Page 1 F200C LF200C F225C LF225C SERVICE MANUAL *LIT186160276* LIT-18616-02-76 69J-28197-1F-11...
Page 2: Important Information
NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
Page 3 Contents General information INFO Specifications SPEC Periodic checks and adjustments Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT – Electrical systems ELEC Troubleshooting TRBL SHTG Index...
Page 4: Table Of Contents
INFO General information How to use this manual ................. 1-1 Manual format.................... 1-1 Symbols..................... 1-2 Safety while working..................1-3 Fire prevention................... 1-3 Ventilation....................1-3 Self-protection ................... 1-3 Parts, lubricants, and sealants ..............1-3 Good working practices ................1-4 Disassembly and assembly ............... 1-4 Identification....................1-4 Applicable models ..................1-4 Serial number ....................
Page 5 Predelivery checks ..................1-28 Checking the fuel system ................1-28 Checking the gear oil................1-28 Checking the engine oil ................1-28 Checking the battery................1-28 Checking the outboard motor mounting height........1-29 Checking the remote control cables ............1-29 Checking the steering wheel ..............1-30 Checking the gearshift and throttle operation..........1-30 Checking the tilt system................1-30 Checking the engine start switch and engine stop lanyard switch ..1-30...
Page 6: How To Use This Manual
INFO General information 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 information below as a guide for effective and quality service. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list.
Page 7: Symbols
Symbols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point. 7 Apply Yamaha 4-stroke motor oil 0 Apply corrosion resistant grease 8 Apply water resistant grease (Yamaha grease A) (Yamaha grease D) 9 Apply molybdenum disulfide grease...
Page 8: Safety While Working
Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the outboard motor.
Page 9: Good Working Practices
Safety while working / Identification 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. Good working practices Special tools Use the recommended special tools to pro- tect parts from damage. Use the right tool in the right manner—do not improvise. 3.
Page 10: General Information
INFO General information 1 Model name 2 Approved model code 3 Transom height 4 Serial number Approved Starting Model name model code serial No. F200TR 1001799– LF200TR 1000373– F225TR 1007259– LF225TR 1002513– 69J1D11...
Page 11: Features And Benefits
Identification / Features and benefits Features and benefits Newly developed V6 4-stroke engine The F225 is a newly developed 60-degree V6 4-stroke engine with a very compact and lightweight design. Its size and weight are almost the same as the V6 2-stroke engines that are in current use. This F225 offers numerous advantages of a 4-stroke engine.
Page 12 INFO General information Crankcase The crankcase is made of cast aluminum, however steel has been cast into the areas for the crank- shaft bearings. By distinguishing the area that requires strength from the area that allows the use of a lighter material, both weight reduction and a stronger construction have been achieved. The caps for the crankshaft bearings are secured with four bolts to ensure a high level of assembled rigidity.
Page 13 Features and benefits Piston The piston has been carved out of a forged stock. To prevent the valves from coming in contact with the piston, the piston is provided with a valve recess. If the engine goes out of timing and a valve opens when the piston is at top-dead-center, this recess prevents the valve from coming in contact with the piston, thus preventing engine damage.
Page 14: Valve Train System
INFO General information Valve train system The valve train consists of a total of four camshafts, with two in each bank. The camshafts are driven with the combination of a belt and chains. The crankshaft turns the belt to drive the exhaust camshafts in both banks. Chains connect the exhaust camshafts to the intake camshafts in the cylinder heads to drive the intake camshafts.
Page 15 Features and benefits Tensioner A timing chain tensioner is provided at the mid-span of the timing chain, between both camshafts. The timing chain tensioner uses the force of a spring to maintain its tension. After the engine is started, oil is pumped into the tensioner, and the resulting pressure causes the tension to increase. A total of three tensioners are used, one for the timing belt, and one for each timing chain of both banks, to maintain proper tension and to ensure the reliability of the valve train.
Page 16: Intake System
INFO General information Intake system Throttle valve A total of six intake throttle valves are provided, one for each cylinder. Together with the intake silencer that offers enhanced intake efficiency and the injectors that are provided at each throttle body, the throttle valves help to improve the intake efficiency of the engine. As a result, this engine produces a higher power output and realizes better driveability.
Page 17 Features and benefits Exhaust passage during idle To reduce noise when the engine is idling, the exhaust gas passage of the F225 has adopted a lab- yrinth construction. During idling, the exhaust gas passes through the passage on the side of the exhaust guide, and enters the upper case through a hole in the upper case gasket.
Page 18: Fuel System
INFO General information Fuel system The fuel flows in the following order: fuel filter, low-pressure fuel pump, vapor separator, high-pres- sure fuel pump, and injectors. The excess fuel at the injectors passes through the pressure regula- tor and fuel cooler, and returns to the vapor separator. When the engine start switch is turned on, the injectors of all cylinders operate before the pump relay is actuated to prevent the injectors from sticking.
Page 19 Features and benefits Low-pressure fuel pump The F225 has adopted a newly developed, low-pressure electrical fuel pump, in place of the low- pressure mechanical fuel pump used in the previous electronic fuel injection system. With the adop- tion of the electric pump, the routing of the fuel system has been made more compact. To prevent the over-pumping of fuel, this pump operates for 10 seconds, and stops for 20 seconds when the engine is operating at low speeds.
Page 20 INFO General information Electronic control system The ECM controls the ignition timing, the fuel injection timing, the fuel injection volume, and the ISC and it maintains a stoichiometric air-fuel ratio in all operating conditions, including starting and idling. Also, the ECM converts the signals from the input sensors and sends instructions to each part. Injector #1,4 Pulser coil #1 Injector #2,5...
Page 21 Features and benefits Ignition and fuel injection timing This engine adopted the group injection system that the fuel required for one combustion is injected twice per one cycle. Therefore, the injector driving circuits can be integrated to 3 circuits and a simpler electrical struc- ture is obtained.
Page 22: Ptt (Power Trim And Tilt) Unit
INFO General information PTT (Power trim and tilt) unit The PTT unit has been newly developed for the F225. Based on the field-proven 61A type, its PTT fluid passage and internal valve construction have been changed for this application. Although the valves of the 61A type have been distributed to the various areas of the gear pump housing, the valves of the new PTT unit have been concentrated in the vicinity of the gear pump to improve their serviceability.
Page 23: Technical Tips
Features and benefits / Technical tips Technical tips Fuel injection control The F200/F225 injects fuel simultaneously to the following cylinder pairs: #1 and #4, #2 and #5, and #3 and #6. Optimal injection timing is provided in accordance with the operating conditions of the engine.
Page 24 INFO General information Over-revolution control If the engine speed exceeds 4,500 r/min, while the shift is in neutral, ignition is stopped. The various stages of ignition cutoff are shown in the table below. Ignition cutoff cylinder in neutral Set speed (r/min) 4,500 4,750 : Indicates a misfire at either cylinder (once, due to simultaneously firing).
Page 25: Fail-Safe Function Table
Technical tips Fail-safe function table FAIL-SAFE FUNCTION DIAGNOSIS Symptom Engine CODE Ignition Injection condition Engine starting: All cylinders inject Only the cylinders simultaneously Incorrect pulser outputting normal Only in neutral: Idle speed based on the cylin- coil signal signal ignite at 900 r/min increases der that is output-...
Page 26: Ptt (Power Trim And Tilt) Unit
INFO General information PTT (Power trim and tilt) unit In the newly designed PTT unit, the up-main valve, down-main valve, up-relief valve, and down- relief valve have been concentrated in the gear pump housing in order to improve the serviceability of the engine and ensure reliable operation.
Page 27 Technical tips Trim-up and tilt-up function When the PTT switch is pressed to “UP,” the power trim and tilt motor operates the gear pump and fluid pressure is generated. As a result, the fluid pressure pushes the up-shuttle piston upward, enters the trim cylinder and tilt cylinder lower chambers through the up-main valve, and then pushes the tilt ram and trim ram upward.
Page 28 INFO General information Trim ram retraction function When the outboard motor is tilted up and held in place with the tilt stop lever and the PTT switch is pressed to “DN,” the trim ram will be retracted. Although the gear pump attempts to draw oil from the tilt cylinder and trim cylinder lower chambers, after the PTT switch has been pressed, fluid cannot be drawn from the tilt cylinder lower chamber because the tilt ram is secured in place by the tilt stop lever.
Page 29 Technical tips Trim-down and tilt-down function When the PTT switch is pressed to “DN,” the power trim and tilt motor operates the gear pump and fluid pressure is generated. As a result, the fluid pressure pushes the down-shuttle piston upward, enters the tilt cylinder upper chamber through the down-main valve, and then pushes the tilt ram downward.
Page 30 INFO General information Stationary condition When the PTT switch is not pressed, the gear pump will not pump the fluid, the up-main valve and the down-main valve will remain closed, and the PTT unit in the system remains constant. This will allow the tilt ram and the trim ram to maintain their positions until the PTT fluid flows through the system again.
Page 31: Cooling System
Technical tips Cooling system S69J1460 1 Cooling water inlet 6 In-bank exhaust system 2 Water pump 7 Thermostat 3 Oil pan 8 Propeller boss 4 Exhaust pipe È Water 5 PCV (Pressure control valve) Lubrication system Cylinder head Crankcase Pressure feed Splash Sleeve Return...
Page 32: Propeller Selection
INFO General information a Propeller diameter (in inches) Propeller selection b Propeller pitch (in inches) The performance of a boat and outboard c Propeller type (propeller mark) motor will be critically affected by the size and type of propeller you choose. Propellers Selection greatly affect boat speed, acceleration, When the engine speed is at the full throttle...
Page 33: Predelivery Checks
Propeller selection / Predelivery checks Predelivery checks Checking the engine oil 1. Check the oil level. To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel.
Page 34: Checking The Outboard Motor Mounting Height
INFO General information Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced. Also, the engine speed will increase abnormally and cause the engine to overheat.
Page 35: Checking The Steering Wheel
Predelivery checks Checking the steering wheel Checking the tilt system 1. Check the steering friction for proper 1. Check that the outboard motor tilts up adjustment. and down smoothly when operating the power trim and tilt unit. 2. Check that steering operates smoothly.
Page 36: Checking The Cooling Water Pilot Hole
INFO General information Checking the cooling water pilot hole 1. Check that cooling water is discharged from the cooling water pilot hole. S69J1240 È Hour After test run 1. Check for water in the gear oil. S69J1230 2. Check for fuel leakage in the cowling. Test run 1.
Page 37 SPEC Specifications General specifications................... 2-1 Maintenance specifications ................2-3 Power unit....................2-3 Lower unit ....................2-6 Electrical ....................2-7 Dimensions....................2-11 Tightening torques..................2-14 Specified torques..................2-14 General torques..................2-17 69J1D11...
Page 38: General Specifications
SPEC Specifications General specifications Model Item Unit F200TR LF200TR F225TR LF225TR Dimension Overall length mm (in) 892 (35.1) Overall width mm (in) 634 (25.0) Overall height mm (in) 1,805 (71.1) mm (in) — 1,932 (76.1) Boat transom height mm (in) 635 (25.0) mm (in) —...
Page 39 General specifications Model Item Unit F200TR LF200TR F225TR LF225TR Fuel and oil Fuel type Regular unleaded gasoline (*1) Fuel rating Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, SH, or SJ 10W-30 or 10W-40 Engine oil quantity (with oil filter replacement) 6.0 (6.3, 5.3) (US qt, lmp qt)
Page 40: Maintenance Specifications
SPEC Specifications Maintenance specifications Power unit Model Item Unit F200TR LF200TR F225TR LF225TR Power unit Minimum compression 880 (8.8, 125) (*1) pressure (kgf/cm , psi) (*2) Lubrication oil pressure kPa (kgf/cm 650 (6.5, 924) psi) at 700 r/min Cylinder heads Warpage limit mm (in) 0.1 (0.004)
Page 41 Maintenance specifications Model Item Unit F200TR LF200TR F225TR LF225TR 2nd ring Dimension B mm (in) 1.17–1.19 (0.0461–0.0468) Dimension T mm (in) 3.6–3.8 (0.142–0.150) End gap mm (in) 0.30–0.45 (0.0118–0.0177) Side clearance mm (in) 0.03–0.07 (0.0012–0.0027) Oil ring Dimension B mm (in) 2.40–2.47 (0.0945–0.0972) Dimension T mm (in)
Page 42 SPEC Specifications Model Item Unit F200TR LF200TR F225TR LF225TR Valve springs Free length mm (in) 44.20 (1.740) Minimum free length mm (in) 42.60 (1.677) Tilt limit mm (in) 1.5 (0.06) Valve lifters Valve lifter outside diameter mm (in) 32.98–33.00 (1.2984–1.2992) Valve lifter-to-cylinder head mm (in) 0.02–0.05 (0.0008–0.0020)
Page 43: Lower Unit
Maintenance specifications Model Item Unit F200TR LF200TR F225TR LF225TR Oil pump Discharge L (US gal, 8.8 (2.32, 1.94) at 97–103 °C (207–217 °F) Imp gal)/min with 10W-40 engine oil at 700 r/min Pressure 138 (1.38, 19.62) (kgf/cm , psi) Relief valve opening pressure 529–647 (5.29–6.47, 75.22–92.00) (kgf/cm , psi)
Page 44: Electrical
SPEC Specifications Electrical Model Item Unit F200TR LF200TR F225TR LF225TR Ignition and ignition control system Pulser coil output peak voltage (W/R – B, W/B – B, W/G – B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Ω...
Page 45 Maintenance specifications Model Item Unit F200TR LF200TR F225TR LF225TR Fuel control system (*1) Fuel injector resistance Ω at 20 °C (68 °F) 14.0–15.0 Starter motor Type Sliding gear Output Cranking time limit Second Brushes Standard length mm (in) 15.5 (0.61) Wear limit mm (in) 9.5 (0.37)
Page 46 SPEC Specifications Model Item Unit F200TR LF200TR F225TR LF225TR Power trim and tilt system Trim sensor Ω Setting resistance 9–11 Ω Resistance (P – B) 9–387.6 Fluid type ATF Dexron II Brushes Standard length mm (in) 12.0 (0.47) Wear limit mm (in) 4.0 (0.16) Commutator...
Page 47 Maintenance specifications — MEMO — 2-10 69J1D11...
Page 48: Dimensions
SPEC Specifications Dimensions Exterior 12˚ S69J2130 2-11 69J1D11...
Page 49 Maintenance specifications Model Symbol Unit F200TR LF200TR F225TR LF225TR mm (in) 651 (25.6) mm (in) 219 (8.6) mm (in) — mm (in) 673 (26.5) mm (in) 59 (2.3) mm (in) — 59 (2.3) mm (in) 1,155 (45.5) mm (in) — 1,272 (50.1) mm (in) 618 (24.3)
Page 50 SPEC Specifications Clamp bracket S69J2140 Model Symbol Unit F200TR LF200TR F225TR LF225TR mm (in) 125 (4.9) mm (in) 254 (10.0) mm (in) 163 (6.4) mm (in) 51 (2.0) mm (in) 180 (7.1) mm (in) 411 (16.2) mm (in) — mm (in) —...
Page 51: Tightening Torques
Maintenance specifications / Tightening torques Tightening torques Specified torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel system Fuel filter holder bolt Fuel filter bracket bolt Intake air temperature sensor — Low-pressure fuel pump bracket bolt Fuel cooler nut —...
Page 52 SPEC Specifications Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Spark plug — Cylinder head bolt 90° Engine hanger bolt Cooling water cover bolt Starboard cylinder head plug — Cylinder block plug — Engine temperature sensor — Connecting rod cap —...
Page 53 Tightening torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Upper case mount nut — Engine oil drain bolt Apron stay — Pressure control valve — Upper exhaust guide bolt Oil strainer bolt Oil pan bolt Exhaust manifold bolt Muffler bolt Baffle plate screw Clamp bracket self-locking nut...
Page 54: General Torques
SPEC Specifications General torques This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this man- ual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and pro- gressive stages until the specified torque is reached.
Page 55 Periodic checks and adjustments Special service tools ..................3-1 Maintenance interval chart................3-2 Top cowling ....................3-4 Checking the top cowling................3-4 Fuel system ....................3-4 Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) ....3-4 Measuring the fuel pressure (high-pressure fuel line) ....... 3-5 Checking the fuel filter ................
Page 56: Chk Adj
Periodic checks and adjustments Special service tools Fuel pressure gauge YB-06766 Inductive self-powered tachometer YU-08036-B Battery powered timing light YM-33277-A Pressure/vacuum tester YB-35956-A 69J1D11...
Page 57: Maintenance Interval Chart
Special service tools / Maintenance interval chart Maintenance interval chart Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Initial Every Refer to Item Remarks page Top cowling Top cowling fit Check...
Page 58 Periodic checks and adjustments Initial Every Refer to Item Remarks page Lower unit Gear oil Change 3-17 Impeller/Woodruff key Check/replace (500 hours 6-8, or 30 months) 6-34 Oil seals Check/replace — Propeller Check (before each use) 3-18 General Anodes/Trim tab Check/replace 3-18 Battery...
Page 59: Top Cowling
Maintenance interval chart / Top cowling / Fuel system Top cowling Checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. Fuel system Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) 1.
Page 60: Measuring The Fuel Pressure (High-Pressure Fuel Line)
Periodic checks and adjustments Measuring the fuel pressure (high-pressure fuel line) 1. Remove the cap 1. 2. Install the fuel pressure gauge onto the pressure check valve. È NOTE: Be sure not to spill any fuel when removing the fuel filter cup. Power unit Checking the engine oil Fuel pressure gauge: YB-06766...
Page 61: Changing The Engine Oil Using An Oil Changer
Fuel system / Power unit Changing the engine oil using an oil 6. Install the oil filler cap and dipstick, and then start the engine and warm it up for 5 changer minutes. 1. Start the engine and warm it up. 7.
Page 62: Replacing The Oil Filter
Periodic checks and adjustments S69J3140 Apron bolt: 8 N·m (0.8 kgf·m, 5.8 ft·lb) Replacing the oil filter NOTE: 1. Extract the engine oil with an oil changer Be sure to clean up any oil spills. or drain it. 2. Remove the oil filter cover 1. 5.
Page 63: Checking The Timing Belt
Power unit 5. Install the oil filter, and then tighten it to 3. Turn the crankshaft clockwise two turns the specified torque using a 72.5 mm to take up slack in the timing belt. (2.9 in) oil filter wrench. Replacing the timing belt NOTE: For replacement procedures, see Chapter 5, “Replacing the timing belt.”...
Page 64: Checking The Thermostat
Periodic checks and adjustments 5. Check the spark plug gap a. Adjust if out of specification. Specified spark plug: LFR5A-11 (NGK) Spark plug gap a: 1.0–1.1 mm (0.039–0.043 in) S69J3220 6. Install the spark plug, tighten it finger tight b, then to the specified torque with 2.
Page 65: Adjusting The Throttle Link And Throttle Cable Operation (With A Stop Bolt)
Power unit / Control system 4. Push the throttle control lever 8 against the stop bolt 7. Adjusting the throttle link and throttle cable operation (with a stop NOTE: bolt) Use a general bolt with the specified mea- surements. NOTE: •...
Page 66: Adjusting The Throttle Link And Throttle Cable Operation (Without A Stop Bolt)
Periodic checks and adjustments 12. Check the throttle cable for smooth oper- ation and adjust the cable length, if nec- essary, repeating steps 1–10. Adjusting the throttle link and throttle cable operation (without a stop bolt) NOTE: • Be sure to synchronize the throttle valves before adjusting the throttle link.
Page 67: Checking The Gearshift Operation
Control system 5. Check that the alignment mark a is between the alignment marks b. If not, repeat steps 2–4. S69J3340 CAUTION: The throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) f. 8. Connect the cable joint, install the clip, and then tighten the locknut.
Page 68: Checking The Engine Idle Speed
Periodic checks and adjustments 5. Adjust the position of the shift cable joint Inductive self-powered tachometer: until its hole is aligned with the set pin. YU-08036-B Engine idle speed: 650–750 r/min 4. Turn the engine off, loosen the locknut 2, and then disconnect the link rod 3 from the magnet control lever 4.
Page 69 Control system 10. Install the link rod 3, and then tighten the locknut 2. 11. Check that the alignment mark c is between the alignment marks d. If nec- essary, repeat steps 8–10. NOTE: • To increase the idle speed, turn the throttle stop screw in direction a.
Page 70: Checking The Ignition Timing
Periodic checks and adjustments 4. Attach the special service tool to spark plug wire #1. S69J3470 CAUTION: The throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) h. 14. Connect the cable joint, install the clip, and then tighten the locknut.
Page 71: Checking The Power Trim And Tilt Fluid Level
Control system / Power trim and tilt unit / Lower unit NOTE: Be sure to listen to the winding sound of the power trim and tilt motor for smooth opera- tion. 2. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1 to check the lock mechanism of the lever.
Page 72: Changing The Gear Oil
Periodic checks and adjustments NOTE: If the oil is at the correct level, the oil should overflow out of the check hole when the check screw is removed. 3. If necessary, add sufficient gear oil of the recommended type until it overflows out of the check hole.
Page 73: Checking The Lower Unit (For Air Leakage)
Lower unit / General Checking the lower unit Checking the propeller (for air leakage) 1. Check the propeller blades and splines 1. Remove the check screw 1, and then for cracks, damage, or wear. Replace if necessary. install the special service tool. È...
Page 74: Checking The Battery
Periodic checks and adjustments WARNING Battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. •...
Page 75: Lubrication
General Lubrication 1. Apply water resistant grease to the areas shown. 3-20 69J1D11...
Page 76 Periodic checks and adjustments NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply corrosion resistant grease to the areas shown. 3-21 69J1D11...
Page 77 FUEL Fuel system Special service tools ..................4-1 Hose routing ....................4-2 Fuel and blowby hoses................4-2 Intake silencer, fuel filter, and fuel pump ............ 4-3 Vapor separator....................4-5 Removing the hose clamps ............... 4-7 Installing the hose clamps ................. 4-7 Checking the check valve................4-7 Reducing the fuel pressure................
Page 78: Fuel System
FUEL Fuel system Special service tools Pressure/vacuum tester YB-35956-A Digital multimeter YU-34899-A Test harness (3 pins) YB-06793 Carburetor synchronizer YU-08030 69J1D11...
Page 79: Hose Routing
Special service tools / Hose routing Hose routing Fuel and blowby hoses 1 Blowby hose 7 High-pressure fuel hose 2 Fuel hose (fuel joint-to-fuel filter) (starboard fuel rail-to-port fuel rail) 3 Fuel hose (fuel filter-to-fuel pump) 8 Fuel hose (pressure regulator-to-fuel cooler) 4 Fuel hose (fuel pump-to-vapor separator) 9 Fuel hose (fuel cooler-to-vapor separator) 5 Fuel hose (vapor separator-to-fuel pump)
Page 80: Intake Silencer, Fuel Filter, And Fuel Pump
FUEL Fuel system Intake silencer, fuel filter, and fuel pump 69J1D11...
Page 81 Intake silencer, fuel filter, and fuel pump Part name Q’ty Remarks Cover M6 × 28 mm Bolt M6 × 16 mm Bolt Washer Holder M6 × 14 mm Bolt Bracket M6 × 19 mm Bolt Fuel hose Fuel joint O-ring Not reusable Fuel filter element Spring...
Page 82: Vapor Separator
FUEL Fuel system Vapor separator 69J1D11...
Page 83 Vapor separator Part name Q’ty Remarks Float chamber Cover High-pressure fuel pump Float Water hose Fuel hose Joint Fuel cooler Washer Water hose Bracket M8 × 16 mm Bolt Collar Bushing M8 × 16 mm Bolt Hose M4 × 15 mm Screw Bracket M6 ×...
Page 84: Removing The Hose Clamps
FUEL Fuel system Removing the hose clamps 1. Remove the hose clamps by cutting the joint. CAUTION: If the hose clamps are removed without cutting the joint first, the fuel hose will be damaged. Pressure/vacuum tester: Installing the hose clamps YB-35956-A 1.
Page 85: Checking The Vapor Separator
Vapor separator WARNING Reduce the fuel pressure before removing the vapor separator drain screw, or pres- surized fuel will spray out and may result in serious injury. Checking the vapor separator 1. Check the needle valve for bends or wear. Replace if necessary. WARNING Always reduce the fuel pressure in the high-pressure fuel line before servicing...
Page 86: Intake Manifold And High-Pressure Fuel Line
FUEL Fuel system Intake manifold and high-pressure fuel line 69J1D11...
Page 87 Intake manifold and high-pressure fuel line Part name Q’ty Remarks Hose High-pressure fuel hose Clamp Joint Joint Screw Washer Throttle position sensor Screw Bracket Bracket M5 × 15 mm Screw Bracket Joint O-ring Not reusable Metal gasket Not reusable M5 × 15 mm Screw Intake air pressure sensor O-ring...
Page 88 FUEL Fuel system 4-11 69J1D11...
Page 89 Intake manifold and high-pressure fuel line Part name Q’ty Remarks Starboard intake manifold Throttle body #1 Throttle body #3 Throttle body #5 Starboard fuel rail Port intake manifold Throttle body #2 Throttle body #4 Throttle body #6 Port fuel rail Pressure regulator M8 ×...
Page 90: Throttle Control
FUEL Fuel system Throttle control 4-13 69J1D11...
Page 91 Throttle control Part name Q’ty Remarks Bracket Joint Magnet control lever Shaft Bracket M6 × 20 mm Bolt Washer Bushing Gear Throttle control lever Circlip Bolt Wave washer Washer Throttle cam Spring M6 × 14 mm Bolt Bracket M8 × 20 mm Bolt Terminal Starter motor lead...
Page 92: Removing The Pressure Regulator
Checking the idle speed control (ISC) 1. Check the operation of the idle speed control using the “Stationary test” or the “Active test” of the Yamaha Diagnostic System. S69J4130 Checking the fuel injector 1. Check the filter for dirt or residue. Clean if necessary.
Page 93: Synchronizing The Throttle Valve
Throttle control Synchronizing the throttle valve 1. Loosen the bank synchronizing screw 1. 2. Remove the port link rod 2 and star- board link rod 3. 6. Loosen the port throttle stop screw 8 until it separates from the throttle body lever 9.
Page 94 FUEL Fuel system Test harness (3 pins): YB-06793 10. Turn the engine start switch to ON. 13. Tighten the starboard throttle stop screw 4 until the output voltage is adjusted to 11. Measure the throttle position sensor out- put voltage. Adjust the throttle position specification as mentioned in step 11, sensor B position if out of specification.
Page 95 Throttle control 15. Tighten the synchronizing screw 0 of È cylinder #4, and stop tightening when the throttle plate starts to move. Similarly, tighten and adjust the synchronizing screw A of cylinder #6. Carburetor synchronizer: YU-08030 16. Tighten the port throttle stop screw 8 until it contacts the throttle body lever 9, and then turn it one additional turn.
Page 96 FUEL Fuel system 19. Measure the vacuum of cylinders #1, #3, and #5. Repeat step 12 if out of specifi- cation. Vacuum difference between cylinders: 20 mmHg (27 mbar, 0.79 inHg) 20. Measure the vacuum of cylinders #2, #4, and #6. Repeat step 12 if out of specifi- cation.
Page 97 Throttle control 25. Check that there is no clearance a between the port and starboard throttle stop screws 4 and 8, and the throttle body levers 5 and 9. If there is any clearance, repeat step 24. 26. Start the engine, and when the engine speed is at idle, check the average vac- uum difference between the port and starboard banks.
Page 98 POWR Power unit Special service tools ..................5-1 Power unit....................... 5-3 Checking the compression pressure ............5-14 Checking the oil pressure ................5-14 Checking the oil pressure sensor ............5-15 Checking the valve clearance..............5-15 Replacing the timing belt .................5-21 Removing the power unit.................5-23 Removing the oil filter ................
Page 99 Cylinder block ....................5-43 Disassembling the cylinder block ............5-47 Checking the piston diameter ..............5-47 Checking the cylinder bore ..............5-48 Checking the piston clearance ..............5-48 Checking the piston rings ................5-48 Checking the piston ring grooves ............5-49 Checking the piston ring side clearance..........5-49 Checking the piston pin boss bore ............
Page 100: Special Service Tools
POWR Power unit Special service tools Compression gauge Valve spring compressor YU-33223-1 YM-01253 Valve spring compressor attachment YB-06320 Compression gauge extension YB-06563 Valve guide remover YB-06801 Test harness (3 pins) YB-06769 Valve guide installer YB-06810 Flywheel magnet holder YB-06139 Valve guide reamer YB-06804 Universal puller YB-06117...
Page 101 Special service tools Piston ring compressor YM-08037 69J1D11...
Page 102: Power Unit
POWR Power unit Power unit 69J1D11...
Page 103 Power unit Part name Q’ty Remarks Power unit Screw Cover Dipstick M6 × 20 mm Bolt Dipstick guide O-ring Not reusable Plastic tie Not reusable Fuel hose M6 × 10 mm Bolt PTT motor lead Sky blue, light green Gasket Not reusable Clip Shift cable...
Page 104 POWR Power unit 69J1D11...
Page 105 Power unit Part name Q’ty Remarks Washer Flywheel magnet M6 × 30 mm Screw Stator coil M6 × 35 mm Bolt Blowby hose guide Blowby hose Blowby hose Stator coil bracket Collar Woodruff key Plastic tie Not reusable Wiring harness guide M6 ×...
Page 106 POWR Power unit 69J1D11...
Page 107 Power unit Part name Q’ty Remarks Wiring harness Bracket M6 × 20 mm Bolt Ground lead M6 × 16 mm Bolt Bracket M6 × 16 mm Bolt M6 × 25 mm Bolt Power trim and tilt relay Washer Spring washer Battery lead Screw Main relay...
Page 108 POWR Power unit Part name Q’ty Remarks Starter motor Spring washer Battery cable From terminal and power trim and tilt relay M8 × 45 mm Bolt M6 × 20 mm Bolt Ground lead M6 × 35 mm Bolt Rectifier Regulator Gasket Not reusable Cover...
Page 109 Power unit Part name Q’ty Remarks Ignition coil M6 × 20 mm Bolt M6 × 20 mm Bolt Bracket Clamp Clamp M6 × 20 mm Screw Plate Gasket Grommet Idle speed control hose 5-10 69J1D11...
Page 110 POWR Power unit 5-11 69J1D11...
Page 111 Power unit Part name Q’ty Remarks M6 × 30 mm Bolt Washer Link rod arm Plug O-ring Not reusable M6 × 20 mm Bolt Link rod Long Link rod Short Link rod Oil filler cap O-ring Not reusable Oil filler neck M6 ×...
Page 112 POWR Power unit Part name Q’ty Remarks Timing belt M5 × 45 mm Bolt Drive sprocket Plate Woodruff key Timing belt tensioner M10 × 35 mm Bolt Driven sprocket Dowel pin M6 × 30 mm Bolt Port cylinder head cover Gasket Not reusable Starboard cylinder head cover...
Page 113: Checking The Compression Pressure
Power unit Checking the compression pressure NOTE: 1. Start the engine, warm it up for 5 min- • If the compression pressure increases, utes, and then turn it off. check the piston and piston rings for wear. Replace if necessary. 2.
Page 114: Checking The Oil Pressure Sensor
POWR Power unit 5. Check the oil pressure. Check the oil Oil pressure sensor input voltage: pump, oil leakage, and oil strainer if out Orange (O) – Black (B) of specification. Oil pressure (reference data): Oil pressure sensor output voltage 650 kPa (6.5 kgf/cm , 92.4 psi) at (reference data):...
Page 115 Power unit 9. Similarly, check the valve clearance of cylinders #1, #2, and #3 in order, and be sure to turn the flywheel magnet 120° clockwise each time. Adjust if out of specification. NOTE: Do not turn the flywheel magnet counter- clockwise.
Page 116 POWR Power unit 10. Turn the flywheel magnet an additional NOTE: 120° clockwise and align the “1TDC” Apply force to the crankshaft end until the fly- mark on the flywheel magnet with the wheel magnet comes off the tapered portion pointer, and check that the “I”...
Page 117 Power unit 15. Remove the driven sprockets. 19. Measure the valve shim thickness with a micrometer, and then note the measure- ment. 20. Select the necessary valve shim by cal- culating its thickness with the following formula. Necessary valve shim thickness = Removed valve shim thickness + Measured valve clearance –...
Page 118 POWR Power unit NOTE: • Install the camshaft caps in the proper posi- tion as shown and with the stamped num- bers facing upside down. • Apply engine oil to the camshaft cap bolts before installation. Camshaft cap bolt: 1st: 8 N·m (0.8 kgf·m, 5.8 ft·lb) 2nd: 17 N·m (1.7 kgf·m, 12 ft·lb) Timing chain tensioner bolt: 12 N·m (1.2 kgf·m, 8.7 ft·lb)
Page 119 Power unit Flywheel magnet nut: 240 N·m (24 kgf·m, 174 ft·lb) 30. Turn the flywheel magnet clockwise two turns, and then check that all alignment marks are aligned. 28. Install the Woodruff key. 29. Install the flywheel magnet. È NOTE: Do not turn the flywheel magnet counter- clockwise.
Page 120: Replacing The Timing Belt
POWR Power unit 35. Install the ignition coil cover, wiring har- È ness guide, and flywheel magnet cover. Replacing the timing belt 1. Remove the flywheel magnet cover, igni- tion coil cover, and intake silencer. 2. Turn the flywheel magnet clockwise and align the “1TDC”...
Page 121 Power unit 5. Disconnect the stator coil couplers 3 and pulser coil coupler 4, and remove the blowby hose 5 and stator coil bracket 6. 9. Check that “I” marks c and d on the driven sprockets are aligned with marks e and f, and that the “...
Page 122: Removing The Power Unit
POWR Power unit È CAUTION: CAUTION: • Do not twist, turn inside out, or bend the Apply force in the direction of the arrows timing belt beyond the maximum limit of shown, to prevent the flywheel holder 25 mm (1.0 in) j, otherwise it may be from slipping off easily.
Page 123 Power unit 5. Remove the upper case cover 9 and aprons 0. 6. Remove the power unit by removing the bolts A. 3. Remove the dipstick guide 5, and dis- connect the fuel hose 6, PTT motor leads 7, and flushing device hose (flush- ing device model) 8.
Page 124: Removing The Oil Filter
POWR Power unit È NOTE: Be sure to clean up any oil spills. Removing the timing belt and sprockets 1. Turn the drive sprocket clockwise and align the “ ” mark a on the plate with the “ ” mark b on the cylinder block, and check that “I”...
Page 125: Checking The Timing Belt And Sprockets
Power unit Checking the timing belt and 2. Using a hexagon wrench, turn the timing belt tensioner 1 clockwise to push the sprockets timing belt, increase strength gradually, 1. Check the interior and exterior of the tim- and then insert a ø5.0 mm (0.2 in) pin 2 ing belt for cracks, damage, or wear.
Page 126: Installing The Sprockets And Timing Belt
POWR Power unit Installing the sprockets and timing belt 1. Install the driven sprockets 1, and then tighten the bolts to the specified torque. 2. Check that “I” marks a and b on the driven sprockets are aligned with marks c and d.
Page 127 Power unit 7. Install the timing belt 6 from the drive sprocket side with its part number in the upright position, turn the belt a half turn counterclockwise to align it, and then remove the pin 5. 8. Turn the drive sprocket clockwise two turns, and then check that the alignment marks are aligned.
Page 128: Cylinder Head
POWR Power unit Cylinder head 5-29 69J1D11...
Page 129 Cylinder head Part name Q’ty Remarks Timing chain tensioner M6 × 25 mm Bolt Timing chain tensioner M7 × 37 mm Bolt M7 × 48 mm Bolt Camshaft cap Camshaft cap Timing chain Oil seal Not reusable Camshaft 3 Camshaft 4 Camshaft 2 Camshaft 1 M6 ×...
Page 130 POWR Power unit 5-31 69J1D11...
Page 131 Cylinder head Part name Q’ty Remarks Spark plug M10 × 120 mm Bolt M8 × 55 mm Bolt M8 × 90 mm Bolt Port cylinder head M6 × 20 mm Bolt Engine hanger M6 × 12 mm Bolt Ground lead Gasket Not reusable Starboard cylinder head...
Page 132: Removing The Cylinder Head
POWR Power unit Removing the cylinder head CAUTION: 1. Remove the exhaust cover bolts in the Do not scratch or damage the mating sur- sequence shown. faces of the cylinder head and cylinder block. 5. Remove the valve shim 2 from the valve lifter 3 using compressed air.
Page 133: Checking The Valve Springs
Cylinder head Valve spring compressor 4: YM-01253 Valve spring compressor attachment YB-06320 Checking the valve springs 1. Measure the valve spring free length a. Replace if out of specification. Valve margin thickness a: Intake: 0.7 mm (0.028 in) Exhaust: 1.0 mm (0.039 in) 3.
Page 134: Checking The Valve Guides
POWR Power unit Valve stem runout: Intake: 0.01 mm (0.0004 in) Exhaust: 0.01 mm (0.0004 in) Checking the valve guides NOTE: Before checking the valve guide make sure that the valve stem diameter is within specifi- S69J5790 cation. Valve guide remover: YB-06801 1.
Page 135: Checking The Valve Seat
Cylinder head NOTE: • Turn the valve guide reamer clockwise to ream the valve guide. • Do not turn the reamer counterclockwise when removing the reamer. Valve guide reamer: YB-06804 4. Measure the valve guide inside diameter. Replace the valve guide if out of specifi- cation.
Page 136 POWR Power unit 2. Cut the surface of the valve seat with a 45° cutter by turning the cutter clockwise until the valve seat face has become smooth. È 60° S69J5890 b Previous contact width 5. Use a 45° cutter to adjust the contact width of the valve seat to specification.
Page 137: Checking The Camshaft
Cylinder head 10. After every lapping procedure, be sure to clean off any remaining lapping com- pound from the cylinder head and the valve. 11. Check the valve seat contact area of the valve again. Checking the camshaft 1. Check the timing chain sprockets for b Previous contact width damage or wear.
Page 138: Checking The Timing Chain Tensioner
POWR Power unit 3. Measure the camshaft runout. Replace if Camshaft oil clearance e = out of specification. Camshaft cap inside diameter d – Camshaft journal diameter c: 0.02–0.06 mm (0.0008–0.0023 in) Checking the timing chain tensioner 1. Measure the plunger extended length a. Replace if out of specification.
Page 139: Installing The Valves
Cylinder head 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in six directions as shown. Replace if out of specification. NOTE: The valve spring can be installed in any direction. Valve spring compressor 5: YM-01253 Valve spring compressor attachment YB-06320...
Page 140: Installing The Cylinder Head
POWR Power unit 4. Lightly tap the valve spring retainer with NOTE: a plastic hammer to set the valve cotter • Apply enginLe oil to the cylinder head bolts securely. before installation. • Tighten the M10 bolts to the specified torques in three stages first, and then tighten the M8 bolts to the specified torques in two stages.
Page 141 Cylinder head NOTE: • Install the camshaft caps in the proper posi- tion as shown and with the stamped num- bers facing upside down. • Apply engine oil to the camshaft cap bolts before installation. Camshaft cap bolt: 1st: 8 N·m (0.8 kgf·m, 5.8 ft·lb) 2nd: 17 N·m (1.7 kgf·m, 12 ft·lb) Timing chain tensioner bolt: 12 N·m (1.2 kgf·m, 8.7 ft·lb)
Page 142: Cylinder Block
POWR Power unit Cylinder block 5-43 69J1D11...
Page 143 Cylinder block Part name Q’ty Remarks Crankcase cover M8 × 45 mm Bolt M6 × 20 mm Bolt Engine hanger Plate M4 × 8 mm Screw Gasket Not reusable Baffle plate Dowel pin Bolt Not reusable Connecting rod cap Connecting rod bearing Connecting rod Piston Clip...
Page 144 POWR Power unit 5-45 69J1D11...
Page 145 Cylinder block Part name Q’ty Remarks Crankshaft Cylinder block Crankcase Oil seal Not reusable Thrust bearing Thrust bearing Main bearing Main bearing M8 × 95 mm Stud bolt M10 × 105 mm Bolt M8 × 95 mm Bolt M8 × 55 mm Bolt O-ring Not reusable...
Page 146: Disassembling The Cylinder Block
POWR Power unit Disassembling the cylinder block NOTE: 1. Remove the cooling water passage • Be sure to keep the bearings in the order as cover bolts in the sequence shown. they were removed, and to note the bearing color. •...
Page 147: Checking The Cylinder Bore
Cylinder block Checking the piston clearance Piston diameter a: 1. Rebore the cylinder or replace the piston 93.921–93.941 mm and piston rings as a set, or the cylinder (3.6977–3.6985 in) block, or all parts if out of specification. Measuring point b: 5 mm (0.2 in) up from the bottom of Piston clearance: the piston skirt...
Page 148: Checking The Piston Ring Grooves
POWR Power unit Checking the piston ring side clearance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. Piston ring end gap d: Top ring: Piston ring side clearance: 0.15–0.30 mm Top ring a: (0.0059–0.0118 in)
Page 149: Checking The Piston Pin
Cylinder block Checking the piston pin 1. Measure piston diameter. Replace if out of specification. Piston pin diameter: Connecting rod big end side 21.00 mm (0.827 in) clearance a: 0.20–0.25 mm (0.008–0.010 in) Checking the connecting rod small end inside diameter Checking the crankshaft 1.
Page 150: Checking The Crankpin Oil Clearance
POWR Power unit Crankshaft journal diameter a: 62.968–62.992 mm (2.4791–2.4800 in) Crankpin diameter b: 49.976–50.000 mm (1.9676–1.9685 in) Crankpin width c: 21.50–21.55 mm (0.8465–0.8484 in) NOTE: 2. Measure the crankshaft runout. Replace Install the connecting rod bearings in their the crankshaft if out of specification. original positions.
Page 151: Selecting The Connecting Rod Bearing
Cylinder block Connecting rod bolt: 1st: 23 N·m (2.3 kgf·m, 17 ft·lb) 2nd: 48 N·m (4.8 kgf·m, 35 ft·lb) 3rd: 90° 7. Remove the connecting rod cap and measure the width of the compressed Plastigauge (PG-1) on each crankpin. Replace the connecting rod bearing if out of specification.
Page 152: Checking The Crankshaft Main Journal Oil Clearance
POWR Power unit 4. Insert the projection a of the bearing into the notch in the cylinder block. NOTE: Install the main bearings in their original posi- tions. 5. Put a piece of Plastigauge (PG-1) on each main journal parallel to the crank- 3.
Page 153: Selecting The Crankshaft Main Bearing
Cylinder block 9. Tighten the crankcase bolts to the speci- 10. Remove the crankcase and measure the fied torques in two stages and in the width of the compressed Plastigauge sequence shown. (PG-1) on each main journal. Replace the main bearing if out of specification. Crankshaft main journal oil clearance: 0.025–0.050 mm...
Page 154: Disassembling The Oil Pump
POWR Power unit Disassembling the oil pump 1. Remove the screws 1 and disassemble the oil pump. 3. Select the suitable main bearing number c from the table. Checking the oil pump 1. Check the oil seals and gasket for tears. Replace if necessary.
Page 155: Assembling The Piston And Cylinder Block
Cylinder block NOTE: 45° 45° Install the oil seals using a general pipe of the proper size. Screw 3: #1,#4 4 N·m (0.4 kgf·m, 2.9 ft·lb) Assembling the piston and cylinder block 1. Assemble the piston 1, connecting rod 2, piston pin 3, and new piston pin clips S60C5E90 CAUTION: Do not scratch the piston or break the pis-...
Page 156 POWR Power unit 6. Install half of the bearings 9 into the cyl- 10. Apply sealant to the mating surface of inder block 0. the crankcase. 7. Insert the projection f of the bearing into 11. Insert the projection g of the bearing into the notch in the cylinder block.
Page 157 Cylinder block NOTE: • The oil seals must be installed before tight- ening the crankcase bolts. • Apply engine oil to the crankcase bolts before installation. • Tighten crankcase bolts 1–F to the speci- fied torques in two stages first, and then tighten crankcase bolts G–S to the speci- fied torques in two stages.
Page 158 POWR Power unit Crankcase cover bolt: 1st: 14 N·m (1.4 kgf·m, 10 ft·lb) 2nd: 28 N·m (2.8 kgf·m, 20 ft·lb) 18. Install the new gasket and cooling water passage cover, and then tighten the bolts to the specified torque in the sequence shown.
Page 159: Checking The Thermostat
Cylinder block 20. Install the oil filter, and then tighten it to 4. Check the thermostat valve opening at the specified torque using a 72.5 mm specified water temperatures. (2.9 in) oil filter wrench. Replace if out of specification. Water Valve lift a temperature 58–62 °C...
Page 160 POWR Power unit PTT motor lead bolt: 4 N·m (0.4 kgf·m, 2.9 ft·lb) 6. Connect the shift cable A and throttle cable B, and then adjust their lengths. For adjustment procedures, see Chapter 3, “Checking the throttle link and throttle cable operation,”...
Page 161 Cylinder block 7. Install the holders C and retaining plate NOTE: Apply engine oil to the flywheel magnet nut before installation. Flywheel magnet holder: YB-06139 Flywheel magnet nut: 240 N·m (24 kgf·m, 174 ft·lb) 11. Reinstall the all removed parts. 8.
Page 162 LOWR Lower unit Special service tools ..................6-1 Lower unit (regular rotation model) ............. 6-4 Removing the lower unit ................6-7 Removing the water pump and shift rod............ 6-7 Checking the water pump and shift rod .............6-8 Propeller shaft housing (regular rotation model) ........6-9 Removing the propeller shaft housing assembly........
Page 163 Propeller shaft housing (counter rotation model) ........6-35 Removing the propeller shaft housing assembly........6-37 Disassembling the propeller shaft housing..........6-37 Checking the propeller shaft housing ............6-38 Checking the propeller shaft..............6-38 Assembling the propeller shaft housing...........6-39 Drive shaft and lower case (counter rotation model) .......6-41 Removing the drive shaft.................6-43 Disassembling the drive shaft housing ............6-43 Disassembling the reverse gear ..............6-43...
Page 164: Lower Unit
LOWR Lower unit Special service tools Slide hammer and adapters Drive shaft needle bearing remover and YB-06096 installer YB-06196 Needle bearing installer and remover YB-06194 Propeller shaft and bearing housing remover YB-06335 Forward bearing installer YB-06430 Puller claw YB-06523 Bearing outer race attachment YB-06109 Oil seal installer YB-06168, YB-06195...
Page 165 Special service tools Needle bearing installer Shimming gauge I YB-06434, YB-06435 YB-06439 Pinion gear bushing installer Shift rod push arm YB-06029-4 YB-06052 Needle bearing remover and installer Bearing housing puller YB-06213 YB-06207 Taper roller bearing installer Universal puller YB-06431 YB-06117 Forward gear bearing cup installer YB-06276-B Backlash indicator gauge...
Page 166: Lower Unit (Regular Rotation Model)
LOWR Lower unit Magnetic plate Shimming gauge YB-07003 YB-06440-A Dial gauge YU-03097 Magnetic flexible stand YU-34481 Ring nut wrench YB-06578 Puller bolt YB-41707 69J1D11...
Page 167 Special service tools / Lower unit (regular rotation model) Lower unit (regular rotation model) Part name Q’ty Remarks Lower unit Plate Rubber seal Check screw Gasket Not reusable Dowel pin M10 × 45 mm Bolt Drain screw Grommet M10 × 44 mm Bolt M10 ×...
Page 168 LOWR Lower unit S69J6010U 69J1D11...
Page 169 Lower unit (regular rotation model) Part name Q’ty Remarks Shift rod Oil seal Not reusable Oil seal housing O-ring Not reusable 3.1 × 70.6 mm Spring Circlip M6 × 20 mm Bolt Seal Woodruff key M8 × 45 mm Bolt Cover Seal Water pump housing...
Page 170: Removing The Lower Unit
LOWR Lower unit Removing the lower unit 1. Drain the gear oil. For draining proce- dures, see Chapter 3, “Changing the gear oil.” 2. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller.
Page 171: Checking The Water Pump And Shift Rod
Lower unit (regular rotation model) Checking the water pump and shift 4. Check the shift rod for cracks or wear. Replace if necessary. 1. Check the water pump housing for defor- mation. Replace if necessary. S69J6045 S69J6030 2. Check the impeller 1 and insert car- tridge 2 for cracks or wear.
Page 172: Propeller Shaft Housing (Regular Rotation Model)
LOWR Lower unit Propeller shaft housing (regular rotation model) 69J1D11...
Page 173 Propeller shaft housing (regular rotation model) Part name Q’ty Remarks Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Propeller shaft Washer Reverse gear Reverse gear shim — As required Ball bearing Not reusable O-ring Not reusable 3.1 ×...
Page 174: Removing The Propeller Shaft Housing Assembly
LOWR Lower unit Removing the propeller shaft Disassembling the propeller shaft housing assembly housing 1. Remove the bolts 1, ring 2, and bolts 1. Remove the reverse gear and reverse gear shim(s). È Slide hammer and adapters 1: 2. Pull out the propeller shaft housing assembly.
Page 175: Checking The Propeller Shaft Housing
Propeller shaft housing (regular rotation model) 3. Remove the oil seals and needle bear- 3. Check the bearings for pitting or rum- ing. bling. Replace if necessary. È S69J6115 Oil seal installer 4: YB-06168 Checking the propeller shaft Driver handle 5: YB-06071 1.
Page 176: Assembling The Propeller Shaft Assembly
LOWR Lower unit Assembling the propeller shaft 2. Apply grease to the new oil seals, and then install them into the propeller shaft assembly housing to the specified depth. 1. Install the dog clutch 1 as shown. È NOTE: NOTE: Install an oil seal halfway into the propeller Install the dog clutch 1 with the “F”...
Page 177 Propeller shaft housing (regular rotation model) 4. Install the reverse gear 7 and original shim(s) 8 to the propeller shaft housing using a press. È CAUTION: Add or remove shim(s), if necessary, when replacing the reverse gear or ball bearing. Bearing outer race attachment 9: YB-06109 6-14...
Page 178: Drive Shaft And Lower Case (Regular Rotation Model)
LOWR Lower unit Drive shaft and lower case (regular rotation model) 6-15 69J1D11...
Page 179 Drive shaft and lower case (regular rotation model) Part name Q’ty Remarks Drive shaft Cover Oil seal Not reusable M8 × 25 mm Bolt Drive shaft housing Needle bearing O-ring Not reusable 3 × 60.5 mm Pinion shim — As required Thrust bearing Lower case Needle bearing outer case...
Page 180: Removing The Drive Shaft
LOWR Lower unit Removing the drive shaft Disassembling the forward gear 1. Remove the drive shaft, drive shaft hous- 1. Remove the taper roller bearing from the ing, and pinion, and then pull out the for- forward gear using a press. ward gear.
Page 181: Checking The Pinion And Forward Gear
Drive shaft and lower case (regular rotation model) S69J6210 Roller bearing installer/remover 3: Checking the lower case YB-06432 1. Check the skeg and torpedo for cracks or Driver handle 4: YB-06071 damage. Replace if necessary. Checking the pinion and forward gear 1.
Page 182: Assembling The Forward Gear
LOWR Lower unit 2. Install the needle bearing outer case into Assembling the drive shaft housing the lower case. 1. Install the needle bearing into the drive shaft housing to the specified depth. È NOTE: Apply engine oil to the needle bearing outer Needle bearing installer and remover case before installation.
Page 183: Installing The Propeller Shaft Housing
Drive shaft and lower case (regular rotation model) 2. Install the drive shaft housing 1, thrust Installing the propeller shaft housing bearing 2, and original shim(s) 3 to the 1. Install the washer 1 and propeller shaft drive shaft 4. assembly 2 into the propeller shaft housing assembly 3.
Page 184 LOWR Lower unit 5. Install the washers 7, wave washer 8, spacer 9, and collar 0 to the drive shaft. 2. Install the new gasket 2, outer plate car- NOTE: tridge 3, and dowel pins 4. • The collar and spacer should fit together firmly.
Page 185: Installing The Lower Unit
Drive shaft and lower case (regular rotation model) 7. Install the O-ring D and pump housing È assembly E into the lower case, tighten the bolts F, and then install the seal G and cover H. Shift rod push arm: YB-06052 2.
Page 186 LOWR Lower unit 5. Install the propeller and propeller nut, and then tighten the nut finger tight. Place a block of wood between the anti- cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque. WARNING Do not hold the propeller with your hands when loosening or tightening it.
Page 187: Shimming (Regular Rotation Model)
Drive shaft and lower case (regular rotation model) / Shimming (regular rotation model) Shimming (regular rotation model) 65.0 B1 39.4 41.0 S69J6550 6-24 69J1D11...
Page 188: Shimming
LOWR Lower unit Shimming 3. Install the pinion and pinion nut, and then tighten the nut to the specified torque. NOTE: Pinion shimming gauge III 4: • Shimming is not required when assembling the original lower case and inner parts. YB-06441 •...
Page 189: Selecting The Forward Gear Shims
Shimming (regular rotation model) Selecting the forward gear shims 1. Calculate the specified value (M0) as shown in the examples below. NOTE: Measure the taper roller bearing at three points to find the clearance average. NOTE: “F” is the deviation of the lower case dimen- 4.
Page 190: Selecting The Reverse Gear Shims
LOWR Lower unit Selecting the reverse gear shims 3. Measure the clearance (M) between the shimming tool and the ball bearing 2 as 1. Calculate the specified value (M0) as shown. shown in the examples below. NOTE: NOTE: Measure the ball bearing at three points to “R”...
Page 191: Backlash (Regular Rotation Model)
Shimming (regular rotation model) / Backlash (regular rotation model) Backlash È (regular rotation model) Measuring the forward and reverse gear backlash 1. Remove the water pump assembly. 2. Set the gearshift to the neutral position. È NOTE: Install the dial gauge so that the plunger a contacts the mark b on the backlash indica- tor.
Page 192: Lower Unit (Counter Rotation Model)
LOWR Lower unit 8. Remove the special service tools from 11. Add or remove shim(s) if out of specifica- the propeller shaft. tion. Reverse gear 9. Apply a load to the reverse gear by Shim thickness installing the propeller 7, the spacer 8 backlash (without the washer 9), then the washer To be decreased by...
Page 193 Backlash (regular rotation model) / Lower unit (counter rotation model) Lower unit (counter rotation model) Part name Q’ty Remarks Lower unit Plate Rubber seal Check screw Gasket Not reusable Dowel pin M10 × 45 mm Bolt Drain screw Grommet M10 × 44 mm Bolt M10 ×...
Page 194 LOWR Lower unit 6-31 69J1D11...
Page 195 Lower unit (counter rotation model) Part name Q’ty Remarks Shift rod Oil seal Not reusable Oil seal housing O-ring Not reusable 3.1 × 70.6 mm Spring Circlip M6 × 20 mm Bolt Seal Woodruff key M8 × 45 mm Bolt Cover Seal Water pump housing...
Page 196: Removing The Lower Unit
LOWR Lower unit Removing the lower unit 1. Drain the gear oil. For draining proce- dures, see Chapter 3, “Changing the gear oil.” 2. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller.
Page 197: Checking The Water Pump And Shift Rod
Lower unit (counter rotation model) Checking the water pump and shift 4. Check the shift rod for cracks or wear. Replace if necessary. 1. Check the water pump housing for defor- mation. Replace if necessary. S69J6360 S69J6030 2. Check the impeller 1 and insert car- tridge 2 for cracks or wear.
Page 198: Propeller Shaft Housing (Counter Rotation Model)
LOWR Lower unit Propeller shaft housing (counter rotation model) 6-35 69J1D11...
Page 199 Propeller shaft housing (counter rotation model) Part name Q’ty Remarks Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Forward gear Forward gear shim — As required Ring nut Claw washer Bearing outer race Not reusable Taper roller bearing Not reusable Propeller shaft Thrust bearing...
Page 200: Removing The Propeller Shaft Housing Assembly
LOWR Lower unit Removing the propeller shaft 2. Remove the forward gear and forward gear shim(s) from the propeller shaft housing assembly housing using a press. 1. Remove the bolts 1, ring 2, and bolts Bearing splitter plate 4: (commercially obtainable) 2.
Page 201: Checking The Propeller Shaft Housing
Propeller shaft housing (counter rotation model) S69J6105 2. Check the teeth and dogs of the forward gear for cracks or wear. Replace the gear if necessary. CAUTION: • Do not press the propeller shaft threads a directly. • Do not reuse the taper roller bearing, S69J6110 always replace it with a new one.
Page 202: Assembling The Propeller Shaft Housing
LOWR Lower unit 2. Check the dog clutch, shift rod joint, and È shift slider for cracks or wear. Replace if necessary. NOTE: Install an oil seal halfway into the propeller shaft housing, then the other oil seal. Assembling the propeller shaft housing Oil seal installer 3: YB-06195 1.
Page 203 Propeller shaft housing (counter rotation model) Ring nut 0: 108 N·m (10.8 kgf·m, 78 ft·lb) 7. Install the forward gear B, original shim(s) C, and dog clutch D using a press. Ring nut wrench 9: YB-06578 5. Install the propeller shaft assembly in the reverse direction into the lower case.
Page 204: Drive Shaft And Lower Case (Counter Rotation Model)
LOWR Lower unit Drive shaft and lower case (counter rotation model) 6-41 69J1D11...
Page 205 Drive shaft and lower case (counter rotation model) Part name Q’ty Remarks Drive shaft Cover Oil seal Not reusable M8 × 25 mm Bolt Drive shaft housing Needle bearing O-ring Not reusable 3 × 60.5 mm Pinion shim — As required Thrust bearing Lower case Needle bearing case...
Page 206: Removing The Drive Shaft
LOWR Lower unit Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the reverse gear and thrust bearing. È Disassembling the lower case 1. Remove the retainer and shim(s). È Drive shaft holder 1: YB-06201 Disassembling the drive shaft housing 1.
Page 207: Checking The Pinion And Reverse Gear
Drive shaft and lower case (counter rotation model) S69J6210 Roller bearing installer/remover 5: Checking the lower case YB-06432 1. Check the skeg and torpedo for cracks or Driver handle 6: YB-06071 damage. Replace if necessary. Checking the pinion and reverse gear 1.
Page 208: Assembling The Drive Shaft Housing
LOWR Lower unit NOTE: Apply engine oil or grease to the needle bearing, and then install it. 5. Install the new needle bearings into the reverse gear to the specified depth. È CAUTION: Add or remove shim(s), if necessary, when replacing the forward gear or lower case.
Page 209: Installing The Drive Shaft
Drive shaft and lower case (counter rotation model) Depth a: CAUTION: 4.25–4.75 mm (0.167–0.187 in) Add or remove shim(s), if necessary, when replacing the drive shaft housing or 2. Apply grease to the new oil seals, and drive shaft. then install them into the drive shaft housing to the specified depth.
Page 210: Installing The Water Pump And Shift Rod
LOWR Lower unit 2. Install the new gasket 2, outer plate car- NOTE: tridge 3, and dowel pins 4. Apply grease to the new O-rings before installation. 2. Install the bolts 1, ring 2, and bolts 3, and then tighten the bolts 1 to the speci- fied torque.
Page 211: Installing The Lower Unit
Drive shaft and lower case (counter rotation model) 5. Install the washers 7, wave washer 8, spacer 9, and collar 0 to the drive shaft. NOTE: • The collar and spacer should fit together firmly. • While pulling the drive shaft up, install the collar with an appropriate tool a that fits over the drive shaft as shown.
Page 212 LOWR Lower unit 5. Install the propeller and propeller nut, È and then tighten the nut finger tight. Place a block of wood between the anti- cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque. Shift rod push arm: YB-06052 2.
Page 213: Shimming (Counter Rotation Model)
Drive shaft and lower case (counter rotation model) / Shimming (counter rotation model) Shimming (counter rotation model) 65.0 B1 38.4 47.5 T´4 S69J6670 6-50 69J1D11...
Page 214: Shimming
LOWR Lower unit Shimming 3. Install the pinion and pinion nut, and then tighten the nut to the specified torque. NOTE: Pinion shimming gauge III 4: • Shimming is not required when assembling the original lower case and inner parts. YB-06441 •...
Page 215: Selecting The Reverse Gear Shims
Shimming (counter rotation model) Selecting the reverse gear shims NOTE: 1. Calculate the specified value (M0) as Measure the bearing retainer at three points shown in the examples below. to find the clearance average. 4. Select the reverse gear shim(s) (T1). NOTE: “F”...
Page 216 LOWR Lower unit 4. Measure the clearance (M) between the NOTE: shimming tool and the propeller shaft “R” is the deviation of the lower case dimen- housing 8 as shown. sion from standard. The “R” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units.
Page 217: Selecting The Propeller Shaft Shims
Shimming (counter rotation model) / Backlash (counter rotation model) Magnet flexible stand 7: YU-34481 Calculation formula: Dial gauge 8: YU-03097 Forward gear shim thickness (T2) = M0 – M 3. Select the propeller shaft shim(s) (T’4). Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm Selecting the propeller shaft shims 1.
Page 218 LOWR Lower unit 3. Install the special service tool so that it Backlash indicator gauge 3: pushes against the propeller shaft. YB-06265 È Magnetic plate 4: YB-07003 Dial gauge 5: YU-03097 Magnet flexible stand 6: YU-34481 6. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction.
Page 219: Backlash (Counter Rotation Model)
Backlash (counter rotation model) 9. Turn the shift rod into the reverse posi- NOTE: tion c with the shift rod push arm. When measuring the reverse gear backlash, turn the shift rod push arm towards the 10. Turn the drive shaft clockwise until the reverse position c with force.
Page 220 BRKT Bracket unit Special service tools ..................7-1 Bottom cowling ....................7-3 Upper case, steering arm, swivel bracket and clamp brackets ....7-7 Draining the engine oil................7-13 Disassembling the oil pan................7-13 Checking the oil strainer ................7-13 Assembling the oil pan ................7-13 Removing the steering arm ..............
Page 221 Power trim and tilt electrical system............7-43 Checking the fuse..................7-44 Checking the power trim and tilt relay .............7-44 Checking the power trim and tilt switch ...........7-45 Checking the trim sensor.................7-45 69J1D11...
Page 222: Special Service Tools
BRKT Bracket unit Special service tools PTT oil pressure gauge assembly YB-06580 PTT oil pressure gauge adapter YB-06581 Trim and tilt cylinder wrench YB-06175-2B PTT piston vice attachment YB-06572 Tilt rod wrench YB-06569 69J1D11...
Page 223 Special service tools — MEMO — 69J1D11...
Page 224: Bottom Cowling
BRKT Bracket unit Bottom cowling 69J1D11...
Page 225 Bottom cowling Part name Q’ty Remarks Bracket Shift cut switch Bracket Neutral switch M4 × 16 mm Screw Plate Spring Bushing Grease nipple Bolt M6 × 35 mm Bolt Clamp M6 × 35 mm Bolt M4 × 16 mm Screw Plate Clip Bushing...
Page 226 BRKT Bracket unit 69J1D11...
Page 227 Bottom cowling Part name Q’ty Remarks Bottom cowling Rubber seal Cowling lock lever Bushing Plate M6 × 30 mm Bolt Wave washer Lever Washer M6 × 20 mm Bolt Spring Hook M6 × 20 mm Bolt Bracket M6 × 25 mm Bolt Plate Grommet...
Page 228: Upper Case, Steering Arm, Swivel Bracket And Clamp Brackets
BRKT Bracket unit Upper case, steering arm, swivel bracket and clamp brackets 69J1D11...
Page 229 Upper case, steering arm, swivel bracket and clamp brackets Part name Q’ty Remarks Upper case assembly Damper M14 × 190 mm Bolt Washer Upper mount Bracket M10 × 40 mm Bolt M10 × 40 mm Bolt Mount housing M14 × 205 mm Bolt Washer Rubber washer...
Page 230 BRKT Bracket unit 69J1D11...
Page 231 Upper case, steering arm, swivel bracket and clamp brackets Part name Q’ty Remarks Upper exhaust guide M8 × 35 mm Bolt Pressure control valve M6 × 20 mm Bolt Plate Collar M10 × 45 mm Bolt Gasket Not reusable Dowel pin Lower exhaust guide Gasket Not reusable...
Page 232 BRKT Bracket unit 7-11 69J1D11...
Page 233 Upper case, steering arm, swivel bracket and clamp brackets Part name Q’ty Remarks Through tube Port clamp bracket M10 × 45 mm Bolt Ground lead Screw Washer Bushing Friction plate M6 × 10 mm Screw M6 × 15 mm Screw Trim sensor Grease nipple M6 ×...
Page 234: Draining The Engine Oil
BRKT Bracket unit 2. Remove the oil pan 4 from the upper Draining the engine oil exhaust guide 5 and lower exhaust 1. Place a drain pan under the drain hole, guide 6. and then remove the drain bolt 1 and let the oil drain completely.
Page 235 Upper case, steering arm, swivel bracket and clamp brackets 2. Install the oil strainer 4 and bolts, and Exhaust manifold bolt 7: then tighten the bolts to the specified 20 N·m (2.0 kgf·m, 14 ft·lb) torque. Oil pan bolt 8: 20 N·m (2.0 kgf·m, 14 ft·lb) 6.
Page 236: Removing The Steering Arm
BRKT Bracket unit Bracket bolt: 54 N·m (5.4 kgf·m, 39 ft·lb) 13. Install the lower mounts I and mount housings J. Removing the steering arm 1. Remove the circlip 1. Muffler assembly bolt D: 2. Remove the steering yoke 2 by striking 20 N·m (2.0 kgf·m, 14 ft·lb) Muffler assembly bolt E: it with a plastic hammer.
Page 237: Installing The Steering Arm
Upper case, steering arm, swivel bracket and clamp brackets Installing the steering arm 1. Install the washer 1 and bushing 2 onto the steering arm 3. 2. Place the swivel bracket 4 in an upright position, and then install the steering arm onto the swivel bracket.
Page 238: Installing The Upper Case
BRKT Bracket unit Installing the upper case WARNING 1. Install the upper and lower mounting bolts into the swivel bracket 1 simulta- After tilting up the outboard motor, be sure to support it with the tilt stop lever. neously. Otherwise, the outboard motor could sud- 2.
Page 239: Removing The Clamp Brackets
Upper case, steering arm, swivel bracket and clamp brackets Removing the clamp brackets 2. Assemble the clamp brackets and the 1. Remove the self-locking nut 1 and swivel bracket by connecting the ground lead 2, installing the through tube 3, ground lead 2, then clamp brackets 3 then tightening the self-locking nut 4 fin- and 4.
Page 240: Adjusting The Trim Sensor
BRKT Bracket unit 3. Install the tilt ram upper end into the Adjusting the trim sensor swivel bracket with the shaft 4 and cir- 1. Fully tilt the outboard motor up, and then clip 5. support it with the tilt stop lever 1. 4.
Page 241 Upper case, steering arm, swivel bracket and clamp brackets 7. Fully tilt the outboard motor up, and then support it with the tilt stop lever. WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower if the power trim and tilt unit should lose fluid pressure.
Page 242: Power Trim And Tilt Unit
BRKT Bracket unit Power trim and tilt unit 7-21 69J1D11...
Page 243 Power trim and tilt unit Part name Q’ty Remarks Cylinder block Reservoir M8 × 20 mm Bolt O-ring Not reusable 1.9 × 12.6 mm M12 × 10 mm Reservoir cap O-ring Not reusable Sheet Filter Spacer M8 × 20 mm Bolt O-ring Not reusable...
Page 244 BRKT Bracket unit 7-23 69J1D11...
Page 245 Power trim and tilt unit Part name Q’ty Remarks Circlip Dust seal Not reusable Trim cylinder end screw O-ring Not reusable Trim ram Trim piston Washer M8 × 20 mm Bolt Backup ring O-ring Not reusable Spring Adapter Circlip Tilt ram Dust seal Not reusable Tilt cylinder end screw...
Page 246 BRKT Bracket unit 7-25 69J1D11...
Page 247 Power trim and tilt unit Part name Q’ty Remarks Gear housing 1 M5 × 40 mm Bolt Plate Filter Valve lock screw Down-relief spring Valve support pin Relief valve seal Up-relief spring Valve support pin O-ring Not reusable 1.8 × 11.35 mm Ball Circlip Main valve seal...
Page 248: Disassembling The Power Trim And Tilt Motor
BRKT Bracket unit Disassembling the power trim and Checking the power trim and tilt tilt motor motor 1. Remove the PTT motor screws 1, then 1. Check the commutator for dirt or foreign the yoke 2. substances. Clean with #600 grit sand- paper if necessary.
Page 249: Assembling The Power Trim And Tilt Motor
Power trim and tilt unit 8. Check the bearing for damage or wear. Replace if necessary. Assembling the power trim and tilt motor 1. Install the new oil seal 1 and bearing 2 into the motor base 3 as shown. Armature coil continuity Commutator segments b Continuity...
Page 250: Checking The Hydraulic Pressure
BRKT Bracket unit 4. Install the PTT oil pressure gauge adapter set 2. 6. Install the wave washer A and washer B into the yoke C. NOTE: Cover the removed pipe joint a with a rag. PTT oil pressure gauge adapter set: YB-06580 7.
Page 251 Power trim and tilt unit 6. Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams. NOTE: Cover the removed pipe joint b with a rag. Battery PTT motor lead PTT oil pressure gauge adapter set: terminal YB-06580 Sky blue (Sb)
Page 252: Disassembling The Gear Pump
BRKT Bracket unit NOTE: If the fluid is at the correct level, the fluid should overflow out of the filler hole when the cap is removed. 14. Remove the PTT oil pressure gauge adapter set 2. Recommended power trim and tilt fluid: 15.
Page 253: Disassembling The Tilt Cylinder And Trim Cylinders
Power trim and tilt unit Disassembling the tilt cylinder and trim cylinders 1. Hold the tilt cylinder 1 in a vise using aluminum plates a on both sides. 2. Loosen the tilt cylinder end screw 2, and then remove the tilt piston assembly. 3.
Page 254 BRKT Bracket unit WARNING Never look into the tilt cylinder opening because the free piston and power trim and tilt fluid may be expelled out force- fully. 5. Hold the tilt piston in a vise using the special service tool 4 on both sides. 6.
Page 255: Checking The Reservoir
Power trim and tilt unit Checking the reservoir 1. Check the reservoir for cracks or corro- sion. Replace if necessary. 4. Check the trim and tilt rams for bends or excessive corrosion. Polish with #400– 600 grit sandpaper if there is light rust or replace if necessary.
Page 256: Checking The Filters
BRKT Bracket unit Checking the filters 1. Check gear pump filters 1 and 2, and shuttle piston filters 3 for dirt or residue. Clean if necessary. 2. Check the up-relief valve and down-relief valve for dirt or residue. Clean if neces- sary.
Page 257: Assembling The Tilt Ram
Power trim and tilt unit 3. Install the balls 7, manual release spring Up-relief lock screw a height 8, and bracket 9 by installing the bolts (from the top of the gear housing): 0, then tightening them to the specified 1.8–2.0 mm (0.071–0.079 in) Down-relief lock screw b depth torque.
Page 258: Assembling The Trim Rams
BRKT Bracket unit Tilt ram 0: 55 N·m (5.5 kgf·m, 40 ft·lb) 5. Install the new O-ring C and backup ring D into the tilt piston 9. 6. Install the balls E, absorber valve pins F, and springs G as shown. 7.
Page 259: Installing The Tilt Cylinder
Power trim and tilt unit 3. Install the tilt cylinder 3 to the cylinder block 4. 4. Install pipes 5 and 6, and then tighten them to the specified torque. Trim piston bolt: 38 N·m (3.8 kgf·m, 27 ft·lb) 4. Install the new O-ring 3, backup ring 4, spring 5, adapter 6, and circlip 7 to the trim piston 1.
Page 260: Installing The Power Trim And Tilt Motor
BRKT Bracket unit Recommended power trim and tilt 2. Fill the pump housing with the recom- mended fluid to the correct level a as fluid: ATF Dexron II shown. 3. Install the trim piston assembly into the trim cylinder, and then tighten the trim cylinder end screw 2 to the specified torque.
Page 261: Installing The Reservoir
Power trim and tilt unit Reservoir bolt 6: 18 N·m (1.8 kgf·m, 13 ft·lb) Reservoir cap 7: 7 N·m (0.7 kgf·m, 5.1 ft·lb) Installing the tilt ram 1. Fill the tilt cylinder with the recommended fluid to the correct level a as shown. 2.
Page 262: Bleeding The Power Trim And Tilt Unit
BRKT Bracket unit WARNING Recommended power trim and tilt fluid: To prevent the power trim and tilt fluid ATF Dexron II from spurting out due to internal pres- sure, the tilt ram should be kept at full 5. Install the reservoir cap. length.
Page 263: Built-In
Power trim and tilt unit / Bleeding the power trim and tilt unit 6. Support the outboard motor with the tilt NOTE: stop lever, and then let the fluid settle for • Repeat this procedure so that the rams go 5 minutes.
Page 264: Power Trim And Tilt Electrical System
BRKT Bracket unit Power trim and tilt electrical system Sb Lg S69J7520U 1 Fuse (30 A) : Black 2 Fuse (20 A) : Light green 3 Power trim and tilt relay : Pink 4 Power trim and tilt motor : Red 5 10-pin coupler : Sky blue 6 Battery...
Page 265: Checking The Fuse
Power trim and tilt electrical system Checking the fuse 1. Check the fuse for continuity. Replace if Power trim and tilt relay continuity there is no continuity. Sky blue (Sb) – Black (B) Continuity Light green (Lg) – Black (B) Terminal 1 –...
Page 266: Checking The Power Trim And Tilt Switch
BRKT Bracket unit NOTE: Turn the lever 1 and measure the resistance as it gradually changes. Trim sensor resistance: Pink (P) – Black (B) 9–11 Ω at 20 °C (68 °F) a 247.6–387.6 Ω at 20 °C (68 °F) b Checking the power trim and tilt switch 1.
Page 267 – ELEC Electrical systems Special service tools ..................8-1 Checking the electrical components............8-2 Measuring the peak voltage ..............8-2 Measuring the lower resistance..............8-2 Electrical components................... 8-3 Starboard and rear views ................8-3 Port view....................8-4 Front view ....................8-5 Top view ....................8-6 Wiring harness ....................
Page 268: Electrical Systems
– ELEC Electrical systems Special service tools Dynamic spark tester Test harness (3 pins) YM-34487 YB-06793 Digital multimeter Test harness (3 pins) YU-34899-A YB-06770 Peak voltage adaptor Test harness (2 pins) YU-39991 YB-06787 Test harness (2 pins) YB-06792 Test harness (4 pins) YB-06771 69J1D11...
Page 269: Troubleshooting
Special service tools / Checking the electrical components Checking the electrical Measuring the lower resistance When measuring a resistance of 10 Ω or less components with the digital circuit tester, the correct mea- Measuring the peak voltage surement cannot be obtained because of the internal resistance of the tester.
Page 270: Electrical Components
– ELEC Electrical systems Electrical components Starboard and rear views S69J8030 1 Thermoswitch 2 Starter motor 3 Oil pressure sensor 4 Ignition coils 69J1D11...
Page 271: Port View
Electrical components Port view S69J8040U 1 Fuel injectors 2 Fuel pump driver and isolator 3 Low-pressure fuel pump 4 ECM 5 High-pressure fuel pump 6 Fuses 69J1D11...
Page 272: Front View
– ELEC Electrical systems Front view S69J8050U 1 Starter motor 2 Fuses 3 ECM 4 Main relay 5 Rectifier Regulator 6 Power trim and tilt relay 7 Starter relay 69J1D11...
Page 273: Top View
Electrical components Top view S69J8060 1 Spark plugs A Stator coil 2 Idle speed control B Throttle position sensor 3 Thermoswitches C Ignition coils 4 Intake air pressure sensor 5 Engine temperature sensor 6 Fuses 7 Rectifier Regulator 8 Intake air temperature sensor 9 Starter motor 0 Oil pressure sensor 69J1D11...
Page 274: Wiring Harness
– ELEC Electrical systems Wiring harness 1 : G 16 : B/W 31 : Br 2 : Y/G 17 : L/R 32 : B 3 : P 18 : G/B 33 : P/G 4 : W 19 : G 34 : P 20 : G/R 35 : B/Y 6 : L/W...
Page 275 Wiring harness Connect to: 1 Neutral switch 2 Shift cut switch 3 Fuel injector 4 Throttle position sensor 5 Thermoswitch 6 Ignition coil 7 Intake air pressure sensor 8 Low-pressure fuel pump 9 Trim meter 0 Fuel pump driver and isolator A High-pressure fuel pump B Idle speed control C Engine temperature sensor...
Page 276 – ELEC Electrical systems S69J8090U.eps S69J8090U Connect to: : Green B/W : Black/white : Orange/red 1 Accessory battery : Gray : Black/yellow : Orange/yellow 2 Main relay : Blue Br/W : Brown/white : Pink/black 3 Fuel pump driver and : Light green : Green/black : Pink/green : Orange...
Page 277: Ignition And Ignition Control System
Wiring harness / Ignition and ignition control system Ignition and ignition control system S69J8100U 1 ECM 9 Pulser coil H Spark plug B/W : Black/white 2 Oil pressure sensor 0 Stator coil : Black/yellow 3 Intake air temperature A Rectifier Regulator : Black : Blue/yellow B Intake air pressure...
Page 278: Checking The Ignition Spark Gap
– ELEC Electrical systems Checking the ignition spark gap Checking the ignition coil 1. Remove the ignition coil cover and dis- 1. Remove the spark plug wires from the connect the spark plug caps from the spark plugs. spark plugs. 2.
Page 279: Checking The Ecm
Ignition and ignition control system Checking the ECM 3. Measure the pulser coil output peak volt- age. Replace the pulser coil if below 1. Remove the ignition coil cover and dis- specification. connect the ignition coil coupler. 2. Connect the test harness (2 pins) to the ignition coil.
Page 280: Checking The Intake Air Temperature Sensor
– ELEC Electrical systems Checking the engine temperature sensor 1. Place the engine temperature sensor in a container of water and slowly heat the water. Test harness (3 pins): YB-06793 S69J8240 Throttle position sensor input voltage: 2. Measure the engine temperature sensor Orange (O) –...
Page 281: Checking The Thermoswitch
Ignition and ignition control system Checking the thermoswitch Checking the shift cut switch 1. Place the thermoswitch in a container of 1. Check the shift cut switch for continuity. water and slowly heat the water. Replace if there is no continuity. S69J8270 S69J8250 Lead color...
Page 282: Checking The Main Relay
– ELEC Electrical systems Checking the main relay 1. Connect the digital circuit tester leads to main relay terminals 1, 2, and 3. 2. Connect the terminal 4 to the positive battery terminal. 3. Connect the terminal 5 to the negative battery terminal.
Page 283: Fuel Control System
Ignition and ignition control system / Fuel control system Fuel control system S69J8290U 1 ECM A Stator coil K Fuel pump driver and isolator 2 Oil pressure sensor B Rectifier Regulator L Fuel injector 3 Intake air temperature sensor C Intake air pressure sensor 4 Engine temperature sensor D Thermoswitch 5 Main relay...
Page 284 – ELEC Electrical systems S69J8290U : Black : Green/black P/W : Pink/white : Brown : Green/red : Red/yellow : Green G/W : Green/white W/B : White/black : Blue : Green/yellow W/G : White/green : Orange : Blue/red W/R : White/red : Pink : Blue/yellow : Yellow/green...
Page 285: Checking The Low-Pressure Fuel Pump And High-Pressure Fuel Pump
• After the engine start switch is turned to ON, the high-pressure fuel pump will oper- ate for 5 seconds. • Check the operation of the low-pressure fuel pump 3 using the “Stationary test” of the Yamaha Diagnostic System. 8-18 69J1D11...
Page 286: Starting System
– ELEC Electrical systems Starting system Br/W Br/W S69J8330 1 Fuse (30 A) : Black 2 Fuse (20 A) : Brown 3 Starter relay : Red 4 Starter motor Br/W : Brown/white 5 Battery 8-19 69J1D11...
Page 287: Checking The Fuse
Starting system Checking the fuse 1. Check the fuse for continuity. Replace if there is no continuity. S69J8340 Checking the wiring harness (10 pins) 1. Check the wiring harness for continuity. Replace if there is no continuity. Checking the starter relay 1.
Page 288: Starter Motor
– ELEC Electrical systems Starter motor 8-21 69J1D11...
Page 289 Starter motor Part name Q’ty Remarks Clip Pinion stopper Starter motor pinion Spring M6 × 35 mm Bolt Housing Rubber seal Bearing Clutch assembly E-clip Not reusable Thrust washer Center bracket Pinion shaft Planetary gear Outer gear Plate Armature Stator Brush holder assembly Plate Thrust washer...
Page 290: Removing The Starter Motor Pinion
– ELEC Electrical systems Removing the starter motor pinion 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2. 2. Measure commutator diameter. Replace the armature if out of specifica- tion. NOTE: Remove the clip with a thin screwdriver. Checking the starter motor pinion 1.
Page 291: Checking The Brushes
Starter motor Brush continuity Brush 1 – Brush 2 No continuity Checking the magnet switch 1. Connect the tester leads between the magnet switch terminals as shown. 2. Connect the positive battery terminal to the black and white (B/W) lead. Armature continuity 3.
Page 292: Charging System
– ELEC Electrical systems Charging system S69J8460U 1 Stator coil : Black 2 Rectifier Regulator : Green 3 Fuse (30 A) : Red 4 Starting battery : White 5 Accessory battery : Yellow 6 Fuel pump driver and isolator G/W : Green/white : Red/yellow 8-25 69J1D11...
Page 293: Checking The Stator Coil
Charging system Checking the stator coil Stator coil resistance (use as 1. Remove the intake silencer and discon- reference): nect the stator coil coupler. Green (G) – Green (G) 0.28–0.42 Ω at 20 °C (68 °F) 2. Connect the test harness (3 pins) to the 0.24–0.36 Ω...
Page 294 – ELEC Electrical systems Digital multimeter: YU-34899-A Peak voltage adaptor: YU-39991 Test harness (2 pins): YB-06787 Rectifier Regulator output peak voltage: Red (R) – Black (B) Red/yellow (R/Y) – Black (B) Unloaded r/min 1,500 3,500 DC V 8-27 69J1D11...
Page 295 TRBL SHTG Troubleshooting Special service tools ..................9-1 Yamaha Diagnostic System ................9-2 Introduction....................9-2 Power unit....................... 9-5 Bracket unit ....................9-14 Electrical systems..................9-18 Self-diagnosis....................9-19 Diagnosing the electronic control system ..........9-19 69J1D11...
Page 296: Trbl Shtg
TRBL SHTG Troubleshooting Special service tools Yamaha Diagnostic System 60V-85300-02 YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL Yamaha Diagnostic System 60V-WS853-02 Diagnostic test lead YB-06795 69J1D11...
Page 297 Yamaha Diagnostic System Introduction Features The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of an outboard motor using the communication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor.
Page 298 • Window XP is a multiuser operating system, therefore, be sure to end this program if the login user is changed. • The USB adapter cannot be used with Windows 95. For operating instructions of the Yamaha Diagnostic System, refer to the “Yamaha Diagnostic Sys- tem Instruction Manual.” 69J1D11...
Page 299 Yamaha Diagnostic System Connecting the communication cable to the outboard motor 3-pin communication coupler 69J1D11...
Page 300: Power Unit
TRBL SHTG Troubleshooting NOTE: • To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters 4– 8 for safe maintenance procedures. • Check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V.
Page 301 Power unit Is there Replace the engine stop lan- continuity? yard switch. Check the fuse for continuity. Is there Replace the fuse. continuity? Check the wiring harnesses for continuity. Is there Replace the wiring harnesses. continuity? Listen for the operation sound of the starter relay.
Page 302 TRBL SHTG Troubleshooting Symptom: Engine cranks, but will not start (engine stop lanyard switch is operating nor- mally). • Check the ignition system. • Check the fuel system. • Check the compression pressure of the power unit. WARNING Check that the spark plugs pro- •...
Page 303 Power unit Does the Check the compression pres- engine start? sure of the combustion chamber. Out of specification? Check the condition of the spark Failure in starting operation plugs again. Check the valve Wet spark plugs? Failure in starting operation clearance.
Page 304 Check the fuel Out of Check the pressure regulator. injector resistance. specification? Check the fuel system using the Out of Yamaha Diagnostic System. specification? Replace the fuel Good operat- Replace the pressure regulator. injector. ing condition? Check the fuel system using the Yamaha Diagnostic System.
Page 305 Check the ignition system out- specification? put peak voltage. Check the ignition Out of Replace the spark plug. system using the specification? Yamaha Diagnostic System. Check the ignition coils resist- ence. Check the ignition Out of Replace the ignition coil. system using the...
Page 306 Check the second- ary air intake on the O-ring and manifold Out of Synchronize the throttle valves. plate, idle speed specification? control hose, and the gaskets of the vacuum check bolts. Check the engine using the Yamaha Diagnostic System. 9-11 69J1D11...
Page 307 The engine turns off when the throttle is opened quickly. Acceleration is tardy and the engine is likely to stop at any moment. • Check the engine using the diagnostic flash indicator or the Yamaha Diagnostic System. Symptom: Engine can run, but engine speed will not increase.
Page 308 Check the oil pump for debris or specification? oil leaks. Check the oil Debris or leaks? passage. Clean or replace the respective Check the oil pressure sensor. parts. Good condition? Replace the oil pressure sensor. Check the engine using the Yamaha Diagnostic System. 9-13 69J1D11...
Page 309: Bracket Unit
Power unit / Bracket unit Bracket unit Symptom: Power trim and tilt unit does not operate. Listen for the operation sound of the power trim and tilt relay. Can the oper- Check the voltage between each terminal. ation sound • Between the sky blue (Sb) lead and black (B) lead. be heard? •...
Page 310 TRBL SHTG Troubleshooting At specified Add fluid to the correct level. level? Measure the hydraulic pressure. Out of Check the power trim and tilt specification? unit for leaks. Disassemble the power trim and tilt unit, and then check the filter for debris or dirt.
Page 311 Bracket unit Symptom: Power trim and tilt unit does not hold the outboard motor up. Check that the manual valve is closed. Is it closed? Close the valve. Check the power trim and tilt fluid level. At specified Add fluid to the correct level. level? Disassemble the power trim and tilt unit, and then check the...
Page 312 TRBL SHTG Troubleshooting Symptom: Shift mechanism of the forward gear and reverse gear does not operate properly. Check the shift cable operation. Good operat- Check the shift cables and links ing condition? of the remote control box. Check the operation of the shift rod.
Page 313: Electrical Systems
Bracket unit / Electrical systems Electrical systems Symptom: Battery becomes weaker quickly. • Check the charging system. Measure the output peak voltage of the stator coil. Out of Replace the stator coil. specification? Measure the Rectifier Regulator output peak voltage. Out of Replace the Rectifier Regulator.
Page 314: Self-Diagnosis
TRBL SHTG Troubleshooting Self-diagnosis Diagnosing the electronic control system 1. Connect the special tools to the outboard motor as shown. È • Trouble code indication Example: The illustration indicates code number 23. a: Light on, 0.33 second b: Light off, 4.95 seconds b: Light off, 0.33 second d: Light off, 1.65 seconds R/B, W/B, B...
Page 315 Self-diagnosis Code Symptom Normal Incorrect pulser coil signal Incorrect engine temperature sensor signal Incorrect throttle position sensor signal Incorrect battery voltage Incorrect intake air temperature sensor signal Incorrect neutral switch signal Incorrect intake air pressure sensor signal Incorrect idle speed control signal Incorrect oil pressure sensor signal...
Page 316 Index Checking the cooling water passage..3-9 Checking the cooling water pilot hole ..1-31 Adjusting the throttle link and throttle Checking the crankpin oil clearance..5-51 cable operation (with a stop bolt) ....3-10 Checking the crankshaft ......5-50 Adjusting the throttle link and throttle Checking the crankshaft main journal oil cable operation (without a stop bolt) ..3-11 clearance ..........
Page 317 Checking the piston clearance....5-48 Cooling system ......... 1-26 Checking the piston diameter ....5-47 Cylinder block ........... 5-43 Checking the piston pin......5-50 Cylinder head ........... 5-29 Checking the piston pin boss bore....5-49 Checking the piston ring grooves....5-49 Checking the piston ring side clearance ...5-49 Diagnosing the electronic control system ..
Page 318 Index Measuring the forward and reverse gear backlash ....6-28 6-54 General .............3-18 Measuring the fuel pressure General specifications.........2-1 (high-pressure fuel line)......3-5 General torques ........2-17 Measuring the lower resistance....8-2 Good working practices ......1-4 Measuring the peak voltage ....... 8-2 Hose routing..........4-2 Newly developed V6 4-stroke engine ..
Page 319 Technical tips ..........1-18 Test run.............1-31 Throttle control ..........4-13 Tightening torques ........2-14 Top cowling..........3-4 Top view............8-6 Upper case, steering arm, swivel bracket and clamp brackets ...7-7 Valve train system........1-9 Vapor separator ..........4-5 Ventilation ...........1-3 Wiring harness ..........8-7 Yamaha Diagnostic System......9-2 60C5D11...
Page 320 Wiring diagram F200TR, LF200TR, F225TR, LF225TR 1 Low-pressure fuel pump Color code 2 Accessory battery : Black 3 Fuel pump driver and isolator : Brown 4 High-pressure fuel pump : Green 5 Idle speed control : Blue 6 Fuel injector : Light green 7 Spark plug : Orange...
Page 321 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Sep. 2003 –...
Page 322 F200TR, LF200TR, F225TR, LF225TR É — È — Ê — — Sb R Lg Y/G3 R/Y1 B B B B B B R/Y4 R/Y5 R/Y6 1 2 3 4 5 6 G G G Lg R Sb Br/W Br/W (∗2) (∗1) S60LWD01U...
Page 323 È É Ê Ë Ì 6=EFG S60LWD02U...

This manual is also suitable for:

Lf200c F225c Lf225c F200tr Lf200trl F225tr ... Show all

Yamaha F200C Service Manual

Gen Info General Information

How to Use this Manual

Safety While Working

Identification

Features and Benefits

Technical Tips

Propeller Selection

Predelivery Checks

Spec Specifications

General Specifications

Maintenance Specifications

Tightening Torques

Chk Adj/Chk Adj

Chk Adj

Special Service Tools

Periodic Checks and Adjustments

Maintenance Interval Chart

Top Cowling

Fuel System

Power Unit

Control System

Power Trim and Tilt Unit

Lower Unit

General

Fuel Fuel System

Special Service Tools

Fuel System

Hose Routing

Intake Silencer, Fuel Filter, and Fuel Pump

Vapor Separator

Intake Manifold and High-Pressure Fuel Line

Throttle Control

Powr Power Unit

Special Service Tools

Power Unit

Cylinder Head

Cylinder Block

Lowr Lower Unit

Special Service Tools

Lower Unit

Lower Unit (Regular Rotation Model)

Propeller Shaft Housing (Regular Rotation Model)

Drive Shaft and Lower Case (Regular Rotation Model)

Shimming (Regular Rotation Model)

Backlash (Regular Rotation Model)

Lower Unit (Counter Rotation Model)

Propeller Shaft Housing (Counter Rotation Model)

Drive Shaft and Lower Case (Counter Rotation Model)

Shimming (Counter Rotation Model)

Backlash (Counter Rotation Model)

Brkt Bracket Unit

Special Service Tools

Bottom Cowling

Upper Case, Steering Arm, Swivel Bracket and Clamp Brackets

Power Trim and Tilt Unit

Bleeding the Power Trim and Tilt Unit

Power Trim and Tilt Electrical System

Elec Electrical Systems

Electrical Systems

Special Service Tools

Checking the Electrical Components

Electrical Components

Wiring Harness

Ignition and Ignition Control System

Fuel Control System

Starting System

Starter Motor

Charging System

Quick Links

Chapters

Troubleshooting

Related Manuals for Yamaha F200C

Summary of Contents for Yamaha F200C