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Yamaha F90D, Service Manual

The Yamaha F90D Service Manual is a comprehensive and essential resource for owners of this powerful outboard motor. Packed with detailed instructions and diagrams, this manual allows users to troubleshoot, maintain, and repair their F90D with ease. Download the free manual from manualshive.com and unleash the full potential of your Yamaha F90D.

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BRKT

Bracket unit

7-15

6D81G11

Assembling the upper case

1.

Install the drive shaft bushing into the
upper case, and then install the circlip.

2.

Install the muffler assembly 

3

 by insert-

ing the tip of the water pipe 

4

 into the

joint hole 

a

 of the upper case.

3.

Install the muffler assembly bolts 

5

, and

then tighten them to the specified torque.

Installing the upper case

1.

Install the upper mount 

1

 and bolts 

2

into the upper case.

2.

Install the bolts 

3

, and then tighten them

to the 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.

Drive shaft needle bearing installer 
and remover 

1

:

YB-06196

Driver handle (large) 

2

:

YB-06071

Muffler assembly bolt 

5

:

20 N·m (2.0 kgf·m, 14.8 ft·lb)

S6D87180

2

1

WR-No.1

S6D87190

A

A

A

A

A

LT

572

LT

572

5

3

4

4

LT

271

LT

a

T

 

R

.

.

Upper mount bolt 

3

:

28 N·m (2.8 kgf·m, 20.7 ft·lb)

S6D87590

LT

572

LT

572

A

1

2

3

S6D87200

A

4

Summary of Contents for F90D

Page 1: ...F90D SERVICE MANUAL 6D8 28197 1G 11 LIT 18616 02 86 LIT186160286 ...

Page 2: ... 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 de...

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: ...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 5: ...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 6: ...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 7: ...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 8: ...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 9: ...speed acceleration 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 e...

Page 10: ...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 11: ... 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 position...

Page 12: ... 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 13: ...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 14: ... 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 15: ...operating range r min 5 000 6 000 Maximum fuel consumption L US gal Imp gal hr 33 0 8 72 7 26 at 6 000 r min Engine idle speed r min 700 50 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 Starting system Electric Fuel system Fuel injection Ignition ...

Page 16: ...ut 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 GEAR CASE LUBE Gear oil grade 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 Reduction gear typ...

Page 17: ...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 47 1...

Page 18: ...mm in 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 m...

Page 19: ...7 0 0598 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...

Page 20: ...lly open temperature C F 70 158 Valve open lower limit mm in 4 3 0 17 Item Unit Model F90TR 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 F90TR Ignition and ignition control system Spark plug gap mm in 1 0 1 1 0 039 0 043 Ignition coil resistance at 20 C ...

Page 21: ...engine 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...

Page 22: ...e R Ground 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 fi...

Page 23: ...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 6 204 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 24: ...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 25: ... 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 26: ... 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 51...

Page 27: ...re 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 0 4 3 0 Trim cyli...

Page 28: ...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 29: ...K ADJ Periodic checks and adjustments 3 1 6D81G11 Special service tools 3 Digital tachometer YU 39951 B Battery powered timing light YM 33277 A Pressure vacuum tester YB 35956 A Oil filter wrench YU 38411 ...

Page 30: ... 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 38 Power trim and tilt unit Check 3 11 Propeller and cotter pin Check replace 3 13 Shift link shift cable...

Page 31: ... 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 32: ...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 33: ...d correct 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 Instal...

Page 34: ...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 35: ...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 36: ...passage 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 t...

Page 37: ...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 38: ...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 39: ...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 40: ...commended 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 ...

Page 41: ... is 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 cra...

Page 42: ... 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 43: ...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 44: ...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 45: ...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 15 Installing the fuel hose clamp 4 15 Disassembling the vapor separator 4 15 Checking the va...

Page 46: ...FUEL Fuel system 4 1 6D81G11 Special service tools 4 Pressure vacuum tester YB 35956 A Fuel pressure gauge YB 06766 Fuel pressure gauge adapter B YB 06942 ...

Page 47: ...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 48: ...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 49: ... 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 50: ...outlet 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...

Page 51: ...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 52: ...take silencer 1 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 S6D84040 2 1 3 3 15 4 14 13 12 7 11 5 10 8 9 6 ...

Page 53: ...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 1 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 54: ...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 55: ... 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 56: ...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 57: ...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 58: ...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 59: ...efore disconnecting the quick connector release the fuel pressure 2 Connect fuel pressure gauge adapter B between the quick connector and fuel rail 3 Connect the fuel pressure gauge to fuel pressure gauge adapter B 4 Disconnect the pressure regulator hose and then connect the special service tools to the pressure regulator WARNING When connecting the fuel pressure gauge first cover the connection ...

Page 60: ...rized fuel may spray out 3 Place a container under the vapor sepa rator drain hose and then loosen the drain screw 2 4 Drain the fuel from the vapor separator drain hose by pressing the pressure check valve using a thin screwdriver WARNING Reduce the fuel pressure before loosen ing the vapor separator drain screw or pressurized fuel will spray out and may result in serious injury Removing the fuel...

Page 61: ...ean if necessary Assembling the vapor separator 1 Install the needle valve float and float pin and then check the float for smooth operation NOTE Do not reuse the float pin always replace it with a new one Install the float pin in the direction of the arrow a shown Install the float pin with its tapered end towards the punch mark b on the vapor separator cover 2 Check the float height c as shown A...

Page 62: ...float chamber Adjusting the float 1 Adjust the stopper a of the float by bending it until the float height b is within specification 2 Adjust the lever c of the float by bending it until the float height d is within specifi cation 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 T R Float chamber screw 3 N m 0 3 kgf m 2 2 ft lb Float height b 46 ...

Page 63: ...6 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 Vapor separator Canister ...

Page 64: ... the special 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 Pressure vacuum tester YB 35956 A Specified pressure 19 6 kPa 0 196 kgf cm2 2 8 psi S6D84160 1 ...

Page 65: ...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 31 Checking the cylinder head 5 32 Installing the valves 5 33 Installing the cylinder...

Page 66: ...rings 5 41 Checking the piston ring grooves 5 42 Checking the piston ring side clearance 5 42 Checking the connecting rod big end side clearance 5 43 Checking the crankshaft 5 43 Checking the crankpin oil clearance 5 43 Selecting the connecting rod bearing 5 45 Checking the crankshaft journal oil clearance 5 46 Selecting the main bearing 5 47 Assembling the power unit 5 49 Installing the power uni...

Page 67: ...ion YB 06563 Flywheel magnet holder YB 06139 Universal puller YB 06117 Crankshaft holder YB 06552 Valve spring compressor YM 01253 Valve spring compressor attachment YB 06320 Valve guide remover installer YM 04064 A Valve guide reamer YM 04066 Neway valve seat kit YB 91044 Piston ring compressor YM 08037 ...

Page 68: ...6D81G11 5 2 1 2 3 4 5 6 7 8 9 Oil filter wrench YU 38411 Special service tools ...

Page 69: ... engine 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 ...

Page 70: ...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 71: ...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 72: ...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 73: ... 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 74: ... 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 75: ... 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 76: ...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 77: ...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 78: ...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 79: ...t 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 80: ...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 81: ...he 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 the...

Page 82: ...to improve working efficiency 1 Remove the flywheel magnet cover 2 Disconnect the battery leads and trim sensor coupler 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...

Page 83: ...the 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 bolt...

Page 84: ...e 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 magnet holder YB 0613...

Page 85: ... that 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 8 YB 06552 T R Drive sprocket nut...

Page 86: ...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 87: ...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 88: ... 7 Bolt 2 M6 20 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 S6D85060 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 ECM Junction box ...

Page 89: ...ion box 1 20 Collar 5 21 Grommet 5 22 Bolt 2 M6 10 mm 23 Clamp 1 24 Grommet 1 S6D85060 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 ...

Page 90: ...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 91: ...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 92: ...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 93: ...on 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 YM 01253 Valve spring compressor attachment 9 YB 06320 Valve spring free length a 5...

Page 94: ...Replacing 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 ins...

Page 95: ...e diameter 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 s...

Page 96: ...e seat Be sure to turn the cutter evenly downward at a pres sure of 40 50 N 4 5 kgf 8 8 11 lbf to prevent chatter marks 3 Use a 30 cutter to adjust the contact width of the top edge of the valve seat b Previous contact width 4 Use a 60 cutter to adjust the contact width of the bottom edge of the valve seat b Previous contact width Valve seat contact width a 1 20 1 60 mm 0 0472 0 0630 in Neway valv...

Page 97: ...enter 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 bottom edge of the valve seat If neces sary use a 45 cutter to center the area and set its width b Previous contact width 9 Apply a thin even layer of lapping com pound onto the valve seat and then lap the valve usi...

Page 98: ...cylinder head warpage using a straightedge 1 and thickness gauge 2 in the directions shown Replace if above specification 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 Exhaust 29 92 30 08 mm 1 1780 1 1842 in Camshaft runout limit 0 03 mm 0 0012 in S6D85450 Camshaft journal diameter c 24 960 24 980 mm 0 98...

Page 99: ...valve spring and then install the valve cotters 8 using a thin screwdriver with a small amount of grease applied to it 4 Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters securely Installing the cylinder head 1 Check that the piston of cylinder 1 is at TDC 2 Install a new gasket and the cylinder head and then tighten the bolts to the specified torques in the sequ...

Page 100: ...oil to the valve shims and valve lifters before installation Install the valve shims and valve lifters in their original positions 4 Install the camshaft intake 1 and cam shaft exhaust 2 with the new oil seals 3 NOTE Apply molybdenum disulfide grease to the cam lobes Be sure to install the camshaft with the fuel pump drive cam b on the intake side 5 Check that the camshaft dowel holes c are in the...

Page 101: ... bolts before installation 8 Install the cylinder head cover 9 Install the sprockets and timing belt NOTE For sprocket and timing belt installation pro cedures see Installing the sprockets and timing belt T R Camshaft cap bolt 1st 8 N m 0 8 kgf m 5 9 ft lb 2nd 17 N m 1 7 kgf m 12 5 ft lb S6D85510 5 2 A 1 1 A 7 2 A 2 2 A 3 2 A 4 2 A 5 2 A 8 2 A 9 2 A 10 2 A 6 1 A 6 7 8 9 10 1 1 A 1 2 3 4 5 T R Cyli...

Page 102: ...able 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 271 T R 2 N m ...

Page 103: ...reusable 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 kg...

Page 104: ...he 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 exhaust cove...

Page 105: ...il seal 1 Not 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 S6D85100 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...

Page 106: ...t 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 specification ...

Page 107: ...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 3 Check the piston ring end gap d at the specified measuring point Replace if out of specification Cylinder bore D1 D6 79 000 79 020 mm 3 1102 3 1110 in Taper limit D1 D5 di...

Page 108: ...ing 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 Piston ring groove Top ring a 1 23 1 25 mm 0 048 0 049 in Second ring b 1 52 1 54 mm 0 060 0 061 in Oil ring c 2 51 2 53 mm 0 099 0 100 in S63P5720 a b c Piston ring side clearance Top ring a 0 04 0 08 mm 0 0016 0 0031 in Second ring b...

Page 109: ...cation 2 Measure the crankshaft runout Replace the crankshaft if above specification Checking the crankpin oil clearance 1 Clean the bearings and the connecting rod 2 Install the upper bearing into the con necting rod 1 and the lower bearing into the connecting rod cap 2 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 88...

Page 110: ... 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 measurement has been completed S60C5960 1 2 T R Connecting ...

Page 111: ...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 5 Select the suitable color b for the con necting rod bearing...

Page 112: ...l 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 to the crankshaft NOTE Do not put the Plastigauge PG 1 over the oil hole in the main journals of the crankshaft 5 Install the remaining half of t...

Page 113: ...nkcase 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 main bearing select the suitable bearing as follows 2 Check the crankshaft journal mark on the crankshaft 1 and the cylinder block mark on the cylinder block 2 3 Subtract crankshaft journal diameters 1 5 f...

Page 114: ...ain 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 thrust bearing blue Bearing crankcase side blue 5 If the calculated value is more than ...

Page 115: ...con necting 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 o...

Page 116: ...aces towards the flywheel magnet side of the 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...

Page 117: ...on procedure see Installing the cylinder head 13 Install all parts removed during disas sembly 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 T R Cra...

Page 118: ...hen adjust their lengths For adjustment procedures 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 Posit...

Page 119: ...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 120: ... YB 06207 Universal puller YB 06117 Slide hammer YB 06096 Bearing puller legs YB 06523 Bearing housing needle bearing remover YB 06112 YB 06153 Driver handle large YB 06071 Propeller shaft oil seal installer YB 06269 Drive shaft needle bearing depth stop YB 34473 Bearing outer race attachment YB 06109 ...

Page 121: ...rward gear bearing cup installer YB 06276 B Forward gear outer race installer YB 06085 Shift rod push arm YB 06052 Pinion shim selecting tool YB 34432 9 YB 34432 10A YB 34432 11A YB 34432 17 Forward gear shim selecting tool YB 34446 1 YB 34446 3 YB 34446 5 YB 34446 7 Backlash indicator rod YB 06265 Backlash adjustment plate YB 07003 Special service tools ...

Page 122: ...LOWR Lower unit 6 3 6D81G11 Dial indicator gauge YU 03097 Magnetic base stand YU A8438 ...

Page 123: ...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 124: ...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 125: ... 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 126: ... 6 7 6D81G11 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 127: ...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 128: ...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 129: ... clutch 1 4 Spring 1 5 Propeller shaft 1 6 Shim 1 0 3 mm 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 130: ...assembly Disassembling the propeller shaft assembly 1 Remove the spring 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 CAUTION Do not reuse the bearing always replace it with a new one Gland nut wrench 1 YB 34447 Bearing housing puller 2 YB 06207 Universal puller...

Page 131: ...ng 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 Slide hammer 2 YB 0609...

Page 132: ...alfway into the propeller shaft housing then the other oil seal 3 Install the thrust washer 5 and new ball bearing 6 to the reverse gear 7 using a press NOTE Install the ball bearing with the manufacture identification mark d facing outward propel ler side 4 Install the reverse gear assembly into the propeller shaft housing using a press Driver handle large 1 YB 06071 Bearing housing needle bearin...

Page 133: ...6D81G11 6 14 1 2 3 4 5 6 7 8 9 Bearing outer race attachment 9 YB 06109 Propeller shaft housing ...

Page 134: ... 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 135: ...6D81G11 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 136: ...e shaft collar 4 Do not 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...

Page 137: ...ecking the bearings 1 Check 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 Slide hammer 1 YB 06096 Bearing puller legs 2 YB 06523 Slide hammer 3 YB 06096 Dr...

Page 138: ...ore installation Install the sleeve by facing the projection c 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 a press Driver handle large 1 YB 06071 Drive shaft needle bearing remover an...

Page 139: ...ighten the nut to the 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 Forward gear outer race installer 1 YB 06085 Bearing housing needle bearing remover 1 YB 06112 Driver handle large 2 YB 06071 Depth a 1 20 0 25 mm 0 05 0 01 in General pipe 1 a 33 mm 1 30 in b ...

Page 140: ...ly Installing the water 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 Gland nut wrench 9 YB 34447 T R R...

Page 141: ...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 142: ...it 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 YB 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 143: ...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 144: ...LOWR Lower unit 6 25 6D81G11 Shimming 6 ...

Page 145: ...e backlash when the unit is assembled Example If P is 5 then M0 0 20 5 100 mm 0 20 0 05 mm 0 25 mm If P is 5 then M0 0 20 5 100 mm 0 20 0 05 mm 0 15 mm 2 Install the drive shaft and drive shaft bearing 1 to the special service tools 3 Attach the clamp 2 to the gauge base using the bolts of an appropriate size NOTE Tighten the clamp bolts another 1 4 of a turn after they contact the clamp 2 4 Insta...

Page 146: ...the lower case dimen sion from standard The F mark a is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is unreadable assume that F is zero and check the backlash when the unit is assembled Example If F is 5 then M0 1 61 5 100 mm 1 61 0 05 mm 1 66 mm If F is 5 then M0 1 61 5 100 mm 1 61 0 05 mm 1 56 mm 2 Install the taper roller bearing 1 onto the special ...

Page 147: ...cedure 2 Set the gear shift to the neutral position at the lower unit 3 Install the special service tools so that it pushes against the propeller shaft NOTE Tighten the universal puller while turning the drive shaft until the drive shaft can no longer be turned Forward gear shim selecting tool YB 34446 1 2 YB 34446 3 3 YB 34446 5 4 YB 34446 7 5 Calculation formula Forward gear shim thickness T1 M0...

Page 148: ... each direction 6 Add or remove shim s if out of specifica tion M Measurement 7 Remove the special service tools and then install the water pump assembly Backlash indicator rod 3 YB 06265 Backlash adjustment plate 4 YB 07003 Dial indicator gauge 5 YU 03097 Magnetic base stand 6 YU A8438 Forward gear backlash 0 28 0 63 mm 0 0110 0 0248 in Forward gear backlash Shim thickness Less than 0 28 mm 0 011...

Page 149: ... 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 150: ...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 151: ...staller YB 41446 Bearing cup installer YB 06167 Driver handle large YB 06071 Driver handle small YB 06229 Roller bearing installer remover YB 06432 Oil seal installer YB 06023 Drive shaft needle bearing installer and remover YB 06196 Trim cylinder wrench YB 06175 2B ...

Page 152: ...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 153: ...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 154: ...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 155: ...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 156: ...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 157: ... 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 S6D87040 T R 4 N m 0 4 kgf m 3 0 ft Ib 12 WR No 1 WR No 1 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 1 ...

Page 158: ...Drain bolt 1 M14 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 S6D87050 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 1 Upper case ...

Page 159: ...rclip 1 22 Lower mount 2 23 Washer 2 24 Washer 2 25 Washer 2 26 Bolt 2 M12 200 mm S6D87050 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 1 ...

Page 160: ... 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 161: ...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 162: ...pump Checking 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 ...

Page 163: ...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 Roller bearing installer remover 4 YB 06432 Driver handle large 2 YB 06071 T R Oil pump cover screw 4 N m 0 4 kgf m 3 0 ft lb S6D...

Page 164: ...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 165: ...r case 2 Install the bolts 3 and then tighten them to the 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 Drive shaft needle bearing installer and remover 1 YB 06196 Driver handle large 2 YB 06071...

Page 166: ...ghten them to the specified torque NOTE When installing the oil pump 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 5...

Page 167: ...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 168: ... 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 169: ...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 170: ... 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 171: ...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 172: ...lower 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 P B S63P725...

Page 173: ...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 174: ...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 175: ...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 176: ...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 177: ... 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 178: ...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 179: ... 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 180: ...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 181: ... 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 182: ...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 183: ...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 184: ...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 185: ...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 186: ... 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 187: ...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 188: ...rain the power trim and tilt 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 Trim c...

Page 189: ...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 190: ...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 191: ...p Z Assembling 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 Trim cylinder wrench YB 06175 2B T R...

Page 192: ...ylinder 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 10 Install the reservoir cap 9 Recommended power trim and tilt fluid ATF Dexron II T R PTT motor bolt 4 N m 0 4 kgf m 3 0 ft ...

Page 193: ...ufficient 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 m 0 2 kgf m 1 5 ft lb Recommended power trim and...

Page 194: ...im 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 Connect the ground lead 6 Bleeding the power trim and tilt unit built in 1 Fully turn the manual valve counterclock wise 2 Fully tilt the outboard mot...

Page 195: ... torque NOTE Repeat this procedure until the fluid remains at the correct level Power trim and tilt electrical system 7 Checking the fuse 1 Check the fuse for continuity Replace if there is no continuity Checking the power trim and tilt relay 1 Check the power trim and tilt relay for continuity Replace if out of specification NOTE Be sure to set the measurement range a shown in the illustration wh...

Page 196: ...e 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 Checking the trim sensor 1 Measure the trim sensor resistance Replace if out of specification NOTE Turn the lever 1 and measure the resistance as it gradually cha...

Page 197: ... 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 198: ...G11 Special service tools 8 Spark checker YM 34487 Digital multimeter YU 34899 A Peak volt meter adapter YU 39991 Test harness 2 pins YB 06792 Test harness 3 pins YB 06791 Test harness 6 pins YB 06848 Pressure vacuum tester YB 35956 A ...

Page 199: ...do not 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...

Page 200: ...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 201: ...6D81G11 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 202: ...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 203: ...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 204: ... 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 ...

Page 205: ...E Do not loosen 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 multimeter YU 34899 A Peak volt meter adapter YU 39991 Test harness 2 pins YB 06792 ECM output peak voltage Black red B R Ground Black white B W Ground r min Loa...

Page 206: ...or resistance 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 positio...

Page 207: ...ween 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 O...

Page 208: ... 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 209: ...6D81G11 8 12 1 2 3 4 5 6 7 8 9 S60V8265 Br B Fuel control system Starting system ...

Page 210: ... 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 211: ...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 212: ...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 213: ...et 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 the ...

Page 214: ...elow 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 multimeter YU 34899 A Peak volt meter adapter YU 39991 Test harness 6 pins YB 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 reference data W...

Page 215: ...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 216: ...SHTG Troubleshooting 9 1 6D81G11 Special service tools 9 Yamaha Diagnostic System 60V 85300 02 Yamaha Diagnostic System 60V WS853 02 Diagnostic test lead YB 06795 YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL ...

Page 217: ...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 218: ...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 219: ...6D81G11 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 220: ...nose a malfunctioning sensor or switch use the diagnostic test lead 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 No ...

Page 221: ...r the operation sound of the starter relay Check the power unit Can the oper ation sound be heard Yes Yes No Is there continuity Replace the fuse Yes No Replace the starter motor No Check the starter motor opera tion Replace the wiring harnesses Is there continuity Yes No Good operat ing condition Power unit ...

Page 222: ...ads Do not let sparks leak out of the removed spark plug caps Keep flammable gas or liquids away since this test can produce sparks Start the engine using dried or new spark plugs No Yes Yes No Check that the spark plugs pro duce sparks No Yes Are there sparks Check the ignition coil Check the ignition system output peak voltage Check the ignition spark using the spark checker Continued on next pa...

Page 223: ...tarting operation Failure in starting operation Check the fuel system Check the condition of the spark plugs again Check the compression pres sure of the combustion chamber Check the valve clearance Adjust the valve clearance Yes Yes Yes Yes No No No No Check the cylinder head cylin der block and piston assembly Power unit ...

Page 224: ...el system from the fuel tank to the fuel filter Check the fuel hose for kinks or fuel leakage No Yes Yes No Check that the fuel vent screw of the fuel tank is open Yes Replace the defective parts Check the fuel pressure No Within specification Yes No Check the fuel injector resistance Within specification Yes No Replace the fuel injector Check the fuel system using the Yamaha Diagnostic System Che...

Page 225: ... the ignition coils resis tance Yes Check the ignition system using the Yamaha Diagnostic System WARNING Do not touch any of the connections of the spark checker 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 Is there air intake Replace the defective seals Check the compression pres sure of the combus...

Page 226: ...rning indicator is on and buzzer is sounding Check the cooling system Check the lubrication system Cooling system Check the cooling water inlet for clogs or debris Check that cooling water is discharged from the cooling water pilot hole Replace the thermostat Check the water pump impeller Check the water passage Clogs or debris Is water discharged Clean the cooling water inlet Yes No No Yes Yes Ye...

Page 227: ...oil pressure Check the oil pressure switch 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 228: ...e oper ation sound be heard Can the oper ation 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 Y...

Page 229: ... 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 230: ...el 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 filters for debris or dirt Clogs or debris Stuck foreign substance or clogs ...

Page 231: ... case Replace the shift rod Check the shift cables and links of the remote control box Check the detent of the bottom cowling Good operat ing condition Good operat ing condition Connected properly Yes Yes Yes No No No Check the shift cable operation Disassemble the lower case and then check the operation of the dog clutch Check the forward gear and reverse gear Yes No Replace the defective parts G...

Page 232: ...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 233: ...e flash 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 ...

Page 234: ...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 29 Incorrect sen...

Page 235: ...the cooling water temperature sensor 8 9 Checking the crankpin oil clearance 5 43 Checking the crankshaft 5 43 Checking the crankshaft journal oil clearance 5 46 Checking the cylinder bore 5 41 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 ECM 8 8 Checking the electric fuel pump 8 10 Checking t...

Page 236: ...8 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 39 Cylinder head 5 24 D Diagnosing the electronic control system 9 18 Dimensions 2 9 Disassembling the cylinder block 5 40 D...

Page 237: ...lt 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 38 Removing the fuel hose clamp 4 15 Removing t...

Page 238: ...Index i 4 6D81G11 U Upper case 7 6 V Vapor separator 4 10 Ventilation 1 3 Y Yamaha Diagnostic System 9 2 ...

Page 239: ...3 1 2 2 1 1 2 3 4 2 1 4 3 321 654 2 1 1 2 321 YXWVUTSRQPONMLKJI lkjihgfedcba Z 987654321 HGFEDCBA0 2 1 4 3 4321 BA0987654321 NMLKJIHGFEDC 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 Br R B P B P P B P B P W P B P R R R R R R R R R Lg Sb G Br W Y P B R R R R B Br Br 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...

Page 240: ...h O Sensor assembly P Fuel injector Q Idle speed control R Variable trolling RPM switch optional È To warning indicator trim meter 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 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 Yellow...

Page 241: ...YAMAHA MOTOR CORPORATION USA Printed in USA Jul 2004 0 0 1 CR E ...

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