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Preface

This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have the Bronze Technical Certificate of the YTA
(Yamaha Technical Academy) marine or the equivalent basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual. Also, up-to-date parts information is available on YPEC-web. Additional information and up-
to-date information on Yamaha products and services are available on Yamaha Service Portal.

Important information

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

A WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.

A NOTICE indicates special precautions that must be taken to avoid damages to the out-
board motor or other property.

TIP:

A TIP provides key information to make procedures easier or clearer.

F(L)225F, F(L)250D, F(L)300B

SERVICE MANUAL

©2010 by Yamaha Motor Co., Ltd.

1st Edition, May 2010

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

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Summary of Contents for F225F

Page 1: ...SERVICE MANUAL 6CE 28197 3N 11 F L 225F F L 250D F L 300B ...

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

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

Page 4: ......

Page 5: ...lation 0 1 Self protection 0 2 Working with crane 0 2 Handling of gas torch 0 2 Part lubricant and sealant 0 2 Handling of sealant 0 3 Special service tool 0 3 Tightening torque 0 3 Non reusable part 0 3 Disassembly and assembly 0 3 How to use this manual 0 4 Manual format 0 4 Abbreviation 0 5 Lubricant sealant and thread locking agent 0 7 Symbol 0 7 Special service tool 0 9 ...

Page 6: ...ric shock Do not touch any electrical parts while start ing or operating the engine Otherwise shock or electrocution could result Propeller Do not hold the propeller with your hands when loosening or tightening the propeller nut Handling of gasoline Gasoline is highly flammable Keep gaso line and all flammable products away from heat sparks and open flames Gasoline is poisonous and can cause injur...

Page 7: ...ion If the outboard motor does not have three or more points to be suspended support it using additional ropes or the like so that the outboard motor can be lifted and carried in a stable manner Handling of gas torch Improper handling of a gas torch may result in burns For information on the proper han dling of the gas torch see the operation manual issued by the manufacturer When using a gas torc...

Page 8: ... the large sizes first and then tighten the small sizes starting from the center and moving outward Non reusable part Always use new gaskets seals O rings cot ter pins and so on when installing or assem bling parts Disassembly and assembly Use compressed air to remove dust and dirt during disassembly Apply engine oil to the contact surfaces of moving parts before assembly Install bearings so that ...

Page 9: ...ons see b in the following figure Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and the lubrication points see c in the following figure Tightening torque specifications are provided in the exploded diagrams see d in the following fig ure and in the related detailed instructions Some torque specifications are listed in stages as torque figures or angl...

Page 10: ...ronic Throttle Valve EN European Norm European standard ENG Engine EX Exhaust EXH Exhaust F Forward GPS Global Positioning System ID Identification IEC International Electro technical Commission IN Intake INT Intake ISO International Organization for Standardization LPS Lever Position Sensor N Neutral OCV Oil Control Valve PCV Pressure Control Valve PORT Port side PTT Power Trim and Tilt R Reverse...

Page 11: ...6 How to use this manual 0 1 2 3 4 5 6 7 8 9 10 A UP Up side VCT Variable Camshaft Timing W F Water in Fuel Y COP Yamaha Customer Outboard Protection YDIS Yamaha Diagnostic System Abbreviation Description ...

Page 12: ...Symbol Name Application Yamaha 4 stroke motor oil Lubricant Gear oil Lubricant Water resistant grease Yamaha grease A Lubricant Molybdenum disulfide grease Lubricant Corrosion resistant grease Yamaha grease D Lubricant Low temperature resistant grease Yamaha grease C Lubricant WR No 2 grease Lubricant Symbol Name Application Gasket Maker Sealant ThreeBond 1280B Sealant ThreeBond 1303 Thread lockin...

Page 13: ... 3 4 5 6 7 8 9 10 A ThreeBond 1386B Sealant ThreeBond 1530D Sealant LOCTITE 210 red Thread locking agent LOCTITE 242 blue Thread locking agent LOCTITE 271 red Thread locking agent LOCTITE 572 white Sealant Silicone sealant Sealant Symbol Name Application ...

Page 14: ...d by the Parts Division Engine lifting eye 90890 06820 Drilling plate 90890 06783 YDIS CD ROM Ver 1 33 60V WS853 06 YDIS USB adapter and cable 60V WS850 00 Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 Test harness 3 pins 90890 06869 Vacuum pressure pump gauge set 90890 06756 Test harness 1 pin 90890 06888 Test harness 2 pins 90890 06887 ...

Page 15: ... 06754 Test harness 2 pins 90890 06867 Test harness 3 pins 90890 06791 Fuel pressure gauge adapter 90890 06842 Fuel pressure gauge 90890 06786 Leakage tester 90890 06840 Compression gauge 90890 03160 Compression gauge extension 90890 06563 Balance hanger 90890 06822 Rotor holder 90890 01235 ...

Page 16: ...90 04019 Valve spring compressor attachment 90890 06320 Valve guide remover installer 90890 06801 Valve guide reamer 90890 06804 Valve lapper 90890 04101 Valve seat cutter holder 90890 06316 Valve seat cutter 30 90890 06331 Valve seat cutter 45 90890 06332 Valve seat cutter 60 90890 06333 ...

Page 17: ...t cutter 45 90890 06325 Valve seat cutter 60 90890 06324 Oil filter wrench 90890 06830 Driver rod L3 90890 06652 Needle bearing attachment 90890 06612 Bearing inner race attachment 90890 06640 Piston ring compressor 90890 05158 Needle bearing attachment 90890 06653 Shift rod socket 90890 06679 ...

Page 18: ...xtension 90890 06513 Ring nut wrench 6 90890 06677 Bearing housing puller claw L 90890 06502 Stopper guide plate 90890 06501 Center bolt 90890 06504 Ball bearing attachment 90890 06634 Needle bearing attachment 90890 06611 Bearing inner race attachment 90890 06661 Driver rod LL 90890 06605 ...

Page 19: ...achment 90890 06640 Drive shaft ring nut wrench 90890 06674 Drive shaft holder 6 90890 06520 Pinion nut holder 90890 06715 Needle bearing attachment 90890 06680 Ball bearing attachment 90890 06655 Bearing outer race puller assembly 90890 06523 Bearing outer race attachment 90890 06628 Backlash indicator 90890 06836 ...

Page 20: ...gauge set 90890 01252 Magnet base B 90890 06844 Pinion shimming gauge 90890 06675 Pinion shimming gauge rod 90890 06676 Slide hammer 90890 06531 Puller head 90890 06514 Needle bearing attachment 90890 06607 Ring nut wrench 90890 06578 Bearing puller assembly 90890 06535 ...

Page 21: ...0 16 Special service tool 0 1 2 3 4 5 6 7 8 9 10 A PTT oil pressure gauge assembly 90890 06580 Cylinder end screw wrench 90890 06568 PTT piston vice attachment 90890 06572 Tilt rod wrench 90890 06569 ...

Page 22: ...ol system 1 10 Engine speed control system 1 11 VCT system 1 12 Shift actuator 1 13 PTT system 1 13 Charging system 1 14 Starting system 1 14 Gauge sensor 1 15 Fuel system technical data 1 17 Fuel system 1 17 Power unit technical data 1 18 Power unit 1 18 Cylinder head assembly 1 19 Crankcase assembly 1 21 Lower unit technical data 1 24 Lower unit assembly regular rotation model 1 24 Lower unit as...

Page 23: ...0 1 2 4 5 6 7 8 9 10 A Lower unit regular rotation model 1 27 Lower unit counter rotation model 1 28 Bracket unit 1 28 PTT unit 1 29 General tightening torque 1 30 ...

Page 24: ...y gas reburning system Vapor gas treatment b Electrical Electronic fuel injection control Ignition timing control VCT control Knock control Engine speed control ETV control Electronic shift control Fail safe control New YDIS 1 33 version Multi engine system for alert mode and auto engine speed synchronization Adjusting trolling speed function High output stator assembly Isolator for house accessor...

Page 25: ...ption F 4 stroke regular rotation FL 4 stroke counter rotation b Model name 300 225 250 300 c Product generation B A and later d Functions E Electric starter e T PTT f Transom height X UL 25 in U SUL 30 in F 300 B E T X b a c d e f YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON a b c d e Model name Approved model code Starting serial No F225FET 6CL 1000001 FL225FET 6CM 1000001 F250DET 6CG ...

Page 26: ...l length mm in 958 0 37 7 Overall width mm in 634 0 25 0 Overall height X mm in 1890 0 74 4 U mm in 2017 0 79 4 Boat transom height X mm in 643 0 25 3 U mm in 770 0 30 3 Weight without propeller X kg lb 260 0 573 U kg lb 268 0 591 Item Unit Model F225FET FL225FET F250DET FL250DET Maximum output At 5500 r min kW HP 165 5 225 183 8 250 Full throttle operating range r min 5000 6000 Maximum fuel consu...

Page 27: ...rator output V A 12 0 70 0 Spark plug LFR6A 11 NGK Firing order 1 2 3 4 5 6 normal operation Cooling system Water Exhaust system Propeller boss Lubrication system Wet sump Item Unit Model F300BET FL300BET Type 4 stroke DOHC Cylinder quantity V6 Total displacement cm cu in 4169 0 254 4 Bore stroke mm in 96 0 96 0 3 78 3 78 Compression ratio 10 3 1 Control system Digital Electronic Control Starting ...

Page 28: ...l F300BET FL300BET Gear shift positions F N R Gear ratio 1 75 21 12 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear view Clockwise Counter clockwise Propeller mark T TL Item Unit Model F225FET FL225FET F250DET FL250DET Trim angle At 12º boat transom degree 3 to 16 Tilt up angle degree 67 Steering angle degree 32 32 Trim and tilt sys...

Page 29: ...ne oil 4 stroke motor oil with combination of the fol lowing SAE and API oil classifications Engine oil grade 1 API SE SF SG SH SJ SL SAE 5W 30 10W 30 10W 40 Total engine oil quantity oil pan capacity L US qt Imp qt 7 1 7 50 6 25 Gear oil type Hypoid gear oil Gear oil grade 2 API GL 5 SAE 90 80W 90 Gear oil quantity L US qt Imp qt 1 040 1 10 0 92 Item Unit Model F300BET FL300BET Fuel type Premium ...

Page 30: ...m cold cranking amps CCA EN A 640 0 Minimum rated capacity 20HR IEC Ah 80 0 Item Unit Model F300BET FL300BET Minimum cold cranking amps CCA EN A 640 0 Minimum rated capacity 20HR IEC Ah 80 0 Item Unit Model F225FET FL225FET F250DET FL250DET Fluid type ATF DEXRON II Item Unit Model F300BET FL300BET Fluid type ATF DEXRON II ...

Page 31: ... 23 9 At 3500 r min loaded V 25 1 Resistance At 20 C 68 F Ω 396 0 594 0 Air temperature sensor Input voltage V 4 75 5 25 Resistance 1 At 20 C 68 F kΩ 2 21 2 69 At 80 C 176 F kΩ 0 32 Air pressure sensor Input voltage V 4 75 5 25 Output voltage 1 At 20 0 kPa 0 20 kgf cm2 2 9 psi V 3 21 At 46 7 kPa 0 467 kgf cm2 6 8 psi V 2 16 Engine temperature sensor Input voltage V 4 75 5 25 Resistance 1 At 5 C 41...

Page 32: ...stance At 20 C 68 F Ω 396 0 594 0 Air temperature sensor Input voltage V 4 75 5 25 Resistance 1 At 20 C 68 F kΩ 2 21 2 69 At 80 C 176 F kΩ 0 32 Air pressure sensor Input voltage V 4 75 5 25 Output voltage 1 At 20 0 kPa 0 20 kgf cm2 2 9 psi V 3 21 At 46 7 kPa 0 467 kgf cm2 6 8 psi V 2 16 Engine temperature sensor Input voltage V 4 75 5 25 Resistance 1 At 5 C 41 F kΩ 4 2 4 9 At 25 C 77 F kΩ 1 9 2 1 ...

Page 33: ...t voltage V 12 0 Resistance 1 At 20 C 68 F Ω 11 5 12 5 Low pressure fuel pump Input voltage V 12 0 Resistance 1 At 20 C 68 F Ω 0 5 4 0 High pressure fuel pump Input voltage V 12 0 Resistance 1 At 20 C 68 F Ω 0 2 3 0 Vapor shut off valve Input voltage V 12 0 Resistance At 20 C 68 F Ω 30 0 34 0 Item Unit Model F300BET FL300BET Fuel line Pressure 1 Within 5 seconds after engine start switch turned to...

Page 34: ...istance At 20 C 68 F Ω 30 0 34 0 Item Unit Model F225FET FL225FET F250DET FL250DET TPS Output voltage 1 With throttle valve fully closed TPS1 V 0 37 0 63 TPS2 V 2 5 3 5 Throttle valve opening angle 1 With throttle valve fully closed degree 4 5 Input voltage V 4 75 5 25 SPS Output voltage F V 0 2 1 5 N V 2 412 2 588 R V 3 5 4 8 Input voltage V 4 75 5 25 Oil pressure sensor Input voltage V 4 75 5 25...

Page 35: ... fully closed degree 4 5 Input voltage V 4 75 5 25 SPS Output voltage F V 0 2 1 5 N V 2 412 2 588 R V 3 5 4 8 Input voltage V 4 75 5 25 Oil pressure sensor Input voltage V 4 75 5 25 Output voltage 1 At 392 0 kPa 3 92 kgf cm2 56 8 psi V 2 5 At 784 0 kPa 7 84 kgf cm2 113 7 psi V 4 5 Item Unit Model F225FET FL225FET F250DET FL250DET OCV Input voltage V 12 0 Resistance At 20 C 68 F Ω 6 7 7 7 Item Unit...

Page 36: ... 41 1 1 62 Motor resistance 1 At 20 C 68 F Ω 1 7 Item Unit Model F300BET FL300BET Shift actuator Rod stroke 1 F mm in 78 2 3 08 N mm in 59 2 2 33 R mm in 41 1 1 62 Motor resistance 1 At 20 C 68 F Ω 1 7 Item Unit Model F225FET FL225FET F250DET FL250DET Trim sensor Free position resistance Ω 247 6 387 6 Setting resistance Ω 9 0 11 0 Item Unit Model F300BET FL300BET Trim sensor Free position resistan...

Page 37: ... At 3500 r min loaded V 13 0 Item Unit Model F300BET FL300BET Lighting coil Output peak voltage At cranking unloaded V 6 9 At 1500 r min unloaded V 38 0 At 3500 r min unloaded V 83 2 Resistance 1 At 20 C 68 F Ω 0 1056 0 1584 Fuse A 100 Rectifier Regulator Output peak voltage At 1500 r min loaded V 13 0 At 3500 r min loaded V 13 0 Item Unit Model F225FET FL225FET F250DET FL250DET Y COP Input voltag...

Page 38: ... in 28 0 1 10 Standard undercut mm in 0 5 0 8 0 02 0 03 Wear limit mm in 0 2 0 01 Brush Standard length mm in 15 5 0 61 Wear limit mm in 9 5 0 37 Item Unit Model F225FET FL225FET F250DET FL250DET Water pressure sensor Input voltage V 4 75 5 25 Output voltage 1 At 392 0 kPa 3 92 kgf cm2 56 8 psi V 2 5 At 784 0 kPa 7 84 kgf cm2 113 7 psi V 4 5 Speed sensor Input voltage V 4 75 5 25 Output voltage 1 ...

Page 39: ... Model F300BET FL300BET Water pressure sensor Input voltage V 4 75 5 25 Output voltage 1 At 392 0 kPa 3 92 kgf cm2 56 8 psi V 2 5 At 784 0 kPa 7 84 kgf cm2 113 7 psi V 4 5 Speed sensor Input voltage V 4 75 5 25 Output voltage 1 At 392 0 kPa 3 92 kgf cm2 56 8 psi V 2 5 At 784 0 kPa 7 84 kgf cm2 113 7 psi V 4 5 ...

Page 40: ... 8 Primer pump Holding pressure Positive pressure kPa kgf cm2 psi 170 0 1 70 24 7 Vapor separator tank Float height mm in 67 5 2 5 2 66 0 10 Item Unit Model F300BET FL300BET Fuel filter assembly Holding pressure Positive pressure kPa kgf cm2 psi 200 0 2 00 29 0 Negative pressure kPa kgf cm2 psi 80 0 0 80 11 6 Canister Holding pressure Positive pressure kPa kgf cm2 psi 19 6 0 196 2 8 Primer pump Ho...

Page 41: ...000 r min kPa kgf cm2 psi 590 0 5 90 85 6 Timing belt Installation height mm in 2 5 0 10 Thermostat Valve opening temperature C F 50 0 54 0 122 0 129 0 Fully open temperature C F 62 0 144 0 Fully open stroke mm in 4 3 0 17 Replacement engine oil quan tity at periodic maintenance Without oil filter replacement L US qt Imp qt 6 0 6 34 5 28 With oil filter replacement L US qt Imp qt 6 3 6 66 5 54 Ite...

Page 42: ...tside diameter mm in 30 970 30 980 1 2193 1 2197 Valve lifter clearance mm in 0 020 0 055 0 0008 0 0022 Camshaft Cam lobe height Intake mm in 46 661 46 761 1 8370 1 8410 Exhaust mm in 46 960 47 060 1 8488 1 8528 Cam lobe width Intake and exhaust mm in 35 950 36 050 1 4154 1 4193 Journal diameter mm in 24 960 24 980 0 9827 0 9835 Runout mm in 0 030 0 0012 Cylinder head Warpage limit mm in 0 10 0 00...

Page 43: ...0008 0 0022 Camshaft Cam lobe height Intake mm in 46 661 46 761 1 8370 1 8410 Exhaust mm in 46 960 47 060 1 8488 1 8528 Cam lobe width Intake and exhaust mm in 35 950 36 050 1 4154 1 4193 Journal diameter mm in 24 960 24 980 0 9827 0 9835 Runout mm in 0 030 0 0012 Cylinder head Warpage limit mm in 0 10 0 0039 Journal inside diameter mm in 25 000 25 021 0 9843 0 9851 Valve spring Free length mm in ...

Page 44: ... 1 240 0 0480 0 0488 Ring groove oil mm in 2 510 2 530 0 0988 0 0996 Pin boss inside diameter mm in 22 011 22 018 0 8666 0 8668 Pin outside diameter mm in 21 996 22 005 0 8660 0 8663 Cylinder Bore mm in 96 000 96 012 3 7795 3 7800 Piston ring Top ring Type Barrel Dimension height B mm in 1 200 0 0472 Dimension width T mm in 2 800 3 000 0 1102 0 1181 End gap 1 mm in 0 200 0 300 0 0079 0 0118 Side c...

Page 45: ...p mm in 1 230 1 250 0 0484 0 0492 Ring groove 2nd mm in 1 220 1 240 0 0480 0 0488 Ring groove oil mm in 2 510 2 530 0 0988 0 0996 Pin boss inside diameter mm in 22 011 22 018 0 8666 0 8668 Pin outside diameter mm in 21 996 22 005 0 8660 0 8663 Cylinder Bore mm in 96 000 96 012 3 7795 3 7800 Piston ring Top ring Type Barrel Dimension height B mm in 1 200 0 0472 Dimension width T mm in 2 800 3 000 0...

Page 46: ...2 2051 Big end side clearance mm in 0 140 0 310 0 0055 0 0122 Oil clearance 1 mm in 0 025 0 050 0 0010 0 0020 Crankshaft Journal diameter mm in 72 976 72 996 2 8731 2 8739 Crankpin diameter mm in 52 980 53 000 2 0858 2 0866 Runout mm in 0 030 0 0012 Crankpin width mm in 21 000 21 100 0 8268 0 8307 Crankcase Oil clearance 1 mm in 0 029 0 045 0 0011 0 0018 Item Unit Model F300BET FL300BET ...

Page 47: ...0 9 1 0 1 1 1 2 Propeller shaft Motive torque N m kgf m ft lb 0 44 1 32 0 04 0 13 0 32 0 97 Runout mm in 0 02 0 0008 Drive shaft Motive torque N m kgf m ft lb 0 27 1 94 0 03 0 20 0 20 1 43 Runout mm in 1 0 0 0394 Item Unit Model FL225F FL250D FL300B Lower unit Holding pressure kPa kgf cm2 psi 68 6 0 686 9 9 Forward gear backlash 1 mm in 0 18 0 76 0 0071 0 0299 Reverse gear backlash 1 mm in 0 19 0 ...

Page 48: ...ter mm in 23 0 0 91 Wear limit mm in 22 0 0 87 Standard undercut 1 mm in 1 4 0 06 Wear limit mm in 0 9 0 04 Motor brush Standard length mm in 11 5 0 45 Wear limit mm in 4 5 0 18 Item Unit Model F300BET FL300BET PTT Hydraulic pressure Down MPa kgf cm2 psi 6 7 8 7 67 0 87 0 971 5 1261 5 Up MPa kgf cm2 psi 13 0 15 0 130 0 150 0 1885 0 2175 0 Motor commutator Standard diameter mm in 23 0 0 91 Wear lim...

Page 49: ...2 4 17 7 1st M6 11 1 1 8 1 2nd 11 1 1 8 1 Intake silencer bolt M6 7 0 7 5 2 Surge tank bracket bolt M6 11 1 1 8 1 Fuel pump cover bolt M6 5 0 5 3 7 Vapor separator drain screw 2 0 2 1 5 Needle valve assembly screw M4 2 0 2 1 5 Float pin screw M4 2 0 2 1 5 Float chamber cover screw M5 2 0 2 1 5 Vapor separator cover bolt M4 2 0 2 1 5 Pressure regulator screw M5 4 0 4 3 0 Fuel cooler cover screw M5 ...

Page 50: ...3 9 28 8 2nd 180 1st M8 14 1 4 10 3 2nd 28 2 8 20 7 Oil pump cover screw M6 4 0 4 3 0 Oil cooler bolt 1st M6 6 0 6 4 4 2nd 12 1 2 8 9 Bracket bolt M6 12 1 2 8 9 Oil filter union bolt UNF 49 4 9 36 1 Oil pressure sensor 13 1 3 9 6 Oil filter 18 1 8 13 3 Thermostat housing bolt M6 12 1 2 8 9 Thermostat cover bolt M6 12 1 2 8 9 Knock sensor 32 3 2 23 6 Knock sensor bracket bolt M6 12 1 2 8 9 Pulley b...

Page 51: ...4 2 31 0 Propeller nut 54 5 4 39 8 Lower case mounting bolt X transom model M10 47 4 7 34 7 Lower case stud bolt U transom model 23 2 3 17 0 Lower case mounting nut U transom model 47 4 7 34 7 Lower case mounting bolt U transom model M10 47 4 7 34 7 Water inlet cover screw M5 1 0 1 0 7 Propeller shaft housing ring nut 155 15 5 114 3 Cover bolt M8 8 0 8 5 9 Drive shaft nut 40 4 0 29 5 Drive shaft r...

Page 52: ... lb Reservoir mounting bolt M8 19 1 9 14 0 Reservoir cap 7 0 7 5 2 PTT motor mounting bolt M8 19 1 9 14 0 Pump bracket bolt M5 7 0 7 5 2 Gear pump bolt M5 7 0 7 5 2 Manual valve 2 0 2 1 5 Tilt ram 65 6 5 47 9 Tilt piston screw M6 7 0 7 5 2 Pipe joint 15 1 5 11 1 Pipe joint adapter 20 2 0 14 8 Trim cylinder end screw 160 16 0 118 0 Tilt cylinder end screw 90 9 0 66 4 Part to be tightened Screw size...

Page 53: ...ightening torques for standard fasteners with a standard ISO thread pitch Width across flats A Screw size B General torque specifications N m kgf m ft lb 8 mm 10 mm 12 mm 14 mm 17 mm M5 M6 M8 M10 M12 5 8 18 36 43 0 5 0 8 1 8 3 6 4 3 3 7 5 9 13 3 26 6 31 7 Specified tightening torque General tightening torque ...

Page 54: ...1 31 SPEC Specification MEMO ...

Page 55: ...t control system 2 15 Fail safe control 2 16 Charging system 2 18 Digital network control 2 19 Sensor switch 2 21 Y COP 2 22 Power unit system 2 23 Shimless valve lifter 2 24 Sleeveless cylinder 2 24 Oil cooler 2 25 Fuel system 2 26 Fuel diagram 2 26 Lubrication system 2 28 Lubrication diagram 2 28 Cooling system 2 29 Cooling diagram 2 29 Intake and exhaust system 2 31 Intake and exhaust diagram 2...

Page 56: ...P as an anti theft measure LPS OCV TPS ETV OCV Y COP YDIS SPS Check valve Air Pressure regulator Filter Check valve High pressure fuel pump Vapor separator Fuel injector Ignition coil Canister Low pressure fuel pump Water separator Fuel Water detection switch Vapor shut off valve Air Shift actuator Ignition coil Fuel injector Shift control Valve control Fuel control Ignition control 6Y9 Multifunct...

Page 57: ...itch PORT h OCV PORT i Cam position sensor PORT IN j Fuel injector PORT k High pressure fuel pump l Low pressure fuel pump m TPS n SPS o Shift actuator p OCV STBD q Thermoswitch STBD r Cam position sensor STBD IN s Oil pressure sensor t Fuel injector STBD u Ignition coil STBD v Knock sensor w Engine ECM x Ignition coil PORT y Cam position sensor PORT EX a b c d e f g h i j k y x w v s p q r l m o ...

Page 58: ... main sensor and TPS 2 is the sub sensor TPS 1 and TPS 2 mutually monitor each other for malfunc tions TPS 2 SPS 1 Detect the shift position SPS 1 is the main sensor and SPS 2 is the sub sensor SPS 1 and SPS 2 mutually monitor each other for malfunctions SPS 2 ETV Opens and closes the throttle valve using a motor Shift actuator Drives the motor according to the engine ECM command for engaging or d...

Page 59: ...2 4 Electronic control system 0 1 2 3 4 5 6 7 8 9 10 A Low pressure fuel pump Sends the fuel from the fuel tank to the vapor separator ...

Page 60: ...According to the engine operating conditions during the control the control mode switches automatically between the start up mode normal operating mode and fuel injection cutoff mode In addition vari ous compensations are made to determine the actual fuel injection timing and fuel injection amount Also a fuel injector anti sticking control has been adopted TPS SPS LPS Pulser coil Cam position sens...

Page 61: ...Until engine starting is detected 500 r min or more Group fuel injection in the normal operating mode Each cylinder group 1 and 4 2 and 5 and 3 and 6 according to the exhaust and compression TDCs According to the fuel injection setting data for the fuel octane rating and the knock learning value which are recorded in the engine ECM Until cylinder identification is completed by the cam position sen...

Page 62: ...g to the engine operating conditions The compensations are determined according to the signals from the following sensors Fuel injector anti sticking control After the engine start switch is turned to ON and before the high pressure fuel pump starts operat ing the engine ECM sends a signal once to actuate all of the fuel injectors simultaneously to pre vent the fuel injector valves from sticking C...

Page 63: ...coil energization time The engine ECM also applies various restrictions and compensations to determine the actual ignition timing The ignition timing is also controlled according to the knock control See Knock control 2 11 TPS LPS SPS Pulser coil Cam position sensor PORT EX Cam position sensor PORT IN Cam position sensor STBD IN Air pressure sensor Engine temperature sensor Knock sensor Engine shu...

Page 64: ...gnition timing Engine speed is at engine idle speed Each cylinder sequentially Normal basic ignition timing Engine speed is more than engine idle speed Each cylinder sequentially Restriction Corresponding sensor Details Engine speed restriction Pulser coil The ignition timing is restricted between BTDC 50 advance angle and ATDC 20 retard angle according to the engine speed Engine temperature restr...

Page 65: ...the sensors According to the engine operating conditions the OCVs are oper ated and the VCT assemblies are advanced retarded or maintained in the current position to con trol the intake valve opening timing TPS LPS Pulser coil Cam position sensor PORT EX Cam position sensor PORT IN Cam position sensor STBD IN Air pressure sensor Engine temperature sensor Engine ECM OCV PORT OCV STBD ...

Page 66: ...ion timing is retarded until the knocking is no longer detected and the retarded ignition timing is maintained using the learning function The knock control activates according to the following conditions The knock control also activates when the engine temperature sensor is malfunctioning regardless of the preceding conditions Engine temperature Less than 20 C 68 F 20 25 C 68 77 F More than 25 C ...

Page 67: ...t alert indicator comes on Criteria Description The pressure decreases to less than 250 kPa 2 5 kgf cm2 36 25 psi The engine ECM controls the throttle valve opening As a result the engine speed cannot increase to more than 2000 3000 r min Also the alert buzzer sounds and the oil pressure alert indicator comes on TPS LPS SPS Pulser coil Cam position sensor PORT EX Cam position sensor PORT IN Cam po...

Page 68: ...ylinders 6399 6449 r min Firing and fuel injection will be skipped for cylinders 1 2 3 5 and 6 6353 6398 r min Firing and fuel injection will be skipped for cylinders 2 3 5 and 6 6302 6352 r min Firing and fuel injection will be skipped for cylinders 2 3 and 5 6251 6301 r min Firing and fuel injection will be skipped for cylinders 2 and 5 6200 6250 r min Firing and fuel injection will be skipped f...

Page 69: ...and controls the throttle valve The engine ECM is equipped with a learn ing function that records all of the compensations made by the control to the throttle valve opening for the operating conditions up to that point In addition the engine idle speed is controlled using the ETV control TPS LPS SPS Pulser coil Air pressure sensor Engine temperature sensor Thermoswitch Engine ECM ETV motor ...

Page 70: ... the shift actuator based on the Digital Electronic Control communication data transmitted by the Digital Electronic Control ECM TPS SPS Pulser coil Cam position sensor PORT EX Cam position sensor PORT IN Cam position sensor STBD IN Digital Electronic Control ECM Engine ECM Fuel injector Ignition coil ETV motor Shift actuator ...

Page 71: ...or PORT EX C E Signal error irregular 29 Air pressure sensor C E Output voltage is less than 0 20 V or more than 4 50 V 39 Oil pressure sensor L 1 Output voltage is less than 0 30 V more than 4 80 V for 260 seconds or more than 4 80 V when the engine is stopped 71 Cam position sensor PORT EX C E Signal error irregular 72 Cam position sensor PORT IN C E Signal error irregular 73 OCV STBD C E Open o...

Page 72: ...circuit and shift actuator does not operate 156 157 Extension wiring harness C E Communication error between the engine ECM and Digital Electronic Control 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 LPS C E Open or short circuit in the LPS circuit Trouble code Item LAN gauge display Trouble conditions to be detected ...

Page 73: ... voltage of the main battery and house accessory battery based on the signals from the Rectifier Regulator If the main battery voltage decreases below 13 5 V when the house accessory battery is con nected the regulator function of the Rectifier Regulator will be turned off by the engine ECM to increase the efficiency of charging the main battery Lighting coil stator assembly Engine ECM Fuse box Re...

Page 74: ...ion of ETV and shift actuator based on the electrical sig nals The electric controlled shift in or shift out provides smooth reliable and quiet gear shift engage ment The 6Y9 Multifunction Color Gauge and the new engine start switch can be installed optional SET MENU CANCEL SET MENU CANCEL Y COP LPS LPS LPS LPS LPS LPS 6Y9 Multifunction Color Gauge 6Y9 Multifunction Color Gauge Hub Hub Engine star...

Page 75: ... e Digital Electronic Control ECM f Active indicator g Alert indicator h Engine selector switch i Engine start switch j Main switch k 6Y9 Multifunction Color Gauge l Engine start stop button single type m Engine start stop button twin type n Engine start stop button triple type o Engine start stop button all type p Station selector switch a c d e f g a a b c d f g B e h b d f g C e D b c d e f g a...

Page 76: ...ed while in neutral using the control lever Active indicator Displays operational conditions of the Digital Electronic Control Active indicator Comes on when communication error occurs between the 6Y9 Digital Electronic Control and the engine ECM Engine selector switch Selects the outboard motor to be operated Engine start stop button Starts and stops the engine while the system is activated Engin...

Page 77: ...tained even when the battery switch is turned to off TIP The receiver can register up to 5 transmitters Additional transmitters cannot be registered if none of the transmitters is functioning properly The transmitter and receiver function within a distance of approximately 3 m 10 ft Installation location requires special attention to avoid electrical interferences obstructions or water exposure St...

Page 78: ...ads The cylinder block features a crankcase equipped with an oil cooler a crankshaft with an integrated drive sprocket and sleeveless cylinders Other features include compact VCT assemblies with a narrow timing belt and a plastic bottom cowling These newly designed components have reduced the weight by 4 compared with previous V6 models a Compact VCT assembly b Narrow timing belt c Plastic cylinde...

Page 79: ... b can be adjusted by replacing the current valve lifter with a new valve lifter of the appropriate thickness A Previous V6 model B New V6 model Sleeveless cylinder To reduce the weight of the cylinder block the newly designed cylinder block utilizes spray coated cylinders instead of steel sleeved cylinders The inner walls of the cylinders are spray coated using metal powder b a a b A B Metal powd...

Page 80: ...il filter bracket c to improve the cool ing performance Engine oil that has lubricated the engine is cooled in the oil cooler in the crank case b and returned to the oil pan The oil that flows from the oil pan to the main journal will be cooled in the oil filter bracket c A Engine oil flow B Cooling water flow b a A B c a ...

Page 81: ...el rail Fuel injector Vapor shut off valve Pressure regulator Fuel rail Fuel injector Vapor separator High pressure fuel pump Fuel cooler Low pressure fuel pump Fuel filter with water separator and water detection switch Primer pump Canister Power unit system Fuel system ...

Page 82: ... chamber Check valve Check valve Atmosphere Atmosphere Canister Vapor shut off valve Surge tank Vapor separator assembly Pressure regulator High pressure fuel pump Fuel rail PORT Fuel rail STBD Fuel injector 6 Fuel injector 4 Fuel injector 2 Fuel injector 1 Fuel injector 3 Fuel injector 5 Combustion chamber 6 Combustion chamber 4 Combustion chamber 2 Combustion chamber 1 Combustion chamber 3 Combu...

Page 83: ...ssure sensor Oil filter Relief valve Oil pan Oil pump Strainer Piston Camshaft oil passage VCT assembly Cylinder head oil passage Crankpin connecting rod big end Camshaft journal Crankshaft main journal Cylinder block main gallery Valve and related parts Oil pressure sensor Oil filter Oil pump Strainer Relief valve Oil pan Fuel system Lubrication system ...

Page 84: ...o simplify the structure of the cooling system The crankcase vapor separator and Rectifier Regulator are cooled using the cooling water Cooling diagram E Cooling water flow C C D D E A A B B Thermostat Rectifier Regulator Fuel cooler Oil cooler Exhaust guide Upper case Water pump Water inlet ...

Page 85: ...r block PORT Cylinder block STBD Cylinder head PORT Cylinder head STBD Rectifier Regulator Cylinder block Cooling water outlet Fuel cooler Oil cooler crankcase Oil cooler oil filter bracket Exhaust guide Exhaust guide Oil pan Oil pan Water pump Upper case Lower case Trim tab Water inlet Propeller boss Water ...

Page 86: ...description Intake and exhaust system Intake and exhaust diagram A Intake air flow B Exhaust gas flow A B Throttle body Surge tank Intake manifold Intake manifold Cylinder head Exhaust guide Idle silencer Exhaust manifold Muffler Propeller ...

Page 87: ... b The drive shaft b is secured in the lower case using a ring nut c As a result the axial free play is removed and the pinion position is secured Propeller shaft bearing regular rotation model The propeller shaft is supported using 3 bearings to decrease the radial motion of the propeller shaft Because 2 bearings are taper roller bearings axial free play also decreases c a b Intake and exhaust sy...

Page 88: ...hifting gears this propeller absorbs much of the resulting force and noise using the damper a movement for smooth operation The damper a is replaceable When shifting gears the protrusions a on the dedicated spacer b transmit the rotational force of the propeller shaft directly to the propeller c A Neutral B Shift in a c b a a A B ...

Page 89: ...2 34 Lower unit 0 1 2 3 4 5 6 7 8 9 10 A MEMO ...

Page 90: ...ent 3 10 Installing the isolator lead 3 10 Installing the water pressure sensor 3 10 Installing the speed sensor 3 11 Installing the Digital Electronic Control box and switch panel 3 12 Installing Y COP optional in non European markets 3 12 Registering the receiver ID to the ECM 3 12 Battery installation 3 15 Battery wiring without house accessory battery 3 15 Battery wiring with house accessory b...

Page 91: ...0 1 2 3 4 5 6 7 8 9 10 A Rigging recommendation 3 30 Extension length recommendation of battery cable 3 30 Propeller selection 3 32 Propeller size 3 32 Selection 3 32 ...

Page 92: ...erformance of the boat which could cause loss of control or swamping Con sult the boat manufacturer for the maximum engine weight allowable on the transom which is different from the overall boat capacity Overloading the transom with an outboard motor that is too heavy could also damage the hull transom deck or helm area as well as the out board motor and other equipment Before mounting the outboa...

Page 93: ...om height U 1272 50 1 639 25 2 951 37 4 317 12 5 724 28 5 3 2 454 17 9 X 1078 42 4 U 1205 47 4 25 1 0 812 32 0 510 20 1 48 1 9 X 99 3 9 U 84 3 3 45 1 8 X 643 25 3 U 770 30 3 216 8 5 X 1155 45 5 230 9 1 728 28 7 X 239 9 4 75 3 0 240 19 5 59 2 3 673 26 5 X 847 33 3 U 924 36 4 3 67 12 X 53 2 1 U 59 2 3 U 241 9 5 T1 1 H 2 mm in Outboard motor installation Dimension ...

Page 94: ...3 3 RIG GING Rigging information Clamp bracket 411 16 2 18 5 0 7 50 8 2 0 180 7 1 180 7 1 163 5 6 4 163 5 6 4 13 0 5 52 2 0 55 5 2 2 13 0 5 125 4 4 9 125 4 4 9 254 10 0 79 3 1 mm in ...

Page 95: ... storing the crate IMPORTANT This unit delivered to carrier in a good condition For protection against loss due to damage inspect thoroughly If damage is noted make note on freight bill Shipper assumes no further liability to the transportation company Your claim should be filed against carrier for damage of any nature Lifting fork insert position Avoid water Handle with care Product barycentric p...

Page 96: ...ywheel magnet NOTICE When lifting the outboard motor make sure to use the specified special service tool Other bolts and hanging jigs could bend or break causing the outboard motor to fall 7 Install the lifting harness to the eye bolt a 8 Tension the lifting harness 9 Lift up the outboard motor along with the bottom plate c carefully NOTICE Make sure that the lifting harness does not damage any pa...

Page 97: ...ithout strakes B Hull with strakes C L Centerline of transom TIP Make sure that the distance a is equal to distance b and the distance c is equal to distance d For twin outboard motor installation place the outboard motors so that the distance from the C L of each outboard motor to the C L of the boat transom are equal on both sides TIP Make sure that the distance e is equal to distance f For the ...

Page 98: ... refer ence only It is impossible to provide com plete instructions for every possible boat and outboard motor combination 3 Adjust the height of the scale m to the transom height H and place it on the special service tool a Secure the special service tool a to the boat transom using screws or vises TIP For the transom height H see Dimension 3 2 4 When the outboard motor mounting position has been...

Page 99: ...he mounting bolts and then tighten the nuts firmly NOTICE Make sure that the clamp brackets do not bite into the boat transom 7 Tighten the locknuts firmly Rigging grommet mounting Rigging grommet description a Battery cable b Isolator lead optional c Extension wiring harness d Fuel hose e Flushing hose Installing the main harness 1 Remove the grommet holder a and rig ging grommet b 2 Remove the p...

Page 100: ...ositive battery cable a and negative battery cable b 2 Install the rubber cap a Installing the rigging grommet 1 Route each harness through the proper hole in the rigging grommet See Rig ging grommet description 3 8 2 Align the white tape a on the battery cable with the outer end of the rigging grommet 3 Install the grommet holder a along with the rigging grommet 4 Install the rigging tube retaine...

Page 101: ... and gasket b 2 Install a new gasket c and the adapter d and then tighten the adapter d to the specified torque NOTICE Do not reuse a gasket always replace it with a new one 3 Install the water pressure sensor e and then tighten it to the specified torque 4 Remove the water pressure sensor harness a from the holder f 5 Remove the water pressure sensor coupler b from the bracket g and then remove t...

Page 102: ...he tip a of the nipple a 2 Install the extension hose b to the nipple a and then fasten it using the plastic tie c 3 Remove the speed sensor coupler b from the engine ECM bracket d and then remove the cap c 4 Install the speed sensor e to the speed sensor adapter f and then tighten the speed sensor e to the specified torque 5 Install the speed sensor adapter f to the bottom cowling f a g b c a h b...

Page 103: ...o not install the receiver in a location where it will be exposed to water Do not cover the receiver with metal objects Otherwise signals may not be received 1 Install the receiver a and then tighten the receiver screws b to the specified torque TIP Mount the receiver within 3 m 10 ft from the steering position For installation position and drill holes see Yamaha Security System Y COP installa tio...

Page 104: ...r of the receiver will sound 1 short beep 6 Turn the engine start switch to ON A 6Y9 Multifunction Color Gauge B 6Y8 Multifunction Meter TIP If the outboard motor is equipped with the 6Y9 Multifunction Color Gauge Y COP mark c is displayed on the gauge when the engine start switch is turned to ON If the outboard motor is equipped with the 6Y8 Multifunction Meter mark d is dis played on the tachome...

Page 105: ... the outboard motor is equipped with the 6Y9 Multifunction Color Gauge Y COP mark c will not be displayed when the engine start switch is turned to ON If the outboard motor is equipped with the 6Y8 Multifunction Meter 0 mark e is dis played on the tachometer when the engine start switch is turned to ON 8 Turn the engine start switch to OFF e B ...

Page 106: ...ithout house accessory battery When only one battery is used for one engine connect the positive battery cable and isola tor lead to the positive battery terminal If the isolator lead is left unconnected accidental contact of the isolator lead with the negative terminal of the battery can cause a short cir cuit which may result in a fire When using a dual battery installation a negative battery ca...

Page 107: ...board motor Red Isolator lead Black Black Outboard motor Red Black Red Isolator lead Black Outboard motor Battery switch ON OFF STBD PORT Outboard motor Red Isolator lead Black Outboard motor Battery switch Black ON OFF Red Black Battery switch Isolator lead ON OFF ...

Page 108: ...cuit which may result in a fire When using a house battery a negative battery cable must be installed between the house battery and the engine battery This cable must be sized equivalent to the engine battery cables or larger AWG cable size in accordance with ABYC specifications Battery switches must be capable of meeting intermittent and continuous current ratings for engines and accessories STBD...

Page 109: ...9 10 A 1 2 Isolator lead Outboard motor Battery switch ON OFF Battery switch Black Red House battery Red Black Black House battery Outboard motor Isolator lead Red 1 2 Isolator lead Black Outboard motor Battery switch Black Red House battery Red ...

Page 110: ...ck Black House battery Isolator lead Battery switch Battery switch ON OFF Red Isolator lead ON OFF Black Battery switch 1 2 1 2 STBD PORT Outboard motor Outboard motor Red Black Black Black House battery Isolator lead Battery switch ON OFF Red Battery switch Black Battery switch Isolator lead ...

Page 111: ...motor Black House battery Isolator lead Battery switch Red Black Black Red Black Isolator lead Battery switch STBD PORT House battery Outboard motor Outboard motor Isolator lead Battery switch Red Red Black ON OFF Isolator lead ON OFF ON OFF Black Black Black Battery switch House battery Black ...

Page 112: ...0 ft 7 0 m 23 0 ft 8 0 m 26 2 ft 10 0 m 32 8 ft and 12 0 m 39 4 ft Select the one that fits the boat length 3 Y COP a Engine ECM b Extension wiring harness c Digital Electronic Control d Engine start switch with engine shut off switch e Receiver f Pigtail bus wire g Fuse 10 A h Power wire i Wire lead for 6Y9 j Main bus wire k 6Y9 Multifunction Color Gauge l Wire lead for 6Y9 m Wire lead for NMEA 0...

Page 113: ...22 Digital network system diagram 0 1 2 3 4 5 6 7 8 9 10 A SET MENU CANCEL n q b a f r d g h f NMEA 0183 GPS e k i l o m O B O Br B Br W L G B G p p p P B P p j j f t u s a b b c c c B B Y Y G R R c 1 2 3 ...

Page 114: ...5 A j Fuse 5 A k Fuse 10 A l Power wire m Station selector switch n Wire lead for 6Y9 o Main bus wire p 6Y9 Multifunction Color Gauge q Wire lead for 6Y9 r Wire lead for NMEA 0183 s GPS t Wire lead for fuel tank 6Y9 u Fuel tank fuel tank sensor v Cap 1 white w Hub x Single hub y Wire lead for 6Y9 Multisensor z 6Y9 Multisensor A Extension wire harness B Extension wire harness C In line resister D C...

Page 115: ...stem diagram 0 1 2 3 4 5 6 7 8 9 10 A SET MENU CANCEL i g f j h s v w a a b b h B B Y Y Y d NMEA 0183 GPS e m 2 3 1 1 p n q t r O B O Br B Br W L G B G u u u P B P u o C C C C C c o h y z x R R Y Y a b b c c c A A B A B k l o ...

Page 116: ...3 25 RIG GING Rigging information SET MENU CANCEL a b b c c c D q e E p v w o v C m h A B D D A B D D D F B ...

Page 117: ...s wire i Fuse 5 A j Fuse 5 A k Fuse 10 A l Power wire m Station selector switch n Wire lead for 6Y9 o Main bus wire p 6Y9 Multifunction Color Gauge q Wire lead for 6Y9 r Wire lead for NMEA 0183 s GPS t Wire lead for fuel tank 6Y9 u Fuel tank fuel tank sensor v Cap 1 white w Hub x Single hub y Wire lead for 6Y9 Multisensor z 6Y9 Multisensor A Extension wire harness B Extension wire harness C In lin...

Page 118: ...ging information SET MENU CANCEL i g h j k l s v w b a a a b b h Y d NMEA 0183 GPS e m 2 1 1 1 p n q t r O B O Br B Br W L G B G u u u P B P u o C C C C C C C c o h y z x Y Y a b b c c c A B B Y Y R R o A B A B A B f 3 ...

Page 119: ...3 28 Digital network system diagram 0 1 2 3 4 5 6 7 8 9 10 A SET MENU CANCEL a b b c c c D q e E p v w o v C m h A B D D A B D D A B D D D F B ...

Page 120: ...he OK button or press the Enter key on the keyboard 4 Click the OK button or press the Enter key on the keyboard 5 Turn the engine start switch to OFF and then remove the extension wiring harness of the Digital Electronic Control TIP The outboard motor will automatically identify the newly connected Digital Electronic Con trol under any of the following conditions When the extension wiring harness...

Page 121: ...om corroding Ambient temperature 5 C to 35 C 23 95 F Battery requirements Number of batteries in parallel Cable specifications Unit Minimum capacity Maximum total extension length Positive battery cable Negative battery cable 20 mm2 AWG4 30 mm2 AWG2 50 mm2 AWG1 0 60 mm2 AWG2 0 CCA EN 640 Amps 1 20HR IEC 80 Ah CCA EN 620 Amps 1 4 4 m 14 4 ft 6 7 m 22 0 ft 11 1 m 36 4 ft 13 4 m 44 0 ft 20HR IEC 110 ...

Page 122: ...m 5 9 ft 2 8 m 2 8 ft 4 6 m 15 1 ft 5 6 m 18 4 ft 20HR IEC 110 Ah CCA EN 620 Amps 2 2 6 m 8 5 ft 3 9 m 12 8 ft 6 5 m 21 3 ft 7 8 m 25 6 ft 20HR IEC 110 Ah CCA EN 670 Amps 1 2 1 m 6 9 ft 3 2 m 10 5 ft 5 3 m 17 4 ft 6 4 m 21 0 ft 20HR IEC 110 Ah CCA EN 670 Amps 2 3 0 m 9 8 ft 4 6 m 15 1 ft 7 6 m 24 9 ft 9 2 m 30 2 ft 20HR IEC 110 Ah CCA EN 750 Amps 1 2 3 m 7 5 ft 3 5 m 11 5 ft 5 8 m 19 0 ft 7 0 m 23...

Page 123: ...rd motor Propeller size The size of the propeller is indicated on the propeller boss end and on the side of the propeller boss a Propeller diameter in inches b Propeller pitch in inches c Propeller type propeller mark The propeller sizes listed in the propeller list indicate the following information a Propeller diameter in inches b Propeller pitch in inches c Propeller type propeller mark d Numbe...

Page 124: ...eller size Material 3 X 14 1 2 X 19 T 1 Stainless 3 X 15 X 17 T 1 3 X 14 3 4 X 23 T 3 X 15 3 4 X 13 T 3 X 15 3 4 X 15 T 3 X 15 1 2 X 17 T 3 X 15 1 4 X 19 T 3 X 15 X 21 T 4 X 15 X 21 T 4 X 15 X 22 T 4 X 15 X 23 T Propeller size Material 3 X 14 1 2 X 19 TL 1 Stainless 3 X 15 X 17 TL 1 3 X 14 3 4 X 23 TL 3 X 15 3 4 X 13 TL 3 X 15 3 4 X 15 TL 3 X 15 1 2 X 17 TL 3 X 15 1 4 X 19 TL 3 X 15 X 21 TL 4 X 15...

Page 125: ... communication cable to the outboard motor 4 4 Troubleshooting the power unit 4 5 Troubleshooting procedure 4 5 Troubleshooting the power unit using the YDIS 4 5 Trouble code and checking step 4 8 Troubleshooting the power unit trouble code not detected 4 29 Troubleshooting the PTT unit 4 35 Troubleshooting the lower unit 4 36 ...

Page 126: ...sk could cause errors and result in insufficient memory This software will not run properly on some computers When starting up this program do not start other software programs Do not use the screen saver function or the energy saving feature when using this program If the engine ECM is changed restart the program Windows XP and Windows Vista are multiuser operating systems Therefore make sure to ...

Page 127: ...l pressure 3 Cooling water pressure 4 Engine shut off switch Stationary test Operation tests can be performed while the engine is stopped 1 OCV drive STBD 2 OCV drive PORT 3 Operate high pressure fuel pump 4 Operate low pressure fuel pump Engine speed Battery voltage Shift cut off Intake pressure 1 Fuel injection duration Overheat thermoswitch Throttle position sensor main Ignition timing Main swi...

Page 128: ...ntrol voltage that the engine ECM requires to set the target opening angle of the throttle valve 3 Reference TPS voltage This item shows the criterion output voltage of the TPS This value is used to detect the TPS output voltage during engine operation 4 Engine ECM controls the engine idle speed using the throttle valve that is connected to the TPS This target voltage is used by the engine ECM to ...

Page 129: ...4 4 YDIS 0 1 2 3 4 5 6 7 8 9 10 A Connecting the communication cable to the outboard motor a YDIS coupler gray b a a YDIS CD ROM Ver 1 33 a 60V WS853 06 YDIS USB adapter and cable b 60V WS850 00 ...

Page 130: ...tage of a part the coupler or connector must be disconnected As a result the engine ECM determines that the part is disconnected and a trouble code is detected Therefore make sure to delete the diagnosis record after checking the input voltage Because the main relay comes on for approximately 10 seconds after the engine start switch is turned to OFF the power of the engine ECM cannot be turned off...

Page 131: ...function U U 37 Intake air passage malfunction U U 39 Oil press sensor malfunction Oil pressure sensor malfunction U U 44 Engine stop lanyard switch ON Engine shut off switch ON 68 Variable cam timing STBD 69 Variable cam timing PORT 71 Cam position sensor STBD INT malfunction U U 72 Cam position sensor PORT INT malfunction U U 73 OCV STBD malfunction U U 74 OCV PORT malfunction U U 86 Immobilizer...

Page 132: ...178 179 180 181 183 184 and 186 are applicable only to the dual station model 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 183 184 186 187 Remote control system malfunction Digital Electronic Control U U Code No Item YDIS diagnosis YDIS diagno sis record ...

Page 133: ...gine ECM 5 47 A 7 Check the protrusions on the fly wheel magnet for damage 7 14 15 Engine temp sen sor malfunction Out of specifica tion C E High engine idle speed Degraded acceleration performance Declining maximum engine speed Difference in engine idle speeds Engine speeds do not synchro nize Measure the engine tempera ture sensor input voltage 5 50 Measure the engine tempera ture sensor resista...

Page 134: ...e the Rectifier Regulator output peak voltage 5 42 Check the Rectifier Regulator for continuity 5 42 23 Intake temp sen sor malfunction Out of specifica tion C E High engine idle speed Engine speeds do not synchro nize Check the air temperature using the YDIS 5 48 Measure the air temperature sensor input voltage 5 48 Measure the air temperature sensor resistance 5 48 Check for wiring continuity be...

Page 135: ... buzzer comes on while the shift is in the N position Check the fuel filter for water Measure the water detection switch input voltage 5 34 Check the water detection switch for continuity 5 34 Check for wiring continuity between the water detection switch and the engine ECM 5 34 A 5 29 Intake press sen sor malfunction Out of specifica tion C E High engine idle speed Declining maximum engine speed ...

Page 136: ...3 A 3 71 Cam position sensor STBD INT malfunction Irregular signal C E High engine idle speed Degraded acceleration performance Declining maximum engine speed Difference in engine idle speeds Engine speeds do not synchro nize Measure the cam position sen sor input voltage 5 49 Measure the cam position sen sor output voltage 5 49 Check for wiring continuity between the cam position sen sor and the ...

Page 137: ...gine speed Engine speeds do not synchro nize Check the OCV operation using the YDIS 5 32 Measure the OCV input voltage 5 32 Measure the OCV resistance 5 32 Check for wiring continuity between the OCV and the main relay 5 32 A 3 Check for wiring continuity between the OCV and the engine ECM 5 32 A 3 Check the OCV filter 7 53 86 Immobilizer Communication error C E Declining maximum engine speed Chec...

Page 138: ...ference in engine idle speeds Engine speeds do not synchro nize Engine speed is set at approximately 1500 r min Check the ETV circuit 5 25 A 3 Check the fuse 5 3 A 3 Check the ETV motor relay 5 25 Check the throttle body 6 23 119 Electronic throt tle system mal function Throttle valve malfunction C E High engine idle speed Throttle does not operate Difference in engine idle speeds Engine speeds do...

Page 139: ...S 5 24 Check the ETV circuit 5 25 A 3 124 125 126 127 128 Throttle position sensor malfunc tion Out of specifica tion C E High engine idle speed Throttle does not operate Difference in idle speeds Engine speeds do not synchro nize Difference in maximum engine speeds Engine speed is set at approximately 1500 r min Measure the TPS output voltage using the YDIS 5 24 Check the throttle opening angle u...

Page 140: ...e does not operate Difference in idle speeds Engine speeds do not synchro nize Engine speed is set at approximately 1500 r min Replace the engine ECM 7 32 138 139 Electronic throt tle system mal function Throttle valve malfunction C E High engine idle speed Throttle does not operate Difference in engine idle speeds Engine speeds do not synchro nize Engine speed is set at approximately 1500 r min C...

Page 141: ...roper connection Check the ETV circuit 5 25 A 3 Check the fuse 5 3 A 3 Check the ETV motor relay 5 25 145 Electronic throt tle system mal function Throttle valve malfunction C E High engine idle speed Throttle does not operate Difference in engine idle speeds Engine speeds do not synchro nize Engine speed is set at approximately 1500 r min Measure the TPS output voltage using the YDIS 5 24 Check t...

Page 142: ...rt 1 Shift actuator does not operate High engine idle speed Alert indicator is on Engine speeds do not synchro nize 1 In a shift in position Measure the SPS input voltage 5 26 Measure the SPS output volt age 5 26 Check for wiring continuity between the SPS and the engine ECM 5 28 A 3 Measure the shift actuator rod stroke 5 28 Shift position sensor Sub malfunction Out of specifica tion C E Engine d...

Page 143: ...y input voltage 5 27 Measure the shift actuator motor resistance 5 27 Check for wiring continuity between the shift actuator and the engine ECM 5 27 A 3 Check the shift actuator relay 5 27 Check for wiring continuity between the shift actuator relay and the engine ECM 5 27 A 3 Measure the shift actuator rod stroke 5 27 Check the shift mechanism 7 34 Check the lower unit 8 9 8 14 8 68 8 71 Descript...

Page 144: ...e the shift actuator motor resistance 5 27 Check for wiring continuity between the shift actuator and the engine ECM 5 27 A 3 Check the shift actuator relay 5 27 Check for wiring continuity between the shift actuator relay and the engine ECM 5 27 A 3 Measure the shift actuator rod stroke 5 27 Check the shift mechanism 7 34 Check the lower unit 8 9 8 14 8 68 8 71 Descriptions of 1 in the Symptom co...

Page 145: ...tage 5 27 Measure the shift actuator motor resistance 5 27 Check for wiring continuity between the shift actuator and the engine ECM 5 27 A 3 Check the shift actuator relay 5 27 Check for wiring continuity between the shift actuator relay and the engine ECM 5 27 A 3 Measure the shift actuator rod stroke 5 27 Check the shift mechanism 7 34 Check the lower unit 8 9 8 14 8 68 8 71 Descriptions of 1 i...

Page 146: ...e does not restart Fully closed throttle Shift actuator rod returns to neutral LAN gauge does not operate Alert indicator is on Engine speeds do not synchro nize Unable to switch the active station in the case of dual station arrange ment trouble code 186 Trouble codes 156 and 157 detected simul taneously Check that the extension wiring harness is connected properly and that there is no damage Che...

Page 147: ...lace simultaneously Measure the LPS output voltage using the YDIS Check for wiring continuity between the LPS and the Digital Electronic Control ECM 164 Remote control system malfunc tion Main station LPS Irregular sig nal C E Fully closed throttle Throttle does not operate Shift actuator rod returns to the N position Shift actuator can be operated man ually Alert indicator is on Difference in idl...

Page 148: ...ngine speed Difference in idle speeds Engine speeds do not synchro nize These are symptoms of the center out board motor 1 Unstable Measure the LPS output voltage using the YDIS See the Digital network control service manual Check for wiring continuity between the LPS and the Digital Electronic Control ECM Fully closed throttle Shift actuator rod returns to the N position Alert indicator is on Eng...

Page 149: ...ance Declining maximum engine speed Alert indicator is on Difference in idle speeds Engine speeds do not synchro nize Difference in maximum engine speeds 1 Unstable Measure the LPS output voltage using the YDIS See the Digital network control service manual Check for wiring continuity between the LPS and the Digital Electronic Control ECM Fully closed throttle Shift actuator rod returns to the N p...

Page 150: ... a new one resetting of Digital Electronic Control ECM is nec essary See the Digital network control service manual 176 Remote control system malfunc tion Sub station LPS Irregular sig nal C E Fully closed throttle Throttle does not operate Shift actuator rod returns to the N position Shift actuator does not operate Alert indicator is on Difference in idle speeds Engine speeds do not synchro nize ...

Page 151: ...When either one of the trou ble codes 177 and 178 and either one of the trouble codes 179 and 180 took place simultaneously These are symptoms of the center out board motor Measure the LPS output voltage using the YDIS Check for wiring continuity between the LPS and the Digital Electronic Control ECM 181 Remote control system malfunc tion Sub station LPS Irregular sig nal C E Fully closed throttle...

Page 152: ...displayed Sub station Digital Electronic Con trol does not operate Unable to change to the sub station Digital Electronic Control 1 Fully closed throttle Shift actuator rod returns to the N position Alert indicator is on Engine speeds do not synchro nize 2 1 When main Digital Elec tronic Control ECM detects a communication error trouble codes 156 and 157 during operation at a main station with dua...

Page 153: ...ar sig nal C E Replace the Digital Electronic Control ECM When replacing the Digital Electronic Control ECM with a new one resetting of Digital Electronic Control ECM is nec essary See the Digital network control service manual Trouble code Item Condition LAN gauge display Symptom Remarks Checking steps See page ...

Page 154: ...er relay malfunction Check the starter relay 5 53 Engine start switch malfunction Check the engine start switch or main switch 5 53 LPS malfunction Check the LPS See the Digital network control service manual Short open or loose connec tion in starter motor circuit Measure the starter relay input voltage 5 53 Check the wiring harness continuity A 9 Starter motor malfunction Disassemble and check t...

Page 155: ...Electronic Control ECM ID do not match Digital Electronic Control system reset using the YDIS 3 29 Engine ECM malfunction Replace the engine ECM 7 32 Extension wiring harness mal function Check the extension wiring harness con tinuity 5 65 Spark plug does not spark all cylinders Check the ignition spark 5 45 Spark plug malfunction Check the spark plug 7 48 Short open or loose connec tion in igniti...

Page 156: ...pump and high pres sure fuel pump relay 5 37 A 5 Blown fuse Check the fuse 5 3 High pressure fuel pump relay malfunction Check the high pressure fuel pump relay 5 38 Short open or loose connec tion in low pressure fuel pump circuit Check the low pressure fuel pump input voltage 5 37 Check for wiring continuity between the low pressure fuel pump and engine ECM 5 37 A 5 Check for wiring continuity b...

Page 157: ...gulator malfunction Check the pressure regulator 6 8 Clogged fuel filter Check the fuel filter for dirt and obstruc tions 6 12 High pressure fuel pump mal function Measure the high pressure fuel pump resistance 5 37 Fuel not supplied some cylinders Fuel injector malfunction Check the fuel injector operation using the YDIS 5 35 Measure the fuel injector resistance 5 35 Short open or loose connec ti...

Page 158: ...valve cyl inder head Check the gaskets of the intake mani folds surge tank and throttle body 6 14 6 20 Symptom 2 Cause Checking step See page Improper intake cam timing Stuck OCV plunger Check the OCV valve operation using the YDIS 5 32 Check the OCV plunger 5 32 Clogged OCV filter Replace the OCV filter 7 53 Clogged oil passage Check the oil passage 2 28 Stuck VCT Replace the VCT assembly 7 42 ...

Page 159: ...zzer comes on Oil pressure alert indica tor comes on Insufficient engine oil Check the engine oil 10 4 Check the engine oil leakage 2 28 Check the valve seals and valves 7 53 Check the piston rings 7 79 Measure the oil pressure 7 1 Engine oil pressure decrease Check the oil pump 7 67 Check the oil strainer 9 20 Check the oil passage power unit and oil pump 2 28 Replace the oil filter 10 9 Symptom ...

Page 160: ...T motor does not operate PTT motor malfunction Check the PTT motor 9 41 Short open or loose connec tion of the PTT motor lead Check for wiring continuity between the PTT motor and the PTT relay terminal A 11 PTT fluid pressure does not increase Measure the PTT fluid pressure 9 33 Manual valve opened Check the manual valve 9 35 Insufficient PTT fluid Add sufficient PTT fluid 10 13 PTT fluid leakage...

Page 161: ...Cause Trouble causes of symptom 2 Not applicable Symptom 1 Shift mechanism of the forward gear and reverse gear does not operate prop erly Symptom 2 Cause 1 Checking step See page Shift rod does not operate properly Check the shift lever operation 7 34 Check the shift rod for wear 8 12 9 1 Shift mechanism malfunction in lower unit Check the dog clutch 8 18 Check the forward gear reverse gear and p...

Page 162: ... 5 22 Checking the main relay 5 22 Checking the engine ECM circuit 5 23 Checking the ETV and TPS 5 24 Checking the ETV motor relay 5 25 Checking the ETV TPS circuit 5 25 Checking the SPS 5 26 Checking the shift actuator relay 5 27 Checking the shift actuator 5 27 Checking the SPS and shift actuator circuit 5 28 Checking the cam position sensor 5 29 Checking the OCV 5 32 Checking the oil pressure s...

Page 163: ...itch and main switch 5 53 Checking the engine start stop button 5 54 Checking Y COP 5 54 Starter motor 5 56 Removing the starter motor 5 58 Checking the starter motor operation 5 58 Checking the magnet switch 5 58 Checking the starter motor pinion 5 58 Disassembling the starter motor 5 59 Checking the armature starter motor 5 60 Checking the brush holder 5 61 Assembling the starter motor 5 61 Inst...

Page 164: ...5 1 ELEC Electrical system Electrical component Port a ETV TPS b Vapor shut off valve c Thermoswitch PORT d OCV PORT e Fuel injector f High pressure fuel pump g Low pressure fuel pump a b c d e g f ...

Page 165: ...5 2 Electrical component 0 1 2 3 4 5 6 7 8 9 10 A Starboard a OCV STBD b Thermoswitch STBD c Fuse holder d PTT relay e Rectifier Regulator f Oil pressure sensor g Fuel injector e f a b c d g ...

Page 166: ...nic Control ECM c Fuse 100 A house accessory battery d Fuse 15 A high pressure fuel pump e Fuse 10 A ETV f Fuse 30 A ignition coil VCT fuel injec tor and engine ECM g Main relay h Fuse 30 A starter relay i Fuse 15 A shift actuator j Shift actuator relay k ETV motor relay l Fuel pump relay high pressure a b c d e f g h i j k l m n ...

Page 167: ...5 4 Electrical component 0 1 2 3 4 5 6 7 8 9 10 A m Starter relay n Fuse 10 A low pressure fuel pump a b c d e f g h i j k l m n ...

Page 168: ...5 ELEC Electrical system Rear a Engine ECM b Ignition coil c Knock sensor d Speed sensor coupler optional e Joint connector 3 f Diode g Joint connector 2 h Water pressure sensor coupler a b b c d e g h f ...

Page 169: ...5 6 Electrical component 0 1 2 3 4 5 6 7 8 9 10 A Front a Starter motor b YDIS coupler c Water detection switch in fuel cup assem bly a b c ...

Page 170: ...nnector 4 c Joint connector 1 d Cam position sensor PORT EX e Condenser f Condenser g Condenser h Cam position sensor PORT IN i Engine temperature sensor j Pulser coil k Air temperature sensor l Air pressure sensor m Lighting coil stator assembly a c b d e f g h i j l k m ...

Page 171: ... 1 2 3 4 5 6 7 8 9 10 A Bottom cowling a PTT switch b SPS c Shift actuator d Water detection switch coupler e Trim sensor coupler f Extension wiring harness A Regular rotation model B Counter rotation model A B a b d e a f b c c ...

Page 172: ...rmoswitch connec tors using the holder C Install the holders to the intake manifold connect the fuel injector couplers and then fasten the fuel injector leads using the holders D Install the holders to the intake manifold so that the catch of each holder is facing up and then fasten the main wiring har ness using the holders E Route the main wiring harness through the guide A B C D E ...

Page 173: ...ighting coil lead f Power supply lead g Ground lead A Install the holders to the intake manifold and then fasten the main wiring harness using the holder B Fasten the main wiring harness ther moswitch connectors and cooling water hose using the plastic tie a a e d a f a g g a b A A C E F G H J c B A A D D E E C C B A A E E B D D C C D ...

Page 174: ... E Fasten the shift actuator lead and fuel hose using the holder F Install the holders to the intake manifold and then fasten the PTT motor lead using the holder G Install the terminal of the ground lead with gray tape so that it contacts the stopper H Install the terminals of the ground leads that are fastened together using tape so that they contact the stopper a a e d a f a g g a b A A C E F G ...

Page 175: ... 0 1 2 3 4 5 6 7 8 9 10 A J Install the Rectifier Regulator ground lead terminal and PTT relay ground lead termi nal so that they contact the stopper a a e d a f a g g a b A A C E F G H J c B A A D D E E C C B A A E E B D D C C D ...

Page 176: ...he main wiring harness using the holder so that the catch of the holder is facing up C Fasten the grommet of the main wiring harness using the holder D Fasten the main wiring harness and igni tion coil lead using the holder E Fasten the main wiring harness at the white tape using the holder C C a b b b b b b a b b A A B B A B C E D a A A B B C C ...

Page 177: ...5 14 Wiring harness routing 0 1 2 3 4 5 6 7 8 9 10 A Front A Fasten the PTT relay lead using the holder B Align the starter motor lead with the arrow mark on the terminal A B A A ...

Page 178: ...l the holders to the wiring harness guide and then fasten the main wiring harness using the holders B Fasten the low pressure fuel pump lead and air pressure sensor lead using the holder C Route the lighting coil leads under the holder A C B ...

Page 179: ...tom cowling a Flushing hose b SPS lead c Trim sensor lead d Speedometer hose e PTT motor lead f PTT switch lead g Vapor gas hose A Regular rotation model B Counter rotation model A B e f c d a a c a d f g d A A B B C C a f g c a b A A C C B B D D D D D D D D ...

Page 180: ...nsor Oil pressure sensor Ground Ground Ground Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4 Fuel injector 5 Fuel injector 6 Ignition coil 1 Ignition coil 4 Ignition coil 2 Ignition coil 3 Ignition coil 5 Ignition coil 6 ETV relay ETV motor Engine ECM Cam position sensor PORT EX Cam position sensor PORT IN Cam position sensor STBD IN Pulser coil Ground Ground Ground Engine ECM Fue...

Page 181: ...e ECM High pressure fuel pump relay High pressure fuel pump Water pressure sensor Speed sensor Engine start switch Starter motor Starter relay Battery Digital Electronic Control ECM Water pressure sensor Speed sensor Trim sensor Air temperature sensor Engine temperature sensor Water detection switch Thermoswitch Knock sensor Digital Electronic Control ECM Engine shut off switch PTT switch UP PTT s...

Page 182: ...er source Red Green 44 Battery power source Red Yellow 45 PTT UP switch Sky blue 46 47 Cam position sensor STBD IN White Black 48 Water pressure sensor Blue Black 49 OCV STBD Purple 50 OCV PORT Purple 51 Shift power source Red Green 52 Battery power source Red Yellow No Connecting part Color 53 Wake up pulse Digital Electronic Control Yellow 54 PTT DN switch Light green 55 YDIS White Black 56 Low ...

Page 183: ...urple Black 89 Starter relay Black 90 Digital Electronic Con trol 1 H White 91 Digital Electronic Con trol 1 L Blue 92 Digital Electronic Con trol 2 H White 93 Digital Electronic Con trol 2 L Blue 94 ETV motor Green Red 95 ETV ground Black 96 Fuel injector 3 Purple Yellow 97 Fuel injector 4 Purple Green 98 Ignition coil 2 Black White 99 Engine ECM ground Black 100 Ignition coil 5 Black Blue 101 Ig...

Page 184: ...any of the connections of the digital tester probes When measuring the peak voltage between the terminals of an electrical component using the digital tester make sure that the leads do not contact any metal parts Otherwise the electrical com ponent may short circuit and be dam aged To check the electrical components or mea sure the peak voltage use the special ser vice tools A malfunctioning elec...

Page 185: ...ver and main relay a 2 Connect the positive battery lead to the terminal a connect the negative battery lead to the terminal b and then check for continuity between the terminals c and d Replace the relay if there is no continuity NOTICE Do not reverse the battery leads 3 Measure the input voltage between the terminal e and ground and the terminal f and ground 4 Turn the engine start switch to ON ...

Page 186: ...ure the input voltage between the engine ECM coupler terminal 53 and ground 5 Turn the engine start switch to OFF 6 Remove the intake manifold STBD 7 Remove the fuse holder a and then disconnect the fuse holder coupler d Main relay input voltage Terminal e Terminal g 12 0 V battery voltage e g c b a 86 99 41 42 a b c Wiring harness continuity Terminal 41 Ground Terminal 42 Ground Terminal 86 Groun...

Page 187: ...hrottle position sensor sub 2 Start the engine warm it up for 5 10 minutes and then stop it 3 Turn the engine start switch to ON and then measure the TPS output voltages and the throttle valve opening angles when the Digital Electronic Control is at the fully closed position TIP The actual TPS output voltage and throttle valve opening angle may vary according to environmental conditions and engine...

Page 188: ...ecking the main relay 5 22 3 Measure the input voltage between the terminal a and ground 4 Turn the engine start switch to ON and then measure the input voltage between terminals b and c 5 Turn the engine start switch to OFF 6 Install the ETV motor relay a and relay cover Checking the ETV TPS circuit 1 Disconnect the engine ECM couplers a and b 2 Disconnect the ETV coupler c TPS input voltage Oran...

Page 189: ...e intake manifold STBD See Installing the intake manifold 6 16 Checking the SPS 1 Connect the YDIS to display Shift posi tion sensor 2 Operate the Digital Electronic Control to measure the output voltage at the F N and R positions Wiring harness continuity Terminal 62 Terminal 6 Terminal 68 Terminal 2 Terminal 69 Terminal 3 Terminal 94 Terminal 1 Terminal 117 Terminal 4 Terminal 116 Terminal 5 c 1...

Page 190: ...sure the input voltage between the terminal a and ground 4 Turn the engine start switch to ON and then measure the input voltage between terminals b and c 5 Turn the engine start switch to OFF 6 Install the shift actuator relay a and relay cover Checking the shift actuator 1 Remove the intake manifold PORT 2 Operate the Digital Electronic Control to check the shift actuator rod stroke a at the pos...

Page 191: ...manifold 6 16 Checking the SPS and shift actuator circuit 1 Disconnect the engine ECM couplers a and b 2 Disconnect the SPS coupler c 3 Remove the intake manifold PORT and then disconnect the shift actuator motor coupler d 4 Check the wiring harness for continuity Shift actuator rod stroke a F 78 2 mm 3 08 in N 59 2 mm 2 33 in R 41 1 mm 1 62 in Shift actuator motor resistance reference data 1 7 Ω ...

Page 192: ... the cam position sensor 1 Disconnect the cam position sensor cou plers a b and c 2 Turn the engine start switch to ON and then measure the input voltage at the cam position sensor coupler Wiring harness continuity a Terminal 32 d Terminal 2 a Terminal 34 d Terminal 1 b Terminal 63 c Terminal 2 b Terminal 75 c Terminal 4 b Terminal 78 c Terminal 1 b Terminal 80 c Terminal 5 b Terminal 81 c Termina...

Page 193: ...the engine start switch to ON and then measure the output voltage when moving a screwdriver close to the cam position sensor NOTICE Make sure to remove the high pressure fuel pump fuse Cam position sensor input voltage Red Yellow R Y Black B 12 0 V battery voltage White Black W B Black B STBD IN White Green W G Black B PORT IN White Blue W L Black B PORT EX 4 75 5 25 V Test lead Terminal male a 9E...

Page 194: ...the engine ECM couplers n and p 18 Check the wiring harness for continuity 19 Set the digital circuit tester to the diode mode and then check the wiring harness continuity Cam position sensor output voltage White Black W B Black B STBD IN White Green W G Black B PORT IN White Blue W L Black B PORT EX Position Voltage g k More than 4 8 h Less than 1 0 e m n p Wiring harness continuity aTerminal 1 T...

Page 195: ... then measure the input voltage between the OCV coupler and ground 4 Turn the engine start switch to OFF 5 Remove the OCV 6 Measure the OCV resistance 7 Remove the OCV 8 Connect the battery leads to the terminals and check the operation of the spool valve Replace the OCV if the spool valve does not operate Wiring harness continuity testing diode mode Tester probe Display value refer ence data m Te...

Page 196: ...engine ECM coupler d 16 Connect the fuse holder coupler c and then install the fuse holder a 17 Install the intake manifold STBD See Installing the intake manifold 6 16 Checking the oil pressure sensor 1 Disconnect the oil pressure sensor cou pler a 2 Turn the engine start switch to ON and then measure the input voltage at the oil pressure sensor coupler c a d Wiring harness continuity a Terminal ...

Page 197: ...pler a Fuel control unit and component Checking the water detection switch 1 Disconnect the water detection switch coupler a 2 Turn the engine start switch to ON and then measure the input voltage at the water detection switch coupler Oil pressure sensor input voltage Orange O Black B 4 75 V 5 25 V Pressure pump a commercially available Test harness 3 pins b 90890 06869 Oil pressure sensor output ...

Page 198: ...Fuel filter assembly 6 9 10 Connect the water direction switch coupler a Checking the fuel injector 1 Check the operation of the fuel injector using the YDIS Stationary test and check the operating sound 2 Disconnect the fuel injector couplers a 3 Turn the engine start switch to ON and then measure the input voltage between the fuel injector coupler terminal and ground Water detection switch input...

Page 199: ...nifold STBD 7 Remove the fuse holder a and then disconnect the fuse holder coupler b 8 Disconnect the engine ECM coupler c 9 Check the wiring harness for continuity Fuel injector input voltage Red Yellow R Y Ground 12 0 V battery voltage Fuel injector resistance reference data 11 5 12 5 Ω at 20 C 68 F R Y STBD a R Y PORT a b a c 18 87 88 96 97 1 2 104 114 a b c ...

Page 200: ...gine start switch to OFF 5 Disconnect the high pressure fuel pump coupler b 6 Connect the tester probes to the terminals of the high pressure fuel pump coupler b and then measure the input voltage within 5 seconds after turning the engine start switch to ON 7 Measure the resistance of the fuel pump motors Wiring harness continuity Injector 1 Terminal 1 Terminal 18 Terminal 2 Terminal 87 Injector 2...

Page 201: ...e ECM coupler e 15 Connect the low pressure fuel pump coupler a and high pressure fuel pump coupler b Checking the high pressure fuel pump relay 1 Remove the relay cover and high pres sure fuel pump relay a 2 Check the high pressure fuel pump relay See Checking the main relay 5 22 Low pressure fuel pump a resistance reference data 0 5 4 0 Ω at 20 C 68 F High pressure fuel pump b resistance referen...

Page 202: ...t off valve and then connect the special service tool a to the vapor shut off valve 4 Apply the specified negative pressure to the vapor shut off valve 5 Check that the vapor shut off valve opens and the negative pressure is released when the battery leads are connected to the vapor shut off valve terminals NOTICE Do not connect the battery leads to the vapor shut off valve terminals for more than...

Page 203: ...e coupler a 13 Connect the fuse holder coupler b and then install the fuse holder b 14 Install the intake manifold STBD and intake silencer See Installing the intake manifold 6 16 15 Connect the engine ECM coupler c Charging unit and component Checking the lighting coil stator assembly 1 Remove the intake manifold STBD 2 Disconnect the lighting coil couplers a and b 3 Connect the special service t...

Page 204: ...the intake manifold STBD 7 Disconnect the special service tools a and b 8 Disconnect the lighting coil couplers c and d and then connect the special service tools a and b 9 Repeat steps 4 and 5 10 Remove the intake manifold STBD 11 Disconnect the special service tools a and b 12 Measure the lighting coil resistance 13 Connect the lighting coil couplers 14 Install the intake manifold STBD See Insta...

Page 205: ... B when measuring the Rectifier Regulator output peak voltage 3 Remove the intake manifold STBD 4 Disconnect the Rectifier Regulator couplers a b c d and e and ground lead f 5 Remove the fuse holder and then remove the Rectifier Regulator couplers g h and k 6 Set the digital circuit tester to the diode mode and then check the Rectifier Regulator for continuity Rectifier Regulator output peak volta...

Page 206: ...OL p r 0 000 V s OL t u v w x y A B n m OL p r s t u v w x y A B m n r s t u y A v w x B p p m OL n r s t u v w x y A B r m 0 000 V n OL p s t u v w x y A B s m 0 447 V n 0 441 V p 0 447 V r OL t u v w x y A B OL Indicates an overload Rectifier Regulator continuity testing diode mode Tester probe Display value reference data ...

Page 207: ... p r s t u w x y 0 445 V A 0 446 V B OL Rectifier Regulator continuity testing diode mode Tester probe Display value reference data w m OL n p r s t u v x y 0 445 V A 0 445 V B OL x m OL n p r s t u v w y 0 445 V A 0 445 V B OL y m OL n p r s t u v w x A B OL Indicates an overload Rectifier Regulator continuity testing diode mode Tester probe Display value reference data ...

Page 208: ...special service tool a to an ignition coil TIP Repeat steps 2 4 for each ignition coil 3 Check the ignition spark using the YDIS Stationary test WARNING Do not touch any of the connections of the special service tool A m OL n p r s t u v w x y B B m 0 809 V n 0 807 V p 0 809 V r OL s 0 445 V t 0 440 V u 0 443 V v 0 443 V w 0 446 V x 0 443 V y 0 809 V A 0 807 V OL Indicates an overload Rectifier Re...

Page 209: ...tion coil coupler 3 Turn the engine start switch to OFF and then disconnect the engine ECM coupler b 4 Remove the intake manifold STBD 5 Remove the fuse holder a and then disconnect the fuse holder coupler c 6 Check the wiring harness for continuity Ignition tester spark gap tester a 90890 06754 Ignition coil input voltage Red Yellow R Y Black B 12 0 V battery voltage a B R Y a b c a 18 98 1 2 3 1...

Page 210: ...from starting 4 Disconnect the special service tool a 5 Measure the pulser coil resistance 6 Disconnect the engine ECM couplers b and c Wiring harness continuity Ignition coil 1 Terminal 1 Terminal 106 Terminal 2 Ground Terminal 3 Terminal 18 Ignition coil 2 Terminal 1 Terminal 98 Terminal 2 Ground Terminal 3 Terminal 18 Ignition coil 3 Terminal 1 Terminal 110 Terminal 2 Ground Terminal 3 Terminal...

Page 211: ...ine is cold When checking the air temperature sensor remove the top cowling and do not start the engine 4 Disconnect the air temperature sensor coupler a 5 Turn the engine start switch to ON and then measure the input voltage at the air temperature sensor coupler 6 Turn the engine start switch to OFF 7 Remove the air temperature sensor 8 Place the air temperature sensor in a container of water and...

Page 212: ...ensor coupler 4 Turn the engine start switch to OFF 5 Remove the air pressure sensor 6 Connect the special service tools a and b 7 Turn the engine start switch to ON 8 Apply negative pressure to the air pressure sensor slowly and then measure the output voltage at the specified pressure Air temperature sensor resistance reference data 2 21 2 69 kΩ at 20 C 68 F 0 32 kΩ at 80 C 176 F Wiring harness ...

Page 213: ...mperature sensor coupler 3 Turn the engine start switch to OFF 4 Remove the engine temperature sensor 5 Place the engine temperature sensor in a container of water and heat the water slowly 6 Measure the engine temperature sensor resistance 7 Disconnect the engine ECM coupler b Air pressure sensor output voltage reference data Pink Green P G Black B 3 21 V at 20 0 kPa 0 20 kgf cm2 2 9 psi 2 16 V a...

Page 214: ... connectors 3 Turn the engine start switch to OFF 4 Remove the thermoswitches 5 Place the thermoswitches in a container of water and heat the water slowly 6 Check the thermoswitches for continuity at the specified temperatures Replace if out of specification c Temperature d Time e No continuity f Continuity Wiring harness continuity Terminal 1 Terminal 64 Terminal 2 Terminal 77 b 77 64 a b 1 2 STB...

Page 215: ...connect the engine ECM coupler b 4 Check the wiring harness for continuity 5 Connect the engine ECM coupler b and knock sensor coupler a Checking the engine shut off switch 1 Disconnect the engine start switch cou pler or main switch coupler 2 Turn the engine start switch to ON and then check the engine shut off switch for continuity between the terminals a and b Wiring harness continuity Pink P T...

Page 216: ...tween the terminals b and c and then turn the engine start switch to START and measure the input voltage 5 Install the starter relay a and relay cover Checking the engine start switch and main switch 1 Disconnect the engine start switch cou pler or main switch coupler 2 Check the engine start switch or main switch for continuity at the engine start switch coupler or main switch coupler Switch posi...

Page 217: ...p button coupler A Single sub station B PORT C STBD D Center 3 Connect the engine start stop button coupler Checking Y COP 1 Disconnect the Y COP coupler a and then measure the Y COP input voltage Switch position Terminal a b c d e OFF C C ON C C START 1 C C C b a a B b e A c d c d ON OFF START ON OFF Engine start stop button continuity Button pushed in A Terminal a Terminal b B Terminal c Termina...

Page 218: ...5 55 ELEC Electrical system 2 Connect the Y COP coupler a Y COP input voltage Red R Ground 12 0 V battery voltage R B a ...

Page 219: ... set 1 5 Starting motor gear assembly 1 6 Bracket 1 7 Screw 2 M4 16 mm 8 Bolt 2 M5 127 mm 9 Planetary gear 3 10 Outer gear 1 11 Plate 1 12 Stator 1 13 Armature 1 14 Pinion assembly 1 15 Bracket 1 16 Bracket 1 17 Gasket 1 39 4 9 9 14 15 17 19 10 11 12 13 1 1 1 2 5 3 7 8 6 7 5 4 4 4 4 18 16 22 21 21 23 25 24 26 20 Starting unit and component Starter motor ...

Page 220: ...y Remarks 18 Bracket assembly 1 19 Pinion shaft 1 20 Cover 1 21 Bolt 2 M6 35 mm 22 Lever assembly 1 23 Seal set 1 39 24 Magnet switch 1 25 Washer 1 26 Nut 1 4 9 9 14 15 17 19 10 11 12 13 1 1 1 2 5 3 7 8 6 7 5 4 4 4 4 18 16 22 21 21 23 25 24 26 20 ...

Page 221: ...enance make sure to check the oper ation again after assembling it 4 Disconnect the negative and positive battery cables from the battery terminals Checking the magnet switch 1 Connect the tester probes to the magnet switch terminals a and b 2 Connect the negative battery cable a to the starter motor body 3 Connect the lead b to the magnet switch terminal c 4 Connect the positive battery cable c t...

Page 222: ...the magnet switch a and spring a 2 Remove the stator assembly b 3 Remove the plate b outer gear c and planetary gears d 4 Remove the rubber seal c lever d and pinion shaft assembly e 5 Push the pinion stopper e down and then remove the clip f 6 Remove the pinion stopper k and pinion assembly g a a b c b d Pipe f commercially available g 18 0mm 0 71 in h 13 0mm 0 51 in c d e e g h f e f f k g ...

Page 223: ...m 10 Remove the plate r and then remove the armature k from the brush holder assembly l Checking the armature starter motor 1 Check the commutator Clean using 600 grit sandpaper and compressed air if dirty 2 Measure the commutator diameter a Replace the armature if below specification 3 Measure the commutator undercut b n p m i h j l m k Commutator standard diameter a 29 0 mm 1 14 in Wear limit 28...

Page 224: ... not apply grease or oil to the commu tator of the armature Do not reuse a gasket or seal set always replace it with a new one 1 Push the brushes a into the holders and then install the armature a to the brush holder assembly b 2 Install the plate b Commutator standard undercut b 0 5 0 8 mm 0 02 0 03 in Wear limit 0 2 mm 0 01 in Armature continuity c d e f C C b d e f c e c d b a a e c b d Brush h...

Page 225: ...holes e and f in the bracket c 4 Install the shim g the brackets e a new gasket f and the shim h and then install the E clip k onto the pinion shaft g 5 Install the pinion assembly h pinion stopper m and clip n 6 Install the pinion shaft assembly p the lever r and a new rubber seal s 7 Install the outer gear i planetary gears j and plate k b b a a a a b b d b c a f d c c e h g k f g e m m n h h h ...

Page 226: ...ecking the water pressure sensor optional 1 Disconnect the water pressure sensor coupler a 2 Turn the engine start switch to ON and then measure the input voltage at the water pressure sensor coupler 3 Remove the water pressure sensor and then connect the pressure pump a and special service tool b 4 Apply positive pressure to the water pressure sensor slowly and then measure the output voltage at ...

Page 227: ... the input voltage at the speed sensor coupler 3 Remove the speed sensor and then connect the pressure pump a and special service tool b 4 Apply positive pressure to the speed sensor slowly and then measure the output voltage at the specified pressures Pressure pump a commercially available Test harness 3 pins b 90890 06869 Water pressure sensor output voltage reference data Blue Black L B Black B...

Page 228: ...n wiring harness 1 Check the extension wiring harness for continuity Check the wire terminal num bers from a to r Checking the main wiring harness 1 Disconnect the main wiring harness cou pler a Pressure pump a commercially available Test harness 3 pins b 90890 06869 Speed sensor output voltage reference data Blue L Black B 2 5 V at 392 0 kPa 3 92 kgf cm2 56 8 psi 4 5 V at 784 0 kPa 7 84 kgf cm2 1...

Page 229: ...put voltage between the PTT relay coupler terminal and ground b c d a b a c d 15 14 2 3 4 8 7 6 5 9 4 5 3 12 10 36 53 38 90 91 92 93 11 Wiring harness continuity a Terminal 2 b Terminal 91 a Terminal 3 b Terminal 90 a Terminal 4 c Terminal 36 a Terminal 5 b Terminal 38 a Terminal 6 Ground a Terminal 7 d Terminal 4 a Terminal 8 c Terminal 53 a Terminal 9 Ground a Terminal 10 d Terminal 3 a Terminal...

Page 230: ... check the PTT relay for continuity Replace if out of specification 8 Connect the positive battery lead to the connector g connect the negative battery lead to the connector h and then check the PTT relay for continuity Replace if out of specification 9 Remove the intake manifold STBD PTT relay input voltage Red R Ground 12 0 V battery voltage Test harness 3 pins a 90890 06791 PTT relay continuity...

Page 231: ...all the intake manifold STBD See Installing the intake manifold 6 16 17 Connect the engine ECM coupler m Checking the PTT switch bottom cowling 1 Disconnect the PTT switch coupler a 2 Measure the input voltage between the PTT switch coupler terminal and ground A Regular rotation model B Counter rotation model 3 Check the PTT switch for continuity Replace if out of specification Wiring harness cont...

Page 232: ...6 16 10 Connect the engine ECM coupler f 11 Connect the PTT switch coupler a Checking the trim sensor 1 Disconnect the trim sensor coupler a and then remove the trim sensor 2 Turn the trim sensor lever b from the position c to the position d and then measure the resistance as it gradually changes Switch position Terminal b c d UP C C Free DN C C e a f 16 54 45 a e f 3 2 1 Wiring harness continuity...

Page 233: ...s e and f 4 Check the wiring harness for continuity 5 Connect the engine ECM couplers e and f 6 Install the trim sensor and then connect the trim sensor coupler a See Adjusting the trim sensor 9 29 Wiring harness continuity Terminal 1 Terminal 77 Terminal 2 Terminal 27 e f 27 77 e f a 2 1 ...

Page 234: ...er assembly 6 12 Installing the fuel filter assembly 6 12 Intake manifold 6 14 Removing the intake silencer 6 15 Removing the intake manifold 6 15 Checking the intake manifold 6 16 Installing the intake manifold 6 16 Installing the intake silencer 6 18 Throttle body 6 20 Removing the throttle body and surge tank 6 22 Checking the ETV 6 23 Installing the throttle body and surge tank 6 23 Canister 6...

Page 235: ...por separator 6 36 Vapor separator and high pressure fuel pump 6 37 Disassembling the vapor separator 6 39 Checking the high pressure fuel pump 6 40 Checking the vapor separator 6 40 Checking the check valve 6 40 Assembling the vapor separator 6 40 Fuel injector 6 43 Removing the fuel injector 6 44 Checking the fuel rail 6 44 Installing the fuel injector 6 44 ...

Page 236: ...tor e Fuel hose vapor separator to joint f Fuel hose joint to quick connector g Fuel hose joint to quick connector h Fuel hose vapor separator to joint i Blowby hose cylinder head cover to intake silencer a Primer pump b Joint c Fuel filter assembly d Joint e Low pressure fuel pump f Vapor separator g Joint h Quick connector k Fuel rail m Fuel injector n Pressure regulator p Fuel cooler a g a c b ...

Page 237: ...f valve to joint e Vapor gas hose joint to surge tank f Vapor gas hose canister atmospheric port to joint g Vapor gas hose joint to check valve h Vapor gas hose check valve to bottom cowling i Vapor gas hose atmosphere to check valve j Vapor gas hose check valve to joint k Pressure regulator hose pressure regula tor to surge tank l Air pressure sensor hose surge tank to air pressure sensor c a b k...

Page 238: ...6 3 FUEL Fuel system a Vapor separator b Joint c Canister d Joint e Vapor shut off valve f Check valve g Pressure regulator h Air pressure sensor c a b k e a i j g h b f l d e g a c d f f h b ...

Page 239: ...l inder block e Cooling water hose oil cooler to oil filter bracket f Cooling water hose oil cooler to joint g Cooling water hose thermostat cover STBD to joint h Cooling water hose joint to Rectifier Reg ulator i Cooling water hose Rectifier Regulator to joint j Cooling water hose joint to joint k Cooling water hose joint to cooling water outlet l Cooling water hose flushing hose adapter to joint...

Page 240: ...D p Cooling water hose thermostat cover PORT to cylinder block q Cooling water hose thermostat cover STBD to joint r Cooling water hose joint to cylinder block a Oil cooler b Fuel cooler vapor separator c Rectifier Regulator d Cooling water outlet on the bottom cowl ing e Flushing hose adapter f b h q i l a b a c d b o r a d e m k j e c g f p e c a b c n ...

Page 241: ...the engine start switch to OFF 5 Install the fuse 15 A b and then install the fuse holder cover a Disconnecting the quick connector Before disconnecting the quick connec tor reduce the fuel pressure Otherwise pressurized fuel could spray out 1 Reduce the fuel pressure See Reducing the fuel pressure 6 6 2 Wrap a rag around the quick connector a and then push the quick connector tab a toward the sto...

Page 242: ...o make sure that the drain screw a is tightened securely before measuring the fuel pressure 5 Turn the engine start switch to ON and then measure the fuel pressure within 5 seconds TIP The fuel pressure will decrease 5 seconds after the engine start switch is turned to ON The high pressure fuel pump does not operate when the engine start switch is turned to ON again within 10 seconds after turning...

Page 243: ...pressure See Reducing the fuel pressure 6 6 2 Disconnect the quick connector from the fuel rail See steps 2 and 3 in Disconnecting the quick connector 6 6 3 Connect the special service tools See steps 3 and 4 in Measuring the fuel pressure 6 7 4 Disconnect the pressure regulator hose a and then connect the special service tool b to the pressure regulator c 5 Block the end of the pressure regulator...

Page 244: ... 4 Holder 1 5 Cover 1 6 Bolt 4 M6 16 mm 7 Holder 1 8 Bracket 1 9 Bolt 2 M6 25 mm 10 Grommet 2 11 Collar 2 12 Plastic tie 2 13 Fuel filter assembly 1 14 O ring 1 39 15 Fuel filter element 1 16 Fuel cup assembly 1 17 Clip 1 6 5 12 6 8 9 3 6 2 1 4 7 12 15 13 16 17 18 14 6 11 10 5 N m 0 5 kgf m 3 7 ft lb ...

Page 245: ...6 10 Fuel filter assembly 0 1 2 3 4 5 6 7 8 9 10 A No Part name Q ty Remarks 18 Float 1 6 5 12 6 8 9 3 6 2 1 4 7 12 15 13 16 17 18 14 6 11 10 5 N m 0 5 kgf m 3 7 ft lb ...

Page 246: ... the fuel filter assembly 1 Connect the special service tool a to the fuel inlet a 2 Block the fuel outlet b using a rubber plug b and then apply the specified positive pressure Replace the O ring fuel cup assembly or fuel filter assembly if the specified pressure cannot be maintained for 15 seconds or more 3 Connect the special service tool a to the fuel outlet b a a b c Vacuum pressure pump gaug...

Page 247: ...assembly Clean using straight gasoline if there is foreign material or replace if cracked NOTICE When cleaning the fuel cup assembly do not remove the clip and float 2 Check the water detection switch See Checking the water detection switch 5 34 Assembling the fuel filter assembly 1 Install the fuel filter element a a new O ring b and the fuel cup assembly c and then tighten the fuel cup assembly ...

Page 248: ...6 13 FUEL Fuel system 2 Connect the fuel hoses c and d and then fasten them using the plastic ties e 3 Install the cover f 4 Connect the water detection switch coupler a a b c d e f a ...

Page 249: ... manifold assembly 2 9 Gasket 2 39 10 Intake manifold 2 11 Gasket 2 39 12 Holder 9 13 Holder 2 14 Intake manifold bolt 8 M8 40 mm 15 Intake manifold bolt 10 M6 35 mm 16 Blowby hose 1 a b UP 8 2 1 12 12 12 14 15 10 11 12 9 5 6 3 4 7 8 9 10 11 12 12 12 15 13 14 13 16 24 N m 2 4 kgf m 17 7 ft lb 24 N m 2 4 kgf m 17 7 ft lb a b 7 N m 0 7 kgf m 5 2 ft lb 11 N m 1 1 kgf m 8 1 ft lb 11 N m 1 1 kgf m 8 1 ...

Page 250: ...emperature sensor c 4 Remove the plastic tie d and then remove the joint e Removing the intake manifold 1 Remove the caps a and then remove the PTT motor leads a 2 Remove the PTT motor leads a from the holder b 3 Remove the fuel injector lead b and thermoswitch lead c from the holders c 4 Remove the fuel injector lead d from the holders d a a b c e d a b a c STBD c b ...

Page 251: ...if cracked or deformed Installing the intake manifold Do not reuse a gasket always replace it with a new one 1 Install new gaskets a and b onto the intake manifolds Check that the tabs on the gaskets a and b are properly and firmly fitted into the grooves a and b in the intake manifold 2 Install the intake manifolds c and intake manifold bolts d and e temporarily d d PORT e e f PORT f STBD a a b b...

Page 252: ...d in the order a b and so on TIP Tighten the intake manifold bolts e to the same torque in both stages 5 Fasten the main wiring harness c using the holders f 6 Fasten the fuel injector lead d using the holders g Intake manifold bolt d M8 1st 24 N m 2 4 kgf m 17 7 ft lb 2nd 24 N m 2 4 kgf m 17 7 ft lb c e d PORT c d e STBD c a b d c a b d d d PORT STBD Intake manifold bolt e M6 1st 11 N m 1 1 kgf m...

Page 253: ... leads g through the guide and then fasten them using the holder l 11 Install the drain hose m to the intake manifold Installing the intake silencer 1 Install the joint a and then fasten it using the plastic tie b 2 Install the intake silencer c and air temperature sensor d and then tighten the intake silencer bolt e to the specified torque PTT motor lead bolt j 4 N m 0 4 kgf m 3 0 ft lb d g PORT ...

Page 254: ...6 19 FUEL Fuel system 3 Install the blowby hose f 4 Connect the air temperature sensor coupler a f a ...

Page 255: ...ket 1 7 Bolt 1 M6 20 mm 8 Air pressure sensor 1 9 Hose 1 10 Throttle body 1 11 Gasket 1 39 12 Surge tank 1 13 Bolt 5 M8 30 mm 14 Surge tank bracket bolt 6 M6 16 mm 15 Bolt 2 M6 30 mm 16 Grommet 4 17 Collar 2 11 N m 1 1 kgf m 8 1 ft lb 1 1 14 14 14 21 2 3 3 6 5 7 8 9 12 13 4 10 11 15 16 20 15 16 16 17 16 17 18 19 22 23 24 25 Intake manifold Throttle body ...

Page 256: ...e Q ty Remarks 18 Bracket 1 19 Bracket 1 20 Bracket 1 21 Bolt 2 M6 16 mm 22 Bracket 1 23 Holder 1 24 Hose 1 25 Hose 1 11 N m 1 1 kgf m 8 1 ft lb 1 1 14 14 14 21 2 3 3 6 5 7 8 9 12 13 4 10 11 15 16 20 15 16 16 17 16 17 18 19 22 23 24 25 ...

Page 257: ...low pressure fuel pump coupler d 3 Remove the air pressure sensor a 4 Remove the cooling water hose b from the holder c 5 Remove the throttle body d 6 Disconnect the pressure regulator hose e and vapor gas hose f 7 Remove the vapor gas hoses g and h from the holder i and then remove the bracket j 8 Remove the brackets k and l 9 Remove the surge tank m b c a d b c a d f e j g h i k l ...

Page 258: ... throttle body and surge tank 1 Install the vapor gas hose a pressure regulator hose b and air pressure sen sor hose c 2 Install the surge tank d 3 Install the brackets e and f and then tighten the surge tank bracket bolts g to the specified torque 4 Install the bracket h and then install the vapor gas hoses i and j to the holder k m n e f Surge tank bracket bolt g 11 N m 1 1 kgf m 8 1 ft lb c b a...

Page 259: ...firmly fitted into the groove a in the surge tank NOTICE Do not reuse a gasket always replace it with a new one 7 Fasten the cooling water hose n using the holder o 8 Connect the air pressure sensor hose c and then install the air pressure sensor p 9 Install the low pressure pump coupler b and YDIS coupler c 10 Connect the ETV coupler d and air pressure sensor coupler e j i k h a b l a m n o p c b...

Page 260: ...er No Part name Q ty Remarks 1 Hose 1 2 Check valve 2 3 Hose 1 4 Joint 1 5 Hose 1 6 Hose 1 7 Bolt 2 8 Grommet 2 9 Collar 2 10 Bracket 1 11 Bracket 1 12 Bolt 1 M6 15 mm 13 Canister 1 14 Hose 1 1 3 4 6 5 2 8 9 7 7 11 12 9 8 10 13 14 ...

Page 261: ...acked 2 Connect the special service tool a to the atmospheric port a and block the other ports using rubber plugs b 3 Apply the specified positive pressure and check that there is no air leakage Replace the canister if there is air leakage Checking the canister check valve 1 Connect the special service tool a to the canister check valve port a c b a d d a Vacuum pressure pump gauge set a 90890 067...

Page 262: ...nd check that no air comes out of the opposite end of the canister check valve Replace the canister check valve if air comes out Installing the canister 1 Install the canister a 2 Connect the vapor gas hoses b c d e and f to the joint g and check valves h 3 Fasten the vapor gas hoses a using the holders i 4 Connect the vapor gas hoses b j and k to the canister 5 Connect the vapor gas hose f to the...

Page 263: ...6 28 Canister 0 1 2 3 4 5 6 7 8 9 10 A j k f b ...

Page 264: ...ie 1 4 Hose 1 5 Clamp 2 6 Joint 1 7 Bushing 2 8 Low pressure fuel pump 1 9 Holder 1 10 Clamp 2 11 Holder 2 12 Hose 1 13 Holder 1 14 Cover 1 15 Pump cover bolt 2 M6 15 mm 5 12 mm 0 47 in 12 mm 0 47 in 12 mm 0 47 in 9 mm 0 35 in 2 11 10 12 11 10 10 6 5 1 13 14 15 9 3 2 7 8 5 4 7 5 N m 0 5 kgf m 3 7 ft lb ...

Page 265: ...t the fuel hoses h and i 5 Remove the cover j and low pressure fuel pump k 6 Remove the hose l from the low pressure fuel pump k and joint m Checking the low pressure fuel pump 1 Check the low pressure fuel pump See Checking the low pressure fuel pump and high pressure fuel pump 5 37 Checking the primer pump 1 Connect the special service tool a to the primer pump inlet hose 2 Block the fuel outlet...

Page 266: ...l hose h 5 Connect the fuel hose h and then fasten it using the clamps g 6 Install the fuel hose h to the holders i and j 7 Install the clamp k temporarily onto the fuel hose l 8 Connect the fuel hose l and then fasten it using the clamp k 9 Connect the fuel hose m to the joint and fasten the fuel hose using the plastic tie n and then install the fuel hose to the holder o 10 Connect the low pressu...

Page 267: ...6 32 Low pressure fuel pump 0 1 2 3 4 5 6 7 8 9 10 A 11 Fasten the vapor gas hoses p and q using the holder r q r p ...

Page 268: ...1 4 Hose 1 5 Hose 1 6 Holder 3 7 Holder 1 8 Clamp 2 9 Hose 1 10 Bolt 4 M6 35 mm 11 Collar 8 12 Grommet 4 13 Vapor separator assembly 1 14 Clamp 1 15 Hose 1 16 Plastic tie 1 17 Bolt 2 M6 15 mm 22 16 15 14 13 21 19 18 17 10 11 11 8 9 8 12 11 12 11 10 11 10 11 10 11 7 5 1 1 3 4 2 6 6 12 20 8 14 ...

Page 269: ... 0 1 2 3 4 5 6 7 8 9 10 A No Part name Q ty Remarks 18 Vapor shut off valve 1 19 Bracket 1 20 Nut 1 21 Hose 1 22 Holder 1 22 16 15 14 13 21 19 18 17 10 11 11 8 9 8 12 11 12 11 10 11 10 11 10 11 7 5 1 1 3 4 2 6 6 12 20 8 14 ...

Page 270: ...ifold PORT See Installing the intake manifold 6 16 Removing the vapor separator Cover the fuel components using a rag to prevent fuel from spilling out 1 Disconnect the high pressure fuel pump coupler a and vapor shut off valve cou pler b 2 Disconnect the vapor gas hoses a b and c cooling water hose d and fuel hose e 3 Remove the vapor separator assembly f and then disconnect the cooling water hos...

Page 271: ...ll the cooling water hose a and fuel hose b 2 Install the vapor shut off valve c and bracket d 3 Connect the cooling water hose e and then fasten the cooling water hose e using the plastic tie f 4 Install the vapor separator assembly g 5 Install the clamp h temporarily onto the fuel hose i 6 Connect the fuel hose i and then fasten it using the clamp h 7 Connect the cooling water hose a and vapor g...

Page 272: ...et 1 39 8 Filter 1 9 Check valve 1 10 Float chamber cover screw 6 M4 16 mm 11 Gasket 1 39 12 Grommet 1 13 Joint 1 14 Damper 1 15 High pressure fuel pump 1 16 Lead 1 17 Filter 1 3 2 5 4 8 9 5 6 7 10 1 12 15 11 19 16 17 18 13 14 20 23 21 22 28 29 24 25 27 26 25 4 N m 0 4 kgf m 3 0 ft lb 4 N m 0 4 kgf m 3 0 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 ...

Page 273: ... pin screw 1 M4 8 mm 24 Float chamber assembly 1 25 Fuel cooler cover screw 3 M5 4 mm 26 Cover 1 27 Gasket 1 39 28 Drain screw 1 29 Drain hose 1 3 2 5 4 8 9 5 6 7 10 1 12 15 11 19 16 17 18 13 14 20 23 21 22 28 29 24 25 27 26 25 4 N m 0 4 kgf m 3 0 ft lb 4 N m 0 4 kgf m 3 0 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 kgf m 1 5 ft lb 2 N m 0 2 kgf m ...

Page 274: ...remove the pressure regulator f 4 Remove the cover g gasket h filter i and check valve j 5 Remove the cover k gasket l high pressure fuel pump m and grommet n 6 Remove the screw o and then remove the pin p float q and needle valve assembly r 7 Remove the lead s and filter holder t and then remove the filter u adapter v and damper w a b e f c d i g h j l n m k o q p r u w v t s ...

Page 275: ...ecking the check valve 1 Connect the special service tool a to the check valve port a 2 Apply positive pressure and check that air comes out of the opposite end b of the check valve Replace the check valve if no air comes out 3 Connect the special service tool a to the opposite check valve port b 4 Apply positive pressure and check that no air comes out of the opposite end a of the check valve Rep...

Page 276: ... and high pressure fuel pump l 5 Install a new gasket m and the cover n and then tighten the float chamber cover screws o to the specified torque 6 Install the check valve p the filter q a new gasket r and the cover s and then tighten the cover bolts t to the specified torque Needle valve assembly screw b 2 N m 0 2 kgf m 1 5 ft lb Float pin screw e 2 N m 0 2 kgf m 1 5 ft lb e c d a b h i j f g R Y...

Page 277: ...gasket x and the fuel cooler cover y and then tighten the fuel cooler cover screws z to the specified torque 9 Install the drain hose A and drain screw B and then tighten the drain screw B to the specified torque Cover bolt t 2 N m 0 2 kgf m 1 5 ft lb Pressure regulator screw w 4 N m 0 4 kgf m 3 0 ft lb Fuel cooler cover screw z 4 N m 0 4 kgf m 3 0 ft lb Drain screw B 2 N m 0 2 kgf m 1 5 ft lb z v...

Page 278: ...ks 1 Bolt 4 M6 25 mm 2 Quick connector 2 3 Fuel rail PORT 1 4 Holder 6 5 Fuel injector 6 6 O ring set 6 39 7 Fuel rail STBD 1 8 Clamp 5 9 Hose 1 10 Joint 1 11 Hose 1 12 Hose 1 1 2 7 1 4 4 4 6 6 5 5 5 3 2 8 8 10 8 8 8 9 1 4 6 6 5 11 12 1 6 6 6 6 4 6 6 5 4 6 6 5 ...

Page 279: ... fuel hoses a b and c 3 Disconnect the fuel injector couplers a 4 Remove the fuel rails d 5 Remove the holders e and then remove the fuel injectors b and O rings c and d Checking the fuel rail 1 Check the fuel rails Replace if cracked or deformed 2 Check the fuel injectors See step 5 in Checking the fuel injector 5 35 Installing the fuel injector Do not reuse an O ring always replace it with a new...

Page 280: ... onto the fuel rail a and then install the holders b 3 Install the fuel rails c onto the cylinder head 4 Tighten the bolts d equally 5 Install the fuel hoses e f and g and then connect the quick connectors 6 Connect the fuel injector couplers d a c b a b b b c c d d PORT c d d STBD e g f d PORT STBD d ...

Page 281: ...ring harness 7 18 Installing the wiring harness 7 20 Fuse box 7 24 Junction box 7 25 Removing the Rectifier Regulator 7 28 Removing the junction box 7 28 Installing the junction box 7 28 Installing the Rectifier Regulator 7 29 Starter motor 7 30 Removing the starter motor 7 31 Installing the starter motor 7 31 Engine ECM 7 32 Removing the engine ECM 7 33 Installing the engine ECM 7 33 Shift actuat...

Page 282: ...ing the cylinder head 7 60 Installing the cylinder head 7 62 Oil cooler and oil pump assembly 7 63 Removing the oil filter bracket 7 66 Removing the oil cooler 7 66 Removing the oil pump assembly 7 66 Disassembling the oil pump assembly 7 66 Checking the oil pump assembly 7 67 Checking the oil cooler 7 67 Checking the oil cooler anode 7 67 Assembling the oil pump assembly 7 67 Installing the oil p...

Page 283: ...ng rod small end inside diameter and big end inside diameter 7 80 Checking the connecting rod big end side clearance 7 80 Checking the crankshaft 7 81 Checking the crankcase bolt 7 81 Checking the crankpin oil clearance 7 82 Selecting the crankpin bearing 7 83 Crankpin bearing selection table 7 85 Checking the crankshaft journal oil clearance 7 86 Selecting the crankshaft journal bearing 7 87 Cran...

Page 284: ...rs Checking the oil pressure 1 Connect the YDIS to display Oil pres sure 2 Start the engine and warm it up until the engine idle speed stabilizes at 650 750 r min 3 Measure the oil pressure Checking the pulser coil air gap Do not turn the flywheel magnet counter clockwise Otherwise the water pump impeller could be damaged 1 Remove the intake silencer 2 Turn the flywheel magnet clockwise to align a...

Page 285: ...racket b and speed sensor coupler d 5 Remove the ignition coils and spark plugs 6 Remove the engine ECM and engine ECM bracket 7 Turn the flywheel magnet c clockwise until the dowel hole e in the flywheel magnet c is aligned between the VCT assembly STBD d and driven sprocket STBD e 8 Check that the II marks f on the VCT assembly PORT and driven sprocket PORT are aligned and check that the I marks...

Page 286: ...ed cylinder 14 Install the cylinder head covers 15 Install the timing belt guide STBD and then adjust the timing belt guide clearance See step 8 in Installing the timing belt 7 39 16 Install the engine ECM bracket and engine ECM 17 Install the spark plugs and ignition coils and then tighten the spark plugs to the specified torque 18 Install the bracket b and speed sensor coupler d 19 Connect the i...

Page 287: ...ng the timing belt 7 38 9 Remove the VCT assemblies driven sprockets and camshafts See Removing the driven sprocket and camshaft 7 45 TIP Make sure to keep the parts in the order of removal 10 Measure the valve lifter thickness a and then write down the measurement data 11 Select the necessary valve lifter by calculating its thickness using the following formula Calculation formula Necessary valve...

Page 288: ...ywheel magnet See step 5 in Installing the flywheel magnet 7 15 18 Check the pulser coil air gap See steps 2 and 3 in Checking the pulser coil air gap 7 1 19 Install the intake manifold STBD See Installing the intake manifold 6 16 20 Install the wiring harness guide a 21 Install the wiring harness See Installing the wiring harness 7 20 a ...

Page 289: ...35 mm 10 Power unit mounting bolt 6 M10 140 mm 11 Apron screw 4 M6 20 mm 12 Grommet 4 13 Apron STBD 1 14 Apron PORT 1 15 Nut 4 16 Bolt 11 M6 14 mm 17 Bolt 3 M6 30 mm 3 N m 0 3 kgf m 2 2 ft lb 1 2 3 16 16 20 18 17 19 18 19 17 16 16 14 15 9 10 10 8 4 5 6 11 12 17 16 7 9 9 12 21 22 23 22 24 a b 42 N m 4 2 kgf m 31 0 ft lb 42 N m 4 2 kgf m 31 0 ft lb a b 42 N m 4 2 kgf m 31 0 ft lb 42 N m 4 2 kgf m 31...

Page 290: ...M6 15 mm 23 Idle silencer 1 24 Rubber seal 1 3 N m 0 3 kgf m 2 2 ft lb 1 2 3 16 16 20 18 17 19 18 19 17 16 16 14 15 9 10 10 8 4 5 6 11 12 17 16 7 9 9 12 21 22 23 22 24 a b 42 N m 4 2 kgf m 31 0 ft lb 42 N m 4 2 kgf m 31 0 ft lb a b 42 N m 4 2 kgf m 31 0 ft lb 42 N m 4 2 kgf m 31 0 ft lb 13 16 16 16 16 3 ...

Page 291: ...p f and then remove the shift lever g 5 Remove the PTT motor leads a and b 6 Remove the plastic tie h and then disconnect the extension wiring harness coupler c 7 Remove the PTT switch coupler d from the bracket i and then disconnect the PTT switch coupler d 8 Remove the SPS coupler e from the bracket j and then disconnect the SPS coupler e 9 Remove the main wiring harness k from the holder l 10 R...

Page 292: ...sensor coupler f 15 Remove the aprons r s rubber seal t idle silencer u and grommet v 16 Install the special service tools w and x 17 Hook a lifting harness y onto the special service tools w and x and then suspend the power unit z 18 Remove the power unit mounting bolts A and B and then remove the power unit z and dowels C n l k m o p q q f r s v u t ...

Page 293: ... then tighten the power unit mounting bolts g and h to the specified torque in 2 stages TIP Tighten the power unit mounting bolts to the same torque in both stages 5 Install the grommet i idle silencer j and rubber seal k 6 Install the aprons l and m and then tighten the apron screws n to the specified torque Engine lifting eye w 90890 06820 Balance hanger x 90890 06822 w x y z A A A B B B B C C B...

Page 294: ...e vapor gas hose q 10 Connect the cooling water hose r 11 Install the brackets s and t and then tighten the surge tank bracket bolts u to the specified torque 12 Install the main wiring harness v to the holder w Apron screw n 3 N m 0 3 kgf m 2 2 ft lb n l m i j k a o p o p Surge tank bracket bolt u 11 N m 1 1 kgf m 8 1 ft lb q r u s t u ...

Page 295: ...ss coupler d and then fasten it using the plastic tie z 16 Install the PTT motor leads e and f and then tighten the PTT motor lead bolts A to the specified torque 17 Install the caps B 18 Install the shift lever C and then install the clip D 19 Install the battery cable E 20 Install the rigging grommet F and then install the grommet holder G w v x y c b d z PTT motor lead bolt A 4 N m 0 4 kgf m 3 ...

Page 296: ...7 13 Power unit POWR 21 Install the tube retainer H and then fasten it using the plastic tie I I H H ...

Page 297: ...1 4 Dowel 2 5 Bracket 1 6 Plastic tie 1 7 Pulser coil bolt 2 M5 20 mm 8 Pulser coil 1 9 Flywheel magnet bolt 6 39 M10 50 mm 10 Flywheel magnet 1 11 Dowel 1 12 Holder 1 13 Bolt 1 M6 16 mm 14 Bolt 4 M6 30 mm 4 N m 0 4 kgf m 3 0 ft lb 14 9 10 14 3 5 2 1 1 1 7 6 8 4 11 12 13 4 a b 90 40 N m 4 0 kgf m 29 5 ft lb Power unit assembly Flywheel magnet ...

Page 298: ...gnet bolt always replace it with a new one 1 Install the dowel a to the base a 2 Install the base a and pulser coil b and then tighten the pulser coil bolts c to the specified torque 3 Install the stator assembly d and holder e and dowel f 4 Connect the stator assembly couplers b and pulser coil coupler c 5 Install the flywheel magnet and then tighten new flywheel magnet bolts g to the specified t...

Page 299: ... bolts and flywheel magnet with identification marks e and then tighten the bolts 90 from the marks on the flywheel magnet 6 Check the pulser coil air gap See steps 2 and 3 in Checking the pulser coil air gap 7 1 Rotor holder h 90890 01235 Flywheel magnet bolt g 1st 40 N m 4 0 kgf m 29 5 ft lb 2nd 90 g h g 90 e e f d c b a ...

Page 300: ... unit POWR Wiring harness No Part name Q ty Remarks 1 Wiring harness 1 2 Wiring harness guide 1 3 Bolt 5 M6 20 mm 4 Holder 1 5 Holder 2 6 Holder 1 7 Holder 2 8 Holder 1 9 Plastic tie 1 3 3 3 5 2 5 8 7 3 1 9 4 6 7 ...

Page 301: ...om the holders b 4 Remove the holders g from the engine ECM bracket 5 Disconnect the cam position sensor coupler PORT EX h 6 Remove the condensers k 7 Remove the wiring harness a from the holders b and c 8 Remove the holders g from the wiring harness guide 9 Disconnect the OCV couplers m cam position sensor couplers n and thermoswitch connectors p 10 Disconnect the oil pressure sensor coupler r 11...

Page 302: ... and u Rectifier Regulator couplers v w and x power source coupler y and isolator coupler A 13 Disconnect the PTT relay coupler B 14 Disconnect the Rectifier Regulator coupler D 15 Disconnect the shift actuator coupler E 16 Remove the ground leads F G and H s PORT STBD s r d t v A u y w x B D ...

Page 303: ...rs L from the wiring harness guide e and then remove the main wiring harness 19 Remove the wiring harness guide d Installing the wiring harness 1 Install the wiring harness guide a 2 Install the main wiring harness and then install the holders a to the wiring harness guide a F G H E J L L e e a a a a ...

Page 304: ...nnect the PTT relay coupler h 8 Connect the fuse holder couplers k and m Rectifier Regulator couplers n p and r power source coupler s and isolator coupler t 9 Remove the fuse box c and then tighten the fuse box screw d to the specified torque 10 Install the ground leads u 11 Connect the oil pressure sensor coupler v Starter motor lead screw b 2 N m 0 2 kgf m 1 5 ft lb b b c d e f g Fuse box screw...

Page 305: ...all the holders D to the wiring harness guide 14 Fasten the wiring harness e using the holders f and g 15 Install the condensers E 16 Connect the cam position sensor coupler PORT EX F 17 Install the holders D to the engine ECM bracket 18 Install the wiring harness e to the holders f 19 Install the speed sensor coupler G joint couplers H and water pressure sensor coupler J u PORT STBD u v y w X POR...

Page 306: ...7 23 Power unit POWR 20 Connect the ignition coil couplers L engine ECM couplers M and knock sensor coupler N L L f f e H G D J D M N ...

Page 307: ... 10 mm 7 Fuse 3 100 A spare is included 8 Fuse 3 10 A spare is included 9 Fuse 2 20 A spare is included 10 Fuse 3 30 A spare is included 11 Fuse 3 15 A spare is included 12 Screw 13 M3 10 mm 13 Grommet 1 14 Fuse box screw 4 ø5 20 mm 2 N m 0 2 kgf m 1 5 ft lb 13 3 14 14 2 12 6 6 6 8 9 10 8 11 11 7 7 4 12 1 7 9 3 10 4 8 11 A A 5 5 5 Wiring harness Fuse box ...

Page 308: ...lder 2 11 Holder 1 12 Holder 1 13 Bracket 2 14 Bolt 1 M6 15 mm 15 Bolt 3 M6 35 mm 16 Rectifier Regulator 1 17 Gasket 1 39 5 N m 0 5 kgf m 3 7 ft lb 4 N m 0 4 kgf m 3 0 ft lb a b 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb 29 30 14 38 22 20 21 23 25 19 26 28 25 24 27 15 17 16 11 6 7 6 7 8 8 13 9 10 12 10 32 33 36 34 35 3 4 4 31 1 2 1 2 5 18 9 37 9 N m 0 9 kgf m 6 6 ft lb 25 N m 2 5 kgf m 1...

Page 309: ...se 1 29 Power source lead 1 30 Isolator lead 1 31 Bolt 1 M8 16 mm 32 Terminal 1 33 Terminal bolt 1 M8 20 mm 34 Bolt 2 M6 15 mm 5 N m 0 5 kgf m 3 7 ft lb 4 N m 0 4 kgf m 3 0 ft lb a b 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb 29 30 14 38 22 20 21 23 25 19 26 28 25 24 27 15 17 16 11 6 7 6 7 8 8 13 9 10 12 10 32 33 36 34 35 3 4 4 31 1 2 1 2 5 18 9 37 9 N m 0 9 kgf m 6 6 ft lb 25 N m 2 5 kg...

Page 310: ...er motor nut 1 5 N m 0 5 kgf m 3 7 ft lb 4 N m 0 4 kgf m 3 0 ft lb a b 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb 29 30 14 38 22 20 21 23 25 19 26 28 25 24 27 15 17 16 11 6 7 6 7 8 8 13 9 10 12 10 32 33 36 34 35 3 4 4 31 1 2 1 2 5 18 9 37 9 N m 0 9 kgf m 6 6 ft lb 25 N m 2 5 kgf m 18 4 ft lb ...

Page 311: ...t c Removing the junction box 1 Disconnect the starter motor lead a 2 Disconnect the PTT relay leads b and c 3 Remove the power source lead a and isolator lead b 4 Remove the terminal c and junction box d Installing the junction box 1 Install the junction box a 2 Install the terminal b and then terminal bolt c to the specified torque 3 Install the power source lead d and isolator lead e a b c a b ...

Page 312: ... then tighten the Rectifier Regulator cover bolts c to the specified torques in 2 stages NOTICE Do not reuse a gas ket always replace it with a new one 2 Install the Rectifier Regulator d 3 Install the ground lead a 4 Connect the cooling water hoses b and c Terminal bolt c 25 N m 2 5 kgf m 18 4 ft lb PTT relay lead nut f 5 N m 0 5 kgf m 3 7 ft lb Starter motor nut g 9 N m 0 9 kgf m 6 6 ft lb d e b...

Page 313: ... bolt 2 M8 35 mm 3 Dowel 1 4 Bracket 1 5 Starter motor bracket bolt 1 M6 40 mm 6 Starter motor 1 7 Starter motor bolt 3 M8 45 mm 8 Starter motor lead screw 1 M4 6 mm 1 2 3 7 7 7 6 4 5 12 N m 1 2 kgf m 8 9 ft lb 25 N m 2 5 kgf m 18 4 ft lb 30 N m 3 0 kgf m 22 1 ft lb 2 N m 0 2 kgf m 1 5 ft lb 8 Junction box Starter motor ...

Page 314: ...and c and then tighten the starter motor bracket bolts d and e to the specified torque 2 Install the starter motor f and then tighten the starter motor bolts g to the specified torque a b c f d g e g g c b a Starter motor bracket bolt M6 d 12 N m 1 2 kgf m 8 9 ft lb Starter motor bracket bolt M8 e 25 N m 2 5 kgf m 18 4 ft lb Starter motor bolt g 30 N m 3 0 kgf m 22 1 ft lb ...

Page 315: ... A Engine ECM No Part name Q ty Remarks 1 Engine ECM 1 2 Engine ECM bolt 4 M6 20 mm 3 Bolt 4 M6 30 mm 4 Grommet 4 5 Collar 4 6 Holder 2 7 Holder 1 8 Bracket 1 7 N m 0 7 kgf m 5 2 ft lb 2 2 1 3 7 6 4 5 4 4 5 3 8 4 6 Starter motor Engine ECM ...

Page 316: ...gine ECM 1 Remove the engine ECM a and bracket b Installing the engine ECM 1 Install the bracket a and engine ECM b and then tighten the engine ECM bolts c to the specified torque Engine ECM bolt c 7 N m 0 7 kgf m 5 2 ft lb a b c c c b a ...

Page 317: ...ame Q ty Remarks 1 Shift actuator 1 2 Bracket 1 3 Nut 1 4 Pin 1 5 Bushing 1 6 Shift link assembly 1 7 Bolt 2 M6 25 mm 8 Bushing 1 9 Washer 1 10 Clip 1 11 Shift actuator bolt 4 M6 55 mm 9 11 11 11 11 5 6 4 2 1 3 10 19 N m 1 9 kgf m 14 0 ft lb 8 7 Engine ECM Shift actuator ...

Page 318: ...g d bushing e and shift link assembly f Assembling the shift actuator assembly 1 Install the shift link assembly a bushing b bushing c pin d washer e and clip f Installing the shift actuator assembly 1 Install the nut a to the bracket b 2 Install the bracket b and shift actuator c and then tighten the shift actuator bolts d to the specified torque in the order a b and so on a b b a e f c d e f b a...

Page 319: ...7 36 Shift actuator 0 1 2 3 4 5 6 7 8 9 10 A Shift actuator bolts d 19 N m 1 9 kgf m 14 0 ft lb c b d d a ...

Page 320: ...ks 1 Timing belt 1 2 Timing belt tensioner 1 3 Pulley bolt 2 M10 55 mm 4 Washer 2 5 Pulley 2 6 Collar 2 7 Bolt 6 M6 14 mm 8 Guide 2 9 Guide 1 39 N m 3 9 kgf m 28 8 ft lb 39 N m 3 9 kgf m 28 8 ft lb 39 N m 3 9 kgf m 28 8 ft lb 1 2 7 9 6 5 7 7 8 8 3 4 5 6 3 4 ...

Page 321: ...T are aligned and check that the I marks d on the VCT assembly STBD and driven sprocket STBD are aligned 3 Remove the timing belt guides a and b 4 Turn the timing belt tensioner gradually clockwise using a hexagon wrench and then insert a 5 0 mm 0 2 in diameter pin c into the hole e TIP When turning the timing belt tensioner apply a force of 15 N m 1 5 kgf m 11 1 ft lb or less Leave the pin c inse...

Page 322: ... that the part number b is in the upright position and the belt position mark c is aligned with the small L mark on the crankshaft NOTICE Do not apply grease or oil to the timing belt h Belt teeth number TIP Before installing the timing belt make sure that the marks on the crankshaft and cylinder block are aligned Also make sure that the marks on the VCT assemblies and driven sprockets are aligned...

Page 323: ...h and then remove the pin f TIP When turning the timing belt tensioner apply a force of 15 N m 1 5 kgf m 11 1 ft lb or less Make sure that the belt position marks are aligned with the marks L See steps 2 and 3 6 Install the timing belt guides g and h 7 Turn the crankshaft clockwise 2 full turns until the large L mark m on the crankshaft is aligned with the rib n on the cylinder block Check that th...

Page 324: ...7 41 Power unit POWR 8 Adjust the timing belt guide clearance s Timing belt guide clearance s 0 5 1 5 mm 0 02 0 06 in n m r p s s g g h ...

Page 325: ...shaft STBD IN 1 14 Dowel 4 15 Collar 8 16 Camshaft cap EX 2 17 Camshaft cap IN 2 28 N m 2 8 kgf m 20 7 ft lb 32 N m 3 2 kgf m 23 6 ft lb 60 N m 6 0 kgf m 44 3 ft lb 60 N m 6 0 kgf m 44 3 ft lb a b 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb a b 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb 26 29 21 30 30 22 31 32 32 33 34 35 1 2 27 28 3 4 29 23 30 28 30 30 32 31 35 33 34 25 28 29...

Page 326: ...t 6 31 Bolt 20 M6 30 mm 32 Holder 4 33 Bolt 6 M6 25 mm 34 Ignition coil 6 28 N m 2 8 kgf m 20 7 ft lb 32 N m 3 2 kgf m 23 6 ft lb 60 N m 6 0 kgf m 44 3 ft lb 60 N m 6 0 kgf m 44 3 ft lb a b 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb a b 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb 26 29 21 30 30 22 31 32 32 33 34 35 1 2 27 28 3 4 29 23 30 28 30 30 32 31 35 33 34 25 28 29 27 30 ...

Page 327: ... kgf m 44 3 ft lb 60 N m 6 0 kgf m 44 3 ft lb a b 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb a b 8 N m 0 8 kgf m 5 9 ft lb 17 N m 1 7 kgf m 12 5 ft lb 26 29 21 30 30 22 31 32 32 33 34 35 1 2 27 28 3 4 29 23 30 28 30 30 32 31 35 33 34 25 28 29 27 30 18 14 12 24 1 2 3 5 8 18 19 19 20 14 13 15 16 17 15 10 14 14 11 20 8 9 9 9 9 8 7 6 6 8 7 ...

Page 328: ...is aligned with the mating surface of the crankcase and cylinder block NOTICE Do not turn the crankshaft counterclockwise more than 60 Otherwise the pistons and valves could collide with each other and be damaged 3 Secure the VCT assemblies e and f using the special service tool g and then remove the VCT caps h NOTICE When removing the VCT cap do not secure the camshaft Otherwise the VCT assembly ...

Page 329: ... and exhaust valves could collide with each other and be damaged 6 Secure the exhaust camshaft using a wrench and then remove the driven sprocket i NOTICE When removing the driven sprocket do not turn the exhaust camshaft Otherwise the intake and exhaust valves could collide with each other and be damaged 7 Remove the camshaft caps j k and l in the order a b and so on 8 Remove the camshafts m n o ...

Page 330: ...shaft STBD that is used for the cam position sensor Replace the camshaft if damaged rough or scratched TIP Be careful not to scratch or damage the face of the flange If there is a scratch that is more than 0 2 mm 0 008 in deep or more than 0 5 mm 0 020 in wide on the surface of the flange a malfunction may occur in the cam position sensor signal 2 Measure the cam lobe height a and width b Valve li...

Page 331: ...ocket If the valve clearances are adjusted or any parts related to valve movement are replaced after installing the timing belt check the valve clearances See Checking the valve clear ance 7 2 Do not reuse a gasket or oil seal always replace it with a new one When the timing belt is not installed do not turn the crankshaft or camshafts Otherwise the pistons and valves or intake and exhaust valves ...

Page 332: ...s with the sealant 3 Install the valve lifters d 4 Install the camshafts e f g and h in the proper positions and new oil seals i TIP Install the valve lifters in their original posi tions 5 Check that the dowels a and b on the camshafts PORT are aligned with the mating surface of the cylinder head 6 Check that the dowels c and d on the camshafts STBD are positioned 60 from the mating surface of th...

Page 333: ...es and in the order a b and so on 10 Check that the dowels a and b on the camshafts PORT are aligned and check that the dowels c and d on the camshafts STBD are aligned 11 Install the driven sprockets o STBD 60 60 c d k j l l l l m m n n n n PORT k l l k j j 2P 1P 3P 4P 6P 5P 7P 8P 6S 5S 7S 8S 2S 1S 3S 4S STBD Camshaft cap bolts m and n 1st 8 N m 0 8 kgf m 5 9 ft lb 2nd 17 N m 1 7 kgf m 12 5 ft lb...

Page 334: ...VCT bolt do not secure the driven sprocket Otherwise the VCT assembly could be damaged When tightening the VCT bolt do not turn the intake camshaft Otherwise the intake and exhaust valves could collide with each other and be damaged 16 Install a new gasket t and the VCT cap u secure the VCT assembly using the special service tool v and then tighten the VCT cap u to the specified torque NOTICE When...

Page 335: ...k k on the crankshaft is aligned with the rib m on the cylinder block NOTICE Do not turn the crankshaft clockwise more than 60 Otherwise the pistons and valves could collide with each other and be damaged 20 Install the cylinder head covers w and x 21 Install the spark plugs and then tighten them to the specified torque 22 Install the ignition coils Sheave holder v 90890 01701 VCT cap u 32 N m 3 2...

Page 336: ...8 70 mm 13 Bolt 16 M8 25 mm 14 Anode assembly 8 15 Bolt 8 M6 20 mm 16 Gasket 8 39 17 Cover 8 39 N m 3 9 kgf m 28 8 ft lb 180 a b 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb a b 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb a b 7 23 N m 2 3 kgf m 17 0 ft lb 56 N m 5 6 kgf m 41 3 ft lb 12 10 10 11 11 29 28 27 26 30 25 7 N m 0 7 kgf m 5 2 ft lb 14 23 3 2 1 6 5 4 22 13 16 13 15 2...

Page 337: ...ing retainer 24 30 Valve cotter 48 31 Braided plug 1 M14 12 mm 32 Gasket 1 39 39 N m 3 9 kgf m 28 8 ft lb 180 a b 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb a b 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb a b 7 23 N m 2 3 kgf m 17 0 ft lb 56 N m 5 6 kgf m 41 3 ft lb 12 10 10 11 11 29 28 27 26 30 25 7 N m 0 7 kgf m 5 2 ft lb 14 23 3 2 1 6 5 4 22 13 16 13 15 24 19 18 17 31 3...

Page 338: ...mblies b exhaust plug c and braided plug d 2 Remove the intake and exhaust valves TIP Make sure to keep the parts in the order of removal 3 Remove the valve seal g Checking the cylinder head 1 Remove carbon deposits from the com bustion chambers and check the cylinder head for damage and scratches 2 Check the cylinder head warpage in 6 directions Replace the cylinder head if above specification a ...

Page 339: ...ilt b Replace if above specification Checking the valve 1 Check the valve face Replace if pitted or worn 2 Measure the valve margin thickness a Replace if out of specification Cylinder head warpage limit 0 10 mm 0 0039 in Cylinder head bolt diameter difference limit a b Less than 0 20 mm 0 0079 in Measuring point c 10 0 mm 0 39 in Measuring point d 85 0 mm 3 35 in b a c d Valve spring free length ...

Page 340: ...uide a from the com bustion chamber side using the special service tool b 2 Install a new valve guide c from the camshaft side to the specified position a using the special service tool b NOTICE Do not reuse a valve guide always replace it with a new one Valve stem diameter b Intake 5 477 5 492 mm 0 2156 0 2162 in Exhaust 5 464 5 479 mm 0 2151 0 2157 in Valve stem runout Intake and exhaust 0 01 mm...

Page 341: ... Push the valve lightly against the valve seat using the special service tool a 4 Measure the valve seat contact width a where the blueing dye 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 Check the valve guide if the valve seat contact width is uneven Valve guide remover installer b 90890 06801 Valve ...

Page 342: ...tter evenly using a downward force of 40 50 N 4 0 5 0 kgf 8 8 11 0 lbf a Slag or rough surface 3 Adjust the top edge of the valve seat contact width using a 30 cutter b Previous contact width 4 Adjust the bottom edge of the valve seat contact width using a 60 cutter b Previous contact width 5 Adjust the valve seat contact width to specification using a 45 cutter Valve seat cutter holder 90890 0631...

Page 343: ... area is too narrow and situated near the bottom edge of the valve face cut the bottom edge of the valve seat using a 60 cutter to center the area and then set its width using a 45 cutter b Previous contact width 7 After refacing the valve seat to the specified contact width apply a thin even layer of lapping compound onto the valve seat and then lap the valve using the special service tool a NOTI...

Page 344: ...ve spring retainer lightly using a plastic hammer to seat the valve cotters h securely 5 Install the cam position sensors i and anode assemblies j 6 Install the exhaust plug k and braided plug l and then tighten them to the specified torque Valve spring compressor f 90890 04019 Valve spring compressor attachment g 90890 06320 a c c d d e e b b f g h Exhaust plug k 56 N m 5 6 kgf m 41 3 ft lb Braid...

Page 345: ...order a b and so on 3 Tighten the cylinder head bolts g and h to the specified torques in 2 stages and in the order i j and so on TIP In the second stage mark the M11 bolts and cylinder heads with identification marks b tighten the M11 bolts 90 from the marks and then tighten another 90 a f e h g d d a c b 1377B OCV bolt b 7 N m 0 7 kgf m 5 2 ft lb Cylinder head bolt f a h M11 1st 39 N m 3 9 kgf m...

Page 346: ...1 11 Cover 1 12 Gasket 1 39 13 Oil filler cap 1 14 O ring 1 39 15 Oil filler neck 1 16 O ring 1 39 17 Holder 1 4 N m 0 4 kgf m 3 0 ft lb 13 N m 1 3 kgf m 9 6 ft lb 12 N m 1 2 kgf m 8 9 ft lb 12 N m 1 2 kgf m 8 9 ft lb a b 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb 49 N m 4 9 kgf m 36 1 ft lb 18 N m 1 8 kgf m 13 3 ft lb 1 2 3 6 4 5 9 8 11 10 12 28 31 34 35 35 32 32 33 29 30 20 24 23 20 22...

Page 347: ...se 1 29 Oil pump assembly 1 30 Relief valve 1 31 Oil seal 1 39 32 O ring 2 39 33 Gasket 1 39 34 Oil seal 1 39 4 N m 0 4 kgf m 3 0 ft lb 13 N m 1 3 kgf m 9 6 ft lb 12 N m 1 2 kgf m 8 9 ft lb 12 N m 1 2 kgf m 8 9 ft lb a b 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb 49 N m 4 9 kgf m 36 1 ft lb 18 N m 1 8 kgf m 13 3 ft lb 1 2 3 6 4 5 9 8 11 10 12 28 31 34 35 35 32 32 33 29 30 20 24 23 20 22 ...

Page 348: ...3 kgf m 9 6 ft lb 12 N m 1 2 kgf m 8 9 ft lb 12 N m 1 2 kgf m 8 9 ft lb a b 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb 49 N m 4 9 kgf m 36 1 ft lb 18 N m 1 8 kgf m 13 3 ft lb 1 2 3 6 4 5 9 8 11 10 12 28 31 34 35 35 32 32 33 29 30 20 24 23 20 22 22 19 27 27 26 25 19 16 17 18 15 13 14 21 21 7 ...

Page 349: ...er f gasket g oil filter bracket h and gasket i Removing the oil cooler 1 Remove the cover a oil cooler b gas kets c and anodes d Removing the oil pump assembly 1 Remove the oil pump assembly a O rings b and oil seal c Disassembling the oil pump assembly 1 Remove the oil pump cover a gasket a inner rotor b outer rotor c and oil seals b and c Oil filter wrench b 90890 06830 a b c d e h f g i c b a ...

Page 350: ...il or paint to the anode Assembling the oil pump assembly Do not reuse an oil seal always replace it with a new one 1 Install new oil seals a into the oil pump housing a TIP Install an oil seal halfway into the oil pump housing and then install the other oil seal 2 Install a new oil seal d into the oil pump housing a 3 Install the outer rotor b the inner rotor c a new gasket f and the oil pump cov...

Page 351: ...ng the oil cooler Do not reuse a gasket always replace it with a new one 1 Install the anodes a 2 Install a new gasket b the oil cooler c a new gasket d and the cover e and then tighten the oil cooler bolts f to the specified torques in 2 stages and in the order a b and so on Oil pump cover screw e 4 N m 0 4 kgf m 3 0 ft lb e c d f g b b a a Oil cooler bolt f 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N...

Page 352: ...the specified torque 3 Install a new O ring i and the oil pressure sensor j and then tighten the oil pressure sensor to the specified torque 4 Add a small amount of engine oil through the oil passage a of the oil filter bracket 5 Install the oil filter k and then tighten it to the specified torque Oil filter bracket bolt f and g 12 N m 1 2 kgf m 8 9 ft lb b d c a e f g a b c d e f f g g g g g Oil ...

Page 353: ...hermostat 2 12 Gasket 2 39 13 Cover 2 14 Plastic tie 6 15 Holder 2 16 Hose 1 17 Hose 1 12 N m 1 2 kgf m 8 9 ft lb 12 N m 1 2 kgf m 8 9 ft lb 12 N m 1 2 kgf m 8 9 ft lb 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb a b 16 5 1 32 1 1 7 4 3 2 15 29 20 21 14 14 19 18 14 17 8 33 9 11 11 12 12 10 10 33 14 29 26 24 14 31 30 28 9 27 28 27 34 34 13 13 22 23 25 6 6 32 N m 3 2 kgf m 23 6 ft lb Oil ...

Page 354: ...switch 2 30 Bolt 1 M6 16 mm 31 Bracket 1 32 Plastic tie 1 33 Thermostat cover bolt 4 M6 25 mm 34 Thermostat housing bolt 6 M6 25 mm 12 N m 1 2 kgf m 8 9 ft lb 12 N m 1 2 kgf m 8 9 ft lb 12 N m 1 2 kgf m 8 9 ft lb 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb a b 16 5 1 32 1 1 7 4 3 2 15 29 20 21 14 14 19 18 14 17 8 33 9 11 11 12 12 10 10 33 14 29 26 24 14 31 30 28 9 27 28 27 34 34 13 13 ...

Page 355: ... then remove the thermo stats a and gaskets c 2 Remove the thermostat housings d and gaskets e 3 Remove the thermoswitches f Checking the thermostat 1 Suspend the thermostat in a container of water 2 Place a thermometer in the water and heat the water slowly 3 Measure the thermostat valve opening a at the specified water temperatures Replace if out of specification a a b d c e e g f c d Water temp...

Page 356: ...en the hoses using the clamps f and g 2 Install the knock sensor h to the bracket i and then tighten the knock sensor h to the specified torque 3 Install the bracket i and then tighten the knock sensor bracket bolts j to the specified torque in the order a b and so on Installing the pulley bracket 1 Install the bracket a and then tighten the timing belt pulley bracket bolts b to the specified torq...

Page 357: ...7 74 Cylinder block sensor and switch 0 1 2 3 4 5 6 7 8 9 10 A Timing belt pulley bracket bolt b 1st 14 N m 1 4 kgf m 10 3 ft lb 2nd 28 N m 2 8 kgf m 20 7 ft lb b a a b a c d ...

Page 358: ...nal bearing upper 4 11 Crankshaft journal bearing lower 4 12 O ring 2 39 13 Piston ring set 6 14 Piston 6 15 Clip 12 39 16 Piston pin 6 17 Connecting rod assembly 6 40 N m 4 0 kgf m 29 5 ft lb 90 a b 55 N m 5 5 kgf m 40 6 ft lb 90 a b 55 N m 5 5 kgf m 40 6 ft lb 90 a b 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb a b 21 23 17 19 18 18 15 24 5 3 4 19 20 16 15 9 11 22 25 8 12 9 10 2 5 4 6...

Page 359: ...22 Crankcase 1 23 Crankcase bolt 8 M10 105 mm 24 Crankcase bolt 8 M10 130 mm 25 Crankcase bolt 16 M8 50 mm 40 N m 4 0 kgf m 29 5 ft lb 90 a b 55 N m 5 5 kgf m 40 6 ft lb 90 a b 55 N m 5 5 kgf m 40 6 ft lb 90 a b 14 N m 1 4 kgf m 10 3 ft lb 28 N m 2 8 kgf m 20 7 ft lb a b 21 23 17 19 18 18 15 24 5 3 4 19 20 16 15 9 11 22 25 8 12 9 10 2 5 4 6 7 4 4 5 5 13 14 3 2 1 ...

Page 360: ...g rods and connecting rod caps mark each with an identification number b of the cor responding cylinder Mark each connecting rod and connecting rod cap with mark c on the side facing toward the flywheel magnet end of the crankshaft Make sure to keep the parts in the order of removal 3 Remove the crankshaft d crankshaft journal bearings e thrust bearings f and oil seal g 4 Remove the collar h a b a...

Page 361: ... and c and in direction d D1 D3 D5 which is parallel to the crankshaft and direction e D2 D4 D6 which is at a right angle to the crankshaft a 10 0 mm 0 39 in b 77 0 mm 3 03 in c 106 0 mm 4 17 in Checking the piston ring 1 Measure piston ring dimensions B and T Bearing splitter plate i commercially available Gear puller j commercially available General cylindrical tool k d 19 mm 0 7 in e 90 mm 3 5 ...

Page 362: ...n T 2 800 3 000 mm 0 1102 0 1181 in 2nd ring b B 1 170 1 190 mm 0 0461 0 0469 in T 3 800 4 000 mm 0 1496 0 1575 in Oil ring c B 2 400 2 470 mm 0 0945 0 0972 in T 2 350 2 750 mm 0 0925 0 1083 in Measuring point a reference data 20 0 mm 0 8 in Piston ring end gap b reference data Top ring 0 200 0 300 mm 0 0079 0 0118 in 2nd ring 0 600 0 750 mm 0 0236 0 0295 in Oil ring 0 150 0 600 mm 0 0059 0 0236 i...

Page 363: ...onnecting rod bolt In the second tightening stage for the con necting rod bolts a mark the connecting rod bolts and the connecting rod cap with identification marks c and then tighten the bolts 90 from the marks on the connecting rod cap Checking the connecting rod big end side clearance 1 Measure the connecting rod big end side clearance a Piston pin boss inside diameter a 22 011 22 018 mm 0 8666...

Page 364: ...between the diameters is above specification A M10 130 mm B M10 105 mm Connecting rod big end side clearance a 0 140 0 310 mm 0 0055 0 0122 in a a b c Crankshaft journal diameter a 72 976 72 996 mm 2 8731 2 8739 in Crankpin diameter b 52 980 53 000 mm 2 0858 2 0866 in Crankpin width c 21 000 21 100 mm 0 8268 0 8307 in Crankshaft runout 0 030 mm 0 0012 in Crankcase bolt diameter difference limit a ...

Page 365: ...lace the Plastigauge PG 1 over the oil hole in the crankpin of the crankshaft 4 Install the connecting rod a and connecting rod cap b onto the crankpin c TIP When checking the oil clearance reuse the removed connecting rod bolts Make sure that the marks d on the con necting rod a and connecting rod cap b face toward the flywheel magnet end of the crankshaft Do not turn the connecting rod until the...

Page 366: ...ankpin bearing select the bearing as follows 1 Measure the connecting rod big end inside diameter a Example 2 Check the crankpin mark b on the crankshaft 3 Select the suitable colors c for the crankpin bearing from the Crankpin bearing selection table Crankpin oil clearance reference data 0 025 0 050 mm 0 0010 0 0020 in Connecting rod big end inside diameter a 55 990 56 010 mm 2 2043 2 2051 in a C...

Page 367: ...8 9 10 A Example If the connecting rod big end inside diameter a is 05 h and the crankpin mark b is 81 k select the bearing colors in g The upper bearing color is blue and the lower bearing color is green h k g 90 91 80 81 82 04 05 06 07 ...

Page 368: ...ankpin bearing selection table a Connecting rod big end inside diameter b Crankpin mark a 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 b 80 81 82 83 g 84 85 86 87 88 f 89 90 91 92 93 e 94 95 96 97 d 98 99 00 ...

Page 369: ...ournal bearings a in the original positions 4 Place a piece of Plastigauge PG 1 on each crankshaft journal a parallel to the crankshaft TIP Do not place the Plastigauge PG 1 over the oil hole in each crankshaft journal 5 Install the crankshaft journal bearings into the crankcase TIP Install the crankshaft journal bearings in the original positions 6 Install the crankcase d and then tighten the cra...

Page 370: ...Selecting the crankshaft journal bearing When replacing the crankshaft journal bear ing select the bearing as follows 1 Check the crankshaft journal mark a on the crankshaft and the cylinder block mark b on the cylinder block 2 Select the suitable colors c for the crankshaft journal bearing from the Crankshaft journal bearing selection table Crankcase bolts e and f a p M10 1st 55 N m 5 5 kgf m 40 ...

Page 371: ... mark b is 17 s select the bearing colors in p The upper bearing color is brown and the lower bearing color is brown Upper bearing color Lower bearing color d Purple Purple e Purple Yellow f Yellow Yellow g Yellow Red h Red Red k Red Green m Green Green n Green Brown p Brown Brown s r p 00 01 76 77 78 17 16 18 19 20 ...

Page 372: ...ft journal bearing selection table a Crankshaft journal mark b Cylinder block mark b 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 a 76 77 p 78 79 80 n 81 82 m 83 84 k 85 86 h 87 88 g 89 90 f 91 92 e 93 94 95 d 96 ...

Page 373: ...nnecting rod a the piston pin c and new piston pin clips d TIP Face the mark b on the connecting rod a in the same direction as the mark c on the piston crown Install the piston pin from the side marked with c Do not align the piston pin clip end with the groove d in the piston pin boss 3 Install the oil rings e 2nd ring f and top ring g 4 Offset the piston ring end gaps NOTICE Be careful not to s...

Page 374: ... crankshaft and thrust bearings i TIP Install each thrust bearing with its grooves facing outward 8 Install the piston j so that the mark n on the piston crown is facing toward the flywheel magnet end of the crankshaft 9 Install the connecting rod caps m to the connecting rods and then tighten new bolts l to the specified torques in 2 stages f f g h i Piston ring compressor k 90890 05158 Connectin...

Page 375: ...e n TIP Do not apply any sealant to the crankshaft journal bearings 12 Install new O rings o and the crankcase n and then tighten the bolts p and q to the specified torques in 2 stages and in the order a b and so on 13 Tighten the bolts r to the specified torques in 2 stages and in the order q r and so on TIP In the second tightening stage for the M10 bolts p and q mark the M10 bolts and the crank...

Page 376: ...ller shaft housing regular rotation model 8 14 Removing the propeller shaft housing assembly 8 16 Disassembling the propeller shaft assembly 8 17 Disassembling the reverse gear 8 17 Disassembling the propeller shaft housing assembly 8 17 Checking the propeller shaft 8 18 Checking the dog clutch 8 18 Checking the propeller shaft housing 8 18 Checking the reverse gear 8 18 Assembling the propeller s...

Page 377: ...ing the pinion shim T3 8 43 Calculated value B table 8 46 Pinion shim T3 selection table 8 47 Measuring the forward gear backlash 8 54 Adjusting the forward gear shim T1 thickness 8 54 Forward gear shim T1 selection table 8 56 Measuring the reverse gear backlash 8 57 Adjusting the reverse gear shim T2 thickness 8 57 Reverse gear shim T2 selection chart 8 59 Selecting the propeller shaft shim T4 8 ...

Page 378: ...he lower case 8 78 Checking the pinion 8 78 Checking the reverse gear 8 78 Checking the drive shaft 8 78 Checking the lower case 8 78 Assembling the drive shaft 8 78 Assembling the reverse gear 8 78 Assembling the lower case 8 79 Assembling the oil seal housing 8 79 Install the reverse gear 8 79 Installing the drive shaft 8 79 Installing the propeller shaft housing assembly 8 79 Installing the shi...

Page 379: ...rd gear backlash 8 91 Adjusting the forward gear shim T2 thickness 8 91 Forward gear shim T2 selection chart 8 93 Measuring the reverse gear backlash 8 95 Adjusting the reverse gear shim T1 thickness 8 95 Reverse gear shim T1 selection table 8 97 ...

Page 380: ... 7 Hose nipple 1 8 O ring 1 39 9 Dowel 2 10 Check screw 1 11 Trim tab bolt 1 M10 45 mm 12 Grommet 1 13 Lower unit 1 14 Propeller 1 15 Cotter pin 1 39 16 Propeller nut 1 17 Washer 1 9 13 11 12 14 15 21 2 1 3 4 6 5 22 22 23 20 16 9 N m 0 9 kgf m 6 6 ft lb 42 N m 4 2 kgf m 31 0 ft lb 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 54 N m 5 4 kgf m 39 8 ft lb 18 17 19 9 3 10 9 N m 0 9 kgf m 6 ...

Page 381: ... Trim tab 1 22 Lower case mounting bolt 7 M10 45 mm 23 Lower case mounting bolt 1 M10 70 mm 9 13 11 12 14 15 21 2 1 3 4 6 5 22 22 23 20 16 9 N m 0 9 kgf m 6 6 ft lb 42 N m 4 2 kgf m 31 0 ft lb 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 54 N m 5 4 kgf m 39 8 ft lb 18 17 19 9 3 10 9 N m 0 9 kgf m 6 6 ft lb 8 7 2 N m 0 2 kgf m 1 5 ft lb ...

Page 382: ...e N position 4 Place a block of wood between the anti cavitation plate and the propeller to prevent the propeller from turning and then remove the propeller nut and propeller 5 Mark a the trim tab a and lower case and then remove the trim tab a 6 Remove the lower case mounting bolts b and c and then remove the lower unit d TIP When disassembling the lower unit measure the backlash before disassemb...

Page 383: ...ropeller b 2 Install the damper a using the special service tool c and spacer d to the specified height c NOTICE Be careful not to install the spacer in the opposite direction TIP When installing the damper a make sure that the spacer d does not contact the pro peller boss 3 Check the installation depth d of the damper a A Before tightening the propeller nut e to the specified torque B After tight...

Page 384: ...in contact with the spacer f after the propeller nut e has been tight ened to the specified torque Therefore when installing the propeller to the outboard motor make sure to tighten the propeller nut e to the specified torque See step 7 in Installing the lower unit X transom model 8 33 ...

Page 385: ...astic tie 1 12 Extension 1 13 Dowel 4 14 Rubber seal 1 15 Lower case stud bolt 6 16 Trim tab bolt 1 M10 45 mm 17 Grommet 1 10 11 9 29 28 13 13 19 16 17 20 3 27 2 1 3 6 5 30 31 26 18 12 13 14 13 15 9 N m 0 9 kgf m 6 6 ft lb 42 N m 4 2 kgf m 31 0 ft lb 23 N m 2 3 kgf m 17 0 ft lb 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 8 7 9 N m 0 9 kgf m 6 6 ft lb 4 21 24...

Page 386: ...Washer 6 30 Lower case mounting bolt 1 M10 170 mm 31 Lower case mounting bolt 1 M10 200 mm 10 11 9 29 28 13 13 19 16 17 20 3 27 2 1 3 6 5 30 31 26 18 12 13 14 13 15 9 N m 0 9 kgf m 6 6 ft lb 42 N m 4 2 kgf m 31 0 ft lb 23 N m 2 3 kgf m 17 0 ft lb 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 8 7 9 N m 0 9 kgf m 6 6 ft lb 4 21 24 23 22 54 N m 5 4 kgf m 39 8 ft ...

Page 387: ...ps 1 6 in Changing the gear oil 10 10 2 Remove the propeller and trim tab See steps 2 5 in Removing the lower unit 8 3 3 Remove the lower case mounting nuts a lower case mounting bolts b and c and then remove the lower unit d 4 Remove the speedometer hose e and then remove the extension f TIP When disassembling the lower unit measure the backlash before disassembly See Mea suring the forward gear ...

Page 388: ... clip 1 3 O ring 1 39 4 Plate 1 5 Oil seal 1 39 6 Bolt 3 M8 25 mm 7 Cover 1 8 Seal plate 1 9 Woodruff key 1 10 Dowel 2 11 Impeller 1 12 Outer plate cartridge 1 13 Gasket 1 39 14 Rubber seal 1 15 Plate 1 16 O ring 1 39 17 Insert cartridge 1 7 6 5 4 3 2 1 8 9 10 10 15 14 13 12 11 6 20 20 22 20 23 22 21 19 18 17 16 ...

Page 389: ...r rotation model 0 1 2 3 4 5 6 7 8 9 10 A No Part name Q ty Remarks 18 O ring 1 39 19 Water pump housing 1 20 Bolt 4 M8 45 mm 21 Oil seal 2 39 22 Cover 2 23 Seal 1 7 6 5 4 3 2 1 8 9 10 10 15 14 13 12 11 6 20 20 22 20 23 22 21 19 18 17 16 ...

Page 390: ...e i rubber seal j and plate k 4 Set the gear shift to the N position 5 Remove the plate m oil seal n O ring o and shift rod p TIP To remove the shift rod p lift it up slightly and then turn the shift rod p 90 counter clockwise to pull it up Disassembling the water pump housing 1 Remove the insert cartridge a and O ring b 2 Remove the cover c and oil seals d a b b c d e f g h i j k R N F l Shift ro...

Page 391: ...d or worn 3 Check the Woodruff key and the keyway in the drive shaft Replace the drive shaft if deformed or worn 4 Check the shift rod Replace if cracked or worn Assembling the water pump housing Do not reuse an O ring or oil seal always replace it with a new one 1 Install the seal a and cover b 2 Install new oil seals c to the specified depth a TIP Install an oil seal halfway into the water pump ...

Page 392: ...8 13 LOWR Lower unit TIP Fit the protrusions b on the insert cartridge h into the slots c in the water pump housing i g h i b c ...

Page 393: ...r PORT 1 7 Slider 1 8 Ball 2 9 Shift plunger 1 10 Spring 1 11 Dog clutch 1 12 Cross pin 1 13 Propeller shaft 1 14 Reverse gear shim T2 15 Reverse gear 1 16 Thrust washer 1 17 Ball bearing 1 39 15 16 17 1 2 4 7 8 8 14 22 23 24 25 26 25 28 27 12 13 18 19 20 21 9 10 11 3 6 5 30 31 30 31 29 8 7 9 8 10 12 11 13 155 N m 15 5 kgf m 114 3 ft lb 8 N m 0 8 kgf m 5 9 ft lb 1 N m 0 1 kgf m 0 7 ft lb Water pum...

Page 394: ... Rubber seal 1 24 Needle bearing 1 39 25 Oil seal 2 39 26 Key 1 27 Claw washer 1 28 Propeller shaft housing ring nut 1 29 Cover 1 30 Dowel 2 31 Cover bolt 2 M8 25 mm 15 16 17 1 2 4 7 8 8 14 22 23 24 25 26 25 28 27 12 13 18 19 20 21 9 10 11 3 6 5 30 31 30 31 29 8 7 9 8 10 12 11 13 155 N m 15 5 kgf m 114 3 ft lb 8 N m 0 8 kgf m 5 9 ft lb 1 N m 0 1 kgf m 0 7 ft lb ...

Page 395: ...nt outward 4 Loosen the propeller shaft housing ring nut 5 Remove the propeller shaft housing ring nut f and claw washer g 6 Remove the propeller shaft housing assembly 7 Remove the O ring k propeller shaft assembly l and reverse gear shims m a b c a Ring nut wrench extension d 90890 06513 Ring nut wrench 6 e 90890 06677 Bearing housing puller claw L h 90890 06502 Stopper guide plate i 90890 06501...

Page 396: ... of position Disassembling the reverse gear 1 Remove the ball bearing a and thrust washer b Disassembling the propeller shaft housing assembly Use heat resistant gloves Otherwise burns could result To prevent fires remove any flammable substances such as gasoline and oil around the working area Keep good ventilation while working 1 Remove the rubber seal a 2 Remove the oil seals b along with the n...

Page 397: ...ed or worn 2 Measure the propeller shaft runout Checking the dog clutch 1 Check the dog clutch shift plunger cross pin spring balls and slider Replace if cracked or worn Checking the propeller shaft housing 1 Check the water pipe Replace if cor roded cracked or deformed 2 Check the propeller shaft housing Replace if cracked or damaged Checking the reverse gear 1 Check the teeth and dogs of the rev...

Page 398: ...ft housing assembly Use heat resistant gloves Otherwise burns could result To prevent fires remove any flammable substances such as gasoline and oil around the working area Keep good ventilation while working Do not reuse a bearing oil seal or O ring always replace it with a new one 1 Heat the installation area of the taper roller bearing outer race in the propeller shaft housing a using a gas tor...

Page 399: ...earing d to the specified depth b TIP Face the bearing identification mark c on the needle bearing d toward the propeller side 4 Install new oil seals g to the specified depth d TIP Install an oil seal halfway into the propeller shaft housing and then install the other oil seal 5 Install the rubber seal i Driver rod LL b 90890 06605 Bearing outer race attachment c 90890 06623 Driver rod L3 e 90890...

Page 400: ...aw washer 1 6 Drive shaft nut 1 7 Spacer 1 8 Drive shaft ring nut 1 9 Cover 1 10 Bolt 2 M8 20 mm 11 Oil seal housing 1 12 O ring 1 39 13 Oil seal 2 39 14 Lower case 1 15 Dowel 1 16 Adapter 1 17 Roller bearing 1 39 24 25 26 27 1 8 9 10 11 14 19 18 17 16 15 20 21 22 23 12 13 7 6 5 4 2 40 N m 4 0 kgf m 29 5 ft lb 177 N m 17 7 kgf m 130 5 ft lb 143 N m 14 3 kgf m 105 5 ft lb 3 ...

Page 401: ...him T1 1 19 Thrust bearing 1 20 Circlip 1 21 Washer 1 22 Taper roller bearing 1 39 23 Forward gear 1 24 Needle bearing 1 39 25 Pinion 1 26 Washer 1 27 Pinion nut 1 24 25 26 27 1 8 9 10 11 14 19 18 17 16 15 20 21 22 23 12 13 7 6 5 4 2 40 N m 4 0 kgf m 29 5 ft lb 177 N m 17 7 kgf m 130 5 ft lb 143 N m 14 3 kgf m 105 5 ft lb 3 ...

Page 402: ...s and washer Removing the forward gear 1 Remove the forward gear a thrust bear ing b forward gear shim c and adapter d Disassembling the oil seal housing 1 Remove the cover a O ring b and oil seals c Disassembling the drive shaft 1 Straighten the tab a on the claw washer a Drive shaft ring nut wrench d 90890 06674 a b c d g f e h h Drive shaft holder 6 g 90890 06520 Pinion nut holder h 90890 06715...

Page 403: ...sistant gloves Otherwise burns could result To prevent fires remove any flammable substances such as gasoline and oil around the working area Keep good ventilation while working 1 Remove the circlip a and then remove the washer b and taper roller bearing c 2 Remove the dowel d 3 Heat the installation area of the roller bearing in the adapter e using a gas torch and then remove the roller bearing f...

Page 404: ...t the rollers are installed in the needle bearing outer race Checking the pinion 1 Check the teeth of the pinion Replace if cracked or worn Checking the forward gear 1 Check the teeth and dogs of the forward gear Replace if cracked or worn Checking the drive shaft 1 Check the drive shaft Replace if dam aged or worn 2 Measure the drive shaft runout Checking the lower case 1 Check the lower case Rep...

Page 405: ...rn the taper roller bearing 10 turns or more to seat the bearing 5 Install the claw washer c and then tighten the drive shaft nut d temporarily TIP Make sure to fit the tab f on the claw washer c into the slot g in the drive shaft 6 Secure the drive shaft nut d on the drive shaft 7 Tighten the drive shaft nut d to the specified torque Bearing inner race attachment a 90890 06640 Press load bearing ...

Page 406: ... 1 Heat the installation area of the roller bearing in the adapter a using a gas torch and then install a new roller bear ing b NOTICE When heating the adapter heat the entire installation area evenly Otherwise the adapter could be damaged 2 Install the dowel c 3 Install a new taper roller bearing d and the washer e and then install the circlip f Assembling the lower case 1 Install a new needle be...

Page 407: ...l seal housing and then install the other oil seal 2 Install the cover d and a new O ring e Installing the forward gear 1 Install the adapter a original forward gear shim b thrust bearing c and for ward gear d TIP Make sure to fit the dowel e into the slot a in the lower case Installing the drive shaft 1 Install the washer a original pinion shims b and drive shaft c 2 Install the pinion d and wash...

Page 408: ...obtain the correct setting value 4 Install the oil seal housing l TIP Make sure to install the oil seal housing l so that the notch a is facing forward Installing the propeller shaft housing assembly Do not reuse a bearing or O ring always replace it with a new one Drive shaft holder 6 g 90890 06520 Pinion nut holder h 90890 06715 Pinion nut f 143 N m 14 3 kgf m 105 5 ft lb g c d g e f h i j k Dri...

Page 409: ...sure to fit the protrusion b on the pro peller shaft housing into the slot c in the claw washer i 5 Install the propeller shaft housing ring nut j and then tighten it to the specified torque 6 Turn the propeller shaft 10 turns or more and then tighten the propeller shaft housing nut j to the specified torque 7 Bend one of the 4 tabs on the claw washer outward and bend the other 3 tabs inward a b c...

Page 410: ...h a new one 1 Install a new O ring a and a new oil seal b to the plate c 2 Install the plate c to the shift rod d 3 Install the shift rod d TIP Turn the shift rod d clockwise 90 and then push it down so that the tip a of the shift rod d fits into the groove b in the shift slider Installing the water pump Do not reuse a gasket or O ring always replace it with a new one Cover bolt o 8 N m 0 8 kgf m ...

Page 411: ...not turn the drive shaft counterclockwise Otherwise the water pump impeller could be damaged TIP While turning the drive shaft clockwise push the water pump housing down to install it Checking the lower unit for air leakage 1 Remove the check screw a and then install the special service tool b 2 Apply the specified pressure Check that the pressure is maintained in the lower unit for 10 seconds or ...

Page 412: ...he bracket c 2 Set the gear shift to the N position 3 Install the dowels c 4 Install the lower unit d and then tighten the lower case mounting bolts e and f to the specified torque NOTICE Make sure to align the splines on the lower unit shift rod with the splines on the upper case shift rod Otherwise the shift rods could be bent 5 Install the trim tab g to its original position and then tighten th...

Page 413: ...ower unit with the power unit installed make sure to sus pend the outboard motor Otherwise the outboard motor could fall suddenly and result in severe injuries When loosening or tightening the pro peller nut do not hold the propeller using your hands 1 Check that the shift rod is in the N posi tion See steps 1 and 2 in Installing the lower unit X transom model 8 33 2 Install the lower case stud bo...

Page 414: ...ing the lower unit X transom model 8 33 6 Fill the lower unit with gear oil up to the proper level See steps 7 10 in Changing the gear oil 10 10 Lower case mounting nut i 47 N m 4 7 kgf m 34 7 ft lb Lower case mounting bolt j and k 47 N m 4 7 kgf m 34 7 ft lb b b c d e f g g h i j k ...

Page 415: ...t or propeller shaft housing shimming is required Remove the water pump assembly and cover Measure the backlash before disassembly Within specification Shimming is not required Disassemble the lower unit Select the pinion shims T3 Assemble the lower unit Measure the backlash Within specification Select the propeller shaft shims T4 Adjust the forward gear shim thickness T1 and reverse gear shim thi...

Page 416: ...nt 1 Measuring point 2 Measuring point 3 Measuring point 4 Average Round down average M Measurements Before disassembly After disassembly Measuring point 1 Measuring point 2 Measuring point 3 Measuring point 4 Average Round down average Measurements Before disassembly After disassembly Measuring point 1 Measuring point 2 Measuring point 3 Measuring point 4 Average Round down average ...

Page 417: ... 8 9 10 A Forward gear shim T1 thickness measurement in 2 places mm Reverse gear shim T2 thickness measurement in 2 places mm Number of shim s Subtotal 2 00 2 03 2 06 2 09 2 12 2 15 Total Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total ...

Page 418: ...lash between where the drive shaft stops in each direction TIP Do not turn the drive shaft using too much force Otherwise the forward gear will turn leading to incorrect measurements When turning the drive shaft hold it using a little force A knocking sound may be heard when the drive shaft is turned but this is the sound of the pinion contacting the reverse gear and does not affect the back lash ...

Page 419: ...cified torque turn the drive shaft slowly clockwise and counterclockwise and measure the backlash between where the drive shaft stops in each direction TIP Do not turn the drive shaft using too much force Otherwise the reverse gear will turn leading to incorrect measurements When turning the drive shaft hold it using a little force A knocking sound may be heard when the drive shaft is turned but t...

Page 420: ...cation TIP Adjust the shim thicknesses if the reverse gear backlash is out of specification 15 Remove the special service tools and then install the outer plate cartridge cover and water pump assembly See Installing the water pump 8 31 Reverse gear backlash 0 15 0 88 mm 0 0059 0 0346 in ...

Page 421: ... make sure to select the pinion shims T3 When assembling the lower unit to measure the backlash after selecting the pinion shims T3 do not apply gear oil grease or sealant to the parts When assembling the lower unit after shimming is completed make sure to apply gear oil grease and sealant to the specified areas Shim location T4 T3 T1 T2 ...

Page 422: ...e original pinion shims drive shaft pinion and drive shaft ring nut See steps 1 3 in Installing the drive shaft 8 28 TIP If the original shims are missing install new shims with a combined thickness of 0 70 mm Do not reuse a shim if deformed or scratched 3 Check that the drive shaft turns smoothly 4 Set up the special service tools a and b and then remove the special service tool b 5 Measure the d...

Page 423: ... measurement M 0 52 mm k Pinion shim T3 thickness adjustment 0 18 mm The current shim thickness must be increased by 0 18 mm A Pinion distance measurement M B Calculated value B TIP When the difference between the calcu lated value B and the pinion distance measurement M is larger than 0 07 mm adjust the difference by the shims If the shim thickness adjustment value is positive the current shim th...

Page 424: ... mm 0 88 mm Use the following formula when the shim thickness adjustment value is negative Current pinion shim thickness 0 70 mm Shim thickness adjustment 0 09 mm New pinion shim T3 thickness 0 70 mm 0 09 mm 0 61 mm TIP Use up to 3 shims to obtain the required shim thickness If the calculated shim thickness cannot be obtained with a combination of the available shims increase or decrease the pinio...

Page 425: ... 65 0 66 0 67 090 0 55 0 56 0 57 0 58 0 59 0 60 0 61 0 62 0 63 0 64 0 65 0 66 095 0 55 0 56 0 57 0 58 0 59 0 60 0 61 0 62 0 63 0 64 0 65 0 66 100 0 54 0 55 0 56 0 57 0 58 0 59 0 60 0 61 0 62 0 63 0 64 0 65 A 001 002 003 004 005 006 007 008 009 010 011 B 000 0 76 0 77 0 78 0 79 0 80 0 81 0 82 0 83 0 84 0 85 0 86 005 0 76 0 77 0 78 0 79 0 80 0 81 0 82 0 83 0 84 0 85 0 86 010 0 75 0 76 0 77 0 78 0 79...

Page 426: ... 0 40 0 39 0 38 0 37 0 36 0 35 0 34 0 33 0 32 0 31 0 30 0 29 0 68 0 41 0 40 0 39 0 38 0 37 0 36 0 35 0 34 0 33 0 32 0 31 0 30 0 69 0 42 0 41 0 40 0 39 0 38 0 37 0 36 0 35 0 34 0 33 0 32 0 31 0 70 0 43 0 42 0 41 0 40 0 39 0 38 0 37 0 36 0 35 0 34 0 33 0 32 0 71 0 44 0 43 0 42 0 41 0 40 0 39 0 38 0 37 0 36 0 35 0 34 0 33 0 72 0 45 0 44 0 43 0 42 0 41 0 40 0 39 0 38 0 37 0 36 0 35 0 34 0 73 0 46 0 45...

Page 427: ... 19 0 18 0 17 0 68 0 29 0 28 0 27 0 26 0 25 0 24 0 23 0 22 0 21 0 20 0 19 0 18 0 69 0 30 0 29 0 28 0 27 0 26 0 25 0 24 0 23 0 22 0 21 0 20 0 19 0 70 0 31 0 30 0 29 0 28 0 27 0 26 0 25 0 24 0 23 0 22 0 21 0 20 0 71 0 32 0 31 0 30 0 29 0 28 0 27 0 26 0 25 0 24 0 23 0 22 0 21 0 72 0 33 0 32 0 31 0 30 0 29 0 28 0 27 0 26 0 25 0 24 0 23 0 22 0 73 0 34 0 33 0 32 0 31 0 30 0 29 0 28 0 27 0 26 0 25 0 24 0...

Page 428: ... 0 20 0 19 0 18 0 17 0 16 0 15 0 14 0 13 0 12 0 11 0 10 0 73 0 22 0 21 0 20 0 19 0 18 0 17 0 16 0 15 0 14 0 13 0 12 0 11 0 74 0 23 0 22 0 21 0 20 0 19 0 18 0 17 0 16 0 15 0 14 0 13 0 12 0 75 0 24 0 23 0 22 0 21 0 20 0 19 0 18 0 17 0 16 0 15 0 14 0 13 0 76 0 25 0 24 0 23 0 22 0 21 0 20 0 19 0 18 0 17 0 16 0 15 0 14 0 77 0 26 0 25 0 24 0 23 0 22 0 21 0 20 0 19 0 18 0 17 0 16 0 15 0 78 0 27 0 26 0 25...

Page 429: ... 08 0 09 0 10 0 11 0 64 0 09 0 08 0 09 0 10 0 65 0 07 0 08 0 09 0 66 0 07 0 08 0 67 0 07 0 68 0 69 0 70 0 07 0 71 0 08 0 07 0 72 0 09 0 08 0 07 0 73 0 10 0 09 0 08 0 07 0 74 0 11 0 10 0 09 0 08 0 07 0 75 0 12 0 11 0 10 0 09 0 08 0 07 0 76 0 13 0 12 0 11 0 10 0 09 0 08 0 07 0 77 0 14 0 13 0 12 0 11 0 10 0 09 0 08 0 07 0 78 0 15 0 14 0 13 0 12 0 11 0 10 0 09 0 08 0 07 0 79 0 16 0 15 0 14 0 13 0 12 0...

Page 430: ... 0 21 0 22 0 23 0 24 0 63 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 64 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 20 0 21 0 22 0 65 0 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 20 0 21 0 66 0 09 0 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 20 0 67 0 08 0 09 0 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 68 0 07 0 08 0 09 0 10 0 11 0 12 0 13 0 14 0 15 0 16...

Page 431: ... 0 30 0 31 0 32 0 67 0 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 28 0 29 0 30 0 31 0 68 0 19 0 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 28 0 29 0 30 0 69 0 18 0 19 0 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 28 0 29 0 70 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 28 0 71 0 16 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 72 0 15 0 16 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 0 25...

Page 432: ...36 0 37 0 38 0 39 0 40 0 41 0 68 0 31 0 32 0 33 0 34 0 35 0 36 0 37 0 38 0 39 0 40 0 69 0 30 0 31 0 32 0 33 0 34 0 35 0 36 0 37 0 38 0 39 0 70 0 29 0 30 0 31 0 32 0 33 0 34 0 35 0 36 0 37 0 38 0 71 0 28 0 29 0 30 0 31 0 32 0 33 0 34 0 35 0 36 0 37 0 72 0 27 0 28 0 29 0 30 0 31 0 32 0 33 0 34 0 35 0 36 0 73 0 26 0 27 0 28 0 29 0 30 0 31 0 32 0 33 0 34 0 35 0 74 0 25 0 26 0 27 0 28 0 29 0 30 0 31 0 ...

Page 433: ...rward gear backlash and reverse gear backlash before disassembly 8 39 TIP In the Forward gear shim T1 selection table use the round down average for the backlash measurement BL1 Adjusting the forward gear shim T1 thickness 1 Remove the propeller shaft housing assembly and propeller shaft assembly See Removing the propeller shaft hous ing assembly 8 16 2 Remove the drive shaft ring nut pinion and d...

Page 434: ... to obtain the median value within the range for the specified forward gear backlash If the backlash measurement BL1 is less than 0 18 mm install a new shim with a thickness of 2 00 mm If the backlash measurement BL1 is more than 0 44 mm install a new shim with a thickness of 2 15 mm Use only 1 shim to obtain the required shim thickness 6 Install the adapter determined forward gear shim T1 thrust ...

Page 435: ... 06 2 06 2 06 2 15 2 03 2 03 2 03 2 06 2 06 2 06 2 09 2 09 2 09 A 0 27 0 28 0 29 0 30 0 31 0 32 0 33 0 34 0 35 B 2 00 2 03 2 03 2 03 2 03 2 00 2 00 2 00 2 06 2 06 2 06 2 06 2 03 2 03 2 03 2 09 2 09 2 09 2 09 2 06 2 06 2 06 2 12 2 12 2 12 2 12 2 09 2 09 2 09 2 15 2 15 2 15 2 15 2 12 2 12 2 12 A 0 36 0 37 0 38 0 39 0 40 0 41 0 42 0 43 0 44 B 2 00 2 06 2 06 2 06 2 09 2 09 2 09 2 12 2 12 2 12 2 03 2 0...

Page 436: ...disassembly 8 39 TIP In the Reverse gear shim T2 selection chart use the round down average for the backlash measurement BL2 Adjusting the reverse gear shim T2 thickness 1 Remove the propeller shaft housing assembly propeller shaft assembly and original reverse gear shims See Removing the propeller shaft housing assembly 8 16 2 Measure the thickness of each original reverse gear shim in 2 places T...

Page 437: ...s Calculation formula New reverse gear shim T2 thickness Cur rent reverse gear shim thickness Shim thickness adjustment Example Use the following formula when the shim thickness adjustment value is positive Current reverse gear shim thickness 0 75 mm Shim thickness adjustment 0 42 mm New reverse gear shim T2 thickness 0 75 mm 0 42 mm 1 17 mm Use the following formula when the shim thickness adjust...

Page 438: ...ckness adjustment 0 52 0 47 0 42 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 39 0 44 0 49 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Continue next page B mm 0 60 0 40 0 20 0 0 20 0 40 0 60 0 80 1 00 1 20 1 40 1 60 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 A 1 100 mm A B ...

Page 439: ...0 20 0 0 20 0 40 0 60 0 80 1 00 1 20 1 40 1 60 A 1 100 mm 105 0 49 0 54 0 59 0 64 0 69 0 74 0 79 0 84 0 89 0 94 0 99 1 04 1 09 1 14 1 19 1 24 1 29 1 34 1 39 1 44 1 49 100 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 182 190 195 200 A B 105 100 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 182 190 195 200 ...

Page 440: ...more 4 Install the washer b and propeller nut c 5 Measure the motive torque of the propeller shaft TIP Shimming is not required if the measure ment value is within specification If the measurement value is below specifi cation adjust the motive torque to specifi cation by increasing the propeller shaft shim thickness by 0 10 mm If the measurement value is above specifi cation adjust the motive tor...

Page 441: ...ple 1 8 O ring 1 39 9 Dowel 2 10 Check screw 1 11 Trim tab bolt 1 M10 45 mm 12 Grommet 1 13 Lower unit 1 14 Propeller 1 15 Cotter pin 1 39 16 Propeller nut 1 17 Washer 1 15 16 54 N m 5 4 kgf m 39 8 ft lb 18 19 17 9 9 13 11 12 14 3 21 2 1 3 4 6 5 22 22 23 20 10 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kgf m 6 6 ft lb 42 N m 4 2 kgf m 31 0 ft lb 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 8 7...

Page 442: ...nting bolt 7 M10 45 mm 23 Lower case mounting bolt 1 M10 70 mm 15 16 54 N m 5 4 kgf m 39 8 ft lb 18 19 17 9 9 13 11 12 14 3 21 2 1 3 4 6 5 22 22 23 20 10 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kgf m 6 6 ft lb 42 N m 4 2 kgf m 31 0 ft lb 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 8 7 2 N m 0 2 kgf m 1 5 ft lb ...

Page 443: ...moving the lower unit 8 3 TIP When disassembling the lower unit measure the backlash before disassembly See Mea suring the forward gear backlash and reverse gear backlash before disassembly 8 84 Disassembling the propeller See Disassembling the propeller 8 3 Checking the propeller See Checking the propeller 8 3 Checking the lower unit anode See Checking the lower unit anode 8 4 Assembling the prop...

Page 444: ...mm 10 Adapter 1 11 Plastic tie 1 12 Extension 1 13 Dowel 4 14 Rubber seal 1 15 Lower case stud bolt 6 16 Trim tab bolt 1 M10 45 mm 17 Grommet 1 10 11 9 29 28 13 13 19 16 17 20 3 27 2 1 3 4 6 5 26 18 12 13 14 13 15 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kgf m 6 6 ft lb 42 N m 4 2 kgf m 31 0 ft lb 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 8 7 21 24 23 22 54 N m...

Page 445: ... Lower case mounting nut 6 29 Washer 6 30 Lower case mounting bolt 1 M10 170 mm 31 Lower case mounting bolt 1 M10 200 mm 10 11 9 29 28 13 13 19 16 17 20 3 27 2 1 3 4 6 5 26 18 12 13 14 13 15 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kgf m 6 6 ft lb 42 N m 4 2 kgf m 31 0 ft lb 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 47 N m 4 7 kgf m 34 7 ft lb 8 7 21 24 23 22 54 N m 5 4 kgf m 39 8 ft lb 2...

Page 446: ... 4 in Removing the lower unit 8 3 TIP When disassembling the lower unit measure the backlash before disassembly See Mea suring the forward gear backlash and reverse gear backlash before disassembly 8 84 Disassembling the propeller See Disassembling the propeller 8 3 Checking the propeller See Checking the propeller 8 3 Checking the lower unit anode See Checking the lower unit anode 8 4 Assembling ...

Page 447: ...9 4 Plate 1 5 Oil seal 1 39 6 Bolt 3 M8 25 mm 7 Cover 1 8 Seal plate 1 9 Woodruff key 1 10 Dowel 2 11 Impeller 1 12 Outer plate cartridge 1 13 Gasket 1 39 14 Rubber seal 1 15 Plate 1 16 O ring 1 39 17 Insert cartridge 1 7 6 5 4 3 2 1 8 9 10 10 15 14 13 12 11 6 20 20 22 20 23 22 21 19 18 17 16 Lower unit counter rotation model U transom model Water pump and shift rod counter rotation model ...

Page 448: ...WR Lower unit No Part name Q ty Remarks 18 O ring 1 39 19 Water pump housing 1 20 Bolt 4 M8 45 mm 21 Oil seal 2 39 22 Cover 2 23 Seal 1 7 6 5 4 3 2 1 8 9 10 10 15 14 13 12 11 6 20 20 22 20 23 22 21 19 18 17 16 ...

Page 449: ...the plate a oil seal b O ring c and shift rod d TIP To remove the shift rod d lift it up slightly and then turn the shift rod d 90 clockwise to pull it up Disassembling the water pump housing See Disassembling the water pump hous ing 8 11 Checking the water pump and shift rod See Checking the water pump and shift rod 8 12 Assembling the water pump housing See Assembling the water pump housing 8 12...

Page 450: ... Water inlet cover PORT 1 7 Slider 1 8 Ball 2 9 Shift plunger 1 10 Spring 1 11 Dog clutch 1 12 Cross pin 1 13 Forward gear shim T2 14 Forward gear 1 15 Thrust washer 1 16 Taper roller bearing 1 39 17 Propeller shaft 1 4 7 8 8 13 14 15 16 21 22 23 24 25 24 27 26 12 17 18 9 10 11 3 6 5 29 30 29 30 20 19 28 8 7 9 8 10 12 11 17 1 2 155 N m 15 5 kgf m 114 3 ft lb 8 N m 0 8 kgf m 5 9 ft lb 1 N m 0 1 kgf...

Page 451: ... shaft housing 1 22 Rubber seal 1 23 Needle bearing 1 39 24 Oil seal 2 39 25 Key 1 26 Claw washer 1 27 Propeller shaft housing ring nut 1 28 Cover 1 29 Dowel 2 30 Cover bolt 2 M8 25 mm 4 7 8 8 13 14 15 16 21 22 23 24 25 24 27 26 12 17 18 9 10 11 3 6 5 29 30 29 30 20 19 28 8 7 9 8 10 12 11 17 1 2 155 N m 15 5 kgf m 114 3 ft lb 8 N m 0 8 kgf m 5 9 ft lb 1 N m 0 1 kgf m 0 7 ft lb ...

Page 452: ...g clutch See Disassem bling the propeller shaft assembly 8 17 2 Remove the rubber seal a and O ring b 3 Heat the installation area of the taper roller bearing outer race in the propeller shaft housing c using a gas torch and then remove the forward gear d NOTICE When heating the propeller shaft housing heat the entire installation area evenly Otherwise the propeller shaft housing could be damaged ...

Page 453: ...ly and forward gear Use heat resistant gloves Otherwise burns could result To prevent fires remove any flammable substances such as gasoline and oil around the working area Keep good ventilation while working Do not reuse a bearing oil seal or O ring always replace it with a new one 1 Install the needle bearing and oil seals See steps 3 and 4 in Assembling the propeller shaft housing assembly 8 19...

Page 454: ... holding the special service tool d strike the tool to check that the taper roller bearing e is installed properly TIP If a high pitched metallic sound is produced when the special service tool is struck the taper roller bearing outer race is installed properly 6 Install the thrust washer f and forward gear g using the dog clutch h and special service tool d 7 Install the dog clutch See Assembling...

Page 455: ...e shaft nut 1 7 Spacer 1 8 Drive shaft ring nut 1 9 Cover 1 10 Bolt 2 M8 20 mm 11 Oil seal housing 1 12 O ring 1 39 13 Oil seal 2 39 14 Lower case 1 15 Dowel 1 16 Adapter 1 17 Roller bearing 1 39 23 24 25 26 1 8 9 10 11 14 19 18 17 16 15 21 20 22 12 13 7 6 5 4 2 40 N m 4 0 kgf m 29 5 ft lb 177 N m 17 7 kgf m 130 5 ft lb 143 N m 14 3 kgf m 105 5 ft lb 3 Propeller shaft housing counter rotation mode...

Page 456: ...bearing 1 20 Circlip 1 21 Needle bearing 1 39 22 Reverse gear 1 23 Needle bearing 1 39 24 Pinion 1 25 Washer 1 26 Pinion nut 1 23 24 25 26 1 8 9 10 11 14 19 18 17 16 15 21 20 22 12 13 7 6 5 4 2 40 N m 4 0 kgf m 29 5 ft lb 177 N m 17 7 kgf m 130 5 ft lb 143 N m 14 3 kgf m 105 5 ft lb 3 ...

Page 457: ...g the forward gear 8 24 Disassembling the lower case See Disassembling the lower case 8 25 Checking the pinion See Checking the pinion 8 25 Checking the reverse gear 1 Check the teeth and dogs of the reverse gear Replace if cracked or worn Checking the drive shaft See Checking the drive shaft 8 25 Checking the lower case See Checking the lower case 8 25 Assembling the drive shaft See Assembling th...

Page 458: ...rust bearing c and reverse gear d TIP Make sure to fit the dowel e into the slot a in the lower case Installing the drive shaft See Installing the drive shaft 8 28 Installing the propeller shaft housing assembly Do not reuse a bearing or O ring always replace it with a new one 1 Install a new O ring a 2 Install the original forward gear shims b propeller shaft housing c and key d Needle bearing at...

Page 459: ...eakage See Checking the lower unit for air leakage 8 32 Installing the lower unit X transom model 1 Install the lower unit trim tab and propel ler See steps 1 8 in Installing the lower unit X transom model 8 33 2 Fill the lower unit with gear oil up to the proper level See steps 7 10 in Changing the gear oil 10 10 Installing the lower unit U transom model 1 Check that the shift rod is in the N pos...

Page 460: ...gear bearings drive shaft or propeller shaft housing shimming is required Remove the water pump assembly and cover Measure the backlash before disassembly Within specification Shimming is not required Disassemble the lower unit Select the pinion shims T3 and propeller shaft shims T4 Assemble the lower unit Measure the backlash Within specification Install the water pump assembly Adjust the forward...

Page 461: ...rements Measuring point 1 Measuring point 2 Measuring point 3 Measuring point 4 Average Round down average M Measurements Before disassembly After disassembly Measuring point 1 Measuring point 2 Measuring point 3 Measuring point 4 Average Round down average Measurements Before disassembly After disassembly Measuring point 1 Measuring point 2 Measuring point 3 Measuring point 4 Average Round down a...

Page 462: ...r shim T2 thickness measurement in 2 places mm Reverse gear shim T1 thickness measurement in 2 places mm Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total Number of shim s Subtotal 2 00 2 03 2 06 2 09 2 12 2 15 Total ...

Page 463: ...and measure the backlash between where the drive shaft stops in each direction TIP Do not turn the drive shaft using too much force Otherwise the forward gear will turn leading to incorrect measurements When turning the drive shaft hold it using a little force A knocking sound may be heard when the drive shaft is turned but this is the sound of the pinion contacting the reverse gear and does not a...

Page 464: ...2 Apply a load to the reverse gear by installing the propeller j spacer k and washer l without the spacer m 13 Tighten the propeller nut n to the specified torque 14 Set the gear shift to the R position 15 While turning the shift rod toward the R position using the specified torque turn the drive shaft slowly clockwise and counterclockwise and measure the backlash between where the drive shaft sto...

Page 465: ...ash measurement 16 Repeat steps 7 and 8 to measure the reverse gear backlash 17 Check that the reverse gear backlash average is within specification TIP Adjust the shim thicknesses if the reverse gear backlash is out of specification 18 Remove the special service tools and then install the outer plate cartridge cover and water pump assembly See Installing the water pump 8 31 19 Install the cover i...

Page 466: ... the pinion shims T3 When assembling the lower unit to measure the backlash after selecting the pinion shims T3 do not apply gear oil grease or sealant to the parts When assembling the lower unit after shimming is completed make sure to apply gear oil grease and sealant to the specified areas Shim location T1 T3 T2 T4 ...

Page 467: ...the propeller shaft housing assembly 8 29 3 Turn the propeller shaft 10 turns or more 4 Set up the special service tools a and b 5 Measure the propeller shaft free play 6 Round the measurement value to the 1 10 place if out of specification TIP In the Propeller shaft shim T4 selection table use the rounded measurement value for the free play measurement 7 Determine the propeller shaft shim T4 thic...

Page 468: ...him T4 thickness Calculation formula New propeller shaft shim T4 thickness Current propeller shaft shim thickness Shim thickness adjustment Example Use the following formula when the shim thickness adjustment value is positive Current propeller shaft shim thickness 0 8 mm Shim thickness adjustment 0 2 mm New propeller shaft shim T4 thickness 0 8 mm 0 2 mm 1 0 mm Use the following formula when the ...

Page 469: ...be adjusted for the gray colored cell mm A Free play measurement B Shim thickness adjustment A 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 B 0 3 0 2 0 1 0 1 0 2 0 3 0 4 0 5 0 6 A 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 B 0 7 0 8 0 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 A 2 0 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 B 1 7 1 8 1 9 2 0 2 1 2 2 2 3 2 4 2 5 2 6 ...

Page 470: ...sassembly 8 84 TIP In the Forward gear shim T2 selection chart use the round down average for the backlash measurement BL2 Adjusting the forward gear shim T2 thickness 1 Remove the propeller shaft housing assembly and original forward gear shims See steps 1 5 in Removing the propeller shaft housing assembly 8 16 and step 2 in Removing the propeller shaft housing assembly 8 73 2 Measure the thickne...

Page 471: ...rward gear shim T2 thickness Cur rent forward gear shim thickness Shim thickness adjustment Example Use the following formula when the shim thickness adjustment value is positive Current forward gear shim thickness 0 75 mm Shim thickness adjustment 0 34 mm New forward gear shim T2 thickness 0 75 mm 0 34 mm 1 09 mm Use the following formula when the shim thickness adjustment value is negative Curre...

Page 472: ... adjustment 0 44 0 39 0 34 0 26 0 0 0 0 0 0 0 0 0 0 0 0 31 0 36 0 41 0 46 0 51 0 56 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Continue next page B mm 0 60 0 40 0 20 0 0 20 0 40 0 60 0 80 1 00 1 20 1 40 1 60 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 A 1 100 mm A B ...

Page 473: ...0 20 0 0 20 0 40 0 60 0 80 1 00 1 20 1 40 1 60 A 1 100 mm 105 0 56 0 61 0 66 0 71 0 76 0 81 0 86 0 91 0 96 1 01 1 06 1 11 1 16 1 21 1 26 1 31 1 36 1 41 1 46 1 51 1 56 100 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 182 190 195 200 A B 105 100 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 182 190 195 200 ...

Page 474: ...y 8 29 5 Check that the drive shaft turns smoothly 6 Measure the reverse gear backlash See steps 11 17 in Measuring the forward gear backlash and reverse gear backlash before disassembly 8 84 TIP In the Reverse gear shim T1 selection table use the round down average for the backlash measurement BL1 Adjusting the reverse gear shim T1 thickness 1 Remove the propeller shaft housing assembly See steps...

Page 475: ...d by the gray col ored cells The values for the shim thickness specified in the selection table are intended to obtain the median value within the range for the specified reverse gear backlash If the backlash measurement BL1 is less than 0 38 mm install a new shim with a thickness of 2 00 mm If the backlash measurement BL1 is more than 0 64 mm install a new shim with a thickness of 2 15 mm Use onl...

Page 476: ...03 2 03 2 03 2 06 2 06 2 06 2 09 2 09 2 09 A 0 47 0 48 0 49 0 50 0 51 0 52 0 53 0 54 0 55 B 2 00 2 03 2 03 2 03 2 03 2 00 2 00 2 00 2 06 2 06 2 06 2 06 2 03 2 03 2 03 2 09 2 09 2 09 2 09 2 06 2 06 2 06 2 12 2 12 2 12 2 12 2 09 2 09 2 09 2 15 2 15 2 15 2 15 2 12 2 12 2 12 A 0 56 0 57 0 58 0 59 0 60 0 61 0 62 0 63 0 64 B 2 00 2 06 2 06 2 06 2 09 2 09 2 09 2 12 2 12 2 12 2 03 2 09 2 09 2 09 2 12 2 12...

Page 477: ...8 98 Shimming counter rotation model 0 1 2 3 4 5 6 7 8 9 10 A MEMO ...

Page 478: ...ecking the exhaust guide anode 9 16 Checking the drive shaft bushing 9 16 Assembling the upper case 9 16 Oil pan and exhaust manifold 9 18 Disassembling the oil pan and exhaust manifold 9 20 Checking the oil pan and exhaust manifold 9 20 Checking the oil strainer 9 20 Assembling the oil pan and exhaust manifold 9 20 Steering arm 9 22 Removing the steering arm 9 23 Installing the steering arm 9 23 ...

Page 479: ...PTT gear pump 9 45 Disassembling the gear pump housing 9 48 Checking the gear pump 9 48 Assembling the gear pump assembly 9 49 PTT cylinder 9 51 Removing the tilt ram 9 53 Removing the trim ram 9 53 Disassembling the tilt ram 9 53 Disassembling the trim ram 9 54 Checking the tilt cylinder and PTT body 9 54 Checking the valve 9 54 Assembling the tilt ram 9 55 Assembling the trim ram 9 56 Installing...

Page 480: ...hift rod and SPS No Part name Q ty Remarks 1 Bolt 4 M6 25 mm 2 SPS 1 3 Clip 1 4 Bushing 1 5 Washer 1 6 Circlip 1 7 Shift rod 1 8 Shift lever 1 9 Bushing 2 10 Bracket 1 11 Dowel 2 12 Grommet 1 11 1 2 4 5 6 7 8 9 1 3 10 11 12 1 ...

Page 481: ...ng the shift rod and SPS 1 Install the grommet a 2 Install the dowels b bracket c bushings d and shift rod e 3 Install the circlip f washer g and bushing h 4 Fit the protrusion a on the SPS i into the slot b in the tip of the shift rod e and then turn the SPS i in the direction of the arrow to install it 5 Install the shift lever j and then install the clip k a b c d e f g h i e d c a h g f b b k ...

Page 482: ...8 Guide 1 9 Holder 1 10 Bracket 1 11 Bolt 7 M6 12 mm 12 Plastic tie 1 13 Flushing hose adapter screw 2 ø6 20 mm 14 Bracket 1 15 Water outlet 2 16 Hook 3 17 Bushing 6 4 N m 0 4 kgf m 3 0 ft lb 21 11 14 9 11 11 10 7 3 4 5 6 13 13 22 20 19 18 17 17 27 15 11 30 16 11 29 21 22 11 16 11 15 16 24 19 18 17 23 25 1 17 21 22 20 19 18 17 17 26 28 8 1 2 2 12 ...

Page 483: ...pring 3 23 Cowling lock lever STBD 1 24 Lever 1 25 Clamp 1 26 Cowling lock lever PORT 1 27 Grommet 1 28 Cowling lock lever front 1 29 Bracket 1 30 Holder 1 4 N m 0 4 kgf m 3 0 ft lb 21 11 14 9 11 11 10 7 3 4 5 6 13 13 22 20 19 18 17 17 27 15 11 30 16 11 29 21 22 11 16 11 15 16 24 19 18 17 23 25 1 17 21 22 20 19 18 17 17 26 28 8 1 2 2 12 ...

Page 484: ...lead b Installing the flushing hose 1 Route the flushing hose a trim sensor lead a and PTT motor lead b through the grommet b and then fasten them using plastic ties c around the grommet b 2 Install the grommet b and guide d TIP Align the white paint mark c on the flushing hose a with the outer end of the grommet b and align the white tape d on the PTT motor lead b with the inner end of the gromme...

Page 485: ...it to the hose joint i and then fasten the flushing hose a using the plastic tie j 7 Install the hose joint to the adapter f along with the gasket k Installing the cowling lock lever 1 Install the bushing a cowling lock lever b bushing c washer d wave washer e and lever f 2 Install the hook g and then install the spring h Flushing hose adapter screw g 4 N m 0 4 kgf m 3 0 ft lb a e a d b f a j h i ...

Page 486: ...er 2 6 Grommet 1 7 Bracket 1 8 Grommet 12 9 Bolt 6 M6 35 mm 10 Collar 6 11 Rubber seal 1 12 Grommet 2 13 Bolt 4 M6 16 mm 14 Grommet 2 15 Bracket 2 16 Rubber seal 1 39 17 Drain hose 2 17 19 1 24 25 13 13 2 1 3 1 2 5 4 26 11 12 13 12 15 10 8 10 8 4 7 6 8 9 9 9 8 13 8 5 1 3 4 15 19 16 10 8 23 21 22 14 14 17 20 18 21 A A A Counter rotation model ...

Page 487: ...e 1 19 Bolt 4 M6 16 mm 20 Drain box 1 21 Rubber seal 2 22 Drain box 1 23 O ring 1 39 24 Dipstick 1 25 Dipstick guide 1 26 Bottom cowling 1 17 19 1 24 25 13 13 2 1 3 1 2 5 4 26 11 12 13 12 15 10 8 10 8 4 7 6 8 9 9 9 8 13 8 5 1 3 4 15 19 16 10 8 23 21 22 14 14 17 20 18 21 A A A Counter rotation model ...

Page 488: ...gasket c A Regular rotation model B Counter rotation model Installing the PTT switch 1 Install a new gasket a the PTT switch b and the holder c NOTICE Do not reuse a gasket always replace it with a new one A Regular rotation model B Counter rotation model a b c STBD A PORT B a b c c b a STBD A PORT B c b a ...

Page 489: ...er mount 4 11 Lower mount 2 12 Washer 2 13 Ground lead 1 14 Lower mounting bolt 2 M14 227 mm 15 Bracket 2 16 Lower mount bracket bolt 4 M10 45 mm 17 Bolt 1 M6 20 mm 16 10 12 11 14 10 10 17 18 19 17 18 16 13 15 14 12 10 11 22 21 20 11 10 12 13 14 24 23 23 25 26 26 24 15 7 6 6 4 3 1 5 10 4 1 2 72 N m 7 2 kgf m 53 1 ft lb 72 N m 7 2 kgf m 53 1 ft lb 8 8 9 55 N m 5 5 kgf m 40 6 ft lb 55 N m 5 5 kgf m ...

Page 490: ...ie 1 23 Washer 2 24 Lower mounting nut 2 25 Upper mounting nut 2 26 Washer 2 16 10 12 11 14 10 10 17 18 19 17 18 16 13 15 14 12 10 11 22 21 20 11 10 12 13 14 24 23 23 25 26 26 24 15 7 6 6 4 3 1 5 10 4 1 2 72 N m 7 2 kgf m 53 1 ft lb 72 N m 7 2 kgf m 53 1 ft lb 8 8 9 55 N m 5 5 kgf m 40 6 ft lb 55 N m 5 5 kgf m 40 6 ft lb ...

Page 491: ...pper mount bracket bolts e upper mount bracket h damper i upper mounts j plates k stopper l collars m plate n and upper mounting bolts o 7 Remove the lower mount bracket bolts d lower mount brackets p lower mounts q and r lower mounting bolts s and washers t Installing the upper case 1 Install the plate a collars b stopper c plate d and upper mounts e to the upper mounting bolts f 2 Install the da...

Page 492: ...g nuts p and lower mounting nuts s to the specified torque NOTICE When tightening the lower mounting nut make sure that the ground lead does not turn along with the bolt 7 Tighten the upper mount bracket bolts i to the specified torque in the order a b and so on 8 Tighten the lower mount bracket bolts o to the specified torque 9 Connect the ground lead t 10 Install the speedometer hose u and then ...

Page 493: ...9 14 Upper case and mount 0 1 2 3 4 5 6 7 8 9 10 A Lower mount bracket bolt o 55 N m 5 5 kgf m 40 6 ft lb t u v t v u o ...

Page 494: ...ase bolt 2 M8 30 mm 8 Anode screw 2 M6 15 mm 9 Anode 2 10 Upper case bolt 4 M10 45 mm 11 Rubber seal 1 12 Rubber seal 1 39 13 Rubber seal 1 14 Circlip 1 15 Drive shaft bushing 1 16 Upper case 1 4 N m 0 4 kgf m 3 0 ft lb 20 N m 2 0 kgf m 14 8 ft lb 42 N m 4 2 kgf m 31 0 ft lb 6 6 16 15 14 13 12 11 7 7 9 8 10 8 9 5 4 3 2 1 27 N m 2 7 kgf m 19 9 ft lb 10 10 10 ...

Page 495: ...ushing k Checking the exhaust guide anode 1 Check the anode Replace if eroded Clean if there is grease oil or scales NOTICE Do not apply grease oil or paint to the anode Checking the drive shaft bushing 1 Check the drive shaft bushing Replace if cracked or worn Assembling the upper case Do not reuse a gasket always replace it with a new one 1 Install the bushing a a b c d e e a f g h i j Bearing p...

Page 496: ...pecified torque 5 Install the anodes l and then tighten the anode screws m to the specified torque 6 Install the damper n the cover o and a new gasket p and then tighten the drain bolt q to the specified torque Needle bearing attachment b 90890 06611 Driver rod L3 c 90890 06652 d e Upper case bolt j M10 42 N m 4 2 kgf m 31 0 ft lb Upper case bolt k M8 20 N m 2 0 kgf m 14 8 ft lb Anode screw m 4 N ...

Page 497: ...er bolt 3 M6 25 mm 9 Gasket 1 39 10 Exhaust manifold bolt 4 M8 60 mm 11 Exhaust manifold 1 12 Rubber seal 1 39 13 Dowel 2 14 Gasket 1 39 15 Plate 1 16 Gasket 1 39 17 Muffler bolt 9 M8 35 mm 20 N m 2 0 kgf m 14 8 ft lb 20 N m 2 0 kgf m 14 8 ft lb 20 N m 2 0 kgf m 14 8 ft lb 12 N m 1 2 kgf m 8 9 ft lb 1 2 8 9 11 10 10 7 6 3 5 3 3 3 4 3 3 3 3 3 10 16 17 17 20 17 15 14 13 13 10 12 17 17 17 17 19 18 4 ...

Page 498: ... Muffler 1 19 Water pipe 1 20 Rubber seal 1 20 N m 2 0 kgf m 14 8 ft lb 20 N m 2 0 kgf m 14 8 ft lb 20 N m 2 0 kgf m 14 8 ft lb 12 N m 1 2 kgf m 8 9 ft lb 1 2 8 9 11 10 10 7 6 3 5 3 3 3 4 3 3 3 3 3 10 16 17 17 20 17 15 14 13 13 10 12 17 17 17 17 19 18 4 ...

Page 499: ...st manifold and muffler Replace if corroded or cracked 3 Check the oil pan Replace if corroded or cracked Checking the oil strainer 1 Check the oil strainer Clean if there is dirt or residue Assembling the oil pan and exhaust manifold Do not reuse a gasket always replace it with a new one 1 Install the dowels a and new gaskets b and c onto the exhaust guide d 2 Install the oil strainer a and then ...

Page 500: ...ighten the oil pan bolts g to the specified torque 6 Install the dowels l a new gasket m the plate n a new gasket o and the muffler p and then tighten the muffler bolts q to the specified torque 7 Install the rubber seal r and water pipe s Exhaust manifold bolt k 20 N m 2 0 kgf m 14 8 ft lb Oil pan bolt g 20 N m 2 0 kgf m 14 8 ft lb f g g g g g h g i k k j g Muffler bolt q 20 N m 2 0 kgf m 14 8 ft...

Page 501: ...0 1 2 3 4 5 6 7 8 9 10 A Steering arm No Part name Q ty Remarks 1 Steering arm 1 2 Washer 2 3 Bushing 2 4 O ring 1 39 5 Bushing 1 6 Steering yoke 1 7 Circlip 1 7 6 3 4 2 5 1 2 3 Oil pan and exhaust manifold Steering arm ...

Page 502: ...1 Install the bushing a and washer b and then install the steering arm c 2 Install the bushing d a new O ring e the bushing f and the washer g NOTICE Do not reuse an O ring always replace it with a new one 3 Install the steering yoke h so that the steering arm c and steering yoke h are both facing in the same direction a and b are aligned Needle bearing attachment c 90890 06612 Gear puller d comme...

Page 503: ... arm c and then strike the steering yoke h using a copper hammer until the groove for installing the circlip is visible 5 Install the circlip i 6 Inject grease into the grease nipple on the swivel bracket See Lubricating the outboard motor 10 12 h a b c i h h i c ...

Page 504: ... Tilt stop lever 1 9 Bushing 3 10 Tilt stop lever 1 11 Nut 2 12 Through tube 1 13 Clamp bracket PORT 1 14 Washer 2 15 Bushing 2 16 Ground lead 1 17 Plate screw 4 M6 10 mm 32 33 31 32 31 30 18 17 17 16 30 14 19 20 17 17 21 24 24 25 26 27 28 24 23 25 23 24 23 13 10 9 11 12 1 3 7 6 9 15 14 4 5 8 2 2 29 2 2 2 15 22 23 9 3 N m 0 3 kgf m 2 2 ft lb 4 N m 0 4 kgf m 3 0 ft lb 23 N m 2 3 kgf m 17 0 ft lb 4 ...

Page 505: ...ar 2 24 Pin 2 25 Pin 1 26 Spring 1 27 Hook 1 28 Bolt 1 M6 10 mm 29 Swivel bracket 1 30 Anode 1 31 Plate 2 32 Bolt 4 M6 25 mm 33 Ground lead 1 32 33 31 32 31 30 18 17 17 16 30 14 19 20 17 17 21 24 24 25 26 27 28 24 23 25 23 24 23 13 10 9 11 12 1 3 7 6 9 15 14 4 5 8 2 2 29 2 2 2 15 22 23 9 3 N m 0 3 kgf m 2 2 ft lb 4 N m 0 4 kgf m 3 0 ft lb 23 N m 2 3 kgf m 17 0 ft lb 4 N m 0 4 kgf m 3 0 ft lb ...

Page 506: ...Remove the trim sensor h 6 Remove the spring i hook j and pins k 7 Remove the tilt stop levers l and m distance collar assembly n collar o and bushings p Checking the clamp bracket anode 1 Check the anode Replace if eroded Clean if there is grease oil or scales NOTICE Do not apply grease oil or paint to the anodes Installing the clamp bracket 1 Assemble the distance collar assembly b c d g a f e h...

Page 507: ...n tighten the plate screw l to the specified torque 6 Install the trim stopper m 7 Install the through tube n so that its cutout flat corner d is pointing down 8 Tighten the self locking nut o temporarily 9 Install the anode p and ground lead q 10 Tighten the self locking nut o to the specified torque 11 Install the ground leads r and s and grease nipples t and then tighten the grease nipples to t...

Page 508: ...tilt stop lever a 2 Loosen the trim sensor screws b 3 Adjust the position of trim sensor and then tighten the trim sensor screws b temporarily TIP To decrease the resistance turn the trim sensor cam in direction a To increase the resistance turn the trim sensor cam in direction b 4 Fully tilt the swivel bracket down 5 Measure the trim sensor setting resistance Check that the resistance is within s...

Page 509: ...top lever 7 Tighten the trim sensor screws b to the specified torque Check that the trim sensor resistance is within specification 8 Fully tilt the swivel bracket down Digital circuit tester 90890 03174 Trim sensor setting resistance reference data Terminal c Terminal d 9 0 11 0 Ω Trim sensor screw b 4 N m 0 4 kgf m 3 0 ft lb c c d d ...

Page 510: ...BRKT Bracket unit PTT unit No Part name Q ty Remarks 1 Shaft 1 2 Circlip 1 3 Plastic tie 4 4 Bolt 1 M6 14 mm 5 Holder 1 6 Bushing 4 7 PTT unit 1 8 Bolt 8 M10 45 mm 9 Bolt 1 M6 10 mm 7 6 6 3 5 4 2 1 8 8 8 8 9 ...

Page 511: ...ivel bracket up and then support it using the tilt stop lever a 2 Remove the plastic ties b and holder c 3 Disconnect the ground lead d 4 Remove the circlip e and shaft f 5 Connect the PTT motor leads a to the battery terminals to fully retract the PTT rams 6 Remove the PTT unit g a b b c b b d d Ram PTT motor lead Battery terminal Down Light green Lg Sky blue Sb f e Lg Sb a g ...

Page 512: ...l add the recommended fluid 5 Install the reservoir cap a and then tighten it to the specified torque 6 Loosen the pipe joints b and then remove the pipe joint at the end a 7 Install the special service tool c TIP Place the PTT unit in the drain pan 8 Connect the PTT motor leads to the battery terminals to fully retract the trim rams and then measure the hydraulic pressure when the reading on the ...

Page 513: ...motor leads to the battery terminals to fully extend the trim rams and then measure the hydraulic pressure when the reading on the pressure gauge stabilizes 16 Reverse the PTT motor leads between the battery terminals to fully retract the trim rams Ram PTT motor lead Battery terminal Up Sky blue Sb Light green Lg Pipe joint b 15 N m 1 5 kgf m 11 1 ft lb PTT oil pressure gauge assembly c 90890 0658...

Page 514: ...clockwise to close it 3 Check the fluid level See steps 3 5 in Checking the hydraulic pressure 9 33 4 Connect the PTT motor leads to the battery terminals to fully retract the PTT rams 5 Reverse the PTT motor leads between the battery terminals to fully extend the PTT rams TIP If the PTT rams do not move up and down easily push and pull on the PTT rams to assist operation Ram PTT motor lead Batter...

Page 515: ...s to the bat tery terminals to retract the PTT rams 2 Fully tilt the swivel bracket up and then support it using the tilt stop lever a 3 Install the bushings b to the tilt ram end and swivel bracket and then install the PTT unit c 4 Pass the PTT motor lead a through the hole b in the clamp bracket STBD 5 Connect the PTT motor leads a to the battery terminals to extend the PTT rams 6 Insert the sha...

Page 516: ...9 37 BRKT Bracket unit 7 Connect the ground lead f 8 Fasten the PTT motor lead a and trim sensor lead b using the plastic ties g and then install the holder h d e f f g g h g g a b ...

Page 517: ...r mounting bolt 3 M8 20 mm 9 Joint 1 10 O ring 1 39 11 PTT motor mounting bolt 3 M8 20 mm 12 PTT motor assembly 1 13 Stator 1 14 Bolt 2 M5 12 mm 15 Wave washer 1 16 Bearing 2 39 17 Armature 1 7 N m 0 7 kgf m 5 2 ft lb 19 N m 1 9 kgf m 14 0 ft lb 1 2 3 4 5 6 7 11 11 8 8 8 12 10 9 13 14 14 15 16 16 17 20 20 20 20 19 19 19 19 18 21 22 19 N m 1 9 kgf m 14 0 ft lb PTT unit PTT motor ...

Page 518: ... 18 O ring 1 39 19 Spring 4 20 Brush 4 21 Motor base assembly 1 22 Oil seal 1 39 7 N m 0 7 kgf m 5 2 ft lb 19 N m 1 9 kgf m 14 0 ft lb 1 2 3 4 5 6 7 11 11 8 8 8 12 10 9 13 14 14 15 16 16 17 20 20 20 20 19 19 19 19 18 21 22 19 N m 1 9 kgf m 14 0 ft lb ...

Page 519: ... PTT motor 1 Remove the PTT motor assembly a O ring b and joint c Disassembling the PTT motor 1 Remove the stator a and then remove the armature b NOTICE Secure the end of the armature shaft using a pair of pliers and then remove the arma ture along with the motor base assem bly Otherwise the armature could separate from the motor base assem bly due to the magnetic force of the stator and damage t...

Page 520: ...rmature if below specification 3 Measure the commutator undercut b 4 Check the armature for continuity Replace if out of specifications Checking the brush 1 Measure the length of each brush Replace if below specification Bearing splitter f commercially available Bolt h commercially available M8 15 mm f g g h h f f g b Motor commutator standard diameter 23 0 mm 0 91 in Wear limit 22 0 mm 0 87 in Mo...

Page 521: ...not apply grease or oil to the commu tator of the armature 1 Install a new oil seal a 2 Install the brushes b and springs c 3 Install a new bearing d to the specified depth 4 Install a new bearing e to the specified depth b Motor brush standard length a 11 5 mm 0 45 in Wear limit b 4 5 mm 0 18 in Motor base assembly continuity Terminal c Terminal e Terminal c Terminal g Terminal e Terminal g Termi...

Page 522: ... and sheet c 2 Install a new O ring d and the reservoir e and then tighten the reservoir mounting bolts f to the specified torque 3 Install a new O ring g and the reservoir cap h and then tighten the reservoir cap h to the specified torque Installing the PTT motor 1 Install the joint a Depth b reference data 0 95 mm 0 04 in b e e b b f g Reservoir mounting bolt f 19 N m 1 9 kgf m 14 0 ft lb Reserv...

Page 523: ...e air bubbles using a syringe or suitable tool 5 Install a new O ring b and the PTT motor assembly c and then tighten the PTT motor mounting bolts d to the specified torque NOTICE Do not reuse an O ring always replace it with a new one TIP Align the protrusion b on the armature shaft with the slot c in the joint Recommended PTT fluid ATF DEXRON II PTT motor mounting bolt d 19 N m 1 9 kgf m 14 0 ft...

Page 524: ...9 9 Spring 1 10 Valve support pin 1 11 O ring 1 39 12 Ball 1 13 E clip 2 14 Main valve seal 2 15 Down main valve 1 16 O ring 1 39 17 Spring 2 7 N m 0 7 kgf m 5 2 ft lb 7 N m 0 7 kgf m 5 2 ft lb 1 1 1 2 3 4 5 5 6 7 8 9 10 12 11 13 13 14 14 15 16 17 18 17 19 19 20 21 22 22 23 24 25 25 26 26 27 28 29 27 28 29 30 30 34 31 32 33 32 33 35 36 37 35 36 37 38 39 40 2 N m 0 2 kgf m 1 5 ft lb ...

Page 525: ...ll 2 26 Valve pin 2 27 Spring 2 28 Spacer 2 29 O ring 2 39 30 Pin 2 31 Bracket 1 32 Washer 2 33 Pump bracket bolt 2 M5 25 mm 34 Gear pump assembly 1 7 N m 0 7 kgf m 5 2 ft lb 7 N m 0 7 kgf m 5 2 ft lb 1 1 1 2 3 4 5 5 6 7 8 9 10 12 11 13 13 14 14 15 16 17 18 17 19 19 20 21 22 22 23 24 25 25 26 26 27 28 29 27 28 29 30 30 34 31 32 33 32 33 35 36 37 35 36 37 38 39 40 2 N m 0 2 kgf m 1 5 ft lb ...

Page 526: ... 38 O ring 1 39 39 Manual valve 1 40 Circlip 1 7 N m 0 7 kgf m 5 2 ft lb 7 N m 0 7 kgf m 5 2 ft lb 1 1 1 2 3 4 5 5 6 7 8 9 10 12 11 13 13 14 14 15 16 17 18 17 19 19 20 21 22 22 23 24 25 25 26 26 27 28 29 27 28 29 30 30 34 31 32 33 32 33 35 36 37 35 36 37 38 39 40 2 N m 0 2 kgf m 1 5 ft lb ...

Page 527: ...h a and screw height b 4 Remove the bracket k and then remove the filter l spacers m springs n valve pins o and balls p and q 5 Remove the gear housing c and then remove the springs r down main valve s and up main valve t 6 Remove the drive gear d driven gear e balls u and pins v Checking the gear pump 1 Check the drive gear a and driven gear b Replace the gear pump assembly if damaged or worn 2 C...

Page 528: ...wn main valve b up main valve c springs d and pins e 3 Install the balls f and the gear housing c 4 Install the balls g the valve pins h the springs i the spacers j and new O rings k 5 Install the balls l and manual release plate m 6 Install the bracket n and then tighten the pump bracket bolts o temporarily 7 Check that the gear pump turns smoothly and then tighten the pump bracket bolts o to the...

Page 529: ...seal z and plate E and then tighten the gear pump bolts F to the specified torque 14 Install a new O ring G the manual valve H and the circlip I and then tighten the manual valve H to the specified torque 15 Install the PTT motor See Installing the PTT motor 9 43 16 Check the hydraulic pressure See Checking the hydraulic pressure 9 33 TIP If the hydraulic pressure is out of specifica tion adjust t...

Page 530: ...1 Backup ring 1 12 Tilt ram assembly 1 13 Free piston 1 14 O ring 1 39 15 Tilt cylinder 1 16 Tilt cylinder assembly 1 17 Bushing 2 65 N m 6 5 kgf m 47 9 ft lb 90 N m 9 0 kgf m 66 4 ft lb 15 N m 1 5 kgf m 11 1 ft lb 20 N m 2 0 kgf m 14 8 ft lb 1 2 3 4 5 6 7 8 10 11 9 12 13 14 15 16 17 17 24 25 26 27 20 21 22 23 19 28 29 31 32 33 30 18 9 9 9 7 N m 0 7 kgf m 5 2 ft lb 160 N m 16 0 kgf m 118 0 ft lb 1...

Page 531: ... end screw 2 27 O ring 2 39 28 Circlip 1 29 Shaft 1 30 Spacer 1 31 O ring 1 39 32 Pipe joint adapter 1 33 Pipe 1 65 N m 6 5 kgf m 47 9 ft lb 90 N m 9 0 kgf m 66 4 ft lb 15 N m 1 5 kgf m 11 1 ft lb 20 N m 2 0 kgf m 14 8 ft lb 1 2 3 4 5 6 7 8 10 11 9 12 13 14 15 16 17 17 24 25 26 27 20 21 22 23 19 28 29 31 32 33 30 18 9 9 9 7 N m 0 7 kgf m 5 2 ft lb 160 N m 16 0 kgf m 118 0 ft lb 15 N m 1 5 kgf m 11...

Page 532: ...ssembly 4 Drain the PTT fluid 5 Cover the tilt cylinder opening with a rag i and then blow compressed air through the hole a to remove the free piston j WARNING When removing the free piston never look into the tilt cylinder opening because the free piston and PTT fluid could be expelled forcefully Removing the trim ram 1 Loosen the trim cylinder end screws a and then remove the trim ram assem bli...

Page 533: ...atched 3 Check the tilt piston b trim pistons c free piston b and dust seals c and d of tilt cylinder end screw e and trim cylinder end screws f Replace if scratched 4 Check the trim rams d and tilt ram e Clean using 400 600 grit sandpaper if there is rust or replace if bent or corroded 5 Check the pipes g and h Replace if corroded or cracked Checking the valve 1 Check the tilt piston absorber val...

Page 534: ...er end screw e spring f adapter g and tilt piston h 3 Tighten the tilt ram a to the specified torque 4 Install a new O ring k and the backup ring l 5 Install the balls m absorber valve pins b and springs c 6 Install the washers d plate e washer f and tilt piston screw g and then tighten the tilt piston screw g to the specified torque a a a a b a a e d b c d e c h g e f PTT piston vice attachment i...

Page 535: ...get on the PTT unit components causing poor performance Do not reuse an O ring always replace it with a new one 1 Install a new O ring a to the free piston b 2 Push the free piston b into the tilt cylinder c until it bottoms out 3 Install the tilt cylinder c 4 Install a new O ring d and the pipe joint adapter e and then tighten the pipe joint adapter e to the specified torque 5 Install the pipes f...

Page 536: ...at the bottom of the tilt ram assembly 2 Fill the tilt cylinder with the recommended fluid up to the proper level a 3 Add a small amount of the recommended fluid through the PTT body hole b 4 Install the tilt piston assembly into the tilt cylinder and then tighten the tilt cylinder end screw a to the specified torque Cylinder end screw wrench b 90890 06568 Trim cylinder end screw a 160 N m 16 0 kg...

Page 537: ...9 58 PTT cylinder 0 1 2 3 4 5 6 7 8 9 10 A MEMO ...

Page 538: ...10 6 Test run 10 6 Break in 10 7 After test run 10 7 General periodic maintenance 10 7 Checking the anode 10 7 Checking the battery 10 7 Checking the cooling water passage 10 7 Checking the engine idle speed 10 8 Changing the engine oil 10 8 Checking the engine oil level 10 9 Replacing the oil filter 10 9 Checking the engine start switch and engine shut off switch single outboard motor application...

Page 539: ...0 1 2 3 4 6 6 7 8 9 10 A Checking the top cowling 10 14 Checking the valve clearance 10 14 Checking the water pump 10 14 ...

Page 540: ...reater owner satisfaction The maintenance cycle on these charts is based on usage of 100 hours per year and regular flushing of the cooling water passages Adjust the maintenance frequency when operating the engine under adverse conditions such as extended trolling Disassembly or repairs may be necessary depending on the outcome of maintenance checks Expendable or consumable parts and lubricants wi...

Page 541: ...opeller Propeller nut Cotter pin Check Replace U U 8 3 Spark plugs Check Replace U 7 48 Ignition coils Ignition coil leads Check Replace U U 5 46 Pilot water Check U U 10 3 Thermostat Check Replace U 7 72 Timing belt Check Replace U 7 39 Valve clearance Check Adjust U 7 2 7 4 Water inlet Check U U 10 7 Engine start switch Main switch Engine start stop button Engine shut off switch Check Replace U ...

Page 542: ...re sparks or open flames for example welding equipment and lighted cigarettes DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 1 Check the battery electrolyte level If the level is at or below the minimum level mark a add distilled water until the level is between the maximum and minimum level marks 2 Check the specific gravity of the electr...

Page 543: ...Digital Electronic Control Check the SPS output voltage shift request LPS output voltage and throttle request that are displayed on the YDIS engine monitor 1 Move the control lever to the F N and R positions to check the SPS output volt age and shift request in each position 2 Move the control lever to the F fully open position F position N position R posi tion and R fully open position and then c...

Page 544: ...e engine Check that the engine stops when the engine start stop buttons b are pushed 4 Check that the engine stops when the clip c is removed from the engine shut off switch d Checking the fuel system 1 Check that the fuel hoses are connected securely To check the fuel hose connec tions see Fuel hose and blowby hose 6 1 NOTICE This outboard motor is equipped with a 4 stroke engine Never use pre mi...

Page 545: ...mp brackets are secured using the clamp bolts Checking the PTT system 1 Check that the outboard motor tilts up and down smoothly when the PTT switch is pushed 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 cables hoses or leads when the tilted up outboard motor is steered 4 Check that the trim meter points do...

Page 546: ...lush the cooling water passages using fresh water NOTICE When flushing the cooling water passages do not start the engine Otherwise the water pump could be damaged and the engine could be severely damaged due to overheat TIP When using the flushing device flushing hose joint adapter flush the cooling water passages without starting the engine General periodic maintenance Checking the anode Do not ...

Page 547: ...r the YDIS To connect and operate the YDIS see the YDIS Ver 1 33 or later instruction manual Changing the engine oil The engine oil should be extracted using an oil changer Change the engine oil after the first 20 hours of operation or 3 months and every 100 hours or at 1 year intervals thereafter 1 Place the outboard motor in an upright position NOTICE If the outboard motor is not level the oil l...

Page 548: ...ressure alert indicator does not come on Also check that there is no oil leakage NOTICE If the oil pressure alert indicator comes on or if there is oil leakage stop the engine and find the cause Continued operation with a problem could cause severe engine damage Checking the engine oil level 1 Check the engine oil level See Check ing the engine oil level 10 4 Replacing the oil filter 1 Extract the...

Page 549: ...ard motor application 1 Check the engine start stop button and engine shut off switch See Checking the engine start stop button and engine shut off switch twin or triple outboard motor application 10 5 Checking the fuel filter 1 Check the fuel filter See Checking the fuel filter element 6 12 Checking the fuel system for fuel leakage 1 Check the fuel joint and fuel hose con nections See Fuel hose a...

Page 550: ...right position 7 Insert the gear oil pump into the drain hole and then fill the lower unit slowly with gear oil until oil flows out of the check hole and no air bubbles are visible 8 Install a new gasket f and the check screw d and then tighten the check screw d to the specified torque 9 Remove the gear oil pump install a new gasket g and the drain screw b and then tighten the drain screw b to the...

Page 551: ...Checking the gear oil level 10 5 Replacing the OCV filter 1 Remove the OCV assemblies 2 Replace the OCV filter a of each OCV assembly 3 Install the OCV assemblies Lubricating the outboard motor 1 Apply water resistant grease to the spec ified lubrication points Water inlet cover bolt h 2 N m 0 2 kgf m 1 5 ft lb a a h a ...

Page 552: ...heck the fluid level in the reservoir WARNING Before removing the reservoir cap make sure that the PTT rams are fully extended Otherwise fluid could be expelled forcefully from the unit due to internal pressure TIP If the fluid is at the proper level a small amount of fluid should flow out of the filler hole when the reservoir cap is removed 3 If the fluid is below the proper level add the recomme...

Page 553: ...belt 7 37 Checking the thermostat 1 Check the thermostat See Checking the thermostat 7 72 Checking the top cowling 1 Check the fitting by pushing the top cowl ing Adjust if there is free play 2 Loosen the nut a 3 Move the stopper b up or down slightly to adjust its position TIP To loosen the fitting move the stopper b in direction a To tighten the fitting move the stopper b in direction b 4 Tighte...

Page 554: ...cowling 5 8 5 16 Bracket unit 1 5 1 28 Bracket unit technical data 1 25 Break in 10 7 C Calculated value B table 8 46 8 88 Camshaft 7 42 Canister 6 25 Changing the engine oil 10 8 Changing the gear oil 10 10 Charging system 1 14 2 18 Charging unit and starting unit A 9 Charging units and component 5 40 Checking the air pressure sensor 5 49 Checking the air temperature sensor 5 48 Checking the anod...

Page 555: ...6 30 Checking the low pressure fuel pump and high pressure fuel pump 5 37 Checking the magnet switch 5 58 Checking the main relay 5 22 Checking the main wiring harness 5 65 Checking the OCV 5 32 Checking the oil cooler 7 67 Checking the oil cooler anode 7 67 Checking the oil pan and exhaust manifold 9 20 Checking the oil pressure 7 1 Checking the oil pressure sensor 5 33 Checking the oil pump asse...

Page 556: ... 78 Disassembling the forward gear 8 24 8 73 Disassembling the fuel filter assembly 6 12 Disassembling the gear pump housing 9 48 Disassembling the lower case 8 25 8 78 Disassembling the oil pan and exhaust manifold 9 20 Disassembling the oil pump assembly 7 66 Disassembling the oil seal housing 8 23 8 78 Disassembling the propeller 8 3 8 8 8 64 8 67 Disassembling the propeller shaft assembly 8 17...

Page 557: ...ing the drive shaft 8 28 8 79 Installing the engine ECM 7 33 Installing the flushing hose 9 5 Installing the flywheel magnet 7 15 Installing the fuel filter assembly 6 12 Installing the fuel injector 6 44 Installing the intake manifold 6 16 Installing the intake silencer 6 18 Installing the isolator lead 3 10 Installing the junction box 7 28 Installing the knock sensor 7 73 Installing the lower un...

Page 558: ...h before disassembly 8 39 8 84 Measuring the fuel pressure 6 7 Measuring the peak voltage 5 21 Measuring the reverse gear backlash 8 57 8 95 Model data 1 3 Model designation 1 2 Model features 1 1 N Non reusable part 0 3 O Oil cooler 2 25 Oil cooler and oil pump assembly 7 63 Oil pan and exhaust manifold 9 18 Optional equipment 3 10 Outboard motor and Digital Electronic Control connection 5 65 Out...

Page 559: ...ilt ram 9 53 Removing the timing belt 7 38 Removing the trim ram 9 53 Removing the upper case 9 12 Removing the vapor separator 6 35 Removing the water pump and shift rod 8 11 8 70 Removing the wiring harness 7 18 Replacing the OCV filter 10 12 Replacing the oil filter 10 9 Replacing the timing belt 10 14 Replacing the valve guide 7 57 Reverse gear shim T1 selection table 8 97 Reverse gear shim T2...

Page 560: ...ion 3 23 U Uncrating procedure 3 5 Upper case 9 15 Upper case and mount 9 10 Using the digital tester 5 22 Using the YDIS 5 21 V Vapor gas hose 6 2 Vapor separator 6 33 Vapor separator and high pressure fuel pump 6 37 VCT control 2 10 VCT system 1 12 Ventilation 0 1 W Water pump and shift rod counter rotation model 8 68 Water pump and shift rod regular rotation model 8 9 Wiring harness 7 17 Wiring...

Page 561: ...0 1 2 3 5 6 7 8 9 10 10 10 A Appendix A Wiring diagram A 2 How to use the wiring diagram A 2 Engine control unit A 3 Fuel unit A 5 Ignition unit A 7 Charging unit and starting unit A 9 PTT unit A 11 ...

Page 562: ...A 1 MEMO ...

Page 563: ...rt buzzer e Optional parts Color code a b c d e BZ B Black B Br Black Brown B G Black Green B L Black Blue B O Black Orange B W Black White B Y Black Yellow Br Brown G Green G B Green Black G R Green Red L Blue L B Blue Black L G Blue Green L W Blue White Lg Light green O Orange P Pink P G Pink Green P W Pink White Pu Purple Pu B Purple Black Pu G Purple Black Pu G Purple Green Pu L Purple Blue Pu...

Page 564: ... PTT switch Digital Electronic Control ECM high pressure fuel pump h Fuse 100 A engine battery k Fuse 100 A house accessory battery m Starter motor relay n Fuel pump relay high pressure p ETV motor relay r Shift actuator relay s Main relay t Fuse 100 A house accessory battery optional u Condenser connect to cam position sensor v Condenser connect to cam position sensor A To Digital Electronic Cont...

Page 565: ......

Page 566: ...May 2010 1 ABE E_1 YAMAHA MOTOR CO LTD ...

Page 567: ... R Y R G R G R G R G W W O O O O O B W B W B R G R G R G R G P P Pu Pu Y L L L B B B B B B B B B B B B B B P W P W P W R Y R Y G R G R G B G B Y G Y G Y G Y G W G W L P O O Pu B B B P W W B R Y R Y G R G B O B P W P O B P W G R G B B W B R Y Pu R Y B W G R Y B B W L O B L B L O B Br B B B B B B B B B B B B B B B B B B B B B B B B L B W W L L O O O O O R R Y G R Br R R Y B B B R B B B B B B B B R W...

Page 568: ...e fuel pump g Fuse 20 A engine start switch PTT switch Digital Electronic Control ECM high pressure fuel pump h Fuse 100 A engine battery k Fuse 100 A house accessory battery m Starter motor relay n Fuel pump relay high pressure p ETV motor relay r Shift actuator relay s Main relay t Fuse 100 A house accessory battery optional A To Digital Electronic Control B To 6Y9 Multifunction Color Gauge hub ...

Page 569: ... Pu Y L W L W W W Y L L Y G Y G R Y R Y Pu W B B B B B B B G B W W L L R R R Y B B B B B B B B B B B B B B B B Pu G Pu R Pu B Pu L Pu W Pu Y L W L W R Y R Y R Y R Y R Y R Y R Y R Y R Y G B R Y R Y R Y R Y R Y R Y R Y B B R R R R R Y G R Y R Y R Y R Y R Y R Y R R Y G R B B B R W W Y G P Br B Y R R W Br B B G R B B Y B B B B Engine ECM Fuel injector Low pressure fuel pump Joint connector 3 Joint con...

Page 570: ...A engine start switch PTT switch Digital Electronic Control ECM high pressure fuel pump h Fuse 100 A engine battery k Fuse 100 A house accessory battery m Starter motor relay n Fuel pump relay high pressure p ETV motor relay r Shift actuator relay s Main relay t Fuse 100 A house accessory battery optional u Condenser connect to the air pressure sensor A To Digital Electronic Control B To 6Y9 Multi...

Page 571: ... B B B B B B B G B L B W B O B Br R Y Br Y W L W W L G O Y G W R B Y B Y B Y B B R Y O P G B B O P G B W R B B Y P G B L B G B W B O R Y R Y R Y B B Y B B B R Y B R Y B R Y B B Y B B Br P B B B B B B B O R Y R Y R Y R Y R Y R Y R Y R Y B B B B B B P P P O B B B B B B R Y R Y R R R B B B R R R R R W Y L B B B W Br R W W Y G P Br B Y R R W Br B B G R B B Y B B B Engine ECM Air pressure sensor Pulser...

Page 572: ...0 A low pressure fuel pump g Fuse 20 A engine start switch PTT switch Digital Electronic Control ECM high pressure fuel pump h Fuse 100 A engine battery k Fuse 100 A house accessory battery m Starter motor relay n Fuel pump relay high pressure p ETV motor relay r Shift actuator relay s Main relay t Fuse 100 A house accessory battery A To Digital Electronic Control B To 6Y9 Multifunction Color Gaug...

Page 573: ... m n p r 1 11 10 23 1 7 6 14 86 B B B W W L L R R Y B B B R R W W Y G G G G G G G G G G G G G P Br B Y R R W Br B B G R B B Y R R Br B B B B B B B B B B B B B B R R R R Y G Y G R Y R Y R Y B B Y G Y G R Y R Y R R R R R R R R R R R R R R B W W L L L G L G L G B 2 AC 1 AC 1 AC 1 AC 2 AC 2 AC 2 1 2 1 AC 2 Engine ECM Joint connector 3 Starter motor Lighting coil Rectifier Regulator Engine start switch...

Page 574: ...use 20 A engine start switch PTT switch Digital Electronic Control ECM high pressure fuel pump h Fuse 100 A engine battery k Fuse 100 A house accessory battery m Starter motor relay n Fuel pump relay high pressure p ETV motor relay r Shift actuator relay s Main relay t Fuse 100 A house accessory battery optional u Diode connect to PTT relay A To Digital Electronic Control B To 6Y9 Multifunction Co...

Page 575: ...3 8 12 a b c d e f s g h k m n p r 1 11 10 23 86 77 12 1 7 6 14 B B B B R W W Y Y G P P Br B Y R R W Br B B G R B B B B B Y Sb Sb Sb Lg Lg Lg Sb Sb Sb Lg Lg R R W W L L R R R R R Y G Y G Y G Y G R Y R Y R Y R Lg Lg R Y R Y Sb Sb R R B B B B B B B W W L L R R Y B B B R R Y P B B B B R Sb Lg R R R R R Lg R B B B B Engine ECM Joint connector 3 PTT relay Engine start switch OFF ON START SET PULL House...

Page 576: ...A 13 ...

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