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VF200

VF225
VF250
SERVICE MANUAL
6CB-28197-1M-11 LIT-18616-03-21
Preface
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 the Bronze Technical Certificate of the YTA
(Yamaha Technical Academy) marine or the equivalent 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.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual. Also, up-to-date parts information is available on YPEC-web. Additional information and
up-to-date information on Yamaha products and services are available on Yamaha Service Portal.
Important information
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
A WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
A NOTICE indicates special precautions that must be taken to avoid damages to the out-
board motor or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
VF200, VF225, VF250
SERVICE MANUAL
2009 by Yamaha Motor Corporation, U.S.A.
1st Edition, November 2009
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-18616-03-21
Contents
General information
GEN
INFO
0
Specification
SPEC
1
Technical features and description
TECH
FEA
2
Rigging information
RIG
GING
3
Troubleshooting
TRBL
SHTG
4
Electrical system ELEC
5
Fuel system
FUEL
6
Power unit
POWR
7
Lower unit LOWR
8
Bracket unit
BRKT
9
Maintenance
MNT
10
Index
Appendix
A
GEN
INFO
0
General information
Safety while working ..................................................... 0-1
Rotating part ............................................................................... 0-1
Hot part....................................................................................... 0-1
Electric shock ............................................................................. 0-1
Propeller ..................................................................................... 0-1
Handling of gasoline................................................................... 0-1
Ventilation................................................................................... 0-1
Self-protection ............................................................................ 0-2
Working with crane..................................................................... 0-2
Handling of gas torch ................................................................. 0-2
Part, lubricant, and sealant......................................................... 0-2
Handling of sealant..................................................................... 0-2
Special service tool .................................................................... 0-3
Tightening torque ....................................................................... 0-3
Non-reusable part....................................................................... 0-3
Disassembly and assembly........................................................ 0-3
How to use this manual ..................................................... 0-4
Manual format ............................................................................ 0-4
Abbreviation ............................................................................... 0-5
Lubricant, sealant, and thread locking agent .................. 0-7
Symbol ....................................................................................... 0-7
Special service tool............................................................ 0-8
0-1
GEN
INFO
General information
Safety while working
To prevent an accident or injury and to pro-
vide quality service, observe the following
safety procedures.
Rotating part
Hands, feet, hair, jewelry, clothing, per-
sonal flotation device straps, and so on,
can become entangled with internal rotating
parts of the engine, resulting in serious
injury or death.
Keep the top cowling installed whenever
possible. Do not remove or install the top
cowling when the engine is running.
Only operate the engine with the top cowl-
ing removed according to the specific
instructions in the manual. Keep hands,
feet, hair, jewelry, clothing, personal flota-
tion device straps, and so on, away from
any exposed moving parts.
Hot part
During and after operation, engine parts are
hot enough to cause burns. Do not touch any
parts under the top cowling until the engine
has cooled.
Electric shock
Do not touch any electrical parts while start-
ing or operating the engine. Otherwise, shock
or electrocution could result.
Propeller
Do not hold the propeller with your hands
when loosening or tightening the propeller
nut.
Handling of gasoline
Gasoline is highly flammable. Keep gaso-
line and all flammable products away from
heat, sparks, and open flames.
Gasoline is poisonous and can cause injury
or death. Handle gasoline with care. Never
siphon gasoline by mouth. If you swallow
some gasoline, inhale a lot of gasoline
vapor, or get some gasoline in your eyes,
see your doctor immediately. If gasoline
spills on your skin, wash with soap and
water. If gasoline spills on your clothing,
change your clothes.
Ventilation
Gasoline vapor and exhaust gas are
heavier than air and extremely poisonous.
If gasoline vapor or exhaust gas is inhaled
in large quantities, it may cause loss of con-
sciousness and death within a short time.
When test running an engine indoors (for
example, in a water tank) make sure to do
so where adequate ventilation can be main-
tained.
0-2
0
Self-protection
Protect your eyes by wearing safety
glasses or safety goggles during all opera-
tions involving drilling and grinding, or when
using an air compressor.
Protect your hands and feet by wearing
protective gloves and safety shoes when
necessary.
Working with crane
Outboard motors weighing 18.0 kg (39.7 lb)
and over must be carried by a crane.
Use the wire ropes of adequate strength,
and lift up the outboard motor using the
three point suspension.
If the outboard motor does not have three
or more points to be suspended, support it
using additional ropes or the like so that the
outboard motor can be lifted and carried in
a stable manner.
Handling of gas torch
Improper handling of a gas torch may result
in burns. For information on the proper han-
dling of the gas torch, see the operation
manual issued by the manufacturer.
When using a gas torch, keep it away from
the gasoline and oil, to prevent a fire.
Components become hot enough to cause
burns. Do not touch any hot components
directly.
Part, lubricant, and sealant
Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by
Yamaha, when servicing or repairing the out-
board motor.
Handling of sealant
Wear protective gloves to protect your skin,
when using the sealants.
See the material safety data sheet issued
by the manufacturer. Some of the sealants
may be harmful to human health.
Safety while working
0-3
GEN
INFO
General information
Special service tool
Use the recommended special service tools
to work safely, and to protect parts from dam-
age.
Tightening torque
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable part
Always use new gaskets, seals, O-rings, cot-
ter pins, and so on, when installing or assem-
bling parts.
Disassembly and assembly
Use compressed air to remove dust and dirt
during disassembly.
Apply engine oil to the contact surfaces of
moving parts before assembly.
Install bearings so that the bearing identifi-
cation mark is facing in the direction indi-
cated in the installation procedure. In
addition, make sure to lubricate the bear-
ings liberally.
Apply a thin coat of water resistant grease
to the lip and periphery of an oil seal before
installation.
Check that moving parts operate normally
after assembly.
0-4
0
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the following information as a guide for effective and quality service.
Parts are shown and detailed in an exploded diagram and are listed in the component list (see 1
in the following figure for an example page).
The component list consists of part names and quantities, as well as bolt and screw dimensions
(see 2 in the following figure).
Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication points (see 3 in the following figure).
Tightening torque specifications are provided in the exploded diagrams (see 4 in the following fig-
ure), and in the related detailed instructions. Some torque specifications are listed in stages as
torque figures or angles in degrees.
Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see 5 in the following figure for an example page).
TIP:
For troubleshooting procedures, see Chapter 4, Troubleshooting.
8-1
LOWR
Lower unit
Lower unit (regular rotation model)
U-transom model
No. Part name Qty Remarks
1 Water inlet cover (PORT) 1
2 Bolt 1 M5 40 mm
3 Gasket 2 Not reusable
4 Drain screw 1
5 Water inlet cover (STBD) 1
6 Self-locking nut 1
7 Check screw 1
8 Dowel 2
9 Plate 1
10 Rubber seal 1
11 Bolt 1 M10 45 mm
12 Grommet 1
13 Lower unit 1
14 Spacer 1
15 Propeller 1
16 Cotter pin 1 Not reusable
17 Propeller nut 1
14
20
22
1
2
22
13
15
18
16
19
17
22
21
11
12
25
26
24
6
3
7 8
9
10 8
5
4
3
23
34
33
32
31
30
29
25
35
27
28
42 N m (4.2 kgf m, 31.0 ft lb)
54 N m (5.4 kgf m, 39.8 ft lb)
47 N m (4.7 kgf m, 34.7 ft lb)
9 N m (0.9 kgf m, 6.6 ft lb)
9 N m (0.9 kgf m, 6.6 ft lb)
2.3 N m (0.23 kgf m, 1.70 ft lb)
47 N m (4.7 kgf m, 34.7 ft lb)

8-19
LOWR
Lower unit
2. Heat the installation area of the taper
roller bearing outer race in the lower case
with a gas torch, and then install the
outer race 2. NOTICE: When heating
the lower case, heat the entire
installation area evenly. Otherwise,
the paint on the lower case could be
burned.
TIP:
Do not reuse a shim if it is any deformed or
scratched.
3. While holding the special service tool 3,
strike the tool to check that the taper
roller bearing outer race is installed
properly. If a high-pitched metallic sound
is produced when the special service tool
is struck, the outer race is installed
properly.
4. Install the rollers into the needle bearing
outer race, and install the special service
tool into the needle bearing assembly 5,
and then install the needle bearing
assembly 5.
TIP:
The needle bearing contains 28 rollers.
Assembling the forward gear
Do not reuse the bearing, always replace
it with a new one.
1. Install a new taper roller bearing.
Driver rod LL 3: 90890-06605
Bearing outer race attachment 4:
90890-06658
1
2
3
3
4
4
Ball bearing attachment 6:
90890-06655
Bearing outer race puller assembly 7:
90890-06523
Bearing inner race attachment 1:
90890-06659
6
7
5
1
x
x
5
2
3
4
1
Safety while working / How to use this manual
0-5
GEN
INFO
General information
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
ABYC American Boat and Yacht Council
API American Petroleum Institute
APS Accelerator Position Sensor
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
AWG American Wire Gauge
BTDC Before Top Dead Center
C/E Check Engine
C/L Centerline
CARB California Air Resources Board
CCA Cold Cranking Ampere
DN Down side
DOHC Dual Over Head Camshaft
ECM Electronic Control Module
EPA Environmental Protection Agency
ETV Electronic Throttle Valve
EX Exhaust
EXH Exhaust
F Forward
IN Intake
INT Intake
ISC Idle Speed Control
ISO International Organization for Standardization
MCA Marine Cranking Ampere
N Neutral
OCV Oil Control Valve
PON Pump Octane Number
PCV Pressure Control Valve
PORT Port side
PTT Power Trim and Tilt
R Reverse
RC Reserve Capacity
SAE Society of Automotive Engineers
STBD Starboard side
TCI Transistor-Controlled Ignition
TDC Top Dead Center
TPS Throttle Position Sensor
UP Up side
0-6
0
VCT Variable Camshaft Timing
W/F Water in Fuel
YDIS Yamaha Diagnostic System
Abbreviation Description
How to use this manual
0-7
GEN
INFO
General information
Lubricant, sealant, and thread locking agent
Symbol
Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication
points.
Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent
and the application points.
Symbol Name Application
Yamaha 4-stroke motor oil Lubricant
Gear oil Lubricant
Water resistant grease
(Yamaha grease A)
Lubricant
Molybdenum disulfide grease Lubricant
Corrosion resistant grease
(Yamaha grease D)
Lubricant
Low temperature resistant grease
(Yamaha grease C)
Lubricant
WR-No.2 grease Lubricant
Symbol Name Application
LOCTITE 518 Sealant
ThreeBond 1280B Sealant
ThreeBond 1303 Thread locking agent
ThreeBond 1322 Sealant
ThreeBond 1377B Thread locking agent
ThreeBond 1386B Sealant
0-8
0
Special service tool
For U.S.A. and Canada
Special service tools with part numbers YB-***** are distributed by K & L.
Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.
Engine lifting eye
90890-06820
Drilling plate
90890-06783
YDIS (CD-ROM, Ver. 1.33)
60V-WS853-06
YDIS (KIT)
60V-85300-06
ThreeBond 1401 Thread locking agent
ThreeBond 1530D Sealant
LOCTITE 242 (blue) Thread locking agent
LOCTITE 271 (red) Thread locking agent
LOCTITE 572 (white) Sealant
Silicone sealant Sealant
Symbol Name Application
Lubricant, sealant, and thread locking agent / Special service tool
0-9
GEN
INFO
General information
Diagnostic test lead
YB-06795
Digital multimeter
YU-34899-A
Peak volt adapter
YU-39991
Test harness (3 pins)
YB-06869
Spark checker
YM-34487
Test harness (2 pins)
YB-06867
Pressure/vacuum tester
YB-35956-A
Test harness (3 pins)
YB-06870
Fuel pressure gauge adapter
YW-06842
Fuel pressure gauge
YB-06766
0-10
0
Compression gauge
YU-33223
Compression gauge extension
YB-06563
Universal magneto and rotor holder
YU-01235
Balance hanger
90890-06822
Primary sheave holder
YS-01880-A
Valve spring compressor
YM-04019
Valve attachment
YB-06320
Valve guide reamer
YM-01196
Valve guide remover
YB-06801
Neway valve seat kit
YB-91044
Special service tool
0-11
GEN
INFO
General information
Valve lapping tool
YM-A8998
Needle bearing installer
YB-06111
Driver handle (large)
YB-06071
Roller bearing installer/remover
YB-06432
Bearing splitter plate
YB-06219
Piston ring compressor
YM-08037
Shift rod socket
90890-06679
Ring nut wrench extension
90890-06513
Ring nut wrench 6
90890-06677
Universal puller
YB-06117
0-12
0
Bearing housing puller
YB-06207
Bearing cup installer
YB-06167
Driveshaft bearing installer
YB-06155
Forward gear needle bearing installer
YB-06261
Driveshaft needle bearing installer and
remover
YB-06196
Driveshaft bearing installer
YB-06246
Drive shaft ring nut wrench
90890-06674
Driveshaft holder
YB-06520
Bearing inner race attachment
90890-06641
Pinion gear bushing installer
YB-06029
Special service tool
0-13
GEN
INFO
General information
Backlash indicator
90890-06836
Dial indicator gauge
YU-03097
Backlash adjustment plate
YB-07003
Magnetic base stand
YU-A8438
Pinion shimming gauge
90890-06675
Pinion shimming gauge rod
90890-06676
Up relief fitting
90890-06773/06838
Hydraulic pressure gauge
90890-06776/06800
Down relief fitting
90890-06774
Trim wrench
YB-06175-1A
0-14
0
Tilt wrench
YB-06548
Special service tool
SPEC
Specification
Model feature...................................................................... 1-1
General feature .......................................................................... 1-1
Model designation ...................................................................... 1-2
Serial number ............................................................................. 1-2
Model data .......................................................................... 1-3
Dimension and weight ................................................................ 1-3
Performance............................................................................... 1-3
Power unit .................................................................................. 1-3
Lower unit ................................................................................... 1-4
Bracket unit ................................................................................ 1-4
Fuel and oil requirement............................................................. 1-4
Battery requirement .................................................................... 1-5
PTT fluid requirement ................................................................. 1-5
Electrical system technical data....................................... 1-5
Ignition timing control system..................................................... 1-5
Fuel injection control system...................................................... 1-6
Engine speed control system..................................................... 1-7
VCT system................................................................................ 1-8
PTT system................................................................................ 1-8
Charging system ........................................................................ 1-8
Starting system........................................................................... 1-9
Gauge sensor............................................................................. 1-9
Fuel system technical data ............................................. 1-10
Fuel system.............................................................................. 1-10
Power unit technical data................................................ 1-10
Power unit ................................................................................ 1-10
Cylinder head assembly........................................................... 1-11
Crankcase assembly................................................................ 1-12
Lower unit technical data................................................ 1-13
Lower unit assembly................................................................. 1-13
Bracket unit technical data ............................................. 1-14
PTT system.............................................................................. 1-14
Specified tightening torque............................................. 1-14
Rigging information .................................................................. 1-14
Fuel system.............................................................................. 1-14
Power unit ................................................................................ 1-15
Lower unit ................................................................................. 1-16
Bracket unit .............................................................................. 1-16
1
PTT unit .................................................................................... 1-17
General tightening torque ............................................... 1-17
1-1
SPEC
Specification
Model feature
General feature
VF200A, VF225A, and VF250A overall feature
Newly developed 60 V6, DOHC, 24-valve, 4-stroke 4169.0 cm
3
(254.4 cu. in) engine.
Low exhaust emissions conform to US EPA and CARB 3-STAR regulations, and permeation
emissions from exterior fuel hoses conform to EPA regulations.
aPower unit
Plastic cylinder head covers
Shimless valve lifters
Large diameter intake valve heads
Cylinder heads with integrated exhaust
cover
Crankcase with oil cooler
Crankshaft with integrated drive sprocket
Sleeveless cylinders
Compact VCT assemblies with narrow tim-
ing belt
Vapor gas treatment
bElectrical
Electronic fuel injection control
Ignition timing control
VCT control
Knock control
Engine speed control
ETV control
Fail-safe control
Water-cooled Rectifier Regulator
cUpper case
Plastic bottom cowling
Mufflerless upper case
dLower unit
Drive shaft with double taper roller bearing
Propeller shaft with 3 bearings
Skeg with trim tab function
Two propeller spacers
a
c
b
d
1-2
1
Model designation
Serial number
The outboard motor serial number is indi-
cated on a label affixed to the port clamp
bracket.
1Model name
2Approved model code
3Transom height
4Serial number
5Production model year code
1 Model description VF: 4-stroke (bass fishing)
2 Model name 250: 200/225/250
3 Transom height L: L (20 in)
4 Product generation A: A and up
VF 250 L A
1 2 3 4
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
2
3 1
4
5
Model name
Approved
model code
Starting
serial No.
VF200A 6CD 1000001
VF225A 6CC 1000001
VF250A 6CB 1000001
Model feature
1-3
SPEC
Specification
Model data
Dimension and weight
Performance
Power unit
Item Unit
Model
VF200A VF225A VF250A
Overall length mm (in) 959.0 (37.8)
Overall width mm (in) 664.0 (26.1)
Overall height
L mm (in) 1749.0 (68.9)
Boat transom height
L mm (in) 508.0 (20.0)
Weight (without propeller)
L kg (lb) 234.0 (516)
Item Unit
Model
VF200A VF225A VF250A
Maximum output
At 6000 r/min kW (HP) 147.0 (200) 165.0 (225) 184.0 (250)
Full throttle operating range r/min 50006000
Maximum fuel consumption
67.6 (71.5,
59.5)
73.7 (77.9,
64.9)
82.8 (87.5,
72.9) At 5500 r/min
L (US qt,
Imp qt)
Engine idle speed r/min 700800
Item Unit
Model
VF200A VF225A VF250A
Type 4-stroke, DOHC
Cylinder quantity V6
Total displacement cm
3
(cu. in) 4169.0 (254.4)
Bore stroke mm (in) 96.0 96.0 (3.78 3.78)
Compression ratio 10.3:1
Control system Remote control
Starting system Electric
Fuel system Fuel injection
Ignition control system TCI
Advance type Microcomputer
Maximum generator output V, A 12.0, 50.0
Spark plug LFR6A-11(NGK)
Firing order 123456 (Normal operation)
Cooling system Water
Exhaust system Propeller boss
Lubrication system Wet sump
1-4
1
Lower unit
Bracket unit
Fuel and oil requirement
Item Unit
Model
VF200A VF225A VF250A
Gear shift positions F-N-R
Gear ratio 1.75 (21/12)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction (rear view) Clockwise
Propeller mark T
Item Unit
Model
VF200A VF225A VF250A
Trim angle
At 12 boat transom degree 4 to 16
Tilt-up angle degree 66
Steering angle degree 35 + 35
Trim and tilt system PTT
Item Unit
Model
VF200A VF225A VF250A
Fuel type
Regular
unleaded
gasoline
Premium unleaded gasoline
Fuel minimum octane rating PON 87 89
Engine oil YAMALUBE 4-M FC-W oil, 4-stroke motor oil
Engine oil grade API SE, SF, SG, SH, SJ, SL
SAE 5W-30, 10W-30
Total engine oil quantity
(oil pan capacity)
L (US qt,
Imp qt)
7.1 (7.50, 6.25)
Gear oil type
YAMALUBE MARINE LOWER UNIT GEAR
LUBE HD, hypoid gear oil
Gear oil grade (*1) API GL-4, GL-5
SAE 90
Gear oil quantity
L (US qt,
Imp qt)
1.045 (1.10, 0.92)
(*1) If the recommended gear oil grades are not available, use gear oil with an API classification of
GL-5, and an SAE classification of 80W.
Model data
1-5
SPEC
Specification
Battery requirement
PTT fluid requirement
Electrical system technical data
Ignition timing control system
Item Unit
Model
VF200A VF225A VF250A
Minimum cold cranking amps
(*1)
CCA/SAE A 680.0
Minimum marine cranking amps
(*1)
MCA/ABYC A 770.0
Minimum reserve capacity (*1)
RC/SAE minutes 160
(*1) For more information about the battery requirements, see Extension length recommendation
of battery cable (3-17). The figures are for reference only.
Item Unit
Model
VF200A VF225A VF250A
Fluid type ATF DEXRON II
Item Unit
Model
VF200A VF225A VF250A
Spark plug
Gap mm (in) 1.01.1 (0.0390.043)
Pulser coil
Air gap mm (in) 0.41.1 (0.0160.043)
Resistance (*1)
At 20 C (68 F) 396.0594.0
Output peak voltage
At cranking (unloaded) V 8.8
7.7 At cranking (loaded) V
At 1500 r/min (loaded) V 19.8
At 3500 r/min (loaded) V 24.5
Knock sensor
Resistance (*1)
At 20 C (68 F) k 504.0616.0
Input voltage V 4.755.25
Air temperature sensor
Resistance (*1)
At 20 C (68 F) k 2.22.7
At 80 C (176 F) k 0.3
Input voltage V 4.755.25
1-6
1
Fuel injection control system
Air pressure sensor
Input voltage V 4.755.25
Output voltage (*1)
At 20.0 kPa (0.20
kgf/cm
2
, 2.9 psi)
V 3.2
At 46.7 kPa (0.467
kgf/cm
2
, 6.8 psi)
V 2.2
Neutral switch
Input voltage V 4.755.25
Engine temperature sensor
Resistance (*1)
At 5 C (41 F) k 4.24.9
At 25 C (77 F) k 1.92.1
At 100 C (212 F) k 0.1660.204
Thermoswitch
Temperature
Switch ON C (F) 84.090.0 (183.0194.0)
Switch OFF C (F) 68.082.0 (154.0180.0)
(*1) The figures are for reference only.
Item Unit
Model
VF200A VF225A VF250A
Fuel line
Pressure (*1)
Within 5 seconds after
engine start switch
turned to ON
kPa
(kgf/cm
2
,
psi)
300.0 (3.00, 43.5)
At 700800 r/min
kPa
(kgf/cm
2
,
psi)
260.0 (2.6037.7)
Fuel injector
Resistance (*1)
At 20 C (68 F) 11.512.5
Low-pressure fuel pump
Resistance (*1)
At 20 C (68 F) 1.34.0
High-pressure fuel pump
Resistance (*1)
At 20 C (68 F) 0.23.0
Relay
Input voltage V 12.0
Vapor shut-off valve
Resistance (*1)
At 20 C (68 F) 30.034.0
Item Unit
Model
VF200A VF225A VF250A
Model data / Electrical system technical data
1-7
SPEC
Specification
Engine speed control system
Water detection switch
Input voltage V 4.755.25
(*1) The figures are for reference only.
Item Unit
Model
VF200A VF225A VF250A
Oil pressure sensor
Input voltage V 4.755.25
Output voltage (*1)
At 450.0 kPa (4.50
kgf/cm
2
, 65.3 psi) and
60 C (140 F) with SL
10W-30 engine oil and at
750 r/min
V 2.8
APS
Resistance (*1)
With accelerator lever
fully closed
APS 1 and APS 2
At 20 C (68 F) k 0.8
With accelerator lever
fully open
APS 1 and APS 2
At 20 C (68 F) k 5.3
Output voltage (*1)
With throttle lever fully
closed
APS 1 V 0.679
APS 2 V 0.635
With throttle lever fully
open
APS 1 V 4.165
APS 2 V 4.111
TPS
Output voltage (*1)
With throttle lever fully
closed
TPS 1 V 0.732
TPS 2 V 2.715
With throttle lever fully
open
TPS 1 V 4.326
TPS 2 V 4.624
Shift cut switch
Input voltage V 4.755.25
(*1) The figures are for reference only.
Item Unit
Model
VF200A VF225A VF250A
1-8
1
VCT system
PTT system
Charging system
Item Unit
Model
VF200A VF225A VF250A
OCV
Resistance (*1)
At 20 C (68 F) 6.77.7
(*1) The figures are for reference only.
Item Unit
Model
VF200A VF225A VF250A
Trim sensor
Free position resistance (*1) 238.8378.8
Setting resistance 9.011.0
(*1) The figures are for reference only.
Item Unit
Model
VF200A VF225A VF250A
Lighting coil
Resistance (*1)
At 20 C (68 F) 0.130.20
Output peak voltage
At cranking (unloaded) V 10.9
At 1500 r/min (unloaded) V 37.2
At 3500 r/min (unloaded) V 81.4
Fuse A 60
Rectifier Regulator
Output peak voltage
At 1500 r/min (loaded) V 13.0
At 3500 r/min (loaded) V 13.0
(*1) The figures are for reference only.
Electrical system technical data
1-9
SPEC
Specification
Starting system
Gauge sensor
Item Unit
Model
VF200A VF225A VF250A
Starter motor
Type Sliding gear
Output kW 1.4
Cranking time limit second 30
Brush
Standard length mm (in) 15.5 (0.61)
Wear limit mm (in) 9.5 (0.37)
Commutator
Standard diameter mm (in) 29.0 (1.14)
Wear limit mm (in) 28.0 (1.10)
Standard undercut (*1) mm (in) 0.50.8 (0.020.03)
Wear limit mm (in) 0.2 (0.01)
(*1) The figures are for reference only.
Item Unit
Model
VF200A VF225A VF250A
Water pressure sensor
Input voltage V 4.755.25
Output voltage (*1)
At 392.0 kPa (3.92
kgf/cm
2
, 56.8 psi)
V 2.5
At 784.0 kPa (7.84
kgf/cm
2
, 113.7 psi)
V 4.5
Speed sensor
Input voltage V 4.755.25
Output voltage (*1)
At 392.0 kPa (3.92
kgf/cm
2
, 56.8 psi)
V 2.5
At 784.0 kPa (7.84
kgf/cm
2
, 113.7 psi)
V 4.5
(*1) The figures are for reference only.
1-10
1
Fuel system technical data
Fuel system
Power unit technical data
Power unit
Item Unit
Model
VF200A VF225A VF250A
Fuel filter assembly
Holding pressure
Positive pressure
kPa
(kgf/cm
2
,
psi)
200.0 (2.00, 29.0)
Negative pressure
kPa
(kgf/cm
2
,
psi)
80.0 (0.80, 11.6)
Vapor separator tank
Float height mm (in) 67.5 2.5 (2.66 0.10)
Canister
Holding pressure
kPa
(kgf/cm
2
,
psi)
19.6 (0.196, 2.8)
Vapor shut-off valve
Resistance (*1)
At 20 C (68 F) 30.034.0
(*1) The figures are for reference only.
Item Unit
Model
VF200A VF225A VF250A
Cylinder
Minimum compression
pressure (*1)
kPa
(kgf/cm
2
,
psi)
720.0 (7.20, 104.4)
Engine oil
Oil pressure (*2)
At 60 C (140 F) with SL
10W-30 engine oil and at
750 r/min
kPa
(kgf/cm
2
,
psi)
440.0 (4.40, 63.8)
At 62 C (144 F) with SL
10W-30 engine oil and at
3000 r/min
kPa
(kgf/cm
2
,
psi)
660.0 (6.60, 95.7)
Timing belt
Installation height mm (in) 2.5 (0.10)
Electrical system technical data / Fuel system technical data / Power unit technical data
1-11
SPEC
Specification
Cylinder head assembly
Replacement engine oil quantity
(at periodic maintenance)
Without oil filter replacement
L (US qt,
Imp qt)
6.4 (6.76, 5.63)
With oil filter replacement
L (US qt,
Imp qt)
6.7 (7.08, 5.90)
(*1) Measuring conditions: Ambient temperature 20 C (68 F), wide open throttle, with spark plugs
removed from all cylinders. The figures are for reference only.
(*2) For details of the checking method, see Checking the oil pressure (7-1). The figures are for
reference only.
Item Unit
Model
VF200A VF225A VF250A
Cylinder head
Warpage limit mm (in) 0.10 (0.0039)
Journal inside diameter mm (in) 25.00025.021 (0.98430.9851)
Valve stem
Diameter
Intake mm (in) 5.4775.492 (0.21560.2162)
Exhaust mm (in) 5.4645.479 (0.21510.2157)
Runout
Intake and exhaust mm (in) 0.010 (0.0004)
Valve guide
Inside diameter
Intake and exhaust mm (in) 5.5045.522 (0.21670.2174)
Valve guide clearance
Intake mm (in) 0.0120.045 (0.00050.0018)
Exhaust mm (in) 0.0250.058 (0.00100.0023)
Installation height mm (in) 11.30011.700 (0.44490.4606)
Valve spring
Free length mm (in) 48.1 (1.89)
Tilt limit mm (in) 1.7 (0.07)
Valve lifter
Outside diameter mm (in) 30.97030.980 (1.2191.220)
Valve lifter clearance mm (in) 0.0200.055 (0.00080.0022)
Camshaft
Cam lobe height
Intake mm (in) 46.66146.761 (1.83701.8410)
Exhaust mm (in) 46.96047.060 (1.84881.8528)
Cam lobe width
Intake and exhaust mm (in) 35.95036.050 (1.41541.4193)
Journal diameter mm (in) 24.96024.980 (0.98270.9835)
Runout mm (in) 0.030 (0.0012)
Item Unit
Model
VF200A VF225A VF250A
1-12
1
Crankcase assembly
Valve
Clearance
Intake mm (in) 0.205 0.035 (0.0081 0.0014)
Exhaust mm (in) 0.345 0.035 (0.0136 0.0014)
Head diameter
Intake mm (in) 38.40038.600 (1.51181.5197)
Exhaust mm (in) 32.90033.100 (1.29531.3031)
Seat contact width
Intake mm (in) 1.1001.400 (0.04330.0551)
Exhaust mm (in) 1.4001.700 (0.05510.0669)
Margin thickness
Intake mm (in) 0.7501.150 (0.02950.0453)
Exhaust mm (in) 0.9001.300 (0.03540.0512)
Item Unit
Model
VF200A VF225A VF250A
Cylinder
Bore mm (in) 96.00096.012 (3.77953.7800)
Piston
Diameter mm (in) 95.94595.960 (3.77743.7779)
Measuring point mm (in) 13.500 (0.5315)
Piston clearance mm (in) 0.0400.067 (0.00160.0026)
Ring groove (top) mm (in) 1.2301.250 (0.04840.0492)
Ring groove (2nd) mm (in) 1.2201.240 (0.04800.0488)
Ring groove (oil) mm (in) 2.5102.530 (0.09880.0996)
Pin boss inside diameter mm (in) 22.01122.018 (0.86660.8668)
Pin outside diameter mm (in) 21.99622.005 (0.86600.8663)
Piston ring
Top ring
Type Barrel
Dimension height (B) mm (in) 1.200 (0.0472)
Dimension width (T) mm (in) 2.8003.000 (0.11020.1181)
End gap (*1) mm (in) 0.2000.300 (0.00790.0118)
Side clearance mm (in) 0.0300.050 (0.00120.0020)
2nd ring
Type Taper
Dimension height (B) mm (in) 1.1701.190 (0.04610.0469)
Dimension width (T) mm (in) 3.8004.000 (0.14960.1575)
End gap (*1) mm (in) 0.6000.750 (0.02360.0295)
Side clearance mm (in) 0.0300.070 (0.00120.0028)
Oil ring
Dimension height (B) mm (in) 2.4002.470 (0.09450.0972)
Dimension width (T) mm (in) 2.3502.750 (0.09250.1083)
End gap (*1) mm (in) 0.1500.600 (0.00590.0236)
Side clearance mm (in) 0.0400.130 (0.00160.0051)
Item Unit
Model
VF200A VF225A VF250A
Power unit technical data
1-13
SPEC
Specification
Lower unit technical data
Lower unit assembly
Connecting rod
Small end inside diameter mm (in) 22.01022.024 (0.86650.8671)
Big end inside diameter mm (in) 55.99056.010 (2.20432.2051)
Big end side clearance (*1) mm (in) 0.1400.310 (0.00550.0122)
Oil clearance (*1) mm (in) 0.0250.050 (0.00100.0020)
Crankshaft
Journal diameter mm (in) 72.97672.996 (2.87312.8739)
Crankpin diameter mm (in) 52.98053.000 (2.08582.0866)
Runout mm (in) 0.030 (0.0012)
Crankpin width mm (in) 21.00021.100 (0.82680.8307)
Crankcase
Oil clearance (*1) mm (in) 0.0290.045 (0.00110.0018)
Thrust bearing thickness mm (in) 1.8951.945 (0.07460.0766)
Thermostat
Valve opening temperature C (F) 58.062.0 (136.0144.0)
Valve opening stroke mm (in) 1.5 (0.06)
Fully open temperature C (F) 70.0 (158.0)
Fully open stroke mm (in) 4.3 (0.17)
(*1) The figures are for reference only.
Item Unit
Model
VF200A VF225A VF250A
Lower unit
Holding pressure
kPa
(kgf/cm
2
,
psi)
68.6 (0.686, 9.9)
Forward gear backlash (*1) mm (in) 0.120.51 (0.00470.0201)
Reverse gear backlash (*1) mm (in) 0.220.81 (0.00870.0319)
Pinion shim (T3) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shim (T1) mm 2.00, 2.03, 2.06, 2.09, 2.12, 2.15
Reverse gear shim (T2) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Propeller shaft shim (T4) mm 0.7, 0.8, 0.9, 1.0, 1.1, 1.2
Propeller shaft
Free play mm (in) 0.250.35 (0.00980.0138)
Runout mm (in) 0.02 (0.0008)
Drive shaft
Runout mm (in) 1.0 (0.0394)
(*1) Figures obtained using the special service tools.
Item Unit
Model
VF200A VF225A VF250A
1-14
1
Bracket unit technical data
PTT system
Specified tightening torque
Rigging information
Fuel system
Item Unit
Model
VF200A VF225A VF250A
PTT
Hydraulic pressure (*1)
Down
MPa
(kgf/cm
2
,
psi)
5.98.8 (59.088.0, 855.51276.0)
Up
MPa
(kgf/cm
2
,
psi)
9.811.8 (98.0118.0, 1421.01711.0)
Motor brush
Standard length mm (in) 9.8 (0.39)
Wear limit mm (in) 4.8 (0.19)
Motor commutator
Standard diameter mm (in) 22.0 (0.87)
Wear limit mm (in) 21.0 (0.83)
Standard undercut (*1) mm (in) 1.4 (0.06)
Wear limit mm (in) 0.9 (0.04)
(*1) The figures are for reference only.
Part to be tightened Screw size
Tightening torques
Nm kgfm ftlb
Engine lifting eye bolt 36 3.6 26.6
Shift cable locknut 5 0.5 3.7
Throttle cable locknut 5 0.5 3.7
Water pressure sensor adapter 23 2.3 17.0
Water pressure sensor 19 1.9 14.0
Connector bolt M6 23 2.3 17.0
Speed sensor 18 1.8 13.3
Part to be tightened Screw size
Tightening torques
Nm kgfm ftlb
Fuel cup assembly 5 0.5 3.7
Intake manifold bolt
1st
M6
11 1.1 8.1
2nd 11 1.1 8.1
Intake manifold bolt
1st
M8
24 2.4 17.7
2nd 24 2.4 17.7
Surge tank bracket bolt M6 11 1.1 8.1
Low-pressure fuel pump cover bolt M6 5 0.5 3.7
Vapor separator drain screw 2 0.2 1.5
Cover screw M4 2 0.2 1.5
Needle valve screw M4 2 0.2 1.5
Float pin screw M4 2 0.2 1.5
Power unit technical data / Lower unit technical data /
Bracket unit technical data / Specified tightening torque
1-15
SPEC
Specification
Power unit
Float chamber cover screw M4 2 0.2 1.5
Pressure regulator screw M5 4 0.4 3.0
Fuel cooler cover screw M5 4 0.4 3.0
Part to be tightened Screw size
Tightening torques
Nm kgfm ftlb
Spark plug 28 2.8 20.7
Pulser coil bolt M5 4 0.4 3.0
Flywheel magnet bolt
1st
M10
40 4.0 29.5
2nd 90
Timing belt tensioner bolt 39 3.9 28.8
Timing belt pulley bolt M10 39 3.9 28.8
Fuse holder screw 5 2 0.2 1.5
PTT relay bolt M6 5 0.5 3.7
Starter motor lead nut 9 0.9 6.6
Rectifier Regulator bolt
1st
M6
6 0.6 4.4
2nd 12 1.2 8.9
Rectifier Regulator cover bolt
1st
M6
6 0.6 4.4
2nd 12 1.2 8.9
Starter motor bracket bolt M8 25 2.5 18.4
Starter motor bracket bolt M6 12 1.2 8.9
Starter motor bolt M8 30 3.0 22.1
ECM bolt M6 7 0.7 5.2
Power unit mounting bolt
1st
M10
42 4.2 31.0
2nd 42 4.2 31.0
Apron screw M6 3 0.3 2.2
Camshaft cap bolt
1st
M7
8 0.8 5.9
2nd 17 1.7 12.5
Driven sprocket bolt M10 60 6.0 44.3
VCT cap 32 3.2 23.6
VCT bolt M12 60 6.0 44.3
OCV bolt M6 7 0.7 5.2
Cylinder head bolt
1st
M11
39 3.9 28.8
2nd 90
3rd 90
Cylinder head bolt
1st
M8
14 1.4 10.3
2nd 28 2.8 20.7
Exhaust guide plug M18 55 5.5 40.6
Water pressure sensor joint plug M14 23 2.3 17.0
Oil pump cover screw M6 4 0.4 3.0
Oil cooler bolt
1st
M6
6 0.6 4.4
2nd 12 1.2 8.9
Oil filter 18 1.8 13.3
Oil filter bracket bolt M6 12 1.2 8.9
Oil filter union bolt UNF 49 4.9 36.1
Oil pressure sensor 13 1.3 9.6
Part to be tightened Screw size
Tightening torques
Nm kgfm ftlb
1-16
1
Lower unit
Bracket unit
Thermostat housing bolt M6 12 1.2 8.9
Thermostat cover bolt M6 12 1.2 8.9
Knock sensor bracket bolt M6 12 1.2 8.9
Knock sensor 32 3.2 23.6
Timing belt pulley bracket bolt
1st
M8
14 1.4 10.3
2nd 28 2.8 20.7
Connecting rod bolt
1st
M9
40 4.0 29.5
2nd 90
Crankcase bolt
1st
M10
55 5.5 40.6
2nd 90
Crankcase bolt
1st
M8
14 1.4 10.3
2nd 28 2.8 20.7
Part to be tightened Screw size
Tightening torques
Nm kgfm ftlb
Stud bolt 20 2.0 14.8
Lower case mounting nut 47 4.7 34.7
Lower case mounting bolt M10 47 4.7 34.7
Cover bolt M10 42 4.2 31.0
Propeller nut 54 5.4 39.8
Check screw 9 0.9 6.6
Inlet cover bolt M5 2 0.2 1.5
Drain screw 9 0.9 6.6
Ring nut 125 12.5 92.2
Drive shaft nut 39 3.9 28.8
Ring nut 177 17.7 130.5
Pinion nut 142 14.2 104.7
Part to be tightened Screw size
Tightening torques
Nm kgfm ftlb
Shift rod detent bolt 18 1.8 13.3
Shift bracket bolt 19 1.9 14.0
Neutral switch screw M4 2 0.2 1.5
Shift cut switch screw M4 2 0.2 1.5
Grease nipple 1 0.1 0.7
Hose joint adapter screw 6 4 0.4 3.0
Bracket bolt M10 54 5.4 39.8
Upper case bolt M10 42 4.2 31.0
Upper case bolt M8 20 2.0 14.8
Anode screw M6 4 0.4 3.0
Engine oil drain bolt M14 27 2.7 19.9
Oil strainer bolt M6 12 1.2 8.9
Exhaust manifold bolt M8 20 2.0 14.8
Oil pan bolt M8 20 2.0 14.8
Plate bolt M8 20 2.0 14.8
Part to be tightened Screw size
Tightening torques
Nm kgfm ftlb
Specified tightening torque
1-17
SPEC
Specification
PTT unit
General tightening torque
This chart indicates the tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifications
for special components and assemblies are
provided in the applicable sections of this
manual. To prevent warpage, tighten multi-
fastener assemblies in a crisscross fashion
and progressive stages until the specified
torque is reached. Unless otherwise indi-
cated, torque specifications require clean, dry
threads.
Components should be at room temperature.
Grease nipple 3 0.3 2.2
Trim sensor screw M6 4 0.4 3.0
Ground lead screw M6 4 0.4 3.0
Plate screw M6 4 0.4 3.0
Self-locking nut 22 2.2 16.2
Holder screw M6 4 0.4 3.0
Part to be tightened Screw size
Tightening torques
Nm kgfm ftlb
Lower mounting shaft bolt M10 54 5.4 39.8
Reservoir cap 2 0.2 1.5
Manual valve 3 0.3 2.2
PTT motor mounting bolt M6 5 0.5 3.7
Reservoir bolt M6 5 0.5 3.7
Gear pump housing bolt M8 8 0.8 5.9
Gear pump cover bolt M5 6 0.6 4.4
Tilt piston nut 96 9.6 70.8
Filter plug 6 0.6 4.4
Trim cylinder end screw 140 14.0 103.3
Tilt cylinder end screw 127 12.7 93.7
Part to be tightened Screw size
Tightening torques
Nm kgfm ftlb
Width
across
flats (A)
Screw
size (B)
General torque
specifications
Nm kgfm ftlb
8 mm M5 5 0.5 3.7
10 mm M6 8 0.8 5.9
12 mm M8 18 1.8 13.3
14 mm M10 36 3.6 26.6
17 mm M12 43 4.3 31.7
1-18
1
MEMO
Specified tightening torque / General tightening torque
TECH
FEA
Technical features and description
Electronic control system................................................. 2-1
Engine ECM component ............................................................ 2-2
Sensor, switch, and actuator ...................................................... 2-3
Electronic fuel injection control ................................................... 2-4
Synchronous fuel injection ............................................................. 2-5
Asynchronous fuel injection ........................................................... 2-5
Fuel injection control mode ............................................................ 2-5
Fuel injection amount compensation.............................................. 2-6
Fuel injector anti-sticking control .................................................... 2-6
Ignition timing control ................................................................. 2-7
Ignition coil energization time......................................................... 2-8
Basic ignition timing ....................................................................... 2-8
Ignition timing restriction ................................................................ 2-8
Ignition timing compensation.......................................................... 2-8
VCT control ................................................................................ 2-9
Control system............................................................................. 2-10
Construction and operation of the VCT assembly........................ 2-11
Construction and operation of the OCV....................................... 2-11
Advanced timing........................................................................... 2-12
Retarded timing............................................................................ 2-13
Maintained timing......................................................................... 2-14
Knock control............................................................................ 2-15
Engine speed control................................................................ 2-16
Overheat control........................................................................... 2-16
Low oil pressure control ............................................................... 2-16
Skip-firing control ......................................................................... 2-17
ETV control............................................................................... 2-18
Control system............................................................................. 2-19
Throttle valve opening learning.................................................... 2-19
ISC function.................................................................................. 2-19
Fail-safe control ........................................................................ 2-20
Power unit system ........................................................... 2-21
Shimless valve lifter.................................................................. 2-22
Crankcase ................................................................................ 2-23
Crankshaft ................................................................................ 2-24
Sleeveless cylinder................................................................... 2-24
Fuel system ...................................................................... 2-25
Fuel diagram ............................................................................ 2-25
Vapor gas treatment ................................................................. 2-27
Lubrication system.......................................................... 2-28
Lubrication diagram.................................................................. 2-28
Cooling system ................................................................ 2-29
Cooling diagram....................................................................... 2-29
2
Intake and exhaust system ............................................. 2-31
Intake and exhaust diagram..................................................... 2-31
Mufflerless upper case ............................................................. 2-32
PTT unit ............................................................................. 2-33
Trim-up and tilt-up function....................................................... 2-33
Trim ram retraction function ..................................................... 2-34
Trim-down and tilt-down function ............................................. 2-35
Stationary condition.................................................................. 2-36
When the outboard motor hits something in the water............. 2-36
Lower unit ......................................................................... 2-37
Double taper roller bearing....................................................... 2-37
Propeller shaft bearing ............................................................. 2-37
Thrust power train .................................................................... 2-38
Skeg design.............................................................................. 2-39
Propeller spacer ....................................................................... 2-39
2-1
TECH
FEA
Technical features and description
Electronic control system
The VF200A, VF225A, and VF250A use electronic fuel injection control, ignition timing control, VCT
control, knock control, engine speed control, ETV control, and fail-safe control. The engine ECM
performs these controls according to the signals sent from various sensors and switches.
In addition, the engine ECM has a self-diagnosis function to perform troubleshooting using the
YDIS.
The Command Link Multifunction Meter can be installed as an option.
Air
Check valve
Filter
High-pressure
fuel pump
Vapor separator
Check valve
Low-pressure fuel pump
Canister
Water separator
Fuel
Water
detection
switch
OCV
Fuel injector
Vapor shut-off
valve
TPS
ETV
Air
OCV
Ignition
coil
Throttle control
Valve control
Fuel control
Ignition control
Battery
Engine
ECM
Cam position sensor
Pulser coil
Air pressure sensor
Oil pressure sensor
Engine temperature sensor
Air temperature sensor
Knock sensor
APS
Shift cut switch
Neutral switch
Thermoswitch
Engine shut-off switch
Water pressure sensor (optional)
Speed sensor (optional)
Ignition
coil
Fuel injector
Command
Link Multi-
function
Meter
2-2
2
Engine ECM component
1ETV
2Air pressure sensor
3Air temperature sensor
4Pulser coil
5Engine temperature sensor
6Vapor shut-off valve
7Thermoswitch (PORT)
8OCV (PORT)
9Cam position sensor (PORT IN)
0Fuel injector (PORT)
AHigh-pressure fuel pump
BLow-pressure fuel pump
CTPS
DOCV (STBD)
EThermoswitch (STBD)
FCam position sensor (STBD IN)
GAPS
HNeutral switch
IShift cut switch
JOil pressure sensor
KFuel injector (STBD)
LIgnition coil (STBD)
MKnock sensor
NEngine ECM
OIgnition coil (PORT)
PCam position sensor (PORT EX)
1
2
3
5 6
4 7
8
9
0
A B C
O
P
L K
G
H
I
J
E
F
D
N
M
Electronic control system
2-3
TECH
FEA
Technical features and description
Sensor, switch, and actuator
Engine ECM Determines the engine operating conditions according to the input
signals from the sensors, which are installed at various locations on
the engine, and sends output signals to operate the actuators to
perform the various control functions.
Performs troubleshooting using a self-diagnosis function.
Pulser coil Detects the engine speed.
Detects the crankshaft angle and piston positions.
Determines each group of cylinders (#1 and #4, #2 and #5, and #3
and #6).
Cam position sensor
(PORT EX)
Determines the stroke. (For example, distinguishes the
compression stroke TDC from the exhaust stroke TDC.)
Determines each group of cylinders (#1 and #4, #2 and #5, and #3
and #6).
Determines the stroke of each cylinder according to the signals from
both the pulser coil and the cam position sensor (PORT EX).
Cam position sensor
(PORT IN)
Detects the advance angle on the port camshaft.
Cam position sensor
(STBD IN)
Detects the advance angle on the starboard camshaft.
APS 1 Detect the throttle opening. APS 1 is the main sensor and APS 2 is
the sub sensor. APS 1 and APS 2 mutually monitor each other for
malfunctions.
APS 2
TPS 1 Detect the throttle valve opening. TPS 1 is the main sensor and
TPS 2 is the sub sensor. TPS 1 and TPS 2 mutually monitor each
other for malfunctions.
TPS 2
ETV Opens and closes the throttle valve using a motor.
Air pressure sensor Detects the intake air pressure.
Air temperature sensor Detects the intake air temperature.
Engine temperature
sensor
Detects the engine temperature.
Oil pressure sensor Detects the oil pressure.
Thermoswitch Detects engine overheating.
Knock sensor Detects engine knocking.
Shift cut switch Detects when the gear shift moves to the N position.
Neutral switch Detects when the gear shift is in the N position.
Engine shut-off switch Activates the engine stop function compulsorily.
Fuel injector Injects fuel.
Ignition coil Activates the ignition.
Vapor shut-off valve Controls the amount of vapor gas to be sent from the vapor
separator to the intake system.
OCV Advances or retards the camshaft timing by switching the oil
passages through which the engine oil is sent into the advance
chamber or the retard chamber in the rotor vane housing.
High-pressure fuel pump Pressurizes the fuel in the vapor separator, and sends the fuel to
the fuel rails.
Low-pressure fuel pump Sends the fuel from the fuel tank to the vapor separator.
2-4
2
Electronic fuel injection control
In electronic fuel injection control, the engine ECM determines the fuel injection timing and fuel
injection amount according to the signals from the sensors and performs the appropriate fuel injec-
tion. The fuel injection amount is controlled by the fuel injector actuation time. There are 2 types of
fuel injection timing control: synchronous fuel injection and asynchronous fuel injection. According
to the engine operating conditions during the control, the control mode switches automatically
between the start-up mode, normal operating mode, and fuel injection cutoff mode. In addition, vari-
ous compensations are made to determine the actual fuel injection timing and fuel injection amount.
Also, a fuel injector anti-sticking control has been adopted.
Pulser coil
Cam position sensor
(PORT EX)
Cam position sensor
(PORT IN)
Cam position sensor
(STBD IN)
APS
TPS
Air pressure sensor
Air temperature sensor
Engine temperature sensor
Thermoswitch
Engine shut-off switch
Battery
Engine
ECM
Fuel injector
High-pressure
fuel pump
Low-pressure
fuel pump
Vapor shut-off
valve
Electronic control system
2-5
TECH
FEA
Technical features and description
Synchronous fuel injection
Synchronous fuel injection is fuel injection that occurs using a fixed timing, which is synchronized
with the crankshaft angle set by the engine ECM according to the signals from the pulser coil.
Asynchronous fuel injection
Asynchronous fuel injection is fuel injection that occurs using the timing determined necessary by
the engine ECM according to the signals from the sensors, not synchronized with the crankshaft
angle set by the engine ECM. At engine start-up or during acceleration, if the changes in the signals
from the TPS or air pressure sensor exceed a predetermined level, fuel injection is performed simul-
taneously for all of the cylinders.
Fuel injection control mode
In the start-up mode, the engine ECM performs fuel injection simultaneously for all of the cylinders
until the cylinder identification is completed. After that, the engine ECM performs fuel injection for
each cylinder group until the engine starting is detected.
In the normal operating mode after the engine is started, the engine ECM performs fuel injection for
each cylinder group until the cylinder identification is completed. After that, the engine ECM per-
forms sequential fuel injection for each cylinder.
In the fuel injection cutoff mode, the fuel injection is cut off while the engine speed control is per-
formed. See Engine speed control (2-16).
Fuel injection
type
Fuel injection timing Fuel injection amount Condition
Simultaneous
fuel injection
All cylinders according to
the fuel injection setting
data
According to the fuel
injection setting data when
the engine temperature is
7880 C or more and the
fuel injection setting data
when the engine
temperature is less than
7880 C
Until cylinder
identification is
completed by the
pulser coil
Group fuel
injection
Each cylinder group (#1
and #4, #2 and #5, and #3
and #6) at BTDC 430
(BTDC 70 according to
the exhaust TDC)
Until engine starting
is detected
(500 r/min or more)
Fuel injection
type
Fuel injection timing Fuel injection amount Condition
Group fuel
injection
Each cylinder group (#1
and #4, #2 and #5, and #3
and #6) according to the
exhaust and compression
TDCs
According to the fuel
injection setting data for
the fuel octane rating and
the knock learning value,
which are recorded in the
engine ECM
Until cylinder
identification is
completed by the
cam position sensor
(PORT EX)
2 times for every 2 turns of
the crankshaft
Sequential fuel
injection
Each cylinder according to
the injection completion
timing, which is set using
the exhaust TDC
After cylinder
identification is
completed by the
cam position sensor
(PORT EX)
2-6
2
Fuel injection amount compensation
The fuel injection control makes compensations to the fuel injection amount according to the engine
operating conditions. The compensations are determined according to the signals from the following
sensors.
Fuel injector anti-sticking control
Immediately after the engine start switch is turned to ON and before the high-pressure fuel pump
starts operating, the engine ECM sends a signal once to actuate all of the fuel injectors simulta-
neously to prevent the fuel injector valves from sticking.
Compensation Corresponding sensor
For changes in intake air pressure Air pressure sensor
For changes in intake air temperature Air temperature sensor
During warm-up Engine temperature sensor
After start-up Engine temperature sensor
For atmospheric pressure Air pressure sensor
During dashpot function operation Air pressure sensor, APS, neutral switch, and
pulser coil
For changes in air and fuel ratio Air pressure sensor, engine temperature
sensor, and pulser coil
During acceleration Air pressure sensor and TPS
For retarded ignition timing Engine temperature sensor and pulser coil
Electronic control system
2-7
TECH
FEA
Technical features and description
Ignition timing control
In ignition timing control, the engine ECM determines the optimum ignition timing according to the
signals from the sensors and sends the primary current to the ignition coils. According to the engine
operating conditions, the basic ignition timing and ignition coil energization time are determined. In
addition, various restrictions and compensations are made to determine the actual ignition timing.
The ignition timing is also controlled according to the knock control. See Knock control (2-15).
Pulser coil
Cam position sensor
(PORT EX)
Cam position sensor
(PORT IN)
Cam position sensor
(STBD IN)
APS
TPS
Air pressure sensor
Engine temperature
sensor
Battery
Engine
ECM
Ignition coil
Knock sensor
Neutral switch
Shift cut switch
2-8
2
Ignition coil energization time
The time that the ignition coil is energized with the primary current is controlled according to the
engine speed and the battery voltage sent to the ignition coil.
Basic ignition timing
The basic ignition timing is divided into 3 types: engine starting ignition timing, idling basic ignition
timing, and normal basic ignition timing.
Ignition timing restriction
The advancing or retarding of the ignition timing is restricted according to the engine speed, engine
temperature, and dashpot function.
Ignition timing compensation
The ignition timing control makes advance or retard compensations to the ignition timing according
to the engine operating conditions. The compensations are determined according to the signals
from the following sensors.
Basic ignition timing Criteria Ignition cylinder
Engine starting ignition timing
(BTDC 10)
Engine is starting (less than
500 r/min)
All cylinders simultaneously
Idling basic ignition timing Engine speed is at engine idle
speed
Each cylinder sequentially
Normal basic ignition timing Engine speed is more than
engine idle speed
Each cylinder sequentially
Restriction Corresponding sensor Details
Engine speed
restriction
Pulser coil The ignition timing is restricted
between BTDC 50 (advance angle)
and ATDC 20 (retard angle)
according to the engine speed.
Engine temperature
restriction
Engine temperature sensor The ignition timing is restricted
between BTDC 50 (advance angle)
and ATDC 30 (retard angle)
according to the engine temperature.
Dashpot function
restriction
Pulser coil and APS The ignition timing is restricted to
ATDC 20 when the dashpot function
operates.
Compensation Corresponding sensor
After start-up Engine temperature sensor
For stable idle speed APS and pulser coil
During dashpot function operation APS, neutral switch, and pulser coil
For shift-cutout control Pulser coil and shift cut switch
During acceleration Air pressure sensor and TPS
Electronic control system
2-9
TECH
FEA
Technical features and description
VCT control
In VCT control, the engine ECM determines the appropriate intake valve opening timing according
to the signals from the sensors. According to the engine operating conditions, the OCVs are oper-
ated and the VCT assemblies are advanced, retarded, or maintained in the current position to con-
trol the intake valve opening timing.
Pulser coil
Cam position sensor
(PORT EX)
Cam position sensor
(PORT IN)
Cam position sensor
(STBD IN)
APS
TPS
Engine temperature sensor
Engine
ECM
OCV (PORT)
Air pressure sensor
OCV (STBD)
2-10
2
Control system
In VCT control, the engine ECM determines the appropriate intake valve opening timing according
to the engine speed, ETV opening, and engine temperature. The engine ECM also detects the
actual camshaft advance position using the exhaust and intake cam position sensors, and performs
feedback control of the OCV to make the camshaft advance position closer to the target camshaft
advance position.
The OCV receives the signal from the engine ECM and sends the engine oil to the advance cham-
ber or retard chamber located in the rotor vane housing by switching the oil passage leading to each
chamber. Then, the rotor vane is driven by the engine oil pressure, advancing or retarding the angle
of the camshaft onto which the rotor vane is installed.
Engine oil flow
(PORT EX) (PORT IN) (STBD IN)
Camshaft
Cam position
sensor
Engine
temperature
sensor Pulser coil
TPS
Engine
ECM
Advance and
retard directions
Camshaft
Advance and
retard directions
Camshaft
Cam position
sensor
Cam position
sensor
Advance Retard Retard Advance
OCV OCV
Oil filter Oil pump
Oil pan
Actuation signal

Electronic control system


2-11
TECH
FEA
Technical features and description
Construction and operation of the VCT assembly
The VCT assembly consists of a rotor vane and rotor vane housing. The engine ECM operates the
OCV according to the signals from the sensors. The OCV continuously varies the intake camshaft
advance position by controlling the oil pressure in the 2 oil pressure chambers (the advance cham-
ber and retard chamber) to move the rotor vane relative to the rotor vane housing in the circumfer-
ential direction. The appropriate intake valve opening timing is obtained through this process. At
engine start-up when the engine oil pressure is low, the rotor vane is locked to the rotor vane hous-
ing using a lock pin. As the engine speed increases after the start-up, the oil pressure increases and
is exerted on the lock pin. As a result, the lock pin spring is compressed to release the lock pin.
Construction and operation of the OCV
The OCV changes the spool valve position according to the signals from the engine ECM to switch
the oil passage leading to the VCT assembly.
Rotor vane housing
Retard direction
Advance direction
Intake camshaft
Lock pin
Oil pressure chamber
Rotor vane
Lock pin
Spring force
Lock pin
Spring force
Oil pressure
When engine is stopped When engine is running
Coil spring Spool valve
Magnetic coil
Return to oil pan
Advance oil flow
Oil supply
Retard oil flow
2-12
2
Advanced timing
The OCV is activated according to the signals from the engine ECM to slide the spool valve toward
the coil spring. The engine oil is sent to the passage leading to the advance chamber. As the engine
oil pressure is exerted on the advance chamber, the rotor vane turns in the advance direction. As a
result, the intake camshaft is turned in the advance direction because it is secured to the rotor vane
using a bolt. The engine oil in the retard chamber returns to the oil pan through the spool valve.
Engine
ECM
Oil supply
Advance oil flow
Return to oil pan
Coil spring
Spool valve
Advance chamber
Rotor vane
Electronic control system
2-13
TECH
FEA
Technical features and description
Retarded timing
The OCV is activated according to the signals from the engine ECM to slide the spool valve toward
the magnetic coil. The engine oil is sent to the passage leading to the retard chamber. As the engine
oil pressure is exerted on the retard chamber, the rotor vane turns in the retard direction. As a result,
the intake camshaft is turned in the retard direction because it is secured to the rotor vane using a
bolt. The engine oil in the advance chamber returns to the oil pan through the spool valve.
Retard chamber
Engine
ECM
Oil supply
Retard oil flow
Return to
oil pan
Magnetic coil
Spool
valve
Rotor vane
2-14
2
Maintained timing
The engine ECM calculates the target camshaft timing according to the engine operating conditions,
and performs the control accordingly. Once the target camshaft timing is obtained, the spool valve
closes the engine oil passages to maintain the camshaft timing.
Engine
ECM
Oil supply
Retard chamber
Spool valve
Advance chamber
Electronic control system
2-15
TECH
FEA
Technical features and description
Knock control
In knock control, the engine ECM receives the knock signal from the knock sensor, which is
installed on the cylinder block between the cylinder banks. The engine ECM retards the ignition tim-
ing and decreases the engine speed according to the amount of knocking to protect the engine from
damage.
If the knocking occurs frequently, the ignition timing is retarded until the knocking is no longer
detected, and the retarded ignition timing is maintained.
Also, a learning function for the knock control has been adopted.
The knock control activates according to the following conditions:
The knock control also activates when the engine temperature sensor is malfunctioning regardless
of the preceding conditions.
Engine
temperature
Engine speed
Less than 20 C
(68 F)
2025 C (6877 F)
More than 25 C
(77 F)
Less than 4500 r/min Knock control does
not activate
Knock control
activates if conditions
continue for 0.5
second
Knock control
activates
4500 r/min or more Knock control
activates
2-16
2
Engine speed control
In engine speed control, the engine ECM decreases the engine speed to protect the engine from
damage.
Overheat control
Low oil pressure control
Criteria Description
The thermoswitch is on or the
engine temperature is 150 C
(302 F) or more.
The engine ECM controls the throttle valve opening. As a
result, the engine speed cannot increase to more than 2000
3000 r/min. Also, the alert buzzer sounds and the overheat
alert indicator comes on.
Criteria Description
The pressure decreases to less
than the specified value for the
engine speed range.
The engine ECM controls the throttle valve opening. As a
result, the engine speed cannot increase to more than 2000
3000 r/min. Also, the alert buzzer sounds and the oil pressure
alert indicator comes on.
Pulser coil
Cam position sensor
(PORT EX)
Cam position sensor
(PORT IN)
Cam position sensor
(STBD IN)
APS
TPS
Engine temperature
sensor
Thermoswitch
Engine shut-off switch
Engine
ECM
Fuel injector
Oil pressure sensor
Shift cut switch
Ignition coil
ETV motor
Command Link
Multifunction Meter
Air pressure sensor
Electronic control system
2-17
TECH
FEA
Technical features and description
Skip-firing control
Criteria Description
ETV is locked in
an open position.
Controls the
engine speed
when it has been
determined that
the ETV is locked
in an open
position.
Over 1501 r/min Firing and fuel injection will be
skipped for all of the cylinders.
13991500 r/min Firing and fuel injection will be
skipped for cylinders #1, #2, #3, #5,
and #6.
13021398 r/min Firing and fuel injection will be
skipped for cylinders #2, #3, #5,
and #6.
12001301 r/min Firing and fuel injection will be
skipped for cylinders #2, #3, and
#5.
11031199 r/min Firing and fuel injection will be
skipped for cylinders #2 and #5.
10011102 r/min Firing and fuel injection will be
skipped for cylinder #2.
Engine is
overrevving.
Controls the
engine speed
when overrevving
is detected.
Over 6450 r/min Firing and fuel injection will be
skipped for all of the cylinders.
63996449 r/min Firing and fuel injection will be
skipped for cylinders #1, #2, #3, #5,
and #6.
63536398 r/min Firing and fuel injection will be
skipped for cylinders #2, #3, #5,
and #6.
63026352 r/min Firing and fuel injection will be
skipped for cylinders #2, #3, and
#5.
62516301 r/min Firing and fuel injection will be
skipped for cylinders #2 and #5.
62006250 r/min Firing and fuel injection will be
skipped for cylinder #2.
Engine is rotating
in reverse.
Stops the engine
if the engine
reverse rotation is
detected.
Engine reverse rotation is determined using 2
parameters: presence or absence of the cam position
sensor (PORT EX) signal, and the actual advance angle
of the intake camshaft.
If the reverse rotation is detected, the engine ECM cuts
off the fuel injection and ignition to stop the engine.
Shift-cutout
control is
activated.
Detects the
activation of shift-
cutout control,
and controls the
engine speed.
Decreases the engine speed to the extent that the gear
shift can be disengaged safely.
Engine shut-off
switch is on.
Cancels the fuel injection control and ignition control at all of the cylinders.
2-18
2
ETV control
In ETV control, the engine ECM determines the appropriate throttle valve opening according to the
signals from the sensors, and controls the throttle valve. The engine ECM is equipped with a learn-
ing function that records all of the compensations made by the control to the throttle valve opening
for the operating conditions up to that point. In addition, the engine idle speed is controlled using the
ETV control.
Pulser coil
Engine temperature
sensor
Thermoswitch
TPS
APS
Neutral switch
Shift cut switch
ETV motor
Engine
ECM
Air pressure sensor
Electronic control system
2-19
TECH
FEA
Technical features and description
Control system
The APS detects the amount of movement of the remote control lever by the operator, and sends a
signal to the engine ECM. This control uses 2 CPUs: the main CPU and sub CPU, which are in the
engine ECM. The main CPU calculates the target throttle valve opening according to the signals
from the sensors, current throttle valve opening, and throttle valve learning value, and sends the
information to the sub CPU. The sub CPU actuates the ETV motor and controls the throttle valve.
The sub CPU determines the difference between the actual throttle valve opening that is detected
by the TPS and the target throttle valve opening, and performs feedback control to obtain the proper
throttle valve opening. In addition, the APS and TPS each have internal circuits with a dual monitor-
ing system so that APS 1 and APS 2, and TPS 1 and TPS 2 are able to mutually monitor each other
for malfunctions.
Throttle valve opening learning
The main CPU in the engine ECM has learning functions for the APS, TPS, and ISC functions. The
learning functions are used to make compensations to the throttle valve opening.
ISC function
The ISC function adjusts the intake air volume by controlling the throttle valve opening when the
engine is idling to control the engine speed.
Item Learning Description
TPS Fully closed position
and fully open
position learning
The engine ECM records the fully open position and fully
closed position of the throttle valve. If the positions have not
yet been learned, the learning values are used for the TPS
output voltage: 0.5 V for the fully closed position and 4.5 V for
the fully open position.
Middle opening
position learning
The engine ECM records the middle opening position of the
throttle valve. If the position has not yet been learned, the
learning value of 1.5 V is used for the TPS output voltage.
APS APS fully closed
position learning
The engine ECM records the throttle opening when the
engine is idling. In addition, makes compensations to the
learning value.
ISC
function
ISC air volume
difference learning
The engine ECM records the compensations made to the
actual engine idle speed to obtain the target engine idle
speed.
Main CPU
APS 1
ETV motor
Engine ECM
APS
Sub CPU
TPS 1
APS 2
TPS 2
ETV
2-20
2
Fail-safe control
In fail-safe control, the engine ECM enters the fail-safe mode when an electrical component mal-
functions. The fail-safe control system records the trouble codes according to the engine trouble
conditions.
(*1) Low oil pressure alert is displayed.
(*2) Overheat alert is displayed.
Trouble
code
Item
LAN
gauge
display
Trouble conditions to be detected
13 Pulser coil C/E No signal
15
Engine
temperature
sensor
C/E
Open or short circuit in the engine temperature sensor
circuit. Output voltage is less than 0.18 V or more than
4.90 V.
17 Knock sensor C/E Output voltage is less than 0.90 V or more than 4.00 V.
23
Air temperature
sensor
C/E
Output voltage is less than 0.10 V or more than 4.60 V.
24, 71,
72
Cam position
sensor
C/E
Signal error (irregular)
28 Neutral switch C/E Neutral switch is off during the start-up mode.
29
Air pressure
sensor
C/E
Output voltage is less than 0.20 V or more than 4.50 V.
39
Oil pressure
sensor L (*1)
Output voltage is less than 0.30 V, more than 4.80 V
for 260 seconds, or more than 4.80 V when the engine
is stopped.
45
Shift cut switch
C/E
Output voltage is more than 4.50 V, the shift cut switch
is on during the start-up mode for 328 seconds, or
both the neutral switch and shift cut switch are on for 5
seconds.
46
Thermoswitch
O (*2)
Switch is on when the engine temperature is less than
40 C (104 F) or off when the engine temperature is
more than 215 C (419 F).
73, 74 OCV C/E Open or short circuit in the OCV circuit.
112, 113,
114, 115,
116, 117,
118, 119,
121, 122,
123, 129,
136, 137,
138, 139,
141, 142,
143, 144,
145
ETV
C/E
Open or short circuit in the ETV relay and ETV motor
circuit.
124, 125,
126, 127,
128
TPS
C/E
Output voltage is less than 0.35 V or more than 4.80 V,
or the output voltage difference between TPS 1 and
TPS 2 is 2.30 V or more.
131, 132,
133, 134,
135
APS
C/E
Open or short circuit in the APS circuit, or the output
voltage difference between APS 1 and APS 2 is 0.996
V or more.
Electronic control system
2-21
TECH
FEA
Technical features and description
Power unit system
The VF200A, VF225A, and VF250A are equipped with a newly developed V6, 4-stroke engine that
has 60 cylinder banks. The cylinder heads feature plastic cylinder head covers, shimless valve lift-
ers, and exhaust covers that are integrated into the cylinder heads. The cylinder block features a
crankcase equipped with an oil cooler, a crankshaft with an integrated drive sprocket, and sleeve-
less cylinders. Other features include compact VCT assemblies with a narrow timing belt, and a
plastic bottom cowling.
1Compact VCT assembly
2Narrow timing belt
3Plastic cylinder head cover
4Plastic bottom cowling
5Cylinder head integrated with exhaust
cover
5
1
3
2
1
3
4
2
2-22
2
Shimless valve lifter
Newly designed valve lifters 1 have been adopted instead of the usual valve shims 2. The valve
lifters are available in different thicknesses a. Therefore, the valve clearance b can be adjusted by
replacing the current valve lifter with a new valve lifter of the appropriate thickness.
1
2
b
a
Previous F250 New VF200A, VF225A, and VF250A
Power unit system
2-23
TECH
FEA
Technical features and description
Crankcase
The newly designed crankcase 1 is equipped with an oil cooler 2 to increase cooling performance.
Engine oil flow
Cooling water flow

1
2
2-24
2
Crankshaft
The drive sprocket a and flywheel magnet flange b are integrated into the crankshaft. Because the
structure of the crankshaft has been simplified, serviceability is increased.
Sleeveless cylinder
The newly designed cylinder block has adopted spray-coated cylinders instead of sleeved cylinders.
By using spray-coated cylinders, the weight of the cylinder block is decreased, cooling performance
is increased, and so on.
The inner walls of the cylinders are spray-coated using metal powder.
a
b
Metal powder
Cylinder inner wall
Power unit system
2-25
TECH
FEA
Technical features and description
Fuel system
Fuel diagram
Fuel rail
Fuel
injector
Primer pump
Fuel filter
(with water separator and
water detection switch)
Low-pressure
fuel pump
Fuel cooler
High-pressure fuel pump
Vapor separator
Fuel injector
Fuel rail
Pressure regulator
Vapor shut-off valve
Canister
2-26
2
Fuel flow
Air flow
Vapor gas flow

Primer pump Boat fuel filter (optional) Boat fuel tank


Fuel filter (with water
separator and water
detection switch)
Check valve
Atmosphere
Check valve
Atmosphere
Low-pressure
fuel pump
Filter
Float chamber
High-pressure
fuel pump
Canister Vapor shut-off valve Surge tank
Pressure regulator
Fuel rail (PORT)
Fuel
injector #6
Fuel
injector #4
Fuel
injector #2
Combustion
chamber #6
Combustion
chamber #4
Combustion
chamber #2
Intake manifold (PORT)
Fuel rail (STBD)
Fuel
injector #1
Fuel
injector #3
Fuel
injector #5
Combustion
chamber #1
Combustion
chamber #3
Combustion
chamber #5
Intake manifold (STBD)
Check valve
Vapor
separator assembly
Fuel system
2-27
TECH
FEA
Technical features and description
Vapor gas treatment
Vapor gases from the vapor separator are collected in the canister, and then gradually discharged
into the atmosphere after being absorbed and cleaned by the activated charcoal.
After the engine is started, the vapor gases in the canister are drawn into the surge tank through the
vapor shut-off valve, which is controlled by the engine ECM, and then sent to the intake manifolds
and combustion chambers.
Air flow
Vapor gas flow

Combustion chamber Intake manifold Surge tank


Atmosphere
Atmosphere
Check valve
Check valve
Canister Vapor shut-off valve
Vapor separator
2-28
2
Lubrication system
Lubrication diagram
Engine oil flow

Strainer
Oil pan
Relief valve
Oil filter
Oil pressure sensor
OCV
VCT assembly
VCT assembly
OCV
Oil pump
Piston
Crankpin (connecting
rod big end)
OCV
Camshaft oil
passage
VCT
assembly
Camshaft journal
Valve and related parts
Crankshaft main
journal
Cylinder block main gallery
Oil pressure sensor
Oil filter
Relief valve Oil pump
Strainer
Oil pan
Cylinder head oil passage
Fuel system / Lubrication system
2-29
TECH
FEA
Technical features and description
Cooling system
The PCV has been removed to simplify the structure of the cooling system. The crankcase, vapor
separator, and Rectifier Regulator are cooled using the cooling water.
Cooling diagram
Cooling water flow

Oil cooler
Exhaust guide
Water pump
Water inlet
Upper case
Fuel cooler
Thermostat Rectifier Regulator
2-30
2
Cooling water flow

Cooling water
pilot hole
Rectifier Regulator
Oil cooler
Fuel cooler
Thermostat (PORT)
Thermostat (STBD)
Cylinder block (PORT)
Cylinder block (STBD)
Cylinder head (PORT)
Cylinder head (STBD)
Cylinder block
Upper case
Lower case
Propeller boss
Exhaust guide
Oil pan
Water pump
Water inlet
Cover
(anti-cavitation plate)
Water
Oil pan
Exhaust guide
Cooling system
2-31
TECH
FEA
Technical features and description
Intake and exhaust system
The intake system has adopted intake valves with large diameter valve heads to increase the charg-
ing efficiency of the intake air. The exhaust system has adopted a mufflerless upper case.
Intake and exhaust diagram

Throttle body
Surge tank
Intake manifold
Exhaust manifold
Propeller
Intake manifold
Cylinder head
Upper case
Intake air flow
Exhaust gas flow
2-32
2
Mufflerless upper case
The newly designed upper case has an expansion chamber that functions as a muffler.
Exhaust gas flow

Exhaust guide
Upper case
Lower case
Idle silencer
Apron
Exhaust manifold
Expansion chamber
Intake and exhaust system
2-33
TECH
FEA
Technical features and description
PTT unit
Trim-up and tilt-up function
When the UP side of the PTT switch is pushed, the PTT motor 1 operates the gears a of the gear
pump assembly, which increases the PTT fluid pressure. As a result, the PTT fluid pressure opens
the up-main valve b so that the PTT fluid enters the trim cylinder lower chambers c and tilt cylinder
lower chamber d and pushes the trim rods 2 and tilt rod 3 up. If the amount of PTT fluid is insuffi-
cient, PTT fluid is sent from the reservoir 4.
The fluid pressure that pushes the up-shuttle piston e up, pushes the down-shuttle piston f down,
which opens the down-main valve g so that the PTT fluid returns to the gear pump assembly from
the tilt cylinder upper chamber h. The PTT fluid in the trim cylinder upper chambers k returns to
the gear pump assembly through the down-relief valve m.
After the trim rods 2 are fully extended, the tilt rod 3 operates to tilt the outboard motor up.
Return
Send

3
4
1
2
2
e
f
b
a
a
m
g
d
c
k
c
k
h
2-34
2
Trim ram retraction function
If the DN side of the PTT switch is pushed while the outboard motor is secured in the tilted-up posi-
tion using the tilt support shaft, the trim rods 1 will retract. Although the PTT motor 2 will operate
the gears a of the gear pump assembly to attempt to draw out PTT fluid from both the tilt cylinder
lower chamber b and the trim cylinder lower chambers c, the PTT fluid cannot be drawn out from
the tilt cylinder lower chamber b because the tilt rod 3 cannot move when the tilt support shaft is
installed. As a result, PTT fluid is only drawn out from the trim cylinder lower chambers c, and the
trim rods 1 retract into the trim cylinders as the PTT fluid pressure decreases.
Return
Send

3
b
a
a
1
1
2
c
c
PTT unit
2-35
TECH
FEA
Technical features and description
Trim-down and tilt-down function
When the DN side of the PTT switch is pushed, the PTT motor 1 operates the gears a of the gear
pump assembly, which increases the PTT fluid pressure. As a result, the PTT fluid pressure opens
the down-main valve b so that the PTT fluid enters the tilt cylinder upper chamber c and pushes
the tilt rod 2 down.
In addition, the fluid pressure that pushes the down-shuttle piston d up, pushes the up-shuttle pis-
ton e down, which opens the up-main valve f. The gear pump assembly draws out the PTT fluid
from the tilt cylinder lower chamber g and trim cylinder lower chambers h, causing the tilt rod 2
and trim rods 3 to retract.
Because the increased PTT fluid pressure generated by the gear pump assembly causes PTT fluid
to enter the tilt cylinder upper chamber c, the tilt rod 2 retracts first. Then, when the outboard
motor contacts the trim rods 3, the trim rods 3 retract along with the tilt rod 2 due to the weight of
the outboard motor and because PTT fluid is drawn out from the trim cylinder lower chambers h.
Excess PTT fluid returns to the reservoir 4.
Return
Send

2
4
e
d
f
a
a
b
3
3
1
g
h
h
c
2-36
2
Stationary condition
When the PTT switch is not pushed, the gear pump assembly will not pump the PTT fluid, the up-
main valve and down-main valve will remain closed, and the PTT fluid in the system will remain at a
constant pressure. As a result, the tilt ram and trim rams maintain their positions until the PTT
switch is pushed and the PTT fluid flows through the system again.
When the outboard motor hits something in the water
If the lower case strikes an obstacle while the boat is moving, a force causing the tilt rod 1 to
extend will be applied suddenly. Because this force will cause the PTT fluid pressure in the tilt cylin-
der upper chamber a to increase, the tilt piston absorber valves b will open so that PTT fluid
enters the space between the tilt piston c and the free piston 2 to decrease the PTT fluid pressure.
As a result, the damping effect of the tilt piston absorber valves b protects the PTT unit from dam-
age before the tilt piston c strikes the top of the tilt cylinder.
After the collision, a force is generated as the outboard motor returns to its original position due to
the weight of the outboard motor and the thrust of the propeller. The PTT fluid enters the tilt cylinder
upper chamber a through the shock return valve d in the tilt piston c. The tilt rod 1 stops when it
contacts the free piston 2.
The outboard motor strikes an obstacle.
The outboard motor returns to the original position.
1 1
a a
b
c
c
d
2 2

PTT unit
2-37
TECH
FEA
Technical features and description
Lower unit
The newly designed lower unit has adopted a double taper roller bearing for the drive shaft, 3 bear-
ings for the propeller shaft, and 2 spacers in front of the propeller. In addition, the skeg functions as
a trim tab.
Double taper roller bearing
A double taper roller bearing 1 is used to receive the thrust load of the pinion and stabilize the axial
free play of the drive shaft 2. The drive shaft 2 is secured in the lower case using a ring nut 3. As
a result, the axial free play is eliminated and the pinion position is secured.
Propeller shaft bearing
The propeller shaft is supported using 3 bearings to decrease the radial motion of the propeller
shaft. Because 2 bearings are taper roller bearings, axial free play is also decreased.
1 2
3
2-38
2
Thrust power train
The thrust load when the gear shift is in the F position is transmitted from the propeller to the
spacer, propeller shaft, forward gear, thrust bearing, and lower case in the order listed.
Thrust load flow
The thrust load when the gear shift is in the R position is transmitted from the propeller to the propel-
ler shaft, taper roller bearing, propeller shaft housing, ring nut, and lower case in the order listed.
Thrust load flow

Lower
case
Thrust
bearing
Forward
gear
Propeller
shaft
Spacer Propeller
Taper
roller
bearing

Lower
case
Ring nut
Propel-
ler shaft
housing
Taper
roller
bearing
Propeller
shaft
Propeller
Lower unit
2-39
TECH
FEA
Technical features and description
Skeg design
This outboard motor is not equipped with a trim tab. Instead, the skeg a has been designed so that
it functions as the trim tab.
Propeller spacer
There are 2 spacers installed at the front of the propeller to increase wear resistance.
A
A
a
a
RIG
GING
3
Rigging information
Outboard motor installation.............................................. 3-1
Dimension........................................................................... 3-2
Exterior: VF200LA, VF225LA, VF250LA.................................... 3-2
Clamp bracket ............................................................................ 3-3
Crate top cover pictograph description........................... 3-4
Uncrating procedure.......................................................... 3-5
Outboard motor mounting................................................. 3-6
Rigging grommet mounting.............................................. 3-8
Rigging grommet description...................................................... 3-8
Installing the shift cable and throttle cable ................................. 3-8
Installing the wiring harness..................................................... 3-10
Installing the battery cable........................................................ 3-10
Installing the Command Link Multifunction Meter harness
(optional) .................................................................................. 3-11
Installing the water pressure sensor (optional)......................... 3-11
Installing the speed sensor (optional)....................................... 3-12
Installing the rigging grommet .................................................. 3-14
Remote control box and switch panel installation........ 3-14
Battery installation........................................................... 3-14
System diagram ............................................................... 3-15
Single outboard motor application............................................ 3-15
Rigging recommendation................................................ 3-17
Extension length recommendation of battery cable ................. 3-17
Propeller selection........................................................... 3-18
Propeller size............................................................................ 3-18
Selection................................................................................... 3-18
3-1
RIG
GING
Rigging information
Outboard motor installation
Overpowering a boat could cause severe instability. Do not mount an outboard motor with
more horsepower than the maximum rating on the capacity plate of the boat. If the boat
does not have a capacity plate, consult the boat manufacturer.
Improper mounting of the outboard motor could result in hazardous conditions, such as
poor handling, loss of control, or fire hazards. Consult your dealer or have a Yamaha-
trained person experienced in proper rigging mount the outboard motor.
Too much weight on the transom could change the center of gravity, buoyancy, operating
balance, or performance of the boat, which could cause loss of control or swamping. Con-
sult the boat manufacturer for the maximum engine weight allowable on the transom, which
is different from the overall boat capacity. Overloading the transom with an outboard motor
that is too heavy could also damage the hull, transom, deck, or helm area, as well as the out-
board motor and other equipment.
Before mounting the outboard motor, consult the manufacturer of the engine jack plates or
brackets. Excessive loads could damage the engine jack plates, brackets, boat transom,
steering system, or engine. This could cause loss of control.
3-2
3
Dimension
Exterior: VF200LA, VF225LA, VF250LA
(*1) Transom height
mm (in)
688 (27.1)
4
1
2

6
6

3
5

81 (3.2)
237 (9.3)
54 (2.1)
651 (25.6)
741 (29.2) 218 (8.6)
75 (3.0) 261 (10.3)
1
0
0
8

(
3
9
.
7
)
3
5

(
1
.
4
)
2
1
6

(
8
.
5
)
8
1
7

(
3
2
.
2
)
9
3
2

(
3
6
.
7
)
4
9
3

(
1
9
.
4
)
1
3
3

(
5
.
2
)
4
5

(
1
.
8
)
5
0
7

(
2
0
.
0
)
3
3

(
1
.
3
)
4
9
6

(
1
9
.
5
)
3
3
2

(
1
3
.
1
)
7
1
5

(
2
8
.
1
)
H
(
*
1
)

1033 (40.7)
Outboard motor installation / Dimension
3-3
RIG
GING
Rigging information
Clamp bracket
mm (in)
180 (7.1)
13 (0.5)
2
5
4

(
1
0
.
0
)
3
6
8

(
1
4
.
5
)
1
8
.
5

(
0
.
7
)
5
0
.
8

(
2
.
0
)
163.5 (6.4)
125.4 (4.9) 125.4 (4.9)
13 (0.5)
180 (7.1)
82 (3.2) 163.5 (6.4)
5
5
.
5

(
2
.
2
)
3-4
3
Crate top cover pictograph description
The following pictographs are important when handling the crate.
Read the notice and understand what each pictograph means to prevent damage to the outboard
motor when handling, transporting, and storing the crate.
IMPORTANT
This unit delivered to carrier in a good condition.
For protection against loss due to damage, inspect thoroughly.
If damage is noted, make note on freight bill.
Shipper assumes no further liability to the transportation company.
Your claim should be filed against carrier for damage of any nature.
Lifting fork insert position
Stack limit: Maximum units for storage
Upward
Handle with care
Avoid water
Product barycentric position
Dimension / Crate top cover pictograph description
3-5
RIG
GING
Rigging information
Uncrating procedure
1. Check the crate for shipping damage.
2. Remove the top cover.
3. Remove all of the bolts from the bottom
plate, and then remove the frame.
NOTICE: Be careful not to damage the
outboard motor.
4. Remove the wrapping, and then check
the outboard motor for concealed dam-
age.
5. Remove the top cowling, and then
remove the flywheel magnet cover 1.
6. Install the special service tool 2 to the
flywheel magnet. NOTICE: When lifting
the outboard motor, make sure to use
the specified special service tool 2.
Other bolts and hanging jigs could
bend or break, causing the outboard
motor to fall.
7. Install the lifting harness to the eye bolt
a.
8. Lift up the outboard motor along with the
bottom plate 3 carefully. NOTICE: Make
sure that the lifting harness does not
damage any parts of the outboard
motor.
9. Remove the clamp bracket bolts 4.
10. Remove the steering retainer, and then
install a hydraulic steering cylinder fol-
lowing the manufacturers recommenda-
tion.
Engine lifting eye 2: 90890-06820
1
2
a
3
4
3-6
3
Outboard motor mounting
Proper mounting of the outboard motor will
provide better performance, maximum reli-
ability, and the highest customer satisfaction.
This chapter contains the specifications nec-
essary to mount the outboard motor, and
may vary slightly depending on applications.
When mounting the outboard motor, make
sure that there is sufficient clearance for the
outboard motor to fully move to port and star-
board, as well as fully tilt up. See Dimen-
sion (3-2).
1. Place the outboard motor on the vertical
centerline of the boat transom. Check
that distance a is equal to distance b
and that distance c is equal to distance
d.
: Hull without strakes
: Hull with strakes
C/L: Centerline of transom
2. Adjust the position of the outboard motor
so that the height of the anti-cavitation
plate e is equal to or slightly above the
bottom of the boat transom.
TIP:
This mounting height information is for refer-
ence only. It is impossible to provide com-
plete instructions for every possible boat and
outboard motor combination.
3. Adjust the height of the scale f to the
transom height (H), and place it on the
special service tool 1. Secure the spe-
cial service tool 1 to the boat transom
using screws or vises.
TIP:
For the distance (H), see Dimension (3-2).
4. When the outboard motor mounting posi-
tion has been determined, mark the best-
suited 4 symmetrical mounting holes on
the boat transom g. Drill the mounting
holes perpendicular to the surface of the
boat transom using a 13.0 mm (0.5 in)
drill bit.
C/L
a b
c d

C/L
a b
c d

e
Uncrating procedure / Outboard motor mounting
3-7
RIG
GING
Rigging information
C/L: Centerline of transom
5. Apply sealant to the mounting holes and
secure the outboard motor using the
included mounting bolts 2, small wash-
ers 3, large washers 4, and nuts 5.
NOTICE: Make sure that there is no
clearance between the surfaces of the
boat transom and the clamp brackets.
Otherwise, the clamp brackets or boat
transom may be damaged.
TIP:
The second hole from the top of each clamp
bracket is recommended for the upper
mounting bolt.
6. Install the mounting bolts, and then
tighten the nuts firmly. NOTICE: Make
sure that the clamp brackets do not
bite into the boat transom.
7. Tighten the locknuts firmly.
Drilling plate 1: 90890-06783
Mounting hole diameter h:
13.0 mm (0.5 in)
h
(H)
f
f
1
C/L
g
Boat transom
thickness (D)
Mounting bolt
6575 mm
(2.562.95 in)
M12 130 mm
(5.12 in)
2
3
3
4
5
D
5
2
3
3
4
5
2
3
3
4
3-8
3
Rigging grommet mounting
Rigging grommet description
aBattery cable
bShift cable
cSpeedometer hose
dWater temperature sensor harness
(optional), water pressure sensor harness
(optional), or Command Link Multifunction
Meter harness (optional)
eMain wiring harness
fThrottle cable
gFuel hose
hFlushing hose
Installing the shift cable and throttle
cable
Before installing the shift cable and throt-
tle cable, make sure to adjust the cables
according to the procedures in the remote
control operation manual.
1. Remove the grommet holder 1 and rig-
ging grommet 2.
2. Remove the cable guides 3 and 4.
3. Route the shift cable 5 through the bot-
tom cowling.
4. Fit the cable guide 3 into the groove a
in the shift cable 5, and then install the
cable guide 3 and shift cable 5.
5. Fully screw in the shift cable joint 6 to
the shift cable 5.
6. Move the remote control lever to the N
position.
7. Align the mark b on the bushing 7 with
the mark c on the shift bracket 8.
a b
c
d
e
f
g
h
2
1
3
4
3
5
a
5
5
6
Outboard motor mounting / Rigging grommet mounting
3-9
RIG
GING
Rigging information
8. Make a mark d on the fully retracted
inner cable, and then make a mark e on
the fully extended inner cable.
9. Make a mark f in the middle point
between the marks d and e, and then
align the mark f with the outer cable
edge g.
10. Adjust the shift cable joint 6, and then
install the shift cable joint 6 to the pin h.
WARNING! The shift cable joint must
be screwed in 8.0 mm (0.31 in) or
more.
11. Install the clip 9, and then tighten the
shift cable locknut 0 to the specified
torque.
12. Install the cable guide 4, and then route
the throttle cable A through the bottom
cowling.
13. Fasten the throttle cable A using the
cable holder 4 so that the cable holder
4 is fitted into the groove m in the throt-
tle cable A.
14. Fully screw in the throttle cable joint B to
the throttle cable A.
15. Pull the inner cable so that there is no
free play (backlash).
16. Check that the accelerator lever n con-
tacts the stopper p.
Dimension k: 8.0 mm (0.31 in) or more
8
7
c
b
e
d
d f
d f
g
h
6
6
k
Shift cable locknut 0:
5 Nm (0.5 kgfm, 3.7 ftlb)
9
0
m
4
A
A
A
B
3-10
3
17. Adjust the throttle cable joint B, and then
install the throttle cable joint B to the pin
r of the throttle cam. WARNING! The
throttle cable joint must be screwed in
8.0 mm (0.31 in) or more.
18. Install the clip C, and then tighten the
throttle cable locknut D to the specified
torque.
19. Check the shift cable and throttle cable
for proper operation.
Installing the wiring harness
1. Route the extension wiring harness 1
through the bottom cowling.
2. Remove the plastic tie 2 that is fasten-
ing the main wiring harness coupler a.
3. Connect the 10-pin coupler b, and then
fasten the main wiring harness coupler
a using the plastic tie 2.
Installing the battery cable
1. Connect the positive battery cable a and
negative battery cable b.
2. Install the rubber cap 1.
Dimension s: 8.0 mm (0.31 in) or more
Throttle cable locknut D:
5 Nm (0.5 kgfm, 3.7 ftlb)
B r
B
s
p
n
D C
1
a 2
b a 2
a
b
1
Rigging grommet mounting
3-11
RIG
GING
Rigging information
Installing the Command Link
Multifunction Meter harness
(optional)
1. Remove the cap a.
2. Route the Command Link Multifunction
Meter harness 1 through the bottom
cowling, and then connect the Command
Link Multifunction Meter harness coupler
b.
3. Remove the yellow tape 2, and the
remove the caps 3 and 4.
4. Connect the couplers c and d.
Installing the water pressure sensor
(optional)
See the Command Link Multifunction Meter
Set Up Manual for details of the components.
Do not reuse a gasket, always replace it
with a new one.
1. Remove the plug 1 and gasket 2.
2. Install a new gasket 3 and the adapter
4, and then tighten the adapter 4 to the
specified torque.
3. Install the water pressure sensor 5, and
then tighten the water pressure sensor 5
to the specified torque.
a
b
1
2 3 4
Water pressure sensor adapter 4:
23 Nm (2.3 kgfm, 17.0 ftlb)
d c
1 2
4 3
3-12
3
4. Remove the water pressure sensor har-
ness a from the holder 6.
5. Remove the water pressure sensor cou-
pler b from the bracket 7, and then
remove the cap c.
6. Connect the water pressure sensor cou-
pler b, and then fasten the water pres-
sure sensor harness a using the holder
8.
Installing the speed sensor
(optional)
See the Command Link Multifunction Meter
Set Up Manual for details of the components.
1. Remove the speedometer hose 1 from
the rigging grommet 2, and then cut off
the tip a of the nipple 3.
2. Install the extension hose 4 to the nipple
3, and then fasten it using the plastic tie
5.
3. Remove the speed sensor coupler b
from the engine ECM bracket 6, and
then remove the cap c.
4. Install the speed sensor 7 to the speed
sensor adapter 8, and then tighten the
speed sensor 7 to the specified torque.
Water pressure sensor 5:
19 Nm (1.9 kgfm, 14.0 ftlb)
5
b
c
a
6
7
b 8
a
a
2
1
3
3 4
5
6 c
b
Rigging grommet mounting
3-13
RIG
GING
Rigging information
5. Install the speed sensor assembly 9 to
the bottom cowling.
6. Connect the speed sensor coupler b.
7. Route the speedometer hose 1 under
the holder 0, water detection switch cou-
pler d, trim sensor coupler e, and Com-
mand Link Multifunction Meter coupler
f.
8. Route the extension hose 4 to the port
side of the bottom cowling, and then con-
nect the extension hose 4 to the speed
sensor adapter 8.
9. Fasten the extension hose 4 using the
plastic tie A.
10. Install the rubber seal in the hole g.
Speed sensor 7:
18 Nm (1.8 kgfm, 13.3 ftlb)
7
8
9
b
1
f
d
e
0
4
8
A
g
3-14
3
Installing the rigging grommet
1. Route each harness through the proper
hole in the rigging grommet. See Rig-
ging grommet description (3-8) for the
detailed description of the rigging grom-
met.
2. Align the white tape a on the battery
cable with the outer end of the rigging
grommet.
3. Install the grommet holder 1.
4. Install the rigging grommet retainer 2,
and then fasten it using the plastic tie 3.
Remote control box and switch
panel installation
See the Remote Control Box Operation Man-
ual or Rigging Guide for the installation pro-
cedures.
Battery installation
Make sure to connect the battery properly
and select the proper cable sizes. Other-
wise, a fire could result.
Do not reverse the battery connections.
Otherwise, the charging system could be
damaged.
a
1
3
2
Rigging grommet mounting / Remote control box and switch panel installation /
Battery installation
3-15
RIG
GING
Rigging information
System diagram
Single outboard motor application
(*1) Install the waterproof cap to the open terminals.
1Remote control box
2Switch panel
3Extension wiring harness
4Engine ECM
5Pigtail bus wire
6Single hub
7Main bus wire
88 ft power wire
9Fuse (10 A)
0Tachometer unit
ASpeedometer unit
BCap 1 (white)
CIn-line resistor
aPower port
bBus port
cDevice port
Color code
B : Black
G : Green
R : Red
Y : Yellow
3-16
3
4P
5
A
4P
G
B
Y
4P
2P
6P
4P
4P
4P
6P
R
3
C
B
1
5
a
b
b
c
c
c
2
0
4
5
4P
6P
7
6
9
8
B
Y Y
(*1)
System diagram
3-17
RIG
GING
Rigging information
Rigging recommendation
Extension length recommendation of battery cable
Do not exceed the recommended extension length for the battery cable. Otherwise, the elec-
trical system could be damaged or operate improperly.
To extend the length of battery cables, follow the requirements in the tables for your battery capac-
ity, cable size, and ambient temperature.
The maximum total extension length is the total combined length of the positive and negative bat-
tery cables.
Select an extension battery cable and terminal which meet ABYC requirements or the equivalent.
Select a battery stud that is best-suited to the terminal size.
Solder the cable and terminal connections to prevent them from corroding.
Ambient temperature 5C to 35C (2395F)
Battery requirements
Number of batteries
in parallel
Cable specifications
Unit
Minimum
capacity
Maximum total extension length
(Positive battery cable + Negative battery
cable)
20 mm
2
AWG4
30 mm
2
AWG2
50 mm
2
AWG1/0
60 mm
2
AWG2/0
CCA/SAE 680 A
1 MCA/ABYC 770 A
RC/SAE 160 minutes
CCA/SAE 650 A
1
3.6 m
(11.8 ft)
5.4 m
(17.7 ft)
9.0 m
(29.5 ft)
10.8 m
(35.4 ft)
MCA/ABYC 780 A
RC/SAE 210 minutes
CCA/SAE 650 A
2
5.4 m
(17.7 ft)
8.2 m
(26.9 ft)
13.6 m
(44.6 ft)
16.4 m
(53.8 ft)
MCA/ABYC 780 A
RC/SAE 210 minutes
CCA/SAE 700 A
1
4.2 m
(13.8 ft)
6.3 m
(20.7 ft)
10.5 m
(34.4 ft)
12.6 m
(41.3 ft)
MCA/ABYC 900 A
RC/SAE 220 minutes
CCA/SAE 700 A
2
6.5 m
(21.3 ft)
9.8 m
(32.2 ft)
16.3 m
(53.5 ft)
19.6 m
(64.3 ft)
MCA/ABYC 900 A
RC/SAE 220 minutes
CCA/SAE 800 A
1
4.8 m
(15.7 ft)
7.2 m
(23.6 ft)
12.0 m
(39.4 ft)
14.4 m
(47.2 ft)
MCA/ABYC 960 A
RC/SAE 230 minutes
CCA/SAE 800 A
2
7.4 m
(24.3 ft)
11.1 m
(36.4 ft)
18.5 m
(60.7 ft)
22.2 m
(72.8 ft)
MCA/ABYC 960 A
RC/SAE 230 minutes
3-18
3
Propeller selection
The performance of a boat and outboard
motor will be critically affected by the size
and type of propeller that is used. 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.
Use the following information as a guide for
selecting a propeller that meets the operating
conditions of the boat and outboard motor.
Propeller size
The size of the propeller is indicated on the
side of the propeller boss.
aPropeller diameter (in inches)
bPropeller pitch (in inches)
cPropeller type (propeller mark)
Selection
When the engine speed is at the full throttle
operating range, the ideal propeller for the
boat is one that provides maximum perfor-
mance in relation to boat speed and fuel con-
sumption.
TIP:
When selecting a propeller, make sure to use
the propeller size and material specified by
Yamaha.
Full throttle operating range:
50006000 r/min
Propeller size (in) Material
14 1/2 23 T1
Stainless
14 3/4 25 T1
14 3/4 29 T1
15 1/8 27 T1
b
a
c
Rigging recommendation / Propeller selection
3-19
RIG
GING
Rigging information
MEMO
TRBL
SHTG
4
Troubleshooting
YDIS..................................................................................... 4-1
Feature....................................................................................... 4-1
Hardware requirement................................................................ 4-1
Function...................................................................................... 4-2
YDIS kit ...................................................................................... 4-4
Connecting the communication cable to the outboard motor ..... 4-5
Outboard motor troubleshooting...................................... 4-6
Troubleshooting procedure ........................................................ 4-6
Troubleshooting the power unit using the YDIS......................... 4-6
Trouble code and checking step ................................................ 4-9
Troubleshooting the power unit using
the diagnostic flash indicator .................................................... 4-18
Troubleshooting the power unit (trouble code not detected) .... 4-19
Troubleshooting the PTT unit ................................................... 4-26
Troubleshooting the lower unit ................................................. 4-27
4-1
TRBL
SHTG
Troubleshooting
YDIS
This manual contains the model-specific information. See the YDIS Instruction Manual for detailed
information.
Feature
The newly developed YDIS provides quicker detection and analysis of engine malfunctions.
By connecting your computer to the engine ECM of an outboard motor using the communication
cable, this software can be used to display sensor data and data stored in the engine ECM on the
computer monitor.
If this software is run on Microsoft Windows 2000, Windows XP, or Windows Vista, the information
can be displayed in colorful graphics. Also, the software can be operated using either a mouse or a
keyboard.
In addition, the data for the main functions (Diagnosis, Diagnosis record, Engine monitor, Data log-
ger, and Record of engine oil exchange) can be saved on a disk or printed out.
Hardware requirement
Make sure that your computer meets the following requirements before using this software.
Computer: IBM PC/AT compatible computer
Operating system: Microsoft Windows 2000, Windows XP, or Windows Vista
CPU:
Windows 2000: Pentium, 166 MHz or higher (Pentium, 233 MHz or higher
recommended)
Windows XP: Pentium, 300 MHz or higher (Pentium, 500 MHz or higher
recommended)
Windows Vista: Core family, 1.6 GHz or higher (Core family, 2.0 GHz or higher
recommended)
Memory:
Windows 2000: 64 MB or more (128 MB or more recommended)
Windows XP: 128 MB or more (256 MB or more recommended)
Windows Vista: 1 GB or more
Hard disk free space: 20 MB or more (40 MB or more recommended)
Drive: CD-ROM drive
Display: VGA (640 480 pixels) 256 or more colors
SVGA (800 600 pixels or more recommended) 256 or more colors
Mouse: Compatible with the operating systems mentioned previously
Communication port: RS232C (Dsub-9 pin) port, USB port
Printer: Compatible with the operating systems mentioned previously
4-2
4
TIP:
The amount of memory and the amount of free space on the hard disk differs depending on the
computer.
Using this software while there is not enough free space on the hard disk could cause errors and
result in insufficient memory.
This software will not run properly on some computers.
When starting up this program, do not start other software programs.
Do not use the screen saver function or the energy saving feature when using this program.
If the engine ECM is changed, restart the program.
Windows XP and Windows Vista are multiuser operating systems. Therefore, make sure to quit
this program if the login user is changed.
Function
Diagnosis
Displays each part name, and the engine ECM trouble codes and status when the engine start
switch is turned to ON. This enables you to find malfunctioning parts. The trouble codes displayed
are the same as those described in this chapter. See Trouble code and checking step (4-9).
Diagnosis record
Displays each part name and the engine ECM trouble codes that have been recorded. This
enables you to check the record of malfunctions for the outboard motor. The trouble codes dis-
played are the same as those described in this chapter. See Trouble code and checking step (4-
9).
Engine monitor
Each sensor status and the engine ECM data are displayed when the engine start switch is turned
to ON. This enables you to find malfunctioning parts quickly. In addition, the data displayed using
the Engine monitor function can be displayed in a graph.
(*1) Intake air pressure
(*2) Engine oil pressure
(*3) Engine shut-off switch
(*4) Neutral switch
Engine speed Fuel injection duration Dual engine system switch
Intake pressure (*1) Ignition timing Shift cut-off switch
Throttle position sensor 1 Engine temperature Overheat thermoswitch
Throttle valve opening Intake temperature Main switch
Throttle position sensor 2 Oil pressure (*2) Main relay
Accelerator position sensor 1 Intake cam timing (STBD) Electronic throttle relay
Accelerator position sensor 2 Intake cam timing (PORT) Fuel pump relay
Atmospheric pressure Engine stop lanyard switch
(*3)
Battery voltage Shift position switch (*4)
YDIS
4-3
TRBL
SHTG
Troubleshooting
Stationary test
Operation tests can be performed while the engine is stopped.
(*1) OCV drive (STBD)
(*2) OCV drive (PORT)
(*3) Operate high-pressure fuel pump
(*4) Operate low-pressure fuel pump
Active test
The test can be performed while the engine is running and the gear shift is set to the N position. It
is not possible to perform the test while the boat is moving.
Data logger
Displays 13 minutes of recorded data for 2 or more of the items stored in the engine ECM. In addi-
tion, the operating time as compared to the engine speed and the total operating time are dis-
played. This enables you to check the operating status of the engine. You can also save the
engine ECM record data to a file so that you can view and display the graph later.
(*1) Intake air pressure
(*2) Engine oil pressure
ECM record data graph
When a malfunction occurs in the ETV system, 4 seconds (2 seconds before and after the mal-
function) of data is recorded in the engine ECM. This data can be displayed on a graph using the
ECM record data graph of the YDIS.
When the communication cable is used to connect a computer to the engine ECM, the engine
ECM record data can be saved and viewed on the computer.
The saved engine ECM record data can also be viewed offline.
Ignite ignition coil (#1#6)
Oil ctrl. valve drive (STBD)
(*1)
Operate electric fuel pump
(*3)
Operate injector (#1#6)
Oil ctrl. valve drive (PORT)
(*2)
Operate elect. fuel feed
pump (*4)
Drop cylinder (#1#6)
Engine speed Throttle position sensor Intake pressure (*1)
Battery voltage Engine temperature Oil pressure (*2)
Engine speed Ref. TPS voltage (*3) ETV relay
Accelerator position sensor 1
Ref. acc. pos. sensor voltage
(*4)
Overheat warning
Accelerator position sensor 2
Target TPS voltage for ISC
(*5)
Low oil pressure (*8)
Throttle position sensor 1 Engine stop mode Engine hours
Throttle position sensor 2 Engine start mode Trig
Intake pressure (*1) Engine stop mode with SW Code
Battery voltage
Engine stop lanyard switch
(*6)
Target TPS voltage (*2) Main relay (*7)
4-4
4
(*1) Intake air pressure
(*2) This item shows the target output voltage of the TPS.
This value is the control voltage that the engine ECM requires to set the target opening
angle of the throttle valve.
(*3) Reference TPS voltage
This item shows the criterion output voltage of the TPS.
This value is used to detect the TPS output voltage during engine operation.
(*4) Reference APS voltage
This item shows the criterion output voltage of the APS.
This value is used to detect the APS output voltage when the remote control lever is
opened.
(*5) Engine ECM controls the engine idle speed using the throttle valve that is connected to the
TPS.
This target voltage is used by the engine ECM to obtain the target opening angle of the
throttle valve at engine idle speed.
(*6) Engine shut-off switch
(*7) Main relay (ignition coil, fuel injector, VCT, engine ECM, low-pressure fuel pump, high-
pressure fuel pump, vapor shut-off valve, and YDIS)
(*8) Low engine oil pressure
Record of engine oil exchange
Records the history of engine oil changes.
YDIS kit
No. Item Qty
1 CD-ROM (software + instruction manual) 1
2 Adapter 1
3 Communication cable 1
1 2 3
OUTBOARDS
WATERCRAFT
YDIS (CD-ROM, Ver. 1.33) 1:
60V-WS853-06
YDIS (KIT) 1, 2, 3: 60V-85300-06
YDIS
4-5
TRBL
SHTG
Troubleshooting
Connecting the communication cable to the outboard motor
aYDIS coupler (gray)
a
4-6
4
Outboard motor troubleshooting
Troubleshooting procedure
1. Before troubleshooting the outboard motor, check that fresh fuel of the specified type has been
used.
2. Check that all electrical connections are secure and free from corrosion, and that the battery is
fully charged.
3. Check the trouble code using the YDIS first, and then check the electronic control system fol-
lowing the trouble code chart.
4. When a trouble code is detected, check the data logger of the engine ECM record data graph as
well.
5. If a trouble code is not detected, check the power unit according to Troubleshooting the power
unit (trouble code not detected).
6. Before using the YDIS to check the power unit, check the engine ECM circuit. See Checking
the engine ECM circuit (5-24).
TIP:
Make sure to check that the couplers and connectors are connected securely.
When deleting the diagnosis record on the YDIS, make sure to check the time that the trouble
codes were detected.
When checking the input voltage of a part, the coupler or connector must be disconnected. As a
result, the engine ECM determines that the part is disconnected and a trouble code is detected.
Therefore, make sure to delete the diagnosis record after checking the input voltage.
Because the main relay comes on for approximately 10 seconds after the engine start switch is
turned to OFF, the power of the engine ECM cannot be turned off. Therefore, if the engine start
switch is turned to ON within 10 seconds after it was turned to OFF, the trouble codes cannot be
deleted.
Troubleshooting the power unit using the YDIS
1. Use the trouble codes displayed by the YDIS to check each part according to the Trouble code
and checking step table.
2. Delete the trouble codes after checking, repairing, or replacing a part and check that the trouble
codes are not detected again. If the same trouble codes are detected, the engine ECM may be
faulty.
3. Check the items listed in the table. If all of the items are in good condition, delete the trouble
codes, and then check the trouble codes again. If the same trouble codes are detected again,
the engine ECM is faulty.
YDIS / Outboard motor troubleshooting
4-7
TRBL
SHTG
Troubleshooting
Trouble code table
: Indicated
: Not indicated
Trouble
code
Item
Diagnostic
flash indicator
YDIS diagnosis
YDIS diagno-
sis record
1 Normal
13 Pulser coil malfunction
15 Engine temp sensor malfunction (*1)
17 Knock sensor malfunction
19 Battery voltage malfunction
23 Intake temp sensor malfunction (*2)
24 Cam position sensor (EXH) malfunction
27 Water in fuel
28 Shift position switch malfunction (*3)
29 Intake press sensor malfunction (*4)
37 Intake air passage malfunction
39 Oil press sensor malfunction (*5)
44 Engine stop lanyard switch ON (*6)
45 Shift cut-off switch malfunction
46 Overheat thermoswitch malfunction
68 Variable cam timing (STBD)
69 Variable cam timing (PORT)
71
Cam position sensor (STBD INT)
malfunction
72
Cam position sensor (PORT INT)
malfunction
73 Oil control valve (STBD) malfunction
74 Oil control valve (PORT) malfunction
112,
113,
114,
115,
116,
117,
118,
119,
121,
122,
123,
129,
136,
137,
138,
139,
141,
142,
143,
144,
145
Electronic throttle system malfunction
4-8
4
(*1) Engine temperature sensor malfunction
(*2) Air temperature sensor malfunction
(*3) Neutral switch malfunction
(*4) Air pressure sensor malfunction
(*5) Oil pressure sensor malfunction
(*6) Engine shut-off switch ON
124,
125,
126,
127,
128
Throttle position sensor malfunction
131,
132,
133,
134,
135
Accelerator position sensor malfunction
Trouble
code
Item
Diagnostic
flash indicator
YDIS diagnosis
YDIS diagno-
sis record
Outboard motor troubleshooting
4-9
TRBL
SHTG
Troubleshooting
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s
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p
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e
Outboard motor troubleshooting
4-13
TRBL
SHTG
Troubleshooting
7
2
C
a
m

p
o
s
i
t
i
o
n

s
e
n
s
o
r

(
P
O
R
T

I
N
T
)

m
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c
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p
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v
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l
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a
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e
.
5
-
2
9
M
e
a
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t
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e

c
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m

p
o
s
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t
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s
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o
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p
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v
o
l
t
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.
5
-
2
9
C
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c
k

f
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.
5
-
2
9
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-
3
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.
7
-
4
1
7
3
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l

c
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t
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v
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(
S
T
B
D
)

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Y
D
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.
5
-
3
2
M
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V

i
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p
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v
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.
5
-
3
2
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t
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O
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V

r
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s
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t
a
n
c
e
.
5
-
3
2
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c
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f
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r
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l
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5
-
3
2
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3
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5
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f
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.
1
0
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1
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4
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v
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3
2
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.
5
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2
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r
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l
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2
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1
0
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5
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2
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l
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2
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s
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p
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e
4-14
4
1
1
3
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4-18
4
Troubleshooting the power unit
using the diagnostic flash indicator
1. Connect the special service tool 1.
aDiagnostic test lead (Blue/White)
TIP:
When performing this diagnosis, all of the
electrical wires must be connected properly.
2. Start the engine and let it idle.
3. Check the flash patterns of the trouble
codes.
Example: The illustrations indicate code
numbers 23 and 113.
b: Light on, 0.33 second
c: Light off, 4.95 seconds
d: Light off, 0.33 second
e: Light off, 1.65 seconds
4. If trouble code is detected, see Trouble
code and checking step (4-9).
TIP:
When more than 1 trouble code is detected,
the light of the special service tool flashes in
the pattern of the lowest trouble code. After
that trouble code is corrected, the indicator
flashes in the pattern of the next lowest trou-
ble code. This continues until all of the trou-
ble codes are detected and corrected.
Diagnostic test lead 1: YB-06795
1
a
b b e
d
2 3
b b b c
c b b b e b e b
d
1 1
3
Outboard motor troubleshooting
4-19
TRBL
SHTG
Troubleshooting
T
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8
-
1
4
4-20
4
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5
-
3
5
A
-
7
Outboard motor troubleshooting
4-21
TRBL
SHTG
Troubleshooting
F
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e
l

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t

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u
p
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d

(
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l

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6
-
1
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Outboard motor troubleshooting
4-23
TRBL
SHTG
Troubleshooting
S
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0
-
9
Outboard motor troubleshooting
4-25
TRBL
SHTG
Troubleshooting
S
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1
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6
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9
-
4
5
Outboard motor troubleshooting
4-27
TRBL
SHTG
Troubleshooting
S
y
m
p
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1
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9
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8
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6
D
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-
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8
-
1
1
8
-
1
8
4-28
4
MEMO
Outboard motor troubleshooting
ELEC
Electrical system
Electrical component ......................................................... 5-1
Port ............................................................................................. 5-1
Starboard.................................................................................... 5-2
Fuse holder ................................................................................ 5-3
Rear............................................................................................ 5-4
Front ........................................................................................... 5-5
Top ............................................................................................. 5-6
Bottom cowling........................................................................... 5-7
Wiring harness routing...................................................... 5-8
Port ............................................................................................. 5-8
Starboard.................................................................................. 5-10
Rear.......................................................................................... 5-13
Front ......................................................................................... 5-14
Top ........................................................................................... 5-15
Bottom cowling......................................................................... 5-16
Circuit diagram................................................................. 5-18
ECM coupler layout.......................................................... 5-20
Checking the electrical component................................ 5-22
Using the YDIS......................................................................... 5-22
Measuring the peak voltage ..................................................... 5-22
Using the digital tester.............................................................. 5-23
Engine control unit and component............................... 5-23
Checking the main relay........................................................... 5-23
Checking the engine ECM circuit ............................................. 5-24
Checking the APS.................................................................... 5-25
Checking the APS circuit .......................................................... 5-26
Checking the ETV and TPS ..................................................... 5-27
Checking the ETV relay............................................................ 5-28
Checking the ETV and TPS circuit ........................................... 5-28
Checking the cam position sensor ........................................... 5-29
Checking the OCV.................................................................... 5-32
Checking the oil pressure sensor ............................................. 5-34
Ignition unit and component ........................................... 5-35
Checking the ignition spark ...................................................... 5-35
Checking the ignition coil.......................................................... 5-35
Checking the pulser coil ........................................................... 5-36
Checking the air temperature sensor ....................................... 5-37
Checking the air pressure sensor............................................. 5-38
Checking the engine temperature sensor ................................ 5-40
Checking the thermoswitch ...................................................... 5-41
5
Checking the shift cut switch.................................................... 5-42
Checking the neutral switch ..................................................... 5-43
Checking the knock sensor ...................................................... 5-44
Checking the engine shut-off switch......................................... 5-45
Fuel control unit and component ................................... 5-45
Checking the water detection switch........................................ 5-45
Checking the fuel injector ......................................................... 5-46
Checking the low-pressure fuel pump
and high-pressure fuel pump.................................................... 5-48
Checking the high-pressure fuel pump relay............................ 5-49
Checking the vapor shut-off valve............................................ 5-50
Starting unit and component .......................................... 5-51
Checking the starter relay ........................................................ 5-51
Checking the engine start switch.............................................. 5-52
Starter motor .................................................................... 5-53
Removing the starter motor...................................................... 5-55
Checking the starter motor operation....................................... 5-55
Checking the magnet switch .................................................... 5-55
Checking the starter motor pinion ............................................ 5-55
Disassembling the starter motor............................................... 5-56
Checking the armature (starter motor) ..................................... 5-57
Checking the brush holder and brush ...................................... 5-58
Assembling the starter motor ................................................... 5-58
Installing the starter motor........................................................ 5-60
Charging unit and component ........................................ 5-60
Checking the lighting coil.......................................................... 5-60
Checking the Rectifier Regulator.............................................. 5-61
Command Link Multifunction Meter sensor .................. 5-63
Checking the water pressure sensor (optional)........................ 5-63
Checking the speed sensor (optional)...................................... 5-64
PTT electrical system ...................................................... 5-65
Checking the PTT relay............................................................ 5-65
Checking the PTT switch.......................................................... 5-66
Checking the trim sensor.......................................................... 5-67
5-1
ELEC
Electrical system
Electrical component
Port
1ETV (TPS)
2Vapor shut-off valve
3Thermoswitch (PORT)
4OCV (PORT)
5Fuel injector
6High-pressure fuel pump
7Low-pressure fuel pump
1 2 3 4
5
7 6
5-2
5
Starboard
1OCV (STBD)
2Thermoswitch (STBD)
3Fuse holder
4PTT relay
5APS
6Rectifier Regulator
7Oil pressure sensor
8Fuel injector
1 2 3 4
8
7 6 5
Electrical component
5-3
ELEC
Electrical system
Fuse holder
1Fuse (60A) (battery)
2Fuse (10A) (low-pressure fuel pump)
3Fuse (20A) (PTT switch)
4Fuse (30A) (starter relay)
5Fuse (30A) (ignition coil, VCT, fuel
injector, and engine ECM)
6Fuse (10A) (ETV)
7Fuse (15A) (high-pressure fuel pump)
8Main relay
9ETV relay
0High-pressure fuel pump relay
AStarter relay
1 2 3 4 5 6 7
A
0 9 8
5-4
5
Rear
1Ignition coil
2Engine ECM
3Knock sensor
4Speed sensor coupler (optional)
5Joint coupler 3
6Joint coupler 2
7Water pressure sensor coupler (optional)
2
1
1
3 4 5 6 7
Electrical component
5-5
ELEC
Electrical system
Front
1Starter motor
2YDIS coupler
3Water detection switch (in fuel cup assembly)
1 2
3
5-6
5
Top
1Cam position sensor (STBD IN)
2Joint coupler 1
3Cam position sensor (PORT EX)
4Condenser
5Condenser
6Condenser
7Spark plug
8Cam position sensor (PORT IN)
9Engine temperature sensor
0Pulser coil
AAir temperature sensor
BAir pressure sensor
CStator assembly
1
C
2
B A
3
4
5
6
7
8
9
0
Electrical component
5-7
ELEC
Electrical system
Bottom cowling
1PTT switch
2Shift cut switch
3Neutral switch
4Command Link Multifunction Meter
coupler
5Trim sensor coupler
6Alert indicator coupler
1
6
4
5
2
3
5-8
5
Wiring harness routing
Port
Install the pulser coil coupler to the wiring
harness guide.
Install the holder to the intake manifold,
and then fasten the thermoswitch connec-
tors using the holder.
Install the holders to the intake manifold,
connect the fuel injector couplers, and
then fasten the fuel injector leads using
the holders.


Electrical component / Wiring harness routing
5-9
ELEC
Electrical system
Install the holders to the intake manifold
so that the catch of each holder is facing
up, and then fasten the main wiring har-
ness using the holders.
Route the main wiring harness through the
guide.


5-10
5
Starboard
1Stator assembly lead
2PTT relay ground lead
3Main wiring harness
4Wiring harness
5PTT motor lead
Install the holders to the intake manifold,
connect the fuel injector couplers and oil
pressure sensor coupler, and then fasten
the main wiring harness using the holder.
Fasten the main wiring harness, ther-
moswitch connectors, and cooling water
hose using the holder.
D
C C
D
A
A
B
B

1
2
3
1
3
4
3
2 4
5

A-A B-B C-C D-D



A
A
Wiring harness routing
5-11
ELEC
Electrical system
Install the holder to the bracket, and then
fasten the Rectifier Regulator lead using
the holder.
Install the holder to the intake manifold,
and then fasten the PTT motor lead using
the holder so that there is no slack in the
PTT motor lead.
Install the terminals of the ground leads
that are fastened together using tape so
that they contact the stopper.
Install the terminal of the ground lead with
gray tape so that it contacts the stopper.
Fasten the PTT motor lead and fuel hose
using the holder.
D
C C
D
A
A
B
B

1
2
3
1
3
4
3
2 4
5

A-A B-B C-C D-D



A
A
5-12
5
Install the Rectifier Regulator ground lead
terminal and PTT relay ground lead termi-
nal so that they contact the stopper.
Install the holder to the bracket, and then
fasten the Rectifier Regulator ground
leads using the holder.
Install the holder to the bracket, and then
fasten the Rectifier Regulator leads using
the holder.
Align the joint nipple with the marks on the
cooling water hoses.
D
C C
D
A
A
B
B

1
2
3
1
3
4
3
2 4
5

A-A B-B C-C D-D



A
A
Wiring harness routing
5-13
ELEC
Electrical system
Rear
1Main wiring harness
2Water pressure sensor lead
Install the holder on the main wiring har-
ness to the bracket.
Fasten the main wiring harness using the
holder so that the catch of the holder is
facing up.
Fasten the grommet on the main wiring
harness using the holder.
Fasten the main wiring harness and igni-
tion coil lead using the holder.
Fasten the main wiring harness at the
white tape using the holder.
A A


1
2
A-A
5-14
5
Front
Fasten the PTT relay lead using the
holder.
Align the starter motor lead with the arrow
mark on the terminal.
A
A

Wiring harness routing


5-15
ELEC
Electrical system
Top
Install the holders to the wiring harness
guide, and then fasten the main wiring
harness using the holders.
Fasten the low-pressure fuel pump lead
and air pressure sensor lead using the
holder.
Route the stator assembly leads under the
holder.

5-16
5
Bottom cowling
1Shift cut switch lead
2PTT switch lead
3Main wiring harness
4Cooling water hose
5Wiring harness
6Command Link Multifunction Meter lead
710-pin coupler
8Cooling water hose
9Trim sensor lead
0Water detection switch lead
A

A
B
B
C
C
D
D
E
1
2
4
3
2
8
6
9
0
6
7
2
5
A-A B-B C-C D-D E-E
E
Wiring harness routing
5-17
ELEC
Electrical system
Leave some slack in the neutral switch
lead.
Fold the trim sensor lead.
Fasten the main wiring harness, trim sen-
sor lead, and flushing hose using the
holder so that there is no slack in the trim
sensor lead.
Fasten the trim sensor lead, PTT motor
lead, and flushing hose using the holder.
A

A
B
B
C
C
D
D
E
1
2
4
3
2
8
6
9
0
6
7
2
5
A-A B-B C-C D-D E-E
E
5-18
5
Circuit diagram
TIP:
The circled numbers in the illustration indicate the engine ECM terminal numbers.
abc Indicates a connection between the symbols.
c a b
A
B
N
O
P
R
X
S
V
T
h
\
Y
a
]
U
c
b
x
o
r
p

t
s

}
|

Pulser coil
Cam position sensor
(PORT EX)
Cam position sensor
(PORT IN)
Cam position sensor
(STBD IN)
Air pressure sensor
Oil pressure sensor
5V
Ground
5V
TPS 1
TPS 2
APS 1
APS 2
Ground
5V
Ground
5V
Engine
ECM
Fuel injector #1
Fuel injector #2
Fuel injector #3
Fuel injector #4
Fuel injector #5
Fuel injector #6
Ignition coil #1
Ignition coil #4
Ignition coil #2
Ignition coil #3
Ignition coil #5
Ignition coil #6
ETV relay
ETV
motor
Wiring harness routing / Circuit diagram
5-19
ELEC
Electrical system
abc Indicates a connection between the symbols.
BZ
T
P
P
b
[
Z
8
4
0
Q
L
K
E
9
I
u
l
e
J
D

~
w
W
k
6
7

y
z
{
n

v
m
a c
Water pressure sensor
Speed sensor
Trim sensor
Air temperature sensor
Engine temperature sensor
Thermoswitch
Water detection switch
Shift cut switch
Neutral switch
Ground
Knock sensor
Engine shut-off
switch
Main relay
Main switch
Rectifier
Regulator
Battery
CAN BUS
YDIS
OCV (STBD)
OCV (PORT)
Low-pressure fuel pump
Vapor shut-off valve
Oil pressure alert indicator
Overheat alert indicator
Diagnostic flash indicator
Tachometer
Engine
ECM
High-pressure
fuel pump relay
High-pressure
fuel pump
Alert buzzer
5-20
5
ECM coupler layout
1 2 3 4 5 6 7
8 9 10 11 12 13
14 15 16 17 18 19
20212223242526
34 35 36 37 38 39
40 41 42 43 44 45
46474849505152
27282930313233
62 63 64 66 65 67 68 69
70 71 72 74 73 75 76 77
5354555657 59 58 6061
7879808182 84 83 8586
No. Connecting part Color
1
2
3
4 Air temperature
sensor
Black/Yellow
5
6 CAN BUS (L) Blue
7 CAN BUS (H) White
8 Trim sensor Pink
9 Sensor ground Black
10 Engine temperature
sensor
Black/Yellow
11 Pulser coil White/Red
12 Pulser coil ground Black
13
14 Main switch Yellow
15 Neutral switch Blue/Green
16
17
18
19 Knock sensor Green
20 Main relay Yellow/Green
21 Shift cut switch Blue/Yellow
22 Water detection
switch
Blue/White
23
24 Cam position sensor
(PORT EX)
White/Blue
25 Cam position sensor
(PORT IN)
White/Green
26 Cam position sensor
(STBD IN)
White/Black
27 Thermoswitch Pink
28 TPS power source Orange
29 TPS 2 Pink/White
30 APS 1 power source Orange
31 Sensor power
source
Orange
32 TPS ground Black
No. Connecting part Color
33 Ground Black
34 TPS 1 Pink
35 APS 2 power source Orange
36 Speed sensor Blue
37 Water pressure
sensor
Blue/Black
38 APS 1 ground Black
39 APS 2 ground Black
40
41 APS 2 Pink/White
42 Oil pressure sensor Pink/White
43 Air pressure sensor Pink/Green
44
45 Battery power
source
Red/Yellow
46
47
48 APS 1 Pink
49
50
51 YDIS White/Black
52 Battery power
source
Red/Yellow
53 OCV (STBD) Purple
54 Vapor shut-off valve Green/Black
55 ETV ground Black
56 ETV motor (open) Green/Red
57
58 ETV motor (close) Green/Black
59 ETV power source Red/Green
60 ETV power source Red/Green
61 Engine shut-off
switch
White
62 OCV (PORT) Purple
63 Ground Black
64 ETV ground Black
65 Diagnostic flash
indicator
Blue/White
Circuit diagram / ECM coupler layout
5-21
ELEC
Electrical system
1 2 3 4 5 6 7
8 9 10 11 12 13
14 15 16 17 18 19
20212223242526
34 35 36 37 38 39
40 41 42 43 44 45
46474849505152
27282930313233
62 63 64 66 65 67 68 69
70 71 72 74 73 75 76 77
5354555657 59 58 6061
7879808182 84 83 8586
No. Connecting part Color
66 Overheat alert
indicator
Pink/Black
67 Oil pressure alert
indicator
Pink/White
68 Ignition coil #1 Black/Orange
69 Ignition coil #2 Black/White
70 Ground Black
71 Ground Black
72 Alert buzzer Pink
73 ETV relay Yellow/Green
74 High-pressure fuel
pump relay
Black
75 Tachometer Green
76 Ignition coil #3 Black/Yellow
77 Ignition coil #4 Black/Green
78 Low-pressure fuel
pump
Blue/White
79 Fuel injector #2 Purple/Black
80 Fuel injector #1 Purple/Red
81 Fuel injector #3 Purple/Yellow
82 Fuel injector #4 Purple/Green
83 Fuel injector #5 Purple/Blue
84 Fuel injector #6 Purple/White
85 Ignition coil #5 Black/Blue
86 Ignition coil #6 Black/Brown
5-22
5
Checking the electrical
component
Using the YDIS
When checking the ETV, TPS, OCV, ignition
spark, APS, high-pressure fuel pump, fuel
injector, or each sensor, use the YDIS.
When deleting the diagnosis record in the
YDIS, make sure to check the time that the
trouble codes were detected.
When checking the input voltage of a part,
the coupler or connector must be discon-
nected. As a result, the engine ECM deter-
mines that the part is disconnected and a
trouble code is detected. Therefore, make
sure to delete the diagnosis record after
checking the input voltage.
TIP:
Before checking the electrical components,
make sure that the battery is fully charged.
Install the proprietary YDIS software on the
CD-ROM onto the computer. Always use
the exclusive communication cable to con-
nect the engine ECM to the computer. For
a description of the communication cable
and CD-ROM to be used, see YDIS (4-1).
Also, make sure to check the CD-ROM ver-
sion before using it.
To connect and operate the YDIS, see the
YDIS (Ver. 1.33 or later) Instruction Man-
ual.
Measuring the peak voltage
When measuring the peak voltage, do not
touch any of the connections of the digital
tester probes.
When measuring the peak voltage
between the terminals of an electrical
component using the digital tester, make
sure that the leads do not contact any
metal parts. Otherwise, the electrical com-
ponent may short-circuit and be dam-
aged.
To check the electrical components or mea-
sure the peak voltage, use the special ser-
vice tools. A malfunctioning electrical
component can be checked easily by mea-
suring the peak voltage. The specified engine
speed when measuring the peak voltage is
affected by many factors, such as fouled
spark plugs or a weak battery. If one of these
factors is present, the peak voltage cannot be
measured properly.
TIP:
Before measuring the peak voltage, check
all of the wiring harnesses for corrosion.
Also, make sure that the wiring harnesses
are connected properly and that the battery
is fully charged.
Use the peak volt adapter with the recom-
mended digital multimeter.
Connect the positive pin of the peak volt
adapter to the positive terminal of the digital
multimeter, and the negative pin to the neg-
ative terminal.
When measuring the peak voltage, set the
digital multimeter to the DC voltage mode.
YDIS (CD-ROM, Ver. 1.33):
60V-WS853-06
YDIS (KIT): 60V-85300-06
Digital multimeter: YU-34899-A
Peak volt adapter: YU-39991
V
ECM coupler layout / Checking the electrical component
5-23
ELEC
Electrical system
Using the digital tester
The electrical technical data apply to the
measurements taken using the Yamaha-rec-
ommended tester.
The resistance values shown are the values
taken before the engine is started. The actual
resistance may vary depending on the envi-
ronmental conditions and ambient tempera-
ture.
The input voltage changes depending on the
battery voltage.
If the tester probe cannot be inserted into the
coupler, prepare a test lead suitable for the
measurement.
Engine control unit and
component
Checking the main relay
1. Remove the relay cover, and then
remove the main relay 1.
2. Connect the positive battery lead to the
terminal a, connect the negative battery
lead to the terminal b, and then check
for continuity between the terminals c
and d. Replace the relay if there is no
continuity. NOTICE: Do not reverse the
battery leads.
3. Measure the input voltage between the
terminal e and ground, and the terminal
f and ground.
4. Turn the engine start switch to ON, and
then measure the input voltage between
the terminals e and g.
Digital multimeter: YU-34899-A
Test lead:
Terminal, male 1: (commercially
available)
Terminal, female 2: (commercially
available)
1 2
1
Battery lead
Terminal
c d
Connect
Disconnect
Main relay input voltage:
Terminal eGround
Terminal fGround
12.0 V (battery voltage)
a
c
d
b
e
f
5-24
5
5. Turn the engine start switch to OFF.
6. Install the main relay, and then install the
relay cover.
Checking the engine ECM circuit
1. Remove the flywheel magnet cover and
engine ECM cover.
2. Disconnect the engine ECM couplers a,
b, and c.
3. Check the wiring harness for continuity.
4. Measure the input voltage between ter-
minal 20 and ground.
5. Remove the fuse holder 1, and then dis-
connect the fuse holder coupler d.
Main relay input voltage:
Terminal eTerminal g
12.0 V (battery voltage)
e g
a
b
c
Wiring harness continuity:
b Terminal 33Ground
a Terminal 63Ground
a Terminal 70Ground
a Terminal 71Ground
Engine ECM input voltage:
Terminal 20Ground
12.0 V (battery voltage)
a
b
71
33
63
70
c
20
Checking the electrical component / Engine control unit and component
5-25
ELEC
Electrical system
6. Check the wiring harness for continuity.
7. Connect the fuse holder coupler, and
then install the fuse holder.
8. Connect the engine ECM couplers.
9. Install the engine ECM cover and fly-
wheel magnet cover.
Checking the APS
APS 1 and APS 2 are a single unit, which
cannot be disassembled.
1. Connect the YDIS to display Accelerator
position sensor 1 and Accelerator posi-
tion sensor 2.
2. Check that the accelerator lever a con-
tacts the stopper b when the remote
control lever is in the N position.
TIP:
Before checking the APS, make sure to
adjust the throttle cable properly. To adjust
the throttle cable, see Installing the shift
cable and throttle cable (3-8).
3. Turn the engine start switch to ON, and
then measure the APS output voltage
when the remote control lever is at the
fully closed position c and fully open
position d.
4. Check that the output voltages of APS 1
and APS 2 change continuously when
the remote control lever is operated.
5. Turn the engine start switch to OFF.
6. Disconnect the throttle cable joint from
the APS.
7. Disconnect the APS coupler.
Wiring harness continuity:
c Terminal 20d Terminal 10
b Terminal 52d Terminal 22
b Terminal 45d Terminal 23
1
d
b c
d
22
52
23
45
20
10
APS output voltage (reference data):
Item Fully closed c Fully open d
APS 1 0.679 V 4.165 V
APS 2 0.635 V 4.111 V
b a
F
N
R
d
c
5-26
5
8. Measure the APS resistance when the
accelerator lever a is at the fully closed
position e and fully open position f.
Fully closed position
Fully open position
9. Connect the APS coupler.
10. Connect the throttle cable joint to the
APS.
Checking the APS circuit
1. Disconnect the APS coupler a.
2. Turn the engine start switch to ON, and
then measure the input voltage at the
APS coupler a.
3. Turn the engine start switch to OFF.
4. Remove the flywheel magnet cover and
engine ECM cover.
5. Disconnect the engine ECM coupler b.
6. Check the wiring harness for continuity.
APS resistance at 20 C (68 F)
(reference data):
Item Terminal
Fully
closed e
Fully
open f
APS 1 gh
0.8 k 5.3 k
APS 2 km
g h km
a
b
f
b

e
APS input voltage:
Terminal 2Terminal 1
Terminal 8Terminal 7
4.755.25 V
1 2 7 8
a
a
b
41
35
1 2 3 6 7 8
38
48
39
30
a b
Engine control unit and component
5-27
ELEC
Electrical system
7. Connect the engine ECM coupler b.
8. Install the engine ECM cover and fly-
wheel magnet cover.
9. Connect the APS coupler a.
Checking the ETV and TPS
TPS 1 and TPS 2 are components of the
ETV, which cannot be disassembled.
Do not loosen the throttle stop screw nut,
and do not turn the throttle stop screw.
1. Connect the YDIS to display Throttle
position sensor (main), Throttle valve
opening, and Throttle position sensor
(sub).
2. Start the engine, warm it up for 510 min-
utes, and then stop it.
3. Turn the engine start switch to ON, and
then measure the TPS output voltage
and throttle valve opening angles when
the remote control lever is at the fully
closed position a and fully open position
b.
TIP:
The actual TPS output voltage and throttle
valve opening angle may vary according to
environmental conditions and engine temper-
ature.
4. Turn the engine start switch to OFF.
5. Remove the flywheel magnet cover, and
then disconnect the ETV coupler.
6. Turn the engine start switch to ON, and
then measure the TPS input voltage at
the ETV coupler. Check the wiring har-
ness if out of specification. See Check-
ing the ETV and TPS circuit (5-28).
Wiring harness continuity:
a Terminal 1b Terminal 38
a Terminal 2b Terminal 30
a Terminal 3b Terminal 48
a Terminal 6b Terminal 41
a Terminal 7b Terminal 39
a Terminal 8b Terminal 35
TPS output voltage and throttle valve
opening angle (reference data):
Item Fully closed a Fully open b
TPS 1 0.732 V 4.326 V
TPS 2 2.715 V 4.624 V
Opening
angle
5.1 84.5
TPS input voltage:
Orange (O)Black (B)
4.755.25 V
F
N
R
b
a
B O
5-28
5
7. Turn the engine start switch to OFF.
8. Connect the ETV coupler, and then
install the flywheel magnet cover.
Checking the ETV relay
1. Remove the relay cover, and then
remove the ETV relay 1.
2. Check the ETV relay. See Checking the
main relay (5-23).
3. Measure the input voltage between the
terminal a and ground.
4. Turn the engine start switch to ON, and
then measure the input voltage between
the terminals b and c.
5. Turn the engine start switch to OFF.
6. Install the ETV relay, and then install the
relay cover.
Checking the ETV and TPS circuit
1. Remove the flywheel magnet cover and
engine ECM cover.
2. Disconnect the engine ECM couplers a
and b.
3. Disconnect the ETV coupler c.
4. Check the wiring harness for continuity.
ETV relay input voltage:
Terminal aGround
12.0 V (battery voltage)
1
a
c b
ETV relay input voltage:
Terminal bTerminal c
12.0 V (battery voltage)
b
a
c
Engine control unit and component
5-29
ELEC
Electrical system
5. Connect the engine ECM coupler a and
ETV coupler c.
6. Remove the fuse holder 1, and then dis-
connect the fuse holder couplers d and
e.
7. Check the wiring harness for continuity.
8. Connect the fuse holder couplers d and
e, and then install the fuse holder 1.
9. Connect the engine ECM coupler b.
10. Install the engine ECM cover and fly-
wheel magnet cover.
Checking the cam position sensor
1. Remove the flywheel magnet cover and
engine ECM cover.
2. Disconnect the cam position sensor cou-
plers a, b and c.
3. Turn the engine start switch to ON, and
then measure the input voltage at the
cam position sensor coupler.
Wiring harness continuity:
a Terminal 28c Terminal 5
a Terminal 29c Terminal 6
a Terminal 32c Terminal 3
a Terminal 34c Terminal 4
b Terminal 56c Terminal 1
b Terminal 58c Terminal 2
a
b
c
1 2
32
3 4
34
5 6
56
28
58
29
1
e
d
Wiring harness continuity:
b Terminal 59d Terminal 12
b Terminal 60d Terminal 5
b Terminal 73e Terminal 1
b Terminal 55Ground
b Terminal 64Ground
b
d
e
1
12
73
64
5
55 59 60
5-30
5
4. Turn the engine start switch to OFF.
5. Make 3 test leads.
6. Reduce the fuel pressure. See steps 14
in Reducing the fuel pressure (6-6).
TIP:
Make sure to remove the high-pressure fuel
pump fuse.
7. Remove the fuel rails. See Removing
the fuel injector (6-34).
8. Remove the cam position sensors 4.
9. Connect the test leads to the cam posi-
tion sensor 4 and cam position sensor
coupler.
10. Connect the tester probes to the test
leads.
Cam position sensor input voltage:
Red/Yellow (R/Y)Black (B)
12.0 V (battery voltage)
White/Black (W/B)Black (B)
White/Green (W/G)Black (B)
White/Blue (W/L)Black (B)
4.755.25 V
a
R/Y B
W/B
STBD IN
b R/Y B
W/G
PORT IN
c
PORT EX
R/Y B
W/L
Test lead:
Terminal, male 1: YE-32061
Terminal, female 2: YE-32062
Terminal, female 3: (commercially
available)
d = 100 mm (3.94 in)
e = 50 mm (1.97 in)
f = Cutout area
2
3
1
d
e
f
1
Engine control unit and component
5-31
ELEC
Electrical system
11. Turn the engine start switch to ON, and
then measure the output voltage when
moving a screwdriver close to the cam
position sensor 4. Replace if out of
specification.
TIP:
Using an analog circuit tester is recom-
mended.
12. Turn the engine start switch to OFF.
13. Disconnect the test leads, and then
install the cam position sensors.
14. Install the fuel rails. See Installing the
fuel injector (6-34).
15. Install the high-pressure fuel pump fuse.
See Fuse holder (5-3).
16. Remove the fuse holder 5, and then dis-
connect the fuse holder coupler m.
17. Disconnect the engine ECM coupler n.
12V 5V
ECM
4
4
B
W/B
W/G
W/L R/Y
g h k
4
Cam position sensor output voltage:
White/Blue (W/L)Black (B)
(PORT EX)
White/Green (W/G)Black (B)
(PORT IN)
White/Black (W/B)Black (B)
(STBD IN)
Position Voltage
g, h More than 4.8
k Less than 1.0
5
m
n
5-32
5
18. Check the wiring harness for continuity.
19. Set the digital multimeter to the diode
mode p, and then check the wiring har-
ness for continuity.
OL: Indicates an overload
20. Connect the cam position sensor cou-
plers and engine ECM coupler.
21. Connect the fuse holder coupler, and
then install the fuse holder.
22. Install the engine ECM cover and fly-
wheel magnet cover.
Checking the OCV
1. Check the operation of the OCVs using
the YDIS Stationary test and check the
operating sound.
2. Remove the flywheel magnet cover, and
then disconnect the OCV couplers a
and b.
3. Turn the engine start switch to ON, and
then measure the input voltage at the
OCV coupler.
Wiring harness continuity:
a Terminal 1n Terminal 9
a Terminal 2n Terminal 26
b Terminal 1n Terminal 9
b Terminal 2n Terminal 25
c Terminal 1n Terminal 9
c Terminal 2n Terminal 24
n
c b a
2 1 2 1 2 1
24 25 26
9
p
m
c b a
3 3 3
19 20
Wiring harness continuity
(testing diode mode):
Tester probe Display value
(reference
data)
+ -
m Terminal
20
a Terminal
3
0.550 V
a Terminal
3
m Terminal
20
OL
m Terminal
20
b Terminal
3
0.530 V
b Terminal
3
m Terminal
20
OL
m Terminal
19
c Terminal
3
0.551 V
c Terminal
3
m Terminal
19
OL
Engine control unit and component
5-33
ELEC
Electrical system
4. Turn the engine start switch to OFF.
5. Remove the OCV.
6. Measure the OCV resistance.
7. Connect the battery leads to the termi-
nals and check the operation of the spool
valve. Replace the OCV if the spool
valve does not operate.
8. Disconnect the battery leads.
9. Remove the fuse holder 1, and then dis-
connect the fuse holder coupler c.
10. Remove the engine ECM cover, and then
disconnect the engine ECM coupler d.
11. Check the wiring harness for continuity.
OCV input voltage:
Red/Yellow (R/Y)Ground
12.0 V (battery voltage)
OCV resistance (reference data):
6.77.7 at 20 C (68 F)
a
PORT
R/Y
b
STBD
R/Y
1
c
d
5-34
5 12. Install the OCV, and then connect the
OCV couplers.
13. Connect the engine ECM coupler, and
then install the engine ECM cover.
14. Connect the fuse holder coupler, and
then install the fuse holder.
15. Install the flywheel magnet cover.
Checking the oil pressure sensor
1. Disconnect the oil pressure sensor cou-
pler a, and then connect the special ser-
vice tool 1.
2. Turn the engine start switch to ON, and
then measure the oil pressure sensor
input voltage.
3. Start the engine and warm it up for 510
minutes.
4. Measure the oil pressure sensor output
voltage.
5. Turn the engine start switch to OFF, and
then disconnect the special service tool.
6. Remove the flywheel magnet cover and
engine ECM cover.
7. Disconnect the engine ECM couplers b
and c.
Wiring harness continuity:
PORT
a Terminal 1d Terminal 62
a Terminal 2c Terminal 21
STBD
b Terminal 1d Terminal 53
b Terminal 2c Terminal 21
1
21
2
62
53
a
1 2
b
c
d
Test harness (3 pins) 1: YB-06869
Oil pressure sensor input voltage:
Orange (O)Black (B)
4.755.25 V
Oil pressure sensor output voltage
(reference data):
Pink/White (P/W)Black (B)
2.8 V at 450.0 kPa (4.50 kgf/cm
2
,
65.3 psi) and 60 C (140 F) with
10W-30 engine oil and at 750 r/min
G/W
P/W
O
B
B G
P/W O B
1
a
a
1
Engine control unit and component
5-35
ELEC
Electrical system
8. Check the wiring harness for continuity.
9. Connect the engine ECM couplers.
10. Install the engine ECM cover and fly-
wheel magnet cover.
11. Connect the oil pressure sensor coupler.
Ignition unit and component
Checking the ignition spark
Make sure to install the special service
tool to the ignition coil so that sparks do
not leak out.
Keep flammable gas or liquids away,
because this test can produce sparks.
1. Remove the flywheel magnet cover and
engine ECM cover.
2. Remove the ignition coils.
3. Connect the special service tool 1 to an
ignition coil.
TIP:
Repeat steps 35 for each ignition coil.
4. Check the ignition spark using the YDIS
Stationary test. WARNING! Do not
touch any of the connections of the
special service tool.
5. Disconnect the special service tool.
6. Install the ignition coils.
7. Install the engine ECM cover and fly-
wheel magnet cover.
Checking the ignition coil
1. Remove the flywheel magnet cover and
engine ECM cover.
2. Disconnect the ignition coil couplers a.
3. Turn the engine start switch to ON, and
then measure the input voltage at the
ignition coil coupler.
Wiring harness continuity:
a Terminal 1b Terminal 31
a Terminal 2c Terminal 9
a Terminal 3b Terminal 42
b
c
b c
31
42
9
a
1 2 3
Spark checker 1: YM-34487
OK
1
B R/Y
a a
5-36
5
4. Turn the engine start switch to OFF, and
then disconnect the engine ECM coupler
b.
5. Remove the fuse holder 1, and then dis-
connect the fuse holder coupler c.
6. Check the wiring harness for continuity.
7. Connect the fuse holder coupler, and
then install the fuse holder.
8. Connect the engine ECM coupler and
ignition coil couplers.
9. Install the engine ECM cover and fly-
wheel magnet cover.
Checking the pulser coil
1. Remove the flywheel magnet cover.
2. Disconnect the pulser coil coupler a,
and then connect the special service tool
1.
3. Measure the pulser coil output peak volt-
age.
Ignition coil input voltage:
Red/Yellow (R/Y)Black (B)
12.0 V (battery voltage)
b
1
c
b
c
1 2 3
85
76
86
77
68 69
18
a
Wiring harness continuity:
Ignition coil #1
a Terminal 1b Terminal 68
a Terminal 2Ground
a Terminal 3c Terminal 18
Ignition coil #2
a Terminal 1b Terminal 69
a Terminal 2Ground
a Terminal 3c Terminal 18
Ignition coil #3
a Terminal 1b Terminal 76
a Terminal 2Ground
a Terminal 3c Terminal 18
Ignition coil #4
a Terminal 1b Terminal 77
a Terminal 2Ground
a Terminal 3c Terminal 18
Ignition coil #5
a Terminal 1b Terminal 85
a Terminal 2Ground
a Terminal 3c Terminal 18
Ignition coil #6
a Terminal 1b Terminal 86
a Terminal 2Ground
a Terminal 3c Terminal 18
Engine control unit and component / Ignition unit and component
5-37
ELEC
Electrical system
TIP:
When measuring the output peak voltage
under the cranking condition, remove the
clip from the engine shut-off switch to pre-
vent the engine from starting.
When measuring the output peak voltage
under the unloaded condition, disconnect
the pulser coil coupler a.
4. Disconnect the special service tool.
5. Measure the pulser coil resistance.
6. Remove the engine ECM cover, and then
disconnect the engine ECM coupler b.
7. Check the wiring harness for continuity.
8. Connect the engine ECM coupler, and
then install the engine ECM cover.
9. Connect the pulser coil coupler, and then
install the flywheel magnet cover.
Checking the air temperature sensor
1. Measure the ambient temperature.
2. Connect the YDIS to display Intake tem-
perature (air temperature).
3. Check that the difference between the
ambient temperature and the displayed
intake temperature is within 5 C ( 41
F).
TIP:
Check the air temperature sensor when the
engine is cold.
4. Remove the flywheel magnet cover, and
then disconnect the air temperature sen-
sor coupler a.
Test harness (2 pins) 1: YB-06867
Pulser coil output peak voltage:
White/Red (W/R)Black (B)
r/min
Unloaded Loaded
Cranking 1500 3500
DC V 8.8 7.7 19.8 24.5
Pulser coil resistance (reference data):
White/Red (W/R)Black (B)
396.0594.0 at 20 C (68 F)
a
1
W/B
B
W/R
W/R B
G/W G
B
a
1
Wiring harness continuity:
a Terminal 1b Terminal 11
a Terminal 2b Terminal 12
b
2 1
11 12
a b
5-38
5
5. Turn the engine start switch to ON, and
then measure the input voltage at the air
temperature sensor coupler a.
6. Turn the engine start switch to OFF.
7. Remove the air temperature sensor.
8. Place the air temperature sensor in a
container of water and heat the water
slowly.
9. Measure the air temperature sensor
resistance at the specified water temper-
atures.
10. Remove the engine ECM cover, and then
disconnect the engine ECM coupler b.
11. Check the wiring harness for continuity.
12. Connect the engine ECM coupler, and
then install the engine ECM cover.
13. Install the air temperature sensor, and
then connect the air temperature sensor
coupler.
14. Install the flywheel magnet cover.
Checking the air pressure sensor
1. Remove the flywheel magnet cover and
intake silencer.
2. Disconnect the air pressure sensor cou-
pler a.
3. Turn the engine start switch to ON, and
then measure the input voltage at the air
pressure sensor coupler a.
Air temperature sensor input voltage:
Black/Yellow (B/Y)Black (B)
4.755.25 V
Air temperature sensor resistance
(reference data):
2.22.7 k at 20 C (68 F)
0.3 k at 80 C (176 F)
a
B/Y B
Wiring harness continuity:
a Terminal 1b Terminal 4
a Terminal 2b Terminal 9
b
1 2
a b
4
9
Ignition unit and component
5-39
ELEC
Electrical system
4. Turn the engine start switch to OFF.
5. Remove the air pressure sensor.
6. Connect the special service tools 1 and
2.
7. Turn the engine start switch to ON.
8. Apply negative pressure to the air pres-
sure sensor slowly, and then measure
the output voltage at the specified pres-
sures.
9. Turn the engine start switch to OFF.
10. Disconnect the special service tools.
11. Remove the engine ECM cover, and then
disconnect the engine ECM couplers b
and c.
12. Check the wiring harness for continuity.
13. Connect the engine ECM couplers, and
then install the engine ECM cover.
Air pressure sensor input voltage:
Orange (O)Black (B)
4.755.25 V
Pressure/vacuum tester 1: YB-35956-A
Test harness (3 pins) 2: YB-06869
B O
a
2
B
G/W G
P/G
B
O
1
2
Air pressure sensor output voltage
(reference data):
Pink/Green (P/G)Black (B)
3.2 V at 20.0 kPa
(0.20 kgf/cm
2
, 2.9 psi)
2.2 V at 46.7 kPa
(0.467 kgf/cm
2
, 6.8 psi)
Wiring harness continuity:
a Terminal 1b Terminal 31
a Terminal 2c Terminal 9
a Terminal 3b Terminal 43
b
c
a
b c
1
31
2 3
43
9
5-40
5
14. Install the air pressure sensor, and then
connect the air pressure sensor coupler.
15. Install the intake silencer and flywheel
magnet cover.
Checking the engine temperature
sensor
1. Disconnect the engine temperature sen-
sor coupler a.
2. Turn the engine start switch to ON, and
then measure the input voltage at the
engine temperature sensor coupler a.
3. Turn the engine start switch to OFF.
4. Remove the flywheel magnet cover and
flywheel magnet. See Removing the fly-
wheel magnet (7-7).
5. Remove the engine temperature sensor.
6. Place the engine temperature sensor in a
container of water and heat the water
slowly.
7. Measure the engine temperature sensor
resistance at the specified temperatures.
8. Remove the engine ECM cover, and then
disconnect the engine ECM coupler b.
9. Check the wiring harness for continuity.
10. Connect the engine ECM coupler, and
then install the engine ECM cover.
11. Install the engine temperature sensor,
and then connect the engine temperature
sensor coupler.
12. Install the flywheel magnet and flywheel
magnet cover. See Installing the fly-
wheel magnet (7-7).
Engine temperature sensor input voltage:
Black/Yellow (B/Y)Black (B)
4.755.25 V
B B/Y
a
Engine temperature sensor resistance
(reference data):
4.24.9k at 5 C (41 F)
1.92.1 k at 25 C (77 F)
0.1660.204 k at 100 C (212 F)
Wiring harness continuity:
a Terminal 1b Terminal 10
a Terminal 2b Terminal 9
b
a b
1 2
9 10
Ignition unit and component
5-41
ELEC
Electrical system
Checking the thermoswitch
1. Remove the flywheel magnet cover, and
then disconnect the thermoswitch con-
nectors a and b.
2. Turn the engine start switch to ON, and
then measure the input voltage at the
thermoswitch connectors.
3. Turn the engine start switch to OFF.
4. Remove the thermoswitches.
5. Place the thermoswitches in a container
of water and heat the water slowly.
6. Check the thermoswitches for continuity
at the specified temperatures. Replace if
out of specification.
c Temperature
d Time
e No continuity
f Continuity
7. Remove the engine ECM cover, and then
disconnect the engine ECM couplers k
and m.
8. Check the wiring harness for continuity.
Thermoswitch input voltage:
Pink (P)Black (B)
4.755.25 V
a
PORT
P B
b
STBD
P B
P
B
Thermoswitch continuity temperature:
g: 84.090.0 C (183.0194.0 F)
h: 68.082.0 C (154.0180.0 F)
g
c
e
f
f
d
f
h
e
k
m
k m
P B
27
9
5-42
5
9. Connect the engine ECM couplers, and
then install the engine ECM cover.
10. Install the thermoswitches, and then con-
nect the thermoswitch connectors.
11. Install the flywheel magnet cover.
Checking the shift cut switch
1. Disconnect the shift cut switch coupler
a.
2. Connect the special service tool 1 to the
shift cut switch coupler a.
3. Turn the engine start switch to ON, and
then measure the input voltage.
4. Turn the engine start switch to OFF.
5. Disconnect the special service tool 1,
and then connect it to the shift cut switch
coupler b.
6. Measure the shift cut switch resistance
when the gear shift is in the N position.
7. Check the shift cut switch for continuity.
Replace if out of specification.
Wiring harness continuity:
Pink (P)k Terminal 27
Black (B)m Terminal 9
Test harness (2 pins) 1: YB-06867
Shift cut switch input voltage:
Blue/Yellow (L/Y)Black (B)
4.755.25 V
1
a
G/W
G
1
a
B
L/Y
B L/Y
Test harness (2 pins) 1: YB-06867
Shift cut switch resistance (reference
data):
Blue/Yellow (L/Y)Black (B)
4.54.9 k
G/W
G
B
L/Y
1
1
b
b
B L/Y
Ignition unit and component
5-43
ELEC
Electrical system
8. Disconnect the special service tool.
9. Remove the flywheel magnet cover and
engine ECM cover.
10. Disconnect the engine ECM coupler e.
11. Check the wiring harness for continuity.
12. Connect the engine ECM coupler and
shift cut switch coupler.
13. Install the engine ECM cover and fly-
wheel magnet cover.
Checking the neutral switch
1. Disconnect the neutral switch coupler a.
2. Connect the special service tool 1 to the
neutral switch coupler a.
3. Turn the engine start switch to ON, and
then measure the input voltage.
Test harness (2 pins) 1: YB-06867
Switch
position
Lead color
L/Y B
Free c
Pushed d
G/W
G
B
L/Y
1
c
c
d
d
1
B L/Y
e
Wiring harness continuity:
a Terminal 1e Terminal 9
a Terminal 2e Terminal 21
Test harness (2 pins) 1: YB-06867
e a
2 1 9
21
G/W
G
B
L/G a
a
1
1
L/G B
5-44
5
4. Turn the engine start switch to OFF.
5. Disconnect the special service tool 1,
and then connect it to the neutral switch
coupler b.
6. Check the neutral switch for continuity.
Replace if out of specification.
7. Disconnect the special service tool.
8. Remove the flywheel magnet cover and
engine ECM cover.
9. Disconnect the engine ECM coupler e.
10. Check the wiring harness for continuity.
11. Connect the engine ECM coupler and
neutral switch coupler.
12. Install the engine ECM cover and fly-
wheel magnet cover.
Checking the knock sensor
1. Remove the flywheel magnet cover and
engine ECM cover.
2. Disconnect the knock sensor coupler a.
3. Measure the knock sensor resistance.
Neutral switch input voltage:
Blue/Green (L/G)Black (B)
4.755.25 V
Test harness (2 pins) 1: YB-06867
Switch
position
Lead color
L/G B
Pushed c
Free d
G/W
G
B
L/G
1
1
b
b
c
d
c
d
d
L/G B
Wiring harness continuity:
a Terminal 1e Terminal 15
a Terminal 2e Terminal 9
e
e a
1 2 9
15
a
Ignition unit and component
5-45
ELEC
Electrical system
4. Disconnect the engine ECM coupler b.
5. Check the wiring harness for continuity.
6. Connect the knock sensor coupler and
engine ECM coupler.
7. Install the engine ECM cover and fly-
wheel magnet cover.
Checking the engine shut-off switch
1. Disconnect the engine start switch cou-
pler.
2. Turn the engine start switch to ON, and
then check the engine shut-off switch 1
for continuity between the terminals a
and b.
3. Turn the engine start switch to OFF.
4. Connect the engine start switch coupler.
Fuel control unit and component
Checking the water detection switch
1. Disconnect the water detection switch
coupler a.
2. Turn the engine start switch to ON, and
then measure the input voltage at the
water detection switch coupler a.
Knock sensor resistance (reference data):
504.0616.0 k
Wiring harness continuity:
a Terminal 1b Terminal 19
b
1
19
a b
Switch position
Terminal
a b
Clip removed c
Clip installed d
Water detection switch input voltage:
Blue/White (L/W)Black (B)
4.755.25 V
1
a
b
ON
OFF START
d c
a
L/W B
5-46
5
3. Turn the engine start switch to OFF, and
then remove the filter cup assembly.
4. Check that the float 1 moves smoothly.
5. Check the water detection switch for con-
tinuity when the float 1 is in positions
and . NOTICE: Do not remove the
clip 2 and float 1.
6. Remove the flywheel magnet cover and
engine ECM cover.
7. Disconnect the engine ECM coupler e.
8. Check the wiring harness for continuity.
9. Connect the engine ECM coupler.
10. Install the engine ECM cover and fly-
wheel magnet cover.
11. Install the filter cup assembly. See Fuel
filter assembly (6-9).
12. Connect the water detection switch cou-
pler.
Checking the fuel injector
1. Check the operation of the fuel injectors
using the YDIS Stationary test and
check the operating sound.
2. Disconnect the fuel injector couplers a.
3. Turn the engine start switch to ON, and
then measure the input voltage at the
fuel injector coupler.
Float position
Terminal
b c

Float height d:
35.045.0 mm (1.381.77 in)
b
c
2
1

1
2
d
b c

Wiring harness continuity:


a Terminal 1e Terminal 22
a Terminal 2e Terminal 9
e
1 2
22
9
a e
Ignition unit and component / Fuel control unit and component
5-47
ELEC
Electrical system
4. Turn the engine start switch to OFF.
5. Measure the fuel injector resistance.
6. Remove the flywheel magnet cover and
engine ECM cover.
7. Remove the fuse holder 1, and then dis-
connect the fuse holder coupler b.
8. Disconnect the engine ECM coupler c.
9. Check the wiring harness for continuity.
Fuel injector input voltage:
Red/Yellow (R/Y)Ground
12.0 V (battery voltage)
Fuel injector resistance (reference data):
11.512.5 at 20 C (68 F)
a
PORT
R/Y
a
R/Y
STBD
1
b
c
1
21
81
2
82 83 84 79 80
a b
c
5-48
5
10. Connect the fuse holder coupler, and
then install the fuse holder.
11. Connect the engine ECM coupler.
12. Install the engine ECM cover and fly-
wheel magnet cover.
13. Connect the fuel injector couplers.
Checking the low-pressure fuel
pump and high-pressure fuel pump
1. Check the operation of the low-pressure
fuel pump and high-pressure fuel pump
using the YDIS Stationary test and
check the operating sound.
2. Remove the flywheel magnet cover.
3. Disconnect the low-pressure fuel pump
coupler a and high-pressure fuel pump
coupler b.
4. Turn the engine start switch to ON, and
then measure the input voltage at the
low-pressure fuel pump coupler a.
5. Turn the engine start switch to OFF.
6. Connect the tester probes to the termi-
nals of the high-pressure fuel pump cou-
pler b, and then measure the input
voltage within 5 seconds after turning the
engine start switch to ON.
7. Measure the resistance of the fuel pump
motors.
Wiring harness continuity:
Injector #1
a Terminal 1b Terminal 21
a Terminal 2c Terminal 80
Injector #2
a Terminal 1b Terminal 21
a Terminal 2c Terminal 79
Injector #3
a Terminal 1b Terminal 21
a Terminal 2c Terminal 81
Injector #4
a Terminal 1b Terminal 21
a Terminal 2c Terminal 82
Injector #5
a Terminal 1b Terminal 21
a Terminal 2c Terminal 83
Injector #6
a Terminal 1b Terminal 21
a Terminal 2c Terminal 84
Low-pressure fuel pump input voltage:
Red/Yellow (R/Y)Ground
12.0 V (battery voltage)
High-pressure fuel pump input voltage:
Red/Yellow (R/Y)Black (B)
12.0 V (battery voltage)
b
a
R/Y
b
B R/Y
Fuel control unit and component
5-49
ELEC
Electrical system
8. Remove the fuse holder 3, and then dis-
connect the fuse holder couplers c and
d.
9. Remove the engine ECM cover, and then
disconnect the engine ECM coupler e.
10. Check the wiring harness for continuity.
11. Connect the engine ECM coupler, and
then install the engine ECM cover.
12. Connect the fuse holder couplers, and
then install the fuse holder.
13. Connect the low-pressure fuel pump cou-
pler and high-pressure fuel pump cou-
pler.
14. Install the flywheel magnet cover.
Checking the high-pressure fuel
pump relay
1. Remove the relay cover, and then
remove the high-pressure fuel pump
relay 1.
2. Check the high-pressure fuel pump relay.
See Checking the main relay (5-23).
Low-pressure fuel pump 1 resistance
(reference data): 1.34.0
High-pressure fuel pump 2 resistance
(reference data): 0.23.0
2
1
3
d
c
e
Wiring harness continuity:
a Terminal 1c Terminal 7
a Terminal 2e Terminal 78
b Terminal 1c Terminal 1
b Terminal 2Ground
d Terminal 17e Terminal 74
a
b
c
d
e
1 2
1 2
74
7
1
17
14
78
5-50
5
3. Turn the engine start switch to ON, and
then measure the input voltage between
the terminal a and ground, and the ter-
minal b and ground.
4. Measure the input voltage between the
terminals b and c.
5. Turn the engine start switch to OFF.
6. Install the high-pressure fuel pump relay,
and then install the relay cover.
Checking the vapor shut-off valve
1. Remove the flywheel magnet cover, and
then disconnect the vapor shut-off valve
coupler a.
2. Turn the engine start switch to ON, and
then measure the input voltage at the
vapor shut-off valve coupler a.
3. Remove the vapor shut-off valve 1, and
then connect the special service tool 2.
4. Apply the specified negative pressure to
the vapor shut-off valve 1.
5. Check that the vapor shut-off valve 1
opens and the negative pressure is
released when the battery leads are con-
nected to the vapor shut-off valve termi-
nals. NOTICE: Do not connect the
battery leads to the vapor shut-off
valve terminals for more than a few
seconds.
High-pressure fuel pump relay input
voltage:
Terminal aGround
Terminal bGround
12.0 V (battery voltage)
High-pressure fuel pump relay input
voltage:
Terminal bTerminal c
12.0 V (battery voltage)
1
a
b
c b
Vapor shut-off valve input voltage:
Red/Yellow (R/Y)Ground
12.0 V (battery voltage)
R/Y
a
2
1
Fuel control unit and component
5-51
ELEC
Electrical system
6. Disconnect the special service tool.
7. Measure the vapor shut-off valve resis-
tance.
8. Remove the fuse holder 3, and then dis-
connect the fuse holder coupler b.
9. Remove the engine ECM cover, and then
disconnect the engine ECM coupler c.
10. Check the wiring harness for continuity.
11. Install the vapor shut-off valve, and then
connect the vapor shut-off valve coupler.
12. Connect the fuse holder coupler, and
then install the fuse holder.
13. Connect the engine ECM coupler.
14. Install the engine ECM cover and fly-
wheel magnet cover.
Starting unit and component
Checking the starter relay
1. Remove the relay cover, and then
remove the starter relay 1.
2. Check the starter relay. See Checking
the main relay (5-23).
3. Measure the input voltage between the
terminal a and ground.
Pressure/vacuum tester 2: YB-35956-A
Specified negative pressure:
67.0 kPa (0.67 kgf/cm
2
, 9.7 psi)
Vapor shut-off valve resistance
(reference data):
30.034.0 at 20 C (68 F)
3
b
c
Wiring harness continuity:
a Terminal 1c Terminal 54
a Terminal 2b Terminal 21
a b
c
1
21
2
54
1
5-52
5
4. Connect the tester probes between the
terminals b and c, and then turn the
engine start switch to START and mea-
sure the input voltage.
5. Install the starter relay, and then install
the relay cover.
Checking the engine start switch
1. Disconnect the engine start switch cou-
pler.
2. Move the remote control lever to the N
position.
3. Check the engine start switch 1 for con-
tinuity.
4. Connect the engine start switch coupler.
Starter relay input voltage:
Terminal aGround
12.0 V (battery voltage)
Starter relay input voltage:
Terminal bTerminal c
12.0 V (battery voltage)
a
b
c
Switch
position
Terminal
a b c d e
OFF
ON
START
1
a
c
b
e
d
ON
OFF START
Fuel control unit and component / Starting unit and component
5-53
ELEC
Electrical system
Starter motor
No. Part name Qty Remarks
1 Brush spring 4
2 Brush assembly 1
3 Brush holder assembly 1
4 Washer set 1
5 Starting motor gear assembly 1
6 Bracket 1
7 Screw 2 M4 16 mm
8 Bolt 2 M5 127 mm
9 Planetary gear 3
10 Outer gear 1
11 Plate 1
12 Stator 1
13 Armature 1
14 Pinion assembly 1
15 Bracket 1
16 Bearing 1
17 Gasket 1
Not reusable
4
9
9
14
15
17
19
10
11
12
13
1
2
5
3
7
8
6
7
5
4
4
4
4
18
16
23
20
21
21
22
25
24
26
5-54
5
No. Part name Qty Remarks
18 Bracket assembly 1
19 Pinion shaft 1
20 Cover 1
21 Bolt 2 M6 35 mm
22 Seal set 1
Not reusable
23 Lever assembly 1
24 Magnet switch 1
25 Washer 1
26 Nut 1
4
9
9
14
15
17
19
10
11
12
13
1
2
5
3
7
8
6
7
5
4
4
4
4
18
16
23
20
21
21
22
25
24
26
Starter motor
5-55
ELEC
Electrical system
Removing the starter motor
1. Remove the intake manifold (STBD).
2. Remove the starter motor from the power
unit. See Starter motor (7-33).
Checking the starter motor operation
1. Connect the positive battery cable 1 to
the magnet switch terminal a, and then
connect the negative battery cable 2 to
the starter motor body.
2. Connect a lead 3 to the magnet switch
terminal b.
3. Connect the lead 3 to the positive bat-
tery terminal, and then check the starter
motor operation. WARNING! Do not
touch the starter motor pinion.
TIP:
Check the starter motor operation for a few
seconds.
If the starter motor is disassembled for
maintenance, make sure to check the oper-
ation again after assembling it.
4. Disconnect the negative and positive bat-
tery cables from the battery terminals.
Checking the magnet switch
1. Connect the tester probes to the magnet
switch terminals a and b.
2. Connect the negative battery cable 1 to
the starter motor body.
3. Connect a lead 2 to the magnet switch
terminal c.
4. Connect the positive battery cable 3 to
the lead 2, and then check the magnet
switch for continuity between the termi-
nals a and b. Replace if out of specifi-
cation. NOTICE: Do not connect the
positive battery cable to the lead 2
for more than 1 second.
TIP:
The starter motor pinion should be pushed
out while the magnet switch is on.
Checking the starter motor pinion
Before checking the starter motor pinion,
make sure to disconnect the battery
cables.
1. Check the pinion. Replace if cracked or
worn.
2. Turn the pinion counterclockwise to
check that it operates smoothly and turn
it clockwise to check that it locks in place.
3
3
1
2
1
2
a
b
Battery lead
Terminal
a b
Connect
Disconnect
1
3
a
c
b
2
1
3
2
5-56
5
Disassembling the starter motor
1. Remove the magnet switch 1 and spring
a.
2. Disassemble the starter motor.
3. Remove the rubber seal b, lever c, and
pinion shaft assembly 2.
4. Push the pinion stopper d down, and
then remove the clip e.
5. Remove the pinion stopper d and pinion
assembly 4.
6. Remove the E-clip h, and then remove
the shim k, bracket 5, bearing 6, gas-
ket 7, and shim m from the pinion shaft
8.
a
1
2
b
c
Pipe 3: (commercially available)
f: 18.0 mm (0.71 in)
g: 13.0 mm (0.51 in)
f
d
3
3
d
g
e
d
4
5
7
6
m
k
8
h
Starter motor
5-57
ELEC
Electrical system
7. Remove the stator 9.
8. Remove the armature 0, along with the
brush holder assembly A, from the
bracket B.
9. Remove the plate n, and then remove
the armature 0 from the brush holder
assembly A.
Checking the armature (starter
motor)
1. Check the commutator. Clean using 600-
grit sandpaper and compressed air if
dirty.
2. Measure the commutator diameter a.
Replace the armature if below specifica-
tion.
3. Measure the commutator undercut b.
Replace the armature if below specifica-
tion.
4. Check the armature for continuity.
Replace if out of specification.
0
9
B
A
0
0
A
A
n
n
Commutator standard diameter a:
29.0 mm (1.14 in)
Wear limit: 28.0 mm (1.10 in)
Commutator standard undercut b
(reference data):
0.50.8 mm (0.020.03 in)
Wear limit: 0.2 mm (0.01 in)
a
b
5-58
5
Checking the brush holder and
brush
1. Check the brush holder assembly for
continuity. Replace if out of specification.
2. Measure the length of each brush.
Replace the brush assembly if below
specification.
Assembling the starter motor
Do not apply grease or oil to the com-
mutator of the armature.
Do not reuse a gasket or seal set,
always replace it with a new one.
1. Push the brushes a into the holders,
and then install the armature 1 to the
brush holder assembly 2.
2. Install the plate b.
3. Install the armature 1 along with the
brush holder assembly 2 to the bracket
3, and then install the stator 4.
Armature continuity:
c d e f
Brush holder assembly continuity:
a b c d e
d
c
e f
e
c
d
b
a
a
e
c
b d
Brush standard length f:
15.5 mm (0.61 in)
Wear limit g: 9.5 mm (0.37 in)
g f
1
2
1
b
b
a
Starter motor
5-59
ELEC
Electrical system
TIP:
Align the holes c and d in the plate b with
the holes e and f in the bracket 3.
4. Install the shim g, the bearing 5, the
bracket 6, a new gasket 7, and the
shim h, and then install the E-clip k
onto the pinion shaft 8.
5. Install the pinion assembly 9, pinion
stopper m, and clip n.
6. Install the pinion shaft assembly 0, the
lever p, a new rubber seal r, the plane-
tary gears A, the outer gear B, and the
plate C.
7. Assemble the starter motor.
4
1
2
3
3 f
e
d b
c
6
7
5
g
h
8
k
9
m
m
9
n
0
0
B
A
r
p
C
p
5-60
5
8. Install a new gasket s, the spring t,
and the magnet switch D.
Installing the starter motor
1. Install the starter motor to the power unit.
See Starter motor (7-33).
2. Install the intake manifold (STBD). See
Installing the intake manifold (6-13).
Charging unit and component
Checking the lighting coil
1. Remove the intake manifold (STBD).
2. Disconnect the stator assembly couplers
a and b.
3. Move the stator assembly lead away
from the area covered by the intake man-
ifold, and then install the intake manifold
(STBD). See Installing the intake mani-
fold (6-13).
4. Connect the special service tool 1.
5. Measure the lighting coil output peak
voltage between all combinations of the
terminals.
s
t
D
D
t
s
Test harness (3 pins) 1: YB-06870
Lighting coil output peak voltage:
Green (G)Green (G)
Green/White (G/W)Green/White (G/W)
r/min
Unloaded
Cranking 1500 3500
DC V 10.9 37.2 81.4
b
a
WB R
G
G
G
1 a
1
a
STBD
Starter motor / Charging unit and component
5-61
ELEC
Electrical system
TIP:
When measuring the output peak voltage
under the cranking condition, remove the clip
from the engine shut-off switch to prevent the
engine from starting.
6. Disconnect the special service tool.
7. Measure the lighting coil resistance.
8. Remove the intake manifold (STBD), and
then connect the stator assembly cou-
plers.
9. Install the intake manifold (STBD). See
Installing the intake manifold (6-13).
Checking the Rectifier Regulator
Do not connect the battery cables in
reverse. Otherwise, the Rectifier Regula-
tor could be damaged.
1. Remove the fuse cover 1.
2. Measure the Rectifier Regulator output
peak voltage.
TIP:
Do not use the peak volt adapter when mea-
suring the Rectifier Regulator output peak
voltage.
3. Remove the intake manifold (STBD) and
fuse holder.
4. Disconnect the Rectifier Regulator cou-
plers and ground lead.
5. Set the digital multimeter to the diode
mode a, and then check the Rectifier
Regulator for continuity. Replace if out of
specification.
Lighting coil resistance (reference data):
Green (G)Green (G)
Green/White (G/W)Green/White (G/W)
0.130.20 at 20 C (68 F)
1
Rectifier Regulator output peak voltage:
Fuse (60 A)Ground
r/min
Loaded
1500 3500
DC V 13.0 13.0
a
b
c
d
e
k
f
g
h
5-62
5
OL: Indicates an overload
6. Connect the Rectifier Regulator couplers
and ground lead.
7. Install the intake manifold (STBD). See
Installing the intake manifold (6-13).
8. Install the fuse holder, and then install
the fuse cover.
Rectifier Regulator continuity
(testing diode mode):
Tester probe Display value
(reference data) + .
b h OL
g OL
f OL
c OL
d OL
e OL
k OL
c h OL
g OL
f OL
d OL
e OL
b 0.419 V
k OL
d h OL
g OL
f OL
c OL
e OL
b 0.423 V
k OL
e h OL
g OL
f OL
c OL
d OL
b 0.421 V
k OL
b
c
d
e
k
f
g
h
f h OL
g OL
c OL
d OL
e OL
b 0.425 V
k OL
g h OL
f OL
c OL
d OL
e OL
b 0.425 V
k OL
h g OL
f OL
c OL
d OL
e OL
b 0.421 V
k OL
k h 0.425 V
g 0.421 V
f 0.416 V
c 0.427 V
d 0.416 V
e 0.423 V
b 0.698 V
Charging unit and component
5-63
ELEC
Electrical system
Command Link Multifunction
Meter sensor
Checking the water pressure sensor
(optional)
1. Remove the flywheel magnet cover and
engine ECM cover.
2. Disconnect the water pressure sensor
coupler a.
3. Turn the engine start switch to ON, and
then measure the input voltage at the
water pressure sensor coupler a.
4. Remove the water pressure sensor, and
then connect the pressure pump 1 and
special service tool 2.
5. Apply positive pressure to the water
pressure sensor slowly, and then mea-
sure the output voltage at the specified
pressures.
6. Turn the engine start switch to OFF, and
then disconnect the special service tool
2 and pressure pump 1.
7. Disconnect the engine ECM couplers b
and c.
8. Check the wiring harness for continuity.
Water pressure sensor input voltage:
Orange (O)Black (B)
4.755.25 V
a
O B
L/B
O
B
B G/W G
2
1
2
Pressure pump 1:
(commercially available)
Test harness (3 pins) 2: YB-06869
Water pressure sensor output voltage
(reference data):
Blue/Black (L/B)Black (B)
2.5 V at 392.0 kPa
(3.92 kgf/cm
2
, 56.8 psi)
4.5 V at 784.0 kPa
(7.84 kgf/cm
2
, 113.7 psi)
Wiring harness continuity:
a Terminal 1b Terminal 31
a Terminal 2c Terminal 9
a Terminal 3b Terminal 37
b
c
37
a
b c
1
31
2 3
9
5-64
5
9. Install the water pressure sensor, and
then connect the water pressure sensor
coupler. See Installing the water pres-
sure sensor (optional) (3-11).
10. Connect the engine ECM couplers.
11. Install the engine ECM cover and fly-
wheel magnet cover.
Checking the speed sensor
(optional)
1. Remove the flywheel magnet cover and
engine ECM cover.
2. Disconnect the speed sensor coupler a.
3. Turn the engine start switch to ON, and
then measure the input voltage at the
speed sensor coupler a.
4. Remove the speed sensor, and then con-
nect the pressure pump 1 and special
service tool 2.
5. Apply positive pressure to the speed sen-
sor slowly, and then measure the output
voltage at the specified pressures.
6. Turn the engine start switch to OFF, and
then disconnect the special service tool
2 and pressure pump 1.
7. Disconnect the engine ECM couplers b
and c.
8. Check the wiring harness for continuity.
Speed sensor input voltage:
Orange (O)Black (B)
4.755.25 V
a
O B
Pressure pump 1:
(commercially available)
Test harness (3 pins) 2: YB-06869
Speed sensor output voltage (reference
data):
Blue (L)Black (B)
2.5 V at 392.0 kPa
(3.92 kgf/cm
2
, 56.8 psi)
4.5 V at 784.0 kPa
(7.84 kgf/cm
2
, 113.7 psi)
2
1
2
L
O
B
B G/W G
b
c
Command Link Multifunction Meter sensor
5-65
ELEC
Electrical system
9. Install the speed sensor, and then con-
nect the speed sensor coupler.
10. Connect the engine ECM couplers.
11. Install the engine ECM cover and fly-
wheel magnet cover.
PTT electrical system
Checking the PTT relay
1. Remove the flywheel magnet cover.
2. Measure the input voltage between the
PTT relay terminals a and b.
3. Disconnect the PTT relay leads and PTT
relay coupler, and then remove the PTT
relay. NOTICE: Before disconnecting
the PTT relay leads and PTT relay cou-
pler, make sure to disconnect the neg-
ative battery cable.
4. Connect the special service tool 1.
5. Check the PTT relay for continuity.
Replace if out of specification.
6. Connect the positive battery lead to the
connector e, connect the negative bat-
tery lead to the terminal b, and then
check the PTT relay for continuity.
Replace if out of specification.
Wiring harness continuity:
a Terminal 1b Terminal 31
a Terminal 2c Terminal 9
a Terminal 3b Terminal 36
PTT relay input voltage:
Terminal aTerminal b
12.0 V (battery voltage)
a
b c
1
31
2 3
36 9
a
b
Test harness (2 pins) 1: YB-06867
PTT relay continuity:
a b c d e f
G G/W
Lg
Sb
1
e f
d
c
a
b
5-66
5
7. Connect the positive battery lead to the
connector f, connect the negative bat-
tery lead to the terminal b, and then
check the PTT relay for continuity.
Replace if out of specification.
8. Disconnect the special service tool.
9. Install the PTT relay, and then connect
the PTT relay leads and PTT relay cou-
pler.
10. Install the flywheel magnet cover.
Checking the PTT switch
1. Disconnect the PTT switch coupler a.
2. Measure the input voltage at the PTT
switch coupler a.
3. Check the PTT switch 1 for continuity.
Replace if out of specification.
4. Remove the flywheel magnet cover, and
then disconnect the PTT relay coupler
e.
PTT relay continuity:
a b c d
PTT relay continuity:
a b c d
G G/W
Lg
Sb
1
e f
d
c
a
b
Lg
Sb
1
e f
d
c
a
b
G G/W
PTT switch input voltage:
Red (R)Ground
12.0 V (battery voltage)
Switch
position
Terminal
b c d
UP
Free
DN
a
R
c
d
b
Lg
R
Sb
c
d b
1
Command Link Multifunction Meter sensor / PTT electrical system
5-67
ELEC
Electrical system
5. Remove the fuse holder 2, and then dis-
connect the fuse holder coupler f.
6. Check the wiring harness for continuity.
7. Connect the fuse holder coupler f, and
then install the fuse holder.
8. Connect the PTT relay coupler e and
PTT switch coupler a, and then install
the flywheel magnet cover.
Checking the trim sensor
1. Disconnect the trim sensor coupler a,
and then remove the trim sensor. See
Removing the clamp bracket (9-28).
2. Measure the trim sensor resistance when
the trim sensor lever b is at the positions
c and d.
3. Disconnect the alert indicator coupler e.
4. Remove the flywheel magnet cover and
engine ECM cover.
5. Disconnect the engine ECM coupler f.
Wiring harness continuity:
a Terminal 1e Terminal 1
a Terminal 2e Terminal 2
a Terminal 3f Terminal 5
e
2
f
f
1 2
1 2
3
5
e a Trim sensor resistance (reference data):
238.8378.8 at position c
9.011.0 at position d (setting
resistance)
a
b
d
c
e
5-68
5
6. Check the wiring harness for continuity.
7. Connect the engine ECM coupler.
8. Install the engine ECM cover and fly-
wheel magnet cover.
9. Connect the alert indicator coupler.
10. Install the trim sensor, and then connect
the trim sensor coupler. See Installing
the clamp bracket (9-28).
Wiring harness continuity:
a Terminal 1e Terminal 2
a Terminal 2f Terminal 9
f
e
1 2
2
9
a
f
PTT electrical system
FUEL
Fuel system
Hose routing....................................................................... 6-1
Fuel hose and blowby hose........................................................ 6-1
Vapor gas hose .......................................................................... 6-2
Cooling water hose..................................................................... 6-4
Fuel system ........................................................................ 6-6
Reducing the fuel pressure ........................................................ 6-6
Disconnecting the quick connector............................................. 6-6
Measuring the fuel pressure....................................................... 6-7
Checking the pressure regulator ................................................ 6-7
Fuel filter assembly............................................................ 6-9
Checking the fuel filter assembly.............................................. 6-11
Checking the fuel filter element ................................................ 6-11
Checking the fuel cup assembly............................................... 6-11
Intake manifold................................................................. 6-12
Checking the intake manifold ................................................... 6-13
Installing the intake manifold.................................................... 6-13
Throttle body .................................................................... 6-14
Removing the throttle body and surge tank.............................. 6-16
Checking the ETV .................................................................... 6-17
Installing the throttle body and surge tank................................ 6-17
Canister............................................................................. 6-19
Checking the canister............................................................... 6-20
Checking the canister check valve........................................... 6-20
Low-pressure fuel pump ................................................. 6-21
Checking the low-pressure fuel pump...................................... 6-22
Checking the primer pump ....................................................... 6-22
Vapor separator................................................................ 6-23
Draining the fuel ....................................................................... 6-25
Removing the vapor separator ................................................. 6-25
Installing the vapor separator ................................................... 6-25
Vapor separator and high-pressure fuel pump............. 6-27
Disassembling the vapor separator.......................................... 6-29
Checking the high-pressure fuel pump..................................... 6-30
Checking the vapor separator .................................................. 6-30
Checking the check valve......................................................... 6-30
Assembling the vapor separator............................................... 6-30
6
Fuel injector...................................................................... 6-33
Removing the fuel injector........................................................ 6-34
Checking the fuel rail ................................................................ 6-34
Installing the fuel injector.......................................................... 6-34
6-1
FUEL
Fuel system
Hose routing
Fuel hose and blowby hose
1Fuel hose (joint to fuel filter assembly)
2Fuel hose (fuel filter assembly to joint)
3Fuel hose (joint to low-pressure fuel
pump)
4Fuel hose (low-pressure fuel pump to
vapor separator)
5Fuel hose (vapor separator to joint)
6Fuel hose (joint to quick connector)
7Fuel hose (joint to quick connector)
8Fuel hose (vapor separator to joint)
9Blowby hose (cylinder head cover to
intake silencer)
aPrimer pump
bFuel filter assembly
cLow-pressure fuel pump
dVapor separator
eQuick connector
fFuel rail
gFuel injector
hPressure regulator
kFuel cooler
1
b
a
k
d
c
8
2
3
f
g
f
e
e
7
9
6
5
h
g
g
4
6-2
6
Vapor gas hose
1Vapor gas hose (vapor separator to
canister tank port)
2Vapor gas hose (canister purge port to
joint)
3Vapor gas hose (joint to vapor shut-off
valve)
4Vapor gas hose (vapor shut off-valve to
joint)
5Vapor gas hose (joint to surge tank)
6Vapor gas hose (canister atmospheric port
to joint)
7Vapor gas hose (joint to check valve)
8Vapor gas hose (check valve to bottom
cowling)
9Vapor gas hose (check valve to joint)
0Vapor gas hose (atmosphere to check
valve)
AVacuum hose (pressure regulator to surge
tank)
BVacuum hose (surge tank to air pressure
sensor)
1
2
9
0
1
2
5 B
g
b
4
3
f
d
A
a
8
7
6
e
e
c
Hose routing
6-3
FUEL
Fuel system
aVapor separator
bJoint
cCanister
dVapor shut-off valve
eCheck valve
fPressure regulator
gAir pressure sensor
1
2
9
0
1
2
5 B
g
b
4
3
f
d
A
a
8
7
6
e
e
c
6-4
6
Cooling water hose
1Cooling water hose (cylinder block to joint)
2Cooling water hose (joint to oil cooler)
3Cooling water hose (joint to water
pressure sensor adapter)
4Cooling water hose (cylinder block to joint)
5Cooling water hose (joint to fuel cooler)
6Cooling water hose (fuel cooler to oil
cooler)
7Cooling water hose (cylinder block to joint)
8Cooling water hose (joint to oil cooler)
9Cooling water hose (joint to joint)
0Cooling water hose (oil cooler to joint)
ACooling water hose (thermostat cover
[STBD] to joint)
BCooling water hose (joint to Rectifier
Regulator)
CCooling water hose (Rectifier Regulator to
joint)
DCooling water hose (joint to joint)
ECooling water hose (joint to joint)
FCooling water hose (joint to cooling water
pilot hole)
GCooling water hose (flushing hose adapter
to joint)
0
a
c
3
A
9
F
b
7
d
8
6
5
4
1
K
G
2
e
f
d
a
c
b
6 2
0
E
D
C
L
B
A
F
M
9 7
8
3
4
1
J
5
I
H
Hose routing
6-5
FUEL
Fuel system
HCooling water hose (joint to joint)
ICooling water hose (joint to cylinder block
[PORT])
JCooling water hose (joint to cylinder block
[STBD])
KCooling water hose (thermostat cover
[PORT] to cylinder block)
LCooling water hose (thermostat cover
[STBD] to joint)
MCooling water hose (joint to cylinder block)
aOil cooler
bAdapter (water pressure sensor)
cFuel cooler (vapor separator)
dRectifier Regulator
eCooling water pilot hole (on the bottom
cowling)
fFlushing hose adapter
0
a
c
3
A
9
F
b
7
d
8
6
5
4
1
K
G
2
e
f
d
a
c
b
6 2
0
E
D
C
L
B
A
F
M
9 7
8
3
4
1
J
5
I
H
6-6
6
Fuel system
Reducing the fuel pressure
Before servicing the high-pressure fuel
line or vapor separator, make sure to
reduce the fuel pressure in the fuel line.
Otherwise, pressurized fuel could spray
out.
1. Start the engine.
2. Remove the fuse holder cover 1, and
then remove the fuse (15 A) 2.
TIP:
After removing the fuse, wait until the engine
stalls.
3. After the engine stalls, crank the engine
2 or 3 times.
4. Turn the engine start switch to OFF.
5. Install the fuse (15 A) 2, and then install
the fuse holder cover 1.
Disconnecting the quick connector
Before disconnecting the quick connec-
tor, reduce the fuel pressure. Otherwise,
pressurized fuel could spray out.
1. Reduce the fuel pressure. See Reduc-
ing the fuel pressure (6-6).
2. Wrap a rag around the quick connector
1, and then push the quick connector
tab a toward the stopper b. NOTICE:
Do not push the quick connector tab
a past the stopper b. Otherwise, the
quick connector could be damaged.
3. Disconnect the quick connector 1 from
the fuel rail.
6
0
A
2
0
3
0
3
0
1
0
1
5
1
2
1
b
a
PORT
STBD
1
c
Hose routing / Fuel system
6-7
FUEL
Fuel system
TIP:
After disconnecting the quick connector 1,
be careful not to lose the retainer c.
Cover the quick connector and fuel rail with
a plastic bag to prevent damage and to pro-
tect them from dirt.
Measuring the fuel pressure
1. Reduce the fuel pressure. See Reduc-
ing the fuel pressure (6-6).
2. Disconnect the quick connector from the
fuel rail. See steps 2 and 3 in Discon-
necting the quick connector (6-6).
3. Connect the special service tool 1 to the
quick connector and fuel rail.
4. Connect the special service tool 2.
WARNING! To prevent fuel from leak-
ing out, screw in the gauge gently
until it is connected firmly.
5. Turn the engine start switch to ON, and
then measure the fuel pressure within 5
seconds.
TIP:
The fuel pressure will decrease 5 seconds
after the engine start switch is turned to
ON.
The high-pressure fuel pump does not
operate when the engine start switch is
turned to ON again within 10 seconds after
turning the engine start switch to OFF.
6. Start the engine and warm it up until the
engine idle speed stabilizes at 700800
r/min.
7. Measure the fuel pressure.
8. Reduce the fuel pressure. See Reduc-
ing the fuel pressure (6-6).
9. Disconnect the special service tools 1
and 2. WARNING! Before disconnect-
ing the special service tools, cover the
end of the hose using a clean and dry
rag.
10. Connect the quick connector to the fuel
rail.
Checking the pressure regulator
1. Reduce the fuel pressure. See Reduc-
ing the fuel pressure (6-6).
2. Disconnect the quick connector from the
fuel rail. See steps 2 and 3 in Discon-
necting the quick connector (6-6).
Fuel pressure gauge adapter 1:
YW-06842
1
2
1
Fuel pressure gauge 2: YB-06766
Fuel pressure (reference data):
300.0 kPa (3.00 kgf/cm
2
, 43.5 psi)
Fuel pressure (reference data):
260.0 kPa (2.60 kgf/cm
2
, 37.7 psi)
at 750 r/min
6-8
6
3. Connect the special service tools. See
steps 3 and 4 in Measuring the fuel
pressure (6-7).
4. Disconnect the pressure regulator hose
1, and then connect the special service
tool 2 to the pressure regulator 3.
5. Block the end of the pressure regulator
hose 1 using a rubber plug.
6. Start the engine and let it idle.
7. Check that the fuel pressure is reduced
when vacuum pressure is applied to the
pressure regulator.
8. Turn the engine start switch to OFF.
9. Disconnect the special service tool 2,
and then connect the pressure regulator
hose 1.
10. Reduce the fuel pressure. See Reduc-
ing the fuel pressure (6-6).
11. Disconnect the special service tools.
12. Connect the quick connector to the fuel
rail.
Pressure/vacuum tester 2: YB-35956-A
3 1
2
Fuel system
6-9
FUEL
Fuel system
Fuel filter assembly
No. Part name Qty Remarks
1 Joint 1
2 Clamp 1
3 Hose 1
4 Holder 1
5 Cover 1
6 Bolt 4 M6 16 mm
7 Holder 1
8 Bracket 1
9 Bolt 2 M6 25 mm
10 Grommet 2
11 Collar 2
12 Plastic tie 2
Not reusable
13 Fuel filter assembly 1
14 O-ring 1
Not reusable
15 Fuel filter element 1
16 Fuel cup assembly 1
17 Clip 1
6
5
12
6
8
9
3
6
2
1
4
7
12
15
13
16
17
18
14
6
11
10
5 Nm (0.5 kgfm, 3.7 ftIb)
6-10
6
No. Part name Qty Remarks
18 Float 1
6
5
12
6
8
9
3
6
2
1
4
7
12
15
13
16
17
18
14
6
11
10
5 Nm (0.5 kgfm, 3.7 ftIb)
Fuel filter assembly
6-11
FUEL
Fuel system
Checking the fuel filter assembly
1. Connect the vacuum/pressure pump
gauge 1 to the fuel inlet a.
2. Block the fuel outlet b using a rubber
plug 2, and then apply the specified
positive pressure. Replace the O-ring,
fuel cup assembly, or fuel filter assembly
if the specified pressure cannot be main-
tained for 15 seconds or more.
3. Connect the special service tool 3 to the
fuel outlet b.
4. Block the fuel inlet a using a rubber plug
2, and then apply the specified negative
pressure. Replace the O-ring, fuel cup
assembly, or fuel filter assembly if the
specified pressure cannot be maintained
for 15 seconds or more.
Checking the fuel filter element
1. Check the fuel filter element. Replace if
there is dirt or residue.
Checking the fuel cup assembly
1. Check the fuel cup assembly. Clean
using straight gasoline if there is foreign
material or replace if cracked. NOTICE:
When cleaning the fuel cup assembly,
do not remove the clip and float.
2. Check the water detection switch. See
Checking the water detection switch (5-
45).
Vacuum/pressure pump gauge 1:
(commercially available)
Specified positive pressure:
200.0 kPa (2.00 kgf/cm
2
, 29.0 psi)
1
a
b
2
a b
Pressure/vacuum tester 3: YB-35956-A
Specified negative pressure:
80.0 kPa (0.80 kgf/cm
2
, 11.6 psi)
b
a
2
3
a b
6-12
6
Intake manifold
No. Part name Qty Remarks
1 Intake silencer 1
2 Bolt 2 M6 20 mm
3 Joint 1
4 Plastic tie 1
5 Grommet 1
6 Air temperature sensor 1
7 Flywheel magnet cover 1
8 Intake manifold assembly 2
9 Gasket 2
Not reusable
10 Intake manifold 2
11 Gasket 2
Not reusable
12 Holder 9
13 Holder 2
14 Bolt 8 M8 40 mm
15 Bolt 10 M6 35 mm
UP UP UP
8
2
1
12
12
12
14
15
10 11
12
9
5
6
3
4
7
8
9
10 11
12
12
12
15
13
14
13
1 11 Nm (1.1 kgfm, 8.1 ftlb)
2 11 Nm (1.1 kgfm, 8.1 ftlb)
1 24 Nm (2.4 kgfm, 17.7 ftIb)
2 24 Nm (2.4 kgfm, 17.7 ftIb)
Fuel filter assembly / Intake manifold
6-13
FUEL
Fuel system
Checking the intake manifold
1. Check the intake manifolds. Replace if
cracked or deformed.
Installing the intake manifold
Do not reuse a gasket, always replace it
with a new one.
1. Install new gaskets 1 and 2 onto the
intake manifolds.
TIP:
Make sure to fit the protrusion a on each
gasket into its corresponding slot in the
intake manifolds.
2. Install the intake manifolds and bolts
temporarily.
3. Tighten the bolts 3 to the specified
torque in 2 stages and in the order 1, 2,
and so on.
TIP:
Tighten the bolts to the same torque in both
stages.
4. Tighten the bolts 4 to the specified
torque in 2 stages and in the order 1, 2,
and so on.
TIP:
Tighten the bolts to the same torque in both
stages.
a
1
a
2
Intake manifold bolt 3 (M8):
1st: 24 Nm (2.4 kgfm, 17.7 ftlb)
2nd: 24 Nm (2.4 kgfm, 17.7 ftlb)
Intake manifold bolt 4 (M6):
1st: 11 Nm (1.1 kgfm, 8.1 ftlb)
2nd: 11 Nm (1.1 kgfm, 8.1 ftlb)
PORT STBD
3
1
2
4
1
2
4
3
3
3
PORT STBD
3
5
1
2
4
4
1
2
3
5
4
4
6-14
6
Throttle body
No. Part name Qty Remarks
1 Bolt 4 M8 60 mm
2 Holder 1
3 Grommet 2
4 Bracket 1
5 Holder 1
6 Bracket 1
7 Bolt 1 M6 20 mm
8 Air pressure sensor 1
9 Hose 1
10 Throttle body 1
11 Gasket 1
Not reusable
12 Surge tank 1
13 Bolt 5 M8 30 mm
14 Bolt 6 M6 16 mm
15 Bolt 2 M6 30 mm
16 Grommet 4
17 Collar 2
1
1
14
14
14 21
2
3
3
6
5
7
8
9
12
13
4
10
11
15
16
20
15
16
16
17
16
17
18
19
22
23
24
25
11 Nm (1.1 kgfm, 8.1 ftIb)
Intake manifold / Throttle body
6-15
FUEL
Fuel system
No. Part name Qty Remarks
18 Bracket 1
19 Bracket 1
20 Bracket 1
21 Bolt 2 M6 16 mm
22 Bracket 1
23 Holder 1
24 Hose 1
25 Hose 1
1
1
14
14
14 21
2
3
3
6
5
7
8
9
12
13
4
10
11
15
16
20
15
16
16
17
16
17
18
19
22
23
24
25
11 Nm (1.1 kgfm, 8.1 ftIb)
6-16
6
Removing the throttle body and
surge tank
1. Disconnect the air pressure sensor cou-
pler a and ETV coupler b.
2. Remove the YDIS coupler c and low-
pressure fuel pump coupler d.
3. Remove the air pressure sensor 1.
4. Remove the cooling water hose 2 from
the holder 3.
5. Remove the throttle body 4.
6. Disconnect the pressure regulator hose
5 and vapor gas hose 6.
7. Remove the vapor gas hoses 7 and 8
from the holder 9, and then remove the
bracket 0.
8. Remove the surge tank A.
9. Remove the air pressure sensor hose B,
pressure regulator hose 5, and vapor
gas hose 6.
b
a a
c
d
3
1
2
4
5
6
8
7
0
9
A
Throttle body
6-17
FUEL
Fuel system
Checking the ETV
1. Turn the throttle valve manually and
check that it moves smoothly.
Installing the throttle body and surge
tank
Do not reuse a gasket, always replace it
with a new one.
1. Install the vapor gas hose 1, pressure
regulator hose 2, and air pressure sen-
sor hose 3.
2. Install the surge tank 4.
3. Install the bracket 5, and then fasten the
vapor gas hoses 6 and 7 using the
holder 8.
4. Connect the pressure regulator hose 2
and vapor gas hose 1.
5. Install a new gasket 9 and the throttle
body 0.
5
6
B
2
1
3
4
6
7
5
8
2
1
6-18
6
6. Fasten the cooling water hose A using
the holder B.
7. Connect the air pressure sensor hose,
and then install the air pressure sensor
C.
8. Install the low-pressure pump coupler a
and YDIS coupler b.
9. Connect the ETV coupler c and air pres-
sure sensor coupler d.
0
9
C
A
B
c
d
b
a
Throttle body
6-19
FUEL
Fuel system
Canister
No. Part name Qty Remarks
1 Hose 1
2 Check valve 2
3 Hose 1
4 Joint 1
5 Hose 1
6 Hose 1
7 Bolt 2
8 Grommet 2
9 Collar 2
10 Bracket 1
11 Bracket 1
12 Bolt 1 M6 10 mm
13 Canister 1
14 Hose 1
1
3
4
6
5
2
8
9
7
7
11
12
9
8
10
13
14
6-20
6
Checking the canister
1. Check the canister. Replace if cracked.
2. Connect the special service tool 1 to the
atmospheric port a and block the other
ports using rubber plugs 2.
3. Apply the specified positive pressure and
check that there is no air leakage.
Replace the canister if there is air leak-
age.
Checking the canister check valve
1. Connect the special service tool 1 to the
canister check valve port.
2. Apply positive pressure and check that
air comes out of the opposite end of the
canister check valve. Replace the canis-
ter check valve if no air comes out.
3. Connect the special service tool 1 to the
opposite canister check valve port.
4. Apply positive pressure and check that
no air comes out of the opposite end of
the canister check valve. Replace the
canister check valve if air comes out.
Pressure/vacuum tester 1: YB-35956-A
Specified positive pressure:
19.6 kPa (0.196 kgf/cm
2
, 2.8 psi)
Pressure/vacuum tester 1: YB-35956-A
50
20
0
a
1
2
1
1
Canister
6-21
FUEL
Fuel system
Low-pressure fuel pump
No. Part name Qty Remarks
1 Hose 1
2 Holder 1
3 Plastic tie 1
Not reusable
4 Hose 1
5 Clamp 4
6 Joint 1
7 Hose 1
8 Bushing 2
9 Low-pressure fuel pump 1
10 Holder 1
11 Clamp 2
12 Holder 2
13 Hose 1
14 Holder 1
15 Cover 1
16 Bolt 2 M6 15 mm
12 mm
(0.47 in)
12 mm
(0.47 in)
12 mm
(0.47 in)
9 mm
(0.35 in)
2 5 12 11
13
12
11
11
6
5
5
1
7
5
14
15
16
10
3
2
8
9
5
4
8
5 Nm (0.5 kgfm, 3.7 ftIb)
6-22
6
Checking the low-pressure fuel
pump
1. Drain the fuel from the vapor separator
and check the fuel. See Draining the
fuel (6-25). Check and clean the fuel
lines if the fuel is dirty.
2. Check the low-pressure fuel pump. See
Checking the low-pressure fuel pump
and high-pressure fuel pump (5-48).
Checking the primer pump
1. Connect the leakage tester 1 to the
primer pump inlet hose.
2. Block the fuel outlet a using a rubber
plug 2, and then apply the specified
positive pressure. Replace the primer
pump if the specified pressure cannot be
maintained for 30 seconds or more.
Leakage tester 1:
(commercially available)
Specified positive pressure:
170.0 kPa (1.70 kgf/cm
2
, 24.7 psi)
a
1
2
Low-pressure fuel pump
6-23
FUEL
Fuel system
Vapor separator
No. Part name Qty Remarks
1 Hose 2
2 Joint 1
3 Joint 1
4 Hose 1
5 Hose 1
6 Holder 3
7 Holder 1
8 Bolt 4 M6 35 mm
9 Collar 8
10 Grommet 4
11 Vapor separator assembly 1
12 Clamp 1
13 Hose 1
14 Joint 1
15 Hose 1
16 Plastic tie 3
Not reusable
17 Holder 1
17
16
16
13
14
15
12
11
18
8
9
9
10
9
10
9
8
9
8
9
8
9
7
5
1
3
4
2
6
6
10
19
2 Nm (0.2 kgfm, 1.5 ftIb)
6-24
6
No. Part name Qty Remarks
18 Hose 1
19 Drain screw 1
17
16
16
13
14
15
12
11
18
8
9
9
10
9
10
9
8
9
8
9
8
9
7
5
1
3
4
2
6
6
10
19
2 Nm (0.2 kgfm, 1.5 ftIb)
Vapor separator
6-25
FUEL
Fuel system
Draining the fuel
1. Remove the intake manifold (PORT).
2. Disconnect the fuel hose 1 from the
vapor separator assembly 2.
3. Loosen the drain screw 3 to drain the
fuel.
4. Tighten the drain screw 3 to the speci-
fied torque.
5. Connect the fuel hose 1 to the vapor
separator assembly 2.
6. Install the intake manifold (PORT). See
Installing the intake manifold (6-13).
Removing the vapor separator
1. Disconnect the high-pressure fuel pump
coupler a.
2. Disconnect the vapor gas hose 1, cool-
ing water hose 2, and fuel hose 3.
3. Remove the vapor separator assembly
4, and then disconnect the cooling water
hose 5.
Installing the vapor separator
1. Connect the cooling water hose 1, and
then fasten the cooling water hose 1
using the plastic tie 2.
2. Install the vapor separator assembly 3.
Vapor separator drain screw 3:
2 Nm (0.2 kgfm, 1.5 ftlb)
1
2
3
2
1
3
a
4
5
6-26
6
3. Connect the fuel hose 4, cooling water
hose 5, and vapor gas hose 6.
4. Connect the high-pressure fuel pump
coupler a.
3
1 2
5
6
4
a
Vapor separator
6-27
FUEL
Fuel system
Vapor separator and high-pressure fuel pump
No. Part name Qty Remarks
1 Cover assembly 1
2 Screw 1 M5 12 mm
3 Holder 1
4 Pressure regulator 1
5 Bolt 3 M4 12 mm
6 Cover 1
7 Gasket 1
Not reusable
8 Filter 1
9 Check valve 1
10 Screw 6 M4 16 mm
11 Gasket 1
Not reusable
12 Grommet 1
13 Joint 1
14 Damper 1
15 High-pressure fuel pump 1
16 Lead 1
17 Filter 1
3
2
5 4
8
9
5
6
7
10
1
12
15
11
19
16
17
18
13
14
20
23
21
22
28
29
24
25
27
26
25
2 Nm (0.2 kgfm, 1.5 ftIb)
2 Nm (0.2 kgfm, 1.5 ftIb)
2 Nm (0.2 kgfm, 1.5 ftIb)
4 Nm (0.4 kgfm, 3.0 ftIb)
4 Nm (0.4 kgfm, 3.0 ftIb)
6-28
6
No. Part name Qty Remarks
18 Holder 1
19 Needle valve assembly 1
20 Screw 1 M4 8 mm
21 Pin 1
22 Float 1
23 Screw 1 M4 8 mm
24 Float chamber assembly 1
25 Screw 3 M5 4 mm
26 Cover 1
27 Gasket 1
Not reusable
28 Drain screw 1
29 Drain hose 1
3
2
5 4
8
9
5
6
7
10
1
12
15
11
19
16
17
18
13
14
20
23
21
22
28
29
24
25
27
26
25
2 Nm (0.2 kgfm, 1.5 ftIb)
2 Nm (0.2 kgfm, 1.5 ftIb)
2 Nm (0.2 kgfm, 1.5 ftIb)
4 Nm (0.4 kgfm, 3.0 ftIb)
4 Nm (0.4 kgfm, 3.0 ftIb)
Vapor separator and high-pressure fuel pump
6-29
FUEL
Fuel system
Disassembling the vapor separator
1. Remove the cooling water hose 1 and
drain hose 2.
2. Remove the fuel cooler cover 3 and
gasket 4.
3. Remove the holder 5, and then remove
the pressure regulator a, O-rings b and
c, and collar d.
4. Remove the cover 6, gasket 7, filter 8,
check valve 9, and O-ring e.
5. Remove the cover assembly 0, gasket
A, high-pressure fuel pump B, and
grommet C.
6. Remove the screw D, and then remove
the float E, pin F, needle valve assem-
bly G, and O-ring f.
7. Remove the lead H and filter holder I,
and then remove the filter J.
2
1
a
5
d
c
b
3
4
9
e
8 6
7
0
C
B
A
D
F
G
f
E
J
I
H
6-30
6
Checking the high-pressure fuel
pump
1. Check the high-pressure fuel pump. See
Checking the low-pressure fuel pump
and high-pressure fuel pump (5-48).
Checking the vapor separator
1. Check the needle valve. Replace the
needle valve assembly if bent or worn.
2. Check the float. Replace if deteriorated.
3. Check the filter. Clean if there is dirt or
residue.
4. Place the cover assembly upside down,
and then measure the float height a.
TIP:
To measure the height of the float, it should
be resting on the needle valve. Do not press
the float.
Checking the check valve
1. Connect the special service tool 1 to the
check valve port a.
2. Apply positive pressure and check that
air comes out of the opposite end b of
the check valve. Replace the check valve
if no air comes out.
3. Connect the special service tool 1 to the
opposite check valve port b.
4. Apply positive pressure and check that
no air comes out of the opposite end a
of the check valve. Replace the check
valve if air comes out.
Assembling the vapor separator
Do not reuse a gasket or O-ring, always
replace it with a new one.
1. Install a new O-ring a and the needle
valve assembly 1, and then tighten the
screw 2 to the specified torque.
2. Install the float 3 and pin 4, and then
tighten the screw 5 to the specified
torque.
Float height a:
67.5 2.5 mm (2.66 0.10 in)
a
Pressure/vacuum tester 1: YB-35956-A
a b
1
b a
1
Vapor separator and high-pressure fuel pump
6-31
FUEL
Fuel system
3. Install the filter 6, filter holder 7, and
lead 8.
4. Connect the high-pressure fuel pump
coupler b, and then install the grommet
9 and high-pressure fuel pump 0.
5. Install a new gasket A and the cover
assembly B, and then tighten the screws
C to the specified torque.
6. Install a new O-ring c, the check valve
D, the filter E, a new gasket F, and the
cover G, and then tighten the bolts H to
the specified torque.
7. Install new O-rings d and e, the collar
f, the pressure regulator g, and the
holder I, and then tighten the pressure
regulator screw J to the specified
torque.
8. Install a new gasket K and the fuel
cooler cover L, and then tighten the
screws M to the specified torque.
Needle valve assembly screw 2:
2 Nm (0.2 kgfm, 1.5 ftlb)
Float pin screw 5:
2 Nm (0.2 kgfm, 1.5 ftlb)
5 4
1
2
a
3
6
7
8
0
b
9
Float chamber cover screw C:
2 Nm (0.2 kgfm, 1.5 ftlb)
Cover bolt H:
2 Nm (0.2 kgfm, 1.5 ftlb)
B
A
C
D
c
E
G
F
H
6-32
6
9. Install the drain hose N and cooling
water hose O.
Pressure regulator screw J:
4 Nm (0.4 kgfm, 3.0 ftlb)
Fuel cooler cover screw M:
4 Nm (0.4 kgfm, 3.0 ftlb)
g
I
J
f
e
d
L
K
M
N
O
Vapor separator and high-pressure fuel pump
6-33
FUEL
Fuel system
Fuel injector
No. Part name Qty Remarks
1 Bolt 4 M6 25 mm
2 Quick connector 2
3 Fuel rail (PORT) 1
4 Holder 6
5 Fuel injector 6
6 O-ring set 6
Not reusable
7 Fuel rail (STBD) 1
8 Clamp 5
9 Hose 1
10 Joint 1
11 Hose 1
12 Hose 1
1
2
7
1
4
4
4
3
2
8
8
10
8
8
8
9
1
4
4
4
6
5
11
12
1
6-34
6
Removing the fuel injector
Use a rag to catch any spilled gasoline when
removing the fuel components.
1. Disconnect the quick connectors. See
steps 2 and 3 in Disconnecting the quick
connector (6-6).
2. Disconnect the fuel injector couplers a.
3. Remove the fuel rail assembly 1.
4. Remove the holders 2, and then remove
the fuel injectors b and O-rings c and
d.
Checking the fuel rail
1. Check the fuel rails. Replace if cracked
or deformed.
2. Check the fuel injectors. See step 5 in
Checking the fuel injector (5-46).
Installing the fuel injector
Do not reuse an O-ring, always replace it
with a new one.
1. Install new O-rings a and b to each fuel
injector c.
2. Install the fuel injectors c onto the fuel
rail 1, and then install the holders 2.
3. Install the fuel rail assembly 3 onto the
cylinder head.
4. Tighten the bolts 4 equally and gradu-
ally.
5. Connect the fuel injector couplers d and
quick connector 5.
1 a
b
c
d
2
2
2
c
a
b
c
2
2
1
2
3
4
4
d
5
Fuel injector
6-35
FUEL
Fuel system
MEMO
POWR
7
Power unit
Power unit (check and adjustment).................................. 7-1
Checking the compression pressure.......................................... 7-1
Checking the oil pressure........................................................... 7-1
Checking the pulser coil air gap ................................................. 7-1
Checking the valve clearance .................................................... 7-2
Adjusting the valve clearance..................................................... 7-4
Flywheel magnet ................................................................ 7-6
Removing the flywheel magnet .................................................. 7-7
Installing the flywheel magnet .................................................... 7-7
Timing belt .......................................................................... 7-9
Replacing the timing belt .......................................................... 7-10
Power unit assembly ....................................................... 7-15
Removing the power unit.......................................................... 7-17
Installing the power unit............................................................ 7-19
Wiring harness ................................................................. 7-23
Removing the wiring harness................................................... 7-24
Installing the wiring harness..................................................... 7-26
Fuse box ........................................................................... 7-30
Junction box..................................................................... 7-31
Starter motor .................................................................... 7-33
Engine ECM...................................................................... 7-34
Camshaft ........................................................................... 7-35
Removing the timing belt, driven sprocket, and camshaft ........ 7-38
Checking the timing belt and sprocket ..................................... 7-41
Checking the valve lifter ........................................................... 7-41
Checking the camshaft ............................................................. 7-41
Checking the spark plug........................................................... 7-42
Installing the camshaft, driven sprocket, and timing belt .......... 7-43
Cylinder head ................................................................... 7-49
Removing the cylinder head..................................................... 7-51
Disassembling the cylinder head.............................................. 7-51
Checking the cylinder head...................................................... 7-51
Checking the cylinder head bolt ............................................... 7-52
POWR
Checking the valve spring ........................................................ 7-52
Checking the valve................................................................... 7-52
Checking the valve guide ......................................................... 7-53
Replacing the valve guide ........................................................ 7-53
Checking the valve seat ........................................................... 7-54
Refacing the valve seat ............................................................ 7-55
Checking the cylinder head anode........................................... 7-56
Assembling the cylinder head .................................................. 7-56
Installing the cylinder head....................................................... 7-57
Oil cooler and oil pump assembly.................................. 7-59
Removing the oil filter bracket .................................................. 7-62
Removing the oil cooler............................................................ 7-62
Removing the oil pump assembly ............................................ 7-62
Disassembling the oil pump assembly ..................................... 7-62
Checking the oil pump assembly.............................................. 7-63
Checking the oil cooler ............................................................. 7-63
Checking the oil cooler anode.................................................. 7-63
Assembling the oil pump assembly.......................................... 7-63
Installing the oil pump assembly .............................................. 7-64
Installing the oil cooler.............................................................. 7-64
Installing the oil filter bracket .................................................... 7-64
Cylinder block sensor and switch.................................. 7-66
Removing the thermostat ......................................................... 7-68
Checking the thermostat .......................................................... 7-68
Installing the thermostat ........................................................... 7-68
Installing the knock sensor ....................................................... 7-69
Installing the pulley bracket ...................................................... 7-69
Cylinder block .................................................................. 7-70
Disassembling the cylinder block ............................................. 7-72
Checking the piston diameter................................................... 7-73
Checking the cylinder bore....................................................... 7-73
Checking the piston ring........................................................... 7-73
Checking the piston ring end gap............................................. 7-74
Checking the piston ring groove............................................... 7-74
Checking the piston ring side clearance................................... 7-74
Checking the piston pin boss inside diameter .......................... 7-74
Checking the piston pin diameter ............................................. 7-75
Checking the connecting rod small end inside diameter
and big end inside diameter ..................................................... 7-75
Checking the connecting rod big end side clearance............... 7-75
Checking the crankshaft ........................................................... 7-75
Checking the crankcase bolt .................................................... 7-76
Checking the crankpin oil clearance......................................... 7-76
Selecting the crankpin bearing................................................. 7-77
Crankpin bearing selection table.............................................. 7-79
Checking the crankshaft journal oil clearance.......................... 7-80
Selecting the crankshaft journal bearing .................................. 7-81
Crankshaft journal bearing selection table ............................... 7-83
7
Checking the cylinder block anode........................................... 7-84
Assembling the cylinder block.................................................. 7-84
7-1
POWR
Power unit
Power unit (check and
adjustment)
Checking the compression pressure
1. Start the engine, warm it up for 510 min-
utes, and then stop it.
2. Remove the clip from the engine shut-off
switch.
3. Disconnect the fuel injector couplers.
4. Remove the flywheel magnet cover and
engine ECM cover, and then remove the
ignition coils and spark plugs. NOTICE:
Before removing the spark plugs,
remove any dirt or dust in the spark
plug wells that could fall into the cyl-
inders.
5. Install the special service tools 1 and 2
into the spark plug hole.
6. Fully open the throttle.
7. Crank the engine until the reading on the
compression gauge stabilizes, and then
measure the compression pressure.
8. Remove the special service tools 1 and
2.
9. Tighten the spark plugs to the specified
torque.
10. Install the ignition coils.
11. Install the engine ECM cover and fly-
wheel magnet cover.
12. Connect the fuel injector couplers.
Checking the oil pressure
1. Connect the YDIS and use the Engine
monitor to display Oil pressure.
2. Start the engine and warm it up until the
engine idle speed stabilizes at 700800
r/min.
3. Measure the oil pressure.
Checking the pulser coil air gap
1. Remove the intake silencer.
2. Turn the flywheel magnet clockwise to
align a protrusion a on the flywheel
magnet with the protrusion b on the
pulser coil.
3. Measure the pulser coil air gap c.
Compression gauge 1: YU-33223
Compression gauge extension 2:
YB-06563
Minimum compression pressure
(reference data):
720.0 kPa (7.20 kgf/cm
2
, 104.4 psi)
at 20 C (68 F)
1
2
Spark plug: 28 Nm (2.8 kgfm, 20.7 ftlb)
Oil pressure (reference data):
440.0 kPa (4.40 kgf/cm
2
, 63.8 psi) at
60 C (140 F) with SL 10W-30
engine oil and at 750 r/min
660.0 kPa (6.60 kgf/cm
2
, 95.7 psi) at
62 C (144 F) with SL 10W-30
engine oil and at 3000 r/min
Pulser coil air gap c:
0.41.1 mm (0.0160.043 in)
c
a b
7-2
7
Checking the valve clearance
Measure the valve clearances when the
engine is cold.
Do not turn the flywheel magnet counter-
clockwise. Otherwise, the water pump
impeller could be damaged.
1. Remove the flywheel magnet cover and
engine ECM cover.
2. Remove the blowby hose 1.
3. Remove the vapor gas hoses 2, 3, 4,
and 5 from the holders 6, and then
remove the canister 7.
4. Disconnect the ignition coil couplers a,
engine ECM couplers b, and knock sen-
sor coupler c.
5. Remove the bracket 8 and speed sen-
sor coupler d.
6. Remove the ignition coils and spark
plugs.
7. Remove the engine ECM and engine
ECM bracket.
8. Remove the timing belt guide (STBD)
and cylinder head covers.
9. Turn the flywheel magnet 9 clockwise
until the dowel hole e in the flywheel
magnet 9 is aligned between the VCT
assembly (STBD) 0 and driven sprocket
(STBD) A.
10. Check that the II marks f on the VCT
assembly (PORT) and driven sprocket
(PORT) are aligned, and check that the
I marks g on the VCT assembly
(STBD) and driven sprocket (STBD) are
aligned.
6
7
5
2
3
4
1
8 d c
a b
a
0
A
9
g
f
e
Power unit (check and adjustment)
7-3
POWR
Power unit
11. Measure the valve clearances h and k
according to steps 1214.
TIP:
Write down the measurement data.
12. Measure the intake and exhaust valve
clearances of the specified cylinders.
Adjust if out of specification. See Adjust-
ing the valve clearance (7-4).
: Specified cylinder
13. Turn the flywheel magnet 9 an addi-
tional 360 clockwise until the dowel hole
e in the flywheel magnet 9 is aligned
between the VCT assembly (STBD) 0
and driven sprocket (STBD) A.
14. Measure the intake and exhaust valve
clearances of the specified cylinders.
Adjust if out of specification. See Adjust-
ing the valve clearance (7-4).
: Specified cylinder
15. Install the cylinder head covers.
16. Install the timing belt guide (STBD), and
then adjust the timing belt guide clear-
ance. See step 19 in Replacing the tim-
ing belt (7-10).
17. Install the engine ECM bracket and
engine ECM.
18. Install the spark plugs and ignition coils.
19. Install the bracket 8 and speed sensor
coupler d.
20. Connect the ignition coil couplers a,
engine ECM couplers b, and knock sen-
sor coupler c.
Valve clearance:
Intake h:
0.205 0.035 mm (0.0081 0.0014
in)
Exhaust k:
0.345 0.035 mm (0.0136 0.0014
in)
#1 #2 #3 #4 #5 #6
IN


EX

PORT STBD
EX IN EX IN
#2
#4
#6
#1
#3
#5
h
k k
PORT STBD
h
#1 #2 #3 #4 #5 #6
IN



EX


8 d c
a b
a
7-4
7
21. Install the canister 7, and then install the
vapor gas hoses 2, 3, 4, and 5 to the
holders 6.
22. Install the blowby hose 1.
23. Install the engine ECM cover and fly-
wheel magnet cover.
Adjusting the valve clearance
Adjust the valve clearances when the engine
is cold.
When the timing belt is not installed, do
not turn the flywheel magnet or driven
sprockets. Otherwise, the pistons and
valves or intake and exhaust valves could
collide with each other and be damaged.
1. Turn the flywheel magnet 1 clockwise
until the dowel hole a in the flywheel
magnet 1 is aligned between the VCT
assembly (STBD) 2 and driven sprocket
(STBD) 3.
2. Check that the II marks b on the VCT
assembly (PORT) and driven sprocket
(PORT) are aligned, and check that the
I marks c on the VCT assembly
(STBD) and driven sprocket (STBD) are
aligned.
3. Reduce the fuel pressure. See Reduc-
ing the fuel pressure (6-6).
TIP:
When adjusting the valve clearances, the fuel
line must be disconnected. Therefore, make
sure to reduce the fuel pressure before per-
forming the disassembly procedure.
4. Disconnect the quick connectors. See
steps 2 and 3 in Disconnecting the quick
connector (6-6).
5. Remove the fuel hose (high-pressure).
6. Remove the wiring harness. See steps
225 in Removing the wiring harness
(7-24).
7. Remove the wiring harness guide 4.
6
7
5
2
3
4
1
2
3
1
c
b
a
Power unit (check and adjustment)
7-5
POWR
Power unit
8. Remove the flywheel magnet, pulser coil,
and stator assembly. See Removing the
flywheel magnet (7-7).
9. Remove the intake manifold (STBD).
10. Remove the timing belt, VCT assem-
blies, driven sprockets, and camshafts.
See Removing the timing belt, driven
sprocket, and camshaft (7-38).
TIP:
Make sure to keep the parts in the order as
they were removed.
11. Measure the valve lifter thickness d, and
then write down the measurement data.
12. Select the necessary valve lifter by calcu-
lating its thickness using the following
formula.
Calculation formula:
Necessary valve lifter thickness = Removed
valve lifter thickness + Measured valve clear-
ance Specified valve clearance
Example:
Removed valve lifter thickness = 3.000 mm
Measured valve clearance = 0.255 mm
Specified valve clearance = 0.205 mm
Necessary valve lifter thickness
= 3.000 mm + 0.255 mm 0.205 mm
= 3.050 mm
13. Install the necessary valve lifter into the
cylinder head.
14. Install the camshafts, VCT assemblies,
driven sprockets, and timing belt. See
Installing the camshaft, driven sprocket,
and timing belt (7-43).
15. Measure the valve clearances. See steps
1214 in Checking the valve clearance
(7-2).
16. Install the pulser coil and stator assem-
bly. See steps 13 in Installing the fly-
wheel magnet (7-7).
17. Install the flywheel magnet. See step 5 in
Installing the flywheel magnet (7-7).
18. Check the pulser coil air gap. See steps
2 and 3 in Checking the pulser coil air
gap (7-1).
19. Install the intake manifold (STBD). See
Installing the intake manifold (6-13).
20. Install the wiring harness guide 4.
21. Install the wiring harness. See Installing
the wiring harness (7-26).
4
d
4
7-6
7
Flywheel magnet
No. Part name Qty Remarks
1 Bolt 6
Not reusable
M10 50 mm
2 Flywheel magnet 1
3 Stator assembly 1
4 Bolt 4 M6 30 mm
5 Bolt 2 M5 15 mm
6 Pulser coil 1
7 Dowel 2
8 Dowel 1
9 Bolt 1 M6 16 mm
10 Holder 1
4
1
2
4
3
5
6
7
8
10
9
7
4 Nm (0.4 kgfm, 3.0 ftIb)
1 40 Nm (4.0 kgfm, 29.5 ftlb)
2 90
Power unit (check and adjustment) / Flywheel magnet
7-7
POWR
Power unit
Removing the flywheel magnet
1. Loosen the bolts 1 in the order 1, 2,
and so on, and then remove the flywheel
magnet and dowel. NOTICE: Apply
force in the direction of the arrow to
prevent the special service tool 2
from slipping off easily.
2. Remove the intake manifold (STBD).
3. Disconnect the stator assembly couplers
a and pulser coil coupler b.
4. Remove the holder 3 and stator assem-
bly c, and then remove the pulser coil 4
and base d.
Installing the flywheel magnet
Do not reuse a flywheel magnet bolt,
always replace it with a new one.
1. Install the base a and pulser coil 1, and
then tighten the bolts 2 to the specified
torque.
2. Install the stator assembly b and holder
3.
3. Connect the stator assembly couplers c
and pulser coil coupler d.
4. Install the intake manifold (STBD). See
Installing the intake manifold (6-13).
Universal magneto and rotor holder 2:
YU-01235
2
1
2
5
4
6
1
3
Pulser coil bolt 2:
4 Nm (0.4 kgfm, 3.0 ftlb)
a
b
c
d
4
3
c
d
b
a
1
3
2
7-8
7
5. Install the dowel and flywheel magnet,
and then tighten new bolts 4 to the
specified torques in 2 stages and in the
order 1, 2, and so on. NOTICE: Apply
force in the direction of the arrow to
prevent the special service tool 5
from slipping off easily.
TIP:
In the 2nd tightening stage for the flywheel
magnet bolts 4, make marks e on the bolts
and the flywheel magnet, and then tighten
the bolts 90 from the marks on the flywheel
magnet.
6. Check the pulser coil air gap. See steps
2 and 3 in Checking the pulser coil air
gap (7-1)
Universal magneto and rotor holder 5:
YU-01235
Flywheel magnet bolt 4:
1st: 40 Nm (4.0 kgfm, 29.5 ftlb)
2nd: 90
4
4
5
90
e
5
2
3
1
6
4
Flywheel magnet
7-9
POWR
Power unit
Timing belt
No. Part name Qty Remarks
1 Timing belt 1
2 Timing belt tensioner 1
3 Bolt 2 M10 55 mm
4 Washer 2
5 Pulley 2
6 Collar 2
7 Bolt 6 M6 14 mm
8 Guide 2
9 Guide 1
1
2
7
9
6
5
7
7
8
8
3
4
5
6
3
4
39 Nm (3.9 kgfm, 28.8 ftIb)
39 Nm (3.9 kgfm, 28.8 ftIb)
7-10
7
Replacing the timing belt
When the timing belt is not installed, do
not turn the crankshaft or driven sprock-
ets. Otherwise, the pistons and valves or
intake and exhaust valves could collide
with each other and be damaged.
1. Reduce the fuel pressure. See Reduc-
ing the fuel pressure (6-6).
2. Remove the flywheel magnet cover and
engine ECM cover.
3. Remove the timing belt guides 1.
4. Turn the flywheel magnet 2 clockwise
until the dowel hole a in the flywheel
magnet 2 is aligned between the VCT
assembly (STBD) 3 and driven sprocket
(STBD) 4.
5. Check that the II marks b on the VCT
assembly (PORT) and driven sprocket
(PORT) are aligned, and check that the
I marks c on the VCT assembly
(STBD) and driven sprocket (STBD) are
aligned.
6. Remove the wiring harness. See steps
225 in Removing the wiring harness
(7-24).
7. Remove the wiring harness guide 5.
8. Remove the flywheel magnet, pulser coil,
and stator assembly. See Removing the
flywheel magnet (7-7).
9. Check that the large mark d on the
crankshaft is aligned with the rib e on
the cylinder block.
1
1
3
2
4
c
b
a
5
Timing belt
7-11
POWR
Power unit
10. Check that the II marks b on the VCT
assembly (PORT) and driven sprocket
(PORT) are aligned, and check that the
I marks c on the VCT assembly
(STBD) and driven sprocket (STBD) are
aligned.
11. Remove the timing belt guide 6.
12. Turn the timing belt tensioner gradually
clockwise using a hexagon wrench, and
then insert a 5.0 mm (0.2 in) diameter pin
7 into the hole f.
TIP:
When turning the timing belt tensioner,
apply a force of 15 Nm (1.5 kgfm, 11.1
ftlb) or less.
Leave the pin 7 inserted into the hole f of
the timing belt tensioner until the timing belt
is installed again.
13. Remove the timing belt 8 from the VCT
assembly (PORT) or driven sprocket
(STBD), and then remove it from the
crankshaft.
14. Install a new timing belt 9 onto the
crankshaft so that the part number g is
in the upright position and the belt posi-
tion mark h is aligned with the small
mark on the crankshaft. NOTICE: Do not
apply grease or oil to the timing belt.
c
b
d
e
6
7
f
8
7-12
7
rBelt teeth number
TIP:
Before installing the timing belt, make sure
that the marks on the crankshaft and cylinder
block are aligned. Also, make sure that the
marks on the VCT assemblies and driven
sprockets are aligned. See steps 9 and 10.
15. Install the timing belt onto the VCT
assemblies and driven sprockets by
aligning the belt position marks k, m,
n, and p with the marks in the
order listed.
16. Adjust the timing belt installation height
s to specification.
17. Turn the timing belt tensioner gradually
clockwise using a hexagon wrench, and
then remove the pin 7.
9
h
g
k m n p
r
h
6CB-462**-**
172 146 88 63 0123
Timing belt installation height s:
2.5 mm (0.10 in)
n m
p k
s
7
Timing belt
7-13
POWR
Power unit
TIP:
When turning the timing belt tensioner,
apply a force of 15 Nm (1.5 kgfm, 11.1
ftlb) or less.
Make sure that the belt position marks are
aligned with the marks. See steps 14 and
15.
18. Turn the crankshaft clockwise 2 full turns
until the large mark d on the crank-
shaft is aligned with the rib e on the cyl-
inder block, and then check that the
marks b and c on the VCT assemblies
and driven sprockets are aligned.
19. Install the timing belt guides 1 and 6,
and then adjust the timing belt guide
clearance t.
20. Install the pulser coil and stator assem-
bly. See steps 13 in Installing the fly-
wheel magnet (7-7).
21. Install the flywheel magnet. See step 5 in
Installing the flywheel magnet (7-7).
22. Check the pulser coil air gap. See step 2
and 3 in Checking the pulser coil air
gap (7-1).
23. Install the intake manifold (STBD). See
Installing the intake manifold (6-13).
c
b
d
e
Timing belt guide clearance t:
0.51.5 mm (0.020.06 in)
t
t
6
1 1
7-14
7
24. Install the wiring harness guide 5.
25. Install the wiring harness. See Installing
the wiring harness (7-26).
5
Timing belt
7-15
POWR
Power unit
Power unit assembly
No. Part name Qty Remarks
1 Power unit assembly 1
2 Gasket 1
Not reusable
3 Dowel 2
4 Bolt 2 M6 30 mm
5 Grommet 4
6 Collar 2
7 Bolt 4 M6 16 mm
8 Bracket 1
9 Bracket 1
10 Tube retainer 1
11 Plastic tie 1
12 Rigging grommet 1
13 Bolt 2 M6 16 mm
14 Grommet holder 1
15 Bolt 7 M10 35 mm
16 Bolt 6 M10 140 mm
17 Screw 4 M6 20 mm
3 Nm (0.3 kgfm, 2.2 ftIb)
4
5
8
5
6
4
5
9
5
6
1
2
3
3
26
26
22
24
23
25
22
22
20
21
19
15
16 16
14
10
11
12
17
18
7
7
13
15
18
1 42 Nm (4.2 kgfm, 31.0 ftlb)
2 42 Nm (4.2 kgfm, 31.0 ftlb)
WR-No.2
11 Nm (1.1 kgfm, 8.1 ftIb)
7-16
7
No. Part name Qty Remarks
18 Grommet 4
19 Apron (STBD) 1
20 Apron (PORT) 1
21 Nut 4
22 Bolt 6 M6 14 mm
23 Bolt 2 M6 30 mm
24 Collar 2
25 Grommet 2
26 Grommet 4
3 Nm (0.3 kgfm, 2.2 ftIb)
4
5
8
5
6
4
5
9
5
6
1
2
3
3
26
26
22
24
23
25
22
22
20
21
19
15
16 16
14
10
11
12
17
18
7
7
13
15
18
1 42 Nm (4.2 kgfm, 31.0 ftlb)
2 42 Nm (4.2 kgfm, 31.0 ftlb)
WR-No.2
11 Nm (1.1 kgfm, 8.1 ftIb)
Power unit assembly
7-17
POWR
Power unit
Removing the power unit
1. Remove the plastic tie 1, and then
remove the tube retainer 2.
2. Remove the grommet holder 3, and
then remove the rigging grommet 4.
3. Disconnect the throttle cable 5 and bat-
tery cables 6.
4. Disconnect the shift cable 7.
5. Disconnect the PTT motor leads a.
6. Remove the plastic tie 8, and then dis-
connect the 10-pin coupler b.
7. Remove the PTT switch coupler c from
the bracket 9, and then disconnect the
PTT switch coupler c.
8. Remove the main wiring harness 0 from
the holder A.
9. Remove the brackets B and C.
1
2
2
4
3
5
6
7
a
b 8
9
c
C
0
A
B
7-18
7
10. Remove the shift cut switch coupler d
from the bracket D, and then disconnect
the shift cut switch coupler d.
11. Remove the neutral switch coupler e
from the bracket E, and then disconnect
the neutral switch coupler e.
12. Disconnect the cooling water hose F.
13. Disconnect the vapor gas hose G.
14. Disconnect the flushing hose H.
15. Disconnect the trim sensor coupler f
and Command Link Multifunction Meter
coupler g.
16. Remove the aprons I and J.
17. Install the special service tools K and L.
d
e
E
D
F
G
H
f
g
I
J
Power unit assembly
7-19
POWR
Power unit
18. Hook a lifting harness M onto the special
service tools K and L, and then sus-
pend the power unit N.
19. Remove the bolts O and P, and then
remove the power unit N and dowels Q.
Installing the power unit
Before installing the power unit, make sure to
install the shift rod and shift bracket onto the
bottom cowling. See Shift rod and shift
bracket (9-1).
Do not reuse a gasket, always replace it
with a new one.
1. Clean the power unit mating surface, and
then install the dowels 1 and a new gas-
ket 2.
2. Install the special service tools 3 and 4.
3. Hook a lifting harness 5 onto the special
service tools 3 and 4, and then sus-
pend the power unit 6.
4. Install the power unit 6, and then tighten
the bolts 7 and 8 to the specified torque
in 2 stages.
TIP:
Tighten the bolts to the same torque in both
stages.
5. Install the aprons 9 and 0, and then
tighten the screws A to the specified
torques.
Engine lifting eye K: 90890-06820
Balance hanger L: 90890-06822
P
N
K
M
L
O O
P P
P
P P O
Q
Q
Engine lifting eye 3: 90890-06820
Balance hanger 4: 90890-06822
Power unit mounting bolts 7 and 8:
1st: 42 Nm (4.2 kgfm, 31.0 ftlb)
2nd: 42 Nm (4.2 kgfm, 31.0 ftlb)
7
7 7 8
6
3
5
4
2
1
1
WR-No.2
8 8
7 7
7
7-20
7
6. Connect the trim sensor coupler a and
Command Link Multifunction Meter cou-
pler b.
7. Connect the flushing hose B.
8. Connect the vapor gas hose C.
9. Connect the cooling water hose D.
10. Connect the neutral switch coupler c,
and then install the neutral switch coupler
c to the bracket E.
11. Connect the shift cut switch coupler d,
and then install the shift cut switch cou-
pler d to the bracket F.
12. Install the brackets G and H, and then
tighten the bolts I to the specified
torque.
Apron screw A:
3 Nm (0.3 kgfm, 2.2 ftlb)
0
A
9
a
b
B
C
D
d
c
E
F
Power unit assembly
7-21
POWR
Power unit
13. Install the main wiring harness J to the
holder K.
14. Connect the PTT switch coupler e, and
then install the PTT switch coupler e to
the bracket L.
15. Connect the 10-pin coupler f, and then
fasten the 10-pin coupler f using the
plastic tie M.
16. Connect the PTT motor leads g.
17. Connect the shift cable N.
18. Connect the throttle cable O and battery
cables P.
TIP:
To adjust the shift cable and throttle cable,
see Installing the shift cable and throttle
cable (3-8).
Surge tank bracket bolt I:
11 Nm (1.1 kgfm, 8.1 ftlb)
I
G
H
I
J
K
L
e
f M
g
N
O
P
7-22
7
19. Install the rigging grommet Q, and then
install the grommet holder R.
20. Install the tube retainer S, and then fas-
ten the tube retainer S using the plastic
tie T.
Q
R
T
S
S
Power unit assembly
7-23
POWR
Power unit
Wiring harness
No. Part name Qty Remarks
1 Wiring harness 1
2 Wiring harness guide 1
3 Bolt 5 M6 20 mm
4 Holder 1
5 Holder 5
6 Holder 1
7 Plastic tie 1
1
3
3
3
5
6
5
2
7
3
4
5
7-24
7
Removing the wiring harness
When removing the wiring harness and wir-
ing harness guide, the fuel line must be dis-
connected. Therefore, make sure to reduce
the fuel pressure before performing the dis-
assembly procedure.
1. Reduce the fuel pressure. See Reduc-
ing the fuel pressure (6-6).
2. Remove the blowby hose 1.
3. Remove the vapor gas hoses 2, 3, 4,
and 5 from the holders 6.
4. Disconnect the ignition coil couplers a,
engine ECM couplers b, and knock sen-
sor coupler c.
5. Remove the speed sensor coupler d,
joint couplers e, and water pressure
sensor coupler f.
6. Remove the wiring harness 7 from the
holders 8.
7. Remove the plastic ties 9 from the
engine ECM bracket.
8. Disconnect the cam position sensor cou-
pler (PORT EX) g.
9. Remove the condensers h.
10. Remove the wiring harness 7 from the
holders 8.
11. Remove the plastic tie 9 from the wiring
harness guide.
12. Disconnect the OCV couplers k, cam
position sensor couplers m, and ther-
moswitch connectors n.
6
2
5
2
3
4
1
8
7
f e d c
8 9
a b
a
9
g
8
h
8
7
9
8
Wiring harness
7-25
POWR
Power unit
13. Disconnect the fuel injector couplers p
and oil pressure sensor coupler r.
14. Disconnect the ground leads s.
15. Disconnect the engine temperature sen-
sor coupler t, vapor shut-off valve cou-
pler u, pulser coil coupler v, and high-
pressure fuel pump coupler w.
16. Disconnect the fuse holder couplers x
and y and PTT relay coupler A.
17. Disconnect the magnet switch lead B.
PORT
n
k
m
m
k
n
STBD
s
p
PORT
p
s
r
STBD
v
u
t
w
A
x y
7-26
7
18. Disconnect the APS coupler D.
19. Disconnect the ground leads E, F, and
G.
20. Disconnect the air temperature sensor
coupler H.
21. Remove the intake silencer, and then
disconnect the ETV coupler J, low-pres-
sure fuel pump coupler L, and air pres-
sure sensor coupler M.
22. Remove the YDIS coupler N.
23. Disconnect the quick connectors. See
steps 2 and 3 in Disconnecting the quick
connector (6-6).
24. Remove the fuel hoses 0, A, and B.
25. Remove the plastic ties C from the wir-
ing harness guide, and then remove the
main wiring harness.
Installing the wiring harness
1. Install the main wiring harness, and then
install the plastic ties 1 to the wiring har-
ness guide.
2. Install the fuel hoses 2, 3, and 4 and
then connect the quick connectors.
B
D
E
G
F
H
J
M
N
L
C
C
B
A
0
Wiring harness
7-27
POWR
Power unit
3. Install the YDIS coupler a.
4. Connect the ETV coupler b, low-pres-
sure fuel pump coupler c, and air pres-
sure sensor coupler d, and then install
the intake silencer.
5. Install the intake silencer, and then con-
nect the air temperature sensor coupler
e.
6. Connect the ground leads f, g, and h.
7. Connect the APS coupler k.
8. Connect the magnet switch lead m.
9. Connect the fuse holder couplers n and
p and PTT relay coupler r.
10. Connect the engine temperature sensor
coupler s, vapor shut-off valve coupler
t, pulser coil coupler u, and high-pres-
sure fuel pump coupler v.
1
1
4
3
2
b
d
a
c
e
k
f
g
h
m
r
n p
7-28
7
11. Connect the ground leads w.
12. Connect the fuel injector couplers x and
oil pressure sensor coupler y.
13. Connect the OCV couplers A, cam posi-
tion sensor couplers B, and ther-
moswitch connectors D.
14. Install the plastic tie 5 to the wiring har-
ness guide.
15. Fasten the wiring harness 6 using the
holders 7.
16. Install the condensers E.
17. Connect the cam position sensor coupler
(PORT EX) F.
u
t
s
v
w
x
PORT
x
w
y
STBD
PORT
D
A
B
B
D
STBD
A
7
E
7
6
5
7
F
Wiring harness
7-29
POWR
Power unit
18. Install the plastic ties 1 to the engine
ECM bracket.
19. Install the wiring harness 6 to the hold-
ers 7.
20. Install the speed sensor coupler G, joint
couplers H, and water pressure sensor
coupler J.
21. Connect the ignition coil couplers L,
engine ECM couplers M, and knock sen-
sor coupler N.
22. Install the vapor gas hoses 8, 9, 0,
and A to the holders B.
23. Install the blowby hose C.
7
6
J H G N
7 1
L M
L
1
B
A
8
9
0
C
7-30
7
Fuse box
No. Part name Qty Remarks
1 Fuse box assembly 1
2 Cover 1
3 Cover 1
4 Fuse puller 1
5 Relay 4
6 Screw 2 M5 10 mm
7 Fuse 2 60 A, Spare is included.
8 Fuse 3 10 A, Spare is included.
9 Fuse 2 20 A, Spare is included.
10 Fuse 3 30 A, Spare is included.
11 Fuse 2 15 A, Spare is included.
12 Screw 8 M3 10 mm
13 Grommet 1
14 Screw 4 5 20 mm
13
3
14
14
2
5
5
6
8
9
10
8
11
7
4
12
1
7
9 3 10 4 8 11
2 Nm (0.2 kgfm, 1.5 ftIb)
A
A
Wiring harness / Fuse box
7-31
POWR
Power unit
Junction box
No. Part name Qty Remarks
1 Cap 2
2 Nut 2
3 Spring washer 2
4 PTT relay 1
5 Bolt 2 M6 20 mm
6 Junction box 1
7 Bolt 5 M6 30 mm
8 Grommet 5
9 Collar 5
10 Holder 2
11 Holder 2
12 Holder 1
13 Holder 1
14 Bracket 2
15 Bolt 1 M6 15 mm
16 Bolt 2 M6 35 mm
17 Rectifier Regulator 1
1
2
3
7
6
4
5
27
16
20
21
19
18
17
15
12
7
8
10
8
9
28
14
10
11
13
11
25
22
24
22
24
23
26
29
30
5 Nm (0.5 kgfm, 3.7 ftIb)
9 Nm (0.9 kgfm, 6.6 ftIb)
1 6 Nm (0.6 kgfm, 4.4 ftlb)
2 12 Nm (1.2 kgfm, 8.9 ftlb)
7-32
7
No. Part name Qty Remarks
18 Gasket 1
Not reusable
19 Cover 1
20 Bolt 4 M6 25 mm
21 Hose 1
22 Hose 2
23 Hose 1
24 Joint 2
25 Hose 1
26 Hose 1
27 Wiring harness 1
28 Bolt 1 M8 16 mm
29 Terminal 1
30 Bolt 1 M8 20 mm
1
2
3
7
6
4
5
27
16
20
21
19
18
17
15
12
7
8
10
8
9
28
14
10
11
13
11
25
22
24
22
24
23
26
29
30
5 Nm (0.5 kgfm, 3.7 ftIb)
9 Nm (0.9 kgfm, 6.6 ftIb)
1 6 Nm (0.6 kgfm, 4.4 ftlb)
2 12 Nm (1.2 kgfm, 8.9 ftlb)
Junction box
7-33
POWR
Power unit
Starter motor
No. Part name Qty Remarks
1 Bracket 1
2 Bolt 2 M8 35 mm
3 Dowel 1
4 Bracket 1
5 Bolt 1 M6 40 mm
6 Starter motor 1
7 Bolt 3 M8 45 mm
8 Bracket 1
9 Bolt 2 M6 20 mm
10 APS 1
11 Bolt 3 M6 35 mm
12 Grommet 3
13 Collar 3
1
2
3
10
7
7
7
6
8
9
4
5
11 11
12
12
13
13
12 Nm (1.2 kgfm, 8.9 ftIb)
25 Nm (2.5 kgfm, 18.4 ftIb)
30 Nm (3.0 kgfm, 22.1 ftIb)
7-34
7
Engine ECM
No. Part name Qty Remarks
1 Engine ECM 1
2 Bolt 4 M6 20 mm
3 Bolt 4 M6 30 mm
4 Grommet 4
5 Collar 4
6 Holder 2
7 Holder 1
8 Bracket 1
2
2
1
3
3
7
6
4
4
4
8
4
6
5
5
7 Nm (0.7 kgfm, 5.2 ftIb)
Starter motor / Engine ECM
7-35
POWR
Power unit
Camshaft
No. Part name Qty Remarks
1 Cap 2
2 Gasket 2
Not reusable
3 VCT bolt 2 M12 35 mm
4 VCT assembly (PORT) 1
5 VCT assembly (STBD) 1
6 Bolt 2 M10 35 mm
7 Driven sprocket 2
8 Oil seal 4
Not reusable
9 Valve lifter 24
10 Camshaft (PORT IN) 1
11 Camshaft (PORT EX) 1
12 Camshaft (STBD EX) 1
13 Camshaft (STBD IN) 1
14 Dowel 4
15 Collar 8
16 Camshaft cap (EX) 2
17 Camshaft cap (IN) 2
1
2
33 34
35
27
28
29
23
30
30
30
22
31
32
32
21
18
19
19
20
14
14
13
12
15
16
17
15
10
14
14
11
20
18
8
9
9
9
9
28
28
29
29
26
27
30
30
30
32
31
25
35
33
34
24
1
2
3
4
8
4
3
5
7
6
6
5
7
8
8
28 Nm (2.8 kgfm, 20.7 ftIb) 32 Nm (3.2 kgfm, 23.6 ftIb) 60 Nm (6.0 kgfm, 44.3 ftIb)
1 8 Nm (0.8 kgfm, 5.9 ftIb)
2 17 Nm (1.7 kgfm, 12.5 ftlb)
7-36
7
No. Part name Qty Remarks
18 Bolt 8 M7 48 mm
19 Bolt 24 M7 37 mm
20 Camshaft cap 12
21 Gasket 1
Not reusable
22 Cylinder head cover (PORT) 1
23 Bracket 1
24 Gasket 1
Not reusable
25 Cylinder head cover (STBD) 1
26 Bracket 1
27 Damper 2
28 Bolt 6
29 Nut 4
30 Grommet 6
31 Bolt 20 M6 30 mm
32 Holder 4
33 Bolt 6 M6 25 mm
34 Ignition coil 6
1
2
33 34
35
27
28
29
23
30
30
30
22
31
32
32
21
18
19
19
20
14
14
13
12
15
16
17
15
10
14
14
11
20
18
8
9
9
9
9
28
28
29
29
26
27
30
30
30
32
31
25
35
33
34
24
1
2
3
4
8
4
3
5
7
6
6
5
7
8
8
28 Nm (2.8 kgfm, 20.7 ftIb) 32 Nm (3.2 kgfm, 23.6 ftIb) 60 Nm (6.0 kgfm, 44.3 ftIb)
1 8 Nm (0.8 kgfm, 5.9 ftIb)
2 17 Nm (1.7 kgfm, 12.5 ftlb)
Camshaft
7-37
POWR
Power unit
No. Part name Qty Remarks
35 Spark plug 6
1
2
33 34
35
27
28
29
23
30
30
30
22
31
32
32
21
18
19
19
20
14
14
13
12
15
16
17
15
10
14
14
11
20
18
8
9
9
9
9
28
28
29
29
26
27
30
30
30
32
31
25
35
33
34
24
1
2
3
4
8
4
3
5
7
6
6
5
7
8
8
28 Nm (2.8 kgfm, 20.7 ftIb) 32 Nm (3.2 kgfm, 23.6 ftIb) 60 Nm (6.0 kgfm, 44.3 ftIb)
1 8 Nm (0.8 kgfm, 5.9 ftIb)
2 17 Nm (1.7 kgfm, 12.5 ftlb)
7-38
7
Removing the timing belt, driven
sprocket, and camshaft
When the timing belt is not installed, do
not turn the crankshaft or camshafts. Oth-
erwise, the pistons and valves or intake
and exhaust valves could collide with
each other and be damaged.
1. Check that the large mark a on the
crankshaft 1 is aligned with the rib b on
the cylinder block.
2. Check that the II marks c on the VCT
assembly (PORT) and driven sprocket
(PORT) are aligned, and check that the
I marks d on the VCT assembly
(STBD) and driven sprocket (STBD) are
aligned.
3. Remove the timing belt guides 2 and 3.
4. Remove the ignition coils 4 and spark
plugs 5, and then remove the cylinder
head covers 6 and 7.
5. Make the marks e, f, g, h, k, and m.
d
c
a
b
1
2
2
3
5
6
7
4
f
e
k h
m g
Camshaft
7-39
POWR
Power unit
nBelt teeth number
TIP:
It is not necessary to mark the timing belt
when replacing it.
6. Turn the timing belt tensioner gradually
clockwise using a hexagon wrench, and
then insert a 5.0 mm (0.2 in) pin 8 into
the hole p.
TIP:
When turning the timing belt tensioner,
apply a force of 15 Nm (1.5 kgfm, 11.1
ftlb) or less.
Leave the pin 8 inserted into the hole p of
the timing belt tensioner until the timing belt
is installed again.
7. Remove the timing belt 9 from the VCT
assembly (PORT) or driven sprocket
(STBD), and then remove it from the
crankshaft.
8. Turn the crankshaft counterclockwise 60
gradually until the large mark a on
the crankshaft is aligned with the mating
surface of the crankcase and cylinder
block. NOTICE: Do not turn the crank-
shaft counterclockwise more than 60.
Otherwise, the pistons and valves
could collide with each other and be
damaged.
9. Secure the VCT assembly 0 using the
special service tool A, and then remove
the VCT cap B. NOTICE: When remov-
ing the VCT cap, do not secure the
camshaft. Otherwise, the VCT assem-
bly could be damaged. When remov-
ing the VCT cap, do not turn the VCT
assembly. Otherwise, the intake and
exhaust valves could collide with
each other and be damaged.
6CB-462**-**
172 n 146 88 63 0123
g h k m
e
f
8
p
9
a
7-40
7
10. Remove the special service tool A.
11. Secure the intake camshaft using a
wrench, and then remove the VCT
assemblies C and D. NOTICE: When
removing the VCT assembly, do not
turn the intake camshaft. Otherwise,
the intake and exhaust valves could
collide with each other and be dam-
aged.
12. Hold the exhaust camshaft using a
wrench, and then remove the driven
sprocket E. NOTICE: When removing
the driven sprocket, do not turn the
exhaust camshaft. Otherwise, the
intake and exhaust valves could col-
lide with each other and be damaged.
13. Remove the camshaft caps F, G, and
H in the order 1, 2, and so on.
14. Remove the camshafts I, J, K, and L
and oil seals M, and then remove the
valve lifters N.
Primary sheave holder A: YS-01880-A
B
B
0
A
C
D
E
E
1
3
2
4
1
3
2
4
PORT
STBD
1
3
2
4
1
3
2
4
G F
H
Camshaft
7-41
POWR
Power unit
TIP:
Make sure to keep the parts in the order as
they were removed.
Checking the timing belt and
sprocket
1. Check the interior and exterior of the tim-
ing belt. Replace if cracked, damaged, or
worn.
2. Check the drive sprocket on the crank-
shaft. Replace the crankshaft if cracked,
damaged, or worn.
3. Check the VCT assemblies and driven
sprockets. Replace the VCT assembly or
driven sprocket if cracked, damaged, or
worn.
Checking the valve lifter
1. Check the valve lifters. Replace if dam-
aged, scratched, or worn.
2. Measure the valve lifter outside diameter
a.
Checking the camshaft
1. Check the edge and face of the flange on
the camshafts (PORT) and intake cam-
shaft (STBD) that is used for the cam
position sensor. Replace the camshaft if
damaged, rough, or scratched.
TIP:
Be careful not to scratch or damage the
face of the flange.
If there is a scratch that is more than 0.2
mm (0.008 in) deep or more than 0.5 mm
(0.020 in) wide on the surface of the flange,
a malfunction may occur in the cam posi-
tion sensor signal.
2. Measure the cam lobe height a and
width b.
L
M M
K
N
J
N I
M
M
Valve lifter outside diameter a:
30.97030.980 mm
(1.21931.2197 in)
a
7-42
7
3. Measure the camshaft runout.
4. Measure the camshaft journal diameter
c and camshaft journal inside diameter
d. Replace the camshaft, cylinder head
assembly, or both if out of specification.
Checking the spark plug
1. Clean the electrodes a using a spark
plug cleaner.
2. Check the spark plug. Replace if the
electrodes are eroded, or there is carbon
or other deposits.
3. Check the spark plug gap b. Replace if
out of specification.
Cam lobe height a:
Intake:
46.66146.761 mm
(1.83701.8410 in)
Exhaust:
46.96047.060 mm
(1.84881.8528 in)
Cam lobe width b:
Intake and exhaust:
35.95036.050 mm
(1.41541.4193 in)
Camshaft runout:
0.030 mm (0.0012 in)
a
b
Camshaft journal diameter c:
24.96024.980 mm
(0.98270.9835 in)
Camshaft journal inside diameter d:
25.00025.021 mm
(0.98430.9851 in)
d
c
c
d
a
b
Camshaft
7-43
POWR
Power unit
Installing the camshaft, driven
sprocket, and timing belt
If the valve clearances are adjusted or any
parts related to valve movement are replaced
after installing the timing belt, check the valve
clearances. See Checking the valve clear-
ance (7-2).
Do not reuse a gasket and oil seal,
always replace it with a new one.
When the timing belt is not installed, do
not turn the crankshaft or camshafts.
Otherwise, the pistons and valves or
intake and exhaust valves could collide
with each other and be damaged.
1. Check that the large mark a on the
crankshaft is aligned with the mating sur-
face of the crankcase and cylinder block.
2. Apply a thin, even coat of sealant to the
mating surfaces of the camshaft caps 1
and 2 and cylinder heads 3.
TIP:
Do not block the oil passages or oil holes with
the sealant.
3. Install the valve lifters 4.
4. Install the camshafts 5, 6, 7, and 8 in
the proper positions and new oil seals 9.
Specified spark plug: LFR6A-11 (NGK)
Spark plug gap b:
1.01.1 mm (0.0390.043 in)
a
1 2
3
PORT
3
2 1
STBD
7-44
7
TIP:
Install the valve lifters in their original posi-
tions.
5. Check that the dowel holes in the cam-
shafts (PORT) are aligned with the mat-
ing surface of the cylinder head.
6. Check that the dowel holes in the cam-
shafts (STBD) are positioned 60 from
the mating surface of the cylinder head.
7. Install the camshaft caps 0, A, and B in
their proper positions so that the
stamped numbers are upside down.
8. Tighten the bolts C and D to the speci-
fied torques in 2 stages and in the order
1, 2, and so on.
9. Check that the dowel holes in the cam-
shafts (PORT) are aligned, and check
that the dowel holes in the camshafts
(STBD) are aligned.
6CB
P-IN
6CB
P-EX
6CB
S-EX
6CB
S-IN
5
9
6
7
4
8
9
PORT STBD
Camshaft cap bolts C and D:
1st: 8 Nm (0.8 kgfm, 5.9 ftlb)
2nd: 17 Nm (1.7 kgfm, 12.5 ftlb)
PORT STBD
A 0 A 0
2 P
1 P
3 P
4 P
6 P
5 P
7 P
8 P
6 S
5 S
7 S
8 S
2 S
1 S
3 S
4 S
B B
PORT STBD
D
C 4
3
2
4
3
2
1
4
3
2
1
1
4
3
2
1
PORT STBD
Camshaft
7-45
POWR
Power unit
10. Install the dowels E and driven sprock-
ets F.
11. Secure the exhaust camshaft using a
wrench, and then tighten the bolt G to
the specified torque. NOTICE: When
tightening the bolt, do not turn the
exhaust camshaft. Otherwise, the
intake and exhaust valves could col-
lide with each other and be damaged.
12. Install the dowels H and VCT assem-
blies I.
13. Check that the lower edges of the driven
sprockets and VCT assemblies are
aligned.
14. Secure the intake camshaft using a
wrench, and then tighten the VCT bolt J
to the specified torque. NOTICE: When
tightening the VCT bolt, do not secure
the driven sprocket. Otherwise, the
VCT assembly could be damaged.
When tightening the VCT bolt, do not
turn the intake camshaft. Otherwise,
the intake and exhaust valves could
collide with each other and be dam-
aged.
Driven sprocket bolt G:
60 Nm (6.0 kgfm, 44.3 ftlb)
G
F
G
E
I
I
H
VCT bolt J: 60 Nm (6.0 kgfm, 44.3 ftlb)
J
J
7-46
7
15. Install a new gasket K and the VCT cap
L, secure the VCT assembly using the
special service tool M, and then tighten
the VCT cap L to the specified torque.
NOTICE: When tightening the VCT
cap, do not secure the camshaft. Oth-
erwise, the VCT assembly could be
damaged. When tightening the VCT
cap, do not turn the driven sprocket.
Otherwise, the intake and exhaust
valves could collide with each other
and be damaged.
16. Turn the crankshaft clockwise 60 gradu-
ally until the large mark b on the
crankshaft is aligned with the rib c on
the cylinder block. NOTICE: Do not turn
the crankshaft clockwise more than
60. Otherwise, the pistons and valves
could collide with each other and be
damaged.
17. Check that the II marks d on the VCT
assembly (PORT) and driven sprocket
(PORT) are aligned.
18. Check that the I marks e on the VCT
assembly (STBD) and driven sprocket
(STBD) are aligned.
19. Install the timing belt N onto the crank-
shaft so that the arrow mark f is point-
ing upward and the timing belt mark g is
aligned with the small mark on the
crankshaft. NOTICE: Do not apply
grease or oil to the timing belt.
Primary sheave holder M: YS-01880-A
VCT cap L: 32 Nm (3.2 kgfm, 23.6 ftlb)
L
L
K
M
b
c
PORT
d
e
STBD
Camshaft
7-47
POWR
Power unit
pBelt teeth number
20. Install the timing belt onto the VCT
assemblies and driven sprockets by
aligning the belt position marks h, k,
m, and n with the marks in the
order listed.
21. Adjust the timing belt installation height
r to specification.
22. Turn the timing belt tensioner gradually
clockwise using a hexagon wrench, and
then remove the pin O.
TIP:
When turning the timing belt tensioner,
apply a force of 15 Nm (1.5 kgfm, 11.1
ftlb) or less.
Make sure that the belt position marks are
aligned with the marks.
23. Turn the crankshaft clockwise 2 full turns
until the large mark b on the crank-
shaft is aligned with the rib c on the cyl-
inder block, and then check that the
marks d and e on the VCT assemblies
and driven sprockets are aligned.
N
g
f
6CB-462**-**
172 p 146 88 63 0123
h k m n
f
g
n m
p k
Timing belt installation height r:
2.5 mm (0.10 in)
r
O
7-48
7
24. Install the cylinder head covers P and
Q.
25. Install the timing belt guides R and S,
and then adjust the timing belt guide
clearance s.
e
d
b
c
Q
P
Timing belt guide clearance s:
0.51.5 mm (0.020.06 in)
s
s
S
R R
Camshaft
7-49
POWR
Power unit
Cylinder head
No. Part name Qty Remarks
1 Bolt 6 M6 35 mm
2 OCV assembly 2
3 Filter 2
Not reusable
4 Bolt 3 M6 20 mm
5 Cam position sensor 3
6 O-ring 3
Not reusable
7 Gasket 2
Not reusable
8 Collar 4
9 Cylinder head (PORT) 1
10 Bolt 16 M11 120 mm
11 Bolt 4 M8 50 mm
12 Bolt 2 M8 70 mm
13 Bolt 16 M8 25 mm
14 Anode assembly 8
15 Bolt 8 M6 20 mm
16 Gasket 8
Not reusable
17 Cover 8
1322
1377B
1322
1
2
3
10
4
5
6
9 7
8
8
11
11
13
13
15
20
21
18
16
14
17
19
12
7
6
5
4
8
8
20
21
31
30
29
28
32
33
34
12
10 10
11
30
29
28
27
26
25
6
5
4
22
13
16
13
14
15
19
24
23
3
2
1
11
27
26
25
18
17
23 Nm (2.3 kgfm, 17.0 ftIb)
55 Nm (5.5 kgfm, 40.6 ftIb)
7 Nm (0.7 kgfm, 5.2 ftIb)
1 14 Nm (1.4 kgfm, 10.3 ftlb)
2 28 Nm (2.8 kgfm, 20.7 ftlb)
1 39 Nm (3.9 kgfm, 28.8 ftlb)
2 90
3 90
7-50
7
No. Part name Qty Remarks
18 Anode 8
19 Grommet 8
20 Plug 2 M18 17 mm
21 Gasket 2
Not reusable
22 Intake valve 12
23 Exhaust valve 12
24 Cylinder head (STBD) 1
25 Valve guide 24
Not reusable
26 Valve seal 24
Not reusable
27 Valve spring seat 24
28 Valve spring 24
29 Valve spring retainer 24
30 Valve cotter 48
31 Plug 1 M14 12 mm
32 Gasket 1
Not reusable
33 Joint 1
34 Joint 1
1322
1377B
1322
1
2
3
10
4
5
6
9 7
8
8
11
11
13
13
15
20
21
18
16
14
17
19
12
7
6
5
4
8
8
20
21
31
30
29
28
32
33
34
12
10 10
11
30
29
28
27
26
25
6
5
4
22
13
16
13
14
15
19
24
23
3
2
1
11
27
26
25
18
17
23 Nm (2.3 kgfm, 17.0 ftIb)
55 Nm (5.5 kgfm, 40.6 ftIb)
7 Nm (0.7 kgfm, 5.2 ftIb)
1 14 Nm (1.4 kgfm, 10.3 ftlb)
2 28 Nm (2.8 kgfm, 20.7 ftlb)
1 39 Nm (3.9 kgfm, 28.8 ftlb)
2 90
3 90
Cylinder head
7-51
POWR
Power unit
Removing the cylinder head
1. Remove the OCVs a and filters 1.
2. Loosen the bolts 2, 3, and 4 in the
order 1, 2, and so on, and then remove
the cylinder heads 5 and gaskets 6.
NOTICE: Be careful not to scratch or
damage the mating surfaces of the
cylinder head and cylinder block.
Disassembling the cylinder head
1. Remove the cam position sensors 1 and
anode assemblies 2.
2. Remove the intake and exhaust valves.
TIP:
Make sure to keep the parts in the order as
they were removed.
Checking the cylinder head
1. Remove carbon deposits from the com-
bustion chambers and check the cylinder
head for damage and scratches.
2. Check the cylinder head warpage in 6
directions. Replace the cylinder head
assembly if above specification.
PORT STBD
7
A
8
4
0
6
9
5
0
9
5
A
7
8
4
(T55)
6
1 2 2 3 1 3
4
3 2 2
3
4
1
4
5
3
2
a
6
Valve spring compressor 1: YM-04019
Valve attachment 2: YB-06320
2
2
1
1
2
7-52
7
Checking the cylinder head bolt
1. Measure the diameters a and b of the
cylinder head bolt at the specified mea-
suring points c and d. Replace the cyl-
inder head bolt if the difference between
the diameters is above specification.
Checking the valve spring
1. Measure the valve spring free length a.
2. Measure the valve spring tilt b. Replace
if above specification.
Checking the valve
1. Check the valve face. Replace if pitted or
worn.
2. Measure the valve margin thickness a.
Replace if out of specification.
Cylinder head warpage limit:
0.10 mm (0.0039 in)
Cylinder head bolt diameter difference
limit:
a b = Less than 0.20 mm (0.0079 in)
Measuring point c: 10.0 mm (0.39 in)
Measuring point d: 85.0 mm (3.35 in)
b a
c d
Valve spring free length a:
48.1 mm (1.89 in)
Valve spring tilt limit b: 1.7 mm (0.07 in)
Valve margin thickness a:
Intake:
0.7501.150 mm (0.02950.0453 in)
Exhaust:
0.9001.300 mm (0.03540.0512 in)
a
b
a
Cylinder head
7-53
POWR
Power unit
3. Measure the valve stem diameter b.
Replace if out of specification.
4. Measure the valve stem runout.
Checking the valve guide
Before checking the valve guides, make sure
to check the valves.
1. Measure the valve guide inside diameter
a.
2. Calculate the valve guide clearance.
Replace the valve guide if out of specifi-
cation.
Replacing the valve guide
Do not reuse a valve guide, always
replace it with a new one.
After replacing a valve guide, check the valve
seat contact area.
1. Remove the valve guide 1 from the
combustion chamber side using the spe-
cial service tool 2.
2. Install a new valve guide 3 from the
camshaft side to the specified position a
using the special service tool 2.
Valve stem diameter b:
Intake:
5.4775.492 mm (0.21560.2162 in)
Exhaust:
5.4645.479 mm (0.21510.2157 in)
Valve stem runout:
Intake and exhaust
0.010 mm (0.0004 in)
b
a
Valve guide inside diameter a:
Intake and exhaust:
5.5045.522 mm (0.21670.2174 in)
Valve guide clearance:
Intake:
0.0120.045 mm (0.00050.0018 in)
Exhaust:
0.0250.058 mm (0.00100.0023 in)
Valve guide remover 2: YB-06801
1 2
E
2
3
a
7-54
7
3. Insert the special service tool 4 into the
valve guide 3, and then ream the valve
guide.
TIP:
Turn the special service tool 4 clockwise to
ream the valve guide.
Do not turn the special service tool 4 coun-
terclockwise when removing it.
Make sure to clean the valve guide after
reaming it.
4. Measure the valve guide inside diameter.
Checking the valve seat
1. Remove carbon deposits from the valve.
2. Apply a thin, even layer of Mechanics
blueing dye (Dykem) onto the valve seat.
3. Push the valve lightly against the valve
seat using the special service tool 1.
4. Measure the valve seat contact width a
where the blueing dye adhered to the
valve face. Reface the valve seat if the
valve is not seated properly or if the valve
seat contact width is out of specification.
Check the valve guide if the valve seat
contact width is uneven.
Valve guide remover 2: YB-06801
Valve guide installation height a:
11.30011.700 mm (0.44490.4606
in)
Valve guide reamer 4: YM-01196
Valve guide inside diameter:
Intake and exhaust:
5.5045.522 mm (0.21670.2174 in)
3
4
E
Valve lapping tool 1: YM-A8998
Valve seat contact width a:
Intake:
1.1001.400 mm (0.04330.0551 in)
Exhaust:
1.4001.700 mm (0.05510.0669 in)
1
a
Cylinder head
7-55
POWR
Power unit
Refacing the valve seat
After every lapping procedure, make sure
to clean off any remaining lapping com-
pound from the cylinder head and valves.
1. Reface the valve seat using the special
service tools.
2. Cut the surface of the valve seat using a
45 cutter by turning the cutter clockwise
until the valve seat face has become
smooth. NOTICE: Do not over cut the
valve seat. To prevent chatter marks,
make sure to turn the cutter evenly
using a downward force of 4050 N
(4.05.0 kgf, 8.811.0 lbf).
aSlag or rough surface
3. Adjust the top edge of the valve seat con-
tact width using a 30 cutter.
bPrevious contact width
4. Adjust the bottom edge of the valve seat
contact width using a 60 cutter.
bPrevious contact width
5. Adjust the valve seat contact width to
specification using a 45 cutter.
bPrevious contact width
cSpecified contact width
6. Check the valve seat contact area of the
valve. See Checking the valve seat (7-
54).
Neway valve seat kit: YB-91044
30
45
30
45
60
45
a
30
b
60
b
45
b
c
7-56
7
Example:
If the valve seat contact area is too wide
and situated in the center of the valve face,
cut the top edge of the valve seat using a
30 cutter, and then cut the bottom edge
using a 60 cutter to center the area and set
its width.
bPrevious contact width
If the valve seat contact area is too narrow
and situated near the top edge of the valve
face, cut the top edge of the valve seat
using a 30 cutter to center the area, and
then set its width using a 45 cutter.
bPrevious contact width
If the valve seat contact area is too narrow
and situated near the bottom edge of the
valve face, cut the bottom edge of the valve
seat using a 60 cutter to center the area,
and then set its width using a 45 cutter.
bPrevious contact width
7. After refacing the valve seat to the speci-
fied contact width, apply a thin, even
layer of lapping compound onto the valve
seat, and then lap the valve using the
special service tool 1. NOTICE: Do not
get the lapping compound on the
valve stem and valve guide.
8. Recheck the valve seat contact area of
the valve. See Checking the valve seat
(7-54).
Checking the cylinder head anode
1. Check the anodes. Replace if eroded.
Clean if there is grease, oil, or scales.
NOTICE: Do not apply grease, oil, or
paint to the anodes.
Assembling the cylinder head
Do not reuse a valve seal, always replace
it with a new one.
1. Install a new valve seal 1.
2. Install the valve 2, valve spring seat 3,
valve spring 4, and valve spring retainer
5 in this order, and then install the spe-
cial service tools 6 and 7.
30
60
b
30
b
60
b
Valve lapping tool 1: YM-A8998
1
1
Cylinder head
7-57
POWR
Power unit
3. Compress the valve spring, and then
install the valve cotters 8.
4. Tap the valve spring retainer lightly using
a plastic hammer to seat the valve cot-
ters 8 securely.
5. Install the cam position sensors 9 and
anode assemblies 0.
Installing the cylinder head
Do not reuse a filter, gasket, or O-ring,
always replace it with a new one.
1. Install new filters 1 and the OCVs a,
and then tighten the bolts 2 to the speci-
fied torque.
2. Install new gaskets 3, the collars 4, and
the cylinder heads 5, and then tighten
the bolts 6 to the specified torques in 3
stages and in the order 1, 2, and so on.
3. Tighten the bolts 7 and 8 to the speci-
fied torques in 2 stages and in the order
9, :, and so on.
Valve spring compressor 6: YM-04019
Valve attachment 7: YB-06320
5
4
3
2
6
7
E
E
8
8 8
0
0
9
0
1322
1322
1322
7-58
7
TIP:
In the 2nd and 3rd tightening stages for the
M11 bolts 6, make marks b on the M11
bolts and the cylinder heads 5, and then
tighten the bolts 90 from the marks on the
cylinder heads.
OCV bolt 2: 7 Nm (0.7 kgfm, 5.2 ftlb)
Cylinder head bolt 6 18 (M11):
1st: 39 Nm (3.9 kgfm, 28.8 ftlb)
2nd: 90
3rd: 90
Cylinder head bolts 7 and 8 9A (M8):
1st: 14 Nm (1.4 kgfm, 10.3 ftlb)
2nd: 28 Nm (2.8 kgfm, 20.7 ftlb)
1
6
5
8
7
4
4
a
3
2
b
90
PORT STBD
5
1
4
8
2
6
3
7
2
3
7
1
5
4
8
(T55)
6
A 0 0 9 A 9
6
8
8
7 7
6
Cylinder head
7-59
POWR
Power unit
Oil cooler and oil pump assembly
No. Part name Qty Remarks
1 Oil filter 1
2 Union bolt 1
3 Oil pressure sensor 1
4 O-ring 1
Not reusable
5 Gasket 1
Not reusable
6 Bracket 1
7 Bolt 5 M6 40 mm
8 Nut 1
9 Bracket 1
10 Vapor shut-off valve 1
11 Bolt 1 M6 15 mm
12 Bolt 1 M6 20 mm
13 Oil filler cap 1
14 O-ring 1
Not reusable
15 Oil filler neck 1
16 O-ring 1
Not reusable
17 Holder 1
1
2
3
6
4
5
39
38
7
33 33
38
39
36
36
37
35
34
29
30
28
29
31
31
26
25
25
25
25
24
19
22
25
27
26
21
16
12
11
10
17
18
9
8
15
13
14
32
19
20
22
25
23
12 Nm (1.2 kgfm, 8.9 ftIb)
13 Nm (1.3 kgfm, 9.6 ftIb)
18 Nm (1.8 kgfm, 13.3 ftIb)
49 Nm (4.9 kgfm, 36.1 ftIb)
4 Nm (0.4 kgfm, 3.0 ftIb)
1 6 Nm (0.6 kgfm, 4.4 ftlb)
2 12 Nm (1.2 kgfm, 8.9 ftlb)
7-60
7
No. Part name Qty Remarks
18 Bolt 2 M6 25 mm
19 Hose 2
20 Hose 1
21 Hose 1
22 Joint 2
23 Hose 1
24 Hose 1
25 Plastic tie 7
Not reusable
26 Gasket 2
Not reusable
27 Oil cooler 1
28 Cover 1
29 Bolt 12 M6 40 mm
30 Holder 1
31 Anode 2
32 Screw 2 M6 16 mm
33 Oil seal 1
Not reusable
34 Relief valve 1
1
2
3
6
4
5
39
38
7
33 33
38
39
36
36
37
35
34
29
30
28
29
31
31
26
25
25
25
25
24
19
22
25
27
26
21
16
12
11
10
17
18
9
8
15
13
14
32
19
20
22
25
23
12 Nm (1.2 kgfm, 8.9 ftIb)
13 Nm (1.3 kgfm, 9.6 ftIb)
18 Nm (1.8 kgfm, 13.3 ftIb)
49 Nm (4.9 kgfm, 36.1 ftIb)
4 Nm (0.4 kgfm, 3.0 ftIb)
1 6 Nm (0.6 kgfm, 4.4 ftlb)
2 12 Nm (1.2 kgfm, 8.9 ftlb)
Oil cooler and oil pump assembly
7-61
POWR
Power unit
No. Part name Qty Remarks
35 Oil pump assembly 1
36 O-ring 2
Not reusable
37 Gasket 1
Not reusable
38 Oil seal 1
Not reusable
39 Oil seal 2
Not reusable
1
2
3
6
4
5
39
38
7
33 33
38
39
36
36
37
35
34
29
30
28
29
31
31
26
25
25
25
25
24
19
22
25
27
26
21
16
12
11
10
17
18
9
8
15
13
14
32
19
20
22
25
23
12 Nm (1.2 kgfm, 8.9 ftIb)
13 Nm (1.3 kgfm, 9.6 ftIb)
18 Nm (1.8 kgfm, 13.3 ftIb)
49 Nm (4.9 kgfm, 36.1 ftIb)
4 Nm (0.4 kgfm, 3.0 ftIb)
1 6 Nm (0.6 kgfm, 4.4 ftlb)
2 12 Nm (1.2 kgfm, 8.9 ftlb)
7-62
7
Removing the oil filter bracket
1. Remove the oil filter 1.
2. Remove the oil pressure sensor 3, O-
ring 4, and oil filter union bolt 5.
3. Remove the bracket 6 and gasket 7.
Removing the oil cooler
1. Remove the cover 1, oil cooler 2, gas-
kets 3, and anodes 4.
Removing the oil pump assembly
1. Remove the oil pump assembly 1, O-
rings 2, and oil seal 3.
Disassembling the oil pump
assembly
1. Remove the oil pump cover a, gasket
1, inner rotor b, outer rotor c, and oil
seals 2 and 3.
Oil filter wrench 2:
(commercially available)
1
2
5
3
6
7
4
3
2
1
3
4
3
2
2
1
Oil cooler and oil pump assembly
7-63
POWR
Power unit
Checking the oil pump assembly
1. Check the inner surface of the oil pump
housing. Replace the oil pump assembly
if scratched.
2. Check the gear teeth of the inner rotor
and outer rotor. Replace the oil pump
assembly if the gear teeth are cracked or
worn.
Checking the oil cooler
1. Check the oil cooler. Replace if corroded
or cracked.
Checking the oil cooler anode
1. Check the anode. Replace if eroded.
Clean if there is grease, oil, or scales.
NOTICE: Do not apply grease, oil, or
paint to the anode.
Assembling the oil pump assembly
Do not reuse an oil seal, always replace it
with a new one.
1. Install new oil seals 1 into the oil pump
housing a.
2. Install a new oil seal 4 into the oil pump
housing a.
3. Install the outer rotor b, the inner rotor
c, a new gasket 6, and the oil pump
cover d, and then tighten the screws e
to the specified torque.
4. Install a new oil seal 7 so that it is facing
in the proper direction.
1
a
b
c
2
3
Driver handle (large) 2: YB-06071
Roller bearing installer/remover 3:
YB-06432
Needle bearing installer 5: YB-06111
2
1
1
a
3
WR-No.2
5
WR-No.2
4
a
e
c
d
6
7
b
7-64
7
Installing the oil pump assembly
Do not reuse an O-ring, always replace it
with a new one.
1. Install new O-rings 1 and the oil pump
assembly 2 by aligning the oil pump
gear with the crankshaft. NOTICE:
Before installing the oil pump assem-
bly, make sure to fill it with engine oil
through the oil passages a.
Installing the oil cooler
Do not reuse a gasket, always replace it
with a new one.
1. Install the anodes 1.
2. Install a new gasket 2, the oil cooler 3,
a new gasket 4, and the cover 5, and
then tighten the bolts 6 to the specified
torques in 2 stages and in the order 1,
2, and so on.
Installing the oil filter bracket
Do not reuse a gasket or O-ring, always
replace it with a new one.
Oil pump cover screw e:
4 Nm (0.4 kgfm, 3.0 ftlb)
a
a
2
2
1
1
Oil cooler bolt 6:
1st: 6 Nm (0.6 kgfm, 4.4 ftlb)
2nd: 12 Nm (1.2 kgfm, 8.9 ftlb)
2
3
4
6
1
1
5
6
A
0
7
3
2
9 6 B
8
4
1
5
6
Oil cooler and oil pump assembly
7-65
POWR
Power unit
1. Install a new gasket 1 and the oil filter
bracket 2, and then tighten the bolts 3
to the specified torque in the order 1, 2,
and so on.
2. Install the oil filter union bolt 4, and then
tighten it to the specified torque.
3. Install a new O-ring 5 and the oil pres-
sure sensor 6, and then tighten the oil
pressure sensor to the specified torque.
4. Add a small amount of engine oil through
the oil passage a of the oil filter bracket.
5. Install the oil filter 7, and then tighten it
to the specified torque.
Oil filter bracket bolt 3:
12 Nm (1.2 kgfm, 8.9 ftlb)
1
2
3
1
4
3 2
5
3
2
4
6
5
Oil filter union bolt 4:
49 Nm (4.9 kgfm, 36.1 ftlb)
Oil pressure sensor 6:
13 Nm (1.3 kgfm, 9.6 ftlb)
Oil filter wrench 8:
(commercially available)
Oil filter 7: 18 Nm (1.8 kgfm, 13.3 ftlb)
a
7
8
7-66
7
Cylinder block sensor and switch
No. Part name Qty Remarks
1 Clamp 4
2 Hose 1
3 Hose 1
4 Joint 1
5 Hose 1
6 Clamp 1
7 Clamp 1
8 Joint 1
9 Bolt 14 M6 25 mm
10 Housing 2
11 Gasket 2
Not reusable
12 Thermostat 2
13 Gasket 2
Not reusable
14 Cover 2
15 Plastic tie 6
Not reusable
16 Holder 2
17 Hose 1
17
5
1
33
1
1
8
4
3
2
16
30
21
22
15
15
20
19
15
18
9
9
10
12
12
13
13
11
11
9
15
30
27
25
15
32
31
29
10
28
29
28
9
9
14
14
23
24
26
7
6
12 Nm (1.2 kgfm, 8.9 ftIb)
1 14 Nm (1.4 kgfm, 10.3 ftlb)
2 28 Nm (2.8 kgfm, 20.7 ftlb)
32 Nm (3.2 kgfm, 23.6 ftIb)
12 Nm (1.2 kgfm, 8.9 ftIb)
Oil cooler and oil pump assembly / Cylinder block sensor and switch
7-67
POWR
Power unit
No. Part name Qty Remarks
18 Hose 1
19 Joint 1
20 Hose 1
21 Bracket 1
22 Knock sensor 1
23 Bolt 4 M8 30 mm
24 Bracket 1
25 Engine temperature sensor 1
26 Hose 1
27 Holder 1
28 Bolt 2 M6 12 mm
29 Holder 2
30 Thermoswitch 2
31 Bolt 1 M6 15 mm
32 Bracket 1
33 Plastic tie 1
Not reusable
17
5
1
33
1
1
8
4
3
2
16
30
21
22
15
15
20
19
15
18
9
9
10
12
12
13
13
11
11
9
15
30
27
25
15
32
31
29
10
28
29
28
9
9
14
14
23
24
26
7
6
12 Nm (1.2 kgfm, 8.9 ftIb)
1 14 Nm (1.4 kgfm, 10.3 ftlb)
2 28 Nm (2.8 kgfm, 20.7 ftlb)
32 Nm (3.2 kgfm, 23.6 ftIb)
12 Nm (1.2 kgfm, 8.9 ftIb)
7-68
7
Removing the thermostat
1. Remove the hoses 1 and thermostat
covers 2, and then remove the thermo-
stats a and gaskets 3.
2. Remove the thermostat housings 4 and
gaskets 5.
3. Remove the thermoswitches 6.
Checking the thermostat
1. Suspend the thermostat in a container of
water.
2. Place a thermometer in the water and
heat the water slowly.
3. Measure the thermostat valve opening a
at the specified water temperatures.
Replace if out of specification.
Installing the thermostat
Do not reuse a gasket, always replace it
with a new one.
1. Install the thermoswitches 1.
2. Install new gaskets 2 and the thermostat
housings 3, and then tighten the bolts 4
to the specified torque.
3. Install new gaskets 5 to the thermostats
a.
4. Install the thermostats a, thermostat
covers 6, and hoses 7, and then
tighten the bolts 8 to the specified
torque.
4
a
3
5
6
2
1
Water tempera-
ture
Valve opening a
58.062.0 C
(136.0144.0 F)
Starts opening
above 70.0 C
(158.0 F)
4.3 mm (0.17 in) or above
a
3
a
5
2
1
6
7
4
8
Cylinder block sensor and switch
7-69
POWR
Power unit
Installing the knock sensor
1. Install the hoses 1, 2, and 3 and joints
4 and 5, and then fasten the hoses
using the clamps 6, 7, and 8.
2. Install the knock sensor 9 to the bracket
0, and then tighten the knock sensor 9
to the specified torque.
3. Install the bracket 0, and then tighten
the bolts A to the specified torque in the
order 1, 2, and so on.
Installing the pulley bracket
1. Install the bracket 1, and then tighten
the bolts 2 to the specified torques in 2
stages and in the order 1, 2, and so on.
Thermostat housing bolt 4:
12 Nm (1.2 kgfm, 8.9 ftlb)
Thermostat cover bolt 8:
12 Nm (1.2 kgfm, 8.9 ftlb)
Knock sensor 9:
32 Nm (3.2 kgfm, 23.6 ftlb)
Knock sensor bracket bolt A:
12 Nm (1.2 kgfm, 8.9 ftlb)
6
4
2
1
8
3
3
2
1
5
7
6
6
#
!
$

0
0
9
A
Timing belt pully bracket bolt 2:
1st: 14 Nm (1.4 kgfm, 10.3 ftlb)
2nd: 28 Nm (2.8 kgfm, 20.7 ftlb)
2
1
1

!
#
$
7-70
7
Cylinder block
No. Part name Qty Remarks
1 Cylinder block 1
2 Anode 2
3 Screw 2 M5 26 mm
4 Screw 4 M6 25 mm
5 Anode 4
6 Screw 2 M6 45 mm
7 Anode 2
8 Oil seal 1
Not reusable
9 Thrust bearing 2
10 Crankshaft journal bearing (upper) 4
11 Crankshaft journal bearing (lower) 4
12 O-ring 2
Not reusable
13 Piston ring set 6
14 Piston 6
15 Clip 12
Not reusable
16 Piston pin 6
17 Connecting rod assembly 6
8
5
4
12
6
7
4
4
5
5
19
19
20
18
18
13
15
14
16
15
9
11
9 10
21
22
25
23
24
3
2
1
17
5
2
3
4
1 14 Nm (1.4 kgfm, 10.3 ftlb)
2 28 Nm (2.8 kgfm, 20.7 ftlb)
1 40 Nm (4.0 kgfm, 29.5 ftlb)
2 90
1 55 Nm (5.5 kgfm, 40.6 ftIb)
2 90
Cylinder block sensor and switch / Cylinder block
7-71
POWR
Power unit
No. Part name Qty Remarks
18 Bolt 12
Not reusable
M9 42 mm
19 Crankpin bearing 12
20 Collar 1
Not reusable
21 Crankshaft 1
22 Crankcase 1
23 Bolt 8 M10 105 mm
24 Bolt 8 M10 130 mm
25 Bolt 16 M8 50 mm
8
5
4
12
6
7
4
4
5
5
19
19
20
18
18
13
15
14
16
15
9
11
9 10
21
22
25
23
24
3
2
1
17
5
2
3
4
1 14 Nm (1.4 kgfm, 10.3 ftlb)
2 28 Nm (2.8 kgfm, 20.7 ftlb)
1 40 Nm (4.0 kgfm, 29.5 ftlb)
2 90
1 55 Nm (5.5 kgfm, 40.6 ftIb)
2 90
7-72
7
Disassembling the cylinder block
1. Remove the crankcase 1.
2. Remove the connecting rod caps a, and
then remove the crankpin bearings 2,
connecting rods, and piston assemblies
3.
TIP:
To prevent mixing the pistons, connecting
rods, and connecting rod caps, mark each
with an identification number b of the cor-
responding cylinder.
Mark each connecting rod and connecting
rod cap with mark c on the side facing
toward the flywheel magnet end of the
crankshaft.
Make sure to keep the parts in the order as
they were removed.
3. Remove the crankshaft 4, crankshaft
journal bearings 5, thrust bearings 6,
and oil seal 7.
4. Remove the collar 8.
1
2
a
2
3
c
b
5
5
5
5
7
6
6
4
d
e
8
9
0
A
A
Cylinder block
7-73
POWR
Power unit
5. Remove the piston pin clips B and pis-
ton pin C, and then remove the connect-
ing rod f.
TIP:
Make sure to keep the parts in the order as
they were removed.
6. Remove the piston rings.
Checking the piston diameter
1. Measure the piston diameter a at the
specified measuring point b.
Checking the cylinder bore
1. Measure the cylinder bore (D
1
D
6
) at
measuring points a, b, and c, and in
direction d (D
1
, D
3
, D
5
), which is parallel
to the crankshaft, and direction e (D
2
,
D
4
, D
6
), which is at a right angle to the
crankshaft.
a10.0 mm (0.39 in)
b77.0 mm (3.03 in)
c106.0 mm (4.17 in)
Checking the piston ring
1. Measure piston ring dimensions B and T.
Bearing splitter plate 9: YB-06219
Gear puller 0: (commercially available)
General cylindrical tool A:
d = 19 mm (0.7 in)
e = 90 mm (3.5 in)
Piston diameter a:
95.94595.960 mm
(3.77743.7779 in)
Measuring point b:
13.500 mm (0.5315 in) up from the
bottom of the piston skirt
B
C
B
f
b
a
Cylinder bore (D
1
D
6
):
96.00096.012 mm
(3.77953.7800 in)
Piston ring dimension:
Top ring a:
B: 1.200 mm (0.0472 in)
T: 2.8003.000 mm (0.11020.1181 in)
2nd ring b:
B: 1.1701.190 mm (0.04610.0469 in)
T: 3.8004.000 mm (0.14960.1575 in)
Oil ring c:
B: 2.4002.470 mm (0.09450.0972 in)
T: 2.3502.750 mm (0.09250.1083 in)
D1 D2
D3 D4
D5 D6
a
b
c
d
e
c B
T
T
B
b a
T
B
7-74
7
Checking the piston ring end gap
1. Level the piston ring 1 in the cylinder
using a piston crown at the specified
measuring point a.
2. Measure the piston ring end gap b.
Checking the piston ring groove
1. Measure the piston ring grooves.
Replace the piston if out of specification.
Checking the piston ring side
clearance
1. Measure the piston ring side clearance.
Checking the piston pin boss inside
diameter
1. Measure the piston pin boss inside diam-
eter.
Measuring point a (reference data):
20.0 mm (0.8 in)
Piston ring end gap b (reference data):
Top ring:
0.2000.300 mm (0.00790.0118 in)
2nd ring:
0.6000.750 mm (0.02360.0295 in)
Oil ring:
0.1500.600 mm (0.00590.0236 in)
a
1
b
a
b
c
Piston ring groove:
Top ring a:
1.2301.250 mm (0.04840.0492 in)
2nd ring b:
1.2201.240 mm (0.04800.0488 in)
Oil ring c:
2.5102.530 mm (0.09880.0996 in)
Piston ring side clearance:
Top ring a:
0.0300.050 mm (0.00120.0020 in)
2nd ring b:
0.0300.070 mm (0.00120.0028 in)
Oil ring c:
0.0400.130 mm (0.00160.0051 in)
a
b
c
b
c c
a
Cylinder block
7-75
POWR
Power unit
TIP:
When measuring the piston pin boss inside
diameter, do not measure it at the ring
groove b or oil groove c.
Checking the piston pin diameter
1. Measure the piston pin diameter a.
Checking the connecting rod small
end inside diameter and big end
inside diameter
1. Tighten the bolts 1 to the specified
torques in 2 stages.
TIP:
When checking the oil clearance, reuse the
removed connecting rod bolt.
2. Measure the connecting rod small end
inside diameter a and big end inside
diameter b.
TIP:
In the 2nd tightening stage for the connecting
rod bolts 1, make marks c on the connect-
ing rod bolts and the connecting rod cap, and
then tighten the bolts 90 from the marks on
the connecting rod cap.
Checking the connecting rod big end
side clearance
1. Measure the connecting rod big end side
clearance a.
Checking the crankshaft
1. Measure the crankshaft journal diame-
ters a, crankpin diameters b, and
crankpin widths c.
Piston pin boss inside diameter a:
22.01122.018 mm
(0.86660.8668 in)
Piston pin outside diameter a:
21.99622.005 mm
(0.86600.8663 in)
a
a
b
1
c
90
Connecting rod small end inside diameter
a: 22.01022.024 mm (0.86650.8671 in)
Connecting rod big end inside diameter b:
55.99056.010 mm
(2.20432.2051 in)
Connecting rod bolt 1:
1st: 40 Nm (4.0 kgfm, 29.5 ftlb)
2nd: 90
Connecting rod big end side clearance a:
0.1400.310 mm (0.00550.0122 in)
a
7-76
7
2. Measure the crankshaft runout.
Checking the crankcase bolt
1. Measure the diameters a and b of the
crankcase bolt at the specified measur-
ing points c and d, and c and e.
Replace the crankcase bolt if the differ-
ence between the diameters is above
specification.
M10 130 mm
M10 105 mm
Checking the crankpin oil clearance
1. Clean the crankpin bearings, connecting
rod, connecting rod cap, and crankpin.
2. Install the crankpin bearings 1 into the
connecting rod a and connecting rod
cap b.
TIP:
Install the crankpin bearings in the original
positions.
3. Place a piece of Plastigauge (PG-1) on
the crankpin c, parallel to the crank-
shaft.
Crankshaft journal diameter a:
72.97672.996 mm
(2.87312.8739 in)
Crankpin diameter b:
52.98053.000 mm
(2.08582.0866 in)
Crankpin width c:
21.00021.100 mm
(0.82680.8307 in)
Crankshaft runout:
0.030 mm (0.0012 in)
a
b
c
Crankcase bolt diameter difference limit:
a b = Less than 0.20 mm (0.0079 in)
Measuring point c: 10.0 mm (0.39 in)
Measuring point d: 85.0 mm (3.35 in)
Measuring point e: 60.0 mm (2.36 in)
b a
c d
b a
c e

1
a
b
Cylinder block
7-77
POWR
Power unit
TIP:
Do not place the Plastigauge (PG-1) over the
oil hole in the crankpin of the crankshaft.
4. Install the connecting rod a and con-
necting rod cap b onto the crankpin c.
TIP:
When checking the oil clearance, reuse the
removed connecting rod bolts.
Make sure that the marks d on the con-
necting rod a and connecting rod cap b
face toward the flywheel magnet end of the
crankshaft.
Do not turn the connecting rod until the
crankpin oil clearance measurement has
been completed.
5. Tighten the bolts 2 to the specified
torques in 2 stages.
TIP:
In the 2nd tightening stage for the connecting
rod bolts 2, make marks e on the connect-
ing rod bolts and the connecting rod cap, and
then tighten the bolts 90 from the marks on
the connecting rod cap.
6. Remove the connecting rod cap, and
then measure the width of the com-
pressed Plastigauge (PG-1) on the
crankpin.
Selecting the crankpin bearing
When replacing the crankpin bearing, select
the bearing as follows:
1. Measure the connecting rod big end
inside diameter a.
c
c
d
a
b
Connecting rod bolt 2:
1st: 40 Nm (4.0 kgfm, 29.5 ftlb)
2nd: 90
Crankpin oil clearance (reference data):
0.0250.050 mm (0.00100.0020 in)
e
90 2
7-78
7
Example:
2. Check the crankpin mark b on the
crankshaft.
3. Select the suitable colors c for the
crankpin bearing from the Crankpin
bearing selection table.
Example:
If the connecting rod big end inside diameter
a is 05 h and the crankpin mark b is 81
k, select the bearing colors in g. The
upper bearing color is blue and the lower
bearing color is green.
Connecting rod big end inside diameter a:
55.99056.010 mm
(2.20432.2051 in)
Connecting rod big
end inside diameter
a
Number in table
56.005 mm 05
a
P1
P1
P2
P2
P3
P3
P4
P4
P5
P5
P6
P6
b
Upper bearing
color
Lower bearing
color
d Yellow Yellow
e Yellow Green
f Green Green
g Blue Green
c
c
90 91 9
80
81
82
3 04 05 06 07
h
k
g
Cylinder block
7-79
POWR
Power unit
Crankpin bearing selection table
a: Connecting rod big end inside diameter
b: Crankpin mark
a
90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10
b
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
00
g
f
e
d
7-80
7
Checking the crankshaft journal oil
clearance
After checking the crankshaft journal oil
clearance, check the crankcase bolts. See
Checking the crankcase bolt (7-76).
1. Clean the crankshaft journal bearings,
crankshaft journals, and bearing por-
tions of the crankcase and cylinder block.
2. Place the cylinder block upside down.
3. Install the crankshaft journal bearings 1
and crankshaft 2 into the cylinder block
3.
TIP:
Install the crankshaft journal bearings 1 in
the original positions.
4. Place a piece of Plastigauge (PG-1) on
each crankshaft journal a, parallel to the
crankshaft.
TIP:
Do not place the Plastigauge (PG-1) over the
oil hole in each crankshaft journal.
5. Install the crankshaft journal bearings
into the crankcase.
TIP:
Install the crankshaft journal bearings in the
original positions.
6. Install the crankcase 4, and then tighten
the bolts 5 and 6 to the specified
torques in 2 stages and in the order 1,
2, and so on.
7. Tighten the bolts 7 to the specified
torques in 2 stages and in the order G,
H, and so on.
3
2
1
a
4
7
5
6
b
90
6
5
C
M
9
4
L
P
V
1
I
B
F
8
D
R
N
2
0
J
3
A
K
E
O
7
S
T G H U 7
Q
65
Cylinder block
7-81
POWR
Power unit
TIP:
Do not turn the crankshaft until the crank-
shaft journal oil clearance measurement
has been completed.
In the 2nd tightening stage for the M10
bolts 5 and 6, make marks b on the M10
bolts and the crankcase, and then tighten
the bolts 90 from the marks on the crank-
case.
8. Remove the crankcase, and then mea-
sure the width of the compressed Plasti-
gauge (PG-1) on each crankshaft
journal.
Selecting the crankshaft journal
bearing
When replacing the crankshaft journal bear-
ing, select the bearing as follows:
1. Check the crankshaft journal mark a on
the crankshaft and the cylinder block
mark b on the cylinder block.
2. Select the suitable colors c for the
crankshaft journal bearing from the
Crankshaft journal bearing selection
table.
Crankcase bolts 5 and 6 1F (M10):
1st: 55 Nm (5.5 kgfm, 40.6 ftlb)
2nd: 90
Crankcase bolt 7 GV (M8):
1st: 14 Nm (1.4 kgfm, 10.3 ftlb)
2nd: 28 Nm (2.8 kgfm, 20.7 ftlb)
Crankshaft journal oil clearance
(reference data):
0.0290.045 mm (0.00110.0018 in)
J1
J1
J2
J2
J3
J3
J4
J4
a
b J4 J3 J2 J1
c
7-82
7
Example:
If the crankshaft journal mark a is 77 r
and the cylinder block mark b is 17 s,
select the bearing colors in p. The upper
bearing color is brown and the lower bearing
color is brown.
Upper bearing
color
Lower bearing
color
d Purple Purple
e Purple Yellow
f Yellow Yellow
g Yellow Red
h Red Red
k Red Green
m Green Green
n Green Brown
p Brown Brown
00 01 0
76
77
78
17 16 18 19 20
s
r
p
Cylinder block
7-83
POWR
Power unit
Crankshaft journal bearing selection table
a: Crankshaft journal mark
b: Cylinder block mark
b
00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20
a
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
p
n
m
k
h
g
f
e
d
7-84
7
Checking the cylinder block anode
1. Check the anodes. Replace if eroded.
Clean if there is grease, oil, or scales.
NOTICE: Do not apply grease, oil, or
paint to the anodes.
Assembling the cylinder block
Before assembling the cylinder block, check
the crankcase bolts. See Checking the
crankcase bolt (7-76).
Do not reuse a connecting rod bolt, collar,
oil seal, or piston pin clip, always replace
it with a new one.
1. Install a new collar 1 by striking it using
a plastic hammer.
2. Assemble the piston 2, the connecting
rod a, the piston pin 3, and new piston
pin clips 4.
TIP:
Face the mark b on the connecting rod a
in the same direction as the mark c on the
piston crown.
Do not align the piston pin clip end with the
groove d in the piston pin boss.
3. Install the oil rings e, 2nd ring f, and
top ring g.
TIP:
Make sure that the 2R marks h on the
2nd ring f and 1R marks k on the top
ring g are facing up.
Make sure that the piston rings move
smoothly.
4. Offset the piston ring end gaps. NOTICE:
Be careful not to scratch the pistons
or break the piston rings.
5. Install the crankpin bearings 5 into the
connecting rod a and connecting rod
cap m.
1322
1
4
d c
4
2
4
3
a
b
#3
#4
#5
e
f
g
h
k
#1
#2
45 45
#3
#4
#5
#1
#2
5
a
m
Cylinder block
7-85
POWR
Power unit
TIP:
Install the crankpin bearings in the original
positions.
6. Install the crankshaft journal bearings 6.
TIP:
Install the crankshaft journal bearings 6 in
the original positions.
7. Install a new oil seal 7 onto the crank-
shaft 8, and then install the crankshaft
and thrust bearings 9.
TIP:
Install each thrust bearing with its grooves
facing outward.
8. Install the piston 0 so that the mark n
on the piston crown is facing toward the
flywheel magnet end of the crankshaft.
9. Install the connecting rod caps m to the
connecting rods, and then tighten new
bolts B to the specified torques in 2
stages.
6
6
7
8
9
Piston ring compressor A: YM-08037
Connecting rod bolt B:
1st: 40 Nm (4.0 kgfm, 29.5 ftlb)
2nd: 90
n
0
A
90
B
p
r
m
7-86
7
TIP:
Make sure that the marks p on the con-
necting rod and connecting rod cap m face
toward the flywheel magnet end of the
crankshaft.
In the 2nd tightening stage for the connect-
ing rod bolts B, make a marks r on the
connecting rod bolts and the connecting
rod cap, and then tighten the bolts 90 from
the marks on the connecting rod caps.
Make sure that the crankshaft turns
smoothly.
10. Install the crankshaft journal bearings C
in the original positions.
11. Apply a thin, even layer of sealant onto
the mating surface of the crankcase D.
TIP:
Do not apply any sealant to the crankshaft
journal bearings.
12. Install new O-rings E and the crankcase
D, and then tighten the bolts F and G to
the specified torques in 2 stages and in
the order 1, 2, and so on.
13. Tighten the bolts H to the specified
torques in 2 stages and in the order G,
H, and so on.
C
D
C
Crankcase bolts F and G 1F (M10):
1st: 55 Nm (5.5 kgfm, 40.6 ftlb)
2nd: 90
Crankcase bolt H GV (M8):
1st: 14 Nm (1.4 kgfm, 10.3 ftlb)
2nd: 28 Nm (2.8 kgfm, 20.7 ftlb)
D
H
E
E
F
G
s
90
6
5
C
M
9
4
L
P
V
1
I
B
F
8
D
R
N
2
0
J
3
A
K
E
O
7
S
T G H U H
Q
GF
Cylinder block
7-87
POWR
Power unit
TIP:
In the 2nd tightening stage for the M10
bolts F and G, make marks s on the M10
bolts and the crankcase D, and then
tighten the bolts 90 from the marks on the
crankcase.
Make sure that the crankshaft turns
smoothly.
7-88
7
MEMO
Cylinder block
LOWR
Lower unit
Lower unit ........................................................................... 8-1
Removing the lower unit ............................................................. 8-3
Checking the propeller ............................................................... 8-3
Water pump and shift rod.................................................. 8-4
Removing the water pump and shift rod..................................... 8-6
Checking the water pump and shift rod...................................... 8-6
Propeller shaft housing..................................................... 8-7
Removing the propeller shaft housing assembly........................ 8-9
Disassembling the propeller shaft assembly ............................ 8-10
Disassembling the reverse gear............................................... 8-10
Disassembling the propeller shaft housing assembly .............. 8-10
Checking the propeller shaft..................................................... 8-11
Checking the dog clutch........................................................... 8-11
Checking the propeller shaft housing....................................... 8-11
Checking the reverse gear ....................................................... 8-11
Assembling the propeller shaft assembly................................. 8-11
Assembling the reverse gear.................................................... 8-12
Assembling the propeller shaft housing assembly ................... 8-12
Drive shaft and lower case.............................................. 8-14
Removing the drive shaft.......................................................... 8-16
Removing the forward gear ...................................................... 8-16
Disassembling the oil seal housing .......................................... 8-16
Disassembling the drive shaft .................................................. 8-16
Disassembling the forward gear............................................... 8-17
Disassembling the lower case.................................................. 8-17
Checking the pinion.................................................................. 8-18
Checking the forward gear ....................................................... 8-18
Checking the drive shaft ........................................................... 8-18
Checking the lower case .......................................................... 8-18
Assembling the drive shaft ....................................................... 8-18
Assembling the forward gear.................................................... 8-20
Assembling the lower case....................................................... 8-20
Assembling the oil seal housing............................................... 8-20
Installing the forward gear ........................................................ 8-21
Installing the drive shaft............................................................ 8-21
Installing the propeller shaft housing assembly........................ 8-22
Installing the shift rod ............................................................... 8-23
Installing the water pump ......................................................... 8-23
Checking the lower unit for air leakage .................................... 8-24
Installing the lower unit ............................................................. 8-25
Shimming.......................................................................... 8-27
Shimming workflow .................................................................. 8-27
Shimming check sheet ............................................................. 8-28
8
Measuring the forward gear backlash
and reverse gear backlash before disassembly....................... 8-30
Shimming ................................................................................. 8-33
Shim location............................................................................ 8-33
Selecting the pinion shim (T3).................................................. 8-34
Pinion shim (T3) selection table ............................................... 8-36
Selecting the propeller shaft shim (T4)..................................... 8-37
Propeller shaft shim (T4) selection table.................................. 8-39
Measuring the forward gear backlash ...................................... 8-40
Adjusting the forward gear shim (T1) thickness ....................... 8-40
Forward gear shim (T1) selection table.................................... 8-42
Measuring the reverse gear backlash ...................................... 8-43
Adjusting the reverse gear shim (T2) thickness ....................... 8-43
Reverse gear shim (T2) selection chart ................................... 8-45
LOWR
Lower unit
8-1
Lower unit
No. Part name Qty Remarks
1 Stud bolt 4
2 Dowel 2
3 Check screw 1
4 Gasket 2
Not reusable
5 Lower unit 1
6 Water inlet cover (STBD) 1
7 Bolt 1 M5 40 mm
8 Drain screw 1
9 Bolt 3 M10 45 mm
10 Self-locking nut 1
11 Water inlet cover (PORT) 1
12 Self-locking nut 4
13 Washer 4
14 Bolt 1 M10 35 mm
15 Cover 1
16 Spacer 1
17 Spacer 1
WR-No.2
2 Nm (0.2 kgfm, 1.5 ftIb)
9 Nm (0.9 kgfm, 6.6 ftIb)
9 Nm (0.9 kgfm, 6.6 ftIb)
42 Nm (4.2 kgfm, 31.0 ftIb)
47 Nm (4.7 kgfm, 34.7 ftIb)
54 Nm (5.4 kgfm, 39.8 ftIb)
1
1
3
4
2
6
7
8
4
5
9 10
11
13
12
13
12
14
9
15
16
17
18
19
20
21
22
2
20 Nm (2.0 kgfm, 14.8 ftIb)
8-2
8
No. Part name Qty Remarks
18 Propeller 1
19 Spacer 1
20 Washer 1
21 Propeller nut 1
22 Cotter pin 1
Not reusable
WR-No.2
2 Nm (0.2 kgfm, 1.5 ftIb)
9 Nm (0.9 kgfm, 6.6 ftIb)
9 Nm (0.9 kgfm, 6.6 ftIb)
42 Nm (4.2 kgfm, 31.0 ftIb)
47 Nm (4.7 kgfm, 34.7 ftIb)
54 Nm (5.4 kgfm, 39.8 ftIb)
1
1
3
4
2
6
7
8
4
5
9 10
11
13
12
13
12
14
9
15
16
17
18
19
20
21
22
2
20 Nm (2.0 kgfm, 14.8 ftIb)
Lower unit
LOWR
Lower unit
8-3
Removing the lower unit
Make sure to disconnect the battery
cables from the battery, and remove the
clip from the engine shut-off switch.
When removing the lower unit with the
power unit installed, make sure to sus-
pend the outboard motor. Otherwise, the
outboard motor could fall suddenly and
result in severe injuries.
When loosening or tightening the pro-
peller nut, do not hold the propeller
using your hands.
1. Drain the gear oil. See steps 16 in
Changing the gear oil (10-9).
2. Remove the cotter pin.
3. Set the gear shift to the N position.
4. Place a block of wood between the anti-
cavitation plate and the propeller to pre-
vent the propeller from turning, and then
remove the propeller nut and propeller.
5. Remove the spacers 1 and 2.
6. Remove the cover 3.
7. Remove the lower unit 4 and dowels 5.
TIP:
When disassembling the lower unit, measure
the backlash before disassembly. See Mea-
suring the forward gear backlash and reverse
gear backlash before disassembly (8-30).
Checking the propeller
1. Check the propeller blades and splines.
Replace the propeller if cracked, dam-
aged, or worn.
5
5
4
3
1
2
8-4
8
Water pump and shift rod
No. Part name Qty Remarks
1 Bolt 3 M8 25 mm
2 Cover 1
3 Oil seal 1
Not reusable
4 Plate 1
5 O-ring 1
Not reusable
6 E-clip 1
7 Shift rod 1
8 O-ring 1
Not reusable
9 Hose nipple 1
10 Woodruff key 1
11 Dowel 2
12 Plate 1
13 Rubber seal 1
14 Gasket 1
Not reusable
15 Outer plate cartridge 1
16 Bolt 4 M8 45 mm
17 Cover 1
1
3
4
1
6
5
9
10
8
7
16
16
16
17
18
20
22
23
21
11
11
14
15
13
12
2
19
Lower unit / Water pump and shift rod
LOWR
Lower unit
8-5
No. Part name Qty Remarks
18 Seal 1
19 Water pump housing 1
20 O-ring 1
Not reusable
21 Insert cartridge 1
22 O-ring 1
Not reusable
23 Impeller 1
1
3
4
1
6
5
9
10
8
7
16
16
16
17
18
20
22
23
21
11
11
14
15
13
12
2
19
8-6
8
Removing the water pump and shift
rod
1. Remove the water pump housing 1,
dowels 2, insert cartridge 3, O-rings 4
and 5, impeller 6, and Woodruff key 7.
2. Remove the cover 8, and then remove
the outer plate cartridge 9 and gasket
0.
3. Remove the rubber seal A and plate B.
4. Set the gear shift to the N position.
5. Remove the plate D, oil seal E, O-ring
F, and shift rod G.
Checking the water pump and shift
rod
1. Check the water pump housing. Replace
if deformed.
TIP:
If the engine overheated, the inside of the
water pump housing may be deformed.
Therefore, make sure to remove the insert
cartridge when checking the housing.
2. Check the impeller, insert cartridge, and
outer plate cartridge. Replace if cracked
or worn.
3. Check the Woodruff key and the keyway
in the drive shaft. Replace if deformed or
worn.
4. Check the shift rod. Replace if cracked or
worn.
1
2
2 4
3
5
6
7
8
9
B
A
0
R
N
F
C
Shift rod socket C: 90890-06679
E
D
G
F
Water pump and shift rod
LOWR
Lower unit
8-7
Propeller shaft housing
No. Part name Qty Remarks
1 Rubber seal 1
2 Rubber seal 1
3 Water pipe 1
4 Slider 1
5 Ball 2
6 Shift plunger 1
7 Spring 1
8 Dog clutch 1
9 Cross pin 1
10 Propeller shaft 1
11 Reverse gear shim
12 Reverse gear 1
13 Thrust washer 1
14 O-ring 1
Not reusable
15 Ball bearing 1
Not reusable
16 Washer 1
17 Propeller shaft shim
3
1
2
10 8 9 7 5
5 7
6 4
18
17
16
15
14
13
12
19
11
11
11
5
5
4
6
7
8
9
10
21
22
22
23
20
24
25
26
125 Nm (12.5 kgfm, 92.2 ftIb)
8-8
8
No. Part name Qty Remarks
18 Taper roller bearing 1
Not reusable
19 Propeller shaft housing 1
20 Rubber seal 1
21 Needle bearing 1
Not reusable
22 Oil seal 2
Not reusable
23 Circlip 1
24 Key 1
25 Claw washer 1
26 Ring nut 1
3
1
2
10 8 9 7 5
5 7
6 4
18
17
16
15
14
13
12
19
11
11
11
5
5
4
6
7
8
9
10
21
22
22
23
20
24
25
26
125 Nm (12.5 kgfm, 92.2 ftIb)
Propeller shaft housing
LOWR
Lower unit
8-9
Removing the propeller shaft
housing assembly
1. Remove the water pipe 1 and rubber
seals 2 and 3.
2. Straighten the tab a on the claw washer
that is bent outward.
3. Loosen the ring nut.
4. Remove the ring nut 6 and claw washer
7.
5. Remove the propeller shaft housing
assembly.
6. Remove the O-ring 0, propeller shaft
assembly A, and reverse gear shims B.
7. Remove the taper roller bearing b, pro-
peller shaft shims C, washer D, and
reverse gear assembly E.
Ring nut wrench extension 4:
90890-06513
Ring nut wrench 6 5: 90890-06677
2
3
1
a
4
5
Universal puller 8: YB-06117
Bearing housing puller 9: YB-06207
7
6
8
9
9
A
0
B
8-10
8
Disassembling the propeller shaft
assembly
1. Remove the spring 1, and then remove
the cross pin 2, dog clutch 3, slider 4,
balls 5, and shift plunger 6.
TIP:
Be careful when removing the slider 4 as the
balls 5 may fall out.
Disassembling the reverse gear
1. Remove the ball bearing 1 and thrust
washer 2.
Disassembling the propeller shaft
housing assembly
Use heat-resistant gloves. Otherwise,
burns could result.
To prevent fires, remove any flammable
substances, such as gasoline and oil,
around the working area.
Keep good ventilation while working.
1. Remove the rubber seal 1.
2. Remove the circlip 2.
3. Remove the oil seals 3 along with the
needle bearing 4.
E
D
C
b
1
4
6
2
3
5
5
Bearing cup installer 3: YB-06167
Bearing splitter plate 4:
(commercially available)
3
1
4
3
1
4
2
1
Propeller shaft housing
LOWR
Lower unit
8-11
4. Heat the installation area of the taper
roller bearing outer race in the propeller
shaft housing 7 using a gas torch, and
then remove the taper roller bearing
outer race a. NOTICE: When heating
the propeller shaft housing, heat the
entire installation area evenly. Other-
wise, the propeller shaft housing
could be damaged.
Checking the propeller shaft
1. Check the propeller shaft. Replace if
damaged or worn.
2. Measure the propeller shaft runout.
Checking the dog clutch
1. Check the dog clutch, shift plunger, cross
pin, spring, balls, and slider. Replace if
cracked or worn.
Checking the propeller shaft housing
1. Check the water pipe. Replace if cor-
roded, cracked, or deformed.
2. Check the propeller shaft housing.
Replace if cracked or damaged.
Checking the reverse gear
1. Check the teeth and dogs of the reverse
gear. Replace if cracked or worn.
Assembling the propeller shaft
assembly
1. Install the shift plunger 1, balls 2, and
slider 3.
Driver handle (large) 5: YB-06071
Driveshaft bearing installer 6: YB-06155
5
6
4
2
4
3
6
7
a
Propeller shaft runout:
0.02 mm (0.0008 in)
1
3
2
2
2
3 2 1
8-12
8
TIP:
When installing the slider 3, make sure that
the balls 2 do not fall out of position.
2. Install the dog clutch 4 so that the hole
a in the dog clutch 4 and the hole b in
the propeller shaft are aligned with the
hole c in the slider 3.
TIP:
Make sure to face the F mark d on the dog
clutch 4 toward the slider 3.
3. Install the cross pin 5, and then install
the spring 6.
Assembling the reverse gear
Do not reuse a bearing, always replace it
with a new one.
1. Install the thrust washer 1 and a new
ball bearing 2.
Assembling the propeller shaft
housing assembly
Use heat-resistant gloves. Otherwise,
burns could result.
To prevent fires, remove any flammable
substances, such as gasoline and oil,
around the working area.
Keep good ventilation while working.
Do not reuse a bearing, oil seal, or O-ring,
always replace it with a new one.
1. Heat the installation area of the taper
roller bearing outer race in the propeller
shaft housing 1 using a gas torch, and
then install a new taper roller bearing
outer race a. NOTICE: When heating
the propeller shaft housing, heat the
entire installation area evenly. Other-
wise, the propeller shaft housing
could be damaged.
4
b c
d
a
3
4
b
a
5
6
5
6
Pipe 3: (commercially available)
a: 59.5 mm (2.34 in)
b: 47.5 mm (1.87 in)
1
2
3
1
2
3
a
b
a
1
Propeller shaft housing
LOWR
Lower unit
8-13
2. While holding the special service tool 2,
strike the tool to check that the taper
roller bearing outer race a is installed
properly.
TIP:
If a high-pitched metallic sound is produced
when the special service tool is struck, the
taper roller bearing outer race a is installed
properly.
3. Install a new needle bearing 4 to the
specified depth b.
TIP:
Face the bearing identification mark c on the
needle bearing toward the propeller side.
4. Install new oil seals 6 to the specified
depth d, and then install the circlip 7.
TIP:
Install an oil seal halfway into the propeller
shaft housing, and then install the other oil
seal.
5. Install the rubber seal 9.
Driver handle (large) 2: YB-06071
Forward gear needle bearing installer 3:
YB-06261
Driver handle (large) 2: YB-06071
Driveshaft needle bearing installer and
remover 5: YB-06196
Depth b: 25.125.6 mm (0.9881.008 in)
a
2
3
b
5
4
2
c
Driveshaft bearing installer 8: YB-06246
Depth d: 5.86.3 mm (0.2280.248 in)
d
8
7
6
9
8-14
8
Drive shaft and lower case
No. Part name Qty Remarks
1 Drive shaft 1
2 Pinion shim
3 Ring nut 1
4 Spacer 1
5 Nut 1
6 Claw washer 1
7 Taper roller bearing 1
Not reusable
8 Bolt 2 M8 20 mm
9 Cover 1
10 Oil seal housing 1
11 O-ring 1
Not reusable
12 Oil seal 2
Not reusable
13 Lower case 1
14 Dowel 1
15 Adapter 1
16 Roller bearing 1
Not reusable
17 Forward gear shim 1
25
23
24
26
2
1
7
4
6
3
5
11
21
20
19
22
15
14
16
17
18
13
8
9
10
12
39 Nm (3.9 kgfm, 28.8 ftIb)
142 Nm (14.2 kgfm, 104.7 ftIb)
177 Nm (17.7 kgfm, 130.5 ftIb)
Propeller shaft housing / Drive shaft and lower case
LOWR
Lower unit
8-15
No. Part name Qty Remarks
18 Thrust bearing 1
19 Circlip 1
20 Washer 1
21 Taper roller bearing 1
Not reusable
22 Forward gear 1
23 Needle bearing 1
Not reusable
24 Pinion 1
25 Washer 1
26 Pinion nut 1
25
23
24
26
2
1
7
4
6
3
5
11
21
20
19
22
15
14
16
17
18
13
8
9
10
12
39 Nm (3.9 kgfm, 28.8 ftIb)
142 Nm (14.2 kgfm, 104.7 ftIb)
177 Nm (17.7 kgfm, 130.5 ftIb)
8-16
8
Removing the drive shaft
1. Remove the oil seal housing 1.
2. Remove the ring nut 2 and spacer 3.
3. Loosen the pinion nut, and then remove
the pinion 5, washer, drive shaft 6, and
pinion shims.
Removing the forward gear
1. Remove the forward gear assembly 1,
thrust bearing 2, forward gear shim 3
and adapter assembly 4.
Disassembling the oil seal housing
1. Remove the cover 1, O-ring 2, and oil
seals 3.
Disassembling the drive shaft
1. Straighten the tab a on the claw washer
1.
2. Secure the nut 2 on the drive shaft.
Drive shaft ring nut wrench 4:
90890-06674
Driveshaft holder 7: YB-06520
1
4
2
3
5
6
7
1
2
3
4
3
1
2
a
1
Drive shaft and lower case
LOWR
Lower unit
8-17
3. Loosen the nut 2, and then remove the
claw washer 1.
4. Remove the taper roller bearing 4.
NOTICE: Make sure that the inner race
of the taper roller bearing 4 is placed
properly on the blocks 5.
Disassembling the forward gear
Use heat-resistant gloves. Otherwise,
burns could result.
To prevent fires, remove any flammable
substances, such as gasoline and oil,
around the working area.
Keep good ventilation while working.
1. Remove the circlip 1, and then remove
the washer 2 and taper roller bearing 3.
2. Remove the dowel 4.
3. Heat the installation area of the roller
bearing in the adapter 5 using a gas
torch, and then remove the roller bearing
6. NOTICE: When heating the
adapter, heat the entire installation
area evenly. Otherwise, the adapter
could be damaged.
Disassembling the lower case
Use heat-resistant gloves. Otherwise,
burns could result.
To prevent fires, remove any flammable
substances, such as gasoline and oil,
around the working area.
Keep good ventilation while working.
1. Heat the installation area of the needle
bearing in the lower case using a gas
torch. NOTICE: When heating the
lower case, heat the entire installation
area evenly. Otherwise, the paint on
the lower case could be burned.
Driveshaft holder 3: YB-06520
3 2
1
4
5
5
4
1
2
3
5
4
6
8-18
8
2. Remove the needle bearing 1.
TIP:
Before removing the needle bearing, make
sure to remove the forward gear assembly.
Before installing the special service tool,
make sure that the rollers are installed in
the needle bearing outer race.
Checking the pinion
1. Check the teeth of the pinion. Replace if
cracked or worn.
Checking the forward gear
1. Check the teeth and dogs of the forward
gear. Replace if cracked or worn.
Checking the drive shaft
1. Check the drive shaft. Replace if dam-
aged or worn.
2. Measure the drive shaft runout.
Checking the lower case
1. Check the lower case. Replace if cracked
or damaged.
Assembling the drive shaft
Do not reuse a bearing, always replace it
with a new one.
1. Install a new taper roller bearing a.
NOTICE: Do not press the threads b
of the drive shaft directly. Make sure
that the special service tool 1 and
blocks 2 do not contact the threads
c of the drive shaft.
Driver handle (large) 2: YB-06071
Driveshaft bearing installer 3: YB-06155
1
1
3
3
2
Drive shaft runout: 1.0 mm (0.0394 in)
Bearing inner race attachment 1:
90890-06641
Press load (bearing): 18 10
3
N (1800 kgf)
a
a
b
c
1
2
1
2
Drive shaft and lower case
LOWR
Lower unit
8-19
2. Install a new taper roller bearing outer
race d and taper roller bearing e.
NOTICE: Do not press the threads b
of the drive shaft directly. Make sure
that the special service tool 1 and
blocks 2 do not contact the threads
c of the drive shaft.
3. Turn the taper roller bearing 5 turns or
more to seat the bearing, and then press
the drive shaft again using the specified
load.
4. Install the claw washer 3, and then
tighten the nut 4 temporarily.
TIP:
Make sure to fit the tab f on the claw
washer 3 into the slot g in the drive shaft.
5. Secure the nut 4 on the drive shaft.
6. Tighten the nut 4 to the specified torque.
7. Hold the taper roller bearing outer race,
and then measure the motive torque of
the drive shaft.
8. Bend the tab h on the claw washer 3 to
secure the nut 4.
Bearing inner race attachment 1:
90890-06641
Press load (bearing): 18 10
3
N (1800 kgf)
Press load (bearing): 18 10
3
N (1800 kgf)
d
d
b
2
c
1
e
2
1
4
3
f
f
g
Driveshaft holder 5: YB-06520
Drive shaft nut 4:
39 Nm (3.9 kgfm, 28.8 ftlb)
Drive shaft motive torque:
0.32.1 Nm (0.030.21 kgfm,
0.221.55 ftlb)
5
4
h
4
3
8-20
8
Assembling the forward gear
Use heat-resistant gloves. Otherwise,
burns could result.
To prevent fires, remove any flammable
substances, such as gasoline and oil,
around the working area.
Keep good ventilation while working.
Do not reuse a bearing, always replace it
with a new one.
1. Install the dowel 1.
2. Heat the installation area of the roller
bearing in the adapter 2 using a gas
torch, and then install a new roller bear-
ing 3. NOTICE: When heating the
adapter, heat the entire installation
area evenly. Otherwise, the adapter
could be damaged.
3. Install a new taper roller bearing 4 and
the washer 5, and then install the circlip
6.
Assembling the lower case
Do not reuse a bearing, always replace it
with a new one.
1. Install a new needle bearing 1.
TIP:
The needle bearing contains 18 rollers.
Assembling the oil seal housing
Do not reuse an oil seal or O-ring, always
replace it with a new one.
1. Install new oil seals 1 to the specified
depth a.
3
2
1
6
5
4
Driveshaft bearing installer 2: YB-06246
Pinion gear bushing installer 3:
YB-06029-2
Roller bearing installer/remover 4:
YB-06432-2
2
1
1
2
4
3
2
3
a
AA
1
Drive shaft and lower case
LOWR
Lower unit
8-21
TIP:
Install an oil seal halfway into the oil seal
housing, and then install the other oil seal.
2. Install the cover 4 and a new O-ring 5.
Installing the forward gear
1. Install the adapter assembly 1, original
forward gear shim 2, thrust bearing 3,
and forward gear assembly 4.
TIP:
Make sure to fit the dowel 5 into the slot a
in the lower case.
Installing the drive shaft
1. Install the original pinion shims 1 and
drive shaft 2.
2. Install the pinion 3 and washer, and
then tighten the pinion nut to the speci-
fied torque.
TIP:
When installing the pinion 3, lift up the drive
shaft 2 slightly and align the splines on the
drive shaft with the splines on the pinion.
3. Install the spacer 5, and then tighten the
ring nut 6 to the specified torque.
Driver handle (large) 2: YB-06071
Bearing cup installer 3: YB-06167
Depth a: 0.81.3 mm (0.030.05 in)
5
4
4
3
2
1
5
a
Driveshaft holder 4: YB-06520
Pinion nut:
142 Nm (14.2 kgfm, 104.7 ftlb)
1
2
3
2
4
6
5
7
8-22
8
4. Install the oil seal housing 8.
TIP:
Make sure to install the oil seal housing 8 so
that the notch a is facing forward.
Installing the propeller shaft housing
assembly
Do not reuse a bearing or O-ring, always
replace it with a new one.
1. Install the reverse gear assembly 1, the
washer 2, the original propeller shaft
shims 3, and a new taper roller bearing
a.
2. Install a new O-ring 4 and the propeller
shaft housing assembly 5.
3. Install the original reverse gear shims 6,
propeller shaft housing assembly 5,
along with the propeller shaft assembly
7, and key 8.
4. Install the claw washer 9.
TIP:
Make sure to fit the protrusion b on the pro-
peller shaft housing into the slot c in the
claw washer 9.
Drive shaft ring nut wrench 7:
90890-06674
Ring nut 6:
177 Nm (17.7 kgfm, 130.5 ftlb)
8
a
1
3
2
a
5
4
5
7
8
6
9
b
c
Drive shaft and lower case
LOWR
Lower unit
8-23
5. Install the ring nut 0, and then tighten it
to the specified torque.
6. Bend one of the 4 tabs on the claw
washer outward, and bend the other 3
tabs inward.
7. Install the rubber seals C and D and
water pipe E.
Installing the shift rod
Do not reuse an oil seal or O-ring, always
replace it with a new one.
1. Set the gear shift to the N position, and
then install the shift rod 1, a new O-ring
2, the plate 3, and a new oil seal 4.
TIP:
Make sure to fit the tip a of the shift rod 1
into the groove b in the slider.
Installing the water pump
Do not reuse a gasket or O-ring, always
replace it with a new one.
1. Install the plate 1 and rubber seal 2.
2. Install the dowels 3, a new gasket 4,
the outer plate cartridge 5, the cover 6,
and the Woodruff key 7.
Ring nut wrench extension A:
90890-06513
Ring nut wrench 6 B: 90890-06677
Ring nut 0:
125 Nm (12.5 kgfm, 92.2 ftlb)
A
0
B
D
C
E
4
3
1
a
b
2
8-24
8
3. Align the slot a in the impeller 8 with
the Woodruff key 7, and then install the
impeller 8.
4. Install a new O-ring 9, the insert car-
tridge 0, and a new O-ring A.
TIP:
Fit the protrusions b on the insert cartridge
0 into the slots c in the water pump housing
B.
5. Install the water pump housing B, seal
C, and cover D. NOTICE: Do not turn
the drive shaft counterclockwise. Oth-
erwise, the water pump impeller could
be damaged.
TIP:
While turning the drive shaft clockwise, push
the water pump housing down and install it.
Checking the lower unit for air
leakage
1. Remove the gear oil check screw 1, and
then install the pressure/vacuum tester
2.
2. Apply the specified pressure. Check that
the pressure is maintained in the lower
unit for 10 seconds or more. NOTICE:
Do not overpressurize the lower unit.
Otherwise, the oil seals could be dam-
aged.
6
5
3
7
1
2
3
4
7
a
8 A
9
B
A
0
b
c Pressure/vacuum tester 2:
(commercially available)
Holding pressure:
68.6 kPa (0.686 kgf/cm
2
, 9.9 psi)
B
D
C
1
2
Drive shaft and lower case
LOWR
Lower unit
8-25
Installing the lower unit
Make sure to disconnect the battery
cables from the battery, and remove the
clip from the engine shut-off switch.
When installing the lower unit with the
power unit installed, make sure to sus-
pend the outboard motor. Otherwise, the
outboard motor could fall suddenly and
result in severe injuries.
When loosening or tightening the pro-
peller nut, do not hold the propeller
using your hands.
1. Align the pin a of the shift lever with the
alignment mark b on the shift bracket
assembly 1.
2. Set the gear shift to the N position.
3. Tighten the stud bolts 3 to the specified
torque.
4. Install the dowels 4.
5. Install the lower unit 5, and then tighten
the nuts 6 and bolts 7 to the specified
torque. NOTICE: Make sure to align the
splines on the lower unit shift rod with
the splines on the upper case shift
rod. Otherwise, the shift rods could be
bent.
6. Install the cover 8, and then tighten the
bolt 9 to the specified torque.
Shift rod socket 2: 90890-06679
a
b
1
R
N
F
2
Stud bolt 3: 20 Nm (2.0 kgfm, 14.8 ftlb)
Lower case mounting nut 6:
47 Nm (4.7 kgfm, 34.7 ftlb)
Lower case mounting bolt 7:
47 Nm (4.7 kgfm, 34.7 ftlb)
Cover bolt 9:
42 Nm (4.2 kgfm, 31.0 ftlb)
3
3
WR-No.2
4
7 6
9
8
7
4
5
8-26
8
7. Install the spacer 0.
8. Install the spacer A, propeller B, spacer
C, and washer D. Place a block of wood
between the anti-cavitation plate and the
propeller to prevent the propeller from
turning, and then tighten the propeller nut
E to the specified torque.
9. Install a new cotter pin F.
TIP:
If the slots in the propeller nut E are not
aligned with the cotter pin hole, tighten the
propeller nut E until they are aligned.
10. Fill the lower unit with gear oil up to the
proper level. See steps 710 in Chang-
ing the gear oil (10-9).
Propeller nut E:
54 Nm (5.4 kgfm, 39.8 ftlb)
0
A
B
C
D
E
F
E
Drive shaft and lower case
LOWR
Lower unit
8-27
Shimming
Shimming workflow
TIP:
If the backlash is within specification, shimming is not required.
When assembling the original inner parts and a new lower case, shimming is required.
When replacing the pinion, forward gear, reverse gear, bearings, drive shaft, or propeller shaft
housing, shimming is required.
NO
YES
Shimming is not required.
YES
NO
Within specification?
Disassemble the lower unit.
Select the pinion shims (T3)
and propeller shaft shims (T4).
Assemble the lower unit.
Measure the backlash.
Adjust the forward gear shim
(T1) thickness and reverse gear
shim (T2) thickness.
Install the water pump assembly
and cover.
Within specification?
Remove the water pump
assembly and cover.
Measure the backlash before
disassembly.
8-28
8
Shimming check sheet
Lower case deviation
Pinion height (mm)
Forward gear backlash (mm)
Reverse gear backlash (mm)
Serial number P F R Remarks
Measurements
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
(M)
Measurements
Before disassembly After disassembly
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
Measurements
Before disassembly After disassembly
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
Shimming
LOWR
Lower unit
8-29
Forward gear shim (T1) thickness measurement in 2 places (mm)
Reverse gear shim (T2) thickness measurement in 2 places (mm)
Number of shim(s) Subtotal
2.00
2.03
2.06
2.09
2.12
2.15
Total
Number of shim(s) Subtotal
0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total
8-30
8
Measuring the forward gear backlash
and reverse gear backlash before
disassembly
1. Remove the water pump assembly,
cover, and outer plate cartridge. See
steps 13 in Removing the water pump
and shift rod (8-6).
2. Set the gear shift to the N position.
3. Install the special service tools 2 and 3,
and then tighten the center bolt a to the
specified torque.
4. Install the special service tool 4 at the
lowest possible position where the shaft
diameter is 22.4 mm (0.88 in).
5. Install the special service tools 5, 6,
and 7.
6. Turn the drive shaft slowly clockwise and
counterclockwise and measure the back-
lash between where the drive shaft stops
in each direction.
TIP:
Do not turn the drive shaft using too much
force. Otherwise, the forward gear will turn,
leading to incorrect measurements.
When turning the drive shaft, hold it using a
little force. A knocking sound may be heard
when the drive shaft is turned, but this is
the sound of the pinion contacting the
reverse gear and does not affect the back-
lash measurement.
7. Turn the drive shaft 180 clockwise and
measure the backlash again.
Shift rod socket 1: 90890-06679
Universal puller 2: YB-06117
Bearing housing puller 3: YB-06207
Center bolt a: 5 Nm (0.5 kgfm, 3.7 ftlb)
R
N
F
1
3
2
a
3
Backlash indicator 4: 90890-06836
Dial indicator gauge 5: YU-03097
Backlash adjustment plate 6: YB-07003
Magnetic base stand 7: YU-A8438
7
6
5
4
Shimming
LOWR
Lower unit
8-31
TIP:
Measure the backlash at 4 points: b, c,
d, and e, turning the drive shaft 180
clockwise after each measurement.
Write down the measurement data in the
shimming check sheet.
8. Determine the backlash average, and
then round down the average to the
1/100 place.
Example:
9. Check that the forward gear backlash
average is within specification.
TIP:
Adjust the shim thicknesses if the forward
gear backlash is out of specification.
10. Remove the special service tools from
the propeller shaft.
11. Set the gear shift to the R position.
12. While turning the shift rod toward the R
position using the specified torque, turn
the drive shaft slowly clockwise and
counterclockwise and measure the back-
lash between where the drive shaft stops
in each direction.
TIP:
Do not turn the drive shaft using too much
force. Otherwise, the reverse gear will turn,
leading to incorrect measurements.
When turning the drive shaft, hold it using a
little force. A knocking sound may be heard
when the drive shaft is turned, but this is
the sound of the pinion contacting the for-
ward gear and does not affect the backlash
measurement.
13. Repeat steps 7 and 8 to measure the
reverse gear backlash.
(mm)
Measuring point b 0.25
Measuring point c 0.26
Measuring point d 0.26
Measuring point e 0.24
Average 0.2525
Round-down average 0.25
Forward gear backlash:
0.120.51 mm (0.00470.0201 in)
b
c
d
e
Shift rod socket 1: 90890-06679
Specified torque:
10 Nm (1.0 kgfm, 7.4 ftlb)
R
N
1
8-32
8
14. Check that the reverse gear backlash
average is within specification.
TIP:
Adjust the shim thicknesses if the reverse
gear backlash is out of specification.
15. Remove the special service tools, and
then install the outer plate cartridge,
cover, and water pump assembly. See
Installing the water pump (8-23).
Reverse gear backlash:
0.220.81 mm (0.00870.0319 in)
Shimming
LOWR
Lower unit
8-33
Shimming
Before selecting the forward gear shim (T1) and reverse gear shims (T2), make sure to select the
pinion shims (T3).
When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do
not apply gear oil, grease, or sealant to the parts.
When assembling the lower unit after shimming is completed, make sure to apply gear oil, grease,
and sealant to the specified areas.
Shim location
R
P
F
T1 T2
T4
T3
8-34
8
Selecting the pinion shim (T3)
Spray anti-rust lubricant on the gears and
bearings before installation. Do not apply
gear oil to the parts. Otherwise, correct
measurements cannot be obtained.
Keep the parts free of foreign material,
such as dirt and lint.
1. Install the original pinion shims, drive
shaft, pinion, and ring nut. See steps 13
in Installing the drive shaft (8-21).
TIP:
If the original shims are missing, install new
shims with a combined thickness of 1.00
mm.
Do not reuse a shim if deformed or
scratched.
2. Check that the drive shaft turns
smoothly.
3. Install the special service tools 1 and 2,
and then remove the special service tool
2.
4. Measure the distance a between the
special service tool 1 and the pinion 3.
5. Turn the drive shaft 90 clockwise and
measure the distance again.
TIP:
Measure the distance at 4 points: b, c, d,
and e, turning the drive shaft 90 clock-
wise after each measurement.
Write down the measurement data in the
shimming check sheet.
6. Determine the distance average, and
then round down the average to the
1/100 place.
Pinion shimming gauge 1: 90890-06675
Pinion shimming gauge rod 2:
90890-06676
1
2
2
a
1
1
3
b
d
c e
Shimming
LOWR
Lower unit
8-35
Example:
TIP:
In the Pinion shim (T3) selection table, use
the round-down average for the pinion dis-
tance measurement.
7. Determine the pinion shim (T3) thickness
adjustment using the Pinion shim (T3)
selection table according to the pinion
distance measurement.
Example:
Pinion distance measurement = 0.64 mm f
Pinion shim (T3) thickness adjustment = 0.11
mm g
The current shim thickness must be
increased by 0.11 mm.
Pinion distance measurement
Shim thickness adjustment
TIP:
If the shim thickness adjustment value is
positive, the current shim thickness must
be increased by that amount and, if the
value is negative, the current shim thick-
ness must be decreased by that amount.
The gray-colored cell on the selection table
indicates the specified pinion distance.
Shimming is not required if the measured
pinion distance is 0.75 mm.
The values for the shim thickness adjust-
ments specified in the selection table are
intended to obtain the specified pinion dis-
tance of 0.75 mm.
8. Calculate the new pinion shim (T3) thick-
ness.
Calculation formula:
New pinion shim (T3) thickness = Current
pinion shim thickness + Shim thickness
adjustment
Example:
Current pinion shim thickness = 0.82 mm
Shim thickness adjustment = 0.04 mm
New pinion shim (T3) thickness
= 0.82 mm + 0.04 mm
= 0.86 mm
Current pinion shim thickness = 0.80 mm
Shim thickness adjustment = 0.06 mm
New pinion shim (T3) thickness
= 0.80 mm + (0.06) mm
= 0.74 mm
TIP:
Use up to 3 shims to obtain the required
shim thickness.
If the calculated shim thickness cannot be
obtained with a combination of the avail-
able shims, increase or decrease the pinion
distance measurement by 0.01 mm so that
it is closer to 0.75 mm.
9. Remove the special service tool, and
then install the determined shims.
(mm)
Measuring point b 0.80
Measuring point c 0.81
Measuring point d 0.81
Measuring point e 0.79
Average 0.8025
Round-down average 0.80
0.63 0.64 0.65 . 0.66
+0.12 +0.11 +0.10 +0.09
0.73 0.74 0.75 0.76
+0.02 +0.01 0.01
(mm)
f g
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
0.50 mm
8-36
8
Pinion shim (T3) selection table
The shim thickness does not have to be adjusted for the gray-colored cell.
Pinion distance measurement
Shim thickness adjustment
(mm)

0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36

+0.48 +0.47 +0.46 +0.45 +0.44 +0.43 +0.42 +0.41 +0.40 +0.39

0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.46
+0.38 +0.37 +0.36 +0.35 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29

0.47 0.48 0.49 0.50 0.51 0.52 0.53 0.54 0.55 0.56

+0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19
0.57 0.58 0.59 0.60 0.61 0.62 0.63 0.64 0.65 0.66

+0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09
0.67 0.68 0.69 0.70 0.71 0.72 0.73 0.74 0.75 0.76

+0.08 +0.07 +0.06 +0.05 +0.04 +0.03 +0.02 +0.01 0.01


0.77 0.78 0.79 0.80 0.81 0.82 0.83 0.84 0.85 0.86

0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11
0.87 0.88 0.89 0.90 0.91 0.92 0.93 0.94 0.95 0.96

0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.21
0.97 0.98 0.99 1.00 1.01 1.02 1.03 1.04 1.05 1.06

0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29 0.30 0.31
1.07 1.08

0.32 0.33
Shimming
LOWR
Lower unit
8-37
Selecting the propeller shaft shim
(T4)
1. Install the original propeller shaft shims,
propeller shaft assembly, and propeller
shaft housing assembly. See steps 15
in Installing the propeller shaft housing
assembly (8-22).
TIP:
If the original shims are missing, measure
the free play without any shims.
Do not reuse a shim if deformed or
scratched.
2. Install the special service tools 1 and 2.
3. Measure the propeller shaft free play.
4. Round the measurement value to the
1/10 place if out of specification.
TIP:
In the Propeller shaft shim (T4) selection
table, use the rounded measurement value
for the free play measurement.
5. Determine the propeller shaft shim (T4)
thickness adjustment using the Propeller
shaft shim (T4) selection table according
to the free play measurement.
Example:
Free play measurement = 1.1 mm a
Propeller shaft shim (T4) thickness adjust-
ment = 0.8 mm b
The current shim thickness must be
increased by 0.8 mm.
Free play measurement
Shim thickness adjustment
TIP:
If the shim thickness adjustment value is
positive, the current shim thickness must
be increased by that amount and, if the
value is negative, the current shim thick-
ness must be decreased by that amount.
The gray-colored cell on the selection table
indicates the specified propeller shaft free
play. Shimming is not required if the mea-
sured propeller shaft free play is 0.250.35
mm.
The values for the shim thickness adjust-
ments specified in the selection table are
intended to obtain the specified propeller
shaft free play of 0.3 mm.
Dial indicator gauge 1: YU-03097
Magnetic base stand 2: YU-A8438
Propeller shaft free play:
0.250.35 mm (0.00980.0138 in)
2
1
0.0 0.1 0.2 0.3
0.3 0.2 0.1
1.0 1.1 1.2 1.3
+0.7 +0.8 +0.9 +1.0
2.0 2.1 2.2 2.3
+1.7 +1.8 +1.9 +2.0
(mm)
a
b
8-38
8
6. Calculate the new propeller shaft shim
(T4) thickness.
Calculation formula:
New propeller shaft shim (T4) thickness =
Current propeller shaft shim thickness +
Shim thickness adjustment
Example:
Current propeller shaft shim thickness = 1.7
mm
Shim thickness adjustment = 0.2 mm
New propeller shaft shim (T4) thickness
= 1.7 mm + 0.2 mm
= 1.9 mm
Current propeller shaft shim thickness = 1.9
mm
Shim thickness adjustment = 0.1 mm
New propeller shaft shim (T4) thickness
= 1.9 mm + (0.1) mm
= 1.8 mm
TIP:
Use up to 3 shims to obtain the required shim
thickness.
7. Remove the special service tools, and
then install the determined shims.
Available shim thicknesses:
0.7, 0.8, 0.9, 1.0, 1.1, 1.2 mm
Shimming
LOWR
Lower unit
8-39
Propeller shaft shim (T4) selection table
The shim thickness does not have to be adjusted for the gray-colored cell.
Free play measurement
Shim thickness adjustment
(mm)

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
0.3 0.2 0.1 +0.1 +0.2 +0.3 +0.4 +0.5 +0.6

1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9
+0.7 +0.8 +0.9 +1.0 +1.1 +1.2 +1.3 +1.4 +1.5 +1.6

2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

+1.7 +1.8 +1.9 +2.0 +2.1 +2.2 +2.3 +2.4 +2.5 +2.6
8-40
8
Measuring the forward gear backlash
Spray anti-rust lubricant on the gears and
bearings before installation. Do not apply
gear oil to the parts. Otherwise, correct
measurements cannot be obtained.
Keep the parts free of foreign material,
such as dirt and lint.
When measuring the forward gear or
reverse gear backlash, use the original
bearings and shims.
1. Install the adapter assembly, original for-
ward gear shim, thrust bearing, and for-
ward gear assembly. See Installing the
forward gear (8-21).
TIP:
If the original shim is missing, install a new
shim with a thickness of 2.00 mm.
Do not reuse a shim if deformed or
scratched.
2. Install the drive shaft, pinion, and ring
nut. See steps 13 in Installing the drive
shaft (8-21).
3. Check that the drive shaft turns
smoothly.
4. Install the propeller shaft assembly and
propeller shaft housing assembly. See
steps 15 in Installing the propeller shaft
housing assembly (8-22).
5. Check that the drive shaft turns
smoothly.
6. Measure the forward gear backlash. See
steps 29 in Measuring the forward gear
backlash and reverse gear backlash
before disassembly (8-30).
TIP:
In the Forward gear shim (T1) selection
table, use the round-down average for the
backlash measurement (BL1).
Adjusting the forward gear shim (T1)
thickness
1. Remove the propeller shaft housing
assembly and propeller shaft assembly.
See steps 36 in Removing the propel-
ler shaft housing assembly (8-9).
2. Remove the ring nut, pinion, and drive
shaft. See steps 2 and 3 in Removing
the drive shaft (8-16).
3. Remove the forward gear assembly,
thrust bearing, original forward gear
shim, and adapter assembly. See
Removing the forward gear (8-16).
4. Measure the thickness of the original for-
ward gear shim in 2 places.
TIP:
Do not reuse a shim if deformed or
scratched.
5. Determine the forward gear shim (T1)
thickness using the Forward gear shim
(T1) selection table according to the
backlash measurement (BL1) from Mea-
suring the forward gear backlash and
the current shim thickness.
Example:
Backlash measurement (BL1) = 0.30 mm a
Current forward gear shim thickness = 2.06
mm b
Use the determined shim thickness of 2.03
mm instead of the current shim thickness.
Backlash measurement (BL1)
Current shim thickness
Forward gear backlash:
0.120.51 mm (0.00470.0201 in)
Available shim thicknesses:
2.00, 2.03, 2.06, 2.09, 2.12, 2.15 mm

0.28 0.29 0.30

2.00
2.03
2.03 2.06
2.09
(mm)
a
b
Shimming
LOWR
Lower unit
8-41
TIP:
The gray-colored cells on the selection
table indicate the range where the shim
adjustment is unnecessary. Shimming is
not required if the obtained forward gear
shim thickness is indicated by the gray-col-
ored cells.
The values for the shim thickness specified
in the selection table are intended to obtain
the median value within the range for the
specified forward gear backlash.
If the backlash measurement (BL1) is less
than 0.19 mm, install a new shim with a
thickness of 2.00 mm.
If the backlash measurement (BL1) is more
than 0.45 mm, install a new shim with a
thickness of 2.15 mm.
Use only 1 shim to obtain the required shim
thickness.
6. Install the adapter assembly, determined
shim (T1), thrust bearing, and forward
gear assembly. See Installing the for-
ward gear (8-21).
8-42
8
Forward gear shim (T1) selection table
The shim thickness does not have to be adjusted for gray-colored cells.
Backlash measurement (BL1)
Current shim thickness
(mm)

0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 0.27

2.00
2.03 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00
2.06 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00
2.09 2.00 2.00 2.00 2.00 2.00 2.00 2.03 2.03 2.03
2.12 2.00 2.00 2.00 2.03 2.03 2.03 2.06 2.06 2.06
2.15 2.03 2.03 2.03 2.06 2.06 2.06 2.09 2.09 2.09

0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36

2.00 2.03 2.03 2.03


2.03 2.00 2.00 2.00 2.06 2.06 2.06
2.06 2.03 2.03 2.03 2.09 2.09 2.09
2.09 2.06 2.06 2.06 2.12 2.12 2.12
2.12 2.09 2.09 2.09 2.15 2.15 2.15
2.15 2.12 2.12 2.12

0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45

2.00 2.06 2.06 2.06 2.09 2.09 2.09 2.12 2.12 2.12
2.03 2.09 2.09 2.09 2.12 2.12 2.12 2.15 2.15 2.15
2.06 2.12 2.12 2.12 2.15 2.15 2.15 2.15 2.15 2.15
2.09 2.15 2.15 2.15 2.15 2.15 2.15 2.15 2.15 2.15
2.12 2.15 2.15 2.15 2.15 2.15 2.15 2.15 2.15 2.15
2.15
Shimming
LOWR
Lower unit
8-43
Measuring the reverse gear backlash
Spray anti-rust lubricant on the gears and
bearings before installation. Do not apply
gear oil to the parts. Otherwise, correct
measurements cannot be obtained.
Keep the parts free of foreign material,
such as dirt and lint.
When measuring the forward gear or
reverse gear backlash, use the original
bearings and shims.
1. Install the original reverse gear shims,
propeller shaft assembly, and propeller
shaft housing assembly. See steps 15
in Installing the propeller shaft housing
assembly (8-22).
TIP:
If the original shims are missing, install new
shims with a combined thickness of 0.50
mm.
Do not reuse a shim if deformed or
scratched.
2. Check that the drive shaft turns
smoothly.
3. Measure the reverse gear backlash. See
steps 1114 in Measuring the forward
gear backlash and reverse gear backlash
before disassembly (8-30).
TIP:
In the Reverse gear shim (T2) selection
chart, use the round-down average for the
backlash measurement (BL2).
Adjusting the reverse gear shim (T2)
thickness
1. Remove the propeller shaft housing
assembly, propeller shaft assembly, and
original reverse gear shims. See steps
36 in Removing the propeller shaft
housing assembly (8-9).
2. Measure the thickness of each original
reverse gear shim in 2 places.
TIP:
Do not reuse a shim if deformed or
scratched.
3. Determine the reverse gear shim (T2)
thickness adjustment using the Reverse
gear shim (T2) selection chart according
to the backlash measurement (BL2) from
Measuring the reverse gear backlash.
Example:
Backlash measurement (BL2) = 0.15 mm a
Reverse gear shim (T2) thickness adjustment
= 0.37 mm b
The current shim thickness must be
increased by 0.37 mm.
Backlash measurement (BL2)
Shim thickness adjustment
Reverse gear backlash:
0.220.81 mm (0.00870.0319 in)
25 20 15 10 5 0
25 20 15 10 5 0
0.32 0.37 0.42 0.47 0.52
0.10
0.20
0.30
0.40
0.50

(
m
m
)

(1/100 mm)

a
b
8-44
8
TIP:
If the shim thickness adjustment value is
positive, the current shim thickness must
be increased by that amount and, if the
value is negative, the current shim thick-
ness must be decreased by that amount.
The gray-colored area on the selection
chart indicates the range of the specified
backlash. Shimming is not required if the
measured backlash is within the gray-col-
ored area.
The values for the shim thickness adjust-
ments specified in the selection chart are
intended to obtain the median value within
the range for the specified reverse gear
backlash.
The table that follows the selection chart
shows the shim thickness adjustments for
the points marked on the chart.
4. Calculate the new reverse gear shim (T2)
thickness.
Calculation formula:
New reverse gear shim (T2) thickness = Cur-
rent reverse gear shim thickness + Shim
thickness adjustment
Example:
Current reverse gear shim thickness = 0.75
mm
Shim thickness adjustment = 0.37 mm
New reverse gear shim (T2) thickness
= 0.75 mm + 0.37 mm
= 1.12 mm
Current reverse gear shim thickness = 0.75
mm
Shim thickness adjustment = 0.33 mm
New reverse gear shim (T2) thickness
= 0.75 mm + (0.33) mm
= 0.42 mm
TIP:
Use up to 3 shims to obtain the required
shim thickness.
If the calculated shim thickness cannot be
obtained with a combination of the avail-
able shims, decrease the shim thickness by
0.01 mm.
5. Install the determined shims (T2), propel-
ler shaft assembly, and propeller shaft
housing assembly. See steps 15 in
Installing the propeller shaft housing
assembly (8-22).
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
0.50 mm
Shimming
LOWR
Lower unit
8-45
R
e
v
e
r
s
e

g
e
a
r

s
h
i
m

(
T
2
)

s
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c
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a
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a
c
k
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a
s
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m
e
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(
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L
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9
0
1
.
0
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( m m )

(
1
/
1
0
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m
m
)

8-46
8

B
a
c
k
l
a
s
h

m
e
a
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e
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(
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L
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h
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1
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0
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4
5

(
1
/
1
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m
m
)

( m m )
Shimming
BRKT
Bracket unit
Shift rod and shift bracket................................................. 9-1
Removing the shift rod and shift bracket .................................... 9-3
Disassembling the shift bracket.................................................. 9-3
Assembling the shift bracket ...................................................... 9-4
Installing the shift rod and shift bracket ...................................... 9-4
PTT switch and cowling lock lever................................... 9-6
Removing the PTT switch .......................................................... 9-8
Removing the cowling lock lever ................................................ 9-8
Removing the flushing hose....................................................... 9-8
Installing the flushing hose......................................................... 9-9
Installing the cowling lock lever ................................................ 9-10
Installing the PTT switch .......................................................... 9-10
Bottom cowling ................................................................ 9-11
Upper case and mount .................................................... 9-12
Removing the upper case ........................................................ 9-14
Installing the upper case .......................................................... 9-14
Upper case........................................................................ 9-16
Disassembling the upper case ................................................. 9-17
Checking the exhaust guide anode.......................................... 9-17
Assembling the upper case...................................................... 9-17
Oil pan and exhaust manifold......................................... 9-19
Disassembling the oil pan and exhaust manifold ..................... 9-21
Checking the oil pan and exhaust manifold.............................. 9-21
Checking the oil strainer........................................................... 9-21
Assembling the oil pan and exhaust manifold.......................... 9-22
Steering arm..................................................................... 9-23
Removing the steering arm...................................................... 9-24
Installing the steering arm........................................................ 9-24
Clamp bracket and swivel bracket ................................. 9-26
Removing the clamp bracket .................................................... 9-28
Checking the clamp bracket anode.......................................... 9-28
Installing the clamp bracket ...................................................... 9-28
Adjusting the trim sensor cam.................................................. 9-29
PTT unit ............................................................................. 9-31
Removing the PTT unit............................................................. 9-32
Checking the hydraulic pressure.............................................. 9-32
Installing the PTT unit............................................................... 9-35
9
PTT motor ......................................................................... 9-36
Removing the reservoir ............................................................ 9-38
Removing the PTT motor ......................................................... 9-38
Disassembling the PTT motor .................................................. 9-38
Checking the armature (PTT motor)......................................... 9-39
Checking the brush .................................................................. 9-39
Checking the reservoir ............................................................. 9-40
Assembling the PTT motor....................................................... 9-40
Installing the reservoir .............................................................. 9-40
Installing the PTT motor ........................................................... 9-41
PTT gear pump................................................................. 9-42
Disassembling the gear pump assembly.................................. 9-44
Checking the gear pump .......................................................... 9-44
Checking the gear pump housing............................................. 9-45
Checking the filter..................................................................... 9-45
Assembling the gear pump assembly ...................................... 9-45
PTT cylinder...................................................................... 9-47
Removing the tilt ram and trim ram.......................................... 9-49
Disassembling the tilt ram........................................................ 9-49
Checking the tilt cylinder and trim cylinder ............................... 9-50
Checking the absorber valve.................................................... 9-50
Assembling the tilt ram............................................................. 9-50
Assembling the trim ram........................................................... 9-51
Installing the trim ram............................................................... 9-52
Installing the tilt ram ................................................................. 9-53
Bleeding the PTT unit ............................................................... 9-53
BRKT
Bracket unit
9-1
Shift rod and shift bracket
No. Part name Qty Remarks
1 Screw 4 M4 16 mm
2 Holder 1
3 Neutral switch 1
4 Bushing 1
5 Bracket 1
6 Plate 1
7 Shift cut switch 1
8 Bolt 2 M6 35 mm
9 Spring 1
10 Bushing 2
11 Bracket 1
12 Grease nipple 1
13 Bolt 1
14 Washer 1
15 Clip 3
16 Bushing 1
17 Shift lever 1
28
27
15
17
15
14
22
23
24
25
19
19
16
18
20
26
1
1
2
3
4
5
1
1
6
7
8
9
10
10
13 11
12
21
2 Nm (0.2 kgfm, 1.5 ftIb)
2 Nm (0.2 kgfm, 1.5 ftIb)
18 Nm (1.8 kgfm, 13.3 ftIb)
1 Nm (0.1 kgfm, 0.7 ftIb)
19 Nm (1.9 kgfm, 14.0 ftIb)
9-2
9
No. Part name Qty Remarks
18 Washer 1
19 Bushing 2
20 Bolt 1 M6 35 mm
21 Bracket 1
22 Ball 1
23 Spring 1
24 Bolt 1
25 Pin 1
26 Cotter pin 1
Not reusable
27 Shift rod 1
28 Grommet 1
28
27
15
17
15
14
22
23
24
25
19
19
16
18
20
26
1
1
2
3
4
5
1
1
6
7
8
9
10
10
13 11
12
21
2 Nm (0.2 kgfm, 1.5 ftIb)
2 Nm (0.2 kgfm, 1.5 ftIb)
18 Nm (1.8 kgfm, 13.3 ftIb)
1 Nm (0.1 kgfm, 0.7 ftIb)
19 Nm (1.9 kgfm, 14.0 ftIb)
Shift rod and shift bracket
BRKT
Bracket unit
9-3
Removing the shift rod and shift
bracket
1. Remove the clip 1 and bushing 2, and
then remove the shift bracket assembly
3 and washer 4.
2. Remove the clip 5, shift lever 6, bush-
ing 7, shift rod assembly 8, and grom-
met 9.
3. Remove the bolt 0, spring A, and ball
B.
4. Remove the cotter pin C, washer D,
bushings E, and bracket F.
Disassembling the shift bracket
1. Remove the bracket 1, spring 2, and
bushings 3.
2. Remove the holder 4 and neutral switch
5.
3. Remove the plate 6 and shift cut switch
7.
2
1
4
3
8
5
6
7
9
E
0
F
A
B
D
E
C
1
2
3
3
4
5
9-4
9
Assembling the shift bracket
1. Install the neutral switch 1 and holder
2, and then tighten the screws 3 to the
specified torque.
2. Install the shift cut switch 4 and plate 5,
and then tighten the screws 6 to the
specified torque.
3. Install the bushings 7 and spring 8 onto
the bracket 9.
4. Fit the spring end a into the slot in the
bracket 9 and the spring end b into the
slot in the bracket 0.
5. Turn the bracket 0 to position c, push it
down, and then tighten the bolt A to the
specified torque. NOTICE: Before push-
ing the bracket 0 down, move the
shift cut switch lever d in direction
e. Otherwise, the lever could be dam-
aged.
Installing the shift rod and shift
bracket
1. Install the bushings 1, bracket 2, and
washer 3, and then install a new cotter
pin 4.
2. Install the ball 5 and spring 6, and then
tighten the bolt 7 to the specified torque.
Neutral switch screw 3:
2 Nm (0.2 kgfm, 1.5 ftlb)
Shift cut switch screw 6:
2 Nm (0.2 kgfm, 1.5 ftlb)
6
7
2
1
3
5
4
6
Shift bracket bolt A:
19 Nm (1.9 kgfm, 14.0 ftlb)
9
a
0
8
9
7
7
0 b
A
0
d
c
0
e
Shift rod and shift bracket
BRKT
Bracket unit
9-5
3. Install the bushing 8 and shift lever 9,
and then install the clip 0.
4. Install the grommet A and shift rod
assembly B, and then align the center of
the set pin a with the mark b on the bot-
tom cowling.
TIP:
Install the shorter set pin a of the shift lever
9 to the shift rod assembly.
5. Install the washer C and shift bracket
assembly D, and then install the bushing
E and clip F to the shift lever 9.
Shift rod detent bolt 7:
18 Nm (1.8 kgfm, 13.3 ftlb)
1
7
6
5
3
1
2
4
4
a
b
a B
0
9
A
8
E
F
9
C
D
9-6
9
PTT switch and cowling lock lever
No. Part name Qty Remarks
1 Hose 1
2 Plastic tie 4
Not reusable
3 Joint 1
4 Joint 1
5 Gasket 1
6 Adapter 1
7 Grommet 2
8 Guide 2
9 Holder 1
10 Bracket 1
11 Bolt 12 M6 12 mm
12 Plastic tie 1
13 Bracket 1
14 Screw 2 6 20 mm
15 Holder 2
16 PTT switch 1
17 Gasket 2
4 Nm (0.4 kgfm, 3.0 ftIb)
25
12
13
11
11
18
9
11
11
10
7
1
2
3
4
5
6
14
26
24
23
22
21
21
7
19
2
2
2
11
8
11
11
33
27
11
32
25
26
11
27
11
19
27
28
23
22
21
20 21
25
26
16 11
17
11
15 24
23
22
21
21
29
31
8
15
17
30
Shift rod and shift bracket / PTT switch and cowling lock lever
BRKT
Bracket unit
9-7
No. Part name Qty Remarks
18 Bracket 1
19 Water outlet 2
20 Cowling lock lever (STBD) 1
21 Bushing 6
22 Washer 3
23 Wave washer 3
24 Lever 2
25 Bolt 3 M8 12 mm
26 Spring 3
27 Hook 3
28 Lever 1
29 Cowling lock lever (PORT) 1
30 Cover 1
31 Cowling lock lever (front) 1
32 Bracket 1
33 Holder 2
4 Nm (0.4 kgfm, 3.0 ftIb)
25
12
13
11
11
18
9
11
11
10
7
1
2
3
4
5
6
14
26
24
23
22
21
21
7
19
2
2
2
11
8
11
11
33
27
11
32
25
26
11
27
11
19
27
28
23
22
21
20 21
25
26
16 11
17
11
15 24
23
22
21
21
29
31
8
15
17
30
9-8
9
Removing the PTT switch
1. Remove the brackets 1 and 2.
2. Remove the holder 3, and then remove
the PTT switch 4 and gasket 5.
Removing the cowling lock lever
1. Remove the spring 1, and then remove
the hook 2.
2. Remove the lever 3, wave washer 4,
washer 5, bushing 6, cowling lock lever
7, and bushing 8.
Removing the flushing hose
1. Remove the adapter 1, plastic tie 2,
joint 3, joint 4, and gasket 5.
2. Remove the holders 6, and then pull out
the flushing hose 7, trim sensor lead a,
and PTT motor lead b.
3. Remove plastic tie 8, and then remove
the guide 9, grommet 0, and flushing
hose 7.
4. Remove plastic tie A, and then remove
the guide B, grommet C, trim sensor
lead D, and PTT motor leads E.
5
4
3
1
2
2
8
7
1
3
4
5
6
3
2
4
5
1
a
b
7
6
7
0
9
8
PTT switch and cowling lock lever
BRKT
Bracket unit
9-9
Installing the flushing hose
1. Route the trim sensor lead a and PTT
motor leads b through the grommet 1,
and then fasten them by installing the
plastic tie 2 around the grommet 1.
2. Install the grommet 1 and guide 3.
TIP:
Align the red tape c on the PTT motor lead
b with the end of the grommet 1.
3. Route the flushing hose 4 through the
grommet 5, and then fasten them by
installing the plastic tie 6 around the
grommet 5.
4. Install the grommet 5 and guide 7.
TIP:
Align the white paint mark d on the flushing
hose 4 with the end of the grommet 5.
5. Route the flushing hose 4, trim sensor
lead a, and PTT motor lead b.
TIP:
Fasten the flushing hose 4 and trim sensor
lead a using the holder 8.
Fasten the flushing hose 4, trim sensor
lead a, and PTT motor lead b using the
holder 9.
6. Install the adapter 0, and then tighten
the screws A to the specified torque.
7. Route the flushing hose 4 through the
joint B, connect the flushing hose 4 to
the joint C, and then fasten the flushing
hose 4 using the plastic tie D.
8. Install the gasket E and joint B to the
adapter 0.
E
D
C
A
B
1
b
3
a
2
c
b
a
1
2
3
4
5
6
7
6
5
4
7
d
a
b
4
9 8
9-10
9
Installing the cowling lock lever
1. Install the bushing 1, cowling lock lever
2, bushing 3, washer 4, wave washer
5, and lever 6.
2. Install the hook 7, and then install the
spring 8.
Installing the PTT switch
1. Install the gasket 1, PTT switch 2, and
holder 3.
2. Fasten the PTT switch lead a using the
brackets 4 and 5.
Hose joint adapter screw A:
4 Nm (0.4 kgfm, 3.0 ftlb)
4
D
B
C
E
0
A
7
1
2
8
6
5
4
3
a
5
4
1
2
3
PTT switch and cowling lock lever
BRKT
Bracket unit
9-11
Bottom cowling
No. Part name Qty Remarks
1 Rubber seal 1
2 Bolt 6 M8 35 mm
3 Grommet 12
4 Collar 6
5 Plug 2
6 Grommet 4
7 Grommet 1
8 Bottom cowling 1
9 Rubber seal 1
10 Oil dipstick 1
11 Dipstick guide 1
12 Bolt 2 M6 16 mm
13 O-ring 1
Not reusable
5
3
3
4
3
4
3
4
8
1
13
12
12
10
11
9
2
2
2
6
6
3
3
7
9-12
9
Upper case and mount
No. Part name Qty Remarks
1 Upper mount 2
2 Plate 1
3 Bolt 4 M14 195 mm
4 Damper 1
5 Bolt 7 M10 45 mm
6 Bracket 1
7 Bracket 2
8 Washer 2
9 Rubber washer 2
10 Lower mount 2
11 Washer 2
12 Adapter 1
13 Bolt 1 M6 20 mm
14 Hose 1
15 Plastic tie 1
Not reusable
16 Ground lead 1
17 Bolt 1 M6 10 mm
9 8 10 11
19
3
1
1
5
5
5
6
4
3
3
2
7
5
18
9
10
11
3
8
12
13
14
17
15
16
5
7 10
3
9
8
20
19
20
11
54 Nm (5.4 kgfm, 39.8 ftIb)
Bottom cowling / Upper case and mount
BRKT
Bracket unit
9-13
No. Part name Qty Remarks
18 Self-locking nut 2
19 Nut 2
20 Washer 2
9 8 10 11
19
3
1
1
5
5
5
6
4
3
3
2
7
5
18
9
10
11
3
8
12
13
14
17
15
16
5
7 10
3
9
8
20
19
20
11
54 Nm (5.4 kgfm, 39.8 ftIb)
9-14
9
Removing the upper case
1. Drain the remaining engine oil.
2. Disconnect the ground lead 1 and
speedometer hose 2 and remove the
adapter 3.
3. Loosen the bolts 4 and 5.
4. Remove the self-locking nuts 6 and nuts
7, and then remove the upper case
assembly 8.
5. Remove the bolts 4, bracket 9, upper
mounts 0, damper A, upper mounting
bolts B, and plate C.
6. Remove the bolts 5, lower mount brack-
ets D, lower mounts E, bolts F, wash-
ers G, rubber washers H, and washers
I.
Installing the upper case
1. Install the plate 1 and upper mounts 2
to the upper mounting bolts 3.
2. Install the damper 4, upper mount
assembly 5, and upper mount bracket
6, and then tighten the bolts 7 tempo-
rarily.
3
3
2
1
1
5
4
2
7
8
6
0
9
A
B
C
4
5
D
E
I
F
H
G
2
3
3
1
Upper case and mount
BRKT
Bracket unit
9-15
3. Install the washers 8, rubber washers
9, washers 0, and lower mounting bolts
A to the lower mounts B.
4. Install the lower mount brackets C, and
then tighten the bolts D temporarily.
5. Install the upper case assembly E to the
bracket assembly F, and then tighten
the nuts G and H.
6. Tighten the bolts 7 to the specified
torque in the order 1, 2, and so on.
7. Tighten the bolts D.
8. Connect the ground lead I.
9. Route the speedometer hose J through
the steering arm K, and then connect it
to the speedometer hose adapter L.
6
4
5
7
9 0 B 8 A
D
C
B
8
A
9
0
H
F
E
G
Bracket bolt 7:
54 Nm (5.4 kgfm, 39.8 ftlb)
3
1
7
D
2
K
J
L
L
I
I
J
J
9-16
9
Upper case
No. Part name Qty Remarks
1 Rubber seal 1
2 Idle silencer 1
3 Bolt 2 M6 20 mm
4 Grommet 1
5 Screw 2 M6 15 mm
6 Anode 2
7 Bolt 4 M10 45 mm
8 Bolt 2 M8 30 mm
9 Rubber seal 1
10 Rubber seal 1
11 Dowel 2
12 Drain bolt 1 M14 12 mm
13 Gasket 1
Not reusable
14 Bolt 1 M6 14 mm
15 Cover 1
16 Damper 1
17 Upper case 1
5
5
7
6
6
4
3
2
3
1
11
8
10
9
17
12
13
15
16
14
4 Nm (0.4 kgfm, 3.0 ftIb)
27 Nm (2.7 kgfm, 19.9 ftIb)
42 Nm (4.2 kgfm, 31.0 ftIb)
20 Nm (2.0 kgfm, 14.8 ftIb)
Upper case and mount / Upper case
BRKT
Bracket unit
9-17
Disassembling the upper case
1. Remove the drain bolt 1, gasket 2,
cover 3, and damper 4.
2. Remove the anodes 5, rubber seal 6,
idle silencer 7, and grommet 8.
3. Remove the oil pan assembly 9 and
dowels 0.
4. Remove the rubber seals A and B.
Checking the exhaust guide anode
1. Check the anode. Replace if eroded.
Clean if there is grease, oil, or scales.
NOTICE: Do not apply grease, oil, or
paint to the anode.
Assembling the upper case
Do not reuse a gasket, always replace it
with a new one.
1. Install the rubber seal 1 into the upper
case.
2. Install the rubber seal 2, dowels 3, and
oil pan assembly 4, and then tighten the
bolts 5 and 6 to the specified torque.
3. Install the anodes 7, and then tighten
the screws 8 to the specified torque.
4. Install the grommet 9, idle silencer 0,
and rubber seal A.
TIP:
Make sure to fit the tip of the water pipe B
into the rubber seal 1.
4
1
2
3
5
5
8
7
6
A
9
B
0
Upper case bolt 5 (M10):
42 Nm (4.2 kgfm, 31.0 ftlb)
Upper case bolt 6 (M8):
20 Nm (2.0 kgfm, 14.8 ftlb)
Anode screw 8:
4 Nm (0.4 kgfm, 3.0 ftlb)
1
8
7
5
7
8
9
0
A
2
4
6
B
3
1
9-18
9
5. Install the damper C, the cover D, and a
new gasket E, and then tighten the drain
bolt F to the specified torque.
Engine oil drain bolt F:
27 Nm (2.7 kgfm, 19.9 ftlb)
C
F
E
D
Upper case
BRKT
Bracket unit
9-19
Oil pan and exhaust manifold
No. Part name Qty Remarks
1 Exhaust guide 1
2 Grommet 1
3 Gasket 1
Not reusable
4 Oil strainer 1
5 Gasket 1
Not reusable
6 Collar 3
7 Bolt 3 M6 25 mm
8 Dowel 2
9 Oil pan 1
10 Bolt 19 M8 35 mm
11 Gasket 1
Not reusable
12 Exhaust manifold 1
13 Bolt 4 M8 60 mm
14 Rubber seal 1
15 Gasket 1
Not reusable
16 Plate 1
17 Rubber seal 1
17
18
1
10
8
11
2
3 12
14
16
15
13
6
5
7
8
4
9
10
10
19
12 Nm (1.2 kgfm, 8.9 ftIb)
20 Nm (2.0 kgfm, 14.8 ftIb)
20 Nm (2.0 kgfm, 14.8 ftIb)
20 Nm (2.0 kgfm, 14.8 ftIb)
9-20
9
No. Part name Qty Remarks
18 Pipe 1
19 Hose 1
17
18
1
10
8
11
2
3 12
14
16
15
13
6
5
7
8
4
9
10
10
19
12 Nm (1.2 kgfm, 8.9 ftIb)
20 Nm (2.0 kgfm, 14.8 ftIb)
20 Nm (2.0 kgfm, 14.8 ftIb)
20 Nm (2.0 kgfm, 14.8 ftIb)
Oil pan and exhaust manifold
BRKT
Bracket unit
9-21
Disassembling the oil pan and
exhaust manifold
1. Remove the hose 1, pipe 2, rubber
seal 3, plate 4, and gasket 5.
2. Remove the rubber seal 6, exhaust
manifold 7, and gasket 8.
3. Remove the oil pan 9 and dowels 0.
4. Remove the oil strainer A and gaskets
B and C.
Checking the oil pan and exhaust
manifold
1. Clean the removed parts.
2. Check the exhaust manifold and exhaust
guide. Replace if corroded or cracked.
3. Check the oil pan. Replace if corroded or
cracked.
Checking the oil strainer
1. Check the oil strainer. Clean if there is
dirt or residue.
2
3
4
5
1
6
7
8
9
0
0
A
B
C
9-22
9
Assembling the oil pan and exhaust
manifold
Do not reuse a gasket, always replace it
with a new one.
1. Install new gaskets 1 and 2 onto the
exhaust guide 3.
2. Install the oil strainer 4, and then tighten
the bolts 5 to the specified torque.
3. Install the dowels 6 and oil pan 7, and
then tighten the bolts 8 temporarily.
4. Install a new gasket 9, the exhaust man-
ifold 0, and the rubber seal A, and then
tighten the bolts B temporarily.
5. Tighten the bolts B to the specified
torque, and then tighten the bolts 8 to
the specified torque.
6. Install a new gasket C, the plate D, the
rubber seal E, the pipe F, and the hose
G, and then tighten the bolts H to the
specified torque.
Oil strainer bolt 5:
12 Nm (1.2 kgfm, 8.9 ftlb)
4
5
5
2
1
3
7
6
6
8
8
Exhaust manifold bolt B:
20 Nm (2.0 kgfm, 14.8 ftlb)
Oil pan bolt 8:
20 Nm (2.0 kgfm, 14.8 ftlb)
Plate bolt H: 20 Nm (2.0 kgfm, 14.8 ftlb)
A
0
9
B
8
8
F
E
D
C
H
G
Oil pan and exhaust manifold
BRKT
Bracket unit
9-23
Steering arm
No. Part name Qty Remarks
1 Steering arm 1
2 Washer 2
3 Bushing 2
4 O-ring 1
Not reusable
5 Bushing 1
6 Steering yoke 1
7 Grommet 1
8 Circlip 1
3
4
2
6
8
7
1
2
3
5
9-24
9
Removing the steering arm
1. Remove the circlip 1, and then strike the
steering yoke 2 using a copper hammer
to remove the steering yoke 2.
2. Remove the steering arm 3, and then
remove the washer 4 and bushing 5.
3. Remove the washer 6, bushing 7, O-
ring 8, and bushing 9.
Installing the steering arm
Do not reuse an O-ring, always replace it
with a new one.
1. Install the bushing 1 and washer 2, and
then install the steering arm 3.
2. Install the bushing 4, a new O-ring 5,
the bushing 6, and the washer 7.
3. Install the steering yoke 8 so that the
steering arm 3 and steering yoke 8 are
both facing in the same direction (a and
b are aligned).
4. Hold the steering arm 3, and then strike
the steering yoke 8 using a copper ham-
mer until the groove for installing the cir-
clip is visible.
5. Install the circlip 9.
2
2
1
1
9
8
7
6
3
4
5
4
5
6
7
3
2
1
a
8
b
3
Steering arm
BRKT
Bracket unit
9-25
6. Inject grease into the grease nipple on
the swivel bracket. See Lubricating the
outboard motor (10-11).
8
9
9
8
3
9-26
9
Clamp bracket and swivel bracket
No. Part name Qty Remarks
1 Self-locking nut 1
2 Clamp bracket (STBD) 1
3 Anode 2
4 Bolt 4 M6 25 mm
5 Plate 1
6 Screw 4 M6 10 mm
7 Ground lead 1
8 Screw 1 M6 12 mm
9 Washer 2
10 Bushing 2
11 Grease nipple 3
12 Swivel bracket 1
13 Screw 2 M6 10 mm
14 Trim sensor 1
15 Screw 2 M5 35 mm
16 Holder 1
17 Self-locking nut 2
4
4
5
6
6
1
2
3
3
3
7 8
13
9
10
11
11
11
23
24
15
14
16
13
12
17
10
9
21
22
19
18
20
4 A
A
3 Nm (0.3 kgfm, 2.2 ftIb) 4 Nm (0.4 kgfm, 3.0 ftIb)
4 Nm (0.4 kgfm, 3.0 ftIb)
22 Nm (2.2 kgfm, 16.2 ftIb)
4 Nm (0.4 kgfm, 3.0 ftIb)
Steering arm / Clamp bracket and swivel bracket
BRKT
Bracket unit
9-27
No. Part name Qty Remarks
18 Trim stopper 2
19 Clamp bracket (PORT) 1
20 Plate 1
21 Through tube 1
22 Bolt 1 M8 20 mm
23 Screw 1 M5 35 mm
24 Trim sensor cam 1
4
4
5
6
6
1
2
3
3
3
7 8
13
9
10
11
11
11
23
24
15
14
16
13
12
17
10
9
21
22
19
18
20
4 A
A
3 Nm (0.3 kgfm, 2.2 ftIb) 4 Nm (0.4 kgfm, 3.0 ftIb)
4 Nm (0.4 kgfm, 3.0 ftIb)
22 Nm (2.2 kgfm, 16.2 ftIb)
4 Nm (0.4 kgfm, 3.0 ftIb)
9-28
9
Removing the clamp bracket
1. Remove the PTT unit. See Removing
the PTT unit (9-32).
2. Remove the holder 1 and trim sensor
cam 2.
3. Disconnect the ground lead 3.
4. Remove the bolt 4, and self-locking nut
5.
5. Remove the through tube 6, and then
disassemble the clamp brackets 7 and
8 and swivel bracket 9.
6. Remove the anodes 0 and ground leads
3 and A.
7. Remove the plates B and C.
8. Remove the trim sensor D, grease nip-
ples E, and trim stoppers F.
Checking the clamp bracket anode
1. Check the anodes. Replace if eroded.
Clean if there is grease, oil, or scales.
NOTICE: Do not apply grease, oil, or
paint to the anodes.
Installing the clamp bracket
1. Install the trim stoppers 1.
2. Install the grease nipples 2, and then
tighten them to the specified torque.
3. Install the trim sensor 3, and then
tighten the screws 4 to the specified
torque.
2
1
3
6
4
C
B
8
A
0
0
3
9
5
7
Grease nipple 2:
3 Nm (0.3 kgfm, 2.2 ftlb)
Trim sensor screw 4:
4 Nm (0.4 kgfm, 3.0 ftlb)
E
E
E
F
D
2
2
2
1
1
4
3
Clamp bracket and swivel bracket
BRKT
Bracket unit
9-29
4. Install the anodes 5 and ground leads
6 and 7, and then tighten the screw 8
to the specified torque.
5. Install the plates 9 and 0, and then
tighten the screws A to the specified
torque.
6. Assemble the bushings B, washers C,
clamp brackets D and E, and swivel
bracket F, and then install the through
tube G from the port side.
7. Tighten the self-locking nut H to the
specified torque, and then tighten the bolt
I.
8. Connect the ground lead 7, and then
tighten the screw J to the specified
torque.
9. Install the trim sensor cam K and holder
L, and then tighten the screw M to the
specified torque.
10. Inject grease into the grease nipples on
the swivel bracket. See Lubricating the
outboard motor (10-11).
Adjusting the trim sensor cam
1. Fully tilt the outboard motor down.
2. Loosen the trim sensor cam screw 1.
3. Adjust the trim sensor cam 2 so that the
trim sensor setting resistance is within
specification.
Ground lead screw 8:
4 Nm (0.4 kgfm, 3.0 ftlb)
Plate screw A:
4 Nm (0.4 kgfm, 3.0 ftlb)
Self-locking nut H:
22 Nm (2.2 kgfm, 16.2 ftlb)
G
I
A
A
0
9
E
5
7
F
H
D
8
B
C
6
5
B
C
A
A
Ground lead screw J:
4 Nm (0.4 kgfm, 3.0 ftlb)
Holder screw M:
4 Nm (0.4 kgfm, 3.0 ftlb)
Digital multimeter: YU-34899-A
Trim sensor setting resistance:
Terminal aTerminal b
9.011.0
K
L
M
7
J
1
2
c
d
a b
9-30
9
TIP:
To increase the resistance, turn the trim
sensor cam in direction c.
To decrease the resistance, turn the trim
sensor cam in direction d.
4. Tighten the screw 1 so that the gap e
between the ends of the trim sensor cam
is within specification.
Trim sensor cam end gap e:
19.022.0 mm (0.750.87 in)
e
1
Clamp bracket and swivel bracket
BRKT
Bracket unit
9-31
PTT unit
No. Part name Qty Remarks
1 Shaft 1
2 Circlip 1
3 Bushing 6
4 PTT unit 1
5 Ground lead 1
6 Bolt 1 M6 10 mm
7 Bolt 2 M10 30 mm
8 Washer 2
9 Shaft 1
10 Plastic tie 3
Not reusable
1
9
8
7
2
10
7
8
3
3
3
4
3
5
6
3
54 Nm (5.4 kgfm, 39.8 ftIb)
54 Nm (5.4 kgfm, 39.8 ftIb)
9-32
9
Removing the PTT unit
When removing the PTT unit with the
power unit installed, make sure to sus-
pend the outboard motor. Otherwise, the
outboard motor could fall suddenly and
result in severe injuries.
1. Fully tilt the swivel bracket up, and then
support it using the tilt support shaft 1.
2. Remove the plastic ties 2.
3. Disconnect the ground lead 3.
4. Remove the circlip 4 and shaft 5.
5. Remove the shaft 6, and then remove
the PTT unit 7.
Checking the hydraulic pressure
Check the hydraulic pressure. If out of speci-
fication, check the internal parts.
1. Fully extend the PTT rams.
2. Remove the reservoir cap 1, and then
check the fluid level in the reservoir.
WARNING! Before removing the reser-
voir cap 1, make sure that the PTT
rams are fully extended. Otherwise,
fluid could be expelled forcefully from
the PTT unit due to internal pressure.
Tilt support shaft 1: 6CB-43611-00
1
2
2
2
4
5
3
7
6
PTT unit
BRKT
Bracket unit
9-33
TIP:
If the fluid is at the proper level, a small
amount of fluid should flow out of the filler
hole.
3. If the fluid is below the proper level, add
the recommended fluid.
4. Install the reservoir cap 1, and then
tighten it to the specified torque.
5. Remove the circlip 2, and then remove
the manual valve 3.
6. Install the special service tools 4 and 5.
TIP:
Install the special service tools quickly before
any fluid flows out of the hole.
7. Connect the PTT motor leads to the bat-
tery terminals to fully retract the PTT
rams.
8. Reverse the PTT motor leads between
the battery terminals to fully extend the
PTT rams, and then measure the hydrau-
lic pressure when the reading on the
pressure gauge stabilizes.
Recommended PTT fluid: ATF DEXRON II
Reservoir cap 1:
2 Nm (0.2 kgfm, 1.5 ftlb)
1
3
2
4
5
Up relief fitting 4: 90890-06773/06838
Hydraulic pressure gauge 5:
90890-06776/06800
Ram PTT motor lead
Battery
terminal
Down
Black (B) +
Black/White
(B/W)
-
Hydraulic pressure (up) (reference data):
9.811.8 MPa (98.0118.0 kgf/cm
2
,
1421.01711.0 psi)
B B/W
B B/W
9-34
9
9. Remove the special service tools 4 and
5, and then install the special service
tools 5 and 6.
TIP:
Remove and install the special service tools
quickly before any fluid flows out of the hole.
10. Repeat steps 24 to check the fluid level.
11. Connect the PTT motor leads to the bat-
tery terminals to fully retract the PTT
rams, and then measure the hydraulic
pressure when the reading on the pres-
sure gauge stabilizes.
12. Reverse the PTT motor leads between
the battery terminals to fully extend the
PTT rams.
13. Remove the special service tools.
14. Install the manual valve and circlip, and
then tighten the manual valve to the
specified torque.
TIP:
Install the manual valve quickly before any
fluid flows out of the hole.
15. Repeat steps 24 to check the fluid level.
Ram PTT motor lead
Battery
terminal
Up
Black/White
(B/W)
+
Black (B) -
Hydraulic pressure gauge 5:
90890-06776/06800
Down relief fitting 6: 90890-06774
6
5
4
B B/W
Hydraulic pressure (down)
(reference data): 5.98.8 MPa
(59.088.0 kgf/cm
2
,
855.51276.0 psi)
Ram PTT motor lead
Battery
terminal
Down
Black (B) +
Black/White
(B/W)
-
Ram PTT motor lead
Battery
terminal
Up
Black/White
(B/W)
+
Black (B) -
Manual valve:
3 Nm (0.3 kgfm, 2.2 ftlb)
B B/W
PTT unit
BRKT
Bracket unit
9-35
Installing the PTT unit
When installing the PTT unit with the
power unit installed, make sure to sus-
pend the outboard motor. Otherwise, the
outboard motor could fall suddenly and
result in severe injuries.
1. Fully tilt the swivel bracket up, and then
support it using the tilt support shaft 1.
2. Install the bushings 2.
3. Install the PTT unit 3 and shaft 4, and
then tighten the bolts 5 to the specified
torque.
4. Route the PTT motor lead a through the
hole b.
5. Install the shaft 6 from the port side, and
then install the circlip 7.
6. Connect the ground lead 8.
7. Fasten the PTT motor lead a and trim
sensor lead c using the plastic ties 9.
Tilt support shaft 1: 6CB-43611-00
1
3
2
2
4
5
2
5
Lower mounting shaft bolt 5:
54 Nm (5.4 kgfm, 39.8 ftlb)
a
b
7
6
8
c
a
9
9
9
9-36
9
PTT motor
No. Part name Qty Remarks
1 Bolt 3 M6 14 mm
2 Reservoir 1
3 Cap 1
4 O-ring 1
Not reusable
5 O-ring 1
Not reusable
6 Bolt 4 M6 33 mm
7 O-ring 1
Not reusable
8 Filter 1
9 Joint 1
10 PTT motor assembly 1
11 Screw 1 M4 15 mm
12 Armature 1
13 O-ring 1
Not reusable
14 Screw 2 M4 12 mm
15 Brush holder 1
16 Brush holder 1
17 Brush 1
1
2
3
4
5
6
7
8
9
10
10
11
12
13
14
15
16
17
18
19
19
20
21
14
5 Nm (0.5 kgfm, 3.7 ftIb)
5 Nm (0.5 kgfm, 3.7 ftIb)
2 Nm (0.2 kgfm, 1.5 ftIb)
PTT unit / PTT motor
BRKT
Bracket unit
9-37
No. Part name Qty Remarks
18 Brush 1
19 Spring 2
20 Screw 2 M4 15 mm
21 Oil seal 1
Not reusable
1
2
3
4
5
6
7
8
9
10
10
11
12
13
14
15
16
17
18
19
19
20
21
14
5 Nm (0.5 kgfm, 3.7 ftIb)
5 Nm (0.5 kgfm, 3.7 ftIb)
2 Nm (0.2 kgfm, 1.5 ftIb)
9-38
9
Removing the reservoir
Before removing the reservoir, make sure
that the PTT rams are fully extended. Oth-
erwise, fluid could be expelled forcefully
from the PTT unit due to internal pres-
sure.
1. Remove the reservoir 1 and O-ring 2.
TIP:
Place a container under the PTT unit to catch
the fluid.
Removing the PTT motor
1. Remove the PTT motor assembly 1, O-
ring 2, filter 3, and joint 4.
Disassembling the PTT motor
1. Remove the screw 1, and then slide the
lead holder a and rubber seals b away
from the stator c.
2. Remove the screws 2, and then remove
the stator c. NOTICE: Secure the end
of the armature shaft using a pair of
pliers, and then remove the armature
along with the motor base assembly.
Otherwise, the armature could sepa-
rate from the motor base assembly
due to the magnetic force of the stator
c and damage the brushes.
3. Remove the armature 3.
4. Disconnect the PTT motor leads d and
e.
5. Remove the brushes 4 and 5.
NOTICE: Do not touch the bimetal f.
Otherwise, the operation of the circuit
breaker could be affected.
1
2
1
2
3
4
b
a
2
3
1
b
c
2
B/W
d
B
e
5
4
f
PTT motor
BRKT
Bracket unit
9-39
Checking the armature (PTT motor)
1. Check the commutator. Clean using 600-
grit sandpaper and compressed air if
dirty.
2. Measure the commutator diameter a.
Replace the armature if below specifica-
tion.
3. Measure the commutator undercut b.
Replace the armature if below specifica-
tion.
4. Check the armature for continuity.
Replace if out of specification.
Checking the brush
1. Measure the length of each brush.
Replace if below specification.
2. Check the brush and circuit breaker for
continuity. Replace if there is no continu-
ity. NOTICE: Do not touch the bimetal
c. Otherwise, the operation of the cir-
cuit breaker could be affected.
Motor commutator standard diameter a:
22.0 mm (0.87 in)
Wear limit: 21.0 mm (0.83 in)
Motor commutator standard undercut b
(reference data): 1.4 mm (0.06 in)
Wear limit: 0.9 mm (0.04 in)
a
b
Armature continuity:
c d e f
Motor brush standard length a:
9.8 mm (0.39 in)
Wear limit b: 4.8 mm (0.19 in)
c
d
f
e
b
a
c
9-40
9
3. Check the PTT motor base. Replace the
PTT motor assembly if the base is
cracked or damaged.
Checking the reservoir
1. Check the reservoir. Replace if cracked
or damaged.
Assembling the PTT motor
Do not reuse an oil seal or O-ring,
always replace it with a new one.
Do not apply grease or oil to the com-
mutator of the armature.
1. Install a new oil seal 1.
2. Install the springs 2 and brushes 3 and
4, and then tighten the screw 5.
NOTICE: Do not touch the bimetal a.
Otherwise, the operation of the circuit
breaker could be affected.
3. Install a new O-ring 6.
4. Connect the PTT motor leads b and c,
and then tighten the screw 7.
5. Push the brushes 3 and 4 into the hold-
ers, and then install the armature 8.
6. Install the stator d, and then tighten the
screws 9. NOTICE: Secure the end of
the armature shaft using a pair of pli-
ers, and then install the armature
along with the motor base assembly.
Otherwise, the armature could sepa-
rate from the motor base assembly
due to the magnetic force of the stator
d and damage the brushes.
7. Install the rubber seals e and lead
holder f, and then tighten the screw 0.
Installing the reservoir
Do not reuse an O-ring, always replace it
with a new one.
1 AA
a
3
4
2
6
2
5
7
c b
B/W
B
8
4
3
e
f
9
0
e
d
9
PTT motor
BRKT
Bracket unit
9-41
1. Install a new O-ring 1 and the reservoir
2, and then tighten the bolts 3 to the
specified torque.
2. Install a new O-ring 4 and the reservoir
cap 5, and then tighten the reservoir cap
5 to the specified torque.
Installing the PTT motor
Do not reuse an O-ring, always replace it
with a new one.
When assembling the PTT unit, do not
use a rag. Otherwise, dust and particles
could get on the PTT unit components,
causing poor performance.
1. Install the joint 1 and filter 2.
2. Fill the gear pump housing with the rec-
ommended fluid up to the proper level a.
3. Turn the joint 1 using a screwdriver to
remove any air between the pump gear
teeth.
4. Remove all of the air bubbles using a
syringe or suitable tool.
5. Install a new O-ring 3 and the PTT
motor assembly 4, and then tighten the
bolts 5 to the specified torque.
TIP:
Align the protrusion b on the armature shaft
with the slot c in the joint.
Reservoir bolt 3:
5 Nm (0.5 kgfm, 3.7 ftlb)
Reservoir cap 5:
2 Nm (0.2 kgfm, 1.5 ftlb)
2
3
4 5
1
2
1
Recommended PTT fluid: ATF DEXRON II
PTT motor mounting bolt 5:
5 Nm (0.5 kgfm, 3.7 ftlb)
a
3
4 5
b
c
9-42
9
PTT gear pump
No. Part name Qty Remarks
1 Ball 1
2 Pin 1
3 Valve seat 1
4 O-ring 5
Not reusable
5 Valve 1
6 Filter 2
7 Down-relief valve 1
8 O-ring 1
Not reusable
9 Spring 1
10 Absorber valve pin 1
11 Ball 1
12 Up-relief valve seat 1
13 O-ring 1
Not reusable
14 Bolt 4 M5 16 mm
15 Ball 2
16 Shuttle piston 2
17 O-ring 2
Not reusable
9
10
11
12
13
15
16
17
18
19
21
27
23
22
24
25
26
9
10
11
13
12
6
8
7
5
3
2
2 3
1
1
4
20
27
14
16
17
18
19
4
4
17
18
6 Nm (0.6 kgfm, 4.4 ftIb)
8 Nm (0.8 kgfm, 5.9 ftIb)
3 Nm (0.3 kgfm, 2.2 ftIb)
PTT motor / PTT gear pump
BRKT
Bracket unit
9-43
No. Part name Qty Remarks
18 Main valve 2
19 Ball 2
20 Gear pump assembly 1
21 Bolt 1 M8 85 mm
22 Backup ring 1
23 O-ring 1
Not reusable
24 O-ring 1
Not reusable
25 Manual valve 1
26 Circlip 1
27 Bolt 2 M8 24 mm
9
10
11
12
13
15
16
17
18
19
21
27
23
22
24
25
26
9
10
11
13
12
6
8
7
5
3
2
2 3
1
1
4
20
27
14
16
17
18
19
4
4
17
18
6 Nm (0.6 kgfm, 4.4 ftIb)
8 Nm (0.8 kgfm, 5.9 ftIb)
3 Nm (0.3 kgfm, 2.2 ftIb)
9-44
9
Disassembling the gear pump
assembly
1. Remove the bolts 1 and 2, and then
remove the gear pump assembly 3.
2. Remove the O-rings 4, valve 5, and
valve seat assembly 6.
3. Remove the filters 7, down-relief valve
8, and O-ring 9.
4. Remove the gear pump cover a, and
then remove the gears b, shuttle pistons
0, and balls A and B.
5. Remove the spring C, absorber valve
pin D, ball E, up-relief valve seat F,
and O-ring G.
6. Cover the gear pump using a rag, and
then blow compressed air through the
holes c and d to remove the main
valves H. WARNING! When removing
the main valves, never look into the
gear pump housing opening because
the main valves and PTT fluid could
be expelled forcefully.
7. Remove the circlip I, and then remove
the manual valve J.
Checking the gear pump
1. Check the gears a. Replace the gear
pump assembly if damaged or worn.
2
3
6
1
1
5
4
4
A
7
8
9
7
b
a
b
0 0
B
D
C
G
E
F
c
d
H
H
d c
J
I
PTT gear pump
BRKT
Bracket unit
9-45
2. Check the down-relief valve 1. Clean if
there is dirt or residue.
3. Check the main valves 2 and shuttle
pistons 3. Clean if there is dirt or resi-
due.
4. Check the absorber valve pin 4 and up-
relief valve seat 5. Clean if there is dirt
or residue.
5. Check the valve 6 and valve seat 7.
Clean if there is dirt or residue.
Checking the gear pump housing
1. Check the gear pump housing. Replace
the gear pump assembly if corroded or
cracked.
Checking the filter
1. Check the down-relief valve filters. Clean
if there is dirt or residue.
Assembling the gear pump assembly
When assembling the PTT unit, do not
use a rag. Otherwise, dust and particles
could get on the PTT unit components,
causing poor performance.
Do not reuse an O-ring, always replace it
with a new one.
1. Install a new O-ring 1, the up-relief valve
seat 2, the ball 3, the absorber valve
pin 4, and the spring 5.
2. Install new O-rings 6 onto the main
valves 7, and then install the main
valves.
3. Install the gears a.
4. Install the balls 8, shuttle pistons 9, and
balls 0.
3
2
5
1
7
6
4
a
a
3
2
5
4
3
2
1
1
2
4
3
5
6
7
6
7
6
7
a a
8
9
0
8
9
0
0
8
9
8
9
0
8
9
9-46
9
5. Install the gear pump cover b, and then
tighten the bolts A to the specified
torque.
6. Check that the gears turn smoothly.
7. Install a new O-ring B onto the down-
relief valve C, and then install the filters
D, and down-relief valve C.
8. Install new O-rings E and F and the
backup ring G.
9. Install the manual valve H and circlip I,
and then tighten the manual valve H to
the specified torque.
10. Install new O-rings J, the valve K, and
the valve seat assembly L.
11. Install the gear pump assembly M, and
then tighten the bolts N and O to the
specified torque.
Gear pump cover bolt A:
6 Nm (0.6 kgfm, 4.4 ftlb)
Manual valve H:
3 Nm (0.3 kgfm, 2.2 ftlb)
A
b
D
B
C
D
D
BC D
F
E
H
G
I
Gear pump housing bolts N and O:
8 Nm (0.8 kgfm, 5.9 ftlb)
N
M
L
J
O
O
J
K
PTT gear pump
BRKT
Bracket unit
9-47
PTT cylinder
No. Part name Qty Remarks
1 Tilt ram assembly 1
2 Dust seal 1
Not reusable
3 Tilt cylinder screw 1
4 O-ring 1
Not reusable
5 O-ring 1
Not reusable
6 O-ring 1
Not reusable
7 O-ring 1
Not reusable
8 Free piston 1
9 Backup ring 1
10 O-ring 1
Not reusable
11 Plug 1
12 O-ring 1
Not reusable
13 Filter 1
14 Trim ram assembly 2
15 Dust seal 2
Not reusable
16 Seal 2
Not reusable
17 Trim cylinder screw 2
1
9
8
10
11
12
13
9
8
14
10
15
16
16
15
14
17
18
17
18
19
20
21
19
20
2
4
3
5
2
4
3
5
6
7
17
16
15
18
19
20
6
7
96 Nm (9.6 kgfm, 70.8 ftIb)
127 Nm (12.7 kgfm, 93.7 ftIb)
140 Nm (14.0 kgfm, 103.3 ftIb)
6 Nm (0.6 kgfm, 4.4 ftIb)
9-48
9
No. Part name Qty Remarks
18 O-ring 2
Not reusable
19 Backup ring 2
20 O-ring 2
Not reusable
21 PTT body 1
1
9
8
10
11
12
13
9
8
14
10
15
16
16
15
14
17
18
17
18
19
20
21
19
20
2
4
3
5
2
4
3
5
6
7
17
16
15
18
19
20
6
7
96 Nm (9.6 kgfm, 70.8 ftIb)
127 Nm (12.7 kgfm, 93.7 ftIb)
140 Nm (14.0 kgfm, 103.3 ftIb)
6 Nm (0.6 kgfm, 4.4 ftIb)
PTT cylinder
BRKT
Bracket unit
9-49
Removing the tilt ram and trim ram
Before removing the tilt cylinder end
screw, make sure that the PTT rams are
fully extended. Otherwise, fluid could be
expelled forcefully from the PTT unit due
to internal pressure.
1. Loosen the tilt cylinder end screw 1, and
then remove the tilt ram assembly.
2. Loosen the trim cylinder end screws 3,
and then remove the trim ram assem-
blies.
3. Drain the fluid.
4. Install the trim ram assemblies, and then
tighten the trim cylinder end screws 3
temporarily.
5. Cover the tilt cylinder using a rag, and
then blow compressed air through the
hole a to remove the free piston 5.
WARNING! When removing the free
piston, never look into the tilt cylinder
opening because the free piston and
PTT fluid could be expelled forcefully.
6. Loosen the trim cylinder end screws, and
then remove the trim ram assemblies 6.
Disassembling the tilt ram
1. Remove the nut a, and then remove the
tilt piston absorber valves b.
Tilt wrench 2: YB-06548
Trim wrench 4: YB-06175-1A
2
1
4
3
5
a
3
3
6
6
9-50
9
Checking the tilt cylinder and trim
cylinder
1. Check the PTT body 1. Replace if cor-
roded or cracked.
2. Check the inner surface of the PTT body
1. Replace if scratched.
3. Check the outer surface of the tilt piston
a, trim pistons b, and free piston 2.
Replace if scratched.
4. Check the backup rings 3 and 4.
Replace if damaged or worn.
5. Check the trim rams c and tilt ram d.
Clean using 400600-grit sandpaper if
there is rust or, replace if bent or cor-
roded.
Checking the absorber valve
1. Check the tilt piston absorber valves a.
Clean if there is dirt or residue.
Assembling the tilt ram
When assembling the PTT unit, do not
use a rag. Otherwise, dust and particles
could get on the PTT unit components,
causing poor performance.
Do not reuse a dust seal or O-ring,
always replace it with a new one.
1. Install a new dust seal 1 and new O-
rings 2 and 3.
a
b
2
3
4
4
c
b
1
a
d
c
b
a
PTT cylinder
BRKT
Bracket unit
9-51
2. Install the tilt cylinder end screw 4 and
tilt piston a.
3. Install new O-rings 5 and 6.
4. Install the balls b, absorber valve pins
c, and springs d.
5. Install the washer e, and then tighten
the nut f to the specified torque.
Assembling the trim ram
When assembling the PTT unit, do not
use a rag. Otherwise, dust and particles
could get on the PTT unit components,
causing poor performance.
Do not reuse a dust seal, O-ring, or seal,
always replace it with a new one.
1. Install new O-rings 1 and the backup
rings 2.
2. Install new seals 3, new dust seals 4,
and new O-rings 5.
3. Install the trim cylinder end screws 6.
1
2
1
3
AA
AA
2
3
5
4
6
6
5
a
a
Tilt piston nut f:
96 Nm (9.6 kgfm, 70.8 ftlb)
e
c
d
b
d
c
b
f
e
2
1
2
1
9-52
9
Installing the trim ram
When assembling the PTT unit, do not
use a rag. Otherwise, dust and particles
could get on the PTT unit components,
causing poor performance.
Do not reuse an O-ring, always replace it
with a new one.
1. Add the recommended fluid through the
PTT body hole a.
2. Install a new O-ring 1 and the backup
ring 2 to the free piston 3.
3. Install the free piston assembly 4 and
push it down until it bottoms out.
4. Fill the trim cylinders with the recom-
mended fluid up to the proper level b.
TIP:
Make sure to add the recommended fluid
through the holes c, d and e.
5. Install the trim ram assemblies, and then
tighten the trim cylinder end screws 5 to
the specified torque.
Recommended PTT fluid: ATF DEXRON II
Fluid quantity (reference quantity):
0.03 L (0.032 US qt, 0.026 Imp qt)
4
3
5
6
5
4
3 6
AA
AA
a
1
2
3
1
2
3
Recommended PTT fluid: ATF DEXRON II
4
4
b
c
e
d
PTT cylinder
BRKT
Bracket unit
9-53
Installing the tilt ram
1. Install the gear pump assembly. See
steps 10 and 11 in Assembling the gear
pump assembly (9-45).
2. Install the reservoir. See Installing the
reservoir (9-40).
3. Place the tilt cylinder end screw a at the
bottom of the tilt ram b.
4. Fill the tilt cylinder and PTT body with the
recommended fluid up to the proper level
c.
5. Install the tilt ram assembly, and then
tighten the tilt cylinder end screw 1 to
the specified torque.
6. Install the PTT motor. See Installing the
PTT motor (9-41).
Bleeding the PTT unit
Do not reuse an O-ring, always replace it
with a new one.
1. Place the PTT unit in an upright position.
2. Turn the manual valve 1 clockwise to
close it.
Trim wrench 6: YB-06175-1A
Trim cylinder end screw 5:
140 Nm (14.0 kgfm, 103.3 ftlb)
6
5
c
a
b
c
Recommended PTT fluid: ATF DEXRON II
Tilt wrench 2: YB-06548
Tilt cylinder end screw 1:
127 Nm (12.7 kgfm, 93.7 ftlb)
Manual valve 1:
3 Nm (0.3 kgfm, 2.2 ftlb)
2
1
1
9-54
9
3. Check the fluid level. See steps 24 in
Checking the hydraulic pressure (9-32).
4. Connect the PTT motor leads to the bat-
tery terminals to fully retract the PTT
rams.
5. Reverse the PTT motor leads between
the battery terminals to fully extend the
PTT rams.
TIP:
If the PTT rams do not move up and down
easily, push and pull on the PTT rams to
assist operation.
6. Repeat steps 4 and 5 to fully extend and
retract the PTT rams 4 or 5 times.
7. Fully extend the tilt ram.
8. Remove the reservoir cap, and then
check the fluid level in the reservoir.
WARNING! Before removing the reser-
voir cap, make sure that the PTT rams
are fully extended. Otherwise, fluid
could be expelled forcefully from the
PTT unit due to internal pressure.
TIP:
If the fluid is below the proper level, add the
recommended PTT fluid. Repeat steps 37
until the fluid remains at the proper level.
9. Install a new O-ring and the reservoir
cap, and then tighten the reservoir cap to
the specified torque.
Ram PTT motor lead
Battery
terminal
Down
Black (B) +
Black/White
(B/W)
-
Ram PTT motor lead
Battery
terminal
Up
Black/White
(B/W)
+
Black (B) -
B B/W
B B/W
Reservoir cap:
2 Nm (0.2 kgfm, 1.5 ftlb)
PTT cylinder
BRKT
Bracket unit
9-55
MEMO
MNT
10
Maintenance
Outline............................................................................... 10-1
Maintenance interval chart 1 .................................................... 10-1
Maintenance interval chart 2 .................................................... 10-2
Predelivery check............................................................. 10-3
Checking the battery ................................................................ 10-3
Checking the cooling water pilot hole....................................... 10-3
Checking the engine oil level.................................................... 10-4
Checking the engine start switch and engine shut-off switch... 10-4
Checking the fuel system......................................................... 10-4
Checking the gear oil level ....................................................... 10-4
Checking the gear shift and throttle operation.......................... 10-5
Checking the outboard motor mounting height ........................ 10-5
Checking the PTT system........................................................ 10-5
Checking the steering system.................................................. 10-5
Checking the throttle cable and shift cable............................... 10-5
Test run .................................................................................... 10-6
Break-in.................................................................................... 10-6
After test run............................................................................. 10-6
General periodic maintenance........................................ 10-7
Checking the anode ................................................................. 10-7
Checking the battery ................................................................ 10-7
Checking the cooling water passage........................................ 10-7
Checking the engine idle speed ............................................... 10-7
Changing the engine oil............................................................ 10-8
Checking the engine oil level.................................................... 10-9
Replacing the oil filter ............................................................... 10-9
Checking the engine start switch and engine shut-off switch... 10-9
Checking the fuel filter.............................................................. 10-9
Checking the fuel system for fuel leakage................................ 10-9
Changing the gear oil ............................................................... 10-9
Checking the gear oil level ..................................................... 10-11
Replacing the OCV filter......................................................... 10-11
Lubricating the outboard motor .............................................. 10-11
Checking the propeller ........................................................... 10-12
Checking the PTT fluid level................................................... 10-12
Checking the PTT operation................................................... 10-13
Adjusting the shift cable ......................................................... 10-13
Checking the spark plug......................................................... 10-13
Checking the timing belt ......................................................... 10-13
Replacing the timing belt ........................................................ 10-13
Checking the thermostat ........................................................ 10-13
Adjusting the throttle cable..................................................... 10-13
Checking the top cowling ....................................................... 10-13
Checking the valve clearance ................................................ 10-13
Checking the water pump....................................................... 10-13
10-1
MNT
Maintenance
Outline
To obtain long product life, Yamaha strongly recommends that the specified periodic checks and
maintenance be performed according to the maintenance interval charts.
If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and
quality. Any parts of inferior quality may cause a malfunction, and the resulting loss of control
could endanger the operator and passengers. Yamaha genuine parts and accessories are avail-
able from Yamaha dealers.
The service intervals provided in the maintenance interval charts are based upon typical operat-
ing conditions that include speed variations, sufficient time for engine warm up and cool-down,
medium to light load, and an average cruising speed in the 30004000 r/min range. If your normal
operating conditions are more intensive, more frequent servicing will be required, especially the
engine oil and gear oil changes. Examples of the intensive operation will be: wide-open-throttle,
trolling, or idling operation for extended periods of time, carrying heavy loads, and frequent start-
ing and stopping or shifting. In most cases, the frequent maintenance pays off in increased engine
life and greater owner satisfaction.
The maintenance cycle on these charts is based on usage of 100 hours per year and regular
flushing of the cooling water passages. Adjust the maintenance frequency when operating the
engine under adverse conditions, such as extended trolling.
Disassembly or repairs may be necessary depending on the outcome of maintenance checks.
Expendable or consumable parts and lubricants will lose their effectiveness over time and through
normal usage regardless of the warranty period.
When operating the outboard motor in salt water, or in muddy, turbid (cloudy), or acidic water,
flush the engine using clean water after each use.
Maintenance interval chart 1
Item Actions
Initial Every
See
page
20 hours
(3 months)
100 hours
(1 year)
300 hours
(3 years)
500 hours
(5 years)
Anodes (external) Check/Replace 9-28
Anodes (cylinder head
exhaust passage)
Check/Replace 7-56
Anodes (cylinder head,
cylinder block thermostat
portion, oil cooler cover,
exhaust guide)
Replace 7-56
7-63
7-84
9-17
Battery (electrolyte level,
terminal)
Check/Charge/Replace 10-3
Cooling water leakage Check/Replace 10-7
Cowling lock lever Check 10-13
Engine starting
condition/Noise
Check 10-4
Engine idle speed/Noise Check 10-7
Engine oil Replace 10-8
Engine oil filter Replace 10-9
Fuel filter (can be
disassembled)
Check/Replace 6-11
Fuel line (high pressure) Check/Replace 6-1
Fuel line (low pressure) Check/Replace 6-1
10-2
10
: Not applicable
Maintenance interval chart 2
Fuel pump Check/Replace 6-22
6-30
Fuel/Oil leakage Check 6-1
Gear oil Replace 10-9
Greasing points Lubricate 10-11
Impeller/Water pump
housing
Check/Replace 8-6
Impeller/Water pump
housing
Replace 8-6
OCV filter Replace 10-11
PTT unit Check 10-13
Propeller/Propeller
nut/Cotter pin
Check/Replace 8-3
Shift link/Shift cable Check/Adjust/Replace 3-8
10-5
Spark plugs Check/Replace 7-42
Ignition coils/Ignition coil
leads
Check/Replace 5-35
Pilot water Check 10-3
Throttle link/Throttle
cable
Check/Adjust/Replace 3-8
7-33
Thermostat Check/Replace 7-68
Timing belt Check/Replace 7-41
Valve clearance Check/Adjust 7-2
Water inlet Check 10-7
Engine start switch/
Engine shut-off switch
Check/Replace 10-4
Wiring harness
connections/
Lead coupler
connections
Check/Replace
Yamaha Meter/Gauge Check
Item Actions
Initial Every
See
page
20 hours
(3 months)
100 hours
(1 year)
300 hours
(3 years)
500 hours
(5 years)
Item Actions
Every See
page 1000 hours
Exhaust guide/Exhaust
manifold
Check/Replace 9-21
Timing belt Replace 7-10
Outline
10-3
MNT
Maintenance
Predelivery check
To make the delivery process smooth and
efficient, complete the predelivery checks as
explained in the following procedures.
Checking the battery
Battery electrolyte is dangerous; it con-
tains sulfuric acid, which is poisonous
and highly caustic. Always follow these
preventive measures:
Avoid bodily contact with electrolyte as
it can cause severe burns or permanent
eye injury.
Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
SKIN - Wash with water.
EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
Drink large quantities of water or milk
followed with milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
Batteries produce explosive, hydrogen
gas. Always follow these preventive mea-
sures:
Charge batteries in a well-ventilated
area.
Keep batteries away from fire, sparks, or
open flames (for example, welding
equipment and lighted cigarettes).
DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
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.
2. Check the specific gravity of the electro-
lyte. Fully charge the battery if below
specification.
TIP:
Batteries vary depending on the manufac-
turer. The procedures mentioned in this
manual may not always apply. Therefore,
see the instruction manual of the battery.
Disconnect the negative battery cable first,
and then disconnect the positive battery
cable.
For more information about the battery
requirements, see Extension length rec-
ommendation of battery cable (3-17)
Checking the cooling water pilot
hole
1. Start the engine, and then check that
cooling water is discharged from the
cooling water pilot hole.
Representative examples:
Recommended battery capacity:
CCA/SAE: 680.0 A
MCA/ABYC: 770.0 Ah
RC/SAE: 160 minutes
Electrolyte specific gravity:
1.280 at 20 C (68 F)
10-4
10
Checking the engine oil level
1. Place the outboard motor in an upright
position. NOTICE: If the outboard
motor is not level, the oil level indi-
cated on the oil dipstick may not be
correct.
2. Start the engine and warm it up for 510
minutes.
3. Stop the engine and leave it off for 510
minutes.
4. Remove the top cowling.
5. Remove the oil dipstick 1 and wipe it
clean.
6. Insert the oil dipstick 1 completely for a
correct measurement and remove it
again.
7. Check that the oil level indicated on the
oil dipstick 1 is between the upper mark
a and the lower mark b. If the engine oil
is not at the proper level, add or extract
engine oil.
Checking the engine start switch and
engine shut-off switch
1. Check that the engine starts when the
engine start switch is turned to START.
2. Check that the engine stops when the
engine start switch is turned to OFF.
3. Check that the engine stops when the
clip is removed from the engine shut-off
switch.
Checking the fuel system
1. Check that the fuel hoses are connected
securely. To check the fuel hose connec-
tions, see Fuel hose and blowby hose
(6-1). NOTICE: This outboard motor is
equipped with a 4-stroke engine.
Never use premixed fuel or 2-stroke
outboard motor oil.
Checking the gear oil level
Do not reuse a gasket, always replace it
with a new one.
1. Place the outboard motor in an upright
position.
2. Remove the check screw 1, and then
check the gear oil level.
1
a
b
OFF START
ON
Predelivery check
10-5
MNT
Maintenance
TIP:
If the oil is at the proper level, a small amount
of oil should flow out of the check hole.
3. Install a new gasket 2 and the check
screw 1, and then tighten the check
screw 1 to the specified torque.
Checking the gear shift and throttle
operation
1. Check that the gear shift operates
smoothly when the remote control lever
is moved from the N position to the F or
R position.
2. Check that the throttle operates smoothly
when the remote control lever is moved
from the F or R position to the fully open
position.
Checking the outboard motor
mounting height
1. Check that the anti-cavitation plate a is
aligned with the bottom b of the boat. If
the mounting height is too high, cavita-
tion will occur and propulsion will
decrease. Besides, the engine speed will
increase abnormally and cause the
engine to overheat. If the mounting
height is too low, water resistance will
increase, which will decrease engine effi-
ciency and performance.
TIP:
The appropriate mounting height depends on
the combination of the boat and outboard
motor. To determine the appropriate mount-
ing height, test run the outboard motor at dif-
ferent heights.
2. Check that the clamp brackets are
secured using the clamp bolts.
Checking the PTT system
1. Check that the outboard motor tilts up
and down smoothly when the PTT switch
is operated.
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
cables, hoses, or leads when the tilted-
up outboard motor is steered.
4. Check that the trim meter points down
when the outboard motor is fully tilted
down.
Checking the steering system
1. Check that the steering operates
smoothly.
2. Check that there is no interference with
cables, hoses, or leads when the out-
board motor is steered.
Checking the throttle cable and shift
cable
1. Move the remote control lever to the N
position.
Check screw 1: 9 Nm (0.9 kgfm, 6.6 ftlb)
1
2
b
a
10-6
10
2. Check that the accelerator lever a con-
tacts the stopper b.
3. Check that the pin c is aligned with the
alignment mark d on the shift bracket
1.
Test run
1. Start the engine, and then check that the
gear shift operates smoothly.
2. Warm up the engine, and then check the
engine idle speed.
3. Operate the boat at trolling speed.
4. Operate the outboard motor according to
the break-in procedure.
5. Check that the outboard motor does not
tilt up when the remote control lever is
moved to the R position and that water
does not flow in over the transom.
6. Check that the PTT operates smoothly
while the outboard motor is running.
TIP:
The test run is part of the break-in operation.
Break-in
Operate the engine under load (in gear with a
propeller installed) for 10 hours as follows:
1. For the 1st hour a of operation:
Operate the engine at varying speeds up
to 2000 r/min or approximately 1/2 throt-
tle.
2. For the 2nd hour b of operation:
Increase the engine speed until the boat
is on plane (but do not fully open the
throttle), and then back off on the throttle
while keeping the boat at a planing
speed.
3. For the remaining 8 hours c of opera-
tion:
Operate the engine at any engine speed.
However, do not operate the engine at
full throttle for more than 5 minutes at a
time.
4. After the 1st 10 hours of operation:
Operate the engine normally.
Hour
After test run
1. Check for water in the gear oil.
2. Check for fuel leakage in the cowling.
a b
a
c
d
1
0 1 2 10
a b c
Predelivery check
10-7
MNT
Maintenance
3. Flush the cooling water passages using
fresh water. NOTICE: When flushing
the cooling water passages, do not
start the engine. Otherwise, the water
pump could be damaged and the
engine could be severely damaged
due to overheating.
TIP:
When using the flushing device (flushing
hose joint adapter), flush the cooling water
passages without starting the engine.
General periodic maintenance
Checking the anode
Do not apply grease, oil, or paint to the
anodes.
1. Check the anodes. See Checking the
cylinder head anode (7-56), Checking
the cylinder block anode (7-84), Check-
ing the oil cooler anode (7-63), Check-
ing the exhaust guide anode (9-17), and
Checking the clamp bracket anode (9-
28).
Checking the battery
1. Check the battery. See Checking the
battery (10-3).
Checking the cooling water passage
1. Remove the water inlet covers 1 and
cover 2.
2. Check the water inlet covers 1, cover
2, and water inlets. Clean if clogged.
3. Install the water inlet covers 1 and cover
2, and then tighten the bolts 3 and 4 to
the specified torque.
4. Place the lower unit in water, and then
start the engine.
5. Check for water flow at the cooling water
pilot hole. If there is no water flow, check
the cooling water passages inside the
outboard motor.
Checking the engine idle speed
1. Start the engine and warm it up for 510
minutes.
2. Check the engine idle speed using the
Yamaha genuine tachometer (on-board
meter) or the YDIS. To connect and
operate the YDIS, see the YDIS (Ver.
1.33 or later) Instruction Manual.
1
1
3
Inlet cover bolt 3:
2 Nm (0.2 kgfm, 1.5 ftlb)
Cover bolt 4:
42 Nm (4.2 kgfm, 31.0 ftlb)
2
4
10-8
10
Changing the engine oil
The engine oil should be extracted using an
oil changer.
Change the engine oil after the first 20
hours of operation or 3 months, and every
100 hours or at 1-year intervals thereafter.
1. Place the outboard motor in an upright
position. NOTICE: If the outboard
motor is not level, the oil level indi-
cated on the oil dipstick may not be
correct.
2. Start the engine and warm it up for 510
minutes.
3. Stop the engine and leave it off for 510
minutes.
4. Remove the top cowling.
5. Remove the oil filler cap 1. Remove the
oil dipstick 2 and extract the engine oil
using the oil changer 3.
6. Fill the engine with the specified amount
of the recommended engine oil through
the oil filler hole. Install the oil filler cap 1
and oil dipstick 2. NOTICE: Do not
overfill the engine with engine oil.
Otherwise, the engine could be dam-
aged or oil could leak. If the engine oil
is above the upper level, extract the
excess engine oil until the oil is at the
proper level.
7. Leave the outboard motor off for 510
minutes.
8. Remove the oil dipstick 2 and wipe it
clean.
9. Insert the oil dipstick 2 completely for a
correct measurement and remove it
again.
10. Check that the oil level indicated on the
oil dipstick 2 is between the upper mark
a and the lower mark b.
1
3
2
Recommended engine oil:
YAMALUBE 4-M FC-W oil, 4-stroke
motor oil:
API: SE, SF, SG, SH, SJ, SL
SAE: 5W-30, 10W-30
Replacement engine oil quantity
(at periodic maintenance):
Without oil filter replacement:
6.4 L (6.76 US qt, 5.63 lmp qt)
2
a
b
Predelivery check / General periodic maintenance
10-9
MNT
Maintenance
11. Start the engine and check that the oil
pressure alert indicator does not come
on. Also, check that there is no oil leak-
age. NOTICE: If the oil pressure alert
indicator comes on or if there is oil
leakage, stop the engine and find the
cause. Continued operation with a
problem could cause severe engine
damage.
Checking the engine oil level
1. Check the engine oil level. See Check-
ing the engine oil level (10-4).
Replacing the oil filter
1. Extract the engine oil using an oil
changer. See steps 15 in Changing the
engine oil (10-8).
2. Place a rag under the oil filter, and then
remove the oil filter.
TIP:
Make sure to clean up any oil spills.
3. Install a new oil filter, and then tighten it
to the specified torque.
4. Fill the engine with the specified amount
of the recommended engine oil through
the oil filler hole.
5. Install the oil filler cap and oil dipstick,
and then start the engine and warm it up
for 510 minutes.
6. Stop the engine, and then leave it off for
510 minutes.
7. Check the oil level. If the oil level is low,
add engine oil up to the proper level.
Checking the engine start switch and
engine shut-off switch
1. Check the engine start switch and engine
shut-off switch. See Checking the
engine start switch and engine shut-off
switch (10-9).
Checking the fuel filter
1. Check the fuel filter. See Checking the
fuel filter assembly (6-11).
Checking the fuel system for fuel
leakage
1. Check the fuel joint and fuel hose con-
nections. See Fuel hose and blowby
hose (6-1).
Changing the gear oil
Never get under the lower unit while it is
tilted.
Oil filter wrench 1:
(commercially available)
1
1
Oil filter: 18 Nm (1.8 kgfm, 13.3 ftlb)
Recommended engine oil:
YAMALUBE 4-M FC-W oil, 4-stroke
motor oil:
API: SE, SF, SG, SH, SJ, SL
SAE: 5W-30, 10W-30
Replacement engine oil quantity
(at periodic maintenance):
With oil filter replacement:
6.7 L (7.08 US qt, 5.90 Imp qt)
10-10
10
Do not reuse a gasket, always replace it
with a new one.
1. Remove the water inlet covers 1.
2. Tilt the outboard motor so that the drain
screw is at the lowest point.
3. Place a drain pan 2 under the gear oil
drain hole.
4. Remove the drain screw 3 and gasket
4. NOTICE: If there is a significant
amount of metal particles on the mag-
netic drain screw 3, the lower unit
may have a problem.
5. Remove the check screw 5 and gasket
6 and let the oil drain completely.
NOTICE: After the gear oil has been
drained, check the used oil. If the oil is
milky, water is getting into the lower
case, which can cause gear damage.
TIP:
Remove all metal particles before installing
the magnetic drain screw.
6. Place the outboard motor in an upright
position.
7. Install the gear oil pump into the drain
hole, and then fill the lower unit slowly
with gear oil until oil flows out of the
check hole and no air bubbles are visible.
8. Install a new gasket 7 and the check
screw 5, and then tighten the check
screw 5 to the specified torque.
9. Remove the gear oil pump, install a new
gasket 8 and the drain screw 3, and
then tighten the drain screw 3 to the
specified torque.
1
1
3
5
6
4
2
Recommended gear oil:
YAMALUBE MARINE LOWER UNIT
GEAR LUBE HD, hypoid gear oil
API: GL-4, GL-5
SAE: 90
Oil quantity:
1.045 L

(1.10 US qt, 0.92 Imp qt)
Check screw 5: 9 Nm (0.9 kgfm, 6.6 ftlb)
5
7
General periodic maintenance
10-11
MNT
Maintenance
10. Install the water inlet covers 1, and then
tighten the bolt 9 to the specified torque.
Checking the gear oil level
1. Check the gear oil level. See Checking
the gear oil level (10-4).
Replacing the OCV filter
1. Remove the OCV assemblies.
2. Replace the OCV filter 1 of each OCV
assembly.
3. Install the OCV assemblies.
Lubricating the outboard motor
1. Apply water resistant grease to the spec-
ified areas.
Drain screw 3: 9 Nm (0.9 kgfm, 6.6 ftlb)
Inlet cover bolt 9:
2 Nm (0.2 kgfm, 1.5 ftlb)
3
8
1
1
9
1
10-12
10
2. Apply low temperature resistant grease
to the specified area.
3. Apply corrosion resistant grease to the
specified area.
Checking the propeller
1. Check the propeller. See Checking the
propeller (8-3).
Checking the PTT fluid level
Never get under the outboard motor while
it is tilted.
Do not reuse an O-ring, always replace it
with a new one.
1. Fully tilt the outboard motor up, and then
support it using the tilt support shaft 1.
2. Remove the reservoir cap 2 and O-ring
3, and then check the fluid level in the
reservoir. WARNING! Before removing
the reservoir cap, make sure that the
PTT rams are fully extended. Other-
wise, fluid could be expelled forcefully
from the unit due to internal pressure.
TIP:
If the fluid is at the proper level, a small
amount of fluid should flow out of the filler
hole when the reservoir cap is removed.
3. If the fluid is below the proper level, add
the recommended fluid.
4. Install a new O-ring and the reservoir cap
2, and then tighten the reservoir cap 2
to the specified torque.
Tilt support shaft 1: 6CB-43611-00
Recommended PTT fluid: ATF DEXRON II
Reservoir cap 2:
2 Nm (0.2 kgfm, 1.5 ftlb)
1
2
3
General periodic maintenance
10-13
MNT
Maintenance
Checking the PTT operation
1. Fully tilt the outboard motor up and down
a few times and check that the outboard
motor tilts up and down smoothly. Check
the PTT fluid level if the tilt operation is
not smooth.
2. Check the PTT unit for fluid leakage.
Adjusting the shift cable
1. Disconnect the shift cable, and then
adjust it. See Installing the shift cable
and throttle cable (3-8).
Checking the spark plug
1. Check the spark plugs. See Checking
the spark plug (7-42).
Checking the timing belt
1. Check the timing belt. See Checking the
timing belt and sprocket (7-41).
Replacing the timing belt
1. Replace the timing belt. See Replacing
the timing belt (7-10).
Checking the thermostat
1. Check the thermostat. See Checking the
thermostat (7-68).
Adjusting the throttle cable
1. Adjust the throttle cable. See Installing
the shift cable and throttle cable (3-8).
Checking the top cowling
1. Check the fitting by pushing the top cowl-
ing. Adjust if there is free play.
2. Loosen the nut 1.
3. Move the stopper 2 up or down slightly
to adjust its position.
TIP:
To loosen the fitting, move the stopper 2 in
direction a.
To tighten the fitting, move the stopper 2 in
direction b.
4. Tighten the nut 1.
5. Recheck the fitting. Replace the cowling
seal if the free play cannot be adjusted.
Checking the valve clearance
1. Check the valve clearance. See Check-
ing the valve clearance (7-2).
Checking the water pump
1. Check the water pump housing and
impeller. See Checking the water pump
and shift rod (8-6).
2
1
a
b
i-1
Index
A.
Abbreviation................................................0-5
Adjusting the forward gear shim (T1)
thickness.................................................8-40
Adjusting the reverse gear shim (T2)
thickness.................................................8-43
Adjusting the shift cable.......................... 10-13
Adjusting the throttle cable......................10-13
Adjusting the trim sensor cam...................9-29
Adjusting the valve clearance .....................7-4
After test run .............................................10-6
Assembling the cylinder block...................7-84
Assembling the cylinder head...................7-56
Assembling the drive shaft ........................8-18
Assembling the forward gear ....................8-20
Assembling the gear pump assembly.......9-45
Assembling the lower case .......................8-20
Assembling the oil pan
and exhaust manifold..............................9-22
Assembling the oil pump assembly...........7-63
Assembling the oil seal housing................8-20
Assembling the
propeller shaft assembly......................... 8-11
Assembling the
propeller shaft housing assembly ...........8-12
Assembling the PTT motor .......................9-40
Assembling the reverse gear ....................8-12
Assembling the shift bracket .......................9-4
Assembling the starter motor ....................5-58
Assembling the tilt ram..............................9-50
Assembling the trim ram...........................9-51
Assembling the upper case.......................9-17
Assembling the vapor separator ...............6-30
B.
Battery installation.....................................3-14
Battery requirement ....................................1-5
Bleeding the PTT unit ...............................9-53
Bottom cowling.........................5-7, 5-16, 9-11
Bracket unit ....................................... 1-4, 1-16
Bracket unit technical data........................1-14
Break-in.....................................................10-6
C.
Camshaft...................................................7-35
Canister.....................................................6-19
Changing the engine oil ............................ 10-8
Changing the gear oil ................................10-9
Charging system.........................................1-8
Charging unit and component ...................5-60
Checking the absorber valve ....................9-50
Checking the air pressure sensor .............5-38
Checking the air temperature sensor ....... 5-37
Checking the anode.................................. 10-7
Checking the APS .................................... 5-25
Checking the APS circuit .......................... 5-26
Checking the armature (PTT motor)......... 9-39
Checking the armature (starter motor) ..... 5-57
Checking the battery........................10-3, 10-7
Checking the brush................................... 9-39
Checking the brush holder and brush....... 5-58
Checking the cam position sensor............ 5-29
Checking the camshaft ............................. 7-41
Checking the canister ............................... 6-20
Checking the canister check valve ........... 6-20
Checking the check valve......................... 6-30
Checking the clamp bracket anode .......... 9-28
Checking the compression pressure .......... 7-1
Checking the connecting rod big
end side clearance ................................. 7-75
Checking the connecting rod small
end inside diameter and big
end inside diameter ................................ 7-75
Checking the cooling water passage........ 10-7
Checking the cooling water pilot hole....... 10-3
Checking the crankcase bolt .................... 7-76
Checking the crankpin oil clearance......... 7-76
Checking the crankshaft ........................... 7-75
Checking the crankshaft journal
oil clearance ........................................... 7-80
Checking the cylinder block anode........... 7-84
Checking the cylinder bore....................... 7-73
Checking the cylinder head ...................... 7-51
Checking the cylinder head anode ........... 7-56
Checking the cylinder head bolt ............... 7-52
Checking the dog clutch ........................... 8-11
Checking the drive shaft ........................... 8-18
Checking the electrical component........... 5-22
Checking the engine ECM circuit ............. 5-24
Checking the engine idle speed ............... 10-7
Checking the engine oil level ...........10-4, 10-9
Checking the engine shut-off switch......... 5-45
Checking the engine start switch.............. 5-52
Checking the engine start switch
and engine shut-off switch.............10-4, 10-9
Checking the engine
temperature sensor ................................ 5-40
Checking the ETV..................................... 6-17
Checking the ETV and TPS...................... 5-27
Checking the ETV and TPS circuit ........... 5-28
Checking the ETV relay............................ 5-28
Checking the exhaust guide anode .......... 9-17
Checking the filter..................................... 9-45
Checking the forward gear ....................... 8-18
Checking the fuel cup assembly............... 6-11
Checking the fuel filter .............................. 10-9
i-2
Index
Checking the fuel filter assembly ..............6-11
Checking the fuel filter element.................6-11
Checking the fuel injector..........................5-46
Checking the fuel rail ................................6-34
Checking the fuel system..........................10-4
Checking the
fuel system for fuel leakage ....................10-9
Checking the gear oil level ............ 10-4, 10-11
Checking the gear pump...........................9-44
Checking the gear pump housing .............9-45
Checking the gear shift
and throttle operation..............................10-5
Checking the high-pressure fuel pump .....6-30
Checking the high-pressure
fuel pump relay .......................................5-49
Checking the hydraulic pressure...............9-32
Checking the ignition coil ..........................5-35
Checking the ignition spark.......................5-35
Checking the intake manifold....................6-13
Checking the knock sensor.......................5-44
Checking the lighting coil ..........................5-60
Checking the lower case...........................8-18
Checking the lower unit for air leakage.....8-24
Checking the low-pressure fuel pump.......6-22
Checking the low-pressure fuel
pump and high-pressure fuel pump ........5-48
Checking the magnet switch.....................5-55
Checking the main relay ...........................5-23
Checking the neutral switch......................5-43
Checking the OCV ....................................5-32
Checking the oil cooler..............................7-63
Checking the oil cooler anode...................7-63
Checking the oil pan
and exhaust manifold..............................9-21
Checking the oil pressure ...........................7-1
Checking the oil pressure sensor..............5-34
Checking the oil pump assembly ..............7-63
Checking the oil strainer ...........................9-21
Checking the outboard
motor mounting height ............................ 10-5
Checking the pinion ..................................8-18
Checking the piston diameter ...................7-73
Checking the
piston pin boss inside diameter...............7-74
Checking the piston pin diameter..............7-75
Checking the piston ring ...........................7-73
Checking the piston ring end gap .............7-74
Checking the piston ring groove ...............7-74
Checking the
piston ring side clearance .......................7-74
Checking the pressure regulator.................6-7
Checking the primer pump........................6-22
Checking the propeller .................... 8-3, 10-12
Checking the propeller shaft .....................8-11
Checking the propeller shaft housing ....... 8-11
Checking the PTT fluid level ................... 10-12
Checking the PTT operation................... 10-13
Checking the PTT relay ............................ 5-65
Checking the PTT switch.......................... 5-66
Checking the PTT system ........................ 10-5
Checking the pulser coil ........................... 5-36
Checking the pulser coil air gap ................. 7-1
Checking the Rectifier Regulator .............. 5-61
Checking the reservoir.............................. 9-40
Checking the reverse gear ....................... 8-11
Checking the shift cut switch .................... 5-42
Checking the spark plug................7-42, 10-13
Checking the speed sensor (optional) ...... 5-64
Checking the starter motor operation ....... 5-55
Checking the starter motor pinion............. 5-55
Checking the starter relay......................... 5-51
Checking the steering system .................. 10-5
Checking the thermostat................7-68, 10-13
Checking the thermoswitch ...................... 5-41
Checking the
throttle cable and shift cable................... 10-5
Checking the
tilt cylinder and trim cylinder ................... 9-50
Checking the timing belt ......................... 10-13
Checking the timing belt and sprocket...... 7-41
Checking the top cowling........................ 10-13
Checking the trim sensor.......................... 5-67
Checking the valve ................................... 7-52
Checking the valve clearance..........7-2, 10-13
Checking the valve guide ......................... 7-53
Checking the valve lifter ........................... 7-41
Checking the valve seat ........................... 7-54
Checking the valve spring ........................ 7-52
Checking the vapor separator .................. 6-30
Checking the vapor shut-off valve ............ 5-50
Checking the water detection switch ........ 5-45
Checking the
water pressure sensor (optional) ............ 5-63
Checking the water pump....................... 10-13
Checking the water pump and shift rod...... 8-6
Circuit diagram ......................................... 5-18
Clamp bracket ............................................ 3-3
Clamp bracket and swivel bracket ............ 9-26
Command Link
Multifunction Meter sensor ..................... 5-63
Connecting the communication
cable to the outboard motor...................... 4-5
Cooling diagram ....................................... 2-29
Cooling system......................................... 2-29
Cooling water hose..................................... 6-4
Crankcase ................................................ 2-23
Crankcase assembly ................................ 1-12
Crankpin bearing selection table .............. 7-79
i-3
Index
Crankshaft.................................................2-24
Crankshaft journal bearing
selection table......................................... 7-83
Crate top cover pictograph description .......3-4
Cylinder block ...........................................7-70
Cylinder block sensor and switch..............7-66
Cylinder head............................................7-49
Cylinder head assembly............................ 1-11
D.
Dimension...................................................3-2
Dimension and weight.................................1-3
Disassembling the cylinder block..............7-72
Disassembling the cylinder head ..............7-51
Disassembling the drive shaft ...................8-16
Disassembling the forward gear ...............8-17
Disassembling the
gear pump assembly...............................9-44
Disassembling the lower case ..................8-17
Disassembling the oil pan
and exhaust manifold..............................9-21
Disassembling the oil pump assembly......7-62
Disassembling the oil seal housing...........8-16
Disassembling the
propeller shaft assembly......................... 8-10
Disassembling the
propeller shaft housing assembly ...........8-10
Disassembling the PTT motor...................9-38
Disassembling the reverse gear ...............8-10
Disassembling the shift bracket ..................9-3
Disassembling the starter motor ...............5-56
Disassembling the tilt ram.........................9-49
Disassembling the upper case..................9-17
Disassembling the vapor separator ..........6-29
Disassembly and assembly ........................0-3
Disconnecting the quick connector .............6-6
Double taper roller bearing .......................2-37
Draining the fuel ........................................6-25
Drive shaft and lower case........................8-14
E.
ECM coupler layout...................................5-20
Electric shock..............................................0-1
Electrical component...................................5-1
Electrical system technical data..................1-5
Electronic control system............................2-1
Electronic fuel injection control ...................2-4
Engine control unit and component ..........5-23
Engine ECM..............................................7-34
Engine ECM component .............................2-2
Engine speed control ................................2-16
Engine speed control system......................1-7
ETV control ...............................................2-18
Extension length
recommendation of battery cable ........... 3-17
Exterior
VF200LA, VF225LA, VF250LA.............. 3-2
F.
Fail-safe control ........................................ 2-20
Feature ....................................................... 4-1
Flywheel magnet ........................................ 7-6
Forward gear shim (T1) selection table.... 8-42
Front ..................................................5-5, 5-14
Fuel and oil requirement ............................. 1-4
Fuel control unit and component .............. 5-45
Fuel diagram............................................. 2-25
Fuel filter assembly..................................... 6-9
Fuel hose and blowby hose........................ 6-1
Fuel injection control system...................... 1-6
Fuel injector .............................................. 6-33
Fuel system................... 1-10, 1-14, 2-25, 6-6
Fuel system technical data....................... 1-10
Function...................................................... 4-2
Fuse box................................................... 7-30
Fuse holder................................................. 5-3
G.
Gauge sensor ............................................. 1-9
General feature........................................... 1-1
General periodic maintenance.................. 10-7
General tightening torque......................... 1-17
H.
Handling of gas torch.................................. 0-2
Handling of gasoline................................... 0-1
Handling of sealant ..................................... 0-2
Hardware requirement ................................ 4-1
Hose routing ............................................... 6-1
Hot part ....................................................... 0-1
How to use this manual .............................. 0-4
I.
Ignition timing control.................................. 2-7
Ignition timing control system..................... 1-5
Ignition unit and component ..................... 5-35
Important information.................................. 1-5
Installing the battery cable........................ 3-10
Installing the camshaft,
driven sprocket, and timing belt .............. 7-43
Installing the clamp bracket ...................... 9-28
Installing the Command Link
Multifunction Meter harness (optional) ... 3-11
Installing the cowling lock lever ................ 9-10
Installing the cylinder head....................... 7-57
i-4
Index
Installing the drive shaft ............................ 8-21
Installing the flushing hose..........................9-9
Installing the flywheel magnet .....................7-7
Installing the forward gear......................... 8-21
Installing the fuel injector ..........................6-34
Installing the intake manifold.....................6-13
Installing the knock sensor........................7-69
Installing the lower unit .............................8-25
Installing the oil cooler ..............................7-64
Installing the oil filter bracket.....................7-64
Installing the oil pump assembly ...............7-64
Installing the power unit ............................ 7-19
Installing the
propeller shaft housing assembly ...........8-22
Installing the PTT motor............................ 9-41
Installing the PTT switch...........................9-10
Installing the PTT unit ...............................9-35
Installing the pulley bracket.......................7-69
Installing the reservoir...............................9-40
Installing the rigging grommet ...................3-14
Installing the
shift cable and throttle cable .....................3-8
Installing the shift rod................................8-23
Installing the shift rod and shift bracket.......9-4
Installing the speed sensor (optional) .......3-12
Installing the starter motor ........................5-60
Installing the steering arm......................... 9-24
Installing the thermostat............................7-68
Installing the
throttle body and surge tank ...................6-17
Installing the tilt ram..................................9-53
Installing the trim ram................................9-52
Installing the upper case...........................9-14
Installing the vapor separator....................6-25
Installing the
water pressure sensor (optional) ............ 3-11
Installing the water pump..........................8-23
Installing the wiring harness............ 3-10, 7-26
Intake and exhaust diagram......................2-31
Intake and exhaust system.......................2-31
Intake manifold..........................................6-12
J.
Junction box..............................................7-31
K.
Knock control ............................................2-15
L.
Lower unit ........................ 1-4, 1-16, 2-37, 8-1
Lower unit assembly .................................1-13
Lower unit technical data ..........................1-13
Low-pressure fuel pump........................... 6-21
Lubricant, sealant,
and thread locking agent .......................... 0-7
Lubricating the outboard motor............... 10-11
Lubrication diagram.................................. 2-28
Lubrication system.................................... 2-28
M.
Maintenance interval chart 1 .................... 10-1
Maintenance interval chart 2 .................... 10-2
Manual format............................................. 0-4
Measuring the forward gear backlash ...... 8-40
Measuring the forward gear backlash
and reverse gear backlash
before disassembly................................. 8-30
Measuring the fuel pressure....................... 6-7
Measuring the peak voltage ..................... 5-22
Measuring the reverse gear backlash ...... 8-43
Model data.................................................. 1-3
Model designation ...................................... 1-2
Model feature.............................................. 1-1
Mufflerless upper case ............................. 2-32
N.
Non-reusable part ....................................... 0-3
O.
Oil cooler and oil pump assembly............. 7-59
Oil pan and exhaust manifold................... 9-19
Outboard motor installation ........................ 3-1
Outboard motor mounting........................... 3-6
Outboard motor troubleshooting................. 4-6
Outline ...................................................... 10-1
P.
Part, lubricant, and sealant ......................... 0-2
Performance............................................... 1-3
Pinion shim (T3) selection table ............... 8-36
Port ......................................................5-1, 5-8
Power unit................................ 1-3, 1-10, 1-15
Power unit (check and adjustment) ............ 7-1
Power unit assembly ................................ 7-15
Power unit system.................................... 2-21
Power unit technical data ......................... 1-10
Predelivery check ..................................... 10-3
Preface ....................................................... 1-5
Propeller ..................................................... 0-1
Propeller selection.................................... 3-18
Propeller shaft bearing ............................. 2-37
Propeller shaft housing............................... 8-7
Propeller shaft shim (T4)
selection table......................................... 8-39
i-5
Index
Propeller size ............................................3-18
Propeller spacer........................................2-39
PTT cylinder..............................................9-47
PTT electrical system................................5-65
PTT fluid requirement .................................1-5
PTT gear pump.........................................9-42
PTT motor .................................................9-36
PTT switch and cowling lock lever ..............9-6
PTT system....................................... 1-8, 1-14
PTT unit .................................1-17, 2-33, 9-31
R.
Rear .................................................. 5-4, 5-13
Reducing the fuel pressure.........................6-6
Refacing the valve seat.............................7-55
Remote control box
and switch panel installation ...................3-14
Removing the clamp bracket ....................9-28
Removing the cowling lock lever.................9-8
Removing the cylinder head .....................7-51
Removing the drive shaft ..........................8-16
Removing the flushing hose........................9-8
Removing the flywheel magnet ...................7-7
Removing the forward gear.......................8-16
Removing the fuel injector ........................6-34
Removing the lower unit .............................8-3
Removing the oil cooler ............................ 7-62
Removing the oil filter bracket...................7-62
Removing the oil pump assembly.............7-62
Removing the power unit ..........................7-17
Removing the
propeller shaft housing assembly .............8-9
Removing the PTT motor..........................9-38
Removing the PTT switch...........................9-8
Removing the PTT unit .............................9-32
Removing the reservoir.............................9-38
Removing the shift rod and shift bracket.....9-3
Removing the starter motor ......................5-55
Removing the steering arm.......................9-24
Removing the thermostat ..........................7-68
Removing the
throttle body and surge tank ...................6-16
Removing the tilt ram and trim ram...........9-49
Removing the timing belt,
driven sprocket, and camshaft ................7-38
Removing the upper case......................... 9-14
Removing the vapor separator..................6-25
Removing the water pump and shift rod .....8-6
Removing the wiring harness....................7-24
Replacing the OCV filter .........................10-11
Replacing the oil filter................................10-9
Replacing the timing belt............... 7-10, 10-13
Replacing the valve guide......................... 7-53
Reverse gear shim (T2) selection chart.... 8-45
Rigging grommet description...................... 3-8
Rigging grommet mounting ........................ 3-8
Rigging information................................... 1-14
Rigging recommendation.......................... 3-17
Rotating part ............................................... 0-1
S.
Safety while working................................... 0-1
Selecting the crankpin bearing ................. 7-77
Selecting the
crankshaft journal bearing ...................... 7-81
Selecting the pinion shim (T3) .................. 8-34
Selecting the propeller shaft shim (T4) ..... 8-37
Selection................................................... 3-18
Self-protection ............................................ 0-2
Sensor, switch, and actuator ...................... 2-3
Serial number ............................................. 1-2
Shift rod and shift bracket ........................... 9-1
Shim location............................................ 8-33
Shimless valve lifter .................................. 2-22
Shimming.........................................8-27, 8-33
Shimming check sheet ............................. 8-28
Shimming workflow................................... 8-27
Single outboard motor application............ 3-15
Skeg design.............................................. 2-39
Sleeveless cylinder................................... 2-24
Special service tool..............................0-3, 0-8
Specified tightening torque....................... 1-14
Starboard...........................................5-2, 5-10
Starter motor....................................5-53, 7-33
Starting system........................................... 1-9
Starting unit and component..................... 5-51
Stationary condition.................................. 2-36
Steering arm............................................. 9-23
Symbol........................................................ 0-7
System diagram........................................ 3-15
T.
Test run .................................................... 10-6
Throttle body............................................. 6-14
Thrust power train..................................... 2-38
Tightening torque........................................ 0-3
Timing belt .................................................. 7-9
Top ....................................................5-6, 5-15
Trim ram retraction function...................... 2-34
Trim-down and tilt-down function.............. 2-35
Trim-up and tilt-up function....................... 2-33
Trouble code and checking step................. 4-9
Troubleshooting procedure......................... 4-6
Troubleshooting the lower unit ................. 4-27
Troubleshooting the power unit
(trouble code not detected)..................... 4-19
i-6
Index
Troubleshooting the power unit using
the diagnostic flash indicator...................4-18
Troubleshooting the
power unit using the YDIS ........................4-6
Troubleshooting the PTT unit....................4-26
U.
Uncrating procedure ...................................3-5
Upper case................................................9-16
Upper case and mount..............................9-12
Using the digital tester ..............................5-23
Using the YDIS ......................................... 5-22
V.
Vapor gas hose...........................................6-2
Vapor gas treatment .................................2-27
Vapor separator ........................................6-23
Vapor separator
and high-pressure fuel pump ..................6-27
VCT control .................................................2-9
VCT system ................................................1-8
Ventilation ...................................................0-1
W.
Water pump and shift rod............................8-4
When the outboard motor
hits something in the water .....................2-36
Wiring harness..........................................7-23
Wiring harness routing................................5-8
Working with crane .....................................0-2
Y.
YDIS............................................................4-1
YDIS kit .......................................................4-4
A
Appendix
Wiring diagram............................................................................ A-2
How to use the wiring diagram................................................... A-2
Engine control unit...................................................................... A-3
Fuel unit...................................................................................... A-5
Ignition unit ................................................................................. A-7
Charging unit and starting unit ................................................... A-9
PTT unit .................................................................................... A-11
MEMO
A-1
A
Wiring diagram
How to use the wiring diagram
Composition of the wiring diagrams
The wiring diagram consists of five categories. The engine control unit, fuel unit, ignition unit, charg-
ing unit and starting unit, and PTT unit.
Legend symbols in the wiring diagrams
1Double colors wire
2No wire connector
3A wire is not included in the selected wiring unit.
4Alert buzzer
5Optional parts
Color Code
1 2 3 4 5
B : Black
B/Br : Black/Brown
B/G : Black/Green
B/L : Black/Blue
B/O : Black/Orange
B/W : Black/White
B/Y : Black/Yellow
Br : Brown
G : Green
G/B : Green/Black
G/R : Green/Red
G/W : Green/White
L : Blue
L/B : Blue/Black
L/G : Blue/Green
L/W : Blue/White
L/Y : Blue/Yellow
Lg : Light green
O : Orange
P : Pink
P/B : Pink/Black
P/G : Pink/Green
P/W : Pink/White
Pu : Purple
Pu/B : Purple/Black
Pu/G : Purple/Green
Pu/L : Purple/Blue
Pu/R : Purple/Red
Pu/W: Purple/White
Pu/Y : Purple/Yellow
R : Red
R/G : Red/Green
R/Y : Red/Yellow
Sb : Sky blue
W : White
W/B : White/Black
W/G : White/Green
W/L : White/Blue
W/R : White/Red
Y : Yellow
Y/G : Yellow/Green
A-2
Engine control unit
aFuse (30A) (engine start switch)
bFuse (10A) (ETV)
cFuse (30A) (ignition coil, VCT, fuel injector, and engine ECM)
dFuse (20A) (PTT switch)
eFuse (60A) (battery)
fFuse (15A) (high-pressure fuel pump)
gMain relay
hStarter relay
kHigh-pressure fuel pump relay
mETV relay
nFuse (10A) (low-pressure fuel pump)
pCondenser (connect to the air pressure sensor and oil pressure sensor)
rCondenser (connect to the cam position sensor) PORT EX
sCondenser (connect to the cam position sensor) STBD IN, PORT IN
To remote control
To gauge
To trim meter
To YDIS
To diagnostic test lead
To Command Link Multifunction Meter
A-3
A-4
R
27
28
29
30
31
32
33
34
35
36
37
38
39
41
42
43
45
48
51
52
53
54
55
56
58
59
60
61
62
63
64
65
66
67
70
71
72
73
74
75
4
6
7
8
9
10
11
12
14
15
19
20
21
22
24
25
26
B
B
B
WPYR
B
r
RBB
R
G
B
r
124
1
0
1
1
1
7
1
8
1
9
2
0
2
1
2
2
2
3




5
1
2
1


12
11
10
9
8
7
6
5
4
3
2
1
7
8
9
10
11
13
14
15
16
23
24
24
23
22
21
14
13
12
11
10
9
8
7
6
5
4
3
2
1
10
23
1
11
6
14
1
7
a b
c d
e
g
h
k
f
m
n
Battery
1 8 14 20
7 13 19 26
53 62 70 78
61 69 77 86
27 34 40 46
33 39 45 52
B
W
R
W
Y
G
P
Br
B
YRR
W B
r
BB
R
G
B
Y

Br Y W R B
OFF
ON
START
W B
SET
PULL
BZ
r
p
s
1
1
2
1
3
1
2
4
1
2
1
3
1
2
4
1
2
Joint coupler 1
Joint coupler 3
Engine ECM
Engine control unit
ETV
(TPS)
APS
Water detection
switch
Neutral
switch
Alert indicator
coupler
Air temperature
sensor
Engine
temperature sensor
Shift cut switch Trim sensor
Knock
sensor
Joint coupler 2
Fuse box
Vapor shut-off
valve
Cam position
sensor
(PORT IN)
Cam position
sensor
(PORT EX)
Cam position
sensor
(STBD IN)
Oil pressure
sensor
Thermo-
switch
(PORT)
Thermo-
switch
(STBD) Pulser coil
Air pressure
sensor
OCV
(STBD)
OCV
(PORT)
R/Y
G/R
G/B
P/W
P/W
B
/
Y
L/B
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
B
B
B
B
B
B
B
B
B
B
B
B
B
B
O
B
B
B
/
Y
B
W
/
B
R
/
Y
R
/
Y
W
/
L
P
/
G
W
/
G
R
/
Y
R
/
Y
B
B
B B
B
W
/
R
B
P
/
W
L
/
W
R
/
Y
BO
B P B
B
P
P
u
R
/
Y
R
/
Y
R
/
Y
W
/
B
G
/
B L
/
G
P
/
B
P
/
B
L
/
Y
L
/
W
W/B
Y/G
L/W
W/L
W/G
L/Y
L/G
W/R
B/Y
B/Y
R/Y
R/Y
P/G
P/W
L/B
P/W
P/W
Y/G
Y
/
G
Y
/
G
R
/
Y
R
/
Y
R
/
Y
R
/
Y
R
/
Y
R
/
Y
R
/
G
R
/
G
P/W
P/B
L/W
R/G
G/R
R/G
G/B
G/B
W/B
P
/
W
P
u
O
P/G
B
O
O
O
B
L
B
W
L
O
P
P
O
O
O
O
O
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
P
PB
B B
B
B
G
G
Y
B
B
P
P
B
B
L
O
P
P
G
B
B
B
B
B
B
W
Pu
Pu
P
B
B
O
O
O
W
L
P P
Engine start switch

Speed
sensor
(LAN)
Water
pressure
sensor
(LAN)

A-5
Fuel unit
aFuse (30A) (engine start switch)
bFuse (10A) (ETV)
cFuse (30A) (ignition coil, VCT, fuel injector, and engine ECM)
dFuse (20A) (PTT switch)
eFuse (60A) (battery)
fFuse (15A) (high-pressure fuel pump)
gMain relay
hStarter relay
kHigh-pressure fuel pump relay
mETV relay
nFuse (10A) (low-pressure fuel pump)
pCondenser (connect to the air pressure sensor)
rCondenser (connect to the cam position sensor) PORT EX
sCondenser (connect to the cam position sensor) STBD IN, PORT IN
To remote control
To gauge
A-6
157
1
2
12
11
10
9
8
7
6
5
4
3
2
1
1
12
7
11
15
16
23
24
13 1
24 12
13 1
2412
24
21
20
19
18
17
16
15
14
12
11
10
9
8
3
2
124
1
0
1
1
1
7
1
8
1
9
2
0
2
1
2
2
2
3
1
Br Y W R B
OFF
ON
START
W B
SET
PULL
BZ
9
10
11
12
14
20
22
24
25
26
28
29
30
31
32
33
34
35
38
39
41
43
45
48
52
54
55
56
58
59
60
61
63
64
70
71
72
73
74
75
78
79
80
81
82
83
84
a b
c d
e
g
h
k
f
m
n
10
23
1
11
6
14
1
7
P/W
P/W
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
G/B
G/R
B
O
O
O
P
P
B
B
B
B
B
B
B
B
B
B
B
O
O
B
B
B
B
B
B
B
B
B
B
B
B
Y
/
G
B
r
RB
B
B
Y
/
G
R
/
Y
R
/
Y
R
/
Y
R
/
Y
R
/
Y
R
/
Y
R
/
Y
R
/
G
R
/
GR
R
/
Y
B
W
PYG
B
r
RR
R
W
Y
G
P
Br
B
B
W
YRR
W B
r
BB
R
G
B
Y
G/B
B
G/R
G/B
R/G
W
B
B
B
B
G
B
P
R/G
Y/G
L/W
Pu/B
Pu/R
Pu/Y
Pu/G
Pu/L
Pu/W
O
O
O
O
B
B
B
B
B
B
Y
B
P
P
P/W
P/W
P/G
R/Y
R/Y
B/Y
W/R
Y/G
L/W
W/L
W/G
W/B
P
/
G
B R
/
Y
B
W
/
G
R
/
Y
R
/
Y
BW
/
R
R
/
Y
P
u
/
R
R
/
Y
P
u
/
Y
R
/
Y
P
u
/
L
R
/
Y
P
u
/
B
R
/
Y
P
u
/
G
R
/
Y
BB
/
Y
BL
/
W
G
/
B
R
/
Y
L
/
W
R
/
Y
BR
/
Y
P
u
/
W
B
B
W
/
B
R
/
Y
BO
P/G
B
O
B W
/
L
R
/
Y
B
High-pressure
fuel pump
Fuel
injector
#1
Fuel
injector
#3
Fuel
injector
#5
Fuel
injector
#2
Fuel
injector
#4
Fuel
injector
#6
Pulser coil
Cam position
sensor
(PORT IN)
Cam position
sensor
(STBD IN)
Cam position
sensor
(PORT EX)
Air pressure
sensor
Engine temperature
sensor
Water detection
switch
Vapor shut-off
valve
Low-pressure
fuel pump
Fuse box
Battery

Engine ECM
Fuel unit
p
r
s
Engine start switch
ETV (TPS)
APS

Joint coupler 1
Joint coupler 3
Joint coupler 2
1 8 14 20
7 13 19 26
53 62 70 78
61 69 77 86
27 34 40 46
33 39 45 52
A-7
Ignition unit
aFuse (30A) (engine start switch)
bFuse (10A) (ETV)
cFuse (30A) (ignition coil, VCT, fuel injector, and engine ECM)
dFuse (20A) (PTT switch)
eFuse (60A) (battery)
fFuse (15A) (high-pressure fuel pump)
gMain relay
hStarter relay
kHigh-pressure fuel pump relay
mETV relay
nFuse (10A) (low-pressure fuel pump)
pCondenser (connect to the cam position sensor) PORT EX
rCondenser (connect to the cam position sensor) STBD IN, PORT IN
sCondenser (connect to the oil pressure sensor)
To remote control
To gauge
A-8
r
p
s
B
W
R
W
Y
G
P
Br
B
YRR
W B
r
BB
R
G
B
Y
Br Y W R B
OFF
ON
START
W B
SET
PULL
BZ
12
11
10
9
8
7
6
5
3
2
1
1
2
3
4
5
6
7
11
15
16
17
18
19
20
21
22
23
24
21
14
12
11
10
9
8
7
6
5
4
3
2
27
31
33
42
43
45
52
4
9
10
11
12
14
19
20
21
24
25
26
55
59
60
61
63
64
66
67
68
69
70
71
72
73
74
75
76
77
85
86
12 24
1 13
1
12
12 24
1 13
10
23
1
11
6
14
1
7
53 62 70 78
61 69 77 86
27 34 40 46
33 39 45 52
1 8 14 20
7 13 19 26
124
1
0
1
1
1
7
1
8
1
9
2
0
2
1
2
2
2
3
1 5
1
2
Thermo switch
(PORT)
Thermo switch
(STBD)
B
B
B
B
B
B
B
B
B
Y
G
G
P
P
O
W
R/G
R/G
P/W
B/W
B/Y
B/G
B/L
B/Br
B
/
B
r
Y/G
P/W
P/G
P
/
W
P
/
B
P
/
B
R/Y
R/Y
B/Y
B/Y
B
G
L
/
Y
BB
/
Y
BB
/
Y
B R
/
Y
B
/
W
B R
/
Y
W
/
L
B R
/
Y
W
/
G
BR
/
Y
W
/
B
B




R
/
Y
P
/
W
P
/
G
BB O
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
B
B
B
B
B
B
B
B
B
B
B
R
/
Y
R
/
Y
R
/
Y
R
/
Y
R
/
Y
R
/
Y
R
/
G
Y
/
G
Y
/
G
R
/
G BR R
B
r
R P BYG
B
r
W
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
O
O
O
B
/
L
B R
/
Y
B
/
Y
B R
/
Y
B
/
O
B R
/
Y
B R
/
Y
B
/
G
W/R
B
PBPB
W
/
R
W/L
W/G
W/B
Y/G
L/Y
P/B
B/O
B R
B
B
Engine ECM
Pulser coil
Engine
temperature
sensor
Air
tempeature
sensor
Knock
sensor
Cam position
sensor
(STBD IN)
Cam position
sensor
(PORT IN)
Cam position
sensor
(PORT EX)
Oil
Pressure
sensor
Ignition
coil #4
Ignition
coil #1
Ignition
coil #3
Ignition
coil #5
Ignition
coil #6
Ignition
coil #2
Shift cut
switch
Joint coupler 3
Joint coupler 2
Joint coupler 1
Fuse box
Engine start switch
Alert indicator coupler
Battery

Ignition unit
a b
c d
e
g
h
k
f
m
n
A-9
Charging unit and starting unit
aFuse (30A) (engine start switch)
bFuse (10A) (ETV)
cFuse (30A) (ignition coil, VCT, fuel injector, and engine ECM)
dFuse (20A) (PTT switch)
eFuse (60A) (battery)
fFuse (15A) (high-pressure fuel pump)
gMain relay
hStarter relay
kHigh-pressure fuel pump relay
mETV relay
nFuse (10A) (low-pressure fuel pump)
To remote control
To gauge
A-10

B
W
R
W
Y
G
P
Br
B
YRR
W B
r
BB
R
G
B
Y

Br Y W R B
OFF
ON
START
W B
SET
PULL
BZ
1
1
1
2
1
4
2
112356789
1
0
1
1
1
2
55
59
60
61
63
64
70
71
72
73
74
75
31
33
45
52
9
14
20
7
1
1
1
5
2
3
2
4
2
13
1
24
12
13
1
24
1 12
12
10
23
1
11
6
14
1
7
1 8 14 20
7 13 19 26
53 62 70 78
61 69 77 86
27 34 40 46
33 39 45 52
R
B
B
B
RR BB
B
r
B
r
R
Y
/
G
R
/
Y
R
/
Y
R
/
Y
R
/
Y
R
/
G
R
/
G
Y
/
G
W
G
/
W
G
/
W
G
/
W
B
BB
PYRG
B
r
G
G
G
G
GGR
G/W
G/W
G/W
W
B
B
B
B
B
B
P
G
Y/G
R/G
R/G
B
O
R/Y
R/Y
B
Y
Y/G
BBB BBBBBBBBBBBB O R
/
Y
R
/
Y
R
/
Y
R
/
Y
124
1
0
1
1
1
7
1
8
2
1
2
2
2
3
1 59
1
2
a b
c d
e
g
h
k
f
m
n
Joint coupler 3 Joint coupler 2 Joint coupler 1
Starter motor
Rectifier Regulator
Battery
Stator assembly
Fuse box
Engine start switch
Charging unit and starting unit
Engine ECM
A-11
PTT unit
aFuse (30A) (engine start switch)
bFuse (10A) (ETV)
cFuse (30A) (ignition coil, VCT, fuel injector, and engine ECM)
dFuse (20A) (PTT switch)
eFuse (60A) (battery)
fFuse (15A) (high-pressure fuel pump)
gMain relay
hStarter relay
kHigh-pressure fuel pump relay
mETV relay
nFuse (10A) (low-pressure fuel pump)
pDiode
To remote control
To gauge
To trim meter
A-12

p

B
W
R
W
Y
G
P
Br
B
YRR
W B
r
BB
Br Y W R B
OFF
ON
START
W B
SET
PULL
BZ
R
G
B
Y

55
59
60
61
63
64
66
67
70
71
72
73
74
75
31
33
45
52
8
9
14
20
2
1
1
1
2
1
4
2
112356789
1
0
1
1
1
2 7
1
1
1
5
2
3
2
4
13
1
24
12
13
1
24
1 12
12
10
23
1
11
6
14
1
7
1 8 14 20
7 13 19 26
53 62 70 78
61 69 77 86
27 34 40 46
33 39 45 52
R
B
B
B
RRR BB
B
r
B
r
Y
/
G
R
/
Y
R
/
Y
R
/
Y
R
/
Y
R
/
G
R
/
G
Y
/
G
W
B
B
B
B/W
B
R
PYRG
B
r
S
b
L
g
L
g
S
b
S
b
L
g
S
b
L
g
W
B
B
B
B
B
B
P
G
Y/G
P
/
B
P
/
B
R/G
R/G
B
O
R/Y
R/Y
B
P
PPPP B
Y
Y/G
B BBB BBBBBBBBBBBB
O R
/
Y
R
/
Y
R
/
Y
R
/
Y
R
S
b
L
g
P
/
W
P/B
P/W
59
1
2
1245
1
0
1
1
1
7
1
8
2
1
2
2
2
3
1
a b
c d
e
g
h
k
f
m
n
a b
c d
e
g
h
k
f
n
Engine ECM
Starter motor
Battery
PTT relay
PTT motor
PTT switch
Alert indicator
coupler Trim sensor
Fuse box
Engine start switch
PTT unit
Joint coupler 3 Joint coupler 2 Joint coupler 1
YAMAHA MOTOR CORPORATION, U.S.A.
Printed in U.S.A.
Nov. 2009 ** 1 CR
(E_2)