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SELVA MARINE Grey Whale 200 EFI Service Manual

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Table of Contents

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Grey Whale 200 EFI
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SERVICE MANUAL

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Summary of Contents for SELVA MARINE Grey Whale 200 EFI

  • Page 1 Grey Whale 200 EFI Fin Whale 225 EFI 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 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 5: 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 6: Gen Info

    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 Local Area Network Pressure Control Valve 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 models. Applicable model F200CET, FL200CET, F225BET, FL225BET 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 90890-06612, 90890-06613, 90890-06653, 90890-06654 Stopper guide stand 90890-06538 Piston ring compressor 90890-05158 Bearing puller assembly 90890-06535 Bearing housing puller claw L 90890-06502 Slide hammer 90890-06531 Stopper guide plate 90890-06501 Bearing outer race puller assembly 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 6AL3J11...
  • 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 Selva diagnostic system 90890-03174...
  • Page 18 INFO General information Selva diagnostic system (Ver. 1.32) 60V-WS853-05 Diagnostic flash indicator B 90890-06865 1-13 6AL3J11...

  • Page 19: Feature And Benefit

    Special service tool / Feature and benefit Feature and benefit Water separator For the 2007 models, a fuel filter assembly with a water detection switch has been adopted on the fuel line as a system to improve engine protection. The water detection warnings are given only if the fuel filter assembly with a water detection switch is connected to the 6Y8 Multifunction Meter.

  • Page 20: Injector

    INFO General information Injector The injector for the 2007 models was improved in order to reduce the amount of soot after combus- tion compared to the injector used for the 2006 model F(L)250A. Due to the change in the injector spray angle, the ECM fuel injection mapping was also changed. Therefore, be sure to use the 2007 model injector together with the 2007 model ECMs.

  • Page 21: Ecm

    Feature and benefit The ECM changes due to the yearly modifications are listed in the following table according to the model for the F(L)200C, F(L)225B, F(L)250A. Due to the change in the injector spray angle, the ECM fuel injection mapping was also changed. È...
  • Page 22 INFO General information ECM coupler layout (F(L)200C, F(L)225B) 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 23 Feature and benefit 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 24 INFO General information Circuit diagram (F(L)200C, F(L)225B) 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 25 Feature and benefit Intake air temperature Oil control valve (STBD) sensor Oil control valve (PORT) Engine temperature sensor High-pressure fuel pump relay High-pressure fuel pump Trim sensor Low-pressure fuel pump Thermoswitch Vapor shut-off valve Water detection switch Shift cut switch Low oil pressure warning indicator Neutral switch...

  • Page 26: 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 27: 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 28: 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 29: 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 30: 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. S6AL3180 2.
  • Page 31 SPEC Specification General specification..................2-1 Maintenance specification ................2-3 Power unit....................2-3 Fuel system ....................2-6 PTT unit ..................... 2-7 Lower unit ....................2-7 Electrical ....................2-8 Dimension....................2-12 Tightening torque..................2-14 Specified torque..................2-14 General torque..................2-17 6AL3J11...

  • Page 32: Specification

    SPEC Specification General specification Model Item Unit 200 R 200 L 225 R 225 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)
  • Page 33 General specification Model Item Unit 200 R 200 L 225 R 225 L Fuel and oil Fuel type Regular unleaded gasoline 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 34: Maintenance Specification

    SPEC Specification Maintenance specification Power unit Model Item Unit 200 R 200 L 225 R 225 L Power unit Minimum compression 740 (7.4, 107.3) (*1) pressure (kgf/cm , psi) (*2) Oil pressure 600 (6.0, 87.0) at 600–900 r/min (kgf/cm , psi) Timing belt Timing belt installation height mm (in)
  • Page 35 Maintenance specification Model Item Unit 200 R 200 L 225 R 225 L Piston ring Top ring Dimension B mm (in) 1.17–1.19 (0.046–0.047) Dimension T mm (in) 2.80–3.00 (0.110–0.118) (*1) End gap mm (in) 0.15–0.30 (0.006–0.012) Side clearance mm (in) 0.04–0.08 (0.002–0.003) 2nd piston ring Dimension B...
  • Page 36 SPEC Specification Model Item Unit 200 R 200 L 225 R 225 L Stem diameter Intake mm (in) 5.477–5.492 (0.2156–0.2162) Exhaust mm (in) 5.464–5.479 (0.2151–0.2157) Stem runout limit mm (in) 0.01 (0.0004) Guide inside diameter Intake and exhaust mm (in) 5.504–5.522 (0.2167–0.2174) Stem-to-guide clearance Intake...

  • Page 37: Fuel System

    Maintenance specification Model Item Unit 200 R 200 L 225 R 225 L Crankcase Crankshaft journal oil mm (in) 0.025–0.050 (0.0010–0.0020) clearance Upper crankcase main bearing thickness mm (in) 2.494–2.500 (0.0982–0.0984) mm (in) 2.498–2.504 (0.0983–0.0986) mm (in) 2.502–2.508 (0.0985–0.0987) Lower crankcase main bearing thickness mm (in) 2.494–2.500 (0.0982–0.0984)

  • Page 38: Ptt Unit

    SPEC Specification Model Item Unit 200 R 200 L 225 R 225 L Fuel filter assembly holding pressure Fuel inlet positive pressure 200 (2.0, 29.0) (kgf/cm , psi) Fuel outlet negative pressure 80 (0.8, 11.6) (kgf/cm , psi) Float height Water detection position mm (in) 30 (1.18)

  • Page 39: Electrical

    Maintenance specification Model Item Unit 200 R 200 L 225 R 225 L Propeller shaft Propeller shaft free play mm (in) 0.20–0.50 0.25–0.35 0.20–0.50 0.25–0.35 (0.0079– (0.0098– (0.0079– (0.0098– 0.0197) 0.0138) 0.0197) 0.0138) Propeller shaft shims 1.80, 1.90, 0.10, 0.12, 1.80, 1.90, 0.10, 0.12, 2.00, 2.10,...
  • Page 40 SPEC Specification Model Item Unit 200 R 200 L 225 R 225 L Oil pressure sensor (*1) Output voltage (P/W – B) 3.4 at engine idle speed Electronic throttle valve control system TPS output voltage at 20 °C (68 °F) with remote control lever fully (*1) closed...
  • Page 41 Maintenance specification Model Item Unit 200 R 200 L 225 R 225 L Variable camshaft timing control system Oil control valve resistance Ω at 20 °C (68 °F) 6.7–7.7 Fuel control system (*1) Fuel injector resistance Ω at 21 °C (70 °F) 12.0 Ω...
  • Page 42 SPEC Specification Model Item Unit 200 R 200 L 225 R 225 L PTT system Trim sensor Ω 10 ± 1 Setting resistance Ω Resistance 9–387.6 Fluid type ATF Dexron II PTT motor Output 0.53 Brushes Standard length mm (in) 11.5 (0.45) Wear limit mm (in)

  • Page 43: Dimension

    Maintenance specification Dimension Exterior Grey Whale 200 - Fin Whale 225 mm (in) X: 1,155 (45.5) 619 (24.4) U: 1,272 (50.1) 651 (25.6) 219 (8.6) 75 (3.0) 230 (9.1) X: 52 (2.0) U: 59 (2.3) 673 (26.5) S6P22020 U (U-transom model): F225B regular rotation model only. 2-12 6AL3J11...
  • Page 44 SPEC Specification Clamp bracket Grey Whale 200 - Fin Whale 225 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 2-13 6AL3J11...

  • Page 45: 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 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 46 SPEC Specification Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Negative battery cable nut — Negative terminal bolt — 19.2 PTT relay lead nut — Rectifier Regulator bolt Anode screw ECM bolt Engine hanger bolt 10.3 20.7 17.0 33.2 Cylinder head bolt...
  • Page 47 Tightening torque Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Gear oil drain screw — Lower case mounting bolt (nut) 34.7 Trim tab bolt 31.0 Propeller nut — 39.8 Grease nipple — Propeller shaft housing bolt 22.1 Cooling water inlet cover screw Pinion nut —...

  • Page 48: General Torque

    SPEC Specification Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb PTT unit Reservoir mounting bolt 14.0 PTT motor mounting bolt 14.0 Reservoir cap Manual valve — Pipe joint — 11.1 Pipe joint adapter — 14.8 Gear pump bolt Gear pump bracket bolt Trim cylinder end screw —...
  • Page 49 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 Draining the fuel ..................3-5 Power unit.......................

  • Page 50: 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 51 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 Fuel filter Replace 4-27 (vapor separator tank) Oil control valve filter Replace 5-43 Anodes Replace 3-16 (exhaust cover, cooling water passage cover, Rectifier...

  • Page 52: 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 53: Checking The Fuel Filter

    Top cowling / Fuel system 4. Install the port intake manifold, fuel rail covers, and flywheel magnet cover. NOTE: To install the intake manifold, see Chapter 4, “Installing the intake manifold.” Checking the fuel filter 1. Disconnect the water detection switch S6AS3021 coupler (blue) 1.

  • Page 54: Draining The Fuel

    Periodic check and adjustment Draining the fuel Vapor separator drain screw 2: 1. Reduce the fuel pressure. 2 N·m (0.2 kgf·m, 1.5 ft·lb) NOTE: To reduce the fuel pressure, see Chapter 4, Power unit “Reducing the fuel pressure.” Checking the engine oil 1.

  • Page 55: Changing The Engine Oil (Draining)

    Fuel system / Power unit 3. Insert the tube of the oil changer 2 into the dipstick guide 3. 3. Remove the starboard apron 2. 4. Operate the oil changer to extract the oil. NOTE: Be sure to clean up any oil spills. 5.

  • Page 56: Replacing The Oil Filter

    Periodic check and adjustment 6. Pour the specified amount of the recom- mended engine oil into the oil filler hole. Recommended engine oil: 4-stroke motor oil API: SE, SF, SG, SH, SJ, or SL SAE: 5W-30, 10W-30, or 10W-40 Engine oil quantity: Without oil filter replacement: S6AL3030 5.6 L (5.92 US qt, 4.93 Imp qt)

  • Page 57: Checking The Timing Belt

    Power unit 2. Remove the ignition coils, and then Recommended engine oil: remove the spark plugs. 4-stroke motor oil API: SE, SF, SG, SH, SJ, or SL SAE: 5W-30, 10W-30, or 10W-40 Engine oil quantity: With oil filter replacement: 5.8 L (6.13 US qt, 5.10 Imp qt) 6.

  • Page 58: Checking The Thermostat

    Periodic check and adjustment 5. Check the spark plug gap a. Adjust the spark plug gap if out of specification. PORT S6AL3090 STBD Specified spark plug: LFR6A-11 (NGK) Spark plug gap a: 1.0–1.1 mm (0.039–0.043 in) 6. Install the spark plugs, tighten them tem- S6AL3010 porarily, then to the specified torque using a spark plug wrench.

  • Page 59: Checking The Cooling Water Passage

    Power unit NOTE: CAUTION: It is recommended to check the thermostat Do not reuse the gaskets 6, always cover anodes before installing the thermostat replace them with new ones. covers. 7. Suspend the thermostat in a container of 11. Connect the thermoswitch connectors, water.

  • Page 60: Control System

    Periodic check and adjustment 3. Check for water flow at the cooling water pilot hole. If there is no water flow, check the cooling water passage inside the out- board motor. S6AL3180 S6P23330 Control system 3. Check that the accelerator lever 4 con- tacts the fully closed stopper 5.

  • Page 61: Checking The Gear Shift Operation

    Power unit / Control system Checking the gear shift operation NOTE: 1. Check that the gear shift operates Pull the throttle cable towards the engine to smoothly when shifting it from the neutral remove any free play in the cable before position to forward or reverse.

  • Page 62: Bracket Unit

    Periodic check and adjustment 5. Align the alignment mark a on the bush- ing and alignment mark b on the bracket. 6. Adjust the position of the shift cable joint until its hole is aligned with the set pin. S6P23190 NOTE: Be sure to listen to the winding sound of the PTT motor for smooth operation.

  • Page 63: Lower Unit

    Control system / Bracket unit / Lower unit Lower unit WARNING Checking the gear oil level After tilting up the outboard motor, be 1. Fully tilt the outboard motor down. sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- 2.

  • Page 64: Checking The Lower Unit For Air Leakage

    Periodic check and adjustment 2. Place a drain pan under the gear oil drain Recommended gear oil: hole, remove the gear oil drain screw Hypoid gear oil 1, then the gear oil check screw 2 and API: GL-4 let the oil drain completely. SAE: 90 Gear oil quantity: Regular rotation model:...

  • Page 65: Checking The Propeller

    Lower unit / General NOTE: Cover the check hole with a rag when remov- ing the tester from the lower unit. Lower unit holding pressure: 70 kPa (0.7 kgf/cm , 10 psi) 3. If the specified pressure cannot be main- S6P23270E tained, check the drive shaft, propeller shaft and shift rod oil seals for damage.

  • Page 66: Checking The Battery

    Periodic check and adjustment S69J3620 2. Check the specific gravity of the electro- lyte. Fully charge the battery if below specification. WARNING Battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: •...

  • Page 67: 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. Electrolyte specific gravity: 1.280 at 20 °C (68 °F) Lubricating the outboard motor 1.
  • Page 68 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. 3-19 6AL3J11...
  • Page 69 FUEL Fuel system Hose routing ....................4-1 Fuel hose and blowby hose............... 4-1 Vapor gas hose ..................4-2 Cooling water hose..................4-3 Fuel system ....................4-5 Reducing the fuel pressure................ 4-5 Disconnecting the quick connector............4-5 Measuring the fuel pressure ..............4-6 Checking the pressure regulator ...............

  • Page 70: Fuel System

    FUEL Fuel system Hose routing Fuel hose and blowby hose S6AS4030 1 Fuel hose (fuel joint-to-fuel filter) C Blowby hose (starboard cylinder head cover- 2 Fuel hose (fuel filter-to-joint) to-joint) 3 Fuel hose (joint-to-low-pressure fuel pump) D Blowby hose (joint-to-cylinder block) 4 Fuel hose (low-pressure fuel pump-to-filter) E Blowby hose (joint-to-intake silencer) 5 Fuel hose (filter-to-joint)

  • Page 71: Vapor Gas Hose

    Hose routing Vapor gas hose É È STBD Ê Ê Ì Ì Ë Ë Í Í S6AL4160 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 72: 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 73 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 6AL3J11...

  • Page 74: Fuel System

    FUEL Fuel system Fuel system Disconnecting the quick connector Reducing the fuel pressure WARNING If the quick connector is disconnected WARNING suddenly, pressurized fuel could spray Always reduce the fuel pressure in the out. Be sure to reduce the fuel pressure high-pressure fuel line before servicing before disconnecting the quick connec- the line or the vapor separator.

  • Page 75: Measuring The Fuel Pressure

    Fuel system PORT S6P24280 NOTE: Cover the quick connector, fuel rail, and vapor separator with a plastic bag to prevent S6P24290E damage and to protect them from dirt. WARNING • Gently screw in the gauge until it is Measuring the fuel pressure firmly connected to prevent fuel from 1.

  • Page 76: Checking The Pressure Regulator

    FUEL Fuel system 6. Start the engine, warm it up for 5 min- 4. Connect the fuel pressure gauge to fuel utes, and then measure the fuel pressure pressure gauge adapter B. at engine idle speed. If below specifica- 5. Disconnect the pressure regulator hose, tion, check the high-pressure fuel line and then connect the special service tool and the vapor separator.
  • Page 77 Fuel system NOTE: When the specified vacuum pressure is reached, the pressure regulator is operated and the fuel pressure is reduced. 8. Reduce the fuel pressure. NOTE: To reduce the fuel pressure, see Chapter 4, “Reducing the fuel pressure.” 9. Disconnect the special service tools. WARNING •...

  • Page 78: Intake Manifold

    FUEL Fuel system 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 S6AL4030 Part name Q’ty Remarks Flywheel magnet cover Blowby hose...

  • Page 79: Checking The Intake Manifold

    Intake manifold Checking the intake manifold NOTE: 1. Check the intake manifold. Replace the When installing the intake manifolds, make intake manifold if cracked or deformed. sure that the gaskets do not come off when the projection of the gasket comes into con- 2.

  • Page 80: Installing The Intake Silencer

    FUEL Fuel system Installing the intake silencer 1. Install the intake silencer. S6AL4040 Intake silencer bolt: 7 N·m (0.7 kgf·m, 5.2 ft·lb) 2. Fasten the intake air temperature sensor lead 1 to the holder on the oil filler neck as shown. 3.

  • Page 81: Accelerator Position Sensor

    Intake manifold / Accelerator position sensor Accelerator position sensor S6AL4300 Part name Q’ty Remarks Accelerator position sensor assembly Grommet Collar M6 × 35 mm Bolt Accelerator position sensor coupler 4-12 6AL3J11...

  • Page 82: 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 83 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 È...
  • Page 84 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) S6AL4060 Part name Q’ty Remarks Check valve Holder Holder...

  • Page 85: Checking The Electronic Throttle Valve System

    Throttle body Checking the electronic throttle Vacuum/pressure pump gauge set: valve system 90890-06756 1. For checks related to the APS and TPS, see Chapter 8. Specified pressure: NOTE: 19.6 kPa (0.196 kgf/cm , 2.8 psi) • To check the electronic throttle valve assembly, see Chapter 8, “ECM and elec- Checking the canister check valve tronic throttle valve control system.”...

  • Page 86: Installing The Throttle Body

    FUEL Fuel system Installing the throttle body 1. Connect the check valve to the hoses 1 and 2. È S6AL4220 4. Install the throttle body. S6AL4210 5. Connect the hoses and fasten them. È To the intake silencer 2. Connect the hoses and fasten them. É...
  • Page 87 Throttle body S6AL4240 4-18 6AL3J11...

  • Page 88: Fuel Filter

    FUEL Fuel system Fuel filter · · · m (0.6 kgf m, 4.4 ft · · · m (0.5 kgf m, 3.7 ft 12 mm (0.47 in) 12 mm 12 mm 9 mm (0.47 in) (0.47 in) (0.35 in) S6AL4320 Part name Q’ty Remarks...

  • Page 89: Checking The Fuel Filter Assembly

    Fuel filter 4. Cover the fuel inlet 1 with a finger, and Checking the fuel filter assembly then apply the specified negative pres- NOTE: sure. Replace the O-ring, fuel cup • To check the fuel filter element, see Chap- assembly, or fuel filter assembly if the ter 3, “Checking the fuel filter.”...

  • Page 90: Low-Pressure Fuel Pump

    FUEL Fuel system 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 Fuel filter Plastic tie Not reusable Plastic tie Not reusable Low-pressure fuel pump coupler 4-21...

  • Page 91: Checking The Low-Pressure Fuel Pump

    Low-pressure fuel pump Checking the low-pressure fuel Vacuum/pressure pump gauge set: pump 90890-06756 1. Drain the fuel from the vapor separator and check the condition of the fuel. 2. Apply positive pressure to the check NOTE: valve port. • To drain the fuel, see Chapter 3, “Draining the fuel.”...

  • Page 92: Fuel Injector

    FUEL Fuel system Fuel injector S6AL4120 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) 4-23 6AL3J11...

  • Page 93: Checking The Fuel Rail

    Fuel injector Checking the fuel rail 1. Check the fuel rails. Replace the fuel rail if cracked or deformed. NOTE: • To reduce the fuel pressure, see Chapter 4, “Reducing the fuel pressure.” • To check the fuel injectors, see Chapter 8, “Checking the fuel injector.”...
  • Page 94 FUEL Fuel system 7. Fasten the wiring harness to the holders, and then fasten the plastic ties 8 as shown. PORT STBD S6P24370 4-25 6AL3J11...

  • Page 95: Vapor Separator

    Fuel injector / Vapor separator Vapor separator · · · m (0.5 kgf m, 3.7 ft 12 mm (0.47 in) 10 mm (0.39 in) S6AL4100 Part name Q’ty Remarks Bracket M6 × 16 mm Bolt Collar Grommet M6 × 35 mm Bolt Collar Fuel cooler...
  • Page 96 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 S6AL4110...

  • Page 97: 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 S6AL4110...

  • Page 98: Removing The Fuel Hose Clamp

    FUEL Fuel system Removing the fuel hose clamp Checking the high-pressure fuel pump NOTE: To reduce the fuel pressure, see Chapter 4, NOTE: “Reducing the fuel pressure.” • To check the high-pressure fuel pump, see Chapter 8, “Checking the low-pressure fuel 1.
  • Page 99 Vapor separator S6P24480 NOTE: To measure the height of the float, it should be resting on the needle valve. Do not press the float. Float height a: 60.5 ± 3.0 mm (2.38 ± 0.12 in) 4-30 6AL3J11...
  • Page 100 POWR Power unit Power unit (check and adjustment).............. 5-1 Checking the compression pressure ............5-1 Checking the oil pressure ................5-1 Checking the oil pressure sensor .............. 5-2 ECM base assembly.................. 5-4 Stator assembly..................5-6 Camshaft ....................5-7 Checking the valve clearance..............5-9 Adjusting the valve clearance..............
  • Page 101 Cylinder block ....................5-57 Crankcase ....................5-57 Cylinder block ..................5-59 Disassembling the cylinder block ............5-61 Checking the piston diameter ..............5-62 Checking the cylinder bore ..............5-62 Checking the piston clearance (reference)..........5-62 Checking the piston ring ................5-62 Checking the piston ring end gap (reference) .........5-63 Checking the piston ring groove ..............5-63 Checking the piston ring side clearance..........

  • Page 102: Power Unit

    POWR Power unit Power unit (check and adjustment) Checking the compression pressure 1. Start the engine, warm it up for 5 min- utes, and then turn it off. 2. Remove the engine stop lanyard from the engine stop lanyard switch. S6P25015 3.

  • Page 103: Checking The Oil Pressure Sensor

    Power unit (check and adjustment) S6AL5B30 NOTE: • The intake manifold (STBD), positive bat- tery cable, positive battery terminal, and holder (oil pressure sensor lead, isolator lead, and PTT lead) must be removed before removing the oil pressure sensor. • Use a general oil pressure gauge 1. S6AL5020 2.
  • Page 104 POWR Power unit 4. Measure the oil pressure sensor output voltage. Replace if out of specification. 3.4 V È 600 kpa É (6.0 kgf/cm S6P25040 87.0 psi) È Output voltage É Oil pressure Test harness (3 pins) 1: 90890-06869 Oil pressure sensor input voltage (reference data): Orange (O) –...

  • Page 105: Ecm Base Assembly

    Power unit (check and adjustment) ECM base assembly · · · m (0.7 kgf m, 5.2 ft · · · 25 N m (2.5 kgf m, 18.4 ft 25 26 · · · 11 N m (1.1 kgf m, 8.1 ft ·...
  • Page 106 POWR Power unit · · · m (0.7 kgf m, 5.2 ft · · · 25 N m (2.5 kgf m, 18.4 ft 25 26 · · · 11 N m (1.1 kgf m, 8.1 ft · · · 25 N m (2.5 kgf m, 18.4 ft ·...

  • Page 107: Stator Assembly

    Power unit (check and adjustment) Stator assembly · · · 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 S6AL5050 Part name Q’ty Remarks Width across flats: 36 mm...

  • Page 108: Camshaft

    POWR Power unit Camshaft · · · · · · 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 109 Power unit (check and adjustment) · · · · · · 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 110: Checking The Valve Clearance

    POWR Power unit Checking the valve clearance CAUTION: Do not turn the flywheel magnet counter- clockwise, otherwise the water pump impeller may be damaged. NOTE: Measure the valve clearances when the engine is cold. 1. Reduce the fuel pressure. NOTE: When measuring or adjusting the valve clear- ances, the fuel line must be disconnected, so be sure to reduce the fuel pressure before...
  • Page 111 Power unit (check and adjustment) Valve clearance (cold): Intake e: 0.20 ± 0.03 mm (0.008 ± 0.001 in) Exhaust f: 0.34 ± 0.03 mm (0.013 ± 0.001 in) 12. Measure the intake and exhaust valve clearances for cylinder #4. 13. Turn the flywheel magnet an additional 120°...

  • Page 112: Adjusting The Valve Clearance

    POWR Power unit Adjusting the valve clearance CAUTION: Do not turn the flywheel magnet or the driven sprockets when the timing belt is not installed. Otherwise the pistons and valves or intake and exhaust valves will collide with each other and be damaged. S6AL5150 NOTE: NOTE:...
  • Page 113 Power unit (check and adjustment) S6AL5110 8. Remove the timing belt, driven sprock- ets, and camshafts. NOTE: To remove the timing belt, driven sprockets, S6P25E00 and camshafts, see Chapter 5, “Removing the timing belt, driven sprocket, and cam- CAUTION: shaft.” To prevent damage to the engine or tools, screw in the puller set bolts evenly and completely so that the flywheel puller is...
  • Page 114 POWR Power unit 11. Select the necessary valve shim by cal- NOTE: culating its thickness using the following • Be sure to remove any grease from the formula. tapered portion of the crankshaft e and the flywheel magnet f. Necessary valve shim thickness = •...
  • Page 115 Power unit (check and adjustment) Crank position sensor air gap k: 1280B 1.4–1.6 mm (0.055–0.063 in) 1280B Crank position sensor screw: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 20. Install the timing belt guides 6, and then 1280B adjust the timing belt-to-timing belt guide 1280B clearance m.

  • Page 116: Replacing The Timing Belt

    POWR Power unit 24. Check that the wiring harness, hoses, and other parts do not interfere with any moving parts. Replacing the timing belt CAUTION: • Do not turn the flywheel magnet coun- terclockwise, otherwise the water pump impeller may be damaged. •...
  • Page 117 Power unit (check and adjustment) S6AL5160 NOTE: To remove the wiring harness guide, see Chapter 5, “Removing the wiring harness.” 12. Loosen the flywheel magnet nut. S6P25E00 CAUTION: To prevent damage to the engine or tools, screw in the puller set bolts evenly and completely so that the flywheel puller is parallel to the flywheel magnet.
  • Page 118 POWR Power unit 14. Remove the stator assembly bolts, and then move the stator assembly. S6AL5A30 NOTE: Leave the pin inserted into the hole g of the timing belt tensioner until the timing belt is installed again. S6AL5110 18. Remove the timing belt from the driven 15.
  • Page 119 Power unit (check and adjustment) È 0 1 2 3 S6P25230 È Belt teeth number CAUTION: • Do not twist, turn inside out, or bend the timing belt beyond the maximum limit of 25 mm (1.0 in) otherwise it can be dam- aged.
  • Page 120 POWR Power unit 23. Adjust the timing belt to the specified installation height r. S6P25250 Timing belt installation height r: 2.0 mm (0.08 in) 24. Check that belt position marks h through p are aligned with each alignment mark S6P25180 on the drive sprocket and driven sprock- ets, and then remove the pin 9.
  • Page 121 Power unit (check and adjustment) 28. Tighten the flywheel magnet nut to the specified torque. Flywheel holder: 90890-06522 Flywheel magnet nut: S6AL5120 240 N·m (24.0 kgf·m, 177.0 ft·lb) Timing belt-to-timing belt guide 29. Check the crank position sensor air gap clearance x: 1.0 ±...

  • Page 122: Removing The Timing Belt, Driven Sprocket, And Camshaft

    POWR Power unit Removing the timing belt, driven sprocket, and camshaft CAUTION: • Do not turn the crankshaft counterclock- wise, otherwise the water pump impeller may be damaged. • Do not turn the crankshaft or the driven sprockets when the timing belt is not S6AL5720 installed.
  • Page 123 Power unit (check and adjustment) 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 124 POWR Power unit 9. Hold the intake driven sprocket using the CAUTION: special service tool, and then remove the variable camshaft timing cap 4. • Do not hold the driven sprocket when removing the variable camshaft timing bolt. Otherwise the variable camshaft timing assembly can be damaged.

  • Page 125: Checking The Timing Belt And Sprocket

    Power unit (check and adjustment) 2. Check the drive sprocket. Replace the PORT STBD crankshaft assembly if cracked, dam- aged, or worn. 3. Check the driven sprockets. Replace the variable camshaft timing assembly or driven sprocket if cracked, damaged, or ±...

  • Page 126: Checking The Camshaft

    POWR Power unit Checking the camshaft Cam lobe a: 1. Check the edge and face of the brim on Intake: the port camshafts and starboard intake 46.30–46.40 mm camshaft that is used for the cam posi- (1.823–1.827 in) tion sensor. Replace if rough, damaged, Exhaust: or scratched.

  • Page 127: Installing The Camshaft, Driven Sprocket, And Timing Belt

    Power unit (check and adjustment) 3. Apply a thin, even coat of sealant to the Camshaft journal diameter c: mating surface of the camshaft caps 1 24.96–24.98 mm cylinder heads 2 as shown. (0.9826–0.9834 in) Camshaft cap inside diameter d: 25.000–25.021 mm 1386B 1386B...
  • Page 128 POWR Power unit 4. Install the camshafts with the oil seals. PORT STBD PORT STBD S-IN P-IN S-EX S6P25E20 P-EX S6AL5270 7. Tighten the camshaft cap bolts to the NOTE: specified torques in 2 stages and in the • Apply molybdenum disulfide grease to the sequence shown.
  • Page 129 Power unit (check and adjustment) 8. Install the dowel and exhaust driven 10. Install the dowel and variable camshaft sprocket on the exhaust camshaft. timing assembly on the intake camshaft. 9. Hold the exhaust camshaft using a 11. Check that the lower edge of the intake wrench, and then tighten the driven exhaust driven...
  • Page 130 POWR Power unit 12. Hold the intake camshaft using a wrench, NOTE: and then tighten the variable camshaft Slight turn the driven sprockets in direction Ê timing bolt 6 to the specified torque. to remove any free play Ë before tightening the variable camshaft timing bolt 6.
  • Page 131 Power unit (check and adjustment) PORT STBD S6AL5750 S6AL5740 CAUTION: • Do not turn the port driven sprockets counterclockwise more than 60°, and do not turn the starboard driven sprockets. Otherwise the intake and exhaust valves will collide with each other and be dam- aged.
  • Page 132 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 19. Adjust the timing belt to the specified installation height n.
  • Page 133 Power unit (check and adjustment) 21. Turn the crankshaft clockwise 2 full turns, NOTE: and then check that alignment marks a • Apply sealant to the edge of the cylinder through d are aligned. head cover gasket before installation. • Tighten the cylinder head cover bolts to the same torque in both stages.

  • Page 134: Power Unit

    POWR Power unit Power unit Power unit assembly · · · · · · 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 S6AL5030...
  • Page 135 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 S6AL5030 Part name Q’ty...

  • Page 136: Starter Motor

    POWR Power unit Starter motor · · · 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 137: Junction Box

    Power unit Junction box · · · m (0.4 kgf m, 3.0 ft 15 16 · · · m (0.6 kgf m, 4.4 ft · · · 12 N m (1.2 kgf m, 8.9 ft · · · · · ·...

  • Page 138: Fuse Box

    POWR Power unit Fuse box 6 8 9 13 S6AL5400 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 139: Ecm

    Power unit · · · m (0.7 kgf m, 5.2 ft · · · m (0.7 kgf m, 5.2 ft S6AL5630 Part name Q’ty Remarks M6 × 20 mm Bolt Holder Plastic tie Holder M6 × 16 mm Bolt Plate Holder Holder Plate...

  • Page 140: Removing The Power Unit

    POWR Power unit Removing the power unit STBD NOTE: • Be sure to reduce the fuel pressure before removing the power unit. To reduce the fuel pressure, see Chapter 4, “Reducing the fuel pressure.” • It is recommended to loosen the flywheel magnet nut before removing the power unit S6AL5G90 to improve working efficiency.
  • Page 141 Power unit 11. Removing the PTT switch coupler C, isolator coupler D, water detection switch coupler (blue) E, warning indica- tor coupler F, LAN communication cou- pler (white) G, 10-pin main harness coupler H, and trim sensor coupler I from the brackets, and then disconnect them.

  • Page 142: Removing The Wiring Harness

    POWR Power unit 16. Suspend the power unit from the engine 3. Remove the engine temperature sensor hangers L. coupler 3 and low-pressure fuel pump coupler 5 from the wiring harness guide. 17. Remove the power unit by removing the bolts M and N.
  • Page 143 Power unit NOTE: To disconnect the quick connector, see Chapter 4, “Disconnecting the quick connec- tor.” 8. Remove the wiring harness guide bolts S6AL5190 S6AL5170 9. Remove the plastic ties 0 from the wir- ing harness and the projections a on the plastic ties A from the wiring harness guide, and then pull up the wiring har- ness.

  • Page 144: Cylinder Head

    POWR Power unit Cylinder head 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...
  • Page 145 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 146: 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 147: Removing The Cylinder Head

    Cylinder head 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 148: Checking The Valve Guide

    POWR Power unit 2. Measure the valve margin thickness a. Replace if out of specification. Valve stem runout limit: 0.01 mm (0.0004 in) Valve margin thickness a: Intake: Checking the valve guide 0.50–0.90 mm (0.020–0.035 in) NOTE: Exhaust: Before checking the valve guides, make sure 0.90–1.30 mm (0.035–0.051 in) that the valve stem diameter is within specifi- cation.

  • Page 149: Replacing The Valve Guide

    Cylinder head NOTE: Valve stem-to-valve guide clearance Apply engine oil to the outer surface of a new = valve guide inside diameter – valve valve guide. stem diameter: Intake: 0.012–0.045 mm Valve guide remover/installer: (0.0005–0.0018 in) 90890-06801 Exhaust: Valve guide installer 3: 0.025–0.058 mm 90890-06810 (0.0010–0.0023 in)

  • Page 150: Checking The Valve Seat

    POWR Power unit Checking the valve seat 1. Eliminate carbon deposits from the valves. 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat. 3. Lap the valve slowly on the valve seat with a valve lapper (commercially avail- able) as shown.
  • Page 151 Cylinder head 60˚ S69J5890 b Previous contact width 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. a Slag or rough surface 45˚ CAUTION: S69J5900 Do not over cut the valve seat. Be sure to b Previous contact width turn the cutter evenly downward at a pres- c Specified contact width...

  • Page 152: Checking The Cylinder Head

    POWR Power unit 8. If the valve seat contact width is too nar- CAUTION: row and situated near the top edge of the valve face, use a 30° cutter to cut the top Do not get the lapping compound on the edge of the valve seat.

  • Page 153: Installing The Valve

    Cylinder head Cylinder head warpage limit: 0.1 mm (0.0039 in) 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 7 securely.

  • Page 154: Removing The Exhaust Cover

    POWR Power unit 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 155: Checking The Cooling Water Passage Cover Anode

    Cylinder head 2. Install a new gasket 2 and the cooling NOTE: water passage cover 3. To check the knock sensor, see Chapter 8, “Checking the knock sensor.” 3. Connect the cooling water hose 4 (cylin- der block-to-fuel cooler) to the cylinder block.

  • Page 156: Installing The Cylinder Head

    POWR Power unit 5. Connect the flushing hose and fasten it. PORT STBD NOTE: See the hose routing (4-3) and exploded dia- gram (5-43). 90˚ (T55) 6. Tighten the knock sensor to the specified S6P25910E torque, and then fasten the knock sensor lead 5 and flushing hose 6 as shown.
  • Page 157 Cylinder head Cylinder head bolt 1–8 (M10): 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 45 N·m (4.5 kgf·m, 33.2 ft·lb) 3rd: Loosen completely 4th: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 5th: 45 N·m (4.5 kgf·m, 33.2 ft·lb) 6th: 90° Cylinder head bolt 9–A (M8): 1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb) 2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)

  • Page 158: Cylinder Block

    POWR Power unit Cylinder block 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 28 27 · · · 12 N m (1.2 kgf m, 8.9 ft ·...
  • Page 159 Cylinder block · · · 23 N m (2.3 kgf m, 17.0 ft · · · 43 N m (4.3 kgf m, 31.7 ft 90˚ 27 28 28 27 24 26 · · · 12 N m (1.2 kgf m, 8.9 ft ·...

  • Page 160: 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 161 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 (STBD) Anode Thermoswitch M6 × 16 mm Bolt M6 ×...

  • Page 162: Disassembling The Cylinder Block

    POWR Power unit 6. Remove the clips 1 and piston pin, and Disassembling the cylinder block then remove the piston. 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.

  • Page 163: 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 164: 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 165: Checking The Piston Pin

    Cylinder block Connecting rod small end inside diameter a: 21.017–21.031 mm S6AL5470 (0.8274–0.8280 in) NOTE: When measuring the piston pin boss bore, do Checking the connecting rod big end not measure it at the oil grooves a or ring side clearance groove b.

  • Page 166: Checking The Crankshaft

    POWR Power unit Checking the crankshaft Crankshaft runout limit: 1. Measure the crankshaft journal diameter 0.03 mm (0.0012 in) a, crankpin diameter b, and crankpin width c. Replace the crankshaft if out of Checking the crankpin oil clearance specification. 1. Clean the bearings and the connecting rod.

  • Page 167: Selecting The Connecting Rod Bearing

    Cylinder block Connecting rod cap bolt: 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 43 N·m (4.3 kgf·m, 31.7 ft·lb) 3rd: 90° 6. Remove the connecting rod cap and measure the width of the compressed Plastigauge (PG-1) on each crankpin. Replace the connecting rod bearing if out of specification.

  • Page 168: Checking The Crankshaft Journal Oil Clearance

    POWR Power unit 2. Check the crankpin mark a on the 3. Install half of the main bearings 1 and the crankshaft 2 into the cylinder block crankshaft. NOTE: • Install the bearings in their original posi- tions. • Insert the projection a of each bearing into the slots in the cylinder block.

  • Page 169: Selecting The Main Bearing

    Cylinder block 6. Install the crankcase onto the cylinder Crankcase bolt 1–8 (M8): block and apply engine oil to the threads 1st: 25 N·m (2.5 kgf·m, 18.4 ft·lb) of the crankcase bolts. 2nd: 90° Crankcase bolt 9–F (M10): 7. Tighten the crankcase bolts to the speci- fied torques in 2 stages and in the 1st: 40 N·m (4.0 kgf·m, 29.5 ft·lb) sequence shown.

  • Page 170: Assembling The Power Unit

    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 171 Cylinder block CAUTION: Do not reuse the piston pin clips 4, always replace them with new ones. NOTE: • If a connecting rod is reused, face the mark a on the connecting rod in the same direc- tion as the “UP” mark b on the piston. S6AL5810 •...
  • Page 172 POWR Power unit 6. Set the crankshaft, new oil seal A and thrust bearings B, and new O-rings C and D into the cylinder block as shown. NOTE: • Install the main bearings in their original positions. • Insert the projection m of each bearing into the slots in the crankcase.
  • Page 173 Cylinder block NOTE: Piston ring compressor: • Crankcase bolts 1–F can be reused 5 90890-05158 times. • The oil seal A must be installed before 11. Install the connecting rod cap 8 to the tightening the crankcase bolts. connecting rod, and then tighten new •...

  • Page 174: Disassembling The Oil Pump

    POWR Power unit 12. Install a new gasket and the crankcase cover, and then tighten the bolts to the specified torques in 2 stages and in the sequence shown. STBD PORT NOTE: See the exploded diagram (5-59). S6P25B40 Checking the oil pump CAUTION: 1.
  • Page 175 Cylinder block Driver rod L3 2: 90890-06652 Needle bearing attachment 3: 90890-06613 3. Install a new oil seal into the oil pump housing. Oil pump cover screw 7: 4 N·m (0.4 kgf·m, 3.0 ft·lb) Driver rod L3 2: 90890-06652 Needle bearing attachment 4: 90890-06607 4.

  • Page 176: Installing The Oil Pump

    POWR Power unit Installing the oil pump 1. Install the oil pump 1 by aligning the oil STBD PORT pump gear with the crankshaft. ± S6AL5870 NOTE: Apply engine oil to the oil filter bracket bolts before installation. 3. Supply engine oil to the oil passage b of the oil filter bracket.

  • Page 177: Installing The Wiring Harness

    Cylinder block NOTE: Oil filter wrench: 90890-06830 For the location of the sensors and switches, see Chapter 8, “Electrical component.” Oil filter: 4. Install the engine temperature sensor 18 N·m (1.8 kgf·m, 13.3 ft·lb) lead 3 into the slit in the wiring harness guide 4, and then install the wiring har- Installing the wiring harness ness guide onto the power unit.
  • Page 178 POWR Power unit 11. Fasten the oil pressure sensor lead 0, 5. Install the wiring harness onto the wiring harness guide with the mark a facing isolator lead A, and positive terminal lead B with its cap using the plastic tie upward, and then insert the projections b on the plastic ties 5 into the holes in C, making sure to align the white tape f...

  • Page 179: Installing The Power Unit

    Cylinder block CAUTION: PORT STBD Do not bend the terminals of the starter motor leads when installing them. 14. Install the wiring harness onto the ECM bracket, and then fasten it at the white tape h. S6AL5220 CAUTION: Make sure that the top cowling lock levers are retracted and the engine stoppers are installed before installing the power unit, otherwise the fuel rails could be dam-...
  • Page 180 POWR Power unit 2. Clean the power unit mating surface, and install the dowels 1 and a new gasket 3. Install the power unit by installing the bolts 3 and 4, and then tightening them to the specified torque. Apron bolt and upper case cover bolt: 8 N·m (0.8 kgf·m, 5.9 ft·lb) 5.
  • Page 181 Cylinder block STBD S6AL5570 12. Connect the PTT motor leads L (blue) and M (light green), and then fasten them. S6AL5550 13. Route the positive battery cable N and 8. Connect the cooling water pilot hose F. negative battery cable O along the bot- tom of the bottom cowling a, and then 9.
  • Page 182 POWR Power unit 15. Install the grommet with the speedome- ter hose P, fuel hose Q, positive battery cable N, negative battery cable O, shift cable R, gauge harness S, throttle cable T, and 10-pin main harness U. 16. Install the cable holder V and retaining plate W.
  • Page 183 Cylinder block — MEMO — 5-82 6AL3J11...
  • Page 184 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 185 Lower unit (counter rotation model) ............6-31 Removing the lower unit ................6-33 Removing the water pump and shift rod..........6-33 Checking the water pump and shift rod ...........6-34 Propeller shaft housing (counter rotation model) ........6-35 Removing the propeller shaft housing assembly........6-37 Disassembling the propeller shaft housing..........

  • Page 186: Lower Unit

    LOWR Lower unit Lower unit (regular rotation model) · · · 54 N m (5.4 kgf m, 39.8 ft · · · 42 N m (4.2 kgf m, 31.0 ft WR-No.2 47 N · m (4.7 kgf · m, 34.7 ft · Ib) ·...
  • Page 187 Lower unit (regular rotation model) · · · 54 N m (5.4 kgf m, 39.8 ft · · · 42 N m (4.2 kgf m, 31.0 ft WR-No.2 47 N · m (4.7 kgf · m, 34.7 ft · Ib) ·...
  • Page 188 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 189: 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. Remove the bolts (nuts), and then remove the lower unit from the upper case.

  • Page 190: Removing The Water Pump And Shift Rod

    LOWR Lower unit Removing the water pump and shift 3. Check the water pipe. Replace if corro- sion, deformation or cracked. 1. Remove the water pump housing 1 and 4. Check the Woodruff key and the groove impeller 2. on the drive shaft. Replace if worn. 2.

  • Page 191: Propeller Shaft Housing (Regular Rotation Model)

    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 Propeller shaft shim Reverse gear...
  • Page 192 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 6AL3J11...

  • Page 193: Removing The Propeller Shaft Housing Assembly

    Propeller shaft housing (regular rotation model) Removing the propeller shaft Bearing housing puller claw L 6: housing assembly 90890-06502 1. Remove the water pipe 1 and shift rod Stopper guide plate 7: 90890-06501 Center bolt 8: 90890-06504 Disassembling the propeller shaft assembly 1.

  • Page 194: Checking The Propeller Shaft Housing

    LOWR Lower unit 2. Remove the ball bearing. 4. Check the bearings. Replace the bear- ings if pitted or if there is rumbling. Checking the propeller shaft 1. Check the propeller shaft. Replace the propeller shaft if bent or worn. 2.

  • Page 195: Assembling The Propeller Shaft Housing

    Propeller shaft housing (regular rotation model) NOTE: Install the dog clutch 4 with the “F” mark a facing toward the shift rod joint 3. Assembling the propeller shaft housing 1. Install the needle bearing into the propel- ler shaft housing to the specified depth. NOTE: Install an oil seal halfway into the propeller shaft housing, and then install the other oil...
  • Page 196 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, ball bearing, or lower case. •...
  • Page 197 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 198 LOWR Lower unit Part name Q’ty Remarks Forward gear shim — Taper roller bearing assembly Not reusable Forward gear 6-13 6AL3J11...

  • Page 199: Drive Shaft And Lower Case (Regular Rotation Model)

    Drive shaft and lower case (regular rotation model) Removing the drive shaft 1. Remove the pinion nut. S6AL6A00 CAUTION: S6AL6070 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 2.

  • Page 200: Checking The Pinion And Forward Gear

    LOWR Lower unit 2. Remove the taper roller bearing outer Drive shaft runout limit: race and shim(s). 0.2 mm (0.008 in) Checking the lower case 1. Check the skeg, torpedo, and anti-cavita- tion plate. Replace the lower case if cracked or damaged. Assembling the lower case 1.

  • Page 201: Assembling The Forward Gear

    Drive shaft and lower case (regular rotation model) NOTE: Depth a: • Apply gear oil to the needle bearing outer 4.5 ± 0.25 mm (0.18 ± 0.01 in) case before installation. • The needle bearing contains 24 rollers. 2. Apply grease to new oil seals, and then install them into the drive shaft housing to the specified depth.

  • Page 202: Installing The Propeller Shaft Housing

    LOWR Lower unit 2. Install the washer, spring, thrust bearing 5. Tighten the pinion nut to the specified 1, drive shaft, thrust bearing 2, and torque. original shim(s) 3 into the lower case. 3. Install the pinion, washer, and pinion nut temporarily.

  • Page 203: 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 the propeller shaft, forward gear, or reverse gear. • To select the shims, see Chapter 6, “Shim- ming (regular rotation model).” 4.
  • Page 204 LOWR Lower unit 2. Install a new gasket 2, the outer plate NOTE: cartridge 3, and dowels 4. Align the insert cartridge projections a with the holes b in the pump housing. 6. Install a new O-ring 0 and the pump housing assembly A into the lower case, tighten the bolts B, and then install the seal C and cover D.

  • Page 205: Installing The Lower Unit

    Drive shaft and lower case (regular rotation model) Installing the lower unit 4. Install the lower unit into the upper case, and then tighten the lower case mounting WARNING bolts (nuts) 2 to the specified torque. When installing the lower unit with the 5.
  • Page 206 LOWR Lower unit 6. Install the propeller and propeller nut, 7. Fill the gear oil to the correct level. and then tighten the nut temporarily. Recommended gear oil: Place a block of wood between the anti- Hypoid gear oil cavitation plate and propeller to keep the API: GL-4 propeller from turning, and then tighten SAE: 90...

  • Page 207: 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 6AL3J11...

  • Page 208: Shimming

    LOWR Lower unit Shimming 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. NOTE: • Shimming is not required when assembling Pinion nut: the original lower case and inner parts. 142 N·m (14.2 kgf·m, 104.7 ft·lb) •...

  • Page 209: Selecting The Forward Gear Shim

    Shimming (regular rotation model) 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 0.68 mm.

  • Page 210: 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 211: Selecting The Propeller Shaft Shim

    Shimming (regular rotation model) 3. Select the reverse gear shim(s) (T2) as follows. Calculated number Rounded number 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 212 LOWR Lower unit 1. Measure the forward gear heights M1 and M2 as shown and then calculate the value C1. S6P26340 S6P26330 S6AL6300 NOTE: Measure the gear height at 4 points to find S6AL6300 the height average. NOTE: Measure the gear height at 4 points to find Calculation formula: the height average.

  • Page 213: Backlash (Regular Rotation Model)

    Shimming (regular rotation model) / Backlash (regular rotation model) NOTE: Measure the spline width at 4 points to find the width average. 4. Select the propeller shaft shim T4. S6AL6760 Magnet base plate 1: 90890-07003 Dial gauge set 2: 90890-01252 Magnet base B 3: 90890-06844 Propeller shaft free play: 0.20–0.50 mm (0.0079–0.0197 in)
  • Page 214 LOWR Lower unit 6. Tighten the center bolt to the specified torque while turning the drive shaft. NOTE: S6AL6160 Install the dial gauge so that the plunger a contacts the mark b on the backlash indica- NOTE: tor rod. The drive shaft can no longer be turned when the center bolt is tightened to the specified torque.
  • Page 215 Backlash (regular rotation model) NOTE: Available shim thicknesses: Measure the backlash at 4 points to find the 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and average. 0.50 mm 11. Remove the special service tools from Reverse gear backlash: the propeller shaft. 0.32–0.65 mm (0.0126–0.0256 in) 12.

  • Page 216: Lower Unit (Counter Rotation Model)

    LOWR Lower unit Lower unit (counter rotation model) 54 N · m (5.4 kgf · m, 39.8 ft · Ib) · · · 42 N m (4.2 kgf m, 31.0 ft WR-No.2 · · · m (0.9 kgf m, 6.6 ft 47 N ·...
  • Page 217 Lower unit (counter rotation model) 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...

  • Page 218: Removing The Lower Unit

    LOWR Lower unit 3. Mark the trim tab 1 at the area shown, Removing the lower unit and then remove it. 1. Drain the gear oil. 4. Remove the bolts, and then remove the lower unit from the upper case. 2.

  • Page 219: Checking The Water Pump And Shift Rod

    Lower unit (counter rotation model) S6AL6800 Shift rod push arm: 90890-06052 Checking the water pump and shift 1. Check the water pump housing. Replace if there is deformation. NOTE: If the engine overheated, the inside of the water pump housing may be deformed, so be sure to remove the insert cartridge when checking the housing.

  • Page 220: Propeller Shaft Housing (Counter Rotation Model)

    LOWR Lower unit 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 — Ring nut Claw washer Taper roller bearing assembly Not reusable Propeller shaft...
  • Page 221 Propeller shaft housing (counter rotation model) 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 ×...

  • Page 222: Removing The Propeller Shaft Housing Assembly

    LOWR Lower unit Removing the propeller shaft Slide hammer 6: 90890-06531 housing assembly Puller head 7: 90890-06514 1. Remove the water pipe 1 and shift rod Disassembling the propeller shaft housing 1. Remove the spring 1, and then remove the cross pin 2, dog clutch 3, slider, shift plunger, and shift rod joint.

  • Page 223: Checking The Propeller Shaft Housing

    Propeller shaft housing (counter rotation model) S6AL6370 CAUTION: • Do not press the propeller shaft threads NOTE: a directly. To prevent damage to the parts when install- • Do not reuse the taper roller bearing, ing the propeller shaft housing assembly in always replace it with a new one.

  • Page 224: Checking The Propeller Shaft

    LOWR Lower unit 3. Check the teeth and dogs of the forward NOTE: gear. Replace the forward gear if cracked • Install the needle bearing with the manufac- or worn. ture identification mark a facing toward the oil seal (propeller side). 4.
  • Page 225 Propeller shaft housing (counter rotation model) NOTE: • Be sure to select the propeller shaft shim(s) if replacing the propeller shaft, propeller shaft housing, thrust bearing or taper roller bearing. • To select the shims, see Chapter 6, “Shim- ming (counter rotation model).” S6AL6370 4.
  • Page 226 LOWR Lower unit 7. Install the original shim(s) C, forward gear D, and dog clutch E using a press. NOTE: • Be sure to select the forward gear shim(s) if replacing the propeller shaft housing, taper roller bearing, or lower case. •...
  • Page 227 Propeller shaft housing (counter rotation model) / Drive shaft and lower case (counter rotation model) 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...
  • Page 228 LOWR Lower unit Part name Q’ty Remarks Reverse gear shim — Retainer Needle bearing Thrust bearing Circlip Not reusable Needle bearing Not reusable Reverse gear 6-43 6AL3J11...

  • Page 229: Drive Shaft And Lower Case (Counter Rotation Model)

    Drive shaft and lower case (counter rotation model) Removing the drive shaft 1. Remove the pinion nut. S6AL6840 2. Remove the needle bearing from the S6AL6070 reverse gear using a chisel. Drive shaft holder 6 1: 90890-06520 Pinion nut holder 2: 90890-06715 2.

  • Page 230: Disassembling The Lower Case

    LOWR Lower unit Disassembling the lower case 1. Remove the needle bearing from the lower case. Needle bearing attachment 5: 90890-06654 Driver rod L3 6: 90890-06652 NOTE: • Since the diameter of the passage in the Checking the pinion and reverse lower case and the diameter of the special gear service tool 1 are both 40 mm (1.57 in),...

  • Page 231: Assembling The Lower Case

    Drive shaft and lower case (counter rotation model) Assembling the lower case 1. Install the needle bearing into the retainer to the specified depth. NOTE: • Apply gear oil to the needle bearing outer case before installation. • The needle bearing contains 24 rollers. Needle bearing attachment 1: 90890-06654 Driver rod L3 2: 90890-06652...

  • Page 232: Assembling The Drive Shaft Housing

    LOWR Lower unit 2. Install a new circlip 3 into the reverse NOTE: gear 4. Install an oil seal halfway into the drive shaft housing, and then install the other oil seal. Bearing outer race attachment 3: 90890-06628 Driver rod LS 4: 90890-06606 Depth b: 0.5 ±...

  • Page 233: Installing The Propeller Shaft Housing

    Drive shaft and lower case (counter rotation model) Installing the propeller shaft housing NOTE: 1. Set the shift rod joint and dog clutch 1 to • Be sure to select the pinion shim(s) if the neutral position as shown. replacing the thrust bearing 2, drive shaft housing, drive shaft, or lower case.

  • Page 234: Installing The Water Pump And Shift Rod

    LOWR Lower unit Installing the water pump and shift 1. Install the shift rod assembly 1. 3. Install the Woodruff key 6 into the drive shaft. 4. Align the groove on the impeller 5 with NOTE: the Woodruff key 6, and then install the •...

  • Page 235: Installing The Lower Unit

    Drive shaft and lower case (counter rotation model) Installing the lower unit NOTE: Align the insert cartridge projections a with WARNING the holes b in the pump housing. When installing the lower unit with the power unit installed, be sure to suspend the outboard motor.
  • Page 236 LOWR Lower unit 3. Install the dowels 1 into the lower unit. 4. Install the lower unit into the upper case, and then tighten the lower case mounting bolts 2 to the specified torque. 5. Install the trim tab 3 to its original posi- tion, and then tighten the bolt 4 to the specified torque.
  • Page 237 Drive shaft and lower case (counter rotation model) 7. Fill the gear oil to the correct level. Recommended gear oil: Hypoid gear oil API: GL-4 SAE: 90 Gear oil quantity: Counter rotation model: 1,000 cm (33.8 US oz, 35.3 Imp oz) 6-52 6AL3J11...

  • Page 238: Shimming (Counter Rotation Model)

    LOWR Lower unit Shimming (counter rotation model) 65.0 B1 38.4 47.5 T´4 S6P26300 6-53 6AL3J11...

  • Page 239: Shimming

    Shimming (counter rotation model) Shimming 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. NOTE: • Shimming is not required when assembling Pinion nut: the original lower case and inner parts. 142 N·m (14.2 kgf·m, 104.7 ft·lb) •...

  • Page 240: 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 0.68 mm. If “T3”...
  • Page 241 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 242: 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 S6AL6750 NOTE: “R”...

  • Page 243: 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 number Rounded number tion formula. at 1/100 place • Measure the taper roller bearing at 4 points 1, 2 to find the height average.
  • Page 244 LOWR Lower unit 3. Calculate the propeller shaft shim thick- Available shim thicknesses: ness (T’4) as shown in the examples 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and below. 0.50 mm Example: If “T’4” is 0.49 mm, then the propeller shaft shim is 0.48 mm.

  • Page 245: Backlash (Counter Rotation Model)

    Shimming (counter rotation model) / Backlash (counter rotation model) Magnet base B 0: 90890-06844 Dial gauge set A: 90890-01252 Propeller shaft free play: 0.25–0.35 mm (0.0098–0.0138 in) Backlash (counter rotation model) Measuring the forward and reverse gear backlash 1. Install the lower unit onto a repair stand. S6AL6160 2.
  • Page 246 LOWR Lower unit 8. Install the backlash indicator onto the Forward gear drive shaft (22.4 mm [0.88 in] in diame- Shim thickness backlash ter), and then install the dial gauge. Less than To be decreased by (0.64 – M) × 0.71 0.46 mm (0.0181 in) More than To be increased by...
  • Page 247 Backlash (counter rotation model) 16. Turn the shift rod in direction c to the 19. Remove the special service tools, and reverse position using the shift rod push then install the water pump assembly. arm. 20. Fill the gear oil to the correct level. 17.
  • Page 248 BRKT Bracket unit Shift rod and bottom cowling ............... 7-1 Disassembling the bottom cowling ............7-5 Disassembling the shift bracket..............7-6 Assembling the shift bracket..............7-6 Assembling the bottom cowling ..............7-7 Upper case and steering arm..............7-10 Removing the upper case................7-15 Disassembling the upper case ..............7-15 Checking the drive shaft bushing ............
  • Page 249 Tilt cylinder and trim cylinder ..............7-47 Disassembling the tilt cylinder and trim cylinder........7-49 Checking the tilt cylinder and trim cylinder ..........7-51 Checking the valve .................. 7-51 Assembling the tilt ram ................7-51 Assembling the trim ram................7-53 Installing the tilt cylinder ................7-53 Installing the trim ram ................

  • Page 250: 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 Shift bracket bolt M6 × 35 mm Bolt Clamp ø4 × 16 mm Screw Plate Clip...
  • Page 251 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 Flushing hose joint adapter Hose joint gasket Hose joint Clamp...
  • Page 252 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 6AL3J11...
  • Page 253 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 Holder PTT switch Bracket Bracket Cover Gasket M6 × 20 mm/Regular rotation model Bolt Bracket Clamp Holder...

  • Page 254: Disassembling The Bottom Cowling

    BRKT Bracket unit Disassembling the bottom cowling Ë È 1. Remove the shift bracket assembly 1, and then remove the flushing hose joint adapter 2. Ê S6AL7060 É Ë S6AL7030 NOTE: • If the power unit is installed, remove the Ê...

  • Page 255: Disassembling The Shift Bracket

    Shift rod and bottom cowling É PORT S6AL7080 S6AL7A20 È Regular rotation model NOTE: É Counter rotation model To check the neutral switch 2 and shift cut NOTE: switch 3, see Chapter 8, “Checking the neu- To check the PTT switch, see Chapter 7, tral switch”...

  • Page 256: Assembling The Bottom Cowling

    BRKT Bracket unit 2. Hook the spring end a into the cutout in Assembling the bottom cowling the bracket 2 and the spring end b into 1. Install the PTT switch 1, holder 2, and the cutout in the bracket 4. holder 3 (regular rotation model).
  • Page 257 Shift rod and bottom cowling NOTE: • Fasten the flushing hose 4 and trim sensor lead 5 with the plate 0. • Fasten the flushing hose 4, trim sensor lead 5, and speedometer hose A with the plate B. • Fasten the flushing hose 4, trim sensor lead 5, and PTT switch lead C (counter rotation model) with the clamp D.
  • Page 258 BRKT Bracket unit 7. Install the flushing hose joint adapter G and screws H, and then install the shift bracket assembly I. S6AL7160 Hose joint adapter screw H: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 6AL3J11...

  • Page 259: Upper Case And Steering Arm

    Shift rod and bottom cowling / Upper case and steering arm 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 ×...
  • Page 260 BRKT Bracket unit Part name Q’ty Remarks M6 × 10 mm Bolt Dowel Speedometer hose adapter M6 × 30 mm Bolt Drive shaft bushing Circlip Circlip Bushing O-ring Not reusable Bushing Washer Steering yoke Washer Steering arm Washer Washer 7-11 6AL3J11...

  • Page 261: Upper Case And Steering Arm

    Upper case and steering arm · · · · · · 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 S6AL7210 Part name...
  • Page 262 BRKT Bracket unit 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 263 Upper case and steering arm Part name Q’ty Remarks Rubber seal Gasket Not reusable Plate Pipe Rubber seal Gasket Not reusable Dowel Muffler M8 × 35 mm Bolt 7-14 6AL3J11...

  • Page 264: Removing The Upper Case

    BRKT Bracket unit Removing the upper case 2. Remove the upper mounts and lower mounts from the upper case assembly. 1. Disconnect the ground lead 1 and speedometer hose 2. 3. Remove the oil pan assembly bolts 4 and 5, and then remove the oil pan 2.

  • Page 265: Checking The Drive Shaft Bushing

    Upper case and steering arm Bearing puller assembly 9: 90890-06535 Stopper guide stand 0: 90890-06538 Stopper guide plate A: 90890-06501 Checking the drive shaft bushing 1. Check the drive shaft bushing. Replace if cracked or worn. Disassembling the oil pan and exhaust manifold 1.
  • Page 266 BRKT Bracket unit 2. Install a new gasket, the oil strainer 5 and bolts 6, and then tighten the bolts to the specified torque. 5. Tighten the exhaust manifold bolts E first, and then tighten the oil pan bolts 0 and A to the specified torques.

  • Page 267: Assembling The Upper Case

    Upper case and steering arm 3. Install the rubber seal 6 into the joint hole a of the upper case. 4. Install the oil pan assembly 7. 5. Install the oil pan assembly bolts 8 and 9 and PCV 0, and then tighten them to the specified torques.

  • Page 268: Installing The Upper Case

    BRKT Bracket unit 6. Install the damper B, cover C, and 9. Install the lower mounts I, lower mount engine oil drain bolt D, and then tighten bolts J, and mount housings K. the drain bolt to the specified torque. Engine oil drain bolt D: 27 N·m (2.7 kgf·m, 19.9 ft·lb) 7.

  • Page 269: Removing The Steering Arm

    Upper case and steering arm S6AL7410 È É Needle bearing attachment 3: 90890-06612 Gear puller 4: (commercially available) 3. Remove the steering arm from the swivel bracket by pulling the arm off the bracket. S6AL7390 Installing the steering arm 1. Install the washer 1 and bushing 2 onto Upper mounting nut 4: the steering arm 3.
  • Page 270 BRKT Bracket unit 3. Install the bushing 5, a new O-ring 6, the bushing 7, and the washer 8 onto the swivel bracket. S6AL7430 7. Inject grease into the grease nipple A on the swivel bracket B until grease comes out from both the upper and lower bush- ings d.

  • Page 271: Clamp Bracket And Swivel Bracket

    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 b: 120 mm (4.7 in) Ground lead Bushing Washer Bushing Friction plate 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 b: 180 mm (7.1 in) Ground lead Bushing Bushing Anode b: 350 mm (13.8 in) Ground lead...

  • Page 273: Removing The Ptt Unit

    Clamp bracket and swivel bracket 5. Remove the circlip 9 and shaft 0, then Removing the PTT unit the upper end of the tilt rod from the 1. Fully tilt the outboard motor up, and then swivel bracket. 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 ground lead 1 and self- locking nut 2 of the through tube, then clamp brackets 3 and 4. 2. Remove the trim sensor 5. Installing the clamp bracket 1. Assemble the distance collar. S6AL7510 NOTE: Make sure that the distance a shown is...
  • Page 275 Clamp bracket and swivel bracket 6. Connect the ground lead C, install the NOTE: through tube D, and then tighten the Be sure to install the distance collars 3 and self-locking nut E temporarily. tilt stop levers 4 so that they are facing in the directions shown.

  • Page 276: Installing The Ptt Unit

    BRKT Bracket unit Installing the PTT unit 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. WARNING • When installing the PTT unit with the power unit installed, be sure to suspend the outboard motor.

  • Page 277: Adjusting The Trim Sensor

    Clamp bracket and swivel bracket WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower if the PTT unit should lose fluid pressure. 4. Loosen the trim sensor screws 2. Adjusting the trim sensor 1.
  • Page 278 BRKT Bracket unit 8. Fully tilt the outboard motor up, and then support it with the tilt stop lever. WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower if the PTT unit should lose fluid pressure.
  • Page 279 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 The height a is greater than the height b.
  • Page 280 BRKT Bracket unit Part name Q’ty Remarks Bushing Pipe Pipe Spacer O-ring Not reusable Adapter 7-31 6AL3J11...

  • Page 281: Ptt Unit

    PTT unit Checking the hydraulic pressure NOTE: Check the hydraulic pressure. Using the spe- cial service tool check the internal parts if out of specification. 1. Fully extend the trim and tilt rams. 2. Loosen the pipe joints 1, and then remove the pipe joint at the end a.
  • Page 282 BRKT Bracket unit 6. Remove the special service tool 2. PTT oil pressure gauge assembly 2: WARNING 90890-06580 Make sure that the trim and tilt rams are 11. Connect the PTT motor leads to the bat- fully extended when removing the special service tool 2, otherwise fluid can spurt tery terminals to extend the trim rams, and then measure the hydraulic pres-...
  • Page 283 PTT unit Battery WARNING PTT motor lead terminal Make sure that the trim and tilt rams are Light green (Lg) fully extended when removing the reser- Down voir cap, otherwise fluid can spurt out Sky blue (Sb) from the unit due to internal pressure. 13.

  • Page 284: Ptt Motor

    BRKT Bracket unit PTT motor Part name Q’ty Remarks Stator M5 × 12 mm Bolt Wave washer Washer Bearing Armature Brush Spring O-ring Not reusable Oil seal Not reusable PTT motor base assembly 7-35 6AL3J11...

  • Page 285: Disassembling The Ptt Motor

    PTT motor Disassembling the PTT motor CAUTION: 1. Remove the PTT motor assembly, O- Do not disassemble the PTT motor ring, and joint from the PTT unit. assembly, otherwise the circuit breaker 6 WARNING may be damaged. Do not push the trim and tilt rams down while the PTT motor is removed from the Checking the PTT motor PTT unit, otherwise fluid can spurt out.

  • Page 286: Checking The Brush

    BRKT Bracket unit 3. Measure the commutator undercut a. Replace the armature if below specifica- tion. Motor commutator standard undercut a: 1.40 mm (0.055 in) Wear limit: 0.90 mm (0.035 in) S6AL7650 4. Check armature continuity. PTT motor base assembly continuity Replace the armature if out of specifica- Terminal 1–2 tions.

  • Page 287: Assembling The Ptt Motor

    PTT motor 3. Install the brushes 6 and springs 7 to 3. Check the PTT motor base. Replace the PTT motor base assembly if cracked or the PTT motor base assembly as shown. damaged. 4. Check the bearing and oil seal. Replace the bearing or oil seal if damaged or worn.
  • Page 288 BRKT Bracket unit 6. Install a new O-ring and the stator A to the motor base. CAUTION: Hold the end of the armature shaft with a pair of pliers as shown, and then install the armature together with the PTT motor base assembly, otherwise the armature could separate from the base assembly due to the magnetic force of the stator A...

  • Page 289: Gear Pump

    PTT motor / Gear pump 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...
  • Page 290 BRKT Bracket unit 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 7-41 6AL3J11...
  • Page 291 Gear pump 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 7-42 6AL3J11...

  • Page 292: Gear Pump

    BRKT Bracket unit 3. Remove the bracket 5, then the balls 6. Disassembling the gear pump 1. Remove the manual valve 1, then the gear pump 2 and filters. 4. Remove gear housing 2 7, then the shuttle pistons 8. 2.

  • Page 293: Checking The Gear Pump Housing

    Gear pump 2. Install the drive gear 3, driven gear 4, pins 5, balls 6, and shuttle pistons 7 and 8 into gear housing 1 9. 3. Install gear housing 2 2 onto gear hous- Checking the gear pump housing ing 1 9.
  • Page 294 BRKT Bracket unit 4. Install the balls 0, manual release spring NOTE: A, and bracket B by installing the bolts • If reinstalling the removed parts, install C, and tightening them to the specified them according to the screw height a and torque.
  • Page 295 Gear pump 8. Check the hydraulic pressure. NOTE: • To check the hydraulic pressure, see Chap- ter 7, “Checking the hydraulic pressure.” • If the hydraulic pressure is out of specifica- tion, adjust the relief lock screws to adjust the pressure to specification. 7-46 6AL3J11...

  • Page 296: 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 297 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/T30 Bolt Free piston O-ring Not reusable Tilt cylinder 7-48 6AL3J11...

  • Page 298: 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 299 Tilt cylinder and trim cylinder 12. Drain the PTT fluid. 13. Remove the circlip A, adapter B, and spring C from the trim pistons. PTT piston vice attachment 7: 90890-06572 Tilt rod wrench 8: 90890-06569 9. Hold the PTT body 9 in a vise using alu- minum plates a on both sides.

  • Page 300: Checking The Tilt Cylinder And Trim Cylinder

    BRKT Bracket unit Checking the tilt cylinder and trim cylinder 1. Check the PTT body 1 and tilt cylinder 2. Replace the PTT body 1 or tilt cylin- der 2 if cracked or if there is corrosion. 2. Check the inner surface of the PTT body 1 and tilt cylinder 2.
  • Page 301 Tilt cylinder and trim cylinder 4. Tighten the tilt ram 9 to the specified torque. PTT piston vice attachment 0: S6AL7870 90890-06572 NOTE: Tilt rod wrench A: 90890-06569 • Replace the tilt piston assembly if replacing the tilt piston 8. The shim(s) G are not Tilt ram 9: available as individual parts.

  • Page 302: Assembling The Trim Ram

    BRKT Bracket unit 2. Push the free piston 2 into the tilt cylin- Assembling the trim ram der 3 until it bottoms out. CAUTION: 3. Install the tilt cylinder 3 to the PTT body Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components can lead to poor perfor- 4.

  • Page 303: Installing The Ptt Motor

    Tilt cylinder and trim cylinder Cylinder-end screw wrench: 90890-06568 Trim cylinder end screw 2: 160 N·m (16.0 kgf·m, 118.0 ft·lb) Installing the PTT motor CAUTION: 2. Fill the trim cylinders with the recom- Do not use a rag when assembling the mended fluid to the correct level b as PTT unit as dust and particles on the PTT shown.

  • Page 304: Installing The Reservoir

    BRKT Bracket unit 3. Remove all of the air bubbles with a 3. Install a new O-ring and the reservoir cap 7, and then tighten the reservoir cap to syringe or suitable tool. the specified torque. NOTE: Turn the joint 1 with a screwdriver, and then remove any air between the pump gear teeth.

  • Page 305: Bleeding The Ptt Unit

    Tilt cylinder and trim cylinder 2. Close the manual valve 1 by turning it clockwise. Manual valve 1: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 3. Remove the reservoir cap, and then check the fluid level in the reservoir. WARNING Make sure that the trim and tilt rams are 4.

  • Page 306: Bleeding The Ptt Unit (Built-In)

    BRKT Bracket unit 6. Connect the PTT motor leads 2 to the battery terminals to fully retract the trim and tilt rams. 7. Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams. S6P23190 NOTE: Connect the PTT motor leads directly to the...

  • Page 307: Ptt Electrical System

    Tilt cylinder and trim cylinder / PTT electrical system G/W G NOTE: If the fluid is at the correct level, a small amount of fluid should overflow out of the S6AL7980 filler hole when the cap is removed. Test harness (2 pins): 90890-06867 6.

  • Page 308: Checking The Ptt Switch

    BRKT Bracket unit 2. Connect the positive battery lead to the light green (Lg) lead, and the negative PTT relay continuity battery lead to the terminal 4 as shown, and then check the PTT relay for continu- Terminal 2 – Terminal 3 Continuity ity.

  • Page 309: Checking The Trim Sensor

    PTT electrical system Checking the trim sensor 1. Measure the trim sensor resistance. Replace the trim sensor if out of specifi- cation. S6AL7A10 NOTE: • Turn the trim sensor lever 1 from a to c and measure the resistance as it gradually changes.
  • Page 310 – 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 311 Fuel control system ..................8-37 Checking the water detection switch ............8-37 Checking the fuel injector ................8-38 Checking the low-pressure fuel pump and high-pressure fuel pump ..8-39 Checking the high-pressure fuel pump relay ...........8-39 Checking the vapor shut-off valve ............8-40 Starting system ....................

  • Page 312: 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 313 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 peak voltage adapter B with the rec- ommended digital circuit tester. •...

  • Page 314: Electrical Component

    – ELEC Electrical system Electrical component Port view S6AS8010 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 315: 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) 6AL3J11...

  • Page 316: 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 (ignition coil, fuel injector, variable camshaft timing, ECM) camshaft timing, ECM, low-pressure fuel 3 Fuse (20 A) (engine start switch, PTT switch)

  • Page 317: Aft View

    Electrical component Aft view S6P28860C 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) 6AL3J11...

  • Page 318: 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 319: 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 S6P28320E 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 320 – ELEC Electrical system È É Ê Ë Ó Ô Ò Ñ Í Ì Ï Î S6P28320E 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 321: Starboard View

    Wiring harness routing Starboard view 65 2 Õ È Ô É Ó Ï Ó Ê Ò Ê G Ë Ì Í Ñ Î S6AL8430 1 Wiring harness (A–B–C–D–E–F–H) NOTE: 2 Stator coil lead (A–D–F) The captions identifying the locations where 3 Sub wiring harness (B–C–D–E–F) 4 Rectifier Regulator lead (B–C–D–E–F–H) the leads are routed, fastened, etc., are...
  • Page 322 – ELEC Electrical system 65 2 Õ È Ô É Ó Ó Ï Ê Ò Ê G Ë Ì Í Ñ Î S6AL8430 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 323 Wiring harness routing 65 2 Õ È Ô É Ó Ï Ó Ê Ò Ê G Ë Ì Í Ñ Î S6AL8430 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 324: Aft View

    – ELEC Electrical system Aft view È Í É Ê Ì Ë S6AL8020 1 Cooling water pressure sensor coupler 2 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 325: Top View

    Wiring harness routing Top view È C C C É Ê Ë S6AL8030 È Fasten the fuel injector lead and quick 1 Stator coil lead 2 Wiring harness connector to the holder. É Fasten the fuel injector lead and vapor gas 3 Thermoswitch connector 4 High-pressure fuel hose hose to the holder.

  • Page 326: Bottom Cowling

    – ELEC Electrical system Bottom cowling Ê Ë Ì Í Î È É Ñ Ï Ó Ò FL200C, FL225B S6AS8040 1 Flushing hose A Fuel hose 2 PTT motor lead B Battery cable 3 Trim sensor lead C Wiring harness 4 Water detection switch coupler (blue) D LAN communication coupler 5 Isolator coupler (black)
  • Page 327 Wiring harness routing Ê Ë Ì Í Î È É Ñ Ï Ó Ò FL200C, FL225B S6AS8040 È Make sure that the white paint mark on the Í Fasten the flushing hose, trim sensor lead, flushing hose and the white tape on the PTT and speedometer hose with the plate.
  • Page 328 – ELEC Electrical system Ê Ë Ì Í Î È É Ñ Ï Ó Ò FL200C, FL225B S6AS8040 Ò Fasten the PTT switch lead (wiring harness side) and PTT switch extension lead with the holder. Ó Fasten the flushing hose, PTT switch lead and trim sender lead with the clamp.

  • Page 329: Ignition And Ignition Control System

    Wiring harness routing / Ignition and ignition control system Ignition and ignition control 6. Install the ECM cover. system NOTE: Checking the ignition spark Connect the injector couplers. 1. Remove the ECM cover. Checking the ignition coil input 2. Remove the ignition coils. voltage NOTE: 1.

  • Page 330: Checking The Crank Position Sensor Air Gap

    – ELEC Electrical system 3. Connect the test harness (2 pins) 1 to 4. Measure the crank position sensor resis- the crank position sensor 2, and then tance. measure the crank position sensor out- NOTE: put peak voltage. Disconnect the test harness coupler a but leave the harness connected to the crank position sensor.

  • Page 331: Checking The Intake Air Temperature Sensor

    Ignition and ignition control system 5. Tighten the crank position sensor screws 5. Turn the engine start switch to “ON,” and 1, and then check the crank position then measure the input voltage at the sensor air gap. Adjust again if out of intake air temperature sensor coupler specification.

  • Page 332: Checking The Intake Air Pressure Sensor

    – ELEC Electrical system 10. Install the intake air temperature sensor, 6. Check the intake air pressure using the and then connect the intake air tempera- YDIS. ture sensor coupler. NOTE: To connect and operate the YDIS, see Chap- Checking the intake air pressure ter 9, “YDIS”...

  • Page 333: Checking The Thermoswitch

    Ignition and ignition control system 4. Remove the engine temperature sensor. PORT 5. Place the engine temperature sensor in a STBD container of water and slowly heat the water. S6AL8510 Thermoswitch input voltage: Pink (P) – Black (B) 12 V (battery voltage) S6AL8500 3.

  • Page 334: Checking The Shift Cut Switch

    – ELEC Electrical system 6. Check the switch for continuity at the specified temperatures. Replace if out of specification. B L/Y a Temperature b Time c No continuity d Continuity B L/Y S6AL8380 Thermoswitch continuity temperature: Shift cut switch input voltage Pink (P) –...

  • Page 335: Checking The Neutral Switch

    Ignition and ignition control system Test harness (2 pins) 1: 90890-06867 3. Turn the engine start switch to “ON,” and then measure the input voltage at the neutral switch coupler (wiring harness end). Check the wiring harness if out of specification.

  • Page 336: Checking The Knock Sensor

    – ELEC Electrical system 4. Turn the engine start switch to “OFF.” 5. Disconnect the test harness (2 pins) 1 from the neutral switch coupler (wiring harness end) and connect it to the neu- tral switch coupler (neutral switch end). 6.

  • Page 337: Checking The Engine Stop Lanyard Switch

    Ignition and ignition control system / ECM and electronic throttle valve control system ECM and electronic throttle valve Lead color control system Switch White Black Yellow Brown Checking the throttle valve operation position (Br) 1. Remove the flywheel magnet cover and intake silencer.

  • Page 338: Checking The Main Relay And Electronic Throttle Valve Relay

    – ELEC Electrical system Checking the main relay and electronic throttle valve relay 1. Remove the main relay 1 and electronic throttle valve relay 2. S6AL8550 Terminal 7 – Ground: Terminal 8 – Ground: 12 V (battery voltage) S6P28150 4. Turn the engine start switch to “ON,” and 2.
  • Page 339 ECM and electronic throttle valve control system S6AL8580 S6AL8910 Terminal e (Y) C – Ground: 12 V (battery voltage) 6. Turn the engine start switch to “OFF.” 7. Connect the ECM coupler d. S6AL8570 3. Connect the ECM couplers a and b. 4.

  • Page 340: Checking The Accelerator Position Sensor

    – ELEC Electrical system 8. Disconnect the ECM coupler a. 9. Turn the engine start switch to “ON,” and then measure the input voltage at ECM coupler terminals f (27 and 34, wiring harness end) and ground. Check the fuse, relay, and wiring harness if below specification.
  • Page 341 ECM and electronic throttle valve control system È É S6AL8150 NOTE: Do not start the engine when checking the accelerator position sensor. S6AL8160 È: Fully closed position É: Fully open position Accelerator position sensor output voltage NOTE: When the accelerator lever is in the fully Remote control lever position Item open position d, make sure that it is contact-...

  • Page 342: Checking The Accelerator Position Sensor Circuit

    – ELEC Electrical system Checking the accelerator position sensor circuit Wiring harness continuity 1. Disconnect the ECM coupler a. Terminal No. Color Coupler a Coupler b S6P28560 4. Connect the ECM coupler a. 2. Disconnect the accelerator position sen- sor coupler b. 5.
  • Page 343 ECM and electronic throttle valve control system 4. Turn the engine start switch to “ON,” operate the remote control lever, and then check the output voltages of TPS 1 and TPS 2 and the throttle valve opening angle at the fully closed position a and fully open position b.

  • Page 344: Checking The Electronic Throttle Valve And Tps Circuit

    – ELEC Electrical system 7. Disconnect the electronic throttle valve coupler. 8. Measure the electronic throttle valve motor resistance between the terminals 3 and 4. S6P28510 3. Check the wiring harness for continuity. S6AL8170 CAUTION: Do not loosen the throttle stop screw nut, and do not turn the throttle stop screw.

  • Page 345: Variable Camshaft Timing Control System

    ECM and electronic throttle valve control system / Variable camshaft timing control system 9. Turn the engine start switch to “ON,” and then measure the TPS input voltage at the electronic throttle valve coupler c (wiring harness end). S6P28530 6. Check the wiring harness for continuity. S6AL8592 TPS input voltage (reference data): Terminal 5 (O) –...
  • Page 346 – ELEC Electrical system 2. Turn the engine start switch to “ON,” and 5. Connect the wire leads between cam then measure the input voltage at the position sensor and cam position sensor coupler 5 (wiring harness end) as cam position sensor coupler (wiring har- ness end).

  • Page 347: Checking The Oil Control Valve

    Variable camshaft timing control system 7. Turn the engine start switch to “ON,” and 11. Connect the cam position sensor cou- then measure the output voltage when plers, and then install all parts removed moving the screwdriver close to the sen- during disassembly.

  • Page 348: Fuel Control System

    – ELEC Electrical system 5. Measure the oil control valve resistance. 3. Turn the engine start switch to “ON,” and Replace the oil control valve if out of then measure the input voltage at the specification. water detection switch coupler (wiring harness end).

  • Page 349: Checking The Fuel Injector

    Variable camshaft timing control system / Fuel control system Checking the fuel injector 1. Check the operation of the fuel injectors using the “Stationary test” of the YDIS and listen for the operating sound. 2. Disconnect the fuel injector couplers. È...

  • Page 350: Checking The Low-Pressure Fuel Pump And High-Pressure Fuel Pump

    – ELEC Electrical system Checking the low-pressure fuel Checking the high-pressure fuel pump and high-pressure fuel pump pump relay 1. Check the fuses for continuity. Replace if 1. Remove the high-pressure fuel pump relay 1 and check it. there is no continuity. NOTE: For the location of the fuse, see Chapter 8, “Fuse holder.”...

  • Page 351: Checking The Vapor Shut-Off Valve

    Fuel control system / Starting system 3. Measure the input voltage between the terminal 2 and ground, and the terminal 4 and ground as shown. S6AL8650 Vacuum/pressure pump gauge set: 90890-06756 S6AL8640 Terminal 2 – Ground: Specified negative pressure: Terminal 4 – Ground: 67 kPa (0.7 kgf/cm , 9.7 psi) 12 V (battery voltage)

  • Page 352: Checking The Starter Relay

    – ELEC Electrical system Checking the starter relay Terminal 3 – Terminal 4: 1. Remove the starter relay 1 and check it. 12 V (battery voltage) NOTE: To check the engine start switch, see Chap- ter 8, “Checking the engine start switch.” 4.
  • Page 353 Starting system / Starter motor Starter motor S6AL8181 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 354 – ELEC Electrical system S6AL8181 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 8-43...

  • Page 355: Starter Motor

    Starter motor Removing the starter motor WARNING 1. Remove the starboard intake manifold The pinion 5 moves slightly away from and intake silencer. the starter motor body and rotates at high NOTE: speed, so do not place any objects near To remove the intake manifold, see Chapter the pinion or touch it.

  • Page 356: Checking The Magnet Switch

    – ELEC Electrical system Checking the magnet switch NOTE: 1. Connect the tester leads between the • The starter motor pinion should be pushed magnet switch terminals 1 and 2 as out while the magnet switch is “ON.” shown. • If the starter motor is disassembled for maintenance, be sure to check the magnet 2.
  • Page 357 Starter motor 2. Remove the stator 2. 3. Remove the armature 3 with the brush holder assembly 4 from the bracket 5. S6AL8210 6. Slide the pinion stopper 9 down as shown, and then remove the clip 0. S6AL8260 4. Remove the plate 6, and then remove the armature 3 from the brush holder assembly 4.

  • Page 358: Checking The Starter Motor

    – ELEC Electrical system 8. Remove the E-clip D, and then remove 2. Measure commutator diameter. the clutch assembly E from the pinion Replace the armature if below specifica- shaft F. tion. Commutator standard diameter: 29.0 mm (1.14 in) Wear limit: 28.0 mm (1.10 in) S6AL8240 3.

  • Page 359: Checking The Brush

    Starter motor Brush standard length: Armature continuity 15.5 mm (0.61 in) Wear limit a: 9.5 mm (0.37 in) Commutator segments b Continuity Segment – Armature core c No continuity Assembling the starter motor Segment – Armature shaft d No continuity CAUTION: Checking the brush Do not allow grease or oil to contact the...
  • Page 360 – ELEC Electrical system 3. Install the pinion shaft assembly 6, shift 6. Push the brushes E into the holders, lever 7 and rubber seal 8. and then install the armature F to the brush holder assembly. 7. Install the plate G. S6AL8800 4.

  • Page 361: Installing The Starter Motor

    Starter motor / Charging system 3. Route starter motor lead (brown/white) 3 as shown, fasten it to the junction box using the plastic ties 4, and then install the terminals of the starter motor lead (brown/white) 7 and wiring harness lead (brown) 5 using the same bolt 6.

  • Page 362: Checking The Rectifier Regulator

    – ELEC Electrical system 3. Connect the test harness (1 pin) 1 to Stator coil resistance any stator coil coupler. (reference data): 4. Measure the stator coil output peak volt- Green (G) – Green (G) 0.1144–0.1716 Ω at age. Replace the stator coil if below specification.
  • Page 363 Charging system NOTE: NOTE: Be sure to set the measurement range a, Do not use peak voltage adapter B when and display the mark b by pushing the measuring the Rectifier Regulator output peak voltage. “SHIFT” switch when checking the Rectifier Regulator continuity.
  • Page 364 – ELEC Electrical system — MEMO — 8-53 6AL3J11...
  • Page 365 TRBL SHTG Troubleshooting YDIS......................... 9-1 Introduction....................9-1 Connecting the communication cable to the outboard motor ....9-5 Troubleshooting the power unit ..............9-6 Troubleshooting the power unit using the YDIS ........9-6 Trouble code and checking step..............9-9 Troubleshooting the power unit using the diagnostic flash indicator ..9-17 Troubleshooting the power unit (trouble code not detected) ....

  • Page 366: 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 367 YDIS 3. Engine monitor: Each sensor status and the ECM data are displayed while the engine is run- ning. This enables you to find malfunctioning parts quickly. In addition, the data displayed using the Engine Monitor function can be displayed in a graph. Items: For F(L)200C, F(L)225B Engine speed 10 Fuel injection duration...
  • Page 368 TRBL SHTG Troubleshooting 4. Stationary test: Operation tests can be performed with the engine off. Items: For F(L)200C, F(L)225B Ignite ignition coil Oil ctrl. valve drive Operate electric fuel (*1) (*3) (#1–#6) (STBD) pump Operate injector Oil ctrl. valve drive Operate elect.
  • Page 369 YDIS 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 370 TRBL SHTG Troubleshooting 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 6AL3J11...

  • Page 371: Troubleshooting The Power Unit

    YDIS / Troubleshooting the power unit 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 B) first, and then check the electronic control system follow the trouble code chart.
  • Page 372 TRBL SHTG Troubleshooting Trouble code table Diagnostic Diagnosis Diagnosis flash code output record Code No. Item indicator B (YDIS Ver. (YDIS Ver. code output 1.23a) 1.23a) Normal — — Pulser coil malfunction Engine temp sensor malfunction Knock sensor malfunction Battery voltage malfunction Intake temp sensor malfunction Cam position sensor (EXH) malfunction...
  • Page 373 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 374: 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- 8-18 sor resistance. 2. Check the white/black (W/B) lead and black (B) lead (ECM-to- crank position sensor) for conti- nuity.
  • Page 375 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. 8-34 Cam position sensor 3. Check the white/blue (W/L) lead — (*1) (EXH) (cam position sensor-to-ECM) malfunction for continuity.
  • Page 376 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 press 3. Measure the output voltage. (*1) sensor — 4. Check the pink/white (P/W) lead malfunction (ECM-to-oil pressure sensor) for continuity.
  • Page 377 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. 8-34 3. Check the white/black (W/B) Cam position lead (cam position sensor-to- sensor — ECM) for continuity.
  • Page 378 TRBL SHTG Troubleshooting Symptom Refer Trouble Item Checking steps code Remarks page 1. Check the ECM circuit. 8-27 Electronic 2. Check the electronic throttle 8-33 throttle system — valve circuit. malfunction 3. Check the electronic throttle 8-27 valve relay and fuse. 1.
  • Page 379 Troubleshooting the power unit Symptom Refer Trouble Item Checking steps code Remarks page 1. Check the electronic throttle 8-27 valve relay and fuse. Electronic 2. Check the electronic throttle 8-33 throttle system — valve circuit. malfunction 3. Check the electronic throttle 8-31 valve motor continuity.
  • Page 380 TRBL SHTG Troubleshooting Symptom Refer Trouble Item Checking steps code Remarks page 1. Check the accelerator position 8-29 sensor output voltage using the Accelerator YDIS. position — 2. Check the accelerator position 8-31 sensor sensor circuit. malfunction 3. Measure the accelerator position 8-29 sensor resistance.
  • Page 381 Troubleshooting the power unit Symptom Refer Trouble Item Checking steps code Remarks page 1. Check the battery cables and 3-17 terminals for proper connection. 2. Check the ECM circuit. 8-27 Electronic throttle system — 3. Check the electronic throttle 8-33 malfunction valve circuit.

  • Page 382: 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 383 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 384 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 385 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. 8-27 operate Blown fuse — Check the fuse. Short, open, Check the ECM cir- 8-27...
  • Page 386 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. 8-18 —...
  • Page 387 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 valve-cylinder and gaskets of the 4-13 — head) — intake manifold, surge tank, throttle body.
  • Page 388 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 3-10 — • Overheat warning ter inlet water inlet. indicator comes Water pump mal- Water pump impel-...

  • Page 389: 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 7-59 — operate function switch. Short, open, or loose Check wiring connection...

  • Page 390: 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 7-30 opened function valve. Insufficient PTT flu- Add sufficient fluid. 3-13 —...
  • Page 391 Index Checking the cam position sensor.... 8-34 Checking the camshaft ......5-25 Abbreviation ..........1-3 Checking the canister ....... 4-16 Accelerator position sensor.......4-12 Checking the canister check valve ... 4-16 Adjusting the throttle cable......3-11 Checking the check valve......4-22 Adjusting the trim sensor ......7-28 Checking the compression pressure ..
  • Page 392 Index Checking the gear oil level....1-22 3-14 Checking the PTT motor......7-36 Checking the gear pump......7-43 Checking the PTT operation..... 3-13 Checking the gear pump housing .....7-44 Checking the PTT relay ......7-58 Checking the gear shift and Checking the PTT switch......7-59 throttle operation ........1-24 Checking the PTT system ......
  • Page 393 Index Disassembling the gear pump ....7-43 Disassembling the lower case ..6-14 6-45 Hose routing ..........4-1 Disassembling the oil pan and How to use this manual ......1-1 exhaust manifold........7-16 Disassembling the oil pump ......5-73 Disassembling the Identification ..........1-6 propeller shaft assembly ......6-8 Ignition and ignition control system ..
  • Page 394 Index Replacing the valve guide ......5-48 Maintenance interval chart......3-1 Maintenance specification......2-3 Safety while working........1-4 Manual format ..........1-1 Selecting the connecting rod bearing ..5-66 Measuring the forward Selecting the forward gear shim ..6-24 6-57 and reverse gear backlash.... 6-28 6-60 Selecting the main bearing .......
  • Page 395 Index Water separator ........1-14 Wiring harness routing ........8-8 YDIS............9-1 6AL3J11...

  • Page 396: Wiring Diagram

    Wiring diagram Grey Whale 200 - Fin Whale 225 1 Condenser Color code (connect to the intake air pressure sensor) : Black 2 PTT switch : Brown 3 Trim sensor : Green 4 Crank position sensor : Blue 5 Stator coil : Light green 6 Starter motor : Orange...
  • Page 399 Grey Whale 200 - Fin Whale 225 (*2) (*1) 1 2 3 4 1 2 3 1 2 3 4 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...

This manual is also suitable for:

Fin whale 225 efi

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