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Yamaha XF450 2022 Service Manual

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6KN-28197-Z2-11

LIT-18616-04-18

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Summary of Contents for Yamaha XF450 2022

Page 1 Worldwide: (6LB) (6LC) (6KN) (6KP) USA, CAN, EUR, AUS, and NZL: (6LB) (6KN) 6KN-28197-Z2-11 LIT-18616-04-18...
Page 2 Preface This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained tech- nicians when performing maintenance procedures and repairs to Yamaha equipment. It has been writ- ten to suit the needs of persons who have the Bronze Technical Certificate of the YTA (Yamaha...
Page 3: Table Of Contents
Contents General information Specification Technical feature and description Rigging information Troubleshooting Electrical system Fuel system Power unit Lower unit Bracket unit Maintenance Appendix...
Page 4: General Information
General information Model information .............. 0-1 Applicable model ............... 0-1 Model name designation............0-1 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................... 0-3 Self-protection................
Page 5: Model Information
Model information Model information Applicable model This manual applies to the following models. Worldwide Model name Approved model code Starting serial No. F450AVT 1000001– FL450AVT 1000001– F400AST 1000001– FL400AST 1000001– USA, CAN, EUR, AUS, and NZL Model name Approved model code Starting serial No.
Page 6 Model information X (25 in) Motor transom height U (30 in) E (35 in) USA, CAN, EUR, AUS, and NZL XF 450 X: XTO offshore series Model category F: 4-stroke Horsepower 400/450 X: 25 in U: 30 in Motor transom height E: 35 in N: Without lower unit Starting method/PTT...
Page 7: Important Safety And Service Information
Important safety and service information Important safety and service Handling of gasoline • Gasoline is highly flammable. Keep gasoline information 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: Lifting Outboard Motors
Use only genuine Yamaha parts, lubricants, and sealants, or those recommended by Lifting outboard motors Yamaha, when servicing or repairing the out- • Outboard motors weighing 18 kg (40 lb) and board motor. Failures caused by the use of over must be carried by a crane or equiva- parts, lubricants, or sealants that are not lent.
Page 9: Special Service Tools
Important safety and service information • Apply engine oil to the contact surfaces of moving parts before assembly. Special service tools For safety and to help protect parts from dam- • During disassembly, cover all openings, age, use the recommended special service such as intake and exhaust ports, to prevent tools.
Page 10 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 11: How To Use This Manual
Power-train Control Unit Power Trim and Tilt Steer by Wire Steering Control Unit Shift Dampener System Shift Position Sensor Throttle Position Sensor Variable Camshaft Timing Y-COP Yamaha Customer Outboard Protection YDIS Yamaha Diagnostic System Xtreme Thrust Output Wide Open Throttle...
Page 12: Color Code
How to use this manual Color code Black Light green Sky blue Brown Orange White Green Pink Yellow Gray Purple Blue TIP: For example, “R/Y” stands for a Red with Yellow tracer stripe wire.
Page 13: Specified Tightening Torque
Specified tightening torque Specified tightening torque Specified tightening torques are provided for specific nuts, bolts, and screws. Specified tightening torque specifications are provided in the exploded diagrams and in the related working instructions. When tightening these fasteners, follow the tightening torque specifications and procedures indicated throughout the manual to meet the design aims of the outboard motor.
Page 14: Symbol
Lubricant Grease) Molybdenum disulfide grease Lubricant (Yamalube Molybdenum Disulfide grease) Corrosion resistant grease Lubricant (Yamaha grease D or Yamalube Marine Grease) Low temperature resistant grease (Yamaha grease C or Yamalube Molybdenum Lubricant Disulfide grease) Epnoc grease AP #0 Lubricant YAMAHA WR-No.2 grease...
Page 15 Symbol Symbol Name Application YAMAHA Gasket Maker Sealant ThreeBond 1211* ThreeBond 1280B Sealant (Yamabond 4 Marine) ThreeBond 1322D Thread locking agent ThreeBond 1386B Sealant ThreeBond 1377B Thread locking agent LOCTITE 1342H Thread locking agent 1342H 1342H ThreeBond 1530D Sealant ThreeBond 1303...
Page 16: Special Service Tool
Special service tool Special service tool Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division. USA and Canada tool numbers (YB/YM/YS/YU-*****) are distributed by K&L Supply Co. Some of the special service tools are only available from the Marine Service Division.
Page 17 Special service tool Flywheel guide Shaft holder Valve spring compres- Valve spring compres- 90890-06955 90890-06949 sor attachment 90890-04200 90890-06320 Lever assy Support assy 3 Valve spring compres- Valve guide remover/ 90890-06956 90890-06952 installer 90890-06689 90890-06801 Valve guide reamer Valve lapper Valve seat cutter hold- Valve seat cutter 30–...
Page 18 Special service tool Needle bearing attach- Ring nut wrench Ring nut wrench ex- Stopper guide plate ment 90890-06932 tention 2 90890-06501 90890-06609 90890-06784 Bearing housing puller Center bolt Ball bearing attach- Driver rod LL claw L 90890-06504 ment 90890-06605 90890-06502 90890-06657 Needle bearing attach- Bearing inner race at-...
Page 19 Special service tool Pinion shimming Pinion shimming Backlash indicator Magnet base plate gauge gauge rod 90890-06836 90890-07003 90890-06948 90890-06676 Dial gauge set Magnet base B Ring nut extension Slide hammer handle 90890-03238 90890-06844 90890-06968 90890-06531 Puller head Needle bearing attach- Ball bearing attach- Bearing inner race at- 90890-06514...
Page 20 Special service tool US SST No. Bolt hexagon with Drilling plate Spark checker Pressure/vacuum tes- washer YB-34465-A YM-34487 YB-06821 YB-35956-B Compression gauge Universal magneto Flywheel stopper Valve spring compres- YU-33223 and rotor holder YB-06598 sor adaptor YU-01235 YB-06320 Valve spring compres- Valve guide remover Valve guide reamer Valve lapping tool...
Page 21 Special service tool Ring nut wrench ex- Universal Puller Bearing housing puller Prop end seal bearing tension YB-06117 YB-06207 driver YB-06784 YB-42227 Driver rod LL Taper roller bearing in- Forward gear bearing Forward gear bearing YB-06605 staller installer cup installer YB-06431 YB-06276 YB-06277-A...
Page 22 Special service tool Ring nut wrench Driveshaft needle Needle bearing install- Driveshaft needle YB-06823 bearing installer and bearing installer remover YB-06434 YB-06231 YB-06196 0-18...
Page 23: Specification
Specification Specification data .............. 1-1 External dimensions ............1-2 Clamp bracket dimensions ..........1-3...
Page 24: Specification Data
Specification data Specification data For specification data, see Appendix, “Specification” (A-1).
Page 25: External Dimensions
External dimensions External dimensions TIP: The dimension values may include reference values. mm (in) X:1291 (50.8) U:1412 (55.6) E:1533 (60.4) 708 (27.9) 198 (7.8) 1019 (40.1) X:390 (15.4) 47 (1.9) U:391 (15.4) E:392 (15.4) 295 (11.6) 66 (2.6) 861 (33.9) *1.
Page 26 Clamp bracket dimensions Clamp bracket dimensions TIP: The dimension values may include reference values. mm (in) 222 (8.7) 222 (8.7) 163.5 (6.4) 163.5 (6.4) 21 (0.8) 45 (1.8) 125.4 (4.9) 125.4 (4.9)
Page 27 Technical feature and description Model feature ..............2-1 General feature................2-1 Model comparison table ............2-2 Power unit................2-3 Intake silencer ................2-4 Shift-shock reduction..............2-4 Sleeveless cylinder..............2-5 Heat exhaust fan and heat vent ..........2-5 Direct fuel injection..............2-6 Crankshaft ..................
Page 28: Technical Feature And Description
Technical feature and description Fuel system............... 2-42 Fuel diagram ................2-42 High-pressure fuel pump control ..........2-45 Low-pressure fuel pump control ..........2-45 Vapor separator................ 2-46 Fuel strainer................2-47 Direct injection pump ............... 2-48 Lubrication system ............2-49 Lubrication diagram ..............2-49 Dual rotor oil pump ..............
Page 29: Model Feature
Model feature Model feature e. Lower unit General feature • New lower case • 4-stroke, V8, 5559 cm³ (339.2 cu. in) engine • Dual water pump • Various transom heights available for larger • Gear oil changing system on the water boats (X: 25”, U: 30”, E: 35”) •...
Page 30: Model Comparison Table
Model feature Model comparison table 400- and 450-horsepower 4-stroke models have been newly added to the Yamaha outboard motor lineup. The engine output powers of 400- and 450-horsepower models are controlled by their respective ECMs. Electricity generating capacity of 450-horsepower model is different from that of 400-horse- power model.
Page 31: Power Unit
Power unit Outline Electronically controlled, direct injection V8 engine, the flagship of the Yamaha Outboard Motor model line, is installed. An even higher output engine has been achieved through the optimization of intake/ exhaust system structure, while the design features of F375/F425 (XF375/XF425) to obtain high out-...
Page 32: Intake Silencer
Power unit Intake silencer Newly designed intake silencer “1” is employed. The space provided inside the silencer absorbs the intake air noise and the mechanical noise of the engine. This feature has greatly improved the quiet performance while the engine is in operation compared to F375/F425 (XF375/F425). Shift-shock reduction The gearshift shock has been reduced by the improved engine control program for the gearshift op- eration.
Page 33: Sleeveless Cylinder
Power unit Sleeveless cylinder The newly designed cylinder block has adopted spray-coated cylinders instead of sleeved cylinders. By using spray-coated cylinders, the weight of the cylinder block is decreased, cooling performance is increased, and so on. The inner walls of the cylinders are spray-coated using metal powder. Heat exhaust fan and heat vent The flywheel is equipped with a heat exhaust fan and the top cowling is equipped with a heat vent.
Page 34: Direct Fuel Injection
Power unit Direct fuel injection The direct injection pumps “1” further increase the pressure of the fuel from the fuel tank, low-pressure fuel pump, and vapor separator. The fuel pressure sensors (fuel rails) “2” are used to detect the fuel pressure in the fuel rails, and the injector drivers operate the direct injection pumps and fuel injectors based on information from the ECM to inject the optimum amount of fuel at the optimum timing.
Page 35: Crankshaft
Power unit Crankshaft The size of the journals is the same as for the F300B (F300CA) and the amount of overlap between the crankpins has been increased to ensure sufficient durability for offshore use. In addition, by increasing the surface area of the thrust bearings and reducing the friction by adding a surface treatment to the portion that engages the drive shaft splines, the durability in the thrust direc- tion is increased.
Page 36: Camshaft
Power unit Camshaft The timing belt is located on the top of the engine and the timing chains and VCT assemblies are lo- cated at the bottom of the engine for increased engine reliability. In addition, the overall width of the outboard motor is compact and the distance between outboard motors for multiple engine applica- tions is approximately the same as for previous models.
Page 37: Cowlings
Power unit Cowlings The cowling lock levers, which were located on the rear of the outboard motor for previous models, have been moved closer to the top of the top cowling and the rear portion of the top cowling is shorter. As a result, it is easier to access the cowling lock levers from the boat and remove and install the top cowling.
Page 38: Bracket Unit
Bracket unit Bracket unit Outline The upper mounts use outward-positioned, vibration-isolation upper mounts. The swivel bracket is equipped with the SBW (Steer by Wire) system for easier operation at low to high speeds as well as easier rigging. The PTT-related parts have also been newly designed for increased durability as well as easier remov- al and installation of the PTT unit itself.
Page 39: Upper Mount
Bracket unit Upper mount This model is the first Yamaha large outboard motor to use a layout with the vibration-isolation upper mounts positioned on the outside of the upper case. The installation location of the upper mounts has been changed from being secured inside the exhaust guide to being secured to the left and right sides of the upper case.
Page 40: Sbw (Steer By Wire) System
Bracket unit SBW (Steer by Wire) system Outline The steering system has been changed from a mechanical system that was used for previous models to an electronically controlled power-operated steering system. Because the steering system has been designed with a sufficient margin for use with large boats, the system is responsive and provides a stable feeling when steering the boat.
Page 41: System Diagram
Bracket unit System diagram When the signals from the steering wheel and joystick are input into the steering control unit (SCU), the SCU uses that information together with the information from other sensors to calculate the opti- mal steering control and operates the steering motor to match the intended steering angle of the op- erator.
Page 42 Bracket unit Helm Master model 1. Helm unit / joystick 2. Digital Electronic Control 4. Engine ECM (HCU) 5. Position sensor 3. PCU 6. SCU 7. Steering motor 8. Steering actuator 1. Helm unit/joystick 2. Digital Electronic Control (HCU) 3. PCU 4.
Page 43: Structure
Bracket unit Structure The steering actuator “1” is an integrated unit with a built-in steering control unit (SCU) and a built-in steering motor and cannot be disassembled. The steering motor, which has an integrated pipe, is lo- cated inside the actuator on one end and a shaft runs through the center of that pipe. The pipe is sup- ported by a bearing on the other end.
Page 44: Operation
Bracket unit Operation When power is supplied to the steering motor inside the steering actuator “1”, the pipe integrated with the motor turns. The rotational speed of the pipe is reduced as it is transmitted through the planetary gears to the shaft in the center of the pipe. Because both ends of the shaft are secured to the swivel bracket, the steering actuator moves 2 mm (0.08 in), which is the internal thread pitch distance, in a straight line in the shaft direction for each turn of the pipe.
Page 45: Outboard Motor Manual Steering Method
Bracket unit Outboard motor manual steering method If the SBW (Steer by Wire) system does not operate due to a malfunction, the outboard motor can be steered manually. Usually, the pipe inside the steering actuator moves as it is turned by the motor force, but when the outboard motor is steered manually, the shaft is turned to move the pipe.
Page 46: Ptt Unit
Bracket unit PTT unit The material of the PTT motor has been changed to plastic to increase corrosion resistance. In addi- tion, the PTT relay is a built-in component of the electrical management unit and is controlled by the microcomputer. As a result, the operation of the PTT motor can be controlled according to the trim and tilt angles.
Page 47: Ptt Sensor
Bracket unit PTT sensor This model is equipped with a PTT sensor that detects the trim and tilt angle of the outboard through- out the full range of movement from fully tilted down to fully tilted up. The end of the pin on the tilt rod fits into the PTT sensor that is installed to the swivel bracket.
Page 48: Ptt Lead
Bracket unit PTT lead PTT lead routing has been changed to run inside the clamp bracket, compared to the routing on the outside of the clamp bracket in the previous models. The external appearance around the clamp bracket has been refined further to provide additional product value. PTT TotalTilt™...
Page 49 Bracket unit Activating and deactivating the PTT TotalTilt™ function Make sure that all people are clear of the outboard motor when tilting the outboard motor up and down. Body parts can be crushed between the outboard motor and the clamp bracket when the outboard motor is trimmed or tilted.
Page 50 Bracket unit TIP: • For how to operate the trim zero set, see the owner’s manual included with the gauge. • When the PTT TotalTilt™ function is activated, the PTT buzzer will sound once. • When the PTT TotalTilt™ function is deactivated, the PTT buzzer will sound twice. Automatic tilt-up Make sure that all people are clear of the outboard motor when tilting the outboard motor up and down.
Page 51: Lower Unit
Lower unit Lower unit Outline The lower case has been newly designed to increase the size of the case itself and increase the max- imum speed and stability. The oil passages inside the case have also been revised and stainless steel parts with high strength and high corrosion resistance are used.
Page 52: Lower Case
Lower unit Lower case The lower case for this model has a new shape with low resistance. The maximum speed and stability are increased due to the newly shaped strut and skeg. In addition, by increasing the length of the anti- cavitation plate, the anti-cavitation performance of the propeller is increased.
Page 53: Gear Oil Changing Method
Lower unit Gear oil changing method There are 2 methods that can be used for changing the gear oil of this model. One method, which is similar to the method for previous models, uses the oil level plug, gear oil drain bolt, and oil filler bolt of the lower case, and one method uses a pump and the hoses on the side of the engine.
Page 54 Lower unit Changing the gear oil using the hoses on the side of the engine The gear oil can be changed using the hoses that are routed from the lower unit to the port side of the engine without removing the boat from the water, such as when the boat is docked. The “AIR” hose is connected to the upper portion of the lower case and the “OIL”...
Page 55: Reverse Thrust
Lower unit Reverse thrust The outboard motor has a structure that discharges the exhaust gas from above the anti-cavitation plate when the remote control lever is in the R position and the engine speed is 2000 r/min or less. As a result, propeller cavitation can be prevented when the outboard motor is operating in reverse.
Page 56: Propeller (Xto-Ec Series)
Lower unit Propeller (XTO-EC series) New XTO-EC series is available in addition to the existing XTO-OS series compatible with large horse- power models. XTO-EC series are high performance 3-blade stainless steel propellers having excellent anti-ventila- tion performance compared to the OS series. This allows more comfortable boat operation in the rough sea and on the heavily loaded boat.
Page 57: Electrical System
Electrical system Electrical system Charging system (F400A/FL400A/XF400) This model is equipped with a 3-phase AC magneto type generator. In addition, because the cooling efficiency of the rectifier/regulator “1” is increased and the temperature increase is controlled by the fan “3” on top of the stator assembly “2”, the 400-horsepower models produce of up to 88 net amps per engine at 1500 r/min.
Page 58: Charging System (F450A/Fl450A/Xf450)
Electrical system Charging system (F450A/FL450A/XF450) Outline To help meet the extreme electrical demands of today’s larger boats, the 450-horsepower models now feature a new three-phase, simultaneous charging system that delivers more net amps and at lower r/min, where it’s needed most. Using Phase Angle Control (PAC), which adjusts the intensity of the stator’s magnetic field, the 450- horsepower models produce of up to 96 net amps per engine at idle speed.
Page 59 Electrical system Simultaneous charging Traditionally outboard engines use a dedicated isolator lead to ensure that the start and house batter- ies are separated unless manually paralleled by the captain in an emergency. This allowed simultane- ous charging of both the start and house batteries. As boat-side electrical demand grew, boat side systems such as voltage sensing relays (VSR’s) and diode-based isolator systems appeared.
Page 60 Electrical system Simultaneous charging system 1. GEN 1.GEN 2. Rectifier/regulator 2. Rectifier/regulator 4. Red 4. Red 8. Load is more than charging output 4. Red 4. Red 3. Black 3. Black 9. Load is less than charging output 14.5 V 7.
Page 61: Knocking Detection
Electrical system Knocking detection Although previous models were equipped with 1 knock sensor, the number of sensors for this model was increased to 2 knock sensors. Because the sensitivity for detecting knocking is increased, the minimum amount of fuel within the range that does not produce knocking can be injected to generate the maximum output.
Page 62: Electronic Control System
Electronic control system Electronic control system This model uses an electronic direct injection control, digital ignition control, Digital Electronic Control, electronic shift control, ETV control, VCT control, knock control, over-revolution control, alert control, and fail-safe control. The engine ECM performs these controls based on data received from each sensor and switch. The engine ECM is equipped with a self-diagnosis function.
Page 63 Electronic control system 1. LPS 2. Digital Electronic Control ECM 3. Engine shut-off switch 4. Engine start switch 5. Cam position sensor 6. Crankshaft position sensor 7. Intake air pressure/temperature sensor 8. Oil pressure sensor 9. Engine temperature sensor 10. Fuel pressure sensor (high-pressure fuel pump) 11.
Page 64: Electrical Components
Electronic control system Electrical components 14 17 Part name Function Low-pressure fuel pump Sends the fuel from the fuel tank to the vapor separator. High-pressure fuel pump (sub) Pressurizes the fuel and sends the fuel to the direct injection pump. High-pressure fuel pump (main) Intake air pressure/tem-...
Page 65 Electronic control system Part name Function Contains various relays and fuses, and controls the power Electrical management box supply for the electrical components of the outboard motor. Determines the stroke of each cylinder according to the sig- Cam position sensor (PORT nals from both the crankshaft position sensor and the cam po- sition sensor (PORT EX).
Page 66: Fail-Safe
Electronic control system Fail-safe In the fail-safe control, the engine ECM enters the fail-safe control mode when an electrical component malfunctions. The fail-safe control system records the trouble codes according to the engine trouble conditions. *: For applications with multiple outboard motors Item Trouble conditions to be detected Controls performed by ECM...
Page 67 Electronic control system Item Trouble conditions to be detected Controls performed by ECM Output voltage is less than 0.20 V or Thermo sensor Set to 50 °C (122 °F) when running. more than 4.65 V. Set to 25 °C (77 °F). Intake air tempera- Output voltage is less than 0.20 V or High engine idle speed.
Page 68 Electronic control system Item Trouble conditions to be detected Controls performed by ECM Stop engine synchronization con- Shift actuator Overcurrent or sticking is detected. trol.* Engine speed is limited to 600 r/ Communication error between the Extension wire har- min. engine ECM and Digital Electronic ness Stop engine synchronization con-...
Page 69 Electronic control system Item Trouble conditions to be detected Controls performed by ECM Message is displayed on gauge dis- play when engine stops. “Check fuel supply. Insufficient fuel supply to vapor High-pressure fuel Outboard starter will not function separator. pump supply abnor- for 7 sec.
Page 70: Fuel System
Fuel system Fuel system Fuel diagram 2-42...
Page 71 Fuel system 7. Vapor separator 6. Relief 11. Check 12. Fuel pressure 9. High-pressure valve valve sensor 8. Venturi fuel pump (high-pressure (sub) fuel pump) 10. High-pressure 8. Venturi fuel pump 13. Fuel strainer (main) 5. Feed valve 6. Relief 5.
Page 72 Fuel system 1. Fuel tank 2. Primer pump 3. Fuel filter (water separator) 4. Low-pressure fuel pump 5. Feed valve 6. Relief valve 7. Vapor separator 8. Venturi 9. High-pressure fuel pump (sub) 10. High-pressure fuel pump (main) 11. Check valve 12.
Page 73: High-Pressure Fuel Pump Control
Fuel system High-pressure fuel pump control The vapor separator contains 2 high-pressure fuel pumps: a main pump without a check valve and a sub pump with a check valve. When the engine load is low, only the main pump operates, and when the engine load is high, the sub pump also operates.
Page 74: Vapor Separator
Fuel system Vapor separator This model is equipped with a newly designed vapor separator, which has been changed to a sealed type that eliminates the structure for discharging the vapor gas. Because venturi tubes “a” were added to control the amount of vapor gas so that it does not exceed a certain level, the vapor gas can be handled inside the vapor separator.
Page 75: Fuel Strainer
Fuel system Fuel strainer This model is equipped with a fuel strainer “1” between the vapor separator and the direct injection pumps. The strainer prevents clogging of the filters in the direct injection pumps and fuel injectors, extending the replacement intervals for the parts. In addition, because the fuel strainer element “2” can be re- placed easily without removing the fuel hose, serviceability is improved.
Page 76: Direct Injection Pump
Fuel system Direct injection pump Each direct injection pump “1”, which has a mechanically driven built-in plunger “2” and an electrically driven built-in solenoid “3”, pressurizes the fuel to the high pressure required for direction injection. The fuel inside the pump is sent through the mesh filter “4” and damper “5” to the solenoid chamber and plunger chamber.
Page 77: Lubrication System
Lubrication system Lubrication system Lubrication diagram 3. Oil pump 3. Oil pump 10. OCV 10. OCV 2-49...
Page 78 Lubrication system 16. Piston 9. Exhaust camshaft 17. Cylinder block 15. Crankshaft pin 8. Intake camshaft (oil cooler) 12. VCT 13. Valve and related parts 14. Crankshaft journal 10. OCV 18. Crank case cover 11. Cam chain tensioner (water jacket) 7.
Page 79: Dual Rotor Oil Pump
Lubrication system Dual rotor oil pump The dual rotor oil pump is driven using the crankshaft gear. The pump has 2 built-in rotors and while maintaining its compact size, the flow volume has been increased from 100 L/min to 140 L/min com- pared to previous models.
Page 80: Oil Drain Plug
Lubrication system Oil drain plug The diameter of the oil drain plug “1” has been increased, and the oil strainer “2” can be removed from and installed in the drain hole. As a result, the oil strainer can be checked and cleaned without disas- sembling the upper case.
Page 81: Cooling System
Cooling system Cooling system Cooling diagram 23. Oil cooler 16. Thermo sensor (STBD) 18. Thermostat (STBD) 28. Water jacket (upper) 15. Thermo sensor (PORT) 17. Thermostat (PORT) 8. Water pressure 8. Water pressure sensor sensor 3. Water pump 11. Cooling water 11.
Page 82 Cooling system 29. Thermostat 24. Thermostat 17. Thermostat 18. Thermostat (water jacket) (oil cooler) (STBD) (PORT) 15. Thermo 16. Thermo sensor (PORT) sensor (STBD) 28. Water jacket 23. Oil cooler (upper) 30. Vapor 12. Cylinder separator 13. Cylinder (PORT) 14. Cylinder (STBD) block (fuel cooler) 11.
Page 83 Cooling system 1. Water 2. Water inlet 3. Water pump 4. Muffler 5. Oil pan 6. Exhaust guide 7. Exhaust joint 8. Water pressure sensor 9. Cylinder head (PORT) 10. Cylinder head (STBD) 11. Cooling water pilot hole 12. Cylinder block 13.
Page 84: Dual Water Pump
Cooling system Dual water pump This model is equipped with a dual water pump to ensure sufficient cooling water for the higher output engine. The water pump can discharge 1.3 times the water that the pump for the F350A (F350CC) could discharge, which helps to control the increase in engine temperature when the outboard motor is operating under a high load.
Page 85: Engine Anode
Cooling system Engine anode The locations of the anodes in the engine cooling water passages have been optimized. As a result, checking the anodes at 1000 hours is no longer necessary and the anodes must be replaced only during major maintenance work. A.
Page 86: Thermostat
Cooling system Thermostat In addition to the thermostat in each cylinder bank of the F350A (F350CC), a thermostat has been add- ed to the crankcase and cylinder block for a total of 4 thermostats. Because the cooling water passages have been divided into 2 sections that are controlled separately, the engine temperature and output are stabilized, the warming-up time is reduced, the fuel consump- tion is lower, and condensation in the lubrication system is prevented.
Page 87: Intake And Exhaust System
Intake and exhaust system Intake and exhaust system Intake and exhaust diagram 3. Intake air pressure/ 5. Intake manifold (STBD) 1. Intake silencer temperature sensor 6. Exhaust joint 2. ETV 4. Intake manifold (PORT) 7. Oil pan 10. Idle exhaust 10.
Page 88: Hose Routing
Hose routing Hose routing Fuel hose and blowby hose 12. Relief valve to joint 1. Joint to fuel filter assembly 13. Relief valve to fuel pressure sensor 2. Fuel filter assembly to joint 14. Fuel pressure sensor to fuel strainer 3.
Page 89: Cooling Water Hose
Hose routing Cooling water hose 14. Joint to joint 1. Exhaust joint to cooling water pilot hole 15. Joint to joint 2. Exhaust joint to joint 16. Joint to joint 3. Exhaust joint to joint 17. Water jacket cover to joint 4.
Page 90 Rigging information Important reminder on rigging.......... 3-1 Outboard motor mounting instructions........3-1 Crate handling ..............3-2 Crate top cover symbol description........... 3-2 Uncrating ................3-3 Uncrating procedure (outboard motor without lower unit)..3-3 Uncrating procedure (outboard motor with lower unit) ....3-4 Outboard motor mounting ..........
Page 91: Rigging Information
Rigging information Digital Electronic Control ..........3-62 Digital Electronic Control system reset ........3-62 Tilt limiter ................3-63 Setting the tilt limiter ..............3-63 Clearing the tilt limiter .............. 3-64 Deactivating the tilt limiter............3-64 Calibration (6X9 Digital Electronic Control)....3-66 CL5 display calibration ............
Page 92: 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 93: Crate Handling
Crate handling Crate handling Crate top cover symbol description The following symbol are important when handling the crate. Read the notice and understand what each symbol means to prevent damage to the outboard motor when handling, transporting, and storing the crate. IMPORTANT This unit delivered to carrier in a good condition.
Page 94: Uncrating
1. Check: • Crate for shipping damage 5. Install: If any damage is found, consult your • Special service tool Yamaha distributor. 2. Remove: • Top cover When lifting the outboard motor, make sure • Frame to use the specified special service tool.
Page 95: Uncrating Procedure (Outboard Motor With Lower Unit)
Uncrating 8. Lift up the outboard motor carefully along with the bottom frame “1”. Make sure that the lifting harnesses do not Uncrating procedure (outboard motor damage any parts of the outboard motor. with lower unit) This procedure includes only the information that is different from the information in the pro- cedure for the outboard motor without the lower unit.
Page 96 Uncrating 3. Mount: • Outboard motor (to the boat or maintenance stand) See “Installing the outboard motor” (3-8). 4. Remove: • Lifting harness • Special service tool 5. Install (for U- or E-transom model): • Stud bolts “1” • Dowels “2” A.
Page 97 Uncrating • Lower unit mounting nuts (for U- or E- TIP: transom model) • Align the check valves “2” and “3” with the a. Install the water pipe. holes “a” in the joint. (For X-transom model) • Align the check valves “2” and “3” with the TIP: •...
Page 98 Uncrating Lower case mounting bolt 47 N·m (4.7 kgf·m, 35 lb·ft) Lower case anode bolt 42 N·m (4.2 kgf·m, 31 lb·ft) A. For X-transom model B. For U- or E-transom model Lower case mounting bolt (for X- transom model) 47 N·m (4.7 kgf·m, 35 lb·ft) Lower case mounting nut (for U- or E-transom model) 47 N·m (4.7 kgf·m, 35 lb·ft)
Page 99: Outboard Motor Mounting
Outboard motor mounting Outboard motor mounting For a twin outboard motor application, place the outboard motors so that the dis- Installing the outboard motor tance from the C/L of each outboard mo- Properly mounting the outboard motor will re- tor to the C/L of the boat transom are sult in better engine performance, product re- equal on both sides.
Page 100 Outboard motor mounting For a quint outboard motor application, place the center outboard motor so that the C/L of the outboard motor is aligned with the C/L of the boat transom. Place the other four outboard motors so that the distance from the C/L of each outboard motor to the C/L of the boat transom are equal on both sides.
Page 101 Outboard motor mounting A. Single outboard motor application B. Twin outboard motor application C. Triple outboard motor application D. Quad outboard motor application E. Quint outboard motor application TIP: The mounting height of an outboard motor varies based on the boat and engine model combination.
Page 102 Outboard motor mounting holes perpendicular to the surface of the boat transom using a 13.0 mm (0.5 in) “a” drill bit. Upper mounting bolt “1” Boat tran- Mounting som thick- Part number bolt size C/L.Centerline of the transom ness (D) 6.
Page 103: Outboard Motor Mounting Height
Outboard motor mounting When mounting a 4-stroke outboard motor to Boat tran- Mounting a boat, make sure that the mounting height som thick- Part number bolt size between the water surface and the clamp ness (D) bracket seating point is not less than the spec- M12 ×...
Page 104: Rigging Grommet Mounting
Rigging grommet mounting Rigging grommet mounting TIP: Rigging grommet description Make sure that the hole in the end of the neg- Pass all the control components through the ative battery cable terminal fits over the pro- proper holes in the rigging grommet. jection.
Page 105: Connecting The Fuel Hose
Rigging grommet mounting d. Install the rigging grommet “1” along with the grommet holder “2”. e. Install the rigging tube retainer “1”, and then fasten it using the plastic tie “2”. Connecting the fuel hose • When connecting the fuel hose, bleed the boat fuel line.
Page 106: Optional Equipment
Optional equipment Optional equipment Installing the isolator lead 1. Install • Isolator lead a. Insert the isolator lead into the bottom cowling. b. Remove the isolator terminal cover. c. Install the isolator lead “1” and square washer to the isolator terminal. c.
Page 107: Installing Y-Cop
Optional equipment TIP: Make sure that there is no slack in the wire harness. g. Fasten the SCU communication lead using the plastic ties “1”, “2”, and “3” at the 4 locations shown in the illustration. TIP: • Make sure that the SCU communication lead does not contact the oil filter.
Page 108: Battery Installation
• Wiring the starting battery to the 450-horsepower models are no different that 400-horsepower models. While Yamaha can not make recommendations about competitive engines wiring, most tra- ditional wiring designs will work without issues with the 450-horsepower models. If using the isolator lead, please ensure that the wiring can handle the additional current that can be provided by the 450- horsepower models.
Page 109 Battery installation 3. Main output 7. VSR 7. VSR Fig.1 1. GEN 2. Rectifier/regulator 4. Main battery 5. House battery 6. Thruster battery 8. Isolator 3. Main output Fig.2 1. GEN 2. Rectifier/regulator 4. Main battery 5. House battery 8. Isolator 3.
Page 110: Battery Wiring
Battery installation Battery wiring When using a dual battery installation, a negative battery cable must be installed between both engine batteries. This cable must be sized equivalent to the engine battery cables or larger AWG cable size in accordance with ABYC specifications. 1.
Page 111 Battery installation 1. Outboard motor 3. Red 4. Black 2. Battery switch ON/OFF 3. Red 1. Outboard motor 4. Black 2. Battery switch STBD PORT 1. Outboard motor 1. Outboard motor 3. Red 3. Red 4. Black 4. Black ON/OFF ON/OFF 2.
Page 112 Battery installation STBD PORT 1. Outboard motor 1. Outboard motor 2. Battery switch 2. Battery switch 3. Navigation system 4. Boat system 5. Black 5. Black ON/OFF ON/OFF 6. Red 6. Red 6. Red 6. Red 5. Black 5. Black 5.
Page 113 Battery installation 2. Battery switch 1. Outboard motor 1. Outboard motor STBD CENTER PORT 1. Outboard motor 2. Battery switch 3. Navigation system 4. Boat system 6. Red 6. Red ON/OFF ON/OFF 6. Red 5. Black ON/OFF 5. Black 6. Red 5.
Page 114 Battery installation 1. Outboard motor 1. Outboard motor STBD PORT 1. Outboard motor 2. Battery switch 5. Black 5. Black 3. Navigation system 4. Boat system 5. Black 6. Red ON/OFF ON/OFF 6. Red 6. Red ON/OFF ON/OFF 6. Red 5.
Page 115 Battery installation 2. Battery switch 2. Battery switch 1. Outboard motor 1. Outboard motor STBD 1. Outboard motor CENTER PORT 2. Battery switch 5. Black 5. Black 5. Black 5. Black 3. Navigation system 4. Boat system 6. Red 6. Red ON/OFF ON/OFF 6.
Page 116: System Diagram
System diagram System diagram Single outboard motor application (single station) HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ (*1) 3-25...
Page 117 System diagram Ref. Part name Part No. Remarks Engine ECM — 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft) Main wire harness (16P) 6X6-8258A-21 8 m (26 ft) 6X6-8258A-31 10 m (32 ft) 6X6-8258A-41 12 m (39 ft)
Page 118 System diagram Ref. Part name Part No. Remarks Multi-hub 6Y8-81920-01 w/ resistor cap, Gray 6Y8-82553-01 0.3 m (1 ft) 6Y8-82553-50 3.0 m (10 ft) 6Y8-82553-11 4.6 m (15 ft) Main bus wire 6Y8-82553-21 6.1 m (20 ft) 6Y8-82553-31 7.6 m (25 ft) 6Y8-82553-41 9.1 m (30 ft) System power supply wire 6Y8-83553-02 w/ 10 A fuse, 2.4 m (8 ft)
Page 119: Twin Outboard Motor Application (Single Station)
System diagram Twin outboard motor application (single station) HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ (*2) (*2) (*1) (*1) 3-28...
Page 120 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft) Main wire harness (16P) 6X6-8258A-21 8 m (26 ft) 6X6-8258A-31 10 m (32 ft) 6X6-8258A-41 12 m (39 ft)
Page 121 System diagram Ref. Part name Part No. Remarks 6X9-8591T-23 Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-13 Key fob: 2 pcs. Multi-hub 6Y8-81920-01 w/ resistor cap, Gray 6Y8-82553-01 0.3 m (1 ft) 6Y8-82553-50 3.0 m (10 ft) 6Y8-82553-11 4.6 m (15 ft) Main bus wire...
Page 122: Triple Outboard Motor Application (Single Station)
System diagram Triple outboard motor application (single station) HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ (*2) (*2) (*1) (*1) 3-31...
Page 123 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft) Main wire harness (16P) 6X6-8258A-21 8 m (26 ft) 6X6-8258A-31 10 m (32 ft) 6X6-8258A-41 12 m (39 ft)
Page 124 System diagram Ref. Part name Part No. Remarks Autopilot panel 6X9-8253V-01 Joystick 6X9-482A0-01 Helm unit assembly 6GR-615A0-00 Tilt helm unit 6GR-6154A-00 Helm unit assembly 6X9-762H0-01 6X9-8591T-33 Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-13 Key fob: 2 pcs.
Page 125 System diagram P. Port C. Center S. Starboard TIP: The part numbers are subject to change without notice. Make sure to confirm the latest part numbers. 3-34...
Page 126: Quad Outboard Motor Application (Single Station)
System diagram Quad outboard motor application (single station) HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ (*2) (*2) (*1) (*1) 3-35...
Page 127 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft) Main wire harness (16P) 6X6-8258A-21 8 m (26 ft) 6X6-8258A-31 10 m (32 ft) 6X6-8258A-41 12 m (39 ft)
Page 128 System diagram Ref. Part name Part No. Remarks Autopilot panel 6X9-8253V-01 Joystick 6X9-482A0-01 Helm unit assembly 6GR-615A0-00 Tilt helm unit 6GR-6154A-00 Helm unit assembly 6X9-762H0-01 6X9-8591T-43 Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-13 Key fob: 2 pcs.
Page 129 System diagram a. Power port P. Port b. Bus port CP. Center port c. Device port CS. Center starboard S. Starboard TIP: The part numbers are subject to change without notice. Make sure to confirm the latest part numbers. 3-38...
Page 130: Quint Outboard Motor Application (Single Station)
System diagram Quint outboard motor application (single station) HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ (*1) (*2) (*1) (*1) (*1) 3-39...
Page 131 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft) Main wire harness (16P) 6X6-8258A-21 8 m (26 ft) 6X6-8258A-31 10 m (32 ft) 6X6-8258A-41 12 m (39 ft)
Page 132 System diagram Ref. Part name Part No. Remarks Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-13 Key fob: 2 pcs. BCU harness 6X9-82386-20 DEC to Autopilot/Joystick 6X9-82521-00 4.6 m (15 ft) Extension wire harness 6X9-82521-10 9.1 m (30 ft) Autopilot panel...
Page 133 System diagram P. Port CS. Center starboard CP. Center port S. Starboard C. Center TIP: The part numbers are subject to change without notice. Make sure to confirm the latest part numbers. 3-42...
Page 134: Single Outboard Motor Application (Dual Station)
System diagram Single outboard motor application (dual station) HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ (*1) (*1) 3-43...
Page 135 System diagram Ref. Part name Part No. Remarks Engine ECM — 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft) Main wire harness (16P) 6X6-8258A-21 8 m (26 ft) 6X6-8258A-31 10 m (32 ft) 6X6-8258A-41 12 m (39 ft)
Page 136 System diagram Ref. Part name Part No. Remarks Multi-hub 6Y8-81920-01 w/ resistor cap, Gray 6Y8-82553-01 0.3 m (1 ft) 6Y8-82553-50 3.0 m (10 ft) 6Y8-82553-11 4.6 m (15 ft) Main bus wire 6Y8-82553-21 6.1 m (20 ft) 6Y8-82553-31 7.6 m (25 ft) 6Y8-82553-41 9.1 m (30 ft) System power supply wire 6Y8-83553-02 w/ 10 A fuse, 2.4 m (8 ft)
Page 137: Twin Outboard Motor Application (Dual Station)
System diagram Twin outboard motor application (dual station) HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ 14 37 (*2) (*1) (*1) (*1) (*1) 3-46...
Page 138 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft) Main wire harness (16P) 6X6-8258A-21 8 m (26 ft) 6X6-8258A-31 10 m (32 ft) 6X6-8258A-41 12 m (39 ft)
Page 139 System diagram Ref. Part name Part No. Remarks Helm unit assembly 6X9-762H0-01 6X9-8591T-23 Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-13 Key fob: 2 pcs. Multi-hub 6Y8-81920-01 w/ resistor cap, Gray 6Y8-82553-01 0.3 m (1 ft) 6Y8-82553-50 3.0 m (10 ft) 6Y8-82553-11 4.6 m (15 ft)
Page 140 System diagram Ref. Part name Part No. Remarks Aux joystick harness 6X9-82580-G0 Engine shut-off switch 6X9-82570-D1 Joystick station (*1). Resistor cap (*2). Joint connector A. Main station a. Power port B. Sub station b. Bus port C. Joystick station c. Device port P.
Page 141: Triple Outboard Motor Application (Dual Station)
System diagram Triple outboard motor application (dual station) HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ 17 41 (*2) (*1) (*1) (*1) (*1)
Page 142 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft) Main wire harness (16P) 6X6-8258A-21 8 m (26 ft) 6X6-8258A-31 10 m (32 ft) 6X6-8258A-41 12 m (39 ft)
Page 143 System diagram Ref. Part name Part No. Remarks Autopilot panel 6X9-8253V-01 Joystick 6X9-482A0-01 Helm unit assembly 6GR-615A0-00 Tilt helm unit 6GR-6154A-00 Helm unit assembly 6X9-762H0-01 6X9-8591T-33 Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-13 Key fob: 2 pcs.
Page 144 System diagram Ref. Part name Part No. Remarks EKS harness 6X9-82716-80 All start/stop switch 6X9-82570-B1 2nd station/Joystick station Single (inline) hub 6Y8-81920-11 w/ resistor, 4–6P, White GPS unit 6X9-88107-02 6X9-83553-70 7 m (23 ft) Extension wire harness 6X9-83553-80 10 m (32 ft) Aux joystick harness 6X9-82580-G0 Engine shut-off switch...
Page 145: Quad Outboard Motor Application (Dual Station)
System diagram Quad outboard motor application (dual station) HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ CP CS (*2) (*1) (*1) (*1) (*1)
Page 146 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft) Main wire harness (16P) 6X6-8258A-21 8 m (26 ft) 6X6-8258A-31 10 m (32 ft) 6X6-8258A-41 12 m (39 ft)
Page 147 System diagram Ref. Part name Part No. Remarks Autopilot panel 6X9-8253V-01 Joystick 6X9-482A0-01 Helm unit assembly 6GR-615A0-00 Tilt helm unit 6GR-6154A-00 Helm unit assembly 6X9-762H0-01 6X9-8591T-43 Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-13 Key fob: 2 pcs.
Page 148 System diagram Ref. Part name Part No. Remarks EKS harness 6X9-82716-A0 All start/stop switch 6X9-82570-B1 2nd station/Joystick station Single (inline) hub 6Y8-81920-11 w/ resistor, 4–6P, White GPS unit 6X9-88107-02 6X9-83553-70 7 m (23 ft) Extension wire harness 6X9-83553-80 10 m (32 ft) Aux joystick harness 6X9-82580-G0 (*1).
Page 149: Quint Outboard Motor Application (Dual Station)
System diagram Quint outboard motor application (dual station) HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ HEADING COURSE TRACK PATTERN HOLD HOLD POINT STEER 1˚ / 5˚ 1˚ / 5˚ CP C CS (*1) (*1) (*1) (*1)
Page 150 System diagram Ref. Part name Part No. Remarks Engine ECM — — 6X6-8258A-91 1.5 m (5 ft) 6X6-8258A-51 3.7 m (12 ft) 6X6-8258A-61 5.2 m (17 ft) 6X6-8258A-01 6 m (19 ft) 6X6-8258A-11 7 m (23 ft) Main wire harness (16P) 6X6-8258A-21 8 m (26 ft) 6X6-8258A-31 10 m (32 ft) 6X6-8258A-41 12 m (39 ft)
Page 151 System diagram Ref. Part name Part No. Remarks Radio frequency 433 MHz, 6X9-86254-04 Key fob: 2 pcs. Key fob and receiver assembly Radio frequency 315 MHz, 6X9-86254-13 Key fob: 2 pcs. BCU harness 6X9-82386-20 DEC to Autopilot/Joystick 6X9-82521-00 4.6 m (15 ft) Extension wire harness 6X9-82521-10 9.1 m (30 ft) Autopilot panel...
Page 152 System diagram Ref. Part name Part No. Remarks BCU harness 6X9-82386-10 DEC to Autopilot/Joystick EKS harness 6X9-82716-C0 All start/stop switch 6X9-82570-B1 2nd station/Joystick station Single (inline) hub 6Y8-81920-11 w/ resistor, 4–6P, White GPS unit 6X9-88107-02 6X9-83553-70 7 m (23 ft) Extension wire harness 6X9-83553-80 10 m (32 ft) Aux joystick harness...
Page 153: Digital Electronic Control
Digital Electronic Control Digital Electronic Control 5. Click the “OK” button or press the Enter key on the keyboard. Digital Electronic Control system reset A Digital Electronic Control system reset is re- quired after the replacement of the Digital Electronic Control ECM or the engine ECM. 1.
Page 154: Tilt Limiter
Tilt limiter Tilt limiter 4. Click the “Next” button or press the Enter key on the keyboard. Setting the tilt limiter • Check that the outboard motor is mount- ed on the boat or on a stand securely. • Never get under the outboard motor while it is tilted.
Page 155: Clearing The Tilt Limiter
Tilt limiter 6. Click the “Set” button or press the Enter 2. Click the “Reset” button or press the F1 key on the keyboard. key on the keyboard. 7. Click the “OK” button or press the Enter 3. Click the “OK” button or press the Enter key on the keyboard.
Page 156 Tilt limiter 1. Disconnect the PTT sensor (sub lead) coupler “a”. TIP: When the engine start switch is turned to ON with the PTT sensor coupler disconnected, di- agnosis code 83 (PTT sensor malfunction) will be recorded in the engine ECM. Make sure to connect the PTT sensor coupler and delete the diagnosis code after services or mainte- nance is complete.
Page 157: Calibration (6X9 Digital Electronic Control)
Calibration (6X9 Digital Electronic Control) Calibration (6X9 Digital Electronic Control) • If the steering actuator is removed, the steer- ing sensor must be calibrated after the unit is installed. • Check that the battery is fully charged before performing the calibration. Otherwise, the calibration cannot be performed properly.
Page 158: Cl5 Display Calibration
CL5 display calibration CL5 display calibration 5. Select the number of outboard motors mounted on the boat. • If the steering actuator is removed, the steer- ing sensor must be calibrated after the unit is installed. • Check that the battery is fully charged before performing the calibration.
Page 159: Steering Sensor
CL5 display calibration 3. When the “Technician Settings” message appears, tap “OK”. 4. The “Technician Settings” menu will ap- pear. 3. Tap “Set” to trim all engines to the fully down position. Steering sensor During this process, only the corresponding steering actuator will operate as the steering sensor is being calibrated.
Page 160 CL5 display calibration 4. Check the contents of the display and 6. Turn the steering wheel clockwise until the proceed to the next step. port outboard motor reaches full STBD lock and the message appears. Confirm the port outboard motor is at full STBD lock, and then tap “Set”.
Page 161: Toe Adjust
CL5 display calibration 9. Once the calibration is complete, a mes- sage will appear verifying the procedure is completed. 10. If there is an invalid value when calibrating the steering sensor, a notification will ap- pear. Perform the complete calibration procedure again.
Page 162 CL5 display calibration Wedge/Toe settings 4. Adjust the wedge angle. Tap “Done” to Do this setting for “Wedge/Toe” only if the ad- confirm. justment width of the toe angle is insufficient TIP: due to the shape of the transom. The Helm Master EX control system comes TIP: with the toe set at 00.0°.
Page 163: Lock To Lock
CL5 display calibration TIP: The Helm Master EX control system comes with the toe set at 00.0°. The adjustment range • –2.0° to +22.0° in 0.2° increments. • Minus (–) degrees equals toe-in. • Plus (+) degrees equals toe-out. 7. When the Wedge/Toe calibration is com- pleted, a message will appear.
Page 164 CL5 display calibration 2. Tap “Constant”. 2. Tap “Variable”. 3. Select the steering wheels’ rotation range. 3. Select the positions, 1 to 4, to set. Tap to confirm your setting. TIP: This setting allows you to adjust the number of turns from “Lock to Lock”.
Page 165: Friction Set
CL5 display calibration 5. Tap “Set LTL” and then select a rotational 2. First choose “Regular” or “Heavy”, then angle, from 1 to 9, for the steering wheel. adjust the percentage of friction. Tap “Do- ne” to confirm. TIP: This setting allows you to adjust the number of TIP: turns from “Lock to Lock”.
Page 166 CL5 display calibration 1000 2000 3000 4000 5000 6000 a. Heavy 200% b. Regular 200% c. Heavy 100% d. Regular 100% A. Steering friction (N·m) B. Engine speed (r/min) 3. When the “Friction Set” setting is com- pleted, tap “return mark” to return to the “Technician Settings”...
Page 167: Rigging Recommendation
Rigging recommendation Rigging recommendation Battery cable length The table below shows the battery cable length from the negative terminal of the battery cable to the rigging grommet. The positive battery cable is 100 mm (3.9 in) longer than the negative battery cable. Length (L) 3.55 m (11.6 ft) 100 mm...
Page 168 Rigging recommendation Ambient temperature is below 0 °C (32 °F) Battery requirements Cable specifications Maximum total extension length (Positive battery cable + Negative battery cable) Unit Rating 20 mm² 30 mm² 50 mm² 60 mm² (AWG4) (AWG2) (AWG1/0) (AWG2/0) CCA/SAE 700 A MCA/ABYC 900 A...
Page 169: Propeller Selection
Propeller selection Propeller selection The size and type of propeller that is used will affect the performance of a boat and outboard motor critically. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boat- ing and steering capabilities. An incorrect choice could adversely affect performance and could also damage the engine seriously.
Page 170: Selection
Propeller selection Selection With the engine speed at full throttle operating range and under a maximum boat load, the engine speed should be within the upper half of the full throttle operating speed range. Full throttle operating range 5000–6000 r/min Regular rotation model Blade Dia.
Page 171 Propeller selection Counter rotation model Blade Dia. (in) Pitch (in) Mark Material Part number Remarks 17 1/8 Stainless steel 6GS-45970-20 *1, *2 16 7/8 Stainless steel 6GS-45D70-20 *1, *2 16 7/8 Stainless steel 6GS-45972-20 *1, *2 16 7/8 Stainless steel 6KP-45970-00 *1, *3 16 5/8...
Page 172: Fuel Line Air Purging
Fuel line air purging Fuel line air purging 4. Remove the drain hose “1” from the hold- er on the vapor separator cover. Air purging during initial priming 5. Remove the plug from the drain hose, and • When mounting a new outboard motor to a then squeeze the primer pump until fuel new boat, the fuel line must be bled.
Page 173: Troubleshooting
Troubleshooting YDIS..................4-1 Connecting the communication cable ........4-1 ECM reprogramming..............4-3 Outboard motor troubleshooting........4-4 Troubleshooting procedure............4-4 Troubleshooting the power unit using the YDIS ......4-4 Trouble code and checking step..........4-8 Troubleshooting procedure (trouble code not detected) ..4-25 Troubleshooting the power unit ..........
Page 174: 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 respond to new models and technologies, maintaining compatibility with regulations.
Page 175 YDIS K-Line a. YDIS coupler 2. Adapter cap 1. Adapter interface 3. USB cable 4. K and CAN harness 1. Adapter interface 2. Adapter cap 3. USB cable 4. K and CAN harness a. YDIS coupler (gray)
Page 176: Ecm Reprogramming
YDIS ECM reprogramming Program update function This function allows you to update the engine ECM program to the latest version using a K and CAN harness (VPP harness). Writing function of engine serial numbers A new function enables you to write an engine serial number to a new, replacement part engine ECM (supplied by the Part Division).
Page 177: 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 178 Outboard motor troubleshooting Trouble code table To display trouble codes (code number 300 and higher) for the SBW system, connect using the CAN- Line harness. *1: Crankshaft position sensor *2: Fuel pressure sensor (high-pressure fuel pump) : Indicated —: Not indicated YDIS diagnosis Code No.
Page 179 Outboard motor troubleshooting YDIS diagnosis Code No. Item YDIS diagnosis record 146, 147, 148, 149,   150, 153, 154, 155   156, 157 Engine-R/C communication 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171,  ...
Page 180 Outboard motor troubleshooting YDIS diagnosis Code No. Item YDIS diagnosis record 241, 242, 243, 244,   Injector#1–Injector#8 245, 246, 247, 248   Trim drive   R/C to Steering Communication   322, 323 Remote Control System  ...
Page 181: Trouble Code And Checking Step
Outboard motor troubleshooting Trouble code and checking step For code number 300 and higher checking steps, see the Helm master EX rigging guide (6X9-28197- **). The descriptions enclosed by < > are applicable to multiple engine installations. *1: Crankshaft position sensor *2: See the Helm Master EX rigging guide.
Page 182 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code Measure the knock sensor re- 5-39 “Check Engine” is displayed. sistance. Knock Sensor High engine idle speed. 2 (Irregular sig- Check for wiring continuity <Engine speeds do not syn- nal) between the knock sensor A-14...
Page 183 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code Check the oil pressure using the YDIS. Measure the oil pressure sen- 5-26 “Check Engine” is displayed. sor input voltage. Oil pressure High engine idle speed. sensor (Out of Measure the oil pressure sen- Declining maximum engine 5-26...
Page 184 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code Check the fuse. 5-10 Check for wiring open or short between the engine start A-16 switch and the engine ECM. Check for wiring continuity between the engine start A-16 switch and the electrical man- Starter magnet...
Page 185 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code Check the OCV operation us- 5-25 ing the YDIS. Measure the OCV input volt- “Check Engine” is displayed. 5-25 age. High engine idle speed. Measure the OCV resistance. 5-25 Degraded acceleration perfor- OCV (S bank)
Page 186 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code Check that Y-COP is con- “Check Engine” is displayed. 3-25 nected properly. Immobilizer Declining maximum engine (Communica- speed. Measure the remote control — <Engine speeds do not syn- tion error) receiver input voltage.
Page 187 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code “Check Engine” is displayed. Measure the TPS output volt- 5-21 High engine idle speed. age using the YDIS. TPS (Out of Degraded acceleration perfor- specification) mance. Check the ETV circuit. A-10 Declining maximum engine speed.
Page 188 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code Check the battery cable and terminals for proper connec- 10-9 tion. “Check Engine” is displayed. Check the fuse. 5-10 ETV (Throttle High engine idle speed. Measure the lighting coil re- valve malfunc- Throttle does not operate.
Page 189 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code “Check Engine” is displayed. Measure the SPS input volt- 5-22 High engine idle speed. age. Engine does not restart (In a Measure the SPS output volt- 5-22 shift-in position). age.
Page 190 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code 5-10 Check the fuse. A-14 Measure the shift actuator re- 5-23 lay input voltage. Measure the shift actuator 5-23 motor resistance. “Check Engine” is displayed. Check for wiring continuity Engine does not restart (In a between the shift actuator A-14...
Page 191 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code Measure the LPS output volt- “Check Engine” is displayed. age using the YDIS. Alert indicator is ON. Check for wiring continuity <Engine speeds do not syn- between the LPS and the Dig- chronize>...
Page 192 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps pa ge tion) code Measure the LPS output volt- age using the YDIS. “Check Engine” is displayed. Locked at engine idle speed. Check for wiring continuity Alert indicator is ON. between the LPS and the Dig- Remote con- ital Electronic Control ECM.
Page 193 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code Remote con- Measure the LPS output volt- trol system “Check Engine” is displayed. age using the YDIS. (Sub station, Locked at engine idle speed. center out- Shift actuator rod returns to Check for wiring continuity board motor the N position.
Page 194 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code Sub station Digital Electronic Turn off the engine start Control does not operate. switch once, and turn it on — Remote con- Unable to change to the sub again.
Page 195 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code Check the water pressure — sensor using the YDIS. Water pres- “Check Engine” is displayed. Measure the water pressure sure sensor 5-26 Stop engine synchronization sensor output voltage. (Out of specifi- control.
Page 196 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code Check the fuel pressure sen- sor (direct injection pump) — DI fuel pressure “Check Engine” is displayed. (PORT) using the YDIS. sensor (P) Engine speed is limited to (Out of specifi- Check the wiring is connected 2000 r/min.
Page 197 Outboard motor troubleshooting Trou- Item (Condi- Symptom Checking steps tion) page code DI fuel pressure Check fuel pipe for be — clogged. “Check Engine” is displayed. (DI fuel pres- Engine speed is limited to Check the operation of the in- sure rise S) 2000 r/min.
Page 198: Troubleshooting Procedure (Trouble Code Not Detected)
Outboard motor troubleshooting Troubleshooting procedure (trouble code not detected) Troubleshooting consists of the following 5 items: Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause: Trouble causes of symptom 2 Checking steps: Method for checking See page: Reference page —: Not applicable Troubleshooting the power unit...
Page 199 Outboard motor troubleshooting Symptom 1: Engine will not start (engine cranks). Symptom 2 Cause Checking steps page Blown fuse Check the fuse. 5-10 Check the electrical management Main relay malfunction 5-19 box. Check for wire harness continuity between the electrical manage- A-10 Short, open, or loose con- ment box and the engine ECM.
Page 200 Outboard motor troubleshooting Symptom 2 Cause Checking steps page — Measure the fuel pressure. Pinched or kinked fuel Check the fuel hose. 2-60 hose Fuel leakage Check the fuel line for leakage. 2-60 Check the fuel filter element for dirt Clogged fuel filter element and obstructions.
Page 201 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Check the valve timing. 7-43 Check the timing belt. 7-43 Improper valve timing Check the cam chain. 7-49 Check the chain tensioner. 7-49 Compression pres- Check the VCT for sticking. 7-48 sure is low Check the valve for bends and 7-61...
Page 202 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Fuel leakage Check for fuel leakage. 2-60 Check the fuel filter for dirt and ob- Clogged fuel filter structions. Check the fuel strainer for dirt and Clogged fuel strainer 6-14 obstructions. Direct injection pump mal- Check the direct injection pump.
Page 203 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Check the valve timing. 7-43 Check the timing belt. 7-43 Improper valve timing Check the cam chain. 7-49 Check the chain tensioner. 7-49 Compression pres- Check the VCT for sticking. 7-48 sure is low Check the valve for bends and 7-61...
Page 204 Outboard motor troubleshooting Symptom 1: Limited engine speed (below 2000–3000 r/min). Symptom 2 Cause Checking steps page Measure the thermo senor input 5-38 voltage. Measure the thermo sensor resis- Thermo sensor malfunction 5-38 tance. Check for continuity between the A-14 thermo sensor and the engine ECM.
Page 205 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Check the engine oil level. 10-10 Check for engine oil leakage. 2-49 Insufficient engine oil Check the valve stem seals and 7-63 valves. Check the piston rings. 7-79 Buzzer comes on. —...
Page 206: Troubleshooting The Ptt Unit
Outboard motor troubleshooting Symptom 1: Y-COP lock and unlock do not function. Symptom 2 Cause Checking steps page Check the button cell battery volt- — age. Y-COP remote control transmitter malfunction There is an answer- Replace with a spare remote con- —...
Page 207 Outboard motor troubleshooting Symptom 2 Cause Checking steps page PTT motor malfunction Check the PTT motor. 9-52 Short, open, or loose con- Check for wiring continuity between nection of the PTT motor the PTT motor and the electrical A-18 lead management box.
Page 208: Troubleshooting The Lower Unit
Outboard motor troubleshooting Troubleshooting the lower unit Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate properly. Symptom 2 Cause Checking steps page Check the shift actuator operation. 5-23 9-14 Check that the shift rod, shift actua- Shift rod does not operate tor bracket, and shift actuator are 8-15...
Page 209 Electrical system Electrical component and wire harness routing ..... 5-1 Port..................... 5-1 Starboard ................... 5-3 Rear .................... 5-5 Front ................... 5-7 Top ..................... 5-8 Fuse holder (Electrical management box) ........ 5-10 Bottom cowling ................ 5-11 ECM circuit diagram ............5-12 ECM coupler layout............
Page 210: Electrical System
Electrical system Charging unit and component ........5-34 Checking the lighting coil (stator assembly)......5-34 Checking the rectifier/regulator..........5-34 Ignition unit and component ........... 5-35 Checking the ignition spark............5-35 Checking the ignition coil ............5-35 Checking the crankshaft position sensor......... 5-35 Checking the intake air pressure/temperature sensor .....
Page 211 Electrical system PTT system ............... 5-53 Checking the PTT switch (on bottom cowling) ......5-53 Checking the PTT sensor ............5-53 Checking the PTT buzzer ............5-53...
Page 212: Electrical Component And Wire Harness Routing
Electrical component and wire harness routing Electrical component and wire harness routing Port 15 K L M...
Page 213 Electrical component and wire harness routing M. Do not route the PTT sensor lead and 1. ETV (TPS) injector lead between the wire harness 2. Low-pressure fuel pump relay and the fuel hose. 3. YDIS coupler N. Fasten the wire harness with the fuel 4.
Page 214: Starboard
Electrical component and wire harness routing Starboard 14 L...
Page 215 Electrical component and wire harness routing I. Install the extension wire harness 1. Cam position sensor (STBD IN) terminal that is identified by white tape 2. Starter motor on the lead to the center terminal. 3. Oil pressure sensor J. Fasten the cooling water hose, OCV 4.
Page 216: Rear
Electrical component and wire harness routing Rear...
Page 217 Electrical component and wire harness routing 1. Cam position sensor (PORT EX) 2. Knock sensor 3. Ignition coil 4. Fuel pressure sensor (direct injection pump) 5. Direct injection pump 6. Water pressure sensor 7. Cam position sensor lead 8. Blowby hose 9.
Page 218: Front
Electrical component and wire harness routing Front 1. High-pressure fuel pump (main) 2. Crankshaft position sensor 3. Low-pressure fuel pump 4. High-pressure fuel pump (sub) A. Do not route the intake air pressure/ temperature sensor lead between the 2 main portions of the wire harness.
Page 219: Top
Electrical component and wire harness routing...
Page 220 Electrical component and wire harness routing 1. Lighting coil (stator assembly) 2. Thermo sensor (STBD) 3. Electrical management box 4. Intake air pressure/temperature sensor 5. Bonder (black leads with white tape) 6. Bonder (orange leads) 7. Bonder (black leads) 8. PTT ground lead 9.
Page 221: Fuse Holder (Electrical Management Box)
Electrical component and wire harness routing Fuse holder (Electrical management box) 10 11 12 11. Fuse (30A) (engine ECU/ignition coil) 1. Fuse (15A) (fuel pump 2) 12. Fuse (10A) (fuel feed pump) 2. Fuse (15A) (fuel pump 1) 13. Fuse (100A) (power STRG) 3.
Page 222: Bottom Cowling
Electrical component and wire harness routing Bottom cowling 1. SPS 2. Shift actuator 3. PTT switch 5-11...
Page 223: Ecm Circuit Diagram
ECM circuit diagram ECM circuit diagram , a: Indicate a connection between the symbols. The numbers in a square indicate the engine ECM terminal numbers. <INPUT> <OUTPUT> 19. Injector driver relay C-16 1. Crankshaft position sensor C-40 B-34 17. Ground C-43 B-41 A-27...
Page 224 ECM circuit diagram , a: Indicate a connection between the symbols. The numbers in a square indicate the engine ECM terminal numbers. <INPUT> <OUTPUT> 58. High-pressure fuel 56. High-pressure pump relay fuel pump (main) C-38 39. Knock sensor 57. High-pressure B-35 fuel pump (sub) 39.
Page 225 ECM circuit diagram 45. PTT switch (DN) 1. Crankshaft position sensor 46. Engine shut-off switch 2. Cam position sensor (PORT EX) 47. Digital Electronic Control ECM 3. Cam position sensor (PORT IN) 48. Main switch 4. Cam position sensor (STBD IN) 49.
Page 226: Ecm Coupler Layout
ECM coupler layout ECM coupler layout 36 37 38 39 40 41 42 43 44 36 37 38 39 40 41 42 43 44 36 37 38 39 40 41 42 43 44 27 28 29 30 31 32 33 34 35 27 28 29 30 31 32 33 34 35 27 28 29 30 31 32 33 34 35 18 19 20 21 22 23 24 25 26...
Page 227 ECM coupler layout Connecting part Color Connecting part Color A-21 — — B-8 Unit ground Black Injector driver (direct — — A-22 injection pump fail Green House battery power B-10 [PORT]) source A-23 Sensor power source Orange B-11 Sensor power source Orange Injector driver (fuel B-12...
Page 228 ECM coupler layout Connecting part Color Connecting part Color Cam position sensor C-16 Sensor power source Orange B-32 White/Blue (PORT EX) C-17 ETV power source Red/Green High-pressure fuel Yellow/ Digital Electronic B-33 C-18 Blue pump relay Green Control 1 (L) B-34 Injector driver relay Yellow/Red C-19...
Page 229: Checking The Electrical Component
YDIS 2 HARDWARE KIT III 90890-06980 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...
Page 230: Engine Control Unit And Component
Engine control unit and component Engine control unit and b. Check the wire harness for continuity. component Checking the main relay The main relay cannot be removed for testing or replaced as a single unit because it is a 7 6 5 4 component part of the electrical management box.
Page 231: Checking The Electrical Management Box
Engine control unit and component c. Disconnect the electrical management box coupler “d”. <B> Input voltage 12 V d. Check the wire harness for continuity. Terminal 36 of engine ECM cou- pler “b”–Ground e. Turn the main switch or power switch to OFF.
Page 232: Checking The Etv And Tps
Engine control unit and component b. Start the engine, warm it up for 5–10 Terminal of coupler Terminal of coupler minutes, and then stop it. “b” “d” c. Turn the main switch or power switch – to ON, and then measure the TPS out- put voltages when the Digital Electric –...
Page 233: Checking The Etv Motor Relay
Engine control unit and component b. Operate the Digital Electronic Control Input voltage lever to measure the output voltage at the F, N, and R positions. Orange (Or)–Black (B) h. Turn the main switch or power switch to OFF. i. Connect the ETV coupler. j.
Page 234: Checking The Shift Actuator Relay
Engine control unit and component Checking the shift actuator relay Shift actuator rod stroke “a” The shift actuator relay cannot be removed for 82.0 mm (3.23 in) testing or replaced as a single unit because it 60.0 mm (2.36 in) is a component part of the electrical manage- ment box.
Page 235 Engine control unit and component STBD IN Test lead Terminal, male “1” 9E212-10303 Terminal, female “2” 9E212-11303 Terminal, female “3” (commercially available) “a” = 100 mm (3.94 in) “b” = 50 mm (1.97 in) “c” = Cutout area PORT EX e.
Page 236: Checking The Ocv
Engine control unit and component PORT STBD Output voltage White/Black (W/B)–Black (B) (STBD IN) White/Green (W/G)–Black (B) (PORT IN) White/Blue (W/L)–Black (B) (PORT EX) Position Voltage Input voltage “a”, “c” More than 4.8 12 V Red/Yellow (R/Y)–Ground “b” Less than 1.0 d.
Page 237: Checking The Oil Pressure Sensor
Engine control unit and component h. Disconnect the battery leads. i. Install new gaskets and OCVs, and then connect the OCV couplers. Checking the oil pressure sensor Pressure pump “1” 1. Check: (commercially available) • Oil pressure sensor Test harness EJ–ll–3 “2” a.
Page 238 Engine control unit and component Input voltage Orange (Or)–Black (B) c. Remove the water pressure sensor, and then connect a pressure pump “1” and the special service tool “2”. d. Apply positive pressure to the water pressure sensor slowly, and then mea- sure the output voltage at the specified pressures.
Page 239: Fuel Control Unit And Component
Fuel control unit and component Fuel control unit and component Input voltage Checking the injector driver circuit 12 V 1. Remove: Terminal 1–Ground • Intake manifold (PORT) d. Turn the main switch or power switch See “Intake manifold” (6-24). to OFF. 2.
Page 240: Checking The Fuel Injector
Fuel control unit and component PORT STBD Resistance (reference data) 1.74–2.04 Ω Fuel injector #1, #2 terminal 4–8 Fuel injector #3, #4 terminal 3–7 Fuel injector #5, #6 terminal 2–6 Fuel injector #7, #8 terminal 1–5 Water detection switch continuity d.
Page 241: Checking The Direct Injection Pump
Fuel control unit and component A. Low-pressure fuel pump B. High-pressure fuel pump Low-pressure fuel pump Resistance (reference data) High-pressure fuel pump 0.6 Ω Input voltage High-pressure fuel pump 12 V Resistance (reference data) Yellow/Red (Y/R)–Blue/Red (L/R) 0.3 Ω d. Disconnect low-pressure fuel f.
Page 242: Checking The Low-Pressure Fuel Pump Relay
Fuel control unit and component Do not reverse the battery leads. Direct injection pump Resistance (reference data) 0.45-0.55 Ω Terminal d. Connect the direct injection pump cou- Battery lead plers. Connect Checking the low-pressure fuel pump Disconnect relay 1. Check: Checking the high-pressure fuel •...
Page 243: Checking The Fuel Pressure Sensor
Fuel control unit and component Input voltage 12 V High-pressure fuel pump fuse “a”–Ground e. Turn the main switch or power switch to OFF. f. Install the fuse cover. Checking the fuel pressure sensor Before checking the fuel pressure sensor, make sure that there are no other problems in the fuel system.
Page 244 Fuel control unit and component c. Turn the main switch or power switch to OFF, and then connect the fuel pres- sure sensor couplers. d. Measure the fuel pressure. See “Measuring the fuel pressure” (6-2). Out of specification → Replace the fuel rail assembly.
Page 245: Charging Unit And Component
Charging unit and component Charging unit and component TIP: Checking the lighting coil (stator When the battery is fully charged, the voltage assembly) value at low engine speed may fluctuate due 1. Check: to the influence of voltage control. • Lighting coil a.
Page 246: Ignition Unit And Component
Ignition unit and component Ignition unit and component Checking the ignition spark 1. Check: • Ignition coil a. Remove the ignition coils. b. Connect the special service tool “1” to the ignition coil. TIP: Repeat steps (b)–(d) for each ignition coil. c.
Page 247: Checking The Intake Air Pressure/Temperature Sensor
Ignition unit and component g. Make 3 test leads. Input voltage Orange (Or)–Black (B) c. Turn the main switch or power switch to OFF. d. Connect the crankshaft position sen- sor coupler. Checking the intake air pressure/ temperature sensor 1. Check: •...
Page 248: Checking The Engine Temperature Sensor
Ignition unit and component o. Measure the intake air pressure/tem- perature sensor resistance. Resistance at 0 °C (32 °F) 5.4-6.6 kΩ Resistance at 80 °C (176 °F) 0.28-0.38 kΩ Black/Yellow (B/Y)–Black (B) p. Install the intake air pressure/tempera- Vacuum/pressure pump gauge ture sensor and connect the coupler.
Page 249: Checking The Thermo Sensor
Ignition unit and component c. Turn the main switch or power switch to OFF. d. Remove the engine temperature sen- sor. e. Place the engine temperature sensor in a container of water and heat the water slowly. f. Measure the engine temperature sen- sor resistance.
Page 250: Checking The Knock Sensor
Ignition unit and component Checking the knock sensor b. Turn the main switch to ON, and then check the engine shut-off switch for 1. Check: continuity. Replace if out of specifica- • Knock sensor tion. a. Disconnect the knock sensor couplers “a”...
Page 251 Ignition unit and component a. Disconnect the engine shut-off switch couplers. b. Check the engine shut-off switch for continuity. A. Single type B. Twin type C. Triple type D. Quad/Quint type c. Connect the engine shut-off switch couplers. 5-40...
Page 252: Starting Unit And Component
Starting unit and component Starting unit and component Checking the starter relay 2. ON 2. ON 3. START 1. OFF The starter relay cannot be removed for test- 1. OFF ing or replaced as a single unit because it is a component part of the electrical management box.
Page 253: Checking The Power Switch (Eks)
Starting unit and component A. Single type (sub station) B. Twin type (main station) C. Twin type (sub station) D. Triple type (main station) E. Triple type (sub station) F. Quad type (main station) G. All start/stop button Engine start/stop button continuity Button pushed in: Terminal a–Terminal b Terminal c–Terminal d...
Page 254: Checking The Start/Stop Button (Eks)
Starting unit and component b. Check the engine start/stop button for continuity at the engine start/stop but- ton coupler. A. Single/triple/quad/quint type B. Twin type c. Connect the power switch coupler. Checking the start/stop button (EKS) 1. Check: • Start/stop button continuity Out of specification →...
Page 255: Checking Y-Cop
Starting unit and component Input voltage 12 V t u v w x y Red (R)–Black (B) b. Connect the Y-COP coupler “a”. A. Power switch (single type) B. All start/stop button (sub station/joystick station) C. Power switch (twin type) D.
Page 256: Starter Motor
Starter motor Starter motor Part name ’ Remarks Part name ’ Remarks × × Screw set M6 Pinion shaft M5 Magnet switch assem- Planetary gear O-ring × Shim for pin- Screw set M5 Shim ion gap ad- justment Armature × Bolt M6 150 mm Stator...
Page 257: Removing The Starter Motor
Starter motor Removing the starter motor Bolt “2” M5 × 35 mm Nut “3” Before removing the starter motor, make sure to disconnect the negative battery ter- Washer “4” minal. Inside diameter = 6.5 mm (0.24 in) Outside diameter = 16.0 mm (0.63 in) Checking the starter motor pinion b.
Page 258: Checking The Armature (Starter Motor)
Starter motor Pipe “2” (commercially available) “a” = 12.0 mm (0.47 in) “b” = 17.0 mm (0.67 in) 4. Remove: • Bracket • Armature • Brush holder Armature for continuity Do not scratch or damage the brushes “a” “b” “c” “d”...
Page 259: Assembling The Starter Motor
Starter motor Standard brush length 18.0 mm (0.71 in) Wear limit 11.0 mm (0.43 in) Assembling the starter motor 1. Install: • Brushes • Brushes holder • Armature • Stator • Bracket • O-ring Do not apply grease or oil to the commuta- tor of the armature.
Page 260: Installing The Starter Motor
Starter motor 2. Install: • Intake manifolds See “Intake manifold” (6-24). 3. Assemble: • Starting motor gear assembly • Lever assembly • Cover • Starting motor body • O-ring 4. Install: • Spring • Pinion • Pinion stopper • Clip •...
Page 261: Outboard Motor And Digital Electronic Control Connection
Outboard motor and Digital Electronic Control connection Outboard motor and Digital Electronic Control connection Checking the extension wire harness 1. Check: • Extension wire harness a. Check the extension wire harness for continuity. Check the wire terminal numbers from “a” to “m”. d.
Page 262 Outboard motor and Digital Electronic Control connection Terminal of coupler Terminal of coupler “a” “d” – – – – – Continuity between the main wire har- ness coupler “a” and the ground: Terminal of coupler “a” – Ground – Ground –...
Page 263: Steering Unit
Steering unit Steering unit Terminal of coupler Terminal of coupler Checking the steering actuator “a” “c” 1. Check: – • Steering actuator – a. Disconnect the engine ECM couplers – “a” and “b”. Continuity between the engine ECM coupler “a” and the SCU signal coupler “d”: Terminal of coupler Terminal of coupler...
Page 264: Ptt System
PTT system PTT system b. Tilt the outboard motor up and down, and measure the PTT sensor output Checking the PTT switch (on bottom voltage at the specified positions. cowling) Output voltage 1. Check: • PTT switch Position Voltage a. Disconnect the PTT switch coupler “a”. Tilt support lever up- b.
Page 265 PTT system b. Connect the battery leads to the PTT buzzer coupler, and check that the PTT buzzer comes on. Replace the PTT buzzer if it does not come on. c. Install the PTT buzzer. 5-54...
Page 266 Fuel system Fuel system basic procedure..........6-1 Starting the engine after running out of fuel....... 6-1 Reducing the fuel pressure ............6-1 Disconnecting the quick connector ........... 6-1 Measuring the fuel pressure............6-2 Fuel filter assembly ............6-3 Checking the fuel filter assembly ..........6-4 Checking the fuel filter element..........
Page 267: Fuel System
Fuel system Direct injection pump and fuel injector......6-18 Removing the fuel rail............... 6-19 Removing the fuel injector............6-19 Checking the fuel pressure sensor (direct injection pump)..6-19 Checking the direct injection pump ......... 6-19 Checking the fuel rail and fuel injector ........6-19 Installing the fuel injector and fuel rail ........
Page 268: Fuel System Basic Procedure
Fuel system basic procedure Fuel system basic procedure 3. Start the engine. Starting the engine after running out TIP: of fuel Wait until the engine stalls. Use the following procedure to start the en- gine after running out of fuel. 4.
Page 269: Measuring The Fuel Pressure
Fuel system basic procedure c. Disconnect the quick connector “1” from the fuel pipe “b” directly. TIP: Cover the quick connector and fuel pipe with a plastic bag to prevent damage and to pre- vent dirt from entering them. Measuring the fuel pressure 1.
Page 270: Fuel Filter Assembly
Fuel filter assembly Fuel filter assembly 5 N · m (0.5 kgf · m, 3.7 lb ·ft ) Part name ’ Remarks Part name ’ Remarks × Bolt M6 16 mm Clamp Cover Bracket Plastic tie Retainer × Bolt M6 20 mm Grommet holder Rigging grommet...
Page 271: Checking The Fuel Filter Assembly
Fuel filter assembly Checking the fuel filter assembly b. Block the fuel inlet “b” using a rubber plug “2”, and then apply the specified 1. Check: negative pressure for 15 seconds or • Fuel inlet holding pressure Out of specification → Replace the O-ring, more.
Page 272: Assembling The Fuel Filter
Fuel filter assembly a. Connect the special service tool “1” to TIP: the fuel inlet “a”. Fit the rib “a” on the fuel cup “1” into the slit b. Block the fuel outlet “b” using a rubber “b” in the holder “2”. plug “2”, and then apply the specified positive pressure for at least 30 sec- onds.
Page 273: Low-Pressure Fuel Pump
Low-pressure fuel pump Low-pressure fuel pump 9 mm 12 mm 12 mm (0.35 in) (0.47 in) (0.47 in) 12 mm (0.47 in) Part name ’ Remarks Part name ’ Remarks × Bolt M6 25 mm Hose Collar Feed valve Grommet Hose Plastic tie Low-pressure fuel...
Page 274: Checking The Low-Pressure Fuel Pump
Low-pressure fuel pump Checking the low-pressure fuel pump 1. Check: • Electrical performance of the low-pres- sure-fuel pump See “Checking the low-pressure fuel pump and high-pressure fuel pump” (5-29). Checking the feed valve (low- pressure fuel pump) Vacuum/pressure pump gauge 1.
Page 275: Installing The Low-Pressure Fuel Pump
Low-pressure fuel pump 2. Check: • Relief valve holding pressure Out of specification → Replace. Holding pressure (positive pres- sure) 200.0 kPa (2.00 kgf/cm², 29.0 psi) a. Connect the special service tool “1” to the relief valve outlet “a”. b. Apply the specified positive pressure, and check that the specified pressure is maintained.
Page 276: Vapor Separator And High-Pressure Fuel Pump
Vapor separator and high-pressure fuel pump Vapor separator and high-pressure fuel pump 2.0 N · m (0.20 kgf · m, 1.5 lb ·ft ) Part name ’ Remarks Part name ’ Remarks Plastic tie High-pressure fuel Main, gray × pump inlet Bolt M6 35 mm...
Page 277: Draining The Fuel
Vapor separator and high-pressure fuel pump Draining the fuel Removing the vapor separator Cover the fuel components using a rag to pre- Cover the fuel components using a rag to pre- vent fuel from spilling out. vent fuel from spilling out. 1.
Page 278: Installing The Vapor Separator
Vapor separator and high-pressure fuel pump Installing the vapor separator 1. Install: • Vapor separator 2. Connect: • Quick connector • Cooling water hose • High-pressure fuel pump coupler 6-11...
Page 279: Fuel Hose Assembly
Fuel hose assembly Fuel hose assembly 23 N · m (2.3 kgf · m, 17 lb ·ft ) 7 11 16 17 Part name ’ Remarks Part name ’ Remarks × Bolt M6 25 mm Plastic tie Cover (PORT) Cover Cover (STBD) Fuel pres- Sensor...
Page 280: Fuel Hose, Feed Valve, Relief Valve, And Fuel Strainer
Fuel hose, feed valve, relief valve, and fuel strainer Fuel hose, feed valve, relief valve, and fuel strainer Part name ’ Remarks Part name ’ Remarks Clamp Hose Quick connector Hose Hose Joint Joint Hose Hose Plastic tie Cover Feed valve Hose Hose Cover...
Page 281: Disassembling The Fuel Hose Assembly
Fuel hose, feed valve, relief valve, and fuel strainer Disassembling the fuel hose assembly 1. Remove: • Clamp “1” TIP: Make sure that the protrusion “a” on the clamp fits in the slot “b” in the tool “2”. 3. Check: •...
Page 282: Checking The Feed Valve (High-Pressure Fuel Pump)
Fuel hose, feed valve, relief valve, and fuel strainer b. Apply the specified positive pressure Holding pressure (positive pres- for 15 seconds or more. sure) 490.0 kPa (4.90 kgf/cm², 71.1 psi) a. Connect a pressure pump “1” to the fuel outlet “a”. b.
Page 283: Checking The Fuel Pressure Sensor (High-Pressure Fuel Pump)
Fuel hose, feed valve, relief valve, and fuel strainer Vacuum/pressure pump gauge TIP: set “1” Make sure to face the crimped section of the 90890-06945 clamp in the direction shown in the illustration. Pressure/vacuum tester “1” YB-35956-B Checking the fuel pressure sensor (high-pressure fuel pump) 1.
Page 284: Installing The Fuel Hose Assembly
Fuel hose, feed valve, relief valve, and fuel strainer Installing the fuel hose assembly 1. Install: • Fuel pressure sensor (high-pressure fuel pump) • Fuel hose assembly • Holder • Fuel rail cover Fuel pressure sensor (high-pres- sure fuel pump) 23 N·m (2.3 kgf·m, 17 lb·ft) 6-17...
Page 285: Direct Injection Pump And Fuel Injector
Direct injection pump and fuel injector Direct injection pump and fuel injector 21 20 28 N · m (2.8 kgf · m, 21 lb ·ft ) 14 N · m (1.4 kgf · m, 10 lb ·ft ) 16 12 E E E 16 12 28 N ·...
Page 286: Removing The Fuel Rail
Direct injection pump and fuel injector Removing the fuel rail Do not remove the fuel pressure sensor from the fuel rail. Otherwise, fuel could leak when the fuel pressure sensor is reinstalled to the fuel rail. Removing the fuel injector 1.
Page 287: Installing The Fuel Injector And Fuel Rail
Direct injection pump and fuel injector 2. Check: • Electrical performance of the fuel injec- tors. See “Checking the fuel injector” (5-29). Installing the fuel injector and fuel rail Be careful not to scratch the installation area of the O-ring or the nozzle. Stopper “4”...
Page 288 Direct injection pump and fuel injector d. Push the nozzle seal into the groove • Plastic tie “a” using your fingers. TIP: • If a fuel injector is dropped, replace it. At this time, the nozzle seal is larger than its •...
Page 289 Direct injection pump and fuel injector • Push in the fuel rail gradually and evenly so that the fuel rail is not positioned at an angle. • Be careful not to damage the end of the fuel injector nozzle or the nozzle seal. e.
Page 290 Direct injection pump and fuel injector TIP: • It is easier to perform the work by gradually tightening the nuts on both ends of the pipe alternately. • If the nuts cannot be tightened temporarily until the distances are within specification, the fuel pipe may be connected improperly.
Page 291: Intake Manifold
Intake manifold Intake manifold 24 N · m (2.4 kgf · m, 18 lb ·ft ) 11 N · m (1.1 kgf · m, 8.1 lb ·ft ) Part name ’ Remarks Part name ’ Remarks Plastic tie Gasket Plastic tie Gasket Oil dipstick Intake manifold...
Page 292 Intake manifold 24 N · m (2.4 kgf · m, 18 lb ·ft ) 11 N · m (1.1 kgf · m, 8.1 lb ·ft ) ’ Part name Remarks Joint Hose Hose A. For multiple engine applications 6-25...
Page 293: Checking The Intake Manifold
Intake manifold Checking the intake manifold 1. Check: • Intake manifold Cracked/damaged → Replace. Installing the intake manifold 1. Install: • Cooling water hose “1”, “2”, “3”, “4”, “5”, “6”, “7” • Joint 3. Install: • Plastic tie • Intake manifold (temporarily) TIP: 4.
Page 294 Intake manifold Intake manifold bolt “1” (M8) 24 N·m (2.4 kgf·m, 18 lb·ft) Intake manifold bolt “2” (M6) 11 N·m (1.1 kgf·m, 8.1 lb·ft) 5. Install: • Holder • Bracket • Hose “1”, “2” • Joint • Plastic tie • O-ring •...
Page 295: Etv
7 N · m (0.7 kgf · m, 5.2 lb ·ft ) 3.5 N · m (0.35 kgf · m, 2.6 lb ·ft ) 24 N · m (2.4 kgf · m, 18 lb ·ft ) Part name ’ Remarks ×...
Page 296: Checking The Etv
Checking the ETV 1. Check: • ETV Cracked → Replace. 2. Check: • Throttle valve movement • Rough movement → Replace the ETV. Surge tank bolt 24 N·m (2.4 kgf·m, 18 lb·ft) Intake air pressure/temperature 3. Check: sensor bolt • Electrical performance of the TPS. 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) See “Checking the ETV and TPS”...
Page 297 Power unit Power unit (check and adjustment)........7-1 Checking the compression pressure ......... 7-1 Checking the oil pressure............7-1 Checking the valve clearance ............ 7-1 Adjusting the valve clearance ............ 7-3 Shroud cover and terminal cover ........7-5 Installing the shroud cover and terminal cover ......7-6 Exhaust joint (outside) ............
Page 298: Power Unit
Power unit Wire harness..............7-30 Removing the wire harness ............7-31 Installing the wire harness............7-33 ECM, injector driver, and rectifier/regulator ....7-37 Removing the rectifier/regulator..........7-38 Checking the rectifier/regulator anode........7-38 Installing the ECM and injector driver ........7-38 Installing the rectifier/regulator..........
Page 299 Power unit Checking the valve seat ............7-63 Refacing the valve seat ............7-63 Checking the cylinder head anode........... 7-66 Checking the cam position sensor........... 7-66 Checking the OCV..............7-66 Assembling the cylinder head ..........7-66 Installing the cylinder head............7-68 Oil pump assembly............
Page 300 Power unit Checking the big end oil clearance .......... 7-83 Selecting the crankshaft pin bearing........7-85 Crankshaft pin bearing selection table........7-87 Checking the journal oil clearance ........... 7-88 Selecting the crankshaft journal bearing........7-89 Crankshaft journal bearing selection table....... 7-91 Assembling the cylinder block ..........
Page 301: Power Unit (Check And Adjustment)
Power unit (check and adjustment) Power unit (check and Compression pressure adjustment) Minimum (reference data) Checking the compression pressure 947.9 kPa (9.48 kgf/cm², 137.4 psi) 1. Start the engine, warm it up for 5–10 min- utes, and then stop it. 5.
Page 302 Power unit (check and adjustment) Do not turn the flywheel magneto counter- clockwise. Otherwise, the water pump im- peller could be damaged. 1. Reduce: • Fuel pressure See “Reducing the fuel pressure” (6-1). 2. Remove: • Bottom cowling cover See “Bottom cowling cover and apron cover”...
Page 303: Adjusting The Valve Clearance
Power unit (check and adjustment) See “Direct injection pump and fuel injec- • Camshaft tor” (6-18). (with driven sprocket and VCT assembly) • Spark plug • Valve lifter • Ignition coil See “Removing the camshaft, VCT as- See “Ignition coil and spark plug” (7-40). sembly, and driven sprocket”...
Page 304 Power unit (check and adjustment) • Flywheel magneto See “Installing the flywheel magneto” (7-25). • Intake manifold (PORT) See “Intake manifold” (6-24). • Fuel hose assembly See “Fuel hose assembly” (6-12).
Page 305: Shroud Cover And Terminal Cover
Shroud cover and terminal cover Shroud cover and terminal cover Part name ’ Remarks × Bolt M6 12 mm Shroud cover Rivet Plate Damper × Bolt M6 25 mm Terminal cover (PORT) Terminal cover (STBD) Collar Grommet Grommet...
Page 306: Installing The Shroud Cover And Terminal Cover
Shroud cover and terminal cover Installing the shroud cover and terminal cover 1. Install: • Grommets • Terminal cover grommet • Terminal cover collar • Terminal cover • Shroud cover damper • Shroud cover damper plate • Shroud cover...
Page 307: Exhaust Joint (Outside)
Exhaust joint (outside) Exhaust joint (outside) 21 N · m (2.1 kgf · m, 15 lb ·ft ) 2.0 N · m (0.20 kgf · m, 1.5 lb ·ft ) 1303 1303 11 N · m (1.1 kgf · m, 8.1 lb ·ft ) 19 N ·...
Page 308: Removing The Exhaust Joint Assembly
Exhaust joint (outside) Removing the exhaust joint assembly When not disassemble the exhaust joint as- sembly, use suitable bolts “1” to secure the exhaust joints “2”, “3”, and “4” so that they do not become misaligned, and then remove the exhaust joint assembly.
Page 309 Exhaust joint (outside) 1. Assemble: • Holder • Holder bracket • O-ring • Exhaust joint Bolt “8” a. Install new O-rings “1” and “2” to the (commercially available) exhaust joint (PORT) “3” and exhaust M6 × 40 mm (1.57 in) joint (STBD) “4”.
Page 310 Exhaust joint (outside) c. Tighten the exhaust joint assembly Exhaust joint assembly bolt (low- bolts (PORT and STBD) to the speci- fied torque in the order [1], [2], and so 1st: 11 N·m (1.1 kgf·m, 8.1 lb·ft) 2nd: 23 N·m (2.3 kgf·m, 17 lb·ft) [10] [10] [10]...
Page 311: Exhaust Joint (Inside)
Exhaust joint (inside) Exhaust joint (inside) 14 N · m (1.4 kgf · m, 10 lb ·ft ) 21 N · m (2.1 kgf · m, 15 lb ·ft ) 13 12 10 11 13 12 1303 1303 21 N · m (2.1 kgf · m, 15 lb ·ft ) 18 N ·...
Page 312: Removing The Exhaust Joint
Exhaust joint (inside) Removing the exhaust joint 1. Remove: • Exhaust joint assembly See “Exhaust joint (outside)” (7-7). Checking the exhaust joint 1. Check: • Exhaust joint Corroded/cracked → Replace. Checking the exhaust joint anode 1. Check: • Anode Eroded (1/2 or more worn out) → Replace. Adhered grease, oil, or scales →...
Page 313: Power Unit Assembly
Power unit assembly Power unit assembly 7.6 N · m (0.76 kgf · m, 5.6 lb ·ft ) WR-No.2 WR-No.2 WR-No.2 WR-No.2 42 N · m (4.2 kgf · m, 31 lb ·ft ) 42 N · m (4.2 kgf · m, 31 lb ·ft ) 42 N ·...
Page 314 Power unit assembly 7.6 N · m (0.76 kgf · m, 5.6 lb ·ft ) WR-No.2 WR-No.2 WR-No.2 WR-No.2 42 N · m (4.2 kgf · m, 31 lb ·ft ) 42 N · m (4.2 kgf · m, 31 lb ·ft ) 42 N ·...
Page 315: Removing The Power Unit
Power unit assembly Removing the power unit 1. Remove: • Bottom cowling cover and apron cover See “Bottom cowling cover and apron cover” (9-1). • Bottom cowlings See “Bottom cowling (PORT and STBD)” (9-3). • Aprons See “Apron” (9-8). 5. Disconnect: •...
Page 316 Power unit assembly Lifting eye “1” 90890-06953 Bolt hexagon with washer “2” 90890-06821 Balance hanger “3” 90890-06460 Bolt set “4” 90890-06969 Bolt hexagon with washer “2” YB-06821 8. Remove: • PTT switch lead “1” Lifting eye bolt 36 N·m (3.6 kgf·m, 27 lb·ft) Balance hanger bolt 18 N·m (1.8 kgf·m, 13 lb·ft) 10.
Page 317: Installing The Power Unit
Power unit assembly PORT Lifting eye “1” 90890-06953 Bolt hexagon with washer “2” 90890-06821 Balance hanger “3” 90890-06460 Bolt set “4” 90890-06969 Bolt hexagon with washer “2” YB-06821 Lifting eye bolt 36 N·m (3.6 kgf·m, 27 lb·ft) Balance hanger bolt 18 N·m (1.8 kgf·m, 13 lb·ft) 3.
Page 318 Power unit assembly c. Tighten the power unit mounting bolts “1”, “2” and “3” to the specified torques in 2 stages and in the order [1], [2], and so on. [10][17] [10][17] [7][18] [7][18] [8][19] [8][19] WR-No.2 WR-No.2 [9][16] [9][16] [11][20] [11][20] [6][15]...
Page 319 Power unit assembly 9. Install: • SCU signal coupler (4 pins) • SCU signal coupler (3 pins) TIP: For single engine applications, connect the SCU signal coupler (4 pins) to the wire har- ness, and for multiple engine applications, connect the coupler to the SCU communica- tion lead (optional).
Page 320 Power unit assembly 13. Install: TIP: • Isolator lead “1” • Route the PTT lead and SCU lead. See • Washer “Electrical component and wire harness (equipped with optional isolator lead) routing” (5-1). • Positive battery cable “a” • Connect the specified leads to the terminals •...
Page 321 Power unit assembly 19. Install: • Low-pressure fuel pump holder (to the low-pressure fuel pump bracket) See “Low-pressure fuel pump” (6-6). • Fuel rail covers See “Fuel hose assembly” (6-12). • Gear oil changing system hoses See “Cooling water hose and gear oil changing hose”...
Page 322: Electrical Management Box
Electrical management box Electrical management box 7.6 N · m (0.76 kgf · m, 5.6 lb ·ft ) 3.2 N · m (0.32 kgf · m, 2.4 lb ·ft ) 15* 14* 13* 12* 15 13 15 13 12 *The locations of the spare fuses are not speci- ’...
Page 323: Installing The Electrical Management Box
Electrical management box Installing the electrical management Electrical management box termi- nal nut 1. Install: 7.6 N·m (0.76 kgf·m, 5.6 lb·ft) • Fuses Fuse screw 3.2 N·m (0.32 kgf·m, 2.4 lb·ft) 2. Install: • Fuse cover • Electrical management box •...
Page 324: Flywheel Magneto
Flywheel magneto Flywheel magneto 8 N · m (0.8 kgf · m, 5.9 lb ·ft ) 8 N · m (0.8 kgf · m, 5.9 lb ·ft ) 40 N · m (4.0 kgf · m, 30 lb ·ft ) 90°...
Page 325: Removing The Flywheel Magneto
Flywheel magneto Removing the flywheel magneto 3. Remove: • Flywheel magneto 1. Remove: • Intake silencer TIP: See “ETV” (6-28). Install the guide bolts “a” to the crankshaft, • Fuel hose assembly and then install the guide plate “b” to the fly- See “Fuel hose assembly”...
Page 326 Flywheel magneto TIP: TIP: • Install the guide bolts “a” to the crankshaft, In the second tightening stage for the flywheel and then install the guide plate “b” to the fly- magneto bolts “1”, mark the bolts and fly- wheel magneto “1” using the flywheel mag- wheel magneto with identification marks “a”, neto fan bolts “2”.
Page 327 Flywheel magneto 4. Install: Rotor holder “2” • Intake manifold (PORT) 90890-01235 See “Intake manifold” (6-24). Flywheel stopper “3” • Fuel hose assembly 90890-06598 See “Fuel hose assembly” (6-12). Universal magneto and rotor • Intake silencer holder “2” See “ETV” (6-28). YU-01235 Flywheel stopper “3”...
Page 328 Starter motor and extension wire harness Starter motor and extension wire harness 11 N · m (1.1 kgf · m, 8.1 lb ·ft ) 11 N · m (1.1 kgf · m, 8.1 lb ·ft ) Part name ’ Remarks Part name ’...
Page 329: Starter Motor And Extension Wire Harness
Starter motor and extension wire harness Installing the starter motor 1. Install: • Holder brackets • Battery cable terminal • Terminal cover (when an isolator lead is not installed) • Starter motor • Holders • Cap • Starter motor cable •...
Page 330 Wire harness Wire harness Part name ’ Remarks × Bolt M6 16 mm Bracket Holder × Bolt M6 16 mm Holder Holder Holder O-ring Holder Holder Holder Holder Wire harness 7-30...
Page 331: Wire Harness
Wire harness Removing the wire harness 1. Disconnect: • Crankshaft position sensor coupler “a” 2. Disconnect: • Ground lead “a”, “b”, “c” A. F450A/FL450A/XF450 B. F400A/FL400A/XF400 5. Disconnect: • ECM coupler “a”, “b”, “c” 3. Disconnect: • Thermo sensor coupler (PORT) “d” •...
Page 332 Wire harness 6. Disconnect: • Wire harness “a” (from the guide) • Cam position sensor coupler (PORT IN) “b” • Joint connector “c” (from the guide) 9. Disconnect: • Ground lead “a”, “b” • OCV coupler (PORT) “c” 7. Disconnect: •...
Page 333: Installing The Wire Harness
Wire harness • Knock sensor coupler (upper) “b” 15. Disconnect: 12. Disconnect: • Wire harness “a” • Direct injection pump coupler (STBD) “a” (from the guides) • Sub-wire harness coupler (STBD) “b” • Cam position sensor coupler (STBD IN) • Joint connector “c” “b”...
Page 334 Wire harness 2. Connect: 5. Connect: • Holder “1” • Ignition coil coupler (PORT) “a” • Ground lead “a” • Fuel pressure sensor (direct injection • Ignition coil coupler (STBD) “b” pump) coupler (PORT) “b” • Fuel pressure sensor (direct injection pump) coupler (STBD) “c”...
Page 335 Wire harness • Injector driver coupler “b”, “c”, “d” • PTT buzzer coupler “e” TIP: Fit the injector driver coupler “d” onto the in- jector driver, and then move the lock lever “f” in the direction shown to engage the coupler. Make sure that the tab “g”...
Page 336 Wire harness 13. Connect: • Holder “1” • Low-pressure fuel pump coupler “a” • High-pressure fuel pump coupler “b”, “c” • Intake air pressure/temperature sensor coupler “d” 14. Connect: • Ground lead “a”, “b”, “c” TIP: Connect the ground leads so that they contact 12.
Page 337 ECM, injector driver, and rectifier/regulator ECM, injector driver, and rectifier/regulator 3.9 N · m (0.39 kgf · m, 2.9 lb ·ft ) 2.5 N · m (0.25 kgf · m, 1.8 lb ·ft ) 11 10 1.7 N · m (0.17 kgf · m, 1.3 lb ·ft ) 14 N ·...
Page 338: Ecm, Injector Driver, And Rectifier/Regulator
ECM, injector driver, and rectifier/regulator Removing the rectifier/regulator TIP: 1. Remove: • Install the rectifier/regulator “4” so that its • Low-pressure fuel pump side with the “OUTSIDE” mark “a” is facing See “Low-pressure fuel pump” (6-6). outward. • Vapor separator assembly •...
Page 339 ECM, injector driver, and rectifier/regulator 2. Install: • Surge tank See “Installing the ETV and surge tank” (6-29). • Vapor separator assembly See “Installing the vapor separator” (6-11). • Low-pressure fuel pump See “Installing the low-pressure fuel pump” (6-8). 7-39...
Page 340: Ignition Coil And Spark Plug
Ignition coil and spark plug Ignition coil and spark plug 10 N · m (1.0 kgf · m, 7.4 lb ·ft ) 11 N · m (1.1 kgf · m, 8.1 lb ·ft ) Part name ’ Remarks × Bolt M6 30 mm Ignition coil Spark plug...
Page 341: Checking The Spark Plug
Ignition coil and spark plug Checking the spark plug 1. Check: • Electrode “1” Damaged/worn → Replace. • Insulator “2” Abnormal color → Replace. (Normal color: Medium-to-light tan) 2. Clean: • Spark plug (with a spark plug cleaner) Do not use a wire brush to clean the spark plugs, as it will damage the iridium coating on the electrode.
Page 342: Timing Belt
Timing belt Timing belt 39 N · m (3.9 kgf · m, 29 lb ·ft ) ’ Part name Remarks × Bolt M6 35 mm Wire harness guide Collar Grommet Holder Grommet × Bolt M6 16 mm Bracket Tensioner Timing belt 7-42...
Page 343: Removing The Timing Belt
Timing belt Removing the timing belt Shaft holder “1” 90890-06949 When the timing belt is not installed, do not c. Turn the timing belt tensioner gradually turn the crankshaft or driven sprocket. Oth- clockwise using a hexagon wrench, erwise, the pistons and valves could collide and then insert a 5.0 mm (0.2 in) diam- with each other and be damaged.
Page 344 Timing belt a. Install the timing belt “1” onto the c. Turn the timing belt tensioner “1” so crankshaft so that the part number “a” that the hole “a” in the timing belt ten- is in the upright position and the belt sioner fits onto the protrusion “b”...
Page 345 Timing belt TIP: • When turning the timing belt tensioner, apply a force of 15 N·m (1.5 kgf·m, 11 lb·ft) or less. • Make sure that the belt position marks are aligned with the marks on the crankshaft and driven sprockets. See steps (a) and (b). f.
Page 346: Camshaft
Camshaft Camshaft 60 N · m (6.0 kgf · m, 44 lb ·ft ) 1386B 1386B 2.0 N · m (0.20 kgf · m, 1.5 lb ·ft ) 1280B 1280B 1377B 1377B 1280B 1280B 1280B 1280B 8 N · m (0.8 kgf · m, 5.9 lb ·ft ) 8 N ·...
Page 347 Camshaft 60 N · m (6.0 kgf · m, 44 lb ·ft ) 1386B 1386B 2.0 N · m (0.20 kgf · m, 1.5 lb ·ft ) 1280B 1280B 1377B 1377B 1280B 1280B 1280B 1280B 8 N · m (0.8 kgf · m, 5.9 lb ·ft ) 8 N ·...
Page 348: Removing The Camshaft, Vct Assembly, And Driven Sprocket
Camshaft Removing the camshaft, VCT TIP: assembly, and driven sprocket After removing the timing belt, secure the camshaft using a wrench, and then remove the driven sprocket bolts “3”. When the timing belt is not installed, do not turn the crankshaft or camshaft. Other- wise, the pistons and valves could collide with each other and be damaged.
Page 349: Checking The Sprocket
Camshaft Calculation formula: PORT STBD Chain length of the measured section = (Distance “a” between the inner edges of the rollers + Distance “b” between the outer edges of the rollers)/2 Example: Distance “a” between the inner edges of the rollers = 108.25 mm Distance “b”...
Page 350: Checking The Valve Lifter
Camshaft Maximum wear depth 1.00 mm (0.0394 in) Checking the valve lifter 1. Check: • Valve lifter Damaged/scratched/worn → Replace. 2. Measure: • Valve lifter outside diameter “a” Out of specification → Replace. 2. Measure: • Cam lobe height “a” •...
Page 351: Checking The Camshaft Journal Oil Clearance
Camshaft Cam lobe height IN 47.311–47.411 mm (1.8626– 1.8666 in) Limit 47.261 mm (1.8607 in) Cam lobe height EX 46.600–46.700 mm (1.8346– 1.8386 in) Limit 46.550 mm (1.8327 in) 2. Install: Fuel pump cam width across cor- • Dowels ner (DI pump) •...
Page 352: Checking The Camshaft Journal Outside Diameter And Camshaft Journal Inside Diameter
Camshaft Checking the camshaft journal PORT STBD outside diameter and camshaft journal inside diameter 1. Measure: • Camshaft journal outside diameter “a” Out of specification → Replace. Camshaft cap bolt “1”, “2” 1st: 8 N·m (0.8 kgf·m, 5.9 lb·ft) 2nd: 17 N·m (1.7 kgf·m, 13 lb·ft) 4.
Page 353: Installing The Camshaft, Vct Assembly, And Driven Sprocket
Camshaft Installing the camshaft, VCT TIP: assembly, and driven sprocket Align the mark “a” on the VCT assembly and If the valve clearances are adjusted or any the big slot “b” on the camshaft (EX) with the parts related to valve movement are replaced gold-colored plates “c”...
Page 354 Camshaft b. Install the camshaft caps “1”, “2”, and TIP: “3” in their proper positions so that the Secure the camshaft using a wrench, and then stamped numbers are upside down, tighten the VCT bolt “1” to the specified and then install the camshaft cap bolts torque.
Page 355 Camshaft PORT TIP: • Check that the “ ” mark “a” on the driven sprocket (PORT) is aligned with the “ ” mark “b” on the cylinder head (PORT). • Check that the “ ” mark “c” on the driven sprocket (STBD) is aligned with the “...
Page 356 Camshaft STBD 1280B 1280B 45° 45° 12. Install: • Breather plate (PORT) • Breather plate (STBD) TIP: • Apply a thin, even coat of sealant onto the Breather plate screw cylinder head covers “1” and “2”. 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) •...
Page 357 Camshaft Cylinder head cover bolt 1st: 8 N·m (0.8 kgf·m, 5.9 lb·ft) 2nd: 8 N·m (0.8 kgf·m, 5.9 lb·ft) 14. Install: • O-ring “1” • Hose nipple “2” • Guide (PORT) “3” • Bracket (PORT) “4” • Guide (STBD) “5” •...
Page 358: Cylinder Head
Cylinder head Cylinder head 1322D 1322D 13 14 25 N · m (2.5 kgf · m, 18 lb ·ft ) 1377B 1377B 25 N · m (2.5 kgf · m, 18 lb ·ft ) 6.5 N · m (0.65 kgf · m, 4.8 lb ·ft ) 48 N ·...
Page 359: Removing The Cylinder Head
Cylinder head Removing the cylinder head 1. Remove: • Cylinder head Do not scratch or damage the mating sur- faces of the cylinder head and cylinder block. TIP: A. Conventional special service tool Remove the M11 cylinder head bolts using a B.
Page 360: Checking The Cylinder Head Bolt
Cylinder head Cylinder head bolt (M11) diameter TIP: difference limit Check the cylinder head warpage using a “a” – “b” = Less than 0.20 mm straightedge “1” and a thickness gauge “2” in (0.0079 in) 6 directions. Measuring point “c”: 10.0 mm (0.39 in) Measuring point “d”: 85.0 mm (3.35 in)
Page 361: Checking The Valve
Cylinder head Tilt limit IN Diameter IN 1.7 mm (0.07 in) 5.477–5.492 mm (0.2156– Tilt limit EX 0.2162 in) 1.7 mm (0.07 in) Limit 5.447 mm (0.2144 in) Diameter EX Checking the valve 5.464–5.479 mm (0.2151– 1. Check: 0.2157 in) •...
Page 362: Replacing The Valve Guide
Cylinder head 2. Install: Inside diameter IN • Valve guide “1” 5.504–5.522 mm (0.2167– (from the camshaft side) 0.2174 in) Inside diameter EX TIP: 5.504–5.522 mm (0.2167– Make sure that the valve guide installation 0.2174 in) height “a” is within specification. 2.
Page 363: Checking The Valve Seat
Cylinder head Valve guide reamer “2” TIP: 90890-06804 Reface the valve seat if the valve is not seated Valve guide reamer “2” properly or if the valve seat contact width is YB-06804 out of specification. Check the valve guide if the valve seat contact width is uneven.
Page 364 Cylinder head 1. Reface: • Valve seat Do not overcut the valve seat. To prevent a. Reface the valve seat using the special chatter marks, make sure to turn the cutter service tools. evenly using a downward force of 40–50 N (4.0–5.0 kgf, 8.8–11.0 lbf).
Page 365 Cylinder head 30° 30 ° 60° a. Previous contact width a. Previous contact width d. Adjust the bottom edge of the valve • If the valve seat contact area is too narrow seat contact width using a 60° cutter. and situated near the top edge of the valve face, cut the top edge of the valve seat using a 30°...
Page 366: Checking The Cylinder Head Anode
Cylinder head Checking the OCV 1. Check: Do not get the lapping compound on the • Electrical performance valve stem and valve guide. See “Checking the OCV” (5-25). Assembling the cylinder head TIP: After refacing the contact width of the valve 1.
Page 367 Cylinder head Valve spring compressor attach- ment “6” 90890-06320 Lever assy “7” 90890-06956 Support assy 3 “8” 90890-06952 Valve spring compressor “9” 90890-06689 Valve spring compressor adaptor “6” YB-06320 Valve spring compressor “9” YB-06689 c. Compress the valve spring, and then install the valve cotters “1”.
Page 368: Installing The Cylinder Head
Cylinder head • Anode • Gasket • Anode cover grommet 4. Install: • Anode assembly Do not apply grease, oil, or paint to the an- odes. Installing the cylinder head Before assembling the cylinder head, check the cylinder head bolts. See “Checking the b.
Page 369 Cylinder head Cylinder head bolt (M11) “1” [1]– [10] 1st: 48 N·m (4.8 kgf·m, 35 lb·ft) 2nd: 180° Cylinder head bolt (M8) “2”, “3” [11]–[15] 1st: 14 N·m (1.4 kgf·m, 10 lb·ft) 2nd: 28 N·m (2.8 kgf·m, 21 lb·ft) 7-69...
Page 370: Oil Pump Assembly
Oil pump assembly Oil pump assembly 18 N · m (1.8 kgf · m, 13 lb ·ft ) 49 N · m (4.9 kgf · m, 36 lb ·ft ) 11 N · m (1.1 kgf · m, 8.1 lb ·ft ) 13 N ·...
Page 371: Removing The Oil Pump Assembly
Oil pump assembly Removing the oil pump assembly Oil pump assembly bolt 11 N·m (1.1 kgf·m, 8.1 lb·ft) Do not disassemble the oil pump assembly. Installing the oil filter 1. Install: Removing the oil filter • Gasket 1. Remove: • Oil filter bracket •...
Page 372: Oil Cooler And Water Jacket
Oil cooler and water jacket Oil cooler and water jacket 3.9 N · m (0.39 kgf · m, 2.9 lb ·ft ) 6 N · m (0.6 kgf · m, 4.4 lb ·ft ) 10 N · m (1.0 kgf · m, 7.4 lb ·ft ) 3.9 N ·...
Page 373: Checking The Thermostat
Oil cooler and water jacket Checking the thermostat Checking the oil cooler cover anode and water jacket anode 1. Measure: • Valve opening “a” 1. Check: (at the specified water temperatures) • Anode Out of specification → Replace. Eroded (1/2 or more worn out) → Replace. Adhered grease, oil, or scales →...
Page 374: Installing The Oil Cooler Cover
Oil cooler and water jacket TIP: Tighten the oil coder cover bolts to the speci- fied torques in 2 stages. Oil cooler cover anode screw 3.9 N·m (0.39 kgf·m, 2.9 lb·ft) Oil coder cover bolt 1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft) 2nd: 10 N·m (1.0 kgf·m, 7.4 lb·ft) 3.
Page 375: Cylinder Block Sensor
Cylinder block sensor Cylinder block sensor 18 N · m (1.8 kgf · m, 13 lb ·ft ) 2.0 N · m (0.20 kgf · m, 1.5 lb ·ft ) 2.0 N · m (0.20 kgf · m, 1.5 lb ·ft ) 18 N ·...
Page 376: Checking The Cylinder Block Anode
Cylinder block sensor Checking the cylinder block anode 1. Check: • Anode Eroded (1/2 or more worn out) → Replace. Adhered grease, oil, or scales → Clean. Do not apply grease, oil, or paint to the an- odes. Installing the cylinder block anode 1.
Page 377: Cylinder Block
Cylinder block Cylinder block 13 N · m (1.3 kgf · m, 9.6 lb ·ft ) 28 N · m (2.8 kgf · m, 21 lb ·ft ) 90° 14 N · m (1.4 kgf · m, 10 lb ·ft ) 28 N ·...
Page 378: Disassembling The Cylinder Block
Cylinder block Disassembling the cylinder block 3. Remove: • Crankshaft journal bearings (crankcase 1. Remove: side) “1” • Flange “1” • Crankshaft “2” TIP: • Crankshaft journal bearings (cylinder Install the special service tool “2” to the flange block side) “3” “1”, secure the tool using a wrench, and then TIP: remove the flange bolts “3”.
Page 379: Checking The Cylinder Bore
Cylinder block 2. Calculate: Piston • Piston clearance Diameter Out of specification → Replace the piston 95.945–95.960 mm (3.7774– or cylinder block. 3.7779 in) Limit Piston clearance = maximum cyl- 95.905 mm (3.7758 in) inder bore – piston outside diame- Measuring point 14.5 mm (0.57 in) Piston clearance...
Page 380: Checking The Piston Ring End Gap
Cylinder block Piston ring dimensions Piston ring end gap Top ring Measuring point Height (B) 10.0 mm (0.39 in) 1.170–1.185 mm (0.0461– Top ring 0.0467 in) End gap Width (T) 0.20–0.30 mm (0.0079–0.0118 2.800–3.000 mm (0.1102– 0.1181 in) Limit 2nd ring 0.470 mm (0.0185 in) Height (B) 2nd ring...
Page 381: Checking The Piston Ring Side Clearance
Cylinder block Checking the piston ring side TIP: clearance When measuring the piston pin boss inside di- 1. Measure: ameter, do not measure it at the ring groove • Piston ring side clearance “b” or oil groove “c”. Out of specification → Check the piston ring grooves and piston ring.
Page 382: Checking The Connecting Rod Small End Inside Diameter And Big End Inside Diameter
Cylinder block Checking the connecting rod big end Pin outside diameter side clearance 21.996–22.005 mm (0.8660– 1. Measure: 0.8663 in) • Big end side clearance “a” Limit Out of specification → Check the crank- 21.986 mm (0.8656 in) shaft pin width. See “Checking the crankshaft”...
Page 383: Checking The Crankcase Bolt
Cylinder block Checking the crankcase bolt 1. Measure: • Diameter Above specification → Replace. TIP: Measure the diameters “a” and “b” of the crankcase bolt (M10) at the specified measur- ing points “c” and “d”. Journal diameter 72.976–72.996 mm (2.8731– Crankcase bolt diameter differ- 2.8739 in) ence limit...
Page 384 Cylinder block 2. Install: 4. Tighten: • Plastigauge (PG-1) “1” • Connecting rod bolts “1” TIP: • Tighten the connecting rod bolts “1” to the Do not place the Plastigauge (PG-1) over specified torques in 3 stages. the oil hole in the crankshaft pin of the •...
Page 385: Selecting The Crankshaft Pin Bearing
Cylinder block P1 P2 P5 P6 P3 P4 P7 P8 Big end oil clearance 0.026–0.049 mm (0.0010– 0.0019 in) Limit 0.079 mm (0.0031 in) Selecting the crankshaft pin bearing When replacing the crankshaft pin bearing, 3. Select: select the bearing as follows. •...
Page 386 Cylinder block Example: If the connecting rod big end inside diam- eter is “05” and the crankshaft pin mark is “81”, select the bearing colors in “e”. The rod side bearing color is blue and the cap side bearing color is blue. 90 91 04 05 06 07 7-86...
Page 387: Crankshaft Pin Bearing Selection Table
Cylinder block Crankshaft pin bearing selection table 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 A. Connecting rod big end inside diameter B. Crankshaft pin mark 7-87...
Page 388: Checking The Journal Oil Clearance
Cylinder block Checking the journal oil clearance 3. Install: • Crankshaft journal bearings TIP: (into the crankcase) • After checking the journal oil clearance, TIP: check the crankcase bolts. See “Checking Install the crankshaft journal bearings in their the crankcase bolt” (7-83). original positions.
Page 389: Selecting The Crankshaft Journal Bearing
Cylinder block [19] [19] [10] [10] [20] [20] [35] [35] [36] [36] [31] [31] [15] [15][5] [5] [6] [16] [16] [32] [32] [25] [25] [26] [26] [11] [11][1] [1] [2] [2][12] [12] [21] [21] [22] [22] [14] [14][4] [4] [3] [3][13] [13] Journal oil clearance...
Page 390 Cylinder block TIP: Select the suitable colors “1” for the crank- shaft journal bearing from the “Crankshaft journal bearing selection table” (7-91). Block side bear- Crankcase side ing color bearing color “a” Black Black “b” Blue Blue “c” Pink Pink “d”...
Page 391: Crankshaft Journal Bearing Selection Table
Cylinder block Crankshaft journal bearing selection table 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 A. Cylinder block mark B. Crankshaft journal mark 7-91...
Page 392: Assembling The Cylinder Block
Cylinder block Assembling the cylinder block 1. Install: • Dowel • Pickup rotor • Drive gear TIP: Tighten the drive gear bolts “1” to the speci- fied torque in the order [1], [2], and so on. b. Install the oil rings “1”, 2nd ring “2”, and top ring “3”.
Page 393 Cylinder block 5. Install: TIP: • Crankshaft pin bearings • Install the crankshaft journal bearings “1” in (into the connecting rod and connecting their original positions. rod cap) • Install the crankshaft journal bearings “1” according to the specified dimensions. TIP: Install the crankshaft pin bearings in the origi- nal positions.
Page 394 Cylinder block TIP: • In the third tightening stage for the connect- ing rod bolts “2”, mark the connecting rod bolts and connecting rod cap with paint marks “c”, and then tighten the bolts 90° from the marks on the connecting rod cap. •...
Page 395 Cylinder block Crankcase bolt (M10) “1” [1]–[20] TIP: 1st: 40 N·m (4.0 kgf·m, 30 lb·ft) In the second tightening stage for the M10 2nd: 90° bolts “1”, mark the M10 bolts and the crank- Crankcase bolt (M8) “2”, “3” [21]– case with identification marks “a”, and then [36] tighten the bolts 90°...
Page 396 Cylinder block TIP: • Clean the mating surface of the crankshaft and flange. • Tighten new flange bolts “2” to the specified torques in 2 stages and in the order [1], [2], and so on. • Install the special service tool “3” to the flange, secure the tool using a wrench, and then tighten the flange bolts “2”.
Page 397 Lower unit Propeller and water inlet cover......... 8-1 Removing the propeller .............. 8-2 Disassembling the propeller (Shift Dampener System [SDS] propeller) ..................8-2 Checking the propeller ............... 8-2 Assembling the propeller (Shift Dampener System [SDS] propeller) ..................8-2 Installing the water inlet.............. 8-3 Installing the propeller ..............
Page 398: Lower Unit
Lower unit Checking the propeller shaft housing ........8-21 Checking the reverse gear ............8-22 Assembling the propeller shaft assembly ........ 8-22 Assembling the reverse gear............ 8-22 Assembling the propeller shaft housing assembly....8-23 Installing the propeller shaft housing assembly ....... 8-25 Drive shaft and lower case (regular rotation model) ..
Page 399 Lower unit Drive shaft and lower case (counter rotation model) ... 8-54 Removing the drive shaft ............8-55 Disassembling the drive shaft ..........8-55 Disassembling the reverse gear ..........8-55 Disassembling the lower case..........8-55 Checking the pinion ..............8-55 Checking the reverse gear ............
Page 400: Propeller And Water Inlet Cover
Propeller and water inlet cover Propeller and water inlet cover 80 N · m (8.0 kgf · m, 59 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 ) Part name ’...
Page 401: Removing The Propeller
Propeller and water inlet cover Removing the propeller • Make sure to disconnect the battery ca- bles from the battery, and remove the clip from the engine shut-off switch. • When removing or installing the lower unit with the power unit installed, make sure to suspend the outboard motor.
Page 402: Installing The Water Inlet
Propeller and water inlet cover Installing the water inlet TIP: 1. Install: • Align the mark “a” on the damper “1” with • O-ring the mark “b” on the propeller “2”. • Drain screw • Install the damper “1” using the special ser- vice tools and spacer “3”...
Page 403 Propeller and water inlet cover 2. Tighten: • Propeller nut TIP: Place a block of wood between the anticavita- tion plate and the propeller to prevent the pro- peller from turning, and then tighten the propeller nut. Propeller nut 80 N·m (8.0 kgf·m, 59 lb·ft) 3.
Page 404 Lower unit Lower unit 47 N · m (4.7 kgf · m, 35 lb ·ft ) 47 N · m (4.7 kgf · m, 35 lb ·ft ) 47 N · m (4.7 kgf · m, 35 lb ·ft ) 42 N ·...
Page 405: Lower Unit
Lower unit Removing the lower unit • Make sure to disconnect the battery ca- bles from the battery, and remove the clip from the engine shut-off switch. • When removing or installing the lower unit with the power unit installed, make sure to suspend the outboard motor.
Page 406: Installing The Lower Unit
Lower unit • Special service tool “1” (to the oil level 1. Install: plug hole) • O-rings • Backup rings • Plate • Rubber seal • Dowels • Lower unit • Splash plates • Anode a. Set the gear shift to the N position. Leakage tester “1”...
Page 407 Lower unit Lower case mounting bolt “4” 47 N·m (4.7 kgf·m, 35 lb·ft) Lower case mounting nut “5” 47 N·m (4.7 kgf·m, 35 lb·ft) Lower case anode bolt “6” 42 N·m (4.2 kgf·m, 31 lb·ft) WR-No.2 WR-No.2 WR-No.2 WR-No.2 A. X-transom model B.
Page 408: Extension (Except For X-Transom Model)
Extension (except for X-transom model) Extension (except for X-transom model) 23 N · m (2.3 kgf · m, 17 lb ·ft ) 23 N · m (2.3 kgf · m, 17 lb ·ft ) 1322 1322 1322 1322 1322 1322 1322 1322 47 N ·...
Page 409: Checking The Extension
Extension (except for X-transom model) Checking the extension 1. Check: • Extension Cracked/damaged → Replace. Assembling the extension 1. Install: • Nipples “1”, “2” • O-rings 1322D 1322D 1322D 1322D Installation height “a” 32.2–32.8 mm (1.27–1.29 in) Installing the extension 1.
Page 410: Water Pump And Shift Rod
Water pump and shift rod Water pump and shift rod 16 N · m (1.6 kgf · m, 12 lb ·ft ) 1322D 1322D 4.5 N · m (0.45 kgf · m, 3.3 lb ·ft ) 1530D 1530D 4.5 N · m (0.45 kgf · m, 3.3 lb ·ft ) 1322D 1322D Part name...
Page 411: Removing The Shift Rod (Regular Rotation Model)
Water pump and shift rod Removing the shift rod (regular rotation model) 1. Remove: • Shift rod guide plate • Plate • Gasket • Shift rod a. Set the gear shift to the N position. Shift rod socket “1” 90890-06950 b.
Page 412: Checking The Water Pump
Water pump and shift rod Installing the gear oil passage check valve When heating the lower case, heat the en- 1. Install: tire installation area evenly. Otherwise, the • Gear oil passage check valve (lower case) paint on the lower case could be burned. “1”...
Page 413: Assembling The Water Pump Housing
Water pump and shift rod Driver rod L3 “2” 90890-06652 Needle bearing attachment “3” 90890-06614 Driver handle (small) “4” YB-06229 Oil seal installer reverse gear bearing housing “5” YB-06021 2. Install: • Gear oil passage check valve (shift rod guide plate) “1” A.
Page 414: Installing The Water Pump And Shift Rod (Regular Rotation Model)
Water pump and shift rod 90° 3. Install: • O-ring • Insert cartridge “1” TIP: • Fit the protrusions “a” on the insert cartridge “1” into the slots “b” in the upper water pump housing “2”. • Do not apply sealant to the slot “c” in the up- 2.
Page 415: Installing The Water Pump And Shift Rod (Counter Rotation Model)
Water pump and shift rod TIP: While turning the drive shaft “2” clockwise, push the upper water pump housing “1” down to install it. Spacer bolt “1”, “2” 4.5 N·m (0.45 kgf·m, 3.3 lb·ft) 3. Install: • O-rings • Lower water pump housing •...
Page 416 Water pump and shift rod 90° 2. Install: • Spacers • O-rings • Lower water pump housing • Lower impeller • Dowels • Outer plate cartridge • Impeller key • Upper impeller • Upper water pump housing See steps 2–4 in “Installing the water pump and shift rod (regular rotation mod- el)”...
Page 417: Propeller Shaft Housing (Regular Rotation Model)
Propeller shaft housing (regular rotation model) Propeller shaft housing (regular rotation model) 15 17 16 12 6 16 14 155 N · m (15.5 kgf · m, 114 lb ·ft ) 250 N · m (25 kgf · m, 184 lb ·ft ) Part name ’...
Page 418: Removing The Propeller Shaft Housing Assembly
Propeller shaft housing (regular rotation model) Removing the propeller shaft housing assembly 1. Remove: • Ring nut • Claw washer a. Straighten the bent tab “a” on the claw washer. b. Loosen the ring nut. A. Worldwide B. USA and Canada Stopper guide plate “2”...
Page 419: Disassembling The Propeller Shaft Assembly
Propeller shaft housing (regular rotation model) 4. Remove: Disassembling the reverse gear • Tapered roller bearing inner race “a” 1. Remove: • Propeller shaft shims “1” • Ball bearing “1” • Washer “2” • Thrust washer “2” • Reverse gear assembly “b” Disassembling the propeller shaft assembly 1.
Page 420: Checking The Propeller Shaft
Propeller shaft housing (regular rotation model) 2. Remove: Checking the propeller shaft • Needle bearing “1” 1. Check: • Propeller shaft Damaged/worn → Replace. 2. Measure: • Propeller shaft runout Above specification → Replace. Driver rod LL “2” 90890-06605 Needle bearing attachment “3” 90890-06933 Driver rod LL “2”...
Page 421: Checking The Reverse Gear
Propeller shaft housing (regular rotation model) Checking the reverse gear 1. Check: • Teeth and dogs of the reverse gear Cracked/worn → Replace. Assembling the propeller shaft assembly 1. Install: • Shift plunger “1” • Balls “2” Assembling the reverse gear •...
Page 422: Assembling The Propeller Shaft Housing Assembly
Propeller shaft housing (regular rotation model) Assembling the propeller shaft housing assembly • 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 423 Propeller shaft housing (regular rotation model) Driver rod LS “2” 90890-06606 Bearing outer race attachment “3” 90890-06623 Driver handle (large) “4” YB-06071 Forward gear bearing cup install- er “5” YB-06277-A Needle bearing attachment “2” 90890-06933 Installation depth “a” 12.25–12.75 mm (0.482–0.502 3.
Page 424: Installing The Propeller Shaft Housing Assembly
Propeller shaft housing (regular rotation model) Driver rod LS “2” TIP: 90890-06606 Make sure to fit the protrusion “a” on the pro- Bearing outer race attachment peller shaft housing into the slot “b” in the claw “3” washer “1”. 90890-06623 Driver handle (large) “4”...
Page 425 Propeller shaft housing (regular rotation model) Ring nut wrench “1” 90890-06932 Ring nut wrench extention 2 “2” 90890-06784 Ring nut wrench extension “2” YB-06784 Ring nut 1st: 155 N·m (15.5 kgf·m, 114 lb·ft) 2nd: Rotate the drive shaft by 10 turns or more. 3rd: 250 N·m (25 kgf·m, 184 lb·ft) b.
Page 426: Drive Shaft And Lower Case (Regular Rotation Model)
Drive shaft and lower case (regular rotation model) Drive shaft and lower case (regular rotation model) 46 N · m (4.6 kgf · m, 34 lb ·ft ) 240 N · m (24 kgf · m, 177 lb ·ft ) 175 N ·...
Page 427: Removing The Drive Shaft
Drive shaft and lower case (regular rotation model) Removing the drive shaft TIP: 1. Remove: • When the pinion nut “1” is hard to loosen, re- • Cover move the holder guide, insert a thick rag “6” • Oil seal housing between the pinion nut holder “3”...
Page 428: Disassembling The Forward Gear
Drive shaft and lower case (regular rotation model) c. Loosen the drive shaft nut “1”, and Disassembling the forward gear then remove the drive shaft nut “1” and claw washer “2”. • Use heat-resistant gloves. Otherwise, burns could result. • To prevent fires, remove any flammable substances, such as gasoline and oil, around the working area.
Page 429: Checking The Pinion
Drive shaft and lower case (regular rotation model) Checking the forward gear 1. Check: When heating the lower case, heat the en- • Teeth and dogs of the forward gear tire installation area evenly. Otherwise, the Cracked/worn → Replace. paint on the lower case could be burned. Checking the drive shaft 1.
Page 430: Assembling The Forward Gear
Drive shaft and lower case (regular rotation model) b. Install the circlip “3” and dowel “4”. TIP: Face the bearing identification mark “a” on the roller bearing toward the circlip. Needle bearing attachment “2” 2. Install: 90890-06938 Bearing outer race puller assem- •...
Page 431 Drive shaft and lower case (regular rotation model) e. Install the claw washer “1”, and then Bearing inner race attachment “1” tighten the drive shaft nut “2” tempo- 90890-06639 rarily. Bearing inner race attachment “1” YB-06639 TIP: Make sure to fit the tab “a” on the claw washer “1”...
Page 432: Assembling The Oil Seal Housing
Drive shaft and lower case (regular rotation model) Motive torque Driver rod LL “2” 0.3–3.0 N·m (0.03–0.31 kgf·m, 90890-06605 0.2–2.2 lb·ft) (F400ASTU, Bearing outer race attachment F400ASTX, F450AVTU, “3” F450AVTX) 90890-06628 Driver handle (large) “4” i. Bend the tab “a” on the claw washer YB-06071 “1”...
Page 433: Installing The Forward Gear
Drive shaft and lower case (regular rotation model) Installation depth “a” 0.75–1.25 mm (0.030–0.049 in) Installing the forward gear 1. Install: • Adapter assembly “a” • Forward gear shim “1” • Thrust bearing “2” • Forward gear assembly “b” b. Install the pinion “1” and pinion nut “2” temporarily.
Page 434 Drive shaft and lower case (regular rotation model) Torque wrench setting value = TIP: 240 N·m ÷ (A + 0.045) × A When the pinion nut “2” is hard to tighten, refer Specified tightening torque for to the step 2 in “Removing the drive shaft” the drive shaft ring nut (8-28) that indicates the procedure using a rag.
Page 435: Shimming (Regular Rotation Model)
Shimming (regular rotation model) Shimming (regular rotation model) Shimming workflow 1. Disassemble the lower unit. 2. Select the forward gear shim (T1) and reverse gear shims (T2). 3. Install the forward gear and pinion temporarily. 4. Select the pinion shims (T3). 5.
Page 436: Shimming Check Sheet
Shimming (regular rotation model) TIP: • Make sure to drain the gear oil before measuring the backlash. • If the backlash is within specification, shimming is not required. • When assembling the original inner parts and a new lower case, shimming is required. •...
Page 437: Shimming Procedure
Shimming (regular rotation model) Shimming procedure • Shim thickness is specified for the forward gear shim (T1) and reverse gear shims (T2). • After selecting the pinion shims (T3), do not apply gear oil, grease, or sealant to the lower unit parts to measure the backlash.
Page 438: Selecting The Forward Gear Shim (T1) And Reverse Gear Shim (T2)
Shimming (regular rotation model) Selecting the forward gear shim (T1) • Spacer • Drive shaft ring nut and reverse gear shim (T2) See steps 1 and 2 in “Installing the drive 1. Select: shaft” (8-34). • Forward gear shim (T1) •...
Page 439 Shimming (regular rotation model) TIP: • Measure the distance at 4 points: “a”, “b”, “c”, and “d”, turning the drive shaft 90° (mm) clockwise after each measurement. 0.69 0.70 0.71 • Write down the measurement data in the +0.06 +0.05 +0.04 shimming check sheet.
Page 440: Measuring The Forward Gear Backlash And Reverse Gear Backlash
Shimming (regular rotation model) • Propeller shaft/propeller shaft housing as- Available shim thicknesses sembly Pinion shims • Key 0.10/0.12/0.15/0.18/0.30/0.40/ • Claw washer (do not bend the tabs) 0.50 mm (F400ASTU, • Ring nut F400ASTX, F450AVTU, See steps 2–5 in “Installing the propeller F450AVTX) shaft housing assembly”...
Page 441 Shimming (regular rotation model) Backlash indicator “1” 90890-06836 Magnet base plate “2” 90890-07003 Dial gauge set “3” 90890-03238 Magnet base B “4” 90890-06844 Backlash indicator “1” YB-06836 Backlash adjustment plate “2” A. Worldwide YB-07003 B. USA and Canada Dial indicator gauge “3” YU-03097 Center bolt “1”...
Page 442 Shimming (regular rotation model) 5. Measure: TIP: • Reverse gear backlash • Measure the backlash at 4 points: “a”, “b”, Out of specification → Repeat steps from “c”, and “d”, turning the drive shaft 180° the selection of the forward gear shim (T1) clockwise after each measurement.
Page 443 Shimming (regular rotation model) TIP: • Measure the backlash at 4 points: “a”, “b”, “c”, and “d”, turning the drive shaft 180° clockwise after each measurement. • Write down the measurement data in the shimming check sheet. Shift rod socket “1” 90890-06950 c.
Page 444: Selecting The Propeller Shaft Shim (T4)
Shimming (regular rotation model) 6. Install: 3. Measure: • Oil seal housing • Propeller shaft motive torque • Cover a. Set the gear shift to the N position. See step 3 in “Installing the propeller shaft housing assembly” (8-25). • Shift rod •...
Page 445 Shimming (regular rotation model) 0.07 TIP: 0.06 • Measure the thickness of original propeller shaft shim (T4) in 2 places. 0.05 • Do not reuse shims. 0.04 –0.07 a. Determine the propeller shaft shim (T4) –0.08 thickness adjustment using the “Pro- peller shaft shim (T4) selection chart”...
Page 446 Shimming (regular rotation model) Available shim thicknesses Propeller shaft shims 0.10/0.12/0.15/0.18/0.30/0.40/ 0.50/1.00 mm (F400ASTU, F400ASTX, F450AVTU, F450AVTX) 8-47...
Page 447: Propeller Shaft Housing (Counter Rotation Model)
Propeller shaft housing (counter rotation model) Propeller shaft housing (counter rotation model) 6 14 250 N · m (25 kgf · m, 184 lb ·ft ) 10 8 Part name ’ Remarks Part name ’ Remarks Ring nut M142 Thrust bearing Claw washer Propeller shaft shim —...
Page 448: Removing The Propeller Shaft Housing Assembly
Propeller shaft housing (counter rotation model) Removing the propeller shaft housing Disassembling the propeller shaft assembly housing assembly 1. Remove: 1. Remove: • Ring nut • Spring • Claw washer • Cross pin See step 1 in “Removing the propeller •...
Page 449: Disassembling The Forward Gear
Propeller shaft housing (counter rotation model) A. Worldwide A. Worldwide B. USA and Canada B. USA and Canada Driver rod L3 “1” Ball bearing attachment “3” 90890-06652 90890-06630 Needle bearing attachment “2” Forward gear needle bearing in- 90890-06616 staller “4” Driver handle (small) “3”...
Page 450: Checking The Dog Clutch
Propeller shaft housing (counter rotation model) 3. Install: Runout • Propeller shaft shims “1” 0.02 mm (0.0008 in) (FL400AS- • Thrust bearing “2” TU, FL400ASTX, FL450AVTU, FL450AVTX) TIP: Position the thickest propeller shaft shim to- Checking the dog clutch ward the propeller shaft housing. See “Checking the dog clutch”...
Page 451: Installing The Propeller Shaft Housing Assembly
Propeller shaft housing (counter rotation model) Ring nut wrench 2 “1” 90890-06823 Ring nut wrench extention 2 “2” 90890-06784 Ring nut wrench “1” YB-06823 Ring nut wrench extension “2” YB-06784 5. Install: • Thrust washer • Forward gear a. Install the thrust washer “1” and for- ward gear “2”...
Page 452 Propeller shaft housing (counter rotation model) TIP: Position the thickest forward gear shim toward the lower case. 2. Install: • Claw washer • Ring nut Ring nut 250 N·m (25 kgf·m, 184 lb·ft) See steps 3–5 in “Installing the propeller shaft housing assembly”...
Page 453: Drive Shaft And Lower Case (Counter Rotation Model)
Drive shaft and lower case (counter rotation model) Drive shaft and lower case (counter rotation model) 46 N · m (4.6 kgf · m, 34 lb ·ft ) 240 N · m (24 kgf · m, 177 lb ·ft ) 175 N ·...
Page 454: Removing The Drive Shaft
Drive shaft and lower case (counter rotation model) Removing the drive shaft Driver rod L3 “2” See “Removing the drive shaft” (8-28). 90890-06652 Needle bearing attachment “3” Disassembling the drive shaft 90890-06609 See “Disassembling the drive shaft” (8-28). Driver handle (large) “4” YB-06071 Disassembling the reverse gear Driveshaft needle bearing installer...
Page 455: Assembling The Drive Shaft
Drive shaft and lower case (counter rotation model) Installing the drive shaft TIP: See “Installing the drive shaft” (8-34). Face the bearing identification mark “b” on the roller bearing (outer race) “a” up. A. Worldwide B. USA and Canada Needle bearing attachment “1” 90890-06654 Needle bearing installer “2”...
Page 456: Shimming (Counter Rotation Model)
Shimming (counter rotation model) Shimming (counter rotation model) Shimming workflow 1. Disassemble the lower unit. 2. Select the reverse gear shim (T1) and forward gear shims (T2). 3. Install the reverse gear and pinion temporarily. 4. Select the pinion shims (T3). 5.
Page 457: Shimming Check Sheet
Shimming (counter rotation model) TIP: • Make sure to drain the gear oil before measuring the backlash. • If the backlash is within specification, shimming is not required. • When assembling the original inner parts and a new lower case, shimming is required. •...
Page 458: Shimming Procedure
Shimming (counter rotation model) Shimming procedure • Shim thickness is specified for the reverse gear shim (T1) and forward gear shims (T2). • After selecting the pinion shims (T3), do not apply gear oil, grease, or sealant to the lower unit parts to measure the backlash.
Page 459: Selecting The Reverse Gear Shim (T1) And Forward Gear Shim (T2)
Shimming (counter rotation model) Selecting the reverse gear shim (T1) Selecting the propeller shaft shim (T4) and forward gear shim (T2) 1. Assemble: • Propeller shaft housing assembly 1. Select: • Original propeller shaft shim (T4) • Reverse gear shim (T1) •...
Page 460 Shimming (counter rotation model) The current shim thickness must be in- Dial gauge set “1” creased by 0.6 mm. 90890-03238 Magnet base B “2” 90890-06844 (mm) Dial indicator gauge “1” YU-03097 Magnetic base stand “2” +0.5 +0.6 YU-A8438 Free play 0.42–0.52 mm (0.0165–0.0205 in) (FL400ASTU, FL400ASTX, A.
Page 461: Measuring The Forward Gear Backlash And Reverse Gear Backlash
Shimming (counter rotation model) 5. Remove: TIP: • Special service tools • Do not reuse shims. 6. Install: • Check that the drive shaft turns smoothly. • Determined propeller shaft shim 3. Install: Measuring the forward gear backlash • Shift rod and reverse gear backlash •...
Page 462 Shimming (counter rotation model) Backlash indicator “1” 90890-06836 Magnet base plate “2” 90890-07003 Dial gauge set “3” 90890-03238 Magnet base B “4” 90890-06844 Backlash indicator “1” YB-06836 Backlash adjustment plate “2” A. Worldwide YB-07003 B. USA and Canada Dial indicator gauge “3” YU-03097 Center bolt “1”...
Page 463 Shimming (counter rotation model) i. Remove the special service tools from TIP: the propeller shaft. • Measure the backlash at 4 points: “a”, “b”, 5. Measure: “c”, and “d”, turning the drive shaft 180° • Reverse gear backlash clockwise after each measurement. Out of specification →...
Page 464 Shimming (counter rotation model) TIP: • Measure the backlash at 4 points: “a”, “b”, “c”, and “d”, turning the drive shaft 180° clockwise after each measurement. • Write down the measurement data in the shimming check sheet. Shift rod socket “1” 90890-06950 c.
Page 465 Shimming (counter rotation model) 6. Install: • Oil seal housing • Cover See step 3 in “Installing the drive shaft” (8-34). • Shift rod • Plate • Shift rod guide plate • Spacer • Lower water pump housing • Lower impeller •...
Page 466 Bracket unit Bottom cowling cover and apron cover......9-1 Installing the bottom cowling cover ........... 9-2 Bottom cowling (PORT and STBD) ........9-3 Removing the bottom cowling ........... 9-5 Assembling the bottom cowling..........9-5 Installing the propeller light bracket ........... 9-6 Installing the bottom cowling .............
Page 467: Bracket Unit
Bracket unit Assembling the upper case............9-30 Installing the muffler and upper case ........9-30 Steering actuator and steering arm ....... 9-32 Removing the steering actuator (with the power unit installed) ................... 9-33 Removing the power steering unit (with the power unit removed) ..................
Page 468 Bracket unit PTT gear pump ..............9-57 Disassembling the gear pump assembly ......... 9-59 Checking the gear pump............9-59 Checking the gear pump housing ..........9-59 Checking the filter ..............9-59 Assembling the gear pump assembly ........9-59 Installing the gear pump assembly .......... 9-61 PTT cylinder ..............
Page 469: Bottom Cowling Cover And Apron Cover
Bottom cowling cover and apron cover Bottom cowling cover and apron cover Part name ’ Remarks × Bolt M6 25 mm Cover Collar Grommet Damper Grommet × Bolt M6 14 mm × Bolt M6 30 mm Cover...
Page 470: Installing The Bottom Cowling Cover
Bottom cowling cover and apron cover Installing the bottom cowling cover 1. Assemble: • Grommet “1” • Damper “2” • Grommet “3” • Collar “4” • Bolt “5” 2. Install: • Apron cover • Bottom cowling cover...
Page 471: Bottom Cowling (Port And Stbd)
Bottom cowling (PORT and STBD) Bottom cowling (PORT and STBD) 19 N · m (1.9 kgf · m, 14 lb ·ft ) 27 20 21 19 1342H 1342H 8 N · m (0.8 kgf · m, 5.9 lb ·ft ) 3.0 N ·...
Page 472 Bottom cowling (PORT and STBD) 19 N · m (1.9 kgf · m, 14 lb ·ft ) 27 20 21 19 1342H 1342H 8 N · m (0.8 kgf · m, 5.9 lb ·ft ) 3.0 N · m (0.30 kgf · m, 2.2 lb ·ft ) 0.9 N ·...
Page 473: Removing The Bottom Cowling
Bottom cowling (PORT and STBD) Removing the bottom cowling Assembling the bottom cowling 1. Remove: 1. Install: • Bolts (M6 × 14 mm) • Dampers • Bottom cowlings • Clamp plates a. Remove the bolts (M6 × 14 mm) “1”, Damper screw and then loosen the bolts (M6 ×...
Page 474: Installing The Propeller Light Bracket
Bottom cowling (PORT and STBD) TIP: • Align end of the rubber seals “1” and “2” with the portion “a” of the bottom cowling (PORT) “3”. • Make sure that the rubber seals “1” and “2” are not installed on the portion “b” of the bottom cowling (PORT) “3”.
Page 475: Installing The Bottom Cowling
Bottom cowling (PORT and STBD) Installing the bottom cowling 1. Install: • Cowling brackets • Dipstick guide See “Intake manifold” (6-24). • Cowling stays • Dampers Cowling stay 8 N·m (0.8 kgf·m, 5.9 lb·ft) 2. Install: • Bottom cowlings • Bolts (M6 × 14 mm) a.
Page 476: Apron
Apron Apron 8 N · m (0.8 kgf · m, 5.9 lb ·ft ) 8 N · m (0.8 kgf · m, 5.9 lb ·ft ) Part name ’ Remarks × Bolt M6 14 mm × Bolt M6 30 mm Apron (STBD) Apron (PORT) Nut M6...
Page 477: Cooling Water Hose And Gear Oil Changing Hose
Cooling water hose and gear oil changing hose Cooling water hose and gear oil changing hose a>b 13,14 16,17 c>d 20 N · m (2.0 kgf · m, 15 lb ·ft ) Part name ’ Remarks Part name ’ Remarks “...
Page 478: Removing The Cooling Water Hose (Oil Pan Side)
Cooling water hose and gear oil changing hose Removing the cooling water hose (oil pan side) 1. Remove: • Cooling water hose (engine side) See “Intake manifold” (6-24). 2. Remove: • Plastic ties • Cooling water hoses (oil pan side) •...
Page 479 Cooling water hose and gear oil changing hose c. Fasten the hose (gear oil) “1” and hose (air) “2” using the holders “3”. d. Install the joints “4” and “5” into the a>b hose (gear oil) “1” and hose (air) “2”, and then fasten the hoses using new g.
Page 480: Installing The Cooling Water Hose
Cooling water hose and gear oil changing hose k. Align the white paint marks “c” on the hose (gear oil) “4” and hose (air) “5”, and then fasten the grommet “6” using new plastic ties “7”. 2. Install: • Cooling water hose (engine side) See “Intake manifold”...
Page 481: Shift Actuator And Shift Rod
Shift actuator and shift rod Shift actuator and shift rod 41 N · m (4.1 kgf · m, 30 lb ·ft ) 19 N · m (1.9 kgf · m, 14 lb ·ft ) 19 N · m (1.9 kgf · m, 14 lb ·ft ) Part name ’...
Page 482: Installing The Shift Actuator And Shift Rod
Shift actuator and shift rod Installing the shift actuator and shift 1. Assemble: • SPS • Bushing • Washer • Shift rod • Clip a. Turn the protrusion “a” on the SPS “1” in the direction of the arrow using a slotted screwdriver, and then insert a suitable pin “b”...
Page 483 Shift actuator and shift rod • Clip TIP: a. Install the bushing “1” and shift actua- • Install the joint pin “2” so that the flat sides tor “2” onto the shift bracket “3”. “a” of the pin are parallel to the sides of the rod of the shift actuator “1”.
Page 484: Bottom Cowling (Front) And Flushing Hose
Bottom cowling (front) and flushing hose Bottom cowling (front) and flushing hose 19 N · m (1.9 kgf · m, 14 lb ·ft ) 19 N · m (1.9 kgf · m, 14 lb ·ft ) ’ ’ Part name Remarks Part name Remarks...
Page 485: Assembling The Bottom Cowling (Front)
Bottom cowling (front) and flushing hose Assembling the bottom cowling (front) 1. Install: • Grommets • Clamp plate 2. Assemble: • Washer “1” • Lever shaft “2” • Cowling lock lever “3” • Pin “4” • Retaining clip “5” TIP: Install the pin “4”...
Page 486 Bottom cowling (front) and flushing hose a. Install the grommet “1” and holder “2”. TIP: • Align the slots “a” on the grommet “1” and holder “2” with the protrusion “b” on the bot- tom cowling (front) “3”. • Confirm that the claw “c” of the holder “2” sticks out from the grommet “1”.
Page 487 Bottom cowling (front) and flushing hose b. Install the nipple “3” into the hose “2”, and then fasten the hose “2” using a new plastic tie “4”. TIP: Cut off the excess end of the new plastic tie to 3 mm (0.12 in) or less. c.
Page 488: Upper Case Assembly And Mount
Upper case assembly and mount Upper case assembly and mount 54 N · m (5.4 kgf · m, 40 lb ·ft ) 200 N · m (20 kgf · m, 148 lb ·ft ) 54 N · m (5.4 kgf · m, 40 lb ·ft ) 26 27 54 N ·...
Page 489: Removing The Upper Case Assembly
Upper case assembly and mount Removing the upper case assembly 1. Drain: • Engine oil See step 5 in “Changing the engine oil by removing the drain bolt” (10-11). 2. Suspend: • Upper case assembly 3. Remove: • Caps • Upper mount bolts •...
Page 490 Upper case assembly and mount [2] [1] [2] [1] [1] [2] [1] [2] [4] [5] [4] [5] [5] [4] [5] [4] 3. Install: A. PORT • Washers “1” B. STBD • Damper “2” • Upper case assembly “a” Upper mount bracket bolt “1” •...
Page 491 Upper case assembly and mount d. Fasten the grommet “5” and SCU lead c. Fasten the PTT motor lead “1” and PTT “2” using a new plastic tie “6” so that sensor lead “3” using a new plastic tie the lower edge of the grommet over- “6”...
Page 492 Upper case assembly and mount PORT Distance “c” 10 mm (0.39 in) f. Route the PTT motor lead “1” and PTT sensor lead “2” through the grommet “3”, and then fasten the leads and grommet using new plastic ties “4” so that the white tape “a”...
Page 493: Exhaust Guide
Exhaust guide Exhaust guide 42 N · m (4.2 kgf · m, 31 lb ·ft ) 42 N · m (4.2 kgf · m, 31 lb ·ft ) WR-No.2 WR-No.2 1.3 N · m (0.13 kgf · m, 0.95 lb ·ft ) 42 N ·...
Page 494: Checking The Exhaust Guide
Exhaust guide Checking the exhaust guide 1. Clean: • Removed parts 2. Check: • Exhaust guide Corroded/cracked → Replace. [2] [16] [2] [16] [16] [16] [16] [3] [2] [3] [2] [15] [15] [15] [15] [15] [14] [14] [14] [14] [14] Installing the exhaust guide [6] [5] [6] [5]...
Page 495 Exhaust guide Installation depth “a” 0.30–0.90 mm (0.0118–0.0354 6. Install: • Plate “1” TIP: Install the plate “1” so that the portion “a” of the plate contacts the protrusion “b”. Clamp screw 1.3 N·m (0.13 kgf·m, 0.95 lb·ft) 5. Install: •...
Page 496: Upper Case, Muffler, And Oil Pan
Upper case, muffler, and oil pan Upper case, muffler, and oil pan 42 N · m (4.2 kgf · m, 31 lb ·ft ) 42 N · m (4.2 kgf · m, 31 lb ·ft ) 42 N · m (4.2 kgf · m, 31 lb ·ft ) 42 N ·...
Page 497: Disassembling The Upper Case
Upper case, muffler, and oil pan Disassembling the upper case 2. Check: • Muffler 1. Remove: Corroded/cracked → Replace. • Drive shaft bushing “1” Checking the PCV 1. Check: • PCV Damaged → Replace. • Grommet Deformed → Replace. • Spring Corroded/deformed/fatigued →...
Page 498: Assembling The Upper Case
Upper case, muffler, and oil pan Assembling the upper case 1. Install: • Grommet • Drive shaft bushing “1” Oil pan bolt “1”, “2” 1st: 42 N·m (4.2 kgf·m, 31 lb·ft) 2nd: 42 N·m (4.2 kgf·m, 31 lb·ft) WR-No.2 WR-No.2 b.
Page 499 Upper case, muffler, and oil pan TIP: • Check that the rubber seal where the water pipe is inserted is installed properly, there is no foreign material on the rubber seal, and so on. • Install the water pipe completely. [12] [12] [12]...
Page 500: Steering Actuator And Steering Arm
Steering actuator and steering arm Steering actuator and steering arm 27 N · m (2.7 kgf · m, 20 lb ·ft ) 2.0 N · m (0.20 kgf · m, 1.5 lb ·ft ) 2.0 N · m (0.20 kgf · m, 1.5 lb ·ft ) 13 N ·...
Page 501: Removing The Steering Actuator (With The Power Unit Installed)
Steering actuator and steering arm Removing the steering actuator (with • Rigging grommet See “Power unit assembly” (7-13). the power unit installed) 6. Disconnect: The steering actuator can be removed even • PTT switch coupler “a” when the power unit is installed. •...
Page 502: Removing The Power Steering Unit (With The Power Unit Removed)
Steering actuator and steering arm a. Remove the cotter pin “1”, nut “2”, and manual steering lever “3”. b. Remove the bolts “1”. 11. Remove: • Protector cover • SCU lead (from the holders and exhaust guide) See “Upper case assembly and mount” c.
Page 503: Removing The Steering Arm
Steering actuator and steering arm Removing the steering arm Length “b” 50 mm (1.97 in) 1. Remove: • Ground lead e. Remove the protrusions “a” and “b” on • Circlip the steering arm joint “c” from the hole • Steering yoke “1” “d”...
Page 504: Checking The Steering Arm And Steering Arm Joint
Steering actuator and steering arm Installing the steering arm 1. Install: • Steering arm bushings (into the swivel bracket) • Washers • Steering arm • O-ring • Steering yoke • Circlip • Ground lead a. Install the steering yoke “1” so that it faces the same direction as the steer- ing arm “2”...
Page 505: Installing The Steering Actuator (With The Power Unit Removed)
Steering actuator and steering arm TIP: TIP: Inject grease into the grease nipple “1” until • Fit the grommets “a” on the SCU positive grease “a” comes out from both the upper and lead “b” and SCU negative lead “c” into the lower bushings.
Page 506 Steering actuator and steering arm into the hole “d” and slots “e” in the steering actuator “2”, and install the steering arm joint to the steering actu- ator. e. Install the steering arm joint bolts tem- porarily. Length “b” 50 mm (1.97 in) b.
Page 507: Installing The Steering Actuator (With The Power Unit Installed)
Steering actuator and steering arm *. Apply Valvoline X-ALL. h. Tighten the steering arm joint bolts “1”. Steering shaft end nut “2” 60 N·m (6.0 kgf·m, 44 lb·ft) Installing the steering actuator (with the power unit installed) If the steering actuator is removed, the calibra- tion is required after installation.
Page 508 Steering actuator and steering arm 6. Connect: • PTT switch coupler “a” • Main wire harness coupler “b” Electrical management box termi- nal nut 7.6 N·m (0.76 kgf·m, 5.6 lb·ft) 3. Install: 7. Install: • Protector cover • Rigging grommet •...
Page 509 Steering actuator and steering arm 10. Connect: • Battery cables 11. Install: • Apron (STBD) See “Apron” (9-8). • Bottom cowlings (PORT and STBD) See “Bottom cowling (PORT and STBD)” (9-3). • Apron cover • Bottom cowling cover • Top cowling See “Bottom cowling cover and apron cover”...
Page 510: Clamp Bracket And Swivel Bracket
Clamp bracket and swivel bracket Clamp bracket and swivel bracket 18 N · m (1.8 kgf · m, 13 lb ·ft ) 18 N · m (1.8 kgf · m, 13 lb ·ft ) 3.0 N · m (0.30 kgf · m, 2.2 lb ·ft ) 3.0 N ·...
Page 511: Removing The Clamp Bracket
Clamp bracket and swivel bracket Removing the clamp bracket 1. Remove: • PTT unit See “Removing the PTT unit” (9-46). Checking the clamp bracket anode 1. Check: • Anode Eroded (1/2 or more worn out) → Replace. Adhered is grease, oil, paint, or scales → Clean.
Page 512 Clamp bracket and swivel bracket Bracket bolt 18 N·m (1.8 kgf·m, 13 lb·ft) Grease nipple 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 2. Inject: • Grease TIP: Inject grease into the grease nipples “1” until grease comes out from both the port and star- board bushings “2”.
Page 513: Ptt Unit
PTT unit PTT unit 3.3 N · m (0.33 kgf · m, 2.4 lb ·ft ) 55 N · m (5.5 kgf · m, 41 lb ·ft ) 55 N · m (5.5 kgf · m, 41 lb ·ft ) 3.6 N ·...
Page 514: Removing The Ptt Unit
PTT unit Removing the PTT unit When removing or installing the PTT unit with the power unit or upper case assembly installed, make sure to suspend the out- board motor. 1. Remove: • PTT unit a. Connect the battery jumper leads to the PTT motor lead “a”...
Page 515 PTT unit PTT motor lead Battery TIP: Use a clamp meter “1” that can measure DC Blue (L) Extend 100 A or more. Green (G) (–) c. Remove the reservoir cap “1”, and then check the fluid level in the reservoir. Before removing the reservoir cap “1”, make sure that the PTT rams are fully ex- tended.
Page 516: Bleeding The Ptt Unit
PTT unit PTT motor lead Battery Green (G) Retract Blue (L) (–) Clamp meter “1” (commercially available) Electric current Down PTT motor lead Battery 43-59 A Green (G) Retract Bleeding the PTT unit Blue (L) (–) 1. Bleed: e. Reverse the connection between bat- •...
Page 517: Installing The Ptt Unit
PTT unit TIP: If the fluid is below the proper level, add the recommended PTT fluid. Repeat steps (c)–(g) until the fluid remains at the proper level. i. Install a new O-ring and the reservoir cap. Reservoir cap 7 N·m (0.7 kgf·m, 5.2 lb·ft) Installing the PTT unit When removing or installing the PTT unit PTT unit mounting bolt...
Page 518 PTT unit • PTT sensor lead TIP: • Plate Install the upper mount shaft “3” into the swiv- el bracket so that the groove “d” in the shaft is facing in the direction shown. Do not install the PTT sensor to the upper mounting shaft while the sensor is installed to the adapter.
Page 519 PTT unit TIP: • Route the PTT sensor lead so that they con- tact the points “a” of the swivel bracket. • Align the white tape “b” on the PTT sensor lead “1” with the plate “2”. Plate bolt “3” 3.3 N·m (0.33 kgf·m, 2.4 lb·ft) h.
Page 520: Ptt Motor
PTT motor PTT motor 15 N · m (1.5 kgf · m, 11 lb ·ft ) 15 N · m (1.5 kgf · m, 11 lb ·ft ) 7 N · m (0.7 kgf · m, 5.2 lb ·ft ) Part name ’...
Page 521: Removing The Reservoir
PTT motor Removing the reservoir 2. Measure: • Commutator diameter “a” Out of specification → Replace the arma- Before removing the reservoir, make sure ture. that the PTT rams are fully extended. Oth- erwise, fluid could be expelled forcefully from the PTT unit due to internal pressure. Disassembling the PTT motor 1.
Page 522: Checking The Brush
PTT motor 3. Check: Armature for continuity • PTT motor base assembly “a” “b” “c” “d” Cracked/damaged → Replace the PTT motor assembly. Checking the reservoir Checking the brush 1. Check: 1. Measure: • Reservoir • Brush length Cracked/damaged → Replace. Checking the filter 1.
Page 523: Installing The Reservoir
PTT motor Reservoir mounting bolt TIP: 15 N·m (1.5 kgf·m, 11 lb·ft) Push the brushes “2” into the holders, and Reservoir cap then install the armature “1”. 7 N·m (0.7 kgf·m, 5.2 lb·ft) Installing the PTT motor When assembling the PTT unit, do not use a rag.
Page 524 PTT motor PTT motor mounting bolt 15 N·m (1.5 kgf·m, 11 lb·ft) 9-56...
Page 525: Ptt Gear Pump
PTT gear pump PTT gear pump 13,16,32 33 36 38 a>b 1.8 N · m (0.18 kgf · m, 1.3 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 ’...
Page 526 PTT gear pump 13,16,32 33 36 38 a>b 1.8 N · m (0.18 kgf · m, 1.3 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 ) ’...
Page 527: Disassembling The Gear Pump Assembly
PTT gear pump Disassembling the gear pump assembly 1. Remove: • Valve lock screw “1” TIP: Before removing the valve lock screw “1”, measure and write down the screw depth “a”. Checking the gear pump housing 1. Check: • Gear pump housing Corroded/cracked →...
Page 528 PTT gear pump • Valve support pin “9” 4. Install: • Spring “1” • Plate “2” • Pin “3” • Spring “4” • Valve lock screw “5” 2. Install: • Balls “1”, “2” TIP: • O-ring “3” • Install the valve lock screw “5” to the depth •...
Page 529: Installing The Gear Pump Assembly
PTT gear pump • Relief valve seat “6” Relief valve seat bolt “7” 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) Installing the gear pump assembly 1. Install: • Plate • Filters • O-rings • Gear pump assembly • Manual valve • Circlip Manual valve 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 9-61...
Page 530: Ptt Cylinder
PTT cylinder PTT cylinder 160 N · m (16 kgf · m, 118 lb ·ft ) 65 N · m (6.5 kgf · m, 48 lb ·ft ) 15 N · m (1.5 kgf · m, 11 lb ·ft ) 30 29 65 N ·...
Page 531 PTT cylinder 160 N · m (16 kgf · m, 118 lb ·ft ) 65 N · m (6.5 kgf · m, 48 lb ·ft ) 15 N · m (1.5 kgf · m, 11 lb ·ft ) 30 29 65 N ·...
Page 532: Removing The Tilt Ram
PTT cylinder Removing the tilt ram Before removing the tilt cylinder end screw, make sure that the PTT rams are fully ex- tended. Otherwise, fluid could be expelled forcefully from the PTT unit due to internal pressure. 1. Remove: • Pipe “1” 5.
Page 533: Checking The Tilt Cylinder And Trim Cylinder
PTT cylinder 2. Drain: • Fluid Checking the tilt cylinder and trim cylinder 1. Check: • PTT body • Tilt cylinder Corroded/cracked → Replace. 2. Check: 2. Install: • Inner surface of the PTT body • Dust seal “1” • Inner surface of the tilt cylinder •...
Page 534: Installing The Tilt Cylinder
PTT cylinder • Tilt cylinder end screw “1” Installing the tilt cylinder • Tilt cylinder end “2” • Spring “3” When assembling the PTT unit, do not use • Adapter “4” a rag. Otherwise, dust and particles could • O-ring “5” get on the PTT unit components, causing •...
Page 535: Installing The Tilt Ram
PTT cylinder TIP: • Fill the tilt cylinder and PTT body with the recommended fluid up to the proper level “a”. • Place the tilt cylinder end “1” at the bottom of the tilt ram assembly. 2. Install: • Trim ram assemblies “1” Cylinder end screw wrench “2”...
Page 536 PTT cylinder TIP: Place a block of wood “a” between the tilt cyl- inder and the PTT body to secure the tilt cylin- der when tightening the tilt cylinder end screw “1”. 0.031 m Cylinder end screw wrench “2” 90890-06958 Torque wrench setting value = 150 N·m ÷...
Page 537: Maintenance
Maintenance Outline ................10-1 Maintenance interval chart 1 ............ 10-1 Maintenance interval chart 2 ............ 10-4 General periodic maintenance........10-5 Checking the battery ..............10-9 Checking the cooling water pilot hole........10-9 Checking the engine idle speed..........10-9 Checking the engine oil level..........10-10 Changing the engine oil using an oil changer ......
Page 538: Maintenance Interval Chart
• If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and quality. Any parts of inferior quality may cause a malfunction, and the resulting loss of control could endan- ger the operator and passengers.
Page 539 Outline Initial Every Item Actions hours hours hours hours (1 year) months) years) years) 10-10   Engine oil Replacement 10-11 Engine oil filter (car-  Replacement 10-13 tridge) Fuel filter (can be dis- Inspection or replace- / / assembled) ment as necessary Fuel line (Direct injec- ...
Page 540  switch ment as necessary 5-42 Wire harness connec- Inspection or replace-   tions/wire coupler con- ment as necessary nections   (Yamaha) Meter/gauge Inspection — Inspection or replace- 9-32     ment as necessary 9-42 10-3...
Page 541 Outline Maintenance interval chart 2 Every Item Actions 1000 hours Exhaust guide/ex- Inspection or replace-  7-11 haust manifold ment as necessary 9-26  Timing belt Replacement 7-42 Inspection or replace-  Cam chain 7-49 ment as necessary Inspection or replace- ...
Page 542 General periodic maintenance General periodic maintenance Item Procedures 7-12 7-38 Check the anodes. 7-66 Eroded (1/2 or more worn out) → Replace. Anodes 7-73 Adhered grease, oil, paint, or scales → Clean. 7-76 9-43 Check the battery electrolyte level. Below the minimum level mark → Add distilled water. Battery 10-9 Check the specific gravity of the electrolyte.
Page 543 General periodic maintenance Item Procedures Turn the main switch (or “POWER” switch) to ON, and then push 5-41 the engine start/stop button. Check that the engine starts. 5-41 Out of specification → Check the main switch (or “POWER” 5-42 switch) or engine start/stop button. 5-43 Main switch (or Start the engine.
Page 544 General periodic maintenance Item Procedures Check the gear oil level. 10-14 Below the proper level → Add the recommended gear oil. Check the gear oil. Gear oil Replacement interval has been exceeded/deterioration → 10-15 Change. 10-17 Milky → Overhaul the lower unit. OCV filter Replace the OCV gasket.
Page 545 Cracked/damaged → Replace. Check the impeller key and keyway in the drive shaft. Deformed/worn → Replace. Wire harness Check the wire harness coupler and lead coupler connections. — Yamaha Check the gauge display. — Gauge Check that the steering operates smoothly. 9-32 Not smooth →...
Page 546: Checking The Battery
General periodic maintenance Checking the battery 2. Check: • Specific gravity of the electrolyte Below specification → Fully charge the Battery electrolyte is dangerous; it contains battery. sulfuric acid, which is poisonous and highly TIP: caustic. Always follow these preventive •...
Page 547: Checking The Engine Oil Level
General periodic maintenance Changing the engine oil using an oil Idle speed (in neutral) changer 650–750 r/min Checking the engine oil level Change the engine oil after the first 20 hours of operation or 3 months, and every 100 hours or at 1-year intervals thereafter. Make sure that the engine is filled with en- gine oil before operating the outboard mo- 1.
Page 548 General periodic maintenance a. Fill the engine with the specified Changing the engine oil by removing amount of the recommended engine oil the drain bolt through the oil filler hole. Install the oil filler cap and dipstick. Change the engine oil after the first 20 hours of operation or 3 months, and every Do not overfill the engine with engine oil.
Page 549 General periodic maintenance 6. Check: • Oil strainer See “Checking the oil pan and oil strainer” (9-29). 4. Remove: 7. Install: • Apron (PORT) “1” • Oil strainer “1” • Circlip “2” • O-ring “3” • Drain bolt “4” Drain bolt 5.
Page 550: Replacing The Oil Filter
General periodic maintenance b. Leave the outboard motor off for 5–10 • Top cowling minutes. TIP: c. Remove the dipstick “1” and wipe it Align the seam “a” of the rubber seal “3” with clean. the mating surface “b” of the bottom cowling. d.
Page 551: Checking The Gear Oil Level
General periodic maintenance a. Place a rag under the oil filter, and then Engine oil quantity (with oil filter remove the oil filter. replacement) 7.8 L (8.24 US qt, 6.86 Imp.qt) TIP: Make sure to clean up any oil spills. b.
Page 552 General periodic maintenance a. Fully tilt the outboard motor up, and then support it using the tilt support le- ver “1”. Oil level plug 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) Upper water inlet cover bolt b. Remove the bands “1”. 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) Changing the gear oil using an oil changer...
Page 553 General periodic maintenance Gear oil attachment kit “1” 90890-06963 After the gear oil has been drained, check Oil socket “2” the used oil. If the oil is milky, water is get- 90890-06964 ting into the lower case, which can cause Air socket “3”...
Page 554 General periodic maintenance d. Fill the lower unit slowly with gear oil until oil “a” flows out of the air socket “1”. f. Disconnect oil socket and air socket by wrapping a rag around the socket, and then sliding the portion “a” of the sock- et in the direction of the arrow.
Page 555 General periodic maintenance TIP: Before installing the magnetic drain screw, make sure to remove all metal particles. 4. Remove: • Oil filler plug “3” • O-ring “4” 2. Drain: • Gear oil a. Tilt the outboard motor so that the drain screw is at the lowest point.
Page 556: Greasing Points
General periodic maintenance Gear oil quantity (regular rotation model) 1.950 L (2.061 US qt, 1.716 Imp.qt) Gear oil quantity (counter rota- tion model) 1.830 L (1.934 US qt, 1.610 Imp.qt) d. Remove the gear oil pump, and then in- stall a new O-ring “1” and the oil filler plug “2”.
Page 557: Checking The Ptt Fluid Level
General periodic maintenance b. Apply corrosion resistant grease to the specified lubrication point. Before removing the reservoir cap, make sure that the PTT ram is fully extended. Otherwise, fluid could be expelled forceful- ly from the unit due to internal pressure. TIP: •...
Page 558 General periodic maintenance 3. Check: A. Front • Fluid leakage B. PORT and STBD Leaking → Check the related parts. c. Tighten the cowling stopper nut. See “PTT motor” (9-52), “PTT gear pump” (9-57), or “PTT cylinder” (9-62). Cowling stopper nut 17 N·m (1.7 kgf·m, 13 lb·ft) Checking the top cowling fitting d.
Page 559: 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 10-10 Oil is not at the proper level → Add or extract engine oil. Check the battery electrolyte level.
Page 560 Predelivery check Item Procedures 8-11 Check that the gear shift operates properly when the remote 8-18 control lever is moved from the N position to the F or R position. 8-48 Not properly → Check the shift actuator and related parts. 9-13 Shift and throttle op- eration...
Page 561 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 ap- — proximately 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 562: Checking The Outboard Motor Mounting Height
Predelivery check Checking the outboard motor mounting height 1. Check: • Outboard motor mounting height Improper → Adjust. a. Check that the anti-cavitation plate “1” is aligned with the bottom of the boat “2”. TIP: • If the mounting height is too high, cavitation will occur and propulsion will decrease.
Page 563 Appendix Specification ...............A-1 Model data ................. A-1 Electrical system technical data..........A-3 Fuel system technical data............A-5 Power unit technical data............A-5 Lower unit technical data ............A-7 Bracket unit technical data ............A-8 Wiring diagram ..............A-9 How to use the wiring diagram ..........A-9 Engine control unit ..............
Page 564 Specification Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 Throttle & shift control Model data Remote control system Dimension and weight Starting system Electric starter Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 Fuel system Fuel injection Overall length 1217 mm (47.9 in) Starting carburetion Fuel injection Overall width 652 mm (25.7 in) system...
Page 565 Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 Fuel and oil Battery requirement Recommended fuel Premium unleaded gasoline 700 A 700 A (F450AVTE_*NC 94 (F450AVTE, (FL450AVTE_*N 94 (FL450AVTE, F450AVTU_*EC FL450AVTU_*E Battery rating (CCA/ F450AVTU_*EC 3/*EC4/*EE/ FL450AVTU_*E — C3/*EC4/*EE/ SAE) 3/*EC4/*NC, Min.
Page 566 Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 Battery cable length 3.55 m (11.6 ft) Resistance at 20 °C 2.25–2.65 kΩ (68 °F) Battery cable conduc- 60 mm² (AWG 2/0) tor cross sectional area Resistance at 80 °C 0.31–0.33 kΩ...
Page 567 Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 TPS 2 output voltage at Rod stroke at gear shift throttle valve fully open 4.640 V in the N position (refer- 82.0 mm (3.23 in) (reference data) ence data) Throttle valve opening Rod stroke at gear shift angle at throttle valve in the R position (refer-...
Page 568 Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 Buzzer Relief valve (high-pressure fuel pump) Input voltage 12 V Holding pressure (posi- 490.0 kPa (4.90 kgf/cm², 71.1 psi) tive pressure) Button cell battery - CR2016 Opening pressure (posi- Battery voltage (refer- 445.0–455.0 kPa (4.45–4.55 kgf/cm², 64.5–66.0 psi) tive pressure) ence data)
Page 569 Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 Timing belt Valve Installation height (bot- Margin thickness IN 0.50–0.90 mm (0.0197–0.0354 in) tom of drive sprocket Margin thickness EX 0.90–1.30 mm (0.0354–0.0512 in) 3.25 mm (0.1280 in) [crankshaft] to bottom Seat contact width IN 1.10–1.40 mm (0.0433–0.0551 in) of timing belt)
Page 570 Crankcase assembly Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 End gap 0.15–0.60 mm (0.0059–0.0236 in) Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 Side clearance 0.04–0.12 mm (0.0016–0.0047 in) Cylinder Connecting rod Bore 96.000–96.012 mm (3.7795–3.7800 in) Small end inside diame- Limit 96.072 mm (3.7824 in) 22.008–22.025 mm (0.8665–0.8671 in) Piston Big end inside diameter...
Page 571 Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 Model F450A/XF450 FL450A/XF450 F400A/XF400 FL400A/XF400 0.10/0.12/0.15/ 0.10/0.12/0.15/ 0.10/0.12/0.15/ 0.10/0.12/0.15/ Reverse shims 0.18/0.30/0.40/ — 0.18/0.30/0.40/ — Propeller shaft shims — 0.18/0.30/0.40/ — 0.18/0.30/0.40/ 0.50 mm 0.50 mm 0.50 mm 0.50 mm 0.10/0.12/0.15/ 0.10/0.12/0.15/ Propeller shaft Propeller shaft shims 0.18/0.30/0.40/ —...
Page 572: Wiring Diagram
Wiring diagram Wiring diagram How to use the wiring diagram Composition of the wiring diagrams The wiring diagram consists of five categories: “Engine control unit”, “Fuel unit”, “Ignition unit”, “Charging unit and starting unit”, and “PTT unit and steering unit”. Legend symbols in the wiring diagrams 1.
Page 573 Engine control unit 3.Bonder 8 4.Bonder 6 2.Bonder 5 (PORT) (STBD) 7.Engine battery 5.OCV 6.Shift actuator <A> <B> <A> <B> 8.Electrical management box (fuse box) <C> <B> <A> <A> <A> <B> <A> <B> <C> <B> <C> <C> 1.Engine ECM <A> Twist Twist Twist...
Page 574 Wiring diagram B. To Digital Electronic Control 1. Engine ECM 2. BONDER 5 3. BONDER 8 4. BONDER 6 5. OCV 6. Shift actuator 7. Engine battery 8. Electrical management box (fuse box) 9. Joint connector 1 10. Joint connector 2 11.
Page 575 Fuel unit 5.Bonder 5 8.Low-pressure 4.Direct 7.Low-pressure fuel pump 4.Direct injection pump injection pump fuel pump relay <A> <A><B> <A><B> <B> (STBD) (PORT) 6.High-pressure 9.Electrical management fuel pump box (fuse box) (sub) (main) 10.Engine battery 3.Fuel injector 3.Fuel injector <A> <A><B>...
Page 576 Wiring diagram 1. Engine ECM A. To Digital Electronic Control 2. Injector driver 3. Fuel injector 4. Direct injection pump 5. BONDER 5 6. High-pressure fuel pump (main), (sub) 7. Low-pressure fuel pump relay 8. Low-pressure fuel pump 9. Electrical management box (fuse box) 10.
Page 577 Ignition unit 3.Bonder 6 4.Bonder 4 5.Bonder 5 6.Engine battery 2.Ignition coil <A> <A> <B> <B> 7.Electrical management box (fuse box) <C> <B> <A> <A> <A> <B> <A> <B><C> <B><C> <C> 1.Engine ECM <A> Twist Twist Twist Twist Twist <B> (upper) (lower) (PORT) (STBD)
Page 578 Wiring diagram 1. Engine ECM 2. Ignition coil 3. BONDER 6 4. BONDER 4 5. BONDER 5 6. Engine battery 7. Electrical management box (fuse box) 8. Joint connector 1 9. Joint connector 2 10. Knock sensor 11. Thermo sensor 12.
Page 579 Charging unit and starting unit 2.Bonder 6 3.Bonder 5 Br Br 5.Engine 6.House battery battery 7.Stator assembly 4.Starter motor 8.Rectiﬁer / regulator <A> <A> <B> <A> <B> <C> <B> <C> <C> 1.Engine ECM <C> <B> <A> <A> <B> <A> <B> <A>...
Page 580 Wiring diagram 1. Engine ECM 2. BONDER 6 3. BONDER 5 4. Starter motor 5. Engine battery 6. House battery 7. Stator assembly 8. Rectifier/regulator 9. Electrical management box (fuse box) 10. Joint connector 1 11. Joint connector 2 a. Fuse (100A) (SCU) b.
Page 581 PTT unit and steering unit 2.Bonder 8 3.Bonder 5 6.Engine battery 5.Steering actuator 4. Propeller light <A> <B> <A> <B> 7.Electrical management box (fuse box) <A> <A> <B> <A> <B> <C> <B> <C> <C> 1.Engine ECM <C> <B> <A> 8.PTT motor <A>...
Page 582 Wiring diagram 1. Engine ECM 2. BONDER 8 3. BONDER 5 4. Propeller light 5. Steering actuator 6. Engine battery 7. Electrical management box (fuse box) 8. PTT motor 9. Joint connector 1 10. Joint connector 2 11. PTT buzzer 12.
Page 583 Rectifier/regulator continuity table (F400A/FL400A/XF400A) Rectifier/regulator continuity table (F400A/FL400A/XF400A) OL: Indicates an overload Rectifier/regulator for continuity Tester probe Display value (reference data) (–) “a” All terminals “c” “b” Except for “c” “b” “c” Except for “b” “d” All terminals “d” 0.22–0.43 “e”...
Page 584 Rectifier/regulator continuity table (F400A/FL400A/XF400A) Rectifier/regulator for continuity Tester probe Display value (reference data) (–) “j” All terminals “j” 0.22–0.43 “k” Except for “j” “j” 0.22–0.43 “l” Except for “j” “j” 0.22–0.43 “m” Except for “j” 0.48–0.69 “n” “k”, “l”, “m” 0.22–0.43 Except for “j”, “k”, “l”, and “m”...
Page 585 Rectifier/regulator continuity table (F450A/FL450A/XF450A) Rectifier/regulator continuity table (F450A/FL450A/XF450A) 2 3 4 5 6 W L R OL: Indicates an overload Rectifier/regulator for continuity Tester probe Display value (reference data) (–) “e”, “f” and “g” 1.83 V “h” 1.35 V “n” 1.89 V “a”...
Page 586 Rectifier/regulator continuity table (F450A/FL450A/XF450A) Rectifier/regulator for continuity Tester probe Display value (reference data) (–) “e”, “f” and “g” 0.48 V “k”, “l”, “m”, “q”, “r” and “s” 1.08 V “n” and “t” 0.61 V “h” “v” 0.47 V Except for “e”, “f”, “g”, “k”, “l”, “m”, “n”, “q”, “r”, “s”, “t”...
Page 587 Rectifier/regulator continuity table (F450A/FL450A/XF450A) Rectifier/regulator for continuity Tester probe Display value (reference data) (–) “u” All terminals “v” All terminals A-24...
Page 588 Shim selection table and chart (regular rotation model) Pinion shim (T3) selection table The shim thickness does not have to be adjusted for the blue-colored cells. (mm) 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.46 0.47 0.48 0.49 0.50 0.51 0.52 0.53...
Page 589 Propeller shaft shim (T4) selection chart 0.10 0.09 0.08 0.07 0.06 0.05 0.04 0.03 0.02 0.01 –0.01 –0.02 –0.03 –0.04 –0.05 –0.06 –0.07 –0.08 A (N·m) 0.07 0.06 0.05 0.04 0.03 0.02 –0.02 –0.03 –0.04 –0.05 –0.06 –0.07 –0.08 –0.09 A.
Page 590 Shim selection table and chart (counter rotation model) Pinion shim (T3) selection table See “Pinion shim (T3) selection table” (A-25). Propeller shaft shim (T4) selection table The shim thickness does not have to be adjusted for the blue-colored cell. (mm) A.
Page 591 Jan. 2023 CR (E_1)
Page 592 Worldwide: (6LB) (6LC) (6KN) (6KP) USA, CAN, EUR, AUS, and NZL: (6LB) (6KN) 6KN-28197-Z2-11 LIT-18616-04-18 Jan. 2023 CR (E_1)