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Yamaha 250GETO, Service Manual

The Yamaha 250GETO Service Manual is a comprehensive and essential resource for all Yamaha 250GETO owners. Easily downloaded for free from our website, this manual provides detailed instructions and diagrams to ensure optimal performance and maintenance of your Yamaha 250GETO.

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i-3

6S35H11

Index

H.

Hose routing  ............................................ 4-1
How to use this manual  ........................... 1-1

I.

Identification ............................................. 1-5
Ignition and ignition control system ...........8-8
Installing the clamp bracket .....................7-19
Installing the drive shaft..................6-17, 6-48
Installing the lower unit...................6-20, 6-51
Installing the oil pump .............................4-18
Installing the PCV  .................................. 5-20
Installing the power unit ......................... 5-44
Installing the propeller shaft housing

......................................................6-18, 6-49

Installing the PTT unit ..............................7-19
Installing the steering arm .......................7-14
Installing the upper case..........................7-15
Installing the water pump and shift rod

......................................................6-19, 6-50

Intake manifold  ...................................... 5-15

J.

Junction box...............................................8-4

L.

Lower unit (counter rotation model).........6-30
Lower unit (regular rotation model)............6-1
Lower unit............................... 1-16, 2-5, 3-11
Lubricating the outboard motor  ............. 3-15

M.

Maintenance interval chart  ...................... 3-1
Maintenance specification .........................2-3
Manual format .......................................... 1-1
Measuring the forward and reverse gear

backlash .......................................6-27, 6-61

Measuring the peak voltage ......................8-1

O.

Oil feed pump control system ..................8-22
Oil injection system ................................ 4-16

P.

Parts, lubricant, and sealant  .................... 1-3
Port view ....................................................8-2
Power unit ...................................2-3, 3-3, 5-1
Predelivery check  .................................. 1-25
Propeller selection  ................................. 1-24

Propeller shaft housing (counter rotation

model) ....................................................6-35

Propeller shaft housing (regular rotation

model) ......................................................6-6

Propeller size  ......................................... 1-24
PTT motor ................................................7-27
PTT unit ...................................................7-22

R.

Removing the clamp bracket ...................7-18
Removing the crankcase  ....................... 5-28
Removing the cylinder head  .................. 5-22
Removing the drive shaft................6-14, 6-45
Removing the electrical component  ...... 5-13
Removing the exhaust cover  ................. 5-20
Removing the flywheel magnet  ............. 5-12
Removing the intake manifold  ............... 5-17
Removing the lower unit...................6-4, 6-33
Removing the piston, connecting rod 

assembly and crankshaft assembly  .... 5-29

Removing the power unit  ....................... 5-11
Removing the propeller shaft housing 

assembly ........................................6-8, 6-37

Removing the propeller shaft housing 

assembly..................................................6-8

Removing the PTT unit ............................7-18
Removing the starter motor pinion ..........8-18
Removing the steering arm .....................7-14
Removing the water pump and 

shift rod...........................................6-5, 6-34

S.

Safety while working ................................ 1-3
Selecting the forward gear shim.....6-25, 6-58
Selecting the pinion shim ...............6-24, 6-55
Selecting the propeller shaft shim ...........6-59
Selecting the reverse gear shim.....6-26, 6-56
Selection ................................................ 1-24
Self-protection .......................................... 1-3
Serial number  .......................................... 1-5
Shimming (counter rotation model) .........6-54
Shimming (regular rotation model) ..........6-23
Shimming........................................6-24, 6-55
Special service tool .................................. 1-6
Specified torque .......................................2-11
Starboard view ...........................................8-3
Starter motor ............................................8-17
Starting system ........................................8-15
Symbol ..................................................... 1-2
Synchronizing the carburetor ................... 3-5

 6S35H11_2index  05.9.20 19:02  Page 4

Summary of Contents for 250GETO

Page 1: ...L250G SERVICE MANUAL 6S3 28197 5H 116 250G 250G L250G ...

Page 2: ...y of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Important information Particularly important information is distinguished in this manual by the following notations Q The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED w Failure to follow WARNING instructions could result in severe ...

Page 3: ...neral information Periodic check and adjustment Fuel system Power unit Bracket unit Electrical system Troubleshooting Index Contents Lower unit 9 8 7 6 2 1 GEN INFO SPEC CHK ADJ FUEL POWR LOWR BRKT ELEC TRBL SHTG 3 4 5 ...

Page 4: ......

Page 5: ...t 1 12 Bracket upper case 1 15 Lower unit 1 16 Fuel system 1 19 Propeller selection 1 24 Propeller size 1 24 Selection 1 24 Predelivery check 1 25 Checking the fuel system 1 25 Checking the gear oil 1 25 Checking the outboard motor mounting height 1 26 Checking the remote control cable 1 26 Checking the steering system 1 27 Checking the gear shift and throttle operation 1 27 Checking the PTT syste...

Page 6: ...er unit No Part name Q ty Remarks 1 Lower unit 1 2 Plastic tie 1 Not reusable 3 Hose 1 4 Check screw 1 5 Gasket 2 Not reusable 6 Dowel pin 2 7 Bolt 4 M10 40 mm 8 Drain screw 1 9 Grommet 1 10 Bolt 1 M10 45 mm 11 Bolt 1 M8 60 mm 12 Thrust washer 1 13 Propeller 1 14 Washer 1 15 Washer 1 16 Cotter pin 1 Not reusable 17 Propeller nut 1 18 Trim tab 1 LOWR Lower unit 6 19 62Y5A11 Removing the drive shaft...

Page 7: ...oded diagram or illustration indicate the grade of lubricant and the lubri cation point 7 Apply Yamaha 2 stroke outboard motor oil 8 Apply gear oil 9 Apply water resistant grease Yamaha grease A 0 Apply molybdenum disulfide grease q Apply corrosion resistant grease Yamaha grease D w Apply low temperature resistant grease Yamaha grease C e Apply injector grease Symbols r to o in an exploded diagram...

Page 8: ...sing an air compressor Protect your hands and feet by wearing pro tective gloves and safety shoes when neces sary Parts lubricant and sealant Use only genuine Yamaha parts lubricants and sealants or those recommended by Yamaha when servicing or repairing the out board motor Under normal conditions the lubricants men tioned in this manual should not harm or be hazardous to your skin However you sho...

Page 9: ...ners starting in the center and moving outward Non reusable parts Always use new gaskets seals O rings cot ter pins circlips etc when installing or assembling parts Disassembly and assembly 1 Use compressed air to remove dust and dirt during disassembly 2 Apply engine oil to the contact surfaces of moving parts before assembly 3 Install bearings with the manufacture identification mark in the dire...

Page 10: ...rd motor serial number is stamped on a label attached to the port clamp bracket 1 Model name 2 Approved model code 3 Transom height 4 Serial number YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON 1 3 2 4 6B410020 Applicable model 250GETO L250GETO Model name Approved Starting model code serial No 250G 6S3 1000001 L250G 6S4 1000001 ...

Page 11: ...akage tester 90890 06840 Vacuum pressure pump gauge set 90890 06756 Digital caliper 90890 06704 Timing light 90890 03141 Compression gauge 90890 03160 Flywheel holder 90890 06522 Flywheel puller 90890 06521 Piston slider ø85 90890 06530 Needle bearing attachment 90890 06608 90890 06610 90890 06653 90890 06654 90890 06611 ...

Page 12: ...394 Pressure pin B 90890 02390 B Driver rod L3 90890 06652 Driver rod LS 90890 06606 Gear puller 90890 06540 Dial gauge set 90890 01252 Cylinder gauge 90890 06759 Bearing separator 90890 06534 Pinion nut holder 90890 06715 Ring nut wrench extension 90890 06513 ...

Page 13: ...pper guide plate 90890 06501 Bearing housing puller claw L 90890 06502 Center bolt 90890 06504 Stopper guide stand 90890 06538 Drive shaft holder 6 90890 06520 Bearing depth plate 90890 06603 Bearing puller assembly 90890 06535 Driver rod LL 90890 06605 Driver rod SS 90890 06604 ...

Page 14: ...0 06533 Slide hammer handle 90890 06531 Bearing outer race attachment 90890 06622 90890 06624 90890 06626 90890 06628 90890 06658 Ball bearing attachment 90890 06635 90890 06655 90890 06656 90890 06657 Shimming plate 90890 06701 Shift rod push arm 90890 06052 Pinion height gauge 90890 06710 Bearing inner race attachment 90890 06640 90890 06659 ...

Page 15: ...nd screw wrench 90890 06568 PTT piston vice attachment 90890 06572 Ring nut wrench 4 90890 06510 Ignition tester 90890 06754 Digital circuit tester 90890 03174 Backlash indicator 90890 06706 Ring nut wrench 90890 06578 Peak voltage adaptor B 90890 03172 Diagnostic flash indicator B 90890 06865 ...

Page 16: ...INFO 1 11 6S35H11 General information PTT oil pressure gauge assembly 90890 06580 Test harness 2 pins 90890 06867 Tilt rod wrench 90890 06569 Test harness 3 pins 90890 06857 Test harness 4 pins 90890 06871 Test harness 6 pins 90890 06872 ...

Page 17: ... 1st or 2nd oversized piston in available for overhaul service NOTE This piston is the same as the electronic fuel injected V6 3 1L models Connecting rod The following treatment has been given to the connecting rod to enhance the stiffness Silver plating is given to the side of big end A carbonizing is given to the big end portion Larger size big end is adopted Molybdenum coating Location mark UP ...

Page 18: ...el Exhaust slit Sleeve 250A 250G Cylinder body The shallow water jacket is designed to increase the rigidity of cylinder body Wider rib is used to obtain rigid cylinder body Smoother curve structure is given to the 1 and 2 exhaust passages to reduce resistance of exhaust gases Rib 5mm Wider rib 6mm Deep water jacket 44 96mm Average 72mm Shallow water jacket 44 60mm Average 57mm Cylinder body 250A ...

Page 19: ...a sealing function to the bolt which will prevent the bolt from sticking by saltwater enter ing into the bolt hole for crystallizing and corroding Therefore the bolts can be removed easily which obtained better servicing NOTE If the bolt is reused apply LOCTITE 572 to the bolt threads Bolt Sealing material No corroded particles Sealing agent coated Engine mount bolt ...

Page 20: ...988 psi Main valve Gear pump UP relief valve 12 3 MPa 125 kgf cm 1 784 psi 2 DOWN relief valve 5 7 MPa 58 kgf cm 827 psi 2 Trim down valve 0 5 MPa 5 kgf cm 2 73 psi Tilt cylinder Impact relief valve 20 6 MPa 210 kgf cm 2 988 psi 2 Trim cylinder PTT fluid flow diagram PTT specifications PTT ID mark 61A 25 Tilt stroke 147 mm 5 8 in Trim stroke 99 mm 3 9 in Fluid ATF Dexron 2 ...

Page 21: ...e The oil passages have been added to the drive shaft at pinion end and the lower case between gear housing and shifter room to increase the gear oil fluidity so that the lubrication ability has increased 86 5 mm 3 41 in Drive shaft oil passage 8 m m Lower case oil passage ...

Page 22: ...d anodic oxide coating has been given to the exhaust passage s components to obtain corro sion resistance The effected components are as follows Exhaust pipe 61A 41132 20 Muffler 61A 14711 30 Example Muffler M Mark M is stamped to recognize Hard anodic oxide coated components ...

Page 23: ...outer race which can obtain durability and reliability Compared with the taper roller bearing this structure can remove the thrust load from the taper rollers of bearing Thrust power transmission structure Lower case Roller bearing outer race Thrust bearing Thrust force transmitting Forward gear Prop shaft Lower case Taper roller bearing Forward gear Prop shaft 250A 250G ...

Page 24: ...s the remote oil tank The oil feed pump is controlled as below ID mark OUT IN Air bleed screw 5 Nm 0 5 kgf m 4 ft lb Oil Remote oil tank Engine oil tank Oil pump Check valve 1 2 3 4 5 6 Carburetors Fuel Premixed fuel Fuel feed pumps Fuel filter Primer pump Fuel tank Fuel system diagram Oil level switch Oil pump operation SW 1 SW 2 SW 3 SW B ON OFF OFF ON OFF OFF OFF OFF ON OFF ON OFF ON OFF ON OFF...

Page 25: ...er is accumulated into the fuel filter water is precipitated to the bottom of cup because water is heavier than fuel Therefore top clear layer fuel passes through the filter element and flows to the carburetors The red ring will float to the boundary between fuel and water to indicate water in fuel Fuel filter with water separator For 30 seconds after Over 30 seconds after switch ON switch ON Note...

Page 26: ...fier Regulator Propeller boss Lower case Upper case Exhaust outer cover PCV Cylinder body Thermostat Cylinder head Sea River Lake Cooling water flow chart NOTE The cylinder head gasket has been newly designed for 250G This gasket controls the cooling water flow between the cylinder head and the cylinder body Be sure to use the original gasket to obtain proper cooling water flow ...

Page 27: ...operation hours after the engine was manufactured Hour is counted by the signal of crank position sensor and kept even if the engine is turned off When the key switch is turned on all of segments light for 2 seconds to check the display Hour meter Hour meter wiring diagram Battery Power source Y Fuse Key switch Pulse G W B B B Crank position sensor Flywheel magneto CDI unit Pulse G HOUR METER GND ...

Page 28: ...eds 6 100 rpm for example jumping with boat misfire is immediately started to prevent the engine from damage because of over rev For detail ignition control see the table below NOTE If the wire Gy of CDI unit has been cut off the over rev limiter is no longer activated This is a tuning for competition use If the gray wire is cut off the warranty never covers your outboard motor Engine temp Ignitio...

Page 29: ...selecting a propeller that meets the operating conditions of the boat and the outboard motor Propeller size The size of the propeller is indicated as shown 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 4 500 5 500 r min the ideal propeller for the boat is one that pro vides maximum ...

Page 30: ...start swich to ON and check that the oil injection system automatically feed the engine oil from the remote oil tank to engine oil tank 3 Make sure the oil level is between the upper 1 and lower level marks 2 NOTE Make sure that air bleeding must be operate after fill the engine Refer to the chapter 4 Bleeding the oil pump Checking the battery 1 Check the capacity electrolyte level and specified g...

Page 31: ...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 mounting bolts Checking the remote control cable 1 Set the remote control lever to the neutral position and fully close the throttle lever 69D10080 2 Check that the control lever 1 is in its fully closed position and check that the center of the throttle c...

Page 32: ...TT system 1 Check that the outboard 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 tilt ed up or down 3 Check that there is no interference with wires or hoses when the tilted up out board motor is steered 4 Check that the trim meter points down when the outboard motor is tilted all the way down Checking the ...

Page 33: ...the engine cool between full throttle runs Vary engine speed occasionally 5 After the first 10 hours Use only straight gasoline into the fuel tank Refer to page 1 25 å Hours 6F610180 0 1 2 10 4 Check that the engine turns off when the lock plate of engine stop lanyard is pulled from the engine stop lanyard switch Checking the cooling water pilot hole 1 Start the engine then check that the cooling ...

Page 34: ...gear oil 2 Check for fuel leakage in the cowling 3 Flush the cooling water passage with fresh water using the flushing kit 1 and with the engine running at idle cC Be sure to supply sufficient water when flushing the cooling water passage other wise the engine may overheat 6S310070 1 ...

Page 35: ... 7 6 5 4 3 2 1 SPEC Specification General specification 2 1 Maintenance specification 2 3 Power unit 2 3 Lower unit 2 5 Electrical 2 5 Dimension 2 9 Tightening torque 2 11 Specified torque 2 11 General torque 2 13 ...

Page 36: ...in 4 500 5 500 Maximum fuel consumption L 106 US gal 28 0 23 3 lmp gal hr at 5 500 r min Engine idle speed r min 675 725 Power unit Engine type 2 stroke V Cylinder quantity 6 Total displacement cm3 cu in 3 130 190 94 Bore x stroke mm in 90 0 82 0 3 54 3 23 Compression ratio 5 7 1 Intake system Reed valve Scavenging system Loop charge Control system Remote control Starting system Electric Fuel syst...

Page 37: ...rim angle Degree 3 to 16 at 12 boat transom Tilt up angle Degree 70 Steering angle Degree 32 32 Drive unit Gear shift positions F N R Gear ratio 1 81 29 16 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear view Clockwise Counterclockwise Propeller ID mark T M TL ML Electrical Battery minimum capacity 3 CCA EN A 711 20HR IEC Ah 100 6S3...

Page 38: ...9 840 89 860 3 5370 3 5378 Measuring point H mm in 10 0 0 39 Piston clearance mm in 0 155 0 161 0 0061 0 0063 Piston pin boss bore mm in 26 004 26 015 1 0238 1 0242 Oversize piston 1st mm in 0 25 0 010 2nd mm in 0 50 0 020 Oversize piston diameter 1st mm in 90 090 90 110 3 5468 3 5476 2nd mm in 90 340 90 360 3 5567 3 5575 Piston pins Piston pin diameter mm in 25 995 26 000 1 0234 1 0236 1 Measurin...

Page 39: ... 0 0157 Side clearance mm in 0 02 0 06 0 0008 0 0024 Oversize outside diameter 1st mm in 90 25 3 5531 2nd mm in 90 50 3 5630 Connecting rods Small end inside diameter mm in 31 000 31 012 1 2205 1 2209 Connecting rod big end mm in 0 080 0 400 0 0032 0 0157 side clearance Small end axial play limit mm in 2 0 0 08 Crankshaft Crankshaft journal diameter mm in 58 975 58 991 2 3219 2 3225 Crankpin diame...

Page 40: ...in 0 13 0 45 0 32 0 52 0 0051 0 0177 0 0126 0 0205 Pinion to reverse mm in 0 64 0 93 0 0252 0 0366 Pinion gear shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Forward gear shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Reverse gear shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Propeller shaft shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Propeller shaft free play mm in 0 25 0 35 0 0098 0 0138 Electrical Item...

Page 41: ...at 1 500 r min loaded V 20 0 at 3 500 r min loaded V 38 0 Pulser coil resistance Ω 294 398 at 20 C 68 F W R B W B B W Y B W G B W L B W Br B Crank position sensor output peak voltage G W G L at Cranking unloaded V 4 0 at Cranking loaded V 4 0 at 1 500 r min loaded V 10 0 at 3 500 r min loaded V 15 0 Crank position sensor Ω 179 242 resistance at 20 C 68 F G W G L Crank position sensor air gap mm in...

Page 42: ...24 336 B R L Ω 224 336 Starter motor Type Bendix Output kW 1 10 Brushes Standard length mm in 17 0 0 67 Wear limit mm in 10 0 0 39 Commutator Standard diameter mm in 33 0 1 30 Wear limit mm in 32 0 1 26 Standard undercut mm in 0 8 0 03 Wear limit mm in 0 2 0 01 Charging system Fuse A 80 20 Lighting coil output peak voltage G G at Cranking unloaded V 8 0 at 1 500 r min unloaded V 45 0 at 3 500 r mi...

Page 43: ...388 at 20 C 68 F P B Fluid type ATF Dexron 2 Motor type 61A02 Output kW 0 38 Brushes Standard length mm in 12 0 0 47 Wear limit mm in 4 0 0 16 Commutator Standard diameter mm in 25 0 0 98 Wear limit mm in 24 0 0 95 Standard undercut mm in 1 8 0 07 Wear limit mm in 1 2 0 05 Hydraulic pressure down MPa kgf cm2 4 7 6 7 47 67 Hydraulic pressure up MPa kgf cm2 11 3 13 3 113 133 ...

Page 44: ...U 1 271 50 0 556 22 3 181 7 1 74 0 2 9 185 7 3 70 3 12 X 846 33 3 U 923 36 3 U 89 3 5 X 69 2 7 79 3 1 673 26 5 X 52 2 0 U 58 2 3 4 4 1 1 7 4 818 32 2 X 1 077 42 4 U 1 203 47 4 X 642 25 3 U 768 30 2 216 8 5 710 28 0 242 9 5 45 1 8 21 0 8 25 1 0 6S32001M Dimension Exterior mm in ...

Page 45: ...9 8 7 6 5 4 3 2 1 Maintenance specification 79 3 1 13 0 5 180 7 1 163 5 6 4 254 10 0 55 5 2 2 411 16 2 163 5 6 4 125 4 4 9 125 4 4 9 101 5 4 0 101 5 4 0 180 7 1 13 0 5 50 8 2 0 18 5 0 7 6S32002M Clamp bracket mm in ...

Page 46: ...0 3 2 2 Starter motor mount bolt M8 18 1 8 13 3 Starter motor positive terminal nut 7 0 7 5 2 Negative battery cable bolt M8 18 1 8 13 3 Intake manifold bolt 1st M6 4 0 4 3 0 2nd 8 0 8 5 9 Reed valve mount screw 3 0 3 2 2 Thermostat cover bolt M6 10 1 0 7 4 Cover bolt thermostat base M6 10 1 0 7 4 PCV cover bolt M6 11 1 1 8 1 Exhaust cover bolt 1st M6 5 0 5 3 7 2nd 10 1 0 7 4 Cylinder head cover b...

Page 47: ...M8 18 1 8 13 3 Shift rod cover bolt M6 8 0 8 5 9 Trim tab bolt M10 42 4 2 31 0 Propeller shaft housing bolt M8 30 3 0 22 1 Ring bolt M8 18 1 8 13 3 Ring nut 108 10 8 79 7 Grease nipple 6 0 6 4 4 Pinion nut 142 14 2 104 7 Drive shaft housing bolt M8 18 1 8 13 3 Propeller nut 54 5 4 39 8 Cooling water inlet cover screw 4 0 4 3 0 Bracket unit Upper mount nut 72 7 2 53 1 Lower mount nut 72 7 2 53 1 Sp...

Page 48: ...cation require clean dry threads Components should be at room temperature General torque Nut A Bolt B specifications N m kgf m ft lb 8 mm M5 5 0 5 3 6 10 mm M6 8 0 8 5 8 12 mm M8 18 1 8 13 14 mm M10 36 3 6 26 17 mm M12 43 4 3 31 Part to be tightened Thread size Tightening torques N m kgf m ft lb PTT unit PTT motor mount bolt M6 7 0 7 5 2 Reservoir tank mount bolt M6 7 0 7 5 2 Reservoir cap 7 0 7 5...

Page 49: ...onizing the carburetor 3 5 Checking the throttle sensor 3 6 Checking the engine idle speed 3 7 Checking the stopper and throttle link position 3 7 Adjusting the throttle cable 3 8 Checking the gear shift operation 3 9 Checking the ignition timing 3 9 Checking the choke solenoid 3 10 Bracket 3 10 Checking the PTT operation 3 10 Checking the PTT fluid level 3 11 Lower unit 3 11 Checking the gear oil...

Page 50: ...ck 1 3 2 Fuel filter can be dis Check clean 1 1 1 3 2 assembled Fuel system Check 1 1 1 3 2 Fuel tank Yamaha por Check clean 1 table tank Gear oil Change 1 1 3 12 Lubrication points Lubricate 1 3 14 Idling speed carbure Check adjust 1 1 3 7 tor model PCV Check 1 5 20 PTT unit Check replace 1 1 3 10 Propeller and cotter pin Check replace 1 1 3 13 Shift link shift cable Check adjust 1 3 9 Thermostat...

Page 51: ...nce interval chart Top cowling Fuel system Fuel system Checking the fuel joint and fuel hose fuel joint to carburetor 1 Check the fuel hose connections and fuel joint for leaks Replace them if necessary Also check the fuel filter 1 fuel pumps 2 and carburetors 3 for leaks or deteri oration Replace if necessary Checking the fuel filter 1 Check the fuel filter element 1 for dirt and residue and chec...

Page 52: ... Spark plug 25 N m 2 5 kgf m 18 4 ft lb 6S330110 1 3 2 Power unit Checking the engine oil level 1 Place the outboard motor in an upright position 2 Check the engine oil level 3 Make sure the oil level is between the upper 1 and lower 2 level marks Checking the spark plug 1 Disconnect the spark plug caps and then remove the spark plugs 2 Clean the electrodes 1 with a spark plug cleaner or wire brus...

Page 53: ...52 C 0 05 mm 0 002 in 118 4 125 6 F valve begins to tilt above more than 60 C 140 F 3 0 mm 0 12 in 6B430070 Checking the cooling water passage 1 Check the cooling water inlet cover 1 screw 2 and cooling water inlet for clog ging Clean the water inlet cover and cooling water inlet if necessary 2 Place the lower unit in water and then start the engine 3 Check for water flow at the cooling water pilo...

Page 54: ...et the throttle screw to its original position by turning it the same number of times as when you lossened it 6S330240 2 3 6S330210 4 4 Control system Synchronizing the carburetor 1 Remove the throttle cable and intake silencer 2 Loosen the throttle lever tightening screw 1 to clockwise on the middle carburetor NOTE The screw 1 is left hand thread 3 Turn out the throttle stop screw 2 of the middle...

Page 55: ...djust or replace the carburetor 1 Remove the hour meter cover 1 6S330190 6 5 1 2 Remove the throttle link rod 2 from the upper carburetor 3 Connect the test harness 3 to the throt tle sensor coupler as shown 4 Turn the engine start switch to ON 5 Check the throttle sensor output voltage Adjust the throttle sensor if out of specifi cation Refer to Adjusting the throttle sensor in chapter 4 6 Instal...

Page 56: ... screws should be properly adjusted 1 Attach the special service tool 1 to the spark plug wire 1 2 2 Start the engine and warm it up for 5 min utes and then check the engine idle speed Adjust if out of specification NOTE Verify the stability of the engine idling speed 3 Turn the throttle stop screw 3 in direction a or b until the specified engine idle speed is obtained NOTE 9 To increase the idle ...

Page 57: ...he fully closed position 3 Adjust the position of the throttle cable joint 3 until its hole aligned with the set pin 4 on control lever 6S330320 2 3 1 w The throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in a NOTE Pull the throttle cable towards the engine to remove any free play in the cable before adjusting the position of the throttle cable joint 4 Connect the cable joint 3 in...

Page 58: ...ft cable joint must be screwed in a minimum of 8 0 mm 0 31 in c CHK ADJ 3 9 6S35H11 Periodic check and adjustment 6 Install the shift cable joint 3 install the clip 2 and then tighten the locknut 1 7 Check the gear shift for smooth operation and adjust the shift cable length if nec essary repeat the steps 3 6 Checking the ignition timing 1 Start the engine and warm it up for 5 min utes NOTE Turn o...

Page 59: ...f necessary NOTE Make sure that the choke valves is fully open 6S35H11 3 10 9 8 7 6 5 4 3 2 1 Control system Bracket 6S330340 3 b a Ignition timing ATDC 2 6 6S330370 a b Bracket Checking the PTT operation 1 Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation Check the PTT fluid level if necessary NOTE Be sure to listen to the winding ...

Page 60: ...iodic check and adjustment 3 If necessary add sufficient fluid of the recommended type until it overflows out of the filler hole 4 Install the new O ring reservoir cap 2 and then tighten it to the specified torque 6S330130 2 Recommended PTT fluid ATF Dexron 2 Reservoir cap 2 7 N m 0 7 kgf m 5 2 ft lb Lower unit Checking the gear oil level 1 Fully tilt the outboard motor down 2 Remove the check scr...

Page 61: ...of the lower case if necessary 4 Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible 69D10050 69D30140 1 2 5 Install the new gaskets check screw and quickly install the drain screw and then tighten them to the specified torque 6G430420 Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Gear ...

Page 62: ... over pressurize the lower unit oth erwise the oil seals may be damaged 1 Remove the check screw 1 and then install the special service tool 2 Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds NOTE Cover the check hole with a rag when remov ing the special service tool from the lower unit 3 If the pressure drops below specification chec...

Page 63: ...h water for 15 minutes and get immediate medical attention Antidote INTERNAL 9 Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention 9 Charge batteries in a well ventilated area 9 Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes 9 DO NOT SMOKE when charging or han dling batterie...

Page 64: ...ment NOTE Apply grease to the grease nipple until it flows from the bushings a 6S330060 6S330070 6S330080 2 Apply low temperature resistant grease to the area shown 3 Apply corrosion resistant grease to the area shown 6S330090 a C 6G430540 6S330100 ...

Page 65: ... 10 Assembling the carburetor 4 11 Adjusting the throttle sensor 4 12 Fuel pump 4 13 Checking the fuel pump 4 14 Disassembling the fuel pump 4 14 Assembling the fuel pump 4 15 Oil injection system 4 16 Checking the check valve 4 18 Checking the oil filter 4 18 Checking the oil tank 4 18 Assembling the oil tank 4 18 Installing the oil pump 4 18 Bleeding the oil pump 4 19 FUEL ...

Page 66: ... Fuel hose fuel tank to fuel filter 2 Fuel hose fuel filter to fuel pumps 3 Fuel hose fuel pumps to carburetors 4 Oil hose remote oil tank to engine oil tank 5 Oil hose engine oil tank to oil injection pump 6 Oil hose oil injection pump to fuel hose 6S34001A 3 3 2 1 4 5 6 ...

Page 67: ... 2 Breather hose manifold to cylinder body 2 3 Breather hose manifold to cylinder body 4 4 Breather hose manifold to cylinder body 6 5 Breather hose manifold to cylinder body 1 6 Breather hose manifold to cylinder body 3 7 Breather hose manifold to cylinder body 5 8 Breather hose manifold to intake silencer ...

Page 68: ...M6 16 mm 2 Fuel filter assembly 1 3 Lock tie 23 4 Fuel hose 1 5 Fuel hose 1 6 Fuel hose 1 7 Oil hose 1 8 Fuel hose 1 9 Fuel hose 1 10 Fuel pump assembly 2 11 Gasket 2 12 Fuel hose 2 13 Fuel hose 2 14 Fuel hose 1 15 Fuel joint 1 16 Fuel joint 2 17 Fuel joint 1 Not reusable Not reusable ...

Page 69: ...6S35H11 4 4 9 8 7 6 5 4 3 2 1 6S34020E No Part name Q ty Remarks 18 Bolt 4 M6 50 mm 19 Holder 3 20 Hose 1 Fuel line ...

Page 70: ...ty Remarks 1 Bolt 1 M6 16 mm 2 Washer 1 3 Holder 1 4 Bolt 1 M6 14 mm 5 Bracket 1 6 Fuel filter assembly 1 7 O ring 1 8 O ring 1 9 Fuel filter element 1 10 Spring 1 11 Float 1 12 Fuel filter cup 1 13 Nut 1 14 O ring 1 Not reusable Not reusable Not reusable ...

Page 71: ... mm 2 Intake silencer 1 3 Hose 1 4 Hose 1 5 Gasket 3 6 Nut 12 7 Upper carburetor assembly 1 8 Middle carburetor assembly 1 9 Lower carburetor assembly 1 10 Link rod 1 11 Rod 2 12 Joint 4 13 Gasket 3 14 Bolt 2 M6 16 mm 15 Choke solenoid 1 16 Clamp 1 17 O ring 1 Not reusable Not reusable Not reusable Fuel line Carburetor ...

Page 72: ... kgf m 3 0 ft lb 4 N m 0 4 kgf m 3 0 ft lb 6S34060E No Part name Q ty Remarks 1 Plug 6 2 Gasket 6 3 Screw 3 4 Plate 3 5 Pilot screw 6 6 Spring 6 7 Screw 3 8 Gasket 3 9 Air bleed plug 6 10 Pilot air jet 6 11 Carburetor body 3 12 Needle valve 6 13 Clip 6 14 Float pin 6 15 Float 6 16 Gasket 3 17 Drain plug 6 Not reusable ...

Page 73: ... kgf m 3 0 ft lb 6S34060E No Part name Q ty Remarks 18 Gasket 6 19 Main jet 6 20 Float chamber 3 21 Plug 6 22 Gasket 6 23 Pilot jet 6 24 Screw 12 ø5 16 mm 25 Throttle stop screw 1 26 Spring 1 27 Middle carburetor assembly 1 28 Lower carburetor assembly 1 29 Screw 3 ø5 25 mm 30 Washer 3 31 Grommet 3 32 Bracket 1 33 Collar 3 34 Joint 1 Carburetor ...

Page 74: ...N m 0 6 kgf m 4 4 ft lb 2 N m 0 2 kgf m 1 5 ft lb 10 N m 1 0 kgf m 7 4 ft lb 4 N m 0 4 kgf m 3 0 ft lb 4 N m 0 4 kgf m 3 0 ft lb 6S34060E No Part name Q ty Remarks 35 Screw 2 ø5 10 mm 36 Throttle sensor 1 37 Pin 1 38 Joint 1 39 Arm 1 ...

Page 75: ...sed air downward otherwise cleaning solvent may be blown into your eyes or small parts of the carburetor may be blown off 9 Do not use steel wire for cleaning the jets otherwise the jet diameters may be enlarged which may seriously affect performance 3 Check the main jet pilot jet and main nozzle for dirt or residue Clean if neces sary 4 Check the pilot screw and needle valve for bends or wear Rep...

Page 76: ...d then install the needle valves floats and float pins onto the carburetor body Check the float for smooth operation after install them 3 Install the main jets 5 and pilot jets 6 onto the float chamber 4 Install the gaskets 7 plugs 8 gaskets 9 and plugs 0 onto the float chamber q 5 Install the float chamber q onto the car buretor body and install the gaskets w and plugs e onto the carburetor body ...

Page 77: ...crews 7 Adjust the position of the throttle sensor until the specified output voltage is obtained 8 Tighten the throttle sensor screws 9 Disconnect the test harness and install the throttle link rod and then install the hour meter cover and intake silencer cover NOTE Be sure to check the engine idle speed after adjusting the throttle sensor Test harness 3 pins 90890 06857 6S340150 6S330260 2 6S330...

Page 78: ... Remarks 1 Base 2 2 Gasket 2 3 Diaphragm 2 4 Body assembly 2 5 Nut 8 6 Screw 8 ø5 28 mm 7 Washer 8 8 Check valve 8 9 Body 2 10 Gasket 2 11 Diaphragm 2 12 Collar 4 13 O ring 4 14 Cover 2 15 Plate 2 16 Spring 2 17 Screw 6 ø5 35 mm Not reusable Not reusable Not reusable ...

Page 79: ...cessary Disassembling the fuel pump 1 Disconnect the inlet and outlet hose from the fuel pumps 2 Remove the 2 bolts 1 securing the pumps to the crankcase 3 Remove the 3 screws securing the pump together Refer to exploded diagram P4 13 NOTE Take care to let the spring fly out or lose the plate 4 Check the diaphragms for tears or dam age Replace the diaphragms if neces sary 5 Check the valves for be...

Page 80: ...and soak the valves and the diaphragms in gasoline before assembly to obtain prompt operation of the fuel pumps when starting the engine 1 Install the check valves 1 onto the fuel pump body 2 Install the spring 2 3 Install the new gaskets 3 diaphragms 4 collars 5 O rings 6 base 7 and cover 8 on to the fuel pump body 2 6G440050 3 7 4 3 4 5 8 6 6G440060 1 1 1 1 1 6G440040 ...

Page 81: ...me Q ty Remarks 1 Oil level sensor 1 2 Oil filter 1 3 Washer 1 4 Oil tank 1 5 Air vent hose 1 6 Emergency switch 1 7 Collar 3 8 Grommet 3 9 Lock tie 6 10 Water trap 1 11 Bolt 3 M6 30 mm 12 Oil hose 1 13 Oil hose 1 14 Check valve 1 15 Oil hose 1 16 Cotter pin 1 17 Plastic washer 1 Not reusable Fuel pump Oil injection system ...

Page 82: ...5H11 Fuel system 3 N m 0 3 kgf m 2 2 ft lb 7 N m 0 7 kgf m 5 2 ft lb 6S34110E No Part name Q ty Remarks 18 Oil pump link rod 1 19 Bolt 2 M6 20 mm 20 Oil pump 1 21 O ring 1 22 Cover 1 23 Screw 4 ø5 20 mm Not reusable ...

Page 83: ... the oil pump 1 and then tighten the bolts 2 to the specified torque Checking the check valve 1 Connect the special service tool to the check valve 2 Apply positive pressure to the check valve port Replace if necessary NOTE Check that no air leakage from the opposite end of the check valve Checking the oil filter 1 Check the oil filter for dirt residue or cracks Clean or replace if necessary Check...

Page 84: ...t the engine for 5 10 minutes 9 Check that the air bubbles flows into the oil hose translucent If the air bubbles still leaves into the oil hose repeat the steps 1 6 Bleeding the oil pump cC 9 Make sure that the engine oil is filled in the engine oil tank 9 If the engine oil is not in the engine oil tank fill the engine oil tank 1 Place rags around the air bleed screw 1 to catch any oil that might...

Page 85: ...ce a between the oil pump lever and stopper 11 If the oil pump lever clearance is out of specification remove the oil pump link rod and adjust the length until the speci fied clearance 6S35H11 4 20 9 8 7 6 5 4 3 2 1 6S340030 a 4 Oil pump lever clearance a 1 mm 0 039 in Oil injection system ...

Page 86: ...der head 5 21 Removing the cylinder head 5 22 Checking the cylinder head 5 22 Crankcase 5 23 Removing the crankcase 5 28 Disassembling the oil seal housing 5 29 Removing the piston connecting rod assembly and crankshaft assembly 5 29 Disassembling the piston and connecting rod assembly 5 30 Checking the bearing 5 30 Disassembling the crankshaft 5 30 Checking the oil pump driven gear and the oil pu...

Page 87: ...cting rod big end side clearance 5 34 Checking the crankshaft 5 34 Assembling the crankshaft 5 35 Assembling the crankshaft roller bearing 5 36 Assembling the oil seal housing 5 36 Assembling the piston and connecting rod assembly 5 37 Assembling the power unit 5 37 Installing the power unit 5 44 Adjusting the timing plate 5 46 ...

Page 88: ...en the throttle and then crank the engine until the reading on the compres sion gauge stabilizes NOTE Disconnect the choke solenoid blue lead from the wireharness 5 If the compression pressure is below specification and the compression pres sure for each cylinder is unbalanced add a small amount of engine oil to the cylin ders and then check the compression pressure again NOTE 9 If the compression...

Page 89: ...E No Part name Q ty Remarks 1 Grommet 3 2 Flywheel cover 1 3 Dowel 2 4 Gasket 1 5 Bolt 4 M6 20 mm 6 Bolt 3 M6 16 mm 7 Retaining plate 1 8 Grommet 1 9 Bolt 6 M8 30 mm 10 Bolt 2 M6 30 mm 11 Apron 1 12 Apron 1 13 Bolt 8 M8 135 mm 14 Negative battery cable 1 15 Positive battery cable 1 16 PTT motor lead 3 17 Fuse holder 1 Not reusable ...

Page 90: ...rt name Q ty Remarks 1 Flywheel magnet 1 2 Nut 1 3 Washer 1 4 Bolt 4 M6 35 mm 5 Stator assembly 1 6 Bolt 2 M6 20 mm 7 Screw 3 ø5 30 mm 8 Pulser coil assembly 1 9 Crank position sensor 1 10 Screw 2 ø5 12 mm 11 Thermo sensor 1 12 Washer 1 13 Woodruff key 1 14 Timing plate 1 15 Screw 1 ø5 10 mm 16 Bolt 1 M6 12 mm 17 Holder 1 ...

Page 91: ...gf m 148 ft lb 10 N m 1 0 kgf m 7 4 ft lb 6S35020E No Part name Q ty Remarks 18 Bolt 1 M6 16 mm 19 Hour meter 1 20 Screw 2 ø5 20 mm 21 Bolt 4 M6 30 mm 22 Grommet 4 23 Clamp 2 24 Collar 4 25 Case 1 26 Cover 1 27 Cover 1 28 Screw 6 ø5 20 mm 29 Cover 1 30 Screw 4 M6 25 mm 31 Clamp 2 ...

Page 92: ...8 kgf m 13 3 ft lb 6S35030E No Part name Q ty Remarks 1 Control lever 1 2 Bolt 1 M8 40 mm 3 Wave washer 1 4 Collar 1 5 Throttle link rod 1 6 Lock nut 1 7 Joint 1 8 Accelerator cam 1 9 Bolt 1 M6 25 mm 10 Wave washer 1 11 Collar 1 12 Screw 2 ø4 16 mm 13 Plate 1 14 Shift cut switch 1 15 Bushing 1 16 Bracket 1 17 Washer 1 ...

Page 93: ...N m 0 3 kgf m 2 2 ft lb 18 N m 1 8 kgf m 13 3 ft lb 6S35030E No Part name Q ty Remarks 18 Lever 1 19 Spring 1 20 Washer 1 21 Bracket 1 22 Bolt 2 M6 20 mm 23 Stay 1 24 Cap 1 25 Lock nut 1 26 Screw 1 ø6 50 mm 27 Bush 2 28 Collar 1 29 Washer 1 30 Bolt 1 M8 35 mm 31 Clip 1 32 Clip 1 33 Plastic washer 1 ...

Page 94: ...t lb 7 N m 0 7 kgf m 5 2 ft lb 6S35040E No Part name Q ty Remarks 1 Bolt 2 M8 45 mm 2 Bolt 1 M8 35 mm 3 Bolt 1 M8 16 mm 4 Negative battery cable 1 5 Nut 1 6 Spring washer 1 7 Positive battery lead 1 8 Starter motor 1 9 Nut 2 10 Spring washer 2 11 Positive battery lead 1 12 Cap 3 13 Positive battery cable 1 ...

Page 95: ...rt name Q ty Remarks 1 Case 1 2 Grommet 4 3 Bolt 4 M6 28 mm 4 Collar 4 5 Bolt 6 M6 20 mm 6 Bolt 4 M6 14 mm 7 Ignition coil 6 8 Plug cap 6 9 Ground lead 1 10 Bolt 2 M6 16 mm 11 Plate 1 12 Wire harness 1 13 Holder 1 14 Bolt 4 M6 24 mm 15 CDI unit 1 16 Tube 2 ...

Page 96: ... 1 2 Clamp 2 3 Bolt 2 M6 30 mm 4 Wireharness 1 5 Ground lead 1 6 Starter relay 1 7 Holder 1 8 Screw 3 ø5 12 mm 9 Stay 2 10 Fuse 2 80A 11 Spare fuse 1 80A 12 Positive battery lead 1 13 Fuse holder 1 14 Fuse 1 20A 15 Bolt 2 M6 14 mm 16 Joint connector 1 17 Rectifier Regulator 1 ...

Page 97: ...6S35H11 5 10 9 8 7 6 5 4 3 2 1 Power unit 6S35060E No Part name Q ty Remarks 18 Bolt 6 M6 30 mm 19 Clamp 1 20 Clip 2 21 Hose 2 22 Grommet 4 23 Collar 4 24 Case 1 ...

Page 98: ...otor lead 4 2 Remove the retaining plate 5 and plate 6 3 Loosen the cable holder 7 and remove the shift lever 8 4 Set the remote control lever in the neutral position and then disconnect the shift cable 9 throttle cable 0 5 Disconnect the main coupler q and PTT switch coupler 6 Remove the flywheel cover and the intake silencer 7 Disconnect the fuel hose and oil hose 8 Disconnect cooling the water ...

Page 99: ...E Make an alignment mark a at the installation point of the timing plate and then remove the timing plate 1 2 Loosen the flywheel magnet nut cC Apply force in the direction of the arrows shown While working do not allow the fly wheel holder to slip off the flywheel 3 Remove the flywheel magnet 6F650200 Flywheel holder 90890 06522 6B450090 6S350280 r t y t 6S350060 a 1 S60V5410 ...

Page 100: ... Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft 4 Remove the Woodruff key Removing the electrical component 1 Remove the cover 1 2 Remove the hour meter 2 Flywheel puller 90890 06521 3 Remove the stator assembly 3 pulser coil assembly 4 and crank position sen sor 5 4 Remove the starter motor 6 6S350400 3 5 4 6S350390 6 6S350410 2 1 6S35...

Page 101: ...4 3 2 1 Power unit 5 Remove the starter relay 7 the PTT relay assembly 8 and rectifier regulator 9 onto the power unit 6 Disconnect the ignition coil leads and then remove the CDI unit 0 and case q 6S350525 8 7 9 6S350420 q 0 ...

Page 102: ... 3 kgf m 2 2 ft lb 6S35070E No Part name Q ty Remarks 1 Intake manifold 1 2 Reed valve assembly 6 3 Gasket 6 4 Reed valve set 6 5 Gasket 1 6 Bolt 19 M6 25 mm 7 Clamp 1 8 Screw 12 ø5 16 mm 9 Clamp 1 10 Stud bolt 3 11 Hose 2 12 Hose 4 13 Hose 9 14 Check valve 6 15 Joint 3 16 Clamp 3 17 Clamp 2 Not reusable Not reusable Intake manifold ...

Page 103: ...2 1 Intake manifold 12mm 0 47in 7mm 0 27in 7mm 0 27in 7mm 0 27in 4 N m 0 4 kgf m 3 0 ft lb 8 N m 0 8 kgf m 5 9 ft lb 3 N m 0 3 kgf m 2 2 ft lb 6S35070E No Part name Q ty Remarks 18 Bolt 1 M6 20 mm 19 Bracket 1 20 Hose 3 21 Hose 1 ...

Page 104: ...3 Remove the intake manifold bolts in the sequence shown Checking the reed valve 1 Check the reed valves for bends a Replace the reed valves if above specifi cation 2 Measure the reed valve stopper height b Replace the reed valve stopper if out of specification 6S350140 Valve bend limit a 0 2 mm 0 0079 in Valve stopper height b 8 7 9 3 mm 0 34 0 36 in S60V5530 a S60V5540 b 6S350730 1 6S350740 1 ...

Page 105: ... ft lb 10 N m 1 0 kgf m 7 4 ft lb 6S35080E No Part name Q ty Remarks 1 Bolt 4 M6 35 mm 2 Cover 2 3 Thermostat 2 4 Gasket 2 5 Bolt 7 M6 20 mm 6 Cover 1 7 Gasket 1 8 Gasket 1 9 Exhaust cover 1 10 Bolt 25 M6 30 mm 11 Clamp 1 12 Bolt 2 M6 20 mm 13 Cover 1 14 Gasket 1 15 Grommet 1 16 PCV 1 17 Spring 1 Not reusable Not reusable Not reusable Not reusable Exhaust cover ...

Page 106: ...1 Power unit 11 N m 1 1 kgf m 8 1 ft lb 5 N m 0 5 kgf m 3 7 ft lb 10 N m 1 0 kgf m 7 4 ft lb 10 N m 1 0 kgf m 7 4 ft lb 10 N m 1 0 kgf m 7 4 ft lb 6S35080E No Part name Q ty Remarks 18 Lock tie 2 19 Hose 1 Not reusable ...

Page 107: ...orma tion Replace the spring if necessary Installing the PCV 1 Install a new gasket 1 and the pressure control valve 2 with the its rounded side facing towards the exhaust cover and then tighten the bolts to the specified torque Removing the exhaust cover 1 Remove the exhaust cover bolts in the sequence shown Checking the exhaust cover 1 Check the exhaust cover for distortion or corrosion Replace ...

Page 108: ...gf m 8 1 ft lb 15 N m 1 5 kgf m 11 1 ft lb 30 N m 3 0 kgf m 22 1 ft lb 6S35090E No Part name Q ty Remarks 1 Gasket 2 2 Cylinder head 2 3 Thermo switch 2 4 Gasket 2 5 Cylinder head cover 2 6 Bolt 40 M8 60 mm 7 Bolt 4 M6 12 mm 8 Bolt 40 M6 25 mm 9 Spark plug 6 10 Clamp 2 Not reusable Cylinder head ...

Page 109: ...r head and cylinder block NOTE Insert a flat head screw driver between the pry tabs to pry off the cylinder heads Checking the cylinder head 1 Eliminate carbon deposits from the com bustion chambers and check for deterio ration 2 Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in 4 directions as shown Replace the cylinder head if above specification 6G450295 1 2 6S3503...

Page 110: ...N m 4 0 kgf m 29 5 ft lb 6S35100E No Part name Q ty Remarks 1 Crankcase 1 2 Dowel 2 3 Bolt 4 M10 70 mm 4 Bolt 4 M10 90 mm 5 Bolt 14 M6 30 mm 6 Hose 1 7 Clamp 1 8 Oil pump driven gear 1 9 Washer 1 10 O ring 1 11 Grommet 1 12 Circlip 1 13 Oil seal 1 14 O ring 1 15 Housing 1 16 Bolt 4 M6 20 mm 17 Crankshaft balancer 1 Not reusable Not reusable Not reusable Crankcase ...

Page 111: ...t lb 4 N m 0 4 kgf m 3 0 ft lb 8 N m 0 8 kgf m 5 9 ft lb 20 N m 2 0 kgf m 14 8 ft lb 40 N m 4 0 kgf m 29 5 ft lb 6S35100E No Part name Q ty Remarks 18 Oil seal 1 19 Nut 1 20 Bolt 3 M6 20 mm 21 Plate 3 22 Bolt 3 M5 12 mm 23 Cover 3 24 Anode 3 25 Grommet 3 26 Cramp 1 27 Cramp 2 Not reusable ...

Page 112: ...110E No Part name Q ty Remarks 1 Bolt 12 2 Piston and connecting rod assembly 6 3 Roller bearing 6set 4 Crankshaft 1 5 Circlip 2 6 Main bearing 2set 7 O ring 1 8 Oil seal 1 9 Roller bearing 1 10 Stopper ring 1 11 Ball bearing 1 12 Oil pump drive gear 1 13 Ball bearing 1 14 Circlip 1 15 Seal ring 9 16 Bolt 2 M8 20 mm 17 Engine hanger 1 Not reusable Not reusable Not reusable Not reusable Not reusabl...

Page 113: ...f m 26 6 ft lb 19 N m 1 9 kgf m 14 0 ft lb 36 N m 3 6 kgf m 26 6 ft lb 23 N m 2 3 kgf m 17 0 ft lb 8 N m 0 8 kgf m 5 9 ft lb 6S35110E No Part name Q ty Remarks 18 Plug 2 19 Gasket 2 20 Stopper 2 21 Cap 2 22 Bolt 4 M6 20 mm 23 Joint 1 24 Cylinder block 1 Not reusable Loosen completely ...

Page 114: ...7 6S35H11 Power unit 6S35120E No Part name Q ty Remarks 1 Connecting rod 6 2 Piston Starboard side 3 3 Washer 12 4 Needle bearing 6 5 Clip 12 6 Piston pin 6 7 Piston ring set 6 8 Piston Port side 3 Not reusable ...

Page 115: ... bolts evenly to the crankshaft balancer NOTE 9 Apply force to the bolts a until the crank shaft balancer comes off the tapered por tion of the crankshaft 9 Use bolts a with the specified measure ments S60V5640 Flywheel holder 90890 06522 6S350460 a b 3 Remove the oil seal housing bolts 4 Remove the crankcase bolts in the sequence shown NOTE Insert a flat head screw driver between the pry tabs to ...

Page 116: ...order as they were removed 9 Mark each piston with the identification number a of the corresponding cylinder Also mark each connecting rod and con necting rod cap with an identification num ber b as shown 9 Do not mix the connecting rods and caps Keep them organized in their each groups a 6S350310 6G450350 b Disassembling the oil seal housing 1 Remove the circlip from oil seal housing 2 Remove the...

Page 117: ...g 3 and washers 4 2 Remove the top ring 5 and 2nd piston ring 6 S60V5730 1 2 6S350320 1 2 5 6 4 3 Checking the bearing 1 Check the bearings for pitting or rum bling Disassembling the crankshaft 1 Remove the seal rings 1 NOTE To remove the seal rings 1 widen the seal ring end gap a and then remove the ring from the groove and remove the crankpin b 2 Remove the upper ball bearing cC Do not reuse the...

Page 118: ...60 mm 3 5370 3 5378 in Measuring point b 10 0 mm 0 39 in up from the bottom of the piston skirt Oversize piston diameter a 1st 90 090 90 110 mm 3 5468 3 5476 in 2nd 90 340 90 360 mm 3 5576 3 5575 in 3 Remove the circlip 4 and then remove the lower ball bearing cC Do not reuse the ball bearing always replace it with a new one 4 Remove the oil pump drive gear cC Do not reuse the oil pump drive gear ...

Page 119: ...eter and the cylinder bore specifications Replace the piston and piston rings as a set or the cylinder block or all parts or rebore the cylinder if out of specification NOTE Be sure to rebore the cylinder for matching the replacement oversize pistons when using the specified oversize pistons Checking the piston ring 1 Check the piston ring dimensions of B and T Replace the piston and piston rings ...

Page 120: ...e piston pin boss bore 1 Measure the piston pin boss bore Replace the piston if out of specification Checking the piston pin 1 Measure the piston pin outside diameter Replace the piston pin if out of specifica tion Piston ring side clearance Top ring and 2nd piston ring 0 02 0 06 mm 0 0008 0 0024 in 6G450420 6G450430 6S350110 Piston pin boss bore 26 004 26 015 mm 1 0238 1 0242 in Piston pin diamet...

Page 121: ...rance 1 Measure the connecting rod big end side clearance a Replace the connecting rod or crankshaft or both if out of specifica tion Checking the crankshaft 1 Measure the crankshaft journal diameter a and crankpin diameter b Replace the crankshaft if out of specification 6G450550 6G450570 a 6G450580 b Connecting rod small end axial play limit 2 0 mm 0 08 in 6G450560 a a Connecting rod big end sid...

Page 122: ...0 02 mm 0 0008 in c c c 6S350100 E S60V5930 2 1 3 a b General pipe 2 a 50 mm 1 97 in b 80 mm 3 14 in or more Support 3 90890 02394 2 Install the lower ball bearing 4 then the circlip cC Do not reuse the ball bearing always replace it with a new one 3 Install the upper ball bearing 5 cC Do not reuse the ball bearing always replace it with a new one E S60V5940 2 4 3 a b General pipe 2 a 50 mm 1 97 i...

Page 123: ...ing 7 over the crankpin f and then widen the seal ring end gap g to install the ring into the crankshaft groove 5 Install the main bearings onto the crank shaft NOTE Face the dowel hole on the main bearings toward the bottom of the power unit Assembling the crankshaft roller bearing 1 Apply grease to the new oil seal and then install it into the roller bearing Needle bearing attachment 1 90890 066...

Page 124: ...Install a new O ring 3 and the circlip 4 into the oil seal housing Assembling the piston and connect ing rod assembly 1 Assemble the piston 1 connecting rod 2 needle bearing 3 washer 4 piston pin 5 and new piston pin clips 6 NOTE 9 Face the embossed YAMAHA mark a on the connecting rod in the same direction as the UP mark b on the piston 9 Always use new piston pin clips 9 Be sure to align the pist...

Page 125: ... made during disassembly Also be sure to install the assemblies with an S mark on the star board side and the assemblies with a P mark on the port side 3 Install the connecting rod bearings and connecting rod caps onto the connecting rods and then tighten the connecting rod bolts 6 to the specified torques in five stages NOTE 9 Align the identification numbers c on the connecting rod caps and conn...

Page 126: ...spec ified torques in two stages 8 Tighten the oil seal housing bolts 6S350080 E E z Crankcase bolt M10 1st 20 N m 2 0 kgf m 14 8 ft lb 2nd 40 N m 4 0 kgf m 29 5 ft lb 2 Crankcase bolt M6 1st 4 N m 4 0 kgf m 3 0 ft lb 2nd 8 N m 8 0 kgf m 5 9 ft lb 4 Install the oil seal housing onto the cylin der block NOTE Install the oil seal housing with the arrow mark facing toward the crankcase 5 Install the ...

Page 127: ...ten the exhaust cover bolts to the specified torques in two stages and in the sequence shown NOTE Apply LOCTITE 572 to the exhaust cover bolts before installation 11 Install the new gasket 9 thermostat base 0 new gaskets q thermostats w and thermostat cover e NOTE Apply LOCTITE 572 to the exhaust cover bolts before installation 6S350240 S60V5B50 Crankshaft balancer nut 100 N m 10 kgf m 73 8 ft lb ...

Page 128: ...d in the sequence shown 6G450780 u i 12 Install the new gaskets r and the cylin der heads t and then tighten the cylin der head bolts y to the specified torques in two stages and in the sequence shown å Block side NOTE Apply engine oil to the cylinder head bolts y before installation r 6S350350 t y å Cylinder head bolt y 1st 15 N m 1 5 kgf m 11 1 ft lb 2nd 30 N m 3 0 kgf m 22 1 ft lb PORT STBD 6S3...

Page 129: ...asket s and the intake manifold assembly d and then tighten the intake manifold bolts f to the speci fied torques in two stages and in the sequence shown 17 Connect the hoses as shown below Spark plug 25 N m 2 5 kgf m 18 4 ft lb Intake manifold bolt 1st 4 N m 0 4 kgf m 3 0 ft lb 2nd 8 N m 0 8 kgf m 5 9 ft lb 6S350370 s d f f Cylinder head cover bolt 1st 5 N m 0 5 kgf m 3 7 ft lb 2nd 11 N m 1 1 kgf...

Page 130: ...eter v onto the power unit 18 Install the starter motor g crank position sensor h pulser coil assembly j and stator coil k onto the power unit 19 Install the case l and the CDI unit onto the power unit 6S350425 l Starter motor mount bolt 18 N m 1 8 kgf m 13 3 ft lb 6S350395 g 6S350405 k h j 6S350415 v 6S350526 x z c Hour meter 3 N m 0 3 kgf m 2 2 ft lb ...

Page 131: ...the power unit matching surface and install the dowels 1 and a new gas ket 2 2 Install the power unit 3 and then tighten the power unit mounting bolts 4 and 5 to the specified torque 6S350380 n b 4 4 5 6S350065 572 LT 572 LT 572 LT 572 LT 3 Power unit bolt 4 5 25 N m 2 5 kgf m 18 4 ft lb Apron bolt 8 N m 0 8 kgf m 5 9 ft lb 6S350285 6 572 LT 572 LT 572 LT 572 LT 2 1 1 6S350625 ...

Page 132: ...nstall the shift lever e 6S350055 e w Flywheel magnet nut 200 N m 20 kgf m 148 ft lb Flywheel holder 90890 06522 4 Connect the cooling water pilot hose 7 and ground lead 8 5 Connect the fuel hose and oil hose 6 Install the intake silencer 7 Connect the main coupler 9 8 Connect the PTT switch connector and trim sensor coupler 9 Connect the shift cable 0 and throttle cable q and then adjust their le...

Page 133: ...ly turn the flywheel magnet clock wise align the piston of the 1 cylinder at the TDC 3 Install the dial gauge 1 into the 1cylin der NOTE Set the dial gauge to zero position which is more than 3 mm from TDC 13 Install the retaining plate r 14 Connect the negative battery cable t positive battery cable y positive battery lead u and PTT motor lead i 15 Install the timing plate o 6S350025 u t i i y a ...

Page 134: ...h the flywheel at BTDC 19 and install the timing plate 2 NOTE When finish the adjusting of timing plate fly wheel must be turn clockwise twice 6 Start the engine and then check the igni tion timing once more 7 If the ignition timing out of specification Replace the CDI unit 6S330360 2 Cylinder 1 piston stroke BTDC 2 76 mm 0 108 in Ignition timing ATDC 2 6 ...

Page 135: ... MEMO 9 8 7 6 5 4 3 2 1 6S35H11 5 48 ...

Page 136: ...el 6 12 Removing the drive shaft 6 14 Disassembling the drive shaft housing 6 14 Disassembling the forward gear 6 14 Disassembling the lower case 6 15 Checking the pinion and forward gear 6 15 Checking the bearing 6 15 Checking the drive shaft 6 15 Checking the lower case 6 16 Assembling the lower case 6 16 Assembling the forward gear 6 16 Assembling the drive shaft housing 6 17 Installing the dri...

Page 137: ...ase counter rotation model 6 43 Removing the drive shaft 6 45 Disassembling the drive shaft housing 6 45 Disassembling the reverse gear 6 45 Disassembling the lower case 6 46 Checking the pinion and reverse gear 6 46 Checking the bearing 6 46 Checking the drive shaft 6 46 Checking the lower case 6 47 Assembling the lower case 6 47 Assembling the reverse gear 6 47 Assembling the drive shaft housing...

Page 138: ... m 0 9 kgf m 6 6 ft lb 6S36010E No Part name Q ty Remarks 1 Lower unit 1 2 Plate 1 3 Rubber seal 1 4 Check screw 1 5 Gasket 2 6 Bolt 7 M10 45 mm 7 Drain screw 1 8 Grommet 1 9 Bolt 1 M10 45 mm 10 Bolt 1 M10 70 mm 11 Spacer 1 12 Propeller 1 13 Washer 1 14 Washer 1 15 Cotter pin 1 16 Propeller nut 1 17 Trim tab 1 Not reusable Not reusable Lower unit regular rotation model ...

Page 139: ...6020E No Part name Q ty Remarks 1 Shift rod 1 2 Oil seal 1 3 Cover 1 4 O ring 1 5 Spring 1 6 Circlip 1 7 Bolt 3 M6 20 mm 8 Seal 1 9 Woodruff key 1 10 Bolt 4 M8 45 mm 11 Cover 1 12 Seal 1 13 Water pump housing 1 14 O ring 1 15 Insert cartridge 1 16 O ring 1 17 Impeller 1 Not reusable Not reusable Not reusable Not reusable ...

Page 140: ...LOWR 6 3 6S35H11 Lower unit 8 N m 0 8 kgf m 5 9 ft lb 18 N m 1 8 kgf m 13 3 ft lb 6S36020E No Part name Q ty Remarks 18 Outer plate cartridge 1 19 Gasket 1 20 Dowel 2 21 Dowel 2 Not reusable ...

Page 141: ...n plate and propeller to keep the propeller from turning and then remove the propeller nut and propeller w 9 Do not hold the propeller with your hands when loosening or tightening it 9 Be sure to disconnect the battery cables from the battery and the lock plate from the engine stop lanyard switch 9 Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turni...

Page 142: ...t the shift rod is in the neutral position using a spe cial service tool 5 Remove the shift rod assembly 7 Checking the water pump and shift rod 1 Check the water pump housing Replace if there is deformation 2 Check the impeller and insert cartridge Replace if cracked or worn 3 Check the Woodruff key 1 and the groove a on the drive shaft Replace if worn 4 Check the shift rod Replace if cracked or ...

Page 143: ... 0 4 kgf m 3 0 ft lb 18 N m 1 8 kgf m 13 3 ft lb 6S36030E No Part name Q ty Remarks 1 Shift rod joint 1 2 Ball 2 3 Shift slider 1 4 Shift plunger 1 5 Dog clutch 1 6 Cross pin 1 7 Spring 1 8 Propeller shaft 1 9 Washer 1 10 Reverse gear 1 11 Reverse gear shim 12 Ball bearing 1 13 O ring 1 14 Propeller shaft housing 1 15 Grease nipple 1 16 O ring 1 17 Needle bearing 1 Not reusable Not reusable Not re...

Page 144: ... 30 N m 3 0 kgf m 22 1 ft lb 4 N m 0 4 kgf m 3 0 ft lb 18 N m 1 8 kgf m 13 3 ft lb 6S36030E No Part name Q ty Remarks 18 Oil seal 2 19 Ring 1 20 Bolt 2 M8 20 mm 21 Cooling water inlet cover 2 22 Nut 1 23 Screw 1 24 Bolt 2 M8 36 mm 25 Washer 2 Not reusable ...

Page 145: ...e the spring 1 and then remove the cross pin 2 shift rod joint 3 shift plunger 4 balls 5 shift slider 6 and dog clutch 7 NOTE Mark the front side of the dog clutch 7 Disassembling the propeller shaft housing 1 Remove the reverse gear and ball bear ings 3 1 2 6S360030 2 1 3 6 4 5 7 6S360040 60h60140 1 3 2 4 5 4 6 6F660545 Bearing housing puller claw L 4 90890 06502 Stopper guide plate 5 90890 06501...

Page 146: ...tall the dog clutch 1 LOWR 6 9 6S35H11 Lower unit 2 Remove the ball bearing from reverse gear and then remove the reverse gear shims cC Do not reuse the bearing always replace it with a new one 3 Remove the oil seals and needle bearing Checking the propeller shaft hous ing 1 Clean the propeller shaft housing using a soft brush and cleaning solvent and then check it Replace if cracked or damaged 6S...

Page 147: ...eller shaft hous ing to the specified depth NOTE Install an oil seal halfway into the propeller shaft housing then the other oil seal S6P26050E b b c 1 3 2 a d 4 S6P26060E Driver rod SS 1 90890 06604 Needle bearing attachment 2 90890 06610 Bearing depth plate 3 90890 06603 Depth b 25 05 25 55 mm 0 98 1 00 in Bearing inner race attachment 4 90890 06640 Depth d 4 75 5 25 mm 0 187 0 207 in 3 Install ...

Page 148: ...s NOTE 9 Be sure to select the reverse gear shim s if replacing the propeller shaft housing lower case or ball bearing 9 To select the shims see Shimming regu lar rotation model 9 After installing the reverse gear and shim s check that the reverse gear rotates smoothly S6S16050 9 7 8 Bearing outer race attachment 9 90890 06622 ...

Page 149: ...6S36040E 18 N m 1 8 kgf m 13 3 ft lb No Part name Q ty Remarks 1 Drive shaft 1 2 Cover 1 3 Oil seal 2 4 Bolt 4 M8 25 mm 5 Drive shaft housing 1 6 Needle bearing 1 7 O ring 1 8 Pinion shim 9 Thrust bearing 1 10 Lower case 1 11 Needle bearing 1 12 Pinion 1 13 Washer 1 14 Nut 1 15 Forward gear shin 16 Roller bearing 1 17 Thrust bearing 1 Not reusable Not reusable Not reusable Not reusable ...

Page 150: ...LOWR 6 13 6S35H11 Lower unit 142 N m 14 2 kgf m 104 7 ft lb 6S36040E 18 N m 1 8 kgf m 13 3 ft lb No Part name Q ty Remarks 18 Needle bearing 2 19 Forward gear 1 Not reusable ...

Page 151: ...move the cover oil seals and needle bearing Disassembling the forward gear 1 Remove the bearing inner race from the forward gear using a press cC Do not reuse the bearing always replace it with a new one 6F660190 1 2 6S630055 3 4 5 6 7 8 6S360060 1 2 1 2 Drive shaft holder 6 1 90890 06520 Pinion nut holder 2 90890 06715 Needle bearing attachment 1 90890 06610 Driver rod L3 2 90890 06652 Bearing se...

Page 152: ...bearing outer race and shim s NOTE Install the claws a as shown Checking the pinion and forward gear 1 Check the teeth of the pinion and the teeth and dogs of the forward gear Replace if cracked or worn Checking the bearing 1 Check the bearing Replace if pitted or if there is rumbling Checking the drive shaft 1 Check the drive shaft Replace if bent or worn 2 Measure the drive shaft runout LOWR 6 1...

Page 153: ... the forward gear shim s if replacing the lower case or roller bearing assembly 9 To select the shim s see Shimming reg ular rotation model 2 Install the needle bearing into the lower case NOTE 9 Apply gear oil to the needle bearing before installation 9 The needle bearing contains 24 rollers Bearing outer race attachment 1 90890 06658 Driver rod LL 2 90890 06605 Ball bearing attachment 3 90890 06...

Page 154: ...e to select the pinion shim s if replacing the thrust bearing drive shaft housing drive shaft or lower case 9 To select the shim s see Shimming reg ular rotation model 3 Install the drive shaft 3 into the lower case Install the pinion 4 washer 5 pin ion nut 6 and then tighten the pinion nut 6 to the specified torque NOTE Install the drive shaft by lifting it up slightly then aligning it with the p...

Page 155: ...ft assembly 3 into the propeller shaft housing assembly NOTE Face the shift plunger connect part to upward 4 Install the propeller shaft housing assem bly into the lower case and then tighten the bolts 4 to the specified torque 5 Install the ring 5 and bolts 6 NOTE Apply LOCTITE 271 to the drive shaft hous ing bolts 4 and LOCTITE 572 to the bolts 6 before installation 6F660310 7 8 Drive shaft hold...

Page 156: ...check that the shift rod operates smoothly and check that the drive shaft and propeller shaft rotates smoothly 2 Install a new gasket 4 the outer plate cartridge 5 and dowels 6 3 Install the Woodruff key 7 into the drive shaft 4 Align the groove in the impeller 8 with the Woodruff key 7 and then install the impeller onto the drive shaft 6S360127 1 2 3 Shift rod cover bolt 3 8 N m 0 8 kgf m 5 9 ft ...

Page 157: ...rwise the water pump impeller may be damaged NOTE 9 When installing the pump housing apply grease to the inside of the housing and then turn the drive shaft clockwise while pushing down the pump housing 9 Align the cover projection c with the hole d in the pump housing Installing the lower unit w When installing the lower unit without removing the power unit be sure to sus pend the outboard motor ...

Page 158: ...ut Place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then tighten the nut to the specified torque w 9 Do not hold the propeller with your hands when loosening or tightening it 9 Be sure to disconnect the battery cables from the battery and remove the lock plate from the engine stop lanyard switch 9 Put a block of wood between the anti cavi...

Page 159: ...flows out of the check hole and no air bubbles are visible 9 Install the new gasket check screw 7 and quickly install the drain screw then tighten to specified torque 69D10050 7 Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Gear oil quantity 1 150 cm3 38 88 US oz 40 56 Imp oz Propeller nut 6 54 N m 5 4 kgf m 39 8 ft lb Check screw 7 and drain screw 9 N m 0 9 kgf m 6 6 ft lb ...

Page 160: ...LOWR 6 23 6S35H11 Lower unit Shimming regular rotation model T3 M3 M4 M2 6S36050EA T2 T1 M1 F R P ...

Page 161: ...f the hole 9 Tighten the wing nuts another 1 4 of a turn after they contact the fixing plate 2 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M4 between the special service tool and the pinion as shown NOTE 9 Measure the pinion at 4 points to find the distance average 9 Make of note the each measurement numerical 4 Turn the thrust bearin...

Page 162: ... 3 90890 06704 5 Calculate the pinion shim thickness T3 as shown in the examples below NOTE P is the deviation of the lower case dimen sion from standard The P mark a is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is unreadable assume that P is zero and check the backlash when the unit is assembled Example If M3 is 50 75 mm and M4 is 30 57 mm and P is ...

Page 163: ...tion of the lower case dimen sion from standard The F mark a is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is unreadable assume that F is zero and check the backlash when the unit is assembled Example If M1 is 30 20 mm and F is 5 then T1 30 60 5 100 30 20 mm 30 60 0 05 30 20 mm 0 45 mm If M1 is 30 20 mm and F is 0 then T1 30 60 0 100 30 20 mm 30 60 0 ...

Page 164: ...1 00 1 100 3 100 19 92 mm 21 00 0 01 0 03 19 92 mm 1 10 mm If M2 is 19 92 mm and R is 3 and A is 5 then T2 21 00 3 100 5 100 19 92 mm 21 00 0 03 0 05 19 92 mm 1 16 mm 3 Select the reverse gear shim s T2 as follows Example If T2 is 1 10 mm then the reverse gear shim is 1 08 mm If T2 is 1 16 mm then the reverse gear shim is 1 15 mm Backlash regular rotation model Measuring the forward and reverse ge...

Page 165: ...s to contact the gear evenly it tightens center bolt 3 to specified torque 4 Install the backlash indicator onto the drive shaft 22 4 mm 0 88 in in diame ter then the dial gauge onto the lower unit Bearing housing puller claw L 1 90890 06502 Stopper guide plate 2 90890 06501 Center bolt 3 90890 06504 Backlash indicator 4 90890 06706 Magnet base plate 5 90890 07003 Dial gauge set 6 90890 01252 Magn...

Page 166: ...the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction 11 Add or remove shim s if out of specifica tion M Measurement 12 Remove the special service tools and then install the water pump assembly Reverse gear backlash 0 64 0 93 mm 0 0252 0 0366 in Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Reverse gear Shim thic...

Page 167: ...34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kgf m 6 6 ft lb 6S36050E No Part name Q ty Remarks 1 Lower unit 1 2 Plate 1 3 Rubber seal 1 4 Check screw 1 5 Gasket 2 6 Bolt 7 M10 45 mm 7 Drain screw 1 8 Grommet 1 9 Bolt 1 M10 45 mm 10 Bolt 1 M10 70 mm 11 Spacer 1 12 Propeller 1 13 Washer 1 14 Washer 1 15 Cotter pin 1 16 Propeller nut 1 17 Trim tab 1 Not reusable Not reu...

Page 168: ...e Q ty Remarks 1 Shift rod 1 2 Oil seal 1 3 Cover 1 4 O ring 1 5 Spring 1 6 Circlip 1 7 Bolt 3 M6 20 mm 8 Seal 1 9 Woodruff key 1 10 Bolt 4 M8 45 mm 11 Cover 1 12 Seal 1 13 Water pump housing 1 14 O ring 1 15 Insert cartridge 1 16 O ring 1 17 Impeller 1 Not reusable Not reusable Not reusable Not reusable ...

Page 169: ...9 8 7 6 5 4 3 2 1 Lower unit counter rotation model 8 N m 0 8 kgf m 5 9 ft lb 18 N m 1 8 kgf m 13 3 ft lb 6S36070E No Part name Q ty Remarks 18 Outer plate cartridge 1 19 Gasket 1 20 Dowel 2 21 Dowel 2 Not reusable ...

Page 170: ...en loosening or tightening it 9 Be sure to disconnect the battery cables from the battery and the lock plate from the engine stop lanyard switch 9 Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning 9 When removing the lower unit without removing the power unit be sure to sus pend the outboard motor Otherwise the outboard motor could suddenly fall...

Page 171: ...unit Make sure that the shift rod is in the neutral position using a spe cial service tool 5 Remove the shift rod assembly 7 Checking the water pump and shift rod 1 Check the water pump housing Replace if there is deformation 2 Check the impeller and insert cartridge Replace if cracked or worn 3 Check the Woodruff key 1 and the groove a on the drive shaft Replace if worn 4 Check the shift rod Repl...

Page 172: ... 18 N m 1 8 kgf m 13 3 ft lb 6S36080E No Part name Q ty Remarks 1 Shift rod joint 1 2 Ball 2 3 Shift slider 1 4 Shift plunger 1 5 Dog clutch 1 6 Cross pin 1 7 Spring 1 8 Propeller shaft 1 1 9 Forward gear 1 10 Needle bearing 1 11 Bushing 1 12 Ring nut 1 13 Claw washer 1 14 Forward gear shim 15 Taper roller bearing 1 16 Propeller shaft 2 1 17 Thrust bearing 1 Not reusable Not reusable ...

Page 173: ...t lb 18 N m 1 8 kgf m 13 3 ft lb 6S36080E No Part name Q ty Remarks 18 Propeller shaft shim 19 Needle bearing 1 20 O ring 1 21 Propeller shaft housing 1 22 Grease nipple 1 23 O ring 1 24 Needle bearing 1 25 Oil seal 2 26 Ring 1 27 Bolt 2 M8 20 mm 28 Water inlet cover 2 29 Nut 1 30 Screw 1 31 Bolt 2 M8 36 mm 32 Washer 2 Not reusable Not reusable Not reusable Not reusable Not reusable ...

Page 174: ...e spring 1 and then remove the cross pin 2 shift rod joint 3 shift plunger 4 balls 5 shift slider 6 and dog clutch 7 NOTE Mark the front side of the dog clutch 7 Disassembling the propeller shaft assembly 2 1 Remove the forward gear and forward gear shim s from the propeller shaft housing using a press NOTE Use a pressure pin B 2 or proper size exten sion D 25 mm L 160 mm Bearing separator 1 90890...

Page 175: ...t with a new one 5 Remove the needle bearing w Bearing puller assembly e 90890 06535 Stopper guide plate r 90890 06501 Stopper guide stand t 90890 06538 2 Install the propeller shaft housing assem bly in the reverse direction into the lower case NOTE Use M8 bolt 3 for mount the propeller hous ing 3 Remove the ring nut 4 and claw washer 5 using the special service tools 3 3 6S360250 6S360260 7 6 5 ...

Page 176: ...eedle bearing and bushing from the forward gear using the chisel cC Do not reuse the bearing always replace it with a new one Checking the propeller shaft housing 1 Clean the propeller shaft housing using a soft brush and cleaning solvent and then check it Replace if cracked or damaged 2 Check the bearings Replace if pitted or if there is rumbling Needle bearing attachment 1 90890 06610 Driver rod...

Page 177: ...ard the oil seal propeller side 9 Be careful not to let the stopper c get out of position when using the driver rod SS 1 3 Apply grease to new oil seals and then install them into the propeller shaft hous ing using a press to the specified depth NOTE Install an oil seal halfway into the propeller shaft housing then the other oil seal Needle bearing attachment 6 90890 06653 Driver rod LS 7 90890 06...

Page 178: ...ation model 5 Install a new taper roller bearing 8 into the propeller shaft housing using a press 6 Install the propeller shaft housing assem bly in the reverse direction into the lower case NOTE Use M8 bolt 0 for mount the propeller hous ing 7 Install the claw washer q and ring nut w and then tighten the ring nut to the spec ified torque 6S360360 6 7 0 0 6S360255 6S360370 r e q w 8 6S360370 9 Rin...

Page 179: ...lect shim s see Shimming counter rotation model 9 After installing the forward gear check that the propeller shaft and forward gear rotates smoothly Ring nut wrench 9 90890 06578 S6S16210 9 t y u Assembling the propeller shaft assembly 1 1 Install the dog clutch 1 shift plunger 2 ball 3 slider 4 and shift rod joint 5 into the propeller shaft 6 and then install the cross pin 7 and spring 8 2 Instal...

Page 180: ...f m 13 3 ft lb No Part name Q ty Remarks 1 Drive shaft 1 2 Cover 1 3 Oil seal 2 4 Bolt 4 M8 25 mm 5 Drive shaft housing 1 6 Needle bearing 1 7 O ring 1 8 Pinion shim 9 Thrust bearing 1 10 Lower case 1 11 Needle bearing 1 12 Pinion 1 13 Washer 1 14 Nut 1 15 Reverse gear shim 16 Retainer 1 17 Thrust bearing 1 Not reusable Not reusable ...

Page 181: ...5 4 3 2 1 Drive shaft and lower case counter rotation model 142 N m 14 2 kgf m 104 7 ft lb 6S36090E 18 N m 1 8 kgf m 13 3 ft lb No Part name Q ty Remarks 18 Needle bearing 1 19 Reverse gear 1 20 Washer 1 21 Needle bearing 2 ...

Page 182: ... the bearing always replace it with a new one Removing the drive shaft 1 Loosen the pinion nut 2 Remove the pinion nut 3 washer 4 pinion 5 drive shaft housing 6 thrust bearing 7 pinion shim s 8 from lower case 3 Pull out the reverse gear 6F660190 1 2 6S630055 3 4 5 6 7 8 6G460100 Drive shaft holder 6 1 90890 06520 Pinion nut holder 2 90890 06715 Needle bearing attachment 1 90890 06610 Driver rod L...

Page 183: ...e the needle bearing from the retainer Checking the pinion and reverse gear 1 Check the teeth of the pinion and the teeth and dogs of the reverse gear Replace if cracked or worn Checking the bearing 1 Check the bearing Replace if pitted or if there is rumbling Checking the drive shaft 1 Check the drive shaft Replace if bent or worn 2 Measure the drive shaft runout S6P26070E 2 1 2 1 Ball bearing at...

Page 184: ...r to the specified depth 2 Install the original shim s and retainer into the lower case NOTE 9 Be sure to select the reverse gear shim s if replacing the thrust bearing retainer or lower case 9 To select the shim s see Shimming counter rotation model Needle bearing attachment 1 90890 06654 Driver rod L3 2 90890 06652 Ball bearing attachment 3 90890 06657 Driver rod LL 4 90890 06605 1 2 S6P26475E a...

Page 185: ... the drive shaft 1 Install the thrust bearing 1 and reverse gear 2 into the lower case 2 Install the thrust bearing 3 and original shim s 4 onto the drive shaft 5 NOTE 9 Be sure to select the pinion shim s if replacing the thrust bearing drive shaft housing drive shaft or lower case 9 To select the shim s see Shimming counter rotation model 4 5 3 6G460165 6S360410 1 2 S6P26800E 2 1 a b 4 3 S6P2612...

Page 186: ...t w NOTE Apply LOCTITE 572 to the drive shaft hous ing bolts before installation Installing the propeller shaft housing 1 Set the shift rod joint and dog clutch 1 to the neutral position 2 Apply grease to a new O ring and then install it onto the propeller shaft housing 3 Install the washer 2 and propeller shaft assembly 3 into the lower case NOTE Face the shift plunger connect part to upward 6F66...

Page 187: ...ift to the neutral position when installing the shift rod 9 After assembling the lower unit check that the shift rod operates smoothly and check that the drive shaft and propeller shaft rotates smoothly 2 Install a new gasket 4 the outer plate cartridge 5 and dowels 6 3 Install the Woodruff key 7 into the drive shaft 4 Align the groove in the impeller 8 with the Woodruff key 7 and then install the...

Page 188: ...oard motor could suddenly fall and result in injury 1 Align the center of the set pin a with the alignment mark b on the bottom cowl ing 5 Install the new O ring 9 and insert car tridge 0 into the pump housing q NOTE Align the insert cartridge projections a with the holes b in the pump housing 6 Install the new O ring w and pump hous ing assembly e into the lower case tighten the bolts r and then ...

Page 189: ... lanyard switch 9 Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning 2 Set the gear shift to the neutral position at the lower unit Make sure that the shift rod is in the neutral position using a spe cial service tool 3 Install the 2 dowels 1 into the lower unit 4 Install the lower unit into the upper case and then tighten the lower case mounting...

Page 190: ...lowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible 9 Install the new gasket check screw 7 and quickly install the drain screw then tighten to specified torque 69D10055 7 Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Gear oil quantity 1 000 cm3 33 81 US oz 35 27 Imp oz Propeller nut 6 54 N m 5 4 kgf m 39 8 ft lb Check screw 7 and drain screw 9 N m 0 ...

Page 191: ...6S35H11 6 54 9 8 7 6 5 4 3 2 1 Drive shaft and lower case counter rotation model Shimming counter rotation model Shimming counter rotation model T3 M3 M4 M5 6S36060EL T2 T1 M1 T 4 M6 10 M7 F R P ...

Page 192: ...Tighten the wing nuts another 1 4 of a turn after they contact the fixing plate 2 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M4 between the special service tool and the pinion as shown NOTE 9 Measure the pinion at 4 points to find the distance average 9 Make of note the each measurement numerical 4 Turn the thrust bearing 5 2 or 3 ti...

Page 193: ...al caliper 3 90890 06704 5 Calculate the pinion shim thickness T3 as shown in the examples below NOTE P is the deviation of the lower case dimen sion from standard The P mark a is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is unreadable assume that P is zero and check the backlash when the unit is assembled Example If M3 is 50 75 mm and M4 is 30 57 mm...

Page 194: ...r case in 0 01 mm units If the F mark is unreadable assume that F is zero and check the backlash when the unit is assembled Example If M1 is 30 20 mm and F is 5 then T1 30 60 5 100 30 20 mm 30 60 0 05 30 20 mm 0 45 mm If M1 is 30 20 mm and F is 0 then T1 30 60 0 100 30 20 mm 30 60 0 30 20 mm 0 40 mm 3 Select the reverse gear shim s T1 as follows Calculation formula Reverse gear shim thickness T1 3...

Page 195: ...E R is the deviation of the lower case dimen sion from standard and A is the deviation of the propeller shaft housing 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 propeller shaft housing in 0 01 mm units If the R mark or A mark is unreadable assume that R and A are zero and check the backlash when the unit is assembled ...

Page 196: ...re the bearing height M6 as shown NOTE 9 Select the shim thickness T 4 by using the specified measurement s and the calcula tion formula 9 Measure the taper roller bearing at 4 points to find the height average 9 Make of note the each measurement numerical 2 Install the thrust bearing 4 onto the pro peller shaft 2 5 and then measure the propeller shaft flange and thrust bearing thickness M7 as sho...

Page 197: ... 28 00 7 100 6 100 14 75 12 50 mm 28 00 0 03 0 06 14 75 12 50 mm 0 88 mm 4 Round the numerals for the propeller shaft shim s T4 as follows Example If T4 is 0 83 mm then the propeller shaft shim is 0 82 mm If T4 is 0 88 mm then the propeller shaft shim is 0 85 mm 5 Calculate and select the propeller shaft shim thickness T 4 as shown in the examples below Example If T4 is 0 82 mm then T 4 0 82 0 30 ...

Page 198: ...nit Magnet base B 0 90890 06844 Dial gauge set q 90890 01252 Propeller shaft free play 0 25 0 35 mm 0 0098 0 0138 in 3 Install the special service tools so that it pushes against the propeller shaft NOTE While turning the drive shaft clockwise 5 6 times to contact the gear evenly it tightens center bolt 3 to specified torque 6S360490 9 8 7 6 5 4 S6S16440 q 0 Ring nut 9 108 N m 10 8 kgf m 79 7 ft l...

Page 199: ...him s if out of specifica tion M Measurement 8 Remove the special service tools from the propeller shaft 9 Turn the shift rod into the reverse position c with the shift rod push arm 10 Turn the drive shaft clockwise until the dog clutch 8 is fully engaged Backlash indicator 4 90890 06706 Magnet base plate 5 90890 07003 Dial gauge set 6 90890 01252 Magnet base B 7 90890 06844 Forward gear backlash ...

Page 200: ...direction NOTE When measuring the reverse gear backlash turn the shift rod push arm towards the reverse position c with force 15 Add or remove shim s if out of specifica tion M Measurement 16 Remove the special service tools and then install the water pump assembly 6S360510 d 6S360510 c Reverse gear backlash 0 64 0 93 mm 0 0252 0 0366 in Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and...

Page 201: ...6S35H11 6 64 9 8 7 6 5 4 3 2 1 MEMO ...

Page 202: ...mp bracket 7 19 Installing the PTT unit 7 19 Adjusting the trim sensor 7 20 PTT unit 7 22 Checking the hydraulic pressure 7 24 PTT motor 7 27 Disassembling the PTT motor 7 28 Checking the PTT motor 7 29 Assembling the PTT motor 7 30 Gear pump 7 31 Disassembling the gear pump 7 33 Disassembling the relief valve 7 33 Checking the gear pump and main valve 7 34 Checking the main valve 7 34 Checking th...

Page 203: ...ng the tilt ram 7 42 Assembling the trim ram 7 43 Installing the tilt cylinder 7 43 Installing the trim ram 7 43 Installing the PTT motor 7 44 Installing the reservoir 7 45 Installing the tilt ram 7 45 Bleeding the PTT unit 7 46 Bleeding the PTT unit built in 7 47 PTT electrical system 7 48 Checking the fuse 7 48 Checking the PTT relay 7 48 Checking the PTT switch 7 49 Checking the trim sensor 7 4...

Page 204: ... Part name Q ty Remarks 1 Bolt 3 M8 45 mm 2 Bolt 1 M8 45 mm 3 Washer 1 4 Grommet 8 5 Collar 4 6 Seal 4 7 Ground lead 1 8 Hose 1 9 Cooling water pilot hole 1 10 Grommet 1 11 PTT motor lead 1 12 Trim sensor coupler 1 13 Screw 1 ø5 20 mm 14 Adapter 1 15 Hose joint 1 16 Lock tie 1 17 Flushing hose 1 Not reusable ...

Page 205: ...t lb 6S37010E No Part name Q ty Remarks 18 Bottom cowling 1 19 Bolt 2 M6 30 mm 20 Bolt 1 M6 12 mm 21 Spring 1 22 Nut 2 23 Stay 1 24 Washer 1 25 Bushing 2 26 Seal 1 27 Grease nipple 1 28 Bracket 1 29 Shift rod 1 30 Cotter pin 1 31 Grommet 1 32 Plate 1 33 O ring 1 34 Screw 2 ø6 8 mm Not reusable ...

Page 206: ... 0 8 kgf m 5 9 ft lb 8 N m 0 8 kgf m 5 9 ft lb 6S37020E No Part name Q ty Remarks 1 Clamp 2 2 Bolt 1 M6 20 mm 3 Plate 1 4 Bolt 1 M8 20 mm 5 Holder 1 6 Grommet 1 7 Bolt 6 M6 16 mm 8 Bracket 1 9 Plate 1 10 Clamp 2 11 PTT switch 1 12 Spring hook 1 13 Spring 3 14 Bolt 3 M8 17 mm 15 Hook 1 16 Bushing 6 17 Wave washer 3 ...

Page 207: ... 9 ft lb 8 N m 0 8 kgf m 5 9 ft lb 8 N m 0 8 kgf m 5 9 ft lb 8 N m 0 8 kgf m 5 9 ft lb 8 N m 0 8 kgf m 5 9 ft lb 6S37020E No Part name Q ty Remarks 18 Clamp lever 1 19 Holder 1 20 Spring hook 1 21 Hook 1 22 Hook 1 23 Clamp lever 1 24 Spring hook 1 25 Clamp lever 1 ...

Page 208: ...5 9 ft lb 6S37030E No Part name Q ty Remarks 1 Upper case assembly 1 2 Cover 2 3 Ground lead 1 4 Bolt 1 M6 10 mm 5 Bolt 1 M6 17 mm 6 Speed sensor adapter 1 7 Dowel 1 8 Lock tie 1 9 Hose 1 10 Nut 2 11 Washer 2 12 Washer 2 13 Washer 2 14 Grommet 4 15 Nut 2 16 Washer 1 Not reusable Upper case steering arm ...

Page 209: ...ty Remarks 1 Upper case 1 2 Dowel 2 3 Upper mount 2 4 Washer 2 5 Rubber washer 2 6 Washer 2 7 Bolt 2 M14 190 mm 8 Bracket 1 9 Muffler assembly 1 10 Rubber seal 1 11 Mount housing 2 12 Ground lead 1 13 Washer 2 14 Rubber washer 2 15 Lower mount 2 16 Bolt 3 M10 45 mm 17 Bolt 1 M8 45 mm Not reusable å U transom ...

Page 210: ...N m 1 8 kgf m 13 3 ft lb å 6S37045E No Part name Q ty Remarks 18 Bolt 2 M8 30 mm 19 Extension 1 U transom 20 Bolt 3 M6 35 mm 21 Bolt 4 M10 45 mm 22 Bolt 2 M14 205 mm 23 Circlip 1 24 Bushing 1 25 Grommet 1 26 Rubber seal 2 Not reusable ...

Page 211: ...t lb S60V7050 No Part name Q ty Remarks 1 Muffler 1 2 Exhaust manifold 1 3 Gasket 1 4 Lower exhaust guide 1 5 Gasket 1 6 Upper exhaust guide 1 7 Flushing hose 1 8 Lock tie 1 9 Joint 1 10 Rubber seal 1 11 Pipe 1 12 Bolt 6 M8 50 mm 13 Rubber damper 2 14 Clip 2 15 Bolt 4 M8 50 mm 16 Bolt 4 M8 35 mm Not reusable Not reusable Not reusable ...

Page 212: ...ing water pipe 5 and rubber dampers 6 3 Remove the exhaust manifold 7 4 Remove the lower exhaust guide 8 from the upper exhaust guide 9 5 Remove the circlip and then remove drive shaft bushing S60V7120 1 2 3 å S60V7130 4 6 5 S60V7140 7 S60V7150 9 8 S6P27840E 0 q w q Bearing puller assembly 0 90890 06535 Stopper guide stand q 90890 06538 Stopper guide plate w 90890 06501 ...

Page 213: ...he upper case and then install the circlip NOTE After installing the drive shaft bushing apply grease to the inside of the bushing 2 Install a new gasket 3 the lower exhaust guide 4 and bolts 5 and then tighten the bolts to the specified torque 3 Install a new gasket 6 the exhaust man ifold 7 and bolts and then tighten the bolts to the specified torque S6P27850E 1 2 Needle bearing attachment 1 908...

Page 214: ...specified torque 7 Install the muffler assembly t during inserting the tip of the cooling water pipe w into the joint hole a of the upper case 8 Tighten the muffler assembly bolts y to the specified torque å U transom 9 Install the upper mounts u and bolts i into the upper case assembly 6S370015 q 9 w e 0 r Muffler bolt r 18 N m 1 8 kgf m 13 3 ft lb S60V7220 t a å y y y w w Muffler assembly bolt y...

Page 215: ...Upper case steering arm 10 Install the bracket o and then tighten the bolts p NOTE First tighten the center located when tighten the bolts a 11 Install the lower mounts a and mount housings s S60V7240 s a S60V7230 u o i p 6S370017 a ...

Page 216: ...RKT 7 13 6S35H11 Bracket unit 6S37040E No Part name Q ty Remarks 1 Steering arm 1 2 Washer 2 3 Bushing 2 4 Bracket assembly 1 5 O ring 1 6 Bushing 1 7 Steering yoke 1 8 Circlip 1 9 Damper 1 Not reusable ...

Page 217: ... Remove the steering arm from the swivel bracket by pulling the arm off the bracket Installing the steering arm 1 Install the washer 1 and bushing 2 onto the steering arm 3 2 Place the swivel bracket 4 in an upright position and then install the steering arm onto the swivel bracket assembly 3 Install the bushing 5 new O ring 6 bushing 7 and washer 8 onto the swiv el bracket assembly 6S370010 a 2 4...

Page 218: ... 6 Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c Installing the upper case 1 Install the upper and lower mount bolts into the bracket assembly 1 simultane ously 2 Install the upper mount nuts 2 and lower mount nuts 3 and then tighten them to the specified torques NOTE Before tight the uppercase wiring the ground lead 3 Install the covers 6S370...

Page 219: ...f m 16 2 ft lb 6S37050E No Part name Q ty Remarks 1 Through tube 1 2 Port clamp bracket 1 3 Bolt 8 M10 45 mm 4 Bushing 2 5 Screw 1 ø6 10 mm 6 Washer 2 7 Bushing 4 8 Friction plate 2 9 Screw 4 ø6 10 mm 10 Screw 2 ø6 15 mm 11 Trim sensor 1 12 Grease nipple 6 13 Starboard clamp bracket 1 14 Self locking nut 1 15 Collar 1 16 Pin 2 17 Tilt lever joint 2 a 30 3 30 4 mm 1 19 1 20 in Clamp bracket and swi...

Page 220: ... 22 N m 2 2 kgf m 16 2 ft lb 6S37050E No Part name Q ty Remarks 18 Pin 1 19 Bolt 1 M6 10 mm 20 Spring 1 21 Spring holder 1 22 Port tilt stop lever 1 23 Shaft 1 24 Trim stopper 2 25 Starboard tilt stop lever 1 26 Circlip 1 27 Nut 2 28 Swivel bracket 1 29 PTT unit 1 30 Bolt 1 M6 10 mm 31 Bolt 4 M6 25 mm 32 Bracket 2 33 Anode 1 34 Bushing 4 ...

Page 221: ...uld suddenly fall and result in injury NOTE If the PTT does not operate turn the manual valve counterclockwise and tilt the outboard motor up manually 2 Remove the anode 2 and PTT mount bolts 3 3 Loosen the self locking nut 4 and then move the clamp brackets slightly in the direction of the arrows w Do not remove the tilt stop lever 1 from the clamp brackets 4 Remove the lock ties 5 and then pull ...

Page 222: ...rough tube 7 and then tightening the self locking nut 8 temporary cC Do not pinch the trim sensor pin 9 when down the swivel bracket Installing the PTT unit 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 w 9 When installing the PTT unit without removing the power unit be sure to sus pend the outboard motor Otherwise the outboard motor could suddenly fall and resu...

Page 223: ...the PTT motor lead and trim sen sor lead with the lockties 8 6S35H11 7 20 9 8 7 6 5 4 3 2 1 Clamp bracket and swivel bracket Self locking nut 6 22 N m 2 2 kgf m 16 2 ft lb 8 Inject grease into all grease nipples until grease comes out from the bushings a Adjusting the trim sensor 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 w After tilting up the outboard motor...

Page 224: ...o increase the resistance turn the trim sensor in direction b 4 Fully tilt the outboard motor down 5 Measure the trim sensor resistance Repeat steps 1 4 if out of specification 6 Tighten the screws 2 7 Fully tilt the outboard motor down NOTE Check the trim sensor resistance after tighten the screws and fully tilt the outboard motor down 6S370039 B P Trim sensor resistance Pink P Black B 9 11 Ω at ...

Page 225: ... kgf m 11 1 ft lb 15 N m 1 5 kgf m 11 1 ft lb 6S37060E No Part name Q ty Remarks 1 PTT body 1 2 Reservoir 1 3 Bolt 3 M3 30 mm 4 O ring 1 5 Reservoir cap 1 6 O ring 1 7 PTT motor 1 8 Bolt 3 M3 30 mm 9 O ring 1 10 O ring 2 11 O ring 2 12 O ring 2 13 Main valve 2 14 O ring 1 15 Piston 1 16 Circlip 1 17 Valve support 1 Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not r...

Page 226: ... 1 5 kgf m 11 1 ft lb 15 N m 1 5 kgf m 11 1 ft lb 6S37060E No Part name Q ty Remarks 18 O ring 1 19 O ring 1 20 Main valve seat 2 21 Spring 1 22 Adopter 1 23 O ring 1 24 Valve seat 1 25 Ball 1 26 O ring 1 27 Circlip 1 28 Manual release rod 1 29 Spring 1 30 Manual valve 1 31 Circlip 1 32 Bushing 2 33 Pipe 1 34 Pipe 1 Not reusable Not reusable Not reusable Not reusable ...

Page 227: ...e hydraulic pres sure 6 Reverse the PTT motor leads between the battery terminals to fully extend the rams 7 Remove the special service tools 8 Install the pipe joints and then tightening them to the specified torque 9 Connect the PTT motor leads to the bat tery terminals to fully retract the trim and tilt rams 6S370050 1 a 2 6S370070 6S370060 PTT oil pressure gauge assembly 2 90890 06580 Rams PTT...

Page 228: ...verse the PTT motor leads between the battery terminals to fully retract the rams 14 Remove the special service tool 15 Install the pipe joints and then tightening them to the specified torque 16 After measuring the hydraulic pressure connect the PTT motor leads to the bat tery terminals to fully extend the trim and tilt rams 6S370080 3 b 2 6S370100 6S370110 6S370090 PTT oil pressure gauge assembl...

Page 229: ...voir cap otherwise fluid can spurt out from the unit due to internal pressure NOTE If the fluid is at the correct level the fluid should overflow out of the filler hole when the cap is removed 19 If necessary add sufficient fluid of the recommended type to the correct level 20 Install the new O ring and reservoir cap 4 then tighten it to the specified torque 6S370115 4 Reservoir cap 4 7 N m 0 7 kg...

Page 230: ... Remarks 1 Frame 1 2 Bolt 2 M5 100 mm 3 O ring 1 4 Brush holder assembly 1 5 Spring 4 6 Brush 2 7 Screw 5 ø4 10 mm 8 Stator assembly 1 9 Wave washer 3 10 Bearing 2 11 Armature 1 12 O ring 1 13 PTT motor base 1 14 Oil seal 1 Not reusable Not reusable PTT motor ...

Page 231: ...tor is removed from the PTT unit otherwise fluid can spurt out 2 Remove the PTT motor bolts 1 then the stator 2 cC Do not allow grease or oil to contact the commutator NOTE Place a clean cloth over the end of the arma ture shaft hold it with a pair of pliers and then carefully slide the stator off of the arma ture 3 Remove the stator 2 and O ring 3 4 Remove the screws 4 and slide the holder and th...

Page 232: ...for continuity Replace if out of specifications 5 Measure the brush length Replace if below specification 6G480220 a f 6S370150 6S370140 c d e Motor commutator standard diameter a 25 0 mm 0 98 in Wear limit 24 0 mm 0 95 in 6F680180 b Motor commutator standard undercut b 1 8 mm 0 07 in Wear limit 1 2 mm 0 05 in Armature continuity Commutator segments c Continuity Segment c No continuity Armature co...

Page 233: ... frame 3 Connect the PTT motor leads 4 to the brush holder 5 and then install the brush holder 5 to the frame 6 4 Install the springs 7 and brushes 8 to the brush holder 5 Push the brushes 8 into the holders and then install the armature 9 6 Install a new O ring and align the line with mating mark and then install the sta tor NOTE Align the line on the frame with the mating on the flame 7 Install ...

Page 234: ...4 kgf m 3 0 ft lb 6S37070E No Part name Q ty Remarks 1 Gear housing 1 1 2 Ball 2 3 Screw 3 ø4 30 mm 4 Gear pump filter 1 5 Drive gear 1 6 Gear housing 2 1 7 Bolt 4 M5 12 mm 8 Pin 2 9 O ring 2 10 Joint 1 11 O ring 1 12 Driven gear 1 Not reusable Not reusable Gear pump ...

Page 235: ...4 kgf m 3 0 ft Ib No Part name Q ty Remarks 1 Trim down plate 1 2 Seal 1 3 Screw 2 ø5 10 mm 4 Trim down spring 1 5 Main valve seal 1 6 Screw 2 ø5 10 mm 7 Relief valve plate 1 8 Up relief valve spring 1 9 Down relief valve spring 1 10 Pin 2 11 Washer 2 12 Valve seat 2 13 Valve seal 2 14 Ball 2 15 Relief valve seat 1 16 O ring 1 17 Filter 1 Not reusable ...

Page 236: ...til remove the gear pump housing 1 7 press the pins 5 4 Separate the gear pump housing 2 8 from the gear pump as shown NOTE Upside down the gear pump housing and then remove the gear pump housing 2 8 Disassembling the relief valve 1 Remove the trim down spring 1 and main valve seal 2 2 Remove the trim down plate 3 and seal 4 then the relief valve plate 5 S60V7320 1 2 S60V7330 3 3 4 6S370240 8 7 6S...

Page 237: ...e gear pump housing 1 Check the inside of the gear pump hous ing Replace if scratched or worm Checking the reservoir 1 Check the reservoir and O ring Replace if deterioration and corrosion Checking the filter 1 Check gear pump filter 1 Clean if there is dirt or residue Checking relief valve 1 Check the up relief valve 1 and down relief valve 2 Clean if there is dirt or residue 2 Check the valve se...

Page 238: ...th 8 to install into the relief valve seat 0 4 Install the relief valve plate q by install ing the screws w then tighten them to the specified torque 5 Install the seal e and tilt down plate r NOTE Install the seal e as shown direction 6 Install the main valve seal t and trim down spring y and then tighten the screws u to the specified torque 6S370277 1 2 6S370278 4 3 6S370279 0 5 4 9 8 9 5 4 8 6 ...

Page 239: ...then tighten the bolts 6 3 Check the gear pump operation NOTE Inject a small amount fluid to the gear pump and then rotate the drive gear direction shown 4 Install the new O rings piston 8 main valves 9 and valve support 0 5 Install the new O rings q gear pump w by installing the screws e then tighten ing them to the specified torque 6S370270 1 3 3 4 5 2 6S370275 6 6 6 7 7 7 Gear pump bolt 6 4 N m...

Page 240: ...ngs r joint t gear pump filter y and then install the new O ring u valve seat i new O ring o ball p manual valve assembly a and circlip s Gear pump screw e 2 N m 0 2 kgf m 1 5 ft lb Manual valve a 2 N m 0 2 kgf m 1 5 ft lb 6S370315 e e e r t y u i o p a s ...

Page 241: ... name Q ty Remarks 1 Circlip 2 2 Dust seal 2 3 Trim cylinder end screw 2 4 O ring 2 5 Trim ram assembly 2 6 Trim piston 2 7 Backup ring 2 8 O ring 2 9 Spring 2 10 Adapter 2 11 Circlip 2 12 Tilt piston assembly 1 13 Tilt ram assembly 1 14 Power tilt assembly 1 15 Tilt ram 1 16 Dust seal 1 17 Tilt cylinder end screw 1 Not reusable Not reusable Not reusable Not reusable Tilt cylinder and trim cylinde...

Page 242: ...9 0 kgf m 66 4 ft lb 6S37090E No Part name Q ty Remarks 18 O ring 1 19 Backup ring 1 20 O ring 1 21 Spring 1 22 Adapter 1 23 Tilt piston 1 24 O ring 1 25 Backup ring 1 26 Free piston 1 27 O ring 1 28 Tilt cylinder 1 29 Ball 5 30 Absorber valve pin 5 31 Pin 5 32 Spring 5 Not reusable Not reusable Not reusable Not reusable ...

Page 243: ...ed air through the hole b to remove the free piston 3 w 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 cylinder with a rag 6 Hold the tilt ram end in a vice using alu minum plates on both sides 7 Remove the piston absorber valves 8 Hold the tilt piston in a vice ...

Page 244: ... cylinder 2 Replace if cracked or if there is corro sion 2 Check the inner walls of the PTT body 1 and tilt cylinder 2 Replace if scratched 3 Check the outer surface of the tilt piston 3 trim piston 4 adapter 5 free piston 6 and dust seal 7 of end screw Replace if scratched 4 Check the trim rams 8 and tilt ram 9 Polish with 400 600 grit sandpaper if there is light rust or replace if bent or if the...

Page 245: ... 5 spring 6 adapter 7 and tilt piston 8 to the tilt ram 9 3 Hold the tilt piston in a vice using the spe cial service tool on both sides 4 Tighten the tilt ram 9 to the specified torque 5 Install the new O ring w and backup ring e onto the tilt piston 8 6 Install the balls r absorber valve pins t and springs y as shown 7 Install the washers u plate i and bolt o to the tilt piston 8 and then tighte...

Page 246: ...he tilt cylinder 1 Install the new O ring 1 to the free pis ton 2 2 Push the free piston 2 into the tilt cylin der 3 until it bottoms out 3 Install the tilt cylinder 3 to the PTT body 4 4 Install pipes 5 and 6 and then tighten the pipe joints to the specified torque Installing the trim ram cC Do not use a rag when installing the PTT unit as dust and particles on the PTT unit components can lead to...

Page 247: ...m rams down while installing them into the trim cylinders Otherwise the PTT fluid may spurt out from the unit Installing the PTT motor 1 Install the joint 1 into the gear pump 2 Fill the pump housing with the recom mended fluid to the correct level a as shown 3 Remove all of the air bubbles with a syringe or suitable tool NOTE Turn the joint with a screwdriver and then remove any air between the p...

Page 248: ...he new O ring 4 and reservoir cap 5 and then tighten it to the specified torque NOTE Add sufficient fluid of the recommended type until it overflows out of the filler hole Installing the tilt ram 1 Fill the tilt cylinder with the recommended fluid to the correct level a as shown 2 Add a small amount of the recommended fluid through the PTT body hole b as shown 6S370320 4 2 3 PTT motor mount bolt 4...

Page 249: ... level add fluid of the recommended type 5 Install the reservoir cap and then tighten it to the specified torque 6 Connect the PTT motor leads 2 to the battery terminals to fully retract the rams 7 Reverse the PTT motor leads between the battery terminals to fully extend the rams NOTE 9 Repeat this procedure so that the rams go up and down 4 or 5 times be sure to wait a few seconds before switchin...

Page 250: ...oard motor with the tilt stop lever and then let the fluid settle for 5 minutes w After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the PTT unit should lose fluid pressure 5 Remove the reservoir cap 1 and then check the fluid level in the reservoir NOTE If the fluid is at the correct level the fluid should overf...

Page 251: ...g lead to the positive battery terminal and the terminal 4 lead to the negative battery terminal as shown 5 Check for continuity between terminals 1 and 3 Replace if there is no continu ity 6 Connect the digital circuit tester between PTT relay terminals 2 and 3 7 Connect the sky blue Sb lead to the positive battery terminal and the terminal 4 lead to the negative battery terminal as shown 8 Check...

Page 252: ...ecification Checking the trim sensor 1 Measure the trim sensor resistance Replace if out of specification NOTE Turn the lever 1 and measure the resis tances it gradually changes Trim sensor resistance Pink P Black B 248 388 Ω at a 9 11 Ω at b Lead color Switch Sky blue Red R Light green position Sb Lg Up Free Down ...

Page 253: ...2 Checking the charge coil 8 13 Checking the thermoswitch 8 14 Checking the shift cut switch 8 14 Starting system 8 15 Checking the fuse 8 15 Checking the engine start switch 8 15 Checking the engine stop lanyard switch 8 16 Checking the starter relay 8 16 Starter motor 8 17 Removing the starter motor pinion 8 18 Checking the starter motor pinion 8 18 Checking the armature 8 18 Checking the brush ...

Page 254: ...al circuit tester leads cC When measuring the voltage of an electri cal component with the digital circuit tester make sure that the tester leads do not contact each other Otherwise the electrical component could be damaged NOTE 9 Before measuring the peak voltage check all wiring for proper connection and corro sion and check that the battery is fully charged 9 Use the peak voltage adapter with t...

Page 255: ...ƒ 6S380010 1 Throttle sensor 2 Hour meter 3 Spark plug 4 Spark plug cap 5 PTT switch 6 Oil feed pump coupler 7 Pulser coil coupler 8 Throttle sensor coupler 9 Hour meter coupler å To pulser coil To oil feed pump wiring harness ç To CDI unit wiring harness To throttle sensor Connect to remote control 10P coupler ƒ To tachometer To trim meter ...

Page 256: ...board view 7 5 6 3 4 2 1 8 9 0 6S380020 1 Spark plug cap 2 Spark plug 3 Engine temperature sensor 4 Crank position sensor 5 Pulse coil assembly 6 Stator assembly 7 Starter motor 8 Choke solenoid 9 Shift cut switch 0 Shift cut switch coupler ...

Page 257: ...PTT relay 3 Fuse holder 80A 4 Starter relay 5 Fuse holder 20A 6 Lighting coil coupler 7 Crank position sensor coupler å To stator assembly To crank position sensor ç To engine temperature sensor Push into the crank position sensor coupler and engine temperature sensor coupler Connect to lighting coil coupler ƒ To starter motor Clamp the battery lead ...

Page 258: ... with battery lead and PTT relay lead Clamp with ground lead battery leads bat tery cable and PTT relay leads Section A Wiring for Rectifier Regulator starter relay PTT relay and fuse holder Section B Wiring for fuse holder engine temperature sen sor coupler and PTT relay leads Section C Wiring for PTT relay leads battery leads and battery cable ...

Page 259: ...ion coil 6 7 CDI unit å To locate the charge coil coupler To locate the coupler to center of the CDI unit case and then bend the harness and clamp them after install the tube ç Face the cutting side to front and then locate the center of CDI unit mount bolt Do not tighten with ground lead and ignition coil out side Route the ground lead of left and right into the CDI unit case and ignition coil ...

Page 260: ... w 1 2 5 6 7 3 2 4 6S380030 1 Spark plug 2 Thermoswitch 3 Ignition coil 1 4 Ignition coil 2 5 Oil level gauge 6 Emergency switch 7 Throttle sensor 8 Pulser coil assembly 9 Stator assembly 0 Starter motor q Crank position sensor w Engine temperature sensor ...

Page 261: ...ions of the ignition tester leads 9 Do not let sparks leak out of the removed spark plug caps 9 Keep flammable gas or liquids away since this test can produce sparks Checking the spark plug cap 1 Remove the CDI unit cover and then remove the ignition coils 2 Check the spark plug caps for cracks or damage Replace the spark plug cap if necessary 3 Remove the spark plug caps 1 from the spark plug wir...

Page 262: ...all spark plug caps to prevent the engine ignite when measure the CDI unit peak voltage at engine cranking Checking the ignition coil 1 Remove the CDI unit cover and then remove the ignition coils 2 Disconnect the ignition coil connectors 3 Measure the ignition coil resistance Replace the ignition coil if out of specifi cation 6G480105 Ignition coil resistance å Primary coil Black white B W Black ...

Page 263: ... 2 Connect the test harness to the pulser coil 3 Measure the pulser coil output peak volt age Replace the pulser coil if less than specification Pulser coil resistance reference data White red W R 1 Ground White black W B 2 Ground White yellow W Y 3 Ground White green W G 4 Ground White blue W L 5 Ground White brown W Br 6 Ground 294 398 Ω at 20 C 68 F 6S380130 W R W B W Y W G W L W Br W Y W B W R...

Page 264: ... position sensor resis tance Replace the crank position sensor resistance if out of specification 7 Connect the digital circuit tester to the crank position sensor coupler a and CDI unit coupler b wiring harness side 8 Check the continuity Replace the wiring harness if no continuity 6S380100 G W G L G L G W Test harness 2 pins 90890 06867 Crank position sensor output peak voltage reference data ai...

Page 265: ...r 2 Disconnect the engine temperature sen sor coupler 3 Turn the engine start switch to ON a 6S380110 1 6S380120 Crank position sensor air gap 0 5 1 5 mm 0 02 0 06 in 4 Measure the input voltage at the engine temperature sensor coupler engine tem perature sensor side Check the wiring harness if less than specification 5 Connect the digital circuit tester to the engine temperature sensor coupler a ...

Page 266: ...emperature sensor 8 Place the engine temperature sensor in a container of water and slowly heat the water 9 Measure the engine temperature sensor resistance Replace the engine tempera ture sensor if out of specification S6P28740 Engine temperature sensor resis tance Black yellow B Y Black yellow B Y at 5 C 41 F 128 kΩ reference at 20 C 68 F 54 2 69 0 kΩ at 100 C 212 F 3 12 3 48 kΩ 6S380140 R B R B...

Page 267: ...2 Turn the engine start switch to ON 3 Measure the input voltage at the shift cut switch coupler wiring harness side Check the wiring harness to shift cut switch coupler continuity if there is no voltage 4 Check the shift cut switch for continuity Replace the shift cut switch if no continu ity 6S380145 Charge coil resistance reference data Red 1 Brown Br 3 224 336 Ω at 20 C 68 F Black red B R 2 Bl...

Page 268: ... main harness coupler engine start switch side Check the wiring harness or replace the engine start switch if there is no continuity 5 Check the continuity at the shift cut switch coupler a to CDI unit coupler b wiring harness side Replace the wiring harness if no continuity NOTE Connect the coupler 2 and ground then check the continuity of the shift cut switch 4 1 2 5 3 69D80206 6S380175 1 a b Le...

Page 269: ...continuity between the starter relay terminals Replace the starter relay if there is no continuity 6 Check that there is no continuity between the starter relay terminals after discon necting a battery terminal from the brown 2 or black lead 3 Replace the starter relay if there is continuity Checking the engine stop lanyard switch 1 Check the engine stop lanyard switch for continuity Replace if th...

Page 270: ...tarting motor bracket 1 3 Retainer 2 4 Starter motor pinion 1 5 Front bracket 1 6 Washer 7 Armature 1 8 Stator 1 9 Spring 4 10 Brush holder 1 11 Washer 1 12 Washer 1 13 Nut 1 14 Washer 2 15 Rear bracket 1 16 Screw 2 17 Bolt 2 M6 115 mm 9 N m 0 9 kgf m 6 6 ft lb 6S38010E Starter motor ...

Page 271: ...if necessary NOTE Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place Checking the armature 1 Check the commutator for dirt Clean with 600 grit sandpaper and compressed air if necessary 2 Measure the commutator diameter a Replace the armature if below specifica tion limit 3 Measure the commutator undercut b Replace the armature ...

Page 272: ...asure the resistance of the choke solenoid Replace the choke solenoid if out of specification 4 Check the armature for continuity Replace the armature if out of specifica tions Checking the brush 1 Measure the brush length a Replace the brush assembly if below specification limit 6G480256 c d e Armature continuity Commutator segments c Continuity Segment Armature core d No continuity Segment Armat...

Page 273: ... measuring the output peak voltage of the Rectifier Regulator Charging system Checking the lighting coil 1 Remove the junction box cover 2 Connect the test harness to the lighting coil 3 Measure the lighting coil output peak voltage Replace the stator assembly if less than specification 4 Disconnect the lighting coil coupler 5 Connect the digital circuit tester to the lighting coil coupler lightin...

Page 274: ...ulator output peak voltage Red R Ground or Red white R W Ground r min Unloaded 1 500 3 500 DC V 13 13 2 3 4 5 6 7 8 R R R W R W R G G G B 6S380210 2 3 4 6 5 7 8 S6S18360 b a Rectifier Regulator continuity Tester lead G 4 R 2 G 4 R 3 G 5 R 2 G 5 R 3 G 6 R 2 G 6 R 3 0 42 0 45 V G 4 R W 7 reference data G 4 R W 8 G 5 R W 7 G 5 R W 8 G 6 R W 7 G 6 R W 8 R 2 G 4 R 2 G 5 R 2 G 6 R 3 G 4 R 3 G 5 R 3 G 6 ...

Page 275: ...sec onds Replace the hour meter if there is no illuminated Oil feed pump control system Checking the oil level sensor 1 Remove the oil level sensor from engine oil tank and remote oil tank 2 Check the oil level sensor for continuity Replace if oil level sensor is no continuity 1 2 6S380230 S60V8320 L W L R L G B å S60V8330 ON OFF ON OFF ON OFF å a b c 1 2 3 S60V8340 d B B R Lead color Float Black ...

Page 276: ... remote oil tank Replace if there is no sound Checking the emergency switch 1 Remove the emergency switch from the engine oil tank 2 Disconnect the emergency switch con nector from the wiring harness 3 Check the emergency switch for continu ity Replace if there is no continuity 4 Check that the emergency switch returns automatically to the home position from the on position when released Switch Le...

Page 277: ...oubleshooting Troubleshooting the power unit 9 1 Troubleshooting the power unit using the diagnostic flash indicator 9 1 Troubleshooting the power unit trouble code not available 9 2 Troubleshooting the PTT unit 9 7 Troubleshooting the lower unit 9 8 ...

Page 278: ...b Light off 4 95 seconds 9 Trouble code indication Example The illustration indicates code number13 Pulser coil malfunction a Light on 0 33 second b Light off 4 95 seconds c Light off 0 33 second d Light off 1 65 seconds 4 If a flash pattern listed in the trouble code chart is displayed check the malfunction ing part according to the flash pattern NOTE When more than one problem is detected the li...

Page 279: ...ry Starter motor does not operate Starter motor operates but the engine does not crank Check the battery for electrolyte level gravity and voltage 3 14 Loose connection of battery terminal Check the battery terminal Short open or loose connection in starter motor circuit Check the wiring har ness continuity 1 Starter relay malfunction Check the starter relay 8 16 Blown fuse 80A Check the fuse 80A ...

Page 280: ...tion in ignition coil ground circuit Check the wiring harness continuity 8 11 Crank position sensor malfunction Check the crank position sensor 8 8 Spark plug malfunction Check the ignition spark check the spark plug wires Spark plug does not spark 1 Short open or loose connection in ignition coil circuit Check the wiring harness continuity Ignition coil malfunction Ignition coil resistance out of...

Page 281: ... reed valves 5 1 5 17 Low compres sion pressure Scratched piston or wear the piston rings Disassemble and check the power unit Scratched cylinder wall Reed valves malfunction 5 29 Refer Symptom 2 Cause 1 Cause 2 Checking step to page Symptom 1 Unstable engine idle speed poor acceleration poor performance Throttle cable adjusting improperly Check and adjust the throttle cable Check and adjust 3 8 T...

Page 282: ...Change the ignition coil and check the ignition spark 8 9 5 8 8 8 CDI unit malfunction Measure the charge coil output peak volt age and resistance Change the CDI unit and check the ignition spark CDI unit output peak voltage less than specifications 3 3 Check the spark plug gap and condition Spark plug gap improperly Cylinder head gasket malfunction Reed valves malfunction Check the compression pr...

Page 283: ...ing water passage Thermostat malfunction Check the impeller 6 5 6 34 Water pump impeller malfunction Check the Woodruff key 6 5 6 34 Water leakage from water pump housing Check the water pump housing 6 5 6 34 Check the insert car tridge 6 5 6 34 Check the outer plate cartridge 6 5 6 34 Check the cooling water passage exhaust guide and upper case Check the thermostat 7 10 3 3 Oil level decrease Oil...

Page 284: ...r lead Check the PTT motor lead 1 PTT motor does not operate Oil pressure does not increase PTT motor malfunction Disassemble and check the PTT motor 7 28 Blown fuse 80A Check the fuse 80A 7 48 Loose connection of the battery terminal Check the battery ter minal Discharged battery Check the battery for electrolyte level gravity and voltage 3 14 Manual valve opened Check the manual valve Manual val...

Page 285: ...Disassemble and check the PTT unit 7 34 Refer Symptom 2 Cause 1 Cause 2 Checking step to page Troubleshooting the lower unit Symptom 1 Shift mechanism of the forward gear and reverse gear does not operate properly 3 9 3 9 6 9 6 39 6 5 6 34 Remote control box malfunction Shift rod operation malfunction Shift cable and shift cable end malfunction Check the remote con trol box Check the shift cable a...

Page 286: ... 4 10 Checking the CDI unit 8 9 Checking the charge coil 8 13 Checking the check valve 4 18 Checking the choke solenoid 3 10 8 19 Checking the compression pressure 5 1 Checking the connecting rod big end side clearance 5 34 Checking the connecting rod small end axial play 5 34 Checking the cooling water passage 3 4 Checking the cooling water pilot hole 1 28 Checking the crank position sensor 8 11 ...

Page 287: ...ing system 1 27 Checking the stopper and throttle link position 3 7 Checking the thermostat 3 3 Checking the thermoswitch 8 14 Checking the throttle sensor 3 6 Checking the top cowling 3 2 Checking the upper case 7 10 Checking the water pump and shift rod 6 5 6 34 Clamp bracket and swivel bracket 7 16 Control system 3 5 Crankcase 5 23 Cylinder head 5 21 D Dimension 2 9 Disassembling the carburetor...

Page 288: ...g counter rotation model 6 35 Propeller shaft housing regular rotation model 6 6 Propeller size 1 24 PTT motor 7 27 PTT unit 7 22 R Removing the clamp bracket 7 18 Removing the crankcase 5 28 Removing the cylinder head 5 22 Removing the drive shaft 6 14 6 45 Removing the electrical component 5 13 Removing the exhaust cover 5 20 Removing the flywheel magnet 5 12 Removing the intake manifold 5 17 Re...

Page 289: ...iew 8 7 Troubleshooting the lower unit 9 8 Troubleshooting the power unit 9 1 Troubleshooting the power unit trouble code not available 9 2 Troubleshooting the power unit using the diagnostic flash indicator 9 1 Troubleshooting the PTT unit 9 7 U Upper case steering arm 7 5 V Ventilation 1 3 ...

Page 290: ...Starter relay f Battery g Choke solenoid h Oil feed pump remote oil tank j Oil level sensor remote oil tank å To remote control box switch panel To trim meter ç To oil level lamp Color code B Black B Br Black brown B G Black green B R Black red B W Black white B Y Black yellow Br Brown G Green G L Green blue G R Green red G W Green white Gy Gray L Blue L G Blue green L R Blue red L W Blue white L ...

Page 291: ......

Page 292: ...YAMAHA MOTOR CO LTD Printed in Japan Aug 2005 1 4 1 E_2 Printed on recycled paper 250G L250G ...

Page 293: ...L G R R R R R R R Br Br B B Sb Lg R Sb Lg Sb Lg Lg B Sb B B B B B B B B B B Br B P Sb Lg W Y L L L B B R L W L G L Y L R L R B Y B Y P O G P Y L W R W B W Y W G W L W Br L B R R Br L B R R Br W B B P G Y G L G R G W R W R W R R R W R W B W B W B W B B B B B W B W B W B O B G B Y B R B R L Y L Y L W Y R B Y B Y G G G G L G W B Y B Y G G G W R W B W Y W G W L W Br W R W B W Y W G W L W Br B Br B L L...

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