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Yamaha F30A 2018, Service Manual

The Yamaha F30A 2018 is a powerful and reliable outboard motor designed for boating enthusiasts. To ensure optimal performance and maintenance, a comprehensive Service Manual is available for free download on manualshive.com. This manual provides step-by-step instructions and valuable insights, allowing users to keep their Yamaha F30A 2018 in top-notch condition.

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4-4

Outboard motor troubleshooting

Trouble code table

✔

: Indicated

—: Not indicated

Code No.

Item

YDIS diagnosis

YDIS diagnosis 

record

15

Thermo sensor

✔

✔

18

TPS

✔

✔

19

Battery voltage

✔

✔

23

Air temperature sensor

✔

✔

27

Water in fuel filter

✔

✔

28

Shift position switch

✔

✔

29

Air pressure sensor

✔

✔

37

Intake air passage

✔

✔

44

Engine shut-off switch

✔

—

49

Over cooling

✔

✔

86

Immobilizer

✔

✔

Summary of Contents for F30A 2018

Page 1: ...6BG 28197 ZX 11 LIT 18616 03 84 USA CAN AUS and NZL Worldwide 6BG 6BT 6BG 6BT ...

Page 2: ...p to date parts information is available on YMBS Yamaha Marine Business System USA only or YPEC web except USA Additional information and up to date information on Yamaha products and services are available on YMBS YMPE Yamaha Multimedia Product Ency clopedia Canada only or Yamaha Service Portal except USA and Canada Important information Particularly important information is distinguished in this...

Page 3: ... 8 6 7 0 10 A Contents General information Specification Technical feature and description Rigging information Troubleshooting Electrical system Fuel system Power unit Lower unit Bracket unit Maintenance Appendix ...

Page 4: ...ing of gas torch 0 5 Parts lubricants and sealants 0 5 Handling of lubricants and sealants 0 5 Special service tools 0 6 Tightening torque 0 6 Non reusable parts 0 6 Disassembly and assembly 0 6 Disposal of used components and chemicals 0 6 How to use this manual 0 7 Manual format 0 7 Conditions when testing and adjusting 0 8 Abbreviation 0 8 Color code 0 8 Specified tightening torque 0 9 General ...

Page 5: ...F40FET Model name Approved model code Starting serial No F30EHA 6BTK 1000001 F30HA F30A F40EHA 6BGK 1000001 F40HA F40A 1 Model category F 4 stroke 2 Output horsepower 30 40 3 Model generation B F 4 Model variation Level 1 Starting method E Electric start Level 2 Control method None Remote control without tiller handle H Tiller handle Level 3 Trim and tilt method D Hydraulic tilt T PT T Power trim ...

Page 6: ...category F 4 stroke 2 Horsepower 30 40 3 Motor transom height S 15 in L 20 in 4 Starting method PTT Blank PTT and E start E Electric start 5 Control method Blank Remote control H Tiller handle 6 Generation A 1st change on motor 2 1 3 4 5 6 F 40 L E H A ...

Page 7: ...ction control ISC Idle Speed Control Over revolution control Fail safe Self diagnosis system with YDIS 1 33 and later versions Alert systems including low oil pressure overheat and water detection High generator output maximum 17 A Y COP acceptable optional Variable troll speed control 650 900 r min Conventional gauge 6Y5 6Y7 or 6Y8 6YC Multifunction Meters acceptable Speed sensor optional Water p...

Page 8: ... not hold the propeller with your hands when loosening or tightening the propeller nut Sharp propeller edges can cause injury Place a wood block between gear case and propeller to hold the propeller for removal and installa tion Handling of gasoline Gasoline is highly flammable Keep gasoline and all flammable products away from heat sparks and open flames Gasoline is poisonous and can cause injury...

Page 9: ...see the operation man ual issued by the manufacturer When using a gas torch keep it away from gasoline and oil to prevent a fire Components become hot enough to cause burns Do not touch any hot components di rectly Parts lubricants and sealants Use only genuine Yamaha parts lubricants and sealants or those recommended by Ya maha when servicing or repairing the out board motor Failures caused by th...

Page 10: ... ports to prevent foreign materials from entering the engine Foreign materials could cause severe inter nal damage when the engine is started Install bearings so that the bearing identifica tion mark is facing in the direction indicated in the installation procedure In addition make sure to lubricate the bearings liberally Apply a thin coat of water resistant grease to the lip and periphery of an ...

Page 11: ...ter 4 Troubleshooting 7 25 Cylinder head Cylinder head 2 1 1 1 3 6 15 16 16 14 11 4 10 8 7 7 13 12 9 9 9 5 6 N m 0 6 kgf m 4 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft 90 17 N m 1 7 kgf m 13 lb ft 34 N m 3 4 kgf m 25 lb ft New New New Part name Q ty Remarks 1 Bolt M6 45 mm 4 2 Oil pump assembly 1 3 Gasket 1 4 Bolt M6 20 mm 7 5 Cylinder head cover 1 6 Gasket 1 7 Screw M4 10 mm 4 8 Plate 1 9 Grommet 5 10 Oi...

Page 12: ...rottle valve at WOT depending on model specification Trim tilt angles shown are when the transom angle is 12 degrees Abbreviation The following abbreviations are used in this service manual Color code TIP For example R Y stands for a Red with Yellow tracer stripe wire Abbreviation Description ECM Electronic Control Module ISC Idle Speed Control PTT Power Trim and Tilt TPS Throttle Position Sensor ...

Page 13: ...ightening these fasteners follow the tightening torque specifications and procedures indicated throughout the manual to meet the design aims of the outboard motor General tightening torque This chart indicates the tightening torques for standard fasteners with a standard ISO thread pitch Width across flats A Thread size B General torque specifications N m kgf m lb ft 8 mm M5 5 0 5 3 7 10 mm M6 8 0...

Page 14: ...arance Engine speed Electrical data Replace the part with a new one Symbol Name Application YAMALUBE 4 or YAMALUBE 4M FC W Lubricant YAMALUBE outboard gear oil or Yamalube Ma rine Gearcase Lube Lubricant Water resistant grease Yamaha grease A or Yamalube Marine Grease Lubricant Low temperature resistant grease Yamaha grease C or Yamalube Molybdenum Disulfide grease Lubricant Corrosion resistant gr...

Page 15: ...0 11 Symbol ThreeBond 1377B Thread locking agent ThreeBond 1901 Lubricant LOCTITE 242 blue Thread locking agent LOCTITE 271 red Thread locking agent LOCTITE 572 white Sealant Symbol Name Application ...

Page 16: ...k voltage adapter B 90890 03172 Test harness FWY 6 90890 06872 Vacuum pressure pump gauge set 90890 06945 Test harness 3 pins 90890 06870 Test harness FW13613 2 90890 06887 Ignition checker Spark gap tester 90890 06754 Test harness SM6195043 90890 06861 Test harness 3 pins 90890 06869 Test harness 2 pins 90890 06867 Fuel pressure gauge adapter 90890 06946 Fuel pressure gauge 90890 06753 Leakage te...

Page 17: ...cutter 60 90890 06323 Valve seat cutter 30 90890 06328 Valve seat cutter 45 90890 06325 Valve seat cutter 60 90890 06315 Driver rod LS 90890 06606 Bearing outer race at tachment 90890 06626 Oil filter wrench 90890 01426 Piston slider 90890 06529 Stopper guide plate 90890 06501 Bearing separator 90890 06534 Bearing puller assem bly 90890 06535 Stopper guide stand 90890 06538 Driver rod L3 90890 066...

Page 18: ...er race at tachment 90890 06627 Bearing inner race at tachment 90890 06644 Ball bearing attach ment 90890 06634 Shift rod socket 90890 06681 Bearing housing puller claw L 90890 06502 Center bolt 90890 06504 Backlash indicator 90890 06706 Magnet base plate 90890 07003 Dial gauge set 90890 03238 Magnet base B 90890 06844 Pinion height gauge 90890 06668 Pinion Gear Bushing Installer 90890 06601 Needl...

Page 19: ... Test harness 3 pins YB 06869 Test harness 2 pins YB 06867 Fuel pressure gauge adapter YB 06946 Fuel pressure gauge YU 03153M Combination compres sion gauge and cylin der leakdown test kit YB 45544 A Flywheel magneto holder YB 06139 Universal Puller YB 06117 Crankshaft holder YW 06355 Valve spring compres sor YM 04019 Valve spring compres sor adaptor YB 06320 Valve guide remover YB 06801 Valve gui...

Page 20: ...installer YB 06111 Oil seal installer YB 06168 Bearing inner race at tachment YB 06639 Bearing cup installer YB 06167 Driveshaft holder YB 06079 Pinion nut holder YB 06715 Bearing splitter plate YB 06219 Roller bearing installer remover YB 06432 Driveshaft needle bearing remover and installer YB 06063 Forward gear bearing installer YB 06270 A Forward gear outer race installer YB 41446 Bearing inne...

Page 21: ...rod YB 06265 Backlash adjustment plate YB 07003 Dial indicator gauge YU 03097 Magnetic base stand YU A8438 Pinion height gauge YB 06668 Reverse gear bearing remover YB 41707 Pinion gear bushing in staller YB 06029 4 Driveshaft needle bearing installer and remover YB 06196 Trim cylinder wrench YB 06175 2B ...

Page 22: ...1 Specification Specification data 1 1 External dimensions 1 1 Clamp bracket dimensions 1 9 ...

Page 23: ...1 1 Specification data Specification data For specification data see Appendix Specification A 1 External dimensions TIP The dimension values may include reference values ...

Page 24: ...y tilt up angle Not tilt support angle 364 14 3 mm in 4 0 3 12 192 7 6 342 13 5 779 30 7 235 9 3 178 7 0 583 23 0 65 2 6 175 6 9 19 0 7 304 12 0 43 1 7 43 1 7 522 20 6 695 27 4 128 5 0 654 25 7 471 18 5 770 30 3 H 1 29 1 1 660 26 0 879 34 6 536 21 1 66 2 6 923 36 3 65 2 ...

Page 25: ...t up angle Not tilt support angle 364 14 3 mm in 4 0 3 12 192 7 6 345 13 6 925 36 4 779 30 7 235 9 3 177 7 0 583 23 0 65 2 6 175 6 9 536 21 1 19 0 7 306 12 0 43 1 7 44 1 7 29 1 1 522 20 6 66 2 6 695 27 4 879 34 6 128 5 0 654 25 7 471 18 5 667 26 3 770 30 3 H 1 66 2 ...

Page 26: ...ot tilt support angle 364 14 3 4 0 3 12 192 7 6 345 13 6 134 5 3 583 23 0 65 2 6 175 6 9 19 0 7 306 12 0 43 1 7 14 0 6 158 6 2 522 20 6 L 29 1 1 S 0 0 L 66 2 6 S 77 3 0 L 667 26 3 S 606 23 9 L 879 34 6 S 757 29 8 695 27 4 471 18 5 L 536 21 1 S 414 16 3 L 924 36 4 S 817 32 2 H 1 66 2 ...

Page 27: ...le 364 14 3 4 0 3 12 65 2 192 7 6 342 13 5 779 30 7 235 9 3 178 7 0 583 23 0 65 2 6 175 6 9 19 0 7 304 12 0 43 1 7 43 1 7 522 20 6 695 27 4 128 5 0 654 25 7 471 18 5 770 30 3 H 1 L 29 1 1 L 660 26 0 S 594 23 4 L 879 34 6 S 757 29 8 S 0 0 L 536 21 1 S 414 16 3 L 66 2 6 S 77 3 0 L 923 36 3 S 816 32 1 mm in ...

Page 28: ...t up angle Not tilt support angle 364 14 3 4 0 3 12 192 7 6 345 13 6 925 36 4 779 30 7 235 9 3 177 7 0 583 23 0 65 2 6 175 6 9 536 21 1 19 0 7 306 12 0 43 1 7 44 1 7 29 1 1 522 20 6 66 2 6 695 27 4 879 34 6 128 5 0 654 25 7 471 18 5 667 26 3 770 30 3 H 1 mm in 66 2 ...

Page 29: ...lt support angle 65 2 364 14 3 4 0 3 H 1 12 192 7 6 342 13 5 134 5 3 583 23 0 65 2 6 175 6 9 19 0 7 304 12 0 43 1 7 15 0 6 158 6 2 L 29 1 1 522 20 6 L 660 26 0 S 594 23 4 L 879 34 6 S 757 29 8 S 0 0 695 27 4 471 18 5 L 536 21 1 S 414 16 3 L 66 2 6 S 77 3 0 L 923 36 3 S 816 32 1 mm in ...

Page 30: ...tilt support angle L 29 1 1 S 0 0 364 14 3 4 0 3 12 192 7 6 345 13 6 134 5 3 583 23 0 65 2 6 175 6 9 19 0 7 306 12 0 43 1 7 14 0 6 158 6 2 522 20 6 L 667 26 3 S 606 23 9 L 879 34 6 S 757 29 8 695 27 4 471 18 5 L 536 21 1 S 414 16 3 L 924 36 4 S 817 32 2 H 1 66 2 mm in L 66 2 6 S 77 3 0 ...

Page 31: ... dimensions Clamp bracket dimensions TIP The dimension values may include reference values 254 10 0 13 0 5 69 2 7 50 8 2 0 18 5 0 7 13 0 5 180 7 1 163 5 6 4 55 5 2 2 338 13 3 163 5 6 4 125 9 5 0 125 9 5 0 180 7 1 mm in ...

Page 32: ...ine ECM 2 7 Intake silencer 2 7 Fuel system 2 8 Fuel diagram 2 8 Lubrication system 2 10 Lubrication diagram 2 10 Cooling system 2 12 Cooling diagram 2 12 Intake and exhaust system 2 14 Intake and exhaust diagram 2 14 Hose routing 2 15 Fuel hose 2 15 Vapor gas hose and blowby hose 2 16 Cooling water hose 2 17 ...

Page 33: ...to check trouble codes on the YDIS It is also equipped with Y COP as an anti theft measure optional 8 Ignition coil 16 Engine ECM 1 Pulser coil 14 Intake air pressure sensor 15 Intake air temperature sensor 2 Oil pressure switch 3 Thermo sensor 4 Shift position switch 21 Battery 23 Ignition control 22 Fuel injection control 20 Multi hub 19 Y COP 1 18 6Y8 6YC Multifunction Meters 5 Water detection ...

Page 34: ...essure sensor 1 7 Speed sensor 1 8 Ignition coil 9 Fuel injector 10 Vapor shut off valve 11 High pressure fuel pump 12 ISC valve 13 TPS 14 Intake air pressure sensor 15 Intake air temperature sensor 16 Engine ECM 17 YDIS 18 6Y8 6YC Multifunction Meters 19 Y COP 1 20 Multi hub 21 Battery 22 Fuel injection control 23 Ignition control 24 ISC valve control ...

Page 35: ...2 3 Electronic control system Electrical components 3 4 5 6 7 8 9 10 11 1 2 ...

Page 36: ... signals to each actuator 6 Vapor shut off valve Controls the amount of vapor gas that is sent from the VST to the intake system to be reburned 7 Throttle body TPS Detects the throttle valve opening angle Intake air pressure sensor Detects the intake air pressure Intake air temperature sensor Detects the intake air temperature ISC valve Adjusts the intake air distribution to the engine when the th...

Page 37: ...3 Intake air tempera ture sensor Open or short circuit in the in take air temperature sensor circuit Output voltage is 0 4 V or less or 4 8 V or more Set to 40 C 104 F High engine idle speed 27 Water in fuel filter The shift position switch is on and the water detection switch is on The alert buzzer sounds 28 Shift position switch Cranking while in gear Cranking while the shift posi tion switch ci...

Page 38: ... r min or more for 2 minutes or more ECM does not control 86 Immobilizer Open or short circuit in the Y COP circuit Communication error contin ues for more than 3 seconds The engine starts but the en gine speed is limited to less than 2600 r min Trouble code Item Trouble conditions to be detect ed Control and operation ...

Page 39: ...ped based on the F40F engine The approved model codes a identify each engine ECM Intake silencer The intake silencer comes in shapes suitable for the intake air volume of each model Model name Approved model code a F30B 6BT F40F 6BG 6BT EC1302 8125 a A B A F30B B F40F ...

Page 40: ... system Fuel system Fuel diagram 2 Primer pump 11 Fuel rail 12 Fuel injector 4 Low pressure fuel pump 3 Fuel filter 15 Fuel cooler 6 Vapor separator 5 Fuel strainer 16 Vapor shut off valve 10 Pressure regulator ...

Page 41: ...el cooler 16 Vapor shut off valve 14 Combustion chamber 2 14 Combustion chamber 1 12 Fuel injector 2 12 Fuel injector 1 284kPa 2 84kgf cm2 41 2 psi 1 Fuel tank 2 Primer pump 3 Fuel filter Water separator 4 Low pressure fuel pump 5 Fuel strainer 6 Vapor separator 7 Float chamber 8 Filter 9 High pressure fuel pump 10 Pressure regulator 11 Fuel rail 12 Fuel injector 13 Intake port 14 Combustion chamb...

Page 42: ...pan 10 Sleeve 14 Intake and exhaust valves 9 Piston 13 Rocker arm 3 Oil pump 3 Oil pump 4 Oil filter 4 Oil filter 5 Main gallery 6 Oil pressure switch 2 Oil strainer 2 Oil strainer 15 Relief valve 8 Crankshaft pin 12 Rocker arm shaft 11 Camshaft journal 7 Crankshaft journal 441 kPa 4 41 kgf cm2 63 9 psi ...

Page 43: ...trainer 3 Oil pump 4 Oil filter 5 Main gallery 6 Oil pressure switch 7 Crankshaft journal 8 Crankshaft pin 9 Piston 10 Sleeve 11 Camshaft journal 12 Rocker arm shaft 13 Rocker arm 14 Intake and exhaust valves 15 Relief valve A Engine oil flow ...

Page 44: ...2 12 Cooling system Cooling system Cooling diagram 2 Water inlet 3 Water pump 15 Trim tab water inlet 8 Fuel cooler 10 Thermostat 11 Exaust guide ...

Page 45: ...ermostat 2 Water inlet 9 Cooling water pilot hole 12 Upper case A B 1 Water 2 Water inlet 3 Water pump 4 Exhaust port 5 Cylinder block 6 Cylinder head 7 Exhaust cover 8 Fuel cooler 9 Cooling water pilot hole 10 Thermostat 11 Exhaust guide 12 Upper case 13 Lower case 14 Propeller boss 15 Trim tab water inlet A Cooling water flow B Hydrodynamic water pressure for cool ing the propeller boss damper ...

Page 46: ...ake manifold 2 Throttle body 1 Intake silencer 4 Exhaust guide 5 Exhaust manifold 8 Idle exhaust hole 6 Muffler 7 Propeller boss 1 Intake silencer 2 Throttle body 3 Intake manifold 4 Exhaust guide 5 Exhaust manifold 6 Muffler 7 Propeller 8 Idle exhaust hole A Intake air flow B Exhaust gas flow ...

Page 47: ...Fuel joint to joint 2 Joint to fuel filter 3 Fuel filter to fuel pump 4 Fuel pump to strainer 5 Strainer to vapor separator 6 Pressure regulator to fuel cooler 7 Fuel cooler to vapor separator 8 Vapor separator to fuel rail 9 Pressure regulator to intake manifold ...

Page 48: ...uting Vapor gas hose and blowby hose 5 1 2 4 3 1 Vapor separator to joint 2 Vapor separator to joint 3 Joint to vapor shut off valve 4 Vapor shut off valve to throttle body 5 Cylinder head cover to intake silencer ...

Page 49: ... hose 1 7 6 8 5 4 2 3 1 Exhaust cover to joint 2 Joint to fuel cooler 3 Fuel cooler to fuel cooler 4 Fuel cooler to joint 5 Joint to joint 6 Joint to exhaust guide 7 Joint to cooling water pilot hole 8 Flushing hose adapter to joint ...

Page 50: ...scription 3 5 Installing the battery cable 3 5 Installing the shift cable and throttle cable 3 6 Installing the main wire harness 3 8 Installing the 6Y8 multifunction meter harness pigtail bus wire 3 8 Installing the conventional gauge 6Y5 6Y7 harness 3 9 Installing the rigging grommet 3 9 Tiller handle 3 9 Installing the tiller handle 3 9 Battery installation 3 11 Rigging recommendation 3 11 Batt...

Page 51: ...the transom can change the center of gravity buoyancy operating bal ance or performance of the boat which could cause loss of control or swamping Consult 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 a...

Page 52: ...RNING Wear suitable protective gear such as gloves and eye protection when han dling and opening crate 2 NOTICE Use forklifts with forks that are at least 1 m 40 in in length Only stack with crate of the same size Be sure unit is stacked securely all four corners fit securely on unit below it Stack Limit 2 units at handling 3 IMPORTANT This unit delivered to carrier in a good condition For protect...

Page 53: ... remove the frame Be careful not to damage the outboard mo tor d Remove the wrapping and then check the outboard motor for concealed damage If any damage is found consult your Yama ha agency e Remove the top cowling f Remove the bolt 1 and then remove the flywheel magneto cover 2 g Install the shackles 1 to the engine hang ers 2 and then install the lifting harness es 3 to the shackles 1 h Apply t...

Page 54: ...lder 1 k Remove the bolts 1 l Remove the steering retainer and then in stall a hydraulic steering cylinder or steer ing cable following the recommendation of the manufacturer remote control model m For the procedure of outboard motor mounting on boat see Rigging Guide 6YR 2819Y n Remove the lifting harness and shackles and then install the fiywheel magneto cov er and top cowling 1 1 1 ...

Page 55: ...d then re move the main wire harness coupler a b Remove the cover 2 c Route the battery cable 1 through the bottom cowling d Connect the positive and negative termi nals of the battery cable TIP The positive battery cable is marked with mark e Install the rubber caps 2 f 1 Alert indicator harness 2 Trolling switch harness 3 Main wire harness 4 Speedometer hose 5 Battery cable 6 6Y8 multifunction m...

Page 56: ...able joint 1 to the shift cable 2 b Move the remote control lever to the N po sition c Align the pin 1 with the mark a on the shift bracket 2 d Make a mark a on the fully retracted inner cable and then make a mark b on the ful ly extended inner cable e Make a mark c in the middle point be tween marks a and b and then align the mark c with the outer cable edge d f Adjust the shift cable joint 1 and...

Page 57: ... 5 kgf 3 4 lbf to remove any free play in the cable m Adjust the throttle cable joint 4 and then install it to the pin 5 of the throttle lever The throttle cable joint must be screwed in 8 0 mm 0 31 in or more n Install the clip 1 and then check that the throttle cable locknut 2 is fully seated on the throttle cable joint 3 o Tighten the throttle cable locknut 2 from its fully seated position to t...

Page 58: ...rness coupler 10 pin a and then secure it using the plastic tie 3 d Install the main wire harness 2 to the clamp 4 and then fasten the main wire harness 2 to the bracket 5 with a plastic tie 6 TIP Before fastening the main wire harness 2 to the clamp 4 and the bracket 5 pull it to pre vent loosening Installing the 6Y8 multifunction meter harness pigtail bus wire 1 Remove the cap 1 2 Route the pigt...

Page 59: ...the battery cable with the positive battery cable 1 on top and align the white tape 2 on the battery cable with the outer end of the rigging grommet c Install the rigging grommet 3 along with the grommet holder 4 and then tighten the grommet holder bolts 5 to the speci fied torque Tiller handle Installing the tiller handle 1 Install Tiller handle a Fit the cable guide 1 into the grooves a in the s...

Page 60: ...g and then con nect the alert indicator harness coupler a h Remove the cap 1 i Route the trolling switch harness 2 through the bottom cowling and then con nect the trolling switch harness coupler a j Install the shift cable and throttle cable See steps 2 4 in Installing the shift cable and throttle cable 3 6 k Install the rigging grommet and grommet holder See Installing the rigging grom met 3 9 l...

Page 61: ... friction tighten the friction ad justing nut 1 in direction b To decrease the friction loosen the friction adjusting nut 1 in direction c Battery installation Make sure to connect the battery properly and select the proper cable sizes Other wise a fire could result Do not reverse the battery connections Otherwise the charging system could be damaged Rigging recommendation Battery cable length The...

Page 62: ... 3 11 1 4 14 G Aluminum 663 45958 01 3 10 3 4 16 G Aluminum 663 45949 01 3 10 3 4 17 G Aluminum 663 45941 01 3 10 5 8 12 G Aluminum 6H5 45952 00 3 10 3 8 13 G Aluminum 6H5 45945 00 3 10 1 4 14 G Aluminum 6H5 45958 00 3 10 15 G Aluminum 6H5 45943 00 3 11 5 8 11 G Aluminum 69W 45947 00 3 11 3 8 12 G Aluminum 69W 45952 00 3 11 1 8 13 G Aluminum 69W 45945 00 3 11 1 4 14 G Aluminum 69W 45958 00 3 11 15...

Page 63: ...eshooting 4 3 Troubleshooting procedure 4 3 Troubleshooting the power unit using the YDIS 4 3 Trouble code and checking step 4 5 Troubleshooting procedure trouble code not detected 4 7 Troubleshooting the power unit 4 7 Troubleshooting the PTT unit 4 12 Troubleshooting the lower unit 4 13 ...

Page 64: ... Diagnostic System features updated software and expanded tool functions that allow it to re spond to new models and technologies maintaining compatibility with regulations See YDIS Ver 2 33 or later instruction manual for detailed information Connecting the communication cable CAN Line YDIS2 Hardware Kit 90890 06884 YDIS2 Hardware Kit LIT YDIS2 01 KT 3 Adapter interface 4 USB cable 5 Multi hub 5 ...

Page 65: ...4 2 YDIS K Line 4 K Line harness 1 Adapter interface 3 USB cable 2 Adapter cap a YDIS coupler 1 Adapter interface 2 Adapter cap 3 USB cable 4 K Line harness a YDIS coupler gray ...

Page 66: ...part the coupler or connector must be disconnected As a result the engine ECM determines that the part is disconnected and a trouble code is detected Therefore make sure to delete the diagnosis record after checking the input voltage Since the main relay comes on for approximately 10 seconds after the engine start switch is turned to OFF the power of the engine ECM cannot be turned off Therefore i...

Page 67: ...ated Code No Item YDIS diagnosis YDIS diagnosis record 15 Thermo sensor 18 TPS 19 Battery voltage 23 Air temperature sensor 27 Water in fuel filter 28 Shift position switch 29 Air pressure sensor 37 Intake air passage 44 Engine shut off switch 49 Over cooling 86 Immobilizer ...

Page 68: ...ci fied voltage Battery voltage and battery alert are displayed Engine operates normally Engine does not restart de pends on battery condition Check the battery cable and terminals for proper connec tion 10 7 Measure the lighting coil out put peak voltage 5 26 Measure the lighting coil resis tance 5 26 Measure the rectifier regulator output peak voltage 5 27 Check the rectifier regulator for conti...

Page 69: ...31 Check for wiring continuity be tween the throttle body and the engine ECM A 15 37 Intake air pas sage Air leak Check Engine is displayed Engine operates normally ex cept at idle Check the gaskets of the in take manifold and the throttle body 6 12 Check the intake manifold for cracks 6 13 Check the opening condition of TPS and the ISC valve using the YDIS 5 19 49 Over cooling Irregular sig nal E...

Page 70: ...tart switch mal function Check the engine start switch 5 35 Neutral switch malfunction Check the neutral switch Short open or loose con nection in starter motor cir cuit Check the starter relay input voltage 5 34 Check the wire harness for continui ty A 16 Starter motor malfunction Disassemble and check the starter motor 5 36 Starter motor oper ates but the engine does not crank Stuck piston or cr...

Page 71: ... fuel line for leakage 2 15 High pressure fuel pump malfunction Check the high pressure fuel pump operation using the YDIS 5 24 Measure the high pressure fuel pump resistance 5 24 Main relay malfunction Check the main relay 5 17 Short open or loose con nection in high pressure fuel pump circuit Measure the high pressure fuel pump input voltage 5 24 Check for continuity between the high pressure fu...

Page 72: ...park plug cap malfunction Measure the spark plug cap resis tance 5 30 Engine ECM malfunction Check the engine ECM output peak voltage 5 29 Fuel pressure is low Fuel leakage Check for fuel leakage 2 15 Clogged fuel filter element Check the fuel filter element for dirt and obstructions 6 5 Clogged fuel strainer Check the fuel strainer for dirt and obstructions 6 22 High pressure fuel line mal functi...

Page 73: ...y 6 12 Check the intake manifold for cracks 6 13 Throttle link rod and the throttle cable are not in stalled properly Adjust the throttle link rod and the throttle cable 3 6 6 15 ISC valve malfunction Check the ISC valve operation using the YDIS 5 20 Symptom 2 Cause Checking steps See page Buzzer comes on overheat alert indica tor comes on Clogged cooling water inlet Check the pilot hole for cooli...

Page 74: ...ance de crease Check the battery capacity and spe cific gravity 10 7 Short open or loose con nection in charging circuit Check the battery cable and termi nals for proper connections 3 5 Check the charging circuit for wiring connection and damage A 16 Lighting coil malfunction Measure the lighting coil output peak voltage 5 26 Measure the lighting coil resistance 5 26 Rectifier regulator malfunc t...

Page 75: ... Check for continuity between the PTT switch and the PTT relay A 16 A 17 PTT motor does not operate PTT motor malfunction Check the PTT motor 9 33 Bent trim and tilt ram Check the trim and tilt ram 9 41 Stuck trim and tilt ram Disassemble and check the PTT unit 9 41 Short open or loose con nection in PTT motor circuit Check for continuity between the PTT motor and the PTT relay termi nal A 16 PTT ...

Page 76: ...d leakage Check for PTT fluid leakage 10 20 Clogged fluid passages Disassemble and check the PTT unit 9 38 9 41 Check the valves for damage 9 40 Check the fluid passages for ob structions 9 38 9 41 Symptom 2 Cause Checking steps See page Shift cable is not adjusted properly Adjust the shift cable 3 6 Shift rod does not operate properly Check the shift rod for wear 8 4 Check the detent mechanism 9 ...

Page 77: ...it and component 5 17 Checking the main relay 5 17 Checking the engine ECM circuit 5 18 Checking the TPS 5 19 Checking the ISC valve 5 20 Checking the oil pressure switch 5 20 Checking the alert indicator tiller handle model 5 21 Checking the alert buzzer 5 22 Checking the trolling switch tiller handle model 5 22 Fuel control unit and component 5 22 Checking the water detection switch 5 22 Checkin...

Page 78: ...nd component 5 34 Checking the starter relay 5 34 Checking the engine start switch 5 35 Starter motor 5 36 Removing the starter motor 5 37 Disassembling the starter motor 5 37 Checking the starter motor pinion 5 37 Checking the armature starter motor 5 38 Checking the brush holder 5 38 Assembling the starter motor 5 39 Installing the starter motor 5 41 6Y8 Multifunction Meters sensor 5 42 Checking...

Page 79: ...5 1 Electrical component and wire harness routing Electrical component and wire harness routing Port D 1 E D E 3 2 4 5 6 7 8 9 10 11 C B A 14 13 12 15 6 16 17 18 19 20 21 D D E E ...

Page 80: ...h 11 YDIS coupler 12 Diode connect to the PTT relay 13 Joint connector 2 14 Joint connector 1 15 Trim sensor lead 16 PTT motor lead 17 Starter relay lead 18 Main wire harness 19 Rectifier regulator lead 20 Thermo sensor lead 21 Oil pressure connector A Pass the lighting coil lead 5 through the groove of the magnet base B Pass the wire harness 6 between the engine hanger and the cylinder head C Con...

Page 81: ...5 3 Electrical component and wire harness routing Starboard F F F F G G G G H H H H 3 3 3 2 2 8 1 4 5 6 7 1 8 9 C B A D E b a ...

Page 82: ... the positions a and then install the wire harness into the positions b B Clamp the fuel hose 8 and the wire harness 3 at the position marked with white tape C Install the wire harness holders to the holes of the intake manifold D Clamp the holder to the wire harness 3 at the position marked with white tape and then install the vapor gas hose 4 and the blowby hose 2 to the holder E Fasten the thro...

Page 83: ...5 PTT motor lead green 6 Main relay 7 Starter relay lead red 8 Starter relay 9 Shift position sensor 10 Starter relay lead brown 11 10 pin coupler A Install the negative battery cable 2 into the slots of the bracket B After fastening the 10 pin coupler 11 fold the end of plastic tie inward so that it does not come out C The PTT motor leads 7 and 10 must be installed within 30 ...

Page 84: ...component and wire harness routing Rear B B B B 4 4 1 3 2 2 A 1 Water detection switch 2 Water detection switch lead 3 Speed sensor optional 4 Fuel hose A Wind the water detection switch lead se curing it with a clamp ...

Page 85: ...rness routing Top 3 2 1 4 5 6 10 9 8 7 B B B B 1 Vapor shut off valve 2 Spark plug 3 Thermo sensor 4 Pulser coil 5 Lighting coil stator assembly 6 Starter motor 7 Blowby hose 8 Vapor gas hose 9 High pressure fuel pump lead 10 Wire harness ...

Page 86: ...2 Water pressure sensor coupler 3 Shift position switch coupler 4 Trolling switch coupler 5 Alert indicator coupler 6 6Y8 multifunction meter communication coupler 7 Trim sensor coupler 8 Fuel hose 9 Speedometer hose 10 PTT motor lead PTT model 11 Trolling switch lead 12 Shift position switch lead 13 Alert indicator harness 14 Water pressure sensor lead 15 Main wire harness 16 Trim sensor lead ...

Page 87: ...5 9 Electrical component and wire harness routing Bottom cowling remote control model A A B B C C D D A A B B C C D D 8 9 1 7 6 5 4 3 2 10 11 14 13 13 13 12 12 15 16 17 18 ...

Page 88: ...osition switch coupler 6 Trolling switch coupler 7 Alert indicator coupler 8 6Y8 multifunction meter communication coupler 9 Trim sensor coupler 10 Fuel hose 11 Speedometer hose 12 PTT motor lead PTT model 13 Trim sensor lead PTT model 14 Alert indicator harness 15 Shift position switch lead 16 Water pressure sensor lead 17 PTT switch lead PTT model 18 Sub wire harness ...

Page 89: ...5 11 Electrical component and wire harness routing Tiller handle tiller handle model F F 8 10 9 7 1 2 6 5 4 3 11 C B A D E ...

Page 90: ...k under the control link assembly B Run the neutral switch leads brown under the buzzer C Bend the extension wire harness 2 and then connect the harness coupler This harness bending position must be 10 0 mm 0 39 in or more away from the engine start switch coupler 1 The bend radius should be 10 0 mm 0 39 in or more D Align the tape ends of the extension wire harness 2 and the alert indicator harne...

Page 91: ...take air pressure sensor 9 Oil pressure switch 5 Water pressure sensor 4 Speed sensor 15 Ground 7 Thermo sensor 10 Engine shut off switch 13 Shift position switch 14 Water detection switch 16 Main relay 19 Engine start switch 26 Oil pressure alert indicator 27 Overheat alert indicator 29 Tachometer 28 Alert buzzer 21 Fuel injector 1 22 Fuel injector 2 23 Fuel injector 3 24 Vapor shut off valve 11 ...

Page 92: ...tch UP 12 Trolling switch DN 13 Shift position switch 14 Water detection switch 15 Ground 16 Main relay 17 Battery 18 High pressure fuel pump 19 Engine start switch 20 Engine ECM 21 Fuel injection 1 22 Fuel injection 2 23 Fuel injection 3 24 Vapor shut off valve 25 YDIS 26 Oil pressure alert indicator 27 Overheat alert indicator 28 Alert buzzer 29 Tachometer 30 ISC 31 Ignition coil 1 32 Ignition c...

Page 93: ...urce Orange 25 Water pressure sensor Blue Black 26 Sensor ground Black 27 Trim sensor Pink 28 Oil pressure switch Pink White 29 Trolling switch UP Orange White 30 Shift position switch Blue Green 31 Tachometer remote control Green 32 ISC Green Black 33 ISC Green Red 34 Pulser coil White Red 35 36 Engine start switch Yellow 37 38 Oil pressure alert indi cator Pink White 39 Ground Black 40 Alert buz...

Page 94: ...ent using the digital tester make sure that the leads do not contact any metal parts Other wise the electrical component may short circuit and be damaged To check the electrical components or mea sure the peak voltage use the special service tools A malfunctioning electrical component can be checked easily by measuring the peak voltage The specified engine speed when measuring the peak voltage is ...

Page 95: ...cking the main relay 1 Check Main relay a Disconnect the main relay coupler a b Measure the input voltage between the ter minal and ground c Turn the engine start switch to ON and then measure the input voltage between the terminal and ground d Turn the engine start switch to OFF e Connect the special service tool 2 to the main relay 1 Digital circuit tester 90890 03243 Digital multimeter YU 34899...

Page 96: ...ead to the connector a and the negative battery lead to the connector b and then check for continuity between the connectors c and d Replace the relay if out of specifi cation Do not reverse the battery leads i Disconnect the special service tool j Connect the main relay coupler Checking the engine ECM circuit 1 Disconnect Engine ECM coupler a and b Test harness FWY 6 2 90890 06872 Test harness FW...

Page 97: ... ground b Turn the engine start switch to OFF 5 Connect Engine ECM couplers Checking the TPS 1 Measure TPS output voltage Out of specification Check the TPS in put voltage a Connect the YDIS to display TPS volt age b Start the engine and warm it up for 5 10 minutes and then stop it Engine ECM ground circuit continu ity Terminal 39 Ground Terminal 48 Ground Terminal 17 Ground Engine ECM input volta...

Page 98: ...Check ISC valve operation using the YDIS Ac tive test No change in engine speed Replace the throttle body a Start the engine and then check that the engine speed increases using the YDIS Active test b Stop the engine Checking the oil pressure switch 1 Measure Oil pressure switch input voltage Out of specification Check the wire har ness for continuity a Disconnect the oil pressure switch lead a b ...

Page 99: ...t the battery 1 5 V to the alert in dicator couplers a and b Check that the overheat alert indicator c or the oil pres sure alert indicator d comes on Replace the alert indicator if it does not come on Do not apply a voltage higher than 1 7 V when checking the LED c Connect the alert indicator couplers and and then install the tiller handle cover Vacuum pressure pump gauge set 2 90890 06945 Pressu...

Page 100: ...ng switch coupler a 2 Check Trolling switch continuity Out of specification Replace Fuel control unit and component Checking the water detection switch 1 Measure Water detection switch input voltage Out of specification Check the wire har ness for continuity a Disconnect the water detection switch coupler a b Turn the engine start switch to ON and then measure the input voltage at the wa ter detec...

Page 101: ...ter assembly 6 7 Checking the fuel injector 1 Check Fuel injector operation using the YDIS Stationary test No operating sound Check the fuel in jector input voltage 2 Measure Fuel injector input voltage Out of specification Check the wire har ness for continuity a Disconnect the fuel injector couplers a b Turn the engine start switch to ON and then measure the input voltage between the fuel inject...

Page 102: ...ire har ness for continuity a Disconnect the high pressure fuel pump coupler a b Connect the tester probes to the terminals of the high pressure fuel pump coupler and then measure the input voltage within 3 seconds after turning the engine start switch to ON c Turn the engine start switch to OFF d Connect the high pressure fuel pump cou pler 3 Measure High pressure fuel pump resistance Out of spec...

Page 103: ... the specified negative pressure to the vapor shut off valve c 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 Connect the battery leads to the vapor shut off valve terminals for only a few sec onds d Disconnect the special service tool e Install the vapor shut off valve 3 Measure Vapor shut ...

Page 104: ...ak voltage at the specified engine speed g Measure the lighting coil output peak volt age between all combinations of the con nectors h Stop the engine and then disconnect the special service tool i Connect the lighting coil coupler 2 Measure Lighting coil resistance Out of specification Replace a Disconnect the lighting coil coupler a b Measure the lighting coil resistance c Connect the lighting ...

Page 105: ...e the rectifier regulator output voltage at the specified engine speed c Disconnect the special service tool d Connect the rectifier regulator coupler 2 Check Rectifier regulator continuity Out of specification Replace a Disconnect the rectifier regulator coupler b Set the digital circuit tester to the diode mode and then check the rectifier regula tor for continuity Rectifier regulator output vol...

Page 106: ... the special service tool 1 c Check the ignition spark using the YDIS Stationary test Do not touch any of the connections of the special service tool d Remove the special service tool and then connect the spark plug cap Rectifier regulator continuity testing diode mode Tester probe Display value reference data a b OL c d e b a 0 7 0 8 V c 0 4 0 5 V d e c a 0 4 0 5 V b OL d e d a 0 4 0 5 V b OL c e...

Page 107: ...ition coil couplers b Disconnect the spark plug caps from the spark plugs c Remove the spark plug caps from the igni tion coil d Measure the ignition coil resistance e Install the spark plug caps to the ignition coil f Connect the spark plug caps and ignition coil couplers Engine ECM output peak voltage reference data 1 Black Orange B Or Black B 2 Black White B W Black B 3 Black Yellow B Y Black B...

Page 108: ... output peak voltage Out of specification Measure the pulser coil resistance a Disconnect the pulser coil connectors a b While cranking the engine measure the peak voltage under unloaded condition c Connect the pulser coil connectors a d Remove the clip from the engine shut off switch e While cranking the engine measure the peak voltage under loaded condition f Insert the clip into the engine shut...

Page 109: ...ture c Check that the difference between the am bient temperature and the displayed intake air temperature is within 5 C 9 F TIP Check the intake air temperature sensor when the engine is cold When checking the intake air temperature sensor remove the top cowling and do not start the engine Checking the intake air pressure sen sor The intake air pressure sensor is a component of the throttle body ...

Page 110: ...er and heat the water slowly c Measure the thermo sensor resistance d Install the thermo sensor See Installing the thermo sensor 7 47 Checking the shift position switch 1 Measure Shift position switch input voltage Out of specification Check the wire har ness for continuity a Disconnect the shift position switch cou pler a b Turn the engine start switch to ON and then measure the input voltage at ...

Page 111: ...ess coupler or switch panel coupler b Turn the engine start switch to ON and then check the engine shut off switch for continuity c Turn the engine start switch to OFF d Connect the main wire harness coupler or switch panel coupler Shift position switch continuity No continuity Switch position a Continuity Switch position b a b 1 OFF 2 ON 3 START A Switch panel 704 binnacle mount re mote control B...

Page 112: ...e Negative battery lead Positive battery lead Starter relay See Wire harness 7 20 Before disconnecting the starter relay ter minals make sure to disconnect the nega tive battery terminal 3 Check Starter relay operation Out of specification Replace a Connect the positive battery lead to the re lay connector a and the negative battery lead to the relay connector b and then check for continuity betwe...

Page 113: ... switch panel coupler b Check the engine start switch for continui ty c Connect the main wire harness coupler or switch panel coupler 1 OFF 2 ON 3 START A Switch panel 704 binnacle mount re mote control B Tiller handle model and 703 side mount remote control Engine start switch continuity Switch posi tion Terminal a b c d e OFF ON START a a b b c c d d e e B A 3 START 2 ON 1 OFF ...

Page 114: ... 4 Screw set Cover screw M6 25 mm Bracket screw M5 8 mm 1 5 Magnet switch 1 6 Bolt M5 25 mm 2 7 Bracket 1 8 Bolt M5 105 mm 2 9 Stator 1 10 Armature 1 11 Brush holder assembly 1 12 Bracket 1 13 Lever assembly 1 14 Starting motor gear as sembly 1 15 Cover 1 16 Planetary gear 3 17 Pinion stopper set 1 18 Pinion shaft 1 19 Outer gear 1 20 Clutch assembly 1 Part name Q ty Remarks ...

Page 115: ...ture 2 along with the brush holder assembly 3 from the brack et 4 2 Remove Cap Pinion stopper Clip a Push the pinion stopper 1 down and then remove the clip 2 Checking the starter motor pinion 1 Check Pinion teeth Cracked worn Replace the pinion 2 Check Pinion movement Not smooth Replace a Turn the pinion counterclockwise to check that it operates smoothly and turn it clock wise to check that it l...

Page 116: ...ecification Replace the arma ture 4 Check Armature continuity Out of specification Replace the arma ture Checking the brush holder 1 Check Brush holder assembly continuity Out of specification Replace Standard commutator diameter 29 4 mm 1 16 in Wear limit 28 8 mm 1 13 in a a Standard commutator undercut 0 5 mm 0 02 in Wear limit 0 2 mm 0 01 in Armature continuity a b c d Brush holder assembly con...

Page 117: ...o the brush holder 2 Install Armature a Push the brushes 1 into the holders and then install the armature 2 to the brush holder assembly 3 b 3 Install Brush holder assembly Bracket Bracket screw Stator a Install the armature 1 along with the brush holder assembly 2 to the bracket 3 and then install the stator 4 a Standard brush length b Wear limit Standard brush length 12 3 mm 0 48 in Wear limit 5...

Page 118: ...4 Assemble Clutch assembly 1 Outer gear 2 Pinion shaft 3 5 Install Pinion stopper 1 Clip 2 6 Install Pinion shaft assembly 1 Lever 2 Planetary gear 3 Rubber seal 4 7 Install Stator 1 Bracket 2 3 2 1 2 1 New 3 3 2 1 4 1 2 ...

Page 119: ...ll Cap 1 Magnet switch 2 Starter motor lead 3 Starter motor lead screw 4 Installing the starter motor 1 Install Starter motor See Installing the starter motor 7 25 Stator motor lead screw 3 0N m 0 30 kgf m 2 2 lb ft 1 4 3 2 T R ...

Page 120: ...pressure sensor a Remove the water pressure sensor and then connect the pressure pump 1 and special service tool 2 b Turn the engine start switch to ON c Apply positive pressure to the water pres sure sensor slowly and then measure the output voltage d Turn the engine start switch to OFF and then disconnect the special service tool and pressure pump e Install the water pressure sensor Input voltag...

Page 121: ...sor and then con nect the pressure pump 1 and special service tool 2 b Turn the engine start switch to ON c Apply positive pressure to the speed sen sor slowly and then measure the output voltage d Turn the engine start switch to OFF and then disconnect the special service tool and pressure pump e Install the speed sensor Input voltage 5 V Orange Or Black B Output voltage at 392 kPa 3 9 kgf cm 57 ...

Page 122: ...nd PTT relay coupler Before disconnecting the PTT relay termi nals make sure to disconnect the battery negative terminal b Remove the PTT relay c Connect the special service tool 1 d Check the PTT relay for continuity e Connect the positive battery lead to the terminal a and the negative battery lead to the terminal b and then check the PTT relay for continuity Input voltage 12 V Terminal a Termin...

Page 123: ... PTT switch input voltage Out of specification Check the wire har ness for continuity a Disconnect the PTT switch coupler a b Measure the input voltage between the PTT switch coupler terminal and ground c Connect the PTT switch coupler 2 Check PTT switch continuity Out of specification Replace a Disconnect the PTT switch coupler b Check the PTT switch for continuity c Connect the PTT switch couple...

Page 124: ...isconnect the PTT switch connector b Check the PTT switch for continuity c Connect the PTT switch connector Checking the trim sensor 1 Measure Trim sensor resistance Out of specification Replace a Disconnect the trim sensor coupler a and then remove the trim sensor b Measure the trim sensor resistance Input voltage 12 V Red R Ground R a UP DN Lg Sb R b a c b a c Lg R Sb PTT switch continuity Switc...

Page 125: ...em c Turn the trim sensor lever 1 from the free position a to the setting position b and then measure the resistance as it gradual ly changes d Install the trim sensor and then connect the trim sensor coupler 1 b a ...

Page 126: ...ing the fuel filter assembly 6 7 Fuel pump assembly 6 8 Checking the fuel pump assembly 6 9 Disassembling the fuel pump 6 9 Checking the diaphragm and valve 6 10 Assembling the fuel pump 6 10 Installing the fuel pump assembly 6 11 Intake silencer intake manifold and throttle body 6 12 Checking the throttle body 6 13 Checking the intake manifold 6 13 Checking the vapor shut off valve 6 13 Installin...

Page 127: ...ump 6 21 Checking the fuel strainer 6 22 Checking the vapor separator 6 22 Adjusting the float height 6 22 Assembling the vapor separator 6 23 Fuel injector 6 25 Removing the fuel injector 6 26 Checking the fuel rail and fuel injector 6 26 Installing the fuel injector 6 26 ...

Page 128: ...nector Before disconnecting the quick connector reduce the fuel pressure Otherwise pres surized fuel could spray out Cover the fuel components using a rag to pre vent fuel from spilling out 1 Disconnect Quick connector a Reduce the fuel pressure See Reducing the fuel pressure 6 1 b Wrap a rag around the quick connector 1 c Disconnect the quick connector 1 TIP Cover the quick connector and fuel rai...

Page 129: ... fuel pressure will decrease 3 seconds af ter the engine start switch is turned to ON The high pressure fuel pump does not oper ate when the engine start switch is turned to ON again within 10 seconds after turning the engine start switch to OFF g Start the engine and warm it up until the engine idle speed stabilizes at the speci fied engine idle speed range h Measure the fuel pressure i Turn the ...

Page 130: ... special service tools 1 and 2 See Measuring the fuel pressure 6 1 b Disconnect the pressure regulator hose 3 and then connect the special service tool 4 to the pressure regulator 5 c Block the end of the pressure regulator hose 3 using a rubber plug 6 d Start the engine and let it idle e Check that the fuel pressure is reduced when negative pressure is applied to the pressure regulator f Stop the...

Page 131: ...w Part name Q ty Remarks 1 Cover 1 2 Clip 4 3 Hose 1 4 Plastic tie 2 5 Hose 1 6 Nut 1 7 Fuel filter assembly 1 8 Fuel cup assembly 1 9 O ring 1 10 Fuel filter element 1 11 Clip 1 12 Float 1 13 Clamp 1 14 Joint 1 15 Hose 1 16 Bolt M6 25 mm 1 17 Fuel joint 1 18 Grommet 1 19 Bolt M8 20 mm 1 20 Bracket 1 Part name Q ty Remarks ...

Page 132: ...e fuel inlet b using a rubber plug 2 and then apply the specified negative pressure Replace the O ring fuel cup as sembly or fuel filter assembly if the speci fied pressure cannot be maintained for 15 seconds or more Checking the fuel filter element 1 Check Fuel filter element Dirt residue Replace Checking the fuel cup assembly 1 Check Fuel cup assembly Foreign material Clean Cracked Replace When ...

Page 133: ...al service tool 1 to the fuel joint outlet a b Apply the specified positive pressure Re place the fuel joint if the specified pressure cannot be maintained for at least 10 sec onds Assembling the fuel filter assembly 1 Install Fuel filter element O ring Fuel cup assembly Clamp Vacuum pressure pump gauge set 1 90890 06945 Pressure vacuum tester 1 YB 35956 B Positive pressure 170 0 kPa 1 70 kgf cm 2...

Page 134: ...6 7 Fuel filter Installing the fuel filter assembly 1 Install Fuel joint Fuel filter assembly Clamp Hose Plastic tie New ...

Page 135: ... 5 5 1 6 6 6 3 0 N m 0 30 kgf m 2 2 lb ft New New Part name Q ty Remarks 1 Bolt M6 30 mm 2 2 Fuel pump assembly 1 3 O ring 1 4 Screw M5 43 mm 4 5 Washer 4 6 Nut 4 7 Cover 1 8 Diaphragm 1 9 Fuel pump body 1 10 Pin 1 11 Plunger 1 12 Spring 1 13 Diaphragm 1 14 Spring 1 15 Fuel pump body 1 ...

Page 136: ...al service tool 1 to the fuel pump outlet a e Block the fuel pump inlet b using a rubber plug 2 f Apply the specified positive pressure and then check that there is no air leakage Disassembling the fuel pump 1 Disassemble Fuel pump body a Align the groove a in the fuel pump body 1 with the hole b in the plunger 2 by turning them Vacuum pressure pump gauge set 1 90890 06945 Pressure vacuum tester 1...

Page 137: ... Replace the fuel pump body 3 Assembling the fuel pump Before assembling the fuel pump clean the parts and soak the valves and diaphragm in gasoline to obtain prompt operation of the fuel pump 1 Assemble Fuel pump body a Install the springs 1 and 2 plunger 3 and diaphragm 4 b Align the hole a in the plunger 1 with the hole b in the diaphragm 2 by pushing the plunger and diaphragm c Install the pin...

Page 138: ... same direction 2 Install Fuel pump body 1 Diaphragm 2 Fuel pump cover 3 Nut 4 Fuel pump screw 5 Installing the fuel pump assembly 1 Install O ring to the fuel pump assembly Fuel pump assembly Fuel pump assembly bolt Hose Clip to the hose Fuel pump screw 3 0 N m 3 0 kgf m 2 2 lb ft b 1 a New 4 5 1 2 3 5 4 T R New ...

Page 139: ...d and throttle body 12 11 10 5 4 1 2 10 3 10 6 6 6 6 7 7 9 8 New New New Part name Q ty Remarks 1 Plastic tie 1 2 Cover 1 3 Bolt M6 12 mm 2 4 Intake silencer 1 5 O ring 1 6 Bolt M8 40 mm 4 7 Bolt M6 35 mm 2 8 Intake manifold 1 9 Gasket 1 10 Bolt M6 16 mm 3 11 Throttle body 1 12 Gasket 1 ...

Page 140: ...ot smooth Clean Checking the intake manifold 1 Check Intake manifold Cracked deformed Replace Checking the vapor shut off valve 1 Check Vapor shut off valve exterior Cracked Replace Installing the intake manifold 1 Install Gasket to the intake manifold O ring to the intake manifold Throttle body to the intake manifold Intake manifold Intake manifold bolt New New ...

Page 141: ...2 3 4 5 10 11 6 7 9 8 1 New Part name Q ty Remarks 1 Throttle link rod 1 2 Bolt M6 45 mm 1 3 Collar 1 4 Wave washer 1 5 Throttle cam 1 6 Bolt M6 35 mm 1 7 Throttle control lever 1 8 Collar 1 9 Spring 1 10 Cotter pin 1 11 Throttle cam roller 1 ...

Page 142: ...nd a of the spring 2 into the hole b in the crankcase c Install the wave washer 1 collar 2 and bolt 3 d Install the throttle cam assembly 1 e Install the throttle link rod f Adjust the throttle link rod See Adjusting the throttle link rod 6 15 Adjusting the throttle link rod 1 Adjust Throttle link rod a Loosen the link rod locknut 1 and then remove the throttle link rod 2 from the throttle cam 3 3...

Page 143: ...slightly d Adjust the throttle link rod length so that its end a fits onto the protrusion b on the throttle cam and then install the throttle link rod to the throttle cam e Check that the link rod locknut 1 is fully seated on the throttle link rod joint 2 f Tighten the link rod locknut 1 from its fully seated position to the specified angle Link rod locknut 1 90 b a b a 3 1 2 b 1 2 a T R ...

Page 144: ...Part name Q ty Remarks 1 Bolt M6 20 mm 1 2 Cover 1 3 Collar 1 4 Grommet 1 5 Fuse puller 1 6 Hose 1 7 Holder 2 8 Holder 1 9 Holder 1 10 Hose 1 11 Nut 1 12 Vapor shut off valve 1 13 Bolt M6 16 mm 1 14 Bracket 1 15 Bolt M6 20 mm 1 16 Bracket 1 17 Bolt M6 30 mm 3 18 Collar 3 19 Grommet 3 Part name Q ty Remarks ...

Page 145: ...Fuel See Draining the fuel 6 18 2 Disconnect Quick connector Blowby hose Vapor gas hose High pressure fuel pump coupler Cooling water hoses 3 Remove Vapor separator assembly Installing the vapor separator 1 Install Vapor separator assembly a Install the vapor separator assembly 1 2 Connect High pressure fuel pump coupler Cooling water hose Quick connector Vapor gas hose Blowby hose a Install the h...

Page 146: ... the cooling water hoses 1 and 2 c Connect the vapor gas hoses 1 and 2 and then install the holder 3 d Connect the quick connector 1 and then install the holder 2 aligning it with the white tape 3 of the wire harness 2 1 3 2 1 3 2 1 ...

Page 147: ... kgf m 2 6 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft Part name Q ty Remarks 1 Clamp 3 2 Hose 1 3 Clip 1 4 Hose 1 5 Strainer 1 6 Holder 1 7 Clamp 1 8 Clamp 1 9 Hose 1 10 Quick connector 1 11 Plastic tie 13 12 Hose 1 13 Hose 1 14 Drain hose 1 15 Hose 1 16 Holder 1 17 Screw M6 14 mm 2 18 Fuel cooler 1 19 Hose 1 20 Hose 2 21 Joint 1 22 Hose 1 23 Hose 1 24 Joint 1 25 Holder 1 Part name Q ty Remarks ...

Page 148: ...0 N m 0 30 kgf m 2 2 lb ft 5 N m 0 5 kgf m 3 7 lb ft New New New New New New New Part name Q ty Remarks 1 Hose 1 2 Bolt M6 12 mm 2 3 Pressure regulator 1 4 Plastic tie 1 5 Lead 1 6 Screw M5 14 mm 6 7 Cover 1 8 Gasket 1 9 High pressure fuel pump 1 10 O ring 1 11 Holder 1 12 Clip 1 13 Joint 1 14 Clip 1 15 Filter 1 16 Pin 1 17 Float 1 18 Needle valve 1 19 Screw M4 7 mm 2 20 Plate 1 21 Plate 1 22 Nipp...

Page 149: ...ainer if the specified pressure cannot be maintained for 15 seconds or more Checking the vapor separator 1 Check Needle valve Bent worn Replace the float 2 Check Float Deteriorated Replace 3 Check Filter Dirt or residue Clean Adjusting the float height 1 Measure Float height a Float height b Out of specification Adjust the float height Leakage tester 1 90890 06840 Leakage tester 1 commercially ava...

Page 150: ...or separator 1 Assemble Vapor separator a Install the plates 1 and 2 and then tight en the float chamber plate screws 3 to the specified torque b Install the needle valve 1 float 2 and float pin 3 TIP Do not reuse the float pin Always replace it with a new one Install the float pin with its tapered end facing towards the mark a on the float chamber cover Float height 40 7 42 7 mm 1 60 1 68 in Floa...

Page 151: ...n tighten the float chamber cover screws 4 to the specified torque f Connect the lead a g Install the pressure regulator 1 the pres sure regulator bolts 2 new O rings 3 and the nipples 4 and then tighten the pressure regulator bolts 2 and the nipple 4 to the specified torque a 3 1 1 2 a a Float chamber cover screw 4 3 0 N m 0 30 kgf m 2 2 lb ft Pressure regulator bolt 2 5 N m 0 5 kgf m 3 7 lb ft N...

Page 152: ...6 25 Fuel injector Fuel injector 4 5 2 1 3 3 3 5 5 4 4 1 New New New Part name Q ty Remarks 1 Bolt M6 40 mm 2 2 Fuel rail 1 3 Holder 3 4 Fuel injector 3 5 O ring set 3 2 pcs set ...

Page 153: ...of the fuel injec tion meter TIP When measuring obtain a result from the av erage of 4 measurements It is not possible to obtain correct measure ments under disparate test conditions Make sure to fully charge the battery The cylinder is graduated in increments of 2 5 cm 2 5 cc Make sure to comply with the laws and regu lations of the region when disposing of the used test fuel Installing the fuel ...

Page 154: ... and sprocket 7 15 Checking the timing belt and sprocket 7 15 Installing the sprocket and timing belt 7 16 Installing the stator assembly 7 17 Installing the flywheel magneto 7 18 Engine ECM rectifier regulator and ignition coil 7 19 Wire harness 7 20 Installing the wire harness 7 21 Starter motor 7 24 Installing the starter motor 7 25 Cylinder head 7 26 Removing the cylinder head 7 27 Checking th...

Page 155: ...sassembling the cylinder block 7 50 Checking the piston diameter 7 51 Checking the cylinder bore 7 51 Checking the piston clearance 7 52 Checking the piston ring 7 52 Checking the piston ring end gap 7 52 Checking the piston ring groove 7 53 Checking the piston ring side clearance 7 53 Checking the piston pin boss inside diameter 7 54 Checking the piston pin diameter 7 54 Checking the connecting r...

Page 156: ...en tight en the spark plugs to the specified torque j Connect the spark plug caps and fuel in jector couplers Checking the oil pressure 1 Check Oil pressure Below specification Check the engine internal parts a Disconnect the oil pressure switch lead from the oil pressure switch end b Remove the oil pressure switch and then install an oil pressure gauge 1 to the oil pressure switch installation ho...

Page 157: ...magneto clockwise to align the protrusion a on the pulser coil with the protrusion b on the pulser coil b Measure the pulser coil air gap c Adjusting the pulser coil air gap 1 Loosen Pulser coil bolt 1 2 Adjust Pulser coil air gap a 3 Tighten Pulser coil bolt 4 Recheck Pulser coil air gap Checking the pulser coil air gap 7 2 Checking the valve clearance Measure the valve clearances when the en gin...

Page 158: ...ignition coils 5 d Remove the clamps b from the cylinder head cover 6 and then remove the cylin der head cover 6 e Turn the flywheel magneto clockwise and align the 1 mark a on the driven sprocket 1 with the mark b on the cylinder head f Measure each valve clearance a and b following the step g k TIP Write down the measurement data Valve clearance IN cold engine 0 15 0 25 mm 0 0059 0 0098 in Valve...

Page 159: ... applicable Specified cylinder j Turn the flywheel magneto an additional 240 clockwise and align the alignment mark a on the driven sprocket 1 with the mark b on the cylinder head k Measure the intake and exhaust valve clearances of the applicable cylinder Not applicable Specified cylinder l Install a new gasket 1 and the cylinder head cover 2 m Install the clamps 1 to the cylinder head cover 2 n ...

Page 160: ...ged 1 Adjust Valve clearance a Loosen the valve adjusting locknut 1 and then turn the adjusting screw 2 until the valve clearance is within specification TIP To decrease the valve clearance turn the ad justing screw 2 in direction a To increase the valve clearance turn the ad justing screw 2 in direction b b Tighten the valve adjusting locknut to the specified torque and then recheck the valve cle...

Page 161: ...ft 3 0 N m 0 30 kgf m 2 2 lb ft New Part name Q ty Remarks 1 Bolt M6 20 mm 3 2 Grommet holder 1 3 Grommet 1 4 Cable guide 1 5 Rigging grommet 1 6 Dipstick 1 7 Bolt M6 16 mm 2 8 Screw M6 25 mm 2 9 Nut 2 10 Apron 1 11 Bolt M8 80 mm 8 12 Gasket 1 13 Bolt M6 25 mm 2 14 Bracket 1 15 Screw M4 16 mm 2 16 Plate 1 17 Shift position switch 1 18 Collar 1 ...

Page 162: ...tie 1 and then dis connect the 10 pin coupler a d Remove the main wire harness b from the clamp 2 and the plastic tie 3 e Remove the cover 4 f Remove the battery cables 1 g Remove the caps 2 and then remove the PTT motor leads 3 from the PTT relay 4 clamp 5 and plastic tie 6 PTT mod el h Disconnect the shift position switch cou pler a and the 6Y8 multifunction meter harness coupler b i Disconnect ...

Page 163: ...or har ness a from the clamp 1 l Disconnect the cooling water hose 1 m Disconnect the fuel hose 1 n Disconnect the cooling water hoses 1 o Remove the dipstick 1 p Remove the clip 1 and then remove the shift rod lever 2 from the shift rod bracket 3 q Remove the bracket 4 1 1 a b c d 1 a 1 1 1 1 1 2 3 4 ...

Page 164: ...lling the power unit 1 Install Power unit assembly a Clean the power unit mating surface and then install a new gasket 1 b Install the power unit with the power unit mounting bolts 2 c Tighten the power unit mounting bolts 2 to the specified torques in 2 stages and in the order 1 2 and so on 1 3 2 2 1 1 3 Power unit mounting bolt 2 1st 21 N m 2 1 kgf m 15 lb ft 2nd 21 N m 2 1 kgf m 15 lb ft 1 2 2 ...

Page 165: ...he bracket 1 f Install the shift rod lever 2 to the shift rod bracket 3 and then install the clip 4 g Install the dipstick 1 h Connect the cooling water hoses 1 i Connect the fuel hose 1 j Connect the cooling water hose 1 and then fasten it using a new plastic tie 2 Apron screw 3 3 0 N m 0 30 kgf m 2 2 lb ft 1 2 3 T R 4 2 3 1 1 1 1 1 2 ...

Page 166: ...y 4 PTT model p Tighten the PTT motor lead bolts 5 to the specified torque PTT model q Install the caps 6 PTT model r Install the battery cables 7 s Install the cover 1 t Connect the 10 pin coupler a and then fasten it to the cover 1 with a plastic tie 2 u Install the main wire harness 3 to the clamp 4 and then fasten the main wire harness 3 to the bracket 5 with a plastic tie 6 TIP Before fasteni...

Page 167: ...7 12 Power unit assembly v Install the shift cable and throttle cable See Installing the shift cable and throttle cable remote control model 3 14 ...

Page 168: ...Remarks 1 Nut Width across flats 30 mm 1 2 Washer 1 3 Flywheel magneto 1 4 Woodruff key 1 Flywheel magneto 5 Bolt M5 16 mm 2 6 Pulser coil 1 7 Bolt M6 30 mm 7 8 Stator assembly 1 9 Base assembly 1 10 Dowel pin 2 11 Timing belt 1 12 Nut Width across flats 41 mm 1 13 Retaining plate 1 14 Drive sprocket 1 15 Woodruff key 1 Drive sprock et 16 Bolt M10 35 mm 1 17 Washer 1 18 Driven sprocket 1 19 Dowel ...

Page 169: ...revent the special service tool 2 from slipping off easily 3 Remove Flywheel magneto Woodruff key To prevent damage to the engine or tools screw in the flywheel puller set bolts evenly and completely so that the flywheel puller is parallel to the flywheel magneto A Worldwide B USA and Canada 1 a b A 2 1 B 2 1 Flywheel holder 2 90890 06522 Flywheel magneto holder 2 YB 06139 A Worldwide B USA and Ca...

Page 170: ...nut 1 TIP Use the air tool to loosen the drive sprocket nut easily 3 Loosen Driven sprocket bolt 1 When loosening the driven sprocket bolt do not turn the camshaft Checking the timing belt and sprocket 1 Check Interior and exterior of the timing belt Drive sprocket Driven sprocket Cracked damaged worn Replace 1 1 2 2 Crankshaft holder 16 2 90890 06355 Crankshaft holder 2 YW 06355 A Worldwide B USA...

Page 171: ... 1 Install Dowel pin to the camshaft Driven sprocket Washer 2 Tighten Driven sprocket bolt 1 3 Install Woodruff key 1 Drive sprocket 2 Retaining plate 3 Drive sprocket nut 4 4 Tighten Drive sprocket nut 1 A Worldwide B USA and Canada Flywheel holder 2 90890 06522 Flywheel magneto holder 3 YB 06139 Driven sprocket bolt 1 38 N m 3 8 kgf m 28 lb ft 1 2 A 1 3 B T R Crankshaft holder 16 2 90890 06355 C...

Page 172: ...d with the mark d on the cylinder block b Install the timing belt 1 TIP Be careful not to install the timing belt with the part number upside down Installing the stator assembly 1 Install Base assembly 1 Stator assembly 2 Stator assembly bolt 3 Stator assembly coupler 4 Pulser coil 5 Pulser coil bolt 6 Pulser coil connector 7 Drive sprocket nut 1 150 N m 15 kgf m 111 lb ft T R a b c d 1 1 2 4 3 5 ...

Page 173: ...nkshaft a and the fly wheel magneto b 2 Tighten Flywheel magneto nut 1 a Tighten the flywheel magneto nut to the specified torque Apply force in the direction of the arrow to prevent the special service tool 2 from slipping off easily 1 2 2 a b 1 2 A A Worldwide B USA and Canada Flywheel holder 2 90890 06522 Flywheel magneto holder 2 YB 06139 Flywheel magneto nut 1 160 N m 16 kgf m 118 lb ft B 1 2...

Page 174: ... Engine ECM rectifier regulator and ignition coil 1 1 3 1 1 1 7 4 1 8 8 7 5 5 4 1 9 4 5 2 6 6 6 Part name Q ty Remarks 1 Bolt M6 25 mm 9 2 Engine ECM 1 3 Rectifier regulator 1 4 Spark plug cap 3 5 Ignition coil 3 6 Grommet 6 7 Plate 2 8 Clamp 2 9 Plate 1 ...

Page 175: ...arks 1 Bolt M6 16 mm 6 2 Cap 2 3 Bolt M6 10 mm 2 4 Bolt M6 20 mm 2 5 PTT relay 1 6 Screw M6 20 mm 3 7 Plate 1 8 Cap 2 9 Bolt M6 10 mm 3 10 Starter relay 1 11 Cap 1 12 Main relay 1 13 Bolt M6 28 mm 6 14 Collar 6 15 Grommet 6 16 Bracket 1 17 Cap Yellow 2 18 Cap Green 1 19 Fuse 4 20 A spare is included 20 Fuse 2 30 A spare is included 21 Plastic tie 1 22 Plastic tie 1 23 Holder 1 24 Plastic tie 2 25 ...

Page 176: ...ler a Fuse holder 2 Clamp 3 Diode 4 Plastic tie 5 YDIS coupler b YDIS coupler screw 6 2 Install Bracket 1 Terminal 2 Terminal lead 3 Terminal bolt 4 1 a 2 3 4 5 b 6 YDIS coupler screw 6 3 0 N m 0 30 kgf m 2 2 lb ft Terminal bolt 4 4 0 N m 0 40 kgf m 3 0 lb ft T R 1 1 1 2 3 4 T R ...

Page 177: ...oupler a PTT relay lead 2 PTT relay lead nut 3 Cap 4 7 Install Ground lead 1 Ground lead 2 Clamp 3 Rectifier regulator coupler a Thermo sensor coupler b Oil pressure switch connector c Ground lead 4 Clamp 5 Main relay screw 2 3 0 N m 0 30 kgf m 2 2 lb ft Starter relay screw 3 3 0 N m 0 30 kgf m 2 2 lb ft 2 1 a T R 1 a 2 3 T R 3 2 3 1 Starter relay lead bolt 2 4 0 N m 0 40 kgf m 3 0 lb ft PTT relay...

Page 178: ...7 23 Wire harness 2 3 1 a c b 3 4 5 ...

Page 179: ...b ft 9 N m 0 9 kgf m 6 6 lb ft Part name Q ty Remarks 1 Bolt M6 25 mm 1 2 Bolt M6 20 mm 3 3 Bracket 1 4 Clip 2 5 Bushing 1 6 Washer 1 7 Shift rod lever 1 8 Nut 1 9 Spring washer 1 10 Cap 1 11 Bolt M6 10 mm 1 12 Starter motor lead 1 13 Terminal 1 14 Bolt M8 45 mm 3 15 Starter motor 1 16 Bolt M8 45 mm 4 17 Bracket 1 18 Dowel pin 2 19 Engine hanger 1 ...

Page 180: ...motor lead 1 Starter motor lead nut 2 Starter motor lead bolt 3 Starter motor 4 Starter motor bolt 5 Starter motor lead nut 2 9 N m 0 9 kgf m 6 6 lb ft Starter motor lead bolt 3 4 0 N m 0 40 kgf m 3 0 lb ft Starter motor bolt 5 30 N m 3 0 kgf m 22 lb ft 1 2 3 4 5 T R ...

Page 181: ...1 7 kgf m 13 lb ft 34 N m 3 4 kgf m 25 lb ft New New New Part name Q ty Remarks 1 Bolt M6 45 mm 4 2 Oil pump assembly 1 3 Gasket 1 4 Bolt M6 20 mm 7 5 Cylinder head cover 1 6 Gasket 1 7 Screw M4 10 mm 4 8 Plate 1 9 Grommet 5 10 Oil filler cap 1 11 O ring 1 12 Bolt M6 25 mm 4 13 Bolt M9 93 mm 8 14 Cylinder head assem bly 1 15 Gasket 1 16 Dowel pin 2 ...

Page 182: ...Loosen Cylinder head bolt M6 1 Cylinder head bolt M9 2 TIP Loosen the cylinder head bolts in the order 1 2 and so on 4 Remove Cylinder head bolt 1 Cylinder head bolt 2 Cylinder head 3 Do not scratch or damage the mating sur faces of the cylinder head and cylinder block 1 1 6 10 2 4 3 1 5 9 12 8 11 7 1 2 1 2 3 ...

Page 183: ...ylinder head bolts M9 1 to the specified torques in 3 stages and in the order 1 2 and so on TIP In the third tightening stage for the cylinder head bolts M9 1 mark the bolts and cylinder head with identification marks a and then tighten the bolts 90 from the marks on the cyl inder head b Tighten the cylinder head bolts M6 2 to the specified torques in 2 stages and in the order 9 10 and so on Cylin...

Page 184: ... a Fill the oil pump assembly 1 with engine oil through the oil passages a 6 Install Gasket 1 Oil pump assembly 2 a Install a new gasket 1 the oil pump as sembly 2 and the oil pump bolts aligning the slot in the oil pump drive shaft a with the camshaft pin b New 1 2 3 1 a New 1 2 2 a b ...

Page 185: ... ty Remarks 1 Anode plug 3 2 O ring 3 3 Anode 3 4 Screw M5 24 mm 3 5 Spark plug 3 6 Bolt M6 20 mm 2 7 Engine hanger 1 8 Bolt M8 22 mm 4 9 Washer 2 10 Stopper 2 11 Tensioner 2 12 Rocker arm shaft 1 13 Nut 5 14 Adjusting screw 5 15 Rocker arm 5 16 Nut 1 17 Adjusting screw 1 18 Rocker arm 1 19 Washer 6 20 Retaining bolt 1 21 Gasket 1 22 Camshaft 1 23 Oil seal 1 24 Valve cotter 12 25 Valve spring reta...

Page 186: ...Gradually loosen the rocker arm shaft bolts in several stages and in the order 1 2 and so on 3 Remove Rocker arm shaft bolt 1 Washer 2 Stopper 3 Tensioner 4 Washer 5 Rocker arm 6 Rocker arm 7 TIP Make sure to keep the parts in the order of re moval 4 Remove Retaining bolt 1 Camshaft 2 Oil seal 3 1 2 3 3 2 4 1 1 1 1 1 1 2 2 3 3 4 4 5 5 5 5 6 6 6 7 1 2 3 ...

Page 187: ...ad warpage Out of specification Replace a Remove carbon deposits from the com bustion chambers and then check the cyl inder head for damage and scratches b Check the cylinder head warpage using a straightedge 1 and a thickness gauge 2 in 7 directions Valve spring compressor 1 90890 04019 Valve spring compressor 1 YM 04019 Valve spring compressor attach ment 2 90890 06320 Valve spring compressor ad...

Page 188: ... Measure Stem diameter a Below specification Replace Free length IN 39 85 mm 1 57 in Limit 37 86 mm 1 49 in Free length EX 39 85 mm 1 57 in Limit 37 86 mm 1 49 in Tilt limit IN 1 7 mm 0 07 in Tilt limit EX 1 7 mm 0 07 in a a Margin thickness IN 0 80 1 20 mm 0 0315 0 0472 in Margin thickness EX 1 00 1 40 mm 0 0394 0 0551 in Diameter IN 5 475 5 490 mm 0 2156 0 2161 in Limit 5 445 mm 0 2144 in Diamet...

Page 189: ...replacing a valve guide check the valve seat contact area 1 Remove Valve guide 1 from the combustion chamber side Runout limit EX 0 01 mm 0 0004 in Runout limit IN 0 01 mm 0 0004 in Inside diameter IN 5 500 5 512 mm 0 2165 0 2170 in Inside diameter EX 5 500 5 512 mm 0 2165 0 2170 in a Valve stem to valve guide clear ance valve guide inside diameter valve stem diameter Clearance IN 0 010 0 037 mm 0...

Page 190: ...n it counterclockwise After reaming the valve guide make sure to clean it 4 Measure Inside diameter Valve guide remover installer 2 90890 06801 Valve guide remover 2 YB 06801 Valve guide installer 3 90890 06810 Valve guide installer 3 YB 06810 Installation height 16 30 16 70 mm 0 6417 0 6575 in New 1 2 3 a Valve guide reamer 2 90890 06804 Valve guide reamer 2 YB 06804 Inside diameter IN 5 500 5 51...

Page 191: ...pecial service tool 1 d Measure the valve seat contact width a where the blue layout fluid is adhered to the valve face Refacing the valve seat After every lapping procedure make sure to clean off any remaining lapping com pound from the cylinder head and valves 1 Reface Valve seat Seat contact width IN 1 20 1 60 mm 0 0472 0 0630 in Limit 2 050 mm 0 0807 in Seat contact width EX 1 20 1 60 mm 0 047...

Page 192: ... the valve seat con tact width using a 30 cutter c Adjust the bottom edge of the valve seat contact width using a 60 cutter A Worldwide B USA and Canada Valve seat cutter holder 90890 06316 Intake Valve seat cutter 30 90890 06326 Valve seat cutter 45 90890 06312 Valve seat cutter 60 90890 06323 Exhaust Valve seat cutter 30 90890 06328 Valve seat cutter 45 90890 06325 Valve seat cutter 60 90890 063...

Page 193: ...rea and set its width If the valve seat contact area is too nar row and situated near the top edge of the valve face cut the top edge of the valve seat using a 30 cutter to center the area Set its width using a 45 cutter If the valve seat contact area is too nar row and situated near the bottom edge of the valve face cut the bottom edge of the valve seat using a 60 cutter Set its width using a 45 ...

Page 194: ... 36 Checking the rocker arm and rocker arm shaft 1 Check Rocker arms rocker arm shaft and con tact surface a of each rocker arm Worn Replace 2 Measure Rocker arm inside diameter b and rocker arm shaft outside diameter c Out of specification Replace Valve lapper 1 90890 04101 Valve lapping tool 1 YM A8998 1 Rocker arm Inside diameter IN 16 000 16 018 mm 0 6299 0 6306 in Inside diameter EX 16 000 16...

Page 195: ... Out of specification Replace Checking the spark plug 1 Clean the electrodes a using a spark plug cleaner Cam lobe height IN 30 737 30 837 mm 1 2101 1 2141 in Limit 30 587 mm 1 2042 in Cam lobe height EX 30 933 31 033 mm 1 2178 1 2218 in Limit 30 783 mm 1 2119 in Runout 0 030 mm 0 0012 in a Camshaft Journal diameter 36 925 36 945 mm 1 4537 1 4545 in Cylinder head Journal inside diameter 37 000 37 ...

Page 196: ...es Assembling the cylinder head 1 Install Valve stem seal 1 2 Install Intake valve Exhaust valve Valve spring seat Valve spring Retainer Valve cotter a Install the valve 1 valve spring seat 2 valve spring 3 and valve spring retainer 4 in this order and then install the valve spring compressor 5 and valve spring compressor attachment 6 Spark plug NGK DPR6EB 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 i...

Page 197: ... hammer to seat the valve cotters 1 securely TIP Make sure that both valve cotters 1 are seat ed securely and evenly 3 Install Oil seal 1 1 1 1 A Worldwide B USA and Canada Driver rod LS 2 90890 06606 Bearing outer race attachment 3 90890 06626 Driver handle large 4 YB 06071 Driveshaft bearing installer 5 YB 06110 New 1 1 2 2 3 3 A 1 1 4 4 B 5 5 ...

Page 198: ... then install the tensioners 5 stop pers 6 washers 7 and rocker arm shaft bolts 8 TIP Make sure that the arrow marks a on the ten sioners 5 are facing towards the driven sprocket c Tighten the rocker arm shaft bolts 1 grad ually to the specified torque and in the or der 1 2 and so on 6 Install Cylinder head See Installing the cylinder head 7 28 7 Adjust Valve clearance See Adjusting the valve clea...

Page 199: ... lb ft 12 N m 1 2 kgf m 8 9 lb ft 6 N m 0 6 kgf m 4 4 lb ft New New New New New New New New Part name Q ty Remarks 1 Bolt M6 16 mm 3 2 Bracket 1 3 Clamp 3 4 Clamp 1 5 Plug M18 17 mm 1 6 Gasket 1 7 Plug M14 12 mm 2 8 Gasket 2 9 Anode plug 1 10 O ring 1 11 Screw M5 24 mm 1 12 Anode 1 13 Hose joint 1 14 Bolt M6 35 mm 10 15 Thermostat cover 1 16 Gasket 1 17 Gasket 1 18 Thermostat 1 19 Exhaust cover 1 ...

Page 200: ... 3 Hose joint 4 3 Loosen Exhaust cover bolt Loosen the exhaust cover bolts 1 in the order 1 2 and so on 4 Remove Exhaust cover bolt 1 Thermostat cover 2 Thermostat 3 Exhaust cover 4 Removing the oil filter 1 Remove Oil filter 1 1 1 2 2 3 4 3 8 9 6 2 7 10 5 4 1 1 Oil filter wrench 2 90890 01426 Oil filter wrench 2 YB 01426 1 1 2 3 4 1 2 ...

Page 201: ...g at the specified water temperatures Out of specification Replace a Suspend the thermostat in a container of water b Place a thermo meter in the water and then heat the water slowly c Measure the thermostat valve opening a at the specified water temperatures Installing the oil filter 1 Install Union bolt 1 1 Water tempera ture Valve opening a 58 62 C 136 144 F Starts opening above 70 C 158 F 3 0 ...

Page 202: ...st cover 1 Install Gasket 1 Exhaust cover 2 Gasket 3 Thermostat 4 Gasket 5 Thermostat cover 6 Exhaust cover bolt 7 Oil filter wrench 2 90890 01426 Oil filter wrench 2 YB 01426 Oil filter 1 18 N m 1 8 kgf m 13 lb ft Oil pressure switch 1 9 N m 0 9 kgf m 6 6 lb ft Oil pressure switch bolt 3 2 0 N m 0 20 kgf m 1 5 lb ft 1 2 T R 1 2 3 T R Thermo sensor 2 23 N m 2 3 kgf m 17 lb ft 1 2 T R New New New 1...

Page 203: ... Install Hose joint 1 a Install the hose joint 1 to the specified in stallation height a 5 Install Bracket 1 Exhaust cover bolt 1 1st 6 N m 0 6 kgf m 4 4 lb ft 2nd 12 N m 1 2 kgf m 8 9 lb ft 8 3 2 5 9 9 10 1 6 7 1 T R New New 1 2 4 3 5 5 6 6 7 8 Exhaust cover anode screw 3 2 0 N m 0 20 kgf m 1 5 lb ft Exhaust cover anode plug 4 18 N m 1 8 kgf m 13 lb ft Exhaust cover plug M14 6 23 N m 2 3 kgf m 17...

Page 204: ...22 lb ft 6 N m 0 6 kgf m 4 4 lb ft 17 N m 1 7 kgf m 13 lb ft New New New New New Part name Q ty Remarks 1 Bolt M8 82 mm 8 2 Bolt M6 35 mm 8 3 Crankcase 1 4 Dowel pin 4 5 Bolt M6 30 mm 6 6 Connecting rod as sembly 3 7 Crankshaft pin bearing 6 8 Clip 6 9 Piston pin 3 10 Piston 3 11 Piston ring set 3 12 Crankshaft 1 13 Crankshaft journal bearing 8 14 Oil seal 1 15 Oil seal 1 16 Cylinder block 1 ...

Page 205: ... Connecting rod cap 2 Piston assembly 3 TIP Make sure to keep the crankshaft pin bear ings in their original groups Mark each piston with an identification num ber a of the corresponding cylinder Do not mix the connecting rods and caps Keep them organized in their proper groups 4 Remove Crankshaft 1 Crankshaft journal bearing 2 Oil seal 3 Oil seal 4 3 7 6 2 4 8 5 1 12 16 13 9 11 15 14 10 1 2 1 1 1...

Page 206: ... Above specification Replace the cylin der block 1 1 2 3 a b Piston Diameter 64 950 64 965 mm 2 5571 2 5577 in Limit 64 910 mm 2 5555 in 1st oversize diameter 65 200 65 215 mm 2 5669 2 5675 in 2nd oversize diameter 65 450 65 465 mm 2 5768 2 5774 in Measuring point 5 0 mm 0 20 in above the bottom of the piston skirt a 10 0 mm 0 39 in b 48 0 mm 1 89 in c 85 0 mm 3 35 in d Parallel to the crankshaft ...

Page 207: ...wn at the specified measur ing point a Piston clearance maximum cylin der bore piston outside diameter Piston clearance 0 035 0 065 mm 0 0014 0 0026 in Limit 0 115 mm 0 0045 in a Top ring b 2nd ring c Oil ring T B T T B B a b c Piston ring dimensions Top ring Height B 1 170 1 190 mm 0 0461 0 0469 in Width T 2 300 2 500 mm 0 0906 0 0984 in 2nd ring Height B 1 470 1 490 mm 0 0579 0 0587 in Width T 2...

Page 208: ...ng point 10 0 mm 0 39 in a Ring groove Top b Ring groove 2nd c Ring groove Oil Piston ring groove Ring groove Top 1 21 1 23 mm 0 0476 0 0484 in Ring groove 2nd 1 51 1 53 mm 0 0594 0 0602 in Ring groove Oil 2 52 2 54 mm 0 0992 0 1000 in 1 a b a a b c a Top ring side clearance b 2nd ring side clearance c Oil ring side clearance Piston ring side clearance Top ring Side clearance 0 02 0 06 mm 0 0008 0...

Page 209: ...ecking the connecting rod small end inside diameter and big end in side diameter 1 Measure Connecting rod small end inside diameter and big end inside diameter Above specification Replace a Tighten the connecting rod bolts 1 to the specified torques in 2 stages TIP When checking the big end inside diameter re use the removed connecting rod bolts Pin boss inside diameter 15 974 15 985 mm 0 6289 0 6...

Page 210: ...al diameters a crank shaft pin diameters b and crankshaft pin widths c Out of specification Replace 2 Measure Runout Above specification Replace Connecting rod bolt 1 1st 6 N m 0 6 kgf m 4 4 lb ft 2nd 17 N m 1 7 kgf m 13 lb ft Big end side clearance 0 050 0 220 mm 0 0020 0 0087 in Limit 0 27 mm 0 0106 in 1 a b T R a a Journal diameter 42 984 43 000 mm 1 6923 1 6929 in Crankshaft pin diameter 32 98...

Page 211: ...1 on the crankshaft pin parallel to the crankshaft Do not place the Plastigauge PG 1 over the oil hole in the crankshaft pin of the crankshaft d Install the connecting rod 1 and connect ing rod cap 2 onto the crankshaft pin TIP When checking the oil clearance reuse the removed connecting rod bolts Make sure that the protrusions a on the con necting rod 1 and connecting rod cap 2 face toward the fl...

Page 212: ...lect the bearing as follows 1 Select Crankshaft pin bearing a Check the connecting rod mark a or painted color b b Check the crankshaft pin mark c c Select the bearing color d for the crank shaft pin bearing from the table a b Crankshaft pin bearing selection table at 20 C 68 F Connecting rod mark a color b Crankshaft pin mark c Bearing color d Red A Yellow B Red Blue A B Pink Yellow A B Green P1 ...

Page 213: ... Do not turn the crankshaft 2 until the journal oil clearance measurement has been com pleted d Place a piece of Plastigauge PG 1 on each crankshaft journal parallel to the crankshaft Do not place the Plastigauge PG 1 over the oil hole in each crankshaft journal e Install the crankshaft journal bearings into the crankcase TIP Install the crankshaft journal bearings in their original positions f In...

Page 214: ...ing select the bearing as follows 1 Select Crankshaft journal bearing a Remove the crankshaft journal bearings b Check the mark a on the crank web and the mark b on the cylinder block c Select the suitable colors c for the crank shaft journal bearing Crankcase bolt M8 2 1 8 1st 15 N m 1 5 kgf m 11 lb ft 2nd 30 N m 3 0 kgf m 22 lb ft Crankcase bolt M6 3 9 16 1st 6 N m 0 6 kgf m 4 4 lb ft 2nd 12 N m...

Page 215: ...l Oil ring 2nd ring Top ring a Install the oil rings 1 2nd ring 2 and top ring 3 Do not scratch the pistons or break the pis ton rings TIP Make sure that the T mark a on the top ring 3 and 2nd ring 2 are facing up Make sure that the piston rings move smoothly b Offset the piston ring end gaps Crankshaft journal bearing selection table at 20 C 68 F Crankshaft journal mark a Cylinder block mark b Be...

Page 216: ...stall the piston so that the UP mark on the piston crown is facing toward the flywheel magneto end of the crankshaft 5 Install Crankshaft journal bearing 1 into the cyl inder block 2 TIP Install the crankshaft journal bearings 1 in their original positions Align the oil holes a in the crankshaft journal bearings 1 with the oil holes b in the cylin der block 2 and then install the crankshaft journa...

Page 217: ...facing toward the flywheel magneto end of the crankshaft After tightening the connecting rod bolts 2 make sure that the crankshaft turns smooth ly 8 Install Dowel pin 9 Install Crankshaft journal bearing Crankcase Crankcase bolt M8 Crankcase bolt M6 a Install the crankshaft journal bearings 1 onto the crankcase 2 Distance c 14 2 14 8 mm 0 56 0 58 in Distance d 95 4 96 0 mm 3 76 3 78 in Distance e ...

Page 218: ...stall the crankcase 1 and then tighten the crankcase bolts M8 2 to the speci fied torques in 2 stages and in the order 1 2 and so on d Tighten the crankcase bolts M6 3 to the specified torques in 2 stages and in the or der 9 10 and so on TIP After tightening the crankcase bolts 2 and 3 make sure that the crankshaft turns smoothly 1 1 1 1 2 3 3 3 3 3 2 2 2 2 2 1 Crankcase bolt M8 2 1 8 1st 15 N m 1...

Page 219: ...bling the propeller shaft housing assembly 8 9 Drive shaft and lower case 8 11 Removing the drive shaft 8 12 Disassembling the drive shaft assembly 8 12 Disassembling the forward gear 8 12 Disassembling the lower case 8 13 Checking the shift rod 8 14 Checking the pinion 8 14 Checking the forward gear 8 14 Checking the drive shaft 8 14 Checking the lower case 8 14 Assembling the forward gear 8 15 A...

Page 220: ...sh and reverse gear backlash before disassembly 8 27 Shimming procedure 8 31 Shim location 8 31 Selecting the pinion shim T3 8 32 Measuring the forward gear backlash 8 34 Adjusting the forward gear shim thickness T1 8 35 Measuring the reverse gear backlash 8 36 Adjusting the reverse gear shim thickness T2 8 36 ...

Page 221: ... 26 lb ft New New New New New Part name Q ty Remarks 1 Cotter pin 1 2 Propeller nut 1 3 Washer 1 4 Washer 1 5 Propeller 1 6 Spacer 1 7 Bolt M8 25 mm 1 8 Trim tab 1 9 Bolt M10 40 mm 4 10 Bolt M8 60 mm 1 11 Drain screw 1 12 Oil level plug 1 13 Gasket 2 14 Plastic tie 2 15 Nipple 1 16 Hose 1 17 Hose nipple 1 18 Bolt M8 35 mm 1 19 Anode 1 20 Dowel pin 2 21 Lower unit 1 Part name Q ty Remarks ...

Page 222: ...acklash before disassembly 8 27 1 Drain Gear oil See step 1 in Changing the gear oil 10 18 2 Set the gear shift to the N position 3 Remove Propeller nut TIP Place a block of wood between the anti cavita tion plate and the propeller to prevent the pro peller from turning 4 Remove Trim tab bolt Trim tab a Mark the trim tab 1 and lower case with an identification mark a and then remove the trim tab 1...

Page 223: ...10 3 1 11 12 8 New New Part name Q ty Remarks 1 Bolt M8 30 mm 4 2 Cover 1 3 Seal 1 4 Water pump housing 1 5 Insert cartridge 1 6 Impeller 1 7 O ring 1 8 Impeller key 1 9 Outer plate cartridge 1 10 Gasket 1 11 Rubber seal 1 12 Plate 1 13 Dowel pin 2 ...

Page 224: ...engine overheats the inside of the water pump housing may be deformed Therefore make sure to remove the insert car tridge when checking the water pump housing 2 Check Impeller Insert cartridge Outer plate cartridge Cracked worn Replace Impeller key Keyway in the drive shaft Deformed worn Replace ...

Page 225: ... 4 New New New New New Part name Q ty Remarks 1 Bolt M8 25 mm 2 2 Propeller shaft housing 1 3 Propeller shaft 1 4 Shift plunger 1 5 Spring 1 6 Cross pin 1 7 Dog clutch 1 8 Slider 1 9 Spring 1 10 O ring 1 11 O ring 2 12 Washer 1 13 Reverse gear 1 14 Reverse gear shim T2 15 Ball bearing 1 16 Oil seal 2 17 Needle bearing 1 ...

Page 226: ...se Disassembling the propeller shaft as sembly 1 Remove Shift plunger 1 Spring 2 Cross pin 3 Dog clutch 4 Slider 5 Spring 6 Disassembling the propeller shaft housing assembly 1 Remove Reverse gear 1 Reverse gear shim s T2 2 1 2 1 2 3 4 5 6 A Worldwide B USA and Canada Stopper guide plate 3 90890 06501 Bearing separator 4 90890 06534 Bearing puller assembly 5 90890 06535 Stopper guide stand 6 90890...

Page 227: ...ft housing Stopper guide plate 2 90890 06501 Stopper guide stand 3 90890 06538 Bearing puller assembly 4 90890 06535 Slide hammer 5 YB 06096 Bearing puller legs 6 YB 06523 1 2 3 4 A 1 5 6 B A Worldwide B USA and Canada Driver rod L3 3 90890 06652 Needle bearing attachment 4 90890 06614 Driver handle large 5 YB 06071 Needle bearing attachment 6 YB 06112 3 1 2 4 A 1 2 5 6 B ...

Page 228: ... Check Teeth and dogs of the reverse gear Cracked worn Replace Assembling the propeller shaft as sembly 1 Install Dog clutch 1 Propeller shaft 2 Spring in the slider 3 Slider 4 TIP Install the dog clutch 1 onto the propeller shaft 2 with the F mark a facing toward the forward gear Align the hole b in the dog clutch 1 with the hole c in the propeller shaft 2 2 Install Cross pin 1 Spring in the dog ...

Page 229: ...Install Oil seal 1 into the propeller shaft hous ing TIP Install an oil seal halfway into the propeller shaft housing and then install the other oil seal A Worldwide B USA and Canada New 1 2 3 b a A 1 4 5 b a B Driver rod L3 2 90890 06652 Needle bearing attachment 3 90890 06614 Driver handle large 4 YB 06071 Bearing housing bearing oil seal installer 5 YB 06111 Installation depth b 3 0 3 5 mm 0 11...

Page 230: ...moothly 5 Check Reverse gear movement Not smooth Repeat from step 3 6 Install O ring to the propeller shaft hous ing Driver rod L3 2 90890 06652 Needle bearing attachment 3 90890 06614 Driver handle large 4 YB 06071 Oil seal installer 5 YB 06168 Installation depth a 4 0 4 5 mm 0 157 0 177 in Bearing inner race attachment 4 90890 06639 Bearing inner race attachment 4 YB 06639 1 2 3 4 a Needle beari...

Page 231: ...Oil seal housing as sembly 1 3 Oil seal housing 1 4 O ring 1 5 Oil seal 2 6 Washer 1 7 Shift rod 1 8 Plate 1 9 O ring 1 10 Oil seal 1 11 O ring 1 12 E clip 1 13 Shift cam 1 14 Nut 1 15 Pinion 1 16 Drive shaft 1 17 Taper roller bearing 1 18 Shim T3 19 Sleeve 1 20 Needle bearing 1 21 Forward gear 1 22 Taper roller bearing 1 23 Shim T1 24 Nut 1 25 Screw M5 25 mm 1 26 Water inlet cover STBD 1 27 Water...

Page 232: ... propel ler shaft directly Disassembling the forward gear 1 Remove Tapered roller bearing inner race 1 Drive shaft holder 3 2 90890 06517 Driveshaft holder 2 YB 06079 Pinion nut holder 3 90890 06715 Pinion nut holder 3 YB 06715 1 2 3 3 2 1 3 a A A Worldwide B USA and Canada Bearing inner race attachment 3 90890 06641 Bearing splitter plate 4 YB 06219 A Worldwide B USA and Canada 2 4 a B 1 1 2 3 4 ...

Page 233: ...he en tire installation area evenly Otherwise the paint on the lower case could be burned TIP Before removing the taper roller bearing out er race 1 place some cushioning material under the lower case to catch the outer race when it falls out If the taper roller bearing outer race does not come out lightly tap the lower case torpedo with a plastic hammer Driver rod L3 2 90890 06652 Needle bearing ...

Page 234: ...per roller bearing out er race 1 place some cushioning material under the lower case to catch the outer race when it falls out If the taper roller bearing outer race does not come out lightly tap the lower case with a plastic hammer Checking the shift rod 1 Check Shift rod Bent worn Replace Checking the pinion 1 Check Teeth of the pinion Cracked worn Replace Checking the forward gear 1 Check Teeth...

Page 235: ...aring outer race is to be in stalled using a gas torch and then install a new tapered roller bearing outer race 2 When heating the lower case heat the en tire installation area evenly Otherwise the paint on the lower case could be burned TIP Do not reuse a shim if deformed or scratched c While holding the special service tool strike the tool to check that the tapered roll er bearing outer race is ...

Page 236: ...lation depth Make sure to measure the depth on the driver handle from the flange bottom of the special service tool 5 A Worldwide B USA and Canada Driver rod LL 1 90890 06605 Bearing outer race attachment 2 90890 06622 Driver handle large 3 YB 06071 Forward gear outer race installer 4 YB 41446 3 3 4 4 B New A Worldwide B USA and Canada Driver rod SL 2 90890 06602 Needle bearing attachment 3 90890 ...

Page 237: ...uld be burned TIP Install the drive shaft sleeve with the protru sion a facing forward Do not reuse a shim if deformed or scratched 4 Install Taper roller bearing outer race a While holding the special service tool 1 strike the tool to check that the taper roller bearing outer race is installed properly If a high pitched metallic sound is produced when the special service tool is struck the outer ...

Page 238: ...inner race 1 Assembling the oil seal housing 1 Install Oil seal 1 Water inlet cover screw 1 0 N m 0 10 kgf m 0 73 lb ft Bearing inner race attachment 2 90890 06644 Bearing inner race attachment 2 YB 06644 1 2 3 4 T R New 1 2 2 A Worldwide B USA and Canada Driver rod LS 2 90890 06606 Ball bearing attachment 3 90890 06634 Driver handle large 4 YB 06071 Bearing installer Reverse gear bearing 5 YB 060...

Page 239: ...Drive shaft assembly 1 Pinion 2 Pinion nut 3 TIP When installing the pinion 2 lift up the drive shaft 1 slightly and then align the pinion splines with the shaft splines 5 Tighten Pinion nut 1 6 Check Drive shaft movement Not smooth Repeat from step 1 New New New 1 2 4 6 3 5 2 1 Drive shaft holder 3 2 90890 06517 Driveshaft holder 2 YB 06079 Pinion nut holder 3 90890 06715 Pinion nut holder 3 YB 0...

Page 240: ...shaft Propeller shaft assembly 2 to the propel ler shaft housing assembly 2 Install Shift plunger 1 Propeller shaft housing assembly 2 3 Tighten Propeller shaft housing bolt 1 Installing the water pump 1 Install Plate 1 Rubber seal 2 Dowel pin 3 Gasket 4 Outer plate cartridge 5 1 2 3 1 2 1 2 Propeller shaft housing bolt 1 16 N m 1 6 kgf m 12 lb ft 1 1 T R New 1 2 3 3 4 5 ...

Page 241: ...2 Seal 3 Cover 4 Do not turn the drive shaft counterclock wise otherwise the water pump impeller may be damaged TIP When installing the water pump housing apply grease to the inside of the insert cartridge and then turn the drive shaft clockwise while push ing down on the water pump housing Checking the lower unit for air leakage 1 Check No air leakage Air leakage Repair the location of the leak a...

Page 242: ...rwise the outboard motor could fall suddenly and result in severe injuries When loosening or tightening the propel ler nut do not hold the propeller using your hands 1 Check that the pin a is aligned with the alignment mark b on the shift bracket 1 2 Set the gear shift to the N position 3 Install Dowel pin 1 Speedometer hose 2 Hose joint Plastic tie Lower unit Lower case mounting bolt 3 Lower case...

Page 243: ...ta tion plate and the propeller to prevent the pro peller from turning 5 Install Cotter pin 1 TIP If the slots in the propeller nut 2 are not aligned with the cotter pin hole tighten the pro peller nut until they are aligned 6 Fill Gear oil See step 2 in Changing the gear oil 10 18 Propeller nut 5 35 N m 3 5 kgf m 26 lb ft 2 1 3 4 5 T R New 1 2 ...

Page 244: ...cification 5 Shimming is not required 3 Within specification 12 Install the water pump assembly 11 Adjust the forward gear shim thickness T1 and reverse gear shim thickness T2 4 YES 6 NO 6 NO 4 YES 7 Disassemble the lower unit 8 Select the pinion shims T3 9 Assemble the lower unit 10 Measure the backlash 1 Remove the water pump assembly 2 Measure the backlash before disassem bly 3 Within specifica...

Page 245: ...uring point b Measuring point c Measuring point d Average Round down average M Measurements mm Before disassembly After disassembly Measuring point a Measuring point b Measuring point c Measuring point d Average Round down average Measurements mm Before disassembly After disassembly Measuring point a Measuring point b Measuring point c Measuring point d Average Round down average ...

Page 246: ... T1 thickness measurement in 2 places Reverse gear shim T2 thickness measurement in 2 places mm Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total mm Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total ...

Page 247: ...tools 1 2 and 3 and then tighten the center bolt 3 temporarily c Turn the lower unit so that the propeller shaft is pointing down d Turn the drive shaft 10 turns or more to seat the tapered roller bearing Forward gear backlash 0 18 0 65 mm 0 0071 0 0256 in Reverse gear backlash 0 75 1 22 mm 0 0295 0 0480 in Shift rod socket 1 90890 06681 Shift rod socket 1 YB 06681 R N F 1 A Worldwide B USA and Ca...

Page 248: ...e stopper 3 in the upper end a position of the tape 2 on the drive shaft and then tighten the nuts 4 to the specified torque 1 Order from Yamaha Parts Distribution Center j Set up the special service tools 1 2 and 3 and then place another special service tool 4 on the handle stopper 5 to apply a load A Worldwide B USA and Canada Center bolt 1 shimming 5 N m 0 5 kgf m 3 7 lb ft 1 A 1 B T R Backlash...

Page 249: ...lockwise after each measurement Write down the measurement data in the shimming check sheet m Determine the backlash average and then round down the average to 2 decimal plac es Example mm n Check that the forward gear backlash av erage is within specification TIP Adjust the shim thicknesses if the forward gear backlash is out of specification o Remove the special service tools from the propeller ...

Page 250: ...peat steps k m to measure the reverse gear backlash s Check that the reverse gear backlash av erage is within specification TIP Adjust the shim thicknesses if the reverse gear backlash is out of specification t Remove the special service tools and pro peller 4 Install Outer plate cartridge Water pump assembly See Installing the water pump 8 20 Propeller nut 4 shimming 10 N m 1 0 kgf m 7 4 lb ft 3 ...

Page 251: ...ct the pin ion 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 T2 T1 T3 ...

Page 252: ...then tighten the pinion height gauge bolts c temporarily TIP Do not install the pinion shim s T3 c Install the pinion 1 and pinion nut 2 and then tighten the pinion nut 2 temporarily When tightening the pinion nut check that the drive shaft turns smoothly d Check that there is a gap a between the pinion 1 and the special service tool 3 If there is no gap and the drive shaft does not turn the speci...

Page 253: ... may not have been removed k Measure the distance between the pinion 1 and the special service tool 2 TIP When measuring the distance insert the end of the thickness gauge straight into the gap at the measurement point Do not insert the thickness gauge at an angle Measure the distance at 4 points a b c and d Write down the measurement data in the shimming check sheet Drive shaft holder 3 1 90890 0...

Page 254: ...wise correct mea surements cannot be obtained Keep the parts free of foreign material such as dirt and lint When measuring the forward gear or reverse gear backlash use the original bearings and shim s 1 Install Forward gear shim T1 Tapered roller bearing outer race TIP If the original forward gear shim s T1 are missing install new shims with a combined thickness of 0 50 mm Do not reuse a shim if ...

Page 255: ... thickness by that amount and if the value is negative de crease the current shim thickness by that amount The gray colored area on the selection chart indicates the range of the specified backlash Shimming is not required if the measured backlash is within the gray colored area The values for the shim thickness adjust ments specified in the selection chart are in tended to obtain the median value...

Page 256: ...sh Spray anti rust lubricant on the gears and bearings before installation Do not apply gear oil to the parts Otherwise correct mea surements cannot be obtained Keep the parts free of foreign material such as dirt and lint When measuring the forward gear or reverse gear backlash use the original bearings and shims 1 Install Reverse gear shim T2 Propeller shaft housing assembly See Installing the p...

Page 257: ... measurement BL2 0 20 mm a Reverse gear shim T2 thickness adjust ment 0 42 mm b The current shim thickness must be de creased by 0 42 mm b Calculate the new reverse gear shim T2 thickness TIP Use the lowest number of shims to obtain the required shim thickness If the calculated shim thickness cannot be ob tained with a combination of the available shims increase or decrease the shim thick ness by ...

Page 258: ...8 38 Shimming 4 Install Determined reverse gear shim T2 Propeller shaft housing assembly Available shim thicknesses Reverse shims 0 10 0 12 0 15 0 18 0 30 0 40 0 50 mm ...

Page 259: ...11 Upper case assembly and mount 9 13 Removing the upper case 9 14 Installing the upper case 9 14 Upper case 9 15 Disassembling the upper case 9 16 Checking the drive shaft bushing 9 16 Assembling the upper case 9 16 Oil pan and exhaust guide 9 18 Checking the oil pan and exhaust guide 9 19 Checking the oil strainer 9 19 Checking the exhaust guide anode 9 19 Assembling the oil pan and exhaust guid...

Page 260: ... the trim sensor cam 9 31 PTT motor 9 33 Removing the PTT motor 9 34 Disassembling the PTT motor 9 34 Checking the armature PTT motor 9 34 Checking the brush 9 35 Assembling the PTT motor 9 36 Installing the PTT motor 9 37 PTT gear pump 9 38 Checking the gear pump 9 40 Checking the gear pump housing 9 40 Checking the filter 9 40 Checking the valve seal 9 40 PTT cylinder 9 41 Removing the trim and ...

Page 261: ...ft Part name Q ty Remarks 1 Self locking nut 1 2 Washer 1 3 Bolt M12 80 mm 1 4 Collar 1 5 Wave washer 1 6 Washer 1 7 Washer 2 8 Bushing 2 9 Tiller handle assembly 1 10 Self locking nut 2 11 Tiller handle bracket 1 12 Bolt M6 12 mm 2 13 Spring washer 2 14 Friction plate 1 15 Nut 1 16 Nut 1 17 Steering lock washer 1 18 Friction piece 2 19 Collar 1 20 Washer 2 21 Collar 1 Black 22 Steering lock lever...

Page 262: ...r 6 Washer 7 Friction adjusting nut 8 Friction plate nut 9 3 Move the steering lock lever 1 to the maximum 4 Install Friction plate assembly 1 Washer 2 Bolt 3 5 Install Tiller handle See Installing the tiller handle 3 9 6 Tighten Friction adjusting nut 1 7 Check Steering lock lever operation Incorrect Retighten the friction adjusting nut Bolt 1 7 N m 0 7 kgf m 5 2 lb ft 3 4 1 2 a 1 4 1 3 2 5 4 4 7...

Page 263: ...amp 2 5 Shift cable 1 6 Throttle cable 1 7 Bracket 1 8 Bolt M6 30 mm 2 9 Holder 1 10 Holder 1 11 Screw M6 15 mm 1 12 PTT switch 1 13 Cap 1 14 Screw M6 15 mm 1 15 Cap 1 16 Screw M5 22 mm 1 17 Throttle grip 1 18 Bushing 1 19 Bolt M8 40 mm 1 20 Screw M6 16 mm 2 21 Shift lever 1 22 Bushing 2 23 Cotter pin 1 24 Throttle friction adjust er 1 25 Bolt M6 30 mm 2 26 Control link assembly 1 27 Plastic tie 3...

Page 264: ...15 17 18 22 23 24 9 45 4 10 4 30 32 31 3 28 2 6 2 5 33 27 1 1 1 1 1 29 34 25 7 8 16 26 13 11 12 44 2 0 N m 0 20 kgf m 1 5 lb ft New New New 3 0 N m 0 30 kgf m 2 2 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft Part name Q ty Remarks 38 Washer 2 39 Plate 1 40 Collar 1 41 Retainer 2 42 Spring 1 43 Bushing 1 44 Cap 1 45 Grease nipple 1 ...

Page 265: ...r pin 4 d Install the neutral switch 1 and then fas ten it using the new plastic ties 2 e Install the throttle arm 3 and bushing 4 f Align the marks a and b and align the cutouts c and d and then install the control link assembly 1 TIP Route the neutral switch lead under the control link assembly 1 See Tiller handle tiller han dle model 5 11 g Install the nut 1 the throttle friction ad juster 2 an...

Page 266: ...l the cap 3 or PTT switch 4 and then tighten the PTT switch screw 5 to the specified torque m Install the shift lever 6 n Check that the throttle grip operates smoothly Also check that the marks a and b are aligned and that the cutouts c and d are aligned o Check that the shift link lever operates smoothly when the shift lever is moved from the N position to the F or R position p Check that the ne...

Page 267: ...Brown Br leads and then install the holders 1 and 2 and the bracket 3 s Install the shift cable 1 throttle cable 2 clips 3 and cable clamps 4 t Connect the alert indicator couplers a and b and then install the cover 1 u Install the grease nipple 2 and then tight en it to the specified torque Lg R Sb a Br a 1 1 2 2 3 A 1 1 4 2 4 4 2 3 3 3 Grease nipple 2 3 0 N m 0 30 kgf m 2 2 lb ft b a 1 2 T R ...

Page 268: ...5 kgf m 3 7 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft Part name Q ty Remarks 1 Cover 1 2 Clamp 2 3 Screw M6 20 mm 2 4 Plate 1 5 Alert indicator 1 6 Grommet 1 7 Gasket 1 8 Bolt M6 15 mm 1 9 Bracket 1 10 Buzzer 1 11 Engine shut off switch 1 12 Engine start switch 1 13 Extension wire har ness 1 14 Alert indicator harness 1 15 Trolling switch 1 16 Grommet 1 17 Tiller handle 1 ...

Page 269: ... off switch 7 and then tighten the engine shut off switch nut 8 to the specified torque e Connect the engine shut off switch con nectors c f Install the buzzer 9 and then connect the buzzer connectors d g Align the white tapes a on the extension wire harness 1 and alert indicator har ness 2 with the inner end of the grommet 3 h Install the alert indicator 1 and then tight en the alert indicator sc...

Page 270: ...t bracket 4 5 6 7 8 9 10 3 2 1 11 6 18 N m 1 8 kgf m 13 lb ft New Part name Q ty Remarks 1 Shift rod detent bolt M12 23 mm 1 2 Spring 1 3 Ball 1 4 Cotter pin 1 5 Washer 1 6 Bushing 2 7 Bracket 1 8 Bolt M5 14 mm 1 9 Bushing 1 10 Shift rod 1 11 Grommet 1 ...

Page 271: ...Grommet 4 3 Collar 4 4 Rubber seal 1 5 Plastic tie 8 6 Hose 1 7 Hose joint 1 8 Hose joint 1 9 Gasket 1 10 Screw M6 19 mm 2 11 Adapter 1 12 Cap 1 13 Grommet 1 14 Hose joint 2 15 Holder 2 16 Hose 1 17 Hose 1 18 Clip 1 19 Hose 1 20 Water outlet 1 21 Bolt M6 20 mm 7 22 Bracket 1 23 Clamp 2 24 Bracket 1 25 Clamp 1 26 Plate 1 27 Holder 1 28 Holder 1 29 Bracket 1 30 Spring 1 31 Hook 1 32 Bolt M6 14 mm 1 ...

Page 272: ...23 1 10 5 5 5 27 17 5 15 5 5 5 18 15 33 34 38 43 37 36 44 42 3 40 A 29 3 2 39 35 16 1 4 24 23 22 21 25 21 2 2 3 6 13 12 21 41 26 2 20 3 1 41 45 5 N m 0 5 kgf m 3 7 lb ft 14 Part name Q ty Remarks 39 Cover 1 40 PTT switch 1 41 Grommet 2 42 Grommet 2 43 Collar 2 44 Grommet 2 45 Bottom cowling 1 ...

Page 273: ...7 18 13 15 10 4 2 17 24 N m 2 4 kgf m 18 lb ft Part name Q ty Remarks 1 Bolt M6 7 mm 1 2 Ground lead 1 3 Self locking nut 2 4 Nut 2 5 Washer 2 6 Bolt M8 30 mm 3 7 Bolt M8 175 mm 2 8 Upper mount 1 9 Plate 1 10 Bolt M8 30 mm 4 11 Cover 2 12 Cap 2 13 Bolt M12 170 mm 2 14 Washer 2 15 Rubber washer 2 16 Washer 2 17 Lower mount 2 18 Washer 2 ...

Page 274: ...g bolt Upper mount Upper mount bolt temporarily tighten 2 Install Washer 1 Rubber washer 2 Washer 3 Lower mounting bolt 4 Lower mount 5 Washer 6 Cap 7 Lower mount cover 8 Lower mount cover bolt 9 TIP Tighten the lower mount cover bolts temporar ily 3 Install Upper case assembly 1 Ground lead 2 Washer 3 Upper mounting nut 4 Lower mounting nut 5 4 Tighten Upper mount bolt Lower mount cover bolt 1 2 ...

Page 275: ...27 N m 2 7 kgf m 20 lb ft New New New A Part name Q ty Remarks 1 Clip 1 2 Hose 1 3 Drain bolt 1 4 Gasket 1 5 Damper 1 6 Bolt M8 30 mm 4 7 Upper case 1 8 Dowel pin 2 9 Rubber seal 1 10 Guide 1 11 Screw M5 16 mm 2 12 Baffle plate 1 13 Grommet 1 14 Plug M14 12 mm 1 15 Gasket 1 16 Circlip 1 17 Drive shaft bushing 1 18 Rubber seal 1 19 Rubber seal 1 20 Dowel pin 2 Part name Q ty Remarks ...

Page 276: ...ip 2 A Worldwide B USA and Canada Stopper guide plate 3 90890 06501 Reverse gear bearing remover 3 YB 41707 Pinion Gear Bushing Installer 4 90890 06601 Pinion gear bushing installer 4 YB 06029 4 4 3 1 2 A 4 1 3 2 B A Worldwide B USA and Canada Driver rod L3 3 90890 06652 Driver handle large 3 YB 06071 Needle bearing attachment 4 90890 06611 Driveshaft needle bearing installer and remover 4 YB 0619...

Page 277: ...ipe rubber seal Cooling water pipe Muffler rubber seal Dowel pin Muffler rubber seal Upper case assembly Upper case bolt Drain bolt gasket Drain bolt Plug 27 N m 2 7 kgf m 20 lb ft Upper case bolt 21 N m 2 1 kgf m 15 lb ft Drain bolt 27 N m 2 7 kgf m 20 lb ft New New New New T R ...

Page 278: ... Remarks 1 Bolt M6 25 mm 6 2 Muffler 1 3 Gasket 2 4 Plate 1 5 Bolt M6 50 mm 3 6 Gasket 1 7 Exhaust manifold 1 8 Gasket 1 9 Bolt M6 25 mm 10 10 Oil pan 1 11 Dowel pin 2 12 Gasket 1 13 Pipe 1 14 Rubber seal 1 15 Bolt M6 25 mm 3 16 Bolt M6 16 mm 2 17 Oil strainer 1 18 Cover 1 19 Gasket 1 20 Gasket 1 21 Bolt M5 12 mm 1 22 Bolt M6 20 mm 1 23 Plate 1 24 Cover 1 25 Anode 1 26 Grommet 1 27 Oil seal 1 28 E...

Page 279: ...aust guide anode 1 Check Anode Eroded 1 2 or more Replace There is grease oil or scales Clean Do not apply grease oil or paint to the an ode Assembling the oil pan and exhaust guide 1 Install Oil seal 1 Anode grommet Anode Anode cover Anode bolt Anode plate Anode plate bolt New 3 A 2 1 A Worldwide B USA and Canada Driver rod L3 2 90890 06652 Driver handle large 2 YB 06071 Needle bearing attachment...

Page 280: ... 4 Oil pan 5 Oil pan bolt 6 temporarily tighten 3 Install Exhaust manifold gasket 1 Exhaust manifold 2 Exhaust manifold bolt 3 temporarily tighten Exhaust manifold gasket 4 4 Tighten Exhaust manifold bolt Oil pan bolt 5 Install Muffler gasket Muffler plate Muffler New New New 5 6 3 2 1 4 4 572 572 LT LT 572 572 LT LT 572 572 LT LT New New 3 3 2 1 4 Exhaust manifold bolt 11 N m 1 1 kgf m 8 1 lb ft ...

Page 281: ...1 2 11 12 4 5 10 9 7 7 9 9 6 8 20 N m 2 0 kgf m 15 lb ft A New New Part name Q ty Remarks 1 Circlip 1 2 Steering yoke 1 3 Bushing 1 4 O ring 2 5 Bushing 2 6 Self locking nut 2 7 Washer 2 8 Steering hook 1 9 Stud bolt 2 10 Steering arm 1 11 Washer 1 12 Bushing 1 ...

Page 282: ... the steering arm Steering arm Bushing to the swivel bracket O ring to the swivel bracket Bushing to the swivel bracket Steering yoke TIP Make sure that the steering yoke 1 is facing the same direction as the steering arm 2 aligning a with b 2 Install Circlip 1 Stud bolt TIP Hold the steering arm and then strike the steering yoke using a copper hammer until the groove a for installing the circlip ...

Page 283: ...9 23 Steering arm 3 Inject Grease TIP Inject grease into the grease nipple 1 until it comes out from both the upper and lower bushings a a 1 ...

Page 284: ...14 16 13 12 5 4 Part name Q ty Remarks 1 Bolt M8 15 mm 2 2 Washer 2 3 Shaft 1 4 Collar 1 5 Collar 1 6 Bushing 2 7 E clip 2 8 Shaft 1 9 Bushing 1 10 Bushing 2 11 Hydro tilt assembly 1 12 Screw M6 25 mm 1 13 Anode 1 14 Bolt M6 10 mm 1 15 Tilt lock lever 1 16 Cap 1 ...

Page 285: ...e Do not disassemble or puncture the hydro tilt unit as high pressure gas is con tained Do not apply heat or fire to the hydro tilt unit as high pressure gas is contained Checking the hydro tilt anode 1 Check Anode Eroded 1 2 or more Replace There is grease oil or scales Clean Do not apply grease oil or paint to the an ode Installing the hydro tilt assembly 1 Install Anode Bushing to the hydro til...

Page 286: ... 9 12 4 10 1 1 2 13 13 3 New Part name Q ty Remarks 1 Plastic tie 2 2 Corrugated tube 1 3 Plastic tie 2 4 Bolt M6 10 mm 2 5 Bolt M8 15 mm 2 6 Washer 2 7 Shaft 1 8 Bushing 2 9 Bushing 1 10 E clip 2 11 Shaft 1 12 PTT unit 1 13 Bushing 2 14 Bushing 1 ...

Page 287: ...ully from the PTT unit due to internal pressure 1 Bleed PTT unit a Place the PTT unit in an upright position b Turn the manual valve 1 counterclock wise to check that it is closed c Remove the reservoir cap 1 and then check the fluid level TIP If the fluid is at the proper level a small amount of fluid should flow out of the filler hole d If the fluid is below the proper level add the recommended ...

Page 288: ...check the fluid level TIP If the fluid is below the proper level add the recommended PTT fluid Repeat steps c i until the fluid is at the proper level k Install a new O ring and the reservoir cap and then tighten the reservoir cap to the specified torque Installing the PTT unit 1 Install Bushing to the PTT unit clamp bracket and swivel bracket PTT unit Shaft upper side E clip Shaft lower side Wash...

Page 289: ...ie a Fasten the PTT motor lead 1 and the speedometer hose 2 at the white tape a with a new plastic tie 3 4 Install Corrugated tube Plastic tie a Install the corrugated tube 1 and then fasten it with the plastic ties 2 New 1 2 a 3 1 2 2 ...

Page 290: ...emarks 1 Screw M6 15 mm 2 2 Trim sensor 1 3 Bolt M6 14 mm 2 4 Ground lead 1 5 Ground lead 1 6 Self locking nut 1 7 Clamp bracket STBD 1 8 Screw M5 35 mm 1 9 Trim sensor cam 1 10 Swivel bracket 1 11 Grease nipple 2 12 Clamp 1 13 Bushing 2 14 Bolt M8 20 mm 1 15 Through tube 1 16 Clamp bracket PORT 1 17 Bolt M10 50 mm 2 18 Stopper 2 19 Pin 1 20 Stopper knob 1 21 Stopper shaft 1 22 Bushing 1 23 Bolt M...

Page 291: ...lder PTT model TIP Secure the trim sensor lead 1 using the clamp 2 and holder 3 2 Inject Grease a Inject grease into the grease nipples until grease comes out from the bushings a Adjusting the trim sensor cam 1 Adjust Trim sensor setting resistance a Fully tilt the swivel bracket down b Loosen the trim sensor cam screw 1 c Measure the trim sensor setting resis tance Adjust if out of specification ...

Page 292: ...between the ends of the trim sensor cam is within specification 2 Check Trim sensor setting resistance Out of specification Repeat from step 1 Setting resistance 9 11 F30A F30BET F30HA F40A F40FET F40HA Terminal c Terminal d Trim sensor cam end gap a 16 0 19 0 mm 0 63 0 75 in 1 a ...

Page 293: ...ft 7 N m 0 7 kgf m 5 2 lb ft Part name Q ty Remarks 1 PTT motor assembly 1 2 Screw M4 12 mm 2 3 Stator 1 4 O ring 1 5 Armature 1 6 Screw M4 16 mm 2 7 PTT motor lead 1 8 Brush 1 9 Brush assembly 1 10 Spring 2 11 Holder 1 12 Bolt M6 20 mm 4 13 Base 1 14 Oil seal 1 15 O ring 1 16 Spring 1 17 Joint 1 18 Reservoir cap 1 19 O ring 1 ...

Page 294: ...the end of the armature shaft using a pair of pliers and then remove the arma ture along with the motor base assembly Otherwise the armature could separate from the motor base assembly due to the magnetic force of the stator 2 and dam age the brushes Checking the armature PTT motor 1 Check Commutator Dirty Clean using 600 grit sandpaper and compressed air 2 Measure Commutator diameter a Below spec...

Page 295: ...tion of the circuit breaker could be affected 3 Check PTT motor base Cracks damage Replace the PTT motor assembly Standard commutator undercut 1 50 mm 0 0591 in F30A F30BET F30HA F40A F40FET F40HA Wear limit 1 35 mm 0 0532 in F30A F30BET F30HA F40A F40FET F40HA Digital circuit tester 90890 03243 Digital multimeter YU 34899 A Armature continuity a b c d a a b c d a Standard brush length b Wear limi...

Page 296: ...ircuit breaker could be affected 3 Install Armature a Push the brushes 1 into the brush holder and then install the armature 2 4 Install Stator 1 Screw 2 Secure the end of the armature shaft using a pair of pliers and then install the arma ture along with the motor base assembly Otherwise the armature could separate from the motor base assembly due to the magnetic force of the stator 1 and dam age...

Page 297: ...tor 1 Install Joint Spring O ring to the motor base PTT motor assembly PTT motor mounting bolt O ring to the reservoir cap Reservoir cap PTT motor mounting bolt 7 N m 0 7 kgf m 5 2 lb ft Reservoir cap 7 N m 0 7 kgf m 5 2 lb ft New New T R ...

Page 298: ...Remarks 1 Bolt M6 75 mm 3 2 Gear pump housing 1 3 Ball 2 4 Absorber valve pin 2 5 Spring 2 6 O ring 2 7 Filter 1 8 O ring 1 9 O ring 4 10 Bolt M4 25 mm 4 11 Gear pump assembly 1 12 O ring 2 13 Spring 1 14 Valve pin 1 15 Valve seal 1 16 Filter 2 17 O ring 2 18 Circlip 1 19 Manual valve 1 20 O ring 1 21 O ring 1 22 Manual valve seat 2 23 Spring 1 24 Adapter 1 25 Main valve assembly 2 26 Main valve 2...

Page 299: ... 17 16 17 2 31 30 29 28 26 25 5 4 3 9 7 3 4 6 8 14 15 15 14 6 N m 0 6 kgf m 4 4 lb ft 11 N m 1 1 kgf m 8 1 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 1 9 N m 0 9 kgf m 6 6 lb ft New New New New New New New New New New New New New New New New New Part name Q ty Remarks 39 Spring 1 40 Lock screw 1 ...

Page 300: ...p housing 1 Check Gear pump housing Corrosion cracks Replace the gear pump assembly Checking the filter 1 Check Down relief valve filter Dirt residue Clean Clogged damaged Replace Checking the valve seal 1 Check Main valve Shuttle piston Absorber valve pin Relief valve Valve seal Valve pin Manual valve Manual valve seat Spring Damage wear Replace ...

Page 301: ...N m 9 0 kgf m 66 lb ft 61 N m 6 1 kgf m 45 lb ft 7 6 3 5 2 1 8 New New New New 4 New Part name Q ty Remarks 1 Trim and tilt ram as sembly 1 2 Dust seal 1 3 O ring 1 4 O ring 1 5 O ring 1 6 Free piston assembly 1 7 O ring 1 8 Cylinder 1 ...

Page 302: ...cause the free piston and PTT fluid could be expelled forcefully 5 Remove Tilt piston Tilt cylinder end screw Absorber valve Checking the PTT cylinder and piston 1 Check PTT body Corroded cracked Replace Inner surface of the PTT body Tilt cylinder end screw Outer surface of the tilt piston Outer surface of the free piston Cracks scratched Replace Trim and tilt ram assembly Rust Clean using 400 600...

Page 303: ...ew 1 Tilt piston 2 O ring 3 3 Install Ball 1 Absorber valve pin 2 Spring 3 Washer 4 Tilt piston bolt 5 Installing the trim and tilt ram assem bly 1 Install Gear pump See PTT gear pump 9 38 2 Add the recommended fluid through the PTT body hole a New New New 1 2 3 2 1 3 New 1 2 3 Tilt piston bolt 1 61 N m 6 1 kgf m 45 lb ft Fluid quantity reference quantity 60 at tilt cylinder 1 3 2 1 1 3 1 2 5 4 T ...

Page 304: ...rew 1 at the bottom of the trim and tilt ram b Install the trim and tilt ram assembly into the cylinder 5 Tighten Trim cylinder end screw 1 New 2 1 1 A Worldwide B USA and Canada Cylinder end screw wrench 2 90890 06591 Trim cylinder wrench 2 YB 06175 2B Trim cylinder end screw 1 90 N m 9 0 kgf m 66 lb ft 2 1 A 1 B 2 T R ...

Page 305: ...r trim and tilt unit 10 9 Checking the hydro tilt unit 10 9 General periodic maintenance 10 11 Checking the engine idle speed noise 10 14 Checking the cooling water inlet 10 14 Changing the engine oil using an oil changer 10 14 Changing the engine oil by removing the drain bolt 10 15 Replacing the oil filter 10 17 Changing the gear oil 10 18 Checking the gear oil level 10 19 Greasing points 10 19 ...

Page 306: ... 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 will los...

Page 307: ...housing Inspection or replace ment as necessary Impeller water pump housing Replacement Power trim and tilt unit Inspection Propeller propeller nut cotter pin Inspection or replace ment as necessary Shift link shift cable Inspection adjustment or replacement as nec essary Spark plug s Inspection or replace ment as necessary Spark plug caps spark plug wires Inspection or replace ment as necessary W...

Page 308: ...essary Wire harness connec tions wire coupler con nections Inspection or replace ment as necessary Yamaha Meter gauge Inspection Fuel tank Yamaha por table tank Inspection and cleaning as necessary Item Actions Every 1000 hours Exhaust guide exhaust manifold Inspection or replace ment as necessary Timing belt Replacement Item Actions Initial Every 20 hours 3 months 100 hours 1 year 300 hours 3 yea...

Page 309: ...tion Check the engine start switch 5 35 Engine shut off switch Check that the engine stops when the clip is removed from the en gine shut off switch Out of specification Check the engine shut off switch 5 33 Fuel line Check the fuel line connection Disconnect Connect 2 15 Check all the fuel lines for leakage Leaking Check the related parts Gear oil Check the gear oil level Below the proper level A...

Page 310: ...otor up and then support it using the tilt support knob Outboard motor is not supported Check the tilt support knob Steer the tilted up outboard motor Hose interference Check the hose routing Steering system Check that the steering operates smoothly Not smooth Check the steering arm swivel bracket helm unit or related parts 9 30 Check that the there is no interference with hose or leads when the o...

Page 311: ...ying speeds up to 2000 r min or approx imately 1 2 throttle For the second hour of operation Increase the engine speed until the boat is on plane but do not ful ly open the throttle and then back off on the throttle while keeping the boat at a planing speed For the remaining 8 hours of operation Operate the engine at any engine speed However do not operate the engine at full throttle for more than...

Page 312: ...cking the battery Battery electrolyte is dangerous it con tains sulfuric acid which is poisonous and highly caustic Always follow these preven tive measures Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury Wear protective eye gear when handling or working near batteries Antidote EXTERNAL SKIN Wash with water EYES Flush with water for 15 minutes and get imm...

Page 313: ...il level Below the proper level Add the recom mended gear oil a Place the outboard motor in an upright po sition b Remove the oil level plug 1 and gasket 2 and then check the gear oil level TIP If the oil is at the proper level a small amount of oil should flow out of the check hole c Install a new gasket and the oil level plug and then tighten the oil level plug to the specified torque Recommende...

Page 314: ...iffer ent heights 2 Check Mount bolts Loosen Tighten Checking the power trim and tilt unit 1 Check Power trim and tilt unit Abnormal noise Check the PTT unit Interference Check the hose and wire harness routing or mounting of the out board motor Does not display Adjust the trim sensor cam See Adjusting the trim sensor cam 9 31 a Check that there is no abnormal noise pro duced when the outboard mot...

Page 315: ... 1 is in the lock position a c Fully tilt the outboard motor up and then support it using the tilt support knob 1 Check that the tilt support knob locks in place properly 2 Check Steer the tilted up outboard motor Interference Check the hose and wire harness routing or mounting of the out board motor 1 a 1 ...

Page 316: ...e idle speed 10 14 Engine oil Check the oil level using the dipstick Not at the proper level Add or extract the engine oil 10 7 Check the engine oil Replacement interval has been exceeded deterioration Change Milky Overhaul the outboard motor 10 14 10 15 Oil filter Replace the oil filter 5 35 Main switch stop switch Check that the engine starts when the engine start switch is turned to START Out o...

Page 317: ...heck the engine oil line Leaking Check the related parts 2 10 Gear oil Check the gear oil level Below the proper level Add the recommended gear oil 10 19 Check the gear oil Replacement interval has been exceeded deterioration Change Milky Overhaul the lower unit 10 18 8 1 Greasing Apply lubricants 10 19 Propeller Propeller nut Cotter pin Check the propeller blade and spline Cracked damaged worn Re...

Page 318: ...osed position tiller handle model Not at the proper position Adjust the throttle cable joint or check the related parts 3 6 Timing belt Check the timing belt Cracked damage worn Replace 7 15 Thermostat Measure the thermostat valve opening Out of specification Replace 7 46 Cowling lock lever Check the fitting by pushing the top cowling Looseness rattling Adjust or replace the top cowling stopper 10...

Page 319: ...l the water inlet covers 1 and trim tab 2 and then tighten the water inlet cover screw 3 to the specified torque TIP After installing the water inlet covers 1 make sure that there is no rattling Changing the engine oil 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 Warm up Engine a Place the outbo...

Page 320: ...dipstick 1 and wipe it clean d Insert the dipstick 1 completely for a cor rect measurement and remove it again e Check that the oil level indicated on the dipstick 1 is between the upper mark a and the lower mark b f Start the engine and check that the oil pressure alert indicator does not come on Also check that there is no oil leakage If the oil pressure alert indicator comes on or if there is o...

Page 321: ... oil filler cap Do not overfill the engine with engine oil Otherwise the engine could be damaged or oil could leak If the engine oil is above the upper level extract the excess engine oil until the oil is at the proper level b Leave the outboard motor off for 5 10 min utes c Remove the dipstick 1 and wipe it clean d Insert the dipstick 1 completely for a cor rect measurement and remove it again e ...

Page 322: ...ngine oil was changed by removing the drain bolt install the drain bolt See step 3 in Changing the engine oil by removing the drain bolt 10 15 4 Replace Oil filter a Place a rag under the oil filter and then re move the oil filter TIP Make sure to clean up any oil spills b Install a new oil filter 1 5 Fill Recommended engine oil a Fill the engine with the specified amount of the recommended engine...

Page 323: ...etic drain screw the low er unit may have a problem d Remove the oil level plug 4 and gasket 5 and let the oil drain completely After the gear oil has been drained check the used oil If the oil is milky water is get ting into the lower case which can cause gear damage e After the gear oil has been drained check the used oil Pressure test the lower case and inspect the oil seal for damage if the oi...

Page 324: ...ve all metal particles Checking the gear oil level 1 Check the gear oil level See Checking the gear oil level 10 8 Greasing points 1 Apply Specified lubrication points a Apply water resistant grease to the speci fied lubrication points Gear oil quantity 0 430 L 0 455 US qt 0 378 Imp qt Oil level plug 2 7 N m 0 7 kgf m 5 2 lb ft Drain screw 2 7 N m 0 7 kgf m 5 2 lb ft T R 2 1 T R ...

Page 325: ...be 2 Clean inside of the through tube and the hydraulic steering cylinder rod or steering cable 3 Apply a sufficient amount of grease to the inside of the through tube and to the hy draulic steering cylinder rod or steering ca ble 4 Assemble the hydraulic steering cylinder or steering cable to the through tube Checking the PTT fluid level Never get under the outboard motor while it is tilted 1 Che...

Page 326: ... If the fluid is below the proper level add the recommended fluid d Install a new O ring and the reservoir cap and then tighten the reservoir cap to the specified torque Checking the cowling lock lever 1 Check Top cowling fitting Looseness ratting Adjust a Check the fitting by pushing the top cowl ing 2 Adjust Top cowling fitting Looseness rattling Replace the cowling seal a Loosen the nuts 1 b Mo...

Page 327: ...m A 14 Engine control unit fuel unit and ignition unit A 15 Charging unit starting unit and PTT unit A 16 Control unit A 17 Shim selection table and chart A 18 Pinion shim T3 selection table A 18 Forward gear shim T1 selection chart A 19 Reverse gear shim T2 selection chart A 19 ...

Page 328: ...6 mm 21 1 in Dry weight AL S 94 kg 207 lb F30BET_EUR 91 kg 201 lb RUS 98 kg 216 lb F40FEH D_EUR 94 kg 207 lb Dry weight AL L 102 kg 225 lb 105 kg 231 lb 98 kg 216 lb F30A F30BET_CHN EUR 95 kg 209 lb EUR 102 kg 225 lb F40EHA F40FEHD_ EC2 EUR NME OTH 105 kg 231 lb Dry weight With AL aluminum propeller Performance Rated power 22 1 kW 30 HP 29 4 kW 40 HP Full throttle operating range 5000 6000 r min M...

Page 329: ...et sump Lower unit Gear shift positions Forward neutral reverse Gear ratio 2 00 26 13 Gear type Spiral bevel gear Clutch type Dog clutch Propeller fitting mecha nism Spline Propeller direction rear view Clockwise Propeller mark G Bracket unit Trim angle 3 9 3 16 3 9 3 16 Full Tilt up angle 65 66 65 66 Tilt support angle 54 Steering angle 40 40 Trim and tilt system Hydro tilt Power trim and tilt Hy...

Page 330: ...oil filter replacement 1 7 L 1 80 US qt 1 50 Imp qt Recommended gear oil YAMALUBE outboard gear oil or Hypoid gear oil F30BEHD Yamalube Marine Gearcase Lube or Hypoid gear oil F30EHA Yamalube Marine Gearcase Lube or Hypoid gear oil YAMALUBE outboard gear oil or Hypoid gear oil F30BET Yamalube Marine Gearcase Lube or Hypoid gear oil F30A YAMALUBE outboard gear oil or Hypoid gear oil YAMALUBE outboa...

Page 331: ...fluid or ATF Dexron II F30A Yamalube Marine Power Trim and Tilt fluid or ATF Dexron II ATF Dexron II F40FET Yamalube Marine Power Trim and Tilt fluid or ATF Dexron II F40A Electrical system technical data Ignition timing control system Spark plug Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cap resistance 5 0 k Ignition coil Primary coil resistance 0 180 0 240 Secondary coil resis tance 3 26 4 88 k Pu...

Page 332: ...or Resistance at 20 C 68 F 2 49 k Resistance at 60 C 140 F 0 589 k Resistance at 100 C 212 F 0 193 k Shift position switch Input voltage 12 V Fuel injection control system Water detection switch Input voltage 5 V Fuel injector Input voltage 12 V Resistance reference data 12 00 High pressure fuel pump Input voltage 12 V Resistance reference data 1 4 1 7 Vapor shut off valve Input voltage 12 V Resis...

Page 333: ...e 29 40 58 80 kPa 0 294 0 588 kgf cm 4 26 8 53 psi PTT system Trim sensor Free position resistance 239 379 239 379 Setting resistance 9 11 9 11 Charging system Lighting coil Output peak voltage at cranking unloaded ref erence data 14 0 V Output peak voltage at 1500 r min unloaded reference data 45 0 V Output peak voltage at 3500 r min unloaded reference data 102 0 V Resistance reference data 0 561...

Page 334: ...or undercut 0 5 mm 0 02 in Wear limit 0 2 mm 0 01 in Y COP Receiver Input voltage 12 V Buzzer Input voltage 12 V Button cell battery CR2016 Battery voltage refer ence data 3 V Gauge sensor Water pressure sensor Input voltage 5 V Output voltage at 392 kPa 3 92 kgf cm 56 8 psi reference data 2 5 V Output voltage at 784 kPa 7 84 kgf cm 113 7 psi reference data 4 5 V Speed sensor Input voltage 5 V Out...

Page 335: ...g pressure posi tive pressure 200 0 kPa 2 0 kgf cm 29 00 psi Fuel filter assembly Fuel inlet holding pres sure positive pressure 200 kPa 2 0 kgf cm 29 0 psi Fuel outlet holding pres sure negative pressure 80 kPa 0 8 kgf cm 11 6 psi Fuel pump Fuel inlet holding pres sure positive pressure 50 0 kPa 0 50 kgf cm 7 3 psi Fuel inlet holding pres sure negative pressure 30 0 kPa 0 3 kgf cm 4 4 psi Fuel ou...

Page 336: ...it 0 10 mm 0 0039 in Journal inside diameter 37 000 37 025 mm 1 4567 1 4577 in Camshaft Cam lobe height IN 30 737 30 837 mm 1 2101 1 2141 in Limit 30 587 mm 1 2042 in Cam lobe height EX 30 933 31 033 mm 1 2178 1 2218 in Limit 30 783 mm 1 2119 in Journal diameter 36 925 36 945 mm 1 4537 1 4545 in Runout 0 030 mm 0 0012 in Valve clearance Valve clearance IN cold engine 0 15 0 25 mm 0 0059 0 0098 in ...

Page 337: ...0 025 0 052 mm 0 0010 0 0020 in Limit 0 070 mm 0 0028 in Installation height 16 30 16 70 mm 0 6417 0 6575 in Valve spring Free length IN 39 85 mm 1 57 in Limit 37 86 mm 1 49 in Tilt limit IN 1 7 mm 0 07 in Free length EX 39 85 mm 1 57 in Limit 37 86 mm 1 49 in Tilt limit EX 1 7 mm 0 07 in Rocker arm shaft Outside diameter IN 15 971 15 991 mm 0 6288 0 6296 in Outside diameter EX 15 971 15 991 mm 0 ...

Page 338: ...5 965 15 970 mm 0 6285 0 6287 in Limit 15 955 mm 0 6281 in Piston ring Top Type Barrel Height B 1 170 1 190 mm 0 0461 0 0469 in Width T 2 300 2 500 mm 0 0906 0 0984 in End gap 0 15 0 30 mm 0 0059 0 0118 in Limit 0 500 mm 0 0197 in End gap measuring point 10 0 mm 0 39 in Side clearance 0 02 0 06 mm 0 0008 0 0024 in Limit 0 110 mm 0 0043 in Piston ring 2nd Type Taper Height B 1 470 1 490 mm 0 0579 0...

Page 339: ...t 0 03 mm 0 0012 in Limit 0 04 mm 0 0016 in Crankshaft pin width 21 00 21 07 mm 0 8268 0 8295 in Journal oil clearance 0 012 0 036 mm 0 0005 0 0014 in Limit 0 066 mm 0 0026 in Lower unit technical data Lower unit assembly Lower unit Holding pressure 68 6 kPa 0 69 kgf cm 9 9 psi Gear backlash Forward gear backlash 0 18 0 65 mm 0 0071 0 0256 in Reverse gear backlash 0 75 1 22 mm 0 0295 0 0480 in Fig...

Page 340: ... psi Down 2 00 Mpa 20 0 kgf cm 290 0 psi 2 00 Mpa 20 0 kgf cm 290 0 psi Motor Standard commutator diameter 17 60 mm 0 6929 in 17 60 mm 0 6929 in Wear limit 16 60 mm 0 6535 in 16 60 mm 0 6535 in Standard commutator undercut 1 50 mm 0 0591 in 1 50 mm 0 0591 in Wear limit 1 35 mm 0 0532 in 1 35 mm 0 0532 in Standard brush length 7 00 mm 0 2756 in 7 00 mm 0 2756 in Wear limit 3 5 mm 0 14 in 3 5 mm 0 1...

Page 341: ... the wiring diagrams Terminal numbers Terminal numbers are indicated for cases where terminal locations of wires are unclear In the coupler illustrations only the rightmost and leftmost terminal numbers are indicated and termi nal numbers between them are omitted 1 2 3 4 5 6 1 Double colors wire 2 Not used vacant 3 A wire is not included in the selected wiring unit 4 Alert buzzer 5 Optional parts ...

Page 342: ...Jul 2018 ABE E ...

Page 343: ... B 1 2 3 1 2 3 Pu R Pu B Pu Y R Y G B P G Or B P G B Y G R G B G Y B R G W P Br Y R Y R Y R Y R Y R Y B B B B B B B B B B B 1 12 1 2 4 5 6 1 12 13 24 24 20 21 22 23 3 1 2 4 10 11 R R 1 3 4 5 6 7 8 R R L L R Y R Y Y G B B R R B B B R R R Br Br Br R L B B L 17 34 1 18 35 52 43 44 Br B b c A G R G B 3 18 1 Engine ECM 2 Thermo sensor 3 Pulser coil 4 Oil pressure switch 5 Ignition coil 6 Water detectio...

Page 344: ...R R B B B R R R Br Br Br B W B R B L Or B Or L B Or W W L W L Lg Sb R P B P P B P B P W R B Lg Sb G G G G L G L P P Br B 1 12 a b c d 17 34 1 18 35 52 43 44 1 Engine ECM 2 Speed sensor 3 Water pressure sensor 4 PTT motor 5 PTT switch 6 Trim sensor 7 Joint connector 1 8 Joint connector 2 9 Starter motor 10 Starter relay 11 Stator assembly 12 Rectifier regulator 13 Main relay 14 PTT relay 15 Battery...

Page 345: ... switch 4 PTT switch 2 Engine start switch 3 Engine shut off switch W B 8 Clip removed 9 Clip installed 3 Engine shut off switch 16 Main wire harness 13 Neutral switch A A A B 13 Neutral switch 13 Neutral switch 10 UP 12 DN 11 Free 10 UP 12 DN 11 Free 6 OFF 7 START 5 ON R Y Y BZ R Y B G Lg Br P W G Gy P G R Sb Or W W L B L B Br Br Y Y P B P W P W Br B Y Sb Lg W B W B W Br Y B B R R P P Br Y W R B ...

Page 346: ...0 52 0 55 0 55 0 55 0 58 0 58 0 58 0 60 0 60 0 62 0 62 0 65 0 65 0 65 0 68 0 68 0 68 0 70 0 70 0 72 0 72 0 75 0 75 0 75 0 78 0 78 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 0 45 0 45 0 45 0 48 0 48 0 48 0 50 0 50 0 52 0 52 0 55 0 55 0 55 0 58 0 58 0 58 0 60 0 60 0 62 0 62 0 65 0 65 0 65 0 68 0 68 0 68 0 70 0 70 0 72 0 72 0 75 0 75 0 75 0 78 0 78 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 88 1 0 45 0...

Page 347: ... 0 30 0 20 0 10 0 0 10 0 20 0 30 0 40 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 B mm A 1 100 mm 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 A B 0 53 0 50 0 47 0 45 0 42 0 39 0 37 0 34 0 31 0 29 0 26 0 2...

Page 348: ...Jul 2018 ABE E 6BG 28197 ZX 11 LIT 18616 03 84 USA CAN AUS and NZL Worldwide 6BG 6BT 6BG 6BT LIT 18616 03 84 6BG 28197 ZX 11 ...

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