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NOTICE

This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.

Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.

Important information

1

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

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

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.

NOTE:

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

F30A, F40B

SERVICE MANUAL

©2007 by Yamaha Motor Co., Ltd.

1st Edition, August 2007

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

Printed in China

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Summary of Contents for F30A

Page 1: ...F30A F40B SERVICE MANUAL 67C 28197 3K 11 ...

Page 2: ...modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Important information 1 Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe...

Page 3: ... information 1 GEN INFO Specification 2 SPEC Periodic check and adjustment 3 CHK ADJ Fuel system 4 FUEL Power unit 5 POWR Lower unit 6 LOWR Bracket unit 7 BRKT Electrical system 8 ELEC Troubleshooting 9 TRBL SHTG Index ...

Page 4: ......

Page 5: ...ction 1 13 Predelivery check 1 14 Checking the outboard motor mounting height 1 14 Checking the fuel system 1 14 Checking the engine oil level 1 14 Checking the gear oil level 1 15 Checking the battery E and W model 1 15 Connecting the throttle cable and shift cable 1 15 Checking the gear shift and throttle operation 1 16 Checking the steering system 1 17 Checking the tilt system D model 1 17 Chec...

Page 6: ...rew dimensions see 2 in the figure below Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point see 3 in the figure below Tightening torque specifications are provided in the exploded diagrams see 4 in the figure below for an example and in the related detailed instructions Some torque specifications are listed in stages as torque figures...

Page 7: ...ls 7 to C in an exploded diagram or illustration indicate the grade of lubricant and the lubri cation point 7 Apply 4 stroke motor oil 8 Apply gear oil 9 Apply water resistant grease Yamaha grease A 0 Apply molybdenum disulfide grease A Apply corrosion resistant grease Yamaha grease D B Apply low temperature resistant grease Yamaha grease C C Apply injector grease Symbols D to I in an exploded dia...

Page 8: ...CDI Capacitor Discharge Ignition D model Hydraulic tilt model E model Electric starter model EN European Norm European standard EX Exhaust F position Forward position H model Tiller handle model IEC International Electrotechnical Commission IN Intake M model Manual starter model N position Neutral position PORT Port side PTT Power trim and tilt R model Remote control model R position Reverse posit...

Page 9: ... your hands and feet by wearing pro tective gloves and safety shoes when neces sary Part lubricant and sealant Use only genuine Yamaha parts lubricants and sealants or those recommended by Yamaha when servicing or repairing the out board motor Under normal conditions the lubricants men tioned in this manual should not harm or be hazardous to your skin However you should follow these precautions to...

Page 10: ...ing in the center and moving outward Non reusable part Always use new gaskets seals O rings cot ter pins circlips etc when installing or assembling parts Disassembling and assembling 1 Use compressed air to remove dust and dirt during disassembly 2 Apply oil or fluid to the contact surfaces of moving parts before assembly 3 Install bearings with the manufacture identification mark in the direction...

Page 11: ...ber is stamped on a label attached to the port clamp bracket 1 Model name 2 Approved model code 3 Transom height 4 Serial number Applicable model F30AMHD F30AEHT F30AET F40BMHD F40BWHD F40BWHT F40BED F40BET Model name Approved model code Starting serial No F30A 69H 1008205 F40B 67C 1035037 S67C1010 Safety while working Identification ...

Page 12: ...90 01426 Digital tachometer 90890 06760 Timing light 90890 03141 Leakage tester 90890 06840 Vacuum pressure pump gauge set 90890 06756 Pilot screw adjusting tool 90890 03154 Vacuum gauge 90890 03094 Compression gauge 90890 03160 Flywheel holder 90890 06522 Flywheel puller 90890 06521 ...

Page 13: ...guide remover installer 90890 06801 Valve guide reamer 90890 06804 Valve seat cutter holder 90890 06316 Valve seat cutter 90890 06312 90890 06323 90890 06325 90890 06327 90890 06328 Driver rod LS 90890 06606 Ball bearing attachment 90890 06631 Piston slider 90890 06529 Bearing separator 90890 06534 Special service tool ...

Page 14: ...Bearing puller assembly 90890 06535 Driver rod L3 90890 06652 Needle bearing attachment 90890 06612 90890 06614 Driver rod SS 90890 06604 Bearing depth plate 90890 06603 Ball bearing attachment 90890 06637 Bearing inner race attachment 90890 06639 90890 06640 90890 06641 Ball bearing attachment 90890 06633 ...

Page 15: ... outer race puller assembly 90890 06523 Driver rod LL 90890 06605 Bearing outer race attachment 90890 06622 90890 06627 Driver rod SL 90890 06602 Ball bearing attachment 90890 06634 Bearing inner race attachment 90890 06644 Shimming plate 90890 06701 Pinion height gauge 90890 06710 Special service tool ...

Page 16: ...Digital caliper 90890 06704 Center bolt 90890 06504 Bearing housing puller claw S 90890 06564 Backlash indicator 90890 06706 Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base B 90890 06844 Bushing installer center bolt 90890 06601 Digital circuit tester 90890 03174 ...

Page 17: ... 8 9 Needle bearing attachment 90890 06615 Cylinder end screw wrench 90890 06568 Peak voltage adapter B 90890 03172 Test harness 2 pins 90890 06867 Ignition tester 90890 06754 Test harness 2 pins 90890 06868 Special service tool ...

Page 18: ...f the propeller is indicated on a propeller blade on the propeller boss end and on the side of the propeller boss a Propeller diameter in inches b Propeller pitch in inches c Propeller type propeller mark Selection When the engine speed is in the full throttle operating range 4 500 5 500 r min F30A or 5 000 6 000 r min F40B the ideal propeller for the boat is one that provides maximum performance ...

Page 19: ... the combination of the boat and the outboard motor To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that the clamp brackets are secured with the clamp bolts Checking the fuel system 1 Check that the fuel hoses are securely connected and that the fuel tank is full with fuel CAUTION This is a 4 stroke engine Never use pre mixed fuel or 2 stroke outb...

Page 20: ...ing the gear shift operation 3 9 1 Set the shift lever or remote control lever to the N position and the throttle grip or throttle lever to the fully closed position 2 Turn the throttle cam 1 clockwise until the cam contacts the fully closed stopper a on the throttle cam bracket 2 and hold it in that position Connect the throt tle cable 3 to the throttle cam and then install the clip 4 3 Check tha...

Page 21: ...t lever or remote control lever is shifted from the N position to the F position or R position È H model É R model NOTE The shift lever cannot be operated unless the throttle grip is in the fully closed posi tion H model The resistance of the throttle grip H model or remote control lever R model can be adjusted using the throttle friction adjuster 1 3 Set the shift lever to the F position or R pos...

Page 22: ... the release position a and tilt the outboard motor to the fully up position Check that the out board motor tilts up smoothly 2 Set the tilt lock lever 1 to the lock posi tion b and check that the outboard motor is locked in the tilted up position 3 Check that there is no interference with leads cables or hoses when steering the motor in its fully up position 4 Set the tilt lock lever 1 to the rel...

Page 23: ...lly up position Checking the engine start switch and engine shut off switch 1 Check that the engine starts when the engine start switch is turned to START È H model É R model 2 Check that the engine turns off when the engine shut off switch is pushed H model Check that the engine turns off when the engine start switch is turned to OFF H model with electric starter and R model È H model É R model S...

Page 24: ...half throttle then for another hour increase engine speed as much as necessary to put the boat on plane but avoid full throttle operation 5 Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom NOTE The test run is part of the break in operation Break in Run the engine under load in gear with a propeller installed for 10 hours as...

Page 25: ...water and water pressure when flushing the cooling water passages If sufficient water and sufficient water pressure are not supplied the engine can overheat NOTE When using the flushing device flushing hose joint adapter flush the cooling water passages without starting the engine Precaution when transporting or storing the outboard motor 1 When transporting or storing the out board motor while re...

Page 26: ...GEN INFO General information 1 21 67C3K11 MEMO ...

Page 27: ...pecification 2 1 Maintenance specification 2 7 Power unit 2 7 Fuel system 2 10 Lower unit 2 11 Electrical 2 12 Power unit 2 14 Fuel system 2 17 Lower unit 2 18 Electrical 2 19 Dimension 2 22 Tightening torque 2 27 Specified torque 2 27 General torque 2 29 ...

Page 28: ...kg lb 88 1 194 94 2 208 87 7 193 Performance Maximum output kW HP 22 1 30 at 5 000 r min 29 4 40 at 5 500 r min Full throttle operating range r min 4 500 5 500 5 000 6 000 Maximum fuel consumption L US gal Imp gal hr 11 1 2 9 2 4 at 6 000 r min 15 0 4 0 3 3 at 6 000 r min Engine idle speed r min 850 50 Power unit Type 4 stroke L Cylinder quantity 3 Total displacement cm3 cu in 747 45 6 Bore stroke...

Page 29: ...r replacement L US qt Imp qt 2 2 2 33 1 94 Gear oil type Hypoid gear oil Gear oil grade 2 API GL 4 SAE 90 Gear oil quantity cm3 US oz Imp oz 430 14 54 15 17 Bracket unit Trim angle at 12 boat transom Degree 4 to 20 Tilt up angle Degree 66 Steering angle Degree 40 40 Drive unit Gear shift positions F N R Gear ratio 2 00 26 13 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller sh...

Page 30: ...SPEC Specification 2 3 67C3K11 Electrical Battery minimum capacity CCA EN A 430 20HR IEC Ah 70 Electrolyte specific gravity at 20 C 68 F 1 280 Item Unit Model F30AMHD F40BMHD F40BWHD F40BED ...

Page 31: ...lb 92 0 203 90 4 199 96 9 214 90 4 199 Performance Maximum output kW HP 22 1 30 at 5 000 r min 29 4 40 at 5 500 r min Full throttle operating range r min 4 500 5 500 5 000 6 000 Maximum fuel consumption L US gal Imp gal hr 11 1 2 9 2 4 at 6 000 r min 15 0 4 0 3 3 at 6 000 r min Engine idle speed r min 850 50 Power unit Type 4 stroke L Cylinder quantity 3 Total displacement cm3 cu in 747 45 6 Bore ...

Page 32: ...nt L US qt Imp qt 2 2 2 33 1 94 Gear oil type Hypoid gear oil Gear oil grade 2 API GL 4 SAE 90 Gear oil quantity cm3 US oz Imp oz 430 14 54 15 17 Bracket unit Trim angle at 12 boat transom Degree 4 to 20 Tilt up angle Degree 66 Steering angle Degree 40 40 PTT system Fluid type ATF Dexron II Drive unit Gear shift positions F N R Gear ratio 2 00 26 13 Reduction gear type Spiral bevel gear Clutch typ...

Page 33: ...K11 2 6 1 2 3 4 5 6 7 8 9 Electrical Battery minimum capacity CCA EN A 430 20HR IEC Ah 70 Electrolyte specific gravity at 20 C 68 F 1 280 Item Unit Model F30AEHT F30AET F40BWHT F40BET General specification ...

Page 34: ...18 Intake and exhaust B mm in 25 900 26 100 1 0197 1 0276 Camshaft journal diameter C mm in 36 925 36 945 1 4537 1 4545 Camshaft journal diameter D mm in 36 935 36 955 1 4541 1 4549 Camshaft runout limit mm in 0 03 0 0012 1 Measuring conditions Ambient temperature 20 C 68 F wide open throttle with spark plugs removed from all cylinders Since this outboard motor is equipped with an automatic decomp...

Page 35: ... and exhaust mm in 0 9 1 1 0 035 0 043 Margin thickness D Intake mm in 0 6 1 0 0 024 0 039 Exhaust mm in 0 7 1 1 0 028 0 043 Stem diameter Intake mm in 5 475 5 490 0 2156 0 2161 Exhaust mm in 5 460 5 475 0 2150 0 2156 Stem runout limit Intake mm in 0 030 0 0012 Exhaust mm in 0 016 0 0006 Guide inside diameter Intake and exhaust mm in 5 500 5 512 0 2165 0 2170 Stem to guide clearance Intake mm in 0...

Page 36: ... 0118 Side clearance mm in 0 02 0 06 0 0008 0 0024 2nd ring Taper Dimension B mm in 1 47 1 49 0 0579 0 0587 Dimension T mm in 2 60 2 80 0 1024 0 1102 End gap 1 mm in 0 30 0 50 0 0118 0 0197 Side clearance mm in 0 02 0 06 0 0008 0 0024 Oil ring Dimension B mm in 2 36 2 48 0 0929 0 0976 Dimension T mm in 2 75 0 1083 End gap 1 mm in 0 20 0 70 0 0079 0 0276 Side clearance mm in 0 04 0 18 0 0016 0 0071...

Page 37: ...kPa kgf cm2 psi 389 451 3 89 4 51 56 4 65 4 Thermostat Opening temperature at 0 05 mm 0 0020 in C F 58 62 136 144 Fully open temperature C F 70 158 Valve open lower limit mm in 3 0 0 12 Manual starter Starter rope length mm in 1 750 68 9 Starter rope extended length mm in 1 400 1 600 55 12 62 99 1 The figures are for reference only Item Unit Model F30AMHD F40BMHD F40BWHD F40BED Carburetor ID mark ...

Page 38: ... 035 10 35 150 1 Item Unit Model F30AMHD F40BMHD F40BWHD F40BED Lower unit Holding pressure kPa kgf cm2 psi 100 1 0 14 5 Gear backlash Pinion to forward gear 1 mm in 0 18 0 57 0 0071 0 0224 Pinion to reverse gear 1 mm in 0 75 1 13 0 0295 0 0445 Pinion shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Forward gear shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Reverse gear shims mm 0 10 0 12 0 15 0 18 0 30 ...

Page 39: ...ulser coil resistance 1 R B at 20 C 68 F Ω 300 350 Charge coil output peak voltage W G G W at cranking unloaded V 200 at cranking loaded V 190 at 1 500 r min loaded V 200 at 3 500 r min loaded V 200 Charge coil resistance 1 W G G W at 20 C 68 F Ω 660 710 CDI unit output peak voltage O B at cranking loaded V 120 at 1 500 r min loaded V 170 at 3 500 r min loaded V 170 Thermo sensor resistance 1 Br B...

Page 40: ...ear limit mm in 6 4 0 25 Commutator Undercut wear limit mm in 0 8 0 03 Charging system Fuse A 20 Lighting coil output peak voltage Y Y at cranking unloaded V 14 1 8 4 at 1 500 r min unloaded V 39 7 28 5 at 3 500 r min unloaded V 95 2 66 6 Lighting coil resistance 2 Y Y at 20 C 68 F Ω 0 90 1 10 0 26 0 28 Rectifier Regulator output peak voltage R Ground at 1 500 r min loaded V 13 at 3 500 r min load...

Page 41: ...Intake and exhaust A mm in 30 834 31 034 1 2139 1 2218 Intake and exhaust B mm in 25 900 26 100 1 0197 1 0276 Camshaft journal diameter C mm in 36 925 36 945 1 4537 1 4545 Camshaft journal diameter D mm in 36 935 36 955 1 4541 1 4549 Camshaft runout limit mm in 0 03 0 0012 Rocker arm shaft Outside diameter mm in 15 971 15 991 0 6288 0 6296 1 Measuring conditions Ambient temperature 20 C 68 F wide ...

Page 42: ... 9 1 1 0 035 0 043 Margin thickness D Intake mm in 0 6 1 0 0 024 0 039 Exhaust mm in 0 7 1 1 0 028 0 043 Stem diameter Intake mm in 5 475 5 490 0 2156 0 2161 Exhaust mm in 5 460 5 475 0 2150 0 2156 Stem runout limit Intake mm in 0 030 0 0012 Exhaust mm in 0 016 0 0006 Guide inside diameter Intake and exhaust mm in 5 500 5 512 0 2165 0 2170 Stem to guide clearance Intake mm in 0 010 0 037 0 0004 0 ...

Page 43: ...earance mm in 0 02 0 06 0 0008 0 0024 2nd ring Taper Dimension B mm in 1 47 1 49 0 0579 0 0587 Dimension T mm in 2 60 2 80 0 1024 0 1102 End gap 1 mm in 0 30 0 50 0 0118 0 0197 Side clearance mm in 0 02 0 06 0 0008 0 0024 Oil ring Dimension B mm in 2 36 2 48 0 0929 0 0976 Dimension T mm in 2 75 0 1083 End gap 1 mm in 0 20 0 70 0 0079 0 0276 Side clearance mm in 0 04 0 18 0 0016 0 0071 Connecting r...

Page 44: ... 1 494 0 0587 0 0588 Oil pump Type Trochoid Relief valve opening pressure kPa kgf cm2 psi 389 451 3 89 4 51 56 4 65 4 Thermostat Opening temperature at 0 05 mm 0 0020 in C F 58 62 136 144 Fully open temperature C F 70 158 Valve open lower limit mm in 3 0 0 12 Manual starter Starter rope length mm in 1 750 68 9 Starter rope extended length mm in 1 400 1 600 55 12 62 99 1 The figures are for referen...

Page 45: ...ding pressure Positive pressure kPa kgf cm2 psi 1 035 10 35 150 1 Item Unit Model F30AEHT F30AET F40BWHT F40BET Lower unit Holding pressure kPa kgf cm2 psi 100 1 0 14 5 Gear backlash Pinion to forward gear 1 mm in 0 18 0 57 0 0071 0 0224 Pinion to reverse gear 1 mm in 0 75 1 13 0 0295 0 0445 Pinion shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Forward gear shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50...

Page 46: ...aded V 25 8 Pulser coil resistance 1 R B at 20 C 68 F Ω 300 350 Charge coil output peak voltage W G G W at cranking unloaded V 200 at cranking loaded V 190 at 1 500 r min loaded V 200 at 3 500 r min loaded V 200 Charge coil resistance 1 W G G W at 20 C 68 F Ω 660 710 CDI unit output peak voltage O B at cranking loaded V 120 at 1 500 r min loaded V 170 at 3 500 r min loaded V 170 Thermo sensor resi...

Page 47: ...ear limit mm in 6 4 0 25 Commutator Undercut wear limit mm in 0 8 0 03 Charging system Fuse A 20 Lighting coil output peak voltage Y Y at cranking unloaded V 8 4 at 1 500 r min unloaded V 28 5 at 3 500 r min unloaded V 66 6 Lighting coil resistance 2 Y Y at 20 C 68 F Ω 0 26 0 28 Rectifier Regulator output peak voltage R Ground at 1 500 r min loaded V 13 at 3 500 r min loaded V 13 1 The following r...

Page 48: ... 20 C 68 F Ω 238 8 378 8 PTT motor Output kW 0 18 Brushes Standard length mm in 6 0 0 24 Wear limit mm in 3 0 0 12 Commutator Standard diameter mm in 16 5 0 65 Wear limit mm in 15 5 0 61 Standard undercut mm in 1 00 0 039 Wear limit mm in 0 50 0 020 1 The figures are for reference only Item Unit Model F30AEHT F30AET F40BWHT F40BET ...

Page 49: ...D For Europe S transom model S67C2002 mim in 12 605 23 8 4 753 29 6 754 29 7 24 0 9 384 15 1 763 30 0 814 32 0 569 22 4 234 9 2 175 6 9 65 2 6 522 20 6 294 11 6 493 19 4 411 16 2 175 6 9 43 1 7 44 1 7 189 7 4 124 4 9 313 12 3 688 27 1 40 62 Maintenance specification ...

Page 50: ...pe F30AEHT F40BWHD F40BWHT For Oceania L transom model S67C2003 mim in 189 7 4 124 4 9 313 12 3 688 27 1 40 671 26 4 4 753 29 6 877 34 5 24 0 9 384 15 1 763 30 0 923 36 3 569 22 4 234 9 2 175 6 9 65 2 6 522 20 6 294 11 6 493 19 4 534 21 0 175 6 9 43 1 7 44 1 7 12 62 ...

Page 51: ...30AET F40BET For Europe S transom model S67C2001 mim in 189 7 4 313 12 3 40 12 62 600 23 6 4 708 27 9 754 29 7 24 0 9 354 13 9 814 32 0 569 22 4 132 5 2 65 2 6 522 20 6 286 11 3 465 18 3 411 16 2 175 6 9 43 1 7 15 0 6 Maintenance specification ...

Page 52: ...T F40BED F40BET For Europe F30AET F40BET For Oceania L tran som model S67C2004 mim in 522 20 6 4 189 7 4 313 12 3 40 12 666 26 2 708 27 9 877 34 5 24 0 9 354 13 9 923 36 3 569 22 4 132 5 2 65 2 6 286 11 3 465 18 3 534 21 0 175 6 9 43 1 7 15 0 6 62 ...

Page 53: ...3K11 2 26 1 2 3 4 5 6 7 8 9 Clamp bracket S67C2005 mim in 180 7 1 180 7 1 124 5 4 9 124 5 4 9 338 13 3 254 10 0 55 5 2 2 57 2 2 13 0 5 18 5 0 7 50 8 2 0 13 0 5 163 5 6 4 163 5 6 4 Maintenance specification ...

Page 54: ...olt E and W model M8 29 2 9 21 4 Terminal bolt PTT model M6 8 0 8 5 9 Starter relay bolt E and W model M6 8 0 8 5 9 Starter motor cover bolt E and W model M6 8 0 8 5 9 Pinion stopper nut E and W model 30 3 0 22 1 PTT relay bolt PTT model M6 8 0 8 5 9 Oil pressure switch 6 0 6 4 4 Thermo sensor 4 0 4 3 0 Throttle cam bolt M6 8 0 8 5 9 Throttle cam bracket bolt M6 8 0 8 5 9 Accelerator lever bolt M6...

Page 55: ...1 8 Pinion nut 74 7 4 54 6 Bracket unit Shift lever bolt M8 18 1 8 13 3 Tiller handle nut H model 37 3 7 27 3 Tiller handle bracket nut H model 32 3 2 23 6 Tiller handle bracket bolt M12 32 3 2 23 6 PTT switch screw H model with PTT M6 2 0 2 1 5 PTT switch bracket bolt R model with PTT M6 10 1 0 7 4 Warning indicator assembly screw H model with electric starter M6 2 0 2 1 5 Engine start switch nut...

Page 56: ...2 0 14 8 Upper case plug L transom model M14 17 1 7 12 5 Baffle plate screw M5 3 0 3 2 2 Steering arm lock bolt M6 4 0 4 3 0 Engine oil drain bolt 17 1 7 12 5 Exhaust manifold bolt M6 10 1 0 7 4 Upper case bolt M8 21 2 1 15 5 Self locking nut 22 2 2 16 2 Trim sensor cam screw M6 2 0 2 1 5 Anode bolt M6 8 0 8 5 9 Grease nipple 3 0 3 2 2 PTT unit PTT model PTT motor assembly bolt M6 7 0 7 5 2 Reserv...

Page 57: ... Checking the cooling water passage 3 7 Control system 3 8 Adjusting the throttle link 3 8 Adjusting the throttle cable 3 8 Checking the gear shift operation 3 9 Checking the start in gear protection M and W model 3 10 Checking the engine idle speed 3 11 Checking the ignition timing 3 11 Bracket unit 3 12 Checking the steering operation H model 3 12 Checking the tilt operation 3 12 Checking the PT...

Page 58: ...r joint Replace 3 15 Battery Check charge replace 3 16 Cooling water leakage Check replace 3 7 Cowling clamp Check 3 3 Engine starting condition noise Check Engine idle speed noise Check 3 11 Engine oil Replace 3 4 Engine oil filter cartridge Replace 3 5 Fuel filter Replace 3 3 Fuel pump Check replace 4 4 Fuel oil leakage Check 3 3 Fuel pipe Check replace 3 3 Fuel pipe Replace 4 1 Gear oil Replace...

Page 59: ...k replace 3 7 Timing belt Check replace 3 6 Valve clearance Check adjust 5 2 Water inlet Check 3 7 Engine start switch engine shut off switch choke switch Check replace 8 13 8 18 8 19 Wiring harness connections lead coupler connections Check replace 8 1 Yamaha Meter gauge Check Yamaha Fuel tank Check clean Item Remarks Initial Every Refer to page 20 hours 3 months 100 hours 1 year 300 hours 3 year...

Page 60: ...on b 4 Tighten the nuts 1 5 Check the fitting again and if necessary repeat steps 2 4 6 Check the air intake duct Clean if there are obstructions Fuel system Checking the fuel joint and fuel hose fuel joint to carburetor 1 Check the fuel hose connections for leaks Also check the fuel joint 1 fuel hoses fuel filter 2 fuel pump 3 and carburetors 4 Replace if there is leak age or deterioration Checki...

Page 61: ...t position 2 Remove the oil dipstick wipe it clean and then insert it back into the oil dipstick hole 3 Remove the oil dipstick again to check the oil level and to check the oil for dis coloration and its viscosity NOTE If the oil appears milky or dirty check for and repair the cause and then change the oil If the engine oil is below the minimum level mark a add sufficient oil until the level is b...

Page 62: ...eplacing the oil filter 1 Drain the engine oil or use an oil changer to extract it 2 Place a rag under the oil filter and then remove the oil filter using a 64 mm 2 5 in oil filter wrench 1 NOTE Wait more than 5 minutes after turning the engine off to replace the oil filter Be sure to clean up any oil spills 3 Apply a thin coat of engine oil to the O ring of the new oil filter 4 Install the oil fi...

Page 63: ...iming belt see Replacing the timing belt 5 3 Checking the spark plug 1 Disconnect the spark plug caps and remove the spark plugs 2 Clean the electrodes 1 with a spark plug cleaner or wire brush 3 Check the spark plug Replace if the electrodes are eroded there is excessive carbon or other deposits or the gasket is damaged 4 Check the spark plug gap a Adjust the spark plug gap if out of specificatio...

Page 64: ... 5 Install a new gasket the thermostat 2 and the thermostat cover 1 and then tighten the bolts to the specified torque Checking the cooling water passage 1 Check the cooling water inlet covers 1 and cooling water inlets Clean if clogged 2 Place the lower unit in water and then start the engine 3 Check for water flow at the cooling water pilot hole If there is no water flow check the cooling water ...

Page 65: ...ink lever 6 counter clockwise until there is no free play in the throttle link rod 7 5 Tighten the throttle link adjusting screw 1 6 Turn the throttle grip H model or move the remote control lever R model to the fully open and fully closed positions and check that the throttle cam operates smoothly NOTE After adjusting the throttle link adjust the throttle cable See Adjusting the throttle cable 3 ...

Page 66: ... throttle grip H model or move the remote control lever R model to the fully open and fully closed positions and check that the carburetors fully open and fully close Checking the gear shift operation 1 Check that the gear shift operates smoothly when the shift lever H model or remote control lever R model is shifted from the N position to the F posi tion or R position Adjust the shift cable and s...

Page 67: ...nd then check that the shift lock cam d on the throttle shaft 6 is not in the slot e in the shift lever cam 7 and that the shift lever can be operated Next turn the throttle grip to the fully open position and then check that the shift lock cam d on the throttle shaft 6 is fit ted into the slot e in the shift lever cam 7 and that the shift lever cannot be oper ated H model È Fully closed position ...

Page 68: ... until the specified engine idle speed is obtained NOTE To increase the engine idle speed turn the throttle stop screw 2 in direction a To decrease the engine idle speed turn the throttle stop screw 2 in direction b 4 After adjusting the engine idle speed rev the engine a few times and let it idle to check the stability of the engine Checking the ignition timing 1 Start the engine and warm it up 2...

Page 69: ... motor to the fully up and fully down positions a few times and check the entire tilt range for smooth operation Check the tilt mechanism D model or PTT fluid level PTT model if necessary NOTE To check the tilt operation see Checking the tilt system D model 1 17 To check the PTT fluid level see Checking the PTT fluid level 3 13 Be sure to listen to the winding sound of the PTT motor for smooth ope...

Page 70: ...y down position 2 Remove the gear oil check screw 1 and then check the gear oil level in the lower case Also check the oil for discoloration and its viscosity NOTE If the oil is at the correct level a small amount of oil should overflow out of the check hole when the gear oil check screw 1 is removed If the oil appears milky or dirty check for and repair the cause and then change the oil 3 If nece...

Page 71: ...y the specified pressure and check that the pressure is maintained in the lower unit for at least 10 seconds CAUTION Do not overpressurize the lower unit oth erwise the oil seals can be damaged NOTE Cover the check hole with a rag when remov ing the special service tool from the lower unit 3 If the specified pressure cannot be main tained check the propeller shaft drive shaft shift rod O rings and...

Page 72: ...iginally installed General Checking the anode 1 Check the anodes Clean the anodes if there are scales grease or oil È D model CAUTION Do not oil grease or paint the anodes otherwise they will be ineffective NOTE Replace the anodes if excessively eroded In addition check the ground lead If it is necessary to disassemble the out board motor to check an anode refer to the applicable disassembly proce...

Page 73: ...water EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries generate explosive hydrogen gas Always follow these preventive mea sures Charge batteries in a well ventilated area Keep batteries away from fire sparks or open f...

Page 74: ...ly water resistant grease to the areas shown È H model NOTE Apply grease until it flows from the bushings a 2 Apply low temperature resistant grease to the areas shown E and W model 3 Apply corrosion resistant grease to the area shown S67C3053 A a S67C3054 A A a È S67C3055 A È S67C3056 C ...

Page 75: ...el joint 4 5 Disassembling the fuel pump 4 5 Checking the diaphragm and valve 4 5 Assembling the fuel pump 4 6 Carburetor unit 4 7 Carburetor 4 10 Removing the carburetor 4 12 Disassembling the carburetor 4 12 Checking the carburetor 4 12 Checking the Prime Start 4 13 Assembling the carburetor 4 14 Installing the carburetor 4 15 Adjusting the pilot screw 4 15 Synchronizing the carburetor 4 17 Adju...

Page 76: ...ver to intake silencer 3 Breather hoses carburetor to carburetor joint 4 Flushing hose flushing hose adapter to exhaust cover 5 Fuel hose fuel joint to fuel filter assembly 6 Fuel hose fuel filter assembly to fuel pump 7 Cooling water hose exhaust cover to cooling water pilot hole 8 Cooling water hose exhaust cover to exhaust guide S67C4001 7 8 2 1 7 6 1 5 3 4 4 ...

Page 77: ...lamp 2 6 Clamp 1 7 Fuel hose 1 8 Fuel hose 1 9 Fuel hose 1 10 Clamp 3 11 Fuel filter 1 12 Fuel hose 1 13 Bolt 4 M6 25 mm 14 Plate 1 15 Retaining plate 1 16 Bolt 1 M6 25 mm 17 Fuel joint 1 S67C4002 3 10 9 6 5 8 7 5 11 10 12 10 13 14 4 2 1 17 13 13 15 16 T R 10 N m 1 0 kgf m 7 4 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib Hose routing Fuel pump fuel filter and fuel joint ...

Page 78: ...m 1 Not reusable 4 Fuel pump body 2 assembly 1 5 Diaphragm 1 6 Spring 1 7 Fuel pump body 1 1 8 Nut 4 9 Spring 1 10 Plunger 1 11 Pin 1 S67C4003 1 1 6 5 4 3 2 1 9 8 8 10 7 11 R 0 5 N m 0 05 kgf m 0 37 ft lb R 0 5 N m 0 05 kgf m 0 37 ft lb T R 3 N m 0 3 kgf m 2 2 ft Ib T R 3 N m 0 3 kgf m 2 2 ft Ib ...

Page 79: ...lter see Checking the fuel filter 3 3 1 Connect a meter to the fuel inlet 2 Cover the fuel outlet with your finger and then apply the specified positive pres sure Replace the fuel filter if the speci fied pressure cannot be maintained for at least 10 seconds NOTE Use a commercially available compressor and meter that can be pressurized up to 1 035 kPa 10 35 kgf cm2 150 1 psi Vacuum pressure pump g...

Page 80: ... 2 and then disassemble fuel pump body 1 3 NOTE Push the plunger 2 and the diaphragm completely inward and then turn fuel pump body 1 3 approximately 90 to a position where the pin 1 can be removed easily Slowly release on the plunger 2 and dia phragm and then remove them Checking the diaphragm and valve 1 Check the diaphragms 1 and valves 2 Replace the diaphragms if torn or replace the fuel pump ...

Page 81: ...g the plunger 1 and diaphragm completely inward Turn fuel pump body 1 2 until the pin 3 is 90 from the slot in the body Make sure that the projection b on the dia phragm is toward the port side 2 Assemble the fuel pump as shown NOTE Moisten the inside of the fuel pump with gasoline to ensure a good seal Make sure that the diaphragms are kept in place through the assembly process After disassemblin...

Page 82: ...p 1 5 Fuel hose 1 6 Fuel hose 1 7 Fuel hose 1 8 Bolt 6 M6 25 mm 9 Bolt 2 M6 20 mm 10 Holder 1 11 Collar 1 12 Throttle link rod 1 13 Carburetor unit 1 14 Dowel 2 S67C4016 T R 8 N m 0 8 kgf m 5 9 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib Y B Y B Y Y Y 14 8 3 5 2 12 13 11 10 9 9 6 7 4 3 1 8 14 ...

Page 83: ...Fuel hose 1 10 Fuel hose 1 11 Fuel hose 1 12 Cotter pin 3 13 Washer 3 14 Screw 2 ø6 10 mm 15 Dashpot 1 16 Throttle link plate 1 17 O ring 3 Not reusable S67C4037 4 3 3 1 3 9 10 11 18 19 20 27 20 20 20 17 23 20 21 21 6 8 2 T R 5 N m 0 5 kgf m 3 7 ft Ib T R 5 N m 0 5 kgf m 3 7 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib 7 13 16 5 12 13 24 12 14 15 12 13 14 22 24 26 26 26 26 26 26 26 26 25 Carburetor unit ...

Page 84: ...0 mm 22 Bolt 1 M6 20 mm 23 Intake silencer 1 24 Hose 4 25 Bracket 1 26 Plastic tie 8 27 Holder 1 S67C4037 4 3 3 1 3 9 10 11 18 19 20 27 20 20 20 17 23 20 21 21 6 8 2 T R 5 N m 0 5 kgf m 3 7 ft Ib T R 5 N m 0 5 kgf m 3 7 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib 7 13 16 5 12 13 24 12 14 15 12 13 14 22 24 26 26 26 26 26 26 26 26 25 ...

Page 85: ...Throttle stop screw 1 5 Spring 1 6 Carburetor body 1 7 Needle valve 1 8 Pilot jet 1 9 Plug 1 10 Main nozzle 1 11 Main jet 1 12 Prime Start 1 13 Screw 1 ø4 9 mm 14 Retainer 1 15 Boot 1 16 Plunger rod 1 17 Spring 1 S67C4018 3 12 8 7 6 5 4 9 29 23 25 21 22 13 14 15 16 26 27 10 11 27 26 24 28 2 1 1 17 18 19 20 Carburetor unit ...

Page 86: ...rew 1 For Europe 20 Pilot screw 1 For Oceania 21 Gasket 1 Not reusable 22 Float 1 23 Float pin 1 24 Screw 1 ø4 8 mm 25 Screw 1 ø3 6 mm 26 Plunger 1 27 Spring 1 28 Float chamber 1 29 Screw 4 ø4 14 mm S67C4018 3 12 8 7 6 5 4 9 29 23 25 21 22 13 14 15 16 26 27 10 11 27 26 24 28 2 1 1 17 18 19 20 ...

Page 87: ...8 intake silencer 9 bolts 0 and throttle link plate A and then remove the carburetor assemblies B Disassembling the carburetor NOTE See the exploded diagram for disassembly 4 10 1 Remove the screw 1 float pin 2 float 3 and needle valve 4 Checking the carburetor 1 Check the air and fuel passages and jets Clean the carburetor body if there is dirt or foreign material S67C4019 2 1 S67C4020 5 5 4 3 6 ...

Page 88: ... a Replace the float 1 or needle valve if out of specifica tion NOTE Take measurements at the float position shown opposite its pivoting side Checking the Prime Start 1 Measure the Prime Start resistance when the Prime Start is cold NOTE The following resistance is when the ambient temperature is 20 C 68 F and there is no power supplied 2 Measure the length of the Prime Start plunger before supply...

Page 89: ...or smooth operation 3 Install the pilot screw 9 turn it in until it is lightly seated and then turn it out the specified number of turns È For Europe É For Oceania Prime Start plunger length a after supplying power reference data 5 minutes 14 2 mm 0 56 in 10 minutes 14 9 mm 0 59 in at 23 C 73 F S67C4025 a Y Y S67C4026 2 1 4 3 Pilot screw adjusting tool 0 for Europe 90890 03154 Pilot screw setting ...

Page 90: ...rottle link 3 8 6 Adjust the engine idle speed NOTE If the carburetor has been disassembled and assembled adjust the pilot screw and then adjust the engine idle speed See Adjusting the pilot screw 4 15 Adjusting the pilot screw 1 Adjust the throttle stop screw NOTE If the carburetor was disassembled turn the throttle stop screw in until it contacts the car buretor throttle lever and then turn it i...

Page 91: ...or d until the specified engine idle speed is obtained NOTE To increase the engine idle speed turn the throttle stop screw 3 in direction c To decrease the engine idle speed turn the throttle stop screw 3 in direction d 6 After adjusting the engine idle speed rev the engine a few times and let it idle to check the stability of the engine Pilot screw adjusting tool 2 for Europe 90890 03154 Pilot sc...

Page 92: ...ure of all cylin ders 5 Turn the synchronizing screws 4 in direction a or b until the specified vac uum pressure is obtained NOTE To increase the vacuum pressure turn the synchronizing screw in direction a To decrease the vacuum pressure turn the synchronizing screw in direction b 6 Check the engine idle speed Repeat steps 3 5 if out of specification Adjusting the dashpot 1 Start the engine and wa...

Page 93: ... model until the engine speed is 3 750 50 r min 4 Turn the adjusting screw 2 until it is just touching the stopper 3 5 Rev the engine a few times and check the dashpot operation Repeat steps 3 4 if the dashpot does not operate properly Digital tachometer 90890 06760 S67C4041 3 3 2 2 Carburetor unit ...

Page 94: ...ier Regulator 5 16 Throttle cam 5 18 Removing the power unit 5 20 Timing belt and sprocket 5 22 Removing the timing belt and sprocket 5 23 Checking the timing belt and sprocket 5 24 Installing the sprocket and timing belt 5 24 Cylinder head 5 26 Removing the cylinder head 5 29 Disassembling the cylinder head 5 29 Checking the cylinder head 5 30 Checking the valve spring 5 30 Checking the valve 5 3...

Page 95: ...ng side clearance 5 45 Checking the piston pin boss bore 5 45 Checking the piston pin diameter 5 45 Checking the connecting rod small end inside diameter and big end inside diameter 5 45 Checking the connecting rod big end side clearance 5 46 Checking the crankshaft 5 46 Checking the crankpin oil clearance 5 46 Selecting the connecting rod bearing 5 47 Checking the crankshaft journal oil clearance...

Page 96: ...is pulled when using the manual starter to crank the engine M and W model 6 If the compression pressure is below specification or the compression pres sure for each cylinder is unbalanced add a small amount of engine oil to the cylin der and then measure the pressure again NOTE If the compression pressure increases check the pistons and piston rings Replace if worn If the compression pressure does...

Page 97: ...and W model Remove the flywheel magnet cover E model 2 Disconnect the ignition coil couplers and spark plug caps and then remove the spark plugs 3 Disconnect the fuel hoses 1 and blowby hose 2 and then remove the fuel pump 3 and cylinder head cover 4 4 Turn the flywheel magnet clockwise and align the 1 mark a on the driven sprocket 5 with the mark b on the cylinder head 5 Measure the intake and ex...

Page 98: ...eplacing the timing belt CAUTION Do not turn the flywheel magnet counter clockwise otherwise the water pump impeller may be damaged NOTE To remove and install the timing belt drive sprocket and driven sprocket see Remov ing the timing belt and sprocket 5 23 and Installing the sprocket and timing belt 5 24 1 Remove the manual starter starter hub and driven spocket cover M and W model Remove the fly...

Page 99: ...lywheel magnet NOTE Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft 5 Remove the stator assembly 1 6 Align the 1 mark a on the driven sprocket 2 with the mark b on the cylinder head NOTE Check that the notch c in the drive sprocket and the mark d on the cylinder block are aligned Flywheel puller 90890 06521 S67C5016 1 S67C5017 2 a b S67C...

Page 100: ...turn inside out or bend the timing belt beyond the maximum limit of 25 mm 1 0 in otherwise it can be dam aged Do not get oil or grease on the timing belt NOTE Before installing the timing belt make sure that the notch on the drive sprocket and the mark on the driven sprocket are aligned with the marks on the cylinder block and cylinder head respectively 9 Turn the drive sprocket clockwise 2 turns ...

Page 101: ... surfaces n of the washer before installa tion 12 Tighten the flywheel magnet nut 9 to the specified torque WARNING Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily 13 Install all parts removed during removal T R Stator assembly bolt 5 6 N m 0 6 kgf m 4 4 ft lb Flywheel holder 90890 06522 T R Flywheel magnet nut 9 157 N m 15 7 kgf m 115 8 ft ...

Page 102: ...ter handle 1 6 Starter rope 1 1 750 mm 68 9 in reference data 7 Damper 1 8 Bolt 3 M6 25 mm 9 Collar 3 10 Starter rope guide 1 11 Manual starter assembly 1 12 Spring 1 13 Cover 1 14 Starter plunger 1 15 Collar 1 16 Roller 1 17 Washer 1 S67C5025 E 1 A A LT 271 LT 271 A A 2 26 27 25 18 17 16 9 8 9 8 15 14 9 8 10 2 12 3 3 13 11 1 4 5 6 7 22 23 24 22 23 24 19 20 21 ...

Page 103: ... E clip 1 21 Sheave drum 1 22 Drive pawl 1 23 Drive pawl spring 2 1 24 Spring 1 25 Drive pawl spring 1 1 26 Drive plate 1 27 Bolt 1 M6 15 mm S67C5025 E 1 A A LT 271 LT 271 A A 2 26 27 25 18 17 16 9 8 9 8 15 14 9 8 10 2 12 3 3 13 11 1 4 5 6 7 22 23 24 22 23 24 19 20 21 Manual starter M and W model ...

Page 104: ...Remove the sheave drum 2 4 Remove the spiral spring 6 from the manual starter cover WARNING The spiral spring 6 can pop out Cover the spiral spring with rags when removing it 5 Remove the starter rope 1 and E clip 7 and then remove the drive pawl 8 drive pawl spring 2 9 and spring 0 from the sheave drum 2 Checking the manual starter 1 Check the roller collar drive pawl E clip starter plunger and d...

Page 105: ... the starter rope 1 into the sheave drum 2 2 Install the starter plunger 3 drive pawl 4 drive pawl spring 2 5 spring 6 and E clip 3 Install the starter handle 7 NOTE Apply engine oil to the starter rope 1 before installation Tie a knot at the end of the starter rope 1 as shown in the illustration Be sure to leave 7 12 mm 0 28 0 47 in a at the end of the starter rope 4 Wind the starter rope 1 twice...

Page 106: ...on of the arrow shown NOTE Push the starter plunger 3 in the direction of the arrow shown while turning the sheave drum 2 as shown 9 Remove the starter rope 1 from the notch b and then fit it into the groove in the sheave drum 2 NOTE Be sure to hold the sheave drum 2 with your hand so that it turns slowly Allow the spring force to slowly turn the drum as the starter rope winds around the drum 10 P...

Page 107: ...n its original position making sure to route it correctly To adjust the start in gear protection cable see Checking the start in gear protection M and W model 3 10 12 Pull the starter handle to extend the starter rope completely and then mea sure the starter rope extended length g Starter rope extended length g 1 400 1 600 mm 55 12 62 99 in S67C5039 g Manual starter M and W model ...

Page 108: ...ction cable 1 M and W model 8 Power unit 1 9 Cooling water hose 1 10 Cooling water hose 1 11 Positive battery cable 1 E and W model 12 PTT relay lead 2 PTT model 13 Bolt 1 M6 12 mm E and W model 14 Negative battery cable 1 E and W model 15 Fuel hose 1 16 Gasket 1 Not reusable 17 Dowel 2 S67C5040 8 2 9 11 12 14 20 13 3 23 4 1 7 18 21 24 24 29 29 30 25 26 27 28 27 22 19 10 15 20 17 16 5 6 29 BOW LT ...

Page 109: ... 22 Nut 2 23 Apron 1 24 Bolt 4 M6 25 mm M and W model 25 Bolt 1 M6 18 mm M and W model 26 Grommet 1 M and W model 27 Plastic tie 2 28 Clamp 1 29 Clip 3 30 Washer 1 S67C5040 8 2 9 11 12 14 20 13 3 23 4 1 7 18 21 24 24 29 29 30 25 26 27 28 27 22 19 10 15 20 17 16 5 6 29 BOW LT 572 LT T R 21 N m 2 1 kgf m 15 5 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib Power unit ...

Page 110: ...model 7 Bolt 2 M6 30 mm PTT model 8 PTT relay 1 PTT model 9 Bolt 2 M6 20 mm PTT model 10 PTT relay lead 2 PTT model 11 Holder 2 12 Bolt 1 M6 12 mm PTT model 13 Terminal 1 PTT model 14 Bolt 2 M6 30 mm 15 Grommet 2 16 Collar 2 17 Starter relay 1 S67C5041 13 4 1 11 12 11 9 2 5 5 16 15 15 14 10 10 8 7 6 7 3 3 9 16 17 14 4 T R 8 N m 0 8 kgf m 5 9 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 29 N m 2 9 kgf m...

Page 111: ...nition coil 3 13 Grommet 3 14 Holder 1 15 Holder 2 16 Bolt 3 M6 20 mm 17 Oil pressure switch 1 S67C5042 10 19 2 11 10 10 11 11 13 12 13 12 14 16 13 15 16 16 15 12 1 7 8 6 5 6 5 6 8 9 8 9 9 5 4 27 25 26 25 3 3 23 22 24 17 18 25 21 20 LT 572 LT LT 242 LT T R 5 N m 0 5 kgf m 3 7 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 8 N m 0 8 kgf m 5 9 ft ...

Page 112: ...c tie 3 26 Bolt 2 M5 12 mm 27 Bracket 1 E and W model S67C5042 10 19 2 11 10 10 11 11 13 12 13 12 14 16 13 15 16 16 15 12 1 7 8 6 5 6 5 6 8 9 8 9 9 5 4 27 25 26 25 3 3 23 22 24 17 18 25 21 20 LT 572 LT LT 242 LT T R 5 N m 0 5 kgf m 3 7 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 6 N m 0 6 kgf m 4 4 ft Ib T R 17 N...

Page 113: ...7 Bolt 1 M6 25 mm 8 Bushing 1 9 Cotter pin 1 10 Clip 1 11 Throttle link rod 1 12 Bracket 1 13 Shift link rod 1 14 Bolt 1 M6 14 mm 15 Shift arm 1 16 Washer 1 17 Clip 1 S67C5043 19 18 20 12 17 16 14 8 9 11 21 15 1 2 13 6 5 4 7 10 A T R 8 N m 0 8 kgf m 5 9 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib 3 T R 19 N m 1 9 kgf m 14 0 ft Ib Power unit ...

Page 114: ...arks 18 Spring 1 19 Throttle cam 1 20 Collar 1 21 Bolt 1 M6 45 mm S67C5043 19 18 20 12 17 16 14 8 9 11 21 15 1 2 13 6 5 4 7 10 A T R 8 N m 0 8 kgf m 5 9 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib 3 T R 19 N m 1 9 kgf m 14 0 ft Ib ...

Page 115: ...ct the engine shut off switch leads 5 and warning indicator assembly coupler 6 M model Disconnect the warning indicator assem bly coupler 6 and 10 pin main harness 7 from the power unit E and W model È M model É E and W model 4 Disconnect the flushing hose 8 cooling water hose 9 and fuel hose 0 5 Disconnect the throttle cable and shift cable 6 Remove the clip A and then disconnect the shift link r...

Page 116: ...POWR Power unit 5 21 67C3K11 7 Remove the oil dipstick and apron and then remove the mounting bolts C 8 Remove the power unit D gasket E and dowels F S67C5047 E D C C C C F ...

Page 117: ...3 M5 25 mm M model M5 30 mm E and W model 7 Stator assembly 1 8 Spring washer 1 9 Timing belt 1 10 Drive sprocket 1 11 Woodruff key 1 12 Woodruff key 1 13 Bolt 1 M10 40 mm 14 Washer 1 15 Driven sprocket 1 16 Dowel 1 S67C5048 6 12 10 16 8 5 4 3 1 3 2 1 6 6 7 9 11 14 13 15 2 E LT 242 T R 6 N m 0 6 kgf m 4 4 ft Ib T R 157 N m 15 7 kgf m 115 8 ft lb T R 38 N m 3 8 kgf m 28 0 ft Ib E Power unit Timing ...

Page 118: ...Remove the timing belt 2 from the driven sprocket and then remove it from the drive sprocket CAUTION Unless directed to do so in the following instructions do not turn the drive sprocket or driven sprocket when the tim ing belt is not installed Otherwise the pis tons and valves will collide with each other and be damaged 6 Hold the driven sprocket using the spe cial service tool 3 and then remove ...

Page 119: ...her and be damaged 1 Install the Woodruff key 1 and drive sprocket 2 2 Install the dowel 3 driven sprocket 4 and washer 5 and then install the bolt 6 temporarily NOTE Apply engine oil to the driven sprocket bolt 6 before installation 3 Hold the driven sprocket using the spe cial service tool 7 and then tighten the bolt 6 to the specified torque NOTE Make sure that the driven sprocket does not turn...

Page 120: ...not twist turn inside out or bend the timing belt beyond the maximum limit of 25 mm 1 0 in otherwise it can be dam aged Do not get oil or grease on the timing belt 7 Turn the drive sprocket clockwise 2 turns and then check that the parts are aligned at the areas f and g as shown 8 Install the stator assembly spring washer and flywheel magnet NOTE See Replacing the timing belt 5 3 S67C5063 d c XXXX...

Page 121: ...cap 1 12 Bolt 3 M6 20 mm 13 Plate 3 14 Bolt 3 M5 12 mm 15 Anode cover 3 16 Anode 3 17 Grommet 3 S67C5066 LT 271 A 9 0 B 8 4 1 5 7 3 2 6 3 T R 1 23 N m 2 3 kgf m 17 0 ft Ib 2 46 N m 4 6 kgf m 33 9 ft Ib T R 2 N m 0 2 kgf m 1 5 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib E E A 10 10 11 9 2 7 6 4 8 1 1 12 10 10 10 10 10 12 12 13 14 15 16 17 13 14 15 16 17 13 14 15 16 17 A 4 6 4 5 5 5 T R 1 6 N m 0 6 kgf m 4 ...

Page 122: ...otter 12 14 Valve spring retainer 6 15 Valve spring 6 16 Valve spring seat 6 17 Valve seal 6 Not reusable S67C5067 M M 19 19 20 20 20 19 21 19 27 23 2 3 1 4 18 18 17 16 15 14 13 17 16 15 14 13 18 17 16 15 14 13 18 17 16 15 14 13 6 6 6 7 12 9 12 12 T R 14 N m 1 4 kgf m 10 3 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib E E E E E E E E E 11 28 10 A E 5 5 5 8 26 22 22 22 25 23 24 ...

Page 123: ...er arm shaft 1 S67C5067 M M 19 19 20 20 20 19 21 19 27 23 2 3 1 4 18 18 17 16 15 14 13 17 16 15 14 13 18 17 16 15 14 13 18 17 16 15 14 13 6 6 6 7 12 9 12 12 T R 14 N m 1 4 kgf m 10 3 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib E E E E E E E E E 11 28 10 A E 5 5 5 8 26 22 22 22 25 23 24 22 20 19 20 20 19 E E 18 17 16 15 14 13 18 17 16 15 14 13 A A E E E E 21 21 T R 18 N m 1 8 ...

Page 124: ...aft 5 and rocker arms 6 NOTE Loosen the locknuts and adjusting screws to ease the tension on the rocker arm shaft 5 before removing it Be sure to keep the parts in the order as they were removed 3 Remove the bolt 7 camshaft 8 and oil seal 9 4 Remove the intake and exhaust valves NOTE Be sure to keep the valves springs and other parts in the same order as removed S67C5068 2 1 4 3 5 6 7 8 9 0 A B S6...

Page 125: ...sure the valve spring free length a Replace if below specification 2 Measure the valve spring tilt b Replace if above specification Checking the valve 1 Check the valve face Replace the valve if pitted or worn 2 Measure the valve margin thickness a Replace the valve if out of specification Cylinder head warpage limit 0 10 mm 0 0039 in Valve spring free length a 39 85 mm 1 5689 in S67C5073 2 1 S67C...

Page 126: ...e guide 1 Remove the valve seal 2 Insert the special service tool 1 into the combustion chamber end of the valve guide 2 and then strike the tool to drive the guide out of the cylinder head Valve stem diameter b Intake 5 475 5 490 mm 0 2156 0 2161 in Exhaust 5 460 5 475 mm 0 2150 0 2156 in Valve stem runout limit Intake 0 030 mm 0 0012 in Exhaust 0 016 mm 0 0006 in Valve guide inside diameter a In...

Page 127: ...efore reaming it Turn the valve guide reamer clockwise to ream the valve guide Do not turn the reamer counterclockwise when removing it Be sure to clean the valve guide after ream ing it 5 Measure the valve guide inside diameter Checking the valve seat 1 Eliminate carbon deposits from the valve 2 Apply a thin even layer of Mechanic s blueing dye Dykem onto the valve seat 3 Press the valve lightly ...

Page 128: ...45 cutter by turning the cutter clockwise until the valve seat face has become smooth a Slag or rough surface CAUTION Do not over cut the valve seat Be sure to turn the cutter evenly downward at a pres sure of 40 50 N 4 5 kgf 8 8 11 lbf to prevent chatter marks 3 Use a 30 cutter to adjust the contact width of the top edge of the valve seat Valve seat contact width a Intake and exhaust 0 9 1 1 mm 0...

Page 129: ...e valve seat 5 32 7 If the valve seat contact area is too wide and situated in the center of the valve face use a 30 cutter to cut the top edge of the valve seat and then use a 60 cut ter to cut the bottom edge to center the area and set its width b Previous contact width 8 If the valve seat contact area is too nar row and situated near the top edge of the valve face use a 30 cutter to cut the top...

Page 130: ...e be sure to clean off any remaining lapping com pound from the cylinder head and the valve 12 Check the valve seat contact area of the valve again NOTE To check the valve seat contact area see Checking the valve seat 5 32 Checking the rocker arm and rocker arm shaft 1 Check the rocker arms rocker arm shaft and contact surface a of each rocker arm Replace if worn 2 Measure the rocker arm inside di...

Page 131: ...worn M and W model Assembling the cylinder head 1 Install a new valve seal 1 onto the valve guide Cam lobe height a Intake and exhaust 30 834 31 034 mm 1 2139 1 2218 in Cam lobe width b Intake and exhaust 25 900 26 100 mm 1 0197 1 0276 in Camshaft runout limit 0 03 mm 0 0012 in S67C5101 S67C5102 d c c e e e Camshaft journal diameter c 36 935 36 955 mm 1 4541 1 4549 in Camshaft journal diameter d 3...

Page 132: ...ress the valve spring and then install the valve cotters 8 4 Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters 8 securely 5 Install a new oil seal 9 6 Install the camshaft B in the direction of the arrow shown and then tighten the bolt C Valve spring compressor 6 90890 04019 Valve spring compressor attachment 7 90890 06320 S6AG5290 a 5 4 3 2 6 7 E E Driver rod LS...

Page 133: ...sembly by aligning the slot d in the oil pump drive shaft with the camshaft pin I and then tighten the bolts J to the specified torque NOTE Before installing the oil pump assembly be sure to fill it with a small amount of engine oil through the oil passages e T R Rocker arm shaft bolt H 18 N m 1 8 kgf m 13 3 ft lb S67C5110 B C E E M S67C5111 b c S67C5112 D G H E D G H F F G G H H D E E E E T R Oil...

Page 134: ...l to the cylinder head bolts before installation Tighten the bolts to the specified torques in 2 stages 2 Adjust the valve clearances NOTE Be sure to install the timing belt before adjusting the valve clearances To adjust the valve clearances see Checking the valve clearance 5 2 T R Cylinder head bolt M9 1st 23 N m 2 3 kgf m 17 0 ft lb 2nd 46 N m 4 6 kgf m 33 9 ft lb Cylinder head bolt M6 1st 6 N ...

Page 135: ...le 16 Piston 3 17 Piston pin 3 S67C5118 2 4 4 8 10 11 13 14 6 15 18 7 5 4 4 3 3 4 6 7 4 9 11 12 25 26 24 1 E E E E E E E E E T R 1 6 N m 0 6 kgf m 4 4 ft lb 2 12 N m 1 2 kgf m 8 9 ft lb T R 1 6 N m 0 6 kgf m 4 4 ft lb 2 12 N m 1 2 kgf m 8 9 ft lb T R 1 15 N m 1 5 kgf m 11 1 ft lb 2 30 N m 3 0 kgf m 22 1 ft lb T R 7 N m 0 7 kgf m 5 2 ft Ib T R 18 N m 1 8 kgf m 13 3 ft Ib T R 40 N m 4 0 kgf m 29 5 f...

Page 136: ...6 15 18 7 5 4 4 3 3 4 6 7 4 9 11 12 25 26 24 1 E E E E E E E E E T R 1 6 N m 0 6 kgf m 4 4 ft lb 2 12 N m 1 2 kgf m 8 9 ft lb T R 1 6 N m 0 6 kgf m 4 4 ft lb 2 12 N m 1 2 kgf m 8 9 ft lb T R 1 15 N m 1 5 kgf m 11 1 ft lb 2 30 N m 3 0 kgf m 22 1 ft lb T R 7 N m 0 7 kgf m 5 2 ft Ib T R 18 N m 1 8 kgf m 13 3 ft Ib T R 40 N m 4 0 kgf m 29 5 ft Ib 17 16 15 23 19 19 19 20 21 22 3 1 1 1 T R 1 6 N m 0 6 k...

Page 137: ...g rods bearings and piston assemblies 5 Remove the crankshaft main bearings and oil seals NOTE Be sure to keep the main bearings in the order as they were removed 6 Remove the piston pin clips 7 and pis ton pin 8 and then remove the piston 9 NOTE To avoid interchanging the pistons connect ing rods and connecting rod caps mark each with an identification number a of the corresponding cylinder and b...

Page 138: ...ns piston ring sets cylinder block or all parts NOTE The figures are for reference only Depend ing on how the parts are assembled the actual measurements may not be within the specified ranges Checking the piston ring 1 Measure the piston ring dimensions B and T Replace the piston ring set if out of specification Piston diameter a 64 950 64 965 mm 2 5571 2 5577 in Measuring point b 2 0 mm 0 08 in ...

Page 139: ...ication Piston ring dimensions Top ring a B 1 17 1 19 mm 0 0461 0 0469 in T 2 30 2 50 mm 0 0906 0 0984 in 2nd ring b B 1 47 1 49 mm 0 0579 0 0587 in T 2 60 2 80 mm 0 1024 0 1102 in Oil ring c B 2 36 2 48 mm 0 0929 0 0976 in T 2 75 mm 0 1083 in reference data S67C5129 1 a b Piston ring end gap b reference data Top ring 0 15 0 30 mm 0 0059 0 0118 in 2nd ring 0 30 0 50 mm 0 0118 0 0197 in Oil ring 0 ...

Page 140: ...to the specified torques in 2 stages 2 Measure the connecting rod small end inside diameter a and big end inside diameter b Replace the connecting rod if out of specification Piston ring side clearance Top ring a 0 02 0 06 mm 0 0008 0 0024 in 2nd ring b 0 02 0 06 mm 0 0008 0 0024 in Oil ring c 0 04 0 18 mm 0 0016 0 0071 in Piston pin boss bore 15 974 15 985 mm 0 6289 0 6293 in S67C5131 a b c S6AU5...

Page 141: ...e 1 Clean the bearings connecting rods and crankpin 2 Put a piece of Plastigauge PG 1 onto the crankpin parallel to the crankshaft NOTE Be sure not to put the Plastigauge PG 1 over the oil hole in the crankpin of the crank shaft Connecting rod big end side clearance a reference data 0 12 0 15 mm 0 0047 0 0059 in S67C5135 a a S67C5136 a a S67C5137 c b Crankshaft journal diameter a 42 984 43 000 mm ...

Page 142: ...width of the compressed Plastigauge PG 1 on the crankpin Check the connecting rods bearings and crankshaft if out of specification and replace the defective parts Selecting the connecting rod bearing 1 When replacing the connecting rod bear ing select the suitable bearing as fol lows 2 Check the connecting rod mark a or painted color b on the connecting rod 3 Select the suitable bearing color c fo...

Page 143: ... positions Insert the projection a of each bearing into the slots in the cylinder block 3 4 Put a piece of Plastigauge PG 1 on each crankshaft journal parallel to the crankshaft NOTE Be sure not to put the Plastigauge PG 1 over the oil hole in each crankshaft journal 5 Install the remaining half of the main bearings into the crankcase NOTE Install the main bearings in their original positions Inse...

Page 144: ...for tighten ing Selecting the crankshaft main bearing 1 Check the stamped marks a b c and d on the cylinder block NOTE The stamped marks a b c and d indi cate crankshaft main bearings 1 2 3 and 4 respectively 2 Select the suitable bearing color e for the main bearings from the table Assembling the cylinder block 1 Assemble the piston 1 connecting rod 2 piston pin 3 and piston pin clips 4 T R Crank...

Page 145: ...the piston ring end gaps as shown CAUTION Do not scratch the pistons or break the piston rings NOTE After installing the piston rings check that they move smoothly 4 Install the piston with the UP mark on the piston crown facing towards the fly wheel magnet NOTE Apply engine oil to the side of each piston and the piston rings before installation 5 Install half of the main bearings 9 into the cylin...

Page 146: ... cap bolts check that the crankshaft rotates smoothly 8 Install the remaining half of the main bearings into the crankcase NOTE Install the main bearings in their original positions Insert the projection of each bearing into the slots in the crankcase 9 Apply sealant to the mating surface of the crankcase NOTE Do not get any sealant on the main bearings 10 Install the crankcase onto the cylinder b...

Page 147: ...it mating surface 2 Install the dowels 1 a new gasket 2 and the power unit 3 and then tighten the mounting bolts 4 to the specified torque CAUTION Do not reuse the gasket always replace it with a new one T R Crankcase bolt 1 8 M8 1st 15 N m 1 5 kgf m 11 1 ft lb 2nd 30 N m 3 0 kgf m 22 1 ft lb Crankcase bolt 9 F M6 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb Oil filter wrench 90890...

Page 148: ...he flushing hose 7 cooling water hose 8 and fuel hose 9 7 Connect the engine shut off switch leads 0 and the warning indicator assembly coupler A M model Connect the warning indicator assembly coupler A and 10 pin main harness B to the power unit E and W model È M model É E and W model 8 Connect the PTT motor leads C PTT model Connect the PTT switch coupler D and trim sensor coupler E R model with...

Page 149: ...5 54 1 2 3 4 5 6 7 8 9 10 Connect the start in gear protection cable M and W model NOTE To connect the start in gear protection cable see Checking the start in gear protection M and W model 3 10 Cylinder block ...

Page 150: ...POWR Power unit 5 55 67C3K11 MEMO ...

Page 151: ...6 13 Disassembling the oil seal housing 6 13 Disassembling the forward gear 6 13 Disassembling the lower case 6 14 Checking the pinion and forward gear 6 14 Checking the bearing 6 14 Checking the drive shaft 6 14 Checking the shift rod 6 15 Checking the lower case 6 15 Assembling the lower case 6 15 Assembling the forward gear 6 16 Assembling the oil seal housing 6 16 Assembling the drive shaft 6 ...

Page 152: ...10 Screw 1 ø5 25 mm 11 Bolt 4 M10 40 mm 12 Drain screw 1 13 Lower case 1 14 Bolt 1 M8 65 mm 15 Trim tab 1 16 Bolt 1 M8 25 mm 17 Anode 1 S67C6001 T R 4 N m 0 4 kgf m 3 0 ft Ib T R 39 N m 3 9 kgf m 28 8 ft Ib T R 39 N m 3 9 kgf m 28 8 ft Ib 572 LT 572 LT 572 LT 11 8 10 13 12 3 9 7 5 25 24 6 3 1 2 24 4 18 19 20 21 22 15 16 17 14 D M A 23 T R 9 N m 0 9 kgf m 6 6 ft Ib T R 9 N m 0 9 kgf m 6 6 ft Ib 6 1...

Page 153: ...able 24 Plastic tie 2 25 Speedometer hose 1 S67C6001 T R 4 N m 0 4 kgf m 3 0 ft Ib T R 39 N m 3 9 kgf m 28 8 ft Ib T R 39 N m 3 9 kgf m 28 8 ft Ib 572 LT 572 LT 572 LT 11 8 10 13 12 3 9 7 5 25 24 6 3 1 2 24 4 18 19 20 21 22 15 16 17 14 D M A 23 T R 9 N m 0 9 kgf m 6 6 ft Ib T R 9 N m 0 9 kgf m 6 6 ft Ib 6 11 T R 18 N m 1 8 kgf m 13 3 ft Ib Lower unit ...

Page 154: ...M8 30 mm 4 Water pump housing 1 5 Insert cartridge 1 6 Impeller 1 7 O ring 1 Not reusable 8 Dowel 2 9 Outer plate cartridge 1 10 Gasket 1 Not reusable 11 Woodruff key 1 12 Rubber seal 1 13 Plate 1 S67C6002 A A 1 2 3 4 8 5 6 10 9 8 7 6 5 11 12 13 572 LT A T R 18 N m 1 8 kgf m 13 3 ft Ib A 3 3 A ...

Page 155: ... sure to disconnect the battery cables from the battery and remove the clip from the engine shut off switch E and W model 3 Remove the lower mount cover L tran som model 4 Loosen the locknut 1 while holding the adjusting nut 2 and then turn the adjust ing nut to disconnect the shift rod 3 NOTE Set the gear shift to the N position before dis connecting the shift rod 3 5 Remove the lower case mounti...

Page 156: ...se Checking the water pump 1 Check the water pump housing Replace if deformed NOTE If the engine overheated the inside of the water pump housing may be deformed therefore be sure to remove the insert car tridge when checking the housing 2 Check the impeller insert cartridge and outer plate cartridge Replace if cracked or worn 3 Check the Woodruff key and the keyway in the drive shaft Replace if wo...

Page 157: ...r 1 8 Reverse gear 1 9 Reverse gear shim 10 O ring 1 Not reusable 11 Ball bearing 1 Not reusable 12 O ring 2 Not reusable 13 Propeller shaft housing 1 14 Bolt 2 M8 25 mm 15 Needle bearing 1 Not reusable 16 Oil seal 2 Not reusable S67C6008 F 1 7 8 9 10 11 12 16 16 13 15 3 4 5 14 14 6 15 16 13 2 D A T R 16 N m 1 6 kgf m 11 8 ft Ib G G G A A A Lower unit Propeller shaft housing ...

Page 158: ...sh 6 26 Disassembling the propeller shaft assembly 1 Remove the shift plunger 1 from the propeller shaft 2 2 Remove the spring 3 and then remove the cross pin 4 and dog clutch 5 3 Pull out the spring 6 from the propeller shaft 2 Disassembling the propeller shaft housing assembly 1 Remove the reverse gear and shim s 2 Remove the ball bearing CAUTION Do not reuse the bearing always replace it with a...

Page 159: ...unout Replace if above specification 3 Check the dog clutch shift plunger and cross pin Replace if cracked or worn Assembling the propeller shaft assembly 1 Insert the spring 1 into the propeller shaft 2 2 Install the dog clutch 3 cross pin 4 and spring 5 NOTE Install the dog clutch 3 with the F mark fac ing toward the forward gear 3 Install the shift plunger 6 Stopper guide plate 2 90890 06501 St...

Page 160: ... shaft housing and then install the other oil seal 3 Install a new ball bearing and original shim s onto the reverse gear NOTE Install the ball bearing with the manufacture identification mark facing toward the reverse gear 4 Install the reverse gear assembly into the propeller shaft housing Driver rod SS 1 90890 06604 Needle bearing attachment 2 90890 06614 Bearing depth plate 3 90890 06603 Insta...

Page 161: ...10 1 2 3 4 5 6 7 8 9 NOTE After installing the reverse gear and shim s check that the gear rotates smoothly Driver rod LS 4 90890 06606 Ball bearing attachment 7 90890 06633 S67C6089 4 7 G Propeller shaft housing ...

Page 162: ...del 6 Taper roller bearing 1 Not reusable 7 Pinion shim 8 Drive shaft sleeve 1 9 Needle bearing 1 Not reusable 10 Oil seal cover 1 11 Oil seal housing 1 12 O ring 1 Not reusable 13 Oil seal 2 Not reusable 14 Washer 1 15 Drive shaft 1 L transom model S transom model 16 Pinion 1 17 Nut 1 S67C6026 A A 2 3 4 1 6 11 12 14 15 13 10 7 8 9 17 20 16 5 8 18 19 9 G G G G A A T R 74 N m 7 4 kgf m 54 6 ft Ib B...

Page 163: ...ame Q ty Remarks 18 Forward gear shim 19 Taper roller bearing 1 Not reusable 20 Forward gear 1 S67C6026 A A 2 3 4 1 6 11 12 14 15 13 10 7 8 9 17 20 16 5 8 18 19 9 G G G G A A T R 74 N m 7 4 kgf m 54 6 ft Ib BOW BOW Drive shaft and lower case ...

Page 164: ...mbling the oil seal housing 1 Remove the oil seals 1 Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear CAUTION Do not reuse the bearing always replace it with a new one Drive shaft holder 3 6 90890 06517 Pinion nut holder 7 90890 06505 Socket adapter 1 8 90890 06506 S67C6086 3 1 4 5 2 S67C6088 6 8 7 7 Bearing inner race attachment 9 90890 06641 Driver rod L3 1 ...

Page 165: ... a new one Checking the pinion and forward gear 1 Check the teeth of the pinion and the teeth and dogs of the forward gear Replace the pinion or forward gear if cracked or worn Checking the bearing 1 Check the bearings Replace if pitted or if there is rumbling Checking the drive shaft 1 Check the drive shaft Replace if bent or worn Bearing outer race puller assembly 1 90890 06523 Stopper guide sta...

Page 166: ...Install the needle bearing with the manufac ture identification mark b facing upward Install the stopper c onto the driver rod SL 5 at the installation depth a as shown Install the needle bearing until the stopper c contacts the special service tool 6 3 Install the drive shaft sleeve pinion shim s and a new taper roller bearing outer race Drive shaft runout limit 0 5 mm 0 0197 in Driver rod LL 3 9...

Page 167: ... seal housing to the specified depth a NOTE Install an oil seal halfway into the oil seal housing and then install the other oil seal Assembling the drive shaft 1 Install the taper roller bearing onto the drive shaft Driver rod LS 8 90890 06606 Bearing outer race attachment 9 90890 06627 Bearing inner race attachment 1 90890 06640 S67C6109 G 1 S67C6045 a A A 1 2 Driver rod LS 1 90890 06606 Ball be...

Page 168: ...specified torque 4 Install the shift rod 8 washer 9 shift rod housing 0 washer A and oil seal housing B Installing the propeller shaft housing assembly 1 Install the propeller shaft assembly 1 into the lower case 2 Install the washer 2 and propeller shaft housing assembly 3 into the lower case and then tighten the bolts 4 to the speci fied torque S67C6048 G G 3 2 4 1 S67C6098 5 7 6 6 Drive shaft h...

Page 169: ...hen installing the impeller 5 onto the drive shaft align the groove in the impeller with the Woodruff key 4 3 Install the insert cartridge 6 and a new O ring 7 into the water pump housing NOTE Align the insert cartridge projection a with the hole b in the water pump housing T R Propeller shaft housing bolt 4 16 N m 1 6 kgf m 11 8 ft lb S67C6050 G 3 2 4 4 A S67C6052 F N R F N R S67C6053 A 1 1 2 3 S...

Page 170: ... N position R model 2 Set the shift rod to the N position 3 Install the lower unit to the upper case and then tighten the lower case mounting bolts 1 and 2 to the specified torque NOTE Before installing the lower unit to the upper case install the dowels 3 into the lower case When installing the lower unit make sure that the water pipe 4 is inserted securely into the collar 5 4 Connect the speedom...

Page 171: ...ning or tightening the propeller nut Be sure to disconnect the battery cables from the battery and remove the clip from the engine shut off switch E and W model NOTE If the grooves in the propeller nut F do not align with the cotter pin hole tighten the nut until they are aligned 8 Fill the lower unit with gear oil to the cor rect level Screwed in length a 8 0 9 0 mm 0 31 0 35 in T R Trim tab bolt...

Page 172: ...LOWR Lower unit 6 21 67C3K11 Shimming S67C6063 T1 T2 B2 A2 F R P T3 B3 A3 42 0 T1 T2 B1 28 0 28 0 B2 A2 A1 ...

Page 173: ...3 in a vise and then install the drive shaft 1 onto the tool so that the shaft is centered in the hole Tighten the wing nuts another 1 4 of a turn after they contact the special service tool 4 Make sure that the special service tool 3 and drive shaft 1 are parallel 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M1 between the special ser...

Page 174: ...pinion shim thick ness is 0 35 mm If T3 is 0 43 mm then the pinion shim thick ness is 0 45 mm Selecting the forward gear shim 1 Turn the taper roller bearing outer race 1 2 or 3 times to seat the rollers and then measure the bearing height M2 as shown NOTE Select the shim thickness T1 by using the specified measurement s and the calcula tion formula Measure the bearing outer race at 4 points to fi...

Page 175: ...F is 3 then T1 22 75 3 100 22 30 mm 22 75 0 03 22 30 mm 0 42 mm 3 Select the forward gear shim s T1 as follows Example If T1 is 0 50 mm then the forward gear shim thickness is 0 48 mm If T1 is 0 42 mm then the forward gear shim thickness is 0 40 mm Selecting the reverse gear shim 1 Remove the reverse gear and reverse gear shim s from the propeller shaft housing Calculation formula Forward gear shi...

Page 176: ...ble assume that R is zero and check the backlash when the unit is assembled Example If M3 is 96 79 mm and R is 1 then T2 98 00 96 79 1 100 mm 98 00 96 79 0 01 mm 1 20 mm If M3 is 96 79 mm and R is 3 then T2 98 00 96 79 3 100 mm 98 00 96 79 0 03 mm 1 24 mm 4 Select the reverse gear shim s T2 as follows Digital caliper 1 90890 06704 Shimming plate 2 90890 06701 S67C6075 1 2 S67C6076 M3 10 mm 0 39 in...

Page 177: ...r shaft 5 Tighten the center bolt 1 to the specified torque while turning the drive shaft 6 Turn the lower unit upright 7 Install the backlash indicator 4 onto the drive shaft where the shaft diameter is 16 0 mm 0 63 in and then set up the dial gauge as shown NOTE Position the dial gauge so that the plunger tip a is aligned with the mark b on the back lash indicator S67C6052 F N R F N R S67C6081 2...

Page 178: ... drive shaft stops in each direction NOTE Push the drive shaft downward and then turn it Measure the backlash at 4 points to find the average 14 Adjust the current reverse gear shim thickness if the reverse gear backlash is out of specification M Measurement Forward gear backlash 0 18 0 57 mm 0 0071 0 0224 in Forward gear backlash Forward gear shim thickness Less than 0 18 mm 0 0071 in To be decre...

Page 179: ...15 Remove the special service tools and propeller and then install the water pump assembly NOTE To install the water pump assembly see Installing the water pump 6 18 16 Fill the lower unit with gear oil to the cor rect level Backlash ...

Page 180: ...alling the upper case 7 23 Hydraulic tilt unit and PTT unit 7 25 Clamp bracket and swivel bracket 7 26 Removing the hydraulic tilt unit 7 28 Removing the PTT unit 7 28 Removing the clamp bracket 7 29 Checking the hydraulic tilt unit 7 29 Installing the clamp bracket 7 29 Installing the hydraulic tilt unit 7 30 Installing the PTT unit 7 31 Adjusting the trim sensor cam R model 7 32 PTT motor 7 34 D...

Page 181: ...7 Checking the tilt cylinder and piston 7 47 Assembling the tilt cylinder 7 48 Bleeding the PTT unit 7 50 Bleeding the PTT unit installed 7 51 PTT electrical system 7 52 Checking the fuse 7 52 Checking the PTT relay 7 53 Checking the PTT switch 7 54 Checking the trim sensor 7 54 ...

Page 182: ... handle assembly 1 2 Shift cable 1 3 Throttle cable 1 4 Clip 2 5 Bolt 3 M6 25 mm 6 Retaining plate 1 7 Cable holder 1 8 Grommet 1 9 Grommet 1 M model 10 Grommet 1 E and W model 11 Washer 2 12 Self locking nut 2 S67C7001 1 9 6 3 5 5 12 11 12 11 2 4 4 10 8 7 T R 10 N m 1 0 kgf m 7 4 ft Ib ...

Page 183: ...g indicator assembly 1 E and W model 9 Plate 1 E and W model 10 Warning buzzer 1 E and W model 11 Bracket 1 E and W model 12 Bolt 1 M6 14 mm E and W model 13 Screw 1 ø6 16 mm PTT model 14 PTT switch 1 PTT model 15 Grip end 1 16 Screw 1 ø6 16 mm 17 Clamp 2 E and W model S67C7119 3 16 15 2 1 3 13 1 9 4 6 5 8 7 7 10 11 12 17 14 1 T R 4 N m 0 4 kgf m 3 0 ft Ib T R 2 N m 0 2 kgf m 1 5 ft Ib T R 2 N m 0...

Page 184: ...andle bracket 1 12 Collar 1 13 Wave washer 1 14 Washer 1 15 Bolt 1 M12 80 mm 16 Grease nipple 1 17 Holder 2 S67C7002 1 3 4 2 5 6 47 46 11 10 9 8 7 8 7 16 14 13 12 15 25 26 28 27 21 45 T R 18 N m 1 8 kgf m 13 3 ft Ib LT 242 LT 242 38 33 33 29 31 30 33 37 36 35 34 4 20 32 43 44 43 42 40 41 40 39 A A A A A A A 33 33 49 19 17 18 17 48 18 24 22 22 23 572 LT 572 LT 572 LT 572 LT 572 LT A A T R 32 N m 3 ...

Page 185: ...e rod 1 30 Neutral switch 1 E and W model 31 Shift link 1 32 Bolt 2 M6 30 mm 33 Screw 6 ø6 16 mm 34 Tiller handle cover 1 S67C7002 1 3 4 2 5 6 47 46 11 10 9 8 7 8 7 16 14 13 12 15 25 26 28 27 21 45 T R 18 N m 1 8 kgf m 13 3 ft Ib LT 242 LT 242 38 33 33 29 31 30 33 37 36 35 34 4 20 32 43 44 43 42 40 41 40 39 A A A A A A A 33 33 49 19 17 18 17 48 18 24 22 22 23 572 LT 572 LT 572 LT 572 LT 572 LT A A...

Page 186: ...hing 1 46 Nut 1 47 Friction piece 1 48 Cotter pin 1 Not reusable 49 Throttle friction adjuster 1 S67C7002 1 3 4 2 5 6 47 46 11 10 9 8 7 8 7 16 14 13 12 15 25 26 28 27 21 45 T R 18 N m 1 8 kgf m 13 3 ft Ib LT 242 LT 242 38 33 33 29 31 30 33 37 36 35 34 4 20 32 43 44 43 42 40 41 40 39 A A A A A A A 33 33 49 19 17 18 17 48 18 24 22 22 23 572 LT 572 LT 572 LT 572 LT 572 LT A A T R 32 N m 3 2 kgf m 23 ...

Page 187: ...ller handle 1 Assemble the tiller handle NOTE See the exploded diagram for assembly 7 1 2 Connect the 10 pin main harness 1 to the engine start switch coupler 2 as shown E and W model 3 Install the shift link assembly 3 throttle rod 4 and shift lever 5 and then tighten the bolt 6 to the specified torque NOTE When installing the throttle rod 4 be sure to align the mark a on the throttle rod gear wi...

Page 188: ...Install the tiller handle assembly to the steering arm and then tighten the nuts to the specified torque 8 Connect the throttle cable and shift cable NOTE To adjust the throttle cable and shift cable see Adjusting the throttle cable 3 8 and Checking the gear shift operation 3 9 9 Connect the engine shut off switch leads M model or 10 pin main harness and warning indicator assembly coupler E and W ...

Page 189: ...Long 11 Friction plate 1 12 Steering lock washer 1 13 Self locking nut 1 14 Nut 1 15 Speedometer hose 1 16 Holder 1 17 Bolt 2 M6 12 mm S67C7009 TOP 4 10 9 0 mm 0 35 in 3 7 mm 0 15 in 5 4 mm 0 21 in 8 0 mm 0 31 in 3 2 4 8 3 17 17 6 6 5 5 9 12 13 14 16 15 9 7 8 7 4 10 11 3 1 2 T R 7 N m 0 7 kgf m 5 2 ft Ib 572 LT T R 4 N m 0 4 kgf m 3 0 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 37 N m 3 7 kgf m 27 3 f...

Page 190: ...ires less than 90 d for proper align ment 2 Assemble the friction plate assembly NOTE See the exploded diagram for assembly 7 8 Face the TOP mark on the steering lock lever up Be sure to install the collars in the correct positions the collar lengths are different 3 Install the friction plate assembly and tiller handle and then tighten the friction plate bolts 2 and tiller handle nuts 3 to the spe...

Page 191: ... 1 2 3 4 5 6 7 8 9 NOTE To check and adjust the friction plate see Checking the steering operation H model 3 12 T R Friction plate self locking nut 5 4 N m 0 4 kgf m 3 0 ft lb S67C7014 5 4 e Friction plate H model ...

Page 192: ...15 Start in gear protection cable 1 M and W model 16 Bolt 1 M6 20 mm 17 Bracket 1 S67C7015 T R 10 N m 1 0 kgf m 7 4 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib 34 31 35 39 38 37 36 28 27 22 23 24 23 24 25 25 25 22 41 40 14 12 21 10 23 24 20 13 10 11 12 10 29 22 26 23 24 25 45 46 47 5...

Page 193: ...t 1 M6 14 mm 33 Spring 1 34 Clamp lever 1 S67C7015 T R 10 N m 1 0 kgf m 7 4 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib 34 31 35 39 38 37 36 28 27 22 23 24 23 24 25 25 25 22 41 40 14 12 21 10 23 24 20 13 10 11 12 10 29 22 26 23 24 25 45 46 47 5 4 49 48 50 33 32 7 3 6 1 2 8 31 16 15 2...

Page 194: ...ug 1 E and W model 48 Bolt 1 M6 35 mm M model 49 Collar 1 M model 50 Warning indicator assembly 1 M model S67C7015 T R 10 N m 1 0 kgf m 7 4 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib 34 31 35 39 38 37 36 28 27 22 23 24 23 24 25 25 25 22 41 40 14 12 21 10 23 24 20 13 10 11 12 10 29 2...

Page 195: ...1 13 Plate 1 14 Rubber damper 1 15 Steering yoke 1 L transom model 16 Steering yoke 1 S transom model 17 Circlip 1 S67C7016 BOW 8 6 18 20 12 11 11 Ó Ú 9 10 19 17 13 7 6 27 33 7 5 4 1 3 3 2 26 22 24 31 30 29 28 28 30 29 31 33 32 32 33 31 30 29 28 27 26 21 34 14 15 16 23 25 32 18 19 A A A A A A A A A A LT 572 LT LT 572 LT LT 572 LT LT 271 LT R T 3 N m 0 3 kgf m 2 2 ft Ib R T 4 N m 0 4 kgf m 3 0 ft I...

Page 196: ...housing 2 28 Bolt 2 M12 170 mm 29 Washer 2 30 Washer 2 31 Washer 2 32 Lower mount 2 33 Washer 2 34 Screw 1 ø6 7 mm S67C7016 BOW 8 6 18 20 12 11 11 Ó Ú 9 10 19 17 13 7 6 27 33 7 5 4 1 3 3 2 26 22 24 31 30 29 28 28 30 29 31 33 32 32 33 31 30 29 28 27 26 21 34 14 15 16 23 25 32 18 19 A A A A A A A A A A LT 572 LT LT 572 LT LT 572 LT LT 271 LT R T 3 N m 0 3 kgf m 2 2 ft Ib R T 4 N m 0 4 kgf m 3 0 ft I...

Page 197: ...som model 8 Plug 1 M14 12 mm L transom model 9 Grommet 1 L transom model 10 Drive shaft bushing 1 L transom model 11 Collar 1 L transom model 12 Circlip 1 L transom model 13 Oil pan assembly 1 S67C7145 3 5 5 2 1 3 5 6 7 9 8 11 10 12 1 13 4 A A LT 572 LT T R 3 N m 0 3 kgf m 2 2 ft Ib T R 17 N m 1 7 kgf m 12 5 ft Ib M M T R 21 N m 2 1 kgf m 15 5 ft Ib Upper case and steering arm ...

Page 198: ...0 Gasket 1 Not reusable 11 Relief valve assembly 1 12 Bolt 3 M6 25 mm 13 Bolt 2 M6 16 mm 14 Oil strainer 1 15 Cooling water pipe 1 L transom model 16 Cooling water pipe 1 S transom model 17 Dowel 2 S67C7143 16 15 17 12 14 1 2 9 26 27 29 30 32 21 31 28 19 26 17 12 25 24 7 8 6 5 4 3 22 23 20 18 19 10 11 13 LT 572 LT A A A A LT 572 LT LT 572 LT T R 10 N m 1 0 kgf m 7 4 ft Ib T R 17 N m 1 7 kgf m 12 5...

Page 199: ...25 Exhaust manifold 1 26 Bolt 3 M6 50 mm 27 Gasket 1 Not reusable 28 Muffler 1 L transom model 29 Muffler 1 S transom model 30 Rubber seal 1 31 Bolt 6 M6 25 mm 32 Rubber seal 1 S67C7143 16 15 17 12 14 1 2 9 26 27 29 30 32 21 31 28 19 26 17 12 25 24 7 8 6 5 4 3 22 23 20 18 19 10 11 13 LT 572 LT A A A A LT 572 LT LT 572 LT T R 10 N m 1 0 kgf m 7 4 ft Ib T R 17 N m 1 7 kgf m 12 5 ft Ib Upper case and...

Page 200: ...and lower mount assemblies 8 Disassembling the upper case 1 Remove the engine oil drain bolt 1 and damper 2 2 Remove the oil pan assembly 3 and dowels 4 from the upper case 5 3 Remove the rubber seals 6 and 7 4 Remove the baffle plate 8 È S transom model 5 Remove the muffler 9 and gasket 0 from the oil pan assembly 3 6 Remove the exhaust manifold A and gasket B È S transom model 7 Remove the oil p...

Page 201: ...t manifold oil pan and exhaust guide 1 Check the muffler exhaust manifold oil pan and exhaust guide Replace if cracked or corroded NOTE Clean the removed parts before checking them Checking the oil strainer 1 Check the oil strainer Clean if there is dirt or residue S67C7021 D C F K E H H È J G I S67C7127 5 L M N S67C7116 P O Stopper guide plate O 90890 06501 Bushing installer center bolt P 90890 0...

Page 202: ... onto the exhaust guide 8 È S transom model 4 Install the oil pan E 5 Install a new gasket F and the exhaust manifold G and then tighten the bolts H to the specified torque 6 Tighten the bolts I 7 Install a new gasket J and the muffler K and then tighten the bolts L È S transom model Driver rod L3 5 90890 06652 Needle bearing attachment 6 90890 06614 S67C7128 3 4 2 1 M S67C7117 5 3 6 1 S67C7023 7 ...

Page 203: ... the circlip 1 and then remove the steering yoke 2 using a general puller 3 2 Remove the steering arm 4 from the swivel bracket 5 by pulling the arm off the bracket È S transom model É L transom model NOTE To disassemble the clamp brackets see Removing the clamp bracket 7 29 T R Upper case bolt O 21 N m 2 1 kgf m 15 5 ft lb T R Engine oil drain bolt R 17 N m 1 7 kgf m 12 5 ft lb S67C7027 A A A A A...

Page 204: ... strike the steering yoke 0 with a copper hammer to install it 5 Apply grease to the grease nipple A on the swivel bracket until it comes out from the upper bushing c NOTE To assemble the clamp brackets see Install ing the clamp bracket 7 29 Installing the upper case 1 Install the lower mount assemblies 1 to the upper case assembly 2 2 Install the upper case assembly 2 to the steering arm install ...

Page 205: ...K11 7 24 1 2 3 4 5 6 7 8 9 T R Upper mounting nut 4 24 N m 2 4 kgf m 17 7 ft lb Grease nipple 3 N m 0 3 kgf m 2 2 ft lb S67C7031 L S BOW LT 572 LT LT 271 LT 2 6 1 6 1 3 9 7 4 8 5 Upper case and steering arm ...

Page 206: ...T model 6 Bolt 2 M8 15 mm 7 Washer 2 8 Shaft 1 9 Bushing 2 10 Bushing 1 PTT model 11 PTT unit 1 PTT model 12 Bolt 2 M6 10 mm PTT model 13 Hydraulic tilt unit 1 D model 14 Anode 1 D model 15 Screw 1 ø6 20 mm D model 16 Collar 1 D model 17 Collar 1 D model S67C7120 6 7 8 9 5 1 2 3 9 6 7 10 11 12 1 4 4 17 14 15 16 13 5 A A A A A A A A A A LT 242 LT LT 242 ...

Page 207: ...el bracket 1 13 Screw 1 ø6 24 mm R model with PTT 14 Trim sensor cam 1 R model with PTT 15 Screw 2 ø6 15 mm R model with PTT 16 Trim sensor 1 R model with PTT 17 Grease nipple 2 Without friction plate S67C7047 7 È 7 É 3 1 2 5 6 7 11 10 8 9 17 19 20 13 14 22 21 21 11 12 25 26 7 24 6 5 1 27 18 23 4 15 19 20 17 16 A A A A LT 572 LT T R 3 N m 0 3 kgf m 2 2 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 22 N ...

Page 208: ...ad 1 Short PTT model 23 Ground lead 1 Long PTT model 24 Ground lead 1 D model 25 Clamp bracket 1 PORT 26 Through tube 1 27 Bolt 1 M8 20 mm S67C7047 7 È 7 É 3 1 2 5 6 7 11 10 8 9 17 19 20 13 14 22 21 21 11 12 25 26 7 24 6 5 1 27 18 23 4 15 19 20 17 16 A A A A LT 572 LT T R 3 N m 0 3 kgf m 2 2 ft Ib T R 8 N m 0 8 kgf m 5 9 ft Ib T R 22 N m 2 2 kgf m 16 2 ft Ib T R 2 N m 0 2 kgf m 1 5 ft Ib ...

Page 209: ... and then remove the bushings A Removing the PTT unit 1 Tilt the outboard motor to the fully up position and then support it with the tilt stop lever WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the PTT unit should lose fluid pressure NOTE If the PTT unit does not operate open the manual valve by tu...

Page 210: ...n remove the clamp brackets 6 3 Remove the trim sensor 7 R model with PTT È D model É R model with PTT NOTE Be sure to remove the ground lead s 2 before removing the self locking nut 3 Checking the hydraulic tilt unit 1 Check the hydraulic tilt unit Replace if there is oil leakage gas leakage or dam age or if the rod is bent Installing the clamp bracket 1 Install the trim sensor 1 to the swivel br...

Page 211: ...R model with PTT NOTE Adjust the trim sensor cam after installing the PTT unit To adjust the trim sensor cam see Adjusting the trim sensor cam R model 7 32 Installing the hydraulic tilt unit 1 Tilt the outboard motor to the fully up position and then support it with the tilt stop lever WARNING After tilting the outboard motor up be sure to support it with the tilt stop lever S67C7053 È É A A 9 A A...

Page 212: ...or to the fully up position and then support it with the tilt stop lever WARNING After tilting the outboard motor up be sure to support it with the tilt stop lever 2 Install the bushing 1 onto the PTT unit 2 3 Install the PTT unit 2 bushings 3 shaft 4 and washers 5 onto the clamp brackets 6 and then tighten the bolts 7 4 Install a bushing 8 to the PTT unit 2 and install a bushing and the bushing 9...

Page 213: ...Loosen the trim sensor cam screw 1 3 Adjust the trim sensor cam 2 so that the trim sensor setting resistance is within specification NOTE To decrease the resistance turn the trim sensor cam in direction a To increase the resistance turn the trim sensor cam in direction b 4 Tighten the trim sensor cam screw 1 to the specified torque NOTE Check the trim sensor setting resistance again after tighteni...

Page 214: ...with the tilt stop lever Otherwise the outboard motor could sud denly lower if the PTT unit should lose fluid pressure 6 Check the trim sensor resistance If the resistance is out of specification adjust the trim sensor cam position and check the trim sensor NOTE To check the trim sensor see Checking the trim sensor 7 54 Trim sensor resistance Pink P Black B 238 8 378 8 Ω at 20 C 68 F S67C3039 ...

Page 215: ...m 8 Spring 2 9 Brush 1 Long lead 10 Brush 1 Short lead 11 Bolt 4 M6 20 mm 12 PTT motor base 1 13 Oil seal 1 Not reusable 14 O ring 1 Not reusable 15 Spring 1 16 Shaft connector 1 17 Reservoir cap 1 S67C7059 9 6 8 10 5 7 8 9 13 10 a a b b 17 3 9 8 7 2 11 11 11 6 1 5 3 4 12 13 15 16 14 10 8 7 T R 7 N m 0 7 kgf m 5 2 ft Ib T R 7 N m 0 7 kgf m 5 2 ft Ib Clamp bracket and swivel bracket PTT motor ...

Page 216: ... NOTE To prevent the internal PTT unit parts from falling out place the PTT unit in an upright position before disassembling it 3 Remove the PTT motor base bolts 2 and then remove the PTT motor assem bly 3 spring 4 shaft connector 5 and O ring 6 from the gear pump housing 4 Remove the stator 7 and O ring 8 from the PTT motor base 9 5 Remove the armature plate screw 0 and then remove the armature a...

Page 217: ...rcut a Replace the armature if below specifica tion 4 Check the armature for continuity Replace the armature if out of specifica tion 5 Check the bearing Replace the armature if damaged PTT motor commutator standard diameter 16 5 mm 0 65 in Wear limit 15 5 mm 0 61 in S67C7064 D C D 9 B B S6AU7066 S6AU7067 PTT motor commutator standard undercut a 1 00 mm 0 039 in Wear limit 0 50 mm 0 020 in Armatur...

Page 218: ...always replace them with new ones Do not allow grease or oil to contact the commutator of the armature 1 Install a new oil seal into the PTT motor base as shown 2 Install the brush springs 3 brush short lead 4 brush long lead 5 and brush holder screws 6 to the PTT motor base 7 as shown PTT motor base continuity Checking point Continuity Terminal 1 3 L Terminal 2 4 G Yes For all terminal combinatio...

Page 219: ...n the screws B NOTE Align the rounded section c of the stator A with the rounded section d of the PTT motor base 7 5 Install a new O ring C the shaft connec tor D the spring E and the PTT motor assembly F to the gear pump housing and then tighten the PTT motor assembly bolts G to the specified torque S67C7073 8 9 S67C7074 7 A B B c 0 d T R PTT motor assembly bolt G 7 N m 0 7 kgf m 5 2 ft lb S67C70...

Page 220: ...1 Circlip 1 12 Manual valve 1 13 O ring 1 Not reusable 14 O ring 1 Not reusable 15 Manual valve seat 2 16 Spring 1 17 Adapter 1 S67C7076 20 33 1 1 9 35 36 34 9 19 18 20 21 22 35 36 38 39 40 37 32 LT 271 T R 3 N m 0 3 kgf m 2 2 ft Ib T R 6 N m 0 6 kgf m 4 4 ft Ib T R 7 N m 0 7 kgf m 5 2 ft Ib T R 9 N m 0 9 kgf m 6 6 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib 11 12 13 14 15 16 17 15 9 4 2 3 3 7 8 7 8 10 24...

Page 221: ...8 Spring 2 29 O ring 4 Not reusable 30 Filter 1 31 O ring 1 Not reusable 32 Relief valve assembly 1 33 Valve lock screw 1 34 Spring 1 S67C7076 20 33 1 1 9 35 36 34 9 19 18 20 21 22 35 36 38 39 40 37 32 LT 271 T R 3 N m 0 3 kgf m 2 2 ft Ib T R 6 N m 0 6 kgf m 4 4 ft Ib T R 7 N m 0 7 kgf m 5 2 ft Ib T R 9 N m 0 9 kgf m 6 6 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib 11 12 13 14 15 16 17 15 9 4 2 3 3 7 8 7 8...

Page 222: ...ble 40 Valve lock screw 1 S67C7076 20 33 1 1 9 35 36 34 9 19 18 20 21 22 35 36 38 39 40 37 32 LT 271 T R 3 N m 0 3 kgf m 2 2 ft Ib T R 6 N m 0 6 kgf m 4 4 ft Ib T R 7 N m 0 7 kgf m 5 2 ft Ib T R 9 N m 0 9 kgf m 6 6 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib 11 12 13 14 15 16 17 15 9 4 2 3 3 7 8 7 8 10 24 23 22 21 19 18 28 29 27 26 28 29 30 26 25 27 25 31 5 6 6 5 ...

Page 223: ...rber valve pins 4 and filter 5 3 Remove the bolts 6 and then remove the gear pump assembly 7 4 Remove the valve pin 8 main valve seal 9 and filters 0 5 Remove the circlip A and then remove the manual valve B 6 Remove the main valves C and shuttle piston D S67C7077 1 2 3 4 1 1 4 5 3 S67C7078 6 7 6 0 0 8 9 S67C7079 A B S67C7131 C D C PTT gear pump ...

Page 224: ... gear pump assembly if the shafts do not rotate smoothly Checking the gear pump housing 1 Check the gear pump housing Replace the gear pump housing if corroded or cracked Checking the valve seal 1 Check the main valve seal assembly 1 and absorber valve pin assemblies 2 Replace if damaged 2 Check the main valves 3 and shuttle piston 4 Replace if damaged 3 Check the relief valve assembly 5 Replace i...

Page 225: ...lve lock screw 3 into the relief valve 4 2 Install the relief valve assembly 5 and then tighten the valve lock screw 6 to the specified torque NOTE Turn in the valve lock screw 3 the same number of turns it was turned out when it was removed 3 Install the shuttle piston 7 and then tighten the main valves 8 to the speci fied torque 4 Install the manual valve 9 and circlip 0 and then tighten the val...

Page 226: ...lter F absorber valve pins G balls H and gear pump housing I and then tighten the bolts J to the speci fied torque NOTE When installing the gear pump housing I apply grease to the O rings and balls H to prevent them from falling out T R Gear pump bolt E 4 N m 0 4 kgf m 3 0 ft lb S67C7086 E D E A A C B C B S67C7140 LT 271 J I H G J J H G F T R Gear pump housing bolt J 9 N m 0 9 kgf m 6 6 ft lb ...

Page 227: ...mbly 1 2 Dust seal 1 Not reusable 3 O ring 1 Not reusable 4 O ring 1 Not reusable 5 Backup ring 1 6 Free piston assembly 1 7 O ring 1 Not reusable 8 Cylinder 1 S67C7087 7 1 6 8 LT 271 T R 90 N m 9 0 kgf m 66 4 ft Ib T R 61 N m 6 1 kgf m 45 0 ft Ib A A 3 4 5 2 PTT gear pump PTT cylinder ...

Page 228: ...plates a on both sides and then remove the tilt piston 6 and tilt cylinder end screw 7 from the ram 6 Remove the absorber valves 8 from the tilt piston 6 Checking the tilt cylinder and piston 1 Check the tilt piston 1 free piston 2 and backup ring 3 Replace if cracked or scratched 2 Check the tilt cylinder end screw 4 dust seal 5 and backup ring 6 Replace if cracked or scratched 3 Check the tilt r...

Page 229: ...se the dust seal and O rings always replace them with new ones NOTE Lubricate the parts with ATF Dexron II during assembly 1 Install a new dust seal 1 new O rings 2 and 3 and the backup ring 4 into the tilt cylinder end screw 5 2 Install a new O ring 6 and the backup ring 7 to the tilt piston 8 3 Install the tilt cylinder end screw 5 and tilt piston 8 to the tilt ram 9 S67C7092 6 1 2 3 5 4 7 S67C7...

Page 230: ...PTT gear pump housing see Assembling the gear pump 7 44 8 Fill the cylinder with the recommended PTT fluid to about 60 9 Install a new O ring F to the free piston G and then install the piston into the cyl inder H 10 Place the tilt cylinder end screw 5 at the bottom of the tilt ram 9 11 Install the tilt ram assembly into the cylin der 12 Tighten the tilt cylinder end screw 5 to the specified torqu...

Page 231: ... reservoir cap 2 and then check the fluid level in the reservoir NOTE If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole If fluid is below the correct level add the recommended PTT fluid 4 Install the reservoir cap 2 and then tighten it to the specified torque Cylinder end screw wrench I 90890 06568 T R Tilt cylinder end screw 5 90 N m 9 0 kgf m 66 ...

Page 232: ...ut from the unit due to internal pressure NOTE If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole when the cap is removed If the fluid is below the correct level add the recommended PTT fluid 9 Install a new O ring and the reservoir cap and then tighten the cap to the spec ified torque NOTE If the fluid is below the correct level in step 8 repeat st...

Page 233: ... 1 and then check the fluid level in the reservoir NOTE If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole when the cap is removed If the fluid is below the correct level add the recommended PTT fluid 6 Install a new O ring and the reservoir cap 1 and then tighten the cap to the speci fied torque NOTE If the fluid is below the correct level in step ...

Page 234: ...y lead to the black B lead 1 as shown and then check the PTT relay for continuity Replace the PTT relay if out of specification PTT relay continuity Black B 1 Green G 2 Black B 1 Blue L 3 Black B 1 Sky blue Sb 4 Black B 1 Light green Lg 5 Continuity Red R 6 Green G 2 Red R 6 Blue L 3 No continuity S67C7107 L G B R Lg Sb G Lg Sb L R B 4 2 3 6 1 2 3 6 1 5 5 4 PTT relay continuity Red R 6 Green G 2 C...

Page 235: ...changes Position b is the trim sensor lever position when the outboard motor is tilted down To adjust the trim sensor cam see Adjusting the trim sensor cam R model 7 32 The trim sensor resistance will be lower at position c than at position b Range d is the trim and tilt operation range Lead color Switch position Skyblue Sb Red R Light green Lg Free Up Down S67C7110 Lg Sb R Lg Sb R È S67C7141 Sb R...

Page 236: ...BRKT Bracket unit 7 55 67C3K11 MEMO ...

Page 237: ...se E and W model 8 13 Checking the engine start switch 8 13 Checking the neutral switch E and W model 8 14 Checking the starter relay E and W model 8 15 Ignition and ignition control system 8 15 Checking the ignition spark 8 15 Checking the spark plug cap 8 16 Checking the ignition coil 8 16 Checking the pulser coil 8 17 Checking the charge coil 8 17 Checking the engine shut off switch M model 8 1...

Page 238: ... 67C3K11 Electrical component and wiring harness routing Top view 1 Ignition coil 2 Spark plug 3 Pulser coil 4 Oil pressure switch 5 Starter motor E and W model 6 CDI unit 7 Stator assembly 8 Prime Start S67C8001 5 6 3 1 2 4 8 7 ...

Page 239: ...W model 4 10 pin main harness coupler E and W model 5 Battery cable E and W model 6 10 pin main harness E and W model 7 Warning indicator assembly lead H model with electric starter 8 Warning indicator assembly M model 9 Engine shut off switch lead M model S67C8005 6 3 1 2 4 7 5 9 8 Electrical component and wiring harness routing ...

Page 240: ...ch R model with PTT 9 Thermo sensor 0 PTT relay PTT model È Fasten the negative battery cable and fuse holder with the holder É Fasten the pulser coil lead Rectifier Regulator lead and thermo sensor connector with the plastic tie making sure to align the tie with the holder Ê Connect the PTT switch coupler R model with PTT Ë Install the ground lead terminals using the same nut S67C8006 3 4 5 2 1 0...

Page 241: ...he positioning tape on the wiring harness with the bottom of the starter motor Í Install the terminal so that it is facing upward within 15 of vertical S67C8006 3 4 5 2 1 0 8 9 7 6 Ê Ë Ì Í È É Electrical component and wiring harness routing ...

Page 242: ...del 4 PTT switch PTT model 5 Warning indicator assembly E and W model 6 Warning indicator assembly lead E and W model 7 10 pin main harness E and W model 8 Engine shut off switch lead M model È Position the tape on the wiring harness to the inside of the grommet making sure to align the edge of the tape with the end of the grommet S67C8008 B B A C È Ë Ì 3 8 5 É 6 7 2 2 1 B B Í Ê Î A C 4 4 ...

Page 243: ...39 in or more from the coupler and have a bend radius of 10 mm 0 39 in or more E and W model Ë Route the PTT switch lead above the warning buzzer as shown PTT model Ì Route the neutral switch lead below the warning buzzer as shown E and W model Í Fasten the PTT switch lead with the holder PTT model Î Be careful not to pinch the PTT switch lead between the steering handle and the bushing PTT model ...

Page 244: ... tester leads CAUTION When testing the voltage between the ter minals of an electrical component with the digital tester do not allow any of the leads to touch any metal parts If touched the electrical component can short and be damaged NOTE Before measuring the peak voltage check all wiring for corrosion and proper connec tion and check that the battery is fully charged Use peak voltage adapter B...

Page 245: ...Pinion 1 7 Bolt 2 M6 125 mm Width across flats 9 5 mm 3 8 in 8 Cover 1 9 Washer 1 10 Armature 1 11 Stator 1 12 Bracket assembly 1 13 Brush set 1 14 Bolt 2 M5 14 mm 15 Brush holder 1 16 Bracket 1 17 Washer 2 S67C8013 2 3 4 5 7 1 11 12 14 7 17 17 8 9 10 4 6 14 16 15 13 T R 8 N m 0 8 kgf m 5 9 ft Ib T R 30 N m 3 0 kgf m 22 1 ft Ib A A Checking the electrical component Starter motor E and W model ...

Page 246: ...ct the starter relay lead brown 7 to the positive battery terminal Connect the starter relay lead black 8 to the negative battery terminal to check the starter motor operation WARNING Do not place any objects near the pinion or touch it The pinion 9 moves slightly away from the starter motor body and rotates at high speed NOTE Check the starter motor operation for a few seconds If the starter moto...

Page 247: ...Check the pinion for smooth operation NOTE Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place Checking the starter motor 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty 2 Clean the grooves between the commu tator segments S67C8064 3 4 5 6 5 7 8 9 7 8 9 S67C8065 S67C8018 A E D C B B 0 S67C8063 S6...

Page 248: ...on Assembling the starter motor CAUTION Do not allow grease or oil to contact the commutator of the armature Starter motor commutator undercut wear limit a 0 8 mm 0 03 in Armature continuity Checking points Continuity Commutator segments b Yes Segment Armature core c No Segment Armature shaft d No S67C8021 a S67C8022 c d b Brush holder assembly continuity Checking points Continuity Brush 1 Brush 2...

Page 249: ... washer A to the armature B and then tighten the nut C to the specified torque 4 Install the stator D and bracket E and then tighten the bolts F NOTE Align the line marks a as shown Check the starter motor operation again after assembling it S67C8025 1 3 5 3 1 2 4 4 6 S67C8067 9 9 8 7 B C A 0 A A T R Pinion stopper nut C 30 N m 3 0 kgf m 22 1 ft lb S67C8068 8 7 B S67C8026 D E F S67C8027 a Starter ...

Page 250: ...routing 8 1 Checking the engine start switch 1 Disconnect the 10 pin 7 pin main har ness coupler 2 Measure the input voltage at the 10 pin 7 pin main harness coupler outboard motor end Check the fuse and wiring harness if below specification È 7 pin main harness model 3 Set the shift lever or remote control lever to the N position 4 Check the engine start switch for continu ity at the 10 pin 7 pin...

Page 251: ...ntrol box end 3 Set the shift lever or remote control lever to the F position or R position and then check the neutral switch for continuity Check the wiring harness or replace the neutral switch if out of specification È H model É R model Ê 7 pin main harness model 4 Turn the engine start switch to OFF 5 Connect the 10 pin 7 pin main harness coupler Lead color White W 1 Black B 2 Red R 3 Yellow Y...

Page 252: ...o the positive battery termi nal and connect the black B lead to the negative battery terminal Check for con tinuity between the starter relay termi nals Replace if there is no continuity 8 Disconnect the brown Br or black B lead of the starter relay from a battery terminal Check that there is no continuity between the starter relay terminals Replace if there is continuity 9 Install the starter re...

Page 253: ...spark plug cap resistance Replace if out of specification Checking the ignition coil 1 Disconnect the ignition coil coupler 2 Remove the spark plug caps from the spark plug wires by turning the caps counterclockwise 3 Measure the ignition coil resistance Replace if out of specification 4 Install the spark plug caps to the spark plug wires by turning the caps clockwise and then connect the ignition...

Page 254: ...upler When using the manual starter to crank the engine the voltage values may vary depending on the speed at which the starter handle is pulled 4 Disconnect the special service tool 2 5 Measure the pulser coil resistance Replace if out of specification 6 Connect the pulser coil coupler Checking the charge coil 1 Measure the charge coil 1 output peak voltage Replace the stator assembly if below sp...

Page 255: ...manual starter to crank the engine the voltage values may vary depending on the speed at which the starter handle is pulled 2 Disconnect the charge coil connectors 3 Measure the charge coil resistance Replace if out of specification 4 Connect the charge coil connectors Checking the engine shut off switch M model 1 Disconnect the engine shut off switch 1 connector and ground terminal Charge coil ou...

Page 256: ...or remote control box end Check the wiring har ness or replace the engine shut off switch if out of specification È H model É R model Ê 7 pin main harness model 3 Turn the engine start switch to OFF 4 Connect the 10 pin 7 pin main harness coupler Engine electric control system Checking the CDI unit 1 Disconnect the ignition coil 1 coupler 2 Connect the special service tool 2 to the ignition coil c...

Page 257: ...k the engine the voltage values may vary depending on the speed at which the starter handle is pulled Be sure to check the charge coil and pulser coil before measuring the CDI unit output peak voltage 4 Disconnect the special service tool 2 and connect the ignition coil coupler Test harness 2 pins 2 90890 06867 S67C8048 B O O B O O B W O B W B Y O B Y 15 16 13 14 G W G 2 3 1 1 2 3 CDI unit output ...

Page 258: ...o sensor in a container of water and slowly heat the water 7 Measure the thermo sensor resistance at the specified water temperatures Replace if out of specification 8 Install the thermo sensor and then con nect the thermo sensor coupler Checking the oil pressure switch 1 Disconnect the oil pressure switch 1 connector 2 Start the engine and then measure the input voltage between the oil pressure s...

Page 259: ...pressure switch if out of specifica tion 5 Remove the oil pressure switch 6 Connect the special service tool to the oil pressure switch Oil pressure switch input voltage reference data Pink P Ground 10 44 11 35 V at engine idle speed S67C8052 P P 10 1 Oil pressure switch continuity Oil pressure switch Ground Engine condition Continuity Stopped Yes Running No Vacuum pressure pump gauge set 90890 06...

Page 260: ... button M model Turn the engine start switch to OFF E and W model 4 Disconnect the oil pressure switch con nector and then ground the pink P lead wiring harness end 5 Start the engine and then check that the oil pressure warning indicator comes on after about 10 seconds 6 Push the engine stop button M model Turn the engine start switch to OFF E and W model 7 Connect the thermo sensor coupler and o...

Page 261: ...ndicator comes on Replace the warning indicator assembly if it does not come on È M model É E and W model CAUTION Only use a penlight battery 1 5 V when checking the LEDs Other batteries e g alkaline batteries or high voltage batter ies will damage the diodes Do not apply more than 1 7 V to the leads when checking the LEDs NOTE A feature of LEDs is that they only allow cur rent to flow in one dire...

Page 262: ...ut of specification 4 Connect the power bobbin connectors Charging system Checking the lighting coil 1 Disconnect the lighting coil connectors 2 Measure the lighting coil 1 output peak voltage Replace if below specification NOTE To prevent the engine from starting when cranking it be sure to disconnect all spark plug caps Do not remove the clip from the engine shut off switch When using the manual...

Page 263: ...o check the lighting coil before measuring the Rectifier Regulator output peak voltage 2 Disconnect the Rectifier Regulator con nectors and terminal Lighting coil output peak voltage 6 A model Yellow Y Yellow Y r min Unloaded Cranking 1 500 3 500 DC V 14 1 39 7 95 2 Lighting coil output peak voltage 15 A model Yellow Y Yellow Y r min Unloaded Cranking 1 500 3 500 DC V 8 4 28 5 66 6 Lighting coil r...

Page 264: ... Rectifier Regulator if out of specification NOTE Be sure to set the measurement range a and display the mark b by pushing the SHIFT switch when checking the Rectifier Regulator continuity OL Indicates an overload S67C8060 5R 3Y1 6B Gy 4Y2 Y24 Y13 Gy R5 B6 S6S18360 a b Rectifier Regulator continuity testing diode Tester lead Display value V reference data Conti nuity Y1 3 R 5 0 447 Yes Y1 3 B 6 1 ...

Page 265: ... 1 2 3 4 5 6 7 8 9 Troubleshooting Troubleshooting the outboard motor 9 1 Troubleshooting table format 9 1 Troubleshooting the power unit 9 1 Troubleshooting the PTT unit PTT model 9 8 Troubleshooting the lower unit 9 9 ...

Page 266: ...onditions of an area or individual part Cause 1 Content considered as the trouble causes of symptom 2 Cause 2 Content considered as the trouble causes of cause 1 Troubleshooting the power unit Symptom 1 Engine does not crank M and W model Symptom 2 Cause 1 Cause 2 Checking step Refer to page Starter rope does not operate Shift lever not in the N position Set the shift lever to the N position 3 9 S...

Page 267: ... control lever not in the N position Set the shift lever or remote control lever to the N position 3 9 Blown fuse Check the fuse 8 13 Engine start switch malfunction Check the engine start switch 8 13 Neutral switch mal function Check the neutral switch 8 14 Starter relay mal function Check the starter relay 8 15 Short or open con nection in starter motor circuit Check the wiring harness continuit...

Page 268: ...d flywheel magnet Woodruff key Check the flywheel magnet Woodruff key 5 22 Symptom 2 Cause 1 Cause 2 Checking step Refer to page Spark plug does not spark Spark plug malfunc tion Check the spark plug 3 6 Spark plug cap mal function Check the spark plug cap 8 16 Ignition coil mal function Check the ignition coil 8 16 Engine shut off switch malfunction Check the engine shut off switch 8 18 8 19 Char...

Page 269: ...lfunction of the carburetor internal parts Disassemble and check the carbure tor 4 12 Low compression pressure Valve clearance not adjusted correctly Adjust the valve clearance 5 2 Damaged cylinder head gasket Disassemble and check the cylinder head and power unit 5 29 5 42 Damaged valve Valve stuck to valve guide Scratched piston or cylinder Damaged or worn piston ring Symptom 2 Cause 1 Cause 2 C...

Page 270: ...17 Short or open con nection in ignition circuit Check the wiring harness continuity WD CDI unit malfunc tion Check the CDI unit 8 19 Incorrect fuel and air amount supplied Pinched or kinked fuel hose Check the fuel hoses and fuel hose joint 3 3 Clogged fuel filter Replace the fuel fil ter 3 3 Fuel pump malfunc tion Disassemble and check the fuel pump 4 4 Carburetor malfunc tion Carburetors not sy...

Page 271: ...ntake manifold carbure tor to cylinder head 4 12 Symptom 2 Cause 1 Cause 2 Checking step Refer to page Engine speed does not decrease when throttle control lever is in fully closed position Carburetor malfunc tion Carburetors not synchronized Synchronize the carburetors 4 17 Throttle stop screw not adjusted cor rectly Adjust the throttle stop screw 3 11 Pilot screw not adjusted correctly Adjust th...

Page 272: ...k the impeller 6 5 Check the Woo druff key 6 5 Water leakage from water pump hous ing Check the water pump housing 6 5 Check the insert cartridge 6 5 Check the outer plate cartridge 6 5 Thermostat mal function Check the thermo stat 3 7 Thermo sensor mal function Check the thermo sensor 8 21 Buzzer comes on E and W model Oil pressure warning indicator comes on Insufficient engine oil Add sufficient...

Page 273: ...n in PTT motor circuit Check the wiring harness continuity WD PTT motor malfunc tion Disassemble and check the PTT motor 7 35 PTT motor oper ates but the tilt ram does not extend Manual valve left open Manual valve mal function Check the manual valve 7 43 Insufficient PTT fluid Add sufficient fluid 3 13 PTT fluid leakage Check the PTT unit for leakage 7 47 Clogged filter Disassemble and check the ...

Page 274: ... PTT unit 7 42 Malfunction of the PTT unit internal parts Symptom 2 Cause 1 Cause 2 Checking step Refer to page Throttle open Turn the throttle grip or move the throttle lever to the fully closed position 3 9 Shift cable and shift cable joint malfunc tion Check and adjust the shift cable and shift cable joint 3 9 Remote control box malfunction R model Check the remote control box R model 3 9 Shift...

Page 275: ...ages Check the cooling water passages 3 7 Incorrectly con nected cooling water hose Damaged water pipe or incorrect installation Check the water pipe and its installa tion 7 19 Water pump mal function Damaged water pump impeller Check the impeller 6 5 Check the Woo druff key 6 5 Water leakage from water pump hous ing Check the water pump housing 6 5 Check the insert cartridge 6 5 Check the outer p...

Page 276: ...5 1 Checking the connecting rod big end side clearance 5 46 Checking the connecting rod small end inside diameter and big end inside diameter 5 45 Checking the cooling water passage 3 7 Checking the cooling water pilot hole 1 19 Checking the crankpin oil clearance 5 46 Checking the crankshaft 5 46 Checking the crankshaft journal oil clearance 5 48 Checking the cylinder bore 5 43 Checking the cylin...

Page 277: ...hecking the steering operation H model 3 12 Checking the steering system 1 17 Checking the thermo sensor 8 21 Checking the thermostat 3 7 Checking the tilt cylinder and piston 7 47 Checking the tilt operation 3 12 Checking the tilt system D model 1 17 Checking the timing belt 3 6 Checking the timing belt and sprocket 5 24 Checking the top cowling 3 3 Checking the trim sensor 7 54 Checking the valv...

Page 278: ... 7 Measuring the forward and reverse gear backlash 6 26 Measuring the peak voltage 8 7 Model 1 6 P Part lubricant and sealant 1 4 Port view 8 3 Power unit 2 7 2 14 3 4 5 13 Power unit check and adjustment 5 1 Power unit assembly 5 13 Precaution when transporting or storing the outboard motor 1 20 Predelivery check 1 14 Propeller selection 1 13 Propeller shaft housing 6 6 Propeller size 1 13 PTT cy...

Page 279: ...m 8 13 Symbol 1 2 Synchronizing the carburetor 4 17 T Test run 1 19 Throttle cam 5 18 Tightening torque 2 27 Tiller handle 8 5 Tiller handle H model 7 1 Timing belt and sprocket 5 22 Top cowling 3 3 Top view 8 1 Troubleshooting table format 9 1 Troubleshooting the lower unit 9 9 Troubleshooting the outboard motor 9 1 Troubleshooting the power unit 9 1 Troubleshooting the PTT unit PTT model 9 8 U U...

Page 280: ... Oil pressure switch 8 Warning indicator assembly 9 Engine shut off switch 0 Prime Start Color code B Black O Orange P Pink R Red W White Y Yellow B O Black orange B W Black white B Y Black yellow Br B Brown black G W Green white P B Pink black P W Pink white R W Red white W G White green Y B Yellow black Y R Yellow red ...

Page 281: ...ctric starter G Battery H Prime Start I Engine start switch H model J Engine shut off switch H model K Neutral switch H model L Buzzer H model M PTT switch H model with PTT È 10 pin main harness É 7 pin main harness Ê R model with PTT Ë PTT model Ì H model with electric starter Í H model with PTT Color code B Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W ...

Page 282: ......

Page 283: ...YAMAHA MOTOR CO LTD Printed in China Aug 2007 1 2 1 CR E ...

Page 284: ... C B 6 7 5 4 D 6 5 D 6 5 A 0 3 B B B B B W B O O B W O B Y O P P Br B W W W R G W W G Y B Y B B O B Y Y G W W G Y B Y B O B Y B W B O P Br B B Y B P B Y R P W Y B P B Y R P W Br B P Y B Y R Y Y W G G W B P B P W W O B O B Y B W Y Y B Y B Y Y Y B R W R W R W F30AMHD F40BMHD ...

Page 285: ... D 6 5 D C F 1 B Br B B B B B Y Y R Y Y R Sb Lg R R Gy B O O B W O B Y O G B B B B Br B R R P P Br B W R G W W G Y B Y B B O B Y Y G W W G Y B Y B O B Y B W B O B P Br B B R Sb Lg W Br R P B G P W P B G R G P Gy B Y B P B Y R P W Br B P Y B Y R Y Y W G G W B P P B P W W O B O B Y B W Y Y B Y B Y Y Y Lg Sb G B Br Br P R Sb Lg R Sb Lg Y Y Y B W B R Y Br P Sb Lg W B R Y Br P G Sb Lg W B L L G R G L G...

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