Yamaha F250N Service Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Outboard Motor
  5. F250N
  6. Service manual
Yamaha F250N Service Manual

Yamaha F250N Service Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
Table of Contents

Advertisement

Quick Links

6KA-28197-Z3-11
LIT-18616-04-31
●
Worldwide:
USA, CAN, EUR, AUS and NZL:
(6KD)
(6KE)
(6KA)
(6KB)
(6KD)
(6KE)
(6KA)
(6KB)

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the F250N and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Yamaha F250N

Summary of Contents for Yamaha F250N

  • Page 1 Worldwide: (6KD) (6KE) (6KA) (6KB) USA, CAN, EUR, AUS and NZL: (6KD) (6KE) (6KA) (6KB) ● 6KA-28197-Z3-11 LIT-18616-04-31...
  • Page 2 Preface This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained tech- nicians when performing maintenance procedures and repairs to Yamaha equipment. It has been writ- ten to suit the needs of persons who have the Bronze Technical Certificate of the YTA (Yamaha...

  • 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. F300FST 1000001– FL300FST 1000001– F250NST 1000001– FL250NST 1000001– USA, CAN, EUR, AUS and NZL Model name Approved model code Starting serial No.
  • Page 6 Model information USA, CAN, EUR, AUS and NZL LF 300 X S B 2 F: 4-stroke Model category L: Counter rotating propeller Horsepower 250/300 X: 25 in Motor transom height N: Without lower unit Starting method/PTT Blank: PTT and electric start Blank: Remote control Control method S: Built-in SBW and electric start...

  • Page 7: General Feature

    Model information General feature • Electronic fuel injected, 4-stroke, V6, DOHC, 24-valve, 4169 cm³ (254.4 cu. in) engine • Low exhaust emissions conform to EU1, 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: Self-Protection

    • Lift and suspend the outboard motor in a sta- parts, lubricants, or sealants that are not equiv- ble manner using the designated lifting at- alent in design and quality to genuine Yamaha tachment points. parts, lubricants, or sealants will not be cov- •...

  • Page 10: Handling Of Lubricants And Sealants

    Important safety and service information Handling of lubricants and sealants • Follow all instructions and safety precautions provided on the product label and the materi- al safety data sheet (MSDS/SDS) for lubri- cants, sealants, and other shop chemicals. • Wear impervious gloves, eye protection, or other protective apparel when required.

  • Page 11: Disposal Of Used Components And Chemicals

    Important safety and service information Disposal of used components and chemicals Obey all federal, state and local regulations when disposing of used components and/or chemicals such as crate frames, replaced parts, gaskets, oil, and so on.

  • Page 12: 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 13: 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 14: Color Code

    Specified tightening torque Color code Black Light green Sky blue Brown Orange White Green Pink Yellow Gray Purple Blue 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 15: Symbol

    (Yamalube grease A or Yamalube Marine Lubricant Grease) 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 0-11...
  • Page 16 Symbol Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent and the application points. Symbol Name Application YAMAHA Gasket Maker Sealant ThreeBond 1280B Sealant (Yamabond 4 Marine) ThreeBond 1303 Thread locking agent ThreeBond 1303N...

  • Page 17: 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 18 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 3 Valve spring compres- Valve guide Valve guide reamer 90890-06952 remover/installer 90890-06804 90890-06689 90890-06801 Valve lapper Valve seat cutter Valve seat cutter 30...
  • Page 19 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 20 Special service tool Bearing outer race Bearing outer race Pinion shimming Pinion shimming puller assembly attachment 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- Ring nut wrench...
  • Page 21 Special service tool US SST No. Universal magneto and Drilling plate Digital multimeter Peak volt adapter rotor holder YB-34465-A YU-34899-A YU-39991 YU-01235 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 YB-45544-A Rotor holding tool...
  • Page 22 Special service tool Needle bearing Piston slider 96 mm Driveshaft needle Shift rod socket remover and installer YB-06684 bearing installer and YB-06681 YB-06346 remover YB-06196 Needle bearing attach- Ring nut wrench 6 Ring nut wrench exten- Universal Puller ment YB-06677 sion YB-06117 YB-06112...
  • Page 23 Special service tool Propeller shaft and Driveshaft installer Gland nut wrench Forward gear bearing bearing housing YB-06244 YB-06578 installer remover YB-06345 YB-06335 PTT pressure gauge Trim cylinder wrench PTT piston vice tool Tilt rod wrench YB-06580 YB-06175-2B YB-06572 YB-06569 0-19...

  • Page 24: Specification

    Specification Specification data .............. 1-1 External dimensions ............1-1 Clamp bracket dimensions..........1-3...

  • Page 25: Specification Data

    Specification data Specification data For specification data, see Appendix, “Specification” (A-1). External dimensions The dimension values may include reference values.
  • Page 26 External dimensions mm (in) mm (in) X:1253.0 (49.33) U:1370.0 (53.94) 620.0 (24.41) E:1487.0 (58.5) 191.0 (7.52) 835.0 (32.87) 36.0 (1.42) X:279.0 (11.0) U:280.0 (11.0) E:281.0 (11.1) 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 or triple engine application *2.

  • Page 27: Clamp Bracket Dimensions

    Clamp bracket dimensions Clamp bracket dimensions 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 28 Technical feature and description Electronic control system ..........2-1 Electrical components ..............2-4 Fail-safe..................2-6 Rigging information ............2-8 Crate top cover................2-8 Bracket unit................. 2-9 SBW (Steer by Wire) system............2-9 System diagram ............... 2-10 Structure................... 2-12 Operation.................. 2-13 Outboard motor manual steering method.........

  • Page 29: Technical Feature And Description

    Technical feature and description Intake and exhaust system..........2-28 Intake and exhaust diagram ............. 2-28 Hose routing ..............2-29 Fuel hose and blowby hose............2-29 Pressure regulator hose, vapor gas hose, and intake air pressure sensor hose............... 2-30 Cooling water hose..............2-31...

  • Page 30: 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 31 Electronic control system 14. High-pressure fuel pump 15. Low-pressure fuel pump 20. Fuel injector 16. Vapor shut-off valve 21. OCV 22. Ignition coil 17. TPS 18. ETV 22. Ignition coil 21. OCV 19. Shift actuator 20. Fuel injector 1. Cam position sensor 23.
  • Page 32 Electronic control system 20. Fuel injector 1. Cam position sensor 21. OCV 2. Pulser coil 22. Ignition coil 3. Intake air pressure sensor 23. ETV control 4. Oil pressure sensor 24. Shift control 5. Engine temperature sensor 6. Intake air temperature sensor 25.

  • Page 33: Electrical Components

    Electronic control system Electrical components...
  • Page 34 Electronic control system Part name Function Opens and closes the throttle valve using an electric motor. Intake air pressure sensor Detects the intake air pressure. Intake air temperature sen- Detects the intake air temperature. 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 35: Fail-Safe

    Electronic control system Part name Function Determines the engine operating conditions according to the input signals from the sensors and switches which are installed 25 Engine ECM at various locations on the engine, and sends output signals to operate the actuators to perform the various control functions. Determines the stroke of each cylinder according to the signals Cam position sensor (PORT from both the pulser coil and the cam position sensor (PORT...
  • Page 36 Electronic control system Item Trouble conditions to be detected Controls performed by ECM Output voltage is less than 0.30 V, more than 4.80 V for 260 seconds, Oil pressure sensor High engine idle speed. or more than 4.80 V when engine is stopped.

  • Page 37: Rigging Information

    Rigging information Rigging information Crate top cover The material of the crate top cover, which is used for shipping, has been changed from cardboard to polyethylene (PE). Because the cover is semi-transparent, the contents of the crate can be seen through the cover, which helps to prevent the forklift operator from accidentally damaging the product with the forklift forks.

  • Page 38: 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 39: 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 40 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 41: 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 42: 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 43: 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 44: 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 45: 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 46 Bracket unit 3. Hold the “DN” (down) side of the PTT switch pushed. 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. •...

  • Page 47: Upper Case

    Upper case Automatic tilt-down 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 48: Lower Unit

    Lower unit 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 screw. The change of the shaft length has enabled the integrated lower unit to support a wider range of transoms.

  • Page 49: 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 50: 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 51: 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 52 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 53: Lubrication System

    Lubrication system Lubrication system Lubrication diagram 14. VCT assembly 14. VCT assembly 12. OCV 12. OCV 5. Oil pressure sensor 4. Oil filter 16. Relief valve 3. Oil pump 2. Oil strainer 1. Oil pan 13. Camshaft oil 14. VCT 12.
  • Page 54 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 55: 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 2-26...
  • Page 56 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 57: Intake And Exhaust System

    Intake and exhaust system Intake and exhaust system Intake and exhaust diagram 1. ETV 3. Intake manifold 2. Surge tank 4. Cylinder head 3. Intake manifold 5. Exhaust guide 6. Idle silencer 7. Exhaust manifold 8. Muffler 9. Propeller 7. Exhaust manifold 1.

  • Page 58: 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 separa- 5. Vapor separator to joint 6. Joint to quick connector (PORT) 7.

  • Page 59: Pressure Regulator Hose, Vapor Gas Hose, And Intake Air Pressure Sensor Hose

    Hose routing Pressure regulator hose, vapor gas hose, and intake air pressure sensor 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.

  • Page 60: Cooling Water Hose

    Hose routing Cooling water hose 14. Rectifier/regulator/isolator to joint 1. Cylinder block to joint 15. Joint to joint 2. Joint to fuel cooler 16. Joint to cooling water outlet 3. Joint to oil cooler 17. Flushing hose adapter to joint 4.
  • Page 61 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 Installing the outboard motor............3-4 Rigging grommet mounting ..........3-8 Rigging grommet description............

  • Page 62: Rigging Information

    Rigging information Tilt limiter ................3-38 Setting the tilt limiter ..............3-38 Clearing the tilt limiter............... 3-39 Deactivating the tilt limiter ............3-40 Calibration (6X9 Digital Electronic Control)....3-40 CL5 display calibration ............ 3-40 Configuring the number of outboard motors......3-40 Accessing the calibration menu..........

  • Page 63: 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 64: 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 65: Uncrating

    Uncrating procedure Wear gloves to avoid injury from sharp steel edges while uncrating. 2 2 2 1. Check: • Crate for shipping damage Damage  Consult your Yamaha distribu- tor. 2. Remove: • Top cover • Frame Lifting eye “1”...

  • Page 66: 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-**). Make sure that the lifting harnesses do not 12. Remove the lifting harness and shackles, damage any parts of the outboard motor.
  • Page 67 Outboard motor mounting • Make sure that the distance “g” is equal to distance “h”. • If the boat has a V shape hull, the center out- board motor should have a longer transom height than the outboard motors on both sides.
  • Page 68 Outboard motor mounting • Make sure that the distance “i” is equal to dis- tance “j”. • Make sure that the distance “k” is equal to distance “l”. • If the boat has a V shape hull, the center out- board motors should have a longer transom height than the outboard motors on both sides.
  • Page 69 Outboard motor mounting 4. Adjust the height of the scale “2” to the transom height (H), and place it on the The second hole from the top of each clamp special service tool “1”. Secure the special bracket is recommended for the upper mount- service tool “1”...

  • Page 70: Rigging Grommet Mounting

    Rigging grommet mounting Rigging grommet mounting Rigging grommet description Pass all the rigging components through the proper holes in the rigging grommet. 90˚ Installing the battery cable 1. Install: • Negative battery cable “1” • Positive battery cable “2” • Cap “3” 1.

  • Page 71: Optional Equipment

    Optional equipment Installing the SCU communication c. Install the rigging grommet “1” along with the grommet holder “2”. lead To improve working efficiency for the rigging of multiple engine applications, start from the out- board motor on the port side of the boat. 1.

  • Page 72: Battery Installation

    Battery installation Battery installation d. Remove the coupler cap from the SCU communication lead coupler (4P) “2”, and then install the cap to the SCU signal coupler (4P) “1” (female • Make sure to connect the battery properly section). and select the proper cable sizes. Other- wise, a fire could result.

  • Page 73: System Diagram

    System diagram System diagram Single outboard motor application (single station) 3-11...
  • Page 74 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 6.1 m (20 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 75 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 76: Twin Outboard Motor Application (Single Station)

    System diagram Twin outboard motor application (single station) 3-14...
  • Page 77 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X9-81115-00 0.3 m (1 ft) SCU communication lead 6GR-81115-00 w/ resistor cap, 1.5 m (5 ft) 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 6.1 m (20 ft)
  • Page 78 System diagram Ref. Part name Part No. Remarks 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) 6Y8-82521-41 2.7 m (9 ft)

  • Page 79: Triple Outboard Motor Application (Single Station)

    System diagram Triple outboard motor application (single station) 3-17...
  • Page 80 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X9-81115-00 0.3 m (1 ft) SCU communication lead (Starboard 6GR-81115-00 w/ resistor cap, 1.5 m (5 ft) side/Port side) 6GR-81115-10 w/ resistor cap, 3 m (10 ft) 6X9-81115-10 0.3 m (1 ft) SCU communication lead (Center) 6GR-81115-20 w/ resistor cap, 1.5 m (5 ft)
  • Page 81 System diagram Ref. Part name Part No. Remarks Multi-hub 6Y8-81920-01 w/ resistor cap, Gray Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-14 Key fob: 2 pcs. EKS harness 6X9-82716-41 DEC to switch panel System power supply wire 6Y8-83553-02...

  • Page 82: Quad Outboard Motor Application (Single Station)

    System diagram Quad outboard motor application (single station) 3-20...
  • Page 83 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X9-81115-00 0.3 m (1 ft) SCU communication lead (Starboard 6GR-81115-00 w/ resistor cap, 1.5 m (5 ft) side/Port side) 6GR-81115-10 w/ resistor cap, 3 m (10 ft) 6X9-81115-10 0.3 m (1 ft) SCU communication lead (Center) 6GR-81115-20 w/ resistor cap, 1.5 m (5 ft)
  • Page 84 System diagram Ref. Part name Part No. Remarks Multi-hub 6Y8-81920-01 w/ resistor cap, Gray Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-14 Key fob: 2 pcs. EKS harness 6X9-82716-91 DEC to switch panel System power supply wire 6Y8-83553-02...

  • Page 85: Single Outboard Motor Application (Dual Station)

    System diagram Single outboard motor application (dual station) 3-23...
  • Page 86 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 6.1 m (20 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 87 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 88: Twin Outboard Motor Application (Dual Station)

    System diagram Twin outboard motor application (dual station) 3-26...
  • Page 89 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X9-81115-00 0.3 m (1 ft) SCU communication lead 6GR-81115-00 w/ resistor cap, 1.5 m (5 ft) 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 6.1 m (20 ft)
  • Page 90 System diagram Ref. Part name Part No. Remarks 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) 6Y8-82521-41 2.7 m (9 ft)

  • Page 91: Triple Outboard Motor Application (Dual Station)

    System diagram Triple outboard motor application (dual station) 3-29...
  • Page 92 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X9-81115-00 0.3 m (1 ft) SCU communication lead (Starboard 6GR-81115-00 w/ resistor cap, 1.5 m (5 ft) side/Port side) 6GR-81115-10 w/ resistor cap, 3 m (10 ft) 6X9-81115-10 0.3 m (1 ft) SCU communication lead (Center) 6GR-81115-20 w/ resistor cap, 1.5 m (5 ft)
  • Page 93 System diagram Ref. Part name Part No. Remarks Multi-hub 6Y8-81920-01 w/ resistor cap, Gray Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-14 Key fob: 2 pcs. EKS harness 6X9-82716-41 DEC to switch panel System power supply wire 6Y8-83553-02...
  • Page 94 System diagram Ref. Part name Part No. Remarks Resistor cap 6Y8-85371-01 6P, Gray a. Power port P. Port b. Bus port C. Center c. Device port S. Starboard A. Main station B. Sub station The part numbers are subject to change without notice. Make sure to confirm the latest part numbers. 3-32...

  • Page 95: Quad Outboard Motor Application (Dual Station)

    System diagram Quad outboard motor application (dual station) 3-33...
  • Page 96 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X9-81115-00 0.3 m (1 ft) SCU communication lead (Starboard 6GR-81115-00 w/ resistor cap, 1.5 m (5 ft) side/Port side) 6GR-81115-10 w/ resistor cap, 3 m (10 ft) 6X9-81115-10 0.3 m (1 ft) SCU communication lead (Center) 6GR-81115-20 w/ resistor cap, 1.5 m (5 ft)
  • Page 97 System diagram Ref. Part name Part No. Remarks Multi-hub 6Y8-81920-01 w/ resistor cap, Gray Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-14 Key fob: 2 pcs. EKS harness 6X9-82716-91 DEC to switch panel System power supply wire 6Y8-83553-02...
  • Page 98 System diagram Ref. Part name Part No. Remarks Resistor cap 6Y8-85371-01 6P, Gray a. Power port P. Port b. Bus port CP. Center port c. Device port CS. Center starboard S. Starboard A. Main station B. Sub station The part numbers are subject to change without notice. Make sure to confirm the latest part numbers. 3-36...

  • Page 99: Digital Electronic Control

    Digital Electronic Control Digital Electronic Control 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. 1. Connect the YDIS to display “Boat system” menu.

  • Page 100: 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 101: Clearing The Tilt Limiter

    Tilt limiter Clearing the tilt limiter 6. Click the “Set” button or press the Enter key on the keyboard. 1. Connect the YDIS to display “Boat system” menu. To connect and operate the YDIS, see the YDIS (Ver. 2.49 or later) instruc- tion manual.

  • Page 102: Deactivating The Tilt Limiter

    Calibration (6X9 Digital Electronic Control) Calibration (6X9 Digital Electronic Control) To reset the tilt limiter setting, see “Setting the • If the steering actuator is removed, the steer- tilt limiter” (3-38). ing sensor must be calibrated after the unit is installed.

  • Page 103: Accessing The Calibration Menu

    CL5 display calibration Accessing the calibration menu 3. Tap “Reset”. 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. Tap while the screen is scrolled all the way to the top.

  • Page 104: Steering Sensor

    CL5 display calibration 4. The “Technician Settings” menu will ap- pear. 3. Tap “Set” to trim all engines to the fully down position. Steering sensor During this process, only the corresponding steering actuator will operate as the steering sensor is being calibrated. 1.
  • Page 105 CL5 display calibration • For triple engine applications, after this step, do the center outboard motor, and then do the port outboard motor. • For quad engine applications, after this step, do the center starboard outboard motor, then the center port outboard motor, and then do the port outboard motor.

  • Page 106: Toe Adjust

    CL5 display calibration 8. Turn the steering wheel counterclockwise until the starboard outboard motor reaches full PORT lock and the message appears. Confirm the starboard outboard motor is at full PORT lock, and then tap “Set”. CHECK SYSTEM ! - Port Engine - Steering calibration needed.

  • Page 107: Adjustment Settings

    CL5 display calibration 2. Tap “Wedge/Toe”. 6. Adjust the toe angle. Tap “Done” to con- 3. Select “Set” to delete the current setting firm. and select a new wedge angle. The Helm Master EX control system comes with the toe set at 0.0. The adjustment range •...

  • Page 108: Lock To Lock

    CL5 display calibration 1. Tap “Adjustment”. When the engine is running, this function is not available. 2. Tap “Up” or “Down” to adjust the toe angle. 2. Tap “Constant”. Tap “Numeric” to adjust the toe angle. The Helm Master EX control system comes with the toe set at 00.0.
  • Page 109 CL5 display calibration 1. From the “Technician Settings” menu, se- lect “Lock to Lock”. When the engine is running, this function is not available. 2. Tap “Variable”. 5. Tap “Set LTL” and then select a rotational angle, from 1 to 9, for the steering wheel. This setting allows you to adjust the number of turns from “Lock to Lock”.

  • Page 110: 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 111: 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 112: 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 113 Propeller selection Blade Dia. (in) Pitch (in) Mark Material Part number Remarks 15 1/4 Stainless steel 6KA-45970-00 *1, *5 15 1/4 Stainless steel 6KA-45972-00 *1, *5 *1. Shift Dampener System (SDS) propellers *2. Saltwater II propellers *3. Saltwater HS propellers *4.
  • Page 114 Propeller selection Blade Dia. (in) Pitch (in) Mark Material Part number Remarks 15 1/4 Stainless steel 6KB-45970-00 *1, *5 15 1/4 Stainless steel 6KB-45972-00 *1, *5 *1. Shift Dampener System (SDS) propellers *2. Saltwater II propellers *3. Saltwater HS propellers *4.

  • Page 115: Troubleshooting

    Troubleshooting YDIS ..................4-1 Connecting the communication cable ........4-1 ECM reprogramming ..............4-3 Outboard motor troubleshooting........4-4 Troubleshooting procedure ............4-4 Troubleshooting the power unit using the YDIS ......4-4 Trouble code and checking step ..........4-7 Troubleshooting procedure (trouble code not detected) ..4-21 Troubleshooting the power unit ..........

  • Page 116: 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 Yamaha 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 117 YDIS K-Line a. YDIS coupler 2. Adapter cap 1. Adapter interface 3. USB cable 4. K-Line harness 1. Adapter interface 2. Adapter cap 3. USB cable 4. K-Line harness a. YDIS coupler (gray)

  • Page 118: Ecm Reprogramming

    YDIS ECM reprogramming Program update function This function allows you to update the engine ECM program to the latest version using a reprogram- ming harness (K and CAN 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 119: 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 120 Outboard motor troubleshooting Trouble code table To display trouble codes (code number 300 and higher) for the SBW system, connect using the CAN- Line harness. : Indicated —: Not indicated YDIS diagnosis Code No. Item YDIS diagnosis record Pulser coil ...
  • Page 121 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, Remote control system   174, 175, 176, 177, 178, 179, 180, 181, 183, 184, 186, 187 Steering system ...

  • Page 122: 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   Steering System–Control Unit ...
  • Page 123 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page Measure the knock sensor 5-41 resistance. Knock sensor “Check Engine” is displayed. (Irregular sig- Check for wiring continuity High engine idle speed. nal) between the knock sensor and A-13 the engine ECM.
  • Page 124 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page Check the fuel filter for water. — Measure the water detection 5-30 switch input voltage. Water in fuel fil- “Water in fuel” is displayed. Check the water detection ter (Water in Alert buzzer comes on while 5-30 switch for continuity.
  • Page 125 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page Measure the cam position 5-26 sensor input voltage. “Check Engine” is displayed. Measure the cam position High engine idle speed. 5-26 sensor output voltage. Degraded acceleration perfor- Cam position mance.
  • Page 126 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page Measure the PTT sensor 5-51 resistance. PTT sensor Measure the PTT sensor input 5-51 (Out of specifi- “Check Engine” is displayed. voltage. cation) Check for wiring continuity between the PTT sensor and A-15 the engine ECM.
  • Page 127 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page “Check Engine” is displayed. ETV system High engine idle speed. (Throttle valve Throttle does not operate. Check the ETV circuit. A-11 malfunction) Engine speed is set at approx- imately 1500 r/min. “Check Engine”...
  • Page 128 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page 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 129 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page Measure the SPS input volt- 5-24 “Check Engine” is displayed. age. Engine operates normally Measure the SPS output volt- 5-24 unless it is stopped. age. SPS (Out of Engine does not restart (No Check for wiring continuity specification) cranking).
  • Page 130 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page Check the fuse. Measure the shift actuator 5-25 relay input voltage. Measure the shift actuator 5-26 motor resistance. Check for wiring continuity between the shift actuator and A-11 “Check Engine” is displayed. the engine ECM.
  • Page 131 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page Check the extension wire har- ness for proper connection — and damage. “Check Engine” is displayed. Alert indicator is ON. Check for wiring continuity <Engine speeds do not syn- between the engine ECM and A-11 chronize>...
  • Page 132 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page Remote control system (Main “Check Engine” is displayed. Replace the Digital Electronic station LPS Locked at engine idle speed. Control ECM. Irregular signal Shift actuator rod returns to (When replacing the Digital [Digital Elec- the N position.
  • Page 133 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page Measure the LPS output volt- age using the YDIS. “Check Engine” is displayed. Locked at engine idle speed. Check for wiring continuity Alert indicator is ON. between the LPS and the Digi- tal Electronic Control ECM.
  • Page 134 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page “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. station [LPS Check for wiring continuity Shift actuator rod returns to Irregular sig- between the LPS and the Digi-...
  • Page 135 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page Steering sys- tem–Outboard Stop engine synchronization Check detail by using YDIS — (SCU) (Irregu- control. CAN communication cable. lar signal) Steering sys- tem–Helm Stop engine synchronization Check detail by using YDIS —...

  • Page 136: 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 137 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 A-11 Short, open, or loose con- engine ECM.
  • Page 138 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Pinched or kinked fuel hose Check the fuel hose. 2-29 Fuel leakage Check the fuel line for leakage. 2-29 Check the fuel filter element for dirt Clogged fuel filter element and obstructions. Blown fuse Check the fuse.
  • Page 139 Outboard motor troubleshooting Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited engine speed. Symptom 2 Cause Checking steps page Spark plug malfunction Check the spark plug. 7-30 Measure the ignition coil input volt- 5-36 age. Short, open, or loose con- Check for wiring continuity between nection in ignition coil cir- the ignition coil and the engine...
  • Page 140 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 141 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Check the engine oil level. 10-7 Check for engine oil leakage. 2-24 Insufficient engine oil Check the valve stem seals and 7-54 valves. Check the piston rings. 7-75 Buzzer comes on. Oil pressure alert —...

  • Page 142: 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-15 PTT switch malfunction Check the PTT switch. 5-50 PTT relay malfunction Check the PTT relay. 5-49 Measure the PTT switch input volt- 5-50...

  • Page 143: 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. 9-31 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 144 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 145: Electrical System

    Electrical system Checking the rectifier/regulator/isolator........5-35 Ignition unit and component ........... 5-36 Checking the ignition spark ............5-36 Checking the ignition coil............5-36 Checking the pulser coil ............5-37 Checking the intake air temperature sensor......5-38 Checking the intake air pressure sensor ........5-39 Checking the engine temperature sensor ........
  • Page 146 Electrical component and wire harness routing Electrical component and wire harness routing Port...
  • Page 147 Electrical component and wire harness routing 1. ETV (TPS) 2. Vapor shut-off valve 3. Thermo switch (PORT) 4. OCV (PORT) 5. Fuel injector 6. High-pressure fuel pump 7. Low-pressure fuel pump A. Install the pulser coil coupler to the wire harness guide.
  • Page 148 Electrical component and wire harness routing Starboard...
  • Page 149 Electrical component and wire harness routing 1. OCV (STBD) 2. Thermo switch (STBD) 3. Fuse holder 4. PTT relay 5. Rectifier/regulator/isolator 6. Oil pressure sensor 7. Fuel injector 8. Wire harness 9. Ground lead 10. Thermo switch lead 11. PTT ground lead 12.

  • Page 150: Fuse Holder

    Electrical component and wire harness routing Fuse holder 7. Main relay 1. Fuse (100 A) (engine battery) 8. Fuse (30 A) (starter relay) 2. Fuse (20 A) (engine start switch, PTT 9. Fuse (15 A) (shift actuator) switch, and Digital Electronic Control 10.
  • Page 151 Electrical component and wire harness routing Rear...
  • Page 152 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. Speed sensor coupler 8. Ignition coil lead 9. Vapor gas hose 10.
  • Page 153 Electrical component and wire harness routing Front 1. Starter motor 2. YDIS coupler 3. Water detection switch (in fuel cup assembly) A. Fasten the PTT relay lead using the holder. B. Make sure that the starter motor lead contacts the detent, and then install it.
  • Page 154 Electrical component and wire harness routing...
  • Page 155 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 156: Bottom Cowling

    Electrical component and wire harness routing Bottom cowling 5-11...
  • Page 157 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. Speedometer hose (Analog) (optional) 9. SCU communication lead (When using multiple machines) (optional) 10.
  • Page 158 Electrical component and wire harness routing Bracket 5-13...
  • Page 159 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 160 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 161 ECM circuit diagram , a: Indicate a connection between the symbols. The circled numbers in the illustration indicate the engine ECM terminal numbers. < INPUT > < OUTPUT > 47. OCV (PORT) 27. Water pressure sensor 48. OCV (STBD) 28. Speed sensor 49.
  • Page 162 ECM circuit diagram 50. PTT buzzer 1. Pulser coil 51. Propeller light (optional) 2. Cam position sensor (PORT EX) 52. High-pressure fuel pump 3. Cam position sensor (PORT IN) 53. Fuel pump relay (high-pressure) 4. Cam position sensor (STBD IN) 54.

  • Page 163: 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 44 45 46 47 48 49 50 51 104 105...
  • Page 164 ECM coupler layout Connecting part Color Connecting part Color 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 Black Thermo switch Pink 104 Fuel injector #6 Purple/White Water detection —...

  • Page 165: Checking The Electrical Component

    • The software is available through YMAN tester, and the negative pin to the negative (Yamaha Marine Associate Network). terminal. • When measuring the peak voltage, set the digital circuit tester to the DC voltage mode.
  • Page 166 YU-39991 Using the digital tester 2. Check: The electrical technical data applies to the • Relay continuity measurements taken using the Yamaha rec- No continuity  Replace. ommended tester. The resistance values shown are the values Relay continuity taken before the engine is started. The actual Terminal “c”–Terminal “d”...

  • Page 167: Checking The Engine Ecm Circuit

    Engine control unit and component a. Measure the input voltage between the terminal “a” and ground, and the Wire harness continuity terminal “b” and ground. Terminal 41–Ground Terminal 42–Ground Terminal 86–Ground Terminal 99–Ground a. Disconnect the engine ECM couplers “a”, “b” and “c”. Input voltage 12 V Terminal “a”–Ground...

  • Page 168: Checking The Etv And Tps

    Engine control unit and component a. Measure the input voltage between the engine ECM coupler terminal 37 and ground. Input voltage 1. Measure: 12 V • TPS 1 and TPS 2 output voltage Terminal 37–Ground Out of specification  Check the TPS in- put voltage.
  • Page 169 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 170 Engine control unit and component Output voltage at gear shift in the F position (reference data) 0.47–1.68 V Output voltage at gear shift in the N position (reference data) 2.30–2.67 V Output voltage at gear shift in the R position (reference data) 3.21–4.39 V a.
  • Page 171 Engine control unit and component a. Measure the input voltage between the terminal “a” and ground. Motor resistance (reference data) 1.7  a. Remove the intake manifold (PORT). b. Disconnect the shift actuator coupler “a”, and then measure the shift actua- tor motor resistance.
  • Page 172 Engine control unit and component b. Turn the engine start switch to ON, a. Make 3 test leads. and then measure the input voltage at the cam position sensor coupler. STBD IN PORT IN Test lead Terminal, male “1” 9E212-10303 Terminal, female “2”...

  • Page 173: Checking The Ocv

    Engine control unit and component e. Connect the tester probes to the test Connect the cam position sensor cou- leads. plers. Checking the OCV 1. Check: • OCV operation (using the YDIS “Station- ary test”) No operation sound  Check the OCV in- put voltage.
  • Page 174 Engine control unit and component 3. Measure: a. Disconnect the oil pressure sensor • OCV resistance coupler “a”. Out of specification  Replace. b. Turn the engine start switch to ON, a. Remove the OCV. and then measure the input voltage at b.

  • Page 175: Checking The Fuel Injector

    Fuel control unit and component Pressure pump “1” Water detection switch continuity (commercially available) No continuity Test harness EJ–ll–3 “2” Float position “A” 90890-06913 Continuity Float position “B” c. Turn the engine start switch to OFF, a. Remove the fuel cup assembly. See and then disconnect the special ser- “Fuel filter assembly”...

  • Page 176: Checking The Low-Pressure Fuel Pump And High-Pressure Fuel Pump

    Fuel control unit and component 2. Measure: • Fuel injector input voltage Out of specification  Check the wire har- ness for continuity. Input voltage 12 V Red/Yellow (R/Y)–Ground a. Disconnect the fuel injector couplers “a”. c. Connect the fuel injector couplers. b.

  • Page 177: Checking The High-Pressure Fuel Pump Relay

    Fuel control unit and component 3. Measure: • High-pressure fuel pump input voltage Out of specification  Check the wire har- ness for continuity. Input voltage 12 V Red/Yellow (R/Y)–Ground a. Disconnect the high-pressure fuel pump coupler “a”. b. Connect the tester probes to the termi- nals of the high-pressure fuel pump coupler “a”, and then measure the in- A.
  • Page 178 Fuel control unit and component a. Connect the tester probes to the termi- nals “a” and “b”, and then measure the Input voltage input voltage within 5 seconds after 12 V turning the engine start switch to ON. Red/Yellow (R/Y)–Ground a.
  • Page 179 Charging unit and component Charging unit and component Checking the lighting coil (stator as- Connect the battery leads to the vapor sembly) shut-off valve terminals for only a few sec- 1. Measure: onds. • Lighting coil output peak voltage Below specification  Replace the stator assembly.
  • Page 180 Charging unit and component Test harness FW13613–1 “1” Resistance (reference data) 0.1056–0.1584  90890-06915 Test harness FW13613–2 “2” Green (G)–Green (G) 90890-06916 a. Remove the intake manifold (STBD). d. Install the intake manifold (STBD). b. Disconnect the lighting coil couplers. e.

  • Page 181: Checking The Ignition Coil

    Ignition unit and component a. Remove the fuse cover “1”, and then c. Check the ignition spark using the measure the rectifier/regulator/isolator YDIS “Stationary test”. output peak voltage at the specified engine speed. Do not touch any of the connections of the special service tool.
  • Page 182 Ignition unit and component c. Turn the engine start switch to OFF. d. Connect the ignition coil couplers. Checking the pulser coil 1. Measure: • Pulser coil output peak voltage Below specification  Measure the pulser coil resistance. Pulser coil output peak voltage (reference data) White/Red (W/R)–Black (B) Unloaded...
  • Page 183 Ignition unit and component h. Disconnect the special service tool. b. Turn the engine start switch to ON, and then measure the input voltage at Connect the pulser coil coupler. the intake air temperature sensor cou- pler. 2. Measure: • Pulser coil resistance Out of specification ...
  • Page 184 Ignition unit and component Checking the intake air pressure sen- 1. Measure: • Intake air pressure sensor input voltage Out of specification  Check the wire har- ness for continuity. Input voltage Orange (Or)–Black (B) a. Disconnect the intake air pressure sensor coupler “a”.
  • Page 185 Ignition unit and component Input voltage Black/Yellow (B/Y)–Black (B) a. Disconnect the engine temperature sensor coupler “a”. b. Turn the engine start switch to ON, and then measure the input voltage at the engine temperature sensor cou- d. Install the engine temperature sensor pler.

  • Page 186: Checking The Engine Shut-Off Switch

    Ignition unit and component 2. Check: • Thermo switch continuity Resistance Out of specification  Replace. 504–616 k a. Disconnect the knock sensor coupler Switch ON temperature “a”. 84–90 C (183–194 F) Switch OFF temperature b. Measure the knock sensor resistance. 68–82 C (154–180 F) a.

  • Page 187: Checking The Power Switch

    Starting unit and component 3. Measure: • Starter relay input voltage Out of specification  Check the wire har- ness for continuity. Input voltage 12 V Terminal “a”–Ground a. Measure the input voltage between the terminal “a” and ground. A. Single type B.
  • Page 188 Starting unit and component b. Check the power switch for continuity at the power switch coupler. A. Single type B. Twin type c. Connect the power switch coupler. Checking the engine start/stop button 1. Check: h i j • Engine start/stop button continuity Out of specification ...

  • Page 189: Starter Motor

    Starter motor Starter motor Part name Q’ty Remarks Part name Q’ty Remarks Nut M8 Cover Washer Seal set Bolt M6  35 mm Lever assembly Magnet switch Pinion assembly Bolt M5  127 mm Bracket assembly Stator Bearing Screw M4  16 mm Gasket Bracket Pinion shaft...

  • Page 190: Removing The Starter Motor

    Starter motor Removing the starter motor 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. Remove: • Stator • Bracket screw Pipe “3”...
  • Page 191 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 192: Assembling The Starter Motor

    Starter motor 3. Install: • Pinion shaft assembly “1” Standard brush length • Lever “2” 15.5 mm (0.61 in) • Rubber seal “3” Wear limit 9.5 mm (0.37 in) Align the holes “a” in the cover “4” with the holes “b” in the bracket “5”. a.
  • Page 193 Starter motor a. Push the brushes “1” into the holders, 8. Install: and then install the armature “2” to the • Stator bolt “1” brush holder assembly “3”. b. Install the plate “4”. 9. Install: • Gasket “1” • Spring “2” 7.

  • Page 194: Ptt System

    Outboard motor and Digital Electronic Control connection Outboard motor and Digital Elec- e. Measure the input voltage between the PTT relay coupler terminal and tronic Control connection ground. Checking the extension wire harness 1. Check: • Extension wire harness continuity Out of specification ...
  • Page 195 PTT system PTT relay continuity “a” “b” “c” “d” “e” “f” “g” d. Connect the positive battery lead to the connector “f”, connect the negative battery lead to the connector “e”, and then check the PTT relay for continu- ity. PTT relay continuity “a”...
  • Page 196 PTT system b. Measure the input voltage between the PTT switch coupler terminal and Input voltage ground. Orange (Or)–Black (B) a. Disconnect the PTT sensor coupler “a”. b. Turn the engine start switch to ON, and then measure the input voltage at the PTT sensor coupler.
  • Page 197 PTT system b. Connect the battery leads to the PTT buzzer coupler, and check that the PTT buzzer comes on. Replace the PTT buzzer if it does not come on. c. Install the PTT buzzer. 5-52...
  • Page 198 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 199: Fuel System

    Fuel system Checking the vapor separator ..........6-26 Checking the check valve............6-26 Assembling the vapor separator..........6-27 Fuel injector ..............6-29 Checking the fuel rail..............6-30 Installing the fuel injector............6-30...

  • Page 200: 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 201: Measuring The Fuel Pressure

    Fuel system b. Disconnect the quick connector from the fuel rail. See “Disconnecting the • After disconnecting the quick connector “1”, quick connector” (6-1). be careful not to lose the retainer “2”. • Cover the quick connector and fuel rail with a c.

  • Page 202: Checking The Pressure Regulator

    Fuel system Reduce the fuel pressure. See “Re- ducing the fuel pressure” (6-1). 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 203 Fuel system A. Worldwide B. USA and Canada Fuel pressure gauge adapter “1” 90890-06946 Fuel pressure gauge adapter “1” YB-06946 Fuel pressure gauge “2” 90890-06753 Fuel pressure gauge “2” YU-03153M Vacuum/pressure pump gauge set “4” 90890-06945 A. Worldwide Pressure/vacuum tester “4” B.
  • Page 204 Fuel system 6. Connect: • Quick connector “3” A. Worldwide B. USA and Canada...

  • Page 205: 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  14 mm Cover Bolt M6  25 mm Grommet Collar Bolt M6  16 mm Bracket Plastic tie Fuel filter assembly Fuel cup assembly O-ring Fuel filter element...

  • Page 206: Removing The Fuel Filter Assembly

    Fuel filter assembly Removing the fuel filter assembly Fuel outlet holding pressure (nega- Cover the fuel components using a rag to pre- tive pressure) vent fuel from spilling out. 80.0 kPa (0.80 kgf/cm², 11.6 psi) Checking the fuel filter assembly a.

  • Page 207: Checking The Primer Pump

    Fuel filter assembly Checking the primer pump 1. Check: • No air leakage Air leakage  Replace. Positive pressure 166.7 kPa (1.67 kgf/cm², 24.2 psi) a. Connect the special service tool “1” to the fuel inlet “a”. b. Block the fuel outlet “b” using a rubber plug “2”, and then apply the specified positive pressure for at least 30 sec- onds.
  • Page 208 Fuel filter assembly 2. Connect: • Hose “1”, “2” • Plastic tie “3” 3. Install: • Cover “1” 4. Connect: • Water detection switch coupler “a” 5. Check: • Fuel flow Leak/clog  Replace the fuel filter assem- bly.

  • Page 209: Intake Manifold

    Intake manifold Intake manifold 24 N·m (2.4 kgf·m, 18 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft) 12 14 11 N·m (1.1 kgf·m, 8.1 lb·ft) 11 N·m (1.1 kgf·m, 8.1 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks...

  • Page 210: Checking The Intake Manifold

    Intake manifold Checking the intake manifold PORT STBD 1. Check: • Intake manifold Cracked/damaged  Replace. Installing the intake manifold 1. Install: • Gasket Make sure to fit the tabs on the gaskets “1” and STBD PORT [4] [5] “2” properly and firmly with the grooves “a” and “b”...

  • Page 211: Installing The Intake Silencer

    Intake manifold Installing the intake silencer b. Fasten the fuel injector lead “1” using the holders “2”. 1. Install: • Joint STBD • Plastic tie • Intake silencer • Intake air temperature sensor • Blowby hose Intake silencer bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2.

  • Page 212: Etv

    11 N·m (1.1 kgf·m, 8.1 lb·ft) 11 N·m (1.1 kgf·m, 8.1 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Bolt M6  60 mm Bracket Bracket Bracket Bolt M8  30 mm Bracket Grommet Surge tank Bolt M6  16 mm Holder Holder Bracket...

  • Page 213: Checking The Etv

    Checking the ETV 1. Check: • ETV Cracked  Replace. 2. Check: • Throttle valve movement Rough movement  Clean. Surge tank bracket bolt “3” 11 N·m (1.1 kgf·m, 8.1 lb·ft) 4. Install: Checking the intake air pressure sen- • Bracket “1” •...
  • Page 214 5. Connect: • Pressure regulator hose “1” • Vapor gas hose “2” 8. Connect: • Low-pressure fuel pump coupler “a” • YDIS coupler “b” • ETV coupler “c” • Intake air pressure sensor coupler “d” 6. Install: • Gasket “1” •...

  • Page 215: 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 216: 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. Vacuum/pressure pump gauge set “1”...
  • Page 217 Canister 2. Connect: • Vapor gas hose “1”, “2”, “3”, “4”, “5” • Joint “6” • Check valve “7” 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 218: Low-Pressure Fuel Pump

    Low-pressure fuel pump Low-pressure fuel pump 5 N·m (0.5 kgf·m, 3.7 lb·ft) 12 mm 9 mm 12 mm (0.47 in) (0.35 in) (0.47 in) 12 mm 12 mm (0.47 in) (0.47 in) Part name Q’ty Remarks Bolt M6  15 mm Holder Cover Clamp...

  • Page 219: Installing The Low-Pressure Fuel Pump

    Low-pressure fuel pump Installing the low-pressure fuel pump Connect the fuel hose “3” to the joint and fasten the fuel hose using a new 1. Install: plastic tie “4”, and then install the fuel • Low-pressure fuel pump hose to the holder “5”. a.

  • Page 220: 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 Collar Plastic tie Vapor separator Bolt M6  20 mm Hose Bolt M6  16 mm Hose Hose Bracket Hose Nut M6 Holder...

  • Page 221: 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: • Vapor separator vent fuel from spilling out. • Vapor shut-off valve 1. Drain: a. Install the cooling water hose “1” and •...
  • Page 222 Vapor separator and vapor shut-off valve d. Install the vapor separator assembly “3”. e. Connect the fuel hose “1”, and then fasten it using the clamp “2”. Connect the cooling water hose “3” and vapor gas hoses “4”, “5”, and “6”. g.

  • Page 223: 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) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 3.5 ·m (0.35 kgf·m, 2.6 lb·ft) 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 3.5 ·m (0.35 kgf·m, 2.6 b·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) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
  • Page 224 Vapor separator and high-pressure fuel pump 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 3.5 ·m (0.35 kgf·m, 2.6 lb·ft) 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 3.5 ·m (0.35 kgf·m, 2.6 b·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) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Part name...

  • Page 225: 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” (5-31). Checking the vapor separator 1. Check: • Needle valve Float height Bent/worn ...

  • Page 226: Assembling The Vapor Separator

    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. Assembling the vapor separator 3. Install: 1. Install: • Grommet “1” • Needle valve assembly “1” •...
  • Page 227 Vapor separator and high-pressure fuel pump 5. Install: 7. Install: • Check valve “1” • Joint pipe “1” • Filter “2” • Vapor gas hose “2”, “3” • Gasket “3” • Joint pipe screw “4” • Cover “4” • Cover bolt “5” Joint pipe screw “4”...

  • Page 228: Fuel Injector

    Fuel injector Fuel injector Part name Q’ty Remarks Plastic tie Holder Clamp Hose Hose Hose Joint Holder Quick connector Bolt M6  25 mm Fuel rail Holder Fuel injector O-ring set 6-29...

  • Page 229: Checking The Fuel Rail

    Fuel injector Checking the fuel rail PORT 1. Check: • Fuel rail Cracked/deformed  Replace. 2. Check: • Electrical performance of the fuel injector See “Checking the fuel injector” (5-30). Installing the fuel injector 1. Install: STBD • O-ring • Fuel injector •...
  • Page 230 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............. 7-4 Power unit assembly............7-7 Removing the power unit............

  • Page 231: 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.............. 7-41 Checking the valve lifter ............7-41 Checking the camshaft.............
  • Page 232 Power unit Checking the cooling water cover anode ......... 7-69 Installing the thermostat ............7-69 Installing the cooling water cover ..........7-70 Installing the knock sensor ............7-71 Installing the pulley bracket ............7-71 Cylinder block..............7-72 Disassembling the cylinder block ..........7-73 Checking the piston diameter...........

  • Page 233: Checking The Compression Pressure

    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 234: Checking The Pulser Coil Air Gap

    Power unit (check and adjustment) 3. Measure: • Oil pressure Do not turn the flywheel magneto counter- Below specification  Check the engine clockwise. Otherwise, the water pump im- internal parts. peller could be damaged. Engine oil pressure at idle speed (reference data) 1.
  • Page 235 Power unit (check and adjustment) a. Turn the flywheel magneto “1” clock- wise until the dowel pin hole “a” in the flywheel magneto “1” is aligned be- tween the VCT assembly (STBD) “2” and driven sprocket (STBD) “3”. b. Check that the “II” marks “b” on the VCT assembly (PORT) and driven sprocket (PORT) are aligned, and check that the “I”...

  • Page 236: Adjusting The Valve Clearance

    Power unit (check and adjustment) b. Turn the flywheel magneto “1” an ad- ditional 360 clockwise until the dowel Spark plug pin hole “a” in the flywheel magneto 28 N·m (2.8 kgf·m, 21 lb·ft) “1” is aligned between the VCT as- sembly (STBD) “2”...
  • Page 237 Power unit (check and adjustment) 6. Remove: • Timing belt • Do not turn the flywheel magneto coun- See “Removing the timing belt” (7-34). terclockwise. Otherwise, the water pump impeller could be damaged. 7. Remove: • VCT assembly • Do not turn the flywheel magneto, VCT •...
  • Page 238 Power unit (check and adjustment) Example: Removed valve lifter thickness = 3.000 mm Measured valve clearance = 0.255 Specified valve clearance = 0.205 mm Necessary valve lifter thickness = 3.000 mm + 0.255 mm – 0.205 mm = 3.050 mm 10.

  • Page 239: 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 PTT unit lead Screw M6  20 mm Clip Grommet Clip Bolt M6 ...

  • Page 240: Removing The Power Unit

    Power unit assembly Removing the power unit 1. Remove: • Plastic tie “1” • Rigging tube retainer “2” 5. Remove: • Holder “1” 6. Disconnect: • PTT motor lead “2”, “3” (from the holder 2. Remove: “1”) • Grommet holder “1” •...
  • Page 241 Power unit assembly 8. Disconnect: • PTT switch coupler “a” • SPS coupler “b” (from the bracket “1”) 12. Disconnect: • PTT sensor coupler “a” 9. Remove: • Wire harness “1” (from the holder “2”) • Bracket “3”, “4” 13. Remove: •...

  • Page 242: Installing The Power Unit

    Power unit assembly 14. Remove: • Idle silencer “1” Lifting eye “1” 90890-06953 Bolt hexagon with washer “2” 90890-06821 Balance hanger “3” 90890-06822 Lifting eye bolt 36 N·m (3.6 kgf·m, 27 lb·ft) Installing the power unit 15. Remove: 1. Clean: •...
  • Page 243 Power unit assembly [12], [20], [28] Apron screw “7” [11], [19], [27] [13], [21], [29] 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) [10], [18] [7], [22] 4. Connect: • PTT sensor coupler “a” [9], [17] [6], [23] [5], [24] [8], [16] [2], [15] [4], [25] [1], [14]...
  • Page 244 Power unit assembly 8. Install: • Bracket “1”, “2” • Wire harness “3” (to the holder “4”) 9. Connect: • SPS coupler “a” (to the bracket “1”) PTT motor lead bolt “3” • PTT switch coupler “b” 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 13.
  • Page 245 Power unit assembly 15. Install: • Rigging grommet “1” • Grommet holder “2” See “Installing the rigging grommet” (3-8). 7-13...

  • Page 246: Flywheel Magneto

    Flywheel magneto Flywheel magneto 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 40 N·m (4.0 kgf·m, 30 lb·ft) 90° Part name Q’ty Remarks Flywheel magneto Bolt M10  50 mm Dowel pin Plastic tie Bolt M5  20 mm Bracket Pulser coil Bolt M6 ...

  • Page 247: Removing The Flywheel Magneto

    Flywheel magneto Removing the flywheel magneto Installing the flywheel magneto 1. Remove: 1. Install: • Flywheel magneto • Dowel a. Loosen the flywheel magneto bolts “1” • Base • Pulser coil in the order [1], [2], and so on, and •...
  • Page 248 Flywheel magneto Rotor holder “2” 90890-01235 Universal magneto and rotor holder “2” YU-01235 Flywheel magneto bolt “1” 1st: 40 N·m (4.0 kgf·m, 30 lb·ft) 2nd: 90 7-16...

  • Page 249: Wire Harness

    Wire harness Wire harness Part name Q’ty Remarks Holder Holder Holder Holder Holder Wire harness Bolt M6  20 mm Wire harness guide 7-17...

  • Page 250: Installing The Wire Harness

    Wire harness Installing the wire harness Route the wire harness. See “Electrical component and wire harness routing” (5-1). 1. Install: • Wire harness guide • Holder “1” (to the wire harness guide “2”) 5. Connect: • Rectifier/regulator/isolator coupler “a” 2. Install: 6.
  • Page 251 Wire harness 8. Install: STBD • Fuse box “1” 11. Connect: • OCV coupler “a” • Cam position sensor coupler “b” • Thermo switch connector “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 252 Wire harness 13. Install: • Holder “1” (to the wire harness guide) • Wire harness “2” • Holder “3” • Condenser “4” 14. Connect: • Cam position sensor coupler (PORT EX) “a” 15. Install: • Holder “1” (to the ECM bracket) •...

  • Page 253: 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 Fuse is included.

  • Page 254: 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 Cover...
  • Page 255 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 Bracket Bolt M8  20 mm Bolt M6 ...

  • Page 256: Installing The Junction Box

    Junction box Installing the junction box PTT relay lead nut “3” 1. Install: • Junction box “1” 5 N·m (0.5 kgf·m, 3.7 lb·ft) Starter motor nut “5” • Terminal “2” • Terminal bolt “3” 9 N·m (0.9 kgf·m, 6.6 lb·ft) •...
  • Page 257 Junction box 3. Install: • Ground lead “1” • Cooling water hose “2”, “3” • Clamp “4” • Plastic tie “5” 7-25...

  • Page 258: Starter Motor

    Starter motor Starter motor 25 N·m (2.5 kgf·m, 18 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 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 Screw M4  6 mm Bolt M8  45 mm Starter motor Bolt M8 ...

  • Page 259: Installing The 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 30 N·m (3.0 kgf·m, 22 lb·ft) 7-27...

  • Page 260: 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 261: Ignition Coil And Spark Plug

    Ignition coil and spark plug Ignition coil and spark plug 28 N·m (2.8 kgf·m, 21 lb·ft) Part name Q’ty Remarks Ignition coil Bolt M6  25 mm Spark plug 7-29...

  • Page 262: 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 263: Shift Actuator

    Shift actuator Shift actuator 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  60 mm Shift actuator Collar Bushing Washer Bracket 7-31...

  • Page 264: 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 265: 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 Guide Plate Timing belt Timing belt tensioner Bolt M10  55 mm Washer Pulley Collar 7-33...

  • Page 266: Removing The Timing Belt

    Timing belt Removing the timing belt 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. 1. Remove: • Timing belt a.

  • Page 267: Checking The Timing Belt

    Timing belt e. Remove the timing belt “1” from the a. Install the timing belt tensioner “1”, col- VCT assembly (PORT) or driven lars “2”, and pulleys “3”, and then tight- sprocket (STBD), and then remove it en the timing belt tensioner bolt “4” from the crankshaft.
  • Page 268 Timing belt Before installing the timing belt, make sure that the marks on the crankshaft and cylinder block are aligned. Also, make sure that the marks on 6CB-462**-** the VCT assemblies and driven sprockets are aligned. See “Removing the timing belt” (7-34). 0 1 2 3 A.
  • Page 269 Timing belt Make sure that the belt position marks are aligned with the “” marks. See steps (b) and (c). Turn the timing belt tensioner gradual- ly counterclockwise until the timing belt is taut. Timing belt guide clearance “a” g. Install the timing belt guides and plate. 0.5–1.5 mm (0.02–0.06 in) h.

  • Page 270: 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) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) Part name...

  • Page 271: 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 272 Camshaft • When removing the VCT bolt, do not se- cure the VCT assembly. Otherwise, the VCT assembly could be damaged. • When removing the VCT assembly, do not turn the intake camshaft. Otherwise, the intake and exhaust valves could collide with each other and be damaged.

  • Page 273: Checking The Sprocket

    Camshaft Checking the sprocket 1. Check: • Driven sprocket • VCT assembly Cracked/damaged/worn  Replace. Checking the valve lifter 1. Check: • Valve lifter Damaged/scratched/worn  Replace. 2. Measure: 2. Measure: • Cam lobe height “a” • Valve lifter outside diameter “a” Out of specification ...

  • Page 274: Checking The Camshaft Journal Oil Clearance

    Camshaft STBD PORT Runout 0.030 mm (0.0012 in) Checking the camshaft journal oil clearance 1. Install: • Camshaft • Plastigauge (PG-1) “1” Do not place the Plastigauge (PG-1) over the oil hole in each camshaft journal. 3. Tighten: • Camshaft cap bolt “1”, “2” Place the camshafts onto the cylinder head, a.

  • Page 275: Checking The Camshaft Journal Outside Diameter And Camshaft Journal Inside Diameter

    Camshaft 5. Measure: 2. Install: • Width of the Plastigauge (PG-1) “1” • Camshaft cap Out of specification  Check the camshaft See “Checking the camshaft journal oil journal outside diameter and camshaft clearance” (7-42). journal inside diameter. See “Checking the 3.
  • Page 276 Camshaft STBD Check that the large “” mark “a” on the crank- shaft is aligned with the mating surface of the crankcase and cylinder block. 3. Install: • Valve lifter “1” 2. Apply: • Camshaft “2”, “3”, “4”, “5” • Camshaft cap •...
  • Page 277 Camshaft a. Check that the dowel pins “1” and “2” STBD PORT on the camshafts (PORT) are aligned with the mating surface of the cylinder head. PORT b. Check that the dowel pins “1” and “2” e. Tighten the camshaft cap bolts “1” and on the camshafts (STBD) are posi- “2”...
  • Page 278 Camshaft Check that the dowel pins “1” and “2” Check that the lower edges “a” and “b” on the camshafts (PORT) are aligned, of the driven sprocket and VCT as- and check that the dowel pins “3” and semblies are aligned. “4”...
  • Page 279 Camshaft STBD When tightening the VCT cap, do not se- cure the camshaft. Otherwise, the VCT as- sembly could be damaged. o. Turn the crankshaft clockwise 60 gradually until the large “” mark “a” on the crankshaft is aligned with the rib “b”...
  • Page 280 Camshaft Tighten the cylinder head cover bolts to the specified torques in 2 stages. Cylinder head cover bolt 1st: 8 N·m (0.8 kgf·m, 5.9 lb·ft) 2nd: 8 N·m (0.8 kgf·m, 5.9 lb·ft) 7-48...

  • Page 281: 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) 55 N·m (5.5 kgf·m, 41 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 23 N·m (2.3 kgf·m, 17 lb·ft) Part name Q’ty...

  • Page 282: 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 Remove the cylinder head bolts (M11) using a Conventional special service tool triple-square type.

  • Page 283: Checking The Cylinder Head

    Cylinder head Checking the cylinder head bolt 2. Remove: • Valve seal “1” 1. Measure: • Cylinder head bolt diameter Above specification  Replace. Measure the diameters “a” and “b” of the cylin- der head bolt (M11) at the specified measuring points “c”...

  • Page 284: Checking The Valve

    Cylinder head Free length IN Margin thickness IN 48.08 mm (1.89 in) 0.75–1.15 mm (0.0295–0.0453 Limit 45.67 mm (1.80 in) Margin thickness EX Free length EX 0.90–1.30 mm (0.0354–0.0512 48.08 mm (1.89 in) Limit 3. Measure: 45.67 mm (1.80 in) •...

  • Page 285: Checking The Valve Guide

    Cylinder head Replacing the valve guide Runout limit IN After replacing a valve guide, check the valve 0.01 mm (0.0004 in) seat contact area. Runout limit EX 1. Remove: 0.01 mm (0.0004 in) • Valve guide “1” Checking the valve guide (from the combustion chamber side) Before checking the valve guides, make sure that the valve stem diameter is within specifica-...

  • Page 286: Checking The Valve Seat

    Cylinder head 3. Ream: b. Press the valve lightly against the • Valve guide “1” valve seat using the special service tool “1”. • To ream the valve guide “1”, turn the valve guide reamer “2” clockwise. • When removing the valve guide reamer “2”, do not turn it counterclockwise.

  • Page 287: Refacing The Valve Seat

    Cylinder head Valve seat cutter holder 90890-06316 Intake: Valve seat cutter 30 90890-06331 Valve seat cutter 45 90890-06332 Valve seat cutter 60 90890-06333 Exhaust: Valve seat cutter 30 90890-06327 Valve seat cutter 45 90890-06325 Seat contact width IN Valve seat cutter 60 1.10–1.40 mm (0.0433–0.0551 90890-06324 Neway valve seat kit...
  • Page 288 Cylinder head 60° A. Worldwide a. Previous contact width B. USA and Canada e. Adjust the valve seat contact width to specification using a 45 cutter. 45° 45 ° a. Slag or rough surface a. Previous contact width c. Adjust the top edge of the valve seat b.

  • Page 289: Checking The Cylinder Head Anode

    Cylinder head • If the valve seat contact area is too narrow and situated near the top edge of the valve face, cut the top edge of the valve seat using a 30 cutter to center the area, and then set its width using a 45...
  • Page 290 Cylinder head 2. Install: • Valve Valve spring compressor “5” • Valve spring seat 90890-04200 • Valve spring Valve spring compressor attach- • Valve spring retainer ment “6” • Valve cotter 90890-06320 a. Install the valve “1”, valve spring seat Valve spring compressor adaptor “2”, valve spring “3”, and valve spring “6”...

  • Page 291: Installing The Cylinder Head

    Cylinder head c. Tap the valve spring retainer lightly us- ing a plastic hammer to seat the valve cotters “1” securely. Exhaust plug “4” 55 N·m (5.5 kgf·m, 41 lb·ft) Braided plug “5” 23 N·m (2.3 kgf·m, 17 lb·ft) Anode “7” 8 N·m (0.8 kgf·m, 5.9 lb·ft) 3.
  • Page 292 Cylinder head OCV bolt “3” • Tighten the cylinder head bolts (M11) using a 7 N·m (0.7 kgf·m, 5.2 lb·ft) triple-square type. Cylinder head bolt (M11) “7” [1]–[8] • In the second stage, mark the cylinder head 1st: 39 N·m (3.9 kgf·m, 29 lb·ft) bolts (M11) and cylinder head with identifica- 2nd: 180...

  • Page 293: 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) 23 24 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 294: 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 295: Assembling The Oil Pump

    Oil cooler and oil pump assembly Assembling the oil pump 1. Install: • Oil seal “1” (into the oil pump housing “2”) Install an oil seal halfway into the oil pump housing, and then install the other oil seal. A. Worldwide B.

  • Page 296: Installing The Oil Pump Assembly

    Oil cooler and oil pump assembly 2. Tighten: • Oil cooler bolt “6” Oil pump cover screw “5” a. Tighten the oil cooler bolts “6” to the 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) specified torques in 2 stages and in Installing the oil pump assembly the order [1], [2], and so on.

  • Page 297: 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” Tighten the oil filter bracket bolts “3” to the specified torque in the order [1], [2], and so on. Oil filter union bolt “1”...
  • Page 298 Oil cooler and oil pump assembly Oil filter “1” 18 N·m (1.8 kgf·m, 13 lb·ft) 7-66...

  • Page 299: Cylinder Block Sensor And Switch

    Cylinder block sensor and switch Cylinder block sensor and switch 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) 14 N·m (1.4 kgf·m, 10 lb·ft) 28 N·m (2.8 kgf·m, 21 lb·ft) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft) Part name...
  • Page 300 Cylinder block sensor and switch 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) 14 N·m (1.4 kgf·m, 10 lb·ft) 28 N·m (2.8 kgf·m, 21 lb·ft) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft) Part name Q’ty...

  • Page 301: Checking The Thermostat

    Cylinder block sensor and switch Checking the thermostat Installing the thermostat 1. Measure: 1. Install: • Valve opening “a” • Thermo switch “1” (at the specified water temperatures) • Gasket “2” Out of specification  Replace. • Thermostat housing “3” •...

  • Page 302: Installing The Cooling Water Cover

    Cylinder block sensor and switch STBD PORT c. 45 Thermostat housing bolt “4” 12 N·m (1.2 kgf·m, 8.9 lb·ft) Thermostat cover bolt “8” 12 N·m (1.2 kgf·m, 8.9 lb·ft) Installing the cooling water cover 3. Tighten: 1. Install: • Cooling water cover bolt “1” •...

  • Page 303: 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”, “7” •...

  • Page 304: 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) 28 N·m (2.8 kgf·m, 21 lb·ft) 14 N·m (1.4 kgf·m, 10 lb·ft) 90° 28 N·m (2.8 kgf·m, 21 lb·ft) Part name Q’ty Remarks...

  • Page 305: Disassembling The Cylinder Block

    Cylinder block Disassembling the cylinder block 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 306: Checking The Piston Diameter

    Cylinder block Bearing separator “2” 90890-06534 Gear puller “3” 90890-06540 Needle bearing attachment “4” 90890-06615 Bearing separator “5” (commercially available) Gear puller “6” (commercially available) Piston Needle bearing remover and in- Diameter staller “7” 95.945–95.960 mm (3.7774– YB-06346 3.7779 in) Limit 5.

  • Page 307: Checking The Piston Clearance

    Cylinder block Cylinder Piston ring dimensions Bore Top ring 96.000–96.012 mm (3.7795– Height (B) 3.7800 in) 1.170–1.185 mm (0.0461–0.0467 Limit 96.072 mm (3.7824 in) Width (T) 2.800–3.000 mm (0.1102–0.1181 Checking the piston clearance 1. Measure: 2nd ring • Piston diameter Height (B) See “Checking the piston diameter”...

  • Page 308: Checking The Piston Ring Groove

    Cylinder block Checking the piston ring side clear- Piston ring end gap ance End gap measuring point 1. Measure: 20.0 mm (0.79 in) • Piston ring side clearance Top ring Above specification  Check the piston End gap ring grooves and piston ring. 0.20–0.30 mm (0.0079–0.0118 See “Checking the piston ring groove”...

  • Page 309: Checking The Connecting Rod Small End Inside Diameter And Big End Inside Diameter

    Cylinder block Pin outside diameter When measuring the piston pin boss inside di- 21.996–22.005 mm (0.8660– ameter, do not measure it at the ring groove “b” 0.8663 in) or oil groove “c”. Limit 21.986 mm (0.8656 in) Checking the connecting rod small end inside diameter and big end in- side diameter 1.

  • Page 310: Checking The Connecting Rod Big End Side Clearance

    Cylinder block Checking the connecting rod big end side clearance 1. Measure: • Big end side clearance “a” Above specification  Check the crank- shaft pin width. See “Checking the crankshaft” (7-78). Journal diameter 72.976–72.996 mm (2.8731– 2.8739 in) Crankshaft pin diameter 52.980–53.000 mm (2.0858–...

  • Page 311: Checking The Crankcase Bolt

    Cylinder block Checking the crankcase bolt 1. Measure: • Crankcase bolt diameter Above specification  Replace. Measure the diameters “a” and “b” of the crankcase bolt at the specified measuring points “c” and “d”, and “c” and “e”. 2. Install: •...

  • Page 312: Selecting The Crankshaft Pin Bearing

    Cylinder block 90 ° • When checking the oil clearance, reuse the removed connecting rod bolts. • Make sure that the marks “a” on the connect- ing rod “1” and connecting rod cap “2” face toward the flywheel magneto end of the crankshaft.
  • Page 313 Cylinder block 1. Measure: • Connecting rod big end inside diameter “a” Select the suitable colors “1” for the crankshaft pin bearing from the “Crankshaft pin bearing selection table” (7-82). Big end inside diameter 55.990–56.010 mm (2.2043– 2.2051 in) Rod side bear- Cap side bear- ing color ing color...

  • Page 314: 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 315: Checking The Journal Oil Clearance

    Cylinder block Checking the journal oil clearance 3. Install: • Crankshaft journal bearing (into the crankcase) • After checking the journal oil clearance, check the crankcase bolts. See “Checking Install the crankshaft journal bearings in their the crankcase bolt” (7-79). original positions.

  • Page 316: Selecting The Crankshaft Journal Bearing

    Cylinder block Journal oil clearance 90 ° 0.029–0.045 mm (0.0011–0.0018 [13] [14] Limit [27] [28] 0.065 mm (0.0026 in) [23] [24] Selecting the crankshaft journal bear- [10] [19] [20] When replacing the crankshaft journal bearing, [12] select the bearing as follows. [11] [22] [21]...
  • Page 317 Cylinder block Select the suitable colors “1” for the crankshaft journal bearing from the “Crankshaft journal bearing selection table” (7-86). Block side bear- Crankcase side ing color bearing color “a” Purple Purple “b” Purple Yellow “c” Yellow Yellow “d” Yellow “e”...

  • Page 318: Crankshaft Journal Bearing Selection Table

    Cylinder block Crankshaft journal bearing selection table 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 319: 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 Before assembling the cylinder block, check b.
  • Page 320 Cylinder block Install the crankshaft pin bearings in the origi- Install the crankshaft journal bearings “1” in nal positions. their original positions. 4. Install: • Piston • Apply engine oil to the side of the piston, pis- 6. Install: ton rings, and cylinder wall. •...
  • Page 321 Cylinder block • Install each thrust bearing with its grooves Make sure that the marks “a” on the connecting rod and connecting rod caps “1” are facing to- facing outward. • Fit the protrusion on thrust bearing into the ward the flywheel magneto end of the crank- shaft.
  • Page 322 Cylinder block Crankcase bolt (M10) “4”, “5” [1]– In the second tightening stage for the crank- [16] case bolts (M10) “4” and “5”, mark the crank- 1st: 55 N·m (5.5 kgf·m, 41 lb·ft) case bolts (M10) and the crankcase with 2nd: 90...
  • Page 323 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) ..................8-2 Installing the propeller ..............8-3 Lower unit ................8-4 Removing the lower unit.............

  • Page 324: Lower Unit

    Lower unit Drive shaft and lower case (regular rotation model) ..8-25 Removing the drive shaft............8-26 Removing the forward gear ............8-26 Disassembling the oil seal housing .......... 8-26 Disassembling the drive shaft ..........8-26 Disassembling the forward gear..........8-27 Disassembling the lower case..........
  • Page 325 Lower unit Disassembling the oil seal housing .......... 8-54 Disassembling the drive shaft ..........8-54 Disassembling the lower case..........8-54 Checking the pinion..............8-54 Checking the reverse gear ............8-54 Checking the drive shaft............8-54 Checking the lower case ............8-54 Assembling the drive shaft ............
  • Page 326 Propeller Propeller 54 N·m (5.4 kgf·m, 40 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Cotter pin Propeller Propeller nut M18 Spacer Washer Damper Spacer A. Regular rotation model B. Counter rotation model...

  • Page 327: Propeller

    Propeller Removing the propeller • Make sure to disconnect the battery ca- 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 328: Installing The Propeller

    Propeller When installing the damper “1”, make sure that the spacer does not contact the propeller boss. 2. Tighten: • Propeller nut Place a block of wood between the anti-cavita- b. Install the damper “1” using the special tion plate and the propeller to prevent the pro- service tools and spacer “2”...

  • Page 329: 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) Part name Q’ty Remarks Part name Q’ty Remarks Bolt M10 ...

  • Page 330: Removing The Lower Unit

    Lower unit Removing the lower unit a. Place the outboard motor in an upright position. b. Tilt the outboard motor up, and then • Make sure to disconnect the battery ca- install the special service tool “1” to the bles from the battery, and remove the clip lower unit “2”.

  • Page 331: Checking The Lower Unit For Leakage

    Lower unit Checking the lower unit for leakage Installing the lower unit 1. Install: • Gasket • Make sure to disconnect the battery ca- • Drain screw bles from the battery, and remove the clip • Special service tool “1” (to the oil level plug from the engine shut-off switch.
  • Page 332 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 333: 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 Extension Hose nipple Hose nipple O-ring O-ring Dowel pin Dowel pin Cover Cover...

  • Page 334: 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 335: 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 Rubber seal Intermediate drive Plate shaft Insert cartridge O-ring O-ring Bolt M8  25 mm Cover Cover Oil seal...

  • Page 336: 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 337: Assembling The Water Pump Housing

    Water pump and shift rod 2. Measure: • Intermediate drive shaft runout Needle bearing attachment “2” Above specification  Replace. 90890-06614 Driver rod L3 “3” 90890-06652 Needle bearing attachment “4” YB-06112 Driver handle (large) “5” YB-06071 Installation depth “a” 15.5 mm (0.61 in) b.

  • Page 338: Installing The Shift Rod

    Water pump and shift rod Installation depth “a” • Turn the shift rod assembly “1” clockwise or 10.25–10.75 mm (0.404–0.423 counterclockwise 90, and then push it down so that the tip “a” of the shift rod fits into the groove “b” in the shift slider. 2.
  • Page 339 Water pump and shift rod a. Align the slot “a” in the impeller “2” with the impeller key “1”, and then install Assemble the intermediate drive shaft “2”, the impeller “2”. check the position of the groove “b” of the drive shaft from the hole of the intermediate drive shaft “2”, and then assemble the screw “3”.

  • Page 340: 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 341 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 Thrust washer Reverse gear Tapered roller bearing...

  • Page 342: Removing The Propeller Shaft Housing Assembly

    Propeller shaft housing (regular rotation model) Removing the propeller shaft housing assembly 1. Remove: • Cover 2. Remove: • Ring nut • Claw washer a. Straighten the bent tab “a” on the claw washer. A. Worldwide b. Loosen the ring nut. B.

  • Page 343: 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” A. Worldwide When removing the slider “4”, make sure that B.

  • Page 344: 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. A. Worldwide B. USA and Canada Driver rod L3 “4” 90890-06652 Runout Needle bearing attachment “5”...

  • Page 345: Assembling The Reverse Gear

    Propeller shaft housing (regular rotation model) When installing the slider “3”, make sure that the balls “2” do not fall out of position. Assembling the reverse gear 1. Install: • Thrust washer “1” • Ball bearing “2” 2. Install: • Dog clutch •...
  • Page 346 Propeller shaft housing (regular rotation model) 1. Install: • Tapered roller bearing outer race “1” a. Heat the installation area of the ta- pered 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 347 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 348: Installing The Propeller Shaft Housing Assembly

    Propeller shaft housing (regular rotation model) A. Worldwide B. USA and Canada Bearing inner race attachment “2” 3. Install: 90890-06640 • Reverse gear shim “1” Driveshaft bearing installer “3” • Propeller shaft housing assembly “2” YB-06246 • Key “3” a. Turn the drive shaft and check that the Installation depth “a”...
  • Page 349 Propeller shaft housing (regular rotation model) Ring nut “1” Make sure to fit the protrusion “a” on the pro- 155 N·m (15.5 kgf·m, 114 lb·ft) peller shaft housing into the slot “b” in the claw washer “1”. c. Bend one of the 4 tabs on the claw washer outward, and then bend the other 3 tabs inward.

  • Page 350: 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 351: 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 352: Disassembling The Forward Gear

    Drive shaft and lower case (regular rotation model) Disassembling the forward gear b. Secure the drive shaft nut “1” on the drive shaft. c. Loosen the drive shaft nut “1”, and • Use heat-resistant gloves. Otherwise, then remove the drive shaft nut “1” and burns could result.

  • Page 353: 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 354: Checking The Lower Case

    Drive shaft and lower case (regular rotation model) 2. Measure: • Drive shaft runout Above specification  Replace. Runout 0.3 mm (0.012 in) (F250NST, Bearing inner race attachment “2” F250SB, F300FST, F300SB) 90890-06640 Checking the lower case Press load (bearing) 1.
  • Page 355 Drive shaft and lower case (regular rotation model) Press load (bearing) 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 356: 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. • Make sure to face the bearing identification • To prevent fires, remove any flammable mark “a”...

  • Page 357: 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 assembly 2. Install: “3” • Oil seal “1” 90890-06523 Driveshaft bearing installer “4” YB-06246 Pinion gear bushing installer “5” YB-06029 Roller bearing installer/remover “6”...

  • Page 358: Installing The Forward Gear

    Drive shaft and lower case (regular rotation model) 3. Install: • Cover “1” • When installing the pinion “1”, lift up the drive • O-ring “2” shaft “3” slightly and align the splines on the drive shaft with the splines on the pinion. •...
  • Page 359 Drive shaft and lower case (regular rotation model) The correct setting value of the torque wrench varies depending on its length. When tightening the drive shaft ring nut to the specified torque, use the following cal- culation formula to obtain the correct set- ting value.

  • Page 360: 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 361: 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 362: 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 363: Shim Location

    Shimming (regular rotation model) Shim location 8-38...

  • Page 364: 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) • Do not reuse shims. • For forward gear shim (T1), use only 1 shim to obtain the specified shim thickness.
  • Page 365 Shimming (regular rotation model) 4. Measure: • Pinion distance • Measure the distance at 4 points: “a”, “b”, “c”, a. Check that the drive shaft turns and “d”, turning the drive shaft 90 clockwise smoothly. after each measurement. • Write down the measurement data in the b.

  • Page 366: Measuring The Forward Gear Backlash And Reverse Gear Backlash

    Shimming (regular rotation model) Example: Example: Calculated value (B) = 0.70 mm “a” Use the following formula when the Pinion distance measurement (M) = shim thickness adjustment value is 0.52 mm “b” positive. Pinion shim (T3) thickness adjustment Current pinion shim thickness = 0.70 = 0.18 mm The current shim thickness must be Shim thickness adjustment = 0.18 mm...
  • Page 367 Shimming (regular rotation model) 1. Install: • Adapter assembly • Specified forward gear shim (T1) • Thrust bearing • Forward gear assembly See “Installing the forward gear” (8-33). Do not reuse a shim if deformed or scratched. 2. Install: Shift rod socket “1” •...
  • Page 368 Shimming (regular rotation model) d. Turn the drive shaft slowly clockwise and counterclockwise, and then mea- Bearing housing puller claw L “1” sure the backlash between where the 90890-06502 drive shaft stops in each direction. Bearing housing puller “1” YB-06207 Stopper guide plate “2”...
  • Page 369 Shimming (regular rotation model) Example: (mm) Measurement point “a” 0.25 Measurement point “b” 0.26 Measurement point “c” 0.26 Measurement point “d” 0.24 Average 0.2525 Round-down average 0.25 g. Check that the forward gear backlash Propeller nut “5” (shimming) average is within specification. 10 N·m (1.0 kgf·m, 7.4 lb·ft) c.

  • Page 370: 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 Shift rod socket “1” in) (F250NST, F250SB, YB-06681 F300FST, F300SB) d. While turning the shift rod toward the g. Remove the special service tools, and R position using the specified torque, then install the water pump assembly.
  • Page 371 Shimming (regular rotation model) b. Turn the propeller shaft 5 turns or more. Available shim thicknesses Propeller shaft shims c. Install the washer “1” and propeller nut 0.7/0.8/0.9/1.0/1.1/1.2 “2”. (F250NST, F250SB, F300FST, F300SB) d. Measure the motive torque of the pro- peller shaft.

  • Page 372: 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) 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 373 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) 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 Thrust bearing Propeller shaft shim —...

  • Page 374: 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” (8-18). • Ring nut •...

  • Page 375: Checking The Propeller Shaft

    Propeller shaft housing (counter rotation model) Checking the forward gear 1. Check: • Teeth and dogs of the forward gear Cracked/worn  Replace. Assembling the propeller shaft hous- ing and forward gear 1. Install: • Needle bearing • Oil seal A.
  • Page 376 Propeller shaft housing (counter rotation model) b. Install the tapered roller bearing outer race “2” using the special service tool When installing the slider “3”, make sure that “1”. the balls “2” do not fall out of position. Ring nut wrench “1” 90890-06578 Gland nut wrench “1”...

  • Page 377: Installing The Propeller Shaft Housing Assembly

    Propeller shaft housing (counter rotation model) 7. Install: • Cross pin “1” • Spring “2” Installing the propeller shaft housing assembly 1. Install: • Propeller shaft housing assembly a. Install new forward gear shims “1”, propeller shaft housing assembly “2”, and key “3”.

  • Page 378: 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 379: Removing The Drive Shaft

    Drive shaft and lower case (counter rotation model) Removing the drive shaft See “Removing the drive shaft” (8-26). Make sure to fit the dowel “5” into the slot “a” in the lower case. Removing the reverse gear 1. Remove: • Reverse gear assembly •...

  • Page 380: Shimming (Counter Rotation Model)

    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 381 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 382 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 383 Shimming (counter rotation model) Shim location 8-58...
  • Page 384 Shimming (counter rotation model) Selecting the reverse gear shim (T1) and forward gear shim (T2) 1. Select: • Reverse gear shim (T1) • Forward gear shim (T2) • Do not reuse shims. • For reverse gear shim (T1), use only 1 shim to obtain the specified shim thickness.
  • Page 385 Shimming (counter rotation model) 2. Install: • Specified forward gear shim (T2) Use the rounded measurement value for the • Propeller shaft assembly free play measurement. • Propeller shaft housing assembly • Claw washer (do not bend the tabs) • Ring nut b.
  • Page 386 Shimming (counter rotation model) Measuring the forward gear backlash and reverse gear backlash Use up to 3 shims to obtain the required shim • Spray anti-rust lubricant on the gear and thickness. bearings before installation. Do not apply gear oil to the parts. Otherwise, correct mea- Calculation formula: surements cannot be obtained.
  • Page 387 Shimming (counter rotation model) 3. Install: • Specified forward gear shims (T2) • Propeller shaft assembly • Propeller shaft housing assembly • Key • Claw washer (do not bend the tabs) • Ring nut See step (1) in “Installing the propeller shaft housing assembly”...
  • Page 388 Shimming (counter rotation model) c. Install the special service tool “1” onto the drive shaft at the lowest possible position where the shaft diameter is 22.4 mm (0.881 in), and then set up the special service tools “2”, “3”, and “4”.
  • Page 389 Shimming (counter rotation model) h. Check that the forward gear backlash c. While turning the drive shaft, move the average is within specification. gear shift toward the R position. Set the shift rod at the position where the protrusion “a” on the dog clutch hits Repeat steps from the selection of the reverse the protrusion “b”...
  • Page 390 Shimming (counter rotation model) Do not turn the drive shaft using too much force. Otherwise, the reverse gear will turn, leading to incorrect measurements. 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.
  • Page 391 Bracket unit Shift rod and SPS ............... 9-1 Installing the shift rod and SPS ..........9-2 PTT switch and cowling lock lever ........9-3 Bottom cowling ..............9-5 Upper case and mounts ............ 9-6 Removing the upper case ............9-7 Installing the upper case ............

  • Page 392: Bracket Unit

    Bracket unit Installing the PTT unit............... 9-33 PTT motor ................. 9-36 Removing the reservoir ............9-37 Disassembling the PTT motor ..........9-37 Checking the PTT motor ............9-37 Checking the brush ..............9-38 Checking the reservoir ............. 9-38 Checking the filter..............9-38 Assembling the PTT motor............

  • Page 393: 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 394: 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 395: Ptt Switch And Cowling Lock Lever

    PTT switch and cowling lock lever PTT switch and cowling lock lever 1 10 1 Part name Q’ty Remarks Part name Q’ty Remarks Bolt M6  12 mm Clamp Bracket Bracket Joint Bracket Hose Bracket Joint Holder Joint Bracket Gasket Screw M6 ...
  • Page 396 PTT switch and cowling lock lever 1 10 1 Part name Q’ty Remarks Cowling lock lever (STBD) Cowling lock lever (PORT) Cowling lock lever (front)

  • Page 397: Bottom Cowling

    Bottom cowling Bottom cowling Part name Q’ty Remarks Part name Q’ty Remarks Bolt M8  35 mm Bracket Collar Bracket Grommet Rubber seal Cap seal Grommet Bolt M6  16 mm Bracket Grommet Collar Grommet Bottom cowling Rubber seal Rubber seal Oil dipstick Bolt M6 ...

  • Page 398: 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 399: Removing The Upper Case

    Upper case and mounts Removing the upper case 1. Drain: • Engine oil 2. Remove: • Upper case Before removing the upper case, loosen the upper mount bolts “1” and lower mount cover bolts (PORT and STBD) “2”. 2. Install: •...
  • Page 400 Upper case and mounts The ground lead “1” should be installed on the same side as originally installed. 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) 3. Install: •...
  • Page 401 Upper case and mounts Upper mount bolt “1” 55 N·m (5.5 kgf·m, 41 lb·ft) Lower mount bolt “2” 54 N·m (5.4 kgf·m, 40 lb·ft) 5. Install: • Ground lead “1” • Speed sensor hose “2” • Adapter “3” • Plastic tie “4” •...

  • Page 402: 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 403: Disassembling The Upper Case

    Upper case Disassembling the upper case b. Remove the special service tool (hold- er) “3”, and then connect the special 1. Remove: service tools “4” and “5” or “4” and “6” • Circlip “1” to the special service tool (rod) “2”. •...

  • Page 404: 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 housing remover “6” YB-06335 Checking the exhaust guide anode 1. Check: • Anode Eroded (1/2 or more worn out)  Replace. A.
  • Page 405 Upper case 3. Install: • Dowel pin “1” Oil pan assembly bolt (M8) “6” • Rubber seal “2” 20 N·m (2.0 kgf·m, 15 lb·ft) • Rubber seal “3” Oil pan assembly bolt (M10) “7” • Rubber seal “4” 42 N·m (4.2 kgf·m, 31 lb·ft) •...

  • Page 406: 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 407: Checking The Oil Pan And Exhaust Manifold

    Oil pan and exhaust manifold Checking the oil pan and exhaust manifold 1. Clean: • Removed parts 2. Check: • Exhaust guide • Exhaust manifold • Muffler • Oil pan Corroded/cracked  Replace. Checking the oil strainer 1. Check: • Oil strainer 3.
  • Page 408 Oil pan and exhaust manifold Oil pan bolt Muffler bolt “6” 20 N·m (2.0 kgf·m, 15 lb·ft) 1st: 20 N·m (2.0 kgf·m, 15 lb·ft) Exhaust manifold bolt “4” 2nd: 20 N·m (2.0 kgf·m, 15 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 4.

  • Page 409: 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) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 13 N·m (1.3 kgf·m, 9.6 lb·ft) 60 N·m (6.0 kgf·m, 44 lb·ft) Part name Q’ty Remarks...
  • Page 410 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) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 13 N·m (1.3 kgf·m, 9.6 lb·ft) 60 N·m (6.0 kgf·m, 44 lb·ft) Part name Q’ty Remarks Bushing Steering arm *.

  • Page 411: Removing The Power Steering Unit

    Steering actuator and steering arm Removing the power steering unit 1. Remove: • Clamp bracket side cover “1” • Swivel bracket top cover “2” d. Turn the shaft “a” of the steering actu- ator “1” counterclockwise until the port end of the shaft is the specified length “b”, and then move the steering actua- tor to the port side as shown.

  • Page 412: Removing The Steering Arm

    Steering actuator and steering arm Remove the steering arm joint “1”, and then remove the guide “2” from the pin Needle bearing attachment “2” “a”. 90890-06612 Driveshaft bearing installer “2” YB-06155 Gear puller “3” (commercially available) Checking the steering arm and steer- ing arm joint 1.

  • Page 413: Installing The Steering Actuator

    Steering actuator and steering arm a. Install the steering yoke “1” so that it faces the same direction as the steer- ing arm “2” (aligning “a” with “b”). Installing the steering actuator If the steering actuator is removed, the calibra- tion is required after installation.
  • Page 414 Steering actuator and steering arm a. Turn the shaft “a” of the steering actu- ator “1” until the port end of the shaft is • Fit the grommets “a” on the SCU positive the specified length “b”. lead “b” and SCU negative lead “c” into the slots “d”...
  • Page 415 Steering actuator and steering arm d. Turn the shaft “a” of the steering actu- ator “1” clockwise to position the shaft in the center steering position. Steering arm joint bolt “2” 27 N·m (2.7 kgf·m, 20 lb·ft) e. Install the steering actuator brackets 4.

  • Page 416: 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 417: Removing The Clamp Bracket

    Clamp bracket and swivel bracket Removing the clamp bracket 1. Remove: • PTT unit See “Removing the PTT unit” (9-28). Checking the clamp bracket anode 1. Check: • Anode Eroded (1/2 or more worn out)  Replace. Adhered grease, oil, paint, or scales  Clean.
  • Page 418 Clamp bracket and swivel bracket 2. Inject: • Grease Inject grease into the grease nipples “1” until grease comes out from both the port and star- board bushings “2”. 3. Install: • PTT unit See “Installing the PTT unit” (9-33). 9-26...

  • Page 419: Ptt Unit

    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 420: Removing The Ptt Unit

    PTT unit Removing the PTT unit d. Push in the pin “1” to the mark “a” po- sition on the pin-extraction tool, and then remove the shaft “2”. When removing or installing the PTT unit 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 421: 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 a. Place the PTT unit in an upright posi- tighten it to the specified torque.
  • Page 422 PTT unit d. Connect the battery jumper leads to h. Connect the battery jumper leads to the PTT motor lead “1” to fully retract the PTT motor lead to fully retract the the trim rams, and then measure the PTT rams. hydraulic pressure when the reading Loosen the pipe joints “3”, and then re- on the pressure gauge stabilizes.

  • Page 423: Bleeding The Ptt Unit

    PTT unit k. Connect the battery jumper leads to PTT motor lead Battery the PTT motor lead “1” to fully extend Green (G) the trim rams, and then measure the Retract hydraulic pressure when the reading Blue (L) (–) on the pressure gauge stabilizes. m.
  • Page 424 PTT unit b. Turn the manual valve “1” clockwise to close it. PTT motor lead Battery Blue (L) Extend Manual valve “1” Green (G) (–) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Repeat steps (d) and (e) to fully ex- tend and retract the PTT rams 4 or 5 c.

  • Page 425: Installing The Ptt Unit

    PTT unit Installing the PTT unit PTT unit mounting bolt 42 N·m (4.2 kgf·m, 31 lb·ft) When removing or installing the PTT unit with the power unit or upper case assembly c. Route the PTT motor lead “1” through installed, make sure to suspend the out- the hole “a”...
  • Page 426 PTT unit a. Connect the battery jumper leads to d. Assemble the PTT sensor assembly the PTT motor lead “1” to extend the “1” and upper mount shaft assembly PTT rams until the end of the tilt ram is “2” to the swivel bracket. aligned with the mounting position hole.
  • Page 427 PTT unit Push in the pin “1” to the mark “a” po- sition on the pin-extraction tool. By pushing it to the mark “a” position on the pin-extraction tool, the pin “1” will then be in- stalled in the correct position. g.

  • Page 428: 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 429: 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 430: Checking The Brush

    PTT motor 4. Check: • Armature continuity Out of specification  Replace the arma- ture assembly. Motor base assembly continuity “a” “b” “c” “d” “e” “f” Armature continuity “a” “b” “c” “d” Checking the brush 1. Measure: • Brush length 3.

  • Page 431: Installing The Reservoir

    PTT motor 1. Assemble: • Motor base assembly • Oil seal • Washer • Circuit breaker “1” • Spring “2” Stator screw 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) Installing the reservoir 1. Install: • Spacer 2. Install: • Filter • Armature “1” •...
  • Page 432 PTT motor b. Turn the joint “1” using a screwdriver to remove any air between the pump • When the plastic tie securing the PTT motor gear teeth. lead is removed, fasten the PTT motor lead using the 2 plastic ties “1” when installing it. •...

  • Page 433: 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 pin Manual valve Valve seal Bolt M5  25 mm O-ring Bolt M5 ...
  • Page 434 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 O-ring Spring Up-main valve E-clip Main valve seal Down-main valve O-ring 9-42...

  • Page 435: 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” Before removing the valve lock screws “1”, measure and write down the screw depth “a”...
  • Page 436 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 437: Installing The Gear Pump Assembly

    PTT gear pump Installing the gear pump assembly 1. Install: • Install the valve lock screw “4” and valve lock • Filter “1” screw “9” to the depth “a” and height “b” that • Spacer “2” were measured before removing them. •...

  • Page 438: Ptt Cylinder

    PTT cylinder PTT cylinder 160 N·m (16 kgf·m, 118 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 439: Removing The Tilt Ram

    PTT cylinder Removing the tilt ram 4. Remove: • Free piston a. Cover the tilt cylinder using a rag “1”, Before removing the tilt cylinder end screw, and then blow compressed air through make sure that the PTT rams are fully ex- the hole “a”...

  • Page 440: Disassembling The Tilt Ram

    PTT cylinder Cylinder end screw wrench “2” PTT piston vice attachment “2” 90890-06591 90890-06572 Trim cylinder wrench “3” PTT piston vice tool “2” YB-06175-2B YB-06572 Tilt rod wrench “3” 2. Drain: 90890-06569 • PTT fluid Tilt rod wrench “3” YB-06569 Disassembling the tilt ram Checking the tilt cylinder and trim cyl- 1.

  • Page 441: Assembling The Tilt Ram

    PTT cylinder Assembling the tilt ram PTT piston vice attachment “2” 90890-06572 When assembling the PTT unit, do not use PTT piston vice tool “2” a rag. Otherwise, dust and particles could YB-06572 get on the PTT unit components, causing Tilt rod wrench “3”...

  • Page 442: 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 443: Installing The Tilt Ram

    PTT cylinder Installing the tilt ram Fill the trim cylinders with the recommended fluid up to the proper level “a”. When assembling the PTT unit, do not use a rag. Otherwise, dust and particles could get on the PTT unit components, causing poor performance.
  • Page 444 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 445: 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 446: Outline

    • If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and quality. Any parts of inferior quality may cause a malfunction, and the resulting loss of control could endanger the operator and passengers.
  • Page 447 Outline Initial Every Item Actions 20 hours 100 hours 300 hours 500 hours (3 months) (1 year) (3 years) (5 years) Engine oil Replacement Engine oil filter (car- Replacement tridge) Fuel filter (can be disas- Inspection or replace- sembled) ment as necessary Fuel line (High pres- Inspection sure)

  • Page 448: Maintenance Interval Chart 2

    Connector connec- Inspection or replace- tions/lead connections ment as necessary (Yamaha) Meter/gauge Inspection Inspection or replace- SBW (Steer-by-wire) ment as necessary *1 cylinder head exhaust passage *2 cylinder head, cylinder block, cylinder block thermostat portion, oil cooler cover, exhaust guide...

  • Page 449: 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 450 Predelivery check Item Procedures 8-10 Check that the gear shift operates properly when the remote con- 8-15 trol lever is moved from the N position to the F or R position. 8-47 Not properly  Check the shift actuator and related parts. Shift and throttle operation Check that the throttle operates properly when the remote control...
  • Page 451 Predelivery check Item Procedures Operate the engine under load (in gear with a propeller installed) — for 10 hours. For the first hour of operation: Operate the engine at varying speeds up to 2000 r/min or approx- — imately 1/2 throttle. For the second hour of operation: Increase the engine speed until the boat is on plane (but do not Break-in...

  • Page 452: 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 453: Checking The Cooling Water Pilot Hole

    Predelivery check 2. Check: • Specific gravity of the electrolyte Below specification  Fully charge the battery. • Batteries vary depending on the manufactur- er. The procedures mentioned in this manual may not always apply. Therefore, see the in- struction manual of the battery. •...

  • Page 454: Checking The Power Trim And Tilt Unit

    Predelivery check Checking the power trim and tilt unit 1. Check: • Power trim and tilt unit Abnormal noise  Check the PTT unit. Interference  Check the hose and wire harness routing, or mounting of the out- board motor. Does not display ...

  • Page 455: General Periodic Maintenance

    General periodic maintenance General periodic maintenance Item Procedures 7-62 Check the anodes. 7-57 Eroded (1/2 or more worn out)  Replace. Anodes 7-87 Adhered grease, oil, paint, or scales  Clean. 9-25 Check the battery electrolyte level. Below the minimum level mark  Add distilled water. Battery 10-7 Check the specific gravity of the electrolyte.
  • Page 456 General periodic maintenance Item Procedures Exhaust guide Check the exhaust joint and exhaust guide. 9-15 Corroded/cracked/damaged  Replace. Exhaust manifold Check the fuel filter element. Dirt/residue  Replace. Water accumulated  Drain. Checking the fuel cup assembly. Foreign material  Clean. Fuel filter Cracked ...
  • Page 457 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. 9-17 Not smooth ...

  • Page 458: Checking The Cooling Water Inlet

    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- a. Remove the water inlet covers “1”, “2”, shooting procedures.

  • Page 459: Changing The Engine Oil By Removing The Drain Bolt

    General periodic maintenance 3. Drain: d. Insert the dipstick “1” completely for a • Engine oil correct measurement and remove it a. Remove the oil filler cap “1”. again. e. Check that the oil level indicated on the dipstick “1” is between the upper mark “a”...
  • Page 460 General periodic maintenance 2. Remove: a. Install a new gasket “1” and then tight- • Top cowling en the drain bolt “2” with specified • Apron “1” torque. Drain bolt “2” 27 N·m (2.7 kgf·m, 20 lb·ft) 5. Fill: 3. Drain: •...

  • Page 461: Replacing The Oil Filter

    General periodic maintenance Replacing the oil filter e. Check that the oil level indicated on the dipstick “1” is between the upper 1. Warm up: mark “a” and the lower mark “b”. • Engine See step (1) in “Changing the engine oil using an oil changer”...

  • Page 462: Changing The Gear Oil

    General periodic maintenance Changing the gear oil b. Install a new oil filter “1”. 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 463 General periodic maintenance e. After the gear oil has been drained, check the used oil. Pressure test the Gear oil quantity lower case and inspect the oil seal for 0.885 L (0.935 US qt, 0.779 damage if the oil is milky. See “Bleed- Imp.qt) (FL250NST, FL300FST, ing the PTT unit”...

  • Page 464: Greasing Points

    General periodic maintenance Greasing points 1. Apply: • Specified lubrication points a. Apply water resistant grease to the specified lubrication points. b. Apply temperature resistant grease to the specified lubrication point. c. Apply corrosion resistant grease to the specified lubrication point. 10-19...

  • Page 465: 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 466 General periodic maintenance d. Recheck the fitting. Replace the rub- ber seal if looseness or rattling cannot be adjusted. 10-21...

  • Page 467: Appendix

    Appendix Specification ...............A-1 Model data.................. A-1 Electrical system technical data ..........A-3 Fuel system technical data............A-6 Power unit technical data ............A-6 Lower unit technical data............A-8 Bracket unit technical data ............A-9 Wiring diagram ..............A-10 How to use the wiring diagram ..........A-10 Engine control unit..............
  • Page 468 FL250N, Specification F250N, F300F, FL300F, LF250B, Model F250B_EUR, F250B, F300B Model data LF250B_EUR, LF300B F300B_EUR LF300B_EUR Dimension and weight 83.9 L/h at 83.9 L/h at FL250N, F250N, F300F, 5500 r/min 5500 r/min 83.9 L/h at 83.9 L/h at FL300F, LF250B,...
  • Page 469 FL250N, FL250N, F250N, F300F, F250N, F300F, FL300F, LF250B, FL300F, LF250B, Model F250B_EUR, F250B, F300B Model F250B_EUR, F250B, F300B LF250B_EUR, LF300B LF250B_EUR, LF300B F300B_EUR F300B_EUR LF300B_EUR LF300B_EUR Exhaust system Through propeller boss Min. pump octane num- 89 (F300FST_ 89 (FL300FST_ 86 (F250SB)
  • Page 470 FL250N, FL250N, F250N, F300F, F250N, F300F, FL300F, LF250B, FL300F, LF250B, Model F250B_EUR, F250B, F300B Model F250B_EUR, F250B, F300B LF250B_EUR, LF300B LF250B_EUR, LF300B F300B_EUR F300B_EUR LF300B_EUR LF300B_EUR 80 Ah 80 Ah Output peak voltage at (F250SB, (FL300FST_ 1500 r/min (loaded) (ref- 23.9 V...
  • Page 471 Fuel injection control system FL250N, F250N, F300F, FL300F, LF250B, FL250N, Model F250B_EUR, F250B, F300B F250N, F300F, LF250B_EUR, LF300B FL300F, LF250B, F300B_EUR Model F250B_EUR, F250B, F300B LF300B_EUR LF250B_EUR, LF300B F300B_EUR LF300B_EUR Output voltage at gear Water detection switch shift in the F position 0.47–1.68 V...
  • Page 472 PTT system FL250N, F250N, F300F, FL300F, LF250B, FL250N, Model F250B_EUR, F250B, F300B F250N, F300F, LF250B_EUR, LF300B FL300F, LF250B, F300B_EUR Model F250B_EUR, F250B, F300B LF300B_EUR LF250B_EUR, LF300B F300B_EUR Standard commutator LF300B_EUR 0.8 mm (0.03 in) undercut PTT sensor Wear limit 0.2 mm (0.01 in) Output voltage at full tilt- 4.23 V...
  • Page 473 Fuel system technical data FL250N, F250N, F300F, FL300F, LF250B, Model F250B_EUR, F250B, F300B Fuel system LF250B_EUR, LF300B F300B_EUR FL250N, LF300B_EUR F250N, F300F, FL300F, LF250B, Thermostat Model F250B_EUR, F250B, F300B LF250B_EUR, LF300B F300B_EUR Valve opening tempera- LF300B_EUR 50–54 °C (122–129 °F)
  • Page 474 FL250N, Crankcase assembly F250N, F300F, FL300F, LF250B, FL250N, Model F250B_EUR, F250B, F300B F250N, F300F, LF250B_EUR, LF300B FL300F, LF250B, F300B_EUR Model F250B_EUR, F250B, F300B LF300B_EUR LF250B_EUR, LF300B F300B_EUR Valve lifter LF300B_EUR Outside diameter 30.970–30.980 mm (1.2193–1.2197 in) Cylinder Clearance IN (reference Bore 96.000–96.012 mm (3.7795–3.7800 in)
  • Page 475 FL250N, FL250N, F250N, F300F, F250N, F300F, FL300F, LF250B, FL300F, LF250B, Model F250B_EUR, F250B, F300B Model F250B_EUR, F250B, F300B LF250B_EUR, LF300B LF250B_EUR, LF300B F300B_EUR F300B_EUR LF300B_EUR LF300B_EUR Piston ring (Oil) Available shim thicknesses Height (B) 2.400–2.470 mm (0.0945–0.0972 in) 0.10/0.12/0.15/ 0.10/0.12/0.15/ Pinion shims 0.18/0.30/0.40/...
  • Page 476 Lower unit assembly (counter rotation model) FL250N, F250N, F300F, FL300F, LF250B, FL250N, Model F250B_EUR, F250B, F300B F250N, F300F, LF250B_EUR, LF300B FL300F, LF250B, F300B_EUR Model F250B_EUR, F250B, F300B LF300B_EUR LF250B_EUR, LF300B F300B_EUR Drive shaft LF300B_EUR 0.05–2.60 N·m 0.05–2.60 N·m Lower unit (0.01–0.27...

  • Page 477: 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”, “Charg- ing unit and starting unit”, and “PTT unit”. Legend symbols in the wiring diagrams 1.
  • Page 478 Engine control unit 1. Engine ECM 2. Fuse holder 3. House (accessory) battery 4. Battery 5. Joint connector 1 6. Joint connector 2 2. Fuse holder 4. Battery 7. Joint connector 4 8. Joint connector 5 9. Bonder 3 3. House 10.
  • Page 479 Fuel unit 1. Engine ECM 2. Fuse holder 3. House (accessory) battery 4. Battery 5. Joint connector 1 6. Joint connector 2 7. Joint connector 4 4. Battery 8. Joint connector 5 9. Bonder 3 10. Fuel injector 2. Fuse holder 3.
  • Page 480 Ignition unit 1. Engine ECM 2. Fuse holder 3. House (accessory) battery 4. Battery 5. Joint connector 1 6. Joint connector 2 2. Fuse holder 7. Joint connector 4 4. Battery 8. Joint connector 5 9. Bonder 3 10. Thermo switch (PORT) 3.
  • Page 481 Charging unit and starting unit 1. Engine ECM 2. Fuse holder 3. Starter motor 4. House (accessory) battery 5. Battery 6. Rectifier/regulator/isolator 7. Joint connector 5 8. Lighting coil 9. Bonder 3 a. Fuse (30 A) (starter relay) b. Fuse (15 A) (high-pressure fuel pump) 2.
  • Page 482 PTT unit 1. Engine ECM 2. Fuse holder 3. House (accessory) battery 4. Battery 5. Joint connector 1 6. Joint connector 2 2. Fuse holder 7. Joint connector 4 4. Battery 8. Joint connector 5 9. Diode 10. PTT relay 3.House 11.
  • Page 483 Rectifier/regulator/isolator continuity table Rectifier/regulator/isolator continuity table A-16...
  • Page 484 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” Except for “a”, “b”...
  • Page 485 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 486 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 487 (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 488 Shim selection table and chart (counter rotation model) Calculated value (B) table See “Calculated value (B) table” (A-18). Pinion shim (T3) selection table See “Pinion shim (T3) selection table” (A-19). 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...
  • Page 489 Feb. 2024 ! (E_1)
  • Page 490 Worldwide: (6KD) (6KE) (6KA) (6KB) USA, CAN, EUR, AUS and NZL: (6KD) (6KE) (6KA) (6KB) ● 6KA-28197-Z3-11 LIT-18616-04-31 Feb. 2024 ! (E_1) 6KA-28197-Z3-11_cover.indd 2024/01/31 16:14:25...

This manual is also suitable for:

Fl250nF300fFl300fF250bLf250bF300b ... Show all

Table of Contents

Save PDF