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IMPORTANT INFORMATION

In this Service Manual particularly important information is distinguished in the following
ways.

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

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine

operator, a bystander, or a person inspecting or repairing the outboard motor.

CAUTION:

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

board motor.

NOTE:

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

Содержание SX150C

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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