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Yamaha F225A, Service Manual

The Yamaha F225A Owner's Manual is an essential guide for users of this high-performance outboard motor. With detailed instructions and diagrams, this manual helps users understand and maintain their F225A. Download this manual for free from manualshive.com and ensure optimal performance and longevity for your Yamaha F225A.

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69J3D11

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Electrical systems

Special service tools ..................................................................................... 8-1

Checking the electrical components............................................................ 8-2

Measuring the peak voltage ...................................................................... 8-2
Measuring the lower resistance................................................................. 8-2

Electrical components................................................................................... 8-3

Starboard and rear views .......................................................................... 8-3
Port view.................................................................................................... 8-4
Front view .................................................................................................. 8-5
Top view .................................................................................................... 8-6

Wiring harness ............................................................................................... 8-7

Ignition and ignition control system .......................................................... 8-10

Checking the ignition spark gap .............................................................. 8-11
Checking the ignition coil......................................................................... 8-11
Checking the ECM................................................................................... 8-12
Checking the pulser coil .......................................................................... 8-12
Checking the throttle position sensor ...................................................... 8-12
Checking the intake air temperature sensor............................................ 8-13
Checking the engine temperature sensor................................................ 8-13
Checking the thermoswitch ..................................................................... 8-14
Checking the shift cut switch ................................................................... 8-14
Checking the neutral switch..................................................................... 8-14
Checking the main relay .......................................................................... 8-15

Fuel control system ..................................................................................... 8-16

Checking the low-pressure fuel pump and high-pressure fuel pump ...... 8-18
Checking the high-pressure fuel pump relay ........................................... 8-18

Starting system ............................................................................................ 8-19

Checking the fuse.................................................................................... 8-20
Checking the wiring harness (10 pins) .................................................... 8-20
Checking the starter relay........................................................................ 8-20

Starter motor ................................................................................................ 8-21

Removing the starter motor pinion .......................................................... 8-23
Checking the starter motor pinion............................................................ 8-23
Checking the armature ............................................................................ 8-23
Checking the brushes.............................................................................. 8-24
Checking the magnet switch.................................................................... 8-24
Checking the starter motor operation ...................................................... 8-24

Charging system .......................................................................................... 8-25

Checking the stator coil ........................................................................... 8-26
Checking the Rectifier Regulator............................................................. 8-26

Summary of Contents for F225A

Page 1: ...SERVICE MANUAL 290435 69J 28197 3D 11 F225A FL225A ...

Page 2: ...pecifications and procedures and these are incorporated in successive editions of this manual Microsoft and Windows are registered trademarks of Microsoft Corporation Important information 1 Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING inst...

Page 3: ...nformation 1 GEN INFO Specifications 2 SPEC Periodic checks and adjustments 3 CHK ADJ Fuel system 4 FUEL Power unit 5 POWR Lower unit 6 LOWR Bracket unit 7 BRKT Electrical systems 8 ELEC Troubleshooting 9 TRBL SHTG Index ...

Page 4: ...ly 1 4 Identification 1 5 Applicable models 1 5 Serial number 1 5 Features and benefits 1 6 Newly developed V6 4 stroke engine 1 6 Valve train system 1 9 Intake system 1 11 Exhaust system 1 11 Fuel system 1 13 PTT Power trim and tilt unit 1 17 Technical tips 1 18 Fuel injection control 1 18 Fail safe function table 1 20 PTT Power trim and tilt unit 1 21 Cooling system 1 26 Lubrication system 1 26 ...

Page 5: ...g the outboard motor mounting height 1 29 Checking the remote control cables 1 29 Checking the steering wheel 1 30 Checking the gearshift and throttle operation 1 30 Checking the tilt system 1 30 Checking the engine start switch and engine stop switch engine shut off switch 1 30 Checking the cooling water pilot hole 1 31 Test run 1 31 Break in 1 31 After test run 1 31 ...

Page 6: ...ightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions 3 Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point 4 The components list consist of parts and part quantities as well as bolt screw O ring and hose dimensions 5 Service points regarding removal checking and in...

Page 7: ...ance voltage electric current Symbols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point 7 Apply Yamaha 4 stroke motor oil 8 Apply water resistant grease Yamaha grease A 9 Apply molybdenum disulfide grease 0 Apply corrosion resistant grease Yamaha grease D A Apply low temperature resistant grease Yamaha grease C Symbols B to G in an exploded diagram indicate th...

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

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

Page 10: ...Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket 1 Model name 2 Approved model code 3 Transom height 4 Serial number Applicable models F225AET FL225AET Model name Approved model code Starting serial No F225AET 69J X 000101 U 150101 FL225AET 69K X 000101 U 100101 ...

Page 11: ...mits much cleaner exhaust gases offers a better fuel economy and realizes lower noise levels at idle and full throttle Through the newly developed In bank exhaust system which discharges exhaust gases from the center of both banks the engine block and the surrounding equipment have been made compact In addition the six independent intake passages help to achieve a high level of driveability and po...

Page 12: ...truction have been achieved The caps for the crankshaft bearings are secured with four bolts to ensure a high level of assembled rigidity 1 Casted aluminum 2 Steel 3 Crankcase 4 Cylinder block Crankshaft The crankshaft has been forged to realize a high strength and high rigidity construction In the 60 degree V6 cylinder configuration the crankshaft pins are staggered 60 degrees from each other 1 C...

Page 13: ... provided with a valve recess If the engine goes out of timing and a valve opens when the piston is at top dead center this recess prevents the valve from coming in contact with the piston thus preventing engine damage 1 Valve spring 2 Valve seal 3 Piston 4 Valve stem 5 Intake valve 6 Intake camshaft 7 Valve lifter 8 Valve recess S69J1280 Features and benefits ...

Page 14: ...o achieve a compact configuration through the use of individual driven sprockets Timing belt The timing belt which is driven by the drive sprocket that is attached to the crankshaft rotates the driven sprockets that are attached to the exhaust camshafts of both banks The drive sprocket for the timing belt is secured to the crankshaft by four bolts and it can be removed easily for servicing In addi...

Page 15: ...gine is started oil is pumped into the tensioner and the resulting pressure causes the tension to increase A total of three tensioners are used one for the timing belt and one for each timing chain of both banks to maintain proper tension and to ensure the reliability of the valve train 1 Intake camshaft 2 Exhaust camshaft 3 Timing chain 4 Timing chain tensioner 5 Hydraulic timing belt tensioner S...

Page 16: ...le body the throttle valves help to improve the intake efficiency of the engine As a result this engine produces a higher power output and realizes better driveability 1 Throttle valve Exhaust system In bank exhaust system The exhaust passage of the F225 is located in the V bank a layout that is the opposite of conven tional V6 engines By providing the exhaust passage in the V bank the engine has ...

Page 17: ...xhaust gas enters another passage on the side of the exhaust guide through another hole in the upper case gasket Then it is discharged through the idle port that is provided in the upper case The exhaust manifold and muffler in the upper case are surrounded by the water jackets to reduce exhaust noise The water jackets also help prevent corrosion by preventing the exterior of the exhaust manifold ...

Page 18: ... the injectors passes through the pressure regula tor and fuel cooler and returns to the vapor separator When the engine start switch is turned on the injectors of all cylinders operate before the pump relay is actuated to prevent the injectors from sticking 1 Fuel filter 2 Low pressure fuel pump 3 Vapor separator 4 High pressure fuel pump 5 Fuel injector 6 Pressure regulator 7 Fuel cooler S69J134...

Page 19: ... compact To prevent the over pumping of fuel this pump operates for 10 seconds and stops for 20 seconds when the engine is operating at low speeds The pump operates constantly if the engine speed is 1 200 r min or higher or for several seconds which vary by ambient temperature after the engine is started At other times it operates for 10 seconds and stops for 20 seconds to prevent over pumping 1 V...

Page 20: ...onverts the signals from the input sensors and sends instructions to each part ECM Electronic control module Thermo switch Throttle position sensor Tachometer Buzzer Pulser coil Intake air temperature sensor Diagnostic system Intake air pressure sensor Engine temperature sensor Injectors ISC Idle speed control Ignition coils Overheat monitor Oil pressure monitor Personal computer Stop switch Oil p...

Page 21: ... 3 Cylinder 4 Cylinder 5 Cylinder 6 Ignition Injection Ignition Injection Ignition Injection Ignition Injection Ignition Injection Ignition Injection Compression Compression Compression Compression Compression Compression Intake Intake Intake Intake Intake Intake Combustion Exhaust Combustion Exhaust Combustion Exhaust Combustion Exhaust Combustion Exhaust Combustion Exhaust Ignition spark Wasted ...

Page 22: ...ication Although the valves of the 61A type have been distributed to the various areas of the gear pump housing the valves of the new PTT unit have been concentrated in the vicinity of the gear pump to improve their serviceability In addition the material of the gear pump housing has been changed to enhance its corrosion resistance 1 Gear pump 2 Main valve 3 Relief valve 4 Manual valve È 61A type ...

Page 23: ...Compression TDC Compression Combustion Exhaust Intake Compression Expansion Compression Combustion Exhaust Intake Compression Intake Compression Combustion Exhaust Intake Compression Compression Combustion Exhaust Intake Compression Combustion Exhaust Compression Combustion Exhaust Intake Intake Intake Intake Combustion Exhaust Exhaust Combustion Exhaust Starting injection start timing standard po...

Page 24: ...a misfire at either cylinder once due to simultaneously firing Indicates a misfire at both cylinders twice continuous Dual engine control When two outboard engines are used if one of the engines enters any one of the control modes the other engine will also control its ignition This control is activated with the same engine speeds as with other control modes Shift cutoff control If the shift cut s...

Page 25: ...the basic injec tion map Opening angle is fixed to 60 Idle speed increases 18 Incorrect intake air temperature sen sor signal Normal control Intake air tempera ture sensor is fixed to 40 C in order to activate normal control Only in neutral 900 r min Idle speed increases 23 Incorrect neutral switch signal Normal control Normal control Normal control Normal control 28 Incorrect intake air pressure ...

Page 26: ...using in order to improve the serviceability of the engine and ensure reliable operation 1 Tilt cylinder 2 Trim cylinder 3 Manual valve 4 Up main valve 5 Down main valve 6 Up relief valve 7 Down relief valve 8 Gear pump 9 Reservoir 0 Tilt ram A Tilt piston B Tilt piston absorber C Free piston D Shock return valve E Trim ram F Trim piston G Power trim and tilt motor H Up shuttle piston I Down shutt...

Page 27: ...ion the fluid pushes the down shuttle piston downward opens the down main valve and returns the PTT fluid from the tilt cylinder upper chamber to the gear pump The fluid from the trim cylinder upper chamber then returns to the reservoir The tilt ram and the trim ram extend simultaneously and after the trim ram has extended com pletely the tilt ram operates to tilt up 1 Tilt ram 2 Tilt cylinder 3 T...

Page 28: ...ylinder lower chamber because the tilt ram is secured in place by the tilt stop lever Only the PTT fluid from the trim cylinder lower chamber can be drawn and as the fluid pressure decreases the trim ram retracts into the trim cylinder Since the tilt ram is secured in place the PTT fluid pumped by the gear pump flows into the tilt cylinder upper chamber to increase fluid pressure As a result the d...

Page 29: ...im cylinder lower chambers and then retracts the tilt ram and the trim ram Since the fluid pressure from the gear pump is applied to the tilt cylinder upper chamber the tilt ram moves downward first The hydraulic oil flows into the trim cylinder upper chamber from the reservoir When the outboard motor comes in contact with the trim ram the trim ram moves downward simul taneously with the tilt ram ...

Page 30: ...chamber to increase and the tilt piston absorber to open and release the fluid pressure into the space between the tilt piston and the free piston As a result the dampening effect of the tilt pis ton absorber and the oil lock mechanism prevent the PTT unit from damage before the tilt piston comes in contact with the top of the tilt cylinder After the collision a force to return the outboard motor ...

Page 31: ...rankshaft journal Return route Return route Oil pressure regulation Oil pan Oil sump Oil cooling Oil strainer Oil pump with relief valve Oil filter Main gallery Oil pressure sensor Low oil pressure warning Filtration of foreign objects Suction pressure feeding of oil Prevention of air suction Filtration of large foreign objects Camshaft journal Intake and exhaust valves Camshaft Pressure feed Spla...

Page 32: ...the propeller blade or outside of the propeller boss a Propeller diameter in inches b Propeller pitch in inches c Propeller type propeller mark Selection When the engine speed is at the full throttle operating range 5 000 6 000 r min the ideal propeller for the boat is one that pro vides maximum performance in relation to boat speed and fuel consumption S69J1100 S69J1110 S69J1120 Regular rotation ...

Page 33: ... level NOTE If the engine oil is above the maximum level mark H drain sufficient oil until the level is between H and L If the engine oil is below the minimum level mark L add sufficient oil until the level is between H and L Checking the battery 1 Check the capacity electrolyte level and specified gravity of the battery 2 Check that the red and black battery cables are securely connected S69J1130...

Page 34: ... by the combination of the boat and the outboard motor To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that the clamp brackets are secured with the clamp bolts Checking the remote control cables 1 Set the remote control lever to the neu tral position and fully close the throttle lever 2 Check that the throttle cam 1 is in its fully close position ...

Page 35: ...the outboard motor tilts up and down smoothly when operating the power trim and tilt unit 2 Check that there is no abnormal noise produced when the outboard motor is tilted up or down 3 Check that there is no interference with wires and hoses when the tilted up out board motor is steered 4 Check that the trim meter points down when the outboard motor is tilted all the way down Checking the engine ...

Page 36: ...hen shifting into reverse and that water does not flow in over the transom NOTE The test run is part of the break in operation Break in During the test run perform the break in operation in the following three stages 1 One hour a at 2 000 r min or at approxi mately half throttle 2 One hour b at 3 000 r min or 3 4 throttle and one minute out of every ten at full throttle 3 Eight hours c at any spee...

Page 37: ...2 3 4 5 6 7 8 9 Specifications General specifications 2 1 Maintenance specifications 2 3 Power unit 2 3 Lower unit 2 6 Electrical 2 7 Dimensions 2 9 Tightening torques 2 12 Specified torques 2 12 General torques 2 15 ...

Page 38: ...0 r min 165 5 225 0 Full throttle operating range r min 5 000 6 000 Maximum fuel consumption L US gal lmp gal hr at 6 000 r min 70 0 18 5 15 4 Power unit Type V6 4 stroke DOHC 24 valves Cylinder quantity 6 Displacement cm3 cu in 3 352 204 5 Bore stroke mm in 94 0 80 5 3 70 3 17 Compression ratio 9 9 Control system Remote control Starting system Electric Ignition control system Microcomputer TCI Ig...

Page 39: ...l quantity L US qt lmp qt 1 15 1 22 1 01 1 00 1 06 0 88 Bracket Trim angle at 12 degree boat transom Degree 3 16 Tilt up angle Degree 70 Steering angle Degree 32 32 Drive unit Gearshift positions F N R Gear ratio 2 00 30 15 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear view Clockwise Counterclockwise Propeller identification mark ...

Page 40: ...mm in 93 921 93 941 3 6977 3 6985 Measuring point H mm in 5 0 2 Piston to cylinder clearance mm in 0 075 0 080 0 0029 0 0031 Piston pin boss bore mm in 21 02 21 03 0 8276 0 8280 Piston pins Outside diameter mm in 21 00 0 827 Piston rings Top ring Dimension B mm in 1 17 1 19 0 0461 0 0468 Dimension T mm in 2 8 3 0 0 110 0 118 End gap mm in 0 15 0 30 0 0059 0 0118 Side clearance mm in 0 04 0 08 0 00...

Page 41: ... 0 013 0 001 Head diameter A Intake mm in 34 85 35 15 1 3720 1 3839 Exhaust mm in 29 85 30 15 1 1752 1 1870 Face width B Intake mm in 2 11 0 0831 Exhaust mm in 2 43 0 0957 Seat contact width C Intake mm in 1 1 1 4 0 043 0 055 Exhaust mm in 1 4 1 7 0 055 0 067 Margin thickness D Intake mm in 0 7 0 028 Exhaust mm in 1 0 0 039 Stem diameter Intake mm in 5 477 5 492 0 2156 0 2162 Exhaust mm in 5 464 5...

Page 42: ...0592 Crankshaft 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 Crankpin width mm in 21 50 21 55 0 8465 0 8484 Runout limit mm in 0 03 0 0012 Crankcase Crankshaft main journal oil clearance mm in 0 025 0 050 0 0010 0 0020 Upper crankcase main journal bearing thickness 1 mm in 2 494 2 500 0 0981 0 0984 2 mm in 2 498 2 504 0 0983 0 09...

Page 43: ...open lower limit mm in 4 3 0 17 Engine speed Engine idle speed r min 650 750 Item Unit Model F225AET FL225AET Gear backlash Pinion to forward gear mm in 0 21 0 44 0 008 0 017 0 35 0 70 0 014 0 028 Pinion to reverse gear mm in 0 70 1 03 0 028 0 041 0 70 1 03 0 028 0 041 Pinion shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Forward gear shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Reverse gear shims mm ...

Page 44: ... B Y B B W B at cranking loaded V 252 at 1 500 r min loaded V 260 at 3 500 r min loaded V 260 Spark plug gap mm in 11 0 43 Ignition coil resistance Primary coil R Y B O R Y B Y R Y B W Ω 1 5 1 9 Secondary coil spark plug wire spark plug wire kΩ 19 6 35 4 Throttle position sensor output voltage P B mV 695 705 Oil pressure sensor output voltage engine idle speed O B V 3 8 Intake air temperature sens...

Page 45: ...unloaded V 42 at 3 500 r min unloaded V 93 G W G W at cranking unloaded V 9 0 at 1 500 r min unloaded V 34 at 3 500 r min unloaded V 78 Stator coil resistance 1 G G Ω 0 24 0 41 G W G W Ω 0 21 0 30 Rectifier Regulator output peak voltage R B R Y B at 1 500 r min unloaded V 13 at 3 500 r min unloaded V 13 Power trim and tilt system Trim sensor Setting resistance Ω 9 11 Resistance P B Ω 9 387 6 Fluid...

Page 46: ...SPEC Specifications 2 9 69J3D11 Dimensions Exterior S69J2130 W5 A1 T1 W1 L7 H9 H1 H11 H2 H4 H3 H7 H8 H10 L8 L5 A2 H6 L9 L4 A3 12 C3 L2 L1 L10 L6 ...

Page 47: ...2 0 U mm in 59 2 3 L10 mm in 75 3 0 H1 X mm in 1 078 42 4 U mm in 1 205 47 4 H2 mm in 727 28 6 H3 mm in 216 8 5 H4 X mm in 643 25 3 U mm in 770 30 3 H5 mm in H6 X mm in 847 33 3 U mm in 924 36 4 H7 mm in 361 14 2 H8 mm in 39 1 5 H9 mm in 880 34 6 H10 mm in 45 1 8 H11 X mm in 25 1 0 U mm in 25 1 0 W1 mm in 317 12 5 W2 mm in W3 mm in W4 mm in W5 mm in 453 17 8 W6 mm in A1 Degree 32 A2 Degree 70 A3 D...

Page 48: ...del F225AET FL225AET B1 mm in 125 4 9 B2 mm in 254 10 0 B3 mm in 163 6 4 B4 mm in 51 2 0 B5 mm in 180 7 1 B6 mm in 411 16 2 B7 mm in B8 mm in B9 mm in 19 0 7 C2 mm in C3 mm in 79 3 1 D1 mm in 13 0 5 D2 mm in 56 2 2 S69J2140 B5 B6 B1 D1 D2 B2 C3 D1 B4 B9 B9 B9 B3 ...

Page 49: ...8 0 8 5 8 Apron bolt M6 8 0 8 5 8 Power unit bolt M9 M10 42 4 2 30 Flywheel magnet nut 240 24 174 PTT relay nut 4 0 4 2 9 Starter relay lead bolt M6 4 0 4 2 9 Battery cable nut 9 0 9 6 5 Starter motor bolt M8 29 2 9 21 Rectifier Regulator 1st M6 6 0 6 4 3 2nd 12 1 2 8 7 Link rod nut 4 0 4 2 9 Oil pressure sensor 18 1 8 13 Oil filter union bolt 34 3 4 25 Oil filter 18 1 8 13 Driven sprocket bolt M1...

Page 50: ... 4 2 9 Crankcase stud bolt 1st M8 25 2 5 18 2nd 90 Crankcase bolt 1st M10 40 4 0 29 2nd 90 1st M8 14 1 4 10 2nd 28 2 8 20 Lower unit regular rotation model Trim tab bolt M10 43 4 3 31 Lower unit bolt M10 47 4 7 34 Propeller nut 55 5 5 40 Propeller shaft housing grease nipple 6 0 6 4 3 Propeller shaft housing bolt M8 30 3 0 22 Pinion nut 142 14 2 103 Lower unit counter rotation model Trim tab bolt ...

Page 51: ...cket self locking nut 22 2 2 16 Friction plate screw M6 4 0 4 2 9 Trim stopper nut 36 3 6 25 Power trim and tilt unit Power trim and tilt unit bolt M10 42 4 2 30 Reservoir bolt M8 18 1 8 13 Reservoir cap M12 7 0 7 5 1 Manual valve 2 0 2 1 4 Fluid pipe 15 1 5 11 Trim cylinder end screw 160 16 115 Trim piston bolt M8 38 3 8 27 Tilt ram 55 5 5 40 Tilt cylinder end screw 90 9 0 65 Tilt piston bolt M6 ...

Page 52: ...cable sections of this man ual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and pro gressive stages until the specified torque is reached Unless otherwise specified torque specifications require clean dry threads Components should be at room temperature Nut A Bolt B General torque specifications N m kgf m ft lb 8 mm M5 5 0 5 3 6 10 mm M6 8 0 8 5 8 12 mm M8 18 1 8 13 1...

Page 53: ...ecking the spark plugs 3 8 Checking the thermostat 3 9 Checking the cooling water passage 3 9 Control system 3 9 Checking the throttle link and throttle cable operation 3 9 Adjusting the throttle link and throttle cable operation with a stop bolt 3 10 Adjusting the throttle link and throttle cable operation without a stop bolt 3 11 Checking the gearshift operation 3 12 Checking the engine idle spe...

Page 54: ...CHK ADJ Periodic checks and adjustments 3 1 69J3D11 Special service tools 3 Fuel pressure gauge 90890 06786 Digital tachometer 90890 06760 Timing light 90890 03141 Leakage tester 90890 06762 ...

Page 55: ...Power unit Engine oil Check before each use 3 5 Change 3 6 Oil filter Change 3 7 Oil pump Check 5 55 Timing chain Check replace 1 000 hours or 5 years 5 40 Chain tensioner Check replace 5 39 Timing belt 2 Check replace 3 8 5 21 Valve clearance Check adjust 5 15 Spark plugs Clean adjust replace 3 8 Thermostat Check 5 60 Pressure control valve Check Flywheel magnet nut Check Motor exterior Check bef...

Page 56: ... the cylinder head and crankcase bolts Lower unit Gear oil Change 3 17 Impeller Woodruff key Check replace 500 hours or 30 months 6 10 6 38 Oil seals Check replace Propeller Check before each use 3 18 General Anodes Trim tab Check replace 3 18 Battery Check charge 3 19 Wiring and connectors Adjust reconnect Nuts and bolts 4 Tighten Lubrication points Lubricate 3 20 Item Remarks Initial Every Refer...

Page 57: ...Replace if necessary Fuel system 3 Checking the fuel joint and fuel hoses fuel joint to fuel injector 1 Remove the flywheel magnet cover and intake silencer 2 Check the low pressure fuel hose con nections and fuel joint for leaks Replace if necessary Also check the fuel filter 1 low pressure fuel pump 2 and check valve 3 for leaks and deterioration Replace if necessary 3 Check the high pressure fu...

Page 58: ...dirt and residue and check the fuel filter cup 2 for foreign substances and cracks Clean with straight gasoline and replace the cup if necessary NOTE Be sure not to spill any fuel when removing the fuel filter cup Power unit 3 Checking the engine oil 1 Place the outboard motor in an upright position 2 Remove the engine oil dipstick wipe it clean and then insert it back into the oil filler hole 3 R...

Page 59: ... oil filler cap and dipstick and then start the engine and warm it up for 5 minutes 7 Turn the engine off and then check the oil level and correct it if necessary Changing the engine oil by draining it 1 Start the engine and warm it up 2 Remove the engine oil dipstick and oil filler cap 1 3 Remove the starboard apron 2 4 Place a drain pan under the drain hole and then remove the drain bolt 3 and l...

Page 60: ...oard apron 2 and then tighten it to the specified torque Replacing the oil filter 1 Extract the engine oil with an oil changer or drain it 2 Remove the oil filter cover 1 3 Place a rag under the oil filter and then remove the filter using a 72 5 mm 2 9 in oil filter wrench NOTE Be sure to clean up any oil spills 4 Apply a thin coat of engine oil to the O ring of the new oil filter T R Drain bolt 2...

Page 61: ...ary 3 Turn the crankshaft clockwise two turns to take up slack in the timing belt Replacing the timing belt NOTE For replacement procedures see Chapter 5 Replacing the timing belt Checking the valve clearance NOTE For checking procedures see Chapter 5 Checking the valve clearance Checking the spark plugs 1 Remove the ignition coil cover 2 Disconnect the spark plug wires and then remove the spark p...

Page 62: ...it in water and then start the engine 3 Check for water flow at the cooling water pilot hole If there is no water flow check the cooling water passage inside the out board motor Control system 3 Checking the throttle link and throttle cable operation 1 Check that the throttle control cam 1 is in its fully closed position and the align ment mark a is between the alignment mark b when the remote con...

Page 63: ...ntrol lever 6 3 Install the stop bolt general bolt 7 into the threaded hole 4 Push the throttle control lever 8 against the stop bolt 7 NOTE Use a general bolt with the specified mea surements 5 Push the magnet control lever 6 in the direction of the arrow to eliminate any looseness and then adjust the link rod 5 so that it aligns with the magnet control lever joint 9 6 Install the link rod 5 and ...

Page 64: ...n and adjust the cable length if nec essary repeating steps 1 10 Adjusting the throttle link and throttle cable operation without a stop bolt NOTE Be sure to synchronize the throttle valves before adjusting the throttle link For synchronizing procedures see Chapter 4 Synchronizing the throttle valve 1 Loosen the locknut 1 remove the clip 2 and then disconnect the throttle cable joint 3 2 Loosen th...

Page 65: ...nimum of 8 0 mm 0 31 in f 8 Connect the cable joint install the clip and then tighten the locknut 9 Check the throttle cable for smooth oper ation and adjust the cable length if nec essary repeating steps 1 7 Checking the gearshift operation 1 Check that the gearshift operates smoothly when shifting from neutral into forward or reverse Adjust the shift cable length if necessary 2 Set the gearshift...

Page 66: ...le speed 1 Remove the ignition coil cover 2 Start the engine and warm it up for 5 min utes 3 Attach the special service tool to spark plug wire 1 1 and then check the engine idle speed Adjust if out of specifi cation 4 Turn the engine off loosen the locknut 2 and then disconnect the link rod 3 from the magnet control lever 4 5 Loosen the port throttle stop screw 5 until it separates from the throt...

Page 67: ...at the align ment mark c is between the alignment marks d Then push the magnet control lever 4 in the direction of the arrow to eliminate any looseness 10 Install the link rod 3 and then tighten the locknut 2 11 Check that the alignment mark c is between the alignment marks d If nec essary repeat steps 8 10 12 Place the throttle cam A against the fully closed stopper e and check that there is a mi...

Page 68: ... Attach the special service tool to spark plug wire 1 1 and then check the engine idle speed Adjust if out of specifi cation 4 Attach the special service tool to spark plug wire 1 5 Check that the 1TDC mark a on the flywheel magnet is aligned with the mag net base pointer b Power trim and tilt unit 3 Checking the power trim and tilt operation 1 Fully tilt the outboard motor up and down a few times...

Page 69: ...power trim and tilt unit should lose fluid pressure 2 Remove the reservoir cap 2 and then check the fluid level in the reservoir NOTE If the fluid is at the correct level the fluid should overflow out of the filler hole when the cap is removed 3 If necessary add sufficient fluid of the recommended type until it overflows out of the filler hole 4 Install the reservoir cap and then tighten it to the...

Page 70: ...e drain screw then the check screw 2 to drain the oil 3 Check the oil for metal discoloration and its viscosity Check the internal parts of the lower case if necessary 4 Insert the gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible 5 Install the check screw and quickly install the drain screw Recommen...

Page 71: ...TE Cover the check hole with a rag when remov ing the pressure vacuum tester from the lower unit 3 If pressure drops below specification check the drive shaft and propeller shaft oil seals for damage Checking the propeller 1 Check the propeller blades and splines for cracks damage or wear Replace if necessary General 3 Checking the anodes 1 Check the anodes and trim tab for scales grease or oil Cl...

Page 72: ...protective eye gear when handling or working near batteries Antidote EXTERNAL SKIN Wash with water EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries generate explosive hydrogen gas Always follow these preventive mea su...

Page 73: ...69J3D11 3 20 1 2 3 4 5 6 7 8 9 Lubrication 1 Apply water resistant grease to the areas shown General ...

Page 74: ...CHK ADJ Periodic checks and adjustments 3 21 69J3D11 NOTE Apply grease to the grease nipple until it flows from the bushings a 2 Apply corrosion resistant grease to the areas shown ...

Page 75: ...ps 4 7 Installing the hose clamps 4 7 Checking the check valve 4 7 Reducing the fuel pressure 4 7 Checking the vapor separator 4 8 Intake manifold and high pressure fuel line 4 9 Throttle control 4 13 Removing the pressure regulator 4 15 Disconnecting the high pressure fuel hose joint 4 15 Checking the fuel injector 4 15 Checking the idle speed control ISC 4 15 Synchronizing the throttle valve 4 1...

Page 76: ...FUEL Fuel system 4 1 69J3D11 Special service tools 4 Vacuum pressure pump gauge set 90890 06756 Digital circuit tester 90890 03174 Test harness 3 pins 90890 06793 Vacuum gauge 90890 03159 ...

Page 77: ...o fuel pump 4 Fuel hose fuel pump to vapor separator 5 Fuel hose vapor separator to fuel pump 6 High pressure fuel hose vapor separator to starboard fuel rail 7 High pressure fuel hose starboard fuel rail to port fuel rail 8 Fuel hose pressure regulator to fuel cooler 9 Fuel hose fuel cooler to vapor separator Special service tools Hose routing ...

Page 78: ...FUEL Fuel system 4 3 69J3D11 Intake silencer fuel filter and fuel pump 4 ...

Page 79: ...4 Spring 1 15 O ring 1 Not reusable 16 Cup 1 17 Nut 1 18 Bolt 1 M6 16 mm 19 Bolt 1 M7 20 mm 20 Battery cable 1 21 Starboard intake silencer 1 22 Port intake silencer 1 23 Intake air temperature sensor 1 24 Check valve 2 25 Hose 2 26 Joint 1 27 Joint 2 28 Nut 4 29 Grommet 6 30 Screw 1 M5 7 mm 31 Cover 1 32 Fuel filter 1 33 Clamp 2 34 Bolt 2 M5 12 mm 35 Bracket 1 36 Low pressure fuel pump 1 37 Bolt ...

Page 80: ...FUEL Fuel system 4 5 69J3D11 Vapor separator 4 ...

Page 81: ...racket 1 13 Bolt 3 M8 16 mm 14 Collar 6 15 Bushing 4 16 Bolt 4 M8 16 mm 17 Collar 1 18 High pressure fuel pump relay 1 19 Washer 2 20 Nut 1 21 Hose 3 22 Screw 7 M4 15 mm 23 Bracket 1 24 Bolt 1 M6 10 mm 25 Gasket 1 Not reusable 26 Plate 2 27 Grommet 1 28 Screw 3 M4 8 mm 29 Plate 1 30 Needle valve 1 31 Pin 1 32 Bracket 1 33 Screw 1 34 Gasket 1 35 Drain screw 1 36 Joint 1 37 Filter 1 38 Filter holder...

Page 82: ...e hose clamps always replace them with new ones Checking the check valve 1 Install the special service tool onto the check valve 2 Apply the pressure to each check valve port Replace if necessary NOTE Make sure no air comes out of the opposite side of the check valve Reducing the fuel pressure 1 Remove the cap 1 2 Cover the pressure check valve a of the vapor separator with a rag and then press in...

Page 83: ...lace a container under the vapor sepa rator and then drain the fuel from the separator by removing the drain screw 4 WARNING Reduce the fuel pressure before removing the vapor separator drain screw or pres surized fuel will spray out and may result in serious injury Checking the vapor separator 1 Check the needle valve for bends or wear Replace if necessary 2 Check the float for deterioration Repl...

Page 84: ...FUEL Fuel system 4 9 69J3D11 Intake manifold and high pressure fuel line 4 ...

Page 85: ... 1 15 O ring 1 Not reusable 16 Metal gasket 2 Not reusable 17 Screw 2 M5 15 mm 18 Intake air pressure sensor 1 19 O ring 1 Not reusable 20 Screw 3 M4 16 mm 21 Washer 3 22 Idle speed control 1 23 O ring 1 Not reusable 24 Bolt 1 M6 55 mm 25 Bracket 1 26 Bolt 2 M6 30 mm 27 Body 1 28 Hose 1 29 O ring 1 Not reusable 30 Joint 1 31 Screw 2 M5 15 mm 32 O ring 1 Not reusable 33 Joint 1 34 Screw 2 M5 15 mm ...

Page 86: ...FUEL Fuel system 4 11 69J3D11 ...

Page 87: ... rail 1 11 Pressure regulator 1 12 Bolt 18 M8 35 mm 13 Bolt 6 M6 10 mm 14 Gasket 6 Not reusable 15 Gasket 6 Not reusable 16 Collar 12 17 Spring 1 18 Washer 12 19 Bolt 12 M8 80 mm 20 Rubber seal 6 21 Fuel injector 6 22 Grommet 6 Not reusable 23 O ring 6 Not reusable 2 1 11 8 mm 24 Collar 6 25 Bolt 6 M8 45 mm 26 O ring 1 Not reusable 27 Screw 2 M6 12 mm 28 Cap 1 29 Fuel hose 1 30 Hose 6 31 Joint 1 3...

Page 88: ...FUEL Fuel system 4 13 69J3D11 Throttle control 4 ...

Page 89: ...t 1 6 Bracket 1 7 Bolt 2 M6 20 mm 8 Washer 2 9 Bushing 5 10 Gear 2 11 Throttle control lever 1 12 Circlip 1 13 Bolt 1 14 Wave washer 1 15 Washer 1 16 Throttle cam 1 17 Spring 1 18 Bolt 2 M6 14 mm 19 Bracket 2 20 Bolt 1 M8 20 mm 21 Terminal 1 22 Starter motor lead 1 23 Bolt 1 M6 14 mm 24 Bolt 5 M6 45 mm Throttle control ...

Page 90: ...joint Checking the fuel injector 1 Check the filter for dirt or residue Clean if necessary 2 Measure the resistance of the fuel injec tors Replace if out of specification 3 Check the operation of the fuel injector using the Stationary Test of the Yamaha Diagnostic System Checking the idle speed control ISC 1 Check the operation of the idle speed control using the Stationary test or the Active test...

Page 91: ...en the synchronizing screw 6 of cylinder 3 to open throttle valve 3 5 Loosen the synchronizing screw 7 of cylinder 5 to open throttle valve 5 6 Loosen the port throttle stop screw 8 until it separates from the throttle body lever 9 7 Loosen the synchronizing screw 0 of cylinder 4 to open throttle valve 4 8 Loosen the synchronizing screw A of cylinder 6 to open throttle valve 6 9 Connect the test h...

Page 92: ...imilarly tighten and adjust the synchronizing screw 7 of cyl inder 5 13 Tighten the starboard throttle stop screw 4 until the output voltage is adjusted to specification as mentioned in step 11 plus 40 mV 14 Attach a synchronizing check tool C as shown to the port 2 throttle body to facilitate the monitoring of the throttle plate D movement Test harness 3 pins 90890 06793 Digital circuit tester 90...

Page 93: ...8 until it contacts the throttle body lever 9 and then turn it one additional turn 17 Start the engine and warm it up for 5 min utes 18 Remove the plugs E of cylinders 1 3 and 5 and then attach the special ser vice tool and adapters to the intake mani fold as shown NOTE For best results use a vacuum gauge com mercially obtainable like F or G shown in the illustration that has four adapters Vacuum ...

Page 94: ...oltage when the engine speed is at idle Adjust the throttle position sensor position if out of specification 23 Install the port link rod 2 and starboard link rod 3 24 Tighten the bank synchronizing screw 1 NOTE Tighten the screw without tilting the plate Vacuum difference between cylinders 20 mmHg 27 mbar 0 79 inHg Average vacuum difference between port and starboard banks 40 mmHg 53 mbar 1 57 in...

Page 95: ...e throttle body levers 5 and 9 If there is any clearance repeat step 24 26 Start the engine and when the engine speed is at idle check the average vac uum difference between the port and starboard banks Adjust if out of specifi cation Average vacuum difference between port and starboard banks 40 mmHg 53 mbar 1 57 inHg Throttle control ...

Page 96: ... sprockets 5 25 Checking the timing belt and sprockets 5 26 Installing the sprockets and timing belt 5 27 Cylinder head 5 29 Removing the cylinder head 5 33 Checking the valve springs 5 34 Checking the valves 5 34 Checking the valve guides 5 35 Replacing the valve guides 5 35 Checking the valve seat 5 36 Refacing the valve seat 5 36 Checking the camshaft 5 38 Checking the timing chain tensioner 5 ...

Page 97: ...king the piston pin 5 50 Checking the connecting rod small end inside diameter 5 50 Checking the connecting rod big end side clearance 5 50 Checking the crankshaft 5 50 Checking the crankpin oil clearance 5 51 Selecting the connecting rod bearing 5 52 Checking the crankshaft main journal oil clearance 5 53 Selecting the crankshaft main bearing 5 54 Disassembling the oil pump 5 55 Checking the oil ...

Page 98: ...e adaptor 90890 06563 Test harness 3 pins 90890 06769 Flywheel holder 90890 06522 Flywheel puller 90890 06521 Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 06320 Valve guide remover installer 90890 06801 Valve guide installer 90890 06810 Valve guide reamer 90890 06804 ...

Page 99: ...11 5 2 1 2 3 4 5 6 7 8 9 Valve seat cutter holder 90890 06316 Valve seat cutter 90890 06324 90890 06325 90890 06327 Crank stand alignment 90890 03107 Piston ring compressor 90890 05158 Special service tools ...

Page 100: ...POWR Power unit 5 3 69J3D11 Power unit 5 ...

Page 101: ...e 1 15 Throttle cable 1 16 Cooling water pilot hose 1 17 Dowel pin 2 18 Upper case cover 1 19 Bolt 7 M6 14 mm 20 Bolt 7 M9 35 mm 21 Bolt 6 M10 140 mm 22 Bolt 1 M6 30 mm 23 Starboard apron 1 24 Port apron 1 25 Grommet 6 26 Nut 2 27 Low pressure fuel pump driver coupler 1 28 Bolt 1 M6 20 mm 29 Holder 1 30 Grommet 1 31 Bolt 1 M6 30 mm 32 Holder 1 33 Retaining plate 1 34 PTT switch coupler 1 35 Shift ...

Page 102: ...POWR Power unit 5 5 69J3D11 ...

Page 103: ... Blowby hose guide 1 8 Blowby hose 1 9 Blowby hose 1 10 Stator coil bracket 1 11 Collar 2 12 Woodruff key 1 13 Plastic tie 5 Not reusable 14 Wiring harness guide 1 15 Bolt 3 M6 35 mm 16 Idle speed control hose 1 17 Wiring harness 1 18 Bolt 4 19 Ignition coil cover 1 20 Grommet 2 21 Plastic tie 5 Not reusable 22 Plastic tie 2 Not reusable Power unit ...

Page 104: ...POWR Power unit 5 7 69J3D11 ...

Page 105: ... 6 Bracket 1 7 Bolt 4 M6 16 mm 8 ECM 1 9 Bolt 2 M6 25 mm 10 Power trim and tilt relay 1 11 Cap 2 12 Nut 4 13 Washer 2 14 Cap 1 15 Spring washer 2 16 Battery lead 1 Red 17 Screw 1 18 Main relay 1 19 Bolt 2 M6 10 mm 20 Starter motor lead 1 Brown white 21 Screw 1 22 Holder 1 23 Starter relay 1 24 Bolt 6 M6 28 mm 25 Bracket 1 26 Grommet 6 27 Collar 6 Power unit ...

Page 106: ...sher 1 4 Battery cable 1 From terminal and power trim and tilt relay 5 Bolt 3 M8 45 mm 6 Bolt 1 M6 20 mm 7 Ground lead 1 8 Bolt 2 M6 35 mm 9 Rectifier Regulator 1 10 Gasket 1 Not reusable 11 Cover 1 12 Bolt 4 M6 25 mm 13 Clip 3 14 Cooling water hose 1 Out 15 Cooling water hose 1 In 16 Clip 1 ...

Page 107: ...3 4 5 6 7 8 9 No Part name Q ty Remarks 1 Ignition coil 3 2 Bolt 6 M6 20 mm 3 Bolt 6 M6 20 mm 4 Bracket 1 5 Clamp 3 6 Clamp 3 7 Screw 3 M6 20 mm 8 Plate 1 9 Gasket 1 10 Grommet 1 11 Idle speed control hose 1 Power unit ...

Page 108: ...POWR Power unit 5 11 69J3D11 ...

Page 109: ... 1 Long 8 Link rod 1 Short 9 Link rod 1 10 Nut 3 11 Oil filler cap 1 12 O ring 1 Not reusable 13 Oil filler neck 1 14 Bolt 2 M6 45 mm 15 Clamp 1 16 Gasket 1 Not reusable 17 Bolt 3 M6 45 mm 18 Oil pressure sensor 1 19 O ring 1 Not reusable 20 Oil filter bracket 1 21 Gasket 1 Not reusable 22 Bolt 1 23 Oil filter 1 24 Oil filter cover 1 25 Bolt 1 M6 40 mm Power unit ...

Page 110: ... 3 Drive sprocket 1 4 Plate 1 5 Woodruff key 1 6 Timing belt tensioner 1 7 Bolt 2 M10 35 mm 8 Driven sprocket 2 9 Dowel pin 2 10 Bolt 28 M6 30 mm 11 Port cylinder head cover 1 12 Gasket 1 Not reusable 13 Starboard cylinder head cover 1 14 Gasket 1 Not reusable 15 Plate 1 16 Screw 8 M4 8 mm ...

Page 111: ...ngine oil to the cylin der and then check the pressure again NOTE If the compression pressure increases check the piston and piston rings for wear Replace if necessary If the compression pressure does not increase check the valve clearance valve valve seat cylinder sleeve cylinder head gasket and cylinder head Adjust or replace if necessary Checking the oil pressure 1 Place a rag under the oil pre...

Page 112: ...earance 1 Remove the flywheel magnet cover and ignition coil cover 1 2 Disconnect the ignition coil couplers 2 and spark plug caps 3 and remove the ignition coil bracket 4 spark plugs and cylinder head covers 5 3 Turn the flywheel magnet clockwise and align the 1TDC mark a on the flywheel magnet with the pointer b and check that I marks c and d on the driven sprockets are aligned with marks e and ...

Page 113: ...r 5 7 Turn the flywheel magnet an additional 120 clockwise and align the 3TDC mark h on the flywheel magnet with the pointer b 8 Check the intake and exhaust valve clearance for cylinder 6 9 Similarly check the valve clearance of cylinders 1 2 and 3 in order and be sure to turn the flywheel magnet 120 clockwise each time Adjust if out of specification NOTE Check the valve clearance when the engine...

Page 114: ...y so that the flywheel puller plate is parallel to the fly wheel magnet NOTE Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft 12 Remove the wiring harness guide bolts NOTE Move the wiring harness guide 8 to a posi tion that will make servicing easy 13 Using a hexagon wrench turn the timing belt tensioner 9 clockwise to push the timing bel...

Page 115: ...ometer and then note the measure ment 20 Select the necessary valve shim by cal culating its thickness with the following formula Example If the Removed valve shim thickness is 2 10 mm the Checked valve clearance is 0 30 mm and the Specified valve clearance is 0 20 mm then the Necessary valve shim thickness 2 10 0 30 0 20 2 20 mm 21 Install the necessary valve shim into the valve lifter 22 Align t...

Page 116: ...y engine oil to the camshaft cap bolts before installation 25 Install the driven sprockets and then tighten the bolts to the specified torque 26 Turn the driven sprockets clockwise and align I marks c and d on the driven sprockets with marks e and f 27 Install the timing belt A turn the belt from the drive sprocket side a half turn counterclockwise to align it and then remove the pin 0 T R Camshaf...

Page 117: ...turn the flywheel magnet counter clockwise 31 Check each valve clearance and adjust if necessary 32 Install the spark plugs and then tighten them to the specified torque 33 Install the cylinder head cover bolts and then tighten them to the specified torques in two stages 34 Install the ignition coil bracket and con nect the ignition coil couplers and spark plug caps Flywheel holder 90890 06522 É T...

Page 118: ...ction of the arrows shown to prevent the flywheel holder from slipping off easily To prevent damage to the engine or tools screw in the flywheel puller set bolts evenly and completely so that the flywheel puller plate is parallel to the fly wheel magnet NOTE Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft 4 Disconnect the ignition coil c...

Page 119: ...y and then insert a ø5 0 mm 0 2 in pin 9 into the hole g NOTE Leave the pin inserted into the timing belt tensioner until the timing belt has been installed 8 Remove the timing belt 0 from the driven sprocket side 9 Check that I marks c and d on the driven sprockets are aligned with marks e and f and that the mark h on the plate is aligned with the mark i on the cylinder block Align if necessary 1...

Page 120: ...il coupler and stator coil couplers 13 Connect all couplers leads and hoses 14 Install the Woodruff key 15 Install the flywheel magnet CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily NOTE Apply engine oil to the flywheel magnet nut before installation 16 Install the intake silencer ignition coil cover and flywheel magnet cover Removi...

Page 121: ... device hose flush ing device model 8 4 Disconnect the low pressure fuel pump driver coupler PTT switch coupler shift cut switch coupler neutral switch cou pler and cooling water pilot hose 5 Remove the upper case cover 9 and aprons 0 6 Remove the power unit by removing the bolts A 7 Remove the flywheel magnet É Power unit ...

Page 122: ...l magnet comes off the tapered portion of the crankshaft Removing the oil filter 1 Place a rag under the oil filter and then remove the filter using a 72 5 mm 2 9 in oil filter wrench NOTE Be sure to clean up any oil spills Removing the timing belt and sprockets 1 Turn the drive sprocket clockwise and align the mark a on the plate with the mark b on the cylinder block and check that I marks c and ...

Page 123: ... pin and timing belt ten sioner 5 Remove the drive sprocket and plate 6 Remove the cylinder head covers and then remove the driven sprockets NOTE Hold the camshaft with a wrench and be careful not to damage the driven sprocket Checking the timing belt and sprockets 1 Check the interior and exterior of the tim ing belt for cracks damage or wear Replace if necessary 2 Check the drive sprocket 1 and ...

Page 124: ... 3 and timing belt tensioner 4 and then tighten the bolts to the specified torques 5 Check that the mark e on the plate is aligned with the mark f on the cylinder block Align if necessary 6 Using a hexagon wrench turn the timing belt tensioner 4 clockwise to push the timing belt increase strength gradually and then insert a ø5 0 mm 0 2 in pin 5 into the hole g T R Driven sprocket bolt 60 N m 6 0 k...

Page 125: ... with its part number in the upright position turn the belt a half turn counterclockwise to align it and then remove the pin 5 8 Turn the drive sprocket clockwise two turns and then check that the alignment marks are aligned NOTE Do not turn the drive sprocket counterclock wise Power unit ...

Page 126: ...POWR Power unit 5 29 69J3D11 Cylinder head 5 ...

Page 127: ...t cap 2 8 Timing chain 2 9 Oil seal 2 Not reusable 10 Camshaft 3 1 11 Camshaft 4 1 12 Camshaft 2 1 13 Camshaft 1 1 14 Bolt 28 M6 50 mm 15 Bolt 4 M8 14 mm 16 Gasket 4 Not reusable 17 Plug 2 M18 16 mm 18 Gasket 2 Not reusable 19 Port exhaust outer cover 1 20 Starboard exhaust outer cover 1 21 Gasket 2 Not reusable 22 Port exhaust inner cover 1 23 Starboard exhaust inner cover 1 24 Gasket 2 Not reusa...

Page 128: ...POWR Power unit 5 31 69J3D11 ...

Page 129: ... 1 12 Gasket 1 Not reusable 13 Collar 4 14 Joint 1 15 Plastic tie 2 Not reusable 16 Cooling water hose 1 17 Bolt 13 M6 30 mm 18 Cooling water passage cover 1 19 Gasket 1 Not reusable 20 Bolt 4 M8 40 mm 21 Bolt 4 22 Cover 4 23 Anode 4 24 Grommet 4 25 Plug 1 26 Gasket 1 Not reusable 27 Valve shim 24 28 Valve lifter 24 29 Valve cotter 48 30 Valve spring retainer 24 31 Valve spring 24 32 Valve seal 24...

Page 130: ...e ground lead 4 Remove the cylinder head bolts in the sequence shown CAUTION Do not scratch or damage the mating sur faces of the cylinder head and cylinder block 5 Remove the valve shim 2 from the valve lifter 3 using compressed air NOTE Do not mix the valve train parts Keep them organized in their proper groups 6 Remove the intake valve and exhaust valves NOTE Be sure to keep the valves springs ...

Page 131: ...eplace if out of specification 3 Measure the valve stem diameter b Replace if out of specification 4 Measure the valve stem runout Replace if out of specification Valve spring compressor 4 90890 04019 Valve spring compressor attachment 5 90890 06320 Valve spring free length a 44 20 mm 1 740 in Valve spring tilt limit b 1 5 mm 0 06 in Valve margin thickness a Intake 0 7 mm 0 028 in Exhaust 1 0 mm 0...

Page 132: ...pecial service tool from the cam shaft side until the valve guide installer 3 contacts the cylinder head NOTE Apply engine oil to the surface of the new valve guide 3 Insert the special service tool into the valve guide 2 and then ream the valve guide Valve stem runout Intake 0 01 mm 0 0004 in Exhaust 0 01 mm 0 0004 in Valve guide inside diameter a 5 51 5 52 mm 0 2169 0 2173 in Valve stem to valve...

Page 133: ...alve slowly on the valve seat with a valve lapper commercially obtain able as shown 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 is uneven Refacing the valve seat 1 Reface the valve seat...

Page 134: ... a 60 cutter to adjust the contact width of the bottom edge of the valve seat b Previous contact width 5 Use a 45 cutter to adjust the contact width of the valve seat to specification b Previous contact width c Specified contact width 6 If the valve seat contact area is too wide and situated in the center of the valve face use a 30 cutter to cut the top edge of the valve seat a 60 cutter to cut th...

Page 135: ...f neces sary use a 45 cutter to center the area and set its width b Previous contact width 9 Apply a thin even layer of lapping com pound onto the valve seat and then lap the valve using a valve lapper commer cially obtainable CAUTION Do not get the lapping compound on the valve stem and valve guide 10 After every lapping procedure be sure to clean off any remaining lapping com pound from the cyli...

Page 136: ...unger extended length a Replace if out of specification NOTE Check the timing chain tensioner every 400 hours of operation Cam lobe a Intake 45 30 45 40 mm 1 7835 1 7874 in Exhaust 45 35 45 45 mm 1 7854 1 7894 in Cam lobe b Intake 35 95 36 05 mm 1 4154 1 4193 in Exhaust 35 95 36 05 mm 1 4154 1 4193 in Crank stand alignment 90890 03107 Camshaft runout limit 0 1 mm 0 004 in Camshaft journal diameter...

Page 137: ...he valves 1 Install the new valve seal 1 to the valve guide 2 Install the valve 2 valve spring 3 and valve spring retainer 4 in the sequence shown and then attach the special ser vice tool NOTE The valve spring can be installed in any direction 3 Compress the valve spring and then install the valve cotter 7 using a thin screwdriver with a small amount of grease applied to it Timing chain tensioner...

Page 138: ...he cylinder head bolts before installation Tighten the M10 bolts to the specified torques in three stages first and then tighten the M8 bolts to the specified torques in two stages Make a mark a on the M10 bolts and the cylinder head and then tighten the bolts 90 from the mark 2 Connect the ground lead 3 Align the projection wide one b on the camshaft sprockets to the alignment plate gold c on the...

Page 139: ...per posi tion as shown and with the stamped num bers facing upside down Apply engine oil to the camshaft cap bolts before installation 6 Install the new gaskets and exhaust cov ers and then tighten the bolts to the specified torques in two stages and in the sequence shown T R Camshaft cap bolt 1st 8 N m 0 8 kgf m 5 8 ft lb 2nd 17 N m 1 7 kgf m 12 ft lb Timing chain tensioner bolt 12 N m 1 2 kgf m ...

Page 140: ...POWR Power unit 5 43 69J3D11 Cylinder block 5 ...

Page 141: ...ot reusable 8 Nut 6 9 Baffle plate 1 10 Dowel pin 2 11 Bolt 12 Not reusable 12 Connecting rod cap 6 13 Connecting rod bearing 12 14 Connecting rod 6 15 Piston 6 16 Clip 12 Not reusable 17 Piston pin 6 18 Oil ring 6 19 2nd piston ring 6 20 Top ring 6 21 Plug 1 22 Gasket 1 Not reusable 23 Gasket 1 Not reusable 24 Engine temperature sensor 1 25 Bolt 4 M6 25 mm 26 Cap 2 27 Stopper 2 Cylinder block ...

Page 142: ...POWR Power unit 5 45 69J3D11 ...

Page 143: ...8 M10 105 mm 11 Bolt 2 M8 95 mm 12 Bolt 13 M8 55 mm 13 O ring 2 Not reusable 1 9 22 9 mm 14 O ring 1 Not reusable 15 Bolt 2 M6 20 mm 16 Holder 2 17 Thermoswitch 2 18 Cover 2 19 Thermostat 2 20 Bolt 4 M6 25 mm 21 Clip 4 22 Cooling water hose 2 23 Oil seal 1 Not reusable 24 Oil seal 1 Not reusable 25 O ring 2 Not reusable 26 Oil pump assembly 1 27 Gasket 1 Not reusable 28 Oil seal 1 Not reusable 29 ...

Page 144: ... pliers and then remove the piston NOTE Be sure to keep the bearings in the order as they were removed and to note the bearing color Mark each piston with an identification number a of the corresponding cylinder Also mark each connecting rod and con necting rod cap on the up side flywheel side with an identification mark b Do not mix the connecting rods and caps Keep them organized in their proper...

Page 145: ...he piston ring dimensions of B and T Replace if out of specification 2 Level the piston ring 1 in the cylinder with a piston crown 3 Check the piston ring end gap d at the specified measuring point Replace if out of specification Piston diameter a 93 921 93 941 mm 3 6977 3 6985 in Measuring point b 5 mm 0 2 in up from the bottom of the piston skirt Cylinder bore D1 D6 94 00 94 02 mm 3 7008 3 7016 ...

Page 146: ...Replace the piston if out of specification Piston ring end gap d Top ring 0 15 0 30 mm 0 0059 0 0118 in Second ring 0 30 0 45 mm 0 0118 0 0177 in Oil ring 0 15 0 60 mm 0 0059 0 0236 in Measuring point e 20 mm 0 8 in Piston ring groove Top ring a 1 23 1 25 mm 0 048 0 049 in Second ring b 1 22 1 24 mm 0 048 0 049 in Oil ring c 2 51 2 53 mm 0 099 0 100 in Piston ring side clearance Top ring a 0 04 0 ...

Page 147: ...nnecting rod big end side clearance 1 Measure the connecting rod big end side clearance a Replace the connecting rod or crankshaft or both if out of specifi cation Checking the crankshaft 1 Measure the crankshaft journal diameter a crankpin diameter b and crankpin width c Replace the crankshaft if out of specification Piston pin diameter 21 00 mm 0 827 in Connecting rod small end inside diameter a...

Page 148: ...cap and connecting rod NOTE Install the connecting rod bearings in their original positions 4 Put a piece of Plastigauge PG 1 onto the crankpin parallel to the crankshaft NOTE Be sure not to put the Plastigauge PG 1 over the oil hole in the crankpin of the crank shaft 5 Install the connecting rod to the crankpin 3 Crankshaft journal diameter a 62 968 62 992 mm 2 4791 2 4800 in Crankpin diameter b ...

Page 149: ...rk c on the connecting rod bolts connecting rod caps and then tighten the bolts 90 from the mark 7 Remove the connecting rod cap and measure the width of the compressed Plastigauge PG 1 on each crankpin Replace the connecting rod bearing if out of specification Selecting the connecting rod bearing 1 When replacing the connecting rod bear ing select the suitable bearing as fol lows 2 Check the cran...

Page 150: ...tch in the cylinder block NOTE Install the main bearings in their original posi tions 5 Put a piece of Plastigauge PG 1 on each main journal parallel to the crank shaft NOTE Do not put the Plastigauge PG 1 over the oil hole in the main journals of the crankshaft 6 Install the remaining half of the bearings into the crankcase NOTE Install the main bearings in their original posi tions 7 Insert the ...

Page 151: ...crank case bolts 1 F 90 from the mark 10 Remove the crankcase and measure the width of the compressed Plastigauge PG 1 on each main journal Replace the main bearing if out of specification Selecting the crankshaft main bearing 1 When replacing the main bearing select the suitable bearing as follows 2 Check the crankshaft journal mark a on the crankshaft and the cylinder block mark b on the cylinde...

Page 152: ...1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 88 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 87 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 86 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 85 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 84 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 83 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 82 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2...

Page 153: ...il ring 5 second ring 6 and top ring 7 to the piston with the R mark d of the second ring and the RN mark d of the top ring facing upward 3 Offset the piston ring end gaps as shown CAUTION Do not scratch the piston or break the pis ton rings NOTE After installing the piston rings check that they move smoothly 4 Install the upper half of the bearing into the connecting rod 2 and the lower half into...

Page 154: ...ust bearings before installation 9 Install half of the bearings D and the thrust bearing E into the crankcase NOTE Install the main bearings in their original posi tions 10 Apply Gasket Maker to the mating sur face of the crankcase 11 Insert the projection g of the bearing into the notch in the crankcase NOTE Do not get any Gasket Maker on the journal bearings 12 Install the crankcase onto the cyl...

Page 155: ... tighten the con necting rod bolts to the specified torques in three stages CAUTION Do not reuse the connecting rod bolts always replace them with new ones NOTE Align the marks i on the connecting rod cap and connecting rod which you made during disassembly Apply engine oil to the connecting rod cap and connecting rod bolt before installation Make a mark j on the connecting rod bolts and connectin...

Page 156: ...the new gasket and cooling water passage cover and then tighten the bolts to the specified torque in the sequence shown 19 Before installing the power unit be sure to fill it with engine oil through the oil pas sage l of the oil filter bracket NOTE Apply a thin coat of engine oil to the O ring of the new oil filter before installation T R Baffle plate nut 12 N m 1 2 kgf m 8 7 ft lb T R Crankcase c...

Page 157: ...t and cover Installing the power unit 1 Clean the power unit matching surface and install the dowel pins 1 and the new gasket 2 2 Install the power unit 3 by installing the bolts 4 then tightening them to the specified torque 3 Install the aprons 5 and upper case cover 6 then tighten them to the speci fied torque 4 Connect the low pressure fuel pump driver coupler PTT switch coupler shift cut swit...

Page 158: ...nnect the shift cable A and throttle cable B and then adjust their lengths For adjustment procedures see Chapter 3 Checking the throttle link and throttle cable operation and Checking the gearshift operation T R Mounting bolt 4 42 N m 4 2 kgf m 30 ft lb Apron and upper case cover bolt 8 N m 0 8 kgf m 5 8 ft lb T R PTT motor lead bolt 4 N m 0 4 kgf m 2 9 ft lb ...

Page 159: ...f key 10 Install the flywheel magnet CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily NOTE Apply engine oil to the flywheel magnet nut before installation 11 Reinstall the all removed parts É Flywheel holder 90890 06522 T R Flywheel magnet nut 240 N m 24 kgf m 174 ft lb Cylinder block ...

Page 160: ...shaft housing 6 19 Disassembling the forward gear 6 19 Disassembling the lower case 6 19 Checking the pinion and forward gear 6 20 Checking the bearings 6 20 Checking the drive shaft 6 20 Checking the lower case 6 20 Assembling the lower case 6 20 Assembling the forward gear 6 21 Assembling the drive shaft housing 6 21 Installing the drive shaft 6 21 Installing the propeller shaft housing 6 22 Ins...

Page 161: ...embling the lower case 6 47 Checking the pinion and reverse gear 6 48 Checking the bearings 6 48 Checking the drive shaft 6 48 Checking the lower case 6 48 Assembling the lower case 6 48 Assembling the drive shaft housing 6 49 Installing the drive shaft 6 50 Installing the propeller shaft housing 6 50 Installing the water pump and shift rod 6 51 Installing the lower unit 6 52 Shimming counter rota...

Page 162: ...90 06502 Stopper guide plate 90890 06501 Center bolt 90890 06504 Bearing separator 90890 06534 Stopper guide stand 90890 06538 Bearing puller 90890 06535 Bearing puller claw 1 90890 06536 Slide hammer 90890 06531 Bearing outer race puller 90890 06523 Outer race puller claw A 90890 06532 ...

Page 163: ...90890 06604 Bearing depth plate 90890 06603 Bearing inner race attachment 90890 06640 90890 06659 Ball bearing attachment 90890 06636 90890 06656 90890 06657 Driver rod LS 90890 06606 Bearing outer race attachment 90890 06622 90890 06628 90890 06658 Drive shaft holder 6 90890 06520 Pinion nut holder 90890 06505 Special service tools ...

Page 164: ... Driver rod LL 90890 06605 Pinion height gauge 90890 06702 Fixing plate 90890 06711 Digital caliper 90890 06704 Shimming plate 90890 06701 Shift rod push arm 90890 06052 Backlash indicator 90890 06706 Magnet base plate 90890 07003 Dial gauge set 90890 01252 ...

Page 165: ...69J3D11 6 4 1 2 3 4 5 6 7 8 9 Magnet base 90890 06705 Puller head 90890 06514 Ring nut wrench 90890 06578 Flywheel puller 90890 06521 Special service tools ...

Page 166: ...LOWR Lower unit 6 5 69J3D11 Lower unit regular rotation model 6 ...

Page 167: ...4 Check screw 1 5 Gasket 2 Not reusable 6 Dowel pin 2 7 Bolt 7 M10 45 mm 8 Drain screw 1 9 Grommet 1 10 Bolt 1 M10 44 mm 11 Bolt 1 M10 70 mm 12 Spacer 1 13 Washer 1 14 Propeller 1 15 Washer 1 16 Washer 1 17 Cotter pin 1 Not reusable 18 Propeller nut 1 19 Trim tab 1 Lower unit regular rotation model ...

Page 168: ...LOWR Lower unit 6 7 69J3D11 S69J6010 A A A A 11 12 13 14 15 16 17 18 20 19 21 22 23 24 24 9 10 1 4 5 6 LT 572 A A A A A A 8 3 2 7 LT 572 ...

Page 169: ...p 1 7 Bolt 3 M6 20 mm 8 Seal 1 9 Woodruff key 1 10 Bolt 4 M8 45 mm 11 Cover 1 12 Seal 1 13 Water pump housing 1 14 O ring 1 Not reusable 2 5 42 mm 15 Insert cartridge 1 16 O ring 1 Not reusable 2 5 91 5 mm 17 Collar 1 18 Spacer 1 19 Washer 2 20 Wave washer 1 21 Impeller 1 22 Outer plate cartridge 1 23 Gasket 1 Not reusable 24 Dowel pin 2 Lower unit regular rotation model ...

Page 170: ...h your hands when loosening or tightening it Be sure to disconnect the battery cables from the batteries and the engine shut off switch Put a block of wood between the anti cav itation plate and propeller to keep the pro peller from turning 3 Mark the trim tab 1 at the area shown and then remove it 4 Loosen the bolts and then remove the lower unit from the upper case NOTE Check that there is no oi...

Page 171: ... if necessary 2 Check the impeller 1 and insert car tridge 2 for cracks or wear Replace if necessary 3 Check the Woodruff key 3 and the groove a on the drive shaft for wear Replace if necessary 4 Check the shift rod for cracks or wear Replace if necessary S69J6030 S69J6035 S69J6040 S69J6045 Lower unit regular rotation model ...

Page 172: ...LOWR Lower unit 6 11 69J3D11 Propeller shaft housing regular rotation model 6 ...

Page 173: ...verse gear 1 11 Reverse gear shim As required 12 Ball bearing 1 Not reusable 13 O ring 1 Not reusable 3 1 110 6 mm 14 Propeller shaft housing 1 15 Grease nipple 1 16 O ring 1 Not reusable 17 Needle bearing 1 18 Oil seal 2 Not reusable 3 1 110 6 mm 19 Ring 1 20 Bolt 2 M8 20 mm 21 Bolt 2 M8 30 mm 22 Cooling water inlet cover 2 23 Nut 1 24 Screw 1 Propeller shaft housing regular rotation model ...

Page 174: ...r shaft housing 1 Remove the reverse gear and reverse gear shim s 2 Remove the ball bearing CAUTION Do not reuse the bearing always replace it with a new one Bearing housing puller claw L 4 90890 06502 Stopper guide plate 5 90890 06501 Center bolt 6 90890 06504 É Bearing separator 1 90890 06534 Stopper guide plate 2 90890 06501 Stopper guide stand 3 90890 06538 Bearing puller 4 90890 06535 Bearing...

Page 175: ...s of the reverse gear for cracks or wear Replace the gear if necessary 3 Check the bearings for pitting or rum bling Replace if necessary Checking the propeller shaft 1 Check the propeller shaft for bends or wear Replace if necessary 2 Check the dog clutch shift rod joint and shift slider for cracks or wear Replace if necessary Needle bearing attachment 9 90890 06653 Driver rod L3 0 90890 06652 É ...

Page 176: ...will force the stopper c out of place 2 Apply grease to the new oil seals and then install them into the propeller shaft housing to the specified depth NOTE Install an oil seal halfway into the propeller shaft housing then the other oil seal 3 Install the ball bearing into the propeller shaft housing NOTE Install the ball bearing with the manufacture identification mark facing toward the propeller...

Page 177: ...ear 7 and original shim s 8 to the propeller shaft housing using a press CAUTION Add or remove shim s if necessary when replacing the reverse gear or ball bearing Bearing outer race attachment 9 90890 06622 É Propeller shaft housing regular rotation model ...

Page 178: ...LOWR Lower unit 6 17 69J3D11 Drive shaft and lower case regular rotation model 6 ...

Page 179: ...aring 1 7 O ring 1 Not reusable 3 60 5 mm 8 Pinion shim As required 9 Thrust bearing 1 10 Lower case 1 11 Needle bearing outer case 1 12 Needle bearing 24 13 Pinion 1 14 Washer 1 15 Nut 1 16 Forward gear shim As required 17 Bearing outer race 1 Not reusable 18 Taper roller bearing 1 Not reusable 19 Forward gear 1 Drive shaft and lower case regular rotation model ...

Page 180: ...sing a press CAUTION Do not reuse the bearing always replace it with a new one Disassembling the lower case 1 Remove the taper roller bearing outer race and shim s NOTE Install the claws as shown 2 Remove the needle bearing Drive shaft holder 6 1 90890 06520 Pinion nut holder 2 90890 06505 Socket adapter 3 3 90890 06508 Needle bearing attachment 1 90890 06610 Driver rod L3 2 90890 06652 S69J6180 É...

Page 181: ...bends or wear Replace if necessary Checking the lower case 1 Check the skeg and torpedo for cracks or damage Replace if necessary Assembling the lower case 1 Install the original shim s and taper roller bearing outer race CAUTION Add or remove shim s if necessary when replacing the forward gear or lower case Ball bearing attachment 3 90890 06636 Driver rod LL 4 90890 06605 S69J6200 Bearing outer r...

Page 182: ...ing into the drive shaft housing to the specified depth 2 Apply grease to the new oil seals and then install them into the drive shaft housing to the specified depth NOTE Install an oil seal halfway into the drive shaft housing then the other oil seal Installing the drive shaft 1 Install the forward gear to the lower case Bearing outer race attachment 3 90890 06628 Bearing outer race puller 4 9089...

Page 183: ...n the drive shaft housing bolts Installing the propeller shaft housing 1 Install the washer 1 and propeller shaft assembly 2 into the propeller shaft housing assembly 3 2 Apply grease to the new O rings 3 Install the propeller shaft housing assem bly into the lower case 4 Install the bolts 4 ring 5 and bolts 6 and then tighten the bolts 4 to the speci fied torque Installing the water pump and shif...

Page 184: ...he drive shaft 5 Install the washers 7 wave washer 8 spacer 9 and collar 0 to the drive shaft NOTE The collar and spacer should fit together firmly While pulling the drive shaft up install the collar with an appropriate tool a that fits over the drive shaft as shown 6 Install the O ring A and insert cartridge B into the pump housing C NOTE Align the insert cartridge projections b with the holes c ...

Page 185: ...hole e in the pump housing Installing the lower unit 1 Set the gearshift to the neutral position at the lower unit 2 Install the two dowel pins 1 to the lower unit 3 Install the lower unit to the upper case and then tighten the bolts 2 to the speci fied torque 4 Install the trim tab 3 to its original posi tion and then tighten the bolt 4 to the specified torque S69J6315 A A LT 572 Shift rod push a...

Page 186: ...ied torque WARNING Do not hold the propeller with your hands when loosening or tightening it Be sure to disconnect the battery cables from the batteries and the engine shut off switch Put a block of wood between the anti cav itation plate and propeller to keep the pro peller from turning NOTE If the grooves in the propeller nut 5 do not align with the cotter pin hole tighten the nut until they are...

Page 187: ...1 6 26 1 2 3 4 5 6 7 8 9 Shimming regular rotation model 6 A B F R P S69J6550 B4 T3 B3 65 0 T1 B1 39 4 41 0 T2 B2 B5 A1 A2 A3 Drive shaft and lower case regular rotation model Shimming regular rotation model ...

Page 188: ...all the shimming tool to the drive shaft so that the shaft is at the center of the hole Tighten the wing nuts another 1 4 of a turn after they contact the fixing plate 2 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M4 between the shimming tool and the pinion as shown 4 Turn the thrust bearing 5 two or three times to seat the drive shaf...

Page 189: ...If T3 is 0 68 mm then the pinion shim is 0 65 mm If T3 is 0 70 mm then the pinion shim is 0 68 mm Selecting the forward gear shims 1 Turn the taper roller bearing outer race 1 two or three times to seat the rollers and then measure the bearing height M1 as shown NOTE Select the shim thickness T1 by using the specified measurement s and the calcula tion formula Measure the bearing outer race at thr...

Page 190: ...en the forward gear shim is 0 42 mm If T1 is 0 60 mm then the forward gear shim is 0 58 mm Selecting the reverse gear shims 1 Turn the ball bearing 1 two or three times and then measure the bearing height M2 as shown NOTE Select the shim thickness T2 by using the specified measurement s and the calcula tion formula Measure the reverse gear at three points to find the height average 2 Calculate the...

Page 191: ...1 16 mm 3 Select the reverse gear shim s T2 as follows Example If T2 is 1 16 mm then the reverse gear shim is 1 15 mm If T2 is 1 20 mm then the reverse gear shim is 1 18 mm Backlash regular rotation model 6 Measuring the forward and reverse gear backlash 1 Remove the water pump assembly 2 Set the gearshift to the neutral position 3 Install the special service tool so that it pushes against the pro...

Page 192: ...dd or remove shim s if out of specifica tion M Measurement 8 Remove the special service tools from the propeller shaft 9 Apply a load to the reverse gear by installing the propeller 8 the spacer 9 without the washer 0 then the washer A as shown Bearing housing puller claw L 1 90890 06502 Stopper guide plate 2 90890 06501 Center bolt 3 90890 06504 É É Backlash indicator 4 90890 06706 Magnet base pl...

Page 193: ... each direction 11 Add or remove shim s if out of specifica tion M Measurement 12 Remove the special service tools and then install the water pump assembly Reverse gear backlash 0 70 1 03 mm 0 028 0 041 in Reverse gear backlash Shim thickness Less than 0 70 mm 0 028 in To be increased by 0 87 M 0 71 More than 1 03 mm 0 041 in To be decreased by M 0 87 0 71 Available shim thicknesses 0 10 0 12 0 15...

Page 194: ...LOWR Lower unit 6 33 69J3D11 Lower unit counter rotation model 6 ...

Page 195: ...4 Check screw 1 5 Gasket 2 Not reusable 6 Dowel pin 2 7 Bolt 7 M10 45 mm 8 Drain screw 1 9 Grommet 1 10 Bolt 1 M10 44 mm 11 Bolt 1 M10 70 mm 12 Spacer 1 13 Washer 1 14 Propeller 1 15 Washer 1 16 Washer 1 17 Cotter pin 1 Not reusable 18 Propeller nut 1 19 Trim tab 1 Lower unit counter rotation model ...

Page 196: ...LOWR Lower unit 6 35 69J3D11 S69J6350 A A A A 11 12 13 14 15 16 17 18 20 19 21 22 23 24 24 9 10 1 4 5 6 LT 572 A A A A A A 8 3 2 7 LT 572 ...

Page 197: ...ip 1 7 Bolt 3 M6 20 mm 8 Seal 1 9 Woodruff key 1 10 Bolt 4 M8 45 mm 11 Cover 1 12 Seal 1 13 Water pump housing 1 14 O ring 1 Not reusable 2 5 42 mm 15 Insert cartridge 1 16 O ring 1 Not reusable 2 5 91 5 mm 17 Collar 1 18 Spacer 1 19 Washer 2 20 Wave washer 1 21 Impeller 1 22 Outer plate cartridge 1 23 Gasket 1 Not reusable 24 Dowel pin 2 Lower unit counter rotation model ...

Page 198: ...th your hands when loosening or tightening it Be sure to disconnect the battery cables from the batteries and the engine shut off switch Put a block of wood between the anti cav itation plate and propeller to keep the pro peller from turning 3 Mark the trim tab 1 at the area shown and then remove it 4 Loosen the bolts and then remove the lower unit from the upper case NOTE Check that there is no o...

Page 199: ... if necessary 2 Check the impeller 1 and insert car tridge 2 for cracks or wear Replace if necessary 3 Check the Woodruff key 3 and the groove a on the drive shaft for wear Replace if necessary 4 Check the shift rod for cracks or wear Replace if necessary S69J6030 S69J6035 S69J6040 S69J6360 Lower unit counter rotation model ...

Page 200: ...LOWR Lower unit 6 39 69J3D11 Propeller shaft housing counter rotation model 6 ...

Page 201: ... race 1 Not reusable 13 Taper roller bearing 1 Not reusable 14 Propeller shaft 1 15 Thrust bearing 1 16 Propeller shaft shim As required 17 O ring 1 Not reusable 3 1 110 6 mm 18 Propeller shaft housing 1 19 Grease nipple 1 20 O ring 1 Not reusable 21 Needle bearing 1 22 Oil seal 2 Not reusable 3 1 110 6 mm 23 Ring 1 24 Bolt 2 M8 20 mm 25 Bolt 2 M8 30 mm 26 Cooling water inlet cover 2 27 Nut 1 28 S...

Page 202: ...nger and shift rod joint 2 Remove the forward gear and forward gear shim s from the propeller shaft housing using a press 3 Install the propeller shaft assembly in the reverse direction into the lower case 4 Remove the ring nut 5 and claw washer 6 5 Remove the bearing outer race 8 taper roller bearing 9 thrust bearing 0 and propeller shaft shim s A using a press Slide hammer 4 90890 06531 Puller h...

Page 203: ...t brush and cleaning solvent and then check it for cracks Replace if necessary 2 Check the teeth and dogs of the forward gear for cracks or wear Replace the gear if necessary 3 Check the bearings for pitting or rum bling Replace if necessary Checking the propeller shaft 1 Check the propeller shaft for bends or wear Replace if necessary Needle bearing attachment B 90890 06653 Driver rod L3 C 90890 ...

Page 204: ...all them into the propeller shaft housing to the specified depth NOTE Install an oil seal halfway into the propeller shaft housing then the other oil seal 3 Install the original shim s 5 and thrust bearing 6 with the propeller shaft into the propeller shaft housing CAUTION Add or remove shim s if necessary when replacing the propeller shaft thrust bearing or propeller shaft housing 4 Install the n...

Page 205: ...press NOTE Install the dog clutch D with the F mark e facing toward the forward gear CAUTION Add or remove shim s if necessary when replacing the forward gear or taper roller bearing 8 Install the shift plunger E and slider F into the propeller shaft and then install the cross pin G and spring H Ring nut wrench 9 90890 06578 Ring nut wrench 9 90890 06578 T R Ring nut 0 108 N m 10 8 kgf m 78 ft lb ...

Page 206: ...LOWR Lower unit 6 45 69J3D11 Drive shaft and lower case counter rotation model 6 ...

Page 207: ...ng 1 7 O ring 1 Not reusable 3 60 5 mm 8 Pinion shim As required 9 Thrust bearing 1 10 Lower case 1 11 Needle bearing case 1 12 Needle bearing 24 13 Pinion 1 14 Washer 1 15 Nut 1 16 Reverse gear shim As required 17 Retainer 1 18 Needle bearing 1 19 Thrust bearing 1 20 Needle bearing 2 Not reusable 21 Reverse gear 1 Drive shaft and lower case counter rotation model ...

Page 208: ...ring from the reverse gear using a chisel Disassembling the lower case 1 Remove the retainer and shim s 2 Remove the needle bearing from the retainer 3 Remove the needle bearing Drive shaft holder 6 1 90890 06520 Pinion nut holder 2 90890 06505 Socket adapter 3 3 90890 06508 Needle bearing attachment 1 90890 06610 Driver rod L3 2 90890 06652 S69J6180 É Flywheel puller 1 90890 06521 Bearing outer r...

Page 209: ...s or wear Replace if necessary Checking the lower case 1 Check the skeg and torpedo for cracks or damage Replace if necessary Assembling the lower case 1 Install the needle bearing into the retainer to the specified depth 2 Install the original shim s and retainer into the lower case Ball bearing attachment 5 90890 06636 Driver rod LL 6 90890 06605 S69J6200 Needle bearing attachment 1 90890 06654 ...

Page 210: ...gear to the specified depth 6 Install the thrust bearing and reverse gear into the lower case Assembling the drive shaft housing 1 Install the needle bearing into the drive shaft housing to the specified depth Ball bearing attachment 3 90890 06657 Driver rod LL 4 90890 06605 Bearing outer race attachment 5 90890 06628 Bearing outer race puller 6 90890 06523 É Needle bearing attachment 7 90890 0665...

Page 211: ...t housing pinion and pinion nut and then tighten the nut to the specified torque NOTE Install the drive shaft by lifting it up slightly then aligning it with the pinion and the spline of the drive shaft 4 Tighten the housing bolts Installing the propeller shaft housing 1 Install the propeller shaft housing assem bly into the lower case NOTE Apply grease to the new O rings before installation Beari...

Page 212: ...e water pump and shift rod 1 Install the shift rod assembly 1 2 Install the new gasket 2 outer plate car tridge 3 and dowel pins 4 3 Install the Woodruff key into the drive shaft 4 Align the groove on the impeller 5 with the Woodruff key 6 and then install it to the drive shaft T R Propeller shaft housing bolt 1 30 N m 3 0 kgf m 22 ft lb ...

Page 213: ...tridge projections b with the holes c in the pump housing 7 Install the O ring D and pump housing assembly E into the lower case tighten the bolts F and then install the seal G and cover H NOTE When installing the pump housing apply grease to the inside of the housing and then turn the drive shaft clockwise while pushing down the pump housing Align the cover projection d with the hole e in the pum...

Page 214: ... propeller from turning and then tighten the nut to the specified torque WARNING Do not hold the propeller with your hands when loosening or tightening it Be sure to disconnect the battery cables from the batteries and the engine shut off switch Put a block of wood between the anti cav itation plate and propeller to keep the pro peller from turning NOTE If the grooves in the propeller nut 5 do not...

Page 215: ... 2 3 4 5 6 7 8 9 Shimming counter rotation model 6 A B F R P S69J6670 B4 T3 B3 65 0 A3 T1 B1 38 4 A1 T2 B8 B5 A5 A4 A2 T 4 B7 B6 47 5 Drive shaft and lower case counter rotation model Shimming counter rotation model ...

Page 216: ...all the shimming tool to the drive shaft so that the shaft is at the center of the hole Tighten the wing nuts another 1 4 of a turn after they contact the fixing plate 2 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M4 between the shimming tool and the pinion as shown 4 Turn the thrust bearing 5 two or three times to seat the drive shaf...

Page 217: ...s follows Example If T3 is 0 68 mm then the pinion shim is 0 65 mm If T3 is 0 70 mm then the pinion shim is 0 68 mm Selecting the reverse gear shims 1 Turn the thrust bearing 1 two or three times to seat the bearing retainer 2 and then measure the bearing height M1 as shown NOTE Select the shim thickness T1 by using the specified measurement s and the calcula tion formula Measure the bearing retai...

Page 218: ... T1 as follows Example If T1 is 0 75 mm then the reverse gear shim is 0 72 mm If T1 is 0 80 mm then the reverse gear shim is 0 78 mm Selecting the forward gear shims 1 Turn the taper roller bearing outer race 1 two or three times to seat the rollers and then measure the bearing height M5 and M6 as shown NOTE Select the shim thickness T2 by using the specified measurement s and the calcula tion for...

Page 219: ...nd R is 1 and A is 6 then T2 8 45 1 100 6 100 22 95 15 73 mm 8 45 0 01 0 06 22 95 15 73 mm 1 18 mm 3 Select the forward gear shim s T2 as follows Example If T2 is 1 18 mm then the forward gear shim is 1 15 mm If T2 is 1 20 mm then the forward gear shim is 1 18 mm Selecting the propeller shaft shims 1 Turn the taper roller bearing outer race 1 two or three times to seat the rollers and then measure...

Page 220: ... that A and B are zero and check the free play when the unit is assembled Example If M6 is 15 73 mm and M7 is 12 50 mm and A is 6 and B is 5 then T4 29 00 6 100 5 100 15 73 12 50mm 29 00 0 06 0 05 15 73 12 50 mm 0 88 mm 4 Round the numerals for the propeller shaft shim s T4 as follows Example If T4 is 0 88 mm then the propeller shaft shim is 0 85 mm If T4 is 0 90 mm then the propeller shaft shim i...

Page 221: ... service tool so that it pushes against the propeller shaft NOTE Tighten the universal puller or center bolt while turning the drive shaft until the drive shaft can no longer be turned 4 Install the backlash indicator onto the drive shaft 22 4 mm 0 88 in in diame ter then the dial gauge onto the lower unit Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Ring nut wrench 90890 0...

Page 222: ...verse posi tion c with the shift rod push arm 10 Turn the drive shaft clockwise until the dog clutch 8 is fully engaged 11 Turn the shift rod to the neutral position d with the shift rod push arm 12 Turn the drive shaft counterclockwise approximately 30 Backlash indicator 4 90890 06706 Magnet base plate 5 90890 07003 Dial gauge set 6 90890 01252 Magnet base 7 90890 06705 Forward gear backlash 0 35...

Page 223: ...t rod push arm towards the reverse position c with force 15 Add or remove shim s if out of specifica tion M Measurement 16 Remove the special service tools and then install the water pump assembly Reverse gear backlash 0 70 1 03 mm 0 028 0 041 in Reverse gear backlash Shim thickness Less than 0 70 mm 0 028 in To be decreased by 0 87 M 0 71 More than 1 03 mm 0 041 in To be increased by M 0 87 0 71 ...

Page 224: ... the power trim and tilt motor 7 27 Checking the power trim and tilt motor 7 27 Assembling the power trim and tilt motor 7 28 Checking the hydraulic pressure 7 29 Disassembling the gear pump 7 31 Disassembling the tilt cylinder and trim cylinders 7 32 Checking the reservoir 7 34 Checking the tilt cylinder and trim cylinder 7 34 Checking the valves 7 34 Checking the filters 7 35 Checking the gear p...

Page 225: ...D11 1 2 3 4 5 6 7 8 9 Power trim and tilt electrical system 7 43 Checking the fuse 7 44 Checking the power trim and tilt relay 7 44 Checking the power trim and tilt switch 7 45 Checking the trim sensor 7 45 ...

Page 226: ...69J3D11 Special service tools 7 PTT oil pressure gauge assembly 90890 06580 PTT oil pressure gauge adapter 90890 06581 Cylinder end screw wrench 90890 06544 PTT piston vice attachment 90890 06572 Tilt rod wrench 90890 06569 ...

Page 227: ...69J3D11 7 2 1 2 3 4 5 6 7 8 9 MEMO Special service tools ...

Page 228: ...BRKT Bracket unit 7 3 69J3D11 Bottom cowling 7 ...

Page 229: ...M6 35 mm 14 Screw 2 M4 16 mm 15 Plate 1 16 Clip 2 17 Bushing 1 18 Washer 1 19 Shift lever 1 20 Washer 1 21 Bushing 2 22 Bolt 1 M6 30 mm 23 Bracket 1 24 Ball 1 25 Spring 1 26 Bolt 1 27 Shift rod 1 28 O ring 1 Not reusable 1 9 12 6 mm 29 Grommet 1 30 Screw 1 M6 20 mm 31 Adapter 1 32 Hose joint 1 33 Plastic tie 1 Not reusable 34 Flushing hose 1 11 650 mm 35 Grommet 1 36 PTT motor lead 1 37 Trim senso...

Page 230: ...BRKT Bracket unit 7 5 69J3D11 ...

Page 231: ...Spring 3 12 Hook 3 13 Bolt 3 M6 20 mm 14 Bracket 1 15 Bolt 2 M6 25 mm 16 Plate 2 17 Grommet 2 18 Grommet 1 19 Grommet 2 20 Collar 4 21 Grommet 8 22 Bolt 4 M6 30 mm 23 Cooling water pilot hole 1 24 Bolt 2 M6 20 mm 25 Bracket 2 26 Trailer switch 1 27 Bolt 1 M6 18 mm 28 Low pressure fuel pump driver 1 29 Bracket 1 30 Bolt 2 M6 20 mm 31 Cover 1 32 Gasket 1 33 Cowling lock lever 1 34 Plate 1 35 Lever 1...

Page 232: ...BRKT Bracket unit 7 7 69J3D11 Upper case steering arm swivel bracket and clamp brackets 7 ...

Page 233: ... 2 14 Washer 2 15 Drain bolt 1 M14 12 mm 16 Metal gasket 1 Not reusable 17 Cover 1 18 Bolt 2 M6 14 mm 19 Damper 1 20 Apron stay 6 21 Ground lead 1 22 Bolt 1 M6 10 mm 23 Ground lead 1 24 Hose 1 25 Plastic tie 1 26 Dowel pin 1 27 Adapter 1 28 Bolt 1 M6 25 mm 29 Drive shaft bushing 1 30 Circlip 2 31 Nut 4 32 Washer 4 33 Steering arm 1 34 Washer 2 35 Bushing 2 36 O ring 1 Not reusable 37 Bushing 1 38 ...

Page 234: ...BRKT Bracket unit 7 9 69J3D11 ...

Page 235: ...M6 25 mm 15 Gasket 1 Not reusable 16 Dowel pin 2 17 Oil pan 1 18 Bolt 2 M8 30 mm 19 Bolt 10 M8 60 mm 20 Gasket 1 Not reusable 21 Exhaust manifold 1 22 Bolt 4 M8 90 mm 23 Exhaust seal 1 24 Gasket 1 Not reusable 25 Plate 1 26 Dowel pin 2 27 Muffler 1 28 Cooling water pipe 1 29 Rubber seal 1 30 Bolt 10 M8 35 mm 31 Muffler seal 1 32 Rubber seal 1 33 Rubber seal 1 34 Screw 2 M6 16 mm 35 Baffle plate 1 ...

Page 236: ...BRKT Bracket unit 7 11 69J3D11 ...

Page 237: ...14 Clamp 2 15 Starboard clamp bracket 1 16 Self locking nut 1 17 Bolt 1 M6 14 mm 18 Collar 1 19 Pin 2 20 Tilt stop lever joint 2 21 Pin 1 22 Bolt 1 M6 10 mm 23 Spring 1 24 Spring holder 1 25 Port tilt stop lever 1 26 Shaft 1 27 Trim stopper 2 28 Starboard tilt stop lever 1 29 Circlip 1 30 Nut 2 31 Swivel bracket 1 32 Power trim and tilt unit 1 33 Bolt 1 M6 10 mm 34 Plastic tie 4 35 Bolt 4 M6 25 mm...

Page 238: ...ove the muffler assembly from the upper case Disassembling the oil pan 1 Remove the muffler 1 plate 2 and exhaust manifold 3 from the oil pan 4 2 Remove the oil pan 4 from the upper exhaust guide 5 and lower exhaust guide 6 3 Remove the oil strainer 7 from the lower exhaust guide 6 Checking the oil strainer 1 Check the oil strainer for dirt and residue Clean if necessary Assembling the oil pan 1 I...

Page 239: ...ng water pipe 0 into the muffler A 8 Install the muffler A and bolts into the oil pan and then tighten the bolts to the specified torque 9 Install the muffler assembly B by insert ing the tip of the cooling water pipe C into the joint hole a of the upper case 10 Install muffler assembly bolts D and E and pressure control valve F and then tighten them to the specified torques T R Oil strainer bolt ...

Page 240: ... housings J Removing the steering arm 1 Remove the circlip 1 2 Remove the steering yoke 2 by striking it with a plastic hammer 3 Remove the steering arm from the swivel bracket by pulling the arm off the bracket T R Muffler assembly bolt D 20 N m 2 0 kgf m 14 ft lb Muffler assembly bolt E 42 N m 4 2 kgf m 30 ft lb Pressure control valve F 8 N m 0 8 kgf m 5 8 ft lb ...

Page 241: ...he swivel bracket 3 Install the bushing 5 O ring 6 bushing 7 and washer 8 onto the swivel bracket 4 Install the steering arm 3 into the steer ing yoke 9 by aligning the center a of the yoke with the center b of the steer ing arm 5 Install the circlip 0 6 Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c Upper case steering arm swivel bracket and c...

Page 242: ...wise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure NOTE If the power trim and tilt does not operate loosen the manual valve and tilt the outboard motor up manually 2 Remove the anode 2 and bolts 3 3 Loosen the self locking nut 4 and then move the clamp brackets slightly in the direction of the arrows WARNING Do not remove the tilt stop lever 1 ...

Page 243: ... Assemble the clamp brackets and the swivel bracket by connecting the ground lead 2 installing the through tube 3 then tightening the self locking nut 4 fin ger tight Installing the power trim and tilt unit 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 NOTE After tilting up the outboard motor be sure to support it with the tilt stop lever 2 Install the bolts 2 o...

Page 244: ...hen support it with the tilt stop lever 1 WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 2 Loosen the cam screws 2 3 Adjust the position of the trim sensor and then tighten the screws 2 finger tight 4 Fully tilt the outboard motor down 5 Measure ...

Page 245: ...sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 8 Measure the trim sensor resistance Check the trim sensor if out of specifica tion Trim sensor resistance Pink P Black B 247 6 387 6 Ω at 20 C 68 F Upper case steering arm swivel bracket and clamp brackets ...

Page 246: ...BRKT Bracket unit 7 21 69J3D11 Power trim and tilt unit 7 ...

Page 247: ...ng 1 Not reusable 2 4 22 6 mm 12 Joint 1 13 O ring 1 Not reusable 14 Manual valve 1 15 Circlip 1 16 Shaft 1 17 Circlip 1 18 Bushing 2 19 Pipe 1 20 Pipe 1 21 Yoke 1 22 Bolt 2 M5 12 mm 23 Washer 4 24 Wave washer 1 25 Washer 1 26 Bearing 2 27 Armature 1 28 Brush 4 29 Spring 4 30 Screw 2 M4 12 mm 31 Brush holder 1 32 Nut 2 33 Screw 2 M4 6 mm 34 O ring 1 Not reusable 35 PTT motor base 1 36 Oil seal 1 N...

Page 248: ...BRKT Bracket unit 7 23 69J3D11 ...

Page 249: ...reusable 11 Spring 2 12 Adapter 2 13 Circlip 2 14 Tilt ram 1 15 Dust seal 1 Not reusable 16 Tilt cylinder end screw 1 17 O ring 1 Not reusable 18 Backup ring 1 19 O ring 1 Not reusable 20 Spring 1 21 Adapter 1 22 Tilt piston 1 23 O ring 1 Not reusable 24 Backup ring 1 25 Ball 5 26 Pin 5 27 Spring 5 28 Washer 1 29 Plate 1 30 Washer 1 31 Bolt 1 M6 10 mm 32 Free piston 1 33 O ring 1 Not reusable 34 T...

Page 250: ...BRKT Bracket unit 7 25 69J3D11 ...

Page 251: ...sable 1 8 11 35 mm 12 Ball 1 13 Circlip 2 14 Main valve seal 2 15 Shuttle piston 1 16 O ring 1 Not reusable 17 Return spring 2 18 Shuttle piston 1 19 Drive gear 2 20 Ball 2 21 Gear housing 2 1 22 Ball 2 23 Manual release spring 1 24 Dowel pin 1 25 Ball 2 26 Pin 2 27 Spring 2 28 Spacer 2 29 O ring 2 Not reusable 1 9 9 6 mm 30 Dowel pin 2 31 Bracket 1 32 Washer 2 33 Bolt 2 M5 25 mm 34 O ring 2 Not r...

Page 252: ...2 Remove the screws 3 disconnect the PTT motor leads 4 and then remove the springs 5 and brushes 6 Checking the power trim and tilt motor 1 Check the commutator for dirt or foreign substances Clean with 600 grit sand paper if necessary 2 Check the commutator undercut for dirt or foreign substances Clean with com pressed air if necessary 3 Measure the commutator diameter a Replace if out of specifi...

Page 253: ... 1 Install the new oil seal 1 and bearing 2 into the motor base 3 as shown 2 Connect the PTT motor leads 4 to the brush holder 5 and then install the brush holder 5 to the motor base 6 3 Install the brushes 7 and springs 8 to the brush holder as shown 4 Install the bearing 9 to the armature 0 5 Push the brushes 7 into the holders and then install the armature 0 Armature coil continuity Commutator ...

Page 254: ...sure Check the internal parts if out of specification 2 Fully extend the power trim and tilt rams 3 Loosen the pipe joints 1 and then remove the pipe joint a 4 Install the PTT oil pressure gauge adapter set 2 NOTE Cover the removed pipe joint a with a rag 5 Connect the PTT motor leads to the bat tery terminals to retract the tilt ram and then measure the hydraulic pressure PTT oil pressure gauge a...

Page 255: ...nd then remove the pipe joint b 11 Install the PTT oil pressure gauge adapter set 2 NOTE Cover the removed pipe joint b with a rag 12 Connect the PTT motor leads to the bat tery terminals to extend the tilt ram and then measure the hydraulic pressure 13 Reverse the PTT motor leads between the battery terminals to fully retract the trim and tilt rams Ram PTT motor lead Battery terminal Up Sky blue ...

Page 256: ... Remove the reservoir cap and then check the fluid level in the reservoir 18 If necessary add fluid of the recom mended type to the correct level NOTE If the fluid is at the correct level the fluid should overflow out of the filler hole when the cap is removed 19 Install the reservoir cap Disassembling the gear pump 1 Remove the manual valve 1 and gear pump 2 2 Remove the relief valve seal 3 and b...

Page 257: ...ld the tilt cylinder 1 in a vise using aluminum plates a on both sides 2 Loosen the tilt cylinder end screw 2 and then remove the tilt piston assembly WARNING Make sure that the rams are fully extended before removing the end screw 3 Drain the power trim and tilt fluid 4 Remove the free piston 3 and then blow compressed air through the hole b while holding down the cloth Cylinder end screw wrench ...

Page 258: ...nder block 6 in a vise using aluminum plates a on both sides 8 Loosen the trim cylinder end screws 7 and then remove them 9 Remove the trim piston assemblies 10 Drain the power trim and tilt fluid 11 Remove the circlip 8 adapter 9 and spring 0 from the trim piston assem blies 12 Hold the trim ram A in a vise using alu minum plates a on both sides 13 Remove the trim piston B PTT piston vice attachm...

Page 259: ...place if necessary 3 Check the outer surface of the tilt piston 1 trim piston 2 adapter 3 free piston 4 and oil seal of end screw 5 for scratches Replace if necessary 4 Check the trim and tilt rams for bends or excessive corrosion Polish with 400 600 grit sandpaper if there is light rust or replace if necessary 5 Check the pipes for cracks or corrosion Replace if necessary Checking the valves 1 Ch...

Page 260: ...g the filters 1 Check gear pump filters 1 and 2 and shuttle piston filters 3 for dirt or residue Clean if necessary Checking the gear pump 1 Check the drive gear for damage or excessive wear Replace if necessary Checking the gear pump housing 1 Check the gear pump housing for scratches Replace if necessary Assembling the gear pump 1 Install the drive gears 1 dowel pins 2 balls 3 and shuttle piston...

Page 261: ...o the gear housing 1 5 5 Install the filters C and gear pump D by installing the bolts E then tightening them to the specified torque 6 Install the manual valve F Assembling the tilt ram 1 Install the new dust seal 1 O rings 2 and 3 and backup ring 4 into the tilt cylinder end screw 5 T R Gear pump bracket bolt 0 7 N m 0 7 kgf m 5 1 ft lb T R Gear pump bolt E 7 N m 0 7 kgf m 5 1 ft lb Power trim a...

Page 262: ...ll the balls E absorber valve pins F and springs G as shown 7 Install the washers H plate I and bolt J to the tilt piston 9 and then tighten the bolt to the specified torque Assembling the trim rams 1 Install the trim piston 1 to the trim ram 2 2 Hold the trim ram 2 in a vise using alu minum plates a on both sides 3 Tighten the trim piston bolt to the speci fied torque PTT piston vice attachment A...

Page 263: ...ng 1 to the free pis ton 2 2 Push the free piston 2 into the tilt cylin der 3 until it bottoms out 3 Install the tilt cylinder 3 to the cylinder block 4 4 Install pipes 5 and 6 and then tighten them to the specified torque Installing the trim rams 1 Hold the cylinder block 1 in a vise using aluminum plates a on both sides 2 Fill the trim cylinders with the recom mended fluid to the correct level b...

Page 264: ...nt 1 into the pump housing 2 Fill the pump housing with the recom mended fluid to the correct level a as shown 3 Remove all of the air bubbles with a syringe or suitable tool NOTE Turn the joint with a screwdriver and then remove any air between the pump gear teeth 4 Install the new O ring 2 power trim and tilt motor 3 and then tighten the bolts 4 to the specified torque Recommended power trim and...

Page 265: ...torque Installing the tilt ram 1 Fill the tilt cylinder with the recommended fluid to the correct level a as shown 2 Add a small amount of the recommended fluid through the cylinder block hole b as shown 3 Install the tilt piston assembly into the tilt cylinder and then tighten the tilt cylinder end screw 1 to the specified torque T R PTT motor bolt 4 18 N m 1 8 kgf m 13 ft lb T R Reservoir bolt 6...

Page 266: ... Check the fluid level in the reservoir NOTE The fluid level should be at the brim of the filler hole 4 If necessary add sufficient fluid of the recommended type to the correct level 5 Install the reservoir cap 6 Connect the PTT motor leads 2 to the battery terminals 7 Reverse the PTT motor leads between the battery terminals to fully extend the tilt ram and trim rams and then reverse them again t...

Page 267: ...l valve by turning it clockwise 4 Let the fluid settle for 5 minutes 5 Push and hold the power trim and tilt switch in the up position until the out board motor is fully tilted up 6 Support the outboard motor with the tilt stop lever and then let the fluid settle for 5 minutes WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor co...

Page 268: ... A 3 Power trim and tilt relay 4 Power trim and tilt motor 5 10 pin coupler 6 Battery 7 Power trim and tilt switch 8 Trim sensor B Black Gy Gray Lg Light green P Pink R Red Sb Sky blue S69J7520 R R B B B R B R R P B Sb Lg Sb Sb Lg Lg Lg R B Sb Gy Lg R R R R B P Gy Lg R Sb B Lg Lg Sb Sb Sb R Lg ...

Page 269: ...nd the black B lead to the negative battery terminal as shown 4 Check for continuity between terminals 1 and 3 Replace if there is no continu ity 5 Connect the digital circuit tester between power trim and tilt relay terminals 2 and 3 6 Connect the sky blue Sb lead to the positive battery terminal and the black B lead to the negative battery terminal as shown 7 Check for continuity between termina...

Page 270: ...f specification Checking the trim sensor 1 Measure the trim sensor resistance Replace if out of specification NOTE Turn the lever 1 and measure the resistance as it gradually changes Lead color Switch position Skyblue Sb Red R Lightgreen Lg Up Free Down Trim sensor resistance Pink P Black B 9 11 Ω at 20 C 68 F a 247 6 387 6 Ω at 20 C 68 F b ...

Page 271: ...8 13 Checking the engine temperature sensor 8 13 Checking the thermoswitch 8 14 Checking the shift cut switch 8 14 Checking the neutral switch 8 14 Checking the main relay 8 15 Fuel control system 8 16 Checking the low pressure fuel pump and high pressure fuel pump 8 18 Checking the high pressure fuel pump relay 8 18 Starting system 8 19 Checking the fuse 8 20 Checking the wiring harness 10 pins 8...

Page 272: ... 8 Ignition tester 90890 06754 Digital circuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 2 pins 90890 06792 Test harness 4 pins 90890 06771 Test harness 3 pins 90890 06793 Test harness 3 pins 90890 06770 Test harness 2 pins 90890 06787 ...

Page 273: ...any of the connections of the digital tester leads NOTE Use the peak voltage adaptor with the digi tal circuit tester When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode Connect the positive pin on the peak volt age adaptor to the positive terminal of the digital circuit tester Measuring the lower resistance When measuring a resistance of 10 Ω or l...

Page 274: ...ELEC Electrical systems 8 3 69J3D11 Electrical components 8 Starboard and rear views 1 Thermoswitch 2 Starter motor 3 Oil pressure sensor 4 Ignition coils S69J8030 1 3 5 2 4 6 ...

Page 275: ...69J3D11 8 4 1 2 3 4 5 6 7 8 9 Port view 1 Fuel injectors 2 High pressure fuel pump relay 3 Low pressure fuel pump 4 ECM 5 High pressure fuel pump 6 Fuses S69J8040 Electrical components ...

Page 276: ...ELEC Electrical systems 8 5 69J3D11 Front view 1 Starter motor 2 Fuses 3 ECM 4 Main relay 5 Rectifier Regulator 6 Power trim and tilt relay 7 Starter relay S69J8050 E E ...

Page 277: ...ontrol 3 Thermoswitches 4 Intake air pressure sensor 5 Engine temperature sensor 6 Fuses 7 Rectifier Regulator 8 Intake air temperature sensor 9 Starter motor 0 Oil pressure sensor A Stator coil B Throttle position sensor C Ignition coils S69J8060 Electrical components ...

Page 278: ... Y R Y R Y R Y R Y R Y R Y R B R Y B B B B B B B B S69J8071 B L W B W Sb Y G L P Br B P B P W L W L W L W W B R B P W B Br B B B B W O Lg Sb B B B Y R Y R Y W Pv W B B Y B R Y R Y R Y R Y Y G Sb Lg L R Y R Y R 1 G 2 Y G 3 P 4 W 5 6 L W 7 B Y 8 B 9 L Y 10 O 11 O 12 O 13 W G 14 W B 15 W R 16 B W 17 L R 18 G B 19 G 20 G R 21 G Y 22 B O 23 P B 24 P W 25 26 W B 27 L W 28 Y 29 P W 30 R Y 31 Br 32 B 33 P...

Page 279: ...elay I Intake air temperature sensor J Main relay K Fuse 20 A L Oil pressure sensor M Power trim and tilt switch N Computer O Diagnostic indicator P Warning indicator Q Remote control S69J8081 L W P W P B W B B W R Y L R R Y L R L Y R B B B B B B B B B B B B B B B B B B B B R G P P B B B B L B B B Br B P O P L B B Lg Sb Br R Y R Y R Y R Y R Y R B R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y...

Page 280: ...ge B W Black white B Y Black yellow Br W Brown white G B Green black G R Green red G W Green white G Y Green yellow L R Blue red L W Blue white L Y Blue yellow O B Orange black O R Orange red O Y Orange yellow P B Pink black P G Pink green P W Pink white R B Red black R Y Red yellow W B White black W G White green W R White red Y G Yellow green R R R R R R R Y R Y R Y R R R R Y R Y R Y Br W Br W R...

Page 281: ...ow P G Pink green P W Pink white R Y Red yellow W B White black W G White green W R White red Y G Yellow green S69J8100 R Y R Y B R Y R Y R Y R Y R Y R B B R Y R Y R Y R Y B B R B W R Y R B W R Y B Y B O R B W R Y 1 4 3 6 5 2 2 4 6 7 8 9 10 11 Y G P L W B Y B L Y O O 12 13 14 15 22 28 29 30 O W G W B W R B O Y P W R Y B P G P B Y P B B Y B W 32 33 34 35 37 42 43 44 B Y B B Y B Y L W B Y P B O B P ...

Page 282: ...rk gap tester leads Do not let sparks leak out of the removed spark plug caps Keep flammable gas or liquids away since this test can produce sparks Checking the ignition coil 1 Remove the spark plug wires from the spark plugs 2 Disconnect the ignition coil coupler 3 Measure the ignition coil resistance Replace if out of specification Ignition tester 90890 06754 S69J8120 É É S69J8160 OK É Ignition ...

Page 283: ...engine start switch to ON 3 Measure the throttle position sensor input voltage Replace the ECM if out of specification 4 Measure the throttle position sensor out put voltage Adjust the throttle position sensor if out of specification Digital circuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 2 pins 90890 06792 ECM output peak voltage Black orange B O Ground Black yellow B Y G...

Page 284: ...ture sensor in a container of water and slowly heat the water 2 Measure the engine temperature sensor resistance Replace if out of specifica tion Test harness 3 pins 90890 06793 Throttle position sensor input voltage Orange O Black B 5 V Throttle position sensor output voltage Pink P Black B 695 705 mV Intake air temperature sensor resistance at 0 C 32 F 5 4 6 6 kΩ at 80 C 176 F 0 29 0 39 kΩ S69J8...

Page 285: ...ing the shift cut switch 1 Check the shift cut switch for continuity Replace if there is no continuity Checking the neutral switch 1 Check the neutral switch for continuity Replace if there is no continuity Thermoswitch continuity temperature Pink P Black B e 84 90 C 183 194 F f 68 82 C 154 179 F S69J8250 Switch position Lead color Blue yellow L Y Black B Free a Push b Switch position Lead color B...

Page 286: ...ect the terminal 4 to the positive battery terminal 3 Connect the terminal 5 to the negative battery terminal 4 Check for continuity between the main relay terminals Replace if there is no continuity 5 Check that there is no continuity between the main relay terminals after disconnect ing terminal 4 or 5 Replace if there is continuity S69J8280 ...

Page 287: ...Y R Y R B B R Y R Y R Y R Y B B 2 6 7 8 9 10 11 12 13 14 Y G L W B Y B L Y O O O W G W B 15 16 17 18 19 20 21 28 29 30 W R B W L R G B G G R G Y Y P W R Y Br B P G P B Y P O Y O B O R B 31 32 33 34 35 37 38 39 40 42 B Y B B Y B Y Y P B O B P G O P B G G G G L Y B B Br B B R R B O B P W B Y W B W R W G W G B W R R Y L Y R Y R Y W R W G W B R Y Y G R Y R Y R Y B Y R Y B B R R R R R B B Br B B G G G ...

Page 288: ... 6 7 8 9 10 11 12 13 14 Y G L W B Y B L Y O O O W G W B 15 16 17 18 19 20 21 28 29 30 W R B W L R G B G G R G Y Y P W R Y Br B P G P B Y P O Y O B O R B 31 32 33 34 35 37 38 39 40 42 B Y B B Y B Y Y P B O B P G O P B G G G G L Y B B Br B B R R B O B P W B Y W B W R W G W G B W R R Y L Y R Y R Y W R W G W B R Y Y G R Y R Y R Y B Y R Y B B R R R R R B B Br B B G G G G B B B B Y B P P B P B P B P B R...

Page 289: ...r 10 seconds and the high pressure fuel pump will operate for 5 seconds Checking the high pressure fuel pump relay 1 Connect the digital circuit tester leads to high pressure fuel pump relay terminals 1 and 2 2 Connect the terminal 3 to the positive battery terminal 3 Connect the terminal 4 to the negative battery terminal 4 Check for continuity between the high pressure fuel pump relay terminals ...

Page 290: ...ectrical systems 8 19 69J3D11 Starting system 8 1 Fuse 30 A 2 Fuse 20 A 3 Starter relay 4 Starter motor 5 Battery B Black Br Brown R Red Br W Brown white S69J8330 R R B B B R Br Br W Br W R B B R Br Br R R R R ...

Page 291: ...the digital circuit tester leads to the starter relay terminals 2 Connect the brown Br lead to the posi tive battery terminal 3 Connect the black B lead to the nega tive battery terminal 4 Check for continuity between the starter relay terminals Replace if there is no continuity 5 Check that there is no continuity between the starter relay terminals after discon necting the brown or black lead Rep...

Page 292: ...ELEC Electrical systems 8 21 69J3D11 Starter motor 8 ...

Page 293: ... E clip 1 Not reusable 11 Thrust washer 1 12 Center bracket 1 13 Pinion shaft 1 14 Planetary gear 3 15 Outer gear 1 16 Plate 1 17 Armature 1 18 Stator 1 19 Brush holder assembly 1 20 Plate 1 21 Thrust washer 1 22 Lower bracket 1 23 Screw 2 M4 15 mm 24 Bolt 2 M6 120 mm 25 Shift lever 1 26 Spring 1 27 Metal gasket 1 28 Gasket 1 Not reusable 29 Magnet switch 1 30 Brush assembly 1 31 Nut 1 Starter mot...

Page 294: ...n the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place Checking the armature 1 Check the commutator for dirt Clean with 600 grid sandpaper and com pressed air if necessary 2 Measure the commutator diameter Replace the armature if out of specifica tion 3 Measure the commutator undercut a Replace the armature if out of specifica tion 4 ...

Page 295: ...d otherwise the magnet switch may be damaged 4 Check that there is continuity between the magnet switch terminals Replace if there is no continuity 5 Check that there is no continuity after the negative battery terminal is removed Replace if there is continuity NOTE The starter motor pinion should be pushed out while the magnet switch is on Checking the starter motor operation 1 Check the operatio...

Page 296: ... Charging system 8 1 Stator coil 2 Rectifier Regulator 3 Fuse 30 A 4 Battery B Black G Green R Red G W Green white R Y Red yellow S69J8460 G G G G G G B B B R R R R G W G W G W G W R Y R Y R Y G W G W R R R G W G W G W R Y R R Y R G G G G ...

Page 297: ...ncer is not installed 4 Measure the Rectifier Regulator output peak voltage If below specification mea sure the stator coil output peak voltage Replace the Rectifier Regulator if the out put peak voltage of the stator coil is above specification NOTE Disconnect the output lead coupler red and red yellow lead of the Rectifier Regulator when measuring the output peak voltage Digital circuit tester 9...

Page 298: ... 27 69J3D11 Digital circuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 2 pins 90890 06787 Rectifier Regulator output peak voltage Red R Black B Red yellow R Y Black B r min Unloaded 1 500 3 500 DC V 13 13 ...

Page 299: ...bleshooting Special service tools 9 1 Yamaha Diagnostic System 9 2 Introduction 9 2 Operating 9 3 Troubleshooting 9 46 Power unit 9 47 Bracket unit 9 56 Electrical systems 9 60 Self diagnosis 9 61 Diagnosing the electronic control system 9 61 ...

Page 300: ...roubleshooting 9 1 69J3D11 Special service tools 9 Yamaha Diagnostic System 68F 85300 01 Yamaha Diagnostic System upgrade 68F 2819K 10 Diagnostic flash indicator 4 90890 06795 Diagnostic flash adaptor 90890 06794 ...

Page 301: ...s you to find malfunctioning parts and controls quickly 2 Diagnosis record Sensors that had been activated and ECM diagnostic codes that have been recorded are displayed This allows you to check the outboard motor s record of malfunctions 3 Engine monitor Each sensor status and the ECM data are displayed while the engine is run ning This enables you to find malfunctioning parts quickly 4 Stationar...

Page 302: ...r Fig 2 NOTE Use either the COM1 or COM2 port and if necessary set the serial port as specified in the com puter s manual Set the serial port where the RS232C Dsub 9 pin cable is connected to COM1 or COM2 3 Connect the remote control to the outboard motor 4 Connect the 12 V battery to the outboard motor NOTE The following items should be checked before starting the Yamaha Diagnostic System The bat...

Page 303: ...he engine start switch of the outboard motor to ON 2 Turn on your computer and start up Windows 95 Windows 98 Windows Me or Windows 2000 3 From the taskbar at the bottom of your computer screen click the Start button Fig 4 point to Programs and then click Yamaha Diagnostic System Fig 4 3 pin communication coupler Yamaha Diagnostic System ...

Page 304: ...ic System window Fig 5 After about three seconds the display will automatically go to the first menu or click or press any key to go to the first menu See fig 6 Fig 5 5 Click the Starting service tool Enter button or press the Enter key on your keyboard Fig 6 Fig 6 ...

Page 305: ...e error messages If the program doesn t start an error message will explain the problem If the program doesn t start and an error message is not displayed the cause of the problem is most likely insufficient com puter memory 6 Click or press any key to display the main menu Fig 7 Yamaha Diagnostic System ...

Page 306: ...isplayed Fig 8 Fig 8 Selecting commands from the main menu Eight commands appear in the Main Menu Select a command in any of the following three ways Three ways to select command Move the mouse pointer over the selected command 1 or 2 until it appears as a finger mark and then click the selected command Press any key number 1 8 corresponding to the selected command Fig 9 ...

Page 307: ...ons that have occurred can be deleted from the ECM The items are the same as those listed above for Diagnosis except no record of engine stop lan yard switch 3 Engine monitor The input signal of each sensor for the ECM is displayed In addition the sensing item that is displayed can be changed Sensing items Sensors throttle position sensor intake air temperature sensor intake air pressure sensor an...

Page 308: ... displayed 7 ECM No The ECM part number and model information are displayed 8 Exit The program is exited Diagnosis The diagnosis codes of malfunctions recorded in the outboard motor s ECM the diagnosis codes corresponding part name the results of the diagnosis and the condition of the part are listed Eight items can be displayed at one time To check the other items scroll the display Fig 10 NOTE S...

Page 309: ...eyboard NOTE Items where Normal does not appear in the Result column are displayed at the top of the list The selected code is highlighted in light blue and its confirmation procedure is displayed below the table Print By selecting the Print command in the Diagnosis Diagnosis record Engine monitor or Data logger mode the data from the corresponding window can be printed 1 Click the Print F1 button...

Page 310: ...he printer the printing range and the number of copies to be printed Fig 12 3 Click the OK button to begin printing To cancel printing click the Cancel button NOTE The Print Screen function in Windows cannot be used since scroll data cannot be printed ...

Page 311: ...nosis record Engine monitor or Data logger mode the corresponding data can be saved on a disk Operating procedure 1 Click the Save F2 button or press the F2 key on your keyboard The Save As dialog box is displayed Fig 13 Fig 13 Fig 14 Displays keyboard operations Yamaha Diagnostic System ...

Page 312: ...oubleshooting 9 13 69J3D11 2 Select the disk and folder where the data will be saved and specify its file name Fig 15 Fig 15 3 Click the Save button to save the data To cancel saving click the Cancel button Fig 15 ...

Page 313: ...alfunctions occurred are listed A maximum of six items can be displayed at one time The latest occurrence appears on top In addition diagnosis codes stored in the ECM can be deleted Fig 16 NOTE Some items may not be available depending on the model of the outboard motor Displays troubleshooting procedures for selected code Displays keyboard operations Displays time of occurrence Yamaha Diagnostic ...

Page 314: ...TRBL SHTG Troubleshooting 9 15 69J3D11 NOTE When a Diagnosis record is not available Diagnosis Record is unavailable is displayed Fig 17 Fig 17 ...

Page 315: ...utton or press the F3 key on your keyboard See fig 17 A confirmation message appears Fig 18 Fig 18 3 Click the OK button or press the Enter key on your keyboard Fig 18 The selected item is deleted To cancel deleting the item click the Cancel button or press the Esc key on your key board NOTE If an error occurs while an item is being deleted an error message appears Follow the instructions that app...

Page 316: ...ted which could result in a collision CAUTION Be sure to avoid splashing water on the laptop computer adapter and communication cable and to avoid damaging them with strong sudden jolts or vibration The data from the ECM of the outboard motor is displayed Ten items can be displayed at one time To view the other items scroll the display Displayed items can be changed as necessary Fig 20 ...

Page 317: ...n arrow keys on your keyboard and then press the space bar Fig 21 Fig 21 NOTE Selected items have a light blue background Items that are not selected have a blue background The box to the left of items that are being moved are light blue Items that are not selected appear in blue At initialization all items are displayed 4 Click the OK button or press the Enter key on your keyboard The Engine moni...

Page 318: ...rate injector operate electric fuel pump operate electric fuel feed pump and operate ISC valve can be selected WARNING Avoid clicking the Execute and Cancel buttons repeatedly otherwise the ECM or PC may not work properly and they may be damaged Fig 22 Confirmation item before the test Displays keyboard operations Explanation of selected item ...

Page 319: ...keyboard Fig 22 NOTE Make sure that the engine is not running The selected item is highlighted in light blue The details of the selected test are displayed in the column on the right and the items that must be either checked or performed before the test can start are displayed below the table Only one item can be selected at one time A special tool spark gap tester 90890 06754 is needed 2 Connect ...

Page 320: ...TRBL SHTG Troubleshooting 9 21 69J3D11 5 Click the Execute button or press the Enter key on your keyboard Fig 24 Fig 24 Fig 25 ...

Page 321: ...ion column follow the test instructions in the messages that are displayed See fig 25 NOTE If an error occurs while the test is being performed an error message is displayed Follow the instructions that appear in the error message Fig 27 Fig 27 7 To stop the stationary test click the Cancel button See fig 25 8 Observe the spark through the discharge window of the spark gap tester Yamaha Diagnostic...

Page 322: ...n or press the Enter key on your keyboard To perform the test on a different cylinder click the Return ESC button or press the Esc key on your keyboard to return to main menu where a different test can be selected NOTE If an error occurs while the test is being performed the following message is displayed Fig 28 ...

Page 323: ...hly flammable 1 Select the test that you wish to perform by either clicking it or pressing the up or down arrow keys on your keyboard Fig 29 Fig 29 NOTE Make sure that the engine is not running The selected item is highlighted in light blue The details of the selected test are displayed in the column on the right and the items that must be either checked or performed before the test can start are ...

Page 324: ...ting 9 25 69J3D11 3 Click the Execute button or press the Enter key on your keyboard Fig 30 Fig 30 NOTE If an error occurs while the test is being performed an error message is displayed Follow the instructions that appear ...

Page 325: ...rating sound of the injector for the cylinder being tested Fig 31 WARNING Do not touch the injector connector NOTE Before activating the injector operate the electric fuel pump for ten seconds in order to build up fuel pressure Yamaha Diagnostic System ...

Page 326: ...he Enter key on your keyboard To perform the test on a different cylinder click the Return ESC button or press the Esc key on your keyboard to return to the window where a different test can be selected Fig 32 Fig 32 CAUTION Do not test the same cylinder three or more times otherwise the spark plug insulator may be damaged ...

Page 327: ...ources of ignition away from the testing area Gasoline is highly flammable NOTE Make sure that there is fuel in fuel tank otherwise an error will occur and the test cannot be per formed 1 Select the test to be performed and then click the Select button or press the Enter key on your keyboard Fig 33 Fig 33 NOTE Make sure that the engine is not running The selected item is highlighted in light blue ...

Page 328: ... Execute button or press the Enter key on your keyboard Fig 34 Fig 34 NOTE If an error occurs while the test is being performed an error message is displayed Follow the instructions that appear 3 Listen to the operating sound of the electric fuel pump ...

Page 329: ... your keyboard to return to the window where a different test can be selected Fig 35 Fig 35 Operating the electric fuel feed pump Operate the fuel feed pump low pressure pump and listen to its operating sound The operating time is ten seconds NOTE Carry out this test after priming the engine If the fuel pump is not supplied with fuel when it is oper ated the pump may be burned Yamaha Diagnostic Sy...

Page 330: ...ooting 9 31 69J3D11 1 Select the test to be performed and then click the Select button or press the Enter key on your keyboard Fig 36 Fig 36 2 Click the Execute button or press the Enter key on your keyboard Fig 37 Fig 37 ...

Page 331: ... the fuel feed pump Fig 38 4 To test again click the Execute button or press the Enter key on your keyboard To perform a different test click the Return button or return to the test selection menu or press the ESC key on your keyboard Fig 39 Yamaha Diagnostic System ...

Page 332: ...C valve and listen to its operating sound The operating time is three seconds 1 Select the test to be performed and then click the Select button or press the Enter key on your keyboard Fig 40 Fig 40 2 Click the Execute button or press the Enter key on your keyboard Fig 41 Fig 41 ...

Page 333: ... of the ISC valve Fig 42 4 To test again click the Execute button or press the Enter key on your keyboard To perform a different test click the Return button to return to the test selection menu or press the ESC key on your keyboard Fig 43 Yamaha Diagnostic System ...

Page 334: ...he test can be carried out while the engine is running and the shift is in the neutral position It is not possible to carry out the test while the boat is running Fully opening the ISC valve When the shift is in neutral and the engine is idling fully open the ISC valve and then check that the engine speed revs up and that the intake valves are normal The operating time is two seconds WARNING When ...

Page 335: ... 7 8 9 1 Select the test to be performed and then click the Select button or press the Enter key on your keyboard Fig 45 2 Click the Execute button or press the Enter key on your keyboard Fig 46 Fig 46 Yamaha Diagnostic System ...

Page 336: ...y open Check that the engine speed revs up Fig 47 4 To test again click the Execute button or press the Enter key on your keyboard To perform a different test click the Return button to return to the test selection menu or press the ESC key on your keyboard Fig 48 ...

Page 337: ...volume when the engine is idling The operating time is 30 minutes Before testing warm the engine up 1 Select the test to be performed and then click the Select button or press the Enter key on your keyboard Fig 49 2 Click the Execute button or press the Enter key on your keyboard Fig 50 Fig 50 Yamaha Diagnostic System ...

Page 338: ...nual for adjusting pro cedures After 30 minutes have passed the test will end automatically Fig 51 4 To test again click the Execute button or press the Enter key on your keyboard To perform a different test click the Return button to return to the test selection menu or press the ESC key on your keyboard Fig 52 ...

Page 339: ... hours according to engine speed appears Fig 53 Operating procedure 1 Select the desired item by either clicking it or pressing the up or down arrow keys on your key board Fig 53 NOTE A triangle appears to the right of the selected item 2 Press the Enter key on your keyboard The window of the selected item is displayed Fig 53 Yamaha Diagnostic System ...

Page 340: ...ng the up or down arrow keys on your keyboard and then press the space bar Fig 54 NOTE Selected items have a light blue background Items that are not selected have a blue background The box to the left of items that are being moved are light blue Items that are not selected appear in blue At initialization Engine speed r min is selected 2 Click the Graph button or press the Enter key on your keybo...

Page 341: ...stop on the horizontal axis Fig 55 Fig 55 NOTE The item on the left vertical axis is graphed with a solid line and the item on the right vertical axis is graphed with a dotted line Although the engine is running graphs do not show the present engine condition It displays the value at the time the Enter key on your keyboard was pressed in the Monitor item selection Yamaha Diagnostic System ...

Page 342: ...ed Fig 56 Fig 56 A window is displayed showing the amount of hours that the engine is operated at each engine speed range NOTE Although the engine is running the displayed time refers to the added hours until the Data logger starts The sum of the Engine operating hours according to engine speed is not equal to the total hours of operation since the hours are rounded to one decimal ...

Page 343: ...69J3D11 9 44 1 2 3 4 5 6 7 8 9 ECM No The ECM part number of the outboard motor is read from the ECM and is displayed Fig 57 Fig 57 Yamaha Diagnostic System ...

Page 344: ... Exit The program is exited Fig 58 Operating procedure Click the OK button or press the Enter key on your keyboard to exit the program To cancel exiting the program click the Cancel button or press the Esc key on your keyboard Fig 59 Fig 59 ...

Page 345: ... in operation Quit the application in operation since two applications Service tool cannot be operated simultaneously Application related error occurs Error message Program file or Database file is not installed properly Please install again is displayed Install program file or database file again Database related error occurs Error message Database files are not installed properly Please update a...

Page 346: ...ng sensor or switch use the diagnostic flash indicator to determine the cause Power unit 9 Symptom Engine does not crank Check the starting system Check the power unit Check that the gearshift is in the neutral position Check the neutral switch and shift cut switch for continuity Check the engine start switch for continuity Is the gearshift in neutral Is there continuity Is there continuity Set it...

Page 347: ...ck the power unit Can the oper ation sound be heard Yes Yes No Is there continuity Replace the fuse Yes No Replace the engine shut off switch Is there continuity Yes No Check the fuse for continuity Replace the starter motor No Check the starter motor opera tion Replace the wiring harnesses Is there continuity Yes No Good operat ing condition Power unit ...

Page 348: ...eads Do not let sparks leak out of the removed spark plug caps Keep flammable gas or liquids away since this test can produce sparks Start the engine using dried or new spark plugs No Yes Yes No Check that the spark plugs pro duce sparks No Yes Below the spark gap specification Are there sparks Check the ignition coil Check the ignition system output peak voltage Check the ignition spark using the...

Page 349: ...starting operation Failure in starting operation Check the fuel system Check the condition of the spark plugs again Check the compression pres sure of the combustion chamber Check the valve clearance Adjust the valve clearance No No Yes Yes Yes No No Yes Check the cylinder head cylin der body and piston assembly Power unit ...

Page 350: ...fuel filter Open the fuel vent screw Clean the fuel system from the fuel tank to the fuel filter Check the fuel hose for kinks or fuel leakage No Yes Yes No Check that the fuel vent screw of the fuel tank is open Yes Replace the respective parts Check the fuel pressure No Out of specification No Yes Check the fuel injector resistance Out of specification No Yes Replace the fuel injector Check the ...

Page 351: ...ce the high pressure fuel pump relay Out of specification Yes No Out of specification Yes Out of specification No Yes Check the ignition system using the Yamaha Diagnostic System Replace the ignition coil Check the ignition spark gap using the spark gap tester Replace the spark plug Check the ignition system out put peak voltage Check the ignition coils resist ence No Check the ignition system usi...

Page 352: ...ntake on the contact surfaces of the intake manifold and crankcase Out of specification Are the throt tle valves synchronize Check the second ary air intake on the O ring and manifold plate idle speed control hose and the gaskets of the vacuum check bolts Check the ignition timing Yes Yes No No Check the operation of the throttle cable and throttle link Yes No Adjust the throttle cable and throttl...

Page 353: ... on and buzzer is sounding Check the cooling system Check the lubrication system Cooling system Check the cooling water inlet for clogs or debris Check that cooling water is discharged from the cooling water pilot hole Replace the thermostat Check the water pump impeller Check the water passage Clogs or debris Is water discharged Clean the cooling water inlet Yes No No Yes Yes Yes No No Check the ...

Page 354: ...heck the oil pressure Check the oil pressure sensor Clean or replace the respective parts At specified level Out of specification Check the oil passage Yes No Yes No Yes Yes No No Add engine oil to the correct level Replace the oil pressure sensor Check the engine using the Yamaha Diagnostic System Good condition Debris or leaks ...

Page 355: ...im and tilt relay Close the valve Can 12 V be obtained Can 12 V be obtained Can the oper ation sound be heard Can the oper ation sound be heard Replace the power trim and tilt relay Check for continuity between the battery relays and power trim and tilt switch Check the voltage between the sky blue Sb lead and light green Lg lead Check the voltage between each terminal Between the sky blue Sb lead...

Page 356: ...ars etc Clean or replace the filters No Yes No Yes Add fluid to the correct level At specified level Yes No Disassemble the power trim and tilt unit and then check the filter for debris or dirt Clogs or debris Check the power trim and tilt unit for leaks Out of specification Yes No Measure the hydraulic pressure Stuck foreign substance or clogs ...

Page 357: ...e valve Add fluid to the correct level At specified level Is it closed Yes Yes No No Check the fluid passages for clogs or debris Clean the passages Check the internal parts valves pistons gear etc Clean or replace the filters No Yes No Yes Disassemble the power trim and tilt unit and then check the filters for debris or dirt Clogs or debris Stuck foreign substance or clogs Bracket unit ...

Page 358: ... and upper case Replace the shift rod Check the shift cables and links of the remote control box Check the detent of the bottom cowling Good operat ing condition Good operat ing condition Connected properly Yes Yes Yes No No No Check the shift cable operation Disassemble the lower case and then check the operation of the dog clutch Check the forward gear and reverse gear Yes No Replace the respect...

Page 359: ...the Rectifier Regulator output peak voltage Replace the stator coil Out of specification Out of specification Replace the Rectifier Regulator No No Yes Yes Measure the output peak voltage of the stator coil Replace the battery and then check the voltage of all electri cal equipment on your boat Bracket unit Electrical systems ...

Page 360: ... 95 seconds Trouble code indication Example The illustration indicates code number 23 a Light on 0 33 second b Light off 4 95 seconds b Light off 0 33 second d Light off 1 65 seconds 4 If a flash pattern listed in the diagnosis code chart is displayed check the mal functioning part according to the flash pattern NOTE When more than one problem is detected the light of the diagnostic tester flashes...

Page 361: ...signal 19 Incorrect battery voltage 23 Incorrect intake air temperature sensor signal 28 Incorrect neutral switch signal 29 Incorrect intake air pressure sensor signal 37 Incorrect idle speed control signal 39 Incorrect oil pressure sensor signal 45 Incorrect shift cut switch signal 46 Incorrect thermoswitch signal 44 Incorrect engine stop switch signal Self diagnosis ...

Page 362: ...oling water passage 3 9 Checking the cooling water pilot hole 1 31 Checking the crankpin oil clearance 5 51 Checking the crankshaft 5 50 Checking the crankshaft main journal oil clearance 5 53 Checking the cylinder bore 5 48 Checking the cylinder head 5 40 Checking the drive shaft 6 20 6 48 Checking the ECM 8 12 Checking the electrical components 8 2 Checking the engine idle speed 3 13 Checking th...

Page 363: ...e tilt system 1 30 Checking the timing belt 3 8 Checking the timing belt and sprockets 5 26 Checking the timing chain 5 40 Checking the timing chain tensioner 5 39 Checking the top cowling 3 4 Checking the trim sensor 7 45 Checking the valve clearance 3 8 5 15 Checking the valve guides 5 35 Checking the valve seat 5 36 Checking the valve springs 5 34 Checking the valves 5 34 7 34 Checking the vapo...

Page 364: ...brication system 1 26 M Maintenance interval chart 3 2 Maintenance specifications 2 3 Manual format 1 1 Measuring the forward and reverse gear backlash 6 30 6 60 Measuring the fuel pressure high pressure fuel line 3 5 Measuring the lower resistance 8 2 Measuring the peak voltage 8 2 N Newly developed V6 4 stroke engine 1 6 Not installed 7 41 O Operating 9 3 P Parts lubricants and sealants 1 3 Port...

Page 365: ...umber 1 5 Shimming 6 27 6 55 Shimming counter rotation model 6 54 Shimming regular rotation model 6 26 Special service tools 3 1 4 1 5 1 6 1 7 1 8 1 9 1 Specified torques 2 12 Starboard and rear views 8 3 Starter motor 8 21 Starting system 8 19 Symbols 1 2 Synchronizing the throttle valve 4 16 T Technical tips 1 18 Test run 1 31 Throttle control 4 13 Tightening torques 2 12 Top cowling 3 4 Top vie...

Page 366: ... and tilt motor P Trim sensor Q Battery R Intake air temperature sensor S Main relay T Oil pressure sensor U Power trim and tilt switch È To warning indicator É To remote control Ê To trim meter Ë To computer Ì To diagnostic indicator Color code B Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B O Black orange B W Black white B Y Black yello...

Page 367: ......

Page 368: ...YAMAHA MOTOR CO LTD Printed in the Netherlands Jun 2001 1 3 1 CR F225AET FL225AET E ...

Page 369: ... P R B W R B W R P B P B O B P B Y B B Y B Y R B W R Y R Y R R B W R Y B Y B O R B W R Y P W P B L W G Lg R Y W Sb P B Br P B B P Gy W B W R W G W G B W R 1 1 4 6 4 2 3 6 5 2 3 5 1 2 3 4 5 6 1 2 3 4 5 6 B B R R Y R Y R Y R Y R Y R Y R R B B B B B B B B B B B B B B B B B B R Y R R R Br Br Lg Sb Lg Sb Gy R R R R B L 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 G Y G W P L W B Y B L Y O O O W G W B W R 16 17 ...

Page 370: ... Y R Y O Y B O R Y B W L Y O R O Y O B Y G R Y R Y W B L W L W P B R Y G B P B B B B R 1 4 6 5 3 R B B B B B B O B P P B O P B B B Br B Sb Y G Br R Lg Sb Sb O Lg Lg W B G Y G B R Y R Y P W L W R B B Br G Gy L Lg O P R Sb W Y O R O Y P B P G P W R B R Y W B W G W R Y G B O B W B Y Br W G B G R G W G Y L R L W L Y O B S69JWD04 ...

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