6P2 28197 3H 11 PDF

F250A
FL250A
SERVICE MANUAL
6P2-28197-3H-11
NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
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.
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!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
F250A, FL250A
SERVICE MANUAL
2013 by Yamaha Motor Co., Ltd.
3rd Edition, January 2013
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in the Netherlands
Contents
General information
Specification
Periodic check and adjustment
Fuel system
Power unit
Lower unit
Bracket unit
GEN
INFO
SPEC
CHK
ADJ
FUEL
POWR
LOWR
BRKT
Electrical system
Troubleshooting
Index
ELEC
TRBL
SHTG
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
How to use this manual ................................................................................. 1-1
Manual format............................................................................................ 1-1
Symbol....................................................................................................... 1-2
Abbreviation............................................................................................... 1-3
Safety while working......................................................................................1-4
Fire prevention........................................................................................... 1-4
Ventilation..................................................................................................1-4
Self-protection ........................................................................................... 1-4
Part, lubricant, and sealant........................................................................ 1-4
Good working practice............................................................................... 1-5
Disassembly and assembly ....................................................................... 1-5
Identification...................................................................................................1-6
Model......................................................................................................... 1-6
Serial number ............................................................................................ 1-6
Special service tool .......................................................................................1-7
Feature and benefit ......................................................................................1-14
ECM system ............................................................................................ 1-14
Electronic fuel injection control system....................................................1-22
Ignition timing control system .................................................................. 1-25
Knock control system .............................................................................. 1-27
Variable camshaft timing control system ................................................. 1-29
Electronic throttle valve control system ...................................................1-33
Engine speed control system .................................................................. 1-35
Lower unit ................................................................................................1-38
Propeller selection ....................................................................................... 1-39
Propeller size........................................................................................... 1-39
Selection.................................................................................................. 1-39
6P23H11
Predelivery check ........................................................................................ 1-40

Checking the fuel system ........................................................................1-40
Checking the engine oil level................................................................... 1-40
Checking the gear oil level ...................................................................... 1-40
Checking the battery................................................................................ 1-40
Checking the outboard motor mounting height........................................ 1-41
Checking the remote control cable .......................................................... 1-41
Checking the steering system .................................................................1-42
Checking the gear shift and throttle operation.........................................1-42
Checking the PTT system ....................................................................... 1-42
Checking the engine start switch and engine stop lanyard switch ..........1-42
Checking the cooling water pilot hole ......................................................1-43
Test run ................................................................................................... 1-43
Break-in ................................................................................................... 1-43
After test run ............................................................................................ 1-43
6P23H11
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to understand. Use the information below as a guide for effective and quality service.
Parts are shown and detailed in an exploded diagram and are listed in the component list (see 1
in the figure below for an example page).
The component list consists of part names and quantities, as well as bolt and screw dimensions
(see 2 in the figure below).
Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
lubrication point (see 3 in the figure below).
Tightening torque specifications are provided in the exploded diagrams (see 4 in the figure below
for an example), 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 figure below for an example page).
NOTE:
For troubleshooting procedures, see Chapter 9, Troubleshooting.
LOWR
Lower unit
Lower unit
LOWR
Lower unit
Removing the drive shaft

1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.
S62Y6740K
2
S68S6360J
No.
Part name
Qty
Lower unit
Plastic tie
Hose
Check screw
Gasket
Dowel pin
2
4
Bolt
Drain screw
Grommet
10
Not reusable
Disassembling the drive shaft
M10
Bolt
M10
11
Bolt
M8
Thrust washer
13
Propeller
14
Washer
Washer
16
Cotter pin
17
Propeller nut
18
Trim tab
1. Install the pinion nut 1, tighten it finger

tight, and then remove the drive shaft
bearing 2 using a press.
Not reusable
12
15
Drive shaft holder 4 1: 90890-06518

Pinion nut holder 2:
New: 90890-06715
Current: 90890-06505
Remarks
Do not reuse the bearing, always replace

it with a new one.
Bearing separator 1: 90890-06534

2. Remove the needle bearing from the forward gear.
40 mm
45 mm
60 mm
CAUTION:
CAUTION:
6-5
CAUTION:
Do not press the drive shaft threads a

directly.
Do not reuse the bearing, always
replace it with a new one.
Not reusable
Bearing inner race attachment 3:

90890-06639
62Y5A11

it with a new one.
Stopper guide plate 2: 90890-06501
Stopper guide stand 3:
90890-06538
Bearing puller 4: 90890-06535
Bearing puller claw 1 5:
90890-06536
Disassembling the forward gear

1. Remove the taper roller bearing from the
forward gear using a press.
6-19
62Y5A11
1-1
6P23H11
How to use this manual
Symbol
The symbols below are designed to indicate the content of a chapter.
General information
Fuel system
GEN
INFO
Bracket unit
FUEL
Specification
BRKT
Power unit
SPEC
Electrical system
POWR
CHK
ADJ
ELEC
Lower unit
Troubleshooting
TRBL
SHTG
LOWR
Symbols 1 to 6 indicate specific data.

1
T.
R.
1
2
3
4
5 Specified measurement
6 Specified electrical value
(resistance, voltage, electric current)
Special service tool

Specified oil or fluid
Specified engine speed
Specified tightening torque
Symbols 7 to C in an exploded diagram indicate the grade of lubricant and the lubrication point.
7
0
A
E
7
8
9
0
A
M
B
D
C
C
Apply Yamaha 4-stroke motor oil

Apply gear oil
Apply water resistant grease (Yamaha grease A)
Apply molybdenum disulfide grease
A Apply corrosion resistant grease

(Yamaha grease D)
B Apply low temperature resistant grease
(Yamaha grease C)
C Apply injector grease
Symbols D to I in an exploded diagram indicate the type of sealant or locking agent and the application point.
D
E
GM
F
1104J
D Apply Gasket Maker

E Apply ThreeBond 1104J
F Apply LOCTITE 271 (red)
6P23H11
LT
LT
LT
271
242
572
SS
G Apply LOCTITE 242 (blue)

H Apply LOCTITE 572
I Apply silicon sealant
1-2
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation
Description
AFT
Aft end
API
American Petroleum Institute
BOW
Bow end
CCA
Cold Cranking Ampere
DES
Dual Engine System
ECM
Electronic Control Module
EN
European Norm (European standard)
EX
Exhaust
IEC
International Electrotechnical Commission
IN
Intake
PCV
Pressure Control Valve
PON
Pump Octane Number = (RON + Motor Octane Number)/2
PORT
Port side
PTT
Power Trim and Tilt
RON
Research Octane Number
SAE
Society of Automotive Engineers
STBD
Starboard side
TDC
Top Dead Center
TPS
Throttle Position Sensor
UP
Upside
YDIS
Yamaha Diagnostic System
1-3
6P23H11
How to use this manual / Safety while working
Safety while working
To prevent an accident or injury and to

ensure quality service, follow the safety procedures provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Part, lubricant, and sealant

Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the outboard motor.
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where adequate ventilation can be maintained.
Under normal conditions, the lubricants mentioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
Self-protection
Protect your eyes by wearing safety glasses
or safety goggles during all operations involving drilling and grinding, or when using an air
compressor.
Protect your hands and feet by wearing protective gloves and safety shoes when necessary.
6P23H11
3. Avoid contact with skin. Do not, for

example, place a soiled rag in your
pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.
1-4
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
6. Keep a supply of clean, lint-free cloths for

wiping up spills, etc.
Disassembly and assembly

1. Use compressed air to remove dust and
dirt during disassembly.
Good working practice

Use the recommended special service tools
to protect parts from damage. Use the right
tool in the right mannerdo not improvise.
Tightening torque
Follow the tightening torque specifications
provided throughout the manual. When tightening 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, cotter pins, circlips, etc., when installing or
assembling parts.
1-5
2. Apply engine oil to the contact surfaces

of moving parts before assembly.
3. Install bearings with the manufacture

identification mark in the direction indicated in the installation procedure. In
addition, be sure to lubricate the bearings
liberally.
4. Apply a thin coat of water-resistant
grease to the lip and periphery of an oil
seal before installation.
5. Check that moving parts operate normally after assembly.
6P23H11
Safety while working / Identification
Identification
Model
This manual covers the following model.
1
2
3
4
5
6
7
8
9
Applicable model
F250AET, FL250AET
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
1
2
3
4
Model name
Approved model code
Transom height
Serial number
Model name
Approved
model code
Starting
serial No.
F250AET
6P2
1003034
FL250AET
6P3
1000996
6P23H11
1-6
GEN
INFO
General information
Oil filter wrench

90890-06830
Compression gauge
90890-03160
Leakage tester
90890-06840
Compression gauge extension

90890-06563
Fuel pressure gauge adapter B

90890-06942
Test harness (3 pins)

90890-06869
Fuel pressure gauge

90890-06786
Flywheel holder
90890-06522
Vacuum/pressure pump gauge set

90890-06756
Flywheel puller
90890-06521
1-7
6P23H11
Sheave holder
90890-01701
Valve guide reamer

90890-06804
Valve spring compressor

90890-04019
Valve seat cutter holder

90890-06316
Valve spring compressor attachment

90890-06320
Valve seat cutter

90890-06324, 90890-06325, 90890-06326,
90890-06816, 90890-06817
Valve guide remover/installer

90890-06801
Valve guide installer

90890-06810
6P23H11
Bearing inner race attachment

90890-06640, 90890-06659, 90890-06661
Driver rod L3
90890-06652
1-8
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Needle bearing attachment

90890-06607, 90890-06610, 90890-06611,
90890-06613, 90890-06653, 90890-06654
Piston ring compressor

90890-05158
Bearing housing puller claw L

90890-06502
Stopper guide plate

90890-06501
Center bolt
90890-06504
1-9
Bearing separator
90890-06534
Stopper guide stand

90890-06538
Bearing puller assembly

90890-06535
Slide hammer
90890-06531
Bearing outer race puller assembly

90890-06523
6P23H11
Outer race puller claw A

90890-06532
Bearing outer race attachment

90890-06622, 90890-06628, 90890-06658
Driver rod SS
90890-06604
Drive shaft holder 6

90890-06520
Bearing depth plate

90890-06603
Pinion nut holder

90890-06715
Ball bearing attachment

90890-06656, 90890-06657
Ball bearing attachment

90890-06655
Driver rod LS
90890-06606
Driver rod LL
90890-06605
6P23H11
1-10
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Shift rod push arm

90890-06052
Magnet base plate

90890-07003
Pinion height gauge

90890-06710
Dial gauge set

90890-01252
Digital caliper
90890-06704
Magnet base B
90890-06844
Shimming plate
90890-06701
Puller head
90890-06514
Backlash indicator
90890-06706
Ring nut wrench

90890-06578
1-11
6P23H11
PTT oil pressure gauge assembly

90890-06580
Peak voltage adapter B

90890-03172
Cylinder-end screw wrench

90890-06568
Ignition tester
90890-06754
PTT piston vice attachment

90890-06572
Test harness (2 pins)

90890-06867
Tilt rod wrench

90890-06569
Test harness (1 pin)

90890-06888
Digital circuit tester

90890-03174
Yamaha diagnostic system

60V-85300-02-00
6P23H11
1
2
3
4
5
6
7
8
9
1-12
GEN
INFO
General information
Yamaha diagnostic system

60V-WS853-03
Diagnostic flash indicator B

90890-06865
1-13
6P23H11
Special service tool / Feature and benefit
Feature and benefit
ECM system
In the engine of the F250/FL250, the ECM controls the fuel injection volume, ignition timing, intake
valve opening and closing timing, and the electronic throttle valve opening angle as well as the
engine speed when the engine overheats and when the engine oil pressure is low. Reliable starting,
stabilized trolling, excellent acceleration, maximum output, low fuel consumption, and low emissions
are achieved by maintaining the optimum air-fuel ration and ignition timing under various engine
conditions.
Electronic control module system diagram
Canister
Filter
Lowpressure
fuel pump
High-pressure
fuel pump
Check
valve
Fuel
flow
Vapor
separator
tank
Oil control valve (PORT)

Cam position sensor
(PORT IN)
Fuel injector
Fuel filter
with water
separator
Vapor
gas flow
Cam position
sensor
(PORT EX)
Vapor shut-off
valve
Air flow
Control
signal
Electronic throttle
valve assembly
TPS and
Electronic throttle
valve motor
Cam position
sensor (STBD IN)
Oil control valve (STBD)
Accelerator position sensor

Electronic throttle valve control
Crank position sensor
Intake air pressure sensor
Variable camshaft timing control
Oil pressure sensor
Fuel injection control
ECM
Ignition timing control
: Air
: Fuel
: Vapor gas
6P23H11
Engine temperature sensor

Intake air temperature sensor
Knock sensor
Shift cut switch
Battery
Neutral switch
S6P21110
1-14
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
ECM component
4
2
E
D
C
6
0
9
8
S6P21111
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F

Cam position sensor (PORT IN)
Cam position sensor (PORT EX)
ECM
Cam position sensor (STBD IN)
Knock sensor
Fuel injector
Vapor separator tank
High-pressure fuel pump
Check valve
Low-pressure fuel pump
Filter
1-15
6P23H11
Feature and benefit
2
3
4
5
6
A
B
7
0
9
S6P21112
1
2
3
4
5
6
7
8
9
0
A
B
Vapor shut-off valve

TPS 1
TPS 2
Electronic throttle valve assembly
Canister
Fuel filter with water separator
Neutral switch
Shift cut switch
Oil pressure sensor
Accelerator position sensor 1
Accelerator position sensor 2
6P23H11
1-16
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Sensor function
Sensor
Function
Crank position
sensor
Detects the engine speed.

Controls the ignition timing, fuel injection volume, engine speed, engine
knock, variable camshaft timing, and electronic throttle valve opening
angle.
Detects the angle of the crankshaft and the position of the pistons.
(Cannot detect the position of the exhaust and compression strokes.)
Identifies cylinder groups #1 and #4, #2 and #5, and #3 and #6.
Cam position sensor

(PORT EX)
Detects the stroke position.

(Example: TDC of the compression stroke or TDC of the exhaust
stroke.)
Detects the strokes of the different cylinders using signals of both the
crank position sensor and cam position sensor (PORT EX).
Control the variable camshaft timing.
Cam position sensor

(STBD IN)
Detects the starboard advance angle using variable camshaft timing

control.
Cam position sensor

(PORT IN)
Detects the port advance angle using variable camshaft timing control.
TPS 1
Detects the electronic throttle valve opening angle.
TPS 2
Detects the electronic throttle valve opening angle.
Accelerator position
sensor 1
Detects the throttle lever opening angle.
sensor 2
Detects the throttle lever opening angle.
Intake air pressure

sensor
Detects the intake air pressure and controls the ignition timing and fuel
injection volume.
Intake air
temperature sensor
Detects the intake air temperature and controls the correction of the
ignition timing.
Engine temperature
sensor
Controls the correction of the ignition timing and fuel injection volume.
Neutral switch
Detects the neutral position.
Oil pressure sensor
Detects the engine oil pressure and controls the warning and engine
speed when the engine oil pressure is low.
Thermoswitch
Sends signals to warn that the engine is overheating and controls the
engine speed when the overheat warning is activated.
Shift cut switch
Outputs signals to decrease the engine speed to facilitate shifting.
Knock sensor
Detects abnormal combustion knock and controls the ignition timing.
1-17
6P23H11
Feature and benefit

Circuit diagram
NOTE:
The circled numbers in the illustration indicate the ECM terminal numbers.
1
2
3
4
5
6
7
8
9
Fuel injector #1
59
16
Fuel injector #2
60
15
Fuel injector #3
58
Fuel injector #4
Cam position sensor

(PORT EX)
57
Fuel injector #5
56
Cam position sensor

(PORT IN)
Fuel injector #6
55
Cam position sensor
(STBD IN)
1
Ignition coil #1
5V
51
TPS 1
45
TPS 2
50
Ground
Accelerator
position sensor 1
5V
71
Ignition coil #2
70
47
49
Ignition coil #3
ECM
63
31
Ground
Accelerator
position sensor 2
Ignition coil #4
41
62
5V
Ignition coil #5
44
38
Ground
40
54
Ignition coil #6
5V
Intake air
pressure sensor
53
48
36
79
Electronic throttle
valve relay
80
Oil pressure
sensor
66
37
83
81
Electronic
throttle
valve
motor
75
84
ab
cd e
S6P21130
6P23H11
1-18
GEN
INFO
General information
c de
ab
Intake air temperature
sensor
Engine temperature
sensor
5V
86
23
77
5V
High-pressure fuel
pump relay
17

P
Thermoswitch
65
52
61
Shift cut switch
5V
6
85
Neutral switch
5V
Low oil pressure

warning indicator
12
ECM
72
Ground
18
Overheat warning indicator
73
Knock sensor
Diagnosis indicator
8
74
Buzzer (DES switch)
Engine stop
lanyard switch
67
78
BZ
DES
switch
Tachometer
64
Main
relay
27
34
28
YDIS
7
46
68
Rectifier
Regulator
69
Engine start switch
13
+
Battery
1-19
76
S6P21140
6P23H11
Feature and benefit

ECM coupler layout
1234567
8 9 10 11 12 13
14 15 16 17 18 19
20 21 22 23 24 25 26
27 28 29 30 31 32 33
34 35 36 37 38 39
40 41 42 43 44 45
46 47 48 49 50 51 52
53 54 55 56 57 58 59 60 61
62 63 64 65 66 67 68 69
70 71 72 73 74 75 76 77
78 79 80 81 82 83 84 85 86
S6P21150
No.
Connecting part
Color code
Cam position sensor

(STBD IN)
White/black
Cam position sensor

(PORT IN)
White/green
Cam position sensor

(PORT EX)
White/blue
No.
Connecting part
Color code
30
31
sensor 1 (main)
Pink/white
Battery power source
Red/yellow
36
Intake air pressure

sensor
Pink/green
32
33
34
35
5
6
Shift cut switch
Blue/yellow
Main relay
Yellow/green
37
Oil pressure sensor
Pink/white
Knock sensor
Green
38
sensor 2 (sub)
Pink
9
10
39
11
40
sensor 2 ground (sub)
Black
sensor 1 ground
(main)
Black
44
sensor 2 power source
(sub)
Orange
12
Neutral switch
Blue/green
13
Engine start switch
Yellow
41
15

ground
Black
42
16
White/black
17
Engine temperature
sensor
Black/yellow
18
Sensor ground
Black
14
43
45
TPS 1 (main)
Pink
19
46
Unit ground
Black
20
47
TPS ground
Black
21
48
Sensor power source
Orange
49
sensor 1 power source
(main)
Orange
24
50
TPS 2 (sub)
Pink/white
25
51
TPS power source
Orange
26
52
Thermoswitch
Pink
22
23

sensor
Black/yellow
27
Battery power source
Red/yellow
53
Ignition coil #6
Black/brown
28
Personal computer
White/black
54
Ignition coil #5
Black/blue
29
6P23H11
1-20
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
1234567
8 9 10 11 12 13
14 15 16 17 18 19
20 21 22 23 24 25 26
27 28 29 30 31 32 33
34 35 36 37 38 39
40 41 42 43 44 45
46 47 48 49 50 51 52
53 54 55 56 57 58 59 60 61
62 63 64 65 66 67 68 69
70 71 72 73 74 75 76 77
78 79 80 81 82 83 84 85 86
S6P21150
No.
Connecting part
Color code
No.
81
55
Fuel injector #6
Purple/white
56
Fuel injector #5
Purple/blue
57
Fuel injector #4
Purple/green
82
58
Fuel injector #3
Purple/yellow
59
Fuel injector #1
Purple/red
60
Fuel injector #2
Purple/black
61
Low-pressure fuel
pump
Blue/white
62
Ignition coil #4
Black/green
63
Ignition coil #3
Black/yellow
64
Tachometer
Green
65
High-pressure fuel
pump relay
Blue/red
66
Electronic throttle
valve relay
Yellow
67
Buzzer
Pink
68
ECM ground
Black
69
ECM ground
Black
70
Ignition coil #2
Black/white
71
Ignition coil #1
Black/orange
72
Low oil pressure

warning indicator
Pink/white
73
Overheat warning
indicator
Pink/black
74
Diagnostic indicator
Blue/white
75
Electronic throttle
valve ground
Black
76
ECM ground
Black
77
Oil control valve

(PORT)
Purple
78
Engine stop lanyard

switch
White
79
Electronic throttle
valve power source
Red/green
80
Electronic throttle
valve power source
Red/green
1-21
Connecting part
Color code
Electronic throttle
valve motor
Green/black
83
Electronic throttle
valve motor
Green/red
84
Electronic throttle
valve ground
Black
85
Green/black
86
Oil control valve

(STBD)
Purple
6P23H11
Feature and benefit
Electronic fuel injection control system

In the F250/FL250 engine, the electronic fuel injection control system controls the fuel injection timing and volume. Maximum output, low fuel consumption, and low emissions are achieved by maintaining the optimum air-fuel ratio under various engine operating conditions.
Fuel injection control
Description
Injection timing
Injection volume
Asynchronous
injection
6P23H11
Control
Engine condition
Simultaneously injects into cylinder groups

#1 and #4, #2 and #5, and #3 and #6.
Starting
Sequential injection in order of cylinders #1,

#2, #3, #4, #5, and #6.
Normal operation
Controls the operation time of the injectors

according to the atmospheric pressure and
intake air temperature.
From cranking to starting
Controls the operation time of the injectors

according to the atmospheric pressure,
intake air temperature, and engine temperature.
Normal operation
Stops injection.
Turned off
Simultaneously injects into all cylinders to

prevent a lean air-fuel ratio.
Accelerated operating
speeds
1-22
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Electronic fuel injection system diagram

Fuel flows through the fuel filter in the water separator and the low-pressure fuel pump sends the
fuel through the fuel filter and is sent to the vapor separator tank. When the fuel in the vapor separator tank exceeds the specified volume, it returns to the low-pressure fuel pump via the fuel hose.
Fuel in the vapor separator tank that is pressurized by the high-pressure fuel pump is sent to the
port and starboard fuel rails and is injected from the fuel injectors into the combustion chambers.
When the fuel pressure exceeds the specified value, the fuel is sent back to the vapor separator
tank from the pressure regulator via the fuel cooler to maintain the specified fuel pressure.
When the engine is turned off and when the engine is cranked, the vapor shut-off valve closes to
prevent the fuel vapor gas from entering the surge tank. After the engine is started, the vapor shutoff valve opens and closes repeatedly to control the fuel vapor gas volume that enters the surge
tank.
When the vapor shut-off valve is closed, the fuel vapor gas is adsorbed by the activated carbon in
the canister and some is released into the atmosphere.
Primer pump
Inboard fuel filter (optional)
Boat fuel tank
Check valve
Fuel filter with water separator
Intake silencer
Check valve
Check valve
Atmosphere

Canister
Filter
Fuel cooler
Surge tank
Vapor
Separator tank
Fuel rail (STBD)
Fuel rail (PORT)
Injector
#1
Injector
#3
Injector
#5
Injector
#6
Injector
#4
Injector
#2
Combustion
chamber #1
Combustion
chamber #3
Combustion
chamber #5
Combustion
chamber #6
Combustion
chamber #4
Combustion
chamber #2
Intake manifold (STBD)
: Air
: Fuel
: Vapor gas
1-23
Pressure regulator
Intake manifold (PORT)
S6P21116
6P23H11
Feature and benefit

Circuit diagram
Fuel injector #1
16
59
15
Fuel injector #2
60
Cam position sensor

(PORT EX)
Fuel injector #3
58
Cam position sensor

(PORT IN)
Cam position sensor

(STBD IN)
Fuel injector #4
57
Fuel injector #5
5V
56
51
Fuel injector #6
55
TPS 1
45
TPS 2
50
Ground
Accelerator
position sensor 1
5V
47
49
31
Ground
Accelerator
position sensor 2
5V
41
44
38
Ground
40
5V 48
Intake air
pressure sensor
36

sensor
Engine temperature
sensor
Neutral switch
ECM
5V
5V
5V
Ground
23
17
85
12
18
Engine stop
lanyard switch
78
Main
relay
27
34
7
Engine start switch
13
Battery
6P23H11
S6P21160
1-24
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Ignition timing control system

In the F250/FL250 engine, the ignition timing control system controls the ignition timing and the
power supply timing to the ignition coils.
Maximum output, low fuel consumption, and low emissions are achieved by securing the optimum
ignition timing under various engine operating conditions.
Ignition timing control
Description
Ignition timing
Power supply timing
Control
Engine condition
Stops ignition.
Turned off
Simultaneous ignition for cylinder groups #1

and #4, #2 and #5, and #3 and #6.
Cranking and starting
Sequential ignition in order of cylinders #1,

#2, #3, #4, #5, and #6.
Normal operation
Controls the power supply timing to the ignition coils.
Normal operation
Ignition timing when cranking and starting the engine

When the engine is cranked and started, the spark plug ignites at BTDC 10.
Ignition at normal operation
During normal operation, map control is performed according to the engine speed, the intake air
pressure, and the octane value of the fuel. The power supply timing to the ignition coils is controlled
by the battery voltage.
1-25
6P23H11
Feature and benefit

Circuit diagram
16
Ignition coil #1
15
Cam position sensor
(PORT EX)
Cam position sensor

(PORT IN)
Cam position sensor

(STBD IN)
71
Ignition coil #2
70
5V
Ignition coil #3
51
TPS 1
45
TPS 2
50
63
Ignition coil #4
Ground
Accelerator
position sensor 1
5V
47
49
62
Ignition coil #5
31
Ground
Accelerator
position sensor 2
5V
41
54
44
Ignition coil #6
38
Ground
5V
Intake air
pressure sensor
Engine temperature
sensor
Shift cut switch
48
36

sensor
53
40
ECM
ECM
5V 23
5V
5V
Ground
17
6
18
Knock sensor
8
Engine stop
lanyard switch
78
Main
relay
27
34
7
Engine start switch
13
Battery
6P23H11
S6P21170
1-26
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Knock control system

In the F250/FL250 engine, the knock sensor detects the engine knock that occurs due to abnormal
combustion during operation and determines whether there is engine knock and its size. When
engine knock is determined, the knock control system retards the ignition timing to prevent the
occurrence of engine knock.
Knock control
Description
Knock
1-27
Control
Engine condition
Detects whether engine knock occurs at

ignition. When engine knock is detected, the
ignition timing is retarded by a fixed amount.
When the engine speed is

higher than the engine idle
speed after warming the
engine up.
6P23H11
Feature and benefit

Circuit diagram
16
15
Ignition coil #1
71
Ignition coil #2
70
5V
51
TPS 1
45
TPS 2
50
Ground
5V
Intake air
pressure sensor
Ignition coil #3
63
Ignition coil #4
47
62
54
48
Ignition coil #5
Ignition coil #6
36
53
ECM
Ground
18
Knock sensor
Main
relay
27
34
7
S6P21180
6P23H11
1-28
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Variable camshaft timing control system

In the F250/FL250 engine, the opening and closing timing of the intake valves is controlled.
The ECM operates the oil control valve according to the engine speed and the electronic throttle
valve opening angle and controls the optimum opening and closing timing of the intake valves. Maximum output is achieved by increasing the volumetric efficiency of the combustion chambers under
various engine operating conditions.
Description
Variable camshaft
timing
Control
Engine condition
Sets the advance target angle according

to the engine speed and electronic throttle
valve opening.
Detects the exhaust and intake camshaft
positions, operates the oil control valve to
reach the advance target angle, and controls the optimum opening and closing timing of the intake valves.
At mid-speed range, operates to the advance angle,

and at engine idle speed
and the fully open range,
operates to the retard
angle.
Variable camshaft timing control diagram

The ECM determines the intake valve opening and closing timing suitable for the operating conditions according to the engine speed, electronic throttle valve opening angle, and engine temperature. In addition, the exhaust and intake cam position sensors detect the actual advance position
and perform feedback control of the oil control valve to reach the target advance position.
The ECM sends a signal to the oil control valve to switch the oil passage to send engine oil to the
advance chamber or retard chamber in the rotor vane housing. According to the engine oil pressure
in the respective chamber, the rotor vane operates to advance or retard the camshaft that is connected to the rotor vane.
(PORT EX)
(PORT IN)
(STBD IN)
Rotor vane housing
Rotor vane housing
Advance/Retard
Advance/Retard
Cam
Cam direction
Cam
direction
Cam position
sensor
Cam position
sensor
Sensor
signal
Engine
temperature
sensor
Crank position
sensor
TPS
Advance
Retard
Retard
Cam position
sensor
Advance
Oil flow
Oil control valve
Return
Oil control valve
Oil filter
Oil pump
Return
Oil pan
ECM
Drive signal
S6P21113
1-29
6P23H11
Feature and benefit

Oil control valve operation
When the camshaft advances, the spool valve moves toward the coil spring according to the magnetic force of the magnetic coil, the spring is compressed, and the engine oil is sent to the advance
chamber passage. The engine oil in the retard chamber returns to the oil pan via the spool valve
passage.
When the camshaft retards, the spool valve moves toward the magnetic coil according to the magnetic force of the magnetic coil and the force of the coil spring, and the engine oil is sent to the
retard chamber passage. The engine oil in the advance chamber returns to the oil pan via the spool
valve passage.
S6P21190
1 Coil spring
2 Magnetic coil
Advance
Retard
Advance oil flow
Retard oil flow
Operation direction of spool valve
Oil return
Oil supply
6P23H11
1-30
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Rotor vane operation

The variable camshaft timing unit consists of a rotor vane and rotor vane housing. The rotor vane is
fastened to the intake camshaft with a bolt, which allows them to rotate together. The rotor vane
housing is fastened to the driven sprocket of the intake camshaft with a bolt, which allows them to
rotate together.
The rotor vane in the rotor vane housing is operated by the engine oil pressure to advance or retard
the camshaft. When the engine is started, the engine oil pressure is low and the rotor vane is fixed
to the housing by a lock pin. After the engine is started, the engine oil pressure increases as the
engine speed increases and the engine oil enters the advance chamber in the housing and the lock
pin is released. When the camshaft advances, the engine oil that entered the advance chamber in
the housing moves the rotor vane to the advance direction, and the engine oil in the retard chamber
passes through the spool valve and returns to the oil pan. When the camshaft retards, the engine oil
enters the retard chamber in the housing and moves the rotor vane to the retard direction, and the
engine oil in the advance chamber passes through the spool valve and returns to the oil pan.
B
2
A
0
1
7
9
D
0
2
3
4
C
1
2
3
4
5
6
7
8
Rotor vane
Rotor vane housing
Bolt
Retard passage
Drive sprocket (IN)
Camshaft
Advance port
Retard port
1-31
6
9
0
A
B
C
D
S6P21115
Advance chamber
Lock pin
Seal
Retard chamber
Advance passage
Spring
Rotation direction of variable camshaft timing
6P23H11
Feature and benefit

Circuit diagram
16
15
Cam position sensor
(PORT EX)
Cam position sensor

(PORT IN)
Cam position sensor

(STBD IN)
1
5V
51
TPS 1
45
TPS 2
50
Ground
47
86
77
Engine temperature
sensor
ECM
5V
Ground
Main
relay
17
18
27
34
7
S6P21200
6P23H11
1-32
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Electronic throttle valve control system

In the F250/FL250 engine, the electronic throttle valve control system converts the opening and
closing of the remote control lever accelerator to an electronic signal and the ECM controls the
throttle valves according to the operating condition of the accelerator opening.
Electronic throttle valve control
Description
Control
Engine condition
Setting of the target

throttle valve
opening
Detects the accelerator sensor signal and

the ECM sets the target throttle valve opening.
Starting and normal operation.
Throttle valve
opening feedback
Checks the difference between the signal

from the TPS and the target throttle valve
opening and performs feedback control on
the throttle valve opening.
Starting and normal operation.
Engine idle speed
Controls the throttle valve opening to stabilize the engine speed at idle while controlling the intake air volume.
Operation at engine idle

speed.
Limp home
processing
(electronic throttle
valve fail-safe)
Fixes the throttle valve opening to the specified opening angle and controls the ignition
timing control according to the accelerator
position sensor opening angle.
The engine idle speed is

increased and stabilized.
The engine speed is
fixed even if the accelerator lever is opened.
Electronic throttle valve operation

A cable transmits the operation of the remote control lever to the accelerator position sensor, which
converts the accelerator lever opening angle to an electronic signal. The ECM uses this signal to set
the target opening angle of the throttle valve. At the same time, the TPS detects the throttle valve
opening angle and checks the difference to that of the target opening angle. Then, the ECM sends
an electronic signal to the electronic throttle valve motor and performs feedback control of the difference of the target opening angle and throttle valve opening angle.
3
1
1
2
3
4
5
6
S6P21121
Remote control box

Accelerator lever
ECM
Electronic throttle valve assembly (TPS)
Electronic throttle valve motor
Throttle cable
Sensor signal
1-33
6P23H11
Feature and benefit

Circuit diagram
Fuel injector #1
59
5V
51
Fuel injector #2
60
TPS 1
45
TPS 2
50
Fuel injector #3
58
Fuel injector #4
Ground
Accelerator
position sensor 1
5V
57
47
Fuel injector #5
56
49
31
Ground
Accelerator
position sensor 2
5V
Fuel injector #6
55
41
44
38
Ground
40
79
Electronic throttle
valve relay
80
66
Engine temperature
sensor
5V
17
ECM
83
81
Electronic
throttle
valve
motor
75
84
Shift cut switch
Neutral switch
5V
5V
Ground
Main
relay
6
12
18
27
34
7
Engine start switch
13
Battery
6P23H11
S6P21210
1-34
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Engine speed control system

In the F250/FL250 engine, the engine speed control system decreases the engine speed to protect
the engine from damage when the engine overheats or when the engine oil pressure is low.
Engine speed control
Description
Control
Engine condition
Overheat
Detects when the engine overheats and

controls the engine speed.
Detects that the engine

is overheating when the
thermoswitch is turned
on or the engine temperature exceeds 120 C
(248 F).
The ECM causes the
cylinders to misfire, cuts
off injection, decreases
the engine speed to less
than 2,000 r/min, activates the warning buzzer, and turns the overheat warning indicator
on.
Low oil pressure
Detects when the engine oil pressure is low

and controls the engine speed.
Detects that the engine

oil pressure is low when
the oil pressure decreases to less than the specified value for the engine
speed range.
The ECM causes the
cylinders to misfire, cuts
off injection, decreases
the engine speed to less
than 2,000 r/min, activates the warning buzzer, and turns the low oil
pressure warning indicator on.
DES
Detects the status of the DES control and

When
the
overheat
warning or low oil pressure warning is activated, the DES switch is
turned on and the warning buzzer is activated.
When this occurs, the
ECM causes the cylinders to misfire, injection
is cut off, and the engine
speed decreases to less
than 2,000 r/min.
1-35
6P23H11
Feature and benefit

Description
Control
Engine condition
Shift cut
Detects the status of the shift cut control and

Two cylinders misfire and

the engine speed decreases so that the shift can be
shifted.
Over-revolution
Detects the status of the over-revolution

control and controls the engine speed.
When the engine over

revs and the engine
speed exceeds 6,449
r/min, all cylinders misfire.
When the engine over
revs and the engine
speed exceeds 6,199
r/min and is 6,449 r/min
or less, cylinders #2 to
#5, #3, and #6 misfire for
a short time.
Normal operation when
the engine speed is
6,199 r/min or less.
6P23H11
1-36
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Circuit diagram
Fuel injector #1
16
59
15
Fuel injector #2
60
5V
TPS 1
Fuel injector #3
51
58
Fuel injector #4
45
57
50
TPS 2
Fuel injector #5
Ground
56
47
Fuel injector #6
5V
55
48
Ignition coil #1
Oil pressure
sensor
71
37
Ignition coil #2
70
Ignition coil #3
Engine temperature
sensor
5V
Thermoswitch
63
17
ECM
Ignition coil #4
52
62
Shift cut switch
Ignition coil #5
5V
6
54
Ignition coil #6
Ground
18
53
Low oil pressure

warning indicator
72
Overheat warning indicator
Main
relay
73
27
34
7
Buzzer (DES switch)
67
BZ
DES
switch
Engine start switch
13
Battery
1-37
S6P21220
6P23H11
Feature and benefit
Lower unit
A spring has been added to the lower unit for the F250/FL250
The spring is used to push the drive shaft toward the water pump and stabilize the thrust free play of
the shaft.
This spring facilitates the backlash measurement procedure since the lower unit does not need to
be turned upsidedown to carry out the measurement.
S6P21126C
1
2
3
4
5
Shim
Thrust bearing
Drive shaft
Spring
Washer
Water pump side
6P23H11
1-38
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Propeller selection
The performance of a boat and outboard

motor will be critically affected by the size
and type of propeller you choose. Propellers
greatly affect boat speed, acceleration,
engine life, fuel economy, and even boating
and steering capabilities. An incorrect choice
could adversely affect performance and
could also seriously damage the engine.
Use the following information as a guide for
selecting a propeller that meets the operating
conditions of the boat and the outboard
motor.
Selection
When the engine speed is at the full throttle
operating range (5,0006,000 r/min), the
ideal propeller for the boat is one that provides maximum performance in relation to
boat speed and fuel consumption.
Regular rotation model
Propeller size (in)
Material
13 3/4 17 - M2
13 3/4 19 - M2
13 3/4 21 - M
14 1/2 15 - M
14 1/2 19 - T
Propeller size
The size of the propeller is indicated on the
propeller boss end, on the side of the propeller boss.
14 1/2 21 - T
14 1/2 23 - M
14 7/8 21 - M
Stainless
15 17 - T
15 21 - T
15 1/4 15 - M
15 1/4 17 - M
15 1/4 19 - M
15 1/4 19 - T
15 1/2 17 - T
S69J1100
Counter rotation model

Propeller size (in)
Material
13 3/4 17 - ML1
13 3/4 19 - ML1
b c
13 3/4 21 - ML
14 1/2 19 - TL
14 1/2 21 - TL
S6P21100
a Propeller diameter (in inches)

b Propeller pitch (in inches)
c Propeller type (propeller mark)
14 1/2 23 - ML
14 7/8 21 - ML
15 17 - TL
Stainless
15 21 - TL
15 1/4 15 - ML
15 1/4 17 - ML
15 1/4 19 - ML
15 1/4 19 - TL
15 1/2 17 - TL
1-39
6P23H11
Propeller selection / Predelivery check
Predelivery check
To make the delivery process smooth and

efficient, the predelivery checks should be
completed as explained below.
NOTE:
If the engine oil is below the minimum level
mark (L), add sufficient oil until the level is
between (H) and (L).
Checking the fuel system

1. Check that the fuel hoses are securely
connected and that the fuel tank is full
with fuel.
Recommended engine oil:

4-stroke motor oil
API: SE, SF, SG, SH, SJ, or SL
SAE: 5W-30, 10W-30, or 10W-40
Engine oil quantity:
Without oil filter replacement:
5.6 L (5.92 US qt, 4.93 Imp qt)
Checking the gear oil level

1. Check the gear oil level.
S60C1140
CAUTION:
This is a 4-stroke engine. Never use premixed fuel or 2-stroke outboard motor oil.
Checking the engine oil level

1. Check the engine oil level.
Checking the battery

1. Check the capacity, electrolyte level, and
specified gravity of the battery.
Recommended battery capacity:
CCA/EN: 711 A
20HR/IEC: 100 Ah
Electrolyte specified gravity:
1.280 at 20 C (68 F)
2. Check that the positive and negative battery cables are securely connected.
6P23H11
1-40
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Checking the outboard motor

mounting height
1. Check that the anti-cavitation plate is
aligned with the bottom of the boat. If the
mounting height is too high, cavitation
will occur and propulsion will be reduced.
Also, the engine speed will increase
abnormally and cause the engine to
overheat. If the mounting height is too
low, water resistance will increase and
reduce engine efficiency.
S6P21030
NOTE:
To adjust the throttle cable, see Chapter 3,
Adjusting the throttle cable.
NOTE:
The optimum mounting height is affected by
the combination of the boat and the outboard
motor. To determine the optimum mounting
height, test run the outboard motor at different heights.
3. Check that the center of the set pin a is

aligned with the alignment mark b on
the bracket.
2. Check that the clamp brackets are

secured with the clamp bolts.
Checking the remote control cable

1. Set the remote control lever to the neutral position and fully close the throttle
lever.
2. Check that the accelerator lever 1 contacts the fully closed stopper 2.
S69J3370
WARNING
The shift/throttle cable joint must be
screwed in a minimum of 8.0 mm (0.31 in)
c.
1-41
6P23H11
Predelivery check
Checking the steering system

1. Check that
smoothly.
the
steering
operates
3. Check that there is no interference with

wires or hoses when the tilted-up outboard motor is steered.
4. Check that the trim meter points down
when the outboard motor is tilted all the
way down.
Checking the engine start switch and

engine stop lanyard switch
1. Check that the engine starts when the
engine start switch is turned to START.
2. Check that there is no interference with

wires or hoses when the outboard motor
is steered.
2. Check that the engine turns off when the

engine start switch is turned to OFF.
OFF
ON
START
OFF
ON
START
Checking the gear shift and throttle

operation
1. Check that the gear shift operates
smoothly when the remote control lever
is shifted from the neutral position to forward or reverse.
S6P21080
2. Check that the throttle operates smoothly

when the remote control lever is shifted
from forward or reverse to the fully open
position a.
3. Check that the engine turns off when the

engine stop lanyard is pulled from the
engine stop lanyard switch.
N
F
a
a
S6P21070
S6P21090E
Checking the PTT system

1. Check that the outboard motor tilts up
and down smoothly when operating the
PTT unit.
2. Check that there is no abnormal noise
produced when the outboard motor is
tilted up or down.
6P23H11
1-42
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Checking the cooling water pilot

hole
1. Start the engine, check that cooling water
is discharged from the cooling water pilot
hole.
a
0
10
S69J1240
Hour
After test run

1. Check for water in the gear oil.
S6P21050
Test run
1. Start the engine, and then check that the
gear shift operates smoothly.
2. Check the engine idle speed after the
engine has been warmed up.
3. Operate at trolling speed.
4. Run the outboard motor for 1 hour at
2,000 r/min or at half throttle, then for
another hour at 3,000 r/min or at 3/4
throttle.
2. Check for fuel leakage in the cowling.

3. Flush the cooling water passage with
fresh water using the flushing kit and with
the engine running at idle.
CAUTION:
Be sure to supply sufficient water and
water pressure when flushing the cooling
water passage. If sufficient water and sufficient water pressure are not supplied,
the engine can overheat.
5. Check that the outboard motor does not

tilt up when shifting into reverse and that
water does not flow in over the transom.
NOTE:
The test run is part of the break-in operation.
Break-in
During the test run, perform the break-in
operation in the following three stages.
1. 1 hour a at 2,000 r/min or at approximately half throttle
2. 1 hour b at 3,000 r/min or 3/4 throttle
and 1 minute out of every 10 at full throttle
3. 8 hours c at any speed, however, avoid
running at full speed for more than 5 minutes
1-43
6P23H11
SPEC
Specification
General specification.....................................................................................2-1
Maintenance specification ............................................................................2-3
Power unit..................................................................................................2-3
Lower unit ..................................................................................................2-6
Electrical .................................................................................................... 2-7
Dimension................................................................................................2-10
Tightening torque......................................................................................... 2-12
Specified torque....................................................................................... 2-12
General torque......................................................................................... 2-15
6P23H11
1
2
3
4
5
6
7
8
9
SPEC
Specification
General specification
Item
Dimension
Overall length
Overall width
Overall height
(X)
(U)
Boat transom height
(X)
(U)
Weight
(with stainless propeller)
(X)
(U)
Performance
Maximum output
Full throttle operating range
Maximum fuel consumption
Engine idle speed
Power unit
Type
Cylinder quantity
Total displacement
Bore stroke
Compression ratio
Control system
Starting system
Fuel system
Ignition control system
Advance type
Maximum generator output
Spark plug
Firing order
Cooling system
Exhaust system
Lubrication system
2-1
Unit
Model
F250AET
FL250AET
mm (in)
mm (in)
892 (35.1)
634 (25.0)
mm (in)
mm (in)
1,829 (72.0)
1,956 (77.0)
mm (in)
mm (in)
635 (25.0)
762 (30.0)
kg (lb)
kg (lb)
278.0 (613)
284.0 (626)
kW (hp)
r/min
L (US gal,
Imp gal)/hr
r/min
183.9 (250) at 5,500 r/min

5,0006,000
81.0 (21.4, 17.8) at 6,000 r/min
cm3 (cu. in)

mm (in)
V, A
600700
4-stroke, DOHC
V6
3,352 (204.5)
94.0 80.5 (3.70 3.17)
9.9
Remote control
Electric
Fuel injection
TCI
Micro computer
12, 46
LFR6A-11 (NGK)
123456 (Normal operation)
Water
Propeller boss
Wet sump
6P23H11
General specification
Item
Fuel and oil
Fuel type
Fuel minimum rating
Engine oil
Engine oil grade(*1)
Engine oil quantity
(without oil filter replacement)
(with oil filter replacement)
Gear oil type
Gear oil grade(*2)
Gear oil quantity
Bracket unit
Trim angle
(at 12 boat transom)
Tilt-up angle
Steering angle
Drive unit
Gear shift positions
Gear ratio
Reduction gear type
Clutch type
Propeller shaft type
Propeller direction (rear view)
Propeller mark
Electrical
Battery minimum capacity
CCA/EN
20HR/IEC
Unit
RON
PON
API
SAE
L (US qt,
Imp qt)
L (US qt,
Imp qt)
API
SAE
cm3 (US oz,
Imp oz)
Model
F250AET
FL250AET
Premium unleaded gasoline

94
89
4-stroke motor oil
SE, SF, SG, SH, SJ, or SL
5W-30, 10W-30, or 10W-40
5.6 (5.92, 4.93)
5.8 (6.13, 5.10)
Hypoid gear oil
GL-4
90
1,150 (38.9, 40.6)
1,000 (33.8, 35.3)
Degree
3 to 16
Degree
Degree
70
32 + 32
F-N-R
2.00 (30/15)
Spiral bevel gear
Dog clutch
Spline
Clockwise
Counterclockwise
T, M
TL, ML
A
Ah
711
100
(*1) If
the recommended engine oil grades are not available, use engine oil with an SAE classification of
15W-40, 20W-40, or 20W-50 and an API classification of SH, SJ, or SL.
(*2) Meeting both API and SAE requirements
6P23H11
2-2
1
2
3
4
5
6
7
8
9
SPEC
Specification
Maintenance specification
Power unit
Item
Power unit
Minimum compression
pressure(*1)
Oil pressure(*2)
Cylinder head
Warpage limit
(lines indicate straightedge

position)
Camshaft cap inside diameter
Cylinder
Bore size
Piston
Piston diameter (D)
Measuring point (H)
Piston clearance(*3)
Piston pin boss bore
Piston pin
Outside diameter
Piston ring
Top ring
Dimension B
Dimension T
End gap(*3)
Side clearance
2nd piston ring
Dimension B
Dimension T
End gap(*3)
Side clearance
Unit
Model
F250AET
FL250AET
kPa
(kgf/cm2, psi)
kPa
(kgf/cm2, psi)
740 (7.4, 107.3)

600 (6.0, 87.0) at 60 C (140 F) with SL 10W30 engine oil and at 900 r/min
mm (in)
0.1 (0.0039)
mm (in)
25.00025.021 (0.98430.9851)
mm (in)
94.00094.017 (3.70083.7014)
mm (in)
mm (in)
mm (in)
mm (in)
93.92193.941 (3.69773.6985)
5.0 (0.20)
0.0750.080 (0.00300.0031)
21.01721.031 (0.82740.8280)
mm (in)
20.99521.000 (0.82660.8268)
mm (in)
mm (in)
mm (in)
mm (in)
1.171.19 (0.0460.047)
2.803.00 (0.1100.118)
0.150.30 (0.0060.012)
0.040.08 (0.0020.003)
mm (in)
mm (in)
mm (in)
mm (in)
1.171.19 (0.0460.047)
3.703.90 (0.1460.154)
0.300.45 (0.0120.018)
0.030.07 (0.0010.003)
(*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 Chapter 5, Checking the oil pressure.
(*3) The figures are for reference only.
2-3
6P23H11
Item
Oil ring
Dimension B
Dimension T
End gap(*1)
Side clearance
Camshaft
Intake (A)
Exhaust (A)
Intake and
exhaust (B)
Camshaft journal diameter
Camshaft runout limit
Valve
Valve clearance (cold)
Intake
Exhaust
Head diameter (A)
Intake
Exhaust
Face width (B)
Intake
Exhaust
Seat contact width (C)
Intake
Exhaust
Margin thickness (D)
Intake
Exhaust
Stem diameter
Intake
Exhaust
Guide inside diameter
Intake and exhaust
Stem-to-guide clearance
Intake
Exhaust
Stem runout limit
Valve spring
Free length
Tilt limit
(*1)
Unit
Model
F250AET
FL250AET
mm (in)
mm (in)
mm (in)
mm (in)
2.402.47 (0.0940.097)
2.302.70 (0.0910.106)
0.150.60 (0.0060.024)
0.040.13 (0.0020.005)
mm (in)
mm (in)
mm (in)
46.3046.40 (1.8231.827)
45.3545.45 (1.7851.789)
35.9536.05 (1.4151.419)
mm (in)
mm (in)
24.9624.98 (0.98260.9834)
0.015 (0.0006)
mm (in)
mm (in)
0.20 0.03 (0.008 0.001)

0.34 0.03 (0.013 0.001)
mm (in)
mm (in)
36.436.6 (1.431.44)
31.431.6 (1.241.24)
mm (in)
mm (in)
2.352.78 (0.0920.110)
2.133.30 (0.0840.130)
mm (in)
mm (in)
1.101.40 (0.0430.055)
1.401.70 (0.0550.067)
mm (in)
mm (in)
0.500.90 (0.0200.035)
0.901.30 (0.0350.051)
mm (in)
mm (in)
5.4775.492 (0.21560.2162)
5.4645.479 (0.21510.2157)
mm (in)
5.5045.522 (0.21670.2174)
mm (in)
mm (in)
mm (in)
0.0120.045 (0.00050.0018)
0.0250.058 (0.00100.0023)
0.01 (0.0004)
mm (in)
mm (in)
44.2 (1.74)
1.2 (0.05)
1
2
3
4
5
6
7
8
9
6P23H11
2-4
SPEC
Specification
Item
Valve lifter
Valve lifter outside diameter
Valve lifter-to-cylinder head
clearance
Valve shim
Valve shim thickness
(in 0.020 mm increments)
Connecting rod
Small end inside diameter
Big end inside diameter
Big end side clearance(*1)
Crankpin oil clearance
Big end bearing thickness
Yellow
Green
Blue
Crankshaft
Crankshaft journal diameter
Crankpin diameter
Crankpin width
Runout limit
Crankcase
Crankshaft journal oil
clearance
Upper crankcase main bearing
thickness
1
2
3
Lower crankcase main bearing
thickness
1
2
3
Lower crankcase main bearing
thickness (J3)
1
2
3
Thrust bearing thickness (J3)
(*1)
Unit
Model
F250AET
FL250AET
mm (in)
mm (in)
32.98232.997 (1.29851.2991)
0.0200.055 (0.00080.0022)
mm (in)
2.3202.960 (0.09130.1165)
mm (in)
mm (in)
mm (in)
mm (in)
21.01721.031 (0.82740.8280)
53.01553.035 (2.08722.0880)
0.150.30 (0.0060.012)
0.0280.066 (0.00110.0026)
mm (in)
mm (in)
mm (in)
1.4921.496 (0.05870.0589)
1.4961.500 (0.05890.0591)
1.5001.504 (0.05910.0592)
mm (in)
mm (in)
mm (in)
mm (in)
62.96862.992 (2.47912.4800)
49.97650.000 (1.96761.9685)
21.5021.55 (0.84650.8484)
0.03 (0.0012)
mm (in)
0.0250.050 (0.00100.0020)
mm (in)
mm (in)
mm (in)
2.4942.500 (0.09820.0984)
2.4982.504 (0.09830.0986)
2.5022.508 (0.09850.0987)
mm (in)
mm (in)
mm (in)
2.4942.500 (0.09820.0984)
2.4982.504 (0.09830.0986)
2.5022.508 (0.09850.0987)
mm (in)
mm (in)
mm (in)
mm (in)
2.4922.500 (0.09810.0984)
2.4962.504 (0.09830.0986)
2.5002.508 (0.09840.0987)
1.9071.957 (0.07510.0770)
2-5
6P23H11
Item
Thermostat
Opening temperature
Fully open temperature
Valve open lower limit
Unit
C (F)
C (F)
mm (in)
Model
F250AET
FL250AET
5862 (136144)
70 (158)
4.3 (0.17)
Lower unit
Item
Unit
Gear backlash
Pinion-to-forward gear
mm (in)
Pinion-to-reverse gear
mm (in)
Propeller shaft free play
mm (in)
Pinion shims
Forward gear shims
Reverse gear shims
Propeller shaft shims
6P23H11
mm
mm
mm
mm
Model
F250AET
FL250AET
0.320.55
0.460.82
(0.01260.0217)
(0.01810.0323)
0.320.65
0.450.78
(0.01260.0256)
(0.01770.0307)
0.200.50
0.250.35
(0.00790.0197)
(0.00980.0138)
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
1.80, 1.90, 2.00, 2.10, 0.10, 0.12, 0.15, 0.18,
2.20
0.30, 0.40, 0.50
2-6
1
2
3
4
5
6
7
8
9
SPEC
Specification
Electrical
Item
Ignition and ignition control
system
Spark plug gap
Crank position sensor output
peak voltage
(W/B B)
at cranking (unloaded)
at cranking (loaded)
at 1,500 r/min (loaded)
at 3,500 r/min (loaded)
resistance(*1)
(W/R B)
Crank position sensor air gap
Knock sensor resistance
resistance
at 20 C (68 F)
resistance
(B/Y B/Y)
at 20 C (68 F)
at 100 C (212 F)
Electronic throttle valve
control system
TPS output voltage(*1)
at 20 C (68 F)
with remote control lever fully
closed
Sensor 1
open
Sensor 2
resistance(*1)
at 2030 C (6886 F)
output voltage(*1)
(P B)
closed
Sensor 1
Sensor 2
open
Sensor 1 and 2
(*1)
Unit
Model
F250AET
FL250AET
mm (in)
1.01.1 (0.0390.043)
V
V
V
V
3.0
2.7
14.5
17.8
396594
mm (in)
k
1.41.6 (0.0550.063)
504616
2.212.69
k
k
54.269.0
3.123.48
0.750
4.550
1.231.67
V
V
0.5500.850
0.4001.000
Above 3.250
2-7
6P23H11
Item
resistance(*1)
at 20 C (68 F)
with accelerator lever fully
closed
with accelerator lever fully
open
Variable camshaft timing
control system
Oil control valve resistance
at 20 C (68 F)
Fuel control system
Fuel injector resistance(*1)
at 21 C (70 F)
Starter motor
Type
Output
Cranking time limit
Brushes
Standard length
Wear limit
Commutator
Standard diameter
Wear limit
Standard undercut
Wear limit
Charging system
Fuse
Stator coil output peak voltage
(G G)
at cranking (unloaded)
at 1,500 r/min (unloaded)
Stator coil resistance(*1)
(G G)
at 20 C (68 F)
Rectifier Regulator output
peak voltage
(R Ground)
(*1)
Unit
Model
F250AET
FL250AET
0.800
5.300
6.77.7
12.0
kW
Second
Sliding gear
1.40
30
mm (in)
mm (in)
15.5 (0.61)
9.5 (0.37)
mm (in)
mm (in)
mm (in)
mm (in)
29.0 (1.14)
28.0 (1.10)
0.8 (0.03)
0.2 (0.01)
80
V
V
V
8.3
44.7
97.7
0.11440.1716
V
V
13.0
13.0
1
2
3
4
5
6
7
8
9
6P23H11
2-8
SPEC
Specification
Item
PTT system
Trim sensor
Setting resistance
Resistance
Fluid type
Motor brushes
Standard length
Wear limit
Motor commutator
Standard diameter
Wear limit
Standard undercut
Wear limit
2-9
Unit
Model
F250AET
FL250AET
10 1
9387.6
ATF Dexron II
mm (in)
mm (in)
11.5 (0.45)
4.5 (0.18)
mm (in)
mm (in)
mm (in)
mm (in)
23.0 (0.91)
22.0 (0.87)
1.40 (0.055)
0.90 (0.035)
6P23H11
Dimension
Exterior
723.9 (28.5)
453 (17.8)
mm (in)
317 (12.5)
32
X: 1,155 (45.5)
U: 1,272 (50.1)
619 (24.4)
651 (25.6)
219 (8.6)
59 (2
.3)
67
X: 847 (33.3)
U: 924 (36.4)
45 (1.8)
387 (15.2)
39 (1.5)
752 (29.6)
X: 643 (25.3)
U: 770 (30.3)
230 (9.1)
216 (8.5)
X: 1,078 (42.4)
U: 1,205 (47.4)
902 (35.5)
75 (3.0)
25 (1.0)
12
3
X: 52 (2.0)
U: 59 (2.3)
673 (26.5)
S6P22020
6P23H11
2-10
1
2
3
4
5
6
7
8
9
SPEC
Specification
Clamp bracket
mm (in)
180 (7.1)
180 (7.1)
163.5 (6.4)
50.8 (2.0)
163.5 (6.4)
101.5 (4.0)
101.5 (4.0)
125.4 (4.9)
125.4 (4.9)
55.5 (2.2)
13 (0.5)
254 (10.0)
411 (16.2)
13 (0.5)
18.5 (0.7)
79 (3.1)
S6P22010
2-11
6P23H11
Maintenance specification / Tightening torque
Tightening torque
Specified torque
Part to be tightened
Fuel system
Filter cup
Intake manifold bolt
Intake silencer bolt
Electronic throttle valve assembly nut
Throttle damper plate bolt
Canister mounting bolt
Canister bracket bolt
Vapor shut-off valve mounting nut
Intake air pressure sensor bolt
Low-pressure fuel pump cover bolt
Check valve holder screw
Fuel cooler bolt
Pressure regulator screw
Float chamber cover screw
Float chamber cover inner plate screw
Float pin screw
Vapor separator drain screw
Power unit
Power unit mounting bolt
Apron bolt
Upper case cover bolt
PTT motor lead bolt
Ignition coil bolt
Spark plug
Cooling water pressure sensor adapter plug
Flywheel magnet nut
Crank position sensor screw
Timing belt tensioner bolt
Timing belt pulley bolt
Variable camshaft timing cap
Variable camshaft timing bolt
Driven sprocket bolt
Cylinder head cover plate screw
1st
Camshaft cap bolt
2nd
1st
Cylinder head cover bolt
2nd
Positive battery cable bolt
Negative battery cable nut
Negative terminal bolt
6P23H11
Thread size
Tightening torques
Nm
kgfm
ftlb
M6
M6
M8
M6
M6
M6
M6
M5
M6
M6
M4
M4
M4
3.5
10
7
13
13
5
5
5
5
9
4
5
5
2
2
2
2
0.35
1.0
0.7
1.3
1.3
0.5
0.5
0.5
0.5
0.9
0.4
0.5
0.5
0.2
0.2
0.2
0.2
2.6
7.4
5.2
9.6
9.6
3.7
3.7
3.7
3.7
6.6
3.0
3.7
3.7
1.5
1.5
1.5
1.5
M10
M6
M6
M6
M6
M14
M5
M10
M12
M10
M4
42
8
8
4
7
25
23
240
4
39
39
32
60
60
2
8
17
8
8
18
13
26
4.2
0.8
0.8
0.4
0.7
2.5
2.3
24.0
0.4
3.9
3.9
3.2
6.0
6.0
0.2
0.8
1.7
0.8
0.8
1.8
1.3
2.6
31.0
5.9
5.9
3.0
5.2
18.4
17.0
177.0
3.0
28.8
28.8
23.6
44.3
44.3
1.5
5.9
12.5
5.9
5.9
13.3
9.6
19.2
M7
M6
M8
2-12
1
2
3
4
5
6
7
8
9
SPEC
Specification
Thread size
ECM bolt
PTT relay lead nut
Rectifier Regulator bolt
Exhaust cover bolt
Exhaust cover plug
M6
1st
2nd
1st
2nd
1st
2nd
1st
2nd
1st
2nd
3rd
4th
5th
6th
Knock sensor
Cooling water passage cover bolt
Oil filter
Oil pressure sensor
Oil filter joint
Crankcase cover bolt
Connecting rod cap bolt
Oil pump cover screw

Thermostat cover plug
Lower unit (regular rotation model)
Gear oil check screw
Gear oil drain screw
Lower case mounting bolt (nut)
Trim tab bolt
Propeller nut
2-13
M8
M8
M10
M6
1st
2nd
1st
2nd
3rd
Crankcase bolt
M6
M18
M4
M6
Anode screw
Engine hanger bolt
Cylinder head bolt
M6
M8
M9
1st
2nd
1st
2nd
1st
2nd
M8
M8
M10
M6
M14
M10
M10
Tightening torques
Nm
kgfm
ftlb
7
0.7
5.2
4
0.4
3.0
6
0.6
4.4
12
1.2
8.9
6
0.6
4.4
12
1.2
8.9
14
1.4
10.3
28
2.8
20.7
55
5.5
40.6
3
0.3
2.2
12
1.2
8.9
14
1.4
10.3
28
2.8
20.7
23
2.3
17.0
45
4.5
33.2
Loosen completely
23
2.3
17.0
45
4.5
33.2
90
32
3.2
23.6
12
1.2
8.9
18
1.8
13.3
18
1.8
13.3
34
3.4
25.1
14
1.4
10.3
28
2.8
20.7
23
2.3
17.0
43
4.3
31.7
90
15
1.5
11.1
14
1.4
10.3
28
2.8
20.7
25
2.5
18.4
90
40
4.0
29.5
90
4
0.4
3.0
23
2.3
17.0
9
9
47
42
54
0.9
0.9
4.7
4.2
5.4
6.6
6.6
34.7
31.0
39.8
6P23H11
Tightening torque
Grease nipple
Propeller shaft housing bolt
Cooling water inlet cover screw
Pinion nut
Lower unit (counter rotation model)
Gear oil check screw
Gear oil drain screw
Lower case mounting bolt (nut)
Trim tab bolt
Propeller nut
Ring nut
Grease nipple
Propeller shaft housing bolt
Cooling water inlet cover screw
Pinion nut
Bracket unit
Shift cut switch screw
Shift cut switch bracket bolt
Neutral switch screw
Grease nipple
Shift rod detent bolt
Grease nipple
Flushing hose adapter screw
Upper mount bracket bolt
Apron stay
Engine oil drain bolt
Upper mount nut
Lower mount nut
Oil pan assembly bolt
PCV
Baffle plate screw
Oil strainer bolt
Oil pan bolt
Exhaust manifold bolt
Muffler bolt
Friction plate screw
Grease nipple
Self- locking nut
Thrust receiver nut
PTT unit
Reservoir mounting bolt
PTT motor mounting bolt
Reservoir cap
6P23H11
M8
M5
Tightening torques
Nm
kgfm
ftlb
6
0.6
4.4
30
3.0
22.1
4
0.4
3.0
142
14.2
104.7
M10
M10
M8
M5
9
9
47
42
54
108
6
30
4
142
0.9
0.9
4.7
4.2
5.4
10.8
0.6
3.0
0.4
14.2
6.6
6.6
34.7
31.0
39.8
79.7
4.4
22.1
3.0
104.7
M4
M4
M6
M10
M14
M8
M10
M6
M6
M8
M8
M8
M6
2
19
2
1
18
1
5
54
8
27
72
72
20
42
8
4
10
20
20
20
4
3
22
36
0.2
1.9
0.2
0.1
1.8
0.1
0.5
5.4
0.8
2.7
7.2
7.2
2.0
4.2
0.8
0.4
1.0
2.0
2.0
2.0
0.4
0.3
2.2
3.6
1.5
14.0
1.5
0.7
13.3
0.7
3.7
39.8
5.9
19.9
53.1
53.1
14.8
31.0
5.9
3.0
7.4
14.8
14.8
14.8
3.0
2.2
16.2
26.6
M8
M8
M12
19
19
7
1.9
1.9
0.7
14.0
14.0
5.2
Thread size
2-14
1
2
3
4
5
6
7
8
9
SPEC
Specification
Manual valve
Pipe joint
Pipe joint adapter
Gear pump bolt
Gear pump bracket bolt
Trim cylinder end screw
Tilt ram
Tilt cylinder end screw
Tilt piston bolt
Thread size
M5
M5
M6
Tightening torques
Nm
kgfm
ftlb
2
0.2
1.5
15
1.5
11.1
20
2.0
14.8
7
0.7
5.2
7
0.7
5.2
160
16
118.0
55
5.5
40.6
90
9.0
66.4
7
0.7
5.2
General torque
This chart specifies tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifications
for special components or assemblies are
provided in applicable sections of this manual. To avoid warpage, tighten multi-fastener
assemblies in a crisscross fashion and progressive stages until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads.
Components should be at room temperature.
Nut (A)
Bolt (B)
8 mm
10 mm
12 mm
14 mm
17 mm
M5
M6
M8
M10
M12
2-15
General torque
specifications
Nm kgfm ftlb
5
0.5
3.7
8
0.8
5.9
18
1.8
13.3
36
3.6
26.6
43
4.3
31.7
6P23H11
CHK
ADJ

Maintenance interval chart............................................................................3-1
Top cowling .................................................................................................... 3-3
Checking the top cowling...........................................................................3-3
Fuel system .................................................................................................... 3-3
Checking the fuel joint and fuel hose (fuel joint-to-fuel injector) ................ 3-3
Checking the fuel filter ............................................................................... 3-4
Power unit....................................................................................................... 3-4
Checking the engine oil .............................................................................3-4
Changing the engine oil using an oil changer............................................3-4
Changing the engine oil by draining it .......................................................3-5
Replacing the oil filter ................................................................................ 3-6
Checking the timing belt ............................................................................3-6
Checking the spark plug ............................................................................3-7
Checking the thermostat............................................................................3-7
Checking the cooling water passage.........................................................3-9
Control system ............................................................................................... 3-9
Checking the engine idle speed ................................................................3-9
Adjusting the throttle cable ...................................................................... 3-10
Checking the gear shift operation............................................................ 3-11
Bracket unit .................................................................................................. 3-12
Checking the PTT operation.................................................................... 3-12
Checking the PTT fluid level.................................................................... 3-12
Lower unit ..................................................................................................... 3-13
Checking the gear oil level ...................................................................... 3-13
Changing the gear oil .............................................................................. 3-13
Checking the lower unit for air leakage ...................................................3-14
Checking the propeller............................................................................. 3-14
General..........................................................................................................3-14
Checking the anode................................................................................. 3-14
Checking the battery................................................................................ 3-15
Lubricating the outboard motor................................................................3-16
6P23H11
1
2
3
4
5
6
7
8
9
CHK
ADJ
Maintenance interval chart
Use the following chart as a guideline for general maintenance.

Adjust the maintenance intervals according to the operating conditions of the outboard motor.
Initial
Item
Anodes (external)
Anodes (cylinder head,
thermostat cover)
Battery
Cooling water passages
Top cowling
Fuel filter
(can be disassembled)
Fuel system
Gear oil
Lubrication points
Engine idle speed
PCV
PTT unit
Propeller and cotter pin
Shift link/shift cable
Thermostat
Throttle link/throttle cable/
throttle pick-up timing
Water pump
Engine oil
Oil filter (cartridge)
Spark plugs
Timing belt
Remarks
Every
10 hours 50 hours 100 hours 200 hours

(1 month) (3 months) (6 months) (1 year)
Refer to
page
Check/replace
Check/replace
3-14
3-14
Check/charge
Clean
Check
Check/replace
3-15
3-9
3-3
3-4
Check
Change
Lubricate
Check
Check
Check
Check/replace
Check/adjust
Check/replace
Check/adjust
3-3
3-13
3-16
3-9
7-7
3-12
3-14
3-11
3-7
3-10
Check/replace
Check/change
Change
Clean/adjust/
replace
Check/replace
6-5, 6-35
3-4
3-6
3-7
3-6
NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed with clean water
after each use.
3-1
6P23H11
Maintenance interval chart

Every
Item
Timing belt
Valve clearance (DOHC)
Fuel filter
(vapor separator tank)
Oil control valve filter
Anodes
(exhaust cover, cooling water
passage cover, Rectifier
Regulator cover)
Exhaust guide, exhaust
manifold
6P23H11
Remarks
500 hours
(2.5 years)
1,000 hours
(5 years)
Refer to
page
Replace
Check/adjust
Replace
5-15
5-10
4-23
Check/replace
Replace
5-41
3-14
Check/replace
7-8
3-2
1
2
3
4
5
6
7
8
9
CHK
ADJ
Top cowling
Checking the top cowling

1. Check the fitting by pushing the cowling
with both hands. Adjust if necessary.
Fuel system
Checking the fuel joint and fuel hose

(fuel joint-to-fuel injector)
2. Loosen the bolts 1.
1. Remove the flywheel magnet cover, port

intake manifold, and fuel rail covers.
3. Move the hook 2 up or down slightly to

adjust its position.
NOTE:
See the exploded diagram (4-12, 4-26).
2. Check the low-pressure fuel hose connections. Also, check the fuel filter 1,
low-pressure fuel pump 2, filter 3,
check valve 4, and fuel cooler 5.
Replace if there is leakage or deterioration.
NOTE:
To loosen the fitting, move the hook in
direction a.
To tighten the fitting, move the hook in
direction b.
3. Check the high-pressure fuel hose connections. Also, check the vapor separator 6, pressure regulator 7, fuel rails 8,
and fuel injectors 9. Replace if there is
leakage or deterioration.
4. Tighten the bolts.
3
5. Check the fitting again and, if necessary,
repeat steps 24.
6. Check the top cowling hoses. Replace if
cracked or damaged.
4
1
5
6
S6P23020
4. Install the port intake manifold, fuel rail

covers, and flywheel magnet cover.
3-3
6P23H11
Top cowling / Fuel system / Power unit

NOTE:
To install the intake manifold, see Chapter 4,
Installing the intake manifold.
Checking the fuel filter

1. Check the fuel filter element 1. Replace
if there is dirt or residue.
2. Check the cup 2. Clean with straight
gasoline if there are foreign substance or
replace if cracked.
NOTE:
Change the oil if it appears milky or dirty.
If the engine oil is below the minimum level
mark (L), add sufficient oil until the level is
between (H) and (L).
Changing the engine oil using an oil

changer
1. Start the engine, warm it up, and then
turn it off.
2. Remove the oil dipstick and oil filler cap
1.
NOTE:
Be sure not to spill any fuel when removing
the fuel filter cup.
Power unit
3. Insert the tube of the oil changer 2 into

the dipstick guide 3.
Checking the engine oil

1. Place the outboard motor in an upright
position.
2. Remove the oil dipstick, wipe it clean,
and then insert it back into the dipstick
guide.
3. Remove the oil dipstick again to check
the oil level, and to check the oil for discoloration and its viscosity.
4. Operate the oil changer to extract the oil.

NOTE:
Be sure to clean up any oil spills.
6P23H11
3-4
1
2
3
4
5
6
7
8
9
CHK
ADJ
5. Pour the specified amount of the recommended engine oil into the oil filler hole.
4. Place a drain pan under the drain hole,

and then remove the engine oil drain bolt
3 and let the oil drain completely.

4-stroke motor oil
SAE: 5W-30, 10W-30, or 10W-40
5.6 L (5.92 US qt, 4.93 Imp qt)
6. Install the oil filler cap and oil dipstick,
and then start the engine and warm it up
for 5 minutes.
7. Turn the engine off, and then check the
oil level and that there is no oil leakage. If
the oil level is low, add engine oil to the
correct level.
Changing the engine oil by draining

it
1. Start the engine, and warm it up, and
then turn it off.
5. Install the engine oil drain bolt, and then

tighten it to the specified torque.
T.
R.
2. Remove the oil dipstick and oil filler cap

1.
NOTE:
Engine oil drain bolt 3:

27 Nm (2.7 kgfm, 19.9 ftlb)
4-stroke motor oil
SAE: 5W-30, 10W-30, or 10W-40
5.6 L (5.92 US qt, 4.93 Imp qt)
3. Remove the starboard apron 2.

for 5 minutes.
correct level.
9. Install the starboard apron 2, and then
tighten the bolts to the specified torque.
3-5
6P23H11
Power unit
4. Install the oil filter, and then tighten it to
the specified torque using a 72.5 mm
(2.9 in) oil filter wrench.
2
LT
572
LT
572
S6S13220
T.
R.
Apron bolt:
8 Nm (0.8 kgfm, 5.9 ftlb)
Replacing the oil filter

CAUTION:
S6P23090
Do not damage the oil pressure sensor

and its lead when replacing the oil filter.
T.
R.
1. Extract the engine oil with an oil changer

or drain it.
2. Place a rag under the oil filter, and then
remove the oil filter using a 72.5 mm (2.9
in) oil filter wrench 1.
S6P23080
NOTE:
Wait more than 5 minutes after turning the
engine off to replace the oil filter.
Oil filter:
18 Nm (1.8 kgfm, 13.3 ftlb)
4-stroke motor oil
SAE: 5W-30, 10W-30, or 10W-40
With oil filter replacement:
5.8 L (6.13 US qt, 5.10 Imp qt)
for 5 minutes.
correct level.
Checking the timing belt

Oil filter wrench 1: 90890-06830
3. Apply a thin coat of engine oil to the Oring of the new oil filter.
CAUTION:
Do not turn the flywheel magnet counterclockwise, otherwise the water pump
impeller may be damaged.
1. Remove the flywheel magnet cover.
6P23H11
3-6
1
2
3
4
5
6
7
8
9
CHK
ADJ
2. While turning the flywheel magnet clockwise, check the interior a and the exterior b of the timing belt. Replace if
cracked, damaged, or worn.
b
S6P23100
NOTE:
To replace the timing belt, see Chapter 5,
Replacing the timing belt.
4. Check the electrodes for erosion and

excessive carbon or other deposits, and
the gasket for damage. Replace the
spark plug if necessary.
5. Check the spark plug gap a. Adjust if out
of specification.
Checking the spark plug

1. Remove the ECM cover.
2. Remove the ignition coils, and then
remove the spark plugs.
Specified spark plug:

LFR6A-11 (NGK)
Spark plug gap a:
1.01.1 mm (0.0390.043 in)
6. Install the spark plugs, tighten them temporary, then to the specified torque using
a spark plug wrench.
T.
R.
Spark plug:
25 Nm (2.5 kgfm, 18.4 ftlb)
7. Install the ignition coils.
T.
R.
3. Clean the electrodes 1 with a spark plug

cleaner or wire brush. Replace the spark
plug if necessary.
Ignition coil bolt:

8. Install the ECM cover.
Checking the thermostat

1. Reduce the fuel pressure.
3-7
6P23H11
Power unit
NOTE:
To reduce the fuel pressure, see Chapter 4,
Reducing the fuel pressure.
5
6

3. Disconnect the oil control valve couplers
1.
4. Disconnect the thermoswitch connectors
2.
5. Disconnect the quick connectors 3.
PORT
3
S6P23320E
CAUTION:
Do not reuse the gaskets 6, always
replace them with new ones.
7. Suspend the thermostat in a container of
water.
8. Place a thermometer in the water and
slowly heat the water.
S6P23120
STBD
S69J5E40
1
S6P23130
WARNING
It is dangerous if the quick connector is
removed suddenly since pressurized fuel
will spray out. Be sure to reduce the fuel
pressure before removing the quick connector.
NOTE:
To disconnect the quick connector, see
Chapter 4, Disconnecting the quick connector.
6. Remove the covers 4 and thermostats
5 (port and starboard).
6P23H11
3-8
1
2
3
4
5
6
7
8
9
CHK
ADJ
9. Check the thermostat valve opening at

the specified water temperatures.
Replace if out of specification.
1
1
Water
temperature
Valve lift a
5862 C
(136144 F)
0.05 mm
(0.0020 in)
(valve begins to lift)
above
70 C (158 F)
more than
4.3 mm (0.17 in)
10. Install the thermostats and covers.

NOTE:
It is recommended to check the thermostat
cover anodes before installing the thermostat
covers.
S6P23150
2. Place the lower unit in water, and then

start the engine.
3. Check for water flow at the cooling water
pilot hole. If there is no water flow, check
the cooling water passage inside the outboard motor.
11. Connect the thermoswitch connectors,

quick connectors, and oil control valve
couplers.
12. Route and fasten the wiring harness in its
original position.
13. Install the flywheel magnet cover.
Checking the cooling water passage

1. Check the cooling water inlet covers 1
and cooling water inlet. Clean if clogged.
S6P21050
Control system
Checking the engine idle speed

1. Start the engine and warm it up for 5 minutes.
2. Check the engine idle speed using the
Yamaha genuine tachometer (on-board
meter) or using the YDIS.
NOTE:
To connect and operate the YDIS, see Chapter 9, YDIS and the YDIS (version 1.23a or
later) Instruction Manual.
3-9
6P23H11
Power unit / Control system
Engine idle speed: 600700 r/min
Adjusting the throttle cable

1. Set the remote control lever to the neutral position and fully close the throttle
lever.
2. Loosen the locknut 1, remove the clip
2, and then disconnect the throttle cable
joint 3.
a
S6D53190
WARNING
The throttle cable joint must be screwed
in a minimum of 8.0 mm (0.31 in) a.
2 3 1
NOTE:
Pull the throttle cable towards the engine to
remove any free play in the cable before
adjusting the position of the throttle cable
joint.
5. Connect the throttle cable joint 3, install
the clip 2, and then tighten the locknut
1.
S6P23330
3. Check that the accelerator lever 4 contacts the fully closed stopper 5.
3
1
S6P23350
4
S6P23340
4. Adjust the position of the throttle cable

joint until its hole is aligned with the set
pin on the lever.
6P23H11
3-10
1
2
3
4
5
6
7
8
9
CHK
ADJ
6. Operate the remote control lever several

times, and then check that the mark b
on the lever 4 has passed the mark c
on the stopper 5 when the remote control lever is in the fully open position of
the throttle.
4. Loosen the locknut 1, remove the clip

2, and then disconnect the shift cable
joint 3.
4
5
b
S6P23360
5. Align the alignment mark a on the bushing and alignment mark b on the
bracket.
7. Check that the lever 4 contacts the fully

closed stopper 5 when the remote control lever is in the fully closed position.
8. Check the throttle cable for smooth operation and, if necessary, repeat steps 27.
Checking the gear shift operation

1. Check that the gear shift operates
smoothly when shifting it from the neutral
position to forward or reverse. Adjust the
shift cable length if necessary.
6. Adjust the position of the shift cable joint

until its hole is aligned with the set pin.
2. Check the neutral switch for continuity.

Adjust the shift cable length or check the
neutral switch if necessary.
NOTE:
To check the neutral switch, see Chapter 8,
Checking the neutral switch.
Gear shift
position
Lead color
Blue/green
(L/G)
Black (B)
Forward or
reverse
S69J3370
WARNING
The shift cable joint must be screwed in a
minimum of 8.0 mm (0.31 in) c.
Neutral
3. Set the gear shift to the neutral position.
3-11
7. Connect the cable joint, install the clip,

and then tighten the locknut.
6P23H11
Control system / Bracket unit

8. Check the gear shift for smooth operation,
check the operation of the neutral switch
and, if necessary, repeat steps 37.
Bracket unit
Checking the PTT fluid level

1. Fully tilt the outboard motor up, and then
support it with the tilt stop lever 1.
Checking the PTT operation

1. Fully tilt the outboard motor up and down
a few times and check the entire trim and
tilt range for smooth operation. Check the
PTT fluid level if necessary.
WARNING
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
Otherwise, the outboard motor could suddenly lower if the PTT unit should lose
fluid pressure.
2. Remove the reservoir cap 2, and then
check the fluid level in the reservoir.
S6P23190
NOTE:
Be sure to listen to the winding sound of the
PTT motor for smooth operation.
support it with the tilt stop lever 1 to
check the lock mechanism of the lever.
WARNING
Make sure that the trim and tilt rams are
fully extended when removing the reservoir cap, otherwise fluid can spurt out
from the unit due to internal pressure.
NOTE:
If the fluid is at the correct level, a small
amount of fluid should overflow out of the
filler hole when the cap is removed.
6P23H11
3-12
1
2
3
4
5
6
7
8
9
CHK
ADJ
R.
Recommended PTT fluid:

ATF Dexron II
T.
3. If necessary, add sufficient fluid of the

recommended type until it overflows out
of the filler hole.
Gear oil check screw:

Changing the gear oil

1. Tilt the outboard motor up slightly.
4. Install the new O-ring and reservoir cap,

and then tighten the cap to the specified
torque.
2. Place a drain pan under the drain screw

1, remove the drain screw, then the
check screw 2 and let the oil drain completely.
T.
R.
Reservoir cap:
Lower unit
Checking the gear oil level

1. Fully tilt the outboard motor down.
2. Remove the check screw 1, and then
check the gear oil level in the lower case.
3. Check the oil for metal and discoloration,

and check its viscosity. Check the internal parts of the lower case if necessary.
1
S60V3320
NOTE:
If the oil is at the correct level, a small
amount of oil should overflow out of the
check hole when the check screw is
removed.
4. Insert a gear oil tube or gear oil pump

into the drain hole and slowly fill the gear
oil until oil flows out of the check hole and
no air bubbles are visible.
3. If necessary, add sufficient gear oil of the

recommended type until it overflows out
of the check hole.
Recommended gear oil:
Hypoid gear oil
API: GL-4
SAE: 90
4. Install the new gasket and check screw,
and then tighten the screw to the specified torque.
3-13
6P23H11
Bracket unit / Lower unit / General

Recommended gear oil:
Hypoid gear oil
API: GL-4
SAE: 90
Gear oil quantity:
Regular rotation model:
1,150 cm3
(38.9 US oz, 40.6 Imp oz)
Counter rotation model:
1,000 cm3
(33.8 US oz, 35.3 Imp oz)
5. Install the new gaskets, check screw,
and quickly install the drain screw, and
then tighten them to the specified torque.
T.
R.
Gear oil check screw and drain

screw:
Checking the lower unit for air

leakage
NOTE:
Cover the check hole with a rag when removing the tester from the lower unit.
Lower unit holding pressure:
70 kPa (0.7 kgf/cm2, 10 psi)
3. If the specified pressure cannot be maintained, check the drive shaft, propeller
shaft and shift rod oil seals for damage. If
necessary, check the each shaft for
bends and damage.
Checking the propeller

1. Check the propeller blades and splines.
Replace if cracked, damaged, or worn.
General
Checking the anode

1. Check the anodes and trim tab. Clean if
there are scales, grease, or oil.
1. Remove the check screw 1, and then

install the special service tool.
Leakage tester: 90890-06840

2. Apply the specified pressure to check
that the pressure is maintained in the
lower unit for at least 10 seconds.
S6P23310E
CAUTION:
Do not over pressurize the lower unit, otherwise the oil seals may be damaged.
6P23H11
3-14
1
2
3
4
5
6
7
8
9
CHK
ADJ
S6P23270E
CAUTION:
S6P23210
Do not oil, grease, or paint the anodes or

the trim tab, otherwise they will be ineffective.
NOTE:
If it is necessary to disassemble the outboard
motor to check an anode, refer to the applicable disassembly procedure in this manual.
2. Replace the anodes or trim tab if excessively eroded. In addition, check the
ground lead.
Checking the battery
S6P23400
3-15
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.
6P23H11
General
NOTE:
Batteries vary per manufacturer. The procedures mentioned in this manual may not
always apply, therefore, consult the instruction manual of the battery.
Disconnect the negative battery cable first,
then the positive battery cable.
S69J3620
2. Check the specific gravity of the electrolyte. Fully charge the battery if below
specification.
WARNING
Battery electrolyte is dangerous; it contains 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 generate explosive, hydrogen
gas. Always follow these preventive measures:
Charge batteries in a well-ventilated
area.
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO NOT SMOKE when charging or handling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
6P23H11
Electrolyte specific gravity:

1.280 at 20 C (68 F)
Lubricating the outboard motor

1. Apply water resistant grease to the areas
shown.
S6P23240
3-16
1
2
3
4
5
6
7
8
9
CHK
ADJ
S6D03010
NOTE:
Apply grease to the grease nipple until it
flows from the bushings a.
2. Apply low temperature resistant grease
to the area shown.
S6P23410
3. Apply corrosion resistant grease to the

area shown.
3-17
6P23H11
FUEL
Fuel system
Hose routing ...................................................................................................4-1
Fuel hose and blowby hose....................................................................... 4-1
Vapor gas hose ......................................................................................... 4-2
Cooling water hose.................................................................................... 4-3
Checking the throttle valve operation ........................................................4-5
Checking the TPS......................................................................................4-5
Measuring the fuel pressure ...................................................................... 4-7
Checking the pressure regulator ............................................................... 4-8
Reducing the fuel pressure........................................................................ 4-9
Disconnecting the quick connector............................................................ 4-9
Draining the fuel ......................................................................................4-10
Fuel filter ....................................................................................................... 4-11
Intake manifold............................................................................................. 4-12
Installing the intake manifold ................................................................... 4-13
Installing the intake silencer .................................................................... 4-13
Throttle body ................................................................................................4-15
Checking the canister .............................................................................. 4-18
Checking the canister check valve .......................................................... 4-18
Installing the throttle body........................................................................4-18
Low-pressure fuel pump ............................................................................. 4-20
Checking the check valve........................................................................4-21
Vapor separator............................................................................................ 4-22
Removing the fuel hose clamp ................................................................4-25
Installing the fuel hose clamp .................................................................. 4-25
Checking the vapor separator .................................................................4-25
Fuel injector.................................................................................................. 4-26
Installing the fuel injector .........................................................................4-27
6P23H11
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Hose routing
Fuel hose and blowby hose
4
6
1
3
B
7
2
S6P24010
1
2
3
4
5
6
7
8
9
0
A
B
C
Fuel hose (fuel joint-to-fuel filter)

Fuel hose (fuel filter-to-joint)
Fuel hose (joint-to-low-pressure fuel pump)
Fuel hose (low-pressure fuel pump-to-filter)
Fuel hose (filter-to-joint)
Fuel hose (joint-to-check valve)
Fuel hose (check valve-to-joint)
Fuel hose (vapor separator-to-quick connector)
Fuel hose (quick connector-to-joint)
Fuel hose (joint-to-quick connector)
Fuel hose (pressure regulator-to-fuel cooler)
Fuel hose (fuel cooler-to-vapor separator)
Blowby hose (starboard cylinder head cover-to-intake silencer)
4-1
6P23H11
Hose routing
Vapor gas hose
STBD
E
1
9
0
F
G
8
E
G
8
7
6
6
5
S6P24020E
1
2
3
4
5
6
7
8
Vapor gas hose (vapor separator-to-joint)

Vapor gas hose (vapor separator-to-joint)
Vapor gas hose (joint-to-joint)
Vapor gas hose (joint-to-joint)
Vapor gas hose (joint-to-canister tank port)
Vapor gas hose (canister purge port-to-joint)
Vapor gas hose (joint-to-vapor shut-off valve)
Vapor gas hose (vapor shut-off valve-to-surge
tank)
9 Vapor gas hose (intake silencer-to-check
valve)
0 Vapor gas hose (check valve-to-joint)
A Vapor gas hose (canister atmospheric port-tojoint)
6P23H11
B Vapor gas hose (joint-to-joint)

C Vapor gas hose (joint-to-check valve)
D Vapor gas hose (check valve-to-top cowling
lock)
E Vacuum hose (pressure regulator-to-joint)
F Vacuum hose (intake air pressure sensor-tojoint)
G Vacuum hose (joint-to-surge tank)
4-2
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Cooling water hose

2
PORT
STBD
2
b
4
5
a
3
6
1
c
d
e
1
2
3
4
5
6
7
Cooling water hose (cylinder block-to-fuel cooler)

Cooling water hose (fuel cooler-to-Rectifier Regulator)
Cooling water hose (Rectifier Regulator-to-cooling water pilot hole)
Cooling water hose (port thermostat cover-to-cylinder block)
Cooling water hose (starboard thermostat cover-to-cylinder block)
Cooling water hose (starboard cylinder head-to-cooling water pressure sensor adapter)
Flushing hose (joint-to-cooling water passage cover)
a
b
c
d
e
Fuel cooler
Rectifier Regulator
Cooling water pilot hole (on the bottom cowling)
Cooling water pressure sensor adapter
Cooling water passage cover (on the cylinder block)
4-3
S6P24450E
6P23H11
Hose routing
1
3
5
S6P24490
1
2
3
4
5
Cooling water hose (cylinder block-to-fuel cooler)

Cooling water hose (Rectifier Regulator-to-cooling water pilot hole)
Flushing hose (joint-to-cooling water passage cover)
Flushing hose (flushing hose adapter-to-joint)
Speedometer hose
6P23H11
4-4
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Checking the throttle valve operation

1. Remove the flywheel magnet cover and
intake silencer.
NOTE:
See the exploded diagram (4-12).
2. Push the throttle valve, and check that
the valve moves smoothly when the
engine start switch is turned to OFF.
3. Turn the engine start switch to ON.
4. Check that the throttle valves operate
smoothly when the remote control lever
is shifted from the fully closed position to
the fully open position.
S6P24140
NOTE:
Be sure to check the accelerator position
sensor before checking the TPS.
To connect and operate the YDIS, see
Chapter 9, YDIS and the YDIS (version
1.23a or later) Instruction Manual.
2. Check that the accelerator lever 1 contacts the fully closed stopper 2 when the
remote control lever is at the fully closed
position.
2
S6P24130
5. Install the intake silencer and flywheel

magnet cover.
NOTE:
To install the intake silencer, see Installing
the intake silencer.
To check the accelerator position sensor,
see Chapter 8, Checking the accelerator
position sensor circuit and Checking the
accelerator position sensor.
Checking the TPS

1. Connect a computer to the outboard
motor and use the YDIS to display
Throttle position sensor 1, Throttle
valve opening, and Throttle position
sensor 2.
4-5
S6P21030
NOTE:
3. Start the engine, warm it up, and then
turn it off.
6P23H11
Hose routing
4. Check that the remote control lever is in
the fully closed position of the throttle,
and then check the output voltage of TPS
1 and the throttle valve opening angle.
S6P24150
S6P24440
CAUTION:
Do not loosen the throttle stop screw nut,
and do not turn the throttle stop screw.
NOTE:
Check the TPS after the engine has been
warmed up.
When checking the TPS, do not start the
engine.
The actual TPS output voltage and throttle
valve opening angle may vary according to
environmental conditions and engine temperature.
6P23H11
Output voltage of TPS 1 with the

remote control lever at the fully
closed position:
at 20 C (68 F):
0.750 V (reference data)
Throttle valve opening angle with the
remote control lever at the fully
closed position:
at 20 C (68 F):
0.57.0 (reference data)
5. Shift the remote control lever to the fully
open position and hold it.
S6P24160
6. Check the output voltage of TPS 2 and

the throttle valve opening angle.
TPS 2 output voltage with the remote
control lever at the fully open
position:
at 20 C (68 F):
4.550 V
Throttle valve opening angle with the
remote control lever at the fully open
position:
Above 80 (reference data)
7. Operate the remote control lever, and
check that the output voltages of TPS 1
and TPS 2 change continuously.
4-6
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Measuring the fuel pressure

1. Disconnect the quick connector from the
vapor separator.
NOTE:
Before disconnecting the quick connector,
reduce the fuel pressure.
2. Connect fuel pressure gauge adapter B
1 between the quick connector and
vapor separator.
3. Connect the fuel pressure gauge 2 to
fuel pressure gauge adapter B.
PORT
4. Turn the engine start switch to ON, and

then measure the fuel pressure within 5
seconds.
NOTE:
The fuel pressure will decreases after 5
seconds later when 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 switch to OFF.
Fuel pressure (reference data):
300 kPa (3.0 kgf/cm2, 43.5 psi)
5. Measure the fuel pressure 5 seconds
after turning the engine start switch to
ON.
280 kPa (2.8 kgf/cm2, 40.6 psi)
S6P24290E
WARNING
Gently screw in the gauge until it is
firmly connected to prevent fuel from
leaking out.
Before measuring the fuel pressure,
make sure that the drain screw is tightened securely.
Do not loosen the drain screw while
measuring the fuel pressure. Loosening
the drain screw can cause fuel to spray
out creating a fire hazard.
Fuel pressure gauge adapter B 1:
90890-06942
Fuel pressure gauge 2:
90890-06786
6. Start the engine, warm it up for 5 minutes, and then measure the fuel pressure
at engine idle speed. If below specification, check the high-pressure fuel line
and the vapor separator.
260 kPa (2.6 kgf/cm2, 37.7 psi)
8. Remove the special service tools.
WARNING
After measuring the fuel pressure, cover
the end of the hose with a clean, dry rag,
point the hose downward, and then
loosen the drain screw to drain the
remaining fuel from the hose and gauge.
When storing the fuel pressure gauge,
9. Connect the quick connector.
4-7
6P23H11
Hose routing
Checking the pressure regulator

1. Disconnect the quick connector from the
vapor separator.
NOTE:
Before disconnecting the quick connector,
reduce the fuel pressure.
Fuel pressure gauge: 90890-06786

Fuel pressure gauge adapter B:
90890-06942
Vacuum/pressure pump gauge set:
90890-06756
5. Start the engine and let it idle.
2. Connect fuel pressure gauge adapter B

between the quick connector and vapor
separator.
3. Connect the fuel pressure gauge to fuel
pressure gauge adapter B.
4. Disconnect the pressure regulator hose,
and then connect the special service tool
to the pressure regulator.
6. Check that the fuel pressure reduces

when vacuum pressure is applied to the
pressure regulator. If the fuel pressure
does not reduce, replace the pressure
regulator.
NOTE:
When the specified vacuum pressure is
reached, the pressure regulator is operated
and the fuel pressure is reduced.
WARNING
S6P24300E
WARNING
Gently screw in the gauge until it is
firmly connected to prevent fuel from
leaking out.
Before measuring the fuel pressure,
Do not loosen the drain screw while
measuring the fuel pressure. Loosening
the drain screw can cause fuel to spray
out creating a fire hazard.
6P23H11
After measuring the fuel pressure, cover

the end of the hose with a clean, dry rag,
point the hose downward, and then
loosen the drain screw to drain the
remaining fuel from the hose and gauge.
When storing the fuel pressure gauge,
9. Connect the pressure regulator hose and
quick connector.
4-8
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Reducing the fuel pressure

WARNING
Always reduce the fuel pressure in the
high-pressure fuel line before servicing
the line or the vapor separator. If the fuel
pressure is not released, pressurized fuel
may spray out.
Disconnecting the quick connector

WARNING
If the quick connector is removed suddenly, pressurized fuel could spray out.
Be sure to reduce the fuel pressure before
removing the quick connector.
1. Remove the fuse holder cover 1, and

then remove the high-pressure fuel pump
fuse (15 A) 2.
2. Wrap the quick connector with a rag, and

then rotate the quick connector tab 1 to
the stopper position a.
PORT
1
2
STBD
S6P24270
2. Start the engine.
CAUTION:
NOTE:
If the engine starts, it will stall after a few
seconds.
If the engine does not start, crank the
engine 2 or 3 times.
3. After the engine stalls, crank the engine
2 or 3 times.
4. Turn the engine start switch to OFF.
4-9
Do not rotate the quick connector tab 1

past the stopper position a, otherwise it
could be damaged.
When the fuel hose is disconnected,
quickly remove the retainer 2 from the
quick connector, otherwise the retainer
could be lost.
3. Disconnect the quick connector 3 from
the fuel rail or vapor separator directly.
6P23H11
Hose routing
WARNING
Reduce the fuel pressure before loosening the vapor separator drain screw, or
pressurized fuel will spray out and may
result in serious injury.
6. Tighten the drain screw.

S6P24280
T.
R.
Draining the fuel
Vapor separator drain screw:


2. Remove the cap 1.
3. Cover the pressure check valve of the
vapor separator with a rag, and then
press in the pressure check valve using a
thin screwdriver to release the fuel pressure.
4. Place a drain pan under the vapor separator drain hose, and then loosen the
drain screw 2.
5. Drain the fuel from the vapor separator
drain hose by pressing the pressure
check valve using a thin screwdriver.
2
1
S6P24310
6P23H11
4-10
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Fuel filter
6
1
13
13
3
10
10
4
5
11
T.
R.
12
3.5 N m (0.35 kgf m, 2.6 ft lb)
13
S6P24040E
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
4-11
Part name
O-ring
O-ring
Fuel filter element
Float
Cup
Fuel filter assembly
Bracket
Bolt
Bolt
Fuel hose
Holder
Joint
Plastic tie
Qty
1
1
1
1
1
1
1
2
2
2
1
1
3
Remarks
Not reusable
Not reusable
M6 16 mm
M6 20 mm
Not reusable
6P23H11
Fuel filter / Intake manifold
Intake manifold
T.
R.
7 N m (0.7 kgf m, 5.2 ft Ib)
16
1
3
A
13
15
13
9
10
11
12
T.
R.
10 N m (1.0 kgf m, 7.4 ft Ib)
14
T.
R.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Part name
Flywheel magnet cover
Damper
Grommet
Blowby hose
Plastic tie
Grommet
Bolt
Bolt
Bolt
Intake manifold (STBD)
Gasket
Gasket
Gasket
Intake manifold (PORT)
Intake silencer
6P23H11
Qty
1
1
4
1
1
1
1
4
8
7
1
1
6
1
1
1
10
10 N m (1.0 kgf m, 7.4 ft Ib)
S6P24050E
Remarks
M6 25 mm
M8 40 mm
M6 40 mm
Not reusable
Not reusable
Not reusable
4-12
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Installing the intake manifold

STBD
1. Install new gaskets onto the intake manifolds.
PORT
$
!
T.
R.
S6P24060
NOTE:
Be sure to install the projection on each gasket into its corresponding slit in the intake
manifolds.
S6P24090
Intake manifold bolt:

10 Nm (1.0 kgfm, 7.4 ftlb)
4. Tighten the M8 bolts in the sequence

shown.
PORT
STBD
2. Install the intake manifolds and bolts

temporarily.
3
1
2
4
S6P24100E
Installing the intake silencer

1. Install the intake silencer.
T.
S6P24080E
R.
NOTE:
When installing the intake manifolds, make
sure that the gaskets do not come off when
the projection of the gasket comes into contact with the fuel rail cover.
Intake silencer bolt:

2. Fasten the intake air temperature sensor

lead 1 to the holder on the oil filler neck
as shown.
3. Connect the blowby hose 2, and then
fasten the plastic tie 3 as shown.
3. Tighten the M6 bolts to the specified

torque in the sequence shown.
4-13
6P23H11
Intake manifold
1
2
3
4
5
6
7
8
9
1
3
2
2
S6P24380
6P23H11
4-14
FUEL
Fuel system
Throttle body
R.
R.
R.
13 N m (1.3 kgf m, 9.6 ft Ib)
T.
T.
T.
13 N m (1.3 kgf m, 9.6 ft Ib)
13 N m (1.3 kgf m, 9.6 ft Ib)

T.
R.
5 N m (0.5 kgf m, 3.7 ft Ib)
22
23
3
LT
LT
242
242
24
25
15
6
26
16
27
11
17
28
12
18
T.
R.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
4-15
10
14
13
R.
21
29
T.
20
19
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
Part name
Joint
Plastic tie
Nut
Washer
Gasket
Bolt
Plate
Gasket
Surge tank
Collar
Bolt
Holder
Bolt
Canister
Bolt
Bracket
S6P24530
Qty
1
1
4
2
1
1
4
1
1
1
2
4
2
2
1
1
1
Remarks
Not reusable
M8 18 mm
Not reusable
M8 40 mm
M6 14 mm
M6 10 mm
6P23H11
Throttle body
4
R.
R.
R.
13 N m (1.3 kgf m, 9.6 ft Ib)
T.
T.
T.
13 N m (1.3 kgf m, 9.6 ft Ib)
13 N m (1.3 kgf m, 9.6 ft Ib)

T.
R.
5 N m (0.5 kgf m, 3.7 ft Ib)
22
23
3
LT
LT
242
242
24
25
15
6
26
16
27
11
17
28
12
18
T.
R.
No.
18
19
20
21
22
23
24
25
26
27
28
29
10
14
13
R.
21
29
T.
20
19
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
Part name
Bolt
Collar
Grommet
Bracket
Nut
Holder
Bracket
Sub wiring harness
Bolt
Washer
6P23H11
S6P24530
Qty
2
2
2
1
1
1
1
1
1
1
1
1
Remarks
M6 28 mm
M6 20 mm
4-16
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
4
1
3
4
5
2
2
6
7
9 mm 7 mm
(0.35 in) (0.27 in)
3
7
7
8
8
9
9
9 mm 7 mm
9 mm
(0.35 in) (0.27 in) (0.35 in)
9
10
9 mm
(0.35 in)
10
12 mm 9 mm
(0.47 in) (0.35 in)
S6P24500E
No.
1
2
3
4
5
6
7
8
9
10
4-17
Part name
Check valve
Holder
Holder
Joint
Joint
Joint
Holder
Joint
Holder
Holder
Qty
1
3
2
1
2
1
2
2
2
1
Remarks
6P23H11
Throttle body
Checking the canister

1. Check the canister. Replace if cracked.
2. Apply positive pressure to the check

valve port.
2. Connect the special service tool to the

atmospheric port 1 and cover the other
ports, each with a finger.
3. Check that air comes out of the opposite

end of the check valve. Replace if no air
comes out.
opposite check valve port as shown.
S6P24180
3. Apply the specified positive pressure and

check that there is no air leakage.
Replace if there is air leakage.
90890-06756
Specified pressure:
19.6 kPa (0.196 kgf/cm2, 2.8 psi)

valve port.
6. Check that no air comes out of the opposite end of the check valve. Replace if air
comes out.
Installing the throttle body

1. Connect the check valve to the hose 1
and 2.
Checking the canister check valve

check valve port as shown.
S6P24390
To the intake silencer

90890-06756
6P23H11
4-18
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
2. Connect the hoses and fasten them.
21
4
6
3
S6P24410
NOTE:
Fasten the pressure regulator hose 3 and
vapor separator hose 6 to the holder.
S6P24400E
To the pressure regulator

To the atmosphere (top cowling lock)
To the vapor separator
6. Fasten the wiring harness to the holders.
NOTE:
Fasten the pressure regulator hose 3 and
canister vent hose 4 to the holder.
7. Fasten the vapor gas hose 7 and fuel

hose 8 to the holder.
3. Fasten hoses 2 and 5 to the holder.
2
5
8
7
S6P24420E
S6P24470
4. Install the throttle body.

5. Connect the hoses and fasten them.
4-19
6P23H11
Throttle body / Low-pressure fuel pump
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Part name
Cover
Bolt
Screw
Holder
Check valve
Clamp
Clamp
Joint
Holder
Cover
Filter
Fuel hose
Plastic tie
Plastic tie
6P23H11
Qty
1
1
2
1
1
1
6
4
1
1
1
1
5
1
1
1
2
3
4
5
6
7
8
9
Remarks
M6 15 mm
5 8 mm
Not reusable
Not reusable
4-20
FUEL
Fuel system
Checking the check valve

check valve port as shown.

90890-06756
valve port.
3. Check that air comes out of the opposite
end of the check valve. Replace if no air
comes out.
opposite check valve port as shown.

valve port.
6. Check that no air comes out of the opposite end of the check valve. Replace if air
comes out.
4-21
6P23H11
Low-pressure fuel pump / Vapor separator
Vapor separator
11
12
T.
R.
13
1
14
13
2
3
5 N m (0.5 kgf m, 3.7 ft Ib)
12
11
13
2
3
11
4
15
10
12
10
3
12 mm
(0.47 in)
9
4
10
7
3
11
8
11
10
10 mm
(0.39 in)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Part name
Bracket
Bolt
Collar
Grommet
Nut
Bolt
Collar
Fuel cooler
Bolt
Clamp
Clamp
Quick connector
Clamp
Joint
Clamp
Clamp
6P23H11
3
6
Qty
1
2
8
4
2
2
2
1
2
3
4
3
3
1
1
1
16
5
S6P24520
Remarks
M6 16 mm
M6 35 mm
M6 25 mm
Not reusable
4-22
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
4
T.
R.
5 N m (0.5 kgf m, 3.7 ft Ib)
T.
R.
2 N m (0.2 kgf m, 1.5 ft Ib)
24
3
23
4
24
19
2
25
12
1
11
14
13
13
15
7
T.
2 N m (0.2 kgf m, 1.5 ft Ib)
R.
17
21
22
Part name
Cover assembly
O-ring
Pressure regulator
Screw
Screw
Wiring harness
Grommet
Filter
Filter holder
Plate
Plate
Screw
O-ring
Needle valve
Float
Pin
Qty
1
1
1
2
7
1
1
1
1
1
1
1
3
1
1
1
1
R.
R.
2 N m (0.2 kgf m, 1.5 ft Ib)
T.
T.
4-23
9
10
16
18
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
20
2 N m (0.2 kgf m, 1.5 ft Ib)
S6P24250E
Remarks
Not reusable
6 12 mm
4 16 mm
4 8 mm
Not reusable
6P23H11
Vapor separator
4
T.
R.
5 N m (0.5 kgf m, 3.7 ft Ib)
T.
R.
2 N m (0.2 kgf m, 1.5 ft Ib)
24
3
23
4
24
19
2
25
12
1
11
14
13
13
15
7
T.
2 N m (0.2 kgf m, 1.5 ft Ib)
R.
17
22
R.
R.
Qty
1
1
1
1
1
1
2
1
T.
T.
6P23H11
21
2 N m (0.2 kgf m, 1.5 ft Ib)
Part name
Screw
Gasket
Float chamber
Drain screw
Drain hose
Joint
Hose
Cap
9
10
16
18
No.
18
19
20
21
22
23
24
25
20
2 N m (0.2 kgf m, 1.5 ft Ib)
S6P24250E
Remarks
4 8 mm
Not reusable
4-24
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Removing the fuel hose clamp

1. Remove the fuel hose clamps by cutting
the crimped section of the clamp.
S6D54200
2. Check the float. Replace if there is deterioration.
CAUTION:
If the fuel hose clamps are removed without cutting the crimp first, the fuel hose
could be damaged.
Installing the fuel hose clamp

1. Crimp the fuel hose clamps properly to
securely fasten them.
3. Check the filter. Clean if there is dirt or

residue.
4. Install the needle valve and float to the
vapor separator cover.
5. Place the vapor separator cover assembly in the position shown in the illustration, and then check the float height a.
S6P24480
WARNING
Do not reuse the fuel hose clamps, always
replace them with new ones, otherwise
the fuel leakage may occur.
Checking the vapor separator
NOTE:
To measure the height of the float, it should
be resting on the needle valve. Do not press
the float.
Float height a:
60.5 3.0 mm (2.38 0.12 in)
1. Check the needle valve. Replace if bent

or worn.
4-25
6P23H11
Vapor separator / Fuel injector
Fuel injector
10
8
1
3
12
5
3
10
E
3
6
3
7
10
11
2
5
No.
1
2
3
4
5
6
7
8
9
10
11
12
Part name
Fuel injector
O-ring set
Holder
Fuel rail (PORT)
Bolt
Cover
Bolt
Fuel rail (STBD)
Cover
Plastic tie
Fuel rail assembly (PORT)
Fuel rail assembly (STBD)
6P23H11
Qty
6
2
6
1
4
1
4
1
1
3
1
1
S6P24320
Remarks
Not reusable
M6 35 mm
M6 20 mm
4-26
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Installing the fuel injector

1. Apply engine oil to new O-rings, and then
install them onto the fuel injectors.
4. Install the fuel rails onto the cylinder

heads.
5. Tighten the bolts 7 equally and gradually.
7
7
S6P24330
2. Install the fuel injectors 1 onto the port

fuel rail 2, and then install the holders 3
as shown.
6. Connect the fuel injector couplers.

7. Fasten the wiring harness to the holders,
and then fasten the plastic ties 8 as
shown.
3
1
S6P24360E
3
PORT
2
STBD
S6P24340
3. Install the fuel injectors 4 onto the starboard fuel rail 5, and then install the
holders 6 as shown.
S6P24370
6
4
5
S6P24350
4-27
6P23H11
Fuel injector
MEMO
1
2
3
4
5
6
7
8
9
6P23H11
4-28
POWR
Power unit
Power unit....................................................................................................... 5-1
Checking the compression pressure .........................................................5-1
Checking the oil pressure ..........................................................................5-1
Checking the oil pressure sensor .............................................................. 5-2
Checking the valve clearance.................................................................. 5-10
Adjusting the valve clearance.................................................................. 5-11
Replacing the timing belt .........................................................................5-15
Removing the wiring harness guide ........................................................ 5-20
Removing the power unit.........................................................................5-21
Removing the timing belt, driven sprocket, and camshaft .......................5-23
Checking the timing belt and sprocket.....................................................5-27
Checking the valve lifter ..........................................................................5-27
Checking the camshaft ............................................................................5-27
Installing the camshaft, driven sprocket, and timing belt ......................... 5-28
Starter motor and accelerator position sensor .........................................5-35
ECM ............................................................................................................... 5-36
Fuse box ....................................................................................................... 5-37
Junction box.................................................................................................5-38
Exhaust cover ..............................................................................................5-39
Removing the exhaust cover ................................................................... 5-40
Checking the exhaust cover anode ......................................................... 5-40
Installing the exhaust cover ..................................................................... 5-40
Cylinder head ...............................................................................................5-41
Removing the cylinder head .................................................................... 5-43
Checking the valve spring ....................................................................... 5-43
Checking the valve .................................................................................. 5-43
Checking the valve guide ........................................................................5-44
Replacing the valve guide ....................................................................... 5-45
Checking the valve seat ..........................................................................5-45
Refacing the valve seat ...........................................................................5-46
Checking the cylinder head ..................................................................... 5-48
Installing the valve ...................................................................................5-49
Removing the cooling water passage cover............................................5-49
Checking the cooling water passage cover anode ..................................5-50
Installing the cooling water passage cover.............................................. 5-50
Installing the cylinder head ...................................................................... 5-51
6P23H11
Crankcase ..................................................................................................... 5-53

Cylinder block ..............................................................................................5-55
Disassembling the cylinder block ............................................................ 5-57
Checking the piston diameter .................................................................. 5-58
Checking the cylinder bore ...................................................................... 5-58
Checking the piston clearance (reference).............................................. 5-58
Checking the piston ring ..........................................................................5-58
Checking the piston ring end gap (reference) .........................................5-59
Checking the piston ring groove ..............................................................5-59
Checking the piston ring side clearance.................................................. 5-59
Checking the piston pin boss bore .......................................................... 5-59
Checking the piston pin ...........................................................................5-60
Checking the connecting rod small end inside diameter ......................... 5-60
Checking the connecting rod big end side clearance ..............................5-60
Checking the crankshaft ..........................................................................5-61
Checking the crankpin oil clearance........................................................ 5-61
Selecting the connecting rod bearing ......................................................5-63
Checking the crankshaft journal oil clearance .........................................5-63
Selecting the main bearing ...................................................................... 5-64
Disassembling the oil pump..................................................................... 5-65
Checking the oil pump ............................................................................. 5-66
Assembling the oil pump .........................................................................5-66
Assembling the power unit ...................................................................... 5-67
Installing the wiring harness .................................................................... 5-72
Installing the power unit...........................................................................5-73
6P23H11
1
2
3
4
5
6
7
8
9
POWR
Power unit
Power unit
Checking the compression pressure

1. Start the engine, warm it up for 5 minutes, and then turn it off.
2. Remove the engine stop lanyard from the
3. Disconnect all fuel injector couplers.
4. Remove the ECM cover, all ignition coils
and spark plugs, and then install the special service tools into a spark plug hole.
2
S6P25010
6. Crank the engine until the reading on the

compression gauge stabilizes, and then
check the compression pressure.
Minimum compression pressure
(reference data):
740 kPa (7.4 kgf/cm2, 107.3 psi)
7. If the compression pressure is below
specification and the compression pressure for each cylinder is unbalanced, add
a small amount of engine oil to the cylinder, and then check the compression
pressure again.
NOTE:
If the compression pressure increases,
check the pistons and piston rings. Replace
if worn.
If the compression pressure does not
increase, check the valve clearances,
valves, valve seats, cylinder head gaskets,
and cylinder heads. Adjust or replace if
necessary.
CAUTION:
Before removing the spark plugs, blow
compressed air in the spark plug well to
clear out any dirt or dust that may fall into
the cylinder.
Compression gauge 1:
90890-03160
Compression gauge extension 2:
90890-06563
Checking the oil pressure

1. Place a rag under the oil pressure sensor.
2. Remove the oil pressure sensor, and
then install an oil pressure gauge 1 into
the oil pressure sensor installation hole.
5. Disconnect the throttle cable joint from

the accelerator lever, and then place and
hold the lever in the fully open position of
the throttle.
S6P25020
NOTE:
Use a general pressure gauge.
S6P25015
5-1
6P23H11
Power unit
4. Check the oil pressure. Check for oil
leakage and check the oil pump and oil
strainer if out of specification.
NOTE:
If the oil pressure sensor is removed, the
engine idle speed will increase about 900
r/min due to an oil pressure sensor malfunction condition. Delete the diagnosis
record using the YDIS after checking the oil
pressure.
The actual oil pressure may vary depending on the temperature and viscosity of the
engine oil being used.
Oil pressure (reference data):
600 kPa (6.0 kgf/cm2, 87.0 psi) at
60 C (140 F) with SL 10W-30
engine oil and at 900 r/min
Checking the oil pressure sensor

1. Connect the test harness to the oil pressure sensor.
3.4 V
600 kpa
(6.0 kgf/cm2,
87.0 psi)
S6P25040
Output voltage
Oil pressure
Test harness (3 pins): 90890-06869
Oil pressure sensor input voltage

(reference data):
Orange (O) Black (B)
4.755.25 V
Oil pressure sensor output voltage
(reference data):
Pink/white (P/W) Black (B)
3.4 V at engine idle speed

3. Measure the oil pressure sensor input
voltage. Check the wiring harness connection or replace the ECM if out of specification.
4. Measure the oil pressure sensor output
voltage. Replace if out of specification.
S6P25030
6P23H11
5-2
1
2
3
4
5
6
7
8
9
POWR
Power unit
5
R.
R.
4 N m (0.4 kgf m, 3.0 ft Ib)
T.
T.
8 N m (0.8 kgf m, 5.9 ft Ib)
17
1
20
17
18
19
4
7
11
10
LT
11
572
14
LT
2
3
13
12
572
11
11
13
LT
572
16
LT
572
T.
R.
11
8 N m (0.8 kgf m, 5.9 ft Ib)
4
LT
R.
Part name
Power unit
Gasket
Dowel
Bolt
Bolt
Oil dipstick
Dipstick guide
O-ring
Bolt
Upper case cover
Bolt
Apron (STBD)
Grommet
Apron (PORT)
Bolt
Nut
Bolt
572
T.
5-3
LT
572
15
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
LT
572
42 N m (4.2 kgf m, 31.0 ft Ib)
Qty
1
1
2
6
7
1
1
1
1
1
7
1
6
1
1
2
2
S6P25050E
Remarks
Not reusable
M10 140 mm
M10 35 mm
Not reusable
M6 20 mm
M6 14 mm
M6 30 mm
M6 10 mm
6P23H11
Power unit
5
R.
R.
4 N m (0.4 kgf m, 3.0 ft Ib)
T.
T.
8 N m (0.8 kgf m, 5.9 ft Ib)
17
1
20
17
18
19
4
7
11
10
LT
11
572
14
LT
2
3
13
12
572
11
11
13
LT
572
16
LT
572
11
T.
R.
8 N m (0.8 kgf m, 5.9 ft Ib)
5
4
LT
572
T.
R.
Part name
Cap
PTT motor lead
Clamp
6P23H11
LT
572
15
No.
18
19
20
LT
572
42 N m (4.2 kgf m, 31.0 ft Ib)
Qty
2
1
3
S6P25050E
Remarks
5-4
1
2
3
4
5
6
7
8
9
POWR
Power unit
5
2
3
24
1
T.
R.
4
T.
R.
25 N m (2.5 kgf m, 18.4 ft Ib)
6
8
14
15
12
14
11
10
7 N m (0.7 kgf m, 5.2 ft Ib)
25 26
18
17
9
E
13
12
T.
R.
25 N m (2.5 kgf m, 18.4 ft Ib)
T.
R.
7 N m (0.7 kgf m, 5.2 ft Ib)
18
27 19
17
23
T.
R.
14
15
16
17
5-5
Part name
Wiring harness guide
Plastic tie
Bolt
Holder
Damper
Bolt
Timing belt guide (PORT)
Timing belt guide (STBD)
Bolt
ECM cover
Bolt
Bolt
Cam position sensor
(STBD IN, PORT EX)
O-ring
Bolt
Ignition coil
14
13
21
22
16
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
20
Qty
1
2
6
3
2
4
1
1
4
1
4
3
2
3
1
12
6
16
12
E
23 N m (2.3 kgf m, 17.0 ft Ib)
S6P25060E
Remarks
M6 35 mm
M6 14 mm
M6 20 mm
M6 28 mm
M6 20 mm
Not reusable
M6 20 mm
6P23H11
Power unit
5
2
3
24
1
T.
R.
4
T.
R.
25 N m (2.5 kgf m, 18.4 ft Ib)
6
8
14
15
12
14
11
10
7 N m (0.7 kgf m, 5.2 ft Ib)
25 26
18
17
9
E
13
12
T.
R.
25 N m (2.5 kgf m, 18.4 ft Ib)
T.
R.
7 N m (0.7 kgf m, 5.2 ft Ib)
18
27 19
17
23
T.
R.
Part name
Spark plug
Clamp
Gasket
Plug
Bolt
ECM base assembly
Bolt
Holder
Hose
6P23H11
14
13
21
22
16
No.
18
19
20
21
22
23
24
25
26
27
20
Qty
6
1
1
1
1
2
1
1
1
1
16
12
E
23 N m (2.3 kgf m, 17.0 ft Ib)
S6P25060E
Remarks
Not reusable
M14 12 mm
M6 30 mm
M6 12 mm
5-6
1
2
3
4
5
6
7
8
9
POWR
Power unit
5
T.
R.
240 N m (24.0 kgf m, 177.0 ft lb)
1
2
11
E
5
T.
R.
39 N m (3.9 kgf m, 28.8 ft Ib)
5
7
12
4
17
10
5
8
13
14
13
15
14
16
15
16
T.
R.
4 N m (0.4 kgf m, 3.0 ft Ib)
S6P25070
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
5-7
Part name
Nut
Washer
Flywheel magnet
Stator assembly
Bolt
Collar
Holder
Bracket
Screw
Timing belt
Timing belt tensioner
Bolt
Washer
Pulley
Collar
Woodruff key
Qty
1
1
1
1
4
2
2
1
1
2
1
1
2
2
2
2
1
Remarks
Width across flats: 36 mm
M6 35 mm
5 12 mm
M10 55 mm
6P23H11
Power unit
5
R.
2 N m (0.2 kgf m, 1.5 ft Ib)
T.
R.
LT
7
8
7
26
1280B
11
24
33
8
7
9
8
7
10
12
11
14
14
R.
1
2
18
R.
R.
6P23H11
E
T.
T.
Part name
Cap
Gasket
Bolt
Variable camshaft timing assembly
Bolt
Driven sprocket
Dowel
Oil seal
Camshaft (STBD IN)
Camshaft (STBD EX)
Valve lifter
Valve shim
Camshaft cap
Gasket
Bolt
Bolt
Camshaft cap
8 N m (0.8 kgf m, 5.9 ft lb)

17 N m (1.7 kgf m, 12.5 ft lb)
12
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
16
15
8 N m (0.8 kgf m, 5.9 ft lb)

8 N m (0.8 kgf m, 5.9 ft lb)
15
13
T.
34
32 N m (3.2 kgf m, 23.6 ft Ib)
5
E
8 N m (0.8 kgf m, 5.9 ft lb)

8 N m (0.8 kgf m, 5.9 ft lb)
60 N m (6.0 kgf m, 44.3 ft Ib)
R.
12
T.
R.
11
T.
1
2
12 11
E
23
1
2
R.
27
30
22
25
T.
29
31
21
6
1
2
23
24
271
28
19
1386B
25
1280B
20
1
2
3
32
T.
8 N m (0.8 kgf m, 5.9 ft lb)

17 N m (1.7 kgf m, 12.5 ft lb)
1
2
17
Qty
2
2
2
2
2
2
4
4
1
1
24
24
1
4
4
1
7
18
1
2
8 N m (0.8 kgf m, 5.9 ft lb)

17 N m (1.7 kgf m, 12.5 ft lb)
S6P25080E
Remarks
Not reusable
M12 35 mm
M10 35 mm
Not reusable
Not reusable
M7 48 mm
M6 30 mm
5-8
1
2
3
4
5
6
7
8
9
POWR
Power unit
5
R.
2 N m (0.2 kgf m, 1.5 ft Ib)
T.
R.
LT
7
8
7
26
1280B
11
24
33
8
7
9
8
7
10
12
11
14
14
R.
1
2
18
T.
R.
T.
R.
5-9
Part name
Bolt
Gasket
Screw
Plate
Cylinder head cover (STBD)
Grommet
Bolt
Bolt
Camshaft (PORT EX)
Camshaft (PORT IN)
Camshaft cap
Bolt
Camshaft cap
Camshaft cap
Bolt
Gasket
Cylinder head cover (PORT)
8 N m (0.8 kgf m, 5.9 ft lb)

17 N m (1.7 kgf m, 12.5 ft lb)
12
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
16
15
8 N m (0.8 kgf m, 5.9 ft lb)

8 N m (0.8 kgf m, 5.9 ft lb)
15
13
T.
34
32 N m (3.2 kgf m, 23.6 ft Ib)
5
E
8 N m (0.8 kgf m, 5.9 ft lb)

8 N m (0.8 kgf m, 5.9 ft lb)
60 N m (6.0 kgf m, 44.3 ft Ib)
R.
12
T.
R.
11
T.
1
2
12 11
E
23
1
2
R.
27
30
22
25
T.
29
31
21
6
1
2
23
24
271
28
19
1386B
25
1280B
20
1
2
3
32
T.
8 N m (0.8 kgf m, 5.9 ft lb)

17 N m (1.7 kgf m, 12.5 ft lb)
1
2
17
Qty
14
1
8
1
1
2
2
28
1
1
1
6
1
6
12
1
1
18
1
2
8 N m (0.8 kgf m, 5.9 ft lb)

17 N m (1.7 kgf m, 12.5 ft lb)
S6P25080E
Remarks
M7 37 mm
Not reusable
4 8 mm
M6 19 mm
M6 30 mm
M7 48 mm
M7 37 mm
Not reusable
6P23H11
Power unit
Checking the valve clearance
7. Remove the cylinder head covers.
CAUTION:
NOTE:
Check the valve clearances when the
engine is cold.
When adjusting the valve clearances, the
fuel pressure must be reduced before
removing any parts. To reduce the fuel
pressure, see Chapter 4, Reducing the
fuel pressure.
NOTE:
8. Turn the flywheel magnet clockwise and
align the 1TDC mark a on the flywheel
magnet with the pointer b.
9. Check that the II marks c on the port
driven sprockets are aligned, and check
that the I marks d on the starboard
driven sprockets are aligned.

ECM cover.
2. Remove the blowby hose 1.
3. Disconnect the ignition coil couplers 2,
cam position sensor couplers 3, and
knock sensor coupler 4.
4. Disconnect the cooling water pressure
sensor adapter hose 5.
5. Remove all ignition coils and spark plugs.
6. Remove the ECM bracket bolts 6.
a
b
S6P25100
6
2
2
3
4
5
S6P25090E
6P23H11
5-10
1
2
3
4
5
6
7
8
9
POWR
Power unit
10. Check the valve clearances to the following steps.
IN
EX
UP
EX
IN
14. Turn the flywheel magnet an additional

120 clockwise and align the 3TDC
mark h on the flywheel magnet with the
pointer b.
15. Check the intake and exhaust valve
clearances for cylinder #6.
#1
#2
#3
#4
#5
#6
PORT
STBD
S6P25110
STBD
16. Similarly, check the valve clearances for

cylinders #1, #2, and #3 in order, and be
sure to turn the flywheel magnet 120
clockwise each time. Adjust the valve
clearances if out of specification.
Adjusting the valve clearance
PORT
S6P25120
CAUTION:
NOTE:
Note the measurement data.
Valve clearance (cold):
Intake e:
0.20 0.03 mm (0.008 0.001 in)
Exhaust f:
0.34 0.03 mm (0.013 0.001 in)
clearance for cylinder #4.
12. Turn the flywheel magnet an additional
120 clockwise and align the 2TDC
mark g on the flywheel magnet with the
pointer b.
Do not turn the flywheel magnet or the

driven sprockets when the timing belt is
not installed. Otherwise the pistons and
valves or intake and exhaust valves will
collide with each other and be damaged.

clearances for cylinder #5.
5-11
6P23H11
Power unit
CAUTION:
Apply force in the direction of the arrows
shown to prevent the flywheel holder from
slipping off easily.
Flywheel holder: 90890-06522
5. Remove the flywheel magnet and Woodruff key, and then remove the stator
assembly.
a
b
S6P25100
3. Remove the wiring harness guide 1.
S6P25125E
NOTE:
To remove the wiring harness guide, see
Removing the wiring harness guide.
S6P25E00
CAUTION:
4. Loosen the flywheel magnet nut.
To prevent damage to the engine or tools,

screw in the puller set bolts evenly and
completely so that the flywheel puller is
parallel to the flywheel magnet.
NOTE:
Apply force to the crankshaft end until the flywheel magnet comes off the tapered portion
of the crankshaft.
Flywheel puller: 90890-06521
6P23H11
5-12
1
2
3
4
5
6
7
8
9
POWR
Power unit
6. Remove the timing belt, driven sprockets, and camshafts.

NOTE:
To remove the timing belt, driven sprockets,
and camshafts, see Removing the timing
belt, driven sprocket, and camshaft.
NOTE:
To install the camshafts, driven sprockets,
and timing belt, see Installing the camshaft,
driven sprocket, and timing belt.
12. Install the stator assembly.
7. Remove the valve shim 2 from the valve

lifter 3 using compressed air.
13. Install the Woodruff key and then flywheel magnet.
NOTE:
Do not mix the valve train parts. Keep them
organized in their proper groups.
NOTE:
Apply engine oil to the thread of the flywheel magnet nut and washer before
installation.
Be sure to remove any grease from the
tapered portion of the crankshaft and the
flywheel magnet.
8. Measure the valve shim thickness using

a micrometer, and then note the measurement data.
9. Select the necessary valve shim by calculating its thickness using the following
formula.
10. Install the necessary valve shim into the

valve lifter.
R.
Example:
If the Removed valve shim thickness is 2.10
mm, the Measured valve clearance is 0.30
mm and the Specified valve clearance is
0.20 mm, then the Necessary valve shim
thickness = 2.10 + 0.30 0.20 = 2.20 mm.
T.
Necessary valve shim thickness =

Removed valve shim thickness +
Measured valve clearance Specified
valve clearance
Flywheel magnet nut:

240 Nm (24.0 kgfm, 177.0 ftlb)
14. Check each valve clearance and adjust

again if out of specification.
Valve clearance (cold):
Intake:
0.20 0.03 mm (0.008 0.001 in)
Exhaust:
0.34 0.03 mm (0.013 0.001 in)
15. Install the cylinder head covers.
11. Install the camshafts, driven sprockets,

and timing belt.
5-13
6P23H11
Power unit
NOTE:
Apply sealant to the edge of the cylinder
head cover gasket before installation.
NOTE:
It is recommended to check the crank position sensor air gap before installing the wiring
harness guide to improve working efficiency.
T.
R.
Crank position sensor air gap f:

1.41.6 mm (0.0550.063 in)
Cylinder head cover bolt:

1st: 8 Nm (0.8 kgfm, 5.9 ftlb)
2nd: 8 Nm (0.8 kgfm, 5.9 ftlb)
T.
R.
16. Install the timing belt guides, and then

adjust the timing belt-to-timing belt guide
clearance e.
Crank position sensor screw:

18. Install the wiring harness guide.

NOTE:
To install the wiring harness guide, see
Installing the wiring harness.
19. Install the spark plugs and ignition coils.
T.
R.
Spark plug:
25 Nm (2.5 kgfm, 18.4 ftlb)
Ignition coil bolt:
e
20. Install all parts removed during disassembly.
S6P25145
21. Check that the wiring harness, hoses,

and other parts do not interfere with any
moving parts.
Timing belt-to-timing belt guide

clearance e:
1.0 0.5 mm (0.04 0.02 in)
17. Check the crank position sensor air gap
f.
S6P25160
6P23H11
5-14
1
2
3
4
5
6
7
8
9
POWR
Power unit
Replacing the timing belt

CAUTION:
Do not turn the flywheel magnet or the
driven sprockets when the timing belt is
not installed. Otherwise the pistons and
6 7
6
2
2
4
NOTE:
To remove and install the timing belt without
replacing it, see Removing the timing belt,
driven sprocket, and camshaft and Installing the camshaft, driven sprocket, and timing
belt.
NOTE:
To reduce the fuel pressure, see Chapter 4,
Reducing the fuel pressure.
ECM cover.
S6P25170E

3. Remove the blowby hose 1.

4. Disconnect the ignition coil couplers 2,
port cam position sensor couplers 3,
starboard cam position sensor coupler
4, and knock sensor coupler 5.
5. Remove all ignition coils and spark plugs.
6. Remove the ECM bracket bolts 6.

7. Remove the timing belt guides 7.
a
b
S6P25100
10. Remove the wiring harness guide 8.
5-15
6P23H11
Power unit
S6P25130E
NOTE:
To remove the wiring harness guide, see
Removing the wiring harness guide.
11. Loosen the flywheel magnet nut.
S6P25E00
CAUTION:
To prevent damage to the engine or tools,
screw in the puller set bolts evenly and
completely so that the flywheel puller is
parallel to the flywheel magnet.
NOTE:
Apply force to the crankshaft end until the flywheel magnet comes off the tapered portion
of the crankshaft.
Flywheel puller: 90890-06521
CAUTION:
Apply force in the direction of the arrows
shown to prevent the flywheel holder from
slipping off easily.
13. Remove the stator assembly bolt, and

then move the stator assembly to remove
the timing belt.

12. Remove the flywheel magnet and Woodruff key.
6P23H11
5-16
1
2
3
4
5
6
7
8
9
POWR
Power unit
14. Check that the mark e on the drive

sprocket and the mark f on the cylinder block are aligned.
S6P25200
18. Check that the mark e on the drive

sprocket and the mark f on the cylinder block are aligned.
d
c

f
e
S6P25180
16. Turn the timing belt tensioner gradually

clockwise using a hexagon wrench, and
then insert a 5.0 mm (0.2 in) pin 9 into
the hole g.
d
c
f
e
9
g
S6P25210
S6P25190E
NOTE:
Leave the pin inserted into the timing belt
tensioner until the timing belt is installed
again.
20. Install a new timing belt onto the drive

sprocket with its part number in the
upright position and align the belt position mark h with the mark on the
drive sprocket.
17. Remove the timing belt from the driven

sprockets, then from the drive sprocket.
5-17
6P23H11
Power unit
p
S6P25220
k
S6P25240E
p
r
0123
60 88
133 160
S6P25250
S6P25230
Number of belt teeth
Timing belt installation height r:

2.0 mm (0.08 in)
CAUTION:
Do not twist, turn inside out, or bend the
timing belt beyond the maximum limit of
25 mm (1.0 in) otherwise it can be damaged.
Do not get oil or grease on the timing
belt.
21. Install the timing belt onto the driven
sprockets by aligning belt position marks
k through p with the marks on the
driven sprockets.
22. Check that belt position marks h through

p are aligned with each alignment mark
on the sprockets, and then remove the
pin 9.
S6P25260E
6P23H11
5-18
1
2
3
4
5
6
7
8
9
POWR
Power unit
T.
R.
23. Turn the crankshaft clockwise two full

turns, and then check that alignment
marks c through f are aligned.
Flywheel magnet nut:

240 Nm (24.0 kgfm, 177.0 ftlb)

s.
d
c
f
S6P25270
S6P25180
NOTE:
24. Install the stator assembly.
Crank position sensor air gap s:

1.41.6 mm (0.0550.063 in)
25. Install the Woodruff key.

26. Install the flywheel magnet.
T.
R.
Crank position sensor screw:

28. Install the timing belt guide, and then

clearance t.
NOTE:
Apply engine oil to the thread of the flywheel magnet nut and washer before
installation.
Be sure to remove any grease from the
tapered portion of the crankshaft and flywheel magnet.
t
t
S6P25280
5-19
6P23H11
Power unit
clearance t:
1.0 0.5 mm (0.04 0.02 in)
PORT
29. Install the wiring harness guide.

NOTE:
To install the wiring harness guide, see
Installing the wiring harness.
30. Install all parts removed during disassembly.
2
7
S6P25390
STBD

and other parts do not interfere with any
moving parts.
Removing the wiring harness guide

NOTE:
This procedure is for adjusting the valve
clearance and replacing the timing belt.
1. Remove the joint connector 1 from the
wiring harness guide.
2
S6P25400
5. Remove the port and starboard fuel rail

covers and plastic ties.
NOTE:
6. Disconnect all fuel injector couplers.
S6P25380
2. Disconnect the oil control valve couplers

2, engine temperature sensor coupler
3, and thermoswitch connectors 4.
3. Remove the engine temperature sensor
coupler 3 and low-pressure fuel pump
coupler 5 from the wiring harness guide.
4. Remove the 3-pin communication coupler 6 and diagnosis connector 7 from
the bracket.
6P23H11
5-20
1
2
3
4
5
6
7
8
9
POWR
Power unit
7. Disconnect the quick connectors 8 and

remove the high-pressure fuel hose
assembly (vapor separator-to-starboard
fuel rail).
Removing the power unit

NOTE:
It is recommended to loosen the flywheel
magnet nut before removing the power unit to
improve working efficiency.
8
2. Remove the retaining plate 1, grommet
2, and cable holder 3, and then disconnect the remote control cables.
S6P25410
NOTE:
Be sure to reduce the fuel pressure before
removing the quick connector. To reduce
the fuel pressure, see Chapter 4, Reducing the fuel pressure.
To disconnect the quick connector, see
Chapter 4, Disconnecting the quick connector.
8. Remove the plastic ties 9 and clips 0,
and then pull up the wiring harness.
0
9
3. Remove the starboard intake manifold.

NOTE:
4. Remove the clamps 4 and caps 5, and
then disconnect the PTT motor lead 6.
0
0
9
4
S6P25420
5
9. Remove the bolts and wiring harness
guide A.
6
S6P25300
5. Disconnect the vapor gas hose 7 from

the starboard top cowling lock.
S6P25135E
5-21
6P23H11
Power unit
G
F
S6P25310
6. Disconnect the cooling water pilot hose

8.
7. Remove the neutral switch coupler 9
from the bracket, and disconnect the
neutral switch coupler and shift cut
switch coupler 0.
S6P25330E
12. Disconnect the flushing hose H.
8. Remove the oil dipstick A and dipstick

guide B.
S6P25340E
13. Remove the aprons and upper case

cover.
9
8
S6P25320
9. Disconnect the battery cables.

NOTE:
10. Disconnect the fuel hose from the fuel filter.
11. Removing the PTT switch coupler C,
isolator coupler D, warning indicator
coupler E, 10-pin main harness coupler
F, and trim sensor coupler G from the
brackets, and then disconnect them.
6P23H11
5-22
1
2
3
4
5
6
7
8
9
POWR
Power unit
14. Retract the port and starboard top cowling lock levers.
PORT
I
I
STBD
K
J
S6P25360
STBD
PORT
S6P25370E
Removing the timing belt, driven

sprocket, and camshaft
S6P25365
CAUTION:
Make sure that the top cowling lock levers
are retracted and the engine stoppers are
installed before removing the power unit,
otherwise the fuel rails could be damaged.
15. Suspend the power unit from the engine
hangers I.
16. Remove the power unit by removing the
bolts J and K.
CAUTION:
Do not turn the crankshaft counterclockwise, otherwise the water pump impeller
may be damaged.
Do not turn the crankshaft or the driven
sprockets when the timing belt is not
installed. Otherwise the piston and
Do not turn the crankshaft and camshafts unless instructions have been
given.
1. Check that the mark a on the drive
sprocket and the mark b on the cylinder block are aligned.
5-23
6P23H11
Power unit
d
c
b
g
e
f
S6P25430
3. Remove the timing belt guides 1 and

cylinder head covers 2.
S6P25450E
e 0123
2
60 88
133 160
S6P25460

S6P25440E
NOTE:
NOTE:
It is not necessary to mark the timing belt
when replacing it.
4. Make marks e through m on the timing

belt as shown.
6P23H11
5-24
1
2
3
4
5
6
7
8
9
POWR
Power unit
5. Turn the timing belt tensioner gradually

clockwise using a hexagon wrench, and
then insert a 5.0 mm (0.2 in) pin 3 into
the hole n.
CAUTION:
Do not turn the crankshaft counterclockwise more than 60. Otherwise the piston
and valves will collide with each other and
be damaged.
3
8. Align the I marks p on the port driven
sprockets by turning them clockwise 60
gradually.
PORT
S6P25470E
NOTE:
Leave the pin inserted into the timing belt
tensioner until the timing belt is installed
again.
p
S6P25490
6. Remove the timing belt from the driven

sprockets, then from the drive sprocket.
CAUTION:
Do not turn the driven sprockets clockwise more than 60, and do not turn the
starboard driven sprockets. Otherwise the
intake and exhaust valves will collide with
each other and be damaged.
S6P25200
7. Align the mark a on the drive

sprocket with the mating surface of the
crankcase and cylinder block by turning
the crankshaft counterclockwise 60
gradually.
STBD
9. Hold the intake driven sprocket using the

special service tool, and then remove the
variable camshaft timing cap 4.
4
5
PORT
S6P25500
a
S6P25480
5-25
6P23H11
Power unit
13. Remove the exhaust driven sprocket.
CAUTION:
Do not hold the camshaft when removing the variable camshaft timing cap.
Otherwise the variable camshaft timing
assembly can be damaged.
Do not turn the driven sprocket when
removing the variable camshaft timing
cap. Otherwise the intake and exhaust
valves will collide with each other and
be damaged.
Do not reuse the gasket 5, always
replace it with a new one.
S6P25520
CAUTION:
Do not turn the exhaust camshaft when
removing the bolt. Otherwise the intake
and exhaust valves will collide with each
other and be damaged.
Sheave holder: 90890-01701

10. Hold the intake camshaft using a wrench,
and then remove the variable camshaft
timing bolt 6.
11. Remove the variable camshaft timing
assembly with the driven sprocket.
6
6
S6P25510
CAUTION:
Do not hold the driven sprocket when
bolt. Otherwise the variable camshaft
timing assembly can be damaged.
Do not turn the intake camshaft when
bolt. Otherwise the intake and exhaust
be damaged.
12. Hold the exhaust camshaft using a
wrench, and then remove the bolt 7.
6P23H11
5-26
1
2
3
4
5
6
7
8
9
POWR
Power unit
14. Remove the camshaft caps in the

sequence shown.
Checking the timing belt and

sprocket
15. Remove the camshafts 8 and oil seals

9.
1. Check the interior and exterior of the timing belt. Replace if cracked, damaged, or
worn.
PORT
UP
STBD
2. Check the drive sprocket. Replace the

crankshaft assembly if cracked, damaged, or worn.
!
!
3. Check the driven sprockets. Replace the

variable camshaft timing assembly or
driven sprocket if cracked, damaged, or
worn.
Checking the valve lifter

1. Check the valve lifters. Replace if damaged, scratched, or worn.
S6P25530
Checking the camshaft
9
8 0
1. Check the edge and face of the brim on

the port camshafts and starboard intake
camshaft that is used for the cam position sensor. Replace if rough, damaged,
or scratched.
0
S6P25540E
CAUTION:
Do not reuse the gaskets 0, always
replace them with new ones.
S6P25550C
16. Remove the valve lifters from the cylinder

heads.
NOTE:
Do not scratch or damage the face of the
brim.
If there is a scratch more than 0.2 mm
(0.008 in) deep or more than 0.5 mm (0.020
in) wide on the surface of the brim, a malfunction may occur in the cam position sensor signal.
NOTE:
Do not mix the valve train parts. Keep them
organized in their proper groups.
2. Measure the cam lobe. Replace if out of

specification.
NOTE:
5-27
6P23H11
Power unit
d
S69J5970C
Cam lobe a:
Intake:
46.3046.40 mm
(1.8231.827 in)
Exhaust:
45.3545.45 mm
(1.7851.789 in)
Cam lobe b:
Intake and exhaust:
35.9536.05 mm
(1.4151.419 in)
Camshaft journal diameter c:

24.9624.98 mm
(0.98260.9834 in)
Camshaft cap inside diameter d:
25.00025.021 mm
(0.98430.9851 in)
Installing the camshaft, driven

sprocket, and timing belt
CAUTION:
3. Measure the camshaft runout. Replace if

above specification.
S6P25560
Camshaft runout limit:

0.015 mm (0.0006 in)
Do not turn the crankshaft counterclockwise, otherwise the water pump impeller
may be damaged.
Do not turn the crankshaft or the driven
sprockets when the timing belt is not
installed. Otherwise the pistons and
Do not turn the crankshaft and camshafts unless instructions have been
given.
1. Check that the mark a on the drive
sprocket is aligned with the mating surface of the crankcase and cylinder block.
STBD
PORT
4. Measure the camshaft journal diameter

c and cylinder head journal inside diameter d. Replace the camshaft or cylinder
head assembly, or both if out of specifications.
a
S6P25480
S6P25570
6P23H11
5-28
1
2
3
4
5
6
7
8
9
POWR
Power unit
2. Install the valve lifters onto the cylinder

heads.
NOTE:
Apply engine oil to the valve shims and
valve lifters before installation.
Install the valve shims and valve lifters in
their original positions.
PORT
STBD
3. Apply a thin, even coat of sealant to the

mating surface of the cylinder heads as
shown.
UP
6P2
P-IN
6P2
S-IN
E
M
6P2
P-EX
6P2
S-EX
S6P25590
STBD
NOTE:
Apply molybdenum disulfide grease to the
cam lobes.
Be sure to install the camshafts in the
proper positions.
1386B
5. Check that the camshaft dowel holes are

in the position shown in the illustration.
AFT
S6P25580
STBD
UP
PORT
PORT
1386B
1386B
BOW
S6P25600
6. Install the camshaft caps in their proper

positions as shown and with the stamped
numbers upside down.
S6P25D40
NOTE:
When applying the sealant, be sure not to
block the oil passages or oil holes.
4. Install the camshafts with the oil seals.
5-29
6P23H11
Power unit
UP
STBD
6S
1S
7S
2S
PORT
5P
1P
6P
3S
2P
8S
7P
PORT
4S
3P
9S
4P
8P
5S
S6P25E20
7. Tighten the camshaft cap bolts to the

specified torques in 2 stages and in the
sequence shown.
PORT
STBD
S6P25F10E
STBD
5
1
4
S6P25610E
NOTE:
Apply engine oil to the camshaft caps and
camshaft cap bolts before installation.
T.
R.
Camshaft cap bolts:

2nd: 17 Nm (1.7 kgfm, 12.5 ftlb)
6P23H11
CAUTION:
Do not turn the exhaust camshaft when
tightening the bolt. Otherwise the intake
and exhaust valves will collide with each
other and be damaged.
NOTE:
Slight turn the driven sprockets in direction
to remove any free play before tightening
the driven sprocket bolt 1.
R.
9. Hold the exhaust camshaft using a

wrench, and then tighten the driven
sprocket bolt 1 to the specified torque.
S6P25620
T.
8. Install the dowel and exhaust driven

sprocket on the exhaust camshaft.
Driven sprocket bolt 1:

60 Nm (6.0 kgfm, 44.3 ftlb)
10. Install the dowel and variable camshaft

timing assembly on the intake camshaft.
5-30
1
2
3
4
5
6
7
8
9
POWR
Power unit
11. Check that the lower edge of the intake

and exhaust driven sprockets are
aligned.
CAUTION:
Do not hold the driven sprocket when
tightening the variable camshaft timing
bolt. Otherwise the variable camshaft
timing assembly could be damaged.
Do not turn the intake camshaft when
bolt. Otherwise the intake and exhaust
be damaged.
S6P25630
12. Hold the intake camshaft using a wrench,

and then tighten the variable camshaft
timing bolt 2 to the specified torque.
T.
NOTE:
Slight turn the driven sprockets in direction
to remove any free play before tightening
the driven sprocket bolt 2.
R.
Variable camshaft timing bolt 2:

60 Nm (6.0 kgfm, 44.3 ftlb)
13. Hold the driven sprocket using the special service tool, and then tighten the
variable camshaft timing cap 3 to the
specified torque.
PORT
STBD
S6P25F20E
S6P25650
CAUTION:
E
Do not hold the camshaft when tightening the variable camshaft timing cap.
Otherwise the variable camshaft timing
assembly could be damaged.
Do not turn the driven sprocket when
cap. Otherwise the intake and exhaust
be damaged.
S6P25640E
5-31
6P23H11
Power unit
CAUTION:
Sheave holder: 90890-01701
T.
R.
Variable camshaft timing cap 3:

32 Nm (3.2 kgfm, 23.6 ftlb)
14. Align the II marks b on the port driven

sprockets by turning them counterclockwise 60 gradually.
Do not turn the crankshaft clockwise

more than 60. Otherwise the piston and
valves will collide with each other and be
damaged.
16. Check that the I marks d on the starboard driven sprockets are aligned.
STBD
PORT
d
b
S6P25680
S6P25660
CAUTION:
Do not turn the port driven sprockets
counterclockwise more than 60, and do
not turn the starboard driven sprockets.
Otherwise the intake and exhaust valves
will collide with each other and be damaged.
15. Align the mark a on the drive
sprocket with the mark c on the cylinder block by turning the crankshaft
clockwise 60 gradually.
c
STBD
a
PORT
S6P25480
S6P25670
6P23H11
5-32
1
2
3
4
5
6
7
8
9
POWR
Power unit
17. Install the timing belt onto the drive

sprocket with the arrow mark e facing
upward and align the timing belt mark f
with the mark on the drive sprocket.
m
e
g
S6P25700E
f
S6P25690
S6P25710
e 0123
60 88
133 160
Timing belt installation height n:

2.0 mm (0.08 in)
S6P25460E
CAUTION:
Do not twist, turn inside out, or bend the
timing belt beyond the maximum limit of
25 mm (1.0 in) otherwise it can be damaged.
Do not get oil or grease on the timing
belt.
18. Install the timing belt onto the driven
sprockets by aligning belt position marks
g through m with the marks on the
driven sprockets.
5-33
19. Check that belt position marks g through

m are aligned with each alignment mark
on the drive sprocket and driven sprockets, and then remove the pin 4.
S6P25720E
6P23H11
Power unit
20. Turn the crankshaft clockwise two full
turns, and then check that alignment
marks a through d are aligned.
22. Install the timing belt guide, and then

clearance p.
d
b
c
p
a
S6P25725
21. Install the cylinder head covers, and then

tighten the bolts to the specified torque in
2 stages.
S6P25150

clearance p:
1.0 0.5 mm (0.04 0.02 in)
1280B
1280B
S6P25730E
NOTE:
T.
R.
Cylinder head cover bolt:

2nd: 8 Nm (0.8 kgfm, 5.9 ftlb)
6P23H11
5-34
1
2
3
4
5
6
7
8
9
POWR
Power unit
Starter motor and accelerator position sensor
16
17
13
14
4
8
7
12
R.
10
T.
11
15
18 N m (1.8 kgf m, 13.3 ft Ib)
T.
R.
18 N m (1.8 kgf m, 13.3 ft Ib)
T.
R.
26 N m (2.6 kgf m, 19.2 ft Ib)
T.
R.
13 N m (1.3 kgf m, 9.6 ft Ib)

S6P25740E
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
5-35
Part name
Starter motor
Bolt
Nut
Bolt
Positive battery cable
Terminal
Bolt
Terminal bolt
Negative battery cable
Washer
Nut
Accelerator position sensor assembly
Grommet
Collar
Bolt
Bolt
Cap
Qty
1
3
1
2
1
1
1
1
1
1
1
1
3
3
3
1
1
Remarks
M8 45 mm
M8 16 mm
M8 20 mm
M6 35 mm
M6 20 mm
6P23H11
Starter motor and accelerator position sensor / ECM
ECM
12
4
14
13
T.
R.
7 N m (0.7 kgf m, 5.2 ft Ib)
5
5
14
13
7
6
10
8
11
S6P25750
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part name
Bolt
ECM
Holder
Plastic tie
Holder
Bolt
Plate
Holder
Holder
Plate
Holder
ECM bracket
Grommet
Collar
6P23H11
Qty
4
1
1
2
5
2
1
1
1
1
2
1
4
4
Remarks
M6 20 mm
M6 16 mm
5-36
1
2
3
4
5
6
7
8
9
POWR
Power unit
Fuse box
2
1
5 6 7 6 8 9 13
2
6
4
3
8 9
13
11
12
10
14
S6P25760
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
5-37
Part name
Fuse box assembly
Screw
Cover
Fuse puller
Fuse
Fuse
Fuse
Fuse
Fuse
Screw
Cover
Screw
Fuse
Grommet
Qty
1
4
1
1
2
3
2
2
2
4
1
4
3
1
Remarks
5 20 mm
10 A, Spare is included.
3 10 mm
5 10 mm
6P23H11
Fuse box / Junction box
Junction box
17
T.
R.
4 N m (0.4 kgf m, 3.0 ft Ib)
14
6
13
15
16
5
4
10
2
12
11
3
8
7
T.
R.
6P23H11
R.
R.
Part name
Cap
Nut
Bolt
Sub wiring harness
Bolt
PTT relay
Bolt
Rectifier Regulator
Gasket
Anode
Cover
Bolt
Bolt
Junction box
Grommet
Collar
Wiring harness
T.
T.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
6 N m (0.6 kgf m, 4.4 ft lb)

12 N m (1.2 kgf m, 8.9 ft lb)
1
2
1
2
6 N m (0.6 kgf m, 4.4 ft lb)

12 N m (1.2 kgf m, 8.9 ft lb)
3 N m (0.3 kgf m, 2.2 ft Ib)

S6P25770E
Qty
2
2
3
1
2
1
2
1
1
1
1
4
5
1
5
5
1
Remarks
M6 20 mm
M6 25 mm
M6 35 mm
Not reusable
M6 25 mm
M6 28 mm
5-38
1
2
3
4
5
6
7
8
9
POWR
Power unit
Exhaust cover
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
5-39
Part name
Bolt
Plug
Gasket
Plug
Gasket
Exhaust outer cover (PORT)
Gasket
Exhaust inner cover (PORT)
Anode
Screw
Anode
Screw
Gasket
Exhaust outer cover (STBD)
Exhaust inner cover (STBD)
Gasket
Qty
28
4
4
2
2
1
2
1
2
2
2
2
1
1
1
1
Remarks
M6 50 mm
M8 14 mm
Not reusable
M18 17 mm
Not reusable
Not reusable
6 16 mm
4 12 mm
Not reusable
Not reusable
6P23H11
Exhaust cover
Removing the exhaust cover

1. Remove the exhaust cover bolts in the
sequences shown.
Checking the exhaust cover anode

1. Check the anodes. Clean if there are
scales, grease, or oil.
CAUTION:
Do not oil, grease, or paint the anodes,
otherwise they will be ineffective.
2. Replace
eroded.
the
anodes
if
excessively
Installing the exhaust cover

1. Install the anodes to the exhaust covers.
2. Install new gaskets and the exhaust covers, and then tighten the bolts to the
sequence shown.
NOTE:
Apply engine oil to the exhaust cover bolts
before installation.
T.
R.
6P23H11
Anode screws 1:
Exhaust cover bolt:
2nd: 12 Nm (1.2 kgfm, 8.9 ftlb)
5-40
1
2
3
4
5
6
7
8
9
POWR
Power unit
Cylinder head
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Bolt
Oil control valve assembly
Filter
Engine hanger (PORT)
Bolt
Bolt
Bolt
Cover
Anode
Grommet
Bolt
Bolt
Bolt
Cylinder head (PORT)
Gasket
Collar
Knock sensor
Qty
6
2
2
1
6
16
4
4
4
4
4
4
2
1
1
4
1
Remarks
M6 40 mm
Not reusable
M6 20 mm
M10 120 mm/T55
M6 20 mm
M8 40 mm
M8 55 mm
M8 90 mm
Not reusable
*: Loosen completely
5-41
6P23H11
Cylinder head
5
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Part name
Flushing hose
Bolt
Cooling water passage cover
Gasket
Anode
Screw
Valve cotter
Valve spring retainer
Valve spring
Valve seal
Valve guide
Intake valve
Exhaust valve
Engine hanger (STBD)
Gasket
Cylinder head (STBD)
hose
Qty
1
13
1
1
4
4
48
24
24
24
24
12
12
1
1
1
1
1
2
3
4
5
6
7
8
9
Remarks
M6 30 mm
Not reusable
4 12 mm
Not reusable
Not reusable
Not reusable
*: Loosen completely
6P23H11
5-42
POWR
Power unit
Removing the cylinder head

1. Remove the cylinder head bolts in the
sequence shown.
PORT
UP
STBD
Valve spring compressor 1:

90890-04019
attachment 2:
90890-06320
Checking the valve spring

1. Measure the valve spring free length a.
Replace if below specification.
(T55)
S6P25810E
CAUTION:
Do not scratch or damage the mating surfaces of the cylinder head and cylinder
block.
2. Remove the intake and exhaust valves.
Valve spring free length a:

44.2 mm (1.74 in)
2. Measure the valve spring tilt b. Replace
if above specification.
Valve spring tilt limit b:

1.2 mm (0.05 in)
Checking the valve

1. Check the valve face. Replace if pitted or
worn.
NOTE:
Be sure to keep the valves, springs, and
other parts in the order as they were
removed.
5-43
2. Measure the valve margin thickness a.

6P23H11
Cylinder head
Valve stem runout limit:
0.01 mm (0.0004 in)
Checking the valve guide

NOTE:
Before checking the valve guides, make sure
that the valve stem diameter is within specification.
Valve margin thickness a:
Intake:
0.500.90 mm (0.0200.035 in)
Exhaust:
0.901.30 mm (0.0350.051 in)
3. Measure the valve stem diameter b.
1. Measure the valve guide inside diameter

a.
S69J5770
Valve guide inside diameter a:

Intake and exhaust:
5.5045.522 mm
(0.21670.2174 in)
Valve stem diameter b:

Intake:
5.4775.492 mm
(0.21560.2162 in)
Exhaust:
5.4645.479 mm
(0.21510.2157 in)
4. Measure the valve stem runout. Replace
if above specification.
6P23H11
2. Calculate the valve stem-to-valve guide

clearance as follows. Replace the valve
guide if out of specification.
Valve stem-to-valve guide clearance
= valve guide inside diameter valve
stem diameter:
Intake:
0.0120.045 mm
(0.00050.0018 in)
Exhaust:
0.0250.058 mm
(0.00100.0023 in)
5-44
1
2
3
4
5
6
7
8
9
POWR
Power unit
Replacing the valve guide

1. Remove the valve guide 1 using the
special service tool from the combustion
chamber side.
1
S69J5790
Valve guide remover/installer:

90890-06801
2. Install the new valve guide 2 using the
special service tools from the camshaft
side until the valve guide installer 3 contacts the cylinder head.
NOTE:
Turn the valve guide reamer clockwise to
ream the valve guide.
Do not turn the reamer counterclockwise
when removing the reamer.
Valve guide reamer: 90890-06804

4. Measure the valve guide inside diameter.
Valve guide inside diameter:
Intake and exhaust
5.5045.522 mm
(0.21670.2174 in)
3
a
Checking the valve seat

1. Eliminate carbon or deposits from the
valves.
E
S6P25E30
NOTE:
Apply engine oil to the surface of the new
valve guide.
2. Apply a thin, even layer of Mechanics

blueing dye (Dykem) onto the valve seat.
3. Lap the valve slowly on the valve seat
with a valve lapper (commercially available) as shown.
Valve guide remover/installer:

90890-06801
Valve guide installer: 90890-06810
Valve guide position a:
13.8 0.2 mm (0.5 0.01 in)
3. Insert the special service tool into the
valve guide 2, and then ream the valve
guide.
5-45
6P23H11
Cylinder head
4. Measure the valve seat contact width a
where the blueing dye is 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.
Replace the valve guide if the valve seat
contact is uneven.
1
2
3
4
5
6
7
8
9
Valve seat cutter holder:

90890-06316
Valve seat cutter:
30 (intake): 90890-06817
30 (exhaust): 90890-06326
45 (intake): 90890-06816
45 (exhaust): 90890-06325
60 (intake and exhaust):
90890-06324
Valve seat contact width a:

Intake:
1.101.40 mm (0.0430.055 in)
Exhaust:
1.401.70 mm (0.0550.067 in)
Refacing the valve seat

1. Reface the valve seat with the valve seat
cutter.
6P23H11
5-46
POWR
Power unit
2. Cut the surface of the valve seat with a

45 cutter by turning the cutter clockwise
until the valve seat face has become
smooth.
60
S69J5890
b Previous contact width
5. Use a 45 cutter to adjust the contact

width of the valve seat to specification.
b
c
45
S69J5900

c Specified contact width
a Slag or rough surface
CAUTION:
Do not over cut the valve seat. Be sure to
turn the cutter evenly downward at a pressure of 4050 N (45 kgf, 8.811 lbf) to
prevent chatter marks.
6. If the valve seat contact area is too wide

and situated in the center of the valve
face, use a 30 cutter to cut the top edge
of the valve seat, a 60 cutter to cut the
bottom edge to center the area and set
its width.

width of the top edge of the valve seat.
30
S69J5880

width of the bottom edge of the valve
seat.
5-47
7. If the valve seat contact area is too narrow and situated near the top edge of the
valve face, use a 30 cutter to cut the top
edge of the valve seat. If necessary, use
a 45 cutter to center the area and set its
width.
6P23H11
Cylinder head
10. After every lapping procedure, be sure to
clean off any remaining lapping compound from the cylinder heads and the
valves.
11. Check the valve seat contact area of the
valve again.
Checking the cylinder head

8. If the valve seat contact area is too narrow and situated near the bottom edge of
the valve face, use a 60 cutter to cut the
bottom edge of the valve seat. If necessary, use a 45 cutter to center the area
and set its width.
1. Eliminate carbon deposits from the combustion chambers and check for deterioration.
2. Check the cylinder head warpage using a
straightedge 1 and thickness gauge 2
in the directions shown. Replace the cylinder head assembly if above specification.
9. Apply a thin, even layer of lapping compound onto the valve seat, and then lap
the valve using a valve lapper (commercially available).
Cylinder head warpage limit:

0.1 mm (0.0039 in)
CAUTION:
Do not get the lapping compound on the
valve stem and valve guide.
6P23H11
5-48
1
2
3
4
5
6
7
8
9
POWR
Power unit
Installing the valve

1. Install a new valve seal 1 onto the valve
guide.
4. Lightly tap the valve spring retainer with

a plastic hammer to set the valve cotters
securely.
2. Install the valve 2, valve spring 3, and
valve spring retainer 4 in the sequence
shown, and then attach the special service tools.
NOTE:
Be sure to install the camshafts after completing the procedure in Installing the cylinder head.
Removing the cooling water passage

cover
NOTE:
The valve spring can be installed in any
direction.
Valve spring compressor 5:
90890-04019
attachment 6:
90890-06320
1. Remove the knock sensor.

2. Disconnect the flushing hose.
3. Remove the cooling water passage
cover bolts in the sequence shown.
3. Compress the valve spring, and then

install the valve cotters 7.
5-49
6P23H11
Cylinder head
4
5
9
C
0
6
1
3
8
B
A
7
NOTE:
2
S6P25860
NOTE:
3. Tighten the cooling water passage cover

bolts to the specified torque in the
sequence shown.

cover anode
1. Check the anodes. Clean if there are

scales, grease, or oil.
5
D1
CAUTION:
Do not oil, grease, or paint the anodes,
otherwise they will be ineffective.
G4
8
2. Replace
eroded.
the
anodes
if
excessively
A
6
2E
3F
7
B
S6P25880
S6P25860
T.
Installing the cooling water passage

cover
R.
1. Install the anodes to the cooling water

passage cover.
Cooling water passage cover bolt:

12 Nm (1.2 kgfm, 8.9 ftlb)
4. Connect the flushing hose and fasten it.

T.
R.
Anode screw:
2. Install the new gasket and cooling water

passage cover.
6P23H11
5-50
1
2
3
4
5
6
7
8
9
POWR
Power unit
5. Tighten the knock sensor to the specified

torque, and then fasten the knock sensor
lead 1 and flushing hose 2 as shown.
1
2
1
2
PORT
UP
S6P25900
NOTE:
Fasten the knock sensor lead so that it is
taut.
STBD
9
0 A
a
90
(T55)
S6P25910E
T.
R.
Knock sensor:
32 Nm (3.2 kgfm, 23.6 ftlb)
Installing the cylinder head

1. Install the grommets and collars into the
cylinder block.
NOTE:
2. Install the new gaskets and cylinder
heads, and then tighten the bolts to the
specified torques in the sequence
shown.
CAUTION:
Do not reuse the cylinder head gaskets,
always replace them with new ones.
NOTE:
Apply engine oil to the cylinder head bolts
Tighten the M10 bolts to the specified
torques in 6 stages first, and then tighten
the M8 bolts to the specified torques in 2
stages.
Make a mark a on the M10 bolts and the
cylinder heads, and then tighten the bolts
90 from the mark.
T.
R.
Cylinder head bolt (M10):

1st: 23 Nm (2.3 kgfm, 17.0 ftlb)
2nd: 45 Nm (4.5 kgfm, 33.2 ftlb)
3rd: Loosen completely
4th: 23 Nm (2.3 kgfm, 17.0 ftlb)
5th: 45 Nm (4.5 kgfm, 33.2 ftlb)
6th: 90
Cylinder head bolt (M8):
1st: 14 Nm (1.4 kgfm, 10.3 ftlb)
2nd: 28 Nm (2.8 kgfm, 20.7 ftlb)
3. Install the new filters and oil control valve

assemblies.
5-51
6P23H11
Cylinder head
CAUTION:
Do not reuse the oil control valve filters,
always replace them with new ones.
1
2
3
4
5
6
7
8
9
NOTE:
Make sure that the oil control valve filter does
not come off when installing the oil control
valve.
4. Install the camshafts, driven sprockets,
and timing belt.
NOTE:
To install the camshafts, driven sprockets,
and timing belt, see Installing the camshaft,
driven sprocket, and timing belt.
6P23H11
5-52
POWR
Power unit
Crankcase
30
33
31
32
23 N m (2.3 kgf m, 17.0 ft lb)
43 N m (4.3 kgf m, 31.7 ft Ib)
90
T.
1
2
3
R.
34
E
17
18
24
33
19
23
25
E
27 28
28
29
T.
R.
T.
R.
20
16
R.
7
5
16
T.
R.
34 N m (3.4 kgf m, 25.1 ft Ib)

T.
5-53
Part name
Oil filter
Oil pressure sensor
O-ring
Bolt
Joint
Oil filter bracket
Gasket
Bolt
Engine hanger
Crankcase cover
Bolt
Oil filler cap
O-ring
Holder
Gasket
Dowel
Cap
R.
15 N m (1.5 kgf m, 11.1 ft Ib)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
17
19
T.
10
22
12
13
14
18 N m (1.8 kgf m, 13.3 ft Ib)
2R
24 26
21
12 N m (1.2 kgf m, 8.9 ft Ib)
27
11
Qty
1
1
1
5
1
1
1
2
1
1
17
1
1
1
1
2
2
1
2
15
14 N m (1.4 kgf m, 10.3 ft lb)
28 N m (2.8 kgf m, 20.7 ft lb)
S6P25840E
Remarks
Not reusable
M6 45 mm
Not reusable
M6 20 mm
M8 45 mm
Not reusable
6P23H11
Crankcase
5
30
33
31
32
23 N m (2.3 kgf m, 17.0 ft lb)
43 N m (4.3 kgf m, 31.7 ft Ib)
90
T.
1
2
3
R.
34
E
17
18
24
33
19
23
25
E
27 28
28
29
T.
R.
T.
R.
10
20
16
R.
7
5
16
T.
R.
34 N m (3.4 kgf m, 25.1 ft Ib)

T.
30
31
32
33
34
Part name
Engine stopper (STBD)
Bolt
Engine stopper (PORT)
Washer
Piston ring set
Clip
Piston pin
Piston
Connecting rod
Connecting rod bearing
Bolt
Bolt
Holder
Cooling water hose
Vapor gas hose
Check valve
6P23H11
R.
15 N m (1.5 kgf m, 11.1 ft Ib)
No.
18
19
20
21
22
23
24
25
26
27
28
29
17
19
T.
22
12
13
14
18 N m (1.8 kgf m, 13.3 ft Ib)
2R
24 26
21
12 N m (1.2 kgf m, 8.9 ft Ib)
27
11
Qty
1
4
1
1
1
6
12
6
6
6
12
12
1
1
1
2
1
1
2
15
14 N m (1.4 kgf m, 10.3 ft lb)
28 N m (2.8 kgf m, 20.7 ft lb)
S6P25840E
Remarks
M6 25 mm
Not reusable
Not reusable
M9 42 mm
M6 12 mm
5-54
1
2
3
4
5
6
7
8
9
POWR
Power unit
Cylinder block
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
5-55
Part name
Bolt
Bolt
Bolt
Crankcase assembly
Main bearing
Main bearing
Oil seal
Crankshaft
Main bearing
Thrust bearing
O-ring
O-ring
Oil seal
Oil seal
O-ring
Gasket
Oil seal
Qty
8
8
13
1
3
1
1
1
4
2
2
1
1
1
2
1
1
Remarks
M10 105 mm
M8 95 mm
M8 55 mm
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
6P23H11
Cylinder block
5
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Part name
Oil seal
Oil pump assembly
Bolt
Bolt
Plug
O-ring
Gasket
Thermostat cover
Anode
Thermoswitch
Bolt
Bolt
Thermostat
Plug
Gasket
Thermostat cover
Bolt
6P23H11
Qty
2
1
4
2
1
1
2
1
2
2
4
4
2
1
1
1
2
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
M6 40 mm
M6 20 mm
Not reusable
Not reusable
M6 16 mm
M6 25 mm
M14 12 mm
Not reusable
M5 20 mm
5-56
POWR
Power unit
Disassembling the cylinder block

1. Remove the oil filter using a 72.5 mm
Oil filter wrench: 90890-06830
2. Remove the oil filter bracket bolts in the
sequence shown.
STBD
UP
PORT
%
!
$
#
S6P25930
3. Remove the crankcase cover bolts in the

sequence shown.
UP
3
2 1
NOTE:
Be sure to keep the bearings in the order as
they were removed.
Mark each piston with an identification
number a of the corresponding cylinder.
Mark each connecting rod and connecting
rod cap on the side facing up (flywheel
magnet side) with an identification mark b.
Do not mix the connecting rods and caps.
Keep them organized in their proper
groups.
Remove the piston rings and arrange them
in order.
8
9
6. Remove the oil pump.
C
STBD
PORT
NOTE:
7. Remove the crankcase bolts in the

sequence shown.
A
0
4
5 6
S6P25940
UP
4. Remove the connecting rod cap bolts

and the connecting rod caps, and then
remove the connecting rod and piston
assemblies.
OG
FN
SK
JR
8
9
B PORT
STBD
NOTE:
C
0
5. Remove the clips 1 and piston pin, and

then remove the piston.
PH
IQ
LD
EM
A
3
S6P25960J
8. Remove the crankshaft and bearings.
5-57
6P23H11
Cylinder block
NOTE:
Be sure to keep the bearings in the order as
they were removed.
Checking the piston diameter

1. Measure the piston outside diameter at
the specified measuring point. Replace
the piston if out of specification.
Cylinder bore (D1D6):

94.00094.017 mm
(3.70083.7014 in)
Checking the piston clearance

(reference)
1. Check the clearances by referring to the
specified values if replacing the piston,
the piston rings as a set, the cylinder
block, or all parts.
Piston clearance (reference data):
0.0750.080 mm
(0.00300.0031 in)
Checking the piston ring
Piston diameter a:
93.92193.941 mm
(3.69773.6985 in)
Measuring point b:
5.0 mm (0.2 in) up from the bottom
of the piston skirt
1. Check the piston ring dimensions of B

and T. Replace the piston ring set if out
of specification.
Checking the cylinder bore

1. Measure the cylinder bore (D1D6) at
measuring points a, b, and c, and in
direction d (D1, D3, D5), which is parallel
to the crankshaft, and direction e (D2,
D4, D6), which is at a right angle to the
crankshaft.
D2
D1
D4
D3
D6
D5
S69J5B70
a 20 mm (0.8 in)
b 50 mm (2.0 in)
c 80 mm (3.1 in)
6P23H11
Piston ring dimensions:

Top ring a:
B: 1.171.19 mm
(0.0460.047 in)
T: 2.803.00 mm
(0.1100.118 in)
Second ring b:
B: 1.171.19 mm
(0.0460.047 in)
T: 3.703.90 mm
(0.1460.154 in)
Oil ring c:
B: 2.402.47 mm
(0.0940.097 in)
T: 2.302.70 mm
(0.0910.106 in)
5-58
1
2
3
4
5
6
7
8
9
POWR
Power unit
Checking the piston ring end gap

(reference)
1. Level the piston ring 1 in the cylinder
with a piston crown.
2. Check the piston ring end gap a at the
specified measuring point b.
Piston ring groove:

Top ring a:
1.231.25 mm (0.0480.049 in)
Second ring b:
1.221.24 mm (0.0480.049 in)
Oil ring c:
2.512.53 mm (0.0990.100 in)
Checking the piston ring side

clearance
1. Measure the piston ring side clearance.
Replace the piston and piston rings as a
set if out of specification.
Piston ring end gap a

(reference data):
Top ring:
0.150.30 mm (0.0060.012 in)
Second ring:
0.300.45 mm (0.0120.018 in)
Oil ring:
0.150.60 mm (0.0060.024 in)
Measuring point b (reference data):
20 mm (0.8 in)
Piston ring side clearance:

Top ring a:
0.040.08 mm (0.0020.003 in)
Second ring b:
0.030.07 mm (0.0010.003 in)
Oil ring c:
0.040.13 mm (0.0020.005 in)
Checking the piston ring groove
Checking the piston pin boss bore
1. Measure the piston ring grooves.

Replace the piston if out of specification.
1. Measure the piston pin boss bore.

Replace the piston if out of specification.
5-59
6P23H11
Cylinder block
Piston pin boss bore:
21.01721.031 mm
(0.82740.8280 in)
Checking the piston pin

1. Measure the piston pin outside diameter.
Replace the piston pin if out of specification.
Connecting rod big end side

clearance a (reference data):
0.150.30 mm (0.0060.012 in)
Piston pin outside diameter:

20.99521.000 mm
(0.82660.8268 in)
Checking the connecting rod small

end inside diameter
1. Measure the connecting rod small end
inside diameter a. Replace the connecting rod assembly if out of specification.
Connecting rod small end inside

diameter a:
21.01721.031 mm
(0.82740.8280 in)
Checking the connecting rod big end

side clearance
1. Measure the connecting rod big end side
clearance a.
6P23H11
5-60
1
2
3
4
5
6
7
8
9
POWR
Power unit
Checking the crankshaft

1. Measure the crankshaft journal diameter
a, crankpin diameter b, and crankpin
width c. Replace the crankshaft if out of
specification.
S6P25970
Crankshaft runout limit:

0.03 mm (0.0012 in)
Checking the crankpin oil clearance

1. Clean the bearings and the connecting
rod.
2. Install the upper bearing into the connecting rod 1 and the lower bearing into
the connecting rod cap 2.
Crankshaft journal diameter a:
62.96862.992 mm
(2.47912.4800 in)
Crankpin diameter b:
49.97650.000 mm
(1.96761.9685 in)
Crankpin width c:
21.5021.55 mm
(0.84650.8484 in)
2. Measure the crankshaft runout. Replace
the crankshaft if above specification.
NOTE:
Install the connecting rod bearings in their
original positions.
Insert the projection a of each bearing into
the slots in the connecting rod cap and connecting rod.
3. Put a piece of Plastigauge (PG-1) onto
the crankpin, parallel to the crankshaft.
5-61
6P23H11
Cylinder block
NOTE:
Be sure not to put the Plastigauge (PG-1)
over the oil hole in the crankpin of the crankshaft.
4. Install the connecting rod onto the crankpin 3.
NOTE:
Reuse the removed connecting rod cap
bolts when checking the oil clearance.
Do not turn the connecting rod until the
crankpin oil clearance measurement has
been completed.
Make a mark c on the connecting rod cap
bolts, connecting rod caps, and then tighten
the bolts 90 from the mark.
T.
R.
Connecting rod cap bolt:

1st: 23 Nm (2.3 kgfm, 17.0 ftlb)
2nd: 43 Nm (4.3 kgfm, 31.7 ftlb)
3rd: 90
6. Remove the connecting rod cap and

measure the width of the compressed
Plastigauge (PG-1) on each crankpin.
Replace the connecting rod bearing if out
of specification.
NOTE:
Make sure that the marks b of the connecting rod face toward the flywheel magnet end
of the crankshaft.
5. Tighten the connecting rod cap bolts to
the specified torques in 3 stages.
6P23H11
Crankpin oil clearance:

0.0280.066 mm
(0.00110.0026 in)
5-62
1
2
3
4
5
6
7
8
9
POWR
Power unit
Selecting the connecting rod bearing

1. When replacing the connecting rod bearing, select the suitable bearing as follows.
2. Check the crankpin mark a on the
crankshaft.
2. Place the cylinder block upside down on

a bench.
3. Install half of the main bearings 1 and
the crankshaft 2 into the cylinder block
3.
NOTE:
Install the bearings in their original positions.
the slots in the cylinder block.
3. Select the suitable color b for the connecting rod bearing from the table.
Crankpin mark a
Bearing color b
9200
Yellow
8491
Green
7683
Blue
Checking the crankshaft journal oil

clearance
1. Clean the bearings, crankshaft journals,
and bearing portions of the crankcase
and cylinder block.
5-63
4. Put a piece of Plastigauge (PG-1) on

each crankshaft journal parallel to the
crankshaft.
NOTE:
Do not put the Plastigauge (PG-1) over the
oil hole in the main journals of the crankshaft.
5. Install the remaining half of the main
bearings into the crankcase.
NOTE:
the slots in the crankcase.
6P23H11
Cylinder block
6. Install the crankcase onto the cylinder
block and apply engine oil to the threads
of the crankcase bolts.
7. Tighten the crankcase bolts to the specified torques in 2 stages and in the
sequence shown.
8. Gently remove the crankcase, and then

measure the width of the compressed
Plastigauge (PG-1) on each crankshaft
journal. Replace the main bearing if out
of specification.
90
UP
E
P
5C
D6
19
02
O
L
K
H PORT
STBD
G
J
R
4B
A3
8F
E7
Crankshaft journal oil clearance:

0.0250.050 mm
(0.00100.0020 in)
Selecting the main bearing
1. When replacing the main bearing, select

the suitable bearing as follows.
S6P25990J
NOTE:
Crankcase bolts 1F can be reused 5
times.
Do not turn the crankshaft until the crankshaft journal oil clearance measurement
has been completed.
Tighten crankcase bolts 1F to the specified torques in 2 stages first, and then
tighten crankcase bolts GS to the specified torques in 2 stages.
Make a mark b on the crankcase and
crankcase bolts, and then tighten crankcase bolts 1F 90 from the mark.
T.
R.
18 Crankcase bolt (M8):

1st: 25 Nm (2.5 kgfm, 18.4 ftlb)
2nd: 90
9F Crankcase bolt (M10):
1st: 40 Nm (4.0 kgfm, 29.5 ftlb)
2nd: 90
GS Crankcase bolt (M8):
1st: 14 Nm (1.4 kgfm, 10.3 ftlb)
2nd: 28 Nm (2.8 kgfm, 20.7 ftlb)
6P23H11
5-64
1
2
3
4
5
6
7
8
9
POWR
Power unit
2. Check the crankshaft journal mark a on

the crankshaft and the cylinder block
mark b on the cylinder block.
Cylinder block mark b
Crankshaft journal mark a
98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22
92 1
91 1
90 1
89 1
88 1
87 1
86 1
85 1
84 1
83 1
82 1
81 1
80 1
79 1
78 1
77 1
76 1
75 1
74 2
73 2
72 2
71 2
70 2
69 2
68 2
NOTE:
Example: If the crankshaft journal mark a
is 81 and the cylinder block mark b is
04, then the main bearing number c is
1.
Lower main bearing for J3 is a thrust bearing 1.
Disassembling the oil pump

1. Remove the screws 1 and disassemble
the oil pump.
3. Select the suitable main bearing number

c from the table.
NOTE:
5-65
6P23H11
Cylinder block
Checking the oil pump

1. Check the gear teeth and inner surface
of the oil pump case. Replace the oil
pump assembly if the gear teeth are
cracked or worn, or if inner surface of the
oil pump case is scratched.
Assembling the oil pump

1. Install a new oil seal into the oil pump
cover.
Driver rod L3 2: 90890-06652
Needle bearing attachment 4:
90890-06607
4. Install a new gasket 5, and then tighten
the screws 7 to the specified torque.
5. Install a new oil seal 6 into the oil pump,
making sure to install it in the proper
direction.
90890-06661
2. Install new oil seals into the oil pump
housing.
Driver rod L3 2: 90890-06652

90890-06613
T.
6P23H11
R.
3. Install a new oil seal into the oil pump

housing.
Oil pump cover screw 7:

5-66
1
2
3
4
5
6
7
8
9
POWR
Power unit
Assembling the power unit
d
#3
NOTE:
45
45
#2
UP
2R
1. Assemble the piston 1, connecting rod

2, piston pin 3, and new piston pin clips
4.
5
#1,#4
#5
#5
#4
#3
#2
#1
d
S6P25A70
CAUTION:
Do not scratch the pistons or break the
piston rings.
NOTE:
After installing the piston rings, check that
they move smoothly.
NOTE:
Face the mark a on the connecting rod in
the same direction as the UP mark b on
the piston.
Always use new piston pin clips, and do not
allow the piston pin clip end to align with the
piston pin slot c.
4. Install the upper bearing into the connecting rod 2 and the lower bearing into
the connecting rod cap 8.
2. Install the oil rings 5, second ring 6,

and top ring 7 to the piston with the 2R
mark d of the second ring and the R
mark d of the top ring facing upward.
3. Offset the piston ring end gaps as
shown.
NOTE:
Install the connecting rod bearings in their
original positions.
Insert the projection e of the bearing into
the slots on the connecting rod cap and
connecting rod.
5. Install half of the main bearings 9 into
the cylinder block 0.
5-67
6P23H11
Cylinder block
8. Apply sealant to the mating surface of
the crankcase.
S69J5F10
NOTE:
Insert the projection f of each bearing into
the slots in the cylinder block.
6. Set the crankshaft A, new oil seal B,
and thrust bearings C into the cylinder
block as shown.
NOTE:
Install the main bearings in their original
positions.
Insert the projection h of each bearing into
the slots in the crankcase.
Do not get any sealant on the main bearings.
CAUTION:
Do not damage the oil seal when installing
it by contacting the edge g of the drive
sprocket.
NOTE:
Apply engine oil to the inner oil seal and the
thrust bearings before installation.
Do not get any engine oil to the drive
sprocket.
7. Install half of the main bearings D and
the thrust bearing E into the crankcase.
6P23H11
5-68
1
2
3
4
5
6
7
8
9
POWR
Power unit
9. Install the crankcase onto the cylinder

block, and then tighten the crankcase
bolts to the specified torques in 2 stages
and in the sequence shown.
10. Install the piston with the UP mark on

the piston crown facing towards the flywheel magnet.
90
UP
E
P
5C
D6
19
02
O
L
STBD
H
G
J
4B
A3
8F
E7
PORT
I
Q
S6P25B00J
NOTE:
Crankcase bolts 1F can be reused 5
times.
The oil seal must be installed before tightening the crankcase bolts.
Apply engine oil to the crankcase bolts
Tighten crankcase bolts 1F to the specified torques in 2 stages first, and then
tighten crankcase bolts GS to the specified torques in 2 stages.
Make a mark k on the crankcase and
crankcase bolts, and then tighten crankcase bolts 1F 90 from the mark.
After tightening the crankcase bolts, check
that the crankshaft rotates smoothly.
T.
R.
5-69
NOTE:
Apply engine oil to the side of the pistons and
piston rings before installation.
18 Crankcase bolt (M8):

1st: 25 Nm (2.5 kgfm, 18.4 ftlb)
2nd: 90
9F Crankcase bolt (M10):
1st: 40 Nm (4.0 kgfm, 29.5 ftlb)
2nd: 90
GS Crankcase bolt (M8):
1st: 14 Nm (1.4 kgfm, 10.3 ftlb)
2nd: 28 Nm (2.8 kgfm, 20.7 ftlb)
Piston ring compressor:

90890-05158
11. Install the connecting rod cap 8 to the
connecting rod, and then tighten the connecting rod cap bolts to the specified
torques in 3 stages.
CAUTION:
Do not reuse the connecting rod cap
bolts, always replace them with new ones.
6P23H11
Cylinder block
NOTE:
Align the marks m on the connecting rod
cap and connecting rod.
Apply engine oil to the connecting rod caps
and connecting rod cap bolts before installation.
Make a mark n on the connecting rod cap
bolts and connecting rod caps, and then
tighten the bolts 90 from the mark.
After tightening the connecting rod cap
bolts, check that the crankshaft rotates
smoothly.
T.
R.
Connecting rod cap bolt:

1st: 23 Nm (2.3 kgfm, 17.0 ftlb)
2nd: 43 Nm (4.3 kgfm, 31.7 ftlb)
3rd: 90
CAUTION:
Before installing the oil pump, be sure to
fill it with engine oil through the oil passage p.
NOTE:
When installing the oil pump, install it so that
the oil seal does not get damaged.
13. Install the new gasket and crankcase
cover, and then tighten the bolts to the
sequence shown.
UP
E
F G
0
12. Install the oil pump F by aligning the oil

pump gear with the crankshaft.
5
STBD
PORT
7
8
D
C B
S6P25B40
NOTE:
Apply engine oil to the crankcase bolts before
installation.
T.
R.
Crankcase cover bolt:

1st: 14 Nm (1.4 kgfm, 10.8 ftlb)
2nd: 28 Nm (2.8 kgfm, 20.7 ftlb)
F
E
S6P25B30E
6P23H11
5-70
1
2
3
4
5
6
7
8
9
POWR
Power unit
14. Install the new gasket and oil filter

bracket, and then tighten the bolts in the
sequence shown.
STBD
UP
NOTE:
Apply a thin coat of engine oil to the O-ring of
the new oil filter before installation.
PORT
Oil filter wrench: 90890-06830
%
$
T.
R.
Oil filter:
18 Nm (1.8 kgfm, 13.3 ftlb)
#
S6P25B50
NOTE:
Apply engine oil to the oil filter bracket bolts
15. Supply engine oil to the oil passage r of
the oil filter bracket.
17. Fasten the cooling water hose G, vapor

gas hoses, and check valve H using the
holder as shown.
16. Install the oil filter, and then tighten it to

the specified torque using a 72.5 mm
S6P25B80
18. Install the cooling water passage cover

and cylinder heads.
NOTE:
To install the cooling water passage cover
and cylinder heads, see Installing the cooling water passage cover and Installing the
cylinder head.
5-71
6P23H11
Cylinder block
Installing the wiring harness

NOTE:
To install all of the wiring harnesses, see
Chapter 8, Wiring harness routing.
Perform this procedure after assembling
the power unit.
1. Install the wiring harness and sub wiring
harness to the junction box.
2. Fasten the wiring harnesses at the white
tape a using a plastic tie 1.
3. Fasten the oil pressure sensor lead 2,
isolator lead 3, positive terminal lead 4
and its cap, with white tape b of the oil
pressure sensor lead is in the position as
shown.
S6P25C00E
CAUTION:
Do not bend the terminal of the starter
motor leads when connecting them.
6. Install the engine temperature sensor
lead 7 into the slit in the wiring harness
guide, and then install the wiring harness
guide.
7
5
6
a
1
7
S6P25C10
4
3
NOTE:
b
2
S6P25B90
NOTE:
Do not fasten the PTT relay lead 5 with the
plastic tie 6.
4. Install the junction box onto the power
unit.
5. Connect the starter motor leads.
6P23H11
5-72
1
2
3
4
5
6
7
8
9
POWR
Power unit
7. Install the wiring harness onto the wiring

harness guide with the mark c facing
upward, and then install the clips 8 in
the sequence shown.

and the other parts do not interfere with
any moving parts.
Installing the power unit

8. Fasten the wiring harness using the plastic ties.
!
c
8
8
1. Retract the port and starboard top cowling lock levers.
PORT
STBD
d
#
S6P25C20
NOTE:
Be sure to install the wiring harness onto
the wiring harness guide so that the wiring
harness does not come out from the top
edge of the wiring harness guide.
Be sure to install the wiring harness
between swells d.
9. Install the wiring harness onto the ECM
bracket, and fasten it at the white tape
e.
S6P25360
STBD
PORT
S6P25365
CAUTION:
Make sure that the top cowling lock levers
are retracted and the engine stoppers are
installed before installing the power unit,
otherwise the fuel rails could be damaged.
2. Clean the power unit mating surface, and
install the dowels 1 and a new gasket
2.
3. Install the power unit by installing the
bolts 3 and 4, then tightening them to
the specified torque.
S6P25D90E
5-73
6P23H11
Cylinder block
3
4
7
4
3
3
S6P25C60E
2
6. Connect the warning indicator coupler
8, trim sensor coupler 9, isolator coupler 0, PTT switch coupler A, 10-pin
main harness coupler B, and then install
them onto the brackets.
LT
LT
572
572
S6P25C40E
T.
R.
Power unit mounting bolt 3 and 4:

42 Nm (4.2 kgfm, 31.0 ftlb)
4. Install the upper case cover 5 and

aprons 6.
9
B
A
S6P25C70E
T.
R.
Apron bolt and upper case cover

bolt:
5. Connect the flushing hose 7.
6P23H11
5-74
1
2
3
4
5
6
7
8
9
POWR
Power unit
7. Connect the cooling water pilot hose C.

8. Connect the neutral switch coupler D
and shift cut switch coupler E, and then
install them onto the bracket.
9. Install the dipstick guide F and oil dipstick G.
K
J
a
S6P25D00E
NOTE:
To wire the battery cables, see Chapter 8,
Wiring harness routing.
T.
R.
S6P25C80E
NOTE:
Apply engine oil to the O-ring before installing
the dipstick guide.
10. Connect the vapor gas hose H to the
starboard top cowling lock.
PTT motor lead bolt:

Positive battery cable bolt:
18 Nm (1.8 kgfm, 13.3 ftlb)
Negative battery cable nut:
13 Nm (1.3 kgfm, 9.6 ftlb)
13. Connect the fuel hose.

14. Install the grommet with the speedometer hose L, fuel hose M, positive battery
cable J, negative battery cable K, shift
cable N, gauge harness O, throttle
cable P, and 10-pin main harness Q.
15. Install the cable holder R and retaining
plate S.
S6P25C90E
11. Connect the PTT motor leads I, and

then fasten them.
12. Connect the positive battery cable J and
negative battery cable K along the bottom of the bottom cowling a.
5-75
6P23H11
Cylinder block
1
2
3
4
5
6
7
8
9
16. Connect the shift cable and throttle

cable, and then adjust their lengths. To
adjust the shift cable and throttle cable,
see Chapter 3, Adjusting the throttle
cable and Checking the gear shift operation.
17. Install the starboard intake manifold.
NOTE:
18. Install all the parts that were removed.
6P23H11
5-76
LOWR
Lower unit
Lower unit (regular rotation model) ............................................................. 6-1
Removing the lower unit ............................................................................6-4
Removing the water pump and shift rod.................................................... 6-5
Checking the water pump and shift rod .....................................................6-5
Propeller shaft housing (regular rotation model) ....................................... 6-6
Removing the propeller shaft housing assembly....................................... 6-8
Disassembling the propeller shaft assembly .............................................6-8
Disassembling the propeller shaft housing................................................ 6-8
Checking the propeller shaft housing ........................................................6-9
Checking the propeller shaft...................................................................... 6-9
Assembling the propeller shaft assembly .................................................. 6-9
Assembling the propeller shaft housing.....................................................6-9
Drive shaft and lower case (regular rotation model) ................................6-12
Removing the drive shaft.........................................................................6-14
Disassembling the drive shaft housing ....................................................6-14
Disassembling the forward gear ..............................................................6-14
Disassembling the lower case .................................................................6-14
Checking the pinion and forward gear.....................................................6-15
Checking the bearing............................................................................... 6-15
Checking the drive shaft ..........................................................................6-15
Checking the lower case .........................................................................6-15
Assembling the lower case...................................................................... 6-15
Assembling the forward gear................................................................... 6-16
Assembling the drive shaft housing......................................................... 6-16
Installing the drive shaft...........................................................................6-16
Installing the propeller shaft housing .......................................................6-17
Installing the water pump and shift rod....................................................6-18
Installing the lower unit ............................................................................6-19
Shimming (regular rotation model) ............................................................ 6-22
Shimming.................................................................................................6-23
Selecting the pinion shim.........................................................................6-23
Selecting the forward gear shim ..............................................................6-24
Selecting the reverse gear shim ..............................................................6-25
Selecting the propeller shaft shim ........................................................... 6-27
Backlash (regular rotation model)..............................................................6-28
Measuring the forward and reverse gear backlash .................................6-28
6P23H11
Lower unit (counter rotation model) .......................................................... 6-31

Removing the lower unit ..........................................................................6-34
Removing the water pump and shift rod.................................................. 6-35
Checking the water pump and shift rod ...................................................6-35
Propeller shaft housing (counter rotation model) .................................... 6-36
Removing the propeller shaft housing assembly..................................... 6-38
Disassembling the propeller shaft housing.............................................. 6-38
Checking the propeller shaft housing ......................................................6-39
Checking the propeller shaft.................................................................... 6-39
Assembling the propeller shaft housing...................................................6-40
Drive shaft and lower case (counter rotation model) ...............................6-43
Removing the drive shaft.........................................................................6-45
Disassembling the drive shaft housing ....................................................6-45
Disassembling the reverse gear ..............................................................6-45
Disassembling the lower case .................................................................6-45
Checking the pinion and reverse gear.....................................................6-46
Checking the bearing............................................................................... 6-46
Checking the drive shaft ..........................................................................6-46
Checking the lower case .........................................................................6-46
Assembling the lower case...................................................................... 6-46
Assembling the reverse gear................................................................... 6-47
Assembling the drive shaft housing......................................................... 6-47
Installing the drive shaft...........................................................................6-48
Installing the propeller shaft housing .......................................................6-49
Installing the water pump and shift rod....................................................6-49
Installing the lower unit ............................................................................6-51
Shimming (counter rotation model) ........................................................... 6-53
Shimming.................................................................................................6-54
Selecting the pinion shim.........................................................................6-54
Selecting the reverse gear shim ..............................................................6-55
Selecting the forward gear shim ..............................................................6-57
Selecting the propeller shaft shim ........................................................... 6-58
Backlash (counter rotation model)............................................................. 6-60
Measuring the forward and reverse gear backlash .................................6-60
6P23H11
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
6-1
Part name
Lower unit
Plate
Rubber seal
Check screw
Gasket
Bolt
Drain screw
Grommet
Bolt
Bolt
Spacer
Propeller
Washer
Washer
Cotter pin
Propeller nut
Trim tab
Qty
1
1
1
1
2
7
1
1
1
1
1
1
1
1
1
1
1
Remarks
Not reusable
M10 45 mm/X-transom model
M10 45 mm
Not reusable
6P23H11

6
No.
18
19
20
21
22
23
24
25
26
27
Part name
Extension
Rubber seal
Dowel
Rubber seal
Stud bolt
Bolt
Bolt
Nut
Spring washer
Washer
6P23H11
Qty
1
1
2
1
6
1
1
6
6
6
1
2
3
4
5
6
7
8
9
Remarks
M10 190 mm
M10 200 mm
M10 174 mm
6-2
LOWR
Lower unit
6
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
6-3
Part name
Shift rod
Oil seal
Oil seal housing
O-ring
Bolt
Seal
Woodruff key
Bolt
Water pump housing
O-ring
Insert cartridge
O-ring
Impeller
Outer plate cartridge
Gasket
Dowel
Dowel
Qty
1
1
1
1
3
1
1
4
1
1
1
1
1
1
1
2
2
Remarks
Not reusable
Not reusable
M6 20 mm
M8 45 mm
Not reusable
Not reusable
Not reusable
6P23H11
Removing the lower unit

1. Drain the gear oil.
3. Mark the trim tab 1 at the area shown,

and then remove it.
4. Loosen the bolts (nuts), and then remove
the lower unit from the upper case.
2. Set the gear shift to the neutral position,

and place a block of wood between the
anti-cavitation plate and propeller to keep
the propeller from turning, and then
remove the propeller nut and propeller.
U-transom model
WARNING
Do not hold the propeller with your
hands when loosening or tightening it.
Be sure to disconnect the battery cables
from the battery and the clip from the
Put a block of wood between the anticavitation plate and propeller to keep
the propeller from turning.
When removing the lower unit with the
power unit installed, be sure to suspend
the outboard motor. If the outboard
motor is not suspended it can fall suddenly and result in severe injury.
6P23H11
6-4
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
Removing the water pump and shift

rod
1. Remove the water pump housing 1 and
impeller 2.
a
1
2. Remove the Woodruff key 3.

3. Remove the outer plate cartridge 4.
and then remove the shift rod assembly
5.
S6P26660
4. Check the shift rod. Replace if cracked or

worn.
Shift rod push arm: 90890-06052
Checking the water pump and shift

rod
1. Check the water pump housing. Replace
if there is deformation.
2. Check the impeller and insert cartridge.
Replace if cracked or worn.
3. Check the Woodruff key 1 and the
groove a on the drive shaft. Replace if
worn.
6-5
6P23H11
Lower unit (regular rotation model) / Propeller shaft housing (regular rotation model)
Propeller shaft housing (regular rotation model)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Water pipe
Rubber seal
Rubber seal
Shift rod joint
Ball
Slider
Shift plunger
Dog clutch
Cross pin
Spring
Propeller shaft
Shim
Reverse gear
Reverse gear shim
Ball bearing
O-ring
Propeller shaft housing
6P23H11
Qty
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
Not reusable
6-6
LOWR
Lower unit
6
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
6-7
Part name
Dowel
Grease nipple
Rubber seal
O-ring
Needle bearing
Oil seal
Ring
Bolt
Bolt
Washer
Cooling water inlet cover
Nut
Screw
Qty
1
1
1
1
1
2
1
2
2
2
2
1
1
Remarks
Not reusable
Not reusable
Not reusable
M8 20 mm
M8 33 mm
5 53 mm
6P23H11
Removing the propeller shaft

housing assembly
Disassembling the propeller shaft

assembly
1. Remove the water pipe 1 and shift rod

2.
1. Remove the spring 1, and then remove

the cross pin 2, dog clutch 3, shift
plunger 4, slider 5, and shift rod joint
6.
2. Remove the bolts 3, ring 4, and bolts

5.

housing
1. Remove the reverse gear and reverse
gear shim(s).
3. Pull out the propeller shaft housing, and

then remove the propeller shaft.
NOTE:
Before removing the propeller shaft from the
lower case, remove the shift rod.

90890-06538
Bearing puller assembly 4:
90890-06535
Bearing housing puller claw L 6:

90890-06502
Center bolt 8: 90890-06504
6P23H11
6-8
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
Checking the propeller shaft
2. Remove the ball bearing.
1. Check the propeller shaft. Replace if bent

or worn.
2. Measure the propeller shaft runout.
S6S16390
CAUTION:
it with a new one.
Slide hammer 5: 90890-06531
Bearing outer race puller
assembly 6:
90890-06523
3. Remove the oil seals and needle bearing.
S6P26200C
Runout limit: 0.02 mm (0.0008 in)

3. Check the dog clutch, shift rod joint, and
slider. Replace if cracked or worn.
Assembling the propeller shaft

assembly
1. Install the dog clutch 1 as shown.

90890-06611
Driver rod L3 8: 90890-06652
NOTE:
Install the dog clutch 1 with the F mark a
facing toward the shift plunger.
Checking the propeller shaft housing

1. Clean the propeller shaft housing using a
soft brush and cleaning solvent, and then
check it. Replace if cracked or damaged.
2. Check the teeth and dogs of the reverse
gear. Replace if cracked or worn.

housing
1. Install the needle bearing into the propeller shaft housing to the specified depth.
3. Check the bearings. Replace if pitted or if

there is rumbling.
6-9
6P23H11

Depth d:
5.0 0.25 mm (0.20 0.01 in)
3. Install the new ball bearing into the propeller shaft housing.
NOTE:
Install the needle bearing with the manufacture identification mark a facing toward the
oil seal (propeller side).
When using the driver rod, do not strike the
special service tool in a manner that will
force the stopper c out of place.
Driver rod SS 1: 90890-06604
90890-06610
Bearing depth plate 3: 90890-06603
Depth b:
25.3 0.25 mm (1.00 0.01 in)
NOTE:
Install the ball bearing with the manufacture
identification mark facing toward the propeller
shaft housing (propeller side).
Ball bearing attachment 5:
90890-06656
Driver rod LS 6: 90890-06606
2. Apply grease to the new oil seals, and

then install them into the propeller shaft
housing to the specified depth.
NOTE:
Install an oil seal halfway into the propeller
shaft housing, then the other oil seal.
90890-06640
6P23H11
6-10
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
4. Install the reverse gear 7 and original

shim(s) 8 into the propeller shaft housing using a press.
NOTE:
Be sure to select the reverse gear shim(s) if
replacing the propeller shaft housing, lower
case, or ball bearing. Select the propeller
shaft shim if replacing the reverse gear.
To select the shims, see Shimming (regular rotation model).
After installing the reverse gear and
shim(s), check that the reverse gear rotates
smoothly.
Bearing outer race attachment 9:
90890-06622
6-11
6P23H11
Propeller shaft housing (regular rotation model) / Drive shaft and lower case (regular rotation model)
Drive shaft and lower case (regular rotation model)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Drive shaft
Thrust bearing
Spring
Washer
Cover
Oil seal
Bolt
Drive shaft housing
Needle bearing
O-ring
Pinion shim
Thrust bearing
Lower case
Needle bearing assembly
Pinion
Washer
Nut
6P23H11
Qty
1
1
1
1
1
2
4
1
1
1
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
M8 25 mm
Not reusable
6-12
LOWR
Lower unit
6
No.
18
19
20
6-13
Part name
Forward gear shim
Taper roller bearing assembly
Forward gear
Qty
1
1
Remarks
Not reusable
6P23H11

1. Loosen the pinion nut.
1
1
2
S68S6360J

Pinion nut holder 2: 90890-06715
2. Remove the drive shaft, drive shaft housing, pinion, thrust bearing, spring and
washer.
3. Pull out the forward gear.
S69J6186
CAUTION:
it with a new one.
Disassembling the lower case

1. Remove the taper roller bearing outer
race and shim(s).

housing
1. Remove the cover, oil seals, and needle
bearing.
NOTE:
Install the claws as shown.

90890-06610
Driver rod L3 2: 90890-06652

assembly 1:
90890-06523
Outer race puller claw A 2:
90890-06532
Disassembling the forward gear

1. Remove the taper roller bearing from the
6P23H11
6-14
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
2. Remove the needle bearing from the

lower case.
S6P26210

NOTE:
Since the diameter of the passage in the
lower case and the diameter of the special
service tool 3 are both 40 mm (1.57 in), the
special service tool may not fit into the lower
case. In that case, use a special service tool
with a smaller diameter.
Checking the lower case

1. Check the skeg and torpedo. Replace
the lower case if cracked or damaged.
Assembling the lower case

1. Install the original shim(s) and taper roller
bearing outer race.

90890-06655
Driver rod LL 4: 90890-06605
Checking the pinion and forward

gear
1. Check the teeth of the pinion, and the
teeth and dogs of the forward gear.
Checking the bearing

there is rumbling.
Checking the drive shaft

1. Check the drive shaft. Replace if bent or
worn.
2. Measure the drive shaft runout.
NOTE:
Be sure to select the forward gear shim(s) if
replacing the lower case or taper roller
bearing assembly. Select the propeller
shaft shim if replacing the forward gear.
90890-06658
Driver rod LL 2: 90890-06605
2. Install the needle bearing into the lower
case.
6-15
6P23H11

90890-06610
Driver rod SS 2: 90890-06604
NOTE:
Apply gear oil to the needle bearing outer
case before installation.
The needle bearing contains 24 rollers.
90890-06655
assembly 4:
90890-06523
Depth a:
4.5 0.25 mm (0.18 0.01 in)
then install them into the drive shaft
Assembling the forward gear

1. Install a new taper roller bearing into the
4
3
S6P26120E
NOTE:
Install an oil seal halfway into the drive shaft
housing, then the other oil seal.
90890-06659
Assembling the drive shaft housing

1. Install the needle bearing into the drive
shaft housing to the specified depth.

90890-06628
Driver rod LS 4: 90890-06606
Depth b:
0.5 0.25 mm (0.02 0.01 in)
Installing the drive shaft

1. Install the forward gear into the lower
case.
6P23H11
6-16
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
2. Install the washer, spring and thrust

bearing into the lower case.
6
S63P6310
NOTE:
To install the pinion nut, push down on the
drive shaft.
3. Install the drive shaft housing 1, thrust

bearing 2, and original shim(s) 3 onto
the drive shaft 4.
T.
R.
Pinion nut:
142 Nm (14.2 kgfm, 104.7 ftlb)
5. Tighten the drive shaft housing bolts.

NOTE:
Apply LOCTITE 572 to the drive shaft housing bolts before installation.
Installing the propeller shaft housing

NOTE:
Be sure to select the pinion shim(s) if
replacing the thrust bearing, drive shaft
housing, drive shaft or lower case.
1. Set the shift rod joint and dog clutch 1 to

the neutral position as shown.
2. Install the propeller shaft shim 2 and
propeller shaft assembly 3 into the propeller shaft housing assembly.
3. Apply grease to the new O-rings and propeller shaft housing.
4. Install the drive shaft and drive shaft

housing into the lower case, then the pinion, washer and pinion nut, and then
tighten the nut to the specified torque.
6-17
6P23H11
NOTE:
Be sure to select the propeller shaft shim if
replacing propeller shaft, forward gear or
reverse gear.
4. Install the propeller shaft housing assembly into the lower case, and then tighten
the bolts 4 to the specified torque.
NOTE:
Check the gear shift to the neutral position,
when installing the shift rod.
After assembling the lower unit, check that
the shift rod operates smoothly, and check
that the drive shaft and propeller shaft
rotate smoothly.
5. Install the ring 5 and bolts 6.

2. Install a new gasket 2, the outer plate
cartridge 3, and dowels 4.
T.
R.
Propeller shaft housing bolt 4:

30 Nm (3.0 kgfm, 22.1 ftlb)
6. Install the water pipe and rubber seals.
Installing the water pump and shift

rod
1. Install the shift rod assembly 1.
6P23H11
6-18
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
3. Install the Woodruff key into the drive

shaft.
4. Align the groove on the impeller 5 with
the Woodruff key 6, and then install the
impeller onto the drive shaft.
5. Install the new O-ring 7 and insert cartridge 8 into the pump housing 9.
CAUTION:
7
A
Do not turn the drive shaft counterclockwise, otherwise the water pump impeller
may be damaged.
b
b
1104J
S6P26110
NOTE:
Align the insert cartridge projections a with
the holes b in the pump housing.
6. Install the new O-ring 0 and pump housing assembly A into the lower case,
tighten the bolts B, and then install the
seal C and cover D.
NOTE:
When installing the pump housing, apply
grease to the inside of the housing, and
then turn the drive shaft clockwise while
pushing down the pump housing.
Align the cover projection c with the hole
d in the pump housing.
Installing the lower unit

WARNING
When installing the lower unit with the
the outboard motor. If the outboard motor
is not suspended it can fall suddenly and
result in severe injury.
1. Align the center of the set pin a with the
alignment mark b on the bottom cowling.
6-19
6P23H11
2. Set the gear shift to the neutral position

at the lower unit.
U-transom model
T.
R.
Lower case mounting bolt (nut) 2:

47 Nm (4.7 kgfm, 34.7 ftlb)
Trim tab bolt 4:
42 Nm (4.2 kgfm, 31.0 ftlb)

3. Install the dowels 1 into the lower unit.
4. Install the lower unit into the upper case,
and then tighten the lower case mounting
bolts (nuts) 2 to the specified torque.
5. Install the trim tab 3 to its original position, and then tighten the bolt 4 to the
specified torque.
6P23H11
6-20
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
6. Install the propeller and propeller nut,

and then tighten the nut temporary. Place
a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then tighten the
nut to the specified torque.
7. Fill the gear oil to the correct level.
WARNING
NOTE:
If the grooves in the propeller nut 5 do not
align with the cotter pin hole, tighten the nut
until they are aligned.
T.
R.
6-21
Propeller nut 5:
54 Nm (5.4 kgfm, 39.8 ftlb)
6P23H11
Drive shaft and lower case (regular rotation model) / Shimming (regular rotation model)
Shimming (regular rotation model)
F
P
1
2
3
4
5
6
7
8
9
B4
T3
A3
B3
65.0
C3
C1
C2
T4
B5
T2
T1
B2
B1 39.4 41.0
A1
A2
S6P26270
6P23H11
6-22
LOWR
Lower unit
Shimming
T.
R.
NOTE:
Shimming is not required when assembling
the original lower case and inner parts.
Shimming is required when assembling the
original inner parts and a new lower case.
Shimming is required when replacing the
inner part(s).
Pinion nut:
142 Nm (14.2 kgfm, 104.7 ftlb)
3. Measure the distance (M4) between the

special service tool and the pinion as
shown.
Selecting the pinion shim

1. Install the special service tool onto the
drive shaft 1.
NOTE:
Measure the pinion at 3 points to find the distance average.
Digital caliper 4: 90890-06704

4. Turn the thrust bearing 5 2 or 3 times to
seat the drive shaft housing 6, and then
measure the housing height (M3) as
shown.
NOTE:
Select the shim thickness (T3) by using the
specified measurement(s) and the calculation formula.
Install the special service tool onto the drive
shaft so that the shaft is at the center of the
hole.
Tighten the wing nuts another 1/4 of a turn
after they contact the plate 2.
Pinion height gauge 3:
90890-06710
NOTE:
Measure the thrust bearing at 3 points to find
the height average.
5. Calculate the pinion shim thickness (T3)
as shown in the examples below.
2. Install the pinion and pinion nut, and then

6-23
6P23H11

Example:
If T3 is 0.70 mm, then the pinion shim is
0.68 mm.
0.72 mm.
Selecting the forward gear shim
NOTE:
P is the deviation of the lower case dimension from standard. The P mark a is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the P
mark is unreadable, assume that P is zero
and check the backlash when the unit is
assembled.
1. Turn the taper roller bearing outer race

1 2 or 3 times to seat the rollers, and
then measure the bearing height (M1) as
shown.
Calculation formula:
Pinion shim thickness (T3) =
82.00 + P/100 M3 M4
Example:
If M3 is 50.75 mm and M4 is 30.57 mm
and P is (+2), then
T3 = 82.00 + (+2)/100 50.75 30.57 mm
= 82.00 + 0.02 50.75 30.57 mm
= 0.70 mm
and P is (3), then
T3 = 82.00 + (3)/100 50.70 30.53 mm
= 82.00 0.03 50.70 30.53 mm
= 0.74 mm
6. Select the pinion shim(s) (T3) as follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
3, 4, 5
6, 7, 8
9, 10
NOTE:
Measure the bearing outer race at 3 points
to find the height average.
Shimming plate 2: 90890-06701
Available shim thicknesses:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
6P23H11
6-24
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
2. Calculate the forward gear shim thickness (T1) as shown in the examples
below.

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
Example:
If T1 is 0.45 mm, then the forward gear
shim is 0.42 mm.
shim is 0.38 mm.
Selecting the reverse gear shim

NOTE:
F is the deviation of the lower case dimension from standard. The F mark a is
the lower case in 0.01 mm units. If the F
mark is unreadable, assume that F is zero
assembled.
1. Turn the ball bearing 1 2 or 3 times, and

shown.
Forward gear shim thickness (T1) =
29.50 + F/100 M1
Example:
If M1 is 29.10 mm and F is (+5), then
T1 = 29.50 + (+5)/100 29.10 mm
= 29.50 + 0.05 29.10 mm
= 0.45 mm
If M1 is 29.10 mm and F is (0), then
T1 = 29.50 + (0)/100 29.10 mm
= 29.50 + 0 29.10 mm
= 0.40 mm
3. Select the forward gear shim(s) (T1) as
follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
3, 4, 5
6, 7, 8
9, 10
6-25
NOTE:
Measure the bearing outer race at 3 points
2. Calculate the reverse gear shim thickness (T2) as shown in the examples
below.
6P23H11

3. Select the reverse gear shim(s) (T2) as
follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
3, 4, 5
6, 7, 8
9, 10

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
A3
S69J6625
Example:
If T2 is 1.10 mm, then the reverse gear
shim is 1.08 mm.
shim is 1.15 mm.
NOTE:
R is the deviation of the lower case dimension from standard, and A is the deviation of
the propeller shaft housing from standard.
The R mark a is stamped on the trim tab
mounting surface of the lower case, and the
A mark b is stamped on the propeller shaft
housing in 0.01 mm units. If the R mark or
A mark is unreadable, assume that R and
A are zero and check the backlash when
the unit is assembled.
Reverse gear shim thickness (T2) =
21.00 + R/100 A/100 M2
Example:
If M2 is 19.92 mm and R is (1) and A is
(3), then
T2 = 21.00 + (1)/100 (3)/100 19.92 mm
= 21.00 0.01 + 0.03 19.92 mm
= 1.10 mm
If M2 is 19.92 mm and R is (+3) and A is
(5), then
T2 = 21.00 + (+3)/100 (5)/100 19.92 mm
= 21.00 + 0.03 + 0.05 19.92 mm
= 1.16 mm
6P23H11
6-26
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
Selecting the propeller shaft shim

NOTE:
Be sure to make this measurement in metrics.
1. Measure the forward gear height M1, M2
as shown and then calculate the value
C1.
C2
M3
M4
S6P26340
C1
M1
M2
S6P26330
S6P26360
Reverse gear height C2 = M3 M4
3. Measure the propeller shaft spline width
C3.
S6P26360
C3
Digital caliper: 90890-06704
Forward gear height C1 = M1 M2
2. Measure the reverse gear height M3, M4
as shown and then calculate the value
C2.
S6P26370
4. Select the propeller shaft shim T4.
6-27
6P23H11
Shimming (regular rotation model) / Backlash (regular rotation model)
Backlash
(regular rotation model)
Measuring the forward and reverse

gear backlash
1. Remove the water pump assembly.
at the lower unit.
NOTE:
Select the shim with the closest thickness.
Propeller shaft shim thickness T4 =
79.8 C1 C2 C3
Calculated numeral
Shim thickness (mm)
1.811.84
1.80
1.851.94
1.90
1.952.04
2.00
2.052.14
2.10
2.152.20
2.20

3. Install the special service tools so that it
pushes against the propeller shaft.
5. Assembling the lower unit.

6. Measure the propeller shaft axial free
play. Reselect the propeller shaft shim if
out of specification.
3
2
NOTE:
Tighten the center bolt while turning the drive
shaft until the drive shaft can no longer be
turned.
S6P26530
Magnet base plate 1: 90890-07003

Dial gauge set 2: 90890-01252
Magnet base B 3: 90890-06844

90890-06502
Center bolt 3: 90890-06504
Propeller shaft free play:

0.200.50 mm (0.00790.0197 in)
6P23H11
6-28
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
4. Install the backlash indicator onto the

drive shaft (22.4 mm [0.88 in] in diameter), then the dial gauge.

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
7. Remove the special service tools from
the propeller shaft.
8. Apply a load to the reverse gear by
installing the propeller 7, the spacer 8
(without the washer 9), then the washer
0 as shown.
NOTE:
Install the dial gauge so that the plunger a
contacts the mark b on the backlash indicator rod.
Backlash indicator 4: 90890-06706
Magnet base B 7: 90890-06844
5. Slowly turn the drive shaft clockwise and
counterclockwise and measure the backlash when the drive shaft stops in each
direction.
NOTE:
Tighten the propeller nut A while turning the
drive shaft until the drive shaft can no longer
be turned.
direction.
Forward gear backlash:

0.320.55 mm (0.01260.0216 in)
6. Add or remove shim(s) if out of specification.
Forward gear
backlash
Shim thickness
Less than
0.32 mm (0.0126 in)
To be decreased by
(0.44 M) 0.71
More than
0.55 mm (0.0216 in)
To be increased by
(M 0.44) 0.71
M: Measurement
6-29
Reverse gear backlash:

0.320.65 mm (0.01260.0256 in)
6P23H11
Backlash (regular rotation model)

Reverse gear
backlash
Shim thickness
Less than
0.32 mm (0.0126 in)
To be decreased by
(0.49 M) 0.71
More than
0.65 mm (0.0256 in)
To be increased by
(M 0.49) 0.71
1
2
3
4
5
6
7
8
9
M: Measurement
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
11. Remove the special service tools, and
then install the water pump assembly.
6P23H11
6-30
LOWR
Lower unit
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
6-31
Part name
Lower unit
Plate
Rubber seal
Check screw
Gasket
Bolt
Drain screw
Grommet
Bolt
Bolt
Spacer
Propeller
Washer
Washer
Cotter pin
Propeller nut
Trim tab
Qty
1
1
1
1
2
7
1
1
1
1
1
1
1
1
1
1
1
Remarks
Not reusable
M10 45 mm
Not reusable
6P23H11

6
No.
18
19
20
21
22
23
24
25
26
27
Part name
Extension
Rubber seal
Dowel
Rubber seal
Stud bolt
Bolt
Bolt
Nut
Spring washer
Washer
6P23H11
Qty
1
1
2
1
6
1
1
6
6
6
1
2
3
4
5
6
7
8
9
Remarks
M10 190 mm
M10 200 mm
M10 174 mm
6-32
LOWR
Lower unit
6
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
6-33
Part name
Shift rod
Oil seal
Oil seal housing
O-ring
Bolt
Seal
Woodruff key
Bolt
Water pump housing
O-ring
Insert cartridge
O-ring
Impeller
Outer plate cartridge
Gasket
Dowel
Dowel
Qty
1
1
1
1
3
1
1
4
1
1
1
1
1
1
1
2
2
Remarks
Not reusable
Not reusable
M6 20 mm
M8 45 mm
Not reusable
Not reusable
Not reusable
6P23H11
Removing the lower unit

1. Drain the gear oil.
3. Mark the trim tab 1 at the area shown,

and then remove it.
4. Loosen the bolts (nuts), and then remove
the lower unit from the upper case.

and place a block of wood between the
anti-cavitation plate and propeller to keep
the propeller from turning, and then
remove the propeller nut and propeller.
U-transom model
WARNING
When removing the lower unit with the
6P23H11
6-34
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
Removing the water pump and shift

rod
1. Remove the water pump housing 1 and
impeller 2.
a
1
2. Remove the Woodruff key 3.

3. Remove the outer plate cartridge 4.
and then remove the shift rod assembly
5.
S6P26660
4. Check the shift rod. Replace if cracked or

worn.
Checking the water pump and shift

rod
1. Check the water pump housing. Replace
if there is deformation.
2. Check the impeller and insert cartridge.
3. Check the Woodruff key 1 and the
groove a on the drive shaft. Replace if
worn.
6-35
6P23H11
Lower unit (counter rotation model) / Propeller shaft housing (counter rotation model)
Propeller shaft housing (counter rotation model)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Water pipe
Rubber seal
Rubber seal
Shift rod joint
Ball
Slider
Shift plunger
Dog clutch
Cross pin
Spring
Forward gear
Forward gear shim
Ring nut
Claw washer
Taper roller bearing assembly
Propeller shaft
Thrust bearing
6P23H11
Qty
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
6-36
LOWR
Lower unit
6
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
6-37
Part name
Propeller shaft shim
O-ring
Dowel
Grease nipple
Rubber seal
O-ring
Needle bearing
Oil seal
Ring
Bolt
Bolt
Washer
Cooling water inlet cover
Nut
Screw
Qty
1
1
1
1
1
1
1
2
1
2
2
2
2
1
1
Remarks
Not reusable
Not reusable
Not reusable
Not reusable
M8 20 mm
M8 33 mm
5 53 mm
6P23H11
Removing the propeller shaft

housing assembly

housing
1. Remove the water pipe 1 and shift rod

2.
1. Remove the spring 1, and then remove

the cross pin 2, dog clutch 3, slider,
shift plunger, and shift rod joint.
3
2. Remove the bolts 3, ring 4, and bolts
5.
1
S69J6375
2. Remove the forward gear and forward

gear shim(s) from the propeller shaft
housing using a press.
3. Pull out the propeller shaft housing with

3. Remove the dowel from the lower case.
4. Install the propeller shaft housing assembly in the reverse direction into the lower
case.
NOTE:
Before removing the propeller shaft from the
lower case, remove the shift rod.
Slide hammer 6: 90890-06531
Puller head 7: 90890-06514
6P23H11
6-38
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
5. Remove the ring nut 5 and claw washer

6.
Ring nut wrench 7: 90890-06578

6. Remove the bearing outer race 8, taper
roller bearing 9, thrust bearing 0, and
propeller shaft shim(s) A using a press.
Needle bearing attachment B:

90890-06611
Driver rod L3 C: 90890-06652
Checking the propeller shaft housing

1. Clean the propeller shaft housing using a
soft brush and cleaning solvent, and then
check it. Replace if cracked or damaged.
2. Check the teeth and dogs of the forward
gear. Replace if cracked or worn.
there is rumbling.

1. Check the propeller shaft. Replace if bent
or worn.
2. Measure the propeller shaft runout.
CAUTION:
Do not press the propeller shaft threads
a directly.
Do not reuse the taper roller bearing,
always replace it with a new one.
7. Remove the oil seals and needle bearing.
6-39
S6P26220C

3. Check the dog clutch, shift rod joint, and
slider. Replace if cracked or worn.
6P23H11

housing
1. Install the needle bearing into the propeller shaft housing to the specified depth.

90890-06640
Depth d:
5.0 0.25 mm (0.20 0.01 in)
3. Install the original shim(s) 5 and thrust
bearing 6 with the propeller shaft into
the propeller shaft housing.
NOTE:
Install the needle bearing with the manufacture identification mark a facing toward the
oil seal (propeller side).
When using the driver rod, do not strike the
special service tool in a manner that will
force the stopper c out of place.
Driver rod SS 1: 90890-06604
90890-06610
Bearing depth plate 3: 90890-06603
NOTE:
Be sure to select the propeller shaft shim(s)
if replacing the propeller shaft, propeller
shaft housing, thrust bearing or taper roller
bearing.
To select the shims, see Shimming
(counter rotation model).
Depth b:
25.3 0.25 mm (1.00 0.01 in)
then install them into the propeller shaft
NOTE:
Install an oil seal halfway into the propeller
shaft housing, then the other oil seal.
6P23H11
6-40
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
4. Install the new taper roller bearing 7 and

bearing outer race 8 into the propeller
shaft housing using a press.
T.
R.
NOTE:
After installing the taper roller bearing and
bearing outer race, check that the propeller
shaft rotates smoothly.
Ring nut A:
108 Nm (10.8 kgfm, 79.7 ftlb)
7. Install the original shim(s) B, forward

gear C, and dog clutch D using a press.

5. Install the propeller shaft housing assembly in the reverse direction into the lower
case.
6. Install the claw washer 0 and ring nut

A, and then tighten the ring nut to the
specified torque.
NOTE:
Be sure to select the forward gear shim(s) if
replacing the propeller shaft housing, taper
roller bearing, or lower case.
To select shims, see Shimming (counter
rotation model).
Install the dog clutch D with the F mark e
facing toward the forward gear.
After installing the forward gear, check that
the propeller shaft and forward gear rotate
smoothly.
6-41
6P23H11

8. Install the shift plunger E and slider F
into the propeller shaft, and then install
the cross pin G and spring H.
1
2
3
4
5
6
7
8
9
F
G
S69J6445
6P23H11
6-42
LOWR
Lower unit
Drive shaft and lower case (counter rotation model)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
6-43
Part name
Drive shaft
Thrust bearing
Spring
Washer
Cover
Oil seal
Bolt
Drive shaft housing
Needle bearing
O-ring
Pinion shim
Thrust bearing
Lower case
Needle bearing
Pinion
Washer
Nut
Qty
1
1
1
1
1
2
4
1
1
1
1
1
1
1
1
1
Remarks
Not reusable
M8 25 mm
Not reusable
6P23H11

6
No.
18
19
20
21
22
23
24
Part name
Reverse gear shim
Retainer
Needle bearing
Thrust bearing
Circlip
Needle bearing
Reverse gear
6P23H11
Qty
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
Not reusable
6-44
LOWR
Lower unit

1. Loosen the pinion nut.
2
S68S6360J
S6P26190

reverse gear using a chisel.

2. Remove the drive shaft, drive shaft housing, pinion, thrust bearing, spring and
washer.
3. Pull out the reverse gear.

housing
1. Remove the cover, oil seals, and needle
bearing.
S68S6160
CAUTION:
it with a new one.
Disassembling the lower case

1. Remove the retainer and shim(s).

90890-06610
Driver rod L3 2: 90890-06652
Disassembling the reverse gear

1. Remove the circlip 1 from the reverse
gear 2.
Flywheel puller 1: 90890-06521

assembly 2:
90890-06523
retainer.
6-45
6P23H11
Checking the drive shaft

1. Check the drive shaft. Replace if bent or
worn.
2. Measure the drive shaft runout.

90890-06654
Driver rod L3 4: 90890-06652
S6P26210

lower case.
Checking the lower case

1. Check the skeg and torpedo. Replace
the lower case if cracked or damaged.
Assembling the lower case

1. Install the needle bearing into the
retainer to the specified depth.
NOTE:
Since the diameter of the passage in the
lower case and the diameter of the special
service tool 5 are both 40 mm (1.57 in), the
special service tool may not fit into the lower
case. In that case, use a special service tool
with a smaller diameter.
90890-06655
Driver rod LL 6: 90890-06605
Checking the pinion and reverse

gear
1. Check the teeth of the pinion, and the
teeth and dogs of the reverse gear.

90890-06654
Driver rod L3 2: 90890-06652
Depth a:
0 0.25 mm (0 0.01 in)
Checking the bearing

there is rumbling.
6P23H11
6-46
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
2. Install the original shim(s) and retainer

into the lower case.
Assembling the reverse gear

1. Install the new needle bearing into the
reverse gear to the specified depth.
S6P26170E
NOTE:
Be sure to select the reverse gear shim(s) if
replacing the thrust bearing, retainer or
lower case.
90890-06657
Driver rod LL 4: 90890-06605

90890-06653
Driver rod SS 2: 90890-06604
Depth a:
7 0.25 mm (0.28 0.01 in)
2. Install the new circlip 3 into the reverse
gear 4.
3. Install the needle bearing into the lower

case.
S6P26230
Assembling the drive shaft housing

NOTE:
Apply gear oil to the needle bearing outer
case before installation.
The needle bearing contains 24 rollers.
1. Install the needle bearing into the drive

shaft housing to the specified depth.

90890-06655
assembly 6:
90890-06523
6-47
6P23H11

2. Install the washer, spring and thrust
bearing into the lower case.

90890-06610
Driver rod SS 2: 90890-06604
Depth a:
4.5 0.25 mm (0.18 0.01 in)
then install them into the drive shaft
4
3
b
3. Install the drive shaft housing 1, thrust
bearing 2, and original shim(s) 3 onto
the drive shaft 4.
S6P26120E
NOTE:
Install an oil seal halfway into the drive shaft
housing, then the other oil seal.
90890-06628
Driver rod LS 4: 90890-06606
Depth b:
0.5 0.25 mm (0.02 0.01 in)
Installing the drive shaft

1. Install the thrust bearing and reverse
gear into the lower case.
6P23H11
NOTE:
Be sure to select the pinion shim(s) if
replacing the thrust bearing, drive shaft
housing, drive shaft or lower case.
6-48
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
4. Install the drive shaft and drive shaft

housing into the lower case, then the pinion, washer and pinion nut, and then
6
S63P6310
NOTE:
To install the pinion nut, push down on the
drive shaft.
S6P26190E
4. Install the washer and propeller shaft

housing bolts 1, and then tighten the
bolts to the specified torque.
5. Install the ring 2 and bolts 3.
T.
R.
Pinion nut:
142 Nm (14.2 kgfm, 104.7 ftlb)
5. Tighten the drive shaft housing bolts.

NOTE:
Apply LOCTITE 572 to the drive shaft housing bolts before installation.
T.
R.
Propeller shaft housing bolt 1:

30 Nm (3.0 kgfm, 22.1 ftlb)
Installing the propeller shaft housing

1. Set the shift rod joint and dog clutch to
the neutral position as shown.
2. Apply grease to the new O-rings and propeller shaft housing.
6. Install the water pipe and rubber seals.
Installing the water pump and shift

rod
1. Install the shift rod assembly 1.
3. Install the dowel and propeller shaft

housing assembly into the lower case.
6-49
6P23H11

3. Install the Woodruff key into the drive
shaft.
4. Align the groove on the impeller 5 with
the Woodruff key 6, and then install the
impeller onto the drive shaft.
5. Install the new O-ring 7 and insert cartridge 8 into the pump housing 9.
NOTE:
Check the gear shift to the neutral position,
when installing the shift rod.
After assembling the lower unit, check that
the shift rod operates smoothly, and check
that the drive shaft and propeller shaft
rotate smoothly.
7
A
b
b
2. Install a new gasket 2, the outer plate

cartridge 3, and dowels 4.
6P23H11
1104J
S6P26110
NOTE:
Align the insert cartridge projections a with
the holes b in the pump housing.
6-50
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
6. Install the new O-ring 0 and pump housing assembly A into the lower case,
tighten the bolts B, and then install the
seal C and cover D.

at the lower unit.
CAUTION:
Do not turn the drive shaft counterclockwise, otherwise the water pump impeller
may be damaged.
NOTE:
When installing the pump housing, apply
grease to the inside of the housing, and
then turn the drive shaft clockwise while
pushing down the pump housing.
Align the cover projection c with the hole
d in the pump housing.

3. Install the dowels 1 into the lower unit.
4. Install the lower unit into the upper case,
and then tighten the lower case mounting
bolts (nuts) 2 to the specified torque.
5. Install the trim tab 3 to its original position, and then tighten the bolt 4 to the
specified torque.
Installing the lower unit

WARNING
When installing the lower unit with the
the outboard motor. If the outboard motor
is not suspended it can fall suddenly and
result in severe injury.
1. Align the center of the set pin a with the
alignment mark b on the bottom cowling.
6-51
6P23H11
WARNING
U-transom model
T.
R.
Lower case mounting bolt (nut) 2:

47 Nm (4.7 kgfm, 34.7 ftlb)
Trim tab bolt 4:
42 Nm (4.2 kgfm, 31.0 ftlb)
R.
6P23H11
NOTE:
If the grooves in the propeller nut 5 do not
align with the cotter pin hole, tighten the nut
until they are aligned.
T.
6. Install the propeller and propeller nut,

and then tighten the nut temporary. Place
a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then tighten the
nut to the specified torque.

Propeller nut 5:
54 Nm (5.4 kgfm, 39.8 ftlb)
7. Fill the gear oil to the correct level.
6-52
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
Shimming (counter rotation model)
F
P
B4
T3
A3
B3
65.0
B8
B5
A5
T2
T1
B1 38.4 47.5
A1
B7
B6
A4
A2
T4
S6P26300
6-53
6P23H11
Shimming
T.
R.
NOTE:
Shimming is not required when assembling
the original lower case and inner parts.
Shimming is required when assembling the
original inner parts and a new lower case.
Shimming is required when replacing the
inner part(s).
Pinion nut:
142 Nm (14.2 kgfm, 104.7 ftlb)
3. Measure the distance (M4) between the

special service tool and the pinion as
shown.
Selecting the pinion shim

1. Install the special service tools onto the
drive shaft 1.
NOTE:
Measure the pinion at 3 points to find the distance average.

seat the drive shaft housing 6, and then
measure the housing height (M3) as
shown.
NOTE:
Install the special service tool onto the drive
shaft so that the shaft is at the center of the
hole.
Tighten the wing nuts another 1/4 of a turn
after they contact the plate 2.
NOTE:
Measure the thrust bearing at 3 points to find
the height average.
Pinion height gauge 3:

90890-06710
2. Install the pinion and pinion nut, and then
6P23H11
6-54
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
5. Calculate the pinion shim thickness (T3)

as shown in the examples below.

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
Example:
0.78 mm.
0.72 mm.
Selecting the reverse gear shim

NOTE:
P is the deviation of the lower case dimension from standard. The P mark a is
the lower case in 0.01 mm units. If the P
mark is unreadable, assume that P is zero
assembled.

seat the bearing retainer 2, and then
measure the bearing height (M1) as
shown.
Pinion shim thickness (T3) =
82.00 + P/100 M3 M4
Example:
and P is (+2), then
T3 = 82.00 + (+2)/100 50.75 30.57 mm
= 82.00 + 0.02 50.75 30.57 mm
= 0.70 mm
and P is (3), then
T3 = 82.00 + (3)/100 50.70 30.53 mm
= 82.00 0.03 50.70 30.53 mm
= 0.74 mm
6. Select the pinion shim(s) (T3) as follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
3, 4, 5
6, 7, 8
9, 10
NOTE:
Measure the bearing retainer at 3 points to
find the height average.

2. Calculate the reverse gear shim thickness (T1) as shown in the examples
below.
6-55
6P23H11

Example:
shim is 0.70 mm.
shim is 0.68 mm.
NOTE:
F is the deviation of the lower case dimension from standard. The F mark a is
the lower case in 0.01 mm units. If the F
mark is unreadable, assume that F is zero
assembled.
Reverse gear shim thickness (T1) =
30.60 + F/100 M1
Example:
T1 = 30.60 + (+5)/100 29.94 mm
= 30.60 + 0.05 29.94 mm
= 0.71 mm
T1 = 30.60 + (+4)/100 29.94 mm
= 30.60 + 0.04 29.94 mm
= 0.70 mm
3. Select the reverse gear shim(s) (T1) as
follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
3, 4, 5
6, 7, 8
9, 10

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
6P23H11
6-56
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
Selecting the forward gear shim

then measure the bearing height (M5)
and (M6) as shown.
A3
S69J6625
NOTE:
R is the deviation of the lower case dimension from standard, and A is the deviation of
the propeller shaft housing dimension from
standard. The R mark a is stamped on the
trim tab mounting surface of the lower case,
and the A mark b is stamped on the propeller shaft housing in 0.01 mm units. If the
R mark or A mark is unreadable, assume
that R and A are zero and check the backlash when the unit is assembled.
NOTE:
Measure the taper roller bearing at 3 points
2. Calculate the forward gear shim thickness (T2) as shown in the examples
below.
6-57
Forward gear shim thickness (T2) =
8.45 + R/100 A/100 M5 + M6
Example:
and R is (1) and A is (3), then
T2 = 8.45 + (1)/100 (3)/100 22.95 + 15.73 mm
= 8.45 0.01 + 0.03 22.95 + 15.73 mm
= 1.25 mm
and R is (1) and A is (+2), then
T2 = 8.45 + (1)/100 (+2)/100 22.95 + 15.73 mm
= 8.45 0.01 0.02 22.95 + 15.73 mm
= 1.20 mm
6P23H11

3. Select the forward gear shim(s) (T2) as
follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
3, 4, 5
6, 7, 8
9, 10
NOTE:
Measure the taper roller bearing at 3 points

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
Example:
shim is 1.22 mm.
shim is 1.18 mm.
2. Install the thrust bearing 4 onto the propeller shaft 5, and then measure the
propeller shaft flange and thrust bearing
thickness (M7) as shown.
Selecting the propeller shaft shim

shown.
T4
6P23H11
S69J6705
6-58
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
3. Calculate the propeller shaft shim thickness (T4) as shown in the examples
below.
Example:
If T4 is 0.79 mm, then the propeller shaft
shim is 0.78 mm.
If T4 is 0.90 mm, then the propeller shaft
shim is 0.88 mm.
5. Calculate and select the propeller shaft
shim thickness (T4) as shown in the
examples below.
S69J6626
NOTE:
A and B are the deviation of the propeller
shaft housing dimension from standard. The
A mark a and B mark b are stamped on
the propeller shaft housing in 0.01 mm units.
If the A mark or B mark is unreadable,
assume that A and B are zero and check
the free play when the unit is assembled.
Calculation formula 1:
Propeller shaft shim thickness (T4) =
29.00 + A/100 B/100 M6 M7
Example:
and A is (3) and B is (5), then
T4 = 29.00 + (3)/100 (5)/100 15.73 12.50 mm
= 29.00 0.03 + 0.05 15.73 12.50 mm
= 0.79 mm
and A is (+7) and B is (6), then
T4 = 29.00 + (+7)/100 (6)/100 15.73 12.50 mm
= 29.00 + 0.07 + 0.06 15.73 12.50 mm
= 0.90 mm
Calculation formula 2:
Propeller shaft shim thickness (T4) =
T4 0.30
Example:
If T4 is 0.78 mm, then
T4 = 0.78 0.30 mm
= 0.48 mm
If T4 is 0.88 mm, then
T4 = 0.88 0.30 mm
= 0.58 mm
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
6. If the A mark or B mark is unreadable,
measure the propeller shaft free play as
shown.
7. Install the shim(s) 6, thrust bearing 4,
propeller shaft 5, taper roller bearing 7,
and claw washer 8, and then tighten the
ring nut 9 to the specified torque.
4. Round the numerals for the propeller

shaft shim(s) (T4) as follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
3, 4, 5
6, 7, 8
9, 10
Ring nut wrench: 90890-06578
T.
R.
6-59
Ring nut 9:
108 Nm (10.8 kgfm, 79.7 ftlb)
6P23H11
Shimming (counter rotation model) / Backlash (counter rotation model)

8. Measure the propeller shaft axial free
play. Reselect the propeller shaft shim(s)
(T4), if out of specification.
NOTE:
Tighten the center bolt while turning the drive
shaft until the drive shaft can no longer be
turned.
Propeller shaft free play:

0.250.35 mm (0.00980.0138 in)

90890-06502
Center bolt 3: 90890-06504
Magnet base B 0: 90890-06844

Dial gauge set A: 90890-01252
Backlash
(counter rotation model)

gear backlash
4. Install the backlash indicator onto the

drive shaft (22.4 mm [0.88 in] in diameter), and then install the dial gauge.
1. Remove the water pump assembly.

at the lower unit.

3. Install the special service tools so that it
pushes against the propeller shaft.
6P23H11
NOTE:
Install the dial gauge so that the plunger a
contacts the mark b on the backlash indicator.
Backlash indicator 4: 90890-06706
Magnet base B 7: 90890-06844
6-60
1
2
3
4
5
6
7
8
9
LOWR
Lower unit

direction.
Forward gear backlash:
0.460.82 mm (0.01810.0323 in)
Forward gear
backlash
Shim thickness
Less than
0.46 mm (0.0181 in)
To be decreased by
(0.64 M) 0.71
More than
0.82 mm (0.0323 in)
To be increased by
(M 0.64) 0.71
M: Measurement
12. Turn the shift rod in direction c to the

reverse position using the shift rod push
arm.
direction.

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
7. Remove the special service tools from
8. Turn the shift rod in direction c to the
reverse position using the shift rod push
arm.
9. Turn the drive shaft clockwise until the
dog clutch 7 is fully engaged.
NOTE:
When measuring the reverse gear backlash,
add force to the reverse direction c using
the shift rod push arm.
Reverse gear backlash:
0.450.78 mm (0.01770.0307 in)
10. Turn the shift rod in direction d to the

neutral position using the shift rod push
arm.
11. Turn the drive shaft counterclockwise

approximately 30.
6-61
6P23H11
Backlash (counter rotation model)

Reverse gear
backlash
Shim thickness
Less than
0.45 mm (0.0177 in)
To be decreased by
(0.62 M) 0.71
More than
0.78 mm (0.0307 in)
To be increased by
(M 0.62) 0.71
1
2
3
4
5
6
7
8
9
M: Measurement
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
15. Remove the special service tools, and
then install the water pump assembly.
6P23H11
6-62
BRKT
Bracket unit
Shift rod and bottom cowling ....................................................................... 7-1
Upper case and steering arm........................................................................ 7-5
Removing the upper case........................................................................7-10
Disassembling the upper case ................................................................7-10
Checking the drive shaft bushing ............................................................ 7-10
Disassembling the oil pan........................................................................7-10
Checking the oil strainer ..........................................................................7-11
Assembling the oil pan ............................................................................7-11
Assembling the upper case ..................................................................... 7-12
Installing the upper case..........................................................................7-13
Removing the steering arm ..................................................................... 7-14
Installing the steering arm ....................................................................... 7-14
Clamp bracket and swivel bracket ............................................................. 7-16
Removing the PTT unit............................................................................7-18
Removing the clamp bracket ................................................................... 7-19
Installing the clamp bracket ..................................................................... 7-19
Installing the PTT unit.............................................................................. 7-19
Adjusting the trim sensor .........................................................................7-20
PTT unit.........................................................................................................7-22
Checking the hydraulic pressure ............................................................. 7-24
PTT motor ..................................................................................................... 7-27
Disassembling the PTT motor .................................................................7-28
Checking the PTT motor..........................................................................7-28
Assembling the PTT motor ...................................................................... 7-29
Gear pump .................................................................................................... 7-31
Disassembling the gear pump .................................................................7-34
Checking the gear pump .........................................................................7-35
Checking the gear pump housing............................................................ 7-35
Checking the reservoir............................................................................. 7-35
Checking the filter....................................................................................7-35
Assembling the gear pump...................................................................... 7-35
6P23H11
Tilt cylinder and trim cylinder ..................................................................... 7-37

Disassembling the tilt cylinder and trim cylinder...................................... 7-39
Checking the tilt cylinder and trim cylinder .............................................. 7-40
Checking the valve .................................................................................. 7-41
Assembling the tilt ram ............................................................................7-41
Assembling the trim ram..........................................................................7-42
Installing the tilt cylinder ..........................................................................7-42
Installing the trim ram .............................................................................. 7-42
Installing the PTT motor ..........................................................................7-43
Installing the reservoir ............................................................................. 7-44
Installing the tilt ram................................................................................. 7-44
Bleeding the PTT unit .............................................................................. 7-45
Bleeding the PTT unit (built-in) ................................................................7-46
PTT electrical system .................................................................................. 7-46
Checking the fuse....................................................................................7-46
Checking the PTT relay ...........................................................................7-47
Checking the PTT switch.........................................................................7-47
Checking the trim sensor.........................................................................7-48
6P23H11
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Shift rod and bottom cowling
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
7-1
Part name
Bracket
Shift cut switch
Bracket
Neutral switch
Screw
Plate
Spring
Bushing
Grease nipple
Bolt
Bolt
Clamp
Screw
Plate
Clip
Bushing
Washer
Qty
1
1
1
1
2
1
1
2
1
1
2
1
2
1
2
1
1
Remarks
4 16 mm
M6 35 mm
4 16 mm
6P23H11

7
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Part name
Shift lever
Cotter pin
Bushing
Bolt
Bracket
Ball
Spring
Bolt
Shift rod
O-ring
Grommet
Screw
Adapter
Hose joint gasket
Hose joint
Clamp
Grommet
6P23H11
Qty
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
M6 30 mm
Not reusable
6 20 mm
7-2
BRKT
Bracket unit
7
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
7-3
Part name
Bottom cowling
Rubber seal
Cowling lock lever
Bushing
Plate
Bolt
Bolt
Wave washer
Lever
Bolt
Spring
Hook
Bracket
Bracket
Rivet
Bolt
Plate
Qty
1
1
3
6
3
11
7
3
3
3
3
3
1
1
2
2
2
Remarks
M6 20 mm
M6 30 mm
M6 20 mm
M6 25 mm
6P23H11

7
No.
18
19
20
21
22
23
24
25
26
27
28
Part name
Collar
Grommet
Bolt
Cooling water pilot hole
Wire lead extension
Bracket
Switch
Bracket
Bracket
Cover
Gasket
6P23H11
Qty
4
1
4
1
1
2
1
1
1
1
2
1
2
3
4
5
6
7
8
9
Remarks
M8 35 mm
Counter rotation model
7-4
BRKT
Bracket unit
Upper case and steering arm
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
7-5
Part name
Upper case assembly
Bolt
Washer
Washer
Washer
Upper mount
Bracket
Bolt
Bolt
Mount housing
Bolt
Lower mount
Engine oil drain bolt
Gasket
Bolt
Damper
Apron stay
Qty
1
2
2
2
2
2
1
3
4
2
2
2
1
1
2
1
6
Remarks
M14 190 mm
M10 45 mm
M10 45 mm
M14 205 mm
M14 12 mm
Not reusable
M6 14 mm
6P23H11

7
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Part name
Bolt
Dowel
Adapter
Bolt
Drive shaft bushing
Circlip
Nut
Circlip
Bushing
O-ring
Bushing
Washer
Steering yoke
Washer
Steering arm
Washer
Washer
6P23H11
Qty
1
1
1
1
1
1
4
1
2
1
1
2
1
2
1
2
2
1
2
3
4
5
6
7
8
9
Remarks
M6 10 mm
M6 30 mm
Not reusable
7-6
BRKT
Bracket unit
7
T.
R.
20 N m (2.0 kgf m, 14.8 ft Ib)
T.
R.
4 N m (0.4 kgf m, 3.0 ft Ib)

LT
R.
R.
T.
T.
8 N m (0.8 kgf m, 5.9 ft Ib)
42 N m (4.2 kgf m, 31.0 ft Ib)
2
3 4
5
6
LT
572
13
A
572
16
14
12
11
LT
271
14
15
10
13
S6P27040E
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
7-7
Part name
Bolt
Plate
Collar
Bolt
O-ring
O-ring
PCV
Bolt
Rubber seal
Rubber seal
Screw
Baffle plate
Rubber seal
Dowel
Upper case
Rubber seal
Qty
1
1
1
7
1
1
1
2
1
1
2
1
1
2
1
1
Remarks
M6 20 mm
M10 45 mm
Not reusable
Not reusable
M8 30 mm
6 16 mm
6P23H11

7
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Upper exhaust guide
Gasket
Dowel
Lower exhaust guide
Gasket
Oil strainer
Collar
Bolt
Gasket
Dowel
Rubber seal
Oil pan
Gasket
Exhaust manifold
Bolt
Bolt
Bolt
6P23H11
Qty
1
1
2
1
1
1
3
3
1
2
1
1
1
1
10
2
4
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
Not reusable
M6 25 mm
Not reusable
Not reusable
M8 60 mm
M8 30 mm
M8 90 mm
7-8
BRKT
Bracket unit
7
No.
18
19
20
21
22
23
24
25
26
7-9
Part name
Rubber seal
Gasket
Plate
Pipe
Rubber seal
Gasket
Dowel
Muffler
Bolt
Qty
1
1
1
1
1
1
2
1
10
Remarks
Not reusable
Not reusable
M8 35 mm
6P23H11
Removing the upper case
Disassembling the oil pan
1. Place a drain pan under the drain hole,

and then remove the engine oil drain bolt
1 and let the oil drain completely.
1. Remove the muffler 1, plate 2, and

exhaust manifold 3 from the oil pan 4.
1
2
3
4
5
6
7
8
9
2. Remove the cover 2 and damper 3.
3. Disconnect the ground lead and speedometer hose.

4. Remove the upper and lower mounting
nuts, and then remove the upper case.
Disassembling the upper case

1. Remove the oil pan assembly from the
upper case.
2. Remove the circlip as shown.
3. Remove the drive shaft bushing.
3
2
S6P27840E
Bearing puller assembly 1:

90890-06535
90890-06538
Checking the drive shaft bushing

1. Check the drive shaft bushing. Replace if
cracked or worn.
6P23H11
7-10
BRKT
Bracket unit
2. Remove the oil pan 4 from the upper

exhaust guide 5 and lower exhaust
guide 6.
2. Install the new gasket, oil strainer 4 and

bolts, and then tighten the bolts to the
specified torque.
3. Remove the oil strainer 7 from the lower

exhaust guide 6.
NOTE:
Clean dirt from the removed parts and check
the parts for cracks or corrosion.
T.
R.
Oil strainer bolt:

10 Nm (1.0 kgfm, 7.4 ftlb)
3. Install the new gasket, oil pan 5, and

then tighten the bolts 6 temporary.
4. Install the new gasket, exhaust manifold
7, rubber seal, and then tighten the bolts
8 temporary.
Checking the oil strainer

1. Check the oil strainer. Clean if there is
dirt and residue.
Assembling the oil pan

1. Install the dowels, new gasket 1 and
lower exhaust guide 2 onto the upper
exhaust guide 3.
5. Tighten the exhaust manifold bolts 8,

then the oil pan bolts 6 to the specified
torques.
7-11
6P23H11
T.
R.
Oil pan bolt 6:

20 Nm (2.0 kgfm, 14.8 ftlb)
Exhaust manifold bolt 8:
20 Nm (2.0 kgfm, 14.8 ftlb)
2
1
6. Install the new gasket and plate 9.

7. Install the rubber seal and cooling water
pipe 0 into the muffler A.
8. Install the new gasket, muffler A and
bolts onto the oil pan, and then tighten
the bolts to the specified torque.
WR-No.2
S6P27850E
NOTE:
After installing the drive shaft bushing, apply
grease to the inside of the bushing.
90890-06653
Driver rod L3 2: 90890-06652
NOTE:
Install the cooling water pipe positioned as
shown.
T.
R.
Muffler bolt:
20 Nm (2.0 kgfm, 14.8 ftlb)
Assembling the upper case

1. Install the drive shaft bushing into the
upper case, and then install the circlip.
6P23H11
7-12
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
2. Install the rubber seal 3 into the joint

hole a of the upper case.
6. Install the upper mounts B and bolts into

the upper case.
3. Install the oil pan assembly 4 by inserting the tip of the cooling water pipe 5
into the joint hole a of the upper case.
7. Install the bracket C, and then tighten

the bolts D to the specified torque.
4. Install muffler assembly bolts 6 and 7,

and PCV 8, and then tighten them to the
specified torques.
A
7
LT
LT
572
572
A
3
4
T.
R.
5
A
Upper mount bracket bolt D:

54 Nm (5.4 kgfm, 39.8 ftlb)
8. Install the lower mounts E and mount

housings F.
3
S6P27480E
T.
R.
Oil pan assembly bolt (M8) 6:

20 Nm (2.0 kgfm, 14.8 ftlb)
Oil pan assembly bolt (M10) 7:
42 Nm (4.2 kgfm, 31.0 ftlb)
PCV 8: 8 Nm (0.8 kgfm, 5.9 ftlb)
5. Install the damper 9, cover 0, and

engine oil drain bolt A.
Installing the upper case

1. Install the upper and lower mounting
bolts into the swivel bracket 1 simultaneously.
T.
R.
7-13
Engine oil drain bolt A:

27 Nm (2.7 kgfm, 19.9 ftlb)
2. Install the upper mounting nuts 2 and

lower mounting nuts 3, and then tighten
them to the specified torques.
6P23H11

3. Pass the speedometer hose through the
steering arm, and then connect it to the
adapter.
3. Remove the steering arm from the swivel

bracket by pulling the arm off the bracket.
Installing the steering arm

4. Connect the ground lead.
1. Install the washer 1 and bushing 2 onto

the steering arm 3.
2. Place the swivel bracket 4 in an upright
position, and then install the steering arm
onto the swivel bracket.
T.
R.
Upper mounting nut 2:

72 Nm (7.2 kgfm, 53.1 ftlb)
Lower mounting nut 3:
72 Nm (7.2 kgfm, 53.1 ftlb)
3. Install the bushing 5, new O-ring 6,

bushing 7, and washer 8 onto the
swivel bracket.
Removing the steering arm

1. Remove the circlip 1.
2. Remove the steering yoke 2 by striking
it with a plastic hammer.
6P23H11
7-14
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
4. Install the steering yoke 9 onto the

steering arm 3, making sure that they
are both facing in the same direction (a
and b are aligned).
5. Install the circlip 0.
6. Inject grease into the grease nipple until

grease comes out from both the upper
and lower bushings c.
7-15
6P23H11
Upper case and steering arm / Clamp bracket and swivel bracket
Clamp bracket and swivel bracket
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Through tube
Clamp bracket (PORT)
Bolt
Ground lead
Bushing
Washer
Bushing
Friction plate
Screw
Screw
Trim sensor
Grease nipple
Clamp bracket (STBD)
Self-locking nut
Collar
Pin
Distance collar
6P23H11
Qty
1
1
8
1
2
2
4
2
4
2
1
6
1
1
1
2
2
1
2
3
4
5
6
7
8
9
Remarks
M10 45 mm
6 10 mm
6 15 mm
a: 30.330.4 mm (1.191.20 in)
7-16
BRKT
Bracket unit
7
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
7-17
Part name
Pin
Bolt
Spring
Spring holder
Tilt stop lever (PORT)
Shaft
Trim stopper
Tilt stop lever (STBD)
Circlip
Nut
Swivel bracket
PTT unit
Ground lead
Bushing
Bushing
Anode
Ground lead
Qty
1
2
1
1
1
1
2
1
1
2
1
1
1
2
2
1
1
Remarks
M6 10 mm
6P23H11
Removing the PTT unit

5. Remove the PTT motor lead from the

holder 7, and then pull out the PTT
motor lead 8.
6. Remove the circlip 9 and shaft 0, then
the upper end of the tilt rod from the
swivel bracket.
7. Remove the PTT unit A.
WARNING
Otherwise, the outboard motor could
suddenly lower if the PTT unit should
lose fluid pressure.
When removing the PTT unit with the
NOTE:
If the PTT does not operate, turn the manual
valve counter clockwise and tilt the outboard
motor up manually.
2. Remove the anode 2 and the PTT unit
bolts 3 (8 bolts).
3. Loosen the self-locking nut 4 of the
through tube, and then move the clamp
brackets slightly in the direction of the
arrows.
WARNING
Do not remove the tilt stop lever 1 from
the clamp brackets.
4. Remove the PTT motor lead and trim
sensor lead holder 5 and the plastic ties
6.
6P23H11
7-18
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Removing the clamp bracket

1. Remove the self-locking nut 1 of the
through tube and ground lead 2, then
clamp brackets 3 and 4.
2. Remove the trim sensor 5.
T.
R.
Grease nipple 5:
Installing the PTT unit

Installing the clamp bracket

1. Install the trim sensor 1 onto the starboard clamp bracket.
WARNING
NOTE:
Adjust the trim sensor after installing the PTT
unit. To adjust the trim sensor, see Adjusting
the trim sensor.
2. Assemble the clamp brackets and the
swivel bracket by connecting the ground
lead 2, installing the through tube 3,
then tightening the self-locking nut 4
temporary.
7-19
When installing the PTT unit with the

After tilting the outboard motor up, be
2. Install the PTT unit mounting bolts 2
onto both clamp brackets together with
the PTT unit 3, and then tighten them.
6P23H11

3. Install the upper end of the tilt ram into
the swivel bracket with the shaft 4 and
circlip 5.
4. Tighten the self-locking nut 6 of the
through tube to the specified torque.
5. Install the anode 7.
6. Install the PTT motor lead to the holder
8.
7. Pass the PTT motor lead and trim sensor
lead through the hole of the starboard
clamp bracket.
8. Fasten the PTT motor lead and trim sensor lead with the plastic ties 9 and then
install the holder 0.
Adjusting the trim sensor

WARNING
T.
R.
Self-locking nut 6:
22 Nm (2.2 kgfm, 16.2 ftlb)

fluid pressure.
9. Inject grease into all grease nipples until

grease comes out from the bushings a.
6P23H11
7-20
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
2. Loosen the trim sensor screws 2.
WARNING
3. Adjust the position of the trim sensor,

and then tighten the trim sensor screws
2 temporary.

fluid pressure.
7. Tighten the trim sensor screws 2.
NOTE:
To decrease the resistance, turn the trim
sensor in direction a.
To increase the resistance, turn the trim
sensor in direction b.
NOTE:
Check the trim sensor resistance again
after tighten the trim sensor screws 2 and
fully tilt the outboard motor down.
To check the trim sensor, see Checking
the trim sensor.

5. Measure the trim sensor resistance.
Repeat steps 14 if out of specification.
S6P27810E
Trim sensor resistance:

Pink (P) Black (B)
10 1
support it with the tilt stop lever.
7-21
6P23H11
Clamp bracket and swivel bracket / PTT unit
PTT unit
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
PTT body
Reservoir
Bolt
O-ring
Reservoir cap
O-ring
Sheet
Filter
Spacer
PTT motor assembly
O-ring
Joint
O-ring
Manual valve
Circlip
Shaft
Circlip
6P23H11
Qty
1
1
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
Remarks
M8 20 mm
Not reusable
M12 10 mm
Not reusable
Not reusable
Not reusable
7-22
BRKT
Bracket unit
7
No.
18
19
20
21
22
23
7-23
Part name
Bushing
Pipe
Pipe
Spacer
O-ring
Adapter
Qty
2
1
1
1
1
1
Remarks
Not reusable
6P23H11
PTT unit
Checking the hydraulic pressure

1. Check the hydraulic pressure. Check the
internal parts if out of specification.
2. Fully extend the PTT rams.
Ram
Down
3. Loosen the pipe joints 1, and then

remove the pipe joint at end a.
PTT motor lead
Battery
terminal
Light green (Lg)
Sky blue (Sb)
Hydraulic pressure (down):

6.78.7 MPa (6889 kgf/cm2)
4. Install the special service tools.

6. Reverse the PTT motor leads between
the battery terminals to fully extend the
rams.
NOTE:
Put the PTT unit in the drain pan.
PTT oil pressure gauge assembly 2:
90890-06580
Ram
Up
5. Connect the PTT motor leads to the battery terminals to retract the trim rams,
and then measure the hydraulic pressure.
PTT motor lead
Battery
terminal
Sky blue (Sb)
Light green (Lg)

8. Install the pipe joints 1, and then tightening them to the specified torque.
T.
R.
Pipe joint 1:
15 Nm (1.5 kgfm, 11.1 ftlb)
9. Connect the PTT motor leads to the battery terminals to fully retract the trim and
tilt rams.
6P23H11
7-24
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
10. Loosen the pipe joints 3, and then

remove the pipe joint at end b.
Hydraulic pressure (up):

13.015.0 MPa (130150 kgf/cm2)
11. Install the special service tools.

the battery terminals to fully retract the
rams.
NOTE:
Put the PTT unit in the drain pan.
PTT oil pressure gauge assembly 2:
90890-06580
Ram
Down
12. Connect the PTT motor leads to the battery terminals to extend the trim rams,
and then measure the hydraulic pressure.
PTT motor lead
Battery
terminal
Light green (Lg)
Sky blue (Sb)

15. Install the pipe joints 3, and then tightening them to the specified torque.
T.
R.
Pipe joint 3:
15 Nm (1.5 kgfm, 11.1 ftlb)
16. After measuring the hydraulic pressure,

connect the PTT motor leads to the battery terminals to fully extend the trim and
tilt rams.
Ram
Up
7-25
PTT motor lead
Battery
terminal
Sky blue (Sb)
Light green (Lg)
6P23H11
PTT unit
1
2
3
4
5
6
7
8
9
17. Place the PTT unit in an upright position.

WARNING
Make sure that the trim and tilt rams are
fully extended when removing the reservoir cap, otherwise fluid can spurt out
from the unit due to internal pressure.
NOTE:
19. If necessary, add sufficient fluid of the
recommended type to the correct level.
20. Install the reservoir cap 4, and then

T.
R.
Reservoir cap 4:
6P23H11
7-26
BRKT
Bracket unit
PTT motor
No.
1
2
3
4
5
6
7
8
9
10
11
7-27
Part name
Stator
Bolt
Wave washer
Washer
Bearing
Armature
Brush
Spring
PTT motor base assembly
O-ring
Oil seal
Qty
1
2
1
1
2
1
4
4
1
1
1
Remarks
M5 12 mm
Not reusable
Not reusable
6P23H11
PTT motor
Disassembling the PTT motor

1. Remove the PTT motor assembly, Oring, and joint from the PTT unit.
WARNING
Do not push the trim and tilt rams down
while the PTT motor is removed from the
PTT unit, otherwise fluid can spurt out.
2. Remove the PTT motor screws 1, then
the stator 2.
Checking the PTT motor
CAUTION:
1. Check the commutator. Clean with 600

grit sandpaper and compressed air if
dirty.
Do not allow grease or oil to contact the

commutator.
NOTE:
Place a clean cloth over the end of the armature shaft, hold it with a pair of pliers, and
then carefully slide the stator off of the armature.
3. Remove the screws 3, disconnect the
PTT motor leads 4, and then remove
the springs 5 and brushes 6 from the
PTT motor base assembly.
6P23H11
7-28
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
2. Measure the commutator diameter.

Replace the armature if below specification.
Armature continuity
Commutator segments b
Continuity
Segment Armature core c No continuity

Segment Armature shaft d No continuity
5. Check the circuit breaker of brush holder
for continuity. Replace the PTT motor
base assembly if there is no continuity.
Motor commutator standard

diameter:
23.0 mm (0.91 in)
Wear limit: 22.0 mm (0.87 in)
3. Measure the commutator undercut a.
Motor commutator standard

undercut a:
1.40 mm (0.055 in)
4. Check the armature for continuity.
Replace if out of specifications.
6. Measure the brush length. Replace if

below specification.
Motor brush standard length:

11.5 mm (0.45 in)
Wear limit e: 4.5 mm (0.18 in)
7. Check the motor base. Replace if
cracked or damaged.
8. Check the bearing and oil seal. Replace
if damaged or worn.
Assembling the PTT motor

1. Install the new oil seal 1 and bearing 2
into the motor base 3 as shown.
7-29
6P23H11
PTT motor
6. Install the wave washer A and washer
B into the stator C.
2. Connect the PTT motor leads 4 to the

brush holder 5, and then install the
brush holder 5 to the motor base 6.
3. Install the brushes 7 and springs 8 to
the brush holder as shown.
7. Install the new O-ring and stator C to the

motor base.
NOTE:
Place a clean cloth over the end of the armature shaft, hold it with a pair of pliers, and
then carefully slide the stator over the armature.
4. Install the bearing 9 to the armature 0.

5. Push the brushes 7 into the holders,
and then install the armature 0.
6P23H11
7-30
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Gear pump
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
7-31
Part name
Gear housing 1
Bolt
Plate
Filter
Plate
Valve lock screw
Down-relief spring
Valve support pin
Relief valve seal
Up-relief spring
Valve support pin
O-ring
Ball
Circlip
Main valve seal
Shuttle piston
O-ring
Qty
1
3
1
1
1
2
1
1
1
1
1
1
1
2
2
1
1
Remarks
M5 40 mm
Not reusable
Not reusable
6P23H11
Gear pump
7
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Part name
Return spring
Shuttle piston
Driven gear
Drive gear
Ball
Gear housing 2
Manual release spring
Pin
Ball
Valve pin
Spring
Spacer
O-ring
Pin
Filter
Bracket
Washer
6P23H11
Qty
2
1
1
1
2
1
1
1
4
2
2
2
2
2
1
1
2
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
7-32
BRKT
Bracket unit
7
No.
35
36
37
38
39
40
41
42
43
44
45
46
47
7-33
Part name
Bolt
O-ring
Spacer
Filter
Gear pump assembly
Relief valve seat
O-ring
Down-relief valve
Up-relief valve
Down-absorber valve
Up-absorber valve
Down-main valve
Up-main valve
Qty
2
2
2
2
1
1
1
1
1
1
1
1
1
Remarks
M5 25 mm
Not reusable
Not reusable
6P23H11
Gear pump
3. Remove the bracket 5, then the balls 6.
Disassembling the gear pump

1. Remove the manual valve 1, then gear
pump 2 and filters.
4. Remove the gear housing 2 7, then the

shuttle pistons 8.
2. Remove the relief valve seal 3 and ball
4.
5. Remove the drive gear 9 and driven

gear 0, balls A, and pins B.
S6AL7771
NOTE:
Before removing the relief valves, measure
and note the screw height a and screw
depth b.
6P23H11
7-34
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Checking the gear pump

1. Check the drive gear 1 and driven gear
2. Replace if damaged or excessive
worn.
2. Check the up-relief valve 3 and downrelief valve 4. Clean if there is dirt or residue.
3. Check the main valves 5, 6. Clean if
there is dirt or residue.
Assembling the gear pump

4. Check the absorber valves 7, 8. Clean
if there is dirt or residue.
1. Install the drive gear 1 and driven gear

2, pins 3, balls 4, and shuttle pistons
5, 6 into the gear housing 1 7.
2. Install the gear housing 2 8.
Checking the gear pump housing

1. Check the gear pump housing. Replace if
scratched.
Checking the reservoir

1. Check the reservoir. Replace if cracked
or if there is corrosion.
3. Install the balls 9, manual release spring

0, and bracket A by installing the bolts
B, then tightening them to the specified
torque.
Checking the filter

1. Check gear pump filters 1 and 2, and
shuttle piston filters 3. Clean if there is
dirt or residue.
7-35
6P23H11
Gear pump
T.
R.
Gear pump bracket bolt B:

Up-relief lock screw height a

(reference data):
From the top of the gear housing:
1.071.27 mm (0.0420.050 in)
Down-relief lock screw depth b
(reference data):
From the top of the gear housing:
1.952.45 mm (0.0770.096 in)
4. Install the relief valve seal C and ball D

into the gear housing 1 7, and then
install the up-relief lock screw E and
down-relief lock screw F as shown.
5. Install the filters G, H and gear pump I

by installing the bolts J, then tightening
them to the specified torque.
6. Install the manual valve K.
6P23H11
R.
NOTE:
If reinstalling the removed parts, install
them according to the screw height a and
screw depth b measurements noted
before they were removed.
If installing new parts, install them according to the following reference data for the
screw height a and screw depth b.
T.
S6P27590E
Gear pump bolt J:

7. Check the hydraulic pressure.

NOTE:
To check the hydraulic pressure, see Chapter 7, Checking the hydraulic pressure.
If the hydraulic pressure is out of specification, adjust the relief lock screws to adjust
the pressure to specification.
7-36
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Tilt cylinder and trim cylinder
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
7-37
Part name
Circlip
Dust seal
Trim cylinder end screw
O-ring
Trim ram assembly
Trim piston
Backup ring
O-ring
Spring
Adapter
Circlip
Tilt piston assembly
Tilt ram assembly
Power tilt assembly
Tilt ram
Dust seal
Tilt cylinder end screw
Qty
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
Remarks
Not reusable
Not reusable
Not reusable
Not reusable
6P23H11

7
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Part name
O-ring
Backup ring
O-ring
Spring
Adapter
Tilt piston
O-ring
Backup ring
Ball
Pin
Spring
Bolt
Free piston
O-ring
Tilt cylinder
6P23H11
Qty
1
1
1
1
1
1
1
1
5
5
5
1
1
1
1
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
Not reusable
Not reusable
M6 10 mm
Not reusable
7-38
BRKT
Bracket unit
Disassembling the tilt cylinder and

trim cylinder
1. Hold the tilt cylinder 1 in a vise using
aluminum plates a on both sides.
2. Loosen the tilt cylinder end screw, and
then remove the tilt ram assembly.
WARNING
Never look into the tilt cylinder opening
when removing the free piston. The free
piston and PTT fluid can be forcefully
expelled out.
NOTE:
Be sure to cover the opposite end of the tilt
cylinder with a rag.
5. Hold the tilt ram end in a vise using aluminum plates on both sides.
6. Remove the piston absorber valves.
a
a
S6S17110
WARNING
Make sure that the ram are fully extended
before removing the end screw.
S6P27740E
Cylinder-end screw wrench 2:

90890-06568
3. Drain the PTT fluid.
7. Hold the tilt piston in a vise using the

special service tool 4 on both sides.
8. Remove the tilt piston from tilt ram
assembly.
4. Blow compressed air through the hole b

to remove the free piston 3.
PTT piston vice attachment 4:

90890-06572
Tilt rod wrench 5: 90890-06569
7-39
6P23H11

9. Hold the PTT body 6 in a vise using aluminum plates a on both sides.
Checking the tilt cylinder and trim

cylinder
1. Check the PTT body 1 and tilt cylinder
2. Replace if cracked or if there is corrosion.
2. Check the inner surface of the PTT body
1 and tilt cylinder 2. Replace if
scratched.
10. Loosen the trim cylinder end screws 7,

and then remove them.
3. Check the outer surface of the tilt piston

3, trim piston 4, adapter 5, free piston
6, and dust seal 7 of end screw.
Replace if scratched.
4. Check the trim rams 8 and tilt ram 9.
Polish with 400600grit sandpaper if
there is light rust or replace if bent or if
there is excessive corrosion.
5. Check the pipes 0. Replace if cracked

or if there is corrosion.
7
S6S17120
Cylinder-end screw wrench:

90890-06568
11. Remove the trim ram assemblies.
12. Drain the PTT fluid.
13. Remove the circlip 8, adapter 9, and
spring 0 from the trim pistons.
6P23H11
7-40
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Checking the valve

1. Check the tilt piston absorber valves 1.
Clean if there is dirt or residue.
3. Hold the tilt piston in a vise using the

special service tool 0 on both sides.
4. Tighten the tilt ram 9 to the specified
torque.
1
S6P27560E
Assembling the tilt ram

CAUTION:
Do not use a rag when assembling the
PTT unit as dust and particles on the PTT
unit components can lead to poor performance.
PTT piston vice attachment 0:

90890-06572
Tilt rod wrench A: 90890-06569
1. Install the new dust seal 1, new O-rings

2 and 3, and backup ring 4 into the tilt
cylinder end screw 5.
T.
R.
Tilt ram 9:
55 Nm (5.5 kgfm, 40.6 ftlb)
5. Install the new O-ring B and backup ring

C onto the tilt piston 8.
6. Install the balls D, absorber valve pins
E, and springs F as shown.
2. Install the tilt cylinder end screw 5,

spring 6, adapter 7, and tilt piston 8 to
the tilt ram 9.
7. Install the washers G, plate H, and bolt

I to the tilt piston 8, and then tighten
the bolt to the specified torque.
I
LT
271
H
F E
G
C
B
8
E
D
G
C
B
8
D
S6P27210
T.
R.
7-41
Tilt piston bolt I:

6P23H11
Assembling the trim ram

1. Install the new O-ring 1, backup ring 2,
spring 3, adapter 4, and circlip 5 to the
trim piston 6.
2. Install the new dust seal 7, circlip 8,

and new O-ring 9 to the trim cylinder
end screw 0.
T.
R.
3. Install the trim cylinder end screw 0 onto

the trim ram A.
Pipe joint:
15 Nm (1.5 kgfm, 11.1 ftlb)
Installing the trim ram

CAUTION:
Do not use a rag when installing the PTT
unit as dust and particles on the PTT unit
components can lead to poor performance.
Installing the tilt cylinder
1. Hold the PTT body 1 in a vise using aluminum plates a on both sides.
1. Install the new O-ring 1 to the free piston 2.

2. Push the free piston 2 into the tilt cylinder 3 until it bottoms out.
3. Install the tilt cylinder 3 to the PTT body
4.
4. Install pipes 5 and 6, and then tighten
the pipe joints to the specified torque.
6P23H11
7-42
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
2. Fill the trim cylinders with the recommended fluid to the correct level b as
shown.
2. Fill the pump housing with the recommended fluid to the correct level a as
shown.
3. Install the trim ram assembly into the trim
cylinder, and then tighten the trim cylinder end screws 2 to the specified
torque.
2
3. Remove all of the air bubbles with a
syringe or suitable tool.
2
S6S17130
WARNING
Do not push the trim rams down while
installing them into the trim cylinders.
Otherwise, the PTT fluid may spurt out
from the unit.
NOTE:
Turn the joint 1 with a screwdriver, and then
remove any air between the pump gear teeth.
4. Install the new O-ring 2 and PTT motor
3, and then tighten the bolts 4 to the
specified torque.

90890-06568
T.
R.
Trim cylinder end screw 2:

160 Nm (16.0 kgfm, 118.0 ftlb)
Installing the PTT motor

1. Install the joint 1 into the gear pump.
7-43
6P23H11

NOTE:
Align the armature shaft with the recess in
the joint.
T.
R.
PTT motor mounting bolt 4:

19 Nm (1.9 kgfm, 14.0 ftlb)
Installing the reservoir

1. Install the spacer 1, filter 2 and sheet
3 to the PTT body.
2. Install the new O-ring 4 and reservoir
5, and then tighten the bolts 6 to the
specified torque.
3. Install the reservoir cap 7, and then
3. Install the tilt piston assembly into the tilt

cylinder, and then tighten the tilt cylinder
end screw 1 to the specified torque.
S6S17140
T.
R.
Reservoir mounting bolt 6:

19 Nm (1.9 kgfm, 14.0 ftlb)
Reservoir cap 7:
NOTE:
Place the tilt cylinder end screw at the bottom
of the tilt ram a and install the tilt piston
assembly into the tilt cylinder.
Installing the tilt ram

90890-06568
2. Add a small amount of the recommended

fluid through the PTT body hole b as
shown.
Tilt cylinder end screw:

90 Nm (9.0 kgfm, 66.4 ftlb)
R.
6P23H11
T.
1. Fill the tilt cylinder with the recommended

fluid to the correct level a as shown.
7-44
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Bleeding the PTT unit

1. Close the manual valve 1 by turning it
clockwise.
T.
R.
Manual valve 1:
2. Place the PTT unit in an upright position.

3. Remove the reservoir cap, and then
Ram
NOTE:
filler hole.
Up
4. If fluid is below the correct level, add fluid

of the recommended type.
5. Install the reservoir cap, and then tighten
it to the specified torque.
T.
R.
Reservoir cap:
6. Connect the PTT motor leads 2 to the

battery terminals to fully retract the rams.
the battery terminals to fully extend the
rams.
7-45
Down
PTT motor lead
Battery
terminal
Sky blue (Sb)
Light green (Lg)
Light green (Lg)
Sky blue (Sb)
NOTE:
Repeat this procedure so that the rams go
up and down 4 to 5 times (be sure to wait a
few seconds before switching the leads).
If the rams do not move up and down easily, push and pull on the rams to assist
operation.
8. Check the fluid level when the rams are
fully extended. If the fluid level is low, add
sufficient fluid, and then repeat steps 6
7.
6P23H11
Tilt cylinder and trim cylinder / PTT electrical system
Bleeding the PTT unit (built-in)

1. Fully tilt the outboard motor up and down
a few times.
NOTE:
6. If the fluid is below the correct level, add
fluid of the recommended type.
S6P23190
NOTE:
Connect the PTT motor leads directly to the
battery terminals when the power unit is not
installed. To connect the PTT motor leads,
see Bleeding the PTT unit.
7. Install the reservoir cap, and then tighten

it to the specified torque.
NOTE:
Repeat steps 17 until the fluid remains at
the correct level.
T.
R.
Reservoir cap 1:
2. Let the fluid settle for 5 minutes.

3. Push the PTT switch to fully tilt the outboard motor up.
4. Support the outboard motor with the tilt
stop lever, and then let the fluid settle for
5 minutes.
WARNING
PTT electrical system
Checking the fuse

1. Check the fuse for continuity. Replace if
there is no continuity.
NOTE:
For the location of the fuse, see Chapter 8,
Fuse holder.

fluid pressure.
6P23H11
7-46
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Checking the PTT relay

1. Check the PTT relay for continuity.
4. Connect the sky blue (Sb) lead to the

positive battery terminal and the terminal
4 lead to the negative battery terminal
as shown.
Lg
Sb
2
3
1
5. Check for continuity between terminals

2 and 3. Replace the PTT relay if there
is no continuity.
Lg
Sb
3
S6P27260J
NOTE:
Be sure to set the measurement range a
when checking for continuity.
S6P27280J
Checking the PTT switch
PTT relay continuity
1. Check the PTT switch for continuity.

Sky blue (Sb)

Terminal 4
Light green (Lg)
Terminal 4
Continuity
Terminal 1 Terminal 4
Continuity
No continuity
2. Connect the light green (Lg) lead to the

positive battery terminal and the terminal
4 lead to the negative battery terminal
as shown.
3. Check for continuity between terminals
1 and 3. Replace the PTT relay if there
is no continuity.
Lead color
Switch
position
Sky blue
(Sb)
Red (R)
Light green
(Lg)
Up
Free
Lg
Down
Sb
3
7-47
S6P27270J
6P23H11
PTT electrical system
Checking the trim sensor

1. Measure the trim sensor resistance.
1
2
3
4
5
6
7
8
9
NOTE:
Turn the lever 1 and measure the resistance
as it gradually changes.
Trim sensor resistance:
Pink (P) Black (B)
911 at a
247.6387.6 at b
6P23H11
7-48
ELEC
Electrical system
Checking the electrical component.............................................................. 8-1
Checking using the YDIS...........................................................................8-1
Measuring the peak voltage ...................................................................... 8-1
Electrical component.....................................................................................8-3
Port view.................................................................................................... 8-3
Starboard view........................................................................................... 8-4
Fuse holder................................................................................................8-5
Aft view ...................................................................................................... 8-6
Top view .................................................................................................... 8-7
Wiring harness routing.................................................................................. 8-8
Port view.................................................................................................... 8-8
Starboard view......................................................................................... 8-10
Aft view .................................................................................................... 8-13
Top view .................................................................................................. 8-14
Ignition and ignition control system .......................................................... 8-15
Checking the ignition spark ..................................................................... 8-15
Checking the ignition coil input voltage ...................................................8-15
Checking the crank position sensor......................................................... 8-15
Checking the crank position sensor air gap............................................. 8-16
Checking the intake air temperature sensor............................................8-16
Checking the intake air pressure sensor ................................................. 8-17
Checking the engine temperature sensor................................................ 8-18
Checking the thermoswitch ..................................................................... 8-18
Checking the shift cut switch ................................................................... 8-19
Checking the neutral switch..................................................................... 8-19
Checking the knock sensor ..................................................................... 8-20
Checking the engine start switch............................................................. 8-20
Checking the engine stop lanyard switch ................................................ 8-21
ECM and electronic throttle valve control system.................................... 8-21
Checking the main relay and electronic throttle valve relay ....................8-21
Checking the ECM circuit ........................................................................8-22
Checking the electronic throttle valve and TPS circuit ............................ 8-23
Checking the electronic throttle valve motor............................................8-25
Checking the accelerator position sensor circuit ..................................... 8-25
Checking the accelerator position sensor................................................ 8-26
Variable camshaft timing control system .................................................. 8-28
Checking the cam position sensor........................................................... 8-28
Checking the oil control valve.................................................................. 8-30
6P23H11
Fuel control system .....................................................................................8-30

Checking the fuel injector ........................................................................8-30
Checking the low-pressure fuel pump and high-pressure fuel pump ...... 8-31
Checking the high-pressure fuel pump relay ...........................................8-31
Checking the vapor shut-off valve ........................................................... 8-32
Starting system ............................................................................................ 8-32
Checking the fuse....................................................................................8-32
Checking the starter relay........................................................................8-32
Starter motor ................................................................................................8-34
Disassembling the starter motor..............................................................8-36
Checking the starter motor pinion............................................................ 8-36
Checking the armature ............................................................................8-36
Checking the brush.................................................................................. 8-37
Checking the magnet switch.................................................................... 8-37
Checking the starter motor operation ......................................................8-38
Charging system .......................................................................................... 8-38
Checking the stator coil ...........................................................................8-38
Checking the Rectifier Regulator............................................................. 8-38
6P23H11
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
Checking the electrical

component
Measuring the peak voltage

8
Checking using the YDIS

When checking the electronic throttle valve,
accelerator position sensor, oil control valve,
or each sensor, use the YDIS.
When deleting the diagnosis record using the
YDIS, be sure to check the occurrence time
of diagnosis codes.
When deleting the diagnosis record in the
YDIS, be 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 ECM determines that
the part is disconnected and a trouble code is
detected. Therefore, be sure to delete the
diagnosis record after checking the input voltage.
Since the main relay comes on for approximately 10 seconds after the start switch is
turned to OFF, the power of the ECM cannot
be turned off. Therefore, if the start switch is
turned to ON within 10 seconds after it was
turned to OFF, the trouble codes cannot be
deleted.
NOTE:
Before checking the electrical components,
make sure that the battery is fully charged.
The YDIS requires that you use an exclusive communication cable and CD-ROM to
connect to a computer. For a description of
the communication cable and CD-ROM to
be used, see Chapter 9, YDIS. Also, be
sure to check the CD-ROM version before
using it.
To connect the YDIS, see Chapter 9,
YDIS or the YDIS (version 1.23a or later)
Instruction Manual.
To check the electrical components or measure the peak voltage, use the special service tools. A faulty electrical component can
be easily checked by measuring the peak
voltage. The specified engine speed when
measuring the peak voltage is effected 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.
DC V
S69J8020J
WARNING
When checking the peak voltage, do not
touch any of the connections of the digital
tester leads.
CAUTION:
When testing the voltage between the terminals of an electrical component with
the digital tester, do not allow any of the
leads to touch any metal parts. If touched,
the electrical component can short and be
damaged.
YDIS (connecting kit):

60V-85300-02-00
YDIS (CD-ROM, ver 1.23a)
60V-WS853-03
8-1
6P23H11
Checking the electrical component

NOTE:
Before measuring the peak voltage, check
all wiring for proper connection and corrosion, and check that the battery is fully
charged.
Use the peak voltage adapter B with the
recommended digital circuit tester.
Connect the positive pin of the peak voltage
adapter B to the positive terminal of the digital tester, and the negative pin to the negative terminal.
When measuring the peak voltage, set the
selector on the digital circuit tester to the
DC voltage mode.
1
2
3
4
5
6
7
8
9
Digital circuit tester: 90890-03174

Peak voltage adapter B:
90890-03172
6P23H11
8-2
ELEC
Electrical system
Electrical component
Port view
A
1
2
0
7
5
S6P28010E
1
2
3
4
5
6
7
8

Fuel injector
Ignition coil
8-3
9
0
A
B

3-pin communication coupler
Condenser assembly (connect to the intake air
pressure sensor)
6P23H11
Starboard view
2
0
8
S6P28020E
1
2
3
4
5
6
7
8
9
0
Ignition coil
Fuel injector
PTT relay
Rectifier Regulator
Oil pressure sensor
Starter motor
Diode (connect to the PTT relay)
6P23H11
8-4
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
Fuse holder
S6P28025
1 Fuse (10 A) (electronic throttle valve, ECM)

2 Fuse (30 A)
(ignition coil, fuel injector, variable camshaft
timing, ECM)
3 Fuse (20 A) (engine start switch, PTT switch)
4 Fuse (30 A) (starter relay)
5 Fuse (5 A) (low-pressure fuel pump)
6 Fuse (15 A) (high-pressure fuel pump relay)
7 Fuse (80 A) (starting battery)
8 Fuse (80 A) (accessory battery)
8-5
9
0
A
B
High-pressure fuel pump relay

Electronic throttle valve relay
Main relay
Starter relay
6P23H11
Aft view
2
4
4
5
6
8
S6P28860E
1
2
3
4
5
6
7
ECM
Ignition coil
Knock sensor
Condenser assembly (connect to the cam
position sensor (PORT EX))
8 Coupler (knock sensor) (white)
6P23H11
8-6
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
Top view
1
2
4
5
S6P28040E
1
2
3
4
5
6
7
8
9
0

Thermoswitch (STBD)
Thermoswitch (PORT)
Stator assembly
Neutral switch
Shift cut switch
8-7
A Neutral switch coupler (blue)

B Shift cut switch coupler (black)
6P23H11
Electrical component / Wiring harness routing
Wiring harness routing
Port view
S6P28320
Install the low-pressure fuel pump coupler onto the wiring harness guide.
Fasten the thermoswitch connectors and wiring harness (oil control valve and fuel injectors) to the holder.
Fasten the engine temperature sensor lead and thermoswitch lead on the hook of the wiring harness
guide.
Install the engine temperature sensor coupler onto the wiring harness guide.
Fasten the wiring harness to the holder at the white tape.
Fasten the fuel injector lead in the order of , , and .
Fasten the fuel injector lead (#6) using a plastic tie at the white tape.
6P23H11
8-8
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
S6P28320
Fasten the fuel injector lead (#4) to the clip. It is not necessary to fasten the lead if its length is short.
Fasten the fuel injector lead (#2), and then fasten the fuel injector lead (#4 and #6) to the clip.
Fasten the fuel injector harness using a plastic tie.
Fasten the fuel injector harness to the fuel rail cover after installing the cover.
Fasten the intake air temperature sensor lead to the holder on the oil filler neck.
8-9
6P23H11
Starboard view
1
3 1
5
1
2
A
3
3
1
2
C
2
6 45
E
8
7
1
2
1
F
4
H
3
2
4
A
B
652
G
C
D
G
E
F
S6P28330E
1
2
3
4
5
6
7
8
Wiring harness
Stator coil lead
Sub wiring harness
Rectifier Regulator lead
Starter motor lead
PTT motor lead
Oil pressure sensor lead
Isolator lead
6P23H11
8-10
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
3 1
5
1
2
A
3
3
1
2
C
2
6 45
E
8
7
1
2
1
F
4
H
3
2
4
A
B
652
G
C
D
G
E
F
S6P28330E
Fasten the PTT motor lead and ground lead of the wiring harness to the holder.
Install the starter motor lead and brown lead of the wiring harness with the bolt.
Fasten the starter motor lead and sub wiring harness to the holders.
Fasten the starter motor lead, oil pressure sensor lead, sub wiring harness, and isolator lead to the holder.
Route the oil pressure sensor lead, isolator lead, and PTT motor leads through the guide. Align the white
tape on the oil pressure sensor lead with the guide of the positive battery terminal.
Fasten the oil pressure sensor lead, isolator lead, and PTT motor lead to the holder.
Route the battery cables along the bottom of the bottom cowling.
8-11
6P23H11
3 1
5
1
2
A
3
3
1
2
C
2
6 45
E
8
7
1
2
1
F
4
H
3
2
4
A
B
652
G
C
D
G
E
F
S6P28330E
Fasten the fuel injector lead in the order of , , , and .

Fasten the fuel injector lead (#5) to the clip at the white tape.
Fasten the fuel injector lead (#3) to the clip. It is not necessary to fasten the lead if its length is short.
Fasten the fuel injector lead (#1), and then fasten the fuel injector lead (#3 and #5) to the clip.
Fasten the fuel injector harness using a plastic tie.
Fasten the fuel injector lead and quick connector to the holder.
6P23H11
8-12
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
Aft view
S6P28870E
1 Joint connector
Fasten the wiring harness and cam position sensor lead (PORT IN) using a plastic tie.
Fasten the cam position sensor lead (PORT IN) to the holder.
Install the clip of knock sensor coupler to the hole of the ECM bracket.
Fasten the ignition coil lead (#5) and cam position sensor lead (STBD IN) to the holder at the white tape.
Fasten the wiring harness and condenser assembly using a plastic tie.
8-13
6P23H11
Top view
7
D-D
C
6
E
D
B
E-E
4
2
1
A-A
3
2
B-B
C-C
S6P28350E
1
2
3
4
5
6
7
Stator coil lead

Wiring harness
Thermoswitch connector
High-pressure fuel hose
Vapor gas hose
Engine temperature sensor lead
Joint connector
6P23H11
Fasten the fuel injector lead and quick

connector to the holder.
Fasten the fuel injector lead and vapor gas
hose to the holder.
Face the white mark on the wiring harness
upward.
Install the crank position sensor coupler to the
bracket.
8-14
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
Ignition and ignition control

system
Checking the ignition spark
NOTE:
The ignition spark can also be checked using
the Stationary test of the YDIS.
1. Remove the ECM cover.

2. Remove the ignition coils.
Checking the ignition coil input

voltage
3. Connect a ignition coil assembly to the

special service tool.
1. Disconnect the ignition coil coupler.

3. Measure the voltage at the ignition coil
coupler. Check the wiring harness if
1
2
S6P28050
3
4
Ignition tester: 90890-06754
5
4. Crank the engine and check the spark. If
the spark is weak, check the ignition system.
S6P28605E
Ignition coil input voltage:

Red/yellow (R/Y) Black (B)
12 V (battery voltage)
Checking the crank position sensor

S6P28060
WARNING
Do not touch any of the connections of
the spark checker leads.
Be sure to install the special service tool
to the ignition coil so that sparks do not
leak out.
Keep flammable gas or liquids away,
since this test can produce sparks.
8-15

2. Disconnect the crank position sensor
coupler.
3. Connect the test harness (2 pins) to the
crank position sensor and measure the
crank position sensor out put peak voltage.
and projection of the flywheel magnet if
6P23H11
Ignition and ignition control system

3. Measure the crank position sensor air
gap a. Adjust if out of specification.
Crank position sensor air gap a:
1.41.6 mm (0.0550.063 in)
4. Loosen the screws 1 and adjust the
crank position sensor air gap.
S6P28110
CAUTION:
Check that the wiring harness does not
interfere with the flywheel magnet.
Test harness (2 pins): 90890-06867
90890-03172
5. Tighten the screws 1, and then check

the crank position sensor air gap. Adjust
again if out of specification.
T.
R.
Crank position sensor output peak

voltage:
White/black (W/B) Black (B)
r/min
Unloaded
Loaded
Cranking
DC V
3.0
2.7
S6P28260
Crank position sensor screw 1:

Checking the intake air temperature

sensor
1. Measure the ambient temperature.
1,500
3,500
14.5
17.8
5. Measure the resistance of the crank position sensor.

motor and use the YDIS to display the
intake air temperature.
Crank position sensor resistance

(reference data):
White/red (W/R) Black (B)
396594

air gap
1. Remove the wiring harness guide bolts
and uphold wiring harness guide.
S6P28270
2. Turn the flywheel magnet clockwise to

align the projection of the flywheel magnet with the crank position sensor projection.
6P23H11
8-16
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
3. Check that the difference between the

ambient temperature and the displayed
intake air temperature is within 5 C (
9 F).
NOTE:
Check the intake air temperature sensor
when the engine is cold.
When checking the intake air temperature
sensor, remove the top cowling and do not
start the engine.
4. Disconnect the intake air temperature
sensor coupler.
6. Measure the input voltage at the intake
air temperature sensor coupler (wiring
harness end). Check the wiring harness
if out of specification.
8. Measure the intake air temperature sensor resistance. Replace if out of specification.
resistance:
at 20 C (68 F): 2.212.69 k
Checking the intake air pressure

sensor
1. Disconnect the intake air pressure sensor coupler.
3. Measure the input voltage at the intake
air pressure sensor coupler (wiring harness end). Check the wiring harness if
PORT
S6P28625E
S6P28615E
Intake air temperature sensor input

voltage (reference data):
Black/yellow (B/Y) Black (B)
4.755.25 V
7. Place the intake air temperature sensor
in a container of water and slowly heat
the water.
Intake air pressure sensor input

voltage (reference data):
Orange (O) Black (B)
4.755.25 V
4. Remove the intake air pressure sensor,
and then connect the coupler.
5. Connect the special service tool.
S6P28280
S6P28730
8-17
6P23H11

6. Check the intake air pressure using the
YDIS.
7. Apply the negative pressure to the intake
air pressure sensor slowly. Check that
the displayed intake air pressure is varied.
NOTE:
When checking the intake air pressure sensor, do not start the engine.
90890-06756
Checking the engine temperature

sensor
1. Disconnect the engine temperature sensor coupler.
S6P28740
5. Measure the engine temperature sensor

resistance. Replace if out of specification.
resistance:
Black/yellow (B/Y)
Black/yellow (B/Y)
at 20 C (68 F): 54.269.0 k
at 100 C (212 F): 3.123.48 k

3. Measure the input voltage at the engine
temperature sensor coupler (wiring harness end). Check the wiring harness if
Checking the thermoswitch

1. Disconnect the thermoswitch connectors.
3. Measure the input voltage at the thermoswitch connector (wiring harness
end). Check the wiring harness if below
specification.
PORT
STBD
S6P28636E
Engine temperature sensor coupler

input voltage (reference data):
Black/yellow (B/Y) Black (B)
4.755.25 V
4. Place the engine temperature sensor in a
container of water and slowly heat the
water.
6P23H11
S6P28645E
Thermoswitch input voltage:

Pink (P) Black (B)
8-18
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
4. Place the thermoswitches in a container

of water and slowly heat the water.
S6P28655E
S6P28750
5. Check the switch for continuity at the

specified temperatures. Replace if out of
specification.
Shift cut switch input voltage

(reference data):
Blue/yellow (L/Y) Black (B)
4.755.25 V
4. To check the shift cut switch, measure
the resistance of the shift cut switch at
position a. Replace if out of specification.
5. Check the shift cut switch for continuity at
position b. Replace if there is no continuity.
a
b
c
d
a
b
Temperature
Time
No continuity
Continuity
Thermoswitch continuity
temperature:
Pink (P) Black (B)
e: 8490 C (183194 F)
f: 6882 C (154180 F)
Checking the shift cut switch
S6P28760E
Shift cut switch resistance:

4.4654.935 k
1. Disconnect the shift cut switch coupler.

3. Measure the input voltage at the shift cut
switch coupler (wiring harness end).
Check the wiring harness if out of specification.
Switch
position
Lead color
Blue/yellow
(L/Y)
Black (B)
Free a
Push b
Checking the neutral switch

1. Disconnect the neutral switch coupler.
8-19
6P23H11

3. Measure the input voltage at the neutral
switch coupler (wiring harness end).
Check the wiring harness if out of specification.
1
S6P28200E
S6P28635E
2. Measure the knock sensor resistance.

Check the installation (ground state) of
the knock sensor if out of specification.
NOTE:
To check the installation of the knock sensor,
the cylinder head must be removed.
Neutral switch input voltage

(reference data):
Blue/green (L/G) Black (B)
4.755.25 V
4. To check the neutral switch, check the
neutral switch for continuity. Replace if
there is no continuity at position b.
Knock sensor resistance:

504616 k
Checking the engine start switch

1. Disconnect the 10-pin main harness coupler.
a
b
S6P28760
Switch
position
Lead color
Blue/green
(L/G)
Black (B)
Free a
Push b
Checking the knock sensor

1. Disconnect the knock sensor coupler 1
and connect the tester leads to the sensor coupler and ground.
6P23H11
8-20
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
2. Check the engine start switch for continuity at the 10-pin main harness coupler
(engine start switch end). Check the wiring harness or replace the engine start
switch if there is no continuity.
OFF
ON
START
OFF
ON
START
1
2
S6P28370E
3
4
Switch
position
1
2
Lead color
White (W) 1 Black (B) 2
Clip removed
S6P28360
Lead color
Switch White Black Red Yellow Brown
position (W) (B) (R) (Y) (Br)
4
1
2
3
5
Off
On
Start
Clip installed
ECM and electronic throttle valve

control system
Checking the main relay and

electronic throttle valve relay
1. Remove the main relay 1 and electronic
throttle valve relay 2.
Checking the engine stop lanyard

switch
1. Disconnect the 10-pin main harness coupler.
3. Check the engine stop lanyard switch for
continuity at the 10-pin main harness
coupler (engine stop lanyard switch end).
Check the wiring harness or replace the
engine stop lanyard switch if out of specification.
S6P28150
2. Connect the digital circuit tester (checking continuity) leads to relay terminals 3
and 4.
3. Connect the positive battery lead to the
relay terminal 5.
4. Connect the negative battery lead to the
relay terminal 6.
8-21
6P23H11
Ignition and ignition control system / ECM and electronic throttle valve control system
5. Check for continuity between relay terminals 3 and 4. Replace if there is no
continuity.
6. Check that there is no continuity between

relay terminals 3 and 4 after disconnecting a battery terminal from relay terminal 5 or 6. Replace if there is
continuity.
S6P28390
Terminal 89:
Checking the ECM circuit

1. Disconnect the ECM couplers a and b.
6
S6P28160J
CAUTION:
Do not reverse the battery leads.
7. Measure the voltage between the terminal 7 and ground, and the terminal 8
and ground as shown.
2. Check for continuity between the ECM

coupler terminals c (46, 68, 69, 75, 76,
and 84, wiring harness end) and ground.
Check the wiring harness and ground if
a
b
DC V
S6P28450
a
8
7
S6P28380J
Terminal 7 Ground:
Terminal 8 Ground:

9. Measure the voltage between terminals
8 and 9 as shown.
S6P28820
3. Connect ECM couplers a and b.
6P23H11
8-22
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
4. Disconnect the ECM coupler d, and

then turn the engine start switch to ON.
5. Check the voltage at ECM coupler terminal e (13, wiring harness end). Check
the fuse, wiring harness, and engine start
switch if below specification.
d
a
S6P28490
d
a
S6P28470
S6P28500
e
Terminal f (red/yellow) (R/Y):
Q Ground:
X Ground:
S6P28480
Terminal e (yellow) C Ground:

6. Turn the engine start switch to OFF, and
then connect the ECM coupler d.
Checking the electronic throttle

valve and TPS circuit
NOTE:
To check the TPS output voltage, see Chapter 4, Checking the TPS.
1. Disconnect ECM couplers a and b.
7. Disconnect the ECM coupler a, and

then turn the engine start switch to ON.
8. Check the voltage at ECM coupler terminals f (27 and 34, wiring harness end).
Check the fuse, relay, and wiring harness
if below specification.
a
b
S6P28450
8-23
6P23H11
ECM and electronic throttle valve control system

2. Disconnect the electronic throttle valve
coupler c.
d
S6P28530
S6P28510
6. Check the wiring harness for continuity.
c
S6P28840
S6P28830
Wiring harness continuity

Terminal No.
NOTE:
Depending on the outboard motor, the location of the red/green terminals (79 and 80) of
the coupler b may be switched.
Color
Coupler c
Coupler a, b
83
G/R
81
G/B
47
Coupler d, e
Coupler b
45
10
79
R/G
51
11
80
R/G
50
P/W
27
66
4. Connect the electronic throttle valve coupler c.
Terminal No.
Color
7. Connect the ECM couplers and fuse

holder couplers, and then disconnect the
electronic throttle valve coupler.
5. Disconnect fuse holder couplers d and

e.
6P23H11
8-24
1
2
3
4
5
6
7
8
9
ELEC
Electrical system

then measure the TPS input voltage at
the electronic throttle valve coupler (wiring harness end).
S6P28560
2. Disconnect the accelerator position sensor coupler b.

S6P28555E
TPS input voltage (reference data):

Terminal 5 (O) terminal 3 (B):
5.0 V
then connect the electronic throttle valve
coupler.
Checking the electronic throttle

valve motor
1. Disconnect the electronic throttle valve
coupler.
b
S6P28570
2. Check the electronic throttle valve motor

continuity between the terminal 1 and
2.
S6P28850
1 2
Terminal No.
S6P28130E

resistance 12 (reference data):
1.231.67 at 2030 C
(6886 F)
Checking the accelerator position

sensor circuit
1. Disconnect the ECM coupler a.
8-25
Color
Coupler b
Coupler a
40
44
38
31
P/W
41
49
4. Connect the ECM coupler a, and then

turn the engine start switch to ON.
6P23H11
ECM and electronic throttle valve control system

5. Measure the input voltage at each terminal of the accelerator position sensor
coupler b (wiring harness end).
STBD
2. Check that the accelerator lever 1 contacts the fully closed stopper 2 when the
remote control lever is at the fully closed
position.
S6P28595E
Accelerator position sensor input

voltage:
5.0 V
then connect the accelerator position
sensor coupler b.

sensor
motor and use the YDIS to display
Accelerator position sensor 1 and
Accelerator position sensor 2.
S6P21030
NOTE:
3. Check that the remote control lever is in
the fully closed position of the throttle,
and then check the output voltages of
accelerator sensor 1 and accelerator
sensor 2.
S6P24150
S6P24140
NOTE:
To connect and operate the YDIS, see Chapter 9, YDIS and the YDIS (version 1.23a or
later) Instruction Manual.
6P23H11
Output voltage of accelerator

position sensor 1 with the remote
control lever at the fully closed
position (reference data):
0.5500.850 V
position sensor 2 with the remote
control lever at the fully closed
0.4001.000 V
8-26
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
4. Shift the remote control lever to the fully

open position and hold it.
S6P24160
5. Check the output voltages of accelerator

position sensor 1 and accelerator position sensor 2.
position sensor 1 and 2 with the
remote control lever at the fully open
Above 3.250 V
6. Operate the remote control lever, and
check that the output voltages of accelerator position sensor 1 and accelerator
position sensor 2 change continuously.
56
S6P28300

resistance between 3 4, and
between 5 6 with the accelerator
lever at the fully closed position
(reference data):
at 20 C (68 F):
0.800 k
10. Measure the resistance at the fully open
position.
7. Disconnect the throttle cable joint from

the accelerator position sensor.
8. Disconnect the accelerator position sensor coupler.
7
9. Connect the tester leads to the accelerator position sensor terminals and measure the resistance at the fully closed
position.
S6P28290J
NOTE:
Be sure to contact the accelerator lever to the
stopper 7.
resistance between 3 4, and
between 5 6 with the accelerator
lever at the fully open position
(reference data):
at 20 C (68 F):
5.300 k
8-27
6P23H11
ECM and electronic throttle valve control system / Variable camshaft timing control system

system
Checking the cam position sensor

1. Disconnect the cam position sensor coupler.
3. Measure the input voltage at the cam
position sensor coupler (wiring harness
end). Check the wiring harness if below
specification.
Cam position sensor input voltage:

Red/yellow (R/Y) 1 Black (B)
White/blue (W/L) 2 Black (B)
(PORT EX)
White/black (W/B) 2 Black (B)
(STBD IN)
White/green (W/G) 2 Black (B)
(PORT IN)
4.755.25 V (reference data)
PORT EX
STBD IN
AFT
1
DC V
S6P28665EU
PORT IN
AFT
2
DC V
S6P28885EU
6P23H11
8-28
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
5. Remove the cam position sensor 3.

6. Connect the wire leads between cam
position sensor and cam position sensor
coupler (wiring harness end) as shown.
7. Connect the tester leads to the wire
leads.
12V
ECM
5V
NOTE:
Be sure to connect the wire leads to the corresponding terminals.
9. Measure the output voltage when moving
the screwdriver close to the sensor.
Replace the cam position sensor if out of
specification.
S6P28000EU
PORT EX
STBD IN
DC V
S6P28240F
NOTE:
Be sure to move the screwdriver in front of
the cam position sensor in direction as
shown, otherwise the correct output voltage
measurement cannot be obtained.
S6P28002EU
PORT IN
Cam position sensor output voltage:

White/blue (W/L) Black (B)
(PORT EX)
White/black (W/B) Black (B)
(STBD IN)
DC V
Position
Voltage (V)
a, c
More than 4.8
Less than 1.0
White/green (W/G) Black (B)

(PORT IN)
S6P28003EU
Position
Voltage (V)
a, c
Less than 1.0
More than 4.8
8-29
6P23H11
Variable camshaft timing control system / Fuel control system

11. Disconnect the wire leads.
Checking the oil control valve

1. Operate the oil control valve using the
Stationary test of the YDIS and listen
for the operating sound.
2. Disconnect the oil control valve coupler.
4. Measure the input voltage between the
oil control valve coupler and ground.
Check the wiring harness if below specification.
PORT
STBD
S6P28220
Oil control valve resistance:

6.77.7 at 20 C (68 F)
6. Connect the battery leads to the oil control valve terminals, and then check the
operation of the spool valve. Replace the
oil control valve if it does not operate.
S6P28210
Fuel control system
Checking the fuel injector

S6P28687C
Oil control valve input voltage:

Red/yellow (R/Y) Ground
1. Check the operation of the fuel injectors

using the Stationary test of the YDIS.
2. Disconnect the fuel injector coupler.
5. Measure the oil control valve resistance.

Replace the oil control valve if out of
specification.
6P23H11
8-30
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
4. Measure the input voltage between the

fuel injector coupler terminal and ground.
Check the wiring harness if below specification.
STBD
1
2
S6P28445E
Fuel injector input voltage:

Red/yellow (R/Y) Ground
5. Measure the resistance of the fuel injectors.
S6P28250
Low-pressure fuel pump resistance

1 (reference data):
1.34.0
High-pressure fuel pump resistance
2 (reference data):
0.510
Checking the high-pressure fuel

pump relay
1. Remove the high-pressure fuel pump
relay 1 and check it. To check the relay,
see Checking the main relay and electronic throttle valve relay in this chapter.
S6P28780
Fuel injector resistance

(reference data):
12.0 at 21 C (70 F)
Checking the low-pressure fuel

pump and high-pressure fuel pump
1. Check the low-pressure fuel pump and
high-pressure fuel pump operating sound
with Stationary test of the YDIS. Check
the fuel pump motors if there is no sound.
S6P28180
2. Connect the tester leads to terminals 2

and 3 as shown.
2. Disconnect the low-pressure fuel pump

coupler 1 and high-pressure fuel pump
coupler 2.
3. Measure the resistance of the fuel pump
motors.
8-31
6P23H11
Fuel control system / Starting system

3. Check that the vapor shut-off valve
opens and the negative pressure is
released when the battery voltage is
applied to the vapor shut-off valve terminals 1.
1
S6P28400

then measure the voltage within 5 seconds.
S6P28170
Terminal 23:
4. Measure resistance of vapor shut-off

valve.
4. Measure the voltage between the terminal 2 and ground, and the terminal 4
and ground as shown.
Vapor shut-off valve resistance

(reference data):
30.034.0 at 20 C (68 F)
Starting system
Checking the fuse

1. Check the fuses for continuity. Replace if
4
2
S6P28410
Terminal 2 Ground:
Terminal 4 Ground:
Checking the vapor shut-off valve

vapor shut-off valve.
NOTE:
For the location of the fuse, see Fuse
holder.
Checking the starter relay

1. Remove the starter relay 1 and check it.
To check the relay, see Checking the
main relay and electronic throttle valve
relay in this chapter.
2. Apply the specified negative pressure to

the vapor shut-off valve.
90890-06756
Specified negative pressure:
67 kPa (0.7 kgf/cm2, 9.7 psi)
6P23H11
S6P28190
8-32
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
2. Measure the voltage between the terminal 2 and ground as shown.
S6P28420
Terminal 2 Ground:
3. Connect the tester leads to terminals 3
and 4 as shown.
S6P28430
4. Turn the engine start switch to START

position, and then measure the voltage.
Terminal 34:
8-33
6P23H11
Starting system / Starter motor
Starter motor
1
2
30
4
6
16
7
8
9
10
17
34
31
26
11
33
32
31
27
25
18
19
28
20
12
21
22
13
32
29
14
15
23
24
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Clip
Pinion stopper
Starter motor pinion
Spring
Bolt
Cover assembly
Bearing
Clutch assembly
E-clip
Washer
Bracket
Pinion shaft
Planetary gear
Outer gear
Plate
Armature
Stator
6P23H11
S6P28070
Qty
1
1
1
1
2
1
1
1
1
1
1
1
3
1
1
1
1
Remarks
M6 35 mm
Not reusable
8-34
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
8
1
2
30
4
6
16
7
8
9
10
17
34
31
26
11
33
32
31
27
25
18
19
28
20
12
21
22
13
32
29
14
15
23
24
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
8-35
Part name
Brush assembly
Brush spring
Plate
Plate
Bracket
Screw
Bolt
Rubber seal
Shift lever
Spring
Magnet switch assembly
Nut
Pinion stopper set
Washer set
Starting motor gear assembly
Brush holder assembly
Lever assembly
S6P28070
Qty
1
4
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
Remarks
4 15 mm
M6 120 mm
6P23H11
Starter motor
Disassembling the starter motor

1. Slide the pinion stopper 1 down as
shown, and then remove the clip 2.
NOTE:
Remove the clip with a screwdriver.
2. Remove the bolts, and then disassemble
the starter motor.
NOTE:
2. Measure the commutator diameter.

Commutator standard diameter:

29.0 mm (1.14 in)
3. Measure the commutator undercut a.
Checking the starter motor pinion

1. Check the teeth of the pinion. Replace if
cracked or worn.
2. Check for smooth operation.
NOTE:
Turn the pinion counterclockwise to check
that it operates smoothly and turn it clockwise
to check that it locks in place.
Commutator standard undercut a:

0.8 mm (0.03 in)
Checking the armature

1. Check the commutator. Clean with 600
grit sandpaper and compressed air if
dirty.
6P23H11
8-36
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
4. Check the armature for continuity.

Replace if out of specifications.
S69J8440
Brush continuity
Brush 1 Brush 2
Armature continuity
No continuity
Commutator segments b
Continuity
Checking the magnet switch
Segment
Armature core c
No continuity
1. Connect the tester leads between the

magnet switch terminals as shown.
Segment
Armature shaft d
No continuity
Checking the brush

1. Measure the brush length. Replace the
brush assembly if below specification.
2. Connect the positive battery lead to the

brown (Br) lead.
3. Connect the negative battery lead to the
starter motor body.
Br
S6P28790C
Brush standard length:

15.5 mm (0.61 in)
Wear limit a: 9.5 mm (0.37 in)
2. Check the brush holder assembly for
continuity. Replace if out of specification.
CAUTION:
Do not connect the battery for more than
1 second, otherwise the magnet switch
can be damaged.
4. Check that there is continuity between
the magnet switch terminals. Replace if
5. Check that there is no continuity between
the main switch terminals when the negative battery terminal is removed from
the starter motor body. Replace if there is
continuity.
8-37
6P23H11
Starter motor / Charging system

NOTE:
The starter motor pinion should be pushed
out while the magnet switch is ON.
Stator coil output peak voltage:

Green (G) Green (G)
r/min
Unloaded
Cranking
1,500
3,500
8.3
44.7
97.7
Checking the starter motor operation
DC V
1. Check the operation of the starter motor

after installing it onto the power unit.
6. Measure the resistance of the stator coil.
Charging system
Checking the stator coil

2. Disconnect the stator coil couplers.
NOTE:
Select any two of the three couplers (leads)
and measure the resistance between the
selected couplers. Then, measure the resistance between the coupler that was not measured and any coupler.
3. Install the intake manifold.

NOTE:
4. Connect the test harness (1 pin) to any
stator coil coupler.
5. Measure the stator coil output peak voltage. Replace the stator coil if below
specification.
Stator coil resistance

(reference data):
Green (G) Green (G)
0.11440.1716 at 20 C
(68 F)
Checking the Rectifier Regulator

CAUTION:
If the battery cables are connected in
reverse, the Rectifier Regulator can be
damaged.
2. Remove the fuse holder and disconnect
the Rectifier Regulator coupler 1.
3. Install the intake manifold.
S6P28080
NOTE:
Select any two of the three couplers (leads)
and measure the peak voltage between the
selected couplers. Then, measure the voltage between the coupler that was not measured and any coupler.
NOTE:
Test harness (1 pin): 90890-06888

90890-03172
6P23H11
8-38
1
2
3
4
5
6
7
8
9
ELEC
Electrical system
4. Measure the Rectifier Regulator output

peak voltage. If below specification, measure the stator coil output peak voltage.
Check the Rectifier Regulator if the output peak voltage of the stator coil is
above specification.
b
a
S6S18360
R
1
S6P28090E
NOTE:
Do not use the peak volt adapter when measuring the output peak voltage of the Rectifier
Regulator.
Rectifier Regulator output peak
voltage:
Red (R) Ground
Unloaded
r/min
DC V
NOTE:
Be sure to set the measurement range a,
and display the mark b by pushing the
SHIFT switch when checking the Rectifier
Regulator continuity.
Rectifier Regulator continuity
(testing diode)
Tester lead
+
G4
R2
G4
R3
G5
R2
G5
R3
1,500
3,500
G6
R2
13.0
13.0
G6
R3
R2
G4
R2
G5
R2
G6
R3
G4
R3
G5
R3
G6
5. Check the Rectifier Regulator for continuity. Replace if out of specification.
R2
R3
Display value (V)
0.420.45 V
(reference data)
OL
(over load)
G4
G5
G6
B
R2
R3
G4
G5
G6
B
S6P28100
8-39
6P23H11
TRBL
SHTG
Troubleshooting
YDIS................................................................................................................. 9-1
Introduction................................................................................................9-1
Connecting the communication cable to the outboard motor .................... 9-4
Troubleshooting the power unit ...................................................................9-5
Troubleshooting the power unit using the YDIS ........................................ 9-5
Trouble code and checking step................................................................9-7
Troubleshooting the power unit using the diagnostic flash indicator ....... 9-15
Troubleshooting the power unit (trouble code not detected) ................... 9-17
Troubleshooting the PTT unit .................................................................. 9-22
Troubleshooting the lower unit ................................................................9-23
6P23H11
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Troubleshooting
YDIS
Introduction
Feature
The newly developed YDIS provides quicker detection and analysis of engine malfunctions.
By connecting your computer to the ECM of an outboard motor using the communication cable, this
software can be used to display sensor data and data stored in the ECM on a computers monitor.
If this software is run on Microsoft Windows 95, Windows 98, Windows Me, Windows 2000, or Windows XP, 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, and Data
logger) can be saved on a disk or printed out.
Function
1. Diagnosis: Displays each part name, and the ECM trouble codes and status when the engine
start switch is turned to ON. This allows you to quickly specify malfunctioning parts. The trouble
codes displayed are the same as those described in Trouble code and checking step in this
chapter (9-7).
2. Diagnosis record: Displays each part name and the ECM trouble codes that have been registered. This allows you to check the outboard motors record of malfunctions. The trouble codes
displayed are the same as those described in Trouble code and checking step in this chapter
(9-7).
3. Engine monitor: Each sensor status and the ECM data are displayed while the engine is running. This enables you to find malfunctioning parts quickly. In addition, the data displayed using
the Engine Monitor function can be displayed in a graph.
Items: For F250/FL250
1
Engine speed
10
Fuel injection duration
19
Dual engine system

switch
Intake pressure(*1)
11
Ignition timing
20
Shift cut-off switch(*4)
Throttle position sensor 1 12
Engine temperature
21
Overheat
thermoswitch(*5)
Throttle valve opening

(090)
Intake temperature(*2)
22
Main switch(*6)
Oil pressure
23
Main relay
sensor 1
15
Intake cam timing

(STBD)
24
Electronic throttle
relay(*7)
sensor 2
16
Intake cam timing

(PORT)
25
Fuel pump relay(*8)
Atmospheric pressure
17
Engine stop lanyard

switch
Battery voltage (1216)
18
Shift position switch(*3)
(*1):
(*5):
(*2):
(*6):
Intake air pressure

(*3): Neutral switch
(*4): Shift cut switch
9-1
13
Thermoswitch
Engine start switch
(*7): Electronic throttle valve relay
(*8): High-pressure fuel pump relay
6P23H11
YDIS
4. Stationary test: Operation tests can be performed with the engine off.
1
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)
(*1):
Oil control valve drive (starboard)

Oil control valve drive (port)
(*3): Operate high-pressure fuel pump
(*4): Operate low-pressure fuel pump
(*2):
5. Data logger: Displays 13 minutes of recorded data for 2 or more of the items stored in the ECM.
In addition, the operating time as compared to the engine speed and the total operating time are
displayed. This allows you to check the operating status of the engine. For the F250/FL250
models, you can also save the ECM record data on a file so that you can view and display the
graph later.
1
Engine speed
Throttle position sensor
Intake pressure(*1)
Battery voltage
Engine temperature
Oil pressure
(*1):
Intake air pressure
6P23H11
9-2
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Troubleshooting
6. ECM record data graph: When a malfunction occurs in the electronic throttle valve system, 4
seconds (2 seconds before and after the malfunction) of recorded data are saved in the ECM.
This data can be displayed on a graph using the ECM record data graph of the Data logger
function.
When the communication cable is used to connect a computer to the ECM, the ECM record
data can be saved and viewed on the computer.
The saved ECM record data can also be viewed offline.
1
Engine speed
Target TPS voltage(*2)
15
Engine stop lanyard

switch
sensor 1
Ref. TPS voltage(*3)
16
Main relay
sensor 2
10
Ref. acc. pos. sensor

voltage(*4)
17
Electronic throttle
relay(*7)
Throttle position sensor

1
11
Target TPS voltage for

ISC(*5)
18
Overheat warning
Engine stop mode
19
Low oil pressure
Intake pressure(*1)
13
Engine start mode
Battery voltage
14
Engine stop mode with

SW(*6)
(*1):
Intake air pressure

Target TPS voltage
This item shows the target output voltage of the TPS.
This value is the control voltage that the 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 accelerator position sensor voltage
This item shows the criterion output voltage of the accelerator position sensor.
This value is used to detect the accelerator position sensor output voltage when the remote control
throttle lever is opened.
(*5): Target TPS voltage for Idle Speed Control
ECM controls the engine idle speed by using the throttle valve attached to the TPS.
This target voltage is used by the ECM to achieve the target opening angle of the throttle valve at the
engine idle speed.
(*6): Engine stop mode with switch
(*7): Electronic throttle valve relay
(*2):
NOTE:
To display the displays and graphs, see the YDIS (version 1.23a or later) Instruction Manual.
9-3
6P23H11
YDIS
Contents
1. CD-ROM (software + instruction manual) (1)
2. Adapter (1)
3. Communication cable (1)
Connecting the communication cable to the outboard motor
3-pin communication coupler (gray)

S6P29010
6P23H11
9-4
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Troubleshooting
Troubleshooting the power unit
NOTE:
Before troubleshooting the outboard motor, make sure that fresh fuel of the specified type has
been used.
Check the trouble code using the YDIS (or diagnostic flash indicator) first, and then check the
electronic control system follow the trouble code chart.
When a three-digit trouble code is detected, check the data logger of the ECM record data graph
as well.
It is recommended to use the YDIS for troubleshooting, it is not enough to check the electronic
throttle valve system (electronic throttle valve, TPS, and accelerator position sensor) when only
using the diagnostic flash indicator.
If a trouble code is not detected, check the power unit according to Troubleshooting the power
unit (trouble code not detected).
Before using the YDIS or diagnosis indicator B to check the power unit, check the ECM circuit. To
check the ECM circuit, see Chapter 8, Checking the ECM circuit.
Be sure to check that the couplers and connectors are securely connected.
When deleting the diagnosis record on the YDIS, be 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 ECM determines that the part is disconnected and a trouble code is detected. Therefore, be sure to delete the diagnosis record after checking the input voltage.
Since the main relay comes on for approximately 10 seconds after the start switch is turned to
OFF, the power of the ECM cannot be turned off. Therefore, if the 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

NOTE:
Use the trouble codes displayed by the YDIS to check each part according to the Trouble code
and checking step table.
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 ECM may be faulty.
Check the items listed in the table, if all the items are in good condition delete the trouble code,
and then check the trouble codes again. If the same trouble codes are detected again, the ECM is
faulty.
A break down of the engine symptoms are described in the table below, however, multiple malfunctions that have been duplicated cannot be limited to these items. The symptoms may change
according to the operating conditions and other conditions.
9-5
6P23H11

Symptoms table
Engine
startability
Starts
Engine idle
speed
Normal(*1)
Increases
(steady)
Maximum engine speed
Symptom
Normal(*2)
Normal(*4)
Decreases(*3)
Poor(*5)
Normal
Normal
Poor
Normal
Poor
Decreases
Does not starts
Acceleration
Increases
(unsteady)
Normal
Normal
Down
Poor
Unsteady
Down
Poor
Increases(*6)
1,2001,500 r/min
Impossible
Engine does not operate
1
2
3
4
5
6
7
8
9
(*1):
600700 r/min at engine idle speed

5,0006,000 r/min
(*3): Less than the specified engine speed
(*4): Engine speed increases according to throttle opening angle
(*5): Engine speed does not increase according to throttle opening angle
(*6): Limp home processing
(*2):
6P23H11
9-6
TRBL
SHTG
Troubleshooting
Trouble code and checking step

Trouble
code
13
15
17
19
23
Symptom
Item
Crank position
sensor
(pulser coil in
YDIS)
Engine
temperature
sensor
malfunction
Knock sensor
malfunction
Battery voltage
malfunction
Intake air
temperature
sensor
malfunction
Remarks
Trolling speed
is unstable
Maximum
power
decreases
Checking steps
Refer
to
page
1. Measure the crank position sensor resistance.
8-15
2. Check the white/black (W/B)

lead and black (B) lead (ECM-tocrank position sensor) for continuity.
*1
3. Measure the crank position sensor output peak voltage.
8-15
4. Measure the crank position sensor air gap.
8-16
5. Check the projections of the flywheel magnet for damage.
5-7
1. Check the engine temperature

using the YDIS.
9-1
2. Measure the input voltage.
8-18
3. Measure the resistance.
8-18
8-20
2. Check the green (G) lead (ECMto-knock sensor) for continuity.
*1
1. Check the battery voltage using

the YDIS.
9-1
2. Measure the Rectifier Regulator

output peak voltage.
8-38
3. Measure the stator coil output

peak voltage.
8-38
4. Check the fuse.
8-5
5. Check the battery cables and

terminals for proper connection.
3-15
1. Check the intake air temperature

using the YDIS.
9-1
8-16
8-16
*1: See the wiring diagram.
9-7
6P23H11

Trouble
code
24
28
29
37
Symptom
Item
Cam position
sensor
(PORT EX)
malfunction
Neutral switch
malfunction
Intake air
pressure
sensor
malfunction
Intake air
passage
malfunction
Remarks
Maximum
power
decreases
Trolling speed
is unstable
Refer
to
page
Checking steps
1. Check the cam timing using the
YDIS.
9-1
8-28
3. Check the white/blue (W/L) lead

(cam position sensor-to-ECM)
for continuity.
*1
4. Measure the output voltage.
8-28
5. Check the brim of the camshaft.
5-27
1. Check the switch

using the YDIS.
9-1
operation
2. Check the switch continuity.
8-19
8-19
4. Check the shift bushing and shift

mechanism.
7-1
1. Check the intake air pressure

using the YDIS.
9-1
2. Check the vacuum hoses.
4-2
8-17
4. Check the operation of the

intake air pressure sensor.
8-17
5. Check the pink/green (P/G) lead

(ECM-to-sub wiring harness-tointake air pressure sensor) for
continuity.
*1
1. Check the O-rings and gaskets

of the intake manifold, surge
tank, and throttle body.
4-12
4-15
2. Check the hose between the

vapor shut-off valve and surge
tank.
4-2
3. Check the throttle valve condition.
4-5
4. Check the intake air pressure

sensor hose.
4-2
5. Check the pressure regulator

hose.
4-2
6P23H11
9-8
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Trouble
code
39
44
45
46
Troubleshooting
Symptom
Item
Oil pressure
sensor
malfunction
Engine stop
lanyard switch
malfunction
Shift cut switch

malfunction
Thermoswitch
malfunction
Remarks
Engine stalls
(when running
engine)
Buzzer comes
on
Shifting to
neutral is
difficult
Refer
to
page
Checking steps
1. Check the engine oil pressure
using the YDIS.
9-1
5-2
5-2
4. Check the pink/white (P/W) lead

(ECM-to-oil pressure sensor) for
continuity.
*1
5. Check the oil pressure using an

oil pressure gauge.
5-1
1. Check the switch

using the YDIS.
9-1
operation
2. Check the clip.
8-21
8-21
4. Check the white (W) lead (ECMto-10-pin main harness coupler)

for continuity.
*1
5. Check the black (B) lead (10-pin

main harness coupler-to-joint
connector-to-ground) for continuity.
*1
1. Check the switch

using the YDIS.
operation
9-1
2. Check the switch continuity and

resistance.
8-19
8-19
4. Check the shift bracket and shift

mechanism.
7-1
1. Check the switch condition using

the YDIS.
9-1
8-18
8-18
4. Check the engine temperature

sensor.
8-18
9-9
6P23H11

Trouble
code
71
72
73
Symptom
Item
Cam position
sensor
(STBD IN)
malfunction
Cam position
sensor
(PORT IN)
malfunction
Remarks
112
114
Oil control
valve (STBD)
D
74
Oil control
valve (PORT)
Electronic
throttle valve
malfunction
Checking steps
Refer
to
page

YDIS.
9-1
8-28
3. Check the white/black (W/B)

lead (cam position sensor-toECM) for continuity.
*1
8-28
5-27

3-15

YDIS.
9-1
8-28
3. Check the white/green (W/G)

lead (cam position sensor-toECM) for continuity.
*1
8-28
5-27

3-15
1. Check the valve operation using

the YDIS.
9-1
8-30
8-30
4. Check the purple (Pu) lead (oil

control valve-to-ECM) for continuity.
*1
5. Check the filter and plunger.
8-30
1. Check the ECM circuit.
8-22
2. Check the electronic throttle

valve circuit.
8-23

valve relay and fuse.
8-21
6P23H11
9-10
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Trouble
code
113
115
116
117
118
Troubleshooting
Symptom
Item
Electronic
throttle valve
malfunction
Electronic
throttle valve
malfunction
Electronic
throttle valve
malfunction
Remarks
119
Electronic
throttle valve
malfunction
121
Electronic
throttle valve
malfunction
122
Electronic
throttle valve
malfunction
123
9-11
Electronic
throttle valve
malfunction
Checking steps
Refer
to
page

valve operation.
4-5
2. Check the TPS output voltage

using the YDIS.
9-1
3. Check the throttle opening angle

using the YDIS.
9-1
8-22

valve circuit.
8-23

8-21

valve motor continuity.
8-25

valve circuit.
8-23

8-21

8-25

valve circuit.
8-23

8-21

8-25

valve circuit.
8-23
1. Replace the ECM.
5-36
1. Replace the electronic throttle

valve assembly (electronic throttle valve motor malfunction).
4-15

8-21

valve circuit.
8-23

8-25
6P23H11

Trouble
code
124
125
124
125
126
127
128
127
128
129
129
131
132
6P23H11
Symptom
Item
TPS
malfunction
TPS
malfunction
TPS
malfunction
TPS
malfunction
TPS
malfunction
Accelerator
position
sensor
malfunction
Remarks
Checking steps
Refer
to
page

using the YDIS.
9-1

using the YDIS.
9-1

valve circuit.
8-23

using the YDIS.
9-1

using the YDIS.
9-1

valve circuit.
8-23

using the YDIS.
9-1

using the YDIS.
9-1

valve circuit.
8-23

using the YDIS.
9-1

using the YDIS.
9-1

valve circuit.
8-23

using the YDIS.
9-1

using the YDIS.
9-1

valve circuit.
8-23
1. Check the accelerator position

sensor output voltage using the
YDIS.
9-1

sensor circuit.
8-25

sensor resistance.
8-26
9-12
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Trouble
code
131
132
133
134
133
134
135
136
137
138
139
141
9-13
Troubleshooting
Symptom
Item
Accelerator
position
sensor
malfunction
Accelerator
position
sensor
malfunction
Accelerator
position
sensor
malfunction
Electronic
throttle valve
malfunction
Electronic
throttle valve
malfunction
TPS
malfunction
Remarks
Checking steps
Refer
to
page

YDIS.
9-1

sensor circuit.
8-25

sensor resistance.
8-26

YDIS.
9-1

sensor circuit.
8-25

sensor resistance.
8-26

YDIS.
9-1

sensor circuit.
8-25

sensor resistance.
8-26
8-22

8-21

valve circuit.
8-23

3-15
8-22

valve circuit.
8-23

8-21

3-15
8-22

valve circuit.
8-23

8-21
6P23H11

Trouble
code
142
143
144
145
6P23H11
Symptom
Item
Electronic
throttle valve
malfunction
Electronic
throttle valve
malfunction
Electronic
throttle valve
malfunction
Remarks
J
Checking steps
Refer
to
page

valve operation.
4-5

3-15
8-22

valve circuit.
8-23

8-21

valve operation.
4-5
9-14
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Troubleshooting

using the diagnostic flash indicator
outboard motor as shown.
Trouble code indication

Example: The illustration
code numbers 23 and 113.
a: Light on, 0.33 second
b: Light off, 4.95 seconds
c: Light off, 0.33 second
d: Light off, 1.65 seconds
L/W
indicates
S6P29030E
NOTE:
When performing this diagnosis, all of the
electrical wires must be properly connected.
Diagnostic flash indicator B:
90890-06865
1
2. Start the engine and let it idle.
3. Check the flash pattern of the special
service tool to determine if there are any
malfunctions.
1
c
d
d
a
b
a a a
S6P29040
Normal condition
(no defective part or irregular processing is found)
4. If a flash pattern listed in the trouble code

chart is displayed, check the malfunctioning part according to the flash pattern.
Single flash is given every 4.95 seconds.

a: Light on, 0.33 second
b: Light off, 4.95 seconds
9-15
6P23H11

NOTE:
When more than one problem is detected,
the light of the special service tool flashes
in the pattern of the lowest numbered problem. After that problem is corrected, the
light flashes in the pattern of the next lowest numbered problem. This continues until
all of the problems are detected and corrected.
See Trouble code and checking step in
this chapter for the trouble code.
6P23H11
1
2
3
4
5
6
7
8
9
9-16
TRBL
SHTG
Troubleshooting
Troubleshooting the power unit (trouble code not detected)

Troubleshooting when a trouble code is not available consists of the following 4 items.
Symptom 1: Specific trouble conditions
Symptom 2: Trouble conditions of an area or individual part
Cause 1: The content considered as the trouble factors of symptom 2.
Cause 2: The content considered as the trouble causes of cause 1 (described if necessary).
Symptom 1: Engine does not crank
Symptom 2
Starter motor
does not
operate
Cause 1
Cause 2
Discharged battery
Loose connection
battery terminal
of
Refer
to
page
Check the battery.
3-15
Check the battery terminal.
3-15
Check the wiring harness continuity.
*1
Check the starter relay.
8-32
Short, open, or loose

connection in starter
motor circuit
Starter relay malfunction
Blown fuse
Check the fuse.
8-5
Starter motor malfunction
Disassemble and check

the starter motor.
8-34
Engine start
malfunction
Check the engine start

switch.
8-20
Shift the remote control

lever to the neutral
position.
1-42

the power unit.
5-1
switch
Gear shift not in the

neutral position
Starter motor
operates, but
the engine does
not crank
Checking step
Stuck piston
Piston lock due to water
or oil in the combustion
chamber
Salt buildup on the

drive shaft and bushing

the upper case.
7-5
Starter motor malfunction

the starter motor.
8-34
9-17
6P23H11

Symptom 1: Engine will not start (engine cranks)
Symptom 2
ECM does not
operate
Spark plug does not

spark (all cylinders)
Cause 1
Cause 2
Check the relay.
8-21
Blown fuse
Check the fuse.
8-5
Short, open, or
loose connection in
ECM circuit
8-22
Check the ECM circuit.
Engine start switch

malfunction
Check the engine

start switch.
8-20
Check the crank

position sensor and
cam position sensor.
8-15
8-28
Check the wiring

harness continuity.
*1
Short, open, or
loose connection in
high-pressure fuel
pump circuit
Check the wiring

harness continuity.
*1
Blown fuse
Check the fuse.
8-5
Relay malfunction
Check the relay.
8-31
High-pressure fuel
pump malfunction
Check the highpressure fuel pump

continuity.
8-31
Short, open, or
loose connection in
low-pressure
fuel
pump circuit
Check the wiring

harness continuity.
*1
Blown fuse
Check the fuse.
8-5
Low-pressure fuel
pump malfunction
Check the low-pressure fuel pump continuity.
8-31
Crank position sensor malfunction and

cam position sensor
(PORT EX) malfunction
High-pressure
pump does
operate
Low-pressure
pump does
operate

does not close
Refer
to
page
Relay malfunction
Short, open, or
loose connection in
ignition coil ground
circuit
Fuel not supplied
(all cylinders)
Checking step
fuel
not
fuel
not
Fuel not supplied to

the fuel rails
Check the fuel pressure.
4-7
Fixed vapor shut-off

valve
Check the vapor

shut-off valve.
8-32
6P23H11
9-18
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Troubleshooting
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited
engine speed
Symptom 2
Cause 1
Spark plug does not

spark
(some cylinders)
Spark plug malfunction
Short, open, or
loose connection in
ignition coil circuit
Ignition coil
function
Cause 2
Checking step
Check the ignition

spark.
Check the spark
plugs.
3-7
8-15
Check the wiring

harness continuity.
*1
8-15
Change the ignition

coil and check the
ignition spark.
Change the ignition
coil and check the
ignition spark.
8-15
Check the pressure

regulator.
4-8
Check the highpressure fuel pump

continuity.
8-31
8-30
Check
the
fuel
injector operation.
Check
the
fuel
injector resistance.
Check the wiring
harness continuity.
*1
Change the fuel injector and check the fuel

injector operation.
4-26
8-30
Replace
injector.
fuel
4-26
5-1
Check the compression pressure.

Disassemble
and
check the power
unit.
mal-
ECM malfunction
High-pressure fuel
line malfunction
(fuel pressure is
low)
Pressure regulator
malfunction
Fuel not supplied

(some cylinders)
Fuel injector malfunction
High-pressure fuel
pump malfunction
Short, open, or
loose connection in
fuel injector circuit
ECM malfunction
Clogged fuel injector filter

Low compression
pressure
Scratched piston
Damaged valve
Valve stuck to valve
guide
Refer
to
page
the
9-19
6P23H11

Symptom 1: High engine idle speed (below 1,200 r/min)
Symptom 2
Cause 1
Air leakage (throttle

valve-cylinder
head)
Cause 2
Checking step
Check the O-rings

and gaskets of the intake manifold, surge
tank, and throttle
body.
Refer
to
page
4-12
4-15
Symptom 1: Engine stalls, unstable engine idle speed, or poor acceleration
Symptom 2
Incorrect intake
cam timing
(check using the
YDIS)
6P23H11
Cause 1
Cause 2
Checking step
Refer
to
page
Variable
camshaft Stuck oil control
timing operation mal- valve plunger
function
Check the oil control valve operation

using the YDIS.
Check the oil control valve plunger.
8-30
9-1
Clogged oil control

valve filter
Replace the oil control valve filter.
5-41
Clogged
sage
pas-
Check the oil passage.
1-29
Stuck variable camshaft timing
Replace the variable camshaft timing.
5-8
oil
9-20
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Troubleshooting
Symptom 1: Limited engine speed (below 2,000 r/min)

Refer
to
page
Symptom 2
Cause 1
Cause 2
Checking step
Buzzer comes on
Overheat warning
indicator comes
on
Cooling water
does not
discharge from
the cooling water
pilot hole
Clogged cooling water inlet
Check the cooling

water inlet.
3-9
Water pump malfunction
Water pump impeller malfunction
Check the impeller.
6-5
6-35
Check the
druff key.
Woo-
6-5
6-35
Check the water

pump housing.
6-5
6-35
Check the
cartridge.
insert
6-5
6-35
Check the outer

plate cartridge.
6-5
6-35
3-9
Check the cooling

water
passage
(power unit, exhaust
guide, and upper
case).
Thermostat malfunction
Check the thermostat.
3-7
Insufficient engine oil
Add sufficient oil.
3-4
de- Oil pump malfunction
Check the oil pump.
5-66
Clogged oil strainer
Check the oil strainer.
7-11
Clogged
sage
Check the oil passage (power unit

and oil pump).
5-2
Replace the oil filter.
3-6
Water leakage from

water pump housing
Clogged cooling water passage
Buzzer comes on
Oil pressure
warning indicator
comes on
Oil pressure
crease
oil
pas-
Clogged oil filter
9-21
6P23H11
Troubleshooting the PTT unit

Symptom 1: PTT unit does not operate
Symptom 2
PTT relay does not
operate
PTT motor does not

operate
Oil pressure does

not increase
Cause 1
PTT switch
function
Cause 2
mal-

connection of the
wiring harness
PTT relay malfunction

connection of the
PTT motor lead
Checking step
Check
switch.
the
PTT
Refer
to
page
7-47
Check the wiring harness continuity.
*1
Check the PTT relay.
7-47
Check the PTT motor lead.
7-28
PTT motor malfunction
Disassemble
and
check the PTT motor.
7-27
Blown fuse
Check the fuse.
8-5
Loose connection of
the battery terminal
Check the
terminal
3-15
Discharged battery
Check the battery.
3-15
Check the manual

valve.
7-22
Add sufficient fluid.
3-12
Check the PTT unit

for leakage.
7-22
Disassemble
and
check the PTT unit.
7-22
Manual
opened
valve
Insufficient PTT fluid

PTT fluid leakage
Manual valve malfunction
Clogged filter
Clogged fluid passage
battery
6P23H11
9-22
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Troubleshooting
Symptom 1: PTT unit does not hold the outboard motor up
Symptom 2
Cause 1
Manual
opened
valve
Insufficient PTT fluid

PTT fluid leakage
Clogged fluid passage
Refer
to
page
Cause 2
Checking step
Manual valve malfunction
Check the manual

valve.
7-22
Add sufficient fluid.
3-12
Check the PTT unit

for leakage.
7-22
Disassemble
and
check the PTT unit.
7-22
Troubleshooting the lower unit

Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate properly
Symptom 2
Cause 1
Cause 2
Checking step
Remote control box

malfunction
Check the remote

control box.
1-42
Check the shift cable and shift cable

end.
3-11
Adjust the shift cable.
3-11
Detent malfunction
Check the detent.
7-1
Shift rod connection malfunction
Check the shift rod

connection.
6-5
6-35
Check the internal

parts of the lower
unit.
6-1
6-31
Shift cable and shift

cable end malfunction
Shift rod operation

malfunction
Shift
mechanism
malfunction (in lower unit)
9-23
Refer
to
page
6P23H11
Index
A.
Abbreviation ................................................1-3
Adjusting the throttle cable........................3-10
Adjusting the trim sensor ..........................7-20
Adjusting the valve clearance ...................5-11
Aft view ............................................. 8-6, 8-13
After test run .............................................1-43
Assembling the drive shaft
housing ......................................... 6-16, 6-47
Assembling the forward gear ....................6-16
Assembling the gear pump .......................7-35
Assembling the lower case ............. 6-15, 6-46
Assembling the oil pan..............................7-11
Assembling the oil pump...........................5-66
Assembling the power unit........................5-67
assembly...................................................6-9
housing ........................................... 6-9, 6-40
Assembling the PTT motor .......................7-29
Assembling the reverse gear ....................6-47
Assembling the tilt ram..............................7-41
Assembling the trim ram ...........................7-42
Assembling the upper case.......................7-12
B.
Backlash (counter rotation model) ............6-60
Backlash (regular rotation model) .............6-28
Bleeding the PTT unit ...............................7-45
Bleeding the PTT unit (built-in) .................7-46
Bracket unit ...............................................3-12
Break-in.....................................................1-43
C.
Changing the engine oil by draining it.........3-5
Changing the engine oil using an oil
changer .....................................................3-4
Changing the gear oil................................3-13
Charging system .......................................8-38
sensor .....................................................8-26
sensor circuit...........................................8-25
Checking the anode ..................................3-14
Checking the armature..............................8-36
Checking the battery ....................... 1-40, 3-15
Checking the bearing ...................... 6-15, 6-46
Checking the brush ...................................8-37
Checking the cam position sensor ............8-28
Checking the camshaft .............................5-27
Checking the canister ...............................4-18
Checking the canister check valve............4-18
6P23H11
Checking the check valve......................... 4-21

Checking the compression pressure .......... 5-1
Checking the connecting rod big end
side clearance ........................................ 5-60
Checking the connecting rod small
end inside diameter ................................ 5-60
Checking the cooling water passage.......... 3-9
cover anode............................................ 5-50
Checking the cooling water pilot hole ....... 1-43
Checking the crank position sensor.......... 8-15
air gap..................................................... 8-16
Checking the crankpin oil clearance......... 5-61
Checking the crankshaft ........................... 5-61
Checking the crankshaft journal oil
clearance ................................................ 5-63
Checking the cylinder bore ....................... 5-58
Checking the cylinder head ...................... 5-48
Checking the drive shaft ..................6-15, 6-46
Checking the drive shaft bushing ............. 7-10
Checking the ECM circuit ......................... 8-22
Checking the electrical component............. 8-1
Checking the electronic throttle valve
and TPS circuit ....................................... 8-23
Checking the electronic throttle valve
motor ...................................................... 8-25
Checking the engine idle speed ................. 3-9
Checking the engine oil .............................. 3-4
Checking the engine oil level.................... 1-40
Checking the engine start switch.............. 8-20
Checking the engine start switch and
engine stop lanyard switch ..................... 1-42
Checking the engine stop lanyard
switch...................................................... 8-21
Checking the engine temperature
sensor..................................................... 8-18
Checking the exhaust cover anode .......... 5-40
Checking the filter..................................... 7-35
Checking the fuel filter ................................ 3-4
Checking the fuel injector ......................... 8-30
Checking the fuel joint and fuel hose
(fuel joint-to-fuel injector) .......................... 3-3
Checking the fuel system ......................... 1-40
Checking the fuse............................7-46, 8-32
Checking the gear oil level ..............1-40, 3-13
Checking the gear pump .......................... 7-35
Checking the gear pump housing............. 7-35
Checking the gear shift and throttle
operation................................................. 1-42
Checking the gear shift operation............. 3-11
Checking the high-pressure fuel
pump relay.............................................. 8-31
i-1
1
2
3
4
5
6
7
8
9
Index
Checking the hydraulic pressure...............7-24
Checking the ignition coil input voltage.....8-15
Checking the ignition spark.......................8-15
Checking the intake air pressure
sensor .....................................................8-17
Checking the intake air temperature
sensor .....................................................8-16
Checking the knock sensor.......................8-20
Checking the lower case................. 6-15, 6-46
Checking the lower unit for air leakage.....3-14
Checking the low-pressure fuel pump
and high-pressure fuel pump ..................8-31
Checking the magnet switch .....................8-37
Checking the main relay and electronic
throttle valve relay...................................8-21
Checking the neutral switch ......................8-19
Checking the oil control valve ...................8-30
Checking the oil pressure ...........................5-1
Checking the oil pressure sensor................5-2
Checking the oil pump ..............................5-66
Checking the oil strainer ...........................7-11
Checking the outboard motor mounting
height ......................................................1-41
Checking the pinion and forward gear ......6-15
Checking the pinion and reverse gear ......6-46
Checking the piston clearance
(reference) ..............................................5-58
Checking the piston diameter ...................5-58
Checking the piston pin.............................5-60
Checking the piston pin boss bore............5-59
Checking the piston ring ...........................5-58
Checking the piston ring end gap
(reference) ..............................................5-59
Checking the piston ring groove ...............5-59
Checking the piston ring side clearance ...5-59
Checking the pressure regulator.................4-8
Checking the propeller ..............................3-14
Checking the propeller shaft ............. 6-9, 6-39
housing ........................................... 6-9, 6-39
Checking the PTT fluid level .....................3-12
Checking the PTT motor ...........................7-28
Checking the PTT operation .....................3-12
Checking the PTT relay ............................7-47
Checking the PTT switch ..........................7-47
Checking the PTT system.........................1-42
Checking the Rectifier Regulator ..............8-38
Checking the remote control cable ...........1-41
Checking the reservoir ..............................7-35
Checking the shift cut switch.....................8-19
Checking the spark plug .............................3-7
Checking the starter motor operation........8-38
Checking the starter motor pinion .............8-36
i-2
Checking the starter relay......................... 8-32

Checking the stator coil ............................ 8-38
Checking the steering system .................. 1-42
Checking the thermostat............................. 3-7
Checking the thermoswitch ...................... 8-18
Checking the throttle valve operation ......... 4-5
Checking the tilt cylinder and trim
cylinder ................................................... 7-40
Checking the timing belt ............................. 3-6
Checking the timing belt and sprocket...... 5-27
Checking the top cowling............................ 3-3
Checking the TPS....................................... 4-5
Checking the trim sensor.......................... 7-48
Checking the valve ..........................5-43, 7-41
Checking the valve clearance................... 5-10
Checking the valve guide ......................... 5-44
Checking the valve lifter ........................... 5-27
Checking the valve seat ........................... 5-45
Checking the valve spring ........................ 5-43
Checking the vapor separator .................. 4-25
Checking the vapor shut-off valve ............ 8-32
Checking the water pump and
shift rod............................................6-5, 6-35
Checking using the YDIS............................ 8-1
Clamp bracket and swivel bracket............ 7-16
Connecting the communication cable
to the outboard motor ............................... 9-4
Control system............................................ 3-9
Cooling water hose..................................... 4-3
Crankcase ................................................ 5-53
Cylinder block ........................................... 5-55
Cylinder head ........................................... 5-41
D.
Dimension................................................. 2-10
Disassembling the cylinder block ............. 5-57
housing ..........................................6-14, 6-45
Disassembling the forward gear ............... 6-14
Disassembling the gear pump .................. 7-34
Disassembling the lower case .........6-14, 6-45
Disassembling the oil pan......................... 7-10
Disassembling the oil pump...................... 5-65
assembly .................................................. 6-8
housing ............................................6-8, 6-38
Disassembling the PTT motor .................. 7-28
Disassembling the reverse gear ............... 6-45
Disassembling the starter motor............... 8-36
Disassembling the tilt cylinder and
trim cylinder ............................................ 7-39
Disassembling the upper case ................. 7-10
6P23H11
Index
Installing the cylinder head ....................... 5-51
Installing the drive shaft...................6-16, 6-48
Installing the exhaust cover ...................... 5-40
Installing the fuel hose clamp ................... 4-25
Installing the fuel injector .......................... 4-27
Installing the intake manifold .................... 4-13
Installing the intake silencer ..................... 4-13
Installing the lower unit ....................6-19, 6-51
Installing the power unit............................ 5-73
Installing the propeller shaft
housing ..........................................6-17, 6-49
Installing the PTT motor ........................... 7-43
Installing the PTT unit............................... 7-19
Installing the reservoir .............................. 7-44
Installing the steering arm ........................ 7-14
Installing the throttle body......................... 4-18
Installing the tilt cylinder ........................... 7-42
Installing the tilt ram.................................. 7-44
Installing the trim ram ............................... 7-42
Installing the upper case........................... 7-13
Installing the valve .................................... 5-49
Installing the water pump and
shift rod..........................................6-18, 6-49
Installing the wiring harness ..................... 5-72
Intake manifold ......................................... 4-12
Introduction................................................. 9-1
Disassembly and assembly ........................1-5

Disconnecting the quick connector .............4-9
Draining the fuel........................................4-10
Drive shaft and lower case
(counter rotation model)..........................6-43
Drive shaft and lower case
(regular rotation model)...........................6-12
E.
ECM ..........................................................5-36
ECM and electronic throttle valve
control system.........................................8-21
ECM system..............................................1-14
Electrical .....................................................2-7
Electrical component...................................8-3
Electronic fuel injection control system .....1-22
Electronic throttle valve control system.....1-33
Engine speed control system....................1-35
Exhaust cover ...........................................5-39
F.
Feature and benefit...................................1-14
Fire prevention ............................................1-4
Fuel control system...................................8-30
Fuel filter ...................................................4-11
Fuel hose and blowby hose ........................4-1
Fuel injector ..............................................4-26
Fuel system.................................................3-3
Fuse box ...................................................5-37
Fuse holder .................................................8-5
J.
Junction box ............................................. 5-38
K.
G.
Gear pump ................................................7-31
General .....................................................3-14
General specification ..................................2-1
General torque ..........................................2-15
Good working practice ................................1-5
H.
Hose routing................................................4-1
How to use this manual...............................1-1
I.
Identification................................................1-6
Ignition and ignition control system...........8-15
Ignition timing control system....................1-25
Installing the camshaft, driven sprocket,
and timing belt.........................................5-28
Installing the clamp bracket ......................7-19
Installing the cooling water passage
cover .......................................................5-50
6P23H11
Knock control system ............................... 1-27
L.
Lower unit ................................ 1-38, 2-6, 3-13
Lower unit (counter rotation model).......... 6-31
Lower unit (regular rotation model)............. 6-1
Low-pressure fuel pump ........................... 4-20
Lubricating the outboard motor................. 3-16
M.
Maintenance interval chart ......................... 3-1
Maintenance specification .......................... 2-3
Manual format............................................. 1-1
gear backlash ................................6-28, 6-60
Measuring the fuel pressure ....................... 4-7
Measuring the peak voltage ....................... 8-1
Model.......................................................... 1-6
i-3
1
2
3
4
5
6
7
8
9
Index
P.
Part, lubricant, and sealant .........................1-4
Port view ............................................. 8-3, 8-8
Power unit ....................................2-3, 3-4, 5-1
Predelivery check......................................1-40
Propeller selection ....................................1-39
(counter rotation model)..........................6-36
(regular rotation model).............................6-6
Propeller size ............................................1-39
PTT electrical system................................7-46
PTT motor .................................................7-27
PTT unit ....................................................7-22
R.
Reducing the fuel pressure .........................4-9
Refacing the valve seat.............................5-46
Removing the clamp bracket ....................7-19
Removing the cooling water passage
cover .......................................................5-49
Removing the cylinder head .....................5-43
Removing the drive shaft ................ 6-14, 6-45
Removing the exhaust cover ....................5-40
Removing the fuel hose clamp..................4-25
Removing the lower unit ................... 6-4, 6-34
Removing the power unit ..........................5-21
Removing the propeller shaft housing
assembly......................................... 6-8, 6-38
Removing the PTT unit .............................7-18
Removing the steering arm.......................7-14
Removing the timing belt,
driven sprocket, and camshaft ................5-23
Removing the upper case .........................7-10
Removing the water pump and
shift rod ........................................... 6-5, 6-35
Removing the wiring harness guide..........5-20
Replacing the oil filter..................................3-6
Replacing the timing belt...........................5-15
Replacing the valve guide.........................5-45
S.
Safety while working ...................................1-4
Selecting the connecting rod bearing........5-63
Selecting the forward gear shim ..... 6-24, 6-57
Selecting the main bearing .......................5-64
Selecting the pinion shim ................ 6-23, 6-54
Selecting the propeller shaft shim... 6-27, 6-58
Selecting the reverse gear shim ..... 6-25, 6-55
Selection ...................................................1-39
Self-protection.............................................1-4
Serial number..............................................1-6
i-4
Shift rod and bottom cowling ...................... 7-1

Shimming.........................................6-23, 6-54
Shimming (counter rotation model) .......... 6-53
Shimming (regular rotation model) ........... 6-22
Special service tool..................................... 1-7
Specified torque........................................ 2-12
Starboard view...................................8-4, 8-10
Starter motor............................................. 8-34
Starter motor and accelerator position
sensor..................................................... 5-35
Starting system......................................... 8-32
Symbol........................................................ 1-2
T.
Test run .................................................... 1-43
Throttle body............................................. 4-15
Tightening torque...................................... 2-12
Tilt cylinder and trim cylinder .................... 7-37
Top cowling ................................................ 3-3
Top view ............................................8-7, 8-14
Trouble code and checking step................. 9-7
Troubleshooting the lower unit ................. 9-23
Troubleshooting the power unit .................. 9-5
(trouble code not detected)..................... 9-17
Troubleshooting the power unit using the
diagnostic flash indicator ........................ 9-15
Troubleshooting the power unit using
the YDIS ................................................... 9-5
Troubleshooting the PTT unit ................... 9-22
U.
Upper case and steering arm ..................... 7-5
V.
Vapor gas hose .......................................... 4-2
Vapor separator........................................ 4-22
system ...........................................1-29, 8-28
Ventilation................................................... 1-4
W.
Wiring harness routing................................ 8-8
Y.
YDIS ........................................................... 9-1
6P23H11
Index
MEMO
1
2
3
4
5
6
7
8
9
6P23H11
i-5
Wiring diagram
F250A, FL250A
1 Condenser (connect to the intake air pressure
sensor)
2 PTT switch
3 Trim sensor
4 Crank position sensor
5 Stator coil
6 Starter motor
7 Battery
8 Accessory battery
9 PTT motor
0 Rectifier Regulator
A PTT relay
B Fuse box
C Diode (connect to the PTT relay)
D Oil pressure sensor
E Shift cut switch
F Neutral switch
G Accelerator position sensor
H Fuel injector
I Thermoswitch (STBD)
J Oil control valve (STBD)
K Knock sensor
L Cam position sensor (STBD IN)
M Ignition coil
N Spark plug
O ECM
P Cam position sensor (PORT IN)
Q Cam position sensor (PORT EX)
R Engine temperature sensor
S Oil control valve (PORT)
T Thermoswitch (PORT)
U High-pressure fuel pump
V Low-pressure fuel pump
W Intake air temperature sensor
X Electronic throttle valve assembly
Y Vapor shut-off valve
Z Intake air pressure sensor
[ Condenser (connect to the cam position
sensor (PORT EX))
To remote control/switch panel
To warning indicator
To diagnostic flash indicator (special service
tool)
To personal computer for diagnosis
To trim meter
(*1) Isolator cable (optional)
(*2) Negative battery cable (commercially available)
Color code
B
Br
G
L
Lg
O
P
R
Sb
W
Y
B/R
B/W
B/Y
Br/W
G/B
G/R
G/Y
L/G
L/W
L/Y
O/W
P/B
P/G
P/W
Pu/B
Pu/R
R/B
R/Y
W/B
W/L
W/R
: Black
: Brown
: Green
: Blue
: Light green
: Orange
: Pink
: Red
: Sky blue
: White
: Yellow
: Black/red
: Black/white
: Black/yellow
: Brown/white
: Green/black
: Green/red
: Green/yellow
: Blue/green
: Blue/white
: Blue/yellow
: Orange/white
: Pink/black
: Pink/green
: Pink/white
: Purple/black
: Purple/red
: Red/black
: Red/yellow
: White/black
: White/blue
: White/red
NOTE:
Depending on the outboard motor, the location of the coupler terminal may be changed
as indicated in the table below.
Coupler
Terminal No.
Color
E (on the wiring

harness guide)
2 through 17
(except 13,
15 and 16)
E (on the ECM

bracket)
1 through 12
14 through 17
R/Y
22 through 24
1 and 8
R/Y
16, 17, 23,

24, and 32
27 and 28
R/Y
1 through 22
(except 11
through 15)
R/Y
3 and 4
11 and 12
R/G
Printed in the Netherlands

Oct. 2005 1.0 2 CR
(E_8)
F250AET, FL250AET
(*1)
B
B
B
B
B
B
B
B
B
B
B
(*2)
12
Sb
1 2 3 4 5 6 7 8 9 10111213 14151617181920212223
1 2 3 4 5 6 7 8 9 101112
Br
R/Y
R
R
R
R
12
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
G/R
G/B
B
P
O
P/W
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
Y
1
2
3
4
5
6
20A
30A
5A
R/Y
G/B
P/G
B
O
R/Y
G/B
R
R
Br
B
Y/G
L/R
R
R/G
R/G
1
2
3
4
5
6
P/G
B
O
15A
O
B
P/G
123
Lg
1
2
1
2
1
2
B
B
1
2
3
R/Y
L/W
Lg
12
Sb
Lg
Sb
Lg
Sb
B/Y
B
O
B
P/W
1
2
3
B
L/Y
1
2
B
L/Y
L/G
B
1
2
L/G
B
B
O
P
P/W
B
O
1
2
3
4
5
6
7
8
R/Y
Pu/L
1
2
#5
R/Y
Pu/Y
1
2
#3
R/Y
Pu/R
1
2
#1
R
B
R/Y
W/B
B
123
1 2 3 4 5 6 7 8 9 10111213 14151617181920212223 24252627 28 29 30 3132 33 34
1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526
123
123
123
123
12
Pu
R/Y
1
2
B
B
B
B
B
B
B
B
B
B
B
B
B
B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526
123
L/W
B
123
R/Y
W/B
B
123
G/R
B
G/B
Pu
123
B
B
B
B
B
B
B
B
B
B
B
B
R
R/Y
R/Y
R/Y
R/Y
1 2 3 4 5 6 7 8 9 10111213 1415161718192021222324
B/L
B
R/Y
R/Y
B/Br
B/L
Pu/W
Pu/L
Pu/G
Pu/Y
Pu/R
Pu/B
L/W
B/G
B/Y
G
L/R
Y
P
B
B
B/W
B/O
P/W
P/B
L/W
B
B
Pu
W
R/G
R/G
G/B
B
W/G
R/Y
R/Y
W/L
B
B/W
B
R/Y
B/Y
B
B/G
B
R/Y
1
2
B/Br
B
R/Y
1
2
Pu
R/Y
B/Y
B
R/Y
B/O
B
R/Y
B/Y
O
O
O
B/Y
B/Y
B
W/B
B/Y
B
R/Y
Pu/B
L/G
Y
1
2
L/Y
Y/G
G
#2
W/B
W/G
W/L
L/W
R/Y
Pu/G
O
P
B
B
O
O
P/W
O
P
1
2
B
B
#4
R/Y
R/Y
Pu/W
P/G
P/W
P
1
2
P/W
#6
R/Y
W/B
L/W
L/W
#6
#4
#2
#1
#3
#5
W/R
G
1
2
10A
1
2
30A
P
B
G
B
W/B
80A
Lg
Sb
R
80A
12
G
R
Y
Lg
P
Sb
W
Br
B
123
L/W
1234
P/B
P/W
1234
R
R
Sb
Br
Br
P
B
Lg
Sb
R
R
R
Lg

6P2 28197 3H 11 PDF

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F250A

Particularly important information is distinguished in this manual by the following notations:

Predelivery check ........................................................................................ 1-40

How to use this manual

Removing the drive shaft

Disassembling the drive shaft

1. Install the pinion nut 1, tighten it finger

Drive shaft holder 4 1: 90890-06518

Do not reuse the bearing, always replace

Bearing separator 1: 90890-06534

Do not press the drive shaft threads a

Bearing inner race attachment 3:

Do not reuse the bearing, always replace

Disassembling the forward gear

How to use this manual

Periodic check and adjustment

Symbols 1 to 6 indicate specific data.

Special service tool

Apply Yamaha 4-stroke motor oil

A Apply corrosion resistant grease

D Apply Gasket Maker

G Apply LOCTITE 242 (blue)

American Petroleum Institute

Cold Cranking Ampere

Dual Engine System

Electronic Control Module

European Norm (European standard)

International Electrotechnical Commission

Pressure Control Valve

Pump Octane Number = (RON + Motor Octane Number)/2

Power Trim and Tilt

Research Octane Number

Society of Automotive Engineers

Top Dead Center

Throttle Position Sensor

Yamaha Diagnostic System

How to use this manual / Safety while working

Safety while working

To prevent an accident or injury and to

Part, lubricant, and sealant

3. Avoid contact with skin. Do not, for

6. Keep a supply of clean, lint-free cloths for

Disassembly and assembly

Good working practice

2. Apply engine oil to the contact surfaces

3. Install bearings with the manufacture

Safety while working / Identification

Special service tool

Oil filter wrench

Compression gauge extension

Fuel pressure gauge adapter B

Test harness (3 pins)

Fuel pressure gauge

Vacuum/pressure pump gauge set

Special service tool

Valve guide reamer

Valve spring compressor

Valve seat cutter holder

Valve spring compressor attachment

Valve seat cutter

Valve guide remover/installer

Valve guide installer