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SELVA MARINE Blue Whale 250 EFI Service Manual

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Blue Whale 250

SERVICE MANUAL

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Summary of Contents for SELVA MARINE Blue Whale 250 EFI

Page 1 Blue Whale 250 SERVICE MANUAL...
Page 2: Important Information
NOTICE This manual has been prepared by Selva primarily for use by Selva dealers and their trained mechanics when performing maintenance procedures and repairs to Selva 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: Gen Info
Contents General information INFO Specification SPEC Periodic check and adjustment Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT – Electrical system ELEC Troubleshooting TRBL SHTG Index...
Page 4: Table Of Contents
INFO General information How to use this manual ................. 1-1 Manual format.................... 1-1 Symbol....................... 1-2 Abbreviation....................1-3 Safety while working..................1-4 Fire prevention................... 1-4 Ventilation....................1-4 Self-protection ................... 1-4 Part, lubricant, and sealant................ 1-4 Good working practice................1-5 Disassembly and assembly ............... 1-5 Identification....................1-6 Model......................
Page 5 Predelivery check ..................1-40 Checking the fuel system ................1-40 Checking the engine oil level..............1-40 Checking the gear oil level ..............1-40 Checking the battery................1-40 Checking the outboard motor mounting height........1-41 Checking the remote control cable ............1-41 Checking the steering system ..............1-42 Checking the gear shift and throttle operation.........1-42 Checking the PTT system ...............
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. •...
Page 7: Symbol
How to use this manual Symbol The symbols below are designed to indicate the content of a chapter. General information Fuel system Bracket unit FUEL BRKT INFO Specification Power unit Electrical system – SPEC POWR ELEC Periodic check and adjustment Lower unit Troubleshooting TRBL...
Page 8: Abbreviation
INFO General information Abbreviation The following abbreviations are used in this service manual. Abbreviation Description Aft end American Petroleum Institute Bow end Cold Cranking Ampere Dual Engine System Electronic Control Module European Norm (European standard) Exhaust International Electrotechnical Commission Intake Pressure Control Valve Pump Octane Number = (RON + Motor Octane Number)/2 PORT...
Page 9: Safety While Working
How to use this manual / Safety while working Safety while working To prevent an accident or injury and to ensure quality service, follow the safety pro- cedures provided below. Fire prevention Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames.
Page 10: Good Working Practice
INFO General information 6. Keep a supply of clean, lint-free cloths for Disassembly and assembly wiping up spills, etc. 1. Use compressed air to remove dust and dirt during disassembly. Good working practice Special service tool 2. Apply engine oil to the contact surfaces Use the recommended special service tools of moving parts before assembly.
Page 11: Identification
Safety while working / Identification Identification Model This manual covers the following model. Applicable model F250AET, FL250AET Serial number outboard motor serial number stamped on a label attached to the port clamp bracket. 1 Model name 2 Approved model code 3 Transom height 4 Serial number Approved...
Page 12: Special Service Tool
INFO General information Special service tool Oil filter wrench Compression gauge 90890-06830 90890-03160 Leakage tester Compression gauge extension 90890-06840 90890-06563 Fuel pressure gauge adapter B Test harness (3 pins) 90890-06942 90890-06869 Fuel pressure gauge Flywheel holder 90890-06786 90890-06522 Vacuum/pressure pump gauge set Flywheel puller 90890-06756 90890-06521...
Page 13 Special service tool Sheave holder Valve guide reamer 90890-01701 90890-06804 Valve spring compressor Valve seat cutter holder 90890-04019 90890-06316 Valve spring compressor attachment Valve seat cutter 90890-06320 90890-06324, 90890-06325, 90890-06326, 90890-06816, 90890-06817 Valve guide remover/installer 90890-06801 Bearing inner race attachment 90890-06640, 90890-06659, 90890-06661 Valve guide installer 90890-06810...
Page 14 INFO General information Needle bearing attachment Bearing separator 90890-06607, 90890-06610, 90890-06611, 90890-06534 90890-06613, 90890-06653, 90890-06654 Stopper guide stand Piston ring compressor 90890-06538 90890-05158 Bearing puller assembly Bearing housing puller claw L 90890-06535 90890-06502 Slide hammer Stopper guide plate 90890-06531 90890-06501 Bearing outer race puller assembly Center bolt 90890-06523...
Page 15 Special service tool Outer race puller claw A Bearing outer race attachment 90890-06532 90890-06622, 90890-06628, 90890-06658 Driver rod SS Drive shaft holder 6 90890-06604 90890-06520 Bearing depth plate Pinion nut holder 90890-06603 90890-06715 Ball bearing attachment Ball bearing attachment 90890-06656, 90890-06657 90890-06655 Driver rod LS Driver rod LL...
Page 16 INFO General information Shift rod push arm Magnet base plate 90890-06052 90890-07003 Pinion height gauge Dial gauge set 90890-06710 90890-01252 Digital caliper Magnet base B 90890-06704 90890-06844 Shimming plate Puller head 90890-06701 90890-06514 Backlash indicator Ring nut wrench 90890-06706 90890-06578 1-11 6P23H11...
Page 17 Special service tool PTT oil pressure gauge assembly Peak voltage adapter B 90890-06580 90890-03172 Cylinder-end screw wrench Ignition tester 90890-06568 90890-06754 PTT piston vice attachment Test harness (2 pins) 90890-06572 90890-06867 Tilt rod wrench Test harness (1 pin) 90890-06569 90890-06888 Digital circuit tester Diagnostic system 90890-03174...
Page 18 INFO General information Diagnostic system 60V-WS853-05 Diagnostic flash indicator B 90890-06865 1-13 6P23H11...
Page 19: Feature And Benefit
Special service tool / Feature and benefit Feature and benefit ECM system In the engine of the Blue Whale 250, the ECM controls the fuel injection volume, ignition timing, intake valve opening and closing timing, and the electronic throttle valve opening angle as well as the engine speed when the engine overheats and when the engine oil pressure is low.
Page 20 INFO General information ECM component S6P21111 1 Crank position sensor 2 Oil control valve (PORT) 3 Cam position sensor (PORT IN) 4 Oil control valve (STBD) 5 Cam position sensor (PORT EX) 6 ECM 7 Cam position sensor (STBD IN) 8 Knock sensor 9 Fuel injector 0 Vapor separator tank...
Page 21 Feature and benefit S6P21112 1 Vapor shut-off valve 2 TPS 1 3 TPS 2 4 Electronic throttle valve assembly 5 Intake air pressure sensor 6 Canister 7 Fuel filter with water separator 8 Neutral switch 9 Shift cut switch 0 Oil pressure sensor A Accelerator position sensor 1 B Accelerator position sensor 2 1-16...
Page 22 INFO General information Sensor function Sensor Function Crank position • Detects the engine speed. sensor • Controls the ignition timing, fuel injection volume, engine speed, engine knock, variable camshaft timing, and electronic throttle valve opening angle. • Detects the angle of the crankshaft and the position of the pistons. (Cannot detect the position of the exhaust and compression strokes.) •...
Page 23 Feature and benefit Circuit diagram NOTE: The circled numbers in the illustration indicate the ECM terminal numbers. Crank position sensor Fuel injector #1 Fuel injector #2 Fuel injector #3 Fuel injector #4 Cam position sensor (PORT EX) Fuel injector #5 Cam position sensor Fuel injector #6 (PORT IN)
Page 24 INFO General information Intake air temperature Oil control valve (STBD) sensor Oil control valve (PORT) Engine temperature sensor High-pressure fuel pump relay High-pressure fuel pump Thermoswitch Low-pressure fuel pump Shift cut switch Vapor shut-off valve Neutral switch Low oil pressure warning indicator Ground Overheat warning indicator...
Page 25 Feature and benefit ECM coupler layout 1 2 3 4 5 6 7 27 28 29 30 31 32 33 53 54 55 56 57 58 59 60 61 8 9 10 11 12 13 34 35 36 37 38 39 62 63 64 65 66 67 68 69 14 15 16 17 18 19 40 41 42 43 44 45...
Page 26 INFO General information 1 2 3 4 5 6 7 27 28 29 30 31 32 33 53 54 55 56 57 58 59 60 61 8 9 10 11 12 13 34 35 36 37 38 39 62 63 64 65 66 67 68 69 14 15 16 17 18 19 40 41 42 43 44 45 70 71 72 73 74 75 76 77...
Page 27: Electronic Fuel Injection Control System
Feature and benefit Electronic fuel injection control system In the Blue Wlale 250 engine, the electronic fuel injection control system controls the fuel injection tim- ing and volume. Maximum output, low fuel consumption, and low emissions are achieved by main- taining the optimum air-fuel ratio under various engine operating conditions.
Page 28 INFO General information Electronic fuel injection system diagram Fuel flows through the fuel filter in the water separator and the low-pressure fuel pump sends the fuel through the fuel filter and is sent to the vapor separator tank. When the fuel in the vapor separa- tor tank exceeds the specified volume, it returns to the low-pressure fuel pump via the fuel hose.
Page 29 Feature and benefit Circuit diagram Crank position sensor Fuel injector #1 Fuel injector #2 Cam position sensor (PORT EX) Fuel injector #3 Cam position sensor (PORT IN) Fuel injector #4 Cam position sensor (STBD IN) Fuel injector #5 Fuel injector #6 TPS 1 TPS 2 Ground...
Page 30: Ignition Timing Control System
INFO General information Ignition timing control system In the Blue Wlale 250 engine, the ignition timing control system controls the ignition timing and the power supply timing to the ignition coils. Maximum output, low fuel consumption, and low emissions are achieved by securing the optimum ignition timing under various engine operating conditions.
Page 31 Feature and benefit Circuit diagram Crank position sensor Ignition coil #1 Cam position sensor (PORT EX) Cam position sensor Ignition coil #2 (PORT IN) Cam position sensor (STBD IN) Ignition coil #3 TPS 1 TPS 2 Ignition coil #4 Ground Accelerator position sensor 1 Ignition coil #5...
Page 32: Knock Control System
INFO General information Knock control system In the Blue Wlale 250 engine, the knock sensor detects the engine knock that occurs due to abnormal combustion during operation and determines whether there is engine knock and its size. When engine knock is determined, the knock control system retards the ignition timing to prevent the occurrence of engine knock.
Page 33 Feature and benefit Circuit diagram Crank position sensor Ignition coil #1 Ignition coil #2 Ignition coil #3 TPS 1 TPS 2 Ignition coil #4 Ground Ignition coil #5 Ignition coil #6 Intake air pressure sensor Ground Knock sensor Main relay S6P21180 1-28 6P23H11...
Page 34: Variable Camshaft Timing Control System
INFO General information Variable camshaft timing control system In the Blue Wlale 250 engine, the opening and closing timing of the intake valves is controlled. The ECM operates the oil control valve according to the engine speed and the electronic throttle valve opening angle and controls the optimum opening and closing timing of the intake valves.
Page 35 Feature and benefit Oil control valve operation When the camshaft advances, the spool valve moves toward the coil spring according to the mag- netic force of the magnetic coil, the spring is compressed, and the engine oil is sent to the advance chamber passage.
Page 36 INFO General information Rotor vane operation The variable camshaft timing unit consists of a rotor vane and rotor vane housing. The rotor vane is fastened to the intake camshaft with a bolt, which allows them to rotate together. The rotor vane housing is fastened to the driven sprocket of the intake camshaft with a bolt, which allows them to rotate together.
Page 37 Feature and benefit Circuit diagram Crank position sensor Cam position sensor (PORT EX) Cam position sensor (PORT IN) Cam position sensor (STBD IN) TPS 1 TPS 2 Ground Oil control valve (STBD) Oil control valve (PORT) Engine temperature sensor Ground Main relay S6P21200...
Page 38: Electronic Throttle Valve Control System
INFO General information Electronic throttle valve control system In the Blue Wlale 250 engine, the electronic throttle valve control system converts the opening and closing of the remote control lever accelerator to an electronic signal and the ECM controls the throttle valves according to the operating condition of the accelerator opening.
Page 39 Feature and benefit Circuit diagram Fuel injector #1 Fuel injector #2 TPS 1 Fuel injector #3 TPS 2 Fuel injector #4 Ground Accelerator Fuel injector #5 position sensor 1 Fuel injector #6 Ground Accelerator position sensor 2 Ground Electronic throttle valve relay Engine temperature Electronic...
Page 40: Engine Speed Control System
INFO General information Engine speed control system In the Blue Wlale 250 engine, the engine speed control system decreases the engine speed to protect the engine from damage when the engine overheats or when the engine oil pressure is low. Engine speed control Description Control...
Page 41 Feature and benefit Description Control Engine condition Detects the status of the DES control and • When overheat controls the engine speed. warning or low oil pres- sure warning is acti- vated, the DES switch is turned on and the warn- ing buzzer is activated.
Page 42 INFO General information Circuit diagram Crank position sensor Fuel injector #1 Fuel injector #2 Fuel injector #3 Fuel injector #4 TPS 1 TPS 2 Fuel injector #5 Ground Fuel injector #6 Ignition coil #1 Oil pressure sensor Ignition coil #2 Ignition coil #3 Engine temperature sensor...
Page 43: Lower Unit
Feature and benefit Lower unit A spring has been added to the lower unit for the Blue Wlale 250 The spring is used to push the drive shaft toward the water pump and stabilize the thrust free play of the shaft. This spring facilitates the backlash measurement procedure since the lower unit does not need to be turned upsidedown to carry out the measurement.
Page 44: Propeller Selection
INFO General information Propeller selection Selection When the engine speed is at the full throttle The performance of a boat and outboard operating range (5,000–6,000 r/min), the motor will be critically affected by the size ideal propeller for the boat is one that pro- and type of propeller you choose.
Page 45: Predelivery Check
Propeller selection / Predelivery check Predelivery check NOTE: To make the delivery process smooth and If the engine oil is below the minimum level efficient, the predelivery checks should be mark (L), add sufficient oil until the level is completed as explained below. between (H) and (L).
Page 46: 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 47: Checking The Steering System
Predelivery check Checking the steering system 3. Check that there is no interference with wires or hoses when the tilted-up out- 1. Check that steering operates board motor is steered. smoothly. 4. Check that the trim meter points down when the outboard motor is tilted all the way down.
Page 48: Checking The Cooling Water Pilot Hole
INFO General information Checking the cooling water pilot hole 1. Start the engine, check that cooling water is discharged from the cooling water pilot hole. È S69J1240 È Hour After test run 1. Check for water in the gear oil. S6P21050 2.
Page 49 SPEC Specification General specification..................2-1 Maintenance specification ................2-3 Power unit....................2-3 Lower unit ....................2-6 Electrical ....................2-7 Dimension....................2-10 Tightening torque..................2-12 Specified torque..................2-12 General torque..................2-15 6P23H11...
Page 50: Specification
SPEC Specification General specification Model Item Unit 250 R 250 L Dimension Overall length mm (in) 892 (35.1) Overall width mm (in) 634 (25.0) Overall height mm (in) 1,829 (72.0) mm (in) 1,956 (77.0) Boat transom height mm (in) 635 (25.0) mm (in) 762 (30.0) Weight...
Page 51 General specification Model Item Unit 250 R 250 L Fuel and oil Fuel type Premium unleaded gasoline Fuel minimum rating Engine oil 4-stroke motor oil (*1) Engine oil grade SE, SF, SG, SH, SJ, or SL 5W-30, 10W-30, or 10W-40 Engine oil quantity (without oil filter replacement) L (US qt,...
Page 52: Maintenance Specification
SPEC Specification Maintenance specification Power unit Model Item Unit 250 R 250 L Power unit Minimum compression 740 (7.4, 107.3) (*1) pressure (kgf/cm , psi) (*2) Oil pressure 600 (6.0, 87.0) at 60 °C (140 °F) with SL 10W- (kgf/cm , psi) 30 engine oil and at 900 r/min Cylinder head...
Page 53 Maintenance specification Model Item Unit 250 R 250 L Oil ring Dimension B mm (in) 2.40–2.47 (0.094–0.097) Dimension T mm (in) 2.30–2.70 (0.091–0.106) (*1) End gap mm (in) 0.15–0.60 (0.006–0.024) Side clearance mm (in) 0.04–0.13 (0.002–0.005) Camshaft Intake (A) mm (in) 46.30–46.40 (1.823–1.827) Exhaust (A) mm (in)
Page 54 SPEC Specification Model Item Unit 250 R 250 L Valve lifter Valve lifter outside diameter mm (in) 32.982–32.997 (1.2985–1.2991) Valve lifter-to-cylinder head mm (in) 0.020–0.055 (0.0008–0.0022) clearance Valve shim Valve shim thickness mm (in) 2.320–2.960 (0.0913–0.1165) (in 0.020 mm increments) Connecting rod Small end inside diameter mm (in)
Page 55: Lower Unit
Maintenance specification Model Item Unit 250 R 250 L Thermostat Opening temperature °C (°F) 58–62 (136–144) Fully open temperature °C (°F) 70 (158) Valve open lower limit mm (in) 4.3 (0.17) Lower unit Model Item Unit 250 R 250 L Gear backlash Pinion-to-forward gear mm (in)
Page 56: Electrical
SPEC Specification Electrical Model Item Unit 250 R 250 L Ignition and ignition control system Spark plug gap mm (in) 1.0–1.1 (0.039–0.043) Crank position sensor output peak voltage (W/B – B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) 14.5 at 3,500 r/min (loaded) 17.8...
Page 57 Maintenance specification Model Item Unit 250 R 250 L Accelerator position sensor (*1) resistance at 20 °C (68 °F) with accelerator lever fully kΩ 0.800 closed with accelerator lever fully kΩ 5.300 open Variable camshaft timing control system Oil control valve resistance Ω...
Page 58 SPEC Specification Model Item Unit 250 R 250 L PTT system Trim sensor Ω 10 ± 1 Setting resistance Ω Resistance 9–387.6 Fluid type ATF Dexron II Motor brushes Standard length mm (in) 11.5 (0.45) Wear limit mm (in) 4.5 (0.18) Motor commutator Standard diameter mm (in)
Page 59: Dimension
Maintenance specification Dimension Exterior mm (in) X: 1,155 (45.5) 619 (24.4) U: 1,272 (50.1) 219 (8.6) 651 (25.6) 75 (3.0) 230 (9.1) X: 52 (2.0) U: 59 (2.3) 673 (26.5) S6P22020 2-10 6P23H11...
Page 60 SPEC Specification Clamp bracket mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 79 (3.1) 13 (0.5) 13 (0.5) 101.5 (4.0) 101.5 (4.0) 125.4 (4.9) 125.4 (4.9) S6P22010 2-11 6P23H11...
Page 61: Tightening Torque
Maintenance specification / Tightening torque Tightening torque Specified torque Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel system Filter cup — 0.35 Intake manifold bolt Intake silencer bolt Electronic throttle valve assembly nut — Throttle damper plate bolt Canister mounting bolt Canister bracket bolt Vapor shut-off valve mounting nut...
Page 62 SPEC Specification Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb ECM bolt PTT relay lead nut — Rectifier Regulator bolt Exhaust cover bolt 10.3 Exhaust cover plug 20.7 40.6 Anode screw Engine hanger bolt 10.3 20.7 17.0 33.2 Cylinder head bolt Loosen completely...
Page 63 Tightening torque Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Grease nipple — Propeller shaft housing bolt 22.1 Cooling water inlet cover screw Pinion nut — 14.2 104.7 Lower unit (counter rotation model) Gear oil check screw —...
Page 64: General Torque
SPEC Specification Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Manual valve — Pipe joint — 11.1 Pipe joint adapter — 14.8 Gear pump bolt Gear pump bracket bolt Trim cylinder end screw — 118.0 Tilt ram —...
Page 65 Periodic check and adjustment Maintenance interval chart................3-1 Top cowling ....................3-3 Checking the top cowling................3-3 Fuel system ....................3-3 Checking the fuel joint and fuel hose (fuel joint-to-fuel injector) ....3-3 Checking the fuel filter ................3-4 Power unit....................... 3-4 Checking the engine oil ................3-4 Changing the engine oil using an oil changer..........3-4 Changing the engine oil by draining it ............3-5...
Page 66: Chk Adj
Periodic check and adjustment 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 10 hours 50 hours 100 hours 200 hours page...
Page 67 Maintenance interval chart Every Refer to Item Remarks 500 hours 1,000 hours page (2.5 years) (5 years) Timing belt Replace 5-15 Valve clearance (DOHC) Check/adjust 5-10 Fuel filter Replace 4-23 (vapor separator tank) Oil control valve filter Check/replace 5-41 Anodes Replace 3-14 (exhaust cover, cooling water...
Page 68: Top Cowling
Periodic check and adjustment 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 hose (fuel joint-to-fuel injector) 1. Remove the flywheel magnet cover, port 2.
Page 69: Checking The Fuel Filter
Top cowling / Fuel system / Power unit NOTE: NOTE: To install the intake manifold, see Chapter 4, • Change the oil if it appears milky or dirty. “Installing the intake manifold.” • If the engine oil is below the minimum level mark (L), add sufficient oil until the level is between (H) and (L).
Page 70: Changing The Engine Oil By Draining It
Periodic check and adjustment 5. Pour the specified amount of the recom- 4. Place a drain pan under the drain hole, mended engine oil into the oil filler hole. and then remove the engine oil drain bolt 3 and let the oil drain completely. Recommended engine oil: 4-stroke motor oil API: SE, SF, SG, SH, SJ, or SL...
Page 71: Replacing The Oil Filter
Power unit 4. Install the oil filter, and then tighten it to the specified torque using a 72.5 mm (2.9 in) oil filter wrench. S6S13220 Apron bolt: 8 N·m (0.8 kgf·m, 5.9 ft·lb) Replacing the oil filter CAUTION: S6P23090 Do not damage the oil pressure sensor Oil filter: and its lead when replacing the oil filter.
Page 72: Checking The Spark Plug
Periodic check and adjustment 2. While turning the flywheel magnet clock- wise, check the interior a and the exte- rior b of the timing belt. Replace if cracked, damaged, or worn. 4. Check the electrodes for erosion and excessive carbon or other deposits, and the gasket for damage.
Page 73 Power unit NOTE: To reduce the fuel pressure, see Chapter 4, “Reducing the fuel pressure.” 2. Remove the flywheel magnet cover. 3. Disconnect the oil control valve couplers S6P23320E 4. Disconnect the thermoswitch connectors CAUTION: Do not reuse the gaskets 6, always 5.
Page 74: Checking The Cooling Water Passage
Periodic check and adjustment 9. Check the thermostat valve opening at specified water temperatures. Replace if out of specification. Water Valve lift a temperature 0.05 mm 58–62 °C S6P23150 (0.0020 in) (136–144 °F) (valve begins to lift) 2. Place the lower unit in water, and then above more than start the engine.
Page 75: Adjusting The Throttle Cable
Power unit / Control system Engine idle speed: 600–700 r/min Adjusting the throttle cable 1. Set the remote control lever to the neu- tral position and fully close the throttle lever. 2. Loosen the locknut 1, remove the clip S6D53190 2, and then disconnect the throttle cable WARNING joint 3.
Page 76: Checking The Gear Shift Operation
Periodic check and adjustment 4. Loosen the locknut 1, remove the clip 6. Operate the remote control lever several 2, and then disconnect the shift cable times, and then check that the mark b on the lever 4 has passed the mark c joint 3.
Page 77: Bracket Unit
Control system / Bracket unit Checking the PTT fluid level 8. Check the gear shift for smooth operation, check the operation of the neutral switch 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. and, if necessary, repeat steps 3–7.
Page 78: Lower Unit
Periodic check and adjustment 3. If necessary, add sufficient fluid of the Gear oil check screw: recommended type until it overflows out 9 N·m (0.9 kgf·m, 6.6 ft·lb) of the filler hole. Recommended PTT fluid: Changing the gear oil ATF Dexron II 1.
Page 79: Checking The Lower Unit For Air Leakage
Bracket unit / Lower unit / General NOTE: Recommended gear oil: Cover the check hole with a rag when remov- Hypoid gear oil ing the tester from the lower unit. API: GL-4 SAE: 90 Gear oil quantity: Lower unit holding pressure: Regular rotation model: 70 kPa (0.7 kgf/cm , 10 psi)
Page 80: Checking The Battery
Periodic check and adjustment S6P23270E CAUTION: Do not oil, grease, or paint the anodes or the trim tab, otherwise they will be ineffec- S6P23210 tive. NOTE: If it is necessary to disassemble the outboard motor to check an anode, refer to the applica- ble disassembly procedure in this manual.
Page 81: Lubricating The Outboard Motor
General NOTE: • Batteries vary per manufacturer. The pro- cedures mentioned in this manual may not always apply, therefore, consult the instruc- tion manual of the battery. • Disconnect the negative battery cable first, then the positive battery cable. S69J3620 Electrolyte specific gravity: 1.280 at 20 °C (68 °F) 2.
Page 82 Periodic check and adjustment S6D03010 NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the area shown. S6P23410 3. Apply corrosion resistant grease to the area shown. 3-17 6P23H11...
Page 83 FUEL Fuel system Hose routing ....................4-1 Fuel hose and blowby hose............... 4-1 Vapor gas hose ..................4-2 Cooling water hose..................4-3 Checking the throttle valve operation ............4-5 Checking the TPS..................4-5 Measuring the fuel pressure ..............4-7 Checking the pressure regulator ............... 4-8 Reducing the fuel pressure................
Page 84: Fuel System
FUEL Fuel system Hose routing Fuel hose and blowby hose S6P24010 1 Fuel hose (fuel joint-to-fuel filter) 2 Fuel hose (fuel filter-to-joint) 3 Fuel hose (joint-to-low-pressure fuel pump) 4 Fuel hose (low-pressure fuel pump-to-filter) 5 Fuel hose (filter-to-joint) 6 Fuel hose (joint-to-check valve) 7 Fuel hose (check valve-to-joint) 8 Fuel hose (vapor separator-to-quick connector) 9 Fuel hose (quick connector-to-joint)
Page 85: Vapor Gas Hose
Hose routing Vapor gas hose È STBD Ê É Ê Ì È É Ì Ë Ë Í Í S6P24020E 1 Vapor gas hose (vapor separator-to-joint) B Vapor gas hose (joint-to-joint) 2 Vapor gas hose (vapor separator-to-joint) C Vapor gas hose (joint-to-check valve) 3 Vapor gas hose (joint-to-joint) D Vapor gas hose (check valve-to-top cowling 4 Vapor gas hose (joint-to-joint)
Page 86: Cooling Water Hose
FUEL Fuel system Cooling water hose PORT STBD S6P24450E 1 Cooling water hose (cylinder block-to-fuel cooler) 2 Cooling water hose (fuel cooler-to-Rectifier Regulator) 3 Cooling water hose (Rectifier Regulator-to-cooling water pilot hole) 4 Cooling water hose (port thermostat cover-to-cylinder block) 5 Cooling water hose (starboard thermostat cover-to-cylinder block) 6 Cooling water hose (starboard cylinder head-to-cooling water pressure sensor adapter) 7 Flushing hose (joint-to-cooling water passage cover)
Page 87 Hose routing S6P24490 1 Cooling water hose (cylinder block-to-fuel cooler) 2 Cooling water hose (Rectifier Regulator-to-cooling water pilot hole) 3 Flushing hose (joint-to-cooling water passage cover) 4 Flushing hose (flushing hose adapter-to-joint) 5 Speedometer hose 6P23H11...
Page 88: Checking The Throttle Valve Operation
FUEL Fuel system Checking the throttle valve operation 1. Remove the flywheel magnet cover and intake silencer. NOTE: See the exploded diagram (4-12). 2. Push the throttle valve, and check that the valve moves smoothly when the S6P24140 engine start switch is turned to OFF. NOTE: 3.
Page 89 Hose routing 4. Check that the remote control lever is in Output voltage of TPS 1 with the the fully closed position of the throttle, remote control lever at the fully and then check the output voltage of TPS closed position: 1 and the throttle valve opening angle.
Page 90: Measuring The Fuel Pressure
FUEL Fuel system Measuring the fuel pressure 4. Turn the engine start switch to ON, and then measure the fuel pressure within 5 1. Disconnect the quick connector from the seconds. vapor separator. NOTE: NOTE: • The fuel pressure will decreases after 5 Before disconnecting the quick connector, seconds later when the engine start switch reduce the fuel pressure.
Page 91: Checking The Pressure Regulator
Hose routing Checking the pressure regulator Fuel pressure gauge: 90890-06786 1. Disconnect the quick connector from the Fuel pressure gauge adapter B: vapor separator. 90890-06942 NOTE: Vacuum/pressure pump gauge set: Before disconnecting the quick connector, 90890-06756 reduce the fuel pressure. 5.
Page 92: Reducing The Fuel Pressure
FUEL Fuel system Reducing the fuel pressure Disconnecting the quick connector WARNING WARNING Always reduce the fuel pressure in the If the quick connector is removed sud- high-pressure fuel line before servicing denly, pressurized fuel could spray out. the line or the vapor separator. If the fuel Be sure to reduce the fuel pressure before pressure is not released, pressurized fuel removing the quick connector.
Page 93: Draining The Fuel
Hose routing WARNING Reduce the fuel pressure before loosen- ing the vapor separator drain screw, or pressurized fuel will spray out and may result in serious injury. 6. Tighten the drain screw. S6P24280 Vapor separator drain screw: 2 N·m (0.2 kgf·m, 1.5 ft·lb) Draining the fuel 1.
Page 94: Fuel Filter
FUEL Fuel system Fuel filter · · · 3.5 N m (0.35 kgf m, 2.6 ft S6P24040E Part name Q’ty Remarks O-ring Not reusable O-ring Not reusable Fuel filter element Float Fuel filter assembly Bracket M6 × 16 mm Bolt M6 ×...
Page 95: Intake Manifold
Fuel filter / Intake manifold Intake manifold · · · m (0.7 kgf m, 5.2 ft · · · 10 N m (1.0 kgf m, 7.4 ft · · · 10 N m (1.0 kgf m, 7.4 ft S6P24050E Part name Q’ty Remarks Flywheel magnet cover...
Page 96: Installing The Intake Manifold
FUEL Fuel system Installing the intake manifold STBD PORT 1. Install new gaskets onto the intake mani- folds. ± ± S6P24090 Intake manifold bolt: 10 N·m (1.0 kgf·m, 7.4 ft·lb) S6P24060 NOTE: 4. Tighten the M8 bolts in the sequence Be sure to install the projection on each gas- shown.
Page 97 Intake manifold S6P24380 4-14 6P23H11...
Page 98: Throttle Body
FUEL Fuel system Throttle body · · · · · · · · · 13 N m (1.3 kgf m, 9.6 ft 13 N m (1.3 kgf m, 9.6 ft 13 N m (1.3 kgf m, 9.6 ft · · ·...
Page 99 Throttle body · · · · · · · · · 13 N m (1.3 kgf m, 9.6 ft 13 N m (1.3 kgf m, 9.6 ft 13 N m (1.3 kgf m, 9.6 ft · · · m (0.5 kgf m, 3.7 ft ·...
Page 100 FUEL Fuel system 9 mm 7 mm (0.35 in) (0.27 in) 9 mm 7 mm 9 mm (0.35 in) (0.27 in) (0.35 in) 9 mm 12 mm 9 mm (0.35 in) (0.47 in) (0.35 in) S6P24500E Part name Q’ty Remarks Check valve Holder Holder...
Page 101: Checking The Canister
Throttle body Checking the canister 2. Apply positive pressure to the check valve port. 1. Check the canister. Replace if cracked. 3. Check that air comes out of the opposite 2. Connect the special service tool to the atmospheric port 1 and cover the other end of the check valve.
Page 102 FUEL Fuel system 2. Connect the hoses and fasten them. É Ê Ë S6P24410 NOTE: Fasten the pressure regulator hose 3 and vapor separator hose 6 to the holder. S6P24400E É To the pressure regulator 6. Fasten the wiring harness to the holders. Ê...
Page 103: Low-Pressure Fuel Pump
Throttle body / Low-pressure fuel pump Low-pressure fuel pump Part name Q’ty Remarks Low-pressure fuel pump Cover M6 × 15 mm Bolt ø5 × 8 mm Screw Holder Check valve Clamp Clamp Joint Holder Cover Filter Fuel hose Plastic tie Not reusable Plastic tie Not reusable...
Page 104: Checking The Check Valve
FUEL Fuel system Checking the check valve 1. Connect the special service tool to the check valve port as shown. Vacuum/pressure pump gauge set: 90890-06756 2. Apply positive pressure to the check valve port. 3. Check that air comes out of the opposite end of the check valve.
Page 105: Vapor Separator
Low-pressure fuel pump / Vapor separator Vapor separator · · · m (0.5 kgf m, 3.7 ft 12 mm (0.47 in) 10 mm (0.39 in) S6P24520 Part name Q’ty Remarks Bracket M6 × 16 mm Bolt Collar Grommet M6 × 35 mm Bolt Collar Fuel cooler...
Page 106 FUEL Fuel system · · · m (0.5 kgf m, 3.7 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.2 kgf m, 1.5 ft · · · · · · m (0.2 kgf m, 1.5 ft m (0.2 kgf m, 1.5 ft S6P24250E...
Page 107: Vapor Separator
Vapor separator · · · m (0.5 kgf m, 3.7 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.2 kgf m, 1.5 ft · · · · · · m (0.2 kgf m, 1.5 ft m (0.2 kgf m, 1.5 ft S6P24250E...
Page 108: Removing The Fuel Hose Clamp
FUEL Fuel system Removing the fuel hose clamp 1. Remove the fuel hose clamps by cutting the crimped section of the clamp. S6D54200 2. Check the float. Replace if there is deteri- oration. 3. Check the filter. Clean if there is dirt or CAUTION: residue.
Page 109: Fuel Injector
Vapor separator / Fuel injector Fuel injector S6P24320 Part name Q’ty Remarks Fuel injector O-ring set Not reusable Holder Fuel rail (PORT) M6 × 35 mm Bolt Cover M6 × 20 mm Bolt Fuel rail (STBD) Cover Plastic tie Fuel rail assembly (PORT) Fuel rail assembly (STBD) 4-26 6P23H11...
Page 110: Installing The Fuel Injector
FUEL Fuel system Installing the fuel injector 4. Install the fuel rails onto the cylinder heads. 1. Apply engine oil to new O-rings, and then install them onto the fuel injectors. 5. Tighten the bolts 7 equally and gradu- ally. S6P24330 2.
Page 111 Fuel injector — MEMO — 4-28 6P23H11...
Page 112 POWR Power unit Power unit....................... 5-1 Checking the compression pressure ............5-1 Checking the oil pressure ................5-1 Checking the oil pressure sensor .............. 5-2 Checking the valve clearance..............5-10 Adjusting the valve clearance..............5-11 Replacing the timing belt .................5-15 Removing the wiring harness guide ............5-20 Removing the power unit.................5-21 Removing the timing belt, driven sprocket, and camshaft .......5-23 Checking the timing belt and sprocket.............5-27...
Page 113 Crankcase ..................... 5-53 Cylinder block ....................5-55 Disassembling the cylinder block ............5-57 Checking the piston diameter ..............5-58 Checking the cylinder bore ..............5-58 Checking the piston clearance (reference)..........5-58 Checking the piston ring ................5-58 Checking the piston ring end gap (reference) .........5-59 Checking the piston ring groove ..............5-59 Checking the piston ring side clearance..........
Page 114: Power Unit
POWR Power unit Power unit 6. Crank the engine until the reading on the compression gauge stabilizes, and then Checking the compression pressure check the compression pressure. 1. Start the engine, warm it up for 5 min- utes, and then turn it off. Minimum compression pressure (reference data): 2.
Page 115: Checking The Oil Pressure Sensor
Power unit 4. Check the oil pressure. Check for oil leakage and check the oil pump and oil strainer if out of specification. 3.4 V NOTE: È • If the oil pressure sensor is removed, the engine idle speed will increase about 900 r/min due to an oil pressure sensor mal- 600 kpa É...
Page 116 POWR Power unit · · · · · · m (0.8 kgf m, 5.9 ft m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft · · · 42 N m (4.2 kgf m, 31.0 ft S6P25050E Part name Q’ty...
Page 117 Power unit · · · · · · m (0.8 kgf m, 5.9 ft m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft · · · 42 N m (4.2 kgf m, 31.0 ft S6P25050E Part name Q’ty...
Page 118 POWR Power unit · · · m (0.7 kgf m, 5.2 ft · · · 25 N m (2.5 kgf m, 18.4 ft 25 26 · · · 25 N m (2.5 kgf m, 18.4 ft · · · m (0.7 kgf m, 5.2 ft ·...
Page 119 Power unit · · · m (0.7 kgf m, 5.2 ft · · · 25 N m (2.5 kgf m, 18.4 ft 25 26 · · · 25 N m (2.5 kgf m, 18.4 ft · · · m (0.7 kgf m, 5.2 ft ·...
Page 120 POWR Power unit · · · 240 N m (24.0 kgf m, 177.0 ft · · · 39 N m (3.9 kgf m, 28.8 ft · · · m (0.4 kgf m, 3.0 ft S6P25070 Part name Q’ty Remarks Width across flats: 36 mm Washer Flywheel magnet Stator assembly...
Page 121 Power unit · · · · · · m (0.8 kgf m, 5.9 ft m (0.2 kgf m, 1.5 ft 1280B · · · 17 N m (1.7 kgf m, 12.5 ft 1386B · · · m (0.8 kgf m, 5.9 ft ·...
Page 122 POWR Power unit · · · · · · m (0.8 kgf m, 5.9 ft m (0.2 kgf m, 1.5 ft 1280B · · · 17 N m (1.7 kgf m, 12.5 ft 1386B · · · m (0.8 kgf m, 5.9 ft ·...
Page 123: Checking The Valve Clearance
Power unit Checking the valve clearance 7. Remove the cylinder head covers. NOTE: CAUTION: See the exploded diagram (5-8). Do not turn the flywheel magnet counter- clockwise, otherwise the water pump impeller may be damaged. 8. Turn the flywheel magnet clockwise and align the “1TDC”...
Page 124: Adjusting The Valve Clearance
POWR Power unit 10. Check the valve clearances to the follow- 14. Turn the flywheel magnet an additional ing steps. 120° clockwise and align the “3TDC” mark h on the flywheel magnet with the pointer b. 15. Check the intake and exhaust valve clearances for cylinder #6.
Page 125 Power unit CAUTION: Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily. Flywheel holder: 90890-06522 5. Remove the flywheel magnet and Woo- druff key, and then remove the stator assembly. S6P25100 3.
Page 126 POWR Power unit 6. Remove the timing belt, driven sprock- NOTE: ets, and camshafts. To install the camshafts, driven sprockets, and timing belt, see “Installing the camshaft, NOTE: To remove the timing belt, driven sprockets, driven sprocket, and timing belt.” and camshafts, see “Removing the timing belt, driven sprocket, and camshaft.”...
Page 127 Power unit NOTE: NOTE: • Apply sealant to the edge of the cylinder It is recommended to check the crank posi- head cover gasket before installation. tion sensor air gap before installing the wiring • See the exploded diagram (5-8). harness guide to improve working efficiency.
Page 128: Replacing The Timing Belt
POWR Power unit Replacing the timing belt CAUTION: • Do not turn the flywheel magnet coun- terclockwise, otherwise the water pump impeller may be damaged. • Do not turn the flywheel magnet or the driven sprockets when the timing belt is not installed.
Page 129 Power unit S6P25130E S6P25E00 NOTE: CAUTION: To remove the wiring harness guide, see To prevent damage to the engine or tools, “Removing the wiring harness guide.” screw in the puller set bolts evenly and completely so that the flywheel puller is parallel to the flywheel magnet.
Page 130 POWR Power unit 14. Check that the “ ” mark e on the drive sprocket and the “ ” mark f on the cyl- inder block are aligned. 15. Check that the “II” marks c on the port driven sprockets are aligned, and check that the “I”...
Page 131 Power unit S6P25220 S6P25240E È 0 1 2 3 S6P25250 S6P25230 È Number of belt teeth Timing belt installation height r: CAUTION: 2.0 mm (0.08 in) • Do not twist, turn inside out, or bend the timing belt beyond the maximum limit of 22.
Page 132 POWR Power unit 23. Turn the crankshaft clockwise two full Flywheel magnet nut: turns, and then check that alignment 240 N·m (24.0 kgf·m, 177.0 ft·lb) marks c through f are aligned. 27. Check the crank position sensor air gap S6P25270 NOTE: It is recommended to check the crank posi- tion sensor air gap before installing the wiring...
Page 133: Removing The Wiring Harness Guide
Power unit Timing belt-to-timing belt guide PORT clearance t: 1.0 ± 0.5 mm (0.04 ± 0.02 in) 29. Install the wiring harness guide. NOTE: To install the wiring harness guide, see “Installing the wiring harness.” S6P25390 STBD 30. Install all parts removed during disas- sembly.
Page 134: Removing The Power Unit
POWR Power unit 7. Disconnect the quick connectors 8 and Removing the power unit remove the high-pressure fuel hose NOTE: assembly (vapor separator-to-starboard It is recommended to loosen the flywheel fuel rail). magnet nut before removing the power unit to improve working efficiency.
Page 135 Power unit S6P25310 S6P25330E 12. Disconnect the flushing hose H. 6. Disconnect the cooling water pilot hose 7. Remove the neutral switch coupler 9 from the bracket, and disconnect the neutral switch coupler and shift cut switch coupler 0. 8. Remove the oil dipstick A and dipstick guide B.
Page 136: Removing The Timing Belt, Driven Sprocket, And Camshaft
POWR Power unit 14. Retract the port and starboard top cowl- ing lock levers. PORT STBD S6P25360 STBD PORT S6P25370E Removing the timing belt, driven sprocket, and camshaft S6P25365 CAUTION: CAUTION: • Do not turn the crankshaft counterclock- Make sure that the top cowling lock levers wise, otherwise the water pump impeller are retracted and the engine stoppers are may be damaged.
Page 137 Power unit S6P25430 S6P25450E 3. Remove the timing belt guides 1 and cylinder head covers 2. È 0 1 2 3 S6P25460 È Number of belt teeth NOTE: S6P25440E It is not necessary to mark the timing belt when replacing it. NOTE: See the exploded diagram (5-8).
Page 138 POWR Power unit 5. Turn the timing belt tensioner gradually CAUTION: clockwise using a hexagon wrench, and then insert a ø5.0 mm (0.2 in) pin 3 into Do not turn the crankshaft counterclock- the hole n. wise more than 60°. Otherwise the piston and valves will collide with each other and be damaged.
Page 139 Power unit 13. Remove the exhaust driven sprocket. CAUTION: • Do not hold the camshaft when remov- ing the variable camshaft timing cap. Otherwise the variable camshaft timing assembly can be damaged. • Do not turn the driven sprocket when removing the variable camshaft timing cap.
Page 140: Checking The Timing Belt And Sprocket
POWR Power unit 14. Remove the camshaft caps in the Checking the timing belt and sequence shown. sprocket 1. Check the interior and exterior of the tim- 15. Remove the camshafts 8 and oil seals ing belt. Replace if cracked, damaged, or worn.
Page 141: Installing The Camshaft, Driven Sprocket, And Timing Belt
Power unit S69J5970C Cam lobe a: Camshaft journal diameter c: Intake: 24.96–24.98 mm 46.30–46.40 mm (0.9826–0.9834 in) Camshaft cap inside diameter d: (1.823–1.827 in) Exhaust: 25.000–25.021 mm 45.35–45.45 mm (0.9843–0.9851 in) (1.785–1.789 in) Cam lobe b: Installing the camshaft, driven Intake and exhaust: sprocket, and timing belt 35.95–36.05 mm...
Page 142 POWR Power unit 2. Install the valve lifters onto the cylinder heads. NOTE: • Apply engine oil to the valve shims and valve lifters before installation. PORT STBD • Install the valve shims and valve lifters in their original positions. S-IN 3.
Page 143 Power unit PORT STBD È É PORT S6P25E20 É 7. Tighten the camshaft cap bolts to the È specified torques in 2 stages and in the sequence shown. STBD S6P25F10E PORT STBD S6P25620 CAUTION: Do not turn the exhaust camshaft when S6P25610E tightening the bolt.
Page 144 POWR Power unit 11. Check that the lower edge of the intake CAUTION: exhaust driven sprockets aligned. • Do not hold the driven sprocket when tightening the variable camshaft timing bolt. Otherwise the variable camshaft timing assembly could be damaged. •...
Page 145 Power unit CAUTION: Sheave holder: 90890-01701 Do not turn the crankshaft clockwise more than 60°. Otherwise the piston and valves will collide with each other and be Variable camshaft timing cap 3: damaged. 32 N·m (3.2 kgf·m, 23.6 ft·lb) 14. Align the “II” marks b on the port driven 16.
Page 146 POWR Power unit 17. Install the timing belt onto the drive sprocket with the arrow mark e facing upward and align the timing belt mark f with the “ ” mark on the drive sprocket. S6P25700E S6P25690 S6P25710 Ì 0 1 2 3 Timing belt installation height n: 2.0 mm (0.08 in) S6P25460E...
Page 147 Power unit 20. Turn the crankshaft clockwise two full 22. Install the timing belt guide, and then turns, and then check that alignment adjust the timing belt-to-timing belt guide marks a through d are aligned. clearance p. S6P25725 S6P25150 21. Install the cylinder head covers, and then Timing belt-to-timing belt guide clearance p: tighten the bolts to the specified torque in...
Page 148: Starter Motor And Accelerator Position Sensor
POWR Power unit Starter motor and accelerator position sensor · · · 18 N m (1.8 kgf m, 13.3 ft · · · 18 N m (1.8 kgf m, 13.3 ft · · · 26 N m (2.6 kgf m, 19.2 ft ·...
Page 149: Ecm
Starter motor and accelerator position sensor / ECM · · · m (0.7 kgf m, 5.2 ft S6P25750 Part name Q’ty Remarks M6 × 20 mm Bolt Holder Plastic tie Holder M6 × 16 mm Bolt Plate Holder Holder Plate Holder ECM bracket Grommet...
Page 150: Fuse Box
POWR Power unit Fuse box 6 8 9 13 S6P25760 Part name Q’ty Remarks Fuse box assembly ø5 × 20 mm Screw Cover Fuse puller Fuse 10 A, Spare is included. Fuse 30 A, Spare is included. Fuse 20 A, Spare is included. Fuse 5 A, Spare is included.
Page 151: Junction Box
Fuse box / Junction box Junction box · · · m (0.4 kgf m, 3.0 ft · · · m (0.6 kgf m, 4.4 ft · · · 12 N m (1.2 kgf m, 8.9 ft · · · · ·...
Page 152: Exhaust Cover
POWR Power unit Exhaust cover Part name Q’ty Remarks M6 × 50 mm Bolt M8 × 14 mm Plug Gasket Not reusable M18 × 17 mm Plug Gasket Not reusable Exhaust outer cover (PORT) Gasket Not reusable Exhaust inner cover (PORT) Anode ø6 ×...
Page 153: Removing The Exhaust Cover
Exhaust cover Removing the exhaust cover 1. Remove the exhaust cover bolts in the sequences shown. Checking the exhaust cover anode 1. Check the anodes. Clean if there are scales, grease, or oil. CAUTION: Do not oil, grease, or paint the anodes, otherwise they will be ineffective.
Page 154: Cylinder Head
POWR Power unit Cylinder head Part name Q’ty Remarks M6 × 40 mm Bolt Oil control valve assembly Filter Not reusable Engine hanger (PORT) M6 × 20 mm Bolt M10 × 120 mm/T55 Bolt M6 × 20 mm Bolt Cover Anode Grommet M8 ×...
Page 155 Cylinder head Part name Q’ty Remarks Flushing hose M6 × 30 mm Bolt Cooling water passage cover Gasket Not reusable Anode ø4 × 12 mm Screw Valve cotter Valve spring retainer Valve spring Valve seal Not reusable Valve guide Not reusable Intake valve Exhaust valve Engine hanger (STBD)
Page 156: Removing The Cylinder Head
POWR Power unit Removing the cylinder head Valve spring compressor 1: 1. Remove the cylinder head bolts in the 90890-04019 sequence shown. Valve spring compressor attachment 2: PORT STBD 90890-06320 Checking the valve spring 1. Measure the valve spring free length a. (T55) Replace if below specification.
Page 157: Checking The Valve Guide
Cylinder head Valve stem runout limit: 0.01 mm (0.0004 in) Checking the valve guide NOTE: Before checking the valve guides, make sure that the valve stem diameter is within specifi- cation. Valve margin thickness a: 1. Measure the valve guide inside diameter Intake: 0.50–0.90 mm (0.020–0.035 in) Exhaust:...
Page 158: Replacing The Valve Guide
POWR Power unit Replacing the valve guide 1. Remove the valve guide 1 using the special service tool from the combustion chamber side. NOTE: • Turn the valve guide reamer clockwise to ream the valve guide. S69J5790 • Do not turn the reamer counterclockwise when removing the reamer.
Page 159: Refacing The Valve Seat
Cylinder head 4. Measure the valve seat contact width a where the blueing dye is adhered to the valve face. Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification. Replace the valve guide if the valve seat contact is uneven.
Page 160 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 161: Checking The Cylinder Head
Cylinder head 10. After every lapping procedure, be sure to clean off any remaining lapping com- pound from the cylinder heads and the valves. 11. Check the valve seat contact area of the valve again. Checking the cylinder head 1. Eliminate carbon deposits from the com- b Previous contact width bustion chambers and check for deterio- ration.
Page 162: Installing The Valve
POWR Power unit Installing the valve 1. Install a new valve seal 1 onto the valve guide. 4. Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters securely. 2. Install the valve 2, valve spring 3, and valve spring retainer 4 in the sequence shown, and then attach the special ser- vice tools.
Page 163: Checking The Cooling Water Passage Cover Anode
Cylinder head NOTE: See the exploded diagram (5-41). S6P25860 S6P25860 3. Tighten the cooling water passage cover NOTE: bolts to the specified torque in the See the exploded diagram (5-41). sequence shown. Checking the cooling water passage cover anode 1. Check the anodes. Clean if there are scales, grease, or oil.
Page 164: Installing The Cylinder Head
POWR Power unit 5. Tighten the knock sensor to the specified torque, and then fasten the knock sensor PORT STBD lead 1 and flushing hose 2 as shown. S6P25900 NOTE: 90˚ Fasten the knock sensor lead so that it is taut.
Page 165 Cylinder head CAUTION: Do not reuse the oil control valve filters, always replace them with new ones. NOTE: Make sure that the oil control valve filter does not come off when installing the oil control valve. 4. Install the camshafts, driven sprockets, and timing belt.
Page 166: Crankcase
POWR Power unit Crankcase · · · 23 N m (2.3 kgf m, 17.0 ft · · · 43 N m (4.3 kgf m, 31.7 ft 90˚ 27 28 24 26 · · · 12 N m (1.2 kgf m, 8.9 ft ·...
Page 167 Crankcase · · · 23 N m (2.3 kgf m, 17.0 ft · · · 43 N m (4.3 kgf m, 31.7 ft 90˚ 27 28 24 26 · · · 12 N m (1.2 kgf m, 8.9 ft · ·...
Page 168: Cylinder Block
POWR Power unit Cylinder block Part name Q’ty Remarks M10 × 105 mm Bolt M8 × 95 mm Bolt M8 × 55 mm Bolt Crankcase assembly Main bearing Main bearing Oil seal Not reusable Crankshaft Main bearing Thrust bearing O-ring Not reusable O-ring Not reusable...
Page 169 Cylinder block Part name Q’ty Remarks Oil seal Not reusable Oil pump assembly M6 × 40 mm Bolt M6 × 20 mm Bolt Plug O-ring Not reusable Gasket Not reusable Thermostat cover Anode Thermoswitch M6 × 16 mm Bolt M6 × 25 mm Bolt Thermostat M14 ×...
Page 170: Disassembling The Cylinder Block
POWR Power unit Disassembling the cylinder block 1. Remove the oil filter using a 72.5 mm (2.9 in) oil filter wrench. Oil filter wrench: 90890-06830 2. Remove the oil filter bracket bolts in the sequence shown. STBD PORT NOTE: • See the exploded diagram (5-53). •...
Page 171: Checking The Piston Diameter
Cylinder block NOTE: Cylinder bore (D –D Be sure to keep the bearings in the order as 94.000–94.017 mm they were removed. (3.7008–3.7014 in) Checking the piston clearance Checking the piston diameter (reference) 1. Measure the piston outside diameter at 1.
Page 172: Checking The Piston Ring End Gap (Reference)
POWR Power unit Checking the piston ring end gap Piston ring groove: (reference) Top ring a: 1. Level the piston ring 1 in the cylinder 1.23–1.25 mm (0.048–0.049 in) with a piston crown. Second ring b: 1.22–1.24 mm (0.048–0.049 in) 2.
Page 173: Checking The Piston Pin
Cylinder block Piston pin boss bore: 21.017–21.031 mm (0.8274–0.8280 in) Checking the piston pin 1. Measure the piston pin outside diameter. Replace the piston pin if out of specifica- tion. Connecting rod big end side clearance a (reference data): 0.15–0.30 mm (0.006–0.012 in) Piston pin outside diameter: 20.995–21.000 mm (0.8266–0.8268 in)
Page 174: Checking The Crankshaft
POWR Power unit Checking the crankshaft 1. Measure the crankshaft journal diameter a, crankpin diameter b, and crankpin width c. Replace the crankshaft if out of specification. S6P25970 Crankshaft runout limit: 0.03 mm (0.0012 in) Checking the crankpin oil clearance 1.
Page 175 Cylinder block NOTE: NOTE: Be sure not to put the Plastigauge (PG-1) • Reuse the removed connecting rod cap over the oil hole in the crankpin of the crank- bolts when checking the oil clearance. shaft. • Do not turn the connecting rod until the crankpin oil clearance measurement has been completed.
Page 176: Selecting The Connecting Rod Bearing
POWR Power unit Selecting the connecting rod bearing 2. Place the cylinder block upside down on a bench. 1. When replacing the connecting rod bear- ing, select the suitable bearing as fol- 3. Install half of the main bearings 1 and lows.
Page 177: Selecting The Main Bearing
Cylinder block 6. Install the crankcase onto the cylinder 8. Gently remove the crankcase, and then block and apply engine oil to the threads measure the width of the compressed of the crankcase bolts. Plastigauge (PG-1) on each crankshaft journal. Replace the main bearing if out 7.
Page 178: Disassembling The Oil Pump
POWR Power unit 2. Check the crankshaft journal mark a on Cylinder block mark b the crankshaft and the cylinder block 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 mark b on the cylinder block.
Page 179: Checking The Oil Pump
Cylinder block Checking the oil pump 1. Check the gear teeth and inner surface of the oil pump case. Replace the oil pump assembly if the gear teeth are cracked or worn, or if inner surface of the oil pump case is scratched. Assembling the oil pump 1.
Page 180: Assembling The Power Unit
POWR Power unit Assembling the power unit 45˚ 45˚ NOTE: See the exploded diagram (5-55). 1. Assemble the piston 1, connecting rod #1,#4 2, piston pin 3, and new piston pin clips S6P25A70 CAUTION: Do not scratch the pistons or break the piston rings.
Page 181 Cylinder block 8. Apply sealant to the mating surface of the crankcase. S69J5F10 NOTE: • Install the bearings in their original posi- tions. • Insert the projection f of each bearing into the slots in the cylinder block. NOTE: 6. Set the crankshaft A, new oil seal B, •...
Page 182 POWR Power unit 9. Install the crankcase onto the cylinder 10. Install the piston with the “UP” mark on block, and then tighten the crankcase the piston crown facing towards the fly- bolts to the specified torques in 2 stages wheel magnet.
Page 183 Cylinder block NOTE: CAUTION: • Align the marks m on the connecting rod Before installing the oil pump, be sure to cap and connecting rod. fill it with engine oil through the oil pas- • Apply engine oil to the connecting rod caps sage p.
Page 184 POWR Power unit 14. Install the new gasket and oil filter NOTE: bracket, and then tighten the bolts in the Apply a thin coat of engine oil to the O-ring of sequence shown. the new oil filter before installation. STBD PORT Oil filter wrench: 90890-06830 Oil filter:...
Page 185: Installing The Wiring Harness
Cylinder block Installing the wiring harness NOTE: • To install all of the wiring harnesses, see Chapter 8, “Wiring harness routing.” • Perform this procedure after assembling the power unit. 1. Install the wiring harness and sub wiring harness to the junction box. S6P25C00E 2.
Page 186: Installing The Power Unit
POWR Power unit 7. Install the wiring harness onto the wiring 10. Check that the wiring harness, hoses, harness guide with the mark c facing and the other parts do not interfere with upward, and then install the clips 8 in any moving parts.
Page 187 Cylinder block S6P25C60E 6. Connect the warning indicator coupler 8, trim sensor coupler 9, isolator cou- pler 0, PTT switch coupler A, 10-pin main harness coupler B, and then install them onto the brackets. S6P25C40E Power unit mounting bolt 3 and 4: 42 N·m (4.2 kgf·m, 31.0 ft·lb) 4.
Page 188 POWR Power unit 7. Connect the cooling water pilot hose C. 8. Connect the neutral switch coupler D and shift cut switch coupler E, and then install them onto the bracket. 9. Install the dipstick guide F and oil dip- stick G.
Page 189 Cylinder block 16. Connect the shift cable and throttle cable, and then adjust their lengths. To adjust the shift cable and throttle cable, see Chapter 3, “Adjusting the throttle cable” and “Checking the gear shift oper- ation.” 17. Install the starboard intake manifold. NOTE: To install the intake manifold, see Chapter 4, “Installing the intake manifold.”...
Page 190 LOWR Lower unit Lower unit (regular rotation model) ............. 6-1 Removing the lower unit ................6-4 Removing the water pump and shift rod............ 6-5 Checking the water pump and shift rod .............6-5 Propeller shaft housing (regular rotation model) ........6-6 Removing the propeller shaft housing assembly........6-8 Disassembling the propeller shaft assembly ..........6-8 Disassembling the propeller shaft housing..........
Page 191 Lower unit (counter rotation model) ............6-31 Removing the lower unit ................6-34 Removing the water pump and shift rod..........6-35 Checking the water pump and shift rod ...........6-35 Propeller shaft housing (counter rotation model) ........6-36 Removing the propeller shaft housing assembly........6-38 Disassembling the propeller shaft housing..........
Page 192: Lower Unit
LOWR Lower unit Lower unit (regular rotation model) Part name Q’ty Remarks Lower unit Plate Rubber seal Check screw Gasket Not reusable M10 × 45 mm/X-transom model Bolt Drain screw Grommet M10 × 45 mm Bolt M10 × 70 mm/X-transom model Bolt Spacer Propeller...
Page 193 Lower unit (regular rotation model) Part name Q’ty Remarks Extension Rubber seal Dowel Rubber seal M10 × 190 mm Stud bolt M10 × 200 mm Bolt M10 × 174 mm Bolt Spring washer Washer 6P23H11...
Page 194 LOWR Lower unit Part name Q’ty Remarks Shift rod Oil seal Not reusable Oil seal housing O-ring Not reusable M6 × 20 mm Bolt Seal Woodruff key M8 × 45 mm Bolt Water pump housing O-ring Not reusable Insert cartridge O-ring Not reusable Impeller...
Page 195: Removing The Lower Unit
Lower unit (regular rotation model) 3. Mark the trim tab 1 at the area shown, Removing the lower unit and then remove it. 1. Drain the gear oil. 4. Loosen the bolts (nuts), and then remove the lower unit from the upper case. 2.
Page 196: Removing The Water Pump And Shift Rod
LOWR Lower unit Removing the water pump and shift 1. Remove the water pump housing 1 and impeller 2. 2. Remove the Woodruff key 3. 3. Remove the outer plate cartridge 4. 4. Set the gear shift to the neutral position, S6P26660 and then remove the shift rod assembly 4.
Page 197 Lower unit (regular rotation model) / Propeller shaft housing (regular rotation model) Propeller shaft housing (regular rotation model) Part name Q’ty Remarks Water pipe Rubber seal Rubber seal Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Propeller shaft Shim Reverse gear...
Page 198 LOWR Lower unit Part name Q’ty Remarks Dowel Not reusable Grease nipple Rubber seal O-ring Not reusable Needle bearing Oil seal Not reusable Ring M8 × 20 mm Bolt M8 × 33 mm Bolt Washer Cooling water inlet cover ø5 × 53 mm Screw 6P23H11...
Page 199: Propeller Shaft Housing (Regular Rotation Model)
Propeller shaft housing (regular rotation model) Removing the propeller shaft Disassembling the propeller shaft housing assembly assembly 1. Remove the water pipe 1 and shift rod 1. Remove the spring 1, and then remove the cross pin 2, dog clutch 3, shift plunger 4, slider 5, and shift rod joint 2.
Page 200: Checking The Propeller Shaft Housing
LOWR Lower unit 2. Remove the ball bearing. Checking the propeller shaft 1. Check the propeller shaft. Replace if bent or worn. 2. Measure the propeller shaft runout. S6S16390 CAUTION: Do not reuse the bearing, always replace it with a new one. S6P26200C Runout limit: 0.02 mm (0.0008 in) Slide hammer 5: 90890-06531...
Page 201 Propeller shaft housing (regular rotation model) Depth d: 5.0 ± 0.25 mm (0.20 ± 0.01 in) 3. Install the new ball bearing into the pro- peller shaft housing. NOTE: • Install the needle bearing with the manufac- ture identification mark a facing toward the oil seal (propeller side).
Page 202 LOWR Lower unit 4. Install the reverse gear 7 and original shim(s) 8 into the propeller shaft hous- ing using a press. NOTE: • Be sure to select the reverse gear shim(s) if replacing the propeller shaft housing, lower case, or ball bearing. Select the propeller shaft shim if replacing the reverse gear.
Page 203 Propeller shaft housing (regular rotation model) / Drive shaft and lower case (regular rotation model) Drive shaft and lower case (regular rotation model) Part name Q’ty Remarks Drive shaft Thrust bearing Spring Washer Cover Oil seal Not reusable M8 × 25 mm Bolt Drive shaft housing Needle bearing...
Page 204 LOWR Lower unit Part name Q’ty Remarks Forward gear shim — Taper roller bearing assembly Not reusable Forward gear 6-13 6P23H11...
Page 205: Drive Shaft And Lower Case (Regular Rotation Model)
Drive shaft and lower case (regular rotation model) Removing the drive shaft 1. Loosen the pinion nut. S69J6186 CAUTION: S68S6360J Do not reuse the bearing, always replace Drive shaft holder 6 1: 90890-06520 it with a new one. Pinion nut holder 2: 90890-06715 Bearing separator 1: 90890-06534 2.
Page 206: Checking The Pinion And Forward Gear
LOWR Lower unit 2. Remove the needle bearing from the lower case. S6P26210 Runout limit: 0.2 mm (0.008 in) NOTE: Since the diameter of the passage in the Checking the lower case lower case and the diameter of the special 1.
Page 207: Assembling The Forward Gear
Drive shaft and lower case (regular rotation model) NOTE: Needle bearing attachment 1: • Apply gear oil to the needle bearing outer 90890-06610 case before installation. Driver rod SS 2: 90890-06604 • The needle bearing contains 24 rollers. Depth a: Ball bearing attachment 3: 4.5 ±...
Page 208: Installing The Propeller Shaft Housing
LOWR Lower unit 2. Install the washer, spring and thrust bearing into the lower case. S63P6310 NOTE: To install the pinion nut, push down on the drive shaft. Drive shaft holder 6 5: 90890-06520 Pinion nut holder 6: 90890-06715 3. Install the drive shaft housing 1, thrust bearing 2, and original shim(s) 3 onto the drive shaft 4.
Page 209: Installing The Water Pump And Shift Rod
Drive shaft and lower case (regular rotation model) NOTE: • Be sure to select the propeller shaft shim if replacing propeller shaft, forward gear or reverse gear. • To select the shims, see “Shimming (regu- NOTE: lar rotation model).” • Check the gear shift to the neutral position, when installing the shift rod.
Page 210: Installing The Lower Unit
LOWR Lower unit 3. Install the Woodruff key into the drive shaft. 4. Align the groove on the impeller 5 with the Woodruff key 6, and then install the impeller onto the drive shaft. 5. Install the new O-ring 7 and insert car- tridge 8 into the pump housing 9.
Page 211 Drive shaft and lower case (regular rotation model) 2. Set the gear shift to the neutral position at the lower unit. È U-transom model Lower case mounting bolt (nut) 2: 47 N·m (4.7 kgf·m, 34.7 ft·lb) Trim tab bolt 4: 42 N·m (4.2 kgf·m, 31.0 ft·lb) Shift rod push arm: 90890-06052 3.
Page 212 LOWR Lower unit 6. Install the propeller and propeller nut, 7. Fill the gear oil to the correct level. and then tighten the nut temporary. Place a block of wood between the anti-cavita- tion plate and propeller to keep the pro- peller from turning, and then tighten the nut to the specified torque.
Page 213: 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 S6P26270 6-22 6P23H11...
Page 214: Shimming
LOWR Lower unit Shimming Pinion nut: NOTE: 142 N·m (14.2 kgf·m, 104.7 ft·lb) • Shimming is not required when assembling the original lower case and inner parts. 3. Measure the distance (M4) between the • Shimming is required when assembling the special service tool and the pinion as original inner parts and a new lower case.
Page 215: Selecting The Forward Gear Shim
Shimming (regular rotation model) Example: If “T3” is 0.70 mm, then the pinion shim is 0.68 mm. If “T3” is 0.74 mm, then the pinion shim is 0.72 mm. Selecting the forward gear shim 1. Turn the taper roller bearing outer race 1 2 or 3 times to seat the rollers, and then measure the bearing height (M1) as shown.
Page 216: Selecting The Reverse Gear Shim
LOWR Lower unit 2. Calculate the forward gear shim thick- Available shim thicknesses: ness (T1) as shown in the examples 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and below. 0.50 mm Example: If “T1” is 0.45 mm, then the forward gear shim is 0.42 mm.
Page 217 Shimming (regular rotation model) 3. Select the reverse gear shim(s) (T2) as follows. Calculated numeral Rounded numeral at 1/100 place 1, 2 3, 4, 5 6, 7, 8 9, 10 Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm Example: If “T2”...
Page 218: Selecting The Propeller Shaft Shim
LOWR Lower unit Selecting the propeller shaft shim NOTE: Be sure to make this measurement in met- rics. 1. Measure the forward gear height M1, M2 as shown and then calculate the value S6P26340 S6P26330 S6P26360 Calculation formula: Reverse gear height C2 = M3 – M4 3.
Page 219: Backlash (Regular Rotation Model)
Shimming (regular rotation model) / Backlash (regular rotation model) Backlash (regular rotation model) Measuring the forward and reverse gear backlash 1. Remove the water pump assembly. 2. Set the gear shift to the neutral position at the lower unit. NOTE: Select the shim with the closest thickness.
Page 220 LOWR Lower unit 4. Install the backlash indicator onto the Available shim thicknesses: drive shaft (22.4 mm [0.88 in] in diame- 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and ter), then the dial gauge. 0.50 mm 7. Remove the special service tools from the propeller shaft.
Page 221 Backlash (regular rotation model) 10. Add or remove shim(s) if out of specifica- tion. Reverse gear Shim thickness backlash Less than To be decreased by (0.49 – M) × 0.71 0.32 mm (0.0126 in) More than To be increased by (M –...
Page 222: Lower Unit (Counter Rotation Model)
LOWR Lower unit Lower unit (counter rotation model) Part name Q’ty Remarks Lower unit Plate Rubber seal Check screw Gasket Not reusable M10 × 45 mm/X-transom model Bolt Drain screw Grommet M10 × 45 mm Bolt M10 × 70 mm/X-transom model Bolt Spacer Propeller...
Page 223 Lower unit (counter rotation model) Part name Q’ty Remarks Extension Rubber seal Dowel Rubber seal M10 × 190 mm Stud bolt M10 × 200 mm Bolt M10 × 174 mm Bolt Spring washer Washer 6-32 6P23H11...
Page 224 LOWR Lower unit Part name Q’ty Remarks Shift rod Oil seal Not reusable Oil seal housing O-ring Not reusable M6 × 20 mm Bolt Seal Woodruff key M8 × 45 mm Bolt Water pump housing O-ring Not reusable Insert cartridge O-ring Not reusable Impeller...
Page 225: Removing The Lower Unit
Lower unit (counter rotation model) 3. Mark the trim tab 1 at the area shown, Removing the lower unit and then remove it. 1. Drain the gear oil. 4. Loosen the bolts (nuts), and then remove the lower unit from the upper case. 2.
Page 226: Removing The Water Pump And Shift Rod
LOWR Lower unit Removing the water pump and shift 1. Remove the water pump housing 1 and impeller 2. 2. Remove the Woodruff key 3. 3. Remove the outer plate cartridge 4. 4. Set the gear shift to the neutral position, S6P26660 and then remove the shift rod assembly 4.
Page 227 Lower unit (counter rotation model) / Propeller shaft housing (counter rotation model) Propeller shaft housing (counter rotation model) Part name Q’ty Remarks Water pipe Rubber seal Rubber seal Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Forward gear Forward gear shim —...
Page 228 LOWR Lower unit Part name Q’ty Remarks Propeller shaft shim — O-ring Not reusable Propeller shaft housing Dowel Not reusable Grease nipple Rubber seal O-ring Not reusable Needle bearing Oil seal Not reusable Ring M8 × 20 mm Bolt M8 × 33 mm Bolt Washer Cooling water inlet cover...
Page 229: Propeller Shaft Housing (Counter Rotation Model)
Propeller shaft housing (counter rotation model) Removing the propeller shaft Disassembling the propeller shaft housing assembly housing 1. Remove the water pipe 1 and shift rod 1. Remove the spring 1, and then remove the cross pin 2, dog clutch 3, slider, shift plunger, and shift rod joint.
Page 230: Checking The Propeller Shaft Housing
LOWR Lower unit 5. Remove the ring nut 5 and claw washer Needle bearing attachment B: 90890-06611 Driver rod L3 C: 90890-06652 Ring nut wrench 7: 90890-06578 Checking the propeller shaft housing 6. Remove the bearing outer race 8, taper 1.
Page 231: Assembling The Propeller Shaft Housing
Propeller shaft housing (counter rotation model) Assembling the propeller shaft Bearing inner race attachment 4: housing 90890-06640 1. Install the needle bearing into the propel- ler shaft housing to the specified depth. Depth d: 5.0 ± 0.25 mm (0.20 ± 0.01 in) 3.
Page 232 LOWR Lower unit 4. Install the new taper roller bearing 7 and bearing outer race 8 into the propeller shaft housing using a press. Ring nut wrench 9: 90890-06578 Ring nut A: 108 N·m (10.8 kgf·m, 79.7 ft·lb) 7. Install the original shim(s) B, forward NOTE: gear C, and dog clutch D using a press.
Page 233 Propeller shaft housing (counter rotation model) 8. Install the shift plunger E and slider F into the propeller shaft, and then install the cross pin G and spring H. S69J6445 6-42 6P23H11...
Page 234: Drive Shaft And Lower Case (Counter Rotation Model)
LOWR Lower unit Drive shaft and lower case (counter rotation model) Part name Q’ty Remarks Drive shaft Thrust bearing Spring Washer Cover Oil seal Not reusable M8 × 25 mm Bolt Drive shaft housing Needle bearing O-ring Not reusable Pinion shim —...
Page 235 Drive shaft and lower case (counter rotation model) Part name Q’ty Remarks Reverse gear shim — Retainer Needle bearing Thrust bearing Circlip Not reusable Needle bearing Not reusable Reverse gear 6-44 6P23H11...
Page 236: Removing The Drive Shaft
LOWR Lower unit Removing the drive shaft 1. Loosen the pinion nut. S6P26190 2. Remove the needle bearing from the S68S6360J reverse gear using a chisel. Drive shaft holder 6 1: 90890-06520 Pinion nut holder 2: 90890-06715 2. Remove the drive shaft, drive shaft hous- ing, pinion, thrust bearing, spring and washer.
Page 237: Checking The Pinion And Reverse Gear
Drive shaft and lower case (counter rotation model) Checking the drive shaft 1. Check the drive shaft. Replace if bent or worn. 2. Measure the drive shaft runout. Needle bearing attachment 3: 90890-06654 Driver rod L3 4: 90890-06652 S6P26210 3. Remove the needle bearing from the lower case.
Page 238: Assembling The Reverse Gear
LOWR Lower unit 2. Install the original shim(s) and retainer Assembling the reverse gear into the lower case. 1. Install the new needle bearing into the reverse gear to the specified depth. S6P26170E NOTE: • Be sure to select the reverse gear shim(s) if Needle bearing attachment 1: replacing the thrust bearing, retainer or 90890-06653...
Page 239: Installing The Drive Shaft
Drive shaft and lower case (counter rotation model) 2. Install the washer, spring and thrust Needle bearing attachment 1: bearing into the lower case. 90890-06610 Driver rod SS 2: 90890-06604 Depth a: 4.5 ± 0.25 mm (0.18 ± 0.01 in) 2.
Page 240: Installing The Propeller Shaft Housing
LOWR Lower unit 4. Install the drive shaft and drive shaft housing into the lower case, then the pin- ion, washer and pinion nut, and then tighten the nut to the specified torque. S63P6310 S6P26190E NOTE: 4. Install the washer and propeller shaft To install the pinion nut, push down on the housing bolts 1, and then tighten the drive shaft.
Page 241 Drive shaft and lower case (counter rotation model) 3. Install the Woodruff key into the drive shaft. 4. Align the groove on the impeller 5 with the Woodruff key 6, and then install the impeller onto the drive shaft. 5. Install the new O-ring 7 and insert car- tridge 8 into the pump housing 9.
Page 242: Installing The Lower Unit
LOWR Lower unit 6. Install the new O-ring 0 and pump hous- ing assembly A into the lower case, tighten the bolts B, and then install the seal C and cover D. 2. Set the gear shift to the neutral position at the lower unit.
Page 243 Drive shaft and lower case (counter rotation model) WARNING • Do not hold the propeller with your hands when loosening or tightening it. • Be sure to disconnect the battery cables from the battery and the clip from the engine stop lanyard switch. •...
Page 244: Shimming (Counter Rotation Model)
LOWR Lower unit Shimming (counter rotation model) 65.0 B1 38.4 47.5 T´4 S6P26300 6-53 6P23H11...
Page 245: Shimming
Shimming (counter rotation model) Shimming Pinion nut: NOTE: 142 N·m (14.2 kgf·m, 104.7 ft·lb) • Shimming is not required when assembling the original lower case and inner parts. 3. Measure the distance (M4) between the • Shimming is required when assembling the special service tool and the pinion as original inner parts and a new lower case.
Page 246: Selecting The Reverse Gear Shim
LOWR Lower unit 5. Calculate the pinion shim thickness (T3) Available shim thicknesses: as shown in the examples below. 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm Example: If “T3” is 0.70 mm, then the pinion shim is 0.78 mm. If “T3”...
Page 247 Shimming (counter rotation model) Example: If “T1” is 0.71 mm, then the reverse gear shim is 0.70 mm. If “T1” is 0.70 mm, then the reverse gear shim is 0.68 mm. NOTE: “F” is the deviation of the lower case dimen- sion from standard.
Page 248: Selecting The Forward Gear Shim
LOWR Lower unit Selecting the forward gear shim 1. Turn the taper roller bearing outer race 1 2 or 3 times to seat the rollers, and then measure the bearing height (M5) and (M6) as shown. A – 3 S69J6625 NOTE: “R”...
Page 249: Selecting The Propeller Shaft Shim
Shimming (counter rotation model) 3. Select the forward gear shim(s) (T2) as NOTE: follows. • Select the shim thickness (T’4) by using the specified measurement(s) and the calcula- Calculated numeral Rounded numeral tion formula. at 1/100 place • Measure the taper roller bearing at 3 points 1, 2 to find the height average.
Page 250 LOWR Lower unit 3. Calculate the propeller shaft shim thick- Example: ness (T4) as shown in the examples If “T4” is 0.79 mm, then the propeller shaft below. shim is 0.78 mm. If “T4” is 0.90 mm, then the propeller shaft shim is 0.88 mm.
Page 251: Backlash (Counter Rotation Model)
Shimming (counter rotation model) / Backlash (counter rotation model) 8. Measure the propeller shaft axial free play. Reselect the propeller shaft shim(s) (T’4), if out of specification. NOTE: Tighten the center bolt while turning the drive shaft until the drive shaft can no longer be turned.
Page 252 LOWR Lower unit 5. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction. Forward gear backlash: 0.46–0.82 mm (0.0181–0.0323 in) 6. Add or remove shim(s) if out of specifica- tion.
Page 253 Backlash (counter rotation model) Reverse gear Shim thickness backlash Less than To be decreased by (0.62 – M) × 0.71 0.45 mm (0.0177 in) More than To be increased by (M – 0.62) × 0.71 0.78 mm (0.0307 in) M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm...
Page 254 BRKT Bracket unit Shift rod and bottom cowling ............... 7-1 Upper case and steering arm................ 7-5 Removing the upper case................7-10 Disassembling the upper case ..............7-10 Checking the drive shaft bushing ............7-10 Disassembling the oil pan................7-10 Checking the oil strainer ................7-11 Assembling the oil pan ................7-11 Assembling the upper case ..............
Page 255 Tilt cylinder and trim cylinder ..............7-37 Disassembling the tilt cylinder and trim cylinder........7-39 Checking the tilt cylinder and trim cylinder ..........7-40 Checking the valve .................. 7-41 Assembling the tilt ram ................7-41 Assembling the trim ram................7-42 Installing the tilt cylinder ................7-42 Installing the trim ram ................
Page 256: Shift Rod And Bottom Cowling
BRKT Bracket unit Shift rod and bottom cowling Part name Q’ty Remarks Bracket Shift cut switch Bracket Neutral switch ø4 × 16 mm Screw Plate Spring Bushing Grease nipple Bolt M6 × 35 mm Bolt Clamp ø4 × 16 mm Screw Plate Clip...
Page 257 Shift rod and bottom cowling Part name Q’ty Remarks Shift lever Cotter pin Not reusable Bushing M6 × 30 mm Bolt Bracket Ball Spring Bolt Shift rod O-ring Not reusable Grommet ø6 × 20 mm Screw Adapter Hose joint gasket Hose joint Clamp Grommet...
Page 258 BRKT Bracket unit Part name Q’ty Remarks Bottom cowling Rubber seal Cowling lock lever Bushing Plate M6 × 20 mm Bolt M6 × 30 mm Bolt Wave washer Lever M6 × 20 mm Bolt Spring Hook Bracket Bracket Rivet M6 × 25 mm Bolt Plate 6P23H11...
Page 259 Shift rod and bottom cowling Part name Q’ty Remarks Collar Grommet M8 × 35 mm Bolt Cooling water pilot hole Wire lead extension Counter rotation model Bracket Switch Bracket Bracket Cover Gasket 6P23H11...
Page 260: Upper Case And Steering Arm
BRKT Bracket unit Upper case and steering arm Part name Q’ty Remarks Upper case assembly M14 × 190 mm Bolt Washer Washer Washer Upper mount Bracket M10 × 45 mm Bolt M10 × 45 mm Bolt Mount housing M14 × 205 mm Bolt Lower mount M14 ×...
Page 261 Upper case and steering arm Part name Q’ty Remarks M6 × 10 mm Bolt Dowel Adapter M6 × 30 mm Bolt Drive shaft bushing Circlip Circlip Bushing O-ring Not reusable Bushing Washer Steering yoke Washer Steering arm Washer Washer 6P23H11...
Page 262 BRKT Bracket unit · · · · · · m (0.8 kgf m, 5.9 ft 42 N m (4.2 kgf m, 31.0 ft · · · 20 N m (2.0 kgf m, 14.8 ft · · · m (0.4 kgf m, 3.0 ft S6P27040E Part name...
Page 263 Upper case and steering arm Part name Q’ty Remarks Upper exhaust guide Gasket Not reusable Dowel Lower exhaust guide Gasket Not reusable Oil strainer Collar M6 × 25 mm Bolt Gasket Not reusable Dowel Rubber seal Oil pan Gasket Not reusable Exhaust manifold M8 ×...
Page 264 BRKT Bracket unit Part name Q’ty Remarks Rubber seal Gasket Not reusable Plate Pipe Rubber seal Gasket Not reusable Dowel Muffler M8 × 35 mm Bolt 6P23H11...
Page 265: Removing The Upper Case
Upper case and steering arm Removing the upper case Disassembling the oil pan 1. Remove the muffler 1, plate 2, and 1. Place a drain pan under the drain hole, exhaust manifold 3 from the oil pan 4. and then remove the engine oil drain bolt 1 and let the oil drain completely.
Page 266: Checking The Oil Strainer
BRKT Bracket unit 2. Remove the oil pan 4 from the upper 2. Install the new gasket, oil strainer 4 and exhaust guide 5 and lower exhaust bolts, and then tighten the bolts to the guide 6. specified torque. 3. Remove the oil strainer 7 from the lower exhaust guide 6.
Page 267: Assembling The Upper Case
Upper case and steering arm Oil pan bolt 6: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Exhaust manifold bolt 8: 20 N·m (2.0 kgf·m, 14.8 ft·lb) 6. Install the new gasket and plate 9. 7. Install the rubber seal and cooling water WR-No.2 pipe 0 into the muffler A.
Page 268: Installing The Upper Case
BRKT Bracket unit 2. Install the rubber seal 3 into the joint 6. Install the upper mounts B and bolts into hole a of the upper case. the upper case. 3. Install the oil pan assembly 4 by insert- 7. Install the bracket C, and then tighten ing the tip of the cooling water pipe 5 the bolts D to the specified torque.
Page 269: Removing The Steering Arm
Upper case and steering arm 3. Pass the speedometer hose through the 3. Remove the steering arm from the swivel steering arm, and then connect it to the bracket by pulling the arm off the bracket. adapter. Installing the steering arm 1.
Page 270 BRKT Bracket unit 4. Install the steering yoke 9 onto the steering arm 3, making sure that they are both facing in the same direction (a and b are aligned). 5. Install the circlip 0. 6. Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c.
Page 271 Upper case and steering arm / Clamp bracket and swivel bracket Clamp bracket and swivel bracket Part name Q’ty Remarks Through tube Clamp bracket (PORT) M10 × 45 mm Bolt Ground lead Bushing Washer Bushing Friction plate ø6 × 10 mm Screw ø6 ×...
Page 272 BRKT Bracket unit Part name Q’ty Remarks M6 × 10 mm Bolt Spring Spring holder Tilt stop lever (PORT) Shaft Trim stopper Tilt stop lever (STBD) Circlip Swivel bracket PTT unit Ground lead Bushing Bushing Anode Ground lead 7-17 6P23H11...
Page 273: Clamp Bracket And Swivel Bracket
Clamp bracket and swivel bracket Removing the PTT unit 5. Remove the PTT motor lead from the holder 7, and then pull out the PTT 1. Fully tilt the outboard motor up, and then motor lead 8. support it with the tilt stop lever 1. 6.
Page 274: Removing The Clamp Bracket
BRKT Bracket unit Removing the clamp bracket 1. Remove the self-locking nut 1 of the through tube and ground lead 2, then clamp brackets 3 and 4. 2. Remove the trim sensor 5. Grease nipple 5: 3 N·m (0.3 kgf·m, 2.2 ft·lb) Installing the PTT unit 1.
Page 275: Adjusting The Trim Sensor
Clamp bracket and swivel bracket 3. Install the upper end of the tilt ram into the swivel bracket with the shaft 4 and circlip 5. 4. Tighten the self-locking nut 6 of the through tube to the specified torque. 5. Install the anode 7. 6.
Page 276 BRKT Bracket unit 2. Loosen the trim sensor screws 2. WARNING 3. Adjust the position of the trim sensor, After tilting up the outboard motor, be and then tighten the trim sensor screws sure to support it with the tilt stop lever. 2 temporary.
Page 277: Ptt Unit
Clamp bracket and swivel bracket / PTT unit PTT unit Part name Q’ty Remarks PTT body Reservoir M8 × 20 mm Bolt O-ring Not reusable M12 × 10 mm Reservoir cap O-ring Not reusable Sheet Filter Spacer PTT motor assembly O-ring Not reusable Joint...
Page 278 BRKT Bracket unit Part name Q’ty Remarks Bushing Pipe Pipe Spacer O-ring Not reusable Adapter 7-23 6P23H11...
Page 279: Ptt Unit
PTT unit Checking the hydraulic pressure Battery 1. Check the hydraulic pressure. Check the PTT motor lead terminal internal parts if out of specification. Light green (Lg) Down 2. Fully extend the PTT rams. Sky blue (Sb) 3. Loosen the pipe joints 1, and then Hydraulic pressure (down): remove the pipe joint at end a.
Page 280 BRKT Bracket unit 10. Loosen the pipe joints 3, and then remove the pipe joint at end b. Hydraulic pressure (up): 13.0–15.0 MPa (130–150 kgf/cm 11. Install the special service tools. 13. Reverse the PTT motor leads between the battery terminals to fully retract the rams.
Page 281 PTT unit 17. Place the PTT unit in an upright position. 18. Remove the reservoir cap 4, and then check the fluid level in the reservoir. WARNING Make sure that the trim and tilt rams are fully extended when removing the reser- voir cap, otherwise fluid can spurt out from the unit due to internal pressure.
Page 282: Ptt Motor
BRKT Bracket unit PTT motor Part name Q’ty Remarks Stator M5 × 12 mm Bolt Wave washer Washer Bearing Armature Brush Spring PTT motor base assembly O-ring Not reusable Oil seal Not reusable 7-27 6P23H11...
Page 283: Disassembling The Ptt Motor
PTT motor Disassembling the PTT motor 1. Remove the PTT motor assembly, O- ring, and joint from the PTT unit. WARNING Do not push the trim and tilt rams down while the PTT motor is removed from the PTT unit, otherwise fluid can spurt out. 2.
Page 284: Assembling The Ptt Motor
BRKT Bracket unit 2. Measure commutator diameter. Replace the armature if below specifica- Armature continuity tion. Commutator segments b Continuity Segment – Armature core c No continuity Segment – Armature shaft d No continuity 5. Check the circuit breaker of brush holder for continuity.
Page 285 PTT motor 6. Install the wave washer A and washer B into the stator C. 2. Connect the PTT motor leads 4 to the brush holder 5, and then install the brush holder 5 to the motor base 6. 7. Install the new O-ring and stator C to the motor base.
Page 286: Gear Pump
BRKT Bracket unit Gear pump Part name Q’ty Remarks Gear housing 1 M5 × 40 mm Bolt Plate Filter Plate Valve lock screw Down-relief spring Valve support pin Relief valve seal Up-relief spring Valve support pin O-ring Not reusable Ball Circlip Main valve seal Shuttle piston...
Page 287 Gear pump Part name Q’ty Remarks Return spring Shuttle piston Driven gear Drive gear Ball Gear housing 2 Manual release spring Ball Valve pin Spring Spacer O-ring Not reusable Filter Bracket Washer 7-32 6P23H11...
Page 288 BRKT Bracket unit Part name Q’ty Remarks M5 × 25 mm Bolt O-ring Not reusable Spacer Filter Gear pump assembly Relief valve seat O-ring Not reusable Down-relief valve Up-relief valve Down-absorber valve Up-absorber valve Down-main valve Up-main valve 7-33 6P23H11...
Page 289: Disassembling The Gear Pump
Gear pump 3. Remove the bracket 5, then the balls 6. Disassembling the gear pump 1. Remove the manual valve 1, then gear pump 2 and filters. 4. Remove the gear housing 2 7, then the shuttle pistons 8. 2. Remove the relief valve seal 3 and ball 5.
Page 290: Checking The Gear Pump
BRKT Bracket unit Checking the gear pump 1. Check the drive gear 1 and driven gear 2. Replace if damaged or excessive worn. 2. Check the up-relief valve 3 and down- relief valve 4. Clean if there is dirt or res- idue.
Page 291 Gear pump Gear pump bracket bolt B: Up-relief lock screw height a 7 N·m (0.7 kgf·m, 5.2 ft·lb) (reference data): From the top of the gear housing: 4. Install the relief valve seal C and ball D 1.07–1.27 mm (0.042–0.050 in) Down-relief lock screw depth b into the gear housing 1 7, and then install the up-relief lock screw E and...
Page 292: Tilt Cylinder And Trim Cylinder
BRKT Bracket unit Tilt cylinder and trim cylinder Part name Q’ty Remarks Circlip Dust seal Not reusable Trim cylinder end screw O-ring Not reusable Trim ram assembly Trim piston Backup ring O-ring Not reusable Spring Adapter Circlip Tilt piston assembly Tilt ram assembly Power tilt assembly Tilt ram...
Page 293 Tilt cylinder and trim cylinder Part name Q’ty Remarks O-ring Not reusable Backup ring O-ring Not reusable Spring Adapter Tilt piston O-ring Not reusable Backup ring Ball Spring M6 × 10 mm Bolt Free piston O-ring Not reusable Tilt cylinder 7-38 6P23H11...
Page 294: Disassembling The Tilt Cylinder And Trim Cylinder
BRKT Bracket unit Disassembling the tilt cylinder and WARNING trim cylinder Never look into the tilt cylinder opening 1. Hold the tilt cylinder 1 in a vise using when removing the free piston. The free aluminum plates a on both sides. piston and PTT fluid can be forcefully expelled out.
Page 295: Checking The Tilt Cylinder And Trim Cylinder
Tilt cylinder and trim cylinder 9. Hold the PTT body 6 in a vise using alu- Checking the tilt cylinder and trim minum plates a on both sides. cylinder 1. Check the PTT body 1 and tilt cylinder 2. Replace if cracked or if there is corro- sion.
Page 296: Checking The Valve
BRKT Bracket unit Checking the valve 3. Hold the tilt piston in a vise using the special service tool 0 on both sides. 1. Check the tilt piston absorber valves 1. Clean if there is dirt or residue. 4. Tighten the tilt ram 9 to the specified torque.
Page 297: Assembling The Trim Ram
Tilt cylinder and trim cylinder Assembling the trim ram 1. Install the new O-ring 1, backup ring 2, spring 3, adapter 4, and circlip 5 to the trim piston 6. 2. Install the new dust seal 7, circlip 8, and new O-ring 9 to the trim cylinder end screw 0.
Page 298: Installing The Ptt Motor
BRKT Bracket unit 2. Fill the trim cylinders with the recom- mended fluid to the correct level b as shown. 2. Fill the pump housing with the recom- mended fluid to the correct level a as shown. 3. Install the trim ram assembly into the trim cylinder, and then tighten the trim cylin- der end screws 2 to the specified torque.
Page 299: Installing The Reservoir
Tilt cylinder and trim cylinder NOTE: Align the armature shaft with the recess in the joint. PTT motor mounting bolt 4: 19 N·m (1.9 kgf·m, 14.0 ft·lb) Installing the reservoir 1. Install the spacer 1, filter 2 and sheet 3 to the PTT body. 2.
Page 300: Bleeding The Ptt Unit
BRKT Bracket unit Bleeding the PTT unit 1. Close the manual valve 1 by turning it clockwise. Manual valve 1: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2. Place the PTT unit in an upright position. Battery 3. Remove the reservoir cap, and then PTT motor lead terminal check the fluid level in the reservoir.
Page 301: Bleeding The Ptt Unit (Built-In)
Tilt cylinder and trim cylinder / PTT electrical system Bleeding the PTT unit (built-in) 1. Fully tilt the outboard motor up and down a few times. NOTE: If the fluid is at the correct level, a small amount of fluid should overflow out of the filler hole when the cap is removed.
Page 302: Checking The Ptt Relay
BRKT Bracket unit Checking the PTT relay 4. Connect the sky blue (Sb) lead to the positive battery terminal and the terminal 1. Check the PTT relay for continuity. 4 lead to the negative battery terminal Replace if out of specification. as shown.
Page 303: Checking The Trim Sensor
PTT electrical system Checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification. NOTE: Turn the lever 1 and measure the resistance as it gradually changes. Trim sensor resistance: Pink (P) – Black (B) 9–11 Ω at a 247.6–387.6 Ω...
Page 304 – ELEC Electrical system Checking the electrical component.............. 8-1 Checking using the YDIS................8-1 Measuring the peak voltage ..............8-1 Electrical component..................8-3 Port view....................8-3 Starboard view................... 8-4 Fuse holder....................8-5 Aft view ...................... 8-6 Top view ....................8-7 Wiring harness routing.................. 8-8 Port view....................
Page 305 Fuel control system ..................8-30 Checking the fuel injector ................8-30 Checking the low-pressure fuel pump and high-pressure fuel pump ..8-31 Checking the high-pressure fuel pump relay ...........8-31 Checking the vapor shut-off valve ............8-32 Starting system .................... 8-32 Checking the fuse..................8-32 Checking the starter relay................8-32 Starter motor ....................8-34 Disassembling the starter motor..............8-36...
Page 306: Electrical System
– ELEC Electrical system Checking the electrical Measuring the peak voltage To check the electrical components or mea- component sure the peak voltage, use the special ser- Checking using the YDIS vice tools. A faulty electrical component can When checking the electronic throttle valve, be easily checked by measuring the peak accelerator position sensor, oil control valve, voltage.
Page 307 Checking the electrical component NOTE: • Before measuring the peak voltage, check all wiring for proper connection and corro- sion, and check that the battery is fully charged. • Use the peak voltage adapter B with the recommended digital circuit tester. •...
Page 308: Electrical Component
– ELEC Electrical system Electrical component Port view S6P28010E 1 Intake air temperature sensor 9 Cam position sensor (PORT IN) 2 Electronic throttle valve assembly 0 Cam position sensor (PORT EX) 3 High-pressure fuel pump A 3-pin communication coupler 4 Low-pressure fuel pump B Condenser assembly (connect to the intake air 5 Intake air pressure sensor pressure sensor)
Page 309: Starboard View
Electrical component Starboard view S6P28020E 1 Ignition coil 2 Fuel injector 3 Cam position sensor (STBD IN) 4 Oil control valve (STBD) 5 PTT relay 6 Rectifier Regulator 7 Accelerator position sensor 8 Oil pressure sensor 9 Starter motor 0 Diode (connect to the PTT relay) 6P23H11...
Page 310: Fuse Holder
– ELEC Electrical system Fuse holder S6P28025 1 Fuse (10 A) (electronic throttle valve, ECM) 9 High-pressure fuel pump relay 2 Fuse (30 A) 0 Electronic throttle valve relay A Main relay (ignition coil, fuel injector, variable camshaft B Starter relay timing, ECM) 3 Fuse (20 A) (engine start switch, PTT switch) 4 Fuse (30 A) (starter relay)
Page 311: Aft View
Electrical component Aft view S6P28860E 1 ECM 2 Cam position sensor (PORT EX) 3 Cam position sensor (PORT IN) 4 Ignition coil 5 Cam position sensor (STBD IN) 6 Knock sensor 7 Condenser assembly (connect to the cam position sensor (PORT EX)) 8 Coupler (knock sensor) (white) 6P23H11...
Page 312: Top View
– ELEC Electrical system Top view S6P28040E 1 Oil control valve (STBD) A Neutral switch coupler (blue) 2 Oil control valve (PORT) B Shift cut switch coupler (black) 3 Thermoswitch (STBD) 4 Thermoswitch (PORT) 5 Engine temperature sensor 6 Crank position sensor 7 Vapor shut-off valve 8 Stator assembly 9 Neutral switch...
Page 313: Wiring Harness Routing
Electrical component / Wiring harness routing Wiring harness routing Port view È É Ê Ë Ó Ô Ò Ñ Í Ì Ï Î S6P28320 È Install the low-pressure fuel pump coupler onto the wiring harness guide. É Fasten the thermoswitch connectors and wiring harness (oil control valve and fuel injectors) to the holder. Ê...
Page 314 – ELEC Electrical system È É Ê Ë Ó Ô Ò Ñ Í Ì Ï Î S6P28320 Ï Fasten the fuel injector lead (#4) to the clip. It is not necessary to fasten the lead if its length is short. Ñ...
Page 315: Starboard View
Wiring harness routing Starboard view Õ 65 2 È Ô É Ó Ï Ó Ê Ò Ê F Ë Ì Í Ñ Î S6P28330E 1 Wiring harness 2 Stator coil lead 3 Sub wiring harness 4 Rectifier Regulator lead 5 Starter motor lead 6 PTT motor lead 7 Oil pressure sensor lead 8 Isolator lead...
Page 316 – ELEC Electrical system Õ 65 2 È Ô É Ó Ó Ï Ê Ò Ê F Ë Ì Í Ñ Î S6P28330E È Fasten the PTT motor lead and ground lead of the wiring harness to the holder. É Install the starter motor lead and brown lead of the wiring harness with the bolt. Ê...
Page 317 Wiring harness routing Õ 65 2 È Ô É Ó Ï Ó Ê Ò Ê F Ë Ì Í Ñ Î S6P28330E Ï Fasten the fuel injector lead in the order of Ñ, Ò, Ó, and Ô. Ñ Fasten the fuel injector lead (#5) to the clip at the white tape. Ò...
Page 318: Aft View
– ELEC Electrical system Aft view È Ì É Ê Ë S6P28870E 1 Joint connector È Fasten the wiring harness and cam position sensor lead (PORT IN) using a plastic tie. É Fasten the cam position sensor lead (PORT IN) to the holder. Ê...
Page 319: Top View
Wiring harness routing Top view È C C C É Ê Ë S6P28350E 1 Stator coil lead È Fasten the fuel injector lead and quick 2 Wiring harness connector to the holder. 3 Thermoswitch connector É Fasten the fuel injector lead and vapor gas 4 High-pressure fuel hose hose to the holder.
Page 320: Ignition And Ignition Control System
– ELEC Electrical system Ignition and ignition control NOTE: system The ignition spark can also be checked using Checking the ignition spark the “Stationary test” of the YDIS. 1. Remove the ECM cover. Checking the ignition coil input 2. Remove the ignition coils. voltage 3.
Page 321: Checking The Crank Position Sensor Air Gap
Ignition and ignition control system 3. Measure the crank position sensor air gap a. Adjust if out of specification. Crank position sensor air gap a: 1.4–1.6 mm (0.055–0.063 in) 4. Loosen the screws 1 and adjust the crank position sensor air gap. S6P28110 CAUTION: Check that the wiring harness does not...
Page 322: Checking The Intake Air Pressure Sensor
– ELEC Electrical system 3. Check that the difference between the 8. Measure the intake air temperature sen- ambient temperature and the displayed sor resistance. Replace if out of specifi- intake air temperature is within ± 5 °C (± cation. 9 °F).
Page 323: Checking The Engine Temperature Sensor
Ignition and ignition control system 6. Check the intake air pressure using the YDIS. 7. Apply the negative pressure to the intake air pressure sensor slowly. Check that the displayed intake air pressure is var- ied. NOTE: When checking the intake air pressure sen- S6P28740 sor, do not start the engine.
Page 324: Checking The Shift Cut Switch
– ELEC Electrical system 4. Place the thermoswitches in a container of water and slowly heat the water. S6P28655E Shift cut switch input voltage S6P28750 (reference data): 5. Check the switch for continuity at the Blue/yellow (L/Y) – Black (B) specified temperatures.
Page 325: Checking The Knock Sensor
Ignition and ignition control system 3. Measure the input voltage at the neutral switch coupler (wiring harness end). Check the wiring harness if out of specifi- cation. S6P28200E 2. Measure the knock sensor resistance. Check the installation (ground state) of the knock sensor if out of specification.
Page 326: Checking The Engine Stop Lanyard Switch
– ELEC Electrical system 2. Check the engine start switch for continu- ity at the 10-pin main harness coupler (engine start switch end). Check the wir- ing harness or replace the engine start switch if there is no continuity. START START S6P28370E Lead color...
Page 327: Checking The Ecm Circuit
Ignition and ignition control system / ECM and electronic throttle valve control system 5. Check for continuity between relay termi- nals 3 and 4. Replace if there is no continuity. 6. Check that there is no continuity between relay terminals 3 and 4 after discon- necting a battery terminal from relay ter- minal 5 or 6.
Page 328: Checking The Electronic Throttle Valve And Tps Circuit
– ELEC Electrical system 4. Disconnect the ECM coupler d, and then turn the engine start switch to ON. 5. Check the voltage at ECM coupler termi- nal e (13, wiring harness end). Check the fuse, wiring harness, and engine start switch if below specification.
Page 329 ECM and electronic throttle valve control system 2. Disconnect the electronic throttle valve coupler c. S6P28530 6. Check the wiring harness for continuity. S6P28510 3. Check the wiring harness for continuity. S6P28840 NOTE: S6P28830 Depending on the outboard motor, the loca- tion of the red/green terminals (79 and 80) of Wiring harness continuity the coupler b may be switched.
Page 330: Checking The Electronic Throttle Valve Motor
– ELEC Electrical system 8. Turn the engine start switch to ON, and then measure the TPS input voltage at the electronic throttle valve coupler (wir- ing harness end). S6P28560 2. Disconnect the accelerator position sen- sor coupler b. S6P28555E TPS input voltage (reference data): Terminal 5 (O) –...
Page 331: Checking The Accelerator Position Sensor
ECM and electronic throttle valve control system 2. Check that the accelerator lever 1 con- 5. Measure the input voltage at each termi- tacts the fully closed stopper 2 when the nal of the accelerator position sensor coupler b (wiring harness end). remote control lever is at the fully closed position.
Page 332 – ELEC Electrical system 4. Shift the remote control lever to the fully open position and hold it. S6P24160 5. Check the output voltages of accelerator S6P28300 position sensor 1 and accelerator posi- tion sensor 2. Accelerator position sensor resistance between 3 – 4, and Output voltage of accelerator between 5 –...
Page 333: Variable Camshaft Timing Control System
ECM and electronic throttle valve control system / Variable camshaft timing control system Variable camshaft timing control Cam position sensor input voltage: system Red/yellow (R/Y) 1 – Black (B) Checking the cam position sensor 12 V (battery voltage) 1. Disconnect the cam position sensor cou- White/blue (W/L) 2 –...
Page 334 – ELEC Electrical system 5. Remove the cam position sensor 3. NOTE: Be sure to connect the wire leads to the cor- 6. Connect the wire leads between cam responding terminals. position sensor and cam position sensor coupler (wiring harness end) as shown. 8.
Page 335: Checking The Oil Control Valve
Variable camshaft timing control system / Fuel control system 11. Disconnect the wire leads. Checking the oil control valve 1. Operate the oil control valve using the “Stationary test” of the YDIS and listen for the operating sound. 2. Disconnect the oil control valve coupler. 3.
Page 336: Checking The Low-Pressure Fuel Pump And High-Pressure Fuel Pump
– ELEC Electrical system 4. Measure the input voltage between the fuel injector coupler terminal and ground. Check the wiring harness if below specifi- cation. STBD S6P28445E S6P28250 Fuel injector input voltage: Low-pressure fuel pump resistance 1 (reference data): Red/yellow (R/Y) – Ground 1.3–4.0 Ω...
Page 337: Checking The Vapor Shut-Off Valve
Fuel control system / Starting system 3. Check that the vapor shut-off valve opens and the negative pressure is released when the battery voltage is applied to the vapor shut-off valve termi- nals 1. S6P28400 3. Turn the engine start switch to ON, and then measure the voltage within 5 sec- onds.
Page 338 – ELEC Electrical system 2. Measure the voltage between the termi- nal 2 and ground as shown. S6P28420 Terminal 2 – Ground: 12 V (battery voltage) 3. Connect the tester leads to terminals 3 and 4 as shown. S6P28430 4. Turn the engine start switch to START position, and then measure the voltage.
Page 339: Starter Motor
Starting system / Starter motor Starter motor S6P28070 Part name Q’ty Remarks Clip Pinion stopper Starter motor pinion Spring M6 × 35 mm Bolt Cover assembly Bearing Clutch assembly E-clip Not reusable Washer Bracket Pinion shaft Planetary gear Outer gear Plate Armature Stator...
Page 340 – ELEC Electrical system S6P28070 Part name Q’ty Remarks Brush assembly Brush spring Plate Plate Bracket ø4 × 15 mm Screw M6 × 120 mm Bolt Rubber seal Shift lever Spring Magnet switch assembly Pinion stopper set Washer set Starting motor gear assembly Brush holder assembly Lever assembly 8-35...
Page 341: Starter Motor
Starter motor Disassembling the starter motor 2. Measure commutator diameter. 1. Slide the pinion stopper 1 down as Replace the armature if below specifica- shown, and then remove the clip 2. tion. NOTE: Commutator standard diameter: Remove the clip with a screwdriver. 29.0 mm (1.14 in) Wear limit: 28.0 mm (1.10 in) 2.
Page 342: Checking The Brush
– ELEC Electrical system 4. Check armature continuity. Replace if out of specifications. S69J8440 Brush continuity Brush 1 – Brush 2 No continuity Armature continuity Commutator segments b Continuity Checking the magnet switch 1. Connect the tester leads between the Segment –...
Page 343: Checking The Starter Motor Operation
Starter motor / Charging system NOTE: Stator coil output peak voltage: The starter motor pinion should be pushed Green (G) – Green (G) out while the magnet switch is “ON”. Unloaded r/min Cranking 1,500 3,500 Checking the starter motor operation DC V 44.7 97.7...
Page 344 – ELEC Electrical system 4. Measure the Rectifier Regulator output peak voltage. If below specification, mea- sure the stator coil output peak voltage. Check the Rectifier Regulator if the out- put peak voltage of the stator coil is above specification. S6S18360 NOTE: Be sure to set the measurement range a,...
Page 345 TRBL SHTG Troubleshooting YDIS......................... 9-1 Introduction....................9-1 Connecting the communication cable to the outboard motor ....9-4 Troubleshooting the power unit ..............9-5 Troubleshooting the power unit using the YDIS ........9-5 Trouble code and checking step..............9-7 Troubleshooting the power unit using the diagnostic flash indicator ..9-15 Troubleshooting the power unit (trouble code not detected) ....
Page 346: Trbl Shtg
TRBL SHTG Troubleshooting YDIS Introduction Feature The newly developed YDIS provides quicker detection and analysis of engine malfunctions. By connecting your computer to the ECM 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 347 YDIS 4. Stationary test: Operation tests can be performed with the engine off. Items: For Blue Wlale 250 Ignite ignition coil Oil ctrl. valve drive Operate electric fuel (*1) (*3) (#1–#6) (STBD) pump Operate injector Oil ctrl. valve drive Operate elect. fuel feed (*2) (*4) (#1–#6)
Page 348 TRBL SHTG Troubleshooting 6. ECM record data graph: When a malfunction occurs in the electronic throttle valve system, 4 seconds (2 seconds before and after the malfunction) of recorded data are saved in the ECM. This data can be displayed on a graph using the “ECM record data graph” of the Data logger function.
Page 349 YDIS Contents 1. CD-ROM (software + instruction manual) (1) 2. Adapter (1) 3. Communication cable (1) Connecting the communication cable to the outboard motor 3-pin communication coupler (gray) S6P29010 6P23H11...
Page 350: Troubleshooting The Power Unit
TRBL SHTG Troubleshooting Troubleshooting the power unit NOTE: • Before troubleshooting the outboard motor, make sure that fresh fuel of the specified type has been used. • Check the trouble code using the YDIS (or diagnostic flash indicator) first, and then check the electronic control system follow the trouble code chart.
Page 351 Troubleshooting the power unit Symptoms table Engine Engine idle Maximum engine speed Acceleration Symptom startability speed (*1) (*2) (*4) Starts Normal Normal Normal (*3) (*5) Decreases Poor Increases Normal Normal (steady) Poor Decreases Normal Poor Increases Normal Normal (unsteady) Down Poor Unsteady Down...
Page 352: Trouble Code And Checking Step
TRBL SHTG Troubleshooting Trouble code and checking step Symptom Refer Trouble Item Checking steps code Remarks page 1. Measure the crank position sen- 8-15 sor resistance. 2. Check the white/black (W/B) lead and black (B) lead (ECM-to- crank position sensor) for conti- Crank position nuity.
Page 353 Troubleshooting the power unit Symptom Refer Trouble Item Checking steps code Remarks page 1. Check the cam timing using the YDIS. 2. Measure the input voltage. 8-28 Cam position sensor 3. Check the white/blue (W/L) lead — (PORT EX) (cam position sensor-to-ECM) malfunction for continuity.
Page 354 TRBL SHTG Troubleshooting Symptom Refer Trouble Item Checking steps code Remarks page 1. Check the engine oil pressure using the YDIS. 2. Measure the input voltage. Oil pressure 3. Measure the output voltage. sensor — 4. Check the pink/white (P/W) lead malfunction (ECM-to-oil pressure sensor) for continuity.
Page 355 Troubleshooting the power unit Symptom Refer Trouble Item Checking steps code Remarks page 1. Check the cam timing using the YDIS. 2. Measure the input voltage. 8-28 3. Check the white/black (W/B) Cam position lead (cam position sensor-to- sensor — ECM) for continuity.
Page 356 TRBL SHTG Troubleshooting Symptom Refer Trouble Item Checking steps code Remarks page 1. Check the electronic throttle valve operation. 2. Check the TPS output voltage using the YDIS. 3. Check the throttle opening angle using the YDIS. Electronic throttle valve —...
Page 357 Troubleshooting the power unit Symptom Refer Trouble Item Checking steps code Remarks page 1. Check the TPS output voltage using the YDIS. 2. Check the throttle opening angle — malfunction using the YDIS. 3. Check the electronic throttle 8-23 valve circuit. 1.
Page 358 TRBL SHTG Troubleshooting Symptom Refer Trouble Item Checking steps code Remarks page 1. Check the accelerator position sensor output voltage using the Accelerator YDIS. position — 2. Check the accelerator position 8-25 sensor sensor circuit. malfunction 3. Check the accelerator position 8-26 sensor resistance.
Page 359 Troubleshooting the power unit Symptom Refer Trouble Item Checking steps code Remarks page Electronic 1. Check the electronic throttle throttle valve — valve operation. malfunction 1. Check the battery cables and 3-15 terminals for proper connection. 2. Check the ECM circuit. 8-22 Electronic throttle valve...
Page 360: Troubleshooting The Power Unit Using The Diagnostic Flash Indicator
TRBL SHTG Troubleshooting Troubleshooting the power unit using the diagnostic flash indicator 1. Connect the special service tool to the outboard motor as shown. • Trouble code indication Example: The illustration indicates code numbers 23 and 113. a: Light on, 0.33 second b: Light off, 4.95 seconds c: Light off, 0.33 second d: Light off, 1.65 seconds...
Page 361: Troubleshooting The Power Unit (Trouble Code Not Detected)
Troubleshooting the power unit NOTE: • When more than one problem is detected, the light of the special service tool flashes in the pattern of the lowest numbered prob- lem. After that problem is corrected, the light flashes in the pattern of the next low- est numbered problem.
Page 362 TRBL SHTG Troubleshooting Troubleshooting the power unit (trouble code not detected) Troubleshooting when a trouble code is not available consists of the following 4 items. Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause 1: The content considered as the trouble factors of symptom 2.
Page 363 Troubleshooting the power unit Symptom 1: Engine will not start (engine cranks) Refer Symptom 2 Cause 1 Cause 2 Checking step page ECM does not Relay malfunction — Check the relay. 8-21 operate Blown fuse — Check the fuse. Short, open, Check the ECM cir- 8-22...
Page 364 TRBL SHTG Troubleshooting Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited engine speed Refer Symptom 2 Cause 1 Cause 2 Checking step page Spark plug does not Spark plug malfunc- Check the ignition spark tion spark. 8-15 —...
Page 365 Troubleshooting the power unit Symptom 1: High engine idle speed (below 1,200 r/min) Refer Symptom 2 Cause 1 Cause 2 Checking step page Air leakage (throttle Check the O-rings 4-12 valve-cylinder and gaskets of the in- 4-15 — head) — take manifold, surge tank, throttle...
Page 366 TRBL SHTG Troubleshooting Symptom 1: Limited engine speed (below 2,000 r/min) Refer Symptom 2 Cause 1 Cause 2 Checking step page • Buzzer comes on Clogged cooling wa- Check the cooling — • Overheat warning ter inlet water inlet. indicator comes Water pump mal- Water pump impel- Check the impeller.
Page 367: Troubleshooting The Ptt Unit
Troubleshooting the power unit Troubleshooting the PTT unit Symptom 1: PTT unit does not operate Refer Symptom 2 Cause 1 Cause 2 Checking step page PTT relay does not switch mal- Check 7-47 — operate function switch. Short, open, or loose Check the wiring har- connection —...
Page 368: Troubleshooting The Lower Unit
TRBL SHTG Troubleshooting Symptom 1: PTT unit does not hold the outboard motor up Refer Symptom 2 Cause 1 Cause 2 Checking step page Manual valve Manual valve mal- Check the manual 7-22 opened function valve. Insufficient PTT flu- Add sufficient fluid. 3-12 —...
Page 369 Index Checking the check valve......4-21 Checking the compression pressure ..5-1 Abbreviation ..........1-3 Checking the connecting rod big end Adjusting the throttle cable......3-10 side clearance ........5-60 Adjusting the trim sensor ......7-20 Checking the connecting rod small Adjusting the valve clearance ....5-11 end inside diameter ........
Page 370 Index Checking the hydraulic pressure....7-24 Checking the starter relay......8-32 Checking the ignition coil input voltage..8-15 Checking the stator coil ......8-38 Checking the ignition spark.......8-15 Checking the steering system ....1-42 Checking the intake air pressure Checking the thermostat......3-7 sensor .............8-17 Checking the thermoswitch ......
Page 371 Index Disassembly and assembly ......1-5 Installing the cylinder head ....... 5-51 Disconnecting the quick connector .....4-9 Installing the drive shaft....6-16 6-48 Draining the fuel........4-10 Installing the exhaust cover ...... 5-40 Drive shaft and lower case Installing the fuel hose clamp ....4-25 (counter rotation model)......6-43 Installing the fuel injector ......
Page 372 Index Shift rod and bottom cowling ...... 7-1 Shimming.........6-23 6-54 Part, lubricant, and sealant ......1-4 Shimming (counter rotation model) ..6-53 Port view ..........8-3 Shimming (regular rotation model) ... 6-22 Power unit ........2-3 Special service tool........1-7 Predelivery check........1-40 Specified torque........
Page 373 Index — MEMO — 6P23H11...
Page 374 Wiring diagram Blue Whale 250 1 Condenser (connect to the intake air pressure Color code sensor) : Black 2 PTT switch : Brown 3 Trim sensor : Green 4 Crank position sensor : Blue 5 Stator coil : Light green 6 Starter motor : Orange 7 Battery...
Page 377 Blue Whale 250 (*2) (*1) 1 2 3 4 1 2 3 4 1 2 3 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 3 4 5 6 7 8 9 10 11 12 Pu/W Pu/G...