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Yamaha F150B, Service Manual

The Yamaha F150B Service Manual is a comprehensive guide for maintaining and repairing your outboard motor. Obtain detailed instructions and diagrams to troubleshoot and service your equipment effortlessly. Download this invaluable manual for free from manualshive.com and unlock the expertise to keep your Yamaha F150B performing at its best.

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5-26

Charging units and components

0

1

2

3

4

5

6

7

8

9

10

A

8.

Install the main relay 

a

.

9.

Connect the engine ECM coupler 

b

, and

then install the junction box cover.

10. Connect the high-pressure fuel pump

coupler 

a

.

Charging units and components

Checking the lighting coil (stator 
assembly)

1.

Disconnect the lighting coil coupler 

a

,

and then connect the test harness (3
pins) 

a

.

2.

Measure the lighting coil output peak
voltage between all combinations of the
terminals. Replace the lighting coil if
below specification.

3.

Measure the lighting coil resistance.

4.

Disconnect the test harness 

a

, and then

connect the lighting coil coupler 

a

.

Wiring harness continuity:

Terminal 1–Terminal 

c

 

Terminal 2–Terminal 43

c

b

43

a

Test harness (3 pins) 

a

: 

90890-06847

Lighting coil output peak voltage:

Green (G)–Green (G)

r/min

Unloaded

Cranking

1500

3500

DC V

11.0

50.0

110.0

Lighting coil resistance
(reference data):

0.2–0.3 

Ω

 at 20 °C (68 °F)

a

a

a

G

G

G

Fuel control units and components / Charging units and components

Summary of Contents for F150B

Page 1: ...SERVICE MANUAL 6BM 28197 5L 11 F150B FL150B ...

Page 2: ...tions and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Also up to date parts information is available on YPEC web Additional information and up to date information on Yamaha product and services are available on Service Portal Important information Particularly important information is distinguished in this manual by the foll...

Page 3: ...hnical features and description 2 Rigging information 3 Troubleshooting 4 Electrical system 5 Fuel system 6 Power unit 7 Lower unit 8 Bracket unit 9 Maintenance 10 Index Appendix A GEN INFO SPEC TECH FEA RIG GING TRBL SHTG ELEC FUEL POWR LOWR BRKT MNT ...

Page 4: ......

Page 5: ... 0 1 Ventilation 0 1 Self protection 0 2 Working with crane 0 2 Handling of burner 0 2 Part lubricant and sealant 0 2 Handling of sealant 0 2 Special service tool 0 3 Tightening torque 0 3 Non reusable part 0 3 Disassembly and assembly 0 3 How to use this manual 0 4 Manual format 0 4 Abbreviation 0 5 Sealant and locking agent 0 6 Symbol 0 6 Special service tool 0 8 ...

Page 6: ...gine has cooled Electric shock Do not touch any electrical parts while start ing or operating the engine They can cause shock or electrocution Propeller Do not hold the propeller with your hands when loosening or tightening it Handling of gasoline Gasoline is highly flammable Keep gaso line and all flammable products away from heat sparks and open flames Gasoline is poisonous and can cause injury ...

Page 7: ...pport it with additional ropes or the like so that the outboard motor can be lifted and carried in a stable manner Handling of burner Incorrect handling of burner may result in burns Refer to the operation manual issued by the manufacturer to assure the correct handling When using a burner keep it away from the gasoline and oil to prevent a fire Components become very hot enough to cause burns Do ...

Page 8: ...ays use new gaskets seals O rings cot ter pins circlips and so on when installing or assembling parts Disassembly and assembly Use compressed air to remove dust and dirt during disassembly Apply engine oil to the contact surfaces of moving parts before assembly Install bearings with the manufacture identi fication mark in the direction indicated in the installation procedure In addition be sure to...

Page 9: ...2 6 Seal 2 7 Water pipe 1 8 Grommet 1 9 Bolt 1 M10 45 mm 10 Bolt 12 M10 45 mm 11 Check screw 1 12 Gasket 2 Not reusable 13 Water pipe 1 14 Lower unit 1 15 Spacer 1 16 Propeller 1 17 Washer 1 21 15 14 17 18 19 20 16 2 2 11 12 10 10 9 8 2 7 13 5 6 6 5 10 10 2 23 12 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 42 N m 4 2 kgf m 31 0 ft lb 54 N m 5 4 kgf m 39 8 ft lb 9 N m 0 9 kgf m 6 6 ft l...

Page 10: ...E Check Engine C L Centerline D E S Dual Engine System DN Down side ECM Electronic Control Module EN European Norm European standard EX Exhaust F Forward IEC International Electro technical Commission IN Intake ISC Idle Speed Control M Measurement N Neutral PCV Pressure Control Valve PORT Port side PTT Power Trim and Tilt R Reverse RON Research Octane Number SAE Society of Automotive Engineers STB...

Page 11: ...Application Yamaha 4 stroke motor oil Lubricant Gear oil Lubricant Water resistant grease Yamaha grease A Lubricant Molybdenum disulfide grease Lubricant Corrosion resistant grease Yamaha grease D Lubricant Low temperature resistant grease Yamaha grease C Lubricant WR No 2 grease Lubricant Symbol Name Application Gasket Maker Sealant ThreeBond 1104J Sealant ThreeBond 1280B Sealant ThreeBond 1322 S...

Page 12: ...0 7 GEN INFO General information Symbol Name Application LOCTITE 242 blue Sealant LOCTITE 572 white Sealant ...

Page 13: ...rilling plate 90890 06783 YDIS CD ROM Ver 1 30 60V WS853 04 YDIS KIT 60V 85300 04 Diagnostic flash indicator B 90890 06865 Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 Test harness 3 pins 90890 06869 Test harness 3 pins 90890 06847 Test harness 3 pins 90890 06846 Ignition tester 90890 06754 SOFTWARE Ver OUTBOARDS WATERCRAFT Sealant and locking agent Special service tool ...

Page 14: ...ness 3 pins 90890 06791 Vacuum pressure pump gauge set 90890 06756 Test harness 2 pins 90890 06867 Fuel pressure gauge 90890 06786 Leakage tester 90890 06840 Test harness 3 pins 90890 06793 Vacuum gauge 90890 03159 Digital tachometer 90890 06760 Compression gauge 90890 03160 ...

Page 15: ...l holder 90890 06522 Flywheel puller 90890 06521 Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 06320 Valve guide remover installer 90890 06801 Valve guide installer 90890 06810 Valve guide reamer 90890 06804 Valve lapper 90890 04101 Valve seat cutter holder 90890 06316 ...

Page 16: ...er wrench 90890 06830 Needle bearing attachment 90890 06654 90890 06611 90890 06653 90890 06610 90890 06612 Driver rod L3 90890 06652 Bearing separator 90890 06534 Gear puller 90890 06540 Piston ring compressor 90890 05158 Shift rod push arm 90890 06052 Ring nut wrench 4 90890 06512 Ring nut wrench extension 90890 06513 ...

Page 17: ...502 Stopper guide plate 90890 06501 Center bolt 90890 06504 Stopper guide stand 90890 06538 Bearing puller assembly 90890 06535 Driver rod SS 90890 06604 Bearing depth plate 90890 06603 Bearing inner race attachment 90890 06640 Drive shaft holder 6 90890 06520 Pinion nut holder 90890 06715 ...

Page 18: ...ring attachment 90890 06636 90890 06633 Driver rod LL 90890 06605 Bearing outer race attachment 90890 06619 Bearing outer race puller assembly 90890 06523 Driver rod LS 90890 06606 Backlash indicator 90890 06706 Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base B 90890 06844 ...

Page 19: ...mmer handle 90890 06531 Puller head 90890 06514 Ring nut wrench 90890 06578 Ball bearing attachment 90890 06629 Bearing inner race attachment 90890 06660 Up relief fitting 90890 06773 06838 Hydraulic pressure gauge 90890 06776 06800 Down relief fitting 90890 06774 Trim tilt wrench 90890 06587 ...

Page 20: ... 1 6 Ignition timing control system 1 6 Fuel injection control system 1 7 Engine speed control system 1 8 PTT system 1 8 Charging system 1 9 Starting system 1 9 Gauge sensor 1 10 Fuel system technical data 1 11 Fuel system 1 11 Power unit technical data 1 12 Power unit 1 12 Cylinder head assembly 1 12 Crankcase assembly 1 14 Lower unit technical data 1 16 Lower unit assembly regular rotation model...

Page 21: ... 8 9 10 A Special tightening torque 1 18 Fuel system 1 18 Power unit 1 18 Lower unit regular rotation model 1 19 Lower unit counter rotation model 1 20 Bracket unit 1 20 PTT unit 1 20 General tightening torque 1 21 ...

Page 22: ...ipoint fuel injection Large intake silencer Plastic intake manifold Long intake manifold b Electrical Electronic fuel injection system Self diagnosis system with flush indicator and YDIS New YDIS 1 30 version or later Water cooled Rectifier Regulator Engine running time recorded hour meter c Bracket unit Same bracket as same F150A model F150A type PTT unit d Upper case Water wall cooling system ar...

Page 23: ...ight d Serial number a Model Description F 4 stroke regular rotation FL 4 stroke counter rotation b Model name 150 150 c Product Generation B A and up d Functions E Electric starter e T Power trim and tilt f Transom Height X UL 25 in F 1 5 0 B E T X b a c d e f Model name Approved model code Starting serial No F150BET 6BM 1000001 FL150BET 6BN 1000001 YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGIN...

Page 24: ...4500 5500 Maximum fuel consumption L US gal Imp gal hr 49 5 13 1 10 9 at 5000 r min Engine idle speed r min 650 750 Item Unit Model F150B FL150B Type 4 stroke DOHC Cylinder quantity L4 Total displacement cm3 cu in 2670 162 9 Bore stroke mm in 94 0 96 2 3 70 3 79 Compression ratio 9 0 1 Control system Remote control Starting system Electric Fuel system Fuel injection Ignition control system TCI Adv...

Page 25: ... clutch Propeller shaft type Spline Propeller direction rear view Clockwise Counter clockwise Propeller mark M ML Item Unit Model F150B FL150B Trim angle at 12º boat transom Degree 4 to 16 Tilt up angle Degree 70 Steering angle Degree 35 35 Item Unit Model F150B FL150B Fuel type Regular unleaded gasoline Fuel minimum rating RON 84 Engine oil 4 stroke motor oil Engine oil grade 1 API SE SF SG SH SJ...

Page 26: ...quirement PTT requirement Item Unit Model F150B FL150B Minimum cold cranking amps CCA EN A 711 Minimum rated capacity 20HR IEC Ah 100 Item Unit Model F150B FL150B Fluid type ATF Dexron ΙΙ Fluid type quantity L US qt Imp qt 0 7 0 7 0 6 ...

Page 27: ...eak voltage at cranking unloaded V 210 0 at 1500 r min loaded V 260 0 at 3500 r min loaded V 270 0 Primary coil resistance at 20 C 68 F Ω 1 6 2 0 Secondary coil resistance spark plug wire spark plug wire at 20 C 68 F kΩ 12 50 16 91 Pulser coil Resistance 1 at 20 C 68 F Ω 459 0 561 0 Output peak voltage at cranking unloaded V 3 5 at cranking loaded V 3 0 at 1500 r min loaded V 21 0 at 3500 r min lo...

Page 28: ... Engine temperature sensor Resistance 1 at 20 C 68 F kΩ 54 2 69 0 at 98 C 208 F kΩ 3 12 3 48 Input voltage V 4 75 5 25 Thermoswitch Input voltage V 11 1 Temperature Switch ON C F 84 90 183 194 Switch OFF C F 68 82 154 180 Item Unit Model F150B FL150B Fuel injector Resistance 1 at 20 C 68 F Ω 14 0 15 0 Input voltage 1 V 12 0 High pressure fuel pump Resistance 1 Ω 0 5 10 0 Input voltage 1 V 12 0 ISC...

Page 29: ...40 F with SL 10W 30 engine oil and at 700 r min V 2 8 TPS Output voltage 1 with throttle valve fully closed TPS1 V 0 703 with throttle valve fully open TPS1 V 4 255 Throttle valve opening angle 1 with throttle valve fully closed Degree 0 1 with throttle valve fully open Degree 88 6 Input voltage V 4 75 5 25 Shift cut switch Input voltage V 4 75 5 25 Resistance 1 at 20 C 68 F kΩ 4 465 4 935 Item Un...

Page 30: ...d V 110 0 Resistance 1 at 20 C 68 F Ω 0 2 0 3 Fuse A 50 Rectifier Regulator Output peak voltage at 1500 r min loaded V 13 0 at 3500 r min loaded V 13 0 Item Unit Model F150B FL150B Starter motor Type Sliding gear Output kW 1 4 Cranking time limit Second 30 Brushes Standard length mm in 15 5 0 61 Wear limit mm in 9 5 0 37 Commutator Standard diameter mm in 29 0 1 14 Wear limit mm in 28 0 1 10 Neutr...

Page 31: ...ter Input voltage V 11 2 Water pressure sensor Input voltage V 4 75 5 25 Output voltage at 392 0 kPa 3 92 kgf cm2 56 8 psi V 2 5 at 784 0 kPa 7 84 kgf cm2 113 7 psi V 4 5 Speed sensor Input voltage V 4 75 5 25 Output voltage at 392 0 kPa 3 92 kgf cm2 56 8 psi V 2 5 at 784 0 kPa 7 84 kgf cm2 113 7 psi V 4 5 ...

Page 32: ... kgf cm2 psi 50 0 0 50 7 3 Inlet negative pressure kPa kgf cm2 psi 30 0 0 30 4 4 Outlet positive pressure kPa kgf cm2 psi 50 0 0 50 7 3 Fuel pressure at engine start switch to ON with in 3 seconds 1 kPa kgf cm2 psi 300 0 3 00 43 5 at engine idle speed 1 kPa kgf cm2 psi 260 0 2 60 37 7 Primer pump Holding pressure Positive pressure kPa kgf cm2 psi 170 0 1 70 24 7 Throttle link Roller clearance mm i...

Page 33: ...m2 psi 450 0 4 50 65 3 Replacement engine oil quan tity at periodic maintenance Without oil filter replacement L US qt lmp qt 4 30 4 54 3 78 With oil filter replacement L US qt lmp qt 4 50 4 76 3 96 Item Unit Model F150B FL150B Cylinder head Warpage limit mm in 0 1 0 0039 Valve stem Diameter Intake mm in 5 477 5 492 0 2156 0 2162 Exhaust mm in 5 464 5 479 0 2151 0 2157 Runout limit Intake mm in 0 ...

Page 34: ...n 35 950 36 050 1 4154 1 4193 Exhaust mm in 35 950 36 050 1 4154 1 4193 Journal diameter mm in 24 960 24 980 0 9827 0 9835 Runout limit mm in 0 03 0 0012 Cap inside diameter mm in 25 000 25 021 0 9843 0 9851 Valve Clearance Intake mm in 0 20 0 03 0 008 0 001 Exhaust mm in 0 34 0 03 0 013 0 001 Seat contact width Intake mm in 1 10 1 40 0 043 0 055 Exhaust mm in 1 40 1 70 0 055 0 067 Margin thicknes...

Page 35: ...80 3 00 0 1102 0 1181 End gap mm in 0 15 0 30 0 0059 0 0118 Side clearance mm in 0 04 0 08 0 0016 0 0031 2nd ring Type Taper Dimension height B mm in 1 17 1 19 0 0461 0 0469 Dimension width T mm in 3 70 3 90 0 1457 0 1535 End gap mm in 0 30 0 45 0 0118 0 0177 Side clearance mm in 0 03 0 07 0 0012 0 0028 Oil ring Dimension height B mm in 2 40 2 47 0 0945 0 0972 Dimension width T mm in 2 30 2 70 0 0...

Page 36: ...0B Crankcase Crankshaft journal oil clear ance mm in 0 021 0 050 0 0008 0 0020 Thermostat Valve opening temperature at 0 05 mm 0 0020 in C F 58 0 62 0 136 4 143 6 Fully open temperature C F 70 0 158 0 Fully open stroke at 70 0 C 158 0 F mm in 4 3 0 17 ...

Page 37: ...30 0 40 0 50 Reverse gear shim T2 mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Propeller shaft Runout limit mm in 0 02 0 0008 Drive shaft Runout limit mm in 0 2 0 008 Item Unit Model FL150B Lower unit kPa kgf cm2 psi Holding pressure 68 6 0 686 9 9 Pinion to forward gear Backlash 1 mm in 0 15 0 49 0 0059 0 0193 Pinion to reverse gear Backlash 1 mm in 0 24 0 65 0 0094 0 0256 Pinion shim T3 mm 0 10 0 12 0 ...

Page 38: ...m Unit Model F150B FL150B PTT Hydraulic pressure Down 1 MPa kgf cm2 psi 5 9 8 8 59 0 88 0 855 5 1276 0 Up 1 MPa kgf cm2 psi 9 8 11 8 98 0 118 0 1421 0 1711 0 Motor brush Standard length mm in 9 8 0 39 Wear limit mm in 4 8 0 19 Motor commutator Standard diameter mm in 22 0 0 87 Wear limit mm in 21 0 0 83 ...

Page 39: ...1 5 Needle valve assembly screw M4 2 0 2 1 5 Vapor separator drain screw 2 0 2 1 5 Part to be tightened Thread size Tightening torques N m kgf m ft lb Spark plug 25 2 5 18 4 Power unit mounting bolt M8 20 2 0 14 8 M10 42 4 2 31 0 Upper case cover bolt M6 4 0 4 3 0 PTT motor lead bolt M6 4 0 4 3 0 Flywheel magnet nut 270 27 0 199 1 Ignition coil bolt M6 7 0 7 5 2 Starter relay lead bolt M6 4 0 4 3 ...

Page 40: ... 34 3 4 25 1 Crankcase plug 54 5 4 39 8 Crankcase cover bolt 1st M6 7 0 7 5 2 2nd 13 1 3 9 6 1st M8 18 1 8 13 3 2nd 31 3 1 22 9 Oil pump screw 4 0 4 3 0 Crankcase bolt 1st M10 30 3 0 22 1 2nd 90 1st M8 14 1 4 10 3 2nd 26 2 6 19 2 Main bearing cap bolt 1st M10 30 3 0 22 1 2nd 90 Connecting rod cap 1st 23 2 3 17 0 2nd 43 4 3 31 7 3rd 90 Part to be tightened Thread size Tightening torques N m kgf m f...

Page 41: ...ift rod detent bolt 18 1 8 13 3 Grease nipple 1 0 1 0 7 Hose joint adapter screw ø6 3 0 3 2 2 Upper mounting nut 72 7 2 53 1 Lower mounting nut 72 7 2 53 1 Upper mount bracket bolt M10 54 5 4 39 8 Baffle plate screw M6 4 0 4 3 0 Oil pan assembly bolt M8 20 2 0 14 8 M10 42 4 2 31 0 Engine oil drain bolt 27 2 7 19 9 Oil strainer bolt M6 11 1 1 8 1 Oil pan bolt M8 20 2 0 14 8 Exhaust manifold bolt M8...

Page 42: ...tages until the specified torque is reached Unless otherwise specified torque specifications require clean dry threads Components should be at room temperature Part to be tightened Thread size Tightening torques N m kgf m ft lb Manual valve 3 5 0 35 2 58 Tilt cylinder end screw 128 12 8 94 4 Tilt piston nut 96 9 6 70 8 Trim cylinder end screw 140 14 0 103 3 Filter plug 6 0 6 4 4 Width across flat ...

Page 43: ...tem 2 10 Engine speed control system 2 13 Idle speed control 2 16 Fail safe control 2 17 Power unit system 2 18 Outline of system 2 18 Lubrication system 2 22 Cooling system 2 24 Intake and exhaust system 2 27 Idle exhaust system 2 28 PTT unit 2 29 Trim up and tilt up function 2 29 Trim ram retraction function 2 30 Trim down and tilt down function 2 31 Stationary condition 2 32 When the outboard h...

Page 44: ... be installed in a personal computer F150B has fail safe functions In the event of a failure related to each sensor and actuator the fail safe function works to continue the control using the reference values set by engine ECM or stop the engine It also gives warning to the boat operator of the occurrence of failure by lighting the alert indicator or activating the alert buzzer Electronic control ...

Page 45: ... Electronic control system 0 1 2 3 4 5 6 7 8 9 10 A Engine ECM component a Pulser coil b Thermoswitch c Ignition coil d Oil pressure sensor e Engine ECM f Air temperature sensor g Hour meter e a d b g f c ...

Page 46: ...2 3 TECH FEA Technical features and description h Air pressure sensor i ISC valve j Engine temperature sensor k TPS l Throttle body m High pressure fuel pump n Fuel injector h j n i l k m ...

Page 47: ...sure sensor To detect the oil pressure and apply it to the alert of low oil pres sure and the engine speed control Thermoswitch In case of overheat the thermoswitch is turned on Once it is turned on the engine ECM activates the engine speed control and the alert buzzer goes off Neutral switch Detects the neutral position Engine shut off switch Activates the engine stop function compulsorily Fuel i...

Page 48: ...carried out One is synchronous injection in which the fuel injection always occurs at certain crankshaft angle after the required com pensation is made in accordance with the signals from each sensor The other is asynchronous injection in which the fuel is injected regardless of crankshaft angle once the demand for the fuel injection is detected in the signals from each sensor Block diagram TPS Pu...

Page 49: ...ff switch Battery Main relay Main switch High pressure fuel pump Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4 Tacho meter Check engine lamp Alert buzzer Pulser coil 1 Pulser coil 2 Air pressure sensor Ground Engine temperature sensor Air temperature sensor Engine shut off switch Thermoswitch Neutral switch Engine start switch Battery Main relay Same marks are connected by each o...

Page 50: ... The pressure regulator is installed at the outlet of the electric fuel pump to make the design compact and to allow simple delivery of the fuel The fuel discharged from the pressure regulator is cooled down by the fuel cooler and sent back to the vapor separator The pressure check valve is installed on the fuel rail for improved serviceability of the fuel system A Fuel flow a Primer pump b Fuel f...

Page 51: ...The fuel injectors for a group of cylinders are turned on simultaneously Fuel is injected two times in every two rotations of crankshaft Asynchro nous injec tion Asynchronous injection at acceleration When the increment of throttle opening gets larger than the set value in the course of acceleration for instance the fuel is injected immediately and simultaneously at all cylinders rather than synch...

Page 52: ... Pulser coil signal 2 Injection 1 and 4 Injection 2 and 3 Compression Combustion Exhaust Intake Compression Compression Combustion Exhaust Intake Intake Compression Combustion Exhaust Intake Exhaust Combustion Exhaust Intake Compression Combustion BTDC70 BTDC10 1 and 4 BTDC70 BTDC10 1 and 4 BTDC70 BTDC10 1 and 4 BTDC70 BTDC10 2 and 3 BTDC70 BTDC10 2 and 3 ...

Page 53: ...ed by applying the advanced ignition timing at the engine start up Subsequently the ignition timing is controlled to go back to the standard angle gradually compensati on for acceleration Ignition timing is temporarily retarded at acceleration to improve the throttle response Shift cutout When the conditions are met for implementing the shift cut out control the specified angle is added to the ign...

Page 54: ...ine temperature sensor Main battery Engine shut off switch Shift cut switch Shift cut signal Emergency stop Battery voltage Engine temperature Intake air temperature Intake air pressure Neutral position Throttle valve opening Crankshaft angle Engine speed Engine ECM Ignition signal Ignition signal Ignition coil 1 and 4 Ignition coil 2 and 3 ...

Page 55: ...42 26 13 16 TPS Pulser coil 1 Pulser coil 2 Air pressure sensor Ground Engine temperature sensor Air temperature sensor Shift cut switch Engine shut off switch Neutral switch Main switch Battery Main relay Same marks are connected by each other Ignition coil 1 and 4 Ignition coil 2 and 3 Engine ECM Rectifier Regulator ...

Page 56: ...e speed D E S switch is turned on in the event of an overheat alert or a low oil pressure alert and the alert buzzer goes off Once the above event takes place engine ECM stops the fuel injection to reduce the engine speed to 2000 r min or lower Shift cutout control Detects the shift cutout control activation and controls the engine speed This device misfires and retards the ignition of some cylind...

Page 57: ...t alert and low oil pressure alert control mode deactivate when the engine speed is less than 1600 r min or the throttle opening angle is less than 7 degrees Block diagram TPS Pulser coil Neutral switch Engine temperature sensor Oil pressure sensor Thermoswitch Engine shut off switch Shift cut switch D E S switch ON OFF Shift cut signal Emergency stop ON OFF Engine oil pressure Engine temperature ...

Page 58: ...ture sensor Air temperature sensor Shift cut switch Engine shut off switch Neutral switch Engine start switch Battery Main relay Same marks are connected by each other Ignition coil 1 4 Ignition coil 2 3 Engine ECM Oil pressure sensor Thermoswitch Rectifier Regulator Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4 Oil pressure lamp Over heat lamp Diagnostic flash indicator Alert bu...

Page 59: ...he ISC valve opens when the stepper motor is driven in reverse direction and closes when the stepper motor is driven in forward direction A Intake air flow B Movement of ISC valve a ISC valve b Intake manifold ISC valve opening Engine condition ISC valve opening at engine start At engine start ISC valve is opened relatively wider depending on the engine temperature This increases the amount intake...

Page 60: ... Controlled according to the basic ignition map Controlled by intake air pressure and engine speed 23 Air temperature sensor Output voltage is less 0 10 V or more 4 61 V Normal control Normal control 28 Neutral switch Switch is off when starting the engine Normal control Normal control 29 Air pressure sensor Output voltage is less 0 2 V or more 4 5 V Normal control Fuel injection volume is control...

Page 61: ...ffset by 10 0 mm 0 39 in from the cylinder centerline The long intake manifold made from plastic is used for higher intake efficiency to obtain higher out put power The larger intake silencer is useful to suppress the noise a Oil gas separator b Piston c Connecting rod d Offset crankshaft e Intake manifold f Throttle body g Intake silencer a b c d f g e Electronic control system Power unit system ...

Page 62: ...lowby gas separator is used to obtain low emissions and is built into the cylinder head cover to obtain a compact design The gas and oil flow is shown below A Blowby gas B Oil a Intake silencer b Blowby gas separator integrated with cylinder head cover c Blowby hose a b c A B ...

Page 63: ...he connecting rod and connecting rod cap are manufactured as a single piece Then they are split using impact force Only use the connecting rods and connecting rod caps in their original combina tions do not interchange them a Connecting rod b Connecting rod cap b a ...

Page 64: ...n stroke Such difference in compres sion stroke and combustion stroke makes it possible to cause the earlier expansion and to keep the piston longer at around TDC after the ignition leading to more effective use of combustion pressure and improved combustion efficiency It is also useful to reduce the frictional loss because the piston side force the force in the thrusting direction generated on th...

Page 65: ...as follows A Engine oil flow A Crankcase Cylinder sleeve Piston Crank pin Crankshaft main journal Cylinder head Camshaft journal Intake and exhaust valve Camshaft Main passage Oil filter Oil filter bracket Oil pump Oil strainer Oil pressure sensor Relief valve Oil pan Power unit system Lubrication system ...

Page 66: ...2 23 TECH FEA Technical features and description A Engine oil flow a Oil pan b Oil strainer c Oil pump d Oil filter e Oil pressure sensor f Relief valve a b d f c e A ...

Page 67: ...ool the exhaust gas Cooling water also flows around the muffler to cool the upper case and reduce exhaust noise A Cooling water flow PCV A Thermostat Cylinder block Cylinder head Cylinder block Exhaust cover Exhaust guide Oil pan Water pump Water inlet Water Fuel cooler Cooling water pilot hole Upper case muffler Lower case Propeller boss Trim tab Lubrication system Cooling system ...

Page 68: ...2 25 TECH FEA Technical features and description A Cooling water flow a Water inlet b Water pump c Oil pan d Exhaust guide e Exhaust cover f Thermostat a b c d f e A ...

Page 69: ... a Flushing hose exhaust cover to garden hose adapter b Cooling water hose exhaust cover to fuel cooler c Cooling water hose fuel cooler to cooling water pilot hole d Speedometer hose a Exhaust cover b Fuel cooler c Pilot hole on the bottom cowling A b b c a d a b c ...

Page 70: ...ntake and exhaust system The intake and exhaust air flow diagram A Intake air flow B Exhaust gas flow a Exhaust cover b Exhaust guide c Exhaust manifold d Muffler e Propeller f Intake silencer g Throttle body h Intake manifold e f a b c d g h A B IN EX ...

Page 71: ...tem 0 1 2 3 4 5 6 7 8 9 10 A Idle exhaust system The exhaust gas runs out through the idle exhaust port at idle engine speed The labyrinth structure is used to reduce the exhaust noise A Exhaust gas flow a Labyrinth structure a A ...

Page 72: ...the up main valve and then pushes the trim ram and tilt ram upward In addition the fluid pushes the down shuttle piston opens the down main valve and returns from the tilt cylinder upper chamber to the gear pump After the trim ram has extended completely the tilt ram operates to tilt up A Return B Send a Reservoir b Trim ram c Tilt ram d Up shuttle piston e Up main valve f Trim cylinder g Tilt cyl...

Page 73: ... place by the tilt stop lever Only the PTT fluid from the trim cylinder lower chamber can be drawn and as the fluid pressure decreases the trim ram retracts into the trim cylinder Since the tilt ram is secured in place the PTT fluid pumped by the gear pump flows into the tilt cylinder upper chamber to increase fluid pressure As a result the down relief valve opens and the PTT fluid is released int...

Page 74: ...luid from the tilt cylinder and trim cylinder lower chambers and then retracts the tilt ram and the trim ram Since the fluid pressure from the gear pump is applied to the tilt cylinder upper chamber the tilt ram moves downward first When the outboard motor comes in contact with the trim ram the trim ram moves downward simul taneously with the tilt ram due to its own weight and the suction of the P...

Page 75: ...open and release the fluid pressure into the space between the tilt piston and the free piston As a result the damping effect of the tilt piston absorber and the oil lock mechanism prevent the PTT unit from damage before the tilt piston comes in contact with the top of the tilt cylinder After the collision a force to return the outboard motor to its original position is generated due to the weight...

Page 76: ...r temperature sensor option 3 12 Installing the 6Y8 Multifunction Meter harness option 3 12 Install the speed sensor option for 6Y8 Multifunction Meter 3 12 Installing the water pressure sensor option for 6Y8 Multifunction Meter 3 14 Installing the main wiring harness 3 14 Installing the rigging grommet 3 15 Installing the fuel flow sensor 3 16 Remote control box and switch panel installation 3 16...

Page 77: ...0 1 2 3 4 5 6 7 8 9 10 A Rigging recommendations 3 25 Extension length recommendation of battery cable 3 25 Propeller selection 3 26 Propeller size 3 26 Selection 3 26 ...

Page 78: ...r rigging should mount the motor Too much weight on the transom can change the boat s center of gravity buoyancy operat ing balance or performance which could cause loss of control or swamping Consult the boat manufacturer for the maximum engine weight allowable on the transom which is differ ent from the overall boat capacity Overloading the transom with a motor that is too heavy could also damag...

Page 79: ...4 6 5 698 27 5 75 3 0 1073 42 2 643 25 3 210 8 3 27 1 1 915 36 0 769 30 3 455 17 9 45 1 8 16 0 6 162 6 4 80 3 1 12 6 6 4 3 5 43 1 7 646 25 4 864 34 0 1 H 2 1 The distance between the center of PORT outboard motor and the center of STBD outboard motor 2 Transom height mm in Outboard motor installation Dimensions ...

Page 80: ...3 3 RIG GING Rigging information Clamp bracket 82 3 2 13 0 5 180 7 1 163 5 6 4 254 10 0 55 5 2 2 367 14 4 163 5 6 4 125 4 4 9 125 4 4 9 180 7 1 13 0 5 50 8 2 0 18 5 0 7 mm in ...

Page 81: ...the crate Read the notice and understand what pictographs mean to avoid a damage to the product when handling transporting and or keeping the crate Lifting fork insert position Product barycentric position Stack limit Maximum 4 units for storage Upward indication Care handling indication Water avoidance indication Dimensions Crate top cover pictograph description ...

Page 82: ...the outboard motor for concealed damage If any damage is found use the concealed crate damage claim procedure 5 Remove the top cowling and the flywheel magnet cover a 6 Install a lifting harness b to the engine hangers c 7 Tension the lifting harness 8 Remove the skeg holder d 9 Carefully lift up the outboard motor together with the bottom frame e NOTICE Do not allow the lifting harness to damage ...

Page 83: ...he outboard motor mounting and may vary slightly depending on application When mounting the outboard motor also make sure the outboard motor has the clear ance to provide full movement from both PORT to STBD as well as during trim and tilt functions See Dimensions 3 2 1 Set the outboard motor on the vertical centerline of the boat transom A No strakes hull B Strakes hull C L Centerline of the tran...

Page 84: ...s for every possible boat and outboard motor combination 3 Adjust the scale a to the transom height H and set it on the special service tool b Secure the service tool b to the boat transom by means of a screw or a vise TIP See Dimensions 3 2 for the distance H 4 When the outboard motor mount position has determined mark the best suited 4 symmetrical mounting holes to the boat transom h Drill the m...

Page 85: ... Water pressure hose option d Isolator lead option e Battery cable f Gauge harness g Fuel hose h Speedometer hose i Shift cable j Throttle cable Installing the shift cable Always perform the cable adjustment in advance following the procedures in the remote control operation manual 1 Remove the rubber seal a at the retain ing plate b portion Boat transom thickness D Mounting bolt 55 65 mm 2 17 2 5...

Page 86: ...e shift cable e through the rigging grommet fit the cable groove onto the projection on the cable holder f for installation 7 Align the mark a on the bushing h with the mark b on the plate i 8 Adjust the cable joint d to the pin c of shift lever WARNING The shift cable joint must be screwed in a minimum of 8 0 mm 0 31 in 9 If the cable joint is not maintained the engagement of minimum 8 0 mm 0 31 ...

Page 87: ...r proper operation Installing the throttle cable 1 Fully screw in the cable joint a to the throttle cable b 2 Open the clamp c of the throttle cable holder d TIP Throttle cable position is adjustable by using the throttle cable holder d 3 Pass the throttle cable b through the grommet fit the cable groove onto the projection on the cable holder d for installation 4 Contact the stopper a of the thro...

Page 88: ...nner cable to avoid the free play backlash of the cable and install it to the pin 8 Tighten the locknut h to the specified torque 9 Check the throttle cable for proper operation Installing the isolator lead option Carry out the following procedures only when the isolator lead option is used 1 Remove the cap a from the isolator cou pler 2 Connect the isolator lead b it s coupler Installing the gaug...

Page 89: ...on Meter set up man ual for the installation of 6Y8 Multifunction Meter to the boat Perform the following procedure when the optional 6Y8 Multifunction Meter is used 1 Remove the cap from the coupler a and then connect the meter harness a to the coupler a 2 Remove the yellow tape b to make the wires loose 3 Remove the each caps and then connect the couplers c and d Install the speed sensor option ...

Page 90: ... g to 270 mm 10 6 in 4 Connect the extension hose d to the speed sensor adapter 5 Remove the bracket h 6 Install the speed sensor adapter i 7 Install the speed sensor j onto the speed sensor adapter i and then tighten the speed sensor to the specified torque 8 Remove the bracket h and cap k from the speed sensor coupler b 9 Connect the speed sensor coupler b to the speed sensor j c d e f g h Speed...

Page 91: ...fied torque 3 Install the water pressure sensor d onto the adapter c and then tighten the water pressure sensor d to the specified torque 4 Remove the water pressure sensor coupler a from the cap e 5 Connect the water pressure sensor coupler a to the water pressure sensor d Installing the main wiring harness 1 Route the main wiring harness a in front of the bracket b j b c a a c b Adapter c 23 N m...

Page 92: ... grommet description 3 8 for the detailed description of the rigging grom met 2 Align the white tape a on the battery cable a with the inner end of the rigging grommet 3 Align the white mark b on the fuel hose b with the outer end of the rigging grommet 4 Install the retaining plate c 5 Install the rubber seal d TIP Make sure that the rubber seal is installed securely 6 Install the rigging tube re...

Page 93: ...stall the fuel flow sensor with the UP mark c facing upward If a fuel filter is used install fuel flow sensor between the fuel filter and primer pump 3 Install the fuel hoses c and then fasten them with the clamps d Remote control box and switch panel installation See Remote control box operation manual or Rigging guide for the installation proce dures of remote control box and the switch panel IN...

Page 94: ...tery cable length Battery wiring without house accessory battery When only one battery is used for one engine connect the positive battery cable and the isolator lead to the positive battery terminal If the isolator lead is left unconnected acci dental contact of the isolator lead with the negative terminal of the battery can cause a short circuit which may result in a fire When using a dual batte...

Page 95: ... Red Outboard motor Black Red Black Outboard motor Isolator lead Battery cable Isolator lead Black Red Outboard motor Isolator lead Black Battery switch ON OFF STBD PORT Battery cable Isolator lead Red Outboard motor Isolator lead Black Battery switch ON OFF Red Black Battery switch ON OFF Black Outboard motor ...

Page 96: ...use battery a negative battery cable must be installed between the house battery and the engine battery This cable must be sized equivalent to the engine battery cables or larger AWG cable size in accordance with ABYC specifications Battery switches must be capable of meeting intermittent and continuous current ratings for engines and accessories 1 2 Battery cable Isolator lead Red Outboard motor ...

Page 97: ...ery cable Isolator lead Red Isolator lead Black Battery switch ON OFF Black House battery Battery switch Black ON OFF ON OFF Black Red Outboard motor Outboard motor 1 2 1 2 STBD PORT Battery cable Isolator lead Red Isolator lead Black Battery switch Black House battery Battery switch Black ON OFF Black Red Outboard motor Outboard motor Red Battery switch ...

Page 98: ...ment meter unit c Speedometer unit d Tachometer unit e Fuel tank fuel level sensor f Fuel flow sensor g GPS option h Speedometer hose i Gauge harness j Main wiring harness k Fuel hose Color code B Black G Green Gy Gray L Blue O Orange P Pink Pu Purple R Red W White Y Yellow G R Green Red G W Green White O B Orange Black P B Pink Black P W Pink White Pu W Purple White W R White Red ...

Page 99: ...am 0 1 2 3 4 5 6 7 8 9 10 A IN UP OUT W 1 Gy P B P B Pu Gy NMEA0183 P W G R Gy Pu W Pu W G W O B Pu W R W R G R G W G R G R B G Y Y R R R B B W W W R P P O O B W G P W B R B O O O B B R Y L B G a b c d e f g h i j k 1 Y ...

Page 100: ...er unit e Speedometer unit f Fuel tank fuel level sensor g Fuel flow sensor h GPS option i Speedometer hose j Gauge harness k Main wiring harness l Fuel hose A PORT B STBD Color code B Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink Pu Purple R Red Sb Sky blue W White Y Yellow G R Green Red G W Green White O B Orange Black P B Pink Black P W Pink White Pu W Purple White W R Wh...

Page 101: ... min set mode h Pu Pu B B Br Br B B O O O Y Y Y Y Y Y Y Y Y Y L L L R R R R R G G G G G R G B B B B B B B B L G G P Gy Gy G W G W G W W R Pu W O B W R Pu W Pu W G R G R O B G R G R Gy Gy P P P P P W W B R R B W Pu Pu O O O B B P W P B P B Gy G P P P W G R G R P B P B Gy G P P W W W B B Br Br Br Br Br B Y L Lg G R R G P P W Sb Sb B Br Br Br Lg R Sb Sb B B R W 1 NMEA0183 a b c c d e h f g g l l k k ...

Page 102: ...ve and negative cables Select an extension battery cable and terminal which meets ABYC requirements or equivalent Select a stud of battery which is best suited to the terminal size Solder the connection of terminals and cables to prevent them from corroding CCA Cold Cranking Amperage EN European Norm European standard IEC International Electro technical Commission Ambient temperature above 0 C 32 ...

Page 103: ...e propeller is indicated on the propeller boss end on the side of the propel ler boss a Propeller diameter in inches b Propeller pitch in inches c Propeller type propeller mark Selection When the engine speed is at the full throttle operating range 4500 5500 r min the ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption Regular rotati...

Page 104: ... information Counter rotation model Propeller size in Material 14 19 ML Aluminum 14 1 2 17 ML 13 3 4 17 ML1 Stainless 13 3 4 19 ML1 13 3 4 21 ML 13 3 8 23 ML 14 1 2 23 ML 14 7 8 21 ML 15 1 4 15 ML 15 1 4 17 ML 15 1 4 19 ML ...

Page 105: ...tboard motor 4 3 Troubleshooting the power unit 4 4 Troubleshooting procedure 4 4 Troubleshooting the power unit using the YDIS 4 4 Trouble code and checking step 4 6 Troubleshooting the power unit using the diagnostic flash indicator 4 10 Troubleshooting the power unit trouble code not detected 4 11 Troubleshooting the PTT unit 4 17 Troubleshooting the lower unit 4 18 ...

Page 106: ...ard disk could cause errors and result in insufficient memory This software will not run properly on some computers When starting up this program do not start other software applications Do not use the screen saver function or the energy saving feature when using this program If the ECM is changed restart the program Windows XP and Windows Vista are multiuser operating system therefore make sure t...

Page 107: ...be performed with the engine off Active test The tests can be carried out while the engine is running and the shift is in the N position It is not possible to carry out the test while the boat is running Data logger Displays 13 minutes of recorded data for 2 or more of the items stored in the engine ECM In addi tion the operating time as compared to the engine speed and the total operating time ar...

Page 108: ...rd the history of engine oil exchange YDIS kit Connecting the communication cable to the outboard motor a YDIS coupler gray No Item Q ty a CD ROM software instruction manual 1 b Adapter 1 c Communication cable 1 a b c YDIS CD ROM Ver 1 30 a 60V WS853 04 YDIS KIT a b c 60V 85300 04 a ...

Page 109: ...the trouble codes were detected When checking the input voltage of a part the coupler or connector must be disconnected As a result the engine ECM determines that the part is disconnected and a trouble code is detected Therefore make sure to delete the diagnosis record after checking the input voltage Since the main relay comes on for approximately 10 seconds after the engine start switch is turne...

Page 110: ...Battery voltage malfunction O O O 23 Intake temp sensor malfunction Air temperature sensor malfunc tion O O O 27 Water in fuel O O O 28 Shift position switch malfunction Neutral switch malfunction O O O 29 Intake press sensor malfunction Air pressure sensor malfunction O O O 37 Intake air passage malfunction O O O 39 Oil press sensor malfunction Oil pressure sensor malfunction O O O 44 Engine stop...

Page 111: ... projections of the plate for damage 7 17 15 Engine temp sen sor malfunction Out of specifica tion C E Higher idle speed Degraded acceleration performance Declining maximum engine speed 1 Measure the engine temper ature sensor input voltage 5 33 A 5 2 Measure the engine temper ature sensor resistance 5 33 3 Check for wiring continuity between the engine temper ature sensor and engine ECM 5 33 A 5 ...

Page 112: ...fier Regu lator output peak voltage 5 26 7 Check the Rectifier Regula tor for continuity 5 26 8 Check for wiring continuity between the Rectifier Regu lator and fuse A 7 23 Intake temp sen sor malfunction Out of specifica tion C E Higher idle speed 1 Check the air temperature using the YDIS 5 31 2 Measure the air temperature sensor input voltage 5 31 A 5 3 Measure the air temperature sensor resist...

Page 113: ...uity between the neutral switch and engine ECM 5 37 A 5 29 Intake press sen sor malfunction Out of specifica tion C E Higher idle speed Degraded acceleration performance Declining maximum engine speed 1 Measure the air pressure sensor input voltage 5 32 A 5 2 Measure the air pressure sensor output voltage 5 32 A 5 3 Check for wiring continuity between the air pressure sensor and engine ECM 5 32 A ...

Page 114: ...alfunc tion Irregular signal C E Higher idle speed 1 Measure the shift cut switch input voltage 5 36 A 5 2 Measure the shift cut switch resistance 5 36 3 Check for wiring continuity between the shift cut switch and engine ECM 5 36 A 5 46 Overheat ther moswitch mal function Irregular signal C E Higher idle speed 1 Measure the thermoswitch input voltage 5 34 A 5 2 Check the thermoswitch for continui...

Page 115: ...For example the trouble code is 23 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 trouble code is detected see Trouble code and checking step 4 6 TIP When more than one trouble code is detected the Diagnostic flash indicator B flashes in the pattern of the lowest trouble code After that trouble code is corrected the indicator flashes in the ...

Page 116: ... Starter relay malfunction Check the starter relay 5 38 Engine start switch malfunction Check the engine start switch 5 39 Neutral switch malfunction Check the neutral switch remote control 5 39 Short open or loose connection in starter motor circuit Check the starter relay input voltage 5 38 A 7 Check the wiring harness continuity A 7 Starter motor malfunction Disassemble and check the starter mo...

Page 117: ... Check the main relay 5 14 A 5 Blown fuse Check the fuse 5 2 A 5 Short open or loose connection in engine ECM circuit Check for wiring continuity between the main relay and engine ECM 5 15 A 5 Check for wiring continuity between the engine ECM and ground 5 15 A 5 Engine ECM malfunction Replace the engine ECM 7 15 Spark plug does not spark all cylinders Pulser coil malfunction Check the pulser coil...

Page 118: ...uel pump input voltage 5 25 A 3 Check for wiring continuity between the high pressure fuel pump and engine ECM 5 25 A 3 Check for wiring continuity between the high pressure fuel pump and main relay 5 25 A 3 Fuel pump does not operate Fuel leakage Check the fuel pump 6 10 Check the diaphragm for torn 6 11 Vapor separator malfunction Clogs the filter Check the filter 6 32 Fuel not supplied to the f...

Page 119: ...9 Check for wiring continuity between the igni tion coil and engine ECM 5 29 A 5 Check for wiring continuity between the igni tion coil and main relay 5 29 A 5 Ignition coil malfunction Check the ignition coil resistance 5 29 Engine ECM malfunction Replace the engine ECM 7 15 High pressure fuel line malfunction fuel pres sure is low Pressure regulator malfunction Check the pressure regulator 6 5 H...

Page 120: ...lve stuck to valve guide Symptom 2 Cause 1 Cause 2 Checking step Refer to page Air leakage throttle valve cylinder head Check the O rings and gaskets of the intake silencer and intake manifold 6 16 6 27 Throttle link malfunction Check the throttle link for clack or worn 6 18 Throttle link and throttle cable are not installed correctly Adjust the throttle link and throttle cable 10 16 Symptom 2 Cau...

Page 121: ...Water leakage from water pump housing Check the water pump housing 8 7 Check the insert cartridge 8 7 Check the outer plate cartridge 8 7 Clogged cooling water passage Check the cooling water passage power unit EX guide and upper case 2 24 Thermostat malfunction Check the thermostat 10 16 Buzzer comes on oil pressure alert indicator comes on Insufficient engine oil Add sufficient oil 10 5 Engine o...

Page 122: ...lay input voltage 5 48 A 7 Check for wiring continuity between the PTT switch and PTT relay 5 49 A 7 Check for wiring continuity between the PTT switch and fuse 5 49 A 7 PTT motor malfunction Check the PTT motor 9 42 Short open or loose connection of the PTT motor lead Check for wiring continuity between the PTT motor and PTT relay terminal A 7 PTT fluid pressure does not increase Manual valve ope...

Page 123: ...ual valve opened Manual valve malfunction Check the manual valve 9 45 Insufficient PTT fluid Add sufficient fluid 9 36 PTT fluid leakage Check the hydraulic pressure 9 34 Clogged fluid passage Disassemble and check the PTT unit 2 29 9 32 Symptom 2 Cause 1 Cause 2 Checking step Refer to page Shift rod operation malfunction Shift rod connection mal function Check the detent Check the shift rod con n...

Page 124: ... 13 Checking by use of the digital tester 5 13 Engine control units and components 5 14 Checking the main relay 5 14 Checking the engine ECM circuit 5 15 Checking the TPS 5 16 Checking the ISC 5 17 Checking the oil pressure sensor 5 19 Checking the hour meter 5 19 Checking the water pressure sensor option 5 21 Checking the speed sensor option 5 22 Fuel control units and components 5 23 Checking th...

Page 125: ... 5 37 Checking the engine shut off switch 5 37 Starting units and components 5 38 Checking the starter relay 5 38 Checking the engine start switch 5 39 Checking the neutral switch remote control 5 39 Starter motor 5 40 Removing the starter motor 5 42 Checking the starter motor operation 5 42 Checking the magnet switch 5 42 Checking the starter motor pinion 5 42 Disassembling the starter motor 5 43...

Page 126: ...em Electrical components Port view a Engine ECM b Starter motor c Thermoswitch d Rectifier Regulator e Ignition coil f Speed sensor coupler g Water pressure sensor coupler h Oil pressure sensor i Fuse holder a b c d e f g h i ...

Page 127: ... to the PTT relay e Flash indicator connector f Fuse 30 A starter relay g Fuse 30 A 20 A spare h Fuse 20 A engine start switch PTT switch i Fuse 20 A engine ECM ISC fuel injector high pressure fuel pump ignition coil YDIS j Fuse 50 A house battery k Fuse 50 A engine battery l Air temperature sensor A A a j i k g h e f l c d b A A ...

Page 128: ...5 3 ELEC Electrical system Aft view a Spark plug wire b High pressure fuel pump coupler c Fuel injector d Shift cut switch coupler e Neutral switch coupler a c d e b ...

Page 129: ...5 4 Electrical components 0 1 2 3 4 5 6 7 8 9 10 A Bow view a Hour meter b Main harness coupler c YDIS coupler d Water detection switch in fuel filter a b c d ...

Page 130: ...5 5 ELEC Electrical system Top view a Air pressure sensor b ISC c TPS d Joint connector e Engine temperature sensor f Lighting coil stator assembly g Pulser coil a b c d e f g ...

Page 131: ...lser coil lead under the breather hose and the wiring harness B Run the oil pressure sensor lead behind the Rectifier Regulator coupler C Install the ignition coil lead water pressure sensor lead and speed sensor lead D Install the ignition coil lead and speed sensor lead C D a b A B Electrical components Wiring harness routing ...

Page 132: ... power supply lead b on the left side of the part a B Do not fasten the starter motor lead a with a plastic tie C Fasten the wiring harness Rectifier Regulator lead c and the power supply lead b with a plastic tie D Install the starter motor lead a PTT motor lead d and isolator lead e with the holder E Run the ground lead between the PTT relay and the starter relay A a a b B C D E e d c ...

Page 133: ... 6 7 8 9 10 A Aft view A Run the fuel injector lead back side the fuel rail B Install the clamp to the spark plug wires 1 and 2 C Install the clamp to the spark plug wires 2 and 4 D Install the clamp to the spark plug wires 3 and 4 A B C D ...

Page 134: ...ensor lead c Junction box A Run the wiring harness up side the cooling water pilot hose a B Run the wiring harness in the bottom cowling groove C Hold the engine temperature sensor lead b and fasten them by the clamp D Install the pulser coil coupler to the junction box c c a b A B C D ...

Page 135: ...rness coupler f Isolator coupler g 6Y8 Multifunction Meter communication lead h Trim meter lead i Isolator lead j Trim sensor lead k PTT switch lead A Regular rotation model B Counter rotation model C Install the PTT motor lead and isolator lead with the clamp D Align the positioning tape on the flushing hose to the grommet face a b c f B B A A C d e A A B B D j k i g h c A B ...

Page 136: ...re sensor Ground Engine temperature sensor Air temperature sensor Shift cut switch Engine shut off switch Neutral switch Engine start switch Battery Main relay Ignition coil 1 4 Ignition coil 2 3 Engine ECM Oil pressure sensor Thermoswitch Rectifier Regulator Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4 Oil pressure lamp Over heat lamp Diagnostic flash indicator Alert buzzer Tac...

Page 137: ... Green 17 Fuel injector 4 Purple Green 18 ISC Green Black 19 ISC Green 20 ISC Green Red 21 ISC Green Yellow 22 Ignition coil 1 4 Black Orange 23 6Y8 Multifunction Meter Blue 24 Alert indicator low oil pressure Pink White 25 26 YDIS White Black 27 Diagnostic flash indi cator Blue White 28 Alert indicator overheat Pink Black 29 Oil pressure sensor Pink White 30 Battery power source Red Yellow 31 Neu...

Page 138: ...ction Manual Measuring the peak voltage When checking the peak voltage do not touch any of the connections of the digital tester probes When testing the voltage between the ter minals of an electrical component with the digital tester do not allow any of the leads to touch any metal parts If touched the electrical component can be short cir cuited and be damaged To check the electrical components ...

Page 139: ...elay a 2 Connect the positive battery lead to the relay terminal a and the negative bat tery lead to the relay terminal b and then check for continuity between termi nals c and d Replace the relay if out of specification NOTICE Do not reverse the battery leads 3 Measure the input voltage between the terminal e and ground and the terminal f and ground Test lead Terminal male a 9E212 10303 Terminal ...

Page 140: ...isconnect the engine ECM coupler a 2 Check for continuity between the engine ECM coupler terminals 32 and 42 and ground 3 Measure the input voltage at the engine ECM coupler terminal 16 and ground 4 Turn the engine start switch to ON and then measure the input voltage at the engine ECM coupler terminal 13 and ground Main relay input voltage Terminal f Terminal g 12 0 V battery voltage g f a Engine...

Page 141: ...ine and warm up and then turn it off 3 Turn the engine start switch to ON and then measure the output voltages of TPS and the throttle valve opening angle when the remote control lever is at the fully closed position a and fully open position b Engine ECM input voltage reference data Terminal 13 Ground 11 2 V Wiring harness continuity Terminal 16 Terminal b Terminal 30 Terminal c a 13 a 16 30 c b ...

Page 142: ...pler f 8 Check the wiring harness for continuity 9 Connect the engine ECM coupler f and then install the junction box cover 10 Install the TPS and then connect the TPS coupler e Checking the ISC 1 Remove the ISC 2 Check the proper movement of ISC valve using the Stationary test of the YDIS TPS output voltage reference data Free position c Full turn position d 0 298 V 4 980 V TPS input voltage Oran...

Page 143: ...e main relay a and then disconnect the engine ECM coupler b 7 Check the wiring harness for continuity 8 Install the main relay a 9 Connect the engine ECM coupler b and then install the junction box cover 10 Connect the ISC coupler a ISC input voltage Red Yellow R Y Ground 12 0 V battery voltage a R Y R Y b a Wiring harness continuity Terminal 1 Terminal 20 Terminal 2 Terminal c Terminal 3 Terminal...

Page 144: ... ECM coupler b 6 Check the wiring harness for continuity 7 Connect the engine ECM coupler b and then install the junction box cover 8 Connect the oil pressure sensor coupler a Checking the hour meter 1 Disconnect the hour meter coupler a 2 Turn the engine start switch to ON and then measure the input voltage Test harness 3 pins a 90890 06869 Oil pressure sensor input voltage Orange O Black B 4 75 ...

Page 145: ... the engine ECM coupler c and then install the junction box cover 8 Connect the 10 pin main harness coupler b and hour meter coupler a Hour meter input voltage reference data Yellow Y Black B 11 2 V a Y B b Wiring harness continuity a Terminal 1 b Terminal 3 a Terminal 1 c Terminal 13 a Terminal 2 b Terminal 2 a Terminal 2 c Terminal 2 a Terminal 3 b Terminal 9 a Terminal 3 Ground b Terminal 2 c T...

Page 146: ...a 6 Remove the junction box cover and then disconnect the engine ECM coupler b 7 Check the wiring harness for continuity 8 Install the water pressure sensor and then connect the water pressure sensor coupler a 9 Connect the engine ECM coupler b and then install the junction box cover Water pressure sensor input voltage reference data Orange O Black B 4 75 5 25 V Pressure pump a commercially availa...

Page 147: ...b and pressure pump a 6 Remove the junction box cover and then disconnect the engine ECM coupler b 7 Check the wiring harness for continuity 8 Install the speed sensor and then con nect the speed sensor coupler a 9 Connect the engine ECM coupler b and then install the junction box cover Speed sensor input voltage reference data Orange O Black B 4 75 5 25 V Pressure pump a commercially available Te...

Page 148: ...witch make sure that the float a is able to move smoothly 5 Check the water detection switch for conti nuity with the float in positions A and B NOTICE Make sure not to remove the clip b and float a 6 Remove the junction box cover and then disconnect the engine ECM coupler e 7 Check the wiring harness for continuity Water detection switch input voltage Blue White L W Black B 4 75 5 25 V L W B a b ...

Page 149: ... operating sound 2 Disconnect the fuel injector couplers a 3 Turn the engine start switch to ON and then measure the input voltage between the fuel injector coupler terminal and ground 4 Turn the engine start switch to OFF 5 Measure the fuel injector resistance 6 Remove the junction box cover and the main relay a and then disconnect the engine ECM coupler b 7 Check the wiring harness for continuit...

Page 150: ...s after turning the engine start switch to ON 4 Turn the engine start switch to OFF 5 Measure the resistance of the high pres sure fuel pump motor 6 Remove the junction box cover and the main relay a and then disconnect the engine ECM coupler b 7 Check the wiring harness for continuity Wiring harness continuity Fuel injector 1 Terminal 1 Terminal c Terminal 2 Terminal 40 Fuel injector 2 Terminal 1...

Page 151: ...g coil output peak voltage between all combinations of the terminals Replace the lighting coil if below specification 3 Measure the lighting coil resistance 4 Disconnect the test harness a and then connect the lighting coil coupler a Wiring harness continuity Terminal 1 Terminal c Terminal 2 Terminal 43 c b 43 a Test harness 3 pins a 90890 06847 Lighting coil output peak voltage Green G Green G r ...

Page 152: ...adapter B when measuring the Rectifier Regulator output peak voltage 3 Disconnect the test harness a and light ing coil coupler 4 Make sure to set the measurement range b and display the mark c by pushing the switch d A Tester model CD721 B Tester model CD731a 5 Check the Rectifier Regulator for continu ity Replace if out of specification Test harness 3 pins a 90890 06846 Rectifier Regulator outpu...

Page 153: ... special service tool 5 Remove the special service tool a and then connect the spark plug caps 6 Install the spark plug wire cover Checking the spark plug wire 1 Remove the spark plug wire cover 2 Disconnect the spark plug wires 3 Measure the spark plug wire resistance Replace if out of specification Rectifier Regulator continuity testing diode mode Tester probe Display value reference data e h 0 ...

Page 154: ...place if out of specification 6 Remove the junction box cover and main relay b and then disconnect the engine ECM coupler b 7 Check the wiring harness for continuity Spark plug wire resistance 1 4 6 10 9 kΩ 2 3 3 8 0 kΩ 3 3 8 9 3 kΩ 4 4 2 10 0 kΩ at 20 C 68 F Ignition coil input voltage Red Yellow R Y Ground 12 0 V battery voltage Test harness 2 pins a 90890 06792 a R Y B W B W R R Y B W B O a a I...

Page 155: ...e disconnect the coupler a When measuring the pulser coil output peak voltage under the loaded cranking condition is done remove the clip from the engine shut off switch to prevent the engine from starting 3 Disconnect the test harness a and then measure the pulser coil resistance Wiring harness continuity Ignition coil 1 4 Terminal 1 Terminal 22 Terminal 2 Terminal c Ignition coil 2 3 Terminal 1 ...

Page 156: ... within 5 C 9 F TIP Check the air temperature sensor when the engine is cold When checking the air temperature sensor remove the top cowling and do not start the engine 4 Disconnect the air temperature sensor coupler a 5 Turn the engine start switch to ON and then measure the input voltage at the air temperature sensor coupler 6 Turn the engine start switch to OFF and then remove the air temperatu...

Page 157: ...ture sensor and then connect the air temperature sensor coupler a Checking the air pressure sensor 1 Disconnect the air pressure sensor cou pler a 2 Turn the engine start switch to ON and then measure the input voltage at the air pressure sensor coupler 3 Remove the air pressure sensor Air temperature sensor resistance reference data 2 21 2 69 kΩ at 20 C 68 F 0 32 kΩ at 80 C 176 F Wiring harness c...

Page 158: ...onnect the engine ECM coupler b and then install the junction box cover 10 Connect the air pressure sensor coupler a Checking the engine temperature sensor 1 Disconnect the engine temperature sen sor coupler a 2 Turn the engine start switch to ON and then measure the input voltage at the engine temperature sensor coupler Vacuum pressure pump gauge set a 90890 06756 Test harness 3 pins b 90890 0686...

Page 159: ...tion box cover and then disconnect the engine ECM coupler b 9 Check the wiring harness for continuity 10 Connect the engine ECM coupler b and then install the junction box cover 11 Connect the engine temperature sensor coupler a Checking the thermoswitch 1 Disconnect the thermoswitch connectors Engine temperature sensor input voltage Black Yellow B Y Black B 4 75 5 25 V Engine temperature sensor r...

Page 160: ... 6 Check the switch for continuity at the specified temperatures Replace if out of specification a Temperature b Time c No continuity d Continuity 7 Install the thermoswitch 8 Remove the junction box cover and then disconnect the engine ECM coupler g 9 Check the wiring harness for continuity Thermoswitch input voltage reference data Pink P Black B 11 1V P B P B Thermoswitch continuity temperature ...

Page 161: ...t cut switch resistance 6 Remove the junction box cover and then disconnect the engine ECM coupler d 7 Check the wiring harness for continuity 8 Connect the engine ECM coupler d and then install the junction box cover 9 Install the shift cut switch and then con nect the shift cut switch coupler a Wiring harness continuity Pink P Terminal 37 Black B Terminal 8 Shift cut switch input voltage Blue Ye...

Page 162: ...and then install the junction box cover 9 Install the neutral switch and then con nect the neutral switch coupler a Checking the engine shut off switch 1 Disconnect the engine start switch cou pler 2 Turn the engine start switch to ON and then check the engine shut off switch for continuity at the engine start switch cou pler Check the wiring harness or replace the engine shut off switch if out of...

Page 163: ...then remove the starter relay NOTICE Always disconnect the neg ative battery terminal before discon necting the starter relay terminals 4 Connect the positive battery lead to the relay connector b and the negative bat tery lead to the relay lead c and then check for continuity between terminals a and d Replace the starter relay if out of specification Switch position Terminal a b Clip removed Clip...

Page 164: ...te control B 703 remote control 3 Connect the engine start switch coupler Checking the neutral switch remote control 1 Disconnect the remote control coupler 2 Check the neutral switch for continuity A 704 remote control B 703 remote control TIP Turn the engine start switch to START posi tion when checking the continuity on the 703 remote control 3 Connect the remote control coupler Battery lead Te...

Page 165: ...ssembly 1 6 Starting motor gear assembly 1 7 Washer set 1 8 Bracket 1 9 Screw 2 M4 15 mm 10 Bolt 2 M6 117 mm 11 Bolt 2 M6 35 mm 12 Cover assembly 1 13 Clutch assembly 1 14 Bracket 1 15 Gasket 1 Not reusable 16 Outer gear 1 17 Washer 1 M M 24 9 10 8 5 1 2 13 23 26 28 12 11 21 4 22 7 6 3 6 7 15 19 20 18 17 14 16 25 27 Starting units and components Starter motor ...

Page 166: ... 4 22 7 6 3 6 7 15 19 20 18 17 14 16 25 27 No Part name Q ty Remarks 18 Pinion shaft 1 19 Planetary gear 3 20 Plate 1 21 Starter motor pinion 1 22 Pinion stopper set 1 23 Rubber seal 1 24 Lever assembly 1 25 Gasket 1 Not reusable 26 Magnet switch 1 27 Washer 1 28 Nut 1 ...

Page 167: ...he negative battery cable and positive battery cable from the bat tery terminals Checking the magnet switch 1 Connect the tester probes to the magnet switch terminals a and b 2 Connect the negative battery cable to the starter motor body c 3 Connect the positive battery cable to the starter motor lead Brown White d and then check the magnet switch continuity NOTICE Do not connect the starter motor...

Page 168: ...r 1 Remove the magnet switch a and spring b 2 Slide the pinion stopper c down and then remove the clip d 3 Remove the pinion stopper c pinion e and spring f 4 Remove the bolts g and then disassem ble the starter motor 5 Remove the rubber seal h lever i and pinion shaft assembly j 6 Remove the stator k 7 Remove the armature l with the brush holder assembly m from the bracket n a b d d c c c e f g i...

Page 169: ...ne spline in direction b and then remove it in direction c Checking the starter motor 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty 2 Measure the commutator diameter a Replace the armature if below specifica tion 3 Measure the commutator undercut b Replace the armature if below specifica tion m l l o o m q r r p a b c c b a q q r Commutator standard diameter a 29...

Page 170: ...w specification Assembling the starter motor Do not allow grease or oil to contact the commutator of the armature 1 Push the brushes a into the holders and then install the armature b to the brush holder assembly 2 Install the plate c 3 Install the armature assembly d to the bracket e and then install the screw f and stator g Armature continuity c d e f Brush holder assembly continuity a b c d e c...

Page 171: ...tch assembly j completely down onto the pinion shaft k in direction c and rotate it one spline in direction d and then slide it in direction e 6 Install the E clip l TIP Make sure that the clutch assembly j does not come out from the pinion shaft k 7 Install the pinion shaft assembly m lever n rubber seal o planetary gears p outer gear q and plate r e d f g e d a a b b h k i j j j k k l c d e e c ...

Page 172: ...d magnet switch x TIP Check the operation of the starter motor before installing it to the power unit To check the operation of the starter motor see Checking the starter motor operation 5 42 Installing the starter motor 1 Install the starter motor to the power unit See Starter motor 7 12 2 Install the junction box cover s t t u u v x w x w n ...

Page 173: ...rminals 4 Connect the test harness 2 pins a 5 Check the PTT relay for continuity Replace the PTT relay if out of specifica tion 6 Connect the positive battery lead to the terminal e and the negative battery lead to the terminal b and then check the PTT relay for continuity Replace the PTT relay if out of specification PTT relay input voltage Terminal a Terminal b 12 0 V battery voltage Test harnes...

Page 174: ...box cover Checking the PTT switch on bottom cowling 1 Disconnect the PTT switch coupler a 2 Measure the input voltage between the PTT switch coupler terminal and ground 3 Check the PTT switch for continuity Replace the PTT switch if out of specifi cation 4 Remove the junction box cover 5 Disconnect the PTT relay coupler e 6 Check the wiring harness for continuity PTT relay continuity a b c d G W G...

Page 175: ... and measure the resistance as it grad ually changes 4 Disconnect the gauge harness coupler d 5 Check the wiring harness for continuity 6 Install the trim sensor 7 Connect the gauge harness coupler d and trim sensor coupler a Wiring harness continuity a Terminal 1 e Terminal 1 a Terminal 2 e Terminal 2 a Terminal 3 Terminal c f e a a Trim sensor resistance reference data 238 8 378 8 Ω at b 9 0 11 ...

Page 176: ...embling the fuel pump 6 10 Checking the diaphragm and valve 6 11 Assembling the fuel pump 6 11 Checking the primer pump 6 12 Fuel filter 6 13 Checking the fuel filter assembly 6 14 Intake silencer 6 16 Throttle link 6 17 Checking the throttle link 6 18 Installing the throttle link 6 18 Adjusting the throttle link 6 19 Throttle body 6 20 Checking the TPS 6 21 Adjusting the TPS 6 21 Installing the t...

Page 177: ... 6 28 Checking the air pressure sensor 6 28 Checking the ISC 6 28 Installing the intake manifold 6 28 Vapor separator 6 29 Draining the fuel 6 32 Checking the vacuum hose 6 32 Checking the fuel filter 6 32 Disassembling the vapor separator 6 32 Checking the high pressure fuel pump 6 32 Checking the vapor separator 6 32 Assembling the vapor separator 6 33 ...

Page 178: ...g Fuel hose joint to filter h Fuel hose filter to vapor separator i Fuel hose vapor separator to fuel rail j Fuel hose pressure regulator to fuel cooler k Fuel hose fuel cooler to vapor separator l Blowby hose cylinder block to cylinder head cover m Blowby hose cylinder head cover to intake silencer a Primer pump b Fuel filter c Fuel pump d Filter e Vapor separator f Fuel rail g Pressure regulator...

Page 179: ...ster tank port e Vapor gas hose canister purge port to joint f Vapor gas hose joint to joint g Vapor gas hose canister atmospheric port to filter h Vapor gas hose filter to joint i Vapor gas hose joint to bottom cowling j Vacuum hose intake manifold to pressure regulator a Vapor separator b Joint c Filter d Canister e Filter f Pressure regulator A B A B h g i e d e a b j d a c a b b a c f j f f c ...

Page 180: ...ooling water hose exhaust cover to fuel cooler b Cooling water pilot hose fuel cooler to cooling water pilot hole c Flushing hose exhaust cover to flushing hose adapter a Fuel cooler b Cooling water pilot hole on the bottom cowl ing a a b a c b ...

Page 181: ...uel pressure TIP The fuel pressure decreases after 3 seconds later when the engine start switch is turned to ON 5 Start the engine and warm up and then measure the fuel pressure at the stable idle condition of 650 750 r min If below specification check the high pressure fuel line and the vapor separator 6 Turn the engine start switch to OFF 7 Disconnect the special service tool b and then install ...

Page 182: ...ING Make sure that the drain screw e is tightened securely before starting the engine 5 Check that the fuel pressure is reduced when vacuum pressure is applied to the pressure regulator If the fuel pressure is not reduced replace the pressure regu lator 6 Turn the engine start switch to OFF 7 Disconnect the special service tool c and then connect the pressure regulator hose b 8 To disconnect the s...

Page 183: ...usable 3 Joint 1 4 Hose 1 5 Clamp 1 6 Hose 1 7 Bolt 1 M6 16 mm 8 Filter 1 9 Bracket 1 10 Canister 1 11 Bolt 1 M6 42 mm 12 Grommet 3 13 Collar 3 14 Bolt 2 M6 30 mm 15 Bracket 1 16 Hose 1 17 Hose 1 1 3 11 12 13 12 13 14 2 16 2 2 4 5 2 6 7 8 9 10 2 2 17 10 N m 1 0 kgf m 7 4 ft lb 12 13 15 Fuel line Canister ...

Page 184: ...ll the grommets a and collars b to the bracket c 2 Install the bracket c and temporarily tighten the fuel pump assembly bolt d and cylinder head cover bolts e 3 Tighten the fuel pump assembly bolt d to the specified torque TIP Tighten the cylinder head cover bolts e to the general torque in 2 stages 4 Install the canister using the bracket and the bolt See exploded diagram 6 6 Vacuum pressure pump...

Page 185: ...ump body 1 1 7 Nut 3 8 Spring 1 9 Plunger 1 10 Pin 1 11 Fuel pump assembly 2 12 Hose 1 13 Joint 2 14 Plastic tie 10 Not reusable 15 Hose 1 16 Bolt 3 M6 30 mm 17 Bolt 1 M6 42 mm 10 N m 1 0 kgf m 7 4 ft lb 10 N m 1 0 kgf m 7 4 ft lb 4 N m 0 4 kgf m 3 0 ft lb 1 1 2 3 4 5 6 7 7 8 9 10 11 11 11 12 13 13 14 14 14 14 14 14 18 15 16 17 18 16 19 20 Canister Fuel pump ...

Page 186: ...t name Q ty Remarks 18 O ring 2 Not reusable 19 Hose 1 20 Hose 1 10 N m 1 0 kgf m 7 4 ft lb 10 N m 1 0 kgf m 7 4 ft lb 4 N m 0 4 kgf m 3 0 ft lb 1 1 2 3 4 5 6 7 7 8 9 10 11 11 11 12 13 13 14 14 14 14 14 14 18 15 16 17 18 16 19 20 ...

Page 187: ...t b 5 Apply the specified positive pressure and check that there is no air leakage Disassembling the fuel pump 1 Disassemble the fuel pump assembly into the fuel pump body 1 assembly a the fuel pump body 2 b and the cover c 2 Hold the fuel pump body 1 assembly a Vacuum pressure pump gauge set a 90890 06756 Specified positive pressure 50 0 kPa 0 50 kgf cm2 7 3 psi Specified negative pressure 30 0 k...

Page 188: ... if torn 2 Check the valves b Replace the fuel pump body 2 c if deformed or worn Assembling the fuel pump Before assemble the fuel pump clean the parts and soak the valves and diaphragm in gasoline to obtain prompt operation of the fuel pump 1 Assemble fuel pump body 1 assembly a 2 Hold the fuel pump body 1 assembly a 3 Make sure that the holes c in the plunger c and diaphragm d are aligned a a c ...

Page 189: ... to make sure that it moves smoothly 7 Assemble the fuel pump assembly TIP Make sure to align the projections a b and c Checking the primer pump 1 Connect the special service tool a to the primer pump inlet hose 2 Cover the fuel outlet a with a finger 3 Apply the specified positive pressure to check that the pressure is maintained for at least 30 seconds Replace the primer pump if it does not main...

Page 190: ...usable 4 Hose 1 5 Hose 1 6 Bolt 2 M6 30 mm 7 Bolt 2 M6 14 mm 8 Collar 2 9 Grommet 2 10 Bracket 1 11 Hose 1 12 Fuel filter assembly 1 13 O ring 1 Not reusable 14 Fuel filter element 1 15 Fuel cup assembly 1 16 Clip 1 17 Float 1 5 N m 0 5 kgf m 3 7 ft lb 1 2 2 3 3 3 3 4 5 7 8 9 10 11 12 12 13 14 15 16 17 6 ...

Page 191: ...l outlet b 4 Cover the fuel inlet a with a finger and then apply the specified negative pres sure Replace the O ring fuel cup assembly or fuel filter assembly if the specified pressure cannot be maintained for at least 15 seconds 5 Disassemble the fuel filter assembly TIP Do not twist the water detection switch lead c when removing the fuel cup assembly c 6 Check the fuel filter element d Replace ...

Page 192: ...p assembly c make sure not to remove the clip e and float f otherwise the water detection switch may be dam aged 8 Check the water detection switch See Checking the water detection switch 5 23 9 Assemble the fuel filter assembly TIP Do not twist the water detection switch lead c when installing the fuel cup assembly c Fuel cup assembly c 5 N m 0 5 kgf m 3 7 ft lb c c ...

Page 193: ... Q ty Remarks 1 Intake silencer assembly 1 2 O ring 4 Not reusable 3 Collar 6 4 Collar 2 5 Grommet 4 6 Bolt 6 M6 20 mm 7 Clamp 1 8 Bolt 2 M6 45 mm 1 2 2 3 4 5 7 8 6 N m 0 6 kgf m 4 4 ft lb 2 3 3 8 5 4 5 5 6 6 6 3 3 6 N m 0 6 kgf m 4 4 ft lb 6 6 6 6 Fuel filter Intake silencer ...

Page 194: ...ame Q ty Remarks 1 Bolt 1 M6 35 mm 2 Collar 1 3 Wave washer 3 4 Throttle cam 1 5 Roller 1 6 Bolt 2 M6 25 mm 7 Collar 2 8 Throttle lever 1 1 9 Washer 3 10 Spring 1 11 Throttle link rod 1 12 Throttle lever 2 1 1 2 3 3 3 4 5 6 6 7 7 8 9 9 9 10 11 12 ...

Page 195: ...ng f onto the throt tle cam g make sure to fit the end a of the spring into the slot b in the throttle cam g and then install the washer h wave washer i and collar j onto the throttle cam g 4 Install the throttle cam g to the cylinder block Make sure to fit the end c of the spring on the projection d in the cylinder block 5 Install the throttle link rod k washer l wave washer m and collar n onto t...

Page 196: ... the stopper a on the throttle lever 2 a to the fully closed stopper b on the cylinder block and then adjust the throttle link joint assembly b so that the specified clearance c is obtained 2 Tighten the locknut c Roller clearance c 0 50 mm 0 02 in b a c b a c ...

Page 197: ...16 mm 6 Bolt 2 M8 20 mm 7 Bolt 6 M8 70 mm 8 Throttle body assembly 1 9 Screw 2 M4 12 mm 10 TPS 1 11 O ring 1 Not reusable 12 Synchronizing screw 1 13 Throttle stop screw 1 14 Spring 3 15 Nut 2 16 Spring washer 1 17 Screw 8 M6 16 mm 17 17 17 17 A 4 6 5 16 15 14 11 8 10 9 9 1 14 14 14 13 12 13 12 7 2 3 4 5 6 UP A 7 13 N m 1 3 kgf m 9 6 ft lb Throttle link Throttle body ...

Page 198: ...to ON 6 Measure the TPS output voltage with the throttle valves fully closed If the output voltage is out of specification adjust the position of the TPS d 7 Loosen the TPS screws e and adjust the position of the TPS d to get the specified output voltage TIP To increase the output voltage turn the TPS d in direction b To decrease the output voltage turn the TPS d in direction c 8 Tighten the TPS s...

Page 199: ...dy When adjusting the TPS the output voltage can also be measured using the Engine monitor of the YDIS To connect and operate the YDIS see the YDIS Ver 1 30 or later Instruction Manual 1 Install the throttle body assembly 2 Install the throttle link See Installing the throttle link 6 18 3 Loosen the synchronizing screw a to open throttle valves 3 and 4 4 Loosen the throttle stop screw b to fully c...

Page 200: ...en the throttle stop screw b until the TPS output voltage is within specification 12 Operate the throttle valves several times and make sure that the TPS output volt age is within specification 13 Adjust the throttle link See Adjusting the throttle link 6 19 14 Install the intake silencer See Intake silencer 6 16 Synchronizing the throttle valve Do not adjust the throttle valves when they are oper...

Page 201: ...tion a To decrease the vacuum pressure turn the synchronizing screw e in direction b Example Check results Adjust the difference of the vacuum pressure between cylinders 1 and 4 to within 2 0 kPa 15 0 mmHg Check results Adjust the difference of the vacuum pressure between cylinders 2 and 4 to within 2 0 kPa 15 0 mmHg 5 Attach the special service tool f to spark plug wire 1 g and then check the eng...

Page 202: ...4 Fuel rail 1 5 Clamp 3 6 O ring set 1 Not reusable 7 Fuel injector 4 8 Rubber seal 4 Not reusable 9 Bolt 2 M6 25 mm 10 Fuel cooler 1 11 Clamp 1 1 2 3 3 4 5 6 7 7 7 7 8 8 8 8 5 5 11 9 9 10 13 N m 1 3 kgf m 9 6 ft lb 13 N m 1 3 kgf m 9 6 ft lb 5 N m 0 5 kgf m 3 7 ft lb 11 5 12 mm 0 47 in 10 mm 0 39 in ...

Page 203: ...a new O ring set a and a new rubber seal b to the fuel injector c 2 Install the fuel injectors c onto the fuel rail d 3 Install the fuel rail d onto the intake manifold e 4 Tighten the bolts f equally and gradu ally to the specified torque 5 Install the wiring harness coupler a to the holder 6 Install the wiring harness by fitting the projection of the holders g into the fuel rail stay hole b a b ...

Page 204: ...sket 4 Not reusable 3 O ring 1 Not reusable 4 Holder 1 5 Filter 1 6 Air pressure sensor 1 7 Screw 2 M5 15 mm 8 Screw 3 M4 15 mm 9 ISC 1 10 Intake manifold 1 11 Gasket 2 Not reusable 12 Cap 4 13 Bolt 5 M8 40 mm 1 1 13 12 12 2 13 13 10 5 4 3 11 6 7 7 8 9 5N m 0 5 kgf m 3 7 ft lb ...

Page 205: ...ctrical performance See Checking the air pres sure sensor 5 32 Checking the ISC 1 Check the ISC exterior Replace if cracked 2 Check the ISC electrical performance See Checking the ISC 5 17 Installing the intake manifold 1 Install new gaskets onto the intake mani fold Make sure that tab on the gaskets is properly and firmly fitted into the groove on the intake manifold 2 Install the pins a 3 Align ...

Page 206: ... M6 35 mm 9 Hose 1 10 Clamp 6 11 Hose 1 12 Hose 1 13 Wiring harness 1 14 Hose 1 15 Hose 1 16 Hose 1 17 Holder 1 1 2 3 4 4 5 6 6 7 7 8 8 9 10 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 34 35 36 37 38 39 40 40 41 3 7 7 10 10 10 10 5 N m 0 5 kgf m 3 7 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 kgf m 1 5 ft lb 5 N m 0 5 kgf m 3 7 ft lb ...

Page 207: ...Pressure regulator 1 27 Screw 7 M4 16 mm 28 Cover assembly 1 29 Pin 1 30 Cap 1 31 Grommet 1 32 Plate 1 33 Plate 1 34 Screw 3 M4 8 mm 1 2 3 4 4 5 6 6 7 7 8 8 9 10 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 34 35 36 37 38 39 40 40 41 3 7 7 10 10 10 10 5 N m 0 5 kgf m 3 7 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 kgf m 1 5 ft lb 5 N m 0 5 kgf m 3 7 ft lb ...

Page 208: ... Filter 1 39 Filter holder 1 40 Vapor separator 1 41 Drain screw 1 1 2 3 4 4 5 6 6 7 7 8 8 9 10 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 34 35 36 37 38 39 40 40 41 3 7 7 10 10 10 10 5 N m 0 5 kgf m 3 7 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 kgf m 1 5 ft lb 5 N m 0 5 kgf m 3 7 ft lb ...

Page 209: ... dirt residue or external damage Disassembling the vapor separator 1 Remove the float pin a in the direction of the arrow a 2 Remove the needle valve assembly and other components See exploded dia gram 6 29 Checking the high pressure fuel pump 1 Check the high pressure fuel pump elec trical performance See Checking the high pressure fuel pump 5 25 Checking the vapor separator 1 Place the cover ass...

Page 210: ...filter Clean if there is dirt or residue Assembling the vapor separator 1 Install the needle valve assembly and float to the cover assembly and then insert the float pin a in the direction a 2 Check the float for smooth operation 3 Check the float height See Checking the vapor separator 6 32 step 1 4 Assemble the vapor separator See exploded diagram 6 29 a a ...

Page 211: ...6 34 Vapor separator 0 1 2 3 4 5 6 7 8 9 10 A MEMO ...

Page 212: ...7 9 Starter motor 7 12 Fuse box 7 14 Junction box 7 15 Timing belt 7 17 Replacing the timing belt 7 18 Power unit assembly 7 20 Removing the power unit 7 22 Installing the power unit 7 23 Camshaft 7 26 Removing the timing belt driven sprocket and camshaft 7 28 Checking the timing belt and sprocket 7 29 Checking the camshaft 7 29 Installing the timing belt driven sprocket and camshaft 7 30 Exhaust ...

Page 213: ...48 Checking the oil pump assembly 7 48 Assembling the oil pump assembly 7 49 Installing the oil pump assembly 7 49 Installing the crankcase cover 7 50 Installing the oil filter 7 50 Installing the anode cylinder block 7 51 Crankcase 7 52 Disassembling the cylinder block 7 53 Checking the piston diameter 7 54 Checking the cylinder bore 7 54 Checking the piston ring 7 54 Checking the piston ring end...

Page 214: ...e lever in the fully open position of the throttle 6 Crank the engine until the reading on the compression gauge stabilizes and then measure the compression pressure 7 If the compression pressure is below specification and the compression pressure for each cylinder is unbalanced add a small amount of engine oil to the cylinder and then measure the compression pressure again TIP If the compression ...

Page 215: ...otherwise the water pump impeller may be damaged 1 Reduce the fuel pressure See Reducing the fuel pressure 6 4 TIP When measuring the valve clearances the fuel line must be disconnected so make sure to reduce the fuel pressure before performing the disconnection procedure 2 Remove the flywheel magnet cover and spark plug wire cover 3 Disconnect the fuel hoses a and vapor gas hoses b and then remov...

Page 216: ...ise otherwise the water pump impeller may be damaged Do not turn the flywheel magnet or the driven sprockets when the timing belt is not installed Otherwise the pistons and valves or intake and exhaust valves will collide with each other and be damaged 1 Align the TDC mark on the flywheel magnet with the pointer and check that the I marks on the driven sprockets are aligned See Checking the valve ...

Page 217: ...nstall the necessary valve shim into the valve lifter 9 Install the camshafts driven sprockets and timing belt See Installing the timing belt driven sprocket and camshaft 7 30 10 Install the stator assembly lighting coil 11 Install the flywheel magnet See Installing the flywheel magnet 7 6 12 Measure each valve clearance and adjust again if out of specification 13 Install the cylinder head cover a...

Page 218: ...lats 36 mm 2 Washer 1 3 Base assembly 1 4 Screw 4 M6 30 mm 5 Stator assembly lighting coil 1 6 Pulser coil 1 7 Holder 1 8 Bracket 2 9 Bolt 4 M6 35 mm 10 Holder 1 11 Collar 2 12 Flywheel magnet 1 13 Woodruff key 1 1 2 3 4 4 5 6 7 8 8 9 9 9 9 10 11 11 12 13 270 N m 27 0 kgf m 199 1 ft lb ...

Page 219: ... parallel to the flywheel magnet Installing the flywheel magnet 1 Install the Woodruff key a and then install the flywheel magnet b TIP Make sure to remove any grease from the tapered portion of the crankshaft a and the flywheel magnet b Apply engine oil to the thread c of the fly wheel magnet nut and upper and lower sur face d of the washer before installation 2 Tighten the flywheel magnet nut to...

Page 220: ...7 7 Power unit POWR Wiring harness No Part name Q ty Remarks 1 Wiring harness 1 2 Bolt 3 M6 20 mm 3 Wiring harness 1 4 Bolt 1 M6 12 mm 5 Washer 1 6 Bolt 1 M8 16 mm 7 Wiring harness 1 1 2 3 6 7 4 5 2 ...

Page 221: ...tch coupler e and neutral switch coupler f 6 Disconnect the all fuel injector couplers 7 Disconnect the fuel pump coupler g 8 Remove the projection h of the plastic tie from the fuel rail a 9 Disconnect the TPS coupler k ISC coupler m air pressure sensor coupler n and engine temperature sensor coupler p and then remove the wiring harness from the brackets b 10 Disconnect the hour meter coupler r 1...

Page 222: ...relay leads B PTT relay coupler D and ground leads E 16 Remove the air temperature sensor coupler F and YDIS coupler G Installing the wiring harness To install all of the wiring harnesses see Wiring harness routing 5 6 1 Install the sensors and switches that were removed to the power unit 2 Install the air temperature sensor coupler a and YDIS coupler b 3 Connect the starter relay leads c PTT rela...

Page 223: ... engine ECM b and then connect the engine ECM coupler p and pulser coil coupler r 7 Install the cover c 8 Connect the hour meter coupler s 9 Install the wiring harness to the brackets d and then connect the TPS coupler t ISC coupler u air pressure sensor coupler v and engine temperature sensor coupler w 10 Insert the projections x on the plastic ties e into the holes in the fuel rail f and then co...

Page 224: ...l switch coupler B 13 Connect the PTT switch coupler D trim sensor coupler E gauge harness coupler F and water detection switch coupler G and then install the gauge harness coupler F to the bracket 14 Install the flywheel magnet See Installing the flywheel magnet 7 6 15 Install the flywheel magnet cover B A D E F G ...

Page 225: ...Holder 2 7 Bolt 2 M6 12 mm 8 Ignition coil 2 9 Holder 1 10 Holder 1 11 Bracket 2 12 Holder 2 13 Bolt 4 M6 25 mm 14 Cap 1 15 Bolt 1 M6 10 mm 16 Starter motor lead 1 17 Bolt 3 M8 45 mm 9 N m 0 9 kgf m 6 6 ft lb 29 N m 2 9 kgf m 21 4 ft lb 4 N m 0 4 kgf m 3 0 ft lb 7 N m 0 7 kgf m 5 2 ft lb 20 21 19 18 16 17 15 14 8 8 11 11 12 12 10 9 6 6 5 4 3 2 1 7 7 13 13 Wiring harness Starter motor ...

Page 226: ... ty Remarks 18 Cap 1 19 Nut 1 20 Terminal 1 21 Starter motor 1 9 N m 0 9 kgf m 6 6 ft lb 29 N m 2 9 kgf m 21 4 ft lb 4 N m 0 4 kgf m 3 0 ft lb 7 N m 0 7 kgf m 5 2 ft lb 20 21 19 18 16 17 15 14 8 8 11 11 12 12 10 9 6 6 5 4 3 2 1 7 7 13 13 ...

Page 227: ... Remarks 1 Fuse box assembly 1 2 Fuse 2 50 A 3 Screw 4 M5 10 mm 4 Fuse 2 20 A 5 Relay 1 6 Fuse 1 30 A 7 Screw 3 M5 20 mm 8 Cover 1 9 Gasket 1 10 Fuse puller 1 11 Fuse 1 20 A Spare 12 Fuse 1 30 A Spare 10 1 9 8 2 4 4 6 5 11 12 7 6 4 5 3 3 2 2 7 Starter motor Fuse box ...

Page 228: ...et 1 6 Holder 1 7 Hour meter 1 8 Screw 2 M5 16 mm 9 Collar 3 10 Grommet 3 11 Junction box 1 12 Collar 4 13 Grommet 1 14 Bolt 3 M6 35 mm 15 Plastic tie 2 16 Engine ECM 1 17 Bolt 4 M6 16 mm 17 17 18 19 22 14 11 10 23 1 2 4 4 5 6 1 7 8 3 23 31 29 25 23 24 9 12 13 15 15 26 20 16 21 28 27 4 N m 0 4 kgf m 3 0 ft lb 3 30 10 9 ...

Page 229: ...10 mm 21 Bolt 2 M6 20 mm 22 PTT relay 1 23 Screw 3 ø6 19 mm 24 Holder 1 25 Starter relay 1 26 Holder 1 27 Grommet 1 28 Air temperature sensor 1 29 Grommet 1 30 Bracket 1 31 Holder 1 17 17 18 19 22 14 11 10 23 1 2 4 4 5 6 1 7 8 3 23 31 29 25 23 24 9 12 13 15 15 26 20 16 21 28 27 4 N m 0 4 kgf m 3 0 ft lb 3 30 10 9 ...

Page 230: ...belt No Part name Q ty Remarks 1 Timing belt 1 2 Timing belt tensioner 1 3 Plate 1 4 Washer 1 5 Screw 1 M6 10 mm 6 Plate 1 7 Drive sprocket 1 8 Bolt 4 M5 40 mm 1 2 8 7 6 5 4 3 39 N m 3 9 kgf m 28 8 ft lb 7 N m 0 7 kgf m 5 2 ft lb ...

Page 231: ... the fuel pressure 6 4 2 Remove the flywheel magnet cover 3 Turn the flywheel magnet clockwise and align the TDC mark a on the flywheel magnet with the pointer b and check that I marks c and d on the driven sprockets are aligned 4 Remove the flywheel magnet and Woodruff key See Removing the flywheel magnet 7 6 5 Disconnect the stator assembly coupler e and pulser coil coupler f and then remove the...

Page 232: ...ven sprocket in the counterclockwise direction 11 Turn the drive sprocket clockwise 2 full turns and then check that alignment marks c and d g and h are aligned 12 Adjust the timing belt to the specified installation height m 13 Install the stator assembly lighting coil b and blowby hose a and then connect the pulser coil coupler f and stator assembly coupler e See exploded diagram 7 5 14 Install ...

Page 233: ...10 35 mm 10 Bolt 4 M6 16 mm 11 Grommet 4 12 Plastic tie 1 13 Retaining plate 1 14 Bolt 2 M6 30 mm 15 Dowel 2 16 Gasket 1 Not reusable 17 O ring 1 Not reusable 1 1 2 3 4 5 6 7 7 8 8 8 9 9 9 10 10 10 11 12 13 14 15 15 16 17 18 19 20 21 22 23 23 24 4 N m 0 4 kgf m 3 0 ft lb 42 N m 4 2 kgf m 31 0 ft lb 42 N m 4 2 kgf m 31 0 ft lb 20 N m 2 0 kgf m 14 8 ft lb 4 N m 0 4 kgf m 3 0 ft lb Timing belt Power ...

Page 234: ...1 Bolt 1 M6 20 mm 22 Dipstick 1 23 PTT motor lead 1 24 Bolt 2 M6 10 mm 1 1 2 3 4 5 6 7 7 8 8 8 9 9 9 10 10 10 11 12 13 14 15 15 16 17 18 19 20 21 22 23 23 24 4 N m 0 4 kgf m 3 0 ft lb 42 N m 4 2 kgf m 31 0 ft lb 42 N m 4 2 kgf m 31 0 ft lb 20 N m 2 0 kgf m 14 8 ft lb 4 N m 0 4 kgf m 3 0 ft lb ...

Page 235: ... the flywheel magnet 7 6 1 Remove the flywheel magnet cover 2 Remove the retaining plate a and grommet b and then disconnect the remote control cables 3 Disconnect the battery leads c 4 Remove the junction box cover and then disconnect the PTT motor leads a 5 Disconnect the fuel hose d 6 Disconnect the vapor gas hose e 7 Remove the dipstick guide f 8 Disconnect the PTT switch coupler b 9 Disconnec...

Page 236: ...pend the power unit 13 Remove the power unit by removing the bolts k l and m Installing the power unit 1 Clean the power unit mating surface and install the dowels a and a new gasket b 2 Install the power unit by installing the bolts c d and e and then tightening them to the specified torque d c g h i k m l l k l m m k j j b a c e d d c d e e c ...

Page 237: ...hift cut switch coupler a neutral switch coupler b and cooling water pilot hose h 5 Connect the PTT switch coupler c 6 Connect the flushing hose i 7 Install the dipstick guide j 8 Connect the vapor gas hose k Bolt M8 c 20 N m 2 0 kgf m 14 8 ft lb Bolt M10 d and e 42 N m 4 2 kgf m 31 0 ft lb Bolt g 4 N m 0 4 kgf m 3 0 ft lb f g g b a h c i j k ...

Page 238: ... then install the junction box cover 11 Connect the battery leads n 12 Install the rigging grommet and then connect the shift cable and throttle cable see Mounting the rigging grommet 3 8 13 Install the flywheel magnet cover PTT motor lead bolt m 4 N m 0 4 kgf m 3 0 ft lb l d d m m n ...

Page 239: ... Gasket 1 Not reusable 10 Bolt 2 M10 35 mm 11 Driven sprocket 2 12 Oil seal 2 Not reusable 13 Dowel 2 14 Camshaft cap 2 15 Bolt 4 M7 48 mm 16 Camshaft cap 8 17 Bolt 16 M7 37 mm 4 1 2 3 5 6 7 7 6 7 8 9 10 10 11 11 12 12 13 13 14 15 16 17 18 19 20 20 21 2 N m 0 2 kgf m 1 5 ft lb a b 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb 60 N m 6 0 kgf m 44 3 ft lb 5 Power unit assembly Camshaft ...

Page 240: ...ks 18 Camshaft EX 1 19 Camshaft IN 1 20 Clamp 2 21 Hose 1 4 1 2 3 5 6 7 7 6 7 8 9 10 10 11 11 12 12 13 13 14 15 16 17 18 19 20 20 21 2 N m 0 2 kgf m 1 5 ft lb a b 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb 60 N m 6 0 kgf m 44 3 ft lb 5 ...

Page 241: ... could collide with each other and be damaged 1 Remove the cylinder head cover 2 Remove the timing belt see Replacing the timing belt 7 18 step 6 step 9 3 Remove the timing belt tensioner 4 Remove the drive sprocket a plate b and dowel c 5 Hold the intake and exhaust camshafts d using a wrench and then remove the bolts e 6 Remove the driven sprockets 7 Gradually loosen the camshaft caps f and g in...

Page 242: ...ed damaged or worn Checking the camshaft 1 Measure the cam lobe height a and width b Replace the camshaft if out of specification 2 Measure the camshaft runout Replace if out of specification i i h h a b Cam lobe height a Intake 45 300 45 400 mm 1 7835 1 7874 in Exhaust 44 350 44 450 mm 1 7461 1 7500 in Cam lobe width b Intake and exhaust 35 950 36 050 mm 1 4154 1 4193 in Camshaft runout limit 0 0...

Page 243: ...e valve lifters and shims are installed on the cylinder head Apply engine oil to the valve shims and valve lifters before installation 2 Install the camshafts with the new oil seals a Make sure the camshafts are installed to the original positions Apply some molybdenum disulfide grease on the cam lobes 3 Install the camshafts so that the dowels b are facing inward and that they are aligned with th...

Page 244: ...iven sprockets 7 Hold the camshaft using a wrench and then tighten the driven sprocket bolts d to the specified torque Apply engine oil to the driven sprocket bolts before installation 8 Install the dowel plate and drive sprocket 9 Install the cylinder head cover 10 Install a new timing belt See Replacing the timing belt 7 18 step 10 step 12 Camshaft cap bolt 1st 8 N m 0 8 kgf m 5 9 ft lb 2nd 17 N...

Page 245: ...10 Gasket 1 Not reusable 11 Exhaust cover 1 12 Gasket 1 Not reusable 13 Screw 7 M5 27 mm 14 Anode 7 15 Holder 1 16 Bolt 1 M6 12 mm 17 Gasket 1 Not reusable 1 2 3 11 12 13 14 17 18 19 20 21 22 22 23 23 24 25 26 27 28 29 30 31 32 a b 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb 55 N m 5 5 kgf m 40 6 ft lb 23 N m 2 3 kgf m 17 0 ft lb 15 16 6 8 9 10 7 4 5 a b 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1...

Page 246: ...er 1 26 Anode 1 27 Grommet 1 28 Cover 1 29 Bolt 1 M6 20 mm 30 Bolt 19 M6 30 mm 31 Bolt 1 M8 40 mm 32 Bolt 3 M6 20 mm 1 2 3 11 12 13 14 17 18 19 20 21 22 22 23 23 24 25 26 27 28 29 30 31 32 a b 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb 55 N m 5 5 kgf m 40 6 ft lb 23 N m 2 3 kgf m 17 0 ft lb 15 16 6 8 9 10 7 4 5 a b 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb ...

Page 247: ...ary 3 Check the grommet b for deformation Replace if necessary 4 Check the spring c for fatigue or deformation Replace if necessary Installing the PCV Install a new gasket a and the PCV b and then tighten the bolts Installing the exhaust cover 1 Install a new gasket and the exhaust cover and then tighten the bolts to the specified torques in 2 stages and in the sequence numbers a b 2 Install a new...

Page 248: ...7 35 Power unit POWR 3 Install the thermoswitch e Bolt d 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb a b c d e ...

Page 249: ...Exhaust valve 8 11 Intake valve 8 12 Valve shim 16 13 Valve lifter 16 14 Valve cotter 32 15 Valve spring retainer 16 16 Valve spring 16 17 Valve seal 16 Not reusable 1 2 3 4 5 7 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 a b 19 N m 1 9 kgf m 14 0 ft lb 37 N m 3 7 kgf m 27 3 ft lb a b 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb c 90 25 N m 2 5 kgf m 18 4 ft lb 6 7 9 Exh...

Page 250: ...ug 4 22 Anode 2 23 Grommet 2 24 Cover 2 25 Bolt 2 M8 40 mm 26 Bolt 2 M6 20 mm 27 Gasket 2 Not reusable 1 2 3 4 5 7 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 a b 19 N m 1 9 kgf m 14 0 ft lb 37 N m 3 7 kgf m 27 3 ft lb a b 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb c 90 25 N m 2 5 kgf m 18 4 ft lb 6 7 9 ...

Page 251: ...fter 1 Check the valve lifters Replace if dam aged scratched or worn 2 Measure the valve lifter outside diameter Replace if out of specification 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 a and thickness gauge b in the directions shown Replace the cylinder head assembly if ...

Page 252: ...ness a 3 Measure the valve stem diameter b Replace if out of specification 4 Measure the valve stem runout Replace if above specification Cylinder head warpage limit 0 1 mm 0 0039 in Valve spring free length a 44 2 mm 1 74 in Valve spring tilt limit b 1 2 mm 0 05 in a b a Valve margin thickness a Intake 0 70 mm 0 0276 in Exhaust 1 00 mm 0 0394 in Valve stem diameter b Intake 5 477 5 492 mm 0 2156 ...

Page 253: ... installer d contacts the cylinder head TIP Apply engine oil to the outer surface of new valve guides 3 Insert the special service tool e into the valve guide c and then ream the valve guide TIP Apply engine oil to the inner surface of the valve guide Turn the valve guide reamer clockwise to ream the valve guide Do not turn the reamer counterclockwise when removing it Make sure to clean the valve ...

Page 254: ... is out of specification Replace the valve guide if the valve seat contact width is uneven Refacing the valve seat After every lapping procedure make sure to clean off any remaining lapping compound from the cylinder head and the valves 1 Reface the valve seats with the valve seat cutters Valve guide inside diameter 5 504 5 522 mm 0 2167 0 2174 in Valve lapper a 90890 04101 a a Valve seat contact ...

Page 255: ...at b Previous contact width 4 Use a 60 cutter to adjust the contact width of the bottom edge of the valve seat b Previous contact width 5 Use a 45 cutter to adjust the contact width of the valve seat to specification b Previous contact width c Specified contact width 6 Check the valve seat contact area of the valve See Checking the valve seat 7 41 7 If the valve seat contact area is too wide and s...

Page 256: ...contact width 10 After refacing the valve seat to the specified contact width apply a thin even layer of lapping compound onto the valve seat and then lap the valve using a special service tool a NOTICE Do not get the lapping compound on the valve stem or valve guide 11 Check the valve seat contact area again See Checking the valve seat 7 41 Assembling the cylinder head 1 Install a new valve seal ...

Page 257: ...der head bolts before installation NOTICE Do not reuse the cylinder head gasket always replace it with a new one TIP Tighten the M10 bolts to the specified torques in 2 stages first and then make a mark a on the M10 bolts and the cylinder head and then tighten the bolts 90 from the mark 2 Install the camshafts driven sprockets and timing belt See Installing the timing belt driven sprocket and cams...

Page 258: ...ring 1 Not reusable 1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1718 19 20 21 22 23 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 42 42 43 43 44 45 a b 7 N m 0 7 kgf m 5 2 ft lb 31 N m 3 1 kgf m 22 9 ft lb a b 18 N m 1 8 kgf m 13 3 ft lb 31 N m 3 1 kgf m 22 9 ft lb 54 N m 5 4 kgf m 39 8 ft lb 18 N m 1 8 kgf m 13 3 ft lb 34 N m 3 4 kgf m 25 1 ft lb 12 N m 1 2 kgf m 8 9 ft lb 12 N m 1 2 k...

Page 259: ...le 32 Bolt 2 M6 45 mm 33 Oil filler neck 1 34 O ring 1 1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1718 19 20 21 22 23 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 42 42 43 43 44 45 a b 7 N m 0 7 kgf m 5 2 ft lb 31 N m 3 1 kgf m 22 9 ft lb a b 18 N m 1 8 kgf m 13 3 ft lb 31 N m 3 1 kgf m 22 9 ft lb 54 N m 5 4 kgf m 39 8 ft lb 18 N m 1 8 kgf m 13 3 ft lb 34 N m 3 4 kgf m 25 1 ft lb 12 N...

Page 260: ... assembly 1 1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1718 19 20 21 22 23 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 42 42 43 43 44 45 a b 7 N m 0 7 kgf m 5 2 ft lb 31 N m 3 1 kgf m 22 9 ft lb a b 18 N m 1 8 kgf m 13 3 ft lb 31 N m 3 1 kgf m 22 9 ft lb 54 N m 5 4 kgf m 39 8 ft lb 18 N m 1 8 kgf m 13 3 ft lb 34 N m 3 4 kgf m 25 1 ft lb 12 N m 1 2 kgf m 8 9 ft lb 12 N m 1 2 kgf m 8 9...

Page 261: ...anodes a b c and d Removing the crankcase cover 1 Remove the crankcase cover a bolts in the sequence numbers a b Disassembling the oil pump assembly 1 Remove the screws a and disassemble the oil pump Checking the oil pump assembly 1 Check the gear teeth and inner surface of the oil pump case Replace the oil pump assembly if the gear teeth are cracked or worn or if inner surface of the oil pump cas...

Page 262: ...ng 4 Install a new oil seal f and the gasket g and then tighten the screws h to the specified torque Installing the oil pump assembly When installing the oil pump assembly make sure to prevent the oil seal damage Needle bearing attachment a 90890 06654 Driver rod L3 b 90890 06652 Needle bearing attachment c 90890 06611 Driver rod L3 d 90890 06652 a b d c e a General pipe e a 45 0 mm 1 77 in Screw ...

Page 263: ...nkcase cover a 2 Install the crankcase cover a onto the crankcase and then tighten the bolts b and c to the specified torques in 2 stages and in the sequence numbers a b Apply engine oil to the bolts b and c before installation Installing the oil filter 1 Install the new O rings a and oil filter bracket b 2 Supply engine oil to the oil passage a of the oil filter bracket b a a b a a a Bolt b a j M...

Page 264: ...filter wrench c Apply a thin coat of engine oil to the O ring of a new oil filter before installation 4 Install the exhaust cover See Installing the exhaust cover 7 34 Installing the anode cylinder block 1 Install the anodes a b c and d Oil filter wrench c 90890 06830 Oil filter 18 N m 1 8 kgf m 13 3 ft lb a c b d a c ...

Page 265: ...Not reusable 10 Connecting rod bearing 8 11 Oil seal 1 Not reusable 12 Main bearing 4 13 Thrust bearing 1 14 Main bearing 5 15 Crankshaft 1 16 O ring 1 Not reusable 17 Collar 1 Not reusable 1 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 14 15 16 a b 23 N m 2 3 kgf m 17 0 ft lb 43 N m 4 3 kgf m 31 7 ft lb a b 14 N m 1 4 kgf m 10 3 ft lb 26 N m 2 6 kgf m 19 2 ft lb a b 30 N m 3 0 kgf m 22 1 ft lb 90 a b 30 N...

Page 266: ...eep the bearings in the order as they were removed Mark each piston with an identification number a of the corresponding cylinder Do not mix the connecting rods and caps Keep them organized in their proper groups 3 Remove the main bearing cap bolts in the sequence numbers a b 4 Remove the crankshaft 5 Remove the collar d a a b c d e f g h i j m n k l b c a Bearing separator e 90890 06534 Gear pull...

Page 267: ...Replace the piston ring set if out of specification Checking the piston ring end gap reference 1 Level the piston ring a in the cylinder with a piston crown 2 Check the piston ring end gap a at the specified measuring point b Piston diameter a 93 921 93 941 mm 3 6977 3 6985 in Measuring point b 14 0 mm 0 55 in up from the bottom of the piston skirt Cylinder bore D1 D6 94 000 94 017 mm 3 7008 3 701...

Page 268: ...ft journal diameter a crankpin diameter b and crankpin width c Replace the crankshaft if out of specification Piston ring end gap a Top ring 0 15 0 30 mm 0 0059 0 0118 in Second ring 0 30 0 45 mm 0 0118 0 0177 in Oil ring 0 15 0 60 mm 0 0059 0 0236 in Measuring point b 20 mm 0 8 in Piston ring groove Top ring a 1 23 1 25 mm 0 0484 0 0492 in Second ring b 1 22 1 24 mm 0 0480 0 0488 in Oil ring c 2 ...

Page 269: ...ositions 3 Put a piece of Plastigauge PG 1 onto the crankpin parallel to the crankshaft TIP Make sure not to put the Plastigauge PG 1 over the oil hole in the crankpin of the crank shaft 4 Install the connecting rod to the crankpin c TIP Make sure that the marks a of the connect ing rod faces towards the flywheel magnet side of the crankshaft Crankshaft journal diameter a 51 980 52 000 mm 2 0465 2...

Page 270: ...sed Plastigauge PG 1 on each crankpin Replace the connecting rod bearing if out of specification Selecting the connecting rod bearing 1 When replacing the connecting rod bear ing select the suitable bearing as fol lows 2 Measure the connecting rod big end inside diameter a Example TIP Reuse the removed connecting rod bolts when measuring the connecting rod bearing 3 Check the crankpin mark b on th...

Page 271: ...inder block upside down on a bench 3 Install half of the main bearings a and the crankshaft b into the cylinder block c TIP Install the main bearings in their original posi tions 4 Put a piece of Plastigauge PG 1 onto the crankshaft journals parallel to the crankshaft b P1 P2 P3 P4 P1 P2 P3 P4 c c Connecting rod big end inside diameter a d e f g h Crankpin mark b 25 80 81 82 83 84 85 86 87 88 89 9...

Page 272: ... 2nd stage make a mark a on the crankcase main bearing cap bolts d and crankshaft bolts e and then tighten the bolts 90 from the mark NOTICE Main bearing cap bolt d a f and crankshaft bolts e a d can be reused 3 times 8 Tighten the crankcase bolts f to the specified torques in 2 stages 9 Remove the main bearing cap and crankcase and then measure the width of the compressed Plastigauge PG 1 on each...

Page 273: ...for the main bearing from the table Example If the crankshaft journal mark a is 89 and the cylinder block mark b is 28 and then select the bearing colors in g TIP J3 is a thrust bearing Crankshaft main journal oil clearance 0 021 0 050 mm 0 0008 0 0020 in a J1 J2 J3 J4 J5 J1 J2 J3 J4 J5 J5 J4 J3 J2 J1 b Upper bearing color Lower bearing color d Green Green e Green Red f Red Red g Red Yellow h Yell...

Page 274: ...ly 4 Offset the piston ring end gaps as shown NOTICE Do not scratch the pistons or break the piston rings 5 Install the upper bearing into the connecting rod e and the lower bearing into the connecting rod cap f TIP Install the connecting rod bearings in their original positions 6 Install the upper main bearings g and the thrust bearing h into the cylinder block i TIP Install the main bearings in ...

Page 275: ... UP mark on the piston crown facing towards the flywheel magnet Apply engine oil to the side of the pistons and piston rings before installation 11 Install the connecting rod caps f to the connecting rods and then tighten the connecting rod bolts to the specified torques in 3 stages Apply engine oil to the connecting rod bolts before installation Make sure that the mark c of the connecting rod fac...

Page 276: ...ankcase onto the cylinder block 15 Apply engine oil to the crankshaft bolts q and crankcase bolts r before installation and then tighten them to the specified torques in 2 stages and in the sequence numbers a b In the 2nd stage make a mark e on the crankcase and crankshaft bolts q and then tighten crankshaft bolts q 90 from the mark NOTICE Crankshaft bolts q a d can be reused 3 times TIP After tig...

Page 277: ...bly 8 11 Assembling the propeller shaft housing assembly 8 12 Drive shaft and lower case regular rotation model 8 14 Removing the drive shaft 8 16 Disassembling the drive shaft housing 8 16 Disassembling the forward gear 8 16 Disassembling the lower case 8 16 Checking the pinion and forward gear 8 17 Checking the drive shaft 8 17 Checking the lower case 8 17 Assembling the lower case 8 17 Assembli...

Page 278: ...counter rotation model 8 53 Removing the propeller shaft housing assembly 8 55 Disassembling the propeller shaft housing assembly 8 55 Checking the propeller shaft housing 8 56 Checking the propeller shaft 8 56 Assembling the propeller shaft housing assembly 8 57 Drive shaft and lower case counter rotation model 8 59 Removing the drive shaft 8 61 Disassembling the drive shaft housing 8 61 Disassem...

Page 279: ...ecting the pinion shim T3 8 73 Pinion shim T3 selection table 8 73 Selecting the propeller shaft shim T4 8 73 Propeller shaft shim T4 selection table 8 75 Measuring the forward gear backlash 8 76 Adjusting the forward gear shim thickness T2 8 76 Forward gear shim T2 selection chart 8 78 Measuring the reverse gear backlash 8 80 Adjusting the reverse gear shim thickness T1 8 81 Reverse gear shim T1 ...

Page 280: ...10 Bolt 12 M10 45 mm 11 Check screw 1 12 Gasket 2 Not reusable 13 Water pipe 1 14 Lower unit 1 15 Spacer 1 16 Propeller 1 17 Washer 1 21 15 14 17 18 19 20 16 2 2 11 12 10 10 9 8 2 7 13 5 6 6 5 10 10 2 23 12 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 42 N m 4 2 kgf m 31 0 ft lb 54 N m 5 4 kgf m 39 8 ft lb 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kgf m 6 6 ft lb 22 47 N m 4 7 kgf m 34 7 ft l...

Page 281: ...0 Spacer 1 21 Trim tab 1 22 Bolt 1 M10 200 mm 23 Drain screw 1 21 15 14 17 18 19 20 16 2 2 11 12 10 10 9 8 2 7 13 5 6 6 5 10 10 2 23 12 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 42 N m 4 2 kgf m 31 0 ft lb 54 N m 5 4 kgf m 39 8 ft lb 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kgf m 6 6 ft lb 22 47 N m 4 7 kgf m 34 7 ft lb 1 3 4 4 3 ...

Page 282: ...your hands when loosening or tightening it 1 Drain the gear oil 2 Remove the cotter pin 3 Set the gear shift to the N position and place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then remove the propeller nut and propeller 4 Mark a the trim tab a at the area shown and then remove it 5 Remove the bolts b and c and then remove the lower un...

Page 283: ...housing 1 4 O ring 1 Not reusable 5 Spring 1 6 Circlip 1 7 Shift rod 1 8 Dowel 2 9 Dowel 2 10 Impeller 1 11 Outer plate cartridge 1 12 Gasket 1 Not reusable 13 Woodruff key 1 14 Rubber seal 1 15 Plate 1 16 Water pump housing 1 17 Bolt 4 M8 45 mm 18 19 17 17 16 20 21 22 23 24 26 8 13 8 9 9 12 11 10 7 6 5 4 3 1 2 1 14 15 25 25 Lower unit regular rotation model Water pump and shift rod regular rotati...

Page 284: ...ty Remarks 18 Cover 1 19 Seal 1 20 O ring 1 Not reusable 21 Insert cartridge 1 22 O ring 1 Not reusable 23 Collar 1 24 Spacer 1 25 Washer 2 26 Wave washer 1 18 19 17 17 16 20 21 22 23 24 26 8 13 8 9 9 12 11 10 7 6 5 4 3 1 2 1 14 15 25 25 ...

Page 285: ... pump housing a impeller b and Woodruff key c 3 Remove the outer plate cartridge d and gasket e 4 Set the gear shift to the N position 5 Remove the oil seal housing g and shift rod assembly h Disassembling the water pump housing 1 Remove the O ring a insert cartridge b and O ring c 2 Remove the cover d and seal e Shift rod push arm f 90890 06052 a b c d e R N F f g h a b c d e ...

Page 286: ...ing 2 Check the impeller insert cartridge and outer plate cartridge Replace if cracked or worn 3 Check the Woodruff key and the keyway on the drive shaft Replace if deformed or worn 4 Check the shift rod Replace if cracked or worn Assembling the water pump housing 1 Install the seal a and cover b 2 Install a new O ring c into the water pump housing d 3 Install the insert cartridge e aligning a on ...

Page 287: ...1 6 Ball 2 7 Ball 2 8 Spring 1 9 Propeller shaft 1 10 Cross pin 1 11 Dog clutch 1 12 Spring 1 13 Screw 1 M5 54 mm 14 Water inlet cover PORT 1 15 Shim T2 16 Reverse gear 1 17 Thrust washer 1 5 N m 0 5 kgf m 3 7 ft lb 143 N m 14 3 kgf m 105 5 ft lb 1 2 3 4 6 7 11 15 26 16 17 18 25 24 23 22 21 20 19 10 8 9 12 4 13 14 6 3 5 4 7 6 10 9 8 6 7 4 11 5 12 Water pump and shift rod regular rotation model Pro...

Page 288: ...asher 1 21 Oil seal 2 Not reusable 22 Needle bearing 1 Not reusable 23 Key 1 24 Propeller shaft housing 1 25 O ring 1 Not reusable 26 Washer 1 5 N m 0 5 kgf m 3 7 ft lb 143 N m 14 3 kgf m 105 5 ft lb 1 2 3 4 6 7 11 15 26 16 17 18 25 24 23 22 21 20 19 10 8 9 12 4 13 14 6 3 5 4 7 6 10 9 8 6 7 4 11 5 12 ...

Page 289: ... s T2 using the special service tools e f and g TIP Be careful not to lose the key h Disassembling the propeller shaft assembly 1 Remove the spring a and then remove the cross pin b dog clutch c balls d e f spring g shift slider h and shift rod joint i TIP Be careful when removing the slider h as the balls may fall out Ring nut wrench 4 a 90890 06512 Ring nut wrench extension b 90890 06513 a b d c...

Page 290: ...2 Measure the propeller shaft runout Replace if above specification 3 Check the dog clutch shift rod joint and slider Replace if cracked or worn Assembling the propeller shaft assembly 1 Install the spring a balls b c d shift slider e and shift rod joint f Bearing separator c 90890 06534 Stopper guide plate d 90890 06501 Stopper guide stand e 90890 06538 Bearing puller assembly f 90890 06535 Stopp...

Page 291: ...to avoid the risk of fire Heat the propeller shaft housing in a well ventilated area Do not reuse the bearing always replace it with a new one 1 Install the needle bearing a into the pro peller shaft housing b to the specified depth a TIP Install the needle bearing with the manufac ture identification mark b facing toward the oil seal propeller side When using the driver rod do not strike the spec...

Page 292: ...mark e facing toward the pro peller shaft housing propeller side 4 Heat the installation area of the ball bearing in the propeller shaft housing l with a gas torch and then install the reverse gear assembly m NOTICE When heating the propeller shaft causing heat the entire installation area evenly Otherwise the propeller shaft housing could be damaged 5 After installing the reverse gear assembly ch...

Page 293: ...e 5 Bolt 4 M8 25 mm 6 Oil seal 2 Not reusable 7 Cover 1 8 Drive shaft housing 1 9 Sleeve 1 10 Drive shaft 1 11 Lower case 1 12 Shim T1 13 Taper roller bearing 1 Not reusable 14 Forward gear 1 15 Needle bearing 2 Not reusable 16 Needle bearing 1 Not reusable 17 Pinion 1 94 N m 9 4 kgf m 69 3 ft lb 7 6 5 8 4 3 2 1 9 10 11 12 13 15 14 16 17 5 18 Propeller shaft housing regular rotation model Drive sh...

Page 294: ...8 15 LOWR Lower unit No Part name Q ty Remarks 18 Pinion nut 1 94 N m 9 4 kgf m 69 3 ft lb 7 6 5 8 4 3 2 1 9 10 11 12 13 15 14 16 17 5 18 ...

Page 295: ...the taper roller bearing a 2 Remove the needle bearings from the forward gear Disassembling the lower case Use heat resistant gloves otherwise burns could result Remove any flammable substances such as gasoline and oil around the working area to avoid the risk of fire Heat the lower case in a well ventilated area 1 Remove the water inlet covers Drive shaft holder 6 a 90890 06520 Pinion nut holder ...

Page 296: ...ghtly tap the lower unit tor pedo with a plastic hammer Checking the pinion and forward gear 1 Check the pinion and forward gear Replace if cracked or worn Checking the drive shaft 1 Check the drive shaft Replace if dam aged or worn 2 Measure the drive shaft runout Replace if above specification Checking the lower case 1 Check the lower case Replace if cracked or damaged Assembling the lower case ...

Page 297: ...the taper roller bearing outer race is installed properly If a high pitched metallic sound is produced when the special service tool is struck the outer race is installed properly 4 Install the rollers into the needle bearing outer race and install the special service tool into the needle bearing assembly e and then install the needle bearing assembly e into the lower case TIP The needle bearing c...

Page 298: ...the special service tool in a manner that will force the stopper b out of place 2 Apply grease to new oil seals and then install them into the drive shaft housing to the specified depth c Needle bearing attachment a 90890 06612 Driver rod SS b 901890 06604 Bearing depth plate c 90890 06603 Depth a 20 95 21 45 mm 0 825 0 844 in Depth b 4 45 4 95 mm 0 175 0 195 in Needle bearing attachment d 90890 0...

Page 299: ...drive shaft housing f and then install the drive shaft housing f into the lower case TIP Install the drive shaft housing with the cutout a in the housing facing forward 5 Tighten the pinion nut to the specified torque 6 Check that the drive shaft rotates smoothly If the drive shaft does not rotate smoothly reassemble the lower unit Installing the propeller shaft housing assembly 1 Set the shift ro...

Page 300: ...ng nut to the specified torque 7 Bend one claw toward the propeller and the other 3 claws toward the gear Installing the shift rod 1 Make sure that the gear shift is in the N position and then install the shift rod assembly a 2 Make sure that the drive shaft and the propeller shaft are moving properly when the gear is shifted into F position and into R position Ring nut wrench 4 i 90890 06512 Ring...

Page 301: ...r i TIP The spacer h and collar i should fit together firmly 5 When installing the pump housing and a new O ring j apply grease to the inside of the insert cartridge and then turn the drive shaft clockwise while pushing down the pump housing assembly k NOTICE Do not turn the drive shaft counterclockwise otherwise the water pump impeller may be damaged 6 Install the bolts l Checking the lower unit ...

Page 302: ...h When installing the lower unit with the power unit installed make sure to sus pend the outboard motor If the outboard motor is not suspended it can fall sud denly and result in severe injury 1 Align a of the shift rod with the align ment mark b 2 Set the gear shift to the N position 3 Install the dowels b into the lower unit and extension 4 Install the lower unit and extension to the upper case ...

Page 303: ...peller from turning and then tighten the nut to the specified torque 7 Install a new cotter pin h TIP If the grooves in the propeller nut g do not align with the cotter pin hole tighten the nut until they are aligned 8 Fill the gear oil to the correct level Propeller nut g 54 N m 5 4 kgf m 39 8 ft lb f g h g Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Gear oil quantity 0 980 L 1 036 US qt...

Page 304: ...red when replacing the pinion forward gear reverse gear bearings shaft and housing Remove the water pump assembly Measure the backlash before disassembly Within specification Shimming is not required Disassemble the lower unit Select the pinion shims T3 Assemble the lower unit Measure the backlash Within specification Install the water pump assembly Adjust the forward gear shim thickness T1 and re...

Page 305: ...rial number P F R Remarks mm Measurements Measurement point a Measurement point b Measurement point c Measurement point d Average Truncated average M mm Measurements Before disassembly After disassembly Measurement point a Measurement point b Measurement point c Measurement point d Average Truncated average BL1 mm Measurements Before disassembly After disassembly Measurement point a Measurement po...

Page 306: ... of each forward gear shim T1 in 2 places Adjusting the reverse gear shim thickness T2 Measure the thickness of each reverse gear shim T2 in 2 places mm Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total mm Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total ...

Page 307: ...olt d temporarily 5 Turn the lower unit so that the propeller shaft is pointing downward 6 Turn the drive shaft 10 times or more to seat the taper roller bearing 7 Tighten the center bolt d to the specified torque while holding the drive shaft not to turn 8 Turn the lower unit upright 9 Remove the cover e and then install the outer plate cartridge f Shift rod push arm a 90890 06052 Bearing housing...

Page 308: ...Install the special service tool i onto the drive shaft at the lowest possible position where the shaft diameter is 22 4 mm 0 882 in and then set up the special service tool k TIP Position the special service tool k so that the plunger tip b contacts the mark c on the special service tool i 12 Slowly turn the drive shaft clockwise and counterclockwise and then measure the backlash at the position ...

Page 309: ...ng the reverse gear and does not affect the back lash measurement 14 Determine the backlash average and then truncate it by dropping the numbers after the 1 100 place without rounding Example 15 Check that the forward gear backlash average is within specification TIP Adjust the shim thicknesses if the forward gear backlash is out of specification 16 Remove the special service tools from the propel...

Page 310: ...g the water pump 8 22 Shimming Make sure to select the pinion shim s T3 before selecting the forward gear shim s T1 and reverse gear shim s T2 When assembling the lower unit to mea sure the backlash after selecting the pinion shim s T3 do not apply gear oil grease or sealant to the parts When assembling the lower unit after shim ming is completed make sure to apply gear oil grease and sealant to t...

Page 311: ...8 32 Shimming regular rotation model 0 1 2 3 4 5 6 7 8 9 10 A Shim location F R P T3 T1 T2 ...

Page 312: ...e drive shaft b thrust bearing c and drive shaft housing assembly to the tool TIP Do not install the shim s T3 or O ring Make sure to check the thrust bearing outer race since the shim s T3 sometimes become affixed to the race Make sure to install the thrust bearing outer race so that it is facing in the same direction as when it was removed Make sure that the cutout a in the drive shaft housing a...

Page 313: ...1 mm 0 04 in or more the shim s T3 h may not have been removed 5 Install the special service tool i to the drive shaft and then hold the tool 6 Tighten the pinion nut to the specified torque 7 Hold the special service tool a so that the pinion is facing up 8 Turn the drive shaft 10 times or more to seat the thrust bearing 9 Push down on the pinion so that it does not lift up and then measure the g...

Page 314: ...rom the pinion shim T3 selection table TIP The P mark g is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is unreadable replace the lower case 12 Remove the special service tools and then install the shim s T3 determined mm Measurement point c 0 25 0 25 0 24 Measurement point d 0 24 0 24 0 24 Measurement point e 0 25 0 25 0 25 Measurement point f 0 25 0 2...

Page 315: ... 1 00 0 98 0 98 0 95 0 95 12 1 08 1 08 1 05 1 05 1 05 1 02 1 02 1 02 1 00 1 00 0 98 0 98 0 95 0 95 0 95 13 1 08 1 05 1 05 1 05 1 02 1 02 1 02 1 00 1 00 0 98 0 98 0 95 0 95 0 95 0 92 P M A 0 16 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 28 0 29 0 30 B 13 1 18 1 18 1 15 1 15 1 15 1 12 1 12 1 12 1 10 1 10 1 08 1 08 1 05 1 05 1 05 12 1 18 1 15 1 15 1 15 1 12 1 12 1 12 1 10 1 10 1 08 1 08...

Page 316: ...78 0 75 0 75 0 75 0 72 0 72 0 72 0 70 0 70 0 68 0 68 0 65 0 65 0 62 13 0 78 0 75 0 75 0 75 0 72 0 72 0 72 0 70 0 70 0 68 0 68 0 65 0 65 0 62 0 62 P M A 0 46 0 47 0 48 0 49 0 50 0 51 0 52 0 53 0 54 0 55 0 56 0 57 0 58 0 59 0 60 B 13 0 88 0 88 0 85 0 85 0 85 0 82 0 82 0 82 0 80 0 80 0 78 0 78 0 75 0 75 0 75 12 0 88 0 85 0 85 0 85 0 82 0 82 0 82 0 80 0 80 0 78 0 78 0 75 0 75 0 75 0 72 11 0 85 0 85 0 ...

Page 317: ... s T1 are missing install new shims with a combined thick ness of 0 55 mm Do not reuse a shim if it is any deformed or scratched 2 Install the taper roller bearing outer race See Assembling the lower case 8 17 step 2 and step 3 3 Install the forward gear assembly into the lower case 4 Install the drive shaft thrust bearing a and shim s T3 b TIP Turn the drive shaft 10 times or more to seat the thr...

Page 318: ...all the claw washer Check that the position b is set in place properly 12 Install the ring nut and then tighten the ring nut to the specified torque 13 Check that the drive shaft rotates smoothly If the drive shaft does not rotate smoothly the shim s may be installed incorrectly or there may be foreign material on the shim s 14 Measure the forward gear backlash See Measuring the forward and revers...

Page 319: ...ed backlash is within the gray col ored area The values for the shim thickness adjust ments specified in the selection chart are intended to achieve the median value within the range for the specified forward or reverse gear backlash The selection chart table shows the shim thickness adjustments for marked points on the chart 4 Calculate the new forward gear shim thickness T1 as same way in the ex...

Page 320: ...ing of shim thickness 0 28 0 25 0 21 0 0 0 0 0 0 0 0 06 0 09 0 13 0 16 0 19 0 23 0 26 0 29 0 33 0 36 0 40 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 1 20 B mm Continue next page 1 00 0 80 0 60 0 40 0 20 0 0 20 0 40 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 A 1 100 mm A B ...

Page 321: ... 0 40 0 43 0 46 0 50 0 53 0 56 0 60 0 63 0 67 0 70 0 73 0 77 0 80 0 83 0 87 0 90 0 94 0 97 1 00 1 04 1 07 100 105 110 115 120 125 130 135 145 150 155 160 165 170 175 180 185 190 195 200 140 1 20 B mm 1 00 0 80 0 60 0 40 0 20 0 0 20 0 40 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 A 1 100 mm A B ...

Page 322: ...ment 0 15 mm b from the Reverse gear shim T2 selection chart The current shim thickness must be decreased by 0 15 mm A Backlash measurement BL2 B Shim thickness adjustment TIP If the shim thickness adjustment value is positive the current shim thickness must be increased by that amount and if the value is negative the current shim thickness must be decreased by that amount The gray colored area on...

Page 323: ...current reverse gear shim thickness is 0 62 mm and the shim thickness adjustment is 0 20 mm then T2 0 62 mm 0 20 mm 0 62 mm 0 20 mm 0 42 mm TIP Use the least number of shims to achieve the required shim thickness If the calculated shim thickness cannot be obtained with a combination of the available shims increase the shim thickness by 0 01 mm 5 Install the shim s T2 and propeller shaft housing as...

Page 324: ...f shim thickness 0 36 0 33 0 29 0 26 0 22 0 19 0 16 0 0 0 0 0 01 0 05 0 08 0 11 0 15 0 18 0 21 0 25 0 28 0 32 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 0 40 B mm Continue next page 0 20 0 0 20 0 40 0 60 0 80 1 00 1 20 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 A 1 100 mm A B ...

Page 325: ... 0 32 0 35 0 38 0 42 0 45 0 48 0 52 0 55 0 59 0 62 0 65 0 69 0 72 0 75 0 79 0 82 0 86 0 89 0 92 0 96 0 99 100 105 110 115 120 125 130 135 145 150 155 160 165 170 175 180 185 190 195 200 140 0 40 B mm 0 20 0 0 20 0 40 0 60 0 80 1 00 1 20 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 A 1 100 mm A B ...

Page 326: ...10 Bolt 12 M10 45 mm 11 Check screw 1 12 Gasket 2 Not reusable 13 Water pipe 1 14 Lower unit 1 15 Spacer 1 16 Propeller 1 17 Washer 1 21 15 14 17 18 19 20 16 2 2 11 12 22 10 10 2 7 13 5 6 6 5 10 10 2 23 12 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 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 54 N m 5 4 kgf m 39 8 ft lb 9 8 42 N m 4 2 kgf m 31 0 ft l...

Page 327: ...0 Spacer 2 21 Trim tab 2 22 Bolt 2 M10 200 mm 23 Drain screw 2 21 15 14 17 18 19 20 16 2 2 11 12 22 10 10 2 7 13 5 6 6 5 10 10 2 23 12 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 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 54 N m 5 4 kgf m 39 8 ft lb 9 8 42 N m 4 2 kgf m 31 0 ft lb 1 3 4 3 4 ...

Page 328: ... with your hands when loosening or tightening it 1 Drain the gear oil 2 Remove the cotter pin 3 Set the gear shift to the N position and place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then remove the propeller nut and propeller 4 Mark a the trim tab a at the area shown and then remove it 5 Remove the bolts b and c and then remove it TIP...

Page 329: ...housing 1 4 O ring 1 Not reusable 5 Spring 1 6 Circlip 1 7 Shift rod 1 8 Dowel 2 9 Dowel 2 10 Impeller 1 11 Outer plate cartridge 1 12 Gasket 1 Not reusable 13 Woodruff key 1 14 Rubber seal 1 15 Plate 1 16 Water pump housing 1 17 Bolt 4 M8 45 mm 18 19 17 17 16 20 21 22 23 24 26 8 13 8 9 9 12 11 10 7 6 5 4 3 1 2 1 14 15 25 25 Lower unit counter rotation model Water pump and shift rod counter rotati...

Page 330: ...ty Remarks 18 Cover 1 19 Seal 1 20 O ring 1 Not reusable 21 Insert cartridge 1 22 O ring 1 Not reusable 23 Collar 1 24 Spacer 1 25 Washer 2 26 Wave washer 1 18 19 17 17 16 20 21 22 23 24 26 8 13 8 9 9 12 11 10 7 6 5 4 3 1 2 1 14 15 25 25 ...

Page 331: ...pump and shift rod 8 6 step 1 step 4 1 Remove the oil seal housing a and shift rod assembly b Disassembling the water pump housing See Disassembling the water pump hous ing 8 6 Checking the water pump and shift rod See Checking the water pump and shift rod 8 7 Assembling the water pump housing See Assembling the water pump housing 8 7 b a ...

Page 332: ...t slider 1 6 Ball 2 7 Ball 2 8 Spring 1 9 Forward gear 1 10 Thrust washer 1 11 Taper roller bearing 1 Not reusable 12 Shim T2 13 Cross pin 1 14 Dog clutch 1 15 Spring 1 16 Screw 1 M5 54 mm 17 Water inlet cover PORT 1 3 5 4 7 6 13 27 8 6 7 4 14 15 5 N m 0 5 kgf m 3 7 ft lb 143 N m 14 3 kgf m 105 5 ft lb 1 2 3 4 6 7 14 25 18 26 27 24 23 22 21 20 19 13 12 9 10 11 8 15 4 16 17 6 5 ...

Page 333: ... washer 1 21 Oil seal 2 Not reusable 22 Needle bearing 1 Not reusable 23 Key 1 24 Propeller shaft housing 1 25 O ring 1 Not reusable 26 Thrust bearing 1 27 Propeller shaft 1 3 5 4 7 6 13 27 8 6 7 4 14 15 5 N m 0 5 kgf m 3 7 ft lb 143 N m 14 3 kgf m 105 5 ft lb 1 2 3 4 6 7 14 25 18 26 27 24 23 22 21 20 19 13 12 9 10 11 8 15 4 16 17 6 5 ...

Page 334: ...opeller shaft housing assembly and shim s T2 TIP Be careful not to lose the key g Disassembling the propeller shaft housing assembly 1 Remove the spring a and then remove the cross pin b shift rod joint c dog clutch d balls e f g spring h and shift slider i Ring nut wrench 4 a 90890 06512 Ring nut wrench extension b 90890 06513 a b d c Slide hammer e 90890 06531 Puller head f 90890 06514 e f g a b...

Page 335: ...earing s Checking the propeller shaft housing 1 Check the propeller shaft housing Replace if cracked or damaged 2 Check the forward gear Replace if cracked or worn Checking the propeller shaft 1 Check the propeller shaft Replace if cracked or damaged 2 Measure the propeller shaft runout Replace if above specification Bearing separator p commercially available Bearing separator p commercially avail...

Page 336: ...ller shaft housing 4 After installing the taper roller bearing and bearing outer race check that the propeller shaft rotates smoothly 5 Install the thrust washer f forward gear g and dog clutch h TIP Install the dog clutch h with the F mark a facing toward the forward gear 6 After installing the forward gear check that the propeller shaft and forward gear rotates smoothly 7 Install the spring i ba...

Page 337: ...r shaft housing counter rotation model 0 1 2 3 4 5 6 7 8 9 10 A TIP Install the dog clutch h with the F mark d facing toward the forward gear 9 Install the cross pin o and then install the spring p p o d b h h p o c ...

Page 338: ...ng 1 Not reusable 5 Bolt 4 M8 25 mm 6 Oil seal 2 Not reusable 7 Cover 1 8 Drive shaft housing 1 9 Sleeve 1 10 Drive shaft 1 11 Lower case 1 12 Shim T1 13 Roller bearing 1 Not reusable 14 Thrust bearing 1 15 Reverse gear 1 16 Needle bearing 2 Not reusable 17 Needle bearing 1 Not reusable 5 8 5 94 N m 9 4 kgf m 69 3 ft lb 7 6 4 3 2 1 9 10 11 17 18 16 15 12 14 13 19 ...

Page 339: ...Drive shaft and lower case counter rotation model 0 1 2 3 4 5 6 7 8 9 10 A No Part name Q ty Remarks 18 Pinion 1 19 Pinion nut 1 5 8 5 94 N m 9 4 kgf m 69 3 ft lb 7 6 4 3 2 1 9 10 11 17 18 16 15 12 14 13 19 ...

Page 340: ...e the water inlet covers 2 Remove the needle bearing a TIP Make sure to remove the reverse gear before removing the needle bearing 3 Heat the installation area of the roller bearing in the lower case with a gas torch and then remove the roller bearing d and shim s T1 e NOTICE When heating the lower case heat the entire installation area evenly Otherwise the paint on the lower case could be burned ...

Page 341: ...he lower case with a gas torch and then install the roller bearing b NOTICE When heating the lower case heat the entire installation area evenly Otherwise the paint on the lower case could be burned TIP Do not reuse a shim if it is any deformed or scratched 3 While holding the special service tool c strike the tool to check that the roller bearing is installed properly If a high pitched metallic s...

Page 342: ... For installing the drive shaft see Installing the drive shaft 8 20 step 2 step 6 Installing the propeller shaft housing assembly 1 Set the shift rod joint a and dog clutch b to the N position 2 Apply grease to a new O ring and propeller shaft housing assembly c 3 Install the original shim s T2 d the propeller shaft housing assembly c and the key e 4 For installing the ring nut see Installing the ...

Page 343: ... shaft and the propeller shaft are moving properly when the gear is shifted into F position and into R position Installing the water pump See Installing the water pump 8 22 Checking the lower unit for air leakage See Checking the lower unit for air leakage 8 22 Installing the lower unit See Installing the lower unit 8 23 Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Gear oil quantity 0 870 ...

Page 344: ... forward gear reverse gear bearings shaft and housing Remove the water pump assembly Measure the backlash and propeller shaft free play before disassembly Within specification Shimming is not required Disassemble the lower unit Select the pinion shims T3 and propeller shaft shim T4 Assemble the lower unit Measure the backlash Within specification Install the water pump assembly Adjust the forward ...

Page 345: ...play Measuring the pinion height Measuring the forward gear backlash Serial number P F R Remarks mm Measurements Free play mm Measurements Measurement point a Measurement point b Measurement point c Measurement point d Average Truncated average M mm Measurements Before disassembly After disassembly Measurement point a Measurement point b Measurement point c Measurement point d Average Truncated av...

Page 346: ...gear shim thickness T1 Measure the thickness of each reverse gear shim T1 in 2 places mm Measurements Before disassembly After disassembly Measurement point a Measurement point b Measurement point c Measurement point d Average Truncated average BL1 mm Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total mm Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total ...

Page 347: ...ing the water pump and shift rod 8 6 3 Set the gear shift to the N position 4 Install the special service tools and then tighten the center bolt d temporarily 5 Turn the drive shaft 10 times or more to seat the taper roller bearing 6 Tighten the center bolt d to the specified torque while holding the drive shaft not to turn 7 Turn the lower unit upright 8 Remove the cover e and then install the ou...

Page 348: ...nstall the special service tool i onto the drive shaft at the lowest possible position where the shaft diameter is 22 4 mm 0 882 in and then set up the special service tool k TIP Position the special service tool k so that the plunger tip b contacts the mark c on the special service tool i 11 Slowly turn the drive shaft clockwise and counterclockwise and then measure the backlash at the position w...

Page 349: ...ft is rotated but this is the sound of the pinion contacting the reverse gear and does not affect the back lash measurement 13 Determine the backlash average and then truncate it by dropping the numbers after the 1 100 place without rounding Example 14 Check that the forward gear backlash average is within specification TIP Adjust the shim thicknesses if the forward gear backlash is out of specifi...

Page 350: ...erse gear backlash is out of specification 23 Remove the propeller shaft housing assembly and then remove the washers m 24 Install the water pump assembly Shimming Make sure to select the pinion shim s T3 and propeller shaft shim s T4 before selecting the forward gear shim s T2 and reverse gear shim s T1 When assembling the lower unit to mea sure the backlash after selecting the pinion shim s T3 d...

Page 351: ...8 72 Shimming counter rotation model 0 1 2 3 4 5 6 7 8 9 10 A Shim location F R P T3 T2 T4 T1 ...

Page 352: ...e 8 75 TIP No shim T4 adjustment is required if the measurement falls within specification Example When the measurement is 0 72 mm the need for increasing or decreasing the shim is 0 40 mm This means 0 40 mm thickness must be added to the present shim thickness 3 Remove the O ring from the propeller shaft housing 4 Heat the installation area of the taper roller bearing outer race in the propeller ...

Page 353: ... gear assembly f NOTICE When heating the propeller shaft housing heat the entire installation area evenly Otherwise the propeller shaft housing could be damaged 7 Measure the free play again to make sure that the free play falls within specification TIP If the free play is outside of the specified range it is suspected that the forward gear taper roller bearing may not be installed prop erly in th...

Page 354: ...0 46 0 48 0 50 0 52 B 0 10 0 10 0 10 0 10 0 12 0 15 0 15 0 18 0 20 A 0 54 0 56 0 58 0 60 0 62 0 64 0 66 0 68 0 70 B 0 22 0 25 0 25 0 28 0 30 0 32 0 35 0 35 0 38 A 0 72 0 74 0 76 0 78 0 80 0 82 0 84 0 86 0 88 B 0 40 0 42 0 45 0 45 0 48 0 50 0 52 0 55 0 55 A 0 90 0 92 0 94 0 96 0 98 1 00 1 02 1 04 1 06 B 0 58 0 60 0 62 0 65 0 65 0 68 0 72 0 72 0 75 A 1 08 1 10 1 12 1 14 1 16 1 18 1 20 1 22 1 24 B 0 ...

Page 355: ...assembling the lower unit to measure the backlash do not install the dog clutch and O ring 3 Install the claw washer Check that the position a is set in place properly 4 Install the ring nut and then tighten the ring nut to the specified torque 5 Check that the drive shaft rotates smoothly If the drive shaft does not rotate smoothly the shim s may be installed incorrectly or there may be foreign m...

Page 356: ... ored area The values for the shim thickness adjust ments specified in the selection chart are intended to achieve the median value within the range for the specified forward or reverse gear backlash The selection chart table shows the shim thickness adjustments for marked points on the chart 4 Calculate the new forward gear shim thickness T2 as same way in the example Calculation formula New forw...

Page 357: ...ng or decreasing of shim thickness 0 22 0 18 0 15 0 26 0 22 0 0 0 02 0 06 0 09 0 12 0 16 0 19 0 22 0 26 0 29 0 33 0 36 0 39 0 43 0 46 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 0 40 B mm Continue next page 0 20 0 20 0 40 0 60 0 80 1 00 1 20 0 A 1 100 mm A B ...

Page 358: ...0 60 0 63 0 66 0 70 0 73 0 76 0 80 0 83 0 87 0 90 0 93 0 97 1 00 1 04 1 07 1 10 1 14 100 105 110 115 120 125 130 135 145 150 155 160 165 170 175 180 185 190 195 200 140 0 40 B mm 0 20 0 0 20 0 40 0 60 0 80 1 00 1 20 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 A 1 100 mm A B ...

Page 359: ... thickness of 1 00 mm Do not reuse a shim if it is any deformed or scratched 2 Install the roller bearing See Assembling the lower case 8 62 step 2 and step 3 3 Install the thrust bearing and the reverse gear into the lower case 4 Install the drive shaft thrust bearing a and shim s T3 b into the lower case TIP Turn the drive shaft 10 times or more to seat the thrust bearing 5 Install the pinion an...

Page 360: ... the claw washer Check that the position b is set in place properly 12 Install the ring nut and then tighten the ring nut to the specified torque 13 Check that the drive shaft rotates smoothly If the drive shaft does not rotate smoothly the shim s may be installed incorrectly or there may be foreign material on the shim s 14 Measure the reverse gear backlash See Measuring the forward and reverse g...

Page 361: ...backlash is within the gray col ored area The values for the shim thickness adjust ments specified in the selection chart are intended to achieve the median value within the range for the specified forward or reverse gear backlash The selection chart table shows the shim thickness adjustments for marked points on the chart 4 Calculate the new reverse gear shim thickness T1 as same way in the examp...

Page 362: ...f shim thickness 0 30 0 27 0 23 0 20 0 16 0 0 0 0 0 00 0 04 0 07 0 11 0 14 0 17 0 21 0 24 0 27 0 31 0 34 0 38 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 1 20 B mm Continue next page 1 00 0 80 0 60 0 40 0 20 0 0 20 0 40 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 A 1 100 mm A B ...

Page 363: ... 0 38 0 41 0 44 0 48 0 51 0 54 0 58 0 61 0 65 0 68 0 71 0 75 0 78 0 81 0 85 0 88 0 92 0 95 0 98 1 02 1 05 100 105 110 115 120 125 130 135 145 150 155 160 165 170 175 180 185 190 195 200 140 1 20 B mm 1 00 0 80 0 60 0 40 0 20 0 0 20 0 40 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 A 1 100 mm A B ...

Page 364: ...m cowling 9 10 Upper case and mounts 9 12 Removing the upper case 9 14 Installing the upper case 9 14 Upper case 9 16 Disassembling the upper case 9 17 Checking the drive shaft bushing 9 17 Assembling the upper case 9 17 Oil pan and exhaust manifold 9 19 Disassembling the oil pan and exhaust manifold 9 21 Checking the oil pan and exhaust manifold 9 21 Checking the oil strainer 9 21 Assembling the ...

Page 365: ...rush 9 42 Assembling the PTT motor 9 43 Installing the reservoir 9 44 Installing the PTT motor 9 44 PTT gear pump 9 45 Disassembling the gear pump assembly 9 47 Checking the gear pump 9 47 Assembling the gear pump assembly 9 48 PTT cylinder 9 50 Removing the tilt ram and trim ram 9 52 Disassembling the tilt ram 9 52 Checking the tilt cylinder and trim cylinder 9 53 Checking the valve 9 53 Assembli...

Page 366: ... lever 1 9 Shift cut switch 1 10 Spring 1 11 Bushing 2 12 Bolt 2 M6 50 mm 13 Bracket 1 14 Grease nipple 1 15 Bolt 1 16 Grommet 1 17 Circlip 1 1 N m 0 1 kgf m 0 7 ft lb 2 5 N m 0 25 kgf m 1 84 ft lb 2 5 N m 0 25 kgf m 1 84 ft lb 19 N m 1 9 kgf m 14 0 ft lb 2 1 2 2 3 3 9 2 4 4 5 6 7 8 10 11 11 12 13 14 15 16 17 18 18 19 20 21 22 23 24 25 26 27 28 29 18 N m 1 8 kgf m 13 3 ft lb ...

Page 367: ...19 N m 1 9 kgf m 14 0 ft lb 2 1 2 2 3 3 9 2 4 4 5 6 7 8 10 11 11 12 13 14 15 16 17 18 18 19 20 21 22 23 24 25 26 27 28 29 18 N m 1 8 kgf m 13 3 ft lb No Part name Q ty Remarks 18 Washer 2 19 Bracket 1 20 Ball 1 21 Spring 1 22 Bolt 1 23 Pin 1 24 Grease nipple 1 25 Bushing 1 26 O ring 1 Not reusable 27 Bolt 1 M6 35 mm 28 Shift rod 1 29 Bushing 1 ...

Page 368: ...bling the shift bracket 1 Remove the bolt a and then disassem ble the shift bracket assembly 2 Remove the neutral switch b For checking the neutral switch see Checking the neutral switch 5 37 3 Remove the shift cut switch c For checking the shift cut switch see Check ing the shift cut switch 5 36 Assembling the shift bracket 1 Install the shift cut switch a and then tighten the screws b to the spe...

Page 369: ... f in direction g when pushing the shift bracket e down otherwise the lever may be damaged 5 Tighten the shift bracket bolt g to the specified torque 6 Install the grease nipple h and then tighten it to the specified torque TIP Make sure that the installation angle of the grease nipple h falls within the range h 7 Apply grease into the grease nipple until grease comes out of the bushings k Screw b...

Page 370: ...bolt e to the specified torque 3 Install the shift lever f to the set pin a of the shift rod assembly g 4 Install the shift rod assembly g and then align the center of the set pin a with the mark b on the bottom cowling 5 Install the shift bracket assembly h and then install the bushing i and clip j to the shift lever f Bolt e 18 N m 1 8 kgf m 13 3 ft lb a c b e d a a b f g h i j f ...

Page 371: ...g lock lever AFT 1 7 Cowling lock lever BOW 1 8 Bushing 4 9 Bolt 4 M6 30 mm 10 Housing BOW 1 11 Housing AFT 1 12 Wave washer 2 13 Lever 2 14 Washer 2 15 Bolt 2 M6 20 mm 16 Spring 2 17 Bolt 2 M6 20 mm 8 13 12 18 18 16 16 1 2 1 1 3 3 4 4 5 5 21 21 21 26 19 20 22 23 24 25 27 1 2 6 8 8 9 10 11 9 9 13 12 14 14 15 15 17 17 17 7 18 8 16 3 N m 0 3 kgf m 2 2 ft lb A A Shift rod and shift bracket PTT switch...

Page 372: ...t 1 20 Hose 1 21 Plastic tie 3 Not reusable 22 Hose joint 1 23 Hose joint 1 24 Gasket 1 25 Adapter 1 26 Screw 2 ø6 19 mm 27 Clamp 1 8 13 12 18 18 16 16 1 2 1 1 3 3 4 4 5 5 21 21 21 26 19 20 22 23 24 25 27 1 2 6 8 8 9 10 11 9 9 13 12 14 14 15 15 17 17 17 7 18 8 16 3 N m 0 3 kgf m 2 2 ft lb A A ...

Page 373: ...g the PTT switch on bottom cowling 5 49 A Regular rotation model B Counter rotation model Removing the cowling lock lever 1 Remove the spring a 2 Remove the lever b and cowling lock lever c Removing the flushing hose 1 Remove the adapter a and hose joints b c 2 Remove the flushing hose d PTT motor leads a trim sensor lead b and grom met e STBD A a b a PORT B b a b c a b c d a b e ...

Page 374: ...e a with the outer end of the grommet d Installing the cowling lock lever 1 Install the cowling lock lever a and lever b 2 Install the spring c 3 Apply grease into the housing d until grease comes out from the cowling lock lever bushing Installing the PTT switch 1 Install the gasket a and PTT switch b with in the holder c onto the bottom cowling A Regular rotation model B Counter rotation model a ...

Page 375: ...3 Holder 2 4 Bracket 1 5 Bracket 1 6 Bracket 1 7 Clamp 1 8 Holder 1 9 Grommet 4 10 Collar 4 11 Rubber seal 1 12 Water outlet 1 13 Grommet 2 14 Bolt 4 M8 35 mm 15 Grommet 8 16 Collar 4 17 Rubber seal 1 6 4 1 3 3 2 2 5 1 1 1 8 10 9 14 15 15 16 13 11 13 7 12 17 18 19 PTT switch and cowling lock lever Bottom cowling ...

Page 376: ...9 11 BRKT Bracket unit No Part name Q ty Remarks 18 Bottom cowling 1 19 Grommet 1 6 4 1 3 3 2 2 5 1 1 1 8 10 9 14 15 15 16 13 11 13 7 12 17 18 19 ...

Page 377: ...t 2 9 Washer 2 10 Washer 2 11 Washer 2 12 Bolt 2 M14 225 mm 13 Cap 2 14 Collar 2 15 Washer 4 16 Upper mount 2 17 Bracket 1 72 N m 7 2 kgf m 53 1 ft lb 54 N m 5 4 kgf m 39 8 ft lb 72 N m 7 2 kgf m 53 1 ft lb 1 2 3 3 3 3 4 4 5 6 7 7 7 8 8 8 9 9 9 10 10 10 11 11 11 12 12 12 13 13 13 14 14 14 15 15 15 15 15 15 16 16 16 17 18 19 19 19 20 20 20 21 21 22 23 23 24 25 26 26 Bottom cowling Upper case and mo...

Page 378: ...Nipple 1 23 Plastic tie 2 Not reusable 24 Hose 1 25 Adapter 1 26 Bolt 1 M6 20 mm 72 N m 7 2 kgf m 53 1 ft lb 54 N m 5 4 kgf m 39 8 ft lb 72 N m 7 2 kgf m 53 1 ft lb 1 2 3 3 3 3 4 4 5 6 7 7 7 8 8 8 9 9 9 10 10 10 11 11 11 12 12 12 13 13 13 14 14 14 15 15 15 15 15 15 16 16 16 17 18 19 19 19 20 20 20 21 21 22 23 23 24 25 26 26 ...

Page 379: ...bolts PORT and STBD d 4 Remove the upper mounting nuts e and lower mounting nuts f and then remove the upper case assembly Installing the upper case 1 Install the upper mounts a and bolts b 2 Install the upper mount bracket c and then tighten the upper mount bracket bolts d temporarily 3 Install the lower mounts e and bolts f 4 Install the lower mount covers g and then tighten the lower mount cove...

Page 380: ...specified torque in the sequence numbers a b 8 Tighten the lower mount bracket bolts PORT and STBD n 9 Connect the ground lead o 10 Pass the speedometer hose p through the steering arm q and then connect it to the speedometer hose adapter r 11 Install the drain bolt See Assembling the upper case 9 17 step 7 Upper mounting nut k 72 N m 7 2 kgf m 53 1 ft lb Lower mounting nut l 72 N m 7 2 kgf m 53 1...

Page 381: ...le plate 1 8 Bolt 2 M8 30 mm 9 Dowel 2 10 Bolt 4 M10 45 mm 11 Grommet 2 12 Gasket 1 Not reusable 13 Drain bolt 1 14 Damper 1 15 Rubber seal 1 16 Rubber seal 1 Not reusable 4 N m 0 4 kgf m 3 0 ft lb 1 2 3 4 5 6 7 8 9 9 10 10 11 11 10 8 10 12 13 14 15 16 42 N m 4 2 kgf m 31 0 ft lb 27 N m 2 7 kgf m 19 9 ft lb 20 N m 2 0 kgf m 14 8 ft lb Upper case and mounts Upper case ...

Page 382: ...f and then tighten baffle plate screws g to the spec ified torque 4 Install the rubber seal h into the joint hole a of the upper case 5 Install a new rubber seal i and the rub ber seal j and then install the oil pan assembly k TIP Make sure to insert the tip of the cooling water pipe l into the joint hole a of the upper case 6 Install the oil pan bolts m and n and then tighten them to the specifie...

Page 383: ... bolt p and then tighten it to the specified torque Baffle plate screw g 4 N m 0 4 kgf m 3 0 ft lb Oil pan assembly bolt M8 m 20 N m 2 0 kgf m 14 8 ft lb Oil pan assembly bolt M10 n 42 N m 4 2 kgf m 31 0 ft lb Drain bolt p 27 N m 2 7 kgf m 19 9 ft lb h j k m n l h l a i e f g o p ...

Page 384: ...Bolt 3 M6 25 mm 7 Dowel 2 8 Oil pan 1 9 Bolt 10 M8 35 mm 10 Bolt 4 M8 60 mm 11 Gasket 1 Not reusable 12 Exhaust manifold 1 13 Rubber seal 1 14 Gasket 2 Not reusable 15 Plate 1 16 Water pipe 1 17 Rubber seal 1 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 14 15 16 17 18 19 20 20 N m 2 0 kgf m 14 8 ft lb 20 N m 2 0 kgf m 14 8 ft lb 11 N m 1 1 kgf m 8 1 ft lb 20 N m 2 0 kgf m 14 8 ft lb ...

Page 385: ...6 7 8 9 10 A No Part name Q ty Remarks 18 Dowel 2 19 Muffler 1 20 Bolt 8 M8 35 mm 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 14 15 16 17 18 19 20 20 N m 2 0 kgf m 14 8 ft lb 20 N m 2 0 kgf m 14 8 ft lb 11 N m 1 1 kgf m 8 1 ft lb 20 N m 2 0 kgf m 14 8 ft lb ...

Page 386: ...ifold and muffler if cracked or if there is corrosion 3 Check the oil pan Replace the oil pan if cracked or if there is corrosion Checking the oil strainer 1 Check the oil strainer Clean the oil strainer if there is dirt and residue Assembling the oil pan and exhaust manifold 1 Install a new gasket a and the oil strainer b and then tighten the oil strainer bolts c to the specified torque 2 Install...

Page 387: ...he oil pan bolts g to the specified torques 5 Install the rubber seal l and cooling water pipe m 6 Install the dowels n new gaskets o and the plate p and then install the muf fler assembly q 7 Tighten the muffler assembly bolts r to the specified torque Exhaust manifold bolt k 20 N m 2 0 kgf m 14 8 ft lb Oil pan bolt g 20 N m 2 0 kgf m 14 8 ft lb d e f g g g g h i j k k Muffler assembly bolt r 20 ...

Page 388: ...9 23 BRKT Bracket unit Steering arm No Part name Q ty Remarks 1 Steering arm 1 2 Washer 2 3 Bushing 2 4 O ring 1 Not reusable 5 Bushing 1 6 Steering yoke 1 7 Circlip 1 8 Grommet 1 1 2 2 3 3 4 5 6 7 8 ...

Page 389: ... swivel bracket Installing the steering arm 1 Install the washer a and bushing b onto the steering arm c 2 Place the swivel bracket d in an upright position and then install the steering arm c 3 Install the bushing e a new O ring f the bushing g and washer h 4 Install the steering yoke i making sure it is facing the same direction as the steering arm aligning a with b a a b a b c d e f g h i a b c...

Page 390: ...nd then strike the steering yoke i with a copper hammer until the groove c for installing the circlip is visible 6 Install the circlip j 7 Apply grease into the grease nipple k until it comes out from both the upper and lower bushings d j j i c c d d k ...

Page 391: ... 8 Bushing 2 9 Tilt stop lever 1 10 Bushing 2 11 Washer 2 12 Clamp bracket PORT 1 13 Through tube 1 14 Bolt 1 M8 20 mm 15 Plastic tie 1 Not reusable 16 Swivel bracket 1 17 Trim stopper 2 1 2 3 3 3 3 3 3 4 5 6 8 7 8 9 10 10 11 11 12 13 14 15 16 17 18 19 20 21 21 22 22 23 24 25 26 27 27 28 26 26 26 27 27 28 29 30 31 32 33 34 35 36 15 N m 1 5 kgf m 11 1 ft lb 3 N m 0 3 kgf m 2 2 ft lb 3 N m 0 3 kgf m...

Page 392: ...26 Pin 2 27 Distance collar 2 28 Pin 1 29 Spring 1 30 Hook 1 31 Bolt 1 M6 10 mm 32 Screw 1 M5 35 mm 33 Trim sensor cam 1 34 Clamp 1 1 2 3 3 3 3 3 3 4 5 6 8 7 8 9 10 10 11 11 12 13 14 15 16 17 18 19 20 21 21 22 22 23 24 25 26 27 27 28 26 26 26 27 27 28 29 30 31 32 33 34 35 36 15 N m 1 5 kgf m 11 1 ft lb 3 N m 0 3 kgf m 2 2 ft lb 3 N m 0 3 kgf m 2 2 ft lb ...

Page 393: ...e Q ty Remarks 35 Screw 2 M6 15 mm 36 Trim sensor 1 1 2 3 3 3 3 3 3 4 5 6 8 7 8 9 10 10 11 11 12 13 14 15 16 17 18 19 20 21 21 22 22 23 24 25 26 27 27 28 26 26 26 27 27 28 29 30 31 32 33 34 35 36 15 N m 1 5 kgf m 11 1 ft lb 3 N m 0 3 kgf m 2 2 ft lb 3 N m 0 3 kgf m 2 2 ft lb ...

Page 394: ...und lead d and e 6 Remove the bolt f and self locking nut g 7 Remove the through tube h and then disassemble the clamp brackets i and j 8 Remove the trim sensor k 9 Remove the spring l hook m and pins n 10 Remove the tilt stop levers o p distance collar assembly q collar r and bushings s Installing the clamp bracket 1 Assemble the distance collar assembly a b e f g h j i d c k n n l m o p q r s s ...

Page 395: ...j and temporarily tighten the self locking nut k 6 Install the anode l 7 Tighten the self locking nut k to the specified torque 8 Install the trim sensor cam m 9 Install the grease nipples n and then tighten them n to the specified torque Distance a 30 3 30 6 mm 1 19 1 20 in Distance b 3 0 mm 0 12 in a a a a a b c d e f g h f f b Self locking nut k 15 N m 1 5 kgf m 11 1 ft lb Grease nipple n 3 N m...

Page 396: ...trim sensor cam screw a TIP Check the trim sensor resistance again after tightening the trim sensor cam screw a 5 Fully tilt the swivel bracket up and then support it with the tilt stop lever c WARNING After tilting up the swivel bracket make sure to support it with the tilt stop lever Otherwise the swivel bracket could suddenly lower 6 Check the trim sensor resistance If the resistance is out of ...

Page 397: ... ty Remarks 1 Shaft 1 2 Circlip 1 3 Bushing 6 4 PTT unit 1 5 Ground lead 1 6 Bolt 1 M6 10 mm 7 Bolt 2 M10 30 mm 8 Washer 2 9 Shaft 1 10 Plastic tie 3 Not reusable 1 2 3 3 3 3 4 5 6 7 8 9 10 7 8 39 N m 3 9 kgf m 28 8 ft lb Clamp bracket and swivel bracket PTT unit ...

Page 398: ... Fully tilt the swivel bracket up and then support it with the tilt stop lever a TIP If the PTT unit does not operate open the manual valve b by turning it counterclock wise and then tilt the swivel bracket up man ually 2 Remove the plastic ties c and then pull out the PTT motor lead a from the clamp bracket PORT 3 Disconnect the ground lead d 4 Remove the circlip e and the shaft f 5 Connect the P...

Page 399: ...luid should overflow out of the filler hole when the reservoir cap is removed 3 If the fluid is below the correct level add the recommended fluid 4 Install the reservoir cap a and then tighten it to the specified torque 5 Remove the circlip b and then remove the manual valve c 6 Install the special service tools d and e TIP Quickly install the special service tools before any fluid flows out of th...

Page 400: ...o fully retract the PTT rams and then measure the hydraulic pressure when the reading on the pressure gauge stabilizes 12 Reverse the PTT motor leads between the battery terminals to fully extend the PTT rams Ram PTT motor lead Battery terminal Down Black B Black White B W Hydraulic pressure up reference data 9 8 11 8 MPa 98 0 118 0 kgf cm2 1421 0 1711 0 psi Ram PTT motor lead Battery terminal Up ...

Page 401: ...ully extend the PTT rams TIP If the PTT rams do not move up and down easily push and pull the PTT rams to assist operation 6 Check the fluid level when the PTT rams are fully extended If the fluid level is low add sufficient fluid and then repeat step 3 step 7 Installing the PTT unit After tilting the swivel bracket up make sure to support it with the tilt stop lever When installing the PTT unit w...

Page 402: ... bracket 5 Install the PTT unit d and then install the shaft e 6 Tighten the shaft bolts f to the specified torque 7 Pass the PTT motor leads a through the hole b in the clamp bracket PORT 8 Connect the PTT motor leads a to the battery terminals to extend the PTT rams Ram PTT motor lead Battery terminal Down Black B Black White B W B B W a Bolt f 39 N m 3 9 kgf m 28 7 ft lb Ram PTT motor lead Batt...

Page 403: ...it 0 1 2 3 4 5 6 7 8 9 10 A 9 Insert the shaft g from the port side and install the circlip h 10 Connect the ground lead i 11 Fasten the PTT motor lead a and trim sensor lead with new plastic ties j h g i j j a j ...

Page 404: ... M6 33 mm 7 O ring 1 Not reusable 8 Filter 1 9 Joint 1 10 PTT motor assembly 1 11 Screw 1 M4 15 mm 12 Armature 1 13 O ring 1 Not reusable 14 Screw 2 M4 12 mm 15 Brush holder 1 16 Brush holder 1 17 Brush 2 1 5 N m 0 5 kgf m 3 7 ft lb 5 N m 0 5 kgf m 3 7 ft lb 0 7 N m 0 07 kgf m 0 5 ft lb 1 1 2 3 4 5 6 6 7 8 9 10 10 11 12 13 14 14 15 16 17 18 19 19 20 20 21 ...

Page 405: ...Part name Q ty Remarks 18 Brush 1 1 19 Spring 2 20 Screw 2 M4 15 mm 21 Oil seal 1 Not reusable 5 N m 0 5 kgf m 3 7 ft lb 5 N m 0 5 kgf m 3 7 ft lb 0 7 N m 0 07 kgf m 0 5 ft lb 1 1 2 3 4 5 6 6 7 8 9 10 10 11 12 13 14 14 15 16 17 18 19 19 20 20 21 ...

Page 406: ... PTT motor 1 Remove the screw a and then slide the lead holder a and rubber seals b away from the stator b 2 Remove the PTT motor screws c and then remove the stator b NOTICE Hold the end of the armature shaft with a pair of pliers and then remove the armature together with the motor base assembly otherwise the armature could separate from the motor base assembly due to the magnetic force of the s...

Page 407: ...sh 1 Measure the length of each brush Replace the brushes if below specifica tion 2 Check the brush and circuit breaker for continuity Replace if there is no continuity NOTICE Do not touch the bimetal b otherwise the operation of the circuit breaker can be affected Motor commutator standard diameter a 22 0 mm 0 87 in Wear limit 21 0 mm 0 83 in f e e B d a Digital circuit tester 90890 03174 Armatur...

Page 408: ...uch the bimetal a otherwise the operation of the circuit breaker can be affected 4 Connect the PTT motor lead B W Black White and lead B Black and then tighten the screw g 5 Push the brushes d and e into the holders and then install the armature h 6 Install the stator i and then tighten the screws j NOTICE Hold the end of the armature shaft with a pair of pliers and then install the armature toget...

Page 409: ...gear pump filter b 2 Fill the gear pump housing with the recommended fluid to the correct level a 3 Turn the joint a with a screwdriver and then remove any air between the pump gear teeth 4 Remove all of the air bubbles with a syringe or suitable tool 5 Install a new O ring c and the PTT motor assembly d and then tighten the PTT motor mounting bolts e to the specified torque TIP Align the projecti...

Page 410: ... O ring 2 Not reusable 10 Main valve 2 11 Ball 2 12 Spring 1 13 Absorber valve pin 1 14 Up relief valve seat 1 15 O ring 1 Not reusable 16 Bolt 1 M8 85 mm 17 Bolt 2 M8 24 mm 3 5 N m 0 35 kgf m 2 58 ft lb 8 N m 0 8 kgf m 5 9 ft lb 6 N m 0 6 kgf m 4 4 ft lb 1 2 1 3 3 4 4 5 6 7 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 17 17 16 18 19 20 21 22 23 24 25 26 27 9 8 N m 0 8 kgf m 5 9 ft lb ...

Page 411: ... Not reusable 22 Circlip 1 23 Filter 2 24 O ring 1 Not reusable 25 Down relief valve 1 26 Valve pin 1 27 O ring 4 Not reusable 3 5 N m 0 35 kgf m 2 58 ft lb 8 N m 0 8 kgf m 5 9 ft lb 6 N m 0 6 kgf m 4 4 ft lb 1 2 1 3 3 4 4 5 6 7 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 17 17 16 18 19 20 21 22 23 24 25 26 27 9 8 N m 0 8 kgf m 5 9 ft lb ...

Page 412: ...e gears l shuttle pistons m and balls n o 6 Remove the spring p absorber valve pin q ball r and up relief valve seat s and O ring t 7 Blow compressed air through the holes a and b to remove the main valves u WARNING Never look into the gear pump housing opening while removing the main valves because the main valves and PTT fluid could be forcefully expelled out 8 Remove the manual valve v Checking...

Page 413: ...ag when assembling the PTT unit because dust and particles on the PTT unit components can lead to poor performance Do not reuse the O rings always replace them with new ones 1 Install a new O ring a the up relief valve seat b ball c absorber valve pin d and spring e 2 Install new O rings f onto the main valves g and then install the main valves 3 Install the gears h 4 Install the balls i shuttle p...

Page 414: ... the manual valve s 10 Install the manual valve s and circlip t and then tighten the manual valve to the specified torque 11 Install the valve pin u and new O rings v 12 Install the valve seat assembly w and O rings x 13 Install the gear pump assembly y and then tighten the gear pump mounting bolts z and A to the specified torque 14 Install the PTT motor assembly See Installing the PTT motor 9 44 ...

Page 415: ... assembly 2 9 Dust seal 2 Not reusable 10 Seal 2 Not reusable 11 Trim cylinder screw 2 12 O ring 2 Not reusable 13 Backup ring 2 14 O ring 2 Not reusable 15 Free piston 1 16 Backup ring 1 17 O ring 1 Not reusable 8 8 140 N m 14 0 kgf m 103 3 ft lb 128 N m 12 8 kgf m 94 4 ft lb 6 N m 0 6 kgf m 4 4 ft lb 96 N m 9 6 kgf m 70 8 ft lb 1 2 3 4 5 6 7 9 9 10 10 11 11 12 12 13 13 14 14 15 16 17 17 18 19 20...

Page 416: ... 19 O ring 1 Not reusable 20 Filter 1 8 8 140 N m 14 0 kgf m 103 3 ft lb 128 N m 12 8 kgf m 94 4 ft lb 6 N m 0 6 kgf m 4 4 ft lb 96 N m 9 6 kgf m 70 8 ft lb 1 2 3 4 5 6 7 9 9 10 10 11 11 12 12 13 13 14 14 15 16 17 17 18 19 20 15 16 2 3 4 5 6 7 13 14 9 10 11 12 ...

Page 417: ...e the tilt ram assembly 6 Loosen the trim cylinder end screws d and then remove the trim ram assemblies 7 Drain the fluid 8 Install the trim ram assemblies and then tighten the trim cylinder end screws temporarily 9 Cover the tilt cylinder opening with a rag e and then blow compressed air through the hole a to remove the free piston f WARNING Never look into the tilt cylinder opening while removin...

Page 418: ...r worn 4 Check the trim rams h and tilt ram i Polish with 400 600 grit sandpaper if there is light rust or replace if bent or excessively corroded Checking the valve 1 Check the tilt piston absorber valves a Clean if there is dirt or residue Assembling the tilt ram Do not use a rag when assembling the PTT unit because dust and particles on the PTT unit components can lead to poor performance Do no...

Page 419: ...ld the tilt ram end 5 Install the balls i absorber valve pins j and springs k 6 Install the washer l and nut m to the tilt ram f and then tighten the nut m to the specified torque Assembling the trim ram 1 Install the backup ring a and a new O ring b to the trim ram c a b d c a b c d e e g h h f g Tilt piston nut m 96 N m 9 6 kgf m 70 8 ft lb i i j j f k k l l m b b a a c c ...

Page 420: ...ree piston d 4 Push the free piston d into the tilt cylinder until it bottoms out 5 Fill the PTT body with the recommended fluid to the correct level b through holes c d and e 6 Install the trim ram assemblies into the PTT body and then tighten the trim cylinder end screws e to the specified torque Recommended PTT fluid ATF Dexron ΙΙ Fluid quantity reference quantity 30 cm3 1 0 US oz 1 1 Imp oz e ...

Page 421: ...body with the recommended fluid to the correct level b 3 Place the tilt cylinder end screw at position a install the tilt ram assembly into the tilt cylinder and then tighten the tilt cylinder end screw a to the specified torque 4 Install the PTT motor assembly See Installing the PTT motor 9 44 Trim cylinder end screw e 140 N m 14 0 kgf m 103 3 ft lb Recommended PTT fluid ATF Dexron ΙΙ a a b b Tri...

Page 422: ...ral Periodic Maintenance 10 9 Checking the anode 10 9 Checking the battery 10 9 Checking the cooling water passage 10 10 Checking the engine idle speed 10 10 Checking the engine oil level 10 10 Changing the engine oil 10 10 Replacing the oil filter 10 11 Checking the engine start switch and engine shut off switch 10 12 Checking the fuel joint and fuel hoses fuel joint to fuel injector 10 12 Checki...

Page 423: ... 9 10 A Replacing the timing belt 10 16 Checking the thermostat 10 16 Adjusting the throttle link and throttle cable 10 16 Checking the top cowling 10 17 Checking the valve clearance 10 17 Checking the water pump 10 17 ...

Page 424: ...servicing will be required especially the engine oil and gear oil changes Examples of the intensive operation will be wide open throttle trolling or idling operations for extended period of time carrying heavy loads or frequent starting and stop ping or shifting In most cases the frequent maintenance pays off in increased engine life and greater owner satisfaction Consult Yamaha dealer for additio...

Page 425: ... filter Replace 10 11 Engine start switch engine shut off switch Check replace 10 5 Fuel filter can be disassembled Check replace 6 14 Fuel filter disposal type Replace 6 32 Fuel filter vapor separator Check replace 6 29 Fuel hoses high pressure Check replace 6 1 Fuel hoses low pressure Check replace 6 1 Fuel pump Check replace 6 10 Fuel oil leakage Check 10 12 Gear oil Replace 10 12 Greasing poin...

Page 426: ...throttle cable throttle pick up timing Check adjust replace 10 16 Thermostat Check replace 10 16 Timing belt Check replace 7 29 Valve clearance Check adjust 7 2 Water inlet Check 10 10 Wiring harness connec tions wiring coupler con nections Check replace Yamaha meter gauge Check 1 Item Actions Every Refer to page 1000 hours Guide exhaust exhaust manifold Check replace 9 21 Timing belt Replace 7 18...

Page 427: ...Charge batteries in a well ventilated area Keep batteries away from fire sparks or open flames example welding equip ment lighted cigarettes DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 1 Check the battery electrolyte level If the level is at or below the minimum level mark a add distilled water until the level is between the maximum and...

Page 428: ...falls at the center between the upper level mark a H and lower level mark b L Fill with oil if it is below the lower level mark b L or extract to the center level if it is above the upper level mark a H Checking the engine start switch and engine shut off switch 1 Check that the engine starts when the engine start switch is turned to START 2 Check that the engine turns off when the engine start sw...

Page 429: ...eck that the throttle operates smoothly when the remote control lever is shifted from F or R to the fully open position a Checking the outboard motor mounting height 1 Check that the anti cavitation plate is aligned with the bottom of the boat If the mounting height is too high cavitation will occur and propulsion will be reduced Also the engine speed will increase abnormally and cause the engine ...

Page 430: ...b on the cylinder block 3 Check that the center of the set pin a is aligned with the alignment mark b on the bottom cowling WARNING The shift or throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in c Checking the steering system 1 Check that the steering operates smoothly 2 Check that there is no interference with wires or hoses when the outboard motor is steered Test run 1 Start th...

Page 431: ...hrottle while keeping the boat at a planing speed 3 Remaining 8 hours c run the engine at any speed However avoid operating at full throttle for more than 5 minutes at a time 4 After the 1st 10 hours operate the engine normally A Hour After test run Do not perform this procedure on land while the engine is running The water pump may be damaged and severe engine damage from overheating can take pla...

Page 432: ...des and trim tab Clean the anodes or trim tab if there are scales grease or oil TIP Replace the anodes or trim tab if exces sively eroded In addition check the ground lead If it is necessary to disassemble the out board motor to check an anode refer to the applicable disassembly procedure in this manual Checking the battery 1 Check the battery See Checking the battery 10 4 ...

Page 433: ...k the engine idle speed using the Yamaha genuine tachometer on board meter or using the YDIS To connect and operate the YDIS see the YDIS Ver 1 30 or later Instruction Manual Checking the engine oil level 1 Check the engine oil level See Check ing the engine oil level 10 5 Changing the engine oil Change the engine oil after the first 20 hours of operation or 3 months and every 100 hours or at 1 ye...

Page 434: ...ower level mark L 11 Start the engine and make sure that the low oil pressure alert indicator remains off Also make sure that there are no oil leaks NOTICE If the low oil pressure alert indicator comes on or if there are oil leaks stop the engine and find the cause Continued operation with a problem could cause severe engine damage Replacing the oil filter 1 Extract the engine oil with an oil chan...

Page 435: ...lace the low pressure fuel hoses if there is leakage or deterioration 3 Check the high pressure fuel hose connections Also check the vapor separator d fuel rail e fuel injectors f pressure regulator g and fuel cooler h Replace the high pressure fuel hoses if there is leakage or deterioration Checking the fuel filter 1 Check the fuel filter See Checking the fuel filter assembly 6 14 and Checking th...

Page 436: ...f the check hole and no air bubbles are visible 6 Install new gaskets c and the gear oil check screw d quickly install the gear oil drain screw b and then tighten them to the specified torque Checking the gear shift operation 1 Check that the gear shift operates smoothly when shifting it from N position to F or R Adjust the shift cable length if the gear shift cannot be operated smoothly For adjus...

Page 437: ...tenance 0 1 2 3 4 5 6 7 8 9 10 A TIP Apply grease to the grease nipple until it flows from the bushings a 2 Apply low temperature resistant grease to the area 3 Apply corrosion resistant grease to the area A A A A A A A A a A A C ...

Page 438: ...t the outboard motor to the fully up position and then support it with the tilt stop lever a to check the lock mechanism of the lever Checking the propeller 1 Check the propeller blades and splines Replace the propeller if cracked dam aged or worn Checking the spark plug 1 Disconnect the spark plug wire and then remove the spark plug 2 Clean the electrode a with a spark plug cleaner or wire brush ...

Page 439: ...tainer of water 4 Place a thermometer in the water and slowly heat the water 5 Measure the thermostat valve opening a at the specified water temperatures Replace the thermostat if out of specification 6 Install the thermostat and cover and then tighten the cover bolts to the specified torques in 2 stages Adjusting the throttle link and throttle cable 1 Remove the intake silencer 2 Loosen the lockn...

Page 440: ...the bolts a 3 Move the hook b up or down slightly to adjust its position TIP To loosen the fitting move the hook in direction a To tighten the fitting move the hook in direction b 4 Tighten the bolts a 5 Check the fitting again 6 Check the top cowling hose for cracks or damage Checking the valve clearance 1 Check the valve clearance See Check ing the valve clearance 7 2 Checking the water pump 1 C...

Page 441: ...leeding the PTT unit 9 36 Bottom cowling 5 10 9 10 Bow view 5 4 Bracket unit 1 4 1 20 Bracket unit technical data 1 17 Break in 10 8 C Camshaft 7 26 Canister 6 6 Changing the engine oil 10 10 Changing the gear oil 10 12 Charging system 1 9 Charging units and components 5 26 Checking by use of the digital tester 5 13 Checking by use of YDIS 5 13 Checking the air pressure sensor 5 32 6 28 Checking t...

Page 442: ... 8 56 Checking the PTT fluid level 10 15 Checking the PTT motor 9 42 Checking the PTT operation 10 15 Checking the PTT relay 5 48 Checking the PTT switch on bottom cowling 5 49 Checking the PTT system 10 7 Checking the pulser coil 5 30 Checking the Rectifier Regulator 5 27 Checking the remote control cables 10 7 Checking the shift cut switch 5 36 Checking the spark plug 10 15 Checking the spark pl...

Page 443: ...m 1 8 2 13 Exhaust cover 7 32 Extension length recommendation of battery cable 3 25 Exterior 3 2 F Fail safe control 2 17 Feature 4 1 Flywheel magnet 7 5 Forward gear shim T1 selection chart 8 41 Forward gear shim T2 selection chart 8 78 Fuel and oil requirement 1 4 Fuel control units and components 5 23 Fuel filter 6 13 Fuel hose and blowby hose 6 1 Fuel injection control system 1 7 Fuel injector...

Page 444: ...harness 7 9 Intake and exhaust system 2 27 Intake manifold 6 27 Intake silencer 6 16 J Junction box 7 15 Junction box assembly 5 2 5 7 L Lower unit 1 4 Lower unit counter rotation model 1 20 8 47 Lower unit regular rotation model 1 19 8 1 Lower unit assembly counter rotation model 1 16 Lower unit assembly regular rotation model 1 16 Lower unit technical data 1 16 Lubricating the outboard motor 10 ...

Page 445: ...n chart 8 83 Reverse gear shim T2 selection chart 8 45 Rigging grommet description 3 8 Rigging recommendations 3 25 Rotating part 0 1 S Safety while working 0 1 Sealant and locking agent 0 6 Selecting the connecting rod bearing 7 57 Selecting the main bearing 7 60 Selecting the pinion shim T3 8 33 8 73 Selecting the propeller shaft shim T4 8 73 Selection 3 26 Self protection 0 2 Sensor switch and ...

Page 446: ...separator 6 29 Ventilation 0 1 W Water pump and shift rod counter rotation model 8 50 Water pump and shift rod regular rotation model 8 4 When the outboard hits something in the water 2 32 Wiring harness 7 7 Wiring harness routing 5 6 Working with crane 0 2 Y YDIS 4 1 YDIS kit 4 3 ...

Page 447: ...0 1 2 3 5 6 7 8 9 10 10 10 A Appendix A Wiring diagram A 2 How to use the wiring diagram A 2 Fuel unit A 3 Ignition unit A 5 Charging unit and starting unit A 7 ...

Page 448: ...A 1 MEMO ...

Page 449: ...in the selected wiring unit d Alert buzzer e Option parts Color Code B Black G R Green Red Br Brown G Y Green Yellow G Green L G Blue Green L Blue L W Blue White Lg Light green L Y Blue Yellow O Orange P B Pink Black P Pink P G Pink Green R Red P W Pink White Sb Sky blue Pu B Purple Black W White Pu G Purple Green Y Yellow Pu R Purple Red B O Black Orange Pu Y Purple Yellow B W Black White R Y Red...

Page 450: ...ignition coil YDIS d Fuse 20A engine start switch PTT switch e Fuse 30A starter motor relay f Main relay A To 10 pin main harness B To gauge TIP Depending on the outboard motor the location of the coupler terminal may be changed as indicated in the table below 1 Terminal No Color 6 through 18 except 8 Red Yellow 19 through 21 Red ...

Page 451: ......

Page 452: ...Printed in China Jul 2008 0 6 1 ABE E_4 YAMAHA MOTOR CO LTD ...

Page 453: ...B B B B Y G Pu G Pu R Pu B Pu Y L W L W R Y B W R W Y G P Br B Y R R W Br B B R Y G B L R Y R R R Y R Y R Y R Y R Y R Y G Y R Pu G Pu R Pu B Pu Y R Y R Y R Y R Y 1 3 2 4 A 1 B B R R R R 1 Fuel unit Engine start switch OFF ON START SET PULL Engine ECM Fuel injector High pressure fuel pump Water detection switch Joint connector Fuse box Starter motor PTT relay ...

Page 454: ...p ignition coil YDIS d Fuse 20A engine start switch PTT switch e Fuse 30A starter motor relay f Main relay A To 10 pin main harness B To gauge TIP Depending on the outboard motor the location of the coupler terminal may be changed as indicated in the table below 1 Terminal No Color 6 through 18 except 8 Red Yellow 19 through 21 Red ...

Page 455: ...W R W B W B L G L G L W L W L Y L Y B O B W B W B Y B B Y B Y B Y R Y R Y R Y R Y R Y G R G R G B G B G Y G Y B W R W Y G P Br B Y R R W Br B B R Y G B R B O R R R R Y R Y R Y R Y G Y R 1 1 Ignition unit Engine start switch OFF ON START SET PULL Engine ECM Pulser coil Oilpressure sensor Thermoswitch Waterpressure sensor option Speed sensor option Ignition coil Air pressure sensor Engine temperatur...

Page 456: ...elay f Main relay g Diode connect to the PTT relay A To 10 pin main harness B To gauge C To diagnostic test lead D To gauge E To 6Y8 Multifunction Meter hub F Connect the coupler when the trim meter display is carried out by LAN communication option TIP Depending on the outboard motor the location of the coupler terminal may be changed as indicated in the table below 1 Terminal No Color 6 through ...

Page 457: ... G Lg Lg B B B B B B B B B B B B Y G P B P B P B P W P W W B W B L W L W B W B W R Y R Y B W R W Y G P Br B Y R R W Br B B R Y G B R R R R B R R R R G G G Sb Lg B B R R R R Y R Y G Y R R R 1 1 Charging unit and starting unit Engine start switch OFF ON START SET PULL Engine ECM PTT relay PTT motor Starter relay Starter motor Hour meter PTT switch Trim sensor YDIS coupler Fuse box Starter assembly R...

Page 458: ......

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