6da 28197 3S 11 PDF

F200F
FL200F
SERVICE MANUAL
6DA-28197-3S-11
Preface
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have the Bronze Technical Certificate of the YTA
(Yamaha Technical Academy) marine or the equivalent basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual. Also, up-to-date parts information is available on YPEC-web. Additional information and upto-date information on Yamaha products and services are available on Yamaha Service Portal.
Important information
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
A WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
A NOTICE indicates special precautions that must be taken to avoid damages to the outboard motor or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
F200F, FL200F
SERVICE MANUAL
2013 by Yamaha Motor Co., Ltd.
2nd Edition, May 2013
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Contents
General information
Specification
Technical feature and description
Rigging information
Troubleshooting
Electrical system
Fuel system
Power unit
Lower unit
Bracket unit
Maintenance
10
Index
Appendix
General information
Safety while working .................................................... 0-1
Rotating part .............................................................................. 0-1
Hot part ...................................................................................... 0-1
Electric shock ............................................................................ 0-1
Propeller .................................................................................... 0-1
Handling of gasoline .................................................................. 0-1
Ventilation .................................................................................. 0-1
Self-protection ........................................................................... 0-2
Working with crane .................................................................... 0-2
Handling of gas torch ................................................................ 0-2
Part, lubricant, and sealant ........................................................ 0-2
Handling of sealant .................................................................... 0-3
Special service tool ................................................................... 0-3
Tightening torque ...................................................................... 0-3
Non-reusable part ...................................................................... 0-3
Disassembly and assembly ....................................................... 0-3
How to use this manual .................................................... 0-4

Manual format ........................................................................... 0-4
Abbreviation .............................................................................. 0-5
Lubricant, sealant, and thread locking agent ................. 0-6
0
1
2
3
4
5
6
Symbol ...................................................................................... 0-6
Special service tool ........................................................... 0-8
7
8
9
10
Safety while working
Handling of gasoline
To prevent an accident or injury and to provide quality service, observe the following
safety procedures.
Gasoline is highly flammable. Keep gasoline and all flammable products away from
heat, sparks, and open flames.
Gasoline is poisonous and can cause injury
or death. Handle gasoline with care. Never
siphon gasoline by mouth. If you swallow
some gasoline, inhale a lot of gasoline
vapor, or get some gasoline in your eyes,
see your doctor immediately. If gasoline
spills on your skin, wash with soap and
water. If gasoline spills on your clothing,
change your clothes.
Rotating part
Hands, feet, hair, jewelry, clothing, personal
flotation device straps, and so on, can
become entangled with internal rotating
parts of the engine, resulting in serious
injury or death.
Keep the top cowling installed whenever
possible. Do not remove or install the top
cowling when the engine is running.
Only operate the engine with the top cowling removed according to the specific
instructions in the manual. Keep hands,
feet, hair, jewelry, clothing, personal flotation device straps, and so on, away from
any exposed moving parts.
Hot part
During and after operation, engine parts are
hot enough to cause burns. Do not touch any
parts under the top cowling until the engine
has cooled.
Ventilation
Gasoline vapor and exhaust gas are
heavier than air and extremely poisonous. If
gasoline vapor or exhaust gas is inhaled in
large quantities, it may cause loss of consciousness and death within a short time.
When test running an engine indoors (for
example, in a water tank) make sure to do
so where adequate ventilation can be maintained.
Electric shock
Do not touch any electrical parts while starting or operating the engine. Otherwise, shock
or electrocution could result.
Propeller
Do not hold the propeller with your hands
when loosening or tightening the propeller
nut.
0-1
Self-protection
Handling of gas torch
Protect your eyes by wearing safety

glasses or safety goggles during all operations involving drilling and grinding, or when
using an air compressor.
Protect your hands and feet by wearing protective gloves and safety shoes when necessary.
Improper handling of a gas torch may result

in burns. For information on the proper handling of the gas torch, see the operation
manual issued by the manufacturer.
When using a gas torch, keep it away from
the gasoline and oil, to prevent a fire.
Components become hot enough to cause
burns. Do not touch any hot components
directly.
0
1
2
3
4
Working with crane

Outboard motors weighing 18.0 kg (39.7 lb)
and over must be carried by a crane.
Use the wire ropes of adequate strength to
lift up the outboard motor in a stable manner.
Suspend the outboard motor in a stable
manner using the designated lifting eye or
the like.
Part, lubricant, and sealant

Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by
Yamaha, when servicing or repairing the outboard motor.
5
6
7
8
9
10
A
0-2
Handling of sealant
Non-reusable part
Wear protective gloves to protect your skin,

when using the sealants.
See the material safety data sheet issued
by the manufacturer. Some of the sealants
may be harmful to human health.
Always use new gaskets, seals, O-rings, cotter pins, and so on, when installing or assembling parts.
Disassembly and assembly

Use compressed air to remove dust and dirt
during disassembly.
Apply engine oil to the contact surfaces of
moving parts before assembly.
Special service tool

Use the recommended special service tools
to work safely, and to protect parts from damage.
Install bearings so that the bearing identification mark is facing in the direction indicated in the installation procedure. In
addition, make sure to lubricate the bearings liberally.
Apply a thin coat of water resistant grease
to the lip and periphery of an oil seal before
installation.
Check that moving parts operate normally
after assembly.
Tightening torque
When tightening nuts, bolts, and screws, follow the tightening instructions provided
throughout the manual. If the tightening order
is not specified, tighten the large sizes first,
and then tighten the small sizes, starting from
the center and moving outward.
0-3
How to use this manual

Manual format
The format of this manual has been designed to make service procedures clear and easy to understand. Use the following information as a guide for effective and quality service.
Parts are shown and detailed in an exploded diagram and are listed in the component list (see 1
in the following figure for an example page).
The component list consists of part names and quantities, as well as bolt and screw dimensions
(see 2 in the following figure).
Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication points (see 3 in the following figure).
Tightening torque specifications are provided in the exploded diagrams (see 4 in the following
figure), and in the related detailed instructions. Some torque specifications are listed in stages as
torque figures or angles in degrees.
Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see 5 in the following figure for an example page).
TIP:
1
2
3
4
For troubleshooting procedures, see Chapter 4, Troubleshooting.
4
1
Lower unit (regular rotation model, X-transom model)
Lower unit (regular rotation model, X-transom model)
43 Nm (4.3 kgfm, 31.7 ftlb)
10
2
1
9
8
12
7
13
7
55 Nm (5.5 kgfm, 40.6 ftlb)
6
11
4
5
48 Nm (4.8 kgfm, 35.4 ftlb)
18
16
9 Nm (0.9 kgfm, 6.6 ftlb)
19
17
21
22
4
25
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Par t name
Hose nipple
O -r i ng
Check screw
Gasket
B o lt
Extension
Dowel
Cover
Seal
Water pipe
Water pipe
Grommet
Bolt
Lower unit
Spacer
Propeller
Spacer
Qty
2
2
1
2
12
1
4
2
2
1
1
1
1
1
1
1
1
48 Nm (4.8 kgfm, 35.4 ftlb)
R em a r k s
Not reusable
Not reusable
M10 45 mm
3. Install a new O-ring 1.
8
9
Assembling the lower case
10
3. While holding the special service tool 1,

strike the tool to check that the taper
roller bearing outer race is installed properly.
TIP:
If a high-pitched metallic sound is produced

when the special service tool is struck, the
outer race is installed properly.
Use heat-resistant gloves. Otherwise,

burns could result.
To prevent fires, remove any flammable
substances, such as gasoline and oil,
around the working area.
Keep good ventilation while working.
M10 45 mm
Except SDS propeller
2
1
Installation depth a:
0.250.75 mm (0.0100.030 in)
24
Do not reuse a shim if deformed or

scratched.
Bearing outer race attachment 2:

90890-06628
Driver rod LS 3: 90890-06606
TIP:
23
48 Nm (4.8 kgfm, 35.4 ftlb)
When heating the lower case, heat the

entire installation area evenly. Otherwise,
the paint on the lower case could be
burned.
15
20
14
Drive shaft and lower case (regular rotation model)
10
1. Install the original forward gear shims 1.
8-6
2. Heat the area of the lower case where

the taper roller bearing outer race is to be
installed using a gas torch, and then
install a new taper roller bearing outer
race 2.
1
2
10
8-24
0-4
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation
Description
ABYC
American Boat and Yacht Council
API
American Petroleum Institute
APS
Accelerator Position Sensor
ATF
Automatic Transmission Fluid
AWG
American Wire Gauge
CAN
Controller Area Network
CCA
Cold Cranking Ampere
DN
Down side
DOHC
Double Overhead Camshaft
ECM
Electronic Control Module
EN
European Norm (European standard)
ETV
Electronic Throttle Valve
EX
Exhaust
Forward
ID
Identification
IEC
International Electrotechnical Commission
IN
Intake
ISC
Idle Speed Control
ISO
International Organization for Standardization
Neutral
OCV
Oil Control Valve
PCV
Pressure Control Valve
PORT
Port side
PTT
Power Trim and Tilt
Reverse
RON
Research Octane Number
SAE
Society of Automotive Engineers
STBD
Starboard side
TCI
Transistor-Controlled Ignition
TDC
Top Dead Center
TPS
Throttle Position Sensor
UP
Up side
VCT
Variable Camshaft Timing
VST
Vapor Separator Tank
Y-COP
Yamaha Customer Outboard Protection
YDIS
Yamaha Diagnostic System
0-5
Lubricant, sealant, and thread locking agent

Symbol
Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication
points.
Symbol
Name
Application
YAMALUBE 4-M FC-W oil or Yamaha 4-stroke

motor oil
Lubricant
Yamalube Marine Lower Unit Gearcase Lube or

hypoid gear oil
Lubricant
Water resistant grease

(Yamaha grease A)
Lubricant
Corrosion resistant grease

(Yamaha grease D)
Lubricant
Molybdenum disulfide grease
Lubricant
WR-No.2 grease
Lubricant
Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent
and the application points.
Symbol
Name
5
6
Application
Gasket Maker
Sealant
ThreeBond 1280B
Sealant
ThreeBond 1303
7
8
Thread locking agent
9
ThreeBond 1322
ThreeBond 1377B
ThreeBond 1386B
Sealant
ThreeBond 1401
0-6
10

Symbol
Name
Application
ThreeBond 1530D
Sealant
LOCTITE 271 (red)
LOCTITE 242 (blue)
LOCTITE 572 (white)
Sealant
LOCTITE 648 (green)
Silicone sealant
Sealant
0-7

For all markets except U.S.A. and Canada.
Special service tools with part numbers 90890-06883 and FIM20000ME are distributed by the
Marine Service Division.
Special service tools with part numbers other than 90890-06883 and FIM20000ME are distributed
by the Parts Division.
Tool name/Tool No.
Illustration
Reference
pages
Engine lifting eye

90890-06820
3-3, 7-13
Drilling plate
90890-06783
3-8
0
1
2
3
4
YDIS 2 starter kit

90890-06883
4-1
***
******
******
Digital circuit tester

90890-03189
5-19, 5-20,
9-46
6
7
Peak voltage adapter B

90890-03172
5-19
Test harness (3 pins)

90890-06869
5-26, 5-50,
5-51
Vacuum/pressure pump gauge set

90890-06945
5-29, 6-7,
6-11, 6-18,
6-34, 6-41,
6-42
8
9
10
A
0-8

Tool name/Tool No.
Illustration
Reference
pages

90890-06870
5-30
Ignition tester (Spark gap tester)

90890-06754
5-33

90890-06867
5-33, 5-51
Fuel pressure gauge adapter

90890-06946
6-6, 6-7
Fuel pressure gauge

90890-06753
6-7
Leakage tester
90890-06840
6-10, 8-26
Fuel injection meter

FIM20000ME
6-25
Compression gauge
90890-03160
7-1
0-9

Tool name/Tool No.
Illustration
Reference
pages
Compression gauge extension

90890-06563
7-1
Balance hanger B
90890-06682
7-13
0
1
2
Rotor holder
90890-01235
7-18, 7-20
Flywheel stopper B
90890-06686
7-18, 7-20
3
4
5
Sheave holder
90890-01701
7-44, 7-50
Valve spring compressor

90890-04019
7-56, 7-62
Valve spring compressor attachment

90890-06320
7-56, 7-62
6
7
8
9
Valve guide remover/installer

90890-06801
7-58
10
A
0-10

Tool name/Tool No.
Illustration
Reference
pages
Valve guide installer

90890-06810
7-58
Valve guide reamer

90890-06804
7-58
Valve lapper
90890-04101
7-59, 7-61
Valve seat cutter holder

90890-06316
7-59
Valve seat cutter 30

90890-06331
7-59

90890-06332
7-59

90890-06333
7-59

90890-06327
7-59
0-11

Tool name/Tool No.
Illustration
Reference
pages

90890-06325
7-59

90890-06324
7-59
0
1
2
Oil filter wrench

90890-06830
7-79, 7-83,
10-12
Driver rod L3
90890-06652
7-80, 8-3,
8-13, 8-18,
9-17, 9-32
3
4
5
Needle bearing attachment

90890-06611
7-80

90890-06607
7-80, 8-50
Bearing separator
90890-06534
7-87, 8-13,
8-19, 8-50,
8-55
6
7
8
Gear puller
90890-06540
7-87
9
10
A
0-12

Tool name/Tool No.
Illustration
Reference
pages

90890-06615
7-87
Piston slider 96 mm
90890-06684
7-100

90890-06653
8-3, 8-4, 8-13,

9-17, 9-32
Shift rod socket

90890-06681
8-8, 8-26,
8-31, 8-62
Ring nut wrench extension

90890-06513
8-12, 8-24
Ring nut wrench 4

90890-06512
8-12, 8-24
Bearing housing puller claw L

90890-06502
8-12, 8-31,
8-62
Stopper guide plate

90890-06501
8-12, 8-13,
8-31, 8-62,
9-17, 9-32
0-13

Tool name/Tool No.
Illustration
Reference
pages
Center bolt
90890-06504
8-12, 8-31,
8-62
Stopper guide stand

90890-06538
8-13
0
1
2
Bearing puller assembly

90890-06535
8-13, 9-17,
9-32
Driver rod SS
90890-06604
8-14, 8-20
3
4
5

90890-06610
8-14, 8-18,
8-20
Bearing depth plate

90890-06603
8-14, 8-20
Bearing inner race attachment

90890-06640
8-15
6
7
8
9

90890-06654
8-15, 8-20
10
A
0-14

Tool name/Tool No.
Illustration
Reference
pages
Bearing outer race attachment

90890-06622
8-15
Drive shaft holder 6

90890-06520
8-18, 8-23,
8-36
Pinion nut holder

90890-06715
8-18, 8-23

90890-06608
8-19, 8-55
Ball bearing attachment

90890-06636
8-19
Driver rod LL
90890-06605
8-19, 8-22,
8-57

90890-06612
8-20, 9-39

90890-06628
8-21
0-15

Tool name/Tool No.
Illustration
Reference
pages
Driver rod LS
90890-06606
8-21

90890-06619
8-22
0
1
2

90890-06633
8-22
Bearing outer race puller assembly

90890-06523
8-22
3
4
5
Backlash indicator
90890-06706
8-32, 8-63
Magnet base plate

90890-07003
8-32, 8-63
Dial gauge set

90890-01252
8-32, 8-63,
8-66
6
7
8
9
Magnet base B
90890-06844
8-32, 8-63,
8-66
10
A
0-16

Tool name/Tool No.
Illustration
Reference
pages
Pinion height gauge

90890-06671
8-35
Slide hammer handle

90890-06531
8-49
Puller head
90890-06514
8-49
Ring nut wrench

90890-06578
8-51
Bearing inner race attachment

90890-06660
8-56

90890-06629
8-57
Up relief fitting
90890-06773/06838
9-49
Down relief fitting

90890-06774
9-50
0-17

Tool name/Tool No.
Illustration
Reference
pages
Hydraulic pressure gauge

90890-06776/06800
9-49, 9-50
Trim & tilt wrench

90890-06592
9-68, 9-72,
9-73
0
1
2
3
4
5
6
7
8
9
10
A
0-18
Specification
Model feature ..................................................................... 1-1
General feature ......................................................................... 1-1
Model name designation ........................................................... 1-2
Serial number ............................................................................ 1-3
Model data ......................................................................... 1-4

Dimension and weight ............................................................... 1-4
Performance .............................................................................. 1-4
Power unit ................................................................................. 1-4
Lower unit .................................................................................. 1-4
Bracket unit ............................................................................... 1-5
Fuel and oil requirement ............................................................ 1-5
Battery requirement ................................................................... 1-5
PTT fluid requirement ................................................................ 1-5
Electrical system technical data ...................................... 1-6

Ignition timing control system .................................................... 1-6
Fuel injection control system ..................................................... 1-6
Engine speed control system .................................................... 1-7
VCT system ............................................................................... 1-7
PTT system ............................................................................... 1-7
Charging system ....................................................................... 1-7
Starting system .......................................................................... 1-8
Y-COP ....................................................................................... 1-8
Gauge/sensor ............................................................................ 1-8
Fuel system technical data .............................................. 1-9

Fuel system ............................................................................... 1-9
Power unit technical data ............................................... 1-10

Power unit ............................................................................... 1-10
Cylinder head assembly .......................................................... 1-10
Crankcase assembly ............................................................... 1-11
Lower unit technical data ............................................... 1-13

Lower unit assembly (regular rotation model) ......................... 1-13
Lower unit assembly (counter rotation model) ........................ 1-13
Bracket unit technical data ............................................ 1-14

PTT system ............................................................................. 1-14
Specification
Specified tightening torque ............................................ 1-15
Rigging information ................................................................. 1-15
Electrical system ..................................................................... 1-15
Fuel system ............................................................................. 1-15
Power unit ............................................................................... 1-16
Lower unit (regular rotation model) ......................................... 1-19
Lower unit (counter rotation model) ......................................... 1-19
Bracket unit ............................................................................. 1-20
PTT unit ................................................................................... 1-21
General tightening torque ........................................................ 1-22
0
1
2
3
4
5
6
7
8
9
10
Model feature
Model feature
General feature
F200F, FL200F overall feature
External designs of V6 and V8 engines preserved.
Electronic fuel injected, 4-stroke, L4, DOHC, 16-valve, 2785 cm3 (169.9 cu. in) engine
Low exhaust emissions conform to EU1 regulations.
c. Bracket unit
64E type PTT unit (used on F115, and so
on.)
a. Power unit
Shimless valve lifter
Dimpled cylinder sleeve design (used on
F350)
Offset cylinder
2-axis balancer
Composite cylinder head cover, electrical
bracket
Large diameter intake valve head
Damperless flywheel
VCT (IN)
Oil cooler
Vapor gas treatment
Remote control cable holder attached onto
cylinder block
d. Upper case
Composite bottom cowling
Labyrinth idle exhaust system
e. Lower unit
Patented shift damper system (Shift Dampener System [SDS] propeller for Reliance
series)
b. Electrical
Electronic fuel injection control
Digital ignition control
ETV control
VCT control (IN)
Knock control
Over-revolution control
Fail-safe control
Tilt limiter (optional)
Self-diagnosis system with YDIS (New version 2.10)
Water-cooled Rectifier/Regulator/Isolator
High output recharging system (42 A)
Y-COP acceptable (standard for European
market and optional for other markets)
Variable troll speed control (650900 r/min)
Conventional gauge or Digital Network
Gauge (6Y8) acceptable
Speed sensor (standard for European and
Caribbean markets and optional for other
markets) and water pressure sensor (standard for Caribbean market and optional for
other markets)
c
d
1-1
Model feature
Model name designation
F 200 F E T L
1
Model category
2
3
Output horsepower
Model generation
None: 2-stroke
E: Enduro
F: 4-stroke
L: Counter rotating propeller
T: High thrust (4-stroke)
D: Twin rotating propeller
K: Kerosene
Z: HPDI
Example: 6/9.9/75/150/250/300
A/B/C/D/F/G/H/J/L/N/P/Q/R/S/T/U/V/X/Y (Repeat from A)
Level 1: Starting method
M: Manual start
E: Electric start
W: Electric start with manual start
Level 2: Control method
None: Remote control without tiller handle
H: Tiller handle
C: Remote control with tiller handle
Model variation
Level 3: Trim and tilt method
None: Manual tilt
D: Hydraulic tilt
P: PT (Power tilt)
T: PT/T (Power trim and tilt)
Transom height
(Drive shaft length)
Level 4: Lubrication system (2-stroke model)

None: Premixed fuel with oil model
O: Oil injection model
S (15 in)
L (20 in)
Y (22 in)
X (25 in)
U (31 in)
1
2
3
4
5
6
7
8
9
10
A
1-2
Model feature
Serial number
The outboard motor serial number is indicated on a label affixed to the port clamp
bracket.
4
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
1. Model name
2. Approved model code
3. Motor transom height
4. Serial number
Model name
F200FET
FL200FET
Approved
model code
6DA
6DB
Starting
serial No.
1000001
1000001
1-3
Model data
Model data
Dimension and weight
Overall length
Overall width
Overall height L
Overall height X
Motor transom height L
Motor transom height X
Dry weight (SUS) L *1
Dry weight (SUS) X *1
920 mm (36.2 in)

548 mm (21.6 in)
1742 mm (68.6 in)
1869 mm (73.6 in)
516 mm (20.3 in)
643 mm (25.3 in)
226 kg (498 lb)
227 kg (500 lb)
*1. With SUS (stainless steel) propeller
0
1
2
Performance
Rated power
Full throttle operating range
Maximum fuel consumption (reference data)
Idle speed (in neutral)
147.1 kW (200 HP)

50006000 r/min
72.0 L/h @ 6000 r/min (19.0 US gal/h @ 6000
r/min, 15.8 Imp. gal/h @ 6000 r/min)
650750 r/min
Power unit
Type
Total displacement
Bore stroke
Compression ratio
Throttle & shift control system
Starting system
Starting carburetion system
Ignition system
Advance type
Maximum generator output
Maximum charging capacity
Spark plug (NGK)
Firing order
Cooling system
Exhaust system
Lubrication system
4-stroke DOHC L4 16 valves

2785 cm3 (169.9 c.i.)
96.0 96.2 mm (3.78 3.79 in)
10.3 : 1
Remote control
Electric starter
Fuel injection
TCI
Microcomputer
50 A
42 A
LFR6A-11
1-3-4-2
Water
Through propeller boss
Wet sump
4
5
6
7
8
9
10
Lower unit
Gear shift positions
Gear ratio
Gear type
Clutch type
Propeller fitting mechanism
Propeller direction (rear view)
Forward-neutral-reverse
1.86 (26/14)
Spiral bevel gear
Dog clutch
Spline
F200FET Clockwise
FL200FET Counterclockwise
1-4
Model data
Propeller mark
F200FET M
FL200FET ML
Bracket unit
Trim angle
Tilt support angle
Steering angle
Trim and tilt system
4 to 16 degrees @ 12 boat transom

65 degrees
32 + 32 degrees
PTT
Fuel and oil requirement

Recommended fuel
Min. research octane number (RON)
Recommended engine oil
Recommended engine oil grade 1 *1
Recommended engine oil grade 2 *1
Recommended gear oil
Recommended gear oil grade *1
Gear oil quantity
Engine oil quantity (total amount) *2
Premium unleaded gasoline

94
YAMALUBE 4 or 4-stroke outboard motor oil
SAE 10W-30/10W-40/5W-30
API SE/SF/SG/SH/SJ/SL
SAE 15W-40/20W-40/20W-50
API SH/SJ/SL
Yamalube Marine Gearcase Lube or Hypoid gear
oil
API GL-4
SAE 90
0.980 L (1.036 US qt, 0.862 Imp.qt)
5.2 L (5.50 US qt, 4.58 Imp.qt)
*1. Meeting both API and SAE requirements.

*2. For periodic engine oil replacement quantity, see Power unit technical data (1-10).
Battery requirement
Min. cold cranking amps (CCA/EN)
Min. rated capacity (20HR/IEC)
640.0 A
80.0 Ah
PTT fluid requirement

Fluid type
Yamalube Marine Power Trim and Tilt fluid or ATF

Dexron II
1-5
Electrical system technical data

Ignition timing control system
Spark plug
Spark plug gap
1.01.1 mm (0.0390.043 in)
Cam position sensor

Input voltage
12 V
Ignition coil
Input voltage
12 V
Pulser coil
Air gap
Output peak voltage (reference data)
Resistance
Intake air pressure/temperature sensor
Input voltage
Output voltage
Engine temperature sensor
Input voltage
Resistance (reference data)
0.361.14 mm (0.0140.045 in)

6.2 V @ cranking (unloaded)
5.2 V @ cranking (loaded)
18.1 V @ 1500 r/min (loaded)
21.6 V @ 3500 r/min (loaded)
396.0594.0 @ 20 C (68 F)
4.755.25 V
4.755.25 V
4.55 k @ 5 C (41 F)
1.902.10 k @ 20 C (68 F)
0.170.20 k @ 100 C (212 F)
0
1
2
3
4
5
6
Thermo switch
Input voltage (reference data)
Switch ON temperature
Switch OFF temperature
12 V
8490 C (183194 F)
6882 C (154180 F)
Shift cut-off switch

Input voltage
Free position resistance (reference data)
4.755.25 V
4.4654.935 k @ 20 C (68 F)
Shift position switch

Input voltage
12 V
Knock sensor
Resistance
504616 k @ 20 C (68 F)
10
Fuel injection control system

Water detection switch
Input voltage
4.755.25 V
Fuel injector
Input voltage
12 V
11.5012.50 @ 20 C (68 F)
1-6

Low-pressure fuel pump
Input voltage
12 V
0.54.0 @ 20 C (68 F)
High-pressure fuel pump

Input voltage
12 V
0.23.0 @ 20 C (68 F)
Vapor shut-off valve

Input voltage
Resistance
12 V
30.034.0 @ 20 C (68 F)
Engine speed control system

TPS
TPS1 output voltage (reference data)
TPS2 output voltage (reference data)
Input voltage
Oil pressure sensor
Input voltage
Output voltage (reference data)
0.5 V @ throttle valve fully closed

2.5 V @ throttle valve fully closed
4.755.25 V
4.755.25 V
2.5 V @ 392.0 kPa (3.92 kgf/cm2, 56.8 psi)
4.5 V @ 784.0 kPa (7.84 kgf/cm2, 113.7 psi)
VCT system
OCV
Input voltage
Resistance
12 V
6.77.7 @ 20 C (68 F)
PTT system
Trim sensor
Free position resistance (reference data)
Setting resistance
239379
9.011.0
Charging system
Lighting coil
Output peak voltage (reference data)

Fuse
Rectifier/Regulator/Isolator
Output voltage
8.6 V @ cranking (unloaded)

40.4 V @ 1500 r/min (unloaded)
89.3 V @ 3500 r/min (unloaded)
0.14160.2124 @ 20 C (68 F)
60 A
13 V @ 1500 r/min (loaded)
13 V @ 3500 r/min (loaded)
1-7
Starting system
Starter motor
Type
Output
Cranking time limit
Sliding gear
1.40 kW
30 seconds
Commutator
Standard diameter
Wear limit
Standard undercut
Wear limit
29.0 mm (1.14 in)

28.0 mm (1.10 in)
0.8 mm (0.03 in)
0.2 mm (0.01 in)
Brush
Standard length
Wear limit
15.5 mm (0.61 in)

9.5 mm (0.37 in)
0
1
2
3
Y-COP
Remote control receiver
Input voltage
12 V
Buzzer
Input voltage
12 V
Button cell battery - CR2016

Battery voltage (reference data)
3V
Speed sensor
Input voltage
5
6
Gauge/sensor
Water pressure sensor
Input voltage
4.755.25 V
2.5 V @ 392.0 kPa (3.92 kgf/cm2, 56.8 psi)
4.5 V @ 784.0 kPa (7.84 kgf/cm2, 113.7 psi)
4.755.25 V
2.5 V @ 392.0 kPa (3.92 kgf/cm2, 56.8 psi)
4.5 V @ 784.0 kPa (7.84 kgf/cm2, 113.7 psi)
7
8
9
10
A
1-8
Fuel system technical data
Fuel system technical data

Fuel system
Fuel pressure (reference data)
310.0 kPa (3.10 kgf/cm2, 45.0 psi) @ 5 seconds
after engine start switch turned to ON
250.0 kPa (2.50 kgf/cm2, 36.3 psi) @ engine idle
speed
Fuel filter assembly
Fuel inlet holding pressure
(positive pressure)
Fuel outlet holding pressure
(negative pressure)
80 kPa (0.8 kgf/cm2, 11.6 psi)
Primer pump
Positive pressure
166.7 kPa (1.67 kgf/cm2, 24.2 psi)
Vapor separator tank

Float height
65.070.0 mm (2.562.76 in)
Canister
Holding pressure (positive pressure)
19.6 kPa (0.20 kgf/cm2, 2.8 psi)
200 kPa (2.0 kgf/cm2, 29.0 psi)
1-9
Power unit technical data

Power unit
Compression pressure
Minimum (reference data) *1
Engine oil
Oil pressure *2
770.0 kPa (7.70 kgf/cm2, 111.7 psi) @ 20 C

(68 F)
420.0 kPa (4.20 kgf/cm2, 60.9 psi) @ 60 C
(140 F) / SL 10W-30 engine oil / 700 r/min
520.0 kPa (5.20 kgf/cm2, 75.4 psi) @ 64 C
(147 F) / SL 10W-30 engine oil / 3000 r/min
Thermostat
Valve opening temperature
Fully open temperature
Fully open stroke
5862 C (136144 F)
70 C (158 F)
5.0 mm (0.20 in)
Timing belt
Installation height
3.0 mm (0.12 in)
Replacement engine oil quantity

(at periodic maintenance)
Engine oil quantity
(without oil filter replacement)
Engine oil quantity
(with oil filter replacement)
4.3 L (4.55 US qt, 3.78 Imp.qt)
0
1
2
3
4
5
4.5 L (4.76 US qt, 3.96 Imp.qt)
*1. Measuring conditions: Ambient temperature 20 C (68 F), with all spark plugs removed.
*2. For the checking method, see Checking the oil pressure (7-1). The figures are for reference
only.
6
7
Cylinder head assembly

Valve
Clearance IN (cold engine)
Clearance EX (cold engine)
Margin thickness IN
Margin thickness EX
Seat contact width IN
Limit (reference data)
Seat contact width EX
0.170.24 mm (0.00670.0094 in)

0.310.38 mm (0.01220.0150 in)
0.751.15 mm (0.02950.0453 in)
0.901.30 mm (0.03540.0512 in)
1.101.40 mm (0.04330.0551 in)
1.850 mm (0.0728 in)
1.401.70 mm (0.05510.0669 in)
2.150 mm (0.0846 in)
Camshaft
Camshaft lobe height IN
Camshaft lobe height EX
Camshaft lobe width IN and EX
Journal diameter
Runout limit (reference data)
46.31146.411 mm (1.82331.8272 in)

46.261 mm (1.8213 in)
44.66044.760 mm (1.75831.7622 in)
44.610 mm (1.7563 in)
35.95036.050 mm (1.41541.4193 in)
24.96024.980 mm (0.98270.9835 in)
0.030 mm (0.0012 in)
1-10
8
9
10

Cylinder head
Warpage limit
Journal inside diameter
Camshaft journal oil clearance
0.10 mm (0.0039 in)

25.00025.021 mm (0.98430.9851 in)
0.0260.051 mm (0.00100.0020 in)
0.080 mm (0.0031 in)
Valve lifter
Outside diameter
Valve lifter clearance (reference data)
30.97030.980 mm (1.21931.2197 in)

0.0200.055 mm (0.00080.0022 in)
Valve spring
Free length
Tilt limit
48.08 mm (1.89 in)

45.68 mm (1.79 in)
1.7 mm (0.07 in)
Valve stem
Diameter IN
Diameter EX
Runout IN and EX
5.4775.492 mm (0.21560.2162 in)

5.447 mm (0.2144 in)
5.4645.479 mm (0.21510.2157 in)
5.434 mm (0.2139 in)
0.01 mm (0.0004 in)
Valve guide
Inside diameter IN and EX
Valve guide clearance IN
Valve guide clearance EX
Installation height
5.5045.522 mm (0.21670.2174 in)

0.0120.045 mm (0.00050.0018 in)
0.070 mm (0.0028 in)
0.0250.058 mm (0.00100.0023 in)
0.080 mm (0.0031 in)
11.311.7 mm (0.440.46 in)
Crankcase assembly
Piston
Diameter
Measuring point
Piston clearance
Ring groove (Top)
Ring groove (2nd)
Ring groove (Oil)
Pin boss inside diameter
Pin outside diameter
95.92695.945 mm (3.77663.7774 in)

95.886 mm (3.7775 in)
13.5 mm (0.53 in)
0.0710.077 mm (0.00280.0030 in)
0.186 mm (0.0073 in)
1.231.25 mm (0.04840.0492 in)
1.221.24 mm (0.04800.0488 in)
2.512.53 mm (0.09880.0996 in)
22.01122.018 mm (0.86660.8668 in)
22.038 mm (0.8666 in)
21.99622.005 mm (0.86600.8663 in)
21.986 mm (0.8656 in)
Cylinder
Bore
96.00096.019 mm (3.77953.7803 in)

96.072 mm (3.7824 in)
1-11

Piston ring (Top)
Type
Height (B)
Width (T)
End gap (reference data)
Side clearance
Barrel
1.1701.185 mm (0.04610.0467 in)
2.8003.000 mm (0.11020.1181 in)
0.200.30 mm (0.00790.0118 in)
0.470 mm (0.0185 in)
0.040.08 mm (0.00160.0031 in)
0.130 mm (0.0051 in)
Piston ring (2nd)

Type
Height (B)
Width (T)
Side clearance
Taper
1.1701.190 mm (0.04610.0469 in)
3.8004.000 mm (0.14960.1575 in)
0.600.75 mm (0.02360.0295 in)
0.900 mm (0.0354 in)
0.030.07 mm (0.00120.0028 in)
0.110 mm (0.0043 in)
Piston ring (Oil)

Height (B)
Width (T)
Side clearance
2.4002.470 mm (0.09450.0972 in)

2.3502.750 mm (0.09250.1083 in)
0.150.60 mm (0.00590.0236 in)
0.040.13 mm (0.00160.0051 in)
Connecting rod
Small end inside diameter
Big end inside diameter
Big end side clearance
Big end oil clearance
22.01022.024 mm (0.86650.8671 in)

55.99056.010 mm (2.20432.2051 in)
0.140.31 mm (0.00550.0122 in)
0.36 mm (0.0142 in)
0.0250.050 mm (0.00100.0020 in)
0.080 mm (0.0031 in)
Crankshaft
Journal diameter
Crankshaft pin diameter
Runout
Crankshaft pin width
Journal oil clearance
59.98060.000 mm (2.36142.3622 in)

52.98053.000 mm (2.08582.0866 in)
0.03 mm (0.0012 in)
0.04 mm (0.0016 in)
21.0021.10 mm (0.82680.8307 in)
0.0260.051 mm (0.00100.0020 in)
0.071 mm (0.0028 in)
0
1
2
3
4
5
6
7
8
9
10
A
1-12
Lower unit technical data
Lower unit technical data

Lower unit assembly (regular rotation model)
Lower unit
Holding pressure
68.6 kPa (0.69 kgf/cm2, 9.9 psi)
Gear backlash
Forward gear backlash *1
Reverse gear backlash *1
0.260.77 mm (0.01020.0303 in)

0.591.26 mm (0.02320.0496 in)
Available shim thicknesses

Pinion shim (T3)
Forward gear shim (T1)
Reverse gear shim (T2)
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm
Propeller shaft
Runout
0.02 mm (0.0008 in)
Drive shaft
Runout
1.0 mm (0.04 in)
*1. Figures obtained using the special service tools.
Lower unit assembly (counter rotation model)

Lower unit
Holding pressure
68.6 kPa (0.69 kgf/cm2, 9.9 psi)
Gear backlash
Forward gear backlash *1
Reverse gear backlash *1
0.250.77 mm (0.00980.0303 in)

0.611.26 mm (0.02400.0496 in)
Available shim thicknesses

Pinion shim (T3)
Propeller shaft shim (T4)
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm
Propeller shaft
Free play
Runout
0.250.35 mm (0.00980.0138 in)

0.02 mm (0.0008 in)
Drive shaft
Runout
1.0 mm (0.04 in)
*1. Figures obtained using the special service tools.
1-13
Bracket unit technical data
Bracket unit technical data

PTT system
Hydraulic pressure
Down
Up
5.888.83 MPa (58.888.3 kgf/cm2,

852.61280.4 psi)
9.8111.77 MPa (98.1117.7 kgf/cm2,
1422.51706.7 psi)
Motor commutator
Standard diameter
Limit
Standard undercut
Limit
22.0 mm (0.8661 in)

21.0 mm (0.8268 in)
1.35 mm (0.0531 in)
0.85 mm (0.0335 in)
Motor brush
Standard length
Limit
9.8 mm (0.3858 in)

4.8 mm (0.1890 in)
0
1
2
3
4
5
6
7
8
9
10
A
1-14
Specified tightening torque

Specified tightening torques are provided for specific nuts, bolts, and screws. When tightening these
fasteners, follow the tightening torque specifications indicated throughout the manual to meet the
design aims of the outboard motor.
Rigging information
Qty
Screw
size
Tightening torques
Positive battery cable nut
M8
Shift cable locknut
M5
Throttle cable locknut
M5
G1/8
19 Nm (1.9 kgfm, 14.0 ftlb)
Water pressure sensor adapter
M14
23 Nm (2.3 kgfm, 17.0 ftlb)
Speed sensor
G1/8
19 Nm (1.9 kgfm, 14.0 ftlb)
Water temperature sensor
M14
23 Nm (2.3 kgfm, 17.0 ftlb)
Attachment
M14
23 Nm (2.3 kgfm, 17.0 ftlb)
Clamp screw
M5
Remote control receiver screw
M6
Qty
Screw
size
Tightening torques
Control unit screw
M6
Buzzer screw
M6
Remote control transmitter

screw
M2
0.1 Nm (0.01 kgfm, 0.1 ftlb)
Qty
Screw
size
Tightening torques
Part to be tightened
Remarks
Electrical system
Remarks
Fuel system
Fuel cup assembly
ETV bolt (1st)
18 Nm (1.8 kgfm, 13.3 ftlb)

4
M8
ETV bolt (2nd)
18 Nm (1.8 kgfm, 13.3 ftlb)
1-15
Remarks

Qty
Screw
size
Tightening torques
Intake air pressure/temperature

sensor screw
M5
Intake manifold bolt
M8
24 Nm (2.4 kgfm, 17.7 ftlb)
Vapor separator cover bolt
M4
Float chamber cover screw
M4
Float pin screw
M4
Drain screw
M6
Needle valve assembly screw
M4
Pressure regulator screw
M5
3.5 Nm (0.35 kgfm, 2.58 ftlb)
Fuel cooler cover screw
M5
3.5 Nm (0.35 kgfm, 2.58 ftlb)
Qty
Screw
size
Tightening torques
M14
28 Nm (2.8 kgfm, 20.7 ftlb)
Remarks
0
1
2
3
4
Power unit
Spark plug
Power unit mounting bolt
(35 mm) (1st)
(35 mm) (2nd)
(140 mm) (1st)
(140 mm) (2nd)
42 Nm (4.2 kgfm, 31.0 ftlb)

4
Remarks
5
6
M10
42 Nm (4.2 kgfm, 31.0 ftlb)
42 Nm (4.2 kgfm, 31.0 ftlb)

8
M10
42 Nm (4.2 kgfm, 31.0 ftlb)
Power unit mounting bolt (1st)
20 Nm (2.0 kgfm, 14.8 ftlb)

3
M8
Power unit mounting bolt (2nd)
20 Nm (2.0 kgfm, 14.8 ftlb)
Apron screw
M6
Apron screw (14 mm) (X-transom model)
M6
PTT motor lead bolt
M6
3.5 Nm (0.35 kgfm, 2.58 ftlb)
Positive battery cable nut
M8
Pulser coil bolt
M5
1-16
9
10

Qty
Screw
size
Flywheel magneto bolt (1st)
Tightening torques
40 Nm (4.0 kgfm, 29.5 ftlb)
M10
Flywheel magneto bolt (2nd)
90
Timing belt tensioner bolt
M10
39 Nm (3.9 kgfm, 28.8 ftlb)
Terminal nut
M8
Starter motor lead screw
M4
Starter motor bolt
M8
29 Nm (2.9 kgfm, 21.4 ftlb)
Starter motor bracket bolt
M8
25 Nm (2.5 kgfm, 18.4 ftlb)
Wire harness holder screw
M6
2.5 Nm (0.25 kgfm, 1.84 ftlb)
Fuse box screw
M5
2.5 Nm (0.25 kgfm, 1.84 ftlb)
PTT relay lead nut
M6
4.5 Nm (0.45 kgfm, 3.32 ftlb)
Driven sprocket bolt
M10
60 Nm (6.0 kgfm, 44.3 ftlb)
VCT bolt
M12
60 Nm (6.0 kgfm, 44.3 ftlb)
VCT cap
M27
32 Nm (3.2 kgfm, 23.6 ftlb)
Camshaft cap bolt (48 mm) (1st)

Camshaft cap bolt (48 mm)
(2nd)

4
M7
17 Nm (1.7 kgfm, 12.5 ftlb)
Camshaft cap bolt (37 mm) (1st)

Camshaft cap bolt (37 mm)
(2nd)

16
M7
17 Nm (1.7 kgfm, 12.5 ftlb)
Cylinder head bolt (1st)
39 Nm (3.9 kgfm, 28.8 ftlb)

10
M11
Cylinder head bolt (2nd)
180
Cylinder head bolt (1st)
14 Nm (1.4 kgfm, 10.3 ftlb)

8
M8
Cylinder head bolt (2nd)
28 Nm (2.8 kgfm, 20.7 ftlb)
Plug
M14
23 Nm (2.3 kgfm, 17.0 ftlb)
OCV bolt
M6
1-17
Remarks

Qty
Screw
size
Tightening torques
Thermostat cover bolt
M6
10 Nm (1.0 kgfm, 7.4 ftlb)
Water bypass cover bolt
M6
10 Nm (1.0 kgfm, 7.4 ftlb)
Plug
M18
55 Nm (5.5 kgfm, 40.6 ftlb)
Exhaust cover bolt
14
M6
10 Nm (1.0 kgfm, 7.4 ftlb)
Cover 1 bolt
13
M6
10 Nm (1.0 kgfm, 7.4 ftlb)
Crankcase cover bolt
10
M6
10 Nm (1.0 kgfm, 7.4 ftlb)
M10
Balancer assembly bolt (1st)
18 Nm (1.8 kgfm, 13.3 ftlb)
Balancer assembly bolt (2nd)
Remarks
0
1
2
3
37 Nm (3.7 kgfm, 27.3 ftlb)
Balancer assembly bolt (1st)
14 Nm (1.4 kgfm, 10.3 ftlb)

12
M8
Balancer assembly bolt (2nd)
24 Nm (2.4 kgfm, 17.7 ftlb)
Oil filter
3/416
UNF
Relief valve
M18
32 Nm (3.2 kgfm, 23.6 ftlb)
Oil pressure sensor
G1/8
18 Nm (1.8 kgfm, 13.3 ftlb)
Oil filter bracket bolt
M6
10 Nm (1.0 kgfm, 7.4 ftlb)
Union bolt
3/416
UNF
34 Nm (3.4 kgfm, 25.1 ftlb)
Anode plug
M5
18 Nm (1.8 kgfm, 13.3 ftlb)
Oil pump cover screw
M6
10
M10
Crankcase bolt (1st)
18 Nm (1.8 kgfm, 13.3 ftlb)
5
6
7
8
9
35 Nm (3.5 kgfm, 25.8 ftlb)
Crankcase bolt (2nd)
90
Crankcase bolt (1st)
14 Nm (1.4 kgfm, 10.3 ftlb)

10
10
M8
Crankcase bolt (2nd)
28 Nm (2.8 kgfm, 20.7 ftlb)
A
1-18

Qty
Screw
size
Connecting rod bolt (1st)
Tightening torques
Remarks
40 Nm (4.0 kgfm, 29.5 ftlb)

8
M9
Connecting rod bolt (2nd)
90
Lower unit (regular rotation model)

Qty
Screw
size
Tightening torques
Drain screw
M8
Oil level plug
M8
Trim tab bolt
M10
42 Nm (4.2 kgfm, 31.0 ftlb)
Lower case mounting bolt
M10
47 Nm (4.7 kgfm, 34.7 ftlb)
Propeller nut
M18
54 Nm (5.4 kgfm, 39.8 ftlb)
Ring nut
M111
.25
142 Nm (14.2 kgfm, 104.7 ftlb)
Water inlet cover screw
M5
Pinion nut
M16
93 Nm (9.3 kgfm, 68.6 ftlb)
Qty
Screw
size
Tightening torques
Drain screw
M8
Oil level plug
M8
Trim tab bolt
M10
42 Nm (4.2 kgfm, 31.0 ftlb)
Lower case mounting bolt
M10
47 Nm (4.7 kgfm, 34.7 ftlb)
Propeller nut
M18
54 Nm (5.4 kgfm, 39.8 ftlb)
Ring nut
M111
.25
142 Nm (14.2 kgfm, 104.7 ftlb)
Water inlet cover screw
M5
Pinion nut
M16
93 Nm (9.3 kgfm, 68.6 ftlb)
Remarks
Lower unit (counter rotation model)

1-19
Remarks
Bracket unit
Qty
Screw
size
Tightening torques
Shift position switch screw
M4
2.5 Nm (0.25 kgfm, 1.84 ftlb)
Shift cut-off switch screw
M4
2.5 Nm (0.25 kgfm, 1.84 ftlb)
Shift bracket grease nipple
M6
Grease nipple
M6
Shift bracket bolt
M8
19 Nm (1.9 kgfm, 14.0 ftlb)
Shift rod detent bolt
M12
18 Nm (1.8 kgfm, 13.3 ftlb)
Flushing hose adapter screw
M6
Upper mount bolt
M10
54 Nm (5.4 kgfm, 39.8 ftlb)
Upper mounting nut
M14
75 Nm (7.5 kgfm, 55.3 ftlb)
Lower mounting nut
M14
75 Nm (7.5 kgfm, 55.3 ftlb)
Upper case bolt
M8
20 Nm (2.0 kgfm, 14.8 ftlb)
Upper case bolt
M10
42 Nm (4.2 kgfm, 31.0 ftlb)
Baffle plate screw
M6
Drain bolt
M14
27 Nm (2.7 kgfm, 19.9 ftlb)
Oil strainer bolt
M6
12 Nm (1.2 kgfm, 8.9 ftlb)
Exhaust manifold bolt
M8
20 Nm (2.0 kgfm, 14.8 ftlb)
Oil pan bolt
10
M8
20 Nm (2.0 kgfm, 14.8 ftlb)
Muffler bolt
M8
20 Nm (2.0 kgfm, 14.8 ftlb)
Trim sensor screw
M6
2.5 Nm (0.25 kgfm, 1.84 ftlb)
Self-locking nut
M22
15 Nm (1.5 kgfm, 11.1 ftlb)
Lower mounting shaft bolt
M10
39 Nm (3.9 kgfm, 28.8 ftlb)
Remarks
0
1
2
3
4
5
6
7
8
9
10
A
1-20
PTT unit
Qty
Screw
size
Tightening torques
Reservoir cap
M16
2.5 Nm (0.25 kgfm, 1.84 ftlb)
Manual valve
M14
3.5 Nm (0.35 kgfm, 2.58 ftlb)
Reservoir bolt
M6
PTT motor mounting bolt
M6
Gear pump cover bolt
M5
Gear pump housing bolt
M8
Tilt piston nut
M16
96 Nm (9.6 kgfm, 70.8 ftlb)
Trim cylinder end screw
M42
140 Nm (14.0 kgfm, 103.3 ftlb)
Tilt cylinder end screw
M48
128 Nm (12.8 kgfm, 94.4 ftlb)
Filter plug
M12
1-21
Remarks
General tightening torque

This chart indicates the tightening torques for
standard fasteners with a standard ISO
thread pitch.
Width
across
flats (A)
Screw
size (B)
8 mm
10 mm
12 mm
14 mm
17 mm
M5
M6
M8
M10
M12
General torque
specifications
Nm
kgfm
ftlb
5
8
18
36
52
0.5
0.8
1.8
3.6
5.2
3.7
5.9
13.3
26.6
38.4
1
2
3
4
5
6
7
8
9
10
A
1-22

Electronic control system ................................................ 2-1
Engine ECM components .......................................................... 2-3
VCT control ............................................................................... 2-5
Rectifier/Regulator/Isolator ........................................................ 2-6
Over-revolution control .............................................................. 2-6
Knock control ............................................................................. 2-6
Shift-cut control ......................................................................... 2-7
Reverse rotation control ............................................................ 2-7
Battery removal control ............................................................. 2-7
Warning control ......................................................................... 2-7
Water detection warning ............................................................ 2-8
Fail-safe control ......................................................................... 2-8
YDIS .......................................................................................... 2-9
Additional features .......................................................... 2-10

Y-COP (standard for European market and
optional for Oceanian market) ................................................. 2-10
Tilt limiter (Optional) ................................................................ 2-11
Power unit system .......................................................... 2-12

Overview ................................................................................. 2-12
Shimless valve lifter ................................................................. 2-13
Offset cylinder ......................................................................... 2-14
Balancer .................................................................................. 2-15
Flywheel and crankshaft .......................................................... 2-16
Oil cooler ................................................................................. 2-16
Lower unit ........................................................................ 2-17

Shift Dampener System (SDS) ................................................ 2-18
Fuel system ..................................................................... 2-18

High-pressure fuel pump control ............................................. 2-18
Low-pressure fuel pump control .............................................. 2-19
Fuel diagram ........................................................................... 2-19
Lubrication system ......................................................... 2-21

Lubrication diagram ................................................................. 2-21
Cooling system ............................................................... 2-23

Cooling diagram ...................................................................... 2-23

Intake and exhaust system ............................................ 2-25
Intake and exhaust diagram .................................................... 2-25
0
1
2
3
4
5
6
7
8
9
10
Electronic control system

This model uses an electronic fuel injection control, digital ignition control, ETV control, VCT control,
knock control, over-revolution control, alert control, and fail-safe control.
The engine ECM performs these controls based on data received from each sensor and switch.
The engine ECM is equipped with a self-diagnosis function. This function can be used to check trouble codes on the YDIS.
It is also equipped with Y-COP *1 as an anti-theft measure.
16. Ignition coil

17. OCV
18. Fuel injector
22.ETV
20. Vapor shut-off valve
21. High-pressure fuel pump
19. Low-pressure
fuel pump
32. ETV control
29. Fuel injection control

30. VCT control
31. Digital ignition control
24. YDIS
23. Engine
ECM
25. Digital Network

Gauge (6Y8)
26. Y-COP (*1)
27. Multi-hub
28. Battery
1. Pulser coil
2. TPS
3. Intake air pressure/
temperature sensor
4. Engine temperature sensor
5. Oil pressure sensor
6. Thermo switch
7. Cam position sensor (IN)
8. Cam position sensor (EX)
9. APS
10. Knock sensor
11. Shift cut-off switch
12. Shift position switch
13. Water detection switch
14. Cooling water pressure sensor (*2)
15. Speed sensor (*3)
*1. Standard for European market and optional for other markets.
*2. Standard for Caribbean market and optional for other markets.
*3. Standard for European and Caribbean markets and optional for other markets.
2-1

1. Pulser coil
2. TPS
3. Intake air pressure/temperature sensor
6. Thermo switch
9. APS
10. Knock sensor
14. Cooling water pressure sensor (optional)
15. Speed sensor (optional)
16. Ignition coil
17. OCV
18. Fuel injector
19. Low-pressure fuel pump
22. ETV
23. Engine ECM
24. YDIS
25. Digital Network Gauge (6Y8)
26. Immobilizer (Y-COP)
27. Multi-hub
28. Battery
29. Fuel injection control
30. VCT control
31. Digital ignition control
32. ETV control
0
1
2
3
4
5
6
7
8
9
10
A
2-2
Engine ECM components
5
6
3
1
10
9
11
8
12
13
14
21
15
16
17
18
19
20
2-3

Part name
1. Engine ECM
2. ETV
3. TPS (TPS 1 and TPS 2)
4. Pulser coil

6. Thermo switch
9. OCV
13. Knock sensor
15. APS (APS 1 and APS 2)
19. Fuel injector
21. Ignition coil
Function
Determines the engine operating conditions according to the
input signals from the sensors and switches which are
installed at various locations on the engine, and sends output
signals to operate the actuators to perform the various control
functions.
Opens and closes the throttle valve using a motor.
Detects the throttle valve opening angle. TPS 1 is the main
sensor and TPS 2 is the sub sensor. TPS 1 and TPS 2 mutually monitor each other for malfunctions.
Detects the engine speed.
Detects the crankshaft angle and piston positions.
Determines each group of cylinders (#1 and #4, #2 and #3).
Determines the stroke of each cylinder according to the signals from both the pulser coil and the cam position sensor
(EX).
Detects engine overheating.
Detects the oil pressure.
Detects the advance angle on the intake camshaft.
Advances or retards the intake camshaft timing by switching
the oil passages through which the engine oil is sent into the
advance chamber or the retard chamber in the rotor vane
housing.
Detects the engine temperature.
Detects the intake air temperature and intake air pressure.
Controls the amount of vapor gas to be sent from the vapor
separator to the intake system.
Detects engine knocking.
Detects water intrusion in fuel filter.
Detects the throttle lever operation. APS 1 is the main sensor
and APS 2 is the sub sensor. APS 1 and APS 2 mutually monitor each other for malfunctions.
Detects the neutral position.
Detects the shift-out condition for the forward gearshift.
Pressurizes the fuel and sends the fuel to the fuel rail.
Injects fuel.
Sends the fuel from the fuel tank to the vapor separator.
Produces high voltage to ignite a spark plug.
0
1
2
3
4
5
6
7
8
9
10
A
2-4
VCT control
This model uses the same VCT system as that used for F300B.
The engine ECM receives signals from the cam position sensor (IN) 1 and cam position sensor
(EX) 2, and conducts OCV 3 control. By moving the vanes within the VCT 4, the engine ECM
adjusts the optimum valve a opening/closing timing. The VCT system can continuously control
variable intake valve timing, allowing the system to set the optimum valve timing at all operating
ranges.
3
3
Engine
ECM
2-5
This model has a high-output (42 A max) recharging system. The built-in isolator allows for recharging both the main battery and the accessory battery. The engine ECM monitors the main battery
voltage. If the main battery voltage drops below 13.5 V, the engine ECM stops output to the optional
isolator lead and house battery to increase the output to the main battery. Output to the house battery resumes when the main battery voltage reaches 14.8 V or higher.
1. Lighting coil (stator assembly)
0
1
2. Engine ECM
4. Fuse box
3. Rectifier/
Regulator/
Isolator
5. Isolator lead
(optional)
5
6. House battery (optional)
2. Engine ECM
3. Rectifier/Regulator/Isolator
4. Fuse box
7. Main battery
5. Isolator lead (optional)

6. House battery (optional)
7. Main battery
Over-revolution control
If the engine speed exceeds 6200 r/min, the fuel injection and ignition are shut-off in a specific cylinder order.
When the engine speed drops below 6200 r/min, all cylinders reactivate.
Knock control
If the engine temperature sensor fails, or if a knock signal is detected when the engine temperature
exceeds 25 C (77 F) while the engine is running, the ignition timing is retarded.
6
7
8
9
10
A
2-6
Shift-cut control
This model is equipped with a shift-cut control system for easier shifting.
This system skips and retards the ignition of some cylinders to fluctuate the engine speed instantly
and obtains smooth disengagement of the dog clutch (the shift-cut control is activated when the
engine is running at 400 through 3000 r/min).
OFF
400600
ON
Retard
Engine speed (r/min)

601949
9503000
After firing is skipped for a After firing is skipped for 2

cylinder, the ignition timing
cylinders, the ignition
is retarded.
timing is retarded.
Reverse rotation control

If the reverse rotation is detected based on the timing of the cam position sensor signal, the fuel
injection and ignition for all cylinders are shut off.
Battery removal control

If a battery connection is loosened or removed, the fuel injection and ignition for all cylinders is shutoff to stop the engine and protect the Rectifier/Regulator/Isolator.
Warning control
If the engine overheats or the oil pressure drops, the throttle valve opening is reduced, limiting
engine speed to between 2000 and 3000 r/min.
When the switch is ON or the sensor detects a specific value, the engine is controlled as shown in
the table.
Detector
Thermo switch
Oil pressure sensor
Criterion
Thermo switch is ON (87 C, 188.6 F)

after 120 sec. have elapsed since the
engine was started or when engine
speed exceeds 2000 r/min for more than
43 seconds, except for when the throttle
valve opening angle is less than 9.
The pressure decreases to less than the

specified value for the engine speed
range, except when the throttle valve
opening angle is less than 9.
Activation
Overheat indicator lights and buzzer

sounds.
Low oil pressure alert indicator lights

and buzzer sounds.
2-7
Water detection warning

If water is present in the fuel and the water detection switch in the fuel filter turns ON, the warning
indicator on the meter will be activated as shown in the table.
Water detection switch state
Neutral
Turning from ON to OFF
Constant ON
Remarks
Indicator (symbol)
Displayed for 30 sec.
Always displayed
Check Engine
Always displayed
Sounds for 30 sec.
Sounds constantly
Starts sounding
3 seconds after
shifting into
neutral.
Transmitted for 30 sec.
Always transmitted
Indicator (symbol)
Always displayed
Check Engine
Always displayed
No sound
No sound
Transmitted for 30 sec.
Always transmitted
Buzzer
Trouble code 27
In-gear
Buzzer
Trouble code 27
Fail-safe control
In the fail-safe control, the engine ECM enters the fail-safe mode when an electrical component malfunctions.
The fail-safe control system records the trouble codes according to the engine trouble conditions.
Item
Trouble conditions to be detected
Controls performed by ECM
0
1
2
3
4
5
There is a signal from cam position

sensor (EX) but no signal from
pulser coil.
No control.
Output voltage is less than 0.18 V

or 4.90 V or more.
Set to intake air temperature when

starting.
Set to 40 C (104 F) when running.
High engine idle speed.
Cam position sensor

(EX)
No signal from cam position sensor

(EX) during 2 rotations of the
crankshaft.
Ignition timing advance angle is

limited to BTDC 10.
Switch to group fuel injection mode.
Set VCT in full retard position.
Cam position sensor

(IN)
No signal from cam position sensor

(IN) during 2 rotations of the
crankshaft.

Intake air
temperature sensor

or more than 4.60 V.
Set to 40 C (104 F).

Intake air pressure

sensor

or more than 4.50 V.
Set to TPS value.

OCV
Open or short circuit.

Knock sensor

or 4.00 V or more.
Pulser coil
Engine temperature
sensor
2-8
6
7
10

Item
Trouble conditions to be detected
Controls performed by ECM
Thermo switch
Thermo switch ON with engine

temperature at 40 C (104 F) or
lower.
Output voltage is 4.50 V or more.

Shift cut-off switch is ON at engine
start. Both shift position switch and
shift cut-off switch are ON for 5
seconds or more.
Oil pressure sensor

or 4.80 V or more for 260 seconds,
or 4.80 V or more when engine is
stopped.
Shift position switch is OFF when

the engine is starting.
APS
Output voltage of APS1 or APS2 is

0.293 V or less, or one of them is
less than 4.004 V and the other is
4.805 V or more. Difference
between APS1 and APS2 voltages
is 0.996 V or more.
Throttle valve is set at specified

opening angle.
TPS
TPS1 output voltage is 0.35 V or

less or 4.80 V or more. TPS2 output
voltage is 2.25 V or less or 4.80 V
or more. Difference between TPS1
and TPS2 voltages is 1.7 V or less
or 2.30 V or more.
Set to intake air pressure.

Throttle valve is set at specified
opening angle.
YDIS
These models require YDIS software version 2.1 or later.
The software for Version 2.1 or later versions can be downloaded from the portal site, while previous
versions were distributed only on CD-ROM.
Activation of the YDIS adapter is required to use YDIS Version 2.1.
2-9
Additional features
Additional features
Y-COP (standard for European market and optional for Oceanian market)
Y-COP consists of a remote control transmitter and a remote control receiver. The remote control
receiver transmits an authorization ID to the engine ECM. Pushing the lock and unlock buttons on
the remote control transmitter causes the remote control receiver to recognize the lock and unlock
state, and to send data to the engine ECM. The locked or unlocked state is maintained even when
the battery switch is turned to OFF. If an authorization ID is not received or if the transmitted authorization ID does not match the registered ID in the engine ECM, the remote control receiver cannot
perform data communication with the engine ECM.
TIP:
The remote control receiver can register up to 5 transmitters.
Additional transmitters cannot be registered if none of the transmitters are functioning properly.
The remote control transmitter and remote control receiver function within a distance of approximately 3 m (10 ft).
Installation location requires special attention to avoid electrical interference, obstructions, or
water exposure.
1. Y-COP
7. Ignition coil
2. Remote control transmitter
1
2
3
4
5
3. Remote control receiver
8. Fuel injector
4. Multi-hub
6. Engine
ECM
6
7
9. Alert indicator
5. Battery
8
1. Y-COP
2. Remote control transmitter
3. Remote control receiver
4. Multi-hub
5. Battery
6. Engine ECM
7. Ignition coil
8. Fuel injector
9. Alert indicator
State
Unlocked
Locked
Communication error, improper wiring
connection
Operation
Normal
Stops fuel injection and ignition, and prevents
the engine from starting.
The engine will start, but engine speed is
limited to 20003500 r/min.
Outputs a trouble code.
2-10
9
10
Additional features
Tilt limiter (Optional)

The optional tilt limiter allows the tilt-up action to be halted at a set angle, preventing the outboard
motor from coming in contact with a non standard motor well or other obstructions on the boat.
This tilt limiter consists of a magnet affixed to a through tube, and a sensor on a swivel bracket. The
movement of the swivel bracket when tilting the outboard motor up will move the sensor position.
When the mark a on the magnet is aligned with the mark b on the sensor, power to the PTT for
tilting the outboard motor up will be cut off and the tilt-up operation will be stopped.
TIP:
The set angle can be exceeded if the motor hits an obstruction in the water or when manually raising
the motor by opening the PTT manual release valve.
a
b
2. Tilt limiter unit

Sb
12 V
1. PTT switch (UP)
3. PTT relay
L
4. Output
6. Transistor switch
5. Signal
1. PTT switch (UP)

2. Tilt limiter unit
3. PTT relay
4. Output
5. Signal
6. Transistor switch
7. Sensor
2-11
7. Sensor
Power unit system
Power unit system

Overview
This model is equipped with a newly developed 4-stroke, L4 engine. Its features include the VCT 1,
ETV 2, and direct ignition coils 3 that are used on larger (V6 and V8) models. To reduce weight,
composite cylinder head covers 4, bottom cowling 5, intake manifold 6, and electrical component bracket 7 have been utilized. As a result, this outboard motor weighs only as much as the
F150.
0
1
2
1
4
7
3
4
5
6
7
8
5
6
9
10
A
2-12
Power unit system
Shimless valve lifter

Newly designed valve lifters 1 have been adopted in place of the valve shims previously used 2.
The valve lifters are available in different thicknesses a. Therefore, the valve clearance b can be
adjusted by replacing the current valve lifter with a new valve lifter of the appropriate thickness.
This model uses the same type of valve-related parts that are used on F300B.
2
b
a
1
2-13
Power unit system
Offset cylinder
This model employs an offset cylinder, which has a 10 mm offset a from the center of the crankshaft. During the combustion stroke, pistons receive a side-thrust load due to the angle of the connecting rods between the pistons and crankshaft journals. The offset cylinder design decreases the
angle of the connecting rod on the combustion stroke which reduces friction between the pistons
and cylinders.
The offset cylinder also allows for installation of a larger intake manifold with a larger intake valve,
contributing for a higher output.
The dimpled cylinder sleeve design 1 used on the F350 has been adopted.
0
1
2
3
4
5
a
6
7
8
9
10
A
2-14
Power unit system
Balancer
To reduce engine vibration, this model is equipped with a 2-axis balancer 1 that is driven by the
gear 2 on the crankshaft. The balancer uses twin counterweighted shafts and an integrated dampener to counteract the normal engine vibrations generated by the movement of the pistons, connecting rods and crankshaft.
The balancer cannot be disassembled and must be replaced as an assembly.
2-15
Power unit system
Flywheel and crankshaft

The flywheel 1 is the same flange mount a, damper-less style used on the 4.2L V6. The crankshaft 2 is a one piece assembly which incorporates the timing belt sprocket b and the flywheel
mounting flange c.
The crankshaft is forged to provide increased rigidity.
0
1
2
a
3
4
b
c
5
2
6
7
8
Oil cooler
Oil coolers are incorporated into the crankcase and cylinder block to improve engine cooling performance.
See Cooling water flow in Cooling diagram (2-23).
9
10
A
2-16
Lower unit
Lower unit
The F200 lower unit structure is the same as the 2.7L F150. New pinion, forward and reverse gears
are utilized to handle the higher output. The new gears change the gear ratio and backlash specifications. The 2.7L F150 special service tools and procedures apply to the new 2.8L F200 lower unit.
TIP:
The lower case has the same design as that of F150A. This model can be identified by the punch
mark on the trim tab installation area.
*******
F150: A3P**** gear ratio: 2.00 (28/14)
F200: ADA**** gear ratio: 1.86 (26/14)
2-17
Fuel system
Shift Dampener System (SDS)

The Shift Dampener System (SDS) uses a damper 1 to reduce the shock when the outboard
motor is shifted into gear.
The damper 1 is replaceable.
When shifting gears, the damper compresses to absorb shock, and the protrusions a on the dedicated spacer 2 transmit the rotational force of the propeller shaft directly to the propeller 3.
0
1
1
2
3
a
4
5
6
a
A
A. Neutral
B. Shift in
Fuel system
High-pressure fuel pump control
The high-pressure fuel pump operates for 5 seconds after the engine start switch is turned to ON,
and always operates while the engine is running.
The fuel pump continues to operate for 1 second after the engine is turned OFF.
TIP:
After the engine start switch is turned to ON, all injectors are activated one time to prevent clogging
before the high-pressure fuel pump operates.
9
10
A
2-18
Fuel system
Low-pressure fuel pump control

The low-pressure fuel pump operates for a specific period of time when the ignition switch is turned
ON.
Between idle and 1100 r/min, the pump will cycle ON for 10 seconds and OFF for 20 seconds.
Above 1100 r/min, the pump is ON continuously.
Fuel diagram
11. Fuel rail

15. Canister
5. Vapor separator
12. Fuel injector
9. Fuel pressure
regulator
8. High-pressure
fuel pump
3. Fuel filter
(water separator)
2-19
2. Primer pump
Fuel system
20. Atmosphere
(cowl inside)
15. Canister
19. Atmosphere (cowl outside)
5. Vapor separator
9. Fuel pressure
regulator
294kPa
(2.94kgf/cm2,
42.6 psi)
18. Check valve
21. Charcoal
17. Intake manifold
11. Fuel rail

12.
Fuel injector
#1
8. High-pressure
fuel pump
12.
Fuel injector
#2
12.
Fuel injector
#3
2
12.
Fuel injector
#4
13. Intake port
7. Float chamber
14.
Combustion
chamber #1
6. Filter
14.
Combustion
chamber #2
14.
Combustion
chamber #3
14.
Combustion
chamber #4
10. Check valve
3. Fuel filter
2. Primer pump
1. Fuel tank
A
B
C
8
15. Canister
17. Intake manifold
18. Check valve
19. Atmosphere (cowl outside)
20. Atmosphere (cowl inside)
21. Charcoal
1. Fuel tank
2. Primer pump
3. Fuel filter (water separator)
5. Vapor separator
6. Filter
7. Float chamber
9. Fuel pressure regulator
10. Check valve
11. Fuel rail
12. Fuel injector
13. Intake port
14. Combustion chamber
9
10
A. Fuel flow
B. Vapor gas flow
C. Air flow
D. Purified gas flow
A
2-20
Lubrication system
Lubrication system
Lubrication diagram
12. OCV
14. VCT assembly
16. Balancer
4. Oil filter
18. Relief valve

3. Oil pump
1. Oil pan
2. Oil strainer
9. Piston
13. Camshaft
oil passage
12. OCV
8. Crankshaft
pin
10. Cylinder head

oil passage
7. Crankshaft
main journal
5. Main gallery
16. Balancer
11. Camshaft journal
14. VCT assembly
15. Valve and

related parts
4. Oil filter
18. Relief valve
17. Oil cooler
3. Oil pump
441kPa
(4.41kgf/cm2,
63.9 psi)
2. Oil strainer
1. Oil pan
2-21
Lubrication system
1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil filter
5. Main gallery
7. Crankshaft main journal
8. Crankshaft pin
9. Piston
10. Cylinder head oil passage
11. Camshaft journal
12. OCV
13. Camshaft oil passage
14. VCT assembly
15. Valve and related parts
16. Balancer
17. Oil cooler
18. Relief valve
0
1
2
3
4
A. Engine oil flow
5
6
7
8
9
10
A
2-22
Cooling system
Cooling system
Cooling diagram
9. Thermostat
12. Oil cooler
11. PCV
13. Fuel cooler
18. Flushing
device
4. Oil pan
10. Oil cooler
16. Trim tab

water inlet
3. Water pump
2. Water inlet
2-23
Cooling system
0
8. Cylinder head
7. Cylinder block
9. Thermostat
6. Exhaust cover
10. Oil cooler
13. Fuel cooler

11. PCV
5. Exhaust guide
12. Oil cooler

C
B
17. Lower case
4. Oil pan
15. Propeller boss
18. Flushing
device
14. Cooling water

pilot hole
3. Water pump
16. Trim tab
water inlet
2. Water inlet
A
1. Water
6
7
A. Cooling water flow

B. When flushing the cooling water passages
C. Dynamic water pressure when the boat is
cruising
1. Water
2. Water inlet
3. Water pump
4. Oil pan
5. Exhaust guide
6. Exhaust cover
7. Cylinder block
8. Cylinder head
9. Thermostat
10. Oil cooler
11. PCV
12. Oil cooler
13. Fuel cooler
14. Cooling water pilot hole
15. Propeller boss
16. Trim tab water inlet
17. Lower case
18. Flushing device
8
9
10
A
2-24
Intake and exhaust system

Intake and exhaust diagram
1. Intake silencer
2. ETV
3. Intake manifold
8. Idle exhaust hole
4. Exhaust cover
5. Exhaust manifold
6. Muffler
7. Propeller boss
A
B
1. Intake silencer
2. ETV
3. Intake manifold
4. Exhaust cover
5. Exhaust manifold
6. Muffler
7. Propeller boss
8. Idle exhaust hole
A. Intake air flow

B. Exhaust gas flow
2-25
MEMO
0
1
2
3
4
5
6
7
8
9
10
A
2-26
Rigging information
Important reminder on rigging ......................................... 3-1
Outboard motor mounting instructions ...................................... 3-1
Crate handling ................................................................... 3-2

Crate top cover pictograph description ...................................... 3-2
Uncrating ........................................................................... 3-3

Uncrating procedure .................................................................. 3-3
External dimensions ......................................................... 3-5

Clamp bracket dimensions .............................................. 3-6
Outboard motor mounting ................................................ 3-7
Installing the outboard motor ..................................................... 3-7
Outboard motor mounting height ............................................... 3-9
Rigging grommet mounting ............................................. 3-9

Rigging grommet description ..................................................... 3-9
Installing the battery cable ......................................................... 3-9
Installing the shift cable ........................................................... 3-10
Installing the throttle cable ....................................................... 3-11
Installing the main wire harness .............................................. 3-12
Installing the Digital Network Gauge harness ......................... 3-12
Installing the conventional gauge harness .............................. 3-12
Installing the rigging grommet ................................................. 3-13
Optional equipment ........................................................ 3-13

Installing the isolator lead ........................................................ 3-13
Installing the water pressure sensor
(Digital Network Gauge) .......................................................... 3-14
Installing the speed sensor (Digital Network Gauge) .............. 3-15
Installing the water temperature sensor
(conventional gauge) ............................................................... 3-16
Installing the water pressure sensor (conventional gauge) ..... 3-17
Connecting the speedometer hose (conventional gauge) ....... 3-18
Installing the tilt limiter ............................................................. 3-18
Setting the tilt limiter ................................................................ 3-21
Deactivating the tilt limiter ....................................................... 3-22
Rigging information
optional for other markets) ............................................ 3-23
Installing Y-COP ...................................................................... 3-23
Registering the remote control receiver ID to the ECM ........... 3-23
Battery installation .......................................................... 3-25

Battery wiring without house battery ....................................... 3-25
Battery wiring with house battery ............................................ 3-28
0
1
2
System diagram .............................................................. 3-33

Single engine application (Digital Network Gauge) ................. 3-33
Single engine application (conventional gauge) ...................... 3-35
Twin engine application (Digital Network Gauge) ................... 3-37
Twin engine application (conventional gauge) ........................ 3-41
3
4
Rigging recommendation ............................................... 3-43

Battery cable length ................................................................. 3-43
Extension length recommendation for battery cable ............... 3-43
Propeller selection .......................................................... 3-45

Propeller size ........................................................................... 3-45
Selection .................................................................................. 3-45
5
6
7
8
9
10
Important reminder on rigging
Important reminder on rigging

Outboard motor mounting instructions
Overpowering a boat could cause severe instability. Do not install an outboard motor with
more horsepower than the maximum rating on the capacity plate of the boat. If the boat
does not have a capacity plate, consult the boat manufacturer.
Improper mounting of the outboard motor could result in hazardous conditions, such as
poor handling, loss of control, or fire hazards.
Too much weight on the transom can change the center of gravity, buoyancy, operating balance, or performance of the boat, which could cause loss of control or swamping. Consult
the boat manufacturer for the maximum engine weight allowable on the transom, which is
different from the overall boat capacity. Overloading the transom with an outboard motor
that is too heavy could also damage the hull, transom, deck, or helm area, as well as the outboard motor and other equipment.
Before mounting the outboard motor, consult the manufacturer of the engine jack plates or
brackets. Excessive loads could damage the engine jack plates, brackets, boat transom,
steering system, or engine. These damages could cause loss of control.
3-1
Crate handling
Crate handling
Crate top cover pictograph description
The following pictographs are important when handling the crate.
Read the notice and understand what each pictograph means to prevent damage to the outboard
motor when handling, transporting, and storing the crate.
0
1
2
9
4
5
5
3
IMPORTANT
This unit delivered to carrier in a good condition.
For protection against loss due to damage, inspect thoroughly.
If damage is noted, make note on freight bill.
Shipper assumes no further liability to the transportation company.
Your claim should be filed against carrier for damage of any nature.
1. !WARNING
Wear suitable protective gear such as
gloves and eye protection when handling
and opening crate.
2. NOTICE
Use forklifts with forks that are at least
1 m (40 in) in length.
Only stack with crate of the same size.
Be sure unit is stacked securely (all four
corners fit securely on unit below it).
Stack Limit - 2 units (at handling).
3. IMPORTANT
This unit delivered to carrier in a good
condition.
For protection against loss due to damage, inspect thoroughly.
If damage is noted, make note on freight
bill.
Shipper assumes no further liability to
the transportation company.
Your claim should be filed against carrier
for damage of any nature.
4. Lifting fork insert position
5. Crate barycentric position
6. Stack limit: Maximum 4 units for storage
7. Upward indication
8. Care handling indication
9. Water avoidance indication
3-2
6
7
8
9
10
Uncrating
Uncrating
Uncrating procedure
2
1
Wear gloves to avoid injury from sharp
steel edges while uncrating.
1. Check the crate for shipping damage.
2. Remove the top cover.
Engine lifting eye 1: 90890-06820
3. Remove all of the bolts from the bottom

plate, and then remove the frame.
Lifting eye bolt 2:

36 Nm (3.6 kgfm, 26.6 ftlb)
7. Install the lifting harness 1 to the eye
bolt 2.
Be careful not to damage the outboard

motor.
8. Apply tension to the lifting harness.

4. Remove the wrapping, and then check
the outboard motor for concealed damage.
5. Remove the top cowling, and then

remove the flywheel magneto cover 1.
1
9. Lift up the outboard motor carefully along
with the bottom frame 1.
Make sure that the lifting harnesses do

not damage any parts of the outboard
motor.
6. Install the special service tool 1 to the

flywheel magneto, and then tighten the
lifting eye bolts 2 to the specified
torque.
1
When lifting the outboard motor, make
sure to use the specified special service
tool. Other bolts and hanging jigs could
bend or break, causing the outboard
motor to fall.
10. Remove the skeg holder 1.
3-3
Uncrating
0
1
1
11. Remove the bolts 1.
2
3
4
12. Remove the steering retainer, and then

install a hydraulic steering cylinder or
steering cable following the recommendation of the manufacturer.
5
6
7
8
9
10
A
3-4
External dimensions
External dimensions
TIP:
The dimension values may include reference values.
L:33 (1.3)
X:32 (1.3)
660 (26.0)
T1*1
32
639 (25.2)
198 (7.8)
75 (3.0)
L:1033 (40.7)
X:1149 (45.2)
722 (28.4)
82 (3.
2)
L:53 (
2.
X:63 ( 1)
2.5)
12
L:42 (1.7)
X:51 (2.0)
L:774 (30.5)
X:849 (33.4)
163 (6.4)
66
367 (1
45 (1.8)
4.5) 14 (0.6)
501 (19.7)
796 (31.3)
L:946 (37.2)
X:1073 (42.2)
L:516 (20.3)
210 (8.3) X:643 (25.3)
H*2
928 (36.5)
274 (10.8) 425 (16.7)
mm (in)
4
646 (25.4)
*1. Minimum distance between the outboard motors in twin or triple installation
*2. Motor transom height
3-5
Clamp bracket dimensions
Clamp bracket dimensions

TIP:
The dimension values may include reference values.
1
2
50.8 (2.0)
180 (7.1)
163.5 (6.4)
mm (in)
180 (7.1)
163.5 (6.4)
254 (10.0)
4
5
6
55.5
(2.2)
18.5 (0.7)
13 (0.5)
17 (0.7)
25 (1.0)
367 (14.4)
82 (3.2)
13 (0.5)
125.4 (4.9)
125.4 (4.9)
24 (0.9)
8
9
10
A
3-6
Outboard motor mounting
For twin outboard motor installation, place

the outboard motors so that the distance from
the C/L of each outboard motor to the C/L of
the boat transom are equal on both sides.
Installing the outboard motor

Proper mounting of the outboard motor provides better performance, maximum reliability, and the highest customer satisfaction.
This chapter contains the specifications necessary to mount the outboard motor, and may
vary slightly depending on the applications.
When mounting the outboard motor, make
sure that there is sufficient clearance for the
outboard motor to fully tilt up, and to fully
move to port and starboard. See External
dimensions (3-5).
TIP:
Make sure that distance e is equal to distance f.
For the distance (T1), see External dimensions (3-5).
C/L
f
1. For single outboard motor installation,

place the outboard motor on the vertical
centerline of the boat transom.
TIP:
Make sure that distance a is equal to distance b, and distance c is equal to distance d.
T1
C/L
C/L: Centerline of the transom
2. Adjust the position of the outboard motor

so that the height of the anti-cavitation
plate 1 is equal to or slightly above the
bottom of the boat transom.
TIP:
This mounting height information is for reference only. It is impossible to provide complete instructions for every possible boat and
outboard motor combination.
C/L
b
c
1
A. Hull without strakes
B. Hull with strakes
R: Radius
3-7

Drilling plate 1: 90890-06783

6. Apply sealant to the mounting holes, and
then secure the outboard motor using the
included mounting bolts 1, small washers 2, large washers 3, and nuts 4.
Make sure that there is no clearance

between the surfaces of the boat transom
and the clamp brackets. Otherwise, the
clamp brackets or boat transom may be
damaged.
A. Single outboard motor

B. Twin outboard motor
3. Install the special service tool 1.
4. Adjust the height of the scale 2 to the
transom height (H), and place it on the
special service tool 1. Secure the special service tool 1 to the boat transom
using screws or vises.
The second hole from the top of each clamp

bracket is recommended for the upper
mounting bolt.
TIP:
1
For the transom height (H), see External

dimensions (3-5).
1
2
3
3 2
4
4
5
6
4
2
7
D
TIP:
5. When the outboard motor mounting position has been determined, mark the best
suited 4 symmetrical mounting holes on
the boat transom 3. Drill the mounting
holes perpendicular to the surface of the
boat transom using a 13.0 mm (0.5 in)
a drill bit.
3 2
4
8
9
Boat transom
thickness (D)
6575 mm
(2.562.95 in)
7595 mm
(2.953.74 in)
Mounting bolt
M12 130 mm
(5.12 in)
M12 150 mm
(5.91 in)
10
a
2
C/L
3-8
Rigging grommet mounting

7. Install the mounting bolts, and then
tighten the nuts firmly.
4
Make sure that the clamp brackets do not
bite into the boat transom.
10
8. Tighten the locknuts firmly.
9
5
8
7
1. Main wire harness

2. Throttle cable
3. Isolator lead (optional)
4. Fuel hose
5. Flushing hose (market option)
6. Battery cable
7. Gauge harness
8. Shift cable
9. Speedometer hose
10. Water temperature sensor lead
(optional)/tube (optional)
Outboard motor mounting height

If the water line is too close to the power
head, poor engine performance could result,
and water could enter the cylinders and damage the engine.
When mounting a 4-stroke outboard motor to
a boat, make sure that the mounting height
between the water surface and the clamp
bracket seating point is not less than the
specified minimum mounting height a. Measure the mounting height when the boat is
moored and carrying the maximum load.
1. Remove the grommet holder 1 from the

rigging grommet 2, and then remove
the rigging grommet 2.
1
a
Installing the battery cable

1. Route the battery cable 1 and fasten it
using holders 2.
Minimum mounting height a:

100 mm (3.9 in)

Rigging grommet description
Pass all the control components through the
proper holes in the rigging grommet.
3-9
2
1
2. Connect the positive and negative terminals of the battery cable 1, and then
tighten the positive battery cable nut 2
to the specified torque.
2. Move the remote control lever to the N

position.
3. Disengage the holder 1 from the cable
holder 2.
TIP:
The positive battery cable is marked with red
tape.
3
4
3. Install the rubber cap 3.
2
4. Install the shift cable 1 to the cable
holder 2, and then fasten it using the
holder 3.
2
1
Positive battery cable nut 2:

Installing the shift cable
5. Align the mark a on the bushing 1 with

the mark b on the plate 2.
8
9
10
Always perform the cable adjustment in

advance, following the procedures in the
remote control operation manual.
a
1
1. Fully screw in the shift cable joint 1 to

the shift cable 2.
3-10

6. Adjust the shift cable joint 1, and then
install it to the pin 2.
2. Disengage the holder 1 from the cable

holder 2.
The shift cable joint must be screwed in

8.0 mm (0.31 in) or more.
1
2
3. Install the throttle cable 1 to the cable

holder 2, and then fasten it using the
holder 3.
2
1
Dimension a: 8.0 mm (0.31 in) or more

7. Install the clip 1, and then tighten the
shift cable locknut 2 to the specified
torque.
3
2
1
2
4. Move the throttle lever 1 so that it contacts the stopper 2.
Shift cable locknut 2:

8. Check the shift cable for proper operation.
Installing the throttle cable
5. Pull the inner cable 1 using the force of

15 N (1.5 kgf, 3.4 lbf) to remove any free
play in the cable.
1. Fully screw in the throttle cable joint 1 to

the throttle cable 2.
6. Adjust the throttle cable joint 2, and

then install it to the pin 3 of the throttle
lever.
The throttle cable joint must be screwed

in 8.0 mm (0.31 in) or more.
3-11
3
a
0
1
2 1
Dimension a: 8.0 mm (0.31 in) or more
2. Connect the Digital Network Gauge harness coupler a, and then secure it using
the holder 1.
7. Install the clip 1, and then tighten the

throttle cable locknut 2 to the specified
torque.
2
3
1
a
2
3. Remove the yellow tape 1 and caps 2.
Throttle cable locknut 2:

8. Check the throttle cable for proper operation.
5
6
Installing the main wire harness

1. Connect the main wire harness coupler
a, and then secure it using the holder
1.
4. Connect the trim sensor coupler a.
7
8
9
10
a
1
Installing the Digital Network Gauge

harness
Installing the conventional gauge

harness
1. Remove the cap 1.
1. Remove the gauge harness coupler a

from the holder 1.
3-12
Optional equipment
2. Align the white tape a on the battery
cable 1 with the outer end of the rigging
grommet.
3. Install the rigging grommet 1 along with

the grommet holder 2.
1
2
3. Connect the gauge harness coupler a.
1
4. Install the rigging tube retainer 1, and
then fasten it using the plastic tie 2.
a
4. Install the gauge harness coupler a to
the holder 1.
2
1
Optional equipment
Installing the isolator lead
1. Remove the isolator lead coupler a from
the holder 1.
Installing the rigging grommet

1. Route each harness through the proper
hole in the rigging grommet. See Rigging grommet description (3-9).
3-13
Optional equipment

(Digital Network Gauge)
See 6Y8 MULTIFUNCTION METER SET UP
MANUAL (6Y8-2819K-3K-XX) for details of
the components. XX (2-digit suffix) varies
depending on the language.
a
1. Install the water pressure sensor 1 to
the water pressure sensor adapter 2,
and then tighten the water pressure sensor 1 to the specified torque.
1
2
4
Water pressure sensor 1:
19 Nm (1.9 kgfm, 14.0 ftlb)
3. Connect the isolator lead coupler a.
2. Remove the ignition coil cover.

3. Remove the plug 1 and gasket 2.
7
4. Install the isolator lead coupler a to the
holder 1, and then secure it using the
holder 2.
4. Install a new gasket 1 and the water

pressure sensor adapter 2, and then
tighten it to the specified torque.
2
1
8
9
10
5. Connect the isolator lead to a house battery so that it meets the local regulation
such as the overcurrent protection compliance of ABYC part E-11.
A
3-14
Optional equipment
Water pressure sensor adapter 2:
23 Nm (2.3 kgfm, 17.0 ftlb)

6. Remove the water pressure sensor coupler a from the holder 2.
7. Connect the water pressure sensor coupler a to the water pressure sensor 3.
Extension hose 1:
X-transom model: 400 mm (15.8 in)
L-transom model: 350 mm (13.8 in)
TIP:
The water pressure sensor lead is marked
with W.
4. Cut the corrugated tube 1 to the specified length, and then install it.
3
1
Installing the speed sensor (Digital

Network Gauge)
Corrugated tube 1:
X-transom model: 360 mm (14.2 in)
L-transom model: 310 mm (12.2 in)
See 6Y8 MULTIFUNCTION METER SET UP

MANUAL (6Y8-2819K-3K-XX) for details of
the components. XX (2-digit suffix) varies
depending on the language.
5. Route the speedometer hose 1 under

the couplers a and the harnesses 2.
1. Remove the speedometer hose 1 from

the rigging grommet 2.
2. Cut off about 3 mm (0.12 in) from the tip

a of the nipple 3.
1
a
2
3
a
2
6. Install the speed sensor 1 to the speed

sensor adapter 2, and then tighten the
speed sensor 1 to the specified torque.
3. Cut the extension hose 1 to the specified length, install it to the nipple 2, and
3-15
Optional equipment
12. Seal the area a of the rigging grommet
with a rubber seal.
Speed sensor 1:
19 Nm (1.9 kgfm, 14.0 ftlb)
Installing the water temperature

sensor (conventional gauge)
7. Install the speed sensor adapter 1.
1. Remove the thermo switch 1 and holder

2.
8. Connect the extension hose 2 to the

speed sensor adapter 1, and then fasten it using the plastic tie 3.
2
3
5
2
1
2. Remove the plastic tie 1, and then
disconnect the hose 2.
3. Remove the thermostat cover 3.
10. Remove the speed sensor coupler a

from the holder 2.
11. Connect the speed sensor coupler a to

the speed sensor 3.
1
2
4. Install a thermostat cover 1 that is
appropriate for the water temperature
sensor, and then tighten the thermostat
cover bolts 2 to the specified torque.
7
8
TIP:
The speed sensor lead is marked with S.
9
10
a
2
5. Connect the hose 3, and then fasten it

using the plastic tie 4.
A
3-16
Optional equipment
1
1
5
3
2
4
3
2
5
4
Thermostat cover bolt 2:

10 Nm (1.0 kgfm, 7.4 ftlb)
Water temperature sensor 1:

23 Nm (2.3 kgfm, 17.0 ftlb)
6. Install the thermo switch 1.
10. Route the water temperature sensor lead

1 under the harnesses 2.
7. Install the holder 1.
2
1

(conventional gauge)
1. Remove the plug 1 and gasket 2.
8. Install the water temperature sensor 1

and gasket 2, and then tighten it to the
specified torque.
9. Route the water temperature sensor lead

3, and then fasten it using the holder 4
and clamps 5.
2. Install a new gasket 1 and the
attachment 2, and then tighten it to the
specified torque.
3-17
Optional equipment
0
1
1
Installing the tilt limiter
Attachment 2:
23 Nm (2.3 kgfm, 17.0 ftlb)
The models with a dual steering cable cannot

be fitted with a tilt limiter.
3. Route the tube 1 of the attachment

under the harnesses 2.
1. Disconnect the battery cable from the

battery.
2. If there is any grease, clean the surface

of through tube 1 to which the holder is
to be installed.
3. Install the holder 2 so that the protrusion a on the magnet lever is aligned
with the groove b in the through tube
1, and the protrusion c on the holder is
aligned with the hole d in the through
tube 1.
4. Install the collar 3 and tighten the clamp

screw 4 temporarily.
Connecting the speedometer hose

(conventional gauge)
TIP:
1. Cut off about 3 mm (0.12 in) from the tip

a of the nipple 1 of the speedometer
hose 2.
Tighten the clamp screw 4 to the extent that

the magnet lever can be moved manually to
adjust the tilt limiter.
a
2
5
6
7
8
9
4
1
10
3
2
2. Install the extension hose 1 to the

nipple 2, and then fasten it using the
plastic tie 3.
A
3-18
Optional equipment
5. Install the sensor 1 on the swivel
bracket.
2
1
4
3
6. Fasten the tilt limiter lead 1 using the

holder 2.
11. Remove the plastic tie 1, and then pull

the PTT motor leads 2 out of the bottom
cowling.
1
2
1
7. Remove the PTT relay cover.

8. Remove the caps 1.
12. Route the tilt limiter leads 1 through the
hole in the grommet 2 and into the bottom cowling.
9. Disconnect the PTT motor leads 2.
TIP:
To pass the tilt limiter lead through the hole in
the grommet, remove the PTT motor lead
temporarily.
TIP:
Pass the tilt limiter leads one by one through
the hole in the grommet.
2
2
1
10. Remove the PTT motor leads 1 from

the holders 2, 3, and 4 and clamp
5.
13. Route the PTT motor leads 1 through

the hole in the grommet 2 and into the
bottom cowling.
3-19
Optional equipment
TIP:
Pass the PTT motor leads one by one
through the hole in the grommet.
b
a
2
1
0
1
1
19. Connect the tilt limiter couplers at the
main harness side with the tilt limiter couplers a at the tilt limiter side to the same
colored wires.
14. Align the red tape a on the PTT motor
lead 1 with the outer end of the grommet 2.
Sb
a
a
20. Route the tilt limiter lead 1, and then

fasten it using the clamp 2.
15. Remove the plastic ties that hold the trim

sensor lead.
3
4
Sb
2
6
7
16. Route the tilt limiter lead 1 in the same

manner as the trim sensor lead 2, and
then fasten them using new plastic ties
3 at the positions where original plastic
ties were installed.
8
2
9
3
2
3
21. Route the PTT motor leads 1, and then

fasten them using the holders 2, 3,
and 4 and clamp 5.
10
1
17. Remove the yellow tape 1.
18. Disconnect the tilt limiter coupler a and
remove the cap b.
A
3-20
Optional equipment
1. Check that there is no interference
between the steering system and the tilt
limiter when the outboard motor is
steered to the left and right.
2
1
2. Connect the battery cables.

3. Decide the tilt up angle a.
5
3
TIP:
The tilt up angle can be set at any tilt setting

range.
3
a
22. Connect the PTT motor leads 1, and
then tighten the PTT motor lead bolts 2
23. Install the caps 3.
3
2
4. Align the mark a on the magnet with the

desired angle indicated on the sensor.
3
PTT motor lead bolt 2:
3.5 Nm (0.35 kgfm, 2.58 ftlb)
TIP:
The scales on the sensor indicate the
approximate angles from the full trim down
position.
24. Install the PTT relay cover.
Setting the tilt limiter

Example:
If the desired tilt up angle is 35, align the
mark a on the magnet with the scale mark
b on the sensor.
Check that the outboard motor is

mounted securely.
Never get under the outboard motor
while it is tilted.
Make sure to keep the clearance of

50.8 mm (2.0 in) or more between the outboard motor and the motor well.
3-21
Optional equipment
Clamp screw 1:
To fully tilt the outboard motor up, deactivate

the tilt limiter according to the following procedure.
65
55
45
35
25
Deactivating the tilt limiter
1. Disconnect the tilt limiter couplers a and

b.
1
2
Sb
a
5. Operate the PTT switch on the bottom

cowling to tilt the outboard motor up.
3
L
6. Check that the outboard motor stops at

the set position.
7. Tilt the outboard motor down to adjust

the position of the magnet 1 if the setting angle needs to be adjusted.
2. Connect the tilt limiter couplers a and

b.
TIP:
Sb
To adjust the tilt up angle higher: a

To adjust the tilt up angle lower: b
5
6
b
b
7
8
8. Tighten the clamp screw 1 to the specified torque, and then recheck the tilt up
angle.
10
3-22
Y-COP (standard for European market and optional for other markets)
Y-COP (standard for European

market and optional for other
markets)
Registering the remote control

receiver ID to the ECM
1. Check that the engine start switch is
OFF.
Installing Y-COP
For further information, see the Yamaha
Security System Y-COP installation manual.
2. Push the unlock button 1 of the remote

control transmitter. The buzzer of the
remote control receiver sounds 2 short
beeps.
Install the remote control receiver so

that the UP mark is facing up.
Do not install the remote control
receiver in a location where it will be
exposed to water.
Do not cover the remote control receiver
with metal objects. Otherwise, signals
may not be received.
1
1. Install the remote control receiver 1,
and then tighten the remote control
receiver screws 2 to the specified
torque.
3. Turn the engine start switch to ON. The

buzzer of the remote control receiver
sounds 1 medium beep.
4. Turn the engine start switch to OFF. Initial
registration is complete. Y-COP is
unlocked.
TIP:
Mount the remote control receiver within 3 m
(10 ft) from the helm.
5. Push the lock button 1 of the remote

control transmitter. Check that the buzzer
of the remote control receiver sounds 1
short beep.
1
2
1
Remote control receiver screw 2:

6. Turn the engine start switch to ON.
TIP:
2. Connect the Y-COP wires. See System

diagram (3-33).
If the outboard motor is equipped with the

Digital Network Gauge (6Y8), - is displayed
on the tachometer when the engine start
switch is turned to ON.
3-23
0
1
7. Push the unlock button 1 of the remote
control transmitter. Check that the buzzer
of the remote control receiver sounds 2
short beeps.
TIP:
If the outboard motor is equipped with the

Digital Network Gauge (6Y8), 0 is displayed
on the tachometer when the engine start
switch is turned to ON.
5
6
7
8. Turn the engine start switch to OFF.
8
9
10
A
3-24
Battery installation
Make sure to connect the battery properly and select the proper cable sizes. Otherwise, a
fire could result.
When installing an isolator lead to the positive battery terminal or battery switch, over-current protection in compliance with ABYC (E-11) must be provided.
Do not reverse the battery connections. Otherwise, the charging system could be damaged.
Battery wiring without house battery
When only one battery is used for one engine, connect the positive battery cable and isolator lead to the positive battery terminal. If the isolator lead is left unconnected, accidental
contact of the isolator lead with the negative terminal of the battery can cause a short circuit, which may result in a fire.
When using a dual battery installation, a negative battery cable must be installed between
both engine batteries. This cable must be sized equivalent to the engine battery cables or
larger AWG cable size in accordance with ABYC specifications.
1. Outboard motor
2. Isolator lead
5. Fuse (60 A)
3. Red
4. Black
1. Outboard motor
2. Isolator lead
3. Red
4. Black
5. Fuse (60 A)
3-25
PORT
STBD
1. Outboard motor
1. Outboard motor
2. Isolator lead
5. Fuse (60 A)
3. Red
3. Red
4. Black
4. Black
4. Black
1
2
3
1. Outboard motor
2. Isolator lead
3. Red
4. Black
5. Fuse (60 A)
1. Outboard motor
2. Isolator lead
6. Fuse (60 A)
3. Battery switch
4
5
4. Red
5. Black
ON/OFF
8
1. Outboard motor
2. Isolator lead
3. Battery switch
4. Red
5. Black
6. Fuse (60 A)
9
10
A
3-26
STBD
PORT
1. Outboard motor
1. Outboard motor
2. Isolator lead
2. Isolator lead
6. Fuse (60 A)
6. Fuse (60 A)
4. Red
4. Red
5. Black
5. Black
ON/OFF
ON/OFF
3. Battery switch
3. Battery switch
5. Black
1. Outboard motor
2. Isolator lead
3. Battery switch
STBD
4. Red
5. Black
6. Fuse (60 A)
1. Outboard motor
PORT
1. Outboard motor
2. Battery switch
2. Battery switch
ON/OFF
3. Navigation system
4. Boat system
5. Black
ON/OFF
6. Red
6. Red
6. Red
6. Red
5. Black
5. Black
1. Outboard motor
2. Battery switch
3. Navigation system
4. Boat system
5. Black
6. Red
3-27
5. Black
5. Black
Battery wiring with house battery
When only one battery is used for one engine, connect the positive battery cable and isolator lead to the positive battery terminal. If the isolator lead is left unconnected, accidental
contact of the isolator lead with the negative terminal of the battery can cause a short circuit, which may result in a fire.
When using a house battery, a negative battery cable must be installed between the house
battery and the engine battery. This cable must be sized equivalent to the engine battery
cables or larger AWG cable size in accordance with ABYC specifications.
Battery switches must be capable of meeting intermittent and continuous current ratings
for engines and accessories.
1. Outboard motor
0
1
2
3
2. Isolator lead
7. Fuse (60 A)
3. Battery switch
4. Red
3. Battery switch
ON/OFF
1
5. Black
4. Red
6. House battery
1. Outboard motor
2. Isolator lead
3. Battery switch
4. Red
5. Black
6. House battery
7. Fuse (60 A)
6
7
8
9
10
A
3-28
1. Outboard motor
2. Isolator lead
3. Red
6. Fuse (60 A)
4. Black
4. Black
5. House battery
1. Outboard motor
2. Isolator lead
3. Red
4. Black
5. House battery
6. Fuse (60 A)
1. Outboard motor
2. Isolator lead
3. Black
4. Red
5. Battery switch
7. Fuse (60 A)
2
3. Black
4. Red
6. House battery
1. Outboard motor
2. Isolator lead
3. Black
4. Red
5. Battery switch
6. House battery
7. Fuse (60 A)
3-29
STBD
PORT
1. Outboard motor
1. Outboard motor
2. Isolator lead
3. Black
2. Isolator lead
7. Fuse (60 A)
4. Battery switch
5. Red
5. Red
3. Black
4. Battery switch
ON/OFF
5. Red
ON/OFF
3. Black
4. Battery switch
6. House battery
3. Black
1. Outboard motor
2. Isolator lead
3. Black
4. Battery switch
5. Red
6. House battery
7. Fuse (60 A)
5
1. Outboard motor
STBD
PORT
1. Outboard motor
2. Isolator lead
2. Isolator lead
7. Fuse (60 A)
3. Black
5. Red
4. Battery switch
4. Battery switch
5. Red
ON/OFF
5. Red
5. Red
3. Black
3. Black
3. Black
4. Battery switch
6. House battery
1. Outboard motor
2. Isolator lead
3. Black
4. Battery switch
5. Red
6. House battery
7. Fuse (60 A)
9
10
A
3-30
1. Outboard motor
STBD
PORT
1. Outboard motor
2. Isolator lead
2. Isolator lead
7. Fuse (60 A)
3. Black
4. Battery switch
5. Red
5. Red
3. Black
4. Battery switch
5. Red
5. Red
6. House battery
3. Black
3. Black
1. Outboard motor
2. Isolator lead
3. Black
4. Battery switch
5. Red
6. House battery
7. Fuse (60 A)
STBD
PORT
1. Outboard motor
1. Outboard motor
3. Battery switch
2. Isolator lead
2. Isolator lead
3. Battery switch
7. Fuse (60 A)
5. Black
ON/OFF
3. Battery switch
ON/OFF
4. Red
4. Red
ON/OFF
5. Black
5. Black
5. Black
6. House battery
1. Outboard motor
2. Isolator lead
3. Battery switch
4. Red
5. Black
6. House battery
5. Black
6. House battery
7. Fuse (60 A)
3-31
4. Red
MEMO
0
1
2
3
4
5
6
7
8
9
10
A
3-32
System diagram
System diagram
Single engine application (Digital Network Gauge)
12
14
10
b
c
c
c
13
11
b
a
R
G
B
Y
*1
B
Y
6
Y
9
3-33
P 3
System diagram
Ref.
No.
1
2
3
4
Engine ECM
Speed sensor kit
Trim sensor
Main wire harness
Remote control box
Power supply wire
Pigtail bus wire
Single hub
Main bus wire
10
11
12
13
Multi-hub
Resistor cap
Tachometer
Speedometer
14
Part name
Immobilizer (Y-COP)
Part No.
60V-8A4L1-11
703-48201-A5
703-48205-A7
703-48207-A7
6Y8-83553-01
6Y8-82521-01
6Y8-82521-11
6Y8-82521-21
6Y8-82521-31
6Y8-82521-41
6Y8-82521-51
6Y8-81920-11
6Y8-82553-01
6Y8-82553-50
6Y8-82553-11
6Y8-82553-21
6Y8-82553-31
6Y8-82553-41
6Y8-81920-01
6Y8-85371-01
6Y8-8350T-01
6Y8-8350S-01
6Y8-86254-02
6Y8-86254-22
a. Power port
b. Bus port
c. Device port
*1. Attach the waterproof cap to the open terminal.
Color code
B
: Black
G
: Green
P
: Pink
R
: Red
Y
: Yellow
Remarks
0
w/ tilt switch
For additional trim switch
w/ 10 A fuse, 2.4 m (8 ft)
0.3 m (1 ft)
0.6 m (2 ft)
0.9 m (3 ft)
1.8 m (6 ft)
2.7 m (9 ft)
3.6 m (12 ft)
w/ resistor, 4-6P, White
0.3 m (1 ft)
3.0 m (10 ft)
4.6 m (15 ft)
6.1 m (20 ft)
7.6 m (25 ft)
9.1 m (30 ft)
w/ resistor cap, Black
6P, Gray
Standard for European

market
Optional for other markets
1
2
3
4
5
6
7
8
9
10
A
3-34
System diagram
Single engine application (conventional gauge)
*1 7
W(+) 14
W
15
W B
3
R
R
B
W
R
4
W/R
Or
G/W
Pu/W B
Or
Or/B
Pu/W
B
Gy
Pu
Pu
Or
W/R
R Y L
B G
1
G/W
P
P
G/R
G/R
Gy
B
W
16
L
L
Pu
G
Y R R R B Y
Y
Y
Y
Or
10
OUT
UP
IN
Or
13
5
12
11
Gy
P
P
G
G/R
P/W
P/B
P/B
3-35
8 *1
System diagram
Ref.
No.
Part name
Remote control box
Fuel management gauge
Speedometer
4
5
6
7
8
Tachometer
Fuel tank (fuel level sensor)
Fuel flow sensor
GPS
Speedometer hose
Conventional gauge harness
10
11
Main wire harness

Fuel hose
12
Lamp switch
13
14
15
16
Fuel management gauge harness

GPS wire
Wire lead for speedometer
Wire lead for digital meter
Part No.
703-48201-A5
703-48205-A7
703-48207-A7
6Y5-83500-F2
6Y5-83570-S6
6Y5-83500-30
6Y5-8350T-91
6Y5-85752-02
688-83557-00
6Y5-83653-00
6Y5-83653-10
6Y5-83653-20
6Y5-83653-30
6Y5-83653-40
6Y5-83653-50
688-82520-00
688-82526-00
6Y5-83553-F1
6Y5-85721-F0
6Y5-87122-S0
6Y5-83553-M0
Remarks
w/ tilt switch
For additional trim switch
1
2
NMEA0183
6 m (20 ft)
5 m (16 ft)
6 m (20 ft)
7 m (23 ft)
8 m (26 ft)
9 m (30 ft)
10.5 m (34 ft)
0.1 m (0.33 ft)

0.1 m (0.33 ft)
8.0 m (26 ft)
NMEA0183
2.5 m (8 ft)
*1. When a GPS (NMEA0183) is used, a speedometer hose is not required.

Color code
B
: Black
G
: Green
Gy
: Gray
L
: Blue
Or
: Orange
P
: Pink
Pu
: Purple
R
: Red
W
: White
Y
: Yellow
G/R : Green/Red
G/W : Green/White
Or/B : Orange/Black
P/B : Pink/Black
P/W : Pink/White
Pu/W : Purple/White
W/R : White/Red
3
4
5
6
7
8
9
10
A
3-36
System diagram
Twin engine application (Digital Network Gauge)
15
15
16
17
24
10
b
c
c
L W
11
11
11
A
18
b
a
12
13
b
c
c
c
14
B
18
19
22
7
6
11
RR R
11
P B P/B
13
Y B
23
12
Y B
c
c
c
b
a
11
11
11
10
9
20
2
1
1
3
P
P 4
3-37
3
P 4
21
System diagram
Ref.
No.
1
2
3
4
Part name
Engine ECM
Speed sensor kit
Water pressure sensor kit
Trim sensor
Main wire harness
6
7
8
9
10
Remote control box

Main switch
Multi-hub
Power supply wire
Resistor cap
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Pigtail bus wire
Main bus wire
Waterproof cap
Waterproof cap
Tachometer
Speedometer
GPS
Transom multi-sensor
Thru-hull multi-sensor 1
Thru-hull multi-sensor 2
Immobilizer (Y-COP)
Immobilizer power distribution wire 1
Fuel tank/GPS wire
Part No.
60V-8A4L1-11
63P-8A4L0-00
688-8258A-50
688-8258A-60
688-8258A-70
6K1-8258A-40
61B-8258A-01
704-48207-P1
6Y8-82570-03
6Y8-81920-01
6Y8-83553-01
6Y8-85371-01
6Y8-82521-01
6Y8-82521-11
6Y8-82521-21
6Y8-82521-31
6Y8-82521-41
6Y8-82521-51
6Y8-82553-01
6Y8-82553-50
6Y8-82553-11
6Y8-82553-21
6Y8-82553-31
6Y8-82553-41
6Y8-82582-01
6Y8-82582-11
6Y8-8350T-01
6Y8-8350F-01
6Y8-8350S-01
6Y8-83688-01
6Y8-83688-11
6Y8-83688-20
6Y8-86254-02
6Y8-86254-22
6H5-81315-00
6Y8-8356N-01
Remarks
0
5 m (16 ft)
6 m (20 ft)
7 m (23 ft)
8 m (26 ft)
9.5 m (31 ft)
w/ resistor cap, Black

w/ 10 A fuse, 2.4 m (8 ft)
6P, Gray
0.3 m (1 ft)
0.6 m (2 ft)
0.9 m (3 ft)
1.8 m (6 ft)
2.7 m (9 ft)
3.6 m (12 ft)
0.3 m (1 ft)
3.0 m (10 ft)
4.6 m (15 ft)
6.1 m (20 ft)
7.6 m (25 ft)
9.1 m (30 ft)
2P, Red
4P, White
NMEA0183
Plastic body
Bronze body
Standard for European
market
Optional for other markets
4
5
6
7
8
9
10
NMEA0183
A
3-38
System diagram
a. Power port
b. Bus port
c. Device port
A. PORT
B. STBD
Color code
B
: Black
L
: Blue
P
: Pink
R
: Red
W
: White
Y
: Yellow
P/B : Pink/Black
3-39
System diagram
MEMO
0
1
2
3
4
5
6
7
8
9
10
A
3-40
System diagram
Twin engine application (conventional gauge)
13
L Y
*1
YAMAHA
SPEED
G
R
Y
L
Km/ h
knot
mph
km
mile
TRIP
TIME
set
15
W
16
W R
B W
R
3 W
W (+)
LY Y
R
B
B
B
3
TTL
mode
G/W
B
Pu/W
G/R
Or
G/R Or/B
Pu/W
G
B
2
1
set
ECON SYNC
set
G G
R B Y B YR
mode
mode
G G/W LY
Gy G/W
W/R
Br
Or P
Br
G/R
B G B
G
Pu
P
P
R
P G/R
R
L Y
L
Y
Pu
W
W
W
Y
W
L
G
Gy
Or
L
Y
P
R
P
R B
W/R
B
G
Br G
Br
2
Sb Br
R
R
Lg
Br
Lg Br
R
B
Sb
Br
1
Sb Br
R
B
Lg
Br
Lg
Br
R
B
Sb Br
9
UP
Or
Pu
Pu
14
Pu/W
B
B
IN
IN
OUT
Gy
Km/ L
mpg
2
1
set
Gy
P
P
4
3
R B
Y
L
B
Y
1/h
gph
5
x100
r/min
17
5
4
x100
r/min
TACH
WB
TACH
YAMAHA
FUEL MANAGEMENT
11
10
UP
*1 8
mode
OUT
B
R
BATT
Or
12
Pu
11
Or/B
10
B
B
Or
12
Gy G
P G/R
P P/W
Gy G
P G/R
P P/W
P/ B P/ B
P/B
3-41
P/B
System diagram
Ref.
No.
1
2
3
4
Part name
Remote control box
Main switch
Tachometer
Speedometer
6
7
8
9

Fuel flow sensor
GPS
Speedometer hose
10
Conventional gauge harness
11
Main wire harness
12
Fuel hose
13
Lamp switch
14
15
16
17
Fuel management gauge harness

GPS wire
Wire lead for speedometer
Wire lead for digital meter
Part No.
704-48207-P1
61B-82570-04
6Y5-8350T-91
6Y5-83500-F2
6Y5-83570-S6
6Y5-83500-30
6Y5-85752-02
688-83557-00
6Y5-83653-00
6Y5-83653-10
6Y5-83653-20
6Y5-83653-30
6Y5-83653-40
6Y5-83653-50
688-8258A-50
688-8258A-60
688-8258A-70
6K1-8258A-40
61B-8258A-01
688-82520-00
688-82526-00
6Y5-83553-F1
6Y5-85721-F0
6Y5-87122-S0
6Y5-83553-N0
Remarks
0
1
NMEA0183
6 m (20 ft)
5 m (16 ft)
6 m (20 ft)
7 m (23 ft)
8 m (26 ft)
9 m (30 ft)
10.5 m (34 ft)
5 m (16 ft)
6 m (20 ft)
7 m (23 ft)
8 m (26 ft)
9.5 m (31 ft)
0.1 m (0.33 ft)
0.1 m (0.33 ft)
8.0 m (26 ft)
NMEA0183
2.5 m (8 ft)
*1. When a GPS (NMEA0183) is used, a speedometer hose is not required.

Color code
B
: Black
Br
: Brown
G
: Green
Gy
: Gray
L
: Blue
Lg
: Light green
Or
: Orange
P
: Pink
Pu
: Purple
R
: Red
Sb
: Sky blue
W
: White
Y
: Yellow
G/R
G/W
Or/B
P/B
P/W
Pu/W
W/R
: Green/Red
: Green/White
: Orange/Black
: Pink/Black
: Pink/White
: Purple/White
: White/Red
2
3
4
5
6
7
8
9
10
A
3-42
Rigging recommendation
Battery cable length
The table below shows the battery cable length from the negative terminal of the battery cable to the
rigging grommet.
The positive battery cable is 100 mm (3.9 in) longer than the negative battery cable.
Length (L)
2.61 m (9 ft)
100 mm
(3.9 in)
(L)
Extension length recommendation for battery cable
Do not exceed the recommended extension length for the battery cable. Otherwise, the electrical system could be damaged or operate improperly.
To extend the length of battery cables, follow the requirements in the tables for battery capacity,
cable size, and ambient temperature.
The maximum total extension length is the total combined length of the positive and negative battery
cables.
Select an extension battery cable and terminal that meet ABYC requirements or the equivalent.
Select the battery stud that is best-suited to the terminal size.
Solder the cable and terminal connections to prevent them from corroding.
Ambient temperature is 0 C (32 F) and above
Battery requirements
Cable specifications
Maximum total extension length
(Positive battery cable + Negative battery cable)
Minimum
Unit
capacity
20 mm2
30 mm2
50 mm2
60 mm2
(AWG4)
(AWG2)
(AWG1/0)
(AWG2/0)
CCA/EN
640 A
2.9 m
4.4 m
7.3 m
8.8 m
(9.5 ft)
(14.4 ft)
(24.0 ft)
(28.9 ft)
20HR/IEC
80 Ah
CCA/EN
750 A
3.2 m
4.8 m
8.0 m
9.6 m
(10.5 ft)
(15.7 ft)
(26.2 ft)
(31.5 ft)
20HR/IEC
120 Ah
Ambient temperature is below 0 C (32 F)
Battery requirements
Cable specifications
Maximum total extension length
(Positive battery cable + Negative battery cable)
Minimum
Unit
capacity
30 mm2
50 mm2
60 mm2
20 mm2
(AWG4)
(AWG2)
(AWG1/0)
(AWG2/0)
CCA/EN
750 A
1.8 m
2.7 m
4.5 m
5.4 m
(5.9 ft)
(8.9 ft)
(14.8 ft)
(17.7 ft)
20HR/IEC
120 Ah
3-43
1. Extension battery cable
2. Battery switch
ON/OFF
0
1
2
3. Battery
4. Original battery cable
3
1. Extension battery cable
2. Battery switch
3. Battery
4. Original battery cable
4
5
6
7
8
9
10
A
3-44
Propeller selection
Propeller selection
The size and type of propeller that is used will affect the performance of a boat and outboard motor
critically. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even
boating and steering capabilities. An incorrect choice could adversely affect performance and could
also damage the engine seriously.
Use the following information as a guide for selecting a propeller that meets the operating conditions
of the boat and outboard motor.
Propeller size
The size of the propeller is indicated on the propeller boss end, or on the side of the propeller boss.
c
a
b
c
a. Propeller diameter (in inches)

b. Propeller pitch (in inches)
c. Propeller type (propeller mark)
Selection
With the engine speed at full throttle operating range and under a maximum boat load, the engine
speed should be within the upper half of the full throttle operating speed range.
Full throttle operating range:
50006000 r/min
Regular rotation model
Blade
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Dia. (in)
15 1/4
14 5/8
14 1/2
14
13 3/4
13 1/2
13 3/4
13 3/4
13 3/4
13 3/8
13 3/8
14 1/2
14 1/4
14 1/4
13 3/4
Pitch (in)
15
16
17
19
21
23
17
19
21
23
25
15
17
18
19
Mark
M
M
M
M
M
M
M2
M2
M
M
M
M
M
M
M
Material
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
3-45
Part number
6G5-45941-00
6G5-45952-00
6G5-45947-01
6G5-45945-01
6G5-45943-01
6G5-45949-00
6G5-45978-03
6G5-45974-03
6G5-45972-02
6G5-45976-01
6G5-45930-00
68F-45970-10
68F-45972-10
68F-45978-10
68F-45974-10
Remarks
*1
*1
*1
*1
*1
*1
*1
*1
*1
*1
*1
*2
*2
*2
*2
Propeller selection
Blade
3
3
3
3
3
4
4
4
Dia. (in)
13 3/4
15 1/2
15 1/4
15
14 3/4
15
15
15
Pitch (in)
21
17
19
21
23
21
22
23
Mark
M
T
T
T
T
T
T
T
Material
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Part number
68F-45976-10
6CE-45978-00
6CE-45970-10
6CE-45972-10
6CE-45974-00
6CE-45B70-00
6CE-45B72-00
6CE-45B74-00
Remarks
*2
*2
*2
*2
*2
*2
*2
*2
*1. These propellers cannot be installed using the spacer 1. Use the spacer 2 instead.
*2. Shift Dampener System (SDS) propeller.
0
1
2
3
4
5
6
7
8
9
10
A
3-46
Propeller selection
Counter rotation model
Blade
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
4
4
4
Dia. (in)
14 1/2
14
13 3/4
13 3/4
13 3/4
13 3/8
14 1/2
14 1/4
14 1/4
13 3/4
13 3/4
15 1/2
15 1/4
15
14 3/4
15
15
15
Pitch (in)
17
19
17
19
21
23
15
17
18
19
21
17
19
21
23
21
22
23
Mark
ML
ML
ML1
ML1
ML
ML
ML
ML
ML
ML
ML
TL
TL
TL
TL
TL
TL
TL
Material
Aluminum
Aluminum
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Part number
6K1-45947-00
6K1-45945-00
6K1-45978-02
6K1-45974-02
6K1-45972-01
6K1-45976-00
68G-45970-10
68G-45972-10
68G-45978-10
68G-45974-10
68G-45976-10
6CF-45978-00
6CF-45970-10
6CF-45972-10
6CF-45974-00
6CF-45B70-00
6CF-45B72-00
6CF-45B74-00
Remarks
*1
*1
*1
*1
*1
*1
*2
*2
*2
*2
*2
*2
*2
*2
*2
*2
*2
*2
*1. These propellers cannot be installed using the spacer 1. Use the spacer 2 instead.
*2. Shift Dampener System (SDS) propeller.
3-47
Troubleshooting
YDIS .................................................................................... 4-1
Basic components ..................................................................... 4-1
Function ..................................................................................... 4-2
Connecting the communication cable ....................................... 4-7
Outboard motor troubleshooting ..................................... 4-8

Troubleshooting procedure ....................................................... 4-8
Troubleshooting the power unit using the YDIS ........................ 4-8
Trouble code and checking step ............................................. 4-10
Troubleshooting the power unit
(trouble code not detected) ..................................................... 4-15
Troubleshooting the PTT unit .................................................. 4-20
Troubleshooting the lower unit ................................................ 4-21
0
1
2
3
4
5
6
7
8
9
10
YDIS
YDIS
The Yamaha Diagnostic System uses precision fault diagnosis to offer better serviceability at a time
when there is increasing demand for service tools for electronically controlled products. It provides
quick, reliable, safe, and reasonable service, and is intended to obtain customer satisfaction. The
Yamaha Diagnostic System features updated software and expanded tool functions that allow it to
respond to new models and technologies, maintaining compatibility with regulations. This manual
contains the model-specific information. See YDIS (Ver. 2.10 or later) instruction manual for detailed
information.
Basic components
1
4
***
******
******
5
6
11
10
9
No.
1
2
3
4
5
6
7
8
9
10
11
Part name
YDIS 2 starter kit
CD-ROM
Adapter
USB cable
Adapter cap
AD harness
CAN-Line harness
K-Line harness
Power supply harness
Trigger switch harness
Trigger switch extension harness
Qty
1
1
1
1
1
1
1
1
1
1
1
4-1
Remarks
90890-06883
Software and instruction manual
5 m (16.4 ft)
For external input
YDIS
Function
YDIS version 2.10 comprises the following items.
1. Start
2. Engine
3. Diagnosis
4. Diagnosis
5. Diagnosis
Record
6. Engine Record
7. Engine operating
hours by RPM
8. Engine Monitor
9. Digital Display
10. Graph Display
11. Input Setting
12. Component Test
13. Stationary Test
14. Active Test
28. Update
15. Data Logger
29. Setting
16. Logger Graph
17. ECM Rec Graph
30. Off Line
18. Logging
19. Record Set
20. Show Data
21. Clear Data
22. Engine oil

change record
23. Boat System
24. Tilt Limiter
25. R/C System

Reset
26. Maintenance
31. CAN Information
27. Check Engine
32. Communication
List
9
10
33. Bus Statistics
A
4-2
YDIS
1. Start
2. Engine
3. Diagnosis
4. Diagnosis
5. Diagnosis Record
6. Engine Record
7. Engine operating hours by RPM
8. Engine Monitor
9. Digital Display
10. Graph Display
11. Input Setting
12. Component Test
13. Stationary Test
14. Active Test
15. Data Logger
16. Logger Graph
17. ECM Rec Graph
18. Logging
19. Record Set
20. Show Data
21. Clear Data
22. Engine oil change record
23. Boat System
24. Tilt Limiter
25. R/C System Reset
26. Maintenance
27. Check Engine
28. Update
29. Setting
30. Off Line
31. CAN Information
32. Communication List
33. Bus Statistics
4. Diagnosis
Displays diagnosis codes recorded in the engine ECM, item names, and current item conditions.
This enables detection of items with problems. The trouble codes displayed are the same as those
described in this chapter. See Trouble code and checking step (4-10).
5. Diagnosis Record
Displays diagnosis codes recorded in the engine ECM, item names, and when problems are
detected. The fault diagnosis history can be erased. The trouble codes displayed are the same as
those described in this chapter. See Trouble code and checking step (4-10).
6. Engine Record
Data recorded on the engine ECM related to various controls for engine speed (max.) and engine
speed, and the time and the number of times the controls occurred is displayed as a list.
Engine speed (max.)
Overheat count
Knock count
Over-rev. count
Low oil pressure count
Total hours of operation
7. Engine operating hours by RPM

Displays both operating hours and total operating hours for different engine speeds.
4-3
YDIS
8. Engine Monitor
Displays engine ECM conditions (sensor information) in real time. 9. Digital Display displays
these in digital form, and 10. Graph Display displays these in graph form. Additionally, connecting a commercially available external device and configuring 11. Input Setting enables display of
the Engine Monitor.
Engine speed
Fuel injection duration
Intake air pressure
Ignition timing
Multi-engine system
TPS 1
Engine temperature
Throttle valve opening angle
Intake air temperature
Thermo switch
TPS 2
Oil pressure
Main switch
APS1
Intake cam timing
Main relay
APS2
Cooling water pressure
ETV relay
Atmospheric pressure
Speed
Engine start switch
Battery voltage
Engine shut-off switch
Fuel pump relay
13. Stationary Test

When the engine is stopped and the shift is in the N position, operate the parts to check, and perform tests to check operating conditions and operating noise.
Activate ignition coil (#1#4)
Activate OCV
Activate injector (#1#4)
Activate low-pressure fuel

pump
Activate electric fuel pump *1
*1. Activate high-pressure fuel pump

14. Active test
While the engine is running and the shift is in the N position, operate the parts to check, and perform tests to check operating conditions and the engine condition.
Drop cylinder (#1#4)
16. Logger Graph
Displays in graph form engine operation data stored in the ECM for the last 19 minutes in 1-minute
intervals.
Engine speed
TPS
Intake air pressure
Battery voltage
Engine temperature
Oil pressure
0
1
2
3
4
5
6
7
8
9
10
A
4-4
YDIS
17. ECM record graph
When a problem occurs in the electronic throttle system, the data for 2 seconds before and after
the problem is recorded on the ECM, for a total of 4 seconds. The recorded data is displayed in
graph form.
Engine speed
Ref. TPS voltage *2
ETV relay
APS1
Ref. APS voltage *3
Overheat warning
APS2
Target TPS voltage for ISC *4
Low oil pressure
TPS 1
Engine stop mode
Engine hour
TPS 2
Engine start mode
Trig
Intake air pressure
Engine stop mode with SW
Code
Battery voltage
Target TPS voltage *1
Main relay
*1. This item shows the target output voltage of the TPS.
This value is the control voltage that the engine ECM requires to set the target opening
angle of the throttle valve.
*2. Reference TPS voltage is a recorded value of the TPS voltage when the throttle valve is
fully closed.
*3. Reference APS voltage is a recorded value of the APS voltage when the APS is fully
closed.
*4. Target TPS voltage for ISC is a voltage required for the engine ECM to set the throttle
valve opening angle to the opening angle of the idle speed.
18. Logging
While the computer and the outboard motor are not connected, records Engine Monitor data
using the adapter. Use 19. Record Set to set items to record.
20. Show Data saves logged data in the computer, and displays this data in graph form. 21.
Clear Data deletes data and conditions stored in the adapter.
22. Engine oil change record
It is possible to maintain oil change records using this function.
28. Update
It is possible to update the database when update information is provided.
29. Setting
Switches the language to use in the YDIS (English, French, Spanish, and Japanese).
It is possible to select units when connected via the CAN-Line.
30. Off Line
Displays graph data saved in the Engine Monitor (Graph Display) and Logging even when the
computer is not connected to the outboard motor.
Record settings for logging, deleting data, and data playback are possible even when the computer is not connected to the outboard motor.
4-5
YDIS
32. Communication List
By connecting the YDIS to a multi-hub via a CAN-Line, displays the name of Yamaha genuine
parts connected to the Digital Network. This enables to check that the connections are correct.
33. Bus Statistics
By connecting the YDIS to a multi-hub via a CAN-Line, displays the bus load connected to the Digital Network. If the bus load is higher than 40 %, then check the connection status.
0
1
2
3
4
5
6
7
8
9
10
A
4-6
YDIS
Connecting the communication cable

CAN-Line
2. Adapter cap
3. Adapter
4. USB cable
1. CAN-Line harness
5. Multi-hub
5. Multi-hub
1. CAN-Line harness
2. Adapter cap
3. Adapter
4. USB cable
5. Multi-hub
K-Line
2. Adapter cap
1. Adapter
a. YDIS coupler
3. USB cable
1. Adapter
2. Adapter cap
3. USB cable
4. K-Line harness
4. K-Line harness
a. YDIS coupler (gray)
4-7
Outboard motor troubleshooting

Troubleshooting procedure
1. Before troubleshooting the outboard motor, check that fresh fuel of the specified type has been
used.
2. Check that all electrical connections are secure and free from corrosion, and that the battery is
fully charged.
3. Check the trouble code using the YDIS first, and then check the electronic control system following the trouble code chart.
4. When a trouble code is detected, check the data logger of the engine ECM record graph as well.
5. If a trouble code is not detected, check the power unit according to Troubleshooting the power
unit (trouble code not detected) (4-15).
6. Before using the YDIS to check the power unit, check the engine ECM circuit. See Checking
the engine ECM circuit (5-21).
TIP:
When deleting the diagnosis record on the YDIS, make sure to check the time that the trouble
codes were detected.
When checking the input voltage of a part, the coupler or connector must be disconnected. As a
result, the engine ECM determines that the part is disconnected and a trouble code is detected.
Therefore, make sure to delete the diagnosis record after checking the input voltage.
Since the main relay comes on for approximately 10 seconds after the engine start switch is
turned to OFF, the power of the engine ECM cannot be turned off. Therefore, if the engine start
switch is turned to ON within 10 seconds after it was turned to OFF, the trouble codes cannot be
deleted.
Troubleshooting the power unit using the YDIS

1. Use the trouble codes displayed by the YDIS to check each part according to the Trouble code
and checking step table.
2. Delete the trouble codes after checking, repairing, or replacing a part and check that the trouble
codes are not detected again. If the same trouble codes are detected, the engine ECM may be
faulty.
3. Check the items listed in the table. If all of the items are in good condition, delete the trouble
codes, and then check the trouble codes again. If the same trouble codes are detected again,
the engine ECM is faulty.
0
1
2
3
4
5
6
7
8
9
10
A
4-8

Trouble code table
: Indicated
: Not indicated
Code No.
Item
YDIS diagnosis
YDIS diagnosis record
13
Pulser coil
15
17
19
Knock sensor
Battery voltage
23
Air temperature sensor
24
Cam position sensor (EX)
27
Water in fuel filter
28
29
Air pressure sensor
37
Intake air passage
39
Oil pressure sensor
44
45
72
Cam position sensor
74
OCV
86
Immobilizer
112,113,
114,115,
116,117,
119,123,
129,138,
141,142,
143,144,
145
ETV
124,125,
126,127,
128
TPS
131,132,
133,134,
135
APS
4-9
Trouble code and checking step

: Not applicable
Trouble
code
13
15
17
19
23
24
Item
(Condition)
Symptom
Checking steps
Measure the pulser coil air gap.

Measure the pulser coil output
peak voltage.
Measure the pulser coil resisCheck Engine is displayed.
Pulser coil
tance.
Engine stops suddenly.
(Irregular signal)
Check for wiring continuity
Engine does not restart.
between the pulser coil and the
engine ECM.
Check the protrusions on the flywheel magneto for damage.
Measure the engine temperature
sensor input voltage.
Check Engine is displayed.
Engine temperaHigh engine idle speed
Measure the engine temperature
ture sensor
Degraded acceleration perforsensor resistance.
(Out of specificamance
tion)
Declining maximum engine speed between the engine temperature
sensor and the engine ECM.
Measure the knock sensor resistance.
Knock sensor
(Irregular signal) High engine idle speed
between the knock sensor and the
engine ECM.
Check the battery cable and terminals for proper connection.
Measure the lighting coil output
Battery voltage and battery alert peak voltage.
are displayed.
Battery voltage
Measure the lighting coil resis(Below specified Engine operates normally.
tance.
Engine does not restart (depends
voltage)
Measure the Rectifier/Regulator/
on battery condition).
Isolator output peak voltage.
Check the Rectifier/Regulator/Isolator for continuity.
Check the intake air temperature
using the YDIS.
Air temperature
sensor
(Out of specifica- High engine idle speed
between the intake air pressure/
tion)
temperature sensor and the
engine ECM.
Measure the cam position sensor
input voltage.
Cam position sen- High engine idle speed
output voltage.
sor (EX)
Degraded acceleration perforCheck for wiring continuity
(Irregular signal) mance
between the cam position sensor
Declining maximum engine speed
and the engine ECM.
Check the brim of the camshaft.
See
page
7-1
5-33
5-33
A-5
7-17
5-34
5-34
A-5
2
3
4
5-35
A-5
10-4
5-29
5-29
5-30
5-30
5-34
A-5
5-23
5-23
5
6
7
8
9
10
A-4
7-46
A
4-10

Trouble
code
27
28
29
37
39
45
Item
(Condition)
Water in fuel filter

(Water in fuel filter)
Shift position
switch (Irregular
signal)
Air pressure sensor

(Out of specification)
Intake air passage

(Air leak)
Oil pressure sensor

(Out of specification)

(Irregular signal)
Symptom
Checking steps
Check the fuel filter for water.

Measure the water detection
switch input voltage.
Water in fuel is displayed.
Check the water detection switch
Alert buzzer comes on while the
for continuity.
shift is in the N position.
between the water detection
switch and the engine ECM.
Check the gear shift operation.
Measure the shift position switch
input voltage.
Check the shift position switch for
Engine operates normally.
continuity.
between the shift position switch
and the engine ECM.
Measure the intake air pressure/
temperature sensor input voltage.
Measure the intake air pressure/
temperature sensor output voltHigh engine idle speed
age.
Declining maximum engine speed Check for wiring continuity
between the intake air pressure/
temperature sensor and the
engine ECM.
Check the gaskets of the intake
manifold and ETV.
High engine idle speed
Check the hose between the
Impossible to shift-in (When the
vapor shut-off valve and the intake
engine speed is more than
manifold.
1500 r/min).
Declining maximum engine speed Check the O-ring of the intake air
pressure/temperature sensor.
Check the oil pressure using the
YDIS.
Measure the oil pressure sensor
input voltage.
Measure the oil pressure sensor
Declining maximum engine speed output voltage.
between the oil pressure sensor
and the engine ECM.
Measure the shift cut-off switch
input voltage.
Measure the shift cut-off switch
resistance.
Higher idle speed
between the shift cut-off switch
and the engine ECM.
4-11
See
page
5-26
5-26
A-5
10-6
5-36
5-36
A-5
5-34
5-34
A-5
6-20
6-17
6-27
7-1
5-25
5-25
A-4
5-36
5-36
A-5

Trouble
code
72
74
86
112
113
114
115
116
117
Item
(Condition)
Symptom
Checking steps

input voltage.
Cam position sen- High engine idle speed
output voltage.
sor (IN)
Degraded acceleration perforCheck for wiring continuity
(Irregular signal) mance
between the cam position sensor
and the engine ECM.
Check the brim of the camshaft.
Check the OCV operation using
the YDIS.
Measure the OCV input voltage.
Measure the OCV resistance.
OCV
(Irregular load
Degraded acceleration perforbetween the OCV and the main
current value)
mance
relay.
Declining maximum engine speed Check for wiring continuity
between the OCV and the engine
ECM.
Check the OCV filter.
Check that the Y-COP is connected properly.
Immobilizer
(Communication
Measure the remote control
error)
receiver input voltage.
Check the Y-COP circuit.
ETV system
(Engine ECM
Throttle does not operate.
Replace the engine ECM.
internal circuit
Engine speed is set at approximalfunction)
mately 1500 r/min.
Measure the TPS output voltage
using the YDIS.
ETV system
Check the ETV circuit.
(Throttle valve
malfunction)
Engine speed is set at approxiCheck the fuse.
mately 1500 r/min.
Check the ETV motor relay.
ETV system
(Engine ECM
Engine will not start.
internal circuit
malfunction)
ETV system
(Throttle valve
Check the throttle valve operation.
mately 1500 r/min.
ETV system
Check the fuse.
(Throttle valve
Check the ETV.
mately 1500 r/min.
See
page
5-23
5-23
A-4
7-46
0
1
5-25
5-25
5-25
A-4
2
3
A-4
10-14
3-33
5-40
5-40
7-29
5-21
A-4
5-7
5-22
5
6
7
8
7-29
A-4
6-21
A-4
5-7
5-22
10
6-21
A
4-12

Trouble
code
119
123
124
125
126
127
128
129
131
132
133
134
135
138
Item
(Condition)
Symptom
Checking steps

Engine speed is set at approximately 1500 r/min.
ETV system
(Throttle valve
malfunction)
TPS
(Out of specifica- Degraded acceleration perfortion)
mance
TPS
(Out of specifica- Throttle does not operate.
tion)
TPS
Degraded acceleration perfor(Out of specificamance
tion)
ETV system
(Engine ECM
Degraded acceleration perforinternal circuit
mance
malfunction)
ETV system
(Throttle valve
malfunction)
A-4

Check the fuse.
A-4
5-7
5-22

using the YDIS.
5-21
A-4

using the YDIS.
Measure the TPS input voltage.
4-13
5-21
5-21
A-4

using the YDIS.
5-21
A-4
7-29
Measure the APS output voltage

using the YDIS.
Measure the APS input voltage.
Measure the APS resistance.
Check the APS circuit.
using the YDIS.
APS
mance
Measure the APS resistance.
Declining maximum engine speed Check the APS circuit.
using the YDIS.
APS
(Out of specifica- Throttle does not operate.
tion)
Engine speed is set at approxiMeasure the APS resistance.
mately 1500 r/min.
Check the APS circuit.
ETV system
(Engine ECM
internal circuit
mately 1500 r/min.

APS
mance
See
page
5-22
5-22
5-22
A-4
5-22
5-22
5-22
A-4
5-22
5-22
5-22
A-4
7-29

Trouble
code
Item
(Condition)
Symptom
Checking steps
141
ETV system
(Throttle valve
malfunction)

142
ETV system
(Throttle valve
malfunction)

Declining maximum engine speed Replace the ETV.
143
ETV system
(Engine ECM
internal circuit
malfunction)

144
145
ETV system
(Throttle valve
malfunction)
ETV system
(Throttle valve
malfunction)

Check the battery cable and terminals for proper connection.

Check the fuse.
Measure the lighting coil output
peak voltage.
Measure the lighting coil resistance.
Measure the Rectifier/Regulator/
Isolator output peak voltage.
Check the Rectifier/Regulator/Isolator for continuity.
Check that other trouble codes
(112144) are detected.
See
page
A-4
6-21
6-21
0
1
7-29
10-4
5-7
5-29
5-29
5-30
5-30
4-9
6-21
6
7
8
9
10
A
4-14
Troubleshooting the power unit (trouble code not detected)

Troubleshooting consists of the following 3 items:
Symptom 1: Specific trouble conditions
Symptom 2: Trouble conditions of an area or individual part
Cause: Trouble causes of symptom 2
: Not applicable
Symptom 1: Engine does not crank.
Symptom 2
Starter motor does not

operate
Cause
Checking steps
Gear shift not in the N position

Blown fuse
Starter relay malfunction
Engine start switch malfunction
Neutral switch malfunction
Short, open, or loose connection in starter motor circuit
Starter motor malfunction
Stuck piston or crankshaft

Starter motor operates,
but the engine does not
Stuck drive shaft
crank
Set the gear shift to the N position.

Check the fuse.
Check the starter relay.
Check the engine start switch.
Check the neutral switch.
Measure the starter relay input voltage.
Check the wire harness for continuity.
Disassemble and check the starter
motor.
Disassemble and check the power unit.
Check the drive shaft bushing.
Disassemble and check the lower unit.
See
page
10-6
5-7
5-37
5-38
5-37
A-6
5-45
7-84
9-15
9-30
8-53
Symptom 1: Engine will not start (engine cranks).

Symptom 2
Cause
Checking steps
Blown fuse
Main relay malfunction
Engine ECM does not
operate
Short, open, or loose connection in the engine ECM circuit
Pulser coil malfunction

Spark plug does not produce a spark
Short, open, or loose connec(all cylinders)
tion in the pulser coil circuit
Y-COP is locked.
4-15
Check the fuse.

Check the main relay.
Check for wire harness continuity
between the main relay and the engine
ECM.
Check for continuity between the engine
ECM and ground.
Measure the pulser coil output peak voltage.
Measure the pulser coil resistance.
Check for wire harness continuity
between the pulser coil and the engine
ECM.
Unlock Y-COP.
See
page
5-7
5-20
5-21
5-21
5-33
5-33
A-5
3-23

Symptom 2
Cause
Checking steps
Pinched or kinked fuel hose

Fuel leakage
Fuel not supplied (all

cylinders)
is low
Measure the fuel pressure.

Check the fuel hose.
Check the fuel line for leakage.
Check the fuel filter element for dirt and
Clogged fuel filter element
obstructions.
Blown fuse
Check the fuse.
Check the high-pressure fuel pump operHigh-pressure fuel pump mal- ation using the YDIS.
function
Measure the high-pressure fuel pump
resistance.
Check the high-pressure fuel pump input
voltage.
Check for wiring continuity between the
Short, open, or loose connechigh-pressure fuel pump and the engine
tion in high-pressure fuel pump
ECM.
circuit
high-pressure fuel pump and the highpressure fuel pump relay.
High-pressure fuel pump relay
Check the high-pressure fuel pump relay.
malfunction
Check the low-pressure fuel pump input
voltage.
Short, open, or loose conneclow-pressure fuel pump and the engine
tion in low-pressure fuel pump
ECM.
circuit
low-pressure fuel pump and the main
relay.
Low-pressure fuel pump mal- Check the low-pressure fuel pump resisfunction
tance.
Open check valve
Check the check valve.
Measure the compression pressure.

Check the valve timing.
Improper valve timing
Check the timing belt.
Check the valve for bends and sticking.
Check the piston and piston rings for
Compression leakage
damage.
Check the cylinder for scratches.
See
page
6-6
6-1
6-1
6-11
5-7
5-27
5-27
5-27
A-5
1
2
3
A-5
5-28
5-27
A-5
A-5
4
5
6
5-27
6-41
7-1
7-22
7-22
7-57
7
8
7-84
7-87
9
10
A
4-16

Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited
engine speed.
Symptom 2
Cause
Checking steps
Check the ignition spark.

Check the spark plug.
Measure the ignition coil input voltage.
Spark plug does not pro- Short, open, or loose connecignition coil and the engine ECM.
duce a spark (some cyl- tion in ignition coil circuit
inders)
ignition coil and the main relay.
Exchange the ignition coil with a different
Ignition coil malfunction
one, and then check the ignition spark.
Engine ECM malfunction
Measure the fuel pressure.

Fuel leakage
Check for fuel leakage.
Pressure regulator malfunction Check the pressure regulator.
Check the fuel filter for dirt and obstrucFuel pressure is low
Clogged fuel filter
tions.
High-pressure fuel pump mal- Measure the high-pressure fuel pump
function
resistance.
Open check valve
Check the check valve.
Check the fuel injector operation using
the YDIS.
Fuel injector malfunction
Measure the fuel injector resistance.
Measure the fuel injector input voltage.
Fuel not supplied (some
Short, open, or loose conneccylinders)
fuel injector and the main relay.
tion in fuel injector circuit
fuel injector and the engine ECM.
Clogged fuel injector
Replace the fuel injector.
Engine ECM malfunction
Measure the compression pressure.

Check the valve timing.
Improper valve timing
Check the timing belt.
Check the valve for bends and sticking.
is low
Check the piston and piston rings for
Compression leakage
damage.
Check the cylinder for scratches.
Spark plug malfunction
4-17
See
page
5-32
7-35
5-33
A-5
A-5
5-32
7-29
6-6
6-1
6-7
6-11
5-27
6-41
5-27
5-27
5-27
A-5
A-5
6-23
7-29
7-1
7-22
7-22
7-57
7-84
7-87

Symptom 1: High engine idle speed.
Symptom 2
Cause
Checking steps
Air leakage (ETVcylinder

head)
Check the gaskets of the intake manifolds, intake air pressure/temperature

sensor, and ETV.
See
page
6-20
6-27
Symptom 1: Engine stalls, unstable engine idle speed, or poor acceleration.

Symptom 2
Cause
Checking steps
Check the OCV valve operation using
the YDIS.
Check the OCV plunger.
Replace the OCV filter.
Check the oil passage.
Replace the VCT assembly.
Stuck OCV plunger

Improper intake cam
timing
Clogged OCV filter

Clogged oil passage
Stuck VCT
See
page
5-25
5-25
10-14
2-21
7-42
0
1
2
3
Symptom 1: Limited engine speed (below 20003000 r/min).

Symptom 2
Cause
Checking steps
Thermo switch malfunction
Clogged cooling water inlet

Buzzer comes on.
Overheat alert
indicator comes on.
Water pump malfunction
Clogged cooling water passage

Open PCV
Thermostat malfunction
Insufficient engine oil
Buzzer comes on.

Oil pressure alert indicator comes on.
Engine oil pressure decrease
Measure the thermo switch input voltage.

Check the thermo switch for continuity.
Check for continuity between the thermo
switch and the engine ECM.
Check the cooling water inlet.
Check the impeller.
Check the impeller key.
Check the water pump housing.
Check the insert cartridge.
Check the outer plate cartridge.
See
page
5-35
5-35
A-5
10-8
8-8
8-8
8-8
8-8
8-8
Check the cooling water passage.
2-23
Check the PCV.

Check the thermostat.
Check the engine oil level.
Check for engine oil leakage.
Check the valve stem seals and valves.
Check the piston rings.
Measure the oil pressure.
Check the oil pump.
Check the oil strainer.
Check the relief valve.
Check the oil passage (power unit and
oil pump).
Replace the oil filter.
7-68
7-68
10-5
2-21
7-52
7-88
7-1
7-80
9-21
7-76
5
6
7
8
9
10
2-21
10-12
A
4-18

Symptom 1: Discharged battery.
Symptom 2
Low voltage indicator

activates on the gauge
Cause
Checking steps
Check the battery capacity and specific

gravity.
Battery performance decrease
Check the battery cables and terminals
for proper connection.
Short, open, or loose connec- Check the charging circuit for proper
tion in charging circuit
connection and damage.
Measure the lighting coil output peak
voltage.
Stator assembly malfunction
Measure the lighting coil resistance.
Measure the Rectifier/Regulator/Isolator
output peak voltage.
malfunction
Check the Rectifier/Regulator/Isolator for
continuity.
See
page
10-4
5-29
5-29
5-30
5-30
Symptom 1: Y-COP lock and unlock do not function.

Symptom 2
Cause
Checking steps
Check the button cell battery voltage.

Y-COP remote control transmitReplace with a spare remote control
There is an answer-back ter malfunction
transmitter.
(beep)
Short, open, or loose connecCheck the Y-COP circuit.
tion of the wire harness
See
page
5-41
5-40
Symptom 1: Y-COP lock and unlock function, but there is no answer-back (beep).
Symptom 2
Cause
Checking steps
Buzzer malfunction
Short, open, or loose connection of the wire harness
4-19
Check the buzzer.

Measure the buzzer input voltage.
Check the Y-COP circuit.
See
page
5-40
5-40
5-40
Troubleshooting the PTT unit

: Not applicable
Symptom 1: PTT unit does not operate.

Symptom 2
Cause
Checking steps
Blown fuse
PTT switch malfunction
PTT relay malfunction
PTT relay does not operate
PTT motor does not

operate
PTT fluid pressure does

not increase
Short, open, or loose connection of the wire harness
PTT motor malfunction

Short, open, or loose connection of the PTT motor lead
Bent tilt ram or trim ram
Stuck tilt ram or trim ram
Manual valve opened

Insufficient PTT fluid
PTT fluid leakage
Check the fuse.

Check the PTT switch.
Check the PTT relay.
Measure the PTT switch input voltage.
Measure the PTT relay input voltage.
Check for continuity between the PTT
switch and the PTT relay.
PTT switch and the fuse.
Check the PTT motor.
PTT motor and the PTT relay terminal.
Check the tilt ram and trim ram.
Disassemble and check the PTT unit.
Measure the PTT fluid pressure
Check the manual valve.
Add sufficient PTT fluid.
Check for PTT fluid leakage.
Check the filter for dirt and obstructions.
Check the valves for damage.
Check the fluid passages for obstructions.
Check the PTT motor.
Check the gear pump assembly.
Clogged fluid passage
PTT motor malfunction

Gear pump malfunction
See
page
5-7
5-52
5-51
5-52
5-52
A-6
A-6
9-54
Decrease in PTT fluid

pressure in lower chamber of PTT cylinders
Cause
Checking steps
Manual valve open

Insufficient PTT fluid
PTT fluid leakage
Check the manual valve.

Add sufficient PTT fluid.
Check for PTT fluid leakage.
Clogged or open fluid passage Check the valves for damage.

Check the fluid passages for obstructions.
2
3
4
A-6
9-66
9-66
9-48
9-51
10-16
10-16
9-61
9-66
9-64
9-64
9-61
9-66
9-54
9-64
Symptom 1: PTT unit does not hold the outboard motor up.
Symptom 2
See
page
9-51
10-16
10-16
9-61
9-66
9-64
9-61
9-66
5
6
7
8
9
10
A
4-20
Troubleshooting the lower unit

: Not applicable
Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate properly.
Symptom 2
Cause
Checking steps
Shift cable is not adjusted

properly
Shift rod does not operate
properly
Shift mechanism malfunction

(in lower unit)
4-21
See
page
Adjust the shift cable.
10-7
Check the shift lever operation.

Check the shift rod for wear.
Check the shift rod connection.
Check the dog clutch and related parts.
10-6
8-8
8-26
8-13
8-19
8-13
8-19
Check the forward gear, reverse gear,

and pinion for damage and wear.
Electrical system
Electrical component and wire harness routing ............ 5-1
Port ............................................................................................ 5-1
Starboard ................................................................................... 5-4
Fuse holder ............................................................................... 5-7
Rear ........................................................................................... 5-8
Front .......................................................................................... 5-9
Top .......................................................................................... 5-10
Bottom cowling ........................................................................ 5-12
0
1
2
ECM circuit diagram ....................................................... 5-14

ECM coupler layout ......................................................... 5-17
Checking the electrical component ............................... 5-19
Using the YDIS ........................................................................ 5-19
Measuring the peak voltage .................................................... 5-19
Using the digital tester ............................................................. 5-19
3
4
5
Engine control unit and component .............................. 5-20

Checking the main relay .......................................................... 5-20
Checking the engine ECM circuit ............................................ 5-21
Checking the ETV and TPS .................................................... 5-21
Checking the ETV motor relay ................................................ 5-22
Checking the APS ................................................................... 5-22
Checking the cam position sensor .......................................... 5-23
Checking the OCV ................................................................... 5-25
Checking the oil pressure sensor ............................................ 5-25
6
7
8
Fuel control unit and component .................................. 5-26

Checking the water detection switch ....................................... 5-26
Checking the fuel injector ........................................................ 5-27
Checking the low-pressure fuel pump and
high-pressure fuel pump .......................................................... 5-27
Checking the high-pressure fuel pump relay ........................... 5-28
Checking the vapor shut-off valve ........................................... 5-29
9
10
Charging unit and component ....................................... 5-29

Checking the lighting coil (stator assembly) ............................ 5-29
Checking the Rectifier/Regulator/Isolator ................................ 5-30
Electrical system
Ignition unit and component .......................................... 5-32
Checking the ignition spark ..................................................... 5-32
Checking the ignition coil ......................................................... 5-33
Checking the pulser coil .......................................................... 5-33
Checking the intake air temperature sensor ............................ 5-34
Checking the intake air pressure sensor ................................. 5-34
Checking the engine temperature sensor ............................... 5-34
Checking the thermo switch .................................................... 5-35
Checking the knock sensor ..................................................... 5-35
Checking the shift cut-off switch .............................................. 5-36
Checking the shift position switch ........................................... 5-36
Checking the engine shut-off switch ........................................ 5-37
Starting unit and component ......................................... 5-37

Checking the starter relay ....................................................... 5-37
Checking the engine start switch ............................................. 5-38

optional for other markets) ............................................ 5-39
Checking Y-COP ..................................................................... 5-40
Checking the buzzer ................................................................ 5-40
Checking the Y-COP main wire harness ................................. 5-40
Checking the button cell battery .............................................. 5-41
Starter motor ................................................................... 5-43

Removing the starter motor ..................................................... 5-45
Disassembling the starter motor .............................................. 5-45
Checking the starter motor pinion ........................................... 5-46
Checking the armature (starter motor) .................................... 5-47
Checking the brush holder ...................................................... 5-47
Assembling the starter motor .................................................. 5-48
Installing the starter motor ....................................................... 5-50
Digital Network Gauge sensor ....................................... 5-50

Checking the water pressure sensor ....................................... 5-50
Checking the speed sensor ..................................................... 5-50
PTT system ...................................................................... 5-51

Checking the PTT relay ........................................................... 5-51
Checking the PTT switch (on bottom cowling) ........................ 5-52
Checking the trim sensor ......................................................... 5-52
Electrical system
Checking the tilt limiter ............................................................ 5-53
0
1
2
3
4
5
6
7
8
9
10
Electrical component and wire harness routing

Port
A
I
J
K
O
N
N
M
L
H
6
10
9
8
8
8
5
J-J
L-L
N-N
K-K
M-M
1. PTT relay
2. Starter motor
5. Wire harness
6. Rectifier/Regulator/Isolator lead
7. PTT motor lead
8. Tilt limiter lead
O-O
9. Lighting coil lead

10. Starter motor lead
A. Fasten the PTT motor leads and power
supply lead using the holder so that the
locking portion of the holder is facing
upward.
5-1
0
1
I
J
K
O
N
N
2
3
M
L
5
6
10
8
5
J-J
8
8
L-L
N-N
K-K
M-M
B. Fasten the pulser coil lead and lighting

coil lead using the holder.
C. Fold the PTT motor lead to remove the
slack, and then fasten the wire harness
at the white tape using the clamp.
O-O
D. Secure the connectors of the oil pressure

lead, wire harness, Rectifier/Regulator/
Isolator ground lead, and thermo switch
lead using the clamp.
10
A
5-2
I
J
K
O
N
N
M
L
H
6
10
9
8
8
8
5
J-J
L-L
N-N
K-K
M-M
E. Route the wire harness under the cam

position sensor coupler.
F. Pass the Rectifier/Regulator/Isolator
leads. Starting from the engine side,
pass the leads in this order: Pink, Blue/
Green, Green.
G. Install the negative battery cable holding
it against the stopper.
O-O
H. Route the wire harness in front of the

power supply lead.
I. Route the PTT motor lead between the
ground lead and the engine.
5-3
Starboard
19 18
9
8
10
10
22
21
11
12
20
O-O
G-G
A
B 1
10
H
F-F
F
G
6
O
E
F
M
K
L
7
5
22
17
18
14
16
11
N-N
15
14
M-M

2. Water detection switch (in fuel cup
assembly)
3. APS
5. Knock sensor
6. Fuel injector
8
J
8. Wire harness
9. High-pressure fuel hose
10. Knock sensor lead
11. Vapor gas hoses
12. Engine temperature sensor lead
13. Ground lead
14. APS lead
15. Check valve
5-4
13
13
13
9
10
19 18
9
8
10
10
22
21
11
12
20
O-O
G-G
A
F-F
B 1
10
F
G
6
O
E
K
L
22
17
18
15
14
16
11
N-N
14
M-M
16. High-pressure fuel pump lead

17. Cooling water hose
18. Fuel injector lead
19. Fuel rail
20. Low-pressure fuel hose
21. Pressure regulator hose
22. Blowby hose
8
J
13
13
13
A. Route the cam position sensor (IN) lead

and OCV lead under the fuel hose.
B. Route the vapor shut-off valve lead under
the fuel hose.
C. Fasten the high-pressure fuel pump
extension lead and blowby hose using
the clamp.
5-5
19 18
9
8
10
10
22
21
11
12
20
O-O
G-G
A
B 1
10
H
F-F
F
G
6
O
E
F
M
K
L
7
5
22
17
18
14
16
11
N-N
15
14
M-M
8
J
13
13
13
9
10
D. Fasten the vapor gas hoses and knock

sensor lead using the holder.
E. Install the joint connector to the holder.
A
5-6
Fuse holder
12
3
11
4
5
10
6
8
1. Starter relay
2. Fuse (10 A) (low-pressure fuel pump)
3. Fuse (60 A) (engine battery)
4. Fuse (20 A) (engine start switch, PTT
switch)
5. Fuse (60 A) (isolator)
6. Fuse (15 A) (high-pressure fuel pump)
7. Fuse (10 A) (ETV)
8. Fuse (30 A) (ignition coil, VCT, fuel injector, engine ECM)

9. Main relay
10. Fuse (30 A) (starter relay)
11. ETV motor relay
12. Fuel pump relay (high-pressure)
5-7
Rear
3
0
1
B-B
1
C
C
D
6
1
5
3
F-F
D-D
E-E
C-C
10
1. Ignition coil
2. Joint connector
3. Wire harness
4. Low-pressure fuel pump lead
5. Fuel hose
A. Fasten the low-pressure fuel pump lead

using the plastic tie.
5-8
Front
1
B
A
3
5
D-D
1. ETV
2. YDIS coupler
3. Fuse box assembly
4. Diode (PTT relay)
5. Engine ECM
6. Condenser (cam position sensor)
7. Wire harness
A. Install the ground lead with gray tape

holding it against the stopper.
B. Install the ground lead holding it against
the stopper.
C. Route the wire harness ensuring that it is
not twisted.
5-9
Top
F
10
14
9
11
G
F
F-F
G-G
2
E
H
3
A
J
B
J
4
I
5
B
6
C
6
5
13
10
12
9
J-J
I-I

2. Thermo switch
5. Pulser coil
8. OCV
H-H

10. Wire harness
11. Cam position sensor (EX) lead
12. Lighting coil lead
13. Engine temperature sensor lead
14. Blowby hose
10
A
5-10
F
10
14
9
11
G
F
F-F
G-G
2
E
H
3
A
J
B
J
4
I
C
6
5
13
10
12
J-J
I-I
A. Install the ground lead holding it against

the stopper.
B. Install the holders holding them against
the stopper.
C. Fasten the pulser coil lead to the base
assembly using the plastic tie.
D. Secure both ends of the knock sensor
coupler using the clamps.
H-H
E. Route the cam position sensor lead,

OCV lead, and vapor shut-off valve lead
under the fuel hose.
5-11
Bottom cowling
12
11
H
H
10
9
D
G
1
F
F
A
E
D-D
2
7
7
6
15
14
C
13
16
H-H
13
G-G
F-F
1. PTT switch
2. Isolator coupler
3. Gauge harness coupler
4. Trim sensor coupler
5. Digital Network Gauge harness coupler
6. Main wire harness coupler

11. Shift position switch coupler
12. Shift cut-off switch coupler
13. Fuel hose
14. Shift position switch lead
15. PTT switch lead
16. Shift cut-off switch lead
5-12
10
12
11
H
H
10
9
D
G
1
F
F
A
E
D-D
2
7
15
14
5
C
13
16
H-H
13
G-G
F-F
A. Align the red tape on the PTT motor lead

with the outer end of the grommet.
B. Route the PTT switch lead under the
bracket.
C. Route the hose between the guide and
the inside wall of bottom cowling.
5-13
ECM circuit diagram
ECM circuit diagram

1. Pulser coil
18. Fuel injector #1
2. Cam position sensor

(EX)
33
14
51
39

3. Cam position sensor

(IN)
45
5V
21
22. Ignition coil #1
22
15
20
69
4. TPS 1
61
68
5. TPS 2
16. Ground
5V
60
85
6. APS 1
16. Ground
5V
7. APS 2
16. Ground
5V
8. Intake air pressure
sensor
76
53
84
46
54
73
47
70
41
62
48
17. Engine
ECM
86
10 A
3
4
5
78
79
28. OCV
25
18
28
15 A
80
31. High-pressure fuel pump relay
36
11. Speed sensor
27. ETV
10. Water pressure

sensor
26. ETV relay

26
83
33. Tachometer
T
12. Intake air temperature sensor
35
42
34. Oil pressure alert indicator
64
14. Trim sensor
29
35. Overheat alert indicator
27
16. Ground
71
63
36. Alert buzzer

BZ
49
10
Indicates a connection between the symbols.

The circled numbers in the illustration indicate the engine ECM terminal numbers.
5-14
ECM circuit diagram
37. Thermo switch
59
56
67
49. Multi-hub
55
66
77
40. Engine shut-off switch
58
41. Knock sensor
17. Engine
ECM
42. Main relay

60 A
16
17
65
23
43. Main switch
57
44. Engine start switch
11
30 A
45. Starter motor

M
24
46. Starter relay
52
47. Battery
82
48. Rectifier/
Regulator/
Isolator
Indicates a connection between the symbols.

The circled numbers in the illustration indicate the engine ECM terminal numbers.
5-15
50. YDIS
ECM circuit diagram

1. Pulser coil
4. TPS1
5. TPS2
6. APS1
7. APS2
8. Intake air pressure sensor
10. Cooling water pressure sensor
11. Speed sensor
12. Intake air temperature sensor
14. Trim sensor
16. Ground
17. Engine ECM
26. ETV relay
27. ETV
28. OCV
31. High-pressure fuel pump relay
33. Tachometer
34. Oil pressure alert indicator
35. Overheat alert indicator
36. Alert buzzer
37. Thermo switch
41. Knock sensor
42. Main relay
43. Main switch
45. Starter motor
46. Starter relay
47. Battery
49. Multi-hub
50. YDIS
0
1
2
3
4
5
6
7
8
9
10
A
5-16
ECM coupler layout
ECM coupler layout
53 54 55 56 57 58 59 60 61
62 63 64 65 66 67 68 69
70 71 72 73 74 75 76 77
78 79 80 81 82 83 84 85 86
No.
Connecting part
1 2 3 4 5 6 7
8 9 10 11 12 13
14 15 16 17 18 19
20 21 22 23 24 25 26
27 28 29 30 31 32 33
34 35 36 37 38 39
40 41 42 43 44 45
46 47 48 49 50 51 52
Color
No.
Connecting part
Battery power source
Red/Yellow
29
Battery power source
Red/Yellow
30
31
Green
32
Purple/Black
33
34
35
Intake air temperature

sensor
Black/Yellow
36
Speed sensor
Knock sensor
Fuel injector #2
Fuel injector #4
Purple/Green
Fuel injector #3
Purple/Yellow
Oil pressure sensor
10
11
Pink/White
Start switch
Brown
12
13
Trim sensor
Color
Pulser coil
Pink
White/Red
Blue
37
38
39
Cam position sensor

(EX)
White/Blue
40
41
APS ground
Engine
sensor
14
Fuel injector #1
Purple/Red
15
Ignition coil #3
Black/Yellow
16
Engine ECM ground
Black
42
17
Engine ECM ground
Black
43
18
Green/Black
44
45
Cam position sensor

(IN)
White/Green
19
temperature
20
Ignition coil #4
Black/Green
21
Ignition coil #1
Black/Orange
46
APS power source
22
Ignition coil #2
Black/White
47
APS 2
23
Engine ECM ground
Black
48
Sensor power source
24
Starter relay
Black
49
Sensor ground
25
OCV
Purple
50
26
Low-pressure
pump
27
Blue/Yellow
28
Blue/Black
fuel
Blue/White
5-17
Black
Black/Yellow
Orange
Pink/White
Orange
Black
51
Pulser coil ground
Black
52
Engine ECM ground
Black
53
ETV power source
Red/Green
54
ETV power source
Red/Green
ECM coupler layout
0
1
53 54 55 56 57 58 59 60 61
62 63 64 65 66 67 68 69
70 71 72 73 74 75 76 77
78 79 80 81 82 83 84 85 86
No.
Connecting part
1 2 3 4 5 6 7
8 9 10 11 12 13
14 15 16 17 18 19
20 21 22 23 24 25 26
27 28 29 30 31 32 33
34 35 36 37 38 39
40 41 42 43 44 45
46 47 48 49 50 51 52
Color
No.
Connecting part
Color
55
Multi-hub
Blue
81
56
Multi-hub
White
82
57
Main switch
Yellow
Rectifier/Regulator/
Isolator
58
White
83
Tachometer
Green
59
Thermo switch
Pink
84
APS ground
Black
60
TPS ground
Black
85
APS power source
86
Intake air
sensor
61
TPS 1
62
ETV ground
Green/Black
63
Alert buzzer
Pink
64
Low oil pressure alert

indicator
65
Main relay
66
Blue/Green
67
Water detection switch
Blue/White
68
TPS 2
Pink/White
69
TPS power source
70
ETV motor
Green/Red
71
Overheat alert indicator
Pink/Black
72
73
Pink
Orange
4
5
Pink/Green
Pink/White
Yellow/Green
Orange
ETV power source
pressure
Blue/Green
Yellow/Green
74
75
76
APS 1
Pink
77
YDIS
White/Black
78
ETV ground
Black
79
ETV ground
Black
80
High-pressure
pump
fuel
10
Yellow/Green
5-18
Checking the electrical component
Checking the electrical

component
TIP:
Before measuring the peak voltage, check
all of the wire harnesses for corrosion. Also,
make sure that the wire harnesses are connected properly and that the battery is fully
charged.
Use peak voltage adapter B with the recommended digital circuit tester.
Connect the positive pin of peak voltage
adapter B to the positive terminal of the digital tester, and the negative pin to the negative terminal.
When measuring the peak voltage, set the
digital circuit tester to the DC voltage mode.
Using the YDIS

When checking the ETV, TPS, APS, OCV,
ignition spark, high-pressure fuel pump, fuel
injector, and related sensors, use the YDIS.
TIP:
When deleting the diagnosis record in the
YDIS, make sure to check the time that the
trouble codes were detected.
When checking the input voltage of a part,
the coupler or connector must be disconnected. As a result, the engine ECM determines that the part is disconnected and a
trouble code is detected. Therefore, make
sure to delete the diagnosis record after
checking the input voltage.
To connect and operate the YDIS, see the
YDIS (Ver. 2.10 or later) instruction manual.
DC V
Measuring the peak voltage
When measuring the peak voltage, do not

touch any of the connections of the digital
tester probes.
Digital circuit tester: 90890-03189

Peak voltage adapter B: 90890-03172
Using the digital tester

The electrical technical data applies to the
measurements taken using the Yamaha recommended tester.
The resistance values shown are the values
taken before the engine is started. The actual
resistance may vary depending on the environmental conditions and ambient temperature.
The input voltage changes depending on the
battery voltage.
If the tester probe cannot be inserted into the
coupler, prepare a test lead suitable for the
measurement.
When measuring the peak voltage

between the terminals of an electrical
component using the digital tester, make
sure that the leads do not contact any
metal parts. Otherwise, the electrical component may short-circuit and be damaged.
To check the electrical components or measure the peak voltage, use the special service tools. A malfunctioning electrical
component can be checked easily by measuring the peak voltage. The specified engine
speed when measuring the peak voltage is
affected by many factors, such as fouled
spark plugs or a weak battery. If one of these
factors is present, the peak voltage cannot be
measured properly.
5-19
Engine control unit and component
c
a
2
b
Relay terminals continuity:
Terminal cTerminal d

Test lead:
Terminal, male 1:
(commercially available)
Terminal, female 2:
3. Measure the input voltage between the

terminal a and ground, and the terminal
b and ground.
Engine control unit and

component
1
2
3
4
Checking the main relay

1. Remove the relay cover and main relay
1.
b
Main relay input voltage:
Terminal aGround
Terminal bGround
12 V (battery voltage)
4. Turn the engine start switch to ON, and

then measure the input voltage between
the terminals a and b.
2. Connect the positive battery lead to the

terminal a, and the negative battery
lead to the terminal b, and then check
for continuity between the terminals c
and d. Replace the relay if there is no
continuity.
6
7
8
9
a
Do not reverse the battery leads.
10
b
Main relay input voltage:
Terminal aTerminal b
5-20

6. Install the main relay and relay cover.
Engine ECM input voltage:

Terminal 1Ground
Terminal 2Ground
Checking the engine ECM circuit

1. Disconnect the engine ECM couplers a
and b.

5. Connect the engine ECM couplers.
Checking the ETV and TPS
a
b
TPS 1 and TPS 2 are components of the

ETV, which cannot be disassembled.
Do not loosen the throttle stop screw nut

or turn the throttle stop screw.
2. Check the wire harness for continuity.
17 16
52
23
Wire harness continuity:

Terminal 16Ground
Terminal 17Ground
Terminal 23Ground
Terminal 52Ground
1. Connect the YDIS to display TPS 1 and

TPS 2.
2. Start the engine, warm it up for 510 minutes, and then stop it.

the engine ECM coupler terminal 1 and
ground, and terminal 2 and ground.

then measure the TPS output voltages
when the remote control lever is at the
fully closed position.
TPS output voltage (reference data):

Item
Fully closed
TPS 1
0.5 V
TPS 2
2.5 V
2 1

5. Disconnect the ETV coupler a.
then measure the TPS input voltage at
the ETV coupler.
5-21
Or

a
b
0
1
TPS input voltage:

Orange (Or)Black (B)
4.755.25 V
2
ETV motor relay input voltage:

8. Connect the ETV coupler.
Checking the ETV motor relay

1. Remove the relay cover and ETV motor
relay 1.
6. Install the ETV motor relay and relay

cover.
Checking the APS

1
APS 1 and APS 2 are a single unit, which

cannot be disassembled.
2. Check the ETV motor relay. See Checking the main relay (5-20).
1. Connect the YDIS to display APS 1 and

APS 2.
2. Check that the accelerator lever 1 contacts the stopper 2 when the remote
control lever is in the N position.
7
8

terminal a and ground.
1
then measure the APS output voltage
when the remote control lever is at the
fully closed position and fully open position.
ETV relay input voltage:

Terminal aGround
10
A
5-22

A. Fully closed position
B. Fully open position
APS output voltage (reference data):

Fully
Fully
Item
closed
open
APS 1
0.708 V 4.375 V
APS 2
0.630 V 4.297 V
APS resistance @ 20 C (68 F)

(reference data):
A. Fully
Item
Terminal
closed
APS 1
ab
0.8 k
APS 2
cd
4. Check that the output voltages of APS 1

and APS 2 change continuously when
the remote control lever is operated.
B. Fully
open
5.0 k
12. Connect the APS coupler.

13. Install the APS.
6. Disconnect the throttle cable joint from
the APS.
14. Connect the throttle cable joint to the

APS.
7. Remove the APS.
Checking the cam position sensor

8. Disconnect the APS coupler a.
1. Disconnect the cam position sensor couplers a and b.

then measure the input voltage at the
APS coupler.
Or
Or

cam position sensor coupler.
IN
a
R/Y
W/G
APS input voltage:

4.755.25 V
EX
R/Y W/L B
11. Measure the APS resistance when the

accelerator lever 1 is at the fully closed
position A and fully open position B.
c d
5-23

Cam position sensor input voltage:
Red/Yellow (R/Y)Black (B)
White/Green (W/G)Black (B)
(IN)
White/Blue (W/L)Black (B)
(EX)
4.755.25 V
R/Y
W/G
W/L
0
B
4. Make 3 test leads.
2
then measure the output voltage when
moving a screwdriver close to the cam
position sensor 1.
3
b
TIP:
Using an analog circuit tester is recommended.
1
1
Test lead:
Terminal, male 1: 9E212-10303
Terminal, female 2: 9E212-11303
Terminal, female 3:
a = 100 mm (3.94 in)
b = 50 mm (1.97 in)
c = Cutout area
7
8
5. Remove the cam position sensors 1.

6. Connect the test leads to the cam position sensor 1 and cam position sensor
coupler.
Cam position sensor output voltage:

White/Green (W/G)Black (B)
(IN)
White/Blue (W/L)Black (B)
(EX)
Position
Voltage
a, c
More than 4.8
b
Less than 1.0
Make sure that the test leads do not contact each other and cause a short circuit.
Otherwise, the fuse could blow when the
engine start switch is turned to ON.
9
10

7. Connect the tester probes to the test
leads.
10. Disconnect the test leads, and then

install the cam position sensors.
5-24

11. Connect the cam position sensor couplers.
Checking the OCV

1. Check the operation of the OCV using
the YDIS Stationary test and check the
operating sound.
2. Disconnect the OCV coupler a.
the OCV coupler and ground.
8. Disconnect the battery leads.

9. Install the OCV, and then connect the
OCV coupler.
R/Y
Checking the oil pressure sensor

1. Disconnect the oil pressure sensor coupler a.
Or
OCV input voltage:

Red/Yellow (R/Y)Ground

then measure the input voltage at the oil
pressure sensor coupler.
5. Remove the OCV.

6. Measure the OCV resistance.
Oil pressure sensor input voltage:

4.75 V5.25 V
3. Remove the oil pressure sensor, and
then connect the pressure pump 1 and
special service tool 2.
4. Apply positive pressure to the oil pressure sensor slowly, and then measure
the output voltage at the specified pressures.
OCV resistance:
6.77.7 @ 20 C (68 F)
7. Connect the battery leads to the terminals and check the operation of the spool
valve. Replace the OCV if the spool valve
does not operate.
5-25
Fuel control unit and component
Water detection switch input voltage:

Blue/White (L/W)Black (B)
P/W
Or
G/W B G
3. Turn the engine start switch to OFF, and

then remove the filter cup assembly.
4. Check that the float 1 moves smoothly.
Do not remove the clip and float.
5. Check the water detection switch for continuity when the float 1 is in positions
A and B.
Pressure pump 1:
Test harness (3 pins) 2: 90890-06869
Oil pressure sensor output voltage

(reference data):
Pink/White (P/W)Black (B)
2.5 V @ 392.0 kPa
(3.92 kgf/cm2, 56.8 psi)
4.5 V @ 784.0 kPa
(7.84 kgf/cm2, 113.7 psi)
0
1
2
3
4
5
6

then disconnect the special service tool
and pressure pump.
6. Connect the oil pressure sensor coupler.

Checking the water detection switch
1. Disconnect the water detection switch

coupler a.
Water detection switch continuity:

No continuity:
Float position A
Continuity:
Float position B

water detection switch coupler.
B L/W
6. Install the filter cup assembly. See Fuel
filter (6-9).
9
10
7. Connect the water detection switch coupler.
A
5-26
Checking the fuel injector
Checking the low-pressure fuel

pump and high-pressure fuel pump
1. Check the operation of the fuel injector

using the YDIS Stationary test and
check the operating sound.
1. Check the operation of the low-pressure

fuel pump and high-pressure fuel pump
using the YDIS Stationary test and
check the operating sound.
2. Disconnect the fuel injector couplers a.

the fuel injector coupler terminal and
ground.
2. Disconnect the low-pressure fuel pump

coupler a.
the low-pressure fuel pump coupler terminal and ground.
R/Y
a
R/Y
a
a
a
Low-pressure fuel pump input voltage:
Fuel injector input voltage:


5. Disconnect the high-pressure fuel pump
coupler a.
5. Measure the fuel injector resistance.
6. Connect the tester probes to the terminals of the high-pressure fuel pump coupler a, and then measure the input
voltage within 5 seconds after turning the
engine start switch to ON.
Fuel injector resistance (reference data):

11.5012.50 @ 20 C (68 F)
6. Connect the fuel injector couplers.
5-27
Gr
R/Y

High-pressure fuel pump input voltage:
Red/Yellow (R/Y)Gray (Gr)
7. Measure the resistance of the fuel pump

motors.
1
2. Check the high-pressure fuel pump relay.
See Checking the main relay (5-20).
the terminals a and ground.
2
3
2
a
4
5
Low-pressure fuel pump 1 resistance
(reference data):
0.54.0 @ 20 C (68 F)
High-pressure fuel pump 2 resistance
(reference data):
0.23.0 @ 20 C (68 F)
High-pressure fuel pump relay input voltage:

Terminal aGround
4. Connect the tester probes to the terminals a and b, and then measure the
input voltage within 5 seconds after turning the engine start switch to ON.
8. Connect the low-pressure fuel pump coupler and high-pressure fuel pump coupler.
a
b
Checking the high-pressure fuel

pump relay
1. Remove the relay cover and high-pressure fuel pump relay 1.
6
7
8
9
10
High-pressure fuel pump relay input voltage:

5-28
Charging unit and component

6. Install the high-pressure fuel pump relay

and relay cover.
Checking the vapor shut-off valve

1. Disconnect the vapor shut-off valve coupler a.
the vapor shut-off valve coupler terminal
and ground.
6. Remove the special service tool.

7. Measure the resistance between the
vapor shut-off valve terminals.
R/Y
Vapor shut-off valve resistance:

30.034.0 @ 20 C (68 F)
8. Install the vapor shut-off valve, and then
connect the vapor shut-off valve coupler.

Checking the lighting coil (stator
assembly)
Vapor shut-off valve input voltage:

1. Disconnect the lighting coil coupler a.
a
3. Remove the vapor shut-off valve, and
then connect the special service tool 1
to the vapor shut-off valve.
Vacuum/pressure pump gauge set 1:
90890-06945
4. Apply the specified negative pressure to
the vapor shut-off valve.
2. Connect the special service tool 1.
Specified negative pressure:

67.0 kPa (0.67 kgf/cm2, 9.7 psi)
3. Measure the lighting coil output peak

voltage between all combinations of the
terminals. Replace the stator assembly if
below specification.
Do not connect the battery leads to the

vapor shut-off valve terminals for more
than a few seconds.
TIP:
When measuring the lighting coil output peak
voltage under the cranking (unloaded) condition, remove the clip from the engine shut-off
switch to prevent the engine from starting.
5. Check that the vapor shut-off valve

opens and the negative pressure is
released when the battery leads are connected to the vapor shut-off valve terminals.
5-29
G
G G
WR B
Lighting coil resistance (reference data):
Terminal aTerminal c
Terminal bTerminal c
Terminal dTerminal e
Terminal dTerminal f
Terminal eTerminal f
0.14160.2124 @ 20 C (68 F)

Lighting coil output peak voltage:
Green (G)Green (G)
Unloaded
r/min
Cranking
1500
DC V
8.6
40.4
9. Connect the lighting coil couplers.
3500
89.3
Checking the Rectifier/Regulator/

Isolator
4. Disconnect the special service tool, and

then connect the lighting coil coupler.
5. Disconnect the lighting coil coupler a.
1. Remove the fuse cover.
TIP:
Do not use peak voltage adapter when measuring the Rectifier/Regulator/Isolator output
voltage.
8. Measure the lighting coil resistance.
7. Disconnect the special service tool.
Do not connect the battery cables in

reverse. Otherwise, the Rectifier/Regulator/Isolator could be damaged.
2. Measure the Rectifier/Regulator/Isolator

output voltage.
6. Repeat steps 24.
8
9
10
A
5-30

Rectifier/Regulator/Isolator continuity
(testing diode mode):
Tester probe
Display value
(reference data)
(+)
()
b
c
d
e
a
f
OL
g
h
k
m
a
c
d
e
b
f
OL
g
h
k
m
a
0.40.5 V
b
0.40.5 V
d
e
c
f
g
OL
h
k
m
a
0.40.5 V
b
0.40.5 V
c
e
f
d
g
OL
h
k
m
OL: Indicates an overload
Rectifier/Regulator/Isolator output voltage:

Fuse (60 A)Ground
Loaded
r/min
1500
3500
DC V
13.0
13.0
3. Remove the Rectifier/Regulator/Isolator.
4. Set the digital circuit tester to the diode
mode, and then check the Rectifier/Regulator/Isolator for continuity.
G G
e
f
a
b
c
d
g
h
L/G
B
a
b
c
d
e
f
g
h
m
5-31
Ignition unit and component

Tester probe
Display value
(reference
data)
(+)
()
a
0.40.5 V
b
0.40.5 V
c
d
e
f
g
OL
h
k
m
a
0.40.5 V
b
0.40.5 V
c
d
f
e
g
OL
h
k
m
a
0.40.5 V
b
0.40.5 V
c
d
g
e
f
OL
h
k
m
a
0.40.5 V
b
0.40.5 V
c
d
e
h
f
OL
g
k
m
Tester probe
Display value
(reference
data)
(+)
()
a
b
c
d
k
OL
e
f
g
m
a
0.7 V0.8 V
b
0.7 V0.8 V
c
0.4 V0.5 V
d
0.4 V0.5 V
m
e
0.4 V0.5 V
f
0.4 V0.5 V
g
0.4 V0.5 V
h
0.4 V0.5 V
m
OL
5. Install the Rectifier/Regulator/Isolator.
0
1
2
3
4
5
6
Checking the ignition spark

1. Remove the ignition coils.
2. Connect the special service tool 1 to

the ignition coil.
TIP:
Repeat steps 24 for each ignition coil.

3. Check the ignition spark using the YDIS
Stationary test.
Do not touch any of the connections of

the special service tool.
9
10
A
5-32
Checking the pulser coil

1. Disconnect the pulser coil coupler a.
OK
a
3. Measure the pulser coil output peak voltage.
Ignition tester (Spark gap tester) 1:

90890-06754
W/R
B

5. Install the ignition coils.
G
a
W/R
B
G/W
1
Checking the ignition coil

1. Disconnect the ignition coil couplers a.
ignition coil coupler.
a
1
R/Y B
a
Pulser coil output peak voltage:
White/Red (W/R)Black (B)
UnloadLoaded
ed
r/min
Cranking
1500
DC V
6.2
5.2
18.1
Ignition coil input voltage:

Red/Yellow (R/Y)Black (B)
4. Connect the ignition coil couplers.
5-33
3500
21.6

1. Disconnect the intake air pressure/temperature sensor coupler a.
TIP:
When measuring the pulser coil output
peak voltage under cranking (unloaded)
condition, disconnect the coupler a to prevent the engine from starting.
When measuring the pulser coil output
peak voltage under cranking (loaded) condition, remove the clip from the engine shutoff switch to prevent the engine from starting.

intake air pressure/temperature sensor
coupler.
Or

5. Measure the pulser coil resistance.
Pulser coil resistance:

White/Red (W/R)Black (B)
396.0594.0 @ 20 C (68 F)

input voltage:
4.755.25 V
6. Connect the pulser coil coupler.
Checking the intake air temperature

sensor
The intake air temperature sensor is a component of the intake air pressure/temperature
sensor.
4. Connect the intake air pressure/temperature sensor coupler.
1. Measure the ambient temperature.
Checking the engine temperature

sensor
2. Connect the YDIS to display Intake air

temperature.
1. Disconnect the engine temperature sensor coupler a.
3. Check that the difference between the

ambient temperature and the displayed
intake air temperature is within 5 C
( 9 F).

engine temperature sensor coupler.
4
5
6
7
8
a
B
B/Y
TIP:
Check the intake air temperature sensor
when the engine is cold.
When checking the intake air temperature
sensor, remove the top cowling and do not
start the engine.
9
10
Checking the intake air pressure

sensor
Engine temperature sensor input voltage:

Black/Yellow (B/Y)Black (B)
4.755.25 V
The air pressure sensor is a component of

the intake air pressure/temperature sensor.
5-34

4. Remove the engine temperature sensor.
4. Remove the thermo switch.
5. Place the engine temperature sensor in a

container of water and heat the water
slowly.
5. Place the thermo switch in a container of

water and heat the water slowly.
6. Check the thermo switch for continuity at

the specified temperatures. Replace if
out of specification.
6. Measure the engine temperature sensor

resistance.
Engine temperature sensor resistance
(reference data):
4.55 k @ 5 C (41 F)
1.902.10 k @ 20 C (68 F)
0.170.20 k @ 100 C (212 F)
d
d
a
7. Install the engine temperature sensor

and connect the coupler.
Checking the thermo switch
a. Temperature
b. Time
c. No continuity
d. Continuity
1. Disconnect the thermo switch connectors

a.
thermo switch connector.
Thermo switch continuity temperature:

e: 8490 C (183194 F)
f: 6882 C (154180 F)
STBD
7. Install the thermo switch.
8. Connect the thermo switch connectors.
Checking the knock sensor

1. Disconnect the knock sensor coupler a.
Thermo switch input voltage (reference

data):
Pink (P)Black (B)
11.29 V
5-35

5. Measure the shift cut-off switch resistance.
a
b
0
1
2. Measure the knock sensor resistance.

Shift cut-off switch resistance:
4.4654.935 k @ a position @
20 C (68 F)
0 @ b position @ 20 C (68 F)
6. Install the shift cut-off switch. See Shift
rod and shift bracket (9-1).
7. Connect the shift cut-off switch coupler.
Knock sensor resistance:
504616 k @ 20 C (68 F)
Checking the shift position switch

1. Disconnect the shift position switch coupler a.
3. Connect the knock sensor coupler.

shift position switch coupler.
Checking the shift cut-off switch

1. Disconnect the shift cut-off switch coupler a.
L/G
L/Y
a
a
Shift position switch input voltage:
Blue/Green (L/G)Black (B)
Shift cut-off switch input voltage:

Blue/Yellow (L/Y)Black (B)
4.755.25 V
3
4
5
6
7

shift cut-off switch coupler.
8
9
10
4. Remove the shift position switch.

5. Check the shift position switch for continuity.
4. Remove the shift cut-off switch.
5-36
Starting unit and component

Engine shut-off switch continuity:
Clip removed:
a
b

or engine start switch coupler.

Shift position switch continuity:
No continuity:
Switch position a
Continuity:
Switch position b
Checking the starter relay

1. Remove the relay cover and starter relay
1.
6. Install the shift position switch. See Shift

rod and shift bracket (9-1).
7. Connect the shift position switch coupler.
Checking the engine shut-off switch

1. Disconnect the main wire harness coupler or engine start switch coupler.
2. Check the starter relay. See Checking

the main relay (5-20).

then check the engine shut-off switch for
continuity.
1. OFF
2. ON
A
3. START

the terminals a and ground.
B
a
b
Starter relay input voltage:

Terminal aGround
1. OFF
2. ON
3. START

A. Engine start switch

B. 703 side mount remote control
5-37

Engine start switch continuity:
Switch position OFF:
Switch position ON:
Switch position START:
Terminal dTerminal e
Terminal cTerminal e
Starter relay input voltage:


or engine start switch coupler.
0
1
2
3
6. Install the starter relay and relay cover.
Checking the engine start switch
1. Disconnect the main wire harness coupler or engine start switch coupler.
2. Check the engine start switch for continuity.
A
b
2. ON
1. OFF
3. START
c
B
7
c
a
b
1. OFF
2. ON
3. START
10
A. Engine start switch

B. 703 side mount remote control
A
5-38
11
3
11
2
11
11
5
10
No.
1
2
3
4
5
6
7
8
9
10
11
Part name
Cover
Control unit assembly
Remote control transmitter
Screw
Buzzer
Bracket
Screw
Main wire harness
O-ring
Plastic tie
Seal
Qty
1
1
2
2
1
1
1
1
1
1
4
5-39
Remarks
M6 15 mm
M6 19 mm
Checking Y-COP
1. Disconnect the Y-COP coupler a, and
then measure the Y-COP input voltage.
0
1
3. Measure the Y-COP buzzer input voltage.
2
3
R
Y
Y-COP input voltage:
Red (R)Black (B)
Y-COP buzzer input voltage:

Yellow (Y)Ground
2. Connect the Y-COP coupler.
Checking the Y-COP main wire

harness
Checking the buzzer

1. Remove the Y-COP buzzer 1.
1. Remove the Y-COP main wire harness

1.
4
5
6
7
8
1
9
2. Connect the battery leads to the Y-COP
buzzer connectors, and then check that
the Y-COP buzzer comes on. Replace
the Y-COP buzzer if it does not come on.
10
A
5-40
2. Check the wire harness for continuity.
ih g
rq o
ba
j
b
ab
cd
f
g
b
h
P
Wire harness continuity:
a. Terminal 1b. Terminal 3
a. Terminal 2d. Pink (P)
a. Terminal 8f. White (W)
a. Terminal 9g. White (W)
a. Terminal 17h. Red (R)
a. Terminal 17e. Yellow (Y)
a. Terminal 18c. White (W)
W
b
W
Control unit screw 4:

Checking the button cell battery

Replace the button cell battery in the remote
control transmitter once in the first year, and
once every two years thereafter.
1. Remove the remote control transmitter
cover 1.
3. Install the Y-COP main wire harness 1,

O-ring 2, and control unit 3, and then
tighten the control unit screws 4 to the
specified torque.
Do not connect the connectors a and

b. Otherwise, Y-COP may not operate
properly.
2. Push the Yamaha logo on the remote

control transmitter cover 1 and remove
the button cell battery 2.
5-41
5. Install the remote control
cover 1, and then tighten
control transmitter screws
specified torque in the order
so on.
Do not touch the button cell battery

directly. Otherwise, the button cell battery
could get corroded.
transmitter
the remote
2 to the
[1], [2], and
2
1
[4]
[2]
3. Measure the button cell battery voltage.
TIP:
When disposing of button cell batteries, make
sure to follow local disposal regulations.
[5]
[6]
[1]
[3]
2
Remote control transmitter screw 2:

0.1 Nm (0.01 kgfm, 0.1 ftlb)
4
5
6
7
Button cell battery voltage - CR2016

(reference data): 3 V
4. Install the button cell battery 1 so that

the positive side is facing the remote control transmitter cover 2.
10
2
A
5-42
Starter motor
Starter motor
20
21
1
9
4
21
14
9
10
5
11
4
15
17
16
6
22
12
18
4
23
19
7
7
13
24
5
8
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
25
26
Part name
Brush spring
Brush assembly
Brush holder assembly
Washer set
Starting motor gear assembly
Bracket
Screw
Bolt
Planetary gear
Outer gear
Plate
Stator
Armature
Pinion assembly
Bracket
Bearing
Gasket
Qty
4
1
1
1
1
1
2
2
3
1
1
1
1
1
1
1
1
5-43
Remarks
M4 16 mm
M5 127 mm
Not reusable
Starter motor
20
21
1
9
4
21
14
10
11
4
15
17
16
6
22
12
18
4
23
19
7
7
13
5
8
No.
18
19
20
21
22
23
24
25
26
24
25
26
Part name
Bracket assembly
Pinion shaft
Cover
Bolt
Lever assembly
Seal set
Magnet switch
Washer
Nut
Qty
1
1
1
2
1
1
1
1
1
Remarks
M6 35 mm
Not reusable
7
8
9
10
A
5-44
Starter motor
Removing the starter motor

1
Before removing the starter motor, make
sure to disconnect the negative battery
terminal.
2
3
1. Remove the starter motor from the power

unit. See Removing the starter motor
(7-27).
Disassembling the starter motor

1. Remove the magnet switch 1 and
spring 2.
4. Remove the rubber seal 1, lever 2,
and pinion shaft assembly 3.
2
3
2. Remove the stator assembly 1.
5. Push the pinion stopper 1 down, and

then remove the clip 2.
a
3. Remove the plate 1, outer gear 2, and
planetary gears 3.
b
3
1
2
Pipe 3: (commercially available)

a: 18.0 mm (0.71 in)
b: 13.0 mm (0.51 in)
5-45
Starter motor
6. Remove the pinion stopper 1 and pinion
2.
5
2
3
2
1
4
7. Remove the E-clip 1, and then remove

the shim 2, bracket 3, gasket 4, and
shim 5.
10. Remove the plate 1, and then remove

the armature 2 from the brush holder
assembly 3.
5
2
2
2
1
1
8. Remove the stator 1.
9. Remove the armature 2, along with the

brush holder assembly 3, from the
bracket 4.
6
7
Checking the starter motor pinion

1. Check the pinion teeth. Replace the pinion if cracked or worn.
2. Turn the pinion counterclockwise to
check that it operates smoothly and turn
it clockwise to check that it locks in place.
Do not disassemble the stator. Do not

remove the magnets 5 from it.
8
9
10
A
5-46
Starter motor
Checking the armature (starter

motor)
1. Check the commutator. Clean using
600-grit sandpaper and compressed air if
dirty.
a
b
Armature continuity:
Continuity:
ab
No continuity:
ac
ad
2. Measure the commutator diameter a.

Replace the armature if below specification.
Checking the brush holder

1. Check the brush holder assembly for
continuity. Replace if out of specification.
e
a
c
a
d
c a
Commutator standard diameter a:

29.0 mm (1.14 in)
Wear limit: 28.0 mm (1.10 in)
3. Measure the commutator undercut a.
d b
Brush holder assembly continuity:
Brush aBrush b
Brush aTerminal e
Brush bTerminal e
Brush cBrush d
Commutator standard undercut a:

0.8 mm (0.03 in)
4. Check the armature for continuity.
Replace if out of specification.
5-47
Starter motor
2. Measure the length a of each brush.
Replace the brush assembly if below
specification.
a
b
c
3
Brush standard length a:
15.5 mm (0.61 in)
Wear limit b: 9.5 mm (0.37 in)
Assembling the starter motor

4. Install the shim 1, the bracket 2, a new
gasket 3, and the shim 4, and then
install the E-clip 5 onto the pinion shaft
6.
Do not apply grease or oil to the commutator of the armature.

1. Push the brushes 1 into the holders,
and then install the armature 2 to the
brush holder assembly 3.
4
5
1
4
2. Install the plate 4.
2
2
5
8
1
4
9
10
3. Install the armature 1, along with the

brush holder assembly 2, to the bracket
3, and then install the stator 4.
TIP:
Align the holes a and b in the plate 5 with
the holes c and d in the bracket 3.
A
5-48
Starter motor
5. Install the pinion 1, pinion stopper 2,
and clip 3.
c
3
a
2
1
2
b
8. Align the protrusion a on the stator 1

with the slot b in the cover assembly
2, and then assemble the starter motor.
6. Install the pinion shaft assembly 1, the

lever 2, and a new rubber seal 3.
2
1
TIP:
Align the holes a in the cover 4 with the
holes b in the bracket 1.
b
1
3
1
2
b
9. Install a new gasket 1, the spring 2,

and the magnet switch 3.
2
1
7. Install the outer gear 1, the planetary

gears 2, and the plate 3.
2
1
TIP:
Be careful not to align the protrusions a
on the outer gear 1 with the holes b in
the bracket.
Align the notches c in the plate 3 with
the holes b in the bracket.
5-49
Digital Network Gauge sensor
Installing the starter motor
Water pressure sensor output voltage

(reference data):
Blue/Black (L/B)Black (B)
2.5 V @ 392.0 kPa
(3.92 kgf/cm2, 56.8 psi)
4.5 V @ 784.0 kPa
(7.84 kgf/cm2, 113.7 psi)
1. Install the starter motor to the power unit.

See Installing the starter motor (7-27).
Digital Network Gauge sensor

Checking the water pressure sensor
1. Disconnect the water pressure sensor
coupler a.

and pressure pump.

water pressure sensor coupler.
6. Install the water pressure sensor, and

then connect the water pressure sensor
coupler. See Installing the water pressure sensor (Digital Network Gauge) (314).
Or
Checking the speed sensor

a
Water pressure sensor input voltage:
4.755.25 V
Or

speed sensor coupler.
Or
Speed sensor input voltage:

4.755.25 V
G/W B G
2
3. Remove the speed sensor, and then connect the pressure pump 1 and special
service tool 2.
4. Apply positive pressure to the speed sensor slowly, and then measure the output
voltage.
3
4
L/B
1. Disconnect the speed sensor coupler a.
3. Remove the water pressure sensor, and

then connect the pressure pump 1 and
4. Apply positive pressure to the water pressure sensor slowly, and then measure
the output voltage.
6
7
8
9
10
2
Pressure pump 1:
A
5-50
PTT system
L
Or
G/W B G
2
a
PTT relay input voltage:
1
2
Pressure pump 1:
3. Disconnect the battery power source,

ground lead, PTT motor leads, and PTT
relay coupler.
Speed sensor output voltage

(reference data):
Blue (L)Black (B)
2.5 V @ 392.0 kPa
(3.92 kgf/cm2, 56.8 psi)
4.5 V @ 784.0 kPa
(7.84 kgf/cm2, 113.7 psi)
4. Remove the PTT relay.
Before disconnecting the PTT relay terminals, make sure to disconnect the battery
negative terminal.

and pressure pump.

6. Check the PTT relay for continuity.
6. Install the speed sensor, and then connect the speed sensor coupler. See
Installing the speed sensor (Digital Network Gauge) (3-15).
Lg
Sb
G/W G
e
f
PTT system
Checking the PTT relay
1
b
1. Remove the PTT relay cover.
c
a

PTT relay terminal a and terminal b.
PTT relay continuity:

Terminal bTerminal d
Terminal bTerminal e
Terminal dTerminal f
5-51
PTT system
the PTT relay for continuity. Replace the
PTT relay if out of specification.
11. Connect the PTT relay coupler, battery

power source, ground lead, and PTT
motor leads.
Checking the PTT switch (on bottom

cowling)
Lg
Sb
G/W G
a
12. Install the PTT relay cover.
1. Disconnect the PTT switch coupler a.
d
PTT switch coupler terminal and ground.

Terminal cTerminal e
Terminal bTerminal d
4
5
PTT switch input voltage:

Red (R)Ground

the PTT relay for continuity. Replace the
PTT relay if out of specification.
2
3
3. Check the PTT switch for continuity.

Replace the PTT switch if out of specification.
6
7
Lg
Sb
G/W G
a
Sb
R
Lg
PTT switch continuity:

Switch position UP:
Switch position DN:

Terminal bTerminal e
8
9
10
4. Connect the PTT switch coupler.
Checking the trim sensor
10. Install the PTT relay.
1. Disconnect the trim sensor coupler a,

and then remove the trim sensor.
5-52
PTT system
Tilt limiter input voltage:
Sky blue (Sb)Ground
3. Connect the battery leads to the tilt limiter couplers.
4. Loosen the screw 1, and measure the
output voltage at range a. Slide the
magnet 2 to mark b. When the magnet passes mark b, measure the output
voltage again.
a
2. Measure the trim sensor resistance.
3. Turn the trim sensor lever 1 from the
position a to the position b, and then
measure the resistance as it gradually
changes.
b
2
a
1
Sb
Trim sensor resistance (reference data):

239379 @ a
9.011.0 @ b (setting resistance)
4. Install the trim sensor, and the connect
the trim sensor coupler.
Tilt limiter output voltage:

Blue (L)Ground
12.0 V (battery voltage) @ a
0 V when passing b
Checking the tilt limiter

1. Disconnect the tilt limiter couplers a,
b, and c.
5. Connect the tilt limiter couplers.
2. Measure the input voltage at the tilt limiter coupler a with the up side of the
PTT switch pushed.
6. Set the tilt limiter. See Setting the tilt limiter (3-21).
Sb
c
b
a
5-53
PTT system
MEMO
0
1
2
3
4
5
6
7
8
9
10
A
5-54
Fuel system
Hose routing ...................................................................... 6-1
Fuel hose ................................................................................... 6-1
Pressure regulator hose, vapor gas hose, and blowby hose .... 6-2
Cooling water hose .................................................................... 6-4
Fuel system ....................................................................... 6-6

Reducing the fuel pressure ....................................................... 6-6
Disconnecting the quick connector ............................................ 6-6
Measuring the fuel pressure ...................................................... 6-6
Checking the pressure regulator ............................................... 6-7
Fuel filter ............................................................................ 6-9

Removing the fuel filter assembly ........................................... 6-10
Checking the fuel filter assembly ............................................. 6-10
Disassembling the fuel filter assembly .................................... 6-11
Checking the fuel filter element ............................................... 6-11
Checking the fuel cup assembly .............................................. 6-11
Checking the primer pump ...................................................... 6-11
Assembling the fuel filter assembly ......................................... 6-11
Installing the fuel filter assembly ............................................. 6-11
Low-pressure fuel pump ................................................ 6-13

Draining the fuel ...................................................................... 6-14
Removing the low-pressure fuel pump .................................... 6-14
Checking the low-pressure fuel pump ..................................... 6-15
Installing the low-pressure fuel pump ...................................... 6-15
Canister and vapor shut-off valve ................................. 6-17

Removing the canister and vapor shut-off valve ..................... 6-18
Checking the canister .............................................................. 6-18
Checking the vapor shut-off valve ........................................... 6-18
Installing the vapor shut-off valve and canister ....................... 6-19
ETV ................................................................................... 6-20

Removing the ETV .................................................................. 6-21
Checking the ETV ................................................................... 6-21
Installing the ETV .................................................................... 6-21
Fuel injector ..................................................................... 6-23

Removing the fuel injector ....................................................... 6-24
Checking the fuel rail and fuel injector .................................... 6-25
Fuel system
Installing the fuel injector ......................................................... 6-25
Intake manifold ................................................................ 6-27

Removing the intake manifold ................................................. 6-28
Checking the intake manifold .................................................. 6-28
Checking the intake air pressure/temperature sensor ............. 6-28
Installing the intake manifold ................................................... 6-29
Vapor separator and APS ............................................... 6-31

Removing the vapor separator ................................................ 6-33
Removing the APS .................................................................. 6-34
Checking the canister check valve .......................................... 6-34
Checking the APS ................................................................... 6-35
Installing the APS .................................................................... 6-35
Installing the vapor separator .................................................. 6-35
Vapor separator and high-pressure fuel pump ............ 6-38

Disassembling the vapor separator ......................................... 6-40
Checking the high-pressure fuel pump .................................... 6-41
Checking the vapor separator ................................................. 6-41
Checking the check valve ........................................................ 6-41
Assembling the vapor separator .............................................. 6-42
0
1
2
3
4
5
6
7
8
9
10
Hose routing
Hose routing
Fuel hose
k
g
5
e
k
h
f
k
c
d
a
3
1. Fuel hose (primer pump to joint)

2. Fuel hose (joint to fuel filter assembly)
3. Fuel hose (fuel filter assembly to joint)
4. Fuel hose (joint to low-pressure fuel
pump)
5. Fuel hose (low-pressure fuel pump to
vapor separator)
6. Fuel hose (vapor separator to fuel rail)
7. Fuel hose (vapor separator to joint)
c. Fuel filter assembly

d. Joint
e. Low-pressure fuel pump
f. Vapor separator
g. Quick connector
h. Fuel rail
k. Fuel injector
a. Primer pump
b. Joint
6-1
Hose routing
Pressure regulator hose, vapor gas hose, and blowby hose

f 8
10
1
c
h
4
e
6
g
9
3
A
11
12
b
k
6
a
9
8
1. Vapor gas hose (vapor separator to joint)
2. Vapor gas hose (vapor separator to joint)
3. Vapor gas hose (joint to canister tank
port)
4. Vapor gas hose (canister purge port to
vapor shut-off valve)
5. Vapor gas hose (vapor shut-off valve to
joint)
6. Vapor gas hose (joint to intake manifold)
7. Vapor gas hose (canister atmospheric
port to joint)
8. Vapor gas hose (joint to check valve)
9. Vapor gas hose (check valve to bottom

cowling)
10. Vapor gas hose (check valve to joint)
11. Pressure regulator hose (intake manifold
to pressure regulator)
12. Blowby hose (cylinder head cover to
intake silencer)
a. Vapor separator
b. Joint
c. Canister
d. Vapor shut-off valve
6-2
9
10
Hose routing
f 8
10
c
d
h
4
5
e
6
g
9
3
A
11
12
A
b
k
a
9
2
e. Joint
f. Joint
g. Check valve
h. Check valve
k. Pressure regulator
m. Intake silencer
6-3
Hose routing
Cooling water hose

1
1 9
0
e
10
13
d
11
13
g
10
14
B
B
11
12
b
14
15
3
4
1
h
16
5
6
8
b
7
5
b
4
10 11
A
12
7
8
c
3 b 2 6
1. Cooling water hose (exhaust cover to fuel

cooler)
2. Cooling water hose (fuel cooler to joint)
3. Cooling water pilot hose (joint to cooling
water pilot hole)
4. Cooling water hose (joint to joint)
5. Cooling water hose (joint to joint)
6. Cooling water hose (oil cooler to joint)
8. Cooling water hose (joint to water bypass
cover)
9. Cooling water hose (exhaust cover to oil

cooler)
10. Cooling water hose (exhaust cover to oil
cooler)
12. Cooling water hose (oil cooler to water
bypass cover)
13. Cooling water hose (thermostat cover to
joint)
14. Cooling water hose (joint to water bypass
cover)
6-4
9
10
Hose routing
1 9
e
10
13
g
13
d
11
10
14
B
B
11
12
b
14
15
1
h
16
8
b
7
5
b
4
10 11
A
12
c
3 b 2 6
15. Cooling water hose (PCV to water

bypass cover)
16. Flushing hose (flushing hose adapter to
exhaust cover)
g. Exhaust cover
h. Flushing hose adapter
a. Fuel cooler (vapor separator)

b. Joint
c. Cooling water pilot hole (on the bottom
cowling)
d. Joint
e. Thermostat cover
f. Water bypass cover
6-5
Fuel system
Fuel system
3. Disconnect the quick connector 1 from

the fuel rail.
Reducing the fuel pressure
TIP:
Cover the quick connector and fuel rail with a
plastic bag to prevent damage and dirt from
entering them.
Before servicing the high-pressure fuel

line or vapor separator, make sure to
reduce the fuel pressure in the fuel line.
Otherwise, pressurized fuel could spray
out.
0
1
1. Start the engine.

2. Remove the fuse holder cover, and then
remove the fuse (15 A) 1.
TIP:
After removing the fuse, wait until the engine
stalls.
Measuring the fuel pressure

1. Reduce the fuel pressure. See Reducing
the fuel pressure (6-6).
2. Disconnect the quick connector from the

fuel rail. See step 3 in Disconnecting the
quick connector (6-6).

the quick connector and the fuel rail.
3. After the engine stalls, crank the engine 2

or 3 times.
5. Install the fuse (15 A), and then install the

fuse holder cover.
Disconnecting the quick connector

Fuel pressure gauge adapter 1:
90890-06946
Before disconnecting the quick connector, reduce the fuel pressure. Otherwise,
pressurized fuel could spray out.
9
10
To prevent fuel from leaking out, screw in

the gauge gently until it is connected
firmly.

2. Wrap a rag around the quick connector
1.
A
6-6
Fuel system
11. Connect the quick connector to the fuel
rail.
Checking the pressure regulator

2. Disconnect the quick connector from the
fuel rail. See step 3 in Disconnecting the
quick connector (6-6).
Fuel pressure gauge 1: 90890-06753
3. Connect the special service tools 1 and

2. See steps 3 and 4 in Measuring the
fuel pressure (6-6).

then measure the fuel pressure within 5
seconds.
4. Disconnect the pressure regulator hose

3 from the intake manifold, and then
connect the special service tool 4 to the
pressure regulator 5.
TIP:
The fuel pressure will decrease 5 seconds
after the engine start switch is turned to
ON.
The high-pressure fuel pump does not
operate when the engine start switch is
turned to ON again within 10 seconds after
turning the engine start switch to OFF.
4
3
1
Fuel pressure (reference data):

310.0 kPa (3.10 kgf/cm2, 45.0 psi)
6. Install the flywheel magneto cover.

7. Start the engine and warm it up until the
engine idle speed stabilizes at 650750
r/min.
8. Measure the fuel pressure.
Fuel pressure (reference data):

250.0 kPa (2.50 kgf/cm2, 36.3 psi)
@ engine idle speed
Fuel pressure gauge adapter 1:

90890-06946
Fuel pressure gauge 2: 90890-06753
90890-06945

10. Disconnect the special service tools.
5. Block the end of the intake manifold 1

using a rubber plug 2.
Before disconnecting the special service
tools, cover the end of the hose using a
clean and dry rag.
6. Start the engine and let it idle.
6-7
Fuel system
7. Check that the fuel pressure is reduced
when negative pressure is applied to the
pressure regulator.

9. Disconnect the special service tool 3,
and then connect the pressure regulator
hose 4 to the intake manifold.
3
4
2
1
3
4
4
5
6

11. Disconnect the special service tools 1

and 2, and then connect the quick connector 3.
8
3
1
2
10
A
6-8
Fuel filter
Fuel filter
13
15 16
14
12
6
7
10
4
2
1
8
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Part name
Joint
Clamp
Hose
Plastic tie
Fuel filter assembly
O-ring
Fuel filter element
Fuel cup assembly
Clip
Float
Hose
Bolt
Bolt
Bracket
Grommet
Collar
11
Qty
1
1
1
3
1
1
1
1
1
1
1
2
2
1
2
2
6-9
Remarks
Not reusable
Joint to fuel filter assembly
Not reusable
Fuel filter assembly to joint

M6 25 mm
M6 12 mm
Fuel filter
Removing the fuel filter assembly
2. Block the fuel outlet b using a rubber

plug 2, and then apply the specified
positive pressure. Replace the O-ring,
fuel cup assembly, or fuel filter assembly
if the specified pressure cannot be maintained for 15 seconds or more.
Cover the fuel components using a rag to

prevent fuel from spilling out.
1. Disconnect the fuel hoses 1 and 2.
2. Disconnect the water detection switch
coupler a.
0
1
2
a
2
b
3. Remove the bracket 1 along with the

fuel filter assembly 2.
4
Leakage tester 1:
90890-06840
4. Remove the fuel filter assembly 2.
Specified positive pressure:

200.0 kPa (2.00 kgf/cm2, 29.0 psi)

the fuel outlet a.
4. Block the fuel inlet b using a rubber
plug 2, and then apply the specified
negative pressure. Replace the O-ring,
fuel cup assembly, or fuel filter assembly
if the specified pressure cannot be maintained for 15 seconds or more.
5. Remove the fuel hoses 1 and 2.
1
2
6
7
8
9
10
Checking the fuel filter assembly

the fuel inlet a.
b
6P3
6P3
A
6-10
Fuel filter
3. Apply the specified positive pressure.
Replace the primer pump if the specified
pressure cannot be maintained for 30
seconds or more.

90890-06945
Specified negative pressure:
80.0 kPa (0.80 kgf/cm2, 11.6 psi)
Disassembling the fuel filter

assembly
1. Remove the fuel cup assembly 1,

O-ring 2, and fuel filter element 3.
2
1
3
1

90890-06945
Specified positive pressure:
166.7 kPa (1.67 kgf/cm2, 24.2 psi)
Assembling the fuel filter assembly
Checking the fuel filter element
1. Install the fuel filter element 1, a new

O-ring 2, and the fuel cup assembly 3,
and then tighten the fuel cup assembly
3 to the specified torque.
1. Check the fuel filter element. Replace if

there is dirt or residue.
Checking the fuel cup assembly

1. Check the fuel cup assembly. Clean
using straight gasoline if there is foreign
material or replace if cracked.
2
When cleaning the fuel cup assembly, do
not remove the clip and float.
1
3
2. Check the water detection switch. See

Checking the water detection switch (526).
Checking the primer pump

the primer pump inlet a.
Fuel cup assembly 3:

2. Block the fuel outlet b using a rubber

plug 2.
Installing the fuel filter assembly

1. Route the fuel hose 1 through the
proper holes in the rigging grommet. See
Rigging grommet mounting (3-9).
6-11
Fuel filter
2. Install the retaining plate. See steps 46
in Installing the rigging grommet (3-13).
3. Route the fuel hose 2 through the bottom cowling.
0
a
TIP:
Pass the fuel hose 2 under the bracket 3.
3
4. Connect the fuel hose 2 to the joint, and
TIP:
Connect the fuel hose 2 to the joint so that
the white paint mark a on the fuel hose is
facing up.
4
5
5. Install the fuel filter assembly 1 to the

bracket 2.
6. Install the bracket 2.
10
7. Connect the fuel hoses 1 and 2, and

then fasten them using the plastic ties
3.
8. Connect the water detection switch coupler a.
A
6-12

14
12
2
1
13
2
9
10
16
11
10
11
15
2
4
11
6
5
8
7
10
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Part name
Low-pressure fuel pump cover
Bolt
Hose
Plastic tie
Clamp
Clamp
Holder
Bolt
Bracket
Grommet
Collar
Bushing
Cover
Bracket
Bolt
Qty
1
3
1
2
1
2
1
4
1
4
4
2
1
1
1
2
6-13
Remarks
M6 20 mm
Joint to low-pressure fuel pump
M6 25 mm
M6 12 mm
Draining the fuel

1. Disconnect the vapor gas hose 1 from
the canister 2.
1
4
3
2
a
1
3. Disconnect the fuel hose 1 from the

low-pressure fuel pump 2.
2. Loosen the drain screw 1 to drain the

fuel into a drain pan.
2
3
4
joint 2, and then pull out the fuel hose
1 from the holder 3.
5
6
7
3. Tighten the drain screw to the specified

torque.
Drain screw:
4. Connect the vapor gas hose to the canister.
Removing the low-pressure fuel

pump
1
5. Remove the low-pressure fuel pump
bracket 1 along with the low-pressure
fuel pump 2.

cover.
9
10
6. Remove the fuel hose 3 from the lowpressure fuel pump 2.
2. Disconnect the low-pressure fuel pump

coupler a, and then remove the lowpressure fuel pump lead 1 from the
clamp 2, holder 3, and plastic tie 4.
A
6-14
4
3

brackets 1 and 2, and then remove the
cover 3 and bushings 4 from the lowpressure fuel pump 5.
3. Connect the fuel hose 1 to the low-pressure fuel pump 2, and then fasten it
using the clamp 4.
TIP:
1
Install the fuel hose 1 so that the white paint

mark is facing toward the STBD.
3
4
5
4
4. Install the low-pressure fuel pump

bracket along with the low-pressure fuel
pump 3.
Checking the low-pressure fuel

pump
1. Check the electrical performance of the
low-pressure fuel pump. See Checking
the low-pressure fuel pump and highpressure fuel pump (5-27).
Installing the low-pressure fuel

pump
5. Connect the fuel hose 1 to the joint 2,

and then fasten it using the plastic tie 3.
1. Install the bushings 1 to the low-pressure fuel pump.
6. Insert the grommet a into the holder 4.
2. Install the low-pressure fuel pump brackets 2 and 3 and cover 4.
TIP:
Connect the fuel hose 1 to the joint 2 so
that the white paint mark b on the fuel hose
is facing up.
TIP:
Install the bushings 1 so that their upper
and lower ends are aligned with the upper
and lower ends of the low-pressure fuel
pump bracket 3.
Install the low-pressure fuel pump so that
the low-pressure fuel pump lead is positioned at the rear of the engine.
6-15
0
1
1
2
1
7. Connect the fuel hose 1, and then fasten it using the clamp 2.
5
6
8. Fasten the low-pressure fuel pump lead

1 using the clamp 2, holder 3, and
plastic tie 4.
9. Connect the low-pressure fuel pump coupler a.
8
1
4
3
2
10
A
6-16
Canister and vapor shut-off valve
1
2
3
8
4
12
11
15
5
9
10
14
13
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Part name
Bolt
Bracket
Canister
Bracket
Bolt
Grommet
Collar
Nut
Hose
Joint
Hose
Hose
Holder
Clamp
Qty
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
6-17
Remarks
M6 16 mm
M6 26 mm
Vapor shut-off valve to joint

Joint to intake manifold
Canister to vapor shut-off valve
Removing the canister and vapor

shut-off valve
1. Disconnect the vapor gas hoses 1 and

2.
2. Remove the vapor gas hoses 3 and 4

from the holder 5, and then remove the
holder 5.
3. Remove the vapor gas hose 3 from the

holders 6, and then remove the holder
6.
Checking the canister

1. Check the canister. Replace if cracked.
4. Remove the vapor gas hoses 3 and 4.

the atmospheric port a and block the
other ports using rubber plugs 2.
3. Apply the specified positive pressure and
check that there is no air leakage.
Replace the canister if there is air leakage.
3 6
1
2
3
4
5
5. Disconnect the vapor shut-off valve coupler a.
6. Remove the vapor shut-off valve 1.

7. Remove the cooling water hoses 2 and
3 from the holder 4.
8. Remove the bracket 5 along with the

canister 6.
6
90890-06945
Specified pressure:
19.6 kPa (0.20 kgf/cm2, 2.8 psi)
2 3
Checking the vapor shut-off valve

1. Check the vapor shut-off valve exterior.
Replace if cracked.
9. Remove the bracket 1 and canister 2

from the bracket 3.
9
10
2. Check the functional performance of the

vapor shut-off valve. See Checking the
vapor shut-off valve (5-29).
A
6-18
Installing the vapor shut-off valve

and canister
TIP:
Connect the vapor gas hose end with the
white paint mark c to the vapor shut-off
valve.
1. Install the bracket 1 and canister 2 to

the bracket 3.
9. Fasten the vapor gas hoses 3 and 4

using the holder 5.
3
2. Install the bracket 1 along with the canister.
3. Install the cooling water hoses 2 and 3

to the holder 4.
4 3 b
4. Install the vapor shut-off valve 5.
5. Connect the vapor shut-off valve coupler

a.
4
2 3
6. Connect the vapor gas hoses 1 and 2.
TIP:
Install the vapor gas hose 1 so that the
white paint mark a is facing toward the
engine.
7. Install the vapor gas hose 3, and then
fasten it using the clamp 6.
TIP:
Align the clamp 6 with the paint mark b on
the vapor gas hose 3.
8. Install the vapor gas hose 4.
6-19
ETV
ETV
0
18 Nm (1.8 kgfm, 13.3 ftlb)
1
2
3
9
3
3
a 18 Nm (1.8 kgfm, 13.3 ftlb)

b 18 Nm (1.8 kgfm, 13.3 ftlb)
6
3
3
5
1
18 Nm (1.8 kgfm, 13.3 ftlb)
7
1
No.
1
2
3
4
5
6
7
8
9
Part name
Bolt
Intake silencer
Bolt
Bracket
Bolt
Joint
Plastic tie
ETV
Gasket
Qty
2
1
4
1
2
1
1
1
1
Remarks
6
7
M6 25 mm
M8 60 mm
M6 25 mm
9
Not reusable
10
A
6-20
ETV
Removing the ETV

1. Disconnect the blowby hose 1.
2. Remove the intake silencer 2.
1
TPS. See Checking the ETV and TPS
(5-21).
Installing the ETV
3. Disconnect the ETV coupler a.
1. Install a new gasket 1.

4. Remove the joint 1.
2. Install the ETV 2.
3. Tighten the ETV bolts 3 to the specified

torque.
4. Install the bracket 4 and tighten the
ETV bracket bolts 5 temporarily.
5. Tighten the ETV bolts 6 temporarily.

6. While holding the ETV in the direction of
the arrow, tighten the ETV bracket bolts
5 and the ETV bolts 6 in the order [1],
[2] and so on.
5. Remove the bracket 1 and ETV 2.
7. Tighten the ETV bolts 6 to the specified

torque in 2 stages.
1
1
2
3
4
Checking the ETV
[2]
1. Check the ETV exterior. Replace if

cracked.
[3]
3
2. Turn the throttle valve manually and

check that it moves smoothly.
6-21
[3]
[1]
ETV
ETV bolt 3:
18 Nm (1.8 kgfm, 13.3 ftlb)
ETV bolt 6:
1st: 18 Nm (1.8 kgfm, 13.3 ftlb)
2nd: 18 Nm (1.8 kgfm, 13.3 ftlb)
8. Connect the ETV coupler a.
9. Install the joint 1, and then fasten it

2
1
3
a
10. Install the intake silencer 1.
11. Connect the blowby hose 2.
TIP:
Connect the blowby hose 2 with the white
paint mark a to the intake silencer 1.
6
7
8
a
9
10
A
6-22
Fuel injector
Fuel injector
2
4
3
2
4
3
2
4
6
1
2
4
3
1
5
8
No.
1
2
3
4
5
6
7
8
9
Part name
Holder
O-ring
O-ring
Fuel injector
Bolt
Fuel rail
Holder
Bolt
Holder
Qty
4
4
4
4
3
1
1
2
1
6-23
Remarks
Not reusable
Not reusable
M6 25 mm
M6 12 mm
Fuel injector
Removing the fuel injector

1
2. Disconnect the quick connector. See step

3 in Disconnecting the quick connector
(6-6).
1
1
3. Disconnect the fuel injector couplers a.
a
7. Remove the fuel rail 1 along with the
fuel injectors.
4. Remove the holder 1.
6
7
8. Remove the fuel injectors 1 along with

the holders 2.
5. Remove the holder 1 from the fuel rail

2.
2
1
6. Remove the holder 3.
8
9
10
1
2
1
2
6-24
Fuel injector
Checking the fuel rail and fuel

injector
Installing the fuel injector

1. Install new O-rings 1 and 2 and the
holder 3 to the fuel injector 4.
1. Check the fuel rail. Replace if cracked or

deformed.
fuel injector. See Checking the fuel
injector (5-27).
3. Measure the volume injected by the

injector. See the Fuel Injection Meter
Operation Manual.
2
4
2. Install the fuel injectors 1 onto the fuel

rail 2.
Do not use gasoline when measuring the

fuel injection volume. Otherwise, the cylinder could be damaged, which can cause
a gasoline leakage. Make sure to follow
the instructions for operation of the fuel
injection meter.
1
2
TIP:
When measuring, obtain a result from the

average of 4 measurements.
It is not possible to obtain correct measurements under disparate test conditions.
Make sure to fully charge the battery.
The cylinder is graduated in increments of
2.5 cm3 (2.5 cc).
Make sure to comply with the laws and regulations of the region when disposing of the
used test fuel.
3. Install the fuel rail 1 onto the cylinder

head.
4. Tighten the fuel rail bolts 2 equally.
Fuel injection meter: FIM20000ME

Fuel injection volume:
221224 cm3 (221224 cc)/30 sec
Test fuel:
Dry sorbent (viscosity: 1.2 0.03 mm2/s,
specific gravity: 0.774 [15 C])
Test fuel temperature:
2224 C (room temperature and test
fuel temperature should be the same)
Test fuel pressure: 300 1.5 kPa
Measuring cylinder internal pressure (standard atmosphere pressure):
9601060 hPa
2
1
2
2
5. Route the wire harness 1, and then
install the holder 2 to the fuel rail 3.
6-25
Fuel injector
1
3
2
2
2
3
5
6
1
8. Connect the fuel injector couplers a.

9. Connect the quick connector 1.
1
a
10
A
6-26
Intake manifold
Intake manifold
4
5
7
8
9
5
2
6
6
1
3
1
24 Nm (2.4 kgfm, 17.7 ftlb)
No.
1
2
3
4
5
6
7
8
9
Part name
Bolt
Intake manifold
Gasket
Blowby hose
Clamp
Holder
Clamp
Screw
Qty
9
1
1
1
2
2
2
2
1
6-27
Remarks
M8 40 mm
Not reusable
Cylinder head cover to intake silencer
M5 15 mm
Intake manifold
Removing the intake manifold

1. Remove the clamps 1, 2, 3, and 4.
2. Remove the blowby hose 5 and holder

6 from the intake manifold.
3. Remove the blowby hose 5 from the

cylinder head cover 7.
4. Disconnect the intake air pressure/temperature sensor coupler a.

5. Disconnect the pressure regulator hose
8 from the intake manifold.
3
6
3
3
2
3
a
8
10. Remove the intake manifold 1.
3
2
5
6
1
6
6. Remove the holder 1 from the intake
manifold 2.
7. Remove the holders 3.

8. Disconnect the drain hose 4.

clamp 6.
Checking the intake manifold
1. Check the intake manifold. Replace if

cracked or deformed.
Checking the intake air pressure/

temperature sensor
10
1. Check the intake air pressure/temperature sensor exterior. Replace if cracked.
A
6-28
Intake manifold
intake air pressure/temperature sensor.
See Checking the intake air pressure
sensor (5-34) and Checking the intake
air temperature sensor (5-34).
[8] [6]
[4]
[2]
Installing the intake manifold

1. Install a new gasket 1 onto the intake
manifold 2.
[1]
[7]
[3]
[9]
[5]
Intake manifold bolt 2:
24 Nm (2.4 kgfm, 17.7 ftlb)
3. Fit the drain hose 1 into the holder a

on the intake manifold.
4. Route the wire harness 2, and then

install the holders 3 to the intake manifold.
2. Install the intake manifold 1, and then
tighten the intake manifold bolts 2 to the
specified torque in the order [1], [2] and
so on.
5. Route the fuel hose 4, and then fasten it

using the holder 5.
6
1
6
4
3
3
2
5
3
a 1 a 3
3
7. Connect the blowby hose 1 to the cylinder head cover 2.
6-29
Intake manifold
8. Fasten the blowby hose 1 using the
holder 3, and then install the holder 3
to the intake manifold.
9. Fasten the blowby hose 1 and wire harness using the clamps 4 and 5.
10. Connect the pressure regulator hose 6
to the intake manifold.
11. Connect the intake air pressure/temperature sensor coupler a.
4
3
2
1
5
4
7
8
9
10
A
6-30
Vapor separator and APS

10
12
14
11
23
16 22
15
24
20
17
24
32
18
13
7
6
8
3
30
31
29
19
13
21
28
27
3
25
13
3
26
2
1
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Bolt
Collar
Grommet
Vapor separator
Drain hose
Hose
Hose
Holder
Holder
Hose
Holder
Hose
Plastic tie
Hose
Joint
Hose
Hose
Qty
4
8
4
1
1
1
1
1
1
1
1
1
3
1
1
1
1
6-31
Remarks
M6 35 mm
Joint to canister
Pressure regulator to intake manifold
Vapor separator to fuel rail

Low-pressure fuel pump to vapor separator
Canister to joint
Check valve to joint
Joint to check valve
10
12
14
11
0
23
16 22
15
24
20
17
24
32
18
13
7
6
8
3
30
31
29
19
13
21
28
27
3
25
13
26
2
1
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Part name
Check valve
Hose
Clamp
Clamp
Wire harness
APS
Bolt
Hose
Joint
Holder
Bolt
Hose
Hose
Joint
Clamp
Qty
2
1
1
1
1
1
3
1
1
1
1
1
1
1
1
Remarks
Check valve to bottom cowling
M6 35 mm
Vapor separator to joint
M6 10 mm
7
8
9
10
A
6-32
Removing the vapor separator

1. Drain the fuel. See Draining the fuel (614).

2. Remove the clamps 1, 2, and 3.
3. Remove the cooling water hoses 4 and
5 from the vapor separator assembly.

coupler a.
1
3
7. Disassemble the vapor gas hoses 1,
2, 3, and 4, joint 5, and check
valves 6.
5
5. Remove the vapor separator assembly
1.
4
2
6
6
3
8. Remove the pressure regulator hose 1,

vapor gas hoses 2, 3, and 4, and
joint 5.
6. Remove the clamp 1, and then remove

the vapor gas hoses 2 from the bottom
cowling.
6-33
0
1
Removing the APS
1. Disconnect the APS coupler a.

2. Remove the APS 1.
9. Remove the fuel hose 1 and quick connector 2. See steps 2 and 3 in Disconnecting the quick connector (6-6).
a
1
10. Remove the drain hose 3.

11. Disconnect the fuel pump coupler a.
Checking the canister check valve
a
2

the canister check valve port.
2. Apply positive pressure and check that

air comes out of the opposite end of the
canister check valve. Replace the canister check valve if no air comes out.
12. Remove the fuel hose 1.
10
90890-06945
6-34

the opposite canister check valve port.
no air comes out of the opposite end of
the canister check valve. Replace the
canister check valve if air comes out.
4
2
6
6
3
2. Install the vapor gas hoses 1 to the bottom cowling, and then fasten them using
the clamp 2.
Checking the APS

1. Check the APS exterior. Replace if
cracked.
APS. See Checking the APS (5-22).
Installing the APS

1. Install the APS 1.
2. Connect the APS coupler a.
2
a
1
3. Connect the fuel hose 1 to the vapor

separator assembly, and then fasten it
Installing the vapor separator

1. Connect the vapor gas hoses 1, 2, 3,
and 4 to the joint 5 and check valves
6.
6-35
7
1
3
2
3
2
6
5
5. Connect the fuel pump coupler a.
6. Install the drain hose 1.

7. Connect the quick connector 2.
13. Install the vapor separator assembly 1.
8. Install the fuel hose 3, and then fasten it

using the clamp 4.
6
a
4
5
9. Fasten the fuel hose 3 and 5 using the

holder 6.
3
4
2
7
14. Connect the high-pressure fuel pump
coupler a.
10. Connect the pressure regulator hose 1,

vapor gas hoses 2, 3, and 4, and
joint 5.
11. Fasten the pressure regulator hose 1
and vapor gas hose 2 using the holder
6.
15. Fasten the fuel hose 1 and high-pressure fuel pump lead 2 using the clamp
3.
16. Fasten the high-pressure fuel pump lead

2 and vapor gas hoses 4 using the
clamp 5.
10
17. Connect the cooling water hose 6 to the

vapor separator, and then fasten it using
the plastic tie 7.
12. Fasten the vapor gas hose 4 and fuel

hose using the holder 7.
18. Connect the cooling water hose 8 to the

vapor separator.
6-36

19. Fasten the knock sensor lead 9, pressure regulator hose 10, and vapor gas
hose 11 using the clamp 12.
1
3
4
5
12
9
10
11
6
7
6-37
Vapor separator and high-pressure fuel pump

3.5 Nm (0.35 kgfm, 2.58 ftlb)
11
6
25
10
29
28
4
27
16
12
13
26
30
14
3.5 Nm (0.35 kgfm, 2.58 ftlb)
3
21
19
20
22
15
23
31
24
17
18
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Vapor separator cover assembly
Screw
Holder
Pressure regulator
Bolt
Cover
Gasket
Filter
Check valve
Screw
Gasket
Grommet
Joint
Damper
High-pressure fuel pump
Lead
Filter
Qty
1
1
1
1
3
1
1
1
1
6
1
1
1
1
1
1
1
6-38
M5 12 mm
Remarks
7
8
M4 12 mm
Not reusable
M4 16 mm
Not reusable
10
3.5 Nm (0.35 kgfm, 2.58 ftlb)
11
6
25
10
1
29
28
4
27
16
12
13
26
30
14
3.5 Nm (0.35 kgfm, 2.58 ftlb)
3
21
19
20
22
15
23
31
24
17
18
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Part name
Holder
Needle valve assembly
O-ring
Screw
Pin
Float
Screw
Float chamber assembly
Screw
Cover
Gasket
Gasket
Drain screw
Drain hose
Qty
1
1
1
1
1
1
1
1
3
1
1
1
1
1
6-39
Remarks
Not reusable
M4 8 mm
M4 8 mm
M5 6 mm
Not reusable
Not reusable
Disassembling the vapor separator
5. Remove the vapor separator cover 1

and gasket 2.
1. Remove the drain screw 1 and drain

hose 2.
6. Disconnect the fuel pump coupler a,

and then remove the high-pressure fuel
pump 3 and grommet 4.
2
2. Remove the cover 1 and gaskets 2
and 3.
3. Remove the holder 4, and then remove

the pressure regulator 5.
3
4
7. Remove the screw 1, and then remove

the pin 2 and float 3.
1
5
8. Remove the screw 4, and then remove

the needle valve assembly 5.
3
1
4
5
6
7
4. Remove the cover 1, gasket 2, filter

3, and check valve 4.
8
3
2
4
coupler a, and then remove the filter
holder 1, filter 2, adapter 3, and
damper 4.
10
A
6-40
3
a
a
Float height a:
67.5 2.5 mm (2.66 0.10 in)
1
4
Checking the check valve

the check valve port a.
Checking the high-pressure fuel

pump
high-pressure fuel pump. See Checking
the low-pressure fuel pump and highpressure fuel pump (5-27).

air comes out of the opposite end b of
the check valve. Replace the check valve
if no air comes out.
Checking the vapor separator

1. Check the needle valve. Replace the
needle valve assembly if bent or worn.

90890-06945
the opposite check valve port a.
2. Check the float. Replace if deteriorated.

3. Check the filter. Clean if there is dirt or
residue.

no air comes out of the opposite end b
of the check valve. Replace the check
valve if air comes out.
4. Place the cover assembly upside down,

and then measure the float height a.
TIP:
When measuring the float height, the float
should be resting on the needle valve. Do not
press the float.
6-41

4. Install the grommet 1 and high-pressure fuel pump 2, and then connect the
high-pressure fuel pump coupler a.

90890-06945
Assembling the vapor separator

1. Install the needle valve assembly 1, and
then tighten the needle valve assembly
screw 2 to the specified torque.
2. Install the float 3 and pin 4, and then

tighten the float pin screw 5 to the specified torque.
5. Install a new gasket 1 and the vapor

separator cover 2, and then tighten the
float chamber cover screws 3 to the
specified torque.
3
2
3
4
3
1
Needle valve assembly screw 2:
Float pin screw 5:
5
6
7
3. Install the damper 1, adapter 2, filter

3, and filter holder 4, and then connect the high-pressure fuel pump coupler
a.
Float chamber cover screw 3:

6. Install the check valve 1, the filter 2, a
new gasket 3, and the cover 4, and
then tighten the cover bolts 5 to the
specified torque.
8
9
10
a
4
1
A
6-42
5
2
4
3
Drain screw 2:
Cover bolt 5:
7. Install the pressure regulator 1 and
holder 2, and then tighten the pressure
regulator screw 3 to the specified
torque.
8. Install new gaskets 4 and 5 and the
fuel cooler cover 6, and then tighten the
fuel cooler cover screws 7 to the specified torque.
3
2
6
1
5
4
Pressure regulator screw 3:

3.5 Nm (0.35 kgfm, 2.58 ftlb)
Fuel cooler cover screw 7:
3.5 Nm (0.35 kgfm, 2.58 ftlb)
9. Install the drain hose 1 and drain screw
2, and then tighten the drain screw 2
6-43
Power unit
Power unit (check and adjustment) ................................. 7-1
Checking the compression pressure ......................................... 7-1
Checking the oil pressure .......................................................... 7-1
Checking the pulser coil air gap ................................................ 7-1
Checking the valve clearance ................................................... 7-2
Adjusting the valve clearance .................................................... 7-4
Power unit assembly (L-transom model) ........................ 7-6

Power unit assembly (X-transom model) ........................ 7-8
0
1
2
Removing the power unit ......................................................... 7-10

Installing the power unit ........................................................... 7-13
Flywheel magneto ........................................................... 7-17
Removing the flywheel magneto ............................................. 7-18

Installing the flywheel magneto ............................................... 7-19
Timing belt ....................................................................... 7-21
Removing the timing belt ......................................................... 7-22

Checking the timing belt .......................................................... 7-22
Installing the timing belt ........................................................... 7-22
Starter motor ................................................................... 7-25

Removing the starter motor ..................................................... 7-27
Installing the starter motor ....................................................... 7-27
Engine ECM ..................................................................... 7-29

Fuse box .......................................................................... 7-30
Rectifier/Regulator/Isolator ............................................ 7-31
Removing the Rectifier/Regulator/Isolator ............................... 7-32
Installing the Rectifier/Regulator/Isolator ................................. 7-32
7
8
9
10
Ignition coil and spark plug ........................................... 7-34

Checking the spark plug .......................................................... 7-35
Wire harness .................................................................... 7-36

Removing the wire harness ..................................................... 7-38
Installing the wire harness ....................................................... 7-39
Power unit
Camshaft .......................................................................... 7-42
Removing the driven sprocket and camshaft .......................... 7-44
Checking the sprocket ............................................................. 7-45
Checking the valve lifter .......................................................... 7-45
Checking the camshaft ............................................................ 7-46
Checking the camshaft journal oil clearance ........................... 7-46
Installing the camshaft and driven sprocket ............................ 7-48
Cylinder head .................................................................. 7-52

Removing the cylinder head .................................................... 7-55
Disassembling the cylinder head ............................................. 7-55
Checking the cylinder head ..................................................... 7-56
Checking the cylinder head bolt .............................................. 7-56
Checking the valve spring ....................................................... 7-56
Checking the valve .................................................................. 7-57
Checking the valve guide ........................................................ 7-57
Replacing the valve guide ....................................................... 7-58
Checking the valve seat .......................................................... 7-58
Refacing the valve seat ........................................................... 7-59
Checking the cylinder head and cylinder block anode ............ 7-61
Assembling the cylinder head ................................................. 7-61
Installing the cylinder head ...................................................... 7-62
Exhaust cover .................................................................. 7-64

Removing the exhaust cover ................................................... 7-67
Checking the PCV ................................................................... 7-68
Checking the thermostat ......................................................... 7-68
Checking the exhaust cover anode ......................................... 7-68
Installing the exhaust cover ..................................................... 7-68
Oil cooler .......................................................................... 7-71

Removing the crankcase cover ............................................... 7-74
Checking the crankcase cover anode ..................................... 7-74
Installing the crankcase cover ................................................. 7-74
Cylinder block ................................................................. 7-76

Removing the oil pump assembly ........................................... 7-79
Removing the oil filter bracket ................................................. 7-79
Removing the balancer assembly ........................................... 7-79
Disassembling the oil pump .................................................... 7-79
Checking the oil pump ............................................................. 7-80
Power unit
Assembling the oil pump ......................................................... 7-80
Installing the oil pump assembly ............................................. 7-81
Checking the cylinder block anode .......................................... 7-81
Installing the balancer assembly ............................................. 7-81
Installing the oil filter bracket ................................................... 7-82
0
1
Crankcase ........................................................................ 7-84

Disassembling the cylinder block ............................................ 7-86
Checking the piston diameter .................................................. 7-87
Checking the cylinder bore ...................................................... 7-87
Checking the piston clearance ................................................ 7-87
Checking the piston ring .......................................................... 7-88
Checking the piston ring end gap ............................................ 7-88
Checking the piston ring groove .............................................. 7-88
Checking the piston ring side clearance .................................. 7-89
Checking the piston pin boss inside diameter ......................... 7-89
Checking the piston pin diameter ............................................ 7-89
Checking the connecting rod small end inside diameter and
big end inside diameter ........................................................... 7-90
Checking the connecting rod big end side clearance .............. 7-90
Checking the crankshaft .......................................................... 7-90
Checking the big end oil clearance ......................................... 7-91
Selecting the crankshaft pin bearing ....................................... 7-92
Crankshaft pin bearing selection table .................................... 7-94
Checking the journal oil clearance .......................................... 7-95
Selecting the crankshaft journal bearing ................................. 7-96
Crankshaft journal bearing selection table .............................. 7-98
Assembling the cylinder block ................................................. 7-99
2
3
4
5
6
7
8
9
10
Power unit (check and adjustment)
Power unit (check and

adjustment)
9. Install the ignition coils.

10. Connect the fuel injector couplers.
Checking the compression pressure

1. Start the engine, warm it up for 5 minutes, and then stop it.
Checking the oil pressure

1. Connect the YDIS to display Oil pressure.
2. Remove the clip from the engine shut-off

switch.
2. Start the engine and warm it up until the

engine idle speed stabilizes at
650750 r/min.
3. Disconnect the fuel injector couplers.

4. Remove all of the ignition coils and spark
plugs.
Oil pressure (reference data):

420.0 kPa (4.20 kgf/cm2, 60.9 psi)
@ 60 C (140 F) / SL 10W-30
engine oil / 700 r/min
520.0 kPa (5.20 kgf/cm2, 75.4 psi)
@ 64 C (147 F) / SL 10W-30
engine oil / 3000 r/min
5. Install the special service tools 1 and

2 into the spark plug hole.
1
2
3. Measure the oil pressure.
Before removing the spark plugs, remove

any dirt or dust in the spark plug wells
that could fall into the cylinders.
3
4
Checking the pulser coil air gap
2
Do not turn the flywheel magneto counterclockwise. Otherwise, the water pump
impeller could be damaged.
1. Turn the flywheel magneto clockwise to

align the protrusion a on the flywheel
magneto with the protrusion b on the
pulser coil.
Compression gauge 1: 90890-03160

Compression gauge extension 2:
90890-06563
2. Measure the pulser coil air gap c.
6
7
8
6. Crank the engine until the reading on the

compression gauge stabilizes, and then
measure the compression pressure.
Minimum compression pressure

(reference data):
770.0 kPa (7.70 kgf/cm2, 111.7 psi)
@ 20 C (68 F)
9
10
7. Remove the special service tools.
Pulser coil air gap c:

0.361.14 mm (0.0140.045 in)
8. Install all of the spark plugs, and then

tighten the spark plugs to the specified
torque.
Spark plug: 28 Nm (2.8 kgfm, 20.7 ftlb)
7-1
Checking the valve clearance

Measure the valve clearances when the
engine is cold.
1. Remove the ignition coil cover and lowpressure fuel pump cover.
2. Remove the dampers 1 and 2.
6. Turn the flywheel magneto 1 clockwise
until the dowel pin hole (TDC) a in the
flywheel magneto 1 is aligned between
the VCT assembly 2 and the driven
sprocket 3.
7. Check that the I mark b on the VCT

assembly and oval mark c on the driven
sprocket are aligned.
b
2
3. Disconnect the ignition coil couplers a,
and then remove the holders 1, 2, and
3, clamp 4, joint connector 5, ignition
coils 6, and spark plugs.
c
3
4. Disconnect the blowby hose 7.
2
3
a
2
a
1
5
8. Measure the valve clearances a and b

according to steps 911.
TIP:
Write down the measurement data.
5. Remove the cylinder head cover 1.
7-2
EX
IN
#1
#2
#3
#4
11. Measure the intake and exhaust valve

clearances of the specified cylinders.
Adjust if out of specification. See Adjusting the valve clearance (7-4).
IN
EX
IN
EX
#3
#3
#4
12. Install a new gasket 1 and the cylinder

head cover 2.
9. Measure the intake and exhaust valve

clearances of the specified cylinders.
Adjust if out of specification. See Adjusting the valve clearance (7-4).
#2
#2
: Not applicable
: Specified cylinder
Valve clearance:
Intake a:
0.170.24 mm (0.00670.0094 in)
Exhaust b:
0.310.38 mm (0.01220.0150 in)
#1
#1
#4
4
5
6
7
8
9
10
: Not applicable
: Specified cylinder
10. Turn the flywheel magneto 1 clockwise
until the dowel pin hole (TDC) a in the
flywheel magneto 1 is aligned between
the VCT assembly 2 and the driven
sprocket 3.

tighten them to the specified torque.
7-3

14. Install the ignition coils 1, holders
2,3, and 4, and joint connector 5,
and then connect the ignition coil couplers a.
Do not turn the flywheel magneto, VCT
assembly or driven sprocket when the
timing belt is not installed. Otherwise,
the pistons and valves, or intake and
exhaust valves will collide with each
other and be damaged.
15. Connect the blowby hose 6 and fasten

the blowby hose and wire harness using
the holder 7.
4
a
1. Remove the flywheel magneto. See

Removing the flywheel magneto (7-18).
2. Remove the stator assembly. See

Removing the flywheel magneto (7-18).
2
1
3. Remove the timing belt. See Removing

the timing belt (7-22).
a
4
4. Remove the VCT assembly, driven

sprocket, camshaft caps, camshafts, and
valve lifters. See Removing the driven
sprocket and camshaft (7-44).
16. Install the dampers 1 and 2.
TIP:
Make sure to keep the parts in the order of
removal.
5. Measure the valve lifter thickness a,

and then write down the measurement
data.
17. Install the ignition coil cover and lowpressure fuel pump cover.
Adjusting the valve clearance

Adjust the valve clearances when the engine
is cold.
6. Select the necessary valve lifter by calculating its thickness using the following formula.
7-4

Calculation formula:
Necessary valve lifter thickness = Removed
valve lifter thickness + Measured valve clearance Specified valve clearance
Example:
Removed valve lifter thickness = 3.000 mm
Measured valve clearance = 0.30 mm
Specified valve clearance = 0.20 mm
Necessary valve lifter thickness
= 3.000 mm + 0.30 mm 0.20 mm
= 3.100 mm
0
1
2
7. Install the valve lifters, camshafts, camshaft caps, driven sprocket, and VCT
assembly. See Installing the camshaft
and driven sprocket (7-48).
8. Install the timing belt. See Installing the

timing belt (7-22).
9. Install the stator assembly. See Installing the flywheel magneto (7-19).
10. Install the flywheel magneto. See Installing the flywheel magneto (7-19).
6
7
8
9
10
A
7-5
Power unit assembly (L-transom model)

12
11
13
15
14 16
13
12
19
15
16
20
26
8
30
27 18
22 21
10
28
22
28
4
29
5
29
25
1
23
a 42 Nm (4.2 kgfm, 31.0 ftlb)

b 42 Nm (4.2 kgfm, 31.0 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Rigging tube retainer
Bolt
Grommet holder
Plastic tie
Rigging grommet
Power unit assembly
Dipstick
Dipstick guide
Bolt
O-ring
Bolt
Bolt
Cover
Grommet
Collar
Cover
24
a 20 Nm (2.0 kgfm, 14.8 ftlb)
b 20 Nm (2.0 kgfm, 14.8 ftlb)
Qty
1
2
1
1
1
1
1
1
1
1
1
3
2
1
2
2
1
7-6
Remarks
M6 14 mm
M6 16 mm
Not reusable
M6 20 mm
M6 30 mm
17
12
11
13
15
14 16
13
12
19
15
16
20
1
2
26
8
17
30
27 18
22 21
10
28
22
28
4
29
5
29
25
1
23
a 42 Nm (4.2 kgfm, 31.0 ftlb)

b 42 Nm (4.2 kgfm, 31.0 ftlb)
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
Part name
Cover
Cover
Screw
Gasket
Dowel pin
Bolt
Bolt
Bolt
Apron
Screw
Screw
Nut
Nut
24
a 20 Nm (2.0 kgfm, 14.8 ftlb)
b 20 Nm (2.0 kgfm, 14.8 ftlb)
Qty
2
1
2
1
2
4
8
3
1
2
2
2
2
Remarks
M5 20 mm
Not reusable
6
7
8
M10 35 mm
M10 140 mm
M8 35 mm
M6 20 mm
M6 40 mm
M6
M6
10
A
7-7
Power unit assembly (X-transom model)

12
13
15
14 16
11
13
17
12
19
15
16
20
26
29
31 32
6
34
28 18 30
29
34
22 21
10
22
4
27
29
30
29
32
30
25
1
23
a 42 Nm (4.2 kgfm, 31.0 ftlb)

b 42 Nm (4.2 kgfm, 31.0 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Rigging tube retainer
Bolt
Grommet holder
Plastic tie
Rigging grommet
Power unit assembly
Dipstick
Dipstick guide
Bolt
O-ring
Bolt
Bolt
Cover
Grommet
Collar
Cover
33
24
a 20 Nm (2.0 kgfm, 14.8 ftlb)
b 20 Nm (2.0 kgfm, 14.8 ftlb)
Qty
1
2
1
1
1
1
1
1
1
1
1
3
2
1
2
2
1
7-8
Remarks
M6 14 mm
M6 16 mm
Not reusable
M6 20 mm
M6 30 mm
29 31
12
13
15
14 16
11
13
17
12
19
15
16
20
26
8
29
31 32
6
34
28 18 30
29
34
22 21
10
22
4
27
29
30
29
32
30
25
1
23
a 42 Nm (4.2 kgfm, 31.0 ftlb)

b 42 Nm (4.2 kgfm, 31.0 ftlb)
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Part name
Cover
Cover
Screw
Gasket
Dowel pin
Bolt
Bolt
Bolt
Apron (STBD)
Apron (PORT)
Screw
Bolt
Bolt
Collar
Grommet
Nut
Nut
33
24
a 20 Nm (2.0 kgfm, 14.8 ftlb)
b 20 Nm (2.0 kgfm, 14.8 ftlb)
Qty
2
1
2
1
2
4
8
3
1
1
2
7
3
2
2
2
2
7-9
Remarks
M5 20 mm
Not reusable
M10 35 mm
M10 140 mm
M8 35 mm
M6 20 mm
M6 14 mm
M6 30 mm
M6
M6
29 31
5
6
7
8
9
10
Removing the power unit

1. Remove the rigging tube retainer 1,
grommet holder 2, and rigging grommet
3.
1
2
3
2
1
6. Disconnect the PTT motor leads 1 and
2, and then remove the PTT motor
leads from the holders 3, 4, 5, and
6 and clamp 7.
2. Remove the clips 1, throttle cable 2,

and shift cable 3.
3
1
4
2
1
3
25
3. Release the holders 1, and then

remove the throttle cable 2 and shift
cable 3 from the cable holder 4.
1
4
7. Disconnect the main wire harness coupler a.
2
3
4. Disconnect the battery cables 1, and
then remove the battery cables from the
holders 2.
5. Remove the PTT relay cover 3.

8. Remove the wire harness from the holder
1 and clamp 2.
7-10
0
1
a
13. Remove the isolator lead coupler a from

the bracket 1.
9. Remove the Digital Network Gauge harness coupler a and gauge harness coupler b from the bracket 1.
10. Disconnect the Digital Network Gauge
harness coupler a or gauge harness
coupler b.
1
a
4
5
14. Disconnect the fuel hose 1.
1
a
b
15. Disconnect the vapor gas hose 1 and
cooling water pilot hose 2.
8
9
A. Digital Network Gauge (6Y8)

B. Conventional gauge
11. Remove the trim sensor coupler a from

the bracket 1.
10
12. Disconnect the trim sensor coupler a.
1
16. Disconnect the shift cut-off switch coupler a, shift position switch coupler b,
and PTT switch coupler c.
7-11
b
c
17. Remove the dipstick guide 1.
4
2
21. Remove the apron 1 (aprons 2 and 3
for X-transom model).
A
1
18. Disconnect the speed sensor hose 1

from the speed sensor 2.
B
2
19. Remove the speed sensor hose 1 from
the holder 2.
20. Disconnect the flushing hose 3, and
then remove the flushing hose from the
holder 4.
A. L-transom model
B. X-transom model
2.
7-12

23. Hook a lifting harness onto the special
service tools 1 and 2, and then suspend the power unit 3.
6
7
24. Remove the power unit mounting bolts

4, 5, and 6, and then remove the
power unit 3 and dowel pins 7.
2
A
0
1
A
5
6
4
A
6
6
7
7 8
Power unit mounting bolt (M8) 6:

1st: 20 Nm (2.0 kgfm, 14.8 ftlb)
2nd: 20 Nm (2.0 kgfm, 14.8 ftlb)
Power unit mounting bolt (M10) 7 and 8:
1st: 42 Nm (4.2 kgfm, 31.0 ftlb)
2nd: 42 Nm (4.2 kgfm, 31.0 ftlb)
6
4 5

Balance hanger B 4: 90890-06682

Balance hanger B 2: 90890-06682
Installing the power unit
5. Install the aprons 1 (aprons 2 and 3

for X-transom model), and then tighten
the apron screws 4 and 5 (4 for Xtransom model) to the specified torque.
1. Clean the power unit mating surface, and

then install the dowel pins 1 and a new
gasket 2.

4.
4
1
3. Hook a lifting harness onto the special

service tools 3 and 4, and then suspend the power unit 5.
4
5
6
7
8
9
4. Install the power unit 5, and then tighten

the power unit mounting bolts 6, 7,
and 8 to the specified torque in 2
stages.
10
A
7-13
4
2
2
1
3
a
4
b
3
5
9. Connect the speed sensor hose 1 to

the speed sensor 2 and fasten it using
the plastic tie 3.
A. L-transom model
B. X-transom model
Apron screw 4:
Apron screw 5 (for L-transom model):
1 3 2
6. Connect the flushing hose 1, and then

fasten it using the plastic tie 2 and
holder 3.
TIP:
Align the holder 3 with the white paint mark
a on the flushing hose 1.
10. Install the dipstick guide 1.
7. Fasten the speed sensor hose 4 using

the holder 5.
8. Route the cooling water hose 6 through
the bottom cowling rib.
TIP:
Align the white paint mark c on the cooling
water hose 6 with the rib b.
11. Connect the shift cut-off switch coupler

a, shift position switch coupler b, and
PTT switch coupler c.
7-14
a
b
1
a
12. Connect the vapor gas hose 1 and cooling water pilot hose 2.
15. Connect the trim sensor coupler a, and

then install the trim sensor coupler a to
the bracket 1.
2
3
1
a
1
13. Connect the fuel hose 1, and then fasten it using the plastic tie 2.
16. Connect the Digital Network Gauge harness coupler a or gauge harness coupler b.
TIP:
Connect the fuel hose 1 to the joint so that
the white paint mark a on the fuel hose is
facing up.
17. Install the Digital Network Gauge harness coupler a and gauge harness coupler b to the bracket 1.
5
6
7
8
1
1
2
a
14. Install the isolator lead coupler a to the
bracket 1.
10
1
A
7-15

A. Digital Network Gauge (6Y8)
B. Conventional gauge
PTT motor lead bolt 2:

3.5 Nm (0.35 kgfm, 2.58 ftlb)
18. Fasten the wire harness using the holder

1 and clamp 2.
22. Install the PTT relay cover 1.

23. Connect the positive battery cable 2,
and then tighten the positive battery
cable nut 3 to the specified torque.
24. Install the rubber cap 4.

25. Fasten the battery cables using the holders 5.

a.
Positive battery cable nut 3:

20. Connect the PTT motor leads 1, and

then tighten the PTT motor lead bolts 2
26. Install the throttle cable. See Installing

the throttle cable (3-11).
21. Fasten the PTT motor leads using the

holders 3, 4, 5, and 6 and clamp
7.
3
1
2
4
7
1 5
6
7-16
Flywheel magneto
Flywheel magneto
1
a 40 Nm (4.0 kgfm, 29.5 ftlb)

b 90
8
0
1
11
11
3
11
7
11
4
10
5
6
No.
1
2
3
4
5
6
7
8
9
10
11
Part name
Bolt
Stator assembly
Base assembly
Dowel pin
Plastic tie
Bolt
Pulser coil
Bolt
Flywheel magneto
Dowel pin
Bolt
Qty
6
1
1
2
1
2
1
6
1
1
4
Remarks
M6 35 mm
8
M5 20 mm
Not reusable, M10 50 mm
M6 30 mm
10
A
7-17
Flywheel magneto
Removing the flywheel magneto

1. Loosen the flywheel magneto bolts 1.
4
2
Apply force in the direction of the arrow to

prevent the universal magneto and rotor
holder 2 from slipping off easily.
1
3
1
a
2
6. Remove the stator assembly leads 1
from the holders 2 and 3.
7. Remove the stator assembly coupler a

from the junction box, and then disconnect the stator assembly couplers a and
b.
3
3
A. Conventional special service tool
B. New special service tool
Universal magneto and rotor holder 2:

YU-01235
Flywheel stopper B 3: YB-06686
a
b
2. Remove the flywheel magneto.
8. Remove the stator assembly 1, base

assembly 2, and dowel pins 3.
3. Remove the pulser coil coupler a from

the junction box, and then disconnect the
pulser coil coupler a.
4. Remove the pulser coil lead 1 from the
plastic tie 2 and holder 3.
5. Remove the pulser coil 4.
7-18
Flywheel magneto
5. Connect the stator assembly couplers a
and b.
1
2
2
3
a
b
Installing the flywheel magneto

1. Install the dowel pins 1 to the base
assembly 2.
2. Install the base assembly 2 and stator
assembly 3.
6. Install the pulser coil 1, adjust the air

gap, and then tighten the pulser coil bolts
2 to the specified torque. See Checking the pulser coil air gap (7-1).
7. Connect the pulser coil coupler a, and

then install the pulser coil coupler a to
the junction box.
8. Fasten the pulser coil lead 3 using the

holder 4 and plastic tie 5.
2
3
4
a
Pulser coil bolt 2:

3. Fasten the stator assembly leads 1

using the holders 2 and 3.
10
4. Install the starter assembly coupler a to

the junction box.
A
7-19
Flywheel magneto
9. Install the flywheel magneto, and then
tighten new flywheel magneto bolts 1 to
the specified torques in 2 stages and in
the order [1], [2], and so on.
A. Conventional special service tool

B. New special service tool
Rotor holder 2: 90890-01235
Flywheel stopper B 3:
90890-06686
Apply force in the direction of the arrow to

prevent the special service tool 2 from
slipping off easily.
Flywheel magneto bolt 1:

1st: 40 Nm (4.0 kgfm, 29.5 ftlb)
2nd: 90
TIP:
In the second tightening stage for the flywheel magneto bolts 1, mark the bolts and
flywheel magneto with identification marks
a, and then tighten the bolts 90 from the
marks on the flywheel magneto.
1
2
90
3
3
90
[1]
[6]
[3]
[4]
[5]
[2]
7-20
Timing belt
Timing belt
39 Nm (3.9 kgfm, 28.8 ftlb)
6
5
4
2
3
4
5
6
No.
1
2
3
4
5
6
Part name
Timing belt
Timing belt tensioner
Bolt
Spring
Plate
Bolt
Qty
1
1
1
1
1
1
Remarks
M10 55 mm
M6 16 mm
7
8
9
10
A
7-21
Timing belt
Removing the timing belt

1
When the timing belt is not installed, do
not turn the crankshaft, driven sprocket or
VCT assembly. Otherwise, the pistons and
valves could collide with each other and
be damaged.
1. Turn the crankshaft clockwise to align the
mark a in the crankshaft and the
protrusion b on the cylinder block.
Check that the I mark c on the VCT
assembly and the oval mark d on the
driven sprocket are aligned.
5. Remove the timing belt tensioner 1.
b
a
Checking the timing belt

1. Check the interior and exterior of the timing belt. Replace if cracked, damaged, or
worn.
2. Remove the spring 1.
Installing the timing belt
3. Loosen the timing belt tensioner bolt 2.

not turn the crankshaft, driven sprocket or
VCT assembly. Otherwise, the pistons and
be damaged.
1. Remove all of the ignition coils and spark

plugs.
4. Remove the timing belt 1 from the VCT
assembly side.
TIP:
Before installing the timing belt, remove all
spark plugs to remove compression and prevent the crankshaft from turning.
7-22
Timing belt
2. Press and hold the timing belt tensioner
1 in the loosening direction and tighten
the timing belt tensioner bolt 2.
2
1
1
5. Adjust the timing belt to the specified
installation height a, b, and c.
3. Check that the mark a in the crankshaft and the protrusion b on the cylinder block are aligned. Check that the I
mark c on the VCT assembly and the
oval mark d on the driven sprocket are
aligned.
b
a
Timing belt installation height:

a: 3.0 mm (0.12 in)
b: 5.5 mm (0.22 in)
c: 2.5 mm (0.10 in)
6. Install the timing belt tensioner spring 1.
4
5
6
a
1
7
8
4. Install a new timing belt with its part number in the proper orientation, from the
drive sprocket side to the driven sprocket
and VCT assembly, in the counterclockwise direction.
7. Turn the crankshaft clockwise, and then
align the mark a on the driven
sprocket and protrusion b on the valve
plate.
Do not apply grease or oil to the timing

belt.
8. Check that the timing belt has not slipped

off its tensioner. If the belt has slipped off,
turn the crankshaft clockwise 2 full turns,
and then check that the belt has not
slipped off when the mark a on the
driven sprocket and protrusion b on the
valve plate are aligned.
7-23
9
10
Timing belt
a
b
9. Loosen the timing belt tensioner bolt a

half turn and check that the timing belt is
taut, and then tighten the timing belt tensioner bolt to the specified torque.
Timing belt tensioner bolt:
39 Nm (3.9 kgfm, 28.8 ftlb)
10. Turn the crankshaft clockwise a half turn,
and then check that the mark a in
the crankshaft and the protrusion b on
the cylinder block are aligned. Also,
check that the I mark c on the VCT
assembly and the oval mark d on the
b
a

7-24
Starter motor
Starter motor
11
25 Nm (2.5 kgfm, 18.4 ftlb)
15
13 12
29 Nm (2.9 kgfm, 21.4 ftlb)
14
4
9
10
10
5
16
1
8
18
17
19
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Cap
Nut
Terminal
Starter motor
Bolt
Cap
Screw
Battery cable
Bracket
Dowel pin
Bolt
Bolt
Bolt
Bracket
Holder
Bolt
Bolt
Qty
1
1
1
1
3
1
1
1
1
2
1
2
1
1
1
1
1
7-25
Remarks
M8
5
6
7
8
M8 45 mm
M4 8 mm
M6 15 mm
M8 35 mm
M6 16 mm
M6 35 mm
M8 16 mm
9
10
Starter motor
11
25 Nm (2.5 kgfm, 18.4 ftlb)
15
13 12
29 Nm (2.9 kgfm, 21.4 ftlb)
14
4
9
10
10
5
16
2
1
8
18
17
19
No.
18
19
Part name
Washer
Nut
Qty
1
1
7-26
Remarks
M8
Starter motor
Removing the starter motor
1. Remove the cap 1 and terminal 2, and

then disconnect the positive lead 3.
2. Disconnect the starter motor lead 4.
Starter motor bracket bolt 3:

25 Nm (2.5 kgfm, 18.4 ftlb)
3
4
3. Install the Rectifier/Regulator/Isolator

ground lead 1, and then tighten the
Rectifier/Regulator/Isolator lead bolt 2.
3. Remove the starter motor 1.
3
4
5
4. Install the starter motor 1, and then
tighten the starter motor bolts 2 to the
specified torque.
4. Remove the Rectifier/Regulator/Isolator

ground lead 1.
5. Remove the starter motor bracket 2.
6
7
2
Starter motor bolt 2:
29 Nm (2.9 kgfm, 21.4 ftlb)
Installing the starter motor

1. Install the dowel pins 1 to the starter
motor bracket 2.
9
10
2. Install the starter motor bracket 2, and

then tighten the starter motor bracket
bolts 3 to the specified torque.
A
7-27
Starter motor
5. Connect the starter motor lead 1, and
then tighten the starter motor lead screw
6. Cover with the cap 3.
7. Install the positive lead 4 and terminal
5, and then tighten the terminal nut 6
8. Install the cap 7.
5
1
6
7
2
4
3
Starter motor lead screw 2:

Terminal nut 6:
7-28
Engine ECM
Engine ECM
0
1
5
8
4
3
4
5
9
2
11
6
3 4
10
2
2.5 Nm (0.25 kgfm, 1.84 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
Part name
Engine ECM
Bolt
Bolt
Grommet
Collar
Holder
Screw
Bracket
Bolt
Holder
Holder
2.5 Nm (0.25 kgfm, 1.84 ftlb)
Qty
1
4
3
3
3
1
2
1
2
1
1
Remarks
M6 20 mm
M6 35 mm
M6 20 mm
M6 16 mm
7
8
9
10
A
7-29
Fuse box
Fuse box
7
11 10
A
1
12
7
5
12
2
8
9
6
10
11
4
13
14
25 Nm (0.25 kgfm, 1.84 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part name
Fuse box assembly
Cover
Cover
Fuse puller
Relay
Screw
Fuse
Fuse
Fuse
Fuse
Fuse
Screw
Grommet
Screw
Qty
1
1
1
1
4
4
3
3
2
3
2
13
1
4
7-30
Remarks
M5 10 mm
60 A, spare is included.
M3 10 mm
M5 20 mm
4
5
2
2
3
A
3
4
5
6
No.
1
2
3
4
5
Part name
Gasket
Bolt
Bolt
Clamp
Qty
1
1
6
1
1
Remarks
Not reusable
M6 35 mm
M6 15 mm
7
8
9
10
A
7-31
Removing the Rectifier/Regulator/

Isolator

ground lead from the starter motor
bracket. See step 4 in Removing the
starter motor (7-27).
ground lead 1 from the clamp 2 and
holder 3.
a
1.
2
1
3
3. Remove the positive leads 1 from the

holders 2 and 3.
Installing the Rectifier/Regulator/

Isolator
1. Install a new gasket 1 and the Rectifier/
Regulator/Isolator 2.
1
1
2
3

coupler a from the junction box.
coupler b from the junction box, and
then disconnect the Rectifier/Regulator/
Isolator coupler b.
2. Connect the Rectifier/Regulator/Isolator

coupler a, and then install the Rectifier/
Regulator/Isolator coupler a to the junction box.
7-32
coupler b to the junction box.
1
b
4. Route the positive leads 1, and then

fasten them using the holders 2 and 3.
3
2
4
1
5
3
6
5. Route the Rectifier/Regulator/Isolator
ground lead 1, and then fasten it using
the clamp 2 and holder 3.
9
3
10
ground lead to the starter motor bracket.
See step 3 in Installing the starter motor
(7-27).
A
7-33
Ignition coil and spark plug
3
1
2
3
1
2
3
1
2
3
1
2
28 Nm (2.8 kgfm, 20.7 ftlb)
No.
1
2
3
Part name
Ignition coil
Bolt
Spark plug
Qty
4
4
4
7-34
Remarks
M6 25 mm
M14
Checking the spark plug

1. Clean the electrodes a using a spark
plug cleaner.
1
2
2. Check the spark plug. Replace if the
electrodes are eroded, or there is carbon
or other deposits.
3. Check the spark plug gap a. Replace if

5
6
7
Specified spark plug: LFR6A-11 (NGK)

Spark plug gap a:
1.01.1 mm (0.0390.043 in)
8
9
10
A
7-35
Wire harness
Wire harness
6
22
10
9
11
22
16
11
17
15
13
18
16
12
17
13
18
20
21
12
4.5 Nm (0.45 kgfm, 3.32 ftlb)
17
19
18
16 14
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
13 20
Part name
Wire harness
Damper
Bolt
Damper
Bolt
Holder
Holder
Plastic tie
Clamp
Holder
Clamp
Holder
Holder
Holder
Junction box
Collar
Grommet
Qty
1
1
2
1
2
2
2
1
1
1
2
2
3
1
1
3
3
7-36
Remarks
M6 40 mm
M6 65 mm
Wire harness
22
10
9
11
0
1
3
22
16
11
17
15
13
18
16
12
17
13
18
20
21
12
4.5 Nm (0.45 kgfm, 3.32 ftlb)
17
19
18
16 14
No.
18
19
20
21
22
13 20
Part name
Bolt
PTT relay
Bolt
Nut
Bolt
Qty
3
1
2
2
4
Remarks
M6 35 mm
M6 20 mm
M6 16 mm
9
10
A
7-37
Wire harness
Removing the wire harness

1
1. Disconnect the engine temperature sensor coupler a and knock sensor coupler
b.
a
5. Remove the main wire harness 1 from
the holders 2 and 3.
6. Remove the joint connector a.
2. Remove the ground leads 1.
7. Remove the holders 4 and clamp 5.
3
4
a
1
3. Disconnect the OCV coupler a and cam

position sensor coupler (IN) b.
5
4
8. Disconnect the speed sensor coupler a

and water pressure sensor coupler b,
and then remove the ground lead 1.
a
4. Remove the dampers 1 and 2.
7-38
Wire harness
9. Remove the plastic tie 1, and then disconnect the cam position sensor coupler
(EX) a.
15. Remove the PTT relay leads 1 and 2.

16. Remove the PTT relay coupler a from
the junction box 3, and then disconnect
the PTT relay coupler a.

the holder 3.

the holder 5.
2
2
0
1
1
a
a

the holder 2.
12. Disconnect the thermo switch connectors

a.
13. Disconnect the oil pressure sensor coupler b.
Installing the wire harness

See Electrical component and wire harness
routing (5-1).
1. Install the pulser coil coupler a to the

junction box 1.
5
6
7
a
14. Remove the junction box 1 along with
the main wire harness.
2. Connect the PTT relay coupler b, and

then install the PTT relay coupler b to
the junction box 1.
3. Install the PTT relay leads 2 and 3,

and then tighten the PTT relay lead nuts
4. Fasten the main wire harness 5 using

the holder 6.
10
A
7-39
Wire harness
3
1
b
a
9. Install the main wire harness 1 to the
holder 2.
4
6
10. Connect the cam position sensor coupler

(EX) a, and then fasten it using the
plastic tie 3.
2
PTT relay lead nut 4:
4.5 Nm (0.45 kgfm, 3.32 ftlb)
5. Install the junction box 1 along with the

wire harness.
a
11. Install the ground lead 1.
1
12. Connect the speed sensor coupler a
and water pressure sensor coupler b.
a
1
6. Connect the thermo switch connectors
a.
7. Connect the oil pressure sensor coupler

b.
13. Route the main wire harness 1, and

then fasten it using the holders the 2,
3, and 4.
8. Fasten the main wire harness 1 using

the holder 2.
14. Install the joint connector a.

15. Install the clamp 5.
7-40
Wire harness
4
2
a
1
2
1
3
19. Connect the engine temperature sensor
coupler a and knock sensor coupler b.
5
2
16. Install the dampers 1 and 2.
2
3
a
2
4
5
6
7
17. Connect the OCV coupler a and cam

position sensor coupler (IN) b.
b
a
9
10
18. Install the ground leads 1.
A
7-41
Camshaft
Camshaft
3
32 Nm (3.2 kgfm, 23.6 ftlb)
60 Nm (6.0 kgfm, 44.3 ftlb)
6
3
12
13
15
14
7
8
9
1
17
9
11
11
19
20 18
3
4
5
3
21
a 8 Nm (0.8 kgfm, 5.9 ftlb)

b 17 Nm (1.7 kgfm, 12.5 ftlb)
20
21
22
16
23
22
10
23

b 17 Nm (1.7 kgfm, 12.5 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Bolt
Cylinder head cover
Grommet
Bracket
Bolt
Gasket
Bolt
Driven sprocket
Oil seal
Camshaft
Dowel pin
VCT cap
Gasket
VCT bolt
VCT assembly
Camshaft
Dowel pin
Qty
16
1
4
1
1
1
1
1
2
1
2
1
1
1
1
1
4
7-42
Remarks
M6 30 mm
M6 12 mm
Not reusable
M10 35 mm
Not reusable
EX
M27
Not reusable
M12 35 mm
IN
Camshaft
3
32 Nm (3.2 kgfm, 23.6 ftlb)
60 Nm (6.0 kgfm, 44.3 ftlb)
6
3
12
13
15
14
2
9
17
9
11
11
19
20 18
3
4
5
3
21

b 17 Nm (1.7 kgfm, 12.5 ftlb)
20
21
22
16
23
22
10
23

b 17 Nm (1.7 kgfm, 12.5 ftlb)
No.
18
19
20
21
22
23
Part name
Camshaft cap (EX)
Camshaft cap (IN)
Bolt
Camshaft cap
Bolt
Valve lifter
Qty
1
1
4
8
16
16
Remarks
M7 48 mm
6
7
8
M7 37 mm
9
10
A
7-43
Camshaft
Removing the driven sprocket and

camshaft

not turn the crankshaft or camshafts. Otherwise, the intake and exhaust valves
could collide with each other or with the
pistons and be damaged.
3
1
1. Remove the cylinder head cover.
2
2. Turn the crankshaft counterclockwise 90
gradually until the mark a in the
crankshaft is aligned with the protrusion
b on the cylinder block.
Sheave holder 2: 90890-01701
Do not turn the crankshaft counterclockwise more than 90. Otherwise, the pistons and valves could collide with each
other and be damaged.
4. Remove the special service tool.

5. Secure the intake camshaft using a
wrench, and then remove the VCT
assembly 1.
b
When removing the VCT bolt, do not
secure the VCT assembly. Otherwise,
the VCT assembly could be damaged.
When removing the VCT assembly, do
not turn the intake camshaft. Otherwise,
the intake and exhaust valves could collide with each other and be damaged.
90
3. Secure the VCT assembly 1 using the

special service tool 2, and then remove
the VCT cap 3.
When removing the VCT cap, do not

secure the camshaft. Otherwise, the
VCT assembly could be damaged.
When removing the VCT cap, do not turn
the VCT assembly. Otherwise, the intake
and exhaust valves could collide with
each other and be damaged.
7-44
Camshaft
2
[1]
1
[1]
[5]
[5]
[2]
[2]
[4]
[4]
[3]
[3]
0
1
2
6. Secure the exhaust camshaft using a

wrench, and then remove the driven
sprocket 1.
8. Remove the camshafts 1 and 2 and oil

seals 3, and then remove the valve lifters 4.
TIP:

removal.
When removing the driven sprocket, do

not turn the exhaust camshaft. Otherwise,
the intake and exhaust valves could collide with each other and be damaged.
2
4
6
7
8
Checking the sprocket
1. Check the VCT assembly and driven

sprocket. Replace the VCT assembly or
driven sprocket if cracked, damaged, or
worn.
Checking the valve lifter
9
10
1. Check the valve lifters. Replace if damaged, scratched, or worn.

2. Measure the valve lifter outside diameter
a.
7. Remove the camshaft caps 1, 2, and

3 in the order [1], [2], and so on.
A
7-45
Camshaft
2. Measure the camshaft lobe height a
and width b.
a
a
Valve lifter outside diameter a:
30.97030.980 mm
(1.21931.2197 in)
b
Camshaft lobe height a:
IN:
46.31146.411 mm
(1.82331.8272 in)
Limit (reference data):
46.261 mm (1.8213 in)
EX:
44.66044.760 mm
(1.75831.7622 in)
44.610 mm (1.7563 in)
Camshaft lobe width b:
IN and EX:
35.95036.050 mm
(1.41541.4193 in)
Checking the camshaft

1. Check the edge and face of the pulser
rotor on the camshafts.
3. Measure the camshaft runout.
A. IN
B. EX
Camshaft runout
0.030 mm (0.0012 in)
TIP:
Be careful not to scratch or damage the
face of the flange.
If there is a scratch that is more than
0.2 mm (0.008 in) deep or more than
0.5 mm (0.020 in) wide on the surface of
the flange, a malfunction may occur in the
cam position sensor signal.
Checking the camshaft journal oil

clearance
1. Place the camshafts on the cylinder
head.
7-46
Camshaft
2. Place a piece of Plastigauge (PG-1) 1
on each camshaft journal, parallel to the
camshaft.
EX
3 2
IN
6
7
#2
#3
10
#4
Do not place the Plastigauge (PG-1) over

the oil hole in each camshaft journal.
4
#1
EX
IN
[5]
[5]
#1
[1]
4. Install the camshaft cap bolts 5 and 6.
#2
[4]
6
4
[2]
[3]
[4]
#3
5
4
2
3
[1]
5. Tighten the camshaft cap bolts 1 and

2 to the specified torques in 2 stages
and in the order [1], [2], and so on.
3. Install the dowel pins 1 and camshaft
caps 2, 3, and 4 in their proper positions so that the stamped numbers are
upside down.
[2]
#4
[3]
2
Camshaft cap bolts 1 and 2:

1st: 8 Nm (0.8 kgfm, 5.9 ftlb)
2nd: 17 Nm (1.7 kgfm, 12.5 ftlb)
7
8
TIP:
Do not turn the camshafts when measuring
the camshaft journal oil clearance using the
Plastigauge.
6. Remove the camshaft caps, and then
measure the width of the Plastigauge 1.
9
10
A
7-47
Camshaft
TIP:
Install the valve lifters in their original positions.
3. Install new oil seals 2 and the dowel

pins 3 onto the camshafts 4 and 5.
4. Install the camshafts so that the dowel
pins 3 are facing inward and that they
are aligned with the mating surface of the
cylinder head.
Camshaft journal oil clearance:

0.0260.051 mm (0.00100.0020 in)
0.08 mm (0.0031 in)
TIP:
Make sure that pistons #1 and #4 are positioned at the TDC.
Installing the camshaft and driven

sprocket
If the valve clearances are adjusted or any
parts related to valve movement are replaced
after installing the timing belt, check the valve
clearances. See Checking the valve clearance (7-2).
4
6DA EX
5
not turn the crankshaft or camshafts.
Otherwise, the pistons and valves or
intake and exhaust valves could collide
with each other and be damaged.
Be careful when turning the camshafts.
Compression of the valve spring may
cause the camshafts to rotate too far.
6DA IN
1
3 2
1. Check that the mark a in the crankshaft is aligned with the protrusion b.
IN
3
2
EX
b
5. Apply a thin, even coat of sealant to the
mating surfaces of the camshaft caps 1
and 2 and cylinder head 3.
2. Install the valve lifters 1.
7-48
Camshaft
EX
Do not block the oil passages or oil holes with

the sealant.
4
#1
2
3
#2
#3
10
#4
#1
[1]
[1]
#2
[4]
IN
[5]
[5]
#3
[2]
#4
[4]
[2]
6
4
7. Install the camshaft cap bolts 5 and 6.
8. Tighten the camshaft cap bolts 1 and

EX
6. Install the dowel pins 1 and camshaft

caps 2, 3, and 4 in their proper positions so that the stamped numbers are
upside down.
IN
3 2
TIP:
[3]
[3]
2
2
Camshaft cap bolts 1 and 2:
1st: 8 Nm (0.8 kgfm, 5.9 ftlb)
2nd: 17 Nm (1.7 kgfm, 12.5 ftlb)
7
8
9. Install the driven sprocket 1.

10. Secure the exhaust camshaft using a
wrench, and then tighten the driven
sprocket bolt 2 to the specified torque.
9
10
A
7-49
Camshaft
13. Secure the intake camshaft using a
wrench, and then tighten the VCT bolt 1
When tightening the VCT bolt, do not

secure the driven sprocket. Otherwise,
the VCT assembly could be damaged.
2
1
Driven sprocket bolt 2:

60 Nm (6.0 kgfm, 44.3 ftlb)
11. Install the VCT assembly 1.
VCT bolt 1: 60 Nm (6.0 kgfm, 44.3 ftlb)
1
14. Install a new gasket 1 and the VCT cap
2, secure the VCT assembly using the
special service tool 3, and then tighten
the VCT cap 2 to the specified torque.
When tightening the VCT cap, do not

secure the camshaft. Otherwise, the VCT
assembly could be damaged.
2
12. Check that the lower edges a and b of
the driven sprocket and VCT assembly
are aligned.
Sheave holder 3: 90890-01701
7-50
Camshaft
VCT cap 2: 32 Nm (3.2 kgfm, 23.6 ftlb)
15. Check that the I mark a on the VCT
assembly and the oval mark b on the
1
2
3
16. Turn the crankshaft clockwise 90 gradually until the large mark a on the
crankshaft is aligned with the protrusion
b on the cylinder block.
Do not turn the crankshaft clockwise

more than 90. Otherwise, the pistons and
be damaged.
5
6
90
17. Install the cylinder head cover. See step

13 in Checking the valve clearance (72).
9
10
A
7-51
Cylinder head
Cylinder head
29
28
32
27
30
31 27
21
29
10 Nm (1.0 kgfm, 7.4 ftlb)
26
25
23
18
8
a 14 Nm (1.4 kgfm, 10.3 ftlb)

b 28 Nm (2.8 kgfm, 20.7 ftlb)
24
17
22
45
1 2 3
10
16
11
13
12
15
14 38
39
9
10
9
13
11
12
15
14
41 4
42 3
2
1
20
40
10
19 Nm (1.9 kgfm, 14.0 ftlb)
a 39 Nm (3.9 kgfm, 28.8 ftlb)

b 180
Part name
Valve cotter
Valve spring retainer
Valve spring
Valve spring seat
Valve seal
Valve guide
Intake valve
Exhaust valve
Anode assembly
Bolt
Bolt
Gasket
Cover
Grommet
Anode
Bolt
Bolt
33
19
34
37
36 35 33
23 Nm (2.3 kgfm, 17.0 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
23
Qty
32
16
16
16
16
16
8
8
2
4
2
2
2
2
2
10
8
7-52
Remarks
Not reusable
Not reusable
M8 25 mm
M6 20 mm
Not reusable
M11 120 mm
M8 50 mm
Cylinder head
29
28
32
27
30
31 27
21
29
10 Nm (1.0 kgfm, 7.4 ftlb)
26
25
23
18
8
a 14 Nm (1.4 kgfm, 10.3 ftlb)

b 28 Nm (2.8 kgfm, 20.7 ftlb)
22
45
1 2 3
10
11
24
17
16
13
12
15
14 38
39
9
10
9
13
11
12
15
14
41 4
42 3
2
1
20
40
10
19 Nm (1.9 kgfm, 14.0 ftlb)
a 39 Nm (3.9 kgfm, 28.8 ftlb)

b 180
Part name
Bolt
Plug
Gasket
Cylinder head
Gasket
Dowel pin
Gasket
OCV assembly
Bolt
O-ring
Cam position sensor
Bolt
Cam position sensor
Bracket
Bolt
Bracket
Bolt
23
37
33
19
34
Remarks
36 35 33
23 Nm (2.3 kgfm, 17.0 ftlb)
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Qty
1
1
1
1
1
2
1
1
3
2
1
2
1
1
1
2
4
7-53
M6 40 mm
Other than Caribbean market
Not reusable
Not reusable
Not reusable
M6 35 mm
Not reusable
EX
M6 20 mm
IN
9
10
M6 16 mm
M6 25 mm
Cylinder head
29
28
32
27
30
31 27
21
29
10 Nm (1.0 kgfm, 7.4 ftlb)
26
25
23
18
8
a 14 Nm (1.4 kgfm, 10.3 ftlb)

b 28 Nm (2.8 kgfm, 20.7 ftlb)
24
17
22
45
1 2 3
10
16
11
13
12
15
14 38
39
9
10
9
13
11
12
15
14
41 4
42 3
2
1
20
40
10
19 Nm (1.9 kgfm, 14.0 ftlb)
a 39 Nm (3.9 kgfm, 28.8 ftlb)

b 180
Part name
Collar
Grommet
Bolt
Bolt
Speed sensor adapter
Speed sensor
Water pressure sensor adapter
33
19
34
37
36 35 33
23 Nm (2.3 kgfm, 17.0 ftlb)
No.
35
36
37
38
39
40
41
42
23
Qty
1
1
1
1
1
1
1
1
7-54
Remarks
M6 70 mm
M6 16 mm
For Caribbean market

For Caribbean market
Cylinder head
Removing the cylinder head
EX
1. Remove the anode assemblies 1.
1
4. Remove the cylinder head 1.
1
Do not scratch or damage the mating surfaces of the cylinder head and cylinder
block.
1
2. Remove the OCV assembly 1 and gasket 2.
2
3
4
5
7
3. Remove the cam position sensors 1
and 2.
8
Disassembling the cylinder head
IN
1. Remove the intake and exhaust valves.
TIP:
1

removal.
9
10
A
7-55
Cylinder head
Cylinder head warpage limit:
0.10 mm (0.0039 in)
Checking the cylinder head bolt
1. Measure the diameters a and b of the

cylinder head bolt (M11) at the specified
measuring points c and d. Replace
the cylinder head bolt if the difference
between the diameters is above specification.
1
Valve spring compressor 1: 90890-04019
Valve spring compressor attachment 2:
90890-06320
Cylinder head bolt (M11) diameter difference limit:

a b = Less than 0.20 mm (0.0079 in)
Measuring point c: 10.0 mm (0.39 in)
Measuring point d: 85.0 mm (3.35 in)
Checking the cylinder head

1. Remove carbon deposits from the combustion chambers, and then check the
cylinder head for damage and scratches.
Checking the valve spring
2. Check the cylinder head warpage using a

straightedge 1 and a thickness gauge
2 in 7 directions. Replace the cylinder
head if above specification.
1. Measure the valve spring free length a.
a
Valve spring free length a:
48.08 mm (1.89 in)
45.68 mm (1.79 in)
2. Measure the valve spring tilt a. Replace
if above specification.
7-56
Cylinder head
Valve stem diameter a:
Intake:
5.4775.492 mm (0.21560.2162 in)
5.447 mm (0.2144 in)
Exhaust:
5.4645.479 mm (0.21510.2157 in)
5.434 mm (0.2139 in)
4. Measure the valve stem runout.
Valve spring tilt limit a:

1.7 mm (0.07 in)
0
1
2
Checking the valve

1. Check the valve face. Replace if pitted or
worn.
2. Measure the valve margin thickness a.
Valve stem runout:

Intake and exhaust: 0.01 mm (0.0004 in)
Checking the valve guide
Valve margin thickness a:

Intake:
0.751.15 mm (0.02950.0453 in)
Exhaust:
0.901.30 mm (0.03540.0512 in)
Before checking the valve guides, make sure

that the valve stem diameter is within specification.
1. Measure the valve guide inside diameter

a.
7
8
3. Measure the valve stem diameter a.
9
10
Valve guide inside diameter a:

Intake and exhaust:
5.5045.522 mm (0.21670.2174 in)
7-57
Cylinder head
2. Calculate the valve stem to valve guide
clearance. Replace the valve and valve
guide if out of specification.
Valve guide remover/installer 2:

90890-06801
Valve guide installer 3: 90890-06810
Valve stem to valve guide clearance =

valve guide inside diameter valve stem
diameter:
Intake:
0.0120.045 mm (0.00050.0018 in)
0.070 mm (0.0028 in)
Exhaust:
0.0250.058 mm (0.00100.0023 in)
0.080 mm (0.0031 in)
Installation height a:
11.311.7 mm (0.440.46 in)
3. Insert the special service tool 1 into the
valve guide 2, and then ream the valve
guide.
TIP:
To ream the valve guide, turn the valve
guide reamer clockwise.
When removing the valve guide reamer, do
not turn it counterclockwise.
After reaming the valve guide, make sure to
clean it.
Replacing the valve guide

After replacing a valve guide, check the valve
seat contact area.
1. Remove the valve guide 1 from the
combustion chamber side.
1
2
Valve guide reamer 1: 90890-06804

4. Measure the valve guide inside diameter.
Valve guide remover/installer 2:

90890-06801
Valve guide inside diameter:

Intake and exhaust:
5.5045.522 mm (0.21670.2174 in)
2. Install a new valve guide 1 from the

camshaft side to the specified installation
height a.
Checking the valve seat

1. Remove carbon deposits from the valve.
2. Apply a thin, even layer of Mechanics
blueing dye (Dykem) onto the valve seat.
2
a
3. Push the valve lightly against the valve

seat using the special service tool 1.
3
1
7-58
Cylinder head
Valve seat contact width a:
Intake:
1.101.40 mm (0.04330.0551 in)
1.850 mm (0.0728 in)
Exhaust:
1.401.70 mm (0.05510.0669 in)
2.150 mm (0.0846 in)
Refacing the valve seat
Valve lapper 1: 90890-04101

4. Measure the valve seat contact width a
where the blueing dye is adhered to the
valve face. Reface the valve seat if the
valve is not seated properly or if the valve
seat contact width is out of specification.
Check the valve guide if the valve seat
contact width is uneven.
0
1
2
After every lapping procedure, make sure

to clean off any remaining lapping compound from the cylinder head and valves.
1. Reface the valve seat using the valve
seat cutters.
3
4
5
30
45
60
6
Valve seat cutter holder: 90890-06316
Intake:
Valve seat cutter 30: 90890-06331
Exhaust:
2. Cut the surface of the valve seat using a
45 cutter by turning the cutter clockwise
until the valve seat face has become
smooth.
7
8
9
10
A
7-59
Cylinder head
Do not overcut the valve seat. To prevent

chatter marks, make sure to turn the cutter evenly using a downward force of
4050 N (4.05.0 kgf, 8.811.0 lbf).
60
a. Previous contact width
5. Adjust the valve seat contact width to
specification using a 45 cutter.
a
b
45
45
b. Specified contact width
a. Slag or rough surface
6. Check the valve seat contact area of the

valve. See Checking the valve seat (758).
3. Adjust the top edge of the valve seat contact width using a 30 cutter.
Example:
If the valve seat contact area is too wide
and situated in the center of the valve face,
cut the top edge of the valve seat using a
30 cutter. Cut the bottom edge using a 60
cutter to center the area and set its width.
30
30
a
4. Adjust the bottom edge of the valve seat
contact width using a 60 cutter.
60
7-60
Cylinder head
If the valve seat contact area is too narrow
and situated near the top edge of the valve
face, cut the top edge of the valve seat
using a 30 cutter to center the area. Set its
width using a 45 cutter.
30
1
Valve lapper 1: 90890-04101
8. Recheck the valve seat contact area of
the valve. See Checking the valve seat
(7-58).
Checking the cylinder head and

cylinder block anode
If the valve seat contact area is too narrow

and situated near the bottom edge of the
valve face, cut the bottom edge of the valve
seat using a 60 cutter. Set its width using a
45 cutter.
2
3
1. Check the anodes. Clean if there is

grease, oil, or scales.
Do not apply grease, oil, or paint to the

anodes.
Assembling the cylinder head
1. Install a new valve seal 1 onto the valve

guide 2.
60
7. After refacing the valve seat to the specified contact width, apply a thin, even
layer of lapping compound onto the valve
seat, and then lap the valve using the
9
2. Install the valve 1, valve spring seat 2,
valve spring 3, and valve spring retainer
4 in this order, and then install the special service tools 5 and 6.
Do not get the lapping compound on the

valve stem and valve guide.
10
A
7-61
Cylinder head
4
3
2
Installing the cylinder head
Valve spring compressor 5: 90890-04019

Valve spring compressor attachment 6:
90890-06320
Before assembling the cylinder head, check

the cylinder head bolts. See Checking the
cylinder head (7-56).
3. Compress the valve spring, and then

install the valve cotters 1.
1. Install the dowel pins 1, a new gasket

2, the cylinder head 3, and the cylinder head bolts 4, 5, and 6.
4. Tap the valve spring retainer lightly using

a plastic hammer to seat the valve cotters 1 securely.
1
1
2. Tighten the cylinder head bolts 1 to the

specified torques in 2 stages and in the
order [1], [2], and so on.
7-62
Cylinder head
3. Mark the M11 bolts and cylinder head
with paint marks a, and then tighten the
M11 bolts 180 from the marks on the
cylinder head.
EX
4. Tighten the cylinder head bolts 2 to the

5. Tighten the cylinder head bolt 3 to the

specified torque.
[19] 3 [9]
8. Install a new gasket 1 and the OCV

assembly 2, and then tighten the OCV
bolts 3 to the specified torque.
[11]
[12]
[14]
180
[6]
[5]
[1]
[2]
[4]
[3]
3
[16]
[7]
[8]
[10]
[17]
[15]
[13]
[18]
OCV bolt 3:
Cylinder head bolt 1 [1][10] (M11):

1st: 39 Nm (3.9 kgfm, 28.8 ftlb)
2nd: 180
Cylinder head bolt 2 [11][18] (M8):
3rd: 14 Nm (1.4 kgfm, 10.3 ftlb)
4th: 28 Nm (2.8 kgfm, 20.7 ftlb)
Cylinder head bolt 3 [19] (M6):
5th: 10 Nm (1.0 kgfm, 7.4 ftlb)
9. Install a new gasket 1, the anode 2,

and the grommet 3 to the cover 4.
10. Install the anode assemblies to the cylinder head.
5
6
7
8
6. Install new O-rings 1 to the cam position sensors 2.
4
7. Install the cam position sensors 2.
IN
10
4
1
2
1
3
A
7-63
Exhaust cover
Exhaust cover
38
10 Nm (1.0 kgfm, 7.4 ftlb)
3
38
32
31
2
4
37
33
41
42
6
40
24
26
19
23
25
15
34
37
37
18
29
30
14
43
12
11
35
13
36
16
17
9 10
22
21
39
37
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
10 Nm (1.0 kgfm, 7.4 ftlb)
Part name
Bolt
Holder
Thermo switch
Bolt
Cover
Thermostat
Anode assembly
Bolt
Gasket
Cover
Grommet
Anode
Bolt
Bolt
Cover
Spring
PCV
10 Nm (1.0 kgfm, 7.4 ftlb)
28
20
27
55 Nm (5.5 kgfm, 40.6 ftlb)
Qty
1
1
1
3
1
1
1
1
1
1
1
1
1
2
1
1
1
7-64
Remarks
M6 12 mm
M6 30 mm
M6 20 mm
Not reusable
M8 40 mm
M6 25 mm
Exhaust cover
38
10 Nm (1.0 kgfm, 7.4 ftlb)
38
32
31
4
33
37
41
42
6
40
24
26
19
23
25
15
34
37
37
29
30
43
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
12
11
35
8
9 10
22
21
39
10 Nm (1.0 kgfm, 7.4 ftlb)
Part name
Grommet
Gasket
Bolt
Water bypass cover
Gasket
Bolt
Holder
Holder
Bracket
Plug
Gasket
Plug
O-ring
Anode
Screw
Hose
Joint
10 Nm (1.0 kgfm, 7.4 ftlb)
28
20
37
18
14
13
36
16
17
27
55 Nm (5.5 kgfm, 40.6 ftlb)
Qty
1
1
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
7-65
Remarks
Not reusable
M6 30 mm
Not reusable
M6 16 mm
M18 17 mm
Not reusable
M14 12 mm
Not reusable
7
8
9
10
M5 27 mm
Cover to joint
Exhaust cover
38
10 Nm (1.0 kgfm, 7.4 ftlb)
3
38
32
31
2
4
37
33
41
42
6
40
24
26
19
23
25
15
34
37
37
16
17
18
29
30
14
43
12
11
35
13
36
9 10
22
21
39
37
No.
35
36
37
38
39
40
41
42
43
10 Nm (1.0 kgfm, 7.4 ftlb)
Part name
Hose
Hose
Plastic tie
Plastic tie
Bolt
Exhaust cover
Gasket
Holder
Dowel pin
10 Nm (1.0 kgfm, 7.4 ftlb)
28
20
27
55 Nm (5.5 kgfm, 40.6 ftlb)
Qty
1
1
6
3
14
1
1
1
1
7-66
Remarks
Joint to water bypass cover
Water bypass cover to cover
M6 30 mm
Not reusable
Exhaust cover
Removing the exhaust cover

1. Disconnect the cooling water hoses 1
and 2, and then remove the holder 3.

from the joint 5, and then remove the
holder 6.
1
3
6. Remove the PCV 1, anode 2, and

water bypass cover 3.
2
6
3. Disconnect the cooling water hose 1.
5
3
7. Remove the thermo switch 1 and thermostat 2.
4. Remove the cooling water hoses 1, 2,
and 3 and joint 4.
6
7
1
4
9
8. Remove the exhaust cover 1.
10
3
and 2.
A
7-67
Exhaust cover
3. Measure the thermostat valve opening

a at the specified water temperatures.
Checking the PCV

1. Check the PCV 1. Replace if damaged
or worn.
2. Check the grommet 2. Replace if
deformed.
3. Check the spring 3.
deformed or fatigued.
Replace
Water
temperature
5862 C
(136144 F)
above 70 C
(158 F)
if
Valve opening a
Starts opening
5.0 mm (0.20 in) or above
Checking the exhaust cover anode

2
1. Check the anodes. Clean if there is

1
3

anodes.
Checking the thermostat

1. Suspend the thermostat in a container of
water.
Installing the exhaust cover

1. Install a new gasket 1, the dowel pin
2, and the exhaust cover 3, and then
tighten the exhaust cover bolts 4 to the
specified torque in the order [1], [2], and
so on.
2. Place a thermo meter in the water, and

then heat the water slowly.
7-68
Exhaust cover
[2]
[1]
3
4
[3]
0
1
Thermostat cover bolt 3:

10 Nm (1.0 kgfm, 7.4 ftlb)
4. Install the water bypass cover 1 and a

new gasket 2, and then tighten the
water bypass cover bolts 3 to the specified torque in the order [1], [2], and so on.
4
[11]
[12]
[10]
[9]
[7]
[8]
[6]
[5]
[3]
[4]
[2]
[1]
[14]
[13]
2
3
[2]
[1]
[3]
Exhaust cover bolt 4:
10 Nm (1.0 kgfm, 7.4 ftlb)
[6]
2. Install the thermostat 1 and thermostat

cover 2, and then tighten the thermostat
cover bolts 3 to the specified torque in
[4]
7
8
[5]
Water bypass cover bolt 3:

10 Nm (1.0 kgfm, 7.4 ftlb)
5. Install the grommet 1, the PCV 2, the
spring 3, a new gasket 4, and the
cover 5.
3. Install the thermo switch 4.
9
10
6. Install a new gasket 6, the anode 7,

and the grommet 8 to the cover 9.
7. Install the anode assemblies.
7-69
Exhaust cover
4
1
2
8
6
8. Connect the cooling water hoses 1 and

2.
11. Connect the cooling water hoses 1 to

the joint 2, and then fasten it using the
holder 3.
5 to the exhaust cover, and then fasten
them using the holder 6 and plastic ties
7.
2
1
6
5
9. Install the cooling water hoses 1, 2,

and 3 and joint 4, and then fasten
them using the plastic ties 5.
3
5
1
5
4
5
2
5
3
5
10. Connect the cooling water hose 1, and
7-70
Oil cooler
Oil cooler
32 Nm (3.2 kgfm, 23.6 ftlb)
26
25
30 23
34
17
18
29
21
23
22
23
28 19
20
31
24
21
15
16
27 24
2
32
40
42 41
33
15
12
3
4
35
41
37
39
12
36
14
42
11
6
38
40
7 5
10 Nm (1.0 kgfm, 7.4 ftlb)
Part name
Bolt
Cover 1
Gasket
Cover 2
Dowel pin
Anode
Screw
Bolt
Crankcase cover
Gasket
Hose
Hose
Holder
Hose
Holder
Holder
Hose
10
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
13
21
2
40
10 Nm (1.0 kgfm, 7.4 ftlb)
Qty
13
1
2
1
2
2
2
10
1
1
1
1
1
1
2
1
1
7-71
Remarks
M6 30 mm
Not reusable
M4 14 mm
M6 25 mm
Not reusable
Crankcase cover to water bypass cover
Joint to crankcase cover
8
9
10
Exhaust cover to crankcase cover
Exhaust cover to VST
Oil cooler
32 Nm (3.2 kgfm, 23.6 ftlb)
26
25
30 23
34
17
18
29
21
23
22
23
28 19
20
31
24
21
15
16
27 24
32
40
42 41
33
15
12
3
4
35
41
3
2
40
37
39
12
36
14
42
11
6
38
40
7 5
10
10 Nm (1.0 kgfm, 7.4 ftlb)
10 Nm (1.0 kgfm, 7.4 ftlb)
6
1
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
13
21
Part name
Hose
Holder
Holder
Plastic tie
Bracket
Bolt
Holder
Clamp
Bolt
Bracket
Holder
Holder
Bracket
Knock sensor
Hose
Hose
Qty
1
1
1
8
1
3
3
1
1
1
1
1
1
1
1
1
1
7-72
Remarks
Exhaust cover to crankcase cover
M6 16 mm
M6 14 mm
Cover 1 to joint
Joint to water bypass cover
Oil cooler
32 Nm (3.2 kgfm, 23.6 ftlb)
26
25
30 23
34
17
18
29
21
23
22
23
28 19
20
31
24
21
15
16
27 24
2
32
40
42 41
33
15
12
3
4
35
41
37
39
12
36
14
42
6
38
7 5
10
9
10 Nm (1.0 kgfm, 7.4 ftlb)
Part name
Hose
Hose
Hose
Hose
Hose
Joint
Holder
Bolt
40
11
No.
35
36
37
38
39
40
41
42
13
21
2
40
10 Nm (1.0 kgfm, 7.4 ftlb)
Qty
1
1
1
1
1
3
2
2
Remarks
Joint to joint
Cover 1 to joint
Joint to joint
VST to joint
Joint to cooling water pilot hole
7
8
9
M6 12 mm
10
A
7-73
Oil cooler
Removing the crankcase cover

and 2 and holder 3.
2
1
2. Remove the crankcase cover 1.
Checking the crankcase cover anode

1. Check the anode. Replace if eroded.
Clean if there is grease, oil, or scales.

anode.
Installing the crankcase cover

1. Install the dowel pin 1, new gaskets 2,
cover 2 3, and cover 1 4, and then
tighten the cover 1 bolts 5 to the specified torque in the order [1], [2], and so on.
3. Disconnect the cooling water hoses 1,

2, and 3.
2
3
2
4
3
5
4. Remove the cover 1 1 and cover 2 2.
7-74
Oil cooler
3. Connect the cooling water hose 1.
[13]
5
[9]
4. Install the dowel pin 2, a new gasket

3, and the crankcase cover 4, and
then tighten the crankcase cover bolts 5
to the specified torque in the order [1],
[2], and so on.
[10]
[5]
[6]
[1]
[2]
[4]
[3]
[8]
[7]
0
1
[11]
[12]
3
Cover 1 bolt 5:
10 Nm (1.0 kgfm, 7.4 ftlb)
2. Connect the cooling water hoses 1, 2,

and 3, and then fasten them using the
plastic ties 4 and holders 5.
[6]
[5]
[1]
[2] [7]
[9]
3
4
[10]
1
2
[4]
[8]
[3]
4
Crankcase cover bolt 5:
10 Nm (1.0 kgfm, 7.4 ftlb)
2, and then fasten them using the
holder 3 and plastic ties 4.
5
4
TIP:
Align the holder 3 with the paint marks a
on the cooling water hoses 1 and 2.
7
8
9
1 4
10
A
7-75
Cylinder block
Cylinder block
13 Nm (1.3 kgfm, 9.6 ftlb)
33
13
26
10
12
11
7
5
25
25
34
27
28
35
24
36
4
23
22
15
a 14 Nm (1.4 kgfm, 10.3 ftlb)

31 30
b 24 Nm (2.4 kgfm, 17.7 ftlb) 32
a 18 Nm (1.8 kgfm, 13.3 ftlb)
b 37 Nm (3.7 kgfm, 27.3 ftlb)
Part name
Bolt
Bolt
Balancer assembly
Seal
Bolt
Bracket
Bolt
Cover
Bolt
Oil filler neck
O-ring
O-ring
Oil filler cap
Oil filter
Union bolt
Gasket
Relief valve
21
18 Nm (1.8 kgfm, 13.3 ftlb)
17
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
20
16
29
14
34 Nm (3.4 kgfm, 25.1 ftlb)
18
32 Nm (3.2 kgfm, 23.6 ftlb)
10 Nm (1.0 kgfm, 7.4 ftlb)
19
18 Nm (1.8 kgfm, 13.3 ftlb)
Qty
4
12
1
2
4
1
2
1
2
1
1
1
1
1
1
1
1
7-76
Remarks
M8 50 mm
Not reusable
M8 35 mm
M6 25 mm
M6 25 mm
Not reusable
Not reusable
Not reusable
M18
Cylinder block
13 Nm (1.3 kgfm, 9.6 ftlb)
33
13
26
10
12
11
7
5
25
25
34
27
28
35
24
36
4
23
22
15
a
b
a 18 Nm (1.8 kgfm, 13.3 ftlb)

b 37 Nm (3.7 kgfm, 27.3 ftlb)
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Part name
Oil filter bracket
Bolt
Bolt
Oil pump assembly
Oil seal
Oil seal
Gasket
O-ring
Oil seal
O-ring
Oil pressure sensor
Screw
Anode
O-ring
Plug
Damper bracket
Bolt
32
21
18 Nm (1.8 kgfm, 13.3 ftlb)
17
2
14 Nm (1.4 kgfm, 10.3 ftlb)
24 Nm (2.4 kgfm, 17.7 ftlb)
20
16
29
14
31 30
34 Nm (3.4 kgfm, 25.1 ftlb)
18
32 Nm (3.2 kgfm, 23.6 ftlb)
10 Nm (1.0 kgfm, 7.4 ftlb)
19
18 Nm (1.8 kgfm, 13.3 ftlb)
Qty
1
4
4
1
2
1
1
2
1
1
1
1
1
1
1
1
3
7-77
Remarks
M6 40 mm
M6 40 mm
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
7
8
9
10
M5 26 mm
Not reusable
M5 10 mm
M6 16 mm
Cylinder block
13 Nm (1.3 kgfm, 9.6 ftlb)
33
13
26
10
12
11
7
5
25
25
34
27
28
35
24
36
4
23
22
15
a 14 Nm (1.4 kgfm, 10.3 ftlb)

31 30
b 24 Nm (2.4 kgfm, 17.7 ftlb) 32
a 18 Nm (1.8 kgfm, 13.3 ftlb)
b 37 Nm (3.7 kgfm, 27.3 ftlb)
Part name
Cable bracket
Bolt
21
18 Nm (1.8 kgfm, 13.3 ftlb)
17
No.
35
36
20
16
29
14
34 Nm (3.4 kgfm, 25.1 ftlb)
18
32 Nm (3.2 kgfm, 23.6 ftlb)
10 Nm (1.0 kgfm, 7.4 ftlb)
19
18 Nm (1.8 kgfm, 13.3 ftlb)
Qty
1
2
7-78
Remarks
M8 20 mm
Cylinder block
Removing the oil pump assembly

1. Remove the oil pump assembly 1.
0
1
2
2. Remove the balancer assembly 1.
Removing the oil filter bracket

1. Remove the oil filter 1.
6
Oil filter wrench 2: 90890-06830
Disassembling the oil pump

2. Remove the oil filter bracket 1.
1. Remove the oil pump cover 1, gasket

2, outer rotor 3, inner rotor 4, and oil
seals 5 and 6.
1
2
8
9
4
5
6
Removing the balancer assembly
10
1. Remove the bracket 1 and damper

bracket 2.
A
7-79
Cylinder block
Checking the oil pump
TIP:
1. Check the inner surface of the oil pump

housing. Replace the oil pump assembly
if scratched.
Install an oil seal halfway into the oil pump

housing, and then install the other oil seal.
2. Check the gear teeth of the inner rotor

and outer rotor. Replace the oil pump
assembly if the gear teeth are cracked or
worn.
1
3
3. Measure the inner rotor to outer rotor tip

clearance a, outer rotor to oil pump
housing clearance b, and oil pump
housing to inner rotor and outer rotor
clearance c. Replace the oil pump rotor
if out of specification.
4
Driver rod L3 3: 90890-06652
Needle bearing attachment 4:
90890-06611
a
2. Install a new oil seal 1 into the oil pump
housing 2.
c
3
1
1. Inner rotor
2. Outer rotor
3. Oil pump housing
Inner rotor to outer rotor tip clearance a
(reference data):
0.12 mm (0.0047 in)
0.16 mm (0.0063 in)
Outer rotor to oil pump housing clearance
b (reference data):
0.1 mm (0.0040 in)
0.20 mm (0.0079 in)
Oil pump housing to inner rotor and outer
rotor clearance c (reference data):
0.03 mm (0.0012 in)
0.12 mm (0.0047 in)
Driver rod L3 3: 90890-06652

90890-06607
3. Install the outer rotor 1, the inner rotor
2, a new gasket 3, and the oil pump
cover 4, and then tighten the oil pump
cover screws 5 to the specified torque.
4. Install a new oil seal 6 so that it is facing
in the proper direction.
Assembling the oil pump

1. Install new oil seals 1 into the oil pump
housing 2.
7-80
Cylinder block
Checking the cylinder block anode

5
anode.
1
3
Installing the balancer assembly

1. Align the mark a in the crankshaft
with the protrusion b on the cylinder
block.
1
2
a
Oil pump cover screw 5:
3
a
Installing the oil pump assembly

1. Fill the oil pump assembly with engine oil
through the oil passage.
2. Apply a thin, even layer of sealant onto

the mating surface of the balancer
assembly.
4
5
6
7
2. Install new O-rings 1 and the oil pump

assembly 2 by aligning the oil pump
gear with the crankshaft.
8
3. Align the marks a on the balancer
shafts with the marks b.
9
10
2
a
7-81
Cylinder block
5. Install the balancer assembly 2, and
then tighten new balancer assembly bolts
3 and the balancer assembly bolts 4
to the specified torque in 2 stages and in
2
1
7. Install the damper bracket 1, and then
install the bracket 2.
3
4
2
[15]
[14]
[1]
[13]
[12]
[4]
[11]
[10]
[16]
3
[2]
[5]
[6]
[3]
[7]
Installing the oil filter bracket
1. Install a new gasket 1 and the oil filter

bracket 2, and then tighten the oil filter
bracket bolts 3 to the specified torque.
[8]
[9]
1
Balancer assembly bolt 3:
1st: 18 Nm (1.8 kgfm, 13.3 ftlb)
2nd: 37 Nm (3.7 kgfm, 27.3 ftlb)
Balancer assembly bolt 4:
1st: 14 Nm (1.4 kgfm, 10.3 ftlb)
2nd: 24 Nm (2.4 kgfm, 17.7 ftlb)
3
3
6. Install new seals 1.

Oil filter bracket bolt 3:
10 Nm (1.0 kgfm, 7.4 ftlb)
2. Install the oil filter 1, and then tighten it
7-82
Cylinder block
2
1
0
1
Oil filter 1: 18 Nm (1.8 kgfm, 13.3 ftlb)
3
4
5
6
7
8
9
10
A
7-83
Crankcase
Crankcase
7
a 35 Nm (3.5 kgfm, 25.8 ftlb)
b 90
a 14 Nm (1.4 kgfm, 10.3 ftlb)
b 28 Nm (2.8 kgfm, 20.7 ftlb)
12
23
5
22 21
10
11
11
24
9
5
13
14
25
17
18
1
15
14
17
a 40 Nm (4.0 kgfm, 29.5 ftlb) 16

b 90
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Crankcase
Bolt
Bolt
Dowel pin
Crankshaft journal bearing
Thrust bearing
Oil seal
Crankshaft
Crankshaft journal bearing
Thrust bearing
O-ring
Cylinder block
Collar
Crankshaft pin bearing
Connecting rod assembly
Connecting rod bolt
Clip
Qty
1
10
10
10
5
2
1
1
5
2
2
1
1
8
4
8
8
7-84
19
20
Remarks
M8 55 mm
Not reusable
Not reusable
Not reusable
Not reusable
26
Crankcase
7
a 35 Nm (3.5 kgfm, 25.8 ftlb)
b 90
a 14 Nm (1.4 kgfm, 10.3 ftlb)
b 28 Nm (2.8 kgfm, 20.7 ftlb)
12
0
8
23
5
22 21
10
11
11
24
9
5
13
14
25
17
18
14
17
a 40 Nm (4.0 kgfm, 29.5 ftlb) 16

b 90
No.
18
19
20
21
22
23
24
25
26
Part name
Piston pin
Piston
Piston ring set
Plate
Bolt
O-ring
Plug
O-ring
Bolt
Qty
4
4
4
1
2
1
1
1
1
4
5
1
15
26
19
20
6
Remarks
7
8
M6 12 mm
Not reusable
Not reusable
M6 14 mm
9
10
A
7-85
Crankcase
Disassembling the cylinder block
1. Remove the crankcase 1.
2
3
1
b
3
4
a
3. Remove the thrust bearings 1, crankshaft journal bearings 2, crankshaft 3,
crankshaft journal bearings 4, thrust
bearings 5, and oil seal 6.
2. Remove the connecting rod bolts 1 and

connecting rod caps 2, and then
remove the crankshaft pin bearings 3
and piston and connecting rod assemblies 4.
1
2
2
TIP:
To prevent mixing the piston and connecting rod assemblies 4 and connecting rod
caps 2, mark each with an identification
number a of the corresponding cylinder.
Mark each connecting rod and connecting
rod cap with mark b on the side facing
toward the flywheel magneto end of the
crankshaft.
removal.
4
5
4
4. Remove the collar 1.
7-86
Crankcase
3
4
Piston diameter a:
95.92695.945 mm
(3.77663.7774 in)
95.886 mm (3.7775 in)
Measuring point b:
13.5 mm (0.53 in) above the bottom of
the piston skirt
Bearing separator 2: 90890-06534

Gear puller 3: 90890-06540
90890-06615
5. Remove the clips 1 and piston pin 2,
and then remove the connecting rod 3.
TIP:
Remove the piston pin from the side
marked with a.
removal.
1. Measure the cylinder bore (D1D6) at

measuring points a, b, and c, and in
directions d (D1, D3, D5) and e (D2, D4,
D6).
D2
D1
D4
D3
D6
D5
a. 10.0 mm (0.39 in)

b. 50.0 mm (1.97 in)
c. 106 mm (4.17 in)
d. Parallel to the crankshaft
e. At a right angle to the crankshaft
Cylinder bore (D1D6):
96.00096.019 mm
(3.77953.7803 in)
96.072 mm (3.7824 in)
Checking the piston diameter

1. Measure the piston outside diameter a
at the specified measuring point b.
Checking the cylinder bore
1
2
7
8
9
10
Checking the piston clearance

1. Measure the piston diameter. See
Checking the piston diameter (7-87).
A
7-87
Crankcase
2. Measure the cylinder bore. See Checking the cylinder bore (7-87).
3. Calculate the piston clearance. Replace
the piston or cylinder block if out of specification.
Piston clearance = maximum cylinder bore
piston outside diameter:
0.0710.077 mm (0.00280.0030 in)
0.186 mm (0.0073 in)
1
b
Checking the piston ring

1. Measure piston ring dimensions B and T.
Measuring point a: 10.0 mm (0.39 in)

Piston ring end gap b (reference data):
Top ring:
0.200.30 mm (0.00790.0118 in)
0.47 mm (0.0185 in)
2nd ring:
0.600.75 mm (0.02360.0295 in)
0.90 mm (0.0354 in)
Oil ring:
0.150.60 mm (0.00590.0236 in)
b
B
B
T
Piston ring dimensions:

Top ring a:
B: 1.1701.185 mm (0.04610.0467 in)
T: 2.8003.000 mm (0.11020.1181 in)
2nd ring b:
B: 1.1701.190 mm (0.04610.0469 in)
T: 3.8004.000 mm (0.14960.1575 in)
Oil ring c:
B: 2.4002.470 mm (0.09450.0972 in)
T: 2.3502.750 mm (0.09250.1083 in)
Checking the piston ring groove

1. Measure the piston ring grooves.
a
b
Checking the piston ring end gap

c
1. Level the piston ring 1 in the cylinder

using a piston crown at the specified
measuring point a.
Piston ring groove:
Top ring a:
1.231.25 mm (0.04840.0492 in)
2nd ring b:
1.221.24 mm (0.04800.0488 in)
Oil ring c:
2.512.53 mm (0.09880.0996 in)
2. Measure the piston ring end gap b.
7-88
Crankcase
Checking the piston ring side

clearance
Piston pin boss inside diameter a:

22.01122.018 mm
(0.86660.8668 in)
22.038 mm (0.8676 in)
1. Measure the piston ring side clearance.
Checking the piston pin diameter

b
1. Measure the piston pin outside diameter

a at measuring points b, c, and d,
and in directions e and f. Replace if
a
Piston ring side clearance:
Top ring a:
0.040.08 mm (0.00160.0031 in)
0.13 mm (0.0051 in)
2nd ring b:
0.030.07 mm (0.00120.0028 in)
0.110 mm (0.0043 in)
Oil ring c:
0.040.13 mm (0.00160.0051 in)
1
2
3
4
b
c
Checking the piston pin boss inside

diameter
1. Measure the piston pin boss inside diameter a.

Piston pin outside diameter a:
21.99622.005 mm
(0.86600.8663 in)
21.986 mm (0.8656 in)
TIP:
When measuring the piston pin boss inside
diameter, do not measure it at the ring groove
b or oil groove c.
8
9
a
b
10
A
7-89
Crankcase
Checking the connecting rod small

end inside diameter and big end
inside diameter
1. Tighten the connecting rod bolts 1 to
the specified torques in 2 stages.
TIP:
When checking the big end inside diameter,
reuse the removed connecting rod bolt.
In the second tightening stage for the connecting rod bolts 1, mark the connecting
rod bolts and the connecting rod cap with
identification marks a, and then tighten
the bolts 90 from the marks on the connecting rod cap.
a
Connecting rod big end side clearance a:
0.140.31 mm (0.00550.0122 in)
0.36 mm (0.0142 in)
Checking the crankshaft

1. Measure the crankshaft journal diameters a, crankshaft pin diameters b, and
crankshaft pin widths c.
2. Measure the connecting rod small end

inside diameter b and big end inside
diameter c.
b
a
90
c
1
b
Connecting rod bolt 1:

1st: 40 Nm (4.0 kgfm, 29.5 ftlb)
2nd: 90
Connecting rod small end inside diameter
b:
22.01022.024 mm
(0.86650.8671 in)
Connecting rod big end inside diameter
c:
55.99056.010 mm
(2.20432.2051 in)
c
Crankshaft journal diameter a:
59.98060.000 mm
(2.36142.3622 in)
Crankshaft pin diameter b:
52.98053.000 mm
(2.08582.0866 in)
Crankshaft pin width c:
21.0021.10 mm (0.82680.8307 in)
Checking the connecting rod big end

side clearance
1. Measure the connecting rod big end side
clearance a.
2. Measure the crankshaft runout.
7-90
Crankcase
0
1
Crankshaft runout: 0.03 mm (0.0012 in)
0.04 mm (0.0016 in)
4. Install the connecting rod 1 and connecting rod cap 2 onto the crankshaft
pin.
Checking the big end oil clearance
TIP:
1. Clean the crankshaft pin bearings, connecting rod, connecting rod cap, and
crankshaft.
When checking the oil clearance, reuse the

removed connecting rod bolts.
Make sure that the marks a on the connecting rod 1 and connecting rod cap 2
face toward the flywheel magneto end of
the crankshaft.
Do not turn the connecting rod until the big
end oil clearance measurement has been
completed.
2. Install the crankshaft pin bearings 1 into

the connecting rod 2 and connecting
rod cap 3.
TIP:
Install the crankshaft pin bearings in their
original positions.
2
3
4
5
6
2
1
3
a
7
8
3. Place a piece of Plastigauge (PG-1) on

the crankshaft pin, parallel to the crankshaft.
9
10

the oil hole in the crankshaft pin of the
crankshaft.
5. Tighten the connecting rod bolts 1 to

the specified torques in 2 stages.
A
7-91
Crankcase
TIP:
In the second tightening stage for the connecting rod bolts 1, mark the connecting rod
bolts and the connecting rod cap with identification marks a, and then tighten the bolts
90 from the marks on the connecting rod
cap.
1
90
Connecting rod big end inside diameter

a:
55.99056.010 mm
(2.20432.2051 in)
Example:
Connecting rod big
end inside diameter
a
55.993 mm

1st: 40 Nm (4.0 kgfm, 29.5 ftlb)
2nd: 90
Number in table
93
2. Check the crankshaft pin mark a on the

crankshaft.
6. Remove the connecting rod cap, and

then measure the width of the compressed Plastigauge (PG-1) on the
crankshaft pin.
P1
P4
P2
P3
P2
P4
P1
Big end oil clearance:

0.0250.050 mm (0.00100.0020 in)
0.080 mm (0.0031 in)
Selecting the crankshaft pin bearing
P3
J
P
3. Select the suitable colors 1 for the

crankshaft pin bearing from the Crankshaft pin bearing selection table (7-94).
When replacing the crankshaft pin bearing,

select the bearing as follows:
1. Measure the connecting rod big end
inside diameter a.
7-92
Crankcase
0
1
c
d
e
f
Rod side
bearing color
Blue
Green
Yellow
Yellow
Cap side
bearing color
Green
Green
Green
Yellow
2
3
Example:
If the connecting rod big end inside diameter
is 05 and the crankshaft pin mark is 81,
select the bearing colors in c. The rod side
bearing color is blue and the cap side bearing
color is green.
90 91
4
5
6
04 05 06 07
80
81
82
8
9
10
A
7-93
Crankcase
Crankshaft pin bearing selection table

A
90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10
80
81
82
83
84
85
86
87
88
89
B 90
91
92
e
93
94
95
96
97
98
99
00
A. Connecting rod big end inside diameter
B. Crankshaft pin mark
7-94
Crankcase
Checking the journal oil clearance
6. Install the crankcase 1, and then tighten

the crankcase bolts 2 to the specified
torques in 2 stages and in the order [1],
[2], and so on.
1. Clean the crankshaft journal bearings,

crankshaft journals, and bearing portions
of the crankcase and cylinder block.
7. Tighten the crankcase bolts 3 to the

2. Place the cylinder block upside down.

3. Install the crankshaft journal bearings 1
and crankshaft 2 into the cylinder block
3.
TIP:
When checking the oil clearance, reuse the
removed crankcase bolts (M10).
Do not turn the crankshaft until the journal
oil clearance measurement has been completed.
In the second tightening stage for the M10
bolts 2, mark the M10 bolts and the crankcase with identification marks a, and then
tighten the bolts 90 from the marks on the
crankcase.
TIP:
Install the crankshaft journal bearings 1 in
their original positions.
2
3
4
5
4. Place a piece of Plastigauge (PG-1) on

each crankshaft journal, parallel to the
crankshaft.

the oil hole in each crankshaft journal.
7
8
9
10
5. Install the crankshaft journal bearings

into the crankcase.
TIP:
Install the crankshaft journal bearings in their
original positions.
A
7-95
Crankcase
[9]
2. Check the mark a on the crankshaft

journal and the mark b on the cylinder
block.
90
J1
2 [10]
3
[19]
[5]
[15]
[20]
[6]
[16]
[1]
[11]
[2]
[12]
[4]
[14]
[3]
[13]
[18]
[17]
[8]
[7]
J2
J3
J4
J3
J2
J4
J1
J4
a
Crankcase bolts 2 [1][10] (M10):

1st: 35 Nm (3.5 kgfm, 25.8 ftlb)
2nd: 90
1st: 14 Nm (1.4 kgfm, 10.3 ftlb)
2nd: 28 Nm (2.8 kgfm, 20.7 ftlb)
J
P
J5
J4 J3
J2 J1 b
8. Remove the crankcase, and then measure the width of the compressed Plastigauge (PG-1) on each crankshaft
journal.
3. Select the suitable colors 1 for the

crankshaft journal bearing from the
Crankshaft journal bearing selection
table (7-98).
Journal oil clearance:

0.0260.051 mm (0.00100.0020 in)
0.071 mm (0.0028 in)
Selecting the crankshaft journal

bearing
When replacing the crankshaft journal bearing, select the bearing as follows:
1. Remove the crankshaft pin bearings.
7-96
Crankcase
Block side
bearing color
Blue
Green
Green
Yellow
Yellow
c
d
e
f
g
Crankcase side
bearing color
Blue
Blue
Green
Green
Yellow
0
1
Example:
If the crankshaft journal mark is 81 and the
cylinder block mark is 12, select the bearing
colors in d. The block side bearing color is
green and the crankcase side bearing color is
blue.
2
3
00 01
11 12 13 14 15
80
81
82
5
6
7
8
9
10
A
7-97
Crankcase
Crankshaft journal bearing selection table

A
00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20
80
81
c
82
83
84
85
d
86
87
88
89
B 90
91
92
93
94
95
96
97
98
99
00
A. Cylinder block mark
B. Crankshaft journal mark
7-98
Crankcase
Assembling the cylinder block
TIP:
1. Install a new collar 1 by striking it using

a plastic hammer.
Make sure that the 2R mark a on the

2nd ring 2 and 1R mark b on the top
ring 3 are facing up.
Make sure that the piston rings move
smoothly.
4. Offset the piston ring end gaps.
#5
2. Assemble the piston 1, the connecting
rod 2, the piston pin 3, and new clips
4.
#4
2
3
#2
#1
#3
TIP:
Face the mark a on the connecting rod 2
in the same direction as the mark b on the
piston crown.
Make sure that the clip 4 end is not
aligned with the groove c in the piston pin
boss.
#3
45 45
#2
b
#1
#4
#5
5. Install the crankshaft pin bearings 1 into

the connecting rod 2 and connecting
rod cap 3.
4
5
6
TIP:
c
Install the crankshaft pin bearings in the original positions.
1
3
a
3. Install the oil rings 1, 2nd ring 2, and
top ring 3.
6. Apply engine oil to the side of the piston,
piston rings, and cylinder wall, and then
install the piston so that the mark a on
the piston crown is facing toward the flywheel magneto end of the crankshaft.
Do not scratch the pistons or break the

piston rings.
10
A
7-99
Crankcase
1
2
Piston slider 96 mm 1: 90890-06684
9. Install the connecting rod caps 1 to the

piston and connecting rod assemblies,
and then tighten new connecting rod
bolts 2 to the specified torques in 2
stages.

into the cylinder block 2.
TIP:
TIP:
Make sure that the marks a on the connecting rod and connecting rod caps 1 are
facing toward the flywheel magneto end of
the crankshaft.
In the second tightening stage for the connecting rod bolts 2, mark the connecting
rod bolts and connecting rod cap with paint
marks b, and then tighten the connecting
rod bolts 90 from the marks on the connecting rod cap.
After tightening the connecting rod bolts
2, make sure that the crankshaft turns
smoothly.
1
1
1
2
b
8. Install a new oil seal 1 into the crankshaft 2, and then install the crankshaft
and thrust bearings 3 into the cylinder
block 4.
90
1
TIP:
Make sure that each thrust bearing is
installed with its notches facing outward.
Slide the thrust bearing between the crankshaft and the cylinder block.
7-100
Crankcase
1st: 40 Nm (4.0 kgfm, 29.5 ftlb)
2nd: 90
When installing the crankcase, make sure

that the thrust bearings are in position.

onto the crankcase 2.
TIP:
TIP:
In the second tightening stage for the M10

bolts 3, mark the M10 bolts and the crankcase 2 with identification marks a, and
then tighten the bolts 90 from the marks on
the crankcase.

Do not apply any sealant to the crankshaft
journal bearings 1.
14. Tighten the crankcase bolts 4 to the

11. Apply a thin, even layer of sealant onto

the mating surface of the crankcase.
1
2
3
TIP:
After tightening the crankcase bolts 3 and
4, make sure that the crankshaft turns
smoothly.
1
2
5
6
1
12. Install the thrust bearings 1.
1
1
7
8
9
10
13. Install new O-rings 1 and the crankcase

2, and then tighten new crankcase bolts
A
7-101
Crankcase
[9]
90
3 [10]
4
[19]
[5]
[15]
[20]
[6]
[16]
[1]
[11]
[2]
[12]
[4]
[14]
[3]
[13]
[18]
[17]
[8]
[7]

1st: 35 Nm (3.5 kgfm, 25.8 ftlb)
2nd: 90
Crankcase bolt 4 [11][20] (M8):
1st: 14 Nm (1.4 kgfm, 10.3 ftlb)
2nd: 28 Nm (2.8 kgfm, 20.7 ftlb)
7-102
Crankcase
MEMO
0
1
2
3
4
5
6
7
8
9
10
A
7-103
Lower unit
Lower unit (regular rotation model) ................................. 8-1
Removing the lower unit ............................................................ 8-3
Disassembling the propeller
(Shift Damper System [SDS] propeller) ..................................... 8-3
Checking the propeller .............................................................. 8-3
Checking the lower unit anode .................................................. 8-3
Assembling the propeller
(Shift Damper System [SDS] propeller) ..................................... 8-4
0
1
2
Water pump and shift rod (regular rotation model) ....... 8-6
Removing the water pump and shift rod .................................... 8-8
Disassembling the water pump housing .................................... 8-8
Checking the water pump and shift rod ..................................... 8-8
Assembling the water pump housing ........................................ 8-9
3
4
Propeller shaft housing (regular rotation model) ......... 8-10

Removing the propeller shaft housing assembly ..................... 8-12
Disassembling the propeller shaft assembly ........................... 8-12
Disassembling the propeller shaft housing assembly ............. 8-13
Checking the propeller shaft .................................................... 8-13
Checking the dog clutch .......................................................... 8-13
Checking the propeller shaft housing ...................................... 8-13
Checking the reverse gear ...................................................... 8-13
Assembling the propeller shaft assembly ................................ 8-14
Assembling the propeller shaft housing assembly .................. 8-14
Drive shaft and lower case

(regular rotation model) .................................................. 8-16
Removing the drive shaft ......................................................... 8-18
Removing the forward gear ..................................................... 8-18
Disassembling the drive shaft housing .................................... 8-18
Disassembling the forward gear .............................................. 8-18
Disassembling the lower case ................................................. 8-19
Checking the pinion ................................................................. 8-19
Checking the forward gear ...................................................... 8-19
Checking the drive shaft .......................................................... 8-19
Checking the lower case ......................................................... 8-20
Assembling the forward gear ................................................... 8-20
Assembling the drive shaft housing ......................................... 8-20
Assembling the lower case ...................................................... 8-21
Installing the forward gear ....................................................... 8-22
5
6
7
8
9
10
Lower unit
Installing the drive shaft ........................................................... 8-22
Installing the propeller shaft housing assembly ....................... 8-23
Installing the shift rod .............................................................. 8-24
Installing the water pump ........................................................ 8-24
Checking the lower unit for air leakage ................................... 8-26
Installing the lower unit ............................................................ 8-26
Shimming (regular rotation model) ............................... 8-28

Shimming workflow ................................................................. 8-28
Shimming check sheet ............................................................ 8-29
Measuring the forward gear backlash and
reverse gear backlash before disassembly ............................. 8-31
Shimming procedure ............................................................... 8-34
Shim location ........................................................................... 8-34
Selecting the pinion shim (T3) ................................................. 8-35
Measuring the forward gear backlash ..................................... 8-37
Adjusting the forward gear shim thickness (T1) ...................... 8-38
Measuring the reverse gear backlash ..................................... 8-39
Adjusting the reverse gear shim thickness (T2) ...................... 8-39
Lower unit (counter rotation model) .............................. 8-41

Removing the lower unit .......................................................... 8-43
Disassembling the propeller
(Shift Damper System [SDS] propeller) ................................... 8-43
Checking the propeller ............................................................ 8-43
Checking the lower unit anode ................................................ 8-43
Assembling the propeller
(Shift Damper System [SDS] propeller) ................................... 8-43
Water pump and shift rod

(counter rotation model) ................................................. 8-44
Removing the water pump and shift rod .................................. 8-46
Disassembling the water pump housing .................................. 8-46
Checking the water pump and shift rod ................................... 8-46
Assembling the water pump housing ...................................... 8-46
Propeller shaft housing (counter rotation model) ........ 8-47

Removing the propeller shaft housing assembly ..................... 8-49
Disassembling the propeller shaft housing assembly ............. 8-49
Disassembling the forward gear .............................................. 8-50
Checking the propeller shaft .................................................... 8-50
Lower unit
Checking the dog clutch .......................................................... 8-50
Checking the propeller shaft housing ...................................... 8-50
Checking the forward gear ...................................................... 8-50
Assembling the propeller shaft housing assembly and
forward gear ............................................................................ 8-50
Drive shaft and lower case

(counter rotation model) ................................................. 8-53
Removing the drive shaft ......................................................... 8-55
Removing the reverse gear ..................................................... 8-55
Disassembling the drive shaft housing .................................... 8-55
Disassembling the reverse gear .............................................. 8-55
Disassembling the lower case ................................................. 8-55
Checking the pinion ................................................................. 8-56
Checking the reverse gear ...................................................... 8-56
Checking the drive shaft .......................................................... 8-56
Checking the lower case ......................................................... 8-56
Assembling the reverse gear ................................................... 8-56
Assembling the lower case ...................................................... 8-56
Assembling the drive shaft housing ......................................... 8-57
Installing the reverse gear ....................................................... 8-57
Installing the drive shaft ........................................................... 8-57
Installing the propeller shaft housing assembly ....................... 8-57
Installing the shift rod .............................................................. 8-57
Installing the water pump ........................................................ 8-58
Checking the lower unit for air leakage ................................... 8-58
Installing the lower unit ............................................................ 8-58
Shimming (counter rotation model) .............................. 8-59

Shimming workflow ................................................................. 8-59
Shimming check sheet ............................................................ 8-60
reverse gear backlash before disassembly ............................. 8-62
Shimming procedure ............................................................... 8-65
Shim location ........................................................................... 8-65
Selecting the pinion shim (T3) ................................................. 8-66
Selecting the propeller shaft shim (T4) .................................... 8-66
Measuring the reverse gear backlash ..................................... 8-67
Adjusting the reverse gear shim thickness (T1) ...................... 8-67
Measuring the forward gear backlash ..................................... 8-69
Adjusting the forward gear shim thickness (T2) ...................... 8-69
0
1
2
3
4
5
6
7
8
9
10

42 Nm (4.2 kgfm, 31.0 ftlb)
6
54 Nm (5.4 kgfm, 39.8 ftlb)
15
13
10
5
14
2
12
4
11
9
16
17
20
4
20
19
18
47 Nm (4.7 kgfm, 34.7 ftlb)
47 Nm (4.7 kgfm, 34.7 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
Part name
Hose nipple
O-ring
Oil level plug
Gasket
Dowel pin
Grommet
Bolt
Lower unit
Spacer
Propeller
Damper
Qty
1
1
1
2
2
1
1
1
1
1
1
12
13
14
15
16
17
Spacer
Washer
Propeller nut
Cotter pin
Spacer
Trim tab
1
1
1
1
1
1
8-1
Remarks
Not reusable
M8 8 mm
Not reusable
M10 45 mm
Shift Damper System (SDS) propeller, Not reusable

Shift Damper System (SDS) propeller
M18
Not reusable
Except Shift Damper System (SDS) propeller
42 Nm (4.2 kgfm, 31.0 ftlb)
6
54 Nm (5.4 kgfm, 39.8 ftlb)
15
13
10
5
14
2
12
11
9
16
3
4
17
20
5
4
20
19
18
47 Nm (4.7 kgfm, 34.7 ftlb)
47 Nm (4.7 kgfm, 34.7 ftlb)
No.
18
19
20
Part name
Bolt
Drain screw
Bolt
Qty
1
1
6
Remarks
M10 70 mm
M8 13 mm
M10 45 mm
7
8
9
10
A
8-2
Removing the lower unit
7. Remove the lower case mounting bolts

3 and 4, and then remove the lower
unit 5.
Make sure to disconnect the battery

cables from the battery, and remove the
clip from the engine shut-off switch.
When removing the lower unit with the
power unit installed, make sure to suspend the outboard motor. Otherwise, the
outboard motor could fall suddenly and
result in severe injuries.
When loosening or tightening the propeller nut, do not hold the propeller
using your hands.
TIP:
When disassembling the lower unit, measure

the backlash before disassembly. See Measuring the forward gear backlash and reverse
gear backlash before disassembly (8-31).
Disassembling the propeller (Shift

Damper System [SDS] propeller)
1. Drain the gear oil. See steps 14 in

Changing the gear oil (10-13).
1. Remove the damper 1.
2. Remove the cotter pin.
3. Set the gear shift to the N position.
3 1
4. Place a block of wood between the anticavitation plate and the propeller to
prevent the propeller from turning, and
then remove the propeller nut and
propeller.
Driver rod L3 2: 90890-06652
90890-06653
Checking the propeller

1. Check the propeller blades and damper
rubber splines. Replace the propeller if
cracked, damaged, or worn.
Checking the lower unit anode
5. Remove the grommet 1.
1. Check the trim tab. Clean if there is

6. Mark the trim tab 2 and lower case with

an identification mark a, and then
remove the trim tab 2.
8-3

trim tab.
Assembling the propeller (Shift

1. Place a new damper 1 in the propeller
2.
3
3
2
TIP:
Align the mark a on the damper 1 with the

mark b on the propeller 2.

90890-06653
Installation height a (reference data):
4.0 mm (0.158 in)
2. Install the damper 1 using the special
service tool 2 and spacer 3 to the
specified height a.
3. Check the installation depth a of the

damper 1.
TIP:
The damper 1 will be in the proper position
(the damper 1 is in contact with the spacer
2) after the propeller nut 3 has been tightened to the specified torque. Therefore, when
installing the propeller to the outboard motor,
make sure to tighten the propeller nut 3 to
the specified torque. See step 9 in Installing
the lower unit (8-26).
Be careful not to install the spacer in the

opposite direction.
TIP:
When installing the damper 1, make sure
that the spacer 3 does not contact the propeller boss.
6
7
8
9
a
1
1
10
A
8-4
3
2
1
B
3
2
A. Before tightening the propeller nut 3 to
the specified torque.
B. After tightening the propeller nut 3 to
Installation depth a (reference data):
9.4 mm (0.37 in)
8-5
Water pump and shift rod (regular rotation model)

6
22
23
8
9
10
9
5
5
24
22
22
11
5
20
21
12
4
19
13
18
2
14
17
16
3
4
15
15
5
6
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Shift rod
E-clip
O-ring
Plate
Bolt
Oil seal
Collar
Spacer
Washer
Wave washer
Impeller
Outer plate cartridge
Gasket
Impeller key
Dowel pin
Plate
Rubber seal
Qty
1
1
1
1
3
1
1
1
2
1
1
1
1
1
2
1
1
8-6
Remarks
Not reusable
M6 20 mm
Not reusable
7
8
9
10
Not reusable
22
23
8
9
10
9
5
5
24
22
22
11
20
21
12
4
19
13
18
2
No.
18
19
20
21
22
23
24
Part name
O-ring
Insert cartridge
O-ring
Water pump housing
Bolt
Seal
Cover
14
17
16
15
15
Qty
1
1
1
1
4
1
1
8-7
Remarks
Not reusable
Not reusable
M8 45 mm
Removing the water pump and shift

rod
1. Remove the water pump housing 1,
O-ring 2, dowel pins 3, collar 4,
spacer 5, washers 6, wave washer
7, and impeller 8.
0
1
2. Remove the impeller key 9, outer plate

cartridge 10, and gasket 11.
1
2
8
9
10
1
4
11
Disassembling the water pump

housing
1. Remove the insert cartridge 1 and

O-ring 2.
5
6
7
6
4
5
3. Remove the rubber seal 1 and plate 2.
1
2
6
2. Remove the cover 1 and seal 2.
7
1
9
Checking the water pump and shift
rod
1. Check the water pump housing. Replace

if deformed.
10
F
Shift rod socket 1: 90890-06681
5. Remove the shift rod 1.
A
8-8
TIP:
If the engine overheats, the inside of the
water pump housing may be deformed.
Therefore, make sure to remove the insert
cartridge when checking the water pump
housing.
2. Check the impeller, insert cartridge, and
outer plate cartridge. Replace if cracked
or worn.
3. Check the impeller key and the keyway in
the drive shaft. Replace if deformed or
worn.
4. Check the shift rod. Replace if bent,
cracked, or worn.
Assembling the water pump housing

1. Install the seal 1 and cover 2.
2
1
2. Install a new O-ring 1 and the insert

cartridge 2.
TIP:
Fit the protrusions a on the insert cartridge
2 into the slots b in the water pump housing 3.
a
b
8-9
Propeller shaft housing (regular rotation model)

1
37
2 4 4
2 5
8 6
6
3
21
2
5
3
1 2
16
19
15
20
18
14
13
10
17
4
5
11
142 Nm (14.2 kgfm, 104.7 ftlb)
12
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Slider
Ball
Ball
Ball
Spring
Dog clutch
Cross pin
Spring
Propeller shaft
Washer
Reverse gear
Thrust washer
Ball bearing
O-ring
Propeller shaft housing
Key
Qty
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
8-10
Remarks
5.54 mm (0.22 in) (reference data)
7
8
9
10
Not reusable
Not reusable
37
2 4 4
2 5
8 6
6
3
21
2
5
3
1 2
16
19
15
20
18
14
13
10
17
11
142 Nm (14.2 kgfm, 104.7 ftlb)
12
No.
18
19
20
21
Part name
Needle bearing
Oil seal
Claw washer
Ring nut
Qty
1
2
1
1
8-11
Remarks
Not reusable
Not reusable
M111.25
Removing the propeller shaft

housing assembly
1. Straighten the bent tab 1 on the claw

washer.
4
2
3
3
Bearing housing puller claw L 3:

90890-06502
Stopper guide plate 4: 90890-06501
Center bolt 5: 90890-06504
2. Loosen the ring nut.
5. Remove the washer 1, propeller shaft

assembly 2, and reverse gear shims
3.
3
4
3
2
5
6
Ring nut wrench extension 1:

90890-06513
Ring nut wrench 4 2: 90890-06512
Disassembling the propeller shaft

assembly
3. Remove the ring nut 1 and claw washer

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

the cross pin 2, dog clutch 3, slider
4, balls 5, 6, and 7, and spring 8.
TIP:
When removing the slider 4, make sure that
the balls do not fall out of position.
7
8
9
10
4. Remove the propeller shaft housing

assembly 1 and key 2.
A
8-12

3. Remove the oil seals 1 along with the
needle bearing 2.
1
6
5
3
4
5
4
3
2
1

housing assembly
Driver rod L3 3: 90890-06652
90890-06653
1. Remove the reverse gear 1, thrust

washer 2, and O-ring 3.
Checking the propeller shaft
1. Check the propeller shaft. Replace if

damaged or worn.
2. Measure the propeller shaft runout.

Stopper guide stand 6: 90890-06538
Bearing puller assembly 7: 90890-06535
2. Remove the ball bearing 1.
Propeller shaft runout:
0.02 mm (0.0008 in)
2
3
4
1
Checking the dog clutch
1. Check the dog clutch, cross pin, spring,

balls, and slider. Replace if cracked or
worn.
Checking the propeller shaft housing

1. Check the propeller shaft housing.
Replace if cracked or damaged.

Stopper guide stand 3: 90890-06538
Checking the reverse gear

1. Check the teeth and dogs of the reverse
gear. Replace if cracked or worn.
8-13
Assembling the propeller shaft

assembly
1. Install the spring 1, balls 2, 3, and

4, and slider 5.
TIP:
When installing the slider 5, make sure that
2
5
1
3
2
4

housing assembly
1. Install a new needle bearing 1 in the

propeller shaft housing at the specified
installation depth a.
3
5
2
4
TIP:
Face the bearing identification mark b on

the needle bearing toward the propeller.
When using the driver rod, do not strike the
special service tool in a manner that will
force the stopper 5 out of place.
2. Install the dog clutch 1 so that the hole

a in the dog clutch 1 and the hole b
in the propeller shaft are aligned with the
hole c in the slider 2.
5
6
TIP:
Face the 6DA mark d on the dog clutch 1
toward the slider 2.
2
5
4
1
b
d
a
1
a
Driver rod SS 2: 90890-06604
90890-06610
Bearing depth plate 4: 90890-06603
1
2
b
24.7525.25 mm (0.9740.994 in)
8
9
10
2. Install a new oil seal 1 in the propeller

shaft housing at the specified installation
depth a.
3. Install the cross pin 1, and then install

the spring 2.
A
8-14
a
4
a
4
2
1
3
1
3
Bearing inner race attachment 2:
90890-06640

90890-06654
5. Install the reverse gear assembly 1.
12.0 mm (0.47 in)
3. Install a new oil seal 1 in the propeller

shaft housing at the specified installation
depth a.
a
2
90890-06622
6. Check that the reverse gear turns

smoothly.
90890-06640
4.755.25 mm (0.1870.207 in)
4. Install the thrust washer 1 and a new

ball bearing 2 onto the reverse gear 3.
TIP:
Face the bearing identification mark a on
the ball bearing toward the propeller.
8-15

9
10
13
7
15
6
6
14
1
2
4
17
11
2
20
16
16
18
19
12
21
93 Nm (9.3 kgfm, 68.6 ftlb)
22
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Thrust bearing
Pinion shim (T3)
O-ring
Needle bearing
Drive shaft housing
Bolt
Oil seal
Cover
Self-locking nut
Water inlet cover (STBD)
Drive shaft
Sleeve
Lower case
Tapered roller bearing
Needle bearing
Forward gear
Qty
1
1
1
1
4
2
1
1
1
1
1
1
2
2
1
8-16
Remarks
Not reusable
Not reusable
Not reusable
M8 25 mm
Not reusable
8
9
10
Not reusable
Not reusable
10
13
7
15
6
6
14
4
17
3
11
2
20
16
16
18
19
12
21
93 Nm (9.3 kgfm, 68.6 ftlb)
22
No.
18
19
20
21
22
Part name
Water inlet cover (PORT)
Screw
Needle bearing
Pinion
Pinion nut
Qty
1
1
1
1
1
8-17
Remarks
M5 45 mm
Not reusable
M16
Removing the drive shaft
1. Remove the cover 1, drive shaft housing 2, pinion shims 3, and thrust bearing 4.
1
4
1
3
2. Remove the oil seals 1.
2
1
2. Loosen the pinion nut, and then remove

the pinion 1, drive shaft 2, and sleeve.
4
3. Remove the needle bearing 1.
4
2
3
2
1
2
Drive shaft holder 6 3: 90890-06520

Pinion nut holder 4: 90890-06715
90890-06610
Driver rod L3 3: 90890-06652
Removing the forward gear

1. Remove the forward gear assembly 1.
Disassembling the forward gear

1
1. Remove the tapered roller bearing inner

race 1.
2
1
9
10
Disassembling the drive shaft

housing
1. Remove the O-ring 1.
A
8-18

90890-06608
2. Remove the needle bearings from the
forward gear.
Disassembling the lower case

2

burns could result.
1
3. Remove the needle bearing 1.
3
1. Remove the water inlet covers 1 and
2.
Ball bearing attachment 2:

90890-06636
Driver rod LL 3: 90890-06605
Checking the pinion

the tapered roller bearing outer race is to
be removed using a gas torch, and then
remove the tapered roller bearing outer
race 1 and forward gear shims 2.
1. Check the teeth of the pinion. Replace if

cracked or worn.
Checking the forward gear

1. Check the teeth and dogs of the forward

burned.
Checking the drive shaft

1. Check the drive shaft. Replace if damaged or worn.
2. Measure the drive shaft runout.
8-19
2
2
1
Drive shaft runout: 1.0 mm (0.039 in)

90890-06654
Checking the lower case

Assembling the drive shaft housing
1. Check the lower case. Replace if cracked

or damaged.
Assembling the forward gear

1. Install new needle bearings 1 and 2 at
the specified installation depth a and
b.

drive shaft housing at the specified installation depth a.
TIP:

special service tool in a manner that will force
the stopper 2 out of place.
TIP:
Face the bearing identification mark c on
the needle bearing up.
special service tool in a manner that will
force the stopper 3 out of place.
4
5
2
3
a
c
6 4
a
5
3
4
1

90890-06610
Driver rod SS 4: 90890-06604
5.756.25 mm (0.2260.246 in)

90890-06612
Driver rod SS 5: 90890-06604
2. Install a new oil seal 1 in the drive shaft

housing at the specified installation depth
a.
20.9521.45 mm (0.8250.845 in)
Installation depth b:
4.454.95 mm (0.1750.195 in)
2. Install a new tapered roller bearing inner
race 1.
7
8
9
10
A
8-20

a
burns could result.
3
2
1
90890-06628
Driver rod LS 3: 90890-06606
1. Install the original forward gear shims 1.

the tapered roller bearing outer race is to
be installed using a gas torch, and then
install a new tapered roller bearing outer
race 2.
7.5 mm (0.30 in)
3. Install a new oil seal 1 in the drive shaft
housing at the specified installation depth
a.

burned.
a
3
2
TIP:
scratched.
2
1

90890-06628
Driver rod LS 3: 90890-06606
0.250.75 mm (0.0100.030 in)

strike the tool to check that the tapered
roller bearing outer race is installed
properly.
8-21
TIP:
TIP:

outer race is installed properly.
After installing the water inlet covers, make

sure that there is no rattling.
1
1
1
2
Water inlet cover screw 4:
Installing the forward gear
1. Install the forward gear assembly 1.

Driver rod LL 1: 90890-06605
90890-06619

lower case.
TIP:
Make sure to face the bearing identification
mark a on the needle bearing toward the
pinion.
The needle bearing contains 18 rollers.
Installing the drive shaft

1. Install the sleeve 1, the drive shaft 2, a
new thrust bearing 3, and the original
pinion shims 4.
TIP:
Make sure that the protrusion a on the
sleeve 1 is aligned with the slot b in the
lower case.
a
4
a
Ball bearing attachment 2: 90890-06633

Bearing outer race puller assembly 3:
90890-06523
7
8
9
10
3
b
5. Install the water inlet covers 1 and 2,

nut 3, and water inlet cover screw 4,
and then tighten the water inlet cover
A
8-22

2. Install the
temporarily.
pinion
and
pinion
Installing the propeller shaft housing

assembly
nut
1. Install the washer 1 and propeller shaft

2 into the propeller shaft housing
assembly 3.
TIP:
When installing the pinion, lift up the drive
shaft slightly and align the splines on the
drive shaft with the splines on the pinion.
3
2
3. Install the drive shaft housing 1 and

cover 2 into the lower case.
TIP:
Make sure to face the cutout a in the drive
shaft housing 1 forward.
2. Install the original reverse gear shims 1,

propeller shaft housing assembly 2, and
key 3.
3. Turn the drive shaft and check that the

propeller shaft housing assembly 2 is
installed securely.
a
1
4. Tighten the pinion nut 1 to the specified

torque.
1
2
4. Install the claw washer 1.
TIP:
Make sure to fit the protrusion a on the propeller shaft housing into the slot b in the
claw washer 1.

Pinion nut holder 3: 90890-06715
Pinion nut 1:
93 Nm (9.3 kgfm, 68.6 ftlb)
5. Check that the drive shaft turns smoothly.
8-23
a
1
5. Install the ring nut 1, and then tighten it

2. Install the E-clip 1 and plate 2 to the

shift rod 3.
3
1
Ring nut wrench extension 2:

90890-06513
Ring nut wrench 4 3: 90890-06512
3. Install the shift rod 1.
TIP:
Make sure to install the shift rod 1 in the
proper orientation. Installation orientation is
different between the counter rotation model
and the regular rotation model.
Ring nut 1:
142 Nm (14.2 kgfm, 104.7 ftlb)
6. Bend one of the 4 tabs on the claw
washer outward, and then bend the other
3 tabs inward.
6
7
8
9
10
Installing the shift rod

1. Install a new O-ring 1 and a new oil seal
2 to the plate 3.
4. Check that
smoothly.
the
shift
rod
operates
Installing the water pump

1. Install the plate 1 and rubber seal 2.
8-24
2
1
4
3
1
2
1

2, and the outer plate cartridge 3.
1
3
2
1
1
7. Install the water pump housing 1.
Do not turn the drive shaft counterclockwise. Otherwise, the water pump impeller
could be damaged.
3. Install the impeller key 1.

4. Align the slot a in the impeller 2 with
the impeller key 1, and then install the
impeller 2.
TIP:
While turning the drive shaft clockwise, push
the water pump housing down to install it.
a
2
1
1
5. Install the washers 1, wave washer 2,

spacer 3, and collar 4.
TIP:
The spacer 3 and collar 4 should fit
together firmly.
8-25
Checking the lower unit for air

leakage
1. Remove the oil level plug 1, and then
install the special service tool 2.
0
1
a
b
2
3
Leakage tester 2: 90890-06840

2. Apply the specified pressure. Check that
the pressure is maintained in the lower
unit for 10 seconds or more.
R
N
F
Do not overpressurize the lower unit. Otherwise, the oil seals could be damaged.

3. Install a new O-ring 1 to the hose nipple
2, and then install the hose nipple 2 to
the lower unit 3.
Lower unit holding pressure:

68.6 kPa (0.69 kgf/cm2, 9.9 psi)
Installing the lower unit
4. Install the dowel pins 4.
Make sure to disconnect the battery

cables from the battery, and remove the
clip from the engine shut-off switch.
When installing the lower unit with the
power unit installed, make sure to suspend the outboard motor. Otherwise, the
outboard motor could fall suddenly and
result in severe injuries.
When loosening or tightening the propeller nut, do not hold the propeller
using your hands.
4
5
6
5. Install the lower unit 3, and then tighten

the lower case mounting bolts 5 and 6
6. Install the trim tab 7 to its original

position a, and then tighten the trim tab
bolt 8 to the specified torque.
7. Install the grommet 9.
9
10
1. Check that the mark a on the bushing

1 is aligned with the mark b on the
plate 2.
A
8-26
9
8
1
2
4
3
4
Propeller nut:
54 Nm (5.4 kgfm, 39.8 ftlb)
7
5
a
10. Install a new cotter pin 1.
TIP:
If the slots in the propeller nut 2 are not
aligned with the cotter pin hole, tighten the
propeller nut until they are aligned.
6
Lower case mounting bolts 5 and 6:
47 Nm (4.7 kgfm, 34.7 ftlb)
Trim tab bolt 8:
42 Nm (4.2 kgfm, 31.0 ftlb)
8. Install the spacer 1, propeller 2,
spacer 3, washers 4, and propeller nut
5.
2
4 5
11. Fill the lower unit with gear oil up to the

proper level. See steps 59 in Changing
the gear oil (10-13).
A. Except Shift Damper System (SDS) propeller

B. Shift Damper System (SDS) propeller
9. Place a block of wood between the anticavitation plate and the propeller to
prevent the propeller from turning, and
then tighten the propeller nut to the
specified torque.
8-27
Shimming (regular rotation model)

Shimming workflow
1. Remove the water pump

assembly.
2. Measure the backlash before

disassembly.
3. Within specification?
4. YES
5. Shimming is not required.
6. NO
2
3
7. Disassemble the lower unit.

8. Select the pinion shims (T3).
9. Assemble the lower unit.
10. Measure the backlash.
6. NO 11. Adjust the forward gear shim

thickness (T1) and reverse
gear shim thickness (T2).
4. YES
12. Install the water pump

assembly.
1. Remove the water pump assembly.

2. Measure the backlash before disassembly.
4. YES
6. NO
8. Select the pinion shims (T3).

11. Adjust the forward gear shim thickness
(T1) and reverse gear shim thickness
(T2).
12. Install the water pump assembly.
8
9
10
TIP:
Make sure to drain the gear oil before measuring the backlash.
If the backlash is within specification, shimming is not required.
When assembling the original inner parts and a new lower case, shimming is required.
When replacing the pinion, forward gear, reverse gear, bearings, drive shaft, or propeller shaft
housing, shimming is required.
8-28
Shimming check sheet

Lower case deviation
Serial number
Remarks
Pinion height
(mm)
Measurements
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
(M)
Forward gear backlash
(mm)
Measurements
Before disassembly
After disassembly
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
Reverse gear backlash
(mm)
Measurements
Before disassembly
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
8-29
After disassembly

Forward gear shim (T1) thickness measurement in 2 places
Number of shim(s)
(mm)
Subtotal
0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total
0
1
2
Reverse gear shim (T2) thickness measurement in 2 places

Number of shim(s)
0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total
(mm)
Subtotal
3
4
5
6
7
8
9
10
A
8-30
Measuring the forward gear backlash

and reverse gear backlash before
disassembly
1
1. Install the lower unit onto a repair stand.

2. Remove the water pump assembly and
outer plate cartridge. See steps 13 in
Removing the water pump and shift rod
(8-8).
Center bolt 1 (shimming):

8. Place the lower unit in an upright
position.
9. Remove the cover 1, and then install
the outer plate cartridge 2.
R
N
F
4. Set up the special service tools 1, 2,
and 3, and then tighten the center bolt
3 temporarily.
1
3
90890-06502
Center bolt 3: 90890-06504
10. Set the spring 1 on the outer plate

cartridge, and then install the handle
holder 2 so that the spring is
compressed to the specified setting
height a.
5. Turn the lower unit so that the propeller

shaft is pointing down.
6. Turn the drive shaft 10 turns or more to
seat the tapered roller bearing.
7. While holding the drive shaft to prevent it
from turning, tighten the center bolt 1 to
8-31
TIP:
TIP:
After installing the handle holder, pull the

drive shaft upward to remove any free play.
Do not press the spring more than 5.0 mm
(0.197 in). Otherwise, too much torque will
be required to turn the drive shaft, making it
difficult to obtain correct measurements.
The resistance of the spring increases the

force required to turn the drive shaft. Therefore, to obtain correct measurements, consider the spring resistance force when
turning the drive shaft.
Do not turn the drive shaft using too much
force. Otherwise, the forward gear will turn,
leading to incorrect measurements.
A knocking sound may be heard when the
drive shaft is rotated, but this is the sound
of the pinion contacting the reverse gear
and does not affect the backlash measurement.
2
a
1
0
1
2
3
4
Spring 1: 90501-450A2 *1
Handle holder 2: EU0-23814-31 *1
*1. Order from Yamaha Parts warehouse.
Setting height a:
3.05.0 mm (0.1180.197 in)
11. Install the special service tool 1 onto
the drive shaft at the lowest possible
position where the shaft diameter is
22.4 mm (0.881 in), and then set up the
special service tools 2, 3, and 4.
13. Turn the drive shaft 180 clockwise, and

then measure the backlash again.
TIP:
Measure the backlash at 4 points: a, b,
c, and d, turning the drive shaft 180
clockwise after each measurement.
Write down the measurement data in the
shimming check sheet.
2
1
6
7
8
a
Backlash indicator 1: 90890-06706
Magnet base plate 2: 90890-07003
Dial gauge set 3: 90890-01252
Magnet base B 4: 90890-06844
b
d
12. Turn the drive shaft slowly clockwise and

counterclockwise, and then measure the
backlash between where the drive shaft
stops in each direction.
10
A
8-32

14. Determine the backlash average, and
then round down the average to 2
decimal places.
Example:
20. Check that the reverse gear backlash

average is within specification.
TIP:
Adjust the shim thicknesses if the reverse
gear backlash is out of specification.
(mm)
0.40
0.46
0.44
0.43
0.4325
0.43
Measurement point a
Measurement point b
Measurement point c
Measurement point d
Average
Round-down average
Reverse gear backlash:

0.591.26 mm (0.02320.0496 in)
21. Remove the special service tools and
propeller.
22. Install the cover 1.
15. Check that the forward gear backlash

TIP:
Adjust the shim thicknesses if the forward
Forward gear backlash:
0.260.77 mm (0.01020.0303 in)
16. Remove the special service tools from
the propeller shaft.
23. Install the water pump assembly. See

Installing the water pump (8-24).
17. Apply a load to the reverse gear by

installing the propeller 1, spacer 2
(without installing the spacer 3), and
washer 4.
18. Tighten the propeller nut 5 to the
specified torque.
3
4 5
B
3
A. Except SDS propeller

B. SDS propeller
Propeller nut 5 (shimming):
10 Nm (1.0 kgfm, 7.4 ftlb)
19. Repeat steps 1214 to measure the
reverse gear backlash.
8-33
Shimming procedure
Before selecting the forward gear shim (T1) and reverse gear shims (T2), make sure to select the
pinion shims (T3).
When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do
not apply gear oil, grease, or sealant to the parts.
When assembling the lower unit after shimming is completed, make sure to apply gear oil, grease,
and sealant to the specified areas.
0
1
Shim location
T3
F
P
2
3
4
5
6
7
8
9
10
T1
T2
A
8-34
Selecting the pinion shim (T3)

Spray anti-rust lubricant on the bearing
before installation. Do not apply gear oil to
the parts. Otherwise, correct measurements cannot be obtained.
Keep the parts free of foreign material,
such as dirt and lint.
a
3
4
1
Be careful not to damage the measurement plane surface of the special service
tool. Otherwise, correct measurements
cannot be obtained.
2. Hold the special service tool 1, and
then install the drive shaft 2, thrust
bearing 3, and drive shaft housing
assembly to the special service tool.
Pinion height gauge 1: 90890-06671

3. Tighten the drive shaft housing bolts 1.
TIP:
Do not install the pinion shims (T3) and
O-ring. Make sure that the pinion shims
(T3) are not affixed to the thrust bearing
outer race.
Make sure to install the thrust bearing outer
race so that it is facing the same direction
as when it was removed.
Make sure that the cutout a in the drive
shaft housing assembly is facing the opposite direction of the plate 4 of the special
service tool.
4. Install the pinion 1 and pinion nut 2,

and then tighten the pinion nut 2
temporarily.
When tightening the pinion nut, check

that the drive shaft turns smoothly.
5. Check that there is a gap a between the
pinion 1 and the special service tool 3.
8-35
If there is no gap and the drive shaft does

not turn, the special service tool could be
damaged.
TIP:
If there is no gap, the thrust bearing outer

race 4 may not have been installed. If the
gap is 1.0 mm (0.039 in) or more, the pinion
shims (T3) 5 may not have been removed.
Pinion nut 2:
93 Nm (9.3 kgfm, 68.6 ftlb)
8. Hold the special service tool 1 so that

the pinion is facing up.
3
4
5
6
7
6. Install the special service tool 1 to the

drive shaft spline and hold the special
service tool 1.
8
9. Turn the drive shaft 10 turns or more to
seat the thrust bearing.
7. Tighten the pinion nut 2 to the specified

torque.
10. Push down on the pinion 1 so that it

does not pop up, and then measure the
distance between the pinion 1 and the
9
10
A
8-36

Example:
(M) = 0.35
(P) = 1
TIP:
When measuring the distance, insert the
end of the thickness gauge straight into the
gap at the measurement point. Do not
insert the thickness gauge at an angle.
Measure the distance at 4 points: a, b,
c, and d.
F +03 R +04
P 01
a
a
b
(T3) = 0.85 mm from the Pinion shim (T3)

selection table.
1
c
2
Stamped
value on the
lower case (P)
11. Determine the distance average, and

decimal places.
Example:
Measurement point a
Measurement point b
Measurement point c
Measurement point d
Average
Round-down average (M)
0
1
2
Pinion height
measurement (M)
0.34 0.35 0.36
0.85
13. Remove the special service tools, and

then install the determined pinion shims
(T3).
(mm)
0.36
0.36
0.35
0.35
0.3550
0.35

Spray anti-rust lubricant on the gear and
bearings before installation. Do not apply
gear oil to the parts. Otherwise, correct
measurements cannot be obtained.
When measuring the forward gear or
reverse gear backlash, use the original
bearings and shims.
12. Determine the pinion shim (T3) thickness

adjustment using the Pinion shim (T3)
selection table according to the rounded
average (M) and the deviation (P)
stamped on the lower case. See Pinion
shim (T3) selection table (A-8).
1. Install the original forward gear shims

(T1) and tapered roller bearing outer
race.
TIP:
The (P) mark a is stamped on the trim tab
mounting surface of the lower case in
0.01 mm units. If the (P) mark is unreadable,
replace the lower case.
TIP:
If the original forward gear shims (T1) are
missing, install new shims with a combined
thickness of 0.50 mm.
scratched.
Available shim thicknesses:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
0.50 mm
8-37

2. Install the forward gear assembly, drive
shaft, and pinion. See Installing the drive
shaft (8-22).
TIP:
If the shim thickness adjustment value is
positive, increase the current shim thickness by that amount and, if the value is
negative, decrease the current shim thickness by that amount.
The gray-colored area on the selection
chart indicates the range of the specified
backlash. Shimming is not required if the
measured backlash is within the gray-colored area.
The values for the shim thickness adjustments specified in the selection chart are
intended to obtain the median value within
the range for the specified forward gear or
The table that follows the selection chart
shows the shim thickness adjustments for
the points marked on the chart.

4. Install the propeller shaft housing
assembly. See Installing the propeller
shaft housing assembly (8-23).
6. Measure the forward gear backlash. See
steps 315 in Measuring the forward
gear backlash and reverse gear backlash
before disassembly (8-31).
0.260.77 mm (0.01020.0303 in)
Adjusting the forward gear shim

thickness (T1)
1. Remove the tapered roller bearing outer
race and forward gear shims (T1).
Example:
Backlash measurement (BL1) = 0.20 mm a
Forward gear shim (T1) thickness adjustment
= 0.23 mm b
The current shim thickness must be
decreased by 0.23 mm.
2. Measure the thickness of original forward

gear shim (T1) in 2 places.
TIP:
0.30
0.20
0.10
0
0.10
b
0.20
0.30
0.40
B (mm)

scratched.
3. Determine the forward gear shim (T1)
thickness adjustment using the Forward
gear shim (T1) selection chart according
to the backlash measurement (BL1) from
Measuring the forward gear backlash.
See Forward gear shim (T1) selection
chart (regular rotation model) (A-9).
0
1
2
3
4
5
6
7
8
10 15 20 25 30 35
a
A (1/100 mm)
10 15 20 25 30 35
B 0.38 0.34 0.30 0.27 0.23 0.20 0.16 0.12

A. Backlash measurement (BL1)
B. Shim thickness adjustment
10
4. Calculate the new forward gear shim (T1)

thickness.
A
8-38
Measuring the reverse gear backlash
TIP:
Spray anti-rust lubricant on the gears and

bearings and shims.
Use the lowest number of shims to obtain

the required shim thickness.
If the calculated shim thickness cannot be
obtained with a combination of the available
shims, increase or decrease the shim thickness by 0.01 mm.
New forward gear shim (T1) thickness =
Current forward gear shim thickness + shim
thickness adjustment
1. Install the original reverse gear shims

(T2) and propeller shaft housing assembly. See Installing the propeller shaft
housing assembly (8-23).
Example:
Use the following formula when the shim
thickness adjustment value is positive.
Current forward gear shim thickness =
0.50 mm
Shim thickness adjustment = 0.18 mm
0.50 mm + 0.18 mm
= 0.68 mm
thickness adjustment value is negative.
Current forward gear shim thickness =
0.50 mm
0.50 mm + (0.23 mm)
= 0.27 mm
TIP:
If the original reverse gear shims (T2) are
scratched.
2. Measure the reverse gear backlash. See
0.591.26 mm (0.02320.0496 in)
Adjusting the reverse gear shim

thickness (T2)

0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
0.50 mm

assembly and reverse gear shims (T2).
5. Install the determined forward gear shims

(T1) and tapered roller bearing outer
race.
2. Measure the thickness of original reverse

TIP:
scratched.
3. Determine the reverse gear shim (T2)
thickness adjustment using the Reverse
Measuring the reverse gear backlash.
chart (regular rotation model) (A-9).
8-39
TIP:
TIP:


New reverse gear shim (T2) thickness =
Current reverse gear shim thickness + shim
Example:
Current reverse gear shim thickness =
0.63 mm
0.63 mm + 0.14 mm
= 0.77 mm
Current reverse gear shim thickness =
0.63 mm
0.63 mm + (0.34 mm)
= 0.29 mm
Example:
Reverse gear shim (T2) thickness adjustment
= 0.34 mm b
B (mm)
0.10
0.20
0.30
0.40
0.50
b
0.60
0.70
0.80
5 110 115
0 120
5 10
125 130 135 140 145 150 1
m)

0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
0.50 mm
5. Install the determined reverse gear shims
(T2) and propeller shaft housing
assembly.
5 110
A 115
0 120
5 10
125 130 135 140 145 150 1
0
1
2
3
4
5
6
7
8
9
09 0.12
B 0.67
0.16 0.63
0.19 0.60
0.23 0.27 0.30 0.34 0.37 0.41 0
10

4. Calculate the new reverse gear shim (T2)
thickness.
A
8-40

42 Nm (4.2 kgfm, 31.0 ftlb)
6
54 Nm (5.4 kgfm, 39.8 ftlb)
15
13
14
10
12
4
11
9
16
17
20
4
20
19
18
47 Nm (4.7 kgfm, 37.7 ftlb)
47 Nm (4.7 kgfm, 34.7 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
Part name
Hose nipple
O-ring
Oil level plug
Gasket
Dowel pin
Grommet
Bolt
Lower unit
Spacer
Propeller
Damper
Qty
1
1
1
2
2
1
1
1
1
1
1
12
13
14
15
16
17
Spacer
Washer
Propeller nut
Cotter pin
Spacer
Trim tab
1
1
1
1
1
1
8-41
Remarks
Not reusable
Not reusable
M10 45 mm
Shift Damper System (SDS) propeller, Not reusable

Shift Damper System (SDS) propeller
M18
Not reusable
Except Shift Damper System (SDS) propeller
42 Nm (4.2 kgfm, 31.0 ftlb)
6
54 Nm (5.4 kgfm, 39.8 ftlb)
15
13
14
10
12
11
9
16
3
4
17
20
5
4
20
19
18
47 Nm (4.7 kgfm, 37.7 ftlb)
47 Nm (4.7 kgfm, 34.7 ftlb)
No.
18
19
20
Part name
Bolt
Drain screw
Bolt
Qty
1
1
6
Remarks
M10 70 mm
M10 45 mm
8
9
10
A
8-42
Removing the lower unit

See Removing the lower unit (8-3).
TIP:
When disassembling the lower unit, measure
the backlash before disassembly. See Measuring the forward gear backlash and reverse
gear backlash before disassembly (8-62).
Disassembling the propeller (Shift

See Disassembling the propeller (Shift
Damper System [SDS] propeller) (8-3).
Checking the propeller

See Checking the propeller (8-3).
Checking the lower unit anode

See Checking the lower unit anode (8-3).
Assembling the propeller (Shift

See Assembling the propeller (Shift Damper
System [SDS] propeller) (8-4).
8-43
Water pump and shift rod (counter rotation model)

6
22
23
8
9
10
9
5
5
24
22
22
11
5
20
21
12
4
19
13
18
2
14
17
16
3
4
15
15
5
6
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Shift rod
E-clip
O-ring
Plate
Bolt
Oil seal
Collar
Spacer
Washer
Wave washer
Impeller
Outer plate cartridge
Gasket
Impeller key
Dowel pin
Plate
Rubber seal
Qty
1
1
1
1
3
1
1
1
2
1
1
1
1
1
2
1
1
8-44
Remarks
Not reusable
M6 20 mm
Not reusable
7
8
9
10
Not reusable
22
23
8
9
10
9
5
5
24
22
22
11
20
21
12
4
19
13
18
2
No.
18
19
20
21
22
23
24
Part name
O-ring
Insert cartridge
O-ring
Water pump housing
Bolt
Seal
Cover
14
17
16
15
15
Qty
1
1
1
1
4
1
1
8-45
Remarks
Not reusable
Not reusable
M8 45 mm
Removing the water pump and shift

rod
1. Remove the water pump. See steps 14
in Removing the water pump and shift
rod (8-8).
2. Remove the shift rod 1.
1
2
1
3
4
housing
See Disassembling the water pump housing (8-8).
Checking the water pump and shift

rod
See Checking the water pump and shift rod
(8-8).
Assembling the water pump housing

See Assembling the water pump housing
(8-9).
8
9
10
A
8-46
Propeller shaft housing (counter rotation model)

11
7
4 3
15
9
7
2 5
6
3
10
8 6
2
5
17
16
1 2
23
13
14
15
18
21
22
20
19
142 Nm (14.2 kgfm, 104.7 ftlb)
12
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Slider
Ball
Ball
Ball
Spring
Dog clutch
Cross pin
Spring
Forward gear
Thrust washer
Tapered roller bearing
O-ring
Washer
Propeller shaft
Thrust bearing
Propeller shaft shim (T4)
Qty
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
8-47
Remarks
Not reusable
Not reusable
Not reusable
11
7
4 3
15
9
7
2 5
10
6
3
8 6
0
1
2
2
5
17
16
1 2
23
4
13
14
15
18
21
22
20
19
Part name
Key
Needle bearing
Oil seal
Claw washer
Ring nut
142 Nm (14.2 kgfm, 104.7 ftlb)
12
No.
18
19
20
21
22
23
Qty
1
1
1
2
1
1
Remarks
Not reusable
Not reusable
M111.25
7
8
9
10
A
8-48
Removing the propeller shaft

housing assembly
2
1. Remove the ring nut and claw washer.

See steps 13 in Removing the propeller shaft housing assembly (8-12).
1
assembly 1, key 2, and forward gear
shims.
4. Heat the area of the propeller shaft
housing 1 where the tapered roller
bearing outer race is to be installed using
a gas torch, and then remove the forward
gear assembly 2.
4
3
When heating the propeller shaft housing,

heat the entire installation area evenly.
Otherwise, the propeller shaft housing
could be damaged.
Slide hammer handle 3: 90890-06531

Puller head 4: 90890-06514

housing assembly
1
burns could result.
2
1. Remove the dog clutch. See Disassembling the propeller shaft assembly (812).
5. Remove the propeller shaft 1, thrust

bearing 2, and propeller shaft shims 3.
2. Remove the washer 1.
TIP:
Make sure to remove the washer if it remains
attached on the reverse gear.
3. Remove the O-ring 2.
8-49

housing assembly and forward gear
6. Remove the oil seals and needle

bearing. See step 3 in Disassembling
the propeller shaft housing assembly (813)

burns could result.
Disassembling the forward gear

1. Remove the tapered roller bearing 1
and thrust washer 2.
3
1
1. Install the needle bearing and oil seals.

See steps 1 and 2 in Assembling the
propeller shaft housing assembly (8-14).
2. Install the original propeller shaft shims

1 and a new thrust bearing 2.

90890-06607
0
1
2
3
4
5

1. Check the propeller shaft. Replace if
damaged or worn.
2. Measure the propeller shaft runout.

3. Install the propeller shaft 1 and tapered
roller bearing inner race 2.
7
8
Propeller shaft runout:

0.02 mm (0.0008 in)
Checking the dog clutch
10
See Checking the dog clutch (8-13).
Checking the propeller shaft housing

4. Heat the area of the propeller shaft
housing where the tapered roller bearing
outer race 1 is to be installed using a
gas torch, and then install the tapered
roller bearing outer race 1.
See Checking the propeller shaft housing

(8-13).
Checking the forward gear

1. Check the teeth and dogs of the forward
8-50
When heating the propeller shaft housing,

heat the entire installation area evenly.
Otherwise, the propeller shaft housing
could be damaged.
a
4
3
2
1
4
3
2
Ring nut wrench 4: 90890-06578

7. Install the spring 1, balls 2, 3, and
4, and slider 5.
TIP:
When installing the slider 5, make sure that

strike the tool to check that the tapered
roller bearing 2 is installed properly.
TIP:
tapered roller bearing outer race is installed
properly.
3
1
2
3
2
4
8. Install the dog clutch 1 so that the hole

a in the dog clutch 1 and the hole b
in the propeller shaft are aligned with the
hole c in the slider 2.
Ring nut wrench 1: 90890-06578

6. Install the thrust washer 1 and forward
gear 2 using the dog clutch 3 and
TIP:
Face the 6DA mark d on the dog clutch 1
toward the forward gear.
TIP:
Face the 6DA mark a on the dog clutch 3
toward the forward gear.
8-51
a
b
d
1
1
2
b
9. Install the cross pin 1, and then install

the spring 2.
4
5
10. Install a new O-ring 1 and the washer

2.
10
A
8-52
Drive shaft and lower case (counter rotation model)

9
10
13
7
6
6
15
16
5
14
4
3
18
11
2
21
17
1
17
12
22 19
93 Nm (9.3 kgfm, 68.6 ftlb)
23
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Thrust bearing
Pinion shim (T3)
O-ring
Needle bearing
Drive shaft housing
Bolt
Oil seal
Cover
Self-locking nut
Water inlet cover (STBD)
Drive shaft
Sleeve
Lower case
Roller bearing
Thrust bearing
Needle bearing
Qty
1
1
1
1
4
2
1
1
1
1
1
1
1
1
2
8-53
Remarks
Not reusable
Not reusable
Not reusable
M8 25 mm
Not reusable
Not reusable
Not reusable
Not reusable
20
10
13
7
6
6
15
16
5
14
4
2
3
18
11
2
21
17
1
17
12
22 19
93 Nm (9.3 kgfm, 68.6 ftlb)
23
No.
18
19
20
21
22
23
Part name
Reverse gear
Water inlet cover (PORT)
Screw
Needle bearing
Pinion
Pinion nut
Qty
1
1
1
1
1
1
Remarks
M5 45 mm
Not reusable
20
7
8
9
10
A
8-54
Removing the drive shaft
Disassembling the lower case
See steps 1 and 2 in Removing the drive

shaft (8-18).
burns could result.
Removing the reverse gear

1. Remove the reverse gear 1 and thrust
bearing 2.
1
2

2.

housing

the roller bearing outer race is to be
removed using a gas torch, and then
remove the roller bearing outer race 1
and reverse gear shims 2.
See Disassembling the drive shaft housing

(8-18).
Disassembling the reverse gear

1. Remove the roller bearing inner race 1.
3 2

burned.
1
90890-06608
2. Remove the needle bearings from the
reverse gear.
2
1
8-55

3. Remove the needle bearing. See step 3
in Disassembling the lower case (8-19).
TIP:
Checking the pinion

scratched.
See Checking the pinion (8-19).

the roller bearing outer race is to be
installed using a gas torch, and then
install a new roller bearing outer race 2.
Checking the reverse gear

1. Check the teeth and dogs of the reverse
Checking the drive shaft

See Checking the drive shaft (8-19).

burned.
Checking the lower case

See Checking the lower case (8-20).
Assembling the reverse gear

the roller bearing 2 down.
2. Install a new roller bearing inner race 1.
TIP:

the roller bearing inner race 1 up.
2
3
4
5
2
1
TIP:
1. Install new needle bearings. See step 1

in Assembling the forward gear (8-20).
7
1
strike the tool to check that the roller
bearing outer race is installed properly.

90890-06660
TIP:
roller bearing is installed properly.

burns could result.
8
9
10
1. Install the original reverse gear shims 1.
8-56

assembly
1. Install the original forward gear shims 1,
propeller shaft housing assembly 2, and
key 3.
2. Turn the drive shaft and check that the

propeller shaft housing assembly 2 is
installed securely.
1
2
Driver rod LL 1: 90890-06605

Ball bearing attachment 2: 90890-06629
4. Install the needle bearing and water inlet
covers. See steps 4 and 5 in Assembling
the lower case (8-21).
Assembling the drive shaft housing

See Assembling the drive shaft housing (820).
3. Install the claw washer and ring nut. See

steps 46 in Installing the propeller shaft
Installing the reverse gear

1. Install a new thrust bearing 1 and the
reverse gear 2.
Installing the shift rod

1. Install the plate to the shift rod. See steps
1 and 2 in Installing the shift rod (8-24).
2
1
2. Install the shift rod 1.
TIP:
Make sure to install the shift rod 1 in the
proper orientation. Installation orientation is
different between the counter rotation model
and the regular rotation model.
Installing the drive shaft

See Installing the drive shaft (8-22).
8-57
0
1
1
2
Installing the water pump
See Installing the water pump (8-24).

leakage
See Checking the lower unit for air leakage

(8-26).
Installing the lower unit

See Installing the lower unit (8-26).
6
7
8
9
10
A
8-58
Shimming (counter rotation model)

Shimming workflow
1. Remove the water pump
assembly.
2. Measure the backlash before
disassembly.
4. YES
6. NO
8. Select the pinion shims (T3)
and propeller shaft shims (T4).
6. NO 11. Adjust the forward gear shim

thickness (T2) and reverse gear
shim thickness (T1).
4. YES
12. Install the water pump
assembly.

2. Measure the backlash before disassembly.
4. YES
6. NO
8. Select the pinion shims (T3) and propeller shaft shims (T4).
11. Adjust the forward gear shim thickness
(T2) and reverse gear shim thickness
(T1).
12. Install the water pump assembly.
TIP:
Make sure to drain the gear oil before measuring the backlash.
If the backlash is within specification, shimming is not required.
When assembling the original inner parts and a new lower case, shimming is required.
When replacing the pinion, forward gear, reverse gear, bearings, drive shaft, or propeller shaft
housing, shimming is required.
8-59
Shimming check sheet

Lower case deviation
Serial number
Remarks
Pinion height
0
(mm)
Measurements
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
(M)
1
2
3
Forward gear backlash
(mm)
Measurements
Before disassembly
After disassembly
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
Reverse gear backlash
(mm)
Measurements
Before disassembly
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
After disassembly
8
9
10
A
8-60

Forward gear shim (T2) thickness measurement in 2 places
Number of shim(s)
(mm)
Subtotal
0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total
Reverse gear shim (T1) thickness measurement in 2 places
Number of shim(s)
0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total
8-61
(mm)
Subtotal

and reverse gear backlash before
disassembly
7. While holding the drive shaft to prevent it

from turning, tighten the center bolt 1 to
Two washers (90201-26M00) are required for

the reverse gear backlash measurement in
the counter rotation model. Prepare the
washers before starting the shimming procedure.
1. Install the lower unit onto a repair stand.

3
Center bolt 1 (shimming):
20 Nm (2.0 kgfm, 14.8 ftlb)
R
N
F
9. Remove the cover 1, and then install

the outer plate cartridge 2.

4. Set up the special service tools 1, 2,
and 3, and then tighten the center bolt
3 temporarily.
5
6
7
8. Place the lower unit in an upright

position.
2
3

90890-06502
Center bolt 3: 90890-06504
10
5. Turn the lower unit so that the propeller

shaft is pointing up.
10. Set the spring 1 on the outer plate

cartridge, and then install the handle
holder 2 so that the spring is
compressed to the specified setting
height a.
6. Turn the drive shaft 10 turns or more.
8-62
TIP:
TIP:
After installing the handle holder, pull the

drive shaft upward to remove any free play.
Do not press the spring more than 5.0 mm
(0.197 in). Otherwise, too much torque will
be required to turn the drive shaft, making it
difficult to obtain correct measurements.
The resistance of the spring increases the

force required to turn the drive shaft. Therefore, to obtain correct measurements, consider the spring resistance force when
turning the drive shaft.
Do not turn the drive shaft using too much
force. Otherwise, the forward gear will turn,
leading to incorrect measurements.
A knocking sound may be heard when the
drive shaft is rotated, but this is the sound
of the pinion contacting the reverse gear
and does not affect the backlash measurement.
2
a
1
Spring 1: 90501-450A2 *1
Handle holder 2: EU0-23814-31 *1
Setting height a:
3.05.0 mm (0.1180.197 in)
11. Install the special service tool 1 onto
the drive shaft at the lowest possible
position where the shaft diameter is
22.4 mm (0.881 in), and then set up the
special service tools 2, 3, and 4.
13. Turn the drive shaft 180 clockwise, and

then measure the backlash again.
TIP:
Measure the backlash at 4 points: a, b,
c, and d, turning the drive shaft 180
clockwise after each measurement.
2
1
a
Backlash indicator 1: 90890-06706
Magnet base plate 2: 90890-07003
Magnet base B 4: 90890-06844
b
d
12. Turn the drive shaft slowly clockwise and

counterclockwise, and then measure the
backlash between where the drive shaft
stops in each direction.
8-63

14. Determine the backlash average, and
decimal places.
3
2
Example:
Measurement point a
Measurement point b
Measurement point c
Measurement point d
Average
Round-down average
(mm)
0.40
0.46
0.44
0.43
0.4325
0.43
0
1
Washer 1: 90201-26M00 *1
assembly, and then tighten the ring nut to
15. Check that the forward gear backlash

TIP:
Ring nut (shimming):

70 Nm (7.0 kgfm, 51.6 ftlb)
Adjust the shim thicknesses if the forward

20. Repeat steps 1113 to measure the


0.250.77 mm (0.00980.0303 in)
16. Remove the special service tools from
the propeller shaft.
21. Check that the reverse gear backlash

17. Remove the shift rod and propeller shaft

housing assembly.
TIP:
Adjust the shim thicknesses if the reverse
18. Install the washers 1 between the

reverse gear 2 and the propeller shaft
3.

0.611.26 mm (0.02400.0496 in)
22. Remove the special service tools and
washers, and then install the propeller
shaft housing assembly and shift rod.
2
3
4
5
6
7
8
9
10
A
8-64
Shimming procedure
Before selecting the forward gear shims (T2) and reverse gear shims (T1), make sure to select the
pinion shims (T3) and propeller shaft shims (T4).
When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do
not apply gear oil, grease, or sealant to the parts.
When assembling the lower unit after shimming is completed, make sure to apply gear oil, grease,
and sealant to the specified areas.
Shim location
T3
F
P
T1
T2
8-65
T4
Selecting the pinion shim (T3)
TIP:
See Selecting the pinion shim (T3) (8-35).
In the Propeller shaft shim (T4) selection

table, use the rounded measurement value
for the free play measurement.
Selecting the propeller shaft shim

(T4)
1. Install the original propeller shaft shims
(T4).
7. Determine the value of propeller shaft

shim (T4) thickness adjustment using the
Propeller shaft shim (T4) selection table
according to the free play measurement.
See Propeller shaft shim (T4) selection
table (A-10).
TIP:
If the original shims are missing, measure
the free play without any shims.
scratched.
0
1
2
TIP:
3. Turn the propeller shaft 10 turns or more.
4. Set up the special service tools 1 and
2.
5. Measure the propeller shaft free play.

positive, the current shim thickness must be
increased by that amount and, if the value
is negative, the current shim thickness must
be decreased by that amount.
The gray-colored cell on the selection table
indicates the specified propeller shaft free
play. Shimming is not required if the measured propeller shaft free play is 0.250.35
mm.
The values for the shim thickness adjustments specified in the selection table are
intended to obtain the specified propeller
shaft free play of 0.3 mm.
Example:
Free play measurement = 1.1 mm a
Propeller shaft shim (T4) thickness adjustment = 0.8 mm b
increased by 0.8 mm.
a
Magnet base B 2: 90890-06844
Propeller shaft free play:
0.250.35 mm (0.00980.0138 in)
(mm)
1.0
1.1
+0.7
+0.8
4
5
6
8
9
10
6. Round the measurement value to the

1/10 place if out of specification.
A. Free play measurement

A
8-66
Measuring the reverse gear backlash
8. Calculate the new propeller shaft shim

(T4) thickness.
Spray anti-rust lubricant on the gear and

bearings and shims.
TIP:
Use up to 3 shims to obtain the required shim
thickness.
New propeller shaft shim (T4) thickness =
Current propeller shaft shim thickness +
Shim thickness adjustment
1. Install the original reverse gear shims

(T1) and roller bearing outer race.
Example:
Current propeller shaft shim thickness
= 0.8 mm
New propeller shaft shim (T4) thickness
= 0.8 mm + 0.2 mm
= 1.0 mm
Current propeller shaft shim thickness
= 0.8 mm
New propeller shaft shim (T4) thickness
= 0.8 mm + (0.1) mm
= 0.7 mm
TIP:
If the original reverse gear shims (T1) are
scratched.
2. Install the reverse gear assembly, drive
shaft, and pinion. See Installing the
reverse gear (8-57) and Installing the
drive shaft (8-22).
4. Install the thrust bearing, pinion shims
(T3), and drive shaft housing.

0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
0.50 mm

9. Remove the special service tools, and

then install the determined propeller
shaft shims.

7. Measure the reverse gear backlash. See
0.611.26 mm (0.02400.0496 in)

thickness (T1)
1. Remove the roller bearing outer race and
reverse gear shims (T1).
8-67

2. Measure the thickness of original reverse
B (mm)
0.10
0.20
0.30
0.40
b 0.50
0.60
0.70
25 30 035 540 1045 50 55 60 65 70
a
A (1/100 mm)
TIP:
scratched.
3. Determine the reverse gear shim (T1)
thickness adjustment using the Reverse
Measuring the reverse gear backlash.
chart (counter rotation model) (A-11).
25 A30 035 540 1045 50 55 60 65 70

0.50 B
0.46
0.68
0.42
0.64
0.39
0.60
0.35 0.32 0.28 0.24 0.21 0.17
TIP:
4. Calculate the new reverse gear shim (T1)

thickness.
0
1
2
3
4
TIP:
Current reverse gear shim thickness + shim
Example:
Current reverse gear shim thickness
= 1.00 mm
New reverse gear shim (T1) thickness
= 1.00 mm + 0.26 mm
= 1.26 mm
Current reverse gear shim thickness
= 1.00 mm
Example:
Reverse gear shim (T1) thickness adjustment
= 0.28 mm b
5
6
7
8
9
10
A
8-68

New reverse gear shim (T1) thickness
= 1.00 mm + (0.28 mm)
= 0.72 mm
TIP:
scratched.

0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
0.50 mm
3. Determine the forward gear shim (T2)

thickness adjustment using the Forward
Measuring the forward gear backlash.
chart (counter rotation model) (A-11).
5. Install the determined reverse gear shims

(T1) and roller bearing outer race.

Spray anti-rust lubricant on the gears and
bearings and shims.
TIP:

(T2) and propeller shaft housing assembly. See Installing the propeller shaft
TIP:
If the original forward gear shims (T2) are
scratched.
Example:
Forward gear shim (T2) thickness adjustment
= 0.26 mm b
increased by 0.26 mm.
2. Measure the forward gear backlash. See

0.250.77 mm (0.00980.0303 in)

thickness (T2)
assembly and forward gear shims (T2).
2. Measure the thickness of original forward
8-69

Example:
Current forward gear shim thickness
= 0.58 mm
New forward gear shim (T2) thickness
= 0.58 mm + 0.26 mm
= 0.84 mm
Current forward gear shim thickness
= 0.58 mm
New forward gear shim (T2) thickness
= 0.58 mm + (0.21 mm)
= 0.37 mm
B (mm)
0.40
0.30
0.20
0.10
0
b
0.10
0.20
10 15 20 25 30 35 4
a
10 15 20 25 30 35 4
B 0.37 0.33 0.30 0.26 0.23 0.19 0.15 0.12 0

4. Calculate new forward gear shim (T2)
thickness.

0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
0.50 mm
0
1
2
3
4
TIP:
5. Install the determined forward gear shims
assembly.

5
6
Current forward gear shim thickness + shim
7
8
9
10
A
8-70
MEMO
8-71
Bracket unit
Shift rod and shift bracket ................................................ 9-1
Removing the shift rod and shift bracket ................................... 9-3
Disassembling the shift bracket ................................................. 9-3
Assembling the shift bracket ..................................................... 9-3
Installing the shift rod and shift bracket ..................................... 9-4
PTT switch and cowling lock lever .................................. 9-6

Removing the PTT switch ......................................................... 9-8
Removing the cowling lock lever ............................................... 9-8
Removing the flushing hose ...................................................... 9-8
Installing the flushing hose ........................................................ 9-8
Installing the cowling lock lever ................................................. 9-9
Installing the PTT switch ........................................................... 9-9
Bottom cowling ............................................................... 9-10

Upper case and mounts (L-transom model) ................. 9-11
Removing the upper case ....................................................... 9-13
Installing the upper case ......................................................... 9-13
Upper case (L-transom model) ...................................... 9-15

Disassembling the upper case ................................................ 9-17
Checking the drive shaft bushing ............................................ 9-17
Assembling the upper case ..................................................... 9-17
0
1
2
3
4
5
6
7
Oil pan and exhaust manifold (L-transom model) ........ 9-19

Disassembling the oil pan and exhaust manifold .................... 9-21
Checking the oil pan and exhaust manifold ............................. 9-21
Checking the oil strainer .......................................................... 9-21
Assembling the oil pan and exhaust manifold ......................... 9-21
8
9
Steering arm (L-transom model) .................................... 9-23

Removing the steering arm ..................................................... 9-24
Installing the steering arm ....................................................... 9-24
10
Upper case and mounts (X-transom model) ................. 9-26

Removing the upper case ....................................................... 9-28
Installing the upper case ......................................................... 9-28
Bracket unit
Upper case (X-transom model) ...................................... 9-30
Disassembling the upper case ................................................ 9-32
Checking the drive shaft bushing ............................................ 9-32
Assembling the upper case ..................................................... 9-32
Oil pan and exhaust manifold (X-transom model) ....... 9-34

Disassembling the oil pan and exhaust manifold .................... 9-36
Checking the oil pan and exhaust manifold ............................. 9-36
Checking the oil strainer .......................................................... 9-36
Assembling the oil pan and exhaust manifold ......................... 9-36
Steering arm (X-transom model) ................................... 9-38

Removing the steering arm ..................................................... 9-39
Installing the steering arm ....................................................... 9-39
Clamp bracket and swivel bracket ................................ 9-41

Removing the clamp bracket ................................................... 9-44
Checking the clamp bracket anode ......................................... 9-44
Installing the clamp bracket ..................................................... 9-45
Adjusting the trim sensor cam ................................................. 9-46
PTT unit ............................................................................ 9-47

Removing the PTT unit ............................................................ 9-48
Checking the hydraulic pressure ............................................. 9-48
Bleeding the PTT unit .............................................................. 9-51
Installing the PTT unit .............................................................. 9-52
PTT motor ........................................................................ 9-54

Removing the reservoir ........................................................... 9-56
Removing the PTT motor ........................................................ 9-56
Disassembling the PTT motor ................................................. 9-56
Checking the armature (PTT motor) ........................................ 9-57
Checking the brush ................................................................. 9-57
Checking the reservoir ............................................................ 9-58
Assembling the PTT motor ...................................................... 9-58
Installing the reservoir ............................................................. 9-59
Installing the PTT motor .......................................................... 9-59
PTT gear pump ................................................................ 9-61

Disassembling the gear pump assembly ................................. 9-63
Checking the gear pump ......................................................... 9-64
Bracket unit
Checking the gear pump housing ............................................ 9-64
Checking the filter .................................................................... 9-64
Assembling the gear pump assembly ..................................... 9-64
PTT cylinder ..................................................................... 9-66
Removing the tilt ram and trim ram ......................................... 9-68

Removing the filter .................................................................. 9-68
Checking the filter .................................................................... 9-69
Installing the filter .................................................................... 9-69
Disassembling the tilt ram ....................................................... 9-69
Checking the tilt cylinder and trim cylinder .............................. 9-69
Checking the absorber valve ................................................... 9-70
Assembling the tilt ram ............................................................ 9-70
Assembling the trim ram .......................................................... 9-71
Installing the trim ram .............................................................. 9-71
Installing the tilt ram ................................................................ 9-72
2
3
4
5
6
7
8
9
10
Shift rod and shift bracket

2
3
1
2.5 Nm (0.25 kgfm, 1.84 ftlb)
2.5 Nm (0.25 kgfm, 1.84 ftlb)
4
8
6
12
10
2
29
11
4
28
14
26
18
13
11
15
2
3
4
19 Nm (1.9 kgfm, 14.0 ftlb)
25
24
2
3
9
27
19
23
20
21
22
18
17
16
18 Nm (1.8 kgfm, 13.3 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Screw
Plate
Clip
Bushing
Bracket
Washer
Shift lever
Spring
Bushing
Bolt
Bracket
Grease nipple
Bolt
Grommet
Circlip
Qty
1
4
2
2
1
1
1
1
1
1
2
2
1
1
1
1
1
9-1
Remarks
M4 16 mm
7
8
9
10
M6 50 mm
M6
M8 30 mm
2
3
1
2.5 Nm (0.25 kgfm, 1.84 ftlb)
5
2.5 Nm (0.25 kgfm, 1.84 ftlb)
4
8
6
12
10
2
29
11
4
28
14
26
18
13
11
15
19 Nm (1.9 kgfm, 14.0 ftlb)
25
24
27
19
23
20
21
18
17
16
22
18 Nm (1.8 kgfm, 13.3 ftlb)
No.
18
19
20
21
22
23
24
25
26
27
28
29
Part name
Washer
Bracket
Ball
Spring
Shift rod detent bolt
Dowel pin
Grease nipple
Bushing
O-ring
Bolt
Shift rod
Bushing
Qty
2
1
1
1
1
1
1
1
1
1
1
1
9-2
Remarks

M12 16 mm
M6
Not reusable
M6 35 mm
2
3
9
Removing the shift rod and shift

bracket
1. Remove the shift bracket assembly 1.
0
1
1
2. Remove the shift position switch 1.
2. Remove the shift lever 1, shift rod

assembly 2, and grommet 3.
1
3. Remove the shift cut-off switch 1.
3. Remove the shift rod detent bolt 1,

spring 2, and ball 3.
5
6
4. Remove the circlip 4 and bushing 5.
7
Assembling the shift bracket
1. Install the shift cut-off switch 1 and plate
2, and then tighten the shift cut-off
switch screws 3 to the specified torque.
3
5
2
4
1
3
2
1
Disassembling the shift bracket

1. Remove the bolt 1, and then disassemble the shift bracket assembly.
Shift cut-off switch screw 3:

2.5 Nm (0.25 kgfm, 1.84 ftlb)
9-3
8
9
10

2. Install the shift position switch 1 and
plate 2, and then tighten the shift position switch screws 3 to the specified
torque.
3
2
1
b
2
c
Shift position switch screw 3:

2.5 Nm (0.25 kgfm, 1.84 ftlb)
Shift bracket bolt 3:

19 Nm (1.9 kgfm, 14.0 ftlb)
3. Install the bushing 1 to the bracket 2.
7. Install the grease nipple 1, and then

tighten it to the specified torque.
4. Fit the spring end a into the cutout b in

the bracket 2 and the spring end c into
the cutout d in the bracket 3.
TIP:
Make sure that the installation angle of the
grease nipple 1 is within the range a.
8. Inject grease into the grease nipple until

grease comes out of the bushings b.
3
c
3
a
1
30
b
2
2
5. Turn the bracket 1 to the position a,

push it down, and then install the bushing
2 and shift bracket bolt 3 temporarily.
Shift bracket grease nipple 1:

Installing the shift rod and shift

bracket
Move the shift cut-off switch lever b in

direction c when pushing the shift
bracket 1 down. Otherwise the lever
may be damaged.
1. Install the bushing 1 and washers 2,

and then install the circlip 3.
2. Install the ball 4, spring 5, and shift
rod detent bolt 6, and then tighten the
shift rod detent bolt 6 to the specified
torque.
6. Tighten the shift bracket bolt 3 to the

specified torque.
9-4
4
1
2
Shift rod detent bolt 6:

18 Nm (1.8 kgfm, 13.3 ftlb)
3. Install a new O-ring 1 to the shift rod

assembly 2.
4. Install the grommet 3 to the upper case.

5. Install the shift lever 4 to the set pin a
of the shift rod assembly 2.
6. Install the dowel pin 5 and shift rod

assembly 2.
5
6
2
a
8
9
7. Install the washer 1 and shift bracket

assembly 2, and then install the bushing 3 and clip 4 to the shift lever 5.
10
4
3
2
1
9-5
PTT switch and cowling lock lever
13
12
11
10
9 3
14
14
15
16
14
13
12
11
10
26 27
13
12
11
10
9
15
16
15
16
25
26
28
19
17
20
24
23
22
21
5
1
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Gasket
PTT switch
Bolt
Holder
Cover
Cowling lock lever (STBD)
Cowling lock lever (PORT)
Cowling lock lever (front)
Bushing
Washer
Wave washer
Lever
Bolt
Spring
Bolt
Hook
Guide
20 18
Qty
2
1
4
2
1
1
1
1
6
3
3
3
3
3
3
3
1
9-6
Remarks
M6 12 mm
M8 12 mm
M6 12 mm
13
12
11
10
9 3
14
14
15
16
14
13
12
11
10
26 27
13
12
11
10
9
0
1
15
16
15
16
25
26
28
19
17
20
24
23
22
21
5
1
No.
18
19
20
21
22
23
24
25
26
27
28
Part name
Grommet
Hose
Plastic tie
Hose joint
Hose joint
Gasket
Adapter
Screw
Gasket
Cover
PTT switch
20 18
Qty
1
1
3
1
1
1
1
2
2
1
1
Remarks
Hose joint to exhaust cover
6
7
8
9
M6 19 mm
10
A
9-7
Removing the PTT switch

1. Remove the holder 1, and then remove
the PTT switch 2.
3
1
1
STBD
2
2. Disconnect the guide 1 from the grommet 2.
B
1
PORT
1
2
3. Remove the flushing hose 1, PTT motor
leads 2, trim sensor lead 3, and grommet 4.
A. Regular rotation model

B. Counter rotation model
Removing the cowling lock lever
1. Remove the spring 1, and then remove

the hook 2.
2. Remove the lever 3, wave washer 4,

washer 5, bushing 6, cowling lock
lever 7, and bushing 8.
3
2
3
4
5
6
Installing the flushing hose

1. Install the grommet 1 to the bottom
cowling.
7
2. Pass the flushing hose 2, trim sensor
lead 3, and PTT motor leads 4
through the grommet 1, and then fasten
them using the plastic ties 5 around the
grommet 1.
Removing the flushing hose

1. Remove the adapter 1 and hose joints
2, and 3.
TIP:
Align the red tape a on the PTT motor leads
4 with the outer end of the grommet 1.
9-8
Installing the cowling lock lever

1. Install the bushing 1, cowling lock lever
2, bushing 3, washer 4, wave washer
5, and lever 6.
2. Install the hook 7, and then install the
spring 8.
2
4
5
a
5
5
5
3
3. Install the guide 1 to the grommet 2.
6
5
4
3
3
2
1
2
Installing the PTT switch

1. Install the gasket 1, PTT switch 2, and
holder 3.
4. Install the flushing hose adapter 1, and

then tighten the flushing hose adapter
screws 2 to the specified torque.
1
2
5. Route the flushing hose 5 through the

hose joint 3, install it to the hose joint
4, and then fasten the flushing hose 5
6. Install the hose joint to the adapter 1
along with the gasket 7.
3
4
3
STBD
7
8
PORT
10
2
A. Regular rotation model
B. Counter rotation model
Flushing hose adapter screw 2:
A
9-9
Bottom cowling
Bottom cowling
1
1
10
4
10
10
3
11
11
11
14
14
8
2
10
15
16
16
17
15
11
2
12
13
12
13
12
13
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Bolt
Holder
Holder
Clamp
Bracket
Clamp
Rubber seal
Bottom cowling
Rubber seal
Bolt
Grommet
Grommet
Collar
Cap seal
Grommet
Outlet
Grommet
Qty
5
2
1
1
1
1
1
1
1
4
4
4
4
2
2
2
1
9-10
12
13
9
Remarks
M6 12 mm
M8 35 mm
Upper case and mounts (L-transom model)

9 11 13
18 54 Nm (5.4 kgfm, 39.8 ftlb)

21
17
13
21
8
12 16
15
11 14
9 10
15
14
10 12
8
13
20
15
20
19
16
14
19 21
75 Nm (7.5 kgfm, 55.3 ftlb)
3
13
10
24
12
23
25
27
26
2
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
11
7 8
24
27
22
22
75 Nm (7.5 kgfm, 55.3 ftlb)
Part name
Self-locking nut
Nut
Washer
Bolt
Cover
Cover
Washer
Lower mount
Washer
Washer
Washer
Bolt
Cap
Collar
Washer
Upper mount
Bracket
Qty
2
2
4
4
1
1
2
2
2
2
2
2
2
2
2
2
1
9-11
Remarks
M14
M14
M10 40 mm
7
8
9
10
M14 227 mm
9 11 13
18 54 Nm (5.4 kgfm, 39.8 ftlb)

21
17
13
21
8
12 16
15
11 14
9 10
15
14
10 12
8
13
20
15
20
19
16
14
19 21
75 Nm (7.5 kgfm, 55.3 ftlb)
4
3
13
10
24
12
23
25
27
26
3
No.
18
19
20
21
22
23
24
25
26
27
27
Bolt
Plate
Plate
Bolt
Bolt
Nipple
Plastic tie
Speedometer hose
Adapter
Bolt
22
22
75 Nm (7.5 kgfm, 55.3 ftlb)
Part name
7 8
24
11
Qty
3
1
1
2
1
1
2
1
1
1
9-12
Remarks
M10 45 mm
M14 203 mm
M6 10 mm
Adapter to nipple
M6 20 mm
Removing the upper case
Installing the upper case
1. Drain the remaining engine oil.
1. Install the plates 1 and 2, upper

mounts 3, washers 4, and collars 5
to the upper mount bolts 6.
2. Disconnect the ground lead 1.

3. Remove the adapter 2, and then disconnect the speedometer hose 3.
TIP:
Make sure to face the red paint marks a on
the upper mounts 3 toward the bracket.
4. Loosen the upper mount bracket bolts 4

and lower mount cover bolts (PORT and
STBD) 5.
2. Install the upper mounts 3 and upper

mount bracket 7, and then tighten the
upper mount bracket bolts 8 temporarily.
5 4a
1
6
7
3
4 3
1
3
5
3
5 4
3. Install the caps 1, washers 2, 3, and

4, lower mounts 5, and washers 6 to
the lower mount bolts 7.
5. Remove the upper mounting nuts 1 and

lower mounting nuts 2, and then
remove the upper case assembly 3.
4. Install the lower mounts 5 and lower

mount covers 8, and then tighten the
lower mount cover bolts 9 temporarily.
6
5
7
8
4 3 27 1
9
1
3 2
10
8
2
A
9-13

5. Align the upper and lower mounting bolts
with the holes in the bracket assembly
1, and then insert the bolts into the
bracket holes.
[2]
[1]
1
[3]
6. Install the ground lead (STBD) 2, washers 3, upper mounting nuts 4, and
lower mounting nuts 5, and then tighten
the upper mounting nuts 4 and lower
mounting nuts 5 to the specified torque.
TIP:
Fit the ground lead 2 into the groove a in
the steering yoke.
Upper mount bolt 1:

54 Nm (5.4 kgfm, 39.8 ftlb)
4 3
a
2
9. Connect the ground lead 1.
3
10. Pass the speedometer hose 2 through
the steering arm 3.
1
3
11. Connect the speedometer hose 2 to the

adapter 4, and then fasten it using the
plastic tie 5.
12. Install the adapter 4 to the upper case.
Upper mounting nut 4:

75 Nm (7.5 kgfm, 55.3 ftlb)
Lower mounting nut 5:
75 Nm (7.5 kgfm, 55.3 ftlb)
7. Tighten the upper mount bolts 1 to the

so on.
8. Tighten the lower mount bolts (PORT
and STBD) 2.
2
5
1
9-14
2
5
Upper case (L-transom model)

9
20 Nm (2.0 kgfm, 14.8 ftlb)
42 Nm (4.2 kgfm, 31.0 ftlb)
10
10
5
4
11
0
1
2
11
14
12
13
3
4
19
15
17
16
18
27 Nm (2.7 kgfm, 19.9 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Upper case
Circlip
Bushing
Rubber seal
Dowel pin
Screw
Baffle plate
Bolt
Bolt
Cap
Grommet
Gasket
Drain bolt
Damper
Rubber seal
Rubber seal
Cooling water pipe
Qty
1
1
1
1
2
2
1
2
4
2
2
1
1
1
1
1
1
9-15
Remarks
7
8
M6 15 mm
M8 30 mm
M10 45 mm
9
10
Not reusable
M14
Not reusable
20 Nm (2.0 kgfm, 14.8 ftlb)
42 Nm (4.2 kgfm, 31.0 ftlb)
10
10
5
4
11
11
14
12
13
19
15
17
16
18
27 Nm (2.7 kgfm, 19.9 ftlb)
3
2
No.
18
19
Part name
Hose
Rubber seal
Qty
1
1
9-16
Remarks
Disassembling the upper case
4. Remove the circlip 1, and then remove

the bushing 2.
1. Remove the drain bolt 1.
1
4
0
1
3
2. Remove the upper case bolts 1 and 2,

and then remove the oil pan assembly
3.
Checking the drive shaft bushing

1. Check the bushing. Replace if cracked or
worn.
2
3
4
Assembling the upper case

1. Install the bushing 1, and then install
the circlip 2.
1
1
2
4
3
1
90890-06653
Driver rod L3 4: 90890-06652
3. Remove the baffle plate 1.
6
7
8
3. Install the baffle plate 2, and then

tighten the baffle plate screws 3 to the
specified torque.
4. Install the rubber seal 4 to the joint hole
a in the upper case.
5. Install a new rubber seal 5, the rubber
seal 6, the damper 7, the rubber seal
8, the cooling water pipe 9, the hose
10, and then install the oil pan assembly 11.
9-17
9
10
TIP:
Make sure to fit the tip of the cooling water
pipe 9 into the joint hole a in the upper
case.
6. Install the oil pan bolts 12 and 13, and
then tighten them to the specified
torques.
12
13
3
2
11
4
7
6
9
10
5
9
4
a
10
Baffle plate screw 3:

Oil pan assembly bolt (M8) 12:
20 Nm (2.0 kgfm, 14.8 ftlb)
42 Nm (4.2 kgfm, 31.0 ftlb)
7. Install a new gasket 1 and the drain bolt
2, and then tighten the drain bolt 2 to
1
2
Drain bolt 2: 27 Nm (2.7 kgfm, 19.9 ftlb)
9-18
Oil pan and exhaust manifold (L-transom model)

1
0
7
7
2
14
15
14
8
9
11
4
20 Nm (2.0 kgfm, 14.8 ftlb)
16
5
12
10
17
13
6
18
20 Nm (2.0 kgfm, 14.8 ftlb)

20 Nm (2.0 kgfm, 14.8 ftlb)
12 Nm (1.2 kgfm, 8.9 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Exhaust guide
Gasket
Gasket
Collar
Oil strainer
Bolt
Dowel pin
Oil pan
Bolt
Bolt
Gasket
Exhaust manifold
Rubber seal
Gasket
Plate
Dowel pin
Muffler
Qty
1
1
1
3
1
3
2
1
10
4
1
1
1
2
1
2
1
9-19
Remarks
Not reusable
Not reusable
M6 25 mm
M8 35 mm
M8 60 mm
Not reusable
6
7
8
9
10
Not reusable
7
14
7
2
8
15
14
11
4
20 Nm (2.0 kgfm, 14.8 ftlb)
16
5
12
10
17
13
6
18
20 Nm (2.0 kgfm, 14.8 ftlb)

20 Nm (2.0 kgfm, 14.8 ftlb)
12 Nm (1.2 kgfm, 8.9 ftlb)
No.
18
Part name
Bolt
Qty
8
9-20
Remarks
M8 35 mm
Disassembling the oil pan and

exhaust manifold
3. Check the oil pan. Replace if corroded or

cracked.
1. Remove the muffler 1, plate 2, and

exhaust manifold 3.
Checking the oil strainer

1. Check the oil strainer. Clean if there is
dirt or residue.
1
3
Assembling the oil pan and exhaust

manifold
1. Install the collars 1, a new gasket 2,

and the oil strainer 3, and then tighten
the oil strainer bolts 4 to the specified
torque.
4
1
4
1
1
2
4
5
2. Remove the oil pan 1 and oil strainer

2.
1
Oil strainer bolt 4:
12 Nm (1.2 kgfm, 8.9 ftlb)

2, and the oil pan 3, and then tighten
the oil pan bolts 4 temporarily.
6
7
8
9
10
Checking the oil pan and exhaust

manifold
1. Clean the removed parts.
2. Check the exhaust guide, exhaust manifold, and muffler. Replace if corroded or
cracked.
A
9-21

Exhaust manifold bolt:
20 Nm (2.0 kgfm, 14.8 ftlb)
Oil pan bolt:
20 Nm (2.0 kgfm, 14.8 ftlb)
3
4
5. Install the dowel pins 1, new gaskets

2, the plate 3, and the muffler 4.
4
4
6. Tighten the muffler bolts 5 to the specified torque.
5
2
2
3
4
2
3. Install a new gasket 1, the exhaust

manifold 2, the rubber seal 3, and
then tighten the exhaust manifold bolts
4 temporarily.
TIP:
Make sure that the sealant a side of the
gasket 1 is facing toward the exhaust manifold.
Muffler bolt 5:
20 Nm (2.0 kgfm, 14.8 ftlb)
3
2
4
4
4. Tighten the exhaust manifold bolts first,

and then tighten the oil pan bolts to the
specified torques.
9-22
Steering arm (L-transom model)
0
1
2
3
3
4
3
4
5
2
8
6
No.
1
2
3
4
5
6
7
8
Part name
Steering arm
Washer
Bushing
O-ring
Bushing
Steering yoke
Circlip
Grommet
Qty
1
2
2
1
1
1
1
1
Remarks
Not reusable
7
8
9
10
A
9-23
Removing the steering arm

3

the steering yoke 2 by striking it using a
copper hammer.
1
2
2. Install the bushing 1, a new O-ring 2,

the bushing 3, and the washer 4.
2. Remove the washer 1, bushing 2,

O-ring 3, and bushing 4.
1
2
3
4
4
3
2
1
3. Install the steering yoke 1 so that it

faces the same direction as the steering
arm 2 (aligning a with b).
3. Remove the steering arm from the swivel

bracket.
Installing the steering arm

1. Install the washer 1 and bushing 2
onto the steering arm 3, and then install
the steering arm 3.
9-24
0
1
2
a
2
1
a
3
4
4. Hold the steering arm 1, and then strike

the steering yoke 2 using a copper
hammer until the groove a for installing
the circlip is visible.
5. Install the circlip 3.
6
a
7
8
6. Inject grease into the grease nipple 1

until grease comes out from both the
upper and lower bushings a.
10
A
9-25
Upper case and mounts (X-transom model)

7
17 54 Nm (5.4 kgfm, 39.8 ftlb)
9 11
20
16
8
10 12
8
7
9
13
10 11
20
12 15
14
19
15
13
13
19
15
18
14
14
18 20
75 Nm (7.5 kgfm, 55.3 ftlb)
4
3
10
24
23
12
22
11
6
7 8
23
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
26
25
26
21
21
75 Nm (7.5 kgfm, 55.3 ftlb)
Part name
Self-locking nut
Self-locking nut
Washer
Bolt
Cover
Cover
Washer
Lower mount
Washer
Washer
Washer
Bolt
Collar
Washer
Upper mount
Bracket
Bolt
Qty
2
2
2
4
1
1
2
2
2
2
2
2
2
2
2
1
3
9-26
Remarks
M14
M14
M10 40 mm
M14 227 mm
M10 45 mm
17 54 Nm (5.4 kgfm, 39.8 ftlb)
9 11
20
16
8
10 12
8
7
9
13
10 11
20
12 15
14
19
15
13
13
19
15
18
14
14
18 20
75 Nm (7.5 kgfm, 55.3 ftlb)
4
3
12
22
10
24
23
11
6
7 8
23
No.
18
19
20
21
22
23
24
25
26
26
25
26
21
21
75 Nm (7.5 kgfm, 55.3 ftlb)
Part name
Plate
Plate
Bolt
Bolt
Nipple
Plastic tie
Speedometer hose
Adapter
Bolt
Qty
1
1
2
1
1
2
1
1
1
Remarks
M14 203 mm
M6 10 mm
Adapter to nipple
M6 20 mm
7
8
9
10
A
9-27
Removing the upper case
Installing the upper case
1. Drain the remaining engine oil.
1. Install the plates 1 and 2, upper

mounts 3, washers 4, and collars 5
to the upper mount bolts 6.

3. Remove the adapter 2, and then disconnect the speedometer hose 3.
TIP:
Make sure to face the red paint marks a on
the upper mounts 3 toward the BOW.
4. Loosen the upper mount bracket bolts 4

and lower mount cover bolts (PORT and
STBD) 5.
2. Install the upper mounts 3 and upper

mount bracket 7, and then tighten the
upper mount bracket bolts 8 temporarily.
5 4a
1
6
8
6
5
7
1
1
3
4 3
2
5 4
3. Install the washers 1, 2, and 3, lower

mounts 4, and washers 5 to the lower
mount bolts 6.
5. Remove the upper mounting nuts 1 and

lower mounting nuts 2, and then
remove the upper case assembly 3.
4. Install the lower mounts 4 and lower

mount covers 7, and then tighten the
lower mount cover bolts 8 temporarily.
3 2 16
21
6
3
7
2
9-28

5. Align the upper and lower mounting bolts
with the holes in the bracket assembly
1, and then insert the bolts into the
bracket holes.
[2]
[1]
[3]
6. Install the washers 2, upper mounting

nuts 3, and lower mounting nuts 4,
and then tighten the upper mounting nuts
3 and lower mounting nuts 4 to the
specified torque.
1
2
2
3
2
1
Upper mount bolt 1:

54 Nm (5.4 kgfm, 39.8 ftlb)
9. Connect the ground lead 1.
10. Pass the speedometer hose 2 through

the steering arm 3.
Upper mounting nut 3:

75 Nm (7.5 kgfm, 55.3 ftlb)
Lower mounting nut 4:
75 Nm (7.5 kgfm, 55.3 ftlb)
7. Tighten the upper mount bolts 1 to the
so on.
11. Connect the speedometer hose 2 to the

adapter 4, and then fasten it using the
plastic tie 5.
12. Install the adapter 4 to the upper case.
8. Tighten the lower mount bolts (PORT

and STBD) 2.
9
10
1
2
5
1
4
2
5
A
9-29
Upper case (X-transom model)

9
20 Nm (2.0 kgfm, 14.8 ftlb)
42 Nm (4.2 kgfm, 31.0 ftlb)
10
10
5
4
11
12
13
11
14
15
1
18
16
20
17
19
27 Nm (2.7 kgfm, 19.9 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Upper case
Circlip
Bushing
Rubber seal
Dowel pin
Screw
Baffle plate
Bolt
Bolt
Cap
Grommet
Drain bolt
Gasket
Damper
Cover
Rubber seal
Cooling water pipe
2
Qty
1
1
1
1
2
2
1
2
4
2
2
1
1
1
1
1
1
9-30
Remarks
M6 15 mm
M8 30 mm
M10 45 mm
M14
Not reusable
20 Nm (2.0 kgfm, 14.8 ftlb)
42 Nm (4.2 kgfm, 31.0 ftlb)
10
10
5
7
4
11
12
13
11
14
15
1
18
16
17
5
19
27 Nm (2.7 kgfm, 19.9 ftlb)
Part name
Rubber seal
Rubber seal
Bolt
3
4
20
No.
18
19
20
2
Qty
1
1
1
Remarks
Not reusable
M6 12 mm
7
8
9
10
A
9-31
Disassembling the upper case

the bushing 2.
1. Remove the drain bolt 1, cover 2, and

damper 3.
1
4
2
2
1

2. Remove the upper case bolts 1 and 2,

and then remove the oil pan assembly
3.
Checking the drive shaft bushing

See Checking the drive shaft bushing (917).
Assembling the upper case

1. Install the bushing 1, and then install
the circlip 2.
4
3
1
90890-06653
Driver rod L3 4: 90890-06652
3. Remove the baffle plate 1.
3. Install the baffle plate 2, and then

tighten the baffle plate screws 3 to the
specified torque.
4. Install the rubber seal 4 to the joint hole
a in the upper case.
5. Install a new rubber seal 5, the rubber
seals 6 and 7, the cooling water pipe
8, and then install the oil pan assembly
9.
9-32
TIP:
Make sure to fit the tip of the cooling water
pipe 8 into the joint hole a in the upper
case.
6. Install the oil pan assembly bolts 10 and

11, and then tighten them to the specified torques.
11
10
1
2
2
1
6
7
8
5
8
4
a
Baffle plate screw 3:

20 Nm (2.0 kgfm, 14.8 ftlb)
42 Nm (4.2 kgfm, 31.0 ftlb)
7
8
7. Install the damper 1, the cover 2, a

new gasket 3, and the drain bolt 4,
and then tighten the drain bolt 4 to the
specified torque.
9
10
2
4
1
Drain bolt 4: 27 Nm (2.7 kgfm, 19.9 ftlb)
9-33
Oil pan and exhaust manifold (X-transom model)

1
14
7
7
15
8
9
14
3
16
11
4 20 Nm (2.0 kgfm, 14.8 ftlb)
17
12
10
18
13
6
20 Nm (2.0 kgfm, 14.8 ftlb)
20 Nm (2.0 kgfm, 14.8 ftlb)
12 Nm (1.2 kgfm, 8.9 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Exhaust guide
Gasket
Gasket
Collar
Oil strainer
Bolt
Dowel pin
Oil pan
Bolt
Bolt
Gasket
Exhaust manifold
Rubber seal
Gasket
Plate
Dowel pin
Muffler
Qty
1
1
1
3
1
3
2
1
10
4
1
1
1
2
1
2
1
9-34
Remarks
Not reusable
Not reusable
M6 25 mm
M8 35 mm
M8 60 mm
Not reusable
Not reusable
0
14
7
7
15
9
14
3
16
11
4 20 Nm (2.0 kgfm, 14.8 ftlb)
17
12
10
18
13
4
5
6
20 Nm (2.0 kgfm, 14.8 ftlb)
20 Nm (2.0 kgfm, 14.8 ftlb)
12 Nm (1.2 kgfm, 8.9 ftlb)
No.
18
Part name
Bolt
Qty
8
Remarks
6
7
M8 35 mm
8
9
10
A
9-35
Disassembling the oil pan and

exhaust manifold
Assembling the oil pan and exhaust

manifold
1. Remove the muffler 1, plate 2, and

exhaust manifold 3.
1. Install the collars 1, a new gasket 2,

and the oil strainer 3, and then tighten
the oil strainer bolts 4 to the specified
torque.
1
3
4
1
4
1
4
1
2
Oil strainer bolt 4:

12 Nm (1.2 kgfm, 8.9 ftlb)
2. Remove the oil pan 1 and oil strainer
2.

2, and the oil pan 3, and then tighten
the oil pan bolts 4 temporarily.
3
2
4
4
4
1
Checking the oil pan and exhaust

manifold
3. Install a new gasket 1, the exhaust

manifold 2, and the rubber seal 3, and
then tighten the exhaust manifold bolts
4 temporarily.
See Checking the oil pan and exhaust manifold (9-21).
Checking the oil strainer

See Checking the oil strainer (9-21).
9-36
TIP:
Make sure that the sealant a side of the
gasket 1 is facing toward the exhaust manifold.
2
5
3
3
2
1
1
4
2
1
3
Muffler bolt 5:
20 Nm (2.0 kgfm, 14.8 ftlb)
4
5
4. Tighten the exhaust manifold bolts first,

and then tighten the oil pan bolts to the
specified torques.
Exhaust manifold bolt:

20 Nm (2.0 kgfm, 14.8 ftlb)
Oil pan bolt:
20 Nm (2.0 kgfm, 14.8 ftlb)
5. Install the dowel pins 1, new gaskets

2, the plate 3, and the muffler 4.
6. Tighten the muffler bolts 5 to the specified torque.
9
10
A
9-37
Steering arm (X-transom model)
2
3
3
4
5
2
8
6
7
No.
1
2
3
4
5
6
7
8
Part name
Steering arm
Washer
Bushing
O-ring
Bushing
Steering yoke
Circlip
Grommet
Qty
1
2
2
1
1
1
1
1
9-38
Remarks
Not reusable
Removing the steering arm
5. Remove the washer 4, bushing 5, Oring 6, and bushing 7.
0
1
1
2. Remove the circlip 1.
6
5
3
4
Installing the steering arm
1. Install the washer 1 and bushing 2

onto the steering arm 3, and then install
the steering arm 3.
2. Install the bushing 4, a new O-ring 5,

the bushing 6, and the washer 7.
3. Remove the steering yoke 1.
1
2
3
2
3
1
4
5
6

90890-06612
Gear puller 3: (commercially available)
9
10
7
3. Install the steering yoke 1 so that it
faces the same direction as the steering
arm 2 (aligning a with b).
4. Remove the steering arm 1, and then

remove the washer 2 and bushing 3.
9-39
4. Hold the steering arm 1, and then strike

the steering yoke 2 using a copper
hammer until the groove a for installing
the circlip is visible.
5. Install the circlip 3.
2
3

7. Inject grease into the grease nipple 2
until grease comes out from both the
upper and lower bushings a.
9-40
Clamp bracket and swivel bracket

15 Nm (1.5 kgfm, 11.1 ftlb)
3
4
2
32
31
3
3
11
10
3
18
10
25
26
27
24
12
14
35
16
17
19
26 27 26
25
25
15
20
21
Part name
Self-locking nut
Clamp bracket (STBD)
Grease nipple
Ground lead
Screw
Ground lead
Tilt stop lever
Bushing
Tilt stop lever
Bushing
Washer
Clamp bracket (PORT)
Through tube
Bolt
Plastic tie
Swivel bracket
Trim stopper
4
5
2.5 Nm (0.25 kgfm, 1.84 ftlb)
20
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
11
26
34
30 29
13
3 33
3 6
23
28
Qty
1
1
6
1
1
1
1
2
1
2
2
1
1
1
1
1
2
9-41
22
21
Remarks
M22
M6
M6 10 mm
9
10
M8 20 mm

15 Nm (1.5 kgfm, 11.1 ftlb)
3
4
2
32
31
3
3
11
10
3
18
10
25
26
27
24
12
14
26
35
34
16
17
2.5 Nm (0.25 kgfm, 1.84 ftlb)
19
26 27 26
30 29
25
25
15
20
20
21
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
11
3 33
3 6
23
28
13
Part name
Nut
Anode
Plate
Bolt
Ground lead
Bushing
Collar
Pin
Distance collar
Pin
Spring
Hook
Bolt
Screw
Trim sensor cam
Clamp
Screw
Qty
2
1
2
4
1
1
1
2
2
1
1
1
1
1
1
1
2
9-42
22
21
Remarks
M6 30 mm
M6 10 mm
M5 35 mm
M6 15 mm

15 Nm (1.5 kgfm, 11.1 ftlb)
3
4
2
32
31
3
3
11
10
3
18
10
25
26
27
24
11
12
14
26
35
34
16
17
19
26 27 26
25
25
15
20
20
21
Part name
Trim sensor
4
5
2.5 Nm (0.25 kgfm, 1.84 ftlb)
30 29
No.
35
13
3 33
3 6
23
28
Qty
1
22
21
Remarks
7
8
9
10
A
9-43
Removing the clamp bracket

1. Remove the PTT unit. See Removing
the PTT unit (9-48).
2. Remove the plastic tie 1.
9. Remove the spring 1, hook 2, and

pins 3.
3. Remove the anode 1 and ground lead

2.
1
2
4. Remove the trim sensor cam 3.
5. Remove the ground leads 4 and 5.

6. Remove the bolt 6 and self-locking nut
7.
10. Remove the tilt stop levers 1 and 2,

distance collar assembly 3, collar 4,
and bushings 5 and 6.
7. Remove the through tube 8, and then

disassemble the clamp brackets 9 and
10.
11. Remove the trim stopper nuts 7 and

trim stoppers 8.
1
7
6
7
6
3
2
4
8
6
9
1
10
Checking the clamp bracket anode

2
8. Remove the trim sensor 1.
9-44

anode.
Installing the clamp bracket
1. Assemble the distance collar assembly.
1
1
2
2
Distance a: 2.53.5 mm (0.100.14 in)
5. Install the trim sensor 1, and then
tighten the trim sensor screw 2 to the
specified torque.
Distance a:
30.330.6 mm (1.191.20 in)
2. Install the bushings 1 and 2, collar 3,
distance collar assembly 4, and tilt stop
levers 5 and 6.
1
3. Install the trim stoppers 7 and trim stopper nuts 8.
3
4
5
6
8
2
Trim sensor screw 2:

2.5 Nm (0.25 kgfm, 1.84 ftlb)
4
2
6. Install the bushing 1, through tube 2,

and then temporarily tighten the self-locking nut 3.
1
3
7
7
8
7. Install the anode 4 and ground lead 5.

8. Tighten the self-locking nut 3 to the
specified torque.
7
4. Install the pins 1, hook 2, and spring
3.
9. Install the ground leads 6 and 7.
9
10
10. Install the trim sensor cam 8.

11. Install the grease nipples 9, and then
A
9-45

3. Measure the trim sensor setting resistance. Adjust if out of specification.
9
1
TIP:
9
3
To decrease the resistance, turn the trim

sensor cam in direction a.
To increase the resistance, turn the trim
sensor cam in direction b.
7
9
1
8
9
c
d
2
1
5
Self-locking nut 3:
15 Nm (1.5 kgfm, 11.1 ftlb)
Grease nipple 9:

Trim sensor setting resistance:
9.011.0
12. Inject grease into the grease nipples until

grease comes out from the bushings a.
4. Tighten the trim sensor cam screw.

5. Check that the trim sensor setting resistance is within specification.
13. Install the PTT unit. See Installing the

PTT unit (9-52).
Adjusting the trim sensor cam

1. Fully tilt the swivel bracket down.
2. Loosen the trim sensor cam screw 1.
9-46
PTT unit
PTT unit
2
0
1
2
3
10
7
1
4
8
9
3
8
5
6
39 Nm (3.9 kgfm, 28.8 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
Part name
Upper mounting shaft
Circlip
Bushing
PTT unit
Ground lead
Bolt
Bolt
Washer
Lower mounting shaft
Plastic tie
Qty
1
1
6
1
1
1
2
2
1
3
Remarks
7
8
M6 10 mm
M10 30 mm
9
10
A
9-47
PTT unit
Removing the PTT unit

1
2
When removing the PTT unit with the

power unit installed, make sure to suspend the outboard motor.
1. Fully tilt the swivel bracket up, and then
support it using the tilt stop lever 1.
5. Connect the battery jumper leads to the

PTT motor lead 1 to fully retract the
PTT rams.
1
L
2. Remove the plastic ties 1, and then pull

out the PTT motor lead from the clamp
bracket (PORT).
Ram
1
Retract
PTT motor lead
Battery
Green (G)
(+)
Blue (L)
()
6. Remove the lower mounting shaft 1,

and then remove the PTT unit 2.
Checking the hydraulic pressure
4. Remove the circlip 1 and upper mounting shaft 2.
Check the hydraulic pressure. Check the

internal parts if out of specification.
1. Place the PTT unit in an upright position.
9-48
PTT unit
PTT motor lead 1 to fully extend the
PTT rams.
Reservoir cap:
2.5 Nm (0.25 kgfm, 1.84 ftlb)
the manual valve 2.
1
L
2
1
2
Ram
Extend
PTT motor lead
Battery
Blue (L)
(+)
Green (G)
()

2.
3. Remove the reservoir cap 1, and then

check the fluid level in the reservoir.
TIP:
Install the special service tools quickly before
any fluid flows out of the hole.
Before removing the reservoir cap 1,

make sure that the PTT rams are fully
extended. Otherwise, fluid could be
expelled forcefully from the PTT unit due
to internal pressure.
3
4
5
6
TIP:
If the fluid is at the proper level, a small
amount of fluid should flow out of the filler
hole.
Up relief fitting 1: 90890-06773/06838

Hydraulic pressure gauge 2:
90890-06776/06800
PTT rams.
1
G
7
8
9
10
4. If the fluid is below the proper level, add

the recommended fluid.
Recommended PTT fluid: ATF Dexron II
5. Install the reservoir cap, and then tighten
it to the specified torque.
A
9-49
PTT unit
Ram
Retract
PTT motor lead
Battery
Green (G)
(+)
Blue (L)
()
Down relief fitting 3: 90890-06774

Hydraulic pressure gauge 2:
90890-06776/06800
11. Repeat steps 24 to check the fluid level.
9. Reverse the connection between battery

jumper leads and the PTT motor lead 1
to fully extend the PTT rams, and then
measure the hydraulic pressure when the
reading on the pressure gauge stabilizes.

PTT rams, and then measure the hydraulic pressure when the reading on the
pressure gauge stabilizes.
1
L
1
G
Hydraulic pressure (up):

9.8111.77 MPa
(98.1117.7 kgf/cm2,
1422.51706.7 psi)
Ram
Extend
PTT motor lead
Battery
Blue (L)
(+)
Green (G)
()
Hydraulic pressure (down):

5.888.83 MPa
(58.888.3 kgf/cm2,
852.61280.4 psi)
Ram
PTT motor lead
Battery
Green (G)
(+)
Blue (L)
()
Retract
10. Remove the special service tools 1 and

2, and then install the special service
tools 2 and 3.

to fully extend the PTT rams.
TIP:
Remove and install the special service tools
quickly before any fluid flows out of the hole.
1
L
3
2
Ram
Extend
PTT motor lead
Battery
Blue (L)
(+)
Green (G)
()
14. Remove the special service tools.
9-50
PTT unit
PTT rams.
Be careful when removing the special service tool. Fluid could be expelled forcefully from the PTT unit due to internal
pressure.
TIP:
If the PTT rams do not move down easily,
push on the PTT rams to assist operation.
15. Install the manual valve 1 and circlip

2, and then tighten the manual valve to
TIP:
Install the manual valve 1 quickly before any
fluid flows out of the hole.
3
1
Ram
PTT motor lead
Battery
Green (G)
(+)
Blue (L)
()
Retract

to fully extend the PTT rams.
Manual valve 1:
3.5 Nm (0.35 kgfm, 2.58 ftlb)
TIP:
If the PTT rams do not move up easily, pull on
the PTT rams to assist operation.
16. Repeat steps 24 to check the fluid level.
1
L
2. Turn the manual valve 1 clockwise to

close it.
5
6
7
Bleeding the PTT unit

1. Place the PTT unit in an upright position.
8
9
1
Ram
Extend
PTT motor lead
Battery
Blue (L)
(+)
Green (G)
()
10
6. Repeat steps 4 and 5 to fully extend and

retract the PTT rams 4 or 5 times.
Manual valve 1:
3.5 Nm (0.35 kgfm, 2.58 ftlb)
7. Fully extend the PTT ram.
3. Check the fluid level. See steps 24 in

Checking the hydraulic pressure (9-48).
A
9-51
PTT unit
8. Remove the reservoir cap, and then
check the fluid level in the reservoir.
2. Fully tilt the swivel bracket up, and then

Before removing the reservoir cap, make

sure that the PTT rams are fully extended.
Otherwise, fluid could be expelled forcefully from the PTT unit due to internal
pressure.
TIP:
If the fluid is below the proper level, add the
recommended PTT fluid. Repeat steps 37
until the fluid remains at the proper level.
3. Install the bushings 1, PTT unit 2, and

lower mounting shaft 3, and then
tighten the lower mounting shaft bolts 4
9. Install a new O-ring and the reservoir

cap, and then tighten the reservoir cap to
Reservoir cap:
2.5 Nm (0.25 kgfm, 1.84 ftlb)
Installing the PTT unit

1
1
2
After tilting the swivel bracket up, make

sure to support it using the tilt stop
lever.
When installing the PTT unit with the
power unit installed, make sure to suspend the outboard motor.
4
1
1

PTT motor lead 1 to retract the PTT
rams.
Lower mounting shaft bolt 4:

39 Nm (3.9 kgfm, 28.8 ftlb)
4. Pass the PTT motor lead 1 through the
hole a in the clamp bracket (PORT).

PTT motor lead 1 to extend the PTT
rams until the end of the tilt ram is
aligned with the mounting position hole.
Ram
Retract
PTT motor lead
Battery
Green (G)
(+)
Blue (L)
()
9-52
PTT unit
0
1
Ram
Extend
PTT motor lead
Battery
Blue (L)
(+)
Green (G)
()
6. Install the upper mounting shaft 1 and

circlip 2.
5
6
7
8
1
8. Fasten the PTT motor lead and trim sensor lead using the plastic ties 1.
10
A
9-53
PTT motor
PTT motor
11
10
2.5 Nm (0.25 kgfm, 1.84 ftlb)
3
7
8
4
5
12
10
14
13
14
17
18
16
19
19
15
20
21
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Bolt
Reservoir
Cap
O-ring
O-ring
Bolt
O-ring
Filter
Joint
PTT motor assembly
Screw
Armature
O-ring
Screw
Brush holder
Brush holder
Brush
Qty
3
1
1
1
1
4
1
1
1
1
1
1
1
2
1
1
1
9-54
Remarks
M6 14 mm
M16
Not reusable
Not reusable
M6 35 mm
Not reusable
M4 15 mm
Not reusable
M4 12 mm
PTT motor
11
10
2.5 Nm (0.25 kgfm, 1.84 ftlb)
7
8
4
5
12
10
14
13
14
17
18
16
19
19
15
20
21
Remarks
No.
18
19
20
21
Part name
Brush
Spring
Screw
Oil seal
Qty
1
2
2
1
M4 15 mm
Not reusable
8
9
10
A
9-55
PTT motor
Removing the reservoir
Before removing the reservoir, make sure

that the PTT rams are fully extended. Otherwise, fluid could be expelled forcefully
from the PTT unit due to internal pressure.
1. Remove the reservoir 1 and O-ring 2.
2. Remove the screw 1, and then slide the

lead holder 2 and rubber seals 3 away
from the stator 4.
TIP:
Place a container under the PTT unit to catch
the fluid.
3. Remove the screws 5, and then remove

the stator 4.
Secure the end of the armature shaft

using a pair of pliers, and then remove the
armature along with the motor base
assembly. Otherwise, the armature could
separate from the motor base assembly
due to the magnetic force of the stator 4
and damage the brushes.
Removing the PTT motor

1. Remove the PTT motor assembly 1,
O-ring 2, filter 3, and joint 4.
4. Remove the armature 6.
3 2
6
5
3
1
4
5
2
5. Disconnect the PTT motor leads 1 and
2.
3
4
1
G
2
Disassembling the PTT motor

1. Remove the tape 1, and then slide the
vinyl tube 2 in direction a.
9-56
PTT motor
6. Remove the brushes 1 and 2.
3. Measure the commutator undercut a.

Do not touch the bimetal a. Otherwise,

the operation of the circuit breaker could
be affected.
2
a
2
Motor commutator standard undercut a
(reference data): 1.35 mm (0.0531 in)
Checking the armature (PTT motor)
4. Check the armature for continuity.

1. Check the commutator. Clean using 600grit sandpaper and compressed air if
dirty.
3
4
5
a
b
6
Armature continuity:
Continuity:
ab
No continuity:
ac
ad
2. Measure the commutator diameter a.

7
8
Checking the brush

1. Measure the length of each brush.
Replace if below specification.
9
10
a
b
Motor commutator standard diameter a:

22.0 mm (0.8661 in)
A
9-57
PTT motor
2. Install the springs 1 and brushes 2
and 3, and then tighten the screw 4.
Motor brush standard length a:

9.8 mm (0.3858 in)
Wear limit b: 4.8 mm (0.1890 in)

be affected.
2. Check the brush and circuit breaker for

continuity. Replace if there is no continuity.

be affected.
a
4. Connect the PTT motor leads 1 and 2,
and then tighten the screw 3.
3. Check the PTT motor base. Replace the

PTT motor assembly if the base is
cracked or damaged.
Checking the reservoir

1. Check the reservoir. Replace if cracked
or damaged.
Assembling the PTT motor

5. Push the brushes 1 and 2 into the
holders, and then install the armature 3.
Do not apply grease or oil to the commutator of the armature.
1. Install a new oil seal 1.
1
6. Install the stator 1, and then tighten the
screws 2.
9-58
PTT motor
2
Secure the end of the armature shaft
using a pair of pliers, and then install the
armature along with the motor base
assembly. Otherwise, the armature could
separate from the motor base assembly
due to the magnetic force of the stator 1
and damage the brushes.
0
1
3
7. Install the rubber seals 3 and lead

holder 4, and then tighten the screw 5.
Reservoir bolt 3:
Reservoir cap 5:
2.5 Nm (0.25 kgfm, 1.84 ftlb)
3 4
Installing the PTT motor
3
5
When assembling the PTT unit, do not use
a rag. Otherwise, dust and particles could
get on the PTT unit components, causing
poor performance.
1
2
8. Slide the vinyl tube 1 in direction a,
and then fasten it securely using new
heat-resistant tape 2.
1. Install the joint 1 and filter 2.
4
5
6
1
a
2. Fill the gear pump housing with the recommended fluid up to the proper level
a.
Installing the reservoir

1. Install a new O-ring 1 and the reservoir
2, and then tighten the reservoir bolts
2. Install a new O-ring 4 and the reservoir
cap 5, and then tighten the reservoir
cap 5 to the specified torque.
9-59
8
9
10
PTT motor
3. Turn the joint 1 using a screwdriver to
remove any air between the pump gear
teeth.
4. Remove all of the air bubbles using a
syringe or suitable tool.
5. Install a new O-ring 2 and the PTT
motor assembly 3, and then tighten the
PTT motor mounting bolts 4 to the
specified torque.
TIP:
Align the protrusion a on the armature shaft
with the slot b in the joint.
a
b
PTT motor mounting bolt 4:

9-60
PTT gear pump
PTT gear pump

2
2
3
10
12
13
14
11
12
16
17
18
19
13
7
4
20
10
11
1
15
16
17
18
18
17
19
8
5
22
23
24
25
26
27
27
21
3.5 Nm (0.35 kgfm, 2.58 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Ball
Pin
Valve seat
O-ring
Valve
Filter
Down-relief valve
O-ring
Spring
Absorber valve pin
Ball
Up-relief valve seat
O-ring
Bolt
Ball
Shuttle piston
O-ring
Qty
1
1
1
5
1
2
1
1
1
1
1
1
1
4
2
2
2
9-61
Remarks
Not reusable
Ball: 4.98 mm (0.20 in) (reference data)

Not reusable
7
8
9
10
Not reusable
M5 16 mm
Not reusable
PTT gear pump
2
3
10
12
13
14
11
10
11
12
16
17
18
19
13
7
4
20
15
16
17
18
18
17
19
8
5
22
23
24
25
26
27
27
21

3.5 Nm (0.35 kgfm, 2.58 ftlb)
No.
18
19
20
21
22
23
24
25
26
27
Part name
Main valve
Ball
Gear pump assembly
Bolt
Backup ring
O-ring
O-ring
Manual valve
Circlip
Bolt
Qty
2
2
1
1
1
1
1
1
1
2
9-62
Remarks
M8 85 mm
Not reusable
Not reusable
M14
M8 24 mm
PTT gear pump
Disassembling the gear pump

assembly
1
2
3
1. Remove the bolts 1 and 2, and then

remove the gear pump assembly 3.
2. Remove the O-rings 4, valve 5, and

valve seat assembly 6.
5
6. Cover the gear pump using a rag, and
then blow compressed air through the
holes a and b to remove the main
valves 1.
3
2
When removing the main valves, never

look into the gear pump housing opening
because the main valves and PTT fluid
could be expelled forcefully.
3. Remove the filters 1, down-relief valve

2, and O-ring 3.
4. Remove the gear pump cover 4, and
then remove the gears 5, shuttle pistons 6, and balls 7 and 8.
b
3
4
5
6
7
8

the manual valve 2.
9
10
5. Remove the spring 1, absorber valve

pin 2, ball 3, up-relief valve seat 4,
and O-ring 5.
A
9-63
PTT gear pump
Checking the gear pump
1. Install a new O-ring 1, the up-relief

valve seat 2, the ball 3, the absorber
valve pin 4, and the spring 5.
1. Check the gears 1. Replace the gear

pump assembly if damaged or worn.
5
4
3
2
1
2. Check the down-relief valve 2. Clean if

there is dirt or residue.
4
3
3. Check the main valves 3 and shuttle

pistons 4. Clean if there is dirt or residue.
4. Check the absorber valve pin 5 and

up-relief valve seat 6. Clean if there is
dirt or residue.
2. Install new O-rings 1 onto the main

valves 2, and then install the main
valves.
5. Check the valve 7 and valve seat 8.

Clean if there is dirt or residue.
11
1
2
6
8
3. Install the gears 1.
Checking the gear pump housing

1. Check the gear pump housing. Replace
the gear pump assembly if corroded or
cracked.
Checking the filter

1. Check the down-relief valve filters. Clean
if there is dirt or residue.
4. Install the balls 1, shuttle pistons 2,

and balls 3.
Assembling the gear pump assembly

poor performance.
9-64
PTT gear pump

9. Install the manual valve 4 and circlip
5, and then tighten the manual valve 4
1
2
1
2
3
1
2
3
1
4
2
1
Manual valve 4:
3.5 Nm (0.35 kgfm, 2.58 ftlb)
5. Install the gear pump cover 1, and then

tighten the gear pump cover bolts 2 to
10. Install new O-rings 1, the valve 2, and

the valve seat assembly 3.
11. Install the gear pump assembly 4, and
then tighten the gear pump housing bolts
5 and 6 to the specified torque.
4
5
2
1
4
5
Gear pump cover bolt 2:

6. Check that the gears turn smoothly.
Gear pump housing bolts 5 and 6:

7. Install a new O-ring 1 onto the

down-relief valve 2, and then install the
filters 3 and down-relief valve 2.
3 2 1
3
3
1 2
7
8
9
10
8. Install new O-rings 1 and 2 and the
backup ring 3.
A
9-65
PTT cylinder
PTT cylinder
18
140 Nm (14.0 kgfm, 103.3 ftlb)
15
16
1
14
15
16
17
127 Nm (12.7 kgfm, 93.7 ftlb)
5
2
4
5
7
6
15
16
18
8
17
2
3
9
10
14
17
18
19
20
9
11 10
12
13
19
20
19
20
21
96 Nm (9.6 kgfm, 70.8 ftlb)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Tilt ram assembly
Dust seal
Tilt cylinder end screw
O-ring
O-ring
O-ring
O-ring
Free piston
Backup ring
O-ring
Plug
O-ring
Filter
Trim ram assembly
Dust seal
Seal
Trim cylinder end screw
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
9-66
Remarks
Ball: 3.15 mm (0.12 in) (reference data)
Not reusable
M48
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
M42
PTT cylinder
18
140 Nm (14.0 kgfm, 103.3 ftlb)
15
0
15
16
1
14
16
17
127 Nm (12.7 kgfm, 93.7 ftlb)
5
2
17
2
3
9
4
5
10
14
17
18
19
20
9
11 10
12
13
7
6
4
19
20
19
20
21
96 Nm (9.6 kgfm, 70.8 ftlb)
No.
18
19
20
21
15
16
18
Part name
O-ring
Backup ring
O-ring
PTT body
5
6
Qty
2
2
2
1
Remarks
Not reusable
Not reusable
8
9
10
A
9-67
PTT cylinder
Removing the tilt ram and trim ram

When removing the free piston, never
look into the tilt cylinder opening because
the free piston and PTT fluid could be
expelled forcefully.
Before removing the tilt cylinder end

screw, make sure that the PTT rams are
fully extended. Otherwise, fluid could be
expelled forcefully from the PTT unit due
to internal pressure.
1. Loosen the tilt cylinder end screw 1,
and then remove the tilt ram assembly.
1
1
2
1
Trim & tilt wrench 2: 90890-06592
2. Loosen the trim cylinder end screws 1,

and then remove the trim ram assemblies.
6. Loosen the trim cylinder end screws, and

then remove the trim ram assemblies 1.
1
3. Drain the fluid.
1
4. Install the trim ram assemblies, and then
tighten the trim cylinder end screws 1
temporarily.
Removing the filter

1. Removing the plug 1, O-ring 2 and filter 3.
5. Cover the tilt cylinder using a rag, and

then blow compressed air through the
hole a to remove the free piston 2.
9-68
PTT cylinder
1
2
3
0
1
Checking the filter
1. Check the filter. Clean if there is dirt or

residue. Replace with a new one if damaged.
Installing the filter

1. Install the filter 1 and a new O-ring 2,
and then tighten the plug 3 to the specified torque.
Checking the tilt cylinder and trim

cylinder
3
2
1
1. Check the PTT body 1. Replace if corroded or cracked.

2. Check the inner surface of the PTT body
1. Replace if scratched.
3. Check the outer surfaces of the tilt piston
2, trim pistons 3, and free piston 4.
Replace if scratched.
PTT filter plug 3:

4. Check the backup rings 5 and 6.

Replace if damaged or worn.
Disassembling the tilt ram
5. Check the trim rams 7 and tilt ram 8.

Clean using 400600-grit sandpaper if
there is rust or replace if bent or corroded.
1. Remove the nut 1, and then remove the

tilt piston absorber valves 2.
4
5
6
7
8
9
10
A
9-69
PTT cylinder
7
3
1
4
2. Install the tilt cylinder end screw 1 and

tilt piston 2.
3. Install new O-rings 3 and 4.
Checking the absorber valve

1. Check the tilt piston absorber valves 1.
Clean if there is dirt or residue.
1
4
2
3
2
3
4. Install the balls 1, absorber valve pins

2, and springs 3.
5. Install the washer 4, and then tighten
the tilt piston nut 5 to the specified
torque.
Assembling the tilt ram

poor performance.
Make sure that LOCTITE does not contact

the O-ring.
1. Install a new dust seal 1 and new

O-rings 2 and 3.
9-70
PTT cylinder
2
1
4
3
2
1
4
3
3
2
1
Installing the trim ram

poor performance.
Tilt piston nut 5:
96 Nm (9.6 kgfm, 70.8 ftlb)
1. Add the recommended fluid through the

PTT body hole a.
Assembling the trim ram
3
4
5

poor performance.
1. Install new O-rings 1 and the backup

rings 2.

Fluid quantity (reference quantity):
0.03 L (0.032 US qt, 0.026 Imp qt)
2. Install a new O-ring 1 and the backup
ring 2 to the free piston 3.
2
1
2. Install new seals 1, new dust seals 2,

and new O-rings 3.
7
8
9
10
2
1
3. Install the trim cylinder end screws 4.
3. Install the free piston assembly 1 and

push it down until it bottoms out.
9-71
PTT cylinder
Trim cylinder end screw 1:

140 Nm (14.0 kgfm, 103.3 ftlb)
Installing the tilt ram

1. Install the gear pump assembly. See
steps 10 and 11 in Assembling the gear
pump assembly (9-64).
4. Fill the trim cylinders with the recommended fluid up to the proper level a.
2. Install the reservoir. See Installing the

reservoir (9-59).
TIP:
3. Place the tilt cylinder end screw 1 at the

bottom of the tilt ram 2.
Make sure to add the recommended fluid

through the holes 1, 2, and 3.
4. Fill the tilt cylinder and PTT body with the

recommended fluid up to the proper level
a.
1
2
2
1
a
3
5. Install the trim ram assemblies, and then
tighten the trim cylinder end screws 1 to

5. Install the tilt ram assembly, and then
tighten the tilt cylinder end screw 1 to
9-72
PTT cylinder
2
1
0
1
Tilt cylinder end screw 1:

127 Nm (12.7 kgfm, 93.7 ftlb)
6. Install the PTT motor. See Installing the

PTT motor (9-59).
4
5
6
7
8
9
10
A
9-73
PTT cylinder
MEMO
9-74
Maintenance
Outline .............................................................................. 10-1
Maintenance interval chart 1 ................................................... 10-1
Maintenance interval chart 2 ................................................... 10-3
Predelivery check ............................................................ 10-4

Checking the battery ............................................................... 10-4
Checking the cooling water pilot hole ...................................... 10-5
Checking the engine oil level ................................................... 10-5
Checking the main switch/stop switch ..................................... 10-5
Checking the fuel line .............................................................. 10-6
Checking the gear oil level ...................................................... 10-6
Checking the shift link/shift cable and throttle link/
throttle cable ............................................................................ 10-6
Checking the outboard motor mounting height ....................... 10-6
Checking the power trim and tilt unit ....................................... 10-7
Checking the steering system ................................................. 10-7
Checking the throttle cable and shift cable .............................. 10-7
Test run ................................................................................... 10-7
Break-in ................................................................................... 10-8
After test run ............................................................................ 10-8
General periodic maintenance ....................................... 10-8

Checking the anode ................................................................ 10-8
Checking the battery ............................................................... 10-8
Checking the cooling water inlet .............................................. 10-8
Checking the cooling water pilot hole ...................................... 10-9
Checking the engine idle speed/noise ..................................... 10-9
Changing the engine oil using an oil changer ......................... 10-9
Changing the engine oil by removing the drain bolt .............. 10-10
Checking the engine oil level ................................................. 10-12
Replacing the oil filter ............................................................ 10-12
Checking the exhaust guide/exhaust manifold ...................... 10-13
Checking the main switch/stop switch ................................... 10-13
Checking the fuel filter ........................................................... 10-13
Checking the fuel pump ......................................................... 10-13
Checking for fuel/engine oil leakage ..................................... 10-13
Changing the gear oil ............................................................ 10-13
Checking the gear oil level .................................................... 10-14
Replacing the OCV filter ........................................................ 10-14
Greasing points ..................................................................... 10-14
Checking the PCV ................................................................. 10-16
Checking the propeller/propeller nut/cotter pin ...................... 10-16
10
Maintenance
Checking the PTT fluid level .................................................. 10-16
Checking the power trim and tilt unit operation ..................... 10-16
Adjusting the shift link/shift cable .......................................... 10-17
Checking the spark plug ........................................................ 10-17
Checking the timing belt ........................................................ 10-17
Replacing the timing belt ....................................................... 10-17
Checking the thermostat ....................................................... 10-17
Adjusting the throttle link/throttle cable .................................. 10-17
Checking the cowling lock lever ............................................ 10-17
Checking the valve clearance ............................................... 10-17
Checking the impeller/water pump housing .......................... 10-17
0
1
2
3
4
5
6
7
8
9
10
Outline
Outline
To obtain long product life, Yamaha strongly recommends that the specified periodic checks and
maintenance be performed according to the maintenance interval charts.
If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and quality. Any parts of inferior quality may cause a malfunction, and the resulting loss of control could
endanger the operator and passengers. Yamaha genuine parts and accessories are available
from Yamaha dealers.
The service intervals provided in the maintenance interval charts are based upon typical operating conditions that include speed variations, sufficient time for engine warm up and cool-down,
medium to light load, and an average cruising speed in the 30004000 r/min range. If your normal
operating conditions are more intensive, more frequent servicing will be required, especially the
engine oil and gear oil changes. Examples of the intensive operation will be: wide-open-throttle,
trolling, or idling operation for extended periods of time, carrying heavy loads, and frequent starting and stopping or shifting. In most cases, the frequent maintenance pays off in increased engine
life and greater owner satisfaction.
The maintenance cycle on these charts is based on usage of 100 hours per year and regular
flushing of the cooling water passages. Adjust the maintenance frequency when operating the
engine under adverse conditions, such as extended trolling.
Disassembly or repairs may be necessary depending on the outcome of maintenance checks.
Expendable or consumable parts and lubricants will lose their effectiveness over time and through
normal usage regardless of the warranty period.
When operating the outboard motor in salt water, or in muddy, turbid (cloudy), or acidic water, flush
the engine using clean water after each use.
Maintenance interval chart 1

The symbol indicates the check-ups which the owners or operators may carry out themselves.
The symbol indicates work to be carried out by a Yamaha dealer.
Item
Anode(s) (external)
Anode(s) (exhaust cover)
Anodes (cylinder head,
crankcase cover, cooling
water passage, exhaust
cover)
Battery (electrolyte level,
terminal)
Battery (electrolyte level,
terminal)
Cooling water leakage
Initial
Every
20 hours 100 hours 300 hours 500 hours
(3 months) (1 year)
(3 years) (5 years)
Actions
Inspection or replacement
as necessary
as necessary
Replacement
Inspection
Fill, charging or replacing
as necessary
as necessary
Inspection
Cowling lock lever

Engine starting condition/
Inspection
noise
Engine idle speed/noise
Inspection
10-1
Outline
Item
Actions
Engine oil
Engine oil filter (cartridge)
Fuel filter (can be
disassembled)
Fuel line (High pressure)
Replacement
Replacement
as necessary
Inspection
as necessary
Inspection
as necessary
as necessary
Inspection
Replacement
Greasing
as necessary
Fuel line (High pressure)

Fuel line (Low pressure)
Fuel line (Low pressure)
Fuel pump
Fuel/engine oil leakage
Gear oil
Greasing points
Impeller/water pump
housing
Impeller/water pump
housing
OCV (Oil Control Valve)
filter
Power trim and tilt unit
Propeller/propeller nut/
cotter pin
PCV (Pressure Control
Valve)
Shift link/shift cable
Spark plug(s)
Ignition coils/ignition coil
leads
Water from the cooling
water pilot hole
Throttle link/throttle cable
Thermostat
Timing belt
Valve clearance
Initial
Every
(3 months) (1 year)
(3 years) (5 years)
/
/
/
/
1
2
3
/
/
/
/
Replacement
Replacement
Inspection
as necessary
as necessary
Inspection, adjustment or
replacement as
necessary
as necessary
as necessary
Inspection
Inspection, adjustment or
replacement as
necessary
as necessary
as necessary
Inspection and
adjustment
10-2
6
7
9
10
Outline
Item
Cooling water inlet
Main switch/stop switch
Wire harness
connections/wire coupler
connections
(Yamaha) Meter/gauge
Actions
Inspection
as necessary
Initial
Every
(3 months) (1 year)
(3 years) (5 years)
/
/
as necessary
Inspection
Maintenance interval chart 2

Item
Exhaust guide/exhaust
manifold
Timing belt
Every
1000 hours
Actions
as necessary
Replacement
10-3
Predelivery check
Predelivery check
To make the delivery process smooth and
efficient, complete the predelivery checks as
explained in the following procedures.
Checking the battery
Battery electrolyte is dangerous; it contains sulfuric acid, which is poisonous

and highly caustic. Always follow these
preventive measures:
Avoid bodily contact with electrolyte as
it can cause severe burns or permanent
eye injury.
Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
SKIN - Wash with water.
EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
Drink large quantities of water or milk
followed with milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
Batteries generate explosive, hydrogen
gas. Always follow these preventive measures:
Charge batteries in a well-ventilated
area.
Keep batteries away from fire, sparks, or
open flames (for example, welding
equipment and lighted cigarettes).
DO NOT SMOKE when charging or handling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
2. Check the specific gravity of the electrolyte. Fully charge the battery if below
specification.
TIP:
Batteries vary depending on the manufacturer. The procedures mentioned in this
manual may not always apply. Therefore,
see the instruction manual of the battery.
Disconnect the negative battery cable first,
and then disconnect the positive battery
cable.
Representative examples:
Recommended battery capacity:
CCA/EN: 640.0 Amps
20HR/IEC: 80.0 Ah
Electrolyte specific gravity:
1.280 at 20 C (68 F)
2
3
4
5
6
7
8
9
1. Check the battery electrolyte level. If the

level is at or below the minimum level
mark a, add distilled water until the level
is between the maximum and minimum
level marks.
10
A
10-4
Predelivery check
Checking the cooling water pilot hole

1
1. Start the engine, and then check that

cooling water is discharged from the
cooling water pilot hole.
Checking the main switch/stop

switch
1. Check that the engine starts when the
engine start switch is turned to START.
Checking the engine oil level

2. Check that the engine stops when the
engine start switch is turned to OFF.
1. Place the outboard motor in an upright

position.
2. ON
1. OFF
3. START
If the outboard motor is not level, the oil

level indicated on the dipstick may not be
correct.
2. Start the engine and warm it up for 510
minutes.
3. Stop the engine and leave it off for 510
minutes.
2. ON
1. OFF
3. START
4. Remove the top cowling.

5. Remove the dipstick 1 and wipe it
clean.
6. Insert the dipstick 1 completely for a
correct measurement and remove it
again.
1. OFF
2. ON
3. START
7. Check that the oil level indicated on the

dipstick 1 is between the upper mark a
and the lower mark b. If the engine oil is
not at the proper level, add or extract
engine oil.
A. 703 side mount remote control model

B. 704 binnacle mount remote control
model
3. Check that the engine stops when the
clip is removed from the engine shut-off
switch.
10-5
Predelivery check
A
2
1
0
1
3. Install a new gasket and the oil level plug,

and then tighten the oil level plug to the
specified torque.
Oil level plug:

Checking the shift link/shift cable

and throttle link/throttle cable
A. 703 side mount remote control model
B. 704 binnacle mount remote control
model
Do not overtighten the friction adjuster. If

there is too much resistance, it could be
difficult to operate the remote control
lever, which could result in an accident.
Checking the fuel line

1. Check that the fuel hoses are connected
securely. See Fuel hose (6-1).
1. Check that the gear shift operates

smoothly when the remote control lever
is moved from the N position to the F or R
position.
This outboard motor is equipped with a 4stroke engine. Never use premixed fuel or
2-stroke outboard motor oil.
2. Check that the throttle operates smoothly

when the remote control lever is moved
from the F or R position to the fully open
position.
Checking the gear oil level

position.
Checking the outboard motor

mounting height
2. Remove the oil level plug 1 and gasket

2, and then check the gear oil level.
1. Check that the anti-cavitation plate 1 is

aligned with the bottom of the boat 2. If
the mounting height is too high, cavitation will occur and propulsion will
decrease. Besides, the engine speed will
increase abnormally and cause the
engine to overheat. If the mounting
height is too low, water resistance will
increase, which will decrease engine efficiency and performance.
TIP:
If the oil is at the proper level, a small amount
of oil should flow out of the check hole.
2
3
4
5
6
7
8
9
10
A
10-6
Predelivery check
2. Check that the mark a on the bushing
1 and the mark b on the plate 2 are
aligned.
TIP:
The appropriate mounting height depends on
the combination of the boat and outboard
motor. To determine the appropriate mounting height, test run the outboard motor at different heights.
a
b
2
1
3. Check that the throttle lever 1 contacts
the stopper 2.
2
2
2. Check that the clamp brackets are

secured using the clamp bolts.
Checking the power trim and tilt unit

1. Check that the outboard motor tilts up
and down smoothly when the PTT switch
is pushed.
2. Check that there is no abnormal noise

produced when the outboard motor is
tilted up or down.
Test run
3. Check that there is no interference with

cables, hoses, leads, or the boat when
the tilted-up outboard motor is steered.
2. Warm up the engine, and then check the

engine idle speed.
1. Start the engine, and then check that the

gear shift operates smoothly.
3. Operate the boat at trolling speed.
4. Check that the trim meter points down

when the outboard motor is fully tilted
down.
4. Operate the outboard motor according to

the break-in procedure.
Checking the steering system

1. Check that
smoothly.
the
steering
5. Check that the outboard motor does not

tilt up when the remote control lever is
moved to the R position and that water
does not flow in over the transom.
operates
2. Check that there is no interference with

cables, hoses, or lead when the outboard
motor is steered.
6. Check that the PTT operates smoothly

while the outboard motor is running.
Checking the throttle cable and shift

cable
The test run is part of the break-in operation.
TIP:
1. Move the remote control lever to the N

position and turn the throttle lever to the
fully closed position.
10-7
General periodic maintenance
Break-in
Operate the engine under load (in gear with a
propeller installed) for 10 hours as follows:
When flushing the cooling water passages, do not start the engine. Otherwise,
the water pump could be damaged and
the engine could be severely damaged
due to overheating.
1. For the first hour a of operation:

Operate the engine at varying speeds up
to 2000 r/min or approximately 1/2 throttle.
TIP:
2. For the second hour b of operation:

Increase the engine speed until the boat
is on plane (but do not fully open the
throttle), and then back off on the throttle
while keeping the boat at a planing
speed.
When using the flushing device (flushing

hose joint adapter), flush the cooling water
passages without starting the engine.
3. For the remaining 8 hours c of operation:

Operate the engine at any engine speed.
However, do not operate the engine at
full throttle for more than 5 minutes at a
time.
A 0
1
2
Checking the anode

anodes or the trim tab.
1. Check the anodes and trim tab. See

Checking the cylinder head and cylinder
block anode (7-61), Checking the
exhaust cover anode (7-68), Checking
the crankcase cover anode (7-74),
Checking the cylinder block anode (781), Checking the lower unit anode (83), and Checking the clamp bracket
anode (9-44).
4. After the first 10 hours of operation:

Operate the engine normally.
10
5
6
7
TIP:
Replace the anodes or trim tab if eroded.
Also, check the ground lead.
A. Hour
Checking the battery

After test run
1. Check for water in the gear oil.
1. Check the battery. See Checking the

battery (10-4).
2. Check all the fuel lines for leakage.
Checking the cooling water inlet

2.
3. Flush the cooling water passages using

fresh water.
9
10
2. Mark the trim tab 3 with an identification

mark a, and then remove the trim tab
3.
3. Check the water inlet covers and water
inlets. Clean if clogged.
10-8
Checking the engine idle speed/

noise
minutes.
2. Check the engine idle speed using the

Yamaha genuine tachometer (on-board
meter) or the YDIS. See the YDIS (Ver.
2.10 or later) instruction manual.
4. Install the water inlet covers and trim tab,

and then tighten the water inlet cover
screw and trim tab bolt to the specified
torque.
Changing the engine oil using an oil

changer
Change the engine oil after the first 20

hours of operation or 3 months, and every
100 hours or at 1-year intervals thereafter.
TIP:
After installing the water inlet covers, make
sure that there is no rattling.

position.
Water inlet cover screw:

Trim tab bolt:
42 Nm (4.2 kgfm, 31.0 ftlb)

correct.
Checking the cooling water pilot hole

1. Place the lower unit in water, and then
start the engine.

minutes.
2. Check that cooling water is discharged

from the cooling water pilot hole. If there
is no water flow, check the cooling water
passages inside the outboard motor.

minutes.
5. Remove the oil filler cap 1.
10-9

clean.
6. Remove the dipstick 1 and extract the

engine oil using the oil changer 2.

again.

and the lower mark b.
1
2
3
b
12. Start the engine and check that the oil
pressure alert indicator does not come
on. Also, check that there is no oil leakage.
7. Fill the engine with the specified amount

of the recommended engine oil through
the oil filler hole. Install the oil filler cap
and dipstick.
If the oil pressure alert indicator comes

on or if there is oil leakage, stop the
engine and find the cause. Continued
operation with a problem could cause
severe engine damage.
Do not overfill the engine with engine oil.

Otherwise, the engine could be damaged
or oil could leak. If the engine oil is above
the upper level, extract the excess engine
oil until the oil is at the proper level.
Changing the engine oil by removing

the drain bolt
Change the engine oil after the first 20

hours of operation or 3 months, and every
100 hours or at 1-year intervals thereafter.
Recommended engine oil:

YAMALUBE 4 or 4-stroke outboard motor
oil with combination of the following SAE
and API oil classifications:
API: SE, SF, SG, SH, SJ, SL
SAE: 5W-30, 10W-30, 10W-40
Replacement engine oil quantity:
Without oil filter replacement:
4.3 L (4.55 US qt, 3.78 lmp qt)

position.
4
5
6
7
8
9
10

correct.
8. Leave the outboard motor off for 510

minutes.
10-10

minutes.

minutes.
3
2

5. Remove the oil filler cap 1.
1
A. X-transom model
B. L-transom model
8. Install a new gasket 1 and the drain bolt

2, and then tighten the drain bolt 2 to
6. Place a drain pan 1 under the engine oil

drain hole.
7. Remove the drain bolt 2 and gasket 3
and let the oil drain completely.
1
B
1
2
A. X-transom model
B. L-transom model
10-11

14. Start the engine and check that the oil
pressure alert indicator does not come
on. Also, check that there is no oil leakage.
Drain bolt 2:
27 Nm (2.7 kgfm, 19.9 ftlb)
Apron screw 3:
the oil filler hole. Install the oil filler cap.
If the oil pressure alert indicator comes

on or if there is oil leakage, stop the
engine and find the cause. Continued
operation with a problem could cause
severe engine damage.
Do not overfill the engine with engine oil.

Otherwise, the engine could be damaged
or oil could leak. If the engine oil is above
the upper level, extract the excess engine
oil until the oil is at the proper level.
Checking the engine oil level

1. Check the oil level. See Checking the
engine oil level (10-5).

SAE: 5W-30, 10W-30, 10W-40
Without oil filter replacement:
4.3 L (4.55 US qt, 3.78 lmp qt)
0
1
2
3
Replacing the oil filter

1. Extract the engine oil. See steps 16 in
changer (10-9) or steps 18 in Changing the engine oil by removing the drain
bolt (10-10).
2. Place a rag under the oil filter, and then
remove the oil filter.
10. Leave the outboard motor off for 510

minutes.
4
5
6
TIP:
Make sure to clean up any oil spills.

clean.

again.

and the lower mark b.
8
9
3. Install a new oil filter 1, and then tighten

it to the specified torque.
10
A
10-12
Checking the fuel filter

1. Check the fuel filter. See Checking the
fuel filter assembly (6-10), Checking the
fuel filter element (6-11), and Checking
the fuel cup assembly (6-11).
Checking the fuel pump

1. Check the fuel pump. See Checking the
low-pressure fuel pump and high-pressure fuel pump (5-27).
1
Oil filter 1:
18 Nm (1.8 kgfm, 13.3 ftlb)
Checking for fuel/engine oil leakage

1. Check the fuel joint and fuel hose connections. See Fuel hose (6-1).

the oil filler hole.
2. Check for oil leakage.

SAE: 5W-30, 10W-30, 10W-40
With oil filter replacement:
4.5 L (4.76 US qt, 3.96 lmp qt)
Changing the gear oil
Never get under the lower unit while it is

tilted.
1. Tilt the outboard motor so that the drain
screw is at the lowest point.
2. Place a drain pan 1 under the gear oil
drain hole.
5. Install the oil filler cap and dipstick, and

then start the engine and warm it up for
510 minutes.
3. Remove the drain screw 2 and gasket

3.
6. Stop the engine, and then leave if off for

510 minutes.
7. Check the oil level.
If there is a significant amount of metal

particles on the magnetic drain screw, the
lower unit may have a problem.
Checking the exhaust guide/exhaust

manifold
1. Check the exhaust guide and exhaust
manifold. See Checking the oil pan and
exhaust manifold (9-21).
4. Remove the oil level plug 4 and gasket

5 and let the oil drain completely.

switch
After the gear oil has been drained, check

the used oil. If the oil is milky, water is getting into the lower case, which can cause
gear damage.
1. Check the engine start switch and engine

shut-off switch. See Checking the main
switch/stop switch (10-5).
10-13
TIP:
5
Before installing the magnetic drain screw,

make sure to remove all metal particles.
4
9. Tighten the oil level plug 3 and drain
0
1
3
1

position.
2
3
6. Insert the gear oil pump into the drain

hole, and then fill the lower unit slowly
with gear oil until oil flows out of the
check hole and no air bubbles are visible.
Drain screw 2:
Oil level plug 3:
7. Install a new gasket 1 and the oil level

plug 2.
Checking the gear oil level
1. Check the gear oil level. See Checking

the gear oil level (10-6).
Replacing the OCV filter

1. Remove the OCV assembly. See step 2
in Removing the cylinder head (7-55).
2. Replace the OCV gasket/filter 1.
6
7
8
Recommended gear oil:

Hypoid gear oil
API: GL-4
SAE: 90
Oil quantity:
0.980 L (1.036 US qt, 0.862 lmp qt)
3. Install the OCV assembly. See step 8 in

Installing the cylinder head (7-62)
9
10
Greasing points
8. Remove the gear oil pump, and then

install a new gasket 1 and the drain
screw 2.
1. Apply water resistant grease to the specified lubrication points.
A
10-14
TIP:
Make sure to set the gear shift to the R position before injecting grease into the grease
nipple on the shift rod.
2. Apply corrosion resistant grease to the

specified lubrication point.
10-15
Before removing the reservoir cap, make

sure that the PTT ram is fully extended.
Otherwise, fluid could be expelled forcefully from the unit due to internal pressure.
TIP:
If the fluid is at the proper level, a small
amount of fluid should flow out of the filler
hole when the reservoir cap is removed.
Checking the PCV

1. Check the PCV. See Checking the PCV
(7-68).
Checking the propeller/propeller nut/

cotter pin
2
3
1. Check the propeller. See Checking the

propeller (8-3).
2. Check the propeller nut and cotter pin.

See Installing the lower unit (8-26).
1
2
Checking the PTT fluid level
3. If the fluid is below the proper level, add

the recommended fluid.
Never get under the outboard motor while

it is tilted.
4. Install a new O-ring and the reservoir

cap, and then tighten the reservoir cap to
1. Fully tilt the outboard motor up, and then

Reservoir cap:
2.5 Nm (0.25 kgfm, 1.84 ftlb)
7
8
1. Fully tilt the outboard motor up and down

a few times and check that it tilts up and
down smoothly. Check the PTT fluid level
if the tilt operation is not smooth.
Make sure that the PTT motor makes a winding sound when it is operating smoothly.
2. Fully tilt the outboard motor up, and then
Check that the tilt stop lever locks in
place properly.
10-16
Checking the power trim and tilt unit

operation
TIP:
2. Remove the reservoir cap 1 and O-ring

2, and then check the fluid level in the
reservoir.
10
3. Check the PTT unit for fluid leakage.
2. Loosen the nut 1.
Adjusting the shift link/shift cable
3. Move the stopper 2 up or down slightly

to adjust its position.
1. Disconnect the shift cable, and then

adjust it. See Installing the shift cable
(3-10).
TIP:
To loosen the fitting, move the stopper in
direction a.
To tighten the fitting, move the stopper in
direction b.
Checking the spark plug

1. Check the spark plugs. See Checking
the spark plug (7-35).
Checking the timing belt
1. Check the timing belt. See Checking the

timing belt (7-22).
Replacing the timing belt

1. Replace the timing belt. See Timing belt
(7-21).
b
2
Checking the thermostat

1. Check the thermostat. See Checking the
thermostat (7-68).
4. Tighten the nut.
Adjusting the throttle link/throttle

cable
5. Recheck the fitting. Replace the cowling

seal if looseness or rattling still exists.
1. Install the throttle cable. See Installing

the throttle cable (3-11).
Checking the valve clearance

1. Check the valve clearance. See Checking the valve clearance (7-2).
Checking the cowling lock lever

1. Check the fitting by pushing the top cowling. Adjust if there is looseness or rattling.
Checking the impeller/water pump

housing
1. Check the water pump housing and
impeller. See Checking the water pump
and shift rod (8-8).
10-17
Index
i
Index
A.
Battery requirement .................................... 1-5

Battery wiring with house battery.............. 3-28
Battery wiring without house battery......... 3-25
Bleeding the PTT unit ............................... 9-51
Bottom cowling ................................ 5-12, 9-10
Bracket unit........................................ 1-5, 1-20
Bracket unit technical data ....................... 1-14
Break-in .................................................... 10-8
Abbreviation ................................................0-5
Additional features ....................................2-10
thickness (T1) .........................................8-38
thickness (T2) .........................................8-69
thickness (T1) .........................................8-67
thickness (T2) .........................................8-39
Adjusting the shift link/shift cable ............10-17
Adjusting the throttle link/throttle
cable .....................................................10-17
Adjusting the trim sensor cam...................9-46
Adjusting the valve clearance .....................7-4
After test run .............................................10-8
Assembling the cylinder block...................7-99
Assembling the cylinder head ...................7-61
Assembling the drive shaft
housing ..........................................8-20, 8-57
Assembling the forward gear ....................8-20
Assembling the fuel filter assembly...........6-11
Assembling the gear pump assembly .......9-64
Assembling the lower case ..............8-21, 8-56
Assembling the oil pan and
exhaust manifold............................9-21, 9-36
Assembling the oil pump...........................7-80
assembly.................................................8-14
Assembling the propeller shaft housing
assembly.................................................8-14
Assembling the propeller shaft housing
assembly and forward gear.....................8-50
Assembling the PTT motor .......................9-58
Assembling the reverse gear ....................8-56
Assembling the shift bracket .......................9-3
Assembling the starter motor ....................5-48
Assembling the tilt ram..............................9-70
Assembling the trim ram ...........................9-71
Assembling the upper case..............9-17, 9-32
Assembling the vapor separator ...............6-42
Assembling the water pump housing ..........8-9
Assembling the water pump
housing ...................................................8-46
C.
Camshaft .................................................. 7-42
Canister .................................................... 6-17
Changing the engine oil by removing the drain
bolt........................................................ 10-10
changer................................................... 10-9
Changing the gear oil ............................. 10-13
Charging unit and component .................. 5-29
Charging unit, starting unit, and
PTT unit ....................................................A-6
Checking for fuel/engine oil leakage....... 10-13
Checking the absorber valve .................... 9-70
Checking the anode.................................. 10-8
Checking the APS ........................... 5-22, 6-35
Checking the armature (PTT motor)......... 9-57
Checking the armature (starter motor) ..... 5-47
Checking the battery........................ 10-4, 10-8
Checking the big end oil clearance........... 7-91
Checking the brush................................... 9-57
Checking the brush holder........................ 5-47
Checking the button cell battery ............... 5-41
Checking the buzzer................................. 5-40
Checking the cam position sensor............ 5-23
Checking the camshaft ............................. 7-46
Checking the camshaft journal oil
clearance ................................................ 7-46
Checking the canister ............................... 6-18
Checking the canister check valve ........... 6-34
Checking the check valve ......................... 6-41
Checking the clamp bracket anode .......... 9-44
Checking the compression pressure .......... 7-1
Checking the connecting rod big end side
clearance ................................................ 7-90
Checking the connecting rod small end inside
diameter and big end inside diameter .... 7-90
Checking the cooling water inlet ............... 10-8
Checking the cooling water pilot
hole................................................ 10-5, 10-9
Checking the cowling lock lever ............. 10-17
Checking the crankcase cover anode ...... 7-74
Checking the crankshaft ........................... 7-90
Checking the cylinder block anode ........... 7-81
Checking the cylinder bore ....................... 7-87
B.
Balancer....................................................2-15
Basic components.......................................4-1
Battery cable length ..................................3-43
Battery installation.....................................3-25
Battery removal control ...............................2-7
i-1
0
1
2
3
5
6
7
8
9
10
10
Index
Checking the lower unit
anode............................................... 8-3, 8-43
leakage .......................................... 8-26, 8-58
Checking the low-pressure fuel pump ...... 6-15
Checking the low-pressure fuel pump and
high-pressure fuel pump......................... 5-27
Checking the main relay ........................... 5-20
switch........................................... 10-5, 10-13
Checking the OCV.................................... 5-25
Checking the oil pan and
exhaust manifold ........................... 9-21, 9-36
Checking the oil pressure ........................... 7-1
Checking the oil pressure sensor ............. 5-25
Checking the oil pump .............................. 7-80
Checking the oil strainer .................. 9-21, 9-36
Checking the outboard motor mounting
height...................................................... 10-6
Checking the PCV ......................... 7-68, 10-16
Checking the pinion ......................... 8-19, 8-56
Checking the piston clearance ................. 7-87
Checking the piston diameter ................... 7-87
Checking the piston pin boss inside
diameter.................................................. 7-89
Checking the piston pin diameter ............. 7-89
Checking the piston ring ........................... 7-88
Checking the piston ring end gap ............. 7-88
Checking the piston ring groove ............... 7-88
Checking the piston ring side
clearance ................................................ 7-89
Checking the power trim and tilt unit ........ 10-7
Checking the power trim and
tilt unit operation ................................... 10-16
Checking the pressure regulator ................ 6-7
Checking the primer pump ....................... 6-11
Checking the propeller....................... 8-3, 8-43
Checking the propeller shaft............ 8-13, 8-50
Checking the propeller shaft housing ....... 8-13
housing ................................................... 8-50
Checking the propeller/propeller nut/
cotter pin............................................... 10-16
Checking the PTT fluid level................... 10-16
Checking the PTT relay ............................ 5-51
Checking the PTT switch
(on bottom cowling) ................................ 5-52
Checking the pulser coil ........................... 5-33
Checking the pulser coil air gap ................. 7-1
Checking the Rectifier/Regulator/
Isolator.................................................... 5-30
Checking the reservoir.............................. 9-58
Checking the reverse gear .............. 8-13, 8-56
Checking the shift cut-off switch ............... 5-36
Checking the cylinder head.......................7-56

Checking the cylinder head and cylinder block
anode ......................................................7-61
Checking the cylinder head bolt................7-56
Checking the dog clutch...................8-13, 8-50
Checking the drive shaft ..................8-19, 8-56
Checking the drive shaft bushing.....9-17, 9-32
Checking the electrical component ...........5-19
Checking the engine ECM circuit..............5-21
Checking the engine idle speed/noise ......10-9
Checking the engine oil level .........10-5, 10-12
Checking the engine shut-off switch .........5-37
Checking the engine start switch ..............5-38
Checking the engine temperature
sensor .....................................................5-34
Checking the ETV .....................................6-21
Checking the ETV and TPS ......................5-21
Checking the ETV motor relay ..................5-22
Checking the exhaust cover anode...........7-68
Checking the exhaust guide/
exhaust manifold...................................10-13
Checking the filter ............................9-64, 9-69
Checking the forward gear...............8-19, 8-50
Checking the fuel cup assembly ...............6-11
Checking the fuel filter ............................10-13
Checking the fuel filter assembly ..............6-10
Checking the fuel filter element.................6-11
Checking the fuel injector..........................5-27
Checking the fuel line................................10-6
Checking the fuel pump ..........................10-13
Checking the fuel rail and fuel injector ......6-25
Checking the gear oil level.............10-6, 10-14
Checking the gear pump...........................9-64
Checking the gear pump housing .............9-64
Checking the high-pressure fuel pump .....6-41
Checking the high-pressure fuel pump
relay ........................................................5-28
Checking the hydraulic pressure...............9-48
Checking the ignition coil ..........................5-33
Checking the ignition spark.......................5-32
Checking the impeller/
water pump housing..............................10-17
Checking the intake air pressure
sensor .....................................................5-34
Checking the intake air pressure/temperature
sensor .....................................................6-28
Checking the intake air temperature
sensor .....................................................5-34
Checking the intake manifold....................6-28
Checking the journal oil clearance ............7-95
Checking the knock sensor.......................5-35
Checking the lighting coil
(stator assembly) ....................................5-29
Checking the lower case..................8-20, 8-56
i-2
Index
D.
Checking the shift link/shift cable and

throttle link/throttle cable .........................10-6
Checking the shift position switch .............5-36
Checking the spark plug ................7-35, 10-17
Checking the speed sensor ......................5-50
Checking the sprocket ..............................7-45
Checking the starter motor pinion .............5-46
Checking the starter relay .........................5-37
Checking the steering system...................10-7
Checking the thermo switch......................5-35
Checking the thermostat ................7-68, 10-17
Checking the throttle cable and
shift cable................................................10-7
Checking the tilt cylinder and
trim cylinder.............................................9-69
Checking the tilt limiter..............................5-53
Checking the timing belt.................7-22, 10-17
Checking the trim sensor ..........................5-52
Checking the valve....................................7-57
Checking the valve clearance ..........7-2, 10-17
Checking the valve guide..........................7-57
Checking the valve lifter............................7-45
Checking the valve seat............................7-58
Checking the valve spring.........................7-56
Checking the vapor separator...................6-41
Checking the vapor
shut-off valve..................................5-29, 6-18
Checking the water detection switch.........5-26
Checking the water pressure sensor ........5-50
Checking the water pump and
shift rod ............................................8-8, 8-46
Checking the Y-COP main wire
harness ...................................................5-40
Checking Y-COP.......................................5-40
Clamp bracket.............................................3-6
Clamp bracket and swivel bracket ............9-41
Connecting the communication cable .........4-7
Connecting the speedometer hose
(conventional gauge) ..............................3-18
Control unit................................................. A-7
Cooling diagram........................................2-23
Cooling system .........................................2-23
Cooling water hose .....................................6-4
Crankcase.................................................7-84
Crankcase assembly.................................1-11
Crankshaft journal bearing selection
table ........................................................7-98
Crankshaft pin bearing selection table......7-94
Crate handling.............................................3-2
Crate top cover pictograph description .......3-2
Cylinder block ...........................................7-76
Cylinder head............................................7-52
Cylinder head assembly............................1-10
Deactivating the tilt limiter......................... 3-22

Digital Network Gauge sensor .................. 5-50
Dimension and weight ................................ 1-4
Disassembling the cylinder block ............. 7-86
Disassembling the cylinder head .............. 7-55
housing .......................................... 8-18, 8-55
Disassembling the forward gear ...... 8-18, 8-50
Disassembling the gear pump
assembly ................................................ 9-63
Disassembling the lower case ......... 8-19, 8-55
Disassembling the oil pan and exhaust
manifold ......................................... 9-21, 9-36
Disassembling the oil pump...................... 7-79
assembly ................................................ 8-12
Disassembling the propeller shaft housing
assembly ....................................... 8-13, 8-49
Disassembling the PTT motor .................. 9-56
Disassembling the reverse gear ............... 8-55
Disassembling the shift bracket.................. 9-3
Disassembling the starter motor ............... 5-45
Disassembling the tilt ram ........................ 9-69
Disassembling the upper case ........ 9-17, 9-32
Disassembling the vapor separator .......... 6-40
housing ............................................ 8-8, 8-46
Disassembly and assembly ........................ 0-3
Disconnecting the quick connector............. 6-6
Draining the fuel ....................................... 6-14
Drive shaft and lower case (counter rotation
model)..................................................... 8-53
Drive shaft and lower case (regular rotation
model)..................................................... 8-16
E.
ECM circuit diagram ................................. 5-14
ECM coupler layout .................................. 5-17
Electric shock ............................................. 0-1
Electrical component and wire harness
routing....................................................... 5-1
Electrical system....................................... 1-15
Electrical system technical data ................. 1-6
Electronic control system............................ 2-1
Engine control unit......................................A-4
Engine control unit and component .......... 5-20
Engine ECM ............................................. 7-29
Engine ECM components........................... 2-3
ETV........................................................... 6-20
Exhaust cover........................................... 7-64
i-3
0
1
2
3
5
6
7
8
9
10
10
Index
Installing the clamp bracket ...................... 9-45
Installing the conventional gauge
harness................................................... 3-12
Installing the cowling lock lever .................. 9-9
Installing the crankcase cover .................. 7-74
Installing the cylinder head ....................... 7-62
Installing the Digital Network Gauge
harness................................................... 3-12
Installing the drive shaft................... 8-22, 8-57
Installing the ETV ..................................... 6-21
Installing the exhaust cover ...................... 7-68
Installing the filter...................................... 9-69
Installing the flushing hose ......................... 9-8
Installing the flywheel magneto ................ 7-19
Installing the forward gear ........................ 8-22
Installing the fuel filter assembly............... 6-11
Installing the fuel injector .......................... 6-25
Installing the intake manifold .................... 6-29
Installing the isolator lead ......................... 3-13
Installing the lower unit .................... 8-26, 8-58
Installing the low-pressure fuel pump ....... 6-15
Installing the main wire harness ............... 3-12
Installing the oil filter bracket .................... 7-82
Installing the oil pump assembly............... 7-81
Installing the outboard motor ...................... 3-7
Installing the power unit............................ 7-13
assembly ....................................... 8-23, 8-57
Installing the PTT motor ........................... 9-59
Installing the PTT switch............................. 9-9
Installing the PTT unit............................... 9-52
Installing the Rectifier/Regulator/
Isolator.................................................... 7-32
Installing the reservoir .............................. 9-59
Installing the reverse gear ........................ 8-57
Installing the rigging grommet .................. 3-13
Installing the shift cable ............................ 3-10
Installing the shift rod....................... 8-24, 8-57
Installing the speed sensor (Digital Network
Gauge).................................................... 3-15
Installing the starter motor ............... 5-50, 7-27
Installing the steering arm ............... 9-24, 9-39
Installing the throttle cable........................ 3-11
Installing the tilt limiter .............................. 3-18
Installing the tilt ram.................................. 9-72
Installing the timing belt ............................ 7-22
Installing the trim ram ............................... 9-71
Installing the upper case.................. 9-13, 9-28
Installing the vapor separator ................... 6-35
Installing the vapor shut-off valve and
canister ................................................... 6-19
Installing the water pressure sensor (Digital
Network Gauge) ..................................... 3-14
Installing the water pump................. 8-24, 8-58
Extension length recommendation for battery

cable .......................................................3-43
External dimensions....................................3-5
F.
Fail-safe control ..........................................2-8
Flywheel and crankshaft ...........................2-16
Flywheel magneto.....................................7-17
Forward gear shim (T1) selection chart (regular
rotation model) ......................................... A-9
Forward gear shim (T2) selection chart
(counter rotation model)......................... A-11
Front............................................................5-9
Fuel and oil requirement .............................1-5
Fuel control unit and component...............5-26
Fuel diagram .............................................2-19
Fuel filter .....................................................6-9
Fuel hose ....................................................6-1
Fuel injector ..............................................6-23
Fuel system....................... 1-9, 1-15, 2-18, 6-6
Fuel system technical data .........................1-9
Fuel unit and ignition unit ........................... A-5
Function ......................................................4-2
Fuse box ...................................................7-30
Fuse holder .................................................5-7
G.
General feature ...........................................1-1
General periodic maintenance ..................10-8
General tightening torque .........................1-22
Greasing points.......................................10-14
H.
Handling of gas torch ..................................0-2
Handling of gasoline ...................................0-1
Handling of sealant .....................................0-3
High-pressure fuel pump control...............2-18
Hose routing................................................6-1
Hot part .......................................................0-1
How to use the wiring diagram................... A-1
How to use this manual...............................0-4
I.
Ignition coil and spark plug .......................7-34
Ignition unit and component......................5-32
Important reminder on rigging.....................3-1
Installing the APS......................................6-35
Installing the balancer assembly...............7-81
Installing the battery cable ..........................3-9
Installing the camshaft and driven
sprocket ..................................................7-48
i-4
Index
Oil pan and exhaust manifold (L-transom
model)..................................................... 9-19
Oil pan and exhaust manifold (X-transom
model)..................................................... 9-34
Optional equipment .................................. 3-13
Outboard motor mounting........................... 3-7
Outboard motor mounting height................ 3-9
Outboard motor mounting instructions ....... 3-1
Outboard motor troubleshooting ................. 4-8
Outline ...................................................... 10-1
Over-revolution control ............................... 2-6
Overview................................................... 2-12
Installing the water temperature sensor

Installing the wire harness ........................7-39
Installing Y-COP .......................................3-23
Intake and exhaust diagram......................2-25
Intake and exhaust system .......................2-25
Intake manifold..........................................6-27
K.
Knock control ..............................................2-6
L.
P.
Lower unit ..........................................1-4, 2-17

Lower unit
(counter rotation model).................1-19, 8-41
Lower unit (regular rotation model) ....1-19, 8-1
Lower unit technical data ..........................1-13
Low-pressure fuel pump ...........................6-13
Low-pressure fuel pump control................2-19
Lubricant, sealant, and thread locking
agent .........................................................0-6
Lubrication diagram ..................................2-21
Lubrication system ....................................2-21
Part, lubricant, and sealant......................... 0-2

Performance ............................................... 1-4
Pinion shim (T3) selection table .................A-8
Port ............................................................. 5-1
Power unit.................................1-4, 1-10, 1-16
Power unit (check and adjustment) ............ 7-1
Power unit assembly (L-transom model) .... 7-6
Power unit assembly (X-transom model).... 7-8
Power unit system .................................... 2-12
Power unit technical data ......................... 1-10
Predelivery check ..................................... 10-4
Pressure regulator hose, vapor gas hose, and
blowby hose.............................................. 6-2
Propeller ..................................................... 0-1
Propeller selection .................................... 3-45
(counter rotation model) ......................... 8-47
(regular rotation model) .......................... 8-10
Propeller shaft shim (T4) selection
table........................................................A-10
Propeller size............................................ 3-45
propeller) ....................................8-3, 8-4, 8-43
PTT cylinder ............................................. 9-66
PTT fluid requirement ................................. 1-5
PTT gear pump......................................... 9-61
PTT motor................................................. 9-54
PTT switch and cowling lock lever.............. 9-6
PTT system .............................................. 5-51
PTT unit ........................................... 1-21, 9-47
M.
Maintenance interval chart 1.....................10-1
Maintenance interval chart 2.....................10-3
Manual format .............................................0-4
Measuring the forward and
reverse gear backlash
before disassembly .................................8-62
Measuring the forward gear
backlash.........................................8-37, 8-69
reverse gear backlash before
disassembly ............................................8-31
Measuring the fuel pressure .......................6-6
Measuring the peak voltage......................5-19
Measuring the reverse gear
backlash.........................................8-39, 8-67
Model data ..................................................1-4
Model features ............................................1-1
Model name designation.............................1-2
R.
N.
Rear............................................................ 5-8
Rectifier/Regulator/Isolator ................ 2-6, 7-31
Reducing the fuel pressure......................... 6-6
Refacing the valve seat ............................ 7-59
Registering the remote control receiver ID to
the ECM.................................................. 3-23
Removing the APS ................................... 6-34
Non-reusable part .......................................0-3
O.
Offset cylinder ...........................................2-14
Oil cooler..........................................2-16, 7-71
i-5
0
1
2
3
5
6
7
8
9
10
10
Index
Rigging grommet mounting ........................ 3-9
Rigging information................................... 1-15
Rigging recommendation.......................... 3-43
Rotating part ............................................... 0-1
Removing the balancer assembly.............7-79

Removing the canister and vapor
shut-off valve...........................................6-18
Removing the clamp bracket ....................9-44
Removing the cowling lock lever.................9-8
Removing the crankcase cover.................7-74
Removing the cylinder head .....................7-55
Removing the drive shaft .................8-18, 8-55
Removing the driven sprocket and
camshaft .................................................7-44
Removing the ETV....................................6-21
Removing the exhaust cover ....................7-67
Removing the filter ....................................9-68
Removing the flushing hose........................9-8
Removing the flywheel magneto...............7-18
Removing the forward gear.......................8-18
Removing the fuel filter assembly .............6-10
Removing the fuel injector ........................6-24
Removing the fuel injector and vapor shut-off
valve........................................................6-18
Removing the intake manifold...................6-28
Removing the lower unit ....................8-3, 8-43
Removing the low-pressure fuel pump .....6-14
Removing the oil filter bracket...................7-79
Removing the oil pump assembly .............7-79
Removing the power unit ..........................7-10
Removing the propeller shaft housing
assembly........................................8-12, 8-49
Removing the PTT motor..........................9-56
Removing the PTT switch ...........................9-8
Removing the PTT unit .............................9-48
Removing the Rectifier/Regulator/
Isolator ....................................................7-32
Removing the reservoir.............................9-56
Removing the reverse gear.......................8-55
Removing the shift rod and shift bracket.....9-3
Removing the starter motor .............5-45, 7-27
Removing the steering arm..............9-24, 9-39
Removing the tilt ram and trim ram...........9-68
Removing the timing belt ..........................7-22
Removing the upper case ................9-13, 9-28
Removing the water pump and
shift rod ............................................8-8, 8-46
Removing the wire harness ......................7-38
Replacing the OCV filter .........................10-14
Replacing the oil filter..............................10-12
Replacing the timing belt.........................10-17
Replacing the valve guide.........................7-58
Reverse gear shim (T1) selection chart
(counter rotation model)......................... A-11
Reverse gear shim (T2) selection chart (regular
rotation model) ......................................... A-9
Reverse rotation control..............................2-7
Rigging grommet description ......................3-9
S.
Safety while working................................... 0-1
Assembling the propeller (Shift Damper
System............................................. 8-4, 8-43
Disassembling the propeller (Shift Damper
System............................................. 8-3, 8-43
Selecting the crankshaft journal
bearing.................................................... 7-96
Selecting the crankshaft pin bearing ........ 7-92
Selecting the pinion shim (T3) ......... 8-35, 8-66
Selecting the propeller shaft
shim (T4) ................................................ 8-66
Selection................................................... 3-45
Self-protection ............................................ 0-2
Serial number ............................................. 1-3
Setting the tilt limiter ................................. 3-21
Shift Dampener System (SDS) ................. 2-18
Shift rod and shift bracket........................... 9-1
Shift-cut control........................................... 2-7
Shim location ................................... 8-34, 8-65
Shim selection table and chart (counter rotation
model).....................................................A-10
Shim selection table and chart (regular rotation
model).......................................................A-8
Shimless valve lifter .................................. 2-13
Shimming (counter rotation model) .......... 8-59
Shimming (regular rotation model) ........... 8-28
Shimming check sheet .................... 8-29, 8-60
Shimming procedure ....................... 8-34, 8-65
Shimming workflow.......................... 8-28, 8-59
Single engine application (Digital Network
Gauge).................................................... 3-33
Single outboard motor application
(conventional gauge) .............................. 3-35
Special service tool.............................. 0-3, 0-8
Specified tightening torque ....................... 1-15
Starboard.................................................... 5-4
Starter motor.................................... 5-43, 7-25
Starting unit and component..................... 5-37
Steering arm (L-transom model)............... 9-23
Steering arm (X-transom model) .............. 9-38
Symbol........................................................ 0-6
System diagram........................................ 3-33
T.
Test run .................................................... 10-7
Tightening torque........................................ 0-3
Tilt limiter (Optional) ................................. 2-11
i-6
Index
Timing belt ................................................7-21
Top............................................................5-10
Trouble code and checking step ...............4-10
Troubleshooting procedure .........................4-8
Troubleshooting the lower unit..................4-21
Troubleshooting the power unit (trouble code
not detected) ...........................................4-15
Troubleshooting the power unit using
the YDIS....................................................4-8
Troubleshooting the PTT unit....................4-20
Twin engine application
Twin engine application (Digital Network
Gauge) ....................................................3-37
0
1
2
U.
Uncrating.....................................................3-3
Uncrating procedure ...................................3-3
Upper case (L-transom model) .................9-15
Upper case (X-transom model).................9-30
Upper case and mounts
(L-transom model)...................................9-11
Upper case and mounts
(X-transom model) ..................................9-26
Using the digital tester ..............................5-19
Using the YDIS .........................................5-19
5
6
V.
Vapor separator and APS .........................6-31

Vapor separator and high-pressure fuel
pump .......................................................6-38
VCT Control ................................................2-5
Ventilation ...................................................0-1
W.
Warning control...........................................2-7
Water detection warning .............................2-8
Water pump and shift rod (counter rotation
model) .....................................................8-44
Water pump and shift rod (regular rotation
model) .......................................................8-6
Wire harness.............................................7-36
Wiring diagram........................................... A-1
Working with crane .....................................0-2
10
10
Y.
optional for Oceanian market).................2-10
optional for other markets) .............3-23, 5-39
YDIS............................................................4-1
A
i-7
Appendix
Wiring diagram ..................................................................A-1
How to use the wiring diagram .................................................. A-1
Engine control unit ..................................................................... A-4
Fuel unit and ignition unit .......................................................... A-5
Charging unit, starting unit, and PTT unit .................................. A-6
Control unit ................................................................................ A-7
Shim selection table and chart

(regular rotation model) ....................................................A-8
Pinion shim (T3) selection table ................................................ A-8
(regular rotation model) ............................................................. A-9
(regular rotation model) ............................................................. A-9
Shim selection table and chart

(counter rotation model) .................................................A-10
Pinion shim (T3) selection table .............................................. A-10
Propeller shaft shim (T4) selection table ................................. A-10
(counter rotation model) .......................................................... A-11
(counter rotation model) .......................................................... A-11
0
1
2
3
4
5
6
7
8
9
10
Wiring diagram
How to use the wiring diagram
Composition of the wiring diagrams
The wiring diagram consists of four categories. Engine control unit, Fuel unit and ignition unit, charging unit, starting unit, and PTT unit, control unit.
Legend symbols in the wiring diagrams
1
BZ
6
1. Double colors wire

2. Not used (vacant)
3. A wire is not included in the selected wiring unit.
4. Alert buzzer
5. Optional parts
6. Continuity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Terminal numbers
Terminal numbers are indicated for cases
where terminal locations of wires are
unclear.
In the coupler illustrations, only the rightmost and leftmost terminal numbers are
indicated, and terminal numbers between
them are omitted.
4
8
12
16
1
5
9
13
A-1
Color Code
B
Br
G
L
Lg
Or
P
Pu
R
Sb
W
Y
B/G
B/Or
B/W
B/Y
G/B
G/R
G/W
L/B
L/G
L/W
L/Y
P/B
P/G
P/W
Pu/B
Pu/G
Pu/R
Pu/Y
R/G
R/L
R/G
R/Y
W/B
W/G
W/L
W/R
Y/G
: Black
: Brown
: Green
: Blue
: Light green
: Orange
: Pink
: Purple
: Red
: Sky blue
: White
: Yellow
: Black/Green
: Black/Orange
: Black/White
: Black/Yellow
: Green/Black
: Green/Red
: Green/White
: Blue/Black
Example:
R/Y: Red with Yellow tracer stripe wire
: Blue/Green
: Blue/White
: Blue/Yellow
: Pink/Black
: Pink/Green
: Pink/White
: Purple/Black
: Purple/Green
: Purple/Red
: Purple/Yellow
: Red/Green
: Red/Blue
: Red/Green
: Red/Yellow
: White/Black
: White/Green
: White/Blue
: White/Red
: Yellow/Green
0
1
2
3
4
5
6
7
8
9
10
A
A-2
MEMO
A-3
May 2013 ABE

(E_1)
Engine control unit
A
B
61 69 77 86
R/G
W
P
B
Y/G
B
Or
Or
14. Battery
G/B
R/Y
Sb
Lg
10
11
12
17
22
12 24
R/G
Br
R/G
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
11
10
23
G/R
1 13
15
B
W/B
6
14
12. Joint connector 2

1
1
7
1 13
G
B
Or
B
28
R/Y
P
15. Starter motor
P/W
3
4
5
6
Br
R/Y
Y/G
R/Y
R/Y
Br
R/Y
R/Y
Y/G
Or
Y/G
B
73
P/B
Or
Or
83
84
85
*1
P
P/W
Y/G
68
69
70
71
76
77
78
79
80
G
R
Y
Lg
P
Sb
W
Br
B
*1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
60
61
62
63
64
65
*1
Y/G
Br
53 62 70 78
R/G
16. Fuse box

53
54
55
56
57
58
*1
L/B
9
10
11
12
13
14
15
20
B
B
27 34 40 46
12 24
36
39
41
33 39 45 52
45
46
47
48
49
Or
Or
W/G
P/W
B
R/Y
R/Y
B
9
16
17
R/Y
R/Y
1 8 14 20
R/Y
R/Y
10
11
12
12
B
B
B
B
B
B
2
3
4
5
1 13
10
11
12
7 13 19 26
B
P/B
P
P/B
P/W
*3
B
W/B
R/Y
*2
L/B
B
O
L
B
O
P/W
B
O
R/Y
W/L
B
R/Y
W/G
B
P
O
B
R/Y
Pu
P/B
O
B
P/W
P/B
P/B
16
17
18
20
21
23
24
12 24
2. TPS
3. APS
4. OCV
5. Cam position
sensor (IN)
6. Cam position
sensor (EX)
7. Oil pressure
sensor
8. Speed sensor
A-4
9. Water pressure
sensor
B
Pu
L
W
23
24
25
A. To remote control
B. To multi-hub
C. To YDIS
D. To conventional gauge
Br
R/Y
P/W
11
a. Fuse (30 A) (starter relay)

b. Fuse (15 A) (high-pressure fuel pump)
c. Fuse (10 A) (ETV)
d. Fuse (30 A) (ignition coil, VCT, fuel injector, engine ECM)
e. Fuse (10 A) (low-pressure fuel pump)
f. Fuse (20 A) (engine start switch, PTT
switch)
g. Fuse (60 A) (engine battery)
h. Fuse (60 A) (isolator)
k. Starter relay
m. Fuel pump relay (high-pressure)
n. ETV motor relay
p. Main relay
r. Condenser
P/W
O
P
B
G/B
G/R
1. Engine ECM
24
52
1
2
W/L
1. Engine ECM
2. TPS
3. APS
4. OCV
8. Speed sensor
9. Water pressure sensor
14. Battery
15. Starter motor
16. Fuse box
*1. Not used (vacant)

*2. Standard for European and Caribbean
markets and optional for other markets.
*3. Standard for Caribbean market and
optional for other markets.
Fuel unit and ignition unit
20. Starter motor
*1
*1
Or
Or
1 13
P
Y/G
*1
Br
19. Battery
Br
63
g
L/G
21
22
23
12
R/Y
R/G
R/Y
Br
R/G
17
18
19
Y/G
R/Y
R/Y
Br
R/Y
R/Y
Y/G
10
11
73
Y/G
B
1
11
10
23
12 24
L/W
1
2
65
66
67
Y/G
Br
53 62 70 78
Sb
57
58
59
R/G
R/G
53
54
21. Fuse box
*1
1
2
7
8
1 13
61 69 77 86
78
79
80
B
Y/G
83
6
14
1
7
86
P/G
27
L/Y
27 34 40 46
33
35
42
W/R
12
21
B
23
B
24
B/Y
B/Y
R/Y
R/Y
51
52
1
2
R/Y
4
5
7
8
Pu/G
R/Y
R/Y
R/Y
2
3
4
5
6
7
8
9
10
B
R/Y
16. Joint connector 3 12
Pu/B
B
Pu/Y
Br
2. Fuel injector
3. Ignition coil
B
L/Y
9. Intake air pressure/

temperature sensor
A-5
12. Thermo switch
14. Pulser coil
6. Low-pressure
fuel pump
4. Vapor
shut-off
valve
10. Shift cut-off

switch
B
W/R
#4
B
B/Y
#3
#4
B
P
#2
#2
#3
7. Knock sensor
#1
#1
B
L/G
L/W
B
B
B
B
B
1
2
3
4
1 13
6
7
8
9
10
11
12
B
R/Y
P/G
B
Or
B/Y
G
L/W
R/Y
B/W
B
L/W
B/G
R/Y
G/B
B/O
R/Y
B
B/G
G/B
R/Y
B
B/W
B/Y
R/Y
B
B/Y
Pu/R
26
R/Y
R/Y
B
B/O
20
21
22
23
24
R/Y
Pu/G
R/Y
7 13 19 26
R/Y
11
14
15
16
17
18
R/Y
Pu/Y
R/Y
1 8 14 20
Or
Pu/B
R/Y
1. Engine ECM
48
49
Pu/R
R/Y
33 39 45 52
R/Y
12 24
B
B
20
21
12 24
23
24
1. Engine ECM
2. Fuel injector
3. Ignition coil
7. Knock sensor
12. Thermo switch
14. Pulser coil
19. Battery
20. Starter motor
21. Fuse box

switch)
k. Starter relay
n. ETV motor relay
p. Main relay
Charging unit, starting unit, and PTT unit

1
2
+1
G
G
G
AC1
AC1
AC1
G
G
G
R
AC2
AC2
AC2
+2
11. Lighting coil
*1
53 62 70 78
R/G
57
58
7
R/G
*1
*1
G
G
*1
14. Starter motor
53
54
G
R
Y
Lg
P
Sb
W
Br
B
15. Fuse box
g
63
65
L/G
L/G
L/G
Br
P
Y/G
Sb
Lg
12. Battery
61 69 77 86
82
83
Y/G
L/G
12
6
14
13. House
battery
R/G
Br
R/G
21
22
23
Br
R/Y
R/Y
10
11
4
5
17
Y/G
Y/G
B
78
79
80
R
R
Y/G
1
11
Y/G
Br
10
23
1
2
73
1 13
1
7
G
Sb
29
10. Rectifier/
Regulator/
Isolator
Sb
Sb
Lg
27 34 40 46
17
18
19
Lg
21
22
23
24
Lg
Lg
13
14
12 24
1 13
16
17
18

switch)
k. Starter relay
n. ETV motor relay
p. Main relay
r. Condenser
A. To remote control
33 39 45 52
49
1
2
Sb
Sb
52
B
R/Y
12 24
R/Y
1 8 14 20
B
11
Sb
R
B
P
*2
*3
7 13 19 26
Sb
2. PTT switch
4. Trim sensor
A-6
6. PTT relay
Lg
B
B
3. Tilt limiter
2
3
4
10
11
12
1 13
Lg
5. PTT motor
Sb
23
24
Lg
Sb
16
17
Br
Sb
R
Lg
1. Engine ECM
1. Engine ECM
2. PTT switch
3. Tilt limiter
4. Trim sensor
5. PTT motor
6. PTT relay
11. Lighting coil
12. Battery
13. House battery
14. Starter motor
15. Fuse box
B
B
20
21
22
23
24
12 24

*2. If the outboard motor is not fitted with a tilt
limiter (optional), connect the coupler.
*3. If the Digital Network Gauge (6Y8) is
selected, connect the coupler.
Control unit
14. Switch panel (6R5-82570-06)

W B R
5. OFF
6. ON
7. START
1. 703 side mount remote control
Y
Y
Br
W
B
B
Lg
Lg
Br
Br
BZ
Sb
Lg
R
Br
Br
B
R
Lg
Sb
Br
Br
13. Neutral switch
L
B
Br
Lg
Br
15. 704 binnacle mount remote control

4. PTT switch
Sb R Lg
10. UP
11. Free
12. DN
Y
R
G
B
R
Y
G
W
Y
B
W
P
Br
L
R
G
Sb
Br
B
R
Y
G
W
Sb
P
Lg
L
B
Br
P
Y
BZ
G
B
Y

W B
8. Clip removed
9. Clip installed
Lg
Sb
Sb
4. PTT switch
Sb
10. UP
11. Free
12. DN
W
W

W B
8. Clip removed
9. Clip installed
Br
Br

W B R
5. OFF
6. ON
7. START
Br
13. Neutral switch
R
Y
Y
B
G
Br
Lg
Lg
B
B
R
R
R
Sb
Sb
Br
Br
Br
Br
Sb
Sb
R
B
Lg
Lg
R
B
R
Lg
Sb
Br
Br
Lg
Lg
Y
B
Y
BZ
R
Y
G
W
Y
R
G
W
P
L
B
Br
Lg
Y
R
B
G
Gy
B
Y
Y
L
Y
R
G
W
P
L
B
Br
R
B
25. Relay (left)
R
B
Br
Gy
B
P
Gy
Br
Gy
Y
G
Lg
Lg
Sb
Sb
Sb
Lg
R
Br
Br
B
R
Y
G
W
L
B
Br
BZ
28. Neutral switch (STBD)
L
B
Br
G
B
P
R
Lg
Sb
Br
Br
B
19. Engine start switch (STBD)

W B R Y Br
5. OFF
6. ON
7. START
W
B
Lg
R
R

W B
8. Clip removed
9. Clip installed
Br
Sb
Sb
Lg
Lg
B
B
R
R
R
18. Engine start switch (PORT)

W B R Y Br
5. OFF
6. ON
7. START
Sb
Sb
22. PTT switch (twin)

23. PTT switch (PORT) 24. PTT switch (STBD)
Sb R Lg
Sb R Lg
Sb R Lg
10. UP
10. UP
10. UP
11. Free
11. Free
11. Free
12. DN
12. DN
12. DN
17. Twin switch panel (61B-82570-04)
21. 704 binnacle mount remote control (twin)
27. Neutral switch (PORT)

20. Control unit
26. Relay (right)
A-7
Sb
Lg
R
Br
Br
B
1. 703 side mount remote control

4. PTT switch
5. OFF
6. ON
7. START
8. Clip removed
9. Clip installed
10. UP
11. Free
12. DN
13. Neutral switch
14. Switch panel (6R5-82570-06)
15. 704 binnacle mount remote control
17. Twin switch panel (61B-82570-04)
18. Engine start switch (PORT)
19. Engine start switch (STBD)
20. Control unit
21. 704 binnacle mount remote control (twin)
22. PTT switch (twin)
23. PTT switch (PORT)
24. PTT switch (STBD)
25. Relay (Left)
26. Relay (Right)
27. Neutral switch (PORT)
28. Neutral switch (STBD)
A. To power unit
B. To gauge
C. To power unit (PORT)
D. To power unit (STBD)
E. To switch panel (PORT)
F. To switch panel (STBD)
G. To main wire harness (PORT)
H. To main wire harness (STBD)
Shim selection table and chart (regular rotation model)

Pinion shim (T3) selection table
(mm)
A
13
12
11
10
9
8
7
6
5
4
3
2
1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
0.01
1.32
1.32
1.32
1.30
1.30
1.28
1.28
1.25
1.25
1.25
1.22
1.22
1.22
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
0.02
1.32
1.32
1.30
1.30
1.28
1.28
1.25
1.25
1.25
1.22
1.22
1.22
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
0.03
1.32
1.30
1.30
1.28
1.28
1.25
1.25
1.25
1.22
1.22
1.22
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
0.04
1.30
1.30
1.28
1.28
1.25
1.25
1.25
1.22
1.22
1.22
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
0.05
1.30
1.28
1.28
1.25
1.25
1.25
1.22
1.22
1.22
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
0.06
1.28
1.28
1.25
1.25
1.25
1.22
1.22
1.22
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
0.07
1.28
1.25
1.25
1.25
1.22
1.22
1.22
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
0.08
1.25
1.25
1.25
1.22
1.22
1.22
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
0.09
1.25
1.25
1.22
1.22
1.22
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.10
1.25
1.22
1.22
1.22
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.11
1.22
1.22
1.22
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.12
1.22
1.22
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.13
1.22
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.14
1.20
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.15
1.20
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
13
12
11
10
9
8
7
6
5
4
3
2
1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
0.31
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.32
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.33
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.34
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.35
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.36
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.37
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.38
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.39
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.40
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.41
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.42
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.43
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.44
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.45
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.16
1.18
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.17
1.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.18
1.15
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.19
1.15
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.20
1.15
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.21
1.12
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.22
1.12
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.23
1.12
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.24
1.10
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.25
1.10
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.26
1.08
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.27
1.08
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.28
1.05
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.29
1.05
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.30
1.05
1.02
1.02
1.02
1.00
1.00
0.98
0.98
0.95
0.95
0.95
0.92
0.92
0.92
0.90
0.90
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.46
0.88
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.47
0.88
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.48
0.85
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.60
0.49
0.85
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.60
0.58
0.50
0.85
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.60
0.58
0.58
0.51
0.82
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.60
0.58
0.58
0.55
0.52
0.82
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.60
0.58
0.58
0.55
0.55
0.53
0.82
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.60
0.58
0.58
0.55
0.55
0.55
0.54
0.80
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.60
0.58
0.58
0.55
0.55
0.55
0.52
0.55
0.80
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.60
0.58
0.58
0.55
0.55
0.55
0.52
0.52
0.56
0.78
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.60
0.58
0.58
0.55
0.55
0.55
0.52
0.52
0.52
0.57
0.78
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.60
0.58
0.58
0.55
0.55
0.55
0.52
0.52
0.52
0.50
0.58
0.75
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.60
0.58
0.58
0.55
0.55
0.55
0.52
0.52
0.52
0.50
0.50
0.59
0.75
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.60
0.58
0.58
0.55
0.55
0.55
0.52
0.52
0.52
0.50
0.50
0.48
0.60
0.75
0.72
0.72
0.72
0.70
0.70
0.68
0.68
0.65
0.65
0.62
0.62
0.62
0.60
0.60
0.58
0.58
0.55
0.55
0.55
0.52
0.52
0.52
0.50
0.50
0.48
0.48
A. Pinion height measurement (M)

B. Stamped value on the lower case (P)
A-8
B (mm)
Forward gear shim (T1) selection chart (regular rotation model)

1.10
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0
0.10
0.20
0.30
0.40
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B 0.38 0.34 0.30 0.27 0.23 0.20 0.16 0.12 0.09 0.05 0.02 0.02 0.06 0.09 0.13 0.16 0.20 0.24 0.27 0.31 0.34 0.38 0.42 0.45 0.49 0.52 0.56 0.60 0.63 0.67 0.70 0.74 0.78 0.81 0.85 0.88 0.92 0.96 0.99 1.03 1.06
B (mm)
Reverse gear shim (T2) selection chart (regular rotation model)

0.70
0.60
0.50
0.40
0.30
0.20
0.10
0
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B 0.67 0.63 0.60 0.56 0.53 0.49 0.45 0.42 0.38 0.35 0.31 0.27 0.24 0.20 0.17 0.13 0.09 0.06 0.02 0.01 0.05 0.09 0.12 0.16 0.19 0.23 0.27 0.30 0.34 0.37 0.41 0.45 0.48 0.52 0.55 0.59 0.62 0.66 0.70 0.73 0.77
A-9
Shim selection table and chart (counter rotation model)

Pinion shim (T3) selection table
See Pinion shim (T3) selection table (A-8)
Propeller shaft shim (T4) selection table

The shim thickness does not have to be adjusted for the gray-colored cell.
(mm)
A
B
0.0 0.1 0.2

0.3 0.2 0.1
0.3
0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
+0.1 +0.2 +0.3 +0.4 +0.5 +0.6 +0.7 +0.8 +0.9 +1.0 +1.1 +1.2 +1.3 +1.4 +1.5 +1.6 +1.7 +1.8 +1.9 +2.0 +2.1 +2.2 +2.3 +2.4 +2.5 +2.6
A. Free play measurement

A-10
B (mm)
Forward gear shim (T2) selection chart (counter rotation model)

0.40
0.30
0.20
0.10
0
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B 0.37 0.33 0.30 0.26 0.23 0.19 0.15 0.12 0.08 0.05 0.01 0.03 0.06 0.10 0.13 0.17 0.21 0.24 0.28 0.31 0.35 0.39 0.42 0.46 0.49 0.53 0.57 0.60 0.64 0.67 0.71 0.75 0.78 0.82 0.85 0.89 0.92 0.96 1.00 1.03 1.07
B (mm)
Reverse gear shim (T1) selection chart (counter rotation model)

0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0
0.10
0.20
0.30
0.40
0.50
0.60
0.70
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B 0.68 0.64 0.60 0.57 0.53 0.50 0.46 0.42 0.39 0.35 0.32 0.28 0.24 0.21 0.17 0.14 0.10 0.06 0.03 0.01 0.04 0.08 0.12 0.15 0.19 0.22 0.26 0.30 0.33 0.37 0.40 0.44 0.48 0.51 0.55 0.58 0.62 0.66 0.69 0.73 0.76
A-11

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F200F

Technical feature and description

How to use this manual .................................................... 0-4

Lubricant, sealant, and thread locking agent ................. 0-6

Symbol ...................................................................................... 0-6

Special service tool ........................................................... 0-8

Safety while working

Safety while working

Safety while working

Handling of gas torch

Protect your eyes by wearing safety

Improper handling of a gas torch may result

Working with crane

Part, lubricant, and sealant

Safety while working

Wear protective gloves to protect your skin,

Disassembly and assembly

Special service tool

How to use this manual

How to use this manual

For troubleshooting procedures, see Chapter 4, Troubleshooting.

Lower unit (regular rotation model, X-transom model)

Lower unit (regular rotation model, X-transom model)

43 Nm (4.3 kgfm, 31.7 ftlb)

9 Nm (0.9 kgfm, 6.6 ftlb)

9 Nm (0.9 kgfm, 6.6 ftlb)

48 Nm (4.8 kgfm, 35.4 ftlb)

3. Install a new O-ring 1.

3. While holding the special service tool 1,

If a high-pitched metallic sound is produced

Use heat-resistant gloves. Otherwise,

Except SDS propeller

Do not reuse a shim if deformed or

Bearing outer race attachment 2:

48 Nm (4.8 kgfm, 35.4 ftlb)

When heating the lower case, heat the

Drive shaft and lower case (regular rotation model)

1. Install the original forward gear shims 1.

2. Heat the area of the lower case where

How to use this manual

American Boat and Yacht Council

American Petroleum Institute

Accelerator Position Sensor

Automatic Transmission Fluid

American Wire Gauge

Controller Area Network

Cold Cranking Ampere

Double Overhead Camshaft

Electronic Control Module

European Norm (European standard)

Electronic Throttle Valve

International Electrotechnical Commission

Idle Speed Control

International Organization for Standardization

Oil Control Valve

Pressure Control Valve

Power Trim and Tilt

Research Octane Number

Society of Automotive Engineers

Top Dead Center

Throttle Position Sensor

Variable Camshaft Timing