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Yamaha F200B, Service Manual

The Yamaha F200B Owner's Manual is an essential resource for users of this powerful outboard motor. Discover detailed instructions, maintenance tips, and troubleshooting advice in this comprehensive manual. Download it for free from manualshive.com and unleash the full potential of your Yamaha F200B, ensuring optimal performance and longevity.

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FUEL

Fuel system

Hose routing ....................................................................... 6-1

Fuel hose and blowby hose........................................................ 6-1
Vapor gas hose .......................................................................... 6-3
Cooling water hose..................................................................... 6-5

Fuel system ........................................................................ 6-7

Reducing the fuel pressure ........................................................ 6-7
Disconnecting the quick connector............................................. 6-7
Connecting the quick connector ................................................. 6-8
Measuring the fuel pressure ....................................................... 6-8
Checking the pressure regulator .............................................. 6-10

Fuel filter assembly.......................................................... 6-11

Removing the fuel filter assembly ............................................ 6-13
Checking the fuel filter assembly.............................................. 6-13
Disassembling the fuel filter assembly ..................................... 6-14
Checking the fuel filter element ................................................ 6-14
Checking the fuel cup assembly............................................... 6-14
Assembling the fuel filter assembly .......................................... 6-14
Installing the fuel filter assembly .............................................. 6-14

Intake manifold ................................................................. 6-15

Removing the intake silencer ................................................... 6-17
Removing the intake manifold .................................................. 6-17
Checking the intake manifold ................................................... 6-18
Checking the air temperature sensor ....................................... 6-18
Installing the intake manifold .................................................... 6-18
Installing the intake silencer ..................................................... 6-19

Throttle body .................................................................... 6-21

Removing the throttle body assembly ...................................... 6-23
Checking the canister check valve ........................................... 6-23
Checking the vacuum hose ...................................................... 6-24
Installing the throttle body assembly ........................................ 6-24

Canister, throttle body, and surge tank ......................... 6-26

Removing the canister, throttle body, and surge tank .............. 6-28
Checking the ETV .................................................................... 6-28
Checking the air pressure sensor............................................. 6-28
Checking the vapor shut-off valve ............................................ 6-28
Checking the canister............................................................... 6-28
Installing the canister, throttle body, and surge tank ................ 6-29

Low-pressure fuel pump ................................................. 6-31

Removing the low-pressure fuel pump ..................................... 6-32
Checking the low-pressure fuel pump ...................................... 6-32

Summary of Contents for F200B

Page 1: ...F200B FL200B F250G FL250G SERVICE MANUAL 6DX 28197 5P 11 ...

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 products and services are available on Yamaha Service Portal Important information Particularly important information is distinguished in this manual by ...

Page 3: ...ion SPEC 1 Technical features and description TECH FEA 2 Rigging information RIG GING 3 Troubleshooting TRBL SHTG 4 Electrical system ELEC 5 Fuel system FUEL 6 Power unit POWR 7 Lower unit LOWR 8 Bracket unit BRKT 9 Maintenance MNT 10 Index Appendix A ...

Page 4: ......

Page 5: ...lf protection 0 2 Working with crane 0 2 Handling of gas torch 0 2 Part lubricant and sealant 0 2 Handling of sealant 0 2 Special service tool 0 3 Tightening torque 0 3 Non reusable part 0 3 Disassembly and assembly 0 3 How to use this manual 0 4 Manual format 0 4 Abbreviation 0 5 Lubricant sealant and thread locking agent 0 7 Symbol 0 7 Special service tool 0 9 ...

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

Page 7: ... outboard motor can be lifted and carried in a stable manner Handling of gas torch Improper handling of a gas torch may result in burns For information on the proper han dling of the gas torch see the operation manual issued by the manufacturer When using a gas torch keep it away from the gasoline and oil to prevent a fire Components become hot enough to cause burns Do not touch any hot components...

Page 8: ...s use new gaskets seals O rings cot ter pins and so on when installing or assem bling parts Disassembly and assembly Use compressed air to remove dust and dirt during disassembly Apply engine oil to the contact surfaces of moving parts before assembly Install bearings so that the bearing identifi cation mark is facing in the direction indi cated in the installation procedure In addition make sure ...

Page 9: ...13 Lower unit 1 14 Spacer 1 15 Propeller 1 16 Cotter pin 1 Not reusable 17 Propeller nut 1 14 20 22 1 2 22 13 15 18 16 19 17 22 21 11 12 25 26 24 6 3 7 8 9 10 8 5 4 3 23 34 33 32 31 30 29 25 35 27 28 42 N m 4 2 kgf m 31 0 ft lb 54 N m 5 4 kgf m 39 8 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 2 3 N m 0 23 kgf m 1 70 ft lb 47 N m 4 7 kgf m 34 7 ft lb È 8 19...

Page 10: ...de DOHC Dual Over Head Camshaft ECM Electronic Control Module EN European Norm European standard ETV Electronic Throttle Valve EX Exhaust EXH Exhaust F Forward GPS Global Positioning System IEC International Electro technical Commission IN Intake INT Intake ISC Idle Speed Control ISO International Organization for Standardization LAN Local Area Network N Neutral OCV Oil Control Valve PCV Pressure ...

Page 11: ...0 6 0 TPS Throttle Position Sensor UP Upside VCT Variable Camshaft Timing W F Water in Fuel YDIS Yamaha Diagnostic System Abbreviation Description How to use this manual ...

Page 12: ... Symbol Name 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 LOCTITE 518 Sealant ThreeBond 1280B Sealant ThreeBond 1303N Thread locki...

Page 13: ...1401 Thread locking agent ThreeBond 1530D Sealant LOCTITE 242 blue Thread locking agent LOCTITE 271 red Thread locking agent LOCTITE 572 white Sealant Silicone sealant Sealant Symbol Name Application Lubricant sealant and thread locking agent ...

Page 14: ... by the Parts Divi sion Drilling plate 90890 06783 YDIS CD ROM Ver 1 33 60V WS853 06 YDIS USB adapter and cable 60V WS850 00 Diagnostic flash indicator B 90890 06865 Digital circuit tester 90890 03174 Peak voltage adapter 90890 03172 Test harness 3 pins 90890 06869 Vacuum pressure pump gauge set 90890 06756 Ignition tester 90890 06754 Test harness 2 pins 90890 06867 ...

Page 15: ...kage tester 90890 06840 Compression gauge 90890 03160 Compression gauge extension 90890 06563 Flywheel magnet holder 90890 06522 Flywheel puller 90890 06521 Sheave holder 90890 01701 Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 06320 Special service tool ...

Page 16: ...10 Valve guide reamer 90890 06804 Valve lapper 90890 04101 Valve seat cutter holder 90890 06316 Valve seat cutter 30 intake 90890 06817 Valve seat cutter 30 exhaust 90890 06326 Valve seat cutter 45 intake 90890 06816 Valve seat cutter 45 exhaust 90890 06325 Valve seat cutter 60 intake and exhaust 90890 06324 ...

Page 17: ...ttachment 90890 06613 Needle bearing attachment 90890 06607 Piston ring compressor 90890 05158 Needle bearing attachment 90890 06653 Shift rod socket 90890 06679 Bearing housing puller claw L 90890 06502 Stopper guide plate 90890 06501 Center bolt 90890 06504 Special service tool ...

Page 18: ...assembly 90890 06523 Bearing separator 90890 06534 Stopper guide stand 90890 06538 Bearing puller assembly 90890 06535 Needle bearing attachment 90890 06611 Driver rod SS 90890 06604 Needle bearing attachment 90890 06610 Bearing depth plate 90890 06603 Bearing inner race attachment 90890 06640 ...

Page 19: ...ut holder 90890 06715 Ball bearing attachment 90890 06655 Driver rod LL 90890 06605 Bearing inner race attachment 90890 06658 Bearing inner race attachment 90890 06659 Bearing outer race attachment 90890 06628 Driver rod LS 90890 06606 Backlash indicator 90890 06706 Special service tool ...

Page 20: ... 90890 01252 Magnet base B 90890 06844 Pinion height gauge 90890 06672 Puller head 90890 06514 Ring nut wrench 90890 06578 Ball bearing attachment 90890 06557 PTT oil pressure gauge assembly 90890 06580 Cylinder end screw wrench 90890 06568 PTT piston vice attachment 90890 06572 ...

Page 21: ...0 16 0 Tilt rod wrench 90890 06569 Special service tool ...

Page 22: ...m 1 8 Engine speed control system 1 8 VCT system 1 9 PTT system 1 9 Charging system 1 10 Starting system 1 10 Gauge sensor 1 11 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 13 Lower unit technical data 1 15 Lower unit assembly regular rotation model 1 15 Lower unit assembly counter rotation model 1 ...

Page 23: ...1 Lower unit counter rotation model 1 19 Bracket unit 1 19 PTT unit 1 20 General tightening torque 1 21 ...

Page 24: ... Long intake manifolds Large diameter intake valve heads In bank exhaust system Speed sensor and water pressure sensor optional b Electrical Electronic fuel injection control Digital ignition control VCT control Knock control Over rev control Self diagnosis system ETV control Fail safe control Conventional or LAN gauges acceptable Water cooled Rectifier Regulator with isola tor c Upper case Anodiz...

Page 25: ...tarting method M Manual start E Electric start W Electric start with manual start Level 2 Control method None Remote control without tiller handle H Tiller handle C Remote control with tiller handle Level 3 Trim and tilt method None Manual tilt D Hydraulic tilt P PT Power tilt T PT T Power trim and tilt Level 4 Lubrication system 2 stroke model None Premixed fuel with oil model O Oil injection mod...

Page 26: ...affixed to the port clamp bracket 1 Model name 2 Approved model code 3 Transom height 4 Serial number YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON 2 3 1 4 Model name Approved model code Starting serial No F200BET 6S1 1002876 FL200BET 6S2 1001074 F250GET 6DX 1000001 FL250GET 6DY 1000001 ...

Page 27: ...ttle operating range r min 5000 6000 Maximum fuel consumption At 5500 r min L US gal Imp gal hr 73 7 19 5 16 2 75 6 20 0 16 6 Engine idle speed r min 600 700 Item Unit Model F200BET FL200BET F250GET FL250GET Type 4 stroke DOHC Cylinder quantity V6 Total displacement cm3 cu in 3352 0 204 5 Bore stroke mm in 94 0 80 5 3 70 3 17 Compression ratio 9 9 1 Control system Remote control Starting system El...

Page 28: ...nit Model F200BET FL200BET F250GET FL250GET Fuel type Regular unleaded gasoline Minimum fuel octane number RON 84 90 Engine oil 4 stroke motor oil Engine oil grade 1 2 API SE SF SG SH SJ SL SAE 5W 30 10W 30 10W 40 Total engine oil quantity oil pan capacity 3 L US qt Imp qt 5 6 5 92 4 93 Gear oil type Hypoid gear oil Gear oil grade 2 API GL 4 SAE 90 Gear oil quantity L US qt Imp qt 1 150 1 216 1 01...

Page 29: ...uid requirement Item Unit Model F200BET FL200BET F250GET FL250GET Minimum cold cranking amps CCA EN A 711 0 Minimum rated capacity 20HR IEC Ah 100 0 Item Unit Model F200BET FL200BET F250GET FL250GET Fluid type ATF Dexron II Model data ...

Page 30: ... 8 Cam position sensor Input voltage V 12 0 Knock sensor Resistance 1 At 20 C 68 F kΩ 504 0 616 0 Air temperature sensor Resistance 1 At 20 C 68 F kΩ 2 21 2 69 At 80 C 176 F kΩ 0 32 Input voltage V 4 75 5 25 Neutral switch Input voltage V 4 75 5 25 Air pressure sensor Input voltage V 4 75 5 25 Output voltage At 20 0 kPa 0 20 kgf cm2 2 9 psi V 3 21 At 46 7 kPa 0 467 kgf cm2 6 8 psi V 2 16 Engine te...

Page 31: ... fuel pump Resistance 1 At 20 C 68 F Ω 0 3 10 0 Vapor shut off valve Resistance 1 At 20 C 68 F Ω 30 0 34 0 Water detection switch Input voltage V 4 75 5 25 1 The figures are for reference only Item Unit Model F200BET FL200BET F250GET FL250GET Oil pressure sensor Input voltage V 4 75 5 25 Output voltage 1 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 APS Resista...

Page 32: ...lly open TPS 2 V 4 600 4 700 Shift cut switch Input voltage V 4 75 5 25 1 The figures are for reference only Item Unit Model F200BET FL200BET F250GET FL250GET OCV Resistance 1 At 20 C 68 F Ω 6 7 7 7 Input voltage V 12 0 1 The figures are for reference only Item Unit Model F200BET FL200BET F250GET FL250GET Trim sensor Free position resistance 1 At 20 C 68 F Ω 247 6 387 6 Setting resistance Ω 9 0 11...

Page 33: ...r Output peak voltage At 1500 r min loaded V 13 0 At 3500 r min loaded V 13 0 1 The figures are for reference only Item Unit Model F200BET FL200BET F250GET FL250GET Starter motor Type Sliding gear Output kW 1 4 Cranking time limit second 30 Brush Standard length mm in 15 5 0 61 Wear limit mm in 9 5 0 37 Commutator Standard diameter mm in 29 0 1 14 Wear limit mm in 28 0 1 10 Standard undercut mm in...

Page 34: ...age 1 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 1 The figures are for reference only Item Unit Model F200BET FL200BET F250GET FL250GET Fuel filter assembly Holding pressure Positive pressure kPa kgf cm2 psi 200 0 2 00 29 0 Negative pressure kPa kgf cm2 psi 80 0 0 80 11 6 Primer pump Holding pressure Positive pressure kPa kgf cm2 psi 170 0 1 70 24 7 Vapor se...

Page 35: ...nt temperature 20 C 68 F wide open throttle with spark plugs removed from all cylinders The figures are for reference only 2 For details of the checking method see Checking the oil pressure 7 1 The figures are for reference only Item Unit Model F200BET FL200BET F250GET FL250GET Cylinder head Warpage limit mm in 0 10 0 0039 Journal inside diameter mm in 25 000 25 021 0 9843 0 9851 Valve stem Diamet...

Page 36: ...haust mm in 31 400 31 600 1 2362 1 2441 Seat contact width Intake mm in 1 100 1 400 0 0433 0 0551 Exhaust mm in 1 400 1 700 0 0551 0 0669 Margin thickness Intake mm in 0 500 0 900 0 0197 0 0354 Exhaust mm in 0 900 1 300 0 0354 0 0512 Item Unit Model F200BET FL200BET F250GET FL250GET Cylinder Bore mm in 94 000 94 017 3 7008 3 7014 Piston Diameter mm in 93 921 93 941 3 6977 3 6985 Measuring point mm...

Page 37: ...rance mm in 0 040 0 130 0 0016 0 0051 Connecting rod Small end inside diameter mm in 21 022 21 037 0 8276 0 8282 Big end inside diameter mm in 53 015 53 035 2 0872 2 0880 Big end side clearance mm in 0 150 0 300 0 0059 0 0118 Oil clearance mm in 0 028 0 066 0 0011 0 0026 Crankshaft Journal diameter mm in 62 968 62 992 2 4791 2 4800 Crankpin diameter mm in 49 976 50 000 1 9676 1 9685 Runout mm in 0...

Page 38: ...eller shaft Free play mm in 0 20 0 50 0 0079 0 0197 Runout mm in 0 02 0 0008 Drive shaft Runout mm in 0 2 0 008 1 Figures obtained using the special service tools Item Unit Model FL200BET FL250GET Lower unit Holding pressure kPa kgf cm2 psi 68 6 0 686 9 9 Forward gear backlash 1 mm in 0 46 0 82 0 0181 0 0323 Reverse gear backlash 1 mm in 0 43 0 96 0 0169 0 0378 Pinion shim T3 mm 0 10 0 12 0 15 0 1...

Page 39: ... 5 1261 5 Up MPa kgf cm2 psi 13 0 15 0 130 0 150 0 1885 0 2175 0 Motor brush Standard length mm in 11 5 0 45 Wear limit mm in 4 5 0 18 Motor commutator Standard diameter mm in 23 0 0 91 Wear limit mm in 22 0 0 87 Standard undercut 1 mm in 1 4 0 06 Wear limit mm in 0 9 0 04 1 The figures are for reference only Lower unit technical data Bracket unit technical data ...

Page 40: ...7 5 2 Intake manifold bolt M6 10 1 0 7 4 Throttle body nut 13 1 3 9 6 Throttle damper plate bolt M8 13 1 3 9 6 Canister holder bolt M6 5 0 5 3 7 Canister bracket bolt M6 5 0 5 3 7 Air pressure sensor bolt M6 5 0 5 3 7 Vapor shut off valve nut 5 0 5 3 7 Low pressure fuel pump cover bolt M6 5 0 5 3 7 Pressure regulator holder screw M5 4 0 4 3 0 Vapor separator cover bolt M4 2 0 2 1 5 Float chamber c...

Page 41: ...nder head bolt 1st M8 14 1 4 10 3 2nd 28 2 8 20 7 Cylinder head bolt When using a new bolt 1st M10 30 3 0 22 1 2nd 60 6 0 44 3 3rd Loosen completely 4th 30 3 0 22 1 5th 60 6 0 44 3 6th 90 Cylinder head bolt When reusing the bolt 1st M10 27 2 7 19 9 2nd 54 5 4 39 8 3rd Loosen completely 4th 27 2 7 19 9 5th 54 5 4 39 8 6th 90 Oil pressure sensor 18 1 8 13 3 Oil filter 18 1 8 13 3 Oil filter union bo...

Page 42: ...olt M8 29 2 9 21 4 Grease nipple 6 0 6 4 4 Pinion nut 142 14 2 104 7 Part to be tightened Screw size Tightening torques N m kgf m ft lb Check screw 9 0 9 6 6 Trim tab bolt M10 42 4 2 31 0 Propeller nut 55 5 5 40 6 Lower case mounting bolt M10 47 4 7 34 7 Drain screw 9 0 9 6 6 Lower case mounting nut U transom model 47 4 7 34 7 Ring nut 108 10 8 79 7 Water inlet cover screw M5 1 0 1 0 7 Propeller s...

Page 43: ... 3 2 2 Self locking nut through tube 22 2 2 16 2 Trim sensor screw M6 4 0 4 3 0 Friction plate screw M6 4 0 4 3 0 Part to be tightened Screw size Tightening torques N m kgf m ft lb PTT unit bolt M10 42 4 2 31 0 Reservoir cap 7 0 7 5 2 PTT motor bolt M8 19 1 9 14 0 Reservoir bolt M8 19 1 9 14 0 Gear pump bolt M5 7 0 7 5 2 Gear pump bracket bolt M5 7 0 7 5 2 Manual valve 2 0 2 1 5 Tilt ram 65 6 5 47...

Page 44: ...cates the tightening torques for standard fasteners with a standard ISO thread pitch Width across flats A Screw size B General torque specifications N m kgf m ft lb 8 mm M5 5 0 5 3 7 10 mm M6 8 0 8 5 9 12 mm M8 18 1 8 13 3 14 mm M10 36 3 6 26 6 17 mm M12 43 4 3 31 7 ...

Page 45: ... and alert control 2 8 ETV control 2 9 Fail safe control 2 10 Power unit system 2 11 Shimless valve lifter 2 11 Fuel system 2 12 Fuel diagram 2 12 Blowby gas reburning system 2 14 Vapor gas treatment 2 15 Lubrication system 2 16 Lubrication diagram 2 16 Cooling system 2 17 Cooling diagram 2 17 Intake and exhaust system 2 21 Intake and exhaust diagram 2 21 Lower unit 2 22 Drive shaft spring F250G a...

Page 46: ...be installed as an option Air cowl outside Check valve Filter High pressure fuel pump Vapor separator Check valve Low pressure fuel pump Canister Water separator Fuel Water detection switch OCV Fuel injector Vapor shut off valve TPS ETV Air OCV Ignition coil Throttle control Valve control Fuel control Ignition control Battery Engine ECM Cam position sensor Pulser coil Air pressure sensor Oil press...

Page 47: ...CM A Ignition coil PORT B Cam position sensor PORT EX C Pulser coil D Engine temperature sensor E Thermoswitch PORT F OCV PORT G Cam position sensor PORT IN H Fuel injector PORT I High pressure fuel pump J Low pressure fuel pump K TPS L Oil pressure sensor M ETV N Air pressure sensor O Vapor shut off valve P Air temperature sensor 3 1 2 6 7 8 9 0 A B C D F E G H I J K L M N O P 4 5 Electronic cont...

Page 48: ...S 2 mutually monitor each other for malfunctions APS 2 TPS 1 Detect the throttle valve opening TPS 1 is the main sensor and TPS 2 is the sub sensor TPS 1 and TPS 2 mutually monitor each other for malfunctions TPS 2 ETV Opens and closes the throttle valve using a motor Air pressure sensor Detects the intake air pressure Air temperature sensor Detects the intake air temperature Engine temperature se...

Page 49: ...ontrol mode switches automatically between the start up mode normal operating mode and fuel injection cutoff mode In addition a multi point fuel injection system provides the appropriate fuel injection amount for all weather conditions As a result the outboard motor starts quickly the first time the engine start switch is turned to START Also a fuel injector anti sticking control has been adopted ...

Page 50: ...and ignition coil energization time are determined In addition various restrictions and compensations are made to determine the actual ignition timing The ignition timing is also controlled according to the knock control See Knock control 2 7 Pulser coil Cam position sensor PORT EX Cam position sensor PORT IN Cam position sensor STBD IN APS TPS Air pressure sensor Air temperature sensor Battery En...

Page 51: ...OCVs are oper ated and the VCT assemblies advance and retard the intake valve opening timing in order to increase the intake and exhaust efficiency at low and mid range engine speeds and obtain greater acceleration Pulser coil Cam position sensor PORT EX Cam position sensor PORT IN Cam position sensor STBD IN TPS Engine ECM OCV PORT OCV STBD Engine temperature sensor Electronic control system ...

Page 52: ...rded until the knocking is no longer detected and the retarded ignition timing is maintained Also a learning function for the knock control has been adopted The knock control activates according to the following conditions The knock control also activates when the engine temperature sensor is malfunctioning regardless of the preceding conditions Engine temperature Engine speed Less than 20 C 68 F ...

Page 53: ...e engine ECM decreases the engine speed to protect the engine from damage Pulser coil TPS Engine temperature sensor Thermoswitch Engine ECM Fuel injector Oil pressure sensor Shift cut switch Ignition coil 6Y8 Multifunction Meter Battery Engine start switch Electronic control system ...

Page 54: ...throttle valve The engine ECM is equipped with a learn ing function that records all of the compensations made by the control to the throttle valve opening for the operating conditions up to that point In addition the engine idle speed is controlled using the ETV control Engine temperature sensor TPS APS Shift cut switch Neutral switch ETV motor Engine ECM Battery Engine start switch Fuel injector...

Page 55: ...sure sensor C E Output voltage is less than 0 30 V more than 4 80 V for 260 seconds or more than 4 80 V when the engine is stopped 45 Shift cut switch C E Output voltage is more than 4 50 V the shift cut switch is on during the start up mode or both the neutral switch and shift cut switch are on for 5 seconds 46 Thermoswitch C E Switch is on when the engine temperature is 40 C 104 F or less or off...

Page 56: ...aust system The F L 250G is a new high output outboard motor for use in various environments The outboard motor has adopted structural features that improve durability The F L 200B is an outboard motor for commercial use Shimless valve lifter Newly designed valve lifters 1 have been adopted instead of the usual valve shims 2 The valve lifters are available in different thicknesses a Therefore the ...

Page 57: ... fuel pump Filter Float chamber High pressure fuel pump Canister Vapor shut off valve Surge tank Pressure regulator Fuel rail PORT Fuel injector 6 Fuel injector 4 Fuel injector 2 Combustion chamber 6 Combustion chamber 4 Combustion chamber 2 Intake manifold PORT Fuel rail STBD Fuel injector 1 Fuel injector 3 Fuel injector 5 Combustion chamber 1 Combustion chamber 3 Combustion chamber 5 Intake mani...

Page 58: ...rom the fuel tank 1 Primer pump 2 Fuel filter assembly with water separator 3 Low pressure fuel pump 4 Vapor separator 5 Fuel cooler 6 High pressure fuel pump 7 Pressure regulator 8 Fuel rail PORT 9 Fuel rail STBD 0 Fuel injector 9 8 0 0 7 4 5 3 2 1 6 È ...

Page 59: ...s reburning system removes any unburned fuel from the blowby gases and sends it to the combustion chambers to be burned È Blowby gas flow É Engine oil 1 Intake silencer 2 Blowby gas separator integrated with cylinder head cover È É 1 2 Fuel system ...

Page 60: ...vated charcoal After the engine is started the vapor gases in the canister are drawn into the surge tank through the vapor shut off valve which is controlled by the engine ECM and then sent to the intake manifolds and combustion chambers È Air flow É Vapor gas flow È É Combustion chamber Intake manifold Surge tank Check valve Atmosphere cowl inside Atmosphere cowl outside Check valve Canister Vapo...

Page 61: ... pressure sensor 6 OCV 7 VCT assembly È OCV 1 2 3 4 5 6 6 7 7 Piston Crankpin connecting rod big end Camshaft passage hole VCT assembly Camshaft journal Valve and related parts Crankshaft main journal Main gallery Oil pressure sensor Oil filter Oil pump with relief valve Oil strainer Oil pan Cylinder head Fuel system Lubrication system ...

Page 62: ...the boat is cruising F250G and FL250G PCV È Ê É Rectifier Regulator Fuel cooler Muffler Thermostat PORT Thermostat STBD Exhaust cover PORT Cylinder block Cylinder head PORT Cylinder head STBD Cylinder block Upper case Lower case Propeller boss Oil pan Water pump Water inlet Water Trim tab Upper Exhaust guide Exhaust cover STBD Lower Exhaust guide Pilot hole Flushing device ...

Page 63: ...2 18 2 È Cooling water flow É F L 200B Ê F L 250G 1 Water inlet 2 Water pump 3 Oil pan 4 Exhaust guide 5 PCV 6 Thermostat 1 1 2 3 6 4 5 6 1 1 2 È Ê É Cooling system ...

Page 64: ...ling water hose joint to cylinder block 0 Cooling water hose thermostat cover PORT to cylinder block A Cooling water hose joint to Rectifier Regulator B Cooling water hose Rectifier Regulator to joint C Cooling water hose joint to fuel cooler D Cooling water hose fuel cooler to joint E Cooling water hose joint to joint F Cooling water pilot hose joint to cooling water pilot hole G Cooling water ho...

Page 65: ...er hose a Fuel cooler b Rectifier Regulator c Cooling water pilot hole on the bottom cowling d Adapter water pressure sensor e Water passage cover on the cylinder block 2 C D1 0 6 I H J 5 9 B 3 A 8 7 4 G E F b c 9 3 I 2 1 H J 0 6 4 B A E 7 8 5 G C D d e È a Cooling system ...

Page 66: ...ulting in quicker acceleration The intake system has adopted intake valves with large diameter valve heads to increase the charg ing efficiency of the intake air The exhaust gases are cooled with water as they pass through the in bank exhaust system For increased performance the gases are smoothly vented straight down and out through the propeller The exhaust gas passages are anodized to protect t...

Page 67: ...er The lower case and propeller shaft housing are anodized Drive shaft spring F250G and FL250G The spring pushes the drive shaft toward the water pump and stabilizes the thrust free play of the shaft È Spring force É Water pump side 1 Pinion shim 2 Thrust bearing 3 Drive shaft 4 Thrust bearing 5 Spring 6 Washer 1 2 3 5 6 4 5 1 6 4 2 3 É È Intake and exhaust system Lower unit ...

Page 68: ...oling the propeller damper is incorporated in the lower case The water intake is located in front of the trim tab to drawn in the water by the dynamic pressure and the propeller damper is cooled without disturbing the exhaust gas flow As a result higher output can be obtained È Cooling water flow 1 Water pipe È 1 ...

Page 69: ...optional 3 11 Installing the battery cable 3 12 Installing the speed sensor optional 3 12 Installing the water pressure sensor optional 3 13 Installing the rigging grommet 3 14 Remote control box and switch panel installation 3 15 Battery installation 3 16 Battery cable routing without house accessory battery 3 16 Battery cable routing with house accessory battery 3 18 System diagram 3 22 Single o...

Page 70: ...e outboard motor Too much weight on the transom could change the center of gravity buoyancy operating balance or performance of the boat which could cause loss of control or swamping Con sult the boat manufacturer for the maximum engine weight allowable on the transom which is different from the overall boat capacity Overloading the transom with an outboard motor that is too heavy could also damag...

Page 71: ...nsion values may include reference values mm in 453 17 8 723 9 28 5 T1 32 317 12 5 X 1155 45 5 U 1272 50 1 619 24 4 219 8 6 75 3 0 651 25 6 X 643 25 3 U 770 30 3 X 1078 42 4 U 1205 47 4 45 1 8 387 15 2 752 29 6 902 35 5 39 1 5 216 8 5 25 1 0 230 9 1 59 2 3 12 X 52 2 0 U 59 2 3 673 26 5 3 X 847 33 3 U 924 36 4 6 7 1 H 2 Outboard motor installation External dimensions ...

Page 72: ...tion Clamp bracket TIP The dimension values may include reference values mm in 79 3 1 180 7 1 163 5 6 4 254 10 0 55 5 2 2 411 16 2 163 5 6 4 125 4 4 9 125 4 4 9 180 7 1 13 0 5 50 8 2 0 18 5 0 7 13 0 5 52 2 0 102 4 0 102 4 0 20 0 8 ...

Page 73: ...it delivered to carrier in a good condition For protection against loss due to damage inspect thoroughly If damage is noted make note on freight bill Shipper assumes no further liability to the transportation company Your claim should be filed against carrier for damage of any nature Lifting fork insert position Stack limit Maximum units for storage Upward Handle with care Avoid water Product bary...

Page 74: ...m age 5 Remove the top cowling and then remove the flywheel magnet cover 1 6 Install a lifting harness 2 to the engine hangers 3 7 Tension the lifting harness 8 Lift up the outboard motor along with the bottom plate 4 carefully NOTICE Make sure that the lifting harness does not damage any parts of the outboard motor 9 Remove the skeg holder 5 10 Remove the bolts 6 11 Remove the steering retainer a...

Page 75: ...d have another measurement points È Hull without strakes É Hull with strakes TIP Make sure that the distance a is equal to distance b and the distance c is equal to distance d For twin outboard motor installation place the outboard motors so that the distance from the C L of each outboard motor to the C L of the boat transom are equal on both sides TIP Make sure that the distance e is equal to dis...

Page 76: ...unting height information is for refer ence only It is impossible to provide com plete instructions for every possible boat and outboard motor combination 3 Adjust the height of the scale m to the transom height H and place it on the special service tool 1 Secure the spe cial service tool 1 to the boat transom n using screws or vises TIP For the transom height H see External dimensions 3 2 4 When ...

Page 77: ...same horsepower Therefore if a 2 stroke outboard motor is replaced with a 4 stroke outboard motor the boat will become stern heavy Also the water line will rise and become closer to the power unit If the water line is too close to the power head poor engine performance could result and water could enter the cylinders and dam age the engine When mounting a 4 stroke outboard motor to a boat make sur...

Page 78: ...hose commercially available Installing the shift cable and throttle cable Before installing the shift cable and throt tle cable make sure to adjust the cables according to the procedures in the remote control operation manual 1 Remove the rubber seal 1 from the retaining plate 2 2 Remove the retaining plate 2 3 Remove the rigging grommet 3 4 Remove the cable holder 4 5 Route the shift cable 5 thro...

Page 79: ...ft bracket 8 12 Adjust the shift cable joint 6 and then install the shift cable joint 6 to the pin h WARNING The shift cable joint must be screwed in 8 0 mm 0 31 in or more 13 Install the clip 9 and then tighten the shift cable locknut 0 to the specified torque 14 Route the throttle cable A through the bottom cowling 15 Fasten the throttle cable A using the cable holder 4 so that the cable holder ...

Page 80: ...nstall the clip C and then tighten the throttle cable locknut D to the specified torque 21 Check the shift cable and throttle cable for proper operation Installing the wiring harness 1 Remove the 10 pin coupler a from the holder b on the bracket 2 Route the extension wiring harness through the bottom cowling 3 Connect the 10 pin coupler c and then fasten it using the holders b and d on the bracket...

Page 81: ...le b 4 Install the rubber cap 2 Installing the speed sensor optional See 6Y8 Multifunction Meter set up manual for details of the components 1 Remove the engine ECM cover 1 2 Cut off the tip a of the nipple 2 3 Install the extension hose 3 to the nipple 2 and then fasten it using the plastic tie 4 TIP Cut the extension hose 3 to 50 mm 2 0 in 4 Install the tube 5 Negative battery cable nut 1 13 N m...

Page 82: ...hten the speed sensor adapter bolt A to the specified torque 9 Connect the extension hose 3 to the speed sensor adapter 0 and then fas ten the extension hose using the plastic tie B 10 Connect the speed sensor coupler b 11 Install the engine ECM cover Installing the water pressure sensor optional See 6Y8 Multifunction Meter set up manual for details of the components Do not reuse a gasket always r...

Page 83: ...re sensor coupler b 5 Install the engine ECM cover Installing the rigging grommet 1 Route each harness through the proper hole in the rigging grommet See Rig ging grommet description 3 9 for the detailed description of the rigging grom met 2 Align the white tape a on the battery cable with the outer end of the rigging grommet 3 Install the retaining plate 1 4 Install the rubber seal 2 TIP Make sur...

Page 84: ...ion 5 Install the rigging tube retainer 3 and then fasten it using the plastic tie 4 Remote control box and switch panel installation See the Remote Control Box Operation Man ual or Rigging Guide for the installation pro cedures 3 4 ...

Page 85: ...battery is used for one engine connect the positive battery cable and isola tor lead to the positive battery terminal If the isolator lead is left unconnected accidental contact of the isolator lead with the negative terminal of the battery can cause a short cir cuit which may result in a fire When using a dual battery installation a negative battery cable must be installed between both engine bat...

Page 86: ...tor Outboard motor Isolator lead Black Red Red Black Black Outboard motor Black Red Isolator lead Battery switch ON OFF STBD PORT Outboard motor Outboard motor Isolator lead Battery switch ON OFF Red Black Black Red Battery switch Black ON OFF Isolator lead ...

Page 87: ... in a fire When using a house 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 STBD PORT Outboard motor ...

Page 88: ...utboard motor ON OFF Battery switch Battery switch Isolator lead Black Red Red House battery 1 2 Outboard motor Isolator lead Black Red Black House battery Outboard motor Battery switch Isolator lead Red Black House battery Black Red 1 2 ...

Page 89: ...ch Isolator lead Black Black House battery Red Battery switch Black Red Isolator lead 1 2 Black STBD PORT Outboard motor Outboard motor ON OFF Battery switch Isolator lead Black Battery switch House battery Red Black Black Battery switch Red 1 2 1 2 Isolator lead Black Battery installation ...

Page 90: ...ery switch Red Black Red Isolator lead Battery switch Black Black House battery 1 2 1 2 Isolator lead STBD PORT Outboard motor Outboard motor Isolator lead Battery switch Red Red Battery switch Isolator lead Black ON OFF ON OFF ON OFF House battery House battery Black Black Black Black ...

Page 91: ...ire 9 703 remote control box 0 Fuse 10 A A Terminal resistor B Tachometer unit C Fuel meter unit D Speedometer unit E GPS F Engine start switch with engine shut off switch G 8 ft power wire H Fuel tank fuel level sensor a Bus port b Device port c Power port È 703 remote control model É 704 remote control model Ê PORT Ë STBD Color code B Black G Green L Blue P Pink P B Pink Black R Red W White Y Ye...

Page 92: ...3 23 RIG GING Rigging information Y B G R 1 1 1 1 Y B Y Y B G R B P B P B W L P P 6P 4P 4P 4P 6P 2P 4P 4P 4P 6P Hub 1 A a b b b a c Ê È Ë É B C D E H H 9 0 G F 8 7 6 5 3 4 1 2 6P 4P 4P ...

Page 93: ...re 7 Terminal resistor 8 Main bus wire 9 8 ft power wire 0 Fuse 10 A A Engine start switch with engine shut off switch B Tachometer unit C Fuel meter unit D Speedometer unit E Fuel tank fuel level sensor F GPS G Multisensor speed water temperature and water depth a Bus port b Device port c Power port È PORT É STBD Color code B Black L Blue P Pink P B Pink Black W White Y Yellow System diagram ...

Page 94: ...ion B P B P B W L P P P P Y Y B Y B 6P 4P 4P 4P 6P 2P Hub 3 7 8 8 A a b b b a c 6P 4P 4P 4P 6P 2P Hub 2 a b b b a c 6P 4P 4P 4P 6P 4P 2P Hub 1 7 a b b b a c 4P 4P 4P 6P B 4P B C D 6 G 5 3 4 1 2 4P 2 6 5 4 1 4P 0 9 F È É E E 1 1 1 1 ...

Page 95: ...ire 7 Main bus wire 8 Fuse 10 A 9 Engine start switch with engine shut off switch 0 8 ft power wire A Terminal resistor B Tachometer unit C Fuel meter unit D Speedometer unit E Fuel tank fuel level sensor F GPS G Multisensor speed water temperature and water depth a Bus port b Device port c Power port È PORT É STBD Color code B Black L Blue P Pink P B Pink Black W White Y Yellow System diagram ...

Page 96: ...Y B Y B 6P 4P 4P 4P 6P 2P Hub 3 A a b b b a c 6P 4P 4P 4P 6P 2P Hub 2 a b b b a c 6P 4P 4P 4P 6P 2P Hub 1 a b b b a c 6P 4P 4P 4P 6P 2P Hub 4 A a b b b a c 6 7 5 3 4 1 4P 6 5 4 1 4P 6 5 4 1 2 4P 2 2 4P G 4P 4P 4P 6P B 4P B 4P B C D F È É E E 8 0 9 7 7 1 1 1 1 1 1 ...

Page 97: ...ct a battery stud that is best suited to the terminal size Solder the cable and terminal connections to prevent them from corroding Ambient temperature is 0 C 32 F and above Battery requirements Cable specifications Unit Minimum capacity Maximum total extension length Positive battery cable Negative battery cable AWG4 20 mm2 AWG2 30 mm2 AWG1 0 50 mm2 CCA EN 711 0 Amps 5 4 m 17 7 ft 9 2 m 30 2 ft 1...

Page 98: ...oat and outboard motor Propeller size The size of the propeller is indicated on the propeller boss end and on the side of the propeller boss a Propeller diameter in inches b Propeller pitch in inches c Propeller type propeller mark The propeller sizes listed in the propeller list indicate the following information a Propeller diameter in inches b Propeller pitch in inches c Propeller type propelle...

Page 99: ...R4 45972 A0 15 17 T S Steel 61A 45978 00 15 21 T S Steel 6D0 45972 00 15 21 T S Steel 6BR 45B70 00 4 blades 15 22 T S Steel 6BR 45B72 00 4 blades 15 23 T S Steel 6BR 45B74 00 4 blades 15 1 4 15 M S Steel 6G5 45970 02 15 1 4 15 M S Steel 6R4 45976 A0 15 1 4 17 M S Steel 6R4 45978 A0 15 1 4 19 M S Steel 6R4 45970 A1 15 1 4 19 T S Steel 6D0 45970 00 15 1 2 17 T S Steel 6D0 45978 00 15 3 4 13 M S Stee...

Page 100: ...4 00 14 1 2 21 TL S Steel 61B 45972 00 14 1 2 23 ML S Steel 6R1 45974 A0 14 7 8 21 ML S Steel 6R1 45972 A0 15 17 TL S Steel 61B 45978 00 15 21 TL S Steel 6D1 45972 00 15 21 TL S Steel 6BS 45B70 00 4 blades 15 22 TL S Steel 6BS 45B72 00 4 blades 15 23 TL S Steel 6BS 45B74 00 4 blades 15 1 4 15 ML S Steel 6K1 45970 01 15 1 4 15 ML S Steel 6R1 45976 A0 15 1 4 17 ML S Steel 6R1 45978 A0 15 1 4 19 ML S...

Page 101: ...tboard motor troubleshooting 4 6 Troubleshooting procedure 4 6 Troubleshooting the power unit using the YDIS 4 6 Trouble code and checking step 4 9 Troubleshooting the power unit using the diagnostic flash indicator 4 18 Troubleshooting the power unit trouble code not detected 4 19 Troubleshooting the PTT unit 4 25 Troubleshooting the lower unit 4 26 ...

Page 102: ...k or printed out Hardware requirement Make sure that your computer meets the following requirements before using this software Computer IBM PC AT compatible computer Operating system Microsoft Windows 2000 Windows XP or Windows Vista CPU Windows 2000 Pentium 166 MHz or higher Pentium 233 MHz or higher recommended Windows XP Pentium 300 MHz or higher Pentium 500 MHz or higher recommended Windows Vi...

Page 103: ...each part name and the engine ECM trouble codes that have been recorded This enables you to check the record of malfunctions for the outboard motor The trouble codes dis played are the same as those described in this chapter See Trouble code and checking step 4 9 Engine monitor Each sensor status and the engine ECM data are displayed when the engine start switch is turned to ON This enables you to...

Page 104: ...engine ECM This data can be displayed on a graph using the ECM record data graph of the YDIS When the communication cable is used to connect a computer to the engine ECM the engine ECM record data can be saved and viewed on the computer The saved engine ECM record data can also be viewed offline Ignite ignition coil 1 6 Oil ctrl valve drive STBD 1 Operate electric fuel pump 3 Operate injector 1 6 ...

Page 105: ...APS voltage This item shows the criterion output voltage of the APS This value is used to detect the APS output voltage when the remote control lever is opened 5 Engine ECM controls the engine idle speed using the throttle valve that is connected to the TPS This target voltage is used by the engine ECM to obtain the target opening angle of the throttle valve at engine idle speed 6 Engine shut off ...

Page 106: ...4 5 TRBL SHTG Troubleshooting Connecting the communication cable to the outboard motor a YDIS coupler gray 1 2 a YDIS CD ROM Ver 1 33 1 60V WS853 06 YDIS USB adapter and cable 2 60V WS850 00 ...

Page 107: ...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 Because the main relay comes on for approximately 10 seconds after the engine start switch is turned to OFF the power of the engine ECM cannot be turned ...

Page 108: ...ess sensor malfunction 4 U U U U U U U U U U U U 37 Intake air passage malfunction U U U U U U U U U U U U 39 Oil press sensor malfunction 5 U U U U U U U U U U U U 44 Engine stop lanyard switch ON 6 U U U U U U U U 45 Shift cut off switch malfunction U U U U U U U U U U U U 46 Overheat thermoswitch malfunction U U U U U U U U U U U U 71 Cam position sensor STBD INT malfunction U U U U U U U U U U...

Page 109: ...lfunction 4 Air pressure sensor malfunction 5 Oil pressure sensor malfunction 6 Engine shut off switch ON 131 132 133 134 135 Accelerator position sensor malfunction U U U U U U U U U U U U Trouble code Item Diagnostic flash indicator YDIS diagnosis YDIS diagno sis record Outboard motor troubleshooting ...

Page 110: ...e 5 55 Check for continuity between the pulser coil and the engine ECM 5 55 A 7 Check the protrusions on the flywheel magnet for damage 7 15 15 Engine temp sensor malfunction Out of specification C E High engine idle speed Engine is difficult to start when cold Difference in engine idle speeds Measure the engine temperature sensor input voltage 5 59 Measure the engine temperature sensor resistance...

Page 111: ...ulator output peak voltage 5 51 Check the Rectifier Regulator for continuity 5 51 23 Intake temp sensor malfunction Out of specification C E High engine idle speed Difference in engine idle speeds Check the air temperature using the YDIS 5 56 Measure the air temperature sensor input voltage 5 56 Measure the air temperature sensor resistance 5 56 Check for continuity between the air temperature sen...

Page 112: ...witch input voltage 5 43 Check the water detection switch for continuity 5 43 Check for continuity between the water detection switch and the engine ECM 5 43 A 5 28 Shift position switch malfunction Irregular signal C E Low engine idle speed Difference in engine idle speeds Check the gear shift operation 10 6 Measure the neutral switch input voltage 5 63 Check the neutral switch for continuity 5 6...

Page 113: ...ure sensor output voltage 5 39 Check for continuity between the oil pressure sensor and the engine ECM 5 39 A 3 45 Shift cut off switch malfunction Irregular signal C E High engine idle speed Difference in engine idle speeds Measure the shift cut switch input voltage 5 61 Measure the shift cut switch resistance 5 61 Check the shift cut switch for continuity 5 61 Check for continuity between the sh...

Page 114: ... in engine idle speeds Measure the cam position sensor input voltage 5 34 Measure the cam position sensor output voltage 5 34 Check for continuity between the cam position sensor and the engine ECM 5 34 A 3 Check the edge and face of the flange on the camshaft 7 50 73 Oil control valve STBD malfunction Irregular load current value C E High engine idle speed Degraded acceleration performance Declin...

Page 115: ...em malfunction Throttle valve malfunction C E High engine idle speed Throttle valve does not operate Difference in engine idle speeds Engine speed is set at approximately 1500 r min Measure the TPS output voltage using the YDIS 5 31 Check the throttle valve opening angle using the YDIS 5 31 Check the ETV circuit 5 33 A 3 Check the fuse 5 3 A 3 Check the ETV motor relay 5 32 114 Electronic throttle...

Page 116: ... the engine ECM 7 35 122 Electronic throttle system malfunction Throttle valve malfunction C E High engine idle speed Throttle valve does not operate Difference in engine idle speeds Engine speed is set at approximately 1500 r min Check the throttle body 6 28 Replace the throttle body ETV motor mulfunction 6 26 123 Electronic throttle system malfunction Throttle valve malfunction C E High engine i...

Page 117: ... engine ECM 7 35 131 132 133 134 135 Accelerator position sensor malfunction Out of specification C E High engine idle speed Throttle valve dose not operate Difference in engine idle speeds Measure the APS output voltage using the YDIS 5 29 Measure the APS resistance 5 29 Measure the APS input voltage 5 29 Check for continuity between the APS and the engine ECM 5 30 A 3 136 137 Electronic throttle...

Page 118: ...eeds Engine speed is set at approximately 1500 r min Replace the engine ECM 7 35 144 Electronic throttle system malfunction Throttle valve malfunction C E High engine idle speed Throttle valve does not operate Difference in engine idle speeds Engine speed is set at approximately 1500 r min Check the battery cable and terminals for proper connection Check the fuse 5 3 A 3 Measure the lighting coil ...

Page 119: ...d 113 b Light on 0 33 second c Light off 4 95 seconds d Light off 0 33 second e Light off 1 65 seconds 5 If trouble code is detected see Trouble code and checking step 4 9 TIP When more than 1 trouble code is detected the light of the special service tool flashes in the pattern of the lowest trouble code After that trouble code is corrected the indicator flashes in the pattern of the next lowest t...

Page 120: ... the N position 10 6 Blown fuse Check the fuse 5 3 A 9 Starter relay malfunction Check the starter relay 5 65 Engine start switch malfunction Check the engine start switch 5 66 Neutral switch malfunction Check the remote control box A 11 Short open or loose connection in electric starting system circuit Measure the starter relay input voltage 5 65 Check the wiring harness for continuity A 9 Starte...

Page 121: ...y between the engine ECM and the ground 5 28 A 3 Engine ECM malfunction Replace the engine ECM 7 35 Spark plug does not spark all cylinders Check the ignition spark 5 53 Spark plug malfunction Check the spark plug 7 44 Short open or loose connection in ignition coil circuit Measure the ignition coil input voltage 5 53 Check for continuity between the ignition coil and the engine ECM 5 53 A 7 Check...

Page 122: ...5 46 A 5 Blown fuse Check the fuse 5 3 A 5 High pressure fuel pump relay malfunction Check the high pressure fuel pump relay 5 47 Short open or loose connection in low pressure fuel pump circuit Measure the low pressure fuel pump input voltage 5 46 Check for continuity between the low pressure fuel pump and the engine ECM 5 46 A 5 Check for continuity between the low pressure fuel pump and the mai...

Page 123: ...6 10 Clogged fuel filter element Check the fuel filter element for dirt and obstructions 6 14 High pressure fuel pump malfunction Measure the high pressure fuel pump resistance 5 46 Fuel not supplied some cylinders Fuel injector malfunction Check the fuel injector operation using the YDIS 5 44 Measure the fuel injector resistance 5 44 Short open or loose connection in fuel injector circuit Measure...

Page 124: ... Stuck VCT Replace the VCT assembly 7 46 Symptom 2 Cause Checking step See page Buzzer comes on Overheat alert indicator comes on Clogged cooling water inlet Check the cooling water inlet 10 8 Water pump malfunction Check the impeller 8 9 Check the Woodruff key 8 9 Check the water pump housing 8 9 Check the insert cartridge 8 9 Check the outer plate cartridge 8 9 Clogged cooling water passage Chec...

Page 125: ... properly Short open or loose connection in charging circuit Check the charging circuit for proper connections and damage A 9 Stator assembly malfunction Measure the lighting coil output peak voltage 5 50 Measure the lighting coil resistance 5 50 Rectifier Regulator malfunction Measure the Rectifier Regulator output peak voltage 5 51 Check the Rectifier Regulator for continuity 5 51 Outboard motor...

Page 126: ...etween the PTT switch and the fuse holder 5 75 A 11 Check for continuity between the PTT switch and PTT relay 5 75 A 11 PTT motor does not operate PTT motor malfunction Disassemble and check the PTT motor 9 45 Short open or loose connection in PTT motor circuit Check for wiring continuity between the PTT motor and the PTT relay terminal A 11 PTT fluid pressure does not increase Measure the PTT flu...

Page 127: ...nders Manual valve open Check the manual valve 9 40 Insufficient PTT fluid Add sufficient PTT fluid 10 14 PTT fluid leakage Check the PTT fluid leakage 10 15 Clogged or open fluid passage Disassemble and check the PTT unit 9 50 9 56 Check the valves for damage 9 53 Check the fluid passages for obstructions 9 50 9 56 Symptom 2 Cause Checking step See page Shift cable is not adjusted properly Adjust...

Page 128: ... circuit 5 28 Checking the APS 5 29 Checking the APS circuit 5 30 Checking the ETV and TPS 5 31 Checking the ETV motor relay 5 32 Checking the ETV and TPS circuit 5 33 Checking the cam position sensor 5 34 Checking the OCV 5 37 Checking the oil pressure sensor 5 39 Checking the water pressure sensor optional 5 40 Checking the speed sensor optional 5 41 Fuel control unit and component 5 43 Checking...

Page 129: ...e neutral switch 5 63 Checking the knock sensor 5 64 Checking the engine shut off switch 5 65 Starting unit and component 5 65 Checking the starter relay 5 65 Checking the engine start switch 5 66 Starter motor 5 67 Removing the starter motor 5 69 Checking the starter motor pinion 5 69 Disassembling the starter motor 5 69 Checking the armature starter motor 5 71 Checking the brush holder and brush...

Page 130: ...Port 1 Air temperature sensor 2 YDIS coupler 3 Fuel injector 4 High pressure fuel pump 5 Low pressure fuel pump 6 Condenser connect to the air pressure sensor 7 Water detection switch in fuel cup assembly 8 Air pressure sensor 9 ETV 3 9 5 6 7 8 1 4 2 ...

Page 131: ...5 2 5 Starboard 1 PTT relay 2 Fuse holder 3 Starter motor 4 Diode connect to the PTT relay 5 Oil pressure sensor 6 APS 7 Rectifier Regulator 8 Fuel injector 3 8 5 6 7 2 1 4 Electrical component ...

Page 132: ...ine ECM 3 Fuse 20 A engine start switch PTT switch 4 Fuse 30 A starter relay 5 Fuse 10 A low pressure fuel pump 6 Fuse 15 A high pressure fuel pump 7 Fuse 60 A starting battery 8 Fuse 60 A house accessory battery 9 Starter relay 0 Main relay A ETV motor relay B High pressure fuel pump relay 9 1 2 3 4 5 0 6 7 A 8 B ...

Page 133: ...ensor PORT EX 3 Condenser connect to the cam position sensor PORT EX 4 Engine ECM 5 Ignition coil 6 Cam position sensor STBD IN 7 Knock sensor 8 Water pressure sensor coupler 9 Joint coupler 2 0 Knock sensor coupler 3 8 9 0 5 5 6 7 2 1 4 Electrical component ...

Page 134: ...LEC Electrical system Top 1 Thermoswitch STBD 2 OCV STBD 3 Joint coupler 1 4 OCV PORT 5 Thermoswitch PORT 6 Engine temperature sensor 7 Pulser coil 8 Vapor shut off valve 9 Stator assembly 3 8 9 5 6 7 2 1 4 ...

Page 135: ...ad and thermoswitch lead on the hook of the wiring harness guide Ë Install the engine temperature sensor cou pler onto the wiring harness guide Ì Fasten the wiring harness using the holder on the fuel rail cover Í Fasten the wiring harness to the fuel rail using the plastic tie Make sure that there is no slack in the wiring harness Ë È Ì É Í Ê Ñ Î Ï Ò Ó Ô Ù Õ A D D B C A B C D D Electrical compone...

Page 136: ...uel injector 6 using the holder Ñ Fasten the wiring harness to fuel injector 6 using the plastic tie at the white tape Ò Fasten the wiring harness in the order Ñ Ï and Î Ó Fasten the wiring harness at the white tape using the holder Make sure that there is no slack in the wiring harness Ô Align the paint marks on the hose with the holders Ë È Ì É Í Ê Ñ Î Ï Ò Ó Ô Ù Õ A D D B C A B C D D ...

Page 137: ... air temperature sen sor at the white tape using the holder on the oil filler neck Make sure that the catch of the holder is facing forward Ù Make sure that the end of the plastic tie is pointing rearward Ë È Ì É Í Ê Ñ Î Ï Ò Ó Ô Ù Õ A D D B C A B C D D Wiring harness routing ...

Page 138: ...ad È Fit the stator assembly lead into the groove in the junction box É Fasten the PTT motor lead and wiring har ness ground lead using the holder Ê Connect the starter motor lead and brown lead of the wiring harness together A A E E F F G G B B C C D D A A B B C G G E E F F D D C 5 5 6 Ì Ë Í È Ï Î É Ñ Ê Ó Ò Ô Õ Ù Ú Û 3 3 3 3 3 3 8 8 7 7 7 6 6 6 5 1 1 2 2 2 2 2 2 2 1 1 4 4 4 561 1 4 5 1 4 ...

Page 139: ...iring harnesses and PTT motor lead through the guide on the termi nal Ï Fasten the wiring harnesses and PTT motor lead using the holder Ñ Route the battery cable along the bottom cowling Ò Install the wiring harness ground lead ter minal so that it contacts the stopper A A E E F F G G B B C C D D A A B B C G G E E F F D D C 5 5 6 Ì Ë Í È Ï Î É Ñ Ê Ó Ò Ô Õ Ù Ú Û 3 3 3 3 3 3 8 8 7 7 7 6 6 6 5 1 1 2 ...

Page 140: ...arness to fuel injector 3 and 5 to the holder Ù Fasten the wiring harness to fuel injector 1 and wiring harness to fuel injector 3 and 5 using the holder in the order listed Ú Fasten the wiring harness using the plas tic tie so that there is no slack in the wiring harness Û Fasten the wiring harness using the holder A A E E F F G G B B C C D D A A B B C G G E E F F D D C 5 5 6 Ì Ë Í È Ï Î É Ñ Ê Ó ...

Page 141: ...denser to the engine ECM bracket using the plastic tie Ê Place the condenser between the engine ECM bracket and the wiring harness and then fasten the condenser using the plas tic tie Ë Route the wiring harness to the inside of the blowby hose Ì Install the holder and fasten the plastic ties in the order Ë and É Ë È Í É Î Ê Ó Ï Ñ Ò Ô Õ Ì Wiring harness routing ...

Page 142: ...arness to cam posi tion sensor STBD IN using the holder at the white tape Ï Make sure that the bracket contacts the stopper Ñ Fasten the knock sensor lead using the holder Make sure that the end of the cor rugated tube is positioned 30 mm 1 2 in from the holder Ò Route the knock sensor lead to the inside of the wiring harness Ë È Í É Î Ê Ó Ï Ñ Ò Ô Õ Ì ...

Page 143: ... are positioned under the stoppers on the engine ECM bracket Ô Route the wiring harness to the inside of the joint coupler bracket Õ Make sure that the slot in the joint coupler bracket fits over the rib on the engine ECM bracket Fit the protrusion on the plastic tie into the hole in the engine ECM bracket Ë È Í É Î Ê Ó Ï Ñ Ò Ô Õ Ì Wiring harness routing ...

Page 144: ...ine temperature sensor lead È Fit the protrusion on the plastic tie into the hole in the wiring harness guide É Make sure that the protrusion on the holder contacts the rib on the bracket Ê Route the wiring harness under the high pressure fuel hose and blowby hose A A E E B B C C D D C C B B E A A D D E Ë Ñ É Í Ê Î Ï Ì Ì È 5 6 Õ 4 3 Ô 2 3 1 Ó Ò ...

Page 145: ...the wiring harness guide Î Face the white mark on the wiring harness upward Ï Fasten the wiring harness and vapor gas hose using the holder Ñ Fasten the wiring harness and quick con nector using the holder Ò Fit the protrusion on the plastic tie into the hole in the wiring harness guide A A E E B B C C D D C C B B E A A D D E Ë Ñ É Í Ê Î Ï Ì Ì È 5 6 Õ 4 3 Ô 2 3 1 Ó Ò Wiring harness routing ...

Page 146: ...harness to fuel injector does not protrude above the ribs on the wiring harness guide Ô Point the end of the plastic tie to star board Õ Fold the engine temperature sensor lead A A E E B B C C D D C C B B E A A D D E Ë Ñ É Í Ê Î Ï Ì Ì È 5 6 Õ 4 3 Ô 2 3 1 Ó Ò ...

Page 147: ... Meter coupler 7 Alert indicator coupler 8 PTT switch coupler 9 Isolator coupler 0 Water detection switch coupler A PTT switch wiring harness extension B Wiring harness C PTT switch wiring harness extension coupler È Ë Ì 5 7 8 3 7 É Ò 9 0 8 C 4 3 1 2 Í Ê 6 5 6 4 Ï Î Í Ñ Î Ó Õ Ñ Ï B A Ô B B C C A A B C A A C Wiring harness routing ...

Page 148: ... Ë Fasten the flushing hose cooling water hose trim sensor lead and speedometer hose using the plate Make sure to route the speedometer hose over the flushing hose and trim sensor lead Ì Fasten the flushing hose cooling water hose and trim sensor lead using the holder È Ë Ì 5 7 8 3 7 É Ò 9 0 8 C 4 3 1 2 Í Ê 6 5 6 4 Ï Î Í Ñ Î Ó Õ Ñ Ï B A Ô B B C C A A B C A A C ...

Page 149: ...he alert indicator coupler in the location shown in the illustration Ñ If analog meters are selected connect the alert indicator coupler and then install the coupler in the location shown in the illus tration Ò Fasten the meter lead and extension wir ing harness using the holder È Ë Ì 5 7 8 3 7 É Ò 9 0 8 C 4 3 1 2 Í Ê 6 5 6 4 Ï Î Í Ñ Î Ó Õ Ñ Ï B A Ô B B C C A A B C A A C Wiring harness routing ...

Page 150: ... lead are aligned with the edge of the grommet Ô Fasten the PTT switch wiring harness extension at the white tape using the holder Õ Fasten the flushing hose cooling water hose trim sensor lead and PTT switch lead using the holder È Ë Ì 5 7 8 3 7 É Ò 9 0 8 C 4 3 1 2 Í Ê 6 5 6 4 Ï Î Í Ñ Î Ó Õ Ñ Ï B A Ô B B C C A A B C A A C ...

Page 151: ...tion sensor PORT EX Cam position sensor PORT IN Cam position sensor STBD IN Air pressure sensor Oil pressure sensor 5V Ground 5V TPS 1 TPS 2 APS 1 APS 2 Ground 5V Ground 5V Engine ECM Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4 Fuel injector 5 Fuel injector 6 Ignition coil 1 Ignition coil 4 Ignition coil 2 Ignition coil 3 Ignition coil 5 Ignition coil 6 ETV motor relay ETV moto...

Page 152: ...e sensor Thermoswitch Water detection switch Shift cut switch Neutral switch Ground Knock sensor Engine shut off switch Main relay Main switch Rectifier Regulator Battery CAN BUS YDIS OCV STBD OCV PORT Low pressure fuel pump Vapor shut off valve Oil pressure alert indicator Overheat alert indicator Diagnostic flash indicator Tachometer Engine ECM High pressure fuel pump relay High pressure fuel pu...

Page 153: ...15 Pulser coil ground Black 16 Pulser coil White Black 17 Engine temperature sensor Black Yellow 18 Sensor ground Black 19 Trim sensor Pink 20 CAN BUS H White 21 CAN BUS L Blue 22 23 Air temperature sensor Black Yellow 24 25 No Connecting part Color 26 27 Battery power source Red Yellow 28 YDIS White Black 29 30 31 APS 2 Pink White 32 33 34 Battery power source Red Yellow 35 36 Air pressure sensor...

Page 154: ...ple Black 61 Low pressure fuel pump Blue White 62 Ignition coil 4 Black Green 63 Ignition coil 3 Black Yellow 64 Tachometer Green 65 High pressure fuel pump relay Blue Red 66 ETV motor relay Yellow 67 Alert buzzer Pink 68 Ground Black 69 Ground Black 70 Ignition coil 2 Black White 71 Ignition coil 1 Black Orange 72 Oil pressure alert indicator Pink White 73 Overheat alert indicator Pink Black 74 D...

Page 155: ...tester probes When measuring the peak voltage between the terminals of an electrical component using the digital tester make sure that the leads do not contact any metal parts Otherwise the electrical com ponent may short circuit and be dam aged To check the electrical components or mea sure the peak voltage use the special ser vice tools A malfunctioning electrical component can be checked easily...

Page 156: ...BD See Removing the intake manifold 6 17 2 Remove the fuse cover and relay cover and then remove the main relay 1 NOTICE Be careful not to damage the relay 3 Connect the positive battery lead to the terminal a connect the negative battery lead to the terminal b and then check for continuity between the terminals c and d Replace the relay if there is no continuity NOTICE Do not reverse the battery ...

Page 157: ... couplers a b and c 3 Check the wiring harness for continuity 4 Measure the input voltage at the engine ECM coupler a 5 Remove the intake manifold STBD See Removing the intake manifold 6 17 6 Remove the fuse holder 1 and then dis connect the fuse holder couplers d and e Main relay input voltage Terminal e Terminal g 12 0 V battery voltage e g a b c Wiring harness continuity b Terminal 46 Ground c ...

Page 158: ... are a single unit which cannot be disassembled 1 Connect the YDIS to display Accelerator position sensor 1 and Accelerator posi tion sensor 2 2 Check that the accelerator lever a con tacts the stopper b when the remote control lever is in the N position TIP Before checking the APS make sure to adjust the throttle cable properly To adjust the throttle cable see Installing the shift cable and throt...

Page 159: ...ct the throttle cable joint to the APS 12 Install the intake manifold STBD See Installing the intake manifold 6 18 Checking the APS circuit 1 Remove the intake manifold STBD See Removing the intake manifold 6 17 2 Disconnect the APS coupler a 3 Turn the engine start switch to ON and then measure the input voltage at the APS coupler a APS output voltage reference data Item Fully closed c Fully open...

Page 160: ... the intake manifold 6 18 Checking the ETV and TPS TPS 1 and TPS 2 are components of the ETV which cannot be disassembled Do not loosen the throttle stop screw nut or turn the throttle stop screw 1 Start the engine warm it up for 5 10 min utes and then stop it 2 Connect the YDIS to display Throttle position sensor 1 Throttle valve open ing and Throttle position sensor 2 APS input voltage Terminal ...

Page 161: ...ion See Check ing the ETV and TPS circuit 5 33 7 Turn the engine start switch to OFF 8 Connect the ETV coupler and then install the intake silencer See Installing the intake silencer 6 19 Checking the ETV motor relay 1 Remove the intake manifold STBD See Removing the intake manifold 6 17 2 Remove the fuse cover and relay cover and then remove the ETV motor relay 1 NOTICE Be careful not to damage t...

Page 162: ...er 6 17 2 Disconnect the ETV coupler a 3 Remove the engine ECM cover 4 Remove the engine ECM and then dis connect the engine ECM couplers b and c 5 Check the wiring harness for continuity 6 Connect the ETV coupler ETV motor relay input voltage Terminal a Ground Terminal b Ground 12 0 V battery voltage ETV motor relay input voltage Terminal a Terminal c 12 0 V battery voltage b a a c Wiring harness...

Page 163: ...s NOTICE Make sure that the rubber seal is installed properly in each engine ECM coupler 14 Install the engine ECM and then tighten the engine ECM bolts to the specified torque 15 Install the engine ECM cover Checking the cam position sensor 1 Remove the engine ECM cover 2 Disconnect the cam position sensor cou plers a b and c 3 Turn the engine start switch to ON and then measure the input voltage...

Page 164: ...art switch is turned to ON 9 Turn the engine start switch to ON and then measure the output voltage when moving a screwdriver close to the cam position sensor 4 Replace if out of specification Cam position sensor input voltage Red Yellow R Y Black B 12 0 V battery voltage White Black W B Black B White Green W G Black B White Blue W L Black B 4 75 5 25 V Test lead Terminal male 1 9E212 10303 Termin...

Page 165: ...ity Cam position sensor output voltage White Black W B Black B STBD IN White Blue W L Black B PORT EX Position Voltage g k More than 4 8 h Less than 1 0 White Green W G Black B PORT IN Position Voltage g k Less than 1 0 h More than 4 8 4 g h k Wiring harness continuity a Terminal 1 m Terminals 1 10 and 16 22 a Terminal 2 n Terminal 1 a Terminal 3 n Terminal 18 b Terminal 1 n Terminal 18 b Terminal...

Page 166: ... there is continuity between terminal 1 of the cam position sensor coupler c and one of the terminals of the fuse holder coupler m 20 Connect the fuse holder coupler and then install fuse holder 21 Install the intake manifold STBD See Installing the intake manifold 6 18 22 Connect the cam position sensor cou plers 23 Install the engine ECM cover Checking the OCV 1 Check the operation of the OCVs u...

Page 167: ...ttery leads 9 Install the OCVs See step 4 in Installing the cylinder head 7 68 10 Remove the intake manifold STBD See Removing the intake manifold 6 17 11 Remove the fuse holder 1 and then dis connect fuse holder coupler c 12 Remove the engine ECM cover 13 Remove the engine ECM and then dis connect the engine ECM coupler d 14 Check the wiring harness for continuity OCV input voltage Red Yellow R Y...

Page 168: ...or 1 Disconnect the oil pressure sensor cou pler a 2 Turn the engine start switch to ON and then measure the input voltage at the oil pressure sensor coupler 3 Remove the oil pressure sensor and then connect a pressure pump 1 and the special service tool 2 4 Apply positive pressure to the oil pres sure sensor slowly and then measure the output voltage at the specified pres sures Wiring harness con...

Page 169: ...er Checking the water pressure sensor optional 1 Remove the engine ECM cover 2 Disconnect the water pressure sensor coupler a 3 Turn the engine start switch to ON and then measure the input voltage at the water pressure sensor coupler 4 Remove the water pressure sensor and then connect a pressure pump 1 and the special service tool 2 Oil pressure sensor output voltage reference data Pink White P W...

Page 170: ...r 11 Install the engine ECM and then tighten the engine ECM bolts to the specified torque 12 Connect the water pressure sensor cou pler 13 Install the engine ECM cover Checking the speed sensor optional 1 Remove the engine ECM cover 2 Disconnect the speed sensor coupler a 3 Turn the engine start switch to ON and then measure the input voltage at the speed sensor coupler Pressure pump 1 commerciall...

Page 171: ...ring harness for continuity 10 Connect the engine ECM couplers NOTICE Make sure that the rubber seal is installed properly in each engine ECM coupler 11 Install the engine ECM and then tighten the engine ECM bolts to the specified torque Speed sensor input voltage Orange O Black B 4 75 5 25 V Pressure pump 1 commercially available Test harness 3 pins 2 90890 06869 Speed sensor output voltage refer...

Page 172: ... smoothly 5 Check the water detection switch for con tinuity when the float 1 positions È and É NOTICE Make sure not to remove the clip 2 and float 1 6 Install the fuel cup assembly See step 2 in Assembling the fuel filter assembly 6 14 7 Remove the engine ECM cover 8 Remove the engine ECM and then dis connect the engine ECM coupler e 9 Check the wiring harness for continuity Engine ECM bolt 7 N m...

Page 173: ... switch to ON and then measure the input voltage at the fuel injector coupler 4 Turn the engine start switch to OFF 5 Measure the fuel injector resistance 6 Remove the intake manifold STBD See Removing the intake manifold 6 17 7 Remove the fuse holder 1 and then dis connect the fuse holder coupler b 8 Remove the engine ECM cover 9 Remove the engine ECM and then dis connect the engine ECM coupler c...

Page 174: ...er coupler and then install the fuse holder c 9 10 22 21 20 19 18 17 16 8 7 6 5 4 3 2 1 c b a 60 59 58 57 56 55 1 2 Wiring harness continuity Fuel injector 1 a Terminal 1 b Terminals 1 10 and 16 22 a Terminal 2 c Terminal 59 Fuel injector 2 a Terminal 1 b Terminals 1 10 and 16 22 a Terminal 2 c Terminal 60 Fuel injector 3 a Terminal 1 b Terminals 1 10 and 16 22 a Terminal 2 c Terminal 58 Fuel inje...

Page 175: ...por separator wiring harness extension coupler b 7 Connect the tester probes to the termi nals of the vapor separator wiring har ness extension coupler b and then measure the input voltage within 5 sec onds after turning the engine start switch to ON 8 Turn the engine start switch to OFF 9 Measure the resistance of the fuel pump motors 10 Remove the intake manifold STBD See Removing the intake man...

Page 176: ...ifold 6 18 20 Connect the low pressure fuel pump cou pler and vapor separator wiring harness extension coupler 21 Install the intake silencer See Installing the intake silencer 6 19 Checking the high pressure fuel pump relay 1 Remove the intake manifold STBD See Removing the intake manifold 6 17 2 Remove the fuse cover and relay cover and then remove the high pressure fuel pump relay 1 NOTICE Be c...

Page 177: ...s extension coupler a 3 Turn the engine start switch to ON and then measure the input voltage at the throttle body assembly wiring harness extension coupler 4 Turn the engine start switch to OFF 5 Remove the intake manifold STBD See Removing the intake manifold 6 17 6 Remove the fuse holder 1 and then dis connect the fuse holder coupler b 7 Remove the engine ECM cover 8 Remove the engine ECM and t...

Page 178: ...anifold 6 17 16 Remove the throttle body assembly See Removing the throttle body assembly 6 23 17 Remove the vapor shut off valve from the throttle body assembly 18 Connect the special service tool 2 to the vapor shut off valve 19 Apply the specified negative pressure to the vapor shut off valve 20 Check that the vapor shut off valve opens and the negative pressure is released when the battery lea...

Page 179: ...ntake manifold STBD See Installing the intake mani fold 6 18 4 Measure the lighting coil output peak voltage between all combinations of the terminals TIP When measuring the output peak voltage under the cranking condition remove the clip from the engine shut off switch to prevent the engine from starting 5 Measure the lighting coil resistance 6 Remove the intake manifold STBD See Removing the int...

Page 180: ...voltage adapter B when measuring the Rectifier Regulator output peak voltage 3 Install the fuse cover 4 Remove the intake manifold STBD See Removing the intake manifold 6 17 5 Remove the fuse holder and then dis connect the Rectifier Regulator couplers and ground lead 6 Set the digital circuit tester to the mea surement range a and then push the switch b to display the mark c È Tester model CD721 ...

Page 181: ...take manifold STBD See Installing the intake manifold 6 18 d e f g h k d e f g h k R R G G G B Rectifier Regulator continuity testing diode mode Tester probe Display value reference data d e OL f g h k e d OL f g h k f d 0 420 V e 0 422 V g OL h k g d 0 426 V e 0 421 V f OL h k h d 0 425 V e 0 424 V f OL g k k d 0 756 V e 0 755 V f 0 416 V g 0 417 V h 0 417 V Charging unit and component ...

Page 182: ...ct the special service tool 6 Install the ignition coils and then tighten the ignition coil bolts to the specified torque 7 Install the engine ECM cover Checking the ignition coil 1 Remove the engine ECM cover 2 Disconnect the ignition coil couplers a 3 Turn the engine start switch to ON and then measure the input voltage at the ignition coil coupler 4 Turn the engine start switch to OFF 5 Remove ...

Page 183: ... 20 19 18 17 16 8 7 6 5 4 3 2 1 Wiring harness continuity Ignition coil 1 a Terminal 1 b Terminal 71 a Terminal 2 Ground a Terminal 3 c Terminals 1 10 and 16 22 Ignition coil 2 a Terminal 1 b Terminal 70 a Terminal 2 Ground a Terminal 3 c Terminals 1 10 and 16 22 Ignition coil 3 a Terminal 1 b Terminal 63 a Terminal 2 Ground a Terminal 3 c Terminals 1 10 and 16 22 Ignition coil 4 a Terminal 1 b Te...

Page 184: ...the clip from the engine shut off switch to pre vent the engine from starting When measuring the output peak voltage under the unloaded condition disconnect the pulser coil coupler a 5 Disconnect the special service tool 6 Measure the pulser coil resistance 7 Remove the engine ECM cover 8 Remove the engine ECM and then dis connect the engine ECM coupler b 9 Check the wiring harness for continuity ...

Page 185: ... the engine 4 Remove the flywheel magnet cover 5 Disconnect the air temperature sensor coupler a 6 Turn the engine start switch to ON and then measure the input voltage at the air temperature sensor coupler 7 Turn the engine start switch to OFF 8 Remove the air temperature sensor 9 Place the air temperature sensor in a container of water and heat the water slowly 10 Measure the air temperature sen...

Page 186: ...Removing the intake silencer 6 17 2 Disconnect the throttle body assembly wiring harness extension coupler a 3 Turn the engine start switch to ON and then measure the input voltage at the throttle body assembly wiring harness extension coupler 4 Turn the engine start switch to OFF 5 Remove the engine ECM cover 6 Remove the engine ECM and then dis connect the engine ECM couplers b and c 7 Check the...

Page 187: ... start switch to OFF 18 Disconnect the special service tools 19 Install the air pressure sensor to the throttle body assembly and then tighten the air pressure sensor bolt to the speci fied torque 20 Install the throttle body assembly See Installing the throttle body assembly 6 24 21 Install the intake manifolds See Install ing the intake manifold 6 18 22 Install the intake silencer See Installing...

Page 188: ...gine temperature sensor and then tighten it to the specified torque 10 Remove the engine ECM cover 11 Remove the engine ECM and then dis connect the engine ECM coupler b 12 Check the wiring harness for continuity 13 Connect the engine ECM coupler NOTICE Make sure that the rubber seal is installed properly in the engine ECM coupler 14 Install the engine ECM and then tighten the engine ECM bolts to ...

Page 189: ...ove the thermoswitches 6 Place the thermoswitches in a container of water and heat the water slowly 7 Check the thermoswitches for continuity at the specified temperatures Replace if out of specification c Temperature d Time e No continuity f Continuity 8 Install the thermoswitches 9 Remove the engine ECM cover 10 Remove the engine ECM and then dis connect the engine ECM couplers k and m Engine EC...

Page 190: ...ft cut switch coupler a 2 Connect the special service tool 1 to the shift cut switch coupler a 3 Turn the engine start switch to ON and then measure the input voltage 4 Turn the engine start switch to OFF 5 Disconnect the special service tool 1 and then connect it to the shift cut switch coupler b 6 Measure the shift cut switch resistance when the gear shift is in the N position Wiring harness con...

Page 191: ...ngine ECM coupler 13 Install the engine ECM and then tighten the engine ECM bolts to the specified torque 14 Install the engine ECM cover Test harness 2 pins 1 90890 06867 Shift cut switch resistance reference data Blue Yellow L Y Black B 4 5 4 9 kΩ Test harness 2 pins 1 90890 06867 G W G B L Y 1 b b B L Y 1 G W G B L Y 1 c c d d 1 B L Y Switch position Lead color L Y B Free c Pushed d C C C C C C...

Page 192: ... connect it to the neutral switch coupler b 6 Check the neutral switch for continuity Replace if out of specification 7 Disconnect the special service tool 8 Remove the engine ECM cover 9 Remove the engine ECM and then dis connect the engine ECM coupler e 10 Check the wiring harness for continuity Test harness 2 pins 1 90890 06867 Neutral switch input voltage Blue Green L G Black B 4 75 5 25 V a S...

Page 193: ...ne ECM and then dis connect the engine ECM coupler b 5 Check the wiring harness for continuity 6 Connect the engine ECM coupler NOTICE Make sure that the rubber seal is installed properly in the engine ECM coupler 7 Install the engine ECM and then tighten the engine ECM bolts to the specified torque Wiring harness continuity a Terminal 1 e Terminal 12 a Terminal 2 e Terminal 18 Engine ECM bolt 7 N...

Page 194: ...tch coupler 704 remote control model Starting unit and component Checking the starter relay 1 Remove the intake manifold STBD See Removing the intake manifold 6 17 2 Remove the fuse cover and relay cover and then remove the starter relay 1 NOTICE Be careful not to damage the relay 3 Check the starter relay See step 3 in Checking the main relay 5 27 4 Measure the input voltage between the terminal ...

Page 195: ...control model 2 Check the engine start switch for continu ity È 703 remote control model É 704 remote control model 3 Connect the 10 pin coupler 703 remote control model Connect the engine start switch coupler 704 remote control model Starter relay input voltage Terminal b Terminal c 12 0 V battery voltage Switch position Terminal a b c d e OFF C C C C C C C C ON C C C C C C C C START C C C C C C ...

Page 196: ...ng 4 5 Brush assembly 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 Bearing 1 16 Outer gear 1 17 Gasket 1 39 39 39 39 24 12 9 10 8 5 1 2 13 25 26 28 22 4 23 7 6 3 6 7 20 21 19 18 14 15 16 27 17 11 M M ...

Page 197: ... 20 Planetary gear 3 21 Plate 1 22 Starter motor pinion 1 23 Pinion stopper set 1 24 Lever assembly 1 25 Seal set 1 39 39 39 39 26 Magnet switch 1 27 Washer 1 28 Nut 1 24 12 9 10 8 5 1 2 13 25 26 28 22 4 23 7 6 3 6 7 20 21 19 18 14 15 16 27 17 11 M M Starter motor ...

Page 198: ...motor pinion make sure to disconnect the battery cables 1 Check the pinion Replace if cracked or worn 2 Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place Disassembling the starter motor 1 Disconnect the brush assembly lead a and then remove the magnet switch 1 and spring b 2 Push the pinion stopper c down and then remove the c...

Page 199: ...embly 8 from the bracket 9 8 Remove the plate s and then remove the armature 7 from the brush holder assembly 8 9 Remove the E clip 0 and then remove the clutch assembly A from the pinion shaft B TIP Push the clutch assembly A completely down onto the pinion shaft B in direction t and turn it one spline in direction u and then remove it in direction v n m p 9 6 8 7 r 8 7 7 s s 8 A B B 0 A t u v v ...

Page 200: ...cking the brush holder and brush 1 Check the brush holder assembly for continuity Replace if out of specification 2 Measure the length of each brush Replace the brush assembly if below specification Commutator standard diameter a 29 0 mm 1 14 in Wear limit 28 0 mm 1 10 in Commutator standard undercut b 0 5 0 8 mm 0 02 0 03 in Wear limit 0 2 mm 0 01 in a b Armature continuity c d e f C C C C C C C ...

Page 201: ...der assembly 2 to the bracket 3 and then install the stator 4 TIP Align the holes c and d in the plate b with the holes e and f in the bracket 3 4 Install the bracket 5 a new gasket 6 and the clutch assembly 7 onto the pin ion shaft 8 5 Push the clutch assembly 7 completely down onto the pinion shaft 8 in direction g turn it one spline in direction h and then slide it in direction k 6 Install the ...

Page 202: ... the outer gear s and the plate 0 8 Install the stator assembly t TIP Align the protrusion u on the stator assem bly t with the slot v in the cover assembly w 9 Install the spring x pinion A pinion stopper y and clip z 10 Install a new gasket B the spring A and the magnet switch C and then con nect the brush assembly lead B 7 7 8 8 m g h k k g h n n p p 9 s r 0 C M M t w w t u v A y y x A z C B A ...

Page 203: ...nnecting the PTT relay leads and PTT relay cou pler make sure to disconnect the neg ative battery cable 4 Connect the special service tool 1 5 Check the PTT relay for continuity Replace if out of specification 6 Connect the positive battery lead to the connector e connect the negative bat tery lead to the terminal b and then check the PTT relay for continuity Replace if out of specification PTT re...

Page 204: ...nifold 6 18 Checking the PTT switch bottom cowling 1 Disconnect the PTT switch coupler a 2 Measure the input voltage at the PTT switch coupler È Regular rotation model É Counter rotation model 3 Check the PTT switch 1 for continuity Replace if out of specification 4 Remove the intake manifold STBD See Removing the intake manifold 6 17 PTT relay continuity a b c d C C C C C C C C C C C C C C C C PT...

Page 205: ...oupler Checking the trim sensor 1 Remove the trim sensor and then dis connect the trim sensor coupler a 2 Turn the trim sensor lever b from the position c to the position d and then measure the resistance as it gradually changes 3 Disconnect the alert indicator coupler e Wiring harness continuity a Terminal 1 f Terminal 1 a Terminal 2 f Terminal 2 a Terminal 3 e Terminal 4 2 e f e a f 1 2 3 4 2 1 ...

Page 206: ...roperly in the engine ECM coupler 8 Install the engine ECM and then tighten the engine ECM bolts to the specified torque 9 Install the engine ECM cover 10 Connect the alert indicator coupler 11 Install the trim sensor and then connect the trim sensor coupler 12 Adjust the trim sensor See Adjusting the trim sensor 9 34 Wiring harness continuity a Terminal 1 e Terminal 2 a Terminal 2 f Terminal 18 E...

Page 207: ...5 78 5 MEMO PTT electrical system ...

Page 208: ...Intake manifold 6 15 Removing the intake silencer 6 17 Removing the intake manifold 6 17 Checking the intake manifold 6 18 Checking the air temperature sensor 6 18 Installing the intake manifold 6 18 Installing the intake silencer 6 19 Throttle body 6 21 Removing the throttle body assembly 6 23 Checking the canister check valve 6 23 Checking the vacuum hose 6 24 Installing the throttle body assemb...

Page 209: ...r 6 35 Vapor separator and high pressure fuel pump 6 37 Disassembling the vapor separator 6 39 Checking the high pressure fuel pump 6 40 Checking the vapor separator 6 40 Checking the check valve 6 40 Assembling the vapor separator 6 41 Fuel injector 6 43 Removing the fuel injector 6 45 Checking the fuel rail 6 45 Checking the quick connector 6 46 Installing the fuel injector 6 46 ...

Page 210: ... 5 Fuel hose low pressure fuel pump to vapor separator 6 Fuel hose vapor separator to fuel rail PORT 7 Fuel hose vapor separator to fuel rail STBD 8 Blowby hose cylinder head cover STBD to intake silencer 9 Blowby hose cylinder block to joint a Primer pump b Fuel filter assembly c Joint d Low pressure fuel pump e Vapor separator f Pressure regulator g Quick connector h Fuel injector 7 6 f e 4 c 3 ...

Page 211: ...6 2 6 k Fuel rail STBD m Fuel rail PORT n Joint 7 6 f e 4 c 3 9 8 n 1 2 b d m h g k g h g 5 a Hose routing ...

Page 212: ... shut off valve to surge tank 7 Vacuum hose surge tank to joint 8 Vacuum hose joint to air pressure sensor 9 Vapor gas hose check valve to joint 0 Vapor gas hose intake silencer to check valve A Vacuum hose joint to pressure regulator B Vapor gas hose joint to joint C Vapor gas hose check valve to bottom cowling D Vapor gas hose joint to check valve a Joint b Check valve c Vapor separator STBD A 1...

Page 213: ...d Pressure regulator e Canister f Vapor shut off valve g Air pressure sensor h Intake silencer STBD A 1 1 3 3 4 4 5 6 6 0 h 9 2 2 B D C C A A 8 8 7 7 Í Í Ê Ê Ë Ë È È É É Ì Ì 0 e b b f g 5 6 a c d Hose routing ...

Page 214: ...ling water hose thermostat cover PORT to cylinder block 9 Cooling water hose joint to joint 0 Flushing hose joint to cooling water passage cover A Flushing hose flushing hose adapter to joint B Cooling water hose cylinder block to joint C Cooling water hose joint to joint D Cooling water hose joint to fuel cooler E Cooling water hose fuel cooler to joint F Cooling water hose cylinder head STBD to ...

Page 215: ... to joint a Fuel cooler vapor separator b Rectifier Regulator c Cooling water pilot hole on the bottom cowling d Adapter water pressure sensor e Cooling water passage cover on the cyl inder block C B 8 9 B 8 9 A 0 7 6 1 5 4 3 2 I H G E D F a b c 6 0 C A 2 1 H 3 G 4 5 7 D F I E d e Hose routing ...

Page 216: ... the engine start switch to OFF 5 Install the fuse 15 A and then install the fuse cover Disconnecting the quick connector Before disconnecting the quick connec tor reduce the fuel pressure Otherwise pressurized fuel could spray out 1 Reduce the fuel pressure See Reduc ing the fuel pressure 6 7 2 Remove the flywheel magnet cover 3 Wrap a rag around the quick connector 1 4 Spread apart the ends of t...

Page 217: ...roperly by making sure there is a small amount of free play when the quick connec tor is pulled and pushed If there is no free play in the quick connec tor disconnect the fuel hose and check the O ring for damage and proper installation See Checking the quick connector 6 46 Measuring the fuel pressure 1 Reduce the fuel pressure See Reduc ing the fuel pressure 6 7 2 Disconnect the quick connector f...

Page 218: ...ng the engine start switch to OFF 9 Start the engine and warm it up until the engine idle speed stabilizes at 600 700 r min 10 Measure the fuel pressure 11 Turn the engine start switch to OFF 12 Reduce the fuel pressure See Reduc ing the fuel pressure 6 7 13 Disconnect the OCV coupler PORT 14 Disconnect the special service tools WARNING Before disconnecting the special service tools cover the end ...

Page 219: ...r plug 6 Start the engine and let it idle 7 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 8 Turn the engine start switch to OFF 9 Reduce the fuel pressure See Reduc ing the fuel pressure 6 7 10 Disconnect the special service tool from the pressure regulator and then connect the v...

Page 220: ...2 6 Collar 2 7 Bolt 2 M6 14 mm 8 Fuel filter assembly 1 9 O ring 1 39 39 39 39 10 Fuel filter element 1 11 Clip 1 12 Float 1 13 Fuel cup assembly 1 14 Hose 1 15 Holder 1 16 Joint 2 17 Hose 1 9 mm 0 35 in 12 mm 0 47 in 15 18 12 mm 0 47 in 12 mm 0 47 in 1 2 2 2 2 2 8 9 10 11 12 13 14 16 16 2 17 15 18 5 N m 0 5 kgf m 3 7 ft lb 3 4 5 6 7 ...

Page 221: ... 6 No Part name Q ty Remarks 18 Holder 1 9 mm 0 35 in 12 mm 0 47 in 15 18 12 mm 0 47 in 12 mm 0 47 in 1 2 2 2 2 2 8 9 10 11 12 13 14 16 16 2 17 15 18 5 N m 0 5 kgf m 3 7 ft lb 3 4 5 6 7 Fuel filter assembly ...

Page 222: ...ecified positive pressure Replace the O ring fuel cup assembly or fuel filter assembly if the specified pressure cannot be main tained for 15 seconds or more 3 Connect the special service tool 1 to the fuel outlet b 4 Block the fuel inlet a using a rubber plug 2 and then apply the specified negative pressure Replace the O ring fuel cup assembly or fuel filter assembly if the specified pressure can...

Page 223: ...witch 5 43 Assembling the fuel filter assembly Do not reuse an O ring always replace it with a new one 1 Install the float 1 and clip 2 to the fuel cup assembly 3 2 Install the fuel filter element 4 a new O ring 5 and the fuel cup assembly 3 and then tighten the fuel cup assembly to the specified torque Installing the fuel filter assembly 1 Install the fuel filter assembly 1 2 Connect the fuel hos...

Page 224: ...4 6 Flywheel magnet cover 1 7 Grommet 2 8 Bolt 2 M6 18 mm 9 Plastic tie 1 10 Hose 1 11 Plastic tie 1 12 Hose 1 13 Holder 1 14 Intake manifold assembly PORT 1 15 Gasket 6 39 39 39 39 16 Gasket 1 39 39 39 39 17 Bolt 8 M8 40 mm 7 N m 0 7 kgf m 5 2 ft lb 10 N m 1 0 kgf m 7 4 ft lb 1 1 1 2 3 4 5 5 5 6 9 11 7 8 10 7 8 12 13 14 15 16 17 19 20 18 17 18 15 17 ...

Page 225: ...emarks 18 Bolt 7 M6 40 mm 19 Intake manifold assembly STBD 1 20 Gasket 1 39 39 39 39 7 N m 0 7 kgf m 5 2 ft lb 10 N m 1 0 kgf m 7 4 ft lb 1 1 1 2 3 4 5 5 5 6 9 11 7 8 10 7 8 12 13 14 15 16 17 19 20 18 17 18 15 17 Intake manifold ...

Page 226: ...re sensor coupler a and then remove the air tem perature sensor 1 3 Remove the blowby hose 2 4 Disconnect the vapor gas hose 3 and then remove the intake silencer 4 Removing the intake manifold 1 Remove the fuel drain hose 1 from the intake manifold PORT 2 2 Remove the intake manifolds 2 and 3 1 a 2 4 3 2 1 PORT 3 2 ...

Page 227: ...sensor 5 56 Installing the intake manifold Do not reuse a gasket always replace it with a new one 1 Connect the blowby hose 1 with the paint mark a facing outward and then fasten it using the holder 2 2 Install new gaskets onto the intake mani folds Make sure to fit the protrusion on each gasket into its corresponding slot in the intake manifolds TIP Make sure that the tab on the gaskets is proper...

Page 228: ...manifold bolts 6 5 Fasten the fuel drain hose 7 to the holder on the intake manifold PORT TIP Make sure to tighten the intake manifold bolts in the order 1 2 and so on Installing the intake silencer 1 Install the intake silencer 1 and then tighten the intake silencer bolts 2 to the specified torque 2 Connect the vapor gas hose 3 to the intake silencer 4 3 Intake manifold bolt 5 10 N m 1 0 kgf m 7 ...

Page 229: ...e 7 5 Fasten the blowby hose 4 using the plastic tie 8 6 Install the air temperature sensor 9 and then connect the air temperature sensor coupler a 7 Install the air temperature sensor lead b at the white tape c to the holder d on the oil filler neck 8 Install the flywheel magnet cover Intake silencer bolt 2 7 N m 0 7 kgf m 5 2 ft lb 2 2 2 3 1 4 1 8 5 6 4 7 8 1 4 9 a b d c Intake manifold ...

Page 230: ... 1 3 Bolt 4 M8 40 mm 4 Throttle body assembly 1 5 Bolt 2 M6 16 mm 6 Holder 2 7 Hose 1 8 Holder 2 9 Hose 1 10 Joint 2 ø5 mm 11 Hose 1 12 Holder 2 13 Hose 1 14 Holder 3 15 Hose 1 16 Hose 1 17 Hose 1 3 23 24 20 18 19 19 21 22 27 12 10 10 13 25 26 15 16 17 28 11 5 5 8 8 9 7 3 1 2 4 6 14 14 ...

Page 231: ... 18 Joint 1 ø3 mm 19 Dowel 2 20 Holder 1 21 Joint 1 22 Hose 1 23 Check valve 1 24 Hose 1 25 Hose 1 26 Hose 1 27 Joint 1 28 Hose 1 3 23 24 20 18 19 19 21 22 27 12 10 10 13 25 26 15 16 17 28 11 5 5 8 8 9 7 3 1 2 4 6 14 14 Throttle body ...

Page 232: ...se 2 4 Disconnect the vapor gas hoses 4 and 5 5 Remove the plastic tie 6 and then remove the joint 7 6 Remove the throttle body assembly 8 7 Remove the hoses and check valve 9 Checking the canister check valve 1 Connect the special service tool 1 to the canister check valve port 2 Apply positive pressure and check that air comes out of the opposite end of the canister check valve Replace the canis...

Page 233: ... the hoses 1 2 and 3 Replace any hose that is cracked or damaged Installing the throttle body assembly 1 Install the hoses joint and check valve 1 and then install the holders 2 Install the dowels 2 and throttle body assembly 3 3 Install the joint 4 and then fasten it using the plastic tie 5 4 Connect the vapor gas hoses 6 and 7 5 Connect the vacuum hose 8 and then fasten it using the holder 9 Vac...

Page 234: ...6 25 FUEL Fuel system 6 Fasten the wiring harness 0 using the holders 7 Connect the throttle body assembly wir ing harness extension coupler a and ETV coupler b 6 6 7 8 8 9 0 a b ...

Page 235: ...10 Holder 1 11 Canister 1 12 Bolt 2 M6 28 mm 13 Collar 2 14 Grommet 2 15 Bracket 1 16 Air pressure sensor 1 17 Washer 1 A A 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 5 N m 0 5 kgf m 3 7 ft lb 5 N m 0 5 kgf m 3 7 ft lb 5 N m 0 5 kgf m 3 7 ft lb 1 2 2 1 1 1 3 3 4 5 5 10 9 6 7 8 20 20 21 21 22 22 23 23 24 11 12 13 14 12 13 14 15 19 19 16 17 18 Throttle body Canis...

Page 236: ...ic tie 1 21 Vapor shut off valve 1 22 Bracket 1 23 Holder 1 24 Nut 1 A A 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 5 N m 0 5 kgf m 3 7 ft lb 5 N m 0 5 kgf m 3 7 ft lb 5 N m 0 5 kgf m 3 7 ft lb 1 2 2 1 1 1 3 3 4 5 5 10 9 6 7 8 20 20 21 21 22 22 23 23 24 11 12 13 14 12 13 14 15 19 19 16 17 18 ...

Page 237: ...bracket 7 and throttle body 8 and then remove the throttle damper plate 9 6 Remove the air pressure sensor 0 Checking the ETV 1 Turn the throttle valve manually and check that it moves smoothly Checking the air pressure sensor 1 Check the air pressure sensor See Checking the air pressure sensor 5 57 Checking the vapor shut off valve 1 Check the vapor shut off valve See Checking the vapor shut off ...

Page 238: ... and the bracket 8 and then tighten the throttle body nuts 9 to the specified torque 4 Install the holder 0 and vapor shut off valve A and then tighten the vapor shut off valve nut B to the specified torque 5 Install the throttle body assembly wiring harness extension coupler a to the holder b on the bracket 8 6 Fasten the throttle body assembly wiring harness extension C and holder 0 using the pl...

Page 239: ...ster bracket bolts H to the speci fied torque 10 Secure the canister I using the holder J and then tighten the canister holder bolt K to the specified torque Canister bracket bolt H 5 N m 0 5 kgf m 3 7 ft lb Canister holder bolt K 5 N m 0 5 kgf m 3 7 ft lb G E F E F G H I K J Canister throttle body and surge tank ...

Page 240: ...ressure fuel pump No Part name Q ty Remarks 1 Hose 1 2 Clamp 3 3 Clamp 2 4 Joint 1 5 Bushing 2 6 Low pressure fuel pump 1 7 Hose 1 8 Holder 2 9 Cover 1 10 Bolt 2 M6 15 mm 5 N m 0 5 kgf m 3 7 ft lb 3 2 7 2 2 9 10 8 8 2 1 5 4 3 3 6 ...

Page 241: ...the condition of the fuel See Draining the fuel 6 35 If the fuel is dirty check and clean the fuel lines 2 Check the low pressure fuel pump See Checking the low pressure fuel pump and high pressure fuel pump 5 46 Checking the primer pump 1 Connect the special service tool 1 to the primer pump inlet hose 2 Cover the fuel outlet a 3 Apply the specified positive pressure to check that the pressure is...

Page 242: ...l hose a and then fasten the fuel hose using the clamp 5 3 Connect the fuel hose 6 to the low pres sure fuel pump and joint 4 and then fas ten the fuel hose using the clamps 7 and 8 4 Connect the fuel hose 9 and then fas ten it using the clamps 0 5 Install the fuel hose 9 to the holders A 6 Connect the low pressure fuel pump cou pler b Low pressure fuel pump cover bolt 3 5 N m 0 5 kgf m 3 7 ft lb ...

Page 243: ...5 mm 5 Collar 8 6 Vapor separator assembly 1 7 Grommet 4 8 Bracket 1 9 Bracket 1 10 Vapor separator wiring harness extension 1 11 Plastic tie 3 12 Hose 1 13 Clamp 2 14 Hose 1 15 Joint 1 1 2 3 5 7 5 11 8 9 3 7 5 4 5 7 3 5 7 10 11 5 6 4 4 5 4 5 12 3 13 14 11 15 13 Low pressure fuel pump Vapor separator ...

Page 244: ...r Cover the fuel components using a rag to prevent fuel from spilling out 1 Disconnect the quick connector See steps 3 5 in Disconnecting the quick connector 6 7 2 Remove the vapor separator wiring har ness extension 1 3 Remove the vapor separator assembly 2 and then remove the cooling water hoses 3 and 4 and joint 5 Installing the vapor separator 1 Install the joint 1 to the cooling water hose a ...

Page 245: ...6 36 6 5 Connect the vapor separator wiring har ness extension 9 6 Connect the quick connector See Con necting the quick connector 6 8 3 4 1 8 6 5 7 7 5 6 2 4 3 4 a 9 Vapor separator ...

Page 246: ...7 Gasket 1 39 39 39 39 8 Filter 1 9 Check valve 1 10 Screw 6 M4 16 mm 11 Gasket 1 39 39 39 39 12 Grommet 1 13 Joint 1 14 Damper 1 15 High pressure fuel pump 1 16 Lead 1 17 Filter 1 4 N m 0 4 kgf m 3 0 ft lb 4 N m 0 4 kgf m 3 0 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 kgf m 1 5 ft lb 3 2 5 4 8 9 5 6 7 10 1 12 15 11 19 16 17 18 13 14 20 23 21 22 28 29 24 25 27 26 25 ...

Page 247: ...embly 1 25 Screw 3 M5 6 mm 26 Cover 1 27 Gasket 1 39 39 39 39 28 Drain screw 1 29 Drain hose 1 4 N m 0 4 kgf m 3 0 ft lb 4 N m 0 4 kgf m 3 0 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 kgf m 1 5 ft lb 3 2 5 4 8 9 5 6 7 10 1 12 15 11 19 16 17 18 13 14 20 23 21 22 28 29 24 25 27 26 25 Vapor separator and high pressure fuel pump ...

Page 248: ...move the pressure regulator 6 4 Remove the vapor separator cover 7 gasket 8 filter 9 and check valve 0 5 Remove the float chamber cover A gas ket B high pressure fuel pump C and grommet D 6 Remove the screw E and then remove the pin F float G and needle valve assembly H 7 Remove the lead I and filter holder J and then remove the filter K joint L and damper M 1 2 5 6 3 4 9 7 8 0 B D C A E G F H ...

Page 249: ...t it should be rest ing on the needle valve Do not press the float Checking the check valve 1 Connect the special service tool 1 to the check valve port a 2 Apply positive pressure and check that air comes out of the opposite end b of the check valve Replace the check valve if no air comes out 3 Connect the special service tool 1 to the opposite check valve port b 4 Apply positive pressure and che...

Page 250: ...4 Connect the high pressure fuel pump coupler a and then install the grommet A and high pressure fuel pump B 5 Install a new gasket C and the float chamber cover D and then tighten the float chamber cover screws E to the specified torque 6 Install the check valve F the filter G a new gasket H and the vapor separator cover I and then tighten the vapor sep arator cover bolts J to the specified torqu...

Page 251: ...pecified torque 9 Install the drain hose Q and vapor sepa rator drain screw R and then tighten the vapor separator drain screw to the speci fied torque Vapor separator cover bolt J 2 N m 0 2 kgf m 1 5 ft lb Pressure regulator holder screw M 4 N m 0 4 kgf m 3 0 ft lb Fuel cooler cover screw P 4 N m 0 4 kgf m 3 0 ft lb G I H F J L K O N M P Vapor separator drain screw R 2 N m 0 2 kgf m 1 5 ft lb R Q...

Page 252: ...3 5 Fuel rail assembly STBD 1 6 Fuel rail STBD 1 7 Fuel injector 6 8 O ring set 6 39 39 39 39 9 Holder 6 10 Fuel rail assembly PORT 1 11 Fuel rail PORT 1 12 Cover PORT 1 13 Quick connector 2 14 Clamp 4 15 Hose 1 16 Quick connector 1 17 Hose 1 1 1 2 12 4 10 3 3 3 9 9 9 3 11 4 4 7 16 14 14 8 5 9 7 6 PORT STBD 8 17 18 13 14 15 13 ...

Page 253: ...6 44 6 No Part name Q ty Remarks 18 Fuel hose assembly 1 1 1 2 12 4 10 3 3 3 9 9 9 3 11 4 4 7 16 14 14 8 5 9 7 6 PORT STBD 8 17 18 13 14 15 13 Fuel injector ...

Page 254: ...quick connector 6 7 2 Remove the fuel hoses 1 and 2 3 Remove the fuel rail covers 3 and 4 and then disconnect the fuel injector cou plers a 4 Remove the fuel rails 5 and 6 5 Remove the holders 7 and then remove the fuel injectors b and O rings c and d Checking the fuel rail 1 Check the fuel rails Replace if cracked or deformed 2 1 PORT 2 STBD 3 a a a PORT 4 a a a STBD PORT 5 STBD 6 7 b c d ...

Page 255: ...r damaged Installing the fuel injector Do not reuse an O ring always replace it with a new one 1 Install new O rings a and b to the fuel injector c 2 Install the fuel injectors 1 onto the fuel rails 2 and 3 and then install the hold ers 4 3 Install the fuel rails 2 and 3 onto the cylinder heads 4 Tighten the bolts 5 equally and gradu ally 5 Connect the fuel injector couplers d 1 1 a a c b 1 2 4 2 ...

Page 256: ...ing har ness using the plastic ties 6 See Wiring harness routing 5 6 7 Install the fuel rail covers 7 and 8 8 Connect the quick connectors See Con necting the quick connector 6 8 9 Fasten the fuel hoses 9 and 0 using the holders A B and C 6 6 PORT STBD d 4 d 4 7 PORT 8 STBD 0 B 9 A PORT 0 C STBD ...

Page 257: ...ing harness 7 19 Removing the wiring harness 7 20 Installing the wiring harness 7 23 Starter motor 7 27 Removing the starter motor 7 28 Installing the starter motor 7 28 Fuse box 7 29 Junction box 7 30 Removing the Rectifier Regulator 7 32 Checking the Rectifier Regulator anode 7 32 Removing the junction box 7 32 Installing the junction box 7 33 Installing the Rectifier Regulator 7 33 Engine ECM 7...

Page 258: ...uide 7 63 Checking the valve seat 7 64 Refacing the valve seat 7 65 Checking the cylinder head anode 7 67 Assembling the cylinder head 7 67 Installing the cylinder head 7 68 Cooling water passage cover 7 70 Removing the cooling water passage cover 7 72 Checking the cooling water passage cover anode 7 72 Checking the knock sensor 7 72 Installing the cooling water passage cover 7 72 Crankcase 7 74 R...

Page 259: ... 87 Checking the connecting rod small end inside diameter and big end inside diameter 7 88 Checking the connecting rod big end side clearance 7 88 Checking the crankshaft 7 88 Checking the crankcase bolt 7 89 Checking the crankpin oil clearance 7 89 Selecting the crankpin bearing 7 90 Checking the crankshaft journal oil clearance 7 91 Selecting the crankshaft journal bearing 7 92 Crankshaft journa...

Page 260: ...que 13 Connect the fuel injector couplers and then install the fuel rail covers PORT and STBD and engine ECM cover Checking the oil pressure 1 Connect the YDIS to display Oil pres sure 2 Start the engine and warm it up until the engine idle speed stabilizes at 600 700 r min 3 Measure the oil pressure Checking the pulser coil air gap Do not turn the flywheel magnet counter clockwise Otherwise the w...

Page 261: ...o make sure to reduce the fuel pressure before performing the disassembly procedure 2 Remove the flywheel magnet cover and engine ECM cover 3 Remove the blowby hose See Remov ing the intake silencer 6 17 4 Remove the speed sensor coupler from the bracket See step 16 in Removing the power unit 7 8 5 Remove the wiring harness from the engine ECM bracket and holder See steps 4 16 in Removing the wiri...

Page 262: ...gnet with the pointer c 16 Measure the intake and exhaust valve clearances of the specified cylinders Adjust if out of specification See Adjust ing the valve clearance 7 4 Not applicable Specified cylinder 17 Install the cylinder head covers See Installing the cylinder head cover 7 44 18 Install the engine ECM bracket 2 19 Fasten the knock sensor lead a using the holder 3 on the engine ECM bracket...

Page 263: ...ed 1 Check that the 1TDC mark a on the flywheel magnet and the pointer b are aligned 2 Check that the II marks c on the VCT assembly PORT and driven sprocket PORT are aligned and check that the I marks d on the VCT assembly STBD and driven sprocket STBD are aligned 3 Remove the intake manifolds See Removing the intake manifold 6 17 4 Disconnect the quick connectors See steps 3 5 in Disconnecting t...

Page 264: ...fter into the cylinder head 13 Install the camshafts driven sprockets and VCT assemblies See Installing the camshaft and driven sprocket 7 50 14 Install the timing belt See steps 1 9 in Installing the timing belt 7 39 15 Install the stator assembly and flywheel magnet See steps 1 7 in Installing the flywheel magnet 7 17 16 Measure the valve clearances See steps 14 16 in Checking the valve clearanc...

Page 265: ...retainer 1 9 Plastic tie 1 10 Rigging grommet 1 11 Bolt 7 M10 35 mm 12 Bolt 6 M10 140 mm 13 Nut 2 14 Apron PORT 1 15 Bolt 1 M6 30 mm 16 Bolt 7 M6 14 mm 17 Grommet 6 7 6 21 22 13 17 17 14 19 16 20 16 16 15 18 16 2 3 3 11 11 12 1 25 25 26 24 11 11 12 12 12 3 3 23 4 N m 0 4 kgf m 3 0 ft lb 10 9 4 5 8 42 N m 4 2 kgf m 31 0 ft lb 28 27 28 11 Power unit check and adjustment Power unit assembly ...

Page 266: ...olt 1 M6 16 mm 22 Dipstick guide 1 23 Dipstick 1 24 Holder 3 25 Bolt 2 M6 10 mm 26 Cap 2 27 Engine ECM cover 1 28 Bolt 4 M6 20 mm 7 6 21 22 13 17 17 14 19 16 20 16 16 15 18 16 2 3 3 11 11 12 1 25 25 26 24 11 11 12 12 12 3 3 23 4 N m 0 4 kgf m 3 0 ft lb 10 9 4 5 8 42 N m 4 2 kgf m 31 0 ft lb 28 27 28 11 ...

Page 267: ...en remove the rigging tube retainer 2 3 Remove the retaining plate 3 and rig ging grommet 4 4 Disconnect the battery cables 5 5 Remove the throttle cable 6 from the holder a and then disconnect the throt tle cable 6 Remove the cable holder 7 and then disconnect the shift cable 8 7 Disconnect the fuel hose 9 from the fuel filter 8 Remove the PTT switch coupler b from the bracket 0 and then disconne...

Page 268: ...ler h from the tab on the bracket and then discon nect the trim sensor coupler 14 Remove the wiring harness B from the holders on the bracket A 15 Disconnect the cooling water hose C 16 Remove the engine ECM cover D and then remove the speed sensor coupler k from the bracket E 17 Disconnect the flushing hose F 18 Disconnect the vapor gas hose G from the housing STBD 19 Remove the intake manifold S...

Page 269: ...ng water hose 24 Remove the holders O plastic tie P and caps Q and then disconnect the PTT relay terminals p 25 Remove the aprons R and cover S 26 Retract the cowling lock levers PORT and STBD NOTICE Make sure that the cowling lock levers are retracted and the engine stoppers are installed before removing the power unit Oth erwise the fuel rails could be dam aged 27 Hook a lifting harnesses to the...

Page 270: ...RT and STBD NOTICE Make sure that the cowling lock levers are retracted and the engine stoppers are installed before installing the power unit Oth erwise the fuel rails could be dam aged 2 Clean the power unit mating surface and then the install the dowels 1 and a new gasket 2 3 Hook a lifting harness to the engine hangers 3 and then suspend the power unit 4 4 Install the power unit 4 and then tig...

Page 271: ...ect the cooling water hose C and then fasten it using the clamp D 9 Fasten the cooling water hose C using the holder E 10 Connect the neutral switch coupler d and then install the neutral switch coupler to the bracket F 11 Connect the shift cut switch coupler e 12 Fasten the neutral switch lead and wiring harness using the holder G and H 13 Install a new O ring and the dipstick guide I and then in...

Page 272: ...bracket T 20 Connect the trim sensor coupler g and then install the trim sensor coupler to the tab on the bracket 21 Install the alert indicator coupler h to the bracket 22 Connect the 6Y8 Multifunction Meter coupler k and then install the 6Y8 Multi function Meter coupler to the tab on the bracket 23 Connect the 10 pin coupler m and then fasten the 10 pin coupler to the holders on the bracket T 24...

Page 273: ...e See steps 14 20 in Installing the shift cable and throt tle cable 3 9 30 Connect the battery cables Y and then tighten the negative battery cable nut to the specified torque 31 Install the rigging grommet Z and retain ing plate TIP Route each harness through the proper hole in the rigging grommet See Rigging grom met description 3 9 for the detailed description of the rigging grommet 32 Install ...

Page 274: ...flats 36 mm 2 Washer 1 3 Flywheel magnet 1 4 Stator assembly 1 5 Bolt 4 M6 35 mm 6 Dowel 2 7 Holder 1 8 Holder 1 9 Bracket 1 10 Holder 1 11 Pulser coil 1 12 Screw 2 M5 12 mm 13 Woodruff key 1 1 2 8 3 5 5 5 5 6 6 9 10 12 7 4 11 13 4 N m 0 4 kgf m 3 0 ft lb 240 N m 24 0 kgf m 177 0 ft lb ...

Page 275: ...vice tool 2 and then remove the Woodruff key NOTICE To prevent damage to the engine or tools screw in the puller set bolts evenly and com pletely so that the flywheel puller is parallel to the flywheel magnet 3 Remove the plastic ties 3 and then dis connect the stator assembly couplers a 4 Disconnect the pulser coil coupler b 5 Remove the vapor gas hose 4 from the holder 5 6 Remove the stator asse...

Page 276: ...rque 2 Install the dowels 4 and stator assembly 2 and then install the holders 5 and 6 and bracket 7 3 Fasten the vapor gas hose 8 using the holder 5 4 Connect the pulser coil coupler a and then fasten the pulser coil lead using the holder 9 5 Connect the stator assembly couplers b and then fasten the stator assembly lead using the plastic ties 0 TIP To fasten the stator assembly lead see Wir ing ...

Page 277: ...wer sur faces f of the washer before installation 7 Tighten the flywheel magnet nut to the specified torque NOTICE Apply force in the direction of the arrow to prevent the special service tool C from slip ping off easily 8 Check the pulser coil air gap See Checking the pulser coil air gap 7 1 Flywheel magnet holder C 90890 06522 Flywheel magnet nut 240 N m 24 0 kgf m 177 0 ft lb A B d e f f B c C ...

Page 278: ...nit Wiring harness No Part name Q ty Remarks 1 Wiring harness guide 1 2 Plastic tie 4 3 Damper 2 4 Bolt 6 M6 35 mm 5 Holder 4 6 Wiring harness 1 7 Protector 1 8 Bolt 2 M6 30 mm 9 Bolt 3 M6 16 mm 1 2 2 3 3 4 5 6 2 7 8 9 ...

Page 279: ... the engine ECM couplers a 6 Disconnect the cam position sensor cou pler PORT IN b cam position sensor coupler PORT EX c and ignition coil couplers PORT d 7 Remove the knock sensor coupler e from the engine ECM bracket and then disconnect the knock sensor coupler 8 Remove joint coupler 2 f from the bracket 9 Remove the air fuel sensor coupler g from the bracket 10 Remove joint coupler 1 h from the...

Page 280: ...erature sensor coupler w from the wiring harness guide and then disconnect the engine tempera ture sensor coupler 23 Disconnect the OCV coupler PORT x and fuel injector couplers PORT y 24 Remove the plastic ties 0 and then remove the fuel injector lead from the holders A 25 Remove the plastic tie B and then dis connect the thermoswitch connectors STBD A 26 Disconnect the OCV coupler STBD B and fue...

Page 281: ... 32 Remove the wiring harness 4 from the holders I 33 Remove the fuse holder J and grommet K and then disconnect the fuse holder couplers H 34 Disconnect the PTT relay coupler J 35 Disconnect the ground lead terminals L and M and brown lead of the wiring har ness 4 and then remove the cap L 36 Remove the plastic ties M 37 Remove the Rectifier Regulator protector N and then remove the holder p on t...

Page 282: ...ection switch coupler b 2 Install the wiring harness at the white tape c to the holder 1 and then fasten the wiring harness using the plastic tie 2 3 Connect the APS coupler d 4 Install the holder e on the wiring har ness to the junction box and then install the Rectifier Regulator protector 3 5 Install the cap 4 to the starter motor lead and brown lead of the wiring harness 5 and then connect the...

Page 283: ...lead using the holder 0 13 Install the wiring harness guide A and then install the thermoswitch lead and engine temperature sensor lead to the holder p on the wiring harness guide TIP Fold the engine temperature sensor lead r and route it through the hole s in the wiring harness guide 14 Install the holders e on the wiring har ness to the wiring harness guide in the order 1 2 and so on and then fa...

Page 284: ...moswitch connectors PORT A and vapor separator wiring harness extension coupler B and then fasten the thermoswitch connectors vapor separator wiring harness exten sion and wiring harness using the holder I 22 Fasten the YDIS diagnostic flash indica tor connector lead using the holder J 23 Install the diagnostic flash indicator con nector D to the holder 24 Install the YDIS coupler E to the bracket...

Page 285: ...r PORT EX U and cam position sensor coupler PORT IN Y 36 Connect the engine ECM couplers Z NOTICE Make sure that the rubber seal is installed properly in each engine ECM coupler 37 Install the engine ECM P and then tighten the engine ECM bolts Q to the specified torque 38 Install the fuel hoses and fuel rail covers See steps 7 and 9 in Installing the fuel injector 6 46 39 Connect the quick connect...

Page 286: ...ter motor 1 2 Bolt 3 M8 45 mm 3 Nut 1 4 Holder 2 5 Plastic tie 2 6 Bolt 1 M8 16 mm 7 Terminal 1 8 Bolt 1 M8 20 mm 9 Terminal stud bolt 1 10 APS 1 11 Collar 3 12 Grommet 3 13 Bolt 3 M6 35 mm 14 Bolt 1 M6 16 mm 9 10 14 13 11 12 1 2 7 3 8 6 4 5 26 N m 2 6 kgf m 19 2 ft Ib ...

Page 287: ...terminal 1 junction box wiring harness extension terminal a and termi nal stud bolt 2 and then tighten the ter minal stud bolt to the specified torque 2 Install the starter motor 3 and then install the junction box wiring harness extension terminal b 3 Connect the starter motor lead c and brown lead of the wiring harness and then fasten the starter motor lead using the holders 4 and plastic ties 5...

Page 288: ...Spare is included 4 Fuse 2 20 A Spare is included 5 Fuse 2 15 A Spare is included 6 Screw 4 ø5 20 mm 7 Relay 4 8 Cover 1 9 Fuse 3 60 A Spare is included 10 Screw 4 M5 10 mm 11 Cover 1 12 Fuse puller 1 13 Screw 12 ø3 10 mm 14 Grommet 1 60 60 A A 2 3 3 5 4 2 9 10 10 7 7 7 12 12 2 5 3 4 8 13 13 11 6 13 13 6 14 2 3 3 5 9 9 4 2 1 ...

Page 289: ... 11 Anode 1 12 Screw 1 M4 12 mm 13 Clip 3 14 Plastic tie 1 15 Hose 1 16 Hose 1 17 Gasket 1 39 39 39 39 12 N m 1 2 kgf m 8 9 ft lb 6 N m 0 6 kgf m 4 4 ft lb 1 2 12 N m 1 2 kgf m 8 9 ft lb 6 N m 0 6 kgf m 4 4 ft lb 1 2 3 N m 0 3 kgf m 2 2 ft lb 1 2 3 3 4 4 5 5 6 6 7 7 8 10 11 12 13 17 18 20 20 19 21 22 22 23 23 24 24 25 25 26 3 4 9 16 15 14 13 4 N m 0 4 kgf m 3 0 ft lb Fuse box Junction box ...

Page 290: ...mm 23 Washer 2 24 Nut 2 25 Cap 2 26 Junction box wiring harness extension 1 12 N m 1 2 kgf m 8 9 ft lb 6 N m 0 6 kgf m 4 4 ft lb 1 2 12 N m 1 2 kgf m 8 9 ft lb 6 N m 0 6 kgf m 4 4 ft lb 1 2 3 N m 0 3 kgf m 2 2 ft lb 1 2 3 3 4 4 5 5 6 6 7 7 8 10 11 12 13 17 18 20 20 19 21 22 22 23 23 24 24 25 25 26 3 4 9 16 15 14 13 4 N m 0 4 kgf m 3 0 ft lb ...

Page 291: ... Remove the anode 6 from the cover Checking the Rectifier Regulator anode 1 Check the anode Replace if eroded Clean if there is grease oil or scales NOTICE Do not apply grease oil or paint to the anode Removing the junction box 1 Remove the caps 1 and then discon nect the PTT relay terminals a 2 Disconnect the PTT relay coupler b 3 Remove the PTT relay 2 4 Disconnect the junction box wiring har ne...

Page 292: ... the Rectifier Regulator Do not reuse a gasket always replace it with a new one 1 Install the anode 1 to the cover 2 and then tighten the anode screw 3 to the specified torque 2 Install the gasket 4 and cover 2 to the Rectifier Regulator and then tighten the Rectifier Regulator cover bolts 5 to the specified torques in 2 stages 3 Install the Rectifier Regulator 6 and then tighten the Rectifier Reg...

Page 293: ... Rectifier Regulator leads using the plastic tie 8 7 Connect the cooling water hoses c and d 8 Install the Rectifier Regulator protector 9 TIP To fasten the Rectifier Regulator leads see Wiring harness routing 5 6 Rectifier Regulator bolt 7 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 6 7 8 9 7 c b d 8 Junction box ...

Page 294: ...Bolt 4 M6 20 mm 3 Plastic tie 2 4 Holder 1 5 Bracket 1 6 Collar 4 7 Grommet 4 8 Bolt 4 M6 28 mm 9 Holder 4 10 Bracket 1 11 Bolt 2 M6 16 mm 12 Holder 2 13 Bracket 1 14 Holder 1 15 Holder 1 1 2 2 3 4 5 7 8 9 9 9 9 11 11 10 12 13 14 7 N m 0 7 kgf m 5 2 ft lb 6 7 6 7 6 7 12 15 8 8 ...

Page 295: ...ck sensor lead a from the holder 2 Installing the engine ECM 1 Fasten the knock sensor lead a using the holder 1 2 Install the engine ECM 2 and then tighten the engine ECM bolts 3 to the specified torque Engine ECM bolt 3 7 N m 0 7 kgf m 5 2 ft lb 1 2 a 2 3 1 a 3 Engine ECM ...

Page 296: ...name Q ty Remarks 1 Timing belt 1 2 Timing belt tensioner 1 3 Bolt 2 M10 55 mm 4 Washer 2 5 Pulley 2 6 Collar 2 7 Bolt 4 M6 14 mm 8 Guide PORT 1 9 Guide STBD 1 1 8 9 7 39 N m 3 9 kgf m 28 8 ft lb 39 N m 3 9 kgf m 28 8 ft lb 2 3 4 5 6 3 4 5 6 7 ...

Page 297: ... 6 17 3 Disconnect the quick connectors See steps 3 5 in Disconnecting the quick connector 6 7 4 Remove the fuel hoses and fuel rail cov ers See steps 2 and 3 in Removing the fuel injector 6 45 5 Remove the wiring harness guide See steps 5 29 in Removing the wiring har ness 7 20 6 Align the L L L L mark a on the drive sprocket with the L L L L mark b on the cyl inder block 7 Check that the II mark...

Page 298: ...1 Check the interior and exterior of the tim ing belt Replace if cracked damaged or worn Installing the timing belt 1 Install the timing belt tensioner 1 collar 2 and pulley 3 and then tighten the timing belt tensioner bolt a and pulley bolt 4 to the specified torque 2 Install the timing belt 5 onto the crank shaft so that part number b is in the upright position and the belt position mark c is al...

Page 299: ... pulley 7 and then install the pulley NOTICE Make sure that the pulley 7 is installed properly onto the collar 6 5 Install the washer and then tighten the pulley bolt 8 to the specified torque TIP When installing the pulley make sure to keep the belt position marks and the L L L L marks aligned as specified in step 3 6 Adjust the timing belt installation height m to specification 7 Insert a hexago...

Page 300: ...driven sprockets are aligned 10 Adjust the timing belt guide clearance u 11 Install the wiring harness guide See steps 13 37 in Installing the wiring har ness 7 23 12 Install the fuel hoses and fuel rail covers See steps 7 and 9 in Installing the fuel injector 6 46 13 Connect the quick connectors See Con necting the quick connector 6 8 14 Install the intake manifold PORT See Installing the intake ...

Page 301: ...39 39 10 Bolt 12 M6 20 mm 11 Ignition coil 6 12 Spark plug 6 13 Screw 8 M4 8 mm 14 Plate 1 15 Gasket 1 39 39 39 39 16 Cylinder head cover STBD 1 17 Adapter 1 8 N m 0 8 kgf m 5 9 ft lb 8 N m 0 8 kgf m 5 9 ft lb 1 2 23 N m 2 3 kgf m 17 0 ft lb 25 N m 2 5 kgf m 18 4 ft lb 2 N m 0 2 kgf m 1 5 ft lb 7 N m 0 7 kgf m 5 2 ft lb 1 1 3 4 4 2 5 6 8 9 7 10 11 12 10 11 12 15 14 13 10 11 12 10 11 12 10 10 11 12...

Page 302: ... 20 Bolt 2 M6 30 mm 8 N m 0 8 kgf m 5 9 ft lb 8 N m 0 8 kgf m 5 9 ft lb 1 2 23 N m 2 3 kgf m 17 0 ft lb 25 N m 2 5 kgf m 18 4 ft lb 2 N m 0 2 kgf m 1 5 ft lb 7 N m 0 7 kgf m 5 2 ft lb 1 1 3 4 4 2 5 6 8 9 7 10 11 12 10 11 12 15 14 13 10 11 12 10 11 12 10 10 11 12 11 12 20 7 17 18 19 4 2 1 16 ...

Page 303: ...k the spark plug gap b Replace if out of specification Installing the cylinder head cover Do not reuse a gasket or O ring always replace it with a new one When the timing belt is not installed do not turn the crankshaft or driven sprock ets Otherwise the pistons and valves or intake and exhaust valves could col lide with each other and be damaged 1 Install the cylinder head cover plate 1 to the cy...

Page 304: ...clamp B 7 Install new O rings C and the cam posi tion sensors D and E 8 Install the spark plugs and then tighten them to the specified torque 9 Install the ignition coils and then tighten the ignition coil bolts to the specified torque Cylinder head cover plate screw 3 2 N m 0 2 kgf m 1 5 ft lb Cylinder head cover bolt 7 1st 8 N m 0 8 kgf m 5 9 ft lb 2nd 8 N m 0 8 kgf m 5 9 ft lb 1 2 3 1280B 7 7 2...

Page 305: ... 2 M10 35 mm 15 Driven sprocket 2 16 Camshaft PORT EX 1 17 Valve lifter 24 32 N m 3 2 kgf m 23 6 ft lb 60 N m 6 0 kgf m 44 3 ft lb 60 N m 6 0 kgf m 44 3 ft lb 1 2 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb 1 2 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb 1 2 7 8 10 10 11 12 18 20 4 21 21 6 6 1 5 15 14 6 6 5 5 22 17 17 17 12 ...

Page 306: ... 32 N m 3 2 kgf m 23 6 ft lb 60 N m 6 0 kgf m 44 3 ft lb 60 N m 6 0 kgf m 44 3 ft lb 1 2 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb 1 2 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb 1 2 7 8 10 10 11 12 18 20 4 21 21 6 6 1 5 15 14 6 6 5 5 22 17 17 17 12 16 7 8 9 10 11 11 12 13 12 15 14 11 19 2 4 4 3 17 9 ...

Page 307: ...et STBD Other wise the intake and exhaust valves could collide with each other and be damaged TIP Be careful when turning the VCT assemblies and driven sprockets Depending on the posi tion of the camshafts the force of the valve springs may cause the VCT assemblies and driven sprockets to be rotated too far 3 Secure the VCT assembly using the spe cial service tool 1 and then remove the VCT caps 2 ...

Page 308: ... pre caution not to tilt the camshafts 8 Remove the camshafts 0 A B and C and oil seals D and then remove the valve lifters E TIP Make sure to keep the parts in the order as they were removed Checking the sprocket 1 Check the VCT assemblies and driven sprockets Replace the VCT assembly or driven sprocket if cracked damaged or worn Checking the valve lifter 1 Check the valve lifters Replace if dam ...

Page 309: ...mshaft journal diameter c and cylinder head journal inside diam eter d Replace the camshaft or cylinder head assembly or both if out of specifi cations Installing the camshaft and driven sprocket If the valve clearances are adjusted or any parts related to valve movement are replaced after installing the timing belt check the valve clearances See Checking the valve clear ance 7 2 Cam lobe height a...

Page 310: ...mating sur face of the crankcase and cylinder block 2 Apply a thin even coat of sealant to the mating surface of the camshaft caps 1 and cylinder heads 2 TIP Do not block the oil passages or oil holes with the sealant 3 Install the valve lifters 3 and then install the camshafts 4 5 6 and 7 in the proper positions and new oil seals 8 TIP Install the valve lifters in their original posi tions 4 Chec...

Page 311: ... the dowels G and driven sprock ets H 10 Secure the exhaust camshaft using a wrench I and then tighten the driven sprocket bolts J to the specified torque NOTICE When tightening the bolt do not turn the exhaust camshaft Other wise the intake and exhaust valves could collide with each other and be damaged PORT STBD BOW AFT B A 0 0 F 9 C D D F F 0 E PORT UP STBD 9S 8S 7S 5S 4S 3S 2S 1S 6S 4P 3P 2P 8...

Page 312: ...ligned 13 Secure the intake camshaft using a wrench I and then tighten the VCT bolts M to the specified torque NOTICE When tightening the VCT bolt do not secure the driven sprocket Other wise the VCT assembly could be damaged When tightening the VCT bolt do not turn the intake camshaft Otherwise the intake and exhaust valves could collide with each other and be damaged Driven sprocket bolt J 60 N ...

Page 313: ...e VCT assembly PORT and driven sprocket PORT counterclock wise more than 60 and do not turn the VCT assembly STBD and driven sprocket STBD Otherwise the intake and exhaust valves could col lide with each other and be damaged TIP Be careful when turning the VCT assembly and driven sprocket Depending on the posi tion of the camshafts the force of the valve springs may cause the VCT assembly and driv...

Page 314: ...7 55 POWR Power unit 17 Check that the I marks m on the VCT assembly STBD and driven sprocket STBD are aligned STBD m ...

Page 315: ...st inner cover PORT 1 8 Anode 2 9 Screw 2 M6 16 mm 10 Anode 2 11 Screw 2 M4 12 mm 12 Gasket 1 39 39 39 39 13 Exhaust outer cover STBD 1 14 Exhaust inner cover STBD 1 15 Gasket 1 39 39 39 39 1 1 3 4 5 5 7 8 9 8 9 10 11 10 11 14 15 13 12 6 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb 1 2 3 N m 0 3 kgf m 2 2 ft Ib 55 N m 5 5 kgf m 40 6 ft Ib 2 2 3 6 Camshaft Exhaust cover ...

Page 316: ...ed torque 2 Install new gaskets 4 and the exhaust covers 5 and 6 and then tighten the exhaust cover bolts 7 to the specified torques in 2 stages and in the order 1 2 and so on 3 Tighten the exhaust outer cover plugs 8 to the specified torque STBD PORT UP 1 1 2 3 3 4 5 6 1 1 7 8 9 0 A B C 4 5 8 9 B C D 2 6 7 0 A D 3 3 2 1 1 2 Anode screw 3 3 N m 0 3 kgf m 2 2 ft lb Exhaust cover bolt 7 1st 6 N m 0 ...

Page 317: ...9 39 39 39 7 Dowel 4 8 Gasket STBD 1 39 39 39 39 9 Engine hanger STBD 1 10 Cylinder head STBD 1 11 Exhaust valve 12 12 Hose 1 13 Clip 1 14 Valve guide 24 39 39 39 39 15 Valve spring retainer 24 1 2 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb 1 1 2 2 3 3 4 5 5 6 7 7 8 9 10 11 12 13 14 15 16 17 18 20 23 24 27 28 31 29 30 19 25 26 22 21 7 7 12 N m 1 2 kgf m 8 9 ft lb 32 32 1 2 30 N m 3 0 ...

Page 318: ... 24 20 Bolt 4 M8 40 mm 21 Anode assembly 4 22 Bolt 4 M6 20 mm 23 Gasket 4 39 39 39 39 24 Cover 4 25 Anode 4 26 Grommet 4 27 Intake valve 12 28 Cylinder head PORT 1 29 Bolt 2 M8 90 mm 30 Bolt 4 M8 55 mm 1 2 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb 1 1 2 2 3 3 4 5 5 6 7 7 8 9 10 11 12 13 14 15 16 17 18 20 23 24 27 28 31 29 30 19 25 26 22 21 7 7 12 N m 1 2 kgf m 8 9 ft lb 32 32 1 2 30 ...

Page 319: ... name Q ty Remarks 31 Bolt 16 M10 120 mm T55 32 Water shut grommet 2 1 2 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb 1 1 2 2 3 3 4 5 5 6 7 7 8 9 10 11 12 13 14 15 16 17 18 20 23 24 27 28 31 29 30 19 25 26 22 21 7 7 12 N m 1 2 kgf m 8 9 ft lb 32 32 1 2 30 N m 3 0 kgf m 22 1 ft lb 60 N m 6 0 kgf m 44 3 ft lb 3 4 1 30 N m 3 0 kgf m 22 1 ft lb 5 6 60 N m 6 0 kgf m 44 3 ft lb 90 7 N m 0 7 k...

Page 320: ...n the order 1 2 and so on and then remove the cylinder heads 7 and gaskets 8 NOTICE Be careful not to scratch or damage the mating sur faces of the cylinder head and cylin der block Disassembling the cylinder head 1 Remove the anode assemblies 1 2 Remove the intake and exhaust valves using the special service tools 2 and 3 2 3 1 STBD PORT UP T55 1 1 2 2 3 3 4 5 6 7 8 9 0 5 6 9 0 A 4 8 A 6 6 4 4 5 ...

Page 321: ... inder head assembly if above specifica tion Checking the valve spring 1 Measure the valve spring free length a 2 Measure the valve spring tilt b Replace if above specification Checking the valve 1 Check the valve face Replace if pitted or worn 2 Measure the valve margin thickness a Replace if out of specification Valve spring compressor 2 90890 04019 Valve spring compressor attachment 3 90890 063...

Page 322: ... After replacing a valve guide check the valve seat contact area 1 Remove the valve guide 1 using the special service tool 2 from the combus tion chamber side Valve margin thickness a Intake 0 500 0 900 mm 0 0197 0 0354 in Exhaust 0 900 1 300 mm 0 0354 0 0512 in Valve stem diameter b Intake 5 477 5 492 mm 0 2156 0 2162 in Exhaust 5 464 5 479 mm 0 2151 0 2157 in Valve stem runout Intake and exhaust...

Page 323: ...thin even layer of Mechanic s blueing dye Dykem onto the valve seat 3 Lap the valve slowly on the valve seat with a special service tool 1 4 Measure the valve seat contact width a where the blueing dye is adhered to the valve face Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification Replace the valve guide if the valve seat contact wi...

Page 324: ...atter marks make sure to turn the cutter evenly using a downward force of 40 50 N 4 0 5 0 kgf 8 8 11 0 lbf a Slag or rough surface 3 Adjust the top edge of the valve seat con tact width using a 30 cutter b Previous contact width 4 Adjust the bottom edge of the valve seat contact width using a 60 cutter Valve seat contact width a Intake 1 100 1 400 mm 0 0433 0 0551 in Exhaust 1 400 1 700 mm 0 0551 ...

Page 325: ...o narrow and situated near the top edge of the valve face cut the top edge of the valve seat using a 30 cutter to center the area and then set its width using a 45 cutter b Previous contact width If the valve seat contact area is too narrow and situated near the bottom edge of the valve face cut the bottom edge of the valve seat using a 60 cutter to center the area and then set its width using a 4...

Page 326: ...ways replace it with a new one 1 Install a new valve seal 1 onto the valve guide 2 Install the valve 2 valve spring seat 3 valve spring 4 and valve spring retainer 5 in this order and then install the spe cial service tools 6 and 7 3 Compress the valve spring and then install the valve cotters 8 4 Tap the valve spring retainer lightly using a plastic hammer to set the valve cotters 8 securely Valv...

Page 327: ...stall the dowels 2 new gaskets 3 and the cylinder heads 4 and then tighten the cylinder head bolts 5 to the specified torques in 6 stages and in the order 1 2 and so on 3 Tighten the cylinder head bolts 6 and 7 to the specified torques in 2 stages and in the order 9 0 and so on 8 8 9 PORT STBD 1 1 1 7 5 6 4 2 3 2 PORT UP STBD 1 2 3 4 5 6 7 8 9 9 0 0 A A a 90 5 7 6 7 5 2 3 6 7 1 4 5 8 Cylinder head...

Page 328: ...e specified torque 6 Install the fuel rails See Installing the fuel injector 6 46 Cylinder head bolt 5 1 8 M10 1st 30 N m 3 0 kgf m 22 1 ft lb 2nd 60 N m 6 0 kgf m 44 3 ft lb 3rd Loosen completely 4th 30 N m 3 0 kgf m 22 1 ft lb 5th 60 N m 6 0 kgf m 44 3 ft lb 6th 90 Cylinder head bolt 6 and 7 9 A M8 1st 14 N m 1 4 kgf m 10 3 ft lb 2nd 28 N m 2 8 kgf m 20 7 ft lb Cylinder head bolt 5 1 8 M10 1st 2...

Page 329: ... Joint 1 13 Holder 1 14 Hose 1 15 Holder 1 16 Holder 1 17 Bolt 1 M6 12 mm 19 17 16 14 20 2 27 22 23 26 2 2 24 25 21 3 N m 0 3 kgf m 2 2 ft lb 9 9 18 11 15 13 2 12 10 20 16 1 12 N m 1 2 kgf m 8 9 ft lb 32 N m 3 2 kgf m 23 6 ft Ib 2 2 2 2 3 3 6 7 2 7 8 3 3 2 5 3 6 4 1 A B B A 7 mm 0 28 in 9 mm 0 35 in 13 15 12 mm 0 47 in 12 mm 0 47 in Cylinder head Cooling water passage cover ...

Page 330: ...t 13 M6 30 mm 24 Knock sensor 1 25 Cover 1 26 Hose 1 27 Gasket 1 19 17 16 14 20 2 27 22 23 26 2 2 24 25 21 3 N m 0 3 kgf m 2 2 ft lb 9 9 18 11 15 13 2 12 10 20 16 1 12 N m 1 2 kgf m 8 9 ft lb 32 N m 3 2 kgf m 23 6 ft Ib 2 2 2 2 3 3 6 7 2 7 8 3 3 2 5 3 6 4 1 A B B A 7 mm 0 28 in 9 mm 0 35 in 13 15 12 mm 0 47 in 12 mm 0 47 in ...

Page 331: ...cking the knock sensor 5 64 Installing the cooling water passage cover Do not reuse a gasket always replace it with a new one 1 Install the anodes 1 to the cooling water passage cover 2 and then tighten the anode screws 3 to the specified torque 2 Install a new gasket 4 and the cooling water passage cover 2 3 Tighten the cooling water passage cover bolts 5 to the specified torque in the order 1 2 ...

Page 332: ...ensor 8 and then tighten it to the specified torque 6 Fasten the knock sensor lead a and flushing hose 6 using the plastic tie 9 TIP Fasten the knock sensor lead a so that it is taut Knock sensor 8 32 N m 3 2 kgf m 23 6 ft lb 6 7 a 9 a 6 9 6 8 ...

Page 333: ... 12 Bolt 2 M6 18 mm 13 Crankcase cover 1 14 Bolt 17 M8 45 mm 15 Dowel 2 16 Gasket 1 39 39 39 39 17 Bolt 4 M6 25 mm 18 N m 1 8 kgf m 13 3 ft lb 34 N m 3 4 kgf m 25 1 ft lb 14 17 18 19 23 24 25 16 15 15 8 9 10 13 11 12 1 3 2 4 5 6 7 15 N m 1 5 kgf m 11 1 ft lb 12 N m 1 2 kgf m 8 9 ft lb 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb 1 2 26 26 27 27 28 29 29 30 30 32 31 4 N m 0 4 kgf m 3 0 f...

Page 334: ...27 O ring 2 39 39 39 39 28 Gasket 1 39 39 39 39 29 Oil seal 1 39 39 39 39 30 Oil seal 2 39 39 39 39 31 Bolt 4 M6 40 mm 32 Oil pump assembly 1 18 N m 1 8 kgf m 13 3 ft lb 34 N m 3 4 kgf m 25 1 ft lb 14 17 18 19 23 24 25 16 15 15 8 9 10 13 11 12 1 3 2 4 5 6 7 15 N m 1 5 kgf m 11 1 ft lb 12 N m 1 2 kgf m 8 9 ft lb 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb 1 2 26 26 27 27 28 29 29 30 30 ...

Page 335: ...case cover 1 Remove the fuel filter assembly See Removing the fuel filter assembly 6 13 2 Remove the throttle body assembly See Removing the throttle body assembly 6 23 3 Remove the engine hanger 1 4 Loosen the crankcase cover bolts 2 in the order 1 2 and so on and then remove the crankcase cover 3 and gas ket 4 5 Remove the engine temperature sensor 5 Oil filter wrench 2 90890 06830 2 1 PORT UP S...

Page 336: ...teeth are cracked or worn Assembling the oil pump assembly Do not reuse an oil seal or gasket always replace it with a new one 1 Install new oil seals 1 into the oil pump housing 2 Install a new oil seal 4 into the oil pump housing 3 Install a new gasket 6 and then tighten the oil pump cover screws 7 to the spec ified torque 5 1 Driver rod L3 2 90890 06652 Needle bearing attachment 3 90890 06613 D...

Page 337: ...olts 8 to the specified torque 4 Install the throttle body assembly See Installing the throttle body assembly 6 24 5 Install the fuel filter assembly See Installing the fuel filter assembly 6 14 Installing the oil pump assembly Do not reuse an oil seal or O ring always replace it with a new one 1 Install a new oil seal 1 so that it is facing in the proper direction 2 Install new O rings 2 Engine t...

Page 338: ...and the oil filter bracket 2 and then tighten the oil filter bracket bolts 3 in the order 1 2 and so on 2 Install the oil filter union bolt 4 and then tighten it to the specified torque 3 Install a new O ring 5 and the oil pres sure sensor 6 and then tighten the oil pressure sensor 6 to the specified torque 4 Add a small amount of engine oil through the oil passage a of the oil filter bracket 3 a ...

Page 339: ...7 80 7 5 Install the oil filter 7 and then tighten it to the specified torque Oil filter 7 18 N m 1 8 kgf m 13 3 ft lb Oil filter wrench 8 90890 06830 8 7 Crankcase ...

Page 340: ...1 15 Bolt 4 M6 25 mm 16 Thermostat cover STBD 1 17 Bolt 2 M5 20 mm 1 2 3 4 5 7 8 29 28 9 30 30 31 25 26 27 24 24 16 20 20 21 22 21 19 19 36 35 34 15 14 10 10 15 23 23 32 33 38 37 17 17 23 N m 2 3 kgf m 17 0 ft lb 33 N m 3 3 kgf m 24 3 ft lb 1 2 90 4 12 10 39 40 10 41 46 48 49 2R R 44 45 4443 42 46 47 13N m 1 3 kgf m 9 6 ft lb 23N m 2 3 kgf m 17 0 ft lb 1 2 3 90 6 6 14 N m 1 4 kgf m 10 3 ft lb 28 N...

Page 341: ...4 12 mm 33 Gasket 1 39 39 39 39 34 Holder 1 1 2 3 4 5 7 8 29 28 9 30 30 31 25 26 27 24 24 16 20 20 21 22 21 19 19 36 35 34 15 14 10 10 15 23 23 32 33 38 37 17 17 23 N m 2 3 kgf m 17 0 ft lb 33 N m 3 3 kgf m 24 3 ft lb 1 2 90 4 12 10 39 40 10 41 46 48 49 2R R 44 45 4443 42 46 47 13N m 1 3 kgf m 9 6 ft lb 23N m 2 3 kgf m 17 0 ft lb 1 2 3 90 6 6 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb...

Page 342: ...9 42 mm 49 Collar 1 39 39 39 39 1 2 3 4 5 7 8 29 28 9 30 30 31 25 26 27 24 24 16 20 20 21 22 21 19 19 36 35 34 15 14 10 10 15 23 23 32 33 38 37 17 17 23 N m 2 3 kgf m 17 0 ft lb 33 N m 3 3 kgf m 24 3 ft lb 1 2 90 4 12 10 39 40 10 41 46 48 49 2R R 44 45 4443 42 46 47 13N m 1 3 kgf m 9 6 ft lb 23N m 2 3 kgf m 17 0 ft lb 1 2 3 90 6 6 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb 1 2 28 N m ...

Page 343: ...s and connecting rod caps mark each with an identification number c of the cor responding cylinder Make sure to keep the parts in the order as they were removed 4 Remove the piston pin clips 6 and pis ton pin 7 and then remove the connect ing rod d TIP Make sure to keep the parts in the order as they were removed 5 Remove the piston rings and arrange them in order 6 Remove the crankcase bolts 8 9 ...

Page 344: ...stat in a container of water 2 Place a thermometer in the water and heat the water slowly 3 Measure the thermostat valve opening a at the specified water temperatures Replace if out of specification PORT UP STBD S R Q P O N M L K J I H G F E D C B A 0 9 8 7 6 5 4 3 1 9 8 0 2 C B E D D C C Bearing splitter plate G commercially available Gear puller H commercially available General cylindrical tool ...

Page 345: ...he cylinder using a piston crown at the specified measuring point a 2 Measure the piston ring end gap b Water temperature Valve opening a 58 62 C 136 144 F Starts opening above 70 C 158 F 4 3 mm 0 17 in or above Piston diameter a 93 921 93 941 mm 3 6977 3 6985 in Measuring point b 13 500 mm 0 5315 in up from the bottom of the piston skirt b a D1 D2 D3 D4 D5 D6 a b c d e Cylinder bore D1 D6 94 000 ...

Page 346: ... it at the oil grooves b or ring groove c Checking the piston pin 1 Measure the piston pin outside diameter a Measuring point a reference data 20 0 mm 0 8 in Piston ring end gap b reference data Top ring 0 200 0 300 mm 0 0079 0 0118 in Second ring 0 300 0 450 mm 0 0118 0 0177 in Oil ring 0 150 0 600 mm 0 0059 0 0236 in Piston ring groove Top ring a 1 230 1 250 mm 0 0484 0 0492 in Second ring b 1 2...

Page 347: ...d cap with iden tification marks d and then tighten the bolts 90 from the marks on the connecting rod cap Checking the connecting rod big end side clearance 1 Measure the connecting rod big end side clearance a Checking the crankshaft 1 Measure the crankshaft journal diame ters a crankpin diameters b and crankpin widths c Piston pin outside diameter a 21 008 21 017 mm 0 8271 0 8274 in Connecting r...

Page 348: ...rings 1 into the connecting rod a and connecting rod cap b TIP Install the crankpin bearings in the original positions 3 Place a piece of Plastigauge PG 1 on the crankpin parallel to the crankshaft Crankshaft journal diameter a 62 968 62 992 mm 2 4791 2 4800 in Crankpin diameter b 49 976 50 000 mm 1 9676 1 9685 in Crankpin width c 21 500 21 550 mm 0 8465 0 8484 in Crankshaft runout 0 030 mm 0 0012...

Page 349: ...ing rod bolts 2 to the specified torques in 3 stages TIP In the 3rd tightening stage for the connecting rod bolts 2 mark the connecting rod bolts and the connecting rod cap with identification marks e and then tighten the bolts 90 from the marks on the connecting rod cap 6 Remove the connecting rod cap and then measure the width of the com pressed Plastigauge PG 1 on the crankpin Selecting the cra...

Page 350: ...t 2 into the cylinder block 3 TIP t Install the crankshaft journal bearings 1 in the original positions Insert the protrusion a of each bearing into the slots in the cylinder block 4 Place a piece of Plastigauge PG 1 on each crankshaft journal b parallel to the crankshaft TIP Do not place the Plastigauge PG 1 over the oil hole in each crankshaft journal 5 Install the crankshaft journal bearings in...

Page 351: ... the crankcase 8 Remove the crankcase and then mea sure the width of the compressed Plasti gauge PG 1 on each crankshaft journal TIP When loosening the crankcase bolts loosen them in the opposite order used for tighten ing Selecting the crankshaft journal bearing When replacing the crankshaft journal bear ing select the bearing as follows 6 4 5 7 PORT UP STBD 90 c 1 2 3 4 5 6 7 8 9 0 A B C D E F G...

Page 352: ... cylinder block mark b on the cylinder block 2 Select the suitable colors c for the crankshaft journal bearing from the Crankshaft journal bearing selection table J1 J1 J2 J3 J4 J2 J3 J4 a J4 J3 J2 J1 b c Upper bearing color Lower bearing color d Yellow Yellow e Green Green f Blue Blue ...

Page 353: ...e crankshaft journal bearing color is blue Crankshaft journal bearing selection table a Crankshaft journal mark b Cylinder block mark 99 9 68 69 70 98 06 07 08 09 h g a b f b 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 a 68 69 70 71 72 f 73 74 75 76 77 78 79 80 e 81 82 83 84 85 86 87 88 d 89 90 91 92 Cylinder block ...

Page 354: ...the piston 2 the connecting rod a the piston pin 3 and new piston pin clips 4 TIP Face the protrusion b on the connecting rod a in the same direction as the mark c on the piston crown Do not align the piston pin clip end with the groove d in the piston pin boss 3 Install the oil rings e 2nd ring f and top ring g 4 Offset the piston ring end gaps NOTICE Be careful not to scratch the pistons or brea...

Page 355: ...e the oil seal when installing it by contacting the edge p of the drive sprocket TIP Do not get any engine oil to the drive sprocket Install each thrust bearing with its grooves r facing outward 8 Install the crankshaft journal bearings A into the crankcase 9 Apply sealant to the mating surface of the crankcase TIP Install the crankshaft journal bearings in the original positions Insert the protru...

Page 356: ...he crankcase bolts In the 2nd tightening stage for the M8 bolts F and M10 bolts G mark the bolts and the crankcase E with identification marks u and then tighten the bolts 90 from the marks on the crankcase After tightening the crankcase bolts make sure that the crankshaft turns smoothly 13 Install the piston I so that the mark v on the piston crown is facing toward the flywheel magnet end of the ...

Page 357: ...the marks on the connecting rod caps Make sure that the crankshaft turns smoothly 15 Install new gaskets L and the anode bolts M to the thermostat covers N and then tighten the anode bolts to the speci fied torque 16 Install the anodes O to the thermostat covers N and then tighten them to the specified torque 17 Install new gaskets P to the thermostats Q and then install the thermostats to the cyl...

Page 358: ...7 99 POWR Power unit 20 Install the thermoswitches T Anode bolt M 7 N m 0 7 kgf m 5 2 ft lb Anode O 3 N m 0 3 kgf m 2 2 ft lb Thermostat cover plug S 23 N m 2 3 kgf m 17 0 ft lb N O T S R Q L M P ...

Page 359: ...7 100 7 MEMO Cylinder block ...

Page 360: ...ler shaft housing assembly 8 16 Disassembling the propeller shaft assembly 8 16 Disassembling the propeller shaft housing assembly 8 16 Checking the propeller shaft housing 8 17 Checking the propeller shaft 8 17 Assembling the propeller shaft assembly 8 17 Assembling the propeller shaft housing assembly 8 18 Propeller shaft housing F250G 8 20 Removing the propeller shaft housing assembly 8 22 Disa...

Page 361: ...ng the forward gear 8 35 Assembling the oil seal housing 8 35 Installing the drive shaft 8 35 Installing the propeller shaft housing assembly 8 35 Installing the shift rod 8 36 Installing the water pump 8 36 Checking the lower unit for air leakage 8 36 Installing the lower unit 8 36 Shimming regular rotation model 8 37 Shimming workflow 8 37 Shimming check sheet 8 38 Measuring the forward gear bac...

Page 362: ...8 73 Disassembling the propeller shaft housing assembly 8 73 Checking the propeller shaft housing 8 74 Checking the propeller shaft 8 74 Assembling the propeller shaft housing assembly 8 74 Propeller shaft housing FL250G 8 77 Removing the propeller shaft housing assembly 8 79 Disassembling the propeller shaft housing assembly 8 79 Checking the propeller shaft housing 8 79 Checking the propeller sh...

Page 363: ... Installing the shift rod 8 88 Installing the water pump 8 88 Checking the lower unit for air leakage 8 89 Installing the lower unit 8 89 Shimming counter rotation model 8 90 Shimming workflow 8 90 Shimming check sheet 8 91 Measuring the forward gear backlash and reverse gear backlash before disassembly 8 93 Shimming 8 97 Shim location FL200B 8 97 Shim location FL250G 8 98 Selecting the pinion shi...

Page 364: ...er 1 11 Cotter pin 1 39 39 39 39 12 Propeller nut 1 13 Washer 1 14 Spacer 1 15 Trim tab 1 16 Bolt 1 M10 70 mm X transom model 17 Bolt 7 M10 45 mm X transom model 42 N m 4 2 kgf m 31 0 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 47 N m 4 7 kgf m 34 7 ft lb 55 N m 5 5 kgf m 40 6 ft Ib 9 15 17 18 17 8 10 11 12 14 13 17 16 6 7 3 4 5 3 1 24 23 1 2 19 20 21 22 3...

Page 365: ...he flat end of the stud bolt up 26 Rubber seal 1 U transom model 27 Extension 1 U transom model 28 Bolt 1 M10 200 mm U transom model 29 Bolt 1 M10 175 mm U transom model 30 Nut 6 U transom model 31 Washer 6 U transom model 42 N m 4 2 kgf m 31 0 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 47 N m 4 7 kgf m 34 7 ft lb 55 N m 5 5 kgf m 40 6 ft Ib 9 15 17 18 17...

Page 366: ...a block of wood between the anti cavitation plate and the propeller to keep the propeller from turning and then remove the propeller nut and propeller 5 Make a mark a on the trim tab 1 and lower case and then remove the trim tab 6 Remove the lower unit 2 and extension 3 U transom model È U transom model TIP When disassembling the lower unit measure the backlash before disassembly See Mea suring th...

Page 367: ...39 39 39 12 Propeller nut 1 13 Washer 1 14 Spacer 1 15 Trim tab 1 16 Bolt 1 M10 70 mm X transom model 17 Bolt 7 M10 45 mm X transom model 42 N m 4 2 kgf m 31 0 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 47 N m 4 7 kgf m 34 7 ft lb 55 N m 5 5 kgf m 40 6 ft Ib 9 15 17 18 17 8 10 11 12 14 13 17 16 6 7 3 4 5 3 1 24 23 1 2 19 20 21 22 31 30 29 27 24 25 26 È 28...

Page 368: ...m model Point the flat end of the stud bolt up 26 Rubber seal 1 U transom model 27 Extension 1 U transom model 28 Bolt 1 M10 200 mm U transom model 29 Bolt 1 M10 175 mm U transom model 30 Nut 6 U transom model 31 Washer 6 U transom model 42 N m 4 2 kgf m 31 0 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 47 N m 4 7 kgf m 34 7 ft lb 55 N m 5 5 kgf m 40 6 ft I...

Page 369: ...in Removing the lower unit 8 3 TIP When disassembling the lower unit measure the backlash before disassembly See Mea suring the forward gear backlash and reverse gear backlash before disassembly 8 40 Checking the propeller 1 Check the propeller See Checking the propeller 8 3 Checking the lower unit anode 1 Check the trim tab See Checking the lower unit anode 8 3 Lower unit F250G ...

Page 370: ... M6 20 mm 4 Oil seal 1 39 39 39 39 5 Plate 1 6 O ring 1 39 39 39 39 7 Spring 1 8 E clip 1 9 Woodruff key 1 10 Dowel 2 11 Gasket 1 39 39 39 39 12 Outer plate cartridge 1 13 Impeller 1 14 Washer 2 15 Wave washer 1 16 Spacer 1 17 Collar 1 3 3 5 4 6 7 8 2 11 12 13 17 16 14 15 14 20 20 23 18 19 24 9 10 10 21 22 1 ...

Page 371: ... O ring 1 39 39 39 39 19 Water pump housing 1 20 Bolt 4 M8 45 mm 21 Cover 1 22 Seal 1 23 Insert cartridge 1 24 O ring 1 39 39 39 39 3 3 5 4 6 7 8 2 11 12 13 17 16 14 15 14 20 20 23 18 19 24 9 10 10 21 22 1 Water pump and shift rod F200B ...

Page 372: ... 8 and gasket 9 3 Set the gear shift to the N position 4 Remove the plate A oil seal B O ring C and shift rod D Disassembling the water pump housing 1 Remove the O ring 1 insert cartridge 2 and O ring 3 2 Remove the cover 4 and seal 5 Checking the water pump and shift rod 1 Check the water pump housing Replace if deformed Shift rod socket 0 90890 06679 1 2 3 4 5 4 6 7 8 9 R N F 0 A D C B 3 2 1 4 5...

Page 373: ...3 Check the Woodruff key and the keyway in the drive shaft Replace if deformed or worn 4 Check the shift rod Replace if cracked or worn Assembling the water pump housing Do not reuse an O ring always replace it with a new one 1 Install the seal 1 and cover 2 2 Install a new O ring 3 the insert car tridge 4 and a new O ring 5 TIP Fit the protrusions a on the insert cartridge 4 into the slots b in t...

Page 374: ...20 mm 4 Oil seal 1 39 39 39 39 5 Plate 1 6 O ring 1 39 39 39 39 7 Spring 1 8 E clip 1 9 Woodruff key 1 10 Dowel 2 11 Gasket 1 39 39 39 39 12 Outer plate cartridge 1 13 Impeller 1 14 O ring 1 39 39 39 39 15 Water pump housing 1 16 Bolt 4 M8 45 mm 17 Cover 1 2 1 11 12 13 16 16 19 14 15 20 7 8 9 10 10 17 18 3 3 5 4 6 ...

Page 375: ...8 12 8 No Part name Q ty Remarks 18 Seal 1 19 Insert cartridge 1 20 O ring 1 39 39 39 39 2 1 11 12 13 16 16 19 14 15 20 7 8 9 10 10 17 18 3 3 5 4 6 Water pump and shift rod F250G ...

Page 376: ...l O ring and shift rod See steps 3 and 4 in Removing the water pump and shift rod 8 9 Disassembling the water pump housing 1 Disassemble the water pump housing See Disassembling the water pump housing 8 9 Checking the water pump and shift rod 1 Check the water pump and shift rod See Checking the water pump and shift rod 8 9 Assembling the water pump housing 1 Assemble the water pump housing See As...

Page 377: ...er 1 10 Slider 1 11 Screw 1 M5 55 mm 12 Water inlet cover PORT 1 13 Washer 1 14 Reverse gear 1 15 Reverse gear shim T2 16 Ball bearing 1 39 39 39 39 17 Propeller shaft housing 1 1 N m 0 1 kgf m 0 7 ft lb 29 N m 2 9 kgf m 21 4 ft lb 6 N m 0 6 kgf m 4 4 ft lb 1 2 6 4 9 10 3 4 8 7 5 8 7 9 6 5 3 4 4 10 11 12 13 15 14 16 17 18 25 19 20 21 22 23 24 20 18 19 Water pump and shift rod F250G Propeller shaft...

Page 378: ...9 39 39 39 21 Needle bearing 1 39 39 39 39 22 Oil seal 2 39 39 39 39 23 Cover 1 24 Bolt 2 M8 20 mm 25 Grease nipple 1 1 N m 0 1 kgf m 0 7 ft lb 29 N m 2 9 kgf m 21 4 ft lb 6 N m 0 6 kgf m 4 4 ft lb 1 2 6 4 9 10 3 4 8 7 5 8 7 9 6 5 3 4 4 10 11 12 13 15 14 16 17 18 25 19 20 21 22 23 24 20 18 19 ...

Page 379: ...hat the balls 7 do not fall out of position Disassembling the propeller shaft housing assembly 1 Remove the reverse gear and reverse gear shims 2 Remove the ball bearing 3 Remove the oil seals 7 Bearing housing puller claw L 3 90890 06502 Stopper guide plate 4 90890 06501 Center bolt 5 90890 06504 1 2 3 4 5 3 1 2 3 4 5 6 7 7 Bearing separator 1 90890 06534 Stopper guide plate 2 90890 06501 Stopper...

Page 380: ...worn Assembling the propeller shaft assembly 1 Install the shift plunger 1 slider 2 balls 3 and shift rod joint 4 into the propeller shaft 5 TIP When installing the slider 2 make sure that the balls 3 do not fall out of position 2 Align the hole a in the dog clutch 6 with the hole b in the propeller shaft 3 Install the cross pin 7 and then install the spring 8 TIP Make sure to face the F mark c on...

Page 381: ...will force the stopper c out of place 2 Install new oil seals into the propeller shaft housing to the specified depth d TIP Install an oil seal halfway into the propeller shaft housing and then install the other oil seal 3 Install a new ball bearing 6 and original reverse gear shims 7 TIP Do not reuse a shim if deformed or scratched Face the bearing identification mark e on the ball bearing 6 towa...

Page 382: ... torch and then install the reverse gear assembly 0 NOTICE When heating the propeller shaft housing heat the entire installation area evenly Otherwise the propeller shaft housing could be damaged 5 Install the grease nipple A and then tighten it to the specified torque Grease nipple A 6 N m 0 6 kgf m 4 4 ft lb 0 9 A ...

Page 383: ...ng 1 10 Cross pin 1 11 Dog clutch 1 12 Shift plunger 1 13 Slider 1 14 Screw 1 M5 45 mm 15 Water inlet cover PORT 1 16 Propeller shaft shim T4 1 17 Reverse gear 1 1 N m 0 1 kgf m 0 7 ft lb 29 N m 2 9 kgf m 21 4 ft lb 6 N m 0 6 kgf m 4 4 ft lb 1 2 3 9 7 12 13 6 7 11 10 8 4 5 11 10 12 9 8 6 7 7 13 14 15 16 18 17 19 20 21 22 29 23 24 25 26 27 28 30 24 23 22 Propeller shaft housing F200B Propeller shaf...

Page 384: ... 2 23 Bolt 2 M8 33 mm 24 O ring 2 39 39 39 39 25 Needle bearing 1 39 39 39 39 26 Oil seal 2 39 39 39 39 27 Cover 1 28 Bolt 2 M8 20 mm 29 Grease nipple 1 30 Dowel 1 1 N m 0 1 kgf m 0 7 ft lb 29 N m 2 9 kgf m 21 4 ft lb 6 N m 0 6 kgf m 4 4 ft lb 1 2 3 9 7 12 13 6 7 11 10 8 4 5 11 10 12 9 8 6 7 7 13 14 15 16 18 17 19 20 21 22 29 23 24 25 26 27 28 30 24 23 22 ...

Page 385: ...g assembly 8 16 Checking the propeller shaft housing 1 Check the water pipe Replace if cor roded deformed or cracked 2 Check the propeller shaft housing and reverse gear See Checking the propel ler shaft housing 8 17 Checking the propeller shaft 1 Check the propeller shaft See Checking the propeller shaft 8 17 Assembling the propeller shaft assembly 1 Assemble the propeller shaft assembly See Asse...

Page 386: ...LOWR Lower unit 8 23 2 Install the rubber seal 1 1 ...

Page 387: ... 6 Bolt 4 M8 25 mm 7 Oil seal 2 39 39 39 39 8 Cover 1 9 Drive shaft 1 10 Lower case 1 11 Forward gear shim T1 12 Taper roller bearing 1 39 39 39 39 13 Forward gear 1 14 Needle bearing 1 39 39 39 39 15 Pinion 1 16 Washer 1 17 Pinion nut 1 8 7 6 5 4 3 2 1 9 10 11 14 15 16 17 12 13 6 6 142 N m 14 2 kgf m 104 7 ft lb Propeller shaft housing F250G Drive shaft and lower case F200B ...

Page 388: ...e the taper roller bearing Disassembling the lower case Use heat resistant gloves Otherwise burns could result To prevent fires remove any flammable substances such as gasoline and oil around the working area Keep good ventilation while working 1 Remove the needle bearing Drive shaft holder 6 1 90890 06520 Pinion nut holder 2 90890 06715 2 1 2 1 2 3 4 3 4 Needle bearing attachment 3 90890 06610 Dr...

Page 389: ... not come out lightly tap the lower unit tor pedo using 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 Checking the lower case 1 Check the lower case Replace if cracked or damaged Assembling the lower case Use heat resis...

Page 390: ...always replace it with a new one 1 Install a new taper roller bearing Assembling the oil seal housing Do not reuse a bearing or oil seal always replace it with a new one 1 Install a new needle bearing to the speci fied depth a Driver rod LL 3 90890 06605 Bearing inner race attachment 4 90890 06658 1 2 3 3 4 4 6 7 5 Ball bearing attachment 6 90890 06655 Bearing outer race puller assembly 7 90890 06...

Page 391: ... and washer and then tighten the pinion nut temporarily TIP When installing the pinion lift up the drive shaft slightly and align the splines on the drive shaft with the splines on the pinion 4 Install a new O ring 4 to the oil seal housing 5 and then install the oil seal housing 5 TIP Make sure to install the oil seal housing 5 so that the notch a is facing forward 5 Tighten the pinion nut to the...

Page 392: ...o the specified torque 5 Install the cover 7 6 Install the water inlet covers 8 and then tighten the water inlet cover screw 9 to the specified torque Installing the shift rod Do not reuse an oil seal or O ring always replace it with a new one 1 Check that the shift rod joint is in the N position and then install the shift rod 1 the spring 2 a new O ring 3 the plate 4 and a new oil seal 5 Drive sh...

Page 393: ... Install the Woodruff key 4 3 Align the slot a on the impeller 5 with the Woodruff key 4 and then install the impeller 5 4 Install the washers 6 wave washer 7 spacer 8 and collar 9 TIP The spacer 8 and collar 9 should fit together firmly 5 Install the water pump assembly 0 NOTICE Do not turn the drive shaft counterclockwise Otherwise the water pump impeller could be dam aged 1 a b 5 3 2 4 3 2 1 1 ...

Page 394: ...he outboard motor could fall suddenly and result in severe injuries When loosening or tightening the pro peller nut do not hold the propeller using your hands 1 Align the pin a on the shift lever with the alignment mark b on the bottom cowl ing 2 Set the gear shift to the N position 3 Install the dowels 2 4 Install the extension 3 U transom model and lower unit 4 and then tighten the lower case mo...

Page 395: ...TIP If the slots in the propeller nut A are not aligned with the cotter pin hole tighten the propeller nut A until they are aligned 8 Fill the lower unit with gear oil up to the proper level See steps 5 8 in Changing gear oil 10 11 Lower case mounting bolt 5 47 N m 4 7 kgf m 34 7 ft lb Lower case mounting nut 6 47 N m 4 7 kgf m 34 7 ft lb Trim tab bolt 8 42 N m 4 2 kgf m 31 0 ft lb È 2 2 6 5 7 8 4...

Page 396: ...39 39 39 39 5 Oil seal housing 1 6 Bolt 4 M8 25 mm 7 Oil seal 2 39 39 39 39 8 Cover 1 9 Drive shaft 1 10 Lower case 1 11 Washer 1 12 Spring 1 13 Thrust bearing 1 14 Forward gear shim T1 15 Taper roller bearing 1 39 39 39 39 16 Forward gear 1 17 Needle bearing 1 39 39 39 39 8 7 6 5 4 3 2 1 9 13 12 11 10 14 17 18 19 20 15 16 6 6 142 N m 14 2 kgf m 104 7 ft lb ...

Page 397: ...8 34 8 No Part name Q ty Remarks 18 Pinion 1 19 Washer 1 20 Pinion nut 1 8 7 6 5 4 3 2 1 9 13 12 11 10 14 17 18 19 20 15 16 6 6 142 N m 14 2 kgf m 104 7 ft lb Drive shaft and lower case F250G ...

Page 398: ...semble the lower case See Assem bling the lower case 8 26 Assembling the forward gear 1 Assemble the forward gear See Assem bling the forward gear 8 27 Assembling the oil seal housing 1 Assemble the oil seal housing See Assembling the oil seal housing 8 27 Installing the drive shaft 1 Install the forward gear assembly into the lower case 2 Install the washer 1 spring 2 thrust bearing 3 drive shaft...

Page 399: ... Installing the shift rod 8 29 Installing the water pump 1 Install the water pump See steps 1 3 and 5 in Installing the water pump 8 30 Checking the lower unit for air leakage 1 Check the lower unit for air leakage See Checking the lower unit for air leakage 8 31 Installing the lower unit 1 Install the extension U transom model lower unit trim tab and propeller See steps 1 7 in Installing the lowe...

Page 400: ...rive shaft or propeller shaft housing shimming is required NO YES Shimming is not required YES NO Within specification Disassemble the lower unit Select the pinion shims T3 F200B Select the pinion shims T3 and propeller shaft shim T4 F250G Assemble the lower unit Measure the backlash Adjust the forward gear shim T1 thickness and reverse gear shim T2 thickness Install the water pump assem bly Withi...

Page 401: ...Measuring point 3 Measuring point 4 Average Round down average M Measurements Before disassembly After disassembly Measuring point 1 Measuring point 2 Measuring point 3 Measuring point 4 Average Round down average Measurements Before disassembly After disassembly Measuring point 1 Measuring point 2 Measuring point 3 Measuring point 4 Average Round down average Shimming regular rotation model ...

Page 402: ...shim T1 thickness measurement in 2 places mm Reverse gear shim T2 thickness measurement in 2 places mm Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total ...

Page 403: ...drive shaft 10 times or more to seat the taper roller bearing 6 Tighten the center bolt 4 to the specified torque while holding the drive shaft not to turn 7 Turn the lower unit so that it is in an upright position 8 Remove the cover 5 and then install the outer plate cartridge 6 9 Place the spring 7 on the outer plate cartridge and then install the handle holder 8 so that the spring 7 is com pres...

Page 404: ...he spring makes it difficult to turn the drive shaft Therefore to obtain correct measurements consider the spring resistance force when turning the drive shaft Do not turn the drive shaft using too much force Otherwise the forward gear will turn leading to incorrect measurements When turning the drive shaft hold it using a little force A knocking sound may be heard when the drive shaft is turned b...

Page 405: ... speci fied torque 19 Repeat steps 13 and 14 to measure the reverse gear backlash 20 Check that the reverse gear backlash average is within specification TIP Adjust the shim thicknesses if the reverse gear backlash is out of specification 21 Remove the special service tools handle holder spring and outer plate cartridge and then install the cover outer plate cartridge and water pump assembly See I...

Page 406: ... pinion shims T3 When assembling the lower unit to measure the backlash after selecting the pinion shims T3 do not apply gear oil grease or sealant to the parts When assembling the lower unit after shimming is completed make sure to apply gear oil grease and sealant to the specified areas Shim location F200B P F R T3 T1 T2 ...

Page 407: ...8 44 8 Shim location F250G P F R T3 T1 T2 T4 Shimming regular rotation model ...

Page 408: ...3 sometimes become affixed to the thrust bearing outer race Make sure to install the thrust bearing outer race so that it is facing the same direction as when it was removed Make sure that the notch a in the oil seal housing is facing the opposite side from the plate b of the special service tool 1 2 Tighten the oil seal housing bolts 4 3 Install the pinion 5 washer 6 and pin ion nut 7 and then ti...

Page 409: ...cial service tool 1 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 5 so that it does not lift up and then measure the gap between the pinion 5 and the spe cial service tool 1 When measuring the gap insert the end of the thickness gauge 0 straight into the gap at the measurement point Do not insert the thickness gauge at ...

Page 410: ...ower case Example Pinion height measurement M 0 18 mm k Deviation P 10 m Use the determined shim thickness of 1 12 mm instead of the current shim thickness È Pinion height measurement M É Deviation P TIP The deviation P is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the value is unreadable replace the lower case 12 Remove the special service tool and then install...

Page 411: ...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 È 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 É 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 1 05 1 05 1 05 1 02 11 1 15 1 15 1 15 1 12 1 12 1 12 ...

Page 412: ...5 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 È 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 É 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 85 0 82 0 8...

Page 413: ...d then install the selected propeller shaft shim Measuring the forward gear backlash Spray anti rust lubricant on the gears and bearings before installation Do not apply gear oil to the parts Otherwise correct measurements cannot be obtained Keep the parts free of foreign material such as dirt and lint When measuring the forward gear or reverse gear backlash use the original bearings and shims 1 I...

Page 414: ... Remove the propeller shaft housing assembly and propeller shaft assembly See Removing the propeller shaft hous ing assembly 8 16 F200B See Removing the propeller shaft housing assembly 8 22 F250G 2 Remove the oil seal housing pinion drive shaft and forward gear assembly See Removing the drive shaft 8 25 F200B See step 1 in Removing the drive shaft 8 25 and steps 2 and 3 in Removing the drive shaf...

Page 415: ...ints marked on the chart 6 Calculate the new forward gear shim T1 thickness Calculation formula New forward gear shim T1 thickness Current forward gear shim thickness Shim thickness adjustment Example Use the following formula when the shim thickness adjustment value is negative Current forward gear shim thickness 0 42 mm Shim thickness adjustment 0 12 mm New forward gear shim T1 thickness 0 42 mm...

Page 416: ... thickness adjustment 0 32 0 28 0 25 0 22 0 18 0 15 0 18 0 20 0 24 0 28 0 31 0 35 0 38 1 20 1 00 0 80 0 60 0 40 0 20 0 20 0 0 40 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 mm 1 100 mm É É È È Continue next page ...

Page 417: ... 135 130 125 120 115 110 105 145 100 200 195 190 185 180 175 170 165 160 155 150 140 135 130 125 120 115 110 105 145 0 38 0 43 0 46 0 50 0 53 0 57 0 60 0 64 0 67 0 70 0 74 0 77 0 81 0 85 0 88 0 92 0 95 0 99 1 02 1 06 1 09 1 20 1 00 0 80 0 60 0 40 0 20 0 0 20 0 40 mm 1 100 mm É È È É Shimming regular rotation model ...

Page 418: ...the dog clutch and O ring 3 Check that the drive shaft turns smoothly 4 Measure the reverse gear backlash See steps 17 20 in Measuring the forward gear backlash and reverse gear backlash before disassembly 8 40 TIP In the Reverse gear shim T2 selection chart use the round down average for the backlash measurement BL2 Adjusting the reverse gear shim T2 thickness 1 Remove the propeller shaft housing...

Page 419: ... Calculate the new reverse gear shim T2 thickness Calculation formula New reverse gear shim T2 thickness Current reverse gear shim thickness Shim thickness adjustment Example Use the following formula when the shim thickness adjustment value is negative Current reverse gear shim thickness 1 25 mm Shim thickness adjustment 0 20 mm New reverse gear shim T2 thickness 1 25 mm 0 20 mm 1 05 mm TIP Use t...

Page 420: ...nt BL2 É Shim thickness adjustment mm 1 100 mm 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 1 20 1 00 0 80 0 60 0 40 0 20 0 0 20 0 40 0 35 0 32 0 27 0 24 0 20 0 30 0 34 0 38 É É È È Continue next page ...

Page 421: ... 135 130 125 120 115 110 105 145 100 200 195 190 185 180 175 170 165 160 155 150 140 135 130 125 120 115 110 105 145 mm 1 100 mm 1 20 1 00 0 80 0 60 0 40 0 20 0 0 20 0 40 0 38 0 41 0 45 0 48 0 52 0 55 0 58 0 63 0 65 0 69 0 73 0 76 0 80 0 84 0 87 0 91 0 94 1 01 1 01 1 05 1 07 É É È È Shimming regular rotation model ...

Page 422: ...ler 1 11 Cotter pin 1 39 39 39 39 12 Propeller nut 1 13 Washer 1 14 Spacer 1 15 Trim tab 1 16 Bolt 1 M10 70 mm X transom model 17 Bolt 7 M10 45 mm X transom model 55 N m 5 5 kgf m 40 6 ft Ib 42 N m 4 2 kgf m 31 0 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 47 N m 4 7 kgf m 34 7 ft lb 9 15 17 18 17 8 10 11 12 14 13 17 16 4 5 3 1 3 2 1 6 7 24 23 19 20 21 22 ...

Page 423: ...he flat end of the stud bolt up 26 Rubber seal 1 U transom model 27 Extension 1 U transom model 28 Bolt 1 M10 200 mm U transom model 29 Bolt 1 M10 175 mm U transom model 30 Nut 6 U transom model 31 Washer 6 U transom model 55 N m 5 5 kgf m 40 6 ft Ib 42 N m 4 2 kgf m 31 0 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 47 N m 4 7 kgf m 34 7 ft lb 9 15 17 18 17...

Page 424: ...l See steps 2 6 in Removing the lower unit 8 3 TIP When disassembling the lower unit measure the backlash before disassembly See Mea suring the forward gear backlash and reverse gear backlash before disassembly 8 93 Checking the propeller 1 Check the propeller See Checking the propeller 8 3 Checking the lower unit anode 1 Check the trim tab See Checking the lower unit anode 8 3 ...

Page 425: ...39 39 39 12 Propeller nut 1 13 Washer 1 14 Spacer 1 15 Trim tab 1 16 Bolt 1 M10 70 mm X transom model 17 Bolt 7 M10 45 mm X transom model 55 N m 5 5 kgf m 40 6 ft Ib 42 N m 4 2 kgf m 31 0 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 47 N m 4 7 kgf m 34 7 ft lb 9 15 17 18 17 8 10 11 12 14 13 17 16 6 7 3 4 5 3 1 24 23 1 2 19 20 21 22 31 30 29 27 24 25 26 È 28...

Page 426: ...om model Point the flat end of the stud bolt up 26 Rubber seal 1 U transom model 27 Extension 1 U transom model 28 Bolt 1 M10 200 mm U transom model 29 Bolt 1 M10 175 mm U transom model 30 Nut 6 U transom model 31 Washer 6 U transom model 55 N m 5 5 kgf m 40 6 ft Ib 42 N m 4 2 kgf m 31 0 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 47 N m 4 7 kgf m 34 7 ft ...

Page 427: ...in Removing the lower unit 8 3 TIP When disassembling the lower unit measure the backlash before disassembly See Mea suring the forward gear backlash and reverse gear backlash before disassembly 8 93 Checking the propeller 1 Check the propeller See Checking the propeller 8 3 Checking the lower unit anode 1 Check the trim tab See Checking the lower unit anode 8 3 Lower unit FL250G ...

Page 428: ...3 M6 20 mm 4 Oil seal 1 39 39 39 39 5 Plate 1 6 O ring 1 39 39 39 39 7 Spring 1 8 E clip 1 9 Woodruff key 1 10 Dowel 2 11 Gasket 1 39 39 39 39 12 Outer plate cartridge 1 13 Impeller 1 14 Washer 2 15 Wave washer 1 16 Spacer 1 17 Collar 1 3 3 5 4 6 7 8 2 9 1 11 12 13 17 16 14 15 14 20 20 23 18 19 24 10 10 21 22 ...

Page 429: ... O ring 1 39 39 39 39 19 Water pump housing 1 20 Bolt 4 M8 45 mm 21 Cover 1 22 Seal 1 23 Insert cartridge 1 24 O ring 1 39 39 39 39 3 3 5 4 6 7 8 2 9 1 11 12 13 17 16 14 15 14 20 20 23 18 19 24 10 10 21 22 Water pump and shift rod FL200B ...

Page 430: ...p and shift rod 8 9 2 Remove the plate 1 oil seal 2 O ring 3 and shift rod 4 Disassembling the water pump housing 1 Disassemble the water pump housing See Disassembling the water pump housing 8 9 Checking the water pump and shift rod 1 Check the water pump and shift rod See Checking the water pump and shift rod 8 9 Assembling the water pump housing 1 Assemble the water pump housing See Assembling ...

Page 431: ...1 6 O ring 1 39 39 39 39 7 Spring 1 8 E clip 1 9 Woodruff key 1 10 Dowel 2 11 Gasket 1 39 39 39 39 12 Outer plate cartridge 1 13 Impeller 1 14 O ring 1 39 39 39 39 15 Water pump housing 1 16 Bolt 4 M8 45 mm 17 Cover 1 2 1 11 12 13 16 16 19 14 15 20 7 8 9 10 10 17 18 3 3 5 4 6 Water pump and shift rod FL200B Water pump and shift rod FL250G ...

Page 432: ...LOWR Lower unit 8 69 No Part name Q ty Remarks 18 Seal 1 19 Insert cartridge 1 20 O ring 1 39 39 39 39 2 1 11 12 13 16 16 19 14 15 20 7 8 9 10 10 17 18 3 3 5 4 6 ...

Page 433: ...d 8 9 2 Remove the plate oil seal O ring and shift rod See step 2 in Removing the water pump and shift rod 8 67 Disassembling the water pump housing 1 Disassemble the water pump housing See Disassembling the water pump housing 8 9 Checking the water pump and shift rod 1 Check the water pump and shift rod See Checking the water pump and shift rod 8 9 Assembling the water pump housing 1 Assemble the...

Page 434: ... Ring nut 1 10 Forward gear shim T2 11 Cross pin 1 12 Dog clutch 1 13 Shift plunger 1 14 Screw 1 M5 53 mm 15 Water inlet cover PORT 1 16 Taper roller bearing 1 39 39 39 39 17 Propeller shaft 1 1 N m 0 1 kgf m 0 7 ft lb 17 14 15 1 2 3 4 13 12 11 10 9 5 4 6 7 20 22 28 20 21 26 23 24 27 19 16 18 6 4 13 5 3 4 12 11 17 25 8 22 23 108 N m 10 8 kgf m 79 7 ft lb 29 N m 2 9 kgf m 21 4 ft lb 6 N m 0 6 kgf m...

Page 435: ... mm 24 Needle bearing 1 39 39 39 39 25 Oil seal 2 39 39 39 39 26 Bolt 2 M8 20 mm 27 Cover 1 28 Grease nipple 1 1 N m 0 1 kgf m 0 7 ft lb 17 14 15 1 2 3 4 13 12 11 10 9 5 4 6 7 20 22 28 20 21 26 23 24 27 19 16 18 6 4 13 5 3 4 12 11 17 25 8 22 23 108 N m 10 8 kgf m 79 7 ft lb 29 N m 2 9 kgf m 21 4 ft lb 6 N m 0 6 kgf m 4 4 ft lb L Propeller shaft housing FL200B ...

Page 436: ...the propeller shaft assembly 8 16 2 Remove the forward gear and forward gear shims 3 Install the propeller shaft housing assem bly 2 in the reverse direction into the lower case 4 Remove the ring nut 3 and claw washer 4 5 Remove the taper roller bearing 6 thrust bearing 7 and propeller shaft shims 8 NOTICE Do not press the threads a of the propeller shaft directly Slide hammer handle 1 90890 06531...

Page 437: ... Assembling the propeller shaft housing assembly Use heat resistant gloves Otherwise burns could result To prevent fires remove any flammable substances such as gasoline and oil around the working area Keep good ventilation while working Do not reuse a bearing always replace it with a new one 1 Install a new needle bearing and oil seals See steps 1 and 2 in Assembling the propeller shaft housing a...

Page 438: ...6 strike it to check that the taper roller bearing outer race is installed properly TIP If a high pitched metallic sound is produced when the special service tool is struck the taper roller bearing outer race is installed properly 6 Install the claw washer 7 and ring nut 8 and then tighten the ring nut 8 to the specified torque 7 Install the original forward gear shims 9 and forward gear 0 using t...

Page 439: ...joint E TIP When installing the slider C make sure that the balls D do not fall out of position 9 Align the hole b in the dog clutch A with the hole c in the propeller shaft 10 Install the cross pin F and then install the spring G TIP Make sure to face the F mark a on the dog clutch A toward the forward gear B B C C D D D D E E A A F F G G a b c Propeller shaft housing FL200B ...

Page 440: ...2 8 Slider 1 9 Spring 1 10 Forward gear 1 11 Claw washer 1 12 Ring nut 1 13 Forward gear shim T2 14 Cross pin 1 15 Dog clutch 1 16 Shift plunger 1 17 Screw 1 M5 53 mm 1 N m 0 1 kgf m 0 7 ft lb 20 17 18 1 2 6 7 16 15 14 13 12 8 7 9 10 19 21 11 L 108 N m 10 8 kgf m 79 7 ft lb 29 N m 2 9 kgf m 21 4 ft lb 9 7 16 8 6 7 15 14 20 3 5 4 23 26 25 32 23 24 30 27 28 31 22 33 29 26 27 6 N m 0 6 kgf m 4 4 ft l...

Page 441: ...bber seal 1 26 Washer 2 27 Bolt 2 M8 33 mm 28 Needle bearing 1 39 39 39 39 29 Oil seal 2 39 39 39 39 30 Bolt 2 M8 20 mm 31 Cover 1 32 Grease nipple 1 33 Dowel 1 1 N m 0 1 kgf m 0 7 ft lb 20 17 18 1 2 6 7 16 15 14 13 12 8 7 9 10 19 21 11 L 108 N m 10 8 kgf m 79 7 ft lb 29 N m 2 9 kgf m 21 4 ft lb 9 7 16 8 6 7 15 14 20 3 5 4 23 26 25 32 23 24 30 27 28 31 22 33 29 26 27 6 N m 0 6 kgf m 4 4 ft lb Prop...

Page 442: ...g See steps 3 and 4 in Disassembling the propeller shaft housing assembly 8 16 Checking the propeller shaft housing 1 Check the water pipe Replace if cor roded deformed or cracked 2 Check the propeller shaft housing and forward gear See Checking the propel ler shaft housing 8 74 Checking the propeller shaft 1 Check the propeller shaft See Checking the propeller shaft 8 74 Assembling the propeller ...

Page 443: ...25 mm 7 Oil seal 2 39 39 39 39 8 Cover 1 9 Drive shaft 1 10 Lower case 1 11 Reverse gear shim T1 12 Retainer 1 13 Needle bearing 1 39 39 39 39 14 Thrust bearing 1 15 Reverse gear 1 16 Needle bearing 1 39 39 39 39 17 Circlip 1 39 39 39 39 8 7 6 5 4 3 2 1 9 10 18 16 15 13 12 11 17 21 20 19 14 6 6 142 N m 14 2 kgf m 104 7 ft lb Propeller shaft housing FL250G Drive shaft and lower case FL200B ...

Page 444: ...R Lower unit 8 81 No Part name Q ty Remarks 18 Needle bearing 1 39 39 39 39 19 Pinion 1 20 Washer 1 21 Pinion nut 1 8 7 6 5 4 3 2 1 9 10 18 16 15 13 12 11 17 21 20 19 14 6 6 142 N m 14 2 kgf m 104 7 ft lb ...

Page 445: ...orking 1 Remove the needle bearing See step 1 in Disassembling the lower case 8 25 TIP Before removing the needle bearing make sure to remove the reverse gear 2 Heat the installation area of the retainer in the lower case using a gas torch and then remove the retainer 1 and reverse gear shims 2 NOTICE When heating the lower case heat the entire installa tion area evenly Otherwise the paint on the ...

Page 446: ...ecified depth a 2 Install the original reverse gear shims 4 3 Heat the installation area of the retainer in the lower case using a gas torch and then install the retainer 5 NOTICE When heating the lower case heat the entire installation area evenly Other wise the paint on the lower case could be burned TIP Do not reuse a shim if deformed or scratched Align the notches b in the retainer 5 with the ...

Page 447: ...assembly Do not reuse an O ring always replace it with a new one 1 Install new O rings to the propeller shaft housing 2 Set the shift rod joint 1 and dog clutch 2 to the N position 3 Install the propeller shaft housing assem bly cover and water inlet covers See steps 4 6 in Installing the propeller shaft housing assembly 8 29 Installing the shift rod Do not reuse an oil seal or O ring always repla...

Page 448: ... 30 Checking the lower unit for air leakage 1 Check the lower unit for air leakage See Checking the lower unit for air leakage 8 31 Installing the lower unit 1 Install the extension U transom model lower unit trim tab and propeller See steps 1 7 in Installing the lower unit 8 31 2 Fill the lower unit with gear oil up to the proper level See steps 5 8 in Changing gear oil 10 11 1 5 3 2 4 a b ...

Page 449: ...Bolt 4 M8 25 mm 7 Oil seal 2 39 39 39 39 8 Cover 1 9 Drive shaft 1 10 Lower case 1 11 Washer 1 12 Spring 1 13 Thrust bearing 1 14 Reverse gear shim T1 15 Retainer 1 16 Needle bearing 1 39 39 39 39 17 Thrust bearing 1 8 7 6 5 4 3 2 1 9 13 12 11 10 21 19 18 16 15 14 20 24 23 22 17 6 6 142 N m 14 2 kgf m 104 7 ft lb Drive shaft and lower case FL200B Drive shaft and lower case FL250G ...

Page 450: ...s 18 Reverse gear 1 19 Needle bearing 1 39 39 39 39 20 Circlip 1 39 39 39 39 21 Needle bearing 1 39 39 39 39 22 Pinion 1 23 Washer 1 24 Pinion nut 1 8 7 6 5 4 3 2 1 9 13 12 11 10 21 19 18 16 15 14 20 24 23 22 17 6 6 142 N m 14 2 kgf m 104 7 ft lb ...

Page 451: ...bearing the original reverse gear shim and retainer See steps 1 4 in Assembling the lower case 8 83 2 Install a new needle bearing See step 4 in Assembling the lower case 8 26 Assembling the reverse gear 1 Assemble the reverse gear See Assem bling the reverse gear 8 84 Assembling the oil seal housing 1 Assemble the oil seal housing See Assembling the oil seal housing 8 27 Installing the drive shaf...

Page 452: ...ge See Checking the lower unit for air leakage 8 31 Installing the lower unit 1 Install the extension U transom model lower unit trim tab and propeller See steps 1 7 in Installing the lower unit 8 31 2 Fill the lower unit with gear oil up to the proper level See steps 5 8 in Changing gear oil 10 11 ...

Page 453: ...er shaft housing shimming is required NO YES Shimming is not required YES NO Within specification Disassemble the lower unit Select the pinion shims T3 and propeller shaft shims T4 Assemble the lower unit Measure the backlash Adjust the forward gear shim T2 thickness and reverse gear shim T1 thickness Install the water pump assem bly Within specification Remove the water pump assembly Measure the ...

Page 454: ...nt 1 Measuring point 2 Measuring point 3 Measuring point 4 Average Round down average M Measurements Before disassembly After disassembly Measuring point 1 Measuring point 2 Measuring point 3 Measuring point 4 Average Round down average Measurements Before disassembly After disassembly Measuring point 1 Measuring point 2 Measuring point 3 Measuring point 4 Average Round down average ...

Page 455: ...rement in 2 places mm Reverse gear shim T1 thickness measurement in 2 places mm Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total Shimming counter rotation model ...

Page 456: ...special service tools 2 3 and 4 and then tighten the center bolt 4 temporarily 4 Turn the drive shaft 10 times or more to seat the bearings 5 Tighten the center bolt 4 to the specified torque while holding the drive shaft not to turn 6 Turn the lower unit so that it is in an upright position 7 Remove the cover 5 and then install the outer plate cartridge 6 8 Place the spring 7 on the outer plate c...

Page 457: ...icult to turn the drive shaft Therefore to obtain correct measurements consider the spring resistance force when turning the drive shaft Do not turn the drive shaft using too much force Otherwise the forward gear will turn leading to incorrect measurements When turning the drive shaft hold it using a little force A knocking sound may be heard when the drive shaft is turned but this is the sound of...

Page 458: ...bly 8 73 FL200B See steps 1 and 2 in Remov ing the propeller shaft housing assembly 8 22 and step 2 in Removing the pro peller shaft housing assembly 8 79 FL250G 17 Install the washers C between the reverse gear D and the propeller shaft E 18 Install the propeller shaft housing assem bly without the O ring and dog clutch See step 2 in Installing the propeller shaft housing assembly 8 84 and step 4...

Page 459: ...ep 2 in Removing the propeller shaft hous ing assembly 8 22 and step 2 in Removing the propeller shaft housing assembly 8 79 FL250G 24 Install the propeller shaft housing assem bly See step 2 in Installing the propeller shaft housing assembly 8 84 and steps 4 and 5 in Installing the propeller shaft housing assembly 8 29 FL200B See step 2 in Installing the propeller shaft housing assembly 8 84 and ...

Page 460: ...inion shims T3 When assembling the lower unit to measure the backlash after selecting the pinion shims T3 do not apply gear oil grease or sealant to the parts When assembling the lower unit after shimming is completed make sure to apply gear oil grease and sealant to the specified areas Shim location FL200B F R P T3 T4 T2 T1 ...

Page 461: ...8 98 8 Shim location FL250G F R P T3 T4 T2 T1 Shimming counter rotation model ...

Page 462: ...P 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 thick ness must be decreased by that amount The gray colored cells on the selection table indicate the specified propeller shaft free play Shimming is not required if the measured propeller shaft free play is 0 25 0 35 mm The values for the ...

Page 463: ...propeller shaft assembly See steps 2 5 in Disassembling the pro peller shaft housing assembly 8 73 7 Install the selected propeller shaft shims T4 and then assemble the propeller shaft housing See steps 2 10 in Assembling the propeller shaft housing assembly 8 74 Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 0 50 mm Shimming counter rotation model ...

Page 464: ... 46 0 48 0 50 0 52 É 0 10 0 10 0 10 0 10 0 12 0 15 0 15 0 18 0 20 È 0 54 0 56 0 58 0 60 0 62 0 64 0 66 0 68 0 70 É 0 22 0 25 0 25 0 28 0 30 0 32 0 35 0 35 0 38 È 0 72 0 74 0 76 0 78 0 80 0 82 0 84 0 86 0 88 É 0 40 0 42 0 45 0 45 0 48 0 50 0 52 0 55 0 55 È 0 90 0 92 0 94 0 96 0 98 1 00 1 02 1 04 1 06 É 0 58 0 60 0 62 0 65 0 65 0 68 0 72 0 72 0 75 È 1 08 1 10 1 12 1 14 1 16 1 18 1 20 1 22 1 24 É 0 7...

Page 465: ... gear backlash See steps 2 14 in Measuring the forward gear backlash and reverse gear backlash before disassembly 8 93 TIP In the Forward gear shim T2 selection chart use the round down average for the backlash measurement BL2 Adjusting the forward gear shim T2 thickness 1 Remove the propeller shaft housing assembly See step 1 in Removing the propeller shaft housing assembly 8 16 and step 2 in Rem...

Page 466: ... the chart 5 Calculate the new forward gear shim T2 thickness Calculation formula New forward gear shim T2 thickness Current forward gear shim thickness Shim thickness adjustment Example Use the following formula when the shim thickness adjustment value is negative Current forward gear shim thickness 1 12 mm Shim thickness adjustment 0 20 mm New forward gear shim T2 thickness 1 12 mm 0 20 mm 0 92 ...

Page 467: ...0 32 0 28 0 24 0 20 0 16 0 13 0 04 0 07 0 03 0 01 0 04 0 08 0 11 0 15 0 18 0 23 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 0 26 100 1 00 mm 0 80 0 60 0 40 0 20 0 0 20 0 40 0 60 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 1 100 mm É É È È Continue next page Shimming counter rotation model ...

Page 468: ...135 145 150 155 160 165 170 175 180 185 190 195 200 140 1 00 0 80 0 60 0 40 0 20 0 0 20 0 40 0 60 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 0 26 0 29 0 34 0 36 0 40 0 43 0 46 0 50 0 54 0 56 0 60 0 64 0 68 0 71 0 75 0 78 0 82 0 86 0 89 0 93 0 96 mm 1 100 mm É É È È ...

Page 469: ...mbly 8 84 and step 4 in Installing the propeller shaft housing assembly 8 35 FL250G 6 Check that the drive shaft turns smoothly 7 Measure the reverse gear backlash See steps 12 13 and 21 in Measuring the forward gear backlash and reverse gear backlash before disassembly 8 93 TIP In the Reverse gear shim T1 selection chart use the round down average for the backlash measurement BL1 Adjusting the re...

Page 470: ...ments for the points marked on the chart 5 Calculate the new reverse gear shim T1 thickness Calculation formula New reverse gear shim T1 thickness Current reverse gear shim thickness Shim thickness adjustment Example Use the following formula when the shim thickness adjustment value is negative Current reverse gear shim thickness 0 65 mm Shim thickness adjustment 0 23 mm New reverse gear shim T1 t...

Page 471: ...ustment 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 1 00 0 80 0 60 0 40 0 20 0 0 20 0 40 0 60 0 43 0 40 0 37 0 33 0 30 0 25 0 22 0 18 0 15 0 28 mm 1 100 mm É É È È Continue next page Shimming counter rotation model ...

Page 472: ...135 145 150 155 160 165 170 175 180 185 190 195 200 140 1 00 0 80 0 60 0 40 0 20 0 0 20 0 40 0 60 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 0 28 0 32 0 34 0 38 0 42 0 45 0 48 0 53 0 56 0 59 0 63 0 68 0 70 0 73 0 77 0 81 0 84 0 88 0 91 0 95 0 98 mm 1 100 mm É É È È ...

Page 473: ...8 110 8 MEMO Shimming counter rotation model ...

Page 474: ...moving the upper case 9 16 Installing the upper case 9 16 Upper case 9 18 Disassembling the upper case 9 20 Checking the drive shaft bushing 9 20 Checking the PCV 9 20 Assembling the upper case 9 20 Oil pan and exhaust manifold 9 22 Disassembling the oil pan and exhaust manifold 9 24 Checking the oil pan and exhaust manifold 9 24 Checking the oil strainer 9 24 Assembling the oil pan and exhaust ma...

Page 475: ... PTT motor 9 49 PTT gear pump 9 50 Disassembling the gear pump assembly 9 53 Checking the gear pump 9 53 Assembling the gear pump assembly 9 54 PTT cylinder 9 56 Removing the tilt ram 9 59 Removing the trim ram 9 59 Disassembling the tilt ram 9 59 Disassembling the trim ram 9 60 Checking the tilt cylinder and PTT body 9 60 Checking the valve 9 60 Assembling the tilt ram 9 61 Assembling the trim ra...

Page 476: ...t cut switch 1 8 Bolt 2 M6 35 mm 9 Holder 1 10 Spring 1 11 Bushing 2 12 Bracket 1 13 Grease nipple 1 14 Bolt 1 15 Washer 1 16 Clip 2 17 Bushing 1 29 28 15 18 16 16 23 24 25 26 20 19 17 20 27 1 2 3 4 5 1 1 2 7 8 9 10 11 11 14 12 13 22 6 21 1 N m 0 1 kgf m 0 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 19 N m 1 9 kgf m 14 0 ft Ib ...

Page 477: ... rod detent bolt 1 26 Pin 1 27 Cotter pin 1 39 39 39 39 28 Shift rod 1 29 Grommet 1 29 28 15 18 16 16 23 24 25 26 20 19 17 20 27 1 2 3 4 5 1 1 2 7 8 9 10 11 11 14 12 13 22 6 21 1 N m 0 1 kgf m 0 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 19 N m 1 9 kgf m 14 0 ft Ib Shift rod and shift bracket ...

Page 478: ...ushing 7 4 Remove the shift rod assembly c and grommet 8 5 Remove the shift rod detent bolt 9 spring 0 and ball A 6 Remove the cotter pin B washer C bracket D and bushings E Disassembling the shift bracket 1 Remove the bracket 1 spring 2 and bushings 3 2 Remove the plastic tie 4 and then remove the plate 5 and neutral switch 6 3 Remove the plate 7 and shift cut switch 8 4 Remove the grease nipple ...

Page 479: ...e bracket B 7 Turn the bracket B to position d push it down and then tighten the shift bracket bolt C to the specified torque NOTICE Before pushing the bracket B down move the shift cut switch lever e in direction f Otherwise the lever could be damaged Installing the shift rod and shift bracket 1 Install the bushings 1 bracket 2 and washer 3 and then install a new cotter pin 4 2 Install the ball 5...

Page 480: ...n the center of the pin b on the shift lever 9 with the mark c on the bottom cowling 5 Install the washer B shift bracket assembly d and holder C and then install the bushing D and clip E to the shift lever 9 6 Install the shift switch coupler e Shift rod detent bolt 7 18 N m 1 8 kgf m 13 3 ft lb A 0 9 5 4 3 1 1 4 2 6 7 c b 9 b 8 0 a A E 9 D d B C e ...

Page 481: ... Spring 3 8 Bolt 3 M6 20 mm 9 Washer 3 10 Lever 3 11 Wave washer 3 12 Bushing 6 13 Housing BOW 1 14 Bolt 6 M6 30 mm 15 Housing STBD 1 16 Housing PORT 1 6 7 5 È È 33 14 19 12 18 12 12 13 10 11 9 5 14 6 32 31 15 5 37 31 12 11 32 6 7 9 10 5 7 6 5 16 12 9 10 8 11 8 2 25 26 24 23 20 22 21 1 1 5 7 4 27 29 3 20 20 5 5 4 12 17 3 1 1 2 35 36 8 34 30 28 20 5 N m 3 7 ft lb m 0 5 kgf Shift rod and shift brack...

Page 482: ...Grommet 1 22 Hose 1 23 Joint 1 24 Joint 1 25 Gasket 1 26 Adapter 1 27 Hose 1 28 Joint 1 29 Hose 1 30 Clamp 1 31 Bolt 2 M6 25 mm 32 Plate 2 33 Screw 2 ø6 20 mm 6 7 5 È È 33 14 19 12 18 12 12 13 10 11 9 5 14 6 32 31 15 5 37 31 12 11 32 6 7 9 10 5 7 6 5 16 12 9 10 8 11 8 2 25 26 24 23 20 22 21 1 1 5 7 4 27 29 3 20 20 5 5 4 12 17 3 1 1 2 35 36 8 34 30 28 20 5 N m 3 7 ft lb m 0 5 kgf ...

Page 483: ...del 36 Holder 1 Counter rotation model 37 Holder 1 Regular rotation model 6 7 5 È È 33 14 19 12 18 12 12 13 10 11 9 5 14 6 32 31 15 5 37 31 12 11 32 6 7 9 10 5 7 6 5 16 12 9 10 8 11 8 2 25 26 24 23 20 22 21 1 1 5 7 4 27 29 3 20 20 5 5 4 12 17 3 1 1 2 35 36 8 34 30 28 20 5 N m 3 7 ft lb m 0 5 kgf PTT switch and cowling lock lever ...

Page 484: ...tion model É Counter rotation model Removing the cowling lock lever 1 Remove the spring 1 2 Remove the lever 2 and cowling lock lever 3 Removing the flushing hose and cooling water hose 1 Remove the adapter 1 and joints 2 and 3 2 Remove the plates 4 and holder 5 reg ular rotation model 3 Remove the cooling water pilot hose 6 cooling water hose 7 and joint 8 STBD 3 1 5 4 È 3 4 2 5 PORT É 1 2 3 1 3 ...

Page 485: ... then fasten the hoses 4 and 5 using the clamp 7 and plastic ties 8 3 Route the flushing hose 1 cooling water hose 5 trim sensor lead a PTT motor lead b and speedometer hose 9 4 Fasten the flushing hose 1 cooling water hose 5 and trim sensor lead a using the plates 0 and holder A regular rotation model 5 Install the adapter B and then tighten the flushing hose adapter screws C to the specified tor...

Page 486: ...euse a gasket always replace it with a new one 1 Install a new gasket 1 the PTT switch 2 and the holder 3 2 Fasten the PTT switch lead a using the holder 4 regular rotation model or holder 5 counter rotation model È Regular rotation model É Counter rotation model TIP To fasten the PTT switch lead see Wiring harness routing 5 6 Flushing hose adapter screw C 5 N m 0 5 kgf m 3 7 ft lb B 1 D E G F C 2...

Page 487: ...t 1 6 Bracket 1 7 Bracket 1 8 Rivet 2 9 Water outlet 1 10 Bolt 4 M8 35 mm 11 Grommet 8 12 Collar 4 13 Rubber seal 1 14 Grommet 2 15 Grommet 2 16 Rubber seal 1 17 Grommet 1 15 16 15 1 4 3 8 9 13 17 19 14 11 10 11 12 11 10 10 11 4 5 10 11 2 7 18 18 11 12 11 12 11 12 6 4 PTT switch and cowling lock lever Bottom cowling ...

Page 488: ...BRKT Bracket unit 9 13 No Part name Q ty Remarks 18 Grommet 2 19 Bottom cowling 1 15 16 15 1 4 3 8 9 13 17 19 14 11 10 11 12 11 10 10 11 4 5 10 11 2 7 18 18 11 12 11 12 11 12 6 4 ...

Page 489: ... 2 10 Ground lead 1 11 Lower mounting bolt 2 M14 205 mm 12 Upper mount 2 13 Bracket 1 14 Upper mount bracket bolt 3 M10 45 mm 15 Washer 2 16 Washer 2 17 Washer 2 4 1 2 2 3 3 3 3 5 6 6 6 7 7 7 8 8 8 9 9 9 10 11 11 11 12 12 12 13 15 15 15 16 16 16 17 17 17 18 18 18 19 19 20 20 21 22 22 23 24 25 26 26 54 N m 5 4 kgf m 39 8 ft lb 72 N m 7 2 kgf m 53 1 ft lb 72 N m 7 2 kgf m 53 1 ft lb 4 5 14 È Bottom ...

Page 490: ... Plastic tie 2 23 Hose 1 24 Dowel 1 X transom model 25 Adapter 1 X transom model 26 Bolt 1 M6 25 mm X transom model 4 1 2 2 3 3 3 3 5 6 6 6 7 7 7 8 8 8 9 9 9 10 11 11 11 12 12 12 13 15 15 15 16 16 16 17 17 17 18 18 18 19 19 20 20 21 22 22 23 24 25 26 26 54 N m 5 4 kgf m 39 8 ft lb 72 N m 7 2 kgf m 53 1 ft lb 72 N m 7 2 kgf m 53 1 ft lb 4 5 14 È ...

Page 491: ...ase 1 Install the upper mounts 1 and upper mounting bolts 2 2 Install the upper mount bracket 3 and then tighten the upper mount bracket bolts 4 temporarily TIP Make sure that the notches a in the washer are facing forward 3 Install the lower mounts 5 and lower mounting bolts 6 4 Install the lower mount brackets 7 and then tighten the lower mount bracket bolts 8 temporarily TIP The ground lead sho...

Page 492: ...nstall the caps B 8 Tighten the upper mount bracket bolts 4 to the specified torque in the order 1 2 and so on 9 Tighten the lower mount bracket bolts 8 10 Connect the ground lead C 11 Pass the speedometer hose D through the steering arm E and then connect it to the adapter F X transom model Upper mounting nut 0 72 N m 7 2 kgf m 53 1 ft lb Lower mounting nut A 72 N m 7 2 kgf m 53 1 ft lb b 9 9 9 9...

Page 493: ...mm 11 Rubber seal 1 12 Baffle plate 1 13 Screw 2 M6 16 mm 14 Apron stay 6 15 Bolt 2 M8 30 mm 16 Dowel 2 17 PCV 1 1 4 5 6 8 8 7 9 10 11 12 13 13 14 14 15 15 16 16 17 18 19 20 21 22 23 23 23 24 25 15 2 3 20 N m 2 0 kgf m 14 8 ft lb 42 N m 4 2 kgf m 31 0 ft lb 8 N m 0 8 kgf m 5 9 ft lb 4 N m 0 4 kgf m 3 0 ft lb 8 N m 0 8 kgf m 5 9 ft lb 28 N m 2 8 kgf m 20 7 ft Ib Upper case and mounts Upper case ...

Page 494: ...22 Collar 1 23 Bolt 6 M10 45 mm 24 Rubber seal 1 25 Rubber seal 1 39 39 39 39 1 4 5 6 8 8 7 9 10 11 12 13 13 14 14 15 15 16 16 17 18 19 20 21 22 23 23 23 24 25 15 2 3 20 N m 2 0 kgf m 14 8 ft lb 42 N m 4 2 kgf m 31 0 ft lb 8 N m 0 8 kgf m 5 9 ft lb 4 N m 0 4 kgf m 3 0 ft lb 8 N m 0 8 kgf m 5 9 ft lb 28 N m 2 8 kgf m 20 7 ft Ib ...

Page 495: ...cking the PCV 1 Check the PCV Replace if cracked or damaged Assembling the upper case Do not reuse a gasket always replace it with a new one 1 Install the bushing 1 and then install the circlip 2 2 Install the rubber seal 5 into the upper case TIP Face the mark a on the rubber seal 5 up 1 2 3 4 4 4 5 5 a 6 7 8 9 0 0 A Bearing puller assembly 9 90890 06535 Stopper guide stand 0 90890 06538 Stopper ...

Page 496: ...he specified torque 10 Install the apron stays G and then tighten it to the specified torque TIP Make sure to insert the tip of the water pipe H into the joint hole b of the upper case 11 Install the damper I the cover J a new gasket K and the engine oil drain bolt L and then tighten the engine oil drain bolt L to the specified torque B C D E F 0 9 7 8 c b H H b 6 A 9 G Baffle plate screw 8 4 N m ...

Page 497: ...l strainer 1 8 Collar 3 9 Bolt 3 M6 25 mm 10 Gasket 1 39 39 39 39 11 Dowel 2 12 Rubber seal 1 13 Oil pan 1 14 Gasket 1 39 39 39 39 15 Exhaust manifold 1 16 Bolt 10 M8 60 mm 17 Bolt 2 M8 35 mm 1 2 3 4 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 26 20 N m 2 0 kgf m 14 8 ft lb 12 N m 1 2 kgf m 8 9 ft lb 42 N m 4 2 kgf m 31 0 ft lb Upper case Oil pan and exhaust manifold ...

Page 498: ...9 20 Gasket 1 39 39 39 39 21 Plate 1 22 Water pipe 1 23 Rubber seal 1 24 Gasket 1 39 39 39 39 25 Dowel 2 26 Muffler 1 27 Bolt 10 M8 35 mm 1 2 3 4 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 26 20 N m 2 0 kgf m 14 8 ft lb 12 N m 1 2 kgf m 8 9 ft lb 42 N m 4 2 kgf m 31 0 ft lb ...

Page 499: ...an ifold and muffler Replace if corroded or cracked 3 Check the oil pan Replace if corroded or cracked Checking the oil strainer 1 Check the oil strainer Clean if there is dirt and residue Assembling the oil pan and exhaust manifold Do not reuse a gasket or rubber seal always replace it with a new one 1 Install the dowels 1 a new gasket 2 and the lower exhaust guide 3 2 Install a new gasket 4 and ...

Page 500: ... D and then tighten the exhaust manifold bolts E temporarily 5 Tighten the exhaust manifold bolts E first and then tighten the oil pan bolts 0 and A to the specified torque 6 Install the rubber seal F and water pipe G 7 Install the dowels H a new gasket I the plate J and a new gasket K and then install the muffler L Oil strainer bolt 6 12 N m 1 2 kgf m 8 9 ft lb 4 5 6 6 1 2 3 4 5 a a 8 9 0 A 0 7 0...

Page 501: ...M to the speci fied torque 9 Tighten the oil pan assembly bolt N to the specified torque Muffler bolt M 20 N m 2 0 kgf m 14 8 ft lb Oil pan assembly bolt N 42 N m 4 2 kgf m 31 0 ft lb L M M M J K I G F H H N Oil pan and exhaust manifold ...

Page 502: ...BRKT Bracket unit 9 27 Steering arm No Part name Q ty Remarks 1 Steering arm 1 2 Washer 2 3 Bushing 2 4 O ring 1 39 39 39 39 5 Bushing 1 6 Steering yoke 1 7 Circlip 1 8 Grommet 1 1 2 2 3 3 4 5 6 7 8 ...

Page 503: ...eering arm 3 2 Place the bracket assembly 4 in an upright position and then install the steering arm 3 3 Install the bushing 5 a new O ring 6 the bushing 7 and the washer 8 4 Install the steering yoke 9 so that the steering arm and steering yoke 9 are both facing in the same direction a and b are aligned 5 Hold the steering arm 3 and then strike the steering yoke 9 using a copper ham mer until the...

Page 504: ...BRKT Bracket unit 9 29 7 Inject grease into the grease nipple A until it comes out from both the upper and lower bushings d 0 0 9 3 c A d d ...

Page 505: ... 1 10 Bushing 3 11 Tilt stop lever 1 12 Nut 2 13 Through tube 1 14 Clamp bracket PORT 1 15 Washer 2 16 Bushing 2 17 Ground lead 1 22 N m 2 2 kgf m 16 2 ft lb 4 N m 0 4 kgf m 3 0 ft lb 3 N m 0 3 kgf m 2 2 ft lb 4 N m 0 4 kgf m 3 0 ft lb 33 34 32 33 32 31 19 18 17 6 30 15 20 23 21 18 22 25 25 24 10 26 27 28 29 25 24 26 24 25 24 14 11 10 12 13 1 3 4 5 8 7 10 16 15 5 6 9 2 2 2 2 2 2 16 Steering arm Cl...

Page 506: ... 2 26 Pin 1 27 Spring 1 28 Hook 1 29 Bolt 1 M6 10 mm 30 Swivel bracket 1 31 Anode 1 32 Plate 2 33 Bolt 4 M6 25 mm 34 Ground lead 1 22 N m 2 2 kgf m 16 2 ft lb 4 N m 0 4 kgf m 3 0 ft lb 3 N m 0 3 kgf m 2 2 ft lb 4 N m 0 4 kgf m 3 0 ft lb 33 34 32 33 32 31 19 18 17 6 30 15 20 23 21 18 22 25 25 24 10 26 27 28 29 25 24 26 24 25 24 14 11 10 12 13 1 3 4 5 8 7 10 16 15 5 6 9 2 2 2 2 2 2 16 ...

Page 507: ...6 Remove the spring 9 hook 0 and pins A 7 Remove the tilt stop levers B and C distance collar assembly a collar D and bushings E Checking the clamp bracket anode 1 Check the anode Replace if eroded Clean if there is grease oil or scales NOTICE Do not apply grease oil or paint to the anode Installing the clamp bracket 1 Assemble the distance collar assembly 2 1 3 4 5 6 7 8 Distance a 30 3 30 4 mm 1...

Page 508: ...th its flat cor ner d pointing down 7 Tighten the self locking nut B tempo rarily 8 Install the anode C TIP Face the top of the DO NOT PAINT mark e on the anode C forward 9 Tighten the self locking nut B to the specified torque 10 Install the grease nipples D and then tighten them to the specified torque 11 Install the friction plates E and F and then tighten the friction plate screws G to the spe...

Page 509: ...tilt stop lever 1 2 Loosen the trim sensor screws 2 3 Adjust the position of trim sensor and then tighten the trim sensor screws 2 temporarily TIP To decrease the resistance turn the trim sensor cam in direction a To increase the resistance turn the trim sensor cam in direction b 4 Fully tilt the swivel bracket down 5 Measure the trim sensor setting resis tance Check that the resistance is within ...

Page 510: ...it using the tilt stop lever 7 Tighten the trim sensor screws 2 to the specified torque 8 Fully tilt the swivel bracket down and then check the trim sensor resistance Trim sensor setting resistance Terminal c Terminal d 9 0 11 0 Ω Trim sensor screw 2 4 N m 0 4 kgf m 3 0 ft lb ...

Page 511: ...Remarks 1 Shaft 1 2 Circlip 2 3 Plastic tie 4 4 Bushing 2 5 Bushing 2 6 PTT unit 1 7 Ground lead 1 8 Bolt 1 M6 10 mm 9 Bolt 8 M10 45 mm 42 N m 4 2 kgf m 31 0 ft lb 6 4 5 3 2 1 8 9 7 2 9 9 9 5 4 Clamp bracket and swivel bracket PTT unit ...

Page 512: ...operate open the manual valve 2 by turning it counterclock wise and then tilt the swivel bracket up man ually 2 Remove the plastic ties 3 and then pull out the PTT motor lead a from the clamp bracket STBD 3 Disconnect the ground lead 4 4 Remove the circlips 5 and shaft 6 5 Connect the PTT motor leads a to the battery terminals to fully retract the PTT rams 1 2 Ram PTT motor lead Battery terminal D...

Page 513: ...t the proper level a small amount of fluid should flow out of the filler hole 4 If the fluid is below the proper level add the recommended fluid 5 Install the reservoir cap 1 and then tighten it to the specified torque 6 Loosen the pipe joints 2 and then remove the pipe joint at end a 7 Install the special service tool 3 TIP Place the PTT unit in the drain pan 8 Connect the PTT motor leads to the ...

Page 514: ...e joint at end b 14 Install the special service tool 3 15 Connect the PTT motor leads to the bat tery terminals to fully extend the trim rams and then measure the hydraulic pressure when the reading on the pres sure gauge stabilizes Ram PTT motor lead Battery terminal Down Light green Lg Sky blue Sb Hydraulic pressure down reference data 6 7 8 7 MPa 67 0 87 0 kgf cm2 971 5 1261 5 psi Ram PTT motor...

Page 515: ...T unit in an upright position 2 Close the manual valve 1 by turning it clockwise 3 Check the fluid level See steps 3 5 in Checking the hydraulic pressure 9 38 4 Connect the PTT motor leads to the bat tery terminals to fully retract the PTT rams 5 Reverse the PTT motor leads between the battery terminals to fully extend the PTT rams Ram PTT motor lead Battery terminal Up Sky blue Sb Light green Lg ...

Page 516: ...he PTT unit with the power unit installed make sure to sus pend the outboard motor 1 Connect the PTT motor leads a to the battery terminals to retract the PTT rams 2 Fully tilt the swivel bracket up and then support it using the tilt stop lever 1 3 Install the bushings 2 and 3 to the tilt ram end and swivel bracket 4 Install the PTT unit 4 and then tighten the PTT unit bolts 5 to the specified tor...

Page 517: ...extend the PTT rams 7 Insert the shaft 6 and then install the circlips 7 8 Connect the ground lead 8 9 Fasten the PTT motor lead a and trim sensor lead using the plastic ties 9 PTT unit bolt 5 42 N m 4 2 kgf m 31 0 ft lb Ram PTT motor lead Battery terminal Up Sky blue Sb Light green Lg 4 5 2 5 5 2 3 3 Lg Sb a b a 7 8 6 7 9 9 9 9 a PTT unit ...

Page 518: ... 39 39 39 39 7 Reservoir 1 8 Bolt 6 M8 20 mm 9 PTT motor assembly 1 10 O ring 1 39 39 39 39 11 Joint 1 12 Stator 1 13 Bolt 2 M5 12 mm 14 Wave washer 1 15 Bearing 2 39 39 39 39 16 Armature 1 17 Brush 4 1 2 3 4 5 6 7 8 8 8 8 8 8 9 9 10 11 12 13 13 14 15 15 16 17 17 17 17 18 18 18 18 19 20 21 7 N m 0 7 kgf m 5 2 ft lb 19 N m 1 9 kgf m 14 0 ft lb ...

Page 519: ...Spring 4 19 O ring 1 39 39 39 39 20 Motor base assembly 1 21 Oil seal 1 39 39 39 39 1 2 3 4 5 6 7 8 8 8 8 8 8 9 9 10 11 12 13 13 14 15 15 16 17 17 17 17 18 18 18 18 19 20 21 7 N m 0 7 kgf m 5 2 ft lb 19 N m 1 9 kgf m 14 0 ft lb PTT motor ...

Page 520: ...motor 1 Remove the PTT motor assembly 1 O ring 2 and joint 3 Disassembling the PTT motor 1 Remove the PTT motor bolts 1 and then remove the stator 2 NOTICE Secure the end of the armature shaft using a pair of pliers and then remove the armature 3 along with the motor base assembly Otherwise the arma ture could separate from the motor base assembly due to the magnetic force of the stator 2 and dama...

Page 521: ... tion 3 Check the armature for continuity Replace if out of specifications Checking the brush 1 Measure the length of each brush Replace the brushes if below specifica tion Bearing splitter 7 commercially available Bearing splitter 7 commercially available Bolt 9 commercially available M8 15 mm 7 8 8 9 9 7 7 8 b Motor commutator standard diameter a 23 0 mm 0 91 in Wear limit 22 0 mm 0 87 in Digita...

Page 522: ...replace it with a new one Do not apply grease or oil to the com mutator of the armature 1 Install a new oil seal 1 into the motor base assembly 2 2 Install the brushes 3 and springs 4 3 Install a new bearing 5 to the specified depth a 4 Install a new bearing 6 to the specified depth b Motor base assembly continuity Terminal c Terminal e Terminal c Terminal g Terminal e Terminal g Terminal d Termin...

Page 523: ...ate from the motor base assembly due to the magnetic force of the stator 0 and damage the brushes Installing the reservoir Do not reuse an O ring always replace it with a new one 1 Install the spacer 1 filter 2 and sheet 3 2 Install a new O ring 4 and the reservoir 5 and then tighten the reservoir bolts 6 to the specified torque 3 Install a new O ring 7 and the reservoir cap 8 and then tighten the...

Page 524: ...er level a 3 Turn the joint 1 using a screwdriver to remove any air between the pump gear teeth 4 Remove all of the air bubbles using a syringe or suitable tool 5 Install a new O ring 2 and the PTT motor 3 and then tighten the PTT motor bolts 4 to the specified torque TIP Align the protrusion b on the armature shaft with the slot c in the joint Reservoir bolt 6 19 N m 1 9 kgf m 14 0 ft lb Reservoi...

Page 525: ...rt pin 1 11 O ring 1 39 39 39 39 12 Ball 1 13 Circlip 2 14 Main valve seal 2 15 Down shuttle piston 1 16 O ring 1 39 39 39 39 17 Spring 2 1 1 1 2 3 4 5 5 6 7 8 9 10 12 11 13 13 14 14 15 16 17 18 17 19 19 20 21 22 22 23 24 25 25 26 26 27 28 29 27 28 29 30 30 34 31 32 33 32 33 35 36 37 35 36 37 38 39 40 7 N m 0 7 kgf m 5 2 ft lb 7 N m 0 7 kgf m 5 2 ft lb 2 N m 0 2 kgf m 1 5 ft lb PTT motor PTT gear ...

Page 526: ... 2 26 Valve pin 2 27 Spring 2 28 Spacer 2 29 O ring 2 39 39 39 39 30 Pin 2 31 Bracket 1 32 Washer 2 33 Bolt 2 M5 25 mm 34 Gear pump assembly 1 1 1 1 2 3 4 5 5 6 7 8 9 10 12 11 13 13 14 14 15 16 17 18 17 19 19 20 21 22 22 23 24 25 25 26 26 27 28 29 27 28 29 30 30 34 31 32 33 32 33 35 36 37 35 36 37 38 39 40 7 N m 0 7 kgf m 5 2 ft lb 7 N m 0 7 kgf m 5 2 ft lb 2 N m 0 2 kgf m 1 5 ft lb ...

Page 527: ... 39 39 39 39 Manual valve 1 40 Circlip 1 1 1 1 2 3 4 5 5 6 7 8 9 10 12 11 13 13 14 14 15 16 17 18 17 19 19 20 21 22 22 23 24 25 25 26 26 27 28 29 27 28 29 30 30 34 31 32 33 32 33 35 36 37 35 36 37 38 39 40 7 N m 0 7 kgf m 5 2 ft lb 7 N m 0 7 kgf m 5 2 ft lb 2 N m 0 2 kgf m 1 5 ft lb PTT gear pump ...

Page 528: ...4 Remove the bracket 6 and then remove the balls 7 and 8 5 Remove the gear housing 9 and then remove the down shuttle piston 0 and up shuttle piston A 6 Remove the drive gear B driven gear C balls D and pins E Checking the gear pump 1 Check the drive gear 1 and driven gear 2 Replace the gear pump assembly if damaged or excessive worn 2 Check the up relief valve 3 and down relief valve 4 Clean if t...

Page 529: ...tle piston 6 2 Install the gear housing 7 3 Install the balls 8 and 9 manual release plate 0 and bracket A and then tighten the gear pump bracket bolts B temporarily 4 Check that the gear pump turns smoothly and then tighten the gear pump bracket bolts B to the specified torque 5 Install the relief valve seal C and ball D and then install the screws E È Down relief valve É Up relief valve 1 2 3 4 ...

Page 530: ...torque 9 Install the manual valve M and circlip N and then tighten the manual valve to the specified torque 10 Install the PTT motor See Installing the PTT motor 9 49 11 Check the hydraulic pressure See Checking the hydraulic pressure 9 38 TIP If the hydraulic pressure is out of specifica tion adjust the relief lock screws to adjust the pressure Down relief screw depth a reference data 1 07 1 27 m...

Page 531: ...39 39 39 12 Backup ring 1 13 Ball 5 14 Tilt ram assembly 1 15 Free piston 1 16 O ring 1 39 39 39 39 17 Tilt cylinder 1 1 2 2 3 3 4 4 5 5 6 6 7 8 9 10 10 11 11 12 12 13 13 14 15 16 17 18 19 19 20 20 21 21 22 22 23 23 24 25 26 27 28 29 30 31 32 33 34 35 36 7 N m 0 7 kgf m 5 2 ft lb 65 N m 6 5 kgf m 47 9 ft lb 90 N m 9 0 kgf m 66 4 ft lb 160 N m 16 0 kgf m 118 0 ft lb 15 N m 1 5 kgf m 11 1 ft lb 20 N...

Page 532: ...g 2 27 Adapter 2 28 Circlip 2 29 Trim ram assembly 2 30 Circlip 1 31 Shaft 1 32 O ring 1 39 39 39 39 33 Adapter 1 34 Pipe 1 1 2 2 3 3 4 4 5 5 6 6 7 8 9 10 10 11 11 12 12 13 13 14 15 16 17 18 19 19 20 20 21 21 22 22 23 23 24 25 26 27 28 29 30 31 32 33 34 35 36 7 N m 0 7 kgf m 5 2 ft lb 65 N m 6 5 kgf m 47 9 ft lb 90 N m 9 0 kgf m 66 4 ft lb 160 N m 16 0 kgf m 118 0 ft lb 15 N m 1 5 kgf m 11 1 ft lb...

Page 533: ... 11 11 12 12 13 13 14 15 16 17 18 19 19 20 20 21 21 22 22 23 23 24 25 26 27 28 29 30 31 32 33 34 35 36 7 N m 0 7 kgf m 5 2 ft lb 65 N m 6 5 kgf m 47 9 ft lb 90 N m 9 0 kgf m 66 4 ft lb 160 N m 16 0 kgf m 118 0 ft lb 15 N m 1 5 kgf m 11 1 ft lb 20 N m 2 0 kgf m 14 8 ft lb 24 25 PTT cylinder ...

Page 534: ...ly 6 Drain the fluid 7 Cover the tilt cylinder opening using a rag 8 and then blow compressed air through the hole a to remove the free piston 9 WARNING When removing the free piston never look into the tilt cylinder opening because the free pis ton and PTT fluid could be expelled forcefully Removing the trim ram 1 Hold the PTT body 1 2 Loosen the trim cylinder end screws 2 and then remove the tri...

Page 535: ...f scratched 3 Check the outer surface of the tilt piston 3 trim piston 4 adapter 5 free piston 6 and dust seals 7 of end screws 8 Replace if scratched 4 Check the trim rams 9 and tilt ram 0 Polish with 400 600 grit sandpaper if there is light rust or replace if bent or corrosion 5 Check the pipes A Replace if cracked or corrosion Checking the valve 1 Check the tilt piston absorber valves 1 Clean i...

Page 536: ...ylinder end screw 5 spring 6 adapter 7 and tilt piston 8 3 Hold the tilt piston using the special ser vice tool 9 4 Tighten the tilt ram 0 to the specified torque 5 Hold the tilt ram end 6 Install a new O ring B and the backup ring C 7 Install the balls D absorber valve pins E and springs F 8 Install the washers G plate H and tilt piston bolt I to the tilt piston 8 and then tighten the tilt piston...

Page 537: ...ng the tilt cylinder When assembling the PTT unit do not use a rag Otherwise dust and particles could get on the PTT unit components causing poor performance Do not reuse an O ring always replace it with a new one 1 Install a new O ring 1 to the free piston 2 2 Push the free piston 2 into the tilt cylin der 3 until it bottoms out 3 Install the tilt cylinder 3 to the PTT body 4 4 Install a new O ri...

Page 538: ...ed torque Installing the tilt ram When assembling the PTT unit do not use a rag Otherwise dust and particles could get on the PTT unit components causing poor performance 1 Place the tilt cylinder end screw 1 at the position a 2 Fill the tilt cylinder with the recommended fluid to the proper level b 3 Add a small amount of the recommended fluid through the PTT body hole c Pipe joint adapter 6 20 N...

Page 539: ...1 to the specified torque 5 Install the PTT motor See Installing the PTT motor 9 49 6 Check the hydraulic pressure See Checking the hydraulic pressure 9 38 Recommended PTT fluid ATF Dexron II Cylinder end screw wrench 2 90890 06568 Tilt cylinder end screw 1 90 N m 9 0 kgf m 66 4 ft lb a b b c 1 1 2 PTT cylinder ...

Page 540: ... and replacing anode s 10 8 Checking battery for electric start models 10 8 Checking for cooling water leakage 10 8 Checking the cooling water passage 10 8 Inspecting idle speed 10 9 Changing engine oil 10 9 Checking the engine oil level 10 10 Replacing the oil filter 10 10 Checking the engine start switch and engine shut off switch 10 11 Checking the fuel joint and fuel hose fuel joint to fuel in...

Page 541: ...10 Checking the top cowling 10 15 Checking the valve clearance 10 16 Checking the water pump 10 16 ...

Page 542: ...cy when operating the engine under adverse conditions such as extended trolling Disassembly or repairs may be necessary depending on the outcome of maintenance checks Expendable or consumable parts and lubricants will lose their effectiveness over time and through normal usage regardless of the warranty period When operating the outboard motor in salt water or in muddy turbid cloudy or acidic wate...

Page 543: ...eplacement U U U U 10 12 Power trim and tilt unit Inspection F F F F U U U U F F F F U U U U 10 15 Propeller propeller nut cotter pin Inspection or replace ment as necessary F F F F U U U U F F F F U U U U 8 3 PCV Pressure Control Valve Inspection or replace ment as necessary U U U U 9 20 Shift link shift cable Inspection adjustment or replacement as neces sary U U U U U U U U 3 9 10 6 Spark plug ...

Page 544: ...place ment as necessary U U U U U U U U 10 5 Wire harness connec tions wire coupler con nections Inspection or replace ment as necessary U U U U U U U U Yamaha Meter gauge Inspection U U U U U U U U 1 Item Actions Every See page 1000 hours Exhaust guide exhaust manifold Inspection or replace ment as necessary U U U U 9 24 Timing belt Replacement U U U U 7 37 Item Actions Initial Every See page 20 ...

Page 545: ...r open flames for example welding equipment and 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 minimum level marks 2 Check the specific gravity of the electro lyte Full...

Page 546: ...r a correct measurement and remove it again 7 Check that the oil level indicated on the dipstick 1 is between the upper mark a and the lower mark b If the engine oil is not at the proper level add or extract engine oil 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 stops when the eng...

Page 547: ...hift operates smoothly when the remote control lever is moved from the N position to the F or R position 2 Check that the throttle operates smoothly when the remote control lever is moved from the F or R position to the fully open position Checking the outboard motor mounting height 1 Check that the anti cavitation plate a is aligned with the bottom b of the boat If the mounting height is too high...

Page 548: ...ith the alignment mark d on the shift bracket 1 Test run 1 Start the engine and then check that the gear shift operates smoothly 2 Warm up the engine and then check the engine idle speed 3 Operate the boat at trolling speed 4 Operate the outboard motor according to the break in procedure 5 Check that the outboard motor does not tilt up when the remote control lever is moved to the R position and t...

Page 549: ...e Inspecting and replacing anode s Do not apply grease oil or paint to the anodes or the trim tab 1 Check the anodes and trim tab Clean the anodes or trim tab if there are scales grease or oil TIP Replace the anodes or trim tab if 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 ma...

Page 550: ... board meter or the YDIS To connect and operate the YDIS see the YDIS Ver 1 33 or later Instruction Manual Changing engine oil The engine oil should be extracted using an oil changer Change the engine oil after the first 20 hours of operation or 3 months and every 100 hours or at 1 year intervals thereafter 1 Place the outboard motor in an upright position NOTICE If the outboard motor is not level...

Page 551: ...the oil pressure alert indicator comes on or if there is oil leakage stop the engine and find the cause Continued operation with a problem could cause severe engine damage Checking the engine oil level 1 Check the engine oil level See Check ing the engine oil level 10 5 Replacing the oil filter Do not damage the oil pressure sensor and its lead when replacing the oil filter 1 Extract the engine oi...

Page 552: ... fuel filter assembly 6 13 Changing gear oil Never get under the lower unit while it is tilted Do not reuse a gasket always replace it with a new one 1 Tilt the outboard motor so that the drain screw is at the lowest point 2 Place a drain pan under the gear oil drain hole 3 Remove the drain screw 1 and gasket 2 NOTICE If there is a significant amount of metal particles on the mag netic drain screw...

Page 553: ...sket 6 and the drain screw 1 and then tighten the drain screw 1 to the specified torque Checking the gear oil level 1 Check the gear oil level See Checking the gear oil level 10 6 Replacing the OCV filter 1 Remove the OCV assemblies 2 Replace the OCV filter 1 of each OCV assembly 3 Install the OCV assemblies See step 4 in Installing the cylinder head 7 68 2 1 3 4 3 5 Recommended gear oil Hypoid ge...

Page 554: ...10 13 MNT Maintenance Greasing 1 Apply water resistant grease to the spec ified lubrication points a a a A A A A A a A A A A È ...

Page 555: ...e it with a new one 1 Fully tilt the outboard motor up and then support it using the tilt stop lever 1 2 Remove the reservoir cap 2 and O ring 3 and then check the fluid level in the reservoir WARNING Before removing the reservoir cap make sure that the PTT rams are fully extended Other wise fluid could be expelled forcefully from the unit due to internal pressure TIP If the fluid is at the proper...

Page 556: ...he intake silencer See steps 2 4 in Removing the intake silencer 6 17 4 Removing the flywheel magnet and sta tor assembly See Removing the fly wheel magnet 7 16 5 Remove the fuel rail covers 6 Remove the wiring harness guide See steps 5 29 in Removing the wiring har ness 7 20 7 Remove the timing belt See steps 6 10 in Removing the timing belt 7 38 8 Install a new timing belt See steps 2 10 in Inst...

Page 557: ... 2 Remove the flywheel magnet cover and engine ECM cover 3 Remove the blowby hose See step 2 in Removing the intake silencer 6 17 4 Remove the speed sensor coupler from the bracket See step 16 in Removing the power unit 7 8 5 Remove the wiring harness from the engine ECM bracket and holder See steps 5 16 in Removing the wiring har ness 7 20 6 Remove the ignition coils and spark plugs 7 Check the v...

Page 558: ...wby gas reburning system 2 14 Bottom cowling 5 18 9 12 Bracket unit 1 5 1 19 Bracket unit technical data 1 16 Break in 10 7 C Camshaft 7 46 Canister throttle body and surge tank 6 26 Changing engine oil 10 9 Changing gear oil 10 11 Charging system 1 10 Charging unit and component 5 50 Charging unit and starting unit A 9 Checking battery for electric start models 10 4 10 8 Checking for cooling wate...

Page 559: ...anifold 9 24 Checking the oil pressure 7 1 Checking the oil pressure sensor 5 39 Checking the oil pump assembly 7 77 Checking the oil strainer 9 24 Checking the outboard motor mounting height 10 6 Checking the PCV 9 20 10 14 Checking the pinion and forward gear 8 26 8 35 Checking the pinion and reverse gear 8 83 8 88 Checking the piston diameter 7 86 Checking the piston pin 7 87 Checking the pisto...

Page 560: ...bling the propeller shaft assembly 8 16 8 22 Disassembling the propeller shaft housing assembly 8 16 8 22 8 73 8 79 Disassembling the PTT motor 9 45 Disassembling the reverse gear 8 82 8 88 Disassembling the shift bracket 9 3 Disassembling the starter motor 5 69 Disassembling the tilt ram 9 59 Disassembling the trim ram 9 60 Disassembling the upper case 9 20 Disassembling the vapor separator 6 39 ...

Page 561: ...ake manifold 6 18 Installing the intake silencer 6 19 Installing the isolator lead optional 3 11 Installing the junction box 7 33 Installing the lower unit 8 31 8 36 8 85 8 89 Installing the low pressure fuel pump 6 33 Installing the oil filter bracket 7 79 Installing the oil pump assembly 7 78 Installing the power unit 7 11 Installing the propeller shaft housing assembly 8 29 8 35 8 84 8 88 Insta...

Page 562: ...redelivery check 10 4 Propeller 0 1 Propeller damper cooling F250G and FL250G 2 23 Propeller selection 3 29 Propeller shaft housing F200B 8 14 Propeller shaft housing F250G 8 20 Propeller shaft housing FL200B 8 71 Propeller shaft housing FL250G 8 77 Propeller shaft shim T4 selection table 8 101 Propeller size 3 29 PTT cylinder 9 56 PTT electrical system 5 74 PTT fluid requirement 1 6 PTT gear pump...

Page 563: ... the propeller shaft shim T4 8 99 Selecting the propeller shaft shim T4 F250G 8 50 Selection 3 29 Self protection 0 2 Serial number 1 3 Shift rod and shift bracket 9 1 Shim location F200B 8 43 Shim location F250G 8 44 Shim location FL200B 8 97 Shim location FL250G 8 98 Shimless valve lifter 2 11 Shimming 8 43 8 97 Shimming counter rotation model 8 90 Shimming regular rotation model 8 37 Shimming c...

Page 564: ...shift rod F200B 8 7 Water pump and shift rod F250G 8 11 Water pump and shift rod FL200B 8 65 Water pump and shift rod FL250G 8 68 Wiring diagram A 2 Wiring harness 7 19 Wiring harness routing 5 6 Working with crane 0 2 Y YDIS 4 1 ...

Page 565: ...A Appendix Wiring diagram A 2 How to use the wiring diagram A 2 Engine control unit A 3 Fuel unit A 5 Ignition unit A 7 Charging unit and starting unit A 9 PTT unit and control unit A 11 ...

Page 566: ...A 1 MEMO ...

Page 567: ...parts Color Code B Black B Br Black Brown B G Black Green B L Black Blue B O Black Orange B W Black White B Y Black Yellow Br Brown G Green G B Green Black G R Green Red L Blue L B Blue Black L G Blue Green L R Blue Red L W Blue White L Y Blue Yellow Lg Light green O Orange P Pink P B Pink Black P G Pink Green P W Pink White Pu Purple Pu B Purple Black Pu G Purple Green Pu L Purple Blue Pu R Purpl...

Page 568: ...el pump g Fuse 20 A engine start switch PTT switch h Fuse 15 A high pressure fuel pump k Main relay m ETV motor relay n Starter relay p High pressure fuel pump relay r Condenser connect to the cam position sensor PORT EX s Condenser connect to the air pressure sensor È To remote control 703 remote control model To remote control and switch panel 704 remote control model É If the 6Y8 Multifunction ...

Page 569: ......

Page 570: ...Jul 2011 1 CR E ...

Page 571: ... Y G W G L Y G R B L R R G Br Y Y G R G R Y R Y R Y R Y R Y G R P w Br B Y O O O O O R Y R Y R Y R Y R B B B B B B B B B B B B B B B B B B B B B B B B s Joint coupler 2 13 1 24 12 24 23 22 21 20 17 16 15 14 13 5 4 3 1 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 1 6 5 12 13 1 24 12 2 R R B B B B B B B B B 1 11 10 23 Trim sensor Alert indicator coupler Oil pressure sensor Shift cut switch Neutral s...

Page 572: ...engine ECM e Fuse 30 A starter relay f Fuse 10 A low pressure fuel pump g Fuse 20 A engine start switch PTT switch h Fuse 15 A high pressure fuel pump k Main relay m ETV motor relay n Starter relay p High pressure fuel pump relay r Condenser connect to the cam position sensor PORT EX s Condenser connect to the air pressure sensor È To remote control 703 remote control model To remote control and s...

Page 573: ... B G R R Y P G B R P O B O B G B W B B Y B B Y W B W L L W Y G W G R B L R R G Br Y Y G R R G R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y G R P W Br B Y O O R Y R Y R Y R Y R B B B B B B B B B B B B B s 24 23 17 16 15 14 13 5 3 2 1 1 6 7 8 9 10 12 13 19 B B 2 R R 1 6 5 12 13 1 24 12 13 1 24 12 r B B B B B B B B B 1 11 10 23 APS 5 1 3 Fuel injector 2 6 4 Fuel injector STBD IN PORT EX Cam position senso...

Page 574: ...ngine ECM d Fuse 10 A ETV engine ECM e Fuse 30 A starter relay f Fuse 10 A low pressure fuel pump g Fuse 20 A engine start switch PTT switch h Fuse 15 A high pressure fuel pump k Main relay m ETV motor relay n Starter relay p High pressure fuel pump relay r Condenser connect to the cam position sensor PORT EX È To remote control 703 remote control model To remote control and switch panel 704 remot...

Page 575: ...R Y R Y R Y G R P W Br B Y O O R Y R Y R Y R B B B B B B B B B B B B B B B B B B B B B 24 22 16 15 14 13 12 11 10 9 8 7 5 3 1 1 2 3 4 5 6 7 9 10 12 13 14 B B B B B B B B B B W B R Y R Y W G B B B R W L R Y B B 2 R R 1 6 5 12 r 1 11 10 23 Alert indicator coupler Oil pressure sensor Shift cut switch Knock sensor Ignition coil 5 Ignition coil 3 Ignition coil 1 Ignition coil 2 Ignition coil 4 Ignition...

Page 576: ... A ignition coil fuel injector VCT engine ECM d Fuse 10 A ETV engine ECM e Fuse 30 A starter relay f Fuse 10 A low pressure fuel pump g Fuse 20 A engine start switch PTT switch h Fuse 15 A high pressure fuel pump k Main relay m ETV motor relay n Starter relay p High pressure fuel pump relay È To remote control 703 remote control model To remote control and switch panel 704 remote control model ...

Page 577: ...4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 1 L R R G W Y P G B B B B B R G R Y R Y O B B Y Y G L R R G R R R R B R Br R B Br Br Y Y G R G R Y R Y R Y O B B B R Y B B B B B B G G G G R G B G R 1 11 10 23 Fuse box Starter motor Rectifier Regulator Battery House accessory battery Engine ECM 53 62 70 78 61 69 77 86 27 34 40 46 33 39 45 52 1 8 14 20 7 13 19 26 c k m d h p g f n e b a È Charging unit and st...

Page 578: ... relay f Fuse 10 A low pressure fuel pump g Fuse 20 A engine start switch PTT switch h Fuse 15 A high pressure fuel pump k Main relay m ETV motor relay n Starter relay p High pressure fuel pump relay r Diode connect to the PTT relay È To remote control 703 remote control model To remote control and switch panel 704 remote control model É If the 6Y8 Multifunction Meter is selected connect the coupl...

Page 579: ... Lg B W G R Lg P Sb W Br B Y O R Y B B B B B B B B B B SB Lg 1 11 10 23 Sb R Lg UP Free DN PTT switch W B Set Pull Engine shut off switch W B R Y Br ON Engine start switch OFF START Trim sensor PTT switch Alert indicator coupler PTT motor Starter motor Battery Neutral switch Engine ECM PTT relay 53 62 70 78 61 69 77 86 27 34 40 46 33 39 45 52 1 8 14 20 7 13 19 26 É É r c k m d h p g f n e b a Fuse...

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