SELVA MARINE Kingfish 25 Service Manual Download Page 83

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4-1

TRBL

SHTG

Troubleshooting

Troubleshooting the outboard motor

Troubleshooting procedure

Before troubleshooting the outboard motor, make sure that fresh fuel of the specified type has
been used.

Make sure that all electrical connections are secure and free from corrosion, and that the bat-
tery is fully charged.

Summary of Contents for Kingfish 25

Page 1: ...YAMAHA MOTOR CO LTD F4A F4 Goldfish 4 Kingfish 25 SERVICE MANUAL...

Page 2: ...s and illustrations given in this publication Use only the latest edition of this manual Authorized Selva dealers are notified periodically of modifications and significant changes in specifications a...

Page 3: ...on SPEC 1 Technical features and description TECH FEA 2 Rigging information RIG GING 3 Troubleshooting TRBL SHTG 4 Electrical system ELEC 5 Fuel system FUEL 6 Power unit POWR 7 Lower unit LOWR 8 Brack...

Page 4: ......

Page 5: ...f protection 0 2 Working with crane 0 2 Handling of gas torch 0 2 Part lubricant and sealant 0 2 Handling of sealant 0 2 Special service tool 0 3 Tightening torque 0 3 Non reusable part 0 3 Disassembl...

Page 6: ...ric shock Do not touch any electrical parts while start ing or operating the engine Otherwise shock or electrocution could result Propeller Do not hold the propeller with your hands when loosening or...

Page 7: ...outboard motor can be lifted and carried in a stable manner Handling of gas torch Improper handling of a gas torch may result in burns For information on the proper han dling of the gas torch see the...

Page 8: ...use new gaskets seals O rings cot ter pins and so on when installing or assem bling parts Disassembly and assembly Use compressed air to remove dust and dirt during disassembly Apply engine oil to th...

Page 9: ...e p S 0 1 Not reusable 6 M 1 t l o B 1 1 35 mm 6 M 1 t l o B 2 1 18 mm 1 b a t m i r T 3 1 1 t i n u r e w o L 4 1 1 r e c a p S 5 1 1 r e l l e p o r P 6 1 1 r a l l o C 7 1 3 1 2 3 6 5 5 4 20 19 18...

Page 10: ...efore Top Dead Center CCA Cold Cranking Ampere CDI Capacitor Discharge Ignition C L Centerline EN European Norm European standard EX Exhaust F Forward IEC International Electrotechnical Commission IN...

Page 11: ...ts Symbol Name Application 4 stroke motor oil Lubricant Gear oil Lubricant Water resistant grease Lubricant Molybdenum disulfide grease Lubricant Corrosion resistant grease Lubricant Low temperature r...

Page 12: ...distributed by the Parts Division Drilling plate 90890 06783 Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 Ignition tester spark gap tester 90890 06754 Test harness 2 pins 908...

Page 13: ...90 06673 Compression gauge 90890 03160 Flywheel holder 90890 06522 Flywheel puller 90890 06521 Crankshaft holder 90890 06355 Valve spring compressor 90890 04019 Valve spring compressor attachment 9089...

Page 14: ...r 90890 04101 Valve seat cutter holder 90890 06316 Valve seat cutter 30 90890 06327 Valve seat cutter 45 90890 06325 Valve seat cutter 60 90890 06324 Valve seat cutter 30 90890 06328 Valve seat cutter...

Page 15: ...Piston slider 90890 06529 Stopper guide plate 90890 06501 Bearing separator 90890 06534 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 Needle bearing attachment 90890 06615 Driver...

Page 16: ...ttachment 90890 06628 Drive shaft holder 3 90890 06517 Ball bearing attachment 90890 06637 Bearing inner race attachment 90890 06643 Needle bearing attachment 90890 06616 Driver rod SL 90890 06602 Bea...

Page 17: ...0 06644 Pinion height gauge 90890 06710 Pinion height gauge plate B 90890 06712 Shimming plate 90890 06701 Center bolt 90890 06504 Bearing housing puller claw S 90890 06564 Backlash indicator 90890 06...

Page 18: ...earing attachment 90890 06614 Driver rod SS 90890 06604 Bearing inner race attachment 90890 06639 Ball bearing attachment 90890 06633 Bearing inner race attachment 90890 06641 Needle bearing attachmen...

Page 19: ...hment 90890 06634 Bushing installer center bolt 90890 06601 Needle bearing attachment 90890 06613 Needle bearing attachment 90890 06617 Cylinder end screw wrench 90890 06568 Digital tachometer 90890 0...

Page 20: ...0 15 GEN INFO General information MEMO...

Page 21: ...l system 1 7 Engine speed control system 1 9 Charging system 1 10 Starting system 1 11 Fuel system technical data 1 11 Fuel system 1 11 Power unit technical data 1 13 Power unit 1 13 Manual starter 1...

Page 22: ...stroke regular rotation FT 4 stroke regular rotation high thrust 2 Model name 25 25 3 Product generation A A and up 4 Functions M Manual starter E Electric starter 5 H Tiller handle 6 T Power trim and...

Page 23: ...T PT Overall length mm in 724 0 28 5 735 0 28 9 Overall width mm in 398 15 7 Overall height S mm in 1157 0 45 6 L mm in 1284 0 50 6 1312 0 51 7 X mm in 1426 0 56 1 Boat transom height S mm in 381 0 15...

Page 24: ...tion control system CDI Advance type Micro computer Maximum generator output V A 12 0 13 0 Starting enrichment Prime Start Spark plug DPR6EB 9 NGK Firing order 1 2 Cooling system Water Exhaust system...

Page 25: ...e Degree 73 66 Steering angle Degree 42 42 40 40 Trim and tilt system Manual PTT Item Unit Model STD Gear shift positions F N R Gear ratio 2 08 27 13 Reduction gear type Spiral bevel gear Clutch type...

Page 26: ...it Model E ST E ST PT Fuel type Regular unleaded gasoline Engine oil 4 stroke motor oil with combinations of the following SAE and API oil classifications Engine oil grade 1 API SE SF SG SH SJ SL SAE...

Page 27: ...em Unit Model E ST E ST PT Minimum cold cranking amps CCA EN A 347 0 Minimum rated capacity 20HR IEC Ah 40 0 Item Unit Model Fluid type Item Unit Model E ST E ST PT Fluid type ATF Dexron II Item Unit...

Page 28: ...utput peak voltage at cranking unloaded V 70 0 at cranking loaded V 110 0 at 1500 r min loaded V 190 0 at 3500 r min loaded V 190 0 CDI unit Output peak voltage at cranking loaded V 210 0 at 1500 r mi...

Page 29: ...F 28 9 39 1 Output peak voltage at cranking unloaded V 70 0 at cranking loaded V 110 0 at 1500 r min loaded V 190 0 at 3500 r min loaded V 190 0 CDI unit Output peak voltage at cranking loaded V 210...

Page 30: ...erence only Item Unit Model STD Lighting coil Resistance 1 at 20 C 68 F 0 21 0 29 Output peak voltage at cranking unloaded V 11 5 at 1500 r min unloaded V 25 7 at 3500 r min unloaded V 61 6 Fuse A Rec...

Page 31: ...5 0 22 Commutator Standard diameter mm in 29 4 1 16 Wear limit mm in 28 8 1 13 Standard undercut mm in 0 5 0 02 Wear limit mm in 0 2 0 01 Item Unit Model E ST E ST PT Starter motor Type Sliding gear...

Page 32: ...in jet MJ For Europe 105 For Oceania 108 Main air jet MAJ 70 Main nozzle MN mm in 2 6 0 10 Pilot jet PJ For Europe 45 For Oceania 45 Pilot air jet PAJ 85 Adjustable pilot screw PS For Europe Turns out...

Page 33: ...N mm in 2 6 0 10 Pilot jet PJ For Europe 45 For Oceania 45 Pilot air jet PAJ 85 Adjustable pilot screw PS For Europe Turns out 2 1 2 For Oceania Turns out 2 3 4 1 2 Starter jet SJ 62 Prime Start plung...

Page 34: ...ed at which the starter handle is pulled Manual starter model The figures are for reference only 2 For details of the checking method see Checking the oil pressure 7 1 The figures are for reference on...

Page 35: ...iameter mm in 15 971 15 991 0 6288 0 6296 Rocker arm Inside diameter mm in 16 000 16 018 0 6299 0 6306 Valve Clearance Intake mm in 0 20 0 05 0 008 0 002 Exhaust mm in 0 30 0 05 0 012 0 002 Head diame...

Page 36: ...36 945 1 4537 1 4545 Journal diameter 2 mm in 36 935 36 955 1 4541 1 4549 Cylinder head journal inside diameter mm in 37 000 37 025 1 4567 1 4577 Runout mm in 0 030 0 0012 Rocker arm shaft Outside dia...

Page 37: ...300 2 500 0 0906 0 0984 End gap 1 mm in 0 150 0 300 0 0059 0 0118 Side clearance mm in 0 020 0 060 0 0008 0 0024 2nd ring Type Taper Dimension height B mm in 1 470 1 490 0 0579 0 0587 Dimension width...

Page 38: ...op ring Type Barrel Dimension height B mm in 1 170 1 190 0 0461 0 0469 Dimension width T mm in 2 300 2 500 0 0906 0 0984 End gap 1 mm in 0 150 0 300 0 0059 0 0118 Side clearance mm in 0 020 0 060 0 00...

Page 39: ...2 Pinion to forward gear Backlash 1 mm in 0 30 0 73 0 0118 0 0287 Pinion to reverse gear Backlash 1 mm in 0 92 1 65 0 0362 0 0650 Pinion shim T3 mm 0 7 1 0 1 1 1 2 1 3 1 4 1 5 1 6 Forward gear shim T1...

Page 40: ...the special service tools Item Unit Model STD Motor brush Standard length mm in 7 5 0 30 Wear limit mm in 5 1 0 20 Motor commutator Standard diameter mm in 16 3 0 64 Wear limit mm in 14 9 0 59 Standa...

Page 41: ...4 2 51 PTT relay cover screw 5 3 0 3 2 2 Power unit mounting bolt 1st M8 21 2 1 15 5 2nd 21 2 1 15 5 Apron screw M4 2 0 2 1 5 Drive sprocket nut 150 15 0 110 6 Driven sprocket bolt M6 38 3 8 28 0 Flyw...

Page 42: ...h thrust model M10 39 3 9 28 8 Extension nut 39 3 9 28 8 Propeller shaft housing bolt high thrust model M8 16 1 6 11 8 Part to be tightened Screw size Tightening torques N m kgf m ft lb Self locking n...

Page 43: ...r plate nut 24 2 4 17 7 Tilt lever screw M5 4 0 4 3 0 Self locking nut 45 4 5 33 2 Stopper nut PTT model 36 3 6 26 6 Part to be tightened Screw size Tightening torques N m kgf m ft lb Stator screw M4...

Page 44: ...age tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified torque is reached Unless otherwise indi cated torque specifications require clean dry threads C...

Page 45: ...1 25 SPEC Specification MEMO...

Page 46: ...ving 2 7 Engine speed control during overheating 2 7 Engine speed control during low oil pressure 2 7 Power unit 2 8 Outline 2 8 Balancer 2 9 Automatic decompression device manual starter model 2 9 Lu...

Page 47: ...eed changes engine cooling water temperature and oil pressure If the engine speed exceeds 6200 r min the ignition is cut off so that the engine speed does not increase too high If overheating or low o...

Page 48: ...2 2 2 1 CDI unit 2 Pulser coil 3 Ignition coil 4 Thermo sensor 5 Oil pressure switch 2 3 5 4 1 Engine control system...

Page 49: ...n coil according to the signals from the pulser coil thermo sensor and oil pressure switch In addition during an overheating or low oil pressure alert the CDI unit operates the buzzer remote control m...

Page 50: ...n the engine is started during acceleration and according to the engine cooling water temperature a Ignition timing BTDC b Engine speed r min Starting ignition timing control When the engine is starte...

Page 51: ...hanged as shown in the following graph a Ignition timing BTDC b Engine speed r min 1 Basic ignition timing 2 Acceleration ignition timing Control starting condition Control time Ignition timing Rapid...

Page 52: ...arting condition Corrected ignition timing 20 C 4 F or more and 10 C 50 F or less BTDC 5 degrees More than 10 C 50 F and less than 30 C 86 F Returns from BTDC 5 degrees to the basic ignition timing 30...

Page 53: ...than the specified pressure and the following engine speed con ditions are present control will start by cutting off the power to the ignition coil ignition by the spark plugs is stopped so that the e...

Page 54: ...y 25 the engine is equipped with a balancer 1 to decrease engine vibration and for man ual starter models a camshaft 2 that includes a decompression device for easy starting Optimum combustion is obta...

Page 55: ...ression device manual starter model When the starter rope is pulled the decompression actuator 1 for each exhaust valve retards the closing timing of the valve to reduce the pressure in the cylinder a...

Page 56: ...pressure switch Oil filter Oil strainer Sleeve Piston Crank pin Crankshaft journal Oil pan Intake and exhaust valves Rocker arm Rocker arm shaft Camshaft journal Main gallery Oil filter Oil pump Oil s...

Page 57: ...FT25 Cooling water flow Thermostat Exhaust guide Oil pan Water pump Cooling water inlet Exhaust guide Upper case Lower case Trim tab water inlet Water Exhaust cover Exhaust port Water pump Cooling wat...

Page 58: ...2 12 2 Intake and exhaust system System diagram Intake air flow Exhaust gas flow Intake silencer Carburetor Intake manifold Exhaust manifold Propeller boss Cooling system Intake and exhaust system...

Page 59: ...chment valve 2 is fully open to enrich the air and fuel mixture during engine starting and warm up While the engine is warming up the power to the Prime Start system is turned on and the Prime Start p...

Page 60: ...throttle lever moves past the half open position Air Fuel Air and fuel mixture Before acceleration pump operates throttle valve fully closed position When acceleration pump operation finishes throttle...

Page 61: ...fluid flow direction The relief valves 3 and 4 and the protec tion valves 5 and 6 are installed in both the upstream and downstream fluid passages to control the fluid pressure The manual valve 7 open...

Page 62: ...b which opens the return passage Then the PTT fluid flows into the lower chamber of the cylinder to force the free piston 0 and the tilt ram assembly A to move up The relief valve 3 of the fluid pres...

Page 63: ...re forces the shuttle piston c to slide to the up valve a The protrusion on the shuttle piston c opens the up valve a which opens the return passage Then the PTT fluid flows into the upper chamber of...

Page 64: ...When the outboard motor is tilted up after colliding with an object while operating an upwardly directed force is applied to the tilt ram This force increases the fluid pressure in the tilt cylinder...

Page 65: ...2 19 TECH FEA Technical features and description MEMO...

Page 66: ...3 9 Uncrate procedure 3 10 Mounting the outboard motor 3 11 Mounting the rigging grommet 3 13 Rigging grommet description 3 13 Installing the shift cable and throttle cable remote control model 3 13...

Page 67: ...outboard motor Too much weight on the transom could change the center of gravity buoyancy operating balance or performance of the boat which could cause loss of control or swamping Con sult the boat m...

Page 68: ...12 73 4 2 378 14 9 601 23 7 189 7 4 65 2 6 705 27 8 213 8 4 604 23 8 144 5 7 258 10 2 43 1 7 41 1 6 387 15 2 199 7 8 S 667 26 3 L 748 29 4 S 423 16 7 L 550 21 7 H 1 S 707 27 8 L 834 32 8 S 761 30 0 L...

Page 69: ...0 378 14 9 601 23 7 123 4 8 65 2 6 705 27 8 133 5 7 258 10 2 43 1 7 12 0 5 387 15 2 199 7 8 S 667 26 3 L 748 29 4 S 423 16 7 L 550 21 7 S 23 0 9 L 22 0 9 H 1 S 707 27 8 L 834 32 8 S 761 30 0 L 880 34...

Page 70: ...rior Kingfish 25 E ST PT 1 Transom height mm in 450 17 7 433 17 0 353 13 9 601 23 7 123 4 8 65 2 6 706 27 8 22 0 9 144 5 7 282 11 1 43 1 7 12 0 5 387 15 2 199 7 8 665 26 2 H 1 550 21 7 834 32 8 875 34...

Page 71: ...3 7 RIG GING Rigging information Clamp bracket manual tilt model mm in 37 1 5 150 5 9 70 2 8 10 5 0 4 218 8 8 6 50 2 0 32 1 3 140 5 5 150 5 9 140 5 5...

Page 72: ...3 8 3 Clamp bracket PTT model mm in 180 7 1 13 0 5 254 10 0 338 13 3 18 5 0 7 50 8 2 0 163 5 6 4 125 9 5 0 125 9 5 0 13 0 5 180 7 1 69 2 7 163 5 6 4 55 5 2 2 Dimensions...

Page 73: ...ORTANT This unit delivered to carrier in a good condition For protection against loss due to damage inspect thoroughly If damage is noted make note on freight bill Shipper assumes no further liability...

Page 74: ...es 4 onto the shackle 2 and engine hanger 5 on the crankcase TIP Place a rag a between the manual starter manual starter model or flywheel magnet cover electric starter model and the lifting harness 7...

Page 75: ...akes C L Centerline of transom 2 Adjust the position of the outboard motor so that the height of the anti cavitation plate e is between the bottom of the boat and a maximum of 25 mm 1 in f below it TI...

Page 76: ...maged TIP The second hole from the top of each clamp bracket is recommended for the upper mounting bolt PTT model 6 Install the mounting bolts and then tighten the nuts firmly NOTICE Make sure that th...

Page 77: ...and cable guide 2 3 Fit the cable guide 2 into the grooves a of the shift cable 3 and throttle cable 4 and then install the cable guide 2 shift cable 3 and throttle cable 4 4 Fully screw in the shift...

Page 78: ...m 0 contacts the stopper A 14 Adjust the throttle cable joint 9 and then install the throttle cable joint 9 to the pin h of the throttle cam WARNING The throttle cable joint must be screwed in 8 0 mm...

Page 79: ...Installing the remote control box and tachometer remote control model See Remote control box operation manual or Rigging guide for the installation proce dures Installing the battery Improper battery...

Page 80: ...opeller is indicated on a propeller blade on the propeller boss end and on the side of the propeller boss a Propeller diameter in inches b Propeller pitch in inches c Propeller type propeller mark Sel...

Page 81: ...3 17 RIG GING Rigging information MEMO...

Page 82: ...TRBL SHTG 4 Troubleshooting Troubleshooting the outboard motor 4 1 Troubleshooting procedure 4 1 Troubleshooting the power unit 4 2 Troubleshooting the PTT unit 4 9 Troubleshooting the lower unit 4 10...

Page 83: ...d motor Troubleshooting procedure 1 Before troubleshooting the outboard motor make sure that fresh fuel of the specified type has been used 2 Make sure that all electrical connections are secure and f...

Page 84: ...shift not in the N position Set the gear shift to the N position 10 5 Start in gear protection cable not adjusted properly Adjust the start in gear protection cable 7 11 Manual starter malfunction Dis...

Page 85: ...ystem circuit Measure the starter relay input voltage 5 18 Check the wiring harness continuity A 2 A 4 Starter motor malfunction Disassemble and check the starter motor 5 21 Starter motor operates but...

Page 86: ...it A 2 A 4 Short open or loose connection in pulser coil circuit Check for wiring continuity between the pulser coil and CDI unit 5 12 Fuel not supplied Pinched or kinked fuel hose Check the fuel hose...

Page 87: ...ion spark 5 10 Check the spark plugs 7 45 Charge coil malfunction Measure the charge coil output peak voltage 5 12 Measure the charge coil resistance 5 12 Pulser coil malfunction Measure the pulser co...

Page 88: ...properly Adjust the pilot screw Except tamperproof pilot screw 6 13 Clogged carburetor jets Disassemble and clean the carburetor 6 10 Compression pressure is low Improper valve timing Check the valve...

Page 89: ...properly Adjust the throttle link and throttle cable 6 17 3 13 9 6 Symptom 2 Cause 1 Cause 2 Checking step See page Buzzer comes on remote control model overheat alert indicator comes on located on th...

Page 90: ...passages Check the oil passages power unit and oil pump 2 10 Clogged oil filter Replace the oil filter 10 12 Symptom 2 Cause 1 Cause 2 Checking steps See page Battery performance decrease Check the b...

Page 91: ...ess Check for wiring harness continuity between the PTT switch and PTT relay A 2 A 4 PTT motor does not operate PTT motor malfunction Check the PTT motor 9 63 Short open or loose connection in PTT mot...

Page 92: ...ck the manual valve 9 76 Insufficient PTT fluid Add sufficient fluid 10 14 PTT fluid leakage Check the PTT unit for leakage 10 14 Clogged fluid passages Disassemble and check the PTT unit 9 66 9 73 Ch...

Page 93: ...ndicator 5 15 Checking the Prime Start 5 15 Checking the engine start button tiller handle model with electric starter 5 16 Checking the engine start switch remote control model 5 17 Checking the engi...

Page 94: ...or 5 25 Installing the starter motor 5 27 Charging unit and components 5 27 Checking the lighting coil 5 27 Checking the Rectifier Regulator electric starter model 5 28 PTT electrical system 5 29 Chec...

Page 95: ...rter model 4 Ignition coil 5 Engine shut off switch ground lead tiller handle model 6 Main wiring harness ground lead 7 Negative battery cable electric starter model 8 Starter relay ground lead electr...

Page 96: ...F Tachometer connector G Ignition coil lead Route the Prime Start lead and wiring har ness to the inside of the battery cable Electric starter model Fasten the wiring harness using the holder at the...

Page 97: ...e model and main wiring harness ground lead that have white tape Connect the negative battery cable Elec tric starter model Connect the starter relay ground lead electric starter model and main wiring...

Page 98: ...5 4 5 Starboard view 1 Prime Start 2 PTT relay PTT model Fasten the Prime Start lead using the holders 1 2 Electrical component and wiring harness routing...

Page 99: ...ectric starter 6 10 pin main wiring harness coupler remote control model 7 Neutral switch lead tiller handle model with electric starter 8 Prime Start lead 9 PTT motor lead PTT model 0 PTT relay lead...

Page 100: ...rness lead Connect the battery lead and wiring har ness lead PTT model Fold the PTT motor lead and place the slack in the lead in the bottom cowling High thrust model Route the 10 pin main wiring harn...

Page 101: ...ermo sensor 2 Pulser coil 3 Stator assembly 4 Charge coil lead 5 Lighting coil lead 6 Thermo sensor lead 7 Main wiring harness Route charge coil lead lighting coil lead and Prime Start lead along the...

Page 102: ...off switch 3 Battery cable electric starter model for Oceania 4 Alert indicator 5 PTT switch PTT model for Oceania Fit the protrusion on the bracket into the third indentation in the corrugated tube...

Page 103: ...coil CDI unit Battery Pulser coil 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 No Connecting part Color 1 2 Overheat alert indicator Pink Black 3 4 Overheat alert indicator Yellow Black 5 Tachometer...

Page 104: ...circuit tester Connect the positive pin of peak voltage adapter B to the positive terminal of the dig ital circuit tester and the negative pin to the negative terminal When measuring the peak voltage...

Page 105: ...p resistance 3 Install the spark plug caps to the spark plug wires by turning the spark plug caps clockwise Checking the ignition coil 1 Disconnect the ignition coil connectors 2 Remove the spark plug...

Page 106: ...tool 1 2 Measure the charge coil output peak volt age TIP When measuring the output peak voltage under the cranking condition remove the clip from the engine shut off switch to pre vent the engine fr...

Page 107: ...dle to crank the engine the voltage values may vary depending on the speed at which the starter handle is pulled Manual starter model Checking the thermo sensor 1 Remove the manual starter and driven...

Page 108: ...ch 1 Disconnect the oil pressure switch con nector a 2 Start the engine and then measure the oil pressure switch 1 input voltage 3 Stop the engine 4 Remove the oil pressure switch 1 5 Connect the spec...

Page 109: ...ator comes on 3 Connect the alert indicator coupler to the battery terminals 1 5 V and then check that the overheat alert indicator comes on 4 Connect the alert indicator coupler Checking the Prime St...

Page 110: ...ller handle model with electric starter 1 Disconnect the engine start button con nectors a and b 2 Measure the engine start button 1 input voltage between the connector a and the ground 3 Check the en...

Page 111: ...ty 5 Connect the 10 pin main wiring harness coupler Checking the engine shut off switch tiller handle model 1 Disconnect the engine shut off switch connector a and ground terminal b 2 Check the engine...

Page 112: ...the location of the fuse see Electrical component and wiring harness routing 5 1 Checking the starter relay electric starter model 1 Disconnect the starter relay connector a 2 Push the engine start b...

Page 113: ...electric starter Before checking the neutral switch make sure to check the engine start button 1 Disconnect the start button connector a and neutral switch connector b 2 Push the engine start button 1...

Page 114: ...upler 3 Turn the engine start switch to START and then check the neutral switch for continuity between the terminals a and b 4 Move the remote control lever to the F or R position and then check the n...

Page 115: ...M5 105 mm 5 Screw set 1 M6 25 mm cover screw M5 8 mm bracket screw 6 Bracket 1 7 Starter motor gear assembly 1 8 Pinion shaft 1 9 Planetary gear 3 10 Pinion stopper set 1 11 Clutch assembly 1 12 Outer...

Page 116: ...itch 1 Connect the tester leads between the magnet switch terminals a and b 2 Connect the negative battery cable 1 to the starter motor body 3 Connect a lead 2 to the magnet switch terminal b 4 Connec...

Page 117: ...or 4 Remove the stator 3 5 Remove the armature 4 together with the brush holder assembly 5 from the bracket 6 6 Remove the armature 4 from the brush holder assembly 5 7 Remove the lever 7 and pinion s...

Page 118: ...ng the armature starter motor 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty 2 Measure the commutator diameter a Replace the armature if below specifica tion Pipe 0 c...

Page 119: ...ch brush Replace the brush holder assembly if below specification Assembling the starter motor Do not apply grease or oil to the commu tator of the armature 1 Push the brushes a into the holders and t...

Page 120: ...shaft 7 4 Install the clip c into the pinion shaft groove 5 Install the clip c into the groove in the stopper b by tapping the pinion shaft 7 6 Install the pinion shaft assembly 8 lever 9 planetary ge...

Page 121: ...emove the manual starter See Removing the manual starter 7 7 Manual starter model Remove the flywheel magnet cover Electric starter model 2 Disconnect the lighting coil coupler a and then connect the...

Page 122: ...ulator electric starter model Before checking the Rectifier Regulator make sure to check the lighting coil If the battery cables are connected in reverse the Rectifier Regulator can be damaged 1 Remov...

Page 123: ...erminals a and b 2 Disconnect the battery power source ground lead PTT motor leads and PTT relay coupler NOTICE Always discon nect the battery negative terminal before disconnecting the PTT relay term...

Page 124: ...the special service tool and then connect the PTT relay coupler bat tery power source ground lead and PTT motor leads Checking the PTT switch 1 Disconnect the PTT switch coupler a 2 Measure the input...

Page 125: ...e 5 Remove the fuse 1 6 Check the wiring harness for continuity 7 Install the fuse 1 8 Connect the PTT relay coupler e and PTT switch coupler a Switch position Terminal b c d Up Free Down c d b Lg R S...

Page 126: ...or 6 12 Disassembling the carburetor 6 12 Checking the carburetor 6 12 Checking the Prime Start 6 13 Assembling the carburetor 6 13 Installing the carburetor 6 14 Throttle link throttle cam and shift...

Page 127: ...etor 4 Cooling water hose exhaust cover to joint 5 Cooling water hose joint to exhaust guide 6 Cooling water hose joint to joint 7 Cooling water hose joint to water outlet 8 Flushing hose flushing hos...

Page 128: ...6 Holder 1 7 Holder 1 8 Clamp 2 9 Hose 1 10 Nut 1 11 Bolt 1 M8 20 mm 12 Bracket 1 13 O ring 1 Not reusable 14 Fuel filter element 1 15 Fuel filter cup 1 16 Fuel filter assembly 1 17 Holder 2 15 14 13...

Page 129: ...Fuel system No Part name Q ty Remarks 18 Clamp 4 19 Holder 4 20 Tube 2 21 Hose 1 22 Hose 1 15 14 13 18 20 21 18 19 19 19 19 18 20 17 18 22 17 16 9 8 8 11 12 10 1 2 4 7 3 4 5 6 E 2 5 N m 0 25 kgf m 1...

Page 130: ...nlet a 2 Block the fuel outlet b using a rubber plug 2 and then apply the specified positive pressure Replace the O ring fuel filter cup or fuel filter assembly if the specified pressure cannot be mai...

Page 131: ...er 1 4 Diaphragm 1 Not reusable 5 Fuel pump body 2 1 6 Diaphragm 1 7 Spring 1 8 Plug 1 9 Plastic tie 1 Not reusable 10 Bolt 2 M6 30 mm 11 Fuel pump body 1 1 12 Nut 4 13 Spring 1 14 Plunger 1 15 Pin 1...

Page 132: ...the specified positive pressure and check that there is no air leakage Disassembling the fuel pump 1 Remove the cover 1 diaphragm 2 and fuel pump body 2 3 2 Align the slot a in fuel pump body 1 4 wit...

Page 133: ...assembling the fuel pump clean the parts and soak the valves and diaphragm in gasoline to obtain prompt operation of the fuel pump 1 Install the diaphragm 1 springs 2 and 3 and plunger 4 2 Align the...

Page 134: ...6 8 6 5 Install fuel pump body 2 7 a new dia phragm 8 and the cover 9 and then tighten the screws 0 to the specified torque Fuel pump cover screw 0 3 N m 0 3 kgf m 2 2 ft lb 9 8 7 0 0 LT 271 Fuel pump...

Page 135: ...M6 100 mm 2 Intake silencer 1 3 O ring 1 Not reusable 4 Throttle link rod 1 5 Carburetor 1 6 Gasket 2 Not reusable 7 Joint 1 8 Bolt 4 M6 55 mm 9 Holder 1 10 Bolt 1 M6 16 mm 11 Intake manifold 1 12 Gas...

Page 136: ...tle stop screw 1 7 Spring 1 8 Needle valve 1 9 Pilot jet 1 10 Plug 1 11 Gasket 1 Not reusable 12 Drain screw 1 13 Main nozzle 1 14 Main jet 1 15 Screw 2 M4 8 mm 16 Cover 1 17 Prime Start 1 5 7 6 15 34...

Page 137: ...reusable 24 Pilot screw 1 For Europe 25 Pilot screw 1 For Oceania 26 Gasket 1 Not reusable 27 Screw 1 M3 6 mm 28 Plunger 1 29 Spring 1 30 Float 1 31 Float pin 1 32 Screw 1 M4 8 mm 33 Float chamber 1 3...

Page 138: ...he carburetor body if there is dirt or foreign material 3 Blow compressed air into all passages and jets WARNING When using com pressed air wear safety glasses or safety goggles Otherwise eye injury c...

Page 139: ...3 and main jet 4 2 Install the needle valve 5 float 6 float pin 7 and screw 8 TIP Hook the needle valve 5 onto the tab a on the float 6 and then fit the needle valve into the valve seat b Install the...

Page 140: ...new gasket 5 the carburetor 6 a new O ring 7 and the intake silencer 8 2 Connect the Prim Start coupler a 3 Connect the throttle link rod 9 TIP To adjust the throttle link rod see Adjusting the thrott...

Page 141: ...name Q ty Remarks 1 Throttle link rod 1 2 Holder 1 3 Bolt 1 M6 55 mm 4 Washer 1 5 Free accelerator lever 1 6 Collar 1 7 Throttle cam 1 8 Spring 1 9 Bolt 4 M6 14 mm 10 Bracket 1 11 Clip 1 12 Washer 2 1...

Page 142: ...t 0 clip A washers B roller C stopper D and bracket E Installing the throttle link throttle cam and shift cam 1 Install the bracket 1 stopper 2 wash ers 3 roller 4 clip 5 and bracket 6 2 Connect the s...

Page 143: ...top screw 1 2 Turn the throttle cam 2 counterclock wise so that the fully open stopper a contacts the stopper b and hold it in place 3 Turn the carburetor throttle lever c clockwise so that it contact...

Page 144: ...1 6 Free accelerator lever 1 7 Throttle cam 1 8 Bolt 1 M6 25 mm 9 Bracket 1 10 Spring 1 11 Clip 1 12 Washer 1 13 Bolt 1 M6 35 mm 14 Washer 1 15 Shift cam 1 16 Collar 1 17 Shift link rod 1 15 14 16 11...

Page 145: ...4 Remove the clips 0 and A and washers B and then remove the shift link rod C 5 Remove the washer D shift cam E and collar F Installing the throttle link throttle cam and shift cam 1 Install the colla...

Page 146: ...throttle cam 2 clockwise so that the fully open stopper a contacts the stopper b and hold the throttle cam in place 3 Turn the carburetor throttle lever c clockwise so that it contacts the stopper d 4...

Page 147: ...mbly 7 12 Removing the power unit remote control model 7 14 Removing the power unit tiller handle model 7 16 Installing the power unit remote control model 7 17 Installing the power unit tiller handle...

Page 148: ...ure switch 7 52 Installing the thermo sensor 7 52 Installing the exhaust cover 7 53 Cylinder block 7 54 Disassembling the cylinder block 7 56 Checking the piston diameter 7 57 Checking the cylinder bo...

Page 149: ...rk plug caps Checking the oil pressure 1 Remove the oil pressure switch and then install an oil pressure gauge 1 2 Start the engine and warm it up until the idle speed gets stable at 925 1025 r min 3...

Page 150: ...wise Otherwise the water pump impeller could be damaged 1 Remove the manual starter and driven sprocket cover See Removing the man ual starter 7 7 Manual starter model Remove the flywheel magnet cover...

Page 151: ...ting the valve clearance 7 3 9 Install all of the parts that were removed during disassembly Adjusting the valve clearance Adjust the valve clearances when the engine is cold Do not turn the flywheel...

Page 152: ...To increase the valve clearance turn the adjusting screw 2 in direction b 2 Tighten the locknut 1 to the specified torque and then measure the valve clearances See Checking the valve clearance 7 2 Ad...

Page 153: ...in reference data 8 Cover 1 9 Start in gear protection cable 1 10 Grommet 1 11 Bolt 3 M6 20 mm 12 Spring 1 13 Spring 1 14 Starter plunger 1 15 Spiral spring 1 16 Screw 1 5 12 mm 17 Sheave drum 1 23 22...

Page 154: ...0 Spring 1 21 Drive pawl spring 1 1 22 Drive plate 1 23 Screw 1 5 20 mm 23 22 21 20 19 18 17 18 16 19 20 5 6 7 1 2 3 4 9 8 14 15 10 11 11 11 12 13 9 13 A A 1 5 N m 0 15 kgf m 1 11 ft lb 3 4 N m 0 34 k...

Page 155: ...starter plunger 4 away from the sheave drum 3 while turning the sheave drum 3 Remove the drive plate 5 and drive pawl spring 1 6 4 Remove the sheave drum 3 5 Remove the spiral spring 7 WARNING The spi...

Page 156: ...e if dam aged TIP When replacing the starter rope with a new one make sure that the length is approxi mately 2100 0 mm 82 7 in Checking the spiral spring 1 Check the spiral spring Replace if bent crac...

Page 157: ...t d 5 Install the spiral spring C WARNING The spiral spring can pop out Cover the spiral spring with rags when installing it TIP Hook the end e of the spiral spring C onto the protrusion f on the manu...

Page 158: ...starter rope 0 is wound around the sheave drum B TIP Make sure to hold the sheave drum B so that it turns slowly 10 Install the cover H and then tighten the screws I to the specified torque 11 Pull t...

Page 159: ...nd a with the mark b on the manual starter cover by turning the adjusting nut 2 3 Tighten the locknut 1 4 Check that the starter handle can be pulled 5 Move the shift lever to the F or R posi tion 6 C...

Page 160: ...t 2 M6 20 mm 10 Shift link assembly 1 11 Dowel 2 12 Gasket 1 Not reusable 13 Bolt 2 M6 14 mm 14 Bolt 3 M6 20 mm 15 Grommet holder 1 Tiller handle model 16 Grommet 1 Tiller handle model 17 Grommet hold...

Page 161: ...holder 1 Remote control model 22 Rigging grommet 1 Remote control model 23 Holder 1 Remote control model 24 Bolt 8 M8 80 mm 25 Screw 1 M4 45 mm 26 Clamp 1 27 Bolt 2 M6 20 mm 28 Apron 1 1901 5 11 12 7...

Page 162: ...wiring harness b from the holders 9 5 Disconnect the battery cables 0 and bat tery lead c and then unfasten the nega tive battery cable from the holder A 6 Disconnect the battery lead connector d and...

Page 163: ...J from the exhaust cover 13 Slide the clamp K down and then dis connect the fuel hose L 14 Remove the oil dipstick M apron N and driven sprocket cover O 15 Install the shackle P onto the engine hanger...

Page 164: ...c tric starter model See steps 5 and 6 in Removing the power unit remote con trol model 7 14 5 Disconnect the PTT motor leads PTT model See steps 7 and 8 in Removing the power unit remote control mode...

Page 165: ...ing surface and then install the dowels 1 and a new gas ket 2 2 Install the power unit 3 and then tighten the bolts 4 to the specified torque in 2 stages and in the order 1 2 and so on TIP Tighten the...

Page 166: ...pler a PTT model 9 Connect the alert indicator coupler b 10 Connect the PTT motor leads c and then fasten the PTT motor leads using the holder F PTT model 11 Install the plastic tie G and caps d PTT m...

Page 167: ...g the holders N and then connect the 10 pin main wiring harness coupler k 16 Fasten the 10 pin main wiring harness coupler k using the holders O 17 Connect the shift cable P throttle cable Q and shift...

Page 168: ...ine start button connec tors d Electric starter model 7 Connect the PTT motor leads PTT model See steps 10 12 in Installing the power unit remote control model 7 17 8 Connect the battery lead connecto...

Page 169: ...25 mm 7 Base 1 8 Timing belt 1 9 Nut 1 Width across flats 41 mm 10 Retaining plate 1 11 Drive sprocket 1 12 Woodruff key 1 13 Woodruff key 1 14 Bolt 2 M5 16 mm 15 Pulser coil 1 16 Bolt 1 M6 35 mm 17 W...

Page 170: ...n sprocket 1 19 Dowel 1 6C5 462XX XX 150 N m 15 0 kgf m 110 6 ft Ib 2 3 4 5 1 17 18 19 12 9 10 11 13 16 14 8 6 7 15 38 N m 3 8 kgf m 28 0 ft Ib 157 N m 15 7 kgf m 115 8 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib...

Page 171: ...y NOTICE 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 4 Remove the pulser coil 3 and then...

Page 172: ...maged or worn 2 Check the drive sprocket and driven sprocket Replace if cracked damaged or worn Installing the sprocket and timing belt Do not turn the crankshaft or driven sprocket when the timing be...

Page 173: ...riven sprocket 7 so that the part num ber e is in the upright position NOTICE Do not apply grease or oil to the tim ing belt 6 Turn the crankshaft clockwise 2 full turns until the notch a in the drive...

Page 174: ...lipping off easily TIP Make sure to remove any grease from the tapered portion a of the crankshaft and the inner surface b of the flywheel magnet 5 3 Install the manual starter and driven sprocket cov...

Page 175: ...Holder 1 11 Starter relay 1 Electric starter model 12 Bolt 3 M6 20 mm 13 CDI unit 1 14 Wiring harness 1 PTT model 15 Bolt 4 M6 16 mm 16 Cap 1 Yellow electric starter model 17 Cap 1 Green electric sta...

Page 176: ...5 Bolt 2 M6 14 mm 26 Neutral switch 1 Tiller handle model with electric starter 27 Bracket 1 28 Cap 1 Manual starter model 29 Holder 1 30 Holder 1 Manual starter model 15 28 30 29 27 26 23 20 16 17 10...

Page 177: ...ntrol model 5 Remove the neutral switch 4 Tiller handle model with electric starter 6 Remove the alert indicator coupler e from the bracket 7 Disconnect the wiring harness ground lead f PTT model Till...

Page 178: ...n coil connectors b and ground lead c 3 Fasten the main wiring harness using the holders 1 and 2 4 Connect the Rectifier Regulator coupler d Electric starter model 5 Connect the thermo sensor coupler...

Page 179: ...tarter Remote control model 14 Connect the starter relay lead connector p Electric starter model 15 Install the CDI unit 9 and then connect the CDI unit coupler r Tiller handle model with electric sta...

Page 180: ...nition coil 1 8 Bolt 2 M6 25 mm 9 Holder 1 10 Spark plug cap 2 11 Bolt 2 M6 40 mm 12 Rectifier Regulator 1 Electric starter model 13 Dowel 2 14 Bracket 1 15 Bolt 5 2 M8 45 mm electric starter model M8...

Page 181: ...WR Power unit No Part name Q ty Remarks 17 Starter motor 1 Electric starter model 18 Bolt 1 M6 20 mm 19 Bracket 1 1 2 3 4 5 6 4 10 11 10 8 12 11 13 14 15 16 17 9 7 4 1 15 15 18 19 29 N m 2 9 kgf m 21...

Page 182: ...O ring 1 Not reusable 10 Oil filler cap 1 11 Bolt 1 M6 12 mm 12 Holder 1 13 Bolt 5 M6 20 mm 14 Bolt 4 M6 45 mm 15 Oil pump assembly 1 16 Gasket 1 Not reusable 17 Bolt 3 M6 25 mm 9 10 13 5 6 13 11 13...

Page 183: ...o not scratch or damage the mating surfaces of the cylinder head and cylinder block Installing the cylinder head Do not reuse a gasket always replace it with a new one 1 Install a new gasket 1 and the...

Page 184: ...ump assembly 8 by aligning the slot in the oil pump drive shaft b with the camshaft pin c NOTICE Before installing the oil pump assembly 8 make sure to fill it with engine oil through the oil pas sage...

Page 185: ...spring retainer 4 11 Valve cotter 8 12 Nut 3 13 Adjusting screw 3 14 Washer 4 15 Rocker arm 3 16 Washer 2 17 Bolt 3 M8 22 mm M M E E E E E E E E E E E LT 271 11 14 10 9 8 7 6 2 3 1 4 5 14 12 14 26 27...

Page 186: ...M6 20 mm 31 Engine hanger 1 32 Holder 1 33 Holder 1 34 Cylinder head 1 M M E E E E E E E E E E E LT 271 11 14 10 9 8 7 6 2 3 1 4 5 14 12 14 26 27 28 25 23 15 20 14 24 12 13 30 15 7 6 8 9 10 11 15 13...

Page 187: ...then remove the stopper 6 tensioner 7 washers 8 rocker arms 9 and 0 and rocker arm shaft A TIP Make sure to keep the parts in the order as they were removed 3 Remove the retaining bolt B and gasket C...

Page 188: ...spring free length a 2 Measure the valve spring tilt b Replace if above specification Checking the valve 1 Check the valve face Replace the valve if pitted or worn 2 Measure the valve margin thicknes...

Page 189: ...seal 2 Remove the valve guide 1 from the combustion chamber side using the spe cial service tool 2 3 Install a new valve guide 3 from the camshaft side to the specified position a using the special se...

Page 190: ...the valve seat 3 Press the valve lightly against the valve seat using the special service tool 1 4 Measure the valve seat contact width a where the blueing dye is adhered to the valve face Reface the...

Page 191: ...enly using a downward force of 40 50 N 4 0 5 0 kgf 8 8 11 0 lbf a Slag or rough surface 3 Adjust the top edge of the valve seat con tact width using a 30 cutter b Previous contact width 4 Adjust the b...

Page 192: ...r b Previous contact width If the valve seat contact area is too narrow and situated near the bottom edge of the valve face cut the bottom edge of the valve seat using a 60 cutter to center the area a...

Page 193: ...ith a spark plug cleaner Rocker arm inside diameter b 16 000 16 018 mm 0 6299 0 6306 in Rocker arm shaft diameter c 15 971 15 991 mm 0 6288 0 6296 in Cam lobe height a Intake 30 839 30 939 mm 1 2141 1...

Page 194: ...seal always replace it with a new one 1 Install a new valve seal 1 2 Install the valve 2 valve spring seat 3 valve spring 4 and valve spring retainer 5 in this order and then attach the spe cial serv...

Page 195: ...hten the retaining bolt D 7 Align the dowel hole a in the camshaft with the mark b on the cylinder head 8 Install the rocker arms E and F wash ers G rocker arm shaft H tensioner I and stopper J and th...

Page 196: ...to the speci fied torque 11 Tighten the spark plugs P to the speci fied torque 12 Install the bracket Q and engine hanger R Rocker arm shaft bolt K 18 N m 1 8 kgf m 13 3 ft lb Cylinder head anode plu...

Page 197: ...M18 17 mm 13 Gasket 1 Not reusable 14 Screw 1 M5 24 mm 15 Anode 1 16 O ring 1 Not reusable 17 Anode plug 1 A A LT 572 LT E 1377B 2 2 2 20 20 21 22 4 8 8 10 11 13 14 6 19 18 7 5 9 12 17 16 15 3 1 2 N m...

Page 198: ...8 10 11 13 14 6 19 18 7 5 9 12 17 16 15 3 1 2 N m 0 2 kgf m 1 5 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 23 N m 2 3 kgf m 17 0...

Page 199: ...s ket 2 Removing the oil pressure switch 1 Remove the oil pressure switch 1 Removing the oil filter 1 Remove the oil filter 1 2 Remove the oil filter union bolt 3 Checking the exhaust cover 1 Check th...

Page 200: ...the oil pressure switch a and then tighten it to the specified torque 2 Install the oil pressure switch lead 1 and then tighten the bolt b to the speci fied torque Installing the thermo sensor 1 Insta...

Page 201: ...he anode plug 0 and then tighten the screw A to the specified torque 3 Install new gaskets B and C and then tighten the anode plug 0 and plugs D and E to the specified torques Thermo sensor 2 23 N m 2...

Page 202: ...1 Not reusable 14 Crankshaft journal bearing 6 15 Crankshaft 1 16 Nut 1 17 Balancer piston 1 1 2 4 5 3 6 6 6 10 11 12 14 15 13 3 3 29 27 28 26 26 24 17 16 18 19 20 21 22 24 23 14 14 25 31 30 7 8 9 518...

Page 203: ...ston 2 28 Piston pin 2 29 Crankpin bearing 4 30 Bolt 4 M6 30 mm 31 Connecting rod assembly 2 1 2 4 5 3 6 6 6 10 11 12 14 15 13 3 3 29 27 28 26 26 24 17 16 18 19 20 21 22 24 23 14 14 25 31 30 7 8 9 518...

Page 204: ...bearings 5 connecting rods and piston assemblies 6 TIP To prevent interchanging the pistons con necting rods and connecting rod caps mark each with an identification number b of the corresponding cyli...

Page 205: ...m 0 39 in b 48 0 mm 1 89 in c 85 0 mm 3 35 in Checking the piston ring 1 Measure the piston ring dimensions B and T Piston diameter a 64 950 64 965 mm 2 5571 2 5577 in Measuring point b 5 0 mm 0 20 in...

Page 206: ...iston pin boss inside diam eter a Measuring point a reference data 20 mm 0 79 in Piston ring end gap b reference data Top ring 0 150 0 300 mm 0 0059 0 0118 in 2nd ring 0 300 0 500 mm 0 0118 0 0197 in...

Page 207: ...big end side clearance 1 Measure the connecting rod big end side clearance a Checking the crankshaft 1 Measure the crankshaft journal diameter a crankpin diameter b and crankpin width c Piston pin bos...

Page 208: ...uge PG 1 onto the crankpin e parallel to the crank shaft TIP Do not place the Plastigauge PG 1 over the oil hole in the crankpin of the crankshaft 4 Install the connecting rod a and con necting rod ca...

Page 209: ...nted color b 2 Select the bearing color c for the crank pin bearing from the table Checking the crankshaft journal oil clearance 1 Clean the crankshaft journal bearings crankshaft journal and bearing...

Page 210: ...ed torques in 2 stages and in the order 7 8 and so on TIP Do not turn the crankshaft until the crankshaft journal oil clearance measurement has been completed 8 Remove the crankcase and then mea sure...

Page 211: ...it with a new one 1 Assemble the piston 1 connecting rod a piston pin 2 and piston pin clips 3 TIP Face the protrusion b on the connecting rod a in the same direction as the UP mark c on the piston cr...

Page 212: ...6 in the original positions 7 Install the balancer rod 7 and new oil seals 8 and 9 onto the crankshaft 0 and then install the crankshaft TIP Make sure to install the oil seals into the cylinder block...

Page 213: ...of the crankcase C TIP Install the crankshaft journal bearings B in the original positions Do not apply any sealant on the crankshaft journal bearings 11 Install the crankcase C and then tighten the...

Page 214: ...and crankcase cover I and then tighten the bolts J to the specified torque in the order 1 2 and so on Crankcase bolt D 1 6 M8 1st 15 N m 1 5 kgf m 11 1 ft lb 2nd 30 N m 3 0 kgf m 22 1 ft lb Crankcase...

Page 215: ...7 67 POWR Power unit MEMO...

Page 216: ...ller shaft housing assembly 8 9 Drive shaft and lower case 8 12 Removing the drive shaft oil seal housing and shift rod 8 14 Disassembling the oil seal housing 8 14 Disassembling the drive shaft 8 14...

Page 217: ...peller shaft housing 8 40 Checking the reverse gear 8 40 Assembling the propeller shaft assembly 8 40 Assembling the propeller shaft housing assembly 8 40 Drive shaft and lower case high thrust model...

Page 218: ...g 8 57 Shim location 8 57 Selecting the pinion shim T3 8 58 Pinion shim T3 selection table 8 61 Measuring the forward gear backlash 8 63 Adjusting the forward gear shim thickness T1 8 63 Forward gear...

Page 219: ...Bolt 4 M10 35 mm 9 Anode 1 10 Special washer 1 Not reusable 11 Bolt 1 M6 35 mm 12 Bolt 1 M6 18 mm 13 Trim tab 1 14 Lower unit 1 15 Spacer 1 16 Propeller 1 17 Collar 1 3 1 2 3 6 5 5 4 20 19 18 17 15 1...

Page 220: ...peller nut 1 20 Cotter pin 1 Not reusable 3 1 2 3 6 5 5 4 20 19 18 17 15 16 14 13 12 11 10 9 8 7 518 M A D LT 572 LT LT 572 LT 1901 9 N m 0 9 kgf m 6 6 ft Ib 9 N m 0 9 kgf m 6 6 ft Ib 34 N m 3 4 kgf m...

Page 221: ...eep the propeller from turning and then remove the propeller nut and propeller 5 Set the gear shift to the R position 6 Loosen the locknut 1 while holding the adjusting nut 2 and then turn the adjust...

Page 222: ...t reusable S transom model 4 Water tube 1 S transom model 5 Bolt 4 M6 40 mm 6 Extension plate 1 L transom model 7 Rubber seal 1 8 Water pump housing 1 9 Insert cartridge 1 10 Impeller 1 11 O ring 1 No...

Page 223: ...LOWR Lower unit 8 5 No Part name Q ty Remarks 14 Dowel 2 15 Rubber seal 1 16 Plate 1 LT 572 LT 15 14 12 11 10 13 16 8 9 3 1 2 1 4 1 7 5 6 A A A A A A A A A A A A A A...

Page 224: ...nsom model S transom model Checking the water pump 1 Check the water pump housing Replace if deformed TIP If the engine overheated the inside of the water pump housing may be deformed Therefore make s...

Page 225: ...shaft 1 7 Washer 1 8 Reverse gear 1 9 Reverse gear shim 10 O ring 1 Not reusable 11 Ball bearing 1 Not reusable 12 O ring 2 Not reusable 13 Propeller shaft housing 1 14 Bolt 2 M6 20 mm 15 Needle beari...

Page 226: ...r shaft assembly 1 Remove the shift plunger 1 2 Remove the spring 2 and then remove the cross pin 3 and dog clutch 4 3 Remove the spring 5 Disassembling the propeller shaft housing assembly 1 Remove t...

Page 227: ...or worn Assembling the propeller shaft assembly 1 Align the hole a in the dog clutch 1 with the hole b in the propeller shaft 2 2 Install the spring 3 TIP Install the dog clutch 1 with the F mark c fa...

Page 228: ...aring 7 TIP Face the identification mark d on the ball bearing toward the reverse gear 4 Install the reverse gear assembly 5 Install new O rings 0 and A Needle bearing attachment 2 90890 06615 Driver...

Page 229: ...LOWR Lower unit 8 11 0 A...

Page 230: ...r inlet cover PORT 1 10 Screw 2 M5 27 mm 11 Forward gear shim 12 Taper roller bearing 1 Not reusable 13 Forward gear 1 14 Pinion nut 1 15 Pinion 1 16 Needle bearing 1 Not reusable 17 Drive shaft 1 LT...

Page 231: ...Rubber seal 1 20 Plate 1 21 Bolt 2 M6 25 mm 22 Oil seal 2 Not reusable 23 Oil seal housing 1 24 Gasket 1 Not reusable LT 572 LT G A A A A A A 1104J 11 12 13 17 7 8 4 5 5 3 2 1 19 20 21 22 23 18 24 16...

Page 232: ...sembling the oil seal housing 1 Remove the O ring 1 2 Remove the oil seals 2 Disassembling the drive shaft 1 Remove the taper roller bearing 1 NOTICE Do not press the drive shaft threads a directly Di...

Page 233: ...ion area evenly Otherwise the paint on the lower case could be burned TIP Before removing the taper roller bearing outer race 4 place some cushioning mate rial under the lower case to catch the outer...

Page 234: ...e the drive shaft runout Replace if above specification Checking the lower case 1 Check the lower case Replace if cracked or damaged Assembling the lower case Use heat resistant gloves Otherwise burns...

Page 235: ...ard the water pump side Install the stopper c onto the driver rod 6 at the specified depth a 5 Heat the installation area of the taper roller bearing outer race in the lower case using a gas torch and...

Page 236: ...r inlet cover screws to the specified torque Assembling the forward gear Do not reuse a bearing always replace it with a new one 1 Install a new taper roller bearing 1 Assembling the drive shaft Do no...

Page 237: ...3 Install the drive shaft assembly 5 and pinion 6 and then tighten the nut to the specified torque TIP When installing the pinion 6 lift up the drive shaft slightly and align the pinion and drive shaf...

Page 238: ...slot a in the impeller 6 with the Woodruff key 5 and then install the impeller 6 5 Install the insert cartridge 7 and a new O ring 8 TIP Align the protrusion b on the insert cartridge 7 with the groo...

Page 239: ...ling the lower unit Make sure to disconnect the battery cables from the battery and remove the clip from the engine shut off switch When installing the lower unit with the power unit installed make su...

Page 240: ...screwed in 8 0 mm 0 31 in a or more 6 Install a new special washer 9 the anode 0 and the trim tab A TIP Install the trim tab in the original position 7 Install the spacer B propeller C collar D and w...

Page 241: ...es in the propeller nut F do not align with the cotter pin hole tighten the pro peller nut until they are aligned 9 Fill the lower unit with gear oil up to the proper level See steps 5 9 in Changing t...

Page 242: ...8 24 8 Shimming Shim location T1 T2 T3 T3 A3 B3 42 5 T1 T2 24 0 24 0 B2 A1 A2 B1 Drive shaft and lower case Shimming...

Page 243: ...at the shaft is centered in the hole Tighten the wing nuts a 1 4 turn after they contact the special service tool 2 Make sure that the distance b between the special service tools 1 and 2 is equal Mak...

Page 244: ...m Select the forward gear shims using the mea surement s and calculation formula 1 Turn the taper roller bearing outer race 1 2 or 3 times to seat the rollers 2 Measure the bearing height M1 at 4 poin...

Page 245: ...ove any flammable substances such as gasoline and oil around the working area Keep good ventilation while working When heating the propeller shaft housing heat the entire installation area evenly Othe...

Page 246: ...is 1 1 mm Measuring the forward and reverse gear backlash 1 Remove the water pump assembly and outer plate cartridge See Removing the water pump 8 6 2 Set the gear shift to the N position 3 Install t...

Page 247: ...specified torque 11 Install the special service tools 7 8 and 9 and then install the special ser vice tool 0 to apply a load 12 Slowly turn the drive shaft clockwise and counterclockwise and then mea...

Page 248: ...se gear and does not affect the back lash measurement 14 Determine the backlash average and then round down the average to the 1 100 place Example 15 Check that the forward gear backlash average is wi...

Page 249: ...ation TIP Adjust the shim thicknesses if the reverse gear backlash is out of specification 21 Remove the special service tools and tape and then install the outer plate car tridge and water pump assem...

Page 250: ...1 M8 185 mm X transom model 10 Locknut 1 11 Adjusting nut 1 12 Dowel 2 13 Bolt 1 M8 35 mm 14 Cotter pin 1 Not reusable 15 Propeller nut 1 16 Washer 1 17 Washer 1 518 518 1901 D 572 LT 572 LT 572 LT 2...

Page 251: ...Drain screw 1 28 Hose nipple 1 29 Plastic tie 2 Not reusable 30 Speedometer hose 1 31 Check screw 1 518 518 1901 D 572 LT 572 LT 572 LT 24 25 27 12 31 30 29 28 12 10 1 2 11 29 13 19 18 17 16 15 21 22...

Page 252: ...tation plate and propeller to keep the propeller from turning and then remove the propeller nut and propeller 5 Remove the lower mount cover See Upper case and mounts high thrust model 9 22 For Oceani...

Page 253: ...he propeller See Checking the propeller 8 3 Checking the lower unit anode 1 Check the anode and trim tab Replace if eroded Clean if there is grease oil or scales NOTICE Do not apply grease oil or pain...

Page 254: ...m 4 Water pump housing 1 5 Insert cartridge 1 6 Impeller 1 7 O ring 1 Not reusable 8 Dowel 2 9 Outer plate cartridge 1 10 Gasket 1 Not reusable 11 Woodruff key 1 12 Rubber seal 1 13 Plate 1 1 2 3 4 8...

Page 255: ...ove the water pump housing 1 insert cartridge 2 impeller 3 O ring 4 and Woodruff key 5 2 Remove the outer plate cartridge 6 and gasket 7 3 Remove the rubber seal 8 and plate 9 Checking the water pump...

Page 256: ...ear 1 9 Reverse gear shim 10 O ring 1 Not reusable 11 Ball bearing 1 Not reusable 12 O ring 2 Not reusable 13 Propeller shaft housing 1 14 Bolt 2 M8 25 mm 15 Needle bearing 1 Not reusable 16 Oil seal...

Page 257: ...haft assembly See Disassembling the propeller shaft assembly 8 8 Disassembling the propeller shaft housing assembly 1 Remove the reverse gear 1 and reverse gear shims 2 2 Remove the ball bearing 7 3 R...

Page 258: ...aring toward the propeller side 2 Install new oil seals 5 to the specified depth c TIP Install an oil seal halfway into the propeller shaft housing and then install the other oil seal 3 Install the or...

Page 259: ...LOWR Lower unit 8 41 5 Install new O rings C and D Ball bearing attachment B 90890 06633 A G B C D...

Page 260: ...n shim 8 Sleeve 1 9 Needle bearing 1 Not reusable 10 Cover 1 11 Oil seal housing 1 12 O ring 1 Not reusable 13 Oil seal 2 Not reusable 14 Washer 1 15 Drive shaft 1 16 Pinion 1 17 Nut 1 A A 2 3 4 1 6 1...

Page 261: ...r roller bearing 1 Not reusable 20 Forward gear shim 21 Screw 1 M5 25 mm 22 Water inlet cover PORT 1 23 Water inlet cover STBD 1 24 Nut 1 A A 2 3 4 1 6 11 12 14 15 13 10 7 8 9 17 18 16 5 24 23 8 20 22...

Page 262: ...il seal housing 1 Remove the oil seals 1 and O ring 2 Disassembling the drive shaft 1 Remove the taper roller bearing 1 NOTICE Do not press the drive shaft threads a directly Disassembling the forward...

Page 263: ...8 16 Checking the drive shaft 1 Check the drive shaft Replace if dam aged or worn 2 Measure the drive shaft runout Replace if above specification Checking the lower case See Checking the lower case 8...

Page 264: ...ion shims 9 and a new taper roller bearing outer race 0 NOTICE When heating the lower case heat the entire installation area evenly Otherwise the paint on the lower case could be burned TIP Make sure...

Page 265: ...ng 1 Assembling the oil seal housing Do not reuse an oil seal or O ring always replace it with a new one 1 Install new oil seals 1 to the specified depth a 2 Install a new O ring Installing the shift...

Page 266: ...nd cover C Installing the propeller shaft housing assembly 1 Install the washer 1 and propeller shaft assembly 2 2 Install the propeller shaft housing assem bly 3 and then tighten the bolts 4 to the s...

Page 267: ...er and water pump hous ing assembly See steps 3 6 in Install ing the water pump 8 20 Installing the lower unit Make sure to disconnect the battery cables from the battery and remove the clip from the...

Page 268: ...Install the anode D and trim tab E TIP Install the trim tab in the original position 9 Install the washer F propeller G washer H and bushing I Place a block of wood between the anti cavitation plate...

Page 269: ...If the grooves in the propeller nut J do not align with the cotter pin hole tighten the nut until they are aligned 11 Fill the lower unit with gear oil up to the proper level See steps 5 9 in Changin...

Page 270: ...bearings shaft or propeller shaft housing NO YES Shimming is not required YES NO Within specification Disassemble the lower unit Select the pinion shims T3 Assemble the lower unit Measure the backlas...

Page 271: ...Measuring point 2 Measuring point 3 Measuring point 4 Average Round down average M Measurements Before disassembly After disassembly Measuring point 1 Measuring point 2 Measuring point 3 Measuring poi...

Page 272: ...urement in 2 places mm Reverse gear shim thickness T2 measurement in 2 places mm Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0...

Page 273: ...se and measure the backlash again TIP Measure the backlash at 4 points c d e and f turning the drive shaft 180 clockwise after each measurement Note the measurement data in the shimming check sheet Wh...

Page 274: ...13 Repeat steps 4 8 to measure the reverse gear backlash 14 Check that the reverse gear backlash average is within specification TIP Adjust the shim thicknesses if the reverse gear backlash is out of...

Page 275: ...he pinion shims T3 When assembling the lower unit to measure the backlash after selecting the pinion shims T3 do not apply gear oil grease or sealant to the parts When assembling the lower unit after...

Page 276: ...ms 2 Install the pinion 2 and then tighten the nut 3 temporarily 3 Check the gap d between the special service tool 1 and the pinion 2 NOTICE When tightening the nut 3 check that the drive shaft turns...

Page 277: ...e gap at the measuring point Do not insert the thickness gauge at an angle TIP Measure the gap at 4 points f g h and k Write down the measurement data in the shimming check sheet 11 Determine the gap...

Page 278: ...rim tab mounting surface of the lower case in 0 01 mm units If the P mark is unreadable replace the lower case 13 Remove the special service tools and then install the determined shims Pinion height m...

Page 279: ...60 0 60 0 62 0 62 0 65 0 65 0 65 12 0 55 0 58 0 58 0 58 0 60 0 60 0 62 0 62 0 65 0 65 0 65 0 68 13 0 58 0 58 0 58 0 60 0 60 0 62 0 62 0 65 0 65 0 65 0 68 0 68 P M 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0...

Page 280: ...0 0 82 0 82 0 85 0 85 0 85 8 0 75 0 78 0 78 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 88 9 0 78 0 78 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 88 0 88 10 0 78 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0...

Page 281: ...shift rod oil seal housing and drive shaft 8 47 3 Check that drive shaft turns smoothly 4 Install the propeller shaft housing assem bly See Installing the propeller shaft housing assembly 8 48 5 Check...

Page 282: ...r the points marked on the chart 4 Calculate the new forward gear shim thickness T1 Calculation formula New forward gear shim thickness T1 Cur rent forward gear shim thickness Shim thickness adjustmen...

Page 283: ...sing of shim thickness 0 30 0 20 0 10 0 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 1 00 1 10 1 20 1 30 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 100 95 90 85 80 75 70 65 60 55 50...

Page 284: ...y 8 48 3 Check that the drive shaft turns smoothly 4 Measure the reverse gear backlash See steps 11 14 in Measuring the forward and reverse gear backlash before disas sembly 8 55 Adjusting the reverse...

Page 285: ...kness adjustments for the points marked on the chart 4 Calculate the new reverse gear shim thickness T2 Calculation formula New reverse gear shim thickness T2 Cur rent reverse gear shim thickness Shim...

Page 286: ...5 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 0 10 0 07 0 03 0 01 0 04 0 08 0 11 0 14 0 18 0 22 0 25 0 28 0 33 0 36 0 39 0 43 0 47 0...

Page 287: ...0 20 0 10 0 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 1 00 140 135 130 125 120 115 110 105 100 140 135 130 125 120 115 110 105 100 0 49 0 92 0 88 0 84 0 81 0 78 0 74 0 71 0 67 0 63 0 60 0 57 0 53...

Page 288: ...unts L transom 9 19 Removing the upper case 9 20 Installing the upper case 9 20 Upper case and mounts high thrust model 9 22 Removing the upper case 9 24 Installing the upper case 9 24 Upper case 9 26...

Page 289: ...odel 9 50 Disassembling the swivel bracket 9 52 Assembling the swivel bracket 9 52 Clamp bracket and swivel bracket PTT model 9 54 Removing the clamp bracket 9 56 Checking the clamp bracket anode high...

Page 290: ...9 PTT cylinder 9 73 Disassembling the PTT cylinder 9 74 Checking the PTT cylinder and piston 9 74 Assembling the PTT cylinder 9 75 Bleeding the PTT unit 9 76...

Page 291: ...l for Oceania 11 Collar 1 Electric starter model for Oceania 12 Cover 1 13 Bolt 1 M6 14 mm 14 Holder 1 15 Steering bracket 1 16 Washer 2 17 Self locking nut 2 9 10 11 44 42 41 41 43 42 44 28 30 29 31...

Page 292: ...0 Throttle friction adjuster 1 31 Friction piece 1 32 Cotter pin 1 Not reusable 33 Plate 1 34 Bolt 2 M6 20 mm 9 10 11 44 42 41 41 43 42 44 28 30 29 31 32 34 34 29 27 25 23 24 26 33 22 20 21 20 2 1 3 3...

Page 293: ...T model for Oceania 43 Bracket 1 PTT model for Oceania 44 PTT switch 1 PTT model for Oceania 9 10 11 44 42 41 41 43 42 44 28 30 29 31 32 34 34 29 27 25 23 24 26 33 22 20 21 20 2 1 3 39 38 36 37 36 35...

Page 294: ...ssembly 7 4 Remove the cotter pin 8 and then remove the throttle friction adjuster 9 5 Remove the throttle grip 0 6 Remove the washers A spring B and bushing C 7 Disconnect the throttle cables D 8 Rem...

Page 295: ...d 6 4 Install the plate 7 5 Route the throttle cables 8 engine shut off switch lead b and PTT switch lead c PTT model through the protector 9 TIP Insert the end d of the protector 9 into the steering...

Page 296: ...uster G and then install a new cotter pin H 11 Install the bushing I washers J wave washers K and tiller handle assembly L 12 Install the cover M 13 Install the holder N shift lever O and shift link r...

Page 297: ...open stopper a on the throttle cam 8 contacts the stopper b on the bracket 9 and then tighten the locknut 2 5 Turn the adjusting nut 3 to remove the slack in the throttle cable 5 and then tighten the...

Page 298: ...1 4 Washer 1 5 Friction piece 2 6 Collar 1 7 Grease nipple 1 8 Friction plate 1 9 Bolt 1 M5 16 mm 10 Steering lock washer 1 11 Self locking nut 1 12 Bolt 2 M6 12 mm 13 Spring washer 2 14 Cap 1 TOP 12...

Page 299: ...rn TIP Make sure that the portion a of the steering lock shaft 1 with complete threads around the shaft does not protrude past the portion b of the steering arm 2 2 Install the steering lock lever 3 w...

Page 300: ...adjust the steering friction see Checking the steering system tiller handle model 10 6 Friction plate bolt 0 4 N m 0 4 kgf m 3 0 ft lb Self locking nut A 4 N m 0 4 kgf m 3 0 ft lb A 0 Steering fricti...

Page 301: ...hift rod No Part name Q ty Remarks 1 Clip 1 2 Washer 1 3 Shift link rod 1 4 Lever 1 5 Pin 3 6 Lever 1 7 Bracket 2 8 Shift rod lever 1 9 Stopper 1 10 Shift rod 1 11 Nut 1 12 Nut 1 4 8 mm 0 16 0 31 in 4...

Page 302: ...Bracket 1 7 Hose 1 8 Joint 1 9 Joint 1 10 Gasket 1 11 Adapter 1 12 Holder 1 Tiller handle model 13 Holder 1 14 Holder 1 15 Guide 1 16 Holder 1 4 N m 0 4 kgf m 3 0 ft Ib 2 6 42 3 4 46 45 43 39 38 36 3...

Page 303: ...25 Clamp lever 1 26 Bushing 1 27 Bushing 1 28 Wave washer 1 29 Cowling lock lever 1 30 Collar 2 31 Grommet 2 32 Bracket 1 33 Plug 1 Manual tilt model 4 N m 0 4 kgf m 3 0 ft Ib 2 6 42 3 4 46 45 43 39 3...

Page 304: ...a 43 Plug 1 Remote control model 44 Grommet 1 Tiller handle model 45 Plug 1 Remote control model 46 Guide 1 Tiller handle model 47 Holder 1 Remote control model 48 Grommet 1 PTT model 49 Grommet 1 Man...

Page 305: ...11 Bolt 4 M8 30 mm 12 Screw 1 M6 8 mm 13 Ground lead 1 14 Washer 2 15 Nut 2 16 Grease nipple 1 17 Lower mount housing 1 1 1322 A A LT 572 LT A A LT 572 LT LT 572 LT LT 271 1401 1322 A A A A 18 19 19 2...

Page 306: ...LT 572 LT LT 572 LT LT 271 1401 1322 A A A A 18 19 19 2 4 3 1 9 8 7 6 5 10 11 21 20 15 14 11 10 17 12 13 14 15 16 9 8 7 6 5 3 N m 0 3 kgf m 2 2 ft Ib 24 N m 2 4 kgf m 17 7 ft Ib 54 N m 5 4 kgf m 39 8...

Page 307: ...er case assembly 5 5 Remove the bolts 6 upper mount 7 plate 8 and bolts 9 6 Remove lower mount housing 1 0 and then remove the lower mount covers A lower mounts B rubber washers C washers D bolts E an...

Page 308: ...self locking nuts F to the specified torque 8 Install lower mount housing 2 G and then tighten the bolts H to the specified torques in 2 stages in the order 1 2 and so on 9 Connect the ground lead Up...

Page 309: ...6 Mount housing 2 7 Rubber damper 2 8 Rubber damper 1 9 Screw 1 M6 8 mm 10 Ground lead 1 11 Bolt 2 M10 80 mm 12 Bolt 2 M10 120 mm 13 Grease nipple 1 14 Washer 2 15 Self locking nut 2 13 9 10 7 6 8 7...

Page 310: ...1 Install the plate 1 and bolts 2 to the upper mount 3 and then install the upper mount assembly 2 Tighten the bolts 4 to the specified torque 3 Install the upper case assembly 5 to the bracket assemb...

Page 311: ...housings C and ground lead D 7 Tighten the bolt E in the order 1 2 and so on 8 Install the ground lead F Self locking nut 8 24 N m 2 4 kgf m 17 7 ft lb Grease nipple 0 3 N m 0 3 kgf m 2 2 ft lb Lower...

Page 312: ...mount 2 11 Washer 2 12 Lower mount housing 2 13 Bolt 4 M8 30 mm 14 Screw 1 6 7 mm 15 Grease nipple 1 16 Self locking nut 2 17 Nut 2 10 11 9 8 7 6 12 13 11 16 3 2 4 9 8 7 8 7 9 10 11 12 13 13 14 1 10 1...

Page 313: ...1 20 Bolt 2 M8 20 mm for Oceania 21 Lower mount cover 1 For Oceania 10 11 9 8 7 6 12 13 11 16 3 2 4 9 8 7 8 7 9 10 11 12 13 13 14 1 10 18 17 17 20 18 15 21 19 5 6 6 5 3 N m 0 3 kgf m 2 2 ft Ib 24 N m...

Page 314: ...the washers B bolts C wash ers D rubber washers E and washers F from the lower mounts G and then remove the caps H Installing the upper case 1 Install the washers 1 rubber washers 2 washers 3 bolts 4...

Page 315: ...er case assembly E to the bracket assembly F and then tighten the nuts G and nuts H to the specified torque 6 Tighten the bolts A and D 7 Install the ground lead I 8 Install the lower mount cover J Fo...

Page 316: ...l 2 5 Upper case 1 6 Grommet 1 7 Hose 1 8 Damper 1 9 Gasket 1 Not reusable 10 Drain bolt 1 M14 12 mm 8 9 10 7 1 2 4 6 3 3 4 5 27 N m 2 7 kgf m 19 9 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 1 21 N m 2 1 kgf m 1...

Page 317: ...t 2 and then tighten the screws 3 to the specified torque 2 Install the damper 4 and a new gasket 5 and then tighten the drain bolt 6 to the specified torque 3 Install the dowels 7 and upper case asse...

Page 318: ...reusable 10 Plug 1 M14 12 mm 11 Drive shaft bushing 1 12 Collar 1 13 Circlip 1 14 Hose 1 15 Damper 1 16 Gasket 1 Not reusable 17 Drain bolt 1 A A 1 6 2 5 2 1 3 4 5 1 7 8 9 12 13 10 11 M M 15 16 14 17...

Page 319: ...eal 1 19 Rubber seal 1 Not reusable A A 1 6 2 5 2 1 3 4 5 1 7 8 9 12 13 10 11 M M 15 16 14 17 A A A A 19 18 LT 572 LT 3 N m 0 3 kgf m 2 2 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib 27 N m 2 7 kgf m 19 9 ft Ib...

Page 320: ...he drive shaft bushing 1 Check the drive shaft bushing Replace if cracked or worn Assembling the upper case Do not reuse a gasket or rubber seal always replace it with a new one 1 Install the drive sh...

Page 321: ...tighten the bolts A to the specified torque TIP Make sure to fit the tip of the water pipe B into the rubber seal 9 6 Install a new gasket C and then tighten the drain bolt D to the specified torque B...

Page 322: ...8 Grommet 1 9 Rubber seal 1 10 Gasket 1 Not reusable 11 Gasket 1 Not reusable 12 Cover 1 13 Bolt 3 M6 25 mm 14 Bolt 2 M6 16 mm 15 Oil strainer 1 16 Gasket 1 Not reusable 17 Pipe 1 17 16 18 15 1 2 23 2...

Page 323: ...ks 18 Dowel 2 19 Oil pan 1 20 Bolt 10 M6 25 mm 21 Gasket 1 Not reusable 22 Exhaust manifold 1 23 Bolt 3 M6 50 mm 17 16 18 15 1 2 23 23 23 18 13 7 9 8 5 4 3 6 22 21 19 20 10 11 12 14 LT 572 LT A A LT 5...

Page 324: ...Replace if corroded or cracked 3 Check the oil pan Replace if corroded or cracked Checking the oil strainer 1 Check the oil strainer Clean if there is dirt or residue Checking the exhaust guide anode...

Page 325: ...D temporarily 5 Install a new gasket E and the exhaust manifold F and then tighten the bolts G temporarily 6 Tighten the bolts G to the specified torque and then tighten the bolts D 7 Install the anod...

Page 326: ...eusable 9 Exhaust guide 1 10 Gasket 1 Not reusable 11 Dowel 2 12 Bolt 10 M6 25 mm 13 Grommet 1 14 Oil pan 1 15 Grommet 1 16 Anode 1 17 Cover 1 LT 572 LT A A A A 1 3 5 3 7 6 11 10 8 13 14 12 12 11 2 4...

Page 327: ...2 Exhaust manifold 1 23 Bolt 3 M6 50 mm 24 Rubber seal 1 Not reusable 25 Gasket 2 Not reusable 26 Plate 1 27 Bolt 6 M6 25 mm 28 Muffler 1 LT 572 LT A A A A 1 3 5 3 7 6 11 10 8 13 14 12 12 11 2 4 4 15...

Page 328: ...3 2 Remove the rubber seal 4 exhaust manifold 5 and gasket 6 3 Remove the oil pan 7 dowels 8 pipe 9 and gasket 0 4 Remove the oil strainer A cover B and gaskets C and D 5 Remove the anode E 6 Remove...

Page 329: ...ust manifold Do not reuse a gasket oil seal or rubber seal always replace it with a new one 1 Install a new oil seal See step 1 in Assembling the oil pan and exhaust manifold 9 34 2 Install new gasket...

Page 330: ...e F and the muffler G and then tighten the muf fler bolts H 8 Install the anode I Exhaust manifold bolt D 11 N m 1 1 kgf m 8 1 ft lb A 0 D B C D 0 LT 572 LT A A F E H E G H LT 572 LT I LT 572 Oil pan...

Page 331: ...k 1 Remote control model 4 Stud bolt 2 5 Steering arm 1 6 Washer 1 7 Bushing 1 8 Friction piece 1 9 Rubber seal 1 Not reusable 10 Bolt 1 M6 20 mm 11 Bushing 1 12 O ring 1 Not reusable 13 Bushing 1 a b...

Page 332: ...it with a new one 1 Install the friction piece 1 bushing 2 and washer 3 and then install the steer ing arm 4 2 Install the bushing 5 a new O ring 6 and the bushing 7 3 Install a new rubber seal 8 and...

Page 333: ...1 7 Bushing 1 8 O ring 2 Not reusable 9 Bushing 2 10 Friction piece 1 11 Rubber seal 1 Not reusable 12 Bolt 1 M6 20 mm 13 Bushing 1 14 Steering yoke 1 For Europe 15 Circlip 1 16 Steering yoke 1 For O...

Page 334: ...ber seal always replace it with a new one 1 Install the friction piece 1 the bushing 2 a new O ring 3 the bushing 4 and the washer 5 and then install the steer ing arm 6 2 Install the bushing 7 a new...

Page 335: ...m 6 and then strike the steering yoke B using a copper ham mer until the groove for installing the cir clip is visible 6 Install the circlip C 7 Inject grease into the grease nipple on the swivel brac...

Page 336: ...shing 2 12 Grease nipple 3 13 Swivel bracket 1 14 Pin 1 15 Clamp bracket PORT 1 16 Plate 1 17 Self locking nut 2 a a b b 4 8 9 10 3 1 2 13 12 12 5 6 7 4 9 14 15 16 11 11 22 23 28 27 21 26 25 18 17 24...

Page 337: ...shing 1 23 E clip 2 24 Through tube 1 25 Tilt pin 1 26 Collar 1 27 Washer 1 28 Nut 1 a a b b 4 8 9 10 3 1 2 13 12 12 5 6 7 4 9 14 15 16 11 11 22 23 28 27 21 26 25 18 17 24 20 12 10 19 17 18 1 2 5 6 7...

Page 338: ...ing nuts 9 and plate 0 6 Remove the through tube A and collar B and then disassemble the clamp brackets C and D and swivel bracket E Installing the clamp bracket 1 Tighten the self locking nut 1 compl...

Page 339: ...l the caps E 7 Install the bushings F and G collar H and tilt stopper plate pins I and J to the swivel bracket 9 and then install the E clips K 8 Install the clamp bracket bolt L and tilt pin M 9 Conn...

Page 340: ...1 8 Cotter pin 4 Not reusable 9 Spring 2 10 Collar 1 11 Pin 1 12 Tilt lock plate PORT 1 13 Tilt lock arm 1 14 Tilt lock plate STBD 1 15 Tilt support bar 1 16 E clip 1 17 Spring 1 15 18 17 5 4 6 7 11...

Page 341: ...et unit 9 51 No Part name Q ty Remarks 18 Tilt lever 1 19 Screw 1 M5 5 mm 20 Tilt lock rod 1 21 Collar 1 15 18 17 5 4 6 7 11 10 9 12 13 8 14 8 3 2 1 15 16 21 8 17 20 18 19 A A A A A A 4 N m 0 4 kgf m...

Page 342: ...cotter pin 0 and then remove the pin A and collar B 6 Remove the cotter pins C and then dis assemble the pin D tilt lock rod 8 tilt lock arm E and tilt lock plates F and G Assembling the swivel bracke...

Page 343: ...collar D and tilt support bar E to the swivel bracket 8 5 Hook the tilt lock rod 4 and spring F onto the tilt lever G 6 Install the tilt lever G and then tighten the screw H to the specified torque 7...

Page 344: ...12 Bolt 2 M6 25 mm high thrust model 13 Anode 1 High thrust model 14 Ground lead 1 15 Bolt 2 M6 14 mm 16 Grease nipple 3 17 Swivel bracket 1 A A a a b b 4 3 5 11 10 6 10 18 17 15 15 20 21 11 3 1 2 13...

Page 345: ...und lead 1 20 Clamp bracket PORT 1 21 Trough tube 1 A A a a b b 4 3 5 11 10 6 10 18 17 15 15 20 21 11 3 1 2 13 13 4 5 9 9 8 7 14 16 16 16 12 19 A A A A A A A A A A 3 N m 0 3 kgf m 2 2 ft Ib 36 N m 3 6...

Page 346: ...clamp bracket anode high thrust model 1 Check the anodes Replace if eroded Clean if there is grease oil or scales NOTICE Do not apply grease oil or paint to the anodes Installing the clamp bracket 1...

Page 347: ...to the specified torque 6 Install the stoppers G and then tighten the nuts H to the specified torque 7 Inject grease into the grease nipples on the swivel bracket See Lubricating the outboard motor 10...

Page 348: ...TT unit 1 7 Anode 1 Except high thrust model 8 Bolt 2 M6 25 mm except high thrust model M6 10 mm high thrust model 9 Bushing 1 10 Bushing 2 11 Shaft 1 12 Washer 2 13 Bolt 2 M8 16 mm A A 4 4 5 6 5 7 7...

Page 349: ...model 4 Remove the lower mount shaft 6 5 Remove the E clips 7 and then remove the upper mount shaft 8 busing 9 PTT unit 0 and busings A and B Checking the PTT anode except high thrust model 1 Check th...

Page 350: ...and A to the PTT unit 5 Pass the PTT motor lead B through the hole a in the clamp bracket C and then fasten the PTT motor lead B to the clamp bracket C using the plastic tie D 6 Fasten the PTT motor l...

Page 351: ...mm 7 Brush 1 8 Brush 1 9 Circuit breaker 1 10 Bolt 4 M6 20 mm 11 Spring 2 12 Brush holder 1 13 PTT motor base 1 14 Oil seal 1 Not reusable 15 O ring 1 Not reusable 16 Spring 1 17 Joint 1 18 19 10 10...

Page 352: ...rks 18 O ring 1 Not reusable 19 Reservoir cap 1 18 19 10 10 10 8 1 11 6 10 3 7 9 11 12 6 3 2 4 5 14 13 15 16 17 1 N m 0 1 kgf m 0 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 7 N m 0 7...

Page 353: ...l valve 1 by turning it clock wise 2 Remove the PTT motor assembly 2 O ring 3 spring 4 and joint 5 Disassembling the PTT motor 1 Remove the stator 1 2 Remove the armature assembly 2 3 Remove the brush...

Page 354: ...h brush Replace if below specification Assembling the PTT motor Do not reuse an oil seal or O rings always replace it with new one Do not apply grease or oil to the com mutator of the armature 1 Insta...

Page 355: ...ll the stator B and then tighten the screws C to the specified torque Installing the PTT motor Do not reuse an O ring always replace it with a new one 1 Install a new O ring 1 the joint 2 the spring 3...

Page 356: ...lve 1 13 O ring 1 Not reusable 14 O ring 1 Not reusable 15 Manual valve seat 2 16 Spring 1 17 Adapter 1 20 33 1 1 9 34 9 19 18 20 21 22 35 24 37 38 39 36 32 LT 271 11 12 13 14 15 16 17 15 9 4 2 3 3 7...

Page 357: ...pin 2 28 Spring 2 29 O ring 4 Not reusable 30 Filter 1 31 O ring 1 Not reusable 32 Valve support pin 1 F25 33 O ring 1 Not reusable F25 20 33 1 1 9 34 9 19 18 20 21 22 35 24 37 38 39 36 32 LT 271 11...

Page 358: ...43 Valve pin 1 FT25 44 Valve pin seal 1 FT25 45 O ring 1 Not reusable FT25 46 Relief valve 1 FT25 20 33 1 1 9 34 9 19 18 20 21 22 35 24 37 38 39 36 32 LT 271 11 12 13 14 15 16 17 15 9 4 2 3 3 7 8 7 8...

Page 359: ...assembly 5 4 Remove the spring 6 valve pin 7 valve seal 8 9 5 Remove the circlip 0 and then remove the manual valve A manual valve seats B spring C and adapter D 6 Remove the main valves E and shuttl...

Page 360: ...ng Replace if dam aged 4 Check the manual valve and spring Replace if damaged Checking the filter 1 Check the filters Clean if there is dirt or residue Assemble the gear pump housing Lubricate the par...

Page 361: ...ll new O rings F and G to the man ual valve H 9 Install the manual valve seats I adapter J spring K and manual valve H and then install the circlip L 10 Install new O rings M the filters N the valve s...

Page 362: ...er valve pins Y the balls Z new O rings and the gear pump housing and then tighten the bolts to the specified torque Gear pump bolt T 4 N m 0 4 kgf m 3 0 ft lb Gear pump housing bolt 9 N m 0 9 kgf m 6...

Page 363: ...s 1 Tilt ram assembly 1 2 Dust seal 1 Not reusable 3 O ring 1 Not reusable 4 O ring 1 Not reusable 5 Backup ring 1 6 Free piston assembly 1 7 O ring 1 Not reusable 8 Cylinder 1 7 1 6 8 LT 271 A A 3 4...

Page 364: ...PTT fluid could be forcefully expelled out 4 Remove the tilt piston c and tilt cylinder end screw a 5 Remove the absorber valves d Checking the PTT cylinder and piston 1 Check the tilt piston a and fr...

Page 365: ...er end screw c 2 Install a new O ring 3 and the backup ring 4 to the tilt piston d 3 Install the tilt cylinder end screw c and tilt piston d to the tilt ram e 4 Install the balls f absorber valve pins...

Page 366: ...the tilt cylinder end screw c to the specified torque 12 Install the PTT motor See Installing the PTT motor 9 65 Bleeding the PTT unit Make sure that the tilt ram is fully extended 1 Place the PTT un...

Page 367: ...hen tighten it to the specified torque 5 Connect the PTT motor leads to the bat tery terminals to fully retract the tilt ram 6 Reverse the PTT motor lead connections between the battery terminals to f...

Page 368: ...ly extended when removing the reservoir cap Otherwise fluid can spurt out from the unit due to internal pressure TIP If the fluid is below the proper level add the recommended PTT fluid up to the prop...

Page 369: ...ne manual starter model 10 8 Break in 10 9 After test run 10 9 General periodic maintenance 10 9 Checking the anode 10 9 Checking the battery 10 9 Checking the cooling water passage 10 9 Checking the...

Page 370: ...10 Adjusting the throttle link rod and throttle cable 10 15 Checking the top cowling 10 15 Checking the valve clearance 10 16 Checking the water pump 10 16...

Page 371: ...gine life and greater owner satisfaction Consult a Selva dealer for additional recommendations The maintenance cycle on these charts assumes usage of 100 hours per year and regular flush ing of the co...

Page 372: ...ift cable Check adjust replace 3 13 10 5 Spark plug s Check adjust replace 7 45 Spark plug cap s spark plug wires Check replace 5 11 Throttle link throttle cable Check adjust replace 3 13 6 15 6 18 Th...

Page 373: ...res Charge batteries in a well ventilated area Keep batteries away from fire sparks or open flames for example welding equipment and lighted cigarettes DO NOT SMOKE when charging or han dling batterie...

Page 374: ...the center between the upper level a and the lower level b Fill with oil if it is below the lower level b or extract to the center level if it is above the upper level a Checking the engine start but...

Page 375: ...r oil level TIP If the oil is at the proper level a small amount of oil should flow out of the check hole 3 Install a new gasket 2 and the check screw 1 and then tighten the check screw 1 to the speci...

Page 376: ...mance TIP The optimum mounting height depends on the combination of the boat and outboard motor To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that...

Page 377: ...on and fully close the throttle lever Remote control model 2 Check that the fully closed stopper a on the throttle cam 1 contacts the stopper b Tiller handle model Remote control model 3 Check that th...

Page 378: ...ne 1 Move the shift lever to the N position 2 Turn the throttle grip until the location a on the throttle grip is aligned with the mark b on the tiller handle TIP If the throttle grip is turned too fa...

Page 379: ...perform this procedure on land while the engine is running Otherwise the water pump could be damaged and the engine could be severely dam aged due to overheating TIP When using the flushing device fl...

Page 380: ...tion 4 Turn the throttle stop screw b in direc tion c or d until the specified engine idle speed is obtained TIP To increase the engine idle speed turn the throttle stop screw b in direction c To decr...

Page 381: ...th a rag 8 Insert the dipstick 2 and remove it again Make sure to completely insert the dipstick into the dipstick hole Otherwise the oil level measurement will be incor rect 9 Check the oil level usi...

Page 382: ...start button or switch and engine shut off switch See Check ing the engine start button or switch and engine shut off switch 10 4 Checking the fuel filter 1 Check the fuel filter See Checking the fue...

Page 383: ...ew 5 Put the outboard motor in an upright position 6 Install the gear oil pump into the drain hole and slowly fill with gear oil until oil flows out of the check hole and no air bubbles are visible 7...

Page 384: ...Electric starter model 3 Apply corrosion resistant grease to the specified area Checking the propeller 1 Check the propeller See Checking the propeller 8 3 Checking the PTT fluid level Never get unde...

Page 385: ...check the lock mech anism of the stopper knob 3 Check the PTT unit for fluid leakage Adjusting the shift cable 1 Remove the shift cable and then adjust it See Installing the shift cable and throttle...

Page 386: ...g move the hook 2 in direction b 4 Tighten the nuts 1 5 Recheck the fitting Replace the cowling seal if the free play cannot be adjusted Checking the valve clearance 1 Check the valve clearance See Ch...

Page 387: ...the PTT unit 9 76 Bottom cowling 9 12 Bracket unit 1 5 1 22 Bracket unit technical data 1 20 Break in 10 9 C Camshaft and valve 7 37 Carburetor 2 13 6 10 CDI unit coupler layout 5 9 Changing the engi...

Page 388: ...diameter 7 59 Checking the piston ring 7 57 Checking the piston ring end gap 7 58 Checking the piston ring groove 7 58 Checking the piston ring side clearance 7 58 Checking the Prime Start 5 15 6 13 C...

Page 389: ...ess routing 5 1 Electrical technical data 1 7 Engine control system 2 1 Engine speed control 2 7 Engine speed control during low oil pressure 2 7 Engine speed control during overheating 2 7 Engine spe...

Page 390: ...klash 8 63 Measuring the peak voltage 5 10 Measuring the reverse gear backlash 8 66 Measuring the starter rope 7 11 Model data 1 3 Model designation 1 2 Model features 1 1 Mounting the outboard motor...

Page 391: ...8 57 Shimming high thrust model 8 52 Shimming check sheet 8 53 Shimming workflow 8 52 Special service tool 0 3 0 7 Special tightening torque 1 21 Starboard view 5 4 Starter motor 5 21 7 32 Starting ig...

Page 392: ...A Appendix Wiring diagram A 1 How to use the wiring diagram A 1...

Page 393: ...ouble colors wire 2 No wire connector Color Code B Black Br Brown G Green L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White B R Black Red B Y Black Yellow Br W Brown White G R Green Red...

Page 394: ......

Page 395: ......

Page 396: ...Br W B B Y B Y L L W R P B R Br O Rectifier Regulator Ignition coil Spark plug Thermo sensor Pulser coil Charge coil Power bobbin Oil pressure switch Fuse 30A Fuse 20A CDI unit 2 4 5 6 7 8 9 11 13 14...

Page 397: ...L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White B R Black Red B Y Black Yellow Br W Brown White G R Green Red P B Pink Black P W Pink White W R White Red Y B Yellow Black Y R Yellow R...

Page 398: ...B Br Sb B B Y B Y R Sb Lg L L W R P B R Br O B G G L L Rectifier Regulator Ignition coil Spark plug Thermo sensor Charge coil Power bobbin Oil pressure switch Fuse 30A Fuse 20A CDI unit 2 4 5 6 7 8 9...

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Summary of Contents for Kingfish 25

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SELVA MARINE Kingfish 25, Service Manual

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Summary of Contents for Kingfish 25

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