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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.

F80B, F100D

SERVICE MANUAL

©2004 by Yamaha Motor Co., Ltd.

1st Edition, October 2004

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

Printed in the Netherlands

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Summary of Contents for F80B

Page 1: ...F80B F100D SERVICE MANUAL 6D9 28197 3G 11 ...

Page 2: ...cations 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 injur...

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

Page 4: ......

Page 5: ...ection 1 5 Propeller size 1 5 Selection 1 6 Predelivery checks 1 6 Checking the fuel system 1 6 Checking the engine oil level 1 6 Checking the gear oil level 1 7 Checking the battery 1 7 Checking the outboard motor mounting height 1 7 Checking the remote control cables 1 7 Checking the steering system 1 8 Checking the gear shift and throttle operation 1 8 Checking the power trim and tilt system 1 ...

Page 6: ...Not reusable 6 Dowel pin 2 7 Bolt 4 M10 40 mm 8 Drain screw 1 9 Grommet 1 10 Bolt 1 M10 45 mm 11 Bolt 1 M8 60 mm 12 Thrust washer 1 13 Propeller 1 14 Washer 1 15 Washer 1 16 Cotter pin 1 Not reusable 17 Propeller nut 1 18 Trim tab 1 LOWR Lower unit 6 19 62Y5A11 Removing the drive shaft 1 Remove the drive shaft assembly and pinion and then pull out the forward gear Disassembling the drive shaft 1 I...

Page 7: ...ltage electric current Symbols 7 to C in an exploded diagram indicate the grade of lubricant and the lubrication point 7 Apply Yamaha 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 H ...

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

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

Page 10: ...ion engine life fuel economy and even boating and steering capabilities An incorrect choice could adversely affect performance and could also seriously damage the engine Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor Propeller size The size of the propeller is indicated on the propeller boss end on the side ...

Page 11: ...s full with fuel CAUTION This is a 4 stroke engine Never use pre mixed fuel Checking the engine oil level 1 Check the engine oil level NOTE If the engine oil is below the minimum level mark b add sufficient oil until the level is between a and b Propeller size in Material 12 5 8 21 K Aluminum 13 19 K 13 23 K 13 25 K 13 1 4 17 K 13 1 2 15 K 13 5 8 13 K 14 11 K 13 17 K Stainless 13 19 K 13 21 K 13 2...

Page 12: ...low water resistance will increase and reduce engine efficiency NOTE The optimum mounting height is affected by the combination of the boat and the outboard motor To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that the clamp brackets are secured with the clamp bolts Checking the remote control cables 1 Set the remote control lever to the neu tral...

Page 13: ... shifted from forward or reverse to the fully open position a Checking the power trim and tilt system 1 Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit 2 Check that there is no abnormal noise produced when the outboard motor is tilted up or down 3 Check that there is no interference with wires or hoses when the tilted up out board motor is steer...

Page 14: ...3 4 throttle 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 During the test run perform the break in operation in the following three stages 1 One hour a at 2 000 r min or at approxi mately half throttle 2 One hour b at 3 000 r min or 3 4 throttle and 1 minute ...

Page 15: ... 2 3 4 5 6 7 8 9 Specifications General specifications 2 1 Maintenance specification 2 3 Power unit 2 3 Lower unit 2 6 Electrical 2 6 Dimensions 2 9 Tightening torques 2 11 Specified torques 2 11 General torques 2 13 ...

Page 16: ...100 at 5 500 r min Full throttle operating range r min 5 000 6 000 Maximum fuel consumption L US gal Imp gal hr 28 0 7 40 6 16 at 6 000 r min 35 0 9 2 7 7 at 6 000 r min Engine idle speed r min 650 750 Power unit Type In line 4 stroke DOHC 16 valves Cylinder quantity 4 Total displacement cm3 cu in 1 596 97 39 Bore stroke mm in 79 0 81 4 3 11 3 20 Compression ratio 9 6 Control system Remote control...

Page 17: ...t oil filter replacement L US qt Imp qt 4 3 4 55 3 78 with oil filter replacement L US qt Imp qt 4 5 4 76 3 96 Gear oil type Hypoid gear oil Gear oil grade 2 API GL 4 SAE 90 Gear oil quantity cm3 US oz Imp oz 670 22 7 23 6 Bracket unit Trim angle at 12 boat transom Degree 4 to 16 Tilt up angle Degree 70 Steering angle Degree 35 35 Drive unit Gear shift positions F N R Gear ratio 2 31 30 13 Reducti...

Page 18: ... in 78 928 78 949 3 1074 3 1082 Measuring point H mm in 13 0 0 51 Piston clearance mm in 0 070 0 080 0 0028 0 0031 Over size piston diameter mm in 79 178 79 199 3 1172 3 1181 Piston rings Top ring Dimension B mm in 1 17 1 19 0 0461 0 0469 Dimension T mm in 2 80 3 00 0 1102 0 1181 End gap mm in 0 15 0 30 0 0059 0 0118 Side clearance mm in 0 04 0 08 0 0016 0 0031 2nd piston ring Dimension B mm in 1 ...

Page 19: ... 29 0 29 2 1 14 1 15 Exhaust mm in 24 0 24 2 0 94 0 95 Face width B Intake mm in 1 99 2 44 0 0783 0 0961 Exhaust mm in 2 27 2 72 0 0894 0 1071 Seat contact width C Intake mm in 1 20 1 60 0 0472 0 0630 Exhaust mm in 1 20 1 60 0 0472 0 0630 Margin thickness D Intake mm in 0 80 1 20 0 0315 0 0472 Exhaust mm in 1 00 1 40 0 0394 0 0551 Stem diameter Intake mm in 5 975 5 990 0 2352 0 2358 Exhaust mm in ...

Page 20: ...598 0 0601 Crankshaft Crankshaft journal diameter mm in 47 985 48 000 1 8892 1 8898 Crankpin diameter mm in 43 982 44 000 1 7316 1 7323 Crankpin width mm in 21 00 21 07 0 8268 0 8295 Runout limit mm in 0 03 0 0012 Crankcase Crankshaft journal oil clearance mm in 0 024 0 044 0 0009 0 0017 Upper crankcase main bearing thickness Green mm in 2 992 2 999 0 1178 0 1181 Blue mm in 2 999 3 006 0 1181 0 11...

Page 21: ...rature C F 70 158 Valve open lower limit mm in 4 3 0 17 Item Unit Model F80BET F100DET Gear backlash Pinion to forward gear mm in 0 28 0 63 0 0110 0 0248 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 Item Unit Model F80BET F100DET Ignition and ignition control system Spark plug gap mm in 1 0 1 1 0 039 0 043 Ignition coil resistance at 2...

Page 22: ...ne idle speed Cooling water temperature sensor resistance at 0 C 32 F kΩ 5 21 6 37 at 80 C 176 F kΩ 0 290 0 354 Oil pressure switch Operating pressure kPa kgf cm2 psi 127 5 166 7 1 28 1 67 18 49 24 17 Fuel control system Fuel injector resistance at 21 C 70 F Ω 12 0 Starter motor Type Sliding gear Output kW 1 40 Cranking time limit Second 30 Brushes Standard length mm in 15 5 0 61 Wear limit mm in ...

Page 23: ...round at 1 500 r min unloaded V 13 0 at 3 500 r min unloaded V 13 0 Power trim and tilt system Trim sensor Setting resistance P B Ω 10 1 Resistance P B Ω 9 378 8 Fluid type ATF Dexron II Brushes Standard length mm in 10 0 0 39 Wear limit mm in 3 5 0 14 Commutator Standard diameter mm in 22 0 0 87 Wear limit mm in 21 0 0 83 Mica Standard undercut mm in 1 5 0 06 Wear limit mm in 1 0 0 04 The figure ...

Page 24: ...7 366 14 4 49 1 9 27 1 1 L 766 30 2 X 842 33 1 857 33 7 666 26 2 L 917 36 1 X 1 044 41 1 L 536 21 1 X 663 26 1 L 25 1 0 X 24 0 9 191 7 5 171 6 73 62 2 4 6 6 574 22 6 28 1 1 164 6 5 651 25 6 240 9 4 405 15 9 3 5 L 998 39 3 X 1 115 43 9 63 2 5 12 4 S6D82010 mm in ...

Page 25: ...G11 2 10 1 2 3 4 5 6 7 8 9 Clamp bracket 348 5 13 7 180 7 1 163 5 6 4 163 5 6 4 180 7 1 18 5 0 7 254 10 0 13 0 5 80 3 1 50 8 2 0 55 5 2 2 13 0 5 125 4 4 9 125 4 4 9 mm in S6D82020 Maintenance specification ...

Page 26: ... M4 2 0 2 1 5 Pressure check valve 10 1 0 7 4 Power unit Power unit mounting bolt 1st M10 42 4 2 31 0 2nd 42 4 2 31 0 Apron screw M6 4 0 4 3 0 Flywheel magnet nut M24 215 21 5 158 6 Starter motor bolt M8 29 2 9 21 4 Spark plug wire cover screw M6 4 0 4 3 0 Starter relay lead bolt M6 4 0 4 3 0 Starter relay holder screw M6 3 0 3 2 2 Main and fuel pump relay screw M6 3 0 3 2 2 Oil pressure switch 8 ...

Page 27: ...el M10 39 3 9 28 8 Lower case mounting nut X transom model 39 3 9 28 8 Propeller nut M16 34 3 4 25 1 Ring nut 103 10 3 76 0 Cooling water inlet cover screw 5 0 5 3 7 Pinion nut M16 93 9 3 68 6 Bracket unit Shift rod detent bolt 18 1 8 13 3 Shift position switch screw M4 1 0 1 0 7 Flushing hose adapter screw M6 2 0 2 1 5 Oil pump bolt M6 10 1 0 7 4 Upper mounting nut 51 5 1 37 6 Lower mounting nut ...

Page 28: ...d bolt M6 11 1 1 8 1 Steering arm stud bolt M10 20 2 0 14 8 Self locking nut 15 1 5 11 1 Trim sensor cam screw M6 2 0 2 1 5 Power trim and tilt unit Reservoir cap 7 0 7 5 2 PTT motor bolt M6 4 0 4 3 0 Gear pump bolt M5 5 0 5 3 7 Gear pump housing bolt M5 5 0 5 3 7 Relief valve cap bolt M4 4 0 4 3 0 M5 5 0 5 3 7 Lever bolt M3 2 0 2 1 5 Manual valve 2 0 2 1 5 Gear pump bracket bolt M3 2 0 2 1 5 M5 4...

Page 29: ...ter 3 5 Checking the timing belt 3 6 Checking the spark plugs 3 6 Checking the thermostat 3 7 Checking the cooling water passage 3 8 Control system 3 8 Checking the engine idle speed 3 8 Adjusting the throttle link and throttle cable 3 8 Checking the gear shift operation 3 10 Bracket unit 3 11 Checking the power trim and tilt operation 3 11 Checking the power trim and tilt fluid level 3 11 Lower u...

Page 30: ...CHK ADJ Periodic checks and adjustments 3 1 6D93G11 Special service tools 3 Digital tachometer 90890 06760 Leakage tester 90890 06840 Oil filter wrench 64 90890 01426 ...

Page 31: ... 3 14 Battery Check charge 3 14 Cooling water passages Clean 3 8 Top cowling Check 3 3 Fuel filter can be disassembled Check replace 3 3 Fuel system Check 3 3 Gear oil Change 3 12 Lubrication points Lubricate 3 15 Engine idle speed EFI models Check adjust 3 8 PCV Pressure Control Valve Check 5 39 Power trim and tilt unit Check 3 11 Propeller and cotter pin Check replace 3 13 Shift link shift cable...

Page 32: ... low pressure fuel hose con nections and fuel joint for leaks Replace if necessary Also check the fuel filter 1 fuel pump 2 strainer 3 and fuel cooler 4 for leaks or deterioration Replace if necessary 3 Check the high pressure fuel hose con nections for leaks Replace if necessary Also check the vapor separator 5 fuel rail 6 fuel injectors 7 and pressure regulator 8 for leaks or deterioration Repla...

Page 33: ...Remove the oil dipstick and oil filler cap 1 3 Insert the tube of the oil changer 2 into the dipstick hole 3 4 Operate the oil changer to extract the oil NOTE Be sure to clean up any oil spills 5 Pour the specified amount of the recom mended engine oil into the oil filler hole 6 Install the oil filler cap and oil dipstick and then start the engine and warm it up for 5 minutes 7 Turn the engine off...

Page 34: ...orrect it if necessary Replacing the oil filter 1 Extract the engine oil with an oil changer or drain it 2 Place a rag under the oil filter and then remove the oil filter using the oil filter wrench 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 t...

Page 35: ...b of the timing belt for cracks damage or wear Replace if necessary NOTE For replacement procedures see Chapter 5 Replacing the timing belt Checking the spark plugs 1 Remove the spark plug wire cover 2 Disconnect the spark plug wires and then remove the spark plugs 3 Clean the electrodes 1 with a spark plug cleaner or wire brush Replace the spark plug if necessary 4 Check the electrodes for erosio...

Page 36: ...er 2 Disconnect the cooling water hose 1 and then remove the thermostat cover 2 and thermostat 3 3 Suspend the thermostat in a container of water 4 Place a thermometer in the water and slowly heat the water 5 Check the thermostat valve opening at the specified water temperatures Replace if out of specification Specified spark plug LFR5A 11 NGK Spark plug gap a 1 0 1 1 mm 0 039 0 043 in T R Spark p...

Page 37: ...assage inside the out board motor Control system 3 Checking the engine idle speed 1 Start the engine and warm it up for 5 min utes 2 Attach the special service tool to spark plug wire 1 1 and then check the engine idle speed Adjusting the throttle link and throttle cable 1 Remove the intake silencer 2 Set the remote control lever to the neu tral position and fully close the throttle lever Water te...

Page 38: ...eck that the throttle cam roller 9 contacts the side a of the throttle cam 8 Adjust the throttle link rod joint to align its hole with the ball joint 0 on the throttle body 9 Connect the throttle link rod joint and then tighten the locknut 10 Operate the throttle cam to check that the throttle valve fully closes and fully opens and check that the gap b between the stopper A on the throttle lever a...

Page 39: ...able length if necessary 2 Set the gear shift to the neutral position 3 Loosen the locknut 1 remove the clip 2 and then disconnect the shift cable joint 3 4 Remove the clip 4 5 Align the alignment mark a on the bush ing and alignment mark b on the bracket 6 Install the clip 4 7 Adjust the position of the shift cable joint until its hole is aligned with the set pin WARNING The shift cable joint mus...

Page 40: ...outboard motor up and then support it with the tilt stop lever 1 WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 2 Remove the reservoir cap 2 and then check the fluid level in the reservoir NOTE If the fluid is at the correct level the fluid shoul...

Page 41: ...nded type until it overflows out of the check hole 4 Install the check screw and then tighten it to the specified torque Changing the gear oil 1 Tilt the outboard motor up slightly 2 Place a drain pan under the drain screw 1 remove the drain screw then the check screw 2 and let the oil drain com pletely 3 Check the oil for metal and discoloration and its viscosity Check the internal parts of the l...

Page 42: ...s maintained in the lower unit for at least 10 seconds CAUTION Do not over pressurize the lower unit oth erwise the oil seals can be damaged NOTE Cover the check hole with a rag when remov ing the tester from the lower unit 3 If pressure drops below specification check the drive shaft and propeller shaft oil seals for damage Checking the propeller 1 Check the propeller blades and splines for crack...

Page 43: ... If it is necessary to disassemble the outboard motor to check an anode refer to the applica ble disassembly procedure in this manual 2 Replace the anodes or trim tab if exces sively eroded Checking the battery 1 Check the battery electrolyte level If the level is at or below the minimum level mark a add distilled water until the level is between the maximum and minimum level marks S6D83170 S6D832...

Page 44: ...owed 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 flames e g welding equipment lighted cigarettes DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH ...

Page 45: ...7 8 9 NOTE Apply grease to the grease nipple until it flows from the bushings a 2 Apply low temperature resistant grease to the area shown 3 Apply corrosion resistant grease to the area shown S60C3710 A A a a S6D83190 C General ...

Page 46: ...CHK ADJ Periodic checks and adjustments 3 17 6D93G11 MEMO ...

Page 47: ...sensor 4 9 Installing the throttle position sensor 4 9 Checking the idle speed control 4 9 Vapor separator 4 10 Reducing the fuel pressure 4 13 Disconnecting the quick connector 4 13 Measuring the fuel pressure 4 13 Checking the pressure regulator 4 14 Draining the fuel 4 15 Removing the fuel hose clamp 4 16 Installing the fuel hose clamp 4 16 Disassembling the vapor separator 4 16 Checking the va...

Page 48: ...FUEL Fuel system 4 1 6D93G11 Special service tools 4 Vacuum pressure pump gauge set 90890 06756 Fuel pressure gauge 90890 06786 Fuel pressure gauge adapter B 90890 06942 ...

Page 49: ...ner 5 Fuel hose strainer to vapor separator 6 High pressure fuel hose vapor separator to fuel rail 7 Fuel hose pressure regulator to fuel cooler 8 Fuel hose fuel cooler to vapor separator 9 Canister hose vapor separator to canister 0 Canister hose canister to idle speed control A Canister hose canister to filter B Canister hose filter to bottom cowling Special service tools Hose routing ...

Page 50: ...g 1 Not reusable 4 Fuel filter element 1 5 O ring 1 Not reusable 6 Float 1 7 Cup 1 8 Fuel hose 1 9 Fuel pump 1 10 Bolt 2 M6 30 mm 11 Fuel hose 1 12 Strainer 1 13 Bolt 1 M6 12 mm 14 Bracket 1 15 O ring 1 Not reusable S6D84020 9 10 10 13 12 11 8 3 4 5 6 7 2 1 14 T R 3 N m 0 3 kgf m 2 2 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib 15 ...

Page 51: ... 1 Screw 3 ø6 35 mm 2 Cover 1 3 Gasket 1 Not reusable 4 Fuel pump body 2 assembly 1 5 Diaphragm 1 6 Pin 1 7 Spring 1 8 Fuel pump body 1 1 9 Spring 1 10 Plunger 1 11 Nut 3 S6D84030 4 7 8 9 10 1 2 3 5 6 T R 4 N m 0 4 kgf m 3 0 ft Ib 11 Fuel filter and fuel pump ...

Page 52: ...t 6 Apply the specified positive pressure and check that there is no air leakage Disas semble the fuel pump if necessary NOTE Assemble the fuel pump valve to the fuel pump body and moisten the inside of the fuel pump with gasoline to ensure a good seal Disassembling the fuel pump 1 Disassemble the fuel pump 2 Push down on the plunger and the dia phragm turn fuel pump body 1 1 approximately 90 to a...

Page 53: ...ore assembly to obtain prompt operation of the fuel pump when starting the engine 1 Align the plunger and diaphragm installa tion holes a and then install the plunger into the diaphragm 2 Push down on the plunger and the dia phragm and then install the pin 1 3 Turn fuel pump body 1 2 approximately 90 and then push down on the plunger several times to make sure that the pin does not come out NOTE M...

Page 54: ...ET 2 Bolt 2 M6 80 mm 3 Bushing 4 4 Collar 2 5 Intake manifold assembly 1 6 Bolt 4 M8 30 mm 7 Collar 5 8 Bolt 1 M8 100 mm 9 Spacer 1 10 Bolt 3 M6 45 mm 11 Collar 3 12 Holder 1 13 Gasket 1 Not reusable 14 Pin 2 15 Joint 1 16 Intake silencer 1 F100DET S6D94010 2 1 16 3 3 15 4 14 13 12 7 11 5 10 8 9 6 ...

Page 55: ...sable 7 Throttle body assembly 1 8 Bolt 3 M6 16 mm 9 Gasket 1 Not reusable 10 Throttle position sensor 1 11 Screw 2 12 O ring 1 Not reusable 13 Fuel injector 4 14 O ring set 4 Not reusable 15 Fuel rail 1 16 Bolt 2 M6 38 mm S6D84050 3 2 4 5 3 6 11 10 12 7 8 9 1 13 14 15 16 16 T R 3 7 N m 0 37 kgf m 2 7 ft lb 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 Intake manifold ...

Page 56: ...tput voltage is within specification NOTE If the throttle position sensor output voltage is out of specification reinstall the throttle position sensor Measure the throttle position sensor output voltage using the Yamaha Diagnostic Sys tem Do not turn the throttle stop screw a Checking the idle speed control 1 Check the operation of the idle speed control using the Yamaha Diagnostic System Throttl...

Page 57: ... mm 3 Grommet 3 4 Collar 3 5 Fuel hose 1 6 Fuel inlet hose 1 7 Hose 1 8 Joint 1 9 Hose 1 10 Hose 1 11 Hose 1 12 Hose 1 13 Clamp 1 14 Clamp 1 15 Quick connector 1 16 Clamp 1 Not reusable 17 Plastic tie 5 Not reusable S6D84070 17 10 17 17 17 16 15 6 7 3 4 11 1 2 14 17 12 13 5 8 9 Intake manifold Vapor separator ...

Page 58: ...usable 7 Joint screw 1 8 O ring 1 Not reusable 9 Fuel hose 1 10 Fuel cooler 1 11 Screw 2 ø6 15 mm 12 Fuel hose 1 13 Hose 1 14 Hose 1 15 Hose 1 16 Plastic tie 8 Not reusable S6D84080 1 16 16 16 16 16 14 15 16 16 9 8 6 3 4 5 7 10 11 13 12 16 2 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 T R 1 5 N m 0 15 kgf m 1 1 ft lb T R 4 N m 0 4 kgf m 3 0 ft Ib ...

Page 59: ...ectric fuel pump 1 8 Grommet 1 9 Collar 1 10 Filter 1 11 Screw 3 ø4 6 mm 12 Wiring harness 1 13 Float 1 14 Needle valve 1 15 Pin 1 Not reusable 16 Cap 1 S6D84090 3 1 7 9 8 2 4 6 15 11 11 11 10 13 14 12 5 16 T R 2 N m 0 2 kgf m 1 5 ft Ib T R 2 N m 0 2 kgf m 1 5 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib T R 5 N m 0 5 kgf m 3 7 ft Ib LT 271 Vapor separator ...

Page 60: ...se the fuel pressure be sure to remove the quick connector slowly CAUTION Do not rotate the quick connector tab 1 past the stopper position a otherwise it could be damaged When the fuel hose is disconnected quickly remove the retainer 2 from the quick connector otherwise the retainer could be lost 2 Disconnect the quick connector 3 from the fuel rail 4 directly WARNING Always reduce the fuel press...

Page 61: ...drain screw while measuring the fuel pressure Loosening the drain screw can cause fuel to spray out creating a fire hazard After measuring the fuel pressure cover the end of the hose with a clean dry rag point the hose downward and then loosen the drain screw to drain the remaining fuel from the hose and gauge When storing the fuel pressure gauge make sure that the drain screw is tight ened secure...

Page 62: ...d of the hose with a clean dry rag point the hose downward and then loosen the drain screw to drain the remaining fuel from the hose and gauge When storing the fuel pressure gauge make sure that the drain screw is tight ened securely NOTE When the vacuum pressure reaches the specified level the fuel pressure reduces Draining the fuel 1 Remove the cap 1 2 Cover the pressure check valve a of the vap...

Page 63: ...he crimp first the fuel hose will be damaged Installing the fuel hose clamp 1 Crimp the fuel hose clamp properly to securely fasten it WARNING Do not reuse the fuel hose clamp always replace it with a new one Disassembling the vapor separator 1 Remove the float chamber float pin and float NOTE Remove the float pin in the direction of the arrow a shown 2 Remove the needle valve and other com ponent...

Page 64: ...s shown Adjust the float height if out of specifica tion 3 Check the float height d as shown Adjust the float height if out of specifica tion NOTE The float should be resting on the needle valve but not compressing it Take measurements at the position shown opposite the float pivot 4 Install the float chamber Adjusting the float 1 Adjust the stopper a of the float by bending it until the float hei...

Page 65: ...6D93G11 4 18 1 2 3 4 5 6 7 8 9 NOTE When adjusting the float height do not bend the lever e Float height d 35 0 1 0 mm 1 38 0 04 in Vapor separator ...

Page 66: ... Bolt 1 M6 16 mm 2 Bracket 1 3 Canister 1 4 Bolt 2 M6 28 mm 5 Grommet 2 6 Bracket 1 7 Collar 2 8 Hose 1 9 Hose 1 10 Hose 1 11 Filter 1 12 Hose 1 13 Clamp 1 14 Bolt 1 M6 10 mm 15 Holder 1 16 Bolt 1 M6 16 mm 17 Bracket 1 S6D84150 8 9 7 6 5 4 2 3 11 13 12 10 1 14 15 16 17 ...

Page 67: ...ial service tool to the atmospheric port 1 and cover the other ports each with a finger 3 Apply the specified positive pressure and check that there is no air leakage Replace the canister if there is air leak age Vacuum pressure pump gauge set 90890 06756 Specified pressure 19 6 kPa 0 196 kgf cm2 2 8 psi S6D84160 1 Canister ...

Page 68: ...0 ECM 5 21 Junction box 5 22 Cylinder head 5 24 Removing the cylinder head 5 26 Checking the valve lifters 5 27 Checking the valve springs 5 27 Checking the valves 5 27 Checking the valve guides 5 28 Replacing the valve guides 5 28 Checking the valve seat 5 29 Refacing the valve seat 5 30 Checking the camshafts 5 32 Checking the cylinder head 5 32 Installing the valves 5 33 Installing the cylinder...

Page 69: ...rings 5 42 Checking the piston ring grooves 5 43 Checking the piston ring side clearance 5 43 Checking the connecting rod big end side clearance 5 43 Checking the crankshaft 5 44 Checking the crankpin oil clearance 5 44 Selecting the connecting rod bearing 5 46 Checking the crankshaft journal oil clearance 5 47 Selecting the main bearing 5 48 Assembling the power unit 5 50 Installing the power uni...

Page 70: ...on M14 90890 06563 Flywheel holder 90890 06522 Flywheel puller 90890 06521 Crankshaft holder 20 90890 06552 Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 06320 Valve guide remover installer 5 9 90890 04064 Valve guide reamer 6 0 90890 04066 Valve seat cutter holder 90890 06553 ...

Page 71: ...6D93G11 5 2 1 2 3 4 5 6 7 8 9 Valve seat cutter 90890 06312 90890 06315 90890 06324 90890 06326 90890 06328 90890 06555 Piston slider 90890 06530 Oil filter wrench 64 90890 01426 Special service tools ...

Page 72: ...ne oil to the cylin der and then check the pressure again NOTE If the compression pressure increases check the pistons and piston rings for wear Replace if necessary If the compression pressure does not increase check the valve clearance valve valve seat cylinder head gasket and cylin der head Adjust or replace if necessary Checking the oil pressure 1 Remove the flywheel magnet cover 2 Place a rag...

Page 73: ...1 6 Oil dipstick 1 7 Gasket 1 Not reusable 8 Dowel 2 9 Bolt 5 M6 16 mm 10 Bolt 6 M10 130 mm 11 Screw 2 ø6 40 mm 12 Nut 2 13 Apron 1 14 Bolt 2 M8 35 mm 15 Holder 1 S6D85010 1 7 8 9 10 11 12 13 14 2 3 4 5 6 15 T R 4 N m 0 4 kgf m 3 0 ft Ib T R 1 42 N m 4 2 kgf m 31 0 ft Ib 2 42 N m 4 2 kgf m 31 0 ft Ib LT 572 LT LT 572 LT E Power unit ...

Page 74: ...lywheel magnet 1 4 Screw 1 ø4 10 mm 5 Screw 3 ø6 30 mm 6 Stator coil 1 7 Bolt 4 M6 30 mm 8 Stator assembly 1 9 Collar 2 10 Bolt 1 M6 15 mm 11 Woodruff key 1 12 Bolt 1 M6 15 mm 13 Holder 1 14 Grommet 1 S6D85020 2 3 1 E T R 215 N m 21 5 kgf m 158 6 ft lb 4 5 6 7 8 9 10 11 12 13 14 ...

Page 75: ...Bracket 1 7 Bolt 1 M10 45 mm 8 Timing belt tensioner 1 9 Spring 1 10 Plastic tie 1 Not reusable 11 Hose 1 12 Clamp 1 13 Nut 1 14 Drive sprocket 1 15 Plate 1 16 Woodruff key 1 S6D85030 67F 46241 00 11 12 10 14 15 R 265 N m 26 5 kgf m 195 5 ft lb 8 16 7 6 1 2 5 3 4 E E R 60 N m 6 0 kgf m 44 3 ft Ib 13 R 39 N m 3 9 kgf m 28 8 ft Ib E 9 Power unit ...

Page 76: ... Ignition coil 2 12 Bracket 2 13 Bolt 4 M6 25 mm 14 Holder 2 15 Starter motor 1 16 Bolt 3 M8 45 mm 17 Terminal 1 S6D85040 T R 29 N m 2 9 kgf m 21 4 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 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 T R 4 N m 0 4 kgf m 3 0 ft Ib 11 1 2 3 5 5 3 4 4 27 28 8 9 29 6 7 10 25 26 24 15 23 17 18 19 16 14 13 13 12 13 22 21 20 LT 572...

Page 77: ... 26 Cap 1 27 Oil pressure switch 1 28 Bolt 1 M4 8 mm 29 Holder 1 30 Bolt 1 M6 25 mm 31 Clamp 1 S6D85040 T R 29 N m 2 9 kgf m 21 4 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 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 T R 4 N m 0 4 kgf m 3 0 ft Ib 11 1 2 3 5 5 3 4 4 27 28 8 9 29 6 7 10 25 26 24 15 23 17 18 19 16 14 13 13 12 13 22 21 20 LT 572 LT 31 30 Power un...

Page 78: ... 2 10 Camshaft cap 8 11 Bolt 4 M7 48 mm 12 Bolt 16 M7 37 mm 13 Oil seal 2 Not reusable 14 Camshaft 2 S6D85070 S1280B S1280B 4 3 8 7 1 2 5 6 11 10 12 14 9 9 13 13 10 10 10 LT 271 E E E E E E E E M T R 2 N m 0 2 kgf m 1 5 ft Ib T R 1 8 N m 0 8 kgf m 5 9 ft lb 2 17 N m 1 7 kgf m 12 5 ft lb T R 1 8 N m 0 8 kgf m 5 9 ft lb 2 17 N m 1 7 kgf m 12 5 ft lb T R 1 8 N m 0 8 kgf m 5 9 ft lb 2 8 N m 0 8 kgf m ...

Page 79: ...f the timing belt driven sprockets and cam shafts see the applicable procedures in this manual 1 Remove the flywheel magnet cover 1 filter 2 and spark plug wire cover 3 disconnect the spark plug wires 4 fuel hoses 5 and blowby hose 6 and then remove all spark plugs 2 Turn the flywheel magnet clockwise and align the TDC mark a on the flywheel magnet with the pointer b and check that marks c and d o...

Page 80: ...exhaust valve clearance for cylinders 2 and 4 Adjust if out of specification 8 Turn the flywheel magnet clockwise and align the TDC mark on the flywheel magnet with the pointer and check that the marks on the driven sprockets are aligned 9 Loosen the tensioner bolt 7 and then remove the spring 8 timing belt 9 driven sprockets 0 camshaft caps A and camshafts B NOTE Do not mix the valve train parts ...

Page 81: ...s driven sprockets and timing belt and then tighten the tensioner bolt 16 Check the valve clearance Adjust if nec essary 17 Loosen the tensioner bolt and then remove the timing belt and driven sprock ets 18 Install the cylinder head cover and driven sprockets 19 Check that the TDC mark a on the fly wheel magnet is aligned with the pointer b and that marks c and d on the driven sprockets are aligne...

Page 82: ...nt the flywheel holder from slipping off easily 3 Remove the flywheel magnet CAUTION To prevent damage to the engine or tools screw in the puller set bolts evenly and completely so that the puller plate is par allel to the flywheel magnet NOTE Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft 4 Remove the Woodruff key 1 and stator assembly...

Page 83: ...t tensioner 6 and then remove the timing belt 7 from the driven sprockets then from the drive sprocket 8 Check that the hole a on the retaining plate and the projection b on the cylin der block are aligned 9 Check that marks c and d on the driven sprockets are aligned S6D85220 c d a b S6D85230 4 3 6 7 5 S6D85240 c d a b Power unit ...

Page 84: ...the bottom of the driven sprockets 11 Install the timing belt tensioner 9 and finger tighten the bolt 0 until the bolt seat contacts the timing belt tensioner 12 Loosen the timing belt tensioner bolt 90 13 Install the spring A 14 Take up the timing belt slack by turning the drive sprocket clockwise at least two full turns 15 Tighten the timing belt tensioner bolt to the specified torque 16 Turn th...

Page 85: ...he power unit to improve working efficiency 1 Remove the flywheel magnet cover 2 Disconnect the battery leads 3 Remove the junction box cover and then disconnect the PTT motor leads and PTT switch coupler 4 Disconnect the throttle cable and shift cable 5 Disconnect the fuel hose and shift posi tion switch coupler 6 Disconnect the cooling water pilot hose canister hose and flushing hose 7 Remove th...

Page 86: ...he driven sprockets are aligned 2 Loosen the drive sprocket nut 1 NOTE Use a deep socket 2 for this procedure Do not turn the camshaft when loosening the drive sprocket nut 3 Disconnect the cooling water hose and remove the bracket 4 Remove the spring and timing belt ten sioner and then remove the timing belt from the driven sprockets then from the drive sprocket 5 Loosen the driven sprocket bolts...

Page 87: ...the sprockets and timing belt 1 Install the dowels and driven sprockets 1 and check that marks a and b on the driven sprockets are aligned 2 Tighten the driven sprocket bolts 2 to the specified torque NOTE Apply engine oil to the driven sprocket bolts before installation Do not turn the camshafts when tightening the driven sprocket bolts 1 6 7 8 S6D85380 S6D85660 1 a b Flywheel holder 90890 06522 ...

Page 88: ...at the hole c on the retaining plate is aligned with the projection d on the cylinder block 5 Install the timing belt and timing belt ten sioner NOTE For timing belt installation procedure see Replacing the timing belt 6 Tighten the drive sprocket nut 6 to the specified torque NOTE Use a deep socket 7 for this procedure S60C5240 E S6D85300 c d Crankshaft holder 20 8 90890 06552 T R Drive sprocket ...

Page 89: ...M6 35 mm 3 Collar 1 4 Wave washer 2 5 Washer 2 6 Spring 1 7 Washer 2 8 Throttle lever 1 9 Bolt 1 M6 25 mm 10 Collar 1 11 Throttle link rod 1 12 Nut 1 13 Throttle link rod joint 1 14 Bracket 1 15 Bolt 2 M6 30 mm S6D84140 A A A A A A 13 12 11 8 7 5 4 10 9 6 7 15 14 15 1 5 4 3 2 Power unit Throttle link ...

Page 90: ...Bolt 2 M6 15 mm 4 Bolt 2 M6 12 mm 5 Bracket 1 6 Bracket 1 7 Bracket 1 8 Bolt 2 M6 20 mm 9 Collar 4 10 Grommet 4 11 Bolt 4 M6 30 mm 12 ECM 1 13 Rectifier Regulator 1 14 Bolt 2 M6 25 mm 15 Bolt 2 M6 20 mm 16 Bracket 1 17 Bolt 5 M6 30 mm S6D85050 1 2 3 4 5 3 8 9 10 11 12 13 14 4 16 17 17 15 7 6 15 ...

Page 91: ... mm 8 Ground lead 1 9 Fuse 1 30 A 10 Fuse 3 20 A 11 Cap 1 12 Cap 3 13 Starter relay 1 14 Holder 1 15 Screw 1 ø6 20 mm 16 Bolt 1 M6 10 mm 17 Cap 1 S6D95020 1 2 9 13 11 10 12 4 3 7 5 6 14 15 16 18 19 21 20 17 8 4 5 6 22 22 24 23 T R 3 N m 0 3 kgf m 2 2 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib T R 3 N m 0 3 kgf m 2 2 ft Ib ECM Junction box ...

Page 92: ...llar 5 21 Grommet 5 22 Bolt 2 M6 10 mm 23 Clamp 1 24 Grommet 1 S6D95020 1 2 9 13 11 10 12 4 3 7 5 6 14 15 16 18 19 21 20 17 8 4 5 6 22 22 24 23 T R 3 N m 0 3 kgf m 2 2 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib T R 3 N m 0 3 kgf m 2 2 ft Ib ...

Page 93: ...10 143 mm 11 Spark plug 4 12 Bolt 2 M8 40 mm 13 Bolt 2 M6 22 mm 14 Anode cover 2 15 Anode 2 16 Grommet 2 17 Valve shim 16 S6D85080 1 4 7 8 9 5 6 3 13 14 22 20 18 17 19 21 23 24 24 16 15 12 11 10 2 23 22 21 20 19 18 17 E E E E E E LT 271 A A T R 25 N m 2 5 kgf m 18 4 ft Ib 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 3 90 T R 1 14 N m 1 4 kgf m 10 3 ft lb 2 28 N m 2 8 kgf m 20 7 ...

Page 94: ...g seat 16 23 Valve seal 16 Not reusable 24 Valve guide 16 Not reusable S6D85080 1 4 7 8 9 5 6 3 13 14 22 20 18 17 19 21 23 24 24 16 15 12 11 10 2 23 22 21 20 19 18 17 E E E E E E LT 271 A A T R 25 N m 2 5 kgf m 18 4 ft Ib 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 3 90 T R 1 14 N m 1 4 kgf m 10 3 ft lb 2 28 N m 2 8 kgf m 20 7 ft lb E E ...

Page 95: ...cam shaft exhaust 4 and oil seals 5 4 Remove the valve shims 6 from the valve lifters 7 NOTE Do not mix the valve train parts Keep them organized in their proper groups 5 Remove the cylinder head bolts in the sequence shown CAUTION Do not scratch or damage the mating sur faces of the cylinder head and cylinder block S6D85420 2 1 S6D85430 5 4 3 S60C5380 S6D85440 Cylinder head ...

Page 96: ...2 Measure the valve spring tilt b Replace if above specification Checking the valves 1 Check the valve face for pitting or wear Replace if necessary 2 Measure the valve margin thickness a Replace if out of specification 3 Measure the valve stem diameter b Replace if out of specification Valve spring compressor 8 90890 04019 Valve spring compressor attachment 9 90890 06320 Valve spring free length ...

Page 97: ...placing the valve guides 1 Remove the valve guide 1 by striking the special service tool from the combus tion chamber side Valve stem diameter b Intake 5 975 5 990 mm 0 2352 0 2358 in Exhaust 5 960 5 975 mm 0 2346 0 2352 in Valve stem runout limit 0 01 mm 0 0004 in Valve guide inside diameter a Intake and exhaust 6 000 6 018 mm 0 2362 0 2369 in Valve stem to valve guide clearance valve guide insid...

Page 98: ...eter Checking the valve seat 1 Eliminate carbon deposits from the valve with a scraper 2 Apply a thin even layer of Mechanic s blueing dye Dykem onto the valve seat 3 Lap the valve slowly on the valve seat with a valve lapper commercially avail able as shown 4 Measure the valve seat contact width a where the blueing dye is adhered to the valve face Reface the valve seat if the valve is not seated ...

Page 99: ...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 b Previous contact width Valve seat contact width a 1 20 1 60 mm 0 0472 0 0630 in Valve seat cutter holder 90890 06553 Valve seat cutter 30 intake 90890 06326 30 exhaust 90890 06328 45 intake 90890 06555 45 ...

Page 100: ...th b Previous contact width 7 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 edge of the valve seat If necessary use a 45 cutter 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 bottom edge of the valve face use a 60 cutter to cut the bot...

Page 101: ...he camshaft journal diameter c and cylinder head journal inside diam eter d Replace the camshaft and cylin der head if out of specification Checking the cylinder head 1 Eliminate carbon deposits from the com bustion chambers and check for deterio ration Cam lobe a Intake 36 48 36 58 mm 1 4362 1 4402 in Exhaust 36 90 37 06 mm 1 4528 1 4591 in Cam lobe b Intake 29 95 30 05 mm 1 1791 1 1831 in Exhaus...

Page 102: ...g seat 3 valve spring 4 and valve spring retainer 5 in the sequence shown and then attach the special service tools NOTE The valve spring can be installed in any direction 3 Compress the valve spring and then install the valve cotters 8 using a thin screwdriver with a small amount of grease applied to it Cylinder head warpage limit 0 1 mm 0 0039 in S6D85470 1 2 S6D85460 S60C5660 E Valve spring com...

Page 103: ...h a new one NOTE Apply engine oil to the cylinder head bolts before installation Tighten the M10 bolts to the specified torques in two stages first and then tighten the M8 bolts to 14 N m 1 4 kgf m 10 3 ft lb Make a mark a on the M10 bolts and the cylinder head and then tighten the bolts 90 from the mark Tighten the M8 bolts to 28 N m 2 8 kgf m 20 7 ft lb S60C5680 8 S60C5690 T R Cylinder head bolt...

Page 104: ...hat the camshaft dowel holes c are in the position shown in the illustra tion Adjust if necessary 6 Install the camshaft caps in their proper positions as shown with the stamped numbers upside down 7 Tighten the camshaft cap bolts to the specified torques in two stages and in the sequence shown NOTE Apply engine oil to the camshaft caps and camshaft cap bolts before installation 8 Install the cyli...

Page 105: ...prockets and timing belt NOTE For sprocket and timing belt installation pro cedures see Installing the sprockets and timing belt T R Cylinder head cover bolt 1st 8 N m 0 8 kgf m 5 9 ft lb 2nd 8 N m 0 8 kgf m 5 9 ft lb S6D85520 S1280B Cylinder head ...

Page 106: ...et 1 Not reusable 12 Grommet 1 13 Pressure control valve 1 14 Spring 1 15 Cover 1 16 Bolt 3 M6 20 mm 17 Gasket 1 Not reusable S6D85090 23 18 5 6 7 14 12 11 19 20 21 24 22 4 1 27 28 15 16 13 9 10 8 E E A A LT 271 T R 23 N m 2 3 kgf m 17 0 ft Ib 17 2 3 2 2 3 3 25 26 T R 49 N m 4 9 kgf m 36 1 ft Ib T R 55 N m 5 5 kgf m 40 6 ft Ib 29 30 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 LT 2...

Page 107: ...le 28 Plug 1 M14 12 mm 29 Plastic tie 1 Not reusable 30 Hose 1 S6D85090 23 18 5 6 7 14 12 11 19 20 21 24 22 4 1 27 28 15 16 13 9 10 8 E E A A LT 271 T R 23 N m 2 3 kgf m 17 0 ft Ib 17 2 3 2 2 3 3 25 26 T R 49 N m 4 9 kgf m 36 1 ft Ib T R 55 N m 5 5 kgf m 40 6 ft Ib 29 30 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 LT 271 T R 2 N m 0 2 kgf m 1 5 ft Ib LT 271 T R 18 N m 1 8 kgf m 13...

Page 108: ...heck the spring for fatigue or deforma tion Replace if necessary Installing the pressure control valve 1 Install a new gasket and the pressure control valve and then tighten the bolts Installing the exhaust cover 1 Install a new gasket and the exhaust cover 2 Install the bolts and then tighten them to the specified torques in two stages and in the sequence shown NOTE Apply engine oil to the exhaus...

Page 109: ...reusable 11 Crankshaft 1 12 Oil seal 1 Not reusable 13 Connecting rod bearing 8 14 Piston connecting rod assembly 4 15 Bolt 8 Not reusable M8 38 mm 16 Piston ring set 4 17 Stud bolt 2 S6D95010 UP 1 2 1 17 E E E E 3 4 5 8 12 15 13 10 6 11 9 8 E E 16 14 E 7 7 S518 T R 1 19 N m 1 9 kgf m 14 0 ft lb 2 60 T R 1 14 N m 1 4 kgf m 10 3 ft lb 2 28 N m 2 8 kgf m 20 7 ft lb T R 1 18 N m 1 8 kgf m 13 3 ft lb ...

Page 110: ...haft oil seals and the piston assemblies NOTE Be sure to keep the bearings in the order as they were removed Mark each piston with an identification number a of the corresponding cylinder Do not mix the connecting rods and caps Keep them organized in their proper groups Checking the piston diameter 1 Measure the piston outside diameter at the specified measuring point Replace if out of specificati...

Page 111: ...iston rings as a set or the cylinder block or all parts or rebore the cylinder if out of specifica tion Checking the piston rings 1 Check the piston ring dimensions of B and T Replace if out of specification 2 Level the piston ring 1 in the cylinder with a piston crown Cylinder bore D1 D6 79 000 79 020 mm 3 1102 3 1110 in Taper limit D1 D5 direction d D2 D6 direction e 0 08 mm 0 0031 in Out of rou...

Page 112: ...learance 1 Measure the connecting rod big end side clearance a Replace the connecting rod or crankshaft or both if out of specifi cation Piston ring end gap d Top ring 0 15 0 30 mm 0 0059 0 0118 in Second ring 0 70 0 90 mm 0 0276 0 0354 in Oil ring 0 20 0 70 mm 0 0079 0 0276 in Measuring point e 20 mm 0 8 in S63P5720 a b c Piston ring groove Top ring a 1 23 1 25 mm 0 048 0 049 in Second ring b 1 5...

Page 113: ...ace the crankshaft if above specification Checking the crankpin oil clearance 1 Clean the bearings and the connecting rod Connecting rod big end side clearance a 0 14 0 28 mm 0 0055 0 0110 in Crankshaft journal diameter a 47 985 48 000 mm 1 8892 1 8898 in Crankpin diameter b 43 982 44 000 mm 1 7316 1 7323 in Crankpin width c 21 00 21 07 mm 0 8268 0 8295 in Crankshaft runout limit 0 03 mm 0 0012 in...

Page 114: ...er the oil hole in the crankpin of the crank shaft 4 Install the connecting rod to the crankpin 3 NOTE Make sure that the large flat side a on the connecting rod faces towards the flywheel magnet side of the crankshaft 5 Tighten the connecting rod bolts to the specified torques in two stages NOTE Reuse the removed connecting rod bolts Do not turn the connecting rod until the crankpin oil clearance...

Page 115: ... lows 2 Measure the connecting rod big end inside diameter a NOTE Reuse the removed connecting rod bolts 3 Check the crankpin mark on the crank shaft 1 4 Subtract the crankpin diameters 1 4 from the connecting rod big end inside diameters 1 4 NOTE The crankpin diameters 1 4 can be determined by the stamped value as described below Crankpin diameter 43 900 stamped value 1 000 Example 1 92 43 992 Cr...

Page 116: ... the crankshaft jour nals the bearing portions of the crank case and the cylinder block 2 Place the cylinder block upside down on a bench 3 Install half of the bearings 1 and the crankshaft into the cylinder block 2 NOTE Install the bearings in their original posi tions Install the unified thrust bearing at the posi tion a shown 4 Put a piece of Plastigauge PG 1 on each crankshaft journal parallel...

Page 117: ... M8 bolts to 14 N m 1 4 kgf m 10 3 ft lb Make a mark b on the M10 bolts and the crankcase and then tighten the bolts 60 from the mark Tighten the M8 bolts to 28 N m 2 8 kgf m 20 7 ft lb 8 Remove the crankcase and then mea sure the width of the compressed Plasti gauge PG 1 on each crankshaft journal Replace the main bearing if out of specification Selecting the main bearing 1 When replacing the mai...

Page 118: ...hat the colors of the upper and lower bearings are differ ent Be sure to install the main bearings in the middle of the cylinder block and crankcase journal so they do not block the oil holes NOTE Main bearing 3 is a thrust bearing Example If the Crankshaft journal mark is 92 and the Cylinder block mark is 32 then the Calcu lated value 54 032 47 992 6 040 mm Suitable colors Bearing cylinder side t...

Page 119: ...ing rod 4 and the lower bearing into the connecting rod cap 5 NOTE Install the bearings in their original positions 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 the pistons and piston rings before installation 5 Install half of the bearings 6 into the cyl inder block 7 NOTE Install the bearings in their original ...

Page 120: ...he crankshaft Apply engine oil to the connecting rod caps and connecting rod bolts before installation 8 Install half of the bearings B into the crankcase 9 Apply sealant to the mating surface of the crankcase NOTE Install the bearings in their original posi tions Do not get any sealant on the main bear ings 10 Install the crankcase onto the cylinder block and apply engine oil onto the threads of ...

Page 121: ...mbly Installing the power unit 1 Clean the power unit mating surface and install the dowels 1 and a new gasket 2 2 Install the power unit 3 by installing bolts 4 and 5 then tightening them to the specified torques in two stages and in the sequence shown 3 Install the apron 6 4 Install the oil dipstick 5 Connect the flushing hose cooling water pilot hose and canister hose T R Crankcase bolt M10 1st...

Page 122: ...ocedures see Chapter 3 Adjusting the throttle link and throttle cable and Checking the gear shift oper ation 10 Install all parts removed during disas sembly 11 Check the engine oil level NOTE If the engine oil is below the minimum level mark b add sufficient oil until the level is between a and b T R PTT motor lead bolt 4 N m 0 4 kgf m 3 0 ft lb T R Positive battery lead nut 9 N m 0 9 kgf m 6 6 f...

Page 123: ...mbling the propeller shaft housing 6 13 Drive shaft and lower case 6 15 Removing the drive shaft 6 17 Disassembling the drive shaft 6 17 Disassembling the forward gear 6 17 Disassembling the lower case 6 17 Checking the pinion and forward gear 6 18 Checking the bearings 6 18 Checking the drive shaft 6 18 Checking the lower case 6 18 Assembling the lower case 6 19 Assembling the forward gear 6 19 A...

Page 124: ... 90890 06513 Bearing housing puller claw L 90890 06502 Stopper guide plate 90890 06501 Center bolt 90890 06504 Bearing separator 90890 06534 Stopper guide stand 90890 06538 Bearing puller assembly 90890 06535 Needle bearing attachment 90890 06607 90890 06611 90890 06612 90890 06614 Driver rod L3 90890 06652 ...

Page 125: ...g attachment 90890 06655 Bearing inner race attachment 90890 06639 90890 06643 90890 06661 Drive shaft holder 5 90890 06519 Pinion nut holder New 90890 06715 Current 90890 06505 Bearing outer race puller assembly 90890 06523 Driver rod SL 90890 06602 Bearing outer race attachment 90890 06621 90890 06626 Special service tools ...

Page 126: ...0890 06605 Shift rod push arm 90890 06052 Pinion height gauge 90890 06710 Digital caliper 90890 06704 Shimming plate 90890 06701 Backlash indicator 90890 06706 Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnetic base B 90890 06844 ...

Page 127: ...eck screw 1 4 Gasket 2 Not reusable 5 Dowel 2 6 Bolt 4 M10 40 mm L transom model 7 Drain screw 1 8 Grommet 1 9 Bolt 1 M10 45 mm 10 Bolt 1 M8 60 mm L transom model 11 Spacer 1 12 Propeller 1 13 Washer 1 14 Washer 1 15 Cotter pin 1 Not reusable 16 Nut 1 17 Trim tab 1 Special service tools Lower unit ...

Page 128: ...ame Q ty Remarks 18 Dowel 2 X transom model 19 Extension 1 X transom model 20 Stud bolt 4 M10 180 mm X transom model 21 Washer 4 X transom model 22 Spring washer 4 X transom model 23 Nut 4 X transom model 24 Bolt 1 M8 190 mm X transom model ...

Page 129: ... Not reusable 3 Oil seal 1 Not reusable 4 Oil seal housing 1 5 O ring 1 Not reusable 6 Circlip 1 7 Shift rod 1 8 Woodruff key 1 9 Screw 2 ø4 12 mm 10 Bolt 2 M8 75 mm 11 Cover 1 12 Bolt 2 M8 50 mm 13 Seal 1 14 Water pump housing 1 15 Insert cartridge 1 16 Impeller 1 17 Dowel 2 Lower unit ...

Page 130: ... 6 7 6D93G11 6 No Part name Q ty Remarks 18 Gasket 1 Not reusable 19 Outer plate cartridge 1 20 Gasket 1 Not reusable 21 Oil seal housing 1 22 O ring 1 Not reusable 23 Gasket 1 Not reusable 24 Oil seal 2 Not reusable ...

Page 131: ...ot hold the propeller with your hands when loosening or tightening it Be sure to disconnect the battery leads from the battery and the clip from the engine stop lanyard switch Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning 3 Disconnect the speedometer hose 1 4 Mark the trim tab 2 at the area shown and then remove it 5 Loosen the bolts nuts an...

Page 132: ...der 2 turn it clock wise 90 b and then remove it Disassembling the oil seal housing 1 Remove the oil seals using a flat head screw driver Checking the water pump and shift rod 1 Check the water pump housing for defor mation Replace if necessary 2 Check the impeller and insert cartridge for cracks or wear Replace if necessary 3 Check the Woodruff key 1 and the groove a on the drive shaft for wear R...

Page 133: ...oss pin 1 4 Dog clutch 1 5 Spring 1 6 Propeller shaft 1 7 Washer 1 8 Reverse gear 1 9 Thrust washer 1 10 Ball bearing 1 Not reusable 11 O ring 1 Not reusable 12 Propeller shaft housing 1 13 Straight key 1 14 Needle bearing 1 15 Oil seal 2 Not reusable 16 Claw washer 1 17 Ring nut 1 Lower unit Propeller shaft housing ...

Page 134: ...ring 1 and then remove the cross pin 2 dog clutch 3 slider and shift plunger Disassembling the propeller shaft housing 1 Remove the reverse gear and thrust washer 2 Remove the ball bearing Ring nut wrench 3 1 90890 06511 Ring nut wrench extension 2 90890 06513 Bearing housing puller claw L 3 90890 06502 Stopper guide plate 4 90890 06501 Center bolt 5 90890 06504 Bearing separator 1 90890 06534 Sto...

Page 135: ...ing or rum bling Replace if necessary Checking the propeller shaft 1 Check the propeller shaft for bends or wear Replace if necessary 2 Measure the propeller shaft runout 3 Check the dog clutch and slider for cracks or wear Replace if necessary Assembling the propeller shaft assembly 1 Install the dog clutch as shown NOTE Install the dog clutch 1 with the F mark a facing toward the slider Stopper ...

Page 136: ...sing to the specified depth NOTE Install an oil seal halfway into the propeller shaft housing then the other oil seal 3 Install the thrust washer 6 and new ball bearing 7 to the reverse gear 8 using a press NOTE Install the ball bearing with the manufacture identification mark e facing outward propel ler side 4 Install the reverse gear assembly into the propeller shaft housing using a press Driver...

Page 137: ...6D93G11 6 14 1 2 3 4 5 6 7 8 9 Bearing inner race attachment 0 90890 06661 Propeller shaft housing ...

Page 138: ... bearing 1 Not reusable 3 Pinion shim 4 Sleeve 1 5 Hose 1 6 Plastic tie 1 Not reusable 7 Joint 1 8 Nut 1 9 Cooling water inlet cover 2 10 Screw 1 ø5 40 mm 11 Seal 1 12 Plate 1 13 Forward gear shim 14 Taper roller bearing 1 Not reusable 15 Needle bearing 1 Not reusable 16 Forward gear assembly 1 17 Needle bearing 1 ...

Page 139: ...6D93G11 6 16 1 2 3 4 5 6 7 8 9 6 No Part name Q ty Remarks 18 Pinion 1 19 Nut 1 20 Lower case 1 Drive shaft and lower case ...

Page 140: ...t reuse the bearing always replace it with a new one Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press CAUTION Do not reuse the bearing always replace it with a new one 2 Remove the needle bearing from the for ward gear CAUTION Do not reuse the bearing always replace it with a new one Disassembling the lower case 1 Remove the taper roller bearing ...

Page 141: ... the bearings for pitting or rum bling Replace if necessary Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary 2 Measure the drive shaft runout Checking the lower case 1 Check the skeg and torpedo for cracks or damage Replace the lower case if nec essary Bearing outer race puller assembly 1 90890 06523 Stopper guide plate 2 90890 06501 Stopper guide stand 3 908...

Page 142: ...ower case NOTE Apply the gear oil to the inside and outside of the sleeve before installation Install the sleeve by facing the projection d forward 3 Install the original shim s and taper roller bearing outer race CAUTION Add or remove shim s if necessary if replacing the taper roller bearing or lower case Assembling the forward gear 1 Install a new taper roller bearing into the forward gear using...

Page 143: ... specified torque Installing the propeller shaft housing 1 Install the washer 1 and propeller shaft assembly 2 into the propeller shaft housing assembly 3 2 Apply grease to a new O ring Needle bearing attachment 1 90890 06607 Needle bearing attachment 2 90890 06614 Driver rod L3 3 90890 06652 Depth a 1 20 0 25 mm 0 05 0 01 in Bearing inner race attachment 1 90890 06643 Drive shaft holder 5 1 90890...

Page 144: ...r pump and shift rod 1 Install the shift rod assembly 1 NOTE Install the shift rod assembly into the lower case turn it counterclockwise 90 a and then push it down b to connect it to the shift slider 2 2 Install new oil seals into the oil seal hous ing as shown NOTE Install an oil seal halfway into the oil seal housing then the other oil seal Ring nut wrench 3 8 90890 06511 Ring nut wrench extensi...

Page 145: ...water pump housing D NOTE Align the insert cartridge projection d with the hole e in the water pump housing 8 Install the dowels E and the water pump housing D onto the lower case 9 Install and tighten the bolts F NOTE Apply grease to the inside of the water pump housing before installation To install the water pump housing push down on the pump housing and then turn the drive shaft clockwise Inst...

Page 146: ... 4 Install the lower unit into the upper case and then tighten the lower case mounting bolts nuts to the specified torque È X transom model 5 Install the trim tab 2 to its original posi tion and then connect the speedometer hose 3 Shift rod push arm 90890 06052 S6D81040 a b T R Lower case mounting bolt nut 39 N m 3 9 kgf m 28 8 ft lb S6D86180 2 3 LT 572 LT ...

Page 147: ...ler with your hands when loosening or tightening it Be sure to disconnect the battery leads from the battery and the clip from the engine stop lanyard switch Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning NOTE If the grooves in the propeller nut 4 do not align with the cotter pin hole tighten the nut until they are aligned 7 Fill the gear oil...

Page 148: ...LOWR Lower unit 6 25 6D93G11 Shimming 6 ...

Page 149: ...ess T3 by using the specified measurement s and the calcula tion formula Install the special service tool to the drive shaft so that the shaft is at the center of the hole Tighten the wing nuts another 1 4 of a turn after they contact the plate 2 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M between the special service tool and the pi...

Page 150: ...is 0 55 mm then the pinion shim is 0 58 mm If T3 is 0 64 mm then the pinion shim is 0 65 mm Selecting the forward gear shims 1 Turn the taper roller bearing outer race 1 two or three times to seat the rollers and then measure the bearing height M 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 three poin...

Page 151: ... mm 0 37 mm 3 Select the forward gear shim s T1 as follows Example If T1 is 0 47 mm then the forward gear shim is 0 45 mm If T1 is 0 50 mm then the forward gear shim is 0 48 mm Backlash 6 Measuring the forward gear backlash 1 Remove the water pump assembly NOTE Do not remove the oil seal housing in this procedure 2 Set the gear shift to the neutral position at the lower unit Forward gear shim thic...

Page 152: ...ure the back lash when the drive shaft stops in each direction 6 Add or remove shims if out of specifica tion M Measurement 7 Remove the special service tools and then install the water pump assembly Bearing housing puller claw L 1 90890 06502 Stopper guide plate 2 90890 06501 Center bolt 3 90890 06504 Backlash indicator 4 90890 06706 Magnet base plate 5 90890 07003 Dial gauge set 6 90890 01252 Ma...

Page 153: ...6D93G11 6 30 1 2 3 4 5 6 7 8 9 MEMO Backlash ...

Page 154: ... 7 15 Installing the upper case 7 15 Steering arm 7 17 Removing the steering arm 7 18 Installing the steering arm 7 18 Clamp brackets and swivel bracket 7 19 Removing the clamp brackets 7 21 Installing the clamp brackets 7 21 Adjusting the trim sensor 7 21 Power trim and tilt unit 7 23 Removing the power trim and tilt unit 7 24 Power trim and tilt motor 7 25 Disassembling the power trim and tilt m...

Page 155: ...7 39 Assembling the tilt cylinder 7 39 Assembling the power trim and tilt unit 7 41 Bleeding the power trim and tilt unit 7 43 Installing the power trim and tilt unit 7 44 Bleeding the power trim and tilt unit built in 7 44 Power trim and tilt electrical system 7 45 Checking the fuse 7 45 Checking the power trim and tilt relay 7 45 Checking the power trim and tilt switch 7 46 Checking the trim sen...

Page 156: ...r race attachment 90890 06625 90890 06628 Driver rod LL 90890 06605 Driver rod L3 90890 06652 Driver rod LS 90890 06606 Ball bearing attachment 90890 06638 Needle bearing attachment 90890 06612 90890 06653 Cylinder end screw wrench New 90890 06568 Current 90890 06544 ...

Page 157: ...et 1 8 Shift rod 1 9 Screw 2 ø4 16 mm 10 Plate 1 11 Shift position switch 1 12 Bolt 2 M6 50 mm 13 Bushing 1 14 Bracket 1 15 Cotter pin 1 Not reusable 16 Bushing 1 17 Lever 1 S6D87010 9 14 15 1 2 3 4 5 8 7 12 10 11 6 13 5 17 16 T R 18 N m 1 8 kgf m 13 3 ft Ib T R 1 N m 0 1 kgf m 0 7 ft Ib A A A A A A A A LT 572 LT Special service tools Shift rod ...

Page 158: ...2 8 Lever 2 9 Spring 2 10 Bolt 2 M6 20 mm 11 Hook 2 12 Cooling water outlet 1 13 Canister outlet 1 14 Bolt 4 M8 35 mm 15 Grommet 4 16 Collar 5 17 Grommet 5 S6D87020 1 21 22 23 25 28 29 26 25 25 26 30 31 26 42 41 43 44 45 46 24 9 10 11 14 12 27 2 3 4 5 5 6 7 8 13 15 16 17 47 18 19 20 32 33 34 35 36 37 38 39 40 48 A A A A LT 572 LT T R 2 N m 0 2 kgf m 1 5 ft Ib ...

Page 159: ...3 M6 25 mm 26 Plate 3 27 Power trim and tilt switch 1 28 Grommet 1 29 Grommet 3 30 Bolt 1 M6 20 mm 31 Plate 1 32 Grommet 1 33 Screw 2 ø6 19 mm 34 Bracket 1 S6D87020 1 21 22 23 25 28 29 26 25 25 26 30 31 26 42 41 43 44 45 46 24 9 10 11 14 12 27 2 3 4 5 5 6 7 8 13 15 16 17 47 18 19 20 32 33 34 35 36 37 38 39 40 48 A A A A LT 572 LT T R 2 N m 0 2 kgf m 1 5 ft Ib Bottom cowling ...

Page 160: ...ose 1 41 Bolt 1 M6 20 mm 42 Bolt 2 M6 25 mm 43 Retaining plate 1 44 Bolt 1 M6 20 mm 45 Plate 1 46 Grommet 1 47 Rubber seal 1 48 Clamp 1 S6D87020 1 21 22 23 25 28 29 26 25 25 26 30 31 26 42 41 43 44 45 46 24 9 10 11 14 12 27 2 3 4 5 5 6 7 8 13 15 16 17 47 18 19 20 32 33 34 35 36 37 38 39 40 48 A A A A LT 572 LT T R 2 N m 0 2 kgf m 1 5 ft Ib ...

Page 161: ...pper case assembly 1 7 Cover 2 8 Bolt 4 M10 40 mm 9 Grommet 1 10 Grommet 1 11 Nut 2 12 Nut 2 13 Washer 2 14 Washer 2 15 Grease nipple 1 16 Bolt 1 M8 16 mm 17 Ground lead 1 S6D87030 3 5 4 4 11 12 13 14 15 16 17 6 7 8 5 LT LT 572 T R 10 N m 1 0 kgf m 7 4 ft Ib T R 3 N m 0 3 kgf m 2 2 ft Ib LT 572 LT T R 51 N m 5 1 kgf m 37 6 ft Ib 10 9 2 1 A A A A Bottom cowling Upper case ...

Page 162: ... ring 1 Not reusable 5 Shaft 1 6 O ring 1 Not reusable 7 Oil seal 1 Not reusable 8 Oil seal 2 Not reusable 9 O ring 1 Not reusable 10 Oil seal housing 1 11 Screw 4 ø6 10 mm 12 Oil pump assembly 1 S6D97010 T R 4 N m 0 4 kgf m 3 0 ft Ib 12 WR No 2 WR No 2 1 2 3 5 6 4 E T R 4 N m 0 4 kgf m 3 0 ft Ib E 11 9 10 8 7 E E E E E E WR No 2 ...

Page 163: ...4 12 mm 11 Damper 1 12 Rubber seal 1 13 Gasket 1 Not reusable 14 Gasket 1 Not reusable 15 Screw 2 ø6 15 mm 16 Baffle plate 1 17 Grommet 1 S6D97020 A A 1 2 6 5 26 25 24 22 23 7 13 12 8 15 17 20 21 19 16 18 18 14 A LT 572 LT 572 LT 572 LT 572 A A A A A T R 20 N m 2 0 kgf m 14 8 ft Ib T R 28 N m 2 8 kgf m 20 7 ft Ib 9 10 11 3 4 T R 27 N m 2 7 kgf m 20 0 ft Ib LT 271 WR No 2 T R 4 N m 0 4 kgf m 3 0 ft...

Page 164: ...r mount 2 23 Washer 2 24 Washer 2 25 Washer 2 26 Bolt 2 M12 200 mm S6D97020 A A 1 2 6 5 26 25 24 22 23 7 13 12 8 15 17 20 21 19 16 18 18 14 A LT 572 LT 572 LT 572 LT 572 A A A A A T R 20 N m 2 0 kgf m 14 8 ft Ib T R 28 N m 2 8 kgf m 20 7 ft Ib 9 10 11 3 4 T R 27 N m 2 7 kgf m 20 0 ft Ib LT 271 WR No 2 T R 4 N m 0 4 kgf m 3 0 ft Ib ...

Page 165: ... 12 M6 25 mm 9 Oil pan 1 10 Gasket 1 Not reusable 11 Exhaust manifold 1 12 Bolt 4 M6 70 mm 13 Gasket 1 Not reusable 14 Gasket 2 Not reusable 15 Plate 1 16 Dowel 2 17 Bolt 6 M6 30 mm S6D87060 17 19 18 20 21 22 14 15 12 8 3 3 9 7 4 13 10 11 1 2 5 6 16 16 A A LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 A A T R 11 N m 1 1 kgf m 8 1 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib Upper case ...

Page 166: ...8 Muffler 1 19 Bolt 1 M6 50 mm 20 Grommet 1 21 Spacer 1 22 Pipe 1 S6D87060 17 19 18 20 21 22 14 15 12 8 3 3 9 7 4 13 10 11 1 2 5 6 16 16 A A LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 A A T R 11 N m 1 1 kgf m 8 1 ft Ib T R 10 N m 1 0 kgf m 7 4 ft Ib ...

Page 167: ...ing the oil pump 1 Check the gear teeth for cracks or wear and the oil pump case for scratches Replace the oil pump assembly if neces sary 2 Check the shaft for cracks or wear Replace if necessary 3 Check the oil passage for dirt or residue Clean if necessary Assembling the oil pump 1 Install a new oil seal into the oil pump cover to the specified depth 2 Install a new oil seal into the oil pump h...

Page 168: ... the drive shaft bushing for wear or cracks Replace if necessary Disassembling the oil pan 1 Remove the muffler 1 and plate 2 from the oil pan 3 2 Remove the exhaust manifold 4 from the oil pan 3 3 Remove the oil pan 3 from the exhaust guide 5 4 Remove the oil strainer 6 Needle bearing attachment 4 90890 06612 Driver rod LS 2 90890 06606 T R Oil pump cover screw 4 N m 0 4 kgf m 3 0 ft lb S6D97030 ...

Page 169: ...4 finger tight 4 Install a new gasket and the exhaust manifold 5 onto the oil pan and then tighten the exhaust manifold bolts 6 to the specified torque 5 Tighten the oil pan bolts 4 to the speci fied torque 6 Tighten the exhaust manifold bolts 6 again to the specified torque 7 Install new gaskets the plate 7 and the muffler 8 onto the oil pan 8 Install the water pipe 9 Oil strainer bolt 10 N m 1 0...

Page 170: ... specified torque 3 Install the lower mounts 4 onto the upper case 4 Install the upper and lower mounting bolts into the bracket 5 simultaneously 5 Install the upper mounting nut 6 and lower mounting nut 7 and then tighten them to the specified torques NOTE Before tightening the lower mounting nut be sure to connect the ground lead to the lower mounting bolt 6 Install the mount covers 8 Needle bea...

Page 171: ... assembly onto the upper case pour a small amount of engine oil into the oil inlet or oil outlet of the oil pump assembly T R Upper mounting nut 6 51 N m 5 1 kgf m 37 6 ft lb Lower mounting nut 7 51 N m 5 1 kgf m 37 6 ft lb Oil pump bolt 0 10 N m 1 0 kgf m 7 4 ft lb Grease nipple 3 N m 0 3 kgf m 2 2 ft lb S6D87210 7 8 9 0 6 5 LT 572 LT LT LT 572 A A Upper case ...

Page 172: ...Remarks 1 Nut 2 2 Steering hook 1 3 Stud bolt 2 M10 40 mm 4 Steering arm 1 5 Washer 1 6 Bushing 1 7 O ring 2 Not reusable 8 Bushing 2 9 Washer 1 10 Steering yoke 1 11 Damper 1 12 Circlip 1 A A A 11 7 6 5 4 8 12 10 9 7 8 1 2 3 T R 20 N m 2 0 kgf m 14 8 ft Ib S6D87220 ...

Page 173: ... Place the swivel bracket 6 in an upright position and then install the steering arm onto the swivel bracket 3 Install the bushing 7 O ring 8 and washer 9 onto the swivel bracket 4 Install the steering yoke 0 to the steer ing arm 5 by aligning the center a of the yoke with the center b of the steer ing arm 5 Install the circlip A 6 Inject grease into the grease nipple until grease comes out from b...

Page 174: ...p bracket 1 4 Self locking nut 1 5 Screw 1 ø6 12 mm 6 Washer 2 7 Bushing 2 8 Trim sensor cam 1 9 Screw 1 ø6 25 mm 10 Plate 1 11 Anode 1 12 Bolt 1 M6 14 mm 13 Bolt 2 M6 16 mm 14 Through tube 1 15 Bolt 1 M8 20 mm S6D87490 4 15 14 8 9 6 6 7 7 5 2 3 1 10 11 12 13 T R 15 N m 1 5 kgf m 11 1 ft Ib T R 2 N m 0 2 kgf m 1 5 ft Ib A A A A A A A A ...

Page 175: ... 1 20 in 5 Pin 2 6 Hook 1 7 Bolt 1 M6 10 mm 8 Spring 1 9 Tilt stop lever 1 10 Trim sensor 1 11 Screw 2 ø6 15 mm 12 Bolt 1 M6 10 mm 13 Clamp 2 14 Grease nipple 2 15 Ground lead 1 16 Pin 1 4 a 5 4 16 5 S6D87500 T R 3 N m 0 3 kgf m 2 2 ft Ib A A LT 572 LT A A A A A A 1 3 2 10 14 13 12 13 9 3 11 15 14 3 4 5 8 3 6 7 4 16 Clamp brackets and swivel bracket ...

Page 176: ...acket NOTE Adjust the trim sensor after installing the power trim and tilt unit 2 Assemble the clamp brackets and the swivel bracket by installing the anode 2 bolt 3 and self locking nut 4 then tight ening the nut to the specified torque 3 Install the power trim and tilt unit For installation procedure see Installing the power trim and tilt unit Adjusting the trim sensor 1 Fully retract the power ...

Page 177: ...ower if the power trim and tilt unit should lose fluid pressure 5 Check the trim sensor resistance If the resistance is out of specification adjust the trim sensor cam position and check the trim sensor Trim sensor setting resistance Pink P Black B 10 1 Ω at 20 C 68 F T R Trim sensor cam screw 1 2 N m 0 2 kgf m 1 5 ft lb Trim sensor resistance Pink P Black B 238 8 378 8 Ω at 20 C 68 F S60X7160 Gy ...

Page 178: ...emarks 1 Power trim and tilt unit 1 2 Circlip 1 3 Shaft 1 4 Circlip 2 5 Shaft 1 6 Bushing 2 7 Bushing 1 8 Ground lead 1 9 Bolt 1 M6 10 mm 10 Bushing 2 11 Bushing 2 12 Collar 1 13 Holder 2 14 Bolt 2 M6 10 mm S6D87270 2 3 6 5 4 7 6 1 8 9 10 11 11 4 10 12 1314 13 14 A A A A A A A A ...

Page 179: ...or up manually If the manual valve is loosened be sure to tighten it to the specified torque after tilting the outboard motor up 2 Remove the holders 2 and plastic ties and then pull out the PTT motor leads 3 3 Remove the bolt 4 and disconnect the ground lead 5 4 Remove the circlips 6 then the lower mounting shaft 7 5 Remove the circlip 8 then the upper mounting shaft 9 NOTE Hold the power trim an...

Page 180: ...1 5 O ring 1 Not reusable 6 Reservoir cap 1 7 Screw 3 ø5 25 mm 8 Stator 1 9 O ring 1 Not reusable 10 Armature 1 11 Washer 1 12 Bushing 1 13 Wire lead 1 14 Screw 2 ø4 15 mm 15 Brush 1 16 Brush 1 17 Brush holder 1 1 2 3 4 5 6 T R 4 N m 0 4 kgf m 3 0 ft Ib T R 7 N m 0 7 kgf m 5 2 ft Ib A A A A A A 9 10 11 12 8 7 14 13 14 15 17 18 16 19 19 20 21 23 22 A A A A S6D87290 ...

Page 181: ...ker 1 19 Spring 2 20 PTT motor base 1 21 Oil seal 1 Not reusable 22 Plate 1 23 Screw 2 ø4 10 mm 1 2 3 4 5 6 T R 4 N m 0 4 kgf m 3 0 ft Ib T R 7 N m 0 7 kgf m 5 2 ft Ib A A A A A A 9 10 11 12 8 7 14 13 14 15 17 18 16 19 19 20 21 23 22 A A A A S6D87290 Power trim and tilt motor ...

Page 182: ... trim and tilt unit other wise fluid can spurt out 2 Remove the stator 1 NOTE Place a clean cloth over the end of the arma ture shaft hold it with a pair of pliers and then carefully slide the stator off of the arma ture 3 Remove the armature from the PTT motor base CAUTION Do not allow grease or oil to contact the commutator 4 Remove the screws 2 and then disas semble the PTT motor base Checking ...

Page 183: ...e brush length Replace if below specification 7 Check the base for cracks or damage Replace if necessary 8 Check the bushing 1 and oil seal for damage or wear Replace if necessary Commutator diameter wear limit 21 0 mm 0 83 in Commutator undercut wear limit a 1 0 mm 0 04 in Armature continuity Commutator segments b Continuity Segment Armature core c No continuity Segment Armature shaft d No contin...

Page 184: ... holder 6 and connect the wire lead 7 3 Install the springs 8 into the motor base then the brush holder into the motor base together with the brushes and circuit breaker 4 Push the brushes into the brush holder and then install the armature 5 Install the stator onto the base NOTE Place a clean cloth over the end of the arma ture shaft hold it with a pair of pliers and then carefully slide the stat...

Page 185: ...t 1 11 Washer 1 12 Spring 1 13 Pin 1 14 Cap 1 15 Bolt 2 M5 30 mm 16 Bolt 2 M4 30 mm 17 Cap 1 S6D87360 T R 5 N m 0 5 kgf m 3 7 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib 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 27 28 29 30 26 31 32 33 7 24 23 25 2 3 5 6 7 8 9 4 2 16 15 14 13 12 11 10 21 20 19 18 17 16 15 22 1 T R 2 N m 0 2 kgf m 1 5 ft Ib T R 2 N m 0 2 kgf m 1 5 ft Ib A A A A A A Power ...

Page 186: ... mm 27 Filter 1 28 Plate 1 29 O ring 2 Not reusable 30 Filter 2 31 O ring 1 Not reusable 32 Manual valve 1 33 Circlip 1 S6D87360 T R 5 N m 0 5 kgf m 3 7 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib 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 27 28 29 30 26 31 32 33 7 24 23 25 2 3 5 6 7 8 9 4 2 16 15 14 13 12 11 10 21 20 19 18 17 16 15 22 1 T R 2 N m 0 2 kgf m 1 5 ft Ib T R 2 N m 0 2 kgf m 1...

Page 187: ...t 1 M3 5 mm 5 Bolt 2 M5 6 mm 6 Washer 2 7 O ring 2 Not reusable 8 Adapter 2 9 Spring 2 10 Ball 2 11 Gear 2 12 Drive shaft 1 13 Pin 2 14 Driven shaft 1 15 Ball 2 16 Pin 2 S6D87550 T R 2 N m 0 2 kgf m 1 5 ft Ib T R 4 N m 0 4 kgf m 3 0 ft Ib 4 5 6 3 7 8 9 10 7 8 9 10 1 2 13 12 11 11 15 14 13 15 16 A A A A Gear pump ...

Page 188: ...riven gear 9 Checking the gear pump 1 Clean all the pistons and balls and then check them for damage or wear Replace if necessary 2 Check the filters for damage or clogs Replace if necessary 3 Check the drive gear and driven gear for damage or wear Replace the gear pump assembly if necessary Assembling the gear pump 1 Install the drive gear 1 and driven gear 2 into the gear pump housing 2 Install ...

Page 189: ...D and down relief valve seat E 10 Install the relief valve seat caps F by installing bolts G and H then tightening them to the specified torques 11 Tighten the bolts I to the specified torque T R Gear pump bracket bolt M3 2 N m 0 2 kgf m 1 5 ft lb Gear pump bracket bolt M5 4 N m 0 4 kgf m 3 0 ft lb S6C17620 5 5 4 S6C17630 9 6 6 8 7 S6C17640 0 A C B 0 T R Lever bolt M3 B C 2 N m 0 2 kgf m 1 5 ft lb...

Page 190: ...mbly 1 8 Backup ring 1 9 O ring 1 Not reusable 10 O ring 1 Not reusable 11 Washer 1 12 Filter 1 13 O ring 1 Not reusable 14 Trim piston 1 15 Backup ring 1 16 O ring 1 Not reusable 17 Ball 5 S6D87390 10 11 12 13 14 15 16 7 2 17 34 35 36 37 38 39 40 41 38 1 18 19 20 21 22 33 23 24 26 27 28 29 30 25 32 31 31 3 4 5 6 8 9 T R 90 N m 9 0 kgf m 66 4 ft Ib T R 80 N m 8 0 kgf m 59 0 ft Ib T R 85 N m 8 5 kg...

Page 191: ... 29 Spring 2 30 Pin 2 31 Dowel 2 32 Washer 1 33 Tilt piston assembly 1 34 O ring 1 Not reusable S6D87390 10 11 12 13 14 15 16 7 2 17 34 35 36 37 38 39 40 41 38 1 18 19 20 21 22 33 23 24 26 27 28 29 30 25 32 31 31 3 4 5 6 8 9 T R 90 N m 9 0 kgf m 66 4 ft Ib T R 80 N m 8 0 kgf m 59 0 ft Ib T R 85 N m 8 5 kgf m 62 7 ft Ib 6 10 15 13 16 8 9 2 3 4 23 24 A A LT 271 A A A A A A A A A A Tilt cylinder and ...

Page 192: ...asher 1 40 Circlip 1 41 Trim cylinder 1 S6D87390 10 11 12 13 14 15 16 7 2 17 34 35 36 37 38 39 40 41 38 1 18 19 20 21 22 33 23 24 26 27 28 29 30 25 32 31 31 3 4 5 6 8 9 T R 90 N m 9 0 kgf m 66 4 ft Ib T R 80 N m 8 0 kgf m 59 0 ft Ib T R 85 N m 8 5 kgf m 62 7 ft Ib 6 10 15 13 16 8 9 2 3 4 23 24 A A LT 271 A A A A A A A A A A ...

Page 193: ...fluid Disassembling the tilt cylinder 1 Hold the tilt cylinder 1 in a vise using aluminum plates a on both sides NOTE Place the tilt cylinder in the vise horizontally 2 Loosen the tilt cylinder end screw 2 and then remove it CAUTION Do not damage the check valve b when loosening the end screw 3 Hold the tilt ram end in a vise using alu minum plates on both sides Cylinder end screw wrench New 90890...

Page 194: ...er if there is light rust or replace if necessary Checking the valves 1 Check the operation of the check valve a of the tilt cylinder end screw and check the valve for dirt or residue Clean if necessary 2 Check the operation of the absorber valve and check for dirt or residue Clean if necessary Assembling the tilt cylinder 1 Install a new O ring the backup ring and a new dust seal 1 into the trim ...

Page 195: ...nstall balls M and N valves O springs P pins Q dowels R and washer S into the tilt piston 11 Hold the tilt ram end in a vise using alu minum plates on both sides 12 Install the tilt piston to the tilt ram by installing the bolt T then tightening it to the specified torque 13 Install the tilt ram into the tilt cylinder 14 Hold the tilt cylinder G in a vise using aluminum plates a on both sides NOTE...

Page 196: ... the power trim and tilt unit 1 Hold the trim cylinder in a vise using alu minum plates on both sides 2 Install the filters and gear pump assem bly 1 by installing the bolts 2 then tight ening them to the specified torques 3 Install the manual valve 3 and reservoir cap 4 4 Fill the reservoir with the recommended fluid to the correct level as shown Cylinder end screw wrench New 90890 06568 Current ...

Page 197: ...cylinder 7 NOTE Apply grease to the balls from falling out of the cylinder installation 8 Install the trim cylinder end screw 8 and then tighten it to the specified torque 9 Fully extend the tilt rod and then add suf ficient fluid of the recommended type to the correct level Recommended power trim and tilt fluid ATF Dexron II T R PTT motor bolt 4 N m 0 4 kgf m 3 0 ft lb S6D87450 S6D87460 5 Cylinde...

Page 198: ...the reservoir cap is removed 4 If necessary add sufficient fluid of the recommended type until it overflows out of the filler hole 5 Install the reservoir cap and then tighten it to the specified torque 6 Connect the PTT motor leads to the bat tery terminals to fully retract the tilt ram 7 Reverse the PTT motor leads between the battery terminals to fully extend the tilt ram T R Manual valve 1 2 N...

Page 199: ... CAUTION After tilting the outboard motor up be sure to support it with the tilt stop lever 2 Install the collars and bushings 3 Lift the power trim and tilt unit up and then install the upper mounting shaft 2 4 Install the circlip 3 5 Install the lower mounting shaft 4 and then install the circlips 5 6 Route the PTT motor leads through the hole and then install the holders and plastic ties 7 Conn...

Page 200: ... reservoir NOTE If the fluid is at the correct level the fluid should overflow out of the filler hole when the reservoir cap is removed 8 If necessary add sufficient fluid of the recommended type to the correct level 9 Install the reservoir cap and then tighten it to the specified torque NOTE Repeat this procedure until the fluid remains at the correct level Power trim and tilt electrical system 7...

Page 201: ...d to the positive battery terminal and the black B lead to the negative battery terminal as shown 7 Check for continuity between terminals 1 and 3 Replace if there is no continu ity Checking the power trim and tilt switch 1 Check the power trim and tilt switch for continuity Replace if out of specification Power trim and tilt relay continuity Sky blue Sb Black B Light green Lg Black B Continuity T...

Page 202: ...e trim sensor 1 Measure the trim sensor resistance Replace if out of specification NOTE Turn the lever 1 and measure the resistance as it gradually changes Trim sensor resistance Pink P Black B 238 8 378 8 Ω at 20 C 68 F a 9 11 Ω at 20 C 68 F b ...

Page 203: ... cooling water temperature sensor 8 9 Checking the oil pressure switch 8 9 Checking the shift position switch 8 9 Checking the main and fuel pump relay main control 8 10 Fuel control system 8 10 Checking the injectors 8 10 Checking the electric fuel pump 8 10 Checking the main and fuel pump relay fuel control 8 11 Starting system 8 11 Checking the fuses 8 11 Checking the starter relay 8 11 Starter...

Page 204: ...vice tools 8 Ignition tester 90890 06756 Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 Test harness 2 pins 90890 06792 Test harness 3 pins 90890 06791 Test harness 6 pins 90890 06848 Vacuum pressure pump gauge set 90890 06756 ...

Page 205: ...touch any of the connections of the digital tester leads NOTE Use the peak voltage adapter with the digi tal circuit tester When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode Connect the positive pin on the peak volt age adapter to the positive terminal of the digital circuit tester Measuring the lower resistance When measuring a resistance of 10 ...

Page 206: ...ctrical components 8 Port view 1 Idle speed control 2 Sensor assembly intake air temperature and intake air pressure 3 Pulser coil 4 Oil pressure switch 5 Fuel injector 6 Electric fuel pump 7 Throttle position sensor S6D88010 1 7 2 6 5 3 4 5 ...

Page 207: ...6D93G11 8 4 1 2 3 4 5 6 7 8 9 Starboard view 1 Ignition coil 2 Cooling water temperature sensor 3 Starter motor 4 Junction box 5 Spark plug S6D88020 1 5 2 3 4 Electrical components ...

Page 208: ...rol 4 Throttle position sensor 5 Rectifier Regulator 6 Power trim and tilt relay 7 Starter relay 8 Main and fuel pump relay 9 Fuse 20A ECM ignition coil electric fuel pump and fuel injector 0 Fuse 20A main switch and power trim and tilt switch A Fuse 20 A Rectifier Regulator B Fuse 30 A starter relay S6D88030 6 7 8 9 0 A B 1 3 2 4 5 ...

Page 209: ...view 1 Fuel injection 2 Shift position switch 3 Sensor assembly intake air temperature and intake air pressure 4 Idle speed control 5 Stator coil 6 Power trim and tilt switch 7 Starter motor S6D88040 1 3 4 2 5 6 7 Electrical components ...

Page 210: ...caps Keep flammable gas or liquids away since this test can produce sparks NOTE The ignition spark can also be checked using the Stationary test of the Yamaha Diagnos tic System Checking the spark plug wires 1 Remove the spark plug wires from the spark plugs 2 Remove the spark plug wires from the ignition coils 3 Measure the spark plug wire resistance Replace if out of specification Checking the i...

Page 211: ...oosen the pulser coil screw Checking the sensor assembly 1 Measure the ambient temperature Ignition coil resistance Primary coil Red R Black white B W 1 53 2 07 Ω at 20 C 68 F Secondary coil 12 495 16 905 kΩ at 20 C 68 F Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 Test harness 2 pins 90890 06792 ECM output peak voltage Black red B R Ground Black white B W Ground r min Loa...

Page 212: ...esistance Replace if out of spec ification Checking the oil pressure switch 1 Check the oil pressure switch for continu ity Replace if there is no continuity 2 Connect the special service tool to the oil pressure switch 3 Slowly operate the special service tool 4 Check the oil pressure switch for no con tinuity at the specified pressure Replace if there is continuity Checking the shift position sw...

Page 213: ...en the relay terminals 2 and 3 after dis connecting a battery terminal from the relay terminal 4 or 5 Replace if there is continuity Fuel control system 8 Checking the injectors 1 Measure the resistance of the fuel injec tors NOTE Check the operation of the fuel injectors using the Stationary test of the Yamaha Diagnostic System Checking the electric fuel pump 1 Turn the engine start switch to ON ...

Page 214: ... no continuity 6 Check that there is no continuity between the relay terminals 2 and 3 after dis connecting a battery terminal from the relay terminal 2 or 4 Replace if there is continuity Starting system 8 Checking the fuses 1 Check the fuses for continuity Replace if there is no continuity Checking the starter relay 1 Connect the digital circuit tester leads to the starter relay terminals 2 Conn...

Page 215: ...6D93G11 8 12 1 2 3 4 5 6 7 8 9 S60V8265 Br B Fuel control system Starting system ...

Page 216: ... pinion 1 4 Spring 1 5 Bolt 2 M6 35 mm 6 Housing 1 7 Bearing 1 8 Clutch assembly 1 9 E clip 1 Not reusable 10 Washer 1 11 Bracket 1 12 Pinion shaft 1 13 Planetary gear 3 14 Outer gear 1 15 Plate 1 16 Armature 1 17 Stator 1 S63P8050 24 25 23 21 20 18 17 16 15 7 8 9 10 11 26 12 13 14 27 29 31 28 6 5 4 3 2 1 22 19 19 19 19 30 ...

Page 217: ...Brush holder 1 21 Plate 1 22 Washer 1 23 Bracket 1 24 Screw 2 ø4 15 mm 25 Bolt 2 M6 120 mm 26 Rubber seal 1 27 Shift lever 1 28 Spring 1 29 Magnet switch assembly 1 30 Washer 1 31 Nut 1 S63P8050 24 25 23 21 20 18 17 16 15 7 8 9 10 11 26 12 13 14 27 29 31 28 6 5 4 3 2 1 22 19 19 19 19 30 Starter motor ...

Page 218: ...ce if necessary NOTE Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place Checking the armature 1 Check the commutator for dirt Clean with 600 grit sandpaper and com pressed air if necessary 2 Measure the commutator diameter Replace the armature if below specifica tion 3 Measure the commutator undercut a Replace the armature if b...

Page 219: ...agnet switch terminals Replace if there is no continuity 5 Check that there is no continuity after the negative battery terminal is removed Replace if there is continuity NOTE The starter motor pinion should be pushed out while the magnet switch is on Checking the starter motor operation 1 Check the operation of the starter motor after installing it onto the power unit Charging system 8 Checking t...

Page 220: ...low specification measure the stator coil output peak voltage Replace the Rectifier Regulator if the output peak voltage of the stator coil is above specifi cation Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 Test harness 6 pins 90890 06848 Stator coil output peak voltage White W White W r min Unloaded Cranking 1 500 3 500 DC V 12 4 45 3 98 3 Stator coil resistance referen...

Page 221: ...3 4 5 6 7 8 9 Troubleshooting Special service tools 9 1 Yamaha Diagnostic System 9 2 Introduction 9 2 Power unit 9 5 Bracket unit 9 13 Electrical systems 9 17 Self diagnosis 9 18 Diagnosing the electronic control system 9 18 ...

Page 222: ...roubleshooting 9 1 6D93G11 Special service tools 9 Yamaha Diagnostic System 60V 85300 02 Yamaha Diagnostic System 60V WS853 02 Diagnostic flash indicator B 90890 06865 YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL ...

Page 223: ...iagnostic codes that have been recorded are displayed This allows you to check the outboard motor s record of malfunctions 3 Engine monitor Each sensor status and the ECM data are displayed while the engine is run ning This enables you to find malfunctioning parts quickly 4 Stationary test With the engine off the ignition fuel injection electric fuel pump and ISC valve are checked These tests can ...

Page 224: ...isplay VGA 640 480 pixels SVGA 800 600 pixels or more recommended 256 or more colors Mouse Compatible with the operating systems mentioned above Communication port RS232C Dsub 9 pin port USB port Printer Compatible with the operating systems mentioned above NOTE The amount of memory and the amount of free space on the hard disk differs depending on the computer Using this software while there is n...

Page 225: ...6D93G11 9 4 1 2 3 4 5 6 7 8 9 Connecting the communication cable to the outboard motor Bow view S6D89010 3 pin communication coupler Yamaha Diagnostic System ...

Page 226: ...e a malfunctioning sensor or switch use the diagnostic flash indicator to determine the cause Power unit 9 Symptom Engine does not crank Check the starting system Check the power unit Check that the gearshift is in the neutral position Check the engine start switch for continuity Is the gearshift in neutral Is there continuity Set it to the neutral position Replace the engine start switch Yes Yes ...

Page 227: ...tion sound of the starter relay Check the power unit Can the operation sound be heard Yes Yes No Is there continuity Replace the fuse Yes No Disassemble and check the starter motor 8 15 8 16 No Check the starter motor opera tion Replace the wiring harnesses Is there continuity Yes No Good operating condition Power unit ...

Page 228: ...moved spark plug caps Keep flammable gas or liquids away since this test can produce sparks No Yes Check that the spark plugs pro duce sparks No Yes Are there sparks Check the pulser coil output peak voltage 8 8 Check the ignition spark using the ignition tester 8 7 Good spark Check the ignition coil resis tance 8 7 Within specification No Replace the ignition coil Yes Check the spark plug wire re...

Page 229: ...ain Check the compression pres sure of the combustion chamber 5 3 Check the valve clearance 5 10 Adjust the valve clearance Yes Yes Yes Yes No No No No Check the cylinder head cylin der block and piston assembly Wet spark plugs Start the engine using dried or new spark plugs Yes No Check the fuel system Yes No Replace the main and fuel pump relay Is there continuity Check the main and fuel pump re...

Page 230: ...em from the fuel tank to the fuel filter Check the fuel hose for kinks or fuel leakage No Yes Yes No Check that the fuel vent screw of the fuel tank is open Yes Replace the defective parts Check the fuel pressure 4 13 No Within specification Yes No Check the fuel injector resistance 8 10 Within specification Yes No Replace the fuel injector Check the fuel system using the Yamaha Diagnostic System ...

Page 231: ...h any of the connections of the ignition tester leads Do not let sparks leak out of the removed spark plug caps Keep flammable gas or liquids away since this test can produce sparks Good spark Yes No Within specification No Yes Good condition Replace the spark plug wire No Yes Check the ECM output peak voltage 8 8 Is there air intake Replace the defective seals Check the compression pres sure of t...

Page 232: ... buzzer is sounding Check the cooling system Check the lubrication system Cooling system Check the cooling water inlet for clogs or debris 3 8 Check that cooling water is discharged from the cooling water pilot hole Replace the thermostat Check the water pump impeller for cracks or wear Check the water passage for clogs or debris Clogs or debris Is water discharged Clean the cooling water inlet Ye...

Page 233: ...pressure 5 3 Check the oil pressure switch 8 9 Clean or replace the defective parts At specified level Within specification Check the oil passage Yes Yes No No Yes Yes No No Add engine oil to the correct level Replace the oil pressure switch Check the engine using the Yamaha Diagnostic System Good condition Debris or leaks Power unit ...

Page 234: ...n sound be heard Can the operation sound be heard Replace the power trim and tilt relay Check the voltage between the sky blue Sb lead and light green Lg lead Check the voltage between each terminal of the PTT relay coupler when pushing the power trim and tilt switch Between the sky blue Sb lead and black B lead Between the light green Lg lead and black B lead Yes No Yes No Yes No No Yes Continued...

Page 235: ... gears etc Clean or replace the filters No Yes No Yes Add fluid to the correct level At specified level Yes No Disassemble the power trim and tilt unit and then check the filter for debris or dirt Clogs or debris Stuck foreign substance or clogs Check the power trim and tilt fluid level Close the valve Is it closed Yes No Bracket unit ...

Page 236: ...l Close the valve Add fluid to the correct level At specified level Is it closed Yes Yes No No Check the fluid passages for clogs or debris Clean the passages Check the internal parts valves pistons gear etc Clean or replace the filters No Yes No Yes Disassemble the power trim and tilt unit and then check the fil ters for debris or dirt Clogs or debris Stuck foreign substance or clogs ...

Page 237: ...d Check the shift cables and links of the remote control box Check the shift mechanism on the bottom cowling detent spring ball Good operating condition Good operating condition Yes Yes Yes No No No Check the shift cable operation Disassemble the lower case and then check the operation of the dog clutch Check the dogs of the forward gear and reverse gear for cracks and wear Yes No Check the dog cl...

Page 238: ...ging system Measure the Rectifier Regulator output peak voltage Replace the stator coil Within specification Within specification Replace the Rectifier Regulator Yes Yes No No Measure the output peak voltage of the stator coil Replace the battery and then check the voltage of all electri cal equipment on your boat ...

Page 239: ...h pattern of the special service tool to determine if there are any malfunctions Normal condition no defective part or irregular process ing is found Single flash is given every 4 95 sec onds a Light on 0 33 second b Light off 4 95 seconds Trouble code indication Example The illustration indicates code number 23 a Light on 0 33 second b Light off 4 95 seconds c Light off 0 33 second d Light off 1 ...

Page 240: ... the pattern of the next lowest num bered problem This continues until all of the problems are detected and corrected Code Symptom 1 Normal 13 Incorrect pulser coil signal 15 Incorrect cooling water temperature sensor signal 18 Incorrect throttle position sensor signal 19 Incorrect battery voltage 23 Incorrect sensor assembly intake air temperature signal 28 Incorrect shift position switch signal ...

Page 241: ... 8 Checking the cooling water pilot hole 1 9 Checking the cooling water temperature sensor 8 9 Checking the crankpin oil clearance 5 44 Checking the crankshaft 5 44 Checking the crankshaft journal oil clearance 5 47 Checking the cylinder bore 5 42 Checking the cylinder head 5 32 Checking the diaphragm and valves 4 6 Checking the drive shaft 6 18 Checking the drive shaft bushing 7 13 Checking the E...

Page 242: ... sensor 7 47 Checking the valve clearance 5 10 Checking the valve guides 5 28 Checking the valve lifters 5 27 Checking the valve seat 5 29 Checking the valve springs 5 27 Checking the valves 5 27 7 39 Checking the vapor separator 4 16 Checking the water pump and shift rod 6 9 Clamp brackets and swivel bracket 7 19 Control system 3 8 Cylinder block 5 40 Cylinder head 5 24 D Diagnosing the electroni...

Page 243: ... 7 45 Power trim and tilt motor 7 25 Power trim and tilt unit 7 23 Power unit 2 3 3 4 5 3 9 5 Predelivery checks 1 6 Propeller selection 1 5 Propeller shaft housing 6 10 Propeller size 1 5 R Reducing the fuel pressure 4 13 Refacing the valve seat 5 30 Removing the clamp brackets 7 21 Removing the cylinder head 5 26 Removing the drive shaft 6 17 Removing the exhaust cover 5 39 Removing the fuel hos...

Page 244: ...Index i 4 6D93G11 U Upper case 7 6 V Vapor separator 4 10 Ventilation 1 3 Y Yamaha Diagnostic System 9 2 ...

Page 245: ...6D93G11 i 5 1 2 3 4 5 6 7 8 9 Index MEMO ...

Page 246: ...tch O Sensor assembly P Fuel injector Q Idle speed control R Variable trolling RPM switch optional È To warning indicator É To remote control box switch panel Ê To personal computer for diagnosis Ë To diagnostic flash indicator special service tool Ì To Variable trolling RPM switch Í To trim meter Color code B Black Br Brown G Green L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y...

Page 247: ......

Page 248: ...YAMAHA MOTOR CO LTD Printed in the Netherlands Nov 2004 1 2 1 CR E ...

Page 249: ... 2 3 1 1 2 2 1 1 2 3 1 2 3 1 2 3 3 1 2 2 1 3 20A 20A 20A 30A B Gy Gy P B P Lg Sb R W L L Y L W P W O W B W Pu R Pu B B R G Y G R G B W B G L W B R B W B W R Y B R R Y R B W B B B Y B B R P B P W R R R R R R R R R Lg Sb G Br W Y P B R R R R B Br Br W Br Br Br Lg B Sb Lg Sb B B B B Lg Sb Lg Sb Lg Sb R Sb R Sb Lg R Sb R Sb Lg R Sb Lg R Sb Lg Lg Lg R Sb Lg R Sb Lg B B B R R R W W W B L B L L G Y B R R...

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