMP RESISTOR 4160 Order Job/Part Q’ty Remarks High-pressure fuel pump resistor cover Screw (with washer) High-pressure fuel pump resistor Grommet High-pressure fuel pump resistor mounting base For installation, reverse the removal procedure. 5-16...
  • Page 104 POWR JUNCTION BOX ASSEMBLY JUNCTION BOX ASSEMBLY REMOVING/INSTALLING THE JUNCTION BOX ASSEMBLY 5140 Order Job/Part Q’ty Remarks Junction box cover Refer to “POWER UNIT” on page 5-4. Starter motor lead Intake air temperature sensor coupler Atmospheric pressure sensor coupler Clip Cooling water hose (exhaust outer cover-to-rectifier/ regulator)
  • Page 105 POWR JUNCTION BOX ASSEMBLY 5150 Order Job/Part Q’ty Remarks Oxygen density sensor coupler (blue coupler) Fuse holder (80A) Positive terminal lead Bolt Ground lead Bolt Ground lead Ground lead plate Main relay coupler Ground lead connector Continued on next page. 5-18...
  • Page 106 POWR JUNCTION BOX ASSEMBLY 5150 Order Job/Part Q’ty Remarks Power trim and tilt relay coupler Starter relay connector Main relay connector Fuse connector Fuse holder (30A) Bolt Junction box assembly For installation, reverse the removal procedure. 5-19...
  • Page 107 POWR JUNCTION BOX ASSEMBLY DISASSEMBLING/ASSEMBLING THE JUNCTION BOX ASSEMBLY 5160 Order Job/Part Q’ty Remarks Fuse holder (80A) Fuse Screw Main relay Screw Starter relay holder Starter relay Bolt Power trim and tilt relay Bolt Rectifier/regulator Continued on next page. 5-20...
  • Page 108 POWR JUNCTION BOX ASSEMBLY 5160 Order Job/Part Q’ty Remarks Bolt Clip Cooling water hose (to exhaust outer cover) Cooling water hose (to pilot water outlet) Screw Atmospheric pressure sensor Intake air temperature sensor Collar Grommet Junction box For assembly, reverse the disassembly procedure.
  • Page 109 POWR WIRE HARNESSES WIRE HARNESSES REMOVING/INSTALLING THE MAIN WIRE HARNESS 6 × 14 mm 5170 Order Job/Part Q’ty Remarks Trim sensor connector Refer to “POWER UNIT” on page 5-4. Trailer switch coupler Refer to “POWER UNIT” on page 5-4. CDI unit coupler Refer to “CDI UNIT”...
  • Page 110 POWR WIRE HARNESSES REMOVING/INSTALLING THE SUB WIRE HARNESS 5180 Order Job/Part Q’ty Remarks Crank position sensor coupler Refer to “STATOR ASSEMBLY” on page 5-9. Pulser coil coupler Refer to “STATOR ASSEMBLY” on page 5-9. CDI unit coupler Refer to “CDI UNIT” on page 5-11. Bolt Ground lead Thermo switch connector...
  • Page 111 POWR STARTER MOTOR STARTER MOTOR REMOVING/INSTALLING THE STARTER MOTOR kgf, 22 ft 30 Nm (3.0 m • • 8 × 35 mm kgf, 22 ft 30 Nm (3.0 m • • 8 × 45 mm 5190 Order Job/Part Q’ty Remarks Negative battery lead Refer to “POWER UNIT”...
  • Page 112 POWR OXYGEN DENSITY SENSOR OXYGEN DENSITY SENSOR REMOVING/INSTALLING THE OXYGEN DENSITY SENSOR 5200 Order Job/Part Q’ty Remarks Plastic locking tie Rubber cap Bolt (with washer) Oxygen density sensor cover Bolt (with washer) Oxygen density sensor assembly Gasket Not reusable Oxygen density sensor bracket Oxygen density sensor Refer to “INSPECTING THE OXYGEN DENSITY SENSOR”...
  • Page 113 POWR REED VALVES REED VALVES REMOVING/INSTALLING THE REED VALVES 5210 Order Job/Part Q’ty Remarks Fuel injection unit Refer to “HIGH-PRESSURE FUEL LINE” on page 4-1. Recirculation hose Bolt (with washer) Gasket Not reusable Intake manifold Screw Gasket Not reusable Reed valve assembly Continued on next page.
  • Page 114 POWR REED VALVES 5210 Order Job/Part Q’ty Remarks Screw Reed valve stopper Metal reed Reed valve seat For installation, reverse the removal procedure. 5-27...
  • Page 115 POWR REED VALVES INSPECTING THE REED VALVE ASSEMBLY 1. Inspect: • Reed valve Cracks/damage → Replace. 2. Measure: • Warpage limit a Out of specification → Replace. Warpage limit 0.2 mm (0.008 in) 5220 3. Measure: • Reed valve stopper height a Out of specification →...
  • Page 116 POWR EXTERNAL FITTINGS EXTERNAL FITTINGS REMOVING/INSTALLING THE EXTERNAL FITTINGS 6 × 25 mm 6 × 30 mm 6 × 20 mm 5240 Order Job/Part Q’ty Remarks Fuel injection unit Refer to “HIGH-PRESSURE FUEL LINE” on page 4-1. Low-pressure fuel line Refer to “LOW-PRESSURE FUEL LINE”...
  • Page 117 POWR EXTERNAL FITTINGS 6 × 25 mm 6 × 30 mm 6 × 20 mm 5240 Order Job/Part Q’ty Remarks Throttle control lever assembly Collar Bolt Shift rod lever bracket Bolt Clamp bracket Clamp Hose clamp Recirculation hose Recirculation hose For installation, reverse the removal procedure.
  • Page 118 POWR CYLINDER HEADS CYLINDER HEADS REMOVING/INSTALLING THE CYLINDER HEADS 5250 Order Job/Part Q’ty Remarks Ground lead Refer to “CDI UNIT” on page 5-11. Spark plug cap Refer to “CDI UNIT” on page 5-11. Spark plug Bolt Thermostat cover Gasket Not reusable Thermostat Bolt Clamp...
  • Page 119 POWR CYLINDER HEADS 5250 Order Job/Part Q’ty Remarks Gasket Not reusable Thermo switch Engine cooling water temperature sensor Bolt Cylinder head Gasket Not reusable For installation, reverse the removal procedure. 5-32...
  • Page 120 POWR CYLINDER HEADS INSPECTING THE THERMOSTATS 1. Inspect: • Thermostat Damage/valve does not open → Replace. 2. Measure: • Thermostat opening temperature • Valve lift a 5260 Out of specification → Replace. Water temperature Valve lift Below 48 - 52 ˚C 0 mm (118 - 126 ˚F) (0 in)
  • Page 121 POWR CYLINDER HEADS 2. Measure: • Cylinder head warpage (with a straightedge and thickness gauge) Out of specification → Resurface or replace. Warpage limit 0.1 mm (0.004 in) 5270 Resurfacing steps (1) Place a 400 - 600 grit wet sandpaper on the surface plate.
  • Page 122 POWR EXHAUST COVERS EXHAUST COVERS REMOVING/INSTALLING THE EXHAUST COVERS 5300 Order Job/Part Q’ty Remarks Cooling water hose Refer to “POWER UNIT” on page 5-4. CDI unit assembly Refer to “CDI UNIT” on page 5-11. Cooling water hose Refer to “JUNCTION BOX ASSEMBLY” on page 5-17.
  • Page 123 POWR EXHAUST COVERS 5300 Order Job/Part Q’ty Remarks Pressure control valve seat Bolt Lead holder Exhaust outer cover Gasket Not reusable Exhaust inner cover Gasket Not reusable For installation, reverse the removal procedure. 5-36...
  • Page 124 POWR EXHAUST COVERS INSPECTING THE PRESSURE CONTROL VALVE Inspect: • Pressure control valve seat 1 • Pressure control valve 2 • Pressure control valve cover 3 Cracks/damage → Replace any defec- tive parts. 5310 • Spring 4 Damage/wear → Replace. 5-37...
  • Page 125 POWR CRANKCASE CRANKCASE REMOVING/INSTALLING THE CRANKCASE 5320 Order Job/Part Q’ty Remarks Flywheel magnet assembly Refer to “FLYWHEEL MAGNET ASSEMBLY” on page 5-1. Power unit Refer to “POWER UNIT” on page 5-4. Pulser coil assembly Refer to “STATOR ASSEMBLY” on page 5-9. Intake manifold Refer to “REED VALVES”...
  • Page 126 POWR CRANKCASE 5320 Order Job/Part Q’ty Remarks Crankcase Oil seal housing O-ring Oil seal Dowel pin For installation, reverse the removal procedure. 5-39...
  • Page 127 POWR CRANKCASE ASSEMBLING THE OIL SEAL Å HOUSING Install: • Oil seal Bearing/oil seal attachment ..1 YB-06195 / 90890-06637 90890-06631 Driver rod ........2 5330 YB-06071 / 90890-06606 ı Å For USA and Canada ı Except for USA and Canada 5340 INSTALLING THE CRANKCASE Apply:...
  • Page 128 POWR CYLINDER BODY ASSEMBLY CYLINDER BODY ASSEMBLY DISASSEMBLING/ASSEMBLING THE CYLINDER BODY ASSEMBLY 5360 Order Job/Part Q’ty Remarks Cylinder heads Refer to “CYLINDER HEADS” on page 5-31. Crankcase Refer to “CRANKCASE” on page 5-38. Upper bearing housing Oil seal O-ring Needle bearing Connecting rod bolt Connecting rod cap Big-end bearing...
  • Page 129 POWR CYLINDER BODY ASSEMBLY 5360 Order Job/Part Q’ty Remarks Crankshaft assembly Clip Main journal bearing Screw Anode Bolt Lead holder Cylinder cover Gasket Not reusable Bolt Continued on next page. 5-42...
  • Page 130 POWR CYLINDER BODY ASSEMBLY 5360 Order Job/Part Q’ty Remarks Engine hanger Bolt Damper bracket Oil pump driven gear Cylinder body For assembly, reverse the disassembly procedure. 5-43...
  • Page 131 POWR CYLINDER BODY ASSEMBLY DISASSEMBLING/ASSEMBLING THE PISTON AND CONNECTING ROD ASSEMBLIES 5370 Order Job/Part Q’ty Remarks Piston pin clip Not reusable Piston pin Piston Washer Small-end bearing Piston ring Connecting rod For assembly, reverse the disassembly procedure. 5-44...
  • Page 132 POWR CYLINDER BODY ASSEMBLY DISASSEMBLING/ASSEMBLING THE CRANKSHAFT ASSEMBLY 5600 Order Job/Part Q’ty Remarks Labyrinth ring Circlip Ball bearing Oil pump drive gear Crankshaft For assembly, reverse the disassembly procedure. 5-45...
  • Page 133 POWR CYLINDER BODY ASSEMBLY DISASSEMBLING THE UPPER Å BEARING HOUSING Remove: • Needle bearing Needle bearing attachment..1 YB-06205 / 90890-06663 Driver rod ........2 90890-06606 5390 Å For USA and Canada ı ı Except for USA and Canada 5400 REMOVING THE BEARING AND OIL PUMP DRIVE GEAR Remove:...
  • Page 134 POWR CYLINDER BODY ASSEMBLY INSPECTING THE CYLINDER BODY 1. Inspect: • Cylinder sleeves Cracks/score marks → Replace. • Cylinder body water jacket Mineral deposits/rust → Clean. CAUTION: Do not scratch the contacting surfaces of the crankcase and cylinder head. 2. Inspect: •...
  • Page 135 POWR CYLINDER BODY ASSEMBLY INSPECTING THE PISTONS Measure: • Piston diameter (with a micrometer) Out of specification → Replace. Measuring Piston diameter point “H” 5440 Cylinder #1 89.845 - 89.869 mm 10 mm (3.5372 - 3.5381 in) Standard (0.4 in) Cylinders #2 - #6 89.895 - 89.915 mm (3.5392 - 3.5400 in)
  • Page 136 POWR CYLINDER BODY ASSEMBLY CALCULATING THE PISTON-TO- CYLINDER CLEARANCE Calculate: • Piston-to-cylinder clearance a Out of specification → Replace the pis- ton and piston rings, the cylinder or both. Piston-to- Cylinder 5450 Piston cylinder bore – diameter clearance diameter Piston-to-cylinder clearance Cylinder #1 0.150 - 0.156 mm (0.0059 - 0.0061 in)
  • Page 137 POWR CYLINDER BODY ASSEMBLY INSPECTING THE PISTON RINGS NOTE: • Before inspecting the piston rings, be sure to inspect the cylinder body. • Piston rings should always be replaced as a set (per piston). 1. Measure: • Piston ring end gap a (with a thickness gauge) Out of specification →...
  • Page 138 POWR CYLINDER BODY ASSEMBLY INSPECTING THE OIL PUMP DRIVEN GEAR Inspect: • Oil pump driven gear Cracks/pitting/wear → Replace. 5510 INSPECTING THE LABYRINTH RINGS5 1. Inspect: • Labyrinth ring 1 Cracks/damage/wear → Replace. 2. Measure: • Labyrinth ring wear a or b + c Out of specification →...
  • Page 139 POWR CYLINDER BODY ASSEMBLY 4. Inspect: • Crankshaft bearing Pitting/rumbling → Replace. 5. Inspect: • Oil pump drive gear Cracks/pitting/wear → Replace. INSTALLING THE OIL PUMP DRIVE GEAR Install: • Oil pump drive gear Bearing separator ..... 1 YB-06219 / 90890-06534 Bearing/oil seal attachment ..
  • Page 140 The washers must be installed with their convex sides facing towards the piston. NOTE: The embossed YAMAHA mark a on the connecting rod must face the same direc- tion as the “UP” mark on the piston. ASSEMBLING THE UPPER BEARING Å...
  • Page 141 POWR CYLINDER BODY ASSEMBLY INSTALLING THE CRANKSHAFT ASSEMBLY Install: • Cylinder body • Crankshaft assembly NOTE: • Align the crankshaft labyrinth ring end gaps with their respective locating pins. • Install the bearing locating pins into the cylinder body. 5570 INSTALLING THE PISTON AND CONNECTING ROD ASSEMBLIES Install:...

  • Page 142: Lowr

    LOWR CHAPTER 6 LOWER UNIT LOWER UNIT (REGULAR ROTATION MODELS) .......... 6-1 REMOVING/INSTALLING THE LOWER UNIT ........6-1 REMOVING THE PROPELLER ..............6-3 INSPECTING THE PROPELLER ............... 6-3 INSTALLING THE PROPELLER..............6-3 WATER PUMP (REGULAR ROTATION MODELS) ........6-4 REMOVING/INSTALLING THE WATER PUMP........6-4 INSPECTING THE IMPELLER HOUSING ..........
  • Page 143 LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) ........6-17 REMOVING/INSTALLING THE DRIVE SHAFT........6-17 REMOVING THE DRIVE SHAFT ............6-19 DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ... 6-19 DISASSEMBLING THE FORWARD GEAR ASSEMBLY ....... 6-19 INSPECTING THE PINION ..............6-20 INSPECTING THE DRIVE SHAFT ............6-20 INSPECTING THE DRIVE SHAFT HOUSING ........
  • Page 144 LOWR PROPELLER SHAFT HOUSING ASSEMBLY (DUAL PROPELLER MODELS) ..............6-34 REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY .................... 6-34 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY................6-35 REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY.... 6-37 REMOVING THE OUTER PROPELLER SHAFT ........6-37 DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY ....................
  • Page 145 LOWR SHIMMING (REGULAR ROTATION MODELS) ........... 6-53 SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA) ................6-54 SELECTING THE PINION SHIMS ............6-54 SELECTING THE FORWARD GEAR SHIMS ......... 6-56 SELECTING THE REVERSE GEAR SHIMS..........6-58 SHIMMING (REGULAR ROTATION MODELS) (EXCEPT FOR USA AND CANADA) ............
  • Page 146 LOWR LOWER UNIT (REGULAR ROTATION MODELS) LOWER UNIT (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE LOWER UNIT 6010 Order Job/Part Q’ty Remarks Speedometer hose Cotter pin Propeller nut Washer Washer Propeller Spacer Continued on next page.
  • Page 147 LOWR LOWER UNIT (REGULAR ROTATION MODELS) 6010 Order Job/Part Q’ty Remarks Bolt Trim tab Bolt (with washer) Bolt (with washer) Lower unit Dowel pin For installation, reverse the removal procedure.

  • Page 148: Lower Unit (Regular Rotation Models)

    LOWR LOWER UNIT (REGULAR ROTATION MODELS) REMOVING THE PROPELLER Remove: • Propeller WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries 6016 and the clip from the engine stop lanyard switch.

  • Page 149: Water Pump (Regular Rotation Models)

    LOWR WATER PUMP (REGULAR ROTATION MODELS) WATER PUMP (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE WATER PUMP 6020 Order Job/Part Q’ty Remarks Lower unit Refer to “LOWER UNIT (REGULAR ROTATION MODELS)” on page 6-1. Bolt Plate washer Impeller housing Impeller housing cup Grommet Spacer Collar...
  • Page 150 LOWR WATER PUMP (REGULAR ROTATION MODELS) 6020 Order Job/Part Q’ty Remarks Spacer Washer Wave washer Impeller Woodruff key Impeller plate Gasket Not reusable Dowel pin For assembly, reverse the disassembly procedure.

  • Page 151: Inspecting The Impeller Housing

    LOWR WATER PUMP (REGULAR ROTATION MODELS) INSPECTING THE IMPELLER HOUSING Inspect: • Impeller housing Cracks/damage → Replace. INSPECTING THE IMPELLER AND IMPELLER HOUSING CUP Inspect: • Impeller • Impeller housing cup Cracks/damage → Replace any defec- tive parts. INSPECTING THE WOODRUFF KEY Inspect: •...

  • Page 152: Shift Rod Assembly (Regular Rotation Models)

    SHIFT ROD ASSEMBLY LOWR (REGULAR ROTATION MODELS) SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY 6035 Order Job/Part Q’ty Remarks Impeller plate Refer to “WATER PUMP (REGULAR ROTATION MODELS)” on page 6-4. Bolt (with washer) Shift rod assembly Shift rod Spring Oil seal housing...

  • Page 153: Removing The Shift Rod Assembly

    SHIFT ROD ASSEMBLY LOWR (REGULAR ROTATION MODELS) REMOVING THE SHIFT ROD ASSEMBLY Remove: • Shift rod assembly NOTE: Remove the shift rod assembly when the shift rod is in the neutral position.

  • Page 154: Propeller Shaft Housing Assembly (Regular Rotation Models)

    PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6040 Order Job/Part Q’ty Remarks Gear oil Refer to “CHANGING AND INSPECTING THE GEAR OIL” on page 3-14. Shift rod assembly Refer to “SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS)”...
  • Page 155 PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) 6040 Order Job/Part Q’ty Remarks Reverse gear shim Propeller shaft assembly Washer Propeller shaft housing For installation, reverse the removal procedure. *: As required 6-10...

  • Page 156: Disassembling/Assembling The Propeller Shaft Housing

    PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING 6045 Order Job/Part Q’ty Remarks O-ring Reverse gear Thrust washer Ball bearing Oil seal Needle bearing Propeller shaft housing For assembly, reverse the disassembly procedure. 6-11...

  • Page 157: Disassembling/Assembling The Propeller Shaft Assembly

    PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY 6100 Order Job/Part Q’ty Remarks Spring Dog clutch Shift rod joint Shift rod joint slider Ball Spring Ball Propeller shaft For assembly, reverse the disassembly procedure. 6-12...

  • Page 158: Removing The Propeller Shaft Housing Assembly

    PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY 1. Straighten: • Claw washer tabs 2. Remove: • Ring nut • Claw washer Ring nut wrench ....... 1 6050 YB-34447 / 90890-06512 Ring nut wrench extension ..2 Å...

  • Page 159: Inspecting The Bearing

    PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) 2. Remove: Å • Ball bearing Slide hammer......1 YB-06096 Guide plate........ 2 90890-06501 Guide plate stand ..... 3 90890-06538 Bearing puller......4 6070 90890-06535 Small universal claws ....5 ı 90890-06536 Å...

  • Page 160: Inspecting The Dog Clutch

    PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) INSPECTING THE DOG CLUTCH Inspect: • Dog clutch Damage/wear → Replace. INSPECTING THE PROPELLER SHAFT Inspect: • Propeller shaft Damage/wear → Replace. ASSEMBLING THE PROPELLER SHAFT HOUSING 1. Install: • Needle bearing Needle bearing installation position a 24.75 - 25.25 mm...

  • Page 161: Installing The Propeller Shaft Housing Assembly

    PROPELLER SHAFT HOUSING ASSEMBLY LOWR (REGULAR ROTATION MODELS) INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY Install: • Propeller shaft housing assembly • Claw washer • Ring nut Ring nut wrench ....... 1 YB-34447 / 90890-06512 6095 Ring nut wrench extension ..2 90890-06513 NOTE: To secure the ring nut, bend one tab into...

  • Page 162: Drive Shaft (Regular Rotation Models)

    LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) DRIVE SHAFT (REGULAR ROTATION MODELS) REMOVING/INSTALLING THE DRIVE SHAFT 6105 Order Job/Part Q’ty Remarks Propeller shaft housing assembly Refer to “PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)” on page 6-9. Pinion Bolt (with washer) Drive shaft housing assembly Pinion shim Thrust bearing...
  • Page 163 LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) 6105 Order Job/Part Q’ty Remarks Forward gear assembly O-ring Oil seal cover Oil seal Needle bearing Drive shaft housing Tapered roller bearing Not reusable Needle bearing Forward gear For assembly, reverse the disassembly procedure. 6-18...

  • Page 164: Removing The Drive Shaft

    LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) REMOVING THE DRIVE SHAFT Loosen: • Pinion nut Drive shaft holder ..... 1 YB-06201 / 90890-06520 Pinion nut holder ...... 2 90890-06505 Pinion nut holder attachment . 3 90890-06508 6110 DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY Remove: •...

  • Page 165: Inspecting The Pinion

    LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) INSPECTING THE PINION Inspect: • Teeth Damage/wear → Replace. INSPECTING THE DRIVE SHAFT Inspect: • Drive shaft Damage/wear → Replace. INSPECTING THE DRIVE SHAFT HOUSING Inspect: • Drive shaft housing Cracks/damage → Replace. INSPECTING THE BEARINGS Inspect: •...

  • Page 166: Assembling The Drive Shaft Housing Assembly

    LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) 2. Install: • Tapered roller bearing Bearing/oil seal attachment 90890-06659 6155 ASSEMBLING THE DRIVE SHAFT Å HOUSING ASSEMBLY 1. Install: • Needle bearing Position a 5.75 - 6.25 mm (0.226 - 0.246 in) Bearing/oil seal attachment ..1 6125 YB-06196 / 90890-06610 Driver rod ........

  • Page 167: Installing The Drive Shaft

    LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) INSTALLING THE DRIVE SHAFT Tighten: • Pinion nut Pinion nut 95 Nm (9.5 m • kgf, 68 ft • lb) NOTE: Tighten the pinion nut with the same tools that were used for removal. 6-22...

  • Page 168: Lower Case Assembly (Regular Rotation Models)

    LOWER CASE ASSEMBLY LOWR (REGULAR ROTATION MODELS) LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS) DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY 6160 Order Job/Part Q’ty Remarks Forward gear Refer to “DRIVE SHAFT (REGULAR ROTATION MODELS)” on page 6-17. Drive shaft sleeve Needle bearing Tapered roller bearing outer race Forward gear shim Water seal...

  • Page 169: Assembly

    LOWER CASE ASSEMBLY LOWR (REGULAR ROTATION MODELS) DISASSEMBLING THE LOWER CASE ASSEMBLY 1. Remove: • Needle bearing Bearing/oil seal attachment ..1 YB-06194 / 90890-06636 Driver rod ........2 YB-06071 / 90890-06605 6165 2. Remove: • Tapered roller bearing outer race Slide hammer......
  • Page 170 LOWR LOWER UNIT (DUAL PROPELLER MODELS) LOWER UNIT (DUAL PROPELLER MODELS) REMOVING/INSTALLING THE LOWER UNIT 6315 Order Job/Part Q’ty Remarks Speedometer hose Cotter pin Propeller nut Washer Washer Rear propeller Rear spacer Propeller nut Continued on next page. 6-25...

  • Page 171: Lower Unit (Dual Propeller Models)

    LOWR LOWER UNIT (DUAL PROPELLER MODELS) 6315 Order Job/Part Q’ty Remarks Toothed washer Forward propeller Forward spacer Bolt (with washer) Lower unit Dowel pin For installation, reverse the removal procedure. 6-26...

  • Page 172: Removing The Propellers

    LOWR LOWER UNIT (DUAL PROPELLER MODELS) REMOVING THE PROPELLERS 1. Remove: • Rear propeller WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries 6321 and the clip from the engine stop lanyard switch.

  • Page 173: Installing The Propellers

    LOWR LOWER UNIT (DUAL PROPELLER MODELS) INSTALLING THE PROPELLERS 1. Install: • Forward propeller WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries 6327 and the clip from the engine stop lanyard switch.

  • Page 174: Water Pump (Dual Propeller Models)

    LOWR WATER PUMP (DUAL PROPELLER MODELS) WATER PUMP (DUAL PROPELLER MODELS) REMOVING/INSTALLING THE WATER PUMP 6330 Order Job/Part Q’ty Remarks Lower unit Refer to “LOWER UNIT (DUAL PROPELLER MODELS)” on page 6-25. Bolt Plate washer Impeller housing Impeller housing cup Grommet Spacer Drive shaft collar...
  • Page 175 LOWR WATER PUMP (DUAL PROPELLER MODELS) 6330 Order Job/Part Q’ty Remarks Spacer Washer Wave washer Impeller Woodruff key For assembly, reverse the disassembly procedure. 6-30...

  • Page 176: Inspecting The Impeller Housing

    LOWR WATER PUMP (DUAL PROPELLER MODELS) INSPECTING THE IMPELLER HOUSING Inspect: • Impeller housing Cracks/damage → Replace. INSPECTING THE IMPELLER AND IMPELLER HOUSING CUP Inspect: • Impeller • Impeller housing cup Cracks/damage → Replace any defec- tive parts. INSPECTING THE WOODRUFF KEY Inspect: •...

  • Page 177: Shift Rod (Dual Propeller Models)

    LOWR SHIFT ROD (DUAL PROPELLER MODELS) SHIFT ROD (DUAL PROPELLER MODELS) REMOVING/INSTALLING THE SHIFT ROD 6335 Order Job/Part Q’ty Remarks Woodruff key Refer to “WATER PUMP (DUAL PROPELLER MODELS)” on page 6-29. Bolt (with washer) Plate washer Oil seal housing cover Impeller plate Gasket Not reusable...

  • Page 178: Removing The Shift Rod

    LOWR SHIFT ROD (DUAL PROPELLER MODELS) REMOVING THE SHIFT ROD 1. Remove: • Oil seal housing Removing steps (1) Insert a flat-head screwdriver under each projection a. (2) Alternating between each side of the oil seal housing 1, slowly lift the oil 6336 seal housing until it is fully removed from the lower unit.

  • Page 179: Propeller Shaft Housing Assembly (Dual Propeller Models)

    PROPELLER SHAFT HOUSING ASSEMBLY LOWR (DUAL PROPELLER MODELS) PROPELLER SHAFT HOUSING ASSEMBLY (DUAL PROPELLER MODELS) REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6340 Order Job/Part Q’ty Remarks Gear oil Refer to “CHANGING AND INSPECTING THE GEAR OIL” on page 3-14. Ring nut Claw washer Propeller shaft housing assembly Washer...

  • Page 180: Disassembling/Assembling The Propeller Shaft Housing Assembly

    PROPELLER SHAFT HOUSING ASSEMBLY LOWR (DUAL PROPELLER MODELS) DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6345 Order Job/Part Q’ty Remarks O-ring Rear gear assembly Outer propeller shaft Thrust bearing Outer propeller shaft shim Oil seal Needle bearing Continued on next page. *: As required 6-35...
  • Page 181 PROPELLER SHAFT HOUSING ASSEMBLY LOWR (DUAL PROPELLER MODELS) 6345 Order Job/Part Q’ty Remarks Oil seal Needle bearing Propeller shaft housing Rear gear Thrust washer Tapered roller bearing outer race Tapered roller bearing For assembly, reverse the disassembly procedure. 6-36...

  • Page 182: Removing The Propeller Shaft Housing Assembly

    PROPELLER SHAFT HOUSING ASSEMBLY LOWR (DUAL PROPELLER MODELS) REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY 1. Straighten: • Claw washer tabs 2. Remove: • Ring nut • Claw washer Ring nut wrench 6350 YB-42223 3. Remove: • Propeller shaft housing Propeller shaft housing puller . 1 YB-06502 / 90890-06502 Universal puller......

  • Page 183: Disassembling The Outer Propeller Shaft Assembly

    PROPELLER SHAFT HOUSING ASSEMBLY (DUAL LOWR PROPELLER MODELS) DISASSEMBLING THE OUTER PROPELLER SHAFT ASSEMBLY Remove: • Needle bearing Slide hammer YB-06096 6370 REMOVING THE REAR GEAR ASSEMBLY Remove: • Rear gear 1 • Thrust washer 2 • Tapered roller bearing 3 •...

  • Page 184: Assembling The Outer Propeller Shaft Assembly

    PROPELLER SHAFT HOUSING ASSEMBLY LOWR (DUAL PROPELLER MODELS) ASSEMBLING THE OUTER Å PROPELLER SHAFT ASSEMBLY 1. Install: • Needle bearing Needle bearing installation position a 34.75 - 35.25 mm (1.368 - 1.388 in) 6375 Bearing/oil seal attachment ..1 ı YB-42225 / 90890-06653 Driver rod ........
  • Page 185 PROPELLER SHAFT HOUSING ASSEMBLY LOWR (DUAL PROPELLER MODELS) 2. Install: • Oil seal Oil seal installation position a 4.75 - 5.25 mm (0.187 - 0.207 in) Bearing/oil seal attachment ..1 YB-42227 / 90890-06623 Driver rod ........2 6390 YB-06071 / 90890-06606 3.

  • Page 186: Installing The Propeller Shaft Housing Assembly

    PROPELLER SHAFT HOUSING ASSEMBLY LOWR (DUAL PROPELLER MODELS) INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY 1. Install: • Propeller shaft housing assembly NOTE: Engage the pinion with the rear gear by turning the drive shaft to the right and left. Then, push the propeller shaft housing 6410 assembly into the lower case until the claw washer’s insertion slot comes out.

  • Page 187: Drive Shaft (Dual Propeller Models)

    LOWR DRIVE SHAFT (DUAL PROPELLER MODELS) DRIVE SHAFT (DUAL PROPELLER MODELS) REMOVING/INSTALLING THE DRIVE SHAFT 6415 Order Job/Part Q’ty Remarks Propeller shaft housing assembly Refer to “PROPELLER SHAFT HOUSING ASSEMBLY (DUAL PROPELLER MODELS)” on page 6-34. Shift rod Refer to “SHIFT ROD (DUAL PROPELLER MODELS)”...
  • Page 188 LOWR DRIVE SHAFT (DUAL PROPELLER MODELS) 6415 Order Job/Part Q’ty Remarks Thrust bearing Drive shaft Inner propeller shaft assembly O-ring Oil seal cover Oil seal Needle bearing Drive shaft housing For assembly, reverse the disassembly procedure. 6-43...

  • Page 189: Removing The Drive Shaft

    LOWR DRIVE SHAFT (DUAL PROPELLER MODELS) REMOVING THE DRIVE SHAFT Loosen: • Pinion nut Drive shaft holder ..... 1 YB-06201 / 90890-06520 Pinion nut holder ...... 2 YB-42224 6420 NOTE: • First, loosen the drive shaft housing assembly bolts. Then, pull up the drive shaft and insert the pinion nut holder.

  • Page 190: Disassembling The Drive Shaft Housing Assembly

    LOWR DRIVE SHAFT (DUAL PROPELLER MODELS) DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY Remove: • Needle bearing Bearing/oil seal attachment ..1 YB-06196 / 90890-06610 Driver rod ........2 YB-06071 / 90890-06652 6120 INSPECTING THE DRIVE SHAFT HOUSING Inspect: • Drive shaft housing Cracks/damage →...

  • Page 191: Inner Propeller Shaft Assembly (Dual Propeller Models)

    INNER PROPELLER SHAFT ASSEMBLY LOWR (DUAL PROPELLER MODELS) INNER PROPELLER SHAFT ASSEMBLY (DUAL PROPELLER MODELS) DISASSEMBLING/ASSEMBLING THE INNER PROPELLER SHAFT ASSEMBLY 6430 Order Job/Part Q’ty Remarks Spring Front dog clutch Front gear assembly (with oil groove a) Washer Spring Continued on next page. 6-46...
  • Page 192 INNER PROPELLER SHAFT ASSEMBLY LOWR (DUAL PROPELLER MODELS) 6430 Order Job/Part Q’ty Remarks Rear dog clutch Washer Collar Tapered roller bearing Not reusable Front gear For assembly, reverse the disassembly procedure. 6-47...

  • Page 193: Removing The Spring

    INNER PROPELLER SHAFT ASSEMBLY LOWR (DUAL PROPELLER MODELS) REMOVING THE SPRING Remove: • Spring 1 NOTE: Pry the end of the spring out of the groove in the dog clutch and then gradually remove it. 6435 DISASSEMBLING THE FRONT GEAR ASSEMBLY Remove: •...

  • Page 194: Assembling The Front Gear Assembly

    INNER PROPELLER SHAFT ASSEMBLY LOWR (DUAL PROPELLER MODELS) ASSEMBLING THE FRONT GEAR ASSEMBLY Install: • Bearing inner race 1 Bearing/oil seal attachment YB-06276 / 90890-06659 6455 INSTALLING THE SPRING Install: • Spring 1 NOTE: Push the end of the spring into the groove in the dog clutch and then gradually install 6440 6-49...

  • Page 195: Lower Case Assembly (Dual Propeller Models)

    LOWER CASE ASSEMBLY LOWR (DUAL PROPELLER MODELS) LOWER CASE ASSEMBLY (DUAL PROPELLER MODELS) DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY 6465 Order Job/Part Q’ty Remarks Inner propeller shaft assembly Refer to “DRIVE SHAFT (DUAL PROPELLER MODELS)” on page 6-42. Drive shaft sleeve Needle bearing Tapered roller bearing outer race Front gear shim...

  • Page 196: Disassembling The Lower Case Assembly

    LOWER CASE ASSEMBLY LOWR (DUAL PROPELLER MODELS) DISASSEMBLING THE LOWER CASE ASSEMBLY 1. Remove: • Needle bearing Bearing/oil seal attachment ..1 YB-06194 / 90890-06636 Driver rod ........2 YB-06071 / 90890-06605 6470 2. Remove: • Tapered roller bearing outer race Slide hammer......
  • Page 197 LOWER CASE ASSEMBLY LOWR (DUAL PROPELLER MODELS) 2. Install: Å • Needle bearing Needle bearing installation position 10.0 mm (0.39 in) Needle bearing installation position 139.0 mm (5.47 in) 6485 Bearing/oil seal attachment ..1 YB-06194 / 90890-06609 ı Driver rod ........2 YB-06071 / 90890-06602 Bearing/oil seal depth plate ..

  • Page 198: Shimming (Regular Rotation Models)

    LOWR SHIMMING (REGULAR ROTATION MODELS) SHIMMING (REGULAR ROTATION MODELS) NOTE: • There is no need to select shims when reassembling with the original case and inner parts. • Shim calculations are required when reas- sembling with the original inner parts and a new case (the difference between the original inner parts and the new case).

  • Page 199: Shimming (Regular Rotation Models) (For Usa And Canada)

    SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) SELECTING THE PINION SHIMS NOTE: Find the shim thickness (T3) by selecting shims until the specified value (M0) is obtained with the special tool. 6505 1. Measure: • Specified measurement (M) Out of specified value (M0) →...
  • Page 200 SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) (2) Install the pinion height gauge, drive shaft, and thrust bearing 1. Pinion height gauge YB-34432-7, -11 (3) Install the pinion and pinion nut. Pinion nut 95 Nm (9.5 m • kgf, 69 ft • lb) 6515 (4) Measure the specified measurement (M).

  • Page 201: Selecting The Forward Gear Shims

    SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) SELECTING THE FORWARD GEAR SHIMS NOTE: Find the shim thickness (T1) by selecting shims until the specified value (M0) is obtained with the special tool. 6525 1. Measure: • Specified measurement (M) Out of specified value (M0) →...
  • Page 202 SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) (2) Install the shimming gauge, and bear- ing 1. Shimming gauge YB-34446-1, -3, -4, -8 (3) Measure the specified measurement (M). 6535 2. Adjust: • Shim thickness (T1) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm...

  • Page 203: Selecting The Reverse Gear Shims

    SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) SELECTING THE REVERSE GEAR SHIMS NOTE: Find the shim thickness (T2) by selecting shims until the specified value (M0) is obtained with the special tool. 6545 1. Measure: • Specified measurement (M) Out of specified value (M0) →...
  • Page 204 SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) (2) Install the shimming gauge, bearing, thrust washer, and reverse gear. Shimming gauge (150J, 200J/SX150, SX200 models) YB-34468-1 (150L/VX150 model) YB-34468-6 6555 NOTE: Turn the reverse gear assembly a few times until the gear and bearing are horizontal.

  • Page 205: Shimming (Regular Rotation Models) (Except For Usa And Canada)

    SHIMMING (REGULAR ROTATION MODELS) LOWR (EXCEPT FOR USA AND CANADA) SELECTING THE PINION SHIMS NOTE: Select the shim thickness (T3) by using the specified measurement(s) and the calcula- tion formula. Select: • Shim thickness (T3) 6575 Selecting steps (1) Measure (M3). Digital caliper 90890-06704 NOTE:...
  • Page 206 SHIMMING (REGULAR ROTATION MODELS) LOWR (EXCEPT FOR USA AND CANADA) (5) Calculate the pinion shim thickness (T3). Pinion shim thickness (T3) = 80.0 + P/100 – M3 – M4 NOTE: • “P” is the deviation of the lower case dimension from standard. It is stamped 6590 on the trim tab mounting surface of the lower case in 0.01-mm units.

  • Page 207: Selecting The Forward Gear Shims

    SHIMMING (REGULAR ROTATION MODELS) LOWR (EXCEPT FOR USA AND CANADA) SELECTING THE FORWARD GEAR SHIMS NOTE: Select the shim thickness (T1) by using the specified measurement(s) and the calcula- tion formula. Select: 6595 • Shim thickness (T1) Selecting steps (1) Measure (M1). Shimming plate ......

  • Page 208: Selecting The Reverse Gear Shim

    SHIMMING (REGULAR ROTATION MODELS) LOWR (EXCEPT FOR USA AND CANADA) Example: If M1 is “28.10 mm” and F is “+5”, then T1 = 28.6 + (+5)/100 – 28.10 mm = 28.6 + 0.05 – 28.10 mm = 0.55 mm (3) Select the forward gear shim(s) (T1). Calculated numeral Rounded at 1/100th place...
  • Page 209 SHIMMING (REGULAR ROTATION MODELS) LOWR (EXCEPT FOR USA AND CANADA) (2) Calculate the reverse gear shim thick- ness (T2). Reverse gear shim thickness (150J, 200J/SX150, SX200 models) (T2) = M2 – 29.0 – R/100 (150L/VX150 model) (T2) = M2 – 29.9 – R/100 NOTE: •...

  • Page 210: Backlash (Regular Rotation Models)

    LOWR BACKLASH (REGULAR ROTATION MODELS) BACKLASH (REGULAR ROTATION MODELS) NOTE: • Do not install the water pump compo- nents when measuring the backlash. • Measure both the forward and reverse gear backlashes. • If both the forward and reverse gear back- lashes are larger than specification, the pinion may be too high.
  • Page 211 LOWR BACKLASH (REGULAR ROTATION MODELS) (2) Install the propeller shaft housing puller so it pushes against the propel- ler shaft. Propeller shaft housing puller . 1 YB-06207 / 90890-06502 Universal puller......2 YB-06117 Guide plate........ 3 90890-06501 6650 Center bolt ........ 4 90890-06504 Center bolt 10 Nm (1.0 m •...

  • Page 212: Measuring The Reverse Gear Backlash

    LOWR BACKLASH (REGULAR ROTATION MODELS) 2. Adjust: • Forward gear shim Remove or add shim(s). Forward gear Shim thickness backlash Less than To be decreased by (150J, 200J/SX150, (150J, 200J/SX150, SX200 models) SX200 models) (0.36 – M) × 0.72 0.25 mm (0.010 in) (150L/VX150 (150L/VX150 model)
  • Page 213 LOWR BACKLASH (REGULAR ROTATION MODELS) Measuring steps (1) Set the shift rod into the neutral posi- tion. Shift rod wrench YB-06052 / 90890-06052 6645 (2) Load the reverse gear by installing the propeller without the spacer 1 and then tighten the propeller nut. Propeller nut 10 Nm (1.0 m •...
  • Page 214 LOWR BACKLASH (REGULAR ROTATION MODELS) 2. Adjust: • Reverse gear shim Remove or add shim(s). Reverse gear Shim thickness backlash Less than To be increased by (150J, 200J/SX150, (150J, 200J/SX150, SX200 models) SX200 models) (1.02 – M) × 0.72 0.74 mm (0.029 in) (150L/VX150 (150L/VX150 model)

  • Page 215: Shimming (Dual Propeller Models)

    LOWR SHIMMING (DUAL PROPELLER MODELS) SHIMMING (DUAL PROPELLER MODELS) NOTE: • There is no need to select shims when reassembling with the original case and inner parts. • Shim calculations are required when reas- sembling with the original inner parts and a new case (the difference between the original inner parts and the new case).

  • Page 216: Selecting The Pinion Shims

    LOWR SHIMMING (DUAL PROPELLER MODELS) SELECTING THE PINION SHIMS NOTE: Find the shim thickness (T3) by selecting shims until the specified value (M0) is obtained with the special tool. 6735 1. Measure: • Specified measurement (M) Out of specified value (M0) → Adjust. Specified value (M0) = 1.00 + P/100 mm Measuring steps...
  • Page 217 LOWR SHIMMING (DUAL PROPELLER MODELS) (2) Install the pinion height gauge, drive shaft, and thrust bearing 1. Pinion height gauge YB-34432-11, -97 (3) Install the pinion and pinion nut. Pinion nut 95 Nm (9.5 m • kgf, 68 ft • lb) 6745 (4) Measure the specified measurement (M).

  • Page 218: Selecting The Front Gear Shims

    LOWR SHIMMING (DUAL PROPELLER MODELS) SELECTING THE FRONT GEAR SHIMS NOTE: Find the shim thickness (T1) by selecting shims until the specified value (M0) is obtained with the special tool. 1. Measure: • Specified measurement (M) 6755 Out of specified value (M0) → Adjust. Specified value (M0) = 1.00 + F/100 mm Measuring steps...

  • Page 219: Selecting The Rear Gear Shims

    LOWR SHIMMING (DUAL PROPELLER MODELS) (3) Measure the specified measurement (M). 2. Adjust: • Shim thickness (T1) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as pos- sible.
  • Page 220 LOWR SHIMMING (DUAL PROPELLER MODELS) Example: If “R” is “+5”, then M0 = 1.60 – (+5)/100 mm = 1.60 – 0.05 mm = 1.55 mm If “R” is “–3”, then M0 = 1.60 – (–3)/100 mm = 1.60 + 0.03 mm = 1.63 mm (2) Install the shimming gauge, bearing, thrust washer, and rear gear.

  • Page 221: Selecting The Outer Propeller Shaft Shims

    LOWR SHIMMING (DUAL PROPELLER MODELS) SELECTING THE OUTER PROPELLER SHAFT SHIMS NOTE: Find the shim thickness (T4) by selecting shims until the specified measurement is obtained with the special tool. 6785 1. Install: • Shim(s) 1 • Thrust bearing 2 •...

  • Page 222: Backlash (Dual Propeller Models)

    LOWR BACKLASH (DUAL PROPELLER MODELS) BACKLASH (DUAL PROPELLER MODELS) NOTE: • Do not install the water pump compo- nents when measuring the backlash. • Measure both the forward and reverse gear backlashes. • If both the forward and reverse gear back- lashes are larger than specification, the pinion may be too high.
  • Page 223 LOWR BACKLASH (DUAL PROPELLER MODELS) (3) Install the backlash indicator onto the drive shaft (on the 22.4 mm (0.88 in) diameter portion of the drive shaft a). Backlash indicator ....3 YB-06265 / 90890-06706 (4) Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indi- cator.

  • Page 224: Measuring The Rear Gear Backlash

    LOWR BACKLASH (DUAL PROPELLER MODELS) MEASURING THE REAR GEAR BACKLASH 1. Measure: • Rear gear backlash Out of specification → Adjust. Rear gear backlash 0.39 - 0.70 mm (0.015 - 0.027 in) Measuring steps (1) Set the shift rod into the neutral posi- tion.
  • Page 225 LOWR BACKLASH (DUAL PROPELLER MODELS) (3) Install the backlash indicator onto the drive shaft (on the 22.4 mm (0.88 in) diameter portion of the drive shaft a). Backlash indicator ....4 YB-06265 / 90890-06706 (4) Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indi- cator.

  • Page 226: Brkt

    BRKT CHAPTER 7 BRACKET UNIT BOTTOM COWLING ..................7-1 REMOVING/INSTALLING THE BOTTOM COWLING ......7-1 DISASSEMBLING/ASSEMBLING THE BOTTOM COWLING ....7-3 SHIFT ROD ASSEMBLY ................. 7-6 DISASSEMBLING/ASSEMBLING THE SHIFT ROD ASSEMBLY... 7-6 UPPER CASE ASSEMBLY ................7-7 REMOVING/INSTALLING THE UPPER CASE ASSEMBLY ....7-7 DISASSEMBLING/ASSEMBLING THE UPPER CASE ASSEMBLY ....................
  • Page 227 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT ........7-29 REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND GEAR PUMP UNIT ................7-29 REMOVING THE TILT RAM END SCREW ..........7-31 REMOVING THE GEAR PUMP UNIT ............ 7-31 DISASSEMBLING THE GEAR PUMP UNIT .......... 7-31 INSPECTING THE TILT RAM ..............
  • Page 228 BRKT BOTTOM COWLING BOTTOM COWLING REMOVING/INSTALLING THE BOTTOM COWLING 7010 Order Job/Part Q’ty Remarks Power unit Refer to “POWER UNIT” on page 5-4. Shift rod assembly Bolt Holder Bolt Bracket Battery lead Hose guide Continued on next page.
  • Page 229 BRKT BOTTOM COWLING 7010 Order Job/Part Q’ty Remarks Power trim and tilt lead Trim sensor lead Bolt Ground lead Speedometer hose Flushing hose Salt water models Bottom cowling For installation, reverse the removal procedure.
  • Page 230 BRKT BOTTOM COWLING DISASSEMBLING/ASSEMBLING THE BOTTOM COWLING 7030 Order Job/Part Q’ty Remarks Bolt Lower spring holder Spring Bolt Upper spring holder Wave washer Set pin Bushing Continued on next page.
  • Page 231 BRKT BOTTOM COWLING 7030 Order Job/Part Q’ty Remarks Clamp lever Pilot water outlet Wire harness clamp Bolt Cable holder Grommet Bolt Continued on next page.
  • Page 232 BRKT BOTTOM COWLING 7030 Order Job/Part Q’ty Remarks Trailer switch holder Trailer switch Bolt Ground lead Grommet Collar Bottom cowling For assembly, reverse the disassembly procedure.
  • Page 233 BRKT SHIFT ROD ASSEMBLY SHIFT ROD ASSEMBLY DISASSEMBLING/ASSEMBLING THE SHIFT ROD ASSEMBLY 7040 Order Job/Part Q’ty Remarks Screw Spring Ball Clip Shift rod lever Rubber seal Circlip Shift rod bracket Bushing Shift rod For assembly, reverse the disassembly procedure.
  • Page 234 BRKT UPPER CASE ASSEMBLY UPPER CASE ASSEMBLY REMOVING/INSTALLING THE UPPER CASE ASSEMBLY 7050 Order Job/Part Q’ty Remarks Lower unit Refer to “LOWER UNIT (REGULAR ROTATION MODELS)” on page 6-1. Bottom cowling Refer to “BOTTOM COWLING” on page 7-1. Bolt Ground lead (upper case-to-swivel bracket) Screw Lower mount cover...
  • Page 235 BRKT UPPER CASE ASSEMBLY DISASSEMBLING/ASSEMBLING THE UPPER CASE ASSEMBLY 7060 Order Job/Part Q’ty Remarks Bolt Upper mount bracket Upper mount Bolt Bolt Lower mount bracket Spring Lower mount Continued on next page.
  • Page 236 BRKT UPPER CASE ASSEMBLY 7060 Order Job/Part Q’ty Remarks Ground lead Bolt Bolt Bolt Muffler assembly Rubber seal Muffler X transom models Rubber seal X transom models Rubber seal X transom models Continued on next page.
  • Page 237 BRKT UPPER CASE ASSEMBLY 7060 Order Job/Part Q’ty Remarks Upper case Dowel pin Circlip X transom models Bushing X transom models For assembly, reverse the disassembly procedure. 7-10...
  • Page 238 BRKT EXHAUST MANIFOLD ASSEMBLY EXHAUST MANIFOLD ASSEMBLY DISASSEMBLING/ASSEMBLING THE EXHAUST MANIFOLD ASSEMBLY 7070 Order Job/Part Q’ty Remarks Bolt Muffler Gasket Not reusable Water tube Water seal Bolt Exhaust manifold Gasket Not reusable Bolt Continued on next page. 7-11...
  • Page 239 BRKT EXHAUST MANIFOLD ASSEMBLY 7070 Order Job/Part Q’ty Remarks Lower exhaust manifold guide Gasket Not reusable Upper exhaust manifold guide Plastic locking tie Salt water models Not reusable Flushing hose Salt water models Plastic locking tie Not reusable Cooling water hose For assembly, reverse the disassembly procedure.
  • Page 240 BRKT CLAMP BRACKETS CLAMP BRACKETS REMOVING/INSTALLING THE CLAMP BRACKETS 7080 Order Job/Part Q’ty Remarks Upper case assembly Refer to “UPPER CASE ASSEMBLY” on page 7-7. Rubber cap Grease nipple Ground lead Bolt Ground lead Anode bracket Anode Trim sensor Continued on next page. 7-13...
  • Page 241 BRKT CLAMP BRACKETS 7080 Order Job/Part Q’ty Remarks Self-locking nut Bolt Clamp bracket bolt Starboard clamp bracket Port clamp bracket Bushing Swivel bracket assembly For installation, reverse the removal procedure. 7-14...
  • Page 242 BRKT STEERING ARM STEERING ARM REMOVING/INSTALLING THE STEERING ARM 7090 Order Job/Part Q’ty Remarks Upper case assembly Refer to “UPPER CASE ASSEMBLY” on page 7-7. Circlip Steering arm yoke Washer Washer O-ring Steering arm Washer Bushing Swivel bracket assembly For installation, reverse the removal procedure.
  • Page 243 BRKT SWIVEL BRACKET ASSEMBLY SWIVEL BRACKET ASSEMBLY DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET ASSEMBLY 7100 Order Job/Part Q’ty Remarks Steering arm Refer to “STEERING ARM” on page 7-15. Trim stopper Bolt Spring holder Spring Continued on next page. 7-16...
  • Page 244 BRKT SWIVEL BRACKET ASSEMBLY 7100 Order Job/Part Q’ty Remarks Starboard tilt stop lever Port tilt stop lever Bushing Bushing Tilt stop lever joint assembly For assembly, reverse the disassembly procedure. 7-17...
  • Page 245 BRKT POWER TRIM AND TILT UNIT POWER TRIM AND TILT UNIT REMOVING/INSTALLING THE POWER TRIM AND TILT UNIT 7110 Order Job/Part Q’ty Remarks Tilt up the outboard Power trim and tilt lead Plastic locking tie Not reusable Ground lead Circlip Upper mounting pin Lower mounting pin Power trim and tilt unit...
  • Page 246 BRKT POWER TRIM AND TILT UNIT REMOVING THE POWER TRIM AND TILT UNIT WARNING After tilting up the outboard, be sure to support it with the tilt stop levers. Otherwise, the outboard could suddenly lower if the power trim and tilt unit should lose fluid pressure.
  • Page 247 BRKT POWER TRIM AND TILT UNIT (3) Tilt up the outboard fully, then release it, and let it lower by its own weight. (4) Tighten the manual valve by turning it clockwise. (5) Let the power trim and tilt fluid settle for about 5 minutes.
  • Page 248 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR RESERVOIR AND POWER TRIM AND TILT MOTOR REMOVING/INSTALLING THE RESERVOIR AND POWER TRIM AND TILT MOTOR 7160 Order Job/Part Q’ty Remarks Power trim and tilt unit Refer to “POWER TRIM AND TILT UNIT” on page 7-18.
  • Page 249 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR WARNING • To prevent the hydraulic fluid from spurt- ing out due to internal pressure, the out- board should be kept fully tilted up (the tilt rod at full length). • After removing the power trim and tilt motor or reservoir, do not push the tilt ram down.
  • Page 250 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR INSTALLING THE POWER TRIM AND TILT MOTOR 1. Install: • Gear pump housing filter 1 • Drive pin 2 2. Fill: • Gear pump housing Recommended power trim and 7170 tilt fluid ATF Dexron II NOTE: Add power trim and tilt fluid until it reaches...
  • Page 251 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR FILLING THE RESERVOIR WARNING To prevent the hydraulic fluid from spurt- ing out due to internal pressure, the tilt ram should be kept at full length. 1. Fill: • Reservoir Recommended power trim and tilt fluid ATF Dexron II 2.
  • Page 252 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR B. If step A was unsuccessful, connect the leads on the battery terminals and fully compress the tilt ram assembly by hand. C. If step B was unsuccessful, loosen the manual valve, compress the trim and tilt ram assemblies fully by hand, and then tighten the manual valve.
  • Page 253 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR MEASURING THE HYDRAULIC PRESSURE Inspect: • Hydraulic pressure Out of specification → Repair. Hydraulic pressure (with the power trim and tilt ram assemblies fully extended) 9.8 - 11.8 MPa (100 - 120 kg/cm (with the power trim and tilt ram assemblies fully compressed) 5.9 - 8.8 MPa (60 - 90 kg/cm...
  • Page 254 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR (4) Connect the leads on the battery termi- nals in the down position until the power trim and tilt ram assemblies are fully compressed. 7210 (5) Connect the leads on the battery termi- nals in the up position until the power trim and tilt ram assemblies are fully extended.
  • Page 255 BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR (10) After measuring the hydraulic pres- sure, connect the leads on the battery terminals in the up position until the power trim and tilt ram assemblies are fully extended. (11) Remove the special tools. (12) Install the manual valve and circlip.
  • Page 256 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT TILT RAM ASSEMBLY AND GEAR PUMP UNIT REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND GEAR PUMP UNIT 7290 Order Job/Part Q’ty Remarks Reservoir and power trim and tilt Refer to “RESERVOIR AND POWER TRIM motor AND TILT MOTOR”...
  • Page 257 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT 7290 Order Job/Part Q’ty Remarks Check valve assembly Gear pump Shuttle valve Check valve Up-relief valve assembly Down-relief valve assembly For installation, reverse the removal procedure. 7-30...
  • Page 258 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT REMOVING THE TILT RAM END SCREW Loosen: • Tilt ram end screw End screw wrench YB-06548 / 90890-06548 7300 NOTE: Hold the power trim and tilt unit in a vise using aluminum plates on both sides. REMOVING THE GEAR PUMP UNIT Remove: •...
  • Page 259 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT 2. Remove: • Check valves 1 and 2 NOTE: To remove the check valves, cover the gear pump housing with a clean cloth and then blow compressed air through holes a and b. 7330 INSPECTING THE TILT RAM Inspect:...
  • Page 260 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT ASSEMBLING THE GEAR PUMP UNIT CAUTION: Install all components in their original direction and position for proper assembly and operation. 1. Install: • Balls (3.18 mm/0.125 in) 1 • Shuttle valves 2 NOTE: Apply grease to the balls to prevent them from falling out of the gear pump.
  • Page 261 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT INSTALLING THE GEAR PUMP UNIT 1. Install: • O-rings 1 • Ball 2 • Pin 3 • Check valve 4 • Check valve assembly 5 NOTE: 7380 When installing the check valve assembly, make sure the pin is on the tilt ram cylinder side as shown.
  • Page 262 BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT 2. Fill: • Gear pump housing Recommended power trim and tilt fluid ATF Dexron II NOTE: Add power trim and tilt fluid through the 7410 hole a until the fluid level is to the top of the gear pump unit.
  • Page 263 BRKT TRIM RAM ASSEMBLIES AND FREE PISTON TRIM RAM ASSEMBLIES AND FREE PISTON REMOVING/INSTALLING THE TRIM RAM ASSEMBLIES AND FREE PISTON 7440 Order Job/Part Q’ty Remarks Tilt ram assembly and gear Refer to “TILT RAM ASSEMBLY AND pump unit GEAR PUMP UNIT” on page 7-29. Trim ram end screw Trim ram O-ring...
  • Page 264 BRKT TRIM RAM ASSEMBLIES AND FREE PISTON REMOVING THE TRIM RAM END Å ı SCREWS Loosen: • Trim ram end screw End screw wrench YB-06175-1A / 90890-06548 Å For USA and Canada 7450 ı Except for USA and Canada NOTE: Hold the power trim and tilt unit in a vise using aluminum plates on both sides.
  • Page 265 BRKT TRIM RAM ASSEMBLIES AND FREE PISTON INSPECTING THE TRIM RAMS Inspect: • Trim ram Excessive scratches → Replace. Bends/excessive corrosion → Replace. Rust → Polish. (with 400 - 600 grit sandpaper) INSPECTING THE FREE PISTON Inspect: • Free piston Excessive scratches →...
  • Page 266 BRKT TRIM RAM ASSEMBLIES AND FREE PISTON 2. Install: • Piston ring 1 • O-ring 2 • Free piston 3 NOTE: Push the free piston into the tilt ram cylin- der until it bottoms out. 7490 INSTALLING THE TRIM RAMS WARNING Do not push the trim rams down while installing them into the trim ram cylinders.
  • Page 267 BRKT TRIM RAM ASSEMBLIES AND FREE PISTON 3. Install: • Trim ram assemblies 1 NOTE: Place each trim ram end screw at the bot- tom of each trim ram and install them into the trim ram cylinders. 7520 4. Tighten: Å...

  • Page 268: Elec

    – ELEC CHAPTER 8 ELECTRICAL SYSTEMS ELECTRICAL COMPONENTS................. 8-1 (Port view) ....................8-1 (Starboard view) ..................8-2 (Junction box assembly)................. 8-3 (Aft view) ....................8-4 (Top view)....................8-5 WIRE HARNESS....................8-6 ELECTRICAL COMPONENTS ANALYSIS............ 8-10 DIGITAL CIRCUIT TESTER..............8-10 MEASURING THE PEAK VOLTAGE............8-10 PEAK VOLTAGE ADAPTOR..............
  • Page 269 – ELEC STARTING SYSTEM..................8-27 INSPECTING THE BATTERY ..............8-28 INSPECTING THE FUSES ..............8-28 INSPECTING THE WIRE HARNESS CONTINUITY....... 8-28 INSPECTING THE WIRE CONNECTIONS ..........8-29 INSPECTING THE STARTER RELAY............. 8-29 STARTER MOTOR ..................8-30 DISASSEMBLING/ASSEMBLING THE STARTER MOTOR....8-30 REMOVING THE STARTER MOTOR PINION ........
  • Page 270 – ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS (Port view) 8010 1 Fuel injector 6 Oil level sensor 2 High-pressure fuel pump 7 Fuel injector coupler (6P) 3 Throttle position sensor 8 Throttle position sensor coupler (3P) 4 High-pressure fuel pump connectors 9 Oil level sensor coupler (6P) 5 High-pressure fuel pump resistor couplers 0 Pulser coil coupler (6P)
  • Page 271 – ELEC ELECTRICAL COMPONENTS (Starboard view) 8020 1 Atmospheric pressure sensor 2 Crank position sensor coupler (2P) 3 Engine cooling water temperature sensor coupler (2P) 4 Oxygen density sensor 5 Battery lead terminal 6 Starter motor 7 Intake air temperature sensor 8 Junction box assembly...
  • Page 272 – ELEC ELECTRICAL COMPONENTS (Junction box assembly) 8030 Å Complete assembly 1 Oxygen density sensor coupler (2P) ı Sub-assembly 2 Lighting coil coupler (3P) Ç To wire harness 3 Fuse (80A) Î To power trim and tilt motor 4 Atmospheric pressure sensor ‰...
  • Page 273 – ELEC ELECTRICAL COMPONENTS (Aft view) 8040 1 Emergency switch connectors 7 Oxygen density sensor coupler (2P) 2 Emergency switch 8 CDI unit 3 Ignition coil connectors 9 CDI unit couplers (24P, 18P) 4 Ignition coils 0 Wire harness 5 Thermo switch connectors A Sub-wire harness 6 Charge coil coupler (4P)
  • Page 274 – ELEC ELECTRICAL COMPONENTS 8050 1 Remote control coupler (10P) 8 Emergency switch 2 Oxygen density sensor 9 Oil level sensor 3 Crank position sensor 0 Trailer switch 4 Spark plugs A High-pressure fuel pump 5 Thermo switches B High-pressure fuel pump resistor 6 Engine cooling water temperature sensor C Trim sensor coupler (2P) 7 CDI unit...
  • Page 275 – ELEC WIRE HARNESS WIRE HARNESS 9 8 2 2 L/R L/R Y/R B/Y 8060 Connect to: : Black : Sky blue : Blue/yellow 1 Oil level sensor : Brown : White : Red/yellow 2 Ground : Green : Yellow : Yellow/red 3 Emergency switch : Gray...
  • Page 276 – ELEC WIRE HARNESS 9 8 2 2 L/R L/R Y/R B/Y 8060 9 Oxygen density sensor : Black : Red : Blue/red 0 Remote control : Brown : Sky blue L/W : Blue/white A Oil level switch (sub-oil tank) : Green : White : Blue/yellow...
  • Page 277 – ELEC WIRE HARNESS 8070 Connect to: : Black W/Br : White/brown 1 Thermo switches : Orange W/G : White/green 2 Ground lead : Pink W/L : White/blue 3 Pulser coil : Black/yellow W/R : White/red 4 Throttle position sensor : Green/blue W/Y : White/yellow 5 CDI unit...
  • Page 278 – ELEC WIRE HARNESS 8080 Connect to: : Brown 1 Fuel injectors : Blue 2 Main relay Pu/B : Purple/black 3 High-pressure fuel pump resistor Pu/G : Purple/green 4 CDI unit Pu/L : Purple/blue 5 High-pressure fuel pump Pu/R : Purple/red Pu/W : Purple/white Pu/Y : Purple/yellow...
  • Page 279 – ELEC ELECTRICAL COMPONENTS ANALYSIS ELECTRICAL COMPONENTS ANALYSIS DIGITAL CIRCUIT TESTER Digital tester J-39299 / 90890-06752 NOTE: 8090 “ ” indicates a continuity of electric- ity which means a closed circuit at the respective switch position. MEASURING THE PEAK VOLTAGE NOTE: •...
  • Page 280 – ELEC ELECTRICAL COMPONENTS ANALYSIS NOTE: • When measuring the peak voltage, set the selector to the DC voltage mode. • Make sure the peak voltage adaptor leads are properly installed in the digital tester. • Make sure the positive pin (the “+” mark facing up as shown) on the peak voltage adaptor is installed into the positive termi- 8120...
  • Page 281 – ELEC IGNITION SYSTEM IGNITION SYSTEM 8190 1 Charge coil : Black : Black/blue W/B : White/black 2 Pulser coil : Brown : Black/orange W/Br : White/brown 3 CDI unit : Blue : Black/red W/G : White/green 4 Ignition coils : Red B/W : Black/white W/L : White/blue...
  • Page 282 – ELEC IGNITION SYSTEM INSPECTING THE IGNITION SPARK WARNING • Do not touch any of the connections of the spark gap tester lead wires. • Do not let sparks leak out of the removed spark plug cap. • Keep flammable gas or liquids away, 8200 since this test can produce sparks.
  • Page 283 – ELEC IGNITION SYSTEM MEASURING THE IGNITION SYSTEM PEAK VOLTAGE WARNING When checking the peak voltage do not touch any of the connections of the digital tester lead wires. NOTE: • If there is no spark or the spark is weak, continue with the ignition system test.
  • Page 284 – ELEC IGNITION SYSTEM 2. Measure: • Charge coil output peak voltage Above specification → Measure the pulser coil output peak voltage. Below specification → Replace the charge coil. Charge coil output peak voltage Red (R) – Brown (Br) Black/red (B/R) – Blue (L) Circuit Loaded r/min...
  • Page 285 – ELEC IGNITION SYSTEM INSPECTING THE SPARK PLUG CAPS 1. Inspect: • Spark plug cap Loose connection → Tighten. Cracks/damage → Replace. Replacement steps 8280 (1) To remove the spark plug cap turn it counterclockwise. (2) To install the spark plug cap turn it clockwise until it is tight.
  • Page 286 – ELEC IGNITION CONTROL SYSTEM IGNITION CONTROL SYSTEM 8300 1 Pulser coil : Black L/W : Blue/white 2 Crank position sensor : Orange : Red/black 3 Engine cooling water : Pink W/B : White/black temperature sensor : Red W/Br : White/brown 4 Thermo switches : Black/yellow W/G : White/green...
  • Page 287 – ELEC IGNITION CONTROL SYSTEM MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE Refer to “MEASURING THE IGNITION SYSTEM PEAK VOLTAGE” page 8-14. MEASURING THE CRANK POSITION SENSOR OUTPUT PEAK VOLTAGE Measure: • Crank position sensor output peak voltage Below specification → Replace. Crank position sensor output peak voltage Green/white (G/W) –...
  • Page 288 – ELEC IGNITION CONTROL SYSTEM Measuring steps (1) Place the engine cooling water tem- perature sensor in a container filled with water. (2) Place a thermometer in the water. (3) Slowly heat the water. (4) Measure the resistance when the spec- ified temperature is reached.
  • Page 289 – ELEC IGNITION CONTROL SYSTEM MEASURING THE THROTTLE POSITION SENSOR OUTPUT VOLTAGE Measure: • Throttle position sensor output volt- Out of specification → Check the CDI unit. Throttle position sensor output voltage Orange (O) – Pink (P) 0.48 - 5.25 V Measuring steps (1) Connect the test harness (3-pin) as shown.
  • Page 290 – ELEC FUEL CONTROL SYSTEM FUEL CONTROL SYSTEM 8390 1 Pulser coil 9 Main relay : Pink Pu/R : Purple/red 2 Crank position sensor 0 High-pressure fuel pump : Red Pu/W : Purple/white 3 Oxygen density sensor resistor : Yellow Pu/Y : Purple/yellow 4 Engine cooling water A High-pressure fuel pump...
  • Page 291 – ELEC FUEL CONTROL SYSTEM MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE Refer to “MEASURING THE IGNITION SYSTEM PEAK VOLTAGE” page 8-14. MEASURING THE CRANK POSITION SENSOR OUTPUT PEAK VOLTAGE Refer to “MEASURING THE CRANK POSITION SENSOR OUTPUT PEAK VOLTAGE” on page 8-18. INSPECTING THE OXYGEN DENSITY SENSOR 1.
  • Page 292 – ELEC FUEL CONTROL SYSTEM Measuring steps WARNING To prevent an explosion when performing this procedure, keep all flammable prod- ucts (e.g., gasoline) away from the testing area and make sure there is proper ventila- tion. CAUTION: Do not let any silicon anticorrosion solvent touch the oxygen density sensor or its accuracy will be affected.
  • Page 293 – ELEC FUEL CONTROL SYSTEM MEASURING THE ENGINE COOLING WATER TEMPERATURE SENSOR RESISTANCE Refer to “MEASURING THE ENGINE COOLING WATER TEMPERATURE SENSOR RESISTANCE” on page 8-18. INSPECTING THE INTAKE AIR TEMPERATURE SENSOR Measure: • Intake air temperature sensor output voltage Out of specification →...
  • Page 294 – ELEC FUEL CONTROL SYSTEM MEASURING THE THROTTLE POSITION SENSOR OUTPUT VOLTAGE Refer to “MEASURING THE THROT- POSITION SENSOR OUTPUT VOLTAGE” on page 8-20. MEASURING THE HIGH-PRESSURE FUEL PUMP RESISTOR RESISTANCE8 Inspect: • High-pressure fuel pump resistor resistance Out of specification → Replace. High-pressure fuel pump resistor resistance 8470...
  • Page 295 – ELEC FUEL CONTROL SYSTEM INSPECTING THE FUEL INJECTORS 1. Inspect: • Fuel injector operating sound No sound (no fuel is being sprayed) → Inspect the high-pressure fuel pump. Inspecting steps (1) Remove the intake silencer 1. (2) Start the engine. (3) Fully close the throttle valves.
  • Page 296 – ELEC STARTING SYSTEM STARTING SYSTEM 8500 1 Battery : Black 2 Fuse (80A) : Brown 3 Fuse (30A) : Red 4 10P connector 5 Starter relay 6 Starter motor 8-27...
  • Page 297 – ELEC STARTING SYSTEM INSPECTING THE BATTERY Refer to “INSPECTING THE BAT- TERY” on page 3-16. INSPECTING THE FUSES 1. Inspect: • Fuse holder continuity No continuity → Check the fuse holder leads. 2. Inspect: • Fuse holder lead continuity No continuity →...
  • Page 298 – ELEC STARTING SYSTEM INSPECTING THE WIRE CONNECTIONS Inspect: • Wire connections Poor connection → Properly connect. INSPECTING THE STARTER RELAY Inspect: • Starter relay continuity No continuity → Replace. Inspecting steps (1) Connect tester battery between the starter relay terminals. Positive digital tester probe 1 →...
  • Page 299 – ELEC STARTER MOTOR STARTER MOTOR DISASSEMBLING/ASSEMBLING THE STARTER MOTOR 8530 Order Job/Part Q’ty Remarks Starter motor Refer to “STARTER MOTOR” on page 5-24. Bolt Starter motor bracket Clip Starter motor pinion stopper Spring Starter motor pinion Continued on next page. 8-30...
  • Page 300 – ELEC STARTER MOTOR 8530 Order Job/Part Q’ty Remarks Bolt Upper cover Washer Lower bracket Stator Armature Washer Continued on next page. 8-31...
  • Page 301 – ELEC STARTER MOTOR 8530 Order Job/Part Q’ty Remarks O-ring Screw Brush assembly Spring Brush holder For assembly, reverse the disassembly procedure. 8-32...
  • Page 302 – ELEC STARTER MOTOR REMOVING THE STARTER MOTOR PINION Remove: • Clips 1 NOTE: Slide the pinion stopper 1 down as shown and then remove the clips 2. 8540 INSPECTING THE STARTER MOTOR PINION 1. Inspect: • Starter motor pinion teeth Damage/wear →...
  • Page 303 – ELEC STARTER MOTOR 3. Inspect: • Commutator undercut Dirt/foreign matter → Clean. (with compressed air) 8580 4. Measure: • Commutator undercut a Out of specification → Replace the armature. Commutator undercut limit 0.2 mm (0.01 in) 8590 5. Inspect: •...
  • Page 304 – ELEC STARTER MOTOR 2. Inspect: • Brush assembly continuity Out of specification → Replace the brush assembly. Brush assembly continuity Brush 1 – Brush 2 Brush 3 – Brush 4 8620 Continuity Brush (3, 4) – Brush assembly holder 5 Brush 1 –...
  • Page 305 – ELEC CHARGING SYSTEM CHARGING SYSTEM 8630 1 Lighting coil : Black 2 Rectifier/regulator : Green 3 Fuses (80A) : Red 4 Battery R/W : Red/white 8-36...
  • Page 306 – ELEC CHARGING SYSTEM MEASURING THE RECTIFIER/ REGULATOR OUTPUT PEAK VOLTAGE Measure: • Rectifier/regulator output peak voltage Below specification → Check the light- ing coil. Rectifier/regulator output peak 8640 voltage Red (R) – Black (B) Circuit Loaded r/min Cranking 1,500 3,500 —...
  • Page 307 – ELEC CHARGING SYSTEM INSPECTING THE FUSES Refer to “INSPECTING THE FUSES” on page 8-28. INSPECTING THE BATTERY Refer to “INSPECTING THE BAT- TERY” on page 3-16. 8-38...
  • Page 308 – ELEC OIL FEED PUMP CONTROL SYSTEM OIL FEED PUMP CONTROL SYSTEM 8680 1 Fuse (80A) : Black : Blue/green 2 Fuse (30A) : Brown : Blue/red 3 10P connector : Gray L/W : Blue/white 4 Oil level sensor : Blue R/W : Red/white 5 Emergency switch : Pink...
  • Page 309 – ELEC OIL FEED PUMP CONTROL SYSTEM INSPECTING THE FUSES Refer to “INSPECTING THE FUSES” on page 8-28. INSPECTING THE OIL LEVEL SENSOR/SWITCH CONTINUITY Inspect: • Oil level sensor/switch continuity Out of specification → Replace. Lead color Float Blue/ Blue/ Blue/ Black position...
  • Page 310 – ELEC OIL FEED PUMP CONTROL SYSTEM INSPECTING THE EMERGENCY SWITCH 1. Inspect: • Emergency switch continuity Out of specification → Replace. Lead color Switch position Blue (L) – Black (B) 8710 Home a No continuity On b Continuity 2. Inspect: •...
  • Page 311 – ELEC POWER TRIM AND TILT SYSTEM POWER TRIM AND TILT SYSTEM 8730 Å To remote control 1 Battery : Black ı To trim meter 2 Fuse (80A) : Gray 3 Fuse (30A) : Light green 4 Trailer switch : Pink 5 10P connector : Red 6 Power trim and tilt relay...
  • Page 312 – ELEC POWER TRIM AND TILT SYSTEM INSPECTING THE FUSES Refer to “INSPECTING THE FUSES” on page 8-28. INSPECTING THE BATTERY Refer to “INSPECTING THE BAT- TERY” on page 3-16. INSPECTING THE POWER TRIM AND TILT RELAY 1. Inspect: • Power trim and tilt relay continuity Out of specification →...
  • Page 313 – ELEC POWER TRIM AND TILT SYSTEM INSPECTING THE TRAILER SWITCH CONTINUITY Inspect: • Trailer switch continuity Out of specification → Replace. Lead color Switch Light Sky blue position Red (R) green 8780 (Sb) (Lg) Free Down MEASURING THE TRIM SENSOR RESISTANCE Measure: •...
  • Page 314 – ELEC POWER TRIM AND TILT MOTOR POWER TRIM AND TILT MOTOR DISASSEMBLING/ASSEMBLING THE POWER TRIM AND TILT MOTOR 7540 Order Job/Part Q’ty Remarks Power trim and tilt motor Refer to “RESERVOIR AND POWER TRIM AND TILT MOTOR” on page 7-21. Screw Lead holder Screw...
  • Page 315 – ELEC POWER TRIM AND TILT MOTOR 7540 Order Job/Part Q’ty Remarks Brush holder Brush Spring Lower cover Oil seal Bearing For assembly, reverse the disassembly procedure. 8-46...
  • Page 316 – ELEC POWER TRIM AND TILT MOTOR REMOVING THE STATOR Remove: • Stator 1 CAUTION: • Keep the power trim and tilt motor leads inside the stator. • Do not allow grease or oil to contact the 7550 commutator. NOTE: •...
  • Page 317 – ELEC POWER TRIM AND TILT MOTOR 2. Inspect: • Brush continuity No continuity → Replace. CAUTION: Do not touch the bimetal a; touching it may affect the operation of the breaker. 7590 INSPECTING THE ARMATURE 1. Measure: • Commutator diameter a Out of specification →...
  • Page 318 – ELEC POWER TRIM AND TILT MOTOR INSTALLING THE BRUSH Install: • Brushes 1 • Brush holders 2 • Power trim and tilt motor leads 3 • Screw 4 CAUTION: 7640 Do not touch the bimetal; touching it may affect the operation of the breaker. INSTALLING THE ARMATURE Install: •...

  • Page 319: Trbl Anls

    TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS ..................9-1 TROUBLE ANALYSIS CHART ..............9-1 SELF-DIAGNOSIS ................... 9-4 DIAGNOSIS CODE INDICATION ............. 9-4 DIAGNOSIS THE ELECTRONIC CONTROL SYSTEM ......9-4 TROUBLE SHOOTING FOR ELECTRIC FUEL INJECTION......9-6...
  • Page 320 TRBL TROUBLE ANALYSIS ANLS TROUBLE ANALYSIS NOTE: The following items should be checked before the “TROUBLE ANALYSIS CHART” is con- sulted. 1. The battery is charged and its specified gravity is within specification. 2. There are no incorrect wiring connections. 3.
  • Page 321 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter Pistons Bearings Thermostat Water passages LOWER UNIT Neutral position Dog clutch Gears Water inlets Water pump Propeller shaft(s) Shift rod joint/pin Shift cam Shift shaft Lower case BRACKET UNIT Bracket Rubber mount Shift rod...
  • Page 322 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter Ignition/fuel control system • Engine stop lanyard switch — • Main relay • High-pressure fuel pump resistor • Crank position sensor • Atmospheric pressure sensor • Intake air temperature sensor •...
  • Page 323 TRBL SELF-DIAGNOSIS ANLS SELF-DIAGNOSIS DIAGNOSIS CODE INDICATION 1. Normal condition (no defective part or irregular process- ing is found) 2. Single flash is given every 5 seconds. a : Light on, 0.3 second b : Light off, 5 seconds 8160 3.
  • Page 324 TRBL SELF-DIAGNOSIS ANLS Inspecting steps (1) Start the engine and let it idle. (2) Check the diagnostic indicator’s flash pattern to determine if there are any malfunctions. NOTE: When more than one problem is detected, the diagnostic tester’s light flashes in the pattern of the lowest numbered problem.
  • Page 325 TROUBLE SHOOTING FOR ELECTRIC FUEL TRBL INJECTION ANLS TROUBLE SHOOTING FOR ELECTRIC FUEL INJECTION Items Symptoms 1. Poor starting/ 1. No firing. The starter motor cranks the engine, but no firing is Engine will generated in the cylinder. not start 2.
  • Page 326 TROUBLE SHOOTING FOR ELECTRIC FUEL TRBL INJECTION ANLS Items Symptoms 2. Erratic idling 1. The engine speed is not constant when idling. speed 2. The engine stalls when the throttle lever is pulled back. 3. The engine stalls when the throttle lever is opened or during outboard operation.
  • Page 327 TROUBLE SHOOTING FOR ELECTRIC FUEL TRBL INJECTION ANLS Items Symptoms 3. Erratic engine 1. The engine is started, but will not run smoothly. The engine speed speed drops during acceleration. 1. Inspect the high-pressure fuel lines. 1) Inspect for fuel line leaks 2) Inspect the fuel Fuel pressure is...
  • Page 328 COLOR CODE Black B/L : Black/blue Pu/L Purple/blue WIRING DIAGRAM Brown Black/orange Pu/R Purple/red SX150TR, VX150TR, DX150TR, SX200TR Green Black/red Pu/W Purple/white Gray Black/white Pu/Y Purple/yellow Blue Black/yellow Red/white Light green Green/blue Red/yellow Orange Green/red White/black Pink Green/white W/Br White/brown F Oxygen density Blue/green White/green...
  • Page 329 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Jan. 2004 –...

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