Yamaha 40V Service Manual Download

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8-21

–

ELEC

STARTING SYSTEM

STARTER RELAY

1. Inspect:

●

Brown lead terminal

●

Black lead terminal
Loose

→

Tighten.

2. Check:

●

Relay operation
Does not function

→

Replace.

Checking steps:

●

Connect the tester between the termi-
nals of the starter relay as shown.

●

Connect a 12 V battery.

Brown lead

→

Positive terminal

Black lead

→

Negative terminal

●

Check that there is continuity between
the starter relay terminals.

FUSE

1. Check:

●

Fuse
Blown

→

Replace.

Fuse rating:

12 V - 10 A

Summary of Contents for 40V

Page 1: ...LIT 18616 01 81 290320 SERVICE MANUAL 40V 50H WORLD WIDE 40W 50W USA CANADA...

Page 2: ...ls may differ in detail from the descriptions and illustrations given in this publica tion Use only the latest edition of this manual Authorized Yamaha dealers are notified periodically of modificatio...

Page 3: ...h Section MODEL INDICATION Multiple models are shown in this manual These indications are noted as follows THE ILLUSTRATIONS Some illustrations in this manual may differ from the model you have This i...

Page 4: ...MO 40VWH 40VE 40VEO 40VEHTO 40VET Starting system Manual Manual Manual Manual Manual Electric Electric Electric Electric Electric Control system Tiller Tiller Tiller Remote Tiller Remote Remote Tiller...

Page 5: ...contents and notes of the job For the meanings of the symbols refer to the next page s 4 The REMOVAL AND INSTALLATION CHART 4 is attached to the exploded diagram and explains the job steps part names...

Page 6: ...o J in an exploded diagram indicate grade of lubricant and location of lubrication point G Apply Yamaha 2 stroke outboard motor oil H Apply Yamaha gear case lubricant I Apply molybdenum disulfide oil...

Page 7: ...TION 1 SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR LOWER UNIT 6 LOWER BRACKET UNIT 7 BRKT ELECTRICAL SYSTEM 8 ELEC TROUBLE ANALYSIS 9 GEN INFO INSP...

Page 8: ......

Page 9: ...ERIAL NUMBER 1 1 STARTING SERIAL NUMBERS 1 1 SAFETY WHILE WORKING 1 2 FIRE PREVENTION 1 2 VENTILATION 1 2 SELF PROTECTION 1 2 OILS GREASES AND SEALING FLUIDS 1 2 GOOD WORKING PRACTICES 1 3 DISASSEMBLY...

Page 10: ...4 Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as fol lows Model Approved model code Starting serial No Model Approved model code Starting serial No World wide USA CANAD...

Page 11: ...avier than air and is deadly if inhaled in large quantities Engine exhaust gases are harmful to breathe When test running an engine indoors maintain good ventilation SELF PROTECTION Protect your eyes...

Page 12: ...led wiping rag in one s pocket 4 Hands and any other part of the body which have been in contact with lubri cants or lubricant contaminated cloth ing should be thoroughly washed with hot water and soa...

Page 13: ...parts with compressed air on dis assembling them 2 Oil the contact surfaces of moving parts on assembly 3 After assembly check that moving parts operate normally 4 Install bearings with the manufactur...

Page 14: ...tools recommended by Yamaha will aid the work and enable accu rate assembly and tune up Improvisations and use of improper tools can cause damage to the equipment NOTE For U S A and Canada use part n...

Page 15: ...Thickness gauge YU 26900 9 N A Shimming 11 Pinion height gauge N A 90890 06702 Pinion shimming 12 Digital caliper N A 90890 06704 Pinion shimming Forward shimming 13 Gauge block YB 34432 9 N A Pinion...

Page 16: ...1 7 GEN INFO E SPECIAL TOOLS...

Page 17: ...l seal 10 Needle bearing remover YB 06112 90890 06614 Propeller shaft needle bearing 11 Needle bearing installer YB 06111 90890 06614 Propeller shaft needle bearing 12 Bearing outer race puller clow N...

Page 18: ...1 9 GEN INFO E SPECIAL TOOLS...

Page 19: ...ear outer bearing 26 Shift rod wrench YB 06052 N A Shift rod 27 Tilt cylinder wrench YB 06175 2B 90890 06544 PTT 28 Bearing depth plate N A 90890 06603 Propeller shaft needle bearing Drive shaft needl...

Page 20: ......

Page 21: ...EC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 7 ENGINE 2 7 LOWER 2 9 ELECTRICAL 2 10 DIMENSION 1 2 13 DIMENSION 2 2 15 TIGHTENING TORQUE 2 17 SPECIFIED TORQUE 2 1...

Page 22: ...000 Full throttle operating range rpm 4 500 5 500 Maximum fuel con sumption L US gal Imp gal h at rpm 18 5 4 9 4 1 at 5 500 ENGINE Type 2 stroke L Number of cylinder 3 Total displacement cm3 cu in 698...

Page 23: ...tilt system Manual tilt Tilt angle degree 8 12 16 20 24 8 12 16 20 24 Tilt up angle degree 66 69 66 Trim angle degree at 12 transom 4 20 Shallow water crushing angle degree Tilt angle 18 Tilt angle 18...

Page 24: ...NCE Output ISO kW hp rpm 29 4 40 5 000 Full throttle operating range rpm 4 500 5 500 Maximum fuel con sumption L US gal Imp gal h at rpm 18 5 4 9 4 1 at 5 500 ENGINE Type 2 stroke L Number of cylinder...

Page 25: ...ystem Manual tilt Power trim tilt Manual tilt Power trim tilt Tilt angle degree 8 12 16 20 24 Tilt up angle degree 66 69 Trim angle degree at 12 transom 4 20 Shallow water crushing angle degree Tilt a...

Page 26: ...ANCE Output ISO kW hp rpm 36 8 50 5 000 Full throttle operation range rpm 4 500 5 500 Maximum fuel con sumption L US gal Imp gal h at rpm 22 5 8 4 8 at 5 500 ENGINE Type 2 stroke L Number of cylinder...

Page 27: ...nual tilt Hydro tilt Manual tilt Hydro tilt Manual tilt Power trim tilt Tilt angle degree 8 12 16 20 24 8 12 16 20 24 Tilt up angle degree 66 69 66 69 Trim angle degree at 12 transom 4 20 4 20 Shallow...

Page 28: ...0 002 0 003 2nd mm in 0 03 0 07 0 001 0 003 Over size piston mm in Diameter 1st 1 mm in 67 25 2 648 2nd mm in 67 50 2 657 PISTON PIN Diameter mm in 17 995 18 000 0 7085 0 7087 PISTON RING 1st Type mm...

Page 29: ...W model M model E W model Identification mark 63B00 63D00 62W00 62X00 Float height mm in 15 0 1 0 0 59 0 04 Valve seat size mm in 1 2 0 05 Main jet M J 115 118 M 125 130 Main nozzle M N mm in 3 0 0 12...

Page 30: ...10 1 4 14 3 10 3 4 16 3 10 3 4 17 3 10 3 8 13 3 10 5 8 12 3 11 1 8 13 3 11 1 4 14 3 11 3 8 12 3 11 5 8 11 3 11 3 4 10 3 12 1 4 9 3 10 1 4 14 3 10 1 4 15 3 10 1 4 16 3 10 5 8 13 3 11 1 4 14 3 11 1 2 13...

Page 31: ...n 3 0 5 0 0 12 0 20 Rating Sec 30 RECTIFIER REGURATOR Output peak voltage R B cranking V 8 5 1 500 r min V 25 3 500 r min V 25 NEUTRAL SWITCH Length a on mm in 18 5 19 5 0 73 0 77 Length b off mm in 1...

Page 32: ...age minimum B O B W B Y B cranking V 125 1 500 r min V 140 3 500 r min V 110 Lighting coil output peak voltage minimum G G W cranking V 9 0 1 500 r min V 25 3 500 r min V 25 CDI UNIT Over revolution l...

Page 33: ...2 12 SPEC E MAINTENANCE SPECIFICATIONS...

Page 34: ...2 13 SPEC E MAINTENANCE SPECIFICATIONS DIMENSION 1...

Page 35: ...31 4 822 32 4 822 32 4 L 910 35 8 937 36 9 UL 1 010 39 8 1 040 40 9 1 040 40 9 L7 mm in 433 17 0 401 15 8 418 16 5 387 15 2 H4 S mm in 408 16 1 410 16 1 410 16 1 L 535 21 1 537 21 1 UL 649 25 6 651 25...

Page 36: ...2 15 SPEC E MAINTENANCE SPECIFICATIONS DIMENSION 2 MANUAL TILT MODEL HYDRO TILT PTT MODEL...

Page 37: ...208 8 2 254 10 0 B3 mm in 121 5 4 8 163 5 6 4 B4 mm in 32 1 3 50 8 2 0 B5 mm in 131 5 5 2 180 7 1 B6 mm in 245 9 6 355 14 0 B9 mm in 25 1 0 18 5 0 7 B11 mm in 90 5 3 6 B12 mm in 57 2 2 B13 mm in 122 4...

Page 38: ...0 29 572 LT Propeller shaft housing Bolt M8 2 16 1 6 11 Pinion nut Nut M12 1 75 7 5 54 Water inlet Bolt M6 1 5 0 5 3 6 242 LT BRACKET Tiller handle mounting Nut M10 2 38 3 8 27 Steering friction moun...

Page 39: ...ons for special compo nents or assemblies are given in applicable sections of this manual To avoid causing warpage tighten multifastener assemblies in crisscross fashion in progressive stages until th...

Page 40: ......

Page 41: ...ent 3 2 Throttle cable adjustment 3 3 Shift cable adjustment 3 4 Start in gear protection adjustment 3 5 Idle speed adjustment 3 5 OIL INJECTION SYSTEM 3 6 Oil tank water drain 3 6 Oil pump link adjus...

Page 42: ...Exhaust leakage Inspection Cooling water passage Cleaning CONTROL SYSTEM Throttle link Inspection Adjustment 3 2 Throttle cable Inspection Adjustment 3 3 Shift cable Inspection Adjustment 3 4 Start in...

Page 43: ...he full retarding stopper a Check the CDI unit indicator so that it aligns with the specified marking on the plate Full retarded position ATDC 7 Turn the magneto control lever so that it contacts the...

Page 44: ...or aligns with the specified marking on the plate Full retarded position ATDC 7 Connect the magneto control rod Turn the magneto control lever so that it contacts the full advance adjusting screw 4 Ad...

Page 45: ...n 8 mm 0 31 in NOTE Put the UP mark upward Shift cable adjustment 1 Check Shift operation Incorrect Adjust 2 Adjust Shift cable joint position 3 Check Shift operation Unsmooth operation Repair Adjustm...

Page 46: ...case Tighten the lock nut Idle speed adjustment NOTE Before adjusting the idle speed be sure to adjust the throttle link 1 Measure Idle speed Out of specification Adjust 2 Adjust Idle speed Idle spee...

Page 47: ...p screw in or out until specified idle speed is obtained Turning in Idle speed becomes higher Turning out Idle speed becomes lower While lightly pushing the throttle lever of the lower carburetor in t...

Page 48: ...valve Check the clearance a between the oil pump lever and full open side stopper Adjustment steps Loosen the lock nut Remove the oil pump link joint at the pump Fully open the carburetor throttle va...

Page 49: ...lug 1 Remove the drain plug then the oil level plug 2 and drain the oil thor oughly Place the outboard motor in an upright position Fill the gear oil through the drain hole until it overflows at the l...

Page 50: ...ttery electrolyte is poisonous and dan gerous causing severe burns etc It con tains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quant...

Page 51: ...Worn Damaged Replace Insulator color 2 Distinctly different color Check the engine condition 2 Clean Spark plug Clean the spark plug with a plug cleaner or wire brush 3 Inspect Spark plug type Color g...

Page 52: ...ark plug NOTE Before installing the spark plug clean the gasket surface and the plug surface NOTE If a torque wrench is not available a good estimate of the correct torque is a further 1 4 to 1 2 turn...

Page 53: ...ETOR 4 7 EXPLODED DIAGRAM 4 7 REMOVAL AND INSTALLATION CHART 4 8 SERVICE POINTS 4 9 Carburetor inspection 4 9 Carburetor assembly 4 10 PRIME STARTER 4 11 EXPLODED DIAGRAM 4 11 REMOVAL AND INSTALLATION...

Page 54: ...4 1 FUEL E FUEL JOINT FUEL FILTER AND FUEL PUMP FUEL JOINT FUEL FILTER AND FUEL PUMP EXPLODED DIAGRAM...

Page 55: ...1 5 Clip 2 6 Fuel hose joint filter 1 7 Fuel hose filter pump 1 8 Nut 1 9 Fuel filter 1 10 Clip 2 11 Fuel hose filter pump 1 12 Fuel hose pump joint pipe 1 13 Bolt with washer 2 6 40 mm 14 Fuel pump...

Page 56: ...4 3 FUEL E FUEL JOINT FUEL FILTER AND FUEL PUMP FUEL LINE LAYOUT M model 1 Fuel pump 2 Fuel filter W E model 1 Fuel pump 2 Fuel filter 3 Electrothermal valve...

Page 57: ...e for 10 sec Replace Measuring steps Attach the Mity vac Mity vac YB 35956 90890 06756 Apply the specified pressure Specified pressure 50 kPa 0 5 kg cm2 7 1 psi Fuel filter inspection 1 Inspect Filter...

Page 58: ...4 5 FUEL E CARBURETOR REMOVAL CARBURETOR REMOVAL EXPLODED DIAGRAM...

Page 59: ...Bolt 1 15 Electrothermal valve lead black 1 16 Electrothermal valve lead blue 1 17 Accelerator lever rod 1 18 Oil pump link rod 1 Oil injection model 19 Link joint 1 20 Choke link rod 1 M model 21 Li...

Page 60: ...4 7 FUEL E CARBURETOR CARBURETOR EXPLODED DIAGRAM...

Page 61: ...crew 1 7 Spring 1 8 Stopping screw 1 Middle carburetor only 9 Spring 1 10 Screw with washer 4 4 14 mm 11 Float chamber 1 12 Float chamber packing 1 13 Screw 1 4 mm 14 Arm pin 1 15 Float 1 16 Needle va...

Page 62: ...usly affect performance Carburetor inspection 1 Inspect Carburetor body Crack Damage Replace Contamination Clean 2 Inspect Pilot screw Bend Wear Replace 3 Inspect Main jet Pilot jet Main nozzle Contam...

Page 63: ...easure Float height a Out of specification Fold the tab b to adjust float arm height NOTE The float should be resting on the needle valve but not compressing the needle valve Take measurement at the e...

Page 64: ...4 11 FUEL E PRIME STARTER PRIME STARTER EXPLODED DIAGRAM...

Page 65: ...Carburetor ass y Refer to CHARBURETOR REMOVAL 1 Screw with washer 2 4 10 mm 2 Electrothermal valve 1 3 Clip 1 4 Fuel enrichment hose 1 5 Clip 2 6 Fuel hose cover chamber 1 7 Screw with washer 4 8 Pump...

Page 66: ...Bend Damage Replace 2 Measure Fuel enrichment valve resistance Out of specification Replace NOTE When measuring the resistance of 10 or less using the digital tester the correct measurement cannot be...

Page 67: ...4 14 FUEL E PRIME STARTER...

Page 68: ...4 15 FUEL E OIL TANK OIL TANK EXPLODED DIAGRAM...

Page 69: ...Bolt with washer 1 11 Oil tank ass y 1 OIL TANK DISASSEMBLY 1 Oil level sensor 1 2 Oil strainer 1 3 Strainer gasket 1 4 Oil tank cap 1 5 Hook 1 6 Hook band 1 7 Filler tube band 1 8 Filler tube 1 9 Sp...

Page 70: ...4 17 FUEL E OIL TANK OIL LINE LAYOUT 1 Electrothermal valve EM E model 2 Oil level sensor 3 Oil drain hose 4 Oil tank 5 Oil pump...

Page 71: ...rack Replace Oil strainer inspection 1 Inspect Oil strainer Crack Clog Replace Contamination Clean Check valve inspection 1 Check Check valve operation Does not function Replace NOTE Check the operati...

Page 72: ...4 19 FUEL E OIL PUMP OIL PUMP EXPLODED DIAGRAM...

Page 73: ...e 1 3 Clip 1 4 Oil return hose 1 5 Clip 1 6 Plate washer 1 7 Link joint 1 8 Clip 3 9 Oil delivery hose 1 1 250 mm 10 Oil delivery hose 2 1 180 mm 11 Oil delivery hose 3 1 90 mm 12 Bolt 1 13 Bolt 1 14...

Page 74: ...ion 5 6 Spiral spring inspection 5 6 Starter rope inspection 5 6 Starter rope installation 5 7 Sheave drum installation 5 7 Spiral spring setting 5 7 Recoil starter checking 5 7 FLYWHEEL MAGNETO AND M...

Page 75: ...linder body inspection 5 29 Piston to cylinder clearance 5 30 Oil pump driven gear inspection 5 30 Cylinder body and crankcase installation 5 30 CRANK SHAFT AND PISTON 5 31 EXPLODED DIAGRAM 5 31 REMOV...

Page 76: ...5 1 POWR E POWER UNIT REMOVAL POWER UNIT REMOVAL EXPLODED DIAGRAM...

Page 77: ...wire lead coupler 1 9 PTT motor lead 2 PTT model 10 PTT switch lead coupler 1 11 Choke lever rod 1 M model 12 Start in gear projection wire 1 13 Clip 1 14 Shift cable 1 15 Clip 1 16 Throttle cable 1...

Page 78: ...5 3 POWR E RECOIL STARTER RECOIL STARTER EXPLODED DIAGRAM...

Page 79: ...6 Drive pawl spring 1 7 Bolt with washer 1 6 30 mm 8 Stay 1 9 Rope roller 1 0 Collar 1 A Nut 1 B Bolt with washer 2 6 12 mm C Nut 1 D Bolt with washer 1 6 20 mm E Plane washer 1 F Bushing 1 G Sheave d...

Page 80: ...g the sheave drum be sure to turn the sheave drum upside down to prevent the spiral spring from popping up at you NOTE Insert a slotted head screwdriver into the hole in the sheave drum and remove the...

Page 81: ...ace them as a set Bushing inspection 1 Inspect Bushing Crack Damage Replace Sheave drum inspection 1 Inspect Sheave drum Crack Damage Replace Spiral spring inspection 1 Inspect Spiral spring Broken Be...

Page 82: ...sheave drum Place the rope at the cutaway Sheave drum installation 1 Install Sheave drum 1 NOTE Position the inner end of the spiral spring on the retainer post of the sheave drum Spiral spring settin...

Page 83: ...5 8 POWR E RECOIL STARTER...

Page 84: ...5 9 POWR E FLYWHEEL MAGNETO AND MAGNETO BASE FLYWHEEL MAGNETO AND MAGNETO BASE EXPLODED DIAGRAM...

Page 85: ...r to RECOIL STARTER 1 Screw 1 6 40 mm 2 Screw 2 6 35 mm 3 Washer 3 4 Flywheel cover 1 5 Collar 3 6 Bolt E model 3 8 14 mm 7 Bolt M model 3 8 20 mm 8 Starter pulley E model 1 9 Starter pulley M model 1...

Page 86: ...asily slip off Flywheel holder YB 06139 90890 06522 2 Remove Flywheel magneto For USA and CANADA Except for USA and CANADA CAUTION Keep the nut side flush with the crank shaft end until the flywheel c...

Page 87: ...5 12 POWR E FLYWHEEL MAGNETO AND MAGNETO BASE...

Page 88: ...5 13 POWR E ELECTRICAL UNIT REMOVAL ELECTRICAL UNIT REMOVAL EXPLODED DIAGRAM...

Page 89: ...oupler 7 6 Bolt with washer 2 7 Fitting plate ass y 1 8 Battery cable 1 9 Bolt with washer 2 10 PTT switch coupler 1 PTT model 11 PTT motor lead 2 Sky blue and light green leads 12 Bolt with washer 4...

Page 90: ...5 15 POWR E ELECTRICAL UNIT ELECTRICAL UNIT EXPLODED DIAGRAM...

Page 91: ...it Refer to ELECTRICAL UNIT REMOVAL 1 Fuse 1 2 Clamp 1 3 Bolt with washer 1 4 Clamp 1 5 Bolt with washer 1 6 Rectifier regurator 1 7 Nut 2 8 Spring washer 1 9 Bracker 1 10 Relay holder 1 11 Starter re...

Page 92: ...5 17 POWR E REED VALVE AND CHECK VALVE REED VALVE AND CHECK VALVE EXPLODED DIAGRAM...

Page 93: ...tch stay 1 WH EHTO model 5 Intake manifold ass y 1 6 Screw with washer 6 5 14 mm 7 Reed valve ass y 3 8 Valve plate gasket 2 9 Reed valve plate 1 10 Clip 6 Oil injection model 11 Oil delivery hose 1 1...

Page 94: ...d valve inspection 1 Inspect Reed valve Crack Damage Replace 2 Measure Valve bending a Out of specification Replace 3 Measure Valve stopper height b Out of specification Replace Valve bending limit 0...

Page 95: ...5 20 POWR E REED VALVE AND CHECK VALVE...

Page 96: ...5 21 POWR E CYLINDER HEAD THERMOSTAT AND EXHAUST COVER CYLINDER HEAD THERMOSTAT AND EXHAUST COVER EXPLODED DIAGRAM...

Page 97: ...ermostat cover 1 9 Thermostat cover gasket 1 10 Thermostat 1 EXHAUST COVER REMOVAL Oil tank ass y Refer to OIL TANK in chapter 4 11 Clip 1 12 Pilot water hose 1 13 Bolt with washer Bolt with washer 14...

Page 98: ...Do not scratch the fitting surfaces of the cylinder and cylinder cover 2 Measure Cylinder head warpage Use a straightedge and thickness gauge Out of specification Resurface or replace Warpage limit 0...

Page 99: ...sure Valve opening temperature Valve lift Out of specification Replace Water temperature Valve lift Below 48 52 C 118 126 F 0 mm 0 in Above 60 C 140 F Min 3 mm 0 12 in Measuring steps Suspend thermost...

Page 100: ...5 25 POWR E CRANKCASE AND CYLINDER BODY CRANKCASE AND CYLINDER BODY EXPLODED DIAGRAM...

Page 101: ...Clip 8 2 Drain less hose 1 200 mm 3 Drain less hose 1 310 mm 4 Drain less hose 1 360 mm 5 Drain less hose 1 240 mm 6 Bolt with washer 6 6 mm 7 Bolt with washer 8 8 mm 8 Crank case 1 9 Cylinder body 1...

Page 102: ...5 27 POWR E CRANKCASE AND CYLINDER BODY EXPLODED DIAGRAM...

Page 103: ...ASE AND CYLINDER BODY REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points D Hose nipple 1 E Hose joint 3 F Check valve 2 G Check valve 2 H Hose joint 1 Reverse the removal step...

Page 104: ...r NOTE Do not scratch the fitting surfaces of the cyl inder and exhaust cover 3 Measure Cylinder bore D Use cylinder gauge Out of specification Rebore or replace NOTE Measure the cylinder bore D in pa...

Page 105: ...haft and piston NOTE Align the piston ring end gaps with the respective locating pins Fit the bearing and the labyrinth seal locating pins in the cylinder body 2 Apply Gasket maker Onto the connecting...

Page 106: ...5 31 POWR E CRANK SHAFT AND PISTON CRANK SHAFT AND PISTON EXPLODED DIAGRAM...

Page 107: ...13 Oil pump drive gear 1 Oil injection model 14 Spacer 1 Pre mixed model OIL SEAL HOUSING DISASSEMBLY 1 O ring 1 2 Oil seal 1 3 Oil seal 2 Reverse the removal steps for installation NOTE Remove the cr...

Page 108: ...d needle bearings are reused they should be marked with No 1 2 and 3 so that they are not confused Piston ring removal 1 Remove Piston ring NOTE Remove the piston ring from the piston by opening the r...

Page 109: ...e Piston pin boss inside diameter 18 008 18 015 mm 0 7090 0 7093 in Piston pin and small end bearing inspection 1 Inspect Piston pin Small end bearing Signs of heat discoloration Replace Scratch Damag...

Page 110: ...n ring into the cylinder Push the ring with the piston crown End gap Top 0 40 0 60 mm 0 016 0 024 in 2nd 0 40 0 60 mm 0 016 0 024 in End gap limit Top 0 80 mm 0 031 in 2nd 0 80 mm 0 031 in Measuring p...

Page 111: ...95 mm 2 122 2 124 in Crank width B 32 88 33 10 mm 1 294 1 303 in Runout limit 0 03 mm 0 001 in 3 Measure Axial play Out of specification Replace Axial play limit 2 0 mm 0 08 in 4 Inspect Crankshaft b...

Page 112: ...y NOTE Piston rings should be replaced as a set Crankshaft and piston installation 1 Install Small end bearing needle 2 Install Piston 1 Piston pin 2 Piston pin clip 3 CAUTION Do not allow the clip op...

Page 113: ......

Page 114: ...e gear inspection 6 8 Bearing inspection 6 8 Propeller shaft housing inspection 6 8 Dog clutch inspection 6 8 Propeller shaft inspection 6 8 Propeller shaft housing assembly 6 9 DRIVE SHAFT FORWARD GE...

Page 115: ...AND CANADA 6 19 Pinion gear shim 6 19 Forward gear shim 6 21 Reverse gear shim 6 22 SHIM SELECTION EXCEPT FOR USA AND CANADA 6 23 Pinion gear shim 6 23 Forward gear shim 6 25 Reverse gear shim 6 26 B...

Page 116: ...6 1 LOWR E LOWER UNIT REMOVAL LOWER UNIT REMOVAL EXPLODED DIAGRAM...

Page 117: ...odel 14 Spring washer 4 15 Plane washer 4 16 Lower unit 1 17 Dowel pin 2 18 Extension 1 X model 19 Dowel pin 2 20 Stud bolt 4 Reverse the removal steps for installation NOTE If the propeller nut does...

Page 118: ...6 3 LOWR E WATER PUMP WATER PUMP EXPLODED DIAGRAM...

Page 119: ...1 8 Cartridge plate 1 9 Plate gasket 1 10 Pin 2 11 Water seal cover 1 12 Water seal rubber 1 Reverse the removal steps for installation NOTE When installing the water pump housing align the hole in i...

Page 120: ...6 5 LOWR E PROPELLER SHAFT AND REVERSE GEAR PROPELLER SHAFT AND REVERSE GEAR EXPLODED DIAGRAM...

Page 121: ...him 3 Ball bearing 1 4 O ring 1 5 O ring 2 6 Oil seal 2 7 Needle bearing 1 8 Propeller shaft housing 1 PROPELLER SHAFT DISASSEMBLY 9 Cross pin ring 1 0 Cross pin 1 A Shift plunger 1 B Shift slider 1 C...

Page 122: ...17 2 Stopper guide plate 90890 06501 4 Center bolt 90890 06504 5 Propeller shaft housing disassembly 1 Remove Reverse gear 2 Remove Ball bearing 1 For USA and CANADA Except for USA and CANADA Bearing...

Page 123: ...Inspect Tooth Dog Wear Damage Replace Bearing inspection 1 Inspect Bearing Pitting Rumbling Replace Propeller shaft housing inspection 1 Clean Propeller shaft housing Use a soft brush and solvent 2 In...

Page 124: ...NADA Except for USA and CANADA Depth a 3 0 3 5 mm 0 12 0 14 in Depth b 23 0 23 5 mm 0 91 0 93 in Driver rod YB 06071 1 90890 06604 3 Needle bearing attachment YB 06111 2 90890 06614 4 Bearing depth pl...

Page 125: ...6 10 LOWR E PROPELLER SHAFT AND REVERSE GEAR...

Page 126: ...6 11 LOWR E DRIVE SHAFT FORWARD GEAR AND SHIFT ROD DRIVE SHAFT FORWARD GEAR AND SHIFT ROD EXPLODED DIAGRAM...

Page 127: ...using ass y 1 5 Plane washer 1 6 Forward gear ass y 1 7 Shift rod ass y 1 8 Shift cam 1 DRIVE SHAFT OIL SEAL HOUS ING DISASSEMBLY 1 Oil seal cover 1 2 O ring 1 3 Oil seal 2 4 Drive shaft oil seal hous...

Page 128: ...6 13 LOWR E DRIVE SHAFT FORWARD GEAR AND SHIFT ROD EXPLODED DIAGRAM...

Page 129: ...STALLATION CHART Step Procedure Part name Q ty Service points F Forward gear shim G Screw 1 H Water inlet cover 1 1 I Water inlet cover 2 1 J Nut 1 K Hose nipple 1 L Bolt with washer 1 M Anode 1 N Low...

Page 130: ...Drive shaft holder YB 06079 90890 06517 1 Pinion nut wrench 90890 06505 2 Socket adapter 90890 06506 3 Bearing separator YB 06219 90890 06534 Lower case disassembly 1 Remove Drive shaft bearing outer...

Page 131: ...ept for USA and CANADA Slide hammer set YB 06096 1 Bearing outer race puller 90890 06523 2 Bearing outer race puller claw 90890 06532 3 Stopper guide stand 90890 06538 4 Pinion and forward gear inspec...

Page 132: ...Crack Damage Replace Lower case assembly 1 Install Forward gear shim 1 Forward gear bearing outer race 2 Bearing installer YB 41446 90890 06626 Driver rod YB 06071 90890 06605 2 Install Drive shaft ne...

Page 133: ...071 90890 06606 2 Depth a 0 0 0 5 mm 0 00 0 02 in Bearing installer YB 06167 90890 06628 Driver rod YB 06071 90890 06605 Forward gear assembly 1 Install Forward gear Taper roller bearing For USA and C...

Page 134: ...ess T3 by selecting shims until the specified measure ment M is obtained with the special tool 1 Calculate Specified measurement M NOTE P is the deviation of the lower case dimen sion from standard It...

Page 135: ...a 0 50 mm shim 3 Install Pinion Pinion nut 4 Check Specified measurement M Out of specified measurement Adjust NOTE Check the fit between the shimming gauge and lower surface of the pinion Perform th...

Page 136: ...dable assume an F mark of 0 and check the backlash when the unit is assembled If the F value is negative then subtract the F value from the measurement Example If F mark is 5 then M 0 06 mm 5 100 0 06...

Page 137: ...ate Thickness gauge YU 26900 9 4 Adjust Shim s Remove or add Available shim thickness 0 05 0 08 0 12 0 30 and 0 50 mm Reverse gear shim NOTE Find reverse gear shim thickness T2 by backlash measurement...

Page 138: ...haft so that the shaft is at the center of the hole Tighten the wing nuts 1 4 turn after con tacting the fixing plate 2 Install Pinion Pinion nut 3 Measure Measurement M NOTE Measure the fit between t...

Page 139: ...tive then subtract the P value from the measurement Example If M is 11 70 mm and P mark is 5 then T3 11 70 mm 11 30 5 100 0 40 0 05 mm 0 45 mm If M is 11 70 mm and P mark is 5 then T3 11 70 mm 11 30 5...

Page 140: ...the lower case dimen sion from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is missing or unreadable assume an F mark of 0 and check the ba...

Page 141: ...measurement Measure the backlash with the original shim s If the original shim s is unavailable start with a 0 50 mm shim BACKLASH MEASUREMENT NOTE Do not install the water pump compo nents when meas...

Page 142: ...R Center bolt 5 Nm 0 5 m kg 3 6 ft lb Set the lower unit upside down Attach the backlash indicator on the drive shaft 18 mm in diameter Backlash indicator YB 6265 90890 06706 Attach the dial gauge on...

Page 143: ...0 12 0 30 and 0 50 mm Reverse gear 1 Measure Reverse gear backlash Out of specification Adjust Backlash 0 71 0 98 mm 0 028 0 039 in Measuring steps Load the reverse gear by installing the propeller wi...

Page 144: ...ase YU 34481 90890 06705 While pulling the drive shaft slowly turn the drive shaft clockwise and counterclockwise then measure the backlash when the drive shaft stops at each direction Reverse gear ba...

Page 145: ......

Page 146: ...SSEMBLY 7 7 EXPLODED DIAGRAM 7 7 REMOVAL AND INSTALLATION CHART 7 8 SERVICE POINTS 7 8 Throttle arm inspection 7 8 Throttle shift ass y inspection 7 8 Cam plate inspection 7 8 Bushing inspection 7 8 S...

Page 147: ...PUMP HOUSING AND MOTOR REMOVAL 7 27 EXPLODED DIAGRAM 7 27 REMOVAL AND INSTALLATION CHART 7 28 SERVICE POINTS 7 28 TILT CYLINDER 7 29 EXPLODED DIAGRAM 7 29 REMOVAL AND INSTALLATION CHART 7 30 SERVICE P...

Page 148: ...7 1 BRKT E TILLER HANDLE REMOVAL TILLER HANDLE REMOVAL EXPLODED DIAGRAM...

Page 149: ...er 1 EHTO TH model 12 Trim sensor lead coupler 1 13 Extension wire lead coupler 1 14 Clip 1 15 Shift cable 1 16 Clip 1 17 Throttle cable 1 18 Bolt 2 19 Fitting plate ass y 1 20 Clamp 1 M model 21 Engi...

Page 150: ...7 3 BRKT E TILLER HANDLE TILLER HANDLE EXPLODED DIAGRAM...

Page 151: ...rter cable 10 Shift cable 1 Longer cable 11 Bolt with washer 2 6 16 mm 12 Cable bracket 1 13 Screw with washer 2 14 Shift lever cover 1 15 Bolt with washer 4 16 Screw 1 17 Handle grip ass y 1 18 Plain...

Page 152: ...7 5 BRKT E TILLER HANDLE EXPLODED DIAGRAM...

Page 153: ...r installation SERVICE POINTS Control cable inspection 1 Inspect Throttle cable Shift cable Kink Fray Stick Replace Bushing inspection 1 Inspect Bushing Wear Crack Damage Replace Shift lever inspectio...

Page 154: ...7 7 BRKT E LINK ASS Y DISASSEMBLY LINK ASS Y DISASSEMBLY EXPLODED DIAGRAM...

Page 155: ...w 2 7 Spring guide 1 8 Roller 1 9 Actuator 1 10 Spring 1 11 Circlip 1 12 Cam plate 1 13 Bushing 1 14 Frame 1 15 Stopper 1 Neutral opening limit model Reverse the removal steps for installation SERVICE...

Page 156: ...7 9 BRKT E SHIFT ACTUATOR AND BOTTOM COWLING SHIFT ACTUATOR AND BOTTOM COWLING EXPLODED DIAGRAM...

Page 157: ...sor lead 1 PTT model 6 Grommet 1 7 Bolt 4 6 30 mm 8 Plane washer 4 9 Bottom cowling ass y 1 10 Seal rubber 1 11 Collar 4 12 Grommet 4 13 Grommet 1 SHIFT ACTUATOR ASS Y 1 Plug screw 1 2 Spring 1 3 Ball...

Page 158: ...7 11 BRKT E UPPER CASE REMOVAL UPPER CASE REMOVAL EXPLODED DIAGRAM...

Page 159: ...lt with washer 4 8 30 mm 3 Lower mount housing 2 4 Mount damper 2 5 Nut 2 6 Nut 2 7 Plane washer 2 12 8 22 5 mm 8 Lead wire 1 9 Plane washer 2 12 8 22 5 mm 10 Upper case ass y 1 11 Lower rubber mount...

Page 160: ...7 13 BRKT E UPPER CASE AND EXHAUST MANIFOLD UPPER CASE AND EXHAUST MANIFOLD EXPLODED DIAGRAM...

Page 161: ...y Refer to UPPER CASE REMOVAL 1 Bolt with washer 2 2 Upper case 1 3 Dowel pin 2 EXHAUST MANIFOLD REMOVAL 4 Muffler seal 1 5 Seal rubber 1 6 Bolt with washer 4 8 30 mm 7 Exhaust guide 1 8 Grommet 1 9 W...

Page 162: ...7 15 BRKT E CLAMP BRACKET CLAMP BRACKET Manual tilt EXPLODED DIAGRAM...

Page 163: ...1 Bolt 1 12 Collar 1 13 Cap 2 14 Self lock nut 1 15 Clamp bracket plate 1 16 Clamp bracket 2 ass y 1 17 Plane washer 1 18 Shallow water drive lever 1 Shallow water drive model 19 Spring 1 20 Tilt leve...

Page 164: ...7 17 BRKT E CLAMP BRACKET CLAMP BRACKET Hydro tilt Power trim and tilt EXPLODED DIAGRAM...

Page 165: ...nipple 1 9 Wire lead 1 10 Tilt rod ass y 1 11 Nut 1 12 Plane washer 1 13 Stud bolt 1 14 Clamp bracket spacer ass y 1 15 Nut 1 16 Cap 2 17 Self lock nut 1 18 Clamp bracket 2 1 19 Plane washer 1 20 Swi...

Page 166: ...7 19 BRKT E STEERING BRACKET STEERING BRACKET EXPLODED DIAGRAM...

Page 167: ...emoval Upper case ass y Refer to UPPER CASE REMOVAL 1 Flange bolt 1 Manual tilt model 2 Seal rubber 1 3 Circlip 1 4 Lower mount housing 1 5 Steering bracket 1 6 Plane washer 1 7 Bushing 1 8 O ring 1 9...

Page 168: ...7 21 BRKT E SWIVEL BRACKET SWIVEL BRACKET EXPLODED DIAGRAM...

Page 169: ...2 1 3 Rod joint 3 4 Clip 1 5 Tilt lever shaft 1 6 Tilt lever 1 2 Shallow water drive model 7 Tilt lock rod 3 1 2 8 Tilt lock rod 4 1 9 Clip 1 Shallow water drive model 10 Pin 1 11 Lever 1 1 12 Spring...

Page 170: ...7 23 BRKT E SWIVEL BRACKET DISASSEMBLY SWIVEL BRACKET DISASSEMBLY EXPLODED DIAGRAM...

Page 171: ...ep for removal Upper case ass y Refer to UPPER CASE REMOVAL Clamp bracket Refer to CLAMP BRACKET Steering bracket Refer to STEERING BRACKET 1 Bolt with washer 1 6 10 mm 2 Spring hook 1 3 Spring 1 4 Sp...

Page 172: ...7 25 BRKT E TILT UNIT REMOVAL TILT UNIT REMOVAL EXPLODED DIAGRAM...

Page 173: ...motor lead Trim sensor lead 3 Bolt with washer 1 6 10 mm 4 Wire lead 1 5 Bolt with washer 1 6 Wire lead 1 7 Tilt rod ass y 1 8 Nut 1 9 Plane washer 1 10 Stud bolt 1 11 Clamp bracket spacer ass y 1 12...

Page 174: ...7 27 BRKT E TILT CYLINDER PUMP HOUSING AND MOTOR REMOVAL TILT CYLINDER PUMP HOUSING AND MOTOR REMOVAL EXPLODED DIAGRAM...

Page 175: ...ing ass y 1 Reverse the removal steps for installation WARNING When removing the plug screw PTT unit should be fully tilt up positioned SERVICE POINTS WARNING The PTT unit should be fully tilt up posi...

Page 176: ...7 29 BRKT E TILT CYLINDER TILT CYLINDER EXPLODED DIAGRAM...

Page 177: ...4 7 47 7 mm 6 O ring 1 58 5 54 5 mm 7 Inner cylinder end screw 1 8 Tilt rod sub ass y 1 9 Trim piston 1 10 O ring 1 50 7 43 7 mm 11 Backup ring 1 12 O ring 1 35 7 28 7 mm 13 O ring 1 39 0 35 0 mm 14 C...

Page 178: ...ormed Tilt rod inspection 1 Inspect Tilt rod Bend Excessive corrode Replace Rust lightly Polish with 400 600 abrasive paper Tilt cylinder inspection 1 Inspect Tilt cylinder Crack Excessive corrosion R...

Page 179: ...cylinder end screw Tilt cylinder wrench YB 06175 2B 90890 06544 Tilt cylinder assembly 1 Install Ball 1 Tilt cylinder 2 NOTE Apply the grease to the balls to prevent them from falling down To find any...

Page 180: ...7 33 BRKT E PUMP HOUSING PUMP HOUSING EXPLODED DIAGRAM...

Page 181: ...2 10 Retaining plate 1 11 Spring 1 8 8 4 3 mm 12 Valve support pin 1 13 Valve seat 1 14 Spring 1 8 8 21 8 mm 15 Valve seat 1 16 Valve support pin 1 17 Valve seat 1 18 O ring 1 13 7 10 7 mm 19 Filter...

Page 182: ...7 35 BRKT E PTT MOTOR PTT MOTOR EXPLODED DIAGRAM...

Page 183: ...R PUMP HOUS ING AND MOTOR REMOVAL 1 Screw 3 2 Stator 1 3 Armature ass y 1 4 Plane washer 1 5 O ring 1 55 8 52 0 mm 6 Brush ass y 1 7 Screw with washer 2 8 Lead wire 1 9 Brush ass y 1 10 Cover plate 1...

Page 184: ...Clean NOTE Remove all particles of metal with com pressed air 3 Measure Commutator diameter Out of specification Replace Commutator diameter Limit 21 mm 0 83 in 4 Inspect Armature coil continuity Out...

Page 185: ...ification Replace Brush length a Limit 3 5 mm 0 14 in 8 Inspect Base Crack Damage Replace 9 Inspect Stator bushing Base bushing Wear Damage Replace the stator or the base 10 Inspect Base oil seal Wear...

Page 186: ...ge measurement 8 8 Low resistance measurement 8 8 IGNITION SYSTEM 8 9 IGNITION SPARK GAP 8 10 CDI SYSTEM PEAK VOLTAGE 8 10 SPARK PLUG 8 12 SPARK PLUG CAP 8 12 ENGINE STOP SWITCH 8 13 MAIN SWITCH 8 14...

Page 187: ...Armature inspection 8 25 Brush holder inspection 8 26 Cover inspection 8 27 CHARGING SYSTEM 8 28 CHARGING SYSTEM PEAK VOLTAGE 8 29 FUSE 8 29 BATTERY 8 29 ENRICHMENT CONTROL SYSTEM 8 30 LIGHTING COIL 8...

Page 188: ...8 1 ELEC E ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS OIL INJECTION MODEL 1 Electrothermal valve 2 Oil level sensor L Blue B Black...

Page 189: ...Lighting coil 5 Pulser coil 6 CDI unit 7 Ignition coil 8 2P consent 9 Rectifier regulator 0 Thermo switch To engine stop switch To 6 To 6 To 6 To 1 To 2 To 4 Europe model B Black Br Brown B O Black O...

Page 190: ...ng coil 6 Pulser coil 7 CDI unit 8 Starter relay 9 Ignition coil 0 Fuse A Thermo switch B Rectifier regulator C Starter motor B Black Br Brown B O Black Orange B W Black White B Y Black Yellow L Blue...

Page 191: ...9 Starter relay 0 P T T relay A Ignition coil B Fuse C Thermo switch D Rectifier regulator E Starter motor To P T T motor To trim meter To wire harness To 6 To 8 To 0 To remote control To 4 To 2 To b...

Page 192: ...h lead 4 Battery cable 5 Extension wire harness 6 Neutral switch B Black Br Brown B O Black Orange B W Black White B Y Black Yellow L Blue O Orange O G Orange Green P Pink Y R Yellow Red W White To tr...

Page 193: ...OMPONENTS E EO MODEL 1 Starter motor 2 Rectifier regulator 3 Ignition coil 4 Fuse 5 Starter relay a Bracket b Ground terminal B Black Br Brown B O Black Orange B W Black White B Y Black Yellow L Blue...

Page 194: ...1 Starter motor 2 Rectifier regulator 3 Ignition coil 4 Starter relay 5 P T T relay 6 Fuse a Bracket b Ground terminal B Black Br Brown B O Black Orange B W Black White B Y Black Yellow L Blue O Oran...

Page 195: ...age measurement NOTE The coil output varies greatly at cranking speed Cranking a cold engine with the plugs in and a weak battery does not enable proper readings Low resistance measurement When measur...

Page 196: ...Charge coil 4 Pulser coil 5 Main switch 6 Engine stop switch 7 10P coupler 8 7P coupler 9 CDI unit Manual starter model Electrical starter model Br Brown L Blue W R White Red W B White Black W G Whit...

Page 197: ...GE WARNING While taking CDI unit check be careful not to touch any connection of lead wires of the Digital tester NOTE If there is no spark or the spark is weak continue with the CDI test If a good sp...

Page 198: ...3 pins test harness 3 pins test harness YB 06443 90890 06757 Connect the tester to the measurement terminal Set the tester dial to specification Range Crank or start the engine V 2 Measure Charge coi...

Page 199: ...r min Measuring steps Disconnect the pulse coil couple Con nect the 3 pins test harness 3 pins test harness YB 06443 90890 06757 Connect the tester to the measurement terminal Set the tester dial to...

Page 200: ...g close to the spread core wires and bend the spring end for clamping Install the plug cap spring into the spark plug cap Replacement steps For Canada and Europe Remove the spark plug cap by turning t...

Page 201: ...8 14 ELEC E IGNITION SYSTEM MAIN SWITCH 1 Check Continuity Out of specification Replace Checking leads color Switch position White Black Red Yellow Brown OFF ON START...

Page 202: ...3 Warning lamp 4 Oil level sensor 5 Oil level warning lamp 6 Oil level sensor 7 Meter Pre mixed model Oil injection and warning lamp model Oil injection and oil level warning lamp model Oil injection...

Page 203: ...6 34 C 78 8 93 2 F Pink P Black B a 90 96 C 194 0 204 8 F b 76 90 C 168 0 194 0 F Measuring steps Suspend thermostat in a vessel Place reliable thermometer in a water Heat water slowly Observe thermom...

Page 204: ...ng diode lighting No lighting Replace CAUTION Use only originally pen light battery 1 5 V other than batteries such as alkaline battery higher voltage one will be burnt the diode NOTE LED has an direc...

Page 205: ...er voltage one will be burnt the diode NOTE LED has an direction for electrical current Therefore try reverse connection if there is no lighting Battery voltage 1 5 V Green LED Yellow Red lead Positiv...

Page 206: ...TARTING SYSTEM STARTING SYSTEM 1 Fuse 2 10P coupler 3 7P coupler 4 Main switch 5 Starter motor 6 Battery 7 Neutral switch 8 Starter relay Except for remote control model Remote control model B Black B...

Page 207: ...e WIRING CONNECTION 1 Check Wiring connection Poor connection Correct ENGINE STOP SWITCH Refer to IGNITION SYSTEM MAIN SWITCH Refer to IGNITION SYSTEM NEUTRAL SWITCH 1 Check Continuity Out of specific...

Page 208: ...ation Does not function Replace Checking steps Connect the tester between the termi nals of the starter relay as shown Connect a 12 V battery Brown lead 1 Positive terminal Black lead 2 Negative termi...

Page 209: ...8 22 ELEC E STARTING SYSTEM...

Page 210: ...8 23 ELEC E STARTER MOTOR STARTER MOTOR EXPLODED DIAGRAM...

Page 211: ...1 2 Pinion stopper 1 3 Spring 1 4 Pinion 1 5 Through bolt 2 6 Front cover 1 7 Washer 1 25 1 0 mm 8 Washer 2 25 0 15 mm 9 Washer 1 25 2 0 mm 10 Starter ass y 1 11 Armature ass y 1 12 Washer 1 16 0 25 m...

Page 212: ...age Replace 2 Check Clutch movement Damage Replace NOTE Rotate the pinion clockwise and check that it freely Also try to rotate the pinion coun terclockwise and confirm that it locks Armature inspecti...

Page 213: ...Out of specification Replace Commutator under cut Limit 0 2 mm 0 01 in 5 Inspect Armature coil continuity Out of specification Replace Armature coil continuity Commutator segments Continuity Segment L...

Page 214: ...E STARTER MOTOR 2 Check Brush holder continuity Out of specification Replace Brush holder continuity Brush holder 1 Base 2 Discontinuity Cover inspection 1 Inspect Cover bushing Wear Damage Replace t...

Page 215: ...8 28 ELEC E CHARGING SYSTEM CHARGING SYSTEM 1 Rectifier regulator 2 Lighting coil 3 Battery 4 Fuse G Green G W Green White R Red B Black...

Page 216: ...TING SYSTEM BATTERY Refer to GENERAL in chapter 3 Rectifier regurator input electrical model 8 5 V cranking 25 V 1 500 r min 25 V 3 500 r min Measuring steps Connect the tester to the rectifier regu l...

Page 217: ...ROL SYSTEM 1 Rectifier regulator 2 Lighting coil 3 Electrothermal valve G Green G W Green White L Blue B Black LIGHTING COIL Refer to CHARGING SYSTEM ELECTROTHERMAL VALVE Refer to PRIME STARTER in cha...

Page 218: ...CONTROL SYSTEM POWER TRIM AND TILT CONTROL SYSTEM 1 P T T motor 2 P T T relay 3 P T T switch 4 3P coupler Black 5 10P coupler 6 Fuse 7 Battery Bottom cowl P T T switch model To remote control R Red Lg...

Page 219: ...t of specification Replace 2 Check Relay operation Does not function Replace PTT relay continuity Sky blue Sb Black B Light green Lg Black B Continuity Terminal 1 Terminal Terminal 2 Terminal Continui...

Page 220: ...Sky blue Sb lead Positive terminal Black B Negative terminal Check that there is continuity between the PTT relay terminals TRIM SENSOR 1 Measure Trim sensor resistance Out of specification Replace N...

Page 221: ...E 1 2 3 4 5 6 7 8 9 TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS 9 1 TROUBLE ANALYSIS CHART 9 1...

Page 222: ...obtained 8 Engine is free from any Hull problem TROUBLE ANALYSIS CHART Trouble mode Check elements ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LO...

Page 223: ...f valve 7 Fluid passage 7 PTT motor 7 PTT control system 8 ELECTRICAL Ignition system 8 Starting system 8 Enrichment control system 8 Ignition control system 8 Charging system 8 Trouble mode Check ele...

Page 224: ...YAMAHA MOTOR Corporation USA Printed in U S A Printed on recycled paper...

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Yamaha 40V, Service Manual

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