F80B F100D SERVICE MANUAL 6D G-11

Transcription

1 F0B F00D SERVICE MNUL D--G-

2 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. uthorized 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 lert Symbol means TTENTION! BECOME LERT! YOUR SFETY IS INVOLVED! WRNING Failure to follow WRNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. CUTION: CUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE provides key information to make procedures easier or clearer. F0B, F00D SERVICE MNUL 00 by Yamaha Motor Co., Ltd. st Edition, October 00 ll rights reserved. ny reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in the Netherlands

3 Contents General information GEN INFO Specifications SPEC Periodic checks and adjustments CHK DJ Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT + Electrical systems ELEC Troubleshooting TRBL SHTG Index

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5 GEN INFO General information How to use this manual...- Manual format...- Symbols...- Safety while working...- Fire prevention...- Ventilation...- Self-protection...- Parts, lubricants, and sealants...- Good working practices...- Disassembly and assembly...- Identification...- pplicable model...- Serial number...- Propeller selection...- Propeller size...- Selection...- Predelivery checks...- Checking the fuel system...- Checking the engine oil level...- Checking the gear oil level...- Checking the battery...- Checking the outboard motor mounting height...- Checking the remote control cables...- Checking the steering system...- Checking the gear shift and throttle operation...- Checking the power trim and tilt system...- Checking the engine start switch and engine stop lanyard switch...- Checking the cooling water pilot hole...- Test run...- Break-in...- fter test run...- DG

6 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 components list. Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions. Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point. The components list consists of part names and part quantities, as well as bolt and screw dimensions. Service points regarding removal, checking, and installation are shown in individual illustrations to explain the relevant procedure. For troubleshooting procedures, see Chapter, Troubleshooting. LOWR Lower unit Lower unit LOWR Lower unit Removing the drive shaft. Remove the drive shaft assembly and pinion, and then pull out the forward gear. SY0K SY0K CUTION: Do not reuse the bearing, always replace it with a new one. No. Part name Q ty Remarks Lower unit Plastic tie Not reusable Hose Check screw Gasket Not reusable Dowel pin Bolt M0 0 mm Drain screw Grommet 0 Bolt M0 mm Bolt M 0 mm Thrust washer Propeller Washer Washer Cotter pin Not reusable Propeller nut Trim tab - Y Drive shaft holder : 00-0 Pinion nut holder : Socket adapter : Disassembling the drive shaft. Install the pinion nut, tighten it finger tight, and then remove the drive shaft bearing using a press. CUTION: Do not press the drive shaft threads a directly. Do not reuse the bearing, always replace it with a new one. Bearing inner race attachment : 00-0 Bearing separator : Remove the needle bearing from the forward gear. CUTION: Do not reuse the bearing, always replace it with a new one. Stopper guide plate : Stopper guide stand : 00-0 Bearing puller : 00-0 Bearing puller claw : 00-0 Disassembling the forward gear. Remove the taper roller bearing from the forward gear using a press. - Y - DG

7 How to use this manual Symbols The symbols below are designed to indicate the content of a chapter. General information GEN INFO Fuel system FUEL Bracket unit BRKT Specifications Power unit Electrical systems SPEC POWR ELEC + Periodic checks and adjustments Lower unit Troubleshooting CHK DJ LOWR TRBL SHTG Symbols to indicate specific data. Special tool Specified oil or fluid Specified engine speed Specified tightening torque Specified measurement Specified electrical value (resistance, voltage, electric current) Symbols to C in an exploded diagram indicate the grade of lubricant and the lubrication point. 0 B C E G pply Yamaha -stroke motor oil pply gear oil pply water resistant grease (Yamaha grease ) 0 pply molybdenum disulfide grease M D C I pply corrosion resistant grease (Yamaha grease D) B pply low temperature resistant grease (Yamaha grease C) C pply injector grease Symbols D to H in an exploded diagram indicate the type of sealant or locking agent and the application point. D E F G H GM LT LT LT SS D pply Gasket Maker E pply LOCTITE (red) F pply LOCTITE (blue) G pply LOCTITE H pply silicon sealant DG -

8 GEN INFO General information 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. Parts, lubricants, and sealants 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.. Maintain good standards of personal and industrial hygiene.. 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.. void contact with skin. Do not, for example, place a soiled rag in your pocket.. 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.. To protect your skin, apply a protective cream to your hands before working on the outboard motor. - DG

9 . Keep a supply of clean, lint-free cloths for wiping up spills, etc. Good working practices Special service tools Use the recommended special service tools to protect parts from damage. Use the right tool in the right manner do not improvise. Tightening torques 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 parts lways use new gaskets, seals, O-rings, cotter pins, circlips, etc., when installing or assembling parts. Safety while working Disassembly and assembly. Use compressed air to remove dust and dirt during disassembly.. pply engine oil to the contact surfaces of moving parts before assembly.. Install bearings with the manufacture identification mark in the direction indicated in the installation procedure. In addition, be sure to lubricate the bearings liberally.. pply a thin coat of water-resistant grease to the lip and periphery of an oil seal before installation.. Check that moving parts operate normally after assembly. DG -

10 GEN INFO General information Identification pplicable model This manual covers the following model. pplicable model F0BET, F00DET Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket. 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. n 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. Propeller size The size of the propeller is indicated on the propeller boss end, on the side of the propeller boss. SD00 a - b c SJ00 Model name pproved model code Transom height Serial number a - b c Model name pproved model code Starting serial No. F0BET D F00DET D a Propeller diameter (in inches) b Propeller pitch (in inches) c Propeller type (propeller mark) S0C0 - DG

11 Identification / Propeller selection / Predelivery checks Selection When the engine speed is at the full throttle operating range (,000,000 r/min), the ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption. Propeller size (in) Material / - K - K - K - K / - K / - K luminum / - K - K SD00 - K - K - K - K Stainless CUTION: This is a -stroke engine. Never use premixed fuel. - K / - K / - K Checking the engine oil level. Check the engine oil level. Predelivery checks To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the fuel system. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel. a b S0C0 If the engine oil is below the minimum level mark b, add sufficient oil until the level is between a and b. Recommended engine oil: -stroke motor oil PI: SE, SF, SG, SH, or SJ SE: 0W-0 or 0W-0 Engine oil quantity: Without oil filter replacement:. L (. US qt,. Imp qt) DG -

12 GEN INFO General information Checking the gear oil level. Check the gear oil level. 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.. Check that the clamp brackets are secured with the clamp bolts. Checking the battery. Check the capacity, electrolyte level, and specified gravity of the battery. Recommended battery capacity: CC/EN: 0 0HR/IEC: 0 h Electrolyte specified gravity:.0 at 0 C ( F) S0C0 Checking the remote control cables. Set the remote control lever to the neutral position and fully close the throttle lever.. Check that the stopper on the throttle cam contacts the fully closed stopper on the cylinder block.. Check that the positive and negative battery leads are securely connected. Checking the outboard motor mounting height. 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. lso, 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. SD00. Check that the alignment mark a on the bushing is aligned with the alignment mark b on the bracket. a b SD00 - DG

13 Predelivery checks F N R a WRNING c SJ0 The shift/throttle cable joint must be screwed in a minimum of.0 mm (0. in) c. Checking the steering system. Check the steering friction for proper adjustment.. Check that the steering operates smoothly. S0C00. Check that there is no interference with wires or hoses when the outboard motor is steered. Checking the gear shift and throttle operation. Check that the gear shift operates smoothly when the remote control lever is shifted from neutral to forward or reverse.. Check that the throttle operates smoothly when the remote control lever is shifted from forward or reverse to the fully open position a. a SJ0 Checking the power trim and tilt system. Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit.. Check that there is no abnormal noise produced when the outboard motor is tilted up or down.. Check that there is no interference with wires or hoses when the tilted-up outboard motor is steered.. 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. Check that the engine starts when the engine start switch is turned to STRT.. Check that the engine turns off when the engine start switch is turned to OFF. S0V00 DG -

14 GEN INFO General information. Check that the engine turns off when the engine stop lanyard is pulled from the engine stop lanyard switch. Break-in During the test run, perform the break-in operation in the following three stages.. One hour a at,000 r/min or at approximately half throttle. One hour b at,000 r/min or / throttle and minute out of every 0 at full throttle. Eight hours c at any speed, however, avoid running at full speed for more than minutes Checking the cooling water pilot hole. Check that cooling water is discharged from the cooling water pilot hole. a b c È 0 0 È Hour SJ0 fter test run. Check for water in the gear oil. Test run. Start the engine, and then check that the gear shift operates smoothly.. Check the engine idle speed after the engine has been warmed up.. Check for fuel leakage in the cowling.. Flush the cooling water passage with fresh water using the flushing kit and with the engine running at idle.. Operate at trolling speed.. Run the outboard motor for hour at,000 r/min or at half throttle, then for another hour at,000 r/min or at / throttle.. Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom. The test run is part of the break-in operation. - DG

15 SPEC Specifications General specifications...- Maintenance specification...- Power unit...- Lower unit...- Electrical...- Dimensions...- Tightening torques...- Specified torques...- General torques...- DG

16 SPEC Specifications General specifications Item Unit Model F0BET F00DET Dimension Overall length mm (in) (.) Overall width mm (in) (.) Overall height (L) mm (in), (.) (X) mm (in),0 (.) Boat transom height (L) mm (in) 0 (0.0) (X) mm (in) (.0) Weight (with aluminum propeller) (L) kg (lb) 0 () (X) kg (lb) () (with stainless propeller) (L) kg (lb) () (X) kg (lb) () Performance Maximum output kw (hp). (0) at,00 r/min. (00) at,00 r/min Full throttle operating range r/min,000,000 Maximum fuel consumption L (US gal, Imp gal)/hr.0 (.0,.) at,000 r/min.0 (.,.) at,000 r/min Engine idle speed r/min 0 0 Power unit Type In-line, -stroke, DOHC, valves Cylinder quantity Total displacement cm (cu. in), (.) Bore stroke mm (in).0. (..0) Compression ratio. Control system Remote control Starting system Electric Fuel system Fuel injection Ignition control system TCI dvance type Micro computer Maximum generator output V,, Spark plug LFR- (NGK) Cooling system Water Exhaust system Propeller boss Lubrication system Wet sump - DG

17 General specifications Item Unit Model F0BET F00DET Fuel and oil Fuel type Regular unleaded gasoline Fuel minimum rating RON (*) PON Engine oil -stroke motor oil Engine oil grade PI SE SE, SF, SG, SH, or SJ 0W-0 or 0W-0 Engine oil quantity (without oil filter replacement) L (US qt,. (.,.) Imp qt) (with oil filter replacement) L (US qt,. (.,.) Imp qt) Gear oil type Hypoid gear oil Gear oil grade (*) PI GL- SE 0 Gear oil quantity cm (US oz, 0 (.,.) Imp oz) Bracket unit Trim angle Degree to (at boat transom) Tilt-up angle Degree 0 Steering angle Degree + Drive unit Gear shift positions F-N-R Gear ratio. (0/) Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction (rear view) Clockwise Propeller mark K Electrical Battery minimum capacity (*) CC/EN 0 0HR/IEC h 0 (*) RON: Research Octane Number PON: Pump Octane Number = (RON + Motor Octane Number)/ (*) Meeting both PI and SE requirements (*) CC: Cold Cranking mpere EN: European Norm (European standard) IEC: International Electrotechnical Commission DG -

18 SPEC Specifications Maintenance specification Power unit Item Unit Model F0BET F00DET Power unit Minimum compression kpa 0 (.,.) pressure (*) (kgf/cm, psi) Oil pressure (*) kpa 0 (.,.0) at engine idle speed (kgf/cm, psi) Cylinder head Warpage limit mm (in) 0. (0.00) (lines indicate straightedge position) Camshaft cap inside diameter mm (in) (0. 0.) Cylinders Bore size mm (in) (.0.0) Taper limit mm (in) 0.0 (0.00) Out-of-round limit mm (in) 0.0 (0.000) Pistons Piston diameter (D) mm (in).. (.0.0) Measuring point (H) mm (in).0 (0.) Piston clearance mm (in) ( ) Over size piston diameter mm (in).. (..) Piston rings Top ring Dimension B mm (in).. ( ) Dimension T mm (in).0.00 (0.0 0.) End gap mm (in) ( ) Side clearance mm (in) ( ) nd piston ring Dimension B mm (in).. ( ) Dimension T mm (in).00.0 (0. 0.0) End gap mm (in) ( ) Side clearance mm (in) ( ) (*) Measuring conditions: mbient temperature 0 C ( F), wide open throttle, with spark plugs removed from all cylinders. The figures are for reference only. (*) The figures are for reference only. - DG

19 Maintenance specification Item Unit Model F0BET F00DET Oil ring Dimension B mm (in).. ( ) Dimension T (*) mm (in).0 (0.0) End gap mm (in) ( ) Side clearance mm (in) ( ) Camshafts Intake () mm (in).. (..0) Exhaust () mm (in).0.0 (..) Intake (B) mm (in). 0.0 (..) Exhaust (B) mm (in). 0.0 (.0.) Camshaft journal diameter mm (in).0.0 (0. 0.) Camshaft runout limit mm (in) 0.0 (0.00) Valves Valve clearance (cold) Intake mm (in) 0.0 ± 0.0 (0.00 ± 0.00) Exhaust mm (in) 0. ± 0.0 (0.0 ± 0.00) Head diameter () Intake mm (in).0. (..) Exhaust mm (in).0. (0. 0.) Face width (B) Intake mm (in).. ( ) Exhaust mm (in).. ( ) Seat contact width (C) Intake mm (in).0.0 ( ) Exhaust mm (in).0.0 ( ) Margin thickness (D) Intake mm (in) ( ) Exhaust mm (in).00.0 ( ) Stem diameter Intake mm (in)..0 (0. 0.) Exhaust mm (in).0. (0. 0.) Guide inside diameter Intake and exhaust mm (in) (0. 0.) Stem-to-guide clearance Intake mm (in) ( ) Exhaust mm (in) ( ) Stem runout limit mm (in) 0.0 (0.000) Valve springs Free length mm (in).0 (.0) Tilt limit mm (in). (0.0) (*) The figure is for reference only. DG -

20 SPEC Specifications Item Unit Model F0BET F00DET Valve lifters Valve lifter outside diameter mm (in)..0 (.00.0) Valve lifter-to-cylinder head mm (in) ( ) clearance Valve shims Valve shim thickness mm (in).0. (0.0 0.) (in 0.0 mm increments) Connecting rods Big end inside diameter mm (in).0.0 (..) Big end side clearance mm (in) ( ) Crankpin oil clearance mm (in) ( ) Big-end bearing thickness Yellow mm (in)..0 ( ) Green mm (in).0. ( ) Blue mm (in)..0 ( ) Red mm (in).0. ( ) Crankshaft Crankshaft journal diameter mm (in)..000 (..) Crankpin diameter mm (in)..000 (..) Crankpin width mm (in).00.0 (0. 0.) Runout limit mm (in) 0.0 (0.00) Crankcase Crankshaft journal oil mm (in) ( ) clearance Upper crankcase main bearing thickness Green mm (in).. (0. 0.) Blue mm (in)..00 (0. 0.) Red mm (in).00.0 (0. 0.) Upper crankcase main bearing # thickness Green mm (in).. (0. 0.) Blue mm (in)..00 (0. 0.) Red mm (in).00.0 (0. 0.) Lower crankcase main bearing thickness Yellow mm (in).00.0 (0. 0.) Green mm (in).0.0 (0. 0.) Blue mm (in).0.0 (0. 0.) Red mm (in).0.0 (0. 0.) - DG

21 Maintenance specification Oil pump Discharge at 0 C (0 F) with 0W-0 engine oil Pressure at 0 C (0 F) with 0W-0 engine oil Relief valve opening pressure Lower unit Electrical Item Unit L (US gal, Imp gal)/min kpa (kgf/cm, psi) kpa (kgf/cm, psi) F0BET Model. (.,.) at,000 r/min.0 (.,.) at,000 r/min (..,..) Thermostat Opening temperature C ( F) ( ) Fully open temperature C ( F) 0 () Valve open lower limit mm (in). (0.) F00DET Item Unit Model F0BET F00DET Gear backlash Pinion-to-forward gear mm (in) ( ) Pinion shims mm 0.0, 0., 0., 0., 0.0, 0.0, 0.0 Forward gear shims mm 0.0, 0., 0., 0., 0.0, 0.0, 0.0 Item Unit Model F0BET F00DET Ignition and ignition control system Spark plug gap mm (in).0. ( ) Ignition coil resistance at 0 C ( F) Primary coil (R B/W) Ω..0 Secondary coil kω..0 Spark plug wire resistance # kω. 0. # kω..0 # kω.. # kω. 0. DG -

22 SPEC Specifications Item Unit Model F0BET F00DET ECM output peak voltage (B/R, B/W Ground) at cranking (loaded) V 0 at,00 r/min (loaded) V 0 at,00 r/min (loaded) V 0 Pulser coil output peak voltage (W/R, W/B B) at cranking (unloaded) V. at cranking (loaded) V. at,00 r/min (loaded) V. at,00 r/min (loaded) V. Pulser coil resistance (*) Ω (W/R, W/B B) Throttle position sensor Output voltage (P B) V 0.. at engine idle speed Cooling water temperature sensor resistance at 0 C ( F) kω.. at 0 C ( F) kω Oil pressure switch Operating pressure kpa (kgf/cm, psi).. (..,..) Fuel control system Fuel injector resistance (*) at C (0 F) Ω.0 Starter motor Type Sliding gear Output kw.0 Cranking time limit Second 0 Brushes Standard length mm (in). (0.) Wear limit mm (in). (0.) Commutator Standard diameter mm (in).0 (.) Wear limit mm (in).0 (.0) Mica Standard undercut mm (in) 0. (0.0) Wear limit mm (in) 0. (0.0) (*) The figures are for reference only. - DG

23 Maintenance specification Item Unit Model F0BET F00DET Charging system Fuse 0 Stator coil output peak voltage (W W) at cranking (unloaded) V. at,00 r/min (unloaded) V. at,00 r/min (unloaded) V. Stator coil resistance (*) (W W) at 0 C ( F) Ω Rectifier Regulator output peak voltage (R Ground) at,00 r/min (unloaded) V.0 at,00 r/min (unloaded) V.0 Power trim and tilt system Trim sensor Setting resistance (P B) Ω 0 ± Resistance (P B) Ω. Fluid type TF Dexron II Brushes Standard length mm (in) 0.0 (0.) Wear limit mm (in). (0.) Commutator Standard diameter mm (in).0 (0.) Wear limit mm (in).0 (0.) Mica Standard undercut mm (in). (0.0) Wear limit mm (in).0 (0.0) (*) The figure is for reference only. DG -

24 SPEC Specifications Dimensions Exterior mm (in) (0.) (.) (.) (.) L: (.) X:,0 (.) L : (.) X: (.) (.) (.) (.) (.) (.) (.) 0 (.) 0 (.) L: (.) X:, (.) (.) (.) L: (0.) X: (.) L : (.0) X: (0.) (.) (.) SD00 - DG

25 Clamp bracket Maintenance specification mm (in) 0 (.) 0 (.). (.). (.) 0. (.0) 0 (.). (.) (0.). (0.) (0.0). (.). (.). (.) (0.) SD00 DG -0

26 SPEC Specifications Tightening torques Specified torques Part to be tightened Thread size Tightening torques N m kgf m ft lb Fuel system Fuel filter cup 0 Fuel pump mounting bolt M 0.0. Fuel pump screw M 00 Sensor assembly screw M. 0 Idle speed control screw M. 0 Fuel rail mounting bolt M 0 Throttle body mounting bolt M 0 Fuel cooler screw M 0 Float chamber screw M 0 Vapor separator drain screw. 0 Pressure regulator bolt M 0 Fuel hose joint 00 Plate screw M 0 Wiring harness holder screw M 0 Pressure check valve 0.0. Power unit Power unit mounting bolt st 0 M0 nd 0 pron screw M 00 Flywheel magnet nut M Starter motor bolt M Spark plug wire cover screw M 00 Starter relay lead bolt M 00 Starter relay holder screw M 0 Main and fuel pump relay screw M 0 Oil pressure switch 0 Oil pressure switch lead bolt M 0 PTT relay lead nut M 00 PTT motor lead bolt M 00 Positive battery lead nut M 0 Timing belt tensioner bolt M0 Drive sprocket nut M0 Driven sprocket bolt M Camshaft cap bolt st 0 M nd Cylinder head cover plate screw M 0 Cylinder head cover bolt st 0 M nd 0 - DG

27 Tightening torques Part to be tightened Thread size Tightening torques N m kgf m ft lb st. 0. M nd. 0. Cylinder head bolt st nd M rd 0 Spark plug Cylinder block plug M 0 Oil filter joint Oil filter Exhaust cover bolt st 0 M nd node screw M 0 Exhaust cover plug M. 0. Crankcase bolt st. 0. M nd. 0. st 0 M0 nd 0 Connecting rod cap bolt st M nd 0 Lower unit Gear oil drain screw 0 Gear oil check screw 0 Lower case mounting bolt (L-transom model) M0 Lower case mounting nut (X-transom model) Propeller nut M Ring nut 0 00 Cooling water inlet cover screw 0 Pinion nut M Bracket unit Shift rod detent bolt Shift position switch screw M Flushing hose adapter screw M 0 Oil pump bolt M 0.0. Upper mounting nut Lower mounting nut Grease nipple 0 Oil pump cover screw M 00 Oil seal housing screw M 00 Upper mount bolt M. 0. Baffle plate bolt M 00 Muffler assembly bolt M 0.0. Engine oil drain bolt M. 0.0 Oil strainer bolt M 0.0. Oil pan bolt M DG -

28 SPEC Specifications Part to be tightened Thread size Tightening torques N m kgf m ft lb Exhaust manifold bolt M Steering arm stud bolt M Self-locking nut Trim sensor cam screw M 0 Power trim and tilt unit Reservoir cap 0 PTT motor bolt M 00 Gear pump bolt M 0 Gear pump housing bolt M 0 Relief valve cap bolt M 00 M 0 Lever bolt M 0 Manual valve 0 Gear pump bracket bolt M 0 M 00 Trim cylinder end screw 0.0. Tilt cylinder end screw Tilt piston bolt M General torques This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and progressive stages until the specified torque is reached. Unless otherwise specified, torque specifications require clean, dry threads. Components should be at room temperature. Nut () Bolt (B) General torque specifications N m kgf m ft lb mm M 0 0 mm M 0 mm M. mm M0. mm M. - DG

29 CHK DJ Periodic checks and adjustments Special service tools...- Maintenance interval chart...- Top cowling...- Checking the top cowling...- Fuel system...- Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector)...- Checking the fuel filter...- Power unit...- Checking the engine oil...- Changing the engine oil using an oil changer...- Changing the engine oil by draining it...- Replacing the oil filter...- Checking the timing belt...- Checking the spark plugs...- Checking the thermostat...- Checking the cooling water passage...- Control system...- Checking the engine idle speed...- djusting the throttle link and throttle cable...- Checking the gear shift operation...-0 Bracket unit...- Checking the power trim and tilt operation...- Checking the power trim and tilt fluid level...- Lower unit...- Checking the gear oil level...- Changing the gear oil...- Checking the lower unit for air leakage...- Checking the propeller...- General...- Checking the anodes...- Checking the battery...- Lubricating the outboard motor...- DG

30 CHK DJ Periodic checks and adjustments Special service tools Digital tachometer Leakage tester Oil filter wrench DG

31 Special service tools / Maintenance interval chart Maintenance interval chart Use the following chart as a guideline for general maintenance. djust the maintenance intervals according to the operating conditions of the outboard motor. Item Remarks 0 hours ( month) Initial 0 hours ( months) Every 00 hours ( months) 00 hours ( year) Refer to page nodes (external) Check/replace - nodes (internal) Check/replace - Battery Check/charge - Cooling water passages Clean - Top cowling Check - Fuel filter Check/replace - (can be disassembled) Fuel system Check - Gear oil Change - Lubrication points Lubricate - Engine idle speed Check/adjust - (EFI models) PCV (Pressure Control Valve) Check - Power trim and tilt unit Check - Propeller and cotter pin Check/replace - Shift link/shift cable Check/adjust -0 Thermostat Check - Throttle link/throttle cable/ Check/adjust - throttle pick-up timing Water pump Check - Engine oil Check/change - Oil filter Change - Spark plugs Clean/adjust/ - replace Timing belt Check/replace - When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. Item Remarks 00 hours (. years) Every,000 hours ( years) Refer to page Timing belt Replace - Valve clearance (DOHC) Check/adjust -0 When using lead or high-sulfur gasoline, checking valve clearance may be required more frequently than every 00 hours. DG -

32 CHK DJ Periodic checks and adjustments Top cowling Checking the top cowling. Check the fitting by pushing the cowling with both hands. djust if necessary.. Check the low-pressure fuel hose connections and fuel joint for leaks. Replace if necessary. lso, check the fuel filter, fuel pump, strainer, and fuel cooler for leaks or deterioration. Replace if necessary.. Check the high-pressure fuel hose connections for leaks. Replace if necessary. lso, check the vapor separator, fuel rail, fuel injectors, and pressure regulator for leaks or deterioration. Replace if necessary.. Loosen the bolts. S0C00. Move the hook up or down slightly to adjust its position. a b SD00 To loosen the fitting, move the hook in direction a. To tighten the fitting, move the hook in direction b. SD00 Checking the fuel filter. Check the fuel filter element for dirt and residue and check the fuel filter cup for foreign substances and cracks. Clean the cup with straight gasoline and replace the element if necessary.. Tighten the bolts.. Check the fitting again and, if necessary, repeat steps. Fuel system Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector). Remove the flywheel magnet cover. SD00 Be sure not to spill any fuel when removing the fuel filter cup. - DG

33 Top cowling / Fuel system / Power unit Power unit Checking the engine oil. Place the outboard motor in an upright position.. Remove the oil dipstick, wipe it clean, and then insert it back into the dipstick hole.. Remove the oil dipstick again to check the oil level and to check the oil for discoloration and its viscosity. a. Operate the oil changer to extract the oil. b S0C0 Be sure to clean up any oil spills.. Pour the specified amount of the recommended engine oil into the oil filler hole. Change the oil if it appears milky or dirty. If the engine oil is below the minimum level mark b, add sufficient oil until the level is between a and b. Changing the engine oil using an oil changer. Start the engine, warm it up, and then turn it off.. Remove the oil dipstick and oil filler cap. S0C00 Recommended engine oil: -stroke motor oil PI: SE, SF, SG, SH, or SJ SE: 0W-0 or 0W-0 Engine oil quantity: Without oil filter replacement:. L (. US qt,. Imp qt). Install the oil filler cap and oil dipstick, and then start the engine and warm it up for minutes.. Turn the engine off, and then check the oil level and correct it if necessary. Changing the engine oil by draining it. Start the engine, warm it up, and then turn it off.. Insert the tube of the oil changer into the dipstick hole. DG -

34 CHK DJ Periodic checks and adjustments. Remove the oil dipstick and oil filler cap.. Turn the engine off, and then check the oil level and correct it if necessary. Replacing the oil filter. Extract the engine oil with an oil changer or drain it.. Place a rag under the oil filter, and then remove the oil filter using the oil filter wrench. S0C00. Place a drain pan under the drain hole, and then remove the drain bolt and let the oil drain completely. SD00 Wait more than minutes after turning the engine off to replace the oil filter. Be sure to clean up any oil spills. Be sure to clean up any oil spills.. Install the drain bolt, and then tighten it to the specified torque. Engine oil drain bolt: N m (. kgf m, 0.0 ft lb) Oil filter wrench : pply a thin coat of engine oil to the O- ring of the new oil filter.. Install the oil filter, and then tighten it to the specified torque using the oil filter wrench.. Pour the specified amount of the recommended engine oil into the oil filler hole. Recommended engine oil: -stroke motor oil PI: SE, SF, SG, SH, or SJ SE: 0W-0 or 0W-0 Engine oil quantity: Without oil filter replacement:. L (. US qt,. Imp qt). Install the oil filler cap and oil dipstick, and then start the engine and warm it up for minutes. - DG

35 Power unit E. While turning the flywheel magnet clockwise, check the interior a and the exterior b of the timing belt for cracks, damage, or wear. Replace if necessary. a SD00 b SD00 For replacement procedures, see Chapter, Replacing the timing belt. Oil filter: N m (. kgf m,. ft lb) Checking the spark plugs. Remove the spark plug wire cover.. Pour the specified amount of the recommended engine oil into the oil filler hole. Recommended engine oil: -stroke motor oil PI: SE, SF, SG, SH, or SJ SE: 0W-0 or 0W-0 Engine oil quantity: With oil filter replacement:. L (. US qt,. Imp qt). Install the oil filler cap and oil dipstick, and then start the engine and warm it up for minutes.. Turn the engine off, and then check the oil level and correct it if necessary. Checking the timing belt CUTION: Do not turn the flywheel magnet counterclockwise, otherwise the valve system may be damaged.. Remove the flywheel magnet cover.. Disconnect the spark plug wires, and then remove the spark plugs.. Clean the electrodes with a spark plug cleaner or wire brush. Replace the spark plug if necessary.. Check the electrodes for erosion and excessive carbon or other deposits, and the gasket for damage. Replace the spark plug if necessary. DG -

36 CHK DJ Periodic checks and adjustments. Check the spark plug gap a. djust if out of specification. Specified spark plug: LFR- (NGK) Spark plug gap a:.0. mm ( in). Install the spark plugs, tighten them finger tight, then to the specified torque using a spark plug wrench. SD00. Suspend the thermostat in a container of water. Spark plug: N m (. kgf m,. ft lb). Place a thermometer in the water and slowly heat the water.. Install the spark plug wire cover. Spark plug wire cover screw: N m (0. kgf m,.0 ft lb) Checking the thermostat. Remove the flywheel magnet cover.. Disconnect the cooling water hose, and then remove the thermostat cover and thermostat. SJE0. Check the thermostat valve opening at the specified water temperatures. Replace if out of specification. - DG

37 Power unit / Control system Water temperature C ( F) above 0 C ( F) Valve lift a 0.0 mm (0.000 in) (valve begins to lift) more than. mm (0. in). Install the thermostat and cover.. Connect the cooling water hose, and then install the flywheel magnet cover. Checking the cooling water passage. Check the cooling water inlet cover and cooling water inlet for clogs. Clean if necessary. Control system Checking the engine idle speed. Start the engine and warm it up for minutes.. ttach the special service tool to spark plug wire #, and then check the engine idle speed. Digital tachometer: S0C0 Engine idle speed: 0 0 r/min SY0. Place the lower unit in water, and then start the engine.. 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. djusting the throttle link and throttle cable. Remove the intake silencer.. Set the remote control lever to the neutral position and fully close the throttle lever. DG -

38 CHK DJ Periodic checks and adjustments. Loosen the locknut, remove the clip, and then disconnect the throttle cable joint.. Loosen the locknut, and then disconnect the throttle link rod joint from the ball joint of the throttle body. a SD0. djust the throttle link rod joint to align its hole with the ball joint 0 on the throttle body. SD00. Check that the stopper on the throttle cam contacts the fully closed stopper on the cylinder block. 0 SD0. Connect the throttle link rod joint, and then tighten the locknut.. Check that the throttle valve fully close. Do not turn the throttle stop screw. SD00 0. Operate the throttle cam to check that the throttle valve fully closes and fully opens, and check that the gap b between the stopper on the throttle lever and fully open stopper B on the throttle body is less than mm (0.0 in) when the throttle cam is in the fully open position. B. Push the throttle link rod toward the cylinder head and check that the throttle cam roller contacts the side a of the throttle cam. b SD0. djust the position of the throttle cable joint until its hole is aligned with the set pin on the throttle cam. - DG

39 Control system WRNING c The throttle cable joint must be screwed in a minimum of.0 mm (0. in) c.. Connect the throttle cable joint, install the clip, and then tighten the locknut.. Check the throttle cable for smooth operation and, if necessary, repeat steps.. Install the intake silencer. Checking the gear shift operation. Check that the gear shift operates smoothly when shifting it from neutral to forward or reverse. djust the shift cable length if necessary.. Set the gear shift to the neutral position.. Loosen the locknut, remove the clip, and then disconnect the shift cable joint.. Remove the clip. SJ0. lign the alignment mark a on the bushing and alignment mark b on the bracket.. Install the clip.. djust the position of the shift cable joint until its hole is aligned with the set pin. c WRNING The shift cable joint must be screwed in a minimum of.0 mm (0. in) c. a b SD00 SJ0. Connect the cable joint, install the clip, and then tighten the locknut.. Check the gear shift for smooth operation and, if necessary, repeat steps. SD0 DG -0

40 CHK DJ Periodic checks and adjustments Bracket unit Checking the power trim and tilt operation. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation. Check the power trim and tilt fluid level if necessary. SD0 WRNING fter tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure.. Remove the reservoir cap, and then check the fluid level in the reservoir. Be sure to listen to the winding sound of the power trim and tilt motor for smooth operation.. Fully tilt the outboard motor up, and then support it with the tilt stop lever to check the lock mechanism of the lever. SD0 Checking the power trim and tilt fluid level. Fully tilt the outboard motor up, and then support it with the tilt stop lever. SD0 If the fluid is at the correct level, the fluid should overflow out of the filler hole when the reservoir cap is removed.. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole. Recommended power trim and tilt fluid: TF Dexron II. Install the reservoir cap, and then tighten it to the specified torque. Reservoir cap: N m (0. kgf m,. ft lb) - DG

41 Bracket unit / Lower unit Lower unit Checking the gear oil level. Fully tilt the outboard motor down.. Remove the check screw, and then check the gear oil level in the lower case. If the oil is at the correct level, the oil should overflow out of the check hole when the check screw is removed.. If necessary, add sufficient gear oil of the recommended type until it overflows out of the check hole.. Install the check screw, and then tighten it to the specified torque. Recommended gear oil: Hypoid gear oil PI: GL- SE: 0 Changing the gear oil. Tilt the outboard motor up slightly.. Place a drain pan under the drain screw, remove the drain screw, then the check screw and let the oil drain completely. Gear oil check screw: N m (0. kgf m,. ft lb) S0C0. Check the oil for metal and discoloration, and its viscosity. Check the internal parts of the lower case if necessary. DG -

42 CHK DJ Periodic checks and adjustments. 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. Leakage tester: pply the specified pressure to check that the pressure is maintained in the lower unit for at least 0 seconds. CUTION: Do not over pressurize the lower unit, otherwise the oil seals can be damaged. Cover the check hole with a rag when removing the tester from the lower unit. Recommended gear oil: Hypoid gear oil PI: GL- SE: 0 Gear oil quantity: 0 cm (. US oz,. Imp oz). Install the check screw and quickly install the drain screw, and then tighten them to the specified torque. Lower unit holding pressure: 00 kpa (.0 kgf/cm,. psi). If pressure drops below specification, check the drive shaft and propeller shaft oil seals for damage. Checking the propeller. Check the propeller blades and splines for cracks, damage, or wear. Replace if necessary. Gear oil check screw and drain screw: N m (0. kgf m,. ft lb) Checking the lower unit for air leakage. Remove the check screw, and then install the special service tool. - DG

43 Lower unit / General General Checking the anodes. Check the anodes and trim tab for scales, grease, or oil. Clean if necessary. If it is necessary to disassemble the outboard motor to check an anode, refer to the applicable disassembly procedure in this manual.. Replace the anodes or trim tab if excessively eroded. Checking the battery. 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. a SD0 SJ0 SD0 SY0 CUTION: Do not oil, grease, or paint the anodes or the trim tab, otherwise they will be ineffective. DG -

44 CHK DJ Periodic checks and adjustments. Check the specific gravity of the electrolyte. Fully charge the battery if out of specification. Lubricating the outboard motor. pply water resistant grease to the areas shown. WRNING Battery electrolyte is dangerous; it contains sulfuric acid which is poisonous and highly caustic. lways follow these preventive measures: void bodily contact with electrolyte as it can cause severe burns or permanent eye injury. Wear protective eye gear when handling or working near batteries. ntidote (EXTERNL): SKIN Wash with water. EYES Flush with water for minutes and get immediate medical attention. ntidote (INTERNL): 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. lways 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 BTTERIES ND ELECTROLYTE OUT OF RECH OF CHILDREN. a S0C0 S0C0 SD0 a 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 lead first, then the positive battery lead. a S0C Electrolyte specific gravity:.0 at 0 C ( F) - DG

45 General a a S0C0 pply grease to the grease nipple until it flows from the bushings a.. pply low temperature resistant grease to the area shown. C SD0. pply corrosion resistant grease to the area shown. DG -

46 CHK DJ Periodic checks and adjustments MEMO - DG

47 FUEL Fuel system Special service tools...- Hose routing...- Fuel and blowby hoses...- Fuel filter and fuel pump...- Checking the fuel pump...- Disassembling the fuel pump...- Checking the diaphragm and valves...- ssembling the fuel pump...- Intake manifold...- Checking the throttle position sensor...- Installing the throttle position sensor...- Checking the idle speed control...- Vapor separator...-0 Reducing the fuel pressure...- Disconnecting the quick connector...- Measuring the fuel pressure...- Checking the pressure regulator...- Draining the fuel...- Removing the fuel hose clamp...- Installing the fuel hose clamp...- Disassembling the vapor separator...- Checking the vapor separator...- ssembling the vapor separator...- djusting the float...- Canister...- Checking the canister...-0 DG

48 FUEL Fuel system Special service tools Vacuum/pressure pump gauge set 00-0 Fuel pressure gauge 00-0 Fuel pressure gauge adapter B DG

49 Special service tools / Hose routing Hose routing Fuel and blowby hoses Blowby hose Fuel hose (primary pump-to-fuel filter) Fuel hose (fuel filter-to-fuel pump) Fuel hose (fuel pump-to-strainer) Fuel hose (strainer-to-vapor separator) High-pressure fuel hose (vapor separator-to-fuel rail) Fuel hose (pressure regulator-to-fuel cooler) Fuel hose (fuel cooler-to-vapor separator) Canister hose (vapor separator-to-canister) 0 Canister hose (canister-to-idle speed control) Canister hose (canister-to-filter) B Canister hose (filter-to-bottom cowling) DG -

50 FUEL Fuel system Fuel filter and fuel pump 0 N m (.0 kgf m,. ft Ib) 0 0 N m (0. kgf m,. ft Ib) SD00 No. Part name Q ty Remarks Nut Fuel filter assembly O-ring Not reusable Fuel filter element O-ring Not reusable Float Cup Fuel hose Fuel pump 0 Bolt M 0 mm Fuel hose Strainer Bolt M mm Bracket O-ring Not reusable - DG

51 Fuel filter and fuel pump N m (0. kgf m,.0 ft Ib) 0 No. Part name Q ty Remarks Screw ø mm Cover Gasket Not reusable Fuel pump body assembly Diaphragm Pin Spring Fuel pump body Spring 0 Plunger Nut SD00 DG -

52 FUEL Fuel system Checking the fuel pump. Place a drain pan under the fuel hose connections, and then disconnect the fuel hoses from the fuel pump.. pply the specified positive pressure and check that there is no air leakage. Disassemble the fuel pump if necessary.. Connect the special service tool to the fuel pump inlet.. Cover the fuel pump outlet with a finger, and then apply the specified positive pressure. Check that there is no air leakage. SP0 ssemble the fuel pump valve to the fuel pump body, and moisten the inside of the fuel pump with gasoline to ensure a good seal. Vacuum/pressure pump gauge set: 00-0 Specified pressure: 0 kpa (0. kgf/cm,. psi) SP00. pply the specified negative pressure and check that there is no air leakage. Specified pressure: 0 kpa (0. kgf/cm,. psi) Disassembling the fuel pump. Disassemble the fuel pump.. Push down on the plunger and the diaphragm, turn fuel pump body approximately 0 to a position where the pin can be removed easily, and then remove the pin. SP00 Specified pressure: 0 kpa (0. kgf/cm,. psi). Connect the special service tool to the fuel pump outlet. - DG

53 . Slowly let up on the plunger and diaphragm, and then remove them. Fuel filter and fuel pump Checking the diaphragm and valves. Check the diaphragm for tears and the valves for cracks. Replace if necessary. ssembling the fuel pump Clean the parts and soak the valves and the diaphragm in gasoline before assembly to obtain prompt operation of the fuel pump when starting the engine.. lign the plunger and diaphragm installation holes a, and then install the plunger into the diaphragm.. Push down on the plunger and the diaphragm, and then install the pin.. Turn fuel pump body approximately 0, and then push down on the plunger several times to make sure that the pin does not come out. Make sure that the gasket and diaphragm are kept in place through the assembly process. DG -

54 FUEL Fuel system Intake manifold 0 SD00 No. Part name Q ty Remarks Intake silencer F0BET Bolt M 0 mm Bushing Collar Intake manifold assembly Bolt M 0 mm Collar Bolt M 00 mm Spacer 0 Bolt M mm Collar Holder Gasket Not reusable Pin Joint Intake silencer F00DET - DG

55 Intake manifold. N m (0. kgf m,. ft lb) N m (0. kgf m,. ft Ib) 0 N m (0. kgf m,. ft Ib) SD00 No. Part name Q ty Remarks Intake manifold Sensor assembly Screw ø mm O-ring Not reusable Idle speed control O-ring Not reusable Throttle body assembly Bolt M mm Gasket Not reusable 0 Throttle position sensor Screw O-ring Not reusable Fuel injector O-ring set Not reusable Fuel rail Bolt M mm DG -

56 FUEL Fuel system Checking the throttle position sensor. Check the throttle position sensor output voltage using the Yamaha Diagnostic System. If the output voltage is out of specification, replace the throttle position sensor. Throttle position sensor output voltage at engine idle speed: 0.. V Installing the throttle position sensor. Install the throttle position sensor in a position where the output voltage is within specification. a SD0 If the throttle position sensor output voltage is out of specification, reinstall the throttle position sensor. Measure the throttle position sensor output voltage using the Yamaha Diagnostic System. Do not turn the throttle stop screw a. Throttle position sensor output voltage at engine idle speed: 0.. V Checking the idle speed control. Check the operation of the idle speed control using the Yamaha Diagnostic System. - DG

57 Intake manifold / Vapor separator Vapor separator 0 SD00 No. Part name Q ty Remarks Vapor separator Bolt M 0 mm Grommet Collar Fuel hose Fuel inlet hose Hose Joint Hose 0 Hose Hose Hose Clamp Clamp Quick connector Clamp Not reusable Plastic tie Not reusable DG -0

58 FUEL Fuel system N m (0. kgf m,. ft Ib). N m (0. kgf m,. ft lb) 0 N m (0. kgf m,. ft Ib) N m (0. kgf m,.0 ft Ib) SD00 No. Part name Q ty Remarks Screw ø mm Gasket Not reusable Float chamber Damper Drain screw O-ring Not reusable Joint screw O-ring Not reusable Fuel hose 0 Fuel cooler Screw ø mm Fuel hose Hose Hose Hose Plastic tie Not reusable - DG

59 Vapor separator N m (0. kgf m,. ft Ib) 0 N m (.0 kgf m,. ft Ib) N m (0. kgf m,. ft Ib) N m (0. kgf m,.0 ft Ib) LT N m (0. kgf m,. ft Ib) 0 SD00 No. Part name Q ty Remarks Cover Pressure regulator Bolt M mm O-ring Not reusable Joint screw O-ring Not reusable Electric fuel pump Grommet Collar 0 Filter Screw ø mm Wiring harness Float Needle valve Pin Not reusable Cap DG -

60 FUEL Fuel system Reducing the fuel pressure. Remove the cap.. Cover the pressure check valve a of the vapor separator with a rag, and then press in the pressure check valve a using a thin screwdriver to release the fuel pressure. CUTION: Do not rotate the quick connector tab past the stopper position a, otherwise it could be damaged. When the fuel hose is disconnected, quickly remove the retainer from the quick connector, otherwise the retainer could be lost.. Disconnect the quick connector from the fuel rail directly. a SD0 WRNING lways 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. Wrap the quick connector with a cloth, and then rotate the quick connector tab to the stopper position a. WRNING SC0 lways reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe. If the fuel pressure is not released, pressurized fuel could spray out. Measuring the fuel pressure. Disconnect the quick connector from the fuel rail. WRNING If the quick connector is removed suddenly, pressurized fuel could spray out. To gradually release the fuel pressure, be sure to remove the quick connector slowly. a SC0 Before disconnecting the quick connector, release the fuel pressure.. Connect fuel pressure gauge adapter B between the quick connector and fuel rail.. Connect the fuel pressure gauge to fuel pressure gauge adapter B. - DG

61 Vapor separator WRNING When connecting the fuel pressure gauge, first cover the connection between the gauge and the adapter with a clean, dry rag to prevent fuel from leaking out. Gently screw in the gauge until it is firmly connected. Fuel pressure gauge adapter B : 00-0 Fuel pressure gauge : Turn the engine start switch to ON, and then measure the fuel pressure within seconds. The fuel pressure decreases seconds after the engine start switch is turned to ON. Fuel pressure (reference data): 00 kpa (.0 kgf/cm,. psi). Measure the fuel pressure seconds after turning the engine start switch to ON. Fuel pressure (reference data): 0 kpa (. kgf/cm,. psi). Start the engine, warm it up for minutes, and then measure the fuel pressure. If below specification, check the high-pressure fuel line and the vapor separator. SD0 Fuel pressure (reference data): 0 kpa (. kgf/cm,. psi) WRNING 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. fter 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, make sure that the drain screw is tightened securely. Checking the pressure regulator. Disconnect the quick connector from the fuel rail. Before disconnecting the quick connector, release the fuel pressure.. Connect fuel pressure gauge adapter B between the quick connector and fuel rail.. Connect the fuel pressure gauge to fuel pressure gauge adapter B. DG -

62 FUEL Fuel system. Disconnect the pressure regulator hose, and then connect the special service tools to the pressure regulator. SD00 WRNING When connecting the fuel pressure gauge, first cover the connection between the gauge and the adapter with a clean, dry rag to prevent fuel from leaking out. Gently screw in the gauge until it is firmly connected. WRNING 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. fter 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, make sure that the drain screw is tightened securely. When the vacuum pressure reaches the specified level, the fuel pressure reduces. Fuel pressure gauge: 00-0 Fuel pressure gauge adapter B: 00-0 Vacuum/pressure pump gauge set: Start the engine and let it idle.. 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. Draining the fuel. Remove the cap.. Cover the pressure check valve a of the vapor separator with a rag, and then press in the pressure check valve a using a thin screwdriver to release the fuel pressure. WRNING lways 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.. Place a container under the vapor separator drain hose, and then loosen the drain screw.. Drain the fuel from the vapor separator drain hose by pressing the pressure check valve using a thin screwdriver. - DG

63 Vapor separator a WRNING SD00 Reduce the fuel pressure before loosening the vapor separator drain screw, or pressurized fuel will spray out and may result in serious injury. Removing the fuel hose clamp. Remove the fuel hose clamp by cutting the crimped section of the clamp. CUTION: If the fuel hose clamp is removed without cutting the crimp first, the fuel hose will be damaged. Installing the fuel hose clamp. Crimp the fuel hose clamp properly to securely fasten it. WRNING Do not reuse the fuel hose clamp, always replace it with a new one. Disassembling the vapor separator. Remove the float chamber, float pin, and float. Remove the float pin in the direction of the arrow a shown.. Remove the needle valve and other components. Checking the vapor separator. Check the needle valve for bends or wear. Replace if necessary. a SC0 SD00 DG -

64 FUEL Fuel system. Check the float for deterioration. Replace if necessary.. Check the filter for dirt or residue. Clean if necessary. ssembling the vapor separator. Install the needle valve, float, and float pin, and then check the float for smooth operation. d SC00 a The float should be resting on the needle valve, but not compressing it. Take measurements at the position shown, opposite the float pivot. b SC0 Float height d:.0 ±.0 mm (. ± 0.0 in) Do not reuse the float pin, always replace it with a new one. Install the float pin in the direction of the arrow a shown. Install the float pin with its tapered end towards the punch mark b on the vapor separator cover.. Install the float chamber. Float chamber screw: N m (0. kgf m,. ft lb) djusting the float. djust the stopper a of the float by bending it until the float height b is within specification.. Check the float height c as shown. djust the float height if out of specification. Float height b:. ±.0 mm (. ± 0.0 in) Float height c:. ±.0 mm (. ± 0.0 in). djust the lever c of the float by bending it until the float height d is within specification.. Check the float height d as shown. djust the float height if out of specification. - DG

65 Vapor separator Float height d:.0 ±.0 mm (. ± 0.0 in) When adjusting the float height, do not bend the lever e. DG -

66 FUEL Fuel system Canister 0 SD0 No. Part name Q ty Remarks Bolt M mm Bracket Canister Bolt M mm Grommet Bracket Collar Hose Hose 0 Hose Filter Hose Clamp Bolt M 0 mm Holder Bolt M mm Bracket - DG

67 Checking the canister. Check the canister for cracks. Replace if necessary.. Connect the special service tool to the atmospheric port and cover the other ports, each with a finger.. pply the specified positive pressure and check that there is no air leakage. Replace the canister if there is air leakage. SD0 Vacuum/pressure pump gauge set: 00-0 Specified pressure:. kpa (0. kgf/cm,. psi) Canister DG -0

68 POWR Power unit Special service tools...- Power unit...- Checking the compression pressure...- Checking the oil pressure...- Checking the valve clearance...-0 Replacing the timing belt...- Removing the power unit...- Removing the timing belt and sprockets...- Checking the timing belt and sprockets...- Installing the sprockets and timing belt...- Throttle link...-0 ECM...- Junction box...- Cylinder head...- Removing the cylinder head...- Checking the valve lifters...- Checking the valve springs...- Checking the valves...- Checking the valve guides...- Replacing the valve guides...- Checking the valve seat...- Refacing the valve seat...-0 Checking the camshafts...- Checking the cylinder head...- Installing the valves...- Installing the cylinder head...- Exhaust cover...- Removing the exhaust cover...- Checking the pressure control valve...- Installing the pressure control valve...- Installing the exhaust cover...- DG

69 Cylinder block...-0 Disassembling the cylinder block...- Checking the piston diameter...- Checking the cylinder bore...- Checking the piston clearance...- Checking the piston rings...- Checking the piston ring grooves...- Checking the piston ring side clearance...- Checking the connecting rod big end side clearance...- Checking the crankshaft...- Checking the crankpin oil clearance...- Selecting the connecting rod bearing...- Checking the crankshaft journal oil clearance...- Selecting the main bearing...- ssembling the power unit...-0 Installing the power unit...- DG

70 POWR Power unit Special service tools Compression gauge Valve spring compressor Compression gauge extension M 00-0 Valve spring compressor attachment Flywheel holder 00-0 Valve guide remover/installer Flywheel puller 00-0 Valve guide reamer Crankshaft holder Valve seat cutter holder DG

71 Special service tools Valve seat cutter 00-0, 00-0, 00-0, 00-0, 00-0, 00-0 Piston slider Oil filter wrench 00-0 DG -

72 POWR Power unit Power unit Checking the compression pressure. Start the engine, warm it up for minutes, and then turn it off.. Remove the engine stop lanyard from the engine stop lanyard switch on the remote control box.. Remove the spark plug wire cover and all spark plugs, and then install the special service tools into a spark plug hole. If the compression pressure increases, check the pistons and piston rings for wear. Replace if necessary. If the compression pressure does not increase, check the valve clearance, valve, valve seat, cylinder head gasket, and cylinder head. djust or replace if necessary. Checking the oil pressure. Remove the flywheel magnet cover.. Place a rag under the oil pressure switch.. Remove the oil pressure switch, and then install an oil pressure gauge to the oil pressure switch installation hole. SD0 CUTION: 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 : Compression gauge extension M : Fully open the throttle, crank the engine until the reading on the compression gauge stabilizes, and then check the compression pressure. Minimum compression pressure (reference data): 0 kpa (. kgf/cm,. psi) Use a general pressure gauge. SD0. Start the engine and warm it up for minutes.. Check the oil pressure. Check the oil pump, oil leakage, and oil strainer if below specification. Oil pressure (reference data): 0 kpa (. kgf/cm,.0 psi) at engine idle speed. 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 pressure again. - DG

73 Power unit 0 LT E LT N m (0. kgf m,.0 ft Ib) N m (. kgf m,.0 ft Ib) N m (. kgf m,.0 ft Ib) SD00 No. Part name Q ty Remarks Damper Grommet Grommet Flywheel magnet cover Power unit Oil dipstick Gasket Not reusable Dowel Bolt M mm 0 Bolt M0 0 mm Screw ø 0 mm Nut pron Bolt M mm Holder DG -

74 POWR Power unit N m (. kgf m,. ft lb) E 0 SD00 No. Part name Q ty Remarks Nut Washer Flywheel magnet Screw ø 0 mm Screw ø 0 mm Stator coil Bolt M 0 mm Stator assembly Collar 0 Bolt M mm Woodruff key Bolt M mm Holder Grommet - DG

75 R R R Power unit N m (. kgf m,. ft lb) F N m (.0 kgf m,. ft Ib) 0 E E E N m (. kgf m,. ft Ib) SD00 No. Part name Q ty Remarks Timing belt Bolt M0 mm Dowel Driven sprocket Bolt M mm Bracket Bolt M0 mm Timing belt tensioner Spring 0 Plastic tie Not reusable Hose Clamp Nut Drive sprocket Plate Woodruff key DG -

76 POWR Power unit N m (0. kgf m,. ft Ib) 0 0 N m (. kgf m,. ft Ib) N m (0. kgf m,.0 ft Ib) N m (0. kgf m,. ft Ib) LT N m (0. kgf m,.0 ft Ib) 0 N m (0. kgf m,. ft Ib) SD00 No. Part name Q ty Remarks Screw ø 0 mm Cover Spark plug wire Holder Holder Bolt M mm Holder Clamp Hose 0 Plastic tie Not reusable Ignition coil Bracket Bolt M mm Holder Starter motor Bolt M mm Terminal - DG

77 Power unit N m (0. kgf m,. ft Ib) N m (0. kgf m,. ft Ib) LT 0 0 N m (. kgf m,. ft Ib) N m (0. kgf m,.0 ft Ib) N m (0. kgf m,.0 ft Ib) 0 N m (0. kgf m,. ft Ib) SD00 No. Part name Q ty Remarks Nut Cap 0 Positive battery lead Nut Negative battery lead Bolt M 0 mm Junction box cover Bolt M 0 mm Cap Oil pressure switch Bolt M mm Holder 0 Bolt M mm Clamp DG -

78 POWR Power unit N m (0. kgf m,. ft lb) N m (. kgf m,. ft lb) S0B N m (0. kgf m,. ft Ib) E S0B E 0 0 E M LT E 0 0 E E E E N m (0. kgf m,. ft lb) N m (. kgf m,. ft lb) N m (0. kgf m,. ft lb) N m (0. kgf m,. ft lb) SD00 No. Part name Q ty Remarks Oil filler cap O-ring Cylinder head cover Screw ø mm Plate Grommet Gasket Not reusable Bolt M 0 mm Camshaft cap 0 Camshaft cap Bolt M mm Bolt M mm Oil seal Not reusable Camshaft - DG

79 Checking the valve clearance CUTION: Do not turn the flywheel magnet counterclockwise, otherwise the valve system may be damaged. Do not remove the ignition timing pointer. Do not turn the flywheel magnet or the driven sprockets when the timing belt is not installed. Otherwise the piston and valves will interfere with each other and be damaged. For removal and installation procedures of the timing belt, driven sprockets, and camshafts, see the applicable procedures in this manual.. Remove the flywheel magnet cover, filter, and spark plug wire cover, disconnect the spark plug wires, fuel hoses, and blowby hose, and then remove all spark plugs.. Turn the flywheel magnet clockwise and align the TDC mark a on the flywheel magnet with the pointer b, and check that marks c and d on the driven sprockets are aligned. SD0 c. Loosen the tensioner bolt, and then remove the spring, timing belt, driven sprockets 0, and cylinder head cover. 0 a d Power unit 0 b SD0 SD0 DG -0

80 POWR Power unit. Install the driven sprockets 0, timing belt, and spring, and then tighten the tensioner bolt. Valve clearance (cold): Intake e: 0.0 ± 0.0 mm (0.00 ± 0.00 in) Exhaust f: 0. ± 0.0 mm (0.0 ± 0.00 in). Turn the flywheel magnet 0 clockwise.. Check the intake valve clearance for cylinders # and #, and the exhaust valve clearance for cylinders # and #. djust if out of specification. 0 SD0. Check the intake valve clearance for cylinders # and #, and the exhaust valve clearance for cylinders # and #. djust if out of specification.. Turn the flywheel magnet clockwise and align the TDC mark on the flywheel magnet with the pointer, and check that the marks on the driven sprockets are aligned.. Loosen the tensioner bolt, and then remove the spring, timing belt, driven sprockets 0, camshaft caps, and camshafts B. IN EX 0 0 # # # # f e B SD0 SD0 Check the valve clearance when the engine is cold. Note the measurement. Do not mix the valve train parts. Keep them organized in their proper groups. 0. Remove the valve lifters from the cylinder head. - DG

81 . Remove the valve shim C from the valve lifter D using a thin screwdriver. C D SD0. Check that the TDC mark a on the flywheel magnet is aligned with the pointer b, and that marks c and d on the driven sprockets are aligned. c Power unit d. Measure the valve shim thickness with a micrometer, and then note the measurement.. Select the necessary valve shim by calculating its thickness with the following formula. Necessary valve shim thickness = Removed valve shim thickness + Measured valve clearance Specified valve clearance Example: If the Removed valve shim thickness is.0 mm, the Measured valve clearance is 0.0 mm and the Specified valve clearance is 0.0 mm, then the necessary valve shim thickness = =.0 mm. Install the necessary valve shim into the valve lifter, and then install the valve lifters into the cylinder head.. Install the camshafts, camshaft caps, driven sprockets, and timing belt, and then tighten the tensioner bolt.. Check the valve clearance. djust if necessary.. Loosen the tensioner bolt, and then remove the timing belt and driven sprockets.. Install the cylinder head cover and driven sprockets. 0. Install the timing belt.. Install the spark plugs, and then connect the spark plug wires, fuel hoses, and blowby hose. Spark plug: N m (. kgf m,. ft lb). Install the spark plug wire cover, filter, and flywheel magnet cover. a Spark plug wire cover screw: N m (0. kgf m,.0 ft lb) b SD00 DG -

82 POWR Power unit Replacing the timing belt CUTION: Do not turn the drive sprocket counterclockwise, otherwise the valve system may be damaged. Do not remove the ignition timing pointer. Do not turn the drive sprocket or the driven sprockets when the timing belt is not installed. Otherwise the piston and valves will interfere with each other and be damaged.. Remove the flywheel magnet cover.. Loosen the flywheel magnet nut. CUTION: To prevent damage to the engine or tools, screw in the puller set bolts evenly and completely so that the puller plate is parallel to the flywheel magnet. pply force to the crankshaft end until the flywheel magnet comes off the tapered portion of the crankshaft. Flywheel puller: 00-0 CUTION: pply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily.. Remove the Woodruff key and stator assembly. Flywheel holder: Remove the flywheel magnet. SD0 Do not loosen the pulser coil screw.. Turn the drive sprocket clockwise and align the hole a on the retaining plate with the projection b on the cylinder block, and check that marks c and d on the driven sprockets are aligned. - DG

83 c d Power unit. Check that marks c and d on the driven sprockets are aligned. c d b a SD0. Disconnect the cooling water hose and remove the bracket.. Remove the spring and timing belt tensioner, and then remove the timing belt from the driven sprockets, then from the drive sprocket. b a SD0 SD0. Check that the hole a on the retaining plate and the projection b on the cylinder block are aligned. DG -

84 POWR Power unit 0. Install a new timing belt onto the drive sprocket with its part number in the upright position, and then install the belt onto the driven sprockets in a counterclockwise direction.. Install the spring. 0 F--00 SD0 SD0. Take up the timing belt slack by turning the drive sprocket clockwise at least two full turns. e. Tighten the timing belt tensioner bolt to the specified torque. Timing belt tensioner bolt: N m (. kgf m,. ft lb) SD0. Turn the drive sprocket two full turns, and then check that the alignment marks are aligned. CUTION: Do not twist, turn inside out, or bend the timing belt beyond the maximum limit of mm (.0 in) otherwise it can be damaged. Do not get oil or grease on the timing belt. The lower edge of the timing belt should be mm (0.0 in) e from the bottom of the driven sprockets.. Install the timing belt tensioner and finger tighten the bolt 0 until the bolt seat contacts the timing belt tensioner.. Loosen the timing belt tensioner bolt 0. SD0. Install the bracket and connect the cooling water hose. - DG

85 Power unit. Install the stator assembly and Woodruff key.. Install the flywheel magnet.. Disconnect the fuel hose and shift position switch coupler.. Disconnect the cooling water pilot hose, canister hose, and flushing hose.. Remove the oil dipstick.. Remove the apron, and then remove the power unit by removing the bolts. CUTION: pply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily. pply engine oil to the flywheel magnet nut before installation. Flywheel holder: 00-0 SD0 Flywheel magnet nut: N m (. kgf m,. ft lb). Remove the flywheel magnet. 0. Install the flywheel magnet cover. Removing the power unit It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency.. Remove the flywheel magnet cover.. Disconnect the battery leads.. Remove the junction box cover, and then disconnect the PTT motor leads and PTT switch coupler.. Disconnect the throttle cable and shift cable. DG -

86 POWR Power unit Removing the timing belt and sprockets CUTION: Do not turn the drive sprocket counterclockwise, otherwise the valve system may be damaged. Do not turn the drive sprocket or the driven sprockets when the timing belt is not installed. Otherwise the piston and valves will interfere with each other and be damaged.. Turn the drive sprocket clockwise and align the hole a on the retaining plate with the projection b on the cylinder block, and check that marks c and d on the driven sprockets are aligned. c d Use a deep socket for this procedure. Do not turn the camshaft when loosening the drive sprocket nut. Crankshaft holder 0 : Disconnect the cooling water hose and remove the bracket.. Remove the spring and timing belt tensioner, and then remove the timing belt from the driven sprockets, then from the drive sprocket.. Loosen the driven sprocket bolts, and then remove the driven sprockets. b a SD0 Do not turn the camshafts when loosening the driven sprocket bolts. SD0 Flywheel holder: Loosen the drive sprocket nut.. Remove the nut, drive sprocket, retaining plate, and Woodruff key. SD0 - DG

87 Power unit pply engine oil to the driven sprocket bolts before installation. Do not turn the camshafts when tightening the driven sprocket bolts. SD0 SD0 Checking the timing belt and sprockets. Check the interior and exterior of the timing belt for cracks, damage, or wear. Replace if necessary.. Check the drive sprocket and driven sprockets for cracks, damage, or wear. Replace if necessary. Installing the sprockets and timing belt. Install the dowels and driven sprockets, and check that marks a and b on the driven sprockets are aligned. Flywheel holder: 00-0 Driven sprocket bolt : 0 N m (.0 kgf m,. ft lb) a b SD0. Tighten the driven sprocket bolts to the specified torque. DG -

88 POWR Power unit. Install the retaining plate, Woodruff key, drive sprocket, and nut, and then tighten the nut.. Tighten the drive sprocket nut to the specified torque. E SD0 Use a deep socket for this procedure. Crankshaft holder 0 : 00-0 S0C0 pply engine oil to the drive sprocket nut before installation. Tighten the drive sprocket nut finger tight. Drive sprocket nut : N m (. kgf m,. ft lb). Check that the hole c on the retaining plate is aligned with the projection d on the cylinder block. d c SD00. Install the timing belt and timing belt tensioner. For timing belt installation procedure, see Replacing the timing belt. - DG

89 Power unit / Throttle link Throttle link 0 SD0 No. Part name Q ty Remarks Throttle cam Bolt M mm Collar Wave washer Washer Spring Washer Throttle lever Bolt M mm 0 Collar Throttle link rod Nut Throttle link rod joint Bracket Bolt M 0 mm DG -0

90 POWR Power unit ECM 0 SD00 No. Part name Q ty Remarks Wiring harness Bracket Bolt M mm Bolt M mm Bracket Bracket Bracket Bolt M 0 mm Collar 0 Grommet Bolt M 0 mm ECM Rectifier Regulator Bolt M mm Bolt M 0 mm Bracket Bolt M 0 mm - DG

91 ECM / Junction box Junction box 0 N m (0. kgf m,. ft Ib) 0 N m (0. kgf m,.0 ft Ib) N m (0. kgf m,. ft Ib) N m (0. kgf m,.0 ft Ib) N m (0. kgf m,.0 ft Ib) SD00 No. Part name Q ty Remarks Screw ø mm Main and fuel pump relay Power trim and tilt relay Washer Nut Cap Bolt M 0 mm Ground lead Fuse 0 0 Fuse 0 Cap Cap Starter relay Holder Screw ø 0 mm Bolt M 0 mm Cap DG -

92 POWR Power unit 0 N m (0. kgf m,. ft Ib) 0 N m (0. kgf m,.0 ft Ib) N m (0. kgf m,. ft Ib) N m (0. kgf m,.0 ft Ib) N m (0. kgf m,.0 ft Ib) SD00 No. Part name Q ty Remarks Holder Junction box 0 Collar Grommet Bolt M 0 mm Clamp Grommet - DG

93 Junction box / Cylinder head Cylinder head N m (. kgf m,. ft lb) 0 N m (.0 kgf m,. ft lb) 0 E E 0 N m (. kgf m,. ft Ib) LT 0 E 0 E E N m (. kgf m, 0. ft lb) N m (. kgf m, 0. ft lb) E E E SD00 No. Part name Q ty Remarks Cylinder head Exhaust valve Intake valve Gasket Not reusable Collar Bolt M mm Bolt M mm Cover Thermostat 0 Bolt 0 M0 mm Spark plug Bolt M 0 mm Bolt M mm node cover node Grommet Valve shim DG -

94 POWR Power unit N m (. kgf m,. ft lb) 0 N m (.0 kgf m,. ft lb) 0 E E 0 N m (. kgf m,. ft Ib) LT 0 E 0 E E N m (. kgf m, 0. ft lb) N m (. kgf m, 0. ft lb) E E E SD00 No. Part name Q ty Remarks Valve lifter Valve cotter 0 Valve spring retainer Valve spring Valve spring seat Valve seal Not reusable Valve guide Not reusable - DG

95 Removing the cylinder head. Remove the cylinder head cover.. Remove camshaft caps and in the sequence shown.. Remove the camshaft (intake), camshaft (exhaust), and oil seals. SD0 Cylinder head Do not mix the valve train parts. Keep them organized in their proper groups.. Remove the cylinder head bolts in the sequence shown. SD0 CUTION: Do not scratch or damage the mating surfaces of the cylinder head and cylinder block. SD0. Remove the valve shims from the valve lifters. S0C0 DG -

96 POWR Power unit. Remove the intake and exhaust valves. Valve spring free length a:.0 mm (.0 in). Measure the valve spring tilt b. Replace if above specification. Valve spring tilt limit b:. mm (0.0 in) Be sure to keep the valves, springs, and other parts in the order as they were removed. Valve spring compressor : Valve spring compressor attachment : Checking the valves. Check the valve face for pitting or wear. Replace if necessary.. Measure the valve margin thickness a. Replace if out of specification. Checking the valve lifters. Check the valve lifters for damage, scratches, or wear. Replace if necessary. Checking the valve springs. Measure the valve spring free length a. Replace if below specification. Valve margin thickness a: Intake: mm ( in) Exhaust:.00.0 mm ( in). Measure the valve stem diameter b. Replace if out of specification. - DG

97 Cylinder head Valve stem diameter b: Intake:..0 mm (0. 0. in) Exhaust:.0. mm (0. 0. in). Measure the valve stem runout. Replace if above specification. Valve stem runout limit: 0.0 mm (0.000 in) Checking the valve guides Before checking the valve guide make sure that the valve stem diameter is within specification.. Measure the valve guide inside diameter a. a Valve guide inside diameter a: Intake and exhaust: mm (0. 0. in). 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: mm ( in) Exhaust: mm ( in) Replacing the valve guides. Remove the valve guide by striking the special service tool from the combustion chamber side. Valve guide remover/installer.: S0C0 DG -

98 POWR Power unit. Install the new valve guide by striking the special tool from the camshaft side to the specified position a.. Measure the valve guide inside diameter. Valve guide inside diameter: Intake and exhaust: mm (0. 0. in) Checking the valve seat. Eliminate carbon deposits from the valve with a scraper.. pply a thin, even layer of Mechanic s blueing dye (Dykem) onto the valve seat. Before installing the valve guide, mark its installation position b as shown. pply engine oil to the surface of the new valve guide.. Lap the valve slowly on the valve seat with a valve lapper (commercially available) as shown. Valve guide remover/installer.: Valve guide position a:. ± 0. mm (0. ± 0.0 in). Insert the special service tool into the valve guide, and then ream the valve guide.. 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. Turn the valve guide reamer clockwise to ream the valve guide. Do not turn the reamer counterclockwise when removing the reamer. Valve guide reamer.0: DG

99 Cylinder head SP0 Valve seat contact width a:.0.0 mm ( in) Refacing the valve seat. Reface the valve seat with the valve seat cutters. a Slag or rough surface CUTION: Do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pressure of 0 0 N ( kgf,. lbf) to prevent chatter marks.. Use a 0 cutter to adjust the contact width of the top edge of the valve seat. Valve seat cutter holder: 00-0 Valve seat cutter: 0 (intake): (exhaust): 00-0 (intake): 00-0 (exhaust): (intake): (exhaust): 00-0 b b Previous contact width 0 SJ0. Cut the surface of the valve seat with a cutter by turning the cutter clockwise until the valve seat face has become smooth. DG -0

100 POWR Power unit. Use a 0 cutter to adjust the contact width of the bottom edge of the valve seat. b. If the valve seat contact area is too narrow and situated near the top edge of the valve face, use a 0 cutter to cut the top edge of the valve seat. If necessary, use a cutter to center the area and set its width. 0 b Previous contact width SJ0. Use a cutter to adjust the contact width of the valve seat to specification. b c b Previous contact width. If the valve seat contact area is too narrow and situated near the bottom edge of the valve face, use a 0 cutter to cut the bottom edge of the valve seat. If necessary, use a cutter to center the area and set its width. b Previous contact width c Specified contact width SJ00. If the valve seat contact area is too wide and situated in the center of the valve face, use a 0 cutter to cut the top edge of the valve seat, a 0 cutter to cut the bottom edge to center the area and set its width. b Previous contact width. pply a thin, even layer of lapping compound onto the valve seat, and then lap the valve using a valve lapper (commercially available). b Previous contact width - DG

101 Cylinder head CUTION: Do not get the lapping compound on the valve stem and valve guide. 0. fter every lapping procedure, be sure to clean off any remaining lapping compound from the cylinder head and the valve.. Check the valve seat contact area of the valve again. Checking the camshafts. Measure the cam lobe. Replace if out of specification. Cam lobe a: Intake:.. mm (..0 in) Exhaust:.0.0 mm (.. in) Cam lobe b: Intake:. 0.0 mm (.. in) Exhaust:. 0.0 mm (.0. in). Measure the camshaft runout. Replace if above specification. Camshaft runout limit: 0.0 mm (0.00 in). Measure the camshaft journal diameter c and cylinder head journal inside diameter d. Replace the camshaft and cylinder head if out of specification. d SD0 Camshaft journal diameter c:.0.0 mm (0. 0. in) Camshaft cap inside diameter d: mm (0. 0. in) SJ0 Checking the cylinder head. Eliminate carbon deposits from the combustion chambers and check for deterioration. c DG -

102 POWR Power unit. Check the cylinder head warpage using a straightedge and thickness gauge in the directions shown. Replace if above specification. SD0 The valve spring can be installed in any direction. Cylinder head warpage limit: 0. mm (0.00 in) SD0 Installing the valves. Install a new valve seal onto the valve guide. Valve spring compressor : Valve spring compressor attachment : Compress the valve spring, and then install the valve cotters using a thin screwdriver with a small amount of grease applied to it. E S0C0. Install the valve, valve spring seat, valve spring, and valve spring retainer in the sequence shown, and then attach the special service tools. - DG

103 Cylinder head a 0 S0C0. Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters securely. S0C0 Installing the cylinder head. Check that the piston of cylinder # is at TDC. CUTION: Do not reuse the cylinder head gasket, always replace it with a new one. pply engine oil to the cylinder head bolts before installation. Tighten the M0 bolts to the specified torques in two stages first, and then tighten the M bolts to N m (. kgf m, 0. ft lb). Make a mark a on the M0 bolts and the cylinder head, and then tighten the bolts 0 from the mark. Tighten the M bolts to N m (. kgf m, 0. ft lb). E SD0. Install a new gasket and the cylinder head, and then tighten the bolts to the specified torques in the sequence shown. Cylinder head bolt (M0): st: N m (. kgf m,. ft lb) nd: 0 N m (.0 kgf m,. ft lb) rd: 0 Cylinder head bolt (M): st: N m (. kgf m, 0. ft lb) nd: N m (. kgf m, 0. ft lb) DG -

104 POWR Power unit. Install the valve shims and valve lifters. pply engine oil to the valve shims and valve lifters before installation. Install the valve shims and valve lifters in their original positions.. Install the camshaft caps in their proper positions as shown with the stamped numbers upside down.. Tighten the camshaft cap bolts to the specified torques in two stages and in the sequence shown.. Install the camshaft (intake) and camshaft (exhaust) with the new oil seals. M S0B E M E b 0 0 SD0 E SD0 pply engine oil to the camshaft caps and camshaft cap bolts before installation. pply molybdenum disulfide grease to the cam lobes. Be sure to install the camshaft with the fuel pump drive cam b on the intake side. Camshaft cap bolt: st: N m (0. kgf m,. ft lb) nd: N m (. kgf m,. ft lb). Install the cylinder head cover.. Check that the camshaft dowel holes c are in the position shown in the illustration. djust if necessary. c SD00 - DG

105 Cylinder head S0B SD0 Cylinder head cover bolt: st: N m (0. kgf m,. ft lb) nd: N m (0. kgf m,. ft lb). Install the sprockets and timing belt. For sprocket and timing belt installation procedures, see Installing the sprockets and timing belt. DG -

106 POWR Power unit Exhaust cover E N m (. kgf m,. ft Ib) N m (. kgf m,. ft Ib) N m (. kgf m,.0 ft Ib) 0 N m (0. kgf m,. ft Ib) N m (. kgf m, 0. ft Ib) LT E N m (0. kgf m,. ft lb) N m (. kgf m,. ft lb) LT 0 LT 0 SD00 No. Part name Q ty Remarks Gasket Not reusable Screw ø mm node Exhaust cover Gasket Not reusable Cooling water temperature sensor Holder Bolt M mm Holder 0 Bolt M 0 mm Gasket Not reusable Grommet Pressure control valve Spring Cover Bolt M 0 mm Gasket Not reusable - DG

107 Exhaust cover N m (. kgf m,. ft Ib) E N m (. kgf m,. ft Ib) N m (. kgf m,.0 ft Ib) 0 N m (0. kgf m,. ft Ib) N m (. kgf m, 0. ft Ib) LT E N m (0. kgf m,. ft lb) N m (. kgf m,. ft lb) LT 0 LT 0 SD00 No. Part name Q ty Remarks Plug M mm Grommet 0 node Cover Bolt M mm Bolt M 0 mm Bolt M 0 mm Joint Oil filter Gasket Not reusable Plug M mm Plastic tie Not reusable 0 Hose DG -

108 POWR Power unit Removing the exhaust cover. Remove the exhaust cover bolts in the sequence shown. Installing the exhaust cover. Install a new gasket and the exhaust cover.. Install the bolts, and then tighten them to the specified torques in two stages and in the sequence shown. E SD0. Remove the exhaust cover. Checking the pressure control valve. Remove the pressure control valve.. Check the pressure control valve for wear or damage. Replace if necessary. SD0 pply engine oil to the exhaust cover bolts before installation.. Check the grommet for deformation. Replace if necessary.. Check the spring for fatigue or deformation. Replace if necessary. Installing the pressure control valve. Install a new gasket and the pressure control valve, and then tighten the bolts. Exhaust cover bolt: st: N m (0. kgf m,. ft lb) nd: N m (. kgf m,. ft lb) SD0 - DG

109 Exhaust cover / Cylinder block Cylinder block N m (. kgf m,.0 ft lb) 0 0 E E E E E S E E UP N m (. kgf m, 0. ft lb) N m (. kgf m, 0. ft lb) WR-No. E N m (. kgf m,. ft lb) 0 SD00 No. Part name Q ty Remarks Bolt M 0 mm Dowel 0 Bolt 0 M0 mm Crankcase Bolt 0 M mm Cylinder block Main bearing Main bearing Main bearing 0 Oil seal Not reusable Crankshaft Oil seal Not reusable Connecting rod bearing Piston/connecting rod assembly Bolt Not reusable M mm Piston ring set Stud bolt DG -0

110 POWR Power unit Disassembling the cylinder block. Place a rag under the oil filter, and then remove the filter using the oil filter wrench. Be sure to clean up any oil spills. Oil filter wrench : Remove the crankcase bolts in the sequence shown, and then remove the crankcase. 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. Do not mix the connecting rods and caps. Keep them organized in their proper groups. Checking the piston diameter. Measure the piston outside diameter at the specified measuring point. Replace if out of specification. SD0 Do not remove the ignition timing pointer from the crankcase.. Remove the connecting rod bolts and the connecting rod caps, and then remove the crankshaft, oil seals, and the piston assemblies. Piston diameter a:.. mm (.0.0 in) Measuring point b:.0 mm (0. in) up from the bottom of the piston skirt Oversize piston diameter:.. mm (.. in) - DG

111 Checking the cylinder bore. Measure the cylinder bore (D D ) at measuring points a, b, and c, and in direction d (D, D, D ), which is parallel to the crankshaft, and direction e (D, D, D ), which is at a right angle to the crankshaft. D D c b a d Piston clearance: mm ( in) Cylinder block Checking the piston rings. Check the piston ring dimensions of B and T. Replace if out of specification. D D D D e a 0 mm (0. in) b 0 mm (.0 in) c 0 mm (. in) Cylinder bore (D D ): mm (.0.0 in). Calculate the taper limit. Replace or rebore the cylinder block if above specification. Taper limit: D D (direction d) D D (direction e) 0.0 mm (0.00 in). Calculate the out-of-round limit. Replace or rebore the cylinder block if above specification. Out-of-round limit: D D (measuring point a) D D (measuring point c) 0.0 mm (0.000 in) S0C0 Checking the piston clearance. Calculate the piston clearance using the piston outside diameter and the cylinder bore. Replace the piston and piston rings as a set or the cylinder block or all parts, or rebore the cylinder if out of specification. Piston ring dimensions: Top ring a: B:.. mm ( in) T:.0.00 mm ( in) Second ring b: B:.. mm ( in) T:.00.0 mm ( in) Oil ring c: B:.. mm ( in) T (reference data):.0 mm (0.0 in). Level the piston ring in the cylinder with a piston crown. DG -

112 POWR Power unit. Check the piston ring end gap d at the specified measuring point. Replace if out of specification. Piston ring groove: Top ring a:.. mm ( in) Second ring b:.. mm ( in) Oil ring c:.. mm ( in) Checking the piston ring side clearance. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. a Piston ring end gap d: Top ring: mm ( in) Second ring: mm ( in) Oil ring: mm ( in) Measuring point e: 0 mm (0. in) Checking the piston ring grooves. Measure the piston ring grooves. Replace the piston if out of specification. a b c SP0 Piston ring side clearance: Top ring a: mm ( in) Second ring b: mm ( in) Oil ring c: mm ( in) SP0 Checking the connecting rod big end side clearance. Measure the connecting rod big end side clearance a. Replace the connecting rod or crankshaft or both if out of specification. b c - DG

113 Cylinder block Connecting rod big end side clearance a: mm ( in) Checking the crankshaft. Measure the crankshaft journal diameter a, crankpin diameter b, and crankpin width c. Replace the crankshaft if out of specification. Crankshaft journal diameter a:..000 mm (.. in) Crankpin diameter b:..000 mm (.. in) Crankpin width c:.00.0 mm (0. 0. in). Measure the crankshaft runout. Replace the crankshaft if above specification. SD0 Crankshaft runout limit: 0.0 mm (0.00 in) Checking the crankpin oil clearance. Clean the bearings and the connecting rod. DG -

114 POWR Power unit. Install the upper bearing into the connecting rod and the lower bearing into the connecting rod cap. a S0C0 Install the bearings in their original positions.. Put a piece of Plastigauge (PG-) onto the crankpin, parallel to the crankshaft. S0C0 Make sure that the large, flat side a on the connecting rod faces towards the flywheel magnet side of the crankshaft.. Tighten the connecting rod bolts to the specified torques in two stages. Be sure not to put the Plastigauge (PG-) over the oil hole in the crankpin of the crankshaft.. Install the connecting rod to the crankpin. Reuse the removed connecting rod bolts. Do not turn the connecting rod until the crankpin oil clearance measurement has been completed. Connecting rod bolt: st: N m (. kgf m,. ft lb) nd: 0 - DG

115 . Remove the connecting rod cap and measure the width of the compressed Plastigauge (PG-) on each crankpin. Replace the connecting rod bearing if out of specification. Crankpin oil clearance: mm ( in) Selecting the connecting rod bearing Use a metric gauge in this procedure.. When replacing the connecting rod bearing, select the suitable bearing as follows.. Measure the connecting rod big end inside diameter a. a Reuse the removed connecting rod bolts. Connecting rod big end inside diameter a:.0.0 mm S0C0. Check the crankpin mark on the crankshaft. (#) (#) Cylinder block (#) (#) SD0. Subtract the crankpin diameters (# #) from the connecting rod big end inside diameters (# #). The crankpin diameters (# #) can be determined by the stamped value as described below. Crankpin diameter =.00 + (stamped value/,000) Example: # =. DG -

116 POWR Power unit. Select the suitable color b for the connecting rod bearing from the table below according to the calculated values. b Checking the crankshaft journal oil clearance. Clean the bearings, the crankshaft journals, the bearing portions of the crankcase, and the cylinder block.. Place the cylinder block upside down on a bench.. Install half of the bearings and the crankshaft into the cylinder block. Connecting rod bearing selection table (0 C [ F]) Connecting rod big end inside diameters crankpin diameters (mm) Upper bearing Lower bearing.0.0 Yellow Yellow.0.0 Yellow Green*.0.0 Green Green.0.0 Green Blue*.00.0 Blue Blue.0.0 Blue Red* CUTION: The (*) mark indicates that the colors of the upper and lower bearings are different. Example: If the Connecting rod big end inside diameter a is.00 mm and the Crankpin mark is, then the Calculated value =.00. =.0 mm Suitable colors: Upper bearing blue Lower bearing red. If the calculated value is more than the maximum value (.0 mm), replace the connecting rod or crankshaft or both. b SD0 a S0C0 Install the bearings in their original positions. Install the unified thrust bearing at the position a shown.. Put a piece of Plastigauge (PG-) on each crankshaft journal parallel to the crankshaft. Do not put the Plastigauge (PG-) over the oil hole in the main journals of the crankshaft. - DG

117 . Install the remaining half of the bearings into the crankcase.. Install the crankcase onto the cylinder block and apply engine oil onto the threads of the crankcase bolts.. Tighten the crankcase bolts to the specified torques in two stages and in the sequence shown. Cylinder block. Remove the crankcase, and then measure the width of the compressed Plastigauge (PG-) on each crankshaft journal. Replace the main bearing if out of specification. b 0 E Crankshaft journal oil clearance: mm ( in) Selecting the main bearing. When replacing the main bearing, select the suitable bearing as follows. SD00 Do not move the crankshaft until the crankshaft journal oil clearance measurement has been completed. Tighten the M0 bolts to N m (. kgf m,.0 ft lb) first, and then tighten the M bolts to N m (. kgf m, 0. ft lb). Make a mark b on the M0 bolts and the crankcase, and then tighten the bolts 0 from the mark. Tighten the M bolts to N m (. kgf m, 0. ft lb). Crankcase bolt (M0): st: N m (. kgf m,.0 ft lb) nd: 0 Crankcase bolt (M): st: N m (. kgf m, 0. ft lb) nd: N m (. kgf m, 0. ft lb) DG -

118 POWR Power unit. Check the crankshaft journal mark on the crankshaft and the cylinder block mark on the cylinder block. a (#) (#) (#) (#) (#) a SD0 # # # # # S0C0 S0C0. Subtract crankshaft journal diameters # # from cylinder block journal inside diameters # #. Cylinder block journal inside diameters (# #) and crankshaft journal diameters (# #) can be determined by the stamped value as described below. Crankshaft journal diameter =.00 + (stamped value/,000) Example: # =. Cylinder block journal inside diameter = (stamped value/,000) Example: # =.0. Select the suitable color a for the main bearing from the table below according to the calculated values. Main bearing selection table (0 C [ F]) Cylinder block journal inside diameters crankshaft journal diameters (mm) Bearing (cylinder side)/thrust bearing CUTION: The (*) mark indicates that the colors of the upper and lower bearings are different. Be sure to install the main bearings in the middle of the cylinder block and crankcase journal so they do not block the oil holes. Main bearing # is a thrust bearing. Bearing (crankcase side).0.0 Green Yellow*.0.0 Blue Green*.0.0 Blue Blue.0.0 Red Blue*.00.0 Red Red Example: If the Crankshaft journal mark is, and the Cylinder block mark is, then the Calculated value =.0. =.00 mm Suitable colors: Bearing (cylinder side)/thrust bearing blue Bearing (crankcase side) blue. If the calculated value is more than the maximum value (.0 mm), replace the crankshaft. - DG

119 ssembling the power unit. Install the oil ring, second ring, and top ring onto the pistons with the T marks a on the piston rings facing upward.. Offset the piston ring end gaps as shown. a # UP # Cylinder block Install the bearings in their original positions.. Install the piston with the UP mark on the piston crown facing towards the flywheel magnet. # # #,# # E # # # a S0C0 pply engine oil to the side of the pistons and piston rings before installation. S0C0 CUTION: Do not scratch the piston or break the piston rings. fter installing the piston rings, check that they move smoothly.. Install the upper bearing into the connecting rod and the lower bearing into the connecting rod cap. Piston slider: Install half of the bearings into the cylinder block. b S0CB0 E Install the bearings in their original positions. Install the unified thrust bearing at the position b shown. S0C0 DG -0

120 POWR Power unit. Set the crankshaft and oil seals and 0 into the cylinder block as shown. Make sure that the large, flat side c of the connecting rod faces towards the flywheel magnet side of the crankshaft. pply engine oil to the connecting rod caps and connecting rod bolts before installation. 0 Connecting rod bolt : st: N m (. kgf m,. ft lb) nd: 0. Install half of the bearings B into the crankcase.. pply sealant to the mating surface of the crankcase. SD00. Install the connecting rod cap to the connecting rod, and then tighten the new connecting rod bolts to the specified torques in two stages. B GM S c E E SD0 E Install the bearings in their original positions. Do not get any sealant on the main bearings. 0. Install the crankcase onto the cylinder block and apply engine oil onto the threads of the crankcase bolts. S0CB0 CUTION: Do not reuse the connecting rod bolts, always replace them with new ones.. Tighten the crankcase bolts to the specified torques in two stages and in the sequence shown. - DG

121 Cylinder block d 0 E Installing the power unit. Clean the power unit mating surface, and install the dowels and a new gasket.. Install the power unit by installing bolts and, then tightening them to the specified torques in two stages and in the sequence shown.. Install the apron. CUTION: The oil seals must be installed before tightening the crankcase bolts. Tighten the M0 bolts to N m (. kgf m,.0 ft lb) first, and then tighten the M bolts to N m (. kgf m, 0. ft lb). Make a mark d on the M0 bolts and the crankcase, and then tighten the bolts 0 from the mark. Tighten the M bolts to N m (. kgf m, 0. ft lb). Crankcase bolt (M0): st: N m (. kgf m,.0 ft lb) nd: 0 Crankcase bolt (M): st: N m (. kgf m, 0. ft lb) nd: N m (. kgf m, 0. ft lb). Install the cylinder head. SD0 For cylinder head installation procedure, see Installing the cylinder head.. Install all parts removed during disassembly. LT Power unit mounting bolt : st: N m (. kgf m,.0 ft lb) nd: N m (. kgf m,.0 ft lb) pron screw: N m (0. kgf m,.0 ft lb). Install the oil dipstick. LT SD0 SD0. Connect the flushing hose, cooling water pilot hose, and canister hose. DG -

122 POWR Power unit. Connect the fuel hose and shift position switch coupler.. Connect the PTT motor leads and PTT switch coupler, and then install the junction box cover. PTT motor lead bolt: N m (0. kgf m,.0 ft lb). Connect the battery leads. Positive battery lead nut: N m (0. kgf m,. ft lb). Connect the shift cable and throttle cable, and then adjust their lengths. For adjustment procedures, see Chapter, djusting the throttle link and throttle cable and Checking the gear shift operation. 0. Install all parts removed during disassembly.. Check the engine oil level. a b S0C0 If the engine oil is below the minimum level mark b, add sufficient oil until the level is between a and b. Recommended engine oil: -stroke motor oil PI: SE, SF, SG, SH, or SJ SE: 0W-0 or 0W-0 - DG

123 LOWR Lower unit Special service tools...- Lower unit...- Removing the lower unit...- Removing the water pump and shift rod...- Disassembling the oil seal housing...- Checking the water pump and shift rod...- Propeller shaft housing...-0 Removing the propeller shaft housing assembly...- Disassembling the propeller shaft assembly...- Disassembling the propeller shaft housing...- Checking the propeller shaft housing...- Checking the propeller shaft...- ssembling the propeller shaft assembly...- ssembling the propeller shaft housing...- Drive shaft and lower case...- Removing the drive shaft...- Disassembling the drive shaft...- Disassembling the forward gear...- Disassembling the lower case...- Checking the pinion and forward gear...- Checking the bearings...- Checking the drive shaft...- Checking the lower case...- ssembling the lower case...- ssembling the forward gear...- ssembling the drive shaft...-0 Installing the drive shaft...-0 Installing the propeller shaft housing...-0 Installing the water pump and shift rod...- Installing the lower unit...- Shimming...- Shimming...- Selecting the pinion shims...- Selecting the forward gear shims...- Backlash...- Measuring the forward gear backlash...- DG

124 LOWR Lower unit Special service tools Ring nut wrench 00-0 Bearing separator 00-0 Ring nut wrench extension 00-0 Stopper guide stand 00-0 Bearing housing puller claw L Bearing puller assembly 00-0 Stopper guide plate Needle bearing attachment 00-00, 00-0, 00-0, 00-0 Center bolt Driver rod L DG

125 Special service tools Driver rod SS Bearing depth plate Driver rod LS Ball bearing attachment 00-0 Bearing inner race attachment 00-0, 00-0, 00-0 Drive shaft holder 00-0 Pinion nut holder New: 00-0 Current: Bearing outer race puller assembly 00-0 Driver rod SL Bearing outer race attachment 00-0, 00-0 DG -

126 LOWR Lower unit Driver rod LL Backlash indicator Shift rod push arm Magnet base plate Pinion height gauge Dial gauge set 00-0 Digital caliper Magnetic base B 00-0 Shimming plate DG

127 Special service tools / Lower unit Lower unit No. Part name Q ty Remarks Lower unit Hose Check screw Gasket Not reusable Dowel Bolt M0 0 mm/l-transom model Drain screw Grommet Bolt M0 mm 0 Bolt M 0 mm/l-transom model Spacer Propeller Washer Washer Cotter pin Not reusable Nut Trim tab DG -

128 LOWR Lower unit No. Part name Q ty Remarks Dowel X-transom model Extension X-transom model 0 Stud bolt M0 0 mm/x-transom model Washer X-transom model Spring washer X-transom model Nut X-transom model Bolt M 0 mm/x-transom model - DG

129 Lower unit No. Part name Q ty Remarks Bolt M mm O-ring Not reusable Oil seal Not reusable Oil seal housing O-ring Not reusable Circlip Shift rod Woodruff key Screw ø mm 0 Bolt M mm Cover Bolt M 0 mm Seal Water pump housing Insert cartridge Impeller Dowel DG -

130 LOWR Lower unit No. Part name Q ty Remarks Gasket Not reusable Outer plate cartridge 0 Gasket Not reusable Oil seal housing O-ring Not reusable Gasket Not reusable Oil seal Not reusable - DG

131 Lower unit Removing the lower unit. Drain the gear oil.. 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. WRNING Do not hold the propeller with your hands when loosening or tightening it. Be sure to disconnect the battery leads from the battery and the clip from the engine stop lanyard switch. Put a block of wood between the anticavitation plate and propeller to keep the propeller from turning.. Disconnect the speedometer hose.. Mark the trim tab at the area shown, and then remove it.. Loosen the bolts (nuts), and then remove the lower unit from the upper case. È X-transom model SD00 DG -

132 LOWR Lower unit Removing the water pump and shift rod. Remove the water pump housing and impeller.. Remove the Woodruff key.. Remove the outer plate cartridge and oil seal housing.. Remove the shift rod assembly. Checking the water pump and shift rod. Check the water pump housing for deformation. Replace if necessary.. Check the impeller and insert cartridge for cracks or wear. Replace if necessary.. Check the Woodruff key and the groove a on the drive shaft for wear. Replace if necessary. a SD00. Check the shift rod for cracks or wear. Replace if necessary. b a S0C0 Pull up the shift rod assembly a little a to disconnect it from the shift slider, turn it clockwise 0 b, and then remove it. Disassembling the oil seal housing. Remove the oil seals using a flat head screw driver. - DG

133 Lower unit / Propeller shaft housing Propeller shaft housing No. Part name Q ty Remarks Slider Shift plunger Cross pin Dog clutch Spring Propeller shaft Washer Reverse gear Thrust washer 0 Ball bearing Not reusable O-ring Not reusable Propeller shaft housing Straight key Needle bearing Oil seal Not reusable Claw washer Ring nut DG -0

134 LOWR Lower unit Removing the propeller shaft housing assembly. Straighten the claw washer tabs a, and then remove the ring nut and claw washer. Disassembling the propeller shaft assembly. Remove the spring, and then remove the cross pin, dog clutch, slider and shift plunger. Ring nut wrench : 00-0 Ring nut wrench extension : Pull out the propeller shaft housing assembly. Disassembling the propeller shaft housing. Remove the reverse gear and thrust washer. Bearing housing puller claw L : Stopper guide plate : Center bolt : Remove the propeller shaft assembly. Bearing separator : 00-0 Stopper guide plate : Stopper guide stand : 00-0 Bearing puller assembly : Remove the ball bearing. - DG

135 Propeller shaft housing CUTION: Do not reuse the bearing, always replace it with a new one. Stopper guide plate : Stopper guide stand : 00-0 Bearing puller assembly : Remove the oil seals and needle bearing. Needle bearing attachment : 00-0 Driver rod L : 00-0 Checking the propeller shaft housing. Clean the propeller shaft housing using a soft brush and cleaning solvent, and then check it for cracks. Replace if necessary.. Check the teeth and dogs of the reverse gear for cracks or wear. Replace the gear if necessary.. Check the bearings for pitting or rumbling. Replace if necessary. Checking the propeller shaft. Check the propeller shaft for bends or wear. Replace if necessary.. Measure the propeller shaft runout. Runout limit: 0.0 mm (0.000 in). Check the dog clutch and slider for cracks or wear. Replace if necessary. ssembling the propeller shaft assembly. Install the dog clutch as shown. SD0 Install the dog clutch with the F mark a facing toward the slider. DG -

136 LOWR Lower unit ssembling the propeller shaft housing. Install the needle bearing into the propeller shaft housing to the specified depth. Ball bearing attachment : 00-0 Driver rod LS : Depth d:.0 ± 0. mm (0.0 ± 0.0 in). Install the thrust washer and new ball bearing to the reverse gear using a press. 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 tool in a manner that will force the stopper c out of place. Driver rod SS : Needle bearing attachment : 00-0 Bearing depth plate : Depth b:. ± 0. mm (0. ± 0.0 in). pply grease to the new oil seals, and then install them into the propeller shaft housing to the specified depth. Install the ball bearing with the manufacture identification mark e facing outward (propeller side). Bearing inner race attachment : Install the reverse gear assembly into the propeller shaft housing using a press. Install an oil seal halfway into the propeller shaft housing, then the other oil seal. - DG

137 Propeller shaft housing Bearing inner race attachment 0: 00-0 DG -

138 LOWR Lower unit Drive shaft and lower case No. Part name Q ty Remarks Drive shaft Taper roller bearing Not reusable Pinion shim Sleeve Hose Plastic tie Not reusable Joint Nut Cooling water inlet cover 0 Screw ø 0 mm Seal Plate Forward gear shim Taper roller bearing Not reusable Needle bearing Not reusable Forward gear assembly Needle bearing - DG

139 Drive shaft and lower case No. Part name Q ty Remarks Pinion Nut 0 Lower case DG -

140 LOWR Lower unit Removing the drive shaft. Remove the drive shaft assembly and pinion, and then pull out the forward gear. Disassembling the drive shaft. Install the pinion nut, tighten it finger tight, and then remove the drive shaft bearing using a press. SS0J Drive shaft holder : 00-0 Pinion nut holder : New: 00-0 Current: CUTION: Do not reuse the bearing, always replace it with a new one. Bearing separator : Remove the needle bearing from the forward gear. SS0 CUTION: Do not press the drive shaft threads a directly. When removing the drive shaft bearing, do not damage the drive shaft collar. Do not reuse the bearing, always replace it with a new one. CUTION: Do not reuse the bearing, always replace it with a new one. Disassembling the lower case. Remove the taper roller bearing outer race and shim(s). Bearing inner race attachment : 00-0 Disassembling the forward gear. Remove the taper roller bearing from the forward gear using a press. - DG

141 Install the claws as shown. Bearing outer race puller assembly : Remove the drive shaft bearing outer race, shim(s), and drive shaft sleeve. Install the claws as shown. Stopper guide plate : Stopper guide stand : 00-0 Bearing puller assembly : Remove the needle bearing. Needle bearing attachment : 00-0 Driver rod L : 00-0 Drive shaft and lower case Checking the pinion and forward gear. Check the teeth of the pinion, and the teeth and dogs of the forward gear for cracks or wear. Replace if necessary. Checking the bearings. Check the bearings for pitting or rumbling. Replace if necessary. Checking the drive shaft. Check the drive shaft for bends or wear. Replace if necessary.. Measure the drive shaft runout. Runout limit: 0. mm (0.00 in) SD0 Checking the lower case. Check the skeg and torpedo for cracks or damage. Replace the lower case if necessary. DG -

142 LOWR Lower unit ssembling the lower case. Install the needle bearing into the lower case to the specified depth. CUTION: dd or remove shim(s), if necessary, if replacing the taper roller bearing or lower case. pply the gear oil to the inside and outside of the sleeve before installation. Install the sleeve by facing the projection d forward. Install the needle bearing with the manufacture identification mark a facing upward. When using the driver rod, do not strike the special tool in a manner that will force the stopper b out of place. Bearing outer race attachment : 00-0 Driver rod LL : Install the original shim(s) and taper roller bearing outer race. Driver rod SL : Needle bearing attachment : 00-0 Bearing depth plate : Depth c:. ± 0. mm (. ± 0.0 in). Install the sleeve, original shim(s), and taper roller bearing outer race. CUTION: dd or remove shim(s), if necessary, if replacing the taper roller bearing or lower case. Bearing outer race attachment : 00-0 Driver rod LL : ssembling the forward gear. Install a new taper roller bearing into the forward gear using a press. - DG

143 Drive shaft and lower case Needle bearing attachment : Install a new needle bearing into the forward gear to the specified depth. Needle bearing attachment : 00-0 Driver rod L : 00-0 Depth a:.0 ± 0. mm (0.0 ± 0.0 in) ssembling the drive shaft. Install a new drive shaft bearing into the drive shaft using a press. Installing the drive shaft. Install the forward gear, then the drive shaft assembly, pinion, and pinion nut, and then tighten the nut to the specified torque. Bearing inner race attachment : 00-0 Drive shaft holder : 00-0 Pinion nut holder : New: 00-0 Current: Installing the propeller shaft housing. Install the washer and propeller shaft assembly into the propeller shaft housing assembly. Pinion nut: N m (. kgf m,. ft lb). pply grease to a new O-ring. SS00 DG -0

144 LOWR Lower unit. Install the propeller shaft housing assembly into the lower case, and then install the straight key, claw washer, and ring nut. LT. Tighten the ring nut to the specified torque. a b S0C0 Install the shift rod assembly into the lower case, turn it counterclockwise 0 a, and then push it down b to connect it to the shift slider.. Install new oil seals into the oil seal housing as shown. To secure the ring nut, bend one tab a of the claw washer into a slot in the ring nut. Bend all other tabs toward the propeller shaft housing assembly. Ring nut wrench : 00-0 Ring nut wrench extension : 00-0 Install an oil seal halfway into the oil seal housing, then the other oil seal. Ring nut : 0 N m (0. kgf m,.0 ft lb) Installing the water pump and shift rod. Install the shift rod assembly. Ball bearing attachment : 00-0 Driver rod LS : Depth c:.0 ± 0. mm (0. ± 0.0 in) - DG

145 Drive shaft and lower case. Install a new O-ring onto the oil seal housing. e. Install a new gasket, the oil seal housing, a new gasket, the outer plate cartridge, and a new gasket 0. D d 0 lign the insert cartridge projection d with the hole e in the water pump housing. C S0J. Install the dowels E, and the water pump housing D onto the lower case. SD0. Install and tighten the bolts F. SD0. Install the Woodruff key into the drive shaft. LT F F LT. lign the groove on the impeller with the Woodruff key B, and then install the impeller onto the drive shaft. E D E. Install the insert cartridge C into the water pump housing D. SD0 pply grease to the inside of the water pump housing before installation. To install the water pump housing, push down on the pump housing, and then turn the drive shaft clockwise. Installing the lower unit. Set the gear shift to the neutral position at the lower unit. DG -

146 LOWR Lower unit. lign the alignment mark a on the bushing with the alignment mark b on the bracket. a b SD00 È X-transom model Lower case mounting bolt (nut): N m (. kgf m,. ft lb) Shift rod push arm: Install the trim tab to its original position, and then connect the speedometer hose.. Install the dowels into the lower unit.. Install the lower unit into the upper case, and then tighten the lower case mounting bolts (nuts) to the specified torque. LT SD0 - DG

147 . Install the propeller and propeller nut, and then tighten the nut finger tight. Place a block of wood between the anticavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque. WRNING Do not hold the propeller with your hands when loosening or tightening it. Be sure to disconnect the battery leads from the battery and the clip from the engine stop lanyard switch. Put a block of wood between the anticavitation plate and propeller to keep the propeller from turning. If the grooves in the propeller nut do not align with the cotter pin hole, tighten the nut until they are aligned. Drive shaft and lower case. Fill the gear oil to the correct level. Propeller nut : N m (. kgf m,. ft lb) DG -

148 LOWR Lower unit Shimming - DG

149 Shimming 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). Selecting the pinion shims. Install the special service tool onto the drive shaft and drive shaft bearing. Select the shim thickness (T) by using the specified measurement(s) and the calculation formula. Install the special service tool to the drive shaft so that the shaft is at the center of the hole. Tighten the wing nuts another / of a turn after they contact the plate. Pinion height gauge : Pinion nut: N m (. kgf m,. ft lb). Measure the distance (M) between the special service tool and the pinion as shown. Measure the pinion at three points to find the clearance average. Digital caliper : Shimming. Install the pinion and pinion nut, and then tighten the nut to the specified torque. DG -

150 LOWR Lower unit. Calculate the pinion shim thickness (T) as shown in the examples below. Example: If T is 0. mm, then the pinion shim is 0. mm. If T is 0. mm, then the pinion shim is 0. mm. a F + R P + SS0 Selecting the forward gear shims. Turn the taper roller bearing outer race two or three times to seat the rollers, and then measure the bearing height (M) as shown. 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 0.0 mm units. If the P mark unreadable, assume that P is zero and check the backlash when the unit is assembled. Pinion shim thickness (T) = M.0 mm P/00 Example: If M is.0 mm and P is +, then T =.0.0 (+)/00 mm = mm = 0. mm If M is.0 mm and P is, then T =.0.0 ( )/00 mm = mm = 0. mm. Select the pinion shim(s) (T) as follows. Calculated numeral at /00 place Rounded numeral 0,,,,,, 0 Select the shim thickness (T) by using the specified measurement(s) and the calculation formula. Measure the bearing outer race at three points to find the height average. vailable shim thicknesses: 0.0, 0., 0., 0., 0.0, 0.0, and 0.0 mm Shimming plate : Digital caliper : Calculate the forward gear shim thickness (T) as shown in the examples below. - DG

151 Shimming / Backlash a F + Example: If T is 0. mm, then the forward gear shim is 0. mm. If T is 0.0 mm, then the forward gear shim is 0. mm. F is the deviation of the lower case dimension from standard. The F mark a is stamped on the trim tab mounting surface of the lower case in 0.0 mm units. If the F mark unreadable, assume that F is zero and check the backlash when the unit is assembled. Forward gear shim thickness (T) =. + F/00 M Example: If M is.00 mm and F is +, then T =. + (+)/00.00 mm = mm = 0. mm If M is.00 mm and F is, then T =. + ( )/00.00 mm = mm = 0. mm. Select the forward gear shim(s) (T) as follows. Calculated numeral at /00 place Rounded numeral, 0,,,,, 0 vailable shim thicknesses: 0.0, 0., 0., 0., 0.0, 0.0, and 0.0 mm R P + SS0 Backlash Measuring the forward gear backlash. Remove the water pump assembly. Do not remove the oil seal housing in this procedure.. Set the gear shift to the neutral position at the lower unit. Shift rod push arm: DG -

152 LOWR Lower unit. Install the special service tool so that it pushes against the propeller shaft. Backlash indicator : Magnet base plate : Dial gauge set : 00-0 Magnetic base B : Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction. Tighten the center bolt while turning the drive shaft until the drive shaft can no longer be turned. Bearing housing puller claw L : Stopper guide plate : Center bolt : Install the backlash indicator onto the drive shaft (0 mm [0. in] in diameter), then the dial gauge onto the lower unit. Forward gear backlash: mm ( in). dd or remove shims if out of specification. Forward gear backlash Less than 0. mm (0.00 in) More than 0. mm (0.0 in) M: Measurement Shim thickness To be decreased by (0. M) 0. To be increased by (M 0.) 0. vailable shim thicknesses: 0.0, 0., 0., 0., 0.0, 0.0, and 0.0 mm. Remove the special service tools and then install the water pump assembly. Install the dial gauge so that the plunger a contacts the mark b on the backlash indicator. - DG

153 MEMO Backlash DG -0

154 BRKT Bracket unit Special service tools...- Shift rod...- Bottom cowling...- Upper case...- Removing the upper case...- Disassembling the oil pump...- Checking the oil pump...- ssembling the oil pump...- Disassembling the upper case...- Checking the drive shaft bushing...- Disassembling the oil pan...- Checking the oil strainer...- ssembling the oil pan...- ssembling the upper case...- Installing the upper case...- Steering arm...- Removing the steering arm...- Installing the steering arm...- Clamp brackets and swivel bracket...- Removing the clamp brackets...- Installing the clamp brackets...- djusting the trim sensor...- Power trim and tilt unit...- Removing the power trim and tilt unit...- Power trim and tilt motor...- Disassembling the power trim and tilt motor...- Checking the power trim and tilt motor...- ssembling the power trim and tilt motor...- Gear pump...-0 Disassembling the gear pump...- Checking the gear pump...- ssembling the gear pump...- DG

155 Tilt cylinder and trim cylinder...- Disassembling the trim cylinder...- Disassembling the tilt cylinder...- Checking the tilt cylinder and trim cylinder...- Checking the valves...- ssembling the tilt cylinder...- ssembling the power trim and tilt unit...- Bleeding the power trim and tilt unit...- Installing the power trim and tilt unit...- Bleeding the power trim and tilt unit (built-in)...- Power trim and tilt electrical system...- Checking the fuse...- Checking the power trim and tilt relay...- Checking the power trim and tilt switch...- Checking the trim sensor...- DG

156 BRKT Bracket unit Special service tools Bearing outer race attachment 00-0, 00-0 Cylinder-end screw wrench New: 00-0 Current: 00-0 Driver rod LL Driver rod L 00-0 Driver rod LS Ball bearing attachment 00-0 Needle bearing attachment 00-0, DG

157 Special service tools / Shift rod Shift rod N m (. kgf m,. ft Ib) N m (0. kgf m, 0. ft Ib) 0 LT SD00 No. Part name Q ty Remarks Bolt Spring Ball Washer Bushing Bolt M mm Bracket Shift rod Screw ø mm 0 Plate Shift position switch Bolt M 0 mm Bushing Bracket Cotter pin Not reusable Bushing Lever DG -

158 BRKT Bracket unit Bottom cowling 0 0 N m (0. kgf m,. ft Ib) 0 0 LT SD00 No. Part name Q ty Remarks Bolt M mm Washer Lever Washer Bushing Bolt M 0 mm Base Lever Spring 0 Bolt M 0 mm Hook Cooling water outlet Canister outlet Bolt M mm Grommet Collar Grommet - DG

159 Bottom cowling 0 0 N m (0. kgf m,. ft Ib) 0 0 LT SD00 No. Part name Q ty Remarks Bottom cowling Grommet 0 Collar Bolt M 0 mm Holder Bolt M 0 mm Bracket Bolt M mm Plate Power trim and tilt switch Grommet Grommet 0 Bolt M 0 mm Plate Grommet Screw ø mm Bracket DG -

160 BRKT Bracket unit 0 0 N m (0. kgf m,. ft Ib) 0 0 LT SD00 No. Part name Q ty Remarks dapter Gasket Joint Joint Plastic tie Not reusable 0 Hose Bolt M 0 mm Bolt M mm Retaining plate Bolt M 0 mm Plate Grommet Rubber seal Clamp - DG

161 Bottom cowling / Upper case Upper case 0 N m (.0 kgf m,. ft Ib) LT N m (. kgf m,. ft Ib) 0 LT LT N m (0. kgf m,. ft Ib) SD00 No. Part name Q ty Remarks Oil seal Not reusable Bolt M mm Oil pump assembly Dowel O-ring Not reusable Upper case assembly Cover Bolt M0 0 mm Grommet 0 Grommet Nut Nut Washer Washer Grease nipple Bolt M mm Ground lead DG -

162 BRKT Bracket unit E N m (0. kgf m,.0 ft Ib) 0 E E WR-No. E WR-No. E WR-No. E E N m (0. kgf m,.0 ft Ib) E SD00 No. Part name Q ty Remarks Oil seal Not reusable Screw ø 0 mm Gasket Not reusable O-ring Not reusable Shaft O-ring Not reusable Oil seal Not reusable Oil seal Not reusable O-ring Not reusable 0 Oil seal housing Screw ø 0 mm Oil pump assembly - DG

163 Upper case N m (0. kgf m,.0 ft Ib) N m (. kgf m, 0. ft Ib) 0 N m (.0 kgf m,. ft Ib) LT LT LT 0 N m (. kgf m, 0.0 ft Ib) WR-No. 0 SD00 No. Part name Q ty Remarks Bolt M mm Upper mount Plate Washer Washer Bolt M mm Bolt M 0 mm Muffler assembly Gasket 0 Drain bolt M mm Damper Rubber seal Gasket Not reusable Gasket Not reusable Screw ø mm Baffle plate Grommet DG -

164 BRKT Bracket unit 0 N m (.0 kgf m,. ft Ib) N m (0. kgf m,.0 ft Ib) N m (. kgf m, 0. ft Ib) LT LT LT 0 N m (. kgf m, 0.0 ft Ib) WR-No. 0 SD00 No. Part name Q ty Remarks Dowel Upper case 0 Drive shaft bushing Circlip Lower mount Washer Washer Washer Bolt M 00 mm - DG

165 Upper case 0 N m (.0 kgf m,. ft Ib) LT LT LT 0 0 LT N m (. kgf m,. ft Ib) SD00 No. Part name Q ty Remarks Exhaust guide Gasket Not reusable Dowel Gasket Not reusable Oil strainer Collar Bolt M mm Bolt M mm Oil pan 0 Gasket Not reusable Exhaust manifold Bolt M 0 mm Gasket Not reusable Gasket Not reusable Plate Dowel Bolt M 0 mm DG -0

166 BRKT Bracket unit 0 N m (.0 kgf m,. ft Ib) LT LT LT 0 0 LT N m (. kgf m,. ft Ib) SD00 No. Part name Q ty Remarks Muffler Bolt M 0 mm 0 Grommet Spacer Pipe - DG

167 Removing the upper case. Place a drain pan under the drain hole, and then remove the drain bolt and let the oil drain completely.. Remove the oil pump assembly and mount covers.. Disconnect the ground lead and speedometer hose.. Remove the upper and lower mounting nuts, and then remove the upper case. Disassembling the oil pump. Remove the screws and disassemble the oil pump. Checking the oil pump. Check the gear teeth for cracks or wear and the oil pump case for scratches. Replace the oil pump assembly if necessary.. Check the shaft for cracks or wear. Replace if necessary.. Check the oil passage for dirt or residue. Clean if necessary. ssembling the oil pump. Install a new oil seal into the oil pump cover to the specified depth. Bearing outer race attachment : 00-0 Driver rod LS : Depth a: 0. ± 0. mm (0.0 ± 0.0 in) Upper case. Install a new oil seal into the oil pump housing. E SD00 SD0 Bearing outer race attachment : 00-0 Driver rod LS : DG -

168 BRKT Bracket unit. Install new oil seals into the oil seal housing. SD0 WR-No. Needle bearing attachment : 00-0 Driver rod LS : SD00. Install new o-rings and the gasket, and then tighten the screws to the specified torque. Ball bearing attachment : 00-0 Driver rod LL : Checking the drive shaft bushing. Check the drive shaft bushing for wear or cracks. Replace if necessary. Disassembling the oil pan. Remove the muffler and plate from the oil pan.. Remove the exhaust manifold from the oil pan. E WR-No.. Remove the oil pan from the exhaust guide. WR-No.. Remove the oil strainer. E E Oil pump cover screw: N m (0. kgf m,.0 ft lb) SD00 Disassembling the upper case. Remove the muffler assembly from the upper case.. Remove the circlip, then the drive shaft bushing. SD0 - DG

169 Upper case Checking the oil strainer. Check the oil strainer for dirt or residue. Clean if necessary. ssembling the oil pan. Install a new gasket onto the exhaust guide. LT. Install a new gasket and the oil strainer onto the exhaust guide, and then tighten the bolts to the specified torque. LT Oil strainer bolt: 0 N m (.0 kgf m,. ft lb) SD0. Install the dowels and oil pan onto the exhaust guide, and then tighten the oil pan bolts finger tight.. Install a new gasket and the exhaust manifold onto the oil pan, and then tighten the exhaust manifold bolts to the specified torque.. Tighten the oil pan bolts to the specified torque.. Tighten the exhaust manifold bolts again to the specified torque. Oil pan bolt : N m (. kgf m,. ft lb) Exhaust manifold bolt : N m (. kgf m,. ft lb). Install new gaskets, the plate, and the muffler onto the oil pan.. Install the water pipe. SD0 LT SD0 DG -

170 BRKT Bracket unit ssembling the upper case. Install the drive shaft bushing into the upper case, and then install the circlip.. Install the bolts, and then tighten them to the specified torque. LT WR-No. SD00 Needle bearing attachment : 00-0 Driver rod L : Install the muffler assembly by inserting the tip of the water pipe into the joint hole a of the upper case.. Install the muffler assembly bolts, and then tighten them to the specified torque. Upper mount bolt : N m (. kgf m, 0. ft lb) SD0. Install the lower mounts onto the upper case. LT LT SD00 a Muffler assembly bolt : 0 N m (.0 kgf m,. ft lb) SD0 Installing the upper case. Install the upper mount and bolts into the upper case.. Install the upper and lower mounting bolts into the bracket simultaneously.. Install the upper mounting nut and lower mounting nut, and then tighten them to the specified torques. Before tightening the lower mounting nut, be sure to connect the ground lead to the lower mounting bolt.. Install the mount covers. - DG

171 Upper case. Install the oil pump assembly and the bolts 0, and then tighten them to the specified torque. LT 0 SD0 When installing the oil pump assembly onto the upper case, pour a small amount of engine oil into the oil inlet or oil outlet of the oil pump assembly. LT LT Upper mounting nut : N m (. kgf m,. ft lb) Lower mounting nut : N m (. kgf m,. ft lb) Oil pump bolt 0: 0 N m (.0 kgf m,. ft lb) Grease nipple: N m (0. kgf m,. ft lb) DG -

172 BRKT Bracket unit Steering arm 0 N m (.0 kgf m,. ft Ib) 0 SD0 No. Part name Q ty Remarks Nut Steering hook Stud bolt M0 0 mm Steering arm Washer Bushing O-ring Not reusable Bushing Washer 0 Steering yoke Damper Circlip - DG

173 Removing the steering arm. Remove the circlip.. Remove the steering yoke by striking it with a plastic hammer.. Remove the steering arm from the swivel bracket by pulling the arm off the bracket. SD0. Install the steering yoke 0 to the steering arm by aligning the center a of the yoke with the center b of the steering arm.. Install the circlip. b Steering arm SD0 Installing the steering arm. Install the washer, bushing, O-ring, and bushing onto the steering arm.. Place the swivel bracket in an upright position, and then install the steering arm onto the swivel bracket. a 0 SD0. Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c. c SD0. Install the bushing, O-ring, and washer onto the swivel bracket. c S0C DG -

174 BRKT Bracket unit Clamp brackets and swivel bracket N m (0. kgf m,. ft Ib) N m (. kgf m,. ft Ib) 0 SD0 No. Part name Q ty Remarks Swivel bracket Clamp bracket Clamp bracket Self-locking nut Screw ø mm Washer Bushing Trim sensor cam Screw ø mm 0 Plate node Bolt M mm Bolt M mm Through tube Bolt M 0 mm - DG

175 Clamp brackets and swivel bracket LT 0 a N m (0. kgf m,. ft Ib) SD00 No. Part name Q ty Remarks Swivel bracket Tilt stop lever Bushing Distance collar a: mm (..0 in) Pin Hook Bolt M 0 mm Spring Tilt stop lever 0 Trim sensor Screw ø mm Bolt M 0 mm Clamp Grease nipple Ground lead Pin DG -0

176 BRKT Bracket unit Removing the clamp brackets. Remove the power trim and tilt unit. For removal procedure, see Removing the power trim and tilt unit.. Remove the anode.. Disconnect the ground lead.. Remove the trim sensor cam screw. djust the trim sensor after installing the power trim and tilt unit.. ssemble the clamp brackets and the swivel bracket by installing the anode, bolt, and self-locking nut, then tightening the nut to the specified torque.. Loosen the self-locking nut and the bolt, and then remove clamp brackets and.. Remove the trim sensor.. Remove the tilt stop lever. SD0 SD0 Installing the clamp brackets. Install the trim sensor onto the swivel bracket. Self-locking nut : N m (. kgf m,. ft lb). Install the power trim and tilt unit. For installation procedure, see Installing the power trim and tilt unit. djusting the trim sensor. Fully retract the power trim and tilt unit.. Loosen the trim sensor cam screw.. djust the trim sensor cam where the specified trim sensor setting resistance is obtained. LT S0C0 - DG

177 Clamp brackets and swivel bracket B Gy P Trim sensor setting resistance: Pink (P) Black (B) 0 ± Ω at 0 C ( F) Trim sensor cam screw : N m (0. kgf m,. ft lb) S0X0. Fully tilt the outboard motor up, and then support it with the tilt stop lever. WRNING SD0 fter tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure.. Check the trim sensor resistance. If the resistance is out of specification, adjust the trim sensor cam position and check the trim sensor. Trim sensor resistance: Pink (P) Black (B).. Ω at 0 C ( F) DG -

178 BRKT Bracket unit Power trim and tilt unit 0 0 SD0 No. Part name Q ty Remarks Power trim and tilt unit Circlip Shaft Circlip Shaft Bushing Bushing Ground lead Bolt M 0 mm 0 Bushing Bushing Collar Holder Bolt M 0 mm - DG

179 Removing the power trim and tilt unit. Fully tilt the outboard motor up, and then support it with the tilt stop lever. WRNING fter tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure. If the power trim and tilt does not operate, loosen the manual valve and tilt the outboard motor up manually. If the manual valve is loosened, be sure to tighten it to the specified torque after tilting the outboard motor up. Manual valve: N m (0. kgf m,. ft lb) SD0 S0C. Remove the holders and plastic ties, and then pull out the PTT motor leads.. Remove the bolt and disconnect the ground lead.. Remove the circlips, then the lower mounting shaft.. Remove the circlip, then the upper mounting shaft. Hold the power trim and tilt unit with one hand, and pull the upper mount shaft out at a downward angle with the other.. Remove the power trim and tilt unit 0. Power trim and tilt unit 0 SD0 DG -

180 BRKT Bracket unit Power trim and tilt motor N m (0. kgf m,.0 ft Ib) 0 0 N m (0. kgf m,. ft Ib) SD0 No. Part name Q ty Remarks Power trim and tilt motor Bolt M 0 mm O-ring Not reusable Joint O-ring Not reusable Reservoir cap Screw ø mm Stator O-ring Not reusable 0 rmature Washer Bushing Wire lead Screw ø mm Brush Brush Brush holder - DG

181 Power trim and tilt motor N m (0. kgf m,.0 ft Ib) 0 0 N m (0. kgf m,. ft Ib) SD0 No. Part name Q ty Remarks Circuit breaker Spring 0 PTT motor base Oil seal Not reusable Plate Screw ø 0 mm DG -

182 BRKT Bracket unit Disassembling the power trim and tilt motor. Remove the power trim and tilt motor, O- ring, and joint from the power trim and tilt unit.. Remove the armature from the PTT motor base. CUTION: Do not allow grease or oil to contact the commutator.. Remove the screws, and then disassemble the PTT motor base. SD00 CUTION: Make sure that the tilt ram is fully extended when removing the power trim and tilt motor, otherwise fluid can spurt out from the unit due to internal pressure. Do not push the tilt ram down while the power trim and tilt motor is removed from the power trim and tilt unit, otherwise fluid can spurt out. SD0 Checking the power trim and tilt motor. Check the commutator for dirt. Clean with 00 grit sandpaper and compressed air if necessary.. Remove the stator. 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.. Measure the commutator diameter. Replace the armature if below specification. - DG

183 Power trim and tilt motor. Check the circuit breaker for continuity. Replace if there is no continuity. Commutator diameter wear limit:.0 mm (0. in). Measure the commutator undercut a. Replace the armature if below specification. Commutator undercut wear limit a:.0 mm (0.0 in). Check the armature for continuity. Replace if out of specifications. rmature continuity Commutator segments b Continuity Segment rmature core c No continuity Segment rmature shaft d No continuity. Measure the brush length. Replace if below specification. Brush length wear limit e:. mm (0. in). Check the base for cracks or damage. Replace if necessary.. Check the bushing and oil seal for damage or wear. Replace if necessary. DG -

184 BRKT Bracket unit ssembling the power trim and tilt motor. Install a new oil seal and the bushing into the motor base as shown.. ttach the circuit breaker onto the brush together with the brush holder and connect the wire lead. 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.. Install the springs into the motor base, then the brush holder into the motor base together with the brushes and circuit breaker.. Push the brushes into the brush holder, and then install the armature.. Install the stator onto the base. - DG

185 Power trim and tilt motor / Gear pump Gear pump N m (0. kgf m,. ft Ib) N m (0. kgf m,.0 ft Ib) N m (0. kgf m,. ft Ib) N m (0. kgf m,. ft Ib) N m (0. kgf m,. ft Ib) N m (0. kgf m,. ft Ib) SD0 No. Part name Q ty Remarks Gear pump assembly Spacer Pin Lever Bolt M mm Bolt M mm Spring Shuttle piston Backup ring 0 Down-relief valve seat Washer Spring Pin Cap Bolt M 0 mm Bolt M 0 mm Cap DG -0

186 BRKT Bracket unit N m (0. kgf m,. ft Ib) N m (0. kgf m,. ft Ib) N m (0. kgf m,. ft Ib) N m (0. kgf m,.0 ft Ib) N m (0. kgf m,. ft Ib) N m (0. kgf m,. ft Ib) SD0 No. Part name Q ty Remarks Holder Spring 0 Washer Up-relief valve seat Bolt M mm O-ring Not reusable Shuttle piston Bolt M mm Bolt M 0 mm Filter Plate O-ring Not reusable 0 Filter O-ring Not reusable Manual valve Circlip - DG

187 Gear pump 0 N m (0. kgf m,. ft Ib) N m (0. kgf m,.0 ft Ib) 0 No. Part name Q ty Remarks Manual release spring Ball Bracket Bolt M mm Bolt M mm Washer O-ring Not reusable dapter Spring 0 Ball Gear Drive shaft Pin Driven shaft Ball Pin SD0 DG -

188 BRKT Bracket unit Disassembling the gear pump. Remove the manual valve, then the gear pump and filters. SC00. Remove the relief valve seat caps, then the up-relief valve seat and downrelief valve seat.. Remove the lever, then the shuttle pistons. SD0 SD0 Checking the gear pump. Clean all the pistons and balls, and then check them for damage or wear. Replace if necessary.. Check the filters for damage or clogs. Replace if necessary.. Check the drive gear and driven gear for damage or wear. Replace the gear pump assembly if necessary. ssembling the gear pump. Install the drive gear and driven gear into the gear pump housing.. Install the balls into the gear pump housing.. Remove the gear pump bracket, then the adapters.. Remove the pins, then the drive gear and driven gear. SC0. Install the gear pump cover, then the pins. - DG

189 Gear pump. Install the adapters into the gear pump cover.. Install the balls into the gear pump cover with the manual release spring.. Install the gear pump bracket by installing the bolts, then tightening them to the specified torques. Gear pump bracket bolt (M): N m (0. kgf m,. ft lb) Gear pump bracket bolt (M): N m (0. kgf m,.0 ft lb) SC0 SC0. Install the shuttle pistons 0, then the lever.. Tighten bolts B and C to the specified torque.. Install the up-relief valve seat D and down-relief valve seat E. 0. Install the relief valve seat caps F by installing bolts G and H, then tightening them to the specified torques.. Tighten the bolts I to the specified torque. Lever bolt (M) B, C: N m (0. kgf m,. ft lb) G H E F I H D G F Relief valve cap bolt (M) G: N m (0. kgf m,.0 ft lb) Relief valve cap bolt (M) H: N m (0. kgf m,. ft lb) Gear pump housing bolt I: N m (0. kgf m,. ft lb) SD0 0 C B 0 SC0 DG -

190 BRKT Bracket unit Tilt cylinder and trim cylinder 0 N m (.0 kgf m,. ft Ib) LT 0 N m (.0 kgf m,.0 ft Ib) N m (. kgf m,. ft Ib) SD0 No. Part name Q ty Remarks Power trim and tilt assembly Dust seal Not reusable Backup ring O-ring Not reusable Trim cylinder end screw O-ring Not reusable Tilt cylinder end screw assembly Backup ring O-ring Not reusable 0 O-ring Not reusable Washer Filter O-ring Not reusable Trim piston Backup ring O-ring Not reusable Ball - DG

191 Tilt cylinder and trim cylinder 0 N m (.0 kgf m,. ft Ib) LT 0 N m (.0 kgf m,.0 ft Ib) N m (. kgf m,. ft Ib) SD0 No. Part name Q ty Remarks Valve Spring 0 Washer Tilt cylinder Ball O-ring Not reusable Backup ring Tilt piston Ball Ball Valve Spring 0 Pin Dowel Washer Tilt piston assembly O-ring Not reusable DG -

192 BRKT Bracket unit 0 N m (.0 kgf m,. ft Ib) LT 0 N m (.0 kgf m,.0 ft Ib) N m (. kgf m,. ft Ib) SD0 No. Part name Q ty Remarks Free piston Circlip Cylinder base Spring Washer 0 Circlip Trim cylinder - DG

193 Tilt cylinder and trim cylinder Disassembling the trim cylinder. Hold the power trim and tilt unit in a vise using aluminum plates a on both sides.. Loosen the trim cylinder end screw, and then remove it. WRNING Make sure that the ram is fully extended before removing the end screw. Cylinder-end screw wrench: New: 00-0 Current: Drain the power trim and tilt fluid. Disassembling the tilt cylinder. Hold the tilt cylinder in a vise using aluminum plates a on both sides. Place the tilt cylinder in the vise horizontally.. Loosen the tilt cylinder end screw, and then remove it. CUTION: Do not damage the check valve b when loosening the end screw. Cylinder-end screw wrench: New: 00-0 Current: Hold the tilt ram end in a vise using aluminum plates on both sides. DG -

194 BRKT Bracket unit. Remove the bolt, then the tilt piston.. Check the operation of the absorber valve and check for dirt or residue. Clean if necessary. ssembling the tilt cylinder. Install a new O-ring, the backup ring, and a new dust seal into the trim cylinder end screw.. Install the O-ring onto the trim cylinder end screw. Checking the tilt cylinder and trim cylinder. Check the power trim and tilt unit for cracks or corrosion. Replace if necessary.. Install the tilt ram into the trim cylinder end screw.. Check the inner walls of the trim cylinder and tilt cylinder for scratches. Replace if necessary.. Check the outer surface of the tilt piston and free piston for scratches. Replace if necessary.. Check the tilt ram for bends or excessive corrosion. Polish with 00- to 00-grit sandpaper if there is light rust or replace if necessary.. Install the backup ring and new O- rings and into the tilt cylinder end screw. Checking the valves. Check the operation of the check valve a of the tilt cylinder end screw and check the valve for dirt or residue. Clean if necessary.. Install the tilt cylinder end screw onto the tilt ram. S0C0 - DG

195 . Install the new O-rings and 0, and backup ring onto the trim piston B. Tilt cylinder and trim cylinder. Install the balls C, valves D, and springs E into the trim piston, and then install the washer F and trim piston to the tilt cylinder G.. Install the filter H and washer I to the trim piston. C D E G B S0C. Install the backup ring J and new O-ring K to the tilt piston L. 0. Install balls M and N, valves O, springs P, pins Q, dowels R, and washer S into the tilt piston.. Hold the tilt ram end in a vise using aluminum plates on both sides.. Install the tilt piston to the tilt ram by installing the bolt T, then tightening it to the specified torque. F I H 0 0 Tilt piston bolt T: N m (. kgf m,. ft lb). Install the tilt ram into the tilt cylinder.. Hold the tilt cylinder G in a vise using aluminum plates a on both sides. Place the tilt cylinder in the vise horizontally. DG -0

196 BRKT Bracket unit. Install the tilt cylinder end screw, and then tighten it to the specified torque. ssembling the power trim and tilt unit. Hold the trim cylinder in a vise using aluminum plates on both sides. CUTION: Do not damage the check valve b when tightening the end screw. Cylinder-end screw wrench: New: 00-0 Current: Install the filters and gear pump assembly by installing the bolts, then tightening them to the specified torques.. Install the manual valve and reservoir cap. Tilt cylinder end screw : 0 N m (.0 kgf m,.0 ft lb). Install the free piston U into the tilt cylinder G by installing the circlip V. SD0 Gear pump bolt : N m (0. kgf m,. ft lb) Reservoir cap : N m (0. kgf m,. ft lb). Install the cylinder base W, springs X, and washer Y into the tilt cylinder with the circlip Z.. Fill the reservoir with the recommended fluid to the correct level as shown. - DG

197 Tilt cylinder and trim cylinder Recommended power trim and tilt fluid: TF Dexron II. Install a new O-ring, the joint, and the power trim and tilt motor by installing the bolts, then tightening them to the specified torque. SD0 pply grease to the balls from falling out of the cylinder installation.. Install the trim cylinder end screw, and then tighten it to the specified torque. SD0 Cylinder-end screw wrench: New: 00-0 Current: 00-0 Trim cylinder end screw : 0 N m (.0 kgf m,. ft lb) PTT motor bolt: N m (0. kgf m,.0 ft lb) SD0. Fully extend the tilt rod, and then add sufficient fluid of the recommended type to the correct level.. dd fluid of the recommended type to the first level at the bottom of the trim cylinder.. Install the balls into the tilt cylinder, and then insert the tilt cylinder into the trim cylinder. DG -

198 BRKT Bracket unit 0. Install the reservoir cap.. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole. Recommended power trim and tilt fluid: TF Dexron II. Install the reservoir cap, and then tighten it to the specified torque. Bleeding the power trim and tilt unit. Tighten the manual valve by turning it clockwise. Reservoir cap: N m (0. kgf m,. ft lb). Connect the PTT motor leads to the battery terminals to fully retract the tilt ram. Ram PTT motor lead Battery terminal Manual valve : N m (0. kgf m,. ft lb) Down Light green (Lg) + Sky blue (Sb) -. Place the power trim and tilt unit in an upright position.. Reverse the PTT motor leads between the battery terminals to fully extend the tilt ram.. Remove the reservoir cap, and then check the fluid level in the reservoir. If the fluid is at the correct level, the fluid should overflow out of the filler hole when the reservoir cap is removed. - DG

199 Tilt cylinder and trim cylinder Ram Up PTT motor lead Battery terminal Sky blue (Sb) + Light green (Lg) - Repeat this procedure so that the ram goes up and down four or five times (be sure to wait a few seconds before switching the leads). If the ram does not move up and down easily, push and pull on the ram to assist operation.. Check the fluid level when the tilt ram is fully extended. dd sufficient fluid if necessary. Installing the power trim and tilt unit. Fully tilt the outboard motor up, and then support it with the tilt stop lever. CUTION: fter tilting the outboard motor up, be sure to support it with the tilt stop lever.. Install the collars and bushings.. Lift the power trim and tilt unit up, and then install the upper mounting shaft.. Install the circlip.. Install the lower mounting shaft, and then install the circlips.. Route the PTT motor leads through the hole, and then install the holders and plastic ties.. Connect the ground lead. SD0 Bleeding the power trim and tilt unit (built-in). Fully turn the manual valve counterclockwise. S0C S0C DG -

200 BRKT Bracket unit. Fully tilt the outboard motor up, and then release it to let it lower by its own weight four to five times.. Tighten the manual valve by turning it clockwise. If the fluid is at the correct level, the fluid should overflow out of the filler hole when the reservoir cap is removed. Reservoir cap: N m (0. kgf m,. ft lb). If necessary, add sufficient fluid of the recommended type to the correct level.. Let the fluid settle for minutes.. Push and hold the power trim and tilt switch in the up position to check that the outboard motor is fully tilted up.. Support the outboard motor with the tilt stop lever. Recommended power trim and tilt fluid: TF Dexron II. Install the reservoir cap, and then tighten it to the specified torque. Repeat this procedure until the fluid remains at the correct level. Reservoir cap: N m (0. kgf m,. ft lb) WRNING S0C fter tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure. Power trim and tilt electrical system Checking the fuse. Check the fuse for continuity. Replace if there is no continuity. Checking the power trim and tilt relay. Check the power trim and tilt relay for continuity. Replace if out of specification.. Remove the reservoir cap, and then check the fluid level in the reservoir. SD0 Be sure to set the measurement range a shown in the illustration when checking for continuity. - DG

201 Tilt cylinder and trim cylinder / Power trim and tilt electrical system Power trim and tilt relay continuity Sky blue (Sb) Black (B) Light green (Lg) Black (B) Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Continuity Continuity No continuity. Connect the digital circuit tester between power trim and tilt relay terminals and.. Connect the light green (Lg) lead to the positive battery terminal and the black (B) lead to the negative battery terminal as shown.. Check for continuity between terminals and. Replace if there is no continuity. Checking the power trim and tilt switch. Check the power trim and tilt switch for continuity. Replace if out of specification. Lead color Switch position Sky blue (Sb) Red (R) Light green (Lg) Up Free. Connect the digital circuit tester between power trim and tilt relay terminals and. Down. Connect the sky blue (Sb) lead to the positive battery terminal and the black (B) lead to the negative battery terminal as shown.. Check for continuity between terminals and. Replace if there is no continuity. DG -

202 BRKT Bracket unit Checking the trim sensor. Measure the trim sensor resistance. Replace if out of specification. Turn the lever and measure the resistance as it gradually changes. Trim sensor resistance: Pink (P) Black (B).. Ω at 0 C ( F) a Ω at 0 C ( F) b - DG

203 ELEC + Electrical systems Special service tools...- Checking the electrical components...- Measuring the peak voltage...- Measuring the lower resistance...- Electrical components...- Port view...- Starboard view...- Bow view...- Top view...- Ignition and ignition control system...- Checking the ignition spark...- Checking the spark plug wires...- Checking the ignition coils...- Checking the ECM...- Checking the pulser coils...- Checking the sensor assembly...- Checking the cooling water temperature sensor...- Checking the oil pressure switch...- Checking the shift position switch...- Checking the main and fuel pump relay (main control)...-0 Fuel control system...-0 Checking the injectors...-0 Checking the electric fuel pump...-0 Checking the main and fuel pump relay (fuel control)...- Starting system...- Checking the fuses...- Checking the starter relay...- Starter motor...- Disassembling the starter motor...- Checking the starter motor pinion...- Checking the armature...- Checking the brushes...- Checking the magnet switch...- Checking the starter motor operation...- Charging system...- Checking the stator coil...- Checking the Rectifier Regulator...- DG

204 ELEC + Electrical systems Special service tools Ignition tester 00-0 Test harness ( pins) 00-0 Digital circuit tester 00-0 Vacuum/pressure pump gauge set 00-0 Peak voltage adapter B 00-0 Test harness ( pins) 00-0 Test harness ( pins) DG

205 Special service tools / Checking the electrical components Checking the electrical components Measuring the peak voltage Before troubleshooting the peak voltage, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to V. The condition of the ignition system can be determined by measuring the peak voltage. Cranking speed is effected by many factors, such as fouled or weak spark plugs, or a weak battery. If one of these factors is present, the peak voltage will be lower than specification. In addition, if the peak voltage is lower than specification the engine will not operate properly. DC V SJ00 WRNING When checking the peak voltage, do not touch any of the connections of the digital tester leads. Use the peak voltage adapter with the digital circuit tester. When measuring the peak voltage, set the selector on the digital circuit tester to the DC voltage mode. Connect the positive pin on the peak voltage adapter to the positive terminal of the digital circuit tester. Measuring the lower resistance When measuring a resistance of 0 Ω or less with the digital circuit tester, the correct measurement cannot be obtained due to the internal resistance of the tester. To obtain the correct value, subtract the internal resistance from the displayed measurement. To obtain the internal resistance of the digital circuit tester, connect both of its probes and check the display. Correct value = displayed measurement internal resistance DG -

206 ELEC + Electrical systems Electrical components Port view SD00 Idle speed control Sensor assembly (intake air temperature and intake air pressure) Pulser coil Oil pressure switch Fuel injector Electric fuel pump Throttle position sensor - DG

207 Starboard view Electrical components SD00 Ignition coil Cooling water temperature sensor Starter motor Junction box Spark plug DG -

208 ELEC Bow view + Electrical systems B 0 SD00 ECM Sensor assembly (intake air temperature and intake air pressure) Idle speed control Throttle position sensor Rectifier Regulator Power trim and tilt relay Starter relay Main and fuel pump relay Fuse (0) (ECM, ignition coil, electric fuel pump, and fuel injector) 0 Fuse (0) (main switch and power trim and tilt switch) Fuse (0 ) (Rectifier Regulator) B Fuse (0 ) (starter relay) - DG

209 Top view Electrical components SD00 Fuel injection Shift position switch Sensor assembly (intake air temperature and intake air pressure) Idle speed control Stator coil Power trim and tilt switch Starter motor DG -

210 ELEC + Electrical systems Ignition and ignition control system Checking the ignition spark. Remove the spark plug wire cover.. Disconnect the spark plug caps from the spark plugs.. Connect a spark plug cap to the special service tool. The ignition spark can also be checked using the Stationary test of the Yamaha Diagnostic System. Checking the spark plug wires. Remove the spark plug wires from the spark plugs.. Remove the spark plug wires from the ignition coils.. Measure the spark plug wire resistance. Replace if out of specification. SD00 Ignition tester: Crank the engine and observe the spark through the discharge window of the special service tool. Check the ignition system if the spark is weak. Spark plug wire resistance: #:. 0. kω #:..0 kω #:.. kω #:. 0. kω S0C00 Checking the ignition coils. Remove the spark plug wires from the ignition coils. SD00 WRNING Do not touch any of the connections of the ignition tester leads. Do not let sparks leak out of the removed spark plug caps. Keep flammable gas or liquids away, since this test can produce sparks.. Disconnect the ignition coil coupler.. Measure the ignition coil resistance. Replace if out of specification. SP00 - DG

211 Ignition coil resistance: Primary coil: Red (R) Black/white (B/W)..0 Ω at 0 C ( F) Secondary coil:..0 kω at 0 C ( F) Checking the ECM. Disconnect an ignition coil coupler.. Connect the test harness ( pins) to the ignition coil.. Measure the ECM output peak voltage. If below specification, measure the pulser coil output peak voltage. Replace the ECM if the output peak voltage of the pulser coil is above specification. Digital circuit tester: 00-0 Peak voltage adapter B: 00-0 Test harness ( pins): 00-0 ECM output peak voltage: Black/red (B/R) Ground Black/white (B/W) Ground SD00 Loaded r/min Cranking,00,00 DC V Checking the pulser coils. Remove the junction box cover. Disconnect the pulser coil coupler.. Connect the test harness ( pins) to the pulser coil. Ignition and ignition control system. Measure the pulser coil output peak voltage. Replace the stator assembly if below specification. Do not loosen the pulser coil screw. Digital circuit tester: 00-0 Peak voltage adapter B: 00-0 Test harness ( pins): 00-0 Pulser coil output peak voltage: White/red (W/R) Black (B) White/black (W/B) Black (B) r/min Unloaded Loaded Cranking,00,00 DC V Pulser coil resistance (reference data): Ω Checking the sensor assembly. Measure the ambient temperature. SD00 DG -

212 ELEC + Electrical systems. Connect a computer to the outboard motor and use the Yamaha Diagnostic System to display the intake air temperature. Checking the oil pressure switch. Check the oil pressure switch for continuity. Replace if there is no continuity.. Connect the special service tool to the oil pressure switch.. Slowly operate the special service tool. SD0. If the ambient temperature and the displayed intake air temperature differ by more than ± C (± F), replace the sensor assembly. Check the sensor assembly when the engine is cold. Checking the cooling water temperature sensor. Place the cooling water temperature sensor in a container of water and slowly heat the water.. Check the oil pressure switch for no continuity at the specified pressure. Replace if there is continuity. Vacuum/pressure pump gauge set: 00-0 Operating pressure:.. kpa (.. kgf/cm,.. psi) SJ0. Measure the cooling water temperature sensor resistance. Replace if out of specification. Cooling water temperature sensor resistance: at 0 C ( F):.. kω at 0 C ( F): kω Checking the shift position switch. Check the shift position switch for continuity. Replace if there is no continuity. a b SJ0 - DG

213 Ignition and ignition control system / Fuel control system Free a Push b Switch position Lead color Blue/green Black (B) (L/G) Checking the main and fuel pump relay (main control). Remove the main and fuel pump relay. SD00 Fuel control system Checking the injectors. Measure the resistance of the fuel injectors. SD00. Connect the digital circuit tester leads to the relay terminals and.. Connect the positive battery terminal to the relay terminal.. Connect the negative battery terminal to the relay terminal.. Check for continuity between the relay terminals and. Replace if there is no continuity.. Check that there is no continuity between the relay terminals and after disconnecting a battery terminal from the relay terminal or. Replace if there is continuity. Digital circuit tester: 00-0 Fuel injector resistance (reference data):.0 Ω at C (0 F) Check the operation of the fuel injectors using the Stationary test of the Yamaha Diagnostic System. Checking the electric fuel pump. Turn the engine start switch to ON. SC0 DG -0

214 ELEC + Electrical systems. Listen for the operating sound of the electric fuel pump. Check the fuel system if there is no sound.. Check that there is no continuity between the relay terminals and after disconnecting a battery terminal from the relay terminal or. Replace if there is continuity. fter the engine start switch is turned to ON, the electric fuel pump will operate for seconds. Checking the main and fuel pump relay (fuel control). Remove the main and fuel pump relay. SD0 Starting system Checking the fuses. Check the fuses for continuity. Replace if there is no continuity. Checking the starter relay. Connect the digital circuit tester leads to the starter relay terminals.. Connect the positive battery terminal to the brown (Br) lead. SD00. Connect the digital circuit tester leads to the relay terminals and.. Connect the positive battery terminal to the relay terminal.. Connect the negative battery terminal to the relay terminal.. Check for continuity between the relay terminals and. Replace if there is no continuity.. Connect the negative battery terminal to the black (B) lead.. Check for continuity between the starter relay terminals. Replace if there is no continuity.. Check that there is no continuity between the starter relay terminals after disconnecting a battery terminal from the brown (Br) or black (B) lead. Replace if there is continuity. - DG

215 Fuel control system / Starting system Br B S0V DG -

216 ELEC + Electrical systems Starter motor SP00 No. Part name Q ty Remarks Clip Pinion stopper Starter motor pinion Spring Bolt M mm Housing Bearing Clutch assembly E-clip Not reusable 0 Washer Bracket Pinion shaft Planetary gear Outer gear Plate rmature Stator - DG

217 Starter motor SP00 No. Part name Q ty Remarks Brush assembly Brush spring 0 Brush holder Plate Washer Bracket Screw ø mm Bolt M 0 mm Rubber seal Shift lever Spring Magnet switch assembly 0 Washer Nut DG -

218 ELEC + Electrical systems Disassembling the starter motor. Slide the pinion stopper down as shown, and then remove the clip.. Measure the commutator diameter. Replace the armature if below specification. Remove the clip with a thin screwdriver.. Remove the bolts, and then disassemble the starter motor. Checking the starter motor pinion. Check the teeth of the pinion for cracks or wear. Replace if necessary. Commutator diameter wear limit:.0 mm (.0 in). Measure the commutator undercut a. Replace the armature if below specification.. Check for smooth operation. Replace if necessary. Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place. Checking the armature. Check the commutator for dirt. Clean with 00 grit sandpaper and compressed air if necessary. Commutator undercut wear limit a: 0. mm (0.0 in). Check the armature for continuity. Replace if out of specifications. - DG

219 Starter motor / Charging system rmature continuity Commutator segments b Segment rmature core c Segment rmature shaft d Checking the brushes. Measure the brush length. Replace the brush assembly if below specification. Brush length wear limit a:. mm (0. in) Continuity No continuity No continuity. Check the brush holder assembly for continuity. Replace if out of specification.. Connect the negative battery lead to the starter motor body. Br/W SD00 CUTION: Do not connect the battery for more than one second, otherwise the magnet switch can be damaged.. Check that there is continuity between the magnet switch terminals. Replace if there is no continuity.. Check that there is no continuity after the negative battery terminal is removed. Replace if there is continuity. The starter motor pinion should be pushed out while the magnet switch is on. Checking the starter motor operation. Check the operation of the starter motor after installing it onto the power unit. Brush continuity SJ0 Charging system Checking the stator coil. Disconnect the stator coil coupler.. Connect the test harness ( pins) to the stator coil coupler. Brush Brush No continuity Checking the magnet switch. Connect the tester leads between the magnet switch terminals as shown.. Connect the positive battery lead to the brown/white (Br/W) lead. DG -

220 ELEC + Electrical systems. Measure the stator coil output peak voltage. Replace the stator coil if below specification. SD0 SD0 Digital circuit tester: 00-0 Test harness ( pins): 00-0 Digital circuit tester: 00-0 Peak voltage adapter B: 00-0 Test harness ( pins): 00-0 Stator coil output peak voltage: White (W) White (W) Unloaded r/min Cranking,00,00 DC V. Rectifier Regulator output peak voltage: Red (R) Ground Unloaded r/min,00,00 DC V.0.0 Stator coil resistance (reference data): Ω at 0 C ( F) Checking the Rectifier Regulator. Disconnect the stator coil coupler.. Connect the test harness ( pins) between the Rectifier Regulator and stator coil coupler.. Disconnect the test harness coupler and then measure the Rectifier Regulator output peak voltage at the coupler. If below specification, measure the stator coil output peak voltage. Replace the Rectifier Regulator if the output peak voltage of the stator coil is above specification. - DG

221 TRBL SHTG Troubleshooting Special service tools...- Yamaha Diagnostic System...- Introduction...- Power unit...- Bracket unit...- Electrical systems...- Self-diagnosis...- Diagnosing the electronic control system...- DG

222 TRBL SHTG Troubleshooting Special service tools Yamaha Diagnostic System 0V-00-0 YMH DIGNOSTIC SYSTEM INSTLLTION MNUL Yamaha Diagnostic System 0V-WS-0 Diagnostic flash indicator B DG

223 Special service tools / Yamaha Diagnostic System Yamaha Diagnostic System Introduction Features The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of an outboard motor using the communication cable, this software can be used to display sensor data and data stored in the ECM on a computer s monitor. If this software is run on Microsoft Windows, Windows, Windows Me, Windows 000, or Windows XP the information can be displayed in colorful graphics. lso, 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. Functions. Diagnosis: With the engine main switch ON, each sensor s status and each ECM diagnosis code or item is displayed. This enables you to find malfunctioning parts and controls quickly.. Diagnosis record: Sensors that had been activated and ECM diagnostic codes that have been recorded are displayed. This allows you to check the outboard motor s record of malfunctions.. Engine monitor: Each sensor status and the ECM data are displayed while the engine is running. This enables you to find malfunctioning parts quickly.. Stationary test: With the engine off, the ignition, fuel injection, electric fuel pump, and ISC valve are checked. These tests can be performed quickly.. ctive test: With the engine running, each firing cylinder has dropped and the engine speed is checked for changes to determine whether the cylinder is malfunctioning and the ISC valve is checked as well. These tests can be performed quickly.. Data logger: Displays minutes of recorded data for two 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.. Some files: Lets you select and run other applications while continuing to run the diagnostic program. Contents. Software (). dapter (). Communication cable (). Instruction Manual (). Installation Manual () YMH DIGNOSTIC SYSTEM INSTRUCTION MNUL YMH DIGNOSTIC SYSTEM INSTLLTION MNUL DG -