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Yamaha LZ200N, Service Manual

The Yamaha LZ200N Service Manual is a comprehensive guide that provides detailed instructions and insights for maintaining and repairing your Yamaha LZ200N product. This manual is available for free download from manualshive.com, ensuring you have the essential resource at your fingertips to keep your product in optimal condition.

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5-42

POWR

E

CYLINDER HEADS

5

5

Order

Job/Part

Q’ty

Remarks

8

Anode

7

9

Bolt

4

10

Engine hanger

2

11

Bolt

1

12

Anode cover plate

1

13

Bolt

1

14

Anode cover

1

15

Anode

1

16

Grommet

1

For installation, reverse the removal 
procedure.

8 

×

 60 mm

2nd   30 Nm (3.0 m • kgf, 22 ft • Ib)

1st

15 Nm (1.5 m • kgf, 11 ft • Ib)

6 

×

 20 mm

15 Nm (1.5 m 

•

 

kgf, 11 ft 

•

 

Ib)

E

A

A

A

6 

×

 20 mm

5 

×

 12 mm

LT

LT

LT

572

572

13

15

14

16

12

11

1

4

5

6

6

4 

×

 12 mm

7 8

5

4

2

3

1

10

9

C

9

5

1

4

8

B

A

7

3

2

6

0

F

G

H

F

E

5255

Summary of Contents for LZ200N

Page 1: ...68F 28197 Z9 A1 WORLDWIDE Z200N LZ200N Z200Y LZ200Y USA CANADA SERVICE MANUAL 290369 ...

Page 2: ...is manual Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual CAUTION USE UNLEADED STRAIGHT GASOLINE ONLY Gasoline containing lead can cause performance lose and engine damage Do not use gasoline mixed with oil premix Use YAMALUBE 2 stroke outboard oil or anoth...

Page 3: ...equired will follow the symbol e g Bearings Pitting scratches Replace To assist you in finding your way through this manual the section title and major heading is given at the top of every page MODEL INDICATION Multiple models are mentioned in this manual and their model indications are noted as fol lows ILLUSTRATIONS The illustrations within this service manual represent all of the designated mod...

Page 4: ...UR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or deathto the machine operator a bystander or a person inspecting or repairing the outboard motor CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the out board motor NOTE A NOTE provides key information to make procedures easier or clearer ...

Page 5: ...instruction charts at the same time as the exploded views These charts list the sequence that the procedures should be carried out in as well as pro viding explanations on part names quantities dimensions and important points relating to each relevant task Example O ring size 39 5 2 5 mm inside diameter D ring diameter d 5 In addition to tightening torques the dimensions of the bolts or screws are...

Page 6: ...ploded diagram indicate the grade of lubricant and the loca tion of the lubrication point F Apply Yamaha 2 stroke outboard motor oil TC W3 G Apply water resistant grease Yamaha grease A Yamaha marine grease H Apply molybdenum disulfide oil Symbols I to N in an exploded diagram indicate the grade of the sealing or locking agent and the location of the application point I Apply Gasket Maker J Apply ...

Page 7: ...NFORMATION 1 SPECIFICATIONS 2 SPEC PERIODIC INSPECTIONS AND ADJUSTMENTS 3 FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR LOWER UNIT 6 LOWR BRACKET UNIT 7 BRKT ELECTRICAL SYSTEMS 8 ELEC TROUBLE ANALYSIS 9 GEN INFO INSP ADJ TRBL ANLS ...

Page 8: ......

Page 9: ... SERIAL NUMBER 1 1 STARTING SERIAL NUMBERS 1 1 SAFETY WHILE WORKING 1 2 FIRE PREVENTION 1 2 VENTILATION 1 2 SELF PROTECTION 1 2 OILS GREASES AND SEALING FLUIDS 1 2 GOOD WORKING PRACTICES 1 3 DISASSEMBLY AND ASSEMBLY 1 4 SPECIAL TOOLS 1 5 MEASURING 1 5 REMOVING AND INSTALLING 1 8 ...

Page 10: ...cket NOTE If the serial number label is removed VOID marks will be appear on the label 1 Model name 2 Approved model code 3 Transom height 4 Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as fol lows Model name Approved model code Starting serial number Worldwide USA Canada Z200NETO Z200TR Z200TR 6G6 X 100101 LZ200NETO LZ200TR 6K1 X 100101 ...

Page 11: ...Petroleum vapor is heavier than air and is deadly if inhaled in large quantities Engine exhaust gases are harmful to breathe When test running an engine indoors maintain good ventilation SELF PROTECTION Protect your eyes with suitable safety glasses or safety goggles when grinding or when doing any operation which may cause particles to fly off Protect hands and feet by wearing safety gloves or pr...

Page 12: ...soiled wiping rag in your pocket 4 Hands and any other part of the body which have been in contact with lubri cants or lubricant contaminated cloth ing should be thoroughly washed with hot water and soap as soon as practica ble 5 To protect the skin the application of a suitable barrier cream to the hands before working is recommended 6 A supply of clean lint free cloths should be available for wi...

Page 13: ...arts with compressed air when disassembling 2 Oil the contact surfaces of moving parts before assembly 3 After assembly check that moving parts operate normally 4 Install bearings with the manufacturer s markings on the side exposed to view and liberally oil the bearings 5 When installing oil seals apply a light coating of water resistant grease to the outside diameter ...

Page 14: ...hat start with 90890 MEASURING 1 Tachometer P N YU 08036 A a 90890 06760 b 2 Fuel pressure gauge P N YB 06766 90890 06786 3 Mity vac P N YB 35956 90890 06756 4 Pressure tester P N YB 35956 90890 06762 5 Digital caliper P N 90890 06704 6 Pinion height gauge P N YB 34432 7 YB 34432 11 a 90890 06702 b 7 Shimming gauge P N YB 34446 1 YB 34446 3 YB 34446 4 YB 34446 7 YB 34446 8 8 Shimming gauge P N YB ...

Page 15: ... valve attachment P N 90890 06773 Down relief valve attachment P N 90890 06774 G Digital tester P N J 39299 a 90890 06752 b H Peak voltage adapter P N YU 39991 a 90890 03169 b I Spark gap tester P N YM 34487 a 90890 06754 b J Test harness P N YB 06443 YB 06767 YB 06768 YB 06769 YB 06779 YB 06787 YB 06788 90890 06757 90890 06767 90890 06768 90890 06769 90890 06779 90890 06787 90890 06788 K Diagnost...

Page 16: ...change in its speed by stopping the operation of the spark plug on each cylinder while the engine is in the neutral position Engine monitor Indicates information on the sensors and switches by converting it to each value while the engine is running Data logger Indicates in numeric values the engine speed throttle opening voltage oxygen density sensor voltage water temperature sensor voltage and fu...

Page 17: ... 06205 a 90890 06663 b 4 Piston ring compressor P N YU 33294 a 90890 06530 b 5 Bearing separator P N YB 06219 a 90890 06534 b 6 Guide plate stand P N 90890 06538 7 Guide plate P N 90890 06501 8 Bearing puller P N 90890 06535 9 Small universal claws P N 90890 06536 0 Ring nut wrench P N YB 34447 a 90890 06512 b A Ring nut wrench extension P N 90890 06513 1 b a 3 b a 6 7 4 b a 5 b a 2 b a 8 9 A 0 b ...

Page 18: ...2 J Driver rod P N YB 06071 90890 06604 90890 06605 90890 06606 90890 06652 K Bearing oil seal depth plate P N 90890 06603 L Bearing oil seal attachment P N YB 06194 YB 06196 YB 06246 M Bearing oil seal attachment P N YB 06195 YB 06258 N Bearing oil seal attachment P N YB 06200 O Bearing oil seal attachment P N YB 06336 P Bearing oil seal attachment P N 90890 06610 90890 06612 90890 06631 90890 06...

Page 19: ...06659 90890 06660 90890 06661 90890 06662 U Slide hammer attachment P N YB 06335 90890 06514 V End screw wrench P N YB 06548 90890 06548 W End screw wrench P N YB 06175 1A X Universal holder P N YU 01235 90890 01235 Y Sheave holder P N YS 1880 A 90890 01701 Z Universal puller P N YB 06540 90890 06540 S T U V W Y Z X ...

Page 20: ......

Page 21: ... 9 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 POWER UNIT 2 3 LOWER UNIT 2 5 ELECTRICAL 2 5 DIMENSIONS 2 9 TIGHTENING TORQUES 2 11 SPECIFIED TORQUES 2 11 GENERAL TORQUES 2 13 ...

Page 22: ...ull throttle operating range r min 4 500 5 500 Maximum fuel consumption L US gal lmp gal hr 5 500 r min 68 18 0 15 0 POWER UNIT Type 2 stroke V Number of cylinders 6 Displacement cm3 cu in 2 596 158 4 Bore stroke mm in 90 0 68 0 3 54 2 68 Compression ratio Cylinders 1 4 6 4 Cylinders 5 6 6 1 Fuel system Electronic fuel injection Fuel injection system Sequential injection Intake system Reed valve I...

Page 23: ... Hypoid gear oil SAE 90 Gear oil total quantity cm3 US oz lmp oz 980 33 1 34 5 870 29 4 30 6 BRACKET Trim angle at 12 boat transom Degree 4 16 Tilt up angle Degree 70 Steering angle Degree 32 32 DRIVE UNIT Gear shift positions F N R Gear ratio 1 86 26 14 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear view Clockwise Counterclockwise...

Page 24: ... limit mm in 0 08 0 003 Out of round limit mm in 0 05 0 002 PISTONS Piston diameter D mm in 89 845 89 869 3 5372 3 5381 Measuring point H mm in 10 0 4 Piston to cylinder clearance mm in 0 150 0 156 0 0059 0 0061 Limit mm in 0 206 0 0081 Oversize piston diameter 1st mm in 90 11 3 548 2nd mm in 90 36 3 557 PISTON RINGS Type Keystone B mm in 2 0 0 079 T mm in 2 8 0 110 End gap installed mm in 0 30 0 ...

Page 25: ...MP ID mark 68F00 Bleeding Screw type REED VALVES Reed valve stopper height a mm in 9 0 0 35 0 35 0 01 Warpage limit b mm in 0 2 0 008 THERMOSTATS Opening temperature C F 48 52 118 126 Full open temperature C F 60 140 Valve open lower limit mm in 3 0 12 ENGINE SPEED Idling speed r min 700 30 Item Unit Model Worldwide Z200NETO LZ200NETO USA Z200TR LZ200TR Canada Z200TR ...

Page 26: ...40 0 50 Reverse gear shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Item Unit Model Worldwide Z200NETO LZ200NETO USA Z200TR LZ200TR Canada Z200TR IGNITION SYSTEM Ignition timing 1 Degree ATDC 3 BTDC 17 Fuse 1 V A 12 80 Fuse 2 V A 12 30 Fuse 3 V A 12 20 Control unit B O B Y B L B Br B G B W R Y Output peak voltage lower limit cranking 1 V cranking 2 V 140 1 500 r min V 205 3 500 r min V 220 Pulser coi...

Page 27: ...age P O V 0 50 0 02 Thermo switch P B OFF ON C F 84 90 183 194 ON OFF C F 60 74 140 165 FUEL CONTROL SYSTEM Oxygen density sensor Heater resistance R W B Ω 2 100 Output voltage Gy B W V 0 0 1 0 Atmospheric pressure sensor Output voltage at 101 32 kPa P B V 3 2 4 6 Intake air temperature sensor Resistance B Y B Y kΩ 1 5 4 0 Injector driver O R Pu R O B Pu B O Y Pu Y O G Pu G O L Pu L O W Pu W Outpu...

Page 28: ...in 29 0 1 14 Wear limit mm in 28 0 1 10 Mica Standard undercut mm in 0 5 0 8 0 02 0 03 Wear limit mm in 0 2 0 01 CHARGING SYSTEM Rectifier regulator R B Output peak voltage lower limit cranking 1 V cranking 2 V 7 5 1 500 r min V 12 7 3 500 r min V 12 7 Lighting coil G G Output peak voltage lower limit cranking 1 V 7 5 cranking 2 V 8 0 1 500 r min V 12 3 500 r min V 12 Cranking 1 Open circuit volta...

Page 29: ...N mm in 150 153 5 91 6 02 POWER TRIM AND TILT SYSTEM Trim sensor Setting resistance Ω 80 12 Resistance P B Ω 582 873 Resistance O B Ω 800 1 200 POWER TRIM AND TILT MOTOR Fluid type ATF Dexron II Brushes Standard length mm in 9 8 0 39 Wear limit mm in 4 8 0 19 Commutator Standard diameter mm in 22 0 0 87 Wear limit mm in 21 0 0 83 Mica Standard undercut mm in 1 35 0 05 Wear limit mm in 0 85 0 03 It...

Page 30: ...e Z200NETO LZ200NETO USA Z200TR LZ200TR Canada Z200TR L1 mm in 613 24 1 L2 mm in 180 7 1 L4 mm in 646 25 4 L5 mm in 69 2 7 L6 mm in 1 150 45 3 L7 mm in 574 22 6 H1 mm in 1 074 42 3 H2 mm in 708 27 9 H3 mm in 211 8 3 H4 mm in 643 25 3 H6 mm in 850 33 4 H7 mm in 308 12 1 H9 mm in 835 32 9 W1 mm in 277 10 9 W5 mm in 396 15 6 ...

Page 31: ...nit Models Worldwide Z200NETO LZ200NETO USA Z200TR LZ200TR Canada Z200TR B1 mm in 125 4 4 9 B2 mm in 254 10 0 B3 mm in 163 5 6 4 B4 mm in 50 8 2 0 B5 mm in 180 7 1 B6 mm in 367 14 4 B9 mm in 18 5 0 7 C3 mm in 82 3 2 D1 mm in 13 0 5 D2 mm in 55 5 2 2 ...

Page 32: ...ch 4 0 4 2 9 Flywheel magnet assembly M20 190 19 137 Negative battery lead M8 9 0 9 6 5 Positive battery lead M8 9 0 9 6 5 Apron M6 8 0 8 5 8 Power unit mount M8 21 2 1 15 Starter relay holder M5 3 0 3 2 2 Oxygen density sensor cover M6 9 0 9 6 5 Oxygen density sensor bracket M6 14 1 4 10 Oxygen density sensor M18 49 4 9 35 Reed valve assembly M6 10 1 0 7 2 Reed valve M5 3 0 3 2 2 Reed valve stopp...

Page 33: ...screw 24 2 4 17 Upper mount M12 53 5 3 38 Lower mount M14 73 7 3 53 Exhaust manifold assembly M8 21 2 1 15 Muffler M8 18 1 8 13 Exhaust manifold M8 18 1 8 13 Lower exhaust manifold guide M8 18 1 8 13 Clamp bracket M22 15 1 5 11 Trim sensor stopper M6 2 0 2 1 4 Trim stopper 37 3 7 27 POWER TRIM AND TILT UNIT Power trim and tilt reservoir cap 8 0 8 5 8 Power trim and tilt reservoir 1 4 5 0 5 3 6 Pow...

Page 34: ...ns of this manual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached Unless other wise specified tightening torque specifica tions require clean dry threads Components should be at room tempera ture Nut A Bolt B General torque specifications Nm m kgf ft lb 8 mm M5 5 0 5 3 6 10 mm M6 8 0 8 5 8 12 mm M8 1...

Page 35: ......

Page 36: ...ION SENSOR 3 8 ADJUSTING THE ENGINE IDLING SPEED 3 9 ADJUSTING THE REMOTE CONTROL SHIFT CABLE 3 10 ADJUSTING THE REMOTE CONTROL THROTTLE CABLE 3 10 CHECKING THE DRIVE BELT 3 11 ADJUSTING THE CRANK POSITION SENSOR 3 12 COOLING SYSTEM 3 12 CHECKING THE COOLING WATER DISCHARGE 3 12 OIL INJECTION SYSTEM 3 12 CHECKING THE OIL STRAINER 3 12 SYNCHRONIZING THE OIL PUMP 3 13 AIR BLEEDING THE OIL INJECTION ...

Page 37: ...E 1 2 3 4 5 6 7 8 9 INSP ADJ GENERAL 3 18 CHECKING THE ANODES 3 18 CHECKING THE BATTERY 3 19 CHECKING THE SPARK PLUGS 3 20 LUBRICATION POINTS 3 22 ...

Page 38: ...Check Cooling water passage 1 Clean CONTROL SYSTEM Throttle valve synchronization Check adjust 3 7 Engine idling speed Check adjust 3 9 Throttle position sensor Check adjust 3 8 Remote control shift cable Check adjust 3 10 Remote control throttle cable Check adjust 3 10 Drive belt 2 Check adjust 3 11 OIL INJECTION SYSTEM Oil tank water drain Clean Oil pump lever Check adjust 3 13 POWER TRIM AND TI...

Page 39: ...attery Check charge every month 3 19 Spark plugs Clean adjust replace 3 20 Wiring and connectors Adjust reconnect Bolts and nuts Tighten Lubrication points Grease 3 22 Item Remarks Initial Every Refer to page 10 hours Break in 50 hours 3 months 100 hours 6 months 200hours 1 year ...

Page 40: ...1 4 of a turn 2 Move the top cowling hook either up or down slightly 3 Secure the bolts 4 Check the top cowling fitting and repeat the adjustment if necessary NOTE Moving the latch towards the seal will loosen the top cowling Moving the latch away from the seal will tighten the top cowling 1 3020 FUEL SYSTEM 3 CHECKING THE FUEL LINE 3 1 Check Medium pressure fuel line Cracks damage leaks Replace R...

Page 41: ...4 30 3026 3 Check Plastic locking ties Loosen Retighten or replace 4 Check Low pressure fuel line Cracks damage leaks Replace Refer to LOW PRESSURE FUEL LINE on page 4 43 3030 CHECKING THE FUEL FILTER 3 Check Fuel filter element 1 Fuel filter cup 2 Clogs cracks leaks Replace Foreign matter Clean Refer to FUEL FILTER on page 4 46 3040 1 2 ...

Page 42: ...NG THE FUEL PRESSURE MECHANICAL FUEL PUMP 3 Measure Fuel pressure sensor output voltage Out of specification Check the high pressure fuel line Measuring steps 1 Connect the test harness between the fuel pressure sensor and the wire har ness as shown 2 Start the engine 3 Measure the fuel pressure sensor out put voltage Fuel pressure medium pressure fuel line 280 360 kPa 2 8 3 6 kgf cm2 39 8 51 2 ps...

Page 43: ... or Hypoid gear oil SAE 90 1 1 3052 CHANGING THE MECHANICAL FUEL PUMP OIL 3 1 Place Container NOTE Place a container under the gear oil drain screw 2 Remove Gear oil drain screw 1 Gear oil level check screw 2 Drain the gear oil 3 Fill Gear oil Filling steps 1 Insert the gear oil tube into the drain hole and slowly fill the gear oil until oil flows out of the check hole 2 Install the gear oil level...

Page 44: ...he screws 1 clockwise for all of the cylinders 3 Close the valves 2 and turn the screws 1 for cylinder 1 2 3 5 and 6 counterclockwise 4 Connect the oil pump link rod 5 Turn in the throttle stop screw 3 until the throttle valve 4 starts opening and then turn it 1 1 2 turns in 6 Align the center of the throttle control lever cam roller 4 with the mark a and turn screw 4 1 counterclockwise 7 Disconne...

Page 45: ... the 1 throttle valve 2 Connect the test harness 3 pin as shown 3 Connect the digital tester probes to the test harness 3 pin as shown 4 Turn the engine start switch on 5 Measure the output voltage with the throttle valves fully closed 2 Adjust Throttle position sensor Adjustment steps 1 Loosen the screws 2 2 Adjust the position of the throttle posi tion sensor until the specified output voltage i...

Page 46: ...crew 1 2 Align the center of the throttle control lever cam roller 2 with the mark a Engine idling speed 700 30 r min Tachometer YU 08036 A 90890 06760 3082 1 2 a 3080 3 Turn the throttle stop screw 3 in direc tion b or c until the specified engine idling speed is obtained Direction b Engine idling speed increases Direction c Engine idling speed decreases 3 c b 3090 4 Tighten the adjustment screw ...

Page 47: ...wling 6 Adjust the position of the shift cable joint until its hole aligns with the set pin c 7 Install the clip and tighten the locknut CAUTION The remote control cable joint must be screwed in more than 8 mm 0 31 in 3120 3110 ADJUSTING THE REMOTE CONTROL THROTTLE CABLE 3 NOTE Before adjusting the remote control throttle cable be sure to adjust the throttle valves opening and engine idling speed ...

Page 48: ... lever cam roller 6 with the mark a 7 Tighten the stopper screw 2 until it contacts the throttle control lever 7 8 Tighten the locknut 1 9 Adjust the position of the throttle cable joint until its hole aligns with the set pin on the throttle control lever 7 10 Install the clip 4 and tighten the lock nut 3 CAUTION The remote control cable joint must be screwed in more than 8 mm 0 31 in a 6 2 1 4 7 ...

Page 49: ...on sensor to flywheel magnet assembly clearance 1 0 0 5 mm 0 04 0 02 in a 1 3136 COOLING SYSTEM 3 CHECKING THE COOLING WATER DISCHARGE 3 Check Cooling water discharge No discharge Clean and check the cooling water passage Checking steps 1 Place the lower unit in water 2 Start the engine 3 Check that water flows from the cool ing water outlet 3140 OIL INJECTION SYSTEM 3 CHECKING THE OIL STRAINER 3 ...

Page 50: ...ocknut 2 2 Remove the clip and washer 3 Disconnect the oil pump link rod joint 3 4 Fully close the throttle valves 5 Turn the oil pump lever 1 so it con tacts the stopper a fully closed posi tion 6 Adjust the position of the oil pump link rod joint until its hole aligns with the set pin on the oil pump lever 1 7 Install the washer and clip 8 Tighten the locknut CAUTION After adjustment make sure t...

Page 51: ...er 1 and keep it in the fully opened position until the oil flows out of the oil pump feed hoses 2 Recommended engine oil Engine oil type 2 stroke outboard engine oil Engine oil grade TC W3 3180 3185 2 CHECKING THE ELECTRIC OIL PUMP 3 CAUTION DO NOT USE GASOLINE MIXED WITH OIL PREMIX USE UNLEADED STRAIGHT GASOLINE ONLY Check Electric oil pump operation Incorrect Replace Checking steps 1 Disconnect...

Page 52: ...bly fully extended and then slowly remove the power trim and tilt reservoir cap Checking steps 1 Tilt the outboard all the way up and lock it with the tilt stop levers 1 WARNING After tilting up the outboard be sure to support it with the tilt stop levers Otherwise the outboard could suddenly lower if the power trim and tilt unit should lose fluid pressure 2 Remove the reservoir cap 2 and check th...

Page 53: ...Black B 80 12 Ω at 20 C 68 F 3215 2 Adjust Trim sensor cam position Adjusting steps 1 Fully tilt the outboard down 2 Loosen the screw 1 3 Adjust the position of the trim sensor cam 2 until the specified resistance is obtained 4 Tighten the screw Trim sensor resistance Pink P Black B 80 12 Ω at 20 C 68 F T R Trim sensor cam screw 2 Nm 0 2 m kgf 1 4 ft lb 2 1 1 2 3216 LOWER UNIT 3 CHECKING THE GEAR ...

Page 54: ...ar oil Filling steps 1 Place the outboard in an upright posi tion 2 Insert the gear oil tube into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible 3 Install the gear oil level check screw and then quickly install the gear oil drain screw Recommended gear oil GEAR CASE LUBE USA or Hypoid gear oil SAE 90 Total amount Regular rotation mo...

Page 55: ...he gear oil level check screw 2 Install the pressure tester into the check hole 3 Apply the specified pressure NOTE The lower unit should hold the specified pressure for 10 seconds Lower unit holding pressure 100 kPa 1 0 kg cm2 14 2 psi Pressure tester YB 35956 90890 06762 3240 GENERAL 3 CHECKING THE ANODES 3 Check Anodes 1 Trim tab 2 Scales Clean Grease oil Clean Excessive wear Replace CAUTION Do...

Page 56: ...ERNAL Drink large quantities of water or milk fol lowed by milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydrogen gas therefore you should always follow these preventive measures Charge batteries in a well ventilated area Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes etc DO NOT SMOKE whe...

Page 57: ...0 C 68 F CHECKING THE SPARK PLUGS 3 1 Check Electrodes 1 Cracks excessive wear Replace Insulator color 2 Distinctly different color Check the engine condition 2 Clean Spark plugs with a spark plug cleaner or wire brush Color guide Medium to light tan color Normal Whitish color Lean fuel mixture Plugged jet s Air leak Wrong setting Blackish color Rich mixture Excessive oil usage Defective ignition ...

Page 58: ... clean the gasket surface and spark plug surface Also it is suggested to apply a thin film of anti seize compound to the spark plug threads to prevent thread seizure If a torque wrench is not available a good estimate of the correct tightening torque is to finger tighten a the spark plug and then tighten it another 1 4 to 1 2 of a turn b T R Spark plug 25 Nm 2 5 m kgf 18 ft lb 3280 ...

Page 59: ...3 22 E INSP ADJ GENERAL LUBRICATION POINTS 3 Apply Yamaha marine grease for USA and Canada Yamaha grease A for worldwide 3290 3300 3310 3320 3330 ...

Page 60: ... FILTER 4 12 REMOVING INSTALLING THE PRESSURE REGULATOR 4 13 ELECTRIC FUEL PUMP 4 15 DISASSEMBLING ASSEMBLING THE ELECTRIC FUEL PUMP 4 15 THROTTLE CONTROL LEVER CAM 4 18 REMOVING INSTALLING THE THROTTLE CONTROL LEVER CAM 4 18 THROTTLE POSITION SENSOR AND AIR TEMPERATURE SENSOR 4 19 REMOVING INSTALLING THE THROTTLE POSITION SENSOR AND AIR TEMPERATURE SENSOR 4 19 INSTALLING THE THROTTLE POSITION SEN...

Page 61: ...MECHANICAL FUEL PUMP ASSEMBLY 4 40 LOW PRESSURE FUEL LINE 4 43 REMOVING INSTALLING THE LOW PRESSURE FUEL LINE 4 43 DISASSEMBLING ASSEMBLING THE LOW PRESSURE FUEL LINE 4 44 CHECKING THE CHECK VALVE 4 45 FUEL FILTER 4 46 DISASSEMBLING ASSEMBLING THE FUEL FILTER 4 46 FUEL PUMP 4 48 DISASSEMBLING ASSEMBLING THE FUEL PUMP 4 48 CHECKING THE FUEL PUMPS 4 50 OIL INJECTION SYSTEM 4 51 REMOVING INSTALLING T...

Page 62: ...EMBLY COVER 4 REMOVING INSTALLING THE FLYWHEEL MAGNET ASSEMBLY COVER 4 Order Job Part Q ty Remarks 1 Flywheel magnet assembly cover 1 2 Grommet 4 For installation reverse the removal procedure 4005 1 2 FLYWHEEL MAGNET ASSEMBLY COVER ...

Page 63: ...cer 1 3 Suction hose 1 intake silencer to throttle body 4 Oil tank air vent hose 1 intake silencer to oil tank 5 Throttle link rod 1 6 Oil pump link rod 1 7 Throttle position sensor coupler 1 Continued on next page 10 Nm 1 0 m kgf 7 2 ft Ib 6 45 mm 3 Nm 0 3 m kgf 2 2 ft Ib 6 60 mm 1 20 19 2 21 4 3 6 7 9 11 13 10 3 5 22 18 8 19 19 A 9 5 1 4 8 C B 7 3 2 6 0 12 9 8 Nm 0 8 m kgf 5 8 ft Ib 6 12 mm 14 1...

Page 64: ...embly to vapor separator 12 Electric oil pump hose 1 electric oil pump to vapor separator 13 Fuel feed hose 1 high pressure fuel line assembly to vapor separator 14 Atmospheric pressure sensor coupler 1 Continued on next page 10 Nm 1 0 m kgf 7 2 ft Ib 6 45 mm 3 Nm 0 3 m kgf 2 2 ft Ib 6 60 mm 1 20 19 2 21 4 3 6 7 9 11 13 10 3 5 22 18 8 19 19 A 9 5 1 4 8 C B 7 3 2 6 0 12 9 8 Nm 0 8 m kgf 5 8 ft Ib 6...

Page 65: ... Electric fuel pump connector 2 19 Nut 2 20 Bolt 11 21 Fuel injection unit 1 22 Gasket 1 For installation reverse the removal procedure 10 Nm 1 0 m kgf 7 2 ft Ib 6 45 mm 3 Nm 0 3 m kgf 2 2 ft Ib 6 60 mm 1 20 19 2 21 4 3 6 7 9 11 13 10 3 5 22 18 8 19 19 A 9 5 1 4 8 C B 7 3 2 6 0 12 9 8 Nm 0 8 m kgf 5 8 ft Ib 6 12 mm 14 16 15 17 4010 Not reusable ...

Page 66: ...uel pressure medium pressure fuel line Reducing steps 1 Install the fuel pressure gauge onto the pressure check valve a 2 Place the drain hose into a container 3 Open the valve 2 and release the pressure 2 Drain Fuel WARNING Reduce the fuel pressure before removing the vapor separator drain screw or pres surized fuel will spray out and may result in serious injury NOTE Remove the drain screw 3 and...

Page 67: ...ll the fuel pressure gauge onto the pressure check valve and then install the Mity vac onto the pressure regula tor vacuum hose 2 Start the engine 3 Apply vacuum pressure with the Mity vac 4 Check the fuel pressure displacement NOTE Make sure the fuel pressure in the medium pressure fuel line lowers conversely in rela tion to the amount of pressure that is applied to the pressure regulator Fuel pr...

Page 68: ... pump hose electric oil pump assembly fuel feed hose and electric fuel pump connector Refer to MEDIUM PRESSURE FUEL LINE on page 4 2 Before performing the following procedure reduce the fuel pressure medium pressure fuel line 1 Hose 1 vapor separator and pressure regulator to throttle body 2 Bolt 3 3 Large washer 6 Continued on next page 6 35 mm 2 4 10 mm 11 12 9 8 10 8 5 3 4 1 7 6 3 1 4090 VAPOR ...

Page 69: ...4 Small washer 3 5 Vapor separator 1 6 Collar 3 7 Grommet 3 8 Hose clamp 2 9 Fuel strainer 1 10 Fuel hose 1 11 Screw 1 12 Fuel hose joint holder 1 For installation reverse the removal procedure 6 35 mm 2 4 10 mm 11 12 9 8 10 8 5 3 4 1 7 6 3 1 4090 Not reusable ...

Page 70: ... clamps by cutting its joint CAUTION The fuel hose will be damaged if a hose clamps are removed without cutting the joint 4070 INSTALLING THE HOSE CLAMPS 4 Install Hose clamps WARNING Do not reuse hose clamps only use new ones NOTE Properly crimp the hose clamps so it is securely fastened 4080 ...

Page 71: ...marks 1 Screw 2 2 Atmospheric pressure sensor 1 3 Bolt 2 4 Electric oil pump bracket 1 5 Drain screw 1 6 O ring 1 4 8 1 9 mm 7 Screw 9 Continued on next page 4 14 mm 7 7 13 12 11 10 8 9 1 5 6 4 3 2 6 20 mm 4 Nm 0 4 m kgf 2 9 ft Ib 6 20 mm 8 Nm 0 8 m kgf 5 8 ft Ib 4110 VAPOR SEPARATOR ...

Page 72: ...Float chamber 1 10 Electric fuel pump filter 1 11 Rubber damper holder 1 12 Rubber damper 1 13 Vapor separator body 1 For assembly reverse the disassembly procedure 4 14 mm 7 7 13 12 11 10 8 9 1 5 6 4 3 2 6 20 mm 4 Nm 0 4 m kgf 2 9 ft Ib 6 20 mm 8 Nm 0 8 m kgf 5 8 ft Ib 4110 ...

Page 73: ... clockwise 4120 INSTALLING THE ELECTRIC FUEL PUMP FILTER 4 Install Rubber damper 1 Rubber damper holder 2 Electric fuel pump filter 3 NOTE Make sure the rubber damper is correctly installed in its holder Firmly push the electric fuel pump filter into the bottom of the electric fuel pump and then turn the filter counterclockwise until it clicks 4130 4140 ...

Page 74: ...Job Part Q ty Remarks Float chamber Refer to DISASSEMBLING ASSEMBLING THE VAPOR SEPARATOR on page 4 10 1 Hose 3 vapor separator and pressure regulator to throttle body 2 Screw 2 3 Pressure regulator 1 4 O ring 1 Continued on next page 6 14 mm 1 2 3 8 6 7 4 5 1 3 8 6 7 4 5 1 9 1 4100 ...

Page 75: ...L E 4 4 Order Job Part Q ty Remarks 5 Filter 1 6 Fuel return joint 1 7 O ring 1 8 O ring 1 9 Cap 1 For installation reverse the removal procedure 6 14 mm 1 2 3 8 6 7 4 5 1 3 8 6 7 4 5 1 9 1 4100 VAPOR SEPARATOR ...

Page 76: ...P 4 Order Job Part Q ty Remarks 1 Terminal cover 1 2 Positive electric fuel pump terminal cap 1 red lead 3 Negative electric fuel pump terminal cap 1 blue lead 4 Nut 1 M4 a 7 mm 5 Spring washer 1 6 Nut 1 M5 b 8 mm 7 Spring washer 1 8 Positive electric fuel pump terminal 1 Continued on next page 4150 ...

Page 77: ...y Remarks 9 Negative electric fuel pump terminal 1 10 O ring 1 11 Collar 1 12 O ring 1 13 Electric fuel pump guide plate 1 14 Electric fuel pump 1 15 Coupler holder 1 16 Terminal assembly 1 Continued on next page 4150 ELECTRIC FUEL PUMP ...

Page 78: ...L E ELECTRIC FUEL PUMP 4 4 Order Job Part Q ty Remarks 17 O ring 2 18 Insulator 2 19 O ring 2 20 Screw 1 21 Float pin 1 22 Float 1 23 Clip 1 24 Needle valve 1 For assembly reverse the disassembly procedure 4150 ...

Page 79: ...L LEVER CAM 4 Order Job Part Q ty Remarks Throttle link rod Refer to MEDIUM PRESSURE FUEL LINE on page 4 2 1 Throttle link 1 2 Bolt 1 3 Collar 1 4 Wave washer 1 5 Throttle control lever cam 1 6 Washer 1 For installation reverse the removal procedure 4170 THROTTLE CONTROL LEVER CAM ...

Page 80: ...NG INSTALLING THE THROTTLE POSITION SENSOR AND AIR TEMPERATURE SENSOR 4 Order Job Part Q ty Remarks 1 Screw 2 2 Throttle position sensor 1 3 Screw 3 4 Washer 3 5 Throttle position sensor bracket 1 6 Collar 3 7 Grommet 3 8 Throttle position sensor cam 1 9 Spring 1 10 Intake air temperature sensor 1 Continued on next page 4180 ...

Page 81: ...R AND AIR TEMPERATURE SENSOR 4 4 Order Job Part Q ty Remarks 11 Nut 1 12 Washer 1 13 Grommet 1 14 Bolt 1 15 Intake air temperature sensor bracket 1 16 Nut 1 17 Bolt 1 18 Engine hanger 1 For installation reverse the removal procedure 4180 ...

Page 82: ...AIR TEMPERATURE SENSOR INSTALLING THE THROTTLE POSITION SENSOR 4 NOTE During installation make sure the throttle position sensor is properly adjusted Install Throttle position sensor Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 3 8 ...

Page 83: ...agnet assembly cover Refer to FLYWHEEL MAGNET ASSEMBLY COVER on page 4 1 1 Bolt 1 2 Spring 1 3 Drive belt tensioner 1 4 Bolt 1 5 Spring holder 1 6 Drive belt 1 7 Bolt 2 Continued on next page 6 14 10 45 mm 40 Nm 4 0 m kgf 29 ft Ib 8 45 mm 8 12 mm 8 25 mm 9 12 11 10 14 15 13 E 2 0 mm 0 08 in 6 4 7 2 5 1 3 8 4300 ...

Page 84: ...olt 1 10 Drive sprocket plate 1 11 Drive sprocket 1 12 Dowel pin 1 13 Nut 1 14 Driven sprocket 1 15 Woodruff key 1 For installation reverse the removal procedure 6 14 10 45 mm 40 Nm 4 0 m kgf 29 ft Ib 8 45 mm 8 12 mm 8 25 mm 9 12 11 10 14 15 13 E 2 0 mm 0 08 in 6 4 7 2 5 1 3 8 4300 ...

Page 85: ...MOVING THE DRIVE SPROCKET 4 Remove Drive sprocket Universal holder YU 01235 90890 01235 4310 REMOVING THE DRIVEN SPROCKET 4 Remove Driven sprocket Sheave holder 1 YS 1880 A 90890 01701 Universal puller 2 YB 06540 90890 06540 1 4315 2 4316 INSTALLING THE DRIVEN SPROCKET 4 Install Driven sprocket Sheave holder 1 YS 1880 A 90890 01701 1 4315 ...

Page 86: ... belt tensioner bolt 1 and then loosen it 90 2 Install the drive belt 2 by pushing the drive belt tensioner 3 to the loosest point on the belt NOTE Install the drive belt from the drive sprocket side a and working it counterclockwise 3 Install the spring 4 4 Loosen the drive belt tensioner bolt and stretch the drive belt with the force of the spring 5 Adjust the drive belt tension so that side b o...

Page 87: ...rder Job Part Q ty Remarks Flywheel magnet assembly cover Refer to FLYWHEEL MAGNET ASSEMBLY COVER on page 4 1 1 Fuel rail cover 2 2 Spark plug cap 6 3 Ignition coil coupler 6 4 Bolt 4 5 Lower wire harness holder 1 Continued on next page 6 12 mm 6 12 mm 6 35 mm 1 3 2 1 9 10 8 4 5 4 6 7 4340 ...

Page 88: ...ob Part Q ty Remarks 6 Upper wire harness holder 1 7 Wire harness cover 3 8 Bolt 4 9 Injector driver assembly 1 10 Injector driver coupler 1 For installation reverse the removal procedure 6 12 mm 6 12 mm 6 35 mm 1 3 2 1 9 10 8 4 5 4 6 7 4340 ...

Page 89: ...injector driver coupler by pressing on the release plate part a and pressing up the lock plate b using both thumbs unit it stops For disconnection hold the entire the injection driver coupler CAUTION Do not pull on the lock plate b to remove the injector driver coupler otherwise the lock plate could be damaged b a 4355 ...

Page 90: ...HE INJECTOR DRIVER 4 Order Job Part Q ty Remarks 1 Bolt 4 2 Injector driver 1 3 Bolt 12 4 Ignition coil 6 5 Collar 2 6 Collar 2 7 Grommet 4 8 Injector driver case 1 For assembly reverse the disassembly procedure 6 20 mm 5 20 mm 3 4 1 2 5 7 6 7 8 4 4 4 4 4350 ...

Page 91: ...Before performing the following procedure reduce the fuel pressure medium pressure fuel line Driven sprocket Refer to DRIVE BELT on page 4 22 Injector driver assembly Refer to INJECTOR DRIVER on page 4 26 1 Fuel pressure sensor coupler 1 2 Bolt 1 Continued on next page 6 12 mm 6 12 mm 8 25 mm 26 Nm 2 6m kgf 19 ft Ib 18 8 70 mm 23 Nm 2 3 m kgf 17 ft Ib 8 55 mm 23 Nm 2 3 m kgf 17 ft Ib 6 14 mm 2 8 1...

Page 92: ...pler 6 5 Ignition coil coupler 4 6 Bolt 2 7 Ignition coil coupler bracket 2 8 Bolt 3 9 Bolt 2 10 Bolt 2 Continued on next page 6 12 mm 6 12 mm 8 25 mm 26 Nm 2 6m kgf 19 ft Ib 18 8 70 mm 23 Nm 2 3 m kgf 17 ft Ib 8 55 mm 23 Nm 2 3 m kgf 17 ft Ib 6 14 mm 2 8 17 12 10 7 6 6 7 5 4 18 13 14 3 1 11 9 12 16 15 4360 ...

Page 93: ...ctor cap 6 15 Bolt 2 16 Bolt 2 17 High pressure fuel line assembly 1 18 Gasket 12 For installation reverse the removal procedure 6 12 mm 6 12 mm 8 25 mm 26 Nm 2 6m kgf 19 ft Ib 18 8 70 mm 23 Nm 2 3 m kgf 17 ft Ib 8 55 mm 23 Nm 2 3 m kgf 17 ft Ib 6 14 mm 2 8 17 12 10 7 6 6 7 5 4 18 13 14 3 1 11 9 12 16 15 4360 Not reusable ...

Page 94: ... Remarks 1 Fuel injector holder 6 2 Fuel injector 6 3 Seal ring thin 6 4 O ring 6 5 Seal ring thick 6 6 Bolt 8 7 Washer 8 8 Fuel pipe 2 Continued on next page 5 12 mm 8 40 mm 6 16 mm 8 45 mm 6 7 8 12 11 10 16 14 19 15 14 13 9 8 25 24 26 24 23 18 22 17 20 21 10 12 11 12 10 11 2 9 1 3 4 5 4370 Not reusable Not reusable Not reusable ...

Page 95: ... 8 11 O ring 8 12 Seal ring thick 8 13 Bolt 1 14 Washer 2 15 Collar 1 16 Bolt 1 17 Mechanical fuel pump assembly 1 Continued on next page 4370 5 12 mm 8 40 mm 6 16 mm 8 45 mm 6 7 8 12 11 10 16 14 19 15 14 13 9 8 25 24 26 24 23 18 22 17 20 21 10 12 11 12 10 11 2 9 1 3 4 5 Not reusable Not reusable Not reusable ...

Page 96: ... 21 Fuel feed hose guide 1 22 O ring 1 23 O ring 1 24 Hose clamp 2 25 Fuel feed hose connector 1 26 Fuel feed hose 1 For assembly reverse the disassembly procedure 4370 5 12 mm 8 40 mm 6 16 mm 8 45 mm 6 7 8 12 11 10 16 14 19 15 14 13 9 8 25 24 26 24 23 18 22 17 20 21 10 12 11 12 10 11 2 9 1 3 4 5 Not reusable Not reusable Not reusable ...

Page 97: ...ve the hose clamp by cutting its joint CAUTION The fuel hose will be damaged if a hose clamp is removed without cutting the joint 4070 INSTALLING THE HOSE CLAMPS 4 Install Hose clamp WARNING Do not reuse hose clamps only use new ones NOTE Properly crimp the hose clamp so it is securely fastened 4080 ...

Page 98: ... oil Refer to CHANGING THE MECHANICAL FUEL PUMP OIL on page 3 6 1 Gear oil drain screw 1 2 Gasket 2 3 Gear oil level check screw 1 4 Clip 1 5 Fuel return hose 1 mechanical fuel pump regulator to hose joint 6 Bolt 4 7 Washer 4 Continued on next page 6 16 mm 8 30 mm 6 35 mm 8 35 mm 6 7 8 5 4 22 20 16 21 23 17 18 19 9 14 15 13 12 2 3 2 1 10 11 4380 ...

Page 99: ...assembly 1 9 Mechanical fuel pump body 1 10 Joint plate 1 11 O ring 1 12 Bolt 3 13 Mechanical fuel pump body cover 1 14 Camshaft 1 15 O ring 1 Continued on next page 6 16 mm 8 30 mm 6 35 mm 8 35 mm 6 7 8 5 4 22 20 16 21 23 17 18 19 9 14 15 13 12 2 3 2 1 10 11 4380 Not reusable Not reusable ...

Page 100: ... Washer 2 18 Collar 2 19 Mechanical fuel pump regulator 1 20 Bolt 2 21 Washer 2 22 Fuel return hose joint 1 23 O ring 1 For assembly reverse the disassembly procedure 6 16 mm 8 30 mm 6 35 mm 8 35 mm 6 7 8 5 4 22 20 16 21 23 17 18 19 9 14 15 13 12 2 3 2 1 10 11 4380 Not reusable ...

Page 101: ...olt 2 2 Washer 2 3 Fuel pressure sensor plate 1 4 Fuel pressure sensor 1 5 O ring 1 6 Seal ring 1 7 Clip 5 8 Fuel return hose 2 mechanical fuel pump to vapor separator Continued on next page 6 45 mm 8 45 mm 8 20 mm 1 2 3 4 13 12 11 14 15 21 22 23 19 20 16 9 8 7 9 10 7 9 24 22 22 23 21 21 18 17 5 6 4390 Not reusable Not reusable ...

Page 102: ...cal fuel pump 10 Hose joint 1 11 Bolt 3 12 Bolt 2 13 Washer 2 14 Mechanical fuel pump cover 1 15 Fuel return hose adaptor 1 16 O ring 1 17 O ring 1 Continued on next page 6 45 mm 8 45 mm 8 20 mm 1 2 3 4 13 12 11 14 15 21 22 23 19 20 16 9 8 7 9 10 7 9 24 22 22 23 21 21 18 17 5 6 4390 Not reusable Not reusable ...

Page 103: ...oint 1 20 O ring 1 21 Seal ring thin 3 22 O ring 3 23 Seal ring thick 3 24 Mechanical fuel pump 1 For assembly reverse the disassembly procedure 6 45 mm 8 45 mm 8 20 mm 1 2 3 4 13 12 11 14 15 21 22 23 19 20 16 9 8 7 9 10 7 9 24 22 22 23 21 21 18 17 5 6 4390 Not reusable Not reusable Not reusable Not reusable ...

Page 104: ...SURE FUEL LINE 4 Order Job Part Q ty Remarks Vapor separator Refer to VAPOR SEPARATOR on page 4 7 1 Bolt 2 2 Bracket 1 3 Bolt 1 4 Holder 1 5 Water detection switch coupler 1 6 Bolt 2 7 Bolt 4 8 Gasket 2 9 Low pressure fuel line 1 For installation reverse the removal procedure 4190 Not reusable ...

Page 105: ...ks 1 Plastic locking tie 8 2 Fuel hose 1 hose joint to fuel filter 3 Fuel filter 1 4 Fuel hose 1 check valve to fuel filter 5 Check valve 1 6 Fuel hose assembly 1 check valve to fuel pump 7 Fuel pump 2 8 Fuel hose assembly 1 fuel pump to vapor separator For assembly reverse the disassembly procedure 4200 Not reusable ...

Page 106: ...E Do not overpressurize the check valve Excessive pressure may cause air to leak out 1 Install the Mity vac onto the check valve as shown 2 Apply the specified pressure with the Mity vac NOTE Make sure no air comes out of the opposite side of the check valve Mity vac YB 35956 90890 06756 Check valve pressure 80 kPa 0 8 kg cm2 11 4 psi 4230 ...

Page 107: ...Order Job Part Q ty Remarks 1 Bolt 1 2 Washer 1 3 Fuel filter nut holder 1 4 Fuel filter nut 1 5 Fuel filter cup water detection switch assembly 1 6 O ring 1 7 Fuel filter element 1 Continued on next page 4 6 14 mm 12 13 10 11 6 16 mm 8 Nm 0 8 m kgf 5 8 ft Ib 1 2 3 9 7 8 6 14 5 4210 ...

Page 108: ...t Q ty Remarks 8 O ring 1 9 Spring 1 10 Bolt 1 11 Fuel filter bracket 1 12 Collar 2 13 Grommet 2 14 Fuel filter cap 1 For assembly reverse the disassembly procedure 4210 4 6 14 mm 12 13 10 11 6 16 mm 8 Nm 0 8 m kgf 5 8 ft Ib 1 2 3 9 7 8 6 14 5 ...

Page 109: ... PUMP 4 DISASSEMBLING ASSEMBLING THE FUEL PUMP 4 Order Job Part Q ty Remarks 1 Screw 3 2 Diaphragm body 1 3 Diaphragm 1 4 Gasket 1 5 Fuel pump base 1 6 Gasket 1 7 Diaphragm 1 Continued on next page 4220 Not reusable Not reusable ...

Page 110: ...4 49 FUEL E FUEL PUMP 4 4 Order Job Part Q ty Remarks 8 Spring seat 1 9 Spring 1 10 Screw 4 11 Fuel pump valve 4 12 Nut 4 13 Fuel pump body 1 For assembly reverse the disassembly procedure 4220 ...

Page 111: ...e Mity vac onto the fuel pump as shown 2 Apply the specified pressure with the Mity vac NOTE Make sure no air comes out of the oppo site side of the fuel pump To eliminate any gaps between the fuel pump valves and the fuel pump body and to ensure a better seal make sure the inside of the fuel pump is wet i e with gas Mity vac YB 35956 90890 06756 Fuel pump pressure a 50 kPa 0 5 kg cm2 7 1 psi Fuel...

Page 112: ...p coupler and electric oil pump assembly Refer to MEDIUM PRESSURE FUEL LINE on page 4 2 Junction box assembly Refer to JUNCTION BOX ASSEMBLY on page 5 18 Starter motor Refer to STARTER MOTOR on page 5 28 1 Oil tank air vent hose 1 intake silencer to oil tank 2 Metal clamp 6 3 Oil feed hose 6 crankcase to oil pump 4 Oil level sensor coupler 1 Continued on next page 4250 ...

Page 113: ... Order Job Part Q ty Remarks 5 Emergency switch connector 2 6 Clip 1 7 Plastic washer 1 8 Oil pump link rod 1 9 Bolt 2 10 O ring 1 11 Bolt 3 12 Clamp 1 13 Oil injection system assembly 1 For installation reverse the removal procedure 4250 ...

Page 114: ...rt Q ty Remarks 1 Oil tank air vent hose 1 oil tank to intake silencer 2 Plastic locking tie 5 3 Oil hose 1 sub oil tank to oil tank 4 Oil hose 2 oil tank to oil pump 5 Oil tank assembly 1 6 Oil hose joint 1 7 Clip 4 8 Oil hose 2 oil pump to electric oil pump Continued on next page 4260 Not reusable ...

Page 115: ...y Remarks 9 Check valve 1 10 Electric oil pump 1 11 Metal clamp 21 12 Electric oil pump hose 2 electric oil pump to vapor separator 13 Check valve 7 14 Oil feed hose 12 oil pump to crankcase 15 Oil pump 1 For assembly reverse the disassembly procedure 4260 ...

Page 116: ... Do not overpressurize the check valve Excessive pressure may cause air to leak out 1 Install the Mity vac onto the check valve as shown 2 Apply the specified pressure with the Mity vac NOTE Make sure no air comes out of the opposite side of the check valve Mity vac YB 35956 90890 06756 Check valve pressure 80 kPa 0 8 kg cm2 11 4 psi 4230 ...

Page 117: ...SASSEMBLING ASSEMBLING THE OIL TANK 4 Order Job Part Q ty Remarks 1 Oil level sensor 1 2 Oil strainer 1 3 Washer 1 4 Oil tank 1 5 Cap nut 1 6 Emergency switch 1 7 Collar 3 8 Grommet 3 For assembly reverse the disassembly procedure 4270 ...

Page 118: ...MOVING INSTALLING THE STATOR ASSEMBLY 5 12 CONTROL UNIT 5 14 REMOVING INSTALLING THE CONTROL UNIT ASSEMBLY 5 14 FUSE HOLDER 5 16 REMOVING INSTALLING THE FUSE HOLDER 5 16 DISASSEMBLING ASSEMBLING THE FUSE HOLDER 5 17 JUNCTION BOX ASSEMBLY 5 18 REMOVING INSTALLING THE JUNCTION BOX ASSEMBLY 5 18 DISASSEMBLING ASSEMBLING THE JUNCTION BOX ASSEMBLY 5 21 WIRE HARNESSES 5 23 REMOVING INSTALLING THE MAIN W...

Page 119: ...ASSEMBLY 5 50 DISASSEMBLING ASSEMBLING THE CYLINDER BODY ASSEMBLY 5 50 DISASSEMBLING ASSEMBLING THE PISTON AND CONNECTING ROD ASSEMBLIES 5 53 DISASSEMBLING ASSEMBLING THE CRANKSHAFT ASSEMBLY 5 54 DISASSEMBLING THE UPPER BEARING HOUSING 5 55 REMOVING THE BEARING AND OIL PUMP DRIVE GEAR 5 55 CHECKING THE CYLINDER BODY 5 56 CHECKING THE PISTONS 5 57 CALCULATING THE PISTON TO CYLINDER CLEARANCE 5 57 C...

Page 120: ...THE FLYWHEEL MAGNET ASSEMBLY 5 Order Job Part Q ty Remarks Drive sprocket Refer to DRIVE BELT on page 4 22 1 Bolt 3 2 Drive sprocket bracket 1 3 Flywheel magnet assembly nut 1 4 Washer 1 5 Flywheel magnet assembly 1 6 Woodruff key 1 For installation reverse the removal procedure 5010 ...

Page 121: ...he flywheel magnet assembly 2 Remove the flywheel magnet assem bly Å For USA and Canada ı For worldwide NOTE The major load should be applied in the direction of the arrows Apply the load until the flywheel magnet assembly comes off the tapered portion of the crankshaft CAUTION To prevent damage to the engine or tools screw in the universal puller set bolts evenly and completely so that the puller...

Page 122: ...e major load should be applied in the direction of the arrows If the load is not applied as shown the flywheel magnet assembly holder may easily slip off of the flywheel magnet assembly Flywheel magnet assembly holder YB 06139 90890 06522 T R Flywheel magnet assembly nut 190 Nm 19 m kgf 137 ft lb 5060 Å 5070 ı FLYWHEEL MAGNET ASSEMBLY ...

Page 123: ...DS 5 Order Job Part Q ty Remarks Battery leads 1 from the battery Remote control shift and throttle rods and cables 2 1 Bolt 1 2 Negative battery lead 1 3 Nut 1 4 Positive battery lead 1 5 Screw 2 6 Junction box cover 1 Continued on next page 5080 POWER UNIT ...

Page 124: ...emarks 7 Bolt 2 8 Power trim and tilt lead 1 blue 9 Power trim and tilt lead 1 green 10 Trim sensor coupler and connector 2 11 Shift position switch coupler 1 12 Clip 1 13 Shift rod lever bushing 1 For installation reverse the removal procedure 5080 ...

Page 125: ...ocking tie 2 2 Oil hose 1 oil tank to sub oil tank 3 Pilot water hose 1 pilot water outlet to rectifier regulator 4 Fuel hose 1 fuel filter to hose joint 5 Bolt 1 6 Cable guide 1 7 Trailer switch coupler 1 8 Bolt 2 9 Shift rod assembly 1 For installation reverse the removal procedure 5090 Not reusable ...

Page 126: ...E POWER UNIT 5 REMOVING INSTALLING THE EXHAUST EXPANSION CHAMBER 5 Order Job Part Q ty Remarks 1 Screw 1 2 Bolt 2 3 Bolt 2 4 Apron 1 5 Collar 4 6 Hose joint 1 7 Rubber seal 1 8 Bolt 9 Continued on next page 5095 ...

Page 127: ... Remarks 9 Exhaust expansion chamber 1 10 Exhaust expansion chamber hose 1 11 Rubber seal 4 12 Rubber seal 1 13 Clip 1 14 Cooling water hose 1 exhaust manifold to power unit For installation reverse the removal procedure 5095 POWER UNIT ...

Page 128: ...irst insert the hose joint 1 in the exhaust expansion chamber hose 2 and then insert the apron securely in the hose joint 1 2 5096 2 Install Apron CAUTION Make sure not to get the flushing hose 1 caught between the mating surfaces a of the apron when installing it 1 a 5097 ...

Page 129: ... E POWER UNIT 5 REMOVING INSTALLING THE POWER UNIT 5 Order Job Part Q ty Remarks 1 Nut 2 2 Bolt 4 3 Bolt 6 4 Power unit 1 5 Gasket 1 6 Dowel pin 2 For installation reverse the removal procedure 5100 Not reusable ...

Page 130: ...erious injury or death INSTALLING THE POWER UNIT 5 Install Shift rod lever CAUTION Make sure to push the shift rod lever 1 to the outside when placing the power unit onto the bottom cowling otherwise inter ference with the shift position switch plate a may occur and the shift rod lever could be damaged NOTE Make sure to place the shift rod lever 1 in the shift rod lever bracket 2 after placing the...

Page 131: ... Remarks Flywheel magnet assembly Refer to FLYWHEEL MAGNET ASSEMBLY on page 5 1 1 Plastic locking tie 2 2 Crank position sensor coupler 1 3 Screw 2 4 Crank position sensor 1 Refer to ADJUSTING THE CRANK POSITION SENSOR on page 3 12 5 Clamp 1 6 Lighting coil coupler 3 Continued on next page 5110 Not reusable ...

Page 132: ...5 Order Job Part Q ty Remarks 7 Bolt 4 8 Stator assembly holder 1 9 Stator assembly 1 10 Pulser coil coupler 1 11 Screw 3 12 Pulser coil assembly 1 For installation reverse the removal procedure 5110 STATOR ASSEMBLY ...

Page 133: ... CONTROL UNIT ASSEMBLY 5 Order Job Part Q ty Remarks High pressure fuel line assembly Refer to HIGH PRESSURE FUEL LINE ASSEMBLY on page 4 30 1 Bolt 2 2 Control unit coupler guide 1 3 Control unit coupler 3 4 Bolt 5 5 Control unit case 1 Continued on next page 5120 ...

Page 134: ...5 15 POWR E 5 5 Order Job Part Q ty Remarks 6 Collar 2 7 Collar 3 8 Grommet 5 9 Bolt 4 10 Control unit 1 For installation reverse the removal procedure 5120 CONTROL UNIT ...

Page 135: ...Job Part Q ty Remarks Junction box cover Refer to POWER UNIT on page 5 4 1 Fuel holder cover 1 2 Screw 2 3 Grommet holder 1 4 Grommet 1 5 Screw 3 6 Fuse holder assembly 1 7 Fuse holder coupler 4 8 Plastic locking tie 1 For installation reverse the removal procedure 5130 Not reusable ...

Page 136: ...Q ty Remarks 1 Fuse 20A 3 2 Fuse 30A 1 3 Screw 4 4 Fuse 80A 2 5 Screw 6 6 Fuse holder 1 7 Terminal big 4 8 Terminal small 4 9 Driver relay 1 10 Main relay 1 11 Terminal plate 4 For assembly reverse the disassembly procedure 5 10 mm 3 10 mm 5 3 4 10 9 1 2 7 8 11 6 6 1 2 9 10 1 4 1 5135 ...

Page 137: ...r to POWER UNIT on page 5 4 Fuse holder coupler Refer to FUSE HOLDER on page 5 16 1 Terminal cover 1 2 Nut 1 3 Positive battery lead terminal 1 4 Power trim and tilt lead 1 red 5 Electric fuel pump connector 1 red 6 Clip 1 7 Cooling water hose 1 exhaust outer cover to rectifier regulator Continued on next page 7 6 5 3 2 1 4 A 9 Nm 0 9 m kgf 6 5 ft Ib 5140 ...

Page 138: ... green 9 Power trim and tilt lead 1 blue 10 Lighting coil coupler 2 11 Oxygen density sensor coupler 1 blue 12 Starter motor lead 1 13 Starter relay connector 1 14 Power trim and tilt relay coupler 1 15 Fuse holder coupler 1 Continued on next page 5150 JUNCTION BOX ASSEMBLY ...

Page 139: ...EMBLY 5 5 Order Job Part Q ty Remarks 16 Fuse holder connector 1 17 Bolt 1 18 Ground lead 1 19 Bolt 2 20 Ground lead 5 21 Ground lead plate 1 22 Bolt 5 23 Junction box assembly 1 For installation reverse the removal procedure 5150 ...

Page 140: ...r Job Part Q ty Remarks 1 Screw 1 2 Starter relay holder 1 3 Starter relay 1 4 Bolt 2 5 Power trim and tilt relay 1 6 Bolt 2 7 Rectifier regulator 1 8 Bolt 4 9 Rectifier regulator cover 1 10 Gasket 1 11 Clip 2 Continued on next page 5160 Not reusable JUNCTION BOX ASSEMBLY ...

Page 141: ...water hose 1 rectifier regulator to exhaust outer cover 13 Cooling water hose 1 rectifier regulator to pilot water outlet 14 Clamp 1 15 Clamp 1 16 Fuse holder cover hook 2 17 Collar 4 18 Collar 1 19 Grommet 5 20 Junction box 1 For assembly reverse the disassembly procedure 5160 ...

Page 142: ... Trim sensor connector 3 shift position switch coupler 4 and trailer switch coupler 5 Refer to POWER UNIT on page 5 4 Control unit coupler 6 Refer to CONTROL UNIT on page 5 14 Starter relay connector 7 power trim and tilt relay coupler 8 fuse holder coupler 9 fuse holder connector 0 and ground lead A Refer to JUNCTION BOX ASSEMBLY on page 5 18 Continued on next page 6 12 mm 2 3 1 1 A 0 7 9 8 6 1 5...

Page 143: ...5 24 POWR E WIRE HARNESSES 5 5 Order Job Part Q ty Remarks 1 Thermo switch connector 4 2 Bolt 1 3 Ground lead 2 For installation reverse the removal procedure 6 12 mm 2 3 1 1 A 0 7 9 8 6 1 5 2 3 4 5170 ...

Page 144: ... PRESSURE FUEL LINE on page 4 2 Fuel pressure sensor coupler 4 Refer to HIGH PRESSURE FUEL LINE ASSEMBLY on page 4 30 Crank position sensor coupler 5 and pulser coil coupler 6 Refer to STATOR ASSEMBLY on page 5 12 Control unit coupler 7 Refer to CONTROL UNIT on page 5 14 1 Oxygen density sensor coupler 1 green 2 Engine cooling water temperature sensor coupler 1 For installation reverse the removal...

Page 145: ...couplers 3 and injector driver coupler 4 Refer to INJECTOR DRIVER on page 4 26 Fuel injector couplers 5 Refer to HIGH PRESSURE FUEL LINE ASSEMBLY on page 4 30 Water detection switch coupler 6 Refer to LOW PRESSURE FUEL LINE on page 4 43 Control unit coupler 7 Refer to CONTROL UNIT on page 5 14 Fuse holder coupler 8 Refer to FUSE HOLDER on page 5 16 Continued on next page 2 7 5 5 5 5 5 5 9 A 0 6 1 ...

Page 146: ...Oxygen density sensor coupler blue 9 fuse holder coupler 0 and fuse holder connector A Refer to JUNCTION BOX ASSEMBLY on page 5 18 1 Bolt 2 2 Ground lead 2 For installation reverse the removal procedure 2 7 5 5 5 5 5 5 9 A 0 6 1 8 4 3 3 3 3 3 3 6 12 mm 1 2 5180 ...

Page 147: ...ARTER MOTOR 5 Order Job Part Q ty Remarks Positive battery lead Refer to POWER UNIT on page 5 4 Power trim and tilt lead red and starter motor lead Refer to JUNCTION BOX ASSEMBLY on page 5 18 1 Bolt 3 2 Starter motor 1 For installation reverse the removal procedure 5190 ...

Page 148: ...VING INSTALLING THE OXYGEN DENSITY SENSOR 5 Order Job Part Q ty Remarks 1 Plastic locking tie 1 2 Rubber cap 1 3 Bolt 2 4 Oxygen density sensor cover 1 5 Bolt 1 6 Bolt 1 7 Bolt 1 Continued on next page 5200 Not reusable OXYGEN DENSITY SENSOR ...

Page 149: ... 8 Oxygen density sensor assembly 1 9 Gasket set 1 10 Oxygen density sensor bracket 1 11 Oxygen density sensor 1 Refer to CHECKING THE OXYGEN DENSITY SENSOR on page 8 25 12 Oxygen density sensor joint 1 For installation reverse the removal procedure 5200 Not reusable ...

Page 150: ...WR E OXYGEN DENSITY SENSOR INSTALLING THE OXYGEN DENSITY SENSOR 5 Install Bolts 1 2 3 NOTE Make sure to tighten bolts 1 2 and 3 to the specified torque in numerical order T R Bolt 14 Nm 1 4 m kgf 10 ft lb 5205 ...

Page 151: ... VALVES 5 Order Job Part Q ty Remarks Fuel injection unit Refer to MEDIUM PRESSURE FUEL LINE on page 4 2 1 Recirculation hose 6 2 Bolt 2 3 Gasket 1 4 Intake manifold 1 5 Screw 12 6 Gasket 6 7 Reed valve assembly 6 Continued on next page 5210 Not reusable Not reusable ...

Page 152: ...5 33 POWR E REED VALVES 5 5 Order Job Part Q ty Remarks 8 Screw 10 9 Reed valve stopper 4 10 Metal reed 4 11 Reed valve seat 1 For installation reverse the removal procedure 5210 ...

Page 153: ...Y 5 1 Check Reed valve Cracks damage Replace 2 Measure Warpage limit a Out of specification Replace Warpage limit 0 2 mm 0 008 in 5220 3 Measure Reed valve stopper height a Out of specification Replace Reed valve stopper height 9 0 0 35 mm 0 35 0 01 in 5230 ...

Page 154: ...on page 4 2 High pressure fuel line assembly Refer to HIGH PRESSURE FUEL LINE ASSEMBLY on page 4 30 Low pressure fuel line Refer to LOW PRESSURE FUEL LINE on page 4 43 Oil injection system Refer to OIL INJECTION SYSTEM on page 4 51 Shift position switch coupler Refer to POWER UNIT on page 5 4 Junction box Refer to JUNCTION BOX ASSEMBLY on page 5 18 Continued on next page 5240 ...

Page 155: ...otor Refer to STARTER MOTOR on page 5 28 1 Bolt 1 2 Collar 1 3 Wave washer 1 4 Throttle control lever 1 5 Throttle control rod 1 6 Washer 1 7 Screw 2 8 Shift position switch holder 1 9 Shift position switch 1 Continued on next page 5240 EXTERNAL FITTINGS ...

Page 156: ...arks 10 Bolt 2 11 Stopper screw assembly 1 12 Shift rod lever bracket 1 13 Bolt 1 14 High pressure fuel line assembly bracket 2 15 Collar 2 16 Hose clamp 1 17 Recirculation hose 7 18 Bolt 6 19 Ground lead 3 For installation reverse the removal procedure 5245 ...

Page 157: ...SSEMBLY on page 4 30 1 Spark plug 6 2 Copper washer 6 3 Bolt 8 4 Thermostat cover 2 5 Gasket 2 Continued on next page 6 30 mm 2nd 11 Nm 1 1 m kgf 8 0 ft Ib 1st 25 Nm 2 5 m kgf 18 ft Ib LT LT LT 572 7 5 Nm 0 5 m kgf 3 6 ft Ib 1 LT LT LT 572 6 40 mm 2nd 11 Nm 1 1 m kgf 8 0 ft Ib 1st 5 Nm 0 5 m kgf 3 6 ft Ib 3 2 10 9 6 5 4 7 8 5 4 9 10 1 2 6 5 4 3 B H A G 0 F 7 8 9 C D E J L K I 4 9 5250 Not reusable...

Page 158: ...llation reverse the removal procedure 6 30 mm 2nd 11 Nm 1 1 m kgf 8 0 ft Ib 1st 25 Nm 2 5 m kgf 18 ft Ib LT LT LT 572 7 5 Nm 0 5 m kgf 3 6 ft Ib 1 LT LT LT 572 6 40 mm 2nd 11 Nm 1 1 m kgf 8 0 ft Ib 1st 5 Nm 0 5 m kgf 3 6 ft Ib 3 2 10 9 6 5 4 7 8 5 4 9 10 1 2 6 5 4 3 B H A G 0 F 7 8 9 C D E J L K I 4 9 5250 Not reusable CYLINDER HEAD COVERS ...

Page 159: ...e lift a Out of specification Replace Measuring steps 1 Suspend the thermostat in a container filled with water 2 Place a thermometer in the water 3 Slowly heat the water 4 While stirring the water check that the thermostat opens at the specified tem perature Water temperature Valve lift Below 48 52 C 118 126 F 0 mm 0 in Above 60 C 140 F Min 3 mm 0 12 in 5260 ...

Page 160: ...38 1 Thermo switch 2 2 Engine cooling water temperature sensor 1 3 Bolt 28 4 Cylinder head 2 5 Gasket 2 6 Dowel pin 4 7 Screw 7 Continued on next page 8 60 mm 2nd 30 Nm 3 0 m kgf 22 ft Ib 1st 15 Nm 1 5 m kgf 11 ft Ib 6 20 mm 15 Nm 1 5 m kgf 11 ft Ib E A A A 6 20 mm 5 12 mm LT LT LT 572 572 13 15 14 16 12 11 1 4 5 6 6 4 12 mm 7 8 5 4 2 3 1 10 9 C 9 5 1 4 8 B A 7 3 2 6 0 F G H F E 5255 Not reusable ...

Page 161: ...3 Bolt 1 14 Anode cover 1 15 Anode 1 16 Grommet 1 For installation reverse the removal procedure 8 60 mm 2nd 30 Nm 3 0 m kgf 22 ft Ib 1st 15 Nm 1 5 m kgf 11 ft Ib 6 20 mm 15 Nm 1 5 m kgf 11 ft Ib E A A A 6 20 mm 5 12 mm LT LT LT 572 572 13 15 14 16 12 11 1 4 5 6 6 4 12 mm 7 8 5 4 2 3 1 10 9 C 9 5 1 4 8 B A 7 3 2 6 0 F G H F E 5255 ...

Page 162: ...d cylinder head cover 5265 2 Measure Cylinder head warpage with a straightedge and thickness gauge Out of specification Resurface or replace Resurfacing steps 1 Place a 400 600 grit wet sandpaper on the surface plate 2 Resurface the cylinder head by moving it in a figure eight motion along the sandpaper NOTE Rotate the cylinder head several times to ensure an even surface Warpage limit 0 1 mm 0 00...

Page 163: ...n page 5 14 Cooling water hose Refer to JUNCTION BOX ASSEMBLY on page 5 18 1 Bolt 2 2 Pressure control valve cover 1 3 Gasket 1 4 Spring 1 Continued on next page 2nd 8 Nm 0 8 m kgf 5 8 ft Ib 1st 4 Nm 0 4 m kgf 2 9 ft Ib LT LT LT 572 6 30 mm 2nd 8 Nm 0 8 m kgf 5 8 ft Ib 1st 4 Nm 0 4 m kgf 2 9 ft Ib 6 20 mm LT LT LT 572 8 9 7 1 2 3 4 5 6 H C 8 3 4 9 D I J K L M E A 5 2 6 B F G 7 1 0 5300 Not reusabl...

Page 164: ... 23 8 Exhaust outer cover 1 9 Gasket 1 For installation reverse the removal procedure 2nd 8 Nm 0 8 m kgf 5 8 ft Ib 1st 4 Nm 0 4 m kgf 2 9 ft Ib LT LT LT 572 6 30 mm 2nd 8 Nm 0 8 m kgf 5 8 ft Ib 1st 4 Nm 0 4 m kgf 2 9 ft Ib 6 20 mm LT LT LT 572 8 9 7 1 2 3 4 5 6 H C 8 3 4 9 D I J K L M E A 5 2 6 B F G 7 1 0 5300 Not reusable ...

Page 165: ...UST COVERS CHECKING THE PRESSURE CONTROL VALVE 5 Check Pressure control valve seat 1 Pressure control valve 2 Pressure control valve cover 3 Cracks damage Replace any defec tive parts Spring 4 Damage wear Replace 5310 ...

Page 166: ...t assembly Refer to FLYWHEEL MAGNET ASSEMBLY on page 5 1 Power unit Refer to POWER UNIT on page 5 4 Pulser coil assembly Refer to STATOR ASSEMBLY on page 5 12 Intake manifold Refer to REED VALVES on page 5 32 External fittings Refer to EXTERNAL FITTINGS on page 5 35 1 Bolt 12 2 Bolt 8 Continued on next page 5320 ...

Page 167: ...5 48 POWR E 5 5 Order Job Part Q ty Remarks 3 Bolt 4 4 Bolt 4 5 Crankcase 1 6 Oil seal housing 1 7 O ring 1 8 Oil seal 2 9 Dowel pin 2 For installation reverse the removal procedure 5320 CRANKCASE ...

Page 168: ...chment 1 YB 06195 90890 06637 90890 06631 Driver rod 2 YB 06071 90890 06606 5330 Å 5340 ı INSTALLING THE CRANKCASE 5 Apply Gasket Maker onto the crankcase mating surfaces NOTE Clean the mating surfaces of the crank case and cylinder body before applying Gasket Maker Do not allow any sealant to overflow from the mating surfaces 5350 ...

Page 169: ...R BODY ASSEMBLY 5 Order Job Part Q ty Remarks Cylinder heads Refer to CYLINDER HEAD COVERS on page 5 38 Crankcase Refer to CRANKCASE on page 5 47 1 Upper bearing housing 1 2 Oil seal 1 3 O ring 2 4 Needle bearing 2 5 Connecting rod bolt 12 6 Connecting rod cap 6 Continued on next page Loosen 5360 ...

Page 170: ...LY 5 5 Order Job Part Q ty Remarks 7 Big end bearing 6 8 Piston connecting rod assembly 6 9 Crankshaft assembly 1 10 Clip 2 11 Main journal bearing 2 12 Screw 8 13 Anode 8 14 Bolt 6 15 Lead holder 2 Continued on next page Loosen 5360 ...

Page 171: ...Job Part Q ty Remarks 16 Cylinder cover 1 17 Gasket 1 18 Bolt 4 19 Damper bracket 2 20 Oil pump driven gear 1 21 Cylinder body 1 For assembly reverse the disassembly procedure Loosen 5360 Not reusable CYLINDER BODY ASSEMBLY ...

Page 172: ...STON AND CONNECTING ROD ASSEMBLIES 5 Order Job Part Q ty Remarks 1 Piston pin clip 12 2 Piston pin 6 3 Piston 6 4 Washer 12 5 Small end bearing 6 6 Top piston ring 6 7 2nd piston ring 6 8 Connecting rod 6 For assembly reverse the disassembly procedure 5370 Not reusable ...

Page 173: ...ASSEMBLY 5 DISASSEMBLING ASSEMBLING THE CRANKSHAFT ASSEMBLY 5 Order Job Part Q ty Remarks 1 Labyrinth ring 9 2 Circlip 1 3 Ball bearing 1 4 Oil pump drive gear 1 5 Crankshaft 1 For assembly reverse the disassembly procedure 5600 ...

Page 174: ...a ı For worldwide Needle bearing attachment 1 YB 06205 90890 06663 Driver rod 2 90890 06606 5390 Å 5400 ı REMOVING THE BEARING AND OIL PUMP DRIVE GEAR 5 Remove Bearing Oil pump drive gear Bearing separator 1 YB 06219 90890 06534 Guide plate stand 2 90890 06538 Guide plate 3 90890 06501 Bearing puller 4 90890 06535 5610 ...

Page 175: ...d exhaust inner cover 3 Measure Cylinder bore diameter D with a cylinder bore gauge Out of specification Replace NOTE Measure the cylinder bore diameter at three positions for both D1 and D2 Then average the measurements A 10 mm 0 4 in below the top of the cylinder B 5 mm 0 2 in above the exhaust port C 5 mm 0 2 in below the scavenging port Standard Wear limit Cylinder bore diame ter D 90 00 90 02...

Page 176: ...t H Piston diameter Standard 10 mm 0 4 in 89 845 89 869 mm 3 5372 3 5381 in Oversize piston diameter 1st oversize 90 11 mm 3 548 in 2nd oversize 90 36 mm 3 557 in 5440 CALCULATING THE PISTON TO CYLINDER CLEARANCE 5 Calculate Piston to cylinder clearance a Out of specification Replace the pis ton and piston rings the cylinder or both Piston to cylinder clearance Cylinder bore diameter Piston diamet...

Page 177: ...h a micrometer Out of specification Replace Piston pin diameter 23 065 23 070 mm 0 9081 0 9083 in 5460 3 Measure Piston pin boss diameter with a micrometer Out of specification Replace Piston pin boss diameter 23 074 23 085 mm 0 9084 0 9089 in 5470 CHECKING THE PISTON RINGS 5 NOTE Before checking the piston rings be sure to check the cylinder body Piston rings should always be replaced as a set pe...

Page 178: ... 60 mm 0 024 in Measuring point H 20 mm 0 8 in 5480 5490 2 Measure Piston ring side clearance b with a thickness gauge Out of specification Replace the pis ton and piston rings as a set NOTE When measuring the piston ring side clear ance the outside of the piston ring should be flush with the piston wall Piston ring side clearance 0 02 0 06 mm 0 001 0 002 in 5500 CHECKING THE OIL PUMP DRIVEN GEAR ...

Page 179: ...f specification Replace Labyrinth ring wear limit 0 10 mm 0 004 in Runout limit 0 05 mm 0 002 in 5620 5630 2 Measure Small end axial play Out of specification Replace the connecting rod Small end axial play limit 2 0 mm 0 08 in 5640 3 Measure Big end side clearance Out of specification Replace the connecting rod Big end side clearance 0 12 0 26 mm 0 005 0 010 in 5650 4 Check Crankshaft bearing Pit...

Page 180: ...earing oil seal attachment 2 90890 06661 90890 06622 Bearing separator 1 YB 06219 90890 06534 Bearing oil seal attachment 2 90890 06662 90890 06622 5660 5670 INSTALLING THE PISTON RINGS AND PISTON 5 1 Install 2nd piston ring 1 Top piston ring 2 CAUTION Align each piston ring end gap with its respective locating pin After installing the piston rings check that they move smoothly 5520 ...

Page 181: ...their convex sides facing towards the piston NOTE The embossed YAMAHA mark a on the connecting rod must face the same direc tion as the UP mark on the piston 5530 ASSEMBLING THE UPPER BEARING HOUSING 5 1 Install Needle bearing Needle bearing attachment 90890 06661 5550 2 Install Oil seal Bearing oil seal attachment 1 90890 06654 Driver rod 2 90890 06652 5560 ...

Page 182: ...Install Piston and connecting rod assembly NOTE Before installing the piston and connect ing rod assemblies lubricate the cylinder walls with 2 stroke outboard engine oil Reinstall the piston and connecting rod assemblies in their original cylinders Install the piston and connecting rod assemblies with the S mark in the star board side cylinders and those with the P mark in the port side cylinders...

Page 183: ......

Page 184: ... MODELS 6 9 REMOVING INSTALLING THE SHIFT ROD ASSEMBLY 6 9 REMOVING THE SHIFT ROD ASSEMBLY 6 10 PROPELLER SHAFT HOUSING ASSEMBLY REGULAR ROTATION MODELS 6 11 REMOVING INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6 11 DISASSEMBLING ASSEMBLING THE PROPELLER SHAFT HOUSING 6 13 DISASSEMBLING ASSEMBLING THE PROPELLER SHAFT ASSEMBLY 6 14 REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY 6 15 DISASSEMBLIN...

Page 185: ... CASE ASSEMBLY 6 25 DISASSEMBLING THE LOWER CASE ASSEMBLY 6 26 CHECKING THE DRIVE SHAFT SLEEVE 6 26 CHECKING THE NEEDLE BEARING 6 26 ASSEMBLING THE LOWER CASE ASSEMBLY 6 26 LOWER UNIT COUNTER ROTATION MODELS 6 28 REMOVING INSTALLING THE LOWER UNIT 6 28 REMOVING THE PROPELLER 6 30 REMOVING THE TRIM TAB 6 30 CHECKING THE PROPELLER 6 30 INSTALLING THE PROPELLER 6 31 WATER PUMP COUNTER ROTATION MODELS...

Page 186: ... INSTALLING THE PROPELLER SHAFT ASSEMBLY 6 45 INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6 45 DRIVE SHAFT COUNTER ROTATION MODELS 6 46 REMOVING INSTALLING THE DRIVE SHAFT 6 46 REMOVING THE PINION 6 48 REMOVING THE REVERSE GEAR 6 48 DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY 6 48 DISASSEMBLING THE REVERSE GEAR ASSEMBLY 6 48 CHECKING THE PINION 6 49 CHECKING THE DRIVE SHAFT 6 49 CHECKING TH...

Page 187: ...ARD GEAR BACKLASH 6 68 MEASURING THE REVERSE GEAR BACKLASH 6 70 SHIMMING COUNTER ROTATION MODELS FOR USA AND CANADA 6 72 SELECTING THE PINION SHIMS 6 73 SELECTING THE REVERSE GEAR SHIMS 6 75 SELECTING THE FORWARD GEAR SHIMS 6 76 SELECTING THE PROPELLER SHAFT SHIMS 6 78 SHIMMING COUNTER ROTATION MODELS FOR WORLDWIDE 6 79 SELECTING THE PINION SHIMS 6 80 SELECTING THE REVERSE GEAR SHIMS 6 82 SELECTIN...

Page 188: ...ODELS LOWER UNIT REGULAR ROTATION MODELS 6 REMOVING INSTALLING THE LOWER UNIT Order Job Part Q ty Remarks 1 Speedometer hose 1 2 Cotter pin 1 3 Propeller nut 1 4 Washer 1 5 Washer 1 6 Propeller 1 7 Spacer 1 8 Cap 1 Continued on next page 6010 ...

Page 189: ...R 6 Order Job Part Q ty Remarks 9 Bolt 1 10 Trim tab 1 11 Bolt 1 12 Bolt 6 13 Lower unit 1 14 Dowel pin 2 15 Exhaust seal 1 For installation reverse the removal procedure 6010 LOWER UNIT REGULAR ROTATION MODELS ...

Page 190: ... it Be sure to remove the battery leads from the batteries and the lanyard engine stop switch Put a block of wood between the cavitation plate and propeller to keep the propeller from turning 6016 REMOVING THE TRIM TAB Remove Trim tab NOTE Mark the original position a for proper installation 6012 CHECKING THE PROPELLER Check Blades Splines Cracks damage wear Replace ...

Page 191: ...ing it Be sure to remove the battery leads from the batteries and the lanyard engine stop switch Put a block of wood between the cavitation plate and propeller to keep the propeller from turning NOTE If the groove in the propeller nut is not aligned with the cotter pin hole tighten the nut further until they are aligned T R Propeller nut 55 Nm 5 5 m kgf 40 ft lb 6017 ...

Page 192: ...N MODELS 6 REMOVING INSTALLING THE WATER PUMP Order Job Part Q ty Remarks Lower unit Refer to LOWER UNIT REGULAR ROTATION MODELS on page 6 1 1 Bolt 4 2 Plate washer 4 3 Impeller housing 1 4 Impeller housing cup 1 5 Grommet 1 6 Spacer 1 7 Collar 1 Continued on next page 6020 ...

Page 193: ...Q ty Remarks 8 Spacer 1 9 Washer 2 10 Wave washer 1 11 Impeller 1 12 Woodruff key 1 13 Impeller plate 1 14 Gasket 1 15 Dowel pin 2 For installation reverse the removal procedure 6020 Not reusable WATER PUMP REGULAR ROTATION MODELS ...

Page 194: ...tive parts CHECKING THE WOODRUFF KEY Check Woodruff key Damage wear Replace INSTALLING THE IMPELLER AND IMPELLER HOUSING 1 Install Impeller 1 Washers 2 Wave washer 3 Spacer 4 Collar 5 NOTE Make sure that the slit a in the impeller is aligned with the woodruff key The collar and spacer should fit together firmly Install the collar with some appropriate tool inside diameter ø23 23 5 mm b that fits o...

Page 195: ... Install O ring 1 Impeller housing cup 2 Impeller housing 3 O ring 4 NOTE When installing the impeller housing cup align its projection with the hole in the impeller housing When installing the water pump housing turn the drive shaft clockwise 6030 ...

Page 196: ...EMOVING INSTALLING THE SHIFT ROD ASSEMBLY Order Job Part Q ty Remarks Impeller plate Refer to WATER PUMP REGULAR ROTATION MODELS on page 6 5 1 Bolt with plate washer 3 2 Shift rod assembly 1 3 Oil seal housing 1 4 Oil seal 1 5 Spring 1 6 Shift rod 1 For installation reverse the removal procedure 6035 ...

Page 197: ...6 10 E LOWR SHIFT ROD ASSEMBLY REGULAR ROTATION MODELS REMOVING THE SHIFT ROD ASSEMBLY Remove Shift rod assembly NOTE Remove the shift rod assembly when the shift rod is in the neutral position ...

Page 198: ...G INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY Order Job Part Q ty Remarks Gear oil Refer to CHANGING AND CHECKING THE GEAR OIL on page 3 17 Shift rod assembly Refer to SHIFT ROD ASSEMBLY REGULAR ROTATION MODELS on page 6 9 1 Ring nut 1 2 Claw washer 1 3 Propeller shaft housing assembly 1 4 Straight key 1 Continued on next page 6040 ...

Page 199: ...AFT HOUSING ASSEMBLY REGULAR ROTATION MODELS 6 Order Job Part Q ty Remarks 5 Reverse gear shim 6 Propeller shaft assembly 1 7 Washer 1 8 Propeller shaft housing 1 For installation reverse the removal procedure As required 6040 ...

Page 200: ...SING Order Job Part Q ty Remarks 1 O ring 1 2 Reverse gear 1 3 Thrust washer 1 4 Ball bearing 1 5 Oil seal 2 6 Needle bearing 1 7 Propeller shaft housing 1 For assembly reverse the disassembly procedure 6045 PROPELLER SHAFT HOUSING ASSEMBLY REGULAR ROTATION MODELS ...

Page 201: ...LS 6 DISASSEMBLING ASSEMBLING THE PROPELLER SHAFT ASSEMBLY Order Job Part Q ty Remarks 1 Spring 1 2 Pin 1 3 Dog clutch 1 4 Shift rod joint 1 5 Shift rod joint slider 1 6 Ball 4 7 Spring 1 8 Ball 2 9 Propeller shaft 1 For assembly reverse the disassembly procedure 6100 ...

Page 202: ...3 Propeller shaft housing puller 1 YB 06207 90890 06502 Universal puller 2 YB 06117 Guide plate 3 90890 06501 Center bolt 4 90890 06504 6050 6054 Å 1 2 6055 ı DISASSEMBLING THE PROPELLER SHAFT HOUSING 1 Remove Reverse gear Å For USA and Canada ı For worldwide Slide hammer 1 YB 06096 Bearing separator 2 90890 06534 Guide plate 3 90890 06501 Guide plate stand 4 90890 06538 Bearing puller 5 90890 065...

Page 203: ...ler 4 90890 06535 Small universal claws 5 90890 06536 Å 6070 ı 6075 3 Remove Oil seals Needle bearing Bearing oil seal attachment 1 YB 06196 90890 06610 Driver rod 2 YB 06071 90890 06652 6080 CHECKING THE REVERSE GEAR Check Teeth Dogs Wear damage Replace the reverse gear CHECKING THE BEARINGS Check Bearings Pitting rumbling Replace CHECKING THE PROPELLER SHAFT HOUSING Check Propeller shaft housing...

Page 204: ...ER SHAFT HOUSING 1 Install Needle bearing Å For USA and Canada ı For worldwide Needle bearing installation position a 24 75 25 25 mm 0 974 0 994 in Bearing oil seal attachment 1 YB 06196 90890 06610 Driver rod 2 YB 06071 90890 06604 Bearing oil seal depth plate 3 90890 06603 6085 Å 6086 ı 2 Install Oil seals Oil seal installation position a 4 75 5 25 mm 0 187 0 207 in Bearing oil seal attachment Y...

Page 205: ...im s Propeller shaft housing assembly Straight key Claw washer Ring nut NOTE To secure the ring nut bend one claw washer tab into the slot in the ring nut and the other tabs toward the propeller shaft housing assembly Ring nut wrench 1 YB 34447 90890 06512 Ring nut wrench extension 2 90890 06513 T R Ring nut 145 Nm 14 5 m kgf 105 ft lb 6095 ...

Page 206: ...E DRIVE SHAFT Order Job Part Q ty Remarks Propeller shaft housing assembly Refer to PROPELLER SHAFT HOUSING ASSEMBLY REGULAR ROTATION MODELS on page 6 11 1 Pinion nut 1 2 Pinion 1 3 Bolt 4 4 Drive shaft housing assembly 1 5 Pinion shim 6 Thrust bearing 1 7 Drive shaft 1 Continued on next page As required 6105 ...

Page 207: ...art Q ty Remarks 8 Forward gear assembly 1 9 O ring 1 10 Oil seal cover 1 11 Oil seal 2 12 Needle bearing 1 13 Drive shaft housing 1 14 Tapered roller bearing 1 15 Needle bearing 2 16 Forward gear 1 For installation reverse the removal procedure 6105 Not reusable ...

Page 208: ...t with a new one 2 Remove Needle bearings Å For USA and Canada ı For worldwide Drive shaft holder 1 YB 06201 90890 06520 Pinion nut holder 2 90890 06505 Pinion nut holder attachment 3 90890 06508 Bearing oil seal attachment 1 YB 06196 90890 06610 Driver rod 2 YB 06071 90890 06652 Bearing separator YB 06219 90890 06534 Slide hammer 1 YB 06096 Guide plate 2 90890 06501 Guide plate stand 3 90890 0653...

Page 209: ...using Cracks damage Replace CHECKING THE BEARINGS Check Bearings Pitting rumbling Replace ASSEMBLING THE FORWARD GEAR ASSEMBLY 1 Install Needle bearings Needle bearing installation position a 21 0 21 4 mm 0 827 0 843 in Needle bearing installation position b 4 5 4 9 mm 0 177 0 193 in Bearing oil seal attachment 1 YB 06200 90890 06612 Driver rod 2 YB 06071 90890 06604 Bearing oil seal depth plate 3...

Page 210: ...ing Å For USA and Canada ı For worldwide Position a 5 75 6 25 mm 0 226 0 246 in Bearing oil seal attachment 1 YB 06196 90890 06610 Driver rod 2 YB 06071 90890 06604 Bearing oil seal depth plate 3 90890 06603 6125 Å 6126 ı 2 Install Oil seals Oil seal installation position a 0 25 0 75 mm 0 010 0 030 in Bearing oil seal attachment 1 YB 06195 90890 06633 Driver rod 2 YB 06071 90890 06652 6130 ...

Page 211: ...LAR ROTATION MODELS INSTALLING THE PINION Install Pinion Pinion nut Drive shaft holder 1 YB 06201 90890 06520 Pinion nut holder 2 90890 06505 Pinion nut holder attachment 3 90890 06508 T R Pinion nut 95 Nm 9 5 m kgf 68 ft lb 6111 ...

Page 212: ...ING THE LOWER CASE ASSEMBLY Order Job Part Q ty Remarks Forward gear Refer to DRIVE SHAFT REGULAR ROTATION MODELS on page 6 19 1 Drive shaft sleeve 1 2 Needle bearing 1 3 Tapered roller bearing outer race 1 4 Forward gear shim 5 Water seal 1 6 Water seal seat 1 For assembly reverse the disassembly procedure As required 6160 ...

Page 213: ...or USA and Canada ı For worldwide CHECKING THE DRIVE SHAFT SLEEVE Check Drive shaft sleeve Damage wear Replace CHECKING THE NEEDLE BEARING Check Needle bearing Pitting rumbling Replace ASSEMBLING THE LOWER CASE ASSEMBLY 1 Install Forward gear shim s Tapered roller bearing outer race Slide hammer 1 YB 06096 Bearing puller 2 90890 06523 Large universal claws 3 90890 06532 Bearing oil seal attachment...

Page 214: ...WR LOWER CASE ASSEMBLY REGULAR ROTATION MODELS 2 Install Needle bearing Bearing oil seal attachment 1 YB 06246 90890 06636 Bearing puller 2 YB 06029 90890 06523 Needle bearing installation plate 3 YB 06247 6180 ...

Page 215: ... ROTATION MODELS LOWER UNIT COUNTER ROTATION MODELS 6 REMOVING INSTALLING THE LOWER UNIT Order Job Part Q ty Remarks 1 Cotter pin 1 2 Propeller nut 1 3 Washer 1 4 Washer 1 5 Propeller 1 6 Spacer 1 7 Cap 1 Continued on next page 6011 ...

Page 216: ...WR 6 Order Job Part Q ty Remarks 8 Bolt 1 9 Trim tab 1 10 Bolt 1 11 Bolt 6 12 Lower unit 1 13 Dowel pin 2 14 Exhaust seal 1 For installation reverse the removal procedure 6011 LOWER UNIT COUNTER ROTATION MODELS ...

Page 217: ...leads from the batteries and the lanyard engine stop switch Put a block of wood between the cavitation plate and propeller to keep the propeller from turning 6018 REMOVING THE TRIM TAB Remove Trim tab NOTE Mark the original position a for proper installation 6012 CHECKING THE PROPELLER Check Blades Splines Cracks damage wear Replace LOWER UNIT COUNTER ROTATION MODELS ...

Page 218: ...ing it Be sure to remove the battery leads from the batteries and the lanyard engine stop switch Put a block of wood between the cavitation plate and propeller to keep the propeller from turning NOTE If the groove in the propeller nut is not aligned with the cotter pin hole tighten the nut further until they are aligned T R Propeller nut 55 Nm 5 5 m kgf 40 ft lb 6019 ...

Page 219: ...N MODELS 6 REMOVING INSTALLING THE WATER PUMP Order Job Part Q ty Remarks Lower unit Refer to LOWER UNIT COUNTER ROTATION MODELS on page 6 28 1 Bolt 4 2 Plate washer 4 3 Impeller housing 1 4 Impeller housing cup 1 5 Grommet 1 6 Spacer 1 7 Collar 1 Continued on next page 6022 ...

Page 220: ...Q ty Remarks 8 Spacer 1 9 Washer 2 10 Wave washer 1 11 Impeller 1 12 Woodruff key 1 13 Impeller plate 1 14 Gasket 1 15 Dowel pin 2 For installation reverse the removal procedure 6022 Not reusable WATER PUMP COUNTER ROTATION MODELS ...

Page 221: ...Y Check Woodruff key Damage wear Replace INSTALLING THE IMPELLER AND IMPELLER HOUSING 1 Install Impeller 1 Washers 2 Wave washer 3 Spacer 4 Collar 5 NOTE Make sure that the slit a in the impeller is aligned with the woodruff key The collar and spacer should fit together firmly Install the collar with some appropriate tool inside diameter ø23 23 5 mm b that fits over the drive shaft as shown 6021 6...

Page 222: ...2 Install O ring 1 Impeller housing cup 2 Impeller housing 3 O ring 4 NOTE When installing the impeller housing cup align its projection with the hole in the impeller housing When installing the water pump housing turn the drive shaft clockwise 6030 ...

Page 223: ...EMOVING INSTALLING THE SHIFT ROD ASSEMBLY Order Job Part Q ty Remarks Impeller plate Refer to WATER PUMP COUNTER ROTATION MODELS on page 6 32 1 Bolt with plate washer 3 2 Shift rod assembly 1 3 Oil seal housing 1 4 Oil seal 1 5 Spring 1 6 Shift rod 1 For installation reverse the removal procedure 6195 ...

Page 224: ...6 37 E LOWR REMOVING THE SHIFT ROD ASSEMBLY Remove Shift rod assembly NOTE Remove the shift rod assembly when the shift rod is in the neutral position SHIFT ROD ASSEMBLY COUNTER ROTATION MODELS ...

Page 225: ...AFT HOUSING ASSEMBLY Order Job Part Q ty Remarks Gear oil Refer to CHANGING AND CHECKING THE GEAR OIL on page 3 17 Shift rod assembly Refer to SHIFT ROD ASSEMBLY COUNTER ROTATION MODELS on page 6 36 1 Ring nut 1 2 Claw washer 1 3 Propeller shaft housing assembly 1 4 Straight key 1 5 Forward gear shim For installation reverse the removal procedure As required 6200 ...

Page 226: ... DISASSEMBLING ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY Order Job Part Q ty Remarks 1 O ring 1 2 Spring 1 3 Pin 1 4 Dog clutch 1 5 Forward gear assembly 1 6 Propeller shaft assembly 1 7 Thrust bearing 1 8 Propeller shaft shim Continued on next page As required 6205 ...

Page 227: ... bearing 1 11 Propeller shaft housing 1 12 Forward gear 1 13 Thrust washer 1 14 Tapered roller bearing outer race 1 15 Tapered roller bearing 1 For assembly reverse the disassembly procedure 6205 Not reusable PROPELLER SHAFT HOUSING ASSEMBLY COUNTER ROTATION MODELS ...

Page 228: ...TER ROTATION MODELS 6 DISASSEMBLING ASSEMBLING THE PROPELLER SHAFT ASSEMBLY Order Job Part Q ty Remarks 1 Shift rod joint 1 2 Shift rod joint slider 1 3 Ball 4 4 Spring 1 5 Ball 2 6 Propeller shaft 1 For assembly reverse the disassembly procedure 6235 ...

Page 229: ...ch extension 2 90890 06513 6050 3 Remove Propeller shaft housing assembly Straight key Forward gear shim s Slide hammer attachment 1 YB 06335 90890 06514 Slide hammer 2 YB 06096 90890 06531 1 2 6215 REMOVING THE PROPELLER SHAFT ASSEMBLY Remove Propeller shaft assembly Forward gear assembly Propeller shaft housing puller 1 YB 06207 90890 06502 Universal puller 2 YB 06117 Guide plate 2 90890 06501 C...

Page 230: ...ring CAUTION Do not reuse the bearing always replace it with a new one Bearing oil seal attachment 1 YB 06196 90890 06653 Driver rod 2 YB 06071 90890 06652 Bearing separator YB 06219 90890 06534 6225 6230 CHECKING THE FORWARD GEAR Check Teeth Dogs Damage wear Replace CHECKING THE BEARINGS Check Bearings Pitting rumbling Replace CHECKING THE PROPELLER SHAFT HOUSING Check Propeller shaft housing Cra...

Page 231: ...ER SHAFT HOUSING 1 Install Needle bearing Å For USA and Canada ı For worldwide Needle bearing installation position a 24 75 25 25 mm 0 974 0 994 in Bearing oil seal attachment 1 YB 06196 90890 06610 Driver rod 2 YB 06071 90890 06604 Bearing oil seal depth plate 3 90890 06603 6085 Å 6086 ı 2 Install Oil seals Oil seal installation position a 4 75 5 25 mm 0 187 0 207 in Bearing oil seal attachment Y...

Page 232: ...LER SHAFT HOUSING ASSEMBLY Install Forward gear shim s Propeller shaft housing assembly Straight key Claw washer Ring nut NOTE To secure the ring nut bend one claw washer tab into the slot in the ring nut and the other tabs toward the propeller shaft housing assembly Ring nut wrench 1 YB 34447 90890 06512 Ring nut wrench extension 2 90890 06513 T R Ring nut 145 Nm 14 5 m kgf 105 ft lb 6095 ...

Page 233: ...E DRIVE SHAFT Order Job Part Q ty Remarks Propeller shaft housing assembly Refer to PROPELLER SHAFT HOUSING ASSEMBLY COUNTER ROTATION MODELS on page 6 38 1 Pinion nut 1 2 Pinion 1 3 Bolt 4 4 Drive shaft housing assembly 1 5 Pinion shim 6 Thrust bearing 1 7 Drive shaft 1 Continued on next page As required 6240 ...

Page 234: ...1 9 Thrust bearing 1 10 O ring 1 11 Oil seal cover 1 12 Oil seal 2 13 Needle bearing 1 14 Drive shaft housing 1 15 Roller bearing inner race 1 16 Needle bearing 2 17 Reverse gear 1 For installation reverse the removal procedure 6240 DRIVE SHAFT COUNTER ROTATION MODELS ...

Page 235: ...ttachment 3 90890 06508 Slide hammer 1 YB 06096 Bearing puller 2 90890 06535 Small universal claws 3 90890 06536 6110 6250 Å 6172 ı 3 2 DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY Remove Oil seals Needle bearing DISASSEMBLING THE REVERSE GEAR ASSEMBLY 1 Remove Roller bearing inner race Bearing oil seal attachment 1 YB 06196 90890 06610 Driver rod 2 YB 06071 90890 06652 Bearing separator YB 0621...

Page 236: ...de plate stand 3 90890 06538 Bearing puller 4 90890 06535 Small universal claws 5 90890 06536 6145 Å 6146 ı CHECKING THE PINION Check Teeth Damage wear Replace CHECKING THE DRIVE SHAFT Check Drive shaft Damage wear Replace CHECKING THE DRIVE SHAFT HOUSING Check Drive shaft housing Cracks damage Replace CHECKING THE BEARINGS Check Bearings Pitting rumbling Replace ...

Page 237: ...1 YB 06200 90890 06612 Driver rod 2 YB 06071 90890 06604 Bearing oil seal depth plate 3 90890 06603 6150 2 Install Roller bearing inner race Bearing oil seal attachment 90890 06660 6285 ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY 1 Install Needle bearing Å For USA and Canada ı For worldwide Position a 5 75 6 25 mm 0 226 0 246 in Bearing oil seal attachment 1 YB 06196 90890 06610 Driver rod 2 YB 06...

Page 238: ...earing Reverse gear assembly NOTE Install the thrust bearing onto the reverse gear assembly and position the thrust bear ing so its rounded side faces away from the reverse gear INSTALLING THE PINION Install Pinion Pinion nut T R Pinion nut 95 Nm 9 5 m kgf 68 ft lb Drive shaft holder 1 YB 06201 90890 06520 Pinion nut holder 2 90890 06505 Pinion nut holder attachment 3 90890 06508 6255 6111 DRIVE S...

Page 239: ...E LOWER CASE ASSEMBLY Order Job Part Q ty Remarks Reverse gear Refer to DRIVE SHAFT COUNTER ROTATION MODELS on page 6 46 1 Drive shaft sleeve 1 2 Needle bearing 18 3 Needle bearing outer case 1 4 Roller bearing 1 5 Reverse gear shim 6 Water seal 1 7 Water seal seat 1 For assembly reverse the disassembly procedure As required 6290 ...

Page 240: ...s Å For USA and Canada ı For worldwide Slide hammer 1 YB 06096 Bearing puller 2 90890 06523 Large universal claws 3 90890 06532 6300 Å 6171 ı CHECKING THE DRIVE SHAFT SLEEVE Check Drive shaft sleeve Damage wear Replace CHECKING THE NEEDLE BEARING Check Needle bearing Pitting rumbling Replace ASSEMBLING THE LOWER CASE ASSEMBLY 1 Install Reverse gear shim s Roller bearing Bearing oil seal attachment...

Page 241: ...WER CASE ASSEMBLY COUNTER ROTATION MODELS 2 Install Needle bearing outer race Bearing oil seal attachment 1 YB 06246 90890 06636 Bearing puller 2 YB 06029 90890 06523 Needle bearing installation plate 3 YB 06247 6314 ...

Page 242: ...ere is no need to select shims when reassembling with the original case and inner parts Shim calculations are required when reas sembling with the original inner parts and a new case the difference between the original inner parts and the new case Measurements and adjustments are required when replacing the inner part s 6495 ...

Page 243: ...specified value M0 NOTE P is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is missing or unreadable assume a P value of 0 and check the backlash when the unit is assembled If the P mark is negative then sub tract the P value from the measure ment Example If P is 5 then M0 1 00 5 100 mm 1 00 0 ...

Page 244: ...B 34432 7 11 T R Pinion nut 95 Nm 9 5 m kgf 69 ft lb 6515 4 Measure the specified measurement M NOTE Measure the clearance between the pin ion height gauge and the lower surface of the pinion as shown Perform the same measurement at three points on the pinion Find the average of the measurements M 2 Adjust Shim thickness T3 Remove or add shim s NOTE M0 M should be as close to 0 as pos sible Availa...

Page 245: ...he specified value M0 NOTE F is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is missing or unreadable assume an F value of 0 and check the backlash when the unit is assembled If the F mark is negative then sub tract the F value from the measure ment Example If F is 5 then M0 1 60 5 100 mm 1 6...

Page 246: ...m s 2 NOTE If the original shim s is unavailable start with a 0 50 mm shim 3 Measure the specified measurement M Shimming gauge YB 34446 1 3 4 8 6535 2 Adjust Shim thickness T1 Remove or add shim s NOTE M0 M should be as close to 0 as pos sible Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm ...

Page 247: ...te the specified value M0 NOTE R is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the R mark is missing or unreadable assume an R value of 0 and check the backlash when the unit is assembled If the R mark is negative then add the R value to the measurement Example If R is 5 then M0 1 80 5 100 mm 1 80 0 0...

Page 248: ...im s is unavailable start with a 0 50 mm shim Turn the reverse gear assembly a few times until the gear and bearing are hori zontal 3 Measure the specified measurement M 2 Adjust Shim thickness T2 Remove or add shim s NOTE M0 M should be as close to 0 as pos sible Shimming gauge YB 34468 1 Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm M 6555 ...

Page 249: ...s no need to select shims when reassembling with the original case and inner parts Shim calculations are required when reas sembling with the original inner parts and a new case the difference between the original inner parts and the new case Measurements and adjustments are required when replacing the inner part s 6495 ...

Page 250: ...sher 3 2 Install the pinion and pinion nut 3 Install the pinion height gauge NOTE After the wing nuts contact the fixing plate tighten them another 1 4 of a turn 4 Measure M4 NOTE Measure the clearance between the pin ion height gauge and the pinion as shown Perform the same measurement at three points on the pinion Find the average of the measurements M4 Digital caliper 90890 06704 T R Pinion nut...

Page 251: ... and check the backlash when the unit is assembled If the P mark is negative then add the P value to the measurement Example If M3 is 46 85 mm M4 is 32 52 mm and P is 5 then T3 80 0 5 100 46 85 32 52 mm 80 0 0 05 46 85 32 52 mm 0 58 mm 6 Select the pinion shim s T3 Pinion shim thickness T3 80 0 P 100 M3 M4 Calculated numeral at 1 100th place Rounded numeral More than or less 0 00 0 02 0 00 0 02 0 ...

Page 252: ...ement at three points on the roller bearing outer race Find the average of the measurements M1 Shimming plate 1 90890 06701 Digital caliper 2 90890 06704 6595 6600 2 Calculate the forward gear shim thick ness T1 NOTE F is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is missing or unreadable a...

Page 253: ...5 0 08 0 05 0 08 0 10 0 08 Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm SELECTING THE REVERSE GEAR SHIMS NOTE Select the shim thickness T2 by using the specified measurement s and the calcula tion formula Select Shim thickness T2 Selecting steps 1 Measure M2 NOTE Measure the height of the gear as shown Perform the same measurement at three points on the gear Find the average ...

Page 254: ...value of 0 and check the backlash when the unit is assembled If the R mark is negative then sub tract the R value from the measure ment Example If M2 is 30 50 mm R is 2 then T2 30 50 29 0 2 100 mm 30 50 29 0 0 02 mm 1 48 mm 3 Select the reverse gear shim s T2 Reverse gear shim thickness T2 M2 29 0 R 100 Calculated numeral at 1 100th place Rounded numeral More than or less 0 00 0 02 0 02 0 02 0 05 ...

Page 255: ...aller than specification the pinion may be too low MEASURING THE FORWARD GEAR BACKLASH 1 Measure Forward gear backlash Out of specification Adjust Measuring steps 1 Set the shift rod into the neutral posi tion 2 Install the propeller shaft housing puller so it pushes against the propel ler shaft Forward gear backlash 0 25 0 46 mm 0 010 0 018 in Shift rod wrench YB 06052 90890 06052 Propeller shaft...

Page 256: ...own 6 Slowly turn the drive shaft clockwise and counterclockwise When the drive shaft stops in each direction measure the backlash 2 Adjust Forward gear shim Remove or add shim s M Measurement Backlash indicator 5 YB 06265 90890 06706 Magnetic base plate 6 YB 07003 90890 07003 Dial gauge set 7 YU 03097 90890 01252 Magnetic base 8 YU 34481 90890 06705 Forwardgear backlash Shim thickness Less than 0...

Page 257: ...peller without the spacer 1 and then tighten the propeller nut T R Propeller nut 10 Nm 1 0 m kgf 7 2 ft lb 6665 3 Install the backlash indicator onto the drive shaft on the 22 4 mm 0 88 in diameter portion of the drive shaft 4 Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indi cator 5 Set the lower unit upside down Backlash indicator 1 ...

Page 258: ...nterclockwise When the drive shaft stops in each direction measure the backlash 2 Adjust Reverse gear shim Remove or add shim s M Measurement Reverse gear backlash Shim thickness Less than 0 74 mm 0 029 in To be increased by 1 02 M 0 54 More than 1 29 mm 0 051 in To be decreased by M 1 02 0 54 ...

Page 259: ...h the original case and inner parts Shim calculations are required when reas sembling with the original inner parts and a new case the difference between the original inner parts and the new case Measurements and adjustments are required when replacing the inner part s 6500 SHIMMING COUNTER ROTATION MODELS FOR USA AND CANADA ...

Page 260: ...e specified value M0 NOTE P is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is missing or unreadable assume a P value of 0 and check the backlash when the unit is assembled If the P mark is negative then sub tract the P value from the measure ment Example If P is 5 then M0 1 00 5 100 mm 1 00 ...

Page 261: ...B 34432 7 11 T R Pinion nut 95 Nm 9 5 m kgf 69 ft lb 6515 4 Measure the specified measurement M NOTE Measure the clearance between the pin ion height gauge and the lower surface of the pinion as shown Perform the same measurement at three points on the pinion Find the average of the measurements M 2 Adjust Shim thickness T3 Remove or add shim s NOTE M0 M should be as close to 0 as pos sible Availa...

Page 262: ...specified value M0 NOTE F is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is missing or unreadable assume an F value of 0 and check the backlash when the unit is assembled If the F mark is negative then sub tract the F value from the measure ment Example If F is 5 then M0 29 10 5 100 mm 29 10...

Page 263: ...t M 6540 2 Adjust Shim thickness T1 Remove or add shim s NOTE M0 M should be as close to 0 as pos sible Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm SELECTING THE FORWARD GEAR SHIMS NOTE Find the shim thickness T2 by selecting shims until the specified value M0 is obtained with the special tool 6545 1 Measure Specified measurement M Out of specified value M0 Adjust Specified ...

Page 264: ...check the backlash when the unit is assembled If the R mark is negative then add the R value to the measurement Example If R is 5 then M0 1 30 5 100 mm 1 30 0 05 mm 1 25 mm If R is 3 then M0 1 30 3 100 mm 1 30 0 03 mm 1 33 mm 6550 2 Install the shimming gauge bearing thrust washer forward gear and shim s NOTE If the original shim s is unavailable start with a 0 50 mm shim Turn the forward gear ass...

Page 265: ...obtained with the special tool 1 Install Shim s 1 Thrust bearing 2 Propeller shaft 3 Tapered roller bearing 4 Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 6560 6565 2 Measure Propeller shaft free play Out of specification Adjust 3 Adjust Propeller shaft free play Remove or add shim s Propeller shaft free play 0 30 0 05 mm 0 012 0 002 in Magnetic base 1 YU 34481 Dial gauge set...

Page 266: ...s no need to select shims when reassembling with the original case and inner parts Shim calculations are required when reas sembling with the original inner parts and a new case the difference between the original inner parts and the new case Measurements and adjustments are required when replacing the inner part s 6500 ...

Page 267: ...sher 3 2 Install the pinion and pinion nut 3 Install the pinion height gauge NOTE After the wing nuts contact the fixing plate tighten them another 1 4 of a turn 4 Measure M4 NOTE Measure the clearance between the pin ion height gauge and the pinion as shown Perform the same measurement at three points on the pinion Find the average of the measurements M4 Digital caliper 90890 06704 T R Pinion nut...

Page 268: ... and check the backlash when the unit is assembled If the P mark is negative then add the P value to the measurement Example If M3 is 46 85 mm M4 is 32 52 mm and P is 5 then T3 80 0 5 100 46 85 32 52 mm 80 0 0 05 46 85 32 52 mm 0 58 mm 6 Select the pinion shim s T3 Pinion shim thickness T3 80 0 P 100 M3 M4 Calculated numeral at 1 100th place Rounded numeral More than or less 0 00 0 02 0 00 0 02 0 ...

Page 269: ...eight of the bearing as shown Perform the same measurement at three points on the roller bearing outer race Find the average of the measurements M1 Digital caliper 90890 06704 6595 6605 2 Calculate the reverse gear shim thick ness T1 NOTE F is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is m...

Page 270: ... 0 08 0 05 0 08 0 10 0 08 Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm SELECTING THE FORWARD GEAR SHIMS NOTE Select the shim thickness T2 by using the specified measurement s and the calcula tion formula Select Shim thickness T2 Selecting steps 1 Measure M2 NOTE Measure the height of the gear as shown Perform the same measurement at three points on the gear Find the average o...

Page 271: ...value of 0 and check the backlash when the unit is assembled If the R mark is negative then sub tract the R value from the measure ment Example If M2 is 30 50 mm R is 2 then T2 30 50 29 5 2 100 mm 30 50 29 5 0 02 mm 0 98 mm 3 Select the forward gear shim s T2 Forward gear shim thickness T2 M2 29 5 R 100 Calculated numeral at 1 100th place Rounded numeral More than or less 0 00 0 02 0 02 0 02 0 05 ...

Page 272: ...ecial tool 6630 1 Install Shim s 1 Thrust bearing 2 Propeller shaft 3 Tapered roller bearing 4 6635 2 Measure Propeller shaft free play Out of specification Adjust Propeller shaft free play 0 30 0 05 mm 0 012 0 002 in Magnetic base 1 90890 06705 Dial gauge set 2 90890 01252 6640 3 Adjust Propeller shaft free play Remove or add shim s Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 ...

Page 273: ...aller than specification the pinion may be too low MEASURING THE FORWARD GEAR BACKLASH 1 Measure Forward gear backlash Out of specification Adjust Measuring steps 1 Set the shift rod into the neutral posi tion 2 Install the propeller shaft housing puller so it pushes against the propel ler shaft Forward gear backlash 0 21 0 43 mm 0 008 0 017 in Shift rod wrench YB 06052 90890 06052 Propeller shaft...

Page 274: ... drive shaft stops in each direction measure the backlash 2 Adjust Forward gear shim Remove or add shim s M Measurement Backlash indicator 5 YB 06265 90890 06706 Magnetic base plate 6 YB 07003 90890 07003 Dial gauge set 7 YU 03097 90890 01252 Magnetic base 8 YU 34481 90890 06705 Forward gear backlash Shim thickness Less than 0 21 mm 0 008 in To be increased by 0 32 M 0 54 More than 0 43 mm 0 017 i...

Page 275: ...o the drive shaft on the 22 4 mm 0 88 in diameter portion of the drive shaft 4 Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indi cator 5 Set the lower unit upside down Backlash indicator 1 YB 06265 90890 06706 Magnetic base plate 2 YB 07003 90890 07003 Dial gauge set 3 YU 03097 90890 01252 Magnetic base 4 YU 34481 90890 06705 6670 6 Tu...

Page 276: ...ch 11 Slowly turn the drive shaft clockwise and counterclockwise When the drive shaft stops in each direction measure the backlash NOTE When measuring the reverse gear backlash turn the shift rod wrench slightly towards the reverse position 2 Adjust Reverse gear shim Remove or add shim s M Measurement Reversegear backlash Shim thickness Less than 0 97 mm 0 038 in To be decreased by 1 13 M 0 54 Mor...

Page 277: ......

Page 278: ... BRACKETS 7 13 STEERING ARM 7 15 REMOVING INSTALLING THE STEERING ARM 7 15 SWIVEL BRACKET ASSEMBLY 7 16 DISASSEMBLING ASSEMBLING THE SWIVEL BRACKET ASSEMBLY 7 16 POWER TRIM AND TILT UNIT 7 18 REMOVING INSTALLING THE POWER TRIM AND TILT UNIT 7 18 REMOVING THE POWER TRIM AND TILT UNIT 7 20 BLEEDING THE POWER TRIM AND TILT UNIT ON OUTBOARD 7 20 RESERVOIR AND POWER TRIM AND TILT MOTOR 7 22 REMOVING IN...

Page 279: ...HECKING THE GEAR PUMP UNIT 7 33 ASSEMBLING THE GEAR PUMP UNIT 7 34 INSTALLING THE GEAR PUMP UNIT 7 35 INSTALLING THE TILT RAM ASSEMBLY 7 35 TRIM RAM ASSEMBLIES AND FREE PISTON 7 37 REMOVING INSTALLING THE TRIM RAM ASSEMBLIES AND FREE PISTON 7 37 REMOVING THE TRIM RAM END SCREWS 7 38 REMOVING THE FREE PISTON 7 38 CHECKING THE TRIM RAMS 7 39 CHECKING THE FREE PISTON 7 39 CHECKING THE TRIM RAM CYLIND...

Page 280: ...ING 7 REMOVING INSTALLING THE BOTTOM COWLING Order Job Part Q ty Remarks Power unit Refer to POWER UNIT on page 5 4 1 Shift rod assembly 1 2 Bolt 1 3 Holder 1 4 Bolt 2 5 Bracket 1 6 Battery lead 2 7 Hose guide 1 Continued on next page 7010 ...

Page 281: ... Part Q ty Remarks 8 Power trim and tilt lead 1 9 Trim sensor lead 1 10 Bolt 4 11 Ground lead 1 12 Speedometer hose 1 13 Flushing hose 1 14 Bottom cowling 1 For installation reverse the removal procedure 7010 BOTTOM COWLING ...

Page 282: ...SSEMBLING THE BOTTOM COWLING Order Job Part Q ty Remarks 1 Bolt 3 2 Lower spring holder 3 3 Spring 3 4 Bolt 3 5 Upper spring holder 3 6 Wave washer 3 7 Bushing 6 8 Clamp lever 3 9 Bolt 6 Continued on next page 7030 BOTTOM COWLING ...

Page 283: ... Order Job Part Q ty Remarks 10 Clamp plate 3 11 Pilot water outlet 1 12 Wire harness clamp 1 13 Bolt 1 14 Cable holder 1 15 Grommet 2 16 Collar 2 17 Grommet 4 18 Collar 4 Continued on next page 7030 BOTTOM COWLING ...

Page 284: ... Q ty Remarks 19 Bolt 2 20 Trailer switch holder 1 21 Trailer switch 1 22 Bolt 8 23 Ground lead 1 24 Silencer cover 1 25 Gasket 1 26 Bottom cowling 1 For assembly reverse the disassembly procedure 7035 Not reusable BOTTOM COWLING ...

Page 285: ...SEMBLING ASSEMBLING THE SHIFT ROD ASSEMBLY Order Job Part Q ty Remarks 1 Screw 1 2 Spring 1 3 Ball 1 4 Clip 1 5 Shift rod lever 1 6 Rubber seal 1 7 Circlip 1 8 Shift rod bracket 1 9 Bushing 1 10 Shift rod 1 For assembly reverse the disassembly procedure 7040 ...

Page 286: ...UPPER CASE ASSEMBLY Order Job Part Q ty Remarks Lower unit Refer to LOWER UNIT REGULAR ROTATION MODELS on page 6 1 Bottom cowling Refer to BOTTOM COWLING on page 7 1 1 Bolt 1 2 Ground lead 1 upper case to swivel bracket 3 Bolt 2 4 Lower mount cover 2 Continued on next page 7050 ...

Page 287: ...7 8 BRKT E UPPER CASE ASSEMBLY 7 Order Job Part Q ty Remarks 5 O ring 2 6 Nut 2 7 Self locking nut 2 8 Upper case assembly 1 9 Rubber seal 1 For installation reverse the removal procedure 7050 ...

Page 288: ...EMBLING ASSEMBLING THE UPPER CASE ASSEMBLY Order Job Part Q ty Remarks 1 Bolt 3 2 Upper mount bracket 1 3 Upper mount 2 4 Bolt 2 5 Bolt 4 6 Lower mount bracket 2 7 Lower mount 2 8 Ground lead 1 9 Bolt 2 10 Bolt 2 Continued on next page 7060 ...

Page 289: ...y Remarks 11 Bolt 2 12 Muffler assembly 1 13 Rubber seal 1 14 Muffler 1 15 Rubber seal 1 16 Rubber seal 1 17 Upper case 1 18 Dowel pin 2 19 Circlip 1 20 Bushing 1 For assembly reverse the disassembly procedure 7060 UPPER CASE ASSEMBLY ...

Page 290: ...G ASSEMBLING THE EXHAUST MANIFOLD ASSEMBLY Order Job Part Q ty Remarks 1 Bolt 5 2 Muffler 1 3 Gasket 1 4 Water tube 1 5 Water seal 1 6 Bolt 4 7 Exhaust manifold 1 8 Gasket 1 Continued on next page 7070 Not reusable Not reusable EXHAUST MANIFOLD ASSEMBLY ...

Page 291: ... ty Remarks 9 Bolt 4 10 Lower exhaust manifold guide 1 11 Gasket 1 12 Upper exhaust manifold guide 1 13 Plastic locking tie 1 Salt water models 14 Flushing hose 1 Salt water models For assembly reverse the disassembly procedure 7070 Not reusable Not reusable ...

Page 292: ... ty Remarks Upper case assembly Refer to UPPER CASE ASSEMBLY on page 7 7 1 Rubber cap 3 2 Grease nipple 3 3 Ground lead 1 4 Bolt 4 5 Ground lead 1 6 Anode bracket 2 7 Anode 1 8 Trim sensor 1 Refer to ADJUSTING THE TRIM SENSOR CAM on page 3 16 Continued on next page 7080 CLAMP BRACKETS ...

Page 293: ... Q ty Remarks 9 Self locking nut 1 10 Bolt 2 11 Clamp bracket bolt 1 12 Starboard clamp bracket 1 13 Port clamp bracket 1 14 Bushing 2 15 Swivel bracket assembly 1 For installation reverse the removal procedure 7080 CLAMP BRACKETS ...

Page 294: ...M Order Job Part Q ty Remarks Upper case assembly Refer to UPPER CASE ASSEMBLY on page 7 7 1 Circlip 1 2 Steering arm yoke 1 3 Washer 1 4 Washer 1 5 O ring 1 6 Steering arm 1 7 Washer 1 8 Bushing 2 9 Swivel bracket assembly 1 For installation reverse the removal procedure 7090 ...

Page 295: ...RACKET ASSEMBLY 7 DISASSEMBLING ASSEMBLING THE SWIVEL BRACKET ASSEMBLY Order Job Part Q ty Remarks Steering arm Refer to STEERING ARM on page 7 15 1 Nut 2 2 Trim stopper 2 3 Bolt 1 4 Spring holder 1 5 Spring 1 6 Pin 2 Continued on next page 7100 ...

Page 296: ...der Job Part Q ty Remarks 7 Starboard tilt stop lever 1 8 Port tilt stop lever 1 9 Bushing 2 10 Bushing 2 11 Tilt stop lever joint assembly 1 For assembly reverse the disassembly procedure 7100 SWIVEL BRACKET ASSEMBLY ...

Page 297: ...UNIT 7 REMOVING INSTALLING THE POWER TRIM AND TILT UNIT Order Job Part Q ty Remarks Tilt up the outboard 1 Plastic locking tie 3 2 Power trim and tilt lead 2 3 Bolt 1 4 Ground lead 1 5 Circlip 1 6 Upper mounting pin 1 Continued on next page 7110 Not reusable ...

Page 298: ... 19 BRKT E POWER TRIM AND TILT UNIT 7 Order Job Part Q ty Remarks 7 Bolt 2 8 Washer 2 9 Lower mounting pin 1 10 Power trim and tilt unit 1 11 Collar 6 For installation reverse the removal procedure 7110 ...

Page 299: ... and then turn the tilt stop levers 1 to support it Remove Power trim and tilt unit NOTE Slightly lower the tilt ram assembly and then remove the power trim and tilt unit 7120 BLEEDING THE POWER TRIM AND TILT UNIT ON OUTBOARD NOTE Install the power trim and tilt unit onto the outboard before bleeding Bleed Air bubbles from the power trim and tilt unit Bleeding steps 1 Connect the battery leads to ...

Page 300: ...tilt switch in the up position until the out board is fully tilted up 7 Turn the tilt stop levers to support the outboard Then let the power trim and tilt fluid settle for about 5 minutes 8 Remove the reservoir cap 2 and check that fluid is up to the brim as shown Add fluid if the level is below the brim 9 Install the power trim and tilt reservoir cap 10 Repeat the above steps two or three times u...

Page 301: ...ERVOIR AND POWER TRIM AND TILT MOTOR Order Job Part Q ty Remarks Power trim and tilt unit Refer to POWER TRIM AND TILT UNIT on page 7 18 1 Reservoir cap 1 2 Bolt 3 3 Reservoir 1 4 Bolt 4 5 Power trim and tilt motor 1 6 O ring 1 7 Drive pin 1 8 Gear pump housing filter 1 For installation reverse the removal procedure 7160 ...

Page 302: ...r do not push the tilt ram down This may cause hydraulic fluid to spurt out from the port CAUTION Do not wipe hydraulic system components with rags paper tissues or the like as fibers from such material will cause mal functions if they enter the system CHECKING THE RESERVOIR 1 Drain Power trim and tilt fluid 2 Check Reservoir Cracks damage leaks Replace CHECKING THE GEAR PUMP HOUSING FILTER Check ...

Page 303: ...reaches the top of the gear pump housing Recommended power trim and tilt fluid ATF Dexron II 7170 3 Bleed Air bubbles NOTE Remove all of the air bubbles with a syringe or suitable tool as shown Turn the gear pump gears with a screw driver and then remove any air between the gear teeth 4 Install O ring 1 Power trim and tilt motor 2 Bolts 3 NOTE Align the armature shaft with the recess in the drive ...

Page 304: ...ng must be done before install ing the power trim and tilt unit onto the out board 1 Bleed Air bubbles from the power trim and tilt unit Bleeding steps 1 Set the power trim and tilt unit upright 2 Connect the leads of the power trim and tilt on the battery terminals until the trim and tilt ram assemblies are fully compressed NOTE If the rams will not go down refer to the fol lowing A Connect the l...

Page 305: ...minals in the up and down positions D If step C was unsuccessful disassemble check and correct any problems with the power trim and tilt unit 3 Connect the leads on the battery termi nals in the up position until the trim and tilt ram assemblies are fully extended 7220 4 Remove the power trim and tilt reser voir cap and check that fluid is up to the brim as shown Add power trim and tilt fluid if t...

Page 306: ...lve attachment and hydraulic pressure gauge and tighten them to the specified torque NOTE Remove the manual valve and then quickly attach the special tools before any fluid comes out Hydraulic pressure with the power trim and tilt ram assemblies fully extended 9 8 11 8 MPa 100 120 kg cm2 with the power trim and tilt ram assemblies fully compressed 5 9 8 8 MPa 60 90 kg cm2 Up relief valve attachmen...

Page 307: ...es sure remove the special tools and quickly attach the down relief valve attachment 7 Remove the reservoir cap and check that fluid is up to the brim as shown Add fluid if the level is below the brim 8 Install the reservoir cap 9 Connect the leads on the battery termi nals in the down position until the power trim and tilt ram assemblies are fully compressed Then measure the hydraulic pressure Hy...

Page 308: ...s sure connect the leads on the battery terminals in the up position until the power trim and tilt ram assemblies are fully extended 11 Remove the special tools 12 Install the manual valve and circlip NOTE After measuring the hydraulic pressure bleed the power trim and tilt unit 7280 7220 ...

Page 309: ...LING THE TILT RAM ASSEMBLY AND GEAR PUMP UNIT Order Job Part Q ty Remarks Reservoir and power trim and tilt motor Refer to RESERVOIR AND POWER TRIM AND TILT MOTOR on page 7 22 1 Manual valve 1 2 Tilt ram end screw 1 3 Tilt ram assembly 1 4 O ring 2 5 Bolt 3 6 Gear pump unit 1 Continued on next page 7290 ...

Page 310: ...R PUMP UNIT 7 Order Job Part Q ty Remarks 7 Check valve assembly 1 8 Bolt 2 9 Gear pump 1 10 Shuttle valve 2 11 Check valve 2 12 Up relief valve assembly 1 13 Down relief valve assembly 1 For installation reverse the removal procedure 7290 ...

Page 311: ... Remove Bolts 1 Gear pump unit 2 O rings 3 Check valve 4 NOTE Place a container under the power trim and tilt unit End screw wrench YB 06548 90890 06548 7300 7310 DISASSEMBLING THE GEAR PUMP UNIT 1 Remove Bolts 1 Pump gears 2 Up relief valve assembly 3 Balls 4 76 mm 0 187 in 4 Shuttle valves 5 Balls 3 18 mm 0 125 in 6 NOTE When removing the pump gears note their original direction and position for...

Page 312: ...ECKING THE TILT RAM Check Tilt ram Excessive scratches Replace Bends excessive corrosion Replace Rust Polish with 400 600 grit sandpaper CHECKING THE GEAR PUMP UNIT Check Shuttle valves 1 Check valve assemblies 2 Clogs damage wear Replace Pump gears 3 Damage wear Replace the gear pump unit Up relief valve assembly 4 Down relief valve assembly 5 Damage wear Replace the gear pump unit Balls 6 Damage...

Page 313: ...TE Apply grease to the balls to prevent them from falling out of the gear pump 7340 2 Install O ring 1 Ball 3 18 mm 0 125 in 2 Up relief valve pin 3 Spring 4 Up relief valve 5 Up relief valve assembly 6 7350 3 Install O rings 1 Check valves 2 Balls 4 76 mm 0 187 in 3 Pump gears 4 4 Install Gear pump 1 Bolts 2 Filter 3 O ring 4 Down relief valve 5 Filter 6 NOTE Tighten the bolts evenly and make sur...

Page 314: ... is on the tilt ram cylinder side as shown 7380 2 Install Gear pump unit 1 Bolts 2 7390 INSTALLING THE TILT RAM ASSEMBLY WARNING To prevent the hydraulic fluid from spurt ing out due to internal pressure the tilt ram should be kept at full length 1 Fill Tilt ram cylinder NOTE Hold the power trim and tilt unit in a vise using aluminum plates on both sides Recommended power trim and tilt fluid ATF D...

Page 315: ...top of the gear pump unit Recommended power trim and tilt fluid ATF Dexron II 7410 3 Install Tilt ram assembly NOTE Place the tilt ram end screw at the bottom of the tilt ram and install the tilt ram assem bly into the tilt ram cylinder 7420 4 Tighten Tilt ram end screw End screw wrench YB 06548 90890 06548 T R Tilt ram end screw 130 Nm 13 m kgf 94 ft lb 7430 ...

Page 316: ...IM RAM ASSEMBLIES AND FREE PISTON Order Job Part Q ty Remarks Tilt ram assembly and gear pump unit Refer to TILT RAM ASSEMBLY AND GEAR PUMP UNIT on page 7 30 1 Trim ram end screw 2 2 Trim ram 2 3 O ring 2 4 Seal ring 2 5 Free piston 1 6 O ring 1 7 Piston ring 1 For installation reverse the removal procedure 7440 ...

Page 317: ...STON 1 Drain Power trim and tilt fluid NOTE After removing the trim ram assemblies drain the fluid from the power trim and tilt unit 2 Install Trim ram assemblies 1 NOTE Finger tighten the trim ram assemblies and then cover the tilt cylinder openings with a clean cloth 3 Remove Free piston 2 WARNING Never look into the tilt cylinder opening because the free piston and hydraulic fluid may be expell...

Page 318: ...ton Excessive scratches Replace CHECKING THE TRIM RAM CYLINDERS Check Trim ram cylinders Cracks excessive scratches Replace the power trim and tilt unit INSTALLING THE FREE PISTON 1 Fill Fluid passages NOTE Hold the power trim and tilt unit in a vise using aluminum plates on both sides Add power trim and tilt fluid through the hole a Recommended power trim and tilt fluid ATF Dexron II Quantity 30 ...

Page 319: ... installing them into the trim ram cylinders Otherwise the hydraulic fluid may spurt out from the unit 1 Fill Trim ram cylinders NOTE Hold the power trim and tilt unit in a vise using aluminum plates on both sides Recommended power trim and tilt fluid ATF Dexron II 7500 2 Fill Fluid passages NOTE Add power trim and tilt fluid through holes a b and c until all of the passages are filled Recommended...

Page 320: ...NOTE Place each trim ram end screw at the bot tom of each trim ram and install them into the trim ram cylinders 7520 4 Tighten Trim ram end screws Å For USA and Canada ı For worldwide End screw wrench YB 06175 1A 90890 06548 T R Trim ram end screw 80 Nm 8 0 m kgf 58 ft lb 7530 Å ı ...

Page 321: ...ECKING THE FUSE HOLDER 8 13 MEASURING THE CONTROL UNIT OUTPUT PEAK VOLTAGE 8 14 MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE 8 15 CHECKING THE SPARK PLUG CAPS 8 16 IGNITION CONTROL SYSTEM 8 17 CHECKING THE BATTERY 8 18 CHECKING THE FUSES 8 18 CHECKING THE FUSE HOLDER 8 18 MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE 8 18 MEASURING THE CRANK POSITION SENSOR OUTPUT PEAK VOLTAGE 8 18 MEASURING THE ...

Page 322: ...ORS 8 28 CHECKING THE FUEL PRESSURE SENSOR 8 29 CHECKING THE WATER DETECTION SWITCH 8 30 STARTING SYSTEM 8 31 CHECKING THE BATTERY 8 32 CHECKING THE FUSES 8 32 CHECKING THE FUSE HOLDER 8 32 CHECKING THE WIRE HARNESS CONTINUITY 8 32 CHECKING THE WIRE CONNECTIONS 8 32 CHECKING THE STARTER RELAY 8 32 STARTER MOTOR 8 33 DISASSEMBLING ASSEMBLING THE STARTER MOTOR 8 33 REMOVING THE STARTER MOTOR PINION ...

Page 323: ...CHECKING THE BATTERY 8 48 CHECKING THE FUSES 8 48 CHECKING THE FUSE HOLDER 8 48 CHECKING THE POWER TRIM AND TILT RELAY 8 48 CHECKING THE TRAILER SWITCH CONTINUITY 8 49 MEASURING THE TRIM SENSOR RESISTANCE 8 49 POWER TRIM AND TILT MOTOR 8 50 DISASSEMBLING ASSEMBLING THE POWER TRIM AND TILT MOTOR 8 50 REMOVING THE STATOR 8 52 REMOVING THE BRUSH 8 52 CHECKING THE BRUSH 8 52 CHECKING THE ARMATURE 8 53...

Page 324: ...ermo switch connectors 7 Emergency switch connectors 8 Engine cooling water temperature sensor 9 Engine cooling water temperature sensor coupler 2P 0 Water detection switch A Trailer switch coupler 3P B Oil level sensor coupler 6P C Electric oil pump D Atmospheric pressure sensor E Electric oil pump coupler 2P F Throttle position sensor coupler 3P G Electric fuel pump H Water detection switch coup...

Page 325: ...S Starboard view 8 8020 1 3 5 6 7 8 2 2 4 1 Thermo switch 2 Oxygen density sensor coupler 2P 3 Oxygen density sensor 4 Crank position sensor coupler 2P 5 Starter motor 6 Fuse holder 7 Junction box assembly 8 Thermo switch connectors ...

Page 326: ...wer trim and tilt relay coupler 2P 4 Fuse holder coupler 3P 5 Lighting coil couplers 1P 2P 6 Starter relay 7 Power trim and tilt relay 8 Fuse 20A 9 Fuse 80A 0 Main relay A Driver relay B Fuse 30A C Rectifier regulator Å Complete assembly ı Sub assembly Ç To wire harness Î To power trim and tilt motor To lighting coil Ï To ground Ì To starter motor Ó To electric fuel pump ...

Page 327: ...EC E ELECTRICAL COMPONENTS Aft view 8 1 2 4 3 4 6 3 4 3 5 8040 1 Control unit 2 Control unit couplers 26P 26P 34P 3 Ignition coils 4 Ignition coil couplers 2P 5 Injector driver couplers 26P 6 Injector driver ...

Page 328: ... Shift position switch 3 Oxygen density sensor 4 Shift position switch coupler 2P 5 Crank position sensor 6 Thermo switches 7 Spark plugs 8 Fuel injectors 9 Ignition coils 0 Fuel pressure sensor A Oil level sensor B Electric fuel pump connectors C Trailer switch D Electric fuel pump E Intake air temperature sensor ...

Page 329: ... 4 2 3 4 6 7 8 5 98 0 A B C D E Connect to 1 Emergency switch 2 Trailer switch 3 Oil level sensor 4 Thermo switch 5 Ground 6 Control unit 7 Power trim and tilt relay 8 Fuse holder 9 Starter relay 0 Remote control A Oil level meter B Trim sensor C Sub oil tank D Water detection meter E Shift position switch B Black Br Brown G Green Gy Gray L Blue Lg Light green P Pink R Red Sb Sky blue W White Y Ye...

Page 330: ...onnect to 1 Personal computer 2 Intake air temperature sensor 3 Engine cooling water temperature sensor 4 Throttle position sensor 5 Atmospheric pressure sensor 6 Pulser coil 7 Oxygen density sensor 8 Crank position sensor 9 Fuel pressure sensor 0 Control unit B Black G Green Gy Gray O Orange P Pink B W Black white B Y Black yellow R Y Red yellow W B White black W Br White brown W G White green W ...

Page 331: ...trol unit 2 Fuel injectors 3 Ignition coils 4 Injector driver 5 Wire harness 6 Oxygen density sensor 7 Ground 8 Electric oil pump 9 Water detection switch 0 Electric fuel pump A Fuse holder B Black G Green L Blue R Red B Br Black brown B G Black green B L Black blue B O Black orange B W Black white B Y Black yellow L R Blue red L W Blue white L Y Blue yellow O B Orange black O G Orange green O L O...

Page 332: ...ing the condition of the igni tion system it is useful to know the peak voltage Cranking speed is dependant on many factors e g fouled or weak spark plugs a weak battery If one of these is defective the peak voltage will be lower than speci fication If the peak voltage measurement is not within specification the engine will not operate properly PEAK VOLTAGE ADAPTOR 8 NOTE The peak voltage adaptor ...

Page 333: ...oupler connections 2 Connect the test harness between the couplers 3 Connect the peak voltage adaptor probes to the connectors which are being checked 4 Start or crank the engine and observe the measurement 8140 MEASURING A LOW RESISTANCE 8 When measuring a resistance of 10 Ω or less with the digital tester the correct mea surement cannot be obtained because of the tester s internal resistance To ...

Page 334: ... 7 Control unit 8 Ignition coils 9 Spark plugs Å To remote control B Black R Red W White B Br Black brown B G Black green B L Black blue B O Black orange B W Black white B Y Black yellow L Y Blue yellow R L Red blue R Y Red yellow W B White black W Br White brown W G White green W L White blue W R White red W Y White yellow ...

Page 335: ...rk gap Above specification Replace the spark plug Below specification Check the con trol unit output Å For USA and Canada ı For worldwide Checking steps 1 Remove the spark plugs from the engine 2 Connect a spark plug cap to the spark gap tester 3 Set the spark gap length on the adjust ing knob 4 Crank the engine and observe the spark through the discharge window of the spark gap tester Ignition sp...

Page 336: ...HECKING THE FUSE HOLDER 8 1 Check Main relay continuity No continuity Replace the fuse holder Checking steps 1 Remove the fuse 1 2 Connect the tester and battery as shown 3 Check that there is continuity between the main relay terminals Positive digital tester probe Fuse holder terminal 2 Negative digital tester probe Fuse holder terminal 3 Positive battery terminal Fuse holder terminal 4 Negative...

Page 337: ...ter probe Fuse holder terminal 3 Positive battery terminal Fuse holder terminal 4 Negative battery terminal Fuse holder terminal 5 4 1 3 5 2 8197 MEASURING THE CONTROL UNIT OUTPUT PEAK VOLTAGE 8 WARNING When checking the peak voltage do not touch any of the connections of the digital tester lead wires NOTE If there is no spark or the spark is weak continue with the ignition system test If a good s...

Page 338: ... Y Red yellow R Y Black blue B L Red yellow R Y r min Circuit Loaded Cranking 1 500 3 500 V 140 205 220 Test harness 2 pin YB 06767 90890 06767 R Y B W 8250 MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE 8 Measure Pulser coil output peak voltage Below specification Replace the pulser coil Pulser coil output peak voltage White red W R Black B White black W B Black B White yellow W Y Black B White gr...

Page 339: ...nnection Tighten Cracks damage Replace Replacement steps 1 To remove the spark plug cap turn it counterclockwise 2 To install the spark plug cap turn it clockwise until it is tight 2 Measure Spark plug cap resistance Out of specification Replace Spark plug cap resistance 4 0 6 0 kΩ 8280 8290 ...

Page 340: ...nit 9 Thermo switches 0 Throttle position sensor A Engine cooling water temperature sensor B Oil level sensor C Shift position switch B Black O Orange P Pink R Red B Y Black yellow G L Green blue L G Blue green L R Blue red L W Blue white L Y Blue yellow R L Red blue W B White black W Br White brown W G White green W L White blue W R White red W Y White yellow Y R Yellow red ...

Page 341: ...e 8 13 MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE 8 Refer to MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE on page 8 15 MEASURING THE CRANK POSITION SENSOR OUTPUT PEAK VOLTAGE 8 Measure Crank position sensor output peak voltage Below specification Replace Crank position sensor output peak voltage Green G Green blue G L r min Circuit Loaded Cranking 1 500 3 500 V 4 5 4 0 13 20 Test harness 2 pin...

Page 342: ...ature is reached CHECKING THE THERMO SWITCH CONTINUITY 8 Check Thermo switch continuity Out of specification Replace 1 No continuity Å Temperature 2 Continuity ı Time Measuring steps 1 Place the thermo switch in a container filled with water 2 Place a thermometer in the water 3 Slowly heat the water 4 Measure the continuity when the spec ified temperature is reached Engine cooling water temperatur...

Page 343: ...asuring steps 1 Connect the test harness 3 pin as shown 2 Connect the battery leads to a 12 V battery 3 Turn the engine switch to the on posi tion 4 Measure the throttle position sensor output voltage NOTE Make sure the throttle position sensor out put voltage is within specification when the throttle is fully closed and fully opened Throttle position sensor output voltage Orange O Pink P 0 48 5 2...

Page 344: ... POSITION SWITCH 8 1 Check Shift position switch continuity Out of specification Replace 2 Check Shift position switch Does not return to the home position Replace Switch position Lead color Blue yellow L Y Black B Home a No continuity On b Continuity 8345 ...

Page 345: ... 20A 6 Main relay 7 Driver relay 8 Fuse 80A 9 Battery 0 Control unit A Fuel pressure B Throttle position sensor C Engine cooling water temperature sensor D Atmospheric pressure sensor E Intake air temperature sensor F Water detection switch G Electric fuel pump H Injector driver I Fuel injectors J Electric oil pump Å To water detection meter ...

Page 346: ... L Y Blue yellow O B Orange black O G Orange green O L Orange blue O R Orange red O W Orange white O Y Orange yellow Pu B Purple black Pu G Purple green Pu L Purple blue Pu R Purple red Pu W Purple white Pu Y Purple yellow R L Red blue R W Red white R Y Red yellow W B White black W Br White brown W G White green W L White blue W R White red W Y White yellow ...

Page 347: ...VOLTAGE on page 8 15 MEASURING THE CRANK POSITION SENSOR OUTPUT PEAK VOLTAGE 8 Measure Crank position sensor output peak voltage Below specification Replace MEASURING THE THROTTLE POSITION SENSOR OUTPUT VOLTAGE 8 Refer to MEASURING THE THROT TLE POSITION SENSOR OUTPUT VOLTAGE on page 8 20 MEASURING THE ENGINE COOLING WATER TEMPERATURE SENSOR RESISTANCE 8 Refer to MEASURING THE ENGINE COOLING WATER...

Page 348: ...eep all flammable prod ucts e g gasoline away from the testing area and make sure there is proper ventila tion CAUTION Do not let any silicon anticorrosion solvent touch the oxygen density sensor or its accuracy will be affected 1 Remove the oxygen density sensor Refer to OXYGEN DENSITY SEN SOR on page 5 29 Oxygen density sensor heater resistance Red white R W Black B 2 100 Ω Oxygen density sensor...

Page 349: ...at the oxygen density sensor above 800 C 1 472 F or continuously for more than 1 minute at a time or the sen sor will be damaged Do not use a burner with an oxygen tank The sensor may be damaged by a flame of high temperature a Inner cone b Outer cone NOTE If the instantaneous change in the output voltage is 0 6 V or greater the oxygen den sity sensor is OK Gy B W a b 1 2 1 Gy B W a b 1 2 1 8405 C...

Page 350: ... on position 3 Measure the atmospheric pressure sensor output voltage Test harness 3 pin YB 06769 90890 06769 P B O 8410 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 Measure Intake air temperature sensor resis tance Out of specification Replace Intake air temperature sensor resistance Black yellow B Y Black yellow B Y 1 5 4 0 kΩ B Y B Y 8440 FUEL CONTROL SYSTEM ...

Page 351: ... the fuel injector body and check if all of the fuel injectors have a solenoid valve operat ing sound 8450 2 Check Electric fuel pump operating sound Correct Replace the fuel injector no sound No sound Measure the injector driver output peak voltage NOTE The electric fuel pump should sound when the engine start switch is turned on Disconnect the Brown Br starter relay terminal 1 to prevent the eng...

Page 352: ...rness 3 pin as shown 2 Start the engine 3 Measure the fuel pressure sensor out put voltage Injector driver output peak voltage Orange red O R Purple red Pu R Orange black O B Purple black Pu B Orange yellow O Y Purple yellow Pu Y Orange green O G Purple green Pu G Orange blue O L Purple blue Pu L Orange white O W Purple white Pu W r min Circuit Loaded Cranking 1 500 3 500 V 65 60 65 65 Fuel pressu...

Page 353: ...C E FUEL CONTROL SYSTEM CHECKING THE WATER DETECTION SWITCH 8 Check Water detection switch continuity Out of specification Replace Float position Lead color Blue white L W Black B ON OFF L W B L W B OFF ON 8490 ...

Page 354: ...8 31 ELEC E STARTING SYSTEM STARTING SYSTEM 8 8500 1 Battery 2 Fuse holder 3 Fuse 20A 4 Fuse 80A 5 Fuse 30A 6 Starter relay 7 Starter motor Å To remote control B Black Br Brown R Red Br W Brown white ...

Page 355: ...ace CHECKING THE WIRE CONNECTIONS 8 Check Wire connections Poor connection Properly connect CHECKING THE STARTER RELAY 8 Check Starter relay continuity No continuity Replace Checking steps 1 Connect the tester and battery between the starter relay terminals 2 Check that there is continuity between the starter relay terminals Positive digital tester probe 1 Starter relay terminal Negative digital t...

Page 356: ...r Refer to STARTER MOTOR on page 5 28 1 Nut 1 2 Brush terminal 1 3 Bolt 2 4 Magnetic switch relay 1 5 Dust cover 1 6 Spring 1 7 Screw 1 8 Dust seal 1 9 Dust seal cover 1 Continued on next page 4 15 mm 6 120 mm 23 17 18 25 24 22 19 20 27 2 6 50 mm 4 20 mm 36 30 32 35 34 5 33 29 28 31 7 8 9 10 11 12 4 1 6 21 3 16 15 14 13 26 8530 ...

Page 357: ...m 1 12 Spring 1 13 Clip 1 14 Starter motor pinion stopper 1 15 Starter motor pinion 1 16 Spring 1 17 Bolt 2 18 Lower bracket 1 Continued on next page 4 15 mm 6 120 mm 23 17 18 25 24 22 19 20 27 2 6 50 mm 4 20 mm 36 30 32 35 34 5 33 29 28 31 7 8 9 10 11 12 4 1 6 21 3 16 15 14 13 26 8530 ...

Page 358: ...tor bracket 1 22 Brush assembly 1 23 Screw 2 24 Brush holder assembly 1 25 Thrust plate 1 26 Thrust washer 1 27 Planetary gear seat cover 1 Continued on next page 4 15 mm 6 120 mm 23 17 18 25 24 22 19 20 27 2 6 50 mm 4 20 mm 36 30 32 35 34 5 33 29 28 31 7 8 9 10 11 12 4 1 6 21 3 16 15 14 13 26 8530 ...

Page 359: ...h 1 31 Shift lever assembly 1 32 Circlip 1 33 Starter motor pinion shaft 1 34 Planetary gear seat 1 35 Thrust washer 1 36 Shield bearing 1 For assembly reverse the disassembly procedure 4 15 mm 6 120 mm 23 17 18 25 24 22 19 20 27 2 6 50 mm 4 20 mm 36 30 32 35 34 5 33 29 28 31 7 8 9 10 11 12 4 1 6 21 3 16 15 14 13 26 8530 ...

Page 360: ...ge wear Replace 2 Check Starter motor pinion movement Incorrect Replace NOTE Rotate the starter motor pinion clockwise and make sure it moves smoothly Also rotate the starter motor pinion counter clockwise and make sure it locks 8550 CHECKING THE ARMATURE 8 1 Check Commutator Foreign matter Clean with 600 grit sandpaper 8560 2 Measure Commutator diameter Out of specification Replace Commutator dia...

Page 361: ... undercut limit 0 2 mm 0 01 in 8590 5 Check Armature continuity Out of specification Replace Armature continuity Commutator segments a Continuity Segment Armature core b No continuity Segment Armature shaft c No continuity 8600 MEASURING THE BRUSHES 8 1 Measure Brush length a Out of specification Replace the brush assembly Brush length limit 9 5 mm 0 37 in 8610 STARTER MOTOR ...

Page 362: ...LAY 8 Check Magnetic switch relay continuity Out of specification Replace Checking steps 1 Remove the terminal 1 from the mag netic switch relay NOTE Remove the terminal to prevent the pinion gear from turning 2 Connect the tester leads between the magnetic switch relay terminals as shown 3 Connect the Brown white Br W lead to the positive battery terminal 4 Connect the starter motor body to the n...

Page 363: ...tinuity between the magnetic switch relay terminals 6 Check that there is no continuity after the Br W lead is removed NOTE The starter motor pinion should be pushed out while the magnetic switch is on 7 Install the terminal to the magnetic switch relay ...

Page 364: ...8 41 ELEC E CHARGING SYSTEM 8 8630 1 Lighting coil 2 Rectifier regulator 3 Fuse holder 4 Fuses 80A 5 Battery B Black G Green R Red CHARGING SYSTEM ...

Page 365: ...IER REGULATOR OUTPUT PEAK VOLTAGE 8 Measure Rectifier regulator output peak voltage Below specification Replace the rectifier regulator NOTE Before measuring the rectifier regulator output peak voltage Measure the lighting coil output peak volt age Disconnect the rectifier regulator coupler blue 1 Rectifier regulator output peak voltage Red R Black B r min Circuit Loaded Cranking 1 500 3 500 V 7 5...

Page 366: ...on Replace the lighting coil NOTE Before measuring the lighting coil output peak voltage disconnect the rectifier regu lator coupler blue 1 Lighting coil output peak voltage Green G Green G r min Circuit Loaded Cranking 1 500 3 500 V 7 5 8 0 12 12 Test harness 1 pin YB 06788 90890 06788 Test harness 2 pin YB 06787 90890 06787 8276 G G 1 ...

Page 367: ... Fuse 80A 5 Control unit 6 Oil level sensor 7 Emergency switch 8 Oil pump sub oil tank 9 Oil level switch sub oil tank Å To remote control ı To oil level meter B Black Br Brown L Blue R Red Y Yellow B R Black red G R Green red L G Blue green L R Blue red L W Blue white R Y Red yellow W B White black Y R Yellow red ...

Page 368: ...LDER on page 8 13 CHECKING THE OIL LEVEL SENSOR SWITCH CONTINUITY 8 Check Oil level sensor switch continuity Out of specification Replace Float position Lead color Black B Blue white L W Blue green L G Blue red L R Å ON Å OFF ı ON ı OFF Ç ON Ç OFF Float distance a 3 6 mm 0 12 0 24 in b 33 36 mm 1 30 1 42 in c 53 56 mm 2 09 2 20 in d 150 153 mm 5 91 6 02 in 8690 8700 OIL FEED PUMP CONTROL SYSTEM ...

Page 369: ...lace Switch position Lead color Blue L Black B Home a No continuity On b Continuity 8710 CHECKING THE OIL PUMP SUB OIL TANK 8 Check Oil pump sub oil tank Incorrect operation Replace NOTE Connect the oil pump leads to a 12 V bat tery and make sure the oil pump operates properly Blue L lead Positive battery terminal Brown Br lead Negative battery terminal 8720 OIL FEED PUMP CONTROL SYSTEM ...

Page 370: ...e 20A 4 Fuse 80A 5 Power trim and tilt relay 6 Power trim and tilt motor 7 Trailer switch 8 Trim sensor Å To remote control ı To trim meter Ç To control unit B Black G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue R L Red blue POWER TRIM AND TILT SYSTEM ...

Page 371: ...Power trim and tilt relay operation No continuity Replace Checking steps 1 Connect the digital tester between power trim and tilt relay terminals 1 and 2 Connect a 12 V battery as shown 3 Check that there is continuity between the power trim and tilt relay terminals Power trim and tilt relay continuity Sky blue Sb Black B Light green Lg Black B Continuity Terminal 1 Terminal Terminal 2 Terminal Co...

Page 372: ...ative terminal Sb B 2 8770 CHECKING THE TRAILER SWITCH CONTINUITY 8 Check Trailer switch continuity Out of specification Replace Switch position Lead color Skyblue Sb Red R Light green Lg Up Free Down 8780 MEASURING THE TRIM SENSOR RESISTANCE 8 Measure Trim sensor resistance Out of specification Replace NOTE Turn the lever 1 and measure the resis tance as it gradually changes Trim sensor resistanc...

Page 373: ...MBLING ASSEMBLING THE POWER TRIM AND TILT MOTOR 8 Order Job Part Q ty Remarks Power trim and tilt motor Refer to RESERVOIR AND POWER TRIM AND TILT MOTOR on page 7 22 1 Screw 1 2 Lead holder 1 3 Screw 2 4 Stator 1 5 Armature 1 6 O ring 1 7 Screw 2 Continued on next page 8800 ...

Page 374: ... 51 ELEC E POWER TRIM AND TILT MOTOR 8 8 Order Job Part Q ty Remarks 8 Brush holder 2 9 Brush 2 10 Spring 2 11 Lower cover 1 12 Oil seal 1 13 Bearing 1 For assembly reverse the disassembly procedure 8800 ...

Page 375: ...the leads Hold the end of the armature shaft with a clean cloth and pull off the stator 8810 REMOVING THE BRUSH 8 1 Remove Sky blue power trim and tilt motor lead 1 NOTE Hold the brush with a screwdriver as shown Then disconnect the sky blue lead 8820 2 Remove Brush holders 1 Brushes 2 CAUTION Do not touch the bimetal a touching it may affect the operation of the breaker 8830 CHECKING THE BRUSH 8 ...

Page 376: ...easure Commutator diameter a Out of specification Replace Commutator diameter limit 21 0 mm 0 83 in 8860 2 Measure Commutator undercut a Out of specification Replace the armature Commutator undercut limit 0 85 mm 0 03 in 8870 3 Check Armature continuity Out of specification Replace Armature continuity Commutator segments Continuity Segment laminations No continuity Segment shaft No continuity 8880...

Page 377: ...metal touching it may affect the operation of the breaker 8900 INSTALLING THE ARMATURE 8 Install Armature 1 NOTE Push the brushes into the holder and then install the armature 8910 INSTALLING THE STATOR 8 Install Stator 1 NOTE Place a clean cloth over the end of the armature shaft and carefully push the arma ture into the stator with a pair of pliers as shown 8920 ...

Page 378: ......

Page 379: ...NLS CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS 9 1 TROUBLE ANALYSIS CHART 9 1 SELF DIAGNOSIS 9 5 DIAGNOSIS CODE INDICATION 9 5 DIAGNOSIS THE ELECTRONIC CONTROL SYSTEM 9 5 TROUBLE SHOOTING FOR HIGH PRESSURE DIRECT INJECTION 9 7 ...

Page 380: ...levels 8 The rigging and engine settings are correct 9 The engine is free from any Hull problem TROUBLE ANALYSIS CHART 9 Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED OVERHEATING LOOSE STEERING LOOSE TILT HOLDING TILT MOTOR WILL NOT RUN HARD SHIFTING IRREGULAR WARNI...

Page 381: ...ower case 6 BRACKET UNIT Bracket 7 Rubber mounts 7 Shift rod 7 POWER TRIM AND TILT UNIT Fluid level 3 Relief valve 7 Fluid passages Power trim and tilt motor 7 Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED OVERHEATING LOOSE STEERING LOOSE TILT HOLDING TILT MOTOR WIL...

Page 382: ...o switches 8 Shift position switch 8 Injector driver 8 Fuel pressure sensor 8 Starting system Engine start switch Starter relay 8 Starter motor 8 Charging system Lighting coils 8 Rectifier regulator 8 Fuses 8 Battery leads Batteries Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ...

Page 383: ...y 8 Trim sensor 8 Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED OVERHEATING LOOSE STEERING LOOSE TILT HOLDING TILT MOTOR WILL NOT RUN HARD SHIFTING IRREGULAR WARNING INDICATION POOR BATTERY CHARGING Relative part Reference chapter TROUBLE ANALYSIS ...

Page 384: ...c Light off 1 7 seconds d Light off 5 seconds DIAGNOSIS THE ELECTRONIC CONTROL SYSTEM 9 1 Install Diagnostic indicator NOTE When performing this diagnosis all of the electrical wires must be properly con nected 2 Check Diagnosis code Code 1 is indicated Normal Code 13 28 indicated Check the applicable parts Code 33 44 indicated Microcom puter processing information Checking steps 1 Start the engin...

Page 385: ...on sensor input signal 15 Incorrect engine cooling water temperature sensor input signal 18 Incorrect throttle position sen sor input signal 19 Low battery input voltage 22 Incorrect atmospheric pressure sensor input signal out of nor mal operating range 23 Incorrect intake air temperature sensor input signal 25 Incorrect fuel pressure sensor input signal 26 No injector operation signals 27 Water ...

Page 386: ...tem 1 Check for fuel line leaks 2 Check the fuel pressure vapor separator and mechanical fuel pump 3 Check the operation of the fuel injector 4 Check the injector driver 5 Check the diagnosis cord Fuel pressure is out of specification 1 Check the fuses 2 Check the electric fuel pump operation 3 Check the main relay 4 Check the driver relay 5 Check the pressure regulator 6 Check the mechani cal fue...

Page 387: ...rd 6 Check the oxygen density sensor 1 Check the fuses 2 Check the electric fuel pump operation 3 Check the main relay 4 Check the driver relay 5 Check the pressure regulator 6 Check the mechani cal fuel pump Fuel pressure is out of specification 1 Check the wire harness 2 Check the ignition spark 3 Check the ignition coil 4 Check the CDI unit output peak voltage 5 Check the pulser coil output pea...

Page 388: ... fuses 2 Check the electric fuel pump operation 3 Check the main relay 4 Check the driver relay 5 Check the pressure regulator 6 Check the mechani cal fuel pump Fuel pressure is out of specification 1 Check the wire harness 2 Check the ignition spark 3 Check the ignition coil 4 Check the CDI unit output peak voltage 5 Check the pulser coil output peak voltage 6 Check the rectifier regulator output...

Page 389: ... G Sb W L B Br Y Lg ı To remote control Î Option port Å To personal computer Ç Option port Gy Gy O B Gy P O P B To trim meter Y Trim sensor X Fuel pressure sensor 3Atmospheric pressure sensor 4Intake air temperature sensor M N S R Battery S Starter motor T Starter relay L W L G L R L R B Oil level sensor 5 Sb Lg Trailer switch 6 R B W R Y R B W B G R B W B Br 1 3 5 B C C C Spark plug Spark plug Sp...

Page 390: ...e holder 1 2 3 4 5 6 7 8 9 10 L R R B R R R L R L R R L Y R Y R Y R Y R Y R Y R Y R R R W R W 11 12 13 14 15 16 17 18 19 20 R W R Y R Y R W 21 22 23 24 25 26 27 28 B Y B Y B Y B Y O P B O P B O P B B W Gy W Br W L 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 W G W Y W B W R B Gy Gy R Y B W B 73 74 75 76 77 78 79 80 81 82 83 84 85 86 B Br G Gy L Lg O P R Sb W Y B Br B G Black Brown Green G...

Page 391: ......

Page 392: ...Printed on recycled paper Printed in Japan Oct 1999 0 6 1 CR Z200NETO LZ200NETO YAMAHA MOTOR CO LTD ...

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