Page 1 (6JX) (6JY) 6JY-28197-Z0-11...
Page 2 Preface This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained me- chanics 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 ................0-2 Important safety and service information......0-3 Rotating parts ................0-3 Hot parts..................0-3 Electric shock ................0-3 Propeller ..................0-3 Handling of gasoline..............0-3 Ventilation...................
Page 5: Model Information
Model information Model information Applicable model This manual applies to the following models. Model name Approved model code Starting serial No. F75FET F75FEHT 1000001– F100GET F100GEHT Model name designation G EHT X Model category F: 4-stroke Output horsepower 75/100 Model generation Level 1: Starting method E: Electric start Level 2: Control method...
Page 6: General Feature
Model information General feature • Commercial models based on the F90C (6FP) and F100F (6HJ) • External designs of L4 engines (115, 130, 150, 200 HP) preserved. • Electronic fuel injected, 4-stroke, L4, SOHC, 16-valve, 1832 cm³ (111.8 cu. in) engine •...
Page 7: 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 8: 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 9: 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 10: 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 11: How To Use This Manual
How to use this manual How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the following information as a guide for effective and quality service. •...
Page 12: Conditions When Testing And Adjusting
Abbreviation Description Electronic Control Module Idle Speed Control Pressure Control Valve Power Tilt Power Trim and Tilt Throttle Position Sensor Vapor Separator Tank YDIS Yamaha Diagnostic System Color code Black Light green Sky blue Brown Orange White Green Pink Yellow...
Page 13: Specified Tightening Torque
Specified tightening torque Specified tightening torque Specified tightening torques are provided for specific nuts, bolts, and screws. Specified tightening torque specifications are provided in the exploded diagrams and in the related working instructions. When tightening these fasteners, follow the tightening torque specifications and procedures indicated throughout the manual to meet the design aims of the outboard motor.
Page 14: Lubricant, Sealant, And Thread Locking Agent
Symbol Name Application YAMALUBE 4 Lubricant YAMALUBE outboard gear oil Lubricant Water resistant grease Lubricant (Yamaha grease A) Low temperature resistant grease Lubricant (Yamaha grease C) Corrosion resistant grease Lubricant (Yamaha grease D) Molybdenum disulfide grease Lubricant YAMAHA WR-No.2 grease...
Page 15: Special Service Tool
Special service tool Special service tool Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division. Some of the special service tools are only available from the Marine Service Division. Flywheel stopper B Lifting eye Bolt hexagon with...
Page 16 Special service tool Flywheel holder Valve guide Valve guide installer Valve guide reamer 90890-06522 remover/installer 90890-06810 90890-06804 90890-06801 Valve lapper Valve seat cutter Valve seat cutter 30 Valve seat cutter 45 90890-04101 holder 90890-06326 90890-06325 90890-06316 Valve seat cutter 60 Valve seat cutter 30...
Page 17 Special service tool Ring nut wrench exten- Stopper guide plate Bearing housing puller Center bolt sion 90890-06501 claw L 90890-06504 90890-06513 90890-06502 Bearing puller assem- Stopper guide stand Needle bearing attach- Bearing inner race 90890-06538 ment attachment 90890-06535 90890-06653 90890-06640 Drive shaft holder 6 Pinion nut holder Hydraulic drive shaft...
Page 18 Special service tool Tilt rod wrench PTT piston vice attach- 90890-06569 ment 90890-06572 0-14...
Page 19: Specification
Specification Specification data .............. 1-1 External dimensions ............1-1 Clamp bracket dimensions..........1-3...
Page 20: Specification Data
Specification data Specification data For specification data, see Appendix, “Specification” (A-1). External dimensions The dimension values may include reference values. F75FET, F100GET mm (in) L:1006 (39.6) X:1122 (44.2) 544 (21.4) 120 (4.7) 683 (26.9) 75 (3.0) 135 (5.3) 4° L:32 (1.3) X:41 (1.6) 631 (24.8) *1.
Page 21 External dimensions F75FEHT, F100GEHT mm (in) 864 (34.0) L:1006 (39.6) 544 (21.4) X:1122 (44.2) 300 (11.8) 683 (26.9) 75 (3.0) 121 (4.8) L:32 (1.3) X:41 (1.6) 631 (24.8) *1. Motor transom height *2. Fully tilt-up angle (Not tilt support angle)
Page 22: Clamp Bracket Dimensions
Clamp bracket dimensions Clamp bracket dimensions The dimension values may include reference values. mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 82 (3.2) 13 (0.5) 20 (0.8) 13 (0.5) 13 (0.5) 101.5 (4.0) 101.5 (4.0) 125.4 (4.9) 125.4 (4.9)
Page 23 Technical feature and description Electronic control system ..........2-1 Electrical components ..............2-2 Electronic fuel injection control........... 2-4 Ignition timing control ..............2-6 Engine protection control............2-8 ISC valve control ................ 2-9 Knock control................2-9 Battery removal control .............. 2-9 Fail-safe..................
Page 24: Technical Feature And Description
Technical feature and description Fuel system ..............2-18 Silencer ..................2-18 High-pressure fuel pump control ..........2-19 Fuel diagram ................2-19 Lubrication system ............2-21 Lubrication diagram..............2-21 Cooling system ..............2-23 Cooling diagram ............... 2-23 Intake and exhaust system..........2-25 Intake and exhaust diagram .............
Page 25: Electronic Control System
Electronic control system Electronic control system This model uses an electronic fuel injection control, digital ignition control, ISC (Idle Speed Control), knock control, over-rev control, alert control, and fail-safe control. The engine ECM performs these controls based on signals received from each sensor and switch. The engine ECM is equipped with a self-diagnosis function which can be used to check trouble codes on the YDIS.
Page 26: Electrical Components
Electronic control system Electrical components...
Page 27 Electronic control system Part name Function Determines the engine operating conditions based on the input signals from the sensors which are installed at various loca- Engine ECM tions on the engine, and transmits control signals to each actu- ator. Pulser coil Detects the engine speed and crankshaft angle.
Page 28: Electronic Fuel Injection Control
Electronic control system Electronic fuel injection control The engine ECM switches the control mode between the start-up mode, normal operating mode, and fuel injection cutoff mode according to the signals from the sensors. In addition, various compensations are made to determine the actual fuel injection timing and fuel injection volume. Additionally, when the engine start switch is turned to ON, the engine ECM opens the injectors once before activating the high- pressure pump relay to prevent them from sticking.
Page 29 Electronic control system Mode Controls performed by engine ECM For quick engine start (to shorten cranking time), fuel is injected into all cyl- Start-up mode inders until the cylinders have been identified. Normal operating Fuel is injected into cylinders in groups, to #1 and #4, and to #2 and #3 (to mode all cylinders during acceleration).
Page 30: Ignition Timing Control
Electronic control system Ignition timing control This model uses group ignition in cylinders #1 and #4, and in cylinders #2 and #3. The engine ECM switches the control mode between the start-up mode, normal operating mode, and ignition cutoff mode according to the signals from the sensors. In addition, various compensations are made to determine the actual ignition timing and the energiza- tion time of current to the ignition coil.
Page 31 Electronic control system Mode Control items Controls performed by engine ECM Ignition timing when Ignition takes place in all cylinders at BTDC 10 Start-up mode starting during cranking. Ignition timing is set based on signals from the Normal operating Normal ignition tim- pulser coil and the TPS, and all necessary com- mode pensations are made.
Page 32: Engine Protection Control
Electronic control system Engine protection control When engine overheating or low oil pressure is detected, the engine ECM controls fuel injection to pro- tect the engine. 1. Pulser coil 8. Fuel injector #1, #4 2. Thermo sensor 9. Fuel injector #2, #3 3.
Page 33: Isc Valve Control
Electronic control system ISC valve control The engine ECM adjusts the opening of the ISC valve so that engine speed is maintained at a target value when the throttle valve is fully closed. Knock control The engine ECM receives a knock signal from the knock sensor that is installed to the cylinder block. To protect the engine from damage, the engine ECM retards the ignition timing and decreases the en- gine speed according to the amount of knocking.
Page 34 Electronic control system Trouble Trouble conditions to be Item Control and operation code detected The shift position switch is on Water in fuel filter and the water detection switch The alert buzzer sounds. is on. Cranking while in gear. Cranking while the shift posi- Shift position switch ECM does not control.
Page 35: Fuse Box
Fuse box Fuse box This model is fitted with a newly developed fuse box which is an assembly part containing various inte- grated relays. With this new fuse box, the number of parts has been reduced and the serviceability has been improved.
Page 36: Trouble Code Detecting Conditions
Fuse box Trouble code detecting conditions A trouble code is detected if the relays cannot be turned on or off in response to a request from the engine ECM. However, if the main relay cannot be turned on, trouble codes are not detected because the engine ECM is not in operation.
Page 37 Fuse box Relays cannot be turned off (stuck ON) The cause may include: deposition at relay connections, short circuit in wire harnesses, incorrect re- quests or determination of the engine ECM. 8. Fuse box 4. Battery 1. Main relay 3. High-pressure 2.
Page 38: Serviceability
Serviceability Serviceability Rigging grommet The rigging grommet “1” is located on the Lifting the outboard motor STBD side for easier rigging. The outboard motor can be suspended without removing the flywheel magneto cover by at- taching the lifting harness to the designated lift- ing point “1”.
Page 39: Anode
Serviceability Anode The locations of the anodes in the cooling water passages have been optimized, making the anode re- placement easier, for better serviceability. 2-15...
Page 40: Power Unit System
Power unit system Power unit system Flywheel and crankshaft This model uses the flange mount “a” type fly- Overview wheel “1”. This model uses a 4-stroke L4 engine. With the The crankshaft “2” is formed as a one-piece same engine displacement as the larger mod- casting with integrated drive sprocket “b”...
Page 41: Lower Unit
Lower unit Lower unit PTT unit This model uses the PTT unit of the same type Overview as the F115 (6EK). This model uses the proven lower unit that is The up-relief hydraulic pressure setting has used on F115 (6EK). Therefore, required spe- been changed from 16.0 MPa (160.0 kgf/cm², cial service tools and service procedures for 2320.0 psi [F115/6EK]) to 12.5 MPa (125.0...
Page 42: Fuel System
Fuel system Silencer For the F75F model, the orifice plate is located at the silencer joint. On the other hand, the F100G model has no plate. The orifice plate will limit the intake air volume to save the output power.
Page 43: High-Pressure Fuel Pump Control
Fuel system High-pressure fuel pump control The high pressure fuel pump operates for 5 seconds after the engine start switch is turned to ON, and always operates while the engine is running. The pump stops 1 second later after the engine stops. Fuel diagram 5.
Page 44 Fuel system 20. Atmosphere 15. Canister (cowl inside) 18. Check valve 21. Charcoal 19. Atmosphere (cowl outside) 6. Vapor separator 10. Fuel pressure 16. Vapor shut-off valve 17. Intake manifold regulator 294 kPa 11. Fuel rail (2.94 kgf/cm 42.6 psi) Fuel injector Fuel injector Fuel injector...
Page 45: Lubrication System
Lubrication system Lubrication system Lubrication diagram 6. Oil pressure switch 4. Oil filter 1. Oil pan 3. Oil pump 13. Relief valve 2. Oil strainer 9. Piston 10. Cylinder head 12. Valve and 11. Camshaft journal 8. Crankshaft pin oil passage related parts 7.
Page 46 Lubrication system 1. Oil pan 2. Oil strainer 3. Oil pump 4. Oil filter 5. Main gallery 6. Oil pressure switch 7. Crankshaft main journal 8. Crankshaft pin 9. Piston 10. Cylinder head oil passage 11. Camshaft journal 12. Valve and related parts 13.
Page 47: Cooling System
Cooling system Cooling system Cooling diagram 9. Thermostat 10. Oil cooler 12. Joint 5. Exhaust guide 6. PCV 17. Flushing device 4. Oil pan 13. Cooling (muffler) water 11. Fuel pilot hole cooler 18. Drive shaft bushing *1 15. Trim tab water inlet 3.
Page 48 Cooling system 8. Cylinder head 10. Oil cooler 7. Cylinder block 9. Thermostat 12. Joint 11. Fuel cooler 6. PCV 5. Exhaust guide 17. Flushing device 18. Drive shaft 4. Oil pan (muffler) 16. Lower case bushing *1 14. Propeller boss 3.
Page 49: Intake And Exhaust System
Intake and exhaust system Intake and exhaust system Intake and exhaust diagram 3. Intake manifold 1. Intake silencer 2. Throttle body 4. Cylinder head 8. Idle exhaust hole 6. Oil pan (muffler) 5. Exhaust guide 7. Propeller 1. Intake silencer A.
Page 50: Hose Routing
Hose routing Hose routing Fuel hose 1. Joint to fuel filter assembly 2. Fuel filter assembly to low-pressure fuel pump 3. Low-pressure fuel pump to fuel strainer 4. Fuel strainer to vapor separator 5. Vapor separator to fuel rail 2-26...
Page 51: Vapor Gas Hose And Blowby Hose
Hose routing Vapor gas hose and blowby hose 1. Cylinder head cover to intake silencer 2. Vapor separator to joint 3. Joint to canister tank port 4. Canister purge port to vapor shut-off valve 5. Vapor shut-off valve to joint 6.
Page 52: Cooling Water Hose
Hose routing Cooling water hose 1. Cylinder head to cooling water pilot hole 2. Cylinder block to fuel cooler 3. Fuel cooler to joint 4. Cylinder block to oil cooler 5. Oil cooler to joint 6. Joint to thermostat cover 7.
Page 53 Rigging information Important reminder on rigging.......... 3-1 Outboard motor mounting instructions ........3-1 Crate handling ..............3-2 Crate top cover pictograph description........3-2 Uncrating ................3-3 Uncrating procedure..............3-3 Rigging grommet mounting ..........3-4 Rigging grommet description............3-4 Installing the main wire harness ..........3-5 Installing the battery cable............
Page 54: 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 55: Crate Handling
Crate handling Crate handling Crate top cover pictograph description The following pictographs are important when handling the crate. Read the notice and understand what each pictograph means to prevent damage to the outboard motor when handling, transporting, and storing the crate. IMPORTANT This unit delivered to carrier in a good condition.
Page 56: Uncrating
Remove the wrapping, and then check the outboard motor for concealed damage. If any damage is found, con- Remove the bolts “1”. sult your Yamaha agency. e. Remove the top cowling. Install the lifting harness “1” to the en- gine hanger “2”.
Page 57: Rigging Grommet Mounting
Rigging grommet mounting Flywheel stopper B “1” Use the following procedure to suspend the 90890-06686 outboard motor using the special service tool. Lifting eye “2” 90890-06953 Bolt hexagon with washer “3” 1. Remove the bolt “1”, and then remove the 90890-06821 flywheel magneto cover “2”.
Page 58: Installing The Main Wire Harness
Rigging grommet mounting 1. Remove: c. Install the rubber cap “3”. • Grommet holder “1” d. Fasten the battery cable “1” using the • Rigging grommet “2” holder “4”. Installing the main wire harness 1. Install: Positive battery cable nut “2” •...
Page 59: Installing The Throttle Cable
Rigging grommet mounting d. Install the shift cable “3” to the bracket “2”, and then fasten it using the cable Shift cable locknut “4” clamp “1”. 90 Dimension “a” 8.0 mm (0.31 in) or more 2. Check: • Shift cable operation Improper ...
Page 60: Installing The Conventional Gauge (6Y5/6Y7) Harness
Rigging grommet mounting d. Move the accelerator cam “1” so that it contacts the stopper “2”. Dimension “a” 8.0 mm (0.31 in) or more 2. Check: • Throttle cable operation Improper  Repeat from step (1). Installing the conventional gauge (6Y5/6Y7) harness 1.
Page 61: Tiller Handle (Tiller Handle Model)
Tiller handle (tiller handle model) Tiller handle (tiller handle model) c. Install the rigging grommet “1” along with the grommet holder “2”, and then Installing the tiller handle tighten the grommet holder bolts “3” to 1. Install: the specified torque. •...
Page 62: Installing The Friction Plate
Tiller handle (tiller handle model) e. Install the shift cable joint “1” and throt- Install the gauge harness, main wire tle cable joint “1” to the shift cable “2” harness, and battery cable. See “In- and throttle cable “2”. stalling conventional gauge (6Y5/6Y7) harness”...
Page 63: Optional Equipment
Optional equipment Friction plate nut “1” • Tighten or loosen the friction adjusting nut “1” 19.6 N·m (1.96 kgf·m, 14.5 lb·ft) at the steering lock lever in the position “a”. • To increase the friction, tighten the friction b. Install the friction plate assembly “1” adjusting nut “1”...
Page 64: Battery Installation
Battery installation b. Connect the tilt limiter couplers “a” and “b”. Battery installation Make sure to connect the battery properly and select the proper cable sizes. Other- wise, a fire could result. Do not reverse the battery connections. Otherwise, the charging system could be damaged.
Page 65: System Diagram
System diagram System diagram Single engine application (conventional gauge, remote control model) 3-12...
Page 66 System diagram Ref. Part name Part No. Remarks 703-48205-B3 Remote control box 703-48205-23 Tachometer 6Y5-8350T-E0 Conventional gauge harness 6Y5-83653-20 7 m (23 ft) Main wire harness — Wire lead for digital meter 6Y5-83553-00 2.5 m (8 ft) 3-13...
Page 67: Propeller Selection
Propeller selection Propeller selection With the engine speed at full throttle operating range and under a maximum boat load, the engine speed should be within the upper half of the full throttle operating speed range. Full throttle operating range 5000–6000 r/min Blade Dia.
Page 68 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 ..........4-5 Troubleshooting procedure (trouble code not detected) .... 4-7 Troubleshooting the power unit ..........
Page 69: 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 70 YDIS K-Line 1. Adapter interface a. YDIS coupler 2. Adapter cap 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 71: 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 (VPP harness). Writing function of engine serial numbers A new function enables you to write an engine serial number to a new, replacement part engine ECM (supplied by the Part Division).
Page 72: 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 73: Trouble Code And Checking Step
Outboard motor troubleshooting YDIS diagnosis Code No. Item YDIS diagnosis record Battery voltage   Air temperature sensor   Water in fuel filter   Shift position switch   Air pressure sensor   Engine shut-off switch — ...
Page 74 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page Check the battery cable and terminals for proper connec- 10-8 tion. Battery voltage and battery Measure the lighting coil out- 5-25 alert are displayed. put peak voltage. Battery voltage Engine operates normally.
Page 75: Troubleshooting Procedure (Trouble Code Not Detected)
Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page Check for wiring short between the main switch and A-10 “Check Engine” is displayed. the engine ECM. A-12 Main power Main relay is not turned off supply (Irregu- Check for wiring short even if the main switch is OFF.
Page 76: Troubleshooting The Power Unit
Outboard motor troubleshooting Troubleshooting the power unit Symptom 1: Engine does not crank. Symptom 2 Cause Checking steps page Gear shift not in the N posi- Set the gear shift to the N position. 10-5 tion Blown fuse Check the fuse. Main relay malfunction Check the main relay.
Page 77 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Pinched or kinked fuel hose Check the fuel hose. 2-26 Check the fuel filter element for dirt Clogged fuel filter element and obstructions. Check the fuel strainer for dirt and Clogged fuel strainer obstructions.
Page 78 Outboard motor troubleshooting Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited engine speed. Symptom 2 Cause Checking steps page Check the throttle valve for proper Throttle valve malfunction 6-21 movement. Throttle valve does Throttle link rod and the not move properly Adjust the throttle link rod and the 6-22...
Page 79 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Check the valve timing. 7-13 Improper valve timing Check the timing belt. 7-13 Measure the valve clearance. Check the rocker arm for damage. 7-37 Compression pres- Check the camshaft for damage. 7-38 sure is low Check the valve and valve seat for...
Page 80 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Check the engine oil level. 10-8 Check for engine oil leakage. 2-21 Insufficient engine oil Check the valve seals and valves. 7-30 Check the piston rings. 7-49 Check the oil pressure switch. 5-20 Buzzer comes on, oil pressure alert indica-...
Page 81: 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. PTT switch malfunction Check the PTT switch. 5-41 PTT relay malfunction Check the PTT relay. 5-40 Measure the PTT switch input volt- 5-41...
Page 82: Troubleshooting The Lower Unit
Outboard motor troubleshooting Symptom 1: PTT unit does not hold the outboard motor up. Symptom 2 Cause Checking steps page Manual valve open Check the manual valve. 9-25 Insufficient PTT fluid Add sufficient PTT fluid. 10-21 PTT fluid leakage Check for PTT fluid leakage. 10-5 PTT fluid pressure Disassemble and check the PTT...
Page 83 Electrical system Electrical component and wire harness routing ..... 5-1 Port..................... 5-1 Starboard..................5-3 Front ................... 5-4 Fuse holder ................5-5 Rear.................... 5-6 Top ..................... 5-7 Bottom cowling ................5-9 Tiller handle (tiller handle model) ..........5-11 ECM circuit diagram............5-13 ECM coupler layout............
Page 84 Electrical system Ignition unit and component ........... 5-28 Checking the ignition spark ............5-28 Checking the ignition coil............5-28 Checking the spark plug cap ............ 5-29 Checking the pulser coil ............5-29 Checking the intake air temperature sensor......5-30 Checking the intake air pressure sensor ........5-31 Checking the thermo sensor ............
Page 85 Electrical component and wire harness routing Electrical component and wire harness routing Port 16 15...
Page 86 Electrical component and wire harness routing 1. Starter motor 2. Oil pressure switch 3. Ignition coil #1, #4 4. Ignition coil #2, #3 5. Rectifier/regulator 6. PTT relay 7. Water detection switch 8. Diode 9. YDIS coupler 10. Reprogramming connector 11.
Page 87 Electrical component and wire harness routing Starboard 10. Wire harness 1. Fuel injector 11. Vapor gas hose 2. Knock sensor 3. Intake air pressure/temperature sensor A. Tiller handle model 4. ISC valve B. Remote control model 5. TPS 6. Cooling water hose 7.
Page 88 Electrical component and wire harness routing Front B. Tiller handle model 1. Fuse box 2. Engine ECM 3. Hour meter (tiller handle model) 4. TPS lead 5. Pulser coil lead 6. Fuse box lead 7. Hour meter lead (tiller handle model) A.
Page 89: Fuse Holder
Electrical component and wire harness routing Fuse holder 1. Fuse (50 A) (spare) 2. Fuse (50 A) (battery) 3. Fuse (30 A) (starter relay) 4. Fuse (20 A) (main switch, PTT switch) 5. Fuse (20 A) (engine ECM, ignition coil, high-pressure fuel pump, fuel injector, vapor shut-off valve)
Page 90 Electrical component and wire harness routing Rear 1. High-pressure fuel pump A. Tiller handle model B. Remote control model...
Page 91 Electrical component and wire harness routing...
Page 92 Electrical component and wire harness routing 1. Lighting coil (stator assembly) 2. Vapor shut-off valve 3. Pulser coil 4. Thermo sensor 5. Lighting coil lead 6. Intake air pressure/temperature sensor lead 7. ISC valve lead 8. Blowby hose A. 25 mm (0.98 in) or less B.
Page 93: Bottom Cowling
Electrical component and wire harness routing Bottom cowling 10 9 8 G...
Page 94 Electrical component and wire harness routing 1. Shift position switch 2. PTT switch 3. Water detection switch coupler 4. PTT switch coupler 5. Tilt limiter coupler (remote control model) 6. Wire harness 7. 6Y8 multifunction meter communication coupler 8. Main wire harness coupler (10-pin) 9.
Page 95 Electrical component and wire harness routing Tiller handle (tiller handle model) 5-11...
Page 96 Electrical component and wire harness routing 1. Engine start switch coupler 2. Extension wire harness 3. Alert indicator harness 4. Grommet 5. Engine start switch 6. Engine shut-off switch 7. Alert buzzer 8. Neutral switch 9. PTT switch 10. Alert indicator A.
Page 97 ECM circuit diagram ECM circuit diagram : Indicate a connection between the symbols. The circled numbers in the illustration indicate the engine ECM terminal numbers. 1. Pulser coil 27. Fuel injector #1 2. TPS 28. Fuel injector #4 29. Fuel injector #2 30.
Page 98 ECM circuit diagram 1. Pulser coil 2. TPS 3. Air pressure sensor 4. Water pressure sensor 5. Speed sensor 6. Ground 7. Air temperature sensor 8. Thermo sensor 9. Trim sensor 10. Water detection switch 11. Knock sensor 12. Shift position switch 13.
Page 99: Ecm Coupler Layout
ECM coupler layout ECM coupler layout 434241403938373635 525150494847464544 3433323130292827262524232221201918 Connecting part Color Connecting part Color Tachometer Ignition coil #2, #3 Black/White Green (6Y5/6Y7) — — Oil pressure alert — — Green/White indicator Fuel injector #1, #4 Purple Alert buzzer Pink Ground Black ISC valve...
Page 100 ECM coupler layout Connecting part Color Air temperature sen- Black/Yellow Knock sensor Green — — — — *1: F75FET, F100GET 5-16...
Page 101: 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 102 Engine control unit and component Using the digital tester The electrical technical data applies to the measurements taken using the Yamaha rec- ommended tester. The resistance values shown are the values taken before the engine is started. The actual resistance may vary depending on the environ- mental conditions and ambient temperature.
Page 103 Engine control unit and component Engine ECM ground circuit continu- Output voltage at throttle valve fully closed Terminal 5–Ground 0.58 V Terminal 34–Ground Throttle valve opening angle at throttle valve fully closed (reference 3. Measure: data) • Engine ECM input voltage 0.0 ...
Page 104 Engine control unit and component Checking the ISC valve Checking the oil pressure switch 1. Check: 1. Measure: • ISC valve operation (using the YDIS “Sta- • Oil pressure switch input voltage Out of specification  Check the wire har- tionary test”) No operating sound ...
Page 105 Engine control unit and component c. Apply positive pressure to the oil pres- sure switch “1” slowly, and then check that continuity is lost in the range of the working pressure. Vacuum/pressure pump gauge set “2” 90890-06945 Lighting-up Terminal Battery Oil pressure switch Yellow (Y) Overheat alert...
Page 106 Fuel control unit and component b. Connect the battery leads to the alert 2. Check: buzzer connectors, and check that the • Water detection switch continuity Out of specification  Replace the fuel alert buzzer comes on. Replace the alert buzzer if it does not come on. cup assembly.
Page 107: Checking The Fuel Injector
Fuel control unit and component Checking the fuel injector b. Measure the fuel injector resistance. 1. Check: • Fuel injector operation (using the YDIS “Stationary test”) No operating sound  Check the fuel in- jector input voltage. 2. Measure: • Fuel injector input voltage Out of specification ...
Page 108: Checking The High-Pressure Fuel Pump Relay
Fuel control unit and component 1. Check: • Trouble code on the YDIS See “Troubleshooting procedure” (4-4). 2. Measure: • Main fuse input voltage See step (2) in “Checking the main relay” (5-18). Checking the vapor shut-off valve 1. Measure: A.
Page 109 Charging unit and component Charging unit and component c. Check that the vapor shut-off valve opens and the negative pressure is re- Checking the lighting coil (stator as- leased when the battery leads are sembly) connected to the vapor shut-off valve 1.
Page 110: Checking The Rectifier/Regulator
Charging unit and component g. Measure the lighting coil output peak voltage between all combinations of the connectors. c. Connect the lighting coil coupler. Checking the rectifier/regulator Do not connect the battery cables in re- verse. Otherwise, the rectifier/regulator could be damaged. 1.
Page 111: Checking The Hour Meter
Charging unit and component b. Connect the special service tool “1”, and then measure the rectifier/regula- tor output voltage at the specified en- gine speed. Rectifier/regulator continuity (testing diode mode) Tester probe Display value (reference data) (–) Test harness QLW–3 “1” 90890-06922 0.5–0.6 V c.
Page 112 Ignition unit and component 2. Check: • Hour meter operation Hour meter if there is no illuminated  Re- place. a. Connect the battery leads to the hour meter coupler terminals “a” and “b”. b. Check for hour meter displayed all the segment has been illuminated for 2 seconds.
Page 113 Ignition unit and component d. Connect the ignition coil couplers. 2. Measure: • Ignition coil resistance Out of specification  Replace. Primary coil resistance 1.870–2.530  Secondary coil resistance 10.80–14.61 k b. Measure the spark plug cap resis- a. Disconnect the ignition coil couplers. tance.
Page 114: Checking The Intake Air Temperature Sensor
Ignition unit and component a. Disconnect the pulser coil coupler “a”. g. Insert the clip into the engine shut-off switch. h. Start the engine, and then measure the peak voltage at the specified en- gine speed. G/W G b. Connect the special service tool “1” to the pulser coil coupler (pulser coil end).
Page 115 Ignition unit and component 1. Check: c. Turn the engine start switch to OFF. • Intake air temperature sensor operation d. Connect the intake air pressure/tem- Not operating  Check the wire harness perature sensor coupler. for continuity. a. Measure the ambient temperature. Checking the thermo sensor 1.
Page 116: Checking The Knock Sensor
Ignition unit and component c. Measure the thermo sensor resis- a. Disconnect the shift position switch tance. coupler “a”. b. Turn the engine start switch to ON, and then measure the input voltage at the shift position switch coupler. d. Install the thermo sensor. See “Oil cooler”...
Page 117 Starting unit and component Checking the engine shut-off switch 2. Measure: • Main fuse input voltage 1. Check: See step (2) in “Checking the main relay” • Engine shut-off switch continuity (5-18). Out of specification  Replace. a. Disconnect the main wire harness 3.
Page 118 Starting unit and component Engine start switch continuity Terminal Switch position “a” “b” “c” “d” “e” START c. Connect the main wire harness cou- pler or switch panel coupler. 5-34...
Page 119: Starter Motor
Starter motor Starter motor Part name Q’ty Remarks Part name Q’ty Remarks Nut M8 Lever assembly Washer Stopper Bolt M6  35 mm Pinion assembly Magnet switch E-clip Bolt M5  127 mm Washer Stator Bracket assembly Screw M4  16 mm Bearing Bracket Gasket...
Page 120 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” (7-16). Disassembling the starter motor 1. Remove: • Stator • Bracket screw Pipe “3”...
Page 121 Starter motor 2. Measure: • Commutator diameter “a” Below specification  Replace the arma- ture. Armature continuity “a” “b” “c” “d” Checking the brush holder Standard commutator diameter 1. Check: 29.0 mm (1.14 in) • Brush holder assembly continuity Wear limit Out of specification ...
Page 122: Assembling The Starter Motor
Starter motor 2. Measure: • Brush length Below specification  Replace the brush. a. Standard brush length b. Wear limit 3. Install: • Pinion shaft assembly “1” • Lever “2” Standard brush length • Rubber seal “3” 15.5 mm (0.61 in) Wear limit 9.5 mm (0.37 in) Align the holes “a”...
Page 123 Starter motor 7. Install: • Brush holder assembly • Be careful not to align the protrusions “a” on • Bracket the outer gear “1” with the holes “b” in the • Bracket screw bracket. • Stator • Align the notches “c” in the plate “3” with the a.
Page 124: Ptt System
PTT system PTT system 8. Install: • Stator bolt Checking the PTT relay a. Align the protrusion “a” on the stator 1. Measure: “1” with the slot “b” in the cover assem- • PTT relay input voltage bly “2”, and then assemble the starter Out of specification ...
Page 125 PTT system d. Check the PTT relay for continuity. Connect the positive battery lead to the terminal “a”, and the negative bat- tery lead to the terminal “b”, and then check the PTT relay for continuity. G/W G G/W G Test harness FWY–2 “1”...
Page 126 PTT system b. Measure the input voltage between a. Disconnect the trim sensor coupler the PTT switch coupler terminal and “a”, and then remove the trim sensor. ground. b. Measure the trim sensor resistance. c. Connect the PTT switch coupler. c.
Page 127 PTT system b. Measure the input voltage at the tilt limiter coupler “a” with the up side of Output voltage the PTT switch pushed. 12 V at “a” 0 V when passing “b” Blue (L)–Ground d. Connect the tilt limiter couplers. e.
Page 128 Fuel system Fuel system ................ 6-1 Reducing the fuel pressure ............6-1 Disconnecting the quick connector..........6-1 Measuring the fuel pressure............6-2 Fuel filter ................6-4 Fuel tank ................6-5 Removing the fuel filter assembly ..........6-6 Checking the fuel filter assembly..........6-6 Checking the fuel filter element ..........
Page 129 Fuel system Intake silencer, intake manifold and throttle body ..6-19 Checking the throttle body............6-21 Checking the intake air pressure/temperature sensor....6-21 Checking the intake manifold ........... 6-21 Installing the intake manifold ............ 6-21 Installing the throttle body ............6-21 Adjusting the throttle link rod ............
Page 130: Reducing The Fuel Pressure
Fuel system Fuel system 1. Disconnect: • Quick connector Reducing the fuel pressure a. Reduce the fuel pressure. See “Re- ducing the fuel pressure” (6-1). Before servicing the high-pressure fuel line b. Wrap a rag around the quick connec- or vapor separator, make sure to reduce tors “1”.
Page 131: Measuring The Fuel Pressure
Fuel system Fuel pressure gauge adapter “1” • After disconnecting the quick connector “1”, 90890-06946 be careful not to lose the retainer “2”. • Cover the quick connector and vapor separa- d. Connect the special service tool “1”. tor with a plastic bag to prevent damage and dirt from entering them.
Page 132 Fuel system Before disconnecting the special service tools, cover the end of the hose using a clean and dry rag. Connect the quick connector to the fuel rail.
Page 133: Fuel Filter
Fuel filter Fuel filter 4.5 N·m (0.45 kgf·m, 3.3 lb·ft) Part name Q’ty Remarks Band Joint pipe Plastic tie Hose Hose Clamp Fuel filter assembly Fuel cup assembly O-ring Clip Float Fuel filter element Band...
Page 134: Fuel Tank
Part name Q’ty Remarks Fuel tank Clamp Primer pump Fuel filter Primer pump Screw M5  16 mm Joint Seal O-ring Fuel joint Hose Gasket Hose Fuel hose *1: F75F *2: F75F, F100G (Except for CRB (EPA)) *3: F100G (CRB (EPA))
Page 135: Removing The Fuel Filter Assembly
Fuel tank Removing the fuel filter assembly d. Block the fuel inlet “b” using a rubber plug “2”, and then apply the specified Cover the fuel components using a rag to pre- negative pressure. Replace the O- vent fuel from spilling out. ring, fuel cup assembly, or fuel filter Checking the fuel filter assembly assembly if the specified pressure...
Page 136: Checking The Primer Pump
Fuel tank Checking the primer pump Fuel cup assembly 1. Check: • No air leakage 4.5 N·m (0.45 kgf·m, 3.3 lb·ft) Air leakage  Replace. Installing the fuel filter assembly a. Connect the special service tool “1” to the primer pump inlet “a”. 1.
Page 137: Fuel Pump Assembly
Fuel pump assembly Fuel pump assembly 4.2 N·m (0.42 kgf·m, 3.1 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Clamp Diaphragm Clamp Spring Clamp Fuel pump body Bolt M6  16 mm Bracket Plastic tie Clip Hose Hose Fuel strainer Bolt M6 ...
Page 138: Removing The Fuel Pump Assembly
Fuel pump assembly Removing the fuel pump assembly Holding pressure (positive pres- Cover the fuel components using a rag to pre- sure) vent fuel from spilling out. 200.0 kPa (2.00 kgf/cm², 29.0 psi) 1. Disconnect: • Quick connector “1” Checking the fuel pump assembly See “Disconnecting the quick connector”...
Page 139: Disassembling The Fuel Pump Assembly
Fuel pump assembly b. While holding fuel pump body “1” in place, insert a flathead screwdriver Fuel inlet holding pressure (nega- into the hole “a” in the plunger “2” and tive pressure) turn it 90. 30.0 kPa (0.30 kgf/cm², 4.4 psi) d.
Page 140 Fuel pump assembly 1. Install: d. While holding fuel pump body “1” in • Spring (to the fuel pump body) place, insert a flathead screwdriver • Diaphragm (to the fuel pump body) into the hole “a” in the plunger “2” and •...
Page 141: Installing The Fuel Pump Assembly
Fuel pump assembly Installing the fuel pump assembly 1. Install: • O-ring (to the fuel pump assembly) • Fuel pump assembly • Fuel pump assembly bolt • Clip (to the hose) 2. Connect: • Hose “1” • Hose “2” 3. Install: •...
Page 142: Vapor Separator
Vapor separator Vapor separator Part name Q’ty Remarks Part name Q’ty Remarks Bolt M6  14 mm Clamp Clamp Plate Clamp Clamp Plastic tie Clip Drain hose Hose Hose Hose Hose Hose Nipple Bolt M6  30 mm Nut M6 Vapor separator Collar Grommet...
Page 143: Draining The Fuel
Vapor separator Draining the fuel 1. Drain: • Fuel a. Disconnect the vapor gas hose “1”. b. Loosen the drain screw “2”. Installing the vapor separator 1. Install: • Plate • Plate bolt • Grommet • Collar • Vapor separator •...
Page 144: Vapor Separator And High-Pressure Fuel Pump
Vapor separator and high-pressure fuel pump Vapor separator and high-pressure fuel pump 2.9 N·m (0.29 kgf·m, 2.1 lb·ft) 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 1.5 N·m (0.15 kgf·m, 1.1 lb·ft) 6 N·m (0.6 kgf·m, 4.4 lb·ft) Part name Q’ty Remarks Drain screw Screw M6 ...
Page 145: Checking The Vapor Separator
Vapor separator and high-pressure fuel pump Checking the vapor separator Assembling the vapor separator 1. Check: 1. Install: • Needle valve • Float Bent/worn  Replace the float. • Pressure regulator • Lead • High-pressure fuel pump • Filter • Cushion rubber •...
Page 146: Fuel Injector
Fuel injector Fuel injector Part name Q’ty Remarks Bolt M6  35 mm Fuel rail Holder Fuel injector O-ring set 2 pcs/set 6-17...
Page 147: Removing The Fuel Injector
Fuel injector Removing the fuel injector Fuel injection volume Cover the fuel components using a rag to pre- 90 cm³ (90 cc)/30 sec vent fuel from spilling out. Test fuel 1. Reduce: Dry sorbent (viscosity: 1.2 ± 0.03 • Fuel pressure mm²/s, specific gravity: 0.774 [15 See “Reducing the fuel pressure”...
Page 148: Intake Silencer, Intake Manifold And Throttle Body
Intake silencer, intake manifold and throttle body Intake silencer, intake manifold and throttle body 3.4 N·m (0.34 kgf·m, 2.5 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Bolt M6  16 mm Clamp Holder Throttle body Holder Gasket Hose Holder Bolt M6 ...
Page 149 Intake silencer, intake manifold and throttle body 3.4 N·m (0.34 kgf·m, 2.5 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Intake air pres- Gasket sure/temperature sen- *1: F100G *2: F75F 6-20...
Page 150: Checking The Throttle Body
Intake silencer, intake manifold and throttle body Checking the throttle body 2. Tighten: • Intake manifold bolt 1. Check: a. Tighten the intake manifold bolts “1” in • Throttle body exterior the order [1], [2], and so on. Cracked  Replace. 2.
Page 151: Adjusting The Throttle Link Rod
Intake silencer, intake manifold and throttle body 3. Install: e. Loosen the throttle lever plate bolt “1”, • Bushing (to the intake silencer) and then push the throttle lever plate • Collar (to the intake silencer) “2” in the direction of the arrow so that •...
Page 152 Intake silencer, intake manifold and throttle body Turn the accelerator cam to the fully open position. Check that the mark “a” on the throttle lever plate has passed over the mark “b” on the throttle body. Repeat from step (d) if the mark “a” has not passed the mark “b”.
Page 153: Canister And Vapor Shut-Off Valve
Canister and vapor shut-off valve Canister and vapor shut-off valve Part name Q’ty Remarks Part name Q’ty Remarks Plastic tie Hose Hose Nut M6 Check valve Vapor shut-off valve Bolt M6  16 mm Hose Clip Bracket Hose Check valve Hose Joint Hose...
Page 154: Checking The Canister
Canister and vapor shut-off valve Checking the canister b. Apply positive pressure and check that air comes out of the opposite end 1. Check: of the canister check valve. • Canister Cracked  Replace. 2. Check: • No air leakage Air leakage ...
Page 155: Installing The Vapor Shut-Off Valve And Canister
Canister and vapor shut-off valve Installing the vapor shut-off valve and canister 1. Install: • Vapor shut-off valve bracket • Vapor shut-off valve bracket bolt • Vapor shut-off valve • Vapor shut-off valve nut • Joint (to the hose) • Hose (to the vapor shut-off valve) •...
Page 156 Power unit Power unit (check and adjustment) ........7-1 Checking the compression pressure .......... 7-1 Checking the oil pressure............7-1 Checking the pulser coil air gap ..........7-2 Checking the valve clearance ............ 7-2 Adjusting the valve clearance............. 7-5 Power unit assembly............7-6 Removing the power unit............
Page 157: Power Unit
Power unit Cylinder head ..............7-27 Removing the cylinder head............. 7-28 Checking the cylinder head bolt ..........7-28 Checking the cylinder head anode ........... 7-28 Installing the cylinder head............7-28 Camshaft and valve............7-30 Disassembling the cylinder head..........7-31 Checking the cylinder head ............7-31 Checking the valve spring ............
Page 158 Power unit Crankshaft pin bearing selection table ........7-56 Checking the journal oil clearance ........... 7-57 Selecting the crankshaft journal bearing ........7-58 Crankshaft journal bearing selection table ....... 7-60 Assembling the cylinder block ..........7-61...
Page 159: Checking The Compression Pressure
Power unit (check and adjustment) Power unit (check and adjust- g. Crank the engine until the reading on the compression gauge stabilizes, and ment) then measure the compression pres- Checking the compression pressure sure. 1. Check: • Compression pressure h. Remove the special service tools. Below specification ...
Page 160: Checking The Pulser Coil Air Gap
Power unit (check and adjustment) • Use a pressure gauge with an adapter that has a 1/8 pitch thread. • The actual oil pressure may vary depending on the temperature and engine oil viscosity. Checking the valve clearance • Measure the valve clearances when the en- gine is cold.
Page 161 Power unit (check and adjustment) Remove the fuel pump bolts “8”, fuel pump assembly “9”, and O-ring. Turn the flywheel magneto clockwise to align the “1 △ ” mark “a” on the driv- g. Remove the clamp “1”. en sprocket “1” with the “ △ ” mark “b” on the cylinder head.
Page 162 Power unit (check and adjustment) q. Install a new gasket “2” and the cylin- der head cover “1”. a. Intake b. Exhaust Install the vapor separator “9” and va- n. Measure the intake and exhaust valve por separator nuts “8” and bolts “7”. clearances of the specified cylinders.
Page 163: Adjusting The Valve Clearance
Power unit (check and adjustment) Adjusting the valve clearance Adjust the valve clearances when the engine is cold. Do not turn the flywheel magneto counter- clockwise. Otherwise, the water pump im- peller could be damaged. 1. Adjust: • Valve clearance a.
Page 164: Power Unit Assembly
Power unit assembly Power unit assembly 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 3.9 N·m (0.39 kgf·m, 2.9 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 15 16 42 N·m (4.2 kgf·m, 31 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 42 N·m (4.2 kgf·m, 31 lb·ft) Part name Q’ty Remarks...
Page 165: Removing The Power Unit
Power unit assembly Removing the power unit Cover the fuel components using a rag to pre- vent fuel from spilling out. 1. Remove: • Power unit assembly a. Remove the grommet holder “1” and rigging grommet “2”. e. Remove the clamps “1” and “2” from the PTT motor leads.
Page 166 Power unit assembly Disconnect the PTT switch coupler m. Disconnect the vapor gas hose “1” “a”. and cooling water pilot hose “2”. n. Disconnect the shift position switch coupler “a”. Disconnect the gauge harness cou- pler “a”. o. Remove the dipstick “1”. k.
Page 167: Installing The Power Unit
Power unit assembly Installing the power unit Install the special service tool “3” to the flywheel magneto, and then tight- 1. Install: en the lifting eye bolts “2” to the speci- • Power unit assembly fied torque. a. Clean the power unit mating surface, and then install the dowel pins “1”...
Page 168 Power unit assembly h. Install the dipstick “1”. [11] [10] [6], [8] [4], [7] [12] Flywheel stopper B “3” Connect the shift position switch cou- 90890-06686 pler “a”. Bolt hexagon with washer “4” 90890-06821 Connect the vapor gas hose “1” and Lifting eye “5”...
Page 169 Power unit assembly m. Connect the gauge harness coupler “a”. PTT motor lead bolt “2” 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) n. Connect the PTT switch coupler “a”. s. Connect the battery cable “1”, and o. Fasten the wire harness using the then tighten the positive battery cable clamps “1”.
Page 170: Flywheel Magneto And Timing Belt
Flywheel magneto and timing belt Flywheel magneto and timing belt 3.9 N·m (0.39 kgf·m, 2.9 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 90° 38 N·m (3.8 kgf·m, 28 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Bolt M10  33 mm Dowel pin Flywheel magneto Dowel pin...
Page 171: Removing The Flywheel Magneto
Flywheel magneto and timing belt Removing the flywheel magneto Removing the timing belt and sprock- 1. Turn the flywheel magneto clockwise to align the “1 △ ” mark “a” on the driven sprocket “1” with the “ △ ” mark “b” on the When the timing belt is not installed, do not cylinder head.
Page 172: Installing The Stator Assembly
Flywheel magneto and timing belt 2. Tighten: • Driven sprocket bolt “1” Be careful not to install the timing belt with the part number upside down. Flywheel holder “2” 90890-06522 4. Install: • Washer “1” • Bolt Driven sprocket bolt “1” 38 N·m (3.8 kgf·m, 28 lb·ft) Install the washer “1”...
Page 173: Installing The Flywheel Magneto
Flywheel magneto and timing belt Installing the flywheel magneto 1. Install: • Dowel pin (to the crankshaft) • Flywheel magneto 2. Tighten: • Flywheel magneto bolt a. Tighten new flywheel magneto bolts “1” to the specified torque in 2 stages and in the order [1], [2], and so on.
Page 174: Starter Motor
Starter motor Starter motor 25 N·m (2.5 kgf·m, 18 lb·ft) 33 N·m (3.3 kgf·m, 24 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 9 N·m (0.9 kgf·m, 6.6 lb·ft) 9 N·m (0.9 kgf·m, 6.6 lb·ft) Part name Q’ty Remarks Bolt M6  16 mm Nut M8 Washer Battery cable...
Page 175: Rectifier/Regulator, Ignition Coil, And Spark Plug
Rectifier/regulator, ignition coil, and spark plug Rectifier/regulator, ignition coil, and spark plug 25 N·m (2.5 kgf·m, 18 lb·ft) Part name Q’ty Remarks Bolt M6  30 mm Rectifier/regulator Gasket Clamp Clamp Clamp Clamp Clamp Bolt M6  25 mm Ignition coil Ignition coil Spark plug cap Grommet...
Page 176: Checking The Spark Plug
Rectifier/regulator, ignition coil, and spark plug Checking the spark plug 1. Clean the electrodes “a” using a spark plug cleaner. Specified length “a”: 285–295 mm (11.22–11.61 2. Check: “b”: 355–365 mm (13.98–14.37 • Spark plug Electrodes are eroded, edges of elec- trodes are rounded, insulator is damaged, 3.
Page 177: Wire Harness
Wire harness Wire harness Wire harness (tiller handle model) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 4.5 N·m (0.45 kgf·m, 3.3 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Bolt M6  30 mm Nut M6 Bolt M6  20 mm Bracket PTT relay Collar...
Page 178: Wire Harness (Remote Control Model)
Wire harness Wire harness (remote control model) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 4.5 N·m (0.45 kgf·m, 3.3 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Nut M6 Bracket Bolt M6  20 mm Collar PTT relay Grommet Bolt M4  8 mm Holder Bolt M6 ...
Page 179: Installing The Wire Harness
Wire harness Installing the wire harness 1. Install: • Clamp (to the holder) • Holder • Holder bolt • Holder (to the ignition coil bracket) • Grommet (to the ignition coil bracket) • Collar (to the ignition coil bracket) • Ignition coil bracket •...
Page 180: Fuse Box
Fuse box Fuse box 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 2.3 N·m (0.23 kgf·m, 1.7 lb·ft) 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Lock plate...
Page 181: Throttle Control Lever
Throttle control lever Throttle control lever Part name Q’ty Remarks Bolt M6  32 mm Accelerator cam Spring Washer Bolt M6  32 mm Throttle control lever Washer Bushing Bolt M6  25 mm Holder Bracket Holder 7-23...
Page 182: Installing The Throttle Control Lever
Throttle control lever Installing the throttle control lever 1. Install: • Holder • Bracket • Bracket bolt • Bushing (to the throttle control lever) • Washer • Throttle control lever • Throttle control lever bolt 2. Install: • Spring • Washer •...
Page 183: Oil Cooler
Oil cooler Oil cooler 23 N·m (2.3 kgf·m, 17 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Knock sensor Anode Clamp Thermo sensor Gasket Plastic tie Hose Plastic tie Hose Hose...
Page 184: Checking The Thermostat
Oil cooler Checking the thermostat 1. Check: Do not apply grease, oil, or paint to the an- • Thermostat valve opening at the specified ode. water temperatures Out of specification  Replace. a. Suspend the thermostat in a container Installing the crankcase cover of water.
Page 185: Cylinder Head
Cylinder head Cylinder head 26 N·m (2.6 kgf·m, 19 lb·ft) 46 N·m (4.6 kgf·m, 34 lb·ft) 180 ° 18 N·m (1.8 kgf·m, 13 lb·ft) 14 N·m (1.4 kgf·m, 10 lb·ft) 23 N·m (2.3 kgf·m, 17 lb·ft) 28 N·m (2.8 kgf·m, 21 lb·ft) Part name Q’ty Remarks...
Page 186: Removing The Cylinder Head
Cylinder head Removing the cylinder head Installing the cylinder head 1. Remove: Before installing the cylinder head, check the • Cylinder head cylinder head bolts. See “Checking the cylinder head bolt” (7-28). Do not scratch or damage the mating sur- 1.
Page 187 Cylinder head Cylinder head bolt (M10) “1” [1]– [10] 1st: 26 N·m (2.6 kgf·m, 19 lb·ft) 2nd: 46 N·m (4.6 kgf·m, 34 lb·ft) 3rd: 180 Cylinder head bolt (M8) “2” [11]– [13] 1st: 14 N·m (1.4 kgf·m, 10 lb·ft) 2nd: 28 N·m (2.8 kgf·m, 21 lb·ft) 3.
Page 188: Camshaft And Valve
Camshaft and valve Camshaft and valve 14 N·m (1.4 kgf·m, 10 lb·ft) 14 N·m (1.4 kgf·m, 10 lb·ft) 28 N·m (2.8 kgf·m, 21 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Locknut M7 Valve cotter Adjusting screw M7 Retainer Locknut M6 Valve spring Adjusting screw M6...
Page 189: Disassembling The Cylinder Head
Camshaft and valve Disassembling the cylinder head 1. Loosen: Make sure to keep the parts in the order of re- • Valve adjusting locknut moval. • Adjusting screw a. Loosen the valve adjusting locknuts and adjusting screws on cylinders #2 (EX) “a”, #3 (IN) “b”, and #4 (EX “c”...
Page 190: Checking The Valve Spring
Camshaft and valve b. Check the cylinder head warpage us- ing a straightedge “1” and a thickness gauge “2” in 7 directions. Tilt limit IN 1.7 mm (0.07 in) Tilt limit EX 1.7 mm (0.07 in) Checking the valve 1. Check: •...
Page 191: Checking The Valve Guide
Camshaft and valve 3. Measure: 1. Measure: • Stem diameter “a” • Inside diameter “a” Below specification  Replace. Above specification  Replace. Diameter IN Inside diameter IN 5.475–5.490 mm (0.2156–0.2161 5.504–5.522 mm (0.2167–0.2174 Limit Inside diameter EX 5.445 mm (0.2144 in) 5.504–5.522 mm (0.2167–0.2174 Diameter EX 5.460–5.475 mm (0.2150–0.2156...
Page 192: Checking The Valve Seat
Camshaft and valve 1. Remove: • Valve guide “1” (from the combustion • To ream the valve guide, turn the valve guide chamber side) reamer clockwise. • When removing the valve guide reamer, do not turn it counterclockwise. • After reaming the valve guide, make sure to clean it.
Page 193: Refacing The Valve Seat
Camshaft and valve Refacing the valve seat After every lapping procedure, make sure to clean off any remaining lapping com- pound from the cylinder head and valves. 1. Reface: • Valve seat Seat contact width IN 1.10–1.50 mm (0.0433–0.0591 Limit 1.950 mm (0.0768 in) Seat contact width EX 1.10–1.50 mm (0.0433–0.0591...
Page 194 Camshaft and valve a. Cut the surface of the valve seat using a 45 cutter by turning the cutter clock- wise until the valve seat face has be- come smooth. Do not overcut the valve seat. To prevent chatter marks, make sure to turn the cutter 60°...
Page 195: Checking The Rocker Arm And Rocker Arm Shaft
Camshaft and valve • 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. Set its width using a 45...
Page 196: Checking The Camshaft
Camshaft and valve Rocker arm Inside diameter IN 21.000–21.018 mm (0.8268– 0.8275 in) Inside diameter EX 21.000–21.018 mm (0.8268– 0.8275 in) Rocker arm shaft Outside diameter IN 20.971–20.991 mm (0.8256– Runout 0.8264 in) 0.030 mm (0.0012 in) Outside diameter EX 20.971–20.991 mm (0.8256–...
Page 197 Camshaft and valve 2. Install: • Intake valve Make sure that both valve cotters “1” are seat- • Exhaust valve ed securely and evenly. • Valve spring seat • Valve spring • Retainer • Valve cotter a. Install the valve “1”, valve spring seat “2”, valve spring “3”, and valve spring retainer “4”...
Page 198 Camshaft and valve 5. Install: • Rocker arm • Be careful not to damage the washers “3” • Washer when installing the rocker arm shaft as- • Rocker arm shaft sembly to the cylinder head. • Tensioner • Make sure to install the rocker arm shaft •...
Page 199 Camshaft and valve 7. Adjust: • Valve clearance See “Adjusting the valve clearance” (7-5). 7-41...
Page 200: Cylinder Block
Cylinder block Cylinder block 18 N·m (1.8 kgf·m, 13 lb·ft) 4.2 N·m (0.42 kgf·m, 3.1 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 49 N·m (4.9 kgf·m, 36 lb·ft) 18 N·m (1.8 kgf·m, 13 lb·ft) 56 N·m (5.6 kgf·m, 41 lb·ft) Part name Q’ty Remarks...
Page 201: Removing The Oil Filter
Cylinder block 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- 90890-01426 ance 0.12 mm (0.0047 in) Checking the cylinder block anode Limit 1.
Page 202: Installing The Oil Pump Assembly
Cylinder block Driver rod L3 “3” 90890-06652 Needle bearing attachment “4” 90890-06611 2. Install: • Oil seal “1” (into the oil pump hous- ing “2”) Oil pump cover screw “5” 4.2 N·m (0.42 kgf·m, 3.1 lb·ft) Installing the oil pump assembly 1.
Page 203: Installing The Oil Filter
Cylinder block b. Install new O-rings “1” and the oil 3. Install: pump assembly “2” by aligning the oil • Plug gasket • Plug pump gear with the crankshaft. Plug 56 N·m (5.6 kgf·m, 41 lb·ft) 4. Install: • Oil pressure switch Oil pressure switch 8 N·m (0.8 kgf·m, 5.9 lb·ft) 5.
Page 204: Crankcase
Crankcase Crankcase 16 N·m (1.6 kgf·m, 12 lb·ft) 60˚ 14 N·m (1.4 kgf·m, 10 lb·ft) 28 N·m (2.8 kgf·m, 21 lb·ft) 13 N·m (1.3 kgf·m, 9.6 lb·ft) 60˚ Part name Q’ty Remarks Part name Q’ty Remarks Bolt M8  55 mm Bearing Bolt M10 ...
Page 205: Disassembling The Cylinder Block
Crankcase Disassembling the cylinder block 1. Remove: • Connecting rod bolt “1” • Connecting rod cap “2” • Crankshaft pin bearing “3” • Piston and connecting rod assembly “4” • To prevent mixing the piston and connecting rod assemblies “4” and connecting rod caps “2”, mark each with an identification number “a”...
Page 206: Checking The Piston Diameter
Crankcase Checking the piston diameter 1. Measure: • Piston outside diameter “a” (at the speci- fied measuring point “b”) Below specification  Replace. a. 5.0 mm (0.20 in) b. 35.0 mm (1.38 in) c. 94.0 mm (3.70 in) d. Parallel to the crankshaft e.
Page 207: Checking The Piston Ring
Crankcase Checking the piston ring Top ring 1. Measure: • Piston ring dimensions B and T End gap Below specification  Replace. 0.15–0.30 mm (0.0059–0.0118 Limit 0.470 mm (0.0185 in) 2nd ring End gap 0.70–0.90 mm (0.0276–0.0354 Limit 1.050 mm (0.0413 in) Oil ring a.
Page 208: Checking The Piston Ring Groove
Crankcase Checking the piston ring groove 1. Measure: • Piston ring groove Above specification  Replace. a. Top ring side clearance b. 2nd ring side clearance c. Oil ring side clearance a. Ring groove (Top) Piston ring side clearance b. Ring groove (2nd) Top ring c.
Page 209: Checking The Piston Pin Diameter
Crankcase When measuring the piston pin boss inside di- ameter, do not measure it at the ring groove “b” or oil groove “c”. Checking the connecting rod small end inside diameter and big end in- Pin boss inside diameter side diameter 18.004–18.015 mm (0.7088–...
Page 210: Checking The Connecting Rod Big End Side Clearance
Crankcase b. Measure the connecting rod small end inside diameter “b” and big end inside diameter “c”. 60˚ Connecting rod bolt “1” 1st: 13 N·m (1.3 kgf·m, 9.6 lb·ft) 2nd: 60 Checking the connecting rod big end side clearance Journal diameter 51.980–52.000 mm (2.0465–...
Page 211: Checking The Big End Oil Clearance
Crankcase Checking the big end oil clearance 1. Measure: • Big end oil clearance Out of specification  Replace crankshaft pin bearing. See “Selecting the crankshaft pin bearing” (7-54). Big end oil clearance 0.017–0.040 mm (0.0007–0.0016 d. Install the connecting rod “1” and con- Limit necting rod cap “2”...
Page 212: Selecting The Crankshaft Pin Bearing
Crankcase Example: Connecting rod big In the second tightening stage for the connect- Number in table end inside diameter ing rod bolts “1”, mark the connecting rod bolts and the connecting rod cap with identification 50.042 mm marks “a”, and then tighten the bolts 60 from b.
Page 213 Crankcase Rod side bear- Cap side bear- ing color ing color “a” Black Black “b” Black “c” “d” Blue “e” Blue Blue “f” Green Blue “g” Green Green “h” Yellow Green “i” Yellow Yellow Example: If the connecting rod big end inside di- ameter is “42”...
Page 214: Crankshaft Pin Bearing Selection Table
Crankcase Crankshaft pin bearing selection table 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 A. Connecting rod big end inside diameter B. Crankshaft pin mark 7-56...
Page 215: Checking The Journal Oil Clearance
Crankcase Checking the journal oil clearance 1. Measure: • Journal oil clearance Out of specification  Replace crankshaft journal bearing. See “Selecting the crankshaft journal bear- ing” (7-58). Journal oil clearance 0.026–0.050 mm (0.0010–0.0020 e. Install the crankshaft journal bearings Limit into the crankcase.
Page 216: Selecting The Crankshaft Journal Bearing
Crankcase b. Check the mark “a” on the crank web and the mark “b” on the cylinder block. 60° [10] [20] [19] [16] [15] [12] [11] [13] [14] [17] [18] Crankcase bolt (M10) “2” [1]–[10] 1st: 16 N·m (1.6 kgf·m, 12 lb·ft) 2nd: 60...
Page 217 Crankcase Block side bear- Crankcase side ing color bearing color “a” Black Black “b” Black “c” “d” Blue “e” Blue Blue “f” Blue Green “g” Green Green “h” Green Yellow “i” Yellow Yellow Example: If the crank web mark is “81” and the cylinder block mark is “32”, select the bearing colors in “b”.
Page 218: Crankshaft Journal Bearing Selection Table
Crankcase Crankshaft journal bearing selection table 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 A. Cylinder block mark B. Crank web mark 7-60...
Page 219: Assembling The Cylinder Block
Crankcase Assembling the cylinder block 1. Install: Do not scratch the pistons or break the pis- • Collar ton rings. a. Install a new collar “1” by striking it us- ing a plastic hammer. • Make sure that the “2T” mark “a” on the 2nd ring “2”...
Page 220 Crankcase 5. Install: • Piston • Make sure that each thrust bearing is in- a. Apply engine oil to the side of the pis- stalled with its notches facing outward. ton, piston rings, and cylinder wall, • Slide the thrust bearing between the crank- and then install the piston so that the shaft and the cylinder block.
Page 221 Crankcase • Make sure that the protrusions “a” on the • Install the crankshaft journal bearings “1” in connecting rod and connecting rod caps “1” their original positions. • Do not apply any sealant to the crankshaft are facing toward the flywheel magneto end of the crankshaft.
Page 222 Crankcase e. Tighten the crankcase bolts (M8) “4” to the specified torques in 2 stages and in the order [11], [12], and so on. After tightening the crankcase bolts “3” and “4”, make sure that the crankshaft turns smoothly. 60˚ [10] [20] [19]...
Page 223 Lower unit Lower unit ................8-1 Removing the lower unit............. 8-2 Checking the propeller ............... 8-2 Checking the lower unit anode ........... 8-2 Water pump and shift rod ..........8-3 Removing the water pump and shift rod........8-4 Checking the water pump and shift rod........8-4 Assembling the water pump housing .........
Page 224: Lower Unit
Lower unit Measuring the forward gear backlash and reverse gear  backlash before disassembly ........... 8-23 Shimming procedure ..............8-27 Shim location................8-27 Selecting the pinion shim (T3)..........8-28 Measuring the forward gear backlash ........8-30 Adjusting the forward gear shim thickness (T1) ....... 8-31 Measuring the reverse gear backlash ........
Page 225 Lower unit Lower unit 42 N·m (4.2 kgf·m, 31 lb·ft) 54 N·m (5.4 kgf·m, 40 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 40 N·m (4.0 kgf·m, 30 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 40 N·m (4.0 kgf·m, 30 lb·ft) Part name Q’ty Remarks...
Page 226: Lower Unit
Lower unit Removing the lower unit 4. Remove: • Trim tab bolt • Trim tab • Make sure to disconnect the battery ca- a. Mark the trim tab “1” and lower case bles from the battery, and remove the clip with an identification mark “a”, and from the engine shut-off switch.
Page 227: Water Pump And Shift Rod
Water pump and shift rod Water pump and shift rod Part name Q’ty Remarks Part name Q’ty Remarks Bolt M6  20 mm Cover Seal Plate Bolt M8  45 mm Oil seal Water pump housing O-ring O-ring Shift rod Dowel pin E-clip Insert cartridge...
Page 228: Removing The Water Pump And Shift Rod
Water pump and shift rod Removing the water pump and shift 2. Check: • Impeller • Insert cartridge 1. Remove: • Outer plate cartridge • Shift rod Cracked/worn  Replace. a. Set the gear shift to the N position. • Impeller key •...
Page 229: Propeller Shaft Housing
Propeller shaft housing Propeller shaft housing 13 9 10 12 15 13 8 105 N·m (10.5 kgf·m, 77 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Ring nut M101.5 Ball 5.56 mm (0.22 in) Claw washer Ball 4.76 mm (0.19 in) Propeller shaft hous- Ball 8.73 mm (0.34 in) Washer...
Page 230: Removing The Propeller Shaft Housing Assembly
Propeller shaft housing Removing the propeller shaft housing assembly 1. Remove: • Ring nut • Claw washer a. Straighten the bent tab “a” on the claw washer. Stopper guide plate “1” 90890-06501 Bearing housing puller claw L “2” 90890-06502 Center bolt “3” 90890-06504 b.
Page 231: Disassembling The Propeller Shaft Housing Assembly
Propeller shaft housing Disassembling the propeller shaft housing assembly 1. Remove: • Reverse gear “1” • Thrust washer “2” • O-ring “3” Driver rod L3 “3” 90890-06652 Needle bearing attachment “4” Stopper guide plate “4” 90890-06653 90890-06501 Bearing separator “5” Checking the propeller shaft 90890-06534 1.
Page 232: Checking The Dog Clutch
Propeller shaft housing Checking the dog clutch 2. Install: • Dog clutch 1. Check: • Cross pin • Dog clutch • Cross pin ring • Cross pin a. Install the dog clutch “1” so that the • Spring (in the slider) hole “a”...
Page 233 Propeller shaft housing 2. Install: • Thrust washer “1” Face the bearing identification mark “a” on the • Ball bearing “2” (onto the reverse needle bearing toward the propeller. gear “3”) Face the bearing identification mark “a” on the ball bearing toward the propeller. Driver rod L3 “2”...
Page 234: Drive Shaft And Lower Case
Drive shaft and lower case Drive shaft and lower case 1.1 N·m (0.11 kgf·m, 0.81 lb·ft) 93 N·m (9.3 kgf·m, 69 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Screw M5  48 mm Forward gear Self-locking nut Tapered roller bearing Water inlet cover Needle bearing (PORT)
Page 235: Removing The Drive Shaft
Drive shaft and lower case Removing the drive shaft Hydraulic drive shaft pusher “4” 1. Loosen: • Pinion nut “1” 90890-06688 Disassembling the drive shaft hous- 1. Remove: • Needle bearing “1” Drive shaft holder 6 “2” 90890-06520 Needle bearing attachment “2” Pinion nut holder “3”...
Page 236: Disassembling The Lower Case
Drive shaft and lower case 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 237: Checking The Lower Case
Drive shaft and lower case Checking the lower case Assembling the drive shaft housing 1. Check: 1. Install: • Lower case • Needle bearing “1” (in the drive Cracked/damaged  Replace. shaft housing) Assembling the forward gear 1. Install: • Tapered roller bearing inner race “1” Needle bearing attachment “2”...
Page 238: Assembling The Lower Case
Drive shaft and lower case 3. Install: c. While holding the special service tool • O-ring (to the drive shaft housing) “1”, strike the tool to check that the ta- pered roller bearing outer race is in- Assembling the lower case stalled properly.
Page 239: Installing The Drive Shaft
Drive shaft and lower case • Face the bearing identification mark “a” on Make sure that the protrusion “a” on the sleeve the needle bearing up. “1” is aligned with the slot “b” in the lower case. • Mark the driver handle at the specified instal- lation depth “b”...
Page 240: Installing The Propeller Shaft Housing Assembly
Drive shaft and lower case 5. Tighten: • Pinion nut “1” b. Install the ring nut “1”, and then tighten it to the specified torque. Drive shaft holder 6 “2” 90890-06520 Pinion nut holder “3” 90890-06715 Pinion nut “1” Ring nut wrench 3 “2” 93 N·m (9.3 kgf·m, 69 lb·ft) 90890-06511 Ring nut wrench extension “3”...
Page 241: Installing The Shift Rod
Drive shaft and lower case Installing the shift rod 2. Install: • Impeller key 1. Install: • Impeller • O-ring (to the shift rod plate) a. Install the impeller key “1”. • Oil seal “1” b. Align the slot “a” in the impeller “2” with the impeller key “1”, and then install the impeller “2”.
Page 242: Checking The Lower Unit For Air Leakage
Drive shaft and lower case Lower unit While turning the drive shaft clockwise, push Holding pressure the water pump housing down to install it. 68.6 kPa (0.69 kgf/cm², 9.9 psi) Installing the lower unit • Make sure to disconnect the battery ca- bles from the battery, and remove the clip from the engine shut-off switch.
Page 243 Drive shaft and lower case 3. Install: • Dowel pin Place a block of wood between the anti-cavita- • Hose nipple tion plate and the propeller to prevent the pro- • Speedometer hose peller from turning. • Hose joint • Plastic tie •...
Page 244: Shimming
Shimming Shimming Shimming workflow 1. Remove the water pump assembly. 2. Measure the backlash before disassembly. 4. YES 3. Within specification? 5. Shimming is not required. 6. NO 7. Disassemble the lower unit. 8. Select the pinion shims (T3). 9. Assemble the lower unit. 10.
Page 245: Shimming Check Sheet
Shimming Shimming check sheet Lower case deviation Serial number Remarks Pinion height Measurements (mm) Measuring point “a” Measuring point “b” Measuring point “c” Measuring point “d” Average Round-down average Forward gear backlash Measurements (mm) Before disassembly After disassembly Measuring point “a” Measuring point “b”...
Page 246 Shimming Forward gear shim (T1) thickness measurement in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15 0.18 0.30 0.40 0.50 Total Reverse gear shim (T2) thickness measurement in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15 0.18 0.30 0.40...
Page 247: Measuring The Forward Gear Backlash And Reverse Gear Backlash Before Dis- Assembly
Shimming Measuring the forward gear backlash and reverse gear backlash before dis- assembly 1. Install: • Lower unit (onto a repair stand) 2. Remove: • Water pump assembly • Outer plate cartridge See “Water pump and shift rod” (8-3). Bearing housing puller claw L “1” 3.
Page 248 “2”. Spring “1” 90501-450A2 *1 Handle holder “2” EU0-23814-30 (2 required) *1 *1. Order from Yamaha Parts Distribu- tion Center. Setting height 3.0–5.0 mm (0.118–0.197 in) 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...
Page 249 Shimming Determine the backlash average, and then round down the average to 2 dec- • The resistance of the spring increases the imal places. force required to turn the drive shaft. There- fore, to obtain correct measurements, con- Example: sider the spring resistance force when (mm) turning the drive shaft.
Page 250 Shimming Check that the reverse gear backlash average is within specification. Adjust the shim thicknesses if the reverse gear backlash is out of specification. s. Remove the special service tools and propeller. 4. Install: • Cover “1” 5. Install: • Outer plate cartridge •...
Page 251: Shimming Procedure
Shimming Shimming procedure • Before selecting the forward gear shim (T1) and reverse gear shims (T2), make sure to select the pin- ion shims (T3). • When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do not apply gear oil, grease, or sealant to the parts.
Page 252: Selecting The Pinion Shim (T3)
Shimming Selecting the pinion shim (T3) • Spray anti-rust lubricant on the bearing be- fore installation. Do not apply gear oil to the parts. Otherwise, correct measurements cannot be obtained. • Keep the parts free of foreign material, such as dirt and lint. Be careful not to damage the measurement plane surface of the special service tool.
Page 253 Shimming If there is no gap and the drive shaft does not turn, the special service tool could be damaged. If there is no gap, the thrust bearing outer race “4” may not have been installed. If the gap is 1.0 mm (0.039 in) or more, the pinion shims (T3) “5”...
Page 254: Measuring The Forward Gear Backlash
Shimming Available shim thicknesses • When measuring the distance, insert the end Pinion shims of the thickness gauge straight into the gap at 0.10/0.12/0.15/0.18/0.30/0.40/0.50 the measurement point. Do not insert the thickness gauge at an angle. • Measure the distance at 4 points: “a”, “b”, “c”, Example: and “d”.
Page 255: Adjusting The Forward Gear Shim Thickness (T1)
Shimming 3. Select: • Forward gear shim (T1) • If the original forward gear shims (T1) are a. Determine the forward gear shim (T1) missing, install new shims with a combined thickness adjustment using the “For- thickness of 0.72 mm. ward gear shim (T1) selection chart”...
Page 256: Measuring The Reverse Gear Backlash
Shimming Example: Example: Backlash measurement (BL1) = 0.10 Use the following formula when the mm “a” shim thickness adjustment value is Forward gear shim (T1) thickness ad- positive. justment = –0.24 mm “b” Current forward gear shim thickness = The current shim thickness must be 0.72 mm decreased by 0.24 mm.
Page 257: Adjusting The Reverse Gear Shim Thickness (T2)
Shimming • If the original reverse gear shims (T2) are • If the shim thickness adjustment value is pos- missing, install new shims with a combined itive, increase the current shim thickness by thickness of 0.70 mm. that amount and, if the value is negative, de- •...
Page 258 Shimming • Use the lowest number of shims to obtain the required shim thickness. • If the calculated shim thickness cannot be obtained with a combination of the available shims, increase or decrease the shim thick- ness by 0.01 mm. Calculation formula: New reverse gear shim (T2) thickness = Current reverse gear shim thickness...
Page 259 Bracket unit Steering friction plate (tiller handle model) ..... 9-1 Tiller handle (tiller handle model) ........9-2 Disassembling the tiller handle........... 9-4 Assembling the tiller handle ............9-4 Electrical component (tiller handle) ......... 9-7 Assembling the electrical component......... 9-8 Shift rod and shift bracket..........9-9 PTT switch and cowling lock lever .........
Page 260: Bracket Unit
Bracket unit PTT unit ................9-24 Removing the PTT unit............. 9-25 Bleeding the PTT unit............... 9-25 Installing the PTT unit............... 9-26 Clamp bracket and swivel bracket........9-28 Checking the clamp bracket anode .......... 9-29 Installing the clamp bracket............9-29 Adjusting the trim sensor cam ..........9-30 PTT motor .................
Page 261 Steering friction plate (tiller handle model) Steering friction plate (tiller handle model) 20 N·m (2.0 kgf·m, 15 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft) 40 N·m (4.0 kgf·m, 30 lb·ft) 19.6 N·m (1.96 kgf·m, 14.5 lb·ft) Part name Q’ty Remarks...
Page 262: Tiller Handle (Tiller Handle Model)
Tiller handle (tiller handle model) Tiller handle (tiller handle model) 28 48 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 14 8 1.6 N·m (0.16 kgf·m, 1.2 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Screw M6  16 mm Coupler PTT switch Screw M5 ...
Page 263 Tiller handle (tiller handle model) 28 48 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 14 8 1.6 N·m (0.16 kgf·m, 1.2 lb·ft) Part name Q’ty Remarks E-clip Throttle lever Bushing Drive gear Bushing Shift link Cotter pin Washer Plate Collar Retainer Spring Bushing Friction piece...
Page 264: Assembling The Tiller Handle
Tiller handle (tiller handle model) Disassembling the tiller handle 1. Remove: • Cotter pin “1” • Throttle friction adjuster “2” • Bolt “3” Assembling the tiller handle 1. Pass the throttle rod “1” through the friction piece “2” and tiller handle “3”. 2.
Page 265 Tiller handle (tiller handle model) 4. Install: 6. Install: • Control link assembly • Throttle grip • Throttle grip screw a. Align the marks “a” and “b”, and align the cutouts “c” and “d”, and then install a. Align the mark “a” on the throttle grip the control link assembly “1”.
Page 266 Tiller handle (tiller handle model) 9. Check: • Smooth operation of the shift link lever (when the shift lever is moved from the N position to the F or R position) • Proper operation of the neutral switch “1” 13. Install: •...
Page 267 Electrical component (tiller handle) Electrical component (tiller handle) 2.3 N·m (0.23 kgf·m, 1.7 lb·ft) 4.4 N·m (0.44 kgf·m, 3.2 lb·ft) 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Clamp Cover Screw M6  20 mm Tiller handle Plate Alert indicator...
Page 268 Electrical component (tiller handle) Assembling the electrical component 6. Align the blue tape “a” on the extension wire harness “1” and green tape “b” on the 1. Install: alert indicator harness “2” with the inner • Engine start switch “1” end of the grommet “3”.
Page 269: Shift Rod And Shift Bracket
Shift rod and shift bracket Shift rod and shift bracket 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 18 N·m (1.8 kgf·m, 13 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Holder Bushing Clip Shift rod detent bolt M12  16 mm Screw M4 ...
Page 270: Ptt Switch And Cowling Lock Lever
PTT switch and cowling lock lever PTT switch and cowling lock lever 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Part name Q’ty Remarks PTT switch Spring Bolt M8  12 mm Cowling lock lever O-ring Bushing Lever Wave washer...
Page 271 Bottom cowling Bottom cowling 10 N·m (1.0 kgf·m, 7.4 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 16 17 Part name Q’ty Remarks Part name Q’ty Remarks Screw M6  20 mm Holder Bolt M6  25 mm Adapter Bolt M8  35 mm Bracket Bracket Collar...
Page 272 Upper case assembly and mount Upper case assembly and mount 74 N·m (7.4 kgf·m, 55 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Plastic tie Washer Nipple Washer Grommet Speedometer hose Bolt M6  10 mm Ground lead Nut M14 Washer Ground lead Upper case...
Page 273 Upper case assembly and mount Removing the upper case 1. Drain: Fit the ground lead “2” into the groove “a” in the • Engine oil steering yoke. 2. Remove: • Upper case Before removing the upper case, loosen the upper mount bolts “1” and lower mount cover bolts (PORT and STBD) “2”.
Page 274 Upper case (L-transom model) Upper case (L-transom model) 27 N·m (2.7 kgf·m, 20 lb·ft) 42 N·m (4.2 kgf·m, 31 lb·ft) Part name Q’ty Remarks Drain bolt M14 Gasket Plastic tie Damper Rubber seal Bolt M10  45 mm Upper case Rubber seal Dowel pin Rubber seal...
Page 275: Assembling The Upper Case
Upper case (L-transom model) Assembling the upper case 1. Install: • Rubber seal (to the oil pan assembly) • Guide (to the oil pan assembly) • Water pipe • Rubber seal (to the oil pan assembly) • Dowel pin • Rubber seal (to the upper case) •...
Page 276 Upper case (X-transom model) Upper case (X-transom model) 27 N·m (2.7 kgf·m, 20 lb·ft) 42 N·m (4.2 kgf·m, 31 lb·ft) Part name Q’ty Remarks Drain bolt M14 Gasket Plastic tie Damper Rubber seal Bolt M10  45 mm Upper case Rubber seal Dowel pin Rubber seal...
Page 277: Checking The Drive Shaft Bushing
Upper case (X-transom model) Disassembling the upper case 2. Install: • Rubber seal (to the oil pan assembly) 1. Remove: • Guide (to the oil pan assembly) • Drive shaft bushing “1” • Water pipe • Rubber seal (to the oil pan assembly) •...
Page 278 Oil pan and exhaust guide Oil pan and exhaust guide 18 N·m (1.8 kgf·m, 13 lb·ft) 42 N·m (4.2 kgf·m, 31 lb·ft) 42 N·m (4.2 kgf·m, 31 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) Part name Q’ty Remarks...
Page 279: Checking The Oil Strainer
Oil pan and exhaust guide Checking the oil pan and exhaust 2. Install: • Gasket (to the exhaust guide) guide • Pipe 1. Clean: • Dowel pin • Removed parts • Oil pan 2. Check: 3. Tighten: • Exhaust guide •...
Page 280 Oil pan and exhaust guide 5. Tighten: • Muffler bolt a. Tighten the muffler bolts “1” in the or- der [1], [2], and so on. [11] [10] 6. Install: • Grommet • PCV • Spring • Gasket (to the cover) •...
Page 281: Steering Arm
Steering arm Steering arm Part name Q’ty Remarks Plug Damper Circlip Steering yoke Washer Washer Steering arm Washer O-ring Bushing 9-21...
Page 282 Steering arm Removing the steering arm b. Hold the steering arm “1”, and then strike the steering yoke “2” using a 1. Remove: copper hammer until the groove “a” for • Steering yoke installing the circlip is visible. a. Remove the steering yoke “1” by strik- ing it using a copper hammer.
Page 283 Steering arm b. Inject grease into the grease nipple “1” until it comes out from both the upper and lower bushings “a”. 4. Install: • Damper • Plug 9-23...
Page 284 PTT unit PTT unit 54 N·m (5.4 kgf·m, 40 lb·ft) Part name Q’ty Remarks Plastic tie Plastic tie Bolt M6  10 mm Ground lead Circlip Shaft Bushing Bushing Bolt M10  30 mm Washer Shaft Bushing PTT unit 9-24...
Page 285: Removing The Ptt Unit
PTT unit Removing the PTT unit Manual valve “1” 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) When removing the PTT unit with the power unit installed, make sure to suspend the c. Remove the reservoir cap “1”, and outboard motor. then check the fluid level. If the fluid is at the proper level, a small amount Fully tilt the swivel bracket up, and then sup- of fluid should flow out of the filler hole.
Page 286 PTT unit Installing the PTT unit PTT motor lead Battery 1. Install: Green (G) • Bushing (upper side) Retract Blue (L) (–) 2. Route: g. Reverse the connection between the • PTT motor lead battery jumper leads and the PTT mo- a.
Page 287 PTT unit 5. Install: • Plastic tie • Plastic tie a. Fasten the PTT motor lead and trim sensor lead using the plastic tie “1” and new plastic ties “2”. 9-27...
Page 288: Clamp Bracket And Swivel Bracket
Clamp bracket and swivel bracket Clamp bracket and swivel bracket 22 N·m (2.2 kgf·m, 16 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 2.3 N·m (0.23 kgf·m, 1.7 lb·ft) 30 31 Part name Q’ty Remarks Part name Q’ty Remarks...
Page 289: Checking The Clamp Bracket Anode
Clamp bracket and swivel bracket Checking the clamp bracket anode 1. Check: • Anode Eroded (1/2 or more)  Replace. There is grease, oil, or scales  Clean. Do not apply grease, oil, or paint to the an- ode. Installing the clamp bracket 1.
Page 290 Clamp bracket and swivel bracket Grease nipple Digital circuit tester 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 90890-03243 8. Install: Trim sensor • Trim sensor cam Setting resistance • Trim sensor cam screw 9–11  • Plastic tie Terminal “c”–Terminal “d” 9.
Page 291: Ptt Motor
PTT motor PTT motor 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Part name Q’ty Remarks Reservoir cap M12  10 mm O-ring Bolt M6  25 mm PTT motor assembly O-ring Rubber cap Screw M5  20 mm Stator O-ring Armature...
Page 292: Checking The Armature (Ptt Motor)
PTT motor Removing the PTT motor Checking the armature (PTT motor) 1. Check: • Commutator Before removing the reservoir cap, make Dirty  Clean using 600-grit sandpaper sure that the trim and tilt ram is fully ex- and compressed air. tended.
Page 293: Assembling The Ptt Motor
PTT motor 2. Check: • Circuit breaker continuity Standard commutator undercut No continuity  Replace. 1.50 mm (0.0591 in) Wear limit 1.00 mm (0.0394 in) Do not touch the bimetal “1”. Otherwise, the operation of the circuit breaker can be 4.
Page 294 PTT motor 3. Install: • Armature Reservoir cap a. Push the brushes “1” into the brush 7 N·m (0.7 kgf·m, 5.2 lb·ft) holder, and then install the armature “2”. 4. Install: • Stator “1” • Screw “2” • Rubber cap “3” When removing or installing the armature along with the motor base assembly, se- cure the end of the armature shaft using a...
Page 295: Ptt Gear Pump
PTT gear pump PTT gear pump 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 24 25 5 N·m (0.5 kgf·m, 3.7 lb·ft) 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Part name Q’ty Remarks Part name...
Page 296 PTT gear pump 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 24 25 5 N·m (0.5 kgf·m, 3.7 lb·ft) 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Ball 3.95 mm (0.16 in)
Page 297: Checking The Gear Pump
PTT gear pump Disassembling the gear pump assem- 1. Install: • O-ring (to the up-relief valve) • Up-relief valve (to the gear housing (upper 1. Remove: side)) • Valve lock screw “1” • Main valve seal • E-clip Before removing the valve lock screw “1”, mea- •...
Page 298 PTT gear pump 6. Install: • Ball (to the gear housing (lower side)) • Install the valve lock screw “2” to the position • Adapter “a” where it was measured before removing • O-ring the screw. • Spring • When installing new parts, install them ac- •...
Page 299: Ptt Cylinder
PTT cylinder PTT cylinder 65 N·m (6.5 kgf·m, 48 lb·ft) 150 N·m (15 kgf·m, 111 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 150 N·m (15 kgf·m, 111 lb·ft) Part name Q’ty Remarks Part name Q’ty Remarks Trim piston assembly Ball 3.97 mm (0.16 in) Ball 4.76 mm (0.19 in) Tilt piston Trim cylinder...
Page 300 PTT cylinder Disassembling the trim cylinder 1. Loosen: • Trim cylinder end screw “1” Cylinder end screw wrench “2” Tilt rod wrench “2” 90890-06591 90890-06569 PTT piston vice attachment “3” 2. Drain: 90890-06572 • PTT fluid Checking the PTT cylinder and piston Disassembling the tilt cylinder 1.
Page 301 PTT cylinder Assembling the trim and tilt ram as- sembly 1. Install: • O-ring “1” • O-ring “2” Tilt rod wrench “2” 2. Install: 90890-06569 • Dust seal “1” PTT piston vice attachment “3” • O-ring “2” 90890-06572 • O-ring “3” Trim and tilt ram “1”...
Page 302 PTT cylinder 6. Tighten: • Tilt piston bolt “1” c. Tighten the tilt cylinder end screw “1” to the specified torque. When tightening the tilt cylinder end screw, be careful not to damage the check valve “3”. Tilt piston bolt “1” 7 N·m (0.7 kgf·m, 5.2 lb·ft) Assembling the tilt cylinder 1.
Page 303 PTT cylinder Assembling the trim cylinder d. Tighten the trim cylinder end screw “1” to the specified torque. 1. Install: • Ball • Trim piston assembly a. Slide the trim cylinder end screw “1” to the bottom of the trim and tilt ram “2”. Cylinder end screw wrench “2”...
Page 304: Maintenance
Maintenance Outline ................10-1 Maintenance interval chart 1 ............ 10-2 Maintenance interval chart 2 ............ 10-4 Predelivery check............. 10-5 Checking the engine oil level............ 10-8 Checking the battery ..............10-8 Checking the cooling water pilot hole........10-9 Checking the gear oil level ............10-9 Checking the outboard motor mounting height ......
Page 305: 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 306: Maintenance Interval Chart 1
Outline Maintenance interval chart 1 The “ ” symbol indicates the check-ups which the owners or operators may carry out themselves. The “ ” symbol indicates work to be carried out by a Yamaha dealer. Initial Every Item Actions 20 hours...
Page 307 Wire harness connec- Inspection or replace- tions/wire coupler con- ment as necessary nections (Yamaha) Meter/gauge Inspection Fuel tank (Yamaha por- Inspection and cleaning table tank) as necessary *1. Cylinder head, cylinder block *2. Cylinder head, cylinder block, fuel cooler, exhaust guide 10-3...
Page 308: Maintenance Interval Chart 2
Outline Maintenance interval chart 2 Every Item Actions 1000 hours Exhaust guide/exhaust Inspection or replace- manifold ment as necessary Timing belt Replacement 10-4...
Page 309: Predelivery Check
Predelivery check Predelivery check To make the delivery process smooth and efficient, complete the predelivery checks as explained in the following procedures. Item Procedures Check the oil level using the dipstick. Engine oil level 10-8 Oil is not at the proper level  Add or extract engine oil. Check the battery electrolyte level.
Page 310 Predelivery check Item Procedures Check the PTT unit operation. 10-21 Check that there is no abnormal noise produced when the out- board motor is tilted up or down. 9-24 Abnormal noise  Check the PTT unit. Steer the tilted-up outboard motor. 2-26 PTT unit Interference ...
Page 311 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 312: Checking The Engine Oil Level
Predelivery check Checking the engine oil level Make sure that the engine is filled with en- gine oil before operating the outboard mo- tor for the first time. Otherwise, the engine could be damaged severely. The outboard motor is shipped from the factory Checking the battery without engine oil.
Page 313: Checking The Cooling Water Pilot Hole
Predelivery check Checking the cooling water pilot hole 1. Check: • Battery electrolyte level 1. Place the lower unit in the water, and then Below the minimum level mark “a”  Add start the engine. distilled water until the level is between the 2.
Page 314: Checking The Outboard Motor Mounting Height
Predelivery check Oil level plug 7 N·m (0.7 kgf·m, 5.2 lb·ft) Checking the outboard motor mount- ing height 1. Check: • Outboard motor mounting height Improper  Adjust. a. Check that the anti-cavitation plate “1” is aligned with the bottom of the boat “2”.
Page 315: General Periodic Maintenance
General periodic maintenance General periodic maintenance Item Procedures 7-26 7-28 Check the anodes. 7-43 Eroded (1/2 or more worn out)  Replace. Anodes Adhered grease, oil, paint, or scales  Clean. 9-19 9-29 Check the battery electrolyte level. Below the minimum level mark  Add distilled water. Battery 10-8 Check the specific gravity of the electrolyte.
Page 316 General periodic maintenance Item Procedures Check the fuel filter element. Dirt/residue  Replace. Water accumulated  Drain. Checking the fuel cup assembly. Foreign material  Clean. Fuel filter Cracked  Replace. Checking the fuel inlet or fuel outlet holding pressure. Out of specification ...
Page 317 Check the impeller, insert cartridge, and outer plate cartridge. Water pump Cracked/worn  Replace. Check the impeller key and keyway in the drive shaft. Deformed/worn  Replace. Wire harness lead Check the wire harness coupler and lead coupler connections. — (Yamaha) Check the meter/gauge display. — Meter/gauge 10-13...
Page 318 General periodic maintenance Item Procedures Check the fuel tank. Cracked/damaged  Replace. Fuel tank (Yamaha — Leaking  Check the related parts. portable tank) Dirt/residue  Clean. 10-14...
Page 319: Checking The Cooling Water Inlet
“a”, and then remove the trim tab “3”. b. Check the engine idle speed using the Yamaha genuine tachometer (on- c. Check the water inlet covers and wa- board meter) or the YDIS. See the ter inlets. Clean if clogged.
Page 320: 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 321 General periodic maintenance 3. Drain: 5. Fill: • Engine oil • Recommended engine oil a. Remove the oil filler cap “1”. a. Fill the engine with the specified amount of the recommended engine oil through the oil filler hole. Install the oil filler cap.
Page 322: Replacing The Oil Filter
General periodic maintenance Oil filter wrench “1” If the oil pressure alert indicator comes on 90890-01426 or if there is oil leakage, stop the engine and find the cause. Continued operation b. Install a new oil filter “1”, and then with a problem could cause severe engine tighten it to the specified torque.
Page 323 General periodic maintenance 1. Drain: b. Insert the gear oil pump into the drain • Gear oil hole, and then fill the lower unit slowly a. Tilt the outboard motor so that the with gear oil until oil flows out of the drain screw is at the lowest point.
Page 324: Greasing Points
General periodic maintenance Drain screw “2” 7 N·m (0.7 kgf·m, 5.2 lb·ft) Oil level plug “3” 7 N·m (0.7 kgf·m, 5.2 lb·ft) Greasing points 1. Apply: • Specified lubrication points a. Apply water resistant grease to the specified lubrication points. A.
Page 325: Checking The Ptt Fluid Level
General periodic maintenance 3. Apply a sufficient amount of grease to the inside of the through tube and to the hy- Before removing the reservoir cap, make draulic steering cylinder rod or steering ca- sure that the PTT ram is fully extended. ble.
Page 326: Checking The Cowling Lock Lever
General periodic maintenance b. Fully tilt the outboard motor up, and then support it using the tilt stop lever “1”. Check that the tilt stop lever oper- ates properly. c. Tighten the nut. d. Recheck the fitting. Replace the cowl- ing seal if the looseness or rattling cannot be adjusted.
Page 327: Appendix
Appendix Specification ...............A-1 Model data.................. A-1 Electrical system technical data ..........A-2 Fuel system technical data............A-4 Power unit technical data ............A-4 Lower unit technical data............A-6 Bracket unit technical data ............A-6 Wiring diagram ..............A-7 How to use the wiring diagram ........... A-7 Engine control unit, fuel unit, and ignition unit ...
Page 328: Specification
Performance Specification Model F75FEHT F75FET F100GEHT F100GET Model data Rated power 55.2 kW (75 HP) 73.6 kW (100 HP) Dimension and weight Full throttle operating 5000–6000 r/min Model F75FEHT F75FET F100GEHT F100GET range 1547 mm (60.9 803 mm (31.6 1547 mm (60.9 803 mm (31.6 28.7 L/h at 6000 r/min 36.9 L/h at 6000 r/min...
Page 329: Electrical System Technical Data
Lower unit Model F75FEHT F75FET F100GEHT F100GET Recommended gear oil Model F75FEHT F75FET F100GEHT F100GET SAE 90 API GL-4 / SAE 80W API GL-5 / SAE 90 API GL-5 grade Gear shift positions Forward-neutral-reverse Gear oil quantity 0.760 L (0.803 US qt, 0.669 Imp.qt) Gear ratio 2.15 (28/13) * Recommended engine oil and gear oil grade: Meeting both API and SAE requirements.
Page 330 Model F75FEHT F75FET F100GEHT F100GET Engine speed control system Output peak voltage at Model F75FEHT F75FET F100GEHT F100GET cranking (loaded) (refer- 9.0 V ence data) Output voltage at throttle 0.58 V Output peak voltage at valve fully closed 1500 r/min (loaded) (ref- 26.8 V Throttle valve opening erence data)
Page 331: Fuel System Technical Data
Model F75FEHT F75FET F100GEHT F100GET Starting system Fuel pump Model F75FEHT F75FET F100GEHT F100GET Fuel inlet holding pres- Starter motor 196.0 kPa (1.96 kgf/cm², 28.4 psi) sure (positive pressure) Type Sliding gear Fuel outlet holding pres- Output 1.40 kW 196.0 kPa (1.96 kgf/cm², 28.4 psi) sure (positive pressure) Cranking time limit 30 sec...
Page 332 Model F75FEHT F75FET F100GEHT F100GET Cylinder head assembly Valve guide Model F75FEHT F75FET F100GEHT F100GET Inside diameter IN 5.504–5.522 mm (0.2167–0.2174 in) Cylinder head Clearance IN 0.014–0.047 mm (0.0006–0.0019 in) Warpage limit 0.10 mm (0.0039 in) Limit 0.070 mm (0.0028 in) Journal inside diameter 37.000–37.025 mm (1.4567–1.4577 in) Inside diameter EX...
Page 333: Lower Unit Technical Data
Model F75FEHT F75FET F100GEHT F100GET Model F75FEHT F75FET F100GEHT F100GET Limit 18.035 mm (0.7100 in) Crankshaft pin width 21.00–21.10 mm (0.8268–0.8307 in) Pin outside diameter 17.991–18.000 mm (0.7083–0.7087 in) Journal oil clearance 0.026–0.050 mm (0.0010–0.0020 in) Limit 17.981 mm (0.7079 in) Limit 0.070 mm (0.0028 in) Piston ring (Top)
Page 334: 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, and ignition unit (tiller han- dle model)”, “Charging unit, starting unit, and PTT unit (tiller handle model)”, “Engine control unit, fuel unit, and ignition unit (remote control model)”, “Charging unit, starting unit, and PTT unit (remote control model)”, and “Control unit”.
Page 335: Engine Control Unit, Fuel Unit, And Ignition Unit
Engine control unit, fuel unit, and ignition unit (tiller handle model) 1. Engine ECM 2. ISC valve 20. Fuse box 3. Thermo sensor 19. PTT relay 4. Oil pressure switch 5. TPS 6. High-pressure fuel pump 7. Water detection switch 17.
Page 336: Charging Unit, Starting Unit, And Ptt Unit
Charging unit, starting unit, and PTT unit (tiller handle model) 1. Engine ECM 2. Hour meter 14. Fuse box 3. PTT switch 4. Diode 5. Trim sensor 6. PTT motor 7. Joint connector 2 9. Battery 13. Stator assembly 8. Joint connector 1 10.
Page 337: Engine Control Unit, Fuel Unit, And Ignition Unit
Engine control unit, fuel unit, and ignition unit (remote control model) 1. Engine ECM 2. ISC valve 20. Fuse box 3. Thermo sensor 19. PTT relay 4. Oil pressure switch 5. TPS 6. High-pressure fuel pump 7. Water detection switch 17.
Page 338: Charging Unit, Starting Unit, And Ptt Unit (Remote Control Model)
Charging unit, starting unit, and PTT unit (remote control model) 1. Engine ECM 2. Tilt limiter 14. Fuse box 3. PTT switch 4. Diode 5. Trim sensor 6. PTT motor 7. Joint connector 2 9. Battery 13. Stator assembly 8. Joint connector 1 10.
Page 339: Control Unit
Control unit 1. 703 side mount remote control (F75FET, F100GET) 2. Engine start switch 1. 703 side mount remote control (F75FET, F100GET) 14. Tiller handle (F75FEHT, F100GEHT) 3. Engine shut-off switch 2. Engine start switch 4. PTT switch 3. Engine shut-off switch 4.
Page 340: Shim Selection Table And Chart
Shim selection table and chart Pinion shim (T3) selection table (mm) 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29 0.30 1.32 1.32...
Page 341: Forward Gear Shim (T1) Selection Chart
Forward gear shim (T1) selection chart 1.10 1.00 0.90 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 –0.10 –0.20 –0.30 –0.40 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 A (1/100 mm) 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 –0.30 –0.27 –0.24 –0.21 –0.18 –0.15 –0.13 –0.10 –0.07 –0.04 –0.01 0.02 0.05 0.08 0.11 0.14 0.16 0.19 0.22 0.25 0.28 0.31 0.34 0.37 0.40 0.43 0.45 0.48 0.51 0.54 0.57 0.60 0.63 0.66 0.69 0.72 0.74 0.77 0.80 0.83 0.86...
Page 342: List Of Optional Parts
List of optional parts Destinations CRB (EPA) Combination Optional parts Kit P/N F100GET F75FET, F100GET F100GET F75FET, F100GET F75FEHT, F100GEHT F100GET symbol — 6X4-42103-6A Tiller handle kit — 6X4-42102-G2 Handle fitting kit — 63P-825EY-02 Tilt limiter kit To change from remote control to tiller handle —...
Page 343 Jan. 2020 !
Page 344 (6JX) (6JY) 6JY-28197-Z0-11 Jan. 2020 ! 6JY-28197-Z0-11_cover.indd 2019/12/26 15:30:26...

This manual is also suitable for:

F100g

Yamaha F75F Service Manual

Table of Contents

Technical Feature and Description

Rigging Information 0

Troubleshooting 0

Fuel System 0

Power Unit

Lower Unit 0

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Related Manuals for Yamaha F75F

Summary of Contents for Yamaha F75F