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Yamaha F350B Service Manual

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6ML-28197-Z4-11

LIT-18616-04-35

Worldwide:

USA, CAN, AUS, and NZL:

(6ML)

(6MM)

(6ML)

(6MM)

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Summary of Contents for Yamaha F350B

Page 1 Worldwide: (6ML) (6MM) USA, CAN, AUS, and NZL: (6ML) (6MM) 6ML-28197-Z4-11 LIT-18616-04-35...
Page 2 Yamaha equipment. It has been written to suit the needs of persons who have the Bronze Technical Certificate of the YTA (Yamaha Technical Academy) marine or the equivalent basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or ser- vice to the equipment could render it unsafe or unfit for use.
Page 3: Table Of Contents
Contents General information Specification Technical feature and description Rigging information Troubleshooting Electrical system Fuel system Power unit Lower unit Bracket unit Maintenance Appendix...
Page 4: General Information
General information Model information .............. 0-1 Applicable model ................ 0-1 Model name designation ............0-1 General feature ................0-3 Important safety and service information......0-4 Rotating parts ................0-4 Hot parts..................0-4 Electric shock ................0-4 Propeller ..................0-4 Handling of gasoline..............0-4 Ventilation...................
Page 5: Model Information
Model information Model information Applicable model This manual applies to the following models. Worldwide Model name Approved model code Starting serial No. F350BST 1000001– FL350BST 1000001– USA, CAN, AUS, and NZL Model name Approved model code Starting serial No. F350SA 1000001–...
Page 6 Model information USA, CAN, AUS, and NZL LF 350 X S A 2 F: 4-stroke Model category L: Counter rotation Horsepower X: (25 in) U: (30 in) Motor transom height E: (35 in) N: Without lower unit Starting method/PTT Blank: PTT and E-start Control method S: Built-in DES (SBW) and electric start Generation...
Page 7: General Feature
Model information General feature • Electronic fuel injected, 4-stroke, V6, DOHC, 24-valve, 4256 cm³ (259.7 cu. in) engine • Low exhaust emissions conform to EUR2, US EPA, and CARB 3-STAR regulations. • Low fuel evaporative/permeation emissions conform to EPA regulation. •...
Page 8: Important Safety And Service Information
Important safety and service information Important safety and service in- Handling of gasoline • Gasoline is highly flammable. Keep gasoline formation and all flammable products away from heat, To prevent an accident or injury and to provide sparks, and open flames. quality service, observe the following informa- •...
Page 9: Lifting Outboard Motors
Yamaha • Use a wire cable lifting harness of adequate parts, lubricants, or sealants will not be cov- strength to lift up the outboard motor in a sta- ered by warranty.
Page 10: Special Service Tools
Important safety and service information Special service tools For safety and to help protect parts from dam- age, use the recommended special service tools. • During disassembly, cover all openings, such as intake and exhaust ports, to prevent foreign materials from entering the engine. Foreign materials could cause severe inter- nal damage when the engine is started.
Page 11: How To Use This Manual
How to use this manual How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the following information as a guide for effective and quality service. •...
Page 12: Conditions When Testing And Adjusting
Oil Control Valve Power-train Control Unit Power Trim and Tilt Steer By Wire Steering Control Unit Shift Dampener System Shift Position Sensor Throttle Position Sensor Variable Camshaft Timing Y-COP Yamaha Customer Outboard Protection YDIS Yamaha Diagnostic System Wide Open Throttle...
Page 13: Color Code
Specified tightening torque Color code Black Light green Brown Orange Sky blue Green Pink White Blue Purple Yellow TIP: For example, “R/Y” stands for a Red with Yellow tracer stripe wire. Specified tightening torque Specified tightening torques are provided for specific nuts, bolts, and screws. Specified tightening torque specifications are provided in the exploded diagrams and in the related working instructions.
Page 14: Symbol
Low temperature resistant grease (Yamaha grease C or Yamalube Molybdenum Lubricant Disulfide grease) Corrosion resistant grease Lubricant (Yamaha grease D or Yamalube Marine Grease) Molybdenum disulfide grease Lubricant (Yamalube Molybdenum Disulfide grease) YAMAHA WR-No.2 grease Lubricant Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent and the application points.
Page 15 Symbol Symbol Name Application ThreeBond 1280B Sealant (Yamabond 4 Marine) ThreeBond 1303 Thread locking agent ThreeBond 1303N Thread locking agent ThreeBond 1322D Thread locking agent ThreeBond 1377B Thread locking agent ThreeBond 1386B Sealant ThreeBond 1530D Sealant ThreeBond 1533D Sealant LOCTITE 210 (red) Thread locking agent LOCTITE 241 (blue) Thread locking agent...
Page 16: Special Service Tool
Special service tool Special service tool Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division. USA and Canada tool numbers (YB/YM/YS/YU-*****) are distributed by K&L Supply Co. Some of the special service tools are only available from the Marine Service Division.
Page 17 Special service tool Rotor holding tool Valve spring compres- Valve spring compres- Lever assy 90890-04166 sor attachment 90890-06956 90890-04200 90890-06320 Support Assy 4 Valve spring compres- Valve guide remover/ Valve guide reamer 90890-06463 installer 90890-06804 90890-06689 90890-06801 Valve lapper Valve seat cutter hold- Valve seat cutter Valve seat cutter 45...
Page 18 Special service tool Needle bearing attach- Lifting hanger Leakage tester Shift rod socket ment 90890-06951 90890-06840 90890-06681 90890-06610 Needle bearing attach- Ring nut wrench 6 Ring nut wrench exten- Stopper guide plate ment 90890-06677 sion 90890-06501 90890-06614 90890-06513 Bearing housing puller Center bolt Ball bearing attach- Needle bearing attach-...
Page 19 Special service tool Bearing outer race pull- Bearing outer race at- Pinion shimming Pinion shimming er assembly tachment gauge gauge rod 90890-06523 90890-06628 90890-06675 90890-06676 Backlash indicator Magnet base plate Dial gauge set Magnet base B 90890-06836 90890-07003 90890-03238 90890-06844 Slide hammer handle Puller head Needle bearing attach-...
Page 20 Special service tool US SST No. Bolt hexagon with YDIS 2 HARDWARE Digital multimeter Peak volt adapter washer KIT II YU-34899-A YU-39991 YB-06821 LIT-YDIS2-01-KT Pressure/vacuum tes- Fuel pressure gauge Fuel pressure gauge Combination compres- adapter YU-03153M sion gauge and cylin- YB-35956-B YB-06946 der leakdown test kit...
Page 21 Special service tool Roller bearing installer/ Bearing housing bear- Needle bearing remov- Piston slider 96 mm remover ing/oil seal installer er and installer YB-06684 YB-06432 YB-06111 YB-06346 Driveshaft needle Shift rod socket Needle bearing attach- Ring nut wrench 6 bearing installer and YB-06681 ment YB-06677...
Page 22 Special service tool Magnetic base stand Slide hammer Propeller shaft and Driveshaft installer YU-A8438 YB-06096 bearing housing re- YB-06244 mover YB-06335 Gland nut wrench Forward gear bearing PTT pressure gauge Trim cylinder wrench YB-06578 installer YB-06580 YB-06175-2B YB-06345 PTT piston vice tool Tilt rod wrench YB-06572 YB-06569...
Page 23: Specification
Specification Specification data .............. 1-1 External dimensions ............1-1 Clamp bracket dimensions ..........1-3...
Page 24: Specification Data
Specification data Specification data For specification data, see Appendix, “Specification” (A-1). External dimensions TIP: The dimension values may include reference values.
Page 25 External dimensions mm (in) mm (in) X:1253.0 (49.33) U:1370.0 (53.94) 635.0 (25.00) E:1487.0 (58.54) 191.0 (7.52) 835.0 (32.87) 36.0 (1.42) X:278.0 (10.94) U:279.0 (10.98) E:280.0 (11.02) 216.0 (8.50) X:17.0 (0.67) U:20.0 (0.79) E:24.0 (0.94) 733.0 (28.86) *1. Minimum distance between the outboard motors in twin, triple, or quad engine application *2.
Page 26: Clamp Bracket Dimensions
Clamp bracket dimensions Clamp bracket dimensions TIP: The dimension values may include reference values. 203.0 (7.99) 203.0 (7.99) mm (in) 163.5 (6.44) 163.5 (6.44) 20.0 (0.79) 125.4 (4.94) 125.4 (4.94) 30.0 (1.18)
Page 27: Technical Feature And Description
Technical feature and description Electronic control system ..........2-1 Electrical components ..............2-4 Electronic fuel injection control........... 2-7 Ignition timing control ..............2-8 VCT control ................2-9 Knock control................2-9 Engine speed control..............2-10 ETV control................2-11 Electronic shift control system..........2-12 Water detection warning............
Page 28 Technical feature and description Fuel system ..............2-38 High-pressure fuel pump control ..........2-38 Low-pressure fuel pump control ..........2-38 Fuel diagram ................2-39 Lubrication system ............2-41 Lubrication diagram..............2-41 Cooling system ..............2-43 Cooling diagram ............... 2-43 Intake and exhaust system ..........2-45 Intake and exhaust diagram .............
Page 29: Electronic Control System
Electronic control system Electronic control system This model uses an electronic fuel injection control, digital ignition control, ETV control, VCT control, knock control, over-revolution control, alert control, and fail-safe control. The engine ECM performs these controls based on data received from each sensor and switch. This model supports Digital Electronic Control.
Page 30 Electronic control system 12. High-pressure fuel pump 18. Fuel injector 13. Low-pressure fuel pump 19. OCV 14. Vapor shut-off valve 20. Ignition 15. TPS coil 16. ETV 20. Ignition coil 19. OCV 17. Shift actuator 18. Fuel injector 1. Cam position sensor 21.
Page 31 Electronic control system 1. Cam position sensor 2. Pulser coil 3. Intake air pressure/temperature sensor 4. Oil pressure sensor 5. Engine temperature sensor 6. Knock sensor 7. Thermo sensor 8. Water detection switch 9. Water pressure sensor *1 10. SPS 11.
Page 32: Electrical Components
Electronic control system Electrical components...
Page 33 Electronic control system Part name Function Opens and closes the throttle valve using an electric motor. Intake air pressure/tempera- Detects the intake air temperature and intake air pressure. ture sensor Detects the engine speed. Detects the crankshaft angle and piston positions. Pulser coil Determines each group of cylinders (#1 and #4, #2 and #5, and #3 and #6).
Page 34 Electronic control system Part name Function Determines the engine operating conditions according to the in- put signals from the sensors and switches which are installed at 24 Engine ECM various locations on the engine, and sends output signals to op- erate the actuators to perform the various control functions.
Page 35: Electronic Fuel Injection Control
Electronic control system Electronic fuel injection control Based on signals input from the sensors, the engine ECM determines the injection timing and the amount to inject, and then injects fuel appropriately. The amount to inject is controlled by the time that the fuel injectors are operated.
Page 36: Ignition Timing Control
Electronic control system Ignition timing control In digital ignition control, the engine ECM determines the optimum ignition timing according to the sig- nals from the sensors and sends the primary current to the ignition coils. In addition, various restrictions and compensations are made to determine the actual ignition timing. The ignition timing is also con- trolled according to the knock control.
Page 37: Vct Control
Electronic control system VCT control Based on signals input from the sensors, the engine ECM sets the timing to open the intake valve. The OCV operates according to the engine’s operating condition and the VCT assembly advances the an- gle, retards the angle, or keeps the current position to control the timing to open the intake valve. 1.
Page 38: Engine Speed Control
Electronic control system Engine speed control The engine ECM controls the engine speed to protect the engine from damage. 1. Pulser coil 2. Intake air pressure/ temperature sensor 15. Fuel injector 3. Cam position sensor (PORT EX) 4. Cam position sensor (PORT IN) 16.
Page 39: Etv Control
Electronic control system ETV control In ETV control, the engine ECM determines the appropriate throttle valve opening according to the sig- nals from the sensors, and controls the throttle valve. The engine ECM is equipped with a learning function that records all of the compensations made by the control to the throttle valve opening for the operating conditions up to that point.
Page 40: Electronic Shift Control System
Electronic control system Electronic shift control system The electronic shift control system operates the shift actuator based on the Digital Electronic Control communication data transmitted by the Digital Electronic Control ECM. 1. Pulser coil 8. Shift actuator 2. Cam position sensor (PORT EX) 9.
Page 41: Water Detection Warning
Electronic control system Water detection warning If water is present in the fuel and the water detection switch in the fuel filter turns ON, the warning indi- cator on the meter will be activated as shown in the table. Water detection switch state Turning from ON to OFF Constant ON Remarks Indicator (symbol)
Page 42: Fail-Safe
Electronic control system Fail-safe In the fail-safe control, the engine ECM enters the fail-safe control mode when an electrical component malfunctions. The fail-safe control system records the trouble codes according to the engine trouble conditions. Trouble Item gauge Trouble conditions to be detected code display Pulser coil...
Page 43 Electronic control system Trouble Item gauge Trouble conditions to be detected code display 112, 113, 114, 115, 116, 117, Open or short circuit in the ETV relay and ETV motor cir- 119, 123, cuit. 138, 141, 142, 143, 144, 145 TPS 1 output voltage is 0.35 V or less or 4.80 V or more.
Page 44: Charging System
Electronic control system Charging system This model features a high output charging system that provides up to 50 A. (generating a maximum of 74 A) The built-in isolator allows for recharging both the main battery and the house battery. The Rectifier/ Regulator/Isolator is regulated to charging at 14.5 V.
Page 45: Y-Cop
Electronic control system Y-COP Y-COP is composed of the key fob and EKS receiver. The EKS receiver transmits an authorization ID to the Digital Electronic Control ECM. If the authoriza- tion ID that is transmitted does not match the ID registered in the Digital Electronic Control ECM, then the EKS receiver cannot communicate with the Digital Electronic Control ECM.
Page 46: Power Unit
Power unit Power unit Outline This model’s power unit is based on a 6KA (F300) with increased power. Because of this, various parts of the engine have been changed. The main changes are as follows. 1. Air shroud cover 14. Intake manifold 2.
Page 47 Power unit Model 6ML (F350) Bore  stroke 96.0  98.0 mm (3.78  3.86 in) Intake/Exhaust 40 mm/34 mm (1.57 in/1.34 in) valve diameter Compression ratio 11.0 Full throttle operat- 5000–6000 r/min ing range Rated power 257.4 kW (350 HP) 2-19...
Page 48: Oil Dipstick
Power unit Oil dipstick The range from the upper mark to the lower mark on the existing dipstick has been enlarged due to the changes in parts associated with the power increase. a. 104 mm (4.1 in) b. 313 mm (12.3 in) c.
Page 49: Heat Exhaust Fan And Heat Vent
Power unit Heat exhaust fan and heat vent The flywheel is equipped with a heat exhaust fan and the top cowling is equipped with a heat vent. By controlling the temperature increase in the top cowling due to the generation of a large amount of electricity and stabilizing the intake air temperature, high output can be produced.
Page 50: Bracket Unit
Bracket unit Bracket unit SBW (Steer by Wire) system Outline The steering system has been changed from a mechanical system that was used for previous models to an electronically controlled power-operated steering system. Because the steering system has been designed with a sufficient margin for use with large boats, the system is responsive and provides a sta- ble feeling when steering the boat.
Page 51: System Diagram
Bracket unit System diagram When the signals from the steering wheel and joystick are input into the steering control unit (SCU), the SCU uses that information together with the information from other sensors to calculate the optimal steering control and operates the steering motor to match the intended steering angle of the operator. For multiple engine applications, the system controls the steering angle of each outboard motor so that the boat moves in the intended direction.
Page 52 Bracket unit Helm Master model 1. Helm unit / joystick 2. Digital Electronic Control 4. Engine ECM (HCU) 5. Position sensor 3. PCU 6. SCU 7. Steering motor 8. Steering actuator 1. Helm unit/joystick 2. Digital Electronic Control (HCU) 3. PCU 4.
Page 53: Structure
Bracket unit Structure The steering actuator “1” is an integrated unit with a built-in steering control unit (SCU) and a built-in steering motor and cannot be disassembled. The steering motor, which has an integrated pipe, is lo- cated inside the actuator on one end and a shaft runs through the center of that pipe. The pipe is sup- ported by a bearing on the other end.
Page 54: Operation
Bracket unit Operation When power is supplied to the steering motor inside the steering actuator “1”, the pipe integrated with the motor turns. The rotational speed of the pipe is reduced as it is transmitted through the planetary gears to the shaft in the center of the pipe. Because both ends of the shaft are secured to the swivel bracket, the steering actuator moves 2 mm (0.08 in), which is the internal thread pitch distance, in a straight line in the shaft direction for each turn of the pipe.
Page 55: Outboard Motor Manual Steering Method
Bracket unit Outboard motor manual steering method If the SBW (Steer by Wire) system does not operate due to a malfunction, the outboard motor can be steered manually. Usually, the pipe inside the steering actuator moves as it is turned by the motor force, but when the outboard motor is steered manually, the shaft is turned to move the pipe.
Page 56: Clamp Bracket
Bracket unit Clamp bracket Based on the 6KA, the mounting hole at the bottom of the clamp bracket has been enlarged due to the larger installing range for mounting bolts. a. 55.5 mm (2.19 in) b. 92.5 mm (3.64 in) 2-28...
Page 57: Ptt Sensor
Bracket unit PTT sensor This model is equipped with a PTT sensor that detects the trim and tilt angle of the outboard throughout the full range of movement from fully tilted down to fully tilted up. The end of the pin on the tilt rod fits into the PTT sensor that is installed to the swivel bracket.
Page 58: Ptt Totaltilt
Bracket unit PTT TotalTilt™ This outboard motor is equipped with an automatic PTT tilt function. When this function is activated, you can tilt the outboard motor up/down automatically by pressing the switch twice quickly instead of keeping the PTT switch pushed. The PTT TotalTilt™...
Page 59 Bracket unit 3. Hold the “DN” (down) side of the PTT switch pushed. TIP: The PTT switch can be used not only on the remote control lever side, but also on the bottom cowling side. 4. Operate the trim zero set while keeping the “DN” (down) side of the PTT switch pushed. TIP: •...
Page 60 Bracket unit Automatic tilt-up Make sure that all people are clear of the outboard motor when tilting the outboard motor up and down. Body parts can be crushed between the outboard motor and the clamp bracket when the outboard motor is trimmed or tilted. 1.
Page 61: Upper Case
Upper case Upper case Bushing of the drive shaft The passage has been prepared to cool the bushing “1” of the drive shaft. In addition, the adoption of the intermediate drive shaft has changed the position of the bushing to the deeper side.
Page 62: Lower Unit
Lower unit Lower unit A lower unit with the same construction as the 6KA is used. In this model, the number of teeth on the spline section is increased, and the strength of the dog clutch “1” is increased in line with the increase in power. TIP: This model can be identified by the punch mark “a”...
Page 63: Split-Type Drive Shaft
Lower unit Split-type drive shaft For the newly-designed lower unit, a split-type drive shaft has been adopted. The intermediate shaft is secured to the drive shaft component using a bolt. The change of the shaft length has enabled the in- tegrated lower unit to support a wider range of transoms.
Page 64: Reverse Thrust
Lower unit Reverse thrust The outboard motor has a structure that discharges the exhaust gas from above the anti-cavitation plate when the remote control lever is in the R position and the engine speed is 2000 r/min or less. As a result, propeller cavitation can be prevented when the outboard motor is operating in reverse.
Page 65: Engine Ecm
Engine ECM Engine ECM PTT protection control PTT protection control system prevents damage to PTT unit, bracket and other related components when the engine speed becomes excessively high while the outboard motor is raised higher than its trim range. The engine speed is limited to the given rpm or below by the system if the PTT sensor output voltage exceeds the specification value.
Page 66: Fuel System
Fuel system Fuel system High-pressure fuel pump control The high-pressure fuel pump operates for 5 seconds after the “POWER” switch is turned to ON, and always operates while the engine is running. The fuel pump continues to operate for 7 second after the engine is turned OFF. TIP: After the “POWER”...
Page 67: Fuel Diagram
Fuel system Fuel diagram 18. Vapor shut-off valve 9. Pressure regulator 5. Vapor separator 11. Fuel rail (PORT) 13. Fuel injector 8. High-pressure fuel pump 4. Low-pressure fuel pump 3. Fuel filter 2. Primer pump 13. Fuel injector 12. Fuel rail (STBD) 17.
Page 68 Fuel system 4. Low-pressure fuel pump 3. Fuel filter 2. Primer pump 1. Fuel tank 22. Atmosphere 17. Canister 10. Check (cowl inside) valve 20. Check valve 23. Charcoal 21. Atmosphere (cowl outside) 6. Filter 18. Vapor shut-off valve 19. Surge tank 7.
Page 69: Lubrication System
Lubrication system Lubrication system Lubrication diagram 14. VCT assembly 14. VCT assembly 12. OCV 12. OCV 3. Oil pump 2. Oil strainer 5. Oil pressure sensor 4. Oil filter 16. Relief valve 1. Oil pan 13. Camshaft oil 14. VCT 12.
Page 70 Lubrication system 1. Oil pan 2. Oil strainer 3. Oil pump 4. Oil filter 5. Oil pressure sensor 6. Cylinder block main gallery 7. Cylinder head oil passage 8. Camshaft journal 9. Crankshaft main journal 10. Crankshaft pin 11. Piston 12.
Page 71: Cooling System
Cooling system Cooling system Cooling diagram 10. Thermostat (PORT) 17. Rectifier/regulator/isolator 15. Fuel cooler 13. Thermostat (STBD) 19. Oil cooler 16. Cooling water cover 6. Exhaust guide 5. Oil pan 3. Water pump 2. Water inlet 2-43...
Page 72 Cooling system 10. Thermostat (PORT) 13. Thermostat (STBD) 17. Rectifier/ regulator/ isolator 9. Cylinder block (PORT) 12. Cylinder block (STBD) 18. Cooling water pilot hole 14. Flushing device 8. Cylinder head (PORT) 11. Cylinder head (STBD) 16. Cooling water cover 7.
Page 73: Intake And Exhaust System
Intake and exhaust system Intake and exhaust system Intake and exhaust diagram 1. Intake silencer 2. ETV 4. Intake air pressure/ temperatur sensor 5. Intake manifold 6. Cylinder head 3. Surge tank 7. Exhaust guide 8. Idle 5. Intake manifold silencer 9.
Page 74: Hose Routing
Hose routing Hose routing Fuel hose and blowby hose 1. Joint to fuel filter assembly 2. Fuel filter assembly to joint 3. Joint to low-pressure fuel pump 4. Low-pressure fuel pump to vapor sep- arator 5. Vapor separator to joint 6.
Page 75: Pressure Regulator Hose And Vapor Gas Hose
Hose routing Pressure regulator hose and vapor gas hose 1. Vapor separator to canister tank port 2. Canister purge port to joint 3. Joint to vapor shut-off valve 4. Vapor shut-off valve to joint 5. Joint to surge tank 6. Canister atmospheric port to joint 7.
Page 76: Cooling Water Hose
Hose routing Cooling water hose 1. Cylinder block to joint 14. Joint to cooling water outlet 2. Joint to fuel cooler 15. Thermostat cover (STBD) to joint 3. Fuel cooler to joint 16. Joint to cylinder block 4. Joint to oil cooler 17.
Page 77: Rigging Information
Rigging information Important reminder on rigging.......... 3-1 Outboard motor mounting instructions ........3-1 Crate handling ..............3-2 Crate top cover symbol description ..........3-2 Uncrating ................3-3 Uncrating procedure..............3-3 Outboard motor mounting..........3-4 Securing the outboard motor............3-4 Rigging grommet mounting ..........3-5 Rigging grommet description............
Page 78 Rigging information Tilt limiter ................3-35 Setting the tilt limiter ..............3-35 Clearing the tilt limiter............... 3-36 Deactivating the tilt limiter ............3-37 Calibration (6X9 Digital Electronic Control)....3-37 CL5 Display calibration ........... 3-37 Configuring the number of outboard motors......3-37 Accessing the calibration menu..........
Page 79: Important Reminder On Rigging
Important reminder on rigging Important reminder on rigging Outboard motor mounting instructions • Overpowering a boat could cause severe instability. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer.
Page 80: Crate Handling
Crate handling Crate handling Crate top cover symbol description The following symbol are important when handling the crate. Read the notice and understand what each symbol means to prevent damage to the outboard motor when handling, transporting, and storing the crate. IMPORTANT This unit delivered to carrier in a good condition.
Page 81: Uncrating
Uncrating Uncrating procedure Wear gloves to avoid injury from sharp steel edges while uncrating. 1. Check: • Crate for shipping damage Damage  Consult your Yamaha distribu- tor. 2. Remove: • Top cover • Frame Lifting eye “1” • Wrapping 90890-06953 Bolt hexagon with washer “2”...
Page 82: Outboard Motor Mounting
Outboard motor mounting 8. Lift up the outboard motor carefully along 11. For the procedure of outboard motor with the bottom frame “1”. mounting on boat, see “Rigging Guide” (6YR-2819Y-**). 12. Remove the lifting harness and shackles, Make sure that the lifting harnesses do not and then install the air shroud cover and damage any parts of the outboard motor.
Page 83: Rigging Grommet Mounting
Rigging grommet mounting Upper mounting bolt “1” 1. Remove: • Grommet holder “1” Mounting bolt size Part number • Rigging grommet “2” M12  150 mm (5.91 in) 90101-12067 Lower mounting bolt “2” Mounting bolt size Part number M12  130 mm (5.12 in) 90101-12076 2.
Page 84: Installing The Rigging Grommet
Optional equipment Optional equipment Installing the rigging grommet 1. Install: Installing the isolator lead • Rigging grommet 1. Remove: • Cap “1” a. Route each harness through the proper (from the isolator lead “2”) hole in the rigging grommet. See “Rigging grommet description”...
Page 85: Battery Installation
Battery installation 3. Route: 7. Fasten: • SCU communication lead “2” • SCU communication lead “1” (through the bottom cowling) (using the holder “2”) 4. Install: • SCU communication lead coupler (6P) “a” (onto the tab “b”) • SCU communication lead coupler (4P) “c” (onto the tab “d”) Battery installation •...
Page 86: System Diagram
System diagram System diagram Single outboard motor application (single station)
Page 87 System diagram Ref. Part name Part No. Remarks Engine ECM — 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft) Main wire harness (16P) 6X6-8258A-21 8 m (26 ft) 6X6-8258A-31 10 m (32 ft) 6X6-8258A-41 12 m (39 ft)
Page 88 System diagram Ref. Part name Part No. Remarks 6Y8-82521-01 0.3 m (1 ft) 6Y8-82521-11 0.6 m (2 ft) 6Y8-82521-21 0.9 m (3 ft) Pigtail bus wire 6Y8-82521-31 1.8 m (6 ft) 6Y8-82521-41 2.7 m (9 ft) 6Y8-82521-51 3.6 m (12 ft) Conversion harness 6YM-83553-00 0.9 m (3 ft) CL5 Display...
Page 89: Twin Outboard Motor Application (Single Station)
System diagram Twin outboard motor application (single station) 3-11...
Page 90 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6GR-81115-00 w/ resistor cap, 1.5 m (5 ft) SCU communication lead 6GR-81115-10 w/ resistor cap, 3 m (10 ft) 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft)
Page 91 System diagram Ref. Part name Part No. Remarks EKS harness 6X9-82716-50 DEC to switch panel System power supply wire 6Y8-83553-02 w/ 10 A fuse, 2.4 m (8 ft) 6Y8-82521-01 0.3 m (1 ft) 6Y8-82521-11 0.6 m (2 ft) 6Y8-82521-21 0.9 m (3 ft) Pigtail bus wire 6Y8-82521-31 1.8 m (6 ft)
Page 92: Triple Outboard Motor Application (Single Station)
System diagram Triple outboard motor application (single station) 3-14...
Page 93 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6GR-81115-00 w/ resistor cap, 1.5 m (5 ft) SCU communication lead (Starboard side/Port side) 6GR-81115-10 w/ resistor cap, 3 m (10 ft) 6GR-81115-20 w/ resistor cap, 1.5 m (5 ft) SCU communication lead (Center) 6GR-81115-30 w/ resistor cap, 3 m (10 ft) 6X6-8258A-91 1.5 m (5 ft)
Page 94 System diagram Ref. Part name Part No. Remarks Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-15 Key fob: 2 pcs. EKS harness 6X9-82716-41 DEC to switch panel System power supply wire 6Y8-83553-02 w/ 10 A fuse, 2.4 m (8 ft) 6Y8-82521-01...
Page 95: Quad Outboard Motor Application (Single Station)
System diagram Quad outboard motor application (single station) 3-17...
Page 96 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6GR-81115-00 w/ resistor cap, 1.5 m (5 ft) SCU communication lead (Starboard side/Port side) 6GR-81115-10 w/ resistor cap, 3 m (10 ft) 6GR-81115-20 w/ resistor cap, 1.5 m (5 ft) SCU communication lead (Center) 6GR-81115-30 w/ resistor cap, 3 m (10 ft) 6X6-8258A-91 1.5 m (5 ft)
Page 97 System diagram Ref. Part name Part No. Remarks Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-15 Key fob: 2 pcs. EKS harness 6X9-82716-91 DEC to switch panel System power supply wire 6Y8-83553-02 w/ 10 A fuse, 2.4 m (8 ft) 6Y8-82521-01...
Page 98: Single Outboard Motor Application (Dual Station)
System diagram Single outboard motor application (dual station) 3-20...
Page 99 System diagram Ref. Part name Part No. Remarks Engine ECM — 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft) Main wire harness (16P) 6X6-8258A-21 8 m (26 ft) 6X6-8258A-31 10 m (32 ft) 6X6-8258A-41 12 m (39 ft)
Page 100 System diagram Ref. Part name Part No. Remarks 6Y8-82521-01 0.3 m (1 ft) 6Y8-82521-11 0.6 m (2 ft) 6Y8-82521-21 0.9 m (3 ft) Pigtail bus wire 6Y8-82521-31 1.8 m (6 ft) 6Y8-82521-41 2.7 m (9 ft) 6Y8-82521-51 3.6 m (12 ft) Conversion harness 6YM-83553-00 0.9 m (3 ft) CL5 Display...
Page 101: Twin Outboard Motor Application (Dual Station)
System diagram Twin outboard motor application (dual station) 3-23...
Page 102 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6GR-81115-00 w/ resistor cap, 1.5 m (5 ft) SCU communication lead 6GR-81115-10 w/ resistor cap, 3 m (10 ft) 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft)
Page 103 System diagram Ref. Part name Part No. Remarks EKS harness 6X9-82716-50 DEC to switch panel System power supply wire 6Y8-83553-02 w/ 10 A fuse, 2.4 m (8 ft) 6Y8-82521-01 0.3 m (1 ft) 6Y8-82521-11 0.6 m (2 ft) 6Y8-82521-21 0.9 m (3 ft) Pigtail bus wire 6Y8-82521-31 1.8 m (6 ft)
Page 104: Triple Outboard Motor Application (Dual Station)
System diagram Triple outboard motor application (dual station) 3-26...
Page 105 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6GR-81115-00 w/ resistor cap, 1.5 m (5 ft) SCU communication lead (Starboard side/Port side) 6GR-81115-10 w/ resistor cap, 3 m (10 ft) 6GR-81115-20 w/ resistor cap, 1.5 m (5 ft) SCU communication lead (Center) 6GR-81115-30 w/ resistor cap, 3 m (10 ft) 6X6-8258A-91 1.5 m (5 ft)
Page 106 System diagram Ref. Part name Part No. Remarks Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-15 Key fob: 2 pcs. EKS harness 6X9-82716-41 DEC to switch panel System power supply wire 6Y8-83553-02 w/ 10 A fuse, 2.4 m (8 ft) 6Y8-82521-01...
Page 107 System diagram *1. The brake of the helm unit does not function and the steering wheel spins freely. Also, the trouble code 549 (Incompatible Helm version) appears on the CL5 Display, and steering modes other than the helm unit cannot be used. *2.
Page 108: Quad Outboard Motor Application (Dual Station)
System diagram Quad outboard motor application (dual station) 3-30...
Page 109 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6GR-81115-00 w/ resistor cap, 1.5 m (5 ft) SCU communication lead (Starboard side/Port side) 6GR-81115-10 w/ resistor cap, 3 m (10 ft) 6GR-81115-20 w/ resistor cap, 1.5 m (5 ft) SCU communication lead (Center) 6GR-81115-30 w/ resistor cap, 3 m (10 ft) 6X6-8258A-91 1.5 m (5 ft)
Page 110 System diagram Ref. Part name Part No. Remarks Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-15 Key fob: 2 pcs. EKS harness 6X9-82716-91 DEC to switch panel System power supply wire 6Y8-83553-02 w/ 10 A fuse, 2.4 m (8 ft) 6Y8-82521-01...
Page 111 System diagram *1. The brake of the helm unit does not function and the steering wheel spins freely. Also, the trouble code 549 (Incompatible Helm version) appears on the CL5 Display, and steering modes other than the helm unit cannot be used. *2.
Page 112: Digital Electronic Control
Digital Electronic Control Digital Electronic Control 4. Click the “OK” button or press the Enter key on the keyboard. Digital Electronic Control system re- A Digital Electronic Control system reset is re- quired after the replacement of the Digital Elec- tronic Control ECM or the engine ECM.
Page 113: Tilt Limiter
Tilt limiter Tilt limiter Setting the tilt limiter • Check that the outboard motor is mount- ed on the boat or on a stand securely. • Never get under the outboard motor while it is tilted. If there is interference between the top cowling and the motor well when the outboard motor is tilted up, adjust the setting angle of the tilt lim- iter using the following procedures.
Page 114: Clearing The Tilt Limiter
Tilt limiter 6. Click the “Set” button or press the Enter Clearing the tilt limiter key on the keyboard. 1. Connect the YDIS to display “Boat system” menu. To connect and operate the YDIS, see the YDIS (latest version) instruction manual.
Page 115: Deactivating The Tilt Limiter
Calibration (6X9 Digital Electronic Control) Calibration (6X9 Digital Electron- 4. Click the “OK” button or press the Enter key on the keyboard. ic Control) • If the steering actuator is removed, the steer- TIP: ing sensor must be calibrated after the unit is To reset the tilt limiter setting, see “Setting the installed.
Page 116: Accessing The Calibration Menu
CL5 Display calibration 3. Tap “Reset”. Accessing the calibration menu 1. Open the menu screen by swipe. 4. Tap “Number of Engines”. 2. Tap and hold the “Menu” bar for 10 sec- onds. The “Technician Settings” menu will be added to the menu. TIP: Tap while the screen is scrolled all the way to the top.
Page 117: Steer Sensor
CL5 Display calibration 4. The “Technician Settings” menu will ap- pear. 3. Tap “Set” to trim all engines to the fully down position. Steer Sensor During this process, only the corresponding steering actuator will operate as the steering sensor is being calibrated. 1.
Page 118 CL5 Display calibration 7. Turn the steering wheel counterclockwise until the port outboard motor reaches full PORT lock and the message appears. Confirm the port outboard motor is at full PORT lock, and then tap “Set”. TIP: • For triple engine applications, after this step, do the center outboard motor, and then do the port outboard motor.
Page 119: Toe Adjust
CL5 Display calibration Toe Adjust You can freely adjust the toe angle of outboard motors according to the structure of the hull on which they are mounted. This should be determined by on-water testing. TIP: • For twin engines without BCU, triple engines (Toe Adjust: numerical value input) •...
Page 120 CL5 Display calibration 3. Select “Set” to delete the current setting 6. Adjust the toe angle. Tap “Done” to con- and select a new wedge angle. firm. TIP: The Helm Master EX control system comes with the toe set at 0.0. The adjustment range •...
Page 121: Lock To Lock
CL5 Display calibration 2. Tap “Up” or “Down” to adjust the toe angle. 2. Tap “Constant”. Tap “Numeric” to adjust the toe angle. TIP: The Helm Master EX control system comes with the toe set at 00.0. The adjustment range •...
Page 122 CL5 Display calibration Variable 4. Tap “Set RPM” to adjust the RPM of en- Select the rotational angle of the steering gines 1 to 4. wheel according to the engine speed. TIP: You can adjust this to any value in a range of 0 1.
Page 123: Friction Set
CL5 Display calibration Friction Set The Helm Master EX control steering system has a unique function related to the friction of the steering system. The steering will automat- ically adjust the friction setting depending on engine speed. At higher engine speeds, the friction increases.
Page 124: Rigging Recommendation
Rigging recommendation Rigging recommendation Battery cable length The battery cable length from the negative ter- minal of the battery cable to the rigging grom- met. The positive battery cable is 100 mm (3.9 in) longer than the negative battery cable. See “Model data”...
Page 125: Propeller Selection
Propeller selection Propeller selection With the engine speed at full throttle operating range and under a maximum boat load, the engine speed should be within the upper half of the full throttle operating speed range. Full throttle operating range 5000–6000 r/min Regular rotation model Blade Dia.
Page 126 Propeller selection Counter rotation model Blade Dia. (in) Pitch (in) Mark Material Part number Remarks 15 3/4 Stainless steel 6CF-45930-20 *1, *2 15 3/4 Stainless steel 6CF-45D70-20 *1, *2 15 3/4 Stainless steel 6CF-45976-20 *1, *2 15 1/2 Stainless steel 6CF-45938-20 *1, *2 15 1/2...
Page 127: Troubleshooting
Troubleshooting YDIS ..................4-1 Connecting the communication cable ........4-2 ECM reprogramming ..............4-4 Outboard motor troubleshooting........4-5 Troubleshooting procedure ............4-5 Troubleshooting the power unit using the YDIS ......4-5 Trouble code and checking step ..........4-8 Troubleshooting procedure (trouble code not detected) ..4-23 Troubleshooting the power unit ..........
Page 128: Ydis
YDIS YDIS The Yamaha Diagnostic System uses precision fault diagnosis to offer better serviceability at a time when there is increasing demand for service tools for electronically controlled products. It provides quick, reliable, safe, and reasonable service, and is intended to obtain customer satisfaction. The Ya- maha Diagnostic System features updated software and expanded tool functions that allow it to re- spond to new models and technologies, maintaining compatibility with regulations.
Page 129: Connecting The Communication Cable
YDIS Connecting the communication cable CAN-Line 3. Adapter interface 1. K and CAN harness 4. USB cable 2. Adapter cap 7. 6X9 Digital Electronic Control 5. Multi-hub 1. K and CAN harness 3. Adapter interface 4. USB cable 2. Adapter cap 7.
Page 130 YDIS K-Line 4. K and CAN Line harness 2. Adapter cap 1. Adapter interface a. YDIS coupler 3. USB cable 1. Adapter interface 2. Adapter cap 3. USB cable 4. K and CAN Line harness a. YDIS coupler (gray)
Page 131: Ecm Reprogramming
YDIS ECM reprogramming Program update function This function allows you to update the engine ECM program to the latest version using a K and CAN harness (VPP harness). Writing function of engine serial numbers A new function enables you to write an engine serial number to a new, replacement part engine ECM (supplied by the Part Division).
Page 132: Outboard Motor Troubleshooting
Outboard motor troubleshooting Outboard motor troubleshooting Troubleshooting procedure 1. Before troubleshooting the outboard motor, check that fresh fuel of the specified type has been used. 2. Check that all electrical connections are secure and free from corrosion, and that the battery is fully charged.
Page 133 Outboard motor troubleshooting Trouble code table ✔: Indicated —: Not indicated YDIS diagnosis Code No. Item YDIS diagnosis record ✔ ✔ Pulser coil ✔ ✔ Engine temperature sensor ✔ ✔ Knock sensor ✔ ✔ Battery voltage ✔ ✔ Air temperature sensor ✔...
Page 134 Outboard motor troubleshooting YDIS diagnosis Code No. Item YDIS diagnosis record 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, ✔ ✔ 172, 173, RC system 174, 175, 176, 177, 178, 179, 180, 181, 183, 184, 186, 187 ✔...
Page 135: Trouble Code And Checking Step
Outboard motor troubleshooting YDIS diagnosis Code No. Item YDIS diagnosis record ✔ ✔ Steering System Communication ✔ ✔ 537, 538 Steering System–Main Helm ✔ ✔ 539, 540 Steering System–2nd Helm ✔ ✔ Steering System–Control Unit ✔ ✔ Incompatible Hardware ✔ ✔...
Page 136 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code Measure the knock sensor re- 5-41 sistance. Knock sensor “Check Engine” is displayed. (Irregular sig- Check for wiring continuity be- High engine idle speed. nal) tween the knock sensor and A-12 the engine ECM.
Page 137 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code Measure the cam position sen- 5-26 sor input voltage. “Check Engine” is displayed. Measure the cam position sen- High engine idle speed. 5-26 sor output voltage. Degraded acceleration perfor- mance.
Page 138 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code Check the thermo sensor us- 5-40 ing the YDIS. Measure the thermo sensor in- “Check Engine” is displayed. 5-40 Set to 50 C (122 F) when put voltage. Thermo sensor P (Out of speci- running.
Page 139 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code Measure the cam position sen- 5-26 sor input voltage. “Check Engine” is displayed. Measure the cam position sen- High engine idle speed. 5-26 sor output voltage. Degraded acceleration perfor- mance.
Page 140 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code Measure the PTT sensor resis- 5-54 tance. PTT sensor Measure the PTT sensor input 5-54 (Out of specifi- “Check Engine” is displayed. voltage. cation) Check for wiring continuity be- tween the PTT sensor and the A-14 engine ECM.
Page 141 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code “Check Engine” is displayed. ETV system High engine idle speed. (Throttle valve Throttle does not operate. Check the ETV circuit. A-10 malfunction) Engine speed is set at approx- imately 1500 r/min. “Check Engine”...
Page 142 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code Check the throttle valve opera- ETV system “Check Engine” is displayed. 6-14 tion. (Throttle valve Declining maximum engine malfunction) speed. Replace the ETV. 6-13 “Check Engine” is displayed. ETV system High engine idle speed.
Page 143 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code Measure the SPS input volt- 5-25 “Check Engine” is displayed. age. Engine operates normally un- Measure the SPS output volt- 5-25 less it is stopped. age. SPS (Out of Engine does not restart (No Check for wiring continuity be- specification)
Page 144 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code Check the fuse. Measure the shift actuator re- 5-25 lay input voltage. Measure the shift actuator mo- 5-26 tor resistance. Check for wiring continuity be- tween the shift actuator and A-10 “Check Engine”...
Page 145 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code Check the extension wire har- ness for proper connection — and damage. “Check Engine” is displayed. Alert indicator is ON. Check for wiring continuity be- <Engine speeds do not syn- tween the engine ECM and the A-10 chronize>...
Page 146 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code Remote control system (Main “Check Engine” is displayed. Replace the Digital Electronic station LPS Ir- Locked at engine idle speed. Control ECM. regular signal Shift actuator rod returns to the (When replacing the Digital [Digital Elec- N position.
Page 147 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code Measure the LPS output volt- age using the YDIS. “Check Engine” is displayed. Locked at engine idle speed. Check for wiring continuity be- Alert indicator is ON. tween the LPS and the Digital Electronic Control ECM.
Page 148 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code “Check Engine” is displayed. Measure the LPS output volt- Remote control Locked at engine idle speed. age using the YDIS. system (Sub Throttle does not operate. Check for wiring continuity be- station [LPS Ir- Shift actuator rod returns to the tween the LPS and the Digital...
Page 149 Outboard motor troubleshooting Trou- Item (Condition) Symptom Checking steps page code HELM (Irregu- Stop engine synchronization Check detail by using YDIS — lar signal) control. CAN communication cable. 4-22...
Page 150: Troubleshooting Procedure (Trouble Code Not Detected)
Outboard motor troubleshooting Troubleshooting procedure (trouble code not detected) Troubleshooting consists of the following 5 items: Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause: Trouble causes of symptom 2 Checking steps: Method for checking See page: Reference page —: Not applicable Troubleshooting the power unit...
Page 151 Outboard motor troubleshooting Symptom 1: Engine will not start (engine cranks). Symptom 2 Cause Checking steps page Blown fuse Check the fuse. Main relay malfunction Check the main relay. 5-21 Check for wire harness continuity between the main relay and the en- A-10 Short, open, or loose con- gine ECM.
Page 152 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Pinched or kinked fuel hose Check the fuel hose. 2-46 Fuel leakage Check the fuel line for leakage. 2-46 Check the fuel filter element for dirt Clogged fuel filter element and obstructions. Blown fuse Check the fuse.
Page 153 Outboard motor troubleshooting Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited en- gine speed. Symptom 2 Cause Checking steps page Spark plug malfunction Check the spark plug. 7-30 Measure the ignition coil input volt- 5-37 age. Short, open, or loose con- Check for wiring continuity between A-12...
Page 154 Outboard motor troubleshooting Symptom 1: High engine idle speed. Symptom 2 Cause Checking steps page Air leakage (ETV–cylinder Check the gaskets of the intake 6-10 — head) manifolds, surge tank, and ETV. 6-13 Symptom 1: Engine stalls, unstable engine idle speed, or poor acceleration. Symptom 2 Cause Checking steps...
Page 155 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Check the engine oil level. 10-7 Check for engine oil leakage. 2-41 Insufficient engine oil Check the valve stem seals and 7-53 valves. Check the piston rings. 7-74 Buzzer comes on. Oil pressure alert indi- —...
Page 156: Troubleshooting The Ptt Unit
Outboard motor troubleshooting Troubleshooting the PTT unit Symptom 1: PTT unit does not operate. Symptom 2 Cause Checking steps page Blown fuse Check the fuse. A-14 PTT switch malfunction Check the PTT switch. 5-53 PTT relay malfunction Check the PTT relay. 5-52 Measure the PTT switch input volt- 5-53...
Page 157: Troubleshooting The Lower Unit
Outboard motor troubleshooting Symptom 1: PTT unit does not hold the outboard motor up. Symptom 2 Cause Checking steps page Open manual valve Check the manual valve. 9-32 Insufficient PTT fluid Add sufficient PTT fluid. 10-20 PTT fluid leakage Check for PTT fluid leakage. 10-20 Decrease in PTT fluid pressure in lower...
Page 158 Electrical system Electrical component and wire harness routing ..... 5-1 Port..................... 5-1 Starboard..................5-3 Fuse holder ................5-5 Rear.................... 5-6 Front ................... 5-8 Top ..................... 5-9 Bottom cowling ................. 5-11 Bracket ..................5-13 ECM circuit diagram ............5-15 ECM coupler layout............5-18 Checking the electrical component........
Page 159: Electrical System
Electrical system Charging unit and component ........5-35 Checking the lighting coil (stator assembly) ......5-35 Checking the rectifier/regulator/isolator........5-36 Ignition unit and component ........... 5-37 Checking the ignition spark ............5-37 Checking the ignition coil............5-37 Checking the pulser coil ............5-37 Checking the intake air temperature sensor......
Page 160 Electrical system PTT system ............... 5-52 Checking the PTT relay............5-52 Checking the PTT switch (on bottom cowling) ......5-53 Checking the PTT sensor............5-54 Checking the PTT buzzer............5-54...
Page 161: Electrical Component And Wire Harness Routing
Electrical component and wire harness routing Electrical component and wire harness routing Port...
Page 162 Electrical component and wire harness routing 1. ETV (TPS) 2. Vapor shut-off valve 3. OCV (PORT) 4. Fuel injector 5. High-pressure fuel pump 6. Low-pressure fuel pump A. Install the pulser coil coupler to the air shroud. B. Align the installation height of the clamp with the installation position of the vapor shut-off valve.
Page 163: Starboard
Electrical component and wire harness routing Starboard AB-AB...
Page 164 Electrical component and wire harness routing 1. OCV (STBD) L. Install the SBW power source lead con- 2. Fuse holder tacts the stopper. 3. PTT relay M. After connecting the rectifier/regulator/ 4. Rectifier/regulator/isolator isolator coupler, insert it into the hole in 5.
Page 165: Fuse Holder
Electrical component and wire harness routing Fuse holder 1. Fuse (100 A) (engine battery) 7. Main relay 2. Fuse (20 A) (PTT switch, Digital Elec- 8. Fuse (30 A) (starter relay) tronic Control) 9. Fuel pump relay (high-pressure) 3. Fuse (100 A) (house [accessory] bat- 10.
Page 166: Rear
Electrical component and wire harness routing Rear 6, K L, F L, F...
Page 167 Electrical component and wire harness routing 1. Ignition coil 2. Engine ECM 3. Knock sensor 4. Water pressure sensor coupler 5. Joint connector 5 6. Joint connector 2 7. Ignition coil lead 8. Vapor gas hose 9. PTT buzzer lead A.
Page 168: Front
Electrical component and wire harness routing Front 1. Starter motor 2. Intake air pressure/temperature sensor 3. YDIS coupler 4. Water detection switch (in fuel cup as- sembly) A. Fasten the PTT relay lead using the holder.
Page 169: Top
Electrical component and wire harness routing 5, C 6, C...
Page 170 Electrical component and wire harness routing 1. Cam position sensor (STBD IN) 2. Joint connector 4 3. Joint connector 1 4. Cam position sensor (PORT EX) 5. Condenser 6. Condenser 7. Cam position sensor (PORT IN) 8. Engine temperature sensor 9.
Page 171: Bottom Cowling
Electrical component and wire harness routing Bottom cowling A A A 5-11...
Page 172 Electrical component and wire harness routing 1. SPS 2. Shift actuator 3. PTT switch 4. Water detection switch coupler 5. PTT sensor coupler 6. SPS coupler 7. Isolator lead (optional) 8. Shift actuator coupler 9. SCU communication lead (When using multiple machines) (optional) 10.
Page 173: Bracket
Electrical component and wire harness routing Bracket 5-13...
Page 174 Electrical component and wire harness routing 1. PTT sensor lead 2. PTT motor lead 3. SBW harness 4. SCU signal lead 5. SCU positive lead 6. SCU negative lead A. Route the PTT motor lead and PTT sen- sor lead under the clamp. B.
Page 175: Ecm Circuit Diagram
ECM circuit diagram ECM circuit diagram , a: Indicate a connection between the symbols. The circled numbers in the illustration indicate the engine ECM terminal numbers. < INPUT > < OUTPUT > 12. Fuel injector #1 1. Pulser coil 13. Fuel injector #2 14.
Page 176 ECM circuit diagram , a: Indicate a connection between the symbols. The circled numbers in the illustration indicate the engine ECM terminal numbers. < INPUT > < OUTPUT > 46. OCV (PORT) 27. Water pressure sensor 47. OCV (STBD) 48. Vapor shut-off valve Vapor shut-off valve 28.
Page 177 ECM circuit diagram 1. Pulser coil 51. High-pressure fuel pump 2. Cam position sensor (PORT EX) 52. Fuel pump relay (high-pressure) 3. Cam position sensor (PORT IN) 53. Low-pressure fuel pump 4. Cam position sensor (STBD IN) 54. Fuel pump relay (low-pressure) 5.
Page 178: Ecm Coupler Layout
ECM coupler layout ECM coupler layout 61 62 63 64 65 66 67 27 28 29 30 31 32 33 34 35 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 68 69 70 71 72 73 36 37 38 39 40 41 42 43 104 105 106 107...
Page 179 ECM coupler layout Connecting part Color Connecting part Color — — Engine ECM ground Black Shift power source Yellow/Green 100 Ignition coil #5 Black/Blue ETV motor Green/Black 101 Ignition coil #6 Black/Brown TPS ground Black 102 Ignition coil #4 Black/Green Sensor power source Orange 103 ETV ground...
Page 180: Checking The Electrical Component
Checking the electrical component Checking the electrical compo- To check the electrical components or mea- sure the peak voltage, use the special service nent tools. A malfunctioning electrical component Using the YDIS can be checked easily by measuring the peak When checking the ETV, TPS, SPS, OCV, ig- voltage.
Page 181: Using The Digital Tester
Peak volt adapter YU-39991 Using the digital tester The electrical technical data applies to the measurements taken using the Yamaha rec- ommended tester. The resistance values shown are the values taken before the engine is started. The actual resistance may vary depending on the environ- 2.
Page 182: Checking The Engine Ecm Circuit
Engine control unit and component 3. Measure: Checking the engine ECM circuit • Main relay input voltage 1. Check: Out of specification  See “Troubleshoot- • Wire harness continuity Out of specification  Replace the wire ing procedure (trouble code not detected)” (4-23).
Page 183: Checking The Etv And Tps
Engine control unit and component 2. Measure: • Engine ECM input voltage Do not loosen the throttle stop screw nut or Out of specification  Check the wire har- turn the throttle stop screw. ness for continuity. a. Measure the input voltage between the en- gine ECM coupler terminal 37 and ground.
Page 184: Checking The Etv Motor Relay
Engine control unit and component 2. Measure: 3. Measure: • TPS input voltage • ETV motor relay input voltage Out of specification  Check the wire har- Out of specification  Check the wire har- ness for continuity. ness for continuity. a.
Page 185: Checking The Sps
Engine control unit and component Checking the SPS b. Turn the “POWER” switch to ON, and then measure the input voltage at the SPS cou- 1. Measure: pler. • SPS 1 and SPS 2 output voltage Out of specification  Check the SPS in- put voltage.
Page 186: Checking The Shift Actuator
Engine control unit and component 2. Measure: a. Measure the input voltage between the ter- • Shift actuator motor resistance minal “a” and ground. Motor resistance (reference data) 1.7  a. Disconnect the shift actuator coupler “a”, and then measure the shift actuator motor resistance.
Page 187 Engine control unit and component a. Make 3 test leads. STBD IN PORT IN Test lead Terminal, male “1” 9E212-10303 Terminal, female “2” 9E212-11303 PORT EX Terminal, female “3” (commercially available) “a” = 100 mm (3.94 in) “b” = 50 mm (1.97 in) “c”...
Page 188: Checking The Ocv
Engine control unit and component Checking the OCV 1. Check: • OCV operation (using the YDIS “Station- ary test”) No operation sound  Check the OCV in- put voltage. a. Check the operation of the OCV using the YDIS “Stationary test” and check the oper- ating sound.
Page 189: Checking The Oil Pressure Sensor
Engine control unit and component 3. Measure: Checking the oil pressure sensor • OCV resistance 1. Measure: Out of specification  Replace. • Oil pressure sensor input voltage Out of specification  Check the wire har- Resistance ness for continuity. 6.7–7.7 ...
Page 190: Fuel Control Unit And Component
Fuel control unit and component c. Turn the “POWER” switch to OFF. 2. Check: • Water detection switch continuity Out of specification  Replace the fuel Pressure pump “1” cup assembly. (commercially available) Test harness EJ–ll–3 “2” Water detection switch continuity 90890-06913 No continuity Float position “A”...
Page 191: Checking The Fuel Injector
Fuel control unit and component PORT STBD d. Install the fuel cup assembly. See “Fuel fil- ter assembly” (6-6). e. Connect the water detection switch cou- pler. Checking the fuel injector 1. Check: • Fuel injector operation (using the YDIS “Stationary test”) c.
Page 192: Checking The Low-Pressure Fuel Pump And High-Pressure Fuel Pump
Fuel control unit and component Checking the low-pressure fuel pump b. Connect the tester probes to the terminals of the high-pressure fuel pump coupler “a”, and high-pressure fuel pump and then measure the input voltage within 1. Check: 5 seconds after turning the “POWER” •...
Page 193: Checking The Low-Pressure Fuel Pump Relay
Fuel control unit and component 5. Connect: b. Turn the “POWER” switch to ON, and then • Low-pressure fuel pump coupler measure the input voltage between the ter- • High-pressure fuel pump coupler minals “a” and “b”. Checking the low-pressure fuel pump relay 1.
Page 194: Checking The Vapor Shut-Off Valve
Fuel control unit and component Checking the vapor shut-off valve a. Connect the tester probes to the terminals 1. Measure: “a” and “b”, and then measure the input • Vapor shut-off valve input voltage voltage within 5 seconds after turning the Out of specification ...
Page 195: Charging Unit And Component
Charging unit and component Lighting coil output peak voltage (reference data) Green (G)–Green (G) Unloaded r/min Cranking 1500 3500 DC V 38.0 83.2 a. Remove the intake manifold (STBD). See “Intake manifold” (6-10). Vacuum/pressure pump gauge b. Disconnect the lighting coil couplers “a” set “1”...
Page 196: Checking The Rectifier/Regulator/Isolator
Charging unit and component f. While cranking the engine, measure the Checking the rectifier/regulator/isola- peak voltage. g. Insert the clip into the engine shut-off switch. Do not connect the battery cables in re- verse. Otherwise, the rectifier/regulator h. Start the engine, and then measure the could be damaged.
Page 197: Ignition Unit And Component
Ignition unit and component a. Remove the intake manifold (STBD). Checking the ignition coil 1. Measure: b. Disconnect the rectifier/regulator/isolator • Ignition coil input voltage coupler. Out of specification  Check the wire har- ness for continuity. c. Set the digital circuit tester to the diode mode, and then check the rectifier/regula- Input voltage tor/isolator for continuity.
Page 198: Checking The Intake Air Temperature Sensor
Ignition unit and component a. Disconnect the pulser coil coupler “a”. b. Connect the special service tool “1” to the pulser coil coupler “a” (wire harness end). c. Remove the clip from the engine shut-off switch. g. Stop the engine. h.
Page 199: Checking The Intake Air Pressure Sensor
Ignition unit and component a. Connect the YDIS to display “Intake air c. Turn the “POWER” switch to ON, and then temperature”. measure the input voltage at the intake air pressure sensor coupler. b. Check that the difference between the am- bient temperature and the displayed intake air temperature is within ±...
Page 200: Checking The Thermo Sensor
Ignition unit and component a. Disconnect the engine temperature sensor d. Install the engine temperature sensor and coupler “a”. connect the coupler. b. Turn the “POWER” switch to ON, and then Checking the thermo sensor measure the input voltage at the engine 1.
Page 201: Checking The Knock Sensor
Ignition unit and component c. Measure the thermo sensor for resistance. a. Disconnect the engine shut-off switch cou- pler. b. Check the engine shut-off switch for conti- nuity. d. Install the thermo sensors and connect the couplers. Checking the knock sensor 1.
Page 202: Starting Unit And Component
Starting unit and component Starting unit and component Checking the power switch 1. Check: Checking the starter relay • “POWER” switch continuity (Digital Elec- 1. Remove: tronic Control) • Relay cover Out of specification  Replace the Digital • Starter relay “1” Electronic Control.
Page 203: Checking The Engine Start/Stop Switch
Starting unit and component a. Disconnect the “POWER” switch coupler. b. Check the “POWER” switch for continuity at the power switch coupler. d. Insert the clip into the engine shut-off switch. 2. Check: • Engine start/stop switch continuity Out of specification  Replace. Engine start/stop switch continuity A.
Page 204 Starting unit and component c. Connect the engine start/stop switch cou- pler. h i j k l m n o p q r s A. “POWER” switch (single type) B. All “START/STOP” switch C. “POWER” switch (twin type) D. “START/STOP” switch (twin type) E.
Page 205: Starter Motor
Starter motor Starter motor Part name Q’ty Remarks Part name Q’ty Remarks Nut M8 Seal set Washer Lever assembly Bolt M6  35 mm Pinion assembly Magnet switch Bracket assembly Bolt M5  127 mm Bearing Stator Gasket Screw M4  16 mm Pinion shaft Bracket Starter motor gear as-...
Page 206: Removing The Starter Motor
Starter motor Removing the starter motor a. Push the pinion stopper “1” down, and then remove the clip “2”. Before removing the starter motor, make sure to disconnect the negative battery ter- minal. 1. Remove: • Starter motor See “Starter motor” (7-26). Disassembling the starter motor 1.
Page 207: Checking The Brush Holder
Starter motor 2. Measure: • Commutator diameter “a” Below specification  Replace the arma- ture. Standard commutator diameter 29.0 mm (1.14 in) Wear limit 28.0 mm (1.10 in) Checking the brush holder 1. Check: • Brush holder assembly continuity Out of specification  Replace. Brush holder assembly continuity “a”...
Page 208: Assembling The Starter Motor
Starter motor 3. Install: • Pinion shaft assembly “1” • Lever “2” • Rubber seal “3” TIP: Align the holes “a” in the cover “4” with the holes “b” in the bracket “5”. a. Standard brush length b. Wear limit Assembling the starter motor Do not apply grease or oil to the commuta- tor of the armature.
Page 209: Installing The Starter Motor
Starter motor a. Push the brushes “1” into the holders, and 8. Install: then install the armature “2” to the brush • Stator bolt “1” holder assembly “3”. b. Install the plate “4”. 9. Install: • Gasket “1” • Spring “2” 7.
Page 210: Outboard Motor And Digital Electronic Control Connection
Outboard motor and Digital Electronic Control connection Outboard motor and Digital Elec- a. Connect the YDIS to display “LPS 1” and “LPS 2”. tronic Control connection Checking the extension wire harness b. Operate the remote control lever “1”, and 1. Check: then measure the output voltages of LPS 1 •...
Page 211: Checking The Lps Continuity
6X9 Digital Electronic Control circuit a. Turn the “POWER” switch to ON, and then measure the input voltage at the Digital Electronic Control coupler terminals (wire 1 2 3 4 5 6 harness end). 7 8 9 10 11 12 b, d c, e STBD...
Page 212: Ptt System
PTT system PTT system 2. Check: • PTT relay continuity Checking the PTT relay Out of specification  Replace. 1. Measure: a. Disconnect the PTT relay leads and PTT • PTT relay input voltage Out of specification  Check the wire har- motor leads.
Page 213: Checking The Ptt Switch (On Bottom Cowling)
PTT system Checking the PTT switch (on bottom cowling) 1. Measure: • PTT switch input voltage Out of specification  Check the wire har- ness for continuity. Input voltage 12 V Red (R)–Ground a. Disconnect the PTT switch coupler “a”. b.
Page 214: Checking The Ptt Sensor
PTT system PTT switch continuity Output voltage Terminal Position Voltage Switch po- sition “a” “b” “c” Fully tilted-up posi- 4.04 tion Fully tilted-down po- 0.99 sition c. Connect the PTT switch coupler. Checking the PTT buzzer Checking the PTT sensor 1.
Page 215: Fuel System
Fuel system Fuel system ................ 6-1 Reducing the fuel pressure ............6-1 Disconnecting the quick connector..........6-1 Measuring the fuel pressure............6-2 Checking the pressure regulator ..........6-3 Fuel filter assembly............6-6 Removing the fuel filter assembly ..........6-7 Checking the fuel filter assembly..........6-7 Checking the fuel filter element ..........
Page 216 Fuel system Vapor separator and high-pressure fuel pump ..... 6-24 Checking the high-pressure fuel pump........6-26 Checking the vapor separator ..........6-26 Checking the check valve............6-26 Fuel injector ..............6-28 Checking the fuel rail..............6-29 Installing the fuel injector............6-29...
Page 217: Reducing The Fuel Pressure
Fuel system Fuel system Disconnecting the quick connector Reducing the fuel pressure Before disconnecting the quick connector, reduce the fuel pressure. Otherwise, pres- Before servicing the high-pressure fuel line surized fuel could spray out. or vapor separator, make sure to reduce the fuel pressure in the fuel line.
Page 218: Measuring The Fuel Pressure
Fuel system a. Reduce the fuel pressure. See “Reducing PORT the fuel pressure” (6-1). b. Disconnect the quick connector from the fuel rail. See “Disconnecting the quick con- nector” (6-1). c. Connect the special service tool “1” to the quick connector and the fuel rail. STBD Fuel pressure gauge adapter “1”...
Page 219: Checking The Pressure Regulator
Fuel system i. Reduce the fuel pressure. See “Reducing the fuel pressure” (6-1). j. Disconnect the special service tools. Before disconnecting the special service tools, cover the end of the hose using a clean and dry rag. k. Connect the quick connector to the fuel rail.
Page 220 Fuel system g. Remove the rubber plug “2”. h. Disconnect the special service tool “3”, and then connect the pressure regulator hose “1” to the pressure regulator “4”. A. Worldwide B. USA and Canada Fuel pressure gauge adapter “1” 90890-06946 Fuel pressure gauge adapter “1”...
Page 221 Fuel system 6. Connect: • Quick connector “3” A. Worldwide B. USA and Canada...
Page 222: Fuel Filter Assembly
Fuel filter assembly Fuel filter assembly 5 N·m (0.5 kgf·m, 3.7 lb·ft) Part name Q’ty Remarks Bolt M620 mm Cover Grommet Collar Plastic tie Fuel filter assembly Fuel cup assembly O-ring Fuel filter element Clip Float Cover Hose Clamp Joint Holder...
Page 223: Removing The Fuel Filter Assembly
Fuel filter assembly Removing the fuel filter assembly Fuel outlet holding pressure (neg- Cover the fuel components using a rag to pre- ative pressure) vent fuel from spilling out. 80.0 kPa (0.80 kgf/cm², 11.6 psi) Checking the fuel filter assembly a.
Page 224: Checking The Primer Pump
Fuel filter assembly Checking the primer pump Assembling the fuel filter 1. Check: 1. Install: • No air leakage • Fuel filter element “1” Air leakage  Replace. • O-ring “2” • Fuel cup assembly “3” Positive pressure • Fuel filter cap “4” 166.7 kPa (1.67 kgf/cm², 24.2 •...
Page 225 Fuel filter assembly 3. Install: • Cover “1” 4. Connect: • Water detection switch coupler “a” 5. Check: • Fuel flow Leak/clog  Replace the fuel filter assem- bly.
Page 226: Intake Manifold
Intake manifold Intake manifold 11 N·m (1.1 kgf·m, 8.1 lb·ft) 11 N·m (1.1 kgf·m, 8.1 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft) 11 10 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks...
Page 227: Checking The Intake Manifold
Intake manifold Checking the intake manifold PORT 1. Check: • Intake manifold Cracked/damaged  Replace. Installing the intake manifold 1. Install: • Gasket TIP: Make sure to fit the tabs on the gaskets “1” and STBD “2” properly and firmly with the grooves “a” and “b”...
Page 228: Installing The Intake Silencer
Intake manifold b. Fasten the fuel injector lead “1” and Installing the intake silencer ground lead “2” using the holders “3”. 1. Install: • Joint STBD • Plastic tie • Intake silencer • Intake air pressure/temperature sensor • Blowby hose Intake air pressure/temperature sensor screw 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
Page 229: Etv
7 N·m (0.7 kgf·m, 5.2 lb·ft) 11 N·m (1.1 kgf·m, 8.1 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Bolt M8  60 mm Joint Bolt M6  16 mm Hose Bracket Hose...
Page 230: Checking The Etv
Checking the ETV 2. Install: • Surge tank “1” 1. Check: • Surge tank bolt “2” • ETV Cracked  Replace. 2. Check: • Throttle valve movement Rough movement  Clean. Surge tank bolt “2” 1st: 30 N·m (3.0 kgf·m, 22 lb·ft) 2nd: 30 N·m (3.0 kgf·m, 22 lb·ft) 3.
Page 231 4. Install: 7. Install: • Bracket “1” • Gasket “1” • Vapor gas hose “2”, “3” • ETV “2” • Bracket “3” a. Install the vapor gas hoses “2” and “3” to • Holder “4” the holder “4”. TIP: Check that the tab on the gasket “1” is properly and firmly fitted into the groove “a”...
Page 232: Canister
Canister Canister Part name Q’ty Remarks Hose Check valve Hose Joint Hose Hose Holder Holder Bolt M5  25 mm Buzzer Bolt M6  25 mm Collar Grommet Bracket Holder Cover Canister Hose 6-16...
Page 233: Checking The Canister
Canister Checking the canister 1. Check: • Canister Cracked/air leakage  Replace. a. Connect the special service tool “1” to the atmospheric port “a” and block the other ports using rubber plugs “2”. b. Apply the specified positive pressure and check that there is no air leakage.
Page 234 Canister a. Fasten the vapor gas hose “1” using the holders “2”. b. Connect the vapor gas hoses “3”, “4”, and “5” to the canister. 6-18...
Page 235: Low-Pressure Fuel Pump
Low-pressure fuel pump Low-pressure fuel pump 12 11 5 N·m (0.5 kgf·m, 3.7 lb·ft) 12.2 mm 23.6 mm 9 mm 12.2 mm (0.48 in) (0.93 in) (0.35 in) (0.48 in) 12.2 mm 12.2 mm 11.5 mm (0.48 in) (0.48 in) (0.45 in) Part name Q’ty...
Page 236: Installing The Low-Pressure Fuel Pump
Low-pressure fuel pump Installing the low-pressure fuel pump e. Connect the fuel hose “1”, and then fasten it using the clamp “2”. 1. Install: • Low-pressure fuel pump f. Connect the fuel hose “3” to the joint and a. Connect the fuel hose “1” to the low-pres- fasten the fuel hose using a new plastic tie sure fuel pump “2”...
Page 237: Vapor Separator And Vapor Shut-Off Valve
Vapor separator and vapor shut-off valve Vapor separator and vapor shut-off valve Part name Q’ty Remarks Part name Q’ty Remarks Clamp Nut M6 Plastic tie Vapor shut-off valve Hose Hose Hose Hose Holder Holder Holder Joint Clip Hose Bolt M6  35 mm Grommet Collar Vapor separator...
Page 238: Draining The Fuel
Vapor separator and vapor shut-off valve Draining the fuel Installing the vapor separator Cover the fuel components using a rag to pre- 1. Install: vent fuel from spilling out. • Vapor separator • Vapor shut-off valve 1. Drain: a. Install the cooling water hose “1” and fuel •...
Page 239 Vapor separator and vapor shut-off valve e. Connect the fuel hose “1”, and then fasten it using the clamp “2”. f. Connect the cooling water hoses “3” and “4”, and then fasten it using a new plastic tie “5”. g. Connect the vapor gas hose “6”. h.
Page 240: Vapor Separator And High-Pressure Fuel Pump
Vapor separator and high-pressure fuel pump Vapor separator and high-pressure fuel pump 2.0 N · m (0.20 kgf · m, 1.5 lb ·ft ) 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 2.0 N · m (0.20 kgf · m, 1.5 lb ·ft ) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 2.0 N ·...
Page 241 Vapor separator and high-pressure fuel pump 2.0 N · m (0.20 kgf · m, 1.5 lb ·ft ) 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 2.0 N · m (0.20 kgf · m, 1.5 lb ·ft ) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 2.0 N ·...
Page 242: Checking The High-Pressure Fuel Pump
Vapor separator and high-pressure fuel pump Checking the high-pressure fuel pump 1. Check: • Electrical performance of the high-pres- sure fuel pump See “Checking the low-pressure fuel pump and high-pressure fuel pump” (5-32). Checking the vapor separator 1. Check: • Needle valve assembly Checking the check valve Bent/worn ...
Page 243 Vapor separator and high-pressure fuel pump b. Apply positive pressure and check that no air comes out of the opposite end “b” of the check valve. 6-27...
Page 244: Fuel Injector
Fuel injector Fuel injector Part name Q’ty Remarks Holder Clamp Hose Hose Hose Joint Quick connector Bolt M6  28 mm Fuel rail Holder Fuel injector O-ring set 6-28...
Page 245: Checking The Fuel Rail
Fuel injector Checking the fuel rail d. Tighten the bolts “2” equally. 1. Check: PORT • Fuel rail Cracked/deformed  Replace. 2. Check: • Electrical performance of the fuel injector See “Checking the fuel injector” (5-31). Installing the fuel injector 1.
Page 246 Power unit Power unit (check and adjustment)........7-1 Checking the compression pressure .......... 7-1 Checking the oil pressure............7-1 Checking the pulser coil air gap ..........7-2 Checking the valve clearance ............ 7-2 Adjusting the valve clearance............. 7-5 Power unit assembly ............7-7 Removing the power unit............
Page 247: Power Unit
Power unit Timing belt ................ 7-33 Removing the timing belt............7-34 Checking the timing belt ............7-35 Installing the timing belt............7-35 Camshaft ................7-38 Removing the camshaft, VCT assembly, and driven sprocket ..............7-39 Checking the sprocket.............. 7-40 Checking the valve lifter ............7-40 Checking the camshaft.............
Page 248 Power unit Cylinder block sensor and switch ........7-66 Checking the thermostat ............7-68 Checking the cooling water cover anode ......... 7-68 Installing the thermostat ............7-68 Installing the cooling water cover ..........7-69 Installing the knock sensor ............7-70 Installing the pulley bracket ............
Page 249: Power Unit (Check And Adjustment)
Power unit (check and adjustment) Power unit (check and adjust- Compression gauge “1” ment) 90890-03160 Checking the compression pressure Compression gauge extension “2” 1. Start the engine, warm it up for 5–10 min- 90890-06563 utes, and then stop it. Combination compression gauge and cylinder leakdown test kit “3”...
Page 250: Checking The Pulser Coil Air Gap
Power unit (check and adjustment) 3. Measure: Checking the valve clearance • Oil pressure • Measure the valve clearances when the en- Below specification  Check the engine gine is cold. internal parts. • Cover the fuel components using a rag to prevent fuel from spilling out.
Page 251 Power unit (check and adjustment) 5. Align: • Flywheel magneto • Driven sprocket • VCT assembly • Dowel pin hole a. Turn the flywheel magneto “1” clockwise until the dowel pin hole “a” in the flywheel magneto “1” is aligned between the VCT assembly (STBD) “2”...
Page 252 Power unit (check and adjustment) b. Turn the flywheel magneto “1” an addition- 11. Install: al 360 clockwise until the dowel pin hole • Engine ECM bracket “a” in the flywheel magneto “1” is aligned • Engine ECM between the VCT assembly (STBD) “2” •...
Page 253: Adjusting The Valve Clearance
Power unit (check and adjustment) Adjusting the valve clearance 5. Remove: • Flywheel magneto Adjust the valve clearances when the engine is • Pulser coil cold. • Stator assembly See “Removing the flywheel magneto” (7- • Do not turn the flywheel magneto counter- 15).
Page 254 Power unit (check and adjustment) 9. Select: • Valve lifter a. Select the necessary valve lifter by calcu- lating its thickness using the following for- mula. Calculation formula: Necessary valve lifter thickness = Removed valve lifter thickness + Measured valve clearance –...
Page 255: Power Unit Assembly
Power unit assembly Power unit assembly 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 42 N·m (4.2 kgf·m, 31 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Bolt M6  14 mm Clip Screw M6  20 mm Bolt M6  30 mm Bolt M10 ...
Page 256: Removing The Power Unit
Power unit assembly Removing the power unit 4. Remove: • Clip “1” 1. Remove: • Plastic tie “1” • Rigging tube retainer “2” 5. Disconnect: • PTT motor lead “1” 2. Remove: 6. Remove: • Grommet holder “1” • Holder “2” •...
Page 257 Power unit assembly 8. Remove: 12. Remove: • SPS coupler “b” (from the bracket “1”) • SCU communication lead coupler (3P) “a” • Shift actuator coupler “c” (from the bracket (from the holder “1”) “2”) • SCU communication lead coupler (4P) “b” (from the holder “1”) 9.
Page 258: Installing The Power Unit
Power unit assembly 16. Remove: • Cover “1” • Rubber seal Lifting eye “1” 90890-06953 Bolt hexagon with washer “2” 90890-06821 Bolt hexagon with washer “2” 17. Remove: YB-06821 • Idle silencer “1” Balance hanger “3” 90890-06822 Lifting eye bolt “2” 36 N·m (3.6 kgf·m, 27 lb·ft) Installing the power unit 1.
Page 259 Power unit assembly b. Hook a lifting harness “6” onto the special Lifting eye bolt service tools “3” and “5”, and then suspend 36 N·m (3.6 kgf·m, 27 lb·ft) the power unit “7”. Power unit mounting bolt “8”, “9” c. Install the power unit “7”, and then tighten 42 N·m (4.2 kgf·m, 31 lb·ft) the power unit mounting bolts “8”...
Page 260 Power unit assembly 6. Connect: 11. Connect: • Flushing hose “1”, “2” • Shift actuator coupler “a” • Vapor gas hose “3” • SPS coupler “b” • PTT switch coupler “c” 7. Install: • SCU communication lead coupler (4P) “a” 12.
Page 261 Power unit assembly 15. Install: 18. Install: • PTT motor lead bolt “2” • Rigging grommet “1” • PTT motor lead “1” (using a holder “3”) • Grommet holder “2” • Holder “4” See “Installing the rigging grommet” (3-6). PTT motor lead bolt “2” 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 16.
Page 262: Flywheel Magneto
Flywheel magneto Flywheel magneto 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 40 N·m (4.0 kgf·m, 30 lb·ft) 90° Part name Q’ty Remarks Bolt M6  16 mm Bolt M6  16 mm Air shroud Flywheel magneto Bolt M10 ...
Page 263: Removing The Flywheel Magneto
Flywheel magneto Removing the flywheel magneto 1. Remove: • Flywheel magneto a. Loosen the flywheel magneto bolts “1” in the order [1], [2], and so on, and then re- move the flywheel magneto and dowel pin. Apply force in the direction of the arrow to prevent the special service tool “2”...
Page 264: Installing The Flywheel Magneto
Flywheel magneto Installing the flywheel magneto 1. Install: • Dowel • Base • Pulser coil • Bracket 90° • Plastic tie • Stator assembly • Holder • Dowel pin Pulser coil bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 2. Connect: •...
Page 265 Flywheel magneto Rotor holding tool (including han- dle and 3 pins) “2” 90890-04195 Universal magneto and rotor hold- er “2” YU-01235 Flywheel stopper B “3” 90890-06686 Flywheel stopper B “3” YB-06686 Flywheel magneto bolt “1” 1st: 40 N·m (4.0 kgf·m, 30 lb·ft) 2nd: 90...
Page 266: Wire Harness
Wire harness Wire harness Part name Q’ty Remarks Holder Holder Plastic tie Screw M4  6 mm Wire harness Bolt M6  20 mm Wire harness guide 7-18...
Page 267: Installing The Wire Harness
Wire harness Installing the wire harness 4. Connect: • Shift actuator coupler “a” Route the wire harness. See “Electrical component and wire harness routing” (5-1). 1. Install: • Wire harness guide • Holder “1”, “2” (to the wire harness guide “3”) 5.
Page 268 Wire harness 8. Install: STBD • Fuse box “1” • Fuse box screw “2” 11. Connect: • OCV coupler “a” • Cam position sensor coupler “b” • Thermo sensor coupler “c” 12. Install: • Plastic tie “1” Fuse box screw “2” PORT 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 9.
Page 269 Wire harness 13. Install: • Wire harness “1” (to the holders “2”) • Condenser “3” (to the wire harness guide) 14. Connect: • Cam position sensor coupler (PORT EX) “a” 15. Install: • Holder “1” (to the ECM bracket) • Wire harness “2” (to the holders “3”) 16.
Page 270: Fuse Box
Fuse box Fuse box 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 10 2 Part name Q’ty Remarks Fuse box assembly Cover Fuse puller Screw M3  10 mm Cover Relay Screw M5  10 mm 100 A, spare Fuse is included. 10 A, spare is Fuse included.
Page 271: Junction Box
Junction box Junction box 6 N·m (0.6 kgf·m, 4.4 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) 9 N·m (0.9 kgf·m, 6.6 lb·ft) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Plastic tie...
Page 272: Installing The Junction Box
Junction box Installing the junction box PTT relay lead nut “3” 1. Install: 5 N·m (0.5 kgf·m, 3.7 lb·ft) • Junction box “1” Starter motor nut “5” • Terminal “2” 9 N·m (0.9 kgf·m, 6.6 lb·ft) • Terminal bolt “3” •...
Page 273 Junction box 3. Install: • Ground lead “1” • Cooling water hose “2”, “3” • Clamp “4” • Plastic tie “5” 7-25...
Page 274 Starter motor Starter motor 25 N·m (2.5 kgf·m, 18 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) Part name Q’ty Remarks Bolt M8  45 mm Starter motor Bolt M8  35 mm Bracket Bolt M6  40 mm Bracket 7-26...
Page 275: Starter Motor
Starter motor Installing the starter motor 1. Install: • Bracket • Bracket bolt • Starter motor • Starter motor bolt Bracket bolt (M6) 12 N·m (1.2 kgf·m, 8.9 lb·ft) Bracket bolt (M8) 25 N·m (2.5 kgf·m, 18 lb·ft) Starter motor bolt 29 N·m (2.9 kgf·m, 21 lb·ft) 7-27...
Page 276: Engine Ecm
Engine ECM Engine ECM 7 N·m (0.7 kgf·m, 5.2 lb·ft) Part name Q’ty Remarks Bolt M6  20 mm Engine ECM Bolt M6  12 mm Bracket Bolt M6  30 mm Grommet Bracket Collar Holder Holder 7-28...
Page 277: Ignition Coil And Spark Plug
Ignition coil and spark plug Ignition coil and spark plug 11 N·m (1.1 kgf·m, 8.1 lb·ft) Part name Q’ty Remarks Ignition coil Bolt M6  25 mm Spark plug 7-29...
Page 278: Checking The Spark Plug
Ignition coil and spark plug Checking the spark plug 1. Clean the electrodes “a” using a spark plug cleaner. 2. Check: • Spark plug Electrodes are eroded, edges of elec- trodes are rounded, insulator is damaged, or there is carbon or other deposits  Re- place.
Page 279: Shift Actuator
Shift actuator Shift actuator 19 N·m (1.9 kgf·m, 14 lb·ft) 19 N·m (1.9 kgf·m, 14 lb·ft) Part name Q’ty Remarks Clip Nut M6 Joint pin Bushing Washer Washer Shift lever Bushing Bolt M6  25 mm Bracket Bolt M8  35 mm Bolt M8 ...
Page 280: Assembling The Shift Actuator Assembly
Shift actuator Assembling the shift actuator assem- 1. Install: • Bracket “1” • Joint pin “2” • Bushing “3” • Bushing “4” • Washer “5” • Shift lever “6” • Washer “7” • Nut “8” • Clip “9” Installing the shift actuator assembly 1.
Page 281: Timing Belt
Timing belt Timing belt 39 N·m (3.9 kgf·m, 29 lb·ft) 39 N·m (3.9 kgf·m, 29 lb·ft) Part name Q’ty Remarks Bolt M6  14 mm Guide Bolt M6  16 mm Guide Plate Timing belt Timing belt tensioner Bolt M10  55 mm Washer Pulley Collar...
Page 282: Removing The Timing Belt
Timing belt Removing the timing belt c. Remove the timing belt guides “1” and “2” and plate “3”. When the timing belt is not installed, do not turn the crankshaft, driven sprocket or VCT assembly. Otherwise, the pistons and valves could collide with each other and be damaged.
Page 283: Checking The Timing Belt
Timing belt e. Remove the timing belt “1” from the VCT 1. Install: assembly (PORT) or driven sprocket • Timing belt (STBD), and then remove it from the a. Install the timing belt tensioner “1”, collars crankshaft. “2”, and pulleys “3”, and then tighten the timing belt tensioner bolt “4”...
Page 284 Timing belt d. Adjust the timing belt installation height “a” to specification. Timing belt installation height “a” 2.5 mm (0.10 in) c. Install the timing belt onto the VCT assem- blies and driven sprockets by aligning the e. While holding the timing belt tensioner ap- belt position marks “a”, “b”, “c”, and “d”...
Page 285 Timing belt h. Turn the crankshaft clockwise 2 full turns until the large “▲” mark “a” on the crank- shaft is aligned with the rib “b” on the cylin- der block. Check that the marks “c” and “d” on the VCT assemblies and driven sprock- ets are aligned.
Page 286: Camshaft
Camshaft Camshaft 32 N·m (3.2 kgf·m, 24 lb·ft) 60 N·m (6.0 kgf·m, 44 lb·ft) 60 N·m (6.0 kgf·m, 44 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 17 N·m (1.7 kgf·m, 13 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 17 N·m (1.7 kgf·m, 13 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Part name...
Page 287: Removing The Camshaft, Vct Assembly, And Driven Sprocket
Camshaft Removing the camshaft, VCT assem- bly, and driven sprocket • When removing the VCT cap, do not se- cure the camshaft. Otherwise, the VCT as- sembly could be damaged. When the timing belt is not installed, do not • When removing the VCT cap, do not turn turn the crankshaft or camshafts.
Page 288: Checking The Sprocket
Camshaft 3. Remove: • Camshaft cap a. Remove the camshaft caps “1”, “2”, and “3” in the order [1], [2], and so on. PORT STBD e. Secure the exhaust camshaft using a 4. Remove: wrench, and then remove the driven •...
Page 289: Checking The Camshaft
Camshaft Cam lobe height IN 47.511–47.611 (1.8705– 1.8744 in) Limit 47.461 mm (1.8685 in) Cam lobe height EX 47.360–47.460 (1.8646– 1.8685 in) Limit 47.310 mm (1.8626 in) Outside diameter 30.970–30.980 (1.2193– 3. Measure: 1.2197 in) • Camshaft runout Out of specification  Replace. Checking the camshaft 1.
Page 290 Camshaft TIP: Do not turn the camshafts when measuring the camshaft journal oil clearance using the Plasti- gauge (PG-1). STBD PORT 2. Install: • Collar “1” • Camshaft cap “2”, “3”, “4” • Camshaft cap bolt “5”, “6” TIP: Install the camshaft caps “2”, “3”, and “4” in their proper positions so that the stamped numbers are upside down.
Page 291: Checking The Camshaft Journal Outside Diameter And Camshaft Journal Inside Diameter
Camshaft 3. Measure: Camshaft journal oil clearance • Camshaft journal inside diameter “a” Above specification  Replace the cylin- 0.020–0.061 (0.0008– 0.0024 in) der head and camshaft cap as a set. Limit 0.080 mm (0.0032 in) Checking the camshaft journal out- side diameter and camshaft journal in- side diameter 1.
Page 292 Camshaft 3. Install: • Valve lifter “1” • Camshaft “2”, “3”, “4”, “5” • Oil seal “6” • Dowel pin TIP: • Install the valve lifters in their original posi- tions. • Install the camshafts “2”, “3”, “4”, and “5” in the proper positions and new oil seals “6”.
Page 293 Camshaft b. Check that the dowel pins “1” and “2” on e. Tighten the camshaft cap bolts “1” and “2” the camshafts (STBD) are positioned 60 to the specified torques in 2 stages and in from the mating surface of the cylinder the order [1], [2], and so on.
Page 294 Camshaft h. Secure the exhaust camshaft using a wrench, and then tighten the driven sprocket bolts “2” to the specified torque. VCT bolt “1” 60 N·m (6.0 kgf·m, 44 lb·ft) Driven sprocket bolt “2” l. Install new gaskets “1” and the VCT caps 60 N·m (6.0 kgf·m, 44 lb·ft) “2”, secure the VCT assemblies using the special service tool “3”, and then tighten...
Page 295 Camshaft Rotor holding tool “3” 90890-04166 Rotor holding tool “3” YM-04166 60° VCT cap “2” 32 N·m (3.2 kgf·m, 24 lb·ft) m. Check that the “II” marks “a” on the VCT p. Install new gaskets “1” and “2” and the cyl- assembly (PORT) and driven sprocket inder head covers “3”...
Page 296: Cylinder Head
Cylinder head Cylinder head 39 N·m (3.9 kgf·m, 29 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 180˚ 14 N·m (1.4 kgf·m, 10 lb·ft) 28 N·m (2.8 kgf·m, 21 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 55 N·m (5.5 kgf·m, 41 lb·ft) 23 N·m (2.3 kgf·m, 17 lb·ft) Part name Q’ty...
Page 297: Removing The Cylinder Head
Cylinder head Removing the cylinder head 1. Remove: • OCV assembly • Gasket • Cylinder head Do not scratch or damage the mating sur- faces of the cylinder head and cylinder block. A. Conventional special service tool B. New special service tool TIP: Conventional special service tool Remove the cylinder head bolts (M11) using a...
Page 298: Checking The Cylinder Head
Cylinder head 2. Remove: Checking the cylinder head bolt • Valve seal “1” 1. Measure: • Cylinder head bolt diameter Above specification  Replace. TIP: Measure the diameters “a” and “b” of the cylin- der head bolt (M11) at the specified measuring points “c”...
Page 299: Checking The Valve
Cylinder head Free length IN Margin thickness IN 49.52 mm (1.95 in) 0.55–0.95 mm (0.0217–0.0374 Limit 47.04 mm (1.85 in) Margin thickness EX 0.90–1.30 mm (0.0354–0.0512 Free length EX 49.52 mm (1.95 in) Limit 3. Measure: 47.04 mm (1.85 in) •...
Page 300: Checking The Valve Guide
Cylinder head Runout limit IN Valve stem to valve guide clear- 0.01 mm (0.0004 in) ance = Valve guide inside diameter – Valve stem diameter Runout limit EX 0.01 mm (0.0004 in) Clearance IN 0.012–0.045 (0.0005– 0.0018 in) Checking the valve guide Limit Before checking the valve guides, make sure 0.070 mm (0.0028 in)
Page 301: Checking The Valve Seat
Cylinder head 4. Measure: • Inside diameter Inside diameter IN 5.504–5.522 (0.2167– 0.2174 in) Inside diameter EX 5.504–5.522 (0.2167– 0.2174 in) Checking the valve seat Valve guide remover/installer “2” 1. Remove: 90890-06801 • Carbon deposit Valve guide remover “2” YB-06801 2.
Page 302: Refacing The Valve Seat
Cylinder head c. Measure the valve seat contact width “a” Refacing the valve seat where the blue layout fluid is adhered to the valve face. After every lapping procedure, make sure TIP: to clean off any remaining lapping com- • Reface the valve seat if the valve is not seat- pound from the cylinder head and valves.
Page 303 Cylinder head b. Cut the surface of the valve seat using a c. Adjust the top edge of the valve seat con- 45 cutter by turning the cutter clockwise tact width using a 30 cutter. until the valve seat face has become smooth.
Page 304 Cylinder head f. Check the valve seat contact area of the • If the valve seat contact area is too nar- valve. See “Checking the valve seat” (7- row and situated near the bottom edge of 53). the valve face, cut the bottom edge of the valve seat using a 60...
Page 305: Checking The Cylinder Head Anode
Cylinder head 3. Measure: • Valve seat contact width See step (2) in “Checking the valve seat” (7-53). Checking the cylinder head anode 1. Check: • Anode Eroded (1/2 or more worn out)  Replace. Adhered grease, oil, or scales  Clean. Do not apply grease, oil, or paint to the an- odes.
Page 306 Cylinder head New special service tool 3. Install: • O-ring “1” Valve spring compressor attach- • Cam position sensor “2” ment “6” • Cylinder head anode “3” 90890-06320 • Exhaust plug “4” Valve spring compressor adaptor • Braided plug “5” “6”...
Page 307: Installing The Cylinder Head
Cylinder head Installing the cylinder head Before assembling the cylinder head, check the cylinder head bolts. See “Checking the cyl- inder head bolt” (7-50). 1. Install: • Gasket “1” • OCV “2” • OCV bolt “3” • Gasket “4” • Dowel “5” •...
Page 308: Oil Cooler And Oil Pump Assembly
Oil cooler and oil pump assembly Oil cooler and oil pump assembly 6 N·m (0.6 kgf·m, 4.4 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) 49 N·m (4.9 kgf·m, 36 lb·ft) 18 N·m (1.8 kgf·m, 13 lb·ft) 20 21 12 N·m (1.2 kgf·m, 8.9 lb·ft) 13 N·m (1.3 kgf·m, 9.6 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Part name...
Page 309: Removing The Oil Filter
Oil cooler and oil pump assembly Removing the oil filter 1. Remove: • Oil filter “1” 1. Inner rotor 2. Outer rotor 3. Oil pump housing Oil filter wrench “2” Inner rotor to outer rotor tip clear- 90890-06874 ance (reference data) Oil filter wrench “2”...
Page 310: Checking The Oil Cooler Anode
Oil cooler and oil pump assembly Checking the oil cooler anode Driver rod L3 “3” 1. Check: 90890-06652 • Anode Eroded (1/2 or more worn out)  Replace. Needle bearing attachment “4” Adhered grease, oil, or scales  Clean. 90890-06612 Driveshaft bearing installer “4”...
Page 311: Installing The Oil Pump Assembly
Oil cooler and oil pump assembly 3. Install: 2. Install: • Outer rotor “1” • O-ring “1” • Inner rotor “2” • Oil pump assembly “2” • Gasket “3” TIP: • Oil pump cover “4” Aligning the oil pump gear with the crankshaft. •...
Page 312: Installing The Oil Filter
Oil cooler and oil pump assembly Installing the oil filter 1. Install: • Gasket “1” • Oil filter bracket “2” • Oil filter bracket bolt “3” TIP: Tighten the oil filter bracket bolts “3” to the specified torque in the order [1], [2], and so on. [13] [19] [20]...
Page 313 Oil cooler and oil pump assembly Oil filter “1” 18 N·m (1.8 kgf·m, 13 lb·ft) Oil filter union bolt “1” 49 N·m (4.9 kgf·m, 36 lb·ft) Oil pressure sensor “3” 13 N·m (1.3 kgf·m, 9.6 lb·ft) 3. Fill: • Oil passage “a” TIP: Add a small amount of engine oil through the oil passage “a”...
Page 314 Cylinder block sensor and switch Cylinder block sensor and switch 14 N·m (1.4 kgf·m, 10 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) 28 N·m (2.8 kgf·m, 21 lb·ft) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft)
Page 315: Cylinder Block Sensor And Switch
Cylinder block sensor and switch 14 N·m (1.4 kgf·m, 10 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) 28 N·m (2.8 kgf·m, 21 lb·ft) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft) Part name...
Page 316: Checking The Thermostat
Cylinder block sensor and switch Checking the thermostat Installing the thermostat 1. Measure: 1. Install: • Valve opening “a” • Gasket “1” (at the specified water temperatures) • Thermostat housing “2” Out of specification  Replace. • Gasket “3” • Thermo sensor “4” TIP: •...
Page 317: Installing The Cooling Water Cover
Cylinder block sensor and switch 2. Install: • Gasket “1” • Cooling water cover “2” • Cooling water cover bolt “3” STBD PORT c. 45 Thermo sensor “4” 3. Tighten: 15 N·m (1.5 kgf·m, 11 lb·ft) • Cooling water cover bolt “1” Thermostat housing bolt “5”...
Page 318: Installing The Knock Sensor
Cylinder block sensor and switch Installing the knock sensor Installing the pulley bracket 1. Install: 1. Install: • Cooling water hose “1”, “2”, “3” • Dowel pin “1” • Joint “4”, “5” • Pulley bracket “2” • Clamp “6” • Pulley bracket bolt “3” TIP: Tighten the pulley bracket bolts “3”...
Page 319: Cylinder Block
Cylinder block Cylinder block 55 N·m (5.5 kgf·m, 41 lb·ft) 90° 55 N·m (5.5 kgf·m, 41 lb·ft) 90° 13 N·m (1.3 kgf·m, 9.6 lb·ft) 14 N·m (1.4 kgf·m, 10 lb·ft) 28 N·m (2.8 kgf·m, 21 lb·ft) 28 N·m (2.8 kgf·m, 21 lb·ft) 90°...
Page 320: Disassembling The Cylinder Block
Cylinder block Disassembling the cylinder block TIP: 1. Remove: Make sure to keep the parts in the order of re- • Crankcase moval. • Thrust bearing 2. Remove: • Piston and connecting rod assembly a. Remove the connecting rod caps “1”, and then remove the crankshaft pin bearings “2”, piston and connecting rod assemblies “3”.
Page 321: Checking The Piston Diameter
Cylinder block Checking the piston diameter Bearing separator “2” 1. Measure: 90890-06534 • Piston diameter “a” Gear puller “3” (at the specified measuring point “b”) Below specification  Replace. 90890-06540 Needle bearing attachment “4” 90890-06615 Bearing separator “5” (commercially available) Gear puller “6”...
Page 322: Checking The Piston Clearance
Cylinder block Cylinder Piston ring dimensions Bore Top ring 96.000–96.012 (3.7795– Height (B) 3.7800 in) 1.170–1.185 (0.0461– Limit 0.0467 in) 96.072 mm (3.7824 in) Width (T) 2.800–3.000 (0.1102– 0.1181 in) Checking the piston clearance 2nd ring 1. Measure: • Piston diameter Height (B) See “Checking the piston diameter”...
Page 323: Checking The Piston Ring Groove
Cylinder block Piston ring end gap Piston ring groove End gap measuring point Ring groove (Top) 20.0 mm (0.79 in) 1.22–1.25 mm (0.0480–0.0492 Top ring End gap Ring groove (2nd) 0.20–0.30 mm (0.0079–0.0118 1.22–1.24 mm (0.0480–0.0488 Limit Ring groove (Oil) 0.470 mm (0.0185 in) 2.51–2.53 mm (0.0988–0.0996 2nd ring...
Page 324: Checking The Piston Pin Boss Inside Diameter
Cylinder block Checking the piston pin diameter Piston ring side clearance 1. Measure: Top ring • Piston pin outside diameter “a” Side clearance (at measuring points “b”, “c”, and “d”, and 0.04–0.08 mm (0.0016–0.0032 in directions “e” and “f”) Below specification  Replace. Limit 0.130 mm (0.0051 in) 2nd ring...
Page 325: Checking The Connecting Rod Big End Side Clearance
Cylinder block TIP: • When checking the big end inside diameter, reuse the removed connecting rod bolt. • Tighten the connecting rod bolts “1” to the specified torques in 3 stages. • In the third tightening stage for the connecting rod bolts “1”, mark the connecting rod bolts and the connecting rod cap with identification marks “c”, and then tighten the bolts 90...
Page 326: Checking The Crankcase Bolt
Cylinder block Journal diameter 72.976–72.996 (2.8731– 2.8739 in) Crankshaft pin diameter 50.980–51.000 (2.0071– 2.0079 in) Crankshaft pin width 21.00–21.10 (0.8268– 0.8307 in) A. M10 × 130 mm B. M10 × 105 mm 2. Measure: • Crankshaft runout Above specification  Replace the crank- Crankcase bolt diameter differ- shaft.
Page 327 Cylinder block 2. Install: • Plastigauge (PG-1) “1” Do not place the Plastigauge (PG-1) over the oil hole in the crankshaft pin of the crankshaft. TIP: Place a piece of Plastigauge (PG-1) “1” onto the crankshaft pin, parallel to the crankshaft. 4.
Page 328: Selecting The Crankshaft Pin Bearing
Cylinder block 6. Measure: 2. Check: • Width of the compressed Plastigauge • Stamped mark “a” (on the crank web) (PG-1) Above specification  Replace the crank- shaft pin bearing. Big end oil clearance 0.023–0.036 (0.0009– 0.0014 in) Limit 0.066 mm (0.0026 in) 3.
Page 329 Cylinder block Rod side bearing Cap side bearing color color “a” Yellow Yellow “b” Yellow Black “c” Black Black “d” Pink Black “e” Pink Pink “f” Pink “g” “h” Blue “i” Blue Blue Example: If the connecting rod big end inside diame- ter is “05”...
Page 330: Crankshaft Pin Bearing Selection Table
Cylinder block Crankshaft pin bearing selection table 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 A. Connecting rod big end inside diameter B. Crankshaft pin mark 7-82...
Page 331: Checking The Journal Oil Clearance
Cylinder block Checking the journal oil clearance 3. Install: • Crankshaft journal bearing TIP: (into the crankcase) • After checking the journal oil clearance, TIP: check the crankcase bolts. See “Checking Install the crankshaft journal bearings in their the crankcase bolt” (7-78). original positions.
Page 332: Selecting The Crankshaft Journal Bearing
Cylinder block Journal oil clearance (J1) 90 ° 0.029–0.045 (0.0011– 0.0018 in) [13] [14] Journal oil clearance (J2) [27] [28] 0.029–0.045 (0.0011– [23] [24] 0.0018 in) Journal oil clearance (J3) [10] [19] [20] 0.029–0.045 (0.0011– 0.0018 in) [12] [11] Journal oil clearance (J4) [22] [21] 0.037–0.053...
Page 333 Cylinder block 2. Select: • Crankshaft journal bearing Block side bear- Crankcase side ing color bearing color TIP: “a” Orange Orange Select the suitable colors “1” for the crankshaft “b” Orange Black journal bearing from the “Crankshaft journal bearing selection table” (7-86). “c”...
Page 334: Crankshaft Journal Bearing Selection Table
Cylinder block Crankshaft journal bearing selection table J1/J2/J3 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 A. Crankshaft journal mark B. Cylinder block mark 7-86...
Page 335 Cylinder block 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 A. Crankshaft journal mark B. Cylinder block mark 7-87...
Page 336: Checking The Cylinder Block Anode
Cylinder block Checking the cylinder block anode 1. Check: • Anode Eroded (1/2 or more worn out)  Replace. Adhered grease, oil, or scales  Clean. Do not apply grease, oil, or paint to the an- odes. Assembling the cylinder block TIP: Before assembling the cylinder block, check b.
Page 337 Cylinder block 3. Install: 5. Install: • Crankshaft pin bearing “1” • Crankshaft journal bearing “1” (cylinder (into the connecting rod “2” and connecting block side) rod cap “3”) TIP: TIP: Install the crankshaft journal bearings “1” in Install the crankshaft pin bearings in the origi- their original positions.
Page 338 Cylinder block 7. Install: 8. Install: • Connecting rod cap • Thrust bearing “1” (crankcase side) • Crankshaft journal bearing (crankcase • Connecting rod bolt side) a. Install the connecting rod caps “1” to the • O-ring connecting rods. • Crankcase TIP: a.
Page 339 Cylinder block c. Install new O-rings “1”, dowel pins “2” and the crankcase “3”, and then tighten the 90 ° crankcase bolts (M10) “4” and “5” to the specified torques in 2 stages and in the or- [13] [14] der [1], [2], and so on. [27] [28] [23]...
Page 340 Lower unit Propeller................8-1 Removing the propeller .............. 8-2 Disassembling the propeller (Shift Dampener System [SDS] propeller) ..................8-2 Checking the propeller ............... 8-2 Assembling the propeller (Shift Dampener System [SDS] propeller) ..................8-3 Installing the propeller ..............8-3 Lower unit ................8-5 Removing the lower unit.............
Page 341: Lower Unit
Lower unit Drive shaft and lower case (regular rotation model) ..8-26 Removing the drive shaft............8-27 Removing the forward gear ............8-27 Disassembling the oil seal housing .......... 8-27 Disassembling the drive shaft ..........8-27 Disassembling the forward gear..........8-28 Disassembling the lower case..........
Page 342 Lower unit Drive shaft and lower case (counter rotation model)..........8-54 Removing the drive shaft............8-55 Removing the reverse gear ............8-55 Disassembling the oil seal housing .......... 8-55 Disassembling the drive shaft ..........8-55 Disassembling the lower case..........8-55 Checking the pinion..............
Page 343 Propeller Propeller 54 N·m (5.4 kgf·m, 40 lb·ft) Part name Q’ty Remarks Cotter pin Propeller nut M18 Washer Spacer Propeller Spacer Damper A. Regular rotation model B. Counter rotation model...
Page 344: Propeller
Propeller Removing the propeller Disassembling the propeller (Shift Dampener System [SDS] propeller) 1. Remove: • Make sure to disconnect the battery ca- • Damper “1” bles from the battery, and remove the clip from the engine shut-off switch. • When loosening or tightening the propel- ler nut, do not hold the propeller using your hands.
Page 345: Assembling The Propeller (Shift Dampener System [Sds] Propeller)
Propeller Assembling the propeller (Shift Installing the propeller Dampener System [SDS] propeller) 1. Install: • Make sure to disconnect the battery ca- • Damper bles from the battery, and remove the clip a. Align the mark “a” on the damper “1” with from the engine shut-off switch.
Page 346 Propeller 3. Install: • Cotter pin “1” TIP: If the slots in the propeller nut “2” are not aligned with the cotter pin hole, tighten the pro- peller nut “2” until they are aligned.
Page 347: Lower Unit
Lower unit Lower unit 42 N·m (4.2 kgf·m, 31 lb·ft) 47 N·m (4.7 kgf·m, 35 lb·ft) 47 N·m (4.7 kgf·m, 35 lb·ft) 47 N·m (4.7 kgf·m, 35 lb·ft) 47 N·m (4.7 kgf·m, 35 lb·ft) A. X-transom model Part name Q’ty Remarks B.
Page 348: Removing The Lower Unit
Lower unit Removing the lower unit 3. Remove: • Lower case mounting bolt (X-transom model) • Make sure to disconnect the battery ca- • Lower case mounting nut (except for X- transom model) bles from the battery, and remove the clip from the engine shut-off switch.
Page 349: Checking The Lower Unit Anode
Lower unit Checking the lower unit anode Installing the lower unit 1. Check: • Anode Eroded (1/2 or more worn out)  Replace. • Make sure to disconnect the battery ca- Adhered grease, oil, or scales  Clean. bles from the battery, and remove the clip from the engine shut-off switch.
Page 350 Lower unit b. Set the gear shift to the N position. Lifting hanger “1” 90890-06951 d. Install the lower unit. 3. Tighten: • Lower case mounting bolt (X-transom model) • Lower case mounting nut (except for X- transom model) Shift rod socket “1” Lower case mounting bolt (X-tran- 90890-06681 som model)
Page 351: Extension (Except For X-Transom Model)
Extension (except for X-transom model) Extension (except for X-transom model) 23 N·m (2.3 kgf·m, 17 lb·ft) 23 N·m (2.3 kgf·m, 17 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Extension Water tube Hose nipple Water tube O-ring Rubber seal Dowel pin Point the flat Stud bolt M10 ...
Page 352: Checking The Extension
Extension (except for X-transom model) Checking the extension 1. Check: • Extension Cracked/damaged  Replace. Assembling the extension 1. Install: • Rubber seal “1” • Rubber seal “2” • Cover “3” • Water tube “4” • Water tube “5” • Dowel pin “6” •...
Page 353: Water Pump And Shift Rod
Water pump and shift rod Water pump and shift rod 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Screw Oil seal Intermediate drive Cover shaft Seal O-ring Plate Bolt M8  25 mm O-ring Cover Oil seal Bolt M8 ...
Page 354: Removing The Water Pump And Shift Rod
Water pump and shift rod Removing the water pump and shift 1. Remove: • Cover • Intermediate drive shaft • O-ring • Water pump housing 90° • Dowel pin • O-ring • Impeller • Impeller key • Outer plate cartridge •...
Page 355: Checking The Intermediate Drive Shaft
Water pump and shift rod Checking the intermediate drive shaft Needle bearing attachment “2” 1. Check: 90890-06614 • Intermediate drive shaft Damaged/worn  Replace. Driver rod L3 “3” 90890-06652 2. Measure: Needle bearing attachment “4” • Intermediate drive shaft runout YB-06112 Above specification ...
Page 356: Installing The Shift Rod
Water pump and shift rod Installing the shift rod Installation depth “a” 1. Install: 10.25–10.75 mm (0.404–0.423 • Shift rod • E-clip • Plate 2. Install: • O-ring • Cover “1” • Oil seal • Seal “2” • Cover “3” 2.
Page 357: Installing The Water Pump
Water pump and shift rod Installing the water pump 1. Install: • Plate • Rubber seal • Dowel pin • Gasket • Outer plate cartridge • Cover • Impeller key • Impeller a. Align the slot “a” in the impeller “2” with the impeller key “1”, and then install the impel- ler “2”.
Page 358: Propeller Shaft Housing (Regular Rotation Model)
Propeller shaft housing (regular rotation model) Propeller shaft housing (regular rotation model) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 155 N·m (15.5 kgf·m, 114 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Part name Q’ty Remarks...
Page 359 Propeller shaft housing (regular rotation model) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 155 N·m (15.5 kgf·m, 114 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Part name Q’ty Remarks Reverse gear Tapered roller bearing Oil seal...
Page 360: Removing The Propeller Shaft Housing Assembly
Propeller shaft housing (regular rotation model) Removing the propeller shaft housing 3. Remove: • Propeller shaft housing assembly “1” assembly • Key “2” 1. Remove: • Cover 2. Remove: • Ring nut • Claw washer a. Straighten the bent tab “a” on the claw washer.
Page 361: Disassembling The Propeller Shaft Assembly
Propeller shaft housing (regular rotation model) Disassembling the propeller shaft as- sembly 1. Remove: • Spring “1” • Cross pin “2” • Dog clutch “3” • Slider “4” • Ball “5” • Shift plunger “6” TIP: A. Worldwide When removing the slider “4”, make sure that B.
Page 362: Checking The Propeller Shaft
Propeller shaft housing (regular rotation model) Checking the propeller shaft 1. Check: • Propeller shaft Damaged/worn  Replace. 2. Measure: • Propeller shaft runout Above specification  Replace. Runout 0.02 mm (0.0008 in) (F350BST, F350SA) A. Worldwide B. USA and Canada Driver rod L3 “4”...
Page 363: Assembling The Propeller Shaft Assembly
Propeller shaft housing (regular rotation model) Assembling the propeller shaft as- b. Install the cross pin “1”, and then install the spring “2”. sembly 1. Install: • Shift plunger “1” • Ball “2” • Slider “3” TIP: When installing the slider “3”, make sure that the balls “2”...
Page 364 Propeller shaft housing (regular rotation model) 1. Install: • Tapered roller bearing outer race “1” a. Heat the installation area of the tapered roller bearing outer race in the propeller shaft housing “2” using a gas torch, and then install a new tapered roller bearing outer race “1”.
Page 365 Propeller shaft housing (regular rotation model) A. Worldwide A. Worldwide B. USA and Canada B. USA and Canada Driver rod SS “3” Bearing inner race attachment “2” 90890-06604 90890-06642 Needle bearing attachment “4” Bearing cup installer “3” 90890-06653 YB-06167 Bearing depth plate “5” Driver handle (large) “4”...
Page 366: Installing The Propeller Shaft Housing Assembly
Propeller shaft housing (regular rotation model) 2. Install: • O-ring “1” • Propeller shaft housing assembly “2” A. Worldwide B. USA and Canada Bearing inner race attachment “2” 90890-06640 Driveshaft bearing installer “3” YB-06246 3. Install: Installation depth “a” • Reverse gear shim “1” 4.75–5.25 mm (0.187–0.207 in) •...
Page 367 Propeller shaft housing (regular rotation model) b. Turn the propeller shaft 10 turns or more, and then tighten the ring nut to the speci- fied torque. Ring nut 155 N·m (15.5 kgf·m, 114 lb·ft) c. Bend one of the 4 tabs on the claw washer outward, and then bend the other 3 tabs in- ward.
Page 368: Drive Shaft And Lower Case (Regular Rotation Model)
Drive shaft and lower case (regular rotation model) Drive shaft and lower case (regular rotation model) 39 N·m (3.9 kgf·m, 29 lb·ft) 180 N·m (18 kgf·m, 133 lb·ft) 165 N·m (16.5 kgf·m, 121 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Bolt M8 ...
Page 369: Removing The Drive Shaft
Drive shaft and lower case (regular rotation model) Removing the drive shaft 3. Remove: • Pinion 1. Remove: • Drive shaft • Oil seal housing • Pinion shim • Ring nut “1” • Washer • Spacer “2” Removing the forward gear 1.
Page 370: Disassembling The Forward Gear
Drive shaft and lower case (regular rotation model) b. Secure the drive shaft nut “1” on the drive Disassembling the forward gear shaft. c. Loosen the drive shaft nut “1”, and then re- • Use heat-resistant gloves. Otherwise, move the drive shaft nut “1” and claw burns could result.
Page 371: Disassembling The Lower Case
Drive shaft and lower case (regular rotation model) Disassembling the lower case • Use heat-resistant gloves. Otherwise, burns could result. • To prevent fires, remove any flammable substances, such as gasoline and oil, around the working area. • Keep good ventilation while working. 1.
Page 372: Checking The Drive Shaft
Drive shaft and lower case (regular rotation model) Checking the drive shaft 1. Check: • Drive shaft Damaged/worn  Replace. 2. Measure: • Drive shaft runout Above specification  Replace. Runout 0.3 mm (0.012 in) (F350BST, F350SA) Bearing inner race attachment “2” 90890-06640 Press load (bearing) 50 ...
Page 373 Drive shaft and lower case (regular rotation model) g. Tighten the drive shaft nut “1” to the spec- Press load (bearing) ified torque. 50  10³ N (5000 kgf, 11000 lbf) c. Turn the tapered roller bearing 10 turns or more to seat the bearing, and then press the drive shaft again using the specified load.
Page 374: Assembling The Forward Gear
Drive shaft and lower case (regular rotation model) Assembling the forward gear Assembling the lower case 1. Install: • Needle bearing “1” • Use heat-resistant gloves. Otherwise, burns could result. TIP: • To prevent fires, remove any flammable • Make sure to face the bearing identification substances, such as gasoline and oil, mark “a”...
Page 375: Assembling The Oil Seal Housing
Drive shaft and lower case (regular rotation model) Ball bearing attachment “2” Installation depth “a” 90890-06655 7.25–7.75 mm (0.258–0.305 in) Bearing outer race puller assem- bly “3” 2. Install: 90890-06523 • Oil seal “1” Driveshaft bearing installer “4” YB-06246 Pinion gear bushing installer “5” YB-06029 Roller bearing installer/remover “6”...
Page 376: Installing The Forward Gear
Drive shaft and lower case (regular rotation model) 3. Install: 2. Install: • Cover “1” • Pinion “1” • Pinion nut “2” • O-ring “2” a. Check that the drive shaft turns smoothly. TIP: • When installing the pinion “1”, lift up the drive shaft “3”...
Page 377 Drive shaft and lower case (regular rotation model) 3. Install: 4. Install: • Spacer “1” • Oil seal housing • Ring nut “2” TIP: • Make sure to face the cutout “a” in the oil seal housing “1” forward. The correct setting value of the torque wrench varies depending on its length.
Page 378: Shimming (Regular Rotation Model)
Shimming (regular rotation model) Shimming (regular rotation model) Shimming workflow 1. Disassemble the lower unit. 2. Select the forward gear shim (T1) and reverse gear shims (T2). 3. Install the forward gear and pinion temporarily. 4. Select the pinion shims (T3). 5.
Page 379: Shimming Check Sheet
Shimming (regular rotation model) Shimming check sheet Lower case deviation Serial number Remarks — — Pinion height Measurements (mm) Measuring point “a” Measuring point “b” Measuring point “c” Measuring point “d” Average Round-down average Forward gear backlash Measurements (mm) Measuring point “a” Measuring point “b”...
Page 380: Shimming Procedure
Shimming (regular rotation model) Shimming procedure • Shim thickness is specified for the forward gear shim (T1) and reverse gear shims (T2). • After selecting the pinion shims (T3), do not apply gear oil, grease or sealant to the lower unit parts and teeth of the gear to measure the backlash.
Page 381: Shim Location
Shimming (regular rotation model) Shim location 8-39...
Page 382: Selecting The Forward Gear Shim (T1) And Reverse Gear Shim (T2)
Shimming (regular rotation model) Selecting the forward gear shim (T1) and reverse gear shim (T2) 1. Select: • Forward gear shim (T1) • Reverse gear shim (T2) TIP: • Do not reuse shims. • For forward gear shim (T1), use only 1 shim to obtain the specified shim thickness.
Page 383 Shimming (regular rotation model) 4. Measure: d. Turn the drive shaft 90 clockwise and • Pinion distance measure the distance again. a. Check that the drive shaft turns smoothly. TIP: • Measure the distance at 4 points: “a”, “b”, “c”, b.
Page 384: Measuring The Forward Gear Backlash And Reverse Gear Backlash
Shimming (regular rotation model) Calculation formula: TIP: New pinion shim (T3) thickness = Current • If the shim thickness adjustment value is pos- pinion shim thickness + Shim thickness itive, increase the current shim thickness by adjustment that amount and, if the value is negative, de- crease the current shim thickness by that Example: amount.
Page 385 Shimming (regular rotation model) 1. Install: 5. Measure: • Adapter assembly • Forward gear backlash Out of specification  Repeat steps from • Specified forward gear shim (T1) the selection of the forward gear shim (T1) • Thrust bearing and reverse gear shims (T2). •...
Page 386 Shimming (regular rotation model) d. Turn the drive shaft slowly clockwise and Bearing housing puller claw L “1” counterclockwise, and then measure the 90890-06502 backlash between where the drive shaft Bearing housing puller “1” stops in each direction. YB-06207 TIP: Stopper guide plate “2”...
Page 387 Shimming (regular rotation model) f. Determine the backlash average, and then round down the average to 2 decimal plac- Example: (mm) Measurement point “a” 0.25 Measurement point “b” 0.26 Measurement point “c” 0.26 Measurement point “d” 0.24 Propeller nut “5” (shimming) Average 0.2525 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Page 388: Selecting The Propeller Shaft Shim (T4)
Shimming (regular rotation model) Shift rod socket “1” Reverse gear backlash 90890-06681 0.45–1.04 mm (0.0177–0.0409 in) (F350BST, F350SA) Shift rod socket “1” YB-06681 g. Remove the special service tools, and then install the water pump assembly. See d. While turning the shift rod toward the R po- “Installing the water pump”...
Page 389 Shimming (regular rotation model) b. Turn the propeller shaft 5 turns or more. Available shim thicknesses c. Install the washer “1” and propeller nut “2”. Propeller shaft shims 0.7/0.8/0.9/1.0/1.1/1.2 (F350BST, F350SA) d. Measure the motive torque of the propeller shaft. Propeller shaft motive torque 0.44–1.32 N·m (0.04–0.13 kgf·m, 0.32–0.97 lb·ft)
Page 390: Propeller Shaft Housing (Counter Rotation Model)
Propeller shaft housing (counter rotation model) Propeller shaft housing (counter rotation model) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 155 N·m (15.5 kgf·m, 114 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) Part name Q’ty...
Page 391 Propeller shaft housing (counter rotation model) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 155 N·m (15.5 kgf·m, 114 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) Part name Q’ty Remarks...
Page 392: Removing The Propeller Shaft Housing Assembly
Propeller shaft housing (counter rotation model) Removing the propeller shaft housing Disassembling the propeller shaft assembly housing assembly 1. Remove: 1. Remove: • Cover • Dog clutch See “Disassembling the propeller shaft as- 2. Remove: sembly” (8-19). • Ring nut •...
Page 393: Disassembling The Forward Gear
Propeller shaft housing (counter rotation model) Disassembling the forward gear 1. Remove: • Tapered roller bearing “1” • Thrust washer “2” Checking the dog clutch See “Checking the dog clutch” (8-20). Checking the propeller shaft housing See “Checking the propeller shaft housing” (8- 20).
Page 394 Propeller shaft housing (counter rotation model) 3. Install: • Propeller shaft • Tapered roller bearing a. Install the propeller shaft “1” and tapered roller bearing “2”. Ring nut wrench “4” 90890-06578 Gland nut wrench “4” YB-06578 b. Install the tapered roller bearing outer race 5.
Page 395: Installing The Propeller Shaft Housing Assembly
Propeller shaft housing (counter rotation model) 6. Install: b. Turn the drive shaft and check that the pro- • Dog clutch “1” peller shaft housing assembly “2” is in- stalled securely. a. Install the dog clutch “1” so that the hole “a” in the dog clutch “1”...
Page 396: Drive Shaft And Lower Case (Counter Rotation Model)
Drive shaft and lower case (counter rotation model) Drive shaft and lower case (counter rotation model) 39 N·m (3.9 kgf·m, 29 lb·ft) 180 N·m (18 kgf·m, 133 lb·ft) 165 N·m (16.5 kgf·m, 121 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Bolt M8 ...
Page 397 Drive shaft and lower case (counter rotation model) Removing the drive shaft Installing the reverse gear See “Removing the drive shaft” (8-27). 1. Install: • Adapter assembly “1” Removing the reverse gear • Reverse gear shim “2” 1. Remove: • Thrust bearing “3” •...
Page 398 Shimming (counter rotation model) Shimming (counter rotation model) Shimming workflow 1. Disassemble the lower unit. 2. Select the reverse gear shim (T1) and forward gear shims (T2). 3. Install the reverse gear and pinion temporarily. 4. Select the pinion shims (T3). 5.
Page 399 Shimming (counter rotation model) Shimming check sheet Lower case deviation Serial number Remarks — — Pinion height Measurements (mm) Measuring point “a” Measuring point “b” Measuring point “c” Measuring point “d” Average Round-down average Forward gear backlash Measurements (mm) Measuring point “a” Measuring point “b”...
Page 400 Shimming (counter rotation model) Shimming procedure • Shim thickness is specified for the reverse gear shim (T1) and forward gear shims (T2). • After selecting the pinion shims (T3), do not apply gear oil, grease or sealant to the lower unit parts and teeth of the gear to measure the backlash.
Page 401 Shimming (counter rotation model) Shim location 8-59...
Page 402 Shimming (counter rotation model) Selecting the reverse gear shim (T1) b. Obtain the calculated value (B) based on marks (P) and (H) on the pinion. and forward gear shim (T2) 1. Select: • Reverse gear shim (T1) • Forward gear shim (T2) TIP: •...
Page 403 Shimming (counter rotation model) Selecting the propeller shaft shim (T4) Free play 1. Install: 0.25–0.35 mm (0.0098–0.0138 • Original propeller shaft shim (T4) in) (FL350BST, LF350SA) See steps (2)–(7) in “Assembling the pro- peller shaft housing and forward gear” (8- 51).
Page 404 Shimming (counter rotation model) Measuring the forward gear backlash and reverse gear backlash (mm) • Spray anti-rust lubricant on the gear and bearings before installation. Do not apply gear oil to the parts. Otherwise, correct mea- surements cannot be obtained. +0.7 +0.8 •...
Page 405 Shimming (counter rotation model) 3. Install: b. Set up the special service tools “1”, “2”, and “3”, and then tighten the center bolt “3” • Specified forward gear shims (T2) to the specified torque. • Propeller shaft assembly • Propeller shaft housing assembly •...
Page 406 Shimming (counter rotation model) f. Turn the drive shaft 180 clockwise, and then measure the backlash again. TIP: • Measure the backlash at 4 points: “a”, “b”, “c”, and “d”, turning the drive shaft 180 clockwise after each measurement. • Write down the measurement data in the “Shimming check sheet”.
Page 407 Shimming (counter rotation model) Forward gear backlash 0.43–0.97 mm (0.0169–0.0382 in) (FL350BST, LF350SA) i. Remove the special service tools from the propeller shaft. 6. Measure: • Reverse gear backlash Out of specification  Repeat steps from the selection of the reverse gear shim (T1) and forward gear shims (T2).
Page 408 Shimming (counter rotation model) 7. Install: • Cover “1” • Cover bolt “2” Cover bolt “2” 8 N·m (0.8 kgf·m, 5.9 lb·ft) Specified torque 10 N·m (1.0 kgf·m, 7.4 lb·ft) e. Repeat steps (5) (f)–(h) to measure the re- verse gear backlash. f.
Page 409: Bracket Unit
Bracket unit Molding ................9-1 Shift rod and SPS ............... 9-2 Installing the shift rod and SPS ..........9-3 PTT switch and cowling lock lever ........9-4 Installing the flushing hose ............9-6 Installing the SBW harness ............9-6 Installing the PTT sensor lead............ 9-6 Bottom cowling ..............
Page 410 Bracket unit Clamp bracket and swivel bracket ......... 9-25 Removing the clamp bracket............ 9-26 Checking the clamp bracket anode .......... 9-26 Assembling the swivel bracket ..........9-26 Installing the clamp bracket............9-27 PTT unit ................9-28 Removing the PTT unit............. 9-29 Checking the hydraulic pressure ..........
Page 411: Molding
Molding Molding 8 N·m (0.8 kgf·m, 5.9 lb·ft) Part name Q’ty Remarks Nut M6 Molding Washer Sheet Spring nut...
Page 412: Shift Rod And Sps
Shift rod and SPS Shift rod and SPS Part name Q’ty Remarks Clip Shift lever Bolt M6  25 mm Bushing Washer Circlip Shift rod O-ring Bushing Bracket Dowel pin Grommet...
Page 413: Installing The Shift Rod And Sps
Shift rod and SPS Installing the shift rod and SPS 1. Install: • Bushing • Grommet • Dowel pin • Bracket • O-ring • Shift rod • Circlip • Washer • Bushing 2. Install: • SPS a. Fit the protrusion “a” on the SPS “1” into the slot “b”...
Page 414: Ptt Switch And Cowling Lock Lever
PTT switch and cowling lock lever PTT switch and cowling lock lever Part name Q’ty Remarks Part name Q’ty Remarks Bolt M6  12 mm Clamp Bracket Bracket Joint Clamp Hose Bracket Joint Clamp Joint Bracket Gasket Screw M6  20 mm Bracket Holder Adapter...
Page 415 PTT switch and cowling lock lever Part name Q’ty Remarks Cowling lock lever (STBD) Cowling lock lever (PORT) Cowling lock lever (front)
Page 416: Installing The Flushing Hose
PTT switch and cowling lock lever Installing the flushing hose 1. Install: • Grommet “1” (to the bottom cowling) • Flushing hose “2” TIP: Align the white paint “a” on the flushing hose “2” with the outer end of the grommet “1”. Installing the PTT sensor lead 1.
Page 417 Bottom cowling Bottom cowling Part name Q’ty Remarks Part name Q’ty Remarks Bolt M8  35 mm Bracket Collar Rubber seal Grommet Cap seal Grommet Bolt M6  16 mm Bracket Grommet Collar Grommet Bottom cowling Rubber seal Rubber seal Oil dipstick Bolt M6 ...
Page 418: Upper Case And Mounts
Upper case and mounts Upper case and mounts 55 N·m (5.5 kgf·m, 41 lb·ft) 72 N·m (7.2 kgf·m, 53 lb·ft) 54 N·m (5.4 kgf·m, 40 lb·ft) 72 N·m (7.2 kgf·m, 53 lb·ft) 54 N·m (5.4 kgf·m, 40 lb·ft) Part name Q’ty Remarks Part name...
Page 419: Removing The Upper Case
Upper case and mounts Removing the upper case 1. Drain: • Engine oil 2. Remove: • Upper case TIP: Before removing the upper case, loosen the upper mount bolts “1” and lower mount cover bolts (PORT and STBD) “2”. 2. Install: •...
Page 420 Upper case and mounts Upper mounting nut “3” 72 N·m (7.2 kgf·m, 53 lb·ft) Lower mounting nut “4” 72 N·m (7.2 kgf·m, 53 lb·ft) 4. Tighten: • Upper mount bolt • Lower mount bolt (PORT and STBD) a. Tighten the upper mount bolts “1” to the specified torque in the order [1], [2], and so b.
Page 421 Upper case and mounts 5. Install: • Ground lead “1” • Adapter “2” 9-11...
Page 422: Upper Case
Upper case Upper case 27 N·m (2.7 kgf·m, 20 lb·ft) 3.9 N·m (0.39 kgf·m, 2.9 lb·ft) 42 N·m (4.2 kgf·m, 31 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) Part name Q’ty Remarks Drain bolt M14  12 Gasket Bolt M6  12 mm Cover Damper Bolt M10 ...
Page 423: Disassembling The Upper Case
Upper case Disassembling the upper case b. Remove the special service tool (holder) “3”, and then connect the special service 1. Remove: tools “4” and “5” or “4” and “6” to the spe- • Circlip “1” cial service tool (rod) “2”. •...
Page 424: Checking The Exhaust Guide Anode
Upper case Puller head “4” 90890-06514 Slide hammer “4” YB-06096 Slide hammer handle “5” 90890-06531 Propeller shaft and bearing hous- ing remover “6” YB-06335 Checking the exhaust guide anode 1. Check: • Anode A. Worldwide Eroded (1/2 or more worn out)  Replace. B.
Page 425 Upper case 3. Install: Oil pan assembly bolt (M8) “6” • Dowel pin “1” 20 N·m (2.0 kgf·m, 15 lb·ft) • Rubber seal “2” Oil pan assembly bolt (M10) “7” • Rubber seal “3” 42 N·m (4.2 kgf·m, 31 lb·ft) •...
Page 426: Oil Pan And Exhaust Manifold
Oil pan and exhaust manifold Oil pan and exhaust manifold 12 N·m (1.2 kgf·m, 8.9 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) Part name Q’ty Remarks...
Page 427: Checking The Oil Pan And Exhaust Manifold
Oil pan and exhaust manifold Checking the oil pan and exhaust 2. Install: • Oil pan “1” manifold • Oil pan bolt “2” (temporarily tighten) 1. Clean: • Removed parts 2. Check: • Exhaust guide • Exhaust manifold • Muffler •...
Page 428 Oil pan and exhaust manifold [10] [13] [11] [12] [14] Muffler bolt “6” Oil pan bolt 1st: 20 N·m (2.0 kgf·m, 15 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 2nd: 20 N·m (2.0 kgf·m, 15 lb·ft) Exhaust manifold bolt “4” 20 N·m (2.0 kgf·m, 15 lb·ft) 4.
Page 429: Steering Actuator And Steering Arm
Steering actuator and steering arm Steering actuator and steering arm 27 N·m (2.7 kgf·m, 20 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 13 N·m (1.3 kgf·m, 9.6 lb·ft) 68 N·m (6.8 kgf·m, 50 lb·ft) Part name Q’ty...
Page 430: Removing The Power Steering Unit
Steering actuator and steering arm Removing the power steering unit c. Remove the steering actuator brackets “1” and “2”. 1. Remove: • Clamp bracket side cover “1” • Swivel bracket top cover “2” d. Turn the shaft “a” of the steering actuator “1”...
Page 431: Removing The Steering Arm
Steering actuator and steering arm f. Remove the steering arm joint “1”, and Needle bearing attachment “2” then remove the steering actuator “2”. 90890-06612 Driveshaft bearing installer “2” YB-06155 Gear puller “3” (commercially available) Checking the steering arm and steer- ing arm joint 1.
Page 432: Installing The Steering Actuator
Steering actuator and steering arm Installing the steering actuator If the steering actuator is removed, the calibra- tion is required after installation. See “Calibra- tion (6X9 Digital Electronic Control)” (3-37). b. Hold the steering arm “1”, and then strike 1. Install: the steering yoke “2”...
Page 433 Steering actuator and steering arm Length “b” 20 mm (0.79 in) b. Install the guide “1”, and then install the SCU positive terminal bolt “1” steering arm joint “2”. 13 N·m (1.3 kgf·m, 9.6 lb·ft) Terminal cover bolt “4” 1st: 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 2nd: 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 2.
Page 434 Steering actuator and steering arm d. Turn the shaft “a” of the steering actuator f. Tighten the guide bolts “1” and steering “1” clockwise to position the shaft in the arm joint bolts “2”. center steering position. Steering arm joint bolt “2” e.
Page 435: Clamp Bracket And Swivel Bracket
Clamp bracket and swivel bracket Clamp bracket and swivel bracket 36 N·m (3.6 kgf·m, 27 lb·ft) 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 13 16 17 16 13 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Bolt M6 ...
Page 436: Removing The Clamp Bracket
Clamp bracket and swivel bracket Removing the clamp bracket 2. Assemble: • Pin 1. Remove: • Distance collar • PTT unit See “Removing the PTT unit” (9-29). Checking the clamp bracket anode 1. Check: • Anode Eroded (1/2 or more worn out)  Replace. Adhered grease, oil, paint, or scales ...
Page 437: Installing The Clamp Bracket
Clamp bracket and swivel bracket Installing the clamp bracket 1. Install: • Grease nipple • Clamp bracket • Bushing • Clamp bracket anode • Plate • Ground lead Grease nipple 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 2. Inject: • Grease TIP: Inject grease into the grease nipples “1”...
Page 438 PTT unit PTT unit 42 N·m (4.2 kgf·m, 31 lb·ft) 42 N·m (4.2 kgf·m, 31 lb·ft) 3.6 N·m (0.36 kgf·m, 2.7 lb·ft) Part name Q’ty Remarks Plastic tie Cover Lead Bolt M5  15 mm Sensor O-ring Bolt M5  15 mm Adapter Shaft O-ring...
Page 439: Removing The Ptt Unit
PTT unit Removing the PTT unit d. Push in the pin “1” to the mark “a” position on the pin-extraction tool, and then remove the shaft “2”. When removing or installing the PTT unit TIP: with the power unit or upper case assembly Be careful not to push the pin in too much, be- installed, make sure to suspend the out- cause the pin might fall into the swivel bracket...
Page 440: Checking The Hydraulic Pressure
PTT unit Checking the hydraulic pressure d. If the fluid is below the proper level, add the recommended fluid. 1. Check: • PTT fluid level e. Install the reservoir cap, and then tighten it a. Place the PTT unit in an upright position. to the specified torque.
Page 441 PTT unit i. Loosen the pipe joints “3”, and then re- move the pipe joint at the end “a”. j. Install the special service tool “1”. Hydraulic pressure Down 7.70 Mpa (77.0 kgf/cm², 1116.5 psi) PTT motor lead Battery Green (G) Retract Blue (L) (–)
Page 442: Bleeding The Ptt Unit
PTT unit Hydraulic pressure 15.00 (150.0 kgf/cm², 2175.0 psi) PTT motor lead Battery Blue (L) Extend Green (G) (–) l. Reverse the connection between battery jumper leads and the PTT motor lead “1” to fully retract the trim rams. Pipe joint “1” 15 N·m (1.5 kgf·m, 11 lb·ft) PTT motor lead Battery...
Page 443: Installing The Ptt Unit
PTT unit c. Check the fluid level. See step (1) in h. Remove the reservoir cap, and then check “Checking the hydraulic pressure” (9-30). the fluid level in the reservoir. d. Connect the battery jumper leads to the PTT motor lead “1” to fully retract the PTT Before removing the reservoir cap, make rams.
Page 444 PTT unit b. Install the bushings “1” and PTT unit “2”. When removing or installing the PTT unit, do not hold the PTT unit using the tilt cylin- der. Otherwise, the pipe could break, caus- ing PTT fluid to leak. 2.
Page 445 PTT unit PTT motor lead Battery Blue (L) Extend Green (G) (–) b. Assemble the PTT sensor “1”, a new O- ring “2”, and the adapter “3”. e. Put a mark “a” on the specified length “b” on the pin-extraction tool. PTT sensor bolt 3.6 N·m (0.36 kgf·m, 2.7 lb·ft) c.
Page 446 PTT unit g. Fasten the PTT sensor lead “1” using the plastic tie “2” as shown, and then route it through the hole “a” in the swivel bracket. h. Fully tilt the swivel bracket down. 9-36...
Page 447: Ptt Motor
PTT motor PTT motor 7 N·m (0.7 kgf·m, 5.2 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) 15 N · m (1.5 kgf · m, 11 lb ·ft ) Part name Q’ty Remarks Part name Q’ty Remarks Reservoir cap M12 ...
Page 448: Removing The Reservoir
PTT motor Removing the reservoir 2. Measure: • Commutator diameter “a” Out of specification  Replace the arma- Before removing the reservoir, make sure ture. that the PTT rams are fully extended. Other- wise, fluid could be expelled forcefully from the PTT unit due to internal pressure.
Page 449: Checking The Brush
PTT motor Motor base assembly continuity “a” “b” “c” “d” “e” “f” Armature continuity 3. Check: “a” “b” “c” “d” • PTT motor base assembly Cracked/damaged  Replace the PTT motor assembly. Checking the brush 1. Measure: Checking the reservoir •...
Page 450: Installing The Reservoir
PTT motor 2. Install: Installing the reservoir • Armature “1” 1. Install: • Spacer a. Push the brushes “2” into the holders, and • Filter then install the armature “1”. • Sheet • O-ring • Reservoir • Reservoir cap Reservoir mounting bolt 15 N·m (1.5 kgf·m, 11 lb·ft) Reservoir cap 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Page 451 PTT motor 3. Install: • O-ring • PTT motor assembly “1” TIP: Align the protrusion “a” on the armature shaft with the slot “b” in the joint. PTT motor mounting bolt 15 N·m (1.5 kgf·m, 11 lb·ft) 4. Fasten: • PTT motor lead TIP: •...
Page 452: Ptt Gear Pump
PTT gear pump PTT gear pump 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Circlip Valve seal Bolt M5  25 mm Manual valve O-ring Bracket...
Page 453 PTT gear pump 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Part name Q’ty Remarks Up-main valve E-clip Main valve seal Down-main valve O-ring 9-43...
Page 454: Disassembling The Gear Pump Assembly
PTT gear pump Disassembling the gear pump assem- 1. Remove: • Valve lock screw “1” • Spring “2” • Valve support pin “3” • Ball “4” • Spring “5” • Valve pin “6” • Valve seal “7” TIP: Before removing the valve lock screws “1”, measure and write down the screw depth “a”...
Page 455 PTT gear pump 1. Install: • O-ring “1” (to down-main valve “4”) • Main valve seal “2” (to down-main valve “4”) • E-clip “3” (to down-main valve “4”) • Down-main valve “4” • Main valve seal “5” (to up-main valve “7”) •...
Page 456: Installing The Gear Pump Assembly
PTT gear pump Gear pump bolt “8” 7 N·m (0.7 kgf·m, 5.2 lb·ft) Manual valve “10” 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) A. Down-relief valve B. Up-relief valve Installation depth “a” (reference data) 1.46–2.90 mm (0.0575–0.1142 Installation height “b” (reference data) 1.09–1.40 mm (0.0429–0.0551 Installing the gear pump assembly...
Page 457: Ptt Cylinder
PTT cylinder PTT cylinder 290 N·m (29 kgf·m, 214 lb·ft) 90 N·m (9.0 kgf·m, 66 lb·ft) 65 N·m (6.5 kgf·m, 48 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) Part name Q’ty...
Page 458: Removing The Tilt Ram
PTT cylinder Removing the tilt ram 4. Remove: • Free piston a. Cover the tilt cylinder using a rag “1”, and Before removing the tilt cylinder end screw, then blow compressed air through the hole make sure that the PTT rams are fully ex- “a”...
Page 459: Disassembling The Tilt Ram
PTT cylinder Disassembling the tilt ram Checking the tilt cylinder and trim cyl- 1. Remove: inder • Tilt piston absorber valve “1” 1. Check: • PTT body • Tilt cylinder Corroded/cracked  Replace. 2. Check: • Inner surface of the PTT body •...
Page 460 PTT cylinder 1. Install: Tilt ram “1” • Dust seal “1” (to tilt cylinder end 65 N·m (6.5 kgf·m, 48 lb·ft) screw “5”) • Backup ring “2” (to tilt cylinder end screw 4. Install: “5”) • O-ring “1” • O-ring “3”, “4” (to tilt cylinder end •...
Page 461: Assembling The Trim Ram
PTT cylinder Assembling the trim ram Installing the tilt cylinder When assembling the PTT unit, do not use When assembling the PTT unit, do not use a rag. Otherwise, dust and particles could a rag. Otherwise, dust and particles could get on the PTT unit components, causing get on the PTT unit components, causing poor performance.
Page 462: Installing The Trim Ram
PTT cylinder Installing the trim ram Installing the tilt ram When assembling the PTT unit, do not use When assembling the PTT unit, do not use a rag. Otherwise, dust and particles could a rag. Otherwise, dust and particles could get on the PTT unit components, causing get on the PTT unit components, causing poor performance.
Page 463 PTT cylinder 3. Install: • Tilt ram assembly • Tilt cylinder end screw “1” A. Worldwide B. USA and Canada Cylinder end screw wrench “2” 90890-06591 Trim cylinder wrench “3” YB-06175-2B Tilt cylinder end screw “1” 90 N·m (9.0 kgf·m, 66 lb·ft) 4.
Page 464: Maintenance
Maintenance Outline ................10-1 Maintenance interval chart 1 ............ 10-1 Maintenance interval chart 2 ............ 10-3 Predelivery check............. 10-4 Checking the engine oil level............ 10-7 Checking the battery ..............10-7 Checking the cooling water pilot hole........10-8 Checking the gear oil level ............10-8 Checking the power trim and tilt unit ........
Page 465: Maintenance Interval Chart
• If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and quality. Any parts of inferior quality may cause a malfunction, and the resulting loss of control could endanger the operator and passengers.
Page 466 Outline Initial Every Item Actions 20 hours 100 hours 300 hours 500 hours (3 months) (1 year) (3 years) (5 years) Engine oil filter (car- ●/○ Replacement tridge) Fuel filter (can be disas- Inspection or replace- ●/○ ●/○ sembled) ment as necessary Fuel line (High pres- ●...
Page 467 Connector connections/ Inspection or replace- ○ ○ lead connections ment as necessary ○ ○ (Yamaha) Meter/gauge Inspection DES (Digital Electric Inspection or replace- ○ ○ ○ ○ Steering) ment as necessary *1 cylinder head exhaust passage...
Page 468: Predelivery Check
Predelivery check Predelivery check To make the delivery process smooth and efficient, complete the predelivery checks as explained in the following procedures. Item Procedures Check the oil level using the dipstick. Engine oil level 10-7 Oil is not at the proper level  Add or extract engine oil. Check the battery electrolyte level.
Page 469 Predelivery check Item Procedures Outboard motor Check the outboard motor mounting height. 10-9 Improper  Adjust. mounting height Check the PTT unit operation. 10-20 Not smooth  Check the PTT fluid level. 9-28 Check that there is no abnormal noise produced when the out- 9-37 board motor is tilted up or down.
Page 470 Predelivery check Item Procedures Check for water in the gear oil. Oil is milky  Check the lower case for airtightness and oil seal. Check all the fuel lines for leakage. 2-38 Leaking  Check the connection or replace affected parts. After test run Flush the cooling water passages using fresh water.
Page 471: Checking The Engine Oil Level
Predelivery check Checking the engine oil level Checking the battery Make sure that the engine is filled with en- Battery electrolyte is dangerous; it con- gine oil before operating the outboard mo- tains sulfuric acid, which is poisonous and tor for the first time. Otherwise, the engine highly caustic.
Page 472: Checking The Cooling Water Pilot Hole
Predelivery check 2. Check: Checking the cooling water pilot hole • Specific gravity of the electrolyte 1. Place the lower unit in water, and then start Below specification  Fully charge the the engine. battery. 2. Check: TIP: • Cooling water is discharged from the cool- •...
Page 473: Checking The Outboard Motor Mounting Height
Predelivery check Checking the outboard motor mount- ing height 1. Check: • Outboard motor mounting height Improper  Adjust. a. Check that the anti-cavitation plate “1” is aligned with the bottom of the boat “2”. TIP: • If the mounting height is too high, cavitation will occur and propulsion will decrease.
Page 474: General Periodic Maintenance
General periodic maintenance General periodic maintenance Item Procedures 7-62 7-57 Check the anodes. 7-68 Eroded (1/2 or more worn out)  Replace. Anodes 7-88 Adhered grease, oil, paint, or scales  Clean. 9-14 9-26 Check the battery electrolyte level. Below the minimum level mark  Add distilled water. Battery 10-7 Check the specific gravity of the electrolyte.
Page 475 General periodic maintenance Item Procedures Check the fuel filter element. Dirt/residue  Replace. Water accumulated  Drain. Checking the fuel cup assembly. Foreign material  Clean. Fuel filter Cracked  Replace. Checking the fuel inlet or fuel outlet holding pressure. Out of specification ...
Page 476 Cracked/worn  Replace. Check the impeller key and keyway in the drive shaft. Deformed/worn  Replace. Wire harness Check the wire harness coupler and lead connector connections. — (Yamaha) Check the meter/gauge display. — Meter/gauge Check that the steering operates smoothly. 9-19 Not smooth ...
Page 477: Checking The Engine Idle Speed
General periodic maintenance Checking the cooling water inlet Checking the engine idle speed 1. Check: 1. Check: • Cooling water inlet • Engine idling speed Clogged  Clean. Out of specification  Perform the trouble- shooting procedures. See “Troubleshoot- a. Remove the water inlet covers “1”, “2”, out- ing procedure”...
Page 478 General periodic maintenance 3. Drain: b. Leave the outboard motor off for 5–10 min- • Engine oil utes. a. Remove the oil filler cap “1”. c. Remove the dipstick “1” and wipe it clean. d. Insert the dipstick “1” completely for a cor- rect measurement and remove it again.
Page 479 General periodic maintenance 2. Remove: 4. Install: • Top cowling • Gasket “1” • Apron “1” • Drain bolt “2” a. Install a new gasket “1” and then tighten the drain bolt “2” with specified torque. Drain bolt “2” 3. Drain: 27 N·m (2.7 kgf·m, 20 lb·ft) •...
Page 480: Replacing The Oil Filter
General periodic maintenance e. Check that the oil level indicated on the Replacing the oil filter dipstick “1” is between the upper mark “a” 1. Warm up: and the lower mark “b”. • Engine See step (1) in “Changing the engine oil using an oil changer”...
Page 481: Changing The Gear Oil
General periodic maintenance b. Install a new oil filter “1”. Changing the gear oil Never get under the lower unit while it is tilt- 1. Remove: • Water inlet cover “1”, “2” Oil filter “1” 18 N·m (1.8 kgf·m, 13 lb·ft) 5.
Page 482 General periodic maintenance e. After the gear oil has been drained, check Gear oil quantity the used oil. Pressure test the lower case 0.885 L (0.935 US qt, 0.779 and inspect the oil seal for damage if the oil Imp.qt) (FL350BST, LF350SA) is milky.
Page 483: Greasing Points
General periodic maintenance Greasing points 1. Apply: • Specified lubrication points a. Apply water resistant grease to the speci- fied lubrication points. b. Apply low temperature resistant grease to the specified lubrication point. c. Apply corrosion resistant grease to the specified lubrication point.
Page 484: Checking The Ptt Fluid Level
General periodic maintenance Checking the PTT fluid level 2. Install: • O-ring • Reservoir cap Never get under the outboard motor while it is tilted. Reservoir cap 7 N·m (0.7 kgf·m, 5.2 lb·ft) 1. Check: Checking the cowling lock lever •...
Page 485 General periodic maintenance c. Tighten the cowling stopper nut. d. Recheck the fitting. Replace the rubber seal if looseness or rattling cannot be ad- justed. 10-21...
Page 486 Appendix Specification ...............A-1 Model data.................. A-1 Electrical system technical data ..........A-2 Fuel system technical data............A-4 Power unit technical data ............A-5 Lower unit technical data............A-7 Bracket unit technical data ............A-7 Wiring diagram ..............A-9 How to use the wiring diagram ........... A-9 Engine control unit..............
Page 487 F350B FL350B Specification Model F350SA LF350SA Model data Maximum generator out- 74 A Dimension and weight Maximum charging F350B FL350B 50 A Model capacity F350SA LF350SA Spark plug (NGK) ILMAR7E-9 Overall length 1026 mm (40.4 in) Firing order 1-2-3-4-5-6 Overall width 634 mm (25.0 in)
Page 488 F350B FL350B PTT system Model F350SA LF350SA F350B FL350B Model Recommended engine SAE 10W-30/10W-40/5W-30 F350SA LF350SA oil grade 1 API SG/SH/SJ/SL ATF Dexron II (F350BST, ATF Dexron II (FL350BST, Recommended engine SAE 15W-40/20W-40/20W-50 F350SA_*EE1/*EE2) LF350SA_*EE1/*EE2) oil grade 2 API SH/SJ/SL...
Page 489 F350B FL350B F350B FL350B Model Model F350SA LF350SA F350SA LF350SA Resistance at 25 °C (77 TPS 2 output voltage at 1.90–2.10 kΩ °F) (reference data) throttle valve fully closed 2.969 V (reference data) Resistance at 100 °C 0.16–0.20 kΩ TPS 1 output voltage at (212 °F) (reference data)
Page 490 F350B FL350B Starting system Model F350SA LF350SA F350B FL350B Model Rod stroke at gear shift F350SA LF350SA in the N position (refer- 64.6 mm (2.54 in) Starter motor ence data) Type Sliding gear Rod stroke at gear shift Output 1.70 kW in the R position (refer- 37.2 mm (1.46 in)
Page 491 F350B FL350B Cylinder head assembly Model F350SA LF350SA F350B FL350B Model Fuel pressure at idle F350SA LF350SA 260 kPa (2.6 kgf/cm², 37.7 psi) speed Cylinder head Primer pump Warpage limit 0.10 mm (0.0039 in) Positive pressure 166.7 kPa (1.67 kgf/cm², 24.2 psi) Journal inside diameter 25.000–25.021 mm (0.9843–0.9851 in)
Page 492 F350B FL350B F350B FL350B Model Model F350SA LF350SA F350SA LF350SA Runout limit IN 0.01 mm (0.0004 in) Piston ring (Top) Runout limit EX 0.01 mm (0.0004 in) Type Barrel Valve guide Height (B) 1.170–1.185 mm (0.0461–0.0467 in) Inside diameter IN 5.504–5.522 mm (0.2167–0.2174 in)
Page 493 F350B FL350B Lower unit assembly (counter rotation model) Model F350SA LF350SA F350B FL350B Model Journal oil clearance F350SA LF350SA 0.029–0.045 mm (0.0011–0.0018 in) (J1) Lower unit Journal oil clearance 0.029–0.045 mm (0.0011–0.0018 in) Holding pressure — 68.6 kPa (0.69 kgf/cm², 9.9 psi)
Page 494 F350B FL350B Model F350SA LF350SA Standard commutator 1.50 mm (0.0591 in) undercut Wear limit 1.00 mm (0.0394 in) Standard brush length 11.50 mm (0.4528 in) Wear limit 6.5 mm (0.26 in)
Page 495: Wiring Diagram
Wiring diagram Wiring diagram How to use the wiring diagram Composition of the wiring diagrams The wiring diagram consists of five categories: “Engine control unit”, “Fuel unit”, “Ignition unit”, “Charging unit and starting unit”, and “PTT unit and steering unit”. Legend symbols in the wiring diagrams 1.
Page 496 Mar. 2024 ABE (E_1)
Page 497 Engine control unit 1. Engine ECM 4. Shift 2. OCV (PORT) 2. OCV 3. OCV actuator 5. Bonder 3 (PORT) (STBD) 3. OCV (STBD) 4. Shift actuator 5. Bonder 3 6. Battery 6. Battery 7. House (accessory) battery 8. Fuse holder 9.
Page 498 Fuel unit 1. Engine ECM 2. Fuel injector 5. Low-pressure 6. Bonder 3 2. Fuel injector 3. Vapor shut-off 4. High-pressure fuel pump valve fuel pump 3. Vapor shut-off valve 4. High-pressure fuel pump 5. Low-pressure fuel pump 6. Bonder 3 7.
Page 499 Ignition unit 1. Engine ECM 2. Ignition coil 3. Bonder 3 2. Ignition coil 3. Bonder 3 4. Battery 5. House (accessory) battery 6. Pulser coil 4. Battery 7. Fuse holder 8. Joint connector 5 9. Knock sensor 5. House (accessory) 10.
Page 500 Charging unit and starting unit 1. Engine ECM 2. Bonder 3 2. Bonder 3 3. Starter motor 4. Battery 5. House (accessory) battery 6. Lighting coil 3. Starter motor 4. Battery 7. Rectifier/regulator/isolator 8. Fuse holder 5. House 9. Joint connector 5 (accessory) battery a.
Page 501 PTT unit and steering unit 1. Engine ECM 2. Bonder 3 3. PTT relay 2. Bonder 3 3. PTT relay 4. PTT motor 4. PTT motor 5. Starter motor 6. Battery 18. Diode 6. Battery 7. House (accessory) battery 8. Steering actuator 5.
Page 502 Rectifier/regulator/isolator continuity table Rectifier/regulator/isolator continuity table OL: Indicates an overload Rectifier/regulator/isolator for continuity Tester probe Display value (reference data) (–) “d” “a” Except for “d” “b” All terminals “c” All terminals “a” “d” Except for “a” “a”, “b” and “c” 0.4–0.5 V “e”...
Page 503 Rectifier/regulator/isolator continuity table Rectifier/regulator/isolator for continuity Tester probe Display value (reference data) (–) “k” and “l” 0.4–0.5 V “h” Except for “k” and “l” “k” and “l” 0.4–0.5 V “i” Except for “k” and “l” “k” and “l” 0.4–0.5 V “j”...
Page 504 Shim selection table and chart (regular rotation model) Calculated value (B) table (mm) –010 –009 –008 –007 –006 –005 –004 –003 –002 –001 +001 +002 +003 +004 +005 +006 +007 +008 +009 +010 0.65 0.66 0.67 0.68 0.69 0.70 0.71 0.72 0.73 0.74...
Page 505 Pinion shim (T3) selection table (mm) 0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.46 0.47 0.48 0.49 0.50 0.51 0.52 0.53 0.54 0.55 0.56 0.55 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23...
Page 506 (mm) 0.87 0.88 0.89 0.90 0.91 0.92 0.93 0.94 0.95 0.96 0.97 0.98 0.99 1.00 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 0.55 –0.32 –0.33 –0.34 –0.35 –0.36 –0.37 –0.38 –0.39 –0.40 –0.41 –0.42 –0.43 –0.44 –0.45 –0.46 –0.47 –0.48 –0.49 –0.50...
Page 507 Shim selection table and chart (counter rotation model) Calculated value (B) table See “Calculated value (B) table” (A-17). Pinion shim (T3) selection table See “Pinion shim (T3) selection table” (A-18). Propeller shaft shim (T4) selection table (mm) –0.3 –0.2 –0.1 +0.1 +0.2 +0.3 +0.4 +0.5 +0.6 +0.7 +0.8 +0.9 +1.0 +1.1 +1.2 +1.3 +1.4 +1.5 +1.6 +1.7 +1.8 +1.9 +2.0 +2.1 +2.2 +2.3 +2.4 +2.5 +2.6 A.
Page 508 Worldwide: (6ML) (6MM) USA, CAN, AUS, and NZL: (6ML) (6MM) 6ML-28197-Z4-11 ● LIT-18616-04-35 Mar. 2024 ABE (E_1)

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