F200C LF200C F225C LF225C SERVICE MANUAL *LIT186160276* LIT-18616-02-76 69J-28197-1F-11
NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
Contents General information Specifications Periodic checks and adjustments Fuel system Power unit Lower unit Bracket unit GEN INFO SPEC CHK ADJ FUEL POWR LOWR BRKT – Electrical systems Troubleshooting Index + ELEC TRBL SHTG 1 2 3 4 5 6 7 8 9
GEN INFO General information How to use this manual ................................................................................. 1-1 Manual format............................................................................................ 1-1 Symbols..................................................................................................... 1-2 Safety while working......................................................................................1-3 Fire prevention.........................
Predelivery checks ......................................................................................1-28 Checking the fuel system ........................................................................1-28 Checking the gear oil............................................................................... 1-28 Checking the engine oil ...........................................................................1-28 Checking the battery......................................................................
GEN INFO General information How to use this manual 1 Manual format The format of this manual has been designed to make service procedures clear and easy to understand. Use the information below as a guide for effective and quality service. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list. 2 Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions.
How to use this manual Symbols The symbols below are designed to indicate the content of a chapter. General information Fuel system GEN INFO Bracket unit FUEL Specifications BRKT Power unit SPEC Electrical systems POWR ELEC Periodic checks and adjustments Lower unit CHK ADJ – + Troubleshooting TRBL SHTG LOWR Symbols 1 to 6 indicate specific data. 1 2 3 4 5 6 T. R.
GEN INFO General information Safety while working 1 To prevent an accident or injury and to ensure quality service, follow the safety procedures provided below. Fire prevention Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the outboard motor.
Safety while working / Identification 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. Good working practices Special tools Use the recommended special tools to protect parts from damage. Use the right tool in the right manner—do not improvise. 3. Install bearings with the manufacture identification mark in the direction indicated in the installation procedure. In addition, be sure to lubricate the bearings liberally.
GEN INFO 1 2 3 4 General information Model name Approved model code Transom height Serial number Model name Approved model code Starting serial No.
Identification / Features and benefits Features and benefits 1 Newly developed V6 4-stroke engine The F225 is a newly developed 60-degree V6 4-stroke engine with a very compact and lightweight design. Its size and weight are almost the same as the V6 2-stroke engines that are in current use. This F225 offers numerous advantages of a 4-stroke engine.
GEN INFO General information Crankcase The crankcase is made of cast aluminum, however steel has been cast into the areas for the crankshaft bearings. By distinguishing the area that requires strength from the area that allows the use of a lighter material, both weight reduction and a stronger construction have been achieved. The caps for the crankshaft bearings are secured with four bolts to ensure a high level of assembled rigidity.
Features and benefits Piston The piston has been carved out of a forged stock. To prevent the valves from coming in contact with the piston, the piston is provided with a valve recess. If the engine goes out of timing and a valve opens when the piston is at top-dead-center, this recess prevents the valve from coming in contact with the piston, thus preventing engine damage.
GEN INFO General information Valve train system The valve train consists of a total of four camshafts, with two in each bank. The camshafts are driven with the combination of a belt and chains. The crankshaft turns the belt to drive the exhaust camshafts in both banks. Chains connect the exhaust camshafts to the intake camshafts in the cylinder heads to drive the intake camshafts.
Features and benefits Tensioner A timing chain tensioner is provided at the mid-span of the timing chain, between both camshafts. The timing chain tensioner uses the force of a spring to maintain its tension. After the engine is started, oil is pumped into the tensioner, and the resulting pressure causes the tension to increase.
GEN INFO General information Intake system Throttle valve A total of six intake throttle valves are provided, one for each cylinder. Together with the intake silencer that offers enhanced intake efficiency and the injectors that are provided at each throttle body, the throttle valves help to improve the intake efficiency of the engine. As a result, this engine produces a higher power output and realizes better driveability.
Features and benefits Exhaust passage during idle To reduce noise when the engine is idling, the exhaust gas passage of the F225 has adopted a labyrinth construction. During idling, the exhaust gas passes through the passage on the side of the exhaust guide, and enters the upper case through a hole in the upper case gasket. When it fills the upper case, the exhaust gas enters another passage on the side of the exhaust guide through another hole in the upper case gasket.
GEN INFO General information Fuel system The fuel flows in the following order: fuel filter, low-pressure fuel pump, vapor separator, high-pressure fuel pump, and injectors. The excess fuel at the injectors passes through the pressure regulator and fuel cooler, and returns to the vapor separator. When the engine start switch is turned on, the injectors of all cylinders operate before the pump relay is actuated to prevent the injectors from sticking.
Features and benefits Low-pressure fuel pump The F225 has adopted a newly developed, low-pressure electrical fuel pump, in place of the lowpressure mechanical fuel pump used in the previous electronic fuel injection system. With the adoption of the electric pump, the routing of the fuel system has been made more compact. To prevent the over-pumping of fuel, this pump operates for 10 seconds, and stops for 20 seconds when the engine is operating at low speeds.
GEN INFO General information Electronic control system The ECM controls the ignition timing, the fuel injection timing, the fuel injection volume, and the ISC and it maintains a stoichiometric air-fuel ratio in all operating conditions, including starting and idling. Also, the ECM converts the signals from the input sensors and sends instructions to each part.
Features and benefits Ignition and fuel injection timing This engine adopted the group injection system that the fuel required for one combustion is injected twice per one cycle. Therefore, the injector driving circuits can be integrated to 3 circuits and a simpler electrical structure is obtained.
GEN INFO General information PTT (Power trim and tilt) unit The PTT unit has been newly developed for the F225. Based on the field-proven 61A type, its PTT fluid passage and internal valve construction have been changed for this application. Although the valves of the 61A type have been distributed to the various areas of the gear pump housing, the valves of the new PTT unit have been concentrated in the vicinity of the gear pump to improve their serviceability.
Features and benefits / Technical tips Technical tips 1 Fuel injection control The F200/F225 injects fuel simultaneously to the following cylinder pairs: #1 and #4, #2 and #5, and #3 and #6. Optimal injection timing is provided in accordance with the operating conditions of the engine. Starting fuel injection volume and injection timing The injectors are actuated in sync with the standard crankshaft position signals (BTDC 70°) for cylinder pairs #1 and #4, #2 and #5, and #3 and #6, respectively.
GEN INFO General information Over-revolution control If the engine speed exceeds 4,500 r/min, while the shift is in neutral, ignition is stopped. The various stages of ignition cutoff are shown in the table below. Ignition cutoff cylinder in neutral Set speed (r/min) #1 #2 #3 #4 #5 #6 4,500 4,750 : Indicates a misfire at either cylinder (once, due to simultaneously firing). : Indicates a misfire at both cylinders (twice continuous).
Technical tips Fail-safe function table FAIL-SAFE FUNCTION Symptom Ignition Injection ISC Engine condition DIAGNOSIS CODE Engine starting: Only the cylinders outputting normal signal ignite at BTDC10°, and all cylinders thereafter. All cylinders inject simultaneously Only in neutral: Idle speed based on the cylin900 r/min increases der that is outputting a normal signal.
GEN INFO General information PTT (Power trim and tilt) unit In the newly designed PTT unit, the up-main valve, down-main valve, up-relief valve, and downrelief valve have been concentrated in the gear pump housing in order to improve the serviceability of the engine and ensure reliable operation.
Technical tips Trim-up and tilt-up function When the PTT switch is pressed to “UP,” the power trim and tilt motor operates the gear pump and fluid pressure is generated. As a result, the fluid pressure pushes the up-shuttle piston upward, enters the trim cylinder and tilt cylinder lower chambers through the up-main valve, and then pushes the tilt ram and trim ram upward.
GEN INFO General information Trim ram retraction function When the outboard motor is tilted up and held in place with the tilt stop lever and the PTT switch is pressed to “DN,” the trim ram will be retracted. Although the gear pump attempts to draw oil from the tilt cylinder and trim cylinder lower chambers, after the PTT switch has been pressed, fluid cannot be drawn from the tilt cylinder lower chamber because the tilt ram is secured in place by the tilt stop lever.
Technical tips Trim-down and tilt-down function When the PTT switch is pressed to “DN,” the power trim and tilt motor operates the gear pump and fluid pressure is generated. As a result, the fluid pressure pushes the down-shuttle piston upward, enters the tilt cylinder upper chamber through the down-main valve, and then pushes the tilt ram downward. In addition, the fluid pushes the up-shuttle piston downward to open the up-main valve.
GEN INFO General information Stationary condition When the PTT switch is not pressed, the gear pump will not pump the fluid, the up-main valve and the down-main valve will remain closed, and the PTT unit in the system remains constant. This will allow the tilt ram and the trim ram to maintain their positions until the PTT fluid flows through the system again.
Technical tips Cooling system : S69J1460 1 2 3 4 5 6 7 8 È Cooling water inlet Water pump Oil pan Exhaust pipe PCV (Pressure control valve) In-bank exhaust system Thermostat Propeller boss Water Lubrication system Cylinder head Crankcase Pressure feed Splash Sleeve Return Intake and exhaust valves Camshaft Piston Crankshaft pin Camshaft journal Return route Main gallery Oil pressure sensor • Low oil pressure warning Oil filter • Oil pressure regulation Oil pump with relief valve Oil stra
GEN INFO General information Propeller selection 1 The performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities. An incorrect choice could adversely affect performance and could also seriously damage the engine.
Propeller selection / Predelivery checks Predelivery checks 1 To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the engine oil 1. Check the oil level. Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel. NOTE: • If the engine oil is above the maximum level mark (H), drain sufficient oil until the level is between (H) and (L).
GEN INFO General information Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced. Also, the engine speed will increase abnormally and cause the engine to overheat. If the mounting height is too low, water resistance will increase and reduce engine efficiency. 3.
Predelivery checks Checking the steering wheel Checking the tilt system 1. Check the steering friction for proper adjustment. 1. Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit. 2. Check that smoothly. the steering operates 2. Check that there is no abnormal noise produced when the outboard motor is tilted up or down. 3. Check that there is no interference with wires and hoses when the tilted-up outboard motor is steered. 4.
GEN INFO General information Checking the cooling water pilot hole 1. Check that cooling water is discharged from the cooling water pilot hole. 0 1 2 10 S69J1240 È Hour After test run S69J1230 1. Check for water in the gear oil. Test run 2. Check for fuel leakage in the cowling. 1. Start the engine, and then check that the gearshift operates smoothly. 3. After a test run and while the engine is at idle, flush the cooling water passage with fresh water using the flushing kit. 2.
SPEC Specifications General specifications................................................................................... 2-1 Maintenance specifications ..........................................................................2-3 Power unit..................................................................................................2-3 Lower unit ..................................................................................................2-6 Electrical ........................................
SPEC Specifications General specifications Item Dimension Overall length Overall width Overall height (X) (U) Boat transom height (X) (U) Weight (without propeller) (X) (U) Performance Maximum output Full throttle operating range Maximum fuel consumption Power unit Type Cylinder quantity Displacement Bore × stroke Compression ratio Control system Starting system Ignition control system Ignition timing Alternator output Spark plugs Cooling system Exhaust system Lubrication system 2-1 2 Unit Model LF20
General specifications Item Fuel and oil Fuel type Fuel rating Engine oil type Engine oil grade Unit PON(*1) RON API SAE Model LF200TR F225TR F200TR LF225TR Regular unleaded gasoline 86 91 4-stroke motor oil SE, SF, SG, SH, or SJ 10W-30 or 10W-40 Engine oil quantity (with oil filter replacement) L 6.0 (6.3, 5.3) (US qt, lmp qt) (without oil filter replacement) L 5.8 (6.1, 5.1) (US qt, lmp qt) Gear oil type GEAR CASE LUBE Gear oil grade SAE 90 Gear oil quantity L 1.15 1.00 1.15 1.
SPEC Specifications Maintenance specifications 2 Power unit Item Power unit Minimum compression pressure(*1) Lubrication oil pressure(*2) Cylinder heads Warpage limit (lines indicate straightedge position) Camshaft cap inside diameter Cylinders Bore size Taper limit Out-of-round limit Pistons Piston diameter (D) Measuring point (H) Piston-to-cylinder clearance Piston pin boss bore Piston pins Outside diameter Piston rings Top ring Dimension B Dimension T End gap Side clearance Unit F200TR Model LF2
Maintenance specifications Item 2nd ring Dimension B Dimension T End gap Side clearance Oil ring Dimension B Dimension T End gap Side clearance Camshafts Intake (A) Exhaust (A) Intake and exhaust (B) Camshaft journal diameter Camshaft journal oil clearance Camshaft runout limit Valves Valve clearance (cold) Intake Exhaust Head diameter (A) Intake Exhaust Face width (B) Intake Exhaust Seat contact width (C) Intake Exhaust Margin thickness (D) Intake Exhaust Stem diameter Intake Exhaust Guide inside diameter
SPEC Specifications Item Valve springs Free length Minimum free length Tilt limit Valve lifters Valve lifter outside diameter Valve lifter-to-cylinder head clearance Valve shims Valve shim thickness (in 0.
Maintenance specifications Item Oil pump Discharge at 97–103 °C (207–217 °F) with 10W-40 engine oil Pressure Relief valve opening pressure Thermostats Opening temperature Fully open temperature Valve open lower limit Engine speed Engine idle speed Unit L (US gal, Imp gal)/min at 700 r/min kPa (kgf/cm2, psi) kPa (kgf/cm2, psi) F200TR Model LF200TR F225TR LF225TR 8.8 (2.32, 1.94) 138 (1.38, 19.62) 529–647 (5.29–6.47, 75.22–92.00) °C (°F) °C (°F) mm (in) 58–62 (136–144) 70 (158) 4.3 (0.
SPEC Specifications Electrical Item Ignition and ignition control system Pulser coil output peak voltage (W/R – B, W/B – B, W/G – B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Pulser coil resistance(*1) (W/R – B, W/B – B, W/G – B) ECM output peak voltage (B/O – B, B/Y – B, B/W – B) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Spark plug gap Ignition coil resistance Primary coil (R/Y – B/O, R/Y – B/Y, R/Y – B/W) Secondary coil (spark
Maintenance specifications Item Fuel control system Fuel injector resistance(*1) at 20 °C (68 °F) Starter motor Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit Charging system Fuse Stator coil output peak voltage (G – G) at cranking (unloaded) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) (G/W – G/W) at cranking (unloaded) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Stator coil resistance(*1) (G – G) (
SPEC Specifications Item Power trim and tilt system Trim sensor Setting resistance Resistance (P – B) Fluid type Brushes Standard length Wear limit Commutator Standard diameter 2-9 Unit F200TR Model LF200TR F225TR Ω Ω 9–11 9–387.6 ATF Dexron II mm (in) mm (in) 12.0 (0.47) 4.0 (0.16) mm (in) 25.0 (0.
Maintenance specifications — MEMO — 1 2 3 4 5 6 7 8 9 69J1D11 2-10
SPEC Specifications Dimensions Exterior W5 T1 A1 W1 L7 L6 L2 L1 L10 H9 H2 H7 H8 H10 H4 H1 L8 C3 A2 L5 H6 H3 12˚ A3 H11 L9 L4 S69J2130 2-11 69J1D11
Maintenance specifications Symbol L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 W1 W2 W3 W4 W5 W6 A1 A2 A3 T1 69J1D11 Unit (X) (U) (X) (U) (X) (U) (X) (U) (X) (U) (X) (U) (X) (U) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) Degree Degree Degree mm (in) Mode
SPEC Specifications Clamp bracket B5 B3 B4 B9 B9 B9 D1 C3 B2 B6 D2 B1 Symbol B1 B2 B3 B4 B5 B6 B7 B8 B9 C2 C3 D1 D2 2-13 D1 S69J2140 Unit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) F200TR Model LF200TR F225TR 125 (4.9) 254 (10.0) 163 (6.4) 51 (2.0) 180 (7.1) 411 (16.2) — — 19 (0.7) — 79 (3.1) 13 (0.5) 56 (2.
Maintenance specifications / Tightening torques Tightening torques 2 Specified torques Part to be tightened Thread size Fuel system Fuel filter holder bolt Fuel filter bracket bolt Intake air temperature sensor Low-pressure fuel pump bracket bolt Fuel cooler nut Float chamber bracket bolt Vapor separator cover screw Link rod nut Magnet control lever joint Throttle cam bolt Power unit PTT motor lead bolt Upper case cover bolt Apron bolt Power unit bolt Flywheel magnet nut PTT relay nut Starter relay lead
SPEC Specifications Part to be tightened Thread size Spark plug Cylinder head bolt — 1st 2nd 3rd 1st 2nd Engine hanger bolt Cooling water cover bolt Starboard cylinder head plug Cylinder block plug Engine temperature sensor Connecting rod cap 1st 2nd 3rd Crankcase bolt Lower unit (regular rotation model) Trim tab bolt Lower unit bolt Propeller nut Propeller shaft housing grease nipple Propeller shaft housing bolt Pinion nut Lower unit (counter rotation model) Trim tab bolt Lower unit bolt Propeller
Tightening torques Part to be tightened Upper case mount nut Engine oil drain bolt Apron stay Pressure control valve Upper exhaust guide bolt Oil strainer bolt Oil pan bolt Exhaust manifold bolt Muffler bolt Baffle plate screw Clamp bracket self-locking nut Friction plate screw Trim stopper nut Power trim and tilt unit Reservoir bolt Reservoir cap Manual valve Fluid pipe Trim cylinder end screw Trim piston bolt Tilt ram Tilt cylinder end screw Tilt piston bolt Gear housing bolt Gear housing bracket bolt 69
SPEC Specifications General torques This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and progressive stages until the specified torque is reached. Unless otherwise specified, torque specifications require clean, dry threads.
CHK ADJ Periodic checks and adjustments Special service tools .....................................................................................3-1 Maintenance interval chart............................................................................3-2 Top cowling .................................................................................................... 3-4 Checking the top cowling...........................................................................3-4 Fuel system ......................
CHK ADJ Periodic checks and adjustments Special service tools 3 Fuel pressure gauge YB-06766 Inductive self-powered tachometer YU-08036-B Battery powered timing light YM-33277-A Pressure/vacuum tester YB-35956-A 3-1 69J1D11
Special service tools / Maintenance interval chart Maintenance interval chart 3 Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor.
CHK ADJ Periodic checks and adjustments Lower unit Gear oil Impeller/Woodruff key Oil seals Propeller General Anodes/Trim tab Battery Wiring and connectors Nuts and bolts(*4) Lubrication points Change Check/replace Check/replace Check Check/replace Check/charge Adjust/reconnect Tighten Lubricate 400 hours (2 years) 200 hours (1 year) Every 100 hours (6 months) Remarks 50 hours (3 months) Item 10 hours (Break-in) Initial (500 hours or 30 months) (before each use) Refer to page 3-17 6-8, 6-34 —
Maintenance interval chart / Top cowling / Fuel system Top cowling 3 Checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. Fuel system 3 Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) 2. Loosen the bolts 1. 3. Move the hook 2 up or down slightly to adjust its position. NOTE: • To loosen the fitting, move the hook in direction a. • To tighten the fitting, move the hook in direction b. 1.
CHK ADJ Periodic checks and adjustments Measuring the fuel pressure (high-pressure fuel line) 1. Remove the cap 1. 2. Install the fuel pressure gauge onto the pressure check valve. È NOTE: Be sure not to spill any fuel when removing the fuel filter cup. Power unit 3 Checking the engine oil Fuel pressure gauge: YB-06766 3. Turn the engine start switch to ON, and then measure the fuel pressure. NOTE: After the engine start switch is turned to ON, the fuel pressure will decrease gradually. 1.
Fuel system / Power unit Changing the engine oil using an oil changer 1. Start the engine and warm it up. 6. Install the oil filler cap and dipstick, and then start the engine and warm it up for 5 minutes. 2. Remove the engine oil dipstick and oil filler cap 1. 7. Turn the engine off, and then check the oil level and correct it if necessary. Changing the engine oil by draining it 1. Start the engine and warm it up. 2. Remove the engine oil dipstick and oil filler cap 1. 3.
CHK ADJ Periodic checks and adjustments LT 572 S69J3140 T. R. NOTE: Be sure to clean up any oil spills. 5. Install the drain bolt, and then tighten it to the specified torque. Apron bolt: 8 N·m (0.8 kgf·m, 5.8 ft·lb) Replacing the oil filter 1. Extract the engine oil with an oil changer or drain it. 2. Remove the oil filter cover 1. T. R. Drain bolt: 27 N·m (2.7 kgf·m, 19 ft·lb) 6. Pour the specified amount of the recommended engine oil into the oil filler hole.
Power unit 5. Install the oil filter, and then tighten it to the specified torque using a 72.5 mm (2.9 in) oil filter wrench. 3. Turn the crankshaft clockwise two turns to take up slack in the timing belt. Replacing the timing belt NOTE: For replacement procedures, see Chapter 5, “Replacing the timing belt.” T. Oil filter: 18 N·m (1.8 kgf·m, 13 ft·lb) R. Checking the valve clearance 6. Pour the specified amount of the recommended engine oil into the oil filler hole.
CHK ADJ Periodic checks and adjustments 5. Check the spark plug gap a. Adjust if out of specification. Specified spark plug: LFR5A-11 (NGK) Spark plug gap a: 1.0–1.1 mm (0.039–0.043 in) S69J3220 6. Install the spark plug, tighten it finger tight b, then to the specified torque with a spark plug wrench c. 2. Place the lower unit in water, and then start the engine. 3. Check for water flow at the cooling water pilot hole.
Power unit / Control system 4. Push the throttle control lever 8 against the stop bolt 7. Adjusting the throttle link and throttle cable operation (with a stop bolt) NOTE: • Be sure to synchronize the throttle valves before adjusting the throttle link. • For synchronizing procedures, see Chapter 4, “Synchronizing the throttle valve.” 1. Loosen the locknut 1, remove the clip 2, and then disconnect the throttle cable joint 3. NOTE: Use a general bolt with the specified measurements.
CHK ADJ Periodic checks and adjustments 12. Check the throttle cable for smooth operation and adjust the cable length, if necessary, repeating steps 1–10. Adjusting the throttle link and throttle cable operation (without a stop bolt) 9. Place the throttle cam 0 against the fully closed stopper f, and check that there is a minimum clearance g of approximately 1.0 mm (0.04 in). 10. Adjust the position of the throttle cable joint until its hole is aligned with the set pin h on the throttle cam.
Control system 5. Check that the alignment mark a is between the alignment marks b. If not, repeat steps 2–4. S69J3340 CAUTION: The throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) f. 8. Connect the cable joint, install the clip, and then tighten the locknut. 9. Check the throttle cable for smooth operation and adjust the cable length, if necessary, repeating steps 1–7. Checking the gearshift operation 6.
CHK ADJ Periodic checks and adjustments 5. Adjust the position of the shift cable joint until its hole is aligned with the set pin. Inductive self-powered tachometer: YU-08036-B Engine idle speed: 650–750 r/min S69J3370 4. Turn the engine off, loosen the locknut 2, and then disconnect the link rod 3 from the magnet control lever 4. CAUTION: The shift cable joint must be screwed in a minimum of 8.0 mm (0.31 in) c. 6. Connect the cable joint, install the clip, and then tighten the locknut. 7.
Control system 10. Install the link rod 3, and then tighten the locknut 2. 11. Check that the alignment mark c is between the alignment marks d. If necessary, repeat steps 8–10. NOTE: • To increase the idle speed, turn the throttle stop screw in direction a. • To decrease the idle speed, turn the throttle stop screw in direction b. 7. Tighten the port throttle stop screw 5 until it contacts the throttle body lever 6. 8.
CHK ADJ Periodic checks and adjustments 4. Attach the special service tool to spark plug wire #1. S69J3470 CAUTION: The throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) h. 14. Connect the cable joint, install the clip, and then tighten the locknut. 15. Check the throttle cable for smooth operation and adjust the cable length, if necessary, repeating steps 8–12. Checking the ignition timing 1. Remove the ignition coil cover. 2. Start the engine and warm it up for 5 minutes.
Control system / Power trim and tilt unit / Lower unit NOTE: Be sure to listen to the winding sound of the power trim and tilt motor for smooth operation. 2. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1 to check the lock mechanism of the lever. NOTE: If the fluid is at the correct level, the fluid should overflow out of the filler hole when the cap is removed. 3. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole.
CHK ADJ Periodic checks and adjustments NOTE: If the oil is at the correct level, the oil should overflow out of the check hole when the check screw is removed. 3. If necessary, add sufficient gear oil of the recommended type until it overflows out of the check hole. S69J3540 Recommended gear oil: GEAR CASE LUBE Hypoid gear oil SAE: 90 4. Install the check screw. Changing the gear oil 1. Tilt the outboard motor up slightly. 2.
Lower unit / General Checking the lower unit (for air leakage) 1. Remove the check screw 1, and then install the special service tool. Checking the propeller 1. Check the propeller blades and splines for cracks, damage, or wear. Replace if necessary. È S69J3580 Pressure/vacuum tester: YB-35956-A 2. Apply the specified pressure to check whether the lower unit can hold it for at least 10 seconds. General 3 Checking the anodes 1. Check the anodes and trim tab for scales, grease, or oil.
CHK ADJ Periodic checks and adjustments WARNING CAUTION: Do not oil, grease, or paint the anodes, otherwise they will be ineffective. 2. Replace the anodes and trim tab if excessively eroded. Checking the battery 1. Check the battery electrolyte level. If the level is at or below the minimum level mark a, add distilled water until the level is between the maximum and minimum level marks. S69J3620 2. Check the specific gravity of the electrolyte. Fully charge the battery if out of specification.
General Lubrication 1. Apply water resistant grease to the areas shown.
CHK ADJ Periodic checks and adjustments NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply corrosion resistant grease to the areas shown.
FUEL Fuel system Special service tools .....................................................................................4-1 Hose routing ...................................................................................................4-2 Fuel and blowby hoses..............................................................................4-2 Intake silencer, fuel filter, and fuel pump .................................................... 4-3 Vapor separator................................................
FUEL Fuel system Special service tools 4 Pressure/vacuum tester YB-35956-A Digital multimeter YU-34899-A Test harness (3 pins) YB-06793 Carburetor synchronizer YU-08030 4-1 69J1D11
Special service tools / Hose routing Hose routing 4 Fuel and blowby hoses 1 2 3 4 5 6 Blowby hose Fuel hose (fuel joint-to-fuel filter) Fuel hose (fuel filter-to-fuel pump) Fuel hose (fuel pump-to-vapor separator) Fuel hose (vapor separator-to-fuel pump) High-pressure fuel hose (vapor separator-to-starboard fuel rail) 69J1D11 7 High-pressure fuel hose (starboard fuel rail-to-port fuel rail) 8 Fuel hose (pressure regulator-to-fuel cooler) 9 Fuel hose (fuel cooler-to-vapor separator) 4-2 1 2 3 4 5 6 7
FUEL Fuel system Intake silencer, fuel filter, and fuel pump 4-3 4 69J1D11
Intake silencer, fuel filter, and fuel pump No.
FUEL Fuel system Vapor separator 4-5 4 69J1D11
Vapor separator No.
FUEL Fuel system Removing the hose clamps 1. Remove the hose clamps by cutting the joint. CAUTION: If the hose clamps are removed without cutting the joint first, the fuel hose will be damaged. Installing the hose clamps 1. Crimp the hose clamps properly to securely fasten them. Pressure/vacuum tester: YB-35956-A 2. Apply the pressure to each check valve port. Replace if necessary. NOTE: Make sure no air comes out of the opposite side of the check valve. Reducing the fuel pressure 1. Remove the cap 1.
Vapor separator WARNING Reduce the fuel pressure before removing the vapor separator drain screw, or pressurized fuel will spray out and may result in serious injury. Checking the vapor separator 1. Check the needle valve for bends or wear. Replace if necessary. WARNING Always reduce the fuel pressure in the high-pressure fuel line before servicing the line or the vapor separator. If the fuel pressure is not released, pressurized fuel may spray out. 2. Check the float for deterioration.
FUEL Fuel system Intake manifold and high-pressure fuel line 4-9 4 69J1D11
Intake manifold and high-pressure fuel line No.
FUEL 4-11 Fuel system 69J1D11
Intake manifold and high-pressure fuel line No.
FUEL Throttle control 4-13 Fuel system 4 69J1D11
Throttle control No.
FUEL Fuel system Removing the pressure regulator 1. Remove the intake silencer and the port intake manifold. 2. Measure the resistance of the fuel injections. Replace if out of specification. 2. Disconnect the hose 1 and 2, and then remove the pressure regulator 3. Digital multimeter: YU-34899-A S69J4125 Disconnecting the high-pressure fuel hose joint 1. Disconnect the high-pressure fuel hose joint 1 with the collar a slide from the end b of the joint. Fuel injector resistance (use as reference): 14.
Throttle control Synchronizing the throttle valve 1. Loosen the bank synchronizing screw 1. 2. Remove the port link rod 2 and starboard link rod 3. 6. Loosen the port throttle stop screw 8 until it separates from the throttle body lever 9. 3. Loosen the starboard throttle stop screw 4 until it separates from the throttle body lever 5. 7. Loosen the synchronizing screw 0 of cylinder #4 to open throttle valve #4. 8. Loosen the synchronizing screw A of cylinder #6 to open throttle valve #6. 4.
FUEL Fuel system Test harness (3 pins): YB-06793 10. Turn the engine start switch to ON. 11. Measure the throttle position sensor output voltage. Adjust the throttle position sensor B position if out of specification. 13. Tighten the starboard throttle stop screw 4 until the output voltage is adjusted to specification as mentioned in step 11, plus 40 mV.
Throttle control 15. Tighten the synchronizing screw 0 of cylinder #4, and stop tightening when the throttle plate starts to move. Similarly, tighten and adjust the synchronizing screw A of cylinder #6. 16. Tighten the port throttle stop screw 8 until it contacts the throttle body lever 9, and then turn it one additional turn. È Carburetor synchronizer: YU-08030 #1 #3 #5 17. Start the engine and warm it up for 5 minutes. 18.
FUEL Fuel system 19. Measure the vacuum of cylinders #1, #3, and #5. Repeat step 12 if out of specification. Vacuum difference between cylinders: 20 mmHg (27 mbar, 0.79 inHg) 20. Measure the vacuum of cylinders #2, #4, and #6. Repeat step 12 if out of specification. 21. Check the average vacuum difference between the port and starboard banks. Adjust the port throttle stop screw 8 if out of specification. T. R. Link rod nut: 4 N·m (0.4 kgf·m, 2.9 ft·lb) 24. Tighten the bank synchronizing screw 1.
Throttle control 25. Check that there is no clearance a between the port and starboard throttle stop screws 4 and 8, and the throttle body levers 5 and 9. If there is any clearance, repeat step 24. 1 2 3 4 5 6 7 8 9 26. Start the engine, and when the engine speed is at idle, check the average vacuum difference between the port and starboard banks. Adjust if out of specification. Average vacuum difference between port and starboard banks: 40 mmHg (53 mbar, 1.
POWR Power unit Special service tools .....................................................................................5-1 Power unit....................................................................................................... 5-3 Checking the compression pressure .......................................................5-14 Checking the oil pressure ........................................................................5-14 Checking the oil pressure sensor ....................................
Cylinder block ..............................................................................................5-43 Disassembling the cylinder block ............................................................ 5-47 Checking the piston diameter .................................................................. 5-47 Checking the cylinder bore ...................................................................... 5-48 Checking the piston clearance ................................................................
POWR Power unit Special service tools Compression gauge YU-33223-1 5 Valve spring compressor YM-01253 Valve spring compressor attachment YB-06320 Compression gauge extension YB-06563 Valve guide remover YB-06801 Test harness (3 pins) YB-06769 Valve guide installer YB-06810 Flywheel magnet holder YB-06139 Valve guide reamer YB-06804 Universal puller YB-06117 Valve seat cutter set YB-91044 5-1 69J1D11
Special service tools 1 2 3 4 5 6 7 8 9 Piston ring compressor YM-08037 69J1D11 5-2
POWR Power unit 5-3 Power unit 5 69J1D11
Power unit No.
POWR 5-5 Power unit 69J1D11
Power unit No.
POWR 5-7 Power unit 69J1D11
Power unit No.
POWR No.
Power unit No.
POWR 5-11 Power unit 69J1D11
Power unit No.
POWR No.
Power unit Checking the compression pressure 1. Start the engine, warm it up for 5 minutes, and then turn it off. 2. Remove the clip from the engine stop lanyard switch on the remote control box. 3. Remove the ignition coil cover and all spark plugs, and then install the special service tools to each spark plug hole. NOTE: • If the compression pressure increases, check the piston and piston rings for wear. Replace if necessary.
POWR Power unit 5. Check the oil pressure. Check the oil pump, oil leakage, and oil strainer if out of specification. Oil pressure (reference data): 650 kPa (6.5 kgf/cm2, 92.4 psi) at idle speed (700 r/min) Oil pressure sensor input voltage: Orange (O) – Black (B) 5V Oil pressure sensor output voltage (reference data): Pink/white (P/W) – Black (B) 3.8 V at idle speed (700 r/min) Checking the oil pressure sensor 1. Connect the test harness (3 pins) to the oil pressure sensor. 2.
Power unit 9. Similarly, check the valve clearance of cylinders #1, #2, and #3 in order, and be sure to turn the flywheel magnet 120° clockwise each time. Adjust if out of specification. NOTE: Do not turn the flywheel magnet counterclockwise. 4. Check the intake and exhaust valve clearance for cylinder #4. 5. Turn the flywheel magnet an additional 120° clockwise and align the “2TDC” mark g on the flywheel magnet with the pointer b. 6. Check the intake and exhaust valve clearance for cylinder #5. 7.
POWR Power unit 10. Turn the flywheel magnet an additional 120° clockwise and align the “1TDC” mark on the flywheel magnet with the pointer, and check that the “I” marks on the driven sprockets are aligned with the alignment marks on the cylinder head. 11. Remove the flywheel magnet. È NOTE: Apply force to the crankshaft end until the flywheel magnet comes off the tapered portion of the crankshaft. Flywheel magnet holder 6: YB-06139 Universal puller 7: YB-06117 12. Remove the wiring harness guide bolts.
Power unit 15. Remove the driven sprockets. 19. Measure the valve shim thickness with a micrometer, and then note the measurement. 20. Select the necessary valve shim by calculating its thickness with the following formula. Necessary valve shim thickness = Removed valve shim thickness + Measured valve clearance – Specified valve clearance NOTE: Hold the camshaft with a wrench, and be careful not to damage the driven sprocket. 16.
POWR Power unit NOTE: • Install the camshaft caps in the proper position as shown and with the stamped numbers facing upside down. • Apply engine oil to the camshaft cap bolts before installation. T. R. 23. Install the camshaft caps, and then tighten them to the specified torque in the order shown in the illustration. Camshaft cap bolt: 1st: 8 N·m (0.8 kgf·m, 5.8 ft·lb) 2nd: 17 N·m (1.7 kgf·m, 12 ft·lb) Timing chain tensioner bolt: 12 N·m (1.2 kgf·m, 8.7 ft·lb) 25.
Power unit T. R. Flywheel magnet nut: 240 N·m (24 kgf·m, 174 ft·lb) 30. Turn the flywheel magnet clockwise two turns, and then check that all alignment marks are aligned. 28. Install the Woodruff key. 29. Install the flywheel magnet. È NOTE: Do not turn the flywheel magnet counterclockwise. 31. Check each valve clearance and adjust if necessary. CAUTION: Apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. 33.
POWR Power unit 35. Install the ignition coil cover, wiring harness guide, and flywheel magnet cover. È Replacing the timing belt 1. Remove the flywheel magnet cover, ignition coil cover, and intake silencer. 2. Turn the flywheel magnet clockwise and align the “1TDC” mark a on the flywheel magnet with the pointer b, and check that “I” marks c and d on the driven sprockets are aligned with marks e and f.
Power unit 5. Disconnect the stator coil couplers 3 and pulser coil coupler 4, and remove the blowby hose 5 and stator coil bracket 6. 6. Remove the wiring harness guide bolts. 9. Check that “I” marks c and d on the driven sprockets are aligned with marks e and f, and that the “ ” mark h on the plate is aligned with the “ ” mark i on the cylinder block. Align if necessary. NOTE: Move the wiring harness guide 7 to a position that will make servicing easy. 7.
POWR Power unit È CAUTION: • Do not twist, turn inside out, or bend the timing belt beyond the maximum limit of 25 mm (1.0 in) j, otherwise it may be damaged. • Do not get oil or grease on the timing belt. CAUTION: Apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. NOTE: Apply engine oil to the flywheel magnet nut before installation. Flywheel magnet holder: YB-06139 NOTE: Do not turn the drive sprocket counterclockwise.
Power unit 5. Remove the upper case cover 9 and aprons 0. 6. Remove the power unit by removing the bolts A. 3. Remove the dipstick guide 5, and disconnect the fuel hose 6, PTT motor leads 7, and flushing device hose (flushing device model) 8. 7. Remove the flywheel magnet. È 4. Disconnect the fuel pump driver and isolator couplers, PTT switch coupler, shift cut switch coupler, neutral switch coupler, trim sensor coupler, and cooling water pilot hose.
POWR Power unit È NOTE: Be sure to clean up any oil spills. Removing the timing belt and sprockets CAUTION: • Apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. • To prevent damage to the engine or tools, screw in the flywheel puller set bolts evenly and completely so that the flywheel puller plate is parallel to the flywheel magnet. 1.
Power unit 2. Using a hexagon wrench, turn the timing belt tensioner 1 clockwise to push the timing belt, increase strength gradually, and then insert a ø5.0 mm (0.2 in) pin 2 into the hole g. Checking the timing belt and sprockets 1. Check the interior and exterior of the timing belt for cracks, damage, or wear. Replace if necessary. 3. Remove the timing belt 3 from the driven sprocket side. 4. Remove the pin and timing belt tensioner. 2.
POWR Power unit Installing the sprockets and timing belt 1. Install the driven sprockets 1, and then tighten the bolts to the specified torque. 2. Check that “I” marks a and b on the driven sprockets are aligned with marks c and d. Align if necessary. 3. Install the new gaskets, cylinder head cover 2, and then tighten the bolts to the specified torques in two stages. T. R. Drive sprocket bolt: 7 N·m (0.7 kgf·m, 5.1 ft·lb) Timing belt tensioner bolt: 39 N·m (3.9 kgf·m, 28 ft·lb) 6.
Power unit 7. Install the timing belt 6 from the drive sprocket side with its part number in the upright position, turn the belt a half turn counterclockwise to align it, and then remove the pin 5. 1 2 3 4 5 6 7 8 9 8. Turn the drive sprocket clockwise two turns, and then check that the alignment marks are aligned. NOTE: Do not turn the drive sprocket counterclockwise.
POWR Cylinder head 5-29 Power unit 5 69J1D11
Cylinder head No.
POWR 5-31 Power unit 69J1D11
Cylinder head No.
POWR Power unit Removing the cylinder head 1. Remove the exhaust cover bolts in the sequence shown. CAUTION: Do not scratch or damage the mating surfaces of the cylinder head and cylinder block. 5. Remove the valve shim 2 from the valve lifter 3 using compressed air. 2. Remove the timing chain tensioner 1 and camshaft caps in the sequence shown. NOTE: Do not mix the valve train parts. Keep them organized in their proper groups. 6. Remove the intake valve and exhaust valves. 3.
Cylinder head Valve spring compressor 4: YM-01253 Valve spring compressor attachment 5: YB-06320 Checking the valve springs 1. Measure the valve spring free length a. Replace if out of specification. Valve margin thickness a: Intake: 0.7 mm (0.028 in) Exhaust: 1.0 mm (0.039 in) 3. Measure the valve stem diameter b. Replace if out of specification. Valve spring free length a: 44.20 mm (1.740 in) 2. Measure the valve spring tilt b. Replace if out of specification. Valve stem diameter b: Intake: 5.477–5.
POWR Power unit Valve stem runout: Intake: 0.01 mm (0.0004 in) Exhaust: 0.01 mm (0.0004 in) Checking the valve guides NOTE: Before checking the valve guide make sure that the valve stem diameter is within specification. 1. Measure the valve guide inside diameter a. S69J5790 Valve guide remover: YB-06801 2. Install the new valve guide 2 by striking the special service tool from the camshaft side until the valve guide installer 3 contacts the cylinder head. S69J5770 Valve guide inside diameter a: 5.
Cylinder head NOTE: • Turn the valve guide reamer clockwise to ream the valve guide. • Do not turn the reamer counterclockwise when removing the reamer. Valve guide reamer: YB-06804 4. Measure the valve guide inside diameter. Replace the valve guide if out of specification. Valve guide inside diameter: 5.51–5.52 mm (0.2169–0.2173 in) Checking the valve seat 1. Eliminate carbon deposits from the valve with a scraper. 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat. 3.
POWR Power unit 2. Cut the surface of the valve seat with a 45° cutter by turning the cutter clockwise until the valve seat face has become smooth. È 60° S69J5890 b Previous contact width S69J5855 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. 45° S69J5900 b Previous contact width c Specified contact width a Slag or rough surface CAUTION: Do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pressure of 40–50 N (4–5 kgf, 8.
Cylinder head 10. After every lapping procedure, be sure to clean off any remaining lapping compound from the cylinder head and the valve. 11. Check the valve seat contact area of the valve again. Checking the camshaft b Previous contact width 8. If the valve seat contact area is too narrow and situated near the bottom edge of the valve face, use a 60° cutter to cut the bottom edge of the valve seat. If necessary, use a 45° cutter to center the area and set its width. 1.
POWR Power unit 3. Measure the camshaft runout. Replace if out of specification. Camshaft oil clearance e = Camshaft cap inside diameter d – Camshaft journal diameter c: 0.02–0.06 mm (0.0008–0.0023 in) Checking the timing chain tensioner 1. Measure the plunger extended length a. Replace if out of specification. Camshaft runout limit: 0.03 mm (0.0012 in) 4. Measure the camshaft journal diameter c and cylinder head journal inside diameter d. Replace the camshaft and cylinder head if out of specification.
Cylinder head 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in six directions as shown. Replace if out of specification. NOTE: The valve spring can be installed in any direction. Valve spring compressor 5: YM-01253 Valve spring compressor attachment 6: YB-06320 Cylinder head warpage limit: 0.1 mm (0.004 in) Installing the valves 1. Install the new valve seal 1 to the valve guide. 3.
POWR Power unit 4. Lightly tap the valve spring retainer with a plastic hammer to set the valve cotter securely. 1. Install the new gaskets and cylinder heads, and then tighten the bolts to the specified torques in the sequence shown. R. Installing the cylinder head T. NOTE: Apply engine oil to the valve shims and valve lifters before installation. NOTE: • Apply enginLe oil to the cylinder head bolts before installation.
Cylinder head NOTE: • Install the camshaft caps in the proper position as shown and with the stamped numbers facing upside down. • Apply engine oil to the camshaft cap bolts before installation. T. R. 4. Install the camshaft caps, and then tighten the bolts to the specified torques in two stages and in the sequence shown. Camshaft cap bolt: 1st: 8 N·m (0.8 kgf·m, 5.8 ft·lb) 2nd: 17 N·m (1.7 kgf·m, 12 ft·lb) Timing chain tensioner bolt: 12 N·m (1.2 kgf·m, 8.7 ft·lb) 6.
POWR Cylinder block 5-43 Power unit 5 69J1D11
Cylinder block No.
POWR 5-45 Power unit 69J1D11
Cylinder block No. Part name Q’ty Remarks 1 Crankshaft 1 2 Cylinder block 1 3 Crankcase 1 4 Oil seal 1 5 Thrust bearing 2 6 Thrust bearing 1 7 Main bearing 4 8 Main bearing 4 9 Stud bolt 6 M8 × 95 mm 10 Bolt 8 M10 × 105 mm 11 Bolt 2 M8 × 95 mm 12 Bolt 13 M8 × 55 mm 13 O-ring 2 1 2 3 4 5 6 7 8 9 Not reusable Not reusable 1.9 × 22.
POWR Power unit Disassembling the cylinder block 1. Remove the cooling water passage cover bolts in the sequence shown. 2. Remove the crankcase cover bolts in the sequence shown. NOTE: Do not remove the ignition timing pointer from the crankcase cover. NOTE: • Be sure to keep the bearings in the order as they were removed, and to note the bearing color. • Mark each piston with an identification number a of the corresponding cylinder.
Cylinder block Piston diameter a: 93.921–93.941 mm (3.6977–3.6985 in) Measuring point b: 5 mm (0.2 in) up from the bottom of the piston skirt Checking the piston clearance 1. Rebore the cylinder or replace the piston and piston rings as a set, or the cylinder block, or all parts if out of specification. Piston clearance: 0.075–0.080 mm (0.0029–0.0031 in) Checking the cylinder bore 1.
POWR Power unit Checking the piston ring side clearance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. Piston ring end gap d: Top ring: 0.15–0.30 mm (0.0059–0.0118 in) Second ring: 0.30–0.45 mm (0.0118–0.0177 in) Oil ring: 0.15–0.60 mm (0.0059–0.0236 in) Measuring point e: 20 mm (0.8 in) Piston ring side clearance: Top ring a: 0.04–0.08 mm (0.0016–0.0031 in) Second ring b: 0.03–0.07 mm (0.0012–0.0027 in) Oil ring c: 0.04–0.13 mm (0.0016–0.
Cylinder block Checking the piston pin 1. Measure the piston pin diameter. Replace if out of specification. Piston pin diameter: 21.00 mm (0.827 in) Checking the connecting rod small end inside diameter 1. Measure the connecting rod small end inside diameter a. Replace the connecting rod if out of specification. Connecting rod big end side clearance a: 0.20–0.25 mm (0.008–0.010 in) Checking the crankshaft 1. Measure the crankshaft journal diameter a, crankpin diameter b, and crankpin width c.
POWR Power unit Crankshaft journal diameter a: 62.968–62.992 mm (2.4791–2.4800 in) Crankpin diameter b: 49.976–50.000 mm (1.9676–1.9685 in) Crankpin width c: 21.50–21.55 mm (0.8465–0.8484 in) 2. Measure the crankshaft runout. Replace the crankshaft if out of specification. NOTE: Install the connecting rod bearings in their original positions. 4. Put a piece of Plastigauge® (PG-1) onto the crankpin, parallel to the crankshaft. S69J5C80 Crankshaft runout limit: 0.03 mm (0.
Cylinder block T. R. Connecting rod bolt: 1st: 23 N·m (2.3 kgf·m, 17 ft·lb) 2nd: 48 N·m (4.8 kgf·m, 35 ft·lb) 3rd: 90° 7. Remove the connecting rod cap and measure the width of the compressed Plastigauge (PG-1) on each crankpin. Replace the connecting rod bearing if out of specification. NOTE: Align the marks b on the connecting rod cap and connecting rod, which you made during disassembly. 6. Tighten the connecting rod bolts to the specified torques in three stages. Crankpin oil clearance: 0.035–0.
POWR Power unit 4. Insert the projection a of the bearing into the notch in the cylinder block. NOTE: Install the main bearings in their original positions. 3. Select the suitable color b for the connecting rod bearing from the table. Crankpin mark a Bearing color b 92–00 Yellow 84–91 Green 76–83 Blue Checking the crankshaft main journal oil clearance 1. Clean the bearings, main journals, and bearing portions of the crankcase and cylinder block. 2.
Cylinder block 9. Tighten the crankcase bolts to the specified torques in two stages and in the sequence shown. 10. Remove the crankcase and measure the width of the compressed Plastigauge (PG-1) on each main journal. Replace the main bearing if out of specification. Crankshaft main journal oil clearance: 0.025–0.050 mm (0.0010–0.0020 in) NOTE: • Crankcase bolts 1–F can be reused five times. • Do not move the crankshaft until the main journal oil clearance measurement has been completed.
POWR Power unit Disassembling the oil pump 1. Remove the screws 1 and disassemble the oil pump. 3. Select the suitable main bearing number c from the table. Checking the oil pump 1. Check the oil seals and gasket for tears. Replace if necessary.
Cylinder block NOTE: Install the oil seals using a general pipe of the proper size. #3 45° 45° #2 UP RN T. R. Screw 3: 4 N·m (0.4 kgf·m, 2.9 ft·lb) #1,#4 #5 #5 #4 #3 #2 Assembling the piston and cylinder block 1. Assemble the piston 1, connecting rod 2, piston pin 3, and new piston pin clips 4. #1 E R S60C5E90 CAUTION: Do not scratch the piston or break the piston rings. NOTE: After installing the piston rings, check that they move smoothly. 4.
POWR Power unit 6. Install half of the bearings 9 into the cylinder block 0. 10. Apply sealant to the mating surface of the crankcase. 7. Insert the projection f of the bearing into the notch in the cylinder block. 11. Insert the projection g of the bearing into the notch in the crankcase. E S69J5F10 NOTE: Install the main bearings in their original positions. NOTE: Do not get any sealant on the journal bearings. 8.
Cylinder block NOTE: • The oil seals must be installed before tightening the crankcase bolts. • Apply engine oil to the crankcase bolts before installation. • Tighten crankcase bolts 1–F to the specified torques in two stages first, and then tighten crankcase bolts G–S to the specified torques in two stages. • Make a mark h on the crankcase and crankcase bolts, and then tighten crankcase bolts 1–F 90° from the mark. T. R. 1–8 Crankcase bolt (M8): 1st: 25 N·m (2.
POWR Power unit T. R. Crankcase cover bolt: 1st: 14 N·m (1.4 kgf·m, 10 ft·lb) 2nd: 28 N·m (2.8 kgf·m, 20 ft·lb) 18. Install the new gasket and cooling water passage cover, and then tighten the bolts to the specified torque in the sequence shown. CAUTION: Before installing the oil pump, be sure to fill it with engine oil through the oil passage k. 16. Install the baffle plate G to the specified torque. T. R. Cooling water passage cover bolt: 12 N·m (1.2 kgf·m, 8.7 ft·lb) 19.
Cylinder block 20. Install the oil filter, and then tighten it to the specified torque using a 72.5 mm (2.9 in) oil filter wrench. 4. Check the thermostat valve opening at the specified water temperatures. Replace if out of specification. Water temperature T. Oil filter: 18 N·m (1.8 kgf·m, 13 ft·lb) R. Checking the thermostat 1. Remove the cover 1 and thermostat 2. Valve lift a 58–62 °C (136–144 °F) 0 mm (0 in) (valve begins to lift) above 70 °C (158 °F) more than 4.3 mm (0.17 in) 5.
POWR Power unit T. R. PTT motor lead bolt: 4 N·m (0.4 kgf·m, 2.9 ft·lb) 6. Connect the shift cable A and throttle cable B, and then adjust their lengths. For adjustment procedures, see Chapter 3, “Checking the throttle link and throttle cable operation,” and “Checking the gearshift operation.” T. R. Mounting bolt 4: 42 N·m (4.2 kgf·m, 30 ft·lb) Apron and upper case cover bolt: 8 N·m (0.8 kgf·m, 5.8 ft·lb) 5.
Cylinder block 7. Install the holders C and retaining plate D. NOTE: Apply engine oil to the flywheel magnet nut before installation. Flywheel magnet holder: YB-06139 T. R. Flywheel magnet nut: 240 N·m (24 kgf·m, 174 ft·lb) 11. Reinstall the all removed parts. 8. Install the stator coil bracket and stator coil. 9. Install the Woodruff key. 10. Install the flywheel magnet. È CAUTION: Apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily.
LOWR Lower unit Special service tools .....................................................................................6-1 Lower unit (regular rotation model) ............................................................. 6-4 Removing the lower unit ............................................................................6-7 Removing the water pump and shift rod.................................................... 6-7 Checking the water pump and shift rod ..............................................
Propeller shaft housing (counter rotation model) .................................... 6-35 Removing the propeller shaft housing assembly..................................... 6-37 Disassembling the propeller shaft housing.............................................. 6-37 Checking the propeller shaft housing ......................................................6-38 Checking the propeller shaft.................................................................... 6-38 Assembling the propeller shaft housing....
LOWR Lower unit Special service tools Slide hammer and adapters YB-06096 6 Drive shaft needle bearing remover and installer YB-06196 Needle bearing installer and remover YB-06194 Propeller shaft and bearing housing remover YB-06335 Forward bearing installer YB-06430 Puller claw YB-06523 Bearing outer race attachment YB-06109 Oil seal installer YB-06168, YB-06195 Drive shaft holder YB-06201 Driver handle YB-06071 Roller bearing installer/remover YB-06432 6-1 69J1D11
Special service tools Needle bearing installer YB-06434, YB-06435 Shimming gauge I YB-06439 Pinion gear bushing installer YB-06029-4 Shift rod push arm YB-06052 Needle bearing remover and installer YB-06213 Bearing housing puller YB-06207 Taper roller bearing installer YB-06431 Forward gear bearing cup installer YB-06276-B Universal puller YB-06117 1 2 3 4 5 6 7 8 9 Backlash indicator gauge YB-06265 Pinion shimming gauge III YB-06441 69J1D11 6-2
LOWR Lower unit Magnetic plate YB-07003 Shimming gauge YB-06440-A Dial gauge YU-03097 Magnetic flexible stand YU-34481 Ring nut wrench YB-06578 Puller bolt YB-41707 6-3 69J1D11
Special service tools / Lower unit (regular rotation model) Lower unit (regular rotation model) No.
LOWR Lower unit 10 11 12 13 LT 572 14 4 A 15 16 7 17 18 2 A 19 LT 20 3 572 21 A A 4 22 6 23 5 1 24 24 9 8 A S69J6010U 6-5 69J1D11
Lower unit (regular rotation model) No. Part name Q’ty 1 Shift rod 1 2 Oil seal 1 3 Oil seal housing 1 4 O-ring 1 Remarks Not reusable 1 2 3 4 5 6 7 8 9 Not reusable 3.1 × 70.6 mm 5 Spring 1 6 Circlip 1 7 Bolt 3 8 Seal 1 9 Woodruff key 1 10 Bolt 4 11 Cover 1 12 Seal 1 13 Water pump housing 1 14 O-ring 1 M6 × 20 mm M8 × 45 mm Not reusable 2.5 × 42 mm 15 Insert cartridge 1 16 O-ring 1 Not reusable 2.5 × 91.
LOWR Lower unit Removing the lower unit 1. Drain the gear oil. For draining procedures, see Chapter 3, “Changing the gear oil.” 2. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller. WARNING Do not hold the propeller with your hands when loosening or tightening it.
Lower unit (regular rotation model) Checking the water pump and shift rod 4. Check the shift rod for cracks or wear. Replace if necessary. 1. Check the water pump housing for deformation. Replace if necessary. S69J6045 S69J6030 2. Check the impeller 1 and insert cartridge 2 for cracks or wear. Replace if necessary. S69J6035 3. Check the Woodruff key 3 and the groove a on the drive shaft for wear. Replace if necessary.
LOWR Lower unit Propeller shaft housing (regular rotation model) 6-9 6 69J1D11
Propeller shaft housing (regular rotation model) No. Part name Q’ty Remarks 1 Shift rod joint 1 2 Ball 2 3 Slider 1 4 Shift plunger 1 5 Dog clutch 1 6 Cross pin 1 7 Spring 1 8 Propeller shaft 1 9 Washer 1 10 Reverse gear 1 11 Reverse gear shim — As required 12 Ball bearing 1 Not reusable 13 O-ring 1 1 2 3 4 5 6 7 8 9 Not reusable 3.1 × 110.
LOWR Lower unit Removing the propeller shaft housing assembly Disassembling the propeller shaft housing 1. Remove the bolts 1, ring 2, and bolts 3. 1. Remove the reverse gear and reverse gear shim(s). È Slide hammer and adapters 1: YB-06096 2. Pull out the propeller shaft housing assembly. È 2. Remove the ball bearing. È S69J6060 Slide hammer and adapters 4: YB-06096 Propeller shaft and bearing housing remover 5: YB-06335 Disassembling the propeller shaft assembly 1.
Propeller shaft housing (regular rotation model) 3. Remove the oil seals and needle bearing. 3. Check the bearings for pitting or rumbling. Replace if necessary. È S69J6115 Oil seal installer 4: YB-06168 Driver handle 5: YB-06071 Checking the propeller shaft 1. Check the propeller shaft for bends or wear. Replace if necessary. Checking the propeller shaft housing 1. Clean the propeller shaft housing using a soft brush and cleaning solvent, and then check it for cracks or damage. Replace if necessary.
LOWR Lower unit Assembling the propeller shaft assembly 1. Install the dog clutch 1 as shown. 2. Apply grease to the new oil seals, and then install them into the propeller shaft housing to the specified depth. È NOTE: Install the dog clutch 1 with the “F” mark a facing toward the shift plunger. Assembling the propeller shaft housing 1. Install the needle bearing into the propeller shaft housing to the specified depth.
Propeller shaft housing (regular rotation model) 4. Install the reverse gear 7 and original shim(s) 8 to the propeller shaft housing using a press. 1 2 3 4 5 6 7 8 9 È CAUTION: Add or remove shim(s), if necessary, when replacing the reverse gear or ball bearing.
LOWR Lower unit Drive shaft and lower case (regular rotation model) 6-15 6 69J1D11
Drive shaft and lower case (regular rotation model) No. Part name Q’ty Remarks 1 Drive shaft 1 2 Cover 1 3 Oil seal 2 Not reusable 4 Bolt 4 M8 × 25 mm 5 Drive shaft housing 1 6 Needle bearing 1 7 O-ring 1 Not reusable 3 × 60.
LOWR Lower unit Removing the drive shaft Disassembling the forward gear 1. Remove the drive shaft, drive shaft housing, and pinion, and then pull out the forward gear. 1. Remove the taper roller bearing from the forward gear using a press. È S69J6186 CAUTION: Drive shaft holder 1: YB-06201 Do not reuse the bearing, always replace it with a new one. Disassembling the drive shaft housing 1. Remove the cover, oil seals, and needle bearing.
Drive shaft and lower case (regular rotation model) S69J6210 Roller bearing installer/remover 3: YB-06432 Driver handle 4: YB-06071 Checking the lower case 1. Check the skeg and torpedo for cracks or damage. Replace if necessary. Checking the pinion and forward gear 1. Check the teeth of the pinion, and the teeth and dogs of the forward gear for cracks or wear. Replace if necessary. S69J6215 Assembling the lower case 1. Install the original shim(s) and taper roller bearing outer race.
LOWR Lower unit 2. Install the needle bearing outer case into the lower case. È Assembling the drive shaft housing 1. Install the needle bearing into the drive shaft housing to the specified depth. NOTE: Apply engine oil to the needle bearing outer case before installation. Needle bearing installer 3: YB-06435 Pinion gear bushing installer 4: YB-06029-4 Needle bearing remover and installer 5: YB-06213 3. Install the needle bearing into the needle bearing outer case.
Drive shaft and lower case (regular rotation model) 2. Install the drive shaft housing 1, thrust bearing 2, and original shim(s) 3 to the drive shaft 4. Installing the propeller shaft housing 1. Install the washer 1 and propeller shaft assembly 2 into the propeller shaft housing assembly 3. 2. Apply grease to the new O-rings. CAUTION: Add or remove shim(s), if necessary, when replacing the drive shaft housing or drive shaft. 3.
LOWR Lower unit 5. Install the washers 7, wave washer 8, spacer 9, and collar 0 to the drive shaft. 2. Install the new gasket 2, outer plate cartridge 3, and dowel pins 4. NOTE: • The collar and spacer should fit together firmly. • While pulling the drive shaft up, install the collar with an appropriate tool a that fits over the drive shaft as shown. 6. Install the O-ring A and insert cartridge B into the pump housing C. C A A c b B b 4 c S69J6310U 3.
Drive shaft and lower case (regular rotation model) 7. Install the O-ring D and pump housing assembly E into the lower case, tighten the bolts F, and then install the seal G and cover H. È LT 572 Shift rod push arm: YB-06052 A 2. Install the two dowel pins 1 to the lower unit. 3. Install the lower unit to the upper case, and then tighten the bolts 2 to the specified torque. 4. Install the trim tab 3 to its original position, and then tighten the bolt 4 to the specified torque.
LOWR Lower unit 5. Install the propeller and propeller nut, and then tighten the nut finger tight. Place a block of wood between the anticavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque. WARNING Do not hold the propeller with your hands when loosening or tightening it. Be sure to disconnect the battery cables from the batteries and the engine stop lanyard switch.
Drive shaft and lower case (regular rotation model) / Shimming (regular rotation model) Shimming (regular rotation model) 6 F P 1 2 3 4 5 6 7 8 9 R B4 T3 B3 A3 65.0 A B B5 T1 T2 B1 39.4 41.
LOWR Lower unit Shimming R. Selecting the pinion shims Pinion shimming gauge III 4: YB-06441 T. NOTE: • Shimming is not required when assembling the original lower case and inner parts. • Shimming is required when assembling the original inner parts and a new lower case. • Shimming is required when replacing the inner part(s). 3. Install the pinion and pinion nut, and then tighten the nut to the specified torque. Pinion nut: 142 N·m (14.2 kgf·m, 103 ft·lb) 4.
Shimming (regular rotation model) Selecting the forward gear shims 1. Calculate the specified value (M0) as shown in the examples below. NOTE: Measure the taper roller bearing at three points to find the clearance average. NOTE: “F” is the deviation of the lower case dimension from standard. The “F” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “F” mark is unreadable, assume that “F” is zero and check the backlash when the unit is assembled. 4.
LOWR Lower unit Selecting the reverse gear shims 1. Calculate the specified value (M0) as shown in the examples below. NOTE: “R” is the deviation of the lower case dimension from standard. The “R” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “R” mark is unreadable, assume that “R” is zero and check the backlash when the unit is assembled. 3. Measure the clearance (M) between the shimming tool and the ball bearing 2 as shown.
Shimming (regular rotation model) / Backlash (regular rotation model) Backlash (regular rotation model) È 6 Measuring the forward and reverse gear backlash 1. Remove the water pump assembly. 2. Set the gearshift to the neutral position. È NOTE: Install the dial gauge so that the plunger a contacts the mark b on the backlash indicator. Shift rod push arm: YB-06052 3. Install the special service tool so that it pushes against the propeller shaft.
LOWR Lower unit 8. Remove the special service tools from the propeller shaft. 9. Apply a load to the reverse gear by installing the propeller 7, the spacer 8 (without the washer 9), then the washer 0 as shown. 11. Add or remove shim(s) if out of specification. Reverse gear backlash Shim thickness Less than 0.70 mm (0.028 in) To be decreased by (0.87 – M) × 0.71 More than 1.03 mm (0.041 in) To be increased by (M – 0.87) × 0.71 M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.
Backlash (regular rotation model) / Lower unit (counter rotation model) Lower unit (counter rotation model) No.
LOWR 6-31 Lower unit 69J1D11
Lower unit (counter rotation model) No. Part name Q’ty 1 Shift rod 1 2 Oil seal 1 3 Oil seal housing 1 4 O-ring 1 Remarks Not reusable 1 2 3 4 5 6 7 8 9 Not reusable 3.1 × 70.6 mm 5 Spring 1 6 Circlip 1 7 Bolt 3 8 Seal 1 9 Woodruff key 1 10 Bolt 4 11 Cover 1 12 Seal 1 13 Water pump housing 1 14 O-ring 1 M6 × 20 mm M8 × 45 mm Not reusable 2.5 × 42 mm 15 Insert cartridge 1 16 O-ring 1 Not reusable 2.5 × 91.
LOWR Lower unit Removing the lower unit 1. Drain the gear oil. For draining procedures, see Chapter 3, “Changing the gear oil.” 2. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller. WARNING Do not hold the propeller with your hands when loosening or tightening it.
Lower unit (counter rotation model) Checking the water pump and shift rod 4. Check the shift rod for cracks or wear. Replace if necessary. 1. Check the water pump housing for deformation. Replace if necessary. S69J6360 S69J6030 2. Check the impeller 1 and insert cartridge 2 for cracks or wear. Replace if necessary. S69J6035 3. Check the Woodruff key 3 and the groove a on the drive shaft for wear. Replace if necessary.
LOWR Lower unit Propeller shaft housing (counter rotation model) 6-35 6 69J1D11
Propeller shaft housing (counter rotation model) No.
LOWR Lower unit Removing the propeller shaft housing assembly 1. Remove the bolts 1, ring 2, and bolts 3. 2. Pull out the propeller shaft housing assembly. 2. Remove the forward gear and forward gear shim(s) from the propeller shaft housing using a press. Bearing splitter plate 4: (commercially obtainable) 3. Install the propeller shaft assembly in the reverse direction into the lower case. È S69J6060 Slide hammer and adapters 4: YB-06096 Propeller shaft and bearing housing remover 5: YB-06335 4.
Propeller shaft housing (counter rotation model) S69J6105 2. Check the teeth and dogs of the forward gear for cracks or wear. Replace the gear if necessary. CAUTION: • Do not press the propeller shaft threads a directly. • Do not reuse the taper roller bearing, always replace it with a new one. 6. Remove the oil seals and needle bearing. S69J6110 3. Check the bearings for pitting or rumbling. Replace if necessary.
LOWR Lower unit 2. Check the dog clutch, shift rod joint, and shift slider for cracks or wear. Replace if necessary. È NOTE: Install an oil seal halfway into the propeller shaft housing, then the other oil seal. Assembling the propeller shaft housing 1. Install the needle bearing into the propeller shaft housing to the specified depth. È Oil seal installer 3: YB-06195 Driver handle 4: YB-06071 Depth c: 4.75–5.25 mm (0.187–0.207 in) 3.
Propeller shaft housing (counter rotation model) T. R. Ring nut 0: 108 N·m (10.8 kgf·m, 78 ft·lb) 7. Install the forward gear B, original shim(s) C, and dog clutch D using a press. Ring nut wrench 9: YB-06578 5. Install the propeller shaft assembly in the reverse direction into the lower case. NOTE: Install the dog clutch D with the “F” mark e facing toward the forward gear. CAUTION: Add or remove shim(s), if necessary, when replacing the forward gear or taper roller bearing. 6.
LOWR Lower unit Drive shaft and lower case (counter rotation model) 6-41 6 69J1D11
Drive shaft and lower case (counter rotation model) No. Part name Q’ty Remarks 1 Drive shaft 1 2 Cover 1 3 Oil seal 2 Not reusable 4 Bolt 4 M8 × 25 mm 5 Drive shaft housing 1 6 Needle bearing 1 7 O-ring 1 Not reusable 3 × 60.
LOWR Lower unit Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the reverse gear and thrust bearing. È Disassembling the lower case 1. Remove the retainer and shim(s). È Drive shaft holder 1: YB-06201 Disassembling the drive shaft housing 1. Remove the cover, oil seals, and needle bearing. Universal puller 1: YB-06117 Puller bolt 2: YB-41707 2. Remove the needle bearing from the retainer.
Drive shaft and lower case (counter rotation model) S69J6210 Roller bearing installer/remover 5: YB-06432 Driver handle 6: YB-06071 Checking the lower case 1. Check the skeg and torpedo for cracks or damage. Replace if necessary. Checking the pinion and reverse gear 1. Check the teeth of the pinion, and the teeth and dogs of the reverse gear for cracks or wear. Replace if necessary. S69J6215 Assembling the lower case 1. Install the needle bearing into the retainer to the specified depth.
LOWR Lower unit NOTE: Apply engine oil or grease to the needle bearing, and then install it. 5. Install the new needle bearings into the reverse gear to the specified depth. È CAUTION: Add or remove shim(s), if necessary, when replacing the forward gear or lower case. Forward bearing installer 3: YB-06430 Driver handle 4: YB-06071 3. Install the needle bearing outer case into the lower case. Needle bearing installer 8: YB-06435 Driver handle 9: YB-06071 Depth b: 20.75–21.25 mm (0.817–0.
Drive shaft and lower case (counter rotation model) Depth a: 4.25–4.75 mm (0.167–0.187 in) 2. Apply grease to the new oil seals, and then install them into the drive shaft housing to the specified depth. È CAUTION: Add or remove shim(s), if necessary, when replacing the drive shaft housing or drive shaft. 3. Install the drive shaft, housing, pinion, and pinion nut, and then tighten the nut to the specified torque. È NOTE: Install an oil seal halfway into the drive shaft housing, then the other oil seal.
LOWR Lower unit NOTE: Apply grease to the new O-rings before installation. 2. Install the new gasket 2, outer plate cartridge 3, and dowel pins 4. 2. Install the bolts 1, ring 2, and bolts 3, and then tighten the bolts 1 to the specified torque. T. R. Propeller shaft housing bolt 1: 30 N·m (3.0 kgf·m, 22 ft·lb) Installing the water pump and shift rod 1. Install the shift rod assembly 1. 6-47 3. Install the Woodruff key into the drive shaft. 4.
Drive shaft and lower case (counter rotation model) 5. Install the washers 7, wave washer 8, spacer 9, and collar 0 to the drive shaft. LT 572 A NOTE: • The collar and spacer should fit together firmly. • While pulling the drive shaft up, install the collar with an appropriate tool a that fits over the drive shaft as shown. 6. Install the O-ring A and insert cartridge B into the pump housing C.
LOWR Lower unit 5. Install the propeller and propeller nut, and then tighten the nut finger tight. Place a block of wood between the anticavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque. È Shift rod push arm: YB-06052 2. Install the two dowel pins 1 to the lower unit. 3. Install the lower unit to the upper case, and then tighten the bolts 2 to the specified torque. 4.
Drive shaft and lower case (counter rotation model) / Shimming (counter rotation model) Shimming (counter rotation model) 6 F P 1 2 3 4 5 6 7 8 9 R B4 T3 A3 B3 65.0 A B B8 B5 A5 T1 T2 B1 38.4 47.
LOWR Lower unit Shimming R. Selecting the pinion shims Pinion shimming gauge III 4: YB-06441 T. NOTE: • Shimming is not required when assembling the original lower case and inner parts. • Shimming is required when assembling the original inner parts and a new lower case. • Shimming is required when replacing the inner part(s). 3. Install the pinion and pinion nut, and then tighten the nut to the specified torque. Pinion nut: 142 N·m (14.2 kgf·m, 103 ft·lb) 4.
Shimming (counter rotation model) Selecting the reverse gear shims 1. Calculate the specified value (M0) as shown in the examples below. NOTE: Measure the bearing retainer at three points to find the clearance average. 4. Select the reverse gear shim(s) (T1). NOTE: “F” is the deviation of the lower case dimension from standard. The “F” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units.
LOWR Lower unit NOTE: “R” is the deviation of the lower case dimension from standard. The “R” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “R” mark is unreadable, assume that “R” is zero and check the backlash when the unit is assembled. Calculation formula: Specified value (M0) = 2.50 + R/100 mm 4. Measure the clearance (M) between the shimming tool and the propeller shaft housing 8 as shown. S69J6684 Example: If “R” is (+5), then M0 = 2.
Shimming (counter rotation model) / Backlash (counter rotation model) Magnet flexible stand 7: YU-34481 Dial gauge 8: YU-03097 Calculation formula: Forward gear shim thickness (T2) = M0 – M 3. Select the propeller shaft shim(s) (T’4). Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm Selecting the propeller shaft shims 1. Install the shim(s) 1, thrust bearing 2, propeller shaft 3, taper roller bearing 4, and claw washer 5, and then tighten the ring nut 6 to the specified torque.
LOWR Lower unit 3. Install the special service tool so that it pushes against the propeller shaft. È Backlash indicator gauge 3: YB-06265 Magnetic plate 4: YB-07003 Dial gauge 5: YU-03097 Magnet flexible stand 6: YU-34481 6. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction. NOTE: Tighten the universal puller or center bolt while turning the drive shaft until the drive shaft can no longer be turned.
Backlash (counter rotation model) 9. Turn the shift rod into the reverse position c with the shift rod push arm. 10. Turn the drive shaft clockwise until the dog clutch 7 is fully engaged. NOTE: When measuring the reverse gear backlash, turn the shift rod push arm towards the reverse position c with force. Reverse gear backlash: 0.70–1.03 mm (0.028–0.041 in) 15. Add or remove shim(s) if out of specification. 11. Turn the shift rod to the neutral position d with the shift rod push arm. 12.
BRKT Bracket unit Special service tools .....................................................................................7-1 Bottom cowling .............................................................................................. 7-3 Upper case, steering arm, swivel bracket and clamp brackets ................. 7-7 Draining the engine oil............................................................................. 7-13 Disassembling the oil pan.......................................................
Power trim and tilt electrical system.......................................................... 7-43 Checking the fuse....................................................................................7-44 Checking the power trim and tilt relay .....................................................7-44 Checking the power trim and tilt switch ...................................................7-45 Checking the trim sensor.........................................................................
BRKT Bracket unit Special service tools 7 PTT oil pressure gauge assembly YB-06580 PTT oil pressure gauge adapter YB-06581 Trim and tilt cylinder wrench YB-06175-2B PTT piston vice attachment YB-06572 Tilt rod wrench YB-06569 7-1 69J1D11
Special service tools — MEMO — 1 2 3 4 5 6 7 8 9 69J1D11 7-2
BRKT Bottom cowling 7-3 Bracket unit 7 69J1D11
Bottom cowling No.
BRKT 7-5 Bracket unit 69J1D11
Bottom cowling No.
BRKT Bracket unit Upper case, steering arm, swivel bracket and clamp brackets 7-7 7 69J1D11
Upper case, steering arm, swivel bracket and clamp brackets No.
BRKT 7-9 Bracket unit 69J1D11
Upper case, steering arm, swivel bracket and clamp brackets No.
BRKT 7-11 Bracket unit 69J1D11
Upper case, steering arm, swivel bracket and clamp brackets No.
BRKT Bracket unit Draining the engine oil 1. Place a drain pan under the drain hole, and then remove the drain bolt 1 and let the oil drain completely. 2. Remove the cover 2 and damper 3. 2. Remove the oil pan 4 from the upper exhaust guide 5 and lower exhaust guide 6. 3. Remove the oil strainer 7 from the lower exhaust guide 6. 3. Remove the upper and lower mounting nut, and then remove the upper case. 4. Remove the muffler assembly from the upper case. Disassembling the oil pan 1.
Upper case, steering arm, swivel bracket and clamp brackets T. R. 2. Install the oil strainer 4 and bolts, and then tighten the bolts to the specified torque. Exhaust manifold bolt 7: 20 N·m (2.0 kgf·m, 14 ft·lb) Oil pan bolt 8: 20 N·m (2.0 kgf·m, 14 ft·lb) 6. Install the plate 9. 7. Install the cooling water pipe 0 into the muffler A. 8. Install the muffler A and bolts into the oil pan, and then tighten the bolts to the specified torque. T. R. Oil strainer bolt: 10 N·m (1.0 kgf·m, 7.2 ft·lb) 3.
BRKT Bracket unit T. R. Bracket bolt: 54 N·m (5.4 kgf·m, 39 ft·lb) 13. Install the lower mounts I and mount housings J. Removing the steering arm T. R. Muffler assembly bolt D: 20 N·m (2.0 kgf·m, 14 ft·lb) Muffler assembly bolt E: 42 N·m (4.2 kgf·m, 30 ft·lb) Pressure control valve F: 8 N·m (0.8 kgf·m, 5.8 ft·lb) 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer. 11. Install the upper mounts G and bolts into the upper case. 12.
Upper case, steering arm, swivel bracket and clamp brackets Installing the steering arm 1. Install the washer 1 and bushing 2 onto the steering arm 3. 2. Place the swivel bracket 4 in an upright position, and then install the steering arm onto the swivel bracket. 6. Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c. 3. Install the bushing 5, O-ring 6, bushing 7, and washer 8 onto the swivel bracket. 4.
BRKT Bracket unit Installing the upper case 1. Install the upper and lower mounting bolts into the swivel bracket 1 simultaneously. 2. Install the upper mounting nut 2 and lower mounting nut 3, and then tighten them to the specified torques. WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure.
Upper case, steering arm, swivel bracket and clamp brackets Removing the clamp brackets 1. Remove the self-locking nut 1 and ground lead 2, then clamp brackets 3 and 4. 2. Assemble the clamp brackets and the swivel bracket by connecting the ground lead 2, installing the through tube 3, then tightening the self-locking nut 4 finger tight. 2. Remove the trim sensor 5. Installing the power trim and tilt unit Installing the clamp brackets 1. Install the trim sensor 1 onto the port clamp bracket.
BRKT Bracket unit 3. Install the tilt ram upper end into the swivel bracket with the shaft 4 and circlip 5. Adjusting the trim sensor 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. 4. Tighten the self-locking nut 6 to the specified torque. 5. Remove the anode 7. WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure. 2.
Upper case, steering arm, swivel bracket and clamp brackets 7. Fully tilt the outboard motor up, and then support it with the tilt stop lever. WARNING 1 2 3 4 5 6 7 8 9 After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure. 8. Measure the trim sensor resistance. Check the trim sensor if out of specification. Trim sensor resistance: Pink (P) – Black (B) 247.6–387.
BRKT Bracket unit Power trim and tilt unit 7-21 7 69J1D11
Power trim and tilt unit No. Part name Q’ty Remarks 1 Cylinder block 1 2 Reservoir 1 3 Bolt 3 M8 × 20 mm 4 O-ring 1 Not reusable 5 Reservoir cap 1 1.9 × 12.6 mm M12 × 10 mm 6 O-ring 1 Not reusable 7 Sheet 1 8 Filter 1 9 Spacer 1 10 Bolt 3 11 O-ring 1 1 2 3 4 5 6 7 8 9 M8 × 20 mm Not reusable 2.4 × 22.
BRKT 7-23 Bracket unit 69J1D11
Power trim and tilt unit No.
BRKT 7-25 Bracket unit 69J1D11
Power trim and tilt unit No. Part name Q’ty 1 Gear housing 1 1 2 Bolt 3 3 Plate 1 4 Filter 1 5 Valve lock screw 2 6 Down-relief spring 1 7 Valve support pin 1 8 Relief valve seal 1 9 Up-relief spring 1 10 Valve support pin 1 11 O-ring 1 Remarks M5 × 40 mm 1 2 3 4 5 6 7 8 9 Not reusable 1.8 × 11.
BRKT Bracket unit Disassembling the power trim and tilt motor Checking the power trim and tilt motor 1. Remove the PTT motor screws 1, then the yoke 2. 1. Check the commutator for dirt or foreign substances. Clean with #600 grit sandpaper if necessary. CAUTION: Do not allow grease or oil to contact the commutator. 2. Check the commutator undercut for dirt or foreign substances. Clean with compressed air if necessary.
Power trim and tilt unit 8. Check the bearing for damage or wear. Replace if necessary. Assembling the power trim and tilt motor 1. Install the new oil seal 1 and bearing 2 into the motor base 3 as shown. Armature coil continuity Commutator segments b Continuity Segment-laminations c No continuity Segment-shaft d No continuity 5. Check the circuit breaker for continuity. Replace the brush holder if there is no continuity. 2.
BRKT Bracket unit 4. Install the PTT oil pressure gauge adapter set 2. 6. Install the wave washer A and washer B into the yoke C. NOTE: Cover the removed pipe joint a with a rag. PTT oil pressure gauge adapter set: YB-06580 7. Install the new O-ring and yoke C to the motor base. 5. Connect the PTT motor leads to the battery terminals to retract the tilt ram, and then measure the hydraulic pressure.
Power trim and tilt unit 6. Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams. NOTE: Cover the removed pipe joint b with a rag. Ram Up PTT motor lead Battery terminal Sky blue (Sb) + Light green (Lg) - 7. Remove the PTT oil pressure gauge adapter set 2. PTT oil pressure gauge adapter set: YB-06580 12. Connect the PTT motor leads to the battery terminals to extend the tilt ram, and then measure the hydraulic pressure. 8.
BRKT Bracket unit NOTE: If the fluid is at the correct level, the fluid should overflow out of the filler hole when the cap is removed. 14. Remove the PTT oil pressure gauge adapter set 2. 15. Install the pipe joints 3, and then tightening them to the specified torque. T. R. Pipe joint 3: 15 N·m (1.5 kgf·m, 11 ft·lb) 16. After measuring the hydraulic pressure, connect the PTT motor leads to the battery terminals to fully extend the trim and tilt rams.
Power trim and tilt unit Disassembling the tilt cylinder and trim cylinders 1. Hold the tilt cylinder 1 in a vise using aluminum plates a on both sides. 2. Loosen the tilt cylinder end screw 2, and then remove the tilt piston assembly. 3. Remove the bracket 5, then the balls 6. WARNING Make sure that the rams are fully extended before removing the end screw. Trim and tilt cylinder wrench: YB-06175-2B 4. Remove the gear housing 2 7, then the shuttle pistons 8. 5.
BRKT Bracket unit WARNING Never look into the tilt cylinder opening because the free piston and power trim and tilt fluid may be expelled out forcefully. 5. Hold the tilt piston in a vise using the special service tool 4 on both sides. 6. Remove the tilt ram. Trim and tilt cylinder wrench: YB-06175-2B 9. Remove the trim piston assemblies. 10. Drain the power trim and tilt fluid. 11. Remove the circlip 8, adapter 9, and spring 0 from the trim piston assemblies.
Power trim and tilt unit Checking the reservoir 1. Check the reservoir for cracks or corrosion. Replace if necessary. Checking the tilt cylinder and trim cylinder 4. Check the trim and tilt rams for bends or excessive corrosion. Polish with #400– 600 grit sandpaper if there is light rust or replace if necessary. 1. Check the power trim and tilt unit for cracks or corrosion. Replace if necessary. 2. Check the inner walls of the cylinder block and tilt cylinder for scratches. Replace if necessary. 5.
BRKT Bracket unit Checking the filters 1. Check gear pump filters 1 and 2, and shuttle piston filters 3 for dirt or residue. Clean if necessary. 2. Check the up-relief valve and down-relief valve for dirt or residue. Clean if necessary. Checking the gear pump 1. Check the drive gear for damage or excessive wear. Replace if necessary. 3. Check the main valves for dirt or residue. Clean if necessary. Checking the gear pump housing 1. Check the gear pump housing for scratches. Replace if necessary. 4.
Power trim and tilt unit T. R. 3. Install the balls 7, manual release spring 8, and bracket 9 by installing the bolts 0, then tightening them to the specified torque. Up-relief lock screw a height (from the top of the gear housing): 1.8–2.0 mm (0.071–0.079 in) Down-relief lock screw b depth (from the top of the gear housing): 1.5–2.0 mm (0.059–0.079 in) 5. Install the filters C and gear pump D by installing the bolts E, then tightening them to the specified torque. 6. Install the manual valve F. T.
BRKT Bracket unit T. R. Tilt ram 0: 55 N·m (5.5 kgf·m, 40 ft·lb) 5. Install the new O-ring C and backup ring D into the tilt piston 9. 6. Install the balls E, absorber valve pins F, and springs G as shown. 2. Install the tilt cylinder end screw 6, spring 7, adapter 8, and tilt piston 9 to the tilt ram 5. R. 4. Tighten the tilt ram 0 to the specified torque. T. 3. Hold the tilt piston in a vise using the special service tool A on both sides. 7.
Power trim and tilt unit 3. Install the tilt cylinder 3 to the cylinder block 4. 4. Install pipes 5 and 6, and then tighten them to the specified torque. T. R. Trim piston bolt: 38 N·m (3.8 kgf·m, 27 ft·lb) 4. Install the new O-ring 3, backup ring 4, spring 5, adapter 6, and circlip 7 to the trim piston 1. T. R. 5. Install the new oil seal 8, circlip 9, and new O-ring 0 into the trim cylinder end screw A. Pipe joint 5 and 6: 15 N·m (1.5 kgf·m, 11 ft·lb) Installing the trim rams 1.
BRKT Bracket unit Recommended power trim and tilt fluid: ATF Dexron II 2. Fill the pump housing with the recommended fluid to the correct level a as shown. 3. Install the trim piston assembly into the trim cylinder, and then tighten the trim cylinder end screw 2 to the specified torque. Recommended power trim and tilt fluid: ATF Dexron II WARNING Do not push the trim rams down while installing them into the trim cylinders. Otherwise, the power trim and tilt fluid may spurt out from the unit.
Power trim and tilt unit T. R. Reservoir bolt 6: 18 N·m (1.8 kgf·m, 13 ft·lb) Reservoir cap 7: 7 N·m (0.7 kgf·m, 5.1 ft·lb) Installing the tilt ram 1. Fill the tilt cylinder with the recommended fluid to the correct level a as shown. 2. Add a small amount of the recommended fluid through the cylinder block hole b as shown. NOTE: Align the armature shaft with the recess in the joint. T. R. PTT motor bolt 4: 18 N·m (1.8 kgf·m, 13 ft·lb) Installing the reservoir 1.
BRKT Bracket unit WARNING To prevent the power trim and tilt fluid from spurting out due to internal pressure, the tilt ram should be kept at full length. NOTE: Place the tilt cylinder end screw at the bottom of the tilt ram and install the tilt piston assembly into the tilt cylinder. Recommended power trim and tilt fluid: ATF Dexron II 5. Install the reservoir cap. 6. Connect the PTT motor leads 2 to the battery terminals. Trim and tilt cylinder wrench: YB-06175-2B T. R.
Power trim and tilt unit / Bleeding the power trim and tilt unit NOTE: • Repeat this procedure so that the rams go up and down four to five times (be sure to wait a few seconds before switching the leads). • The sound of the power trim and tilt motor will change when the rams are fully extended. • If the rams do not move up and down easily, push and pull on the rams to assist operation. 8. Check the fluid level again when the rams are fully extended.
BRKT Bracket unit Power trim and tilt electrical system R 7 R B R R P R P B Lg P B R B Sb P B B R Sb Sb Lg R B P B Lg Lg Lg Lg R Sb Sb Lg R Sb Lg R Sb B B Sb R Lg B S69J7520U 1 2 3 4 5 6 7 8 Fuse (30 A) Fuse (20 A) Power trim and tilt relay Power trim and tilt motor 10-pin coupler Battery Power trim and tilt switch Trim sensor 7-43 B Lg P R Sb : Black : Light green : Pink : Red : Sky blue 69J1D11
Power trim and tilt electrical system Checking the fuse 1. Check the fuse for continuity. Replace if there is no continuity. S69J7525 Checking the power trim and tilt relay 1. Check the power trim and tilt relay for continuity. Replace if out of specification. Power trim and tilt relay continuity Sky blue (Sb) – Black (B) Light green (Lg) – Black (B) Continuity Terminal 1 – Terminal 4 Terminal 2 – Terminal 4 Continuity Terminal 1 – Terminal 3 Terminal 2 – Terminal 3 No continuity 2.
BRKT Bracket unit NOTE: Turn the lever 1 and measure the resistance as it gradually changes. Trim sensor resistance: Pink (P) – Black (B) 9–11 Ω at 20 °C (68 °F) a 247.6–387.6 Ω at 20 °C (68 °F) b Checking the power trim and tilt switch 1. Check the power trim and tilt switch for continuity. Replace if out of specification. Lead color Switch position Sky blue (Sb) Red (R) Light green (Lg) Up Free Down Checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification.
ELEC – + Electrical systems Special service tools .....................................................................................8-1 Checking the electrical components............................................................ 8-2 Measuring the peak voltage ...................................................................... 8-2 Measuring the lower resistance.................................................................8-2 Electrical components.................................................
ELEC – + Electrical systems Special service tools 8 Dynamic spark tester YM-34487 Test harness (3 pins) YB-06793 Digital multimeter YU-34899-A Test harness (3 pins) YB-06770 Peak voltage adaptor YU-39991 Test harness (2 pins) YB-06787 Test harness (2 pins) YB-06792 Test harness (4 pins) YB-06771 8-1 69J1D11
Special service tools / Checking the electrical components Checking the electrical components Measuring the lower resistance 8 Measuring the peak voltage NOTE: Before troubleshooting the peak voltage, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V. The condition of the ignition system can be determined by measuring the peak voltage. Cranking speed is effected by many factors, such as fouled or weak spark plugs, or a weak battery.
ELEC – + Electrical systems Electrical components 8 Starboard and rear views #2 #4 #6 #1 #3 #5 S69J8030 1 2 3 4 Thermoswitch Starter motor Oil pressure sensor Ignition coils 8-3 69J1D11
Electrical components Port view 6 6 5 4 3 2 1 S69J8040U 1 2 3 4 5 6 Fuel injectors Fuel pump driver and isolator Low-pressure fuel pump ECM High-pressure fuel pump Fuses 69J1D11 8-4 1 2 3 4 5 6 7 8 9
ELEC – + Electrical systems Front view E E S69J8050U 1 2 3 4 5 6 7 Starter motor Fuses ECM Main relay Rectifier Regulator Power trim and tilt relay Starter relay 8-5 69J1D11
Electrical components Top view S69J8060 1 2 3 4 5 6 7 8 9 0 Spark plugs Idle speed control Thermoswitches Intake air pressure sensor Engine temperature sensor Fuses Rectifier Regulator Intake air temperature sensor Starter motor Oil pressure sensor 69J1D11 A Stator coil B Throttle position sensor C Ignition coils 8-6 1 2 3 4 5 6 7 8 9
– ELEC + Electrical systems Wiring harness 8 R/Y R/Y 6 6 R/Y B/O B/Y 6 B/W G P/ 5 5 O B P B 4 P O P 7 B B O/B O/Y O/R R/Y P 3 3 R/Y 3 R/Y R/Y 8 L/W R/Y R/Y O/R A L R/Y G/B R/Y L/W R/Y R/Y 3 R/Y R/Y W/B D W/R R/Y R/Y R/Y B R/Y 3 W/G E Br B R/Y R/Y R/Y B/Y 2 1 0 G/Y G O/B B L B G/R B/W B O/Y 3 L/R R/Y R/Y B L/Y C B F F R/Y R/B R/Y R/Y B B B B B R/Y R/Y R/Y R/Y R/Y B B B B B B B I H B/Y Y/G Br R/Y J R/Y P/W L B R R/B
Wiring harness Connect to: 3 R/Y O/B 1 Br B 2 L/Y B R/Y O/Y R/Y O/R 6 B/O R/Y 4 B P O 5 P B B/Y R/Y R/Y G/R G/Y G/B R/Y G B P P B A R/Y L 8 R/Y L/W 5 O/B R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/B R/Y R/Y R/Y R/Y R/Y R/Y B B B B B B B B/W R/Y O/R R/Y O/Y R/Y 3 R/Y R/Y B R/Y L/R L L/W B/W 0 P/G B O 7 B W/B B B/W Br O/Y B/Y B/O G/Y G O B/Y O W/B B B Y/G E L/Y O/B O/R B/W G/R G/B P P P/G W/R W/G B L/R B B B F C B/Y B R/Y R/Y R/Y L/W B/Y O L/W P/W G P Y W P/W
– ELEC + R/Y R R/Y R/Y R R R/Y R Electrical systems 1 5 Br/W R R R R/Y R R Br/W R R/Y R/Y 2 4 R S69J8090U.
Wiring harness / Ignition and ignition control system Ignition and ignition control system 8 Y 1 R/Y R/Y R/Y R/Y R/B B B P R/Y R/Y R/Y R/Y B R/Y R/Y B B R/Y W/R W/B W/R B W/G B B B/Y B P Y W/G W/G W/B B B W/R B/Y 9 4 0 B/Y B/Y 0 G/W G/W G G G/W G B 5 Y/G G G/W O P/W B L/W B R/Y B/O G G A B B/Y B/W G G/W G R/Y G/W 2 R/Y R R B B/W #4 R/Y 3 R/Y #1 R H R H G 2 3 6 7 8 9 10 11 B R/Y B/Y P/G B/W B B B P P R/Y O R/Y R C P R R/Y
ELEC – + Electrical systems Checking the ignition spark gap Checking the ignition coil 1. Remove the ignition coil cover and disconnect the spark plug caps from the spark plugs. 1. Remove the spark plug wires from the spark plugs. 2. Disconnect the ignition coil coupler. 2. Connect a spark plug cap to the special service tool. È 3. Measure the ignition coil resistance. Replace if out of specification. S69J8110 Dynamic spark tester: YM-34487 3.
Ignition and ignition control system Checking the ECM 1. Remove the ignition coil cover and disconnect the ignition coil coupler. 3. Measure the pulser coil output peak voltage. Replace the pulser coil if below specification. 2. Connect the test harness (2 pins) to the ignition coil. 3. Measure the ECM output peak voltage. If below specification, measure the pulser coil output peak voltage. Replace the ECM if the output peak voltage of the pulser coil is above specification.
ELEC – + Electrical systems Checking the engine temperature sensor 1. Place the engine temperature sensor in a container of water and slowly heat the water. Test harness (3 pins): YB-06793 Throttle position sensor input voltage: Orange (O) – Black (B) 5V Throttle position sensor output voltage: Pink (P) – Black (B) 695–705 mV Checking the intake air temperature sensor S69J8240 2. Measure the engine temperature sensor resistance. Replace if out of specification.
Ignition and ignition control system Checking the thermoswitch Checking the shift cut switch 1. Place the thermoswitch in a container of water and slowly heat the water. 1. Check the shift cut switch for continuity. Replace if there is no continuity. S69J8270 S69J8250 2. Check the switch for continuity at the specified temperatures. Replace if out of specification. Switch position Lead color Blue/yellow (L/Y) Black (B) Free a Push b Checking the neutral switch 1.
ELEC – + Electrical systems Checking the main relay 1. Connect the digital circuit tester leads to main relay terminals 1, 2, and 3. 2. Connect the terminal 4 to the positive battery terminal. 3. Connect the terminal 5 to the negative battery terminal. 4. Check for continuity between the main relay terminals. Replace if there is no continuity. 5. Check that there is no continuity between the main relay terminals after disconnecting terminal 4 or 5. Replace if there is continuity.
Ignition and ignition control system / Fuel control system Fuel control system G G/B R/Y 8 R/Y G/Y G H G/B R/Y G/R G/Y R/Y G/R R/Y R/Y R/Y R/Y R/B P R/Y G/R B R/Y L R/Y 1 B R/Y G/B G I Y R/Y G/Y R/Y R/Y R/Y B B B R/Y B B L R/Y W/R W/R W/B W/G B B Y W/G B W/B W/G B W/R 6 0 J R B/Y B R/Y B B/Y L/W B A A B/Y L/R G/W G/W G/W G B/W B/Y 4 R/Y 5 Y/G G O P/W G B L/W B G G/W B L/W L B/Y B B G G K R/Y B G L/R G G/W B/W R/Y 2 R/Y R
– ELEC + Electrical systems 8 G G/B R/Y R/Y G/Y G H G/B R/Y G/R G/Y R/Y G/R R/Y R/Y R/Y R/Y R/B P R/Y G/R B R/Y L R/Y 1 B R/Y G/B G I Y R/Y G/Y R/Y R/Y R/Y B B B R/Y B B L R/Y W/R W/R W/B W/G B B Y W/G B W/B W/G B W/R 6 0 J R B/Y B R/Y B B/Y L/W B A A B/Y L/R G/W G/W G/W G B/W B/Y 4 R/Y 5 Y/G G O P/W G B L/W B G G/W B L/W L B/Y B B G G K R/Y B G L/R G G/W B/W R/Y 2 R/Y R/Y 3 R/Y G/W R #6 L R O/Y R/Y O/R R/Y
Fuel control system Checking the low-pressure fuel pump and high-pressure fuel pump 1. Disconnect the starter relay lead (brown lead) 1 to prevent the engine from starting. 1 2 3 4 5 6 7 8 9 S69J8300 2. Turn the engine start switch to ON. 3. Listen for the operating sound of the high-pressure fuel pump 2. Replace if there is no sound. S69J8310J NOTE: • After the engine start switch is turned to ON, the high-pressure fuel pump will operate for 5 seconds.
ELEC – + Electrical systems Starting system 8 R Br R R R R R Br/W R B Br R B Br Br/W B R B B S69J8330 1 2 3 4 5 Fuse (30 A) Fuse (20 A) Starter relay Starter motor Battery 8-19 B Br R Br/W : Black : Brown : Red : Brown/white 69J1D11
Starting system Checking the fuse 1. Check the fuse for continuity. Replace if there is no continuity. 1 2 3 4 5 6 7 8 9 S69J8340 Checking the wiring harness (10 pins) 1. Check the wiring harness for continuity. Replace if there is no continuity. Checking the starter relay 1. Connect the digital circuit tester leads to the starter relay terminals. 2. Connect the brown (Br) lead to the positive battery terminal. 3. Connect the black (B) lead to the negative battery terminal. 4.
ELEC – + Starter motor 8-21 Electrical systems 8 69J1D11
Starter motor No.
ELEC – + Electrical systems Removing the starter motor pinion 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2. 2. Measure the commutator diameter. Replace the armature if out of specification. NOTE: Remove the clip with a thin screwdriver. Checking the starter motor pinion 1. Check the teeth of the pinion for cracks or wear. Replace if necessary. Commutator diameter limit: 28.0 mm (1.10 in) 3. Measure the commutator undercut a. Replace the armature if out of specification. 2.
Starter motor Brush continuity Brush 1 – Brush 2 No continuity Checking the magnet switch 1. Connect the tester leads between the magnet switch terminals as shown. 2. Connect the positive battery terminal to the black and white (B/W) lead. Armature continuity Commutator segments b Continuity Segment – Armature core c No continuity Segment – Armature shaft d No continuity 3. Connect the negative battery terminal to the starter motor body. Br/W Checking the brushes 1. Measure the brush length.
ELEC – + Electrical systems Charging system 8 W R Y R/Y Y R/Y R W G 1 G/W G/W G/W G G G G G G G G 2 R W R/Y Y G 6 R G/W B B R R/Y R/Y G/W G/W G/W G/W R R/Y R R/Y G/W R R/Y R/Y 3 R 3 3 3 R R R/Y B R R R B R B B B B 5 4 S69J8460U 1 2 3 4 5 6 Stator coil Rectifier Regulator Fuse (30 A) Starting battery Accessory battery Fuel pump driver and isolator 8-25 B G R W Y G/W R/Y : Black : Green : Red : White : Yellow : Green/white : Red/yellow 69J1D11
Charging system Checking the stator coil Stator coil resistance (use as reference): Green (G) – Green (G) 0.28–0.42 Ω at 20 °C (68 °F) 0.24–0.36 Ω at 20 °C (68 °F) Green/white (G/W) – Green/white (G/W) 0.24–0.36 Ω at 20 °C (68 °F) 0.20–0.31 Ω at 20 °C (68 °F) 1. Remove the intake silencer and disconnect the stator coil coupler. 2. Connect the test harness (3 pins) to the stator coil. 3. Install the intake silencer. CAUTION: Do not start the engine when the intake silencer is not installed. 4.
ELEC – + Electrical systems Digital multimeter: YU-34899-A Peak voltage adaptor: YU-39991 Test harness (2 pins): YB-06787 Rectifier Regulator output peak voltage: Red (R) – Black (B) Red/yellow (R/Y) – Black (B) r/min DC V 8-27 Unloaded 1,500 3,500 13 13 69J1D11
TRBL SHTG Troubleshooting Special service tools .....................................................................................9-1 Yamaha Diagnostic System ..........................................................................9-2 Introduction................................................................................................9-2 Power unit....................................................................................................... 9-5 Bracket unit ............................
TRBL SHTG Troubleshooting Special service tools 9 Yamaha Diagnostic System 60V-85300-02 YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL Yamaha Diagnostic System 60V-WS853-02 Diagnostic test lead YB-06795 9-1 69J1D11
Special service tools / Yamaha Diagnostic System Yamaha Diagnostic System 9 Introduction Features The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of an outboard motor using the communication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor.
TRBL SHTG Troubleshooting Hardware requirements Make sure that your computer meets the following requirements before using this software.
Yamaha Diagnostic System Connecting the communication cable to the outboard motor 1 2 3 4 5 6 7 8 9 3-pin communication coupler 69J1D11 9-4
TRBL SHTG Troubleshooting NOTE: • To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters 4– 8 for safe maintenance procedures. • Check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V. • To diagnose a malfunctioning sensor or switch, use the diagnostic flash indicator to determine the cause.
Power unit Is there continuity? No 1 2 3 4 5 6 7 8 9 Replace the engine stop lanyard switch. Yes Check the fuse for continuity. Is there continuity? No Replace the fuse. Yes Check the wiring harnesses for continuity. Is there continuity? No Replace the wiring harnesses. Yes Listen for the operation sound of the starter relay. Can the operation sound be heard? No Replace the starter relay. Yes Check the starter motor operation. Good operating condition? No Replace the starter motor.
TRBL SHTG Troubleshooting Symptom: Engine cranks, but will not start (engine stop lanyard switch is operating normally). • Check the ignition system. • Check the fuel system. • Check the compression pressure of the power unit. WARNING Check that the spark plugs produce sparks. Are there sparks? Yes • Do not touch any of the connections of the spark gap tester leads. • Do not let sparks leak out of the removed spark plug caps. • Keep flammable gas or liquids away, since this test can produce sparks.
Power unit Does the engine start? No Check the compression pressure of the combustion chamber. Yes Out of specification? Yes No Check the condition of the spark plugs again. Wet spark plugs? No Failure in starting operation Check the valve clearance. Failure in starting operation Yes Check the fuel system. Adjust the valve clearance. Yes Out of specification? No Check the cylinder head, cylinder body, and piston assembly.
TRBL SHTG Troubleshooting Symptom: Engine can be started, but does not remain on. • Check the fuel system. • Check the ignition system. • Check the compression pressure of the power unit. Fuel system Check that the fuel vent screw of the fuel tank is open. Is the vent screw open? No Open the fuel vent screw. Yes Check for water or residue in the fuel filter. Water or residue? No Check the fuel hose for kinks or fuel leakage. Yes Clean the fuel system from the fuel tank to the fuel filter.
Power unit Ignition system Check the ignition spark gap using the spark gap tester. Out of specification? No Check the ignition system output peak voltage. Yes Out of specification? Replace the spark plug. No Check the ignition system using the Yamaha Diagnostic System. No Check the ignition system using the Yamaha Diagnostic System. Yes Check the ignition coils resistence. Yes Replace the ignition coil.
TRBL SHTG Troubleshooting Symptom: The engine idle speed is not steady, but increases or decreases. • Check the intake manifold. • Check the air intake system. • Check the ignition system. Check the operation of the throttle cable and throttle link. Good operating condition? No Adjust the throttle cable and throttle link. Yes Check the synchronization of the throttle valve. Are the throttle valves synchronize? Yes Check the ignition timing. No Synchronize the throttle valves.
Power unit Symptom: Engine does not accelerate when the throttle is opened quickly. The engine turns off when the throttle is opened quickly. Acceleration is tardy and the engine is likely to stop at any moment. • Check the engine using the diagnostic flash indicator or the Yamaha Diagnostic System. Symptom: Engine can run, but engine speed will not increase. Overheat warning indicator is on. Oil pressure warning indicator is on. Warning indicator is on and buzzer is sounding. • Check the cooling system.
TRBL SHTG Troubleshooting Lubrication system Check the engine oil level. No Add engine oil to the correct level. Yes Check the oil pump for debris or oil leaks. At specified level? Yes Check the oil pressure. Out of specification? No Debris or leaks? No Check the oil passage. Yes Clean or replace the respective parts. Check the oil pressure sensor. Good condition? No Replace the oil pressure sensor. Yes Check the engine using the Yamaha Diagnostic System.
Power unit / Bracket unit Bracket unit 9 Symptom: Power trim and tilt unit does not operate. Listen for the operation sound of the power trim and tilt relay. Can the operation sound be heard? No Check the voltage between each terminal. • Between the sky blue (Sb) lead and black (B) lead. • Between the light green (Lg) lead and black (B) lead. Yes Can 12 V be obtained? No Yes Listen for the operation sound of the power trim and tilt motor. Replace the power trim and tilt relay.
TRBL SHTG Troubleshooting At specified level? No Add fluid to the correct level. Yes Measure the hydraulic pressure. Out of specification? No Check the power trim and tilt unit for leaks. Yes Disassemble the power trim and tilt unit, and then check the filter for debris or dirt. Stuck foreign substance or clogs? Yes Clean or replace the filters. No Check the fluid passages for clogs or debris. Clogs or debris? Yes Clean the passages. No Check the internal parts (valves, pistons, gears, etc.
Bracket unit Symptom: Power trim and tilt unit does not hold the outboard motor up. Check that the manual valve is closed. Is it closed? No 1 2 3 4 5 6 7 8 9 Close the valve. Yes Check the power trim and tilt fluid level. At specified level? No Add fluid to the correct level. Yes Disassemble the power trim and tilt unit, and then check the filters for debris or dirt. Stuck foreign substance or clogs? Yes Clean or replace the filters. No Check the fluid passages for clogs or debris.
TRBL SHTG Troubleshooting Symptom: Shift mechanism of the forward gear and reverse gear does not operate properly. Check the shift cable operation. Good operating condition? No Check the shift cables and links of the remote control box. Yes Check the operation of the shift rod. Good operating condition? No Check the detent of the bottom cowling. Yes Check the condition of the shift rod connection between the lower case and upper case. Connected properly? No Replace the shift rod.
Bracket unit / Electrical systems Electrical systems 9 Symptom: Battery becomes weaker quickly. • Check the charging system. 1 2 3 4 5 6 7 8 9 Measure the output peak voltage of the stator coil. Out of specification? Yes Replace the stator coil. No Measure the Rectifier Regulator output peak voltage. Out of specification? Yes Replace the Rectifier Regulator. No Replace the battery, and then check the voltage of all electrical equipment on your boat.
TRBL SHTG Troubleshooting Self-diagnosis 9 Diagnosing the electronic control system 1. Connect the special tools to the outboard motor as shown. È L/W • Trouble code indication Example: The illustration code number 23. a: Light on, 0.33 second b: Light off, 4.95 seconds b: Light off, 0.33 second d: Light off, 1.65 seconds indicates R/B, W/B, B S69J9015U NOTE: When performing this diagnosis, all of the electrical wires must be properly connected. Diagnostic test lead: YB-06795 2.
Self-diagnosis Code Symptom 1 Normal 13 Incorrect pulser coil signal 15 Incorrect engine temperature sensor signal 18 Incorrect throttle position sensor signal 19 Incorrect battery voltage 23 Incorrect intake air temperature sensor signal 28 Incorrect neutral switch signal 29 Incorrect intake air pressure sensor signal 37 Incorrect idle speed control signal 39 Incorrect oil pressure sensor signal 44 Incorrect engine stop lanyard switch signal 45 Incorrect shift cut switch signal 46
Index A. Adjusting the throttle link and throttle cable operation (with a stop bolt) ............3-10 Adjusting the throttle link and throttle cable operation (without a stop bolt) .......3-11 Adjusting the trim sensor ..........................7-19 After test run .............................................1-31 Applicable models.......................................1-4 Assembling the drive shaft housing ......................................... 6-19, 6-45 Assembling the forward gear ....................
Checking the piston clearance..................5-48 Checking the piston diameter ...................5-47 Checking the piston pin.............................5-50 Checking the piston pin boss bore............5-49 Checking the piston ring grooves..............5-49 Checking the piston ring side clearance ...5-49 Checking the piston rings..........................5-48 Checking the power trim and tilt fluid level .................................................3-16 Checking the power trim and tilt motor .....
Index G. General .....................................................3-18 General specifications.................................2-1 General torques ........................................2-17 Good working practices ..............................1-4 H. Hose routing................................................4-2 How to use this manual...............................1-1 I. Identification................................................1-4 Ignition and ignition control system...........
S. Safety while working ...................................1-3 Selecting the connecting rod bearing........5-52 Selecting the crankshaft main bearing......5-54 Selecting the forward gear shims.... 6-26, 6-52 Selecting the pinion shims .............. 6-25, 6-51 Selecting the propeller shaft shims ...........6-54 Selecting the reverse gear shims.... 6-27, 6-52 Selection ...................................................1-27 Self-diagnosis ...........................................9-19 Self-protection.......
Wiring diagram F200TR, LF200TR, F225TR, LF225TR 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U Low-pressure fuel pump Accessory battery Fuel pump driver and isolator High-pressure fuel pump Idle speed control Fuel injector Spark plug Ignition coil Intake air pressure sensor Thermoswitch Engine temperature sensor Pulser coil Stator coil Rectifier Regulator Throttle position sensor Shift cut switch Neutral switch ECM Fuse (5 A) Fuse (30 A) Fuse (20 A) Starter relay Starter motor Power trim and
YAMAHA MOTOR CORPORATION, USA Printed in USA Sep. 2003 – 0.
F200TR, LF200TR, F225TR, LF225TR 4 1 B G R/Y G/Y G/B G/R R/Y R/Y R/Y B R B G/B G 5 L H R R/Y L/R G/Y L G/B L/R R/Y R/Y R/Y R/Y R/B B R/Y R/Y G/R R/Y R/Y B G/Y R/Y B R/Y R/Y G R/Y B/W L/W R/Y L/R B B/W L R/Y B B/W L/W G/R R/Y 3 R/Y 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 B L L B L/W B L/W L R/Y : : : : : : : : : : : : : : : G Y/G P W — L/W B/Y B L/Y O O O W/G W/B W/R 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 : : : : : : : : : : : : : : : B/W L/R G/B
H 5 4 G/R G/Y G R/Y G/B R/Y R/Y R/Y R/Y R/B B B P/B Ê È É P P/W P/B P/B G P W Y Lg Sb R B Br P B R/Y R/Y B B B L B/Y B L/R 1 3 6 B/W R/Y Sb Lg Y/G P/W O Lg Sb L/W R/Y L/W W/B P B R/Y R/Y R/Y O/R O/R O/Y O/Y O/B O/B B/Y W/R W/B W/G B B B B R/Y B R/Y 3 5 6 4 R 1 R P B O B P/G 9 = R/Y R/Y B/O R/Y 8 B/W B/Y O/Y O/R R/Y O/B R/Y R/Y A B I L R N S K T U Ë ÌP L/Y B Br B B P O B P 6=EFG S60LWD02U
