Yamaha LZ200N - 200Y, Z200N - 200Y Service Manual (En)
Yamaha LZ200N - 200Y, Z200N - 200Y Service Manual (En)
Yamaha LZ200N - 200Y, Z200N - 200Y Service Manual (En)
Z200N
LZ200N
USA, CANADA
Z200Y
LZ200Y
SERVICE MANUAL
290369
68F-28197-Z9-A1
E
PREFACE
This manual has been prepared by the Yamaha Motor Company, Ltd. 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 the Yamaha Motor Company, Ltd. has a policy of continuously improving its prod-
ucts, models may differ in detail from the descriptions and illustrations given in this publica-
tion. 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.
CAUTION
Z200N, LZ200N
SERVICE MANUAL
©1999 Yamaha Motor Co., Ltd.
1st Edition, October 1999
All rights reserved.
No part of this publication may be
reproduced or transmitted in any form or by
any means including photocopying and
recording without the written permission of
the copyright holder.
Such written permission must also be
obtained before any part of this publication
is stored in a retrieval system of any nature.
Printed in Japan
P/N 68F-28197-Z9-A1
E
MODEL INDICATION
Multiple models are mentioned in this manual and their model indications are noted as fol-
lows.
USA and
Z200TR LZ200TR
Canada name
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the
appropriate section or chapter.
E
IMPORTANT INFORMATION
In this Service Manual particularly important information is distinguished in the following
ways.
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.
E
5 In addition to tightening torques, the dimensions of the bolts or screws are also men-
tioned.
Example:
Bolt or screw size 10 × 25 mm : diameter (D) × length (L)
D
6 In addition to the exploded views and job instruction charts, this manual provides individ-
ual illustrations when further explanations are required to explain the relevant procedure.
E
1 2 SYMBOLS
Symbols 1 to 9 are designed as thumb-
GEN tabs to indicate the content of a chapter.
INFO SPEC
1 General information
3 4 2 Specifications
3 Periodic inspections and adjustments
INSP FUEL 4 Fuel system
ADJ 5
6
Power unit
Lower unit
5 6 7 Bracket unit
8 Electrical systems
9 Trouble analysis
POWR LOWR
7 8
– +
BRKT ELEC
9 0 Symbols 0 to E indicate specific data.
0 Special tool
TRBL A Specified liquid
ANLS B Specified engine speed
C Specified torque
A B D Specified measurement
E Specified electrical value
[Resistance (Ω), Voltage (V), Electric current
(A)]
C D
T.
R.
CONTENTS
GENERAL INFORMATION GEN
INFO
1
SPECIFICATIONS
SPEC 2
PERIODIC INSPECTIONS AND
ADJUSTMENTS INSP
ADJ
3
FUEL SYSTEM
FUEL 4
POWER UNIT
POWR 5
LOWER UNIT
LOWR 6
BRACKET UNIT
BRKT 7
– +
ELECTRICAL SYSTEMS
ELEC 8
TROUBLE ANALYSIS TRBL
ANLS
9
GEN
E
INFO
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION 1
SERIAL NUMBER
The outboard motor’s serial number is
stamped on a label which is attached to the
port side of the clamp bracket.
NOTE:
If the serial number label is removed,
“VOID” marks will be appear on the label.
1 Model name
2 Approved model code
3 Transom height
4 Serial number
1-1
GEN
INFO SAFETY WHILE WORKING E
FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Petroleum vapor is explosive if ignited.
Do not smoke while handling gasoline and
keep it away from heat, sparks and open
flames.
VENTILATION
Petroleum vapor is heavier than air and is
deadly if inhaled in large quantities. Engine
exhaust gases are harmful to breathe.
When test-running an engine indoors,
maintain good ventilation.
SELF-PROTECTION
Protect your eyes with suitable safety
glasses or safety goggles, when grinding or
when doing any operation which may
cause particles to fly off. Protect hands and
feet by wearing safety gloves or protective
shoes if appropriate to the work you are
doing.
1-2
GEN
INFO SAFETY WHILE WORKING E
1-3
GEN
INFO SAFETY WHILE WORKING E
3. Non-reusable items
Always use new gaskets, packings, O-
rings, split-pins, circlips, etc., on reas-
sembly.
1-4
GEN
INFO SPECIAL TOOLS E
SPECIAL TOOLS 1
NOTE:
• For USA and Canada, use part numbers
that start with “J-”, “YB-”, “YM-”, “YS-”,
“YU-” or “YW-”.
1 • For worldwide, use part numbers that
a b start with “90890-”.
MEASURING
1 Tachometer
2 3 P/N. YU-08036-A ............................ a
90890-06760 ........................... b
2 Fuel pressure gauge
P/N. YB-06766
90890-06786
3 Mity vac
4 5
P/N. YB-35956
90890-06756
4 Pressure tester
P/N. YB-35956
90890-06762
6 5 Digital caliper
a b
P/N. 90890-06704
6 Pinion height gauge
P/N. YB-34432-7, YB-34432-11 ...... a
90890-06702 ........................... b
7 Shimming gauge
7 8 P/N. YB-34446-1, YB-34446-3,
YB-34446-4, YB-34446-7,
YB-34446-8
8 Shimming gauge
P/N. YB-34468-1, YB-34468-2
9 Shimming plate
9 P/N. 90890-06701
0 Shift rod wrench
P/N. YB-06052 ................................ a
90890-06052 ........................... b
0
a b
1-5
GEN
INFO SPECIAL TOOLS E
A Magnetic base
A B P/N. YU-34481
90890-06705
B Magnetic base attaching plate
P/N. YB-07003
90890-07003
C D C Backlash indicator
P/N. YB-06265
90890-06706
D Dial gauge set
P/N. YU-03097
E F 90890-01252
E Hydraulic pressure gauge
P/N. 90890-06776
F Up-relief valve attachment
P/N. 90890-06773
Down-relief valve attachment
G P/N. 90890-06774
a b
G Digital tester
P/N. J-39299 ................................... a
90890-06752 ........................... b
H Peak voltage adapter
H P/N. YU-39991 ................................ a
a b 90890-03169 ........................... b
I Spark gap tester
P/N. YM-34487 ............................... a
90890-06754 ........................... b
J Test harness
P/N. YB-06443, YB-06767,
I YB-06768, YB-06769,
a b YB-06779, YB-06787,
YB-06788
90890-06757, 90890-06767,
90890-06768, 90890-06769,
90890-06779, 90890-06787,
90890-06788
J K Diagnostic indicator
P/N. YB-06765
90890-06765
1-6
GEN
INFO SPECIAL TOOLS E
L Diagnostic unit
Check the engine condition by using a
personal computer when it is connected
to the Electronic Control Unit (ECU).
Diagnosis:
Indicates the name of a failed part.
Diagnosis record:
Displays the name of the part whose diag-
nosis is detected, along with the engine
running total hours.
Static test:
Checks operation sound and ignition sparks
by activating the electric fuel pump, electric
oil pump, injector and spark plug while the
engine is stopped.
Dynamic test:
Checks the engine for operation through
any change in its speed by stopping the
operation of the spark plug on each cylinder
while the engine is in the neutral position.
Engine monitor:
Indicates information on the sensors and
switches by converting it to each value
while the engine is running.
Data logger:
Indicates in numeric values the engine
speed, throttle opening voltage, oxygen
density sensor voltage, water temperature
sensor voltage and fuel pressure sensor
voltage that occurred within 13 minutes.
ECU information:
Displays the ECU identification number.
NOTE:
To use any of these functions a personal
computer, connection cables, adapter and
communication software are required.
The personal computer should be compati-
ble with Windows® 95/98, equipped with a
CD-ROM and the RS232C terminal.
1-7
GEN
INFO SPECIAL TOOLS E
8 9
0
a b
1-8
GEN
INFO SPECIAL TOOLS E
Q R
1-9
GEN
INFO SPECIAL TOOLS E
1-10
SPEC E
CHAPTER 2
SPECIFICATIONS
3
4
5
6
7
8
9
SPEC GENERAL SPECIFICATIONS E
GENERAL SPECIFICATIONS 2
Model
Worldwide Z200NETO LZ200NETO
Item Unit
USA Z200TR LZ200TR
Canada Z200TR —
DIMENSION
Overall length mm (in) 792 (31.2)
Overall width mm (in) 554 (21.8)
Overall height
(X) mm (in) 1,782 (70.2)
Boat transom height
(X) mm (in) 635 (25.0)
WEIGHT
(with aluminum propeller)
(X) kg (lb) 218 (480.6)
(with stainless steel propeller)
(X) kg (lb) 222 (489.4)
PERFORMANCE
Maximum output (ISO) kW (hp) 147.1 (200)
@ 5,000 r/min
Full throttle operating range r/min 4,500 - 5,500
Maximum fuel consumption L (US gal, 68 (18.0, 15.0)
lmp gal)/hr
@ 5,500 r/min
POWER UNIT
Type 2 stroke - V
Number of cylinders 6
Displacement cm3 (cu. in) 2,596 (158.4)
Bore × stroke mm (in) 90.0 × 68.0 (3.54 × 2.68)
Compression ratio Cylinders #1 - #4: 6.4
Cylinders #5 - #6: 6.1
Fuel system Electronic fuel injection
Fuel injection system Sequential injection
Intake system Reed valve
Induction system Loop charge
Starting system Electric
Ignition control system Microcomputer
Alternator output V-A 12 - 45
Spark plugs (NGK) BKR7ES-11
Cooling system Water
Exhaust system Through propeller boss
Lubrication system Oil injection
2-1
SPEC GENERAL SPECIFICATIONS E
Model
Worldwide Z200NETO LZ200NETO
Item Unit
USA Z200TR LZ200TR
Canada Z200TR —
FUEL AND OIL
Fuel type Unleaded regular gasoline
Fuel rating *PON 86
RON 91
Engine oil type 2-stroke outboard engine oil
Engine oil grade TC-W3
Engine oil capacity
(engine oil tank) L (US qt, lmp qt) 0.9 (0.95, 0.79)
(sub-oil tank) L (US qt, lmp qt) 10.5 (11.1, 9.2)
Gear oil type Hypoid gear oil SAE 90
Gear oil total quantity cm3 (US oz, 980 (33.1, 34.5) 870 (29.4, 30.6)
lmp oz)
BRACKET
Trim angle Degree –4 - 16
(at 12˚ boat transom)
Tilt-up angle Degree 70
Steering angle Degree 32 + 32
DRIVE UNIT
Gear shift positions F-N-R
Gear ratio 1.86 (26/14)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction Clockwise Counterclockwise
(rear view)
Propeller mark M ML
ELECTRICAL
Battery capacity Ah (kC) 100 (360)
Minimum cold cranking A 512
performance
2-2
SPEC MAINTENANCE SPECIFICATIONS E
MAINTENANCE SPECIFICATIONS 2
POWER UNIT
Model
Worldwide Z200NETO LZ200NETO
Item Unit
USA Z200TR LZ200TR
Canada Z200TR —
CYLINDER HEADS
Warpage limit mm (in) 0.1 (0.004)
2-3
SPEC MAINTENANCE SPECIFICATIONS E
Model
Worldwide Z200NETO LZ200NETO
Item Unit
USA Z200TR LZ200TR
Canada Z200TR —
CONNECTING RODS
Small-end axial play mm (in) 2.0 (0.08)
limit (F)
Big-end side mm (in) 0.12 - 0.26 (0.005 - 0.010)
clearance (E)
OIL INJECTION PUMP
ID mark 68F00
Bleeding Screw type
REED VALVES
Reed valve stopper height a mm (in) 9.0 ± 0.35 (0.35 ± 0.01)
2-4
SPEC MAINTENANCE SPECIFICATIONS E
LOWER UNIT
Model
Worldwide Z200NETO LZ200NETO
Item Unit
USA Z200TR LZ200TR
Canada Z200TR —
GEAR BACKLASH
Pinion - forward gear mm (in) 0.25 - 0.46 0.21 - 0.43
(0.010 - 0.018) (0.008 - 0.017)
Pinion - reverse gear mm (in) 0.74 - 1.29 0.97 - 1.29
(0.029 - 0.051) (0.038 - 0.051)
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
Reverse gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
ELECTRICAL
Model
Worldwide Z200NETO LZ200NETO
Item Unit
USA Z200TR LZ200TR
Canada Z200TR —
IGNITION SYSTEM
Ignition timing (#1) Degree ATDC 3 - BTDC 17
Fuse 1 V-A 12-80
Fuse 2 V-A 12-30
Fuse 3 V-A 12-20
Control unit (B/O, B/Y, B/L,
B/Br, B/G, B/W – R/Y)
Output peak voltage lower
limit
@ cranking 1 V —
@ cranking 2 V 140
@ 1,500 r/min V 205
@ 3,500 r/min V 220
Pulser coil (W/R, W/Y, W/G,
W/B, W/L, W/Br – B)
Output peak voltage lower
limit
@ cranking 1 V 5.0
@ cranking 2 V 5.0
@ 1,500 r/min V 20
@ 3,500 r/min V 35
* Cranking 1: Open circuit voltage.
Cranking 2: Loaded circuit voltage.
2-5
SPEC MAINTENANCE SPECIFICATIONS E
Model
Worldwide Z200NETO LZ200NETO
Item Unit
USA Z200TR LZ200TR
Canada Z200TR —
IGNITION CONTROL SYSTEM
Crank position sensor (G/L)
Crank-position-sensor-to- mm (in) 1.0 ± 0.5 (0.04 ± 0.02)
flywheel gap
Output peak voltage lower
limit
@ cranking 1 V 4.5
@ cranking 2 V 4.0
@ 1,500 r/min V 13
@ 3,500 r/min V 20
Engine cooling water
temperature sensor
Resistance (B/Y – B/Y)
@ 5˚C (41˚F) kΩ 128
@ 20˚C (68˚F) kΩ 54 - 69
@ 100˚C (212˚F) kΩ 3.02 - 3.48
Throttle position sensor
Input voltage (O – R) V 4.75 - 5.25
Output voltage (P – O) V 0.50 ± 0.02
Thermo switch (P – B)
OFF → ON ˚C (˚F) 84 - 90 (183 - 194)
ON → OFF ˚C (˚F) 60 - 74 (140 - 165)
FUEL CONTROL SYSTEM
Oxygen density sensor
Heater resistance (R/W – B) Ω 2 - 100
Output voltage (Gy – B/W) V 0.0 - 1.0
Atmospheric pressure sensor
Output voltage (at 101.32 kPa) V 3.2 - 4.6
(P – B)
Intake air temperature sensor
Resistance (B/Y – B/Y) kΩ 1.5 - 4.0
Injector driver
(O/R – Pu/R, O/B – Pu/B,
O/Y – Pu/Y, O/G – Pu/G,
O/L – Pu/L, O/W – Pu/W)
Output peak voltage lower
limit
@ cranking 1 V 65
@ cranking 2 V 60
@ 1,500 r/min V 65
@ 3,500 r/min V 65
* Cranking 1: Open circuit voltage.
Cranking 2: Loaded circuit voltage.
2-6
SPEC MAINTENANCE SPECIFICATIONS E
Model
Worldwide Z200NETO LZ200NETO
Item Unit
USA Z200TR LZ200TR
Canada Z200TR —
Fuel pressure sensor
Output voltage (P – B) V 2.8 - 3.2
Water detection switch
Float position a “ON” mm (in) 47
STARTER MOTOR
Type Sliding gear
Output kW 1.4
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) 0.5 - 0.8 (0.02 - 0.03)
Wear limit mm (in) 0.2 (0.01)
CHARGING SYSTEM
Rectifier/regulator (R – B)
Output peak voltage lower
limit
@ cranking 1 V —
@ cranking 2 V 7.5
@ 1,500 r/min V 12.7
@ 3,500 r/min V 12.7
Lighting coil (G – G)
Output peak voltage lower
limit
@ cranking 1 V 7.5
@ cranking 2 V 8.0
@ 1,500 r/min V 12
@ 3,500 r/min V 12
* Cranking 1: Open circuit voltage.
Cranking 2: Loaded circuit voltage.
2-7
SPEC MAINTENANCE SPECIFICATIONS E
Model
Worldwide Z200NETO LZ200NETO
Item Unit
USA Z200TR LZ200TR
Canada Z200TR —
OIL FEED PUMP CONTROL
SYSTEM
Oil level sensor
(engine oil tank)
Float position a mm (in) 3 - 6 (0.12 - 0.24)
“OFF”
Float position b mm (in) 33 - 36 (1.30 - 1.42)
“ON”
Float position c “ON” mm (in) 53 - 56 (2.09 - 2.20)
Oil level switch (sub-oil tank)
Float position d “ON” mm (in) 150 - 153 (5.91 - 6.02)
POWER TRIM AND TILT SYSTEM
Trim sensor
Setting resistance Ω 80 ± 12
Resistance (P – B) Ω 582 - 873
Resistance (O – B) Ω 800 - 1,200
POWER TRIM AND TILT MOTOR
Fluid type ATF Dexron II
Brushes
Standard length mm (in) 9.8 (0.39)
Wear limit mm (in) 4.8 (0.19)
Commutator
Standard diameter mm (in) 22.0 (0.87)
Wear limit mm (in) 21.0 (0.83)
Mica
Standard undercut mm (in) 1.35 (0.05)
Wear limit mm (in) 0.85 (0.03)
2-8
SPEC MAINTENANCE SPECIFICATIONS E
DIMENSIONS
L7 L6
L2 L1
W1
H9 W5
H2
H7
H4
H1
H6
H3
L5
L4
Symbol Models
Worldwide Z200NETO LZ200NETO
Unit
USA Z200TR LZ200TR
Canada Z200TR —
L1 mm (in) 613 (24.1)
L2 mm (in) 180 (7.1)
L4 mm (in) 646 (25.4)
L5 mm (in) 69 (2.7)
L6 mm (in) 1,150 (45.3)
L7 mm (in) 574 (22.6)
H1 mm (in) 1,074 (42.3)
H2 mm (in) 708 (27.9)
H3 mm (in) 211 (8.3)
H4 mm (in) 643 (25.3)
H6 mm (in) 850 (33.4)
H7 mm (in) 308 (12.1)
H9 mm (in) 835 (32.9)
W1 mm (in) 277 (10.9)
W5 mm (in) 396 (15.6)
2-9
SPEC MAINTENANCE SPECIFICATIONS E
Symbol Models
Worldwide Z200NETO LZ200NETO
Unit
USA Z200TR LZ200TR
Canada Z200TR —
B1 mm (in) 125.4 (4.9)
B2 mm (in) 254 (10.0)
B3 mm (in) 163.5 (6.4)
B4 mm (in) 50.8 (2.0)
B5 mm (in) 180 (7.1)
B6 mm (in) 367 (14.4)
B9 mm (in) 18.5 (0.7)
C3 mm (in) 82 (3.2)
D1 mm (in) 13 (0.5)
D2 mm (in) 55.5 (2.2)
2-10
SPEC TIGHTENING TORQUES E
TIGHTENING TORQUES 2
SPECIFIED TORQUES
Tightening torques
Part to be tightened Thread size
Nm m•kgf ft•lb
POWER UNIT
Intake silencer M6 3 0.3 2.2
Electric oil pump M6 8 0.8 5.8
Fuel injection unit M6 10 1.0 7.2
Atmospheric pressure sensor M6 4 0.4 2.9
Electric oil pump bracket M6 8 0.8 5.8
Throttle position sensor M5 4 0.4 2.9
Intake air temperature sensor M12 8 0.8 5.8
Drive belt tensioner M10 40 4.0 29
Mechanical fuel pump M8 23 2.3 17
Fuel rail M8 23 2.3 17
Fuel injector cap M8 26 2.6 19
Fuel filter nut holder M6 8 0.8 5.8
Oil pump M6 7 0.7 5.1
Emergency switch — 4 0.4 2.9
Flywheel magnet assembly M20 190 19 137
Negative battery lead M8 9 0.9 6.5
Positive battery lead M8 9 0.9 6.5
Apron M6 8 0.8 5.8
Power unit mount M8 21 2.1 15
Starter relay holder M5 3 0.3 2.2
Oxygen density sensor cover M6 9 0.9 6.5
Oxygen density sensor bracket M6 14 1.4 10
Oxygen density sensor M18 49 4.9 35
Reed valve assembly M6 10 1.0 7.2
Reed valve M5 3 0.3 2.2
Reed valve stopper M3 1 0.1 0.7
Shift position switch M4 3 0.3 2.2
Spark plug M14 25 2.5 18
1st 5 0.5 3.6
Thermostat cover M6
2nd 11 1.1 8.0
1st 5 0.5 3.6
Cylinder head cover M6
2nd 11 1.1 8.0
Engine cooling water temperature
— 15 1.5 11
sensor
1st 15 1.5 11
Cylinder head M8
2nd 30 3.0 22
Cooling water pressure 1st 4 0.4 2.9
M6
control valve cover 2nd 8 0.8 5.8
1st 4 0.4 2.9
Exhaust port outer cover M6
2nd 8 0.8 5.8
2-11
SPEC TIGHTENING TORQUES E
Tightening torques
Part to be tightened Thread size
Nm m•kgf ft•lb
1st 10 1.0 7.2
M8
2nd 18 1.8 13
Crankcase
1st 20 2.0 14
M10
2nd 40 4.0 29
1st 19 1.9 14
2nd 37 3.7 27
Connecting rod 3rd M8 *
4th 19 1.9 14
5th 37 3.7 27
LOWER UNIT
Propeller M18 55 5.5 40
Lower unit M10 40 4.0 29
Ring nut — 145 14.5 105
Pinion nut M22 95 9.5 68
Gear oil drain screw — 7 0.7 5.1
Gear oil level check screw — 7 0.7 5.1
BRACKET UNIT
Flushing hose M5 5 0.5 3.6
Shift rod detent mechanism screw — 24 2.4 17
Upper mount M12 53 5.3 38
Lower mount M14 73 7.3 53
Exhaust manifold assembly M8 21 2.1 15
Muffler M8 18 1.8 13
Exhaust manifold M8 18 1.8 13
Lower exhaust manifold guide M8 18 1.8 13
Clamp bracket M22 15 1.5 11
Trim sensor stopper M6 2 0.2 1.4
Trim stopper — 37 3.7 27
POWER TRIM AND TILT UNIT
Power trim and tilt reservoir cap — 8 0.8 5.8
Power trim and tilt reservoir 1/4” 5 0.5 3.6
Power trim and tilt motor 1/4” 5 0.5 3.6
Manual valve — 4 0.4 2.9
Tilt ram end screw — 130 13 94
Gear pump unit 5/16” 9 0.9 6.5
Gear pump — 6 0.6 4.3
Trim ram end screw — 80 8.0 52
*: Loosen
2-12
SPEC TIGHTENING TORQUES E
General torque
GENERAL TORQUES
specifications This chart specifies tightening torques for
Nut (A) Bolt (B)
standard fasteners with a standard ISO
Nm m•kgf ft•lb
thread pitch. Tightening torque specifica-
8 mm M5 5 0.5 3.6 tions for special components or assemblies
10 mm M6 8 0.8 5.8 are provided in applicable sections of this
12 mm M8 18 1.8 13 manual. To avoid warpage, tighten multi-
14 mm M10 36 3.6 25 fastener assemblies in a crisscross fashion
17 mm M12 43 4.3 31 and progressive stages until the specified
tightening torque is reached. Unless other-
wise specified, tightening torque specifica-
tions require clean, dry threads.
Components should be at room tempera-
ture.
2-13
INSP
E
ADJ
CHAPTER 3
PERIODIC INSPECTIONS AND ADJUSTMENTS
1
LUBRICATION POINTS.......................................................................... 3-22
2
3
4
5
6
7
8
9
INSP
ADJ MAINTENANCE INTERVAL CHART E
3-1
INSP
ADJ MAINTENANCE INTERVAL CHART E
Initial Every
Refer to
Item Remarks 10 hours 50 hours 100 hours 200 hours page
(Break-in) (3 months) (6 months) (1 year)
GENERAL
Anodes Check/replace 3-18
Battery Check/charge (every month) 3-19
Spark plugs Clean/adjust/ 3-20
replace
Wiring and connectors Adjust/reconnect —
Bolts and nuts Tighten —
Lubrication points Grease 3-22
3-2
INSP
ADJ TOP COWLING/FUEL SYSTEM E
TOP COWLING 3
1. Check:
• Top cowling fitting
Loose/unlatched → Adjust the top
cowling hook.
3010
2. Adjust:
• Top cowling hook position
Adjustment steps
(1) Loosen the bolts 1 approximately 1/4
1 of a turn.
(2) Move the top cowling hook either up
or down slightly.
3020
(3) Secure the bolts.
(4) Check the top cowling fitting and
repeat the adjustment if necessary.
NOTE:
• Moving the latch towards the seal will
loosen the top cowling.
• Moving the latch away from the seal will
tighten the top cowling.
FUEL SYSTEM 3
1. Check:
• Medium-pressure fuel line
Cracks/damage/leaks → Replace.
Refer to “MEDIUM-PRESSURE FUEL
LINE” on page 4-2.
3025
3-3
INSP
ADJ FUEL SYSTEM E
2. Check:
• High-pressure fuel line
Cracks/damage/leaks → Replace.
Refer to “HIGH-PRESSURE FUEL LINE
ASSEMBLY” on page 4-30.
3026
3. Check:
• Plastic locking ties
Loosen → Retighten or replace.
4. Check:
• Low-pressure fuel line
Cracks/damage/leaks → Replace.
Refer to “LOW-PRESSURE FUEL
LINE” on page 4-43.
3030
Check:
1
2 • Fuel filter element 1
• Fuel filter cup 2
Clogs/cracks/leaks → Replace.
Foreign matter → Clean.
Refer to “FUEL FILTER” on page 4-46.
3040
3-4
INSP
ADJ FUEL SYSTEM E
Measure:
• Fuel pressure (medium-pressure fuel
line)
1 Out of specification → Check the
medium-pressure fuel line.
Fuel pressure
(medium-pressure fuel line)
280 - 360 kPa
(2.8 - 3.6 kgf/cm2, 39.8 - 51.2 psi)
Measuring steps
(1) Install the fuel pressure gauge onto the
pressure check valve.
Measure:
• Fuel pressure sensor output voltage
Out of specification → Check the high-
pressure fuel line.
B P O
Fuel pressure sensor output
voltage
Pink (P) – Black (B)
2.8 - 3.2 V
3051
Measuring steps
(1) Connect the test harness between the
fuel pressure sensor and the wire har-
ness as shown.
3-5
INSP
ADJ FUEL SYSTEM E
Check:
• Mechanical fuel pump oil level
Level is low → Add to the proper level.
Checking steps
1 (1) Remove the gear oil level check screw
1 and check the oil level.
(2) Add gear oil if needed, and then install
the gear oil level check screw.
3052 1
1. Place:
• Container
NOTE:
Place a container under the gear oil drain
screw.
2. Remove:
• Gear oil drain screw 1
• Gear oil level check screw 2
2 Drain the gear oil.
3. Fill:
• Gear oil
1
Recommended gear oil
GEAR CASE LUBE (USA) or
3053
Hypoid gear oil SAE 90
Filling steps
(1) Insert the gear oil tube into the drain
hole and slowly fill the gear oil until oil
flows out of the check hole.
(2) Install the gear oil level check screw
and then quickly install the gear oil
drain screw.
3054
3-6
INSP
ADJ CONTROL SYSTEM E
CONTROL SYSTEM 3
1. Check:
• Throttle valve synchronization
Uneven opening → Adjust.
3
Checking steps
(1) Remove the intake silencer 1.
3
(2) Disconnect the throttle lever rod 2
and oil pump link rod.
2 4
(3) Turn the throttle stop screw 3 until it
does not touch the stopper.
(4) Turn the screw 4 clockwise.
(5) Verify that all the throttle valves are
fully closed.
(6) If correct, proceed with adjustment
steps 3-5, 8, and 9 below.
3060
2. Adjust:
• Throttle valve opening
3-7
INSP
ADJ CONTROL SYSTEM E
1. Measure:
• Throttle position sensor output voltage
(with the throttle valves fully closed)
Out of specification → Adjust.
NOTE:
• Be sure to adjust the throttle valve’s open-
ing before measuring the throttle position
sensor output voltage.
• When measuring the throttle position sen-
sor output voltage, set the digital tester to
the manual range.
3101
Measuring steps
(1) Disconnect the throttle link rod 1 at
the #1 throttle valve.
(2) Connect the test harness (3-pin) as
shown.
2. Adjust:
• Throttle position sensor
3102
Adjustment steps
(1) Loosen the screws 2.
(2) Adjust the position of the throttle posi-
tion sensor until the specified output
voltage is obtained.
3100
Throttle position sensor output
voltage (pink (P) – orange (O))
0.50 ± 0.02 V
3-8
INSP
ADJ CONTROL SYSTEM E
1. Measure:
• Engine idling speed
Out of specification → Adjust.
Measuring steps
(1) Start the engine and allow it to warm
up for a few minutes.
(2) Install the tachometer onto the spark
plug lead of cylinder #1.
a Tachometer
YU-08036-A / 90890-06760
2. Adjust:
• Engine idling speed
Adjustment steps
(1) Loosen the adjustment screw 1.
1 (2) Align the center of the throttle control
lever cam roller 2 with the mark a.
2
3080
3090
NOTE:
Turn the adjustment screw 1 counterclock-
wise to tighten it.
2
3081
3-9
INSP
ADJ CONTROL SYSTEM E
1. Check:
• Shift operation
Incorrect → Adjust.
2. Adjust:
• Remote control shift cable length
Adjustment steps
(1) Loosen the locknut 1.
(2) Remove the clip 2.
(3) Disconnect the shift cable joint 3.
(4) Set the remote control lever to the
neutral position.
(5) Align the center of the set pin a with
the mark b on the bottom cowling.
(6) Adjust the position of the shift cable
joint until its hole aligns with the set
pin c.
3120
(7) Install the clip and tighten the locknut.
CAUTION:
The remote control cable joint must be
screwed in more than 8 mm (0.31 in).
3110
NOTE:
Before adjusting the remote control throttle
cable, be sure to adjust the throttle valves’
opening and engine idling speed.
1. Check:
• Throttle operation
Incorrect → Adjust.
NOTE:
Make sure the throttle valves are fully
closed when the remote control lever is
fully closed position.
3-10
INSP
ADJ CONTROL SYSTEM E
2. Adjust:
6 • Remote control throttle cable length
Adjustment steps
(1) Loosen the locknut 1 and stopper
a screw 2.
(2) Loosen the locknut 3.
1 (3) Remove the clip 4.
4 (4) Disconnect the throttle cable joint 5.
(5) Set the remote control lever to the
fully closed position.
2
(6) Align the center of the throttle control
7 lever cam roller 6 with the mark a.
(7) Tighten the stopper screw 2 until it
contacts the throttle control lever 7.
(8) Tighten the locknut 1.
(9) Adjust the position of the throttle cable
joint until its hole aligns with the set
5 pin on the throttle control lever 7.
3
3130 8.0 mm (0.31 in) (10) Install the clip 4 and tighten the lock-
nut 3.
CAUTION:
The remote control cable joint must be
screwed in more than 8 mm (0.31 in).
Check:
• Drive belt
Wear/damage → Replace.
Refer to “DRIVE BELT” on page 4-22.
3135
3-11
INSP CONTROL SYSTEM/COOLING SYSTEM/
ADJ OIL INJECTION SYSTEM E
1 1. Measure:
• Crank position sensor-to-flywheel
magnet assembly clearance a
Out of specification → Adjust.
2. Adjust:
• Crank position sensor
Adjustment steps
(1) Loosen the screws 1.
(2) Adjust the position of the crank posi-
tion sensor until the specified clear-
ance is obtained.
(3) Tighten the screws.
COOLING SYSTEM 3
Check:
• Cooling water discharge
No discharge → Clean and check the
cooling water passage.
3140
Checking steps
(1) Place the lower unit in water.
(2) Start the engine.
(3) Check that water flows from the cool-
ing water outlet.
Check:
• Oil strainer
Clogs/cracks/leaks → Replace.
Foreign matter → Clean.
Refer to “OIL TANK” on page 4-56.
3181
3-12
INSP
ADJ OIL INJECTION SYSTEM E
1. Check:
1 • Oil pump lever position
Incorrect → Adjust.
NOTE:
Make sure the oil pump lever 1 touches the
a stopper a (fully closed position) when the
3150 throttle valves are closed.
2. Adjust:
• Oil pump lever position
Adjustment steps
(1) Loosen the locknut 2.
(2) Remove the clip and washer.
(3) Disconnect the oil pump link rod joint
2 3.
3160 3 1 (4) Fully close the throttle valves.
(5) Turn the oil pump lever 1 so it con-
tacts the stopper a (fully closed posi-
tion).
(6) Adjust the position of the oil pump link
rod joint until its hole aligns with the
set pin on the oil pump lever 1.
(7) Install the washer and clip.
(8) Tighten the locknut.
CAUTION:
After adjustment, make sure the oil pump
lever operates properly.
3-13
INSP
ADJ OIL INJECTION SYSTEM E
CAUTION:
• DO NOT USE GASOLINE MIXED WITH OIL
(PREMIX).
• USE UNLEADED STRAIGHT GASOLINE
ONLY.
Bleed:
• Air bubbles
(from the oil injection system)
Bleeding steps
(1) Fill the oil tank with the engine oil.
3185
1
CAUTION:
• DO NOT USE GASOLINE MIXED WITH OIL
(PREMIX).
• USE UNLEADED STRAIGHT GASOLINE
ONLY.
Check:
• Electric oil pump operation
Incorrect → Replace.
Checking steps
(1) Disconnect the electric oil pump hose
1 from the vapor separator.
(2) Start the engine.
(3) Check the oil flows from the electric oil
pump hose end.
3186 (4) Connect the electric oil pump hose.
3-14
INSP
ADJ POWER TRIM AND TILT SYSTEM E
Check:
• Power trim and tilt fluid level
Level is low → Add power trim and tilt
fluid to the proper level.
WARNING
When removing the power trim and tilt res-
ervoir cap, the power trim and tilt fluid may
spurt out due to internal pressure. Highly
pressurized fluid could sproy out causing
3195 serious injury. Therefore, fully tilt up the
outboard (the tilt ram assembly fully
extended) and then slowly remove the
power trim and tilt reservoir cap.
Checking steps
(1) Tilt the outboard all the way up and
lock it with the tilt stop levers 1.
3200
WARNING
After tilting up the outboard, be sure to
support it with the tilt stop levers.
Otherwise, the outboard could suddenly
lower if the power trim and tilt unit should
lose fluid pressure.
NOTE:
3210
The fluid level should be directly below the
check hole as shown.
Reservoir cap
8 Nm (0.8 m • kgf, 5.8 ft • lb)
T.
R.
3-15
INSP
ADJ POWER TRIM AND TILT SYSTEM/LOWER UNIT E
1. Measure:
• Trim sensor setting resistance
Out of specification → Adjust.
Measuring steps
(1) Fully tilt the outboard down.
(2) Measure the trim sensor resistance.
3215
2. Adjust:
2 2 Trim sensor cam position
Adjusting steps
(1) Fully tilt the outboard down.
(2) Loosen the screw 1.
(3) Adjust the position of the trim sensor
1 1 cam 2 until the specified resistance is
3216
obtained.
LOWER UNIT 3
Check:
• Gear oil level
Level is low → Add gear oil to the
proper level.
3-16
INSP
ADJ LOWER UNIT E
1. Check:
• Gear oil
Milky oil → Replace the oil seal.
Slag oil → Check the gears, bearings,
and clutch dog.
Checking steps
(1) Tilt up the outboard slightly.
(2) Place a container under the gear oil
drain screw 1.
(3) Remove the gear oil drain screw and
gear oil level check screw 2.
3220
2. Fill:
• Gear oil
(with the specified amount of the rec-
ommend gear oil)
Filling steps
(1) Place the outboard in an upright posi-
tion.
(2) Insert the gear oil tube into the drain
hole and slowly fill the gear oil until oil
flows out of the check hole and no air
bubbles are visible.
(3) Install the gear oil level check screw
and then quickly install the gear oil
drain screw.
3-17
INSP
ADJ LOWER UNIT/GENERAL E
Check:
• Lower unit holding pressure
Pressure drops → Check the seals and
components.
Checking steps
CAUTION:
Do not overpressurize the lower unit.
Excessive pressure may damage the oil
seals.
Pressure tester
YB-35956 / 90890-06762
NOTE:
The lower unit should hold the specified
pressure for 10 seconds.
3240
GENERAL 3
Check:
• Anodes 1
• Trim tab 2
Scales → Clean.
Grease/oil → Clean.
Excessive wear → Replace.
CAUTION:
Do not oil, grease or paint the anode, or it
will not operate properly.
3250
3-18
INSP
ADJ GENERAL E
WARNING
Battery electrolytic fluid is dangerous; it
contains sulfuric acid and therefore is poi-
sonous and highly caustic.
Always follow these preventive measures:
• Avoid bodily contact with electrolytic
fluid as it can cause severe burns or per-
manent eye injury.
• Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
• SKIN - Flush with water.
• EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
• Drink large quantities of water or milk fol-
lowed by milk of magnesia, beaten egg,
or vegetable oil. Get immediate medical
attention.
Batteries also generate explosive hydrogen
gas; therefore, you should always follow
these preventive measures:
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes, etc.).
• DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTIC
FLUID OUT OF REACH OF CHILDREN.
NOTE:
• Batteries vary among manufacturers.
Therefore, the following procedures may
not always apply. Consult your battery
manufacturer’s instructions.
• First, disconnect the negative lead, then
the positive lead.
3-19
INSP
ADJ GENERAL E
Check:
• Electrolyte level
Below the minimum level mark →
Add distilled water to the proper level.
• Electrolyte specific gravity
Less than specification → Recharge
the battery.
1. Check:
• Electrodes 1
Cracks/excessive wear → Replace.
• Insulator color 2
Distinctly different color → Check the
engine condition.
2. Clean:
• Spark plugs
(with a spark plug cleaner or wire
brush.)
3-20
INSP
ADJ GENERAL E
3. Measure:
• Spark plug gap a
Out of specification → Regap.
3270
4. Tighten:
• Spark plugs
Spark plug
25 Nm (2.5 m • kgf, 18 ft • lb)
T.
R.
NOTE:
• Before installing the spark plug, clean the
3280 gasket surface and spark plug surface.
Also, it is suggested to apply a thin film of
anti-seize compound to the spark plug
threads to prevent thread seizure.
• If a torque wrench is not available, a good
estimate of the correct tightening torque
is to finger tighten a the spark plug and
then tighten it another 1/4 to 1/2 of a
turn b.
3-21
INSP
ADJ GENERAL E
LUBRICATION POINTS 3
Apply:
• Yamaha marine grease
(for USA and Canada)
• Yamaha grease A (for worldwide)
3290
3300
3310
3320
3330
3-22
FUEL E
CHAPTER 4
FUEL SYSTEM
1
LINE ASSEMBLY................................................................................... 4-33
REMOVING THE HOSE CLAMPS.......................................................... 4-36
INSTALLING THE HOSE CLAMPS ........................................................ 4-36
4005
4-1
FUEL MEDIUM-PRESSURE FUEL LINE E
8
A 19
5 9 0
5 6
1 2
4 3
22 8 7
18 19
C B
3
21
13
2 10
20 19
7 11
9
12
6
9
4-2
FUEL MEDIUM-PRESSURE FUEL LINE E
8
A 19
5 9 0
5 6
1 2
4 3
22 8 7
18 19
C B
3
21
13
2 10
20 19
7 11
9
12
6
9
4-3
FUEL MEDIUM-PRESSURE FUEL LINE E
8
A 19
5 9 0
5 6
1 2
4 3
22 8 7
18 19
C B
3
21
13
2 10
20 19
7 11
9
12
6
9
4-4
FUEL MEDIUM-PRESSURE FUEL LINE E
WARNING
Always reduce the fuel pressure in the
medium-pressure fuel line before servicing
the line or the vapor separator. If the fuel
pressure is not released, pressurized fuel
may spray out.
1. Reduce:
• Fuel pressure (medium-pressure fuel
line)
a Reducing steps
1
(1) Install the fuel pressure gauge onto the
pressure check valve a.
2. Drain:
• Fuel
3 WARNING
Reduce the fuel pressure before removing
4060
the vapor separator drain screw, or pres-
surized fuel will spray out and may result in
serious injury.
NOTE:
Remove the drain screw 3 and drain the
vapor separator of any fuel.
4-5
FUEL MEDIUM-PRESSURE FUEL LINE E
2
Disconnect:
• Fuel hose joint 1
NOTE:
Disconnect from the fuel strainer 2 the fuel
hose with the collar a slid to the end b of
a 4063 the joint.
Check:
• Fuel pressure displacement
Faulty → Replace the pressure regula-
tor.
Checking steps
(1) Install the fuel pressure gauge onto the
pressure check valve and then install
the Mity vac onto the pressure regula-
tor vacuum hose.
Vacuum pressure
Approx.
35 kPa (0.35 kg/cm2, 4.98 psi)
NOTE:
Make sure the fuel pressure in the medium-
4065
pressure fuel line lowers conversely in rela-
tion to the amount of pressure that is
applied to the pressure regulator.
4-6
FUEL VAPOR SEPARATOR E
VAPOR SEPARATOR 4
9
4 × 10 mm
8 12 11
10
8
3
6
7
6 × 35 mm
1 1
4
3
4090
2
4-7
FUEL VAPOR SEPARATOR E
9
4 × 10 mm
8 12 11
10
8
3
6
7
6 × 35 mm
1 1
4
3
4090
2
4-8
FUEL VAPOR SEPARATOR E
Remove:
• Hose clamps
NOTE:
Remove the hose clamps by cutting its
joint.
4070
CAUTION:
The fuel hose will be damaged if a hose
clamps are removed without cutting the
joint.
Install:
• Hose clamps
WARNING
Do not reuse hose clamps, only use new
ones.
4080
NOTE:
Properly crimp the hose clamps so it is
securely fastened.
4-9
FUEL VAPOR SEPARATOR E
4 × 14 mm
9
11
10
6 5
1
4 3 4110
4-10
FUEL VAPOR SEPARATOR E
4 × 14 mm
9
11
10
6 5
1
4 3 4110
4-11
FUEL VAPOR SEPARATOR E
Remove:
• Electric fuel pump filter
NOTE:
To remove the electric fuel pump filter, turn
it clockwise.
4120
Install:
• Rubber damper 1
• Rubber damper holder 2
• Electric fuel pump filter 3
NOTE:
4130 • Make sure the rubber damper is correctly
installed in its holder.
• Firmly push the electric fuel pump filter
into the bottom of the electric fuel pump
and then turn the filter counterclockwise
until it clicks.
4140
4-12
FUEL VAPOR SEPARATOR E
6 × 14 mm
2 1
3
8 4
5
6
7
9
1
6 5
1
7 4
4100
4-13
FUEL VAPOR SEPARATOR E
6 × 14 mm
2 1
3
8 4
5
6
7
9
1
6 5
1
7 4
4100
4-14
FUEL ELECTRIC FUEL PUMP E
4150
4-15
FUEL ELECTRIC FUEL PUMP E
4150
4-16
FUEL ELECTRIC FUEL PUMP E
4150
4-17
FUEL THROTTLE CONTROL LEVER CAM E
4170
4-18
THROTTLE POSITION SENSOR AND
FUEL AIR TEMPERATURE SENSOR E
4180
4-19
THROTTLE POSITION SENSOR AND
FUEL AIR TEMPERATURE SENSOR E
4180
4-20
THROTTLE POSITION SENSOR AND
FUEL AIR TEMPERATURE SENSOR E
NOTE:
During installation, make sure the throttle
position sensor is properly adjusted.
Install:
• Throttle position sensor
Refer to “ADJUSTING THE THROTTLE
POSITION SENSOR” on page 3-8.
4-21
FUEL DRIVE BELT E
DRIVE BELT 4
8 8 × 25 mm
9
13
10
E 14
11
15
12
4300
4-22
FUEL DRIVE BELT E
8 8 × 25 mm
9
13
10
E 14
11
15
12
4300
4-23
FUEL DRIVE BELT E
CAUTION:
Do not loosen or tighten the drive sprocket
bolt and driven sprocket nut when the
drive belt is installed.
4310
REMOVING THE DRIVE SPROCKET 4
Remove:
• Drive sprocket
Universal holder
YU-01235 / 90890-01235
Remove:
• Driven sprocket
4315
4316
Install:
• Driven sprocket
4315
4-24
FUEL DRIVE BELT E
4310
INSTALLING THE DRIVE SPROCKET 4
Install:
• Drive sprocket
Universal holder
YU-01235 / 90890-01235
Install:
• Drive belt
CAUTION:
• Never forcefully twist, turn inside out, or
bend the drive belt.
a • Do not let oil or grease get onto the drive
4330
belt.
• Minimum 25 mm (1.0 in) a.
Installation steps
(1) Finger tighten the drive belt tensioner
bolt 1, and then loosen it 90˚.
(2) Install the drive belt 2 by pushing the
drive belt tensioner 3 to the loosest
point on the belt.
3
NOTE:
Install the drive belt from the drive sprocket
side a and working it counterclockwise.
4
1 (3) Install the spring 4.
b
2 (4) Loosen the drive belt tensioner bolt
and stretch the drive belt with the
force of the spring.
(5) Adjust the drive belt tension so that
a side b of the drive belt has no slack,
4335
and then tighten the drive belt ten-
sioner bolt.
4-25
FUEL INJECTOR DRIVER E
INJECTOR DRIVER 4
6 × 12 mm
1 4
3
2
5
9
6 × 12 mm
4
6 × 35 mm 8
10
4340
4-26
FUEL INJECTOR DRIVER E
6 × 12 mm
1 4
3
2
5
9
6 × 12 mm
4
6 × 35 mm 8
10
4340
4-27
FUEL INJECTOR DRIVER E
Remove:
• Injector driver coupler
NOTE:
a • Disconnect the injector driver coupler by
pressing on the release plate part a and
4355 pressing up the lock plate b using both
thumbs unit it stops.
• For disconnection, hold the entire the
injection driver coupler.
CAUTION:
Do not pull on the lock plate b to remove
the injector driver coupler, otherwise, the
lock plate could be damaged.
4-28
FUEL INJECTOR DRIVER E
5 × 20 mm 4
6
3 6 × 20 mm
7
1
4 5
4 7
4
4 4350
4-29
FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY E
6 × 14 mm
23 Nm (2.3 m • kgf, 17 ft • Ib)
8 × 70 mm
8
17 2
15
16
10
13
7 5 26 Nm (2.6m • kgf, 19 ft • Ib)
7
8 × 25 mm
6
6 × 12 mm 18
6
11 18
12 4
6 × 12 mm
9 4360
4-30
FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY E
6 × 14 mm
23 Nm (2.3 m • kgf, 17 ft • Ib)
8 × 70 mm
8
17 2
15
16
10
13
7 5 26 Nm (2.6m • kgf, 19 ft • Ib)
7
8 × 25 mm
6
6 × 12 mm 18
6
11 18
12 4
6 × 12 mm
9 4360
4-31
FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY E
6 × 14 mm
23 Nm (2.3 m • kgf, 17 ft • Ib)
8 × 70 mm
8
17 2
15
16
10
13
7 5 26 Nm (2.6m • kgf, 19 ft • Ib)
7
8 × 25 mm
6
6 × 12 mm 18
6
11 18
12 4
6 × 12 mm
9 4360
4-32
FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY E
17
23
18 26 24
24 25 20 5 × 12 mm
22
21
10
11
12
15 19
14
13
8 × 45 mm 14
16 12
11
8 × 40 mm 10
8
9 10
11 2
5
12 4
3
8
6 × 16 mm 7 1
6 9
4370
4-33
FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY E
17
23
18 26 24
24 25 20 5 × 12 mm
22
21
10
11
12
15 19
14
13
8 × 45 mm 14
16 12
11
8 × 40 mm 10
8
9 10
11 2
5
12 4
3
8
6 × 16 mm 7 1
6 9
4370
4-34
FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY E
17
23
18 26 24
24 25 20 5 × 12 mm
22
21
10
11
12
15 19
14
13
8 × 45 mm 14
16 12
11
8 × 40 mm 10
8
9 10
11 2
5
12 4
3
8
6 × 16 mm 7 1
6 9
4370
4-35
FUEL HIGH-PRESSURE FUEL LINE ASSEMBLY E
Remove:
• Hose clamp
NOTE:
Remove the hose clamp by cutting its joint.
4070 CAUTION:
The fuel hose will be damaged if a hose
clamp is removed without cutting the joint.
Install:
• Hose clamp
WARNING
Do not reuse hose clamps, only use new
ones.
4080
NOTE:
Properly crimp the hose clamp so it is
securely fastened.
4-36
FUEL MECHANICAL FUEL PUMP E
6 × 35 mm 12
8 × 35 mm 2 13
3
6 7
15
11
8 10
14
4
2
19 1
18
23 17
22 8 × 30 mm
16
20 21
4380
6 × 16 mm
4-37
FUEL MECHANICAL FUEL PUMP E
6 × 35 mm 12
8 × 35 mm 2 13
3
6 7
15
11
8 10
14
4
2
19 1
18
23 17
22 8 × 30 mm
16
20 21
4380
6 × 16 mm
4-38
FUEL MECHANICAL FUEL PUMP E
6 × 35 mm 12
8 × 35 mm 2 13
3
6 7
15
11
8 10
14
4
2
19 1
18
23 17
22 8 × 30 mm
16
20 21
4380
6 × 16 mm
4-39
FUEL MECHANICAL FUEL PUMP E
7
10
9
7
9
8 16 17 18
20 24
19
15 23
22
21
14
6 × 45 mm
22
22
11 21
5 23
6
21
13 4
12
8 × 20 mm
8 × 45 mm 3
2 1 4390
4-40
FUEL MECHANICAL FUEL PUMP E
7
10
9
7
9
8 16 17 18
20 24
19
15 23
22
21
14
6 × 45 mm
22
22
11 21
5 23
6
21
13 4
12
8 × 20 mm
8 × 45 mm 3
2 1 4390
4-41
FUEL MECHANICAL FUEL PUMP E
7
10
9
7
9
8 16 17 18
20 24
19
15 23
22
21
14
6 × 45 mm
22
22
11 21
5 23
6
21
13 4
12
8 × 20 mm
8 × 45 mm 3
2 1 4390
4-42
FUEL LOW-PRESSURE FUEL LINE E
4190
4-43
FUEL LOW-PRESSURE FUEL LINE E
4200
4-44
FUEL LOW-PRESSURE FUEL LINE E
Check:
• Check valve operation
Damage/reverse air flow → Replace.
Checking steps
NOTE:
Do not overpressurize the check valve.
Excessive pressure may cause air to leak
out.
Mity vac
YB-35956 / 90890-06756
NOTE:
Make sure no air comes out of the opposite
side of the check valve.
4-45
FUEL FUEL FILTER E
FUEL FILTER 4
14
11
4210
4-46
FUEL FUEL FILTER E
14
11
4210
4-47
FUEL FUEL PUMP E
FUEL PUMP 4
4220
4-48
FUEL FUEL PUMP E
4220
4-49
FUEL FUEL PUMP E
1. Check:
• Diaphragm
• Fuel pump valves
Damage → Replace.
2. Check:
• Fuel pumps
Reverse air flow → Replace.
Checking steps
NOTE:
Do not overpressurize the fuel pump.
Excessive pressure may cause air to leak
out.
Mity vac
YB-35956 / 90890-06756
NOTE:
• Make sure no air comes out of the oppo-
site side of the fuel pump.
• To eliminate any gaps between the fuel
pump valves and the fuel pump body, and
to ensure a better seal, make sure the
inside of the fuel pump is wet (i.e., with
gas).
4-50
FUEL OIL INJECTION SYSTEM E
4250
4-51
FUEL OIL INJECTION SYSTEM E
4250
4-52
FUEL OIL INJECTION SYSTEM E
4260
4-53
FUEL OIL INJECTION SYSTEM E
4260
4-54
FUEL OIL INJECTION SYSTEM E
Check:
• Check valve operation
Damage/reverse air flow → Replace.
Checking steps
NOTE:
Do not overpressurize the check valve.
Excessive pressure may cause air to leak
out.
Mity vac
YB-35956 / 90890-06756
NOTE:
Make sure no air comes out of the opposite
side of the check valve.
4-55
FUEL OIL TANK E
OIL TANK 4
4270
4-56
POWR E
CHAPTER 5
POWER UNIT
7
CHECKING THE PISTON RINGS ........................................................... 5-58
CHECKING THE OIL PUMP DRIVEN GEAR .......................................... 5-59
CHECKING THE LABYRINTH RINGS .................................................... 5-60
CHECKING THE CRANKSHAFT............................................................. 5-60
INSTALLING THE OIL PUMP DRIVE GEAR .......................................... 5-61
INSTALLING THE BEARING.................................................................. 5-61
8
INSTALLING THE PISTON RINGS AND PISTON................................. 5-61
ASSEMBLING THE UPPER BEARING HOUSING ................................ 5-62
INSTALLING THE CRANKSHAFT ASSEMBLY..................................... 5-63
INSTALLING THE PISTON AND CONNECTING ROD ASSEMBLIES.. 5-63
9
POWR FLYWHEEL MAGNET ASSEMBLY E
5010
5-1
POWR FLYWHEEL MAGNET ASSEMBLY E
Remove:
• Flywheel magnet assembly
Removing steps
(1) Remove the flywheel magnet assem-
bly nut.
5020
Flywheel magnet assembly
holder
ı YB-06139 / 90890-06522
NOTE:
The major load should be applied in the
direction of the arrows. If the load is not
applied as shown, the flywheel magnet
5030
assembly holder may easily slip off of the
flywheel magnet assembly.
Å ı
Universal puller
YB-06117 / 90890-06521
NOTE:
• The major load should be applied in the
direction of the arrows.
• Apply the load until the flywheel magnet
assembly comes off the tapered portion of
the crankshaft.
CAUTION:
5050
To prevent damage to the engine or tools,
screw in the universal puller set-bolts
evenly and completely so that the puller
plate is parallel to the flywheel magnet
assembly.
5-2
POWR FLYWHEEL MAGNET ASSEMBLY E
Install:
• Flywheel magnet assembly nut
5070
Flywheel magnet assembly nut
190 Nm (19 m • kgf, 137 ft • lb)
T.
R.
5-3
POWR POWER UNIT E
POWER UNIT 5
5080
5-4
POWR POWER UNIT E
5080
5-5
POWR POWER UNIT E
5090
5-6
POWR POWER UNIT E
5095
5-7
POWR POWER UNIT E
5095
5-8
POWR POWER UNIT E
1. Install:
• Hose joint
NOTE:
First insert the hose joint 1 in the exhaust
expansion chamber hose 2, and then insert
1 the apron securely in the hose joint.
2
5096
2. Install:
• Apron
CAUTION:
Make sure not to get the flushing hose 1
1
caught between the mating surfaces a of
a the apron when installing it.
5097
5-9
POWR POWER UNIT E
5100
5-10
POWR POWER UNIT E
CAUTION:
Make sure to use engine hangers in three
different areas when suspending the power
unit as shown. If the engine hangers are
not used correctly the power unit will not
be balanced, which could result in serious
5105
injury or death.
a 1
Install:
• Shift rod lever
CAUTION:
Make sure to push the shift rod lever 1 to
the outside when placing the power unit
1 onto the bottom cowling, otherwise, inter-
5106
ference with the shift position switch plate
a may occur and the shift rod lever could
be damaged.
NOTE:
Make sure to place the shift rod lever 1 in
the shift rod lever bracket 2 after placing
the power unit securely onto the bottom
cowling.
5-11
POWR STATOR ASSEMBLY E
STATOR ASSEMBLY 5
5110
5-12
POWR STATOR ASSEMBLY E
5110
5-13
POWR CONTROL UNIT E
CONTROL UNIT 5
5120
5-14
POWR CONTROL UNIT E
5120
5-15
POWR FUSE HOLDER E
FUSE HOLDER 5
5130
5-16
POWR FUSE HOLDER E
6
11
3 × 10 mm
7
5
8
5 × 10 mm
1 1
9 10 4
2
1
9 10 1 4
5135
5-17
POWR JUNCTION BOX ASSEMBLY E
4 2
A 1
5140
5-18
POWR JUNCTION BOX ASSEMBLY E
5150
5-19
POWR JUNCTION BOX ASSEMBLY E
5150
5-20
POWR JUNCTION BOX ASSEMBLY E
5160
5-21
POWR JUNCTION BOX ASSEMBLY E
5160
5-22
POWR WIRE HARNESSES E
WIRE HARNESSES 5
1
A
9 70
6
⁄⁄⁄⁄⁄⁄⁄
8
⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄
1
5
2
3
3 2
6 × 12 mm 5170
5-23
POWR WIRE HARNESSES E
1
A
9 70
6
⁄⁄⁄⁄⁄⁄⁄
8
⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄
1
5
2
3
3 2
6 × 12 mm 5170
5-24
POWR WIRE HARNESSES E
4
5
⁄⁄⁄⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄⁄
1
2 7
6
5175
5-25
POWR WIRE HARNESSES E
⁄⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄
7 ⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄
5 5 5
3 3
3 5
5 5
⁄ ⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄
⁄ ⁄⁄
9
8
3 3 3
⁄⁄ ⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄⁄
0
⁄⁄⁄⁄⁄⁄⁄⁄⁄
4
1
6
2
6 × 12 mm
1
5180
5-26
POWR WIRE HARNESSES E
⁄⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄
7 ⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄
5 5 5
3 3
3 5
5 5
⁄ ⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄
⁄ ⁄⁄
9
8
3 3 3
⁄⁄ ⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄⁄
0
⁄⁄⁄⁄⁄⁄⁄⁄⁄
4
1
6
2
6 × 12 mm
1
5180
5-27
POWR STARTER MOTOR E
STARTER MOTOR 5
5190
5-28
POWR OXYGEN DENSITY SENSOR E
5200
5-29
POWR OXYGEN DENSITY SENSOR E
5200
5-30
POWR OXYGEN DENSITY SENSOR E
Install:
• Bolts 1 2 3
Bolt
14 Nm (1.4 m • kgf, 10 ft • lb)
T.
R.
5205
NOTE:
Make sure to tighten bolts 1, 2, and 3 to
the specified torque, in numerical order.
5-31
POWR REED VALVES E
REED VALVES 5
5210
5-32
POWR REED VALVES E
5210
5-33
POWR REED VALVES E
1. Check:
• Reed valve
Cracks/damage → Replace.
2. Measure:
• Warpage limit a
Out of specification → Replace.
Warpage limit
0.2 mm (0.008 in)
5220
3. Measure:
• Reed valve stopper height a
Out of specification → Replace.
5230
5-34
POWR EXTERNAL FITTINGS E
EXTERNAL FITTINGS 5
5240
5-35
POWR EXTERNAL FITTINGS E
5240
5-36
POWR EXTERNAL FITTINGS E
5245
5-37
POWR CYLINDER HEAD COVERS E
4 L K
4
J I
5
E
C D
9 9 7 8 9
6 2
1
7 5 4 3
A 0
10 B
8
G
H F
3
LT
2 572
5-38
POWR CYLINDER HEAD COVERS E
4 L K
4
J I
5
E
C D
9 9 7 8 9
6 2
1
7 5 4 3
A 0
10 B
8
G
H F
3
LT
2 572
5-39
POWR CYLINDER HEAD COVERS E
1. Check:
• Thermostat
Damage/valve does not open →
Replace.
2. Measure:
• Thermostat opening temperature
• Valve lift a
5260
Out of specification → Replace.
Measuring steps
(1) Suspend the thermostat in a container
filled with water.
(2) Place a thermometer in the water.
(3) Slowly heat the water.
(4) While stirring the water, check that the
thermostat opens at the specified tem-
perature.
5-40
POWR CYLINDER HEADS E
CYLINDER HEADS 5
11
6 × 20 mm 12 13
C F
A 14 5 × 12 mm
16 15 LT
9 0
572
1 A
G5 6H
1 2
4
F4 3E
8 7
B A
6 × 20 mm
E
6 78 3
4
4 × 12 mm 2 15 Nm (1.5 m • kgf, 11 ft • Ib)
5255
5-41
POWR CYLINDER HEADS E
11
6 × 20 mm 12 13
C F
A 14 5 × 12 mm
16 15 LT
9 0
572
1 A
G5 6H
1 2
4
F4 3E
8 7
B A
6 × 20 mm
E
6 78 3
4
4 × 12 mm 2 15 Nm (1.5 m • kgf, 11 ft • Ib)
5255
5-42
POWR CYLINDER HEADS E
1. Check:
• Combustion chamber
Carbon deposits → Clean.
• Water jacket
Mineral deposits/rust→ Clean.
CAUTION:
5265
Do not scratch the contacting surfaces of
the cylinder head and cylinder head cover.
2. Measure:
• Cylinder head warpage
(with a straightedge and thickness
gauge)
Out of specification → Resurface or
replace.
Warpage limit
5270 0.1 mm (0.004 in)
Resurfacing steps
(1) Place a 400 - 600 grit wet sandpaper on
the surface plate.
(2) Resurface the cylinder head by moving
it in a figure-eight motion along the
sandpaper.
NOTE:
Rotate the cylinder head several times to
5280
ensure an even surface.
5290
5-43
POWR EXHAUST COVERS E
EXHAUST COVERS 5
G H
F
C 6 × 20 mm
B 7 1st 4 Nm (0.4 m • kgf, 2.9 ft • Ib)
8
2nd 8 Nm (0.8 m • kgf, 5.8 ft • Ib)
6
3
1 6 × 30 mm
2
4 1st 4 Nm (0.4 m • kgf, 2.9 ft • Ib)
5 2nd 8 Nm (0.8 m • kgf, 5.8 ft • Ib)
9
A 0
D 7
LT
E I
572
M LK J
1
2
3
5 4
6
LT
572
8
9
5300
5-44
POWR EXHAUST COVERS E
G H
F
C 6 × 20 mm
B 7 1st 4 Nm (0.4 m • kgf, 2.9 ft • Ib)
8
2nd 8 Nm (0.8 m • kgf, 5.8 ft • Ib)
6
3
1 6 × 30 mm
2
4 1st 4 Nm (0.4 m • kgf, 2.9 ft • Ib)
5 2nd 8 Nm (0.8 m • kgf, 5.8 ft • Ib)
9
A 0
D 7
LT
E I
572
M LK J
1
2
3
5 4
6
LT
572
8
9
5300
5-45
POWR EXHAUST COVERS E
Check:
• Pressure control valve seat 1
• Pressure control valve 2
• Pressure control valve cover 3
Cracks/damage → Replace any defec-
tive parts.
5310
• Spring 4
Damage/wear → Replace.
5-46
POWR CRANKCASE E
CRANKCASE 5
5320
5-47
POWR CRANKCASE E
5320
5-48
POWR CRANKCASE E
Install:
• Oil seal
5340
Apply:
• Gasket Maker®
(onto the crankcase mating surfaces)
NOTE:
• Clean the mating surfaces of the crank-
case and cylinder body before applying
5350 Gasket Maker®.
• Do not allow any sealant to overflow from
the mating surfaces.
5-49
POWR CYLINDER BODY ASSEMBLY E
5360
5-50
POWR CYLINDER BODY ASSEMBLY E
5360
5-51
POWR CYLINDER BODY ASSEMBLY E
5360
5-52
POWR CYLINDER BODY ASSEMBLY E
5370
5-53
POWR CYLINDER BODY ASSEMBLY E
5600
5-54
POWR CYLINDER BODY ASSEMBLY E
Remove:
• Needle bearing
5400
Remove:
• Bearing
• Oil pump drive gear
5610
5-55
POWR CYLINDER BODY ASSEMBLY E
1. Check:
• Cylinder sleeves
Cracks/score marks → Replace.
• Cylinder body water jacket
Mineral deposits/rust → Clean.
CAUTION:
Do not scratch the contacting surfaces of
the crankcase and cylinder head.
2. Check:
• Exhaust passages
Cracks/damage → Replace.
Carbon deposits → Clean.
CAUTION:
Do not scratch the contacting surfaces of
the cylinder and exhaust inner cover.
3. Measure:
• Cylinder bore diameter “D”
(with a cylinder bore gauge)
Out of specification → Replace.
NOTE:
Measure the cylinder bore diameter at three
5410 positions for both D1 and D2. Then, average
the measurements.
Wear
Standard
limit
Cylinder
90.00 - 90.02 mm 90.1 mm
bore diame-
(3.543 - 3.544 in) (3.55 in)
ter “D”
0.08 mm
5420
Taper limit T —
(0.003 in)
Out of round 0.05 mm
—
limit R (0.002 in)
T = (maximum D1 or D2) – (minimum D5
or D6)
R = Maximum (D1 – D2) or (D3 – D4) or
(D5 – D6)
5-56
POWR CYLINDER BODY ASSEMBLY E
Measure:
• Piston diameter
(with a micrometer)
Out of specification → Replace.
Measuring
Piston diameter
point “H”
5440
10 mm 89.845 - 89.869 mm
Standard
(0.4 in) (3.5372 - 3.5381 in)
NOTE:
When measuring the piston diameter, posi-
tion the micrometer in relation to the piston
pin hole as shown.
Calculate:
• Piston-to-cylinder clearance a
Out of specification → Replace the pis-
ton and piston rings, the cylinder or
both.
Piston-to-cylinder clearance
0.150 - 0.156 mm
(0.0059 - 0.0061 in)
5-57
POWR CYLINDER BODY ASSEMBLY E
1. Check:
• Piston pin
• Small-end bearing
Heat discoloration → Replace.
Damage/scratches → Replace.
2. Measure:
• Piston pin diameter
(with a micrometer)
Out of specification → Replace.
3. Measure:
• Piston pin boss diameter
(with a micrometer)
Out of specification → Replace.
NOTE:
• Before checking the piston rings, be sure
to check the cylinder body.
• Piston rings should always be replaced as
a set (per piston).
5-58
POWR CYLINDER BODY ASSEMBLY E
1. Measure:
• Piston ring end gap a
(with a thickness gauge)
Out of specification → Replace.
NOTE:
Push the piston ring into the cylinder with
the piston crown.
5490
2. Measure:
• Piston ring side clearance b
(with a thickness gauge)
Out of specification → Replace the pis-
ton and piston rings as a set.
NOTE:
When measuring the piston ring side clear-
ance, the outside of the piston ring should
be flush with the piston wall.
Check:
• Oil pump driven gear
Cracks/pitting/wear → Replace.
5510
5-59
POWR CYLINDER BODY ASSEMBLY E
1. Check:
• Labyrinth ring 1
Cracks/damage/wear → Replace.
2. Measure:
• Labyrinth ring wear a or b + c
Out of specification → Replace.
1. Measure:
• Crankshaft runout
(with V-blocks and a dial gauge)
Out of specification → Replace.
Runout limit
5630 0.05 mm (0.002 in)
2. Measure:
• Small-end axial play
Out of specification → Replace the
connecting rod.
5640
3. Measure:
• Big-end side clearance
Out of specification → Replace the
connecting rod.
5650
4. Check:
• Crankshaft bearing
Pitting/rumbling → Replace.
5. Check:
• Oil pump drive gear
Cracks/pitting/wear → Replace.
5-60
POWR CYLINDER BODY ASSEMBLY E
Install:
• Oil pump drive gear
Install:
• Bearing
1. Install:
• 2nd piston ring 1
• Top piston ring 2
CAUTION:
• Align each piston ring end gap with its
5520
respective locating pin.
• After installing the piston rings, check
that they move smoothly.
5-61
POWR CYLINDER BODY ASSEMBLY E
2. Install:
• Small-end bearing 1
• Washers 2
• Piston 3
• Piston pin 4
• Piston pin clips 5
CAUTION:
5530
The washers must be installed with their
convex sides facing towards the piston.
NOTE:
The embossed YAMAHA mark a on the
connecting rod must face the same direc-
tion as the “UP” mark on the piston.
1. Install:
• Needle bearing
5550
2. Install:
• Oil seal
5560
5-62
POWR CYLINDER BODY ASSEMBLY E
Install:
• Cylinder body
• Crankshaft assembly
NOTE:
• Align the crankshaft labyrinth ring end
gaps with their respective locating pins.
• Install the bearing locating pins into the
cylinder body.
5570
Install:
• Piston and connecting rod assembly
5580
NOTE:
• Before installing the piston and connect-
5590 ing rod assemblies, lubricate the cylinder
walls with 2-stroke outboard engine oil.
• Reinstall the piston and connecting rod
assemblies in their original cylinders.
• Install the piston and connecting rod
assemblies with the “S” mark in the star-
board side cylinders, and those with the
“P” mark in the port side cylinders.
• The “UP” mark on the piston crown must
face towards the flywheel.
5-63
LOWR E
CHAPTER 6
LOWER UNIT
1
DISASSEMBLING THE FORWARD GEAR ASSEMBLY ....................... 6-21
CHECKING THE PINION ........................................................................ 6-22
CHECKING THE DRIVE SHAFT.............................................................. 6-22
CHECKING THE DRIVE SHAFT HOUSING ........................................... 6-22
CHECKING THE BEARINGS .................................................................. 6-22
ASSEMBLING THE FORWARD GEAR ASSEMBLY ............................. 6-22
ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ................. 6-23
INSTALLING THE PINION ..................................................................... 6-24
7
8
9
LOWR E
6010
6-1
LOWR LOWER UNIT (REGULAR ROTATION MODELS) E
6010
6-2
LOWR LOWER UNIT (REGULAR ROTATION MODELS) E
WARNING
Do not hold the propeller with your hands
when removing or installing it. Be sure to
remove the battery leads from the batteries
6016
and the lanyard engine stop switch. Put a
block of wood between the cavitation plate
and propeller to keep the propeller from
turning.
NOTE:
Mark the original position a for proper
installation.
6012
6-3
LOWR LOWER UNIT (REGULAR ROTATION MODELS) E
Propeller nut
55 Nm (5.5 m • kgf, 40 ft • lb)
T.
R.
WARNING
6017
Do not hold the propeller with your hands
when removing or installing it. Be sure to
remove the battery leads from the batteries
and the lanyard engine stop switch. Put a
block of wood between the cavitation plate
and propeller to keep the propeller from
turning.
NOTE:
If the groove in the propeller nut is not
aligned with the cotter pin hole, tighten the
nut further until they are aligned.
6-4
LOWR WATER PUMP (REGULAR ROTATION MODELS) E
6020
6-5
LOWR WATER PUMP (REGULAR ROTATION MODELS) E
6020
6-6
LOWR WATER PUMP (REGULAR ROTATION MODELS) E
NOTE:
• Make sure that the slit a in the impeller is
aligned with the woodruff key.
• The collar and spacer should fit together
firmly.
• Install the collar with some appropriate
tool inside diameter ø23 - 23.5 mm b that
fits over the drive shaft as shown.
6025
6-7
LOWR WATER PUMP (REGULAR ROTATION MODELS) E
2. Install:
• O-ring 1
• Impeller housing cup 2
• Impeller housing 3
• O-ring 4
NOTE:
• When installing the impeller housing cup,
6030 align its projection with the hole in the
impeller housing.
• When installing the water pump housing,
turn the drive shaft clockwise.
6-8
SHIFT ROD ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
6035
6-9
SHIFT ROD ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
NOTE:
Remove the shift rod assembly when the
shift rod is in the neutral position.
6-10
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
6040
6-11
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
6040
6-12
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
6045
6-13
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
6100
6-14
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
3. Remove:
• Propeller shaft housing assembly
• Straight key
• Reverse gear shim(s)
1 2
Propeller shaft housing puller . 1
6054 YB-06207 / 90890-06502
Universal puller......................... 2
YB-06117
ı
Guide plate................................ 3
90890-06501
Center bolt ................................ 4
90890-06504
6055
Slide hammer............................ 1
YB-06096
Bearing separator ..................... 2
90890-06534
6060
Guide plate................................ 3
90890-06501
ı Guide plate stand ..................... 4
90890-06538
Bearing puller............................ 5
90890-06535
Small universal claws .............. 6
90890-06536
6-15
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
Å 2. Remove:
• Ball bearing
Slide hammer............................ 1
YB-06096
Guide plate................................ 2
90890-06501
Guide plate stand ..................... 3
90890-06538
6070 Bearing puller............................ 4
90890-06535
Small universal claws .............. 5
ı 90890-06536
6075
3. Remove:
• Oil seals
• Needle bearing
6080
6-16
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
6086
2. Install:
• Oil seals
6-17
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
Ring nut
145 Nm (14.5 m • kgf, 105 ft • lb)
T.
R.
NOTE:
To secure the ring nut, bend one claw
washer tab into the slot in the ring nut and
the other tabs toward the propeller shaft
housing assembly.
6-18
LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) E
6105
6-19
LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) E
6105
6-20
LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) E
Bearing separator
6140 YB-06219 / 90890-06534
Å
CAUTION:
Do not reuse the bearing, always replace it
with a new one.
2. Remove:
• Needle bearings
6-21
LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) E
6-22
LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) E
2. Install:
• Tapered roller bearing
6155
Position a
5.75 - 6.25 mm (0.226 - 0.246 in)
6126
2. Install:
• Oil seals
6-23
LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) E
Pinion nut
95 Nm (9.5 m • kgf, 68 ft • lb)
T.
R.
6-24
LOWER CASE ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
6160
6-25
LOWER CASE ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
Å 2. Remove:
• Tapered roller bearing outer race
• Forward gear shim(s)
Slide hammer............................ 1
YB-06096
Bearing puller............................ 2
90890-06523
Large universal claws............... 3
6170 90890-06532
6171
6-26
LOWER CASE ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
2. Install:
• Needle bearing
6-27
LOWR LOWER UNIT (COUNTER ROTATION MODELS) E
6011
6-28
LOWR LOWER UNIT (COUNTER ROTATION MODELS) E
6011
6-29
LOWR LOWER UNIT (COUNTER ROTATION MODELS) E
WARNING
Do not hold the propeller with your hands
when removing or installing it. Be sure to
remove the battery leads from the batteries
6018
and the lanyard engine stop switch. Put a
block of wood between the cavitation plate
and propeller to keep the propeller from
turning.
NOTE:
Mark the original position a for proper
installation.
6012
6-30
LOWR LOWER UNIT (COUNTER ROTATION MODELS) E
Propeller nut
55 Nm (5.5 m • kgf, 40 ft • lb)
T.
R.
WARNING
6019
Do not hold the propeller with your hands
when removing or installing it. Be sure to
remove the battery leads from the batteries
and the lanyard engine stop switch. Put a
block of wood between the cavitation plate
and propeller to keep the propeller from
turning.
NOTE:
If the groove in the propeller nut is not
aligned with the cotter pin hole, tighten the
nut further until they are aligned.
6-31
LOWR WATER PUMP (COUNTER ROTATION MODELS) E
6022
6-32
LOWR WATER PUMP (COUNTER ROTATION MODELS) E
6022
6-33
LOWR WATER PUMP (COUNTER ROTATION MODELS) E
NOTE:
• Make sure that the slit a in the impeller is
aligned with the woodruff key.
• The collar and spacer should fit together
firmly.
• Install the collar with some appropriate
tool inside diameter ø23 - 23.5 mm b that
fits over the drive shaft as shown.
6025
6-34
LOWR WATER PUMP (COUNTER ROTATION MODELS) E
2. Install:
• O-ring 1
• Impeller housing cup 2
• Impeller housing 3
• O-ring 4
NOTE:
• When installing the impeller housing cup,
6030 align its projection with the hole in the
impeller housing.
• When installing the water pump housing,
turn the drive shaft clockwise.
6-35
SHIFT ROD ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
6195
6-36
SHIFT ROD ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
NOTE:
Remove the shift rod assembly when the
shift rod is in the neutral position.
6-37
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
6200
6-38
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
6205
6-39
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
6205
6-40
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
6235
6-41
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
3. Remove:
• Propeller shaft housing assembly
1
2 • Straight key
• Forward gear shim(s)
Slide hammer attachment....... 1
YB-06335 / 90890-06514
Slide hammer............................ 2
YB-06096 / 90890-06531
6215
6-42
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
Bearing separator
YB-06219 / 90890-06534
6230
CAUTION:
Do not reuse the bearing, always replace it
with a new one.
6-43
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
6086
2. Install:
• Oil seals
6-44
PROPELLER SHAFT HOUSING ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
6233
Ring nut
145 Nm (14.5 m • kgf, 105 ft • lb)
T.
R.
NOTE:
To secure the ring nut, bend one claw
washer tab into the slot in the ring nut and
the other tabs toward the propeller shaft
housing assembly.
6-45
LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) E
6240
6-46
LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) E
6240
6-47
LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) E
Slide hammer............................ 1
YB-06096
6250 Bearing puller............................ 2
90890-06535
Small universal claws .............. 3
ı 90890-06536
3
2 Å For USA and Canada
ı For worldwide
6172
Bearing separator
YB-06219 / 90890-06534
6270
6-48
LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) E
Å 2. Remove:
• Needle bearings
Slide hammer............................ 1
YB-06096
Guide plate................................ 2
90890-06501
Guide plate stand ..................... 3
90890-06538
6145 Bearing puller............................ 4
90890-06535
Small universal claws .............. 5
ı 90890-06536
6146
6-49
LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) E
2. Install:
• Roller bearing inner race
6285
Position a
5.75 - 6.25 mm (0.226 - 0.246 in)
6126
6-50
LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) E
2. Install:
• Oil seals
NOTE:
Install the thrust bearing onto the reverse
gear assembly and position the thrust bear-
6255 ing so its rounded side faces away from the
reverse gear.
Pinion nut
95 Nm (9.5 m • kgf, 68 ft • lb)
T.
6111
R.
6-51
LOWER CASE ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
6290
6-52
LOWER CASE ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
Å 2. Remove:
• Roller bearing
• Reverse gear shim(s)
Slide hammer............................ 1
YB-06096
Bearing puller............................ 2
90890-06523
Large universal claws............... 3
6300 90890-06532
6171
6-53
LOWER CASE ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
2. Install:
• Needle bearing outer race
6-54
SHIMMING (REGULAR ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
NOTE:
• There is no need to select shims when
reassembling with the original case and
inner parts.
• Shim calculations are required when reas-
sembling with the original inner parts and
a new case (the difference between the
original inner parts and the new case).
• Measurements and adjustments are
required when replacing the inner part(s).
6495
6-55
SHIMMING (REGULAR ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
6505
1. Measure:
M • Specified measurement (M)
Out of specified value (M0) → Adjust.
Measuring steps
6520 (1) Calculate the specified value (M0).
NOTE:
• “P” is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “P”
mark is missing or unreadable, assume a
“P” value of “0”, and check the backlash
when the unit is assembled.
• If the “P” mark is negative (–), then sub-
6510
tract the “P” value from the measure-
ment.
Example:
If “P” is “+5”, then
M0 = 1.00 + (+5)/100 mm
= 1.00 + 0.05 mm
= 1.05 mm
If “P” is “–3”, then
M0 = 1.00 + (–3)/100 mm
= 1.00 – 0.03 mm
= 0.97 mm
6-56
SHIMMING (REGULAR ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
NOTE:
If the original shim(s) is unavailable, start
6515 with a 0.50-mm shim.
Pinion nut
95 Nm (9.5 m • kgf, 69 ft • lb)
T.
R.
NOTE:
• Measure the clearance between the pin-
ion height gauge and the lower surface of
the pinion as shown.
• Perform the same measurement at three
points on the pinion.
6520
• Find the average of the measurements (M).
2. Adjust:
• Shim thickness (T3)
Remove or add shim(s).
NOTE:
(M0) – (M) should be as close to “0” as pos-
sible.
6-57
SHIMMING (REGULAR ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
6525
1. Measure:
• Specified measurement (M)
Out of specified value (M0) → Adjust.
Measuring steps
6526 (1) Calculate the specified value (M0).
NOTE:
• “F” is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “F”
mark is missing or unreadable, assume an
“F” value of “0”, and check the backlash
when the unit is assembled.
• If the “F” mark is negative (–), then sub-
6530
tract the “F” value from the measure-
ment.
Example:
If “F” is “+5”, then
M0 = 1.60 + (+5)/100 mm
= 1.60 + 0.05 mm
= 1.65 mm
If “F” is “–3”, then
M0 = 1.60 + (–3)/100 mm
= 1.60 – 0.03 mm
= 1.57 mm
6-58
SHIMMING (REGULAR ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
Shimming gauge
YB-34446-1, -3, -4, -8
NOTE:
If the original shim(s) is unavailable, start
with a 0.50-mm shim.
6535
2. Adjust:
• Shim thickness (T1)
Remove or add shim(s).
NOTE:
(M0) – (M) should be as close to “0” as pos-
sible.
6-59
SHIMMING (REGULAR ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
6545
1. Measure:
• Specified measurement (M)
M Out of specified value (M0) → Adjust.
Measuring steps
6555 (1) Calculate the specified value (M0).
NOTE:
• “R” is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “R”
mark is missing or unreadable, assume an
“R” value of “0”, and check the backlash
when the unit is assembled.
• If the “R” mark is negative (–), then add
6550
the “R” value to the measurement.
Example:
If “R” is “+5”, then
M0 = 1.80 – (+5)/100 mm
= 1.80 – 0.05 mm
= 1.75 mm
If “R” is “–3”, then
M0 = 1.80 – (–3)/100 mm
= 1.80 + 0.03 mm
= 1.83 mm
6-60
SHIMMING (REGULAR ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
NOTE:
6555 • If the original shim(s) is unavailable, start
with a 0.50-mm shim.
• Turn the reverse gear assembly a few
times until the gear and bearing are hori-
zontal.
2. Adjust:
• Shim thickness (T2)
Remove or add shim(s).
NOTE:
(M0) – (M) should be as close to “0” as pos-
sible.
6-61
SHIMMING (REGULAR ROTATION MODELS)
LOWR (FOR WORLDWIDE) E
NOTE:
• There is no need to select shims when
reassembling with the original case and
inner parts.
• Shim calculations are required when reas-
sembling with the original inner parts and
a new case (the difference between the
original inner parts and the new case).
• Measurements and adjustments are
required when replacing the inner part(s).
6495
6-62
SHIMMING (REGULAR ROTATION MODELS)
LOWR (FOR WORLDWIDE) E
Select:
6575 • Shim thickness (T3)
Selecting steps
(1) Measure (M3).
Digital caliper
90890-06704
NOTE:
Install the bearing housing 1, thrust bear-
6580 ing 2, and washer 3.
Pinion nut
95 Nm (9.5 m • kgf, 69 ft • lb)
T.
R.
NOTE:
After the wing nuts contact the fixing plate,
tighten them another 1/4 of a turn.
Digital caliper
90890-06704
6585
NOTE:
• Measure the clearance between the pin-
ion height gauge and the pinion, as
shown.
• Perform the same measurement at three
points on the pinion.
• Find the average of the measurements
(M4).
6-63
SHIMMING (REGULAR ROTATION MODELS)
LOWR (FOR WORLDWIDE) E
NOTE:
• “P” is the deviation of the lower case
6590 dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “P”
mark is missing or unreadable, assume a
“P” value of “0”, and check the backlash
when the unit is assembled.
• If the “P” mark is negative (–), then add
the “P” value to the measurement.
Example:
If M3 is “46.85 mm”, M4 is “32.52 mm” and
P is “–5”, then
T3 = 80.0 + (–5)/100 – 46.85 – 32.52 mm
= 80.0 – 0.05 – 46.85 – 32.52 mm
= 0.58 mm
6-64
SHIMMING (REGULAR ROTATION MODELS)
LOWR (FOR WORLDWIDE) E
6595 Select:
• Shim thickness (T1)
Selecting steps
(1) Measure (M1).
6600
NOTE:
• Turn the roller bearing outer race two or
three times so the rollers seat. Then, mea-
sure the height of the bearing, as shown.
• Perform the same measurement at three
points on the roller bearing outer race.
• Find the average of the measurements
(M1).
NOTE:
• “F” is the deviation of the lower case
6610 dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “F”
mark is missing or unreadable, assume an
“F” value of “0”, and check the backlash
when the unit is assembled.
• If the “F” mark is negative (–), then sub-
tract the “F” value from the measure-
ment.
6-65
SHIMMING (REGULAR ROTATION MODELS) (FOR
LOWR WORLDWIDE) E
Example:
If M1 is “28.10 mm” and F is “+5”, then
T1 = 28.6 + (+5)/100 – 28.10 mm
= 28.6 + 0.05 – 28.10 mm
= 0.55 mm
6615 Select:
• Shim thickness (T2)
Selecting steps
(1) Measure (M2).
6620
NOTE:
• Measure the height of the gear as shown.
• Perform the same measurement at three
points on the gear.
• Find the average of the measurements
(M2).
6-66
SHIMMING (REGULAR ROTATION MODELS) (FOR
LOWR WORLDWIDE) E
NOTE:
• “R” is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “R”
mark is missing or unreadable, assume a
“R” value of “0”, and check the backlash
when the unit is assembled.
• If the “R” mark is negative (–), then sub-
tract the “R” value from the measure-
ment.
6625 Example:
If M2 is “30.50 mm”, R is “+2”, then
T2 = 30.50 – 29.0 – (+2)/100 mm
= 30.50 – 29.0 – 0.02 mm
= 1.48 mm
(3) Select the reverse gear shim(s) (T2).
Calculated numeral
at 1/100th place Rounded
numeral
More than or less
0.00 0.02 0.02
0.02 0.05 0.05
0.05 0.08 0.08
0.08 0.10 0.10
Available shim thickness
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-67
LOWR BACKLASH (REGULAR ROTATION MODELS) E
BACKLASH
(REGULAR ROTATION MODELS) 6
NOTE:
• Do not install the water pump compo-
nents when measuring the backlash.
• Measure both the forward and reverse
gear backlashes.
• If both the forward and reverse gear back-
lashes are larger than specification, the
pinion may be too high.
• If both the forward and reverse gear back-
lashes are smaller than specification, the
pinion may be too low.
Measuring steps
(1) Set the shift rod into the neutral posi-
tion.
Center bolt
6650 10 Nm (1.0 m • kgf, 7.2 ft • lb)
T.
R.
6-68
LOWR BACKLASH (REGULAR ROTATION MODELS) E
Magnetic-base plate................. 6
YB-07003 / 90890-07003
Dial gauge set ........................... 7
YU-03097 / 90890-01252
Magnetic base........................... 8
YU-34481 / 90890-06705
2. Adjust:
• Forward gear shim
Remove or add shim(s).
Forward gear
Shim thickness
backlash
Less than To be decreased by
0.25 mm (0.010 in) (0.36 – M) × 0.54
More than To be increased by
0.46 mm (0.018 in) (M – 0.36) × 0.54
M: Measurement
6-69
LOWR BACKLASH (REGULAR ROTATION MODELS) E
Measuring steps
(1) Set the shift rod into the neutral posi-
tion.
6645
Propeller nut
10 Nm (1.0 m • kgf, 7.2 ft • lb)
T.
R.
6665
Magnetic-base plate................. 2
YB-07003 / 90890-07003
Dial gauge set ........................... 3
YU-03097 / 90890-01252
Magnetic base........................... 4
YU-34481 / 90890-06705
6-70
LOWR BACKLASH (REGULAR ROTATION MODELS) E
2. Adjust:
• Reverse gear shim
Remove or add shim(s).
Reverse gear
Shim thickness
backlash
Less than To be increased by
0.74 mm (0.029 in) (1.02 – M) × 0.54
More than To be decreased by
1.29 mm (0.051 in) (M – 1.02) × 0.54
M: Measurement
6-71
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
NOTE:
• There is no need to select shims when
reassembling with the original case and
inner parts.
• Shim calculations are required when reas-
sembling with the original inner parts and
a new case (the difference between the
original inner parts and the new case).
• Measurements and adjustments are
required when replacing the inner part(s).
6500
6-72
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
6505
1. Measure:
M • Specified measurement (M)
Out of specified value (M0) → Adjust.
Measuring steps
6520 (1) Calculate the specified value (M0).
NOTE:
• “P” is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “P”
mark is missing or unreadable, assume a
“P” value of “0”, and check the backlash
when the unit is assembled.
• If the “P” mark is negative (–), then sub-
6510
tract the “P” value from the measure-
ment.
Example:
If “P” is “+5”, then
M0 = 1.00 + (+5)/100 mm
= 1.00 + 0.05 mm
= 1.05 mm
If “P” is “–3”, then
M0 = 1.00 + (–3)/100 mm
= 1.00 – 0.03 mm
= 0.97 mm
6-73
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
NOTE:
If the original shim(s) is unavailable, start
6515 with a 0.50-mm shim.
Pinion nut
95 Nm (9.5 m • kgf, 69 ft • lb)
T.
R.
NOTE:
• Measure the clearance between the pin-
ion height gauge and the lower surface of
the pinion as shown.
• Perform the same measurement at three
points on the pinion.
6520
• Find the average of the measurements (M).
2. Adjust:
• Shim thickness (T3)
Remove or add shim(s).
NOTE:
(M0) – (M) should be as close to “0” as pos-
sible.
6-74
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
6525
1. Measure:
• Specified measurement (M)
Out of specified value (M0) → Adjust.
Measuring steps
6527 (1) Calculate the specified value (M0).
NOTE:
• “F” is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “F”
mark is missing or unreadable, assume an
“F” value of “0”, and check the backlash
when the unit is assembled.
• If the “F” mark is negative (–), then sub-
6530
tract the “F” value from the measure-
ment.
Example:
If “F” is “+5”, then
M0 = 29.10 + (+5)/100 mm
= 29.10 + 0.05 mm
= 29.15 mm
If “F” is “–3”, then
M0 = 29.10 + (–3)/100 mm
= 29.10 – 0.03 mm
= 29.07 mm
6-75
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
NOTE:
If the original shim(s) is unavailable, start
with a 0.50-mm shim.
2. Adjust:
• Shim thickness (T1)
Remove or add shim(s).
NOTE:
(M0) – (M) should be as close to “0” as pos-
sible.
6545
1. Measure:
• Specified measurement (M)
Out of specified value (M0) → Adjust.
M
Specified value (M0) =
1.30 – R/100 mm
6556
6-76
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
Measuring steps
(1) Calculate the specified value (M0).
NOTE:
• “R” is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “R”
6550
mark is missing or unreadable, assume an
“R” value of “0”, and check the backlash
when the unit is assembled.
• If the “R” mark is negative (–), then add
the “R” value to the measurement.
Example:
If “R” is “+5”, then
M0 = 1.30 – (+5)/100 mm
= 1.30 – 0.05 mm
= 1.25 mm
If “R” is “–3”, then
M0 = 1.30 – (–3)/100 mm
= 1.30 + 0.03 mm
= 1.33 mm
NOTE:
6556 • If the original shim(s) is unavailable, start
with a 0.50-mm shim.
• Turn the forward gear assembly a few
times until the gear and bearing are hori-
zontal.
6-77
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
2. Adjust:
• Shim thickness (T2)
Remove or add shim(s).
NOTE:
(M0) – (M) should be as close to “0” as pos-
sible.
1. Install:
• Shim(s) 1
• Thrust bearing 2
• Propeller shaft 3
• Tapered roller bearing 4
6565
2. Measure:
• Propeller shaft free play
Out of specification → Adjust.
Magnetic base........................... 1
YU-34481
6570
Dial gauge set ........................... 2
YU-03097
3. Adjust:
• Propeller shaft free play
Remove or add shim(s).
6-78
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR WORLDWIDE) E
NOTE:
• There is no need to select shims when
reassembling with the original case and
inner parts.
• Shim calculations are required when reas-
sembling with the original inner parts and
a new case (the difference between the
original inner parts and the new case).
• Measurements and adjustments are
required when replacing the inner part(s).
6500
6-79
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR WORLDWIDE) E
Select:
6575 • Shim thickness (T3)
Selecting steps
(1) Measure (M3).
Digital caliper
90890-06704
NOTE:
Install the bearing housing 1, thrust bear-
6580 ing 2, and washer 3.
Pinion nut
95 Nm (9.5 m • kgf, 69 ft • lb)
T.
R.
NOTE:
After the wing nuts contact the fixing plate,
tighten them another 1/4 of a turn.
Digital caliper
90890-06704
6585
NOTE:
• Measure the clearance between the pin-
ion height gauge and the pinion, as
shown.
• Perform the same measurement at three
points on the pinion.
• Find the average of the measurements
(M4).
6-80
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR WORLDWIDE) E
NOTE:
• “P” is the deviation of the lower case
6590 dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “P”
mark is missing or unreadable, assume a
“P” value of “0”, and check the backlash
when the unit is assembled.
• If the “P” mark is negative (–), then add
the “P” value to the measurement.
Example:
If M3 is “46.85 mm”, M4 is “32.52 mm” and
P is “–5”, then
T3 = 80.0 + (–5)/100 – 46.85 – 32.52 mm
= 80.0 – 0.05 – 46.85 – 32.52 mm
= 0.58 mm
6-81
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR WORLDWIDE) E
6595 Select:
• Shim thickness (T1)
Selecting steps
(1) Measure (M1).
Digital caliper
90890-06704
NOTE:
• Measure the combined thickness of the
roller bearing 1 and thrust bearing 2.
• Turn the roller bearing outer race two or
three times so the rollers seat. Then, mea-
sure the height of the bearing, as shown.
• Perform the same measurement at three
points on the roller bearing outer race.
• Find the average of the measurements
(M1).
6605
NOTE:
• “F” is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “F”
mark is missing or unreadable, assume an
“F” value of “0”, and check the backlash
when the unit is assembled.
• If the “F” mark is negative (–), then sub-
tract the “F” value from the measure-
ment.
6610
6-82
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR WORLDWIDE) E
Example:
If M1 is “28.10 mm” and F is “+5”, then
T1 = 29.1 + (+5)/100 – 28.10 mm
= 29.1 + 0.05 – 28.10 mm
= 1.05 mm
6615 Select:
• Shim thickness (T2)
Selecting steps
(1) Measure (M2).
6620
NOTE:
• Measure the height of the gear as shown.
• Perform the same measurement at three
points on the gear.
• Find the average of the measurements
(M2).
6-83
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR WORLDWIDE) E
NOTE:
• “R” is the deviation of the lower case
6625 dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “R”
mark is missing or unreadable, assume a
“R” value of “0”, and check the backlash
when the unit is assembled.
• If the “R” mark is negative (–), then sub-
tract the “R” value from the measure-
ment.
Example:
If M2 is “30.50 mm”, R is “+2”, then
T2 = 30.50 – 29.5 – (+2)/100 mm
= 30.50 – 29.5 – 0.02 mm
= 0.98 mm
6-84
SHIMMING (COUNTER ROTATION MODELS)
LOWR (FOR WORLDWIDE) E
6630
1. Install:
• Shim(s) 1
• Thrust bearing 2
• Propeller shaft 3
• Tapered roller bearing 4
6635
2. Measure:
• Propeller shaft free play
Out of specification → Adjust.
Magnetic base........................... 1
90890-06705
6640
Dial gauge set ........................... 2
90890-01252
3. Adjust:
• Propeller shaft free play
Remove or add shim(s).
6-85
LOWR BACKLASH (COUNTER ROTATION MODELS) E
BACKLASH
(COUNTER ROTATION MODELS) 6
NOTE:
• Do not install the water pump compo-
nents when measuring the backlash.
• Measure both the forward and reverse
gear backlashes.
• If both the forward and reverse gear back-
lashes are larger than specification, the
pinion may be too high.
• If both the forward and reverse gear back-
lashes are smaller than specification, the
pinion may be too low.
Measuring steps
(1) Set the shift rod into the neutral posi-
tion.
Center bolt
6650 10 Nm (1.0 m • kgf, 7.2 ft • lb)
T.
R.
6-86
LOWR BACKLASH (COUNTER ROTATION MODELS) E
Magnetic-base plate................. 6
YB-07003 / 90890-07003
Dial gauge set ........................... 7
YU-03097 / 90890-01252
Magnetic base........................... 8
YU-34481 / 90890-06705
2. Adjust:
• Forward gear shim
Remove or add shim(s).
Forward gear
Shim thickness
backlash
Less than To be increased by
0.21 mm (0.008 in) (0.32 – M) × 0.54
More than To be decreased by
0.43 mm (0.017 in) (M – 0.32) × 0.54
M: Measurement
6-87
LOWR BACKLASH (COUNTER ROTATION MODELS) E
Measuring steps
(1) Set the shift rod into the neutral posi-
tion.
6645
Propeller nut
5 Nm (0.5 m • kgf, 3.6 ft • lb)
T.
R.
6665
Magnetic-base plate................. 2
YB-07003 / 90890-07003
Dial gauge set ........................... 3
YU-03097 / 90890-01252
Magnetic base........................... 4
YU-34481 / 90890-06705
6715
6-88
LOWR BACKLASH (COUNTER ROTATION MODELS) E
6720
NOTE:
When measuring the reverse gear backlash,
6725
turn the shift rod wrench slightly towards
the reverse position.
2. Adjust:
• Reverse gear shim
Remove or add shim(s).
Reverse gear
Shim thickness
backlash
Less than To be decreased by
0.97 mm (0.038 in) (1.13 – M) × 0.54
More than To be increased by
1.29 mm (0.051 in) (M – 1.13) × 0.54
M: Measurement
6-89
BRKT E
CHAPTER 7
BRACKET UNIT
1
REMOVING THE GEAR PUMP UNIT .................................................... 7-32
DISASSEMBLING THE GEAR PUMP UNIT .......................................... 7-32
CHECKING THE TILT RAM .................................................................... 7-33
CHECKING THE GEAR PUMP UNIT...................................................... 7-33
ASSEMBLING THE GEAR PUMP UNIT ................................................ 7-34
INSTALLING THE GEAR PUMP UNIT................................................... 7-35
INSTALLING THE TILT RAM ASSEMBLY ............................................ 7-35
4
INSTALLING THE TRIM RAMS ............................................................. 7-40
5
6
7
8
9
BRKT BOTTOM COWLING E
BOTTOM COWLING 7
7010
7-1
BRKT BOTTOM COWLING E
7010
7-2
BRKT BOTTOM COWLING E
7030
7-3
BRKT BOTTOM COWLING E
7030
7-4
BRKT BOTTOM COWLING E
7035
7-5
BRKT SHIFT ROD ASSEMBLY E
7040
7-6
BRKT UPPER CASE ASSEMBLY E
7050
7-7
BRKT UPPER CASE ASSEMBLY E
7050
7-8
BRKT UPPER CASE ASSEMBLY E
7060
7-9
BRKT UPPER CASE ASSEMBLY E
7060
7-10
BRKT EXHAUST MANIFOLD ASSEMBLY E
7070
7-11
BRKT EXHAUST MANIFOLD ASSEMBLY E
7070
7-12
BRKT CLAMP BRACKETS E
CLAMP BRACKETS 7
7080
7-13
BRKT CLAMP BRACKETS E
7080
7-14
BRKT STEERING ARM E
STEERING ARM 7
7090
7-15
BRKT SWIVEL BRACKET ASSEMBLY E
7100
7-16
BRKT SWIVEL BRACKET ASSEMBLY E
7100
7-17
BRKT POWER TRIM AND TILT UNIT E
7110
7-18
BRKT POWER TRIM AND TILT UNIT E
7110
7-19
BRKT POWER TRIM AND TILT UNIT E
WARNING
After tilting up the outboard, be sure to
support it with the tilt stop levers.
Otherwise, the outboard could suddenly
lower if the power trim and tilt unit should
lose fluid pressure.
NOTE:
Tilt up the outboard and then turn the tilt
stop levers 1 to support it.
Remove:
• Power trim and tilt unit
7120 NOTE:
Slightly lower the tilt ram assembly and
then remove the power trim and tilt unit.
Bleed:
• Air bubbles
(from the power trim and tilt unit)
Bleeding steps
(1) Connect the battery leads to the bat-
tery.
(2) Loosen the manual valve 1 by turning
it counterclockwise until it stops.
7130
7-20
BRKT POWER TRIM AND TILT UNIT E
7-21
BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR E
7160
7-22
BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR E
WARNING
• To prevent the hydraulic fluid from spurt-
ing out due to internal pressure, the out-
board should be kept fully tilted up (the
tilt rod at full length).
• After removing the power trim and tilt
motor or reservoir, do not push the tilt
ram down. This may cause hydraulic fluid
to spurt out from the port.
CAUTION:
Do not wipe hydraulic system components
with rags, paper, tissues, or the like, as
fibers from such material will cause mal-
functions if they enter the system.
7-23
BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR E
NOTE:
Add power trim and tilt fluid until it reaches
the top of the gear pump housing.
3. Bleed:
• Air bubbles
NOTE:
• Remove all of the air bubbles with a
syringe or suitable tool as shown.
• Turn the gear pump gears with a screw-
driver and then remove any air between
7180 the gear teeth.
4. Install:
• O-ring 1
• Power trim and tilt motor 2
• Bolts 3
NOTE:
Align the armature shaft with the recess in
the drive pin.
7190
7-24
BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR E
WARNING
To prevent the hydraulic fluid from spurt-
ing out due to internal pressure, the tilt
ram should be kept at full length.
1. Fill:
• Reservoir
2. Check:
• Power trim and tilt fluid level
Level is low → Add power trim and tilt
fluid to the proper level.
7200
1. Bleed:
• Air bubbles
(from the power trim and tilt unit)
Bleeding steps
(1) Set the power trim and tilt unit upright.
(2) Connect the leads of the power trim
and tilt on the battery terminals until
the trim and tilt ram assemblies are
fully compressed.
7210
NOTE:
If the rams will not go down, refer to the fol-
lowing.
A. Connect the leads of the power trim and
tilt on the battery terminals until the trim
and tilt ram assemblies are fully
extended. Then, reverse the leads on the
battery terminals until the trim and tilt
ram assemblies are fully compressed.
7220
7-25
BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR E
7220
2. Check:
• Power trim and tilt unit operation
Unsmooth operation → Bleed the
power trim and tilt unit again.
7-26
BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR E
Hydraulic pressure
(with the power trim and tilt ram
assemblies fully extended)
9.8 - 11.8 MPa
(100 - 120 kg/cm2)
(with the power trim and tilt ram
assemblies fully compressed)
5.9 - 8.8 MPa (60 - 90 kg/cm2)
NOTE:
Before measuring the hydraulic pressure,
bleed the power trim and tilt unit.
Measuring steps
(1) Fully tilt up the power trim and tilt ram
assemblies.
(2) Remove the circlip 1.
(3) Remove the manual valve 2 and
install the up-relief valve attachment
and hydraulic pressure gauge and
tighten them to the specified torque.
7240
Up-relief valve attachment ...... 3
90890-06773
Hydraulic pressure gauge ........ 4
90890-06776
NOTE:
7250
Remove the manual valve and then quickly
attach the special tools before any fluid
comes out.
7-27
BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR E
7210
Hydraulic pressure
(with the power trim and tilt ram
assemblies fully extended)
9.8 - 11.8 MPa
7220 (100 - 120 kg/cm2)
Hydraulic pressure
(with the power trim and tilt ram
assemblies fully compressed)
5.9 - 8.8 MPa (60 - 90 kg/cm2)
7-28
BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR E
NOTE:
7280 After measuring the hydraulic pressure,
bleed the power trim and tilt unit.
7220
7-29
BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT E
7290
7-30
BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT E
7290
7-31
BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT E
7300
NOTE:
Hold the power trim and tilt unit in a vise
using aluminum plates on both sides.
NOTE:
Place a container under the power trim and
tilt unit.
NOTE:
When removing the pump gears, note their
original direction and position for proper
assembly.
7-32
BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT E
2. Remove:
• Check valves 1 and 2
NOTE:
To remove the check valves, cover the gear
pump housing with a clean cloth and then
blow compressed air through holes a
and b.
7330
7335
7-33
BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT E
CAUTION:
Install all components in their original
direction and position for proper assembly
and operation.
1. Install:
• Balls (3.18 mm/0.125 in) 1
• Shuttle valves 2
NOTE:
Apply grease to the balls to prevent them
from falling out of the gear pump.
7340
2. Install:
• O-ring 1
• Ball (3.18 mm/0.125 in) 2
• Up-relief valve pin 3
• Spring 4
• Up-relief valve 5
• Up-relief valve assembly 6
7350
3. Install:
• O-rings 1
• Check valves 2
• Balls (4.76 mm/0.187 in) 3
• Pump gears 4
4. Install:
7360 • Gear pump 1
• Bolts 2
• Filter 3
• O-ring 4
• Down-relief valve 5
• Filter 6
NOTE:
Tighten the bolts evenly and make sure the
pump gears turn smoothly.
7370
7-34
BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT E
7380 NOTE:
When installing the check valve assembly,
make sure the pin is on the tilt ram cylinder
side as shown.
2. Install:
7390
• Gear pump unit 1
• Bolts 2
WARNING
To prevent the hydraulic fluid from spurt-
ing out due to internal pressure, the tilt
ram should be kept at full length.
1. Fill:
• Tilt ram cylinder
NOTE:
Hold the power trim and tilt unit in a vise
using aluminum plates on both sides.
7400
7-35
BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT E
2. Fill:
• Gear pump housing
NOTE:
7410 Add power trim and tilt fluid through the
hole a until the fluid level is to the top of
the gear pump unit.
3. Install:
• Tilt ram assembly
NOTE:
Place the tilt ram end screw at the bottom
of the tilt ram and install the tilt ram assem-
bly into the tilt ram cylinder.
7420
4. Tighten:
• Tilt ram end screw
7430
7-36
BRKT TRIM RAM ASSEMBLIES AND FREE PISTON E
7440
7-37
BRKT TRIM RAM ASSEMBLIES AND FREE PISTON E
7450
Å For USA and Canada
ı For worldwide
NOTE:
Hold the power trim and tilt unit in a vise
using aluminum plates on both sides.
NOTE:
After removing the trim ram assemblies,
drain the fluid from the power trim and tilt
unit.
2. Install:
• Trim ram assemblies 1
NOTE:
Finger-tighten the trim ram assemblies and
then cover the tilt cylinder openings with a
clean cloth.
3. Remove:
7460 • Free piston 2
WARNING
Never look into the tilt cylinder opening
because the free piston and hydraulic fluid
may be expelled out forcefully.
NOTE:
Remove the free piston by blowing com-
7470 pressed air through the hole a.
7-38
BRKT TRIM RAM ASSEMBLIES AND FREE PISTON E
NOTE:
• Hold the power trim and tilt unit in a vise
using aluminum plates on both sides.
• Add power trim and tilt fluid through the
hole a.
7480
7-39
BRKT TRIM RAM ASSEMBLIES AND FREE PISTON E
2. Install:
• Piston ring 1
• O-ring 2
• Free piston 3
NOTE:
Push the free piston into the tilt ram cylin-
der until it bottoms out.
7490
WARNING
Do not push the trim rams down while
installing them into the trim ram cylinders.
Otherwise, the hydraulic fluid may spurt
out from the unit.
1. Fill:
• Trim ram cylinders
NOTE:
Hold the power trim and tilt unit in a vise
using aluminum plates on both sides.
7500
2. Fill:
• Fluid passages
NOTE:
7510 Add power trim and tilt fluid through holes
a, b and c until all of the passages are
filled.
7-40
BRKT TRIM RAM ASSEMBLIES AND FREE PISTON E
3. Install:
• Trim ram assemblies 1
NOTE:
Place each trim ram end screw at the bot-
tom of each trim ram and install them into
the trim ram cylinders.
7520
Å ı 4. Tighten:
• Trim ram end screws
7530
Å For USA and Canada
ı For worldwide
7-41
– +
ELEC E
CHAPTER 8
ELECTRICAL SYSTEMS
2
(Top view)................................................................................................. 8-5
5
MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE.............. 8-15
CHECKING THE SPARK PLUG CAPS.................................................... 8-16
8
9
– +
ELEC E
ELECTRICAL COMPONENTS 8
(Port view) 8
4
3
2
I 6
G 7
F
9
D
C
B
A 0
8010
8-1
– +
ELEC ELECTRICAL COMPONENTS E
(Starboard view) 8
1 2 3 2 4
5
7 6
8020
1 Thermo switch
2 Oxygen density sensor coupler (2P)
3 Oxygen density sensor
4 Crank position sensor coupler (2P)
5 Starter motor
6 Fuse holder
7 Junction box assembly
8 Thermo switch connectors
8-2
– +
ELEC ELECTRICAL COMPONENTS E
Å ı
Ç
2
8
1 6 9
4 B A 0
3
C
‰Ï Ì Ì Ó
Ç Î
8030
8-3
– +
ELEC ELECTRICAL COMPONENTS E
(Aft view) 8
4
3
3
5 6
4
4
3
8040
1 Control unit
2 Control unit couplers (26P, 26P, 34P)
3 Ignition coils
4 Ignition coil couplers (2P)
5 Injector driver couplers (26P)
6 Injector driver
8-4
– +
ELEC ELECTRICAL COMPONENTS E
(Top view) 8
9 0
8
7
7
6
5 6
3 A
2
B
E
8050
8-5
– +
ELEC WIRE HARNESS E
WIRE HARNESS 8
5
4 8 98
6
⁄⁄⁄⁄⁄⁄⁄
7
⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄
3
0
2
1
5 A
B
4 C
D
E
1 3 5 4 4 6 88 E D 7 95
L L/G G G/R P B Br B W R L B Br
L/W L/R B
B B BBB BP B P P L/W B/R P L/R L/R L/Y Y/R B Y Gr R W/R RRR R L/Y W/R Lg Sb Br B BB
L L B Y/R L/G L/R
L
Y
Br
W
G
P
0
Sb
Lg
R
B
Gy B
B/R
Y/R
G/R
Y
A
Sb Lg Sb
Lg R B Lg Sb
B/R
L
Y
B
C
2
8060
8-6
– +
ELEC WIRE HARNESS E
1
7
9
8
2 0
⁄⁄⁄⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄⁄
3
4
5
6 9 5 4 0 1 7 2 3 8
W/R W/Y W/G W/Br O P B O B P P O B G B/Y B/Y B P B B O Gy W/L W/Y W/R Gy R/Y W/B Gy B/Y B/Y G
W/B B W/L G B/Y B/Y O P O P B/W W/Br W/G W/B B Gy B W/B R/Y B/W B/Y B/Y G
B
8070
8-7
– +
ELEC WIRE HARNESS E
⁄⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄
1 ⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄
2 2 2
3 3
3 2
2 2
⁄ ⁄⁄⁄⁄⁄⁄⁄ ⁄⁄⁄
⁄ ⁄⁄
6
A
3 3 3
⁄⁄ ⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄⁄⁄ 5
⁄⁄⁄⁄⁄⁄⁄⁄
⁄⁄⁄⁄⁄⁄⁄⁄⁄ 7
4
8
9
0
2 2
2 2
2 Pu/W O/L
2
O/W Pu/L
Pu/G O/Y
0 3 33 98 1 O/B
Pu/B
O/G Pu/Y
O/R
Pu/R 4 3 3 30 A
B B L B/Y B/O B/L W/R W/Y W/L G L/Y L/W B
B L B/W B/Br B/G W/B W/G W/Br L/R L B G W/L B O/W O/L W/Y B Pu/Y Pu/R W/R B O/Y O/R R/Y R/Y R/Y R/Y R/Y R/W R/Y R/Y R/Y L/Y R/L R R
L R/Y R/Y R/Y B L W/Br R/W Pu/W Pu/L W/G R/W Pu/G Pu/B W/B R/W O/G O/B B/O B/Y B/L R/Y R/W R/W R/Y R/Y R/Y L/R R/L R R/W
B/W B/G B/Br L/W R/Y
5 6
BB
BBB
BBB
7 7 7 8080
8-8
– +
ELEC ELECTRICAL COMPONENTS ANALYSIS E
ELECTRICAL COMPONENTS
ANALYSIS 8
Digital tester
J-39299 / 90890-06752
NOTE:
8090
“ ” indicates a continuity of electric-
ity which means a closed circuit at the
respective switch position.
NOTE:
• When checking the condition of the igni-
tion system it is useful to know the peak
voltage.
• Cranking speed is dependant on many
factors (e.g., fouled or weak spark plugs, a
weak battery). If one of these is defective,
the peak voltage will be lower than speci-
fication.
• If the peak voltage measurement is not
within specification the engine will not
operate properly.
NOTE:
The peak voltage adaptor should be used
with the digital circuit tester.
8-9
– +
ELEC ELECTRICAL COMPONENTS ANALYSIS E
NOTE:
• When measuring the peak voltage, set the
selector to the DC voltage mode.
• Make sure the peak voltage adaptor leads
are properly installed in the digital tester.
• Make sure the positive pin (the “+” mark
facing up as shown) on the peak voltage
8120
adaptor is installed into the positive termi-
nal of the digital tester.
• The test harness is needed for the follow-
ing tests.
Measuring steps
(1) Disconnect the coupler connections.
(2) Connect the test harness between the
couplers.
(3) Connect the peak voltage adaptor
probes to the connectors which are
being checked.
(4) Start or crank the engine and observe
the measurement.
8140
Correct value
Displayed measurement –
internal resistance
NOTE:
The internal resistance of the digital tester
can be obtained by connecting both of its
probes.
8-10
– +
ELEC IGNITION SYSTEM E
IGNITION SYSTEM 8
8190
8-11
– +
ELEC IGNITION SYSTEM E
WARNING
• Do not touch any of the connections of
the spark gap tester lead wires.
• Do not let sparks leak out of the removed
spark plug cap.
• Keep flammable gas or liquids away,
8200
since this test can produce sparks.
Å Check:
• Ignition spark gap
Above specification → Replace the
spark plug.
Below specification → Check the con-
trol unit output.
Checking steps
(1) Remove the spark plugs from the
engine.
(2) Connect a spark plug cap to the spark
gap tester.
(3) Set the spark gap length on the adjust-
8220 ing knob.
8230
8240
8-12
– +
ELEC IGNITION SYSTEM E
Check:
• Fuse continuity
No continuity → Replace.
• Fuse rating
Out of specification → Replace.
Fuse rating
1: 12 V - 80 A
2: 12 V - 30 A
3: 12 V - 20 A
8195
1. Check:
• Main relay continuity
No continuity → Replace the fuse
holder.
Checking steps
(1) Remove the fuse 1.
4 1
3 5 (2) Connect the tester and battery as
shown.
Positive digital tester probe →
Fuse holder terminal 2
Negative digital tester probe →
Fuse holder terminal 3
Positive battery terminal →
Fuse holder terminal 4
2 Negative battery terminal →
Fuse holder terminal 5
8196
(3) Check that there is continuity between
the main relay terminals.
8-13
– +
ELEC IGNITION SYSTEM E
2. Check:
4 • Driver relay continuity
No continuity → Replace the fuse
holder.
Checking steps
(1) Remove the fuse 1.
(2) Connect the tester and battery as
1 shown.
5
Positive digital tester probe →
Fuse holder terminal 2
3 Negative digital tester probe →
Fuse holder terminal 3
Positive battery terminal →
Fuse holder terminal 4
Negative battery terminal →
2 Fuse holder terminal 5
(3) Check that there is continuity between
8197 the driver relay terminals.
WARNING
When checking the peak voltage do not
touch any of the connections of the digital
tester lead wires.
NOTE:
• If there is no spark or the spark is weak,
continue with the ignition system test.
• If a good spark is obtained, the problem is
not with the ignition system, but possibly
with the spark plug(s) or another compo-
nent.
8-14
– +
ELEC IGNITION SYSTEM E
Measure:
• Control unit output peak voltage
Below specification → Replace the
control unit.
R/Y (B/W)
Control unit output peak voltage
Black/white (B/W) –
Red/yellow (R/Y)
Black/green (B/G) –
Red/yellow (R/Y)
Black/brown (B/Br) –
Red/yellow (R/Y)
Black/orange (B/O) –
Red/yellow (R/Y)
Black/yellow (B/Y) –
Red/yellow (R/Y)
Black/blue (B/L) –
Red/yellow (R/Y)
Circuit Loaded
r/min
Cranking 1,500 3,500
8250
V — 140 205 220
NOTE:
Before measuring the control unit output
peak voltage, measure the pulser coil out-
put peak voltage.
8270
MEASURING THE PULSER COIL
B W/Y W/B W/R OUTPUT PEAK VOLTAGE 8
Measure:
• Pulser coil output peak voltage
Below specification → Replace the
W/Br W/L W/G pulser coil.
8-15
– +
ELEC IGNITION SYSTEM E
1. Check:
• Spark plug cap
Loose connection → Tighten.
Cracks/damage → Replace.
Replacement steps
(1) To remove the spark plug cap turn it
8280 counterclockwise.
(2) To install the spark plug cap turn it
clockwise until it is tight.
2. Measure:
• Spark plug cap resistance
Out of specification → Replace.
8290
8-16
– +
ELEC IGNITION CONTROL SYSTEM E
8300
8-17
– +
ELEC IGNITION CONTROL SYSTEM E
8310
MEASURING THE CRANK POSITION
SENSOR OUTPUT PEAK VOLTAGE 8
Measure:
• Crank position sensor output peak
G/L G
voltage
Below specification → Replace.
8-18
– +
ELEC IGNITION CONTROL SYSTEM E
Measure:
• Engine cooling water temperature
sensor resistance
Out of specification → Replace.
Measuring steps
(1) Place the engine cooling water tem-
perature sensor in a container filled
with water.
(2) Place a thermometer in the water.
(3) Slowly heat the water.
(4) Measure the resistance when the spec-
ified temperature is reached.
Check:
• Thermo switch continuity
Out of specification → Replace.
1 No continuity Å Temperature
2 Continuity ı Time
Measuring steps
(1) Place the thermo switch in a container
filled with water.
(2) Place a thermometer in the water.
(3) Slowly heat the water.
(4) Measure the continuity when the spec-
ified temperature is reached.
8-19
– +
ELEC IGNITION CONTROL SYSTEM E
Measure:
• Throttle position sensor output volt-
age
Out of specification → Check the con-
trol unit.
Measuring steps
(1) Connect the test harness (3-pin) as
shown.
NOTE:
Make sure the throttle position sensor out-
8341
put voltage is within specification when the
throttle is fully closed and fully opened.
8-20
– +
ELEC IGNITION CONTROL SYSTEM E
1. Check:
• Shift position switch continuity
Out of specification → Replace.
Lead color
Switch
position Blue/yellow (L/Y) –
8345 Black (B)
Home a No continuity
On b Continuity
2. Check:
• Shift position switch
Does not return to the home position
→ Replace
8-21
– +
ELEC FUEL CONTROL SYSTEM E
8390
8-22
– +
ELEC FUEL CONTROL SYSTEM E
8390
8-23
– +
ELEC FUEL CONTROL SYSTEM E
Measure:
• Crank position sensor output peak
voltage
Below specification → Replace.
8-24
– +
ELEC FUEL CONTROL SYSTEM E
1. Measure:
Gy B/W
• Oxygen density sensor heater resis-
tance
Out of specification → Replace.
2. Measure:
• Oxygen density sensor output voltage
Out of specification → Replace.
Measuring steps
WARNING
To prevent an explosion when performing
this procedure, keep all flammable prod-
ucts (e.g., gasoline) away from the testing
area and make sure there is proper ventila-
tion.
CAUTION:
Do not let any silicon anticorrosion solvent
touch the oxygen density sensor or its
accuracy will be affected.
8-25
– +
ELEC FUEL CONTROL SYSTEM E
CAUTION:
• Do not heat the oxygen density sensor
above 800 ˚C (1,472 ˚F) or continuously for
more than 1 minute at a time or the sen-
sor will be damaged.
• Do not use a burner with an oxygen tank.
2 The sensor may be damaged by a flame
Gy of high temperature.
8405 B/W
a Inner cone
b Outer cone
NOTE:
If the instantaneous change in the output
voltage is 0.6 V or greater the oxygen den-
sity sensor is OK.
Measure:
• Atmospheric pressure sensor output
voltage
Out of specification → Replace.
8-26
– +
ELEC FUEL CONTROL SYSTEM E
Measuring steps
(1) Connect the test harness between the
atmospheric pressure sensor and the
wire harness as shown.
P B O
8410
Measure:
• Intake air temperature sensor resis-
tance
Out of specification → Replace.
B/Y B/Y
8440
8-27
– +
ELEC FUEL CONTROL SYSTEM E
1. Check:
• Fuel injector operating sound
No sound (no fuel is being sprayed) →
Check the electric fuel pump.
Checking steps
(1) Start the engine.
(2) Fully close the throttle valves.
(3) Attach the screwdriver 1 onto the fuel
injector body and check if all of the fuel
injectors have a solenoid valve operat-
ing sound.
8450
2. Check:
• Electric fuel pump operating sound
Correct → Replace the fuel injector (no
sound).
No sound → Measure the injector
driver output peak voltage.
NOTE:
• The electric fuel pump should sound
when the engine start switch is turned on.
• Disconnect the Brown (Br) starter relay
terminal 1 to prevent the engine from
starting.
1 8460
8-28
– +
ELEC FUEL CONTROL SYSTEM E
3. Measure:
• Injector driver output peak voltage
Correct → Replace the electric fuel
pump.
Out of specification → Replace the
injector driver.
Circuit Loaded
r/min
Cranking 1,500 3,500
V 65 60 65 65
Measure:
• Fuel pressure sensor output voltage
B P O Out of specification → Replace.
Measuring steps
(1) Connect the test harness (3-pin) as
shown.
8-29
– +
ELEC FUEL CONTROL SYSTEM E
Check:
• Water detection switch continuity
L/W B
Out of specification → Replace.
8-30
– +
ELEC STARTING SYSTEM E
STARTING SYSTEM 8
8500
1 Battery B : Black
2 Fuse holder Br : Brown
3 Fuse (20A) R : Red
4 Fuse (80A) Br/W : Brown/white
5 Fuse (30A)
6 Starter relay
7 Starter motor
Å To remote control
8-31
– +
ELEC STARTING SYSTEM E
Check:
• Wire harness continuity
No continuity → Replace.
Check:
• Wire connections
Poor connection → Properly connect.
Check:
• Starter relay continuity
No continuity → Replace.
Checking steps
(1) Connect the tester and battery
between the starter relay terminals.
8520
Positive digital tester probe 1 →
Starter relay terminal
Negative digital tester probe 2 →
Starter relay terminal
Positive battery terminal →
Brown lead 3
Negative battery terminal →
Black lead 4
(2) Check that there is continuity between
the starter relay terminals.
8-32
– +
ELEC STARTER MOTOR E
STARTER MOTOR 8
13
14
15
27 16
3
6 × 50 mm
20
21
4 × 20 mm
36
19 31 6
2 30 7
32 8
22 35 5
9
24 34
4
10
25
26
18 11 1
33
29 12
23
28
17 4 × 15 mm
6 × 120 mm 8530
8-33
– +
ELEC STARTER MOTOR E
13
14
15
27 16
3
6 × 50 mm
20
21
4 × 20 mm
36
19 31 6
2 30 7
32 8
22 35 5
9
24 34
4
10
25
26
18 11 1
33
29 12
23
28
17 4 × 15 mm
6 × 120 mm 8530
8-34
– +
ELEC STARTER MOTOR E
13
14
15
27 16
3
6 × 50 mm
20
21
4 × 20 mm
36
19 31 6
2 30 7
32 8
22 35 5
9
24 34
4
10
25
26
18 11 1
33
29 12
23
28
17 4 × 15 mm
6 × 120 mm 8530
8-35
– +
ELEC STARTER MOTOR E
13
14
15
27 16
3
6 × 50 mm
20
21
4 × 20 mm
36
19 31 6
2 30 7
32 8
22 35 5
9
24 34
4
10
25
26
18 11 1
33
29 12
23
28
17 4 × 15 mm
6 × 120 mm 8530
8-36
– +
ELEC STARTER MOTOR E
Remove:
2 • Clip 1
NOTE:
Slide the pinion stopper 2 down as shown
and then remove the clip.
8540
1. Check:
• Starter motor pinion teeth
Damage/wear → Replace.
2. Check:
• Starter motor pinion movement
Incorrect → Replace.
8550
NOTE:
Rotate the starter motor pinion clockwise
and make sure it moves smoothly. Also,
rotate the starter motor pinion counter-
clockwise and make sure it locks.
1. Check:
• Commutator
Foreign matter → Clean.
(with 600 grit sandpaper)
8560
2. Measure:
• Commutator diameter
Out of specification → Replace.
8570
8-37
– +
ELEC STARTER MOTOR E
3. Check:
• Commutator undercut
Dirt/foreign matter → Clean.
(with compressed air)
8580
4. Measure:
• Commutator undercut a
Out of specification → Replace the
armature.
8590
5. Check:
• Armature continuity
Out of specification → Replace.
Armature continuity
Commutator
Continuity
segments a
8600
Segment –
No continuity
Armature core b
Segment –
No continuity
Armature shaft c
1. Measure:
• Brush length a
Out of specification → Replace the
brush assembly.
8-38
– +
ELEC STARTER MOTOR E
2. Check:
1 • Brush assembly continuity
3
Out of specification → Replace the
brush assembly.
Check:
• Magnetic switch relay continuity
Out of specification → Replace.
Checking steps
(1) Remove the terminal 1 from the mag-
netic switch relay.
NOTE:
Remove the terminal to prevent the pinion
gear from turning.
CAUTION:
Do not connect the battery for more than
one second. Otherwise, the magnetic
switch relay may be damaged.
8-39
– +
ELEC STARTER MOTOR E
NOTE:
The starter motor pinion should be pushed
out while the magnetic switch is on.
8-40
– +
ELEC CHARGING SYSTEM E
CHARGING SYSTEM 8
8630
8-41
– +
ELEC CHARGING SYSTEM E
Measure:
• Rectifier/regulator output peak voltage
Below specification → Replace the
rectifier/regulator.
NOTE:
Before measuring the rectifier/regulator
output peak voltage;
• Measure the lighting coil output peak volt-
age.
• Disconnect the rectifier/regulator coupler
(blue) 1.
1 R
8275
8-42
– +
ELEC CHARGING SYSTEM E
Measure:
• Lighting coil output peak voltage
Below specification → Replace the
G lighting coil.
G Circuit Loaded
r/min
Cranking 1,500 3,500
V 7.5 8.0 12 12
NOTE:
Before measuring the lighting coil output
peak voltage, disconnect the rectifier/regu-
lator coupler (blue) 1.
1
8276
8-43
– +
ELEC OIL FEED PUMP CONTROL SYSTEM E
8680
8-44
– +
ELEC OIL FEED PUMP CONTROL SYSTEM E
Check:
• Oil level sensor/switch continuity
Out of specification → Replace.
Lead color
Float Blue/ Blue/ Blue/
position Black white green red
(B)
(L/W) (L/G) (L/R)
Å ON
Å OFF
ı ON
ı OFF
Ç ON
Ç OFF
Float distance
8690
a: 3 - 6 mm (0.12 - 0.24 in)
b: 33 - 36 mm (1.30 - 1.42 in)
c: 53 - 56 mm (2.09 - 2.20 in)
d: 150 - 153 mm (5.91 - 6.02 in)
8700
8-45
– +
ELEC OIL FEED PUMP CONTROL SYSTEM E
1. Check:
• Emergency switch continuity
Out of specification → Replace.
2. Check:
• Emergency switch
Does not automatically return to the
home position → Replace.
Check:
• Oil pump (sub-oil tank)
Incorrect operation → Replace.
NOTE:
Connect the oil pump leads to a 12-V bat-
8720 tery and make sure the oil pump operates
properly.
8-46
– +
ELEC POWER TRIM AND TILT SYSTEM E
8730
8-47
– +
ELEC POWER TRIM AND TILT SYSTEM E
2 1. Check:
B • Power trim and tilt relay continuity
Out of specification → Replace.
1
Power trim and tilt relay
+ continuity
Lg Sb
8740
Sky blue (Sb) – Black (B)
Continuity
Light green (Lg) – Black (B)
Terminal 1 – Terminal -
Continuity
Terminal 2 – Terminal -
Terminal 1 – Terminal +
No continuity
Terminal 2 – Terminal +
2. Check:
• Power trim and tilt relay operation
No continuity → Replace.
8750
Checking steps
(1) Connect the digital tester between
power trim and tilt relay terminals 1
and +.
B (2) Connect a 12-V battery as shown.
8-48
– +
ELEC POWER TRIM AND TILT SYSTEM E
Check:
• Trailer switch continuity
Out of specification → Replace.
Lead color
Switch Light
8780 position Sky blue Red (R) green
(Sb)
(Lg)
Up
Free
Down
Measure:
• Trim sensor resistance
Out of specification → Replace.
NOTE:
Turn the lever 1 and measure the resis-
tance as it gradually changes.
8-49
– +
ELEC POWER TRIM AND TILT MOTOR E
8800
8-50
– +
ELEC POWER TRIM AND TILT MOTOR E
8800
8-51
– +
ELEC POWER TRIM AND TILT MOTOR E
Remove:
• Stator 1
CAUTION:
• Keep the power trim and tilt motor leads
inside the stator.
• Do not allow grease or oil to contact the
8810
commutator.
NOTE:
• Remove the lead holder 2 and rubber
spacer 3 from the stator and slide them
towards the leads.
• Hold the end of the armature shaft with a
clean cloth and pull off the stator.
1. Remove:
• Sky blue power trim and tilt motor
lead 1
NOTE:
Hold the brush with a screwdriver as
shown. Then, disconnect the sky blue lead.
8820
2. Remove:
• Brush holders 1
• Brushes 2
CAUTION:
Do not touch the bimetal a; touching it
may affect the operation of the breaker.
8830
1. Measure:
• Brush length a
Out of specification → Replace.
Brush length
4.8 mm (0.19 in)
8840
8-52
– +
ELEC POWER TRIM AND TILT MOTOR E
2. Check
• Brush continuity
No continuity → Replace.
CAUTION:
Do not touch the bimetal a; touching it
may affect the operation of the breaker.
8850
1. Measure:
• Commutator diameter a
Out of specification → Replace.
8860
2. Measure:
• Commutator undercut a
Out of specification → Replace the
armature.
8870
3. Check:
• Armature continuity
Out of specification → Replace.
Armature continuity
8890
8-53
– +
ELEC POWER TRIM AND TILT MOTOR E
Install:
• Brushes 1
• Brush holders 2
• Power trim and tilt motor leads 3
• Screw 4
CAUTION:
8900
Do not touch the bimetal; touching it may
affect the operation of the breaker.
Install:
• Armature 1
NOTE:
Push the brushes into the holder and then
install the armature.
8910
Install:
• Stator 1
NOTE:
Place a clean cloth over the end of the
armature shaft and carefully push the arma-
ture into the stator with a pair of pliers as
8920 shown.
8-54
TRBL
ANLS E
CHAPTER 9
TROUBLE ANALYSIS
TROUBLE ANALYSIS 9
NOTE:
The following items should be checked before the “TROUBLE ANALYSIS CHART” is con-
sulted.
1. The battery is properly charged and its specified gravity is within specification.
2. There are no incorrect wiring connections.
3. Wiring connections are properly secured and are not rusty.
4. The lockplate is attached to the engine stop lanyard switch.
5. The shift position is in neutral.
6. Fuel is reaching the carburetor(s)/vapor separator.
7. The PTT fluid, high-pressure pump oil and gear oil are at the specified levels.
8. The rigging and engine settings are correct.
9. The engine is free from any “Hull problem”.
POOR PERFORMANCE
Reference
Relative part
LOOSE STEERING
HARD STARTING
chapter
ENGINE STALLS
HARD SHIFTING
ROUGH IDLING
OVERHEATING
HIGH IDLING
FUEL SYSTEM
Low-pressure fuel line
• Fuel line 3
• Fuel filter 3
• Fuel pumps 4
Medium/high-pressure fuel line
• Vapor separator 4
• Electric fuel pump 4
• Medium/high-pressure
3
fuel line
• Mechanical fuel pump 4
• Fuel injectors 4
Link adjustment 3
POWER UNIT
Compression 3
Drive belt 4
Reed valves 5
9-1
TRBL
ANLS TROUBLE ANALYSIS E
POOR PERFORMANCE
LOOSE STEERING
HARD STARTING
chapter
ENGINE STALLS
HARD SHIFTING
ROUGH IDLING
OVERHEATING
HIGH IDLING
9-2
TRBL
ANLS TROUBLE ANALYSIS E
POOR PERFORMANCE
LOOSE STEERING
HARD STARTING
chapter
ENGINE STALLS
HARD SHIFTING
ROUGH IDLING
OVERHEATING
HIGH IDLING
ELECTRICAL
Ignition system
• Pulser coils 8
• Control unit 8
• Ignition coils 8
• Spark plugs 3
Ignition/fuel control system
• Lanyard switch —
• Main relay 8
• Driver relay 8
• Crank position sensor 8
• Atmospheric pressure
8
sensor
• Intake air temperature
8
sensor
• Oxygen density sensor 8
• Engine cooling water
8
temperature sensor
• Throttle position sensor 8
• Thermo switches 8
• Shift position switch 8
• Injector driver 8
• Fuel pressure sensor 8
Starting system
• Engine start switch —
• Starter relay 8
• Starter motor 8
Charging system
• Lighting coils 8
• Rectifier/regulator 8
• Fuses 8
• Battery leads —
• Batteries —
9-3
ENGINE WILL NOT START
HARD STARTING
ROUGH IDLING
TRBL
ANLS
HIGH IDLING
ENGINE STALLS
POOR ACCELERATION
ENGINE WILL NOT STOP
POOR PERFORMANCE
LIMITED ENGINE SPEED
OVERHEATING
Trouble mode
LOOSE STEERING
LOOSE TILT HOLDING
TILT MOTOR WILL NOT RUN
HARD SHIFTING
IRREGULAR WARNING INDICATION
9-4
TROUBLE ANALYSIS
• Trim sensor
(sub-oil tank)
• Trailer switch
• Oil level switch
• Oil level sensor
(engine oil tank)
Relative part
8
8
8
8
8
chapter
E
Reference
TRBL
ANLS SELF-DIAGNOSIS E
SELF-DIAGNOSIS 9
1. Normal condition
(no defective part or irregular process-
ing is found)
Single flash is given every 5 seconds.
a : Light on, 0.3 second
b : Light off, 5 seconds
1. Install:
• Diagnostic indicator
Diagnostic indicator
YB-06765 / 90890-06765
NOTE:
When performing this diagnosis, all of the
electrical wires must be properly con-
nected.
2. Check:
• Diagnosis code
Code 1 is indicated → Normal.
Code 13 - 28 indicated → Check the
applicable parts.
Code 33 - 44 indicated → Microcom-
puter processing information.
Checking steps
(1) Start the engine and let it idle.
(2) Check the diagnostic indicator’s flash
pattern to determine if there are any
malfunctions.
9-5
TRBL
ANLS SELF-DIAGNOSIS E
NOTE:
When more than one problem is detected,
the diagnostic indicator’s light flashes in the
pattern of the lowest numbered problem.
After that problem is corrected, the light
flashes in the pattern of the next lowest
numbered problem. This continues until all
of the problems are detected and corrected.
Code Symptoms
13 Incorrect pulser coil input signal
No crank position sensor input
14
signal
Incorrect engine cooling water
15
temperature sensor input signal
Incorrect throttle position sen-
18
sor input signal
19 Low battery input voltage
Incorrect atmospheric pressure
22 sensor input signal (out of nor-
mal operating range)
Incorrect intake air temperature
23
sensor input signal
Incorrect fuel pressure sensor
25
input signal
26 No injector operation signals
27 Water detection switch ON
Incorrect shift position switch
28
input signal
Microcomputer processing
33 ~ 44
information
Ignition timing is being slightly
33 corrected (when starting a cold
engine)
Engine stop switch control
44
operating
9-6
TRBL TROUBLE SHOOTING FOR HIGH-PRESSURE
ANLS DIRECT INJECTION E
Items Symptoms
1. Poor starting/ 1. No firing. The starter motor cranks the engine, but no firing is
Engine will generated in the cylinder.
not start 2. The firing is generated in the cylinder, but the engine soon stops.
3. Start-up time is too long. The engine will not start-up easily.
1. Check the medium/high-pressure fuel lines.
9-7
TRBL TROUBLE SHOOTING FOR HIGH-PRESSURE
ANLS DIRECT INJECTION E
Items Symptoms
2. Erratic idling 1. The engine speed is not constant when idling.
speed 2. The engine stalls when the throttle lever is pulled back.
3. The engine stalls when the throttle lever is opened or during
outboard operation.
1. Check the medium/high-pressure fuel lines.
9-8
TRBL TROUBLE SHOOTING FOR HIGH-PRESSURE
ANLS DIRECT INJECTION E
Items Symptoms
3. Erratic engine 1. The engine is started, but will not run smoothly. The engine speed
speed drops during acceleration.
1. Check the medium/high-pressure fuel lines.
9-9
COLOR CODE
B B Br/W
M
B B R S
L/G L/W B
B B R R
B
L/W B c B
L/G B U Power trim
L/R B
L/R R and tilt motor
B L/R R/L B N
B R B B B
Y/R L M
5 Oil level R R/Y B/O B/W S
sensor B Ignition coil B Ignition coil V
L/G L/W R
R
R Power trim B
and tilt
A B/W B/W relay
2 R/Y R 1
B/W
C B/Y B/W C
R R/Y R Lg
Lg
Spark B Ignition coil B Ignition coil Spark Sb
plug R R plug
R R
Ç Option port
E W/R Y Y/R
Î Option port
O B/R G/R
B
‰ To trim B
meter B/R
X Fuel pressure sensor Y Trim sensor P Gy
L B/R L B/R L
[ Oil level switch (sub-oil tank)
COLOR CODE
A B B : Black L/Y : Blue/yellow
Br : Brown O/B : Orange/black
G : Green O/G : Orange/green
Gy : Gray O/L : Orange/blue
L : Blue O/R : Orange/red
B B B P B
L B Lg : Light green O/W : Orange/white
Pu/B B R/Y R/Y R/Y Pu/R Pu/Y Pu/L
O/B R/W O : Orange O/Y : Orange/yellow
L R/Y R/Y R/Y O/R O/Y O/L
Pu/G R/W P : Pink Pu/B : Purple/black
O/G R/W
Pu/W R : Red Pu/G : Purple/green
O/W Sb : Sky blue Pu/L : Purple/blue
W : White Pu/R : Purple/red
Y : Yellow Pu/W : Purple/white
B/Br : Black/brown Pu/Y : Purple/yellow
B/G : Black/green R/L : Red/blue
Y/R P L/G L B R Sb Lg B/L : Black/blue R/W : Red/white
L B B L/R L/R L/W
B/O : Black/orange R/Y : Red/yellow
B/G G W/L W/Y W/R B B L/Y B L B/O B/L B/R : Black/red W/B : White/black
B/Br B/W W/Br W/G W/B L B B L/R L/W L B/Y B/W : Black/white W/Br : White/brown
B/Y : Black/yellow W/G : White/green
G/R : Green/red W/L : White/blue
L/G : Blue/green W/R : White/red
L/R : Blue/red W/Y : White/yellow
L/W : Blue/white Y/R : Yellow/red
C D E
R/Y R/Y
B/Y B/Y B P B W/Br W/G W/B B P G B/W R/Y W/B
B Y/R B/R P L/G Br W R W/R
B/Y B/Y O P O W/L W/Y W/R O B G Gy B
B G G/R B Y Gy R
B B
Lg
R/Y
Sb
R/Y
R
R/W
B
R/W
L
R/W L/W
L L/G
B L/R
B P
B L/R
B Y/R Y/R
L/Y B
L/R B
B L O
L/W
L
R/Y
R/Y
R/Y
R/Y
R/Y B P
R/Y
G
Sb Lg 8 Injector driver A Control unit
B
1 : G 14 : Pu/G 1 : W/Br 19 : B 37 : Br 55 : B/Y 73 : W/G
2 : W/Br 15 : Pu/Y 2 : W/L 20 : B 38 : Y 56 : B/Y 74 : W/Y
3 : W/L 16 : Pu/B 3 : W/G 21 : L/Y 39 : W 57 : — 75 : W/B
F B
Lg
4 : R/Y 17 : Pu/R 4 : W/Y 22 : L/R 40 : Gy 58 : B/Y 76 : W/R
Sb 5 : B 18 : — 5 : W/B 23 : L 41 : B 59 : B/Y 77 : B
L/Y B
Lg 6 : Pu/W 19 : W/B 6 : W/R 24 : L/W 42 : B 60 : O 78 : Gy
Sb
R R 7 : O/W 20 : W/R 7 : G 25 : B 43 : R 61 : P 79 : Gy
B B 8 : Pu/L 21 : R/Y 8 : B/Br 26 : B 44 : R 62 : B 80 : R/Y
L/Y B L
W/R 9 : O/L 22 : B 9 : B/L 27 : L/W 45 : — 63 : O 81 : B
B B B R
R 10 : W/G 23 : O/G 10 : B/G 28 : L/G 46 : — 64 : P 82 : W/B
Gy 11 : W/Y 24 : O/Y 11 : B/Y 29 : L/R 47 : L/Y 65 : B 83 : —
W
Y/R 12 : R/Y 25 : O/B 12 : B/W 30 : L/R 48 : B 66 : O 84 : —
Y Y 13 : B 26 : O/R 13 : B/O 31 : B/R 49 : L 67 : P 85 : —
Br Br
G/R
14 : B 32 : Y/R 50 : W/R 68 : B 86 : —
Lg Sb
Lg P 15 : L 33 : G/R 51 : — 69 : B/W
G
Lg
Sb
Lg B/R
16 : L 34 : G 52 : — 70 : Gy
Sb Sb 17 : — 35 : P 53 : G 71 : W/Br
R 18 : — 36 : P 54 : G 72 : W/L
B
L K Fuse holder
W/R
R
R
1 :R 11 : R/Y 21 : R/W
Gy 2 :B 12 : R/Y 22 : R/Y
W
Y/R 3 :R 13 : R/Y 23 : R/Y
Y B/R B 4 :R 14 : R/Y 24 : R/W
Br B/R Y Y
5 : R/L 15 : R/Y 25 : —
6 : R/L 16 : R/Y 26 : —
G/R
P 7 :R 17 : R 27 : —
G :R 18 : R 28 : —
B/R
8
9 : L/Y 19 : R/W
10 : L/R 20 : R/W
YAMAHA MOTOR CO., LTD.
Printed in Japan
Oct. 1999 – 0.6 × 1 CR
(Z200NETO, LZ200NETO)
Printed on recycled paper