Yamaha SX150C Service Manual Download Page 104

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5-17

POWR

JUNCTION BOX ASSEMBLY

REMOVING/INSTALLING THE JUNCTION BOX ASSEMBLY

Order

Job/Part

Q’ty

Remarks

Junction box cover

Refer to “POWER UNIT” on page 5-4.

Nut

Starter motor lead

Intake air temperature sensor
coupler

Atmospheric pressure sensor
coupler

Clip

Cooling water hose

(exhaust outer cover-to-rectifier/

regulator)

Continued on next page.

5140

JUNCTION BOX ASSEMBLY

Summary of Contents for SX150C

Page 1: ...SX150C VX150C DX150C SX200C SERVICE MANUAL 67H 28197 1F 11 LIT 18616 02 80 LIT186160280...

Page 2: ...se Yamaha has a policy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edi tion of this manual...

Page 3: ...symbol 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 a...

Page 4: ...R 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 CAU...

Page 5: ...n 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 i...

Page 6: ...oded 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 gr...

Page 7: ...FORMATION 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 INF...

Page 8: ...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 DISASSEMBL...

Page 9: ...to the port clamp bracket 1 Model name 2 Approved model code 3 Transom height 4 Serial number S67H1010 1020 STARTING SERIAL NUMBERS The starting serial number blocks are as fol lows Model name Approv...

Page 10: ...eum 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 1040 SELF PROTECTIO...

Page 11: ...led 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...

Page 12: ...s with compressed air when disassembling 2 Oil the contact surfaces of moving parts before assembly 1090 3 After assembly check that moving parts operate normally 1100 4 Install bearings with the manu...

Page 13: ...h 90890 MEASURING 1 Tachometer P N YU 08036 A a 90890 06760 b 2 Pressure tester P N YB 35956 90890 06762 3 Mity vac P N YB 35956 90890 06756 4 Pinion height gauge P N YB 34432 7 YB 34432 11 YB 34432 9...

Page 14: ...34487 a 90890 06754 b F Diagnostic indicator P N YB 06765 90890 06765 G Shimming gauge P N YB 34446 1 YB 34446 3 YB 34446 4 YB 34446 7 YB 34446 8 H Shimming gauge P N YB 34468 1 YB 34468 6 I Shimming...

Page 15: ...90890 06602 90890 06604 90890 06605 90890 06606 90890 06652 5 Bearing oil seal attachment P N YB 06205 90890 06663 6 Bearing oil seal attachment P N YB 06194 YB 06195 YB 06200 YB 06246 YB 06258 YB 06...

Page 16: ...N 90890 06504 G Slide hammer P N YB 06096 H Small universal claws P N 90890 06536 I Bearing oil seal depth plate P N YB 06213 YB 34474 a 90890 06603 b J Drive shaft holder P N YB 06201 90890 06520 K P...

Page 17: ...ent P N YB 42225 R Bearing oil seal attachment P N YB 42227 S Bearing oil seal attachment P N YB 42229 90890 06607 T Pinion nut holder P N YB 42224 U End screw wrench P N YB 06548 90890 06548 V End sc...

Page 18: ...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 12 SPECIFIED TORQUES 2 12 GEN...

Page 19: ...erating range r min 4 500 5 500 Maximum fuel consumption L US gal lmp gal hr 5 500 r min 74 19 6 16 3 82 21 7 18 0 POWER UNIT Type 2 stroke V Number of cylinders 6 Displacement cm3 cu in 2 596 158 4 B...

Page 20: ...lmp qt 10 5 11 1 9 2 Gear oil type Hypoid gear oil SAE 90 Gear oil total quantity cm3 US oz lmp oz 980 33 1 34 5 900 30 4 31 7 980 33 1 34 5 BRACKET Trim angle at 12 boat transom Degree 4 16 Tilt up...

Page 21: ...895 89 915 3 5392 3 5400 Measuring point H mm in 10 0 4 Piston to cylinder clearance mm in mm in Cylinder 1 0 150 0 156 0 0059 0 0061 Cylinders 2 6 0 100 0 106 0 0039 0 0042 Limit mm in mm in Cylinde...

Page 22: ...cm3 US oz Imp oz 1 500 r min 20 4 4 2 0 700 0 142 0 720 0 148 28 8 6 6 0 974 0 223 1 016 0 233 Bleeding Screw type REED VALVES Reed valve stopper height a mm in 9 0 0 3 0 35 0 01 Warpage limit b mm i...

Page 23: ...0 18 0 30 0 40 0 50 Reverse gear shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Propeller shaft shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 PROPELLER SHAFT End play mm in 0 30 0 05 0 012 0 002 Item Unit...

Page 24: ...4 0 Engine cooling water temperature sensor Resistance B Y B Y 5 C 41 F k 128 20 C 68 F k 54 69 100 C 212 F k 3 02 3 48 Throttle position sensor Input voltage O R V 4 75 5 25 Output voltage P O V 0 4...

Page 25: ...r R B Output peak voltage lower limit cranking 1 V cranking 2 V 1 500 r min V 12 3 500 r min V 12 Lighting coil G G Output peak voltage lower limit cranking 1 V cranking 2 V 1 500 r min V 14 3 500 r m...

Page 26: ...OWER 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...

Page 27: ...0 3 5 290 11 4 406 16 0 L 946 37 2 X 1 072 42 2 L 516 20 3 X 642 25 3 791 31 1 670 26 4 241 9 5 15 0 6 46 1 8 210 8 3 159 6 3 12 4 6 6 L 773 30 4 X 849 33 4 647 25 5 mm in 33 1 3 587 23 1 179 7 0 74 2...

Page 28: ...SPECIFICATIONS EXTERIOR DX150 3 5 290 11 4 406 16 0 882 34 7 452 17 8 864 34 0 691 27 2 241 9 5 15 0 6 46 1 8 210 8 3 159 6 3 12 4 6 6 695 27 4 717 28 2 mm in 36 1 4 587 23 1 179 7 0 74 2 9 557 21 9 1...

Page 29: ...2 11 SPEC E MAINTENANCE SPECIFICATIONS CLAMP BRACKET mm in 82 3 2 13 0 5 180 7 1 163 5 6 4 254 10 0 55 5 2 2 367 14 5 163 5 6 4 125 4 4 9 125 4 4 9 180 7 1 13 0 5 50 8 2 0 18 5 0 7...

Page 30: ...2 Intake air temperature sensor M12 8 0 8 5 8 Starter motor M8 30 3 0 22 Starter motor bracket M8 30 3 0 22 Oxygen density sensor cover M6 9 0 9 6 5 Oxygen density sensor bracket M6 14 1 4 10 Oxygen d...

Page 31: ...m 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 1...

Page 32: ...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...

Page 33: ...TING THE REMOTE CONTROL SHIFT CABLE 3 7 ADJUSTING THE REMOTE CONTROL THROTTLE CABLE 3 8 COOLING SYSTEM 3 9 INSPECTING THE COOLING WATER DISCHARGE 3 9 OIL INJECTION SYSTEM 3 9 SYNCHRONIZING THE OIL PUM...

Page 34: ...aust leakage Inspect Cooling water passage Clean flush CONTROL SYSTEM Engine idling speed Inspect adjust 3 5 Throttle position sensor Inspect adjust 3 6 Remote control shift cable Inspect adjust 3 7 R...

Page 35: ...y 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...

Page 36: ...reign matter Clean Refer to FUEL FILTER on page 4 23 3040 MEASURING THE FUEL PRESSURE HIGH PRESSURE FUEL LINE 3 Measure Fuel pressure high pressure fuel line Out of specification Inspect the high pres...

Page 37: ...screw can be properly reset when the synchronizing has been achieved 4 Verify that all the throttle valves are fully closed when the throttle link rod 4 is connected 3060 2 Adjust Throttle valve open...

Page 38: ...chometer onto the spark plug lead of cylinder 1 Tachometer YU 08036 A 90890 06760 3082 2 Adjust Engine idling speed Adjustment steps 1 Loosen the pickup adjustment screw 1 2 Align the center of the th...

Page 39: ...throttle valve s open ing before measuring the throttle position sensor output voltage When measuring the throttle position sen sor output voltage set the digital tester to the manual range Measuring...

Page 40: ...STING THE REMOTE CONTROL SHIFT CABLE 3 1 Inspect Shift operation Incorrect Adjust 2 Adjust Remote control shift cable length Adjustment steps 1 Disconnect the shift cable joint 1 2 Set the remote cont...

Page 41: ...ever is fully closed position 2 Adjust Remote control throttle cable length Adjustment steps 1 Disconnect the throttle cable joint 1 2 Set the remote control lever to the fully closed position 3 Align...

Page 42: ...the oil pump lever 1 touches the stopper a fully closed position when the throttle valves are closed 2 Adjust Oil pump lever position Adjustment steps 1 Disconnect the oil pump link rod joint 2 2 Ful...

Page 43: ...e 50 1 or engine malfunctions or seizure may result 2 Disconnect the oil pump link rod joint from the oil pump lever 3 Start the engine Recommended fuel Fuel type Unleaded regular gasoline Fuel rating...

Page 44: ...ine oil which is flowing out of the oil feed hose When using the graduated cylinder make sure no engine oil clings to its walls oth erwise the measurement will be incor rect Use only the specified eng...

Page 45: ...t hose 2 from the vapor separator 5 Install the oil inlet hose onto the grad uated cylinder NOTE The measuring range on the graduated cyl inder should be divided into 0 1 cc incre ments 6 Start the en...

Page 46: ...y remove the power trim and tilt reservoir cap Inspecting 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 w...

Page 47: ...bearings and clutch dog Inspecting steps 1 Tilt up the outboard slightly 2 Place a container under the gear oil drain screw 1 3 Remove the gear oil drain screw and gear oil level check screw 2 2 Fill...

Page 48: ...rops Inspect the seals and components Inspecting steps CAUTION Do not overpressurize the lower unit Excessive pressure may damage the oil seals 1 Remove the gear oil level check screw 2 Install the pr...

Page 49: ...nent eye injury Wear protective eye gear when handling or working near batteries Antidote EXTERNAL SKIN Flush with water EYES Flush with water for 15 minutes and get immediate medical attention Antido...

Page 50: ...pecific gravity Less than specification Recharge the battery Electrolyte specific gravity 1 280 at 20 C 68 F INSPECTING THE SPARK PLUGS 3 1 Inspect Electrodes 1 Cracks excessive wear Replace Insulator...

Page 51: ...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...

Page 52: ...3 19 E INSP ADJ GENERAL LUBRICATION POINTS 3 Apply Water resistant grease 3290 3300 3310 3320 3330...

Page 53: ...TOR 4 10 REMOVING INSTALLING THE PRESSURE REGULATOR 4 11 DISASSEMBLING ASSEMBLING THE VAPOR SEPARATOR 4 13 REMOVING THE HIGH PRESSURE FUEL PUMP FILTER 4 14 INSTALLING THE HIGH PRESSURE FUEL PUMP FILTE...

Page 54: ...E FUEL PUMP 4 24 INSPECTING THE CHECK VALVE 4 26 INSPECTING THE FUEL PUMPS 4 26 OIL INJECTION SYSTEM 4 28 REMOVING INSTALLING THE OIL INJECTION SYSTEM 4 28 DISASSEMBLING ASSEMBLING THE OIL INJECTION S...

Page 55: ...ntake silencer 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...

Page 56: ...cking tie 2 12 Fuel inlet hose 1 fuel pump to vapor separator 13 Oil inlet hose 1 oil pump to vapor separator 14 Nut 2 15 Bolt 11 with washer 16 Gasket 1 17 Fuel injection unit 1 For installation reve...

Page 57: ...l pressure high pressure fuel line Reducing steps 1 Install the fuel pressure gauge onto the pressure check valve 2 Place the drain hose into a container 3 Open the valve 2 and release the pressure 2...

Page 58: ...e Mity vac onto the pressure regula tor vacuum hose 2 Start the engine 3 Apply vacuum pressure with the Mity vac 4 Inspect the fuel pressure NOTE Make sure the fuel pressure in the high pressure fuel...

Page 59: ...ncer Refer to HIGH PRESSURE FUEL LINE on page 4 1 Before performing the following procedure reduce the fuel pressure high pressure fuel line 1 Plastic locking tie 1 2 Bolt 4 3 Washer 4 4 Fuel rail 1 5...

Page 60: ...FUEL E 4 DISASSEMBLING ASSEMBLING THE FUEL INJECTORS Order Job Part Q ty Remarks 1 Rubber seal 1 2 Rubber damper 1 3 O ring 1 4 Filter 1 For assembly reverse the disassembly procedure 4030 FUEL INJECT...

Page 61: ...4 7 FUEL E FUEL INJECTORS INSPECTING THE FILTERS Check Filter Damage tears Replace Contaminants Clean 4040...

Page 62: ...o HIGH PRESSURE FUEL LINE on page 4 1 Before performing the following procedure reduce the fuel pressure high pressure fuel line 1 Hose clamp 4 2 Fuel hose 1 fuel pump to fuel rail 3 Fuel hose 1 fuel...

Page 63: ...tting its joint CAUTION The fuel hose will be damaged if a hose clamp is removed without cutting the joint 4070 INSTALLING THE HOSE CLAMPS Install Hose clamp WARNING Do not reuse hose clamps only use...

Page 64: ...y Remarks Fuel hoses Refer to FUEL HOSES on page 4 8 1 High pressure fuel pump connector 2 2 Bolt 3 3 Large washer 6 4 Small washer 3 5 Collar 3 6 Grommet 3 7 Screw 1 8 Fuel outlet joint holder 1 9 Va...

Page 65: ...TOR Order Job Part Q ty Remarks 1 Screw 1 2 Pressure check valve holder 1 3 Hose 3 vapor separator and pressure regulator to throttle body 4 Screw 2 5 Pressure regulator 1 6 O ring 1 Continued on next...

Page 66: ...er Job Part Q ty Remarks 7 Filter 1 8 Fuel return joint 1 9 O ring 1 10 O ring 1 11 Cap 1 For installation reverse the removal procedure 4 5 10 8 9 6 7 3 3 2 1 6 14 mm 3 4 14 mm 9 8 10 5 3 6 7 11 4100...

Page 67: ...Job Part Q ty Remarks 1 Drain screw 1 2 O ring 1 4 8 1 9 mm 3 Screw 9 4 O ring 1 5 Float chamber 1 6 High pressure fuel pump filter 1 7 Rubber damper holder 1 8 Rubber damper 1 9 Vapor separator body...

Page 68: ...TALLING THE HIGH PRESSURE FUEL PUMP FILTER Install Rubber damper 1 Rubber damper holder 2 High pressure fuel pump filter 3 NOTE Make sure the rubber damper is correctly installed in its holder Firmly...

Page 69: ...FUEL PUMP Order Job Part Q ty Remarks 1 Positive high pressure fuel pump terminal cap 1 red lead 2 Negative high pressure fuel pump terminal cap 1 blue lead 3 Nut 1 M4 a 7 mm 4 Spring washer 1 5 Nut...

Page 70: ...ve high pressure fuel pump terminal 1 9 O ring 2 4 5 1 5 mm 10 Washer 2 white 11 Collar 1 12 O ring 1 45 7 3 5 mm 13 High pressure fuel pump guide plate 1 14 High pressure fuel pump 1 15 Insulator 2 C...

Page 71: ...17 FUEL E HIGH PRESSURE FUEL PUMP 4 Order Job Part Q ty Remarks 16 O ring 2 8 1 3 mm 17 Screw 1 18 Float pin 1 19 Float 1 20 Clip 1 21 Needle valve 1 For assembly reverse the disassembly procedure 415...

Page 72: ...CONTROL LEVER CAM 4 REMOVING INSTALLING THE THROTTLE CONTROL LEVER CAM Order Job Part Q ty Remarks 1 Throttle link 1 2 Bolt 1 with washer 3 Wave washer 1 4 Collar 1 5 Throttle control lever cam 1 For...

Page 73: ...OVING INSTALLING THE THROTTLE POSITION SENSOR 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 Spac...

Page 74: ...ON SENSOR INSTALLING THE THROTTLE POSITION SENSOR NOTE During installation make sure the throttle position sensor is properly adjusted Install Throttle position sensor Refer to ADJUSTING THE THROTTLE...

Page 75: ...THE LOW PRESSURE FUEL LINE Order Job Part Q ty Remarks 1 Bolt 2 2 Bracket 1 3 Bolt 1 4 Holder 1 5 Bolt 2 with washer 6 Plastic locking tie 1 7 Bolt 4 with washer 8 Gasket 2 9 Low pressure fuel line 1...

Page 76: ...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...

Page 77: ...ILTER Order Job Part Q ty Remarks 1 Bolt 1 2 Fuel filter nut holder 1 3 Fuel filter nut 1 4 Fuel filter cup 1 5 O ring 1 6 Fuel filter element 1 7 Spring 1 8 O ring 1 9 Bolt 1 10 Fuel filter bracket 1...

Page 78: ...PUMP 4 DISASSEMBLING ASSEMBLING THE FUEL PUMP 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...

Page 79: ...4 25 FUEL E FUEL PUMP 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 80: ...e 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...

Page 81: ...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...

Page 82: ...rder Job Part Q ty Remarks 1 Bolt 2 2 Bracket 1 3 Bolt 1 4 Holder 1 5 Oil level sensor coupler 1 6 Clip 1 7 Washer 1 8 Oil pump link rod 1 9 Plastic locking tie 2 10 Oil hose 1 oil hose assembly joint...

Page 83: ...9 FUEL E 4 Order Job Part Q ty Remarks 11 Bolt 2 12 O ring 1 13 Bolt 3 14 Clamp 1 15 Oil tank assembly 1 16 Collar 3 17 Grommet 3 For installation reverse the removal procedure 4250 OIL INJECTION SYST...

Page 84: ...e 1 oil tank to intake silencer 2 Plastic locking tie 3 3 Oil hose 1 sub oil tank to oil tank 4 Oil hose 1 oil tank to oil pump 5 Oil tank assembly 1 6 Metal clamp 12 7 Oil hose assembly 1 oil pump to...

Page 85: ...UEL E OIL TANK 4 DISASSEMBLING ASSEMBLING THE OIL TANK Order Job Part Q ty Remarks 1 Oil level sensor 1 2 Oil strainer 1 3 Washer 1 4 Oil tank 1 For assembly reverse the disassembly procedure 4270 OIL...

Page 86: ...ASSEMBLY 5 11 REMOVING INSTALLING THE CDI UNIT 5 13 HIGH PRESSURE FUEL PUMP RESISTOR 5 15 REMOVING INSTALLING THE HIGH PRESSURE FUEL PUMP RESISTOR 5 15 JUNCTION BOX ASSEMBLY 5 17 REMOVING INSTALLING...

Page 87: ...LING THE PISTON AND CONNECTING ROD ASSEMBLIES 5 44 DISASSEMBLING ASSEMBLING THE CRANKSHAFT ASSEMBLY 5 45 DISASSEMBLING THE UPPER BEARING HOUSING 5 46 REMOVING THE BEARING AND OIL PUMP DRIVE GEAR 5 46...

Page 88: ...LING THE FLYWHEEL MAGNET ASSEMBLY 5 Order Job Part Q ty Remarks 1 Flywheel magnet assembly cover 1 2 Flywheel magnet assembly nut 1 3 Washer 1 4 Flywheel magnet assembly 1 5 Woodruff key 1 For install...

Page 89: ...f the flywheel magnet assembly 2 Remove the flywheel magnet assem bly For USA and Canada Except for USA and Canada NOTE The major load should be applied in the direction of the arrows Apply the load u...

Page 90: ...TE The 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...

Page 91: ...om the battery Remote control shift and throttle rods and cables 1 Bolt 1 2 Negative battery lead 1 3 Positive battery lead 1 4 Junction box cover 1 5 Power trim and tilt lead 1 blue 6 Power trim and...

Page 92: ...Remarks 1 Screw 4 2 CDI unit cover 1 3 Pilot water hose 1 4 Bolt 1 5 Ground lead 1 6 Plastic locking tie 3 7 Cooling water hose 1 8 Bolt 1 9 Cable guide 1 Continued on next page 6 12 8 10 6 7 5 4 2 1...

Page 93: ...t Q ty Remarks 10 Trailer switch coupler 1 11 Fuel hose 1 check valve to fuel filter 12 Oil hose 1 sub oil tank to oil tank For installation reverse the removal procedure 6 12 8 10 6 7 5 4 2 1 LT LT S...

Page 94: ...ard apron 1 5 Bolt 2 6 Bolt 2 7 Rear apron 1 8 Nut 2 9 Bolt 4 10 Bolt 6 Continued on next page 9 13 10 8 9 10 13 9 8 3 4 5 7 9 10 9 6 13 12 11 2 1 21 Nm 2 1 m kgf 15 ft Ib 6 16 mm 21 Nm 2 1 m kgf 15 f...

Page 95: ...r installation reverse the removal procedure 9 13 10 8 9 10 13 9 8 3 4 5 7 9 10 9 6 13 12 11 2 1 21 Nm 2 1 m kgf 15 ft Ib 6 16 mm 21 Nm 2 1 m kgf 15 ft Ib 6 16 mm 8 30 mm 8 135 mm 8 30 mm 6 20 mm LT L...

Page 96: ...rks Flywheel magnet assembly Refer to FLYWHEEL MAGNET ASSEMBLY on page 5 1 1 Crank position sensor coupler 1 2 Screw 2 3 Crank position sensor 1 4 Lighting coil coupler 1 5 Charge coil coupler 1 6 Bol...

Page 97: ...5 10 POWR E STATOR ASSEMBLY 5 5 Order Job Part Q ty Remarks 9 Pulser coil coupler 1 10 Bolt 1 11 Ground lead 1 12 Screw 3 13 Pulser coil assembly 1 For installation reverse the removal procedure 5110...

Page 98: ...s CDI unit cover Refer to DISCONNECTING CONNECTING THE HOSES on page 5 5 1 Bolt 2 2 Ground lead 2 3 Bolt 2 4 CDI unit coupler guide 1 5 CDI unit coupler 2 6 Emergency switch connector 2 7 Fuel injecto...

Page 99: ...5 5 Order Job Part Q ty Remarks 9 Oxygen density sensor coupler 1 black coupler 10 Bolt 1 11 Bolt 1 12 Ground lead 2 13 Spark plug cap 6 14 Bolt 4 15 CDI unit assembly 1 For installation reverse the r...

Page 100: ...4 2 Ground lead 6 3 Ground lead 3 4 Ignition coil connector 6 5 Bolt 6 6 Ignition coil 6 7 Bolt 4 8 CDI unit 1 9 Collar 4 10 Grommet 4 Continued on next page 4 6 5 1 1 3 7 8 3 13 10 9 12 3 2 11 1 LT L...

Page 101: ...ty Remarks 11 Emergency switch cap 1 12 Emergency switch 1 13 CDI unit case 1 For assembly reverse the disassembly procedure 4 6 5 1 1 3 7 8 3 13 10 9 12 3 2 11 1 LT LT SS 6 12 mm 6 25 mm 6 12 mm 6 20...

Page 102: ...ESISTOR 5 REMOVING INSTALLING THE HIGH PRESSURE FUEL PUMP RESISTOR 5 Order Job Part Q ty Remarks 1 High pressure fuel pump resistor coupler 1 2 Bolt 3 with washer 3 High pressure fuel pump resistor as...

Page 103: ...5 Order Job Part Q ty Remarks 6 High pressure fuel pump resistor cover 1 7 Screw 2 with washer 8 High pressure fuel pump resistor 1 9 Grommet 3 10 High pressure fuel pump resistor mounting base 1 For...

Page 104: ...ty Remarks Junction box cover Refer to POWER UNIT on page 5 4 1 Nut 1 2 Starter motor lead 1 3 Intake air temperature sensor coupler 1 4 Atmospheric pressure sensor coupler 1 5 Clip 1 6 Cooling water...

Page 105: ...Remarks 7 Oxygen density sensor coupler 1 blue coupler 8 Fuse holder 80A 1 9 Positive terminal lead 1 10 Bolt 1 11 Ground lead 1 12 Bolt 2 13 Ground lead 5 14 Ground lead plate 1 15 Main relay coupler...

Page 106: ...7 Power trim and tilt relay coupler 1 18 Starter relay connector 1 19 Main relay connector 3 20 Fuse connector 1 21 Fuse holder 30A 1 22 Bolt 5 23 Junction box assembly 1 For installation reverse the...

Page 107: ...E JUNCTION BOX ASSEMBLY 5 Order Job Part Q ty Remarks 1 Fuse holder 80A 1 2 Fuse 2 3 Screw 1 4 Main relay 1 5 Screw 1 6 Starter relay holder 1 7 Starter relay 1 8 Bolt 2 9 Power trim and tilt relay 1...

Page 108: ...hose 1 to exhaust outer cover 15 Cooling water hose 1 to pilot water outlet 16 Screw 2 17 Atmospheric pressure sensor 1 18 Nut 1 19 Intake air temperature sensor 1 20 Collar 5 21 Grommet 5 22 Junction...

Page 109: ...witch coupler Refer to POWER UNIT on page 5 4 CDI unit coupler Refer to CDI UNIT on page 5 11 Emergency switch connector Refer to CDI UNIT on page 5 11 Junction box assembly Refer to JUNCTION BOX ASSE...

Page 110: ...er to STATOR ASSEMBLY on page 5 9 Pulser coil coupler Refer to STATOR ASSEMBLY on page 5 9 CDI unit coupler Refer to CDI UNIT on page 5 11 1 Bolt 1 2 Ground lead 1 3 Thermo switch connector 4 4 Thrott...

Page 111: ...ad Refer to POWER UNIT on page 5 4 Starter motor lead Refer to JUNCTION BOX ASSEMBLY on page 5 17 1 Bolt 1 2 Washer 1 3 Bolt 2 4 Battery lead terminal 1 5 Starter motor 1 For installation reverse the...

Page 112: ...1 2 Rubber cap 1 3 Bolt 2 with washer 4 Oxygen density sensor cover 1 5 Bolt 3 with washer 6 Oxygen density sensor assembly 1 7 Gasket 1 8 Oxygen density sensor bracket 1 9 Oxygen density sensor 1 Re...

Page 113: ...S 5 Order Job Part Q ty Remarks Fuel injection unit Refer to HIGH PRESSURE FUEL LINE on page 4 1 1 Recirculation hose 12 2 Bolt 2 with washer 3 Gasket 1 4 Intake manifold 1 5 Screw 12 6 Gasket 6 7 Ree...

Page 114: ...5 27 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 115: ...5 1 Inspect 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 Repla...

Page 116: ...LINE on page 4 1 Low pressure fuel line Refer to LOW PRESSURE FUEL LINE on page 4 21 Oil injection system Refer to OIL INJECTION SYSTEM on page 4 28 Junction box Refer to JUNCTION BOX ASSEMBLY on pag...

Page 117: ...4 Collar 1 5 Bolt 2 6 Shift rod lever bracket 1 7 Bolt 1 8 Clamp bracket 1 9 Clamp 2 10 Hose clamp 1 11 Recirculation hose 6 12 Recirculation hose 1 For installation reverse the removal procedure 524...

Page 118: ...rder Job Part Q ty Remarks Ground lead Refer to CDI UNIT on page 5 11 Spark plug cap Refer to CDI UNIT on page 5 11 1 Spark plug 6 2 Bolt 8 3 Thermostat cover 2 4 Gasket 2 5 Thermostat 2 6 Bolt 36 7 C...

Page 119: ...art Q ty Remarks 9 Gasket 2 10 Thermo switch 2 11 Engine cooling water temperature sensor 1 12 Bolt 28 13 Cylinder head 2 14 Gasket 2 For installation reverse the removal procedure 5250 Not reusable N...

Page 120: ...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...

Page 121: ...face 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 cyli...

Page 122: ...Remarks Cooling water hose Refer to POWER UNIT on page 5 4 CDI unit assembly Refer to CDI UNIT on page 5 11 Cooling water hose Refer to JUNCTION BOX ASSEMBLY on page 5 17 1 Bolt 2 2 Pressure control...

Page 123: ...er Job Part Q ty Remarks 6 Pressure control valve seat 1 7 Bolt 29 8 Lead holder 1 9 Exhaust outer cover 1 10 Gasket 1 11 Exhaust inner cover 1 12 Gasket 1 For installation reverse the removal procedu...

Page 124: ...COVERS INSPECTING THE PRESSURE CONTROL VALVE 5 Inspect Pressure control valve seat 1 Pressure control valve 2 Pressure control valve cover 3 Cracks damage Replace any defec tive parts Spring 4 Damage...

Page 125: ...y 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 9 Intake manifold Refer to REED VALVES on page 5 26 E...

Page 126: ...5 39 POWR E 5 5 Order Job Part Q ty Remarks 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 127: ...attachment 1 YB 06195 90890 06637 90890 06631 Driver rod 2 YB 06071 90890 06606 5330 5340 INSTALLING THE CRANKCASE 5 Apply Gasket Maker onto the crankcase mating surfaces NOTE Clean the mating surfac...

Page 128: ...r Job Part Q ty Remarks Cylinder heads Refer to CYLINDER HEADS on page 5 31 Crankcase Refer to CRANKCASE on page 5 38 1 Upper bearing housing 1 2 Oil seal 1 3 O ring 2 4 Needle bearing 1 5 Connecting...

Page 129: ...EMBLY 5 5 Order Job Part Q ty Remarks 9 Crankshaft assembly 1 10 Clip 2 11 Main journal bearing 2 12 Screw 8 13 Anode 8 14 Bolt 7 15 Lead holder 3 16 Cylinder cover 1 17 Gasket 1 18 Bolt 2 Continued o...

Page 130: ...OWR E 5 5 Order Job Part Q ty Remarks 19 Engine hanger 1 20 Bolt 4 21 Damper bracket 2 22 Oil pump driven gear 1 23 Cylinder body 1 For assembly reverse the disassembly procedure 5360 CYLINDER BODY AS...

Page 131: ...LING THE PISTON 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 Piston ring 12 7 Connecting rod 6 For ass...

Page 132: ...SSEMBLY 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...

Page 133: ...ept for USA and Canada Needle bearing attachment 1 YB 06205 90890 06663 Driver rod 2 90890 06606 5390 5400 REMOVING THE BEARING AND OIL PUMP DRIVE GEAR 5 Remove Bearing Oil pump drive gear Bearing sep...

Page 134: ...and 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 av...

Page 135: ...tion the micrometer in relation to the piston pin hole as shown Measuring point H Piston diameter Standard 10 mm 0 4 in Cylinder 1 89 845 89 869 mm 3 5372 3 5381 in Cylinders 2 6 89 895 89 915 mm 3 53...

Page 136: ...0 150 0 156 mm 0 0059 0 0061 in Cylinders 2 6 0 100 0 106 mm 0 0039 0 0042 in 5450 INSPECTING THE PISTON PINS AND SMALL END BEARINGS 5 1 Inspect Piston pin Small end bearing Heat discoloration Replac...

Page 137: ...he piston ring into the cylinder with the piston crown Piston ring end gap 0 30 0 40 mm 0 012 0 016 in Piston ring end gap limit 0 60 mm 0 024 in Measuring point H 20 mm 0 8 in 5480 5490 2 Measure Pis...

Page 138: ...ation Replace INSPECTING THE CRANKSHAFT 5 1 Measure Crankshaft runout with V blocks and a dial gauge Out of specification Replace Labyrinth ring wear limit 0 10 mm 0 004 in Runout limit 0 05 mm 0 002...

Page 139: ...nstall Bearing Bearing separator 1 YB 06219 90890 06534 Bearing oil seal attachment 2 90890 06661 90890 06622 Bearing separator 1 YB 06219 90890 06534 Bearing oil seal attachment 2 90890 06662 90890 0...

Page 140: ...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 For USA and Canada Except...

Page 141: ...Install Piston and connecting rod assembly NOTE Before installing the piston and connect ing rod assemblies lubricate the cylinder walls with 2 stroke outboard motor oil Reinstall the piston and conne...

Page 142: ...EMOVING INSTALLING THE SHIFT ROD ASSEMBLY 6 7 REMOVING THE SHIFT ROD ASSEMBLY 6 8 PROPELLER SHAFT HOUSING ASSEMBLY REGULAR ROTATION MODELS 6 9 REMOVING INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY...

Page 143: ...ISASSEMBLING ASSEMBLING THE LOWER CASE ASSEMBLY 6 23 DISASSEMBLING THE LOWER CASE ASSEMBLY 6 24 INSPECTING THE DRIVE SHAFT SLEEVE 6 24 INSPECTING THE NEEDLE BEARING 6 24 ASSEMBLING THE LOWER CASE ASSE...

Page 144: ...ODELS 6 42 REMOVING INSTALLING THE DRIVE SHAFT 6 42 REMOVING THE DRIVE SHAFT 6 44 INSPECTING THE PINION 6 44 INSPECTING THE DRIVE SHAFT 6 44 INSTALLING THE DRIVE SHAFT 6 44 DISASSEMBLING THE DRIVE SHA...

Page 145: ...6 60 SELECTING THE FORWARD GEAR SHIMS 6 62 SELECTING THE REVERSE GEAR SHIM 6 63 BACKLASH REGULAR ROTATION MODELS 6 65 MEASURING THE FORWARD GEAR BACKLASH 6 65 MEASURING THE REVERSE GEAR BACKLASH 6 67...

Page 146: ...N MODELS 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...

Page 147: ...Order Job Part Q ty Remarks 8 Bolt 1 9 Trim tab 1 10 Bolt 1 with washer 11 Bolt 6 with washer 12 Lower unit 1 13 Dowel pin 2 For installation reverse the removal procedure 6010 LOWER UNIT REGULAR ROT...

Page 148: ...er from turning 6016 INSPECTING THE PROPELLER Inspect Blades Splines Cracks damage wear Replace INSTALLING THE PROPELLER Install Propeller WARNING Do not hold the propeller with your hands when removi...

Page 149: ...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 ho...

Page 150: ...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 assembly reverse the disassembly procedure 6020 Not reusable WATER...

Page 151: ...e wear Replace INSTALLING THE IMPELLER AND IMPELLER HOUSING 1 Install Washers 1 Wave washer 2 Spacer 3 Collar 4 NOTE The collar and spacer should fit together firmly Install the collar with some appro...

Page 152: ...REMOVING INSTALLING THE SHIFT ROD ASSEMBLY Order Job Part Q ty Remarks Impeller plate Refer to WATER PUMP REGULAR ROTATION MODELS on page 6 4 1 Bolt 3 with washer 2 Shift rod assembly 1 3 Shift rod 1...

Page 153: ...6 8 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 154: ...NSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY Order Job Part Q ty Remarks Gear oil Refer to CHANGING AND INSPECTING THE GEAR OIL on page 3 14 Shift rod assembly Refer to SHIFT ROD ASSEMBLY REGULAR RO...

Page 155: ...FT 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 p...

Page 156: ...ING 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 procedur...

Page 157: ...S 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 Pr...

Page 158: ...aft housing puller 1 YB 06207 90890 06502 Universal puller 2 YB 06117 Guide plate 3 90890 06501 Center bolt 4 90890 06504 6050 6054 1 2 6055 DISASSEMBLING THE PROPELLER SHAFT HOUSING 1 Remove Reverse...

Page 159: ...ller 4 90890 06535 Small universal claws 5 90890 06536 6070 6075 3 Remove Oil seal Needle bearing Bearing oil seal attachment 1 YB 06196 90890 06610 Driver rod 2 YB 06071 90890 06652 6080 INSPECTING T...

Page 160: ...LLER SHAFT HOUSING 1 Install Needle bearing For USA and Canada Except for USA and Canada Needle bearing installation position a 24 75 25 25 mm 0 974 0 994 in Bearing oil seal attachment 1 YB 06196 908...

Page 161: ...HOUSING ASSEMBLY Install Propeller shaft housing assembly Claw washer Ring nut NOTE To secure the ring nut bend one tab into the slot in the ring nut and the other tabs toward the propeller shaft hou...

Page 162: ...RIVE SHAFT Order Job Part Q ty Remarks Propeller shaft housing assembly Refer to PROPELLER SHAFT HOUSING ASSEMBLY REGULAR ROTATION MODELS on page 6 9 1 Nut 1 2 Pinion 1 3 Bolt 4 with washer 4 Drive sh...

Page 163: ...rt 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 Fo...

Page 164: ...e Needle bearing Bearing oil seal attachment 1 YB 06196 90890 06610 Driver rod 2 YB 06071 90890 06652 6120 DISASSEMBLING THE FORWARD GEAR ASSEMBLY 1 Remove Tapered roller bearing CAUTION Do not reuse...

Page 165: ...t housing Cracks damage Replace INSPECTING THE BEARINGS Inspect Bearings Pitting rumbling Replace ASSEMBLING THE FORWARD GEAR ASSEMBLY 1 Install Needle bearing Needle bearing installation position a 2...

Page 166: ...g For USA and Canada Except for USA and Canada 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...

Page 167: ...E LOWR DRIVE SHAFT REGULAR ROTATION MODELS INSTALLING THE DRIVE SHAFT Tighten Pinion nut NOTE Tighten the pinion nut with the same tools that were used for removal T R Pinion nut 95 Nm 9 5 m kgf 68 f...

Page 168: ...EMBLING THE LOWER CASE ASSEMBLY Order Job Part Q ty Remarks Forward gear Refer to DRIVE SHAFT REGULAR ROTATION MODELS on page 6 17 1 Drive shaft sleeve 1 2 Needle bearing 1 3 Tapered roller bearing ou...

Page 169: ...wear Replace INSPECTING THE NEEDLE BEARING Inspect Needle bearing Pitting rumbling Replace Slide hammer 1 YB 06096 Bearing puller 2 90890 06523 Large universal claws 3 90890 06532 6170 ASSEMBLING THE...

Page 170: ...UNIT DUAL PROPELLER 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 Rear propeller 1 7 Rear space...

Page 171: ...T DUAL PROPELLER MODELS 6 Order Job Part Q ty Remarks 9 Toothed washer 1 10 Forward propeller 1 11 Forward spacer 1 12 Bolt 7 with washer 13 Lower unit 1 14 Dowel pin 2 For installation reverse the re...

Page 172: ...en the cavitation plate and propeller to keep the propeller from turning 2 Straighten Toothed washer teeth 6321 3 Remove Forward propeller WARNING Do not hold the propeller with your hands when removi...

Page 173: ...plate and propeller to keep the propeller from turning 6327 2 Bend Toothed washer teeth 3 Install Rear propeller WARNING Do not hold the propeller with your hands when removing or installing it Be sur...

Page 174: ...6 REMOVING INSTALLING THE WATER PUMP Order Job Part Q ty Remarks Lower unit Refer to LOWER UNIT DUAL PROPELLER MODELS on page 6 25 1 Bolt 4 2 Plate washer 4 3 Impeller housing 1 4 Impeller housing cu...

Page 175: ...6 30 E LOWR 6 Order Job Part Q ty Remarks 8 Spacer 1 9 Washer 2 10 Wave washer 1 11 Impeller 1 12 Woodruff key 1 For assembly reverse the disassembly procedure 6330 WATER PUMP DUAL PROPELLER MODELS...

Page 176: ...ELLER AND IMPELLER HOUSING 1 Install Washers 1 Wave washer 2 Spacer 3 Collar 4 NOTE The collar and spacer should fit together firmly Install the collar with some appropriate tool a that fits over the...

Page 177: ...rder Job Part Q ty Remarks Woodruff key Refer to WATER PUMP DUAL PROPELLER MODELS on page 6 29 1 Bolt 3 with washer 2 Plate washer 3 3 Oil seal housing cover 1 4 Impeller plate 1 5 Gasket 1 6 Oil seal...

Page 178: ...oving steps 1 Insert a flat head screwdriver under each projection a 2 Alternating between each side of the oil seal housing 1 slowly lift the oil seal housing until it is fully removed from the lower...

Page 179: ...DELS 6 REMOVING INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY Order Job Part Q ty Remarks Gear oil Refer to CHANGING AND INSPECTING THE GEAR OIL on page 3 14 1 Ring nut 1 2 Claw washer 1 3 Propeller...

Page 180: ...DISASSEMBLING ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY Order Job Part Q ty Remarks 1 O ring 3 2 Rear gear assembly 1 3 Outer propeller shaft 1 4 Thrust bearing 1 5 Outer propeller shaft shim 6...

Page 181: ...LLER MODELS 6 Order Job Part Q ty Remarks 8 Oil seal 2 9 Needle bearing 1 10 Propeller shaft housing 1 11 Rear gear 1 12 Thrust washer 1 13 Tapered roller bearing outer race 1 14 Tapered roller bearin...

Page 182: ...ler shaft housing Ring nut wrench YB 42223 Propeller shaft housing puller 1 YB 06502 90890 06502 Universal puller 2 YB 06540 90890 06540 6350 2 1 6355 REMOVING THE OUTER PROPELLER SHAFT Remove Rear ge...

Page 183: ...ller bearing 3 Tapered roller bearing outer race 4 INSPECTING THE BEARINGS Inspect Needle bearing Thrust bearing Tapered roller bearing Pitting rumbling Replace INSPECTING THE PROPELLER SHAFT HOUSING...

Page 184: ...90 06604 Bearing oil seal depth plate 3 90890 06603 Oil seal installation position a 2 75 3 25 mm 0 108 0 128 in Bearing oil seal attachment 1 YB 42225 90890 06636 Driver rod 2 YB 06071 90890 06606 63...

Page 185: ...propeller shaft to protect the oil seal lip from damage 5 Install Tapered roller bearing 1 Tapered roller bearing outer race 2 Oil seal installation position a 4 75 5 25 mm 0 187 0 207 in Bearing oil...

Page 186: ...to the right and left Then push the propeller shaft housing assembly into the lower case until the claw washer s insertion slot comes out 2 Install Claw washer Ring nut NOTE To secure the ring nut ben...

Page 187: ...ller shaft housing assembly Refer to PROPELLER SHAFT HOUSING ASSEMBLY DUAL PROPELLER MODELS on page 6 34 Shift rod Refer to SHIFT ROD DUAL PROPELLER MODELS on page 6 32 1 Nut 1 2 Pinion 1 3 Bolt 4 4 D...

Page 188: ...Thrust bearing 1 7 Drive shaft 1 8 Inner propeller shaft assembly 1 9 O ring 1 10 Oil seal cover 1 11 Oil seal 2 12 Needle bearing 1 13 Drive shaft housing 1 For assembly reverse the disassembly proce...

Page 189: ...E PINION Inspect Teeth Damage wear Replace INSPECTING THE DRIVE SHAFT Inspect Drive shaft Damage wear Replace Drive shaft holder 1 YB 06201 90890 06520 Pinion nut holder 2 YB 42224 6420 INSTALLING THE...

Page 190: ...E SHAFT HOUSING ASSEMBLY 1 Install Needle bearing For USA and Canada Except for USA and Canada 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...

Page 191: ...PROPELLER SHAFT ASSEMBLY DUAL PROPELLER MODELS 6 DISASSEMBLING ASSEMBLING THE INNER PROPELLER SHAFT ASSEMBLY Order Job Part Q ty Remarks 1 Spring 1 2 Pin 1 3 Front dog clutch 1 4 Front gear assembly...

Page 192: ...SHAFT ASSEMBLY DUAL PROPELLER MODELS 6 Order Job Part Q ty Remarks 7 Rear dog clutch 1 8 Washer 2 9 Pin 1 10 Collar 1 11 Tapered roller bearing 1 12 Front gear 1 For assembly reverse the disassembly...

Page 193: ...Y Remove Bearing inner race CAUTION Do not reuse the bearing always replace it with a new one INSPECTING THE DOG CLUTCHES Inspect Dog clutches Damage wear Replace INSPECTING THE INNER PROPELLER SHAFT...

Page 194: ...ELS ASSEMBLING THE FRONT GEAR ASSEMBLY Install Bearing inner race 1 Bearing oil seal attachment YB 06276 90890 06659 6455 INSTALLING THE SPRING Install Spring 1 NOTE Push the end of the spring into th...

Page 195: ...ASSEMBLING THE LOWER CASE ASSEMBLY Order Job Part Q ty Remarks Inner propeller shaft assembly Refer to DRIVE SHAFT DUAL PROPELLER MODELS on page 6 42 1 Drive shaft sleeve 1 2 Needle bearing 1 3 Tapere...

Page 196: ...ng outer race Slide hammer 1 YB 06096 Bearing puller 2 90890 06523 Large universal claws 3 90890 06532 6475 INSPECTING THE DRIVE SHAFT SLEEVE Inspect Drive shaft sleeve Damage wear Replace INSPECTING...

Page 197: ...da Except for USA and Canada Needle bearing installation position a 10 0 mm 0 39 in Needle bearing installation position b 139 0 mm 5 47 in Bearing oil seal attachment 1 YB 06194 90890 06609 Driver ro...

Page 198: ...lect 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 i...

Page 199: ...pecified 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 unread...

Page 200: ...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 p...

Page 201: ...e 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 unr...

Page 202: ...l the shimming gauge and bear ing 1 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...

Page 203: ...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...

Page 204: ...ar assembly a few times until the gear and bearing are horizontal 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 S...

Page 205: ...nd washer 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 cle...

Page 206: ...of 0 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 3...

Page 207: ...easurement 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 sh...

Page 208: ...02 0 05 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 SHIM NOTE Select the shim thickness T2 by using the specified measurement...

Page 209: ...hen the unit is assembled If the R mark is negative then sub tract the R value from the measure ment Example 150L VX150 model If M2 is 30 50 mm R is 2 then T2 30 50 29 9 2 100 mm 30 50 29 9 0 02 mm 0...

Page 210: ...specification the pinion may be too high If both the forward and reverse gear back lashes are smaller than specification the pinion may be too low MEASURING THE FORWARD GEAR BACKLASH 1 Measure Forward...

Page 211: ...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...

Page 212: ...J SX150 SX200 models 0 36 M 0 72 150L VX150 model 0 86 M 0 67 More than 150J 200J SX150 SX200 models 0 46 mm 0 018 in 150L VX150 model 1 01 mm 0 040 in To be increased by 150J 200J SX150 SX200 models...

Page 213: ...dicator 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 in...

Page 214: ...an 150J 200J SX150 SX200 models 0 74 mm 0 029 in 150L VX150 model 0 79 mm 0 031 in To be increased by 150J 200J SX150 SX200 models 1 02 M 0 72 150L VX150 model 1 09 M 0 67 More than 150J 200J SX150 SX...

Page 215: ...ct 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 inn...

Page 216: ...the specified value M0 NOTE P is the deviation of the lower case dimension from standard It is stamped on the lower case in 0 01 mm units If the P mark is missing or unreadable assume a P value of 0...

Page 217: ...b 6745 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 th...

Page 218: ...tion of the lower case dimension from standard It is stamped on 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 as...

Page 219: ...il the specified value M0 is obtained with the special tool 1 Measure Specified measurement M Out of specified value M0 Adjust Measuring steps 1 Calculate the specified value M0 NOTE R is the deviatio...

Page 220: ...himming gauge bearing thrust washer and rear gear NOTE Turn the rear gear assembly a few times until the gear and bearing are horizontal 3 Measure the specified measurement M Shimming gauge YB 34468 1...

Page 221: ...785 1 Install Shim s 1 Thrust bearing 2 Outer propeller shaft 3 Tapered roller bearing 4 6790 2 Measure Outer propeller shaft free play Out of specification Adjust Propeller shaft free play 0 30 0 05...

Page 222: ...lashes are smaller than specification the pinion may be too low MEASURING THE FRONT GEAR BACKLASH 1 Measure Front gear backlash Out of specification Adjust Measuring steps 1 Set the shift rod into the...

Page 223: ...lockwise and counterclockwise When the drive shaft stops in each direction measure the backlash Backlash indicator 3 YB 06265 90890 06706 Magnetic base plate 4 YB 07003 90890 07003 Dial gauge set 5 YU...

Page 224: ...Set the shift rod into the neutral posi tion Shift rod wrench YB 06052 90890 06052 6645 2 Install the propeller shaft housing puller so it pushes against the outer propeller shaft Propeller shaft hou...

Page 225: ...ockwise and counterclockwise When the drive shaft stops in each direction measure the backlash Backlash indicator 4 YB 06265 90890 06706 Magnetic base plate 5 YB 07003 90890 07003 Dial gauge set 6 YU...

Page 226: ...AMP 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 REMOV...

Page 227: ...CTING THE GEAR PUMP UNIT 7 32 ASSEMBLING THE GEAR PUMP UNIT 7 33 INSTALLING THE GEAR PUMP UNIT 7 34 INSTALLING THE TILT RAM ASSEMBLY 7 34 TRIM RAM ASSEMBLIES AND FREE PISTON 7 36 REMOVING INSTALLING T...

Page 228: ...NG 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 Ho...

Page 229: ...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 Salt water models 14 Bottom cowling 1 For installation reverse the remova...

Page 230: ...LING ASSEMBLING 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 Set pin 3 8 Bushing 6 Continued on next pa...

Page 231: ...7 4 BRKT E 7 Order Job Part Q ty Remarks 9 Clamp lever 3 10 Pilot water outlet 1 11 Wire harness clamp 1 12 Bolt 1 13 Cable holder 1 14 Grommet 1 15 Bolt 2 Continued on next page 7030 BOTTOM COWLING...

Page 232: ...Order Job Part Q ty Remarks 16 Trailer switch holder 1 17 Trailer switch 1 18 Bolt 1 19 Ground lead 1 20 Grommet 4 21 Collar 4 22 Bottom cowling 1 For assembly reverse the disassembly procedure 7030 B...

Page 233: ...EMBLING 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...

Page 234: ...wer 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 Screw 2 4 Lower mount cover...

Page 235: ...LY 7 DISASSEMBLING 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 Spring 2 8 Lower mount 2...

Page 236: ...er Job Part Q ty Remarks 9 Ground lead 1 10 Bolt 2 11 Bolt 2 12 Bolt 2 13 Muffler assembly 1 14 Rubber seal 1 15 Muffler 1 X transom models 16 Rubber seal 1 X transom models 17 Rubber seal 1 X transom...

Page 237: ...10 BRKT E 7 Order Job Part Q ty Remarks 18 Upper case 1 19 Dowel pin 2 20 Circlip 1 X transom models 21 Bushing 1 X transom models For assembly reverse the disassembly procedure 7060 UPPER CASE ASSEMB...

Page 238: ...EMBLING 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 9 Bolt 4 Continued on next page...

Page 239: ...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 15 Plastic locking tie 1 16 Cooling water hose 1 For ass...

Page 240: ...BRACKETS Order Job Part Q 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...

Page 241: ...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...

Page 242: ...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 S...

Page 243: ...ACKET 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...

Page 244: ...er 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...

Page 245: ...M AND TILT UNIT Order Job Part Q ty Remarks Tilt up the outboard 1 Power trim and tilt lead 2 2 Plastic locking tie 3 3 Ground lead 1 4 Circlip 3 5 Upper mounting pin 1 6 Lower mounting pin 1 7 Power...

Page 246: ...board 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...

Page 247: ...ilt 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...

Page 248: ...RVOIR 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 a...

Page 249: ...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 wi...

Page 250: ...eaches 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 th...

Page 251: ...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 Con...

Page 252: ...als 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 posit...

Page 253: ...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 pressur...

Page 254: ...s 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...

Page 255: ...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...

Page 256: ...ING 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 21 1 Manual valve 1 2 Tilt r...

Page 257: ...GEAR PUMP UNIT 7 Order Job Part Q ty Remarks 7 Check valve assembly 1 8 Gear pump 1 9 Shuttle valve 2 10 Check valve 2 11 Up relief valve assembly 1 12 Down relief valve assembly 1 For installation r...

Page 258: ...IT Remove Bolt 1 Gear pump unit 2 O ring 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 Re...

Page 259: ...ING THE TILT RAM Inspect Tilt ram Excessive scratches Replace Bends excessive corrosion Replace Rust Polish with 400 600 grit sandpaper INSPECTING THE GEAR PUMP UNIT Inspect Shuttle valves 1 Check val...

Page 260: ...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...

Page 261: ...is on the tilt ram cylinder side as shown 7380 2 Install Gear pump unit 1 Bolt 2 7390 INSTALLING THE TILT RAM ASSEMBLY WARNING To prevent the hydraulic fluid from spurt ing out due to internal pressu...

Page 262: ...op 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 a...

Page 263: ...M 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 29 1 Trim ram end screw 2 2 Trim ram 2 3 O rin...

Page 264: ...ISTON 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 a...

Page 265: ...ston Excessive scratches Replace INSPECTING THE TRIM RAM CYLINDERS Inspect Trim ram cylinder Cracks excessive scratches Replace the power trim and tilt unit INSTALLING THE FREE PISTON 1 Fill Fluid pas...

Page 266: ...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 o...

Page 267: ...TE 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 screw For USA and Canada Except for USA and Canada End screw w...

Page 268: ...MEASURING THE CRANK POSITION SENSOR OUTPUT PEAK VOLTAGE 8 18 MEASURING THE ENGINE COOLING WATER TEMPERATURE SENSOR RESISTANCE 8 18 INSPECTING THE THERMO SWITCH CONTINUITY 8 19 INSPECTING THE OIL LEVEL...

Page 269: ...37 INSPECTING THE FUSES 8 38 INSPECTING THE BATTERY 8 38 OIL FEED PUMP CONTROL SYSTEM 8 39 INSPECTING THE FUSES 8 40 INSPECTING THE OIL LEVEL SENSOR SWITCH CONTINUITY 8 40 INSPECTING THE EMERGENCY SWI...

Page 270: ...pressure fuel pump 3 Throttle position sensor 4 High pressure fuel pump connectors 5 High pressure fuel pump resistor couplers 2P 6 Oil level sensor 7 Fuel injector coupler 6P 8 Throttle position sens...

Page 271: ...w 8 8020 1 Atmospheric pressure sensor 2 Crank position sensor coupler 2P 3 Engine cooling water temperature sensor coupler 2P 4 Oxygen density sensor 5 Battery lead terminal 6 Starter motor 7 Intake...

Page 272: ...hting coil coupler 3P 3 Fuse 80A 4 Atmospheric pressure sensor 5 Power trim and tilt relay 6 Fuse 30A 7 Intake air temperature sensor 8 Main relay 9 Starter relay 0 Rectifier regulator Complete assemb...

Page 273: ...Emergency switch connectors 2 Emergency switch 3 Ignition coil connectors 4 Ignition coils 5 Thermo switch connectors 6 Charge coil coupler 4P 7 Oxygen density sensor coupler 2P 8 CDI unit 9 CDI unit...

Page 274: ...xygen density sensor 3 Crank position sensor 4 Spark plugs 5 Thermo switches 6 Engine cooling water temperature sensor 7 CDI unit 8 Emergency switch 9 Oil level sensor 0 Trailer switch A High pressure...

Page 275: ...5 7 6 9 8 2 2 C B A D F G E 2 3 4 5 6 7 2 9 7 82 A B C D E R P B B KJI ZY SRQ NM PO W X V ba L U T 8060 Connect to 1 Oil level sensor 2 Ground 3 Emergency switch 4 CDI unit 5 Fuse 80A 6 Power trim and...

Page 276: ...4 5 6 7 2 9 7 82 A B C D E R P B B KJI ZY SRQ NM PO W X V ba L U T 9 Oxygen density sensor 0 Remote control A Oil level switch sub oil tank B Trim sensor C Oil level meter D Trim meter E Intake air te...

Page 277: ...4 Throttle position sensor 5 CDI unit 6 Crank position sensor 7 Engine cooling water temperature sensor B Black O Orange P Pink B Y Black yellow G L Green blue G W Green white W B White black W Br Whi...

Page 278: ...el injectors 2 Main relay 3 High pressure fuel pump resistor 4 CDI unit 5 High pressure fuel pump Br Brown L Blue Pu B Purple black Pu G Purple green Pu L Purple blue Pu R Purple red Pu W Purple white...

Page 279: ...ng 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 th...

Page 280: ...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 measu...

Page 281: ...Ignition coils B Black Br Brown L Blue R Red W White B Br Black brown B G Black green B L Black blue B O Black orange B R Black red B W Black white B Y Black yellow G L Green blue G W Green white W B...

Page 282: ...Keep flammable gas or liquids away since this test can produce sparks Inspect Ignition spark Spark is weak Inspect the ignition system Inspecting steps 1 Remove the spark plugs from the engine 2 Conne...

Page 283: ...a good spark is obtained the problem is not with the ignition system but possibly with the spark plug s or another compo nent 1 Measure CDI unit output peak voltage Below specification Measure the ch...

Page 284: ...500 3 500 V 85 110 150 150 Test harness 4 pin YB 38831 90890 06771 8260 3 Measure Pulser coil output peak voltage Above specification Replace the CDI unit Below specification Replace the pulser coil...

Page 285: ...onnection 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 pl...

Page 286: ...rature sensor 4 Thermo switches 5 Oil level sensor 6 Throttle position sensor 7 CDI unit B Black O Orange P Pink R Red B Y Black yellow G L Green blue G W Green white L G Blue green L R Blue red L W B...

Page 287: ...lace Crank position sensor output peak voltage Green white G W Green blue G L r min Circuit Loaded Cranking 1 500 3 500 V 6 0 0 5 3 0 4 0 Test harness 2 pin YB 06767 90890 06767 8310 MEASURING THE ENG...

Page 288: ...Thermo switch continuity Out of specification Replace 1 No continuity Temperature 2 Continuity Time Measuring steps 1 Place the thermo switch in a container filled with water 2 Place a thermometer in...

Page 289: ...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 volt...

Page 290: ...White brown W G White green W L White blue W R White red W Y White yellow FUEL CONTROL SYSTEM FUEL CONTROL SYSTEM 8 8390 1 Pulser coil 2 Crank position sensor 3 Oxygen density sensor 4 Engine cooling...

Page 291: ...ITION SENSOR OUTPUT PEAK VOLTAGE 8 Refer to MEASURING THE CRANK POSITION SENSOR OUTPUT PEAK VOLTAGE on page 8 18 INSPECTING THE OXYGEN DENSITY SENSOR 8 1 Measure Oxygen density sensor heater conti nui...

Page 292: ...lvent and allow the sensor to thor oughly dry 3 Heat the front end of the oxygen den sity sensor 1 with a gas torch 2 in the center of its blue flame a for 10 15 seconds Then remove the oxygen density...

Page 293: ...MPERATURE SENSOR 8 Measure Intake air temperature sensor output voltage Out of specification Replace Measuring steps 1 Connect the test harness 2 pin as shown 2 Turn the engine start switch to the on...

Page 294: ...THROT TLE POSITION SENSOR OUTPUT VOLTAGE on page 8 20 MEASURING THE HIGH PRESSURE FUEL PUMP RESISTOR RESISTANCE8 Inspect High pressure fuel pump resistor resistance Out of specification Replace High...

Page 295: ...have a solenoid valve operat ing sound 8490 2 Inspect High pressure fuel pump operating sound Correct Replace the fuel injector no sound No sound Inspect the main relay NOTE The high pressure fuel pu...

Page 296: ...8 27 ELEC E STARTING SYSTEM STARTING SYSTEM 8 8500 1 Battery 2 Fuse 80A 3 Fuse 30A 4 10P connector 5 Starter relay 6 Starter motor B Black Br Brown R Red...

Page 297: ...nuity Check the fuse holder leads 2 Inspect Fuse holder lead continuity No continuity Replace the fuse holder Continuity Inspect the fuse 3 Inspect Fuse continuity No continuity Replace Fuse rating Ou...

Page 298: ...nuity No continuity Replace Inspecting steps 1 Connect the tester and battery between the starter relay terminals 2 Inspect that there is continuity between the starter relay terminals Positive digita...

Page 299: ...NG ASSEMBLING THE STARTER MOTOR 8 Order Job Part Q ty Remarks Starter motor Refer to STARTER MOTOR on page 5 24 1 Bolt 2 2 Starter motor bracket 1 3 Clip 2 4 Starter motor pinion stopper 1 5 Spring 1...

Page 300: ...8 31 ELEC E STARTER MOTOR 8 8 Order Job Part Q ty Remarks 7 Bolt 2 8 Upper cover 1 9 Washer 3 10 Lower bracket 1 11 Stator 1 12 Armature 1 13 Washer 2 14 Nut 1 Continued on next page 8530...

Page 301: ...8 32 ELEC E STARTER MOTOR 8 8 Order Job Part Q ty Remarks 15 O ring 1 16 Screw 2 17 Brush assembly 1 18 Spring 4 19 Brush holder 1 For assembly reverse the disassembly procedure 8530...

Page 302: ...wear Replace 2 Inspect 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 cloc...

Page 303: ...ndercut limit 0 2 mm 0 01 in 8590 5 Inspect Armature continuity Out of specification Replace Armature continuity Commutator segments a Continuity Segment Armature core b No continuity Segment Armature...

Page 304: ...ion Replace the brush assembly Brush assembly continuity Brush 1 Brush 2 Brush 3 Brush 4 Brush 3 4 Brush assembly holder 5 Continuity Brush 1 Brush 3 Brush 1 Brush 4 Brush 2 Brush 3 Brush 2 Brush 4 Br...

Page 305: ...8 36 ELEC E CHARGING SYSTEM 8 8630 1 Lighting coil 2 Rectifier regulator 3 Fuses 80A 4 Battery B Black G Green R Red R W Red white CHARGING SYSTEM...

Page 306: ...regulator output peak voltage Red R Black B r min Circuit Loaded Cranking 1 500 3 500 V 12 12 Test harness 3 pin YB 06770 90890 06770 8640 8650 8660 MEASURING THE LIGHTING COIL OUTPUT PEAK VOLTAGE 8 M...

Page 307: ...8 38 ELEC E INSPECTING THE FUSES 8 Refer to INSPECTING THE FUSES on page 8 28 INSPECTING THE BATTERY 8 Refer to INSPECTING THE BAT TERY on page 3 16 CHARGING SYSTEM...

Page 308: ...e 30A 3 10P connector 4 Oil level sensor 5 Emergency switch 6 CDI unit 7 4P coupler 8 Oil level switch sub oil tank 9 Oil pump sub oil tank B Black Br Brown Gy Gray L Blue P Pink R Red Y Yellow B R Bl...

Page 309: ...TY 8 Inspect 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 ON OFF ON OFF ON OFF Float distance a 3 6 mm 0...

Page 310: ...lace Switch position Lead color Blue L Black B Home a No continuity On b Continuity 8710 INSPECTING THE OIL PUMP SUB OIL TANK 8 Inspect Oil pump sub oil tank Incorrect operation Replace NOTE Connect t...

Page 311: ...80A 3 Fuse 30A 4 Trailer switch 5 10P connector 6 Power trim and tilt relay 7 Power trim and tilt motor 8 Trim sensor To remote control To trim meter B Black Gy Gray Lg Light green P Pink R Red Sb Sk...

Page 312: ...2 Connect a 12 V battery as shown 3 Check that there is continuity between the power trim and tilt relay terminals 4 Connect the digital tester between power trim and tilt relay terminals and 2 5 Conn...

Page 313: ...ce 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...

Page 314: ...BLING 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 21 1 Screw 1 2 Lead holder 1 3 Screw 2...

Page 315: ...46 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 75...

Page 316: ...eads Hold the end of the armature shaft with a clean cloth and pull off the stator 7550 REMOVING THE BRUSH 8 1 Remove Sky blue power trim and tilt motor lead 1 NOTE Hold the brush with a screwdriver a...

Page 317: ...easure Commutator diameter a Out of specification Replace Commutator diameter limit 21 0 mm 0 83 in 7600 2 Measure Commutator undercut a Out of specification Replace the armature Commutator undercut l...

Page 318: ...etal touching it may affect the operation of the breaker 7640 INSTALLING THE ARMATURE 8 Install Armature 1 NOTE Push the brushes into the holder and then install the armature 7650 INSTALLING THE STATO...

Page 319: ...L ANLS CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS 9 1 TROUBLE ANALYSIS CHART 9 1 SELF DIAGNOSIS 9 4 DIAGNOSIS CODE INDICATION 9 4 DIAGNOSIS THE ELECTRONIC CONTROL SYSTEM 9 4 TROUBLE SHOOTING FOR ELEC...

Page 320: ...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 N...

Page 321: ...Fluid level 3 Relief valve 7 Fluid passages Power trim and tilt motor 7 ELECTRICAL Ignition system Charge coil 8 Pulser coils 8 CDI unit 8 Ignition coils 8 Spark plugs 3 Trouble mode Check elements E...

Page 322: ...8 Charging system Lighting coil 8 Rectifier regulator 8 Fuses 8 Battery leads Battery Oil feed pump control system Oil level sensor engine oil tank 8 Oil level switch sub oil tank 8 Power trim and til...

Page 323: ...ation indicates code number 23 a Light on 0 3 second b Light off 0 3 second c Light off 1 7 seconds d Light off 5 seconds 8170 DIAGNOSIS THE ELECTRONIC CONTROL SYSTEM 9 1 Install Diagnostic indicator...

Page 324: ...chart 8 Code Symptoms 13 Incorrect pulser coil input sig nal 14 No crank position sensor input signal 15 Incorrect engine cooling water temperature sensor input sig nal 18 Incorrect throttle position...

Page 325: ...re fuel lines 2 Inspect the ignition system 1 Inspect for fuel line leaks 2 Inspect the fuel pressure 3 Inspect the operation of the fuel injector 4 Inspect the diagnosis cord Fuel pressure is out of...

Page 326: ...4 Inspect the diagnosis cord 5 Inspect the oxy gen density sensor Fuel pressure is out of specification 1 Inspect the 30 A fuse 2 Inspect the high pres sure fuel pump opera tion 3 Inspect the main rel...

Page 327: ...en density sensor Fuel pressure is out of specification 1 Inspect the 30 A fuse 2 Inspect the high pres sure fuel pump opera tion 3 Inspect the main relay 4 Inspect the main relay drive s ECU output 5...

Page 328: ...CDI unit Thermo switch 1 2 3 4 5 6 Emergency switch 7 8 9 Spark plug Spark plug Spark plug Thermo switch 9 Spark plug Spark plug Spark plug A Ignition coil A A Ignition coil A Ignition coil Ignition c...

Page 329: ...YAMAHA MOTOR CORPORATION USA Printed in USA Jan 2004 0 0 1 CR E...

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