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SELVA MARINE Fin Whale 225 EFI, Service Manual

The SELVA MARINE Fin Whale 225 EFI is a powerful and efficient outboard motor, perfect for marine enthusiasts. For maintenance and troubleshooting, download the free Service Manual from manualshive.com. This comprehensive manual provides step-by-step instructions to keep your motor running smoothly for years to come.

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6AL3J11

1-2

1
2
3
4
5
6
7
8
9

Symbol

The symbols below are designed to indicate the content of a chapter.

General information

Specification

Periodic check and adjustment

Fuel system

Power unit

Lower unit

Bracket unit

Electrical system

Troubleshooting

GEN

INFO

SPEC

CHK

ADJ

FUEL

POWR

LOWR

BRKT

ELEC

TRBL

SHTG

–

+

Symbols 

1

 to 

6

 indicate specific data.

1

Special service tool

2

Specified oil or fluid

3

Specified engine speed

4

Specified tightening torque

5

Specified measurement

6

Specified electrical value 
(resistance, voltage, electric current)

Symbols 

7

 to 

C

 in an exploded diagram or illustration indicate the grade of lubricant and the lubri-

cation point.

7

Apply 4-stroke motor oil

8

Apply gear oil

9

Apply water resistant grease 

 

0

Apply molybdenum disulfide grease

A

Apply corrosion resistant grease 

 

B

Apply low temperature resistant grease 

 

C

Apply injector grease

Symbols 

D

 to 

I

 in an exploded diagram or illustration indicate the type of sealant or locking agent

and the application point.

D

Apply Gasket Maker 

E

Apply ThreeBond 1104J

F

Apply LOCTITE 271 (red)

G

Apply LOCTITE 242 (blue)

H

Apply LOCTITE 572

I

Apply silicon sealant

1

2

3

4

5

6

T

 

R

.

.

7

8

9

0

A

B

C

E

G

A

M

D

C

I

D

E

F

G

H

I

GM

1104J

271

LT

242

LT

572

LT

SS

How to use this manual

Summary of Contents for Fin Whale 225 EFI

Page 1: ...Grey Whale 200 EFI Fin Whale 225 EFI 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: ......

Page 5: ...ator 1 14 Injector 1 15 ECM 1 16 Propeller selection 1 21 Propeller size 1 21 Selection 1 21 Predelivery check 1 22 Checking the fuel system 1 22 Checking the engine oil level 1 22 Checking the gear o...

Page 6: ...rew dimensions see 2 in the figure below Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point see 3 in the figure below Tightening torque...

Page 7: ...e electric current Symbols 7 to C in an exploded diagram or illustration indicate the grade of lubricant and the lubri cation point 7 Apply 4 stroke motor oil 8 Apply gear oil 9 Apply water resistant...

Page 8: ...ne System ECM Electronic Control Module EN European Norm European standard EX Exhaust IEC International Electrotechnical Commission IN Intake LAN Local Area Network PCV Pressure Control Valve PORT Por...

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: ...er 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 F200CET FL200CET F225BET FL225BET Model name Approved m...

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: ...90890 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...

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: ...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 908...

Page 18: ...GEN INFO General information 1 13 6AL3J11 Selva diagnostic system Ver 1 32 60V WS853 05 Diagnostic flash indicator B 90890 06865...

Page 19: ...ion switch black 3 2 pin coupler blue In Out When the water detection switch is on the water detection warnings are given according to the con ditions as listed in the following table Warning conditio...

Page 20: ...ray angle the ECM fuel injection mapping was also changed Therefore be sure to use the 2007 model injector together with the 2007 model ECMs Identification table Injector body color 2006 model 2007 mo...

Page 21: ...njector spray angle the ECM fuel injection mapping was also changed ECM identification Identification table Model ECM identification Description F L 200C 6AL 00 2007 model F L 225B 6AS 00 2007 model F...

Page 22: ...7 Engine temperature sensor Black yellow 18 Sensor ground Black 19 Trim sensor LAN Pink 20 LAN communication H White 21 LAN communication L Blue 22 23 Intake air temperature sensor Black yellow 24 25...

Page 23: ...oil 3 Black yellow 64 Tachometer Green 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 Bla...

Page 24: ...m position 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 senso...

Page 25: ...hift 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 High pressure fue...

Page 26: ...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 27: ...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 battery capacity electroly...

Page 28: ...bination 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 29: ...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 30: ...is part of the break in operation Break in During the test run perform the break in operation in the following 3 stages 1 1 hour a at 2 000 r min or at approxi mately half throttle 2 1 hour b at 3 000...

Page 31: ...8 9 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 torq...

Page 32: ...erating range r min 5 000 6 000 Maximum fuel consumption L US gal Imp gal hr 68 0 18 0 15 0 at 6 000 r min 78 0 20 6 17 2 at 6 000 r min Engine idle speed r min 600 700 Power unit Type 4 stroke DOHC C...

Page 33: ...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 1 000 33 8 35 3 1 150 38 9 40 6 1 000 33 8 35 3 Bracket unit Trim angle at 12 boat...

Page 34: ...ze mm in 94 000 94 017 3 7008 3 7014 Piston Piston diameter D mm in 93 921 93 941 3 6977 3 6985 Measuring point H mm in 5 0 0 20 Piston clearance 3 mm in 0 075 0 080 0 0030 0 0031 Piston pin boss bore...

Page 35: ...e A mm in 46 30 46 40 1 823 1 827 Exhaust A mm in 45 35 45 45 1 785 1 789 Intake and exhaust B mm in 35 95 36 05 1 415 1 419 Camshaft journal diameter mm in 24 96 24 98 0 9826 0 9834 Camshaft runout l...

Page 36: ...20 0 055 0 0008 0 0022 Valve shim Valve shim thickness in 0 020 mm increments mm in 2 320 2 960 0 0913 0 1165 Connecting rod Small end inside diameter mm in 21 017 21 031 0 8274 0 8280 Big end inside...

Page 37: ...492 2 500 0 0981 0 0984 2 mm in 2 496 2 504 0 0983 0 0986 3 mm in 2 500 2 508 0 0984 0 0987 Thrust bearing thickness J3 mm in 1 907 1 957 0 0751 0 0770 Thermostat Opening temperature at 0 05 mm 0 002...

Page 38: ...07 1 27 0 042 0 050 Down relief lock screw depth 1 mm in 1 95 2 45 0 077 0 096 1 The figures are for reference only Item Unit Model 200 R 200 L 225 R 225 L Lower unit Holding pressure kPa kgf cm2 psi...

Page 39: ...Crank position sensor output peak voltage W B B at cranking unloaded V 3 0 at cranking loaded V 2 7 at 1 500 r min loaded V 14 5 at 3 500 r min loaded V 17 8 Crank position sensor resistance 1 W R B 3...

Page 40: ...5 7 0 with remote control lever fully opened Degree Above 39 8 Above 53 8 Electronic throttle valve motor resistance 1 at 20 30 C 68 86 F 1 23 1 67 Accelerator position sensor output voltage P B with...

Page 41: ...s 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 Charging...

Page 42: ...7 6 Fluid type ATF Dexron II PTT motor Output kW 0 53 Brushes Standard length mm in 11 5 0 45 Wear limit mm in 4 5 0 18 Commutator Standard diameter mm in 23 0 0 91 Wear limit mm in 22 0 0 87 Standard...

Page 43: ...model only S6P22020 mm in 453 17 8 317 12 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...

Page 44: ...on 2 13 6AL3J11 Clamp bracket Grey Whale 200 Fin Whale 225 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...

Page 45: ...chamber cover inner plate screw M4 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 Ignition coil bolt M6 7 0 7 5 2 Spark plug 25 2 5 18 4 Cooling water pressure...

Page 46: ...7 0 7 5 2 Exhaust cover bolt 1st M6 6 0 6 4 4 2nd 12 1 2 8 9 Exhaust cover plug 1st M8 14 1 4 10 3 2nd 28 2 8 20 7 M18 55 5 5 40 6 Oil filter 18 1 8 13 3 Oil pressure sensor 18 1 8 13 3 Oil filter jo...

Page 47: ...2 Pinion nut 142 14 2 104 7 Bracket unit Shift cut switch screw M4 2 0 2 1 5 Shift bracket bolt 19 1 9 14 0 Neutral switch screw M4 2 0 2 1 5 Shift rod detent bolt 18 1 8 13 3 Grease nipple 1 0 1 0 7...

Page 48: ...dry threads Components should be at room temperature PTT unit Reservoir mounting bolt M8 19 1 9 14 0 PTT motor mounting bolt M8 19 1 9 14 0 Reservoir cap M12 7 0 7 5 2 Manual valve 2 0 2 1 5 Pipe joi...

Page 49: ...the oil filter 3 7 Checking the timing belt 3 8 Checking the spark plug 3 8 Checking the thermostat 3 9 Checking the cooling water passage 3 10 Control system 3 11 Checking the engine idle speed 3 11...

Page 50: ...s 100 hours 6 months 200 hours 1 year Anodes external Check replace 3 16 Anodes cylinder head thermostat cover Check replace 3 16 Battery Check charge 3 17 Cooling water passages Clean 3 10 Top cowlin...

Page 51: ...ng belt Replace 5 15 Valve clearance DOHC Check adjust 5 9 Fuel filter vapor separator tank Replace 4 27 Oil control valve filter Replace 5 43 Anodes exhaust cover cooling water passage cover Rectifie...

Page 52: ...ged 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 port and starboard NOTE See the explode...

Page 53: ...assembly 7 Clean with straight gasoline if there are foreign substance or replace if cracked NOTE When cleaning the fuel filter cup assembly be sure not to remove the clip 9 and float 0 otherwise the...

Page 54: ...efore loosen ing the vapor separator drain screw or pressurized fuel will spray out and may result in serious injury 6 Tighten the vapor separator drain screw 2 Power unit 3 Checking the engine oil 1...

Page 55: ...e oil to the correct level Changing the engine oil draining 1 Start the engine warm it up and then turn it off 2 Remove the oil dipstick and oil filler cap 1 3 Remove the starboard apron 2 4 Place a d...

Page 56: ...Place a rag under the oil filter and then remove the oil filter using a 72 5 mm 2 9 in oil filter wrench 1 NOTE Wait more than 5 minutes after turning the engine off to replace the oil filter Be sure...

Page 57: ...or a and the exte rior b of the timing belt Replace the timing belt if cracked damaged or worn NOTE To replace the timing belt see Chapter 5 Replacing the timing belt Checking the spark plug 1 Remove...

Page 58: ...rol valve couplers 1 4 Disconnect the thermoswitch connectors 2 5 Disconnect the quick connectors 3 WARNING It is dangerous if the quick connectors are disconnected suddenly since pressur ized fuel wi...

Page 59: ...anodes before installing the thermostat covers 11 Connect the thermoswitch connectors quick connectors and oil control valve couplers 12 Route and fasten the wiring harness in its original position N...

Page 60: ...ap ter 9 YDIS and the YDIS Ver 1 23a or later Instruction Manual Adjusting the throttle cable 1 Set the remote control lever to the neu tral position and fully close the throttle lever 2 Loosen the lo...

Page 61: ...emote control lever is in the fully closed position 8 Check the throttle cable for smooth oper ation and if necessary repeat steps 2 7 Checking the gear shift operation 1 Check that the gear shift ope...

Page 62: ...on check the operation of the neutral switch and if necessary repeat steps 3 7 Bracket unit 3 Checking the PTT operation 1 Fully tilt the outboard motor up and down a few times and check the entire tr...

Page 63: ...ring and the reservoir cap 2 and then tighten the reservoir cap to the specified torque Lower unit 3 Checking the gear oil level 1 Fully tilt the outboard motor down 2 Remove the gear oil check screw...

Page 64: ...gear oil check screw 2 and quickly install the gear oil drain screw 1 and then tighten them to the specified torque Checking the lower unit for air leakage 1 Remove the gear oil check screw 1 and then...

Page 65: ...l seals for damage If necessary check each shaft for bends and damage Checking the propeller 1 Check the propeller blades and splines Replace the propeller if cracked dam aged or worn General 3 Checki...

Page 66: ...y electrolyte is dangerous it con tains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures Avoid bodily contact with electrolyte as it can cause severe burns o...

Page 67: ...al may not always apply therefore consult the instruc tion manual of the battery Disconnect the negative battery cable first then the positive battery cable Lubricating the outboard motor 1 Apply wate...

Page 68: ...ustment 3 19 6AL3J11 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 69: ...position sensor 4 12 Throttle body 4 13 Checking the electronic throttle valve system 4 16 Checking the canister 4 16 Checking the canister check valve 4 16 Installing the throttle body 4 17 Fuel filt...

Page 70: ...joint 6 Fuel hose joint to check valve 7 Fuel hose check valve to joint 8 Fuel hose vapor separator to quick connec tor 9 Fuel hose quick connector to joint 0 Fuel hose joint to quick connector A Fuel...

Page 71: ...lve 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 Vapo...

Page 72: ...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 73: ...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 74: ...t switch to OFF Disconnecting the quick connector WARNING If the quick connector is disconnected suddenly pressurized fuel could spray out Be sure to reduce the fuel pressure before disconnecting the...

Page 75: ...it is firmly connected to prevent fuel from leaking out Before measuring the fuel pressure make sure that the drain screw is tight ened securely Do not loosen the drain screw while measuring the fuel...

Page 76: ...nnect the quick connector see Chapter 4 Disconnecting the quick connec tor 3 Connect fuel pressure gauge adapter B between the quick connector and vapor separator 4 Connect the fuel pressure gauge to...

Page 77: ...educing the fuel pressure 9 Disconnect the special service tools WARNING After measuring the fuel pressure cover the end of the hose with a clean dry rag point the hose downward and then loosen the dr...

Page 78: ...1 7 Grommet 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 I...

Page 79: ...ets onto the intake mani folds NOTE Be sure to install the projection on each gas ket into its corresponding slit in the intake manifolds 2 Install the intake manifolds and bolts temporarily NOTE When...

Page 80: ...ll the intake silencer 2 Fasten the intake air temperature sensor lead 1 to the holder on the oil filler neck as shown 3 Connect the blowby hose 2 and then fasten the plastic tie 3 as shown T R Intake...

Page 81: ...or position sensor 4 No Part name Q ty Remarks 1 Accelerator position sensor assembly 1 2 Grommet 3 3 Collar 3 4 Bolt 3 M6 35 mm 5 Accelerator position sensor coupler 1 S6AL4300 4 1 3 5 2 3 2 3 2 Inta...

Page 82: ...Surge tank 1 11 Collar 2 12 Bolt 4 M8 40 mm 13 Holder 2 14 Bolt 2 M6 16 mm 15 Canister 1 16 Bolt 1 M6 10 mm 17 Bracket 1 26 23 24 25 5 30 S6AL4050 7 8 9 15 16 17 20 19 18 21 10 14 13 12 11 2 1 3 4 5...

Page 83: ...M6 20 mm 28 Washer 1 29 Intake air pressure sensor 1 30 Plastic tie 1 Not reusable 26 23 24 25 5 30 S6AL4050 7 8 9 15 16 17 20 19 18 21 10 14 13 12 11 2 1 3 4 5 6 22 23 25 26 27 28 29 3 24 T R 5 N m...

Page 84: ...lder 3 3 Holder 2 4 Joint 1 5 Joint 1 3 mm 6 Joint 1 7 Holder 2 8 Joint 2 5 mm 9 Holder 2 10 Holder 1 11 Joint 1 5 mm S6AL4060 9 8 8 7 7 3 11 4 1 5 6 2 2 3 10 9 2 9 mm 0 35 in 12 mm 0 47 in 9 mm 0 35...

Page 85: ...rvice tool to the atmospheric port 1 and cover the other ports each with a finger 3 Apply the specified positive pressure and check that there is no air leakage Replace the canister if there is air le...

Page 86: ...vapor separator NOTE Fasten the pressure regulator hose 3 and canister vent hose 4 to the holder 3 Fasten the hoses 2 and 5 to the holder 4 Install the throttle body 5 Connect the hoses and fasten the...

Page 87: ...6AL3J11 4 18 1 2 3 4 5 6 7 8 9 S6AL4240 7 8 Throttle body...

Page 88: ...Fuel cup assembly 1 6 Fuel filter assembly 1 7 Bracket 1 8 Bolt 2 M6 16 mm 9 Bolt 2 M6 14 mm 10 Fuel hose 2 11 Holder 1 12 Joint 1 13 Plastic tie 3 Not reusable 14 Holder 1 6 P 3 9 mm 0 35 in 12 mm 0...

Page 89: ...rcially available vacuum pres sure pump gauge and meter that can be pressurized up to 200 kPa 2 0 kgf cm2 29 0 psi 3 Connect a vacuum pressure pump gauge and a meter to the fuel outlet 2 4 Cover the f...

Page 90: ...Remarks 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 Fuel filter 1 13 Plastic tie 1 Not re...

Page 91: ...filter 1 Check the fuel filter Replace the fuel fil ter if there is dirt residue or external damage Checking the check valve 1 Connect the special service tool to the check valve port as shown 2 Appl...

Page 92: ...njector 6 2 O 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 rai...

Page 93: ...r 1 Apply engine oil to new O rings and then install them onto the fuel injectors 2 Install the fuel injectors 1 onto the port fuel rail 2 and then install the holders 3 as shown 3 Install the fuel in...

Page 94: ...FUEL Fuel system 4 25 6AL3J11 7 Fasten the wiring harness to the holders and then fasten the plastic ties 8 as shown S6P24370 8 8 PORT STBD...

Page 95: ...2 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 S6AL4100 2 2 3 3 3 3 1 4 4 6 5 11 7 7 9 10 1...

Page 96: ...t 1 8 Filter 1 9 Filter holder 1 10 Plate 1 11 Plate 1 12 Screw 3 4 8 mm 13 O ring 1 Not reusable 14 Needle valve assembly 1 15 Float 1 16 Pin 1 17 Screw 1 4 8 mm S6AL4110 2 3 23 23 22 5 4 1 13 14 15...

Page 97: ...eparator drain screw 1 21 Drain hose 1 22 Joint 1 23 Hose 2 24 Cap 1 S6AL4110 2 3 23 23 22 5 4 1 13 14 15 16 17 12 12 11 10 7 6 8 9 18 19 20 21 T R 2 N m 0 2 kgf m 1 5 ft Ib T R 5 N m 0 5 kgf m 3 7 ft...

Page 98: ...el pump NOTE To check the high pressure fuel pump see Chapter 8 Checking the low pressure fuel pump and high pressure fuel pump To check the high pressure fuel pump relay see Chapter 8 Checking the hi...

Page 99: ...AL3J11 4 30 1 2 3 4 5 6 7 8 9 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 S6P24480 a Vapor separator...

Page 100: ...3 Power unit assembly 5 33 Starter motor 5 35 Junction box 5 36 Fuse box 5 37 ECM 5 38 Removing the power unit 5 39 Removing the wiring harness 5 41 Cylinder head 5 43 Cylinder head 5 43 Exhaust cover...

Page 101: ...hecking the piston pin boss bore 5 63 Checking the piston pin 5 64 Checking the connecting rod small end inside diameter 5 64 Checking the connecting rod big end side clearance 5 64 Checking the crank...

Page 102: ...ding on the compression gauge stabilizes and then measure the compression pressure 7 If the compression pressure is below specification and the compression pres sure for each cylinder is unbalanced ad...

Page 103: ...e that an oil pressure sensor malfunction trouble code 39 has occurred and increase the engine idle speed approximately 900 r min Delete the diagnosis record using the YDIS after checking the oil pres...

Page 104: ...pecification Output voltage Oil pressure Test harness 3 pins 1 90890 06869 Oil pressure sensor input voltage reference data Orange O Black B 4 75 5 25 V Oil pressure sensor output voltage reference da...

Page 105: ...0 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 S6AL5040 3 2 2 5 4 4 6 6 8 18 17 16 14 13 12 23 20 19 21...

Page 106: ...mm 24 ECM base assembly 1 25 Bolt 1 M6 12 mm 26 Holder 1 27 Hose 1 S6AL5040 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 m 2 3 kgf m 17 0 f...

Page 107: ...7 Holder 1 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 S6AL5050 11 3...

Page 108: ...M7 37 mm E E S6AL5060 1 2 3 8 7 7 6 5 8 9 13 12 12 11 11 10 14 14 17 16 22 23 21 19 12 11 12 18 20 24 15 4 11 7 6 5 1 2 3 4 8 8 25 26 27 29 31 30 22 33 24 32 23 28 1386B 1280B 1280B E E E A A E M E E...

Page 109: ...13 12 12 11 11 10 14 14 17 16 22 23 21 19 12 11 12 18 20 24 15 4 11 7 6 5 1 2 3 4 8 8 25 26 27 29 31 30 22 33 24 32 23 28 1386B 1280B 1280B E E E A A E M E E E E T R 2 N m 0 2 kgf m 1 5 ft Ib T R 60...

Page 110: ...gnet cover and ECM cover 3 Remove the blowby hose 1 4 Disconnect the ignition coil couplers 2 cam position sensor couplers 3 knock sensor coupler 4 and cooling water pressure sensor adapter hose 5 5 R...

Page 111: ...the flywheel magnet an additional 120 clockwise and align the 3TDC mark h on the flywheel magnet with the pointer b 16 Measure the intake and exhaust valve clearances for cylinder 6 17 Similarly measu...

Page 112: ...ockwise and align the 1TDC mark a on the flywheel magnet with the pointer b 3 Check that the II marks c on the port driven sprockets are aligned and check that the I marks d on the starboard driven sp...

Page 113: ...and then move the stator assembly 8 Remove the timing belt driven sprock ets and camshafts NOTE To remove the timing belt driven sprockets and camshafts see Chapter 5 Removing the timing belt driven...

Page 114: ...e sure to remove any grease from the tapered portion of the crankshaft e and the flywheel magnet f Apply engine oil to the thread g of the fly wheel magnet nut and upper and lower sur face h of the wa...

Page 115: ...de clearance m 21 Install the wiring harness guide NOTE To install the wiring harness guide see Chapter 5 Installing the wiring harness 22 Install the spark plugs and ignition coils 23 Install all par...

Page 116: ...sprocket and timing belt 1 Reduce the 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...

Page 117: ...ket wrench to loosen the fly wheel magnet nut 13 Remove the flywheel magnet and Woo druff key CAUTION To prevent damage to the engine or tools screw in the puller set bolts evenly and completely so th...

Page 118: ...dually clockwise using a hexagon wrench and then insert a 5 0 mm 0 2 in pin 9 into the hole g NOTE Leave the pin inserted into the hole g of the timing belt tensioner until the timing belt is installe...

Page 119: ...ION 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 Do not get oil or grease on the timing belt 22 Install the timing belt on...

Page 120: ...se 2 full turns and then check that alignment marks c through f are aligned 26 Install the stator assembly 27 Install the Woodruff key 0 then the fly wheel magnet A NOTE Be sure to remove any grease f...

Page 121: ...l the wiring harness guide NOTE To install the wiring harness guide see Chapter 5 Installing the wiring harness 32 Install all parts removed during disas sembly 33 Check that the wiring harness hoses...

Page 122: ...ave been given NOTE Check the valve clearances before removing the parts 1 Check that the mark a on the drive sprocket and the mark b on the cyl inder block are aligned 2 Check that the II marks c on...

Page 123: ...AUTION 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 port driven sprockets by turni...

Page 124: ...11 Remove 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...

Page 125: ...ing belt Replace if cracked damaged or worn 2 Check the drive sprocket Replace the crankshaft assembly if cracked dam aged or worn 3 Check the driven sprockets Replace the variable camshaft timing ass...

Page 126: ...the brim a mal function may occur in the cam position sen sor signal 2 Measure the cam lobe Replace if out of specification 3 Measure the camshaft runout Replace if above specification 4 Measure the...

Page 127: ...the crankcase and cylinder block 2 Install the valve lifters onto the cylinder heads NOTE Apply engine oil to the valve shims and valve lifters before installation Install the valve shims and valve l...

Page 128: ...cified torques in 2 stages and in the sequence shown CAUTION Do not reuse the bolts with seal washers 3 always replace them with new ones NOTE Apply engine oil to the camshaft caps and camshaft cap bo...

Page 129: ...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 tightening the driven sprocket bolt 5 10 Ins...

Page 130: ...d the variable camshaft timing cap 8 and then tighten the cap to the specified torque while holding the driven sprocket using the special service tool CAUTION Do not reuse the gaskets 7 always replace...

Page 131: ...fts the force of the valve springs may cause the driven sprockets to be rotated too far 15 Align the mark a on the drive sprocket with the mark c on the cyl inder block by turning the crankshaft clock...

Page 132: ...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 sprockets 19 Adjust the timing be...

Page 133: ...linder head cover bolts to the same torque in both stages See the exploded diagram 5 7 23 Install the timing belt guides 0 and then adjust the timing belt to timing belt guide clearance p NOTE If the...

Page 134: ...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 S6AL5030 7 6 9 8 11 16 13 13 14 10 11 12 11 15 11 2 3 3 4 5 17 1 11 11 17 18...

Page 135: ...25 Bolt 2 M6 20 mm S6AL5030 7 6 9 8 11 16 13 13 14 10 11 12 11 15 11 2 3 3 4 5 17 1 11 11 17 18 19 20 5 5 5 4 4 4 3 3 11 5 25 22 21 24 24 23 E LT 572 LT LT 572 LT A A LT 572 LT LT 572 LT LT 572 LT LT...

Page 136: ...Positive battery cable 1 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 Bolt 1 M6 20 mm 13 Starter motor lead 2 S6AL5640 1 8 12 13 10 11 3 2 6 7 4...

Page 137: ...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 S6AL5750E T R 1 6 N m 0 6 kgf m 4 4 ft lb 2 12 N m 1 2...

Page 138: ...se 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 12 Screw 4 5 10...

Page 139: ...er 1 4 Plastic tie 3 5 Holder 4 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 S6AL5630 3 2 5 6 11 10 7 8 11 13 14 13 14 13 14 12 4...

Page 140: ...trol cables 3 Remove the starboard intake manifold NOTE See the exploded diagram 4 9 4 Remove the clamps 4 and caps 5 and then disconnect the PTT motor lead 6 5 Disconnect the vapor gas hose 7 from th...

Page 141: ...disconnect them 12 Remove the speed sensor coupler J from the bracket and then disconnect it 13 Disconnect the flushing hose K 14 Remove the aprons and upper case cover 15 Retract the port and starbo...

Page 142: ...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 and low pressure fuel pump coupler 5 fr...

Page 143: ...ng harness and the projections a on the plastic ties A from the wiring harness guide and then pull up the wiring har ness NOTE When removing the wiring harness guide the wiring harness does not need t...

Page 144: ...40 mm 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...

Page 145: ...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 146: ...et 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 m...

Page 147: ...other parts in the order as they 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 spec...

Page 148: ...m diameter is within specifi cation 1 Measure the valve guide inside diameter a 2 Calculate the valve stem to valve guide clearance as follows Replace the valve guide if out of specification Valve mar...

Page 149: ...Apply engine oil to the inner surface of the valve guide Turn the valve guide reamer clockwise to ream the valve guide Do not turn the reamer counterclockwise when removing the reamer Be sure to clea...

Page 150: ...properly or if the valve seat contact width is out of specification Replace the valve guide if the valve seat contact is uneven Refacing the valve seat 1 Reface the valve seat with the valve seat cut...

Page 151: ...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 Check the valve seat contact area of...

Page 152: ...ci fied contact width apply a thin even layer of lapping compound onto the valve seat and then lap the valve using a valve lapper commercially available CAUTION Do not get the lapping compound on the...

Page 153: ...installed in any direction 3 Compress the valve spring and then install the valve cotters 7 4 Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters 7 securely NOTE Be su...

Page 154: ...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 bolts to the specified torques...

Page 155: ...s if excessively eroded Installing the cooling water passage cover 1 Install the anodes 1 to the cooling water passage cover 3 2 Install a new gasket 2 and the cooling water passage cover 3 3 Connect...

Page 156: ...the cylinder head gaskets always replace them with new ones NOTE Be sure to install the port and starboard cyl inder head gaskets onto the correct cylin der heads Apply engine oil to the cylinder head...

Page 157: ...Install the camshafts driven sprockets and timing belt NOTE To install the camshafts driven sprockets and timing belt see Chapter 5 Installing the camshaft driven sprocket and timing belt T R Cylinde...

Page 158: ...3 Gasket 1 Not reusable 14 Dowel 2 15 O ring 1 Not reusable 16 Bolt 1 M6 20 mm 17 Blowby hose joint 1 S6AL5460 UP 1 2 3 4 4 5 6 7 8 10 14 13 9 14 12 11 19 18 29 27 28 19 22 21 28 27 24 26 23 25 33 33...

Page 159: ...able 30 Bolt 1 M6 12 mm 31 Holder 1 32 Cooling water hose 1 33 Vapor gas hose 2 34 Check valve 1 S6AL5460 UP 1 2 3 4 4 5 6 7 8 10 14 13 9 14 12 11 19 18 29 27 28 19 22 21 28 27 24 26 23 25 33 33 32 34...

Page 160: ...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 se...

Page 161: ...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 STBD 1 26 Anode 2 27 Thermoswitch 2 28 Bolt 4 M6 16 mm 29 Bolt 4 M6 25 mm 30 Thermos...

Page 162: ...n NOTE See the exploded diagram 5 57 Be sure to 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...

Page 163: ...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 B and T Replace the...

Page 164: ...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 165: ...e connecting rod small end inside diameter a Replace 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 c...

Page 166: ...rod cap 2 NOTE Install the connecting rod bearings in their original positions Insert the projection a of each bearing into the slots in the connecting rod cap and con necting rod 3 Put a piece of Pla...

Page 167: ...d In the 3rd stage make a mark c on the connecting rod cap bolts and connecting rod caps and then tighten the bolts 90 from the mark 6 Remove the connecting rod cap and measure the width of the compre...

Page 168: ...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 the cylinder block 4 Put a piece of Plastigauge PG 1 on each...

Page 169: ...s been completed tighten the M8 bolts G S to the specified torques in 2 stages 8 Gently remove the crankcase and then measure the width of the compressed Plastigauge PG 1 on each crankshaft journal Re...

Page 170: ...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 171: ...rd 3 Offset the piston ring end gaps as shown CAUTION Do not scratch the pistons or break the piston rings NOTE After installing the piston rings check that they move smoothly 4 Install the upper bear...

Page 172: ...ring with its grooves k facing outward as shown 7 Install half of the main bearings E and the thrust bearing F into the crankcase 8 Apply sealant to the mating surface of the crankcase NOTE Install th...

Page 173: ...llation 11 Install the connecting rod cap 8 to the connecting rod and then tighten new connecting rod cap bolts to the specified torques in 3 stages CAUTION Do not reuse the connecting rod cap bolts a...

Page 174: ...the screws 1 and disassemble the oil pump NOTE See the exploded diagram 5 59 Checking the oil pump 1 Check the gear teeth and inner surface of the oil pump case Replace the oil pump assembly if the g...

Page 175: ...rews 7 to the specified torque 5 Install a new oil seal 6 into the oil pump making sure to install it in the proper direction Driver rod L3 2 90890 06652 Needle bearing attachment 3 90890 06613 Driver...

Page 176: ...es not get damaged 2 Install a new gasket and the oil filter bracket and then tighten the bolts in the sequence shown NOTE Apply engine oil to the oil filter bracket bolts before installation 3 Supply...

Page 177: ...the cylinder head 3 Install the sensors and switches that were removed to the power unit NOTE For the location of the sensors and switches see Chapter 8 Electrical component 4 Install the engine temp...

Page 178: ...the junction box onto the power unit and then tighten the bolts tempo rarily 9 Install the wiring harness to the junction box and then fasten the wiring harness at the white tape d and the sub wiring...

Page 179: ...15 Check that the wiring harness hoses and other parts do not interfere with any moving parts Installing the power unit 1 Retract the port and starboard top cowl ing lock levers CAUTION Make sure tha...

Page 180: ...ver 5 and aprons 6 5 Install the speed sensor coupler 7 to the bracket 6 Connect the flushing hose 8 7 Connect the warning indicator coupler 9 trim sensor coupler 0 isolator cou pler A water detection...

Page 181: ...onnect the PTT motor leads L blue and M light green and then fasten them 13 Route the positive battery cable N and negative battery cable O along the bot tom of the bottom cowling a and then connect t...

Page 182: ...nstall the cable holder V and retaining plate W 17 Connect the shift cable and throttle cable and then adjust their lengths NOTE To adjust the shift cable and throttle cable see Chapter 3 Adjusting th...

Page 183: ...6AL3J11 5 82 1 2 3 4 5 6 7 8 9 MEMO Cylinder block...

Page 184: ...drive 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 Ch...

Page 185: ...shaft housing 6 44 Disassembling the reverse gear 6 44 Disassembling the lower case 6 45 Checking the pinion and reverse gear 6 45 Checking the bearing 6 45 Checking the drive shaft 6 45 Checking the...

Page 186: ...10 Bolt 1 M10 70 mm X transom model 11 Spacer 1 12 Propeller 1 13 Spacer 1 14 Washer 1 15 Cotter pin 1 Not reusable 16 Propeller nut 1 17 Trim tab 1 11 17 10 1 5 7 6 12 13 14 16 15 5 4 2 3 8 9 T R 9...

Page 187: ...0 200 mm U transom model 24 Bolt 1 M10 174 mm U transom model 25 Nut 6 U transom model 26 Spring washer 6 U transom model 27 Washer 6 U transom model 11 17 10 1 5 7 6 12 13 14 16 15 5 4 2 3 8 9 T R 9...

Page 188: ...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 189: ...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 190: ...ck 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...

Page 191: ...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 Propeller shaft shim 1 13 Reverse gear 1 14 Reverse gear shim 15 Ball bearin...

Page 192: ...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 193: ...g 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 194: ...s 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 Measure the propeller shaft runout Replace the propeller shaf...

Page 195: ...the propeller shaft hous ing to the specified depth NOTE Install an oil seal halfway into the propeller shaft housing and then install the other oil seal 3 Install a new ball bearing into the propel l...

Page 196: ...erse gear shim s if replacing the propeller shaft housing ball bearing or lower case Be sure to select the propeller shaft shim if replacing the reverse gear To select the shims see Chapter 6 Shim min...

Page 197: ...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 198: ...LOWR Lower unit 6 13 6AL3J11 6 No Part name Q ty Remarks 18 Forward gear shim 19 Taper roller bearing assembly 1 Not reusable 20 Forward gear 1...

Page 199: ...1 Remove the needle bearing from the lower case NOTE Since the diameter of the passage in the lower case and the diameter of the special service tool 1 are both 40 mm 1 57 in the special service tool...

Page 200: ...specification 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 Install the original shim s and taper...

Page 201: ...drive shaft housing to the specified depth NOTE Install an oil seal halfway into the drive shaft housing and then install the other oil seal Installing the drive shaft 1 Install the forward gear into...

Page 202: ...new O ring to the drive shaft housing and then install the drive shaft housing into the lower case NOTE Install the drive shaft housing with the cutout a in the housing facing forward as shown 5 Tigh...

Page 203: ...s Installing the water pump and shift rod 1 Install the shift rod assembly 1 NOTE Set the gear shift to the neutral position when installing the shift rod After assembling the lower unit check that th...

Page 204: ...ridge 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 CAUTIO...

Page 205: ...lignment mark b cannot be aligned so align the set pin c with the alignment mark d on the shift bracket 2 Set the gear shift to the neutral position at the lower unit 3 Install the dowels 1 into the l...

Page 206: ...e sure 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...

Page 207: ...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 208: ...center of the hole Tighten the wing nuts another 1 4 of a turn after they contact the plate 2 Make sure that the special service tool and drive shaft are parallel 2 Install the pinion and pinion nut a...

Page 209: ...m 6 Select the pinion shim 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 ro...

Page 210: ...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 times an...

Page 211: ...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 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 mm 1 16 mm 3 Select the reverse gear s...

Page 212: ...asure the reverse gear heights M3 and M4 as shown and then calculate the value C2 NOTE Measure the gear height at 4 points to find the height average 3 Measure the propeller shaft spline width C3 Digi...

Page 213: ...sh 1 Install the lower unit onto a repair stand 2 Remove the water pump assembly 3 Set the gear shift to the neutral position at the lower unit 4 Turn the lower unit so that it is positioned as shown...

Page 214: ...ockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction NOTE Measure the backlash at 4 points to find the average 10 Add or remove shim s if out of specific...

Page 215: ...in each direction NOTE Measure the backlash at 4 points to find the average 14 Add or remove shim s if out of specifica tion M Measurement 15 Remove the special service tools and then install the wate...

Page 216: ...Bolt 1 M10 45 mm 10 Bolt 1 M10 70 mm 11 Spacer 1 12 Propeller 1 13 Spacer 1 14 Washer 1 15 Cotter pin 1 Not reusable 16 Propeller nut 1 17 Trim tab 1 11 17 1 5 7 6 12 13 14 16 15 5 4 2 3 8 9 T R 9 N m...

Page 217: ...ousing 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 reusable 13 Impelle...

Page 218: ...a block of wood between the anti cavitation plate and propeller to keep the propeller from turning When removing the lower unit with the power unit installed be sure to suspend the outboard motor If t...

Page 219: ...re to remove the insert cartridge when checking the housing 2 Check the impeller insert cartridge and outer plate cartridge Replace if cracked or worn 3 Check the water pipe Replace if corro sion defo...

Page 220: ...1 Water pipe 1 2 Rubber seal 1 3 Rubber 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 1...

Page 221: ...ler 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 mm 29 Bolt 2 M8 33 mm...

Page 222: ...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 2 Remove the forward gear and forward ge...

Page 223: ...TION Do not press the propeller shaft threads a directly Do not reuse the taper roller bearing always replace it with a new one 7 Remove the oil seals and needle bear ing Checking the propeller shaft...

Page 224: ...OTE Install the needle bearing with the manufac ture identification mark a facing toward the oil seal propeller side When using the driver rod do not strike the special service tool in a manner that w...

Page 225: ...er bearing and bearing outer race check that the propeller shaft rotates smoothly 5 Install the propeller shaft housing assem bly in the reverse direction into the lower case NOTE To prevent damage to...

Page 226: ...lower case To select the shims see Chapter 6 Shim ming counter rotation model Install the dog clutch E with the F mark e facing toward the forward gear After installing the forward gear check that the...

Page 227: ...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 shim 12 Thrust bearing 1 13 Lower case 1 14 Ne...

Page 228: ...Lower unit 6 43 6AL3J11 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 ge...

Page 229: ...seals and needle bearing Disassembling the reverse gear 1 Remove the 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...

Page 230: ...f the pinion and the teeth and dogs of the reverse gear Replace the pinion or reverse gear if cracked or worn Checking the bearing 1 Check the bearings Replace the bear ings if pitted or if there is r...

Page 231: ...e lower case NOTE Apply gear oil to the needle bearing outer case before installation The needle bearing contains 24 rollers Assembling the reverse gear 1 Install a new needle bearing into the reverse...

Page 232: ...haft housing and then install the other oil seal Installing the drive shaft 1 Install the thrust bearing and reverse gear into the lower case 2 Install the washer spring thrust bearing 1 drive shaft t...

Page 233: ...ed torque Installing the propeller shaft housing 1 Set the shift rod joint and dog clutch 1 to the neutral position as shown 2 Apply grease to new O rings and propel ler shaft housing 3 Install a new...

Page 234: ...n measuring the backlash be sure to measure it before installing the water pump To measure the backlash see Chapter 6 Measuring the forward and reverse gear backlash counter rotation model 2 Install a...

Page 235: ...lign the cover projection c with the hole d in the pump housing Installing the lower unit WARNING When installing the lower unit with the power unit installed be sure to suspend the outboard motor If...

Page 236: ...keep the propeller from turning and then tighten the nut to the specified torque WARNING Do not hold the propeller with your hands when loosening or tightening it Be sure to disconnect the battery ca...

Page 237: ...7 8 9 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 cm3 33 8 US oz 35 3 Imp oz Drive shaft and lower cas...

Page 238: ...LOWR Lower unit 6 53 6AL3J11 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 239: ...ole Tighten the wing nuts another 1 4 of a turn after they contact the plate 2 Make sure that the special service tool and drive shaft are parallel 2 Install the pinion and pinion nut and then tighten...

Page 240: ...4 mm 6 Select the pinion shim 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 reverse gear shim 1 Turn the thrus...

Page 241: ...0 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...

Page 242: ...e propeller 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 unit...

Page 243: ...e shim thickness T 4 by using the specified measurement s and the calcula tion formula Measure the taper roller bearing at 4 points to find the height average 2 Install the thrust bearing 4 onto the p...

Page 244: ...0 mm 4 Round the numbers for the propeller shaft shim s T 4 as follows Example If T 4 is 0 49 mm then the propeller shaft shim is 0 48 mm If T 4 is 0 60 mm then the propeller shaft shim is 0 58 mm 5 I...

Page 245: ...he specified torque while turning the drive shaft NOTE The drive shaft can no longer be turned when the center bolt is tightened to the specified torque 7 Turn the lower unit back to its original posi...

Page 246: ...om the propeller shaft 12 Turn the shift rod in direction c to the reverse position using the shift rod push arm 13 Turn the drive shaft clockwise until the dog clutch 8 is fully engaged 14 Turn the s...

Page 247: ...od push arm Measure the backlash at 4 points to find the average 18 Add or remove shim s if out of specifica tion M Measurement 19 Remove the special service tools and then install the water pump asse...

Page 248: ...fold 7 16 Assembling the upper case 7 18 Installing the upper case 7 19 Removing the steering arm 7 20 Installing the steering arm 7 20 Clamp bracket and swivel bracket 7 22 Removing the PTT unit 7 24...

Page 249: ...g the tilt ram 7 51 Assembling the trim ram 7 53 Installing the tilt cylinder 7 53 Installing the trim ram 7 53 Installing the PTT motor 7 54 Installing the reservoir 7 55 Installing the tilt ram 7 55...

Page 250: ...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 Shift bracket bolt 1 11 Bolt 2 M6 35 mm 12 Cla...

Page 251: ...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 Flushing hose joint adapter 1 31...

Page 252: ...rks 1 Bottom cowling 1 2 Rubber seal 1 3 Cowling lock lever 3 4 Bushing 6 5 Plate 3 6 Bolt 10 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 253: ...r pilot hole 1 22 Wire lead extension 1 Counter rotation model 23 Holder 2 24 PTT switch 1 25 Bracket 1 26 Bracket 1 27 Cover 1 28 Gasket 2 29 Bolt 1 M6 20 mm Regular rotation model 30 Bracket 1 31 Cl...

Page 254: ...ssembly 3 NOTE The shift rod assembly 3 cannot be removed when the power unit is installed 3 Remove the plates 4 and clamp 5 and then pull out the trim sensor lead 6 PTT motor lead 7 and flushing hose...

Page 255: ...hift cut switch 3 from the brackets 4 and 5 NOTE To check the neutral switch 2 and shift cut switch 3 see Chapter 8 Checking the neu tral switch and Checking the shift cut switch Assembling the shift...

Page 256: ...own otherwise the lever may be dam aged Assembling the bottom cowling 1 Install the PTT switch 1 holder 2 and holder 3 regular rotation model Regular rotation model Counter rotation model NOTE Fasten...

Page 257: ...r 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 mod...

Page 258: ...Bracket unit 7 9 6AL3J11 7 Install the flushing hose joint adapter G and screws H and then install the shift bracket assembly I T R Hose joint adapter screw H 5 N m 0 5 kgf m 3 7 ft lb S6AL7160 A A I...

Page 259: ...0 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 oil drain bolt 1 M14 12 mm 14...

Page 260: ...1 M6 10 mm 19 Dowel 1 20 Speedometer hose 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 Ste...

Page 261: ...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 S6AL7210 A A A A LT 572 LT LT 271 LT 572 LT A A 1 2 3 4 7 5 6 8 11...

Page 262: ...t 1 Not reusable 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 No...

Page 263: ...4 5 6 7 8 9 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 mm Upper case...

Page 264: ...over 2 and damper 3 NOTE If the engine oil has not already been drained place a drain pan under the drain hole before removing the engine oil drain bolt 1 2 Remove the upper mounts and lower mounts fr...

Page 265: ...removed parts 2 Check the exhaust guides exhaust man ifold and muffler Replace the exhaust guides exhaust manifold and muffler if cracked or replace if there is corrosion 3 Check the oil pan Replace...

Page 266: ...anifold bolts E tempo rarily 5 Tighten the exhaust manifold bolts E first and then tighten the oil pan bolts 0 and A to the specified torques 6 Install the dowels F a new gasket G and the plate H 7 In...

Page 267: ...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 NOTE Be sure to insert the tip of the cooling water pipe A into the joint h...

Page 268: ...er mount bolts J and mount housings K NOTE Make sure that the ground lead is not dam aged Installing the upper case 1 Install the washers 1 onto the lower mounting bolts 2 Install the upper and lower...

Page 269: ...g arm 1 Install the washer 1 and bushing 2 onto the steering arm 3 2 Place the swivel bracket 4 in an upright position and then install the steering arm onto the swivel bracket T R Upper mounting nut...

Page 270: ...m 3 making sure that they are both facing in the same direction a and b are aligned 5 Hold the steering arm 3 and then strike the steering yoke 9 until the slot c for installing the circlip is visible...

Page 271: ...0 45 mm 4 Ground lead 1 b 120 mm 4 7 in 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 l...

Page 272: ...6 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 Ground lead 1 b 180 m...

Page 273: ...y and result in severe injury NOTE If the PTT does not operate open the manual valve by turning it counter clockwise and then tilt the outboard motor up manually 2 Remove the holder 2 plastic ties 3 a...

Page 274: ...ead 1 before removing the self locking nut 2 3 Remove the spring 6 holder 7 and pins 8 4 Remove the tilt stop levers 9 distance collar 0 collar A and bushings B Installing the clamp bracket 1 Assemble...

Page 275: ...st the trim sensor see Chapter 7 Adjusting the trim sensor 5 Install the friction plates 9 onto the clamp brackets 0 then install the bush ings A washers B and then assemble the clamp brackets and the...

Page 276: ...ram into the swivel bracket with the shaft 4 and circlip 5 4 Tighten the self locking nut 6 of the through tube to the specified torque NOTE Make sure that the flat corner a of the through tube is po...

Page 277: ...nly lower if the PTT unit should lose fluid pressure 4 Loosen the trim sensor screws 2 5 Adjust the position of the trim sensor and then tighten the trim sensor screws 2 temporarily NOTE To decrease t...

Page 278: ...h the tilt stop lever Otherwise the outboard motor could sud denly lower if the PTT unit should lose fluid pressure 9 Tighten the trim sensor screws 2 10 Fully tilt the outboard motor down NOTE Check...

Page 279: ...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 The height a is greater than the height b...

Page 280: ...BRKT Bracket unit 7 31 6AL3J11 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 281: ...due to internal pressure 3 Install the special service tool 2 NOTE Put the PTT unit in the drain pan 4 Connect the PTT motor leads to the bat tery terminals to retract the trim rams and then measure...

Page 282: ...t at the end b WARNING Make sure that the trim and tilt rams are fully retracted when removing the pipe joints 3 otherwise fluid can spurt out from the unit due to internal pressure 10 Install the spe...

Page 283: ...ht position 17 Remove the reservoir cap 4 and then check the fluid level in the reservoir WARNING Make sure that the trim and tilt rams are fully extended when removing the reser voir cap otherwise fl...

Page 284: ...L3J11 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 O ring 1 Not reusable 10 Oil seal 1 Not reusable 11...

Page 285: ...her with the PTT motor base assembly otherwise the armature could separate from the base assembly due to the magnetic force of the stator 2 and damage the brushes 3 Remove the springs 3 brushes 4 and...

Page 286: ...ce the brushes if below specifica tion Motor commutator standard undercut a 1 40 mm 0 055 in Wear limit 0 90 mm 0 035 in Armature continuity Commutator segments b Continuity Segment Armature core c No...

Page 287: ...he commutator of the armature 1 Install the bearings 1 and 2 onto the armature 3 NOTE Do not install the bearing 1 more than 1 0 mm 0 04 in past the end of the armature shaft as shown 2 Install a new...

Page 288: ...tor 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 th...

Page 289: ...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 reusable 13 Ball...

Page 290: ...18 Return 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...

Page 291: ...5 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 1 45...

Page 292: ...et 5 then the balls 6 4 Remove gear housing 2 7 then the shuttle pistons 8 5 Remove the drive gear 9 driven gear 0 balls A and pins B Checking the gear pump 1 Check the drive gear 1 and driven gear 2...

Page 293: ...1 and 2 and shuttle piston filters 3 Clean if there is dirt or residue Assembling the gear pump CAUTION Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components...

Page 294: ...ted before they were removed If installing new parts install them accord ing to the following reference data for the screw height a and screw depth b 6 Install the filters H and I and gear pump J by i...

Page 295: ...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 t...

Page 296: ...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 297: ...sable 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 T30 30 Free piston...

Page 298: ...n 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 cyli...

Page 299: ...inder end screws 0 and then remove them 11 Remove the trim ram assemblies 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...

Page 300: ...Polish with 400 600 grit sandpaper if there is light rust or replace if bent or if there is excessive corrosion 5 Check the pipes 0 Replace the pipes 0 if cracked or if there is corrosion Checking the...

Page 301: ...n 8 and then tighten the bolt to the specified torque NOTE Replace the tilt piston assembly if replacing the tilt piston 8 The shim s G are not available as individual parts If the tilt piston 8 was n...

Page 302: ...ilt cylinder CAUTION Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components can lead to poor perfor mance 1 Install a new O ring 1 to the free piston 2 2 Push t...

Page 303: ...erwise the PTT fluid may spurt out from the unit Installing the PTT motor CAUTION Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components can lead to poor perfor...

Page 304: ...ring 4 and the reservoir 5 and then tighten the bolts 6 to the specified torque 3 Install a new O ring and the reservoir cap 7 and then tighten the reservoir cap to the specified torque Installing the...

Page 305: ...WARNING Make sure that the trim and tilt rams are fully extended when removing the reser voir cap otherwise fluid can spurt out from the unit due to internal pressure NOTE If the fluid is at the corr...

Page 306: ...to 5 times NOTE Connect the PTT motor leads directly to the battery terminals when the power unit is not installed To connect the PTT motor leads see Chapter 7 Bleeding the PTT unit 2 Let the fluid se...

Page 307: ...for continuity Replace the fuse if there is no continuity NOTE For the location of the fuse see Chapter 8 Fuse holder Checking the PTT relay 1 Using the special service tool check the PTT relay for c...

Page 308: ...then check the PTT relay for continu ity Replace the PTT relay if out of speci fication Checking the PTT switch 1 Check the PTT switch for continuity Replace the PTT switch if out of specifi cation P...

Page 309: ...it gradually changes The position b is the trim sensor lever position when the outboard motor is tilted down To adjust the trim sensor see Chap ter 7 Adjusting the trim sensor The trim sensor resista...

Page 310: ...take air pressure sensor 8 21 Checking the engine temperature sensor 8 21 Checking the thermoswitch 8 22 Checking the shift cut switch 8 23 Checking the neutral switch 8 24 Checking the knock sensor 8...

Page 311: ...ing system 8 40 Checking the fuse 8 40 Checking the starter relay 8 41 Starter motor 8 42 Removing the starter motor 8 44 Checking the starter motor operation 8 44 Checking the magnet switch 8 45 Chec...

Page 312: ...DIS 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 to be used see Chapter 9 YDIS Also be sure to ch...

Page 313: ...ith the rec ommended digital circuit tester Connect the positive pin of peak voltage adapter B to the positive terminal of the dig ital tester and the negative pin to the nega tive terminal When measu...

Page 314: ...e 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 EX A 3 pin communica...

Page 315: ...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 316: ...tch 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 accessory battery 9 High pressure fuel pump relay 0 E...

Page 317: ...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 318: ...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 319: ...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 320: ...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 321: ...r lead D F 6 PTT motor lead F 7 Oil pressure sensor lead and water detection switch lead G 8 Isolator lead G NOTE The captions identifying the locations where the leads are routed fastened etc are enc...

Page 322: ...otor lead sub wiring harness and isolator lead to the holder Route the oil pressure sensor lead isolator lead and PTT motor lead through the guide Align the white tape on the oil pressure sensor lead...

Page 323: ...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 324: ...he cam position sensor lead PORT IN to the holder Install the clip of the knock sensor coupler to the hole of the ECM bracket Fasten the cooling water pressure sensor lead to the holder at the white t...

Page 325: ...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 326: ...blue 5 Isolator coupler black 6 10 pin main harness 7 Throttle cable 8 Gauge harness 9 Shift cable 0 Speedometer hose A Fuel hose B Battery cable C Wiring harness D LAN communication coupler E PTT swi...

Page 327: ...ness with the clamp Fasten the flushing hose and trim sensor lead with the plate Fasten the flushing hose trim sensor lead and speedometer hose with the plate Fasten the flushing hose and trim sensor...

Page 328: ...PTT switch lead wiring harness side and PTT switch extension lead with the holder Fasten the flushing hose PTT switch lead and trim sender lead with the clamp S6AS8040 FL200C FL225B A A B C C B D A A...

Page 329: ...away since this test can produce sparks NOTE The ignition spark can also be checked using the Stationary test of the YDIS 5 Install the ignition coils 6 Install the ECM cover NOTE Connect the injector...

Page 330: ...crank position sensor Checking the crank position sensor air gap 1 Remove the wiring harness guide bolts and lift up the wiring harness guide NOTE To completely remove the wiring harness guide when ch...

Page 331: ...When checking the intake air temperature sensor remove the top cowling and do not start the engine 4 Disconnect the intake air temperature sensor coupler 5 Turn the engine start switch to ON and then...

Page 332: ...anual 7 Apply negative pressure to the intake air pressure sensor slowly and check that the displayed intake air pressure is var ied NOTE When checking the intake air pressure sen sor do not start the...

Page 333: ...the port side of the power unit and one on the star board side 2 Turn the engine start switch to ON and then measure the input voltage at the thermoswitch connectors wiring harness end Check the wirin...

Page 334: ...ut voltage at the shift cut switch coupler wiring harness end Check the wiring harness if out of specification 4 Turn the engine start switch to OFF 5 Disconnect the test harness 2 pins 1 from the shi...

Page 335: ...ler blue 2 Connect the test harness 2 pins 1 to the neutral switch coupler wiring har ness end 3 Turn the engine start switch to ON and then measure the input voltage at the neutral switch coupler wir...

Page 336: ...sure 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 sensor the cylinder head must be removed 3...

Page 337: ...ilencer NOTE See the exploded diagram 4 9 2 Push the throttle valve directly and check that the valve moves smoothly when the engine start switch is turned to OFF 3 Turn the engine start switch to ON...

Page 338: ...ttery con nected and the engine start switch turned to OFF 4 Turn the engine start switch to ON and then measure the input voltage between terminals 8 and 9 as shown 5 Turn the engine start switch to...

Page 339: ...put voltage at ECM coupler terminal e 13 wiring harness end and ground Check the fuse wiring harness and engine start switch if below specification 6 Turn the engine start switch to OFF 7 Connect the...

Page 340: ...sensor 1 and accelera tor position sensor 2 are a single unit which cannot be disassembled To connect and operate the YDIS see Chapter 9 YDIS and the YDIS Ver 1 23a or later Instruction Manual 2 Chec...

Page 341: ...fully open position d Fully closed position Fully open position NOTE When the accelerator lever is in the fully open position d make sure that it is contact ing the stopper 7 when measuring the sen so...

Page 342: ...rness end 6 Turn the engine start switch to OFF 7 Connect the accelerator position sensor coupler b Checking the electronic throttle valve and TPS 1 Connect a computer to the outboard motor and use th...

Page 343: ...ottle valve opening angle at the fully closed position a and fully open position b NOTE Check the TPS after the engine has been warmed up When checking the TPS using the YDIS do not start the engine T...

Page 344: ...ottle valve and TPS circuit 1 Disconnect the ECM couplers a and b 2 Disconnect the electronic throttle valve coupler c 3 Check the wiring harness for continuity 4 Connect the electronic throttle valve...

Page 345: ...tage at the electronic throttle valve coupler c wiring harness end 10 Turn the engine start switch to OFF 11 Connect the electronic throttle valve cou pler c Variable camshaft timing control system 8...

Page 346: ...sor coupler 5 wiring harness end as shown NOTE Be sure to connect the wire leads to the cor responding terminals 6 Connect the tester leads to the wire leads Cam position sensor input voltage Red yell...

Page 347: ...oil control valve 1 Check the operation of the oil control valves using the Stationary test of the YDIS and listen for the operating sound 2 Disconnect the oil control valve couplers 3 Turn the engin...

Page 348: ...ction switch coupler wiring harness end 2 3 Turn the engine start switch to ON and then measure the input voltage at the water detection switch coupler wiring harness end Check the wiring harness if o...

Page 349: ...st of the YDIS and listen for the operating sound 2 Disconnect the fuel injector couplers 3 Turn the engine start switch to ON and then measure the input voltage between the fuel injector coupler term...

Page 350: ...pump relay 1 Remove the high pressure fuel pump relay 1 and check it NOTE The high pressure fuel pump relay and main relay are the same type of relay To check the relay see Chapter 8 Checking the mai...

Page 351: ...e battery voltage is applied to the vapor shut off valve termi nals 1 NOTE Apply the battery voltage to the vapor shut off valve terminals for a few seconds only other wise the vapor shut off valve ma...

Page 352: ...etween the terminal 2 and ground as shown 3 Connect the tester leads between the ter minals 3 and 4 as shown and then turn the engine start switch to START and measure the input voltage NOTE To check...

Page 353: ...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 Stator 1...

Page 354: ...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 holde...

Page 355: ...ositive battery cable 1 to the magnet switch terminal 2 and con nect the negative battery cable 3 to the starter motor body as shown 3 Connect the starter motor lead brown white 4 to the positive batt...

Page 356: ...nal is removed from the starter motor body Replace if there is continuity NOTE The starter motor pinion should be pushed out while the magnet switch is ON If the starter motor is disassembled for main...

Page 357: ...rush holder assembly 4 NOTE Do not scratch or damage the brushes when removing the armature 5 Remove the magnet switch 7 and spring 8 6 Slide the pinion stopper 9 down as shown and then remove the cli...

Page 358: ...ck the commutator Clean with 600 grit sandpaper and compressed air if dirty 2 Measure the commutator diameter Replace the armature if below specifica tion 3 Measure the commutator undercut a Replace t...

Page 359: ...pinion shaft 4 and will not come loose and then install the E clip 5 NOTE Push the clutch assembly 3 completely down onto the pinion shaft 4 in direction a rotate it 1 spline in direction b and then s...

Page 360: ...nd then install the armature F to the brush holder assembly 7 Install the plate G 8 Align the screw holes in the brush holder with the holes a and b in the plate H and then install the plate I and bra...

Page 361: ...e terminals of the starter motor lead brown white 7 and wiring harness lead brown 5 using the same bolt 6 NOTE To wire the starter motor lead brown white see Chapter 8 Wiring harness routing 4 Install...

Page 362: ...can be damaged 1 Remove the starboard intake manifold 2 Remove the fuse holder and disconnect the Rectifier Regulator coupler 1 and then install the starboard intake manifold NOTE When installing the...

Page 363: ...the mark b by pushing the SHIFT switch when checking the Rectifier Regulator continuity Rectifier Regulator output peak voltage Red R Ground r min Unloaded 1 500 3 500 DC V 13 0 13 0 S6P28100 R2 R2 R...

Page 364: ...ELEC Electrical system 8 53 6AL3J11 MEMO...

Page 365: ...or 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...

Page 366: ...r a mouse or a keyboard In addition the data for the main functions Diagnosis Diagnosis record Engine monitor and Data logger can be saved on a disk or printed out Function 1 Diagnosis Displays each p...

Page 367: ...timing ECM low pressure fuel pump high pressure fuel pump 11 Electronic throttle valve relay 12 High pressure fuel pump relay 1 Engine speed 10 Fuel injection duration 19 Dual engine system switch 2 I...

Page 368: ...engine speed and the total operating time are displayed This allows you to check the operating status of the engine For the F L 200C F L 225B models you can also save the ECM record data on a file so...

Page 369: ...the criterion output voltage of the accelerator position sensor This value is used to detect the accelerator position sensor output voltage when the remote control throttle lever is opened 7 Target TP...

Page 370: ...ubleshooting 9 5 6AL3J11 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...

Page 371: ...put 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 delete the diagnos...

Page 372: ...malfunction 29 Intake press sensor malfunction 37 Intake air passage malfunction 39 Oil press sensor malfunction 44 Engine stop lanyard switch malfunction 45 Shift cut off switch malfunction 46 Overhe...

Page 373: ...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 374: ...rature using the YDIS 9 1 2 Measure the input voltage 8 21 3 Measure the resistance 8 21 17 Knock sensor malfunction C Maximum power decreases 1 Measure the resistance 8 25 2 Check the green G lead EC...

Page 375: ...ing the YDIS 9 1 2 Check the vacuum hoses 4 2 3 Measure the input voltage 8 21 4 Check the operation of the intake air pressure sensor 8 21 5 Check the pink green P G lead ECM to sub wiring harness to...

Page 376: ...ad ECM to 10 pin main harness coupler for continuity WD 5 Check the black B lead 10 pin main harness coupler to joint connector to ground for conti nuity WD 45 Shift cut off switch 2 malfunction C Shi...

Page 377: ...e 8 34 3 Check the white green W G lead cam position sensor to ECM for continuity WD 4 Measure the output voltage 8 34 5 Check the brim of the camshaft 5 25 6 Check the battery cables and terminals fo...

Page 378: ...nuity 8 31 115 116 Electronic throttle system malfunction J 1 Check the electronic throttle valve circuit 8 33 2 Check the electronic throttle valve relay and fuse 8 27 3 Check the electronic throttle...

Page 379: ...ning angle using the YDIS 8 31 3 Check the electronic throttle valve circuit 8 33 127 128 Throttle position sensor malfunction B 1 Check the TPS output voltage using the YDIS 8 31 2 Check the throttle...

Page 380: ...Check the accelerator position sensor circuit 8 31 3 Measure the accelerator position sensor resistance 8 29 135 Accelerator position sensor malfunction B 1 Check the accelerator position sensor outpu...

Page 381: ...malfunction J 1 Check the electronic throttle valve operation 8 26 143 144 Electronic throttle system malfunction J 1 Check the battery cables and terminals for proper connection 3 17 2 Check the ECM...

Page 382: ...determine Trouble code indication Example Normal condition no defective part or irregular process ing is found a Light on 0 33 second b Light off 4 95 seconds Trouble code indication Example The illus...

Page 383: ...n 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 detecte...

Page 384: ...tery terminal Check the battery ter minal 3 17 Short open or loose connection in starter motor circuit Check the wiring har ness continuity WD Starter relay malfunc tion Check the starter relay 8 41 B...

Page 385: ...ess continuity WD 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 WD Blow...

Page 386: ...h pressure fuel line malfunction fuel pressure is low Pressure regulator malfunction Check the pressure regulator 4 7 High pressure fuel pump malfunction Check the high pressure fuel pump continuity 8...

Page 387: ...body 4 9 4 13 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 388: ...ge from water pump hous ing Check the water pump housing 6 5 6 34 Check the insert cartridge 6 5 6 34 Check the outer plate cartridge 6 5 6 34 Clogged cooling wa ter passage Check the cooling water pa...

Page 389: ...nnection of the PTT motor lead Check the PTT mo tor lead 7 36 PTT motor malfunc tion Disassemble and check the PTT mo tor 7 35 Blown fuse Check the fuse 8 5 Loose connection of the battery terminal Ch...

Page 390: ...fluid leakage Check the PTT unit for leakage 7 30 Clogged fluid pas sage Disassemble and check the PTT unit 7 30 Symptom 2 Cause 1 Cause 2 Checking step Refer to page Remote control box malfunction C...

Page 391: ...Checking the camshaft 5 25 Checking the canister 4 16 Checking the canister check valve 4 16 Checking the check valve 4 22 Checking the compression pressure 5 1 Checking the connecting rod big end si...

Page 392: ...63 Checking the pressure regulator 4 7 Checking the propeller 3 16 Checking the propeller shaft 6 9 6 39 Checking the propeller shaft housing 6 9 6 38 Checking the PTT fluid level 3 13 Checking the PT...

Page 393: ...2 17 Good working practice 1 5 H Hose routing 4 1 How to use this manual 1 1 I Identification 1 6 Ignition and ignition control system 8 18 Injector 1 15 Installing the camshaft driven sprocket and t...

Page 394: ...7 15 Removing the water pump and shift rod 6 5 6 33 Removing the wiring harness 5 41 Replacing the oil filter 3 7 Replacing the timing belt 5 15 Replacing the valve guide 5 48 S Safety while working 1...

Page 395: ...6AL3J11 i 5 1 2 3 4 5 6 7 8 9 Index W Water separator 1 14 Wiring harness routing 8 8 Y YDIS 9 1...

Page 396: ...icator trim meter To diagnostic test lead special service tool To personal computer for diagnosis To cooling water pressure sensor optional To speed sensor optional To trim meter To 6Y8 Multifunction...

Page 397: ......

Page 398: ......

Page 399: ...B B B B B B B B B B B G G B B G R R R R Br R R Y G L R R G R G R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R B Br R R R Br Y R P B P B P W L W B P B P Sb Lg P R Sb Lg R R...

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