f80b PDF
f80b PDF
f80b PDF
F100D
SERVICE MANUAL
6D9-28197-3G-11
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
Important information 1
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
F80B, F100D
SERVICE MANUAL
©2004 by Yamaha Motor Co., Ltd.
1st Edition, October 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in the Netherlands
Electrical systems
ELEC 8
Troubleshooting TRBL
SHTG
9
Index
Identification...................................................................................................1-5
Applicable model .......................................................................................1-5
Serial number ............................................................................................ 1-5
3
Propeller selection ......................................................................................... 1-5
Propeller size............................................................................................. 1-5
Selection.................................................................................................... 1-6
4
Predelivery checks ........................................................................................1-6
Checking the fuel system ..........................................................................1-6
Checking the engine oil level..................................................................... 1-6
Checking the gear oil level ........................................................................ 1-7
5
Checking the battery.................................................................................. 1-7
6
Checking the outboard motor mounting height.......................................... 1-7
Checking the remote control cables .......................................................... 1-7
Checking the steering system ...................................................................1-8
Checking the gear shift and throttle operation...........................................1-8
Checking the power trim and tilt system.................................................... 1-8
Checking the engine start switch and engine stop lanyard switch ............1-8
Checking the cooling water pilot hole ........................................................1-9
Test run ..................................................................................................... 1-9
Break-in ..................................................................................................... 1-9
After test run .............................................................................................. 1-9
7
8
9
6D93G11
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the information below as a guide for effective and quality service.
1 Parts are shown and detailed in an exploded diagram and are listed in the components list.
2 Tightening torque specifications are provided in the exploded diagrams and after a numbered
step with tightening instructions.
3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant
and lubrication point.
4 The components list consists of part names and part quantities, as well as bolt and screw dimen-
sions.
5 Service points regarding removal, checking, and installation are shown in individual illustrations
to explain the relevant procedure.
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
LOWR
Lower unit
3 2 1
Lower unit
LOWR
Lower unit
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.
S62Y6740K
CAUTION:
Do not reuse the bearing, always replace
S62Y6850K it with a new one.
6-19 62Y5A11
1-1 6D93G11
1 2 3 4
T.
R.
5 6
4
1
2
3
4
Special tool
Specified oil or fluid
Specified engine speed
Specified tightening torque
5 Specified measurement
6 Specified electrical value
(resistance, voltage, electric current)
5
Symbols 7 to C in an exploded diagram indicate the grade of lubricant and the lubrication point.
7 8 9 0 A B C
6
A M D C I
7
E G
Symbols D to H in an exploded diagram indicate the type of sealant or locking agent and the appli-
8
cation point.
D
GM
E
271
LT
F
LT
242
G
LT
572
H
SS
9
D Apply Gasket Maker G Apply LOCTITE 572
E Apply LOCTITE 271 (red) H Apply silicon sealant
F Apply LOCTITE 242 (blue)
6D93G11 1-2
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
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
Under normal conditions, the lubricants men-
a water tank) be sure to do so where ade-
tioned in this manual should not harm or be
quate ventilation can be maintained.
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1-3 6D93G11
2
3
3. Install bearings with the manufacture
4
identification mark in the direction indi-
Tightening torques cated in the installation procedure. In
Follow the tightening torque specifications addition, be sure to lubricate the bearings
provided throughout the manual. When tight- liberally.
ening nuts, bolts, and screws, tighten the
5
large sizes first, and tighten fasteners starting 4. Apply a thin coat of water-resistant
in the center and moving outward. grease to the lip and periphery of an oil
Non-reusable parts seal before installation.
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, etc., when installing or 5. Check that moving parts operate nor-
6
assembling parts. mally after assembly.
7
8
9
6D93G11 1-4
Propeller size
The size of the propeller is indicated on the
propeller boss end, on the side of the propel-
ler boss.
S6D81010
× -
a b c
S69J1100
1 Model name
2 Approved model code × -
3 Transom height
4 Serial number a b c
Approved Starting
Model name S60C1120
model code serial No.
a Propeller diameter (in inches)
F80BET 6D7 1000001–
b Propeller pitch (in inches)
F100DET 6D9 1000001– c Propeller type (propeller mark)
1-5 6D93G11
1
ideal propeller for the boat is one that pro-
vides maximum performance in relation to
boat speed and fuel consumption.
13 × 17 - K
13 × 19 - K
13 × 21 - K
CAUTION:
This is a 4-stroke engine. Never use pre-
mixed fuel.
4
13 × 23 - K Stainless
13 × 25 - K
13 1/2 × 14 - K
13 1/2 × 16 - K
Checking the engine oil level
1. Check the engine oil level. 5
Predelivery checks
6
1
8
If the engine oil is below the minimum level
mark b, add sufficient oil until the level is
between a and b.
6D93G11 1-6
b
S6D81040
1-7 6D93G11
N
F R
a
1
a
WARNING
c S69J3370
2
The shift/throttle cable joint must be system
3
screwed in a minimum of 8.0 mm (0.31 in) 1. Check that the outboard motor tilts up
c. and down smoothly when operating the
power trim and tilt unit.
4
1. Check the steering friction for proper produced when the outboard motor is
adjustment. tilted up or down.
2. Check that the steering operates 3. Check that there is no interference with
smoothly. wires or hoses when the tilted-up out-
5
board motor is steered.
S60C1200
Checking the engine start switch and
engine stop lanyard switch
1. Check that the engine starts when the
6
engine start switch is turned to START.
3. Check that there is no interference with
wires or hoses when the outboard motor
is steered.
2. Check that the engine turns off when the
engine start switch is turned to OFF. 7
Checking the gear shift and throttle
operation
1. Check that the gear shift operates
smoothly when the remote control lever
8
is shifted from neutral to forward or
reverse.
6D93G11 1-8
È 0 1 2 10
S69J1240
È Hour
NOTE:
The test run is part of the break-in operation.
1-9 6D93G11
Specifications
3
General torques....................................................................................... 2-13
4
5
6
7
8
9
6D93G11
Model
Item Unit
F80BET F100DET
Dimension
Overall length mm (in) 817 (32.2)
Overall width mm (in) 479 (18.9)
Overall height
(L) mm (in) 1,582 (62.3)
(X) mm (in) 1,710 (67.3)
Boat transom height
(L) mm (in) 508 (20.0)
(X) mm (in) 635 (25.0)
Weight
(with aluminum propeller)
(L) kg (lb) 170 (375)
(X) kg (lb) 174 (384)
(with stainless propeller)
(L) kg (lb) 172 (379)
(X) kg (lb) 176 (388)
Performance
Maximum output kW (hp) 58.8 (80) at 73.6 (100) at
5,500 r/min 5,500 r/min
Full throttle operating range r/min 5,000–6,000
Maximum fuel consumption L (US gal, 28.0 (7.40, 6.16) at 35.0 (9.2, 7.7) at
Imp gal)/hr 6,000 r/min 6,000 r/min
Engine idle speed r/min 650–750
Power unit
Type In-line, 4-stroke, DOHC, 16 valves
Cylinder quantity 4
Total displacement cm3 (cu. in) 1,596 (97.39)
Bore × stroke mm (in) 79.0 × 81.4 (3.11 × 3.20)
Compression ratio 9.6
Control system Remote control
Starting system Electric
Fuel system Fuel injection
Ignition control system TCI
Advance type Micro computer
Maximum generator output V, A 12, 25
Spark plug LFR5A-11 (NGK)
Cooling system Water
Exhaust system Propeller boss
Lubrication system Wet sump
2-1 6D93G11
Model
Item Unit
F80BET F100DET
Fuel and oil
Fuel type
Fuel minimum rating
Engine oil
RON(*1)
PON
Regular unleaded gasoline
91
86
4-stroke motor oil
1
Engine oil grade API SE, SF, SG, SH, or SJ
L (US qt,
10W-30 or 10W-40
3
(with oil filter replacement) L (US qt, 4.5 (4.76, 3.96)
Imp qt)
Gear oil type Hypoid gear oil
Gear oil grade(*2) API GL-4
SAE 90
Gear oil quantity
Bracket unit
Trim angle
cm3 (US oz,
Imp oz)
Degree
670 (22.7, 23.6)
–4 to 16
4
(at 12° boat transom)
Tilt-up angle
Steering angle
Drive unit
Degree
Degree
70
35 + 35 5
Gear shift positions F-N-R
Gear ratio
Reduction gear type
Clutch type
Propeller shaft type
2.31 (30/13)
Spiral bevel gear
Dog clutch
Spline
6
Propeller direction (rear view) Clockwise
Propeller mark
Electrical
Battery minimum capacity(*3)
K
7
CCA/EN A 430
(*1)
20HR/IEC
RON: Research Octane Number
Ah
8
(*3) CCA: Cold Cranking Ampere
9
EN: European Norm (European standard)
IEC: International Electrotechnical Commission
6D93G11 2-2
Power unit
Model
Item Unit
F80BET F100DET
Power unit
Minimum compression kPa 860 (8.6, 124.7)
pressure(*1) (kgf/cm2, psi)
Oil pressure(*2) kPa 510 (5.1, 74.0) at engine idle speed
(kgf/cm2, psi)
Cylinder head
Warpage limit mm (in) 0.1 (0.0039)
2-3 6D93G11
Model
Item Unit
F80BET F100DET
Oil ring
Dimension B
Dimension T(*)
End gap
Side clearance
mm (in)
mm (in)
mm (in)
mm (in)
2.38–2.48 (0.0937–0.0976)
2.40 (0.0945)
0.20–0.70 (0.0079–0.0276)
0.03–0.15 (0.0012–0.0059)
1
Camshafts
Intake (A)
Exhaust (A)
Intake (B)
mm (in)
mm (in)
mm (in)
36.48–36.58 (1.4362–1.4402)
36.90–37.06 (1.4528–1.4591)
29.95–30.05 (1.1791–1.1831)
2
Exhaust (B) mm (in) 29.92–30.08 (1.1780–1.1842)
Camshaft journal diameter
Camshaft runout limit
Valves
Valve clearance (cold)
mm (in)
mm (in)
24.960–24.980 (0.9827–0.9835)
0.03 (0.0012)
3
Intake mm (in) 0.20 ± 0.03 (0.008 ± 0.001)
Exhaust
Head diameter (A)
Intake
mm (in)
mm (in)
0.34 ± 0.03 (0.013 ± 0.001)
29.0–29.2 (1.14–1.15)
4
Exhaust mm (in) 24.0–24.2 (0.94–0.95)
Face width (B)
Intake
Exhaust
Seat contact width (C)
mm (in)
mm (in)
1.99–2.44 (0.0783–0.0961)
2.27–2.72 (0.0894–0.1071)
5
Intake mm (in) 1.20–1.60 (0.0472–0.0630)
Exhaust
Margin thickness (D)
Intake
mm (in)
mm (in)
1.20–1.60 (0.0472–0.0630)
0.80–1.20 (0.0315–0.0472)
6
Exhaust mm (in) 1.00–1.40 (0.0394–0.0551)
Stem diameter
Intake
Exhaust
Guide inside diameter
mm (in)
mm (in)
5.975–5.990 (0.2352–0.2358)
5.960–5.975 (0.2346–0.2352)
7
Intake and exhaust mm (in) 6.000–6.018 (0.2362–0.2369)
Stem-to-guide clearance
Intake
Exhaust
mm (in)
mm (in)
0.010–0.043 (0.0004–0.0017)
0.025–0.058 (0.0010–0.0023)
8
Stem runout limit mm (in) 0.01 (0.0004)
9
Valve springs
Free length mm (in) 53.20 (2.0945)
Tilt limit mm (in) 2.6 (0.10)
6D93G11 2-4
Model
Item Unit
F80BET F100DET
Valve lifters
Valve lifter outside diameter mm (in) 27.965–27.980 (1.1010–1.1016)
Valve lifter-to-cylinder head mm (in) 0.020–0.056 (0.0008–0.0022)
clearance
Valve shims
Valve shim thickness mm (in) 2.0–3.3 (0.08–0.13)
(in 0.025 mm increments)
Connecting rods
Big end inside diameter mm (in) 47.025–47.045 (1.8514–1.8522)
Big end side clearance mm (in) 0.14–0.28 (0.0055–0.0110)
Crankpin oil clearance mm (in) 0.024–0.044 (0.0009–0.0017)
Big-end bearing thickness
Yellow mm (in) 1.499–1.506 (0.0590–0.0593)
Green mm (in) 1.506–1.513 (0.0593–0.0596)
Blue mm (in) 1.513–1.520 (0.0596–0.0598)
Red mm (in) 1.520–1.527 (0.0598–0.0601)
Crankshaft
Crankshaft journal diameter mm (in) 47.985–48.000 (1.8892–1.8898)
Crankpin diameter mm (in) 43.982–44.000 (1.7316–1.7323)
Crankpin width mm (in) 21.00–21.07 (0.8268–0.8295)
Runout limit mm (in) 0.03 (0.0012)
Crankcase
Crankshaft journal oil mm (in) 0.024–0.044 (0.0009–0.0017)
clearance
Upper crankcase main bearing
thickness
Green mm (in) 2.992–2.999 (0.1178–0.1181)
Blue mm (in) 2.999–3.006 (0.1181–0.1183)
Red mm (in) 3.006–3.013 (0.1183–0.1186)
Upper crankcase main bearing
#3 thickness
Green mm (in) 2.992–2.999 (0.1178–0.1181)
Blue mm (in) 2.999–3.006 (0.1181–0.1183)
Red mm (in) 3.006–3.013 (0.1183–0.1186)
Lower crankcase main bearing
thickness
Yellow mm (in) 3.010–3.017 (0.1185–0.1188)
Green mm (in) 3.017–3.024 (0.1188–0.1191)
Blue mm (in) 3.024–3.031 (0.1191–0.1193)
Red mm (in) 3.031–3.038 (0.1193–0.1196)
2-5 6D93G11
Model
Item Unit
F80BET F100DET
Oil pump
Discharge
at 97–103 °C (207–217 °F)
with 10W-30 engine oil
Pressure
L (US gal,
Imp gal)/min
kPa
5.9 (1.559, 1.298) at 1,000 r/min
3
Opening temperature °C (°F) 58–62 (136–144)
Fully open temperature °C (°F) 70 (158)
Valve open lower limit mm (in) 4.3 (0.17)
Lower unit
Gear backlash
Item Unit
F80BET
Model
F100DET 4
Pinion-to-forward gear mm (in) 0.28–0.63 (0.0110–0.0248)
5
Pinion shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Electrical
Model
Item
7
Ignition coil resistance
at 20 °C (68 °F)
Primary coil (R – B/W) Ω 1.53–2.07
Secondary coil kΩ 12.495–16.905
Spark plug wire resistance
#1
#2
#3
#4
kΩ
kΩ
kΩ
kΩ
4.5–10.7
3.3–8.0
3.7–8.9
4.3–10.2
8
9
6D93G11 2-6
Model
Item Unit
F80BET F100DET
ECM output peak voltage
(B/R, B/W – Ground)
at cranking (loaded) V 210
at 1,500 r/min (loaded) V 290
at 3,500 r/min (loaded) V 290
Pulser coil output peak voltage
(W/R, W/B – B)
at cranking (unloaded) V 3.6
at cranking (loaded) V 3.4
at 1,500 r/min (loaded) V 18.2
at 3,500 r/min (loaded) V 34.3
Pulser coil resistance(*) Ω 459–561
(W/R, W/B – B)
Throttle position sensor
Output voltage (P – B) V 0.8–1.2 at engine idle speed
Cooling water temperature
sensor resistance
at 0 °C (32 °F) kΩ 5.21–6.37
at 80 °C (176 °F) kΩ 0.290–0.354
Oil pressure switch
Operating pressure kPa 127.5–166.7 (1.28–1.67, 18.49–24.17)
(kgf/cm2, psi)
Fuel control system
Fuel injector resistance(*)
at 21 °C (70 °F) Ω 12.0
Starter motor
Type Sliding gear
Output kW 1.40
Cranking time limit Second 30
Brushes
Standard length mm (in) 15.5 (0.61)
Wear limit mm (in) 9.5 (0.37)
Commutator
Standard diameter mm (in) 29.0 (1.14)
Wear limit mm (in) 28.0 (1.10)
Mica
Standard undercut mm (in) 0.8 (0.03)
Wear limit mm (in) 0.2 (0.01)
(*) The figures are for reference only.
2-7 6D93G11
Model
Item Unit
F80BET F100DET
Charging system
Fuse
Stator coil output peak voltage
at cranking (unloaded)
(W – W)
A
V
20
12.4
1
at 1,500 r/min (unloaded) V 45.3
at 3,500 r/min (unloaded)
Stator coil resistance(*)
(W – W)
V 98.3
2
at 20 °C (68 °F) Ω 0.24–0.36
Rectifier Regulator output
peak voltage (R–Ground)
at 1,500 r/min (unloaded)
at 3,500 r/min (unloaded)
V
V
13.0
13.0
3
Power trim and tilt system
Trim sensor
Setting resistance
Resistance
(P – B)
(P – B)
Ω
Ω
10 ± 1
9–378.8
4
Fluid type ATF Dexron II
5
Brushes
Standard length mm (in) 10.0 (0.39)
Wear limit mm (in) 3.5 (0.14)
Commutator
Standard diameter mm (in) 22.0 (0.87)
Wear limit
Mica
Standard undercut
mm (in)
mm (in)
21.0 (0.83)
1.5 (0.06)
6
Wear limit mm (in) 1.0 (0.04)
7
(*) The figure is for reference only.
8
9
6D93G11 2-8
mm (in)
35˚
240 (9.4)
405 (15.9)
L : 998 (39.3)
527 (20.7) X: 1,115 (43.9)
171 (6.73) 651 (25.6)
62 (2.4)
857 (33.7)
666 (26.2)
366 (14.4)
49 (1.9)
27 (1.1)
L : 536 (21.1)
X: 663 (26.1)
164 (6.5)
X: 1,044 (41.1)
L : 917 (36.1)
L : 766 (30.2)
X: 842 (33.1)
191 (7.5)
˚
66
63 (2.5
)
4˚
L : 25 (1.0)
X: 24 (0.9)
12˚
2-9 6D93G11
mm (in)
1
180 (7.1) 180 (7.1)
2
163.5 (6.4) 163.5 (6.4)
3
50.8 (2.0)
80 (3.1) 4
254 (10.0)
5
348.5 (13.7)
13 (0.5)
18.5 (0.7)
6
55.5 (2.2)
Specified torques
Tightening torques
Part to be tightened Thread size
N·m kgf·m ft·lb
Fuel system
Fuel filter cup — 3 0.3 2.2
Fuel pump mounting bolt M6 10 1.0 7.4
Fuel pump screw M6 4 0.4 3.0
Sensor assembly screw M5 3.7 0.37 2.7
Idle speed control screw M5 3.7 0.37 2.7
Fuel rail mounting bolt M6 8 0.8 5.9
Throttle body mounting bolt M6 8 0.8 5.9
Fuel cooler screw M6 3 0.3 2.2
Float chamber screw M5 3 0.3 2.2
Vapor separator drain screw — 1.5 0.15 1.1
Pressure regulator bolt M6 5 0.5 3.7
Fuel hose joint — 4 0.4 3.0
Plate screw M4 2 0.2 1.5
Wiring harness holder screw M4 2 0.2 1.5
Pressure check valve — 10 1.0 7.4
Power unit
1st 42 4.2 31.0
Power unit mounting bolt M10
2nd 42 4.2 31.0
Apron screw M6 4 0.4 3.0
Flywheel magnet nut M24 215 21.5 158.6
Starter motor bolt M8 29 2.9 21.4
Spark plug wire cover screw M6 4 0.4 3.0
Starter relay lead bolt M6 4 0.4 3.0
Starter relay holder screw M6 3 0.3 2.2
Main and fuel pump relay screw M6 3 0.3 2.2
Oil pressure switch — 8 0.8 5.9
Oil pressure switch lead bolt M4 2 0.2 1.5
PTT relay lead nut M6 4 0.4 3.0
PTT motor lead bolt M6 4 0.4 3.0
Positive battery lead nut M8 9 0.9 6.6
Timing belt tensioner bolt M10 39 3.9 28.8
Drive sprocket nut M40 265 26.5 195.5
Driven sprocket bolt M10 60 6.0 44.3
1st 8 0.8 5.9
Camshaft cap bolt M7
2nd 17 1.7 12.5
Cylinder head cover plate screw M4 2 0.2 1.5
1st 8 0.8 5.9
Cylinder head cover bolt M6
2nd 8 0.8 5.9
2-11 6D93G11
Tightening torques
Part to be tightened Thread size
N·m kgf·m ft·lb
1st 14 1.4 10.3
M8
Anode screw
Exhaust cover plug
2nd
1st
M4
M18
12
2
55
14
1.2
0.2
5.5
1.4
8.9
1.5
40.6
10.3
3
M8
2nd 28 2.8 20.7
Crankcase bolt
M8
19
18
1.9
60°
1.8
14.0
13.3
4
2nd 80°
Lower unit
Gear oil drain screw
Gear oil check screw
Lower case mounting bolt (L-transom model)
—
—
M10
9
9
39
0.9
0.9
3.9
6.6
6.6
28.8
5
Lower case mounting nut (X-transom model) — 39 3.9 28.8
Propeller nut
Ring nut
Cooling water inlet cover screw
M16
—
—
34
103
5
3.4
10.3
0.5
25.1
76.0
3.7
6
Pinion nut M16 93 9.3 68.6
Bracket unit
Shift rod detent bolt
Shift position switch screw
Flushing hose adapter screw
—
M4
M6
18
1
2
1.8
0.1
0.2
13.3
0.7
1.5
7
Oil pump bolt M6 10 1.0 7.4
Upper mounting nut
Lower mounting nut
Grease nipple
—
—
—
51
51
3
5.1
5.1
0.3
37.6
37.6
2.2
8
Oil pump cover screw M6 4 0.4 3.0
9
Oil seal housing screw M6 4 0.4 3.0
Upper mount bolt M8 28 2.8 20.7
Baffle plate bolt M6 4 0.4 3.0
Muffler assembly bolt M8 20 2.0 14.8
Engine oil drain bolt M14 27 2.7 20.0
Oil strainer bolt M6 10 1.0 7.4
Oil pan bolt M6 11 1.1 8.1
6D93G11 2-12
Tightening torques
Part to be tightened Thread size
N·m kgf·m ft·lb
Exhaust manifold bolt M6 11 1.1 8.1
Steering arm stud bolt M10 20 2.0 14.8
Self-locking nut — 15 1.5 11.1
Trim sensor cam screw M6 2 0.2 1.5
Power trim and tilt unit
Reservoir cap — 7 0.7 5.2
PTT motor bolt M6 4 0.4 3.0
Gear pump bolt M5 5 0.5 3.7
Gear pump housing bolt M5 5 0.5 3.7
M4 4 0.4 3.0
Relief valve cap bolt
M5 5 0.5 3.7
Lever bolt M3 2 0.2 1.5
Manual valve — 2 0.2 1.5
M3 2 0.2 1.5
Gear pump bracket bolt
M5 4 0.4 3.0
Trim cylinder end screw — 90 9.0 66.4
Tilt cylinder end screw — 80 8.0 59.0
Tilt piston bolt M12 85 8.5 62.7
General torques
General torque
This chart specifies tightening torques for
Nut (A) Bolt (B) specifications
standard fasteners with a standard ISO
thread pitch. Tightening torque specifications N·m kgf·m ft·lb
for special components or assemblies are 8 mm M5 5 0.5 3.6
provided in applicable sections of this man- 10 mm M6 8 0.8 5.8
ual. To avoid warpage, tighten multi-fastener 12 mm M8 18 1.8 13
assemblies in a crisscross fashion and pro- 14 mm M10 36 3.6 25
gressive stages until the specified torque is 17 mm M12 43 4.3 31
reached. Unless otherwise specified, torque
specifications require clean, dry threads.
Components should be at room temperature.
2-13 6D93G11
General..........................................................................................................3-14
Checking the anodes............................................................................... 3-14
8
Checking the battery................................................................................ 3-14
Lubricating the outboard motor................................................................3-15
9
6D93G11
Digital tachometer
90890-06760
Leakage tester
90890-06840
3-1 6D93G11
Item
Anodes (external)
Remarks
Check/replace
Initial Every
10 hours 50 hours 100 hours 200 hours
(1 month) (3 months) (6 months) (1 year)
Refer to
page
3-14
1
Anodes (internal) Check/replace 3-14
Battery
Cooling water passages
Top cowling
Check/charge
Clean
Check
3-14
3-8
3-3
2
Fuel filter Check/replace 3-3
3
(can be disassembled)
Fuel system Check 3-3
Gear oil Change 3-12
Lubrication points Lubricate 3-15
Engine idle speed Check/adjust 3-8
(EFI models)
PCV (Pressure Control Valve)
Power trim and tilt unit
Propeller and cotter pin
Check
Check
Check/replace
5-39
3-11
3-13
4
Shift link/shift cable Check/adjust 3-10
Thermostat
Throttle link/throttle cable/
throttle pick-up timing
Check
Check/adjust
3-7
3-8 5
Water pump Check 6-9
Engine oil
Oil filter
Spark plugs
Check/change
Change
Clean/adjust/
replace
3-4
3-5
3-6
6
Timing belt Check/replace 3-6
NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed with clean water
7
after each use.
NOTE:
Check/adjust 5-10
9
When using lead or high-sulfur gasoline, checking valve clearance may be required more frequently
than every 500 hours.
6D93G11 3-2
a 2
2
4 1
6 S6D83020
b 1
S6D83010 Checking the fuel filter
1. Check the fuel filter element 1 for dirt
NOTE: and residue and check the fuel filter cup
• To loosen the fitting, move the hook in
2 for foreign substances and cracks.
direction a.
Clean the cup with straight gasoline and
• To tighten the fitting, move the hook in
replace the element if necessary.
direction b.
Fuel system 3
2
Checking the fuel joint and fuel S6D83030
hoses (fuel joint-to-fuel injector)
1. Remove the flywheel magnet cover. NOTE:
Be sure not to spill any fuel when removing
the fuel filter cup.
3-3 6D93G11
NOTE:
3
Be sure to clean up any oil spills.
b
S60C1150
5. Pour the specified amount of the recom-
mended engine oil into the oil filler hole.
4
5
NOTE: Recommended engine oil:
• Change the oil if it appears milky or dirty.
4-stroke motor oil
• If the engine oil is below the minimum level
API: SE, SF, SG, SH, or SJ
mark b, add sufficient oil until the level is
SAE: 10W-30 or 10W-40
between a and b.
Engine oil quantity:
7
turn it off.
for 5 minutes.
2. Remove the oil dipstick and oil filler cap
1. 7. Turn the engine off, and then check the
oil level and correct it if necessary.
S60C3060
9
3. Insert the tube of the oil changer 2 into
the dipstick hole 3.
6D93G11 3-4
S60C3060
S6D83050
NOTE:
• Wait more than 5 minutes after turning the
engine off to replace the oil filter.
• Be sure to clean up any oil spills.
wrench.
3-5 6D93G11
1
damage, or wear. Replace if necessary.
a
E
2
b
3
S6D83070
NOTE:
For replacement procedures, see Chapter 5,
S6D83060
“Replacing the timing belt.”
Oil filter:
18 N·m (1.8 kgf·m, 13.3 ft·lb)
Checking the spark plugs 4
T.
R.
5. Pour the specified amount of the recom- 2. Disconnect the spark plug wires, and
mended engine oil into the oil filler hole.
6D93G11 3-6
2 1
3-7 6D93G11
Water
Valve lift a
temperature
58–62 °C
(136–144 °F)
above
0.05 mm
(0.0020 in)
(valve begins to lift)
more than
1
70 °C (158 °F) 4.3 mm (0.17 in)
1 4
5
1
6
S60C3450
1
Digital tachometer: 90890-06760
S62Y3320
Engine idle speed: 650–750 r/min
7
Adjusting the throttle link and
2. Place the lower unit in water, and then
start the engine.
9
6D93G11 3-8
S6D83110
5 2
4 1 3 S6D83090
0
5. Check that the stopper 6 on the throttle
cam contacts the fully closed stopper 7
on the cylinder block.
7 S6D83120
3-9 6D93G11
a
1
WARNING
c S69J3370
b
2
The throttle cable joint must be screwed S6D81040
8
1
3
4
2
S6D83140
9
6D93G11 3-10
S6D83150
WARNING
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
Otherwise, the outboard motor could sud-
denly lower if the power trim and tilt unit
should lose fluid pressure.
NOTE:
Be sure to listen to the winding sound of the
power trim and tilt motor for smooth opera-
tion. 2
Reservoir cap:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
T.
R.
3-11 6D93G11
4
If the oil is at the correct level, the oil should
overflow out of the check hole when the
check screw is removed.
7
it to the specified torque.
CAUTION:
Do not over pressurize the lower unit, oth-
erwise the oil seals can be damaged.
NOTE:
Cover the check hole with a rag when remov-
ing the tester from the lower unit.
3-13 6D93G11
NOTE:
Checking the anodes If it is necessary to disassemble the outboard
1. Check the anodes and trim tab for motor to check an anode, refer to the applica-
scales, grease, or oil. Clean if necessary. ble disassembly procedure in this manual.
6D93G11 3-14
WARNING
Battery electrolyte is dangerous; it con- A
tains sulfuric acid which is poisonous and
highly caustic.
Always follow these preventive measures:
• Avoid bodily contact with electrolyte as
it can cause severe burns or permanent
eye injury.
S60C3660
• Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
• SKIN – Wash with water.
A
• EYES – Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
• Drink large quantities of water or milk
followed with milk of magnesia, beaten
egg, or vegetable oil. Get immediate
S60C3670
medical attention.
Batteries generate explosive, hydrogen
gas. Always follow these preventive mea-
sures:
• Charge batteries in a well-ventilated
area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
A
lighted cigarettes).
• DO NOT SMOKE when charging or han- S6D83180
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN. a a
NOTE:
• Batteries vary per manufacturer. The pro-
cedures mentioned in this manual may not
always apply, therefore, consult the instruc- A
3-15 6D93G11
1
a
A
2
3
S60C3710
NOTE:
Apply grease to the grease nipple until it
flows from the bushings a.
4
2. Apply low temperature resistant grease
to the area shown. 5
C 6
3. Apply corrosion resistant grease to the
S6D83190
7
area shown.
8
9
6D93G11 3-16
— MEMO —
3-17 6D93G11
Fuel system
6
Checking the vapor separator .................................................................4-16
Assembling the vapor separator..............................................................4-17
Adjusting the float ....................................................................................4-17
Canister.........................................................................................................4-19
Checking the canister .............................................................................. 4-20
7
8
9
6D93G11
4-1 6D93G11
1
2
3
4
5
6
7
1
2
3
Blowby hose
Fuel hose (primary pump-to-fuel filter)
Fuel hose (fuel filter-to-fuel pump)
8
4 Fuel hose (fuel pump-to-strainer)
9
5 Fuel hose (strainer-to-vapor separator)
6 High-pressure fuel hose (vapor separator-to-fuel rail)
7 Fuel hose (pressure regulator-to-fuel cooler)
8 Fuel hose (fuel cooler-to-vapor separator)
9 Canister hose (vapor separator-to-canister)
0 Canister hose (canister-to-idle speed control)
A Canister hose (canister-to-filter)
B Canister hose (filter-to-bottom cowling)
6D93G11 4-2
T.
R.
14
1 13
9
15
10
12
10
11
3
4
5
6
2
7
8
3 N · m (0.3 kgf · m, 2.2 ft · Ib)
T.
R.
S6D84020
4-3 6D93G11
1
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
T.
R.
1
3
2
2
5
3
6
8
4
9
7
5
10
11
9
6D93G11 4-4
NOTE:
Assemble the fuel pump valve to the fuel
pump body, and moisten the inside of the fuel
pump with gasoline to ensure a good seal.
Specified pressure:
50 kPa (0.5 kgf/cm2, 7.3 psi)
S63P4090
S63P4100
Specified pressure:
30 kPa (0.3 kgf/cm2, 4.4 psi)
4-5 6D93G11
6D93G11 4-6
3
2 3
4 14
15
13
1
12
7 6
16
9
8
5 11 10 S6D94010
4-7 6D93G11
1
T.
R.
2
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
T.
R.
5 4
13
6
15
11 16
3
10
7 12
9
14
16
4
8
1 5
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
6
T.
R.
S6D84050
Not reusable
9
16 Bolt 2 M6 × 38 mm
6D93G11 4-8
S6D84170
NOTE:
• 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 Sys-
tem.
• Do not turn the throttle stop screw a.
4-9 6D93G11
1
17
8 17
10
9
2
17 1
17
5
3
14
4
17
16
4
11 15
3
7 6
5
13
12
6
2
S6D84070
7
6 Fuel inlet hose 1
7
8
9
10
Hose
Joint
Hose
Hose
1
1
1
1
8
11 Hose 1
12
13
14
15
Hose
Clamp
Clamp
Quick connector
1
1
1
1
9
16 Clamp 1 Not reusable
17 Plastic tie 5 Not reusable
6D93G11 4-10
T.
R.
1.5 N · m (0.15 kgf · m, 1.1 ft · lb)
T.
R.
16
4
16
13
3
12
16 16
10
8
5 6 11 3 N · m (0.3 kgf · m, 2.2 ft · Ib)
7
T.
R.
16
16 16
16
15
9 14
4 N · m (0.4 kgf · m, 3.0 ft · Ib) S6D84080
T.
R.
4-11 6D93G11
1
3
T.
R.
2
16
T.
R.
LT
3
15
11
6
4
5 8
9
11
12
14 11
7
5
13
10
2 N · m (0.2 kgf · m, 1.5 ft · Ib) S6D84090
6
T.
R.
6D93G11 4-12
S6D84180
3
WARNING
Always reduce the fuel pressure in the
high-pressure fuel line before servicing 4
S6C14250
the line or the vapor separator. If the fuel
pressure is not released, pressurized fuel
WARNING
may spray out.
Always reduce the fuel pressure in the
fuel line before servicing the line or the
Disconnecting the quick connector fuel pipe. If the fuel pressure is not
1. Wrap the quick connector with a cloth, released, pressurized fuel could spray
and then rotate the quick connector tab out.
1 to the stopper position a.
4-13 6D93G11
2
1 WARNING
• Before measuring the fuel pressure,
make sure that the drain screw is tight-
1
ened securely.
WARNING
S6D84190 • 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.
2
• When connecting the fuel pressure
• After measuring the fuel pressure, cover
3
gauge, first cover the connection
between the gauge and the adapter with the end of the hose with a clean, dry rag,
a clean, dry rag to prevent fuel from point the hose downward, and then
leaking out. loosen the drain screw to drain the
• Gently screw in the gauge until it is remaining fuel from the hose and gauge.
4
firmly connected. • When storing the fuel pressure gauge,
make sure that the drain screw is tight-
ened securely.
Fuel pressure gauge adapter B 1:
90890-06942
Fuel pressure gauge 2: Checking the pressure regulator
90890-06786
NOTE:
5
then measure the fuel pressure within 3
Before disconnecting the quick connector,
seconds.
NOTE:
The fuel pressure decreases 3 seconds after
release the fuel pressure.
6D93G11 4-14
4-15 6D93G11
a 2
1
WARNING
S6D84100
WARNING
2
Reduce the fuel pressure before loosen- Do not reuse the fuel hose clamp, always
3
ing the vapor separator drain screw, or replace it with a new one.
pressurized fuel will spray out and may
result in serious injury.
Disassembling the vapor separator
1. Remove the float chamber, float pin, and
Removing the fuel hose clamp
4
float.
1. Remove the fuel hose clamp by cutting
the crimped section of the clamp.
5
6
S6C14220
NOTE:
Remove the float pin in the direction of the
CAUTION: arrow a shown.
If the fuel hose clamp is removed without
cutting the crimp first, the fuel hose will
be damaged.
2. Remove the needle valve and other com-
ponents.
7
Checking the vapor separator
8
Installing the fuel hose clamp
1. Check the needle valve for bends or
1. Crimp the fuel hose clamp properly to
wear. Replace if necessary.
securely fasten it.
9
S6D54200
6D93G11 4-16
NOTE:
• The float should be resting on the needle
valve, but not compressing it.
• Take measurements at the position shown,
a opposite the float pivot.
Float height d:
b 35.0 ± 1.0 mm (1.38 ± 0.04 in)
S6C14210
arrow a shown.
• Install the float pin with its tapered end Adjusting the float
towards the punch mark b on the vapor 1. Adjust the stopper a of the float by
separator cover. bending it until the float height b is within
specification.
Float height b:
46.6 ± 1.0 mm (1.83 ± 0.04 in)
4-17 6D93G11
1
Float height d:
2
35.0 ± 1.0 mm (1.38 ± 0.04 in)
NOTE:
When adjusting the float height, do not bend
the lever e.
3
4
5
6
7
8
9
6D93G11 4-18
17
16 8
15
14 6
5
9
7
11 4
12
2
10
1
13
S6D84150
4-19 6D93G11
Specified pressure:
6
19.6 kPa (0.196 kgf/cm2, 2.8 psi)
7
8
9
6D93G11 4-20
Power unit
Junction box.................................................................................................5-22
6D93G11
5-1 6D93G11
1
Valve seat cutter
90890-06312, 90890-06315, 90890-06324,
90890-06326, 90890-06328, 90890-06555
2
3
Piston slider
90890-06530
4
5
Oil filter wrench 64
90890-01426
6
7
8
9
6D93G11 5-2
NOTE:
Checking the compression pressure • If the compression pressure increases,
1. Start the engine, warm it up for 5 min- check the pistons and piston rings for wear.
utes, and then turn it off. Replace if necessary.
• If the compression pressure does not
2. Remove the engine stop lanyard from the
increase, check the valve clearance, valve,
engine stop lanyard switch on the remote
valve seat, cylinder head gasket, and cylin-
control box.
der head. Adjust or replace if necessary.
3. Remove the spark plug wire cover and all
spark plugs, and then install the special Checking the oil pressure
service tools into a spark plug hole. 1. Remove the flywheel magnet cover.
1
S6D85110
CAUTION:
Before removing the spark plugs, blow
compressed air in the spark plug well to
clear out any dirt or dust that may fall into
the cylinder. S6D85120
NOTE:
Compression gauge 1: Use a general pressure gauge.
90890-03160
Compression gauge extension M14
2: 4. Start the engine and warm it up for 5 min-
90890-06563 utes.
5-3 6D93G11
1
2 3
1
7 4
8
5
6
2
15
9
3
4
E
12
LT
572
10
13
LT
572
14 11
5
1 42 N · m (4.2 kgf · m, 31.0 ft · Ib)
42 N · m (4.2 kgf · m, 31.0 ft · Ib)
T.
6
R.
M6 × 16 mm
M10 × 130 mm
8
11 Screw 2 ø6 × 40 mm
12
13
14
15
Nut
Apron
Bolt
Holder
2
1
2
1
M8 × 35 mm
9
6D93G11 5-4
T.
R.
1 5
2 6
4 7
E
3 11
14
13
12
10
S6D85020
5-5 6D93G11
1
1
-00
2
241
-46
265 N · m (26.5 kgf · m, 195.5 ft · lb) 67F
.
R.
.
R.
5 2
E
12
11
10
7 9
6
3
4
E 3
14
13 E
8
4
15
16
5
39 N · m (3.9 kgf · m, 28.8 ft · Ib)
.
6
R.
S6D85030
M6 × 15 mm
7
6 Bracket 1
7
8
9
10
Bolt
Timing belt tensioner
Spring
Plastic tie
1
1
1
1
M10 × 45 mm
Not reusable
8
11 Hose 1
12
13
14
15
Clamp
Nut
Drive sprocket
Plate
1
1
1
1
9
16 Woodruff key 1
6D93G11 5-6
6
29 30 10
8 7
2 N · m (0.2 kgf · m, 1.5 ft · Ib) 29 N · m (2.9 kgf · m, 21.4 ft · Ib)
T.
R.
T.
R.
T.
R.
28
27 9
LT 25
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
26
T.
572
R.
15
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
T.
R.
2 24
3 5
1
22 16
5 23 17
3 18 21
4 12 19
20
14
13 13
9 N · m (0.9 kgf · m, 6.6 ft · Ib)
T.
R.
4
11 13 S6D85040
5-7 6D93G11
6
30 10
T.
R.
T.
R.
T.
R.
28
27 9
572
R.
15
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
3
T.
R.
2 24
3 5
5
3
22
23 17
18
16
21
4
4 12 19
5
20
14
13 13
9 N · m (0.9 kgf · m, 6.6 ft · Ib)
6
T.
R.
4
11 13 S6D85040
T.
2 17 N • m (1.7 kgf • m, 12.5 ft • lb)
R.
13
E
2 N · m (0.2 kgf · m, 1.5 ft · Ib)
9 13
T.
R.
S1280B
4 11 E
10
1 M
E 10
LT
E
2 5 271 10
E
10
E
6 12 14
7 E E
8
1 8 N · m (0.8 kgf · m, 5.9 ft · lb)
8 N · m (0.8 kgf · m, 5.9 ft · lb)
T.
2
R.
S6D85070
5-9 6D93G11
1
• Do not turn the flywheel magnet coun-
terclockwise, otherwise the valve sys-
tem 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
2
be damaged.
NOTE:
For removal and installation procedures of
a
b
3
the timing belt, driven sprockets, and cam- S6D85140
4
shafts, see the applicable procedures in this
manual. 3. Loosen the tensioner bolt 7, and then
remove the spring 8, timing belt 9,
driven sprockets 0, and cylinder head
1. Remove the flywheel magnet cover 1,
cover A.
filter 2, and spark plug wire cover 3,
disconnect the spark plug wires 4, fuel
hoses 5, and blowby hose 6, and then
remove all spark plugs. 7
0
8
0 5
1
5
6
3
9
A
6
4
2 S6D85130
7
2. 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
S6D85150
8
sprockets are aligned.
9
6D93G11 5-10
IN EX 0 0
7 8
#1
#2
#3
#4
A
9
f e
B
S6D85180
S6D85170
NOTE:
NOTE: Do not mix the valve train parts. Keep them
• Check the valve clearance when the engine organized in their proper groups.
is cold.
• Note the measurement.
10. Remove the valve lifters from the cylinder
head.
5-11 6D93G11
1
driven sprockets are aligned.
c d
D
S6D85190
2
12. Measure the valve shim thickness with a
micrometer, and then note the measure-
ment. 3
13. Select the necessary valve shim by cal-
a
culating its thickness with the following
formula.
Example:
If the “Removed valve shim thickness” is 2.10
20. Install the timing belt.
14. Install the necessary valve shim into the 22. Install the spark plug wire cover, filter,
valve lifter, and then install the valve lift-
ers into the cylinder head.
and flywheel magnet cover.
6D93G11 5-12
CAUTION:
• Do not turn the drive sprocket counter-
clockwise, 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
CAUTION:
valves will interfere with each other and
be damaged. To prevent damage to the engine or tools,
screw in the puller set bolts evenly and
1. Remove the flywheel magnet cover. completely so that the puller plate is par-
allel to the flywheel magnet.
2. Loosen the flywheel magnet nut.
NOTE:
Apply force to the crankshaft end until the fly-
wheel magnet comes off the tapered portion
of the crankshaft.
NOTE:
Do not loosen the pulser coil screw.
5-13 6D93G11
3
S6D85220
7
8
8. Check that the hole a on the retaining
plate and the projection b on the cylin-
S6D85230
9
der block are aligned.
6D93G11 5-14
8
-00
6 241
6 7F-4
S6D85260
CAUTION:
• Do not twist, turn inside out, or bend the
timing belt beyond the maximum limit of
25 mm (1.0 in) otherwise it can be dam-
aged.
• Do not get oil or grease on the timing
belt.
NOTE:
The lower edge of the timing belt should be 2
mm (0.08 in) e from the bottom of the driven
sprockets.
12. Loosen the timing belt tensioner bolt 90°. 17. Install the bracket and connect the cool-
ing water hose.
5-15 6D93G11
19. Install the flywheel magnet. 6. Disconnect the cooling water pilot hose,
canister hose, and flushing hose.
4
slipping off easily.
NOTE:
Apply engine oil to the flywheel magnet nut
before installation.
5
2
8
magnet nut before removing the power unit to
improve working efficiency.
6D93G11 5-16
4
4
b 5 S6D85730
a
NOTE:
Do not turn the camshafts when loosening
the driven sprocket bolts.
3 1
S6D85360
5-17 6D93G11
6 2
1
2
7
NOTE:
S6D85740
4
Flywheel holder: 90890-06522
Checking the timing belt and
sprockets
1. Check the interior and exterior of the tim- Driven sprocket bolt 2:
60 N·m (6.0 kgf·m, 44.3 ft·lb)
T.
R.
1
7
a b
8
S6D85660
8 6
S6D85410
NOTE:
Use a deep socket 7 for this procedure.
Crankshaft holder 20 8:
90890-06552
NOTE:
• Apply engine oil to the drive sprocket nut
before installation.
• Tighten the drive sprocket nut finger tight.
d
c
S6D85300
NOTE:
For timing belt installation procedure, see
“Replacing the timing belt.”
5-19 6D93G11
15
1
14
7 A
15
1
2
6
5
4
3 3
7
4
10
9
A
2
4
5
5
8
A
12
11
No.
13
7
6 Spring 1
7
8
9
10
Washer
Throttle lever
Bolt
Collar
2
1
1
1
M6 × 25 mm
8
11 Throttle link rod 1
12
13
14
15
Nut
Throttle link rod joint
Bracket
Bolt
1
1
1
2 M6 × 30 mm
9
6D93G11 5-20
2 3
1 7
3 6
4
5
15 10
11
12
17 13
17 15
14
16
4
S6D85050
5-21 6D93G11
20
21
3 N · m (0.3 kgf · m, 2.2 ft · Ib)
1
T.
R.
23 9 11
13
2
1
2
24
12
3
10
14
15
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
T.
R.
19
18 16 17
4
5
6 5
4 N · m (0.4 kgf · m, 3.0 ft · Ib) 8 4
T.
R.
6
7
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
5 6
22
T.
S6D95020
R.
30 A
20 A
8
11 Cap 1
12
13
14
15
Cap
Starter relay
Holder
Screw
3
1
1
1 ø6 × 20 mm
9
16 Bolt 1 M6 × 10 mm
17 Cap 1
6D93G11 5-22
20
21
3 N · m (0.3 kgf · m, 2.2 ft · Ib)
T.
R.
23 9 11
1
2
24 13
12
10
14
15
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
T.
R.
19
22
3 N · m (0.3 kgf · m, 2.2 ft · Ib)
T.
R.
3
4
5
18 16 17 6
7
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
5 6
22
T.
S6D95020
R.
5-23 6D93G11
7 2
1
1 15 N • m (1.5 kgf • m, 11.1 ft • lb)
2 30 N • m (3.0 kgf • m, 22.1 ft • lb) 8 5
4
T.
R.
3 90˚ 9 E
E
1
10
11 2
3
25 N • m (2.5 kgf • m, 18.4 ft • Ib)
T.
R.
12 16
13
LT
14
15
24
24
3
6
4
271 22 23 E
E
E
21 23
18
19
20 22 1 14 N · m (1.4 kgf · m, 10.3 ft · lb)
28 N · m (2.8 kgf · m, 20.7 ft · lb) 5
T.
21 2
R.
17
20
E 19
18
6
E
E 17
S6D85080
M10 × 143 mm
8
11 Spark plug 4
12
13
14
15
Bolt
Bolt
Anode cover
Anode
2
2
2
2
M8 × 40 mm
M6 × 22 mm
9
16 Grommet 2
17 Valve shim 16
6D93G11 5-24
7 2
1 15 N • m (1.5 kgf • m, 11.1 ft • lb)
2 30 N • m (3.0 kgf • m, 22.1 ft • lb) 8 5
4
T.
R.
3 90˚ 9 E
E
1
11
10
12 16
15
14 6
13
24 3
LT
24
271 22 23 E
E
E
21 23
20 22
19 1 14 N · m (1.4 kgf · m, 10.3 ft · lb)
18 28 N · m (2.8 kgf · m, 20.7 ft · lb)
T.
21 2
R.
17
20
E 19
18
E
E 17
S6D85080
5-25 6D93G11
4
S6D85420
3
S6D85430 7
4. Remove the valve shims 6 from the
valve lifters 7.
8
9
S60C5380
6D93G11 5-26
5-27 6D93G11
a
1
Valve stem diameter b: Valve guide inside diameter a:
S60C5450
2
Intake: Intake and exhaust:
5.975–5.990 mm 6.000–6.018 mm
(0.2352–0.2358 in)
Exhaust:
5.960–5.975 mm
(0.2362–0.2369 in)
NOTE:
• Turn the valve guide reamer clockwise to
ream the valve guide.
• Do not turn the reamer counterclockwise
when removing the reamer.
5-29 6D93G11
1
S63P5240
2
Valve seat contact width a:
1.20–1.60 mm (0.0472–0.0630 in)
3
Refacing the valve seat
1. Reface the valve seat with the valve seat
cutters.
a Slag or rough surface
CAUTION:
4
Do not over cut the valve seat. Be sure to
turn the cutter evenly downward at a pres-
sure of 40–50 N (4–5 kgf, 8.8–11 lbf) to
prevent chatter marks.
5
3. Use a 30° cutter to adjust the contact
width of the top edge of the valve seat. 6
Valve seat cutter holder:
b
90890-06553
Valve seat cutter:
30° (intake): 90890-06326
30° (exhaust): 90890-06328
7
45° (intake): 90890-06555
45° (exhaust): 90890-06312
60° (intake): 90890-06324
60° (exhaust): 90890-06315 b Previous contact width
30˚
S69J5880
8
2. Cut the surface of the valve seat with a
45° cutter by turning the cutter clockwise
until the valve seat face has become
smooth.
9
6D93G11 5-30
60˚
S69J5890
5-31 6D93G11
CAUTION:
Do not get the lapping compound on the
1
valve stem and valve guide.
2
0.03 mm (0.0012 in)
c
4
d
5
S69J5970
Cam lobe a:
Intake:
36.48–36.58 mm
(1.4362–1.4402 in)
Camshaft journal diameter c:
24.960–24.980 mm
(0.9827–0.9835 in)
6
Exhaust: Camshaft cap inside diameter d:
7
36.90–37.06 mm 25.000–25.021 mm
(1.4528–1.4591 in) (0.9843–0.9851 in)
Cam lobe b:
Intake:
Checking the cylinder head
29.95–30.05 mm
1. Eliminate carbon deposits from the com-
8
(1.1791–1.1831 in)
bustion chambers and check for deterio-
Exhaust:
ration.
29.92–30.08 mm
(1.1780–1.1842 in)
S6D85470
NOTE:
The valve spring can be installed in any
direction.
S6D85460
Valve spring compressor 6:
Cylinder head warpage limit: 90890-04019
0.1 mm (0.0039 in) Valve spring compressor attachment
7:
90890-06320
Installing the valves
1. Install a new valve seal 1 onto the valve
guide. 3. Compress the valve spring, and then
install the valve cotters 8 using a thin
screwdriver with a small amount of
grease applied to it.
S60C5660
5-33 6D93G11
1
2
a 90˚ 3
S60C5680 E S6D85480
6
torques in two stages first, and then tighten
the M8 bolts to 14 N·m (1.4 kgf·m, 10.3
ft·lb).
S60C5690 • Make a mark a on the M10 bolts and the
cylinder head, and then tighten the bolts
7
Installing the cylinder head 90° from the mark.
1. Check that the piston of cylinder #1 is at • Tighten the M8 bolts to 28 N·m (2.8 kgf·m,
TDC. 20.7 ft·lb).
8
head, and then tighten the bolts to the Cylinder head bolt (M10):
1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
T.
R.
9
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
6D93G11 5-34
3. 6 1
7 2 1
A1
A 2 A 2
7 2
S1280B
M
8 3
3 A 2
8
A 2
3
E
9 4
A 2 A 2
9 4
M
E
10 5
b A 2
10
A 2
5 5
A 2
S6D85510
E
NOTE:
1
Apply engine oil to the camshaft caps and
2
camshaft cap bolts before installation.
S6D85490
S6D85500
5-35 6D93G11
S1280B
1
2
3
S6D85520
NOTE:
For sprocket and timing belt installation pro-
5
cedures, see “Installing the sprockets and
timing belt.”
6
7
8
9
6D93G11 5-36
T.
R.
26
E 18 N · m (1.8 kgf · m, 13.3 ft · Ib)
T.
R.
23 N • m (2.3 kgf • m, 17.0 ft • Ib)
T.
R.
1
2 4
3
5
2
3 9 6
7 8
10
28 LT
27 271 11 15
12 16
3 18
13 14
17
55 N · m (5.5 kgf · m, 40.6 ft · Ib)
T.
R.
2 19 29
LT
271
2 N · m (0.2 kgf · m, 1.5 ft · Ib) A
30
T.
R.
23 20
21 E
S6D85090
5-37 6D93G11
1
25 49 N · m (4.9 kgf · m, 36.1 ft · Ib)
T.
R.
26
E 18 N · m (1.8 kgf · m, 13.3 ft · Ib)
T.
R.
23 N • m (2.3 kgf • m, 17.0 ft • Ib)
T.
2
R.
1
2 4
3
5
3
2
3 9 6
7 8
10
28 LT
27 11 15
4
271
12 16
3 18
13 14
17
55 N · m (5.5 kgf · m, 40.6 ft · Ib)
T.
R.
2 19 29
LT
23 20
21 E
6
LT
S6D85090
Not reusable
8
28 Plug 1 M14 × 12 mm
29
30
Plastic tie
Hose
1
1
Not reusable
9
6D93G11 5-38
S6D85530
4. Check the spring for fatigue or deforma- 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
tion. Replace if necessary.
S6D85540
5-39 6D93G11
1
1 19 N • m (1.9 kgf • m, 14.0 ft • lb)
T.
2 60˚
R.
10
E
E
2
6 13
3
3 11
E
13
14 16
E 4 S518
7
E
5
17 E
8
9 15 E
UP
4
12
1 14 N · m (1.4 kgf · m, 10.3 ft · lb)
28 N · m (2.8 kgf · m, 20.7 ft · lb)
7 8
5
T.
2
R.
2 80˚
R.
M8 × 55 mm
7
6 Cylinder block 1
7
8
9
10
Main bearing
Main bearing
Main bearing
Oil seal
5
4
1
1 Not reusable
8
11 Crankshaft 1
12
13
14
15
Oil seal
Connecting rod bearing
Piston/connecting rod assembly
Bolt
1
8
4
8
Not reusable
Not reusable
9
M8 × 38 mm
16 Piston ring set 4
17 Stud bolt 2
6D93G11 5-40
NOTE:
Be sure to clean up any oil spills.
S6D85560
NOTE:
Do not remove the ignition timing pointer
from the crankcase. Piston diameter a:
78.928–78.949 mm
(3.1074–3.1082 in)
3. Remove the connecting rod bolts and the Measuring point b:
connecting rod caps, and then remove 13.0 mm (0.51 in) up from the
the crankshaft, oil seals, and the piston bottom of the piston skirt
assemblies. Oversize piston diameter:
79.178–79.199 mm
(3.1172–3.1181 in)
5-41 6D93G11
1
direction d (D1, D3, D5), which is parallel
to the crankshaft, and direction e (D2,
D4, D6), which is at a right angle to the Checking the piston rings
crankshaft. 1. Check the piston ring dimensions of B
and T. Replace if out of specification.
c b
a D2 D1
d
2
D4 D3 e
D6 D5
S60C5830
3
a 20 mm (0.8 in)
4
b 50 mm (2.0 in)
c 80 mm (3.1 in) Piston ring dimensions:
Top ring a:
Cylinder bore (D1–D6):
B: 1.17–1.19 mm
79.000–79.020 mm
(0.0461–0.0469 in)
(3.1102–3.1110 in)
Taper limit:
D1–D5 (direction d)
D2–D6 (direction e)
T: 3.00–3.20 mm
(0.1181–0.1260 in)
Oil ring c:
B: 2.38–2.48 mm
6
0.08 mm (0.0031 in)
(0.0937–0.0976 in)
6D93G11 5-42
5-43 6D93G11
2
21.00–21.07 mm
(0.8268–0.8295 in)
S6D85590
5
Crankshaft runout limit:
0.03 mm (0.0012 in)
2
S60C5960
S60C5A10
NOTE:
Install the bearings in their original positions. NOTE:
Make sure that the large, flat side a on the
connecting rod faces towards the flywheel
3. Put a piece of Plastigauge (PG-1) onto magnet side of the crankshaft.
the crankpin, parallel to the crankshaft.
NOTE:
Be sure not to put the Plastigauge (PG-1)
over the oil hole in the crankpin of the crank-
shaft. NOTE:
• Reuse the removed connecting rod bolts.
• Do not turn the connecting rod until the
4. Install the connecting rod to the crankpin crankpin oil clearance measurement has
3. been completed.
2nd: 80°
5-45 6D93G11
1
Replace the connecting rod bearing if out
of specification.
(#1)
(#2)
2
Crankpin oil clearance:
(#3)
3
0.024–0.044 mm (#4)
4
(0.0009–0.0017 in)
S6D85670
5
Use a metric gauge in this procedure. diameters (#1–#4).
6
described below.
2. Measure the connecting rod big end Crankpin diameter = 43.900 + (stamped
inside diameter a. value/1,000)
Example: #1 = 92 → 43.992
a
7
NOTE:
S60C5980 8
Reuse the removed connecting rod bolts.
6D93G11 5-46
b S6D85710
2
Connecting rod bearing selection table
(20 °C [68 °F]) a 1
Connecting rod big
end inside
Upper Lower
diameters –
bearing bearing
crankpin diameters
(mm)
3.025–3.027 Yellow Yellow
3.028–3.034 Yellow Green*
3.035–3.041 Green Green S60C5910
3.042–3.049 Green Blue*
3.050–3.057 Blue Blue NOTE:
• Install the bearings in their original posi-
3.058–3.063 Blue Red* tions.
• Install the unified thrust bearing at the posi-
CAUTION: tion a shown.
The (*) mark indicates that the colors of
the upper and lower bearings are differ-
4. Put a piece of Plastigauge (PG-1) on
ent.
each crankshaft journal parallel to the
Example: crankshaft.
If the “Connecting rod big end inside diame-
ter a” is 47.050 mm and the “Crankpin mark”
is 92, then the “Calculated value” = 47.050 –
43.992 = 3.058 mm
Suitable colors:
Upper bearing → blue
Lower bearing → red
5-47 6D93G11
1
journal. Replace the main bearing if out
block and apply engine oil onto the of specification.
threads of the crankcase bolts.
4
(0.0009–0.0017 in)
60˚
Selecting the main bearing
1. When replacing the main bearing, select
the suitable bearing as follows.
5
S6D85600
NOTE:
• Do not move the crankshaft until the crank-
shaft journal oil clearance measurement
6
has been completed.
7
• Tighten the M10 bolts to 19 N·m (1.9 kgf·m,
14.0 ft·lb) first, and then tighten the M8
bolts to 14 N·m (1.4 kgf·m, 10.3 ft·lb).
• Make a mark b on the M10 bolts and the
crankcase, and then tighten the bolts 60°
from the mark.
• Tighten the M8 bolts to 28 N·m (2.8 kgf·m,
20.7 ft·lb). 8
9
Crankcase bolt (M10):
1st: 19 N·m (1.9 kgf·m, 14.0 ft·lb)
T.
R.
2nd: 60°
Crankcase bolt (M8):
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
6D93G11 5-48
a S6D85720
Cylinder block
Bearing
#1
journal inside Bearing
(cylinder
2 diameters – (crankcase
side)/thrust
#2 crankshaft journal side)
bearing
diameters (mm)
#3
6.023–6.026 Green Yellow*
#4
6.027–6.034 Blue Green*
#5 6.035–6.042 Blue Blue
S60C5A50 6.043–6.049 Red Blue*
6.050–6.058 Red Red
3. Subtract crankshaft journal diameters
#1–#5 from cylinder block journal inside
diameters #1–#5. CAUTION:
• The (*) mark indicates that the colors of
NOTE: the upper and lower bearings are differ-
Cylinder block journal inside diameters (#1– ent.
#5) and crankshaft journal diameters (#1–#5) • Be sure to install the main bearings in
can be determined by the stamped value as the middle of the cylinder block and
described below. crankcase journal so they do not block
Crankshaft journal diameter = 47.900 + the oil holes.
(stamped value/1,000)
Example: #1 = 92 → 47.992
Cylinder block journal inside diameter = NOTE:
54.000 + (stamped value/1,000) Main bearing #3 is a thrust bearing.
Example: #1 = 32 → 54.032
Example:
If the “Crankshaft journal mark” is 92, and the
4. Select the suitable color a for the main “Cylinder block mark” is 32, then the “Calcu-
bearing from the table below according to lated value” = 54.032 – 47.992 = 6.040 mm
the calculated values. Suitable colors:
Bearing (cylinder side)/thrust bearing → blue
Bearing (crankcase side) → blue
5-49 6D93G11
1
marks a on the piston rings facing
upward. 4. Install the piston with the “UP” mark on
the piston crown facing towards the fly-
2. Offset the piston ring end gaps as wheel magnet.
shown.
a
#3
45˚
UP
45˚
#2
2
1
#5
#4
#3
#2
2
#1,#4
3
#5
S60C5A90
3
#1
4
NOTE:
a Apply engine oil to the side of the pistons and
E
piston rings before installation.
S60C5A70
CAUTION:
Do not scratch the piston or break the pis-
ton rings.
Piston slider: 90890-06530
6
NOTE:
After installing the piston rings, check that
7
they move smoothly.
b 6
3. Install the upper bearing into the con-
necting rod 4 and the lower bearing into
the connecting rod cap 5. 7
4
S60C5B10
8
9
NOTE:
• Install the bearings in their original posi-
tions.
• Install the unified thrust bearing at the posi-
tion b shown.
5 E
S60C5A80
6D93G11 5-50
T.
R.
0
2nd: 80°
8
8. Install half of the bearings B into the
crankcase.
S6D85700
B GM
S518
A
c
5
E
E
S6D85620
NOTE:
E
• Install the bearings in their original posi-
tions.
• Do not get any sealant on the main bear-
ings.
5-51 6D93G11
E
2. Install the power unit 3 by installing bolts
4 and 5, then tightening them to the
1
specified torques in two stages and in the
d
2
sequence shown.
60˚
3. Install the apron 6.
1
3
S6D85680
CAUTION:
The oil seals must be installed before
tightening the crankcase bolts.
4
NOTE:
• Tighten the M10 bolts to 19 N·m (1.9 kgf·m,
14.0 ft·lb) first, and then tighten the M8
5
LT
572
4
5
bolts to 14 N·m (1.4 kgf·m, 10.3 ft·lb).
• Make a mark d on the M10 bolts and the 6
6
LT
572 5 S6D85630
crankcase, and then tighten the bolts 60°
from the mark.
• Tighten the M8 bolts to 28 N·m (2.8 kgf·m,
20.7 ft·lb).
2nd: 60°
8
Crankcase bolt (M8): S6D85310
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb) Power unit mounting bolt 4:
1st: 42 N·m (4.2 kgf·m, 31.0 ft·lb)
T.
R.
12. Install the cylinder head. 2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb)
NOTE:
For cylinder head installation procedure, see
“Installing the cylinder head.”
Apron screw:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
6D93G11 5-52
S60C1150
NOTE:
If the engine oil is below the minimum level
mark b, add sufficient oil until the level is
between a and b.
5-53 6D93G11
Lower unit
3
Disassembling the propeller shaft assembly ...........................................6-11
Disassembling the propeller shaft housing.............................................. 6-11
Checking the propeller shaft housing ......................................................6-12
Checking the propeller shaft.................................................................... 6-12
Assembling the propeller shaft assembly ................................................ 6-12
Assembling the propeller shaft housing...................................................6-13
Shimming...................................................................................................... 6-25
7
Shimming.................................................................................................6-26
Selecting the pinion shims....................................................................... 6-26
Selecting the forward gear shims ............................................................ 6-27
9
6D93G11
Center bolt
90890-06504 Driver rod L3
90890-06652
6-1 6D93G11
1
Driver rod SS Drive shaft holder 5
90890-06604 90890-06519
2
Bearing depth plate Pinion nut holder
3
90890-06603 New: 90890-06715
Current: 90890-06505
4
Driver rod LS
5
90890-06606 Bearing outer race puller assembly
90890-06523
6
Ball bearing attachment
90890-06655 Driver rod SL
7
90890-06602
8
Bearing inner race attachment
90890-06639, 90890-06643, 90890-06661 Bearing outer race attachment
90890-06621, 90890-06626
9
6D93G11 6-2
Shimming plate
90890-06701
6-3 6D93G11
1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Lower unit 1
2
3
4
5
Hose
Check screw
Gasket
Dowel
1
1
2
2
Not reusable 7
6 Bolt 4 M10 × 40 mm/L-transom model
7
8
9
10
Drain screw
Grommet
Bolt
Bolt
1
1
1
1
M10 × 45 mm
M8 × 60 mm/L-transom model
8
11 Spacer 1
12
13
14
15
Propeller
Washer
Washer
Cotter pin
1
1
1
1 Not reusable
9
16 Nut 1
17 Trim tab 1
6D93G11 6-4
6-5 6D93G11
1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Bolt 2 M6 × 16 mm
2
3
4
5
O-ring
Oil seal
Oil seal housing
O-ring
1
1
1
1
Not reusable
Not reusable
Not reusable
7
6 Circlip 1
7
8
9
10
Shift rod
Woodruff key
Screw
Bolt
1
1
2
2
ø4 × 12 mm
M8 × 75 mm
8
11 Cover 1
12
13
14
15
Bolt
Seal
Water pump housing
Insert cartridge
2
1
1
1
M8 × 50 mm
9
16 Impeller 1
17 Dowel 2
6D93G11 6-6
6-7 6D93G11
1 1
2
2
3
2. Set the gear shift to the neutral position, S6D86020
6D93G11 6-8
2. Remove the Woodruff key. 2. Check the impeller and insert cartridge
for cracks or wear. Replace if necessary.
3. Remove the outer plate cartridge and oil
seal housing. 3. Check the Woodruff key 1 and the
groove a on the drive shaft for wear.
4. Remove the shift rod assembly 1. Replace if necessary.
a
1
S6D86050
a 2
S60C6405
NOTE:
Pull up the shift rod assembly a little a to dis-
connect it from the shift slider 2, turn it clock-
wise 90° b, and then remove it.
6-9 6D93G11
1
2
3
4
5
No. Part name Q’ty Remarks
6
1 Slider 1
2
3
4
5
Shift plunger
Cross pin
Dog clutch
Spring
1
1
1
1
7
6 Propeller shaft 1
7
8
9
10
Washer
Reverse gear
Thrust washer
Ball bearing
1
1
1
1 Not reusable
8
11 O-ring 1 Not reusable
12
13
14
15
Propeller shaft housing
Straight key
Needle bearing
Oil seal
1
1
1
2 Not reusable
9
16 Claw washer 1
17 Ring nut 1
6D93G11 6-10
6-11 6D93G11
CAUTION:
Do not reuse the bearing, always replace
1
it with a new one.
3
ing.
3. Check the dog clutch and slider for
cracks or wear. Replace if necessary.
7
facing toward the slider.
2. Check the teeth and dogs of the reverse
gear for cracks or wear. Replace the
gear if necessary.
Depth d:
5.0 ± 0.5 mm (0.20 ± 0.02 in)
NOTE:
• Install the needle bearing with the manufac-
ture 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.
NOTE:
Driver rod SS 1: 90890-06604 Install the ball bearing with the manufacture
Needle bearing attachment 2: identification mark e facing outward (propel-
90890-06612 ler side).
Bearing depth plate 3: 90890-06603
Bearing inner race attachment 9:
Depth b: 90890-06639
25.25 ± 0.25 mm (0.99 ± 0.01 in)
4. Install the reverse gear assembly into the
2. Apply grease to the new oil seals, and propeller shaft housing using a press.
then install them into the propeller shaft
housing to the specified depth.
NOTE:
Install an oil seal halfway into the propeller
shaft housing, then the other oil seal.
6-13 6D93G11
1
2
3
Bearing inner race attachment 0:
90890-06661 4
5
6
7
8
9
6D93G11 6-14
6-15 6D93G11
1
2
3
4
5
No. Part name Q’ty Remarks
6
18 Pinion 1
19
20
Nut
Lower case
1
1
7
8
9
6D93G11 6-16
2 CAUTION:
Do not reuse the bearing, always replace
S68S6360J it with a new one.
S68S6160
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
CAUTION:
• Do not press the drive shaft threads a Disassembling the lower case
directly. 1. Remove the taper roller bearing outer
• When removing the drive shaft bearing, race and shim(s).
do not damage the drive shaft collar 4.
• Do not reuse the bearing, always
replace it with a new one.
6-17 6D93G11
7
8
Needle bearing attachment 5:
90890-06611
Driver rod L3 6: 90890-06652
9
6D93G11 6-18
NOTE:
• Apply the gear oil to the inside and outside
of the sleeve before installation.
• Install the sleeve by facing the projection d
forward.
Depth c:
188.1 ± 0.5 mm (7.41 ± 0.02 in)
6-19 6D93G11
1 2
90890-06607
4
S68S6400
Pinion nut:
5
Needle bearing attachment 2: 93 N·m (9.3 kgf·m, 68.6 ft·lb)
T.
R.
6
90890-06614
Driver rod L3 3: 90890-06652 Installing the propeller shaft housing
1. Install the washer 1 and propeller shaft
assembly 2 into the propeller shaft
Depth a:
housing assembly 3.
1.20 ± 0.25 mm (0.05 ± 0.01 in)
8
9
6D93G11 6-20
a
b
2
S60C6430
NOTE:
Install the shift rod assembly into the lower
case, turn it counterclockwise 90° a, and
then push it down b to connect it to the shift
slider 2.
NOTE:
• 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.
6-21 6D93G11
0 A
d
1
C A
2
9
S1104J S6D86150
8
A
6 NOTE:
5 Align the insert cartridge projection d with
7 the hole e in the water pump housing.
4
F
5
S6D86140 F
9
water pump housing D. the drive shaft clockwise.
6D93G11 6-22
b
S6D81040
È X-transom model
S6D86180
6-23 6D93G11
1
cavitation plate and propeller to keep the
propeller from turning, and then tighten
the nut to the specified torque.
2
3
4
5
WARNING
6
• 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.
7
• Put a block of wood between the anti-
cavitation plate and propeller to keep
the propeller from turning. 8
NOTE:
9
If the grooves in the propeller nut 4 do not
align with the cotter pin hole, tighten the nut
until they are aligned.
Propeller nut 4:
34 N·m (3.4 kgf·m, 25.1 ft·lb)
T.
R.
6D93G11 6-24
6-25 6D93G11
T.
R.
• 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
3. Measure the distance (M) between the
special service tool and the pinion as
shown.
1
inner part(s).
3
NOTE:
Measure the pinion at three points to find the
clearance average. 4
Digital caliper 4: 90890-06704
5
6
NOTE:
• Select the shim thickness (T3) by using the
specified measurement(s) and the calcula-
7
tion 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 1/4 of a turn
8
after they contact the plate 2.
6D93G11 6-26
NOTE:
“P” is the deviation of the lower case dimen-
sion from standard. The “P” mark a is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the “P”
mark unreadable, assume that “P” is zero
and check the backlash when the unit is
assembled.
Example:
If “M” is “32.10 mm” and “P” is “+5”, then
T3 = 32.10 – 31.50 – (+5)/100 mm
= 0.60 – 0.05 mm = 0.55 mm
If “M” is “32.10 mm” and “P” is “–5”, then
T3 = 32.10 – 31.50 – (–5)/100 mm
= 0.60 + 0.05 mm = 0.65 mm
Calculated numeral
Rounded numeral NOTE:
at 1/100 place
• Select the shim thickness (T1) by using the
0, 1 2
specified measurement(s) and the calcula-
2, 3, 4 5 tion formula.
5, 6, 7 8 • Measure the bearing outer race at three
8, 9 10 points to find the height average.
6-27 6D93G11
1
F +5
If “T1” is “0.50 mm”, then the forward gear
shim is 0.48 mm.
R
P +5 Backlash 6
NOTE:
S68S6260
NOTE:
Do not remove the oil seal housing in this
2
procedure.
sion from standard. The “F” mark a is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the “F”
mark unreadable, assume that “F” is zero
and check the backlash when the unit is
2. Set the gear shift to the neutral position
at the lower unit.
3
assembled.
6
follows.
Calculated numeral
at 1/100 place
1, 2
Rounded numeral
0
7
3, 4, 5 2
6, 7, 8
9, 10
5
8 8
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm 9
6D93G11 6-28
Forward gear
Shim thickness
Bearing housing puller claw L 1: backlash
90890-06502 Less than To be decreased by
Stopper guide plate 2: 90890-06501 0.28 mm (0.0110 in) (0.46 – M) × 0.56
Center bolt 3: 90890-06504 More than To be increased by
0.63 mm (0.0248 in) (M – 0.46) × 0.56
4. Install the backlash indicator onto the
M: Measurement
drive shaft (20 mm [0.79 in] in diameter),
then the dial gauge onto the lower unit. Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
NOTE:
Install the dial gauge so that the plunger a
contacts the mark b on the backlash indica-
tor.
6-29 6D93G11
— MEMO —
1
2
3
4
5
6
7
8
9
6D93G11 6-30
Bracket unit
6D93G11
Driver rod LL
90890-06605
Driver rod L3
90890-06652
Driver rod LS
90890-06606
7-1 6D93G11
T.
R.
A 3
15 1 N · m (0.1 kgf · m, 0.7 ft · Ib)
T.
R.
9
4 12
7
5
6 10
2
3
LT
572 13
5 11
A A
8
14
A
4
17
16
5
No. Part name Q’ty Remarks
S6D87010
6
1 Bolt 1
2
3
4
5
Spring
Ball
Washer
Bushing
1
1
1
2
7
6 Bolt 2 M6 × 25 mm
7
8
9
10
Bracket
Shift rod
Screw
Plate
1
1
2
1
ø4 × 16 mm
8
11 Shift position switch 1
12
13
14
15
Bolt
Bushing
Bracket
Cotter pin
2
1
1
1
M6 × 50 mm
Not reusable
9
16 Bushing 1
17 Lever 1
6D93G11 7-2
1 2 3 A
21 9 6
4 7
10 5
22 A
23 11
25 8
24 12 5
27
26 28
29
14 13
48 15
25 30 25 16
26
26 17
31
19 LT
20 572 47
18
32
42
43 33 34
44 40
39
35 38
45 36 37
41
46
2 N · m (0.2 kgf · m, 1.5 ft · Ib) S6D87020
T.
R.
7-3 6D93G11
1 2 3 A
23
22
21
10
9
4
5
6
7
A
1
11
2
25 8
24 12 5
27
26 28
29
13
48
25
26
30 25
14
26
15
16
17
3
31
32
18
19
20
LT
572 47 4
42
43 33 34
44
35
36 37
38
40
39 5
45 41
6
46
2 N · m (0.2 kgf · m, 1.5 ft · Ib) S6D87020
T.
R.
6D93G11 7-4
1 2 3 A
21 9 6
4 7
10 5
22 A
23 11
25 8
24 12 5
27
26 28
29
14 13
48 15
25 30 25 16
26
26 17
31
19 LT
20 572 47
18
32
42
43 33 34
44 40
39
35 38
45 36 37
41
46
2 N · m (0.2 kgf · m, 1.5 ft · Ib) S6D87020
T.
R.
7-5 6D93G11
1
2
10 N · m (1.0 kgf · m, 7.4 ft · Ib)
5 4
1
T.
R.
4
5
LT 3
2
572
A
9
51 N · m (5.1 kgf · m, 37.6 ft · Ib)
10
T.
R.
A
11
6
3
14
7
LT
LT
572
4
8
12
13
15
16
17 5
3 N · m (0.3 kgf · m, 2.2 ft · Ib)
6
T.
R.
S6D87030
Not reusable
7
6 Upper case assembly 1
7
8
9
10
Cover
Bolt
Grommet
Grommet
2
4
1
1
M10 × 40 mm
8
11 Nut 2
12
13
14
15
Nut
Washer
Washer
Grease nipple
2
2
2
1
9
16 Bolt 1 M8 × 16 mm
17 Ground lead 1
6D93G11 7-6
2
1
E
4 N • m (0.4 kgf • m, 3.0 ft • Ib)
T.
R.
E
3
4 12
WR-No.2
E
7 5
8 WR-No.2
9 6 E
10
WR-No.2
11 E
S6D97010
7-7 6D93G11
T.
R.
20 N · m (2.0 kgf · m, 14.8 ft · Ib)
1
T.
R.
28 N · m (2.8 kgf · m, 20.7 ft · Ib)
T.
R.
14
1 3
2
6
A 15
LT A LT
17
572 271
5 18 16
2 4
7
LT
18
3
572 19
8 A
9
10 4
12 11
13
A
WR-No.2
20
A
25
26
5
27 N · m (2.7 kgf · m, 20.0 ft · Ib) 21 24
22 23
6
T.
R.
S6D97020
M14 × 12 mm
8
11 Damper 1
12
13
14
15
Rubber seal
Gasket
Gasket
Screw
1
1
1
2
Not reusable
Not reusable
ø6 × 15 mm
9
16 Baffle plate 1
17 Grommet 1
6D93G11 7-8
T.
R.
20 N · m (2.0 kgf · m, 14.8 ft · Ib)
T.
R.
28 N · m (2.8 kgf · m, 20.7 ft · Ib)
T.
R.
14
1 3
6
A 15
LT A LT
17
572 271
5 18 16
2 4
7
18
LT
572 19
9
8 A 10
12 11
A
A
13 WR-No.2
20 26
25
27 N · m (2.7 kgf · m, 20.0 ft · Ib) 21 24
22 23
T.
R.
S6D97020
7-9 6D93G11
1
10 N · m (1.0 kgf · m, 7.4 ft · Ib)
1
T.
R.
2
4 15 14
2
5
3
6 16
7 3
16
3 LT
18 572
LT
572
20
17
4
8 9 21 LT
5
11 A 19 572
LT
10 22
572 12
13
A
6
11 N · m (1.1 kgf · m, 8.1 ft · Ib)
T.
R.
S6D87060
Not reusable 7
6 Collar 3
7
8
9
10
Bolt
Bolt
Oil pan
Gasket
3
12
1
1
M6 × 25 mm
M6 × 25 mm
Not reusable
8
11 Exhaust manifold 1
12
13
14
15
Bolt
Gasket
Gasket
Plate
4
1
2
1
M6 × 70 mm
Not reusable
Not reusable
9
16 Dowel 2
17 Bolt 6 M6 × 30 mm
6D93G11 7-10
1
10 N · m (1.0 kgf · m, 7.4 ft · Ib)
T.
R.
2
4 15 14
5
6 16
7 3
16
3 LT
18 572
17
20
LT
572
8 9 21 LT
11 A 19 572
LT
10 22
572 12
13
A
11 N · m (1.1 kgf · m, 8.1 ft · Ib)
T.
R.
S6D87060
7-11 6D93G11
1
the oil drain completely. Replace the oil pump assembly if neces-
sary.
3
1. Install a new oil seal into the oil pump
cover to the specified depth.
2. Remove the oil pump assembly and
mount covers.
4
3. Disconnect the ground lead and speed-
ometer hose.
Depth a:
0.5 ± 0.3 mm (0.02 ± 0.01 in)
6
2. Install a new oil seal into the oil pump
housing. 7
2
3 E
8
S6D87070
S6D87610 9
Bearing outer race attachment 3:
90890-06628
Driver rod LS 2: 90890-06606
6D93G11 7-12
2
2 1
S6D87140
5
E
E
S6D97040
6
1
Oil pump cover screw:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
T.
R.
7-13 6D93G11
Clean if necessary.
3
Assembling the oil pan
1. Install a new gasket onto the exhaust
guide 1.
LT
572
5
6
1
2
2. Install a new gasket and the oil strainer LT
3
S6D87160
1
S6D87150
Oil pan bolt 4:
11 N·m (1.1 kgf·m, 8.1 ft·lb)
Exhaust manifold bolt 6:
4
Oil strainer bolt: 11 N·m (1.1 kgf·m, 8.1 ft·lb)
5
10 N·m (1.0 kgf·m, 7.4 ft·lb)
7. Install new gaskets, the plate 7, and the
3. Install the dowels and oil pan 3 onto the muffler 8 onto the oil pan.
exhaust guide, and then tighten the oil
pan bolts 4 finger tight. 8. Install the water pipe 9.
8
7
6. Tighten the exhaust manifold bolts 6
8
A
again to the specified torque.
LT
572
S6D87170
9
6D93G11 7-14
2 LT
A
572
1
1
WR-No.2 S6D97050
T.
2. Install the muffler assembly 3 by insert-
R.
ing the tip of the water pipe 4 into the
joint hole a of the upper case. 3. Install the lower mounts 4 onto the
upper case.
3. Install the muffler assembly bolts 5, and
then tighten them to the specified torque.
LT
LT
A 572
271 A
A
3
4
4
A
S6D87200
7-15 6D93G11
LT
572
0
9
1
A
6
2
5 8
7
3
LT
LT
572
S6D87210 4
NOTE:
5
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.
T.
R.
2
1
4
A
5
6
A
7
8
8
A
7
9
11
10
12 S6D87220
7-17 6D93G11
2
ing arm 5 by aligning the center a of
the yoke with the center b of the steer-
2
ing arm.
b
3. Remove the steering arm from the swivel
bracket by pulling the arm off the bracket.
5
Installing the steering arm
1. Install the washer 1, bushing 2, O-ring
3, and bushing 4 onto the steering arm 5 A
5.
0
a
6
2. Place the swivel bracket 6 in an upright
position, and then install the steering arm
A S6D87260
onto the swivel bracket.
7
grease comes out from both the upper
and lower bushings c.
1
A 2
3
4
c
A
8
3. Install the bushing 7, O-ring 8, and
S6D87240
9
washer 9 onto the swivel bracket. c
S60C7255
6D93G11 7-18
A
2
4 5
6 14
7
15
A
1
A 7
6 3
8
9
10
15 N · m (1.5 kgf · m, 11.1 ft · Ib)
T.
R.
11
13
12 S6D87490
7-19 6D93G11
LT
572
10
5 4 16 4 5
a
1
3
9
A
11
1 2
15
14
14
A
3
2
3
13
A
4
3
16
4
3
13
12
4
5
3 N · m (0.3 kgf · m, 2.2 ft · Ib) 5
T.
R.
8 6
7
A
8
11 Screw 2 ø6 × 15 mm
12
13
14
15
Bolt
Clamp
Grease nipple
Ground lead
1
2
2
1
M6 × 10 mm
9
16 Pin 1
6D93G11 7-20
6 and 7. A
3
6. Remove the trim sensor.
6
4 2
A
S6D87520
Self-locking nut 4:
3
15 N·m (1.5 kgf·m, 11.1 ft·lb)
T.
R.
7
3. Install the power trim and tilt unit. For
1 installation procedure, see “Installing the
power trim and tilt unit.”
S6D87510
LT
271
S60C7160
7-21 6D93G11
1
2 B
Gy
2
Pink (P) – Black (B)
10 ± 1 Ω at 20 °C (68 °F)
6D93G11 7-22
A
2 3
6 7 6
1
13 14 9
A
4 8
13 14
11 10
12
10 11
5
4
A
S6D87270
7-23 6D93G11
NOTE:
Hold the power trim and tilt unit with one
1
1 hand, and pull the upper mount shaft out at a
downward angle with the other.
3
8 9
2
3 0
4
67 6
5
S6D87280
4
S60C7745
WARNING
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
5
Otherwise, the outboard motor could sud-
denly lower if the power trim and tilt unit
should lose fluid pressure.
6
NOTE:
• If the power trim and tilt does not operate,
loosen the manual valve and tilt the out-
board motor up manually.
• If the manual valve is loosened, be sure to
7
tighten it to the specified torque after tilting
8
the outboard motor up.
Manual valve:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
T.
R.
6D93G11 7-24
T.
R.
7 2
14 13 14 1
8 15
3
A
16 17
9
18 4
A 19
10 19
20
22
11 A
A
12
A
21 23
5
6
S6D87290
7-25 6D93G11
T.
R.
7 2
14 13 14 1
8 15
16 17
A
3 2
9
18 4
A
10 19
20
19
3
22
A
11
12
A
21 23
A 4
5
6
5
7 N · m (0.7 kgf · m, 5.2 ft · Ib)
T.
R.
8
9
6D93G11 7-26
2
2
S6D87300
CAUTION:
• Make sure that the tilt ram is fully
extended when removing the power trim S6D87320
and tilt motor, otherwise fluid can spurt
out from the unit due to internal pres- Checking the power trim and tilt
sure.
motor
• Do not push the tilt ram down while the
1. Check the commutator for dirt. Clean
power trim and tilt motor is removed
with 600–grit sandpaper and com-
from the power trim and tilt unit, other-
pressed air if necessary.
wise fluid can spurt out.
7-27 6D93G11
1
Commutator diameter wear limit:
2
21.0 mm (0.83 in)
6. Measure the brush length. Replace if
3. Measure the commutator undercut a.
Replace the armature if below specifica-
tion.
below specification.
3
4
Brush length wear limit e:
5
3.5 mm (0.14 in)
6
Commutator undercut wear limit a:
1.0 mm (0.04 in) 7. Check the base for cracks or damage.
Replace if necessary.
4. Check the armature for continuity.
Replace if out of specifications. 8. Check the bushing 1 and oil seal for
7
damage or wear. Replace if necessary.
8
Armature continuity
6D93G11 7-28
NOTE:
Place a clean cloth over the end of the arma-
ture shaft, hold it with a pair of pliers, and
then carefully slide the stator over the arma-
ture.
2. Attach the circuit breaker 4 onto the
brush 5 together with the brush holder
6 and connect the wire lead 7.
7-29 6D93G11
2 N · m (0.2 kgf · m, 1.5 ft · Ib) 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 5 N · m (0.5 kgf · m, 3.7 ft · Ib)
T.
T.
T.
R.
R.
R.
15 22 27
16 26
9
8
16
15
A
28
2
14 29
13
5
6
7
4
2
12
11
10
17
18
19
20
30
3
4
3 21
2 A
23
24 A
25
S6D87360
6D93G11 7-30
2 N · m (0.2 kgf · m, 1.5 ft · Ib) 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 5 N · m (0.5 kgf · m, 3.7 ft · Ib)
T.
T.
T.
R.
R.
R.
15 22 27
16 26
16 28
15
9
A
8 14
13 29
7 17
12 30
6 18
5 11 19
4
2 10 20
3 21
2 A
23
24 A
25
7
S6D87360
7-31 6D93G11
T.
R.
R.
A 5
4
7 11 11
8 6
13 14
9 15
10
3
12 13
2
3
A
7 15
8
9
10
4
1
2
5
No. Part name Q’ty
16
Remarks
S6D87550
6
1 Manual release spring 1
2
3
4
5
Ball
Bracket
Bolt
Bolt
2
1
1
2
M3 × 5 mm
M5 × 6 mm
7
6 Washer 2
7
8
9
10
O-ring
Adapter
Spring
Ball
2
2
2
2
Not reusable
8
11 Gear 2
12
13
14
15
Drive shaft
Pin
Driven shaft
Ball
1
2
1
2
9
16 Pin 2
6D93G11 7-32
5
6
7
7
S6C17600
1 3
4. Remove the gear pump bracket 5, then
the adapters 6. 3
S6C17610
7-33 6D93G11
T.
R.
4
9. Install the up-relief valve seat D and
down-relief valve seat E. 1
10. Install the relief valve seat caps F by
installing bolts G and H, then tightening
H
G
F
3
installing the bolts, then tightening them
to the specified torques.
6
E
D
S6D87380
4
9
Relief valve cap bolt (M4) G:
4 N·m (0.4 kgf·m, 3.0 ft·lb) 5
T.
R.
B
C A
0 9
S6C17640
6D93G11 7-34
T.
R.
90 N · m (9.0 kgf · m, 66.4 ft · Ib)
17
34
18
A 19 A 35
2 20
2 36
3
3 37
6 4
4 5
21 38 38
A 6 39 1
7
8 22
8 33 40
9 A
10
9 10 26 27
23
28
24 29 41
11
A
12 30
25
13 31 23
15 31
13 14
32 24
16 15
LT
271
16
A
R.
R.
S6D87390
7-35 6D93G11
1
T.
R.
17
34
18
A 19 A 35
20
2
2
2 36
3
3 37
6 4
4 5
21 38 38
3
A 6 39 1
7
8 22
8 33 40
9 A
10
9 10 26 27
23
A
11
12
24
25
28
29
30
41
4
13 31 23
5
15 31
13 14
32 24
16 15
LT
271
16
A
6
T.
T.
R.
R.
S6D87390
6D93G11 7-36
T.
R.
90 N · m (9.0 kgf · m, 66.4 ft · Ib)
17
34
18
A 19 A 35
2 20
2 36
3
3 37
6 4
4 5
21 38 38
A 6 39 1
7
8 22
8 33 40
9 A
10
9 10 26 27
23
28
24 29 41
11
A
12 30
25
13 31 23
15 31
13 14
32 24
16 15
LT
271
16
A
R.
R.
S6D87390
7-37 6D93G11
1
sides.
NOTE:
Place the tilt cylinder in the vise horizontally.
2
2. Loosen the trim cylinder end screw 2,
and then remove it.
2. Loosen the tilt cylinder end screw 2, and
then remove it. 3
4
5
6
WARNING
Make sure that the ram is fully extended
before removing the end screw.
CAUTION:
Do not damage the check valve b when
7
Cylinder-end screw wrench:
New: 90890-06568 loosening the end screw.
Current: 90890-06544
Cylinder-end screw wrench:
3. Drain the power trim and tilt fluid. New: 90890-06568
S60C7870
7-39 6D93G11
C
B
2
D
E
9
H
I
Tilt piston bolt T:
85 N·m (8.5 kgf·m, 62.7 ft·lb)
3
T.
R.
A
0 A
G
9 0 13. Install the tilt ram into the tilt cylinder.
3
S6D87440
Reservoir cap 4:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
7-41 6D93G11
1
Recommended power trim and tilt
S6D87450
NOTE:
Apply grease to the balls from falling out of
2
fluid:
ATF Dexron II the cylinder installation.
4
5 8
S6D87660
5
Cylinder-end screw wrench:
New: 90890-06568
Current: 90890-06544
6
Trim cylinder end screw 8:
90 N·m (9.0 kgf·m, 66.4 ft·lb)
7
T.
R.
S6D87460 9. Fully extend the tilt rod, and then add suf-
ficient fluid of the recommended type to
PTT motor bolt:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
the correct level.
8
T.
R.
6D93G11 7-42
Reservoir cap:
Bleeding the power trim and tilt unit 7 N·m (0.7 kgf·m, 5.2 ft·lb)
T.
R.
1. Tighten the manual valve 1 by turning it
clockwise. 6. Connect the PTT motor leads to the bat-
tery terminals to fully retract the tilt ram.
Battery
Ram PTT motor lead
terminal
Light green (Lg) +
Manual valve 1: Down
Sky blue (Sb) -
2 N·m (0.2 kgf·m, 1.5 ft·lb)
T.
R.
NOTE:
If the fluid is at the correct level, the fluid
should overflow out of the filler hole when the
reservoir cap is removed.
7-43 6D93G11
CAUTION:
After tilting the outboard motor up, be
1
sure to support it with the tilt stop lever.
NOTE:
Light green (Lg) -
3 2 A
4
A
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 eas-
ily, push and pull on the ram to assist oper-
6
5
ation.
7
1. Fully turn the manual valve counterclock-
1 wise.
8
S60C7975
9
S60C7745
6D93G11 7-44
Reservoir cap:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
T.
R.
NOTE:
Be sure to set the measurement range a
S6D83160 shown in the illustration when checking for
continuity.
7-45 6D93G11
Continuity
1
Terminal 1 – Terminal 3
Terminal 2 – Terminal 3
No continuity
2. Connect the digital circuit tester between Checking the power trim and tilt
2
power trim and tilt relay terminals 2 and switch
3.
3
1. Check the power trim and tilt switch for
continuity. Replace if out of specification.
3. Connect the light green (Lg) lead to the
positive battery terminal and the black
(B) lead to the negative battery terminal
as shown.
Lead color
5
Switch
position
Up
Sky blue
(Sb)
Red (R)
Light green
(Lg)
6
Free
7
6. Connect the sky blue (Sb) lead to the
positive battery terminal and the black
(B) lead to the negative battery terminal
as shown.
8
7. Check for continuity between terminals
1 and 3. Replace if there is no continu-
ity. 9
6D93G11 7-46
NOTE:
Turn the lever 1 and measure the resistance
as it gradually changes.
7-47 6D93G11
Electrical systems
3
Top view .................................................................................................... 8-6
4
Checking the ignition coils ......................................................................... 8-7
Checking the ECM.....................................................................................8-8
Checking the pulser coils...........................................................................8-8
Checking the sensor assembly..................................................................8-8
Checking the cooling water temperature sensor ....................................... 8-9
Checking the oil pressure switch ............................................................... 8-9
Checking the shift position switch.............................................................. 8-9
Checking the main and fuel pump relay (main control) ........................... 8-10 5
Fuel control system .....................................................................................8-10
6
Checking the injectors ............................................................................. 8-10
Checking the electric fuel pump ..............................................................8-10
Checking the main and fuel pump relay (fuel control) ............................. 8-11
8-1 6D93G11
1
surement cannot be obtained due to the
NOTE: internal resistance of the tester. To obtain the
Before troubleshooting the peak voltage, correct value, subtract the internal resistance
check that all electrical connections are tight from the displayed measurement.
and free from corrosion, and that the battery
NOTE:
is fully charged to 12 V.
5
WARNING
When checking the peak voltage, do not
S69J8020
6
touch any of the connections of the digital
tester leads.
NOTE:
7
• Use the peak voltage adapter with the digi-
8
tal 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 volt-
age adapter to the positive terminal of the
digital circuit tester.
9
6D93G11 8-2
Port view
2 3 4
S6D88010
8-3 6D93G11
2 3 4
1
2
1
3
4
5
6
5
7
S6D88020 8
1 Ignition coil
2
9
Cooling water temperature sensor
3 Starter motor
4 Junction box
5 Spark plug
6D93G11 8-4
1 2
3
B
A
0
9
8 4
7
5
S6D88030
8-5 6D93G11
1
1 2
2
3
4
7
5
6
3 6
5
4
7
S6D88040 8
1 Fuel injection
2 Shift position switch
3 Sensor assembly
(intake air temperature and intake air
pressure)
4 Idle speed control
9
5 Stator coil
6 Power trim and tilt switch
7 Starter motor
6D93G11 8-6
S6D88050
S60C8100
4. Crank the engine and observe the spark
through the discharge window of the spe-
cial service tool. Check the ignition sys- Spark plug wire resistance:
tem if the spark is weak. #1: 4.5–10.7 kΩ
#2: 3.3–8.0 kΩ
#3: 3.7–8.9 kΩ
#4: 4.3–10.2 kΩ
S63P8100
8-7 6D93G11
8
Black/red (B/R) – Ground
Black/white (B/W) – Ground
Loaded
r/min
Cranking 1,500 3,500
DC V 210 290 290
6D93G11 8-8
S6D88160
NOTE:
Check the sensor assembly when the engine
is cold.
4. Check the oil pressure switch for no con-
tinuity at the specified pressure. Replace
Checking the cooling water
if there is continuity.
temperature sensor
1. Place the cooling water temperature sen- Vacuum/pressure pump gauge set:
sor in a container of water and slowly 90890-06756
heat the water.
Operating pressure:
127.5–166.7 kPa
(1.28–1.67 kgf/cm2,
18.49–24.17 psi)
8-9 6D93G11
Lead color
Switch 3
Blue/green
position Black (B) 2
(L/G)
Free a
Push b
5
4
1
Checking the main and fuel pump
relay (main control)
1. Remove the main and fuel pump relay
1.
5 4
2
2 3
3
S6D88100
S6D88090
4
2. Connect the digital circuit tester leads to
the relay terminals 2 and 3.
7
Fuel injector resistance
no continuity.
(reference data):
6. Check that there is no continuity between 12.0 Ω at 21 °C (70 °F)
the relay terminals 2 and 3 after dis-
connecting a battery terminal from the NOTE:
relay terminal 4 or 5. Replace if there is
continuity.
Check the operation of the fuel injectors
using the “Stationary test” of the Yamaha
Diagnostic System.
8
Checking the electric fuel pump
1. Turn the engine start switch to ON.
9
6D93G11 8-10
3
4
NOTE: 4
After the engine start switch is turned to ON,
the electric fuel pump will operate for 3 sec-
onds.
2 3
S6D88120
1. Remove the main and fuel pump relay Checking the fuses
1. 1. Check the fuses for continuity. Replace if
there is no continuity.
8-11 6D93G11
Br 1
B
S60V8265
2
3
4
5
6
7
8
9
6D93G11 8-12
1
2
3
15 4
5
16
6
7
17
8 27 28
18 9
19 10
19 26
20 11 29
19 19
21
30
22 31
23
12
13
24
14
25 S63P8050
8-13 6D93G11
15
2
3
4
5
1
16
6 2
7
17
8
9
27 28
3
18
10
4
19 19 26
20 11 29
19 19
21
30
22 31
23
24
12
13
5
14
Q’ty Remarks
S63P8050
6
18 Brush assembly 1
19
20
21
22
Brush spring
Brush holder
Plate
Washer
4
1
1
1
7
23 Bracket 1
24
25
26
27
Screw
Bolt
Rubber seal
Shift lever
2
2
1
1
ø4 × 15 mm
M6 × 120 mm
8
28 Spring 1
29
30
31
Magnet switch assembly
Washer
Nut
1
1
1
9
6D93G11 8-14
2. Remove the bolts, and then disassemble 3. Measure the commutator undercut a.
Replace the armature if below specifica-
the starter motor.
tion.
Checking the starter motor pinion
1. Check the teeth of the pinion for cracks
or wear. Replace if necessary.
NOTE:
Turn the pinion counterclockwise to check
that it operates smoothly and turn it clockwise
to check that it locks in place.
Commutator undercut wear limit a:
0.2 mm (0.01 in)
Checking the armature
1. Check the commutator for dirt. Clean 4. Check the armature for continuity.
with 600–grit sandpaper and com- Replace if out of specifications.
pressed air if necessary.
8-15 6D93G11
Commutator segments b
Segment –
Armature core c
Segment –
Continuity
No continuity
Br/W
1
No continuity
Armature shaft d
NOTE:
5
2. Check the brush holder assembly for
The starter motor pinion should be pushed
continuity. Replace if out of specification.
1
out while the magnet switch is on.
Charging system
Checking the stator coil
8
7
1. Disconnect the stator coil coupler.
8
S69J8440
6D93G11 8-16
S6D88150
8-17 6D93G11
Self-diagnosis...............................................................................................9-18
Diagnosing the electronic control system ................................................ 9-18
3
4
5
6
7
8
9
6D93G11
YAMAHA
DIAGNOSTIC
SYSTEM
INSTALLATION MANUAL
9-1 6D93G11
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
1
ECM on a computer’s monitor.
If this software is run on Microsoft Windows® 95, Windows 98, Windows Me, Windows 2000, or
Windows XP the information can be displayed in colorful graphics. Also, the software can be oper-
ated using either a mouse or a keyboard.
In addition, the data for the main functions (Diagnosis, Diagnosis record, Engine monitor, and Data
2
logger) can be saved on a disk or printed out.
Functions
1. 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.
3
2. 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.
3. Engine monitor: Each sensor status and the ECM data are displayed while the engine is run-
4
ning. This enables you to find malfunctioning parts quickly.
4. Stationary test: With the engine off, the ignition, fuel injection, electric fuel pump, and ISC
valve are checked. These tests can be performed quickly.
5
5. Active 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.
6. Data logger: Displays 13 minutes of recorded data for two or more of the items stored in the
6
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.
7. Some files: Lets you select and run other applications while continuing to run the diagnostic
program.
7
Contents
1. Software (1)
9
INSTALLATION MANUAL
INSTRUCTION MANUAL
6D93G11 9-2
NOTE:
• The amount of memory and the amount of free space on the hard disk differs depending on the
computer.
• Using this software while there is not enough free space on the hard disk could cause errors and
result in insufficient memory.
• This software will not run properly on some computers.
• When starting up this program, do not start other software applications.
• Do not use the screen saver function or the energy saving feature when using this program.
• If the ECM is changed, restart the program.
• Windows XP is a multiuser operating system, therefore, be sure to end this program if the login
user is changed.
• The USB adapter cannot be used with Windows 95.
For operating instructions of the Yamaha Diagnostic System, refer to the “Yamaha Diagnostic Sys-
tem Instruction Manual.”
9-3 6D93G11
1
2
3
4
3-pin communication
coupler
5
S6D89010
6
7
8
9
6D93G11 9-4
NOTE:
• Check that all electrical connections are tight and free from corrosion, and that the battery is fully
charged to 12 V.
• To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble
located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters 3–
8 for safe maintenance procedures.
• To diagnose a malfunctioning sensor or switch, use the diagnostic flash indicator to determine the
cause.
Power unit 9
Is the gearshift in No
Set it to the neutral position.
neutral?
Yes
Is there No
Replace the engine start switch.
continuity?
Yes
Check the engine stop lanyard
switch for continuity (with lock
plate).
9-5 6D93G11
1
Is there No
Replace the fuse.
continuity?
Yes
Is there No
2
Replace the wiring harnesses.
continuity?
Yes
7
8
9
6D93G11 9-6
9-7 6D93G11
Yes
No Check the main and fuel pump
relay for continuity. (8-11)
1
Start the engine using dried or Is there No Replace the main
new spark plugs. continuity?
Yes
and fuel pump relay.
2
Check the fuel system.
Within
specification?
No
4
5
Yes
Yes
No
Failure in starting operation
Check the valve
clearance. (5-10) 6
7
Adjust the valve No Within
Check the fuel system.
clearance. specification?
Yes
8
9
6D93G11 9-8
Fuel system
Check that the fuel vent screw of the fuel tank is open.
Is the vent No
Open the fuel vent screw.
screw open?
Yes
Clean the fuel system from the Kinks or fuel Yes Replace the
fuel tank to the fuel filter. leakage? defective parts.
No
9-9 6D93G11
Good spark?
Yes
since this test can produce sparks.
6
No
Good condition? Replace the spark plug wire.
Yes
Compression pressure
7
Check that there is no secondary air intake on the contact surfaces of
the intake manifold and cylinder head.
8
Is there air
intake?
No
Yes
Replace the defective seals.
9
Check the compression pres-
sure of the combustion chamber.
6D93G11 9-10
Symptom: Engine can run, but engine speed will not increase.
Overheat warning indicator is on.
Oil pressure warning indicator is on.
Warning indicator is on and buzzer is sounding.
• Check the cooling system.
• Check the lubrication system.
Cooling system
Is water No
Clean the cooling water inlet.
discharged?
Yes Check the water
pump impeller for
cracks or wear.
No Replace the
Good condition? Replace the thermostat.
impeller.
Yes
9-11 6D93G11
1
Check the engine oil level.
Debris or leaks?
Yes
No Check the oil
passage. 4
Check the oil pressure switch.
(8-9)
Clean or replace the defective
parts.
5
No
Good condition?
6
Replace the oil pressure switch.
Yes
7
8
9
6D93G11 9-12
Can the Check the voltage between each terminal of the PTT relay
No
operation sound coupler when pushing the power trim and tilt switch.
be heard? • Between the sky blue (Sb) lead and black (B) lead.
Yes • Between the light green (Lg) lead and black (B) lead.
Can the
specified battery Yes Replace the power
voltage be trim and tilt relay.
obtained?
No
Listen for the operation sound Check the fuse for continuity.
of the power trim and tilt motor.
Is there No
Replace the fuse.
continuity?
Yes
Check for continuity between
the battery, relays, and power
trim and tilt switch.
9-13 6D93G11
Is it closed?
Yes
No
Close the valve.
1
Check the power trim and tilt
fluid level.
At specified No
2
Add fluid to the correct level.
level?
Yes
Disassemble the power trim and
tilt unit, and then check the filter
3
for debris or dirt.
Stuck foreign
substance or
Yes
Clean or replace the filters.
4
clogs?
No
No
Is it closed? Close the valve.
Yes
At specified No
Add fluid to the correct level.
level?
Yes
Disassemble the power trim and
tilt unit, and then check the fil-
ters for debris or dirt.
Stuck foreign
Yes
substance or Clean or replace the filters.
clogs?
No
Yes
Clogs or debris? Clean the passages.
No
9-15 6D93G11
1
Check the shift cable operation.
Within No
Replace the stator coil.
specification?
Yes
Within No
Replace the Rectifier Regulator.
specification?
Yes
Replace the battery, and then
check the voltage of all electri-
cal equipment on your boat.
9-17 6D93G11
4
S6D89030
NOTE:
When performing this diagnosis, all of the
electrical wires must be properly connected.
5
Diagnostic flash indicator B:
90890-06865 6
2. Start the engine and let it idle.
NOTE:
When more than one problem is detected,
the light of the special service tool flashes in
the pattern of the lowest numbered problem.
After that problem is corrected, the light
flashes in the pattern of the next lowest num-
bered problem. This continues until all of the
problems are detected and corrected.
Code Symptom
1 Normal
13 Incorrect pulser coil signal
Incorrect cooling water
15
temperature sensor signal
Incorrect throttle position sensor
18
signal
19 Incorrect battery voltage
Incorrect sensor assembly
23
(intake air temperature) signal
Incorrect shift position switch
28
signal
Incorrect sensor assembly
29
(intake air pressure) signal
Incorrect idle speed control
37
signal
Incorrect engine stop lanyard
44
switch signal
49 Over cool signal
9-19 6D93G11
1
throttle cable .............................................3-8
Checking the cooling water temperature
Adjusting the trim sensor ..........................7-21
sensor....................................................... 8-9
After test run ...............................................1-9
Checking the crankpin oil clearance......... 5-44
Applicable model.........................................1-5
Checking the crankshaft ........................... 5-44
Assembling the drive shaft........................6-20
Checking the crankshaft journal
2
Assembling the forward gear ....................6-19
oil clearance ........................................... 5-47
Assembling the fuel pump...........................4-6
Checking the cylinder bore ....................... 5-42
Assembling the gear pump .......................7-33
Checking the cylinder head ...................... 5-32
Assembling the lower case .......................6-19
Checking the diaphragm and valves .......... 4-6
Assembling the oil pan..............................7-14
Checking the drive shaft ........................... 6-18
Assembling the oil pump...........................7-12
Assembling the power trim and
tilt motor ..................................................7-29
Assembling the power trim and
tilt unit......................................................7-41
Checking the drive shaft bushing ............. 7-13
Checking the ECM...................................... 8-8
Checking the electric fuel pump ............... 8-10
Checking the electrical components........... 8-2
3
Checking the engine idle speed ................. 3-8
Assembling the power unit........................5-50
4
Checking the engine oil .............................. 3-4
Assembling the propeller shaft
Checking the engine oil level...................... 1-6
assembly.................................................6-12
Checking the engine start switch
Assembling the propeller shaft housing ....6-13
and engine stop lanyard switch ................ 1-8
Assembling the tilt cylinder .......................7-39
Checking the fuel filter ................................ 3-3
Assembling the upper case.......................7-15
Checking the fuel joint and fuel hoses
B.
Assembling the vapor separator ...............4-17
Backlash ...................................................6-28
(fuel joint-to-fuel injector) .......................... 3-3
Checking the fuel pump.............................. 4-5
Checking the fuel system ........................... 1-6
Checking the fuse..................................... 7-45
5
Bleeding the power trim and tilt unit..........7-43 Checking the fuses ................................... 8-11
Bleeding the power trim and tilt unit
(built-in) ...................................................7-44
Bottom cowling............................................7-3
Bow view.....................................................8-5
Checking the gear oil level ................1-7, 3-12
Checking the gear pump .......................... 7-33
Checking the gear shift and throttle
operation................................................... 1-8
6
Bracket unit ..................................... 3-11, 9-13 Checking the gear shift operation............. 3-10
7
Break-in.......................................................1-9 Checking the idle speed control ................. 4-9
Checking the ignition coils .......................... 8-7
C. Checking the ignition spark ........................ 8-7
Canister.....................................................4-19 Checking the injectors .............................. 8-10
Changing the engine oil by draining it.........3-4 Checking the lower case .......................... 6-18
8
Changing the engine oil using Checking the lower unit for air leakage .... 3-13
an oil changer ...........................................3-4 Checking the magnet switch..................... 8-16
Changing the gear oil................................3-12 Checking the main and fuel pump relay
Charging system .......................................8-16 (fuel control)............................................ 8-11
Checking the anodes ................................3-14 Checking the main and fuel pump relay
(main control).......................................... 8-10
9
Checking the armature..............................8-15
Checking the battery ......................... 1-7, 3-14 Checking the oil pressure ........................... 5-3
Checking the bearings ..............................6-18 Checking the oil pressure switch ................ 8-9
Checking the brushes ...............................8-16 Checking the oil pump .............................. 7-12
Checking the camshafts............................5-32 Checking the oil strainer ........................... 7-14
Checking the canister ...............................4-20 Checking the outboard motor
Checking the compression pressure...........5-3 mounting height ........................................ 1-7
Checking the pinion and forward gear...... 6-18
6D93G11 i-1
i-2 6D93G11
3
Installing the power trim and tilt unit..........7-44
Removing the propeller shaft housing
Installing the power unit ............................5-52
assembly ................................................ 6-11
Installing the pressure control valve..........5-39
Removing the steering arm ...................... 7-18
Installing the propeller shaft housing ........6-20
Removing the timing belt and sprockets... 5-17
Installing the sprockets and timing belt .....5-18
Removing the upper case......................... 7-12
Installing the steering arm.........................7-18
Installing the throttle position sensor...........4-9
Installing the upper case ...........................7-15
Installing the valves...................................5-33
Installing the water pump and shift rod .....6-21
Removing the water pump and shift rod..... 6-9
Replacing the oil filter ................................. 3-5
Replacing the timing belt .......................... 5-13
Replacing the valve guides....................... 5-28
4
Intake manifold............................................4-7
J.
Introduction .................................................9-2
Junction box..............................................5-22
S.
Safety while working................................... 1-3
Selecting the connecting rod bearing ....... 5-46
Selecting the forward gear shims ............. 6-27
5
Selecting the main bearing ....................... 5-48
L.
Lower unit ..................................2-6, 3-12, 6-4
Lubricating the outboard motor .................3-15
Selecting the pinion shims........................ 6-26
Selection..................................................... 1-6
Self-diagnosis ........................................... 9-18
Self-protection ............................................ 1-3
6
Serial number ............................................. 1-5
M.
7
Shift rod ...................................................... 7-2
Maintenance interval chart..........................3-2 Shimming.........................................6-25, 6-26
Maintenance specification...........................2-3 Special service
Manual format .............................................1-1 tools .............3-1, 4-1, 5-1, 6-1, 7-1, 8-1, 9-1
Measuring the forward gear backlash.......6-28 Specified torques...................................... 2-11
Starboard view............................................ 8-4
8
Measuring the fuel pressure .....................4-13
Measuring the lower resistance ..................8-2 Starter motor............................................. 8-13
Measuring the peak voltage........................8-2 Starting system......................................... 8-11
Steering arm ............................................. 7-17
Symbols...................................................... 1-2
P.
Parts, lubricants, and sealants....................1-3
Port view .....................................................8-3
Power trim and tilt electrical system..........7-45
Power trim and tilt motor ...........................7-25
T.
Test run ...................................................... 1-9
Throttle link ............................................... 5-20
Tightening torques.................................... 2-11
9
Power trim and tilt unit ..............................7-23
Power unit ............................ 2-3, 3-4, 5-3, 9-5 Tilt cylinder and trim cylinder .................... 7-35
Predelivery checks......................................1-6 Top cowling ................................................ 3-3
Propeller selection ......................................1-5 Top view ..................................................... 8-6
6D93G11 i-3
U.
Upper case..................................................7-6
V.
Vapor separator ........................................4-10
Ventilation ...................................................1-3
Y.
Yamaha Diagnostic System........................9-2
i-4 6D93G11
— MEMO —
1
2
3
4
5
6
7
8
9
6D93G11 i-5
W/B
B
12
W
B
L
B W/R
B B
123
1 2 3 4 5 6 7 8 9 10111213 1415161718192021222324 1 2 3 4 5 6 7 8 9 10111213 1415161718192021222324
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/B
Sb
Sb
Sb
Sb
Lg
Lg
Lg
Lg
W/R
W/B
G
G
G
O
O
O
2
B
B
B
B
B
B
B
B
B
B
B
B/Y
B
1 B
B
B
R
Br/W
1
4 P/W
R 2 R/Y
3 P/B
2 B/W 1 B/R 2
1 L/W
P/G 4
B 3
R O 2
3 B/Y 1
G Y
R 2 R/Y W
B
4 B/W 1 B/W P
Lg Y
W R/Y 1
G Pu/R 2
Br
Sb
1243 P Lg
Sb R
Br
B
O
B
P
Gy
B
P
R/Y 1
1 Pu/B 2
R/B 2
30A Lg 3
R R
W/B 4 213
R/Y
R/Y
Lg 5
G
R
B
Y
L
L
B/Y 6
Sb 7
B
67512384 P 8 R/Y 1
20A R 9 Pu/B 2
R R
R/B 10
L 11
Y 12
W/R 13
20A B/Y 14
R R
Sb 15
Y 16 R/Y 1
L 17
R 18 Pu/R 2
20A P/G 19
R R
O 20
R/Y 21
B 22
W/B 23
Sb R Lg
24
25
UP P/W 26
P 27
FREE P/B 28
G 29
W/B
R/B
L/W
Br Br
B
DOWN G/B 30
B 31
Pu/B 32 Sb R Lg
123 Pu/R 33
34 UP G 1
R Br/W
B/W 35 G/B 2
L/Y 36 FREE G/Y 3
37 G/R 4
Sb
Lg
R
Br Br DOWN
Sb R Lg 38
B
B 39
UP 312 40
FREE
W/L 41
O/W 42 2 Sb
DOWN W 43 3 R
Sb P/W 44 1 Lg
Sb
Lg
R
L/W 45
L 46
Lg 1 Lg Lg 1 G/R 47
Sb 2 Sb Sb 2 R 48
R R R R G 49 2
3 3 R G/Y 50 O/W
51 B 3
B B/R 52 W/L 1
Gy
Lg
Sb R Lg
UP
Sb
Lg
FREE Sb B
Sb 2 Sb B
DOWN
Lg 1 Lg Lg B B
Sb
Lg
R
Lg 1 Lg
Sb 2 Sb L/Y 1 L/G
B
B
B
R 3 R B 2 B
P R R R 1
B B 3
W 4
W 5
W 6
S6D9WD01