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SELVA MARINE Blue Whale 250 EFI, Service Manual

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SELVA MARINE Blue Whale 250 EFI Service Manual Download Page 354

TRBL

SHTG

Troubleshooting

9-9

6P23H11

39

Oil pressure 
sensor 
malfunction

C

—

1. Check the engine oil pressure

using the YDIS.

9-1

2. Measure the input voltage.

5-2

3. Measure the output voltage.

5-2

4. Check the pink/white (P/W) lead

(ECM-to-oil pressure sensor) for
continuity.

*1

5. Check the oil pressure using an

oil pressure gauge.

5-1

44

Engine stop 
lanyard switch 
malfunction

K

Engine stalls 
(when running 
engine) 
Buzzer comes 
on

1. Check the switch operation

using the YDIS.

9-1

2. Check the clip.

8-21

3. Check the switch continuity.

8-21

4. Check the white (W) lead (ECM-

to-10-pin main harness coupler)
for continuity.

*1

5. Check the black (B) lead (10-pin

main harness coupler-to-joint
connector-to-ground) for conti-
nuity.

*1

45

Shift cut switch 
malfunction

C

Shifting to 
neutral is 
difficult

1. Check the switch operation

using the YDIS.

9-1

2. Check the switch continuity and

resistance.

8-19

3. Measure the input voltage.

8-19

4. Check the shift bracket and shift

mechanism.

7-1

46

Thermoswitch 
malfunction

C

—

1. Check the switch condition using

the YDIS.

9-1

2. Measure the input voltage.

8-18

3. Check the switch continuity.

8-18

4. Check the engine temperature

sensor.

8-18

*1: See the wiring diagram.

Trouble 

code

Item

Symptom

Checking steps

Refer 

to 

page

Remarks

Summary of Contents for Blue Whale 250 EFI

Page 1: ...Blue Whale 250 SERVICE MANUAL...

Page 2: ...publication Use only the latest edition of this manual Authorized Selva dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incor...

Page 3: ...information 1 GEN INFO Specification 2 SPEC Periodic check and adjustment 3 CHK ADJ Fuel system 4 FUEL Power unit 5 POWR Lower unit 6 LOWR Bracket unit 7 BRKT Electrical system 8 ELEC Troubleshooting...

Page 4: ...isassembly and assembly 1 5 Identification 1 6 Model 1 6 Serial number 1 6 Special service tool 1 7 Feature and benefit 1 14 ECM system 1 14 Electronic fuel injection control system 1 22 Ignition timi...

Page 5: ...1 40 Checking the outboard motor mounting height 1 41 Checking the remote control cable 1 41 Checking the steering system 1 42 Checking the gear shift and throttle operation 1 42 Checking the PTT syst...

Page 6: ...ower unit No Part name Q ty Remarks 1 Lower unit 1 2 Plastic tie 1 Not reusable 3 Hose 1 4 Check screw 1 5 Gasket 2 Not reusable 6 Dowel pin 2 7 Bolt 4 M10 40 mm 8 Drain screw 1 9 Grommet 1 10 Bolt 1...

Page 7: ...esistance voltage electric current Symbols 7 to C in an exploded diagram indicate the grade of lubricant and the lubrication point 7 Apply 4 stroke motor oil 8 Apply gear oil 9 Apply water resistant g...

Page 8: ...l Engine System ECM Electronic Control Module EN European Norm European standard EX Exhaust IEC International Electrotechnical Commission IN Intake PCV Pressure Control Valve PON Pump Octane Number RO...

Page 9: ...tect your hands and feet by wearing pro tective gloves and safety shoes when neces sary Part lubricant and sealant Use only genuine Selva parts lubricants and sealants or those recommended by Selva wh...

Page 10: ...starting in the center and moving outward Non reusable part Always use new gaskets seals O rings cot ter pins circlips etc when installing or assembling parts Disassembly and assembly 1 Use compressed...

Page 11: ...outboard motor serial number is stamped on a label attached to the port clamp bracket 1 Model name 2 Approved model code 3 Transom height 4 Serial number Applicable model F250AET FL250AET Model name A...

Page 12: ...age tester 90890 06840 Fuel pressure gauge adapter B 90890 06942 Fuel pressure gauge 90890 06786 Vacuum pressure pump gauge set 90890 06756 Compression gauge 90890 03160 Compression gauge extension 90...

Page 13: ...0 Valve guide remover installer 90890 06801 Valve guide installer 90890 06810 Valve guide reamer 90890 06804 Valve seat cutter holder 90890 06316 Valve seat cutter 90890 06324 90890 06325 90890 06326...

Page 14: ...06653 90890 06654 Piston ring compressor 90890 05158 Bearing housing puller claw L 90890 06502 Stopper guide plate 90890 06501 Center bolt 90890 06504 Bearing separator 90890 06534 Stopper guide stand...

Page 15: ...h plate 90890 06603 Ball bearing attachment 90890 06656 90890 06657 Driver rod LS 90890 06606 Bearing outer race attachment 90890 06622 90890 06628 90890 06658 Drive shaft holder 6 90890 06520 Pinion...

Page 16: ...890 06052 Pinion height gauge 90890 06710 Digital caliper 90890 06704 Shimming plate 90890 06701 Backlash indicator 90890 06706 Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base B 9...

Page 17: ...ch 90890 06568 PTT piston vice attachment 90890 06572 Tilt rod wrench 90890 06569 Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 Ignition tester 90890 06754 Test harness 2 pins...

Page 18: ...GEN INFO General information 1 13 6P23H11 Diagnostic system 60V WS853 05 Diagnostic flash indicator B 90890 06865...

Page 19: ...6P21110 High pressure fuel pump Vapor separator tank Low pressure fuel pump Oil control valve PORT Cam position sensor PORT IN Camposition sensor PORT EX Control signal Cam position sensor STBD IN Oil...

Page 20: ...PORT IN 4 Oil control valve STBD 5 Cam position sensor PORT EX 6 ECM 7 Cam position sensor STBD IN 8 Knock sensor 9 Fuel injector 0 Vapor separator tank A High pressure fuel pump B Check valve C Low p...

Page 21: ...onic throttle valve assembly 5 Intake air pressure sensor 6 Canister 7 Fuel filter with water separator 8 Neutral switch 9 Shift cut switch 0 Oil pressure sensor A Accelerator position sensor 1 B Acce...

Page 22: ...using variable camshaft timing control TPS 1 Detects the electronic throttle valve opening angle TPS 2 Detects the electronic throttle valve opening angle Accelerator position sensor 1 Detects the th...

Page 23: ...tion sensor PORT EX Cam position sensor PORT IN Cam position sensor STBD IN TPS 1 TPS 2 Ground Ground Ground Accelerator position sensor 1 Accelerator position sensor 2 Intake air pressure sensor Oil...

Page 24: ...ay Thermoswitch Shift cut switch Neutral switch Ground Knock sensor Engine stop lanyard switch Main relay Rectifier Regulator Battery Engine start switch Oil control valve STBD Oil control valve PORT...

Page 25: ...Black yellow 18 Sensor ground Black 19 20 21 22 23 Intake air temperature sensor Black yellow 24 25 26 27 Battery power source Red yellow 28 Personal computer White black 29 30 31 Accelerator position...

Page 26: ...een 65 High pressure fuel pump relay Blue red 66 Electronic throttle valve relay Yellow 67 Buzzer Pink 68 ECM ground Black 69 ECM ground Black 70 Ignition coil 2 Black white 71 Ignition coil 1 Black o...

Page 27: ...ltaneously injects into cylinder groups 1 and 4 2 and 5 and 3 and 6 Starting Sequential injection in order of cylinders 1 2 3 4 5 and 6 Normal operation Injection volume Controls the operation time of...

Page 28: ...hen the engine is cranked the vapor shut off valve closes to prevent the fuel vapor gas from entering the surge tank After the engine is started the vapor shut off valve opens and closes repeatedly to...

Page 29: ...PORT IN Cam position sensor STBD IN TPS 1 TPS 2 Ground Accelerator position sensor 1 Accelerator position sensor 2 Ground Intake air pressure sensor Ground Intake air temperature sensor Engine temper...

Page 30: ...engine is cranked and started the spark plug ignites at BTDC 10 Ignition at normal operation During normal operation map control is performed according to the engine speed the intake air pressure and...

Page 31: ...n sensor PORT IN Cam position sensor STBD IN TPS 1 TPS 2 Ground Accelerator position sensor 1 Accelerator position sensor 2 Ground Intake air pressure sensor Ground Intake air temperature sensor Engin...

Page 32: ...ngine knock and its size When engine knock is determined the knock control system retards the ignition timing to prevent the occurrence of engine knock Knock control Description Control Engine conditi...

Page 33: ...63 70 71 15 51 36 8 18 48 47 50 45 34 7 27 5V 5V Ignition coil 1 Ignition coil 2 Ignition coil 3 Ignition coil 4 Ignition coil 5 Ignition coil 6 Crank position sensor TPS 1 TPS 2 Ground Intake air pre...

Page 34: ...ignal to the oil control valve to switch the oil passage to send engine oil to the advance chamber or retard chamber in the rotor vane housing According to the engine oil pressure in the respective ch...

Page 35: ...he oil pan via the spool valve passage When the camshaft retards the spool valve moves toward the magnetic coil according to the mag netic force of the magnetic coil and the force of the coil spring a...

Page 36: ...he engine speed increases and the engine oil enters the advance chamber in the housing and the lock pin is released When the camshaft advances the engine oil that entered the advance chamber in the ho...

Page 37: ...2 51 17 18 47 50 45 1 34 7 27 5V Crank position sensor Cam position sensor PORT EX Cam position sensor PORT IN Cam position sensor STBD IN TPS 1 TPS 2 Ground Engine temperature sensor Ground Main rel...

Page 38: ...le and throttle valve opening angle 1 Remote control box 2 Accelerator position sensor 3 Accelerator lever 4 ECM 5 Electronic throttle valve assembly TPS 6 Electronic throttle valve motor Throttle cab...

Page 39: ...S 2 Ground Accelerator position sensor 1 Accelerator position sensor 2 Ground Ground Engine temperature sensor Shift cut switch Ground Engine start switch Battery Main relay Neutral switch ECM Fuel in...

Page 40: ...F The ECM causes the cylinders to misfire cuts off injection decreases the engine speed to less than 2 000 r min acti vates the warning buzz er and turns the over heat warning indicator on Low oil pr...

Page 41: ...atus of the shift cut control and controls the engine speed Two cylinders misfire and the engine speed decreas es so that the shift can be shifted Over revolution Detects the status of the over revolu...

Page 42: ...nd Oil pressure sensor Engine temperature sensor Thermoswitch Shift cut switch Ground Engine start switch Battery Main relay Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4 Fuel inject...

Page 43: ...the drive shaft toward the water pump and stabilize the thrust free play of the shaft This spring facilitates the backlash measurement procedure since the lower unit does not need to be turned upsided...

Page 44: ...ide of the propel ler boss a Propeller diameter in inches b Propeller pitch in inches c Propeller type propeller mark Selection When the engine speed is at the full throttle operating range 5 000 6 00...

Page 45: ...il is below the minimum level mark L add sufficient oil until the level is between H and L Checking the gear oil level 1 Check the gear oil level Checking the battery 1 Check the capacity electrolyte...

Page 46: ...mbination of the boat and the outboard motor To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that the clamp brackets are secured with the clamp bolts...

Page 47: ...d motor tilts up and down smoothly when operating the PTT unit 2 Check that there is no abnormal noise produced when the outboard motor is tilted up or down 3 Check that there is no interference with...

Page 48: ...The test run is part of the break in operation Break in During the test run perform the break in operation in the following three stages 1 1 hour a at 2 000 r min or at approxi mately half throttle 2...

Page 49: ...1 2 3 4 5 6 7 8 9 Specification General specification 2 1 Maintenance specification 2 3 Power unit 2 3 Lower unit 2 6 Electrical 2 7 Dimension 2 10 Tightening torque 2 12 Specified torque 2 12 General...

Page 50: ...ing range r min 5 000 6 000 Maximum fuel consumption L US gal Imp gal hr 81 0 21 4 17 8 at 6 000 r min Engine idle speed r min 600 700 Power unit Type 4 stroke DOHC Cylinder quantity V6 Total displace...

Page 51: ...L US qt Imp qt 5 6 5 92 4 93 with oil filter replacement L US qt Imp qt 5 8 6 13 5 10 Gear oil type Hypoid gear oil Gear oil grade 2 API GL 4 SAE 90 Gear oil quantity cm3 US oz Imp oz 1 150 38 9 40 6...

Page 52: ...080 0 0030 0 0031 Piston pin boss bore mm in 21 017 21 031 0 8274 0 8280 Piston pin Outside diameter mm in 20 995 21 000 0 8266 0 8268 Piston ring Top ring Dimension B mm in 1 17 1 19 0 046 0 047 Dime...

Page 53: ...1 43 1 44 Exhaust mm in 31 4 31 6 1 24 1 24 Face width B Intake mm in 2 35 2 78 0 092 0 110 Exhaust mm in 2 13 3 30 0 084 0 130 Seat contact width C Intake mm in 1 10 1 40 0 043 0 055 Exhaust mm in 1...

Page 54: ...91 0 0592 Crankshaft Crankshaft journal diameter mm in 62 968 62 992 2 4791 2 4800 Crankpin diameter mm in 49 976 50 000 1 9676 1 9685 Crankpin width mm in 21 50 21 55 0 8465 0 8484 Runout limit mm in...

Page 55: ...81 0 0323 Pinion to reverse gear mm in 0 32 0 65 0 0126 0 0256 0 45 0 78 0 0177 0 0307 Propeller shaft free play mm in 0 20 0 50 0 0079 0 0197 0 25 0 35 0 0098 0 0138 Pinion shims mm 0 10 0 12 0 15 0...

Page 56: ...air temperature sensor resistance at 20 C 68 F k 2 21 2 69 Engine temperature sensor resistance B Y B Y at 20 C 68 F k 54 2 69 0 at 100 C 212 F k 3 12 3 48 Electronic throttle valve control system TPS...

Page 57: ...ushes Standard length mm in 15 5 0 61 Wear limit mm in 9 5 0 37 Commutator Standard diameter mm in 29 0 1 14 Wear limit mm in 28 0 1 10 Standard undercut mm in 0 8 0 03 Wear limit mm in 0 2 0 01 Charg...

Page 58: ...istance 9 387 6 Fluid type ATF Dexron II Motor brushes Standard length mm in 11 5 0 45 Wear limit mm in 4 5 0 18 Motor commutator Standard diameter mm in 23 0 0 91 Wear limit mm in 22 0 0 87 Standard...

Page 59: ...2 5 723 9 28 5 X 1 155 45 5 U 1 272 50 1 X 643 25 3 U 770 30 3 X 1 078 42 4 U 1 205 47 4 X 52 2 0 U 59 2 3 X 847 33 3 U 924 36 4 619 24 4 219 8 6 230 9 1 45 1 8 387 15 2 752 29 6 902 35 5 39 1 5 216 8...

Page 60: ...PEC Specification 2 11 6P23H11 Clamp bracket mm in 79 3 1 13 0 5 180 7 1 163 5 6 4 254 10 0 55 5 2 2 411 16 2 163 5 6 4 125 4 4 9 125 4 4 9 101 5 4 0 101 5 4 0 180 7 1 13 0 5 50 8 2 0 18 5 0 7 S6P2201...

Page 61: ...2 0 2 1 5 Float pin screw M4 2 0 2 1 5 Vapor separator drain screw 2 0 2 1 5 Power unit Power unit mounting bolt M10 42 4 2 31 0 Apron bolt M6 8 0 8 5 9 Upper case cover bolt M6 8 0 8 5 9 PTT motor le...

Page 62: ...age cover bolt M6 12 1 2 8 9 Oil filter 18 1 8 13 3 Oil pressure sensor 18 1 8 13 3 Oil filter joint 34 3 4 25 1 Crankcase cover bolt 1st M8 14 1 4 10 3 2nd 28 2 8 20 7 Connecting rod cap bolt 1st M9...

Page 63: ...ew M4 2 0 2 1 5 Grease nipple 1 0 1 0 7 Shift rod detent bolt 18 1 8 13 3 Grease nipple 1 0 1 0 7 Flushing hose adapter screw M6 5 0 5 3 7 Upper mount bracket bolt M10 54 5 4 39 8 Apron stay 8 0 8 5 9...

Page 64: ...ss otherwise specified torque specifications require clean dry threads Components should be at room temperature Manual valve 2 0 2 1 5 Pipe joint 15 1 5 11 1 Pipe joint adapter 20 2 0 14 8 Gear pump b...

Page 65: ...he oil filter 3 6 Checking the timing belt 3 6 Checking the spark plug 3 7 Checking the thermostat 3 7 Checking the cooling water passage 3 9 Control system 3 9 Checking the engine idle speed 3 9 Adju...

Page 66: ...replace 3 14 Anodes cylinder head thermostat cover Check replace 3 14 Battery Check charge 3 15 Cooling water passages Clean 3 9 Top cowling Check 3 3 Fuel filter can be disassembled Check replace 3 4...

Page 67: ...belt Replace 5 15 Valve clearance DOHC Check adjust 5 10 Fuel filter vapor separator tank Replace 4 23 Oil control valve filter Check replace 5 41 Anodes exhaust cover cooling water passage cover Rect...

Page 68: ...or damaged Fuel system 3 Checking the fuel joint and fuel hose fuel joint to fuel injector 1 Remove the flywheel magnet cover port intake manifold and fuel rail covers NOTE See the exploded diagram 4...

Page 69: ...e oil dipstick wipe it clean and then insert it back into the dipstick guide 3 Remove the oil dipstick again to check the oil level and to check the oil for dis coloration and its viscosity NOTE Chang...

Page 70: ...spills 5 Install the engine oil drain bolt and then tighten it to the specified torque 6 Pour the specified amount of the recom mended engine oil into the oil filler hole 7 Install the oil filler cap...

Page 71: ...amount of the recom mended engine oil into the oil filler hole 6 Install the oil filler cap and oil dipstick and then start the engine and warm it up for 5 minutes 7 Turn the engine off and then check...

Page 72: ...brush Replace the spark plug if necessary 4 Check the electrodes for erosion and excessive carbon or other deposits and the gasket for damage Replace the spark plug if necessary 5 Check the spark plu...

Page 73: ...suddenly since pressurized fuel will spray out Be sure to reduce the fuel pressure before removing the quick con nector NOTE To disconnect the quick connector see Chapter 4 Disconnecting the quick con...

Page 74: ...cooling water inlet covers 1 and cooling water inlet Clean if clogged 2 Place the lower unit in water and then start the engine 3 Check for water flow at the cooling water pilot hole If there is no w...

Page 75: ...the position of the throttle cable joint until its hole is aligned with the set pin on the lever WARNING The throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in a NOTE Pull the thrott...

Page 76: ...or reverse Adjust the shift cable length if necessary 2 Check the neutral switch for continuity Adjust the shift cable length or check the neutral switch if necessary NOTE To check the neutral switch...

Page 77: ...k mechanism of the lever Checking the PTT fluid level 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 WARNING After tilting up the outboard motor be sure to support i...

Page 78: ...until it overflows out of the check hole 4 Install the new gasket and check screw and then tighten the screw to the speci fied torque Changing the gear oil 1 Tilt the outboard motor up slightly 2 Plac...

Page 79: ...the specified pressure cannot be main tained check the drive shaft propeller shaft and shift rod oil seals for damage If necessary check the each shaft for bends and damage Checking the propeller 1 C...

Page 80: ...motor to check an anode refer to the applica ble disassembly procedure in this manual 2 Replace the anodes or trim tab if exces sively eroded In addition check the ground lead Checking the battery 1...

Page 81: ...llowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries generate explosive hydrogen gas Always follow these preventive mea sures Charge batteries in a well v...

Page 82: ...ustment 3 17 6P23H11 NOTE Apply grease to the grease nipple until it flows from the bushings a 2 Apply low temperature resistant grease to the area shown 3 Apply corrosion resistant grease to the area...

Page 83: ...e quick connector 4 9 Draining the fuel 4 10 Fuel filter 4 11 Intake manifold 4 12 Installing the intake manifold 4 13 Installing the intake silencer 4 13 Throttle body 4 15 Checking the canister 4 18...

Page 84: ...ump to filter 5 Fuel hose filter to joint 6 Fuel hose joint to check valve 7 Fuel hose check valve to joint 8 Fuel hose vapor separator to quick connector 9 Fuel hose quick connector to joint 0 Fuel h...

Page 85: ...ve 8 Vapor gas hose vapor shut off valve to surge tank 9 Vapor gas hose intake silencer to check valve 0 Vapor gas hose check valve to joint A Vapor gas hose canister atmospheric port to joint B Vapor...

Page 86: ...at 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...

Page 87: ...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...

Page 88: ...k the accelerator position sensor see Chapter 8 Checking the accelerator position sensor circuit and Checking the accelerator position sensor Checking the TPS 1 Connect a computer to the outboard moto...

Page 89: ...remote control lever to the fully open position and hold it 6 Check the output voltage of TPS 2 and the throttle valve opening angle 7 Operate the remote control lever and check that the output voltag...

Page 90: ...N The high pressure fuel pump does not operate when the engine start switch is turned to ON again within 10 seconds after turning the switch to OFF 5 Measure the fuel pressure 5 seconds after turning...

Page 91: ...screw can cause fuel to spray out creating a fire hazard 5 Start the engine and let it idle 6 Check that the fuel pressure reduces when vacuum pressure is applied to the pressure regulator If the fuel...

Page 92: ...2 or 3 times 4 Turn the engine start switch to OFF Disconnecting the quick connector WARNING If the quick connector is removed sud denly pressurized fuel could spray out Be sure to reduce the fuel pre...

Page 93: ...drain pan under the vapor sepa rator drain hose and then loosen the drain screw 2 5 Drain the fuel from the vapor separator drain hose by pressing the pressure check valve using a thin screwdriver WA...

Page 94: ...le 2 O ring 1 Not reusable 3 Fuel filter element 1 4 Float 1 5 Cup 1 6 Fuel filter assembly 1 7 Bracket 1 8 Bolt 2 M6 16 mm 9 Bolt 2 M6 20 mm 10 Fuel hose 2 11 Holder 1 12 Joint 1 13 Plastic tie 3 Not...

Page 95: ...rommet 1 8 Bolt 4 M6 25 mm 9 Bolt 8 M8 40 mm 10 Bolt 7 M6 40 mm 11 Intake manifold STBD 1 12 Gasket 1 Not reusable 13 Gasket 6 Not reusable 14 Gasket 1 Not reusable 15 Intake manifold PORT 1 16 Intake...

Page 96: ...f the gasket comes into con tact with the fuel rail cover 3 Tighten the M6 bolts to the specified torque in the sequence shown 4 Tighten the M8 bolts in the sequence shown Installing the intake silenc...

Page 97: ...6P23H11 4 14 1 2 3 4 5 6 7 8 9 1 2 3 S6P24380 2 3 Intake manifold...

Page 98: ...t reusable 10 Surge tank 1 11 Collar 2 12 Bolt 4 M8 40 mm 13 Holder 2 14 Bolt 2 M6 14 mm 15 Canister 1 16 Bolt 1 M6 10 mm 17 Bracket 1 S6P24530 7 8 9 15 16 17 20 19 18 21 10 14 13 12 11 2 1 3 4 5 6 22...

Page 99: ...b wiring harness 1 27 Bolt 1 M6 20 mm 28 Washer 1 29 Intake air pressure sensor 1 S6P24530 7 8 9 15 16 17 20 19 18 21 10 14 13 12 11 2 1 3 4 5 6 22 23 24 25 26 27 28 29 3 T R 5 N m 0 5 kgf m 3 7 ft Ib...

Page 100: ...valve 1 2 Holder 3 3 Holder 2 4 Joint 1 5 Joint 2 6 Joint 1 7 Holder 2 8 Joint 2 9 Holder 2 10 Holder 1 S6P24500E 9 8 8 7 7 3 5 4 1 5 6 2 2 3 10 9 2 9 mm 0 35 in 12 mm 0 47 in 9 mm 0 35 in 9 mm 0 35...

Page 101: ...ive pressure to the check valve port 3 Check that air comes out of the opposite end of the check valve Replace if no air comes out 4 Connect the special service tool to the opposite check valve port a...

Page 102: ...d canister vent hose 4 to the holder 3 Fasten hoses 2 and 5 to the holder 4 Install the throttle body 5 Connect the hoses and fasten them NOTE Fasten the pressure regulator hose 3 and vapor separator...

Page 103: ...ks 1 Low pressure fuel pump 1 2 Cover 1 3 Bolt 2 M6 15 mm 4 Screw 1 5 8 mm 5 Holder 1 6 Check valve 1 7 Clamp 6 8 Clamp 4 9 Joint 1 10 Holder 1 11 Cover 1 12 Filter 1 13 Fuel hose 5 14 Plastic tie 1 N...

Page 104: ...e port 3 Check that air comes out of the opposite end of the check valve Replace if no air comes out 4 Connect the special service tool to the opposite check valve port as shown 5 Apply positive press...

Page 105: ...M6 35 mm 7 Collar 2 8 Fuel cooler 1 9 Bolt 2 M6 25 mm 10 Clamp 3 11 Clamp 4 12 Quick connector 3 13 Clamp 3 Not reusable 14 Joint 1 15 Clamp 1 16 Clamp 1 S6P24520 2 2 3 3 3 3 1 4 4 6 5 11 7 9 10 15 12...

Page 106: ...re fuel pump 1 8 Grommet 1 9 Filter 1 10 Filter holder 1 11 Plate 1 12 Plate 1 13 Screw 3 4 8 mm 14 O ring 1 Not reusable 15 Needle valve 1 16 Float 1 17 Pin 1 S6P24250E 3 4 24 24 23 2 6 5 1 14 15 16...

Page 107: ...er 1 21 Drain screw 1 22 Drain hose 1 23 Joint 1 24 Hose 2 25 Cap 1 S6P24250E 3 4 24 24 23 2 6 5 1 14 15 16 17 18 13 13 12 11 8 7 9 10 19 20 21 22 T R 2 N m 0 2 kgf m 1 5 ft Ib T R 5 N m 0 5 kgf m 3 7...

Page 108: ...them with new ones otherwise the fuel leakage may occur Checking the vapor separator 1 Check the needle valve Replace if bent or worn 2 Check the float Replace if there is deteri oration 3 Check the f...

Page 109: ...ring set 2 Not reusable 3 Holder 6 4 Fuel rail PORT 1 5 Bolt 4 M6 35 mm 6 Cover 1 7 Bolt 4 M6 20 mm 8 Fuel rail STBD 1 9 Cover 1 10 Plastic tie 3 11 Fuel rail assembly PORT 1 12 Fuel rail assembly ST...

Page 110: ...s 3 as shown 3 Install the fuel injectors 4 onto the star board fuel rail 5 and then install the holders 6 as shown 4 Install the fuel rails onto the cylinder heads 5 Tighten the bolts 7 equally and g...

Page 111: ...6P23H11 4 28 1 2 3 4 5 6 7 8 9 MEMO Fuel injector...

Page 112: ...rocket and timing belt 5 28 Starter motor and accelerator position sensor 5 35 ECM 5 36 Fuse box 5 37 Junction box 5 38 Exhaust cover 5 39 Removing the exhaust cover 5 40 Checking the exhaust cover an...

Page 113: ...59 Checking the piston pin boss bore 5 59 Checking the piston pin 5 60 Checking the connecting rod small end inside diameter 5 60 Checking the connecting rod big end side clearance 5 60 Checking the...

Page 114: ...the compression pressure 7 If the compression pressure is below specification and the compression pres sure for each cylinder is unbalanced add a small amount of engine oil to the cylin der and then c...

Page 115: ...test harness to the oil pres sure sensor 2 Start the engine and warm it up for 5 min utes 3 Measure the oil pressure sensor input voltage Check the wiring harness con nection or replace the ECM if ou...

Page 116: ...pper case cover 1 11 Bolt 7 M6 14 mm 12 Apron STBD 1 13 Grommet 6 14 Apron PORT 1 15 Bolt 1 M6 30 mm 16 Nut 2 17 Bolt 2 M6 10 mm S6P25050E 7 6 9 8 11 16 13 13 14 10 11 12 11 15 11 2 3 3 5 5 4 17 1 17...

Page 117: ...050E 7 6 9 8 11 16 13 13 14 10 11 12 11 15 11 2 3 3 5 5 4 17 1 17 18 19 20 5 5 5 4 4 4 3 3 11 E LT 572 LT LT 572 LT A A LT 572 LT LT 572 LT LT 572 LT LT 572 LT T R 8 N m 0 8 kgf m 5 9 ft Ib T R 4 N m...

Page 118: ...olt 4 M6 28 mm 12 Bolt 3 M6 20 mm 13 Cam position sensor STBD IN PORT EX 2 14 O ring 3 Not reusable 15 Cam position sensor PORT IN 1 16 Bolt 12 M6 20 mm 17 Ignition coil 6 S6P25060E 3 2 2 5 4 4 6 6 8...

Page 119: ...mm 23 Bolt 2 M6 30 mm 24 ECM base assembly 1 25 Bolt 1 M6 12 mm 26 Holder 1 27 Hose 1 S6P25060E 3 2 2 5 4 4 6 6 8 18 17 16 14 13 12 23 20 19 21 22 16 17 18 12 14 15 14 13 12 11 10 9 7 3 1 E E T R 23 N...

Page 120: ...ollar 2 7 Holder 2 8 Bracket 1 9 Crank position sensor 1 10 Screw 2 5 12 mm 11 Timing belt 1 12 Timing belt tensioner 1 13 Bolt 2 M10 55 mm 14 Washer 2 15 Pulley 2 16 Collar 2 17 Woodruff key 1 S6P250...

Page 121: ...1 2 3 8 7 7 6 5 8 9 13 12 12 11 11 10 15 15 18 17 23 24 22 20 12 11 12 19 21 25 16 14 14 4 11 7 6 5 1 2 3 4 8 8 26 27 28 30 32 31 23 34 25 33 24 29 1386B 1280B 1280B E E E A A E M E E E E T R 2 N m 0...

Page 122: ...25080E 1 2 3 8 7 7 6 5 8 9 13 12 12 11 11 10 15 15 18 17 23 24 22 20 12 11 12 19 21 25 16 14 14 4 11 7 6 5 1 2 3 4 8 8 26 27 28 30 32 31 23 34 25 33 24 29 1386B 1280B 1280B E E E A A E M E E E E T R 2...

Page 123: ...Remove the blowby hose 1 3 Disconnect the ignition coil couplers 2 cam position sensor couplers 3 and knock sensor coupler 4 4 Disconnect the cooling water pressure sensor adapter hose 5 5 Remove all...

Page 124: ...linders 1 2 and 3 in order and be sure to turn the flywheel magnet 120 clockwise each time Adjust the valve clearances if out of specification Adjusting the valve clearance CAUTION Do not turn the fly...

Page 125: ...g off easily 5 Remove the flywheel magnet and Woo druff key and then remove the stator assembly CAUTION To prevent damage to the engine or tools screw in the puller set bolts evenly and completely so...

Page 126: ...0 30 0 20 2 20 mm 10 Install the necessary valve shim into the valve lifter 11 Install the camshafts driven sprockets and timing belt NOTE To install the camshafts driven sprockets and timing belt see...

Page 127: ...e NOTE To install the wiring harness guide see Installing the wiring harness 19 Install the spark plugs and ignition coils 20 Install all parts removed during disas sembly 21 Check that the wiring har...

Page 128: ...he fuel pressure NOTE To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure 2 Remove the flywheel magnet cover and ECM cover 3 Remove the blowby hose 1 4 Disconnect the ignition coil co...

Page 129: ...net and Woo druff key 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 NOTE Apply for...

Page 130: ...ted into the timing belt tensioner until the timing belt is installed again 17 Remove the timing belt from the driven sprockets then from the drive sprocket 18 Check that the mark e on the drive sproc...

Page 131: ...ng belt 21 Install the timing belt onto the driven sprockets by aligning belt position marks k through p with the marks on the driven sprockets 22 Check that belt position marks h through p are aligne...

Page 132: ...ortion of the crankshaft and fly wheel magnet 27 Check the crank position sensor air gap s NOTE It is recommended to check the crank posi tion sensor air gap before installing the wiring harness guide...

Page 133: ...ector 1 from the wiring harness guide 2 Disconnect the oil control valve couplers 2 engine temperature sensor coupler 3 and thermoswitch connectors 4 3 Remove the engine temperature sensor coupler 3 a...

Page 134: ...ull up the wiring harness 9 Remove the bolts and wiring harness guide A Removing the power unit NOTE It is recommended to loosen the flywheel magnet nut before removing the power unit to improve worki...

Page 135: ...B 9 Disconnect the battery cables NOTE See the exploded diagram 5 35 10 Disconnect the fuel hose from the fuel fil ter 11 Removing the PTT switch coupler C isolator coupler D warning indicator coupler...

Page 136: ...kshaft 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 installed Otherwise the piston and valves or in...

Page 137: ...rs 2 NOTE See the exploded diagram 5 8 4 Make marks e through m on the timing belt as shown Number of belt teeth NOTE It is not necessary to mark the timing belt when replacing it S6P25430 c d a b S6P...

Page 138: ...counterclockwise 60 gradually CAUTION Do not turn the crankshaft counterclock wise more than 60 Otherwise the piston and valves will collide with each other and be damaged 8 Align the I marks p on the...

Page 139: ...e the variable camshaft timing assembly with the driven sprocket CAUTION Do not hold the driven sprocket when removing the variable camshaft timing bolt Otherwise the variable camshaft timing assembly...

Page 140: ...d dam aged or worn 3 Check the driven sprockets Replace the variable camshaft timing assembly or driven sprocket if cracked damaged or worn Checking the valve lifter 1 Check the valve lifters Replace...

Page 141: ...not installed Otherwise the pistons and valves or intake and exhaust valves will collide with each other and be damaged Do not turn the crankshaft and cam shafts unless instructions have been given 1...

Page 142: ...ot to block the oil passages or oil holes 4 Install the camshafts with the oil seals NOTE Apply molybdenum disulfide grease to the cam lobes Be sure to install the camshafts in the proper positions Se...

Page 143: ...amshaft when tightening the bolt Otherwise the intake and exhaust valves will collide with each other and be damaged NOTE Slight turn the driven sprockets in direction to remove any free play before t...

Page 144: ...with each other and be damaged NOTE Slight turn the driven sprockets in direction to remove any free play before tightening the driven sprocket bolt 2 13 Hold the driven sprocket using the spe cial s...

Page 145: ...r and be dam aged 15 Align the mark a on the drive sprocket with the mark c on the cyl inder block by turning the crankshaft clockwise 60 gradually CAUTION Do not turn the crankshaft clockwise more th...

Page 146: ...otherwise it can be dam aged Do not get oil or grease on the timing belt 18 Install the timing belt onto the driven sprockets by aligning belt position marks g through m with the marks on the driven...

Page 147: ...bolts to the specified torque in 2 stages NOTE See the exploded diagram 5 8 22 Install the timing belt guide and then adjust the timing belt to timing belt guide clearance p T R Cylinder head cover b...

Page 148: ...6 Terminal 1 7 Bolt 1 M8 20 mm 8 Terminal bolt 1 9 Negative battery cable 1 10 Washer 1 11 Nut 1 12 Accelerator position sensor assembly 1 13 Grommet 3 14 Collar 3 15 Bolt 3 M6 35 mm 16 Bolt 1 M6 20 m...

Page 149: ...1 3 Holder 1 4 Plastic tie 2 5 Holder 5 6 Bolt 2 M6 16 mm 7 Plate 1 8 Holder 1 9 Holder 1 10 Plate 1 11 Holder 2 12 ECM bracket 1 13 Grommet 4 14 Collar 4 S6P25750 3 2 5 6 6 10 7 8 9 11 13 14 13 14 12...

Page 150: ...puller 1 5 Fuse 2 10 A Spare is included 6 Fuse 3 30 A Spare is included 7 Fuse 2 20 A Spare is included 8 Fuse 2 5 A Spare is included 9 Fuse 2 15 A Spare is included 10 Screw 4 3 10 mm 11 Cover 1 1...

Page 151: ...Gasket 1 Not reusable 10 Anode 1 11 Cover 1 12 Bolt 4 M6 25 mm 13 Bolt 5 M6 28 mm 14 Junction box 1 15 Grommet 5 16 Collar 5 17 Wiring harness 1 S6P25770E T R 1 6 N m 0 6 kgf m 4 4 ft lb 2 12 N m 1 2...

Page 152: ...ket 4 Not reusable 4 Plug 2 M18 17 mm 5 Gasket 2 Not reusable 6 Exhaust outer cover PORT 1 7 Gasket 2 Not reusable 8 Exhaust inner cover PORT 1 9 Anode 2 10 Screw 2 6 16 mm 11 Anode 2 12 Screw 2 4 12...

Page 153: ...e ineffective 2 Replace the anodes if excessively eroded Installing the exhaust cover 1 Install the anodes to the exhaust covers 2 Install new gaskets and the exhaust cov ers and then tighten the bolt...

Page 154: ...2 Oil control valve assembly 2 3 Filter 2 Not reusable 4 Engine hanger PORT 1 5 Bolt 6 M6 20 mm 6 Bolt 16 M10 120 mm T55 7 Bolt 4 M6 20 mm 8 Cover 4 9 Anode 4 10 Grommet 4 11 Bolt 4 M8 40 mm 12 Bolt 4...

Page 155: ...Gasket 1 Not reusable 22 Anode 4 23 Screw 4 4 12 mm 24 Valve cotter 48 25 Valve spring retainer 24 26 Valve spring 24 27 Valve seal 24 Not reusable 28 Valve guide 24 Not reusable 29 Intake valve 12 30...

Page 156: ...hey were removed Checking the valve spring 1 Measure the valve spring free length a Replace if below specification 2 Measure the valve spring tilt b Replace if above specification Checking the valve 1...

Page 157: ...learance as follows Replace the valve guide if out of specification Valve margin thickness a Intake 0 50 0 90 mm 0 020 0 035 in Exhaust 0 90 1 30 mm 0 035 0 051 in Valve stem diameter b Intake 5 477 5...

Page 158: ...ise to ream the valve guide Do not turn the reamer counterclockwise when removing the reamer 4 Measure the valve guide inside diameter Checking the valve seat 1 Eliminate carbon or deposits from the v...

Page 159: ...cation Replace the valve guide if the valve seat contact is uneven Refacing the valve seat 1 Reface the valve seat with the valve seat cutter Valve seat contact width a Intake 1 10 1 40 mm 0 043 0 055...

Page 160: ...e bottom edge of the valve seat b Previous contact width 5 Use a 45 cutter to adjust the contact width of the valve seat to specification b Previous contact width c Specified contact width 6 If the va...

Page 161: ...commer cially available CAUTION Do not get the lapping compound on the valve stem and valve guide 10 After every lapping procedure be sure to clean off any remaining lapping com pound from the cylind...

Page 162: ...alve spring and then install the valve cotters 7 4 Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters securely NOTE Be sure to install the camshafts after com pleting...

Page 163: ...water passage cover 1 Install the anodes to the cooling water passage cover 2 Install the new gasket and cooling water passage cover NOTE See the exploded diagram 5 41 3 Tighten the cooling water pass...

Page 164: ...l to the cylinder head bolts before installation Tighten the M10 bolts to the specified torques in 6 stages first and then tighten the M8 bolts to the specified torques in 2 stages Make a mark a on th...

Page 165: ...new ones NOTE Make sure that the oil control valve filter does not come off when installing the oil control valve 4 Install the camshafts driven sprockets and timing belt NOTE To install the camshafts...

Page 166: ...iller cap 1 13 O ring 1 14 Holder 1 15 Gasket 1 Not reusable 16 Dowel 2 17 Cap 2 S6P25840E 1 2 3 4 5 6 7 8 9 11 16 15 10 14 16 13 12 19 17 18 29 27 28 19 22 21 28 27 24 26 23 25 33 33 32 34 30 31 24 1...

Page 167: ...9 42 mm 30 Bolt 1 M6 12 mm 31 Holder 1 32 Cooling water hose 1 33 Vapor gas hose 2 34 Check valve 1 S6P25840E 1 2 3 4 5 6 7 8 9 11 16 15 10 14 16 13 12 19 17 18 29 27 28 19 22 21 28 27 24 26 23 25 33...

Page 168: ...55 mm 4 Crankcase assembly 1 5 Main bearing 3 6 Main bearing 1 7 Oil seal 1 Not reusable 8 Crankshaft 1 9 Main bearing 4 10 Thrust bearing 2 11 O ring 2 Not reusable 12 O ring 1 Not reusable 13 Oil s...

Page 169: ...1 20 Bolt 4 M6 40 mm 21 Bolt 2 M6 20 mm 22 Plug 1 23 O ring 1 Not reusable 24 Gasket 2 Not reusable 25 Thermostat cover 1 26 Anode 2 27 Thermoswitch 2 28 Bolt 4 M6 16 mm 29 Bolt 4 M6 25 mm 30 Thermos...

Page 170: ...keep the bearings in the order as they were removed Mark each piston with an identification number a of the corresponding cylinder Mark each connecting rod and connecting rod cap on the side facing up...

Page 171: ...by referring to the specified values if replacing the piston the piston rings as a set the cylinder block or all parts Checking the piston ring 1 Check the piston ring dimensions of B and T Replace th...

Page 172: ...as a set if out of specification Checking the piston pin boss bore 1 Measure the piston pin boss bore Replace the piston if out of specification Piston ring end gap a reference data Top ring 0 15 0 3...

Page 173: ...eplace the connect ing rod assembly if out of specification Checking the connecting rod big end side clearance 1 Measure the connecting rod big end side clearance a Piston pin boss bore 21 017 21 031...

Page 174: ...pper bearing into the con necting rod 1 and the lower bearing into the connecting rod cap 2 NOTE Install the connecting rod bearings in their original positions Insert the projection a of each bearing...

Page 175: ...ecting rod cap bolts when checking the oil clearance Do not turn the connecting rod until the crankpin oil clearance measurement has been completed Make a mark c on the connecting rod cap bolts connec...

Page 176: ...ch 3 Install half of the main bearings 1 and the crankshaft 2 into the cylinder block 3 NOTE Install the bearings in their original posi tions Insert the projection a of each bearing into the slots in...

Page 177: ...k b on the crankcase and crankcase bolts and then tighten crank case bolts 1 F 90 from the mark 8 Gently remove the crankcase and then measure the width of the compressed Plastigauge PG 1 on each cran...

Page 178: ...2 2 87 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 86 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 85 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 84 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2...

Page 179: ...all new oil seals into the oil pump housing 3 Install a new oil seal into the oil pump housing 4 Install a new gasket 5 and then tighten the screws 7 to the specified torque 5 Install a new oil seal 6...

Page 180: ...h the 2R mark d of the second ring and the R mark d of the top ring facing upward 3 Offset the piston ring end gaps as shown CAUTION Do not scratch the pistons or break the piston rings NOTE After ins...

Page 181: ...ting the edge g of the drive sprocket NOTE Apply engine oil to the inner oil seal and the thrust bearings before installation Do not get any engine oil to the drive sprocket 7 Install half of the main...

Page 182: ...r tightening the crankcase bolts check that the crankshaft rotates smoothly 10 Install the piston with the UP mark on the piston crown facing towards the fly wheel magnet NOTE Apply engine oil to the...

Page 183: ...aft CAUTION Before installing the oil pump be sure to fill it with engine oil through the oil pas sage p NOTE When installing the oil pump install it so that the oil seal does not get damaged 13 Insta...

Page 184: ...72 5 mm 2 9 in oil filter wrench NOTE Apply a thin coat of engine oil to the O ring of the new oil filter before installation 17 Fasten the cooling water hose G vapor gas hoses and check valve H usin...

Page 185: ...ith white tape b of the oil pressure sensor lead is in the position as shown NOTE Do not fasten the PTT relay lead 5 with the plastic tie 6 4 Install the junction box onto the power unit 5 Connect the...

Page 186: ...onto the ECM bracket and fasten it at the white tape e 10 Check that the wiring harness hoses and the other parts do not interfere with any moving parts Installing the power unit 1 Retract the port a...

Page 187: ...sor coupler 9 isolator cou pler 0 PTT switch coupler A 10 pin main harness coupler B and then install them onto the brackets T R Power unit mounting bolt 3 and 4 42 N m 4 2 kgf m 31 0 ft lb T R Apron...

Page 188: ...positive battery cable J and negative battery cable K along the bot tom of the bottom cowling a NOTE To wire the battery cables see Chapter 8 Wiring harness routing 13 Connect the fuel hose 14 Install...

Page 189: ...To adjust the shift cable and throttle cable see Chapter 3 Adjusting the throttle cable and Checking the gear shift oper ation 17 Install the starboard intake manifold NOTE To install the intake manif...

Page 190: ...rive shaft 6 14 Disassembling the drive shaft housing 6 14 Disassembling the forward gear 6 14 Disassembling the lower case 6 14 Checking the pinion and forward gear 6 15 Checking the bearing 6 15 Che...

Page 191: ...shaft housing 6 45 Disassembling the reverse gear 6 45 Disassembling the lower case 6 45 Checking the pinion and reverse gear 6 46 Checking the bearing 6 46 Checking the drive shaft 6 46 Checking the...

Page 192: ...t 1 2 Plate 1 3 Rubber seal 1 4 Check screw 1 5 Gasket 2 Not reusable 6 Bolt 7 M10 45 mm X transom model 7 Drain screw 1 8 Grommet 1 9 Bolt 1 M10 45 mm 10 Bolt 1 M10 70 mm X transom model 11 Spacer 1...

Page 193: ...6 No Part name Q ty Remarks 18 Extension 1 19 Rubber seal 1 20 Dowel 2 21 Rubber seal 1 22 Stud bolt 6 M10 190 mm 23 Bolt 1 M10 200 mm 24 Bolt 1 M10 174 mm 25 Nut 6 26 Spring washer 6 27 Washer 6 Lowe...

Page 194: ...le 3 Oil seal housing 1 4 O ring 1 Not reusable 5 Bolt 3 M6 20 mm 6 Seal 1 7 Woodruff key 1 8 Bolt 4 M8 45 mm 9 Water pump housing 1 10 O ring 1 Not reusable 11 Insert cartridge 1 12 O ring 1 Not reus...

Page 195: ...disconnect the battery cables from the battery and the clip from the engine stop lanyard switch Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning...

Page 196: ...the neutral position and then remove the shift rod assembly 5 Checking the water pump and shift rod 1 Check the water pump housing Replace if there is deformation 2 Check the impeller and insert cartr...

Page 197: ...r seal 1 4 Shift rod joint 1 5 Ball 2 6 Slider 1 7 Shift plunger 1 8 Dog clutch 1 9 Cross pin 1 10 Spring 1 11 Propeller shaft 1 12 Shim 1 13 Reverse gear 1 14 Reverse gear shim 15 Ball bearing 1 Not...

Page 198: ...ks 18 Dowel 1 Not reusable 19 Grease nipple 1 20 Rubber seal 1 21 O ring 1 Not reusable 22 Needle bearing 1 23 Oil seal 2 Not reusable 24 Ring 1 25 Bolt 2 M8 20 mm 26 Bolt 2 M8 33 mm 27 Washer 2 28 Co...

Page 199: ...ng the propeller shaft assembly 1 Remove the spring 1 and then remove the cross pin 2 dog clutch 3 shift plunger 4 slider 5 and shift rod joint 6 Disassembling the propeller shaft housing 1 Remove the...

Page 200: ...ng the propeller shaft 1 Check the propeller shaft Replace if bent or worn 2 Measure the propeller shaft runout 3 Check the dog clutch shift rod joint and slider Replace if cracked or worn Assembling...

Page 201: ...an oil seal halfway into the propeller shaft housing then the other oil seal 3 Install the new ball bearing into the pro peller shaft housing NOTE Install the ball bearing with the manufacture identif...

Page 202: ...ct the reverse gear shim s if replacing the propeller shaft housing lower case or ball bearing Select the propeller shaft shim if replacing the reverse gear To select the shims see Shimming regu lar r...

Page 203: ...ing 1 4 Washer 1 5 Cover 1 6 Oil seal 2 Not reusable 7 Bolt 4 M8 25 mm 8 Drive shaft housing 1 9 Needle bearing 1 10 O ring 1 Not reusable 11 Pinion shim 12 Thrust bearing 1 13 Lower case 1 14 Needle...

Page 204: ...LOWR Lower unit 6 13 6P23H11 6 No Part name Q ty Remarks 18 Forward gear shim 19 Taper roller bearing assembly 1 Not reusable 20 Forward gear 1...

Page 205: ...om the forward gear using a press CAUTION Do not reuse the bearing always replace it with a new one Disassembling the lower case 1 Remove the taper roller bearing outer race and shim s NOTE Install th...

Page 206: ...Checking the drive shaft 1 Check the drive shaft Replace if bent or worn 2 Measure the drive shaft runout Checking the lower case 1 Check the skeg and torpedo Replace the lower case if cracked or dama...

Page 207: ...m into the drive shaft housing to the specified depth NOTE Install an oil seal halfway into the drive shaft housing then the other oil seal Installing the drive shaft 1 Install the forward gear into t...

Page 208: ...her and pinion nut and then tighten the nut to the specified torque NOTE To install the pinion nut push down on the drive shaft 5 Tighten the drive shaft housing bolts NOTE Apply LOCTITE 572 to the dr...

Page 209: ...5 and bolts 6 6 Install the water pipe and rubber seals Installing the water pump and shift rod 1 Install the shift rod assembly 1 NOTE Check the gear shift to the neutral position when installing th...

Page 210: ...d cover D CAUTION Do not turn the drive shaft counterclock wise otherwise the water pump impeller may be damaged NOTE When installing the pump housing apply grease to the inside of the housing and the...

Page 211: ...nd then tighten the lower case mounting bolts nuts 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 U transom model Shif...

Page 212: ...the propeller with your hands when loosening or tightening it Be sure to disconnect the battery cables from the battery and the clip from the engine stop lanyard switch Put a block of wood between th...

Page 213: ...1 2 3 4 5 6 7 8 9 Shimming regular rotation model 6 A B F R P S6P26270 B4 T3 B3 65 0 T1 B1 39 4 41 0 T2 B2 B5 A1 A2 A3 C1 C3 T4 C2 Drive shaft and lower case regular rotation model Shimming regular ro...

Page 214: ...is at the center of the hole Tighten the wing nuts another 1 4 of a turn after they contact the plate 2 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure...

Page 215: ...im s T3 as follows Example If T3 is 0 70 mm then the pinion shim is 0 68 mm If T3 is 0 74 mm then the pinion shim is 0 72 mm Selecting the forward gear shim 1 Turn the taper roller bearing outer race...

Page 216: ...s T1 as follows Example If T1 is 0 45 mm then the forward gear shim is 0 42 mm If T1 is 0 40 mm then the forward gear shim is 0 38 mm Selecting the reverse gear shim 1 Turn the ball bearing 1 2 or 3 t...

Page 217: ...2 is 19 92 mm and R is 1 and A is 3 then T2 21 00 1 100 3 100 19 92 mm 21 00 0 01 0 03 19 92 mm 1 10 mm If M2 is 19 92 mm and R is 3 and A is 5 then T2 21 00 3 100 5 100 19 92 mm 21 00 0 03 0 05 19 92...

Page 218: ...culate the value C1 2 Measure the reverse gear height M3 M4 as shown and then calculate the value C2 3 Measure the propeller shaft spline width C3 4 Select the propeller shaft shim T4 Digital caliper...

Page 219: ...opeller shaft NOTE Tighten the center bolt while turning the drive shaft until the drive shaft can no longer be turned Calculation formula Propeller shaft shim thickness T4 79 8 C1 C2 C3 Calculated nu...

Page 220: ...the spacer 8 without the washer 9 then the washer 0 as shown NOTE Tighten the propeller nut A while turning the drive shaft until the drive shaft can no longer be turned 9 Slowly turn the drive shaft...

Page 221: ...al service tools and then install the water pump assembly Reverse gear backlash Shim thickness Less than 0 32 mm 0 0126 in To be decreased by 0 49 M 0 71 More than 0 65 mm 0 0256 in To be increased by...

Page 222: ...it 1 2 Plate 1 3 Rubber seal 1 4 Check screw 1 5 Gasket 2 Not reusable 6 Bolt 7 M10 45 mm X transom model 7 Drain screw 1 8 Grommet 1 9 Bolt 1 M10 45 mm 10 Bolt 1 M10 70 mm X transom model 11 Spacer 1...

Page 223: ...6 No Part name Q ty Remarks 18 Extension 1 19 Rubber seal 1 20 Dowel 2 21 Rubber seal 1 22 Stud bolt 6 M10 190 mm 23 Bolt 1 M10 200 mm 24 Bolt 1 M10 174 mm 25 Nut 6 26 Spring washer 6 27 Washer 6 Low...

Page 224: ...ble 3 Oil seal housing 1 4 O ring 1 Not reusable 5 Bolt 3 M6 20 mm 6 Seal 1 7 Woodruff key 1 8 Bolt 4 M8 45 mm 9 Water pump housing 1 10 O ring 1 Not reusable 11 Insert cartridge 1 12 O ring 1 Not reu...

Page 225: ...disconnect the battery cables from the battery and the clip from the engine stop lanyard switch Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning...

Page 226: ...the neutral position and then remove the shift rod assembly 5 Checking the water pump and shift rod 1 Check the water pump housing Replace if there is deformation 2 Check the impeller and insert cart...

Page 227: ...seal 1 4 Shift rod joint 1 5 Ball 2 6 Slider 1 7 Shift plunger 1 8 Dog clutch 1 9 Cross pin 1 10 Spring 1 11 Forward gear 1 12 Forward gear shim 13 Ring nut 1 14 Claw washer 1 15 Taper roller bearing...

Page 228: ...Not reusable 20 Propeller shaft housing 1 21 Dowel 1 Not reusable 22 Grease nipple 1 23 Rubber seal 1 24 O ring 1 Not reusable 25 Needle bearing 1 26 Oil seal 2 Not reusable 27 Ring 1 28 Bolt 2 M8 20...

Page 229: ...ing 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 2 Remove the forward gear and forward gear shim s from the p...

Page 230: ...g 1 Clean the propeller shaft housing using a soft brush and cleaning solvent and then check it Replace if cracked or damaged 2 Check the teeth and dogs of the forward gear Replace if cracked or worn...

Page 231: ...to the specified depth NOTE Install an oil seal halfway into the propeller shaft housing then the other oil seal 3 Install the original shim s 5 and thrust bearing 6 with the propeller shaft into the...

Page 232: ...tighten the ring nut to the specified torque 7 Install the original shim s B forward gear C and dog clutch D using a press NOTE Be sure to select the forward gear shim s if replacing the propeller sha...

Page 233: ...H11 6 42 1 2 3 4 5 6 7 8 9 8 Install the shift plunger E and slider F into the propeller shaft and then install the cross pin G and spring H S69J6445 F G H E Propeller shaft housing counter rotation m...

Page 234: ...ty Remarks 1 Drive shaft 1 2 Thrust bearing 1 3 Spring 1 4 Washer 1 5 Cover 1 6 Oil seal 2 Not reusable 7 Bolt 4 M8 25 mm 8 Drive shaft housing 1 9 Needle bearing 1 10 O ring 1 Not reusable 11 Pinion...

Page 235: ...6 No Part name Q ty Remarks 18 Reverse gear shim 19 Retainer 1 20 Needle bearing 1 21 Thrust bearing 1 22 Circlip 1 Not reusable 23 Needle bearing 1 Not reusable 24 Reverse gear 1 Drive shaft and low...

Page 236: ...circlip 1 from the reverse gear 2 2 Remove the needle bearing from the reverse gear using a chisel CAUTION Do not reuse the bearing always replace it with a new one Disassembling the lower case 1 Remo...

Page 237: ...ng 1 Check the bearings Replace if pitted or if there is rumbling Checking the drive shaft 1 Check the drive shaft Replace if bent or worn 2 Measure the drive shaft runout Checking the lower case 1 Ch...

Page 238: ...bearing contains 24 rollers Assembling the reverse gear 1 Install the new needle bearing into the reverse gear to the specified depth 2 Install the new circlip 3 into the reverse gear 4 Assembling th...

Page 239: ...into the lower case 3 Install the drive shaft housing 1 thrust bearing 2 and original shim s 3 onto the drive shaft 4 NOTE Be sure to select the pinion shim s if replacing the thrust bearing drive sh...

Page 240: ...utch to the neutral position as shown 2 Apply grease to the new O rings and pro peller shaft housing 3 Install the dowel and propeller shaft housing assembly into the lower case 4 Install the washer a...

Page 241: ...ll a new gasket 2 the outer plate cartridge 3 and dowels 4 3 Install the Woodruff key into the drive shaft 4 Align the groove on the impeller 5 with the Woodruff key 6 and then install the impeller on...

Page 242: ...p housing Installing the lower unit WARNING When installing the lower unit with the power unit installed be sure to suspend the outboard motor If the outboard motor is not suspended it can fall sudden...

Page 243: ...to disconnect the battery cables from the battery and the clip from the engine stop lanyard switch Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turni...

Page 244: ...LOWR Lower unit 6 53 6P23H11 Shimming counter rotation model 6 A B F R P S6P26300 B4 T3 B3 65 0 A3 T1 B1 38 4 A1 T2 B8 B5 A5 A4 A2 T 4 B7 B6 47 5...

Page 245: ...haft so that the shaft is at the center of the hole Tighten the wing nuts another 1 4 of a turn after they contact the plate 2 2 Install the pinion and pinion nut and then tighten the nut to the speci...

Page 246: ...0 74 mm 6 Select the pinion shim s T3 as follows Example If T3 is 0 70 mm then the pinion shim is 0 78 mm If T3 is 0 74 mm then the pinion shim is 0 72 mm Selecting the reverse gear shim 1 Turn the th...

Page 247: ...5 100 29 94 mm 30 60 0 05 29 94 mm 0 71 mm If M1 is 29 94 mm and F is 4 then T1 30 60 4 100 29 94 mm 30 60 0 04 29 94 mm 0 70 mm 3 Select the reverse gear shim s T1 as follows Example If T1 is 0 71 m...

Page 248: ...eller shaft housing dimension from standard The R mark a is stamped on the trim tab mounting surface of the lower case and the A mark b is stamped on the pro peller shaft housing in 0 01 mm units If t...

Page 249: ...elect the shim thickness T 4 by using the specified measurement s and the calcula tion formula Measure the taper roller bearing at 3 points to find the height average 2 Install the thrust bearing 4 on...

Page 250: ...ollows Example If T4 is 0 79 mm then the propeller shaft shim is 0 78 mm If T4 is 0 90 mm then the propeller shaft shim is 0 88 mm 5 Calculate and select the propeller shaft shim thickness T 4 as show...

Page 251: ...shaft can no longer be turned 4 Install the backlash indicator onto the drive shaft 22 4 mm 0 88 in in diame ter and then install the dial gauge NOTE Install the dial gauge so that the plunger a conta...

Page 252: ...shaft counterclockwise approximately 30 12 Turn the shift rod in direction c to the reverse position using the shift rod push arm 13 Slowly turn the drive shaft clockwise and counterclockwise and mea...

Page 253: ...install the water pump assembly Reverse gear backlash Shim thickness Less than 0 45 mm 0 0177 in To be decreased by 0 62 M 0 71 More than 0 78 mm 0 0307 in To be increased by M 0 62 0 71 Available sh...

Page 254: ...Installing the steering arm 7 14 Clamp bracket and swivel bracket 7 16 Removing the PTT unit 7 18 Removing the clamp bracket 7 19 Installing the clamp bracket 7 19 Installing the PTT unit 7 19 Adjusti...

Page 255: ...g the tilt ram 7 41 Assembling the trim ram 7 42 Installing the tilt cylinder 7 42 Installing the trim ram 7 42 Installing the PTT motor 7 43 Installing the reservoir 7 44 Installing the tilt ram 7 44...

Page 256: ...o Part name Q ty Remarks 1 Bracket 1 2 Shift cut switch 1 3 Bracket 1 4 Neutral switch 1 5 Screw 2 4 16 mm 6 Plate 1 7 Spring 1 8 Bushing 2 9 Grease nipple 1 10 Bolt 1 11 Bolt 2 M6 35 mm 12 Clamp 1 13...

Page 257: ...otter pin 1 Not reusable 20 Bushing 2 21 Bolt 1 M6 30 mm 22 Bracket 1 23 Ball 1 24 Spring 1 25 Bolt 1 26 Shift rod 1 27 O ring 1 Not reusable 28 Grommet 1 29 Screw 2 6 20 mm 30 Adapter 1 31 Hose joint...

Page 258: ...rks 1 Bottom cowling 1 2 Rubber seal 1 3 Cowling lock lever 3 4 Bushing 6 5 Plate 3 6 Bolt 11 M6 20 mm 7 Bolt 7 M6 30 mm 8 Wave washer 3 9 Lever 3 10 Bolt 3 M6 20 mm 11 Spring 3 12 Hook 3 13 Bracket 1...

Page 259: ...ame Q ty Remarks 18 Collar 4 19 Grommet 1 20 Bolt 4 M8 35 mm 21 Cooling water pilot hole 1 22 Wire lead extension 1 Counter rotation model 23 Bracket 2 24 Switch 1 25 Bracket 1 26 Bracket 1 27 Cover 1...

Page 260: ...e assembly 1 2 Bolt 2 M14 190 mm 3 Washer 2 4 Washer 2 5 Washer 2 6 Upper mount 2 7 Bracket 1 8 Bolt 3 M10 45 mm 9 Bolt 4 M10 45 mm 10 Mount housing 2 11 Bolt 2 M14 205 mm 12 Lower mount 2 13 Engine o...

Page 261: ...0 mm 19 Dowel 1 20 Adapter 1 21 Bolt 1 M6 30 mm 22 Drive shaft bushing 1 23 Circlip 1 24 Nut 4 25 Circlip 1 26 Bushing 2 27 O ring 1 Not reusable 28 Bushing 1 29 Washer 2 30 Steering yoke 1 31 Washer...

Page 262: ...1 8 Bolt 2 M8 30 mm 9 Rubber seal 1 10 Rubber seal 1 11 Screw 2 6 16 mm 12 Baffle plate 1 13 Rubber seal 1 14 Dowel 2 15 Upper case 1 16 Rubber seal 1 S6P27040E A A A A LT 572 LT LT 271 LT 572 LT A A...

Page 263: ...e 3 Dowel 2 4 Lower exhaust guide 1 5 Gasket 1 Not reusable 6 Oil strainer 1 7 Collar 3 8 Bolt 3 M6 25 mm 9 Gasket 1 Not reusable 10 Dowel 2 11 Rubber seal 1 12 Oil pan 1 13 Gasket 1 Not reusable 14 E...

Page 264: ...T Bracket unit 7 9 6P23H11 7 No Part name Q ty Remarks 18 Rubber seal 1 19 Gasket 1 Not reusable 20 Plate 1 21 Pipe 1 22 Rubber seal 1 23 Gasket 1 Not reusable 24 Dowel 2 25 Muffler 1 26 Bolt 10 M8 35...

Page 265: ...n remove the upper case Disassembling the upper case 1 Remove the oil pan assembly from the upper case 2 Remove the circlip as shown 3 Remove the drive shaft bushing Checking the drive shaft bushing 1...

Page 266: ...residue Assembling the oil pan 1 Install the dowels new gasket 1 and lower exhaust guide 2 onto the upper exhaust guide 3 2 Install the new gasket oil strainer 4 and bolts and then tighten the bolts...

Page 267: ...ipe positioned as shown Assembling the upper case 1 Install the drive shaft bushing into the upper case and then install the circlip NOTE After installing the drive shaft bushing apply grease to the i...

Page 268: ...acket C and then tighten the bolts D to the specified torque 8 Install the lower mounts E and mount housings F Installing the upper case 1 Install the upper and lower mounting bolts into the swivel br...

Page 269: ...ng arm from the swivel bracket by pulling the arm off the bracket Installing the steering arm 1 Install the washer 1 and bushing 2 onto the steering arm 3 2 Place the swivel bracket 4 in an upright po...

Page 270: ...teering yoke 9 onto the steering arm 3 making sure that they are both facing in the same direction a and b are aligned 5 Install the circlip 0 6 Inject grease into the grease nipple until grease comes...

Page 271: ...olt 8 M10 45 mm 4 Ground lead 1 5 Bushing 2 6 Washer 2 7 Bushing 4 8 Friction plate 2 9 Screw 4 6 10 mm 10 Screw 2 6 15 mm 11 Trim sensor 1 12 Grease nipple 6 13 Clamp bracket STBD 1 14 Self locking n...

Page 272: ...in 1 19 Bolt 2 M6 10 mm 20 Spring 1 21 Spring holder 1 22 Tilt stop lever PORT 1 23 Shaft 1 24 Trim stopper 2 25 Tilt stop lever STBD 1 26 Circlip 1 27 Nut 2 28 Swivel bracket 1 29 PTT unit 1 30 Groun...

Page 273: ...evere injury NOTE If the PTT does not operate turn the manual valve counter clockwise and tilt the outboard motor up manually 2 Remove the anode 2 and the PTT unit bolts 3 8 bolts 3 Loosen the self lo...

Page 274: ...ecting the ground lead 2 installing the through tube 3 then tightening the self locking nut 4 temporary Installing the PTT unit 1 Fully tilt the outboard motor up and then support it with the tilt sto...

Page 275: ...8 Fasten the PTT motor lead and trim sen sor lead with the plastic ties 9 and then install the holder 0 9 Inject grease into all grease nipples until grease comes out from the bushings a Adjusting th...

Page 276: ...of specification 6 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 th...

Page 277: ...6 M8 20 mm 4 O ring 1 Not reusable 5 Reservoir cap 1 M12 10 mm 6 O ring 1 Not reusable 7 Sheet 1 8 Filter 1 9 Spacer 1 10 PTT motor assembly 1 11 O ring 1 Not reusable 12 Joint 1 13 O ring 1 Not reus...

Page 278: ...BRKT Bracket unit 7 23 6P23H11 7 No Part name Q ty Remarks 18 Bushing 2 19 Pipe 1 20 Pipe 1 21 Spacer 1 22 O ring 1 Not reusable 23 Adapter 1...

Page 279: ...sure the hydraulic pres sure 6 Reverse the PTT motor leads between the battery terminals to fully extend the rams 7 Remove the special service tools 8 Install the pipe joints 1 and then tight ening th...

Page 280: ...ls to fully retract the rams 14 Remove the special service tools 15 Install the pipe joints 3 and then tight ening them to the specified torque 16 After measuring the hydraulic pressure connect the PT...

Page 281: ...g the reser voir cap otherwise fluid can spurt out from the unit due to internal pressure NOTE If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole when...

Page 282: ...23H11 PTT motor 7 No Part name Q ty Remarks 1 Stator 1 2 Bolt 2 M5 12 mm 3 Wave washer 1 4 Washer 1 5 Bearing 2 6 Armature 1 7 Brush 4 8 Spring 4 9 PTT motor base assembly 1 10 O ring 1 Not reusable 1...

Page 283: ...ews 1 then the stator 2 CAUTION Do not allow grease or oil to contact the commutator NOTE Place a clean cloth over the end of the arma ture shaft hold it with a pair of pliers and then carefully slide...

Page 284: ...h Replace if below specification 7 Check the motor base Replace if cracked or damaged 8 Check the bearing and oil seal Replace if damaged or worn Assembling the PTT motor 1 Install the new oil seal 1...

Page 285: ...der as shown 4 Install the bearing 9 to the armature 0 5 Push the brushes 7 into the holders and then install the armature 0 6 Install the wave washer A and washer B into the stator C 7 Install the ne...

Page 286: ...lt 3 M5 40 mm 3 Plate 1 4 Filter 1 5 Plate 1 6 Valve lock screw 2 7 Down relief spring 1 8 Valve support pin 1 9 Relief valve seal 1 10 Up relief spring 1 11 Valve support pin 1 12 O ring 1 Not reusab...

Page 287: ...eturn spring 2 19 Shuttle piston 1 20 Driven gear 1 21 Drive gear 1 22 Ball 2 23 Gear housing 2 1 24 Manual release spring 1 25 Pin 1 26 Ball 4 27 Valve pin 2 28 Spring 2 29 Spacer 2 30 O ring 2 Not r...

Page 288: ...t 2 M5 25 mm 36 O ring 2 Not reusable 37 Spacer 2 38 Filter 2 39 Gear pump assembly 1 40 Relief valve seat 1 41 O ring 1 Not reusable 42 Down relief valve 1 43 Up relief valve 1 44 Down absorber valve...

Page 289: ...Remove the relief valve seal 3 and ball 4 NOTE Before removing the relief valves measure and note the screw height a and screw depth b 3 Remove the bracket 5 then the balls 6 4 Remove the gear housing...

Page 290: ...pump housing 1 Check the gear pump housing Replace if scratched Checking the reservoir 1 Check the reservoir Replace if cracked or if there is corrosion Checking the filter 1 Check gear pump filters...

Page 291: ...pump I by installing the bolts J then tightening them to the specified torque 6 Install the manual valve K 7 Check the hydraulic pressure NOTE To check the hydraulic pressure see Chap ter 7 Checking t...

Page 292: ...reusable 3 Trim cylinder end screw 2 4 O ring 2 Not reusable 5 Trim ram assembly 2 6 Trim piston 2 7 Backup ring 2 8 O ring 2 Not reusable 9 Spring 2 10 Adapter 2 11 Circlip 2 12 Tilt piston assembly...

Page 293: ...eusable 19 Backup ring 1 20 O ring 1 Not reusable 21 Spring 1 22 Adapter 1 23 Tilt piston 1 24 O ring 1 Not reusable 25 Backup ring 1 26 Ball 5 27 Pin 5 28 Spring 5 29 Bolt 1 M6 10 mm 30 Free piston 1...

Page 294: ...piston 3 WARNING Never look into the tilt cylinder opening when removing the free piston The free piston and PTT fluid can be forcefully expelled out NOTE Be sure to cover the opposite end of the tilt...

Page 295: ...inder 2 Replace if cracked or if there is corro sion 2 Check the inner surface of the PTT body 1 and tilt cylinder 2 Replace if scratched 3 Check the outer surface of the tilt piston 3 trim piston 4 a...

Page 296: ...r 7 and tilt piston 8 to the tilt ram 9 3 Hold the tilt piston in a vise using the special service tool 0 on both sides 4 Tighten the tilt ram 9 to the specified torque 5 Install the new O ring B and...

Page 297: ...e new O ring 1 to the free pis ton 2 2 Push the free piston 2 into the tilt cylin der 3 until it bottoms out 3 Install the tilt cylinder 3 to the PTT body 4 4 Install pipes 5 and 6 and then tighten th...

Page 298: ...fluid may spurt out from the unit Installing the PTT motor 1 Install the joint 1 into the gear pump 2 Fill the pump housing with the recom mended fluid to the correct level a as shown 3 Remove all of...

Page 299: ...s shown 2 Add a small amount of the recommended fluid through the PTT body hole b as shown 3 Install the tilt piston assembly into the tilt cylinder and then tighten the tilt cylinder end screw 1 to t...

Page 300: ...T motor leads 2 to the battery terminals to fully retract the rams 7 Reverse the PTT motor leads between the battery terminals to fully extend the rams NOTE Repeat this procedure so that the rams go u...

Page 301: ...outboard motor could sud denly lower if the PTT unit should lose fluid pressure 5 Remove the reservoir cap 1 and then check the fluid level in the reservoir NOTE If the fluid is at the correct level a...

Page 302: ...ky blue Sb lead to the positive battery terminal and the terminal 4 lead to the negative battery terminal as shown 5 Check for continuity between terminals 2 and 3 Replace the PTT relay if there is no...

Page 303: ...e trim sensor 1 Measure the trim sensor resistance Replace if out of specification NOTE Turn the lever 1 and measure the resistance as it gradually changes Trim sensor resistance Pink P Black B 9 11 a...

Page 304: ...cking the intake air pressure sensor 8 17 Checking the engine temperature sensor 8 18 Checking the thermoswitch 8 18 Checking the shift cut switch 8 19 Checking the neutral switch 8 19 Checking the kn...

Page 305: ...vapor shut off valve 8 32 Starting system 8 32 Checking the fuse 8 32 Checking the starter relay 8 32 Starter motor 8 34 Disassembling the starter motor 8 36 Checking the starter motor pinion 8 36 Ch...

Page 306: ...make sure that the battery is fully charged The YDIS requires that you use an exclu sive communication cable and CD ROM to connect to a computer For a description of the communication cable and CD ROM...

Page 307: ...ith the recommended digital circuit tester Connect the positive pin of the peak voltage adapter B to the positive terminal of the dig ital tester and the negative pin to the nega tive terminal When me...

Page 308: ...sembly 3 High pressure fuel pump 4 Low pressure fuel pump 5 Intake air pressure sensor 6 Oil control valve PORT 7 Fuel injector 8 Ignition coil 9 Cam position sensor PORT IN 0 Cam position sensor PORT...

Page 309: ...l 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 PT...

Page 310: ...t timing ECM 3 Fuse 20 A engine start switch PTT switch 4 Fuse 30 A starter relay 5 Fuse 5 A low pressure fuel pump 6 Fuse 15 A high pressure fuel pump relay 7 Fuse 80 A starting battery 8 Fuse 80 A a...

Page 311: ...ition 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 w...

Page 312: ...ol valve PORT 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 0 Shift cut switch A Neutral switch...

Page 313: ...to the holder Fasten the engine temperature sensor lead and thermoswitch lead on the hook of the wiring harness guide Install the engine temperature sensor coupler onto the wiring harness guide Fasten...

Page 314: ...is short Fasten the fuel injector lead 2 and then fasten the fuel injector lead 4 and 6 to the clip Fasten the fuel injector harness using a plastic tie Fasten the fuel injector harness to the fuel ra...

Page 315: ...tor coil lead 3 Sub wiring harness 4 Rectifier Regulator lead 5 Starter motor lead 6 PTT motor lead 7 Oil pressure sensor lead 8 Isolator lead S6P28330E 1 2 3 1 4 2 1 4 3 3 1 5 4 2 2 45 1 3 2 6 8 7 4...

Page 316: ...re sensor lead sub wiring harness and isolator lead to the holder Route the oil pressure sensor lead isolator lead and PTT motor leads through the guide Align the white tape on the oil pressure sensor...

Page 317: ...s not necessary to fasten the lead if its length is short Fasten the fuel injector lead 1 and then fasten the fuel injector lead 3 and 5 to the clip Fasten the fuel injector harness using a plastic ti...

Page 318: ...ng a plastic tie Fasten the cam position sensor lead PORT IN to the holder Install the clip of knock sensor coupler to the hole of the ECM bracket Fasten the ignition coil lead 5 and cam position sens...

Page 319: ...sensor lead 7 Joint connector Fasten the fuel injector lead and quick connector to the holder Fasten the fuel injector lead and vapor gas hose to the holder Face the white mark on the wiring harness...

Page 320: ...ark can also be checked using the Stationary test of the YDIS Checking the ignition coil input voltage 1 Disconnect the ignition coil coupler 2 Turn the engine start switch to ON 3 Measure the voltage...

Page 321: ...gap 5 Tighten the screws 1 and then check the crank position sensor air gap Adjust again if out of specification Checking the intake air temperature sensor 1 Measure the ambient temperature 2 Connect...

Page 322: ...a container of water and slowly heat the water 8 Measure the intake air temperature sen sor resistance Replace if out of specifi cation Checking the intake air pressure sensor 1 Disconnect the intake...

Page 323: ...sensor in a container of water and slowly heat the water 5 Measure the engine temperature sensor resistance Replace if out of specifica tion Checking the thermoswitch 1 Disconnect the thermoswitch co...

Page 324: ...ness if out of specifi cation 4 To check the shift cut switch measure the resistance of the shift cut switch at position a Replace if out of specifica tion 5 Check the shift cut switch for continuity...

Page 325: ...ds to the sen sor coupler and ground 2 Measure the knock sensor resistance Check the installation ground state of the knock sensor if out of specification NOTE To check the installation of the knock s...

Page 326: ...ess or replace the engine stop lanyard switch if out of speci fication ECM and electronic throttle valve control system 8 Checking the main relay and electronic throttle valve relay 1 Remove the main...

Page 327: ...hown 8 Turn the engine start switch to ON 9 Measure the voltage between terminals 8 and 9 as shown Checking the ECM circuit 1 Disconnect the ECM couplers a and b 2 Check for continuity between the ECM...

Page 328: ...t the ECM coupler a and then turn the engine start switch to ON 8 Check the voltage at ECM coupler termi nals f 27 and 34 wiring harness end Check the fuse relay and wiring harness if below specificat...

Page 329: ...loca tion of the red green terminals 79 and 80 of the coupler b may be switched 7 Connect the ECM couplers and fuse holder couplers and then disconnect the electronic throttle valve coupler Wiring ha...

Page 330: ...tinuity between the terminal 1 and 2 Checking the accelerator position sensor circuit 1 Disconnect the ECM coupler a 2 Disconnect the accelerator position sen sor coupler b 3 Check the wiring harness...

Page 331: ...stopper 2 when the remote control lever is at the fully closed position NOTE To adjust the throttle cable see Chapter 3 Adjusting the throttle cable 3 Check that the remote control lever is in the fu...

Page 332: ...ds to the accelera tor position sensor terminals and mea sure the resistance at the fully closed position 10 Measure the resistance at the fully open position NOTE Be sure to contact the accelerator l...

Page 333: ...ess end Check the wiring harness if below specification 4 Turn the engine start switch to OFF PORT EX STBD IN DC V AFT 1 2 S6P28665EU DC V AFT PORT IN 1 2 S6P28885EU Cam position sensor input voltage...

Page 334: ...he sensor Replace the cam position sensor if out of specification NOTE Be sure to move the screwdriver in front of the cam position sensor in direction as shown otherwise the correct output voltage me...

Page 335: ...place the oil control valve if out of specification 6 Connect the battery leads to the oil con trol valve terminals and then check the operation of the spool valve Replace the oil control valve if it...

Page 336: ...re fuel pump coupler 1 and high pressure fuel pump coupler 2 3 Measure the resistance of the fuel pump motors Checking the high pressure fuel pump relay 1 Remove the high pressure fuel pump relay 1 an...

Page 337: ...termi nals 1 4 Measure resistance of vapor shut off valve Starting system 8 Checking the fuse 1 Check the fuses for continuity Replace if there is no continuity NOTE For the location of the fuse see F...

Page 338: ...he termi nal 2 and ground as shown 3 Connect the tester leads to terminals 3 and 4 as shown 4 Turn the engine start switch to START position and then measure the voltage Terminal 2 Ground 12 V battery...

Page 339: ...t 2 M6 35 mm 6 Cover assembly 1 7 Bearing 1 8 Clutch assembly 1 9 E clip 1 Not reusable 10 Washer 1 11 Bracket 1 12 Pinion shaft 1 13 Planetary gear 3 14 Outer gear 1 15 Plate 1 16 Armature 1 17 Stato...

Page 340: ...w 2 4 15 mm 24 Bolt 2 M6 120 mm 25 Rubber seal 1 26 Shift lever 1 27 Spring 1 28 Magnet switch assembly 1 29 Nut 1 30 Pinion stopper set 1 31 Washer set 1 32 Starting motor gear assembly 1 33 Brush ho...

Page 341: ...or smooth operation NOTE Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place Checking the armature 1 Check the commutator Clean wi...

Page 342: ...d to the starter motor body CAUTION Do not connect the battery for more than 1 second otherwise the magnet switch can be damaged 4 Check that there is continuity between the magnet switch terminals Re...

Page 343: ...lt age between the coupler that was not mea sured and any coupler 6 Measure the resistance of the stator coil NOTE Select any two of the three couplers leads and measure the resistance between the sel...

Page 344: ...fier Regulator for conti nuity Replace if out of specification NOTE Be sure to set the measurement range a and display the mark b by pushing the SHIFT switch when checking the Rectifier Regulator cont...

Page 345: ...or 9 4 Troubleshooting the power unit 9 5 Troubleshooting the power unit using the YDIS 9 5 Trouble code and checking step 9 7 Troubleshooting the power unit using the diagnostic flash indicator 9 15...

Page 346: ...have been regis tered This allows you to check the outboard motor s record of malfunctions The trouble codes displayed are the same as those described in Trouble code and checking step in this chapte...

Page 347: ...red to the engine speed and the total operating time are displayed This allows you to check the operating status of the engine For the Blue Wlale 250 models you can also save the ECM record data on a...

Page 348: ...or position sensor voltage This item shows the criterion output voltage of the accelerator position sensor This value is used to detect the accelerator position sensor output voltage when the remote c...

Page 349: ...1 2 3 4 5 6 7 8 9 Contents 1 CD ROM software instruction manual 1 2 Adapter 1 3 Communication cable 1 Connecting the communication cable to the outboard motor 1 2 3 S6P29010 3 pin communication couple...

Page 350: ...n checking the input voltage of a part the coupler or connector must be disconnected As a result the ECM determines that the part is disconnected and a trouble code is detected There fore be sure to d...

Page 351: ...ding to throttle opening angle 6 Limp home processing Engine startability Engine idle speed Maximum engine speed Acceleration Symptom Starts Normal 1 Normal 2 Normal 4 A Decreases 3 Poor 5 B Increases...

Page 352: ...re sensor malfunction D 1 Check the engine temperature using the YDIS 9 1 2 Measure the input voltage 8 18 3 Measure the resistance 8 18 17 Knock sensor malfunction C Maximum power decreases 1 Measure...

Page 353: ...ases 1 Check the intake air pressure using the YDIS 9 1 2 Check the vacuum hoses 4 2 3 Measure the input voltage 8 17 4 Check the operation of the intake air pressure sensor 8 17 5 Check the pink gree...

Page 354: ...nuity 8 21 4 Check the white W lead ECM to 10 pin main harness coupler for continuity 1 5 Check the black B lead 10 pin main harness coupler to joint connector to ground for conti nuity 1 45 Shift cut...

Page 355: ...to ECM for continuity 1 4 Measure the output voltage 8 28 5 Check the brim of the camshaft 5 27 6 Check the battery cables and terminals for proper connection 3 15 73 Oil control valve STBD D 1 Check...

Page 356: ...valve motor continuity 8 25 117 118 Electronic throttle valve malfunction J 1 Check the electronic throttle valve circuit 8 23 2 Check the electronic throttle valve relay and fuse 8 21 3 Check the ele...

Page 357: ...1 3 Check the electronic throttle valve circuit 8 23 129 TPS malfunction B 1 Check the TPS output voltage using the YDIS 9 1 2 Check the throttle opening angle using the YDIS 9 1 3 Check the electroni...

Page 358: ...heck the accelerator position sensor circuit 8 25 3 Check the accelerator position sensor resistance 8 26 136 137 Electronic throttle valve malfunction J 1 Check the ECM circuit 8 22 2 Check the elect...

Page 359: ...e battery cables and terminals for proper connection 3 15 2 Check the ECM circuit 8 22 3 Check the electronic throttle valve circuit 8 23 4 Check the electronic throttle valve relay and fuse 8 21 145...

Page 360: ...re any malfunctions Normal condition no defective part or irregular process ing is found Single flash is given every 4 95 sec onds a Light on 0 33 second b Light off 4 95 seconds Trouble code indicati...

Page 361: ...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 This continues until all of the problems are detect...

Page 362: ...attery terminal Check the battery ter minal 3 15 Short open or loose connection in starter motor circuit Check the wiring har ness continuity 1 Starter relay malfunc tion Check the starter relay 8 32...

Page 363: ...arness continuity 1 Fuel not supplied all cylinders High pressure fuel pump does not operate Short open or loose connection in high pressure fuel pump circuit Check the wiring harness continuity 1 Blo...

Page 364: ...igh pressure fuel line malfunction fuel pressure is low Pressure regulator malfunction Check the pressure regulator 4 8 High pressure fuel pump malfunction Check the high pressure fuel pump continuity...

Page 365: ...ody 4 12 4 15 Symptom 2 Cause 1 Cause 2 Checking step Refer to page Incorrect intake cam timing check using the YDIS Variable camshaft timing operation mal function Stuck oil control valve plunger Che...

Page 366: ...leakage from water pump hous ing Check the water pump housing 6 5 6 35 Check the insert cartridge 6 5 6 35 Check the outer plate cartridge 6 5 6 35 Clogged cooling wa ter passage Check the cooling wa...

Page 367: ...onnection of the PTT motor lead Check the PTT mo tor lead 7 28 PTT motor malfunc tion Disassemble and check the PTT mo tor 7 27 Blown fuse Check the fuse 8 5 Loose connection of the battery terminal C...

Page 368: ...fluid leakage Check the PTT unit for leakage 7 22 Clogged fluid pas sage Disassemble and check the PTT unit 7 22 Symptom 2 Cause 1 Cause 2 Checking step Refer to page Remote control box malfunction C...

Page 369: ...the compression pressure 5 1 Checking the connecting rod big end side clearance 5 60 Checking the connecting rod small end inside diameter 5 60 Checking the cooling water passage 3 9 Checking the cool...

Page 370: ...Checking the remote control cable 1 41 Checking the reservoir 7 35 Checking the shift cut switch 8 19 Checking the spark plug 3 7 Checking the starter motor operation 8 38 Checking the starter motor p...

Page 371: ...ng water passage cover 5 50 Installing the cylinder head 5 51 Installing the drive shaft 6 16 6 48 Installing the exhaust cover 5 40 Installing the fuel hose clamp 4 25 Installing the fuel injector 4...

Page 372: ...ile working 1 4 Selecting the connecting rod bearing 5 63 Selecting the forward gear shim 6 24 6 57 Selecting the main bearing 5 64 Selecting the pinion shim 6 23 6 54 Selecting the propeller shaft sh...

Page 373: ...6P23H11 i 5 1 2 3 4 5 6 7 8 9 Index MEMO...

Page 374: ...T EX To remote control switch panel To warning indicator To diagnostic flash indicator special service tool To personal computer for diagnosis To trim meter 1 Isolator cable optional 2 Negative batter...

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