F200bet Service Manual PDF

F200B
FL200B
F250G
FL250G
SERVICE MANUAL
6DX-28197-5P-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
up-to-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 out-
board motor or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
F200B, FL200B, F250G, FL250G

SERVICE MANUAL
©2011 by Yamaha Motor Co., Ltd.
1st Edition, July 2011
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Contents
GEN
General information INFO 0
Specification SPEC 1
TECH
Technical features and description FEA 2
RIG
Rigging information GING 3
TRBL
Troubleshooting SHTG 4
Electrical system ELEC 5
Fuel system FUEL 6
Power unit POWR 7
Lower unit LOWR 8
Bracket unit BRKT 9
Maintenance MNT 10
Index
Appendix A
GEN
INFO
General information
Safety while working ..................................................... 0-1

Rotating part............................................................................... 0-1 0
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..................................................................... 0-2
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 .................. 0-7

Symbol ....................................................................................... 0-7
Special service tool............................................................ 0-9

GEN
INFO General information
Safety while working Handling of gasoline
To prevent an accident or injury and to pro- • Gasoline is highly flammable. Keep gaso-
vide quality service, observe the following line and all flammable products away from
safety procedures. heat, sparks, and open flames.
• Gasoline is poisonous and can cause injury
Rotating part or death. Handle gasoline with care. Never
• Hands, feet, hair, jewelry, clothing, per- siphon gasoline by mouth. If you swallow
sonal flotation device straps, and so on, some gasoline, inhale a lot of gasoline
can become entangled with internal rotating vapor, or get some gasoline in your eyes,
parts of the engine, resulting in serious see your doctor immediately. If gasoline
injury or death. spills on your skin, wash with soap and
• Keep the top cowling installed whenever water. If gasoline spills on your clothing,
possible. Do not remove or install the top change your clothes.
cowling when the engine is running.
• Only operate the engine with the top cowl-
ing removed according to the specific
instructions in the manual. Keep hands,
feet, hair, jewelry, clothing, personal flota-
tion 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 Ventilation
parts under the top cowling until the engine • Gasoline vapor and exhaust gas are
has cooled. heavier than air and extremely poisonous.
If gasoline vapor or exhaust gas is inhaled
Electric shock in large quantities, it may cause loss of con-
Do not touch any electrical parts while start- sciousness and death within a short time.
ing or operating the engine. Otherwise, shock • When test running an engine indoors (for
or electrocution could result.
example, in a water tank) make sure to do
so where adequate ventilation can be main-
Propeller
tained.
Do not hold the propeller with your hands
when loosening or tightening the propeller
nut.
0-1
Safety while working
Self-protection Handling of gas torch
• Protect your eyes by wearing safety • Improper handling of a gas torch may result
glasses or safety goggles during all opera- in burns. For information on the proper han-
tions involving drilling and grinding, or when
using an air compressor.
dling of the gas torch, see the operation
manual issued by the manufacturer. 0
• Protect your hands and feet by wearing • When using a gas torch, keep it away from
protective gloves and safety shoes when the gasoline and oil, to prevent a fire.
necessary. • Components become hot enough to cause
burns. Do not touch any hot components
directly.
Working with crane

• Outboard motors weighing 18.0 kg (39.7 lb)
and over must be carried by a crane. Part, lubricant, and sealant
• Use the wire ropes of adequate strength, Use only genuine Yamaha parts, lubricants,
and lift up the outboard motor using the and sealants, or those recommended by
three point suspension. Yamaha, when servicing or repairing the out-
• If the outboard motor does not have three board motor.
or more points to be suspended, support it
using additional ropes or the like so that the
outboard motor can be lifted and carried in
a stable manner.
Handling of sealant
• 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.
0-2
GEN
Special service tool Disassembly and assembly
Use the recommended special service tools • Use compressed air to remove dust and dirt
to work safely, and to protect parts from dam- during disassembly.
age. • Apply engine oil to the contact surfaces of
moving parts before assembly.
Tightening torque
• Install bearings so that the bearing identifi-
Follow the tightening torque specifications
cation mark is facing in the direction indi-
provided throughout the manual. When tight-
cated in the installation procedure. In
ening nuts, bolts, and screws, tighten the
addition, make sure to lubricate the bear-
large sizes first, and tighten fasteners starting
ings liberally.
in the center and moving outward.
• Apply a thin coat of water resistant grease
to the lip and periphery of an oil seal before
Non-reusable part
installation.
Always use new gaskets, seals, O-rings, cot-
• Check that moving parts operate normally
ter pins, and so on, when installing or assem-
after assembly.
bling parts.
0-3
Safety while working / How to use this manual
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the following information as a guide for effective and quality service.
0
• 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 fig-
ure), 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:
For troubleshooting procedures, see Chapter 4, “Troubleshooting.”
3
4
1
LOWR
Lower unit
Lower unit (regular rotation model)
È 28
26
27 25
12
29 42 N m (4.2 kgf m, 31.0 ft lb)
25 11
54 N m (5.4 kgf m, 39.8 ft lb) LOWR
Lower unit
33 15
16 2. Heat the installation area of the taper 4. Install the rollers into the needle bearing
32 30 8 10 roller bearing outer race in the lower case outer race, and install the special service
24 9
34 31 13 with a gas torch, and then install the tool into the needle bearing assembly 5,
23 7 8 outer race 2. NOTICE: When heating and then install the needle bearing
35 14 17
18 the lower case, heat the entire assembly 5.
19
47 N m (4.7 kgf m, 34.7 ft lb) installation area evenly. Otherwise,
the paint on the lower case could be
9 N m (0.9 kgf m, 6.6 ft lb) 3 burned.
7 5
20 2
22
6 1
5 22
22
9 N m (0.9 kgf m, 6.6 ft lb) 4
3 21 6
2 1
Ball bearing attachment 6:
90890-06655
2.3 N m (0.23 kgf m, 1.70 ft lb)
47 N m (4.7 kgf m, 34.7 ft lb) Bearing outer race puller assembly 7:
90890-06523
No. Part name Q’ty Remarks
1 Water inlet cover (PORT) 1 TIP:
2 Bolt 1 M5 x 40 mm The needle bearing contains 28 rollers.
3 Gasket 2 Not reusable TIP:
Do not reuse a shim if it is any deformed or
4 Drain screw 1 Assembling the forward gear
5 Water inlet cover (STBD) 1 scratched.
6 Self-locking nut 1
7 Check screw 1 3. While holding the special service tool 3, Do not reuse the bearing, always replace
8 Dowel 2 strike the tool to check that the taper it with a new one.
9 Plate 1 roller bearing outer race is installed
10 Rubber seal 1 properly. If a high-pitched metallic sound 1. Install a new taper roller bearing.
11 Bolt 1 M10 x 45 mm is produced when the special service tool
12 Grommet 1 is struck, the outer race is installed
13 Lower unit 1 properly.
14 Spacer 1
15 Propeller 1 3 1
16 Cotter pin 1 Not reusable 4 3
17 Propeller nut 1
È U-transom model
4
8-1
Bearing inner race attachment 1:
90890-06659
Driver rod LL 3: 90890-06605

Bearing outer race attachment 4:
2 90890-06658
5 8-19
0-4
GEN
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
ABYC American Boat and Yacht Council
AFT Aft end
API American Petroleum Institute
APS Accelerator Position Sensor
ATF Automatic Transmission Fluid
AWG American Wire Gauge
BOW Bow end
BTDC Before Top Dead Center
C/E Check Engine
C/L Centerline
CCA Cold Cranking Ampere
DN Down side
DOHC Dual Over Head Camshaft
ECM Electronic Control Module
EN European Norm (European standard)
ETV Electronic Throttle Valve
EX Exhaust
EXH Exhaust
F Forward
GPS Global Positioning System
IEC International Electro-technical Commission
IN Intake
INT Intake
ISC Idle Speed Control
ISO International Organization for Standardization
LAN Local Area Network
N Neutral
OCV Oil Control Valve
PCV Pressure Control Valve
PORT Port side
PTT Power Trim and Tilt
R Reverse
RON Research Octane Number
SAE Society of Automotive Engineers
STBD Starboard side
SW Switch
TCI Transistor-Controlled Ignition
TDC Top Dead Center
0-5
How to use this manual
Abbreviation Description
TPS Throttle Position Sensor
UP Upside
VCT Variable Camshaft Timing 0
W/F Water in Fuel
YDIS Yamaha Diagnostic System
0-6
GEN
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

Yamaha 4-stroke motor oil Lubricant
Gear oil Lubricant
Water resistant grease Lubricant

(Yamaha grease A)
Molybdenum disulfide grease Lubricant
Corrosion resistant grease Lubricant

(Yamaha grease D)
Low temperature resistant grease Lubricant

(Yamaha grease C)
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.

LOCTITE 518 Sealant
ThreeBond 1280B Sealant
ThreeBond 1303N Thread locking agent
ThreeBond 1322 Thread locking agent
ThreeBond 1377B Thread locking agent
0-7
Lubricant, sealant, and thread locking agent

ThreeBond 1386B Sealant

0
ThreeBond 1530D Sealant
LOCTITE 242 (blue) Thread locking agent
LOCTITE 271 (red) Thread locking agent
LOCTITE 572 (white) Sealant
Silicone sealant Sealant
0-8
GEN
Special service tool
For all markets except U.S.A. and Canada
Special service tools with Yamaha part numbers (90890/60V-*****) are distributed by the Parts Divi-
sion.
Drilling plate Peak voltage adapter

90890-06783 90890-03172
YDIS (CD-ROM, Ver. 1.33) Test harness (3 pins)

60V-WS853-06 90890-06869
YDIS USB adapter and cable Vacuum/pressure pump gauge set

60V-WS850-00 90890-06756
Diagnostic flash indicator B Ignition tester

90890-06865 90890-06754
Digital circuit tester Test harness (2 pins)

90890-03174 90890-06867
0-9
Fuel pressure gauge adapter B Flywheel magnet holder
90890-06942 90890-06522
Fuel pressure gauge Flywheel puller

90890-06786 90890-06521
Leakage tester Sheave holder

90890-06840 90890-01701
Compression gauge Valve spring compressor

90890-03160 90890-04019
Compression gauge extension Valve spring compressor attachment

90890-06563 90890-06320
0-10
GEN
Valve guide remover/installer Valve seat cutter 30° (intake)
90890-06801 90890-06817
Valve guide installer Valve seat cutter 30° (exhaust)

90890-06810 90890-06326
Valve guide reamer Valve seat cutter 45° (intake)

90890-06804 90890-06816
Valve lapper Valve seat cutter 45° (exhaust)

90890-04101 90890-06325
Valve seat cutter holder Valve seat cutter 60° (intake and exhaust)
90890-06316 90890-06324
0-11
Oil filter wrench Needle bearing attachment
90890-06830 90890-06653
Driver rod L3 Shift rod socket

90890-06652 90890-06679
Needle bearing attachment Bearing housing puller claw L

90890-06613 90890-06502
Needle bearing attachment Stopper guide plate

90890-06607 90890-06501
Piston ring compressor Center bolt

90890-05158 90890-06504
0-12
GEN
Slide hammer handle Needle bearing attachment
90890-06531 90890-06611
Bearing outer race puller assembly Driver rod SS

90890-06523 90890-06604
Bearing separator Needle bearing attachment

90890-06534 90890-06610
Stopper guide stand Bearing depth plate

90890-06538 90890-06603
Bearing puller assembly Bearing inner race attachment

90890-06535 90890-06640
0-13
Needle bearing attachment Bearing inner race attachment
90890-06654 90890-06658
Drive shaft holder 6 Bearing inner race attachment

90890-06520 90890-06659
Pinion nut holder Bearing outer race attachment

90890-06715 90890-06628
Ball bearing attachment Driver rod LS

90890-06655 90890-06606
Driver rod LL Backlash indicator

90890-06605 90890-06706
0-14
GEN
Magnet base plate Ring nut wrench
90890-07003 90890-06578
Dial gauge set Ball bearing attachment

90890-01252 90890-06557
Magnet base B PTT oil pressure gauge assembly

90890-06844 90890-06580
Pinion height gauge Cylinder-end screw wrench

90890-06672 90890-06568
Puller head PTT piston vice attachment

90890-06514 90890-06572
0-15
Tilt rod wrench
90890-06569
0-16
SPEC
Specification
Model features .................................................................... 1-1

General feature .......................................................................... 1-1
Model 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................................................................................... 1-5
Bracket unit ................................................................................ 1-5
Fuel and oil requirement............................................................. 1-5
Battery requirement.................................................................... 1-6
PTT fluid requirement................................................................. 1-6
Electrical system technical data ....................................... 1-7

Ignition timing control system ..................................................... 1-7
Fuel injection control system ...................................................... 1-8
Engine speed control system ..................................................... 1-8
VCT system................................................................................ 1-9
PTT system ................................................................................ 1-9
Charging system ...................................................................... 1-10
Starting system......................................................................... 1-10
Gauge/sensor........................................................................... 1-11
Fuel system technical data ............................................. 1-11

Fuel system .............................................................................. 1-11
Power unit technical data ................................................ 1-12

Power unit ................................................................................ 1-12
Cylinder head assembly ........................................................... 1-12
Crankcase assembly ................................................................ 1-13
Lower unit technical data ................................................ 1-15

Lower unit assembly (regular rotation model) .......................... 1-15
Lower unit assembly (counter rotation model) ......................... 1-15
Bracket unit technical data ............................................. 1-16

PTT system .............................................................................. 1-16
Specified tightening torque............................................. 1-17

Rigging information .................................................................. 1-17
Fuel system .............................................................................. 1-17
Power unit ................................................................................ 1-17
Lower unit (regular rotation model) .......................................... 1-19
Lower unit (counter rotation model).......................................... 1-19
Bracket unit .............................................................................. 1-19
PTT unit.................................................................................... 1-20
General tightening torque ............................................... 1-21
1
SPEC
Specification
Model features
General feature
F200B, FL200B, F250G, and FL250G Overall feature
• Electronic fuel injected, 60° V6, DOHC, 24-valves, VCT, 3352.0 cm3 (204.5 cu. in) engine
• 6Y8 Multifunction Meter for easy rigging and precision engine information
• Low emission in compliance with EU regulation
a Power unit
• Shimless valve lifters a
• Multi-point electronic fuel injection
b
• Blowby gas reburning system
• Vapor gas treatment system
• Single electronic throttle body
• Long intake manifolds
• Large diameter intake valve heads
• In-bank exhaust system
• Speed sensor and water pressure sensor c
(optional)
b Electrical
• Electronic fuel injection control
• Digital ignition control
• VCT control d
• Knock control
• Over-rev control
• Self-diagnosis system
• ETV control
• Fail-safe control
• Conventional or LAN gauges acceptable
• Water-cooled Rectifier Regulator with isola-
tor
c Upper case
• Anodized exhaust passages
d Lower unit
• Hard chromeplated water pump (outer plate
cartridge and insert cartridge)
• Anodized lower case and propeller shaft
housing (F250G and FL250G)
• Drive shaft spring (F250G and FL250G)
• Propeller damper cooling system (F250G
and FL250G)
1-1
Model features
Model designation
F 250 G E T X
1 2 3 4 5
None: 2-stroke
1
E: Enduro
F: 4-stroke
L: Counter rotating propeller
1 Model category
T: High thrust (4-stroke)
D: Twin rotating propeller
K: Kerosene
Z: HPDI
2 Output horsepower Example: 6/9.9/75/150/250/300
3 Model generation 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
4 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)
Level 4: Lubrication system (2-stroke model)

None: Premixed fuel with oil model
O: Oil injection model
S (15 in)
L (20 in)
Transom height
5 Y (22.5 in)
(Drive shaft length)
X (25 in)
U (31 in)
1-2
SPEC
Specification
Serial number Approved Starting
The outboard motor serial number is indi- Model name
model code serial No.
cated on a label affixed to the port clamp
F200BET 6S1 1002876–
bracket.
FL200BET 6S2 1001074–
F250GET 6DX 1000001–
FL250GET 6DY 1000001–
3 1
2 4
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
1 Model name
2 Approved model code
3 Transom height
4 Serial number
1-3
Model features / Model data
Model data
Dimension and weight
Model
Item Unit
F200BET FL200BET F250GET FL250GET
Overall length mm (in) 868.0 (34.2)
Overall width mm (in) 634.0 (25.0)
Overall height
X mm (in) 1829.0 (72.0) 1
U mm (in) 1956.0 (77.0)
Outboard motor transom height
X mm (in) 643.0 (25.3)
U mm (in) 770.0 (30.3)
Weight (SUS) (*1)
X kg (lb) 283.0 (624)
U kg (lb) 290.0 (639)
(*1) With SUS (stainless steel) propeller
Performance
Model
Item Unit
Maximum output
At 5500 r/ min kW (HP) 147.1 (200) 183.9 (250)
Full throttle operating range r/min 5000–6000
Maximum fuel consumption
L (US gal,
At 5500 r/min 73.7 (19.5, 16.2) 75.6 (20.0, 16.6)
Imp gal)/hr
Engine idle speed r/min 600–700
Power unit
Model
Item Unit
Type 4-stroke, DOHC
Cylinder quantity V6
Total displacement cm3 (cu. in) 3352.0 (204.5)
Bore × stroke mm (in) 94.0 × 80.5 (3.70 × 3.17)
Compression ratio 9.9 : 1
Control system Remote control
Starting system Electric
Fuel system Fuel injection
Ignition control system TCI
Advance type Microcomputer
Maximum generator output V, A 12.0, 44.0
Spark plug LFR6A-11(NGK)
Firing order 1–2–3–4–5–6 (Normal operation)
Cooling system Water
Exhaust system Propeller boss
Lubrication system Wet sump
1-4
SPEC
Specification
Lower unit
Model
Item Unit
Gear shift positions F-N-R
Gear ratio 2.00 (30/15)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Clock- Counter- Clock- Counter-
Propeller direction (rear view)
wise clockwise wise clockwise
Propeller mark T, M TL, ML T, M TL, ML
Bracket unit
Model
Item Unit
Trim angle
At 12° boat transom degree –3 to 16
Tilt-up angle degree 70
Steering angle degree 32 + 32
Trim and tilt system PTT
Fuel and oil requirement

Model
Item Unit
Fuel type Regular unleaded gasoline
Minimum fuel octane number RON 84 90
Engine oil 4-stroke motor oil
Engine oil grade (*1) (*2) API SE, SF, SG, SH, SJ, SL
SAE 5W-30, 10W-30, 10W-40
Total engine oil quantity (oil pan L (US qt,
5.6 (5.92, 4.93)
capacity) (*3) Imp qt)
Gear oil type Hypoid gear oil
API GL-4
Gear oil grade (*2)
SAE 90
1.150 1.000 1.150 1.000
L (US qt,
Gear oil quantity (1.216, (1.057, (1.216, (1.057,
Imp qt)
1.012) 0.880) 1.012) 0.880)
(*1) If the recommended engine oil grades are not available, use engine oil with an API classifica-
tion of SH, SJ, or SL and an SAE classification of 15W-40, 20W-40, or 20W-50.
(*2) Meeting both API and SAE requirements.
(*3) For actual engine oil amount required at periodical oil check, see “Power unit technical data”
(1-12).
1-5
Model data
Battery requirement
Model
Item Unit
Minimum cold cranking amps
CCA/EN A 711.0
Minimum rated capacity
20HR/IEC Ah 100.0
PTT fluid requirement

1
Model
Item Unit
Fluid type ATF Dexron II
1-6
SPEC
Specification
Electrical system technical data
Ignition timing control system
Model
Item Unit
Spark plug
Gap mm (in) 1.0–1.1 (0.039–0.043)
Ignition coil
Input voltage V 12.0
Pulser coil
Air gap mm (in) 1.4–1.6 (0.055–0.063)
Resistance (*1)
At 20 °C (68 °F) Ω 396.0–594.0
Output peak voltage
At cranking (unloaded) V 3.0
At cranking (loaded) V 2.7
At 1500 r/min (loaded) V 14.5
Cam position sensor
Knock sensor
Resistance (*1)
At 20 °C (68 °F) kΩ 504.0–616.0
Air temperature sensor
Resistance (*1)
At 20 °C (68 °F) kΩ 2.21–2.69
At 80 °C (176 °F) kΩ 0.32
Input voltage V 4.75–5.25
Neutral switch
Air pressure sensor
Output voltage
At –20.0 kPa (–0.20
V 3.21
kgf/cm2, –2.9 psi)
At –46.7 kPa (–0.467
V 2.16
kgf/cm2, –6.8 psi)
Engine temperature sensor
Resistance (*1)
At 20 °C (68 °F) kΩ 54.2–69.0
At 100 °C (212 °F) kΩ 3.12–3.48
Thermoswitch
Input voltage (*1) V 11.4
Temperature
Switch ON °C (°F) 84–90 (183–194)
Switch OFF °C (°F) 68–82 (154–180)
(*1) The figures are for reference only.
1-7
Fuel injection control system
Model
Item Unit
Fuel line
Pressure (*1)
Within 5 seconds after kPa
engine start switch (kgf/cm2, 290.0 (2.90, 42.1)
turned to ON psi)
kPa
1
At engine idle speed (kgf/cm2, 260.0 (2.60, 37.7)
psi)
Fuel injector
Resistance (*1)
At 20 °C (68 °F) Ω 12.0
Low-pressure fuel pump
Resistance (*1)
At 20 °C (68 °F) Ω 0.5–4.0
High-pressure fuel pump
Resistance (*1)
At 20 °C (68 °F) Ω 0.3–10.0
Vapor shut-off valve
Resistance (*1)
At 20 °C (68 °F) Ω 30.0–34.0
Water detection switch
Engine speed control system

Model
Item Unit
Oil pressure sensor
Output voltage (*1)
At 392.0 kPa (3.92
V 2.5
kgf/cm2, 56.8 psi)
At 784.0 kPa (7.84
V 4.5
kgf/cm2, 113.7 psi)
APS
Resistance (*1)
With accelerator lever
fully closed
APS 1 and APS 2
At 20 °C (68 °F) kΩ 0.8
With accelerator lever
fully open
APS 1 and APS 2
At 20 °C (68 °F) kΩ 5.3
Output voltage (*1)
1-8
SPEC
Specification
Model
Item Unit
With remote control lever
fully closed
APS 1 V 0.550–0.850
APS 2 V 0.400–1.000
With remote control lever
fully open
APS 1 and APS 2 V Above 3.250
TPS
Output voltage (*1)
With throttle valve fully
closed
TPS 1 V 0.500–0.700
With throttle valve fully
open
TPS 2 V 4.600–4.700
Shift cut switch
VCT system
Model
Item Unit
OCV
Resistance (*1)
At 20 °C (68 °F) Ω 6.7–7.7
PTT system
Model
Item Unit
Trim sensor
Free position resistance (*1)
At 20 °C (68 °F) Ω 247.6–387.6
Setting resistance Ω 9.0–11.0
1-9
Charging system
Model
Item Unit
Lighting coil
Resistance (*1)
At 20 °C (68 °F) Ω 0.11–0.17
Output peak voltage
At cranking (unloaded)
At 1500 r/min (unloaded)
V
V
8.3
44.7
1
At 3500 r/min (unloaded) V 97.7
Fuse A 60
Rectifier Regulator
Output peak voltage
Starting system
Model
Item Unit
Starter motor
Type Sliding gear
Output kW 1.4
Cranking time limit second 30
Brush
Standard length mm (in) 15.5 (0.61)
Wear limit mm (in) 9.5 (0.37)
Commutator
Standard diameter mm (in) 29.0 (1.14)
Standard undercut mm (in) 0.5–0.8 (0.02–0.03)
1-10
SPEC
Specification
Gauge/sensor
Model
Item Unit
Water pressure sensor
Output voltage (*1)
At 392.0 kPa (3.92
V 2.5
kgf/cm2, 56.8 psi)
At 784.0 kPa (7.84
V 4.5
kgf/cm2, 113.7 psi)
Speed sensor
Output voltage (*1)
At 392.0 kPa (3.92
V 2.5
kgf/cm2, 56.8 psi)
At 784.0 kPa (7.84
V 4.5
kgf/cm2, 113.7 psi)
Fuel system technical data

Fuel system
Model
Item Unit
Fuel filter assembly
Holding pressure
kPa
Positive pressure (kgf/cm2, 200.0 (2.00, 29.0)
psi)
kPa
Negative pressure (kgf/cm2, 80.0 (0.80, 11.6)
psi)
Primer pump
Holding pressure
kPa
psi)
Vapor separator tank
Float height mm (in) 67.5 ± 2.5 (2.66 ± 0.10)
Canister
Holding pressure
kPa
psi)
1-11
Electrical system technical data / Fuel system technical data / Power unit technical data
Power unit technical data

Power unit
Model
Item Unit
Cylinder
kPa
Minimum compression
(kgf/cm2, 630.0 (6.30, 91.4)
pressure (*1)
psi) 1
Engine oil
Oil pressure (*2)
At 60 °C (140 °F) with SL kPa
10W-30 engine oil and at (kgf/cm2, 507.3 (5.073, 73.6)
650 r/min psi)
At 62 °C (144 °F) with SL kPa
10W-30 engine oil and at (kgf/cm2, 700.6 (7.006, 101.6)
3000 r/min psi)
Timing belt
Installation height mm (in) 2.0 (0.08)
Replacement engine oil quantity
(at periodic maintenance)
L (US qt,
Without oil filter replacement 4.5 (4.76, 3.96)
Imp qt)
L (US qt,
With oil filter replacement 4.7 (4.97, 4.14)
Imp qt)
(*1) Measuring conditions: Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs
removed from all cylinders. The figures are for reference only.
(*2) For details of the checking method, see “Checking the oil pressure” (7-1). The figures are for
reference only.
Cylinder head assembly

Model
Item Unit
Cylinder head
Warpage limit mm (in) 0.10 (0.0039)
Journal inside diameter mm (in) 25.000–25.021 (0.9843–0.9851)
Valve stem
Diameter
Intake mm (in) 5.477–5.492 (0.2156–0.2162)
Exhaust mm (in) 5.464–5.479 (0.2151–0.2157)
Runout
Intake and exhaust mm (in) 0.010 (0.0004)
Valve guide
Inside diameter
Intake and exhaust mm (in) 5.504–5.522 (0.2167–0.2174)
Valve guide clearance
Intake mm (in) 0.012–0.045 (0.0005–0.0018)
Exhaust mm (in) 0.025–0.058 (0.0010–0.0023)
Installation height mm (in) 12.500–12.900 (0.4921–0.5079)
1-12
SPEC
Specification
Model
Item Unit
Valve spring
Free length mm (in) 48.1 (1.89)
Tilt mm (in) 1.7 (0.07)
Valve lifter
Outside diameter mm (in) 30.970–30.980 (1.2193–1.2197)
Valve lifter clearance mm (in) 0.020–0.055 (0.0008–0.0022)
Camshaft
Cam lobe height
Intake mm (in) 46.311–46.411 (1.8233–1.8272)
Exhaust mm (in) 45.360–45.460 (1.7858–1.7898)
Cam lobe width
Intake and exhaust mm (in) 35.950–36.050 (1.4154–1.4193)
Journal diameter mm (in) 24.960–24.980 (0.9827–0.9835)
Runout mm (in) 0.015 (0.0006)
Valve
Clearance
Intake mm (in) 0.205 ± 0.035 (0.0081 ± 0.0014)
Exhaust mm (in) 0.345 ± 0.035 (0.0136 ± 0.0014)
Head diameter
Intake mm (in) 36.400–36.600 (1.4331–1.4409)
Exhaust mm (in) 31.400–31.600 (1.2362–1.2441)
Seat contact width
Intake mm (in) 1.100–1.400 (0.0433–0.0551)
Exhaust mm (in) 1.400–1.700 (0.0551–0.0669)
Margin thickness
Intake mm (in) 0.500–0.900 (0.0197–0.0354)
Exhaust mm (in) 0.900–1.300 (0.0354–0.0512)
Crankcase assembly
Model
Item Unit
Cylinder
Bore mm (in) 94.000–94.017 (3.7008–3.7014)
Piston
Diameter mm (in) 93.921–93.941 (3.6977–3.6985)
Measuring point mm (in) 13.500 (0.5315)
Piston clearance mm (in) 0.075–0.080 (0.0030–0.0031)
Ring groove (top) mm (in) 1.230–1.250 (0.0484–0.0492)
Ring groove (2nd) mm (in) 1.220–1.240 (0.0480–0.0488)
Ring groove (oil) mm (in) 2.510–2.530 (0.0988–0.0996)
Pin boss inside diameter mm (in) 21.021–21.031 (0.8276–0.8280)
Pin outside diameter mm (in) 21.008–21.017 (0.8271–0.8274)
Oversize diameter
1st mm (in) 94.176–94.186 (3.7077–3.7081)
1-13
Power unit technical data
Model
Item Unit
Piston ring
Top ring
Type Barrel
Dimension height (B) mm (in) 1.200 (0.0472)
Dimension width (T) mm (in) 2.800–3.000 (0.1102–0.1181)
End gap (*1)
Side clearance
mm (in)
mm (in)
0.200–0.300 (0.0079–0.0118)
0.030–0.050 (0.0012–0.0020)
1
2nd ring
Type Taper
Dimension height (B) mm (in) 1.170–1.190 (0.0461–0.0469)
End gap (*1) mm (in) 0.300–0.450 (0.0118–0.0177)
Side clearance mm (in) 0.030–0.070 (0.0012–0.0028)
Oil ring
Dimension height (B) mm (in) 2.400–2.470 (0.0945–0.0972)
End gap (*1) mm (in) 0.150–0.600 (0.0059–0.0236)
Side clearance mm (in) 0.040–0.130 (0.0016–0.0051)
Connecting rod
Small end inside diameter mm (in) 21.022–21.037 (0.8276–0.8282)
Big end inside diameter mm (in) 53.015–53.035 (2.0872–2.0880)
Big end side clearance mm (in) 0.150–0.300 (0.0059–0.0118)
Oil clearance mm (in) 0.028–0.066 (0.0011–0.0026)
Crankshaft
Journal diameter mm (in) 62.968–62.992 (2.4791–2.4800)
Crankpin diameter mm (in) 49.976–50.000 (1.9676–1.9685)
Runout mm (in) 0.030 (0.0012)
Crankpin width mm (in) 21.500–21.550 (0.8465–0.8484)
Crankcase
Oil clearance mm (in) 0.035–0.050 (0.0014–0.0020)
Thermostat
Valve opening temperature °C (°F) 58–62 (136–144)
Valve opening stroke mm (in) 0.05 (0.0020)
Fully open temperature °C (°F) 70 (158)
Fully open stroke mm (in) 4.3 (0.17)
1-14
SPEC
Specification
Lower unit technical data
Lower unit assembly (regular rotation model)
Model
Item Unit
F200BET F250GET
Lower unit
kPa
Holding pressure (kgf/cm2, 68.6 (0.686, 9.9)
psi)
Forward gear backlash (*1) mm (in) 0.26–0.65 (0.0102–0.0256)
Reverse gear backlash (*1) mm (in) 0.23–0.88 (0.0091–0.0346)
Pinion shim (T3) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shim (T1) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Reverse gear shim (T2) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
1.80, 1.90, 2.00, 2.10,
Propeller shaft shim (T4) mm —
2.20
Propeller shaft
0.20–0.50 (0.0079–
Free play mm (in) —
0.0197)
Runout mm (in) 0.02 (0.0008)
Drive shaft
Runout mm (in) 0.2 (0.008)
(*1) Figures obtained using the special service tools.
Lower unit assembly (counter rotation model)

Model
Item Unit
FL200BET FL250GET
Lower unit
kPa
Holding pressure (kgf/cm2, 68.6 (0.686, 9.9)
psi)
Forward gear backlash (*1) mm (in) 0.46–0.82 (0.0181–0.0323)
Reverse gear backlash (*1) mm (in) 0.43–0.96 (0.0169–0.0378)
Pinion shim (T3) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shim (T2) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Reverse gear shim (T1) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Propeller shaft shim (T4) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Propeller shaft
Free play mm (in) 0.25–0.35 (0.0098–0.0138)
Runout mm (in) 0.02 (0.0008)
Drive shaft
Runout mm (in) 0.2 (0.008)
(*1) Figures obtained using the special service tools.
1-15
Lower unit technical data / Bracket unit technical data
Bracket unit technical data

PTT system
Model
Item Unit
PTT
Hydraulic pressure (*1)
Down
MPa
(kgf/cm2, 6.7–8.7 (67.0–87.0, 971.5–1261.5) 1
psi)
MPa
Up (kgf/cm2, 13.0–15.0 (130.0–150.0, 1885.0–2175.0)
psi)
Motor brush
Standard length mm (in) 11.5 (0.45)
Motor commutator
Standard diameter mm (in) 23.0 (0.91)
Standard undercut (*1) mm (in) 1.4 (0.06)
1-16
SPEC
Specification
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
Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Shift cable locknut — 4 0.4 3.0
Throttle cable locknut — 4 0.4 3.0
Negative battery cable nut — 13 1.3 9.6
Speed sensor — 18 1.8 13.3
Speed sensor adapter bolt M6 10 1.0 7.4
Water pressure sensor — 18 1.8 13.3
Water pressure sensor adapter — 23 2.3 17.0
Fuel system
Tightening torques
N·m kgf·m ft·lb
Fuel cup assembly — 5 0.5 3.7
Intake silencer bolt M6 7 0.7 5.2
Intake manifold bolt M6 10 1.0 7.4
Throttle body nut — 13 1.3 9.6
Throttle damper plate bolt M8 13 1.3 9.6
Canister holder bolt M6 5 0.5 3.7
Canister bracket bolt M6 5 0.5 3.7
Air pressure sensor bolt M6 5 0.5 3.7
Vapor shut-off valve nut — 5 0.5 3.7
Low-pressure fuel pump cover bolt M6 5 0.5 3.7
Pressure regulator holder screw M5 4 0.4 3.0
Vapor separator cover bolt M4 2 0.2 1.5
Float chamber cover screw M4 2 0.2 1.5
Needle valve assembly screw M4 2 0.2 1.5
Float pin screw M4 2 0.2 1.5
Fuel cooler cover screw M5 4 0.4 3.0
Vapor separator drain screw — 2 0.2 1.5
Power unit
Tightening torques
N·m kgf·m ft·lb
Flywheel magnet nut — 240 24.0 177.0
Pulser coil screw M5 4 0.4 3.0
Power unit mounting bolt M10 42 4.2 31.0
PTT relay terminal bolt M6 4 0.4 3.0
Terminal stud bolt M10 26 2.6 19.2
1st 6 0.6 4.4
Rectifier Regulator cover bolt M6
2nd 12 1.2 8.9
1st 6 0.6 4.4
Rectifier Regulator bolt M6
2nd 12 1.2 8.9
Anode screw M4 3 0.3 2.2
1-17
Tightening torques
N·m kgf·m ft·lb
PTT relay terminal nut — 4 0.4 3.0
Engine ECM bolt M6 7 0.7 5.2
Timing belt tensioner bolt — 39 3.9 28.8
Pulley bolt M10 39 3.9 28.8
1st 8 0.8 5.9
Cylinder head cover bolt M6
Ignition coil bolt
2nd
M6
8
7
0.8
0.7
5.9
5.2
1
Spark plug — 25 2.5 18.4
Cylinder head cover plate screw M4 2 0.2 1.5
Adapter plug M14 23 2.3 17.0
1st 8 0.8 5.9
Camshaft cap bolt M7
2nd 17 1.7 12.5
VCT cap — 32 3.2 23.6
VCT bolt M12 60 6.0 44.3
Driven sprocket bolt M10 60 6.0 44.3
1st 6 0.6 4.4
Exhaust cover bolt M6
2nd 12 1.2 8.9
Exhaust outer cover plug M18 55 5.5 40.6
OCV bolt M6 7 0.7 5.2
Engine hanger bolt M6 12 1.2 8.9
1st 14 1.4 10.3
Cylinder head bolt M8
2nd 28 2.8 20.7
1st 30 3.0 22.1
2nd 60 6.0 44.3
Cylinder head bolt 3rd Loosen completely
M10
(When using a new bolt) 4th 30 3.0 22.1
5th 60 6.0 44.3
6th 90°
1st 27 2.7 19.9
2nd 54 5.4 39.8
Cylinder head bolt 3rd Loosen completely
M10
(When reusing the bolt) 4th 27 2.7 19.9
5th 54 5.4 39.8
6th 90°
Oil pressure sensor — 18 1.8 13.3
Oil filter — 18 1.8 13.3
Oil filter union bolt UNF 34 3.4 25.1
1st 14 1.4 10.3
Crankcase cover bolt M8
2nd 28 2.8 20.7
Cooling water passage cover bolt M6 12 1.2 8.9
Knock sensor — 32 3.2 23.6
Engine temperature sensor — 15 1.5 11.1
Oil pump cover screw — 4 0.4 3.0
1st 33 3.3 24.3
Crankcase bolt M10
2nd 90°
1st 28 2.8 20.7
Crankcase bolt (length: 93 mm) M8
2nd 90°
1-18
SPEC
Specification
Tightening torques
N·m kgf·m ft·lb
1st 14 1.4 10.3
Crankcase bolt (length: 55 mm) M8
2nd 28 2.8 20.7
Anode bolt M5 7 0.7 5.2
Anode — 3 0.3 2.2
Thermostat cover plug M14 23 2.3 17.0
1st 13 1.3 9.6
Connecting rod bolt 2nd M9 23 2.3 17.0
3rd 90°
Lower unit (regular rotation model)

Tightening torques
N·m kgf·m ft·lb
Check screw — 9 0.9 6.6
Trim tab bolt M10 42 4.2 31.0
Propeller nut — 55 5.5 40.6
Lower case mounting bolt M10 47 4.7 34.7
Drain screw — 9 0.9 6.6
Lower case mounting nut (U-transom model) — 47 4.7 34.7
Water inlet cover screw M5 1 0.1 0.7
Propeller shaft housing bolt M8 29 2.9 21.4
Grease nipple — 6 0.6 4.4
Pinion nut — 142 14.2 104.7
Lower unit (counter rotation model)

Tightening torques
N·m kgf·m ft·lb
Check screw — 9 0.9 6.6
Trim tab bolt M10 42 4.2 31.0
Propeller nut — 55 5.5 40.6
Lower case mounting bolt M10 47 4.7 34.7
Drain screw — 9 0.9 6.6
Lower case mounting nut (U-transom model) — 47 4.7 34.7
Ring nut — 108 10.8 79.7
Water inlet cover screw M5 1 0.1 0.7
Propeller shaft housing bolt M8 29 2.9 21.4
Grease nipple — 6 0.6 4.4
Pinion nut — 142 14.2 104.7
Bracket unit
Tightening torques
N·m kgf·m ft·lb
Neutral switch screw M4 2 0.2 1.5
Shift cut switch screw M4 2 0.2 1.5
Grease nipple (shift bracket) — 1 0.1 0.7
Shift bracket bolt — 19 1.9 14.0
Shift rod detent bolt — 18 1.8 13.3
Flushing hose adapter screw ø6 5 0.5 3.7
1-19
Tightening torques
N·m kgf·m ft·lb
Upper mounting nut — 72 7.2 53.1
Lower mounting nut — 72 7.2 53.1
Upper mount bracket bolt M10 54 5.4 39.8
Engine oil drain bolt M14 28 2.8 20.7
Baffle plate screw M6 4 0.4 3.0
Apron stay —
M8
8
20
0.8
2.0
5.9
14.8
1
Oil pan assembly bolt
M10 42 4.2 31.0
PCV — 8 0.8 5.9
Oil strainer bolt M6 12 1.2 8.9
Oil pan bolt M8 20 2.0 14.8
Exhaust manifold bolt M8 20 2.0 14.8
Muffler bolt M8 20 2.0 14.8
Grease nipple (clamp bracket and swivel
— 3 0.3 2.2
bracket)
Self-locking nut (through tube) — 22 2.2 16.2
Trim sensor screw M6 4 0.4 3.0
Friction plate screw M6 4 0.4 3.0
PTT unit
Tightening torques
N·m kgf·m ft·lb
PTT unit bolt M10 42 4.2 31.0
Reservoir cap — 7 0.7 5.2
PTT motor bolt M8 19 1.9 14.0
Reservoir bolt M8 19 1.9 14.0
Gear pump bolt M5 7 0.7 5.2
Gear pump bracket bolt M5 7 0.7 5.2
Manual valve — 2 0.2 1.5
Tilt ram — 65 6.5 47.9
Tilt cylinder end screw — 90 9.0 66.4
Tilt piston bolt — 7 0.7 5.2
Trim cylinder end screw — 160 16.0 118.0
Pipe joint adapter — 20 2.0 14.8
Pipe joint — 15 1.5 11.1
1-20
SPEC
Specification
General tightening torque
This chart indicates the tightening torques for
standard fasteners with a standard ISO
thread pitch.
Width General torque
Screw
across specifications
size (B)
flats (A) N·m kgf·m ft·lb
8 mm M5 5 0.5 3.7
10 mm M6 8 0.8 5.9
12 mm M8 18 1.8 13.3
14 mm M10 36 3.6 26.6
17 mm M12 43 4.3 31.7
1-21
TECH
FEA
Technical features and description
Electronic control system ................................................. 2-1

Engine control system component ............................................. 2-2
Actuator, sensor, and switch ...................................................... 2-3
Electronic fuel injection control................................................... 2-4
Digital ignition control ................................................................. 2-5
VCT control ................................................................................ 2-6
Knock control.............................................................................. 2-7
Over-rev control and alert control............................................... 2-8
ETV control................................................................................. 2-9
Fail-safe control........................................................................ 2-10 2
Power unit system ........................................................... 2-11
Shimless valve lifter.................................................................. 2-11
Fuel system ...................................................................... 2-12

Fuel diagram ............................................................................ 2-12
Blowby gas reburning system .................................................. 2-14
Vapor gas treatment................................................................. 2-15
Lubrication system .......................................................... 2-16

Lubrication diagram.................................................................. 2-16
Cooling system ................................................................ 2-17

Cooling diagram ....................................................................... 2-17
Intake and exhaust system ............................................. 2-21

Intake and exhaust diagram ..................................................... 2-21
Lower unit ......................................................................... 2-22

Drive shaft spring (F250G and FL250G) .................................. 2-22
Propeller damper cooling (F250G and FL250G) ...................... 2-23
TECH
FEA Technical features and description
Electronic control system
These models use electronic fuel injection control, digital ignition control, VCT control, knock con-
trol, over-rev control, alert control, ETV control, and fail-safe control. The engine ECM performs
these controls according to the signals sent from various sensors and switches.
In addition, the engine ECM has a self-diagnosis function to perform troubleshooting using the
YDIS.
The 6Y8 Multifunction Meter can be installed as an option.
Check valve
Air (cowl inside)
Check valve
Air (cowl outside)
Filter
Canister
Check valve Low-pressure fuel pump
High-pressure
Water separator
fuel pump
Fuel
Vapor separator Water
detection
Fuel injector switch
OCV
Ignition
Vapor shut-off
coil
valve
Air
ETV
TPS
Ignition
coil
OCV Fuel injector
Throttle control Cam position sensor

Pulser coil
Valve control Air pressure sensor
Oil pressure sensor
Fuel control Engine temperature sensor
Ignition control Engine
ECM Knock sensor
APS
Shift cut switch
Neutral switch
6Y8 Multi- Thermoswitch
function Engine shut-off switch
Meter Battery Water pressure sensor (optional)
Speed sensor (optional)
2-1
Engine control system component
1
B
2
A
2
3
4 C
D
5
0 E
F
9
P
8 G
7 6
O
N
H
I
L J
1 OCV (STBD) D Engine temperature sensor

2 Thermoswitch (STBD) E Thermoswitch (PORT)
3 APS F OCV (PORT)
4 Neutral switch G Cam position sensor (PORT IN)
5 Shift cut switch H Fuel injector (PORT)
6 Fuel injector (STBD) I High-pressure fuel pump
7 Cam position sensor (STBD IN) J Low-pressure fuel pump
8 Ignition coil (STBD) K TPS
9 Knock sensor L Oil pressure sensor
0 Engine ECM M ETV
A Ignition coil (PORT) N Air pressure sensor
B Cam position sensor (PORT EX) O Vapor shut-off valve
C Pulser coil P Air temperature sensor
2-2
TECH
Actuator, sensor, and switch
Engine ECM Determines the engine operating conditions according to the input
signals from the sensors, which are installed at various locations on
the engine, and sends output signals to operate the actuators to
perform the various control functions.
Performs troubleshooting using a self-diagnosis function.
Pulser coil Detects the engine speed.
Detects the crankshaft angle and piston positions.
Determines each group of cylinders (#1 and #4, #2 and #5, and #3
and #6).
Cam position sensor Determines the stroke. (For example, distinguishes the
(PORT EX) compression stroke TDC from the exhaust stroke TDC.)
Determines each group of cylinders (#1 and #4, #2 and #5, and #3
and #6).
Determines the stroke of each cylinder according to the signals from
both the pulser coil and the cam position sensor (PORT EX).
Cam position sensor Detects the advance angle on the port camshaft.
(PORT IN)
Cam position sensor Detects the advance angle on the starboard camshaft.
(STBD IN)
APS 1 Detect the throttle opening. APS 2 is the main sensor and APS 1 is
APS 2 the sub sensor. APS 1 and APS 2 mutually monitor each other for
malfunctions.
TPS 1 Detect the throttle valve opening. TPS 1 is the main sensor and
TPS 2 TPS 2 is the sub sensor. TPS 1 and TPS 2 mutually monitor each
other for malfunctions.
ETV Opens and closes the throttle valve using a motor.
Air pressure sensor Detects the intake air pressure.
Air temperature sensor Detects the intake air temperature.
Engine temperature Detects the engine temperature.
sensor
Oil pressure sensor Detects the oil pressure.
Thermoswitch Detects engine overheating.
Knock sensor Detects engine knocking.
Shift cut switch Detects when the gear shift moves to the N position.
Neutral switch Detects when the gear shift is in the N position.
Engine shut-off switch Activates the engine stop function compulsorily.
Fuel injector Injects fuel.
Ignition coil Activates the ignition.
Vapor shut-off valve Controls the amount of vapor gas to be sent from the vapor
separator to the intake system.
OCV Advances or retards the 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.
High-pressure fuel pump Pressurizes the fuel in the vapor separator, and sends the fuel to
the fuel rails.
Low-pressure fuel pump Sends the fuel from the fuel tank to the vapor separator.
2-3
Electronic fuel injection control
In electronic fuel injection control, the engine ECM calculates the precise air and fuel mixture
required in each combustion chamber depending on the load and engine speed in order to increase
combustion efficiency. The fuel injection amount is controlled by the fuel injector actuation time.
There are 2 types of fuel injection timing control: synchronous fuel injection and asynchronous fuel
injection. According to the engine operating conditions during the control, the control mode switches
automatically between the start-up mode, normal operating mode, and fuel injection cutoff mode. In
addition, a multi-point fuel injection system provides the appropriate fuel injection amount for all
weather conditions. As a result, the outboard motor starts quickly the first time the engine start
switch is turned to START. Also, a fuel injector anti-sticking control has been adopted.
Pulser coil
2
Cam position sensor
(PORT EX)
Cam position sensor

(PORT IN)
Cam position sensor

(STBD IN)
APS
Fuel injector
TPS
Engine
Air pressure sensor ECM

Vapor shut-off
valve
Neutral switch
Engine shut-off switch
Battery
Engine start switch
2-4
TECH
Digital ignition control
In digital ignition control, the engine ECM determines the optimum ignition timing according to the
signals from the sensors and sends the primary current to the ignition coils. According to the engine
operating conditions, the basic ignition timing and ignition coil energization time are determined. In
addition, various restrictions and compensations are made to determine the actual ignition timing.
The ignition timing is also controlled according to the knock control. See “Knock control” (2-7).
Pulser coil
Cam position sensor

(PORT EX)
Cam position sensor

(PORT IN)
Cam position sensor

(STBD IN)
APS
TPS
Air pressure sensor

Engine
Ignition coil
ECM
Knock sensor
Shift cut switch
Engine shut-off switch
Battery
Engine start switch
2-5
VCT control
In VCT control, the engine ECM determines the appropriate intake valve opening timing according
to the signals from the sensors. According to the engine operating conditions, the OCVs are oper-
ated and the VCT assemblies advance and retard the intake valve opening timing in order to
increase the intake and exhaust efficiency at low and mid-range engine speeds and obtain greater
acceleration.
Pulser coil
Cam position sensor

(PORT EX)
2
Cam position sensor OCV (PORT)
(PORT IN)
Engine
Cam position sensor ECM
(STBD IN) OCV (STBD)
TPS
2-6
TECH
Knock control
In knock control, the engine ECM receives the knock signal from the knock sensor, which is
installed on the cylinder block between the cylinder banks. The engine ECM retards the ignition tim-
ing and decreases the engine speed according to the amount of knocking to protect the engine from
damage.
If the knocking occurs frequently, the ignition timing is retarded until the knocking is no longer
detected, and the retarded ignition timing is maintained.
Also, a learning function for the knock control has been adopted.
The knock control activates according to the following conditions:
Engine
temperature Less than 20 °C More than 25 °C
20–25 °C (68–77 °F)
(68 °F) (77 °F)
Engine speed
Less than 4500 r/min Knock control does Knock control Knock control
not activate activates if conditions activates
continue for 0.5
second
4500 r/min or more Knock control
activates
The knock control also activates when the engine temperature sensor is malfunctioning regardless
of the preceding conditions.
2-7
Over-rev control and alert control
In over-rev control and alert control, the engine ECM decreases the engine speed to protect the
engine from damage.
Pulser coil
TPS
Fuel injector
2
Oil pressure sensor
Engine
Ignition coil
ECM
Thermoswitch
Shift cut switch

6Y8 Multifunction
Meter
Battery
Engine start switch
2-8
TECH
ETV control
In ETV control, the engine ECM determines the appropriate throttle valve opening according to the
signals from the sensors, and controls the throttle valve. The engine ECM is equipped with a learn-
ing function that records all of the compensations made by the control to the throttle valve opening
for the operating conditions up to that point. In addition, the engine idle speed is controlled using the
ETV control.
APS
TPS

ETV motor
Engine
Shift cut switch
ECM
Fuel injector
Neutral switch
Battery
Engine start switch
2-9
Fail-safe control
In fail-safe control, the engine ECM enters the fail-safe mode when an electrical component mal-
functions. The fail-safe control system records the trouble codes according to the engine trouble
conditions.
LAN
Trouble
Item gauge Trouble conditions to be detected
code
display
13 Pulser coil C/E No signal
Engine Open or short circuit in the engine temperature sensor
15 temperature C/E circuit. Output voltage is less than 0.18 V or more than
17
sensor
Knock sensor C/E
4.90 V.
Output voltage is less than 0.90 V or more than 4.00 V. 2
Air temperature Output voltage is less than 0.10 V or more than 4.60 V.
23 C/E
sensor
24, 71, Cam position Signal error (irregular)
C/E
72 sensor
28 Neutral switch C/E Neutral switch is off during the start-up mode.
Air pressure Output voltage is less than 0.20 V or more than 4.50 V.
29 C/E
sensor
Oil pressure Output voltage is less than 0.30 V, more than 4.80 V
39 sensor C/E for 260 seconds, or more than 4.80 V when the engine
is stopped.
Shift cut switch Output voltage is more than 4.50 V, the shift cut switch
45 C/E is on during the start-up mode, or both the neutral
switch and shift cut switch are on for 5 seconds.
Thermoswitch Switch is on when the engine temperature is 40 °C
46 C/E (104 °F) or less, or off when the engine temperature is
more than 120 °C (248 °F).
73, 74 OCV C/E Open or short circuit in the OCV circuit.
112, 113, ETV Open or short circuit in the ETV relay and ETV motor
114, 115, circuit.
116, 117,
118, 119,
121, 122,
123, 129, C/E
136, 137,
138, 139,
141, 142,
143, 144,
145
TPS TPS 1 output voltage is less than 0.35 V or more than
124, 125,
4.80 V, TPS 2 output voltage is less than 2.25 V or
126, 127, C/E
more than 4.80 V, or the output voltage difference
128
between TPS 1 and TPS 2 is 2.30 V or more.
131, 132, APS Open or short circuit in the APS circuit, or the output
133, 134, C/E voltage difference between APS 1 and APS 2 is 0.996
135 V or more.
2-10
TECH
Power unit system
These models are equipped with a V6, 4-stroke engine that has 60° cylinder banks. The power unit
features shimless valve lifters, a blowby gas reburning system, a vapor gas treatment system, a sin-
gle electronic throttle body, long intake manifolds, large diameter intake valve heads, and an in-
bank exhaust system.
The F(L)250G is a new high-output outboard motor for use in various environments. The outboard
motor has adopted structural features that improve durability.
The F(L)200B is an outboard motor for commercial use.
Shimless valve lifter

Newly designed valve lifters 1 have been adopted instead of the usual valve shims 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.
Previous V6 model New V6 model
a
1
2-11
Power unit system / Fuel system
Fuel system
Fuel diagram
Primer pump Boat fuel filter (optional) Boat fuel tank
Fuel filter (with water

separator and water
detection switch)
Check valve
Low-pressure
fuel pump
Atmosphere (cowl inside) 2
Check valve
Canister Atmosphere (cowl outside)
Check valve
Filter
Vapor shut-off valve Surge tank
Float chamber
Vapor High-pressure
fuel pump Pressure regulator
separator assembly
Fuel rail (PORT) Fuel rail (STBD)
Fuel Fuel Fuel Fuel Fuel Fuel

injector #6 injector #4 injector #2 injector #1 injector #3 injector #5
Intake manifold (PORT) Intake manifold (STBD)
Combustion Combustion Combustion Combustion Combustion Combustion

chamber #6 chamber #4 chamber #2 chamber #1 chamber #3 chamber #5
È
É
Ê
È Fuel flow
É Air flow
Ê Vapor gas flow
2-12
TECH
7 0
3
2
5
4
È
È From the fuel tank
1 Primer pump
2 Fuel filter assembly (with water separator)
3 Low-pressure fuel pump
4 Vapor separator
5 Fuel cooler
6 High-pressure fuel pump
7 Pressure regulator
8 Fuel rail (PORT)
9 Fuel rail (STBD)
0 Fuel injector
2-13
Fuel system
Blowby gas reburning system
A blowby gas reburning system removes any unburned fuel from the blowby gases and sends it to
the combustion chambers to be burned.
È
É
È Blowby gas flow

É Engine oil
1 Intake silencer
2 Blowby gas separator (integrated with cylinder head cover)
2-14
TECH
Vapor gas treatment
Vapor gases from the vapor separator are collected in the canister, and then gradually discharged
into the atmosphere after being absorbed and cleaned by the activated charcoal. After the engine is
started, the vapor gases in the canister are drawn into the surge tank through the vapor shut-off
valve, which is controlled by the engine ECM, and then sent to the intake manifolds and combustion
chambers.
Combustion chamber Intake manifold Surge tank
Check valve
Atmosphere (cowl inside)
Vapor shut-off valve
Canister
Check valve Vapor separator
Atmosphere (cowl outside)
È
É
È Air flow
É Vapor gas flow
2-15
Fuel system / Lubrication system
Lubrication system
Lubrication diagram
Piston Camshaft
OCV VCT assembly
passage hole
Crankpin
(connecting rod big end)
Cylinder head Camshaft journal
Crankshaft
main journal
Main gallery Valve and related parts
Oil pressure sensor

2
Oil filter
Oil pump with

relief valve
Oil strainer
Oil pan
7
6
4
2
1 È
È Engine oil flow 4 Oil filter

5 Oil pressure sensor
1 Oil pan 6 OCV
2 Oil strainer 7 VCT assembly
3 Oil pump with relief valve
2-16
TECH
Cooling system
Cooling diagram
Thermostat (PORT) Thermostat (STBD)
Cylinder block
Exhaust cover (PORT) Exhaust cover (STBD)
Cylinder head (PORT) Cylinder head (STBD)
Cylinder block
É
Flushing device
Upper
Exhaust guide
PCV
Muffler
Fuel cooler Rectifier Regulator
Lower
Exhaust guide
Upper case
Oil pan
Lower case Ê
Water pump
Propeller boss Trim tab Water inlet Pilot hole
Water
È Cooling water flow

É When flushing the cooling water passage
Ê Dynamic water pressure when the boat is cruising (F250G and FL250G)
2-17
Cooling system
6
2
4
5
É Ê
2 2
1
1
1 1
È

É F(L)200B
Ê F(L)250G
1 Water inlet
2 Water pump
3 Oil pan
4 Exhaust guide
5 PCV
6 Thermostat
2-18
TECH
9
8
7
4 5
A
B 0
6
3 I
H
a J
5
2
C 8
D1
7
FG
E
6
E
0
e
J
b
A
B
H
c
I 4
2 39
1 d GCD È
È Cooling water flow A Cooling water hose (joint to Rectifier

Regulator)
1 Cooling water hose (cylinder block to joint) B Cooling water hose (Rectifier Regulator to
2 Cooling water hose (joint to joint) joint)
3 Cooling water hose (joint to joint) C Cooling water hose (joint to fuel cooler)
4 Cooling water hose (joint to joint) D Cooling water hose (fuel cooler to joint)
5 Cooling water hose (joint to joint) E Cooling water hose (joint to joint)
6 Cooling water hose (joint to joint) F Cooling water pilot hose (joint to cooling
7 Cooling water hose (joint to joint) water pilot hole)
8 Cooling water hose (thermostat cover G Cooling water hose (cylinder head [STBD]
[STBD] to joint) to adapter [water pressure sensor])
9 Cooling water hose (joint to cylinder block) H Flushing hose (flushing hose adapter to
0 Cooling water hose (thermostat cover joint)
[PORT] to cylinder block)
2-19
Cooling system
9
8
7
4 5
A
B 0
6
3 I
H
2
a J
5
2
C 8
D1
7
FG
E
6
E
0
e
J
b
A
B
H
c
I 4
2 39
1 d GCD È
I Flushing hose (joint to cooling water

passage cover)
J Speedometer hose
a Fuel cooler
b Rectifier Regulator
c Cooling water pilot hole (on the bottom
cowling)
d Adapter (water pressure sensor)
e Water passage cover (on the cylinder
block)
2-20
TECH
Intake and exhaust system
The single electronic throttle valve, which is operated by the engine ECM, enables precise control of
the intake air. The intake air is smoothly routed into each combustion chamber through the surge
tanks and the long intake manifolds for greater power. The long intake manifolds are designed to
increase air flow, thereby boosting low and mid-range torque and resulting in quicker acceleration.
The intake system has adopted intake valves with large diameter valve heads to increase the charg-
ing efficiency of the intake air.
The exhaust gases are cooled with water as they pass through the in-bank exhaust system. For
increased performance, the gases are smoothly vented straight down and out through the propeller.
The exhaust gas passages are anodized to protect the lower unit from corrosion.
Intake and exhaust diagram
1 3
2
3 4
5 4
È
É
È Intake air flow 4 Exhaust cover

É Exhaust gas flow 5 Exhaust guide
6 Exhaust manifold
1 Throttle body
7 Muffler
2 Surge tank
8 Propeller
3 Intake manifold
2-21
Intake and exhaust system / Lower unit
Lower unit
The outer plate cartridge and insert cartridge of the water pump are hard chromeplated for durability
and to protect the parts from abrasion due to muddy water.
The lower case and propeller shaft housing are anodized.
Drive shaft spring (F250G and FL250G)

The spring pushes the drive shaft toward the water pump and stabilizes the thrust free play of the
shaft.
2
1
2 É
4 1 3
5
2
6
4
È Spring force
É Water pump side
1 Pinion shim
2 Thrust bearing
3 Drive shaft
4 Thrust bearing
5 Spring
6 Washer
2-22
TECH
Propeller damper cooling (F250G and FL250G)
The water pipe for cooling the propeller damper is incorporated in the lower case. The water intake
is located in front of the trim tab to drawn in the water by the dynamic pressure, and the propeller
damper is cooled without disturbing the exhaust gas flow. As a result, higher output can be
obtained.

1 Water pipe
2-23
RIG
GING
Rigging information
Outboard motor installation .............................................. 3-1
External dimensions .......................................................... 3-2

F200BET, FL200BET, F250GET, FL250GET............................ 3-2
Clamp bracket ............................................................................ 3-3
Crate top cover pictograph description ........................... 3-4
Uncrating procedure .......................................................... 3-5
Outboard motor mounting................................................. 3-6 3

Outboard motor mounting height..................................... 3-8
Rigging grommet mounting .............................................. 3-9

Rigging grommet description...................................................... 3-9
Installing the shift cable and throttle cable ................................. 3-9
Installing the wiring harness ..................................................... 3-11
Installing the isolator lead (optional)......................................... 3-11
Installing the battery cable........................................................ 3-12
Installing the speed sensor (optional)....................................... 3-12
Installing the water pressure sensor (optional)......................... 3-13
Installing the rigging grommet .................................................. 3-14
Remote control box and switch panel installation........ 3-15
Battery installation ........................................................... 3-16

Battery cable routing without house (accessory) battery.......... 3-16
Battery cable routing with house (accessory) battery............... 3-18
System diagram ............................................................... 3-22

Single outboard motor application............................................ 3-22
Twin outboard motor application .............................................. 3-24
Triple outboard motor application............................................. 3-26
Rigging recommendation ................................................ 3-28

Extension length recommendation for battery cable ................ 3-28
Propeller selection ........................................................... 3-29

Propeller size............................................................................ 3-29
Selection................................................................................... 3-29
RIG
GING Rigging information
Outboard motor installation
• Overpowering a boat could cause severe instability. Do not mount 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. Consult your dealer or have a Yamaha
trained person experienced in proper rigging mount the outboard motor.
Too much weight on the transom could change the center of gravity, buoyancy, operating
balance, or performance of the boat, which could cause loss of control or swamping. Con-
sult 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 out-
board 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. This could cause loss of control.
3-1
Outboard motor installation / External dimensions
External dimensions
F200BET, FL200BET, F250GET, FL250GET
mm (in)
453 (17.8)
723.9 (28.5)
T1(*1)
32˚
3
317 (12.5)
X: 1155 (45.5)
619 (24.4) U: 1272 (50.1)
219 (8.6) 651 (25.6)

75 (3.0)
902 (35.5)
752 (29.6)
387 (15.2)
45 (1.8)
39 (1.5)
U: 770 (30.3)
X: 643 (25.3)
230 (9.1)
U: 1205 (47.4)
X: 1078 (42.4)
H (*2)
U: 924 (36.4)
X: 847 (33.3)
59 (2
.3)
216 (8.5)
˚
67
12˚
X: 52 (2.0)
(1.0)
U: 59 (2.3) –3˚ 673 (26.5)

25
(*1) Minimum distance between the outboard motors in twin or triple installation
(*2) Transom height
TIP:
The dimension values may include reference values.
3-2
RIG
Clamp bracket
mm (in)
180 (7.1) 180 (7.1)
163.5 (6.4) 163.5 (6.4)
50.8 (2.0)
79 (3.1)
254 (10.0)
13 (0.5) 20 (0.8)
18.5 (0.7)
411 (16.2)
13 (0.5)
55.5 (2.2)
52 (2.0)
102 (4.0) 102 (4.0)

125.4 (4.9) 125.4 (4.9)
TIP:
The dimension values may include reference values.
3-3
External dimensions / Crate top cover pictograph description
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.
Stack limit: Maximum units for storage
Upward
Handle with care

Avoid water
3
Product barycentric position

Lifting fork insert position
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.
3-4
RIG
Uncrating procedure
1. Check the crate for shipping damage.
2. Remove the top cover.
3. Remove all of the bolts from the bottom

plate, and then remove the frame.
4
NOTICE: Be careful not to damage the
outboard motor.
4. Remove the wrapping, and then check

the outboard motor for concealed dam-
age.
5. Remove the top cowling, and then

9. Remove the skeg holder 5.
remove the flywheel magnet cover 1.
10. Remove the bolts 6.

6. Install a lifting harness 2 to the engine
hangers 3.
3
6
2
3 11. Remove the steering retainer, and then

install a hydraulic steering cylinder fol-
7. Tension the lifting harness.
lowing the recommendation of the manu-
8. Lift up the outboard motor along with the facturer.
bottom plate 4 carefully. NOTICE: Make
sure that the lifting harness does not
damage any parts of the outboard
motor.
3-5
Uncrating procedure / Outboard motor mounting
Outboard motor mounting

Proper mounting of the outboard motor pro- C/L
vides better performance, maximum reliabil- e f
ity, and the highest customer satisfaction.
This chapter contains the specifications nec-
essary to mount the outboard motor, and
may vary slightly depending on 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” (3-2). T1
1. For single outboard motor installation,

place the outboard motor on the vertical
centerline of the boat transom. For the
TIP:
• Make sure that the distance e is equal to
3
hull without strakes, make a same radius
distance f.
(R) at both sides of hull, and have • For the distance (T1), see “External dimen-
another measurement points.
sions” (3-2).
È C/L
For triple outboard motor installation, place
the center outboard motor so that the C/L of
the outboard motor is aligned with the C/L of
a b the boat transom. Place the other 2 out-
R R board motors on both sides so that the dis-
tances from the C/L of the outboard motors
to the C/L of the boat transom are equal.
c d
C/L
É C/L g h
a b
c d
È Hull without strakes

T1 T1
É Hull with strakes
TIP:
Make sure that the distance a is equal to
distance b, and the distance c is equal to
distance d.
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.
3-6
RIG
TIP: TIP:
• Make sure that the distance g is equal to This mounting height information is for refer-
distance h. ence only. It is impossible to provide com-
• If the boat has a V shape hull, the center plete instructions for every possible boat and
outboard motor should have longer tran- outboard motor combination.
som height than the outboard motors on
both sides. 3. Adjust the height of the scale m to the
• For the distance (T1), see “External dimen- transom height (H), and place it on the
sions” (3-2). special service tool 1. Secure the spe-
cial service tool 1 to the boat transom
2. Adjust the position of the outboard motor n using screws or vises.
so that the height of the anti-cavitation
plate k is equal to or slightly above the TIP:
bottom of the boat transom. For the transom height (H), see “External
dimensions” (3-2).
È
4. When the outboard motor mounting posi-

tion has been determined, mark the best-
suited 4 symmetrical mounting holes in
k the boat transom n. Drill the mounting
holes perpendicular to the surface of the
boat transom using a 13.0 mm (0.5 in)
drill bit.
m 1
É
k k
n
Ê
H
p
m
k k C/L
k
Drilling plate 1: 90890-06783
È Single outboard motor installation Mounting hole diameter p:

É Twin outboard motor installation 13.0 mm (0.5 in) or more
Ê Triple outboard motor installation
3-7
Outboard motor mounting / Outboard motor mounting height
5. Apply sealant to the mounting holes and
secure the outboard motor using the
included mounting bolts 2, small wash-
ers 3, large washers 4, and nuts 5.
NOTICE: 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.
2 Outboard motor mounting height

3 4 4-stroke engines are heavier than 2-stroke
3 5
engines of the same horsepower. Therefore,
if a 2-stroke outboard motor is replaced with
2
3
5
a 4-stroke outboard motor, the boat will
become “stern heavy.” Also, the water line 3
4 3 will rise and become closer to the power unit.
If the water line is too close to the power
head, poor engine performance could result,
and water could enter the cylinders and dam-
D age the engine.
2 When mounting a 4-stroke outboard motor to
3 4
3 5 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. Mea-
sure the mounting height when the boat is
Boat transom moored and carrying the maximum load.
Mounting bolt
thickness (D)
65–75 mm M12 × 130 mm
(2.56–2.95 in) (5.12 in)
75–95 mm M12 × 150 mm
(2.95–3.74 in) (5.91 in) a
TIP:
The second hole from the top of each clamp
bracket is recommended for the upper
mounting bolt.
Minimum mounting height a:
6. Install the mounting bolts, and then 100 mm (3.9 in)
tighten the nuts firmly. NOTICE: Make
sure that the clamp brackets do not
bite into the boat transom.
7. Tighten the locknuts firmly.
3-8
RIG
Rigging grommet mounting
Rigging grommet description
b c
d
a
m 2
e
k 3. Remove the rigging grommet 3.
h f
g
a Throttle cable
b Extension wiring harness
c Water temperature sensor harness
(optional) or water pressure sensor hose
(optional)
d Isolator lead (optional)
e Battery cable
3
f Conventional gauge lead (optional) or 6Y8
Multifunction Meter harness (optional)
g Fuel hose 4. Remove the cable holder 4.
h Speedometer hose
k Shift cable 4
m Flushing hose (commercially available)
Installing the shift cable and throttle

cable
Before installing the shift cable and throt-

tle cable, make sure to adjust the cables
according to the procedures in the remote
control operation manual. 5. Route the shift cable 5 through the bot-
tom cowling.
1. Remove the rubber seal 1 from the 6. Fit the cable holder 4 into the groove a
retaining plate 2. in the shift cable 5, and then install the
cable holder 4 along with the shift cable
5.
a
4
1
2 5
2. Remove the retaining plate 2. 5
3-9
7. Fully screw in the shift cable joint 6 to 12. Adjust the shift cable joint 6, and then
the shift cable 5. install the shift cable joint 6 to the pin h.
WARNING! The shift cable joint must
be screwed in 8.0 mm (0.31 in) or
more.
h
6
5
6
8. Move the remote control lever to the N

position. 6 k
9. Make a mark b on the fully retracted

Dimension k: 8.0 mm (0.31 in) or more
3
inner cable, and then make a mark c on
the fully extended inner cable. 13. Install the clip 9, and then tighten the
shift cable locknut 0 to the specified
10. Make a mark d in the middle point
torque.
between the marks b and c, and then
align the mark d with the outer cable
edge e.
b
0
b d c
b d 9
Shift cable locknut 0:

e
4 N·m (0.4 kgf·m, 3.0 ft·lb)
11. Align the mark f on the bushing 7 with
the mark g on the shift bracket 8. 14. Route the throttle cable A through the
bottom cowling.
7
f 15. Fasten the throttle cable A using the
cable holder 4 so that the cable holder
4 is fitted into the groove m in the throt-
tle cable A.
m
8 g 4
3-10
RIG
16. Fully screw in the throttle cable joint B to
the throttle cable A. Throttle cable locknut D:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
17. Pull the inner cable so that there is no
free play (backlash). 21. Check the shift cable and throttle cable
for proper operation.
Installing the wiring harness

1. Remove the 10-pin coupler a from the
holder b on the bracket.
A
B
a b
18. Check that the accelerator lever n con-

tacts the stopper p.
19. Adjust the throttle cable joint B, and then

connect the throttle cable joint B to the
pin r of the accelerator lever n. 2. Route the extension wiring harness
WARNING! The throttle cable joint through the bottom cowling.
must be screwed in 8.0 mm (0.31 in) or
more. 3. Connect the 10-pin coupler c, and then
fasten it using the holders b and d on
the bracket.
p
n
r d
b
B s B
Dimension s: 8.0 mm (0.31 in) or more c
20. Install the clip C, and then tighten the

Installing the isolator lead (optional)
throttle cable locknut D to the specified 1. Remove the cap 1.
torque.
1
C D
2. Route the isolator lead 2 through the
bottom cowling.
3-11
3. Connect the isolator coupler a.
1
2
a
2. Cut off the tip a of the nipple 2.
Installing the battery cable
1. Route the battery cable through the bot-
tom cowling.
2. Connect the negative battery cable a,

2 a 3
and then tighten the negative battery
cable nut 1 to the specified torque.
3. Connect the positive battery cable b.
1
3. Install the extension hose 3 to the nipple
2, and then fasten it using the plastic tie
4.
2 4 3
a b
Negative battery cable nut 1:

13 N·m (1.3 kgf·m, 9.6 ft·lb)
4. Install the rubber cap 2.
TIP:
Cut the extension hose 3 to 50 mm (2.0 in).
4. Install the tube 5.
2
5
Installing the speed sensor
(optional)
See 6Y8 Multifunction Meter set up manual
for details of the components.
1. Remove the engine ECM cover 1.

3-12
RIG
TIP:
c
Cut the tube 5 to 600 mm (23.6 in).
5. Remove the bracket 6.

A
Speed sensor adapter bolt A:

10 N·m (1.0 kgf·m, 7.4 ft·lb)
6 9. Connect the extension hose 3 to the

speed sensor adapter 0, and then fas-
6. Remove the cap 7, and then remove the ten the extension hose using the plastic
bracket 8 from the speed sensor coupler tie B.
b.
7 B
b 0
10. Connect the speed sensor coupler b.

7. Install the speed sensor 9 to the speed
sensor adapter 0, and then tighten the
speed sensor 9 to the specified torque.
11. Install the engine ECM cover.
Installing the water pressure sensor

Speed sensor 9: (optional)
18 N·m (1.8 kgf·m, 13.3 ft·lb) See 6Y8 Multifunction Meter set up manual
for details of the components.
8. Install the speed sensor assembly c,
and then tighten the speed sensor
adapter bolt A to the specified torque. Do not reuse a gasket, always replace it
with a new one.
3-13
1. Remove the engine ECM cover 1, and
then remove the plug 2.
1
W
2 b
2. Install the water pressure sensor 3 to Installing the rigging grommet

the water pressure sensor adapter 4, 1. Route each harness through the proper
and then tighten the water pressure sen-
sor 3 to the specified torque.
hole in the rigging grommet. See “Rig-
ging grommet description” (3-9) for the 3
detailed description of the rigging grom-
met.
4
2. Align the white tape a on the battery
3 cable with the outer end of the rigging
grommet.
Water pressure sensor 3:

18 N·m (1.8 kgf·m, 13.3 ft·lb)
3. Install a new gasket 5 and the water

pressure sensor assembly a, and then a
tighten the water pressure sensor
adapter 4 to the specified torque. 3. Install the retaining plate 1.
5 4. Install the rubber seal 2.
4 a
2
1
Water pressure sensor adapter 4:
23 N·m (2.3 kgf·m, 17.0 ft·lb)
TIP:
4. Remove the cap, and then connect the
Make sure that the rubber seal is installed
water pressure sensor coupler b.
securely.
3-14
RIG
5. Install the rigging tube retainer 3, and
then fasten it using the plastic tie 4.
Remote control box and switch

panel installation
See the Remote Control Box Operation Man-
ual or Rigging Guide for the installation pro-
cedures.
3-15
Remote control box and switch panel installation / Battery installation
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-cur-
rent protection in compliance with ABYC (E-11) must be provided.
Do not reverse the battery connections. Otherwise, the charging system could be damaged.
Battery cable routing without house (accessory) battery
• When only one battery is used for one engine, connect the positive battery cable and isola-
tor lead to the positive battery terminal. If the isolator lead is left unconnected, accidental 3
contact of the isolator lead with the negative terminal of the battery can cause a short cir-
cuit, 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.
Outboard
motor
Isolator lead
Red Black
3-16
RIG
STBD PORT
Outboard Outboard
Isolator lead motor motor
Red Black Red Black
Black
Outboard
motor
Isolator lead
Black
Battery switch
ON/OFF
Red
STBD PORT
Outboard Outboard
motor motor
Isolator lead Isolator lead
Red Black Red Black
ON/OFF ON/OFF
Battery switch Battery switch

Black
3-17
STBD PORT
Outboard Outboard
motor motor
Battery switch
Battery switch Navigation systems Boat systems
Black Black
ON/OFF ON/OFF
Red
Red
Red Red
3
Black Black Black
Battery cable routing with house (accessory) battery
• When only one battery is used for one engine, connect the positive battery cable and isola-
tor 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 cir-
cuit, 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.
3-18
RIG
Outboard
motor Isolator lead
Battery switch Red

Battery switch
ON/OFF
1 2
Black
Red
House battery
Outboard
motor
Isolator lead
Red
Black
Black
House battery
Outboard
motor Isolator lead
Black
Battery switch Red
1 2
Black
Red
House battery
3-19
STBD PORT
Outboard Outboard
motor motor
Black
Battery switch Red Red Black

Battery switch
ON/OFF
Black ON/OFF
1 2
Black
Battery switch
House battery 3
STBD PORT
Outboard Outboard
motor motor
Black
Red Battery switch Red Black

Battery switch
ON/OFF
1 2 1 2
Black Black
Battery switch
House battery
3-20
RIG
STBD PORT
Outboard Outboard
motor motor
Black
Battery switch Red Black

Red
Battery switch
1 2 1 2
House battery
Black Black
STBD PORT
Outboard Outboard
motor motor
Battery switch
Battery switch
Black
ON/OFF
Red ON/OFF
Red
ON/OFF
Black Black
Black
Black
House battery House battery
3-21
System diagram
Single outboard motor application
(*1) Install the waterproof cap to the open terminals.
1 Trim sensor Color code

2 Trim sensor coupler B : Black
3 Speed sensor
G : Green
4 Water pressure sensor
L : Blue
5 Engine ECM
P : Pink
6 Pigtail bus wire
7 Single hub P/B : Pink/Black
8 Main bus wire R : Red
9 703 remote control box W : White
0 Fuse (10 A) Y : Yellow
A Terminal resistor
B Tachometer unit
C Fuel meter unit
D Speedometer unit
E GPS
F Engine start switch (with engine shut-off
switch)
G 8 ft power wire
H Fuel tank (fuel level sensor)
a Bus port
b Device port
c Power port
È 703 remote control model

É 704 remote control model
Ê PORT
Ë STBD
3-22
Battery installation / System diagram
3
RIG
B C D W
L
6P
4P 4P 4P B P B P/B
É
F
6P a A
4P b Ê Ë
4P b H H
Hub 1 (*1) R
4P b (*1) G
G
6P a B B
2P c Y Y Y
0
È
(*1) R 9
(*1) G
B
8 Y
6P
7
4P
4P
3
5
4
P P
2 1
3-23
Twin outboard motor application

3 Speed sensor
L : Blue
P : Pink
5 Engine ECM
P/B : Pink/Black
6 Pigtail bus wire
7 Terminal resistor W : White
8 Main bus wire Y : Yellow
9 8 ft power wire
0 Fuse (10 A)
A Engine start switch (with engine shut-off
switch)
B Tachometer unit
C Fuel meter unit
D Speedometer unit
E Fuel tank (fuel level sensor)
F GPS
G Multisensor (speed, water temperature,
and water depth)
a Bus port
b Device port
c Power port
È PORT
É STBD
3-24
System diagram
3
RIG
B B C D
6P
4P 4P 4P 4P B P B P/B
6P a 7
4P b
4P b (*1)
4P b (*1) È É
E E L W
6P a
2P c (*1)
8
Hub 3 A
F
6P a
4P b
4P b
4P b
6P a B B
9
Y Y Y
2P c 0
Hub 2
G
6P a 4P
4P b
4P b
4P b
6P a 7
2P c (*1)
6 6
Hub 1
4P 4P
3
5 5
4 4
P P P P
2 1 2 1
3-25
Triple outboard motor application

3 Speed sensor
L : Blue
P : Pink
5 Engine ECM
P/B : Pink/Black
6 Pigtail bus wire
7 Main bus wire W : White
8 Fuse (10 A) Y : Yellow
9 Engine start switch (with engine shut-off
switch)
0 8 ft power wire
A Terminal resistor
B Tachometer unit
C Fuel meter unit
D Speedometer unit
E Fuel tank (fuel level sensor)
F GPS
G Multisensor (speed, water temperature,
and water depth)
a Bus port
b Device port
c Power port
È PORT
É STBD
3-26
System diagram
3
RIG
B B B C D
6P
4P 4P 4P 4P 4P
6P a A
4P b
4P b B P B P/B
4P b
6P a
2P c
7 È É
Hub 3 E E L W
9
6P a
0
4P b (*1)
F
4P b
4P b B B
Y Y Y
6P a 8 G
2P c (*1)
Hub 2
7
4P
6P a 7
4P b
6P a
4P b
4P b (*1)
4P b
4P b (*1)
6P a
4P b
2P c (*1)
6P a A
Hub 1 2P c (*1)
6 6 6
Hub 4
4P 4P 4P
3
5 5 5
4 4 4
P P P P P P
2 1 2 1 2 1
3-27
System diagram / Rigging recommendation
Rigging recommendation
Extension length recommendation for battery cable
Do not exceed the recommended extension length for the battery cable. Otherwise, the elec-
trical system could be damaged or operate improperly.
To extend the length of battery cables, follow the requirements in the tables for your battery capac-
ity, cable size, and ambient temperature.
The maximum total extension length is the total combined length of the positive and negative bat-
tery cables.
Select an extension battery cable and terminal that meet ABYC requirements or equivalent.
Select a 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
3
Maximum total extension length
Minimum (Positive battery cable + Negative battery cable)
Unit
capacity AWG4 AWG2 AWG1/0
(20 mm2) (30 mm2) (50 mm2)
CCA/EN 711.0 Amps 14.2 m
5.4 m (17.7 ft) 9.2 m (30.2 ft)
20HR/IEC 100.0 Ah (46.6 ft)
Ambient temperature is below 0 °C (32 °F)

Battery requirements Cable specifications
Maximum total extension length
Minimum (Positive battery cable + Negative battery cable)
Unit
capacity AWG4 AWG2 AWG1/0
(20 mm2) (30 mm2) (50 mm2)
CCA/EN 711.0 Amps
3.5 m (11.5 ft) 6.0 m (19.7 ft) 9.2 m (30.2 ft)
20HR/IEC 83.0 Ah
3-28
RIG
Propeller selection The propeller sizes listed in the propeller list
The size and type of propeller that is used will indicate the following information:
affect the performance of a boat and out-
board 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. d a b c
Use the following information as a guide for
selecting a propeller that meets the operating
conditions of the boat and outboard motor.
a Propeller diameter (in inches)
Propeller size b Propeller pitch (in inches)
c Propeller type (propeller mark)
The size of the propeller is indicated on the
d Number of propeller blades
propeller boss end, and on the side of the
propeller boss.
Selection
When the engine speed is at full throttle oper-
ating range, the ideal propeller for the boat is
the one that provides maximum performance
a b c in relation to boat speed and fuel consump-
tion.
Full throttle operating range:
5000–6000 r/min
b
a
c
a Propeller diameter (in inches)

b Propeller pitch (in inches)
c Propeller type (propeller mark)
3-29
Propeller selection
Regular rotation model
Dia. (in) Pitch (in) Mark Material Part number Remarks
13 3/8 23 M S-Steel 6G5-45976-01
13 3/8 25 M S-Steel 6G5-45930-00
13 3/4 17 M2 S-Steel 6G5-45978-03
13 3/4 19 M2 S-Steel 6G5-45974-03
13 3/4 19 M S-Steel 68F-45974-00
13 3/4 21 M S-Steel 6G5-45972-02
13 3/4 21 M S-Steel 68F-45976-00
14 1/4 17 M S-Steel 68F-45972-00
14 1/4 18 M S-Steel 68F-45978-00
14 1/2 15 M S-Steel 68F-45970-00
14 1/2 19 T S-Steel 61A-45974-00
14 1/2
14 1/2
21
23
T
M
S-Steel
S-Steel
61A-45972-00
6R4-45974-A0 3
14 7/8 21 M S-Steel 6R4-45972-A0
15 17 T S-Steel 61A-45978-00
15 21 T S-Steel 6D0-45972-00
15 21 T S-Steel 6BR-45B70-00 4 blades
15 1/4 15 M S-Steel 6G5-45970-02
15 1/4 15 M S-Steel 6R4-45976-A0
15 1/4 17 M S-Steel 6R4-45978-A0
15 1/4 19 M S-Steel 6R4-45970-A1
15 1/4 19 T S-Steel 6D0-45970-00
15 1/2 17 T S-Steel 6D0-45978-00
15 3/4 13 M S-Steel 6G5-45932-00
15 3/4 15 T S-Steel 6D0-45976-00
13 1/2 23 M Aluminum 6G5-45949-00 F200B only
14 19 M Aluminum 6G5-45945-01 F200B only
3-30
RIG
Counter rotation model
Dia. (in) Pitch (in) Mark Material Part number Remarks
13 3/8 23 ML S-Steel 6K1-45976-00
13 3/4 17 ML1 S-Steel 6K1-45978-02
13 3/4 19 ML S-Steel 68G-45974-00
13 3/4 19 ML1 S-Steel 6K1-45974-02
13 3/4 21 ML S-Steel 6K1-45972-01
13 3/4 21 ML S-Steel 68G-45976-00
14 1/4 17 ML S-Steel 68G-45972-00
14 1/4 18 ML S-Steel 68G-45978-00
14 1/2 19 TL S-Steel 61B-45974-00
14 1/2 21 TL S-Steel 61B-45972-00
14 1/2 23 ML S-Steel 6R1-45974-A0
14 7/8 21 ML S-Steel 6R1-45972-A0
15 17 TL S-Steel 61B-45978-00
15 21 TL S-Steel 6D1-45972-00
15 21 TL S-Steel 6BS-45B70-00 4 blades
15 1/4 15 ML S-Steel 6K1-45970-01
15 1/4 15 ML S-Steel 6R1-45976-A0
15 1/4 17 ML S-Steel 6R1-45978-A0
15 1/4 19 ML S-Steel 6R1-45970-A1
15 1/4 19 TL S-Steel 6D1-45970-00
15 1/2 17 TL S-Steel 6D1-45978-00
15 3/4 15 TL S-Steel 6D1-45976-00
14 19 ML Aluminum 6K1-45945-00 FL200B only
14 1/2 17 ML Aluminum 6K1-45947-00 FL200B only
3-31
TRBL
SHTG
Troubleshooting
YDIS ..................................................................................... 4-1

Feature ....................................................................................... 4-1
Hardware requirement................................................................ 4-1
Function...................................................................................... 4-2
Connecting the communication cable to the outboard motor ..... 4-5
Outboard motor troubleshooting...................................... 4-6

Troubleshooting procedure ........................................................ 4-6
Troubleshooting the power unit using the YDIS ......................... 4-6
Trouble code and checking step ................................................ 4-9
Troubleshooting the power unit using the
diagnostic flash indicator .......................................................... 4-18
Troubleshooting the power unit (trouble code not detected) .... 4-19
Troubleshooting the PTT unit ................................................... 4-25
Troubleshooting the lower unit ................................................. 4-26
4
TRBL
SHTG Troubleshooting
YDIS
This manual contains the model-specific information. See the YDIS Instruction Manual for detailed
information.
Feature
The YDIS provides quicker detection and analysis of engine malfunctions.
By connecting your computer to the engine ECM of an outboard motor using the communication
cable, this software can be used to display sensor data and data stored in the engine ECM on the
computer monitor.
If this software is run on Microsoft Windows 2000, Windows XP, or Windows Vista, the information
can be displayed in colorful graphics. Also, the software can be operated using either a mouse or a
keyboard.
In addition, the data for the main functions (Diagnosis, Diagnosis record, Engine monitor, Data log-
ger, and Record of engine oil exchange) can be saved on a disk or printed out.
Hardware requirement
Make sure that your computer meets the following requirements before using this software.
Computer: IBM PC/AT compatible computer
Operating system: Microsoft Windows 2000, Windows XP, or Windows Vista
CPU:
Windows 2000: Pentium, 166 MHz or higher (Pentium, 233 MHz or higher
recommended)
Windows XP: Pentium, 300 MHz or higher (Pentium, 500 MHz or higher
recommended)
Windows Vista: Core family, 1.6 GHz or higher (Core family, 2.0 GHz or higher
recommended)
Memory:
Windows 2000: 64 MB or more (128 MB or more recommended)
Windows XP: 128 MB or more (256 MB or more recommended)
Windows Vista: 1 GB or more
Hard disk free space: 20 MB or more (40 MB or more recommended)
Drive: CD-ROM drive
Display: VGA (640 × 480 pixels) 256 or more colors
SVGA (800 × 600 pixels or more recommended) 256 or more colors
Mouse: Compatible with the operating systems mentioned previously
Communication port: RS232C (Dsub-9 pin) port, USB port
Printer: Compatible with the operating systems mentioned previously
4-1
YDIS
TIP:
• The amount of memory and the amount of free space on the hard disk differs depending on the
computer.
• Using this software while there is not enough free space on the hard disk could cause errors and
result in insufficient memory.
• This software will not run properly on some computers.
• When starting up this program, do not start other software programs.
• Do not use the screen saver function or the energy saving feature when using this program.
• If the engine ECM is changed, restart the program.
• Windows XP and Windows Vista are multiuser operating systems. Therefore, make sure to quit
this program if the login user is changed.
Function
• Diagnosis
Displays each part name, and the engine ECM trouble codes and status when the engine start
switch is turned to ON. This enables you to find malfunctioning parts. The trouble codes displayed
are the same as those described in this chapter. See “Trouble code and checking step” (4-9).
• Diagnosis record 4
Displays each part name and the engine ECM trouble codes that have been recorded. This
enables you to check the record of malfunctions for the outboard motor. The trouble codes dis-
played are the same as those described in this chapter. See “Trouble code and checking step” (4-
9).
• Engine monitor
Each sensor status and the engine ECM data are displayed when the engine start switch is turned
to ON. This enables you to find malfunctioning parts quickly. In addition, the data displayed using
the Engine monitor function can be displayed in a graph.
Engine speed Fuel injection duration Dual engine system switch
Intake pressure (*1) Ignition timing Shift cut-off switch
Throttle position sensor 1 Engine temperature Overheat thermoswitch
Throttle valve opening Intake temperature Main switch
Throttle position sensor 2 Oil pressure (*2) Main relay
Accelerator position sensor 1 Intake cam timing (STBD) Electronic throttle relay
Accelerator position sensor 2 Intake cam timing (PORT) Fuel pump relay
Atmospheric pressure Engine stop lanyard switch
(*3)
Battery voltage Shift position switch (*4)
(*1) Intake air pressure
(*2) Engine oil pressure
(*3) Engine shut-off switch
(*4) Neutral switch
4-2
TRBL
• Stationary test
Operation tests can be performed while the engine is stopped.
Oil ctrl. valve drive (STBD) Operate electric fuel pump
Ignite ignition coil (#1–#6)
(*1) (*3)
Oil ctrl. valve drive (PORT) Operate elect. fuel feed
Operate injector (#1–#6)
(*2) pump (*4)
(*1) OCV drive (STBD)
(*2) OCV drive (PORT)
(*3) Operate high-pressure fuel pump
(*4) Operate low-pressure fuel pump
• Data logger
Displays 13 minutes of recorded data for 2 or more of the items stored in the engine ECM. In addi-
tion, the operating time as compared to the engine speed and the total operating time are dis-
played. This enables you to check the operating status of the engine. You can also save the
engine ECM record data to a file so that you can view and display the graph later.
Engine speed Throttle position sensor Intake pressure (*1)
Battery voltage Engine temperature Oil pressure (*2)
(*2) Engine oil pressure
• ECM record data graph

When a malfunction occurs in the ETV system, 4 seconds (2 seconds before and after the mal-
function) of data is recorded in the engine ECM. This data can be displayed on a graph using the
“ECM record data graph” of the YDIS.
When the communication cable is used to connect a computer to the engine ECM, the engine
ECM record data can be saved and viewed on the computer.
The saved engine ECM record data can also be viewed offline.
Engine speed Ref. TPS voltage (*3) Electronic throttle relay
Ref. acc. pos. sensor voltage
Accel position sensor 1 Overheat warning
(*4)
Target TPS voltage for ISC
Accel position sensor 2 Low oil pressure (*8)
(*5)
Throttle position sensor 1 Engine stop mode
Throttle position sensor 2 Engine start mode
Intake pressure (*1) Engine stop mode with SW
Engine stop lanyard switch
Battery voltage
(*6)
Target TPS voltage (*2) Main relay (*7)
4-3
YDIS
(*2) 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.
(*3) Reference TPS voltage
This item shows the criterion output voltage of the TPS.
This value is used to detect the TPS output voltage during engine operation.
(*4) Reference APS voltage
This item shows the criterion output voltage of the APS.
This value is used to detect the APS output voltage when the remote control lever is
opened.
(*5) Engine ECM controls the engine idle speed using the throttle valve that is connected to the
TPS.
This target voltage is used by the engine ECM to obtain the target opening angle of the
throttle valve at engine idle speed.
(*6) Engine shut-off switch
(*7) Main relay (ignition coil, fuel injector, VCT, engine ECM, low-pressure fuel pump, high-
pressure fuel pump, vapor shut-off valve, and YDIS)
(*8) Low engine oil pressure
4
4-4
TRBL
Connecting the communication cable to the outboard motor
a YDIS coupler (gray)

YDIS (CD-ROM, Ver. 1.33) 1:
60V-WS853-06
YDIS USB adapter and cable 2:
60V-WS850-00
4-5
YDIS / Outboard motor troubleshooting
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 fol-
lowing the trouble code chart.
4. When a trouble code is detected, check the data logger of the engine ECM record data 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).”
6. Before using the YDIS to check the power unit, check the engine ECM circuit. See “Checking
the engine ECM circuit” (5-28).
TIP:
• Make sure to check that the couplers and connectors are connected securely.
• 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 4
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.
• Because 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
malfunctioning.
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 malfunctioning.
4-6
TRBL
Trouble code table
U : Indicated
— : Not indicated
Trouble Diagnostic YDIS diagno-
Item YDIS diagnosis
code flash indicator sis record
1 Normal U — —
13 Pulser coil malfunction U U U
15 Engine temp sensor malfunction (*1) U U U
17 Knock sensor malfunction U U U
19 Battery voltage malfunction U U U
23 Intake temp sensor malfunction (*2) U U U
24 Cam position sensor (EXH) malfunction U U U
27 Water in fuel U — —
28 Shift position switch malfunction (*3) U U U
29 Intake press sensor malfunction (*4) U U U
37 Intake air passage malfunction U U U
39 Oil press sensor malfunction (*5) U U U
44 Engine stop lanyard switch ON (*6) U U —
45 Shift cut-off switch malfunction U U U
46 Overheat thermoswitch malfunction U U U
Cam position sensor (STBD INT)
71 U U U
malfunction
Cam position sensor (PORT INT)
72 U U U
malfunction
73 Oil control valve (STBD) malfunction U U U
74 Oil control valve (PORT) malfunction U U U
112,
113,
114,
115,
116,
117,
118,
119,
121,
122,
123, Electronic throttle system malfunction U U U
129,
136,
137,
138,
139,
141,
142,
143,
144,
145
124,
125,
126, Throttle position sensor malfunction U U U
127,
128
4-7
Trouble Diagnostic YDIS diagno-

Item YDIS diagnosis
code flash indicator sis record
131,
132,
133, Accelerator position sensor malfunction U U U
134,
135
(*1) Engine temperature sensor malfunction
(*2) Air temperature sensor malfunction
(*3) Neutral switch malfunction
(*4) Air pressure sensor malfunction
(*5) Oil pressure sensor malfunction
(*6) Engine shut-off switch ON
4-8
Trouble code and checking step
4-9
The descriptions enclosed by < > are applicable to the twin and triple engine installations.
— : Not applicable
TRBL
SHTG
Trouble LAN gauge

Item Condition Symptom Remarks Checking steps See page
code display
13 Pulser coil Irregular signal C/E Degraded acceleration performance Ignition timing Measure the pulser coil air gap. 7-1
malfunction Declining maximum engine speed is set to BTDC Measure the pulser coil output
10° and VCT 5-55
peak voltage.
assemblies are Measure the pulser coil
set to the 5-55
resistance.
maximum
Check for continuity between
retard angle 5-55
the pulser coil and the engine
A-7
ECM.
Check the protrusions on the
Troubleshooting
7-15
flywheel magnet for damage.
15 Engine temp Out of C/E High engine idle speed Measure the engine
sensor specification Engine is difficult to start when cold temperature sensor input 5-59
malfunction <Difference in engine idle speeds> voltage.
Measure the engine
— 5-59
temperature sensor resistance.
5-59
the engine temperature sensor
A-7
and the engine ECM.
17 Knock sensor Irregular signal C/E Degraded acceleration performance Ignition timing Measure the knock sensor
5-64
malfunction Declining maximum engine speed is set to the resistance.
maximum Check for continuity between
retard angle 5-64
the knock sensor and the engine
A-7
ECM.
Trouble LAN gauge
code display
19 Battery voltage Less than V(*1) Engine does not restart (depends on Check the battery capacity and
10-4
malfunction specified voltage battery condition) specific gravity.
Engine operates normally Check the fuse. 5-3
A-9
Check that the battery cables
and terminals are connected —
properly.
— Measure the lighting coil output
5-50
peak voltage.
Measure the lighting coil
5-50
resistance.
Measure the Rectifier Regulator
5-51
output peak voltage.
Check the Rectifier Regulator
5-51
for continuity.
23 Intake temp Out of C/E High engine idle speed Check the air temperature using
5-56
sensor specification <Difference in engine idle speeds> the YDIS.
malfunction Measure the air temperature
5-56
sensor input voltage.
— Measure the air temperature
5-56
sensor resistance.
5-56
the air temperature sensor and
A-7
the engine ECM.
(*1) Battery voltage and low battery voltage alert are displayed.
4-10
4
Trouble LAN gauge
4-11
code display
24 Cam position Irregular signal C/E Degraded acceleration performance Measure the cam position
5-34
TRBL
SHTG
sensor (EXH) Declining maximum engine speed sensor input voltage.

malfunction <Difference in engine idle speeds> Measure the cam position
5-34
sensor output voltage.
5-34
the cam position sensor and the
— A-3
engine ECM.
5-34
A-3
main relay.
Check the edge and face of the
7-50
flange on the camshaft.
27 Water in fuel Water in fuel W/F Alert buzzer comes on intermittently Check for water in the fuel filter. —
Troubleshooting
while the gear shift is in the N Measure the water detection

position 5-43
switch input voltage.
Check the water detection
— 5-43
switch for continuity.
5-43
the water detection switch and
A-5
the engine ECM.
28 Shift position Irregular signal C/E Low engine idle speed Check the gear shift operation. 10-6
switch <Difference in engine idle speeds> Measure the neutral switch input
malfunction 5-63
voltage.
— Check the neutral switch for
5-63
continuity.
5-63
the neutral switch and the
A-3
engine ECM.
29 Intake press Out of C/E Degraded acceleration performance Ignition timing Measure the air pressure sensor
5-57
sensor specification is set to the input voltage.
malfunction maximum Check for continuity between
retard angle 5-57
the air pressure sensor and the
A-7
engine ECM.
Measure the air pressure sensor
5-57
output voltage.
Trouble LAN gauge
code display
37 Intake air Air leak C/E High engine idle speed Check the gaskets of the intake
6-15
passage Declining maximum engine speed manifolds, surge tank, and
6-26
malfunction <Difference in engine idle speeds> throttle body.
Check the hose between the
6-3
vapor shut-off valve and the
— 6-21
surge tank.
Check the vacuum hoses. 6-3
6-21
Check the intake manifolds for
6-18
cracks.
39 Oil press sensor Out of C/E High engine idle speed Measure the oil pressure using
7-1
malfunction specification Declining maximum engine speed the YDIS.
<Difference in engine idle speeds> Measure the oil pressure sensor
5-39
input voltage.
— Measure the oil pressure sensor
5-39
output voltage.
5-39
the oil pressure sensor and the
A-3
engine ECM.
45 Shift cut-off Irregular signal C/E High engine idle speed Measure the shift cut switch
5-61
switch <Difference in engine idle speeds> input voltage.
malfunction Measure the shift cut switch
5-61
resistance.
— Check the shift cut switch for
5-61
continuity.
5-61
the shift cut switch and the
A-3
engine ECM.
46 Overheat Irregular signal C/E High engine idle speed Measure the thermoswitch input
5-60
thermoswitch <Difference in engine idle speeds> voltage.
malfunction Check the thermoswitch for
5-60
— continuity.
5-60
the thermoswitch and the engine
A-3
ECM.
4-12
4
Trouble LAN gauge
4-13
code display
5-34
TRBL
SHTG
sensor (STBD Declining maximum engine speed sensor input voltage.

INT) malfunction <Difference in engine idle speeds> Measure the cam position
5-34
— Check for continuity between
5-34
A-3
engine ECM.
7-50
5-34
sensor (PORT Declining maximum engine speed sensor input voltage.
INT) malfunction <Difference in engine idle speeds> Measure the cam position
5-34
Troubleshooting
— Check for continuity between

5-34
A-3
engine ECM.
7-50
73 Oil control valve Irregular load C/E High engine idle speed Check the OCV operation using
5-37
(STBD) current value Degraded acceleration performance the YDIS.
malfunction Declining maximum engine speed Measure the OCV input voltage. 5-37
Measure the OCV resistance. 5-37
— Check for continuity between 5-37
the OCV and the main relay. A-3
Check for continuity between 5-37
the OCV and the engine ECM. A-3
Check the OCV filter. 10-12
Trouble LAN gauge
code display
74 Oil control valve Irregular load C/E High engine idle speed Check the OCV operation using
5-37
(PORT) current value Degraded acceleration performance the YDIS.
malfunction Declining maximum engine speed Measure the OCV input voltage. 5-37
Measure the OCV resistance. 5-37
— Check for continuity between 5-37
the OCV and the main relay. A-3
the OCV and the engine ECM. A-3
Check the OCV filter. 10-12
112 Electronic throttle Throttle valve C/E High engine idle speed Engine speed Replace the engine ECM.
system malfunction Throttle valve does not operate is set at
malfunction (Engine ECM <Difference in engine idle speeds> approximately 7-35
internal circuit 1500 r/min
malfunction)
113 Electronic throttle Throttle valve C/E High engine idle speed Engine speed Measure the TPS output voltage
5-31
system malfunction Throttle valve does not operate is set at using the YDIS.
malfunction <Difference in engine idle speeds> approximately Check the throttle valve opening
1500 r/min 5-31
angle using the YDIS.
Check the ETV circuit. 5-33
A-3
Check the fuse. 5-3
A-3
Check the ETV motor relay. 5-32
114 Electronic throttle Throttle valve C/E Engine will not start Replace the engine ECM.
system malfunction
malfunction (Engine ECM — 7-35
internal circuit
malfunction)
115 Electronic throttle Throttle valve C/E High engine idle speed Engine speed Check the ETV circuit. 5-33
116 system malfunction Throttle valve does not operate is set at A-3
malfunction <Difference in engine idle speeds> approximately Check the throttle valve
1500 r/min 6-28
operation.
4-14
4
Trouble LAN gauge
4-15
code display
TRBL
SHTG
118 system malfunction Throttle valve does not operate is set at A-3
malfunction <Difference in engine idle speeds> approximately Check the fuse. 5-3
1500 r/min A-3
Check the throttle body. 6-28
119 Electronic throttle Throttle valve C/E High engine idle speed Engine speed Check the ETV circuit.
system malfunction Throttle valve does not operate is set at 5-33
malfunction <Difference in engine idle speeds> approximately A-3
1500 r/min
malfunction (engine ECM approximately 7-35
Troubleshooting

malfunction)
122 Electronic throttle Throttle valve C/E High engine idle speed Engine speed Check the throttle body. 6-28
system malfunction Throttle valve does not operate is set at Replace the throttle body. (ETV
malfunction <Difference in engine idle speeds> approximately motor mulfunction) 6-26
1500 r/min
system malfunction Throttle valve does not operate is set at A-3
1500 r/min A-3
124 Throttle position Out of C/E High engine idle speed Measure the TPS output voltage
5-31
125 sensor specification Degraded acceleration performance using the YDIS.
malfunction Declining maximum engine speed Check the throttle valve opening
<Difference in engine idle speeds> — 5-31
A-3
Trouble LAN gauge
code display
126 Throttle position Out of C/E High engine idle speed Engine speed Measure the TPS output voltage
5-31
sensor specification Throttle valve does not operate is set at using the YDIS.
malfunction <Difference in engine idle speeds> approximately Check the throttle valve opening
1500 r/min 5-31
Measure the TPS input voltage. 5-31
A-3
127 Throttle position Out of C/E Degraded acceleration performance Measure the TPS output voltage
5-31
128 sensor specification Declining maximum engine speed using the YDIS.
malfunction Check the throttle valve opening
— 5-31
A-3
129 Electronic throttle Throttle valve C/E Degraded acceleration performance Replace the engine ECM.
system malfunction Declining maximum engine speed
malfunction (Engine ECM — 7-35
internal circuit
malfunction)
131 Accelerator Out of C/E High engine idle speed Measure the APS output voltage
5-29
132 position sensor specification Throttle valve dose not operate using the YDIS.
133 malfunction <Difference in engine idle speeds> Measure the APS resistance. 5-29
134 —
Measure the APS input voltage. 5-29
135
the APS and the engine ECM. A-3
137 system malfunction Throttle valve does not operate is set at
malfunction)
139 system malfunction Throttle valve does not operate is set at
malfunction)
4-16
4
Trouble LAN gauge
4-17
code display
141 Electronic throttle Throttle valve C/E High engine idle speed Engine speed Check the ETV circuit.
TRBL
SHTG
system malfunction Throttle valve does not operate is set at 5-33

malfunction <Difference in engine idle speeds> approximately A-3
1500 r/min
142 Electronic throttle Throttle valve C/E Declining maximum engine speed Check the throttle valve
6-28
system malfunction <Difference in engine idle speeds> — operation.
malfunction Replace the throttle body. 6-26
malfunction)
144 Electronic throttle Throttle valve C/E High engine idle speed Engine speed Check the battery cable and
Troubleshooting
—
system malfunction Throttle valve does not operate is set at terminals for proper connection.
1500 r/min A-3
Measure the lighting coil output
5-50
peak voltage.
Measure the lighting coil
5-50
resistance.
Measure the Rectifier Regulator
5-51
output peak voltage.
Check the Rectifier Regulator
5-51
for continuity.
145 Electronic throttle Throttle valve C/E High engine idle speed Check for other detected trouble
4-7
system malfunction <Difference in engine idle speeds> codes (112–144).
malfunction —
Check the throttle valve
6-28
operation.
Troubleshooting the power unit
using the diagnostic flash indicator 2 3
1. Remove the flywheel magnet cover.
d
2. Connect the special service tool 1.
b b e b b b c
3
1 1
d
a
b e b e b b b c
4
5. If trouble code is detected, see “Trouble
1 code and checking step” (4-9).
a Diagnostic test lead (Blue/White) TIP:

When more than 1 trouble code is detected,
Diagnostic flash indicator B 1: the light of the special service tool flashes in
90890-06865 the pattern of the lowest trouble code. After
that trouble code is corrected, the indicator
TIP: flashes in the pattern of the next lowest trou-
When performing this diagnosis, all of the ble code. This continues until all of the trou-
electrical wires must be connected properly. ble codes are detected and corrected.
3. Start the engine and let it idle.
4. Check the flash patterns of the trouble

codes.
Example:
The illustrations indicate code numbers 23
and 113.
b: Light on, 0.33 second
c: Light off, 4.95 seconds
d: Light off, 0.33 second
e: Light off, 1.65 seconds
4-18
TRBL
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
Symptom 1: Engine does not crank.
See
Symptom 2 Cause Checking step
page
Starter motor does not Gear shift not in the N Set the gear shift to the N position.
10-6
operate position
Blown fuse Check the fuse. 5-3
A-9
Starter relay malfunction Check the starter relay. 5-65
Engine start switch Check the engine start switch.
5-66
malfunction
Neutral switch malfunction Check the remote control box. A-11
Short, open, or loose Measure the starter relay input voltage. 5-65
connection in electric starting Check the wiring harness for
system circuit A-9
continuity.
Starter motor malfunction Disassemble and check the starter
5-69
motor.
Starter motor Stuck piston or crankshaft Disassemble and check the power
7-81
operates, but the unit.
engine does not crank Stuck drive shaft Checking the drive shaft bushing. 9-20
4-19
Symptom 1: Engine will not start (engine cranks).
See
page
Engine ECM does not Blown fuse Check the fuse. 5-3
operate A-9
Main relay malfunction Check the main relay. 5-27
A-3
Short, open, or loose Check for wiring continuity between 5-28
connection in engine ECM the main relay and the engine ECM. A-3
circuit Check for wiring continuity between 5-28
the engine ECM and the ground. A-3
Engine ECM malfunction Replace the engine ECM. 7-35
Spark plug does not — Check the ignition spark. 5-53
spark (all cylinders) Spark plug malfunction Check the spark plug. 7-44
Short, open, or loose Measure the ignition coil input voltage. 5-53
connection in ignition coil Check for continuity between the 5-53
circuit ignition coil and the engine ECM. A-7
Check for continuity between the
ignition coil and the main relay.
5-53
A-7 4
Check for continuity between the 5-53
ignition coil and ground. A-7
4-20
TRBL
See
page
Fuel not supplied (all — Measure the fuel pressure. 6-8
cylinders) Pinched or kinked fuel hose Check the fuel hose. 6-1
Fuel leakage Check for fuel leakage. 6-1
Clogged fuel filter element Check the fuel filter element for dirt
6-14
and obstructions.
High-pressure fuel pump Check the high-pressure fuel pump
5-46
malfunction operation using the YDIS.
Measure the high-pressure fuel pump
5-46
resistance.
Short, open, or loose Measure the high-pressure fuel pump
5-46
connection in high-pressure input voltage.
fuel pump circuit Check for continuity between the high-
5-46
pressure fuel pump and the engine
A-5
ECM.
Check for continuity between the high-
5-46
pressure fuel pump and the high-
A-5
pressure fuel pump relay.
A-5
High-pressure fuel pump Check the high-pressure fuel pump
5-47
relay malfunction relay.
Short, open, or loose Measure the low-pressure fuel pump
5-46
connection in low-pressure input voltage.
fuel pump circuit Check for continuity between the low-
5-46
pressure fuel pump and the engine
A-5
ECM.
Check for continuity between the low-
5-46
pressure fuel pump and the main relay.
A-5
Low-pressure fuel pump Check the low-pressure fuel pump
5-46
malfunction operation using the YDIS.
Measure the low-pressure fuel pump
5-46
resistance.
Compression pressure — Measure the compression pressure. 7-1
is low Improper valve timing Check the valve timing. 7-39
Check the timing belt. 7-39
Compression leakage Check the valve for bends and sticking. 7-62
Check the piston and piston rings for
7-86
damage.
Check the cylinder for scratches. 7-86
4-21
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited
engine speed.
See
page
Spark plug does not Spark plug malfunction Check the ignition spark. 5-53
spark (some cylinders) Check the spark plug. 7-44
Short, open, or loose Measure the ignition coil input voltage. 5-53
connection in ignition coil Check for continuity between the 5-53
circuit ignition coil and the engine ECM. A-7
ignition coil and the main relay. A-7
ignition coil and ground. A-7
Ignition coil malfunction Exchange the ignition coil with a
different one, and then check the —
ignition spark.
Fuel pressure is low — Measure fuel pressure. 6-8
Fuel leakage Check for fuel leakage. 6-1 4
Pressure regulator Check the pressure regulator.
6-10
malfunction
Clogged fuel filter element Check the fuel filter element for dirt
6-14
and obstructions.
High-pressure fuel pump Measure the high-pressure fuel pump
5-46
malfunction resistance.
Fuel not supplied Fuel injector malfunction Check the fuel injector operation using
5-44
(some cylinders) the YDIS.
Measure the fuel injector resistance. 5-44
Short, open, or loose Measure the fuel injector input voltage. 5-44
connection in fuel injector Check for continuity between the fuel 5-44
circuit injector and the main relay. A-5
Check for continuity between the fuel 5-44
injector and the engine ECM. A-5
Clogged fuel injector filter Replace the fuel injector. 6-45
Compression pressure — Measure the compression pressure. 7-1
is low Improper valve timing Check the valve timing. 7-39
Check the timing belt. 7-39
Compression leakage Check the valve for bends and sticking. 7-62
Check the piston and piston rings for
7-86
damage.
Check the cylinder for scratches. 7-86
— Improper pulser coil air gap Measure the pulser coil air gap. 7-1
4-22
TRBL
Symptom 1: High engine idle speed.
See
page
Air leakage (throttle valve– Check the gaskets of the intake
6-15
cylinder head) manifolds, surge tank, and throttle
6-26
— body.
Throttle cable is not adjusted Adjust the throttle cable.
3-8
properly
Symptom 1: Engine stalls, unstable engine idle speed, or poor acceleration.

See
page
Improper intake cam Stuck OCV spool valve Check the OCV operation using the
5-37
timing YDIS.
Check the OCV spool valve. 5-37
Clogged OCV filter Replace the OCV filter. 10-12
Clogged oil passage Check the oil passage. 2-16
Stuck VCT Replace the VCT assembly. 7-46
Symptom 1: Limited engine speed (approximately 2000 r/min).

See
page
Buzzer comes on, Clogged cooling water inlet Check the cooling water inlet. 10-8
Overheat alert Water pump malfunction Check the impeller. 8-9
indicator comes on
Check the Woodruff key. 8-9
Check the water pump housing. 8-9
Check the insert cartridge. 8-9
Check the outer plate cartridge. 8-9
Clogged cooling water Check the cooling water passage.
2-17
passage
Thermostat malfunction Check the thermostat. 7-85
Buzzer comes on, Insufficient engine oil Check the engine oil level. 10-5
oil pressure alert Check the engine oil leakage. 2-16
indicator comes on
Check the valve seals and valves. 7-58
Check the piston rings. 7-86
— Measure the oil pressure. 7-1
Engine oil pressure decrease Check the oil pump. 7-77
Check the oil strainer. 9-24
Check the oil passage (power unit and
2-16
oil pump).
Replace the oil filter. 10-10
4-23
Symptom 1: Discharged battery.
See
page
Battery performance Check the battery capacity and specific
10-4
decrease gravity.
Check that the battery cables and
—
terminals are connected properly.
Short, open, or loose Check the charging circuit for proper
A-9
connection in charging circuit connections and damage.
— Stator assembly malfunction Measure the lighting coil output peak
5-50
voltage.
Measure the lighting coil resistance. 5-50
Rectifier Regulator Measure the Rectifier Regulator output
5-51
malfunction peak voltage.
Check the Rectifier Regulator for
5-51
continuity.
4-24
TRBL
Troubleshooting the PTT unit
Symptom 1: PTT unit does not operate.
See
page
PTT relay does not Blown fuse (PTT switch) Check the fuse. 5-3
operate A-11
PTT switch malfunction Check the PTT switch. 5-75
PTT relay malfunction Check the PTT relay. 5-74
Short, open, or loose Measure the PTT switch input voltage. 5-75
connection of the wiring Measure the PTT relay input voltage. 5-74
harness
Check for continuity between the PTT 5-75
switch and the fuse holder. A-11
Check for continuity between the PTT 5-75
switch and PTT relay. A-11
PTT motor does not PTT motor malfunction Disassemble and check the PTT
9-45
operate motor.
Short, open, or loose Check for wiring continuity between
connection in PTT motor the PTT motor and the PTT relay A-11
circuit terminal.
PTT fluid pressure — Measure the PTT fluid pressure. 9-38
does not increase Manual valve open Check the manual valve. 9-40
Insufficient PTT fluid Add sufficient PTT fluid. 10-14
PTT fluid leakage Check the PTT fluid leakage. 10-15
Air in PTT Bleed the PTT unit. 9-40
Clogged fluid passage Disassemble and check the PTT unit. 9-50
9-56
Check the filter for dirt and
9-53
obstructions.
Check the valves for damage. 9-53
Check the fluid passages for 9-50
obstructions. 9-56
Gear pump malfunction Check the gear pump operation. 9-53
4-25
Symptom 1: PTT unit does not hold the outboard motor up.
See
page
Decrease in PTT fluid Manual valve open Check the manual valve. 9-40
pressure in lower Insufficient PTT fluid Add sufficient PTT fluid. 10-14
chamber of PTT
cylinders PTT fluid leakage Check the PTT fluid leakage. 10-15
Clogged or open fluid Disassemble and check the PTT unit. 9-50
passage 9-56
Check the valves for damage. 9-53
Check the fluid passages for 9-50
obstructions. 9-56
Troubleshooting the lower unit

Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate prop-
4
erly.
See
page
Shift cable is not adjusted Adjust the shift cable.
3-8
properly
Shift rod does not operate Check the shift rod for wear. 8-9
properly 9-1
— Shift mechanism malfunction Check the dog clutch. 8-17
(in lower unit) Check the forward gear, reverse gear, 8-17
and pinion for damage and wear. 8-26
8-74
8-83
4-26
ELEC
Electrical system
Electrical component ......................................................... 5-1

Port............................................................................................. 5-1
Starboard.................................................................................... 5-2
Fuse holder ................................................................................ 5-3
Rear............................................................................................ 5-4
Top ............................................................................................. 5-5
Wiring harness routing ...................................................... 5-6

Port............................................................................................. 5-6
Starboard.................................................................................... 5-9
Rear.......................................................................................... 5-12
Top ........................................................................................... 5-15
Bottom cowling ......................................................................... 5-18
Circuit diagram ................................................................. 5-22
ECM coupler layout.......................................................... 5-24
Checking the electrical component................................ 5-26

Using the YDIS......................................................................... 5-26
Measuring the peak voltage ..................................................... 5-26
Using the digital tester.............................................................. 5-27
Engine control system and component ......................... 5-27

Checking the main relay........................................................... 5-27
Checking the engine ECM circuit ............................................. 5-28
Checking the APS .................................................................... 5-29
Checking the APS circuit.......................................................... 5-30
Checking the ETV and TPS ..................................................... 5-31
Checking the ETV motor relay ................................................. 5-32
Checking the ETV and TPS circuit ........................................... 5-33
Checking the cam position sensor ........................................... 5-34
Checking the OCV.................................................................... 5-37
Checking the oil pressure sensor ............................................. 5-39
Checking the water pressure sensor (optional)........................ 5-40
Checking the speed sensor (optional)...................................... 5-41
Fuel control unit and component ................................... 5-43

Checking the water detection switch ........................................ 5-43
Checking the fuel injector ......................................................... 5-44
Checking the low-pressure fuel pump and
high-pressure fuel pump........................................................... 5-46
Checking the high-pressure fuel pump relay............................ 5-47
Checking the vapor shut-off valve ............................................ 5-48
Charging unit and component ........................................ 5-50

Checking the lighting coil.......................................................... 5-50
Checking the Rectifier Regulator.............................................. 5-51
Ignition unit and component ........................................... 5-53

Checking the ignition spark ...................................................... 5-53
Checking the ignition coil.......................................................... 5-53
Checking the pulser coil ........................................................... 5-55
Checking the air temperature sensor ....................................... 5-56
Checking the air pressure sensor............................................. 5-57
Checking the engine temperature sensor ................................ 5-59
Checking the thermoswitch ...................................................... 5-60
Checking the shift cut switch .................................................... 5-61
Checking the neutral switch ..................................................... 5-63
Checking the knock sensor ...................................................... 5-64
Checking the engine shut-off switch......................................... 5-65
Starting unit and component .......................................... 5-65

Checking the starter relay ........................................................ 5-65
Checking the engine start switch.............................................. 5-66
Starter motor .................................................................... 5-67

Removing the starter motor...................................................... 5-69
Checking the starter motor pinion ............................................ 5-69
Disassembling the starter motor............................................... 5-69
5
Checking the armature (starter motor) ..................................... 5-71
Checking the brush holder and brush ...................................... 5-71
Assembling the starter motor ................................................... 5-72
Installing the starter motor........................................................ 5-74
PTT electrical system ...................................................... 5-74

Checking the PTT relay............................................................ 5-74
Checking the PTT switch (bottom cowling) .............................. 5-75
Checking the trim sensor.......................................................... 5-76
ELEC
Electrical system
Electrical component
Port
1 2
6
5 4
1 Air temperature sensor 7 Water detection switch (in fuel cup

2 YDIS coupler assembly)
3 Fuel injector 8 Air pressure sensor
4 High-pressure fuel pump 9 ETV
5 Low-pressure fuel pump
6 Condenser (connect to the air pressure
sensor)
5-1
Starboard
1 2
4
8
5
7 6 5
1 PTT relay
2 Fuse holder
3 Starter motor
4 Diode (connect to the PTT relay)
5 Oil pressure sensor
6 APS
7 Rectifier Regulator
8 Fuel injector
5-2
ELEC
Electrical system
Fuse holder
1 2 3 4 5 6 7 8
A 0 9
1 Fuse (10 A) (ETV, engine ECM) 9 Starter relay

2 Fuse (30 A) (ignition coil, fuel injector, 0 Main relay
VCT, engine ECM) A ETV motor relay
3 Fuse (20 A) (engine start switch, PTT
switch) B High-pressure fuel pump relay
4 Fuse (30 A) (starter relay)
5 Fuse (10 A) (low-pressure fuel pump)
6 Fuse (15 A) (high-pressure fuel pump)
7 Fuse (60 A) (starting battery)
8 Fuse (60 A) (house [accessory] battery)
5-3
Rear
2 3 4
5
5
0 9 8 7
1 Cam position sensor (PORT IN) 8 Water pressure sensor coupler

2 Cam position sensor (PORT EX) 9 Joint coupler 2
3 Condenser (connect to the cam position 0 Knock sensor coupler
sensor [PORT EX])
4 Engine ECM
5 Ignition coil
6 Cam position sensor (STBD IN)
7 Knock sensor
5-4
ELEC
Electrical system
Top
1 Thermoswitch (STBD) 9 Stator assembly

2 OCV (STBD)
3 Joint coupler 1
4 OCV (PORT)
5 Thermoswitch (PORT)
6 Engine temperature sensor
7 Pulser coil
8 Vapor shut-off valve
5-5
Electrical component / Wiring harness routing
Wiring harness routing

Port
A
È É Ê Ë Ì Í Î
C
Ô Ï
Ó Ñ
D D
5
Õ × ×
A B C D-D
È Install the low-pressure fuel pump coupler Ì Fasten the wiring harness using the holder
onto the wiring harness guide. on the fuel rail cover.
É Fasten the thermoswitch connectors and Í Fasten the wiring harness to the fuel rail
wiring harness using the holder. using the plastic tie. Make sure that there
Ê Install the engine temperature sensor lead is no slack in the wiring harness.
and thermoswitch lead on the hook of the
wiring harness guide.
Ë Install the engine temperature sensor cou-
pler onto the wiring harness guide.
5-6
ELEC
Electrical system
A
C
Ô Ï
Ó Ñ
D D
Õ × ×
A B C D-D
Î Fasten the wiring harness (to fuel injector Ò Fasten the wiring harness in the order Ñ,
[#2]) and wiring harness (to fuel injector Ï, and Î.
[#4 and #6]) using the holder in the order Ó Fasten the wiring harness at the white
listed. tape using the holder. Make sure that
Ï Fasten the wiring harness (to fuel injector
there is no slack in the wiring harness.
[#6]) using the holder.
Ô Align the paint marks on the hose with the
Ñ Fasten the wiring harness (to fuel injector
holders.
[#6]) using the plastic tie at the white tape.
5-7
A
C
Ô Ï
Ó Ñ
D D
5
Õ × ×
A B C D-D
Õ Before installing the intake silencer, fasten

the wiring harness (to air temperature sen-
sor) at the white tape using the holder on
the oil filler neck.
× Make sure that the catch of the holder is
facing forward.
Ù Make sure that the end of the plastic tie is
pointing rearward.
5-8
ELEC
Electrical system
Starboard
1 2 1 4 65 4 65
3 1
1
2
4
56 3 37
2
46 4 56 1
A-A 5 B-B 1 C-C D-D
1 3
2
2 2
3 7 87 2 3
8
E-E Û F-F È G-G É
Ê
A A
Ù
B
Ô
× C B C
D D
E E Ë
F F
G
Ì Í
Õ G Î
Ó Ò Ñ
1 Wiring harness È Fit the stator assembly lead into the

2 Stator assembly lead groove in the junction box.
3 Rectifier Regulator lead É Fasten the PTT motor lead and wiring har-
4 Power supply lead ness ground lead using the holder.
Ê Connect the starter motor lead and brown
5 Isolator lead
lead of the wiring harness together.
6 Ground lead
7 Starter motor lead
8 PTT motor lead
5-9
1 2 1 4 65 4 65
3 1
1
2
4
56 3 37
2
46 4 56 1
A-A 5 B-B 1 C-C D-D
1 3
2
2 2
3 7 87 2 3
8
Ê
A A
Ù
B 5
Ô
× C B C
D D
E E Ë
F F
G
Ì Í
Õ G Î
Ó Ò Ñ
Ë Fasten the starter motor lead and junction Î Route the wiring harnesses and PTT
box wiring harness extension using the motor lead through the guide on the termi-
holder. nal.
Ì Route the PTT motor lead to the outside of Ï Fasten the wiring harnesses and PTT
the other leads. motor lead using the holder.
Í Fasten the starter motor lead, wiring har- Ñ Route the battery cable along the bottom
ness, and PTT motor lead using the cowling.
holder. Ò Install the wiring harness ground lead ter-
minal so that it contacts the stopper.
5-10
ELEC
Electrical system
1 2 1 4 65 4 65
3 1
1
2
4
56 3 37
2
46 4 56 1
A-A 5 B-B 1 C-C D-D
1 3
2
2 2
3 7 87 2 3
8
Ê
A A
Ù
B
Ô
× C B C
D D
E E Ë
F F
G
Ì Í
Õ G Î
Ó Ò Ñ
Ó Install the junction box wiring harness Ù Fasten the wiring harness (to fuel injector
extension ground lead terminal so that it [#1]) and wiring harness (to fuel injector
contacts the stopper. [#3 and #5]) using the holder in the order
Ô Fasten the wiring harness in the order Õ, listed.
×, Ù, and Ú. Ú Fasten the wiring harness using the plas-
Õ Fasten the wiring harness (to fuel injector tic tie so that there is no slack in the wiring
[#5]) to the holder at the white tape. harness.
× Fasten the wiring harness (to fuel injector Û Fasten the wiring harness using the
[#3 and #5]) to the holder. holder.
5-11
Rear
È É Ê Ë
×
Ì
Õ 5
Í
Ò Ñ Ï Î
È Fasten the wiring harness using the Ê Place the condenser between the engine
holder. ECM bracket and the wiring harness, and
É Fasten the wiring harness (main), wiring then fasten the condenser using the plas-
harness (to cam position sensor [PORT tic tie.
IN]), and wiring harness (to condenser) to Ë Route the wiring harness to the inside of
the engine ECM bracket using the plastic the blowby hose.
tie. Ì Install the holder and fasten the plastic ties
in the order Ë, ×, and É.
5-12
ELEC
Electrical system
È É Ê Ë
×
Ì
Ò Ñ Ï Î
Í Fasten the wiring harness at the white Ñ Fasten the knock sensor lead using the
tape using the holder. holder. Make sure that the end of the cor-
Î Fasten the wiring harnesses (to ignition rugated tube is positioned 30 mm (1.2 in)
coil [#5]) and wiring harness (to cam posi- from the holder.
tion sensor [STBD IN]) using the holder at Ò Route the knock sensor lead to the inside
the white tape. of the wiring harness.
Ï Make sure that the bracket contacts the
stopper.
5-13
È É Ê Ë
×
Ì
Õ 5
Í
Ò Ñ Ï Î
Ó Fit the protrusion on the knock sensor Õ Make sure that the slot in the joint coupler
coupler into the hole in the engine ECM bracket fits over the rib on the engine
bracket. Make sure that the protrusions on ECM bracket.
the sides of the coupler are positioned × Fit the protrusion on the plastic tie into the
under the stoppers on the engine ECM hole in the engine ECM bracket.
bracket.
Ô Route the wiring harness to the inside of
the joint coupler bracket.
5-14
ELEC
Electrical system
Top
È
Ò
C C
Ï
Ì E
D
B B Ê
Î
D
Í A
E
Ì A Ë
1 Ô 4 Õ
3 6
Ó
2
5
3
A-A B-B C-C D-D E-E
1 Stator assembly lead È Fit the protrusion on the plastic tie into the
2 Thermoswitch connector hole in the wiring harness guide.
3 Wiring harness É Make sure that the protrusion on the
4 High-pressure fuel hose holder contacts the rib on the bracket.
5 Vapor gas hose Ê Route the wiring harness under the high-
6 Engine temperature sensor lead pressure fuel hose and blowby hose.
5-15
È
Ò
C C
Ï
Ì E
D
B B Ê
Î
D
Í A
E 5
Ì A Ë
1 Ô 4 Õ
3 6
Ó
2
5
3
A-A B-B C-C D-D E-E
Ë Install the pulser coil coupler to the Ï Fasten the wiring harness and vapor gas
bracket. hose using the holder.
Ì Install the plastic ties to the wiring harness Ñ Fasten the wiring harness and quick con-
guide in the order Í, È, and Ò. nector using the holder.
Í Fit the protrusion on the plastic tie into the Ò Fit the protrusion on the plastic tie into the
hole in the wiring harness guide. hole in the wiring harness guide.
Î Face the white mark on the wiring harness
upward.
5-16
ELEC
Electrical system
È
Ò
C C
Ï
Ì E
D
B B Ê
Î
D
Í A
E
Ì A Ë
1 Ô 4 Õ
3 6
Ó
2
5
3
A-A B-B C-C D-D E-E
Ó Make sure that the wiring harness (to fuel

injector) does not protrude above the ribs
on the wiring harness guide.
Ô Point the end of the plastic tie to star-
board.
Õ Fold the engine temperature sensor lead.
5-17
Bottom cowling
È
Ê
Ë
2 Ì
A A
B
4
5
Ó
Î
Ò 7Ñ Ï 6
5
8 É
3
A-A Ï Õ 8
0
B Í
B Ô
4
A C
C 5
9
6 Î
B C-C Ñ 7
1 Shift cut switch 9 Isolator coupler

2 Neutral switch 0 Water detection switch coupler
3 PTT switch A PTT switch wiring harness extension
4 Trim sensor coupler B Wiring harness
5 10-pin coupler C PTT switch wiring harness extension
6 6Y8 Multifunction Meter coupler coupler
7 Alert indicator coupler
8 PTT switch coupler
5-18
ELEC
Electrical system
Ê
Ë
2 Ì
A A
B
4
5
Ó
Î
Ò 7Ñ Ï 6
8 É
3
A-A Ï Õ 8
0
B Í
B Ô
4
A C
C 5
9
6 Î
B C-C Ñ 7
È Regular rotation model Ë Fasten the flushing hose, cooling water

É Counter rotation model hose, trim sensor lead, and speedometer
Ê Fasten the flushing hose, cooling water hose using the plate. Make sure to route
hose, and trim sensor lead using the plate. the speedometer hose over the flushing
hose and trim sensor lead.
Ì Fasten the flushing hose, cooling water
hose, and trim sensor lead using the
holder.
5-19
Ê
Ë
2 Ì
A A
B
4
5
Ó
Î
Ò 7Ñ Ï 6
5
8 É
3
A-A Ï Õ 8
0
B Í
B Ô
4
A C
C 5
9
6 Î
B C-C Ñ 7
Í If the 6Y8 Multifunction Meter is selected, Ñ If analog meters are selected, connect the
remove the caps and connect the coupler. alert indicator coupler, and then install the
Î Do not route the wiring harness over the coupler in the location shown in the illus-
bolt. tration.
Ï If the 6Y8 Multifunction Meter is selected, Ò Fasten the meter lead and extension wir-
install the alert indicator coupler in the ing harness using the holder.
location shown in the illustration.
5-20
ELEC
Electrical system
Ê
Ë
2 Ì
A A
B
4
5
Ó
Î
Ò 7Ñ Ï 6
8 É
3
A-A Ï Õ 8
0
B Í
B Ô
4
A C
C 5
9
6 Î
B C-C Ñ 7
Ó Make sure that the white paint mark on the Õ Fasten the flushing hose, cooling water
flushing hose and the white tape on the hose, trim sensor lead, and PTT switch
PTT motor lead are aligned with the edge lead using the holder.
of the grommet.
Ô Fasten the PTT switch wiring harness
extension at the white tape using the
holder.
5-21
Wiring harness routing / Circuit diagram
Circuit diagram
TIP:
The circled numbers in the illustration indicate the engine ECM terminal numbers.
Fuel injector #1
Pulser coil s
F Fuel injector #2
t
Fuel injector #3
E r
Fuel injector #4
q
Cam position sensor Fuel injector #5
(PORT EX) 3 p
Fuel injector #6
o
Cam position sensor
(PORT IN) 2 Ignition coil #1
Cam position sensor

1 å
(STBD IN) Ignition coil #2
5V
k
~
TPS 1 e
TPS 2
Ground
j
Ignition coil #3 5
g w
5V Ignition coil #4
d Engine
ECM
APS 1 \ v
Ground Ignition coil #5
^
5V
i
n
APS 2 U
Ground
a Ignition coil #6
5V m
h
ß ETV motor relay
Air pressure sensor Z
®
z
Oil pressure sensor [ ¥ ETV
© motor
£
µ
a b c
abc Indicates a connection between the symbols.
5-22
ELEC
Electrical system
a b c
OCV (STBD)
Water pressure sensor b æ
OCV (PORT)
•
Speed sensor c High-pressure High-pressure
fuel pump relay fuel pump
Air temperature sensor P
M
y
G
Trim sensor I u P
Thermoswitch
l Vapor shut-off valve
Thermoswitch º
Water detection switch
5
Shift cut switch Oil pressure alert indicator
6 ç
Neutral switch Overheat alert indicator
B †
Engine
Ground ECM Diagnostic flash indicator
H
¢
Knock sensor Alert buzzer
8 { BZ
Engine shut-off Tachometer

switch x T
¶
J
CAN BUS
Main relay
Q K
X
7 R YDIS
Rectifier f
Regulator Main switch
C |
}
Battery §
abc Indicates a connection between the symbols.
5-23
Circuit diagram / ECM coupler layout
ECM coupler layout
1 2 3 4 5 6 7 27 28 29 30 31 32 33 53 54 55 56 57 58 59 60 61
8 9 10 11 12 13 34 35 36 37 38 39 62 63 64 65 66 67 68 69
14 15 16 17 18 19 40 41 42 43 44 45 70 71 72 73 74 75 76 77
20 21 22 23 24 25 26
46 47 48 49 50 51 52 78 79 80 81 82 83 84 85 86
No. Connecting part Color No. Connecting part Color

1 Cam position sensor White/Black 26
(STBD IN) 27 Battery power Red/Yellow
2 Cam position sensor White/Green source
3
(PORT IN)
Cam position sensor White/Blue
28
29
YDIS White/Black 5
(PORT EX) 30
4 31 APS 2 Pink/White
5 Water detection Blue/White 32
switch 33
6 Shift cut switch Blue/Yellow 34 Battery power Red/Yellow
7 Main relay Yellow/Green source
8 Knock sensor Green 35
9 36 Air pressure sensor Pink/Green
10 37 Oil pressure sensor Pink/White
11 38 APS 1 Pink
12 Neutral switch Blue/Green 39
13 Main switch Yellow 40 APS 1 ground Black
14 41 APS 2 ground Black
15 Pulser coil ground Black 42 Water pressure Blue/Black
16 Pulser coil White/Black sensor
17 Engine temperature Black/Yellow 43 Speed sensor Blue
sensor 44 APS 1 power source Orange
18 Sensor ground Black 45 TPS 1 Pink
19 Trim sensor Pink 46 Ground Black
20 CAN BUS (H) White 47 TPS ground Black
21 CAN BUS (L) Blue 48 Sensor power Orange
22 source
23 Air temperature Black/Yellow 49 APS 2 power source Orange
sensor 50 TPS 2 Pink/White
24 51 TPS power source Orange
25 52 Thermoswitch Pink
5-24
ELEC
Electrical system
1 2 3 4 5 6 7 27 28 29 30 31 32 33 53 54 55 56 57 58 59 60 61
8 9 10 11 12 13 34 35 36 37 38 39 62 63 64 65 66 67 68 69
14 15 16 17 18 19 40 41 42 43 44 45 70 71 72 73 74 75 76 77
20 21 22 23 24 25 26
46 47 48 49 50 51 52 78 79 80 81 82 83 84 85 86
No. Connecting part Color No. Connecting part Color

53 Ignition coil #6 Black/Brown 79 ETV power source Red/Green
54 Ignition coil #5 Black/Blue 80 ETV power source Red/Green
55 Fuel injector #6 Purple/White 81 ETV motor (close) Green/Black
56 Fuel injector #5 Purple/Blue 82
57 Fuel injector #4 Purple/Green 83 ETV motor (open) Green/Red
58 Fuel injector #3 Purple/Yellow 84 ETV ground Black
59 Fuel injector #1 Purple/Red 85 Vapor shut-off valve Green/Black
60 Fuel injector #2 Purple/Black 86 OCV (STBD) Purple
61 Low-pressure fuel Blue/White
pump
62 Ignition coil #4 Black/Green
63 Ignition coil #3 Black/Yellow
64 Tachometer Green
65 High-pressure fuel Blue/Red
pump relay
66 ETV motor relay Yellow
67 Alert buzzer Pink
68 Ground Black
69 Ground Black
70 Ignition coil #2 Black/White
71 Ignition coil #1 Black/Orange
72 Oil pressure alert Pink/White
indicator
73 Overheat alert Pink/Black
indicator
74 Diagnostic flash Blue/White
indicator
75 ETV ground Black
76 Ground Black
77 OCV (PORT) Purple
78 Engine shut-off White
switch
5-25
ECM coupler layout / Checking the electrical component
Checking the electrical

component When measuring the peak voltage
Using the YDIS between the terminals of an electrical
When checking the ETV, TPS, OCV, ignition component using the digital tester, make
spark, APS, high-pressure fuel pump, fuel sure that the leads do not contact any
injector, or each sensor, use the YDIS. metal parts. Otherwise, the electrical com-
When deleting the diagnosis record in the ponent may short-circuit and be dam-
YDIS, make sure to check the time that the aged.
trouble codes were detected.
When checking the input voltage of a compo- To check the electrical components or mea-
nent, the coupler or connector must be dis- sure the peak voltage, use the special ser-
connected. As a result, the engine ECM vice tools. A malfunctioning electrical
determines that the component is discon- component can be checked easily by mea-
nected and a trouble code is detected. There- suring the peak voltage. The specified engine
fore, make sure to delete the diagnosis speed when measuring the peak voltage is
record after checking the input voltage. affected by many factors, such as fouled
spark plugs or a weak battery. If one of these
YDIS (CD-ROM, Ver. 1.33): factors is present, the peak voltage cannot be
60V-WS853-06 measured properly.
YDIS USB adapter and cable:
60V-WS850-00
TIP:
• Before checking the electrical components, DC V
5
make sure that the battery is fully charged.
• Install the proprietary YDIS software on the
CD-ROM onto the computer. Always use
the exclusive communication cable to con-
nect the engine ECM to the computer. For
a description of the communication cable Digital circuit tester: 90890-03174
and CD-ROM to be used, see “YDIS” (4-1). Peak voltage adapter B: 90890-03172
Also, make sure to check the CD-ROM ver-
sion before using it. TIP:
• To connect and operate the YDIS, see the • Before measuring the peak voltage, check
YDIS (Ver. 1.33 or later) Instruction Man- all of the wiring harnesses for corrosion.
ual. Also, make sure that the wiring harnesses
are connected properly and that the battery
Measuring the peak voltage is fully charged.
• Use the peak voltage adapter B with the
recommended digital circuit tester.
When measuring the peak voltage, do not • Connect the positive pin of the peak voltage
touch any of the connections of the digital adapter B to the positive terminal of the dig-
tester probes. ital circuit tester, and the negative pin to the
negative terminal.
• When measuring the peak voltage, set the
digital circuit tester to the DC voltage
mode.
5-26
ELEC
Electrical system
Using the digital tester
The electrical technical data apply to the
measurements taken using the Yamaha-rec-
ommended tester.
The resistance values shown are the values
taken before the engine is started. The actual
resistance may vary depending on the envi-
ronmental conditions and ambient tempera-
ture. 1
The input voltage changes depending on the
battery voltage. 3. Connect the positive battery lead to the
If the tester probe cannot be inserted into the terminal a, connect the negative battery
coupler, prepare a test lead suitable for the lead to the terminal b, and then check
measurement. for continuity between the terminals c
and d. Replace the relay if there is no
continuity. NOTICE: Do not reverse the
battery leads.
c
1 2 d a
Digital circuit tester: 90890-03174

Test lead: b
Terminal, male 1: (commercially
available) Terminal
Battery lead
Terminal, female 2: (commercially c d
available) Connect C C
Disconnect
Engine control system and
component 4. Measure the input voltage between the
Checking the main relay terminal e and ground, and the terminal
1. Remove the intake manifold (STBD). f and ground.
See “Removing the intake manifold” (6-
e
17).
2. Remove the fuse cover and relay cover,

and then remove the main relay 1.
NOTICE: Be careful not to damage the
relay.
Main relay input voltage:

Terminal e–Ground
Terminal f–Ground
12.0 V (battery voltage)
5-27
Checking the electrical component / Engine control system and component
5. Turn the engine start switch to ON, and
then measure the input voltage between
b
the terminals e and g.
46
c
g
69 68
Main relay input voltage: 76
Terminal e–Terminal g
6. Turn the engine start switch to OFF.

Wiring harness continuity:
7. Install the main relay, and then install the
b Terminal 46–Ground
relay cover and fuse cover.
c Terminal 68–Ground
8. Install the intake manifold (STBD). See
“Installing the intake manifold” (6-18). c Terminal 76–Ground 5
4. Measure the input voltage at the engine
Checking the engine ECM circuit
ECM coupler a.
1. Remove the engine ECM cover.
2. Remove the engine ECM, and then dis- a

connect the engine ECM couplers a, b,
and c. 7
b Engine ECM input voltage:

a Terminal 7–Ground
c
5. Remove the intake manifold (STBD).

3. Check the wiring harness for continuity.
17).
6. Remove the fuse holder 1, and then dis-

connect the fuse holder couplers d and
e.
5-28
ELEC
Electrical system
11. Install the engine ECM, and then tighten
d
the engine ECM bolts to the specified
e torque.
Engine ECM bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)

1
Checking the APS
APS 1 and APS 2 are a single unit, which
7. Check the wiring harness for continuity. cannot be disassembled.
a b 1. Connect the YDIS to display “Accelerator

position sensor 1” and “Accelerator posi-
7 tion sensor 2.”
27
34
2. Check that the accelerator lever a con-
tacts the stopper b when the remote
control lever is in the N position.
d e b
10 9 8 7 6 5 4 3 2 1 a
8 22 21 20 19 18 17 16

a Terminal 7–d Terminal 8
b Terminal 27–
e Terminals 1–10 and 16–22
b Terminal 34– TIP:
e Terminals 1–10 and 16–22 Before checking the APS, make sure to
adjust the throttle cable properly. To adjust
TIP: the throttle cable, see “Installing the shift
Make sure that there is continuity between cable and throttle cable” (3-8).
terminals 27 and 34 of the engine ECM cou-
pler b and one of the terminals of the fuse 3. Turn the engine start switch to ON, and
holder coupler e. then measure the APS output voltages
when the remote control lever is at the
8. Connect the fuse holder couplers, and fully closed position c and fully open
then install the fuse holder. position d.
N
9. Install the intake manifold (STBD). See F R
c
“Installing the intake manifold” (6-18).
10. Connect the engine ECM couplers.

NOTICE: Make sure that the rubber
seal is installed properly in each
engine ECM coupler.
d
5-29
Engine control system and component
F200B and FL200B:
È É
APS output voltage (reference data):
Item Fully closed c Fully open d
APS 1 0.550–0.850 V
Above 3.250 V g
APS 2 0.400–1.000 V
f
F250G and FL250G:
APS output voltage (reference data): a a
Item Fully closed c Fully open d
APS 1 0.500–0.850 V
4.950 V
APS 2 0.400–1.000 V
h k mn
4. Check that the output voltages of APS 1
and APS 2 change continuously when È Fully closed position
the remote control lever is operated. É Fully open position
APS resistance at 20 °C (68 °F)
5. Turn the engine start switch to OFF. (reference data):
6. Remove the intake manifold (STBD). Fully Fully
Item Terminal
See “Removing the intake manifold” (6- closed f open g
17). APS 1 h–k
0.8 kΩ 5.3 kΩ
APS 2 m–n
7. Disconnect the throttle cable joint from
10. Connect the APS coupler.
5
the APS.
8. Disconnect the APS coupler e. 11. Connect the throttle cable joint to the
APS.

Checking the APS circuit

e
17).
2. Disconnect the APS coupler a.

9. Measure the APS resistance when the
accelerator lever a is at the fully closed 3. Turn the engine start switch to ON, and
position f and fully open position g. then measure the input voltage at the
APS coupler a.
5-30
ELEC
Electrical system
a Wiring harness continuity:

a Terminal 1–b Terminal 40
8 7 2 1 a Terminal 2–b Terminal 44
a
8. Connect the engine ECM coupler.
seal is installed properly in the engine
ECM coupler.

APS input voltage:
torque.
Terminal 2–Terminal 1
Terminal 8–Terminal 7 Engine ECM bolt:
4.75–5.25 V 7 N·m (0.7 kgf·m, 5.2 ft·lb)
4. Turn the engine start switch to OFF. 10. Install the engine ECM cover.
5. Remove the engine ECM cover. 11. Connect the APS coupler.
6. Remove the engine ECM, and then dis- 12. Install the intake manifold (STBD). See
connect the engine ECM coupler b. “Installing the intake manifold” (6-18).
Checking the ETV and TPS

TPS 1 and TPS 2 are components of the
ETV, which cannot be disassembled.
b Do not loosen the throttle stop screw nut

or turn the throttle stop screw.

a b
31
8 7 6 3 2 1 38
44 41 40
49
1. Start the engine, warm it up for 5–10 min-
utes, and then stop it.
2. Connect the YDIS to display “Throttle

position sensor 1,” “Throttle valve open-
ing,” and “Throttle position sensor 2.”
5-31
then measure the TPS output voltages
and throttle valve opening angles when
the remote control lever is at the fully
closed position a and fully open position
b.
N
F R O B
a
c
b
TPS input voltage:
Orange (O)–Black (B)
TPS output voltage and throttle valve 4.75–5.25 V
opening angle (reference data):
Item Fully closed a Fully open b 7. Turn the engine start switch to OFF.
TPS 1 0.500–0.700 —
8. Connect the ETV coupler, and then
TPS 2 — 4.600–4.700 install the intake silencer. See “Installing
Opening
angle
5.1° 84.4° the intake silencer” (6-19). 5
Checking the ETV motor relay
TIP: 1. Remove the intake manifold (STBD).
The actual TPS output voltage and throttle See “Removing the intake manifold” (6-
valve opening angle may vary according to 17).
environmental conditions and engine temper-
ature. 2. Remove the fuse cover and relay cover,
and then remove the ETV motor relay 1.
4. Turn the engine start switch to OFF. NOTICE: Be careful not to damage the
relay.
5. Remove the intake silencer, and then
disconnect the ETV coupler c. See
“Removing the intake silencer” (6-17).

then measure the TPS input voltage at
the ETV coupler. Check the wiring har-
ness if out of specification. See “Check-
ing the ETV and TPS circuit” (5-33).
1
3. Check the ETV motor relay. See step 3 in

“Checking the main relay” (5-27).
4. Measure the input voltage between the

terminal a and ground, and the terminal
b and ground.
5-32
ELEC
Electrical system
a
b
ETV motor relay input voltage: 3. Remove the engine ECM cover.
Terminal a–Ground
Terminal b–Ground 4. Remove the engine ECM, and then dis-
12.0 V (battery voltage) connect the engine ECM couplers b and
c.
then measure the input voltage between
the terminals a and c.
b
a
c
c
a b
ETV motor relay input voltage: 6 5 4 3 2 1
Terminal a–Terminal c
12.0 V (battery voltage) 45
51 50 47
c
7. Install the ETV motor relay, and then
install the relay cover and fuse cover.

“Installing the intake manifold” (6-18). 83 81
Checking the ETV and TPS circuit

1. Remove the intake silencer. See Wiring harness continuity:
“Removing the intake silencer” (6-17). a Terminal 1–c Terminal 83
a Terminal 2–c Terminal 81
2. Disconnect the ETV coupler a. a Terminal 3–b Terminal 47
6. Connect the ETV coupler.
5-33
7. Install the intake silencer. See “Installing 11. Connect the fuse holder couplers, and
the intake silencer” (6-19). then install the fuse holder.
8. Remove the intake manifold (STBD). 12. Install the intake manifold (STBD). See
See “Removing the intake manifold” (6- “Installing the intake manifold” (6-18).
17).
9. Remove the fuse holder 1, and then dis- NOTICE: Make sure that the rubber
connect the fuse holder couplers d and seal is installed properly in each
e. engine ECM coupler.
d
e the engine ECM bolts to the specified
torque.
Engine ECM bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
1 15. Install the engine ECM cover.
Checking the cam position sensor

10. Check the wiring harness for continuity. 1. Remove the engine ECM cover.
c d 2. Disconnect the cam position sensor cou-

plers a, b, and c. 5
12 11
66 3. Turn the engine start switch to ON, and
75 then measure the input voltage at the
84 80 79 cam position sensor coupler.
STBD IN
e W/B R/Y a
B
10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16

c Terminal 66–
e Terminals 1–10 and 16–22
PORT IN b
c Terminal 79–d Terminal 11 R/Y W/G B
c Terminal 80–d Terminal 12
TIP:
Make sure that there is continuity between
terminal 66 of the engine ECM coupler c
and one of the terminals of the fuse holder
coupler e.
5-34
ELEC
Electrical system
8. Connect the tester probes to the test
PORT EX c R/Y leads. NOTICE: Make sure that the test
B W/L
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.
STBD IN
4
PORT EX
Cam position sensor input voltage:

Red/Yellow (R/Y)–Black (B)
White/Black (W/B)–Black (B)
White/Green (W/G)–Black (B)
White/Blue (W/L)–Black (B)
4.75–5.25 V
B
4. Turn the engine start switch to OFF. W/B
R/Y W/L
5. Make the 3 test leads.
PORT IN
W/G
2 4
R/Y
3
B
e
d
1
1
f
Test lead: 9. Turn the engine start switch to ON, and

Terminal, male 1: 9E212-10303 then measure the output voltage when
Terminal, female 2: 9E212-11303 moving a screwdriver close to the cam
Terminal, female 3: (commercially position sensor 4. Replace if out of
available) specification.
d = 100 mm (3.94 in)
e = 50 mm (1.97 in)
f = Cutout area
6. Remove the cam position sensors 4.
7. Connect the test leads to the cam posi-

tion sensor 4 and cam position sensor
coupler.
5-35
g h k
4 5
14. Remove the engine ECM, and then dis-

connect the engine ECM coupler n.
Cam position sensor output voltage:

White/Black (W/B)–Black (B)
(STBD IN) n
White/Blue (W/L)–Black (B)
(PORT EX)
Position Voltage
g, k More than 4.8
h Less than 1.0
White/Green (W/G)–Black (B) 15. Check the wiring harness for continuity. 5
(PORT IN) a
Position Voltage 3 2 1
g, k Less than 1.0 n
h More than 4.8 b 3 2 1
3 2 1
TIP: 18
Using an analog circuit tester is recom-
mended. c
3 2

m
10 9 8 7 6 5 4 3 2 1
11. Disconnect the test leads, and then 22 21 20 19 18 17 16
install the cam position sensors.
12. Remove the intake manifold (STBD). Wiring harness continuity:

See “Removing the intake manifold” (6- a Terminal 1–
17). m Terminals 1–10 and 16–22
a Terminal 2–n Terminal 1
13. Remove the fuse holder 5, and then dis- a Terminal 3–n Terminal 18
connect the fuse holder coupler m. b Terminal 1–n Terminal 18
b Terminal 2–n Terminal 2
b Terminal 3–
m Terminals 1–10 and 16–22
c Terminal 2–n Terminal 3
c Terminal 3–n Terminal 18
5-36
ELEC
Electrical system
TIP:
Make sure that there is continuity between c
terminals 1 and 3 of the cam position sensor 1
couplers a and b and one of the terminals
of the fuse holder coupler m. m
10 9 8 7 6 5 4 3 2 1
16. Connect the engine ECM coupler. 22 21 20 19 18 17 16
ECM coupler. Wiring harness continuity
(testing diode mode):
the engine ECM bolts to the specified Tester probe Display value
torque. (reference

data)
Engine ECM bolt: m Terminals
7 N·m (0.7 kgf·m, 5.2 ft·lb) 1–10 and c Terminal 1 0.514 V
16–22
18. Set the digital circuit tester to the mea-
surement range p, and then push the m Terminals
switch r to display the mark s. c Terminal 1 1–10 and OL
16–22
È
OL: Indicates an overload
TIP:
s terminal 1 of the cam position sensor coupler
r c and one of the terminals of the fuse holder
p
coupler m.
20. Connect the fuse holder coupler, and

É then install fuse holder.
r
s 22. Connect the cam position sensor cou-

p plers.
È Tester model CD721 Checking the OCV

É Tester model CD731a 1. Check the operation of the OCVs using
the YDIS “Stationary test” and check the
19. Check the wiring harness for continuity. operating sound. See “Function” (4-2).
2. Remove the flywheel magnet cover, and

then disconnect the OCV couplers a
and b.
5-37
then measure the input voltage at the
OCV coupler.
PORT
R/Y
a
8. Disconnect the battery leads.
9. Install the OCVs. See step 4 in “Installing

the cylinder head” (7-68).
STBD
R/Y
b 10. Remove the intake manifold (STBD).
17).

connect fuse holder coupler c.
OCV input voltage: c 5

Red/Yellow (R/Y)–Ground

1
5. Remove the OCVs.
6. Measure the OCV resistance.


connect the engine ECM coupler d.
OCV resistance (reference data):

6.7–7.7 Ω at 20 °C (68 °F) d
7. Connect the battery leads to the OCV

terminals and check the operation of the 14. Check the wiring harness for continuity.
spool valve. Replace the OCV if the
spool valve does not operate.
5-38
ELEC
Electrical system
a c Checking the oil pressure sensor

1. Disconnect the oil pressure sensor cou-
2 1
10 9 8 7 6 5 4 3 2 1 pler a.
22 21 20 19 18 17 16

then measure the input voltage at the oil
b d pressure sensor coupler.
a
2 1 B O
77
86

a Terminal 2–
c Terminals 1–10 and 16–22 Oil pressure sensor input voltage:
b Terminal 1–d Terminal 86 Orange (O)–Black (B)
b Terminal 2– 4.75V–5.25 V
c Terminals 1–10 and 16–22
3. Remove the oil pressure sensor, and
then connect a pressure pump 1 and
TIP:
the special service tool 2.
terminal 2 of the OCV couplers a and b and
4. Apply positive pressure to the oil pres-
one of the terminals of the fuse holder cou-
sure sensor slowly, and then measure
pler c.
the output voltage at the specified pres-
sures.
NOTICE: Make sure that the rubber P/W
seal is installed properly in the engine B
O
ECM coupler. G/W B G
16. Install the engine ECM, and then tighten 2

torque.
Engine ECM bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
17. Install the engine ECM cover. 1 2

then install the fuse holder.
Pressure pump 1:
19. Install the intake manifold (STBD). See (commercially available)
“Installing the intake manifold” (6-18). Test harness (3 pins) 2: 90890-06869
20. Connect the OCV couplers.
5-39
Oil pressure sensor output voltage Wiring harness continuity:

(reference data): a Terminal 1–c Terminal 48
Pink/White (P/W)–Black (B) a Terminal 2–b Terminal 18
2.5 V at 392.0 kPa a Terminal 3–c Terminal 37
(3.92 kgf/cm2, 56.8 psi)
4.5 V at 784.0 kPa 10. Connect the engine ECM couplers.
(7.84 kgf/cm2, 113.7 psi) NOTICE: Make sure that the rubber
5. Turn the engine start switch to OFF, and engine ECM coupler.
then disconnect the special service tool
and pressure pump. 11. Install the engine ECM, and then tighten
6. Install the oil pressure sensor, and then torque.
tighten it to the specified torque.
Engine ECM bolt:
Oil pressure sensor: 7 N·m (0.7 kgf·m, 5.2 ft·lb)
18 Nm (1.8 kgf·m, 13.3 ft·lb)
13. Connect the oil pressure sensor coupler.
connect the engine ECM couplers b and Checking the water pressure sensor
c. (optional)
1. Remove the engine ECM cover. 5
2. Disconnect the water pressure sensor
coupler a.
b
c then measure the input voltage at the
water pressure sensor coupler.
9. Check the wiring harness for continuity. BO

a b
a
3 2 1
18
c
Water pressure sensor input voltage:
4.75–5.25 V
37
4. Remove the water pressure sensor, and

48
then connect a pressure pump 1 and
the special service tool 2.
5-40
ELEC
Electrical system
5. Apply positive pressure to the water 9. Check the wiring harness for continuity.
pressure sensor slowly, and then mea-
a b
sure the output voltage at the specified
pressures. 3 2 1
L/B 18
B O
G B G/W
2 c
2 42
48
1 Wiring harness continuity:

Pressure pump 1: a Terminal 3–c Terminal 42
(commercially available)
Test harness (3 pins) 2: 10. Connect the engine ECM couplers.
90890-06869 NOTICE: Make sure that the rubber
Water pressure sensor output voltage engine ECM coupler.
(reference data):
Blue/Black (L/B)–Black (B) 11. Install the engine ECM, and then tighten
2.5 V at 392.0 kPa the engine ECM bolts to the specified
(3.92 kgf/cm2, 56.8 psi) torque.
4.5 V at 784.0 kPa Engine ECM bolt:
(7.84 kgf/cm2, 113.7 psi)
7 N·m (0.7 kgf·m, 5.2 ft·lb)
6. Turn the engine start switch to OFF, and
12. Connect the water pressure sensor cou-
then disconnect the special service tool pler.
and pressure pump.
7. Install the water pressure sensor. See
steps 2 and 3 in “Installing the water Checking the speed sensor
pressure sensor (optional)” (3-13).
(optional)
8. Remove the engine ECM, and then dis- 1. Remove the engine ECM cover.
connect engine ECM couplers b and c.
2. Disconnect the speed sensor coupler a.

speed sensor coupler.
b
5-41
BO then disconnect the special service tool
and pressure pump.
7. Install the speed sensor. See steps 7 and

8 in “Installing the speed sensor
(optional)” (3-12).

a
connect the engine ECM couplers b and
c.
Speed sensor input voltage:
4.75–5.25 V
4. Remove the speed sensor, and then con-

nect a pressure pump 1 and the special b
service tool 2.
c
5. Apply positive pressure to the speed sen-
sor slowly, and then measure the output
voltage at the specified pressures.
B
L
O
G B G/W
a b 5
3 2 1
2
18
1 c
2
43
48
Pressure pump 1:
(commercially available) Wiring harness continuity:
Test harness (3 pins) 2: a Terminal 1–c Terminal 48
90890-06869 a Terminal 2–b Terminal 18
Speed sensor output voltage (reference
data): 10. Connect the engine ECM couplers.
Blue (L)–Black (B) NOTICE: Make sure that the rubber
2.5 V at 392.0 kPa seal is installed properly in each
(3.92 kgf/cm2, 56.8 psi) engine ECM coupler.
4.5 V at 784.0 kPa
(7.84 kgf/cm2, 113.7 psi) 11. Install the engine ECM, and then tighten
torque.
5-42
ELEC
Electrical system
Engine ECM bolt: É

7 N·m (0.7 kgf·m, 5.2 ft·lb)
12. Connect the speed sensor coupler. 1

d
b c
2
Fuel control unit and component
Checking the water detection switch
1. Disconnect the water detection switch
coupler a. Terminal
Float position
b c
2. Turn the engine start switch to ON, and È
É C C
water detection switch coupler.
Float height d (reference data):
40.0 mm (1.57 in)
B L/W
6. Install the fuel cup assembly. See step 2
in “Assembling the fuel filter assembly”
(6-14).

a
connect the engine ECM coupler e.
Water detection switch input voltage:
Blue/White (L/W)–Black (B)
4.75–5.25 V

then remove the fuel cup assembly. e
4. Check that the float 1 moves smoothly.
5. Check the water detection switch for con-

tinuity when the float 1 positions È and
É. NOTICE: Make sure not to remove 9. Check the wiring harness for continuity.
the clip 2 and float 1.
È a e
2 1
5
2
b c 18
1
5-43
Engine control system and component / Fuel control unit and component
Wiring harness continuity: STBD

a Terminal 1–e Terminal 5
a Terminal 2–e Terminal 18 R/Y

NOTICE: Make sure that the rubber a
ECM coupler.

the engine ECM bolts to the specified Fuel injector input voltage:
torque. Red/Yellow (R/Y)–Ground
Engine ECM bolt: 12.0 V (battery voltage)
7 N·m (0.7 kgf·m, 5.2 ft·lb) 4. Turn the engine start switch to OFF.
5. Measure the fuel injector resistance.
13. Connect the water direction switch cou-
pler.
Checking the fuel injector

1. Check the operation of the fuel injectors
using the YDIS “Stationary test” and
check the operating sound. See “Func-
5
tion” (4-2).
2. Remove the fuel rail covers, and then

disconnect the fuel injector couplers a. Fuel injector resistance (reference data):
12.0 Ω at 20 °C (68 °F)
then measure the input voltage at the 6. Remove the intake manifold (STBD).
fuel injector coupler. See “Removing the intake manifold” (6-
17).
PORT
R/Y connect the fuse holder coupler b.
a
b

connect the engine ECM coupler c.
5-44
ELEC
Electrical system

Fuel injector #1
a Terminal 1–
b Terminals 1–10 and 16–22
Fuel injector #2
a Terminal 1–
c b Terminals 1–10 and 16–22
Fuel injector #3
10. Check the wiring harness for continuity. a Terminal 1–
b
10 9 8 7 6 5 4 3 2 1 Fuel injector #4
22 21 20 19 18 17 16 a Terminal 1–
a c
Fuel injector #5
1
60 59 58 57 56 55 a Terminal 1–
2
Fuel injector #6
a Terminal 1–
TIP:
terminal 1 of the fuel injector couplers a and
pler b.

ECM coupler.

torque.
Engine ECM bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)

5-45
b
16. Connect the fuel injector couplers, and B R
then install the fuel rail covers.
Checking the low-pressure fuel

pump and high-pressure fuel pump
1. Check the operation of the low-pressure
fuel pump and high-pressure fuel pump
using the YDIS “Stationary test” and High-pressure fuel pump input voltage:
check the operating sound. See “Func- Red (R)–Black (B)
tion” (4-2). 12.0 V (battery voltage)
2. Remove the intake silencer. See 8. Turn the engine start switch to OFF.
9. Measure the resistance of the fuel pump
3. Disconnect the low-pressure fuel pump motors.
coupler a.
4. Turn the engine start switch to ON, and R B R B

low-pressure fuel pump coupler.
a
5
R/Y
Low-pressure fuel pump input voltage: Low-pressure fuel pump resistance

Red/Yellow (R/Y)–Ground (reference data):
12.0 V (battery voltage) Red (R)–Black (B)
0.5–4.0 Ω at 20 °C (68 °F)
High-pressure fuel pump resistance
6. Disconnect the vapor separator wiring (reference data):
harness extension coupler b. Red (R)–Black (B)
0.3–10.0 Ω at 20 °C (68 °F)
7. Connect the tester probes to the termi-
nals of the vapor separator wiring har-
ness extension coupler b, and then
17).
measure the input voltage within 5 sec-
onds after turning the engine start switch
to ON.
connect the fuse holder coupler c.
5-46
ELEC
Electrical system
c
ECM coupler.

1 torque.
Engine ECM bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
connect the engine ECM coupler d. 18. Connect the fuse holder coupler, and

20. Connect the low-pressure fuel pump cou-

pler and vapor separator wiring harness
extension coupler.
d
21. Install the intake silencer. See “Installing
the intake silencer” (6-19).
Checking the high-pressure fuel
pump relay
a b
2 1 2 1 See “Removing the intake manifold” (6-
17).
d 2. Remove the fuse cover and relay cover,

c and then remove the high-pressure fuel
61 pump relay 1. NOTICE: Be careful not
2 65 to damage the relay.
10 9

b Terminal 1–c Terminal 10 1
b Terminal 2–Ground
c Terminal 9–d Terminal 65 3. Check the high-pressure fuel pump relay.
See step 3 in “Checking the main relay”
(5-27).
5-47
4. Turn the engine start switch to ON, and 2. Disconnect the throttle body assembly
then measure the input voltage between wiring harness extension coupler a.
the terminal a and ground, and the ter-
minal b and ground. 3. Turn the engine start switch to ON, and
a throttle body assembly wiring harness
extension coupler.
R/Y
High-pressure fuel pump relay input volt-

age: a
Terminal a–Ground
Terminal b–Ground Vapor shut-off valve input voltage:
12.0 V (battery voltage) Red/Yellow (R/Y)–Ground
terminals b and c. 4. Turn the engine start switch to OFF.
5. Remove the intake manifold (STBD). 5

b 17).

connect the fuse holder coupler b.
c b
High-pressure fuel pump relay input
voltage:
Terminal b–Terminal c
1
7. Install the high-pressure fuel pump relay, 7. Remove the engine ECM cover.
and then install the relay cover and fuse
cover. 8. Remove the engine ECM, and then dis-
connect the engine ECM coupler c.
Checking the vapor shut-off valve

1. Remove the intake silencer. See
5-48
ELEC
Electrical system
14. Measure the vapor shut-off valve resis-

tance.
G/B R/Y
10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16
Vapor shut-off valve resistance (reference
a data):
c Red/Yellow (R/Y)–Green/Black (G/B)
30.0–34.0 Ω at 20 °C (68 °F)
4 5
15. Remove the intake manifold (PORT).
85 17).
16. Remove the throttle body assembly. See

“Removing the throttle body assembly”
Wiring harness continuity: (6-23).
a Terminal 4–
b Terminals 1–10 and 16–22 17. Remove the vapor shut-off valve from the
a Terminal 5–c Terminal 85 throttle body assembly.
TIP: 18. Connect the special service tool 2 to the

Make sure that there is continuity between vapor shut-off valve.
terminal 4 of the throttle body assembly wir-
ing harness extension coupler a and one of 19. Apply the specified negative pressure to
the terminals of the fuse holder coupler b. the vapor shut-off valve.
20. Check that the vapor shut-off valve

opens and the negative pressure is
released when the battery leads are con-
nected to the vapor shut-off valve termi-
ECM coupler.
nals. NOTICE: Do not connect the
battery leads to the vapor shut-off
valve terminals for more than a few
seconds.
torque.
Engine ECM bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
5-49
Fuel control unit and component / Charging unit and component
3. Move the stator assembly leads away
2 from the area covered by the intake man-
ifold, and then install the intake manifold
(STBD). See “Installing the intake mani-
fold” (6-18).
4. Measure the lighting coil output peak

voltage between all combinations of the
terminals.
Vacuum/pressure pump gauge set 2:

90890-06756 STBD
Specified negative pressure:

67.0 kPa (0.67 kgf/cm2, 9.7 psi) G
G G
21. Disconnect the special service tool.
22. Install the vapor shut-off valve to the

throttle body assembly.
23. Install the throttle body assembly. See

“Installing the throttle body assembly” (6-
24).
Lighting coil output peak voltage:
5
24. Install the intake manifolds. See “Install- Green (G)–Green (G)
ing the intake manifold” (6-18). Unloaded
r/min
Cranking 1500 3500
25. Install the intake silencer. See “Installing DC V 8.3 44.7 97.7
TIP:
Charging unit and component When measuring the output peak voltage
Checking the lighting coil under the cranking condition, remove the clip
1. Remove the intake manifold (STBD). from the engine shut-off switch to prevent the
See “Removing the intake manifold” (6- engine from starting.
17).
5. Measure the lighting coil resistance.
2. Remove the stator assembly leads from
the plastic ties 1, and then disconnect Lighting coil resistance (reference data):
the stator assembly couplers a. Green (G)–Green (G)
0.11–0.17 Ω at 20 °C (68 °F)

17).
1
a 7. Connect the stator assembly couplers,
and then fasten the stator assembly
leads using the plastic ties.
5-50
ELEC
Electrical system
8. Install the intake manifold (STBD). See 5. Remove the fuse holder, and then dis-
“Installing the intake manifold” (6-18). connect the Rectifier Regulator couplers
and ground lead.
Checking the Rectifier Regulator
Do not connect the battery cables in

reverse. Otherwise, the Rectifier Regula-
tor could be damaged.
1. Remove the fuse cover 1.
2. Measure the Rectifier Regulator output

peak voltage.
6. Set the digital circuit tester to the mea-

surement range a, and then push the
switch b to display the mark c.
È
c
b
Rectifier Regulator output peak voltage: a
Fuse (60 A)–Ground
Loaded
r/min
1500 3500
DC V 13.0 13.0 É
b
TIP:
Do not use peak voltage adapter B when
measuring the Rectifier Regulator output c
peak voltage.
a
3. Install the fuse cover.
4. Remove the intake manifold (STBD). È Tester model CD721

See “Removing the intake manifold” (6- É Tester model CD731a
17).
5-51
Charging unit and component
7. Check the Rectifier Regulator for conti-
nuity. Rectifier Regulator continuity
(testing diode mode):
d Tester probe Display value
e (reference data)
f e
g f
d g OL
h
h
k k
d
d R f
e R e g OL
h
k
f G
g G d 0.420 V
h G
e 0.422 V
f g
k B h OL
k
d
e
0.426 V
0.421 V
5
g f
h OL
k
d 0.425 V
e 0.424 V
h f
g OL
k
d 0.756 V
e 0.755 V
k f 0.416 V
g 0.417 V
h 0.417 V
OL: Indicates an overload
8. Connect the Rectifier Regulator couplers

and ground lead, and then install the fuse
holder.

5-52
ELEC
Electrical system
Ignition unit and component Checking the ignition coil
Checking the ignition spark 1. Remove the engine ECM cover.
2. Disconnect the ignition coil couplers a.

• Make sure to install the special service
tool to the ignition coil so that sparks do 3. Turn the engine start switch to ON, and
not leak out. then measure the input voltage at the
• Keep flammable gas or liquids away, ignition coil coupler.
because this test can produce sparks.

R/Y B
2. Remove the ignition coils. a
a
3. Connect the special service tool 1 to an
ignition coil.
TIP:
Repeat steps 3–5 for each ignition coil. Ignition coil input voltage:
Red/Yellow (R/Y)–Black (B)
4. Check the ignition spark using the YDIS 12.0 V (battery voltage)
“Stationary test.” See “Function” (4-2).
WARNING! Do not touch any of the
connections of the special service 5. Remove the engine ECM, and then dis-
tool. connect the engine ECM coupler b.
OK
1 b
Ignition tester 1: 90890-06754 6. Remove the intake manifold (STBD).

5. Disconnect the special service tool. See “Removing the intake manifold” (6-
17).
6. Install the ignition coils, and then tighten
the ignition coil bolts to the specified
torque. connect the fuse holder coupler c.
Ignition coil bolt:

7 N·m (0.7 kgf·m, 5.2 ft·lb)
5-53
Ignition unit and component

Ignition coil #1
c
a Terminal 3–
Ignition coil #2
1 a Terminal 1–b Terminal 70
a Terminal 3–
8. Check the wiring harness for continuity. c Terminals 1–10 and 16–22
Ignition coil #3
b
54 53
63 62 a Terminal 3–
71 70 c Terminals 1–10 and 16–22
a Ignition coil #4
3 2 1 a Terminal 1–b Terminal 62
a Terminal 3–
c c Terminals 1–10 and 16–22
Ignition coil #5
10 9 8 7 6
22 21 20 19 18 17 16
5 4 3 2 1
a Terminal 1–b Terminal 54 5
a Terminal 3–
Ignition coil #6
a Terminal 3–
TIP:
terminal 3 of the ignition coil couplers a and
pler c.



ECM coupler.
5-54
ELEC
Electrical system
12. Install the engine ECM, and then tighten Pulser coil output peak voltage:
the engine ECM bolts to the specified White/Red (W/R)–Black (B)
torque. Unloaded Loaded
r/min
Engine ECM bolt: Cranking 1500 3500
7 N·m (0.7 kgf·m, 5.2 ft·lb) DC V 3.0 2.7 14.5 17.8
13. Connect the ignition coil couplers. TIP:

• When measuring the output peak voltage
under the cranking condition, remove the
clip from the engine shut-off switch to pre-
Checking the pulser coil
vent the engine from starting.
• When measuring the output peak voltage
2. Disconnect the pulser coil coupler a. under the unloaded condition, disconnect
the pulser coil coupler a.
6. Measure the pulser coil resistance.

Pulser coil resistance (reference data):
White/Red (W/R)–Black (B)
396.0–594.0 Ω at 20 °C (68 °F)
a
4. Measure the pulser coil output peak volt- connect the engine ECM coupler b.
age. NOTICE: Check that the wiring
harness does not interfere with the
flywheel magnet.
W/B W/R b
B B
G G/W
a 1
W/R B a
1 1 2
a 16 15
Test harness (2 pins) 1: 90890-06867
5-55

B B/Y
ECM coupler. a

torque. Air temperature sensor input voltage:
Black/Yellow (B/Y)–Black (B)
Engine ECM bolt: 4.75–5.25 V
7 N·m (0.7 kgf·m, 5.2 ft·lb)
8. Remove the air temperature sensor.
13. Connect the pulser coil coupler.
9. Place the air temperature sensor in a
14. Install the flywheel magnet cover. container of water and heat the water
slowly.
Checking the air temperature sensor
1. Measure the ambient temperature. 10. Measure the air temperature sensor
resistance at the specified temperatures.
5
2. Connect the YDIS to display “Intake tem-
perature” (air temperature).
3. Check that the difference between the

ambient temperature and the displayed
intake temperature is within ± 5 °C (± 41
°F).
TIP:
• Check the air temperature sensor when the
engine is cold.
• When checking the air temperature sensor, Air temperature sensor resistance
remove the top cowling and do not start the (reference data):
engine. 2.21–2.69 kΩ at 20 °C (68 °F)
0.32 kΩ at 80 °C (176 °F)
11. Install the air temperature sensor.
5. Disconnect the air temperature sensor
coupler a.
connect the engine ECM coupler b.
then measure the input voltage at the air
temperature sensor coupler.
5-56
ELEC
Electrical system
throttle body assembly wiring harness
extension coupler.
b
14. Check the wiring harness for continuity. B O
b a
a Air pressure sensor input voltage:

2 1
18 4.75–5.25 V
23
Wiring harness continuity: 6. Remove the engine ECM, and then dis-
a Terminal 1–b Terminal 23 connect the engine ECM couplers b and
a Terminal 2–b Terminal 18 c.

ECM coupler.
b
16. Install the engine ECM, and then tighten c
torque.
Engine ECM bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb) 7. Check the wiring harness for continuity.
17. Install the engine ECM cover. a
18. Connect the air temperature sensor cou- 1 2 3

pler.
19. Install the flywheel magnet cover. b c
Checking the air pressure sensor

“Removing the intake silencer” (6-17). 36
18
2. Disconnect the throttle body assembly 48
wiring harness extension coupler a.
5-57

1
a Terminal 1–c Terminal 36 2

engine ECM coupler.
9. Install the engine ECM, and then tighten B P/G

O
the engine ECM bolts to the specified B
G G/W
torque. 2
Engine ECM bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
11. Remove the intake manifolds. See Vacuum/pressure pump gauge set 1:
“Removing the intake manifold” (6-17). 90890-06756
Test harness (3 pins) 2:
12. Remove the throttle body assembly. See 90890-06869
(6-23). Air pressure sensor output voltage:
5
Pink/Green (P/G)–Black (B)
13. Remove the air pressure sensor from the 3.21 V at –20.0 kPa
throttle body assembly. (–0.20 kgf/cm2, –2.9 psi)
2.16 V at –46.7 kPa
14. Connect the special service tools 1 and (–0.467 kgf/cm2, –6.8 psi)
2.
15. Turn the engine start switch to ON.
18. Disconnect the special service tools.
16. Apply negative pressure to the air pres-
sure sensor slowly, and then measure 19. Install the air pressure sensor to the
the output voltage at the specified pres- throttle body assembly, and then tighten
sures. the air pressure sensor bolt to the speci-
fied torque.
Air pressure sensor bolt:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
20. Install the throttle body assembly. See

“Installing the throttle body assembly” (6-
24).
21. Install the intake manifolds. See “Install-

ing the intake manifold” (6-18).

5-58
ELEC
Electrical system
Checking the engine temperature Engine temperature sensor resistance
sensor (reference data):
1. Remove the flywheel magnet cover. Black/Yellow (B/Y)–Black/Yellow (B/Y)
54.2–69.0 kΩ at 20 °C (68 °F)
2. Disconnect the engine temperature sen- 3.12–3.48 kΩ at 100 °C (212 °F)
sor coupler a.
9. Install the engine temperature sensor,
3. Turn the engine start switch to ON, and and then tighten it to the specified torque.
engine temperature sensor coupler. Engine temperature sensor:
15 N·m (1.5 kgf·m, 11.1 ft·lb)
PORT a
B B/Y 11. Remove the engine ECM, and then dis-

b
Engine temperature sensor input voltage:
Black/Yellow (B/Y)–Black (B)
4.75–5.25 V
5. Remove the flywheel magnet. See 12. Check the wiring harness for continuity.
“Removing the flywheel magnet” (7-16).
b
6. Remove the engine temperature sensor.
a
7. Place the engine temperature sensor in a
2 1
container of water and heat the water 18 17
slowly.
8. Measure the engine temperature sensor

resistance at the specified temperatures.

ECM coupler.

torque.
5-59
6. Place the thermoswitches in a container
Engine ECM bolt:
of water and heat the water slowly.
7 N·m (0.7 kgf·m, 5.2 ft·lb)
15. Install the engine ECM cover. 7. Check the thermoswitches for continuity
at the specified temperatures. Replace if
16. Connect the engine temperature sensor out of specification.
coupler.
17. Install the flywheel magnet. See “Install-

ing the flywheel magnet” (7-17).
P B
18. Install the flywheel magnet cover.
Checking the thermoswitch

2. Disconnect the thermoswitch connectors.

f
f
then measure the input voltage at the f
g
thermoswitch connectors a and b. c h
e
PORT e
P B 5
d
a
c Temperature
d Time
e No continuity
f Continuity
Thermoswitch continuity temperature:
STBD g: 84–90 °C (183–194 °F)
h: 68–82 °C (154–180 °F)
P B
8. Install the thermoswitches.
b 9. Remove the engine ECM cover.

connect the engine ECM couplers k and
m.
Thermoswitch input voltage (reference
data):
Pink (P)–Black (B)
11.4 V
4. Turn the engine start switch to OFF. k
m
5. Remove the thermoswitches.
5-60
ELEC
Electrical system
11. Check the wiring harness for continuity. 2. Connect the special service tool 1 to the
shift cut switch coupler a.
P B 3. Turn the engine start switch to ON, and

then measure the input voltage.
k m
18
52
1 B
a L/Y
1
Wiring harness continuity: a
Pink (P)–m Terminal 52 G
G/W
Black (B)–k Terminal 18
12. Connect the engine ECM couplers. B L/Y

engine ECM coupler.
13. Install the engine ECM, and then tighten Test harness (2 pins) 1: 90890-06867
torque. Shift cut switch input voltage:
Blue/Yellow (L/Y)–Black (B)
Engine ECM bolt: 4.75–5.25 V
7 N·m (0.7 kgf·m, 5.2 ft·lb)
5. Disconnect the special service tool 1,
15. Connect the thermoswitch connectors. and then connect it to the shift cut switch
coupler b.
6. Measure the shift cut switch resistance
Checking the shift cut switch when the gear shift is in the N position.
1. Disconnect the shift cut switch coupler
a.
STBD
5-61
L/Y B Switch Lead color

position L/Y B
Free c
Pushed d C C

1
G connect the engine ECM coupler e.
b G/W
1
b
B
L/Y e
Shift cut switch resistance (reference

data):
Blue/Yellow (L/Y)–Black (B)
5
4.5–4.9 kΩ
e
7. Check the shift cut switch for continuity. a
Replace if out of specification. 6
1 2
L/Y B 18
c
d

1
G 12. Connect the engine ECM coupler.
G/W NOTICE: Make sure that the rubber
1 c seal is installed properly in the engine
ECM coupler.
d B 13. Install the engine ECM, and then tighten
L/Y the engine ECM bolts to the specified
torque.
Engine ECM bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
5-62
ELEC
Electrical system
15. Connect the shift cut switch coupler. 6. Check the neutral switch for continuity.
Replace if out of specification.
Checking the neutral switch
1. Disconnect the neutral switch coupler a.
STBD
c
d
b
a
1
G
2. Connect the special service tool 1 to the G/W
d 1
neutral switch coupler a.
L/G B
c
3. Turn the engine start switch to ON, and B
b
then measure the input voltage. L/G
Switch Lead color

position L/G B
Pushed c C C
Free d
B
a L/G 7. Disconnect the special service tool.
1
G 8. Remove the engine ECM cover.
1
G/W
a 9. Remove the engine ECM, and then dis-
B L/G connect the engine ECM coupler e.
Test harness (2 pins) 1: 90890-06867 e
Neutral switch input voltage:

Blue/Green (L/G)–Black (B)
4.75–5.25 V
4. Turn the engine start switch to OFF. 10. Check the wiring harness for continuity.
5. Disconnect the special service tool 1,
and then connect it to the neutral switch
coupler b.
5-63
a
12
2 1
18
Knock sensor resistance (reference data):

504.0–616.0 kΩ at 20 °C (68 °F)
a Terminal 2–e Terminal 18 4. Remove the engine ECM, and then dis-
ECM coupler.
b
torque.
Engine ECM bolt:
5
7 N·m (0.7 kgf·m, 5.2 ft·lb)
14. Connect the neutral switch coupler. b
Checking the knock sensor a

8
1. Remove the engine ECM cover. 1
2. Disconnect the knock sensor coupler a.

a

ECM coupler.
3. Measure the knock sensor resistance.
torque.
Engine ECM bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
5-64
ELEC
Electrical system
8. Connect the knock sensor coupler. 2. Remove the fuse cover and relay cover,
and then remove the starter relay 1.
9. Install the engine ECM cover. NOTICE: Be careful not to damage the
relay.
Checking the engine shut-off switch
1. Disconnect the 10-pin coupler. (703
remote control model)
Disconnect the engine start switch cou-
pler. (704 remote control model)

then check the engine shut-off switch for
continuity.
1
ON 3. Check the starter relay. See step 3 in

OFF START
“Checking the main relay” (5-27).

terminal a and ground.
È É b
a
a

a
Switch Terminal
Starter relay input voltage:
position a b
Terminal a–Ground
Clip removed C C 12.0 V (battery voltage)
Clip installed
5. Connect the tester probes between the
3. Turn the engine start switch to OFF. terminals b and c, and then turn the
engine start switch to START and mea-
4. Connect the 10-pin coupler. (703 remote
sure the input voltage.
control model)
Connect the engine start switch coupler. c b
(704 remote control model)
Starting unit and component

Checking the starter relay
17).
5-65
Ignition unit and component / Starting unit and component
Starter relay input voltage:

Terminal b–Terminal c
6. Install the starter relay, and then install

the relay cover and fuse cover.

Checking the engine start switch

1. Disconnect the 10-pin coupler. (703
remote control model)
Disconnect the engine start switch cou-
pler. (704 remote control model)
2. Check the engine start switch for continu-

ity.
ON
OFF START
5
È É b
c d
d
a
a
e
b e c

Switch Terminal
position a b c d e
OFF C C
ON C C
START C C C
3. Connect the 10-pin coupler. (703 remote

control model)
Connect the engine start switch coupler.
(704 remote control model)
5-66
ELEC
Electrical system
Starter motor
11
1 22 23
12
24
2
13
4 7
3 14
5 15
7
6
16 25
17 6
8 26
18 M
19
27
28
9
20
10 21

1 Stator 1
2 Armature 1
3 Brush holder assembly 1
4 Brush spring 4
5 Brush assembly 1
6 Starting motor gear assembly 1
7 Washer set 1
8 Bracket 1
9 Screw 2 M4 × 15 mm
10 Bolt 2 M6 × 117 mm
11 Bolt 2 M6 × 35 mm
12 Cover assembly 1
13 Clutch assembly 1
14 Bracket 1
15 Bearing 1
16 Outer gear 1
17 Gasket 1 39
5-67
Starter motor
11
1 22 23
12
24
2
13
4 7
3 14
5 15
7
6
16 25
17 6
8 26
18 M
19
27 5
28
9
20
10 21

18 Washer 1
19 Pinion shaft 1
20 Planetary gear 3
21 Plate 1
22 Starter motor pinion 1
23 Pinion stopper set 1
24 Lever assembly 1
25 Seal set 1 39
26 Magnet switch 1
27 Washer 1
28 Nut 1
5-68
ELEC
Electrical system
Removing the starter motor 2. Push the pinion stopper c down, and
then remove the clip d.
Before removing the starter motor, make e

sure to disconnect the negative battery f 2
terminal.
2
“Removing the intake silencer” (6-17). c
d c
17). Pipe 2: (commercially available)
e: 26 mm (1.02 in)
3. Remove the starter motor from the power
f: 24 mm (0.94 in)
unit. See “Removing the starter motor”
(7-28). 3. Remove the pinion stopper c, pinion 3,
and spring g.
Checking the starter motor pinion
Before checking the starter motor pinion,

make sure to disconnect the battery
c
cables.
3
1. Check the pinion. Replace if cracked or g
worn.
2. Turn the pinion counterclockwise to

check that it operates smoothly and turn
it clockwise to check that it locks in place.
Disassembling the starter motor

1. Disconnect the brush assembly lead a, 4. Remove the stator assembly h, plate 4,
and then remove the magnet switch 1 planetary gears 5, and outer gear k.
and spring b.
b 5 5
k
1
a
5-69
Starter motor
5. Remove the rubber seal m, lever n, and
pinion shaft assembly p.
7
7
s
p s
n
8
m
9. Remove the E-clip 0, and then remove

the clutch assembly A from the pinion
6. Remove the stator 6. NOTICE: Do not shaft B.
disassemble the stator. Do not
remove the magnets r from it.
v A
7. Remove the armature 7 along with the
A
brush holder assembly 8 from the v
bracket 9. 5
6 r
0 t u
7 B
B t u
8
8. Remove the plate s, and then remove

the armature 7 from the brush holder
assembly 8. B
TIP:
Push the clutch assembly A completely
down onto the pinion shaft B in direction t,
and turn it one spline in direction u, and then
remove it in direction v.
5-70
ELEC
Electrical system
Checking the armature (starter
motor)
1. Check the commutator. Clean using 600-
grit sandpaper and compressed air if c
dirty. d e f
Armature continuity:
c d e f
C C
Checking the brush holder and

2. Measure the commutator diameter a. brush
Replace the armature if below specifica- 1. Check the brush holder assembly for
tion. continuity. Replace if out of specification.
e
a
b
d
ca
a
Commutator standard diameter a: e

29.0 mm (1.14 in)
Wear limit: 28.0 mm (1.10 in) db
3. Measure the commutator undercut b. Brush holder assembly continuity:

a b c d e
C C
C C
b C C
C C
2. Measure the length of each brush.

Replace the brush assembly if below
specification.
Commutator standard undercut b:

0.5–0.8 mm (0.02–0.03 in)
Wear limit: 0.2 mm (0.01 in)
4. Check the armature for continuity.

5-71
Starter motor
f
4
g
c
1
d
2 b
Brush standard length f:
15.5 mm (0.61 in) 3
Wear limit g: 9.5 mm (0.37 in) e
Assembling the starter motor

3 f
• Do not apply grease or oil to the com-

mutator of the armature.
• Do not reuse a gasket or seal set, TIP:
always replace it with a new one. Align the holes c and d in the plate b with
the holes e and f in the bracket 3.
1. Push the brushes a into the holders,
and then install the armature 1 to the 4. Install the bracket 5, a new gasket 6, 5
brush holder assembly 2. and the clutch assembly 7 onto the pin-
ion shaft 8.
2. Install the plate b.
1 1
7
b
2 5
6
8
a
b 5. Push the clutch assembly 7 completely
down onto the pinion shaft 8 in direction
g, turn it one spline in direction h, and
2 then slide it in direction k.
a
3. Install the armature 1 along with the 6. Install the E-clip m.

brush holder assembly 2 to the bracket
3, and then install the stator 4.
5-72
ELEC
Electrical system
w
7 t
7
k
k
m h g w t
8
8 g v u
h
TIP: TIP:
Make sure that the clutch assembly 7 does Align the protrusion u on the stator assem-
not come out from the pinion shaft 8. bly t with the slot v in the cover assembly
w.
7. Install the pinion shaft assembly n, the
lever p, a new rubber seal r, the plane- 9. Install the spring x, pinion A, pinion
tary gears 9, the outer gear s, and the stopper y, and clip z.
plate 0.
y y
A z
A
n
p x
C
n
p
M r 10. Install a new gasket B, the spring A,
and the magnet switch C, and then con-
nect the brush assembly lead B.
9
s A
0
C
8. Install the stator assembly t. A

B
C
B
5-73
Starter motor / PTT electrical system
Installing the starter motor
1. Install the starter motor to the power unit.
See “Installing the starter motor” (7-28). Lg
Sb
G/W G 1
e f c
“Installing the intake manifold” (6-18). b
a
PTT electrical system

Checking the PTT relay d
17). Test harness (2 pins) 1: 90890-06867
2. Measure the input voltage between the PTT relay continuity:

terminals a and b. a b c d e f
C C
C C
a
C C
C C
6. Connect the positive battery lead to the

5
connector e, connect the negative bat-
tery lead to the terminal b, and then
b check the PTT relay for continuity.
PTT relay input voltage:
Terminal a–Terminal b
Lg
12.0 V (battery voltage) Sb
G/W G 1
3. Disconnect the PTT relay leads and PTT c
e f b
relay coupler, and then remove the PTT
relay. NOTICE: Before disconnecting a
the PTT relay leads and PTT relay cou-
pler, make sure to disconnect the neg-
ative battery cable.
d
5. Check the PTT relay for continuity.

PTT relay continuity:
a b c d
C C
C C
5-74
ELEC
Electrical system
7. Connect the positive battery lead to the È
connector f, connect the negative bat-
tery lead to the terminal b, and then
check the PTT relay for continuity. R
a
Lg
Sb
G/W G 1
e f c
b
É
a
R
a
PTT relay continuity:

a b c d È Regular rotation model
C C É Counter rotation model
C C PTT switch input voltage:
Red (R)–Ground
8. Disconnect the special service tool. 12.0 V (battery voltage)
9. Install the PTT relay. 3. Check the PTT switch 1 for continuity.
10. Connect the PTT relay leads and PTT
relay coupler, and then tighten the PTT
relay terminal bolts and PTT relay termi- 1
nal nuts to the specified torque.
PTT relay terminal bolt: b d
c
4 N·m (0.4 kgf·m, 3.0 ft·lb)
Sb d
PTT relay terminal nut:
R c
4 N·m (0.4 kgf·m, 3.0 ft·lb) Lg b
“Installing the intake manifold” (6-18). Terminal
Switch
Checking the PTT switch (bottom
position b c d
cowling) UP C C
1. Disconnect the PTT switch coupler a. Free
DN C C
2. Measure the input voltage at the PTT
switch coupler. 4. Remove the intake manifold (STBD).
17).
5-75
5. Remove the fuse holder 2, and then dis- 11. Connect the PTT switch coupler.
connect the fuse holder coupler e.
Checking the trim sensor
e
1. Remove the trim sensor, and then dis-
connect the trim sensor coupler a.
6. Disconnect the PTT relay coupler f.
2. Turn the trim sensor lever b from the

f position c to the position d, and then
measure the resistance as it gradually
changes.

b
5
B P
e
d
4
a
2 1
3
f
2 1 Trim sensor resistance (reference data):
Pink (P)–Black (B)
247.6–387.6 Ω at position c
9.0–11.0 Ω at position d (setting
resistance)
3. Disconnect the alert indicator coupler e.
a Terminal 1–f Terminal 1
8. Connect the PTT relay coupler.

a
e

5-76
ELEC
Electrical system
4. Remove the engine ECM cover. 12. Adjust the trim sensor. See “Adjusting
the trim sensor” (9-34).
connect the engine ECM coupler f.
a
1 2
e
2
18


ECM coupler.

torque.
Engine ECM bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
10. Connect the alert indicator coupler.
11. Install the trim sensor, and then connect

the trim sensor coupler.
5-77
— MEMO —
5-78
FUEL
Fuel system
Hose routing ....................................................................... 6-1

Fuel hose and blowby hose........................................................ 6-1
Vapor gas hose .......................................................................... 6-3
Cooling water hose..................................................................... 6-5
Fuel system ........................................................................ 6-7

Reducing the fuel pressure ........................................................ 6-7
Disconnecting the quick connector............................................. 6-7
Connecting the quick connector ................................................. 6-8
Measuring the fuel pressure....................................................... 6-8
Checking the pressure regulator .............................................. 6-10
Fuel filter assembly.......................................................... 6-11

Removing the fuel filter assembly ............................................ 6-13
Checking the fuel filter assembly.............................................. 6-13
Disassembling the fuel filter assembly ..................................... 6-14
Checking the fuel filter element ................................................ 6-14
Checking the fuel cup assembly............................................... 6-14
Assembling the fuel filter assembly .......................................... 6-14
Installing the fuel filter assembly .............................................. 6-14
Intake manifold ................................................................. 6-15

Removing the intake silencer ................................................... 6-17
Removing the intake manifold .................................................. 6-17
Checking the intake manifold ................................................... 6-18
Checking the air temperature sensor ....................................... 6-18
Installing the intake manifold .................................................... 6-18
Installing the intake silencer ..................................................... 6-19
Throttle body .................................................................... 6-21

Removing the throttle body assembly ...................................... 6-23
Checking the canister check valve ........................................... 6-23
Checking the vacuum hose ...................................................... 6-24
Installing the throttle body assembly ........................................ 6-24
Canister, throttle body, and surge tank ......................... 6-26

Removing the canister, throttle body, and surge tank .............. 6-28
Checking the ETV .................................................................... 6-28
Checking the air pressure sensor............................................. 6-28
Checking the vapor shut-off valve ............................................ 6-28
Checking the canister............................................................... 6-28
Installing the canister, throttle body, and surge tank ................ 6-29
Low-pressure fuel pump ................................................. 6-31

Removing the low-pressure fuel pump..................................... 6-32
Checking the low-pressure fuel pump ...................................... 6-32
Checking the primer pump ....................................................... 6-32
Installing the low-pressure fuel pump....................................... 6-33
Vapor separator................................................................ 6-34

Draining the fuel ....................................................................... 6-35
Removing the vapor separator ................................................. 6-35
Installing the vapor separator ................................................... 6-35
Vapor separator and high-pressure fuel pump ............. 6-37

Disassembling the vapor separator.......................................... 6-39
Checking the high-pressure fuel pump..................................... 6-40
Checking the vapor separator .................................................. 6-40
Checking the check valve......................................................... 6-40
Assembling the vapor separator............................................... 6-41
Fuel injector ...................................................................... 6-43

Removing the fuel injector........................................................ 6-45
Checking the fuel rail................................................................ 6-45
Checking the quick connector .................................................. 6-46
Installing the fuel injector.......................................................... 6-46
6
FUEL
Fuel system
Hose routing
Fuel hose and blowby hose
7 g
g
6
h
k h
g
m
f
5
d
b e
8
4
c
1 2
a
9
1 Fuel hose (primer pump to fuel filter 8 Blowby hose (cylinder head cover [STBD]
assembly) to intake silencer)
2 Fuel hose (fuel filter assembly to joint) 9 Blowby hose (cylinder block to joint)
3 Fuel hose (joint to low-pressure fuel
pump) a Primer pump
4 Fuel hose (vapor separator to joint) b Fuel filter assembly
5 Fuel hose (low-pressure fuel pump to c Joint
vapor separator) d Low-pressure fuel pump
6 Fuel hose (vapor separator to fuel rail e Vapor separator
[PORT]) f Pressure regulator
7 Fuel hose (vapor separator to fuel rail g Quick connector
[STBD]) h Fuel injector
6-1
Hose routing
7 g
g
6
h
k h
g
m
f
5
d
b e
8
4
c
1 2
a
9
6
k Fuel rail (STBD)

m Fuel rail (PORT)
n Joint
6-2
FUEL
Fuel system
Vapor gas hose
È Ë g
1
A
d 8 b
c A B C
A
7
É b Ê
2
6 D
e
È
Ì Í
4
Ì h
0
3
9
Ê 8 a
f
7
0 6
Ë
6 Í STBD
5
C 5
1
4 2
3 É
1 Vapor gas hose (vapor separator to joint) 9 Vapor gas hose (check valve to joint)
2 Vapor gas hose (canister atmospheric port 0 Vapor gas hose (intake silencer to check
to joint) valve)
3 Vapor gas hose (joint to canister tank port) A Vacuum hose (joint to pressure regulator)
4 Vapor gas hose (canister purge port to B Vapor gas hose (joint to joint)
joint) C Vapor gas hose (check valve to bottom
5 Vapor gas hose (joint to vapor shut-off cowling)
valve) D Vapor gas hose (joint to check valve)
6 Vapor gas hose (vapor shut-off valve to
surge tank) a Joint
7 Vacuum hose (surge tank to joint) b Check valve
8 Vacuum hose (joint to air pressure sensor) c Vapor separator
6-3
Hose routing
È Ë g
1
A
d 8 b
c A B C
A
7
É b Ê
2
6 D
e
È
Ì Í
4
Ì h
0
3
9
Ê 8 a
f
7
0 6
Ë
6 Í STBD
5
6
C 5
1
4 2
3 É
d Pressure regulator
e Canister
f Vapor shut-off valve
g Air pressure sensor
h Intake silencer
6-4
FUEL
Fuel system
Cooling water hose
5
4 6
3 7
2
1
8
I 9
0
A D
B 7
C
D
E
5
F a 8
H G
4
9
G
B
1
A
H
0 c
2
6
I
e C d F E
1 Cooling water hose (Rectifier Regulator to 9 Cooling water hose (joint to joint)
joint) 0 Flushing hose (joint to cooling water
2 Cooling water hose (joint to Rectifier passage cover)
Regulator) A Flushing hose (flushing hose adapter to
3 Cooling water hose (joint to joint) joint)
4 Cooling water hose (joint to joint) B Cooling water hose (cylinder block to joint)
5 Cooling water hose (thermostat cover C Cooling water hose (joint to joint)
[STBD] to joint) D Cooling water hose (joint to fuel cooler)
6 Cooling water hose (joint to cylinder block) E Cooling water hose (fuel cooler to joint)
7 Cooling water hose (joint to joint) F Cooling water hose (cylinder head [STBD]
8 Cooling water hose (thermostat cover to adapter [water pressure sensor])
[PORT] to cylinder block) G Cooling water hose (joint to joint)
6-5
Hose routing
5
4 6
3 7
2
1
8
I 9
0
A D
B 7
C
D
E
5
F a 8
H G
4
9
B
G
6
3
1
A
H
0 c
2
6
I
e C d F E
H Cooling water pilot hose (joint to cooling

water pilot hole)
I Cooling water hose (joint to joint)
a Fuel cooler (vapor separator)

b Rectifier Regulator
c Cooling water pilot hole (on the bottom
cowling)
d Adapter (water pressure sensor)
e Cooling water passage cover (on the cyl-
inder block)
6-6
FUEL
Fuel system
Fuel system 2. Remove the flywheel magnet cover.
Reducing the fuel pressure
3. Wrap a rag around the quick connector
1.
Before servicing the high-pressure fuel
line or vapor separator, make sure to 4. Spread apart the ends of the locking
reduce the fuel pressure in the fuel line. slider a, and then move the locking
Otherwise, pressurized fuel could spray slider to the unlock position.
out. PORT
1. Remove the fuse cover 1, and then

remove the fuse (15 A) 2.
1 a
1
1
2
STBD
2. Start the engine and wait until the engine

stalls.
3. Crank the engine 2 or 3 times.
5. Install the fuse (15 A), and then install the

fuse cover.
Disconnecting the quick connector
Before disconnecting the quick connec-

a
tor, reduce the fuel pressure. Otherwise,
pressurized fuel could spray out.
5. Disconnect the quick connector 1 from
the fuel rail or vapor separator.
1. Reduce the fuel pressure. See “Reduc-
ing the fuel pressure” (6-7).
6-7
Fuel system
TIP:
1
• If the quick connector 1 is not installed
completely onto the fuel rail or vapor sepa-
rator, the locking slider a cannot be moved
to the lock position.
• Confirm that the quick connector is installed
properly by making sure there is a small
amount of free play when the quick connec-
tor is pulled and pushed.
• If there is no free play in the quick connec-
tor, disconnect the fuel hose and check the
2
O-ring for damage and proper installation.
See “Checking the quick connector” (6-46).
Measuring the fuel pressure

1. Reduce the fuel pressure. See “Reduc-
2. Disconnect the quick connector from the

fuel rail (PORT). See steps 2–5 in “Dis-
TIP: connecting the quick connector” (6-7).
Cover the quick connector, fuel rail, and
vapor separator using a plastic bag 2 to pre- 3. Remove the fuel rail cover (PORT) 1,
vent damage and to protect them from dirt. and then disconnect the OCV coupler
(PORT) a.
Connecting the quick connector
1. Connect the quick connector 1 to the 4. Remove the holder 2. 6
fuel rail or vapor separator, and then
move the locking slider a to the lock
position.
a
a
b
2
1
5. Connect the special service tool 3

1 between the quick connector and the fuel
rail (PORT).
6-8
FUEL
Fuel system
Fuel pressure gauge 4: 90890-06786

then measure the fuel pressure within 5
seconds.
Fuel pressure (reference data):
290.0 kPa (2.90 kgf/cm2, 42.1 psi)
3
TIP:
• The fuel pressure decreases 5 seconds
C
b
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
3 turning the engine start switch to OFF.
9. Start the engine and warm it up until the

Fuel pressure gauge adapter B 3:
engine idle speed stabilizes at 600–700
90890-06942
r/min.
TIP: 10. Measure the fuel pressure.
Position the special service tool 3 under the
wiring harness b. Otherwise, the OCV cou- Fuel pressure (reference data):
pler (PORT) cannot be connected to the OCV 260.0 kPa (2.60 kgf/cm2, 37.7 psi) at
(PORT). engine idle speed

WARNING! Gently screw in the gauge 12. Reduce the fuel pressure. See “Reduc-
until it is firmly connected to prevent ing the fuel pressure” (6-7).
fuel from leaking out. Also, make sure
that the drain screw c is tightened 13. Disconnect the OCV coupler (PORT).
securely, before measuring the fuel
pressure. 14. Disconnect the special service tools.
WARNING! Before disconnecting the
7. Connect the OCV coupler (PORT). special service tools, cover the end of
the hose using a clean and dry rag.
15. Fasten the wiring harness and ther-

moswitch connectors (PORT) using the
holder.
16. Connect the OCV coupler (PORT), and

then install the fuel rail cover (PORT).
3
17. Connect the quick connector to the fuel
rail (PORT). See “Connecting the quick
connector” (6-8).
4
c
6-9
Fuel system
Checking the pressure regulator 9. Reduce the fuel pressure. See “Reduc-
1. Reduce the fuel pressure. See “Reduc- ing the fuel pressure” (6-7).
10. Disconnect the special service tool from
2. Disconnect the quick connector from the the pressure regulator, and then connect
fuel rail (PORT). See steps 2–5 in “Dis- the vacuum hose to the pressure regula-
connecting the quick connector” (6-7). tor.
3. Connect the special service tools to the 11. Disconnect the special service tools from
fuel rail (PORT). See steps 3–7 in “Mea- the fuel rail (PORT). See steps 13–16 in
suring the fuel pressure” (6-8). “Measuring the fuel pressure” (6-8).
4. Disconnect the vacuum hose 1 from the 12. Connect the quick connector to the fuel
pressure regulator 2, and then connect rail (PORT). See “Connecting the quick
the special service tool 3 to the pressure connector” (6-8).
regulator 2.
6
2 1
3

90890-06756
5. Block the end of the vacuum hose 1

using a rubber plug.
6. Start the engine and let it idle.
7. Check that the fuel pressure is reduced

when vacuum pressure is applied to the
pressure regulator. If the fuel pressure is
not reduced, replace the pressure regu-
lator.
6-10
FUEL
Fuel system
1 2 5
3
2 6
9
10 7
8 11
12
13 14
5 N m (0.5 kgf m, 3.7 ft lb)
15 15 18
12 mm
(0.47 in)
2
2 18
16
2 2
17 16
12 mm 12 mm 9 mm
(0.47 in) (0.47 in) (0.35 in)

1 Hose 1
2 Plastic tie 6
3 Bracket 1
4 Bolt 2 M6 × 25 mm
5 Grommet 2
6 Collar 2
7 Bolt 2 M6 × 14 mm
8 Fuel filter assembly 1
9 O-ring 1 39
10 Fuel filter element 1
11 Clip 1
12 Float 1
13 Fuel cup assembly 1
14 Hose 1
15 Holder 1
16 Joint 2
17 Hose 1
6-11
1 2 5
3
2 6
9
10 7
8 11
12
13 14
5 N m (0.5 kgf m, 3.7 ft lb)
15 15 18
12 mm
(0.47 in)
2
2 18
16
2 2
17 16
12 mm 12 mm 9 mm
6
(0.47 in) (0.47 in) (0.35 in)

18 Holder 1
6-12
FUEL
Fuel system
Removing the fuel filter assembly
Cover the fuel components using a rag to
prevent fuel from spilling out.
1
17).
2
2. Disconnect the water detection switch
a b
coupler a.
3. Disconnect the fuel hoses 1 and 2.
4. Remove the fuel filter assembly 3. a b

a 90890-06756
3
Specified positive pressure:
2 200.0 kPa (2.00 kgf/cm2, 29.0 psi)
3. Connect the special service tool 1 to the

1
fuel outlet b.
4. Block the fuel inlet a using a rubber plug

2, and then apply the specified negative
a pressure. Replace the O-ring, fuel cup
assembly, or fuel filter assembly if the
specified pressure cannot be maintained
Checking the fuel filter assembly for 15 seconds or more.
fuel inlet a.
2. Block the fuel outlet b using a rubber

plug 2, and then apply the specified 1
positive pressure. Replace the O-ring,
fuel cup assembly, or fuel filter assembly
if the specified pressure cannot be main- 2 b
tained for 15 seconds or more. a
a b

90890-06756
Specified negative pressure:

80.0 kPa (0.80 kgf/cm2, 11.6 psi)
6-13
Disassembling the fuel filter
assembly
1. Remove the fuel cup assembly 1, O-ring
2, and fuel filter element 3, and then
remove the clip 4 and float 5. 5
4
2
3
1
2
3
4
1
5
Fuel cup assembly 3:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
Installing the fuel filter assembly

1. Install the fuel filter assembly 1.
Checking the fuel filter element 2. Connect the fuel hoses 2 and 3, and
1. Check the fuel filter element. Replace if
then fasten them using the plastic ties 4.
there is dirt or residue.
3. Fasten the fuel hoses 2 and 3 using the
Checking the fuel cup assembly holders 5 and 6.
1. Check the fuel cup assembly. Clean
using straight gasoline if there is foreign
material or replace if cracked. NOTICE:
4. Connect the water detection switch cou-
pler a.
6
When cleaning the fuel cup assembly,
do not remove the clip and float.
a
2. Check the water detection switch. See 4
“Checking the water detection switch” (5-
43). 1 2
Assembling the fuel filter assembly 3
Do not reuse an O-ring, always replace it

with a new one. a
1. Install the float 1 and clip 2 to the fuel 5 6 4

cup assembly 3.
5. Install the intake manifold (PORT). See
2. Install the fuel filter element 4, a new O- “Installing the intake manifold” (6-18).
ring 5, and the fuel cup assembly 3,
and then tighten the fuel cup assembly to
the specified torque.
6-14
FUEL
Fuel system
Intake manifold
1 7 N m (0.7 kgf m, 5.2 ft lb) 8
1 4
3 1 7
6
2
7 8
17
5
9 5
5
15
14 10
11
15 12
20 13
17
19
16 17
18
10 N m (1.0 kgf m, 7.4 ft lb) 18

1 Bolt 4 M6 × 25 mm
2 Intake silencer 1
3 Grommet 1
4 Air temperature sensor 1
5 Grommet 4
6 Flywheel magnet cover 1
7 Grommet 2
8 Bolt 2 M6 × 18 mm
9 Plastic tie 1
10 Hose 1
11 Plastic tie 1
12 Hose 1
13 Holder 1
14 Intake manifold assembly (PORT) 1
15 Gasket 6 39
16 Gasket 1 39
17 Bolt 8 M8 × 40 mm
6-15
Intake manifold
1 7 N m (0.7 kgf m, 5.2 ft lb) 8

1 4
3 1 7
6
2
7 8
17
5
9 5
5
15
14 10
11
15 12
20 13
17
19
16 17
18 6
10 N m (1.0 kgf m, 7.4 ft lb) 18

18 Bolt 7 M6 × 40 mm
19 Intake manifold assembly (STBD) 1
20 Gasket 1 39
6-16
FUEL
Fuel system
Removing the intake silencer

coupler a, and then remove the air tem-
perature sensor 1. 4
a
1
Removing the intake manifold

1. Remove the fuel drain hose 1 from the
intake manifold (PORT) 2.
PORT
3. Remove the blowby hose 2.
2
1
2. Remove the intake manifolds 2 and 3.
4. Disconnect the vapor gas hose 3, and

then remove the intake silencer 4.
3
6-17
Intake manifold
3. Remove the blowby hose 4.
1
4
2. Install new gaskets onto the intake mani-

Checking the intake manifold folds. Make sure to fit the protrusion on
1. Check the intake manifolds. Replace if each gasket into its corresponding slot in
cracked or deformed. the intake manifolds.
2. Check the intake silencer. Replace if

cracked or deformed.
3. Check the blowby hoses. Replace if

cracked or damaged.
Checking the air temperature sensor

1. Check the air temperature sensor. See
“Checking the air temperature sensor”
STBD PORT 6
(5-56).
Installing the intake manifold
Do not reuse a gasket, always replace it

with a new one.
1. Connect the blowby hose 1 with the

paint mark a facing outward, and then TIP:
fasten it using the holder 2. Make sure that the tab on the gaskets is
properly and firmly fitted into the slot in the
intake manifolds.
3. Install the intake manifolds 3 and 4

temporarily.
6-18
FUEL
Fuel system
PORT
²
6
4 $ %
! 5
±
&
# 5 6
(
3
STBD
&
6 5
$
!
±
%
6 5 #
TIP: Intake manifold bolt 5:

When the protrusions on the gaskets contact 10 N·m (1.0 kgf·m, 7.4 ft·lb)
the fuel rail cover, make sure that the gaskets
remain installed properly. TIP:
Make sure to tighten the intake manifold bolts
in the order 1, 2, and so on.
4. Tighten the intake manifold bolts 5 to
the specified torque, and then tighten the
intake manifold bolts 6. Installing the intake silencer
1. Install the intake silencer 1, and then
5. Fasten the fuel drain hose 7 to the tighten the intake silencer bolts 2 to the
holder on the intake manifold (PORT). specified torque.
2. Connect the vapor gas hose 3 to the

intake silencer.
6-19
Intake manifold
2 2 b
2 d
1
a
c
3 9
Intake silencer bolt 2: 8. Install the flywheel magnet cover.

7 N·m (0.7 kgf·m, 5.2 ft·lb)
3. Connect the blowby hose 4 into the

intake silencer 1 and cylinder head
cover (STBD), and then connect the
blowby hose 5 into the joint 6.
4. Fasten the blowby hose 5 using the

plastic tie 7.
5. Fasten the blowby hose 4 using the

plastic tie 8.
6
8
1 6 4
4 7
5
1
8
6. Install the air temperature sensor 9, and

then connect the air temperature sensor
coupler a.
7. Install the air temperature sensor lead b

at the white tape c to the holder d on
the oil filler neck.
6-20
FUEL
Fuel system
Throttle body
18
1 14
24
20
2 23 19
22
21 19
16
17
4 28 14
25
27
26 15
12
13 11
3
5 10 10
6
8 9
3 5 8

1 Joint 1
2 Plastic tie 1
3 Bolt 4 M8 × 40 mm
4 Throttle body assembly 1
5 Bolt 2 M6 × 16 mm
6 Holder 2
7 Hose 1
8 Holder 2
9 Hose 1
10 Joint 2 ø5 mm
11 Hose 1
12 Holder 2
13 Hose 1
14 Holder 3
15 Hose 1
16 Hose 1
17 Hose 1
6-21
Throttle body
18
1 14
24
20
2 23 19
22
21 19
16
17
4 28 14
25
27
26 15
12
13 11
3
5 10 10
6
8 9
3 5 8
7 6
18 Joint 1 ø3 mm
19 Dowel 2
20 Holder 1
21 Joint 1
22 Hose 1
23 Check valve 1
24 Hose 1
25 Hose 1
26 Hose 1
27 Joint 1
28 Hose 1
6-22
FUEL
Fuel system
Removing the throttle body 5. Remove the plastic tie 6, and then
assembly remove the joint 7.
1. Disconnect the throttle body assembly
wiring harness extension coupler a and 6. Remove the throttle body assembly 8.
ETV coupler b.
7
a 6
8
b
2. Remove the wiring harness 1.
7. Remove the hoses and check valve 9.
3. Remove the vacuum hose 2 from the

holder 3, and then disconnect the vac-
uum hose 2.
4. Disconnect the vapor gas hoses 4 and

5.
Checking the canister check valve

5 2
canister check valve port.
3
2. Apply positive pressure and check that
5 air comes out of the opposite end of the
canister check valve. Replace the canis-
ter check valve if no air comes out.
4
2
6-23
Throttle body

90890-06756

opposite canister check valve port.

no air comes out of the opposite end of
the canister check valve. Replace the
2. Install the dowels 2 and throttle body
canister check valve if air comes out.
assembly 3.
1
3. Install the joint 4, and then fasten it
using the plastic tie 5.
2
4
5 6
3
Checking the vacuum hose
1. Check the hoses 1, 2, and 3. Replace
any hose that is cracked or damaged.
3
2 4. Connect the vapor gas hoses 6 and 7.
1 5. Connect the vacuum hose 8, and then

fasten it using the holder 9.
Installing the throttle body assembly

1. Install the hoses, joint, and check valve
1, and then install the holders.
6-24
FUEL
Fuel system
6 8
7
8
6. Fasten the wiring harness 0 using the

holders.
7. Connect the throttle body assembly wir-

ing harness extension coupler a and
ETV coupler b.
6-25
Throttle body / Canister, throttle body, and surge tank
Canister, throttle body, and surge tank

13 N m (1.3 kgf m, 9.6 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb)
1 3
24
2 23 20
1 19
3 22
13 N m (1.3 kgf m, 9.6 ft lb)
23
5 21
4 2
1 A
1
A
22 21
20
6
5 N m (0.5 kgf m, 3.7 ft lb)
5 18
9 7 5 N m (0.5 kgf m, 3.7 ft lb) 19
10
11 17
16
14
12
13
13
14
15 6
12
5 N m (0.5 kgf m, 3.7 ft lb)

1 Nut 4
2 Washer 2
3 Throttle body 1
4 Gasket 1 39
5 Bolt 4 M8 × 18 mm
6 Throttle damper plate 1
7 Gasket 1 39
8 Surge tank 1
9 Bolt 1 M6 × 10 mm
10 Holder 1
11 Canister 1
12 Bolt 2 M6 × 28 mm
13 Collar 2
14 Grommet 2
15 Bracket 1
16 Air pressure sensor 1
17 Washer 1
6-26
FUEL
Fuel system

1 3
24
2 23 20
1 19
3 22
13 N m (1.3 kgf m, 9.6 ft lb)
23
5 21
4 2
1 A
1
A
22 21
20
6
5 N m (0.5 kgf m, 3.7 ft lb)
5 18
9 7 5 N m (0.5 kgf m, 3.7 ft lb) 19
10
11 17
16
14
13 14
13 15
12
12
5 N m (0.5 kgf m, 3.7 ft lb)

18 Bolt 1 M6 × 20 mm
19 Throttle body assembly wiring harness 1
extension
20 Plastic tie 1
21 Vapor shut-off valve 1
22 Bracket 1
23 Holder 1
24 Nut 1
6-27
Removing the canister, throttle body,
and surge tank 7
1. Remove the holder 1 and canister 2.
9
8
1
6. Remove the air pressure sensor 0.
2
2. Remove the bracket 3.
3
Checking the ETV
1. Turn the throttle valve manually and
check that it moves smoothly.
3. Disconnect the air pressure sensor cou-
pler a and vapor shut-off valve coupler
b, and then remove the throttle body 6
assembly wiring harness extension 4.
4. Remove the holder 5 and vapor shut-off

valve 6.
6
5
4 Checking the air pressure sensor
1. Check the air pressure sensor. See
“Checking the air pressure sensor” (5-
b 57).
a Checking the vapor shut-off valve

1. Check the vapor shut-off valve. See
5. Remove the bracket 7 and throttle body “Checking the vapor shut-off valve” (5-
8, and then remove the throttle damper 48).
plate 9.
Checking the canister
1. Check the canister. Replace if cracked.
6-28
FUEL
Fuel system
2. Connect the special service tool 1 to the 2. Install a new gasket 3 and the throttle
atmospheric port a and block the other damper plate 4, and then tighten the
ports b with rubber plugs 2. throttle damper plate bolts 5 to the spec-
ified torque.
3. Apply the specified positive pressure and
check that there is no air leakage. 3. Install a new gasket 6, the throttle body
Replace the canister if there is air leak- 7 and the bracket 8, and then tighten
age. the throttle body nuts 9 to the specified
torque.
5 9
8
1
4
7
5
3 9
6
a
2
Throttle damper plate bolt 5:
b 13 N·m (1.3 kgf·m, 9.6 ft·lb)
Throttle body nut 9:
Vacuum/pressure pump gauge set 1: 13 N·m (1.3 kgf·m, 9.6 ft·lb)
90890-06756
4. Install the holder 0 and vapor shut-off
Specified positive pressure: valve A, and then tighten the vapor shut-
19.6 kPa (0.196 kgf/cm2, 2.8 psi) off valve nut B to the specified torque.
Installing the canister, throttle body, 5. Install the throttle body assembly wiring
and surge tank harness extension coupler a to the
holder b on the bracket 8.
Do not reuse a gasket, always replace it 6. Fasten the throttle body assembly wiring
with a new one. harness extension C and holder 0 using
the plastic tie D.
1. Install the air pressure sensor 1, and
7. Connect the air pressure sensor coupler
then tighten the air pressure sensor bolt
c and vapor shut-off valve coupler d.
2 to the specified torque.
D
2 B 0 A
b 8
C
1
a
d
Vapor shut-off valve nut B:

Air pressure sensor bolt 2:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
5 N·m (0.5 kgf·m, 3.7 ft·lb)
6-29
8. Install the grommets E and collars F to
the bracket G.
E
E F
F
9. Install the bracket G, and then tighten

the canister bracket bolts H to the speci-
fied torque.
G
H
Canister bracket bolt H:

5 N·m (0.5 kgf·m, 3.7 ft·lb) 6
10. Secure the canister I using the holder
J, and then tighten the canister holder
bolt K to the specified torque.
J
I
Canister holder bolt K:

5 N·m (0.5 kgf·m, 3.7 ft·lb)
6-30
FUEL
Fuel system
8
5 N m (0.5 kgf m, 3.7 ft lb)
7 8
9
6
3 10
5 4
3 3 2

1 Hose 1
2 Clamp 3
3 Clamp 2
4 Joint 1
5 Bushing 2
6 Low-pressure fuel pump 1
7 Hose 1
8 Holder 2
9 Cover 1
10 Bolt 2 M6 × 15 mm
6-31
Removing the low-pressure fuel
pump
Cover the fuel components using a rag to
1. Disconnect the low-pressure fuel pump

coupler a.
6 5
2. Remove the holders 1 from the fuel
hose 2, and then disconnect the fuel
hose 2.
a
Checking the low-pressure fuel
pump
1. Drain the fuel from the vapor separator
2
1 and check the condition of the fuel. See
“Draining the fuel” (6-35). If the fuel is
dirty, check and clean the fuel lines.
2. Check the low-pressure fuel pump. See

“Checking the low-pressure fuel pump
and high-pressure fuel pump” (5-46).
3. Remove the fuel hose 3 and joint 4. Checking the primer pump
1. Connect the special service tool 1 to the 6
primer pump inlet hose.
2. Cover the fuel outlet a.
3. Apply the specified positive pressure to

check that the pressure is maintained for
4 at least 30 seconds. Replace the primer
3 pump if it does not maintain pressure.
4. Remove the cover 5 and low-pressure

fuel pump 6.
Leakage tester 1: 90890-06840
Specified positive pressure:

170.0 kPa (1.70 kgf/cm2, 24.7 psi)
6-32
FUEL
Fuel system
Installing the low-pressure fuel 6. Connect the low-pressure fuel pump cou-
pump pler b.
1. Install the low-pressure fuel pump 1 and
cover 2, and then tighten the low-pres-
sure fuel pump cover bolts 3 to the
b
specified torque.
9
A
1 2
3 0
Low-pressure fuel pump cover bolt 3:

5 N·m (0.5 kgf·m, 3.7 ft·lb)
2. Install the joint 4 to the fuel hose a, and

then fasten the fuel hose using the clamp
5.
3. Connect the fuel hose 6 to the low-pres-

sure fuel pump and joint 4, and then fas-
ten the fuel hose using the clamps 7 and
8.
8 a
5
6 4
7
4. Connect the fuel hose 9, and then fas-

ten it using the clamps 0.
5. Install the fuel hose 9 to the holders A.
6-33
Low-pressure fuel pump / Vapor separator
Vapor separator
3
10
8 5
3 7
3 6
5 5
7
5 4
7 11
3
5
11 13
4
5
7
12
11 5
2 4
13 15
14
1 5 6
4

1 Hose 1
2 Clamp 1
3 Bolt 4 M6 × 16 mm
4 Bolt 4 M6 × 35 mm
5 Collar 8
6 Vapor separator assembly 1
7 Grommet 4
8 Bracket 1
9 Bracket 1
10 Vapor separator wiring harness 1
extension
11 Plastic tie 3
12 Hose 1
13 Clamp 2
14 Hose 1
15 Joint 1
6-34
FUEL
Fuel system
Draining the fuel

3. Disconnect the fuel hose 1 from the

vapor separator assembly.
4. Loosen the vapor separator drain screw

2 to drain the fuel into a drain pan.
1 1
1
3. Remove the vapor separator assembly

2, and then remove the cooling water
hoses 3 and 4 and joint 5.
3
5. Tighten the vapor separator drain screw
2 to the specified torque. 3
Vapor separator drain screw 2:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
6. Connect the fuel hose to the vapor sepa- 4

rator assembly.
4
7. Install the intake silencer. See “Installing 5
8. Install the flywheel magnet cover. Installing the vapor separator

1. Install the joint 1 to the cooling water
Removing the vapor separator hose a, and then fasten the cooling
Cover the fuel components using a rag to water hose using the clamp 2.
2. Install the cooling water hose 3, and
1. Disconnect the quick connector. See then fasten it using the plastic ties 4.
steps 3–5 in “Disconnecting the quick
connector” (6-7). 3. Install the cooling water hose 5, and
then fasten it using the clamp 6 and
2. Remove the vapor separator wiring har- plastic tie 7.
ness extension 1.
4. Install the vapor separator assembly 8.
6-35
Vapor separator
a 5
6
6 4
7
7
5 4
3
4
1 3
2
5. Connect the vapor separator wiring har-

ness extension 9.
6. Connect the quick connector. See “Con-

necting the quick connector” (6-8).
6-36
FUEL
Fuel system
Vapor separator and high-pressure fuel pump
4 5 2 N m (0.2 kgf m, 1.5 ft lb)
5 10
6
4 N m (0.4 kgf m, 3.0 ft lb) 2 7
3
1 8
9
24
4 N m (0.4 kgf m, 3.0 ft lb) 12
25
25
11 16
13
26 21 20
14
27
22
23 19 15
28 17
2 N m (0.2 kgf m, 1.5 ft lb)
18
2 N m (0.2 kgf m, 1.5 ft lb)
29

1 Cover assembly 1
3 Holder 1
4 Pressure regulator 1
5 Bolt 3 M4 × 12 mm
6 Cover 1
7 Gasket 1 39
8 Filter 1
9 Check valve 1
10 Screw 6 M4 × 16 mm
11 Gasket 1 39
12 Grommet 1
13 Joint 1
14 Damper 1
15 High-pressure fuel pump 1
16 Lead 1
17 Filter 1
6-37
4 5 2 N m (0.2 kgf m, 1.5 ft lb)
5 10
6
4 N m (0.4 kgf m, 3.0 ft lb) 2 7
3
1 8
9
24
4 N m (0.4 kgf m, 3.0 ft lb) 12
25
25
11 16
13
26 21 20
14
27
22
23 19 15
28 17
2 N m (0.2 kgf m, 1.5 ft lb)
18 6
2 N m (0.2 kgf m, 1.5 ft lb)
29

18 Holder 1
19 Needle valve assembly 1
21 Pin 1
22 Float 1
24 Float chamber assembly 1
26 Cover 1
27 Gasket 1 39
28 Drain screw 1
29 Drain hose 1
6-38
FUEL
Fuel system
Disassembling the vapor separator 5. Remove the float chamber cover A, gas-
1. Remove the vapor separator drain screw ket B, high-pressure fuel pump C, and
1 and drain hose 2. grommet D.
2
C
D
2. Remove the fuel cooler cover 3 and
gasket 4.
3. Remove the holder 5, and then remove

the pressure regulator 6. 6. Remove the screw E, and then remove
the pin F, float G, and needle valve
assembly H.
5
3
E F
6 H
4
4. Remove the vapor separator cover 7,

gasket 8, filter 9, and check valve 0.
7. Remove the lead I and filter holder J,
and then remove the filter K, joint L,
9 7 and damper M.
8
0
6-39
I Float height a:
L
67.5 ± 2.5 mm (2.66 ± 0.10 in)
K
TIP:
To measure the float height, it should be rest-
ing on the needle valve. Do not press the
float.
Checking the check valve

J check valve port a.
M
air comes out of the opposite end b of
Checking the high-pressure fuel the check valve. Replace the check valve
pump if no air comes out.
1. Check the high-pressure fuel pump. See
“Checking the low-pressure fuel pump
and high-pressure fuel pump” (5-46). b a 1
Checking the vapor separator

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

6
90890-06756

opposite check valve port b.

2. Check the float. Replace if deteriorated. no air comes out of the opposite end a
of the check valve. Replace the check
3. Check the filter. Clean if there is dirt or valve if air comes out.
residue.
4. Place the cover assembly upside down, a b 1

and then measure the float height a.
6-40
FUEL
Fuel system
Assembling the vapor separator 4. Connect the high-pressure fuel pump
coupler a, and then install the grommet
A and high-pressure fuel pump B.
with a new one.
1. Install the needle valve assembly 1, and B

then tighten the needle valve assembly
screw 2 to the specified torque.
a
2. Install the float 3 and pin 4, and then
tighten the float pin screw 5 to the spec- A
ified torque.
5. Install a new gasket C and the float
2 chamber cover D, and then tighten the
5 4 1
float chamber cover screws E to the
specified torque.
E
3 C
Needle valve assembly screw 2:

2 N·m (0.2 kgf·m, 1.5 ft·lb)
Float pin screw 5:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
Float chamber cover screw E:
3. Install the damper 6, joint 7, filter 8, fil-
2 N·m (0.2 kgf·m, 1.5 ft·lb)
ter holder 9, and lead 0.
0 6. Install the check valve F, the filter G, a
7 new gasket H, and the vapor separator
8 cover I, and then tighten the vapor sep-
arator cover bolts J to the specified
torque.
9
6
6-41
J
G I
H R
F
Vapor separator drain screw R:

2 N·m (0.2 kgf·m, 1.5 ft·lb)
Vapor separator cover bolt J:

2 N·m (0.2 kgf·m, 1.5 ft·lb)
7. Install the pressure regulator K and

holder L, and then tighten the pressure
regulator holder screw M to the specified
torque.
8. Install a new gasket N and the fuel

cooler cover O, and then tighten the fuel
cooler cover screws P to the specified
torque.
M
P
6
L
O
K
N
Pressure regulator holder screw M:

4 N·m (0.4 kgf·m, 3.0 ft·lb)
Fuel cooler cover screw P:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
9. Install the drain hose Q and vapor sepa-

rator drain screw R, and then tighten the
vapor separator drain screw to the speci-
fied torque.
6-42
FUEL
Fuel system
Fuel injector
3 4
STBD
1
6
5
3 9
8 7
18
2
14 13
10
4 PORT
17 13 9
14
12
14 3
8 9
15 7 4 1
16 9
11

1 Bolt 4 M6 × 20 mm
2 Cover (STBD) 1
3 Bolt 4 M6 × 35 mm
4 Plastic tie 3
5 Fuel rail assembly (STBD) 1
6 Fuel rail (STBD) 1
7 Fuel injector 6
8 O-ring set 6 39
9 Holder 6
10 Fuel rail assembly (PORT) 1
11 Fuel rail (PORT) 1
12 Cover (PORT) 1
13 Quick connector 2
14 Clamp 4
15 Hose 1
16 Quick connector 1
17 Hose 1
6-43
Fuel injector
3 4
STBD
1
6
5
3 9
8 7
18
2
14 13
10
4 PORT
17 13 9
14
12
14 3
8 9
15 7 4 1
16 9
11
6
18 Fuel hose assembly 1
6-44
FUEL
Fuel system
Removing the fuel injector
Cover the fuel components using a rag to STBD
4 a
1. Disconnect the quick connectors. See

steps 3–5 in “Disconnecting the quick a
connector” (6-7).
2. Remove the fuel hoses 1 and 2. a
PORT
4. Remove the fuel rails 5 and 6.
PORT 5
1
STBD
6
STBD
5. Remove the holders 7, and then remove

the fuel injectors b and O-rings c and
d.
c d
3. Remove the fuel rail covers 3 and 4,

and then disconnect the fuel injector cou- 7
plers a. b
PORT
a
3
Checking the fuel rail

a
1. Check the fuel rails. Replace if cracked
or deformed.
a
6-45
Fuel injector
2. Check the fuel injectors. See “Checking
PORT 2 4 2
the fuel injector” (5-44).
1 4
Checking the quick connector 1
1. Check the quick connector 1. Replace if
cracked or damaged.
2. Check the O-rings a in the quick con-

nector 1. Replace the quick connector if
an O-ring is cracked or damaged.
1 STBD
3 4
1
1 4
1
3
a
Installing the fuel injector 3. Install the fuel rails 2 and 3 onto the
cylinder heads.
Do not reuse an O-ring, always replace it 4. Tighten the bolts 5 equally and gradu-
with a new one. ally.
2
1. Install new O-rings a and b to the fuel
injector c.
PORT
5
6
a
5
c STBD
b 3
5
2. Install the fuel injectors 1 onto the fuel
rails 2 and 3, and then install the hold-
ers 4.
5
5. Connect the fuel injector couplers d.
6-46
FUEL
Fuel system
6. Fasten the wiring harness using the hold-
PORT
ers 4, and then fasten the wiring har-
ness using the plastic ties 6. See
“Wiring harness routing” (5-6).
PORT STBD
6
0
B
A
4
9
4
d
d STBD
7. Install the fuel rail covers 7 and 8.
PORT C
7
STBD
8
8. Connect the quick connectors. See “Con-

9. Fasten the fuel hoses 9 and 0 using the

holders A, B, and C.
6-47
POWR
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 ......................................................... 7-6

Removing the power unit............................................................ 7-8
Installing the power unit............................................................ 7-11
Flywheel magnet .............................................................. 7-15

Removing the flywheel magnet ................................................ 7-16
Checking the pulser coil ........................................................... 7-17
Installing the flywheel magnet .................................................. 7-17
Wiring harness ................................................................. 7-19

Removing the wiring harness ................................................... 7-20
Installing the wiring harness ..................................................... 7-23
Starter motor .................................................................... 7-27

Removing the starter motor...................................................... 7-28
Installing the starter motor........................................................ 7-28
Fuse box ........................................................................... 7-29
Junction box ..................................................................... 7-30

7
Removing the Rectifier Regulator ............................................ 7-32
Checking the Rectifier Regulator anode................................... 7-32
Removing the junction box ....................................................... 7-32
Installing the junction box ......................................................... 7-33
Installing the Rectifier Regulator .............................................. 7-33
Engine ECM ...................................................................... 7-35

Removing the engine ECM ...................................................... 7-36
Installing the engine ECM ........................................................ 7-36
Timing belt ........................................................................ 7-37

Removing the timing belt.......................................................... 7-38
Checking the timing belt ........................................................... 7-39
Installing the timing belt............................................................ 7-39
Cylinder head cover ......................................................... 7-42

Removing the cylinder head cover ........................................... 7-44
POWR
Checking the spark plug........................................................... 7-44

Installing the cylinder head cover ............................................. 7-44
Camshaft ........................................................................... 7-46

Removing the driven sprocket and camshaft ........................... 7-48
Checking the sprocket.............................................................. 7-49
Checking the valve lifter ........................................................... 7-49
Checking the camshaft............................................................. 7-50
Installing the camshaft and driven sprocket ............................. 7-50
Exhaust cover................................................................... 7-56

Removing the exhaust cover.................................................... 7-57
Checking the exhaust cover anode .......................................... 7-57
Installing the exhaust cover...................................................... 7-57
Cylinder head ................................................................... 7-58

Removing the cylinder head..................................................... 7-61
Disassembling the cylinder head.............................................. 7-61
Checking the cylinder head ...................................................... 7-62
Checking the valve spring ........................................................ 7-62
Checking the valve ................................................................... 7-62
Checking the valve guide ......................................................... 7-63
Replacing the valve guide ........................................................ 7-63
Checking the valve seat ........................................................... 7-64
Refacing the valve seat ............................................................ 7-65
Checking the cylinder head anode ........................................... 7-67
Assembling the cylinder head .................................................. 7-67
Installing the cylinder head....................................................... 7-68
Cooling water passage cover ......................................... 7-70

Removing the cooling water passage cover............................. 7-72
Checking the cooling water passage cover anode................... 7-72
Checking the knock sensor ...................................................... 7-72
Installing the cooling water passage cover............................... 7-72
Crankcase ......................................................................... 7-74

Removing the oil filter bracket .................................................. 7-76
Removing the oil pump assembly ............................................ 7-76
Removing the crankcase cover ................................................ 7-76
Disassembling the oil pump assembly ..................................... 7-77
Checking the oil pump assembly.............................................. 7-77
Assembling the oil pump assembly .......................................... 7-77
Installing the crankcase cover .................................................. 7-78
Installing the oil pump assembly .............................................. 7-78
Installing the oil filter bracket .................................................... 7-79
Cylinder block .................................................................. 7-81

Disassembling the cylinder block ............................................. 7-84
Checking the thermostat .......................................................... 7-85
Checking the piston diameter................................................... 7-86
Checking the cylinder bore....................................................... 7-86
Checking the piston ring........................................................... 7-86
Checking the piston ring end gap (reference) .......................... 7-86
Checking the piston ring groove............................................... 7-87
Checking the piston ring side clearance................................... 7-87
Checking the piston pin boss inside diameter .......................... 7-87
Checking the piston pin ............................................................ 7-87
Checking the connecting rod small
end inside diameter and big end inside diameter..................... 7-88
Checking the connecting rod big end side clearance............... 7-88
Checking the crankshaft........................................................... 7-88
Checking the crankcase bolt .................................................... 7-89
Checking the crankpin oil clearance......................................... 7-89
Selecting the crankpin bearing ................................................. 7-90
Checking the crankshaft journal oil clearance.......................... 7-91
Selecting the crankshaft journal bearing .................................. 7-92
Crankshaft journal bearing selection table ............................... 7-94
Checking the cylinder block anode........................................... 7-95
Assembling the cylinder block .................................................. 7-95
7
POWR
Power unit
Power unit (check and 11. Install the spark plugs, and then tighten
adjustment) them to the specified torque.
Checking the compression pressure Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb)
1. Start the engine, warm it up for 5–10 min-
utes, and then stop it. 12. Install the ignition coils, and then tighten
2. Remove the clip from the engine shut-off torque.
switch. Ignition coil bolt: 7 N·m (0.7 kgf·m, 5.2 ft·lb)
3. Remove the fuel rail covers (PORT and 13. Connect the fuel injector couplers, and
STBD), and then disconnect fuel injector then install the fuel rail covers (PORT
couplers. and STBD) and engine ECM cover.
4. Remove the engine ECM cover, ignition Checking the oil pressure
coils, and spark plugs. NOTICE: Before 1. Connect the YDIS to display “Oil pres-
removing the spark plugs, remove any sure.”
dirt or dust in the spark plug wells that
could fall into the cylinders. 2. Start the engine and warm it up until the
engine idle speed stabilizes at 600–700
5. Install the special service tools 1 and 2 r/min.
into the spark plug hole.
3. Measure the oil pressure.
Oil pressure (reference data):
1 507.3 kPa (5.073 kgf/cm2, 73.6 psi)
at 60 °C (140 °F) with SL 10W-30
engine oil and at 650 r/min
700.6 kPa (7.006 kgf/cm2, 101.6 psi)
at 62 °C (144 °F) with SL 10W-30
2 engine oil and at 3000 r/min
Checking the pulser coil air gap

Compression gauge 1: 90890-03160
Compression gauge extension 2:
90890-06563 Do not turn the flywheel magnet counter-
clockwise. Otherwise, the water pump
6. Turn the engine start switch to ON. impeller could be damaged.
7. Fully open the throttle. 1. Remove the flywheel magnet cover, and
then remove the wiring harness guide
8. Crank the engine until the reading on the
bolts and lift up the wiring harness guide.
compression gauge stabilizes, and then
measure the compression pressure. TIP:
Minimum compression pressure (reference To completely remove the wiring harness
data): 630.0 kPa (6.30 kgf/cm2, 91.4 psi) guide when checking the air gap, see
“Reducing the fuel pressure” (6-7) and
9. Turn the engine start switch to OFF. “Removing the wiring harness” (7-20).
10. Remove the special tools.
7-1
Power unit (check and adjustment)
2. Turn the flywheel magnet clockwise to
align the protrusion a on the flywheel TIP:
magnet with the protrusion b on the When measuring or adjusting the valve clear-
pulser coil. ances, the fuel line must be disconnected, so
make sure to reduce the fuel pressure before
3. Measure the pulser coil air gap c. Adjust performing the disassembly procedure.
if out of specification.
Pulser coil air gap c: 2. Remove the flywheel magnet cover and
1.4–1.6 mm (0.055–0.063 in) engine ECM cover.
4. Loosen the pulser coil screws 1 and 3. Remove the blowby hose. See “Remov-
adjust the pulser coil air gap. ing the intake silencer” (6-17).
4. Remove the speed sensor coupler from

a the bracket. See step 16 in “Removing
c the power unit” (7-8).
5. Remove the wiring harness from the

engine ECM bracket and holder. See
b steps 4–16 in “Removing the wiring har-
ness” (7-20).
1
6. Remove the ignition coils and spark
5. Tighten the pulser coil screws 1, and plugs.
then check the pulser coil air gap.
7. Disconnect the cooling water hose 1.
Pulser coil screw 1:
4 N·m (0.4 kgf·m, 3.0 ft·lb) 8. Remove the knock sensor lead a from
the engine ECM bracket 2.
6. Install the wiring harness guide and wir-
ing harness guide bolts. See “Installing 9. Remove the engine ECM bracket 2.
the wiring harness” (7-23). 7
2
Checking the valve clearance 1
Measure the valve clearances when the
engine is cold.
Do not turn the flywheel magnet counter- a

impeller could be damaged. 10. Turn the flywheel magnet clockwise and
align the “1TDC” mark b on the flywheel
1. Reduce the fuel pressure. See “Reduc- magnet with the pointer c.
11. Check that the “II” marks d on the VCT
assembly (PORT) and driven sprocket
(PORT) are aligned, and check that the
“I” marks e on the VCT assembly
(STBD) and driven sprocket (STBD) are
aligned.
7-2
POWR
Power unit
Valve clearance (cold):

Intake f:
0.205 ± 0.035 mm (0.0081 ± 0.0014
in)
Exhaust g:
0.345 ± 0.035 mm (0.0136 ± 0.0014
in)
d TIP:
e
Write down the measurement data.
14. Measure the intake and exhaust valve

b clearances of the specified cylinders.
Adjust if out of specification. See “Adjust-
c ing the valve clearance” (7-4).
#1 #2 #3 #4 #5 #6
IN — — —
12. Remove the cylinder head covers. EX — — —
13. Measure the valve clearances f and g —: Not applicable

according to steps 14–16. : Specified cylinder
UP 15. Turn the flywheel magnet an additional

IN EX EX IN
360° clockwise and align the “1TDC”
mark b on the flywheel magnet with the
#1 pointer c.
#2
16. Measure the intake and exhaust valve
#3 clearances of the specified cylinders.
#4 Adjust if out of specification. See “Adjust-
ing the valve clearance” (7-4).
#5
#6 #1 #2 #3 #4 #5 #6
IN — — —
PORT STBD
EX — — —
—: Not applicable
: Specified cylinder
17. Install the cylinder head covers. See

“Installing the cylinder head cover” (7-
f f
44).
g g 18. Install the engine ECM bracket 2.
PORT STBD 19. Fasten the knock sensor lead a using

the holder 3 on the engine ECM
bracket.
20. Connect the water cooling hose 1.
7-3
Power unit (check and adjustment)
2. Check that the “II” marks c on the VCT
2 (PORT) are aligned, and check that the
1 “I” marks d on the VCT assembly
aligned.
a
3
21. Install the spark plugs, and then tighten

them to the specified torque.
Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb)
22. Install the ignition coils, and then tighten c

d
torque.
Ignition coil bolt: 7 N·m (0.7 kgf·m, 5.2 ft·lb)
a
23. Install the wiring harness to the engine
ECM bracket. See steps 26–36 in b
“Installing the wiring harness” (7-23).
24. Install the speed sensor to the bracket.

See step 17 in “Installing the power unit” 3. Remove the intake manifolds. See
(7-11). “Removing the intake manifold” (6-17).
25. Install the blowby hose. See “Installing 4. Disconnect the quick connectors. See
the intake silencer” (6-19). steps 3–5 in “Disconnecting the quick
26. Install the engine ECM cover and fly-

connector” (6-7).
7
wheel magnet cover. 5. Remove the fuel hoses and fuel rail cov-
ers.
Adjusting the valve clearance
Adjust the valve clearances when the engine 6. Remove the flywheel magnet and stator
is cold. assembly. See “Removing the flywheel
magnet” (7-16).
When the timing belt is not installed, do 7. Remove the wiring harness and wiring
not turn the flywheel magnet or driven harness guide. See steps 17–29 in
sprockets. Otherwise, the pistons and “Removing the wiring harness” (7-20).
valves or intake and exhaust valves could
collide with each other and be damaged. 8. Remove the timing belt. See steps 9–11
in “Removing the timing belt” (7-38).
1. Check that the “1TDC” mark a on the 9. Remove the VCT assemblies, driven
flywheel magnet and the pointer b are sprockets, and camshafts. See “Remov-
aligned. ing the driven sprocket and camshaft” (7-
48).
7-4
POWR
Power unit
17. Install the intake manifolds. See in
TIP: “Installing the intake manifold” (6-18).
Make sure to keep the parts in the order as
they were removed. 18. Check the pulser coil air gap. See steps
2–5 in “Checking the pulser coil air gap”
10. Measure the valve lifter thickness e, and (7-1).
then write down the measurement data.
19. Install the wiring harness guide and wir-
ing harness. See steps 13 and 14 in
e “Installing the wiring harness” (7-23).
20. Install the fuel hoses and fuel rail covers.

11. Select the necessary valve lifter by calcu-

lating its thickness using the following
formula.
Calculation formula:
Necessary valve lifter thickness =
Removed valve lifter thickness +
Measured valve clearance –
Specified valve clearance
Example:
Removed valve lifter thickness = 2.10 mm
Measured valve clearance = 0.30 mm
Specified valve clearance = 0.20 mm
Necessary valve lifter thickness
= 2.10 + 0.30 – 0.20
= 2.20 mm
12. Install the necessary valve lifter into the

cylinder head.
13. Install the camshafts, driven sprockets,

and VCT assemblies. See “Installing the
camshaft and driven sprocket” (7-50).
14. Install the timing belt. See steps 1–9 in

“Installing the timing belt” (7-39).
15. Install the stator assembly and flywheel

magnet. See steps 1–7 in “Installing the
flywheel magnet” (7-17).
16. Measure the valve clearances. See steps

14–16 in “Checking the valve clearance”
(7-2).
7-5
Power unit (check and adjustment) / Power unit assembly
Power unit assembly

4 N m (0.4 kgf m, 3.0 ft lb) 27 28
1
28
11
12
25 12
3
24
25
21 12 3
26
23 11 11
22
16 14
4
2
3 5
19 3
20
17 16
18
6
16 7
17
13 8
9
16 11 11 10
15 12 42 N m (4.2 kgf m, 31.0 ft lb)
No.
1 Power unit
Part name Q’ty
1
Remarks 7
2 Gasket 1 39
3 Dowel 2
4 Bolt 2 M6 × 20 mm
5 Cable holder 1
6 Bolt 2 M6 × 30 mm
7 Retaining plate 1
8 Rigging tube retainer 1
9 Plastic tie 1
10 Rigging grommet 1
11 Bolt 7 M10 × 35 mm
12 Bolt 6 M10 × 140 mm
13 Nut 2
14 Apron (PORT) 1
15 Bolt 1 M6 × 30 mm
16 Bolt 7 M6 × 14 mm
17 Grommet 6
7-6
POWR
Power unit
4 N m (0.4 kgf m, 3.0 ft lb) 27 28

1
28
11
12
25 12
3
24
25
21 12 3
26
23 11 11
22
16 14
4
2
3 5
19 3
20
17 16
18
6
16 7
17
13 8
9
16 11 11 10
15 12 42 N m (4.2 kgf m, 31.0 ft lb)

18 Apron (STBD) 1
19 Cover 1
20 O-ring 1 39
21 Bolt 1 M6 × 16 mm
22 Dipstick guide 1
23 Dipstick 1
24 Holder 3
25 Bolt 2 M6 × 10 mm
26 Cap 2
27 Engine ECM cover 1
28 Bolt 4 M6 × 20 mm
7-7
Power unit assembly
Removing the power unit 5
Make sure to reduce the fuel pressure before
removing the power unit. See “Reducing the
fuel pressure” (6-7).
It is recommended to loosen the flywheel
magnet nut before removing the power unit to
improve working efficiency. See “Removing 6
the flywheel magnet” (7-16). a
6. Remove the cable holder 7, and then
2. Remove the plastic tie 1, and then disconnect the shift cable 8.
remove the rigging tube retainer 2.
8
2
1
7. Disconnect the fuel hose 9 from the fuel
3. Remove the retaining plate 3 and rig- filter.
ging grommet 4.
3 9
8. Remove the PTT switch coupler b from

the bracket 0, and then disconnect the
PTT switch coupler.
4
9. Remove the water detection switch cou-
4. Disconnect the battery cables 5. pler c and isolator coupler d from the
bracket 0.
5. Remove the throttle cable 6 from the
holder a, and then disconnect the throt-
tle cable.
7-8
POWR
Power unit
c c
b
0 b
10. Remove the 10-pin coupler e from the

holders on the bracket A, and then dis-
C
connect the 10-pin coupler.
11. Remove the 6Y8 Multifunction Meter 16. Remove the engine ECM cover D, and
coupler f from the tab on the bracket, then remove the speed sensor coupler k
and then disconnect the 6Y8 Multifunc- from the bracket E.
tion Meter coupler.
17. Disconnect the flushing hose F.
A
k
E D
F
f e
12. Remove the alert indicator coupler g

from the bracket. 18. Disconnect the vapor gas hose G from
the housing (STBD).
13. Remove the trim sensor coupler h from
the tab on the bracket, and then discon- STBD
G
nect the trim sensor coupler.
14. Remove the wiring harness B from the

holders on the bracket A.
A
h B
17).
g 20. Remove the dipstick H, and then remove

the dipstick guide I.
15. Disconnect the cooling water hose C.
7-9
Power unit assembly
21. Disconnect the shift cut switch coupler
m, and then remove the wiring harness
and neutral switch lead from the holders R
J and K.
22. Remove the neutral switch coupler n,

and then disconnect the neutral switch
coupler from the bracket L. S
23. Remove the cooling water hose M from

the holder N, and then disconnect the
cooling water hose.
R
H I
J
m K
n 26. Retract the cowling lock levers (PORT

L and STBD). NOTICE: Make sure that
N M the cowling lock levers are retracted
and the engine stoppers are installed
24. Remove the holders O, plastic tie P, before removing the power unit. Oth-
and caps Q, and then disconnect the erwise, the fuel rails could be dam-
PTT relay terminals p. aged.
Q Q
O STBD PORT
P 7
O
STBD
27. Hook a lifting harnesses to the engine

p hangers T, and then suspend the power
unit U.
25. Remove the aprons R and cover S.
7-10
POWR
Power unit
28. Remove the power unit mounting bolts V
and W, and then remove the power unit STBD PORT
U, gasket X, and dowels Y.
T T V
V V
U
X
Y Y
V 2. Clean the power unit mating surface, and

V
V W then the install the dowels 1 and a new
gasket 2.
Installing the power unit
Before installing the power unit, make sure to 3. Hook a lifting harness to the engine
install the shift rod and shift bracket onto the hangers 3, and then suspend the power
bottom cowling. See “Shift rod and shift unit 4.
bracket” (9-1).
4. Install the power unit 4, and then tighten
the power unit mounting bolts 5 and 6
Do not reuse a gasket or O-ring, always to the specified torque.
replace it with a new one.
5 3 3
3
6
1. Retract the cowling lock levers (PORT
and STBD). NOTICE: Make sure that
the cowling lock levers are retracted
6
and the engine stoppers are installed
5 5
before installing the power unit. Oth-
erwise, the fuel rails could be dam-
aged.
1
2
4
5
5 6 5
Power unit mounting bolt 5 and 6:

42 N·m (4.2 kgf·m, 31.0 ft·lb)
7-11
Power unit assembly
5. Install the cover 7 and aprons 8.
0 0
B
B
7
8 c
TIP:
To fasten the PTT motor lead, see “Wiring
a harness routing” (5-6).
8. Connect the cooling water hose C, and

TIP: then fasten it using the clamp D.
Make sure that the ground lead a is routed
through the gap between the aprons and is 9. Fasten the cooling water hose C using
not pinched. the holder E.
6. Connect the PTT relay terminals b, and 10. Connect the neutral switch coupler d,
then tighten the PTT relay terminal bolts and then install the neutral switch coupler
9 to the specified torque. to the bracket F.
STBD 11. Connect the shift cut switch coupler e.
b 12. Fasten the neutral switch lead and wiring 7

harness using the holder G and H.
13. Install a new O-ring and the dipstick

b guide I, and then install the dipstick J.
9
J I
H
e G
PTT relay terminal bolt 9:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
7. Install the caps 0, and then fasten the

PTT motor lead c using the plastic tie A d
and holders B. F
E C D

7-12
POWR
Power unit
15. Connect the vapor gas hose K to the 20. Connect the trim sensor coupler g, and
housing (STBD), and then fasten it using then install the trim sensor coupler to the
the plastic tie L. tab on the bracket.
STBD 21. Install the alert indicator coupler h to the

K
bracket.
T
g S
16. Connect the flushing hose M, and then

fasten it using the plastic tie N. h
17. Install the speed sensor coupler f to the 22. Connect the 6Y8 Multifunction Meter
bracket O, and then install the engine coupler k, and then install the 6Y8 Multi-
ECM cover P. function Meter coupler to the tab on the
bracket.
23. Connect the 10-pin coupler m, and then

f fasten the 10-pin coupler to the holders
O P on the bracket T.
N
M
18. Connect the cooling water hose Q, and

then fasten it using the clamp R.
k m
24. Install the water detection switch coupler

n and isolator coupler p to the bracket
U.
25. Connect the PTT switch coupler r, and

R then install the PTT switch coupler to the
bracket U.
19. Install the wiring harness S to the hold-

ers on the bracket T.
7-13
Power unit assembly
Y
n r n
U r
TIP: Negative battery cable nut:

To install the water detection switch coupler 13 N·m (1.3 kgf·m, 9.6 ft·lb)
and isolator coupler, see “Wiring harness
31. Install the rigging grommet Z and retain-
routing” (5-6).
ing plate [.
26. Connect the fuel hose V to the fuel filter, [

and then fasten it using the plastic tie W.
27. Fasten the fuel hose V using the holder

X.
28. Connect the shift cable, and then install

TIP:
Route each harness through the proper hole
7
the cable holder. See steps 5–13 in in the rigging grommet. See “Rigging grom-
“Installing the shift cable and throttle met description” (3-9) for the detailed
cable” (3-9). description of the rigging grommet.
29. Connect the throttle cable. See steps 14– 32. Install the rigging tube retainer \, and
20 in “Installing the shift cable and throt- then fasten it using the plastic tie ].
tle cable” (3-9).
30. Connect the battery cables Y, and then

tighten the negative battery cable nut to
7-14
POWR
Power unit
Flywheel magnet
240 N m (24.0 kgf m, 177.0 ft lb)
1
2
5
5
5 8
7
13
5
11
10 6
9
6
12
4 N m (0.4 kgf m, 3.0 ft lb)

1 Nut 1 Width across flats: 36 mm
2 Washer 1
3 Flywheel magnet 1
4 Stator assembly 1
5 Bolt 4 M6 × 35 mm
6 Dowel 2
7 Holder 1
8 Holder 1
9 Bracket 1
10 Holder 1
11 Pulser coil 1
12 Screw 2 M5 × 12 mm
13 Woodruff key 1
7-15
Flywheel magnet
Removing the flywheel magnet
Do not turn the flywheel magnet counter-

impeller could be damaged.
3
1. Loosen the flywheel magnet nut.

NOTICE: Apply force in the direction
of the arrow to prevent the special a
service tool 1 from slipping off easily.
4. Disconnect the pulser coil coupler b.
Flywheel holder 1: 90890-06522
2. Remove the flywheel magnet using the

special service tool 2, and then remove
the Woodruff key. NOTICE: To prevent
5. Remove the vapor gas hose 4 from the
damage to the engine or tools, screw
holder 5.
in the puller set bolts evenly and com-
pletely so that the flywheel puller is
parallel to the flywheel magnet. 4
7
2
5
6. Remove the stator assembly 6, and

then remove the pulser coil 7.
Flywheel puller 2: 90890-06521
3. Remove the plastic ties 3, and then dis-

connect the stator assembly couplers a. 6
7-16
POWR
Power unit
Checking the pulser coil
1. Check the pulser coil. See step 6 in
“Checking the pulser coil” (5-55).
9
a
Installing the flywheel magnet

impeller could be damaged.
5. Connect the stator assembly couplers b,
1. Install the pulser coil 1 to the stator and then fasten the stator assembly lead
assembly 2, and then tighten the pulser using the plastic ties 0.
coil screws 3 to the specified torque.
2. Install the dowels 4 and stator assembly

2, and then install the holders 5 and 6
and bracket 7.
5 0
6
2
1 b
7 4
4
3
TIP:
Pulser coil screw 3:
To fasten the stator assembly lead, see “Wir-
4 N·m (0.4 kgf·m, 3.0 ft·lb)
ing harness routing” (5-6).
3. Fasten the vapor gas hose 8 using the
holder 5. 6. Install the Woodruff key A, and then
install the flywheel magnet B.
8
4. Connect the pulser coil coupler a, and

then fasten the pulser coil lead using the
holder 9.
7-17
Flywheel magnet
e
B
f
B
A
d
TIP:
t
• Make sure to remove any grease from the

tapered portion c of the crankshaft and the
inner surface d of the flywheel magnet.
• Apply engine oil to the threads e of the fly-
wheel magnet nut and upper and lower sur-
faces f of the washer before installation.
7. Tighten the flywheel magnet nut to the

specified torque. NOTICE: Apply force
in the direction of the arrow to prevent
the special service tool C from slip-
ping off easily.
7
Flywheel magnet holder C: 90890-06522
Flywheel magnet nut:

240 N·m (24.0 kgf·m, 177.0 ft·lb)
8. Check the pulser coil air gap. See

“Checking the pulser coil air gap” (7-1).
7-18
POWR
Power unit
Wiring harness
2
2
7
6
2
8
4
3 3

1 Wiring harness guide 1
2 Plastic tie 4
3 Damper 2
4 Bolt 6 M6 × 35 mm
5 Holder 4
6 Wiring harness 1
7 Protector 1
8 Bolt 2 M6 × 30 mm
9 Bolt 3 M6 × 16 mm
7-19
Wiring harness
Removing the wiring harness
When removing the wiring harness and wir-
b
ing harness guide, the fuel line must be dis-
connected. Therefore, make sure to reduce a
c
the fuel pressure before performing the dis-
assembly procedure.

coupler, and then remove the blowby d 1
hose and intake silencer. See “Removing

e f g
17).
10. Remove joint coupler 1 h from the wiring
harness guide.
11. Disconnect the ignition coil couplers
connector” (6-7).
(STBD) k and cam position sensor cou-
pler (STBD IN) m.
4. Remove the fuel hoses and fuel rail cov-
ers. See steps 2 and 3 in “Removing the
12. Remove the water pressure sensor cou-
fuel injector” (6-45).
pler n from the bracket.
5. Remove the engine ECM 1, and then
disconnect the engine ECM couplers a.
h
6. Disconnect the cam position sensor cou-
pler (PORT IN) b, cam position sensor
coupler (PORT EX) c, and ignition coil
k
couplers (PORT) d.
7
7. Remove the knock sensor coupler e
from the engine ECM bracket, and then
disconnect the knock sensor coupler.
8. Remove joint coupler 2 f from the m

n
bracket.
13. Remove the cam position sensor lead
9. Remove the air-fuel sensor coupler g (PORT IN) from the holder 2.
from the bracket.
14. Remove the plastic ties 3.
15. Remove the holders p on the wiring har-

ness from the engine ECM bracket.
16. Remove the wiring harness 4 from the

holders 5, 6, and 7 on the engine
ECM bracket.
7-20
POWR
Power unit
4 PORT w v 8
3 7 s
x
p y 9
2 t
3 7 0
p u
p
6 r A
y
0
5 7
17. Remove the low-pressure fuel pump cou- 25. Remove the plastic tie B, and then dis-
pler r from the wiring harness guide, connect the thermoswitch connectors
and then disconnect the low-pressure (STBD) A.
fuel pump coupler.
26. Disconnect the OCV coupler (STBD) B
18. Remove the YDIS coupler s from the and fuel injector couplers (STBD) D.
bracket.
27. Remove the plastic tie C, and then
19. Remove the diagnostic flash indicator remove the fuel injector lead from the
connector t from the holder. holders D and E.
20. Remove the YDIS/diagnostic flash indi- A B STBD

cator connector lead from the holder 8.
21. Remove the holder 9, and then discon-

nect the vapor separator wiring harness B
extension coupler u and thermoswitch
connectors (PORT) v. C
E D
0
22. Remove the engine temperature sensor
coupler w from the wiring harness guide, D
and then disconnect the engine tempera-
ture sensor coupler.
23. Disconnect the OCV coupler (PORT) x

and fuel injector couplers (PORT) y. 28. Remove the plastic tie F, and then
remove the holders p on the wiring har-
24. Remove the plastic ties 0, and then ness from the wiring harness guide.
remove the fuel injector lead from the
holders A.
7-21
Wiring harness
p F H
4
I
p p
33. Remove the fuse holder J and grommet
K, and then disconnect the fuse holder
F couplers H.
29. Remove the thermoswitch lead and H

engine temperature sensor lead from the
holder E on the wiring harness guide,
and then remove the wiring harness
guide G. H
K
J
E 34. Disconnect the PTT relay coupler J.
G
7
30. Remove the air temperature sensor lead
from the holder H. 35. Disconnect the ground lead terminals L
and M and brown lead of the wiring har-
31. Disconnect the throttle body assembly ness 4, and then remove the cap L.
wiring harness extension coupler F and
ETV coupler G. 36. Remove the plastic ties M.
32. Remove the wiring harness 4 from the 37. Remove the Rectifier Regulator protector
holders I. N, and then remove the holder p on the
wiring harness from the junction box.
38. Disconnect the APS coupler N.
7-22
POWR
Power unit
2. Install the wiring harness at the white
tape c to the holder 1, and then fasten
the wiring harness using the plastic tie
M 2.
L
4
L 2
N M a
2
1
M c 1
N
p
39. Disconnect the oil pressure sensor cou- 3. Connect the APS coupler d.
pler R and water detection switch cou-
pler T. 4. Install the holder e on the wiring har-
ness to the junction box, and then install
40. Remove the plastic tie O, and then the Rectifier Regulator protector 3.
remove the wiring harness from the
holder P. 5. Install the cap 4 to the starter motor lead
and brown lead of the wiring harness 5,
and then connect them together.
6. Connect the ground lead terminals f

and g.
7. Fasten the Rectifier Regulator lead and

wiring harness using the plastic ties 6.
R
O
P
T
41. Remove the wiring harness.
Installing the wiring harness

To install all of the wiring harness, see “Wir-
ing harness routing” (5-6).
1. Connect the oil pressure sensor coupler

a and water detection switch coupler b.
7-23
Wiring harness
12. Fasten the air temperature sensor lead
using the holder 0.
6 m 0
4
5
5
g
9
3 6
n
13. Install the wiring harness guide A, and

f
then install the thermoswitch lead and
d engine temperature sensor lead to the
e
holder p on the wiring harness guide.
r
8. Connect the PTT relay coupler h. A
s
p
9. Connect the fuse holder couplers k, and
then install the grommet 7 and fuse TIP:
7
holder 8. Fold the engine temperature sensor lead r
and route it through the hole s in the wiring
k harness guide.
14. Install the holders e on the wiring har-

ness to the wiring harness guide in the
k order 1, 2, and so on, and then fasten
7 the wiring harness using the plastic tie
8 B.

holders 9.
11. Connect the throttle body assembly wir-

ing harness extension coupler m and
ETV coupler n.
7-24
POWR
Power unit
21. Connect the thermoswitch connectors
e (PORT) A and vapor separator wiring
harness extension coupler B, and then
1 fasten the thermoswitch connectors,
vapor separator wiring harness exten-
e sion, and wiring harness using the holder
I.
22. Fasten the YDIS/diagnostic flash indica-

2 3 tor connector lead using the holder J.
e
23. Install the diagnostic flash indicator con-
e nector D to the holder.
B
24. Install the YDIS coupler E to the bracket.
15. Connect the fuel injector couplers
(STBD) t and OCV coupler (STBD) u. 25. Connect the low-pressure fuel pump cou-
pler F, and then install the low-pressure
16. Fasten the fuel injector lead to the hold- fuel pump coupler to the wiring harness
ers C and D, and then fasten the fuel guide.
injector lead using the plastic tie E.
PORT y A J
17. Connect the thermoswitch connectors
(STBD) v, and then fasten the ther- E
x
moswitch connectors and wiring harness w I
using the plastic tie F. D
v F STBD H
B
F G
u
w
E H
D t
0
C holders K, L, and M on the engine
ECM bracket.
27. Install the holders e on the wiring har-

ness to the engine ECM bracket and fas-
18. Connect the fuel injector couplers ten the wiring harness using the plastic
(PORT) w and OCV coupler (PORT) x. ties N.
19. Install the fuel injector lead to the holder 28. Install the cam position sensor lead
G, and then fasten the fuel injector lead (PORT IN) to the holder O.
using the plastic ties H.
20. Connect the engine temperature sensor

coupler y, and then install the engine
temperature sensor coupler to the wiring
harness guide.
7-25
Wiring harness
35. Connect the ignition coil couplers
5
(PORT) T, cam position sensor coupler
1 K (PORT EX) U, and cam position sensor
N
coupler (PORT IN) Y.
e
O
36. Connect the engine ECM couplers Z.
3 NOTICE: Make sure that the rubber
N K seal is installed properly in each
2 engine ECM coupler.
e
e
L 37. Install the engine ECM P, and then
tighten the engine ECM bolts Q to the
specified torque.
M K
Q
TIP: Y
Make sure to install the holder e and plastic
ties N in the order 1, 2, and so on. U
Z
29. Install the water pressure sensor coupler
G to the bracket.
T P
30. Connect the cam position sensor coupler
(STBD IN) H and ignition coil couplers
(STBD) J. Q
R N M
31. Install joint coupler 1 L to the wiring har-
ness guide.
Engine ECM bolt Q:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
L
See steps 7 and 9 in “Installing the fuel
7
injector” (6-46).
J 39. Connect the quick connectors. See “Con-


H 41. Install the intake silencer, and then con-

G nect the air temperature sensor coupler
32. Install the air-fuel sensor coupler M to and blowby hose. See “Installing the
the bracket. intake silencer” (6-19).
33. Install joint coupler 2 N to the bracket.
34. Connect the knock sensor coupler R,

and then install the knock sensor coupler
to the engine ECM bracket.
7-26
POWR
Power unit
Starter motor
14
3 4
11 9 6
12
5
8 7
10
13
26 N·m (2.6 kgf·m, 19.2 ft·Ib)

1 Starter motor 1
2 Bolt 3 M8 × 45 mm
3 Nut 1
4 Holder 2
5 Plastic tie 2
6 Bolt 1 M8 × 16 mm
7 Terminal 1
8 Bolt 1 M8 × 20 mm
9 Terminal stud bolt 1
10 APS 1
11 Collar 3
12 Grommet 3
13 Bolt 3 M6 × 35 mm
14 Bolt 1 M6 × 16 mm
7-27
Starter motor
Removing the starter motor
3
1. Disconnect the starter motor lead a, and
then remove the plastic ties 1 and hold-
ers 2.
a
2 2 1
Terminal stud bolt 2:

1
26 N·m (2.6 kgf·m, 19.2 ft·lb)
3. Connect the starter motor lead c and

2. Remove the junction box wiring harness brown lead of the wiring harness, and
extension terminal b, and then remove then fasten the starter motor lead using
the starter motor 3. the holders 4 and plastic ties 5.
3. Remove the junction box wiring harness c

extension terminal c, terminal 4, and
terminal stud bolt 5.
3
4
7
5
b
TIP:
c To fasten the starter motor lead, see “Wiring
5 4 harness routing” (5-6).
Installing the starter motor

1. Install the terminal 1, junction box wiring
harness extension terminal a, and termi-
nal stud bolt 2, and then tighten the ter-
minal stud bolt to the specified torque.
2. Install the starter motor 3, and then

install the junction box wiring harness
extension terminal b.
7-28
POWR
Power unit
Fuse box
6
13
2 6
1 3
43 13
25
2 12 9
8
A
7
7
5
3
4 12 7
11
A 10
13 9
10
2 3 4 3 2 5 9 13
60 60
14

1 Fuse box assembly 1
2 Fuse 3 10 A, Spare is included.
6 Screw 4 ø5 × 20 mm
7 Relay 4
8 Cover 1
10 Screw 4 M5 × 10 mm
11 Cover 1
12 Fuse puller 1
13 Screw 12 ø3 × 10 mm
14 Grommet 1
7-29
Fuse box / Junction box
Junction box
4 N m (0.4 kgf m, 3.0 ft lb)
4
2 22 3 6
24 5
25 23
7
26
4
18
23 10 6
24 17 11
25 12 5
19 8
22
13 7
3 4
21 20 9
16 1 6 N m (0.6 kgf m, 4.4 ft lb)
14
15 13 2 12 N m (1.2 kgf m, 8.9 ft lb)
3 N m (0.3 kgf m, 2.2 ft lb)
20
1 6 N m (0.6 kgf m, 4.4 ft lb)
3 2 12 N m (1.2 kgf m, 8.9 ft lb)
No.
1 Junction box
Part name Q’ty
1
Remarks 7
2 PTT relay 1
3 Bolt 5 M6 × 30 mm
4 Plastic tie 5
5 Grommet 5
6 Collar 5
7 Plastic tie 3
8 Bolt 4 M6 × 25 mm
9 Holder 1
10 Cover 1
11 Anode 1
12 Screw 1 M4 × 12 mm
13 Clip 3
14 Plastic tie 1
15 Hose 1
16 Hose 1
17 Gasket 1 39
7-30
POWR
Power unit
4 N m (0.4 kgf m, 3.0 ft lb)
4
2 22 3 6
24 5
25 23
7
26
4
18
23 10 6
24 17 11
25 12 5
19 8
22
13 7
3 4
21 20 9
16 1 6 N m (0.6 kgf m, 4.4 ft lb)
14
15 13 2 12 N m (1.2 kgf m, 8.9 ft lb)
3 N m (0.3 kgf m, 2.2 ft lb)
20
1 6 N m (0.6 kgf m, 4.4 ft lb)
3 2 12 N m (1.2 kgf m, 8.9 ft lb)

18 Bolt 2 M6 × 25 mm
19 Rectifier Regulator 1
20 Bolt 2 M6 × 35 mm
21 Protector 1
22 Bolt 3 M6 × 16 mm
23 Washer 2
24 Nut 2
25 Cap 2
26 Junction box wiring harness extension 1
7-31
Junction box
Removing the Rectifier Regulator Checking the Rectifier Regulator
1. Remove the Rectifier Regulator protector anode
1. 1. Check the anode. Replace if eroded.
Clean if there is grease, oil, or scales.
2. Disconnect the cooling water hoses a NOTICE: Do not apply grease, oil, or
and b. paint to the anode.
3. Disconnect the Rectifier Regulator Removing the junction box

ground lead c. 1. Remove the caps 1, and then discon-
nect the PTT relay terminals a.
4. Remove the plastic ties 2, and then
remove the Rectifier Regulator leads. 2. Disconnect the PTT relay coupler b.
5. Remove the Rectifier Regulator couplers 3. Remove the PTT relay 2.
d from the junction box.
b
6. Remove the Rectifier Regulator 3.
2
c 2
1
1
2 a
3
1 a
a
4. Disconnect the junction box wiring har-
b
7. Remove the cover 4 and gasket 5 from

ness extension terminal c and ground
lead terminal d. 7
the Rectifier Regulator.
5. Remove the plastic ties 3.
8. Remove the anode 6 from the cover.
6. Remove the holder e on the wiring har-
6 ness from the junction box 4.
5
7. Remove the junction box 4.
7-32
POWR
Power unit
d
4 3
3
e
4
c e
d
c 5 e
d 4
Installing the junction box PTT relay terminal nut 4:

1. Install the junction box 1. 4 N·m (0.4 kgf·m, 3.0 ft·lb)
2. Install the holder a on the wiring har- Installing the Rectifier Regulator
ness to the junction box 1.
3. Fasten the wiring harness using the plas- Do not reuse a gasket, always replace it
tic ties 2. with a new one.
4. Install the ground lead terminal b and 1. Install the anode 1 to the cover 2, and
junction box wiring harness extension then tighten the anode screw 3 to the
terminal c. specified torque.
2. Install the gasket 4 and cover 2 to the

1 2 Rectifier Regulator, and then tighten the
Rectifier Regulator cover bolts 5 to the
a specified torques in 2 stages.
1
3
4 5
b 2
b
c c
5. Install the PTT relay 3.

Anode screw 3:
6. Connect the PTT relay coupler d. 3 N·m (0.3 kgf·m, 2.2 ft·lb)
Rectifier Regulator cover bolt 5:
7. Connect the PTT relay terminals e, and 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
then tighten the PTT relay terminal nuts 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
3. Install the Rectifier Regulator 6, and
8. Install the caps 5. then tighten the Rectifier Regulator bolts
7 to the specified torques in 2 stages.
7-33
Junction box
4. Install the Rectifier Regulator couplers a
to the junction box.
5. Connect the Rectifier Regulator ground

lead b.
6. Fasten the Rectifier Regulator leads

using the plastic tie 8.
7. Connect the cooling water hoses c and

d.
8. Install the Rectifier Regulator protector

9.
b 8
7
8
6
7 c
Rectifier Regulator bolt 7:

1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 7
TIP:
To fasten the Rectifier Regulator leads, see
“Wiring harness routing” (5-6).
7-34
POWR
Power unit
Engine ECM
5
3
6
7
4
6
7
15
7 N m (0.7 kgf m, 5.2 ft lb)
7
1 8
6
7
11
9
13
14
2
9
8 9
12
9
2 8 11 10 12

1 Engine ECM 1
2 Bolt 4 M6 × 20 mm
3 Plastic tie 2
4 Holder 1
5 Bracket 1
6 Collar 4
7 Grommet 4
8 Bolt 4 M6 × 28 mm
9 Holder 4
10 Bracket 1
11 Bolt 2 M6 × 16 mm
12 Holder 2
13 Bracket 1
14 Holder 1
15 Holder 1
7-35
Engine ECM
Removing the engine ECM
1. Remove the engine ECM 1.
2. Remove the knock sensor lead a from

the holder 2.
a 2
Installing the engine ECM

1. Fasten the knock sensor lead a using
the holder 1.
2. Install the engine ECM 2, and then

tighten the engine ECM bolts 3 to the
specified torque.
7
3
a 1
Engine ECM bolt 3:

7 N·m (0.7 kgf·m, 5.2 ft·lb)
7-36
POWR
Power unit
Timing belt
39 N m (3.9 kgf m, 28.8 ft lb)

39 N m (3.9 kgf m, 28.8 ft lb)
1
2 3
7
9 7
4
5
8 3
6
4

1 Timing belt 1
2 Timing belt tensioner 1
3 Bolt 2 M10 × 55 mm
4 Washer 2
5 Pulley 2
6 Collar 2
7 Bolt 4 M6 × 14 mm
8 Guide (PORT) 1
9 Guide (STBD) 1
7-37
Timing belt
Removing the timing belt
• When the timing belt is not installed, do

not turn the crankshaft or driven sprock-
ets. Otherwise, the pistons and valves
or intake and exhaust valves could col-
lide with each other and be damaged.
• Do not twist, turn inside out, or bend the
timing belt beyond the maximum limit of d
25.0 mm (1.0 in). Otherwise, the timing c
belt can be damaged. b
1. Disconnect the air temperature sensor a

coupler, and then remove the blowby
hose and intake silencer. See “Removing
2. Remove the intake manifold (PORT). 8. Remove the timing belt guides 1.
17). 1 1

connector” (6-7).
4. Remove the fuel hoses and fuel rail cov-

ers. See steps 2 and 3 in “Removing the
fuel injector” (6-45).
5. Remove the wiring harness guide. See

steps 5–29 in “Removing the wiring har-
9. Insert a hexagon wrench into the hole e,
turn the timing belt tensioner gradually
7
ness” (7-20). clockwise, and then insert a ø5.0 mm
(0.2 in) pin 2 into the hole f.
6. Align the “L L” mark a on the drive
L” mark b on the cyl-
sprocket with the “L
inder block.
2
7. Check that the “II” marks c on the VCT f e
(PORT) are aligned, and check that the
“I” marks d on the VCT assembly
aligned.
7-38
POWR
Power unit
TIP: a 4
• When turning the timing belt tensioner,
apply a force of 15 N·m (1.5 kgf·m, 11.1
ft·lb) or less. 1 3
• Leave the pin inserted into the hole f of
the timing belt tensioner until the timing belt 2
is installed again.
10. Remove the timing belt 3 from the

driven sprocket (PORT) or driven
sprocket (STBD), and then remove it
from the crankshaft.
3
Timing belt tensioner bolt a:
39 N·m (3.9 kgf·m, 28.8 ft·lb)
Pulley bolt 4:
39 N·m (3.9 kgf·m, 28.8 ft·lb)
2. Install the timing belt 5 onto the crank-

shaft so that part number b is in the
upright position and the belt position
mark c is aligned with the “F F” mark d
11. Remove the timing belt tensioner 4 and on the crankshaft. NOTICE: Do not
pulleys 5. apply grease or oil to the timing belt.
4 b
5
5
Checking the timing belt c

1. Check the interior and exterior of the tim-
ing belt. Replace if cracked, damaged, or
worn.
Installing the timing belt

1. Install the timing belt tensioner 1, collar
2, and pulley 3, and then tighten the
timing belt tensioner bolt a and pulley
bolt 4 to the specified torque.
7-39
Timing belt
5. Install the washer, and then tighten the
TIP: pulley bolt 8 to the specified torque.
Before installing the timing belt, make sure
that the marks on the crankshaft and cylinder 8
block are aligned. Also, make sure that the
marks on the VCT assemblies and driven 7
sprockets are aligned. See steps 6 and 7 in
“Removing the timing belt” (7-38). 6
3. Install the timing belt onto the VCT

assemblies and driven sprockets by
aligning belt position marks e, f, g,
and h with the “L L” marks in the order Pulley bolt 8:
listed. 39 N·m (3.9 kgf·m, 28.8 ft·lb)
TIP:
c h g f e When installing the pulley, make sure to keep
the belt position marks and the “L L” marks
aligned as specified in step 3.
0123 60 88 133 160 k 6. Adjust the timing belt installation height

m to specification.
k Belt teeth number
f g
7
Timing belt installation height m:
2.0 mm (0.08 in)
7. Insert a hexagon wrench into the hole n,

turn the timing belt tensioner gradually
clockwise, remove the pin 9, and then
return the timing belt tensioner slowly.
e h
9
4. Install the collar 6, push the timing belt n
inward using the pulley 7, and then
install the pulley. NOTICE: Make sure
that the pulley 7 is installed properly
onto the collar 6.
7-40
POWR
Power unit
TIP:
• When turning the timing belt tensioner,
apply a force of 15 N·m (1.5 kgf·m, 11.1
ft·lb) or less.
• Make sure that the belt position marks are
L” marks. See steps 6
aligned with the “L
and 7 in “Removing the timing belt” (7-38).
8. Install the timing belt guides 0.

0 0
u
Timing belt guide clearance u:

0.5–1.5 mm (0.02–0.06 in)
9. Turn the crankshaft clockwise 2 full turns
until the marks p and r are aligned, 11. Install the wiring harness guide. See
and then check that the marks s and t steps 13–37 in “Installing the wiring har-
on the VCT assemblies and driven ness” (7-23).
sprockets are aligned.
See steps 7 and 9 in “Installing the fuel
injector” (6-46).


s
t 15. Install the intake silencer, and then con-
nect the air temperature sensor coupler
r and blowby hose. See “Installing the
p intake silencer” (6-19).
10. Adjust the timing belt guide clearance u.
7-41
Timing belt / Cylinder head cover
Cylinder head cover

2 N m (0.2 kgf m, 1.5 ft lb)
5
6
2 4
1
4
13
3
1 7
11 12 8 9
10 15
12 1 8 N m (0.8 kgf m, 5.9 ft lb) 14
11
10 2 8 N m (0.8 kgf m, 5.9 ft lb)
11 12
10
12
25 N m (2.5 kgf m, 18.4 ft lb) 11
12
7 N m (0.7 kgf m, 5.2 ft lb) 10 11 7
12 17
10 4 16
11
2
20 18
10
19 1
23 N m (2.3 kgf m, 17.0 ft lb)
No.
1 Bolt
Part name Q’ty
3 M6 × 20 mm
Remarks 7
2 Cam position sensor (PORT EX/STBD 2
IN)
3 Cam position sensor (PORT IN) 1
4 O-ring 3 39
5 Bolt 1 M6 × 12 mm
6 Holder 1
7 Bolt 28 M6 × 30 mm
8 Cylinder head cover (PORT) 1
9 Gasket 1 39
10 Bolt 12 M6 × 20 mm
11 Ignition coil 6
12 Spark plug 6
14 Plate 1
15 Gasket 1 39
16 Cylinder head cover (STBD) 1
17 Adapter 1
7-42
POWR
Power unit
2 N m (0.2 kgf m, 1.5 ft lb)

5
6
2 4
1
4
13
3
1 7
11 12 8 9
10 15
12 1 8 N m (0.8 kgf m, 5.9 ft lb) 14
11
10 2 8 N m (0.8 kgf m, 5.9 ft lb)
11 12
10
12
25 N m (2.5 kgf m, 18.4 ft lb) 11
12
7 N m (0.7 kgf m, 5.2 ft lb) 10 11 7
12 17
10 4 16
11
2
20 18
10
19 1
23 N m (2.3 kgf m, 17.0 ft lb)

18 Gasket 1 39
19 Plug 1 M14 × 12 mm
20 Bolt 2 M6 × 30 mm
7-43
Cylinder head cover
Removing the cylinder head cover
1. Remove the ignition coils 1, spark plugs
2, cam position sensors 3 and 4, and
adapter 5, and then remove the cylinder a
head covers 6 and 7.
4 6
2. Check the spark plug. Replace if the
1
electrodes are eroded, or there is carbon
1 2 or other deposits.
1 3. Check the spark plug gap b. Replace if

out of specification.
5
1 7
3
b
2. Remove the cylinder head cover plate 8
from the cylinder head cover (STBD) 7.
Specified spark plug: LFR6A-11 (NGK)

Spark plug gap b:
1.0–1.1 mm (0.039–0.043 in)
Installing the cylinder head cover 7

8
• Do not reuse a gasket or O-ring, always
7 replace it with a new one.
not turn the crankshaft or driven sprock-
ets. Otherwise, the pistons and valves
or intake and exhaust valves could col-
Checking the spark plug
1. Clean the electrodes a using a spark 1. Install the cylinder head cover plate 1 to
plug cleaner. the cylinder head cover (STBD) 2, and
then tighten the cylinder head cover plate
screws 3 to the specified torque.
7-44
POWR
Power unit
4. Install the adapter 8.
3
5. Install a new gasket 9 and the adapter
plug 0, and tighten the adapter plug to
6. Connect the cooling water hose A, and

then fasten it using the clamp B.
7. Install new O-rings C and the cam posi-

tion sensors D and E.
1
D C
2
C
Cylinder head cover plate screw 3:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
E
2. Install new gaskets 4 and 5 and the cyl-
inder head covers 2 and 6.
A B 8
3. Tighten the cylinder head cover bolts 7
C
twice to the general tightening torque.
9 D
0
Adapter plug 0:
23 N·m (2.3 kgf·m, 17.0 ft·lb)
8. Install the spark plugs, and then tighten

Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb)
9. Install the ignition coils, and then tighten

1280B torque.
1280B
Ignition coil bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
7 5 7
4
6 2
Cylinder head cover bolt 7:

1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
7-45
Cylinder head cover / Camshaft
Camshaft
7 32 N m (3.2 kgf m, 23.6 ft lb)
8
1 8 N m (0.8 kgf m, 5.9 ft lb) 9 10
2 17 N m (1.7 kgf m, 12.5 ft lb)
11 14
12 15
2 17
4
1 4 17
12
11
3
13 17
6 60 N m (6.0 kgf m, 44.3 ft lb)
10 7
5
14 8 17
16
6 15 9 60 N m (6.0 kgf m, 44.3 ft lb)
11
4 12 10
1 8 N m (0.8 kgf m, 5.9 ft lb) 11

19 12
2 17 N m (1.7 kgf m, 12.5 ft lb)
20
21 18
21
1 8 N m (0.8 kgf m, 5.9 ft lb) 22
2 17 N m (1.7 kgf m, 12.5 ft lb) 6
6
5 5
No.
1 Bolt
Part name Q’ty
6 M7 × 48 mm
Remarks 7
2 Camshaft cap 1
3 Camshaft cap 1
4 Dowel 6
5 Bolt 26 M7 × 37 mm
6 Camshaft cap 13
7 Cap 2
8 Gasket 2 39
9 VCT bolt 2 M12 × 35 mm
10 VCT assembly 2
11 Oil seal 4 39
12 Dowel 4
13 Camshaft (PORT IN) 1
14 Bolt 2 M10 × 35 mm
15 Driven sprocket 2
16 Camshaft (PORT EX) 1
17 Valve lifter 24
7-46
POWR
Power unit
7 32 N m (3.2 kgf m, 23.6 ft lb)

8
1 8 N m (0.8 kgf m, 5.9 ft lb) 9 10
2 17 N m (1.7 kgf m, 12.5 ft lb)
11 14
12 15
2 17
4
1 4 17
12
11
3
13 17
6 60 N m (6.0 kgf m, 44.3 ft lb)
10 7
5
14 8 17
16
6 15 9 60 N m (6.0 kgf m, 44.3 ft lb)
11
4 12 10
1 8 N m (0.8 kgf m, 5.9 ft lb) 11

19 12
2 17 N m (1.7 kgf m, 12.5 ft lb)
20
21 18
21
1 8 N m (0.8 kgf m, 5.9 ft lb) 22
2 17 N m (1.7 kgf m, 12.5 ft lb) 6
6
5 5

18 Camshaft (STBD IN) 1
19 Camshaft (STBD EX) 1
20 Camshaft cap 1
21 Bolt with seal washer 4 39 M7 × 48 mm
22 Bolt 1 M6 × 30 mm
7-47
Camshaft
Removing the driven sprocket and
TIP:
camshaft
Be careful when turning the VCT assemblies
and driven sprockets. Depending on the posi-
When the timing belt is not installed, do tion of the camshafts, the force of the valve
not turn the crankshaft or camshafts. Oth- springs may cause the VCT assemblies and
erwise, the pistons and valves or intake driven sprockets to be rotated too far.
and exhaust valves could collide with
each other and be damaged. 3. Secure the VCT assembly using the spe-
cial service tool 1, and then remove the
1. Align the “LL” mark a on the drive VCT caps 2. NOTICE: When removing
sprocket with the mating surface of the the VCT cap, do not secure the cam-
crankcase and cylinder block by turning shaft. Otherwise, the VCT assembly
the crankshaft counterclockwise 60° could be damaged. When removing
gradually. NOTICE: Do not turn the the VCT cap, do not turn the VCT
crankshaft counterclockwise more assembly. Otherwise, the intake and
than 60°. Otherwise, the piston and exhaust valves could collide with
valves could collide with each other each other and be damaged.
and be damaged.
2
2
STBD PORT
1
Sheave holder 1: 90890-01701

2. Align the “I” marks b on the VCT assem-
bly (PORT) and driven sprocket (PORT)
4. Remove the special service tool. 7
by turning them clockwise 60° gradually. 5. Secure the intake camshaft using a
NOTICE: Do not turn the VCT assem- wrench 3, and then remove the VCT
bly (PORT) and driven sprocket assemblies 4. NOTICE: When remov-
(PORT) clockwise more than 60°, and ing the VCT assembly, do not turn the
do not turn the VCT assembly (STBD) intake camshaft. Otherwise, the intake
and driven sprocket (STBD). Other- and exhaust valves could collide with
wise, the intake and exhaust valves each other and be damaged.
could collide with each other and be
damaged.
4
4
PORT
7-48
POWR
Power unit
6. Secure the exhaust camshaft using a
wrench 3, and then remove the driven D
sprockets 5. NOTICE: When removing
the driven sprocket, do not turn the E
exhaust camshaft. Otherwise, the
intake and exhaust valves could col-
lide with each other and be damaged. C
5 5 D
B
A
0
3 E
7. Loosen the camshaft cap bolts gradually

in several stages and in the order 1, 2, TIP:
and so on, and then remove the cam- Make sure to keep the parts in the order as
shaft caps 6, 7, 8, and 9. Take pre- they were removed.
caution not to tilt the camshafts.
PORT UP STBD Checking the sprocket

6 7 8 1 1. Check the VCT assemblies and driven
1 1 sprockets. Replace the VCT assembly or
4 driven sprocket if cracked, damaged, or
3
3 3 worn.
2 3 Checking the valve lifter

2 2
1. Check the valve lifters. Replace if dam-
4 5 aged, scratched, or worn.
4 4
9 2 2. Measure the valve lifter outside diameter.
8. Remove the camshafts 0, A, B, and C

and oil seals D, and then remove the
valve lifters E.
Valve lifter outside diameter a:

30.970–30.980 mm (1.2193–1.2197
in)
7-49
Camshaft
Checking the camshaft 3. Measure the camshaft runout.
1. Check the edge and face of the flange on
the camshafts (PORT) and intake cam-
shaft (STBD) that is used for the cam
position sensor. Replace the camshaft if
damaged, rough, or scratched.
Camshaft runout:
0.015 mm (0.0006 in)
4. Measure the camshaft journal diameter

c and cylinder head journal inside diam-
eter d. Replace the camshaft or cylinder
TIP:
head assembly, or both if out of specifi-
• Be careful not scratch or damage the face
cations.
of the flange.
• If there is a scratch more than 0.2 mm c
(0.008 in) deep or more than 0.5 mm (0.020
in) wide on the surface of the flange, a mal-
function may occur in the cam position sen-
sor signal.
d
2. Measure the cam lobe height a and

c
width b.
d
7
a
Camshaft journal diameter c:

24.960–24.980 mm (0.9827–0.9835
in)
b
Camshaft cap journal diameter d:
25.000–25.021 mm (0.9843–0.9851
Cam lobe height a: in)
Intake:
46.311–46.411 mm (1.8233–1.8272 Installing the camshaft and driven
in) sprocket
Exhaust: If the valve clearances are adjusted or any
45.360–45.460 mm (1.7858–1.7898 parts related to valve movement are replaced
in) after installing the timing belt, check the valve
Cam lobe width b: clearances. See “Checking the valve clear-
Intake and exhaust: ance” (7-2).
35.950–36.050 mm (1.4154–1.4193
in)
7-50
POWR
Power unit
• Do not reuse a gasket, oil seal, or seal

washer, always replace it with a new 1
one.
UP
not turn the crankshaft or camshafts.
Otherwise, the pistons and valves or
intake and exhaust valves could collide
with each other and be damaged.
2
1. Check that the “LL” mark a on the drive
sprocket is aligned with the mating sur-
face of the crankcase and cylinder block.
STBD PORT
STBD
TIP:
Do not block the oil passages or oil holes with
a the sealant.
3. Install the valve lifters 3, and then install

2. Apply a thin, even coat of sealant to the the camshafts 4, 5, 6, and 7 in the
mating surface of the camshaft caps 1 proper positions and new oil seals 8.
and cylinder heads 2.
UP PORT STBD
8
8
1 7 6P2
8 S-IN
6P2
1 P-IN 3 4
2 6P2 6P2
P-EX S-EX
6 5
TIP:
Install the valve lifters in their original posi-
PORT tions.
4. Check that the camshaft dowel holes are

in the proper position.
7-51
Camshaft
BOW PORT STBD

4 4 4 5
PORT STBD C
E
D
2 2
2 2 E
3 3
3 3
AFT
1 1
1 1
5. Install the camshaft caps 9, 0, A, and
B in their proper positions and with the F F 4
stamped numbers upside down.
6. Install the camshaft cap bolts C, D, E, Camshaft cap bolt D, E, and F:

and F. 1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
B 2nd: 17 N·m (1.7 kgf·m, 12.5 ft·lb)
E TIP:
A Do not tighten the bolt C in this step.
0
F 0 8. Tighten the camshaft cap bolt C to the
9 general tightening torque.
PORT STBD C
D
D
C
F 0 F
B PORT UP STBD 9
7
A
6S 1S
1P 5P
7S 2S
2P 6P
8S 3S
3P 7P
9S 4S 9. Install the dowels G and driven sprock-
4P 8P ets H.
5S
0 10. Secure the exhaust camshaft using a
0 wrench I, and then tighten the driven
sprocket bolts J to the specified torque.
NOTICE: When tightening the bolt, do
7. Tighten the camshaft cap bolts D, E,
not turn the exhaust camshaft. Other-
and F to the specified torques in 2
wise, the intake and exhaust valves
stages and in the order 1, 2, and so on.
could collide with each other and be
damaged.
7-52
POWR
Power unit
b
d e
H c G
PORT
13. Secure the intake camshaft using a

wrench I, and then tighten the VCT
bolts M to the specified torque. NOTICE:
When tightening the VCT bolt, do not
secure the driven sprocket. Other-
c H wise, the VCT assembly could be
STBD damaged. When tightening the VCT
G
b bolt, do not turn the intake camshaft.
Otherwise, the intake and exhaust
valves could collide with each other
J H and be damaged.
G
J g
H
f
PORT
Driven sprocket bolt J:
60 N·m (6.0 kgf·m, 44.3 ft·lb)
f
TIP:
Slightly turn the driven sprockets in direction g
b to remove any free play c before tighten-
ing the driven sprocket bolts J.
11. Install the dowels K and VCT assem-

blies L. STBD
12. Check that the lower edges d and e of

the VCT assemblies and driven sprock-
ets are aligned.
7-53
Camshaft
M VCT cap O: 32 N·m (3.2 kgf·m, 23.6 ft·lb)
15. Align the “II” marks h on the VCT

L
(PORT) by turning them counterclock-
K
wise 60° gradually. NOTICE: Do not
turn the VCT assembly (PORT) and
driven sprocket (PORT) counterclock-
L wise more than 60°, and do not turn
the VCT assembly (STBD) and driven
M sprocket (STBD). Otherwise, the
I intake and exhaust valves could col-
VCT bolt M: 60 N·m (6.0 kgf·m, 44.3 ft·lb) PORT
TIP:
Slightly turn the VCT assemblies in direction
f to remove any free play g before tighten-
ing the VCT bolts M.
14. Install a new gasket N and the VCT cap h

O, and then tighten the VCT cap to the
specified torque while securing the VCT TIP:
assembly using the special service tool Be careful when turning the VCT assembly
P. NOTICE: When tightening the VCT and driven sprocket. Depending on the posi-
cap, do not secure the camshaft. Oth- tion of the camshafts, the force of the valve
erwise, the VCT assembly could be springs may cause the VCT assembly and
damaged. When tightening the VCT driven sprocket to be rotated too far.
cap, do not turn the driven sprocket.
Otherwise, the intake and exhaust 16. Align the “LL” mark a on the drive
7
valves could collide with each other L” mark k on the cyl-
sprocket with the “L
and be damaged. inder block by turning the crankshaft
clockwise 60° gradually. NOTICE: Do
O not turn the crankshaft clockwise
N
more than 60°. Otherwise, the piston
O and valves could collide with each
other and be damaged.
k
a
P
STBD PORT
S6P25480
Sheave holder P: 90890-01701
7-54
POWR
Power unit
17. Check that the “I” marks m on the VCT
assembly (STBD) and driven sprocket
(STBD) are aligned.
STBD
7-55
Camshaft / Exhaust cover
Exhaust cover
12
7
5
4
9
8
1 9
8
11
10
3
2
6 11
10
1 6 N·m (0.6 kgf·m, 4.4 ft·lb) 1

2 12 N·m (1.2 kgf·m, 8.9 ft·lb) 15
14
3 N·m (0.3 kgf·m, 2.2 ft·Ib)
5 6
3 13
55 N·m (5.5 kgf·m, 40.6 ft·Ib) 2
No.
1 Bolt
Part name Q’ty
28 M6 × 50 mm
Remarks 7
2 Plug 2 M18 × 17 mm
3 Gasket 2 39
4 Exhaust outer cover (PORT) 1
5 Gasket 2 39
6 Dowel 2
7 Exhaust inner cover (PORT) 1
8 Anode 2
10 Anode 2
11 Screw 2 M4 × 12 mm
12 Gasket 1 39
13 Exhaust outer cover (STBD) 1
14 Exhaust inner cover (STBD) 1
15 Gasket 1 39
7-56
POWR
Power unit
Removing the exhaust cover 2. Install new gaskets 4 and the exhaust
1. Loosen the exhaust cover bolts 1 in the covers 5 and 6, and then tighten the
order 1, 2, and so on, and then remove exhaust cover bolts 7 to the specified
the exhaust covers 2 and 3. torques in 2 stages and in the order 1,
2, and so on.
UP
1 1
1 3. Tighten the exhaust outer cover plugs 8
1 6 5 to the specified torque.
6 5 0 5
9 4
5 1
0 9
D C
7 23
PORT D C
A B STBD
A B 1
7 8
7 8 2
4
2 4 3
3
3
2
2
1 2
6
4
7 6
7 UP
D
D 9 0
1
9 0 5 6
5 6 1 2
3
PORT 1 2 4 3 STBD
3 4 3 8 7
7 C 8
8 A
Checking the exhaust cover anode 8
C A B
1. Check the anodes. Replace if eroded.
B 7
NOTICE: Do not apply grease, oil, or
paint the anodes. Anode screw 3:
3 N·m (0.3 kgf·m, 2.2 ft·lb)
Installing the exhaust cover Exhaust cover bolt 7:
1. Install the anodes 1 and 2, and then 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
tighten the screws 3 to specified torque. 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
Exhaust outer cover plug 8 (M18):
55 N·m (5.5 kgf·m, 40.6 ft·lb)
7-57
Exhaust cover / Cylinder head
Cylinder head
1 7 N m( 0.7 kgf m, 5.2 ft lb)
1 30 N m (3.0 kgf m, 22.1 ft lb)
2 60 N m (6.0 kgf m, 44.3 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb)
3 (* 1)
È
4 30 N m (3.0 kgf m, 22.1 ft lb)
2 7 1
5 60 N m (6.0 kgf m, 44.3 ft lb)
6 90˚
28 3
2
7
31 3
4
7 9
5
5
27
8
30
6 32 11
29 7
32 10
21
26
20 25 14
24 19
23 18
1 14 N m (1.4 kgf m, 10.3 ft lb)
17
2 28 N m (2.8 kgf m, 20.7 ft lb) 22
13 15
12 16
No.
1 Bolt
Part name Q’ty
6 M6 × 35 mm
Remarks 7
2 OCV 2
3 Filter 2 39
4 Engine hanger (PORT) 1
5 Bolt 6 M6 × 18 mm
6 Gasket (PORT) 1 39
7 Dowel 4
8 Gasket (STBD) 1 39
9 Engine hanger (STBD) 1
10 Cylinder head (STBD) 1
11 Exhaust valve 12
12 Hose 1
13 Clip 1
14 Valve guide 24 39
15 Valve spring retainer 24
È Only the tightening torques for new cylinder head bolts are shown in the exploded diagram. For
the tightening torques when reusing the cylinder head bolts, see “Installing the cylinder head”
(7-68).
(*1): Loosen completely
7-58
POWR
Power unit
1 7 N m( 0.7 kgf m, 5.2 ft lb)

1 30 N m (3.0 kgf m, 22.1 ft lb)
3 (* 1)
È
4 30 N m (3.0 kgf m, 22.1 ft lb)
2 7 1
5 60 N m (6.0 kgf m, 44.3 ft lb)
6 90˚
28 3
2
7
31 3
4
7 9
5
5
27
8
30
6 32 11
29 7
32 10
21
26
20 25 14
24 19
23 18
1 14 N m (1.4 kgf m, 10.3 ft lb)
17
2 28 N m (2.8 kgf m, 20.7 ft lb) 22
13 15
12 16

16 Valve cotter 48
17 Valve spring 24
18 Valve seal 24 39
19 Valve spring seat 24
20 Bolt 4 M8 × 40 mm
21 Anode assembly 4
22 Bolt 4 M6 × 20 mm
23 Gasket 4 39
24 Cover 4
25 Anode 4
26 Grommet 4
27 Intake valve 12
28 Cylinder head (PORT) 1
29 Bolt 2 M8 × 90 mm
30 Bolt 4 M8 × 55 mm
(7-68).
7-59
Cylinder head
1 7 N m( 0.7 kgf m, 5.2 ft lb)

1 30 N m (3.0 kgf m, 22.1 ft lb)
3 (* 1)
È
4 30 N m (3.0 kgf m, 22.1 ft lb)
2 7 1
5 60 N m (6.0 kgf m, 44.3 ft lb)
6 90˚
28 3
2
7
31 3
4
7 9
5
5
27
8
30
6 32 11
29 7
32 10
21
26
20 25 14
24 19
23 18
1 14 N m (1.4 kgf m, 10.3 ft lb)
17
2 28 N m (2.8 kgf m, 20.7 ft lb) 22
13 15
12 16
No.
31 Bolt
Part name Q’ty
16 M10 × 120 mm/T55
Remarks 7
32 Water shut grommet 2
(7-68).
7-60
POWR
Power unit
Removing the cylinder head
6 5
1. Remove the fuel rails. See “Removing
the fuel injector” (6-45). 7
4
2. Remove the engine hangers 1.
3. Remove the OCVs 2 and filters 3.
3 8
2
4. Loosen the cylinder head bolts 4, 5,

and 6 in the order 1, 2, and so on, and Disassembling the cylinder head
then remove the cylinder heads 7 and 1. Remove the anode assemblies 1.
gaskets 8. NOTICE: Be careful not to
scratch or damage the mating sur-
faces of the cylinder head and cylin-
der block.
PORT UP STBD
6 6
6 7
7 6 1
(T55) 0 A
A 0
2. Remove the intake and exhaust valves
9 8 using the special service tools 2 and 3.
8 9
5
5 4
4 5 2
3
3
4 2
1 2 1 4 3
7-61
Cylinder head
Valve spring compressor 2: 90890-04019 Cylinder head warpage limit:

Valve spring compressor attachment 3: 0.10 mm (0.0039 in)
90890-06320
Checking the valve spring
TIP: 1. Measure the valve spring free length a.
they were removed.
3. Remove the valve seals 4.
Valve spring free length a:

48.1 mm (1.89 in)
2. Measure the valve spring tilt b. Replace

if above specification.
Checking the cylinder head
1. Eliminate carbon deposits from the com- b
bustion chambers and check the cylinder
head for damage and scratches.
2. Check the cylinder head warpage using a

straightedge 1 and thickness gauge 2
in the directions shown. Replace the cyl-
inder head assembly if above specifica-
tion.
2 Valve spring tilt limit b: 1.7 mm (0.07 in)

7
1
Checking the valve
1. Check the valve face. Replace if pitted or
worn.
2. Measure the valve margin thickness a.

7-62
POWR
Power unit
Valve margin thickness a:

Intake:
0.500–0.900 mm (0.0197–0.0354 in)
Exhaust:
0.900–1.300 mm (0.0354–0.0512 in) a
3. Measure the valve stem diameter b.

b Valve guide inside diameter a:

Intake and exhaust:
5.504–5.522 mm (0.2167–0.2174 in)
2. Calculate the valve guide clearance as

follows. Replace the valve guide if out of
specification.
Valve guide clearance = valve guide inside
Valve stem diameter b: diameter – valve stem diameter:
Intake: Intake:
5.477–5.492 mm (0.2156–0.2162 in) 0.012–0.045 mm (0.0005–0.0018 in)
Exhaust: Exhaust:
5.464–5.479 mm (0.2151–0.2157 in) 0.025–0.058 mm (0.0010–0.0023 in)
4. Measure the valve stem runout. Replace Replacing the valve guide
if above specification.
Do not reuse a valve guide, always

After replacing a valve guide, check the valve
seat contact area.
1. Remove the valve guide 1 using the

special service tool 2 from the combus-
tion chamber side.
Valve stem runout:

Intake and exhaust: 2
0.010 mm (0.0004 in)
Checking the valve guide

Before checking the valve guides, make sure
that the valve stem diameter is within specifi- 1
cation.
1. Measure the valve guide inside diameter Valve guide remover/installer 2:

a. 90890-06801
7-63
Cylinder head
2. Install a new valve guide 3 using the
Valve guide inside diameter:
special service tools 2 from the cam-
Intake and exhaust:
shaft side until the valve guide installer
5.504–5.522 mm (0.2167–0.2174 in)
4 to the specified height a.
Checking the valve seat
2 1. Eliminate carbon deposits from the valve.
4 2. Apply a thin, even layer of Mechanic’s

a blueing dye (Dykem) onto the valve seat.
3
3. Lap the valve slowly on the valve seat
with a special service tool 1.
E
1
Valve guide remover/installer 2:
90890-06801
Valve guide installer 4: 90890-06810
Valve guide installation height a:

Intake and exhaust:
12.500–12.900 mm (0.4921–0.5079
in)
Valve lapper 1: 90890-04101
3. Insert the special service tool 5 into the
valve guide 3, and then ream the valve 4. Measure the valve seat contact width a
guide. 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
5
seat contact width is out of specification.
Replace the valve guide if the valve seat
3 contact width is uneven. 7
Valve guide reamer 5: 90890-06804 a
TIP:
• Turn the special service tool 5 clockwise to
ream the valve guide.
• Do not turn the reamer counterclockwise
when removing the reamer.
• Make sure to clean the valve guide after
reaming it.
4. Measure the valve guide inside diameter.
7-64
POWR
Power unit
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. NOTICE: Do not over cut the
valve seat. To prevent chatter marks,
make sure to turn the cutter evenly
using a downward force of 40–50 N
(4.0–5.0 kgf, 8.8–11.0 lbf).
Valve seat contact width a:

Intake:
1.100–1.400 mm (0.0433–0.0551 in)
Exhaust:
1.400–1.700 mm (0.0551–0.0669 in)
45
Refacing the valve seat a
After every lapping procedure, make sure

to clean off any remaining lapping com-
pound from the cylinder heads and the
valves.
a Slag or rough surface

1. Reface the valve seat using the special
service tools. 3. Adjust the top edge of the valve seat con-
tact width using a 30° cutter.
30
b
30 45 60
Valve seat cutter holder: 90890-06316

Valve seat cutter: b Previous contact width
30° (intake): 90890-06817
30° (exhaust): 90890-06326 4. Adjust the bottom edge of the valve seat
45° (intake): 90890-06816 contact width using a 60° cutter.
45° (exhaust): 90890-06325
60° (intake and exhaust): 90890-06324
7-65
Cylinder head
b Previous contact width
b • 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, and
then set its width using a 45° cutter.
60
30
b
5. Adjust the valve seat contact width to

specification using a 45° cutter.
b
c
• If the valve seat contact area is too narrow

and situated near the bottom edge of the
45 valve face, cut the bottom edge of the valve
seat using a 60° cutter to center the area,
and then set its width using a 45° cutter.
c Specified contact width
6. Check the valve seat contact area of the b

valve. See “Checking the valve seat” (7-
64).
Example:
• If the valve seat contact area is too wide 7
and situated in the center of the valve face, 60
cut the top edge of the valve seat using a
30° cutter, and then cut the bottom edge
using a 60° cutter to center the area and set
its width. 7. After refacing the valve seat to the speci-
fied contact width, apply a thin, even
30 layer of lapping compound onto the valve
b seat, and then lap the valve using a spe-
cial service tool 1. NOTICE: Do not get
the lapping compound on the valve
stem and valve guide.
60
7-66
POWR
Power unit
1
5
6
7
4
Valve lapper 1: 90890-04101
8. Recheck the valve seat contact area of 2

the valve. See “Checking the valve seat”
(7-64).
Checking the cylinder head anode

Clean if there is grease, oil, or scales. Valve spring compressor 6: 90890-04019
NOTICE: Do not apply grease, oil, or Valve spring compressor attachment 7:
paint to the anodes. 90890-06320
Assembling the cylinder head 3. Compress the valve spring, and then
install the valve cotters 8.
Do not reuse a valve seal, always replace
it with a new one. 8
1. Install a new valve seal 1 onto the valve

guide.
4. Tap the valve spring retainer lightly using

a plastic hammer to set the valve cotters
8 securely.
2. Install the valve 2, valve spring seat 3,

valve spring 4, and valve spring retainer
5 in this order, and then install the spe-
cial service tools 6 and 7.
7-67
Cylinder head
2. Install the dowels 2, new gaskets 3,
8 8 and the cylinder heads 4, and then
tighten the cylinder head bolts 5 to the
specified torques in 6 stages and in the
order 1, 2, and so on.
3. Tighten the cylinder head bolts 6 and 7

to the specified torques in 2 stages and
in the order 9, 0, and so on.
5 6
5. Install the anode assemblies 9.
7 4
9
3
2
Installing the cylinder head
Do not reuse a filter or gasket, always

2
1. Install the water shut grommets 1 into

the cylinder block. PORT UP STBD
5 5
6 5
7
5 6
2 1
1 2
1
3 4
4 3 6
1 7 8
8 7
9
1 9
7 A 0 0 A 7
a 90
PORT STBD
7-68
POWR
Power unit
Tightening procedure when using new cylin- B
der head bolts: A
Cylinder head bolt 5 1–8 (M10):
1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb) 8
2nd: 60 N·m (6.0 kgf·m, 44.3 ft·lb) 9
3rd: Loosen completely
4th: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
5th: 60 N·m (6.0 kgf·m, 44.3 ft·lb)
6th: 90° 0
Cylinder head bolt 6 and 7 9–A (M8):
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb) OCV bolt 0:
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)
Engine hanger bolt B:
Tightening procedure when reusing the cylin-
12 N·m (1.2 kgf·m, 8.9 ft·lb)
der head bolts:
Cylinder head bolt 5 1–8 (M10): 6. Install the fuel rails. See “Installing the
1st: 27 N·m (2.7 kgf·m, 19.9 ft·lb) fuel injector” (6-46).
2nd: 54 N·m (5.4 kgf·m, 39.8 ft·lb)
3rd: Loosen completely
4th: 27 N·m (2.7 kgf·m, 19.9 ft·lb)
5th: 54 N·m (5.4 kgf·m, 39.8 ft·lb)
6th: 90°
Cylinder head bolt 6 and 7 9–A (M8):
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
TIP:
• Make sure to install the cylinder head gas-
kets (PORT and STBD) onto the proper cyl-
inder heads.
• In the 6th stage, mark the M10 bolts 5 and
the cylinder heads with identification marks
a, and then tighten the bolts 90° from the
mark.
4. Install new filters 8 and the OCVs 9,

and then tighten the OCV bolts 0 to the
specified torque.
5. Install the engine hangers A, and then

tighten the engine hanger bolts B to the
specified torque.
7-69
Cylinder head / Cooling water passage cover
Cooling water passage cover

1 16
22
1 19 23
2 18 21
20 2
4 3
B
B 20
2
16 17 2 24
5 2
2 25
3 2
15 12 26
14
2 11 27
10
6 13
3 32 N·m (3.2 kgf·m, 23.6 ft·Ib)

7 2
8
A 2 3
9
7
13 15 12 mm 6
(0.47 in)
3
9
9 mm 7 mm 12 mm
(0.35 in) (0.28 in) (0.47 in) A
No.
1 Hose
Part name Q’ty
1
Remarks 7
2 Plastic tie 16
3 Joint 4
4 Hose 1
5 Hose 1
6 Hose 1
7 Hose 1
8 Clamp 1
9 Hose 1
10 Hose 1
11 Clamp 1
12 Joint 1
13 Holder 1
14 Hose 1
15 Holder 1
16 Holder 1
17 Bolt 1 M6 × 12 mm
7-70
POWR
Power unit

1 16
22
1 19 23
2 18 21
20 2
4 3
B
B 20
2
16 17 2 24
5 2
2 25
3 2
15 12 26
14
2 11 27
10
6 13
3 32 N·m (3.2 kgf·m, 23.6 ft·Ib)

7 2
8
A 2 3
9
7
13 15 12 mm 6
(0.47 in)
3
9
9 mm 7 mm 12 mm
(0.35 in) (0.28 in) (0.47 in) A

18 Holder 1
19 Hose 1
20 Check valve 1
21 Screw 4 M4 × 12 mm
22 Anode 4
23 Bolt 13 M6 × 30 mm
24 Knock sensor 1
25 Cover 1
26 Hose 1
27 Gasket 1
7-71
Cooling water passage cover
Removing the cooling water passage Installing the cooling water passage
cover cover
1. Remove the knock sensor, and then dis-
connect the flushing hose.
2. Loosen the cooling water passage cover with a new one.
bolts 1 in the order 1, 2, and so on,
and then remove the cooling water pas- 1. Install the anodes 1 to the cooling water
sage cover 2 and gasket 3. passage cover 2, and then tighten the
anode screws 3 to the specified torque.
4
5 1 2. Install a new gasket 4 and the cooling

3 water passage cover 2.
9
8 4
C 2 1 3
B
0
A
6
7
1 2
3 Anode screw 3:
3 N·m (0.3 kgf·m, 2.2 ft·lb)
2
1 3. Tighten the cooling water passage cover
bolts 5 to the specified torque in the
0
7
9
A
Checking the cooling water passage 5

6
cover anode
D1
1. Check the anodes. Replace if eroded. 2E
G4
NOTICE: Do not apply grease, oil, or 3F
paint to the anodes. 8
7
Checking the knock sensor C B
1. Check the knock sensor. See “Checking 5
the knock sensor” (5-64).
Cooling water passage cover bolt 5:
12 N·m (1.2 kgf·m, 8.9 ft·lb)
4. Connect the flushing hose 6, and then

fasten it using the plastic tie 7.
7-72
POWR
Power unit
7
6
5. Install the knock sensor 8, and then

6. Fasten the knock sensor lead a and

flushing hose 6 using the plastic tie 9.
8
a a
9
9
6
6
Knock sensor 8:
32 N·m (3.2 kgf·m, 23.6 ft·lb)
TIP:
Fasten the knock sensor lead a so that it is
taut.
7-73
Cooling water passage cover / Crankcase
Crankcase
1
2
3 18
8 17 19
5 7 22
9
6 24
10
15
4 23 21
11 25
18
16
20 17
26
26
12 27 27
4 N m (0.4 kgf m, 3.0 ft lb)
13
15
14 28 29
32
12 N m (1.2 kgf m, 8.9 ft lb)
34 N m (3.4 kgf m, 25.1 ft lb) 30 29

1 14 N m (1.4 kgf m, 10.3 ft lb) 30
31
2 28 N m (2.8 kgf m, 20.7 ft lb)
No.
1 Bolt
Part name Q’ty
5 M6 × 45 mm
Remarks 7
2 Oil pressure sensor 1
3 O-ring 1 39
4 Oil filter 1
5 Union bolt 1
6 Oil filter bracket 1
7 Gasket 1 39
8 Oil filler cap 1
9 O-ring 1 39
10 Holder 1
11 Engine hanger 1
12 Bolt 2 M6 × 18 mm
13 Crankcase cover 1
14 Bolt 17 M8 × 45 mm
15 Dowel 2
16 Gasket 1 39
17 Bolt 4 M6 × 25 mm
7-74
POWR
Power unit
1
2
3 18
8 17 19
5 7 22
9
6 24
10
15
4 23 21
11 25
18
16
20 17
26
26
12 27 27
4 N m (0.4 kgf m, 3.0 ft lb)
13
15
14 28 29
32
12 N m (1.2 kgf m, 8.9 ft lb)
34 N m (3.4 kgf m, 25.1 ft lb) 30 29

1 14 N m (1.4 kgf m, 10.3 ft lb) 30
31
2 28 N m (2.8 kgf m, 20.7 ft lb)

18 Damper 2
19 Engine stopper (STBD) 1
20 Engine stopper (PORT) 1
21 Engine temperature sensor 1
22 Washer 1
23 Bolt 1 M6 × 20 mm
24 Blowby hose joint 1
25 O-ring 1 39
26 Oil seal 1 39
27 O-ring 2 39
28 Gasket 1 39
29 Oil seal 1 39
30 Oil seal 2 39
31 Bolt 4 M6 × 40 mm
32 Oil pump assembly 1
7-75
Crankcase
Removing the oil filter bracket Removing the crankcase cover
1. Remove the oil filter 1. 1. Remove the fuel filter assembly. See
“Removing the fuel filter assembly” (6-
13).
1
2 2. Remove the throttle body assembly. See
(6-23).
3. Remove the engine hanger 1.
4. Loosen the crankcase cover bolts 2 in

the order 1, 2, and so on, and then
Oil filter wrench 2: 90890-06830 remove the crankcase cover 3 and gas-
2. Loosen the oil filter bracket bolts 3 in the ket 4.
order 1, 2, and so on, and then remove UP
the oil filter bracket 4 and gasket 5. 3 2 1 2
STBD UP PORT 9 8
5 C B
1 STBD F PORT
G
E
2 4 D
3 A
3 0
4 5 6 7
3
4
7
3
5 1
4
Removing the oil pump assembly

1. Remove the oil pump assembly 1, O-
rings 2, and oil seal 3.
2
5. Remove the engine temperature sensor

5.
1 23
7-76
POWR
Power unit
1
2
5 1
Disassembling the oil pump Driver rod L3 2: 90890-06652

assembly Needle bearing attachment 3:
1. Remove the screws 1 and disassemble 90890-06613
the oil pump.
2. Install a new oil seal 4 into the oil pump
1 housing.
Driver rod L3 2: 90890-06652

Needle bearing attachment 5:
90890-06607
Checking the oil pump assembly
1. Check the inner surface of the oil pump 3. Install a new gasket 6, and then tighten
housing. Replace the oil pump assembly the oil pump cover screws 7 to the spec-
if scratched. ified torque.
2. Check the gear teeth of the inner rotor

and outer rotor. Replace the oil pump 7
assembly if the gear teeth are cracked or
worn.
Assembling the oil pump assembly 6
Do not reuse an oil seal or gasket, always

1. Install new oil seals 1 into the oil pump

housing.
Oil pump cover screw 7:

4 N·m (0.4 kgf·m, 3.0 ft·lb)
7-77
Crankcase
Installing the crankcase cover
6 E F G
Do not reuse a gasket, always replace it 0

9
with a new one.
5 6
1. Install the washer 1 and engine temper- STBD PORT
2
ature sensor 2, and then tighten the 1
engine temperature sensor to the speci- 3
4
fied torque.
7
8
D C B A
1
Crankcase cover bolt 6 1–G:
2 1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
Engine hanger bolt 8:
12 N·m (1.2 kgf·m, 8.9 ft·lb)
Engine temperature sensor 2: 4. Install the throttle body assembly. See

15 N·m (1.5 kgf·m, 11.1 ft·lb) “Installing the throttle body assembly” (6-
24).
2. Install the dowels 3 a new gasket 4,
and the crankcase cover 5, and then 5. Install the fuel filter assembly. See
tighten the crankcase cover bolts 6 to “Installing the fuel filter assembly” (6-14).
the specified torques in 2 stages and in
the order 1, 2, and so on. Installing the oil pump assembly
3. Install the engine hanger 7, and then

tighten the engine hanger bolts 8 to the
specified torque.
Do not reuse an oil seal or O-ring, always
7
1. Install a new oil seal 1 so that it is facing
3 in the proper direction.
4
5 2. Install new O-rings 2.

7
1
8 2
3
2
6
7-78
POWR
Power unit
3. Install the oil pump assembly 3 by align-
ing the oil pump gear with the crankshaft.
3
NOTICE: Before installing the oil
pump assembly, make sure to fill it
with engine oil through the oil pas-
sages a. 5
1
2
6 4
a
STBD UP PORT
1
a 3
5
4 2
3
3
Oil filter union bolt 4:

34 N·m (3.4 kgf·m, 25.1 ft·lb)
Oil pressure sensor 6:
18 N·m (1.8 kgf·m, 13.3 ft·lb)
4. Add a small amount of engine oil through

3
the oil passage a of the oil filter bracket.
Installing the oil filter bracket
Do not reuse a gasket or O-ring, always

1. Install a new gasket 1 and the oil filter

bracket 2, and then tighten the oil filter
bracket bolts 3 in the order 1, 2, and
so on.
2. Install the oil filter union bolt 4, and then

3. Install a new O-ring 5 and the oil pres-

sure sensor 6, and then tighten the oil
pressure sensor 6 to the specified
torque.
7-79
Crankcase
5. Install the oil filter 7, and then tighten it
to the specified torque.
7
8
Oil filter 7: 18 N·m (1.8 kgf·m, 13.3 ft·lb)
Oil filter wrench 8: 90890-06830
7-80
POWR
Power unit
Cylinder block
7 N m (0.7 kgf m, 5.2 ft lb) 21 23 N m (2.3 kgf m, 17.0 ft lb)
19 22 3 N m (0.3 kgf m, 2.2 ft lb) 21
17 25 34
18 23 37
16 4 26 32 35 19
20 24
27 33
13 36
15 38
14 18
10 13 28 17
24
12 20
1 33 N m (3.3 kgf m, 24.3 ft lb) 23
2 90 29
39
11 30 15
7 10
40 41
10
5 9 30 10
4
6 31
8
44 42 R
6 47 45
1
2
3 46
49 48 44 43
46 2R
1 14 N m (1.4 kgf m, 10.3 ft lb)
2 28 N m (2.8 kgf m, 20.7 ft lb) 1 13N m (1.3 kgf m, 9.6 ft lb)
2 90 3 90

1 Bolt 8 M10 × 102 mm
2 Bolt 8 M8 × 93 mm
3 Bolt 13 M8 × 55 mm
4 Crankcase assembly 1
5 Crankshaft journal bearing (lower) 4
6 Thrust bearing (lower) 2
7 Oil seal 1 39
8 Crankshaft 1
9 Thrust bearing (upper) 2
10 Plastic tie 6
11 Hose 1
12 Holder 2
13 Joint 1
14 Hose 1
15 Bolt 4 M6 × 25 mm
16 Thermostat cover (STBD) 1
17 Bolt 2 M5 × 20 mm
7-81
Cylinder block

19 22 3 N m (0.3 kgf m, 2.2 ft lb) 21
17 25 34
18 23 37
16 4 26 32 35 19
20 24
27 33
13 36
15 38
14 18
10 13 28 17
24
12 20
1 33 N m (3.3 kgf m, 24.3 ft lb) 23
2 90 29
39
11 30 15
7 10
40 41
10
5 9 30 10
4
6 31
8
44 42 R
6 47 45
1
2
3 46
49 48 44 43
46 2R
1 14 N m (1.4 kgf m, 10.3 ft lb)
2 90 3 90
No.
18 Gasket
Part name Q’ty
2 39
Remarks 7
19 Bolt 4 M6 × 16 mm
20 Anode 2
21 Thermoswitch 2
22 Bracket 1
23 Thermostat 2
24 Gasket 2 39
25 Bolt 2 M6 × 20 mm
26 Plug 1
27 O-ring 1 39
28 Dowel 8
29 Crankshaft journal bearing (upper) 4
30 O-ring 2 39
31 O-ring 1 39
32 Plug 1 M14 × 12 mm
33 Gasket 1 39
34 Holder 1
7-82
POWR
Power unit

19 22 3 N m (0.3 kgf m, 2.2 ft lb) 21
17 25 34
18 23 37
16 4 26 32 35 19
20 24
27 33
13 36
15 38
14 18
10 13 28 17
24
12 20
1 33 N m (3.3 kgf m, 24.3 ft lb) 23
2 90 29
39
11 30 15
7 10
40 41
10
5 9 30 10
4
6 31
8
44 42 R
6 47 45
1
2
3 46
49 48 44 43
46 2R
1 14 N m (1.4 kgf m, 10.3 ft lb)
2 90 3 90

35 Holder 1
36 Bracket 1
37 Holder 1
38 Thermostat cover (PORT) 1
39 Holder 1
40 Holder 1
41 Hose 1
42 Piston ring set 6
43 Piston 6
44 Clip 12 39
45 Piston pin 6
46 Connecting rod assembly 6
47 Crankpin bearing 12
48 Bolt 12 39 M9 × 42 mm
49 Collar 1 39
7-83
Cylinder block
Disassembling the cylinder block
6
1. Remove the thermoswitches 1.
2. Remove the thermostat covers 2, and

7
then remove the thermostats 3 and
anodes 4.
d
3
4
2
1 6
TIP:
3. Remove the connecting rod caps a, and they were removed.
then remove the crankpin bearings 5,
connecting rods, and piston assemblies
5. Remove the piston rings and arrange
b.
them in order.
6. Remove the crankcase bolts 8, 9, and

a 0 in the order 1, 2, and so on.
5 7. Remove the thrust bearings A.
0 9
8
5
7
A
b A
TIP:
• To prevent mixing the pistons, connecting
rods, and connecting rod caps, mark each
with an identification number c of the cor-
responding cylinder.
• Make sure to keep the parts in the order as
they were removed.
4. Remove the piston pin clips 6 and pis-

ton pin 7, and then remove the connect-
ing rod d.
7-84
POWR
Power unit
9 8 UP 0 G
1 4 F
OG FN I
5 H
e
8
9 SK JR
f
STBD B PORT
C PH IQ I
LD EM A
0 Bearing splitter plate G:
2 3
6 7 Gear puller H: (commercially available)
General cylindrical tool I:
8. Remove the crankshaft B, crankshaft e = 19 mm (0.7 in)
journal bearings C, thrust bearings D, f = 90 mm (3.5 in)
and oil seal E.
Checking the thermostat
C 1. Suspend the thermostat in a container of
water.
B 2. Place a thermometer in the water and

heat the water slowly.
E
D
D
C C
3. Measure the thermostat valve opening a

at the specified water temperatures.
TIP:
Make sure to keep the bearings in the order
as they were removed. a
9. Remove the collar F.
7-85
Cylinder block
Water Cylinder bore (D1–D6):

Valve opening a
temperature 94.000–94.017 mm (3.7008–3.7014
58–62 °C in)
Starts opening
(136–144 °F)
above 70 °C Checking the piston ring
4.3 mm (0.17 in) or above 1. Check the piston ring dimensions B and
(158 °F)
T.
Checking the piston diameter
1. Measure the piston diameter a at the a b
B B
specified measuring point b.
T T
c
B
b
T
a
Piston ring dimensions:
Top ring a:
B: 1.200 mm (0.0472 in)
Piston diameter a: T: 2.800–3.000 mm (0.1102–0.1181 in)
93.921–93.941 mm (3.6977–3.6985 Second ring b:
in) B: 1.170–1.190 mm (0.0461–0.0469 in)
Measuring point b: T: 3.700–3.900 mm (0.1457–0.1535 in)
13.500 mm (0.5315 in) up from the Oil ring c:
bottom of the piston skirt B: 2.400–2.470 mm (0.0945–0.0972 in)
T: 2.300–2.700 mm (0.0906–0.1063 in)
Checking the cylinder bore
1. Measure the cylinder bore (D1–D6) at Checking the piston ring end gap
measuring points a, b, and c, and in
direction d (D1, D3, D5), which is parallel
(reference)
1. Level the piston ring 1 in the cylinder
7
to the crankshaft, and direction e (D2, using a piston crown at the specified
D4, D6), which is at a right angle to the measuring point a.
crankshaft.
2. Measure the piston ring end gap b.
a
b D2 D1 d
c
D4 D3 e
D6 D5
a
1
a 20 mm (0.8 in)
b 50 mm (2.0 in)
c 80 mm (3.1 in) b
7-86
POWR
Power unit
Measuring point a (reference data):

20.0 mm (0.8 in) a
Piston ring end gap b (reference data):
Top ring:
b
0.200–0.300 mm (0.0079–0.0118 in)
Second ring:
0.300–0.450 mm (0.0118–0.0177 in) c
Oil ring
0.150–0.600 mm (0.0059–0.0236 in)
TIP: Piston ring side clearance:

The figures are for reference only. Depend- Top ring a:
ing on how the parts are assembled, the 0.035–0.050 mm (0.0014–0.0020 in)
actual measurements may not be within the Second ring b:
specified ranges. 0.030–0.070 mm (0.0012–0.0028 in)
Oil ring c:
0.040–0.130 mm (0.0016–0.0051 in)
Checking the piston ring groove
1. Measure the piston ring grooves. Checking the piston pin boss inside
Replace the piston if out of specification. diameter
1. Measure the piston pin boss inside diam-
a eter.
c
b
b b
c a
Piston ring groove:

Top ring a:
1.230–1.250 mm (0.0484–0.0492 in)
Second ring b:
1.220–1.240 mm (0.0480–0.0488 in)
Oil ring c:
2.510–2.530 mm (0.0988–0.0996 in)
Piston pin boss inside diameter a:
Checking the piston ring side 21.021–21.031 mm (0.8276–0.8280
in)
clearance
1. Measure the piston ring side clearance.
TIP:
When measuring the piston pin boss inside
diameter, do not measure it at the oil grooves
b or ring groove c.
Checking the piston pin

1. Measure the piston pin outside diameter
a.
7-87
Cylinder block
TIP:
a • When checking the big end inside diame-
ter, reuse the removed connecting rod bolt.
• Make sure that the protrusions c on the
connecting rod and connecting rod cap are
aligned.
• In the 3rd tightening stage for the connect-
ing rod bolts 1, mark the connecting rod
bolts and the connecting rod cap with iden-
tification marks d, and then tighten the
Piston pin outside diameter a:
bolts 90° from the marks on the connecting
21.008–21.017 mm (0.8271–0.8274
rod cap.
in)
Checking the connecting rod small Checking the connecting rod big end
end inside diameter and big end side clearance
inside diameter 1. Measure the connecting rod big end side
1. Tighten the connecting rod bolts 1 to the clearance a.
specified torques in 3 stages.
2. Measure the connecting rod small end

inside diameter a and big end inside
diameter b.
90 a a
d
7
c
1
Connecting rod big end side clearance a:
Connecting rod bolt 1: 0.150–0.300 mm (0.0059–0.0118 in)
1st: 13 N·m (1.3 kgf·m, 9.6 ft·lb)
2nd: 23 N·m (2.3 kgf·m, 17.0 ft·lb) Checking the crankshaft
3rd: 90° 1. Measure the crankshaft journal diame-
ters a, crankpin diameters b, and
Connecting rod small end inside crankpin widths c.
diameter a:
21.022–21.037 mm (0.8276–0.8282
in)
Connecting rod big end inside diameter b:
53.015–53.035 mm (2.0872–2.0880
in)
7-88
POWR
Power unit
È b a
d c
É b a
b
c e c
c
È M10 × 102 mm
Crankshaft journal diameter a:
É M8 × 93 mm
62.968–62.992 mm (2.4791–2.4800
in) Crankcase bolt diameter difference limit:
Crankpin diameter b: È: a – b = Less than 0.20 mm (0.0079
49.976–50.000 mm (1.9676–1.9685 in)
in) É: a – b = Less than 0.10 mm (0.0039
Crankpin width c: in)
21.500–21.550 mm (0.8465–0.8484 Measuring point c: 10.0 mm (0.39 in)
in) Measuring point d: 65.0 mm (2.56 in)
Measuring point e: 60.0 mm (2.36 in)
2. Measure the crankshaft runout.
Checking the crankpin oil clearance
1. Clean the crankpin bearings, connecting
rod, connecting rod cap, and crankpin.
2. Install the crankpin bearings 1 into the

connecting rod a and connecting rod
cap b.
a
1
b
Crankshaft runout:
0.030 mm (0.0012 in)
Checking the crankcase bolt

1. Measure the diameters a and b of the
crankcase bolt at the specified measur-
ing points c and d, and c and e.
Replace the crankcase bolt if the differ- TIP:
ence between the diameters is above Install the crankpin bearings in the original
specification. positions.
3. Place a piece of Plastigauge (PG-1) on

the crankpin, parallel to the crankshaft.
7-89
Cylinder block
e 90
TIP:
Do not place the Plastigauge (PG-1) over the
oil hole in the crankpin of the crankshaft.
Connecting rod bolt 2:

4. Install the connecting rod a and con-
1st: 13 N·m (1.3 kgf·m, 9.6 ft·lb)
necting rod cap b onto the crankpin c.
2nd: 23 N·m (2.3 kgf·m, 17.0 ft·lb)
3rd: 90°
TIP:
In the 3rd tightening stage for the connecting
rod bolts 2, mark the connecting rod bolts
a and the connecting rod cap with identification
b d
marks e, and then tighten the bolts 90° from
c the marks on the connecting rod cap.
6. Remove the connecting rod cap, and

then measure the width of the com-
pressed Plastigauge (PG-1) on the
crankpin.
7
TIP:
• When checking the oil clearance, reuse the
removed connecting rod bolts.
• Make sure that the protrusions d on the
connecting rod a and connecting rod cap
b face toward the flywheel magnet end of
the crankshaft.
• Do not turn the connecting rod until the
crankpin oil clearance measurement has
been completed.
Crankpin oil clearance:
0.028–0.066 mm (0.0011–0.0026 in)
5. Tighten the connecting rod bolts 2 to the
specified torques in 3 stages. Selecting the crankpin bearing
When replacing the crankpin bearing, select
the bearing as follows:
1. Check the crankpin mark a on the

crankshaft.
7-90
POWR
Power unit
P1 P2 P4 3. Install the crankshaft journal bearings 1

and crankshaft 2 into the cylinder block
3.
P3 P5 P6 1
2
a TIP:
t
• Install the crankshaft journal bearings 1 in

the original positions.
P1 P2P3 P4 P5 P6 • Insert the protrusion a of each bearing into
the slots in the cylinder block.
2. Select the suitable colors b for the con-
necting rod bearing from the table. 4. Place a piece of Plastigauge (PG-1) on
b each crankshaft journal b, parallel to the
crankshaft.
Crankpin mark a Bearing color b

92–00 Yellow
84–91 Green TIP:
76–83 Blue Do not place the Plastigauge (PG-1) over the
oil hole in each crankshaft journal.
Checking the crankshaft journal oil
clearance 5. Install the crankshaft journal bearings
After checking the crankshaft journal oil into the crankcase.
clearance, check the crankcase bolts. See
“Checking the crankcase bolt” (7-89). TIP:
• Install the crankshaft journal bearings in the
1. Clean the crankshaft journal bearings, original positions.
crankshaft journals, and bearing por- • Insert the protrusion of each bearing into
tions of the crankcase and cylinder block. the slots in the crankcase.
2. Place the cylinder block upside down.
7-91
Cylinder block
6. Install the crankcase 4, and then tighten
Crankcase bolt 5 1–8 (M8):
the crankcase bolts 5 and 6 to the
1st: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
2nd: 90°
Crankcase bolt 6 9–F (M10):
1st: 33 N·m (3.3 kgf·m, 24.3 ft·lb)
7. Tighten the crankcase bolts 7 to the
2nd: 90°
Crankcase bolt 7 G–S (M8):
order G, H, and so on.
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
7 5 2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
6
TIP:
• Do not turn the crankshaft until the crank-
shaft journal oil clearance measurement
has been completed.
4 • In the 2nd tightening stage for the M8 bolts
5 and M10 bolts 6, mark the bolts and the
crankcase with identification marks c, and
then tighten the bolts 90° from the marks on
the crankcase.
8. Remove the crankcase, and then mea-

sure the width of the compressed Plasti-
gauge (PG-1) on each crankshaft
journal.
c 90
6 5
UP
S P 7
5C D6 7
O
L
K 19 02
Crankshaft journal oil clearance:
STBD H PORT 0.035–0.050 mm (0.0014–0.0020 in)
G 4B A3
TIP:
8F E7 I When loosening the crankcase bolts, loosen
J them in the opposite order used for tighten-
R Q ing.
N M
Selecting the crankshaft journal

bearing
When replacing the crankshaft journal bear-
ing, select the bearing as follows:
7-92
POWR
Power unit
1. Check the crankshaft journal mark a on
the crankshaft and the cylinder block Upper bearing Lower bearing
mark b on the cylinder block. color color
d Yellow Yellow
J1 J2 J3 J4 e Green Green
f Blue Blue
J2 J3
J1
J4
J4 J3 J2 J1 b
2. Select the suitable colors c for the

crankshaft journal bearing from the
“Crankshaft journal bearing selection
table.”
7-93
Cylinder block
Example:
If the crankshaft journal mark a is “69” g h
and the cylinder block mark b is “07” h, b
select the crankshaft journal bearing color in
98 99 9 06 07 08 09
f. The crankshaft journal bearing color is
blue. 68
a
g 69
f
70
Crankshaft journal bearing selection table

b
98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22
68
69
70
71
72 f
73
74
75
76
77
78
79
a
80 e
81 7
82
83
84
85
86
87
88 d
89
90
91
92
a Crankshaft journal mark
b Cylinder block mark
7-94
POWR
Power unit
Checking the cylinder block anode
TIP:
• Face the protrusion b on the connecting
rod a in the same direction as the mark c
on the piston crown.
paint to the anodes.
• Do not align the piston pin clip end with the
Assembling the cylinder block groove d in the piston pin boss.
Before assembling the cylinder block, check
the crankcase bolts. See “Checking the 3. Install the oil rings e, 2nd ring f, and
crankcase bolt” (7-89). top ring g.
4. Offset the piston ring end gaps. NOTICE:

Do not reuse a connecting rod bolt, collar, Be careful not to scratch the pistons
gasket, oil seal, O-ring, or piston pin clip, or break the piston rings.
always replace it with a new one.
e h
1. Install a new collar 1 by striking it using
#5 #4
a plastic hammer.
#3 f
g
1 #2
#1
45˚ 45˚
#3 #2
k
#1
#4 #5
2. Assemble the piston 2, the connecting TIP:

rod a, the piston pin 3, and new piston • Make sure that the “2R” mark h on the 2nd
pin clips 4. ring f and “R” mark k on the top ring g
are facing up.
4 4 • Make sure that the piston rings move
smoothly.
d c
3 5. Install the crankpin bearings 5 into the
connecting rod a and connecting rod
cap m.
a
5
m
b a 4 2
7-95
Cylinder block
TIP: TIP:
Install the crankpin bearings in the original • Do not get any engine oil to the drive
positions. sprocket.
• Install each thrust bearing with its grooves
6. Install crankshaft journal bearings 6 into r facing outward.
the cylinder block 7.
8. Install the crankshaft journal bearings A
7 into the crankcase.
9. Apply sealant to the mating surface of

6 the crankcase.
UP
E
n
A s
TIP:
• Install the crankshaft journal bearings in the
original positions.
STBD PORT
• Insert the protrusion n of each bearing into
the slots in the cylinder block. A
7. Install a new oil seal 8 onto the crank-

shaft 9, and then install the crankshaft
and thrust bearings 0. NOTICE: Do not
damage the oil seal when installing it TIP:
by contacting the edge p of the drive • Install the crankshaft journal bearings in the
sprocket. original positions.
• Insert the protrusion s of each bearing into
the slots in the crankcase. 7
• Do not get any sealant on the crankshaft
p journal bearings.
8
r
10. Install the thrust bearings B.
0 t B
9
r
t
7-96
POWR
Power unit
TIP: u 90
• Install each thrust bearing with its grooves
t facing outward. UP G F
• Fit the protrusion on each thrust bearing
into the slot in the crankcase. S P
5C D6 H
O
11. Install new O-rings C and D and the
crankcase E onto the cylinder block, and L
then tighten the crankcase bolts F and K 19 02
G to the specified torques in 2 stages STBD H PORT
and in the order 1, 2, and so on. 4B A3
G
12. Tighten the crankcase bolts H to the 8F E7 I
specified torques in 2 stages and in the J
order G, H, and so on. R Q
N M
H F
G
Crankcase bolt F 1–8 (M8):
1st: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
2nd: 90°
Crankcase bolt G 9–F (M10):
E 1st: 33 N·m (3.3 kgf·m, 24.3 ft·lb)
2nd: 90°
Crankcase bolt H G–S (M8):
C 1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
D 2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
8
TIP:
• Make sure that the oil seal 8 must be
installed before tightening the crankcase
bolts.
• In the 2nd tightening stage for the M8 bolts
F and M10 bolts G, mark the bolts and the
crankcase E with identification marks u,
and then tighten the bolts 90° from the
marks on the crankcase.
• After tightening the crankcase bolts, make
sure that the crankshaft turns smoothly.
13. Install the piston I so that the mark v

on the piston crown is facing toward the
flywheel magnet end of the crankshaft.
7-97
Cylinder block
TIP:
• Make sure that the protrusions x on the
connecting rod and connecting rod cap w
face toward the flywheel magnet end of the
crankshaft.
• In the 3rd tightening stage for the connect-
ing rod bolts K, mark the connecting rod
I bolts and the connecting rod cap with iden-
tification marks y, and then tighten the
bolts 90° from the marks on the connecting
J rod caps.
• Make sure that the crankshaft turns
smoothly.
15. Install new gaskets L and the anode

bolts M to the thermostat covers N, and
v
then tighten the anode bolts to the speci-
Piston ring compressor J: 90890-05158 fied torque.
16. Install the anodes O to the thermostat

TIP:
covers N, and then tighten them to the
Install the pistons in the original positions.
specified torque.
14. Install the connecting rod caps w to the 17. Install new gaskets P to the thermostats
connecting rods, and then tighten new Q, and then install the thermostats to the
bolts K to the specified torques in 3 cylinder block.
stages.
18. Install the thermostat covers N.
y 90
19. Install a new gasket R, and then tighten
the thermostat cover plug S to the speci-
7
x fied torque.
K
w
Connecting rod bolt K:

1st: 13 N·m (1.3 kgf·m, 9.6 ft·lb)
2nd: 23 N·m (2.3 kgf·m, 17.0 ft·lb)
3rd: 90°
7-98
POWR
Power unit
20. Install the thermoswitches T.
Q
P
O
R
L S
T
N
M
Anode bolt M:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
Anode O:
3 N·m (0.3 kgf·m, 2.2 ft·lb)
Thermostat cover plug S:
23 N·m (2.3 kgf·m, 17.0 ft·lb)
7-99
Cylinder block
— MEMO —
7-100
LOWR
Lower unit
Lower unit (F200B) ............................................................. 8-1

Removing the lower unit............................................................. 8-3
Checking the propeller ............................................................... 8-3
Checking the lower unit anode ................................................... 8-3
Lower unit (F250G)............................................................. 8-4

Removing the lower unit............................................................. 8-6
Checking the propeller ............................................................... 8-6
Checking the lower unit anode ................................................... 8-6
Water pump and shift rod (F200B).................................... 8-7

Removing the water pump and shift rod..................................... 8-9
Disassembling the water pump housing..................................... 8-9
Checking the water pump and shift rod...................................... 8-9
Assembling the water pump housing ....................................... 8-10
Water pump and shift rod (F250G) ................................. 8-11

Removing the water pump and shift rod................................... 8-13
Disassembling the water pump housing................................... 8-13
Checking the water pump and shift rod.................................... 8-13
Propeller shaft housing (F200B) ..................................... 8-14

Removing the propeller shaft housing assembly...................... 8-16
Disassembling the propeller shaft assembly ............................ 8-16
Disassembling the propeller shaft housing assembly .............. 8-16
Checking the propeller shaft housing ....................................... 8-17
Checking the propeller shaft..................................................... 8-17
Assembling the propeller shaft assembly................................. 8-17
Assembling the propeller shaft housing assembly ................... 8-18
Propeller shaft housing (F250G)..................................... 8-20

Disassembling the propeller shaft assembly ............................ 8-22
Assembling the propeller shaft assembly................................. 8-22
Drive shaft and lower case (F200B)................................ 8-24

Removing the drive shaft.......................................................... 8-25
Disassembling the oil seal housing .......................................... 8-25
Disassembling the forward gear............................................... 8-25
Disassembling the lower case.................................................. 8-25
Checking the pinion and forward gear...................................... 8-26
Checking the drive shaft........................................................... 8-26
Checking the lower case .......................................................... 8-26
Assembling the lower case....................................................... 8-26
Assembling the forward gear.................................................... 8-27
Assembling the oil seal housing ............................................... 8-27
Installing the drive shaft............................................................ 8-28
Installing the propeller shaft housing assembly........................ 8-29
Installing the shift rod ............................................................... 8-29
Installing the water pump ......................................................... 8-30
Checking the lower unit for air leakage .................................... 8-31
Installing the lower unit............................................................. 8-31
Drive shaft and lower case (F250G) ............................... 8-33

Disassembling the forward gear............................................... 8-35
Checking the pinion and forward gear...................................... 8-35
Assembling the forward gear.................................................... 8-35
Shimming (regular rotation model) ................................ 8-37

Shimming workflow .................................................................. 8-37
Shimming check sheet ............................................................. 8-38
Measuring the forward gear backlash and
reverse gear backlash before disassembly .............................. 8-40
Shimming ................................................................................. 8-43 8
Shim location (F200B).............................................................. 8-43
Shim location (F250G) ............................................................. 8-44
Selecting the pinion shim (T3).................................................. 8-45
Pinion shim (T3) selection table ............................................... 8-48
Selecting the propeller shaft shim (T4) (F250G) ...................... 8-50
Measuring the forward gear backlash ...................................... 8-50
Adjusting the forward gear shim (T1) thickness ....................... 8-51
Forward gear shim (T1) selection chart.................................... 8-53
Measuring the reverse gear backlash ...................................... 8-55
Adjusting the reverse gear shim (T2) thickness ....................... 8-55
Reverse gear shim (T2) selection chart ................................... 8-57
LOWR
Lower unit (FL200B)......................................................... 8-59

Removing the lower unit........................................................... 8-61
Checking the propeller ............................................................. 8-61
Checking the lower unit anode ................................................. 8-61
Lower unit (FL250G) ........................................................ 8-62

Removing the lower unit........................................................... 8-64
Checking the propeller ............................................................. 8-64
Checking the lower unit anode ................................................. 8-64
Water pump and shift rod (FL200B) ............................... 8-65

Water pump and shift rod (FL250G) ............................... 8-68

Propeller shaft housing (FL200B)................................... 8-71

Propeller shaft housing (FL250G) .................................. 8-77

Drive shaft and lower case (FL200B) ............................. 8-80

Disassembling the reverse gear............................................... 8-82
Checking the pinion and reverse gear...................................... 8-83
Assembling the reverse gear.................................................... 8-84
Drive shaft and lower case (FL250G) ............................. 8-86

Disassembling the reverse gear............................................... 8-88
Checking the pinion and reverse gear...................................... 8-88
Assembling the reverse gear.................................................... 8-88
Shimming (counter rotation model) ............................... 8-90

Shimming workflow .................................................................. 8-90
Shimming check sheet ............................................................. 8-91
Measuring the forward gear backlash and
reverse gear backlash before disassembly .............................. 8-93
Shimming ................................................................................. 8-97
Shim location (FL200B)............................................................ 8-97
Shim location (FL250G) ........................................................... 8-98
Selecting the pinion shim (T3).................................................. 8-99
Pinion shim (T3) selection table ............................................... 8-99
Selecting the propeller shaft shim (T4)..................................... 8-99
Propeller shaft shim (T4) selection table ................................ 8-101
Measuring the forward gear backlash .................................... 8-102 8
Adjusting the forward gear shim (T2) thickness ..................... 8-102
Forward gear shim (T2) selection chart.................................. 8-104
Measuring the reverse gear backlash .................................... 8-106
Adjusting the reverse gear shim (T1) thickness ..................... 8-106
Reverse gear shim (T1) selection chart ................................. 8-108
LOWR
Lower unit
Lower unit (F200B)
È 26
23
25 24
7
24 6
55 N m (5.5 kgf m, 40.6 ft Ib)
31
30 10 11
20 12
21 28 4 3 5
29
8
19
3 9
2 13
22 14
47 N m (4.7 kgf m, 34.7 ft lb) 1
15
17
17 17
1
18 16
9 N m (0.9 kgf m, 6.6 ft lb)
47 N m (4.7 kgf m, 34.7 ft lb)

1 Gasket 2 39
2 Check screw 1
3 Dowel 2
4 Plate 1
5 Rubber seal 1
6 Bolt 1 M10 × 45 mm
7 Grommet 1
8 Lower unit 1
9 Spacer 1
10 Propeller 1
11 Cotter pin 1 39
12 Propeller nut 1
13 Washer 1
14 Spacer 1
15 Trim tab 1
16 Bolt 1 M10 × 70 mm/X-transom model
È U-transom model
8-1
Lower unit (F200B)
È 26
23
25 24
7
24 6
55 N m (5.5 kgf m, 40.6 ft Ib)
31
30 10 11
20 12
21 28 4 3 5
29
8
19
3 9
2 13
22 14
47 N m (4.7 kgf m, 34.7 ft lb) 1
15
17
17 17
1
18 16
9 N m (0.9 kgf m, 6.6 ft lb)
47 N m (4.7 kgf m, 34.7 ft lb)

18 Drain screw 1
19 Adapter 1 U-transom model
20 Dowel 1 U-transom model
21 Plastic tie 1 U-transom model 8
22 Bolt 1 M6 × 25 mm/U-transom model
23 Rubber seal 1 U-transom model
25 Stud bolt 6 M10 × 190 mm/U-transom model/Point the flat
end of the stud bolt up.
27 Extension 1 U-transom model
30 Nut 6 U-transom model
31 Washer 6 U-transom model
È U-transom model
8-2
LOWR
Lower unit
Removing the lower unit
È
• 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 sus-
pend the outboard motor. Otherwise, the 3
outboard motor could fall suddenly and
result in severe injuries. 1
• When loosening or tightening the pro-
2
peller nut, do not hold the propeller
using your hands.
a
1. Drain the gear oil. See steps 1–5 in
“Changing gear oil” (10-11).
2. Remove the cotter pin. È U-transom model
3. Set the gear shift to the N position. TIP:

When disassembling the lower unit, measure
4. Place a block of wood between the anti- the backlash before disassembly. See “Mea-
cavitation plate and the propeller to keep suring the forward gear backlash and reverse
the propeller from turning, and then gear backlash before disassembly” (8-40).
remove the propeller nut and propeller.
Checking the propeller
1. Check the propeller blades and splines.
Replace the propeller if cracked, dam-
aged, or worn.
Checking the lower unit anode

1. Check the trim tab. Replace if eroded.
paint to the trim tab.
5. Make a mark a on the trim tab 1 and
lower case, and then remove the trim
tab.
6. Remove the lower unit 2 and extension

3 (U-transom model).
8-3
Lower unit (F200B) / Lower unit (F250G)
Lower unit (F250G)

È 26
23
24
25
7 42 N m (4.2 kgf m, 31.0 ft lb)
27 9 N m (0.9 kgf m, 6.6 ft lb)
24 6
55 N m (5.5 kgf m, 40.6 ft Ib)
31
10 11
30
20 12
21 3 5
29 4
28 8
19 2 3 9 13
22 14
47 N m (4.7 kgf m, 34.7 ft lb)
1
15
17
1 17
17
18
16
9 N m (0.9 kgf m, 6.6 ft lb)
47 N m (4.7 kgf m, 34.7 ft lb)

1 Gasket 2 39
2 Check screw 1
3
4
Dowel
Plate
2
1 8
5 Rubber seal 1
6 Bolt 1 M10 × 45 mm
7 Grommet 1
8 Lower unit 1
9 Spacer 1
10 Propeller 1
11 Cotter pin 1 39
12 Propeller nut 1
13 Washer 1
14 Spacer 1
15 Trim tab 1
È U-transom model
8-4
LOWR
Lower unit
È 26
23
24
25
7 42 N m (4.2 kgf m, 31.0 ft lb)
27 9 N m (0.9 kgf m, 6.6 ft lb)
24 6
55 N m (5.5 kgf m, 40.6 ft Ib)
31
10 11
30
20 12
21 3 5
29 4
28 8
19 2 3 9 13
22 14
47 N m (4.7 kgf m, 34.7 ft lb)
1
15
17
1 17
17
18
16
9 N m (0.9 kgf m, 6.6 ft lb)
47 N m (4.7 kgf m, 34.7 ft lb)

18 Drain screw 1
21 Plastic tie 1 U-transom model
È U-transom model
8-5
Lower unit (F250G)
2. Remove the propeller, trim tab, lower

unit, and extension (U-transom model).
See steps 2–6 in “Removing the lower
unit” (8-3).
TIP:
the backlash before disassembly. See “Mea-
suring the forward gear backlash and reverse
gear backlash before disassembly” (8-40).

1. Check the propeller. See “Checking the
propeller” (8-3).

1. Check the trim tab. See “Checking the
lower unit anode” (8-3).
8-6
LOWR
Lower unit
Water pump and shift rod (F200B)
20 21
4 22
17 20
3 3 16
14
15
14
13 19
5 23
18
6 12
7
11
8 24
2
10
10 9

1 Seal 1
2 Shift rod 1
3 Bolt 3 M6 × 20 mm
4 Oil seal 1 39
5 Plate 1
6 O-ring 1 39
7 Spring 1
8 E-clip 1
9 Woodruff key 1
10 Dowel 2
11 Gasket 1 39
12 Outer plate cartridge 1
13 Impeller 1
14 Washer 2
15 Wave washer 1
16 Spacer 1
17 Collar 1
8-7
20 21
4 22
17 20
3 3 16
14
15
14
13 19
5 23
18
6 12
7
11
8 24
2
10
10 9

18 O-ring 1 39
19 Water pump housing 1
M8 × 45 mm
20
21
Bolt
Cover
4
1 8
22 Seal 1
23 Insert cartridge 1
24 O-ring 1 39
8-8
LOWR
Lower unit
Removing the water pump and shift
B
rod
1. Remove the water pump housing 1, col-
lar 2, spacer 3, washers 4, wave D
washer 5, impeller 6, and Woodruff key
7. A
C
2. Remove the outer plate cartridge 8 and
gasket 9.
1
8
9 Disassembling the water pump

2
3 housing
7
1. Remove the O-ring 1, insert cartridge
4
2, and O-ring 3.
5
4
3
6 2
3. Set the gear shift to the N position.

1
R
N
0 2. Remove the cover 4 and seal 5.
F
4
Shift rod socket 0: 90890-06679
4. Remove the plate A, oil seal B, O-ring

C, and shift rod D.
Checking the water pump and shift

rod
1. Check the water pump housing. Replace
if deformed.
8-9
TIP: TIP:
If the engine overheated, the inside of the Fit the protrusions a on the insert cartridge
water pump housing may be deformed. 4 into the slots b in the water pump housing
Therefore, make sure to remove the insert 6.
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 Woodruff key and the keyway

in the drive shaft. Replace if deformed or
worn.
4. Check the shift rod. Replace if cracked or

worn.
Assembling the water pump housing

with a new one.
1. Install the seal 1 and cover 2.
8
2. Install a new O-ring 3, the insert car-
tridge 4, and a new O-ring 5.
5 4
6
8-10
LOWR
Lower unit
Water pump and shift rod (F250G)
16 17
18
4 16
13
3 3
12
15
5 19
11 14
6
7 10
10
8 20
2 9

1 Seal 1
2 Shift rod 1
3 Bolt 3 M6 × 20 mm
4 Oil seal 1 39
5 Plate 1
6 O-ring 1 39
7 Spring 1
8 E-clip 1
9 Woodruff key 1
10 Dowel 2
11 Gasket 1 39
13 Impeller 1
14 O-ring 1 39
16 Bolt 4 M8 × 45 mm
17 Cover 1
8-11
Water pump and shift rod (F250G)
16 17
18
4 16
13
3 3
12
15
5 19
11 14
6
7 10
10
8 20
2 9

18 Seal 1
20 O-ring 1 39
8
8-12
LOWR
Lower unit
rod
1. Remove the water pump housing 1,
impeller 2, and Woodruff key 3.
2. Remove the outer plate cartridge 4 and

gasket 5.
1 5
3. Set the gear shift to the N position, and

then remove the plate, oil seal, O-ring,
and shift rod. See steps 3 and 4 in
“Removing the water pump and shift rod”
(8-9).
Disassembling the water pump

housing
1. Disassemble the water pump housing.
See “Disassembling the water pump
housing” (8-9).

rod
1. Check the water pump and shift rod. See
“Checking the water pump and shift rod”
(8-9).

1. Assemble the water pump housing. See
“Assembling the water pump housing” (8-
10).
8-13
Water pump and shift rod (F250G) / Propeller shaft housing (F200B)
Propeller shaft housing (F200B)

8 7
3 10 4 5
9 4 6
5
6 24
1 2 23
4 8 7 22
3 9
10
4 20 21
12
19
18
11 25
17
16 18 19
15
1 N m (0.1 kgf m, 0.7 ft lb)
14
13 20
29 N m (2.9 kgf m, 21.4 ft lb)
6 N m (0.6 kgf m, 4.4 ft lb)

2 Water inlet cover (STBD) 1
3 Shift rod joint 1
4 Ball 2 8
5 Propeller shaft 1
6 Spring 1
7 Cross pin 1
8 Dog clutch 1
9 Shift plunger 1
10 Slider 1
11 Screw 1 M5 × 55 mm
12 Water inlet cover (PORT) 1
13 Washer 1
14 Reverse gear 1
15 Reverse gear shim (T2) —
16 Ball bearing 1 39
17 Propeller shaft housing 1
8-14
LOWR
Lower unit
8 7
3 10 4 5
9 4 6
5
6 24
1 2 23
4 8 7 22
3 9
10
4 20 21
12
19
18
11 25
17
16 18 19
15
1 N m (0.1 kgf m, 0.7 ft lb)
14
13 20
29 N m (2.9 kgf m, 21.4 ft lb)
6 N m (0.6 kgf m, 4.4 ft lb)

18 Washer 2
19 Bolt 2 M8 × 33 mm
20 O-ring 2 39
21 Needle bearing 1 39
22 Oil seal 2 39
23 Cover 1
24 Bolt 2 M8 × 20 mm
25 Grease nipple 1
8-15
Removing the propeller shaft
TIP:
housing assembly
When removing the slider 5, make sure that
1. Remove the cover 1 and bolts 2.
the balls 7 do not fall out of position.
Disassembling the propeller shaft

housing assembly
1. Remove the reverse gear and reverse
gear shims.
1
2
2
4
2. Remove the propeller shaft housing
assembly, and then remove the propeller 3
shaft assembly and washer.
1
3 4
Bearing separator 1: 90890-06534
5
Stopper guide plate 2: 90890-06501
Stopper guide stand 3: 90890-06538
Bearing puller assembly 4: 90890-06535
2. Remove the ball bearing.

3
Bearing housing puller claw L 3:

90890-06502
Center bolt 5: 90890-06504

assembly
1. Remove the spring 1, and then remove
5
8
the cross pin 2, dog clutch 3, shift rod
joint 4, slider 5, and shift plunger 6. 6
7
4
Slide hammer handle 5: 90890-06531
6
5 Bearing outer race puller assembly 6:
1 90890-06523
7
3 3. Remove the oil seals 7.
8-16
LOWR
Lower unit
3. Check the dog clutch, shift rod joint, and
7 slider. Replace if cracked or worn.
Assembling the propeller shaft

assembly
1. Install the shift plunger 1, slider 2, balls
3, and shift rod joint 4 into the propeller
shaft 5.
4 2 3
4. Remove the needle bearing 8.
1 3
0
5
9
2
3
8 4
1
3
90890-06611 TIP:
Driver rod L3 0: 90890-06652 When installing the slider 2, make sure that
the balls 3 do not fall out of position.
Checking the propeller shaft housing
1. Check the propeller shaft housing.
2. Align the hole a in the dog clutch 6 with
Replace if cracked or damaged.
the hole b in the propeller shaft.
2. Check the reverse gear. Replace if
3. Install the cross pin 7, and then install
cracked or worn.
the spring 8.
Checking the propeller shaft
6 7
1. Check the propeller shaft. Replace if
damaged or worn.
c
2. Measure the propeller shaft runout.
8
8
7
a
6 b
TIP:
Propeller shaft runout: Make sure to face the “F” mark c on the dog
0.02 mm (0.0008 in) clutch 6 toward the shift rod joint.
8-17
housing assembly
5
• Use heat-resistant gloves. Otherwise, d
burns could result.
• To prevent fires, remove any flammable
substances, such as gasoline and oil,
around the working area.
• Keep good ventilation while working.
90890-06640
Do not reuse a bearing or oil seal, always
replace it with a new one. Depth d:
4.75–5.25 mm (0.187–0.207 in)
1. Install a new needle bearing 1 to the
specified depth a.
TIP:
Install an oil seal halfway into the propeller
b shaft housing, and then install the other oil
2 seal.
4 c 1
3. Install a new ball bearing 6 and original
a
reverse gear shims 7.
3 e
6
Driver rod SS 2: 90890-06604 8

Needle bearing attachment 3: 7
90890-06610
Bearing depth plate 4: 90890-06603
Depth a:
25.05–25.55 mm (0.986–1.006 in) Needle bearing attachment 8:
90890-06654
8
TIP:
• Face the bearing identification mark b on TIP:
the needle bearing 1 toward the propeller • Do not reuse a shim if deformed or
side. scratched.
• When using the special service tool 2, do • Face the bearing identification mark e on
not strike it in a manner that will force the the ball bearing 6 toward the propeller
stopper c out of place. side.
2. Install new oil seals into the propeller

shaft housing to the specified depth d.
8-18
LOWR
Lower unit
4. Heat the installation area of the ball bear-
ing in the propeller shaft housing 9
using a gas torch, and then install the
reverse gear assembly 0. NOTICE:
When heating the propeller shaft
housing, heat the entire installation
area evenly. Otherwise, the propeller
shaft housing could be damaged.
5. Install the grease nipple A, and then

Grease nipple A:
6 N·m (0.6 kgf·m, 4.4 ft·lb)
8-19
Propeller shaft housing (F200B) / Propeller shaft housing (F250G)
Propeller shaft housing (F250G)

11 10
6 13 7 8
4 5
3
12 7
9
8
9 28
1 2 27
7 11 10 26
6 12
13
7 24 25
15
21
23
14 22
29
20
19 22 23
18
1 N m (0.1 kgf m, 0.7 ft lb)
17 30
16 24
29 N m (2.9 kgf m, 21.4 ft lb)
6 N m (0.6 kgf m, 4.4 ft lb)

3 Water pipe 1
4 Rubber seal 1 8
5 Rubber seal 1
6 Shift rod joint 1
7 Ball 2
8 Propeller shaft 1
9 Spring 1
10 Cross pin 1
11 Dog clutch 1
12 Shift plunger 1
13 Slider 1
14 Screw 1 M5 × 45 mm
16 Propeller shaft shim (T4) 1
17 Reverse gear 1
8-20
LOWR
Lower unit
11 10
6 13 7 8
4 5
3
12 7
9
8
9 28
1 2 27
7 11 10 26
6 12
13
7 24 25
15
21
23
14 22
29
20
19 22 23
18
1 N m (0.1 kgf m, 0.7 ft lb)
17 30
16 24
29 N m (2.9 kgf m, 21.4 ft lb)
6 N m (0.6 kgf m, 4.4 ft lb)

19 Ball bearing 1 39
21 Rubber seal 1
22 Washer 2
23 Bolt 2 M8 × 33 mm
24 O-ring 2 39
26 Oil seal 2 39
27 Cover 1
28 Bolt 2 M8 × 20 mm
29 Grease nipple 1
30 Dowel 1
8-21
Propeller shaft housing (F250G)
Removing the propeller shaft Disassembling the propeller shaft
housing assembly assembly
1. Remove the water pipe 1. 1. Disassemble the propeller shaft assem-
bly. See “Disassembling the propeller
shaft assembly” (8-16).

housing assembly
1 1. Remove the rubber seal 1.
2. Remove the cover 2 and bolts 3.
2. Disassemble the propeller shaft housing

assembly. See “Disassembling the pro-
peller shaft housing assembly” (8-16).

2 1. Check the water pipe. Replace if cor-
3
roded, deformed, or cracked.
2. Check the propeller shaft housing and

3. Remove the propeller shaft housing reverse gear. See “Checking the propel-
assembly, and then remove the propeller ler shaft housing” (8-17).
shaft assembly and propeller shaft shim.
1. Check the propeller shaft. See “Checking
4 5
the propeller shaft” (8-17). 8
6 Assembling the propeller shaft
assembly
1. Assemble the propeller shaft assembly.
See “Assembling the propeller shaft
assembly” (8-17).
4
Bearing housing puller claw L 4: housing assembly
90890-06502 1. Assemble the propeller shaft housing
Stopper guide plate 5: 90890-06501 assembly. See “Assembling the propeller
Center bolt 6: 90890-06504 shaft housing assembly” (8-18).
8-22
LOWR
Lower unit
2. Install the rubber seal 1.
8-23
Propeller shaft housing (F250G) / Drive shaft and lower case (F200B)
Drive shaft and lower case (F200B)
6
6 13
6
10
12
11
5
4 9
3
2 14
15
16
17
142 N m (14.2 kgf m, 104.7 ft lb)

1 Thrust bearing 1
2 Pinion shim (T3) —
3 O-ring 1 39
4 Needle bearing 1 39 8
5 Oil seal housing 1
6 Bolt 4 M8 × 25 mm
7 Oil seal 2 39
8 Cover 1
9 Drive shaft 1
10 Lower case 1
11 Forward gear shim (T1) —
12 Taper roller bearing 1 39
13 Forward gear 1
15 Pinion 1
16 Washer 1
17 Pinion nut 1
8-24
LOWR
Lower unit
Removing the drive shaft Needle bearing attachment 3:
1. Remove the pinion nut and washer. 90890-06610
Driver rod L3 4: 90890-06652
Disassembling the forward gear

1. Remove the taper roller bearing.
1
2
1
Drive shaft holder 6 1: Bearing separator 1: 90890-06534

90890-06520
Pinion nut holder 2: 90890-06715 Disassembling the lower case
2. Remove the cover, oil seal housing, pin-

ion shims, thrust bearing, drive shaft, and • Use heat-resistant gloves. Otherwise,
pinion. burns could result.
3. Remove the forward gear assembly. substances, such as gasoline and oil,
Disassembling the oil seal housing • Keep good ventilation while working.
1. Remove the oil seals 1.
1. Remove the needle bearing.
1
2
2
2. Remove the needle bearing 2.

Ball bearing attachment 1: 90890-06655
3 4
Driver rod LL 2: 90890-06605
4
2
3
8-25
Checking the drive shaft
TIP:
1. Check the drive shaft. Replace if dam-
• Since the diameter of the passage in the
aged or worn.
lower case and the diameter of the special
service tool 1 are both 40 mm (1.57 in), 2. Measure the drive shaft runout.
the special service tool may not fit into the
lower case. In that case, use a special ser-
vice tool with a smaller diameter.
• Make sure to remove the forward gear
before removing the needle bearing.
2. Heat the installation area of the taper

roller bearing outer race in the lower
case using a gas torch, and then remove
the outer race 3 and forward gear shims
4. NOTICE: When heating the lower Drive shaft runout: 0.2 mm (0.008 in)
case, heat the entire installation area
evenly. Otherwise, the paint on the Checking the lower case
lower case could be burned. 1. Check the lower case. Replace if cracked
or damaged.
Assembling the lower case
• Use heat-resistant gloves. Otherwise,

burns could result.
4 • Keep good ventilation while working.
3
Do not reuse a bearing, always replace it
TIP:
• Before removing the taper roller bearing
with a new one.
8
outer race 3, place some cushioning mate- 1. Install the original forward gear shims 1.
rial below the lower case to catch the outer
race when it falls out.
roller bearing outer race in the lower
• If the taper roller bearing outer race does
case using a gas torch, and then install a
not come out, lightly tap the lower unit tor-
new outer race 2. NOTICE: When heat-
pedo using a plastic hammer.
ing the lower case, heat the entire
installation area evenly. Otherwise,
Checking the pinion and forward the paint on the lower case could be
gear burned.
1. Check the pinion and forward gear.
Replace if cracked or worn.
8-26
LOWR
Lower unit
Ball bearing attachment 6:

2
90890-06655
1 Bearing outer race puller assembly 7:
90890-06523
TIP:
The needle bearing contains 24 rollers.
Assembling the forward gear

with a new one.
TIP: 1. Install a new taper roller bearing.

Do not reuse a shim if deformed or
scratched.
3. While holding the special service tool 3,

strike it to check that the taper roller 1
bearing outer race is installed properly.
3
4 3

90890-06659
4
Assembling the oil seal housing
Driver rod LL 3: 90890-06605 Do not reuse a bearing or oil seal, always

Bearing inner race attachment 4: replace it with a new one.
90890-06658
1. Install a new needle bearing to the speci-
4. Install a new needle bearing 5. fied depth a.
7 5 2
1
6

90890-06610
Driver rod L3 2: 90890-06652
8-27
Depth a: 3
4.25–4.75 mm (0.167–0.187 in)
2. Install new oil seals into the oil seal hous-

ing to the specified depth b.
2
b
4
3 1
3. Install the pinion and washer, and then

Bearing outer race attachment 3: tighten the pinion nut temporarily.
90890-06628
Driver rod LS 4: 90890-06606
TIP:
When installing the pinion, lift up the drive
Depth b: shaft slightly and align the splines on the
0.25–0.75 mm (0.010–0.030 in) drive shaft with the splines on the pinion.
TIP: 4. Install a new O-ring 4 to the oil seal

Install an oil seal halfway into the oil seal housing 5, and then install the oil seal
housing, and then the other oil seal. housing 5.
Installing the drive shaft
Do not reuse a bearing or O-ring, always 5

1. Install the forward gear assembly into the a

lower case.
4
8
2. Install the drive shaft 1, thrust bearing
2, and original pinion shims 3.
TIP:
Make sure to install the oil seal housing 5 so
that the notch a is facing forward.
5. Tighten the pinion nut to the specified

torque.
8-28
LOWR
Lower unit
4. Install the propeller shaft housing assem-
7 bly, and then tighten the propeller shaft
housing bolts 6 to the specified torque.
5. Install the cover 7.
6. Install the water inlet covers 8, and then

tighten the water inlet cover screw 9 to
7 6 the specified torque.
Drive shaft holder 6 6: 90890-06520

Pinion nut holder 7: 90890-06715 6 7
8
Pinion nut: 9
142 N·m (14.2 kgf·m, 104.7 ft·lb)
Propeller shaft housing bolt 6:
Installing the propeller shaft housing 29 N·m (2.9 kgf·m, 21.4 ft·lb)
assembly Water inlet cover screw 9:
1 N·m (0.1 kgf·m, 0.7 ft·lb)
Do not reuse an O-ring, always replace it Installing the shift rod

with a new one.
Do not reuse an oil seal or O-ring, always

1. Install new O-rings to the propeller shaft
housing.
2. Set the shift rod joint 1 and dog clutch 1. Check that the shift rod joint is in the N
2 to the N position. position, and then install the shift rod 1,
the spring 2, a new O-ring 3, the plate
3. Install the washer 3 and propeller shaft 4, and a new oil seal 5.
assembly 4 into the propeller shaft
housing assembly 5.
F N R
1 2
5
3
4
2
8-29
3. Align the slot a on the impeller 5 with
5
the Woodruff key 4, and then install the
1 impeller 5.
4 3 a
2
4. Install the washers 6, wave washer 7,

a spacer 8, and collar 9.
b
9
8
TIP:
Make sure to fit the tip a of the shift rod 1
6
into the slot b in the shift rod joint.
7
Installing the water pump 6
Do not reuse a gasket, always replace it TIP:

with a new one. The spacer 8 and collar 9 should fit
together firmly.
1. Install the dowels 1, a new gasket 2,
and the outer plate cartridge 3. 5. Install the water pump assembly 0.
NOTICE: Do not turn the drive shaft
counterclockwise. Otherwise, the
water pump impeller could be dam-
aged. 8
3
2
1
1
2. Install the Woodruff key 4.

8-30
LOWR
Lower unit
TIP:
While turning the drive shaft clockwise, push
the water pump housing down to install it.
Checking the lower unit for air

leakage
1. Remove the check screw 1, and then a
connect the special service tool 2. b

1
R
2
N
1
F
Leakage tester 2: 90890-06840
2. Apply the specified pressure. Check that Shift rod socket 1: 90890-06679
the pressure is maintained in the lower
unit for 10 seconds or more. NOTICE: 3. Install the dowels 2.
Do not over pressurize the lower unit.
Otherwise, the oil seals could be dam- 4. Install the extension 3 (U-transom
aged. model) and lower unit 4, and then
tighten the lower case mounting bolts 5
Holding pressure:
and lower case mounting nuts 6 (U-tran-
68.6 kPa (0.686 kgf/cm2, 9.9 psi)
som model) to the specified torques.
Installing the lower unit NOTICE: Make sure to align the
splines on the lower unit shift rod with
the splines on the upper case shift
• Make sure to disconnect the battery rod. Otherwise, the shift rods could be
cables from the battery, and remove the bent.
clip from the engine shut-off switch.
• When installing the lower unit with the 5. Install the trim tab 7 to its original posi-
power unit installed, make sure to sus- tion, and then tighten the trim tab bolt 8
pend the outboard motor. Otherwise, the to the specified torque.
outboard motor could fall suddenly and
result in severe injuries.
• When loosening or tightening the pro-
peller nut, do not hold the propeller
using your hands.
1. Align the pin a on the shift lever with the

alignment mark b on the bottom cowl-
ing.
8-31
È
9
8
3
6
2
5
7
Propeller nut A:
2 55 N·m (5.5 kgf·m, 40.6 ft·lb)
5 7. Install a new cotter pin B.
4
È U-transom model B
Lower case mounting bolt 5:
47 N·m (4.7 kgf·m, 34.7 ft·lb)
Lower case mounting nut 6: A
47 N·m (4.7 kgf·m, 34.7 ft·lb)
Trim tab bolt 8:
42 N·m (4.2 kgf·m, 31.0 ft·lb) TIP:
If the slots in the propeller nut A are not
TIP: aligned with the cotter pin hole, tighten the
Point the flat end of the stud bolt 9 up. propeller nut A until they are aligned.
6. Install the propeller 0, place a block of 8. Fill the lower unit with gear oil up to the
wood between the anti-cavitation plate proper level. See steps 5–8 in “Changing
and propeller to keep the propeller from gear oil” (10-11).
turning, and then tighten the propeller nut
A to the specified torque. 8
8-32
LOWR
Lower unit
Drive shaft and lower case (F250G)
8
13
12
7
11
6 16
10
6
6
15
14
5
9
4
3 17
2
1
18
19
20
142 N m (14.2 kgf m, 104.7 ft lb)

1 Thrust bearing 1
3 O-ring 1 39
6 Bolt 4 M8 × 25 mm
7 Oil seal 2 39
8 Cover 1
9 Drive shaft 1
10 Lower case 1
11 Washer 1
12 Spring 1
13 Thrust bearing 1
16 Forward gear 1
8-33
8
13
12
7
11
6 16
10
6
6
15
14
5
9
4
3 17
2
1
18
19
20
142 N m (14.2 kgf m, 104.7 ft lb)

18 Pinion 1
19 Washer 1
20 Pinion nut 1
8
8-34
LOWR
Lower unit
Removing the drive shaft Installing the drive shaft
1. Remove the pinion nut. See step 1 in 1. Install the forward gear assembly into the
“Removing the drive shaft” (8-25). lower case.
2. Remove the oil seal housing, pinion 2. Install the washer 1, spring 2, thrust
shims, thrust bearing, drive shaft, pinion, bearing 3, drive shaft 4, thrust bearing
thrust bearing, spring, and washer. 5, and original pinion shims 6.
3. Remove the forward gear assembly. 6 3
Disassembling the oil seal housing

1. Disassemble the oil seal housing. See 2
“Disassembling the oil seal housing” (8- 1
25). 5
Disassembling the forward gear
1. Disassemble the forward gear. See “Dis-
assembling the forward gear” (8-25). 4
Disassembling the lower case

1. Disassemble the lower case. See “Disas-
sembling the lower case” (8-25).
3. Install the pinion and washer, and then
tighten the pinion nut temporarily.
Checking the pinion and forward
gear TIP:
1. Check the pinion and forward gear. See • When installing the pinion, lift up the drive
“Checking the pinion and forward gear” shaft slightly and align the splines on the
(8-26). drive shaft with the splines on the pinion.
• To install the pinion nut, push down on the
Checking the drive shaft drive shaft.
1. Check the drive shaft. See “Checking the
drive shaft” (8-26).
4. Install the oil seal housing, and then
tighten the pinion nut to the specified
Checking the lower case
torque. See steps 4 and 5 in “Installing
1. Check the lower case. See “Checking the
the drive shaft” (8-28).
lower case” (8-26).
Installing the propeller shaft housing
assembly
1. Assemble the lower case. See “Assem-
bling the lower case” (8-26).
Assembling the forward gear with a new one.
1. Assemble the forward gear. See “Assem-
bling the forward gear” (8-27).
1. Install new O-rings to the propeller shaft
Assembling the oil seal housing housing.
1. Assemble the oil seal housing. See
2. Set the shift rod joint 1 and dog clutch
“Assembling the oil seal housing” (8-27).
2 to the N position.
8-35
3. Install the original propeller shaft shim 3
and propeller shaft assembly 4 into the B
propeller shaft housing assembly 5. A
0
F N R
1 2
Installing the shift rod

5 1. Install the shift rod. See “Installing the
3
shift rod” (8-29).
4
Installing the water pump
2
1. Install the water pump. See steps 1–3
and 5 in “Installing the water pump” (8-
4. Install the propeller shaft housing assem- 30).
bly, and then tighten the propeller shaft
housing bolts 6 to the specified torque. Checking the lower unit for air
leakage
5. Install the cover 7. 1. Check the lower unit for air leakage. See
“Checking the lower unit for air leakage”
6. Install the water inlet covers 8, and then (8-31).
tighten the water inlet cover screw 9 to
the specified torque. Installing the lower unit
1. Install the extension (U-transom model),
lower unit, trim tab, and propeller. See
steps 1–7 in “Installing the lower unit” (8-
31).
8
2. Fill the lower unit with gear oil up to the
6 7 proper level. See steps 5–8 in “Changing
9 gear oil” (10-11).
8
Propeller shaft housing bolt 6:
29 N·m (2.9 kgf·m, 21.4 ft·lb)
Water inlet cover screw 9:
1 N·m (0.1 kgf·m, 0.7 ft·lb)
7. Install the water pipe 0 and rubber seals

A and B.
8-36
LOWR
Lower unit
Shimming (regular rotation model)
Shimming workflow
Remove the water pump

assembly.
Measure the backlash before

disassembly.
YES
Within specification? Shimming is not required.
NO
Disassemble the lower unit.
Select the pinion shims (T3).

(F200B)
Select the pinion shims (T3) and
propeller shaft shim (T4).
(F250G)
Assemble the lower unit.
Measure the backlash.
Adjust the forward gear shim

NO
Within specification? (T1) thickness and reverse gear
shim (T2) thickness.
YES
Install the water pump assem-
bly.
TIP:
• 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.
8-37
Shimming check sheet
Lower case deviation
Serial number P F R 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
Measuring point #1
8
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
8-38
LOWR
Lower unit
Forward gear shim (T1) thickness measurement in 2 places (mm)
Number of shim(s) Subtotal
0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total
Reverse gear shim (T2) thickness measurement in 2 places (mm)

0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total
8-39
Measuring the forward gear backlash 6. Tighten the center bolt 4 to the specified
and reverse gear backlash before torque while holding the drive shaft not to
disassembly turn.
1. Remove the water pump assembly and
outer plate cartridge. See steps 1 and 2
in “Removing the water pump and shift 4
rod” (8-9). (F200B) See steps 1 and 2 in
(8-13). (F250G)
R
Center bolt 4 (shimming):
N 5 N·m (0.5 kgf·m, 3.7 ft·lb)
1
F 7. Turn the lower unit so that it is in an
upright position.
8. Remove the cover 5, and then install the

outer plate cartridge 6.
3. Set up the special service tools 2, 3,

and 4, and then tighten the center bolt
4 temporarily. 5
2 3
4
2 8
90890-06502
Center bolt 4: 90890-06504
9. Place the spring 7 on the outer plate
4. Turn the lower unit so that the propeller cartridge, and then install the handle
shaft is pointing downward. holder 8 so that the spring 7 is com-
pressed the specified compression dis-
5. Turn the drive shaft 10 times or more to tance a from its free length.
seat the taper roller bearing.
8-40
LOWR
Lower unit
Backlash indicator 9: 90890-06706

Magnet base plate 0: 90890-07003
Dial gauge set A: 90890-01252
Magnet base B B: 90890-06844
8
12. Turn the drive shaft slowly clockwise and
a counterclockwise and measure the back-
7 lash between where the drive shaft stops
in each direction.
Spring 7: 90501-450A2
Handle holder 8: EU0-23814-30
Compression distance a:
3.0–5.0 mm (0.118–0.197 in)
TIP:
• After installing the handle holder, pull the
drive shaft up to confirm that there is no
free play.
• Do not compress the spring more than 5.0 TIP:
mm (0.197 in). Otherwise, the drive shaft • The resistance force of the spring makes it
will not turn easily, making it difficult to difficult to turn the drive shaft. Therefore, to
obtain correct measurements. obtain correct measurements, consider the
spring resistance force when turning the
drive shaft.
10. Install the special service tool 9 at the
• Do not turn the drive shaft using too much
lowest possible position where the drive
force. Otherwise, the forward gear will turn,
shaft diameter is 22.4 mm (0.882 in).
leading to incorrect measurements.
• When turning the drive shaft, hold it using a
11. Set up the special service tools 0, A,
little force. A knocking sound may be heard
and B.
when the drive shaft is turned, but this is
the sound of the pinion contacting the
9 reverse gear and does not affect the back-
lash measurement.
13. Turn the drive shaft 180° clockwise and

measure the backlash again.
B
0
A
8-41
18. Tighten the propeller nut G to the speci-
fied torque.
E
b C
G
F
c
e D
d Propeller nut G (shimming):

10 N·m (1.0 kgf·m, 7.4 ft·lb)
TIP:
19. Repeat steps 13 and 14 to measure the
• Measure the backlash at 4 points: b, c,
reverse gear backlash.
d, and e, turning the drive shaft 180°
clockwise after each measurement. 20. Check that the reverse gear backlash
• Write down the measurement data in the average is within specification.
shimming check sheet.
Reverse gear backlash
0.23–0.88 mm (0.0091–0.0346 in)
14. Determine the backlash average, and
then round down the average to the
TIP:
1/100 place.
Adjust the shim thicknesses if the reverse
Example:
gear backlash is out of specification.
(mm)
Measuring point b 0.60
21. Remove the special service tools, handle
Measuring point c 0.51
holder, spring, and outer plate cartridge,
Measuring point d 0.51
and then install the cover, outer plate
Measuring point e 0.55 cartridge, and water pump assembly.
Average 0.5425 See “Installing the water pump” (8-30).
Round-down average 0.54 (F200B) See steps 1–3 and 5 in “Install-
15. Check that the forward gear backlash
ing the water pump” (8-30). (F250G) 8
average is within specification.
Forward gear backlash:
0.26–0.65 mm (0.0102–0.0256 in)
TIP:
Adjust the shim thicknesses if the forward
16. Remove the special service tools from

the propeller shaft.
17. Apply a load to the reverse gear by

installing the propeller C, spacer D,
(without the spacer E), and washer F.
8-42
LOWR
Lower unit
Shimming
• Before selecting the forward gear shims (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.
Shim location (F200B)
F R
T3 P
T2
T1
8-43
Shim location (F250G)
F R
T3 P
8
T4
T2
T1
8-44
LOWR
Lower unit
Selecting the pinion shim (T3) 2. Tighten the oil seal housing bolts 4.
• Spray anti-rust lubricant on the gears and
bearings before installation. Do not apply
gear oil to the parts. Otherwise, correct
measurements cannot be obtained.
4
• Keep the parts free of foreign material,
such as dirt and lint.
Do not damage the measurement plane

surface of the pinion height gauge. Other-
wise, correct measurements cannot be
obtained.
1. Secure the special service tool 1, and

then install the drive shaft 2, thrust bear- 3. Install the pinion 5, washer 6, and pin-
ing 3, and oil seal housing. ion nut 7, and then tighten the pinion nut
temporarily.
7
6
a
5
b 3
1
2 4. Check the gap c between the pinion 5

and the special service tool 1. NOTICE:
When tightening the pinion nut, check
that the drive shaft turns smoothly.
Also, make sure that there is a gap c
between the pinion 5 and the special
service tool 1. If there is no gap and
Pinion height gauge 1: 90890-06672 the drive shaft does not turn, the spe-
cial service tool could be damaged.
TIP:
• Do not install the pinion shims (T3) or O- 5
ring. Make sure to check the thrust bearing
outer race since the pinion shims (T3)
sometimes become affixed to the thrust
c
bearing outer race.
• Make sure to install the thrust bearing outer
race so that it is facing the same direction 1
as when it was removed.
• Make sure that the notch a in the oil seal
housing is facing the opposite side from the
plate b of the special service tool 1.
8-45
d
1
TIP:
If there is no gap, the thrust bearing outer
race d may not have been installed. If the
gap is 1 mm (0.04 in) or more, the pinion
shims (T3) 8 may not have been removed. 8. Turn the drive shaft 10 times or more to
seat the thrust bearing.
5. Install the special service tool 9 to the
9. Push down on the pinion 5 so that it
drive shaft, and then secure the special
does not lift up, and then measure the
service tool 9.
gap between the pinion 5 and the spe-
cial service tool 1. When measuring the
6. Tighten the pinion nut to the specified
gap, insert the end of the thickness
torque.
gauge 0 straight into the gap at the
measurement point. Do not insert the
thickness gauge at an angle.
5
0
9
1
8
e
Drive shaft holder 6 9: 90890-06520
Pinion nut:
142 N·m (14.2 kgf·m, 104.7 ft·lb) h f
7. Secure the special service tool 1 so that

the pinion is facing up.
g
8-46
LOWR
Lower unit
TIP: k
• Measure the gap at 4 points: e, f, g, and È
P/M
h. 0.16 0.17 0.18 0.19
m
• Write down the measurement data in the 13
shimming check sheet. 12
É 11
10. Determine the gap average, and then 10 1.12
round down the average to the 1/100 9
place.
Example: È Pinion height measurement (M)
(mm) É Deviation “P”
Measuring point e 0.25 Available shim thicknesses:
Measuring point f 0.24 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Measuring point g 0.25 mm
Measuring point h 0.25
Average 0.2475 TIP:
Round-down average 0.24 The deviation “P” is stamped on the trim tab
mounting surface of the lower case in 0.01
TIP: mm units. If the value is unreadable, replace
In the “Pinion shim (T3) selection table,” use the lower case.
the round-down average for the pinion height
measurement (M). 12. Remove the special service tool, and
then install the determined pinion shims
11. Determine the pinion shim (T3) thickness (T3).
using the “Pinion shim (T3) selection
table” according to the pinion height
measurement (M) and the deviation “P”
stamped on the lower case.
Example:
Pinion height measurement (M) = 0.18 mm
k
Deviation “P” = +10 m
Use the determined shim thickness of 1.12
mm instead of the current shim thickness.
8-47
Pinion shim (T3) selection table
(mm)
P/M È
0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15
13 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
12 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
11 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
10 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
9 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
8 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
7 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
6 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
5 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
4 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
3 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
2 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 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
É 0 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 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
–2 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
–3 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
–4 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
–5 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
–6 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
–7 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
–8 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
–9 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
–10 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
–11 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
–12 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
–13 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
P/M È
0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29 0.30
13 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
12 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
11 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
10 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
9 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
8 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
7 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
6 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
5
4
3
1.10
1.10
1.08
1.10
1.08
1.08
1.08
1.08
1.05
1.08
1.05
1.05
1.05
1.05
1.05
1.05
1.05
1.02
1.05
1.02
1.02
1.02
1.02
1.02
1.02
1.02
1.00
1.02
1.00
1.00
1.00
1.00
0.98
1.00
0.98
0.98
0.98
0.98
0.95
0.98
0.95
0.95
0.95
0.95
0.95
8
2 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
1 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
É 0 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
–1 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
–2 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
–3 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
–4 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
–5 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
–6 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
–7 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
–8 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
–9 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
–10 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
–11 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
–12 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
–13 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
È Pinion height measurement (M)

É Deviation “P”
8-48
LOWR
Lower unit
(mm)
P/M È
0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45
13 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
12 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
11 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
10 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
9 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
8 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
7 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
6 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
5 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
4 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
3 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
2 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
1 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
É 0 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
–1 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
–2 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
–3 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
–4 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
–5 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
–6 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
–7 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
–8 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
–9 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
–10 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
–11 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
–12 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
–13 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
P/M È
0.46 0.47 0.48 0.49 0.50 0.51 0.52 0.53 0.54 0.55 0.56 0.57 0.58 0.59 0.60
13 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
12 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
11 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
10 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
9 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
8 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
7 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
6 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
5 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
4 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
3 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
2 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
1 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
É 0 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
–1 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
–2 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
–3 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
–4 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
–5 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
–6 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
–7 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
–8 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
–9 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
–10 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
–11 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
–12 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
–13 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
È Pinion height measurement (M)

É Deviation “P”
8-49
Selecting the propeller shaft shim 5. Select the propeller shaft shim (T4) thick-
(T4) (F250G) ness from the following table according
1. Install the original propeller shaft shim. to the free play measurement.
(mm)
TIP: Free play
• If the original shim is missing, install a new Shim thickness
measurement
shim with a thickness of 1.80 mm. 2.16–2.19 1.80
• Do not reuse a shim if deformed or 2.20–2.29 1.90
scratched.
2.30–2.39 2.00
2.40–2.49 2.10
2. Install the propeller shaft assembly and 2.50–2.59 2.20
propeller shaft housing assembly. See
steps 2–4 in “Installing the propeller shaft Available shim thicknesses:
housing assembly” (8-35). 1.80, 1.90, 2.00, 2.10, 2.20 mm
3. Set up the special service tools 1 and 6. Remove the special service tools, and
2, and then measure the propeller shaft then install the selected propeller shaft
free play. shim.
Measuring the forward gear backlash

2 gear oil to the parts. Otherwise, correct
1 such as dirt and lint.
• When measuring the forward gear or
reverse gear backlash, use the original
bearings and shims.
1. Install the original forward gear shims.
TIP:
Dial gauge set 1: 90890-01252 • If the original shims are missing, install new
Magnet base B 2: 90890-06844 shims with a combined thickness of 0.42
mm.
8
Propeller shaft free play:
• Do not reuse a shim if deformed or
0.20–0.50 mm (0.0079–0.0197 in)
scratched.
TIP:
If the free play is within specification, the pro- 2. Install the taper roller bearing outer race.
peller shaft shim thickness does not need to See steps 2 and 3 in “Assembling the
be adjusted. lower case” (8-26).
3. Install the forward gear assembly into the

4. Remove the original propeller shaft shim,
lower case.
and then measure the propeller shaft free
play again without any propeller shaft
shim.
8-50
LOWR
Lower unit
4. Install the pinion shims, drive shaft, pin- 2. Remove the oil seal housing, pinion,
ion, and oil seal housing. See steps 2–5 drive shaft, and forward gear assembly.
in “Installing the drive shaft” (8-28). See “Removing the drive shaft” (8-25).
(F200B) See steps 2 and 3 in “Installing (F200B) See step 1 in “Removing the
the drive shaft” (8-35) and steps 4 and 5 drive shaft” (8-25) and steps 2 and 3 in
in “Installing the drive shaft” (8-28). “Removing the drive shaft” (8-35).
(F250G) (F250G)
5. Check that the drive shaft turns 3. Remove the taper roller bearing outer
smoothly. race. See step 2 in “Disassembling the
6. Install the propeller shaft assembly (with-
out the dog clutch) and propeller shaft 4. Measure the thickness of each original
housing assembly (without the O-ring). forward gear shim in 2 places.
See steps 2–4 in “Installing the propeller
shaft housing assembly” (8-29). (F200B) TIP:
See steps 2–4 in “Installing the propeller Do not reuse a shim if deformed or
shaft housing assembly” (8-35). (F250G) scratched.
TIP: 5. Determine the forward gear shim (T1)

When assembling the lower unit to measure thickness adjustment using the “Forward
the backlash, do not install the dog clutch gear shim (T1) selection chart” according
and O-ring. to the backlash measurement (BL1) from
“Measuring the forward gear backlash.”
7. Check that the drive shaft turns See “Forward gear shim (T1) selection
smoothly. chart” (8-53).
Example:
8. Measure the forward gear backlash. See Backlash measurement (BL1) = 0.15 mm a
steps 2–15 in “Measuring the forward Forward gear shim (T1) thickness adjustment
gear backlash and reverse gear backlash = –0.22 mm b
before disassembly” (8-40). The current shim thickness must be
Forward gear backlash: decreased by 0.22 mm.
0.26–0.65 mm (0.0102–0.0256 in)
É (mm)
TIP:
–0.20
In the “Forward gear shim (T1) selection
chart,” use the round-down average for the
backlash measurement (BL1). b –0.40
0 5 10 15 20 2
Adjusting the forward gear shim (T1) a È (1/100 mm)

thickness
1. Remove the propeller shaft housing È 0 5 10 15 20 2
assembly and propeller shaft assembly.
See “Removing the propeller shaft hous- É –0.32 –0.28 –0.25 –0.22 –0.18 –0.
ing assembly” (8-16). (F200B) See
“Removing the propeller shaft housing È Backlash measurement (BL1)
assembly” (8-22). (F250G) É Shim thickness adjustment
8-51
7. Install the determined forward gear
TIP: shims (T1) and taper roller bearing outer
• If the shim thickness adjustment value is race. See steps 2 and 3 in “Assembling
positive, the current shim thickness must the lower case” (8-26).
be increased by that amount and, if the
value is negative, the current shim thick-
ness must be decreased 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-col-
ored area.
• The values for the shim thickness adjust-
ments specified in the selection chart are
intended to obtain the median value within
the range for the specified forward gear
backlash.
• The table that follows the selection chart
shows the shim thickness adjustments for
the points marked on the chart.
6. Calculate the new forward gear shim (T1)

thickness.
New forward gear shim (T1) thickness =
Current forward gear shim thickness +
Shim thickness adjustment
Example:
Use the following formula when the shim
thickness adjustment value is negative.
Current forward gear shim thickness = 0.42
mm
Shim thickness adjustment = –0.12 mm
New forward gear shim (T1) thickness
= 0.42 mm + (–0.12) mm 8
= 0.30 mm
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
mm
TIP:
• Use the least number of shims to obtain the
required shim thickness.
• If the calculated shim thickness cannot be
obtained with a combination of the avail-
able shims, increase the shim thickness by
0.01 mm.
8-52
Forward gear shim (T1) selection chart
8-53
LOWR
1.20
1.00
0.80
0.60
Lower unit
0.40
É (mm)
0.20
0
Continue next page
–0.20
–0.40
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
È (1/100 mm)
È 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
É –0.32 –0.28 –0.25 –0.22 –0.18 –0.15 0.18 0.20 0.24 0.28 0.31 0.35 0.38
È Backlash measurement (BL1)

É Shim thickness adjustment
1.20
1.00
0.80
0.60
0.40
É (mm)
0.20
–0.20
–0.40
100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
È (1/100 mm)
È 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
É 0.38 0.43 0.46 0.50 0.53 0.57 0.60 0.64 0.67 0.70 0.74 0.77 0.81 0.85 0.88 0.92 0.95 0.99 1.02 1.06 1.09

8-54
8
LOWR
Lower unit
Measuring the reverse gear backlash
TIP:
In the “Reverse gear shim (T2) selection
gear oil to the parts. Otherwise, correct
backlash measurement (BL2).
such as dirt and lint. Adjusting the reverse gear shim (T2)
• When measuring the forward gear or thickness
reverse gear backlash, use the original 1. Remove the propeller shaft housing
bearings and shims. assembly. See “Removing the propeller
shaft housing assembly” (8-16). (F200B)
1. Install the original reverse gear shims See “Removing the propeller shaft hous-
and ball bearing. See steps 3 and 4 in ing assembly” (8-22). (F250G)
“Assembling the propeller shaft housing
assembly” (8-18). 2. Remove the reverse gear. See step 1 in
“Disassembling the propeller shaft hous-
TIP: ing assembly” (8-16).
• If the original shims are missing, install new
shims with a combined thickness of 1.25 3. Measure the thickness of each original
mm. reverse gear shim in 2 places.
scratched. TIP:
2. Install the propeller shaft assembly (with- scratched.
out the dog clutch) and propeller shaft
housing assembly (without the O-ring). 4. Determine the reverse gear shim (T2)
See steps 2–4 in “Installing the propeller thickness adjustment using the “Reverse
shaft housing assembly” (8-29). (F200B) gear shim (T2) selection chart” according
See steps 2–4 in “Installing the propeller to the backlash measurement (BL2) from
shaft housing assembly” (8-35). (F250G) “Measuring the reverse gear backlash.”
See “Reverse gear shim (T2) selection
TIP: chart” (8-57).
When assembling the lower unit to measure Example:
the backlash, do not install the dog clutch Backlash measurement (BL2) = 0.95 mm a
and O-ring. Reverse gear shim (T2) thickness adjustment
= 0.34 mm b
3. Check that the drive shaft turns The current shim thickness must be
smoothly. increased by 0.34 mm.
4. Measure the reverse gear backlash. See

steps 17–20 in “Measuring the forward
gear backlash and reverse gear backlash
before disassembly” (8-40).
Reverse gear backlash:
0.23–0.88 mm (0.0091–0.0346 in)
8-55
0.40 Current reverse gear shim thickness = 1.25

mm
b Shim thickness adjustment = –0.20 mm
0.20
New reverse gear shim (T2) thickness
É (mm)
= 1.25 mm + (–0.20) mm
0 = 1.05 mm
–0.20
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
mm
–0.40
0 5 85 90 95 10
TIP:
È (1/100 mm) • Use the least number of shims to obtain the
a required shim thickness.
• If the calculated shim thickness cannot be
È 0 5 85 90 95 1 obtained with a combination of the avail-
able shims, increase the shim thickness by
É –0.35 –0.32 0.21 0.30 0.34 0. 0.01 mm.
É Shim thickness adjustment 6. Install the determined reverse gear
shims (T2) and reverse gear. See steps
TIP: 3 and 4 in “Assembling the propeller
• If the shim thickness adjustment value is shaft housing assembly” (8-18).
positive, the current shim thickness must
ored area.
the range for the specified reverse gear
8
backlash.
5. Calculate the new reverse gear shim (T2)

thickness.
New reverse gear shim (T2) thickness =
Current reverse gear shim thickness +
Example:
8-56
Reverse gear shim (T2) selection chart
8-57
LOWR
1.20
1.00
0.80
0.60
Lower unit
0.40
É (mm)
0.20
Continue next page
–0.20
–0.40
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
È(1/100 mm)
È 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
É –0.35 –0.32 –0.27 –0.24 –0.20 0.30 0.34 0.38

1.20
1.00
0.80
0.60
0.40
É (mm)
0.20
–0.20
–0.40
100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
È (1/100 mm)
È 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
É 0.38 0.41 0.45 0.48 0.52 0.55 0.58 0.63 0.65 0.69 0.73 0.76 0.80 0.84 0.87 0.91 0.94 1.01 1.01 1.05 1.07

8-58
8
LOWR
Lower unit
Lower unit (FL200B)
È 26 42 N m (4.2 kgf m, 31.0 ft lb)
23
25 24
7
27
24 6
55 N m (5.5 kgf m, 40.6 ft Ib)
31
30 11
20
21 29 28 4 3 5 12
8 10
19
2 3 9
1 13
22 14
47 N m (4.7 kgf m, 34.7 ft lb)
15
9 N m (0.9 kgf m, 6.6 ft lb) 17
1 17 17
18 16

1 Gasket 2 39
2 Check screw 1
3 Dowel 2
4 Plate 1
5 Rubber seal 1
6 Bolt 1 M10 × 45 mm
7 Grommet 1
8 Lower unit 1
9 Spacer 1
10 Propeller 1
11 Cotter pin 1 39
12 Propeller nut 1
13 Washer 1
14 Spacer 1
15 Trim tab 1
È U-transom model
8-59
Lower unit (FL200B)
È 26 42 N m (4.2 kgf m, 31.0 ft lb)

23
25 24
7
27
24 6
55 N m (5.5 kgf m, 40.6 ft Ib)
31
30 11
20
21 29 28 4 3 5 12
8 10
19
2 3 9
1 13
22 14
47 N m (4.7 kgf m, 34.7 ft lb)
15
9 N m (0.9 kgf m, 6.6 ft lb) 17
1 17 17
18 16

18 Drain screw 1
21 Plastic tie 1 U-transom model 8
29 Bolt 1 M10 ×175 mm/U-transom model
È U-transom model
8-60
LOWR
Lower unit

unit” (8-3).
TIP:

propeller” (8-3).

8-61
Lower unit (FL200B) / Lower unit (FL250G)
Lower unit (FL250G)

È 26
23
24
25
7 42 N m (4.2 kgf m, 31.0 ft lb)
27 9 N m (0.9 kgf m, 6.6 ft lb)
24 6
55 N m (5.5 kgf m, 40.6 ft Ib)
31
11
30 10
20 12
21 3 5
29 4
28 8
19 23 9 13
22 14
47 N m (4.7 kgf m, 34.7 ft lb)
1
15
17
1 17
17
18
16
9 N m (0.9 kgf m, 6.6 ft lb)
47 N m (4.7 kgf m, 34.7 ft lb)

1 Gasket 2 39
2 Check screw 1
3
4
Dowel
Plate
2
1 8
5 Rubber seal 1
6 Bolt 1 M10 × 45 mm
7 Grommet 1
8 Lower unit 1
9 Spacer 1
10 Propeller 1
11 Cotter pin 1 39
12 Propeller nut 1
13 Washer 1
14 Spacer 1
15 Trim tab 1
È U-transom model
8-62
LOWR
Lower unit
È 26
23
24
25
7 42 N m (4.2 kgf m, 31.0 ft lb)
27 9 N m (0.9 kgf m, 6.6 ft lb)
24 6
55 N m (5.5 kgf m, 40.6 ft Ib)
31
11
30 10
20 12
21 3 5
29 4
28 8
19 23 9 13
22 14
47 N m (4.7 kgf m, 34.7 ft lb)
1
15
17
1 17
17
18
16
9 N m (0.9 kgf m, 6.6 ft lb)
47 N m (4.7 kgf m, 34.7 ft lb)

18 Drain screw 1
21 Plastic tie 1 U-transom model
È U-transom model
8-63
Lower unit (FL250G)

unit” (8-3).
TIP:

propeller” (8-3).

8-64
LOWR
Lower unit
Water pump and shift rod (FL200B)
20 21
4 22
17 20
3 3 16
14
15
14
13 19
5 23
18
6 12
7
11
8 24
2
10
10 9

1 Seal 1
2 Shift rod 1
3 Bolt 3 M6 × 20 mm
4 Oil seal 1 39
5 Plate 1
6 O-ring 1 39
7 Spring 1
8 E-clip 1
9 Woodruff key 1
10 Dowel 2
11 Gasket 1 39
13 Impeller 1
14 Washer 2
15 Wave washer 1
16 Spacer 1
17 Collar 1
8-65
Water pump and shift rod (FL200B)
20 21
4 22
17 20
3 3 16
14
15
14
13 19
5 23
18
6 12
7
11
8 24
2
10
10 9

18 O-ring 1 39
M8 × 45 mm
20
21
Bolt
Cover
4
1 8
22 Seal 1
24 O-ring 1 39
8-66
LOWR
Lower unit
rod
1. Remove the water pump housing, impel-
ler, Woodruff key, outer plate cartridge,
and gasket, and then set the gear shift to
the N position. See steps 1–3 in “Remov-
ing the water pump and shift rod” (8-9).
2. Remove the plate 1, oil seal 2, O-ring

3, and shift rod 4.
4
1
3

housing
housing” (8-9).

rod
(8-9).

10).
8-67
Water pump and shift rod (FL200B) / Water pump and shift rod (FL250G)
Water pump and shift rod (FL250G)

16 17
18
4 16
13
3 3
12
15
5 19
11 14
6
7 10
10
8 20
2 9

1 Seal 1
2 Shift rod 1
3 Bolt 3 M6 × 20 mm
4 Oil seal 1 39 8
5 Plate 1
6 O-ring 1 39
7 Spring 1
8 E-clip 1
9 Woodruff key 1
10 Dowel 2
11 Gasket 1 39
13 Impeller 1
14 O-ring 1 39
16 Bolt 4 M8 × 45 mm
17 Cover 1
8-68
LOWR
Lower unit
16 17
18
4 16
13
3 3
12
15
5 19
11 14
6
7 10
10
8 20
2 9

18 Seal 1
20 O-ring 1 39
8-69
Water pump and shift rod (FL250G)
rod
1. Remove the water pump housing, impel-
ler, Woodruff key, outer plate cartridge,
and gasket, and then set the gear shift to
the N position. See steps 1 and 2 in
(8-13) and step 3 in “Removing the water
pump and shift rod” (8-9).
2. Remove the plate, oil seal, O-ring, and

shift rod. See step 2 in “Removing the
water pump and shift rod” (8-67).

housing
housing” (8-9).

rod
(8-9).

10).
8-70
LOWR
Lower unit
Propeller shaft housing (FL200B)
12 11
3 5 4 17 108 N m (10.8 kgf m, 79.7 ft lb)
7
13 4 6
6
8
9
10
4 5
1 2
12 11
4 13
3
18 29 N m (2.9 kgf m, 21.4 ft lb)

L
15 25 26
14
24
23
17 22 27
1 N m (0.1 kgf m, 0.7 ft lb)
23
16 22
21 20
20
19
28
6 N m (0.6 kgf m, 4.4 ft lb)

3 Shift rod joint 1
4 Ball 2
5 Slider 1
6 Spring 1
7 Forward gear 1
8 Claw washer 1
9 Ring nut 1
11 Cross pin 1
12 Dog clutch 1
13 Shift plunger 1
14 Screw 1 M5 × 53 mm
17 Propeller shaft 1
8-71
12 11
3 5 4 17 108 N m (10.8 kgf m, 79.7 ft lb)
7
13 4 6
6
8
9
10
4 5
1 2
12 11
4 13
3
18 29 N m (2.9 kgf m, 21.4 ft lb)

L
15 25 26
14
24
23
17 22 27
1 N m (0.1 kgf m, 0.7 ft lb)
23
16 22
21 20
20
19
28
6 N m (0.6 kgf m, 4.4 ft lb)

18 Thrust bearing 1
19 Propeller shaft shim (T4) —
20 O-ring 2 39
21 Propeller shaft housing 1 8
22 Washer 2
23 Bolt 2 M8 × 33 mm
25 Oil seal 2 39
26 Bolt 2 M8 × 20 mm
27 Cover 1
28 Grease nipple 1
8-72
LOWR
Lower unit
Removing the propeller shaft
housing assembly 2
1. Remove the cover and bolts. See step 1
in “Removing the propeller shaft housing
assembly” (8-16).

assembly.
2
1
4. Remove the ring nut 3 and claw washer

4.
Slide hammer handle 1: 90890-06531

Puller head 2: 90890-06514
3
housing assembly
4
1. Remove the dog clutch. See “Disassem-
bling the propeller shaft assembly” (8-
16).
5
2. Remove the forward gear and forward
gear shims.
Ring nut wrench 5: 90890-06578
5. Remove the taper roller bearing 6,

1
thrust bearing 7, and propeller shaft
shims 8. NOTICE: Do not press the
threads a of the propeller shaft
directly.
Bearing separator 1: 90890-06534

bly 2 in the reverse direction into the
lower case.
8-73
housing assembly

a
burns could result.
8
7 • Keep good ventilation while working.

6
with a new one.
1. Install a new needle bearing and oil

seals. See steps 1 and 2 in “Assembling
the propeller shaft housing assembly” (8-
6. Remove the oil seals and needle bear- 18).
ing. See steps 3 and 4 in “Disassembling
the propeller shaft housing assembly” (8- 2. Install the original propeller shaft shims
16). 1 and thrust bearing 2.

1. Check the propeller shaft housing.
Replace if cracked or damaged. 2 1
2. Check the forward gear. Replace if

cracked or worn.

1. Check the propeller shaft. Replace if
damaged or worn.
TIP:
2. Measure the propeller shaft runout. Do not reuse a shim if deformed or
scratched.
8
3. Install the propeller shaft housing 3 in
the reverse direction.
Propeller shaft runout:

3
0.02 mm (0.0008 in)
3. Check the dog clutch, shift rod joint, and

slider. Replace if cracked or worn.
8-74
LOWR
Lower unit
roller bearing outer race in the propeller TIP:
shaft housing 3 using a gas torch, and If a high-pitched metallic sound is produced
then install the propeller shaft 4 and a when the special service tool is struck, the
new taper roller bearing 5. NOTICE: taper roller bearing outer race is installed
When heating the propeller shaft properly.
housing, heat the entire installation
area evenly. Otherwise, the propeller 6. Install the claw washer 7 and ring nut
shaft housing could be damaged. 8, and then tighten the ring nut 8 to the
specified torque.
3
6
4
Ring nut wrench 6: 90890-06578
Ring nut 8:
108 N·m (10.8 kgf·m, 79.7 ft·lb)
3
7. Install the original forward gear shims 9
and forward gear 0 using the dog clutch
A and special service tool 6.
5. While holding the special service tool 6, A

strike it to check that the taper roller
bearing outer race is installed properly. 6
6
a
0
9
Ring nut wrench 6: 90890-06578 Ring nut wrench 6: 90890-06578
8-75
TIP:
scratched.
• Face the “F” mark a on the dog clutch
toward the forward gear.
8. Install the shift plunger B, slider C, balls

D, and shift rod joint E.
E CD
BD
D
E
B
C
D
TIP:
When installing the slider C, make sure that
the balls D do not fall out of position.
9. Align the hole b in the dog clutch A with

the hole c in the propeller shaft.
10. Install the cross pin F, and then install

the spring G.
A F
a G
8
A
G
c
F
b
TIP:
Make sure to face the “F” mark a on the dog
clutch A toward the forward gear.
8-76
LOWR
Lower unit
Propeller shaft housing (FL250G)
15 14
6 8 7 20 108 N m (10.8 kgf m, 79.7 ft lb)
5
4
10
16 7 9 3
9
11
12
13
7 8
1 2
15 14
7 16
6
21 29 N m (2.9 kgf m, 21.4 ft lb)

18 L
30
29
17
28
27
20 26
1 N m (0.1 kgf m, 0.7 ft lb) 25 31
26
19
24 23
23 27
22
32
33
6 N m (0.6 kgf m, 4.4 ft lb)

3 Water pipe 1
4 Rubber seal 1
5 Rubber seal 1
6 Shift rod joint 1
7 Ball 2
8 Slider 1
9 Spring 1
10 Forward gear 1
11 Claw washer 1
12 Ring nut 1
14 Cross pin 1
15 Dog clutch 1
16 Shift plunger 1
17 Screw 1 M5 × 53 mm
8-77
Propeller shaft housing (FL250G)
15 14
6 8 7 20 108 N m (10.8 kgf m, 79.7 ft lb)
5
4
10
16 7 9 3
9
11
12
13
7 8
1 2
15 14
7 16
6
21 29 N m (2.9 kgf m, 21.4 ft lb)

18 L
30
29
17
28
27
20 26
1 N m (0.1 kgf m, 0.7 ft lb) 25 31
26
19
24 23
23 27
22
32
33
6 N m (0.6 kgf m, 4.4 ft lb)

20 Propeller shaft 1
21 Thrust bearing 1 8
22 Propeller shaft shim (T4) —
23 O-ring 2 39
25 Rubber seal 1
26 Washer 2
27 Bolt 2 M8 × 33 mm
29 Oil seal 2 39
30 Bolt 2 M8 × 20 mm
31 Cover 1
32 Grease nipple 1
33 Dowel 1
8-78
LOWR
Lower unit
Removing the propeller shaft Checking the propeller shaft
housing assembly 1. Check the propeller shaft. See “Checking
1. Remove the water pipe, cover, and bolts. the propeller shaft” (8-74).
See steps 1 and 2 in “Removing the pro-
peller shaft housing assembly” (8-22). Assembling the propeller shaft
housing assembly
2. Remove the propeller shaft housing 1. Install a new needle bearing and oil
assembly. seals. See steps 1 and 2 in “Assembling
2 18).
1
2. Assemble the propeller shaft housing
assembly. See steps 2–10 in “Assem-
bling the propeller shaft housing assem-
bly” (8-74).
3. Install the rubber seal. See step 2 in

Slide hammer handle 1: 90890-06531 assembly” (8-22).
Puller head 2: 90890-06514

housing assembly
1. Remove the rubber seal. See step 1 in
“Disassembling the propeller shaft hous-
ing assembly” (8-22).

16).
3. Disassemble the propeller shaft housing

assembly. See steps 2–5 in “Disassem-
bling the propeller shaft housing assem-
bly” (8-73).
4. Remove the oil seals and needle bear-

ing. See steps 3 and 4 in “Disassembling
16).

1. Check the water pipe. Replace if cor-
roded, deformed, or cracked.
2. Check the propeller shaft housing and

forward gear. See “Checking the propel-
ler shaft housing” (8-74).
8-79
Propeller shaft housing (FL250G) / Drive shaft and lower case (FL200B)
Drive shaft and lower case (FL200B)
14
6
6 10
6 13
12
11
5
4 15
3
2 16
17
1 18
9 19
20
142 N m (14.2 kgf m, 104.7 ft lb) 21

1 Thrust bearing 1
3 O-ring 1 39
6 Bolt 4 M8 × 25 mm
7 Oil seal 2 39
8 Cover 1
9 Drive shaft 1
10 Lower case 1
12 Retainer 1
14 Thrust bearing 1
15 Reverse gear 1
17 Circlip 1 39
8-80
LOWR
Lower unit
14
6
6 10
6 13
12
11
5
4 15
3
2 16
17
1 18
9 19
20
142 N m (14.2 kgf m, 104.7 ft lb) 21

19 Pinion 1
20 Washer 1
21 Pinion nut 1
8-81
Removing the drive shaft 2. Heat the installation area of the retainer
1. Remove the oil seal housing and drive in the lower case using a gas torch, and
shaft. See steps 1 and 2 in “Removing then remove the retainer 1 and reverse
the drive shaft” (8-25). gear shims 2. NOTICE: When heating
the lower case, heat the entire installa-
2. Remove the reverse gear assembly and tion area evenly. Otherwise, the paint
thrust bearing. on the lower case could be burned.
Disassembling the oil seal housing

1. Disassemble the oil seal housing. See
“Disassembling the oil seal housing” (8-
25).
Disassembling the reverse gear

1. Remove the circlip 1.
1 2
1
TIP:
• Before removing the retainer 1, place
some cushioning material below the lower
case to catch the retainer 1 when it falls
2. Remove the needle bearing. out.
• If the retainer does not come out, lightly tap
the lower unit torpedo using a plastic ham-
mer.
burns could result. 3. Remove the needle bearing 3.
4 5
8
1. Remove the needle bearing. See step 1

in “Disassembling the lower case” (8-25).
3
TIP:
Before removing the needle bearing, make
sure to remove the reverse gear.
90890-06654
Driver rod L3 5: 90890-06652
8-82
LOWR
Lower unit
Checking the pinion and reverse 3. Heat the installation area of the retainer
gear in the lower case using a gas torch, and
1. Check the pinion and reverse gear. then install the retainer 5. NOTICE:
Replace if cracked or worn. When heating the lower case, heat the
entire installation area evenly. Other-
Checking the drive shaft wise, the paint on the lower case
1. Check the drive shaft. See “Checking the could be burned.
drive shaft” (8-26). 5 b
Checking the lower case b

1. Check the lower case. See “Checking the 4

burns could result.
TIP:
scratched.
• Align the notches b in the retainer 5 with
with a new one.
the bolt holes in the torpedo.
1. Install a new needle bearing 1 to the

4. While holding the special service tool 6,
specified depth a.
strike it to check that the retainer is
installed properly.
a 3 1 6
2
7
90890-06654
Driver rod LL 6: 90890-06605
Driver rod L3 3: 90890-06652
Ball bearing attachment 7: 90890-06657
Depth a:
5. Install a new needle bearing. See step 4
–0.25 to 0.25 mm (–0.010 to 0.010 in)
in “Assembling the lower case” (8-26).
2. Install the original reverse gear shims 4.
8-83
Assembling the reverse gear Installing the propeller shaft housing
assembly
Do not reuse a bearing or circlip, always
replace it with a new one. Do not reuse an O-ring, always replace it
with a new one.
1. Install a new needle bearing to the speci-
fied depth a. 1. Install new O-rings to the propeller shaft
housing.
2. Set the shift rod joint 1 and dog clutch

a 2
2 to the N position.
1
R N F
F
L
1 2
90890-06653
Driver rod SS 2: 90890-06604
Depth a:
6.75–7.25 mm (0.2657–0.2854 in)
2. Install a new circlip 3.

3 bly, cover, and water inlet covers. See
steps 4–6 in “Installing the propeller shaft
housing assembly” (8-29).
Do not reuse an oil seal or O-ring, always 8

Assembling the oil seal housing
1. Assemble the oil seal housing. See 1. Check that the shift rod joint is in the N
“Assembling the oil seal housing” (8-27). position, and then install the shift rod 1,
the spring 2, a new O-ring 3, the plate
Installing the drive shaft 4, and a new oil seal 5.
1. Install the thrust bearing and reverse
gear assembly into the lower case.
2. Install the drive shaft and oil seal hous-

ing. See steps 2–5 in “Installing the drive
shaft” (8-28).
8-84
LOWR
Lower unit
4 3
2
a
b
TIP:
Make sure to fit the tip a of the shift rod 1
into the slot b in the shift rod joint.

1. Install the water pump. See “Installing the
water pump” (8-30).

leakage
1. Check the lower unit for air leakage. See
(8-31).
Installing the lower unit

31).

proper level. See steps 5–8 in “Changing
gear oil” (10-11).
8-85
Drive shaft and lower case (FL200B) / Drive shaft and lower case (FL250G)
Drive shaft and lower case (FL250G)
8
13
12
7
11 17
6
6
6 10 16
15
14
5
4 18
3
2 19
20
1 21
9 22
23
142 N m (14.2 kgf m, 104.7 ft lb) 24

1 Thrust bearing 1
3 O-ring 1 39
6 Bolt 4 M8 × 25 mm
7 Oil seal 2 39
8 Cover 1
9 Drive shaft 1
10 Lower case 1
11 Washer 1
12 Spring 1
13 Thrust bearing 1
15 Retainer 1
17 Thrust bearing 1
8-86
LOWR
Lower unit
8
13
12
7
11 17
6
6
6 10 16
15
14
5
4 18
3
2 19
20
1 21
9 22
23
142 N m (14.2 kgf m, 104.7 ft lb) 24

18 Reverse gear 1
20 Circlip 1 39
22 Pinion 1
23 Washer 1
24 Pinion nut 1
8-87
Drive shaft and lower case (FL250G)
Removing the drive shaft Assembling the lower case
1. Remove the pinion nut. See step 1 in 1. Install a new needle bearing, the original
“Removing the drive shaft” (8-25). reverse gear shim, and retainer. See
steps 1–4 in “Assembling the lower case”
2. Remove the oil seal housing, pinion (8-83).
shims, thrust bearing, drive shaft, pinion,
thrust bearing, spring, and washer. 2. Install a new needle bearing. See step 4
in “Assembling the lower case” (8-26).
3. Remove the reverse gear assembly and
thrust bearing. Assembling the reverse gear
1. Assemble the reverse gear. See “Assem-
Disassembling the oil seal housing bling the reverse gear” (8-84).
1. Disassemble the oil seal housing. See
“Disassembling the oil seal housing” (8- Assembling the oil seal housing
25). 1. Assemble the oil seal housing. See
“Assembling the oil seal housing” (8-27).
Disassembling the reverse gear
1. Disassemble the reverse gear. See “Dis- Installing the drive shaft
assembling the reverse gear” (8-82). 1. Install the thrust bearing and reverse
gear assembly into the lower case.
1. Remove the needle bearing. See step 1 2. Install the drive shaft and pinion nut tem-
in “Disassembling the lower case” (8-25). porarily. See steps 2 and 3 in “Installing
the drive shaft” (8-35).
TIP:
Before removing the needle bearing, make 3. Install the oil seal housing, and then
sure to remove the reverse gear. tighten the pinion nut to the specified
torque. See steps 4 and 5 in “Installing
2. Remove the retainer, reverse gear the drive shaft” (8-28).
shims, and needle bearing. See steps 2
and 3 in “Disassembling the lower case” Installing the propeller shaft housing
(8-82). assembly
1. Install new O-rings and set the shift rod
Checking the pinion and reverse joint and dog clutch to the N position.
gear See steps 1 and 2 in “Installing the pro- 8
1. Check the pinion and reverse gear. See peller shaft housing assembly” (8-84).
“Checking the pinion and reverse gear”
(8-83). 2. Install the propeller shaft housing assem-
bly, cover, water inlet covers, and water
Checking the drive shaft pipe. See steps 4–7 in “Installing the pro-
1. Check the drive shaft. See “Checking the peller shaft housing assembly” (8-35).
drive shaft” (8-26).
Checking the lower case 1. Install the shift rod. See “Installing the
1. Check the lower case. See “Checking the shift rod” (8-84).
1. Install the water pump. See steps 1–3
and 5 in “Installing the water pump” (8-
30).
8-88
LOWR
Lower unit
leakage
1. Check the lower unit for air leakage. See
(8-31).
Installing the lower unit

31).

proper level. See steps 5–8 in “Changing
gear oil” (10-11).
8-89
Drive shaft and lower case (FL250G) / Shimming (counter rotation model)
Shimming (counter rotation model)

Shimming workflow
Remove the water pump

assembly.
Measure the backlash before

disassembly.
YES
Within specification? Shimming is not required.
NO
Disassemble the lower unit.
Select the pinion shims (T3)

and propeller shaft shims (T4).
Assemble the lower unit.
Measure the backlash.
Adjust the forward gear shim

NO
Within specification? (T2) thickness and reverse gear
shim (T1) thickness.
YES
Install the water pump assem-
bly.
TIP:
• 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.
8-90
LOWR
Lower unit
Shimming check sheet
Lower case deviation
Serial number P F R 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
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
Reverse gear backlash (mm)

Measurements
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
8-91
Forward gear shim (T2) thickness measurement in 2 places (mm)
0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total
Reverse gear shim (T1) thickness measurement in 2 places (mm)

0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total
8-92
LOWR
Lower unit
Measuring the forward gear backlash 5. Tighten the center bolt 4 to the specified
and reverse gear backlash before torque while holding the drive shaft not to
disassembly turn.
Two pieces of washers (90201-31M00) are
required to measure the reverse gear back- 4
lash for the shim adjustment on the counter
rotation model. Please prepare the washers
before starting procedure.
1. Remove the water pump assembly and

outer plate cartridge. See steps 1 and 2
in “Removing the water pump and shift
rod” (8-9). (FL200B) See steps 1 and 2 in
(8-13). (FL250G)

Center bolt 4 (shimming):
R 20 N·m (2.0 kgf·m, 14.8 ft·lb)
N 6. Turn the lower unit so that it is in an

1 upright position.
F
7. Remove the cover 5, and then install the
outer plate cartridge 6.
3. Set up the special service tools 2, 3, 5

and 4, and then tighten the center bolt
4 temporarily.
2 3
4

90890-06502
Center bolt 4: 90890-06504 8. Place the spring 7 on the outer plate
cartridge, and then install the handle
4. Turn the drive shaft 10 times or more to holder 8 so that the spring 7 is com-
seat the bearings. pressed the specified compression dis-
tance a from its free length.
8-93
Backlash indicator 9: 90890-06706

Magnet base plate 0: 90890-07003
Dial gauge set A: 90890-01252
Magnet base B B: 90890-06844
8
11. Turn the drive shaft slowly clockwise and
a counterclockwise and measure the back-
7 lash between where the drive shaft stops
in each direction.
Spring 7: 90501-450A2
Handle holder 8: EU0-23814-30
Compression distance a:
3.0–5.0 mm (0.118–0.197 in)
TIP:
• After installing the handle holder, pull the
drive shaft up to confirm that there is no
free play.
• Do not compress the spring more than 5.0 TIP:
mm (0.197 in). Otherwise, the drive shaft • The resistance force of the spring makes it
will not turn easily, making it difficult to difficult to turn the drive shaft. Therefore, to
obtain correct measurements. obtain correct measurements, consider the
spring resistance force when turning the
drive shaft.
9. Install the special service tool 9 at the
• Do not turn the drive shaft using too much
lowest possible position where the drive
force. Otherwise, the forward gear will turn,
shaft diameter is 22.4 mm (0.882 in).
leading to incorrect measurements.
• When turning the drive shaft, hold it using a
10. Set up the special service tools 0, A,
and B.
little force. A knocking sound may be heard 8
when the drive shaft is turned, but this is
the sound of the pinion contacting the
9 reverse gear and does not affect the back-
lash measurement.
12. Turn the drive shaft 180° clockwise and

measure the backlash again.
B
0
A
8-94
LOWR
Lower unit
assembly. See step 1 in “Removing the
propeller shaft housing assembly” (8-16)
and step 2 in “Removing the propeller
b
shaft housing assembly” (8-73).
(FL200B) See steps 1 and 2 in “Remov-
ing the propeller shaft housing assembly”
c
e (8-22) and step 2 in “Removing the pro-
(FL250G)
17. Install the washers C between the

d reverse gear D and the propeller shaft
E.
TIP:
C
• Measure the backlash at 4 points: b, c,
d, and e, turning the drive shaft 180°
clockwise after each measurement.
• Write down the measurement data in the
shimming check sheet.
13. Determine the backlash average, and

then round down the average to the
1/100 place.
Example: E
(mm)
Measuring point b 0.60 C
Measuring point c 0.51 D
Measuring point d 0.51
Measuring point e 0.55
Average 0.5425
Round-down average 0.54
14. Check that the forward gear backlash Washer C: 90201-31M00

Forward gear backlash: bly (without the O-ring and dog clutch).
0.46–0.82 mm (0.0181–0.0323 in) See step 2 in “Installing the propeller
shaft housing assembly” (8-84) and step
TIP: 4 in “Installing the propeller shaft housing
Adjust the shim thicknesses if the forward assembly” (8-29). (FL200B) See step 2 in
gear backlash is out of specification. “Installing the propeller shaft housing
assembly” (8-84) and step 4 in “Installing
15. Remove the special service tools from the propeller shaft housing assembly” (8-
the propeller shaft. 35). (FL250G)
19. Check that the drive shaft turns

smoothly.
8-95
20. Repeat steps 12 and 13 to measure the
reverse gear backlash.
21. Check that the reverse gear backlash

Reverse gear backlash:
0.43–0.96 mm (0.0169–0.0378 in)
TIP:
Adjust the shim thicknesses if the reverse
22. Remove the special service tools, handle

holder, spring, and outer plate cartridge.

assembly, and then remove the washers
C. See step 1 in “Removing the propeller
shaft housing assembly” (8-16) and step
2 in “Removing the propeller shaft hous-
ing assembly” (8-73). (FL200B) See step
2 in “Removing the propeller shaft hous-
ing assembly” (8-22) and step 2 in
“Removing the propeller shaft housing
assembly” (8-79). (FL250G)

bly. See step 2 in “Installing the propeller
shaft housing assembly” (8-84) and
steps 4 and 5 in “Installing the propeller
(FL200B) See step 2 in “Installing the
propeller shaft housing assembly” (8-84)
and steps 4 and 5 in “Installing the pro-
8
(FL250G)
25. Install the cover, outer plate cartridge,

and water pump assembly. See “Install-
ing the water pump” (8-30). (FL200B)
See steps 1–3 and 5 in “Installing the
water pump” (8-30). (FL250G)
8-96
LOWR
Lower unit
Shimming
• Before selecting the forward gear shims (T2) and reverse gear shims (T1), 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.
Shim location (FL200B)
T3 F
P
R
T2 T4
T1
8-97
Shim location (FL250G)
T3 F
P
R
T2 T4
T1
8-98
LOWR
Lower unit
Selecting the pinion shim (T3) Propeller shaft shim (T4) thickness adjust-
See “Selecting the pinion shim (T3)” (8-45). ment = 0.15 mm b
The current shim thickness must be
Pinion shim (T3) selection table increased by 0.15 mm.
See “Pinion shim (T3) selection table” (8-48).
Selecting the propeller shaft shim È 0.18 0.26 0.28 0.30

(T4) É –0.10 –0.10
1. Install the original propeller shaft shims,
and then assemble the propeller shaft È 0.36 0.44 0.46 0.48
housing assembly. See steps 2–10 in É +0.10 +0.12 +0.15 +0.15
assembly” (8-74). a b
TIP: È Free play measurement

• If the original shims are missing, measure É Shim thickness adjustment
the free play without any shims.
TIP:
scratched. • If the shim thickness adjustment value is
2. Set up the special service tools 1 and value is negative, the current shim thick-
2, and then measure the propeller shaft ness must be decreased by that amount.
free play. • The gray-colored cells on the selection
table indicate the specified propeller shaft
free play. Shimming is not required if the
measured propeller shaft free play is 0.25–
0.35 mm.
2 • The values for the shim thickness adjust-
ments specified in the selection table are
intended to obtain the specified propeller
1 shaft free play of 0.3 mm.
4. Calculate the new propeller shaft shim

(T4) thickness.
New propeller shaft shim (T4) thickness =
Current propeller shaft shim thickness +
Dial gauge set 1: 90890-01252 Shim thickness adjustment
Magnet base B 2: 90890-06844 Example:
Propeller shaft free play: Use the following formula when the shim
0.25–0.35 mm (0.0098–0.0138 in) thickness adjustment value is negative.
Current propeller shaft shim thickness = 0.82
3. Determine the propeller shaft shim (T4) mm
thickness adjustment using the “propeller Shim thickness adjustment = –0.15 mm
shaft shim (T4) selection table” according New propeller shaft shim (T4) thickness
to the free play measurement. = 0.82 mm + (–0.15) mm
Example: = 0.67 mm
Free play measurement = 0.46 mm a
8-99

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
mm
TIP:
Use up to 3 shims to obtain the required shim
thickness.

16).
6. Remove the propeller shaft assembly.

See steps 2–5 in “Disassembling the pro-
7. Install the selected propeller shaft shims

(T4), and then assemble the propeller
shaft housing. See steps 2–10 in
assembly” (8-74).
8-100
LOWR
Lower unit
Propeller shaft shim (T4) selection table
The shim thickness does not have to be adjusted for the gray-colored cell.
(mm)
È 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16
É –0.28 –0.25 –0.25 –0.22 –0.20 –0.18 –0.15 –0.15 –0.12
È 0.18 0.20 0.22 0.24 0.26 0.28 0.30 0.32 0.34

É –0.10 –0.10 –0.10 –0.10 –0.10
È 0.36 0.38 0.40 0.42 0.44 0.46 0.48 0.50 0.52

É +0.10 +0.10 +0.10 +0.10 +0.12 +0.15 +0.15 +0.18 +0.20
È 0.54 0.56 0.58 0.60 0.62 0.64 0.66 0.68 0.70

É +0.22 +0.25 +0.25 +0.28 +0.30 +0.32 +0.35 +0.35 +0.38
È 0.72 0.74 0.76 0.78 0.80 0.82 0.84 0.86 0.88

É +0.40 +0.42 +0.45 +0.45 +0.48 +0.50 +0.52 +0.55 +0.55
È 0.90 0.92 0.94 0.96 0.98 1.00 1.02 1.04 1.06

É +0.58 +0.60 +0.62 +0.65 +0.65 +0.68 +0.72 +0.72 +0.75
È 1.08 1.10 1.12 1.14 1.16 1.18 1.20 1.22 1.24

É +0.75 +0.78 +0.80 +0.82 +0.85 +0.85 +0.88 +0.90 +0.92
È 1.26 1.28 1.30 1.32 1.34 1.36 1.38 1.40 1.42

É +0.95 +0.95 +0.98 +1.00 +1.02 +1.05 +1.05 +1.08 +1.10
È 1.44 1.46 1.48 1.50 1.52

É +1.12 +1.15 +1.15 +1.18 +1.20
È Free play measurement
8-101
Measuring the forward gear backlash Adjusting the forward gear shim (T2)
• Spray anti-rust lubricant on the gears and thickness
bearings before installation. Do not apply 1. Remove the propeller shaft housing
gear oil to the parts. Otherwise, correct assembly. See step 1 in “Removing the
measurements cannot be obtained. propeller shaft housing assembly” (8-16)
• Keep the parts free of foreign material, and step 2 in “Removing the propeller
such as dirt and lint. shaft housing assembly” (8-73).
• When measuring the forward gear or (FL200B) See step 2 in “Removing the
reverse gear backlash, use the original propeller shaft housing assembly” (8-22)
bearings and shims. and step 2 in “Removing the propeller
1. Install the original forward gear shims, (FL250G)
and then assemble the propeller shaft
housing assembly. See steps 7–10 in 2. Remove the original forward gear shim.
“Assembling the propeller shaft housing See step 2 in “Disassembling the propel-
assembly” (8-74). ler shaft housing assembly” (8-73).
TIP: 3. Measure the thickness of each original

• If the original shims are missing, install new forward gear shim in 2 places.
shims with a combined thickness of 1.12
mm. TIP:
• Do not reuse a shim if deformed or Do not reuse a shim if deformed or
scratched. scratched.
2. Install the propeller shaft housing assem- 4. Determine the forward gear shim (T2)
bly (without the O-ring and dog clutch). thickness adjustment using the “Forward
See step 2 in “Installing the propeller gear shim (T2) selection chart” according
shaft housing assembly” (8-84) and step to the backlash measurement (BL2) from
4 in “Installing the propeller shaft housing “Measuring the forward gear backlash.”
assembly” (8-29). (FL200B) See step 2 in See “Forward gear shim (T2) selection
“Installing the propeller shaft housing chart” (8-104).
assembly” (8-84) and step 4 in “Installing Example:
the propeller shaft housing assembly” (8- Backlash measurement (BL2) = 0.90 mm a
35). (FL250G) Forward gear shim (T2) thickness adjustment
= 0.18 mm b 8
3. Check that the drive shaft turns The current shim thickness must be
smoothly. increased by 0.18 mm.
4. Measure the forward gear backlash. See

steps 2–14 in “Measuring the forward
gear backlash and reverse gear backlash
before disassembly” (8-93).
Forward gear backlash:
0.46–0.82 mm (0.0181–0.0323 in)
TIP:
In the “Forward gear shim (T2) selection
8-102
LOWR
Lower unit
Current forward gear shim thickness = 1.12
É (mm)
0.20 mm
New forward gear shim (T2) thickness = 1.12
0
b mm + (–0.20) mm = 0.92 mm
–0.20 Available shim thicknesses:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
mm
–0.40
TIP:
–0.60 • Use the least number of shims to obtain the
0 5 80 85 90
required shim thickness.
È (1/100 mm) • If the calculated shim thickness cannot be
a
È 0 5 80 85 90 able shims, increase the shim thickness by
0.01 mm.
É –0.45 –0.42 0.15 0.18
È Backlash measurement (BL2) 6. Install the determined forward gear

É Shim thickness adjustment shims (T2), and then assemble the pro-
peller shaft housing assembly. See steps
TIP: 7–10 in “Assembling the propeller shaft
• If the shim thickness adjustment value is housing assembly” (8-74).
ored area.
the range for the specified forward gear
backlash.
5. Calculate the new forward gear shim (T2)

thickness.
New forward gear shim (T2) thickness =
Current forward gear shim thickness +
Example:
8-103
Forward gear shim (T2) selection chart
1.00
0.80
0.60
0.40
0.20
É (mm)
0
Continue next page
–0.20
–0.40
–0.60
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
È (1/100 mm)
È 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
É –0.45 –0.42 –0.38 –0.35 –0.32 –0.28 –0.24 –0.20 –0.16 –0.13 0.04 0.07 –0.03 0.01 0.04 0.08 0.11 0.15 0.18 0.23 0.26

8-104
8
8-105
1.00
LOWR
0.80
0.60
0.40
0.20
Lower unit
É (mm)
0
–0.20
–0.40
–0.60
100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
È (1/100 mm)
È 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
É 0.26 0.29 0.34 0.36 0.40 0.43 0.46 0.50 0.54 0.56 0.60 0.64 0.68 0.71 0.75 0.78 0.82 0.86 0.89 0.93 0.96

Measuring the reverse gear backlash 7. Measure the reverse gear backlash. See
• Spray anti-rust lubricant on the gears and steps 12, 13, and 21 in “Measuring the
bearings before installation. Do not apply forward gear backlash and reverse gear
gear oil to the parts. Otherwise, correct backlash before disassembly” (8-93).
measurements cannot be obtained. Reverse gear backlash:
• Keep the parts free of foreign material, 0.43–0.96 mm (0.0169–0.0378 in)
such as dirt and lint.
• When measuring the forward gear or TIP:
reverse gear backlash, use the original In the “Reverse gear shim (T1) selection
bearings and shims. chart,” use the round-down average for the
1. Install the original reverse gear shims.
TIP: Adjusting the reverse gear shim (T1)

• If the original shims are missing, install new thickness
shims with a combined thickness of 0.65 1. Remove the propeller shaft housing
mm. assembly. See step 1 in “Removing the
• Do not reuse a shim if deformed or propeller shaft housing assembly” (8-16)
scratched. and step 2 in “Removing the propeller
2. Install the retainer. See steps 3 and 4 in (FL200B) See step 2 in “Removing the
“Assembling the lower case” (8-83). propeller shaft housing assembly” (8-22)
and step 2 in “Removing the propeller
3. Install the thrust bearing and reverse shaft housing assembly” (8-79).
gear assembly into the lower case. (FL250G)
4. Install the pinion shims, drive shaft, pin- 2. Remove the retainer and original reverse
ion, and oil seal housing. See steps 2–5 gear shims. See step 2 in “Disassem-
in “Installing the drive shaft” (8-28). bling the lower case” (8-82).
(FL200B) See steps 2 and 3 in “Installing
the drive shaft” (8-35) and steps 4 and 5 3. Measure the thickness of each original
in “Installing the drive shaft” (8-28). reverse gear shim in 2 places.
(FL250G)
TIP:
5. Install the 2 pieces of washers (90201-
31M00) and propeller shaft housing
scratched.
8
assembly (without the O-ring and dog
clutch). See step 2 in “Installing the pro- 4. Determine the reverse gear shim (T1)
peller shaft housing assembly” (8-84) thickness adjustment using the “Reverse
and step 4 in “Installing the propeller gear shim (T1) selection chart” according
shaft housing assembly” (8-29). to the backlash measurement (BL1) from
(FL200B) See step 2 in “Installing the “Measuring the reverse gear backlash.”
propeller shaft housing assembly” (8-84) See “Reverse gear shim (T1) selection
and step 4 in “Installing the propeller chart” (8-108).
shaft housing assembly” (8-35). Example:
(FL250G) Backlash measurement (BL1) = 1.00 mm a
Reverse gear shim (T1) thickness adjustment
6. Check that the drive shaft turns = 0.28 mm b
smoothly. The current shim thickness must be
increased by 0.28 mm.
8-106
LOWR
Lower unit
Current reverse gear shim thickness = 0.65
b mm
0.20
New reverse gear shim (T1) thickness = 0.65
0 mm + (–0.23) mm = 0.42 mm
É (mm)

–0.20
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
mm
–0.40
TIP:
–0.60 • Use the least number of shims to obtain the
0 5 90 95 100 required shim thickness.
È (1/100 mm) a • If the calculated shim thickness cannot be
È 0 5 10 95 100 able shims, increase the shim thickness by
0.01 mm.
É –0.43 –0.40 –0.37 0.28
È Backlash measurement (BL1) 6. Install the determined reverse gear

É Shim thickness adjustment shims (T1) and retainer. See steps 3 and
4 in “Assembling the lower case” (8-83).
TIP:
• If the shim thickness adjustment value is
ored area.
the range for the specified reverse gear
backlash.
5. Calculate the new reverse gear shim (T1)

thickness.
New reverse gear shim (T1) thickness =
Current reverse gear shim thickness +
Example:
8-107
Reverse gear shim (T1) selection chart
1.00
0.80
0.60
0.40
0.20
É (mm)
0
Continue next page
–0.20
–0.40
–0.60
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
È (1/100 mm)
È 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
É –0.43 –0.40 –0.37 –0.33 –0.30 –0.25 –0.22 –0.18 –0.15 0.28

8-108
8
8-109
LOWR
1.00
0.80
0.60
0.40
Lower unit
0.20
É (mm)
0
–0.20
–0.40
–0.60
100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
È (1/100 mm)
È 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
É 0.28 0.32 0.34 0.38 0.42 0.45 0.48 0.53 0.56 0.59 0.63 0.68 0.70 0.73 0.77 0.81 0.84 0.88 0.91 0.95 0.98

— MEMO —
8-110
BRKT
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 ...................................................... 9-4
Installing the shift rod and shift bracket ...................................... 9-4
PTT switch and cowling lock lever ................................... 9-6

Removing the PTT switch .......................................................... 9-9
Removing the cowling lock lever ................................................ 9-9
Removing the flushing hose and cooling water hose ................. 9-9
Installing the flushing hose and cooling water hose ................. 9-10
Installing the cowling lock lever ................................................ 9-11
Installing the PTT switch .......................................................... 9-11
Bottom cowling ................................................................ 9-12
Upper case and mounts .................................................. 9-14

Removing the upper case ........................................................ 9-16
Installing the upper case .......................................................... 9-16
Upper case ........................................................................ 9-18

Disassembling the upper case ................................................. 9-20
Checking the drive shaft bushing ............................................. 9-20
Checking the PCV .................................................................... 9-20
Assembling the upper case ...................................................... 9-20
Oil pan and exhaust manifold ......................................... 9-22

Disassembling the oil pan and exhaust manifold ..................... 9-24
Checking the oil pan and exhaust manifold.............................. 9-24
Checking the oil strainer........................................................... 9-24
Assembling the oil pan and exhaust manifold .......................... 9-24
Steering arm ..................................................................... 9-27

Removing the steering arm ...................................................... 9-28
Installing the steering arm ........................................................ 9-28
Clamp bracket and swivel bracket ................................. 9-30

Removing the clamp bracket.................................................... 9-32
Checking the clamp bracket anode .......................................... 9-32
Installing the clamp bracket...................................................... 9-32
Adjusting the trim sensor.......................................................... 9-34
PTT unit ............................................................................. 9-36

Removing the PTT unit............................................................. 9-37
Checking the hydraulic pressure .............................................. 9-38
Bleeding the PTT unit............................................................... 9-40
Installing the PTT unit............................................................... 9-41
PTT motor ......................................................................... 9-43

Removing the reservoir ............................................................ 9-45
Removing the PTT motor ......................................................... 9-45
Disassembling the PTT motor .................................................. 9-45
Checking the armature (PTT motor)......................................... 9-46
Checking the brush .................................................................. 9-46
Assembling the PTT motor....................................................... 9-47
Installing the reservoir .............................................................. 9-48
Installing the PTT motor ........................................................... 9-49
PTT gear pump ................................................................. 9-50

Disassembling the gear pump assembly.................................. 9-53
Checking the gear pump .......................................................... 9-53
Assembling the gear pump assembly ...................................... 9-54
PTT cylinder...................................................................... 9-56

Removing the tilt ram ............................................................... 9-59
Removing the trim ram ............................................................. 9-59
Disassembling the tilt ram ........................................................ 9-59
Disassembling the trim ram...................................................... 9-60
Checking the tilt cylinder and PTT body................................... 9-60
Checking the valve ................................................................... 9-60
Assembling the tilt ram ............................................................. 9-61
Assembling the trim ram........................................................... 9-62
Installing the tilt cylinder ........................................................... 9-62
Installing the trim ram ............................................................... 9-63
Installing the tilt ram ................................................................. 9-63
9
BRKT
Bracket unit
Shift rod and shift bracket
18 N·m (1.8 kgf·m, 13.3 ft·Ib) 1 2 N·m (0.2 kgf·m, 1.5 ft·Ib) 1
27
19 2 N·m (0.2 kgf·m, 1.5 ft·Ib) 1 2
7
20 2 8
21
15
3
4 10
9
20
23 22 6
16
26 11 11
17 24
18 25 5 14
13 12
16
28
29
1 N·m (0.1 kgf·m, 0.7 ft·Ib)
19 N·m (1.9 kgf·m, 14.0 ft·Ib)

2 Plate 2
3 Neutral switch 1
4 Bushing 1
5 Bracket 1
6 Plastic tie 1
7 Shift cut switch 1
8 Bolt 2 M6 × 35 mm
9 Holder 1
10 Spring 1
11 Bushing 2
12 Bracket 1
13 Grease nipple 1
14 Bolt 1
15 Washer 1
16 Clip 2
17 Bushing 1
9-1
18 N·m (1.8 kgf·m, 13.3 ft·Ib) 1 2 N·m (0.2 kgf·m, 1.5 ft·Ib) 1
27
19 2 N·m (0.2 kgf·m, 1.5 ft·Ib) 1 2
7
20 2 8
21
15
3
4 10
9
20
23 22 6
16
26 11 11
17 24
18 25 5 14
13 12
16
28
29
1 N·m (0.1 kgf·m, 0.7 ft·Ib)
19 N·m (1.9 kgf·m, 14.0 ft·Ib)

18 Shift lever 1
19 Washer 1
20 Bushing 2
21 Bolt 1 M6 × 35 mm
22 Bracket 1
23 Ball 1
24
25
Spring
Shift rod detent bolt
1
1 9
26 Pin 1
27 Cotter pin 1 39
28 Shift rod 1
29 Grommet 1
9-2
BRKT
Bracket unit
Removing the shift rod and shift B
bracket C
1. Remove the shift cut switch coupler a. E
2. Remove the clip 1 and bushing 2, and
A D
then remove the shift bracket assembly
b, holder 3, and washer 4. 0
E
9
3
a 2
Disassembling the shift bracket
1
1. Remove the bracket 1, spring 2, and
bushings 3.
4 b
2
3
3
3. Remove the clip 5, and then remove the
shift lever 6 and bushing 7.
2. Remove the plastic tie 4, and then
4. Remove the shift rod assembly c and remove the plate 5 and neutral switch
grommet 8. 6.
c
5
6 7
8 6 4
5
3. Remove the plate 7 and shift cut switch

8.
4. Remove the grease nipple 9.

5. Remove the shift rod detent bolt 9,
spring 0, and ball A.
7
6. Remove the cotter pin B, washer C, 8
bracket D, and bushings E.
9-3
Assembling the shift bracket 0
1. Install the neutral switch 1 and plate 2,
and then tighten the neutral switch A
screws 3 to the specified torque. B
9
2. Fasten the neutral switch lead a using b
the plastic tie 4.
3
B c
2
a A
1 4 9
7. Turn the bracket B to position d, push it

down, and then tighten the shift bracket
bolt C to the specified torque. NOTICE:
Neutral switch screw 3: Before pushing the bracket B down,
2 N·m (0.2 kgf·m, 1.5 ft·lb) move the shift cut switch lever e in
direction f. Otherwise, the lever
3. Install the grease nipple 5, and then could be damaged.
4. Install the shift cut switch 6 and plate 7, B

and then tighten the shift cut switch
screws 8 to the specified torque.
B
8 d
7
6
f
e
C
5
Shift bracket bolt C:

Grease nipple 5:
19 N·m (1.9 kgf·m, 14.0 ft·lb)
1 N·m (0.1 kgf·m, 0.7 ft·lb)
Shift cut switch screw 8: Installing the shift rod and shift
9
2 N·m (0.2 kgf·m, 1.5 ft·lb)
bracket
5. Install the bushings 9 and spring 0 onto 1. Install the bushings 1, bracket 2, and
the bracket A. washer 3, and then install a new cotter
pin 4.
6. Fit the spring end b into the slot in the
bracket A and the spring end c into the 2. Install the ball 5 and spring 6, and then
slot in the bracket B. tighten the shift rod detent bolt 7 to the
specified torque.
9-4
BRKT
Bracket unit
4
3 C
1 e D
E
1 2 4
5
A
6
0
7
9 d
B
Shift rod detent bolt 7:
9
18 N·m (1.8 kgf·m, 13.3 ft·lb)
3. Install the bushing 8 and shift lever 9,

and then install the clip 0.
4. Install the grommet A and shift rod

assembly a.
0 a
9
8
b
A
TIP:
Align the center of the pin b on the shift lever
9 with the mark c on the bottom cowling.
5. Install the washer B, shift bracket

assembly d, and holder C, and then
install the bushing D and clip E to the
shift lever 9.
6. Install the shift switch coupler e.
9-5
Shift rod and shift bracket / PTT switch and cowling lock lever
PTT switch and cowling lock lever

8 5 N m (0.5 kgf m, 3.7 ft lb)
10 10
6 7 5 14
5 10
8
9 15 9
11 7 14
11 12 8
7 12 5 9
È 1 3 31 31 33 11
4 5 13 6
20 32 12 7
6 32 16
28 5
5 6
29
30
1 37 27 34
2
20 26
25
22
24 5
23 5
20
4
3
21 12
1
20
12 12
È 1
17 35
2
19 18
36

1 Gasket 2 39
2 PTT switch 1
3 Cover 1
4 Holder 2
5 Bolt 8 M6 × 20 mm/Regular rotation model
7 M6 × 20 mm/Counter rotation model
6
7
Hook
Spring
3
3 9
8 Bolt 3 M6 × 20 mm
9 Washer 3
10 Lever 3
11 Wave washer 3
12 Bushing 6
13 Housing (BOW) 1
14 Bolt 6 M6 × 30 mm
15 Housing (STBD) 1
16 Housing (PORT) 1
È Counter rotation model
9-6
BRKT
Bracket unit
8 5 N m (0.5 kgf m, 3.7 ft lb)

10 10
6 7 5 14
5 10
8
9 15 9
11 7 14
11 12 8
7 12 5 9
È 1 3 31 31 33 11
4 5 13 6
20 32 12 7
6 32 16
28 5
5 6
29
30
1 37 27 34
2
20 26
25
22
24 5
23 5
20
4
3
21 12
1
20
12 12
È 1
17 35
2
19 18
36

17 Cowling lock lever (PORT) 1
18 Cowling lock lever (STBD) 1
19 Cowling lock lever (BOW) 1
20 Plastic tie 5
21 Grommet 1
22 Hose 1
23 Joint 1
24 Joint 1
25 Gasket 1
26 Adapter 1
27 Hose 1
28 Joint 1
29 Hose 1
30 Clamp 1
31 Bolt 2 M6 × 25 mm
32 Plate 2
33 Screw 2 ø6 × 20 mm
9-7
8 5 N m (0.5 kgf m, 3.7 ft lb)

10 10
6 7 5 14
5 10
8
9 15 9
11 7 14
11 12 8
7 12 5 9
È 1 3 31 31 33 11
4 5 13 6
20 32 12 7
6 32 16
28 5
5 6
29
30
1 37 27 34
2
20 26
25
22
24 5
23 5
20
4
3
21 12
1
20
12 12
È 1
17 35
2
19 18
36

34 Holder 1
35 PTT switch wiring harness extension 1 Counter rotation model
36 Holder 1 Counter rotation model
37 Holder 1 Regular rotation model
9-8
BRKT
Bracket unit
Removing the PTT switch
1. Remove the holder 1 (regular rotation
model) or holder 2 (counter rotation
model) and holder 3, and then remove
the PTT switch 4 and gasket 5.
È
3
2
STBD
1
4 5 3
Removing the flushing hose and

É cooling water hose
3
1. Remove the adapter 1 and joints 2 and
3.
PORT 5 4
2 1
2
È Regular rotation model 3
É Counter rotation model
Removing the cowling lock lever

1. Remove the spring 1.
2. Remove the plates 4 and holder 5 (reg-

ular rotation model).
3. Remove the cooling water pilot hose 6,

cooling water hose 7, and joint 8.
2. Remove the lever 2 and cowling lock

lever 3.
9-9
7 TIP:
8 Align the white paint mark c on the flushing
hose 1 and the white tape d on the PTT
motor lead b with the inner end of the grom-
6
met 2.
4 5
2. Install the cooling water pilot hose 4,
cooling water hose 5, and joint 6, and
then fasten the hoses 4 and 5 using the
clamp 7 and plastic ties 8.
3. Route the flushing hose 1, cooling water

7 hose 5, trim sensor lead a, PTT motor
lead b, and speedometer hose 9.
4. Remove the flushing hose 9, trim sensor
lead a, PTT motor lead b, and grommet 4. Fasten the flushing hose 1, cooling
0. water hose 5, and trim sensor lead a
using the plates 0 and holder A (regular
0 rotation model).
5
6
9 4
8
b 7
a 0 A 1
Installing the flushing hose and

cooling water hose
b
1. Pass the flushing hose 1, trim sensor
lead a, and PTT motor lead b through 9
the grommet 2, and then fasten them a 5
using the plastic ties 3 around the grom-
5. Install the adapter B, and then tighten
met 2.
the flushing hose adapter screws C to
6. Route the flushing hose 1 through the 9

3 2 joint D, connect the flushing hose 1 to
the joint E, and then fasten the flushing
hose 1 using the plastic tie F.
1 3
2 c 1 7. Install the gasket G and joint D to the
3 adapter B.
a
d
b b 3
a
9-10
BRKT
Bracket unit
C 4
B
E
D G
1 Installing the PTT switch
0
Flushing hose adapter screw C: with a new one.
5 N·m (0.5 kgf·m, 3.7 ft·lb)
1. Install a new gasket 1, the PTT switch
Installing the cowling lock lever 2, and the holder 3.
1. Install the cowling lock lever 1 and lever
2. 2. Fasten the PTT switch lead a using the
holder 4 (regular rotation model) or
holder 5 (counter rotation model).
È
2 3
STBD
a
4
2 1
1
É
3
2. Install the spring 3.
PORT 1 2 a
3
È Regular rotation model

É Counter rotation model
TIP:
3. Inject grease into the housing 4 until To fasten the PTT switch lead, see “Wiring
grease comes out from the housing. harness routing” (5-6).
9-11
PTT switch and cowling lock lever / Bottom cowling
Bottom cowling
4
3 10 13
8
11
10
14 4
11
10
2 7 5
11
1
11 10 19
12
9 11
18
18
4
15
11 11
15 12 12 6
11
16
12
17

1 Bracket 1
2 Bolt 1 M6 × 30 mm
3 Bracket 1
4 Bolt 3 M6 × 20 mm
5 Bracket 1
6 Bracket 1
7
8
Bracket
Rivet
1
2 9
9 Water outlet 1
10 Bolt 4 M8 × 35 mm
11 Grommet 8
12 Collar 4
13 Rubber seal 1
14 Grommet 2
15 Grommet 2
16 Rubber seal 1
17 Grommet 1
9-12
BRKT
Bracket unit
4
3 10 13
8
11
10
14 4
11
10
2 7 5
11
1
11 10 19
12
9 11
18
18
4
15
11 11
15 12 12 6
11
16
12
17

18 Grommet 2
19 Bottom cowling 1
9-13
Bottom cowling / Upper case and mounts
Upper case and mounts

14 54 N m (5.4 kgf m, 39.8 ft lb)
18 19
13
17
16
11 15
72 N m (7.2 kgf m, 53.1 ft lb) 12 18
9 17 12 16 19
8 16
7 15
6 12
15 17 18
7 8 11
3 5
4
6 9
1 3 23
22 10
3 9
2 21 8 11
26
20 È 22 6 7
3
2 24
5 4
72 N m (7.2 kgf m, 53.1 ft lb) 25 26 20

1 Upper mounting nut 2
2 Lower mounting nut 2
3 Washer 4
4 Lower mount bracket bolt 4 M10 × 45 mm
5 Bracket 2
6 Washer 2
7
8
Lower mount
Washer
2
2 9
9 Washer 2
10 Ground lead 1
11 Lower mounting bolt 2 M14 × 205 mm
12 Upper mount 2
13 Bracket 1
14 Upper mount bracket bolt 3 M10 × 45 mm
15 Washer 2
16 Washer 2
17 Washer 2
È X-transom model
9-14
BRKT
Bracket unit
14 54 N m (5.4 kgf m, 39.8 ft lb)
18 19
13
17
16
11 15
72 N m (7.2 kgf m, 53.1 ft lb) 12 18
9 17 12 16 19
8 16
7 15
6 12
15 17 18
7 8 11
3 5
4
6 9
1 3 23
22 10
3 9
2 21 8 11
26
20 È 22 6 7
3
2 24
5 4
72 N m (7.2 kgf m, 53.1 ft lb) 25 26 20

18 Upper mounting bolt 2 M14 × 190 mm
19 Cap 2
20 Bolt 1 M6 × 10 mm
21 Nipple 1
22 Plastic tie 2
23 Hose 1
24 Dowel 1 X-transom model
25 Adapter 1 X-transom model
È X-transom model
9-15
Upper case and mounts
Removing the upper case Installing the upper case
1. Drain the remained engine oil. 1. Install the upper mounts 1 and upper
mounting bolts 2.
2. Disconnect the ground lead 1 and
adapter 2 (X-transom model). 2. Install the upper mount bracket 3, and
then tighten the upper mount bracket
3. Loosen the upper mount bracket bolts 3 bolts 4 temporarily.
and lower mount bracket bolts 4.
1 a 2
3
4 2
1
4
2
1 TIP:
Make sure that the notches a in the washer
2
are facing forward.
1
3. Install the lower mounts 5 and lower

4. Remove the upper mounting nuts 5 and
mounting bolts 6.
lower mounting nuts 6, and then remove
the upper case assembly a.
4. Install the lower mount brackets 7, and
then tighten the lower mount bracket
bolts 8 temporarily.
5 6
5
6 9
a
5
7 8
TIP:
The ground lead should be installed on the
same side as originally installed.
9-16
BRKT
Bracket unit
5. Install the upper and lower mounting
bolts into the bracket assembly b simul-
2 1
taneously. 4
3
6. Install the washers 9, upper mounting
nuts 0, and lower mounting nuts A, and
then tighten the upper mounting nuts 0
and lower mounting nuts A to the speci-
fied torque.
0
9
Upper mount bracket bolt 4:
54 N·m (5.4 kgf·m, 39.8 ft·lb)
b 9. Tighten the lower mount bracket bolts 8.
9 10. Connect the ground lead C.
11. Pass the speedometer hose D through

A 9 the steering arm E, and then connect it
to the adapter F (X-transom model).
Upper mounting nut 0:
72 N·m (7.2 kgf·m, 53.1 ft·lb)
Lower mounting nut A:
72 N·m (7.2 kgf·m, 53.1 ft·lb) D
7. Install the caps B. E
B
F 8
C
8. Tighten the upper mount bracket bolts 4 F
to the specified torque in the order 1, 2, C
and so on.
9-17
Upper case and mounts / Upper case
Upper case
4 N m (0.4 kgf m, 3.0 ft lb)
17 28 N·m (2.8 kgf·m, 20.7 ft·Ib)
20 N m (2.0 kgf m, 14.8 ft lb)
20 13
18 21
15 15 13
19 22 5 12
16 16
23
4
9 11
8
10
8 14
7
6 1
23 23
24
14
3
25
2
15
8 N m (0.8 kgf m, 5.9 ft lb)

1 Upper case 1
2 Circlip 1
3 Bushing 1
4 Rubber seal 1
5 Dowel 2
6 Damper 1
7
8
Cover
Bolt
1
2 M6 × 14 mm 9
9 Gasket 1 39
10 Drain bolt 1 M14 × 12 mm
11 Rubber seal 1
12 Baffle plate 1
13 Screw 2 M6 × 16 mm
14 Apron stay 6
15 Bolt 2 M8 × 30 mm
16 Dowel 2
17 PCV 1
9-18
BRKT
Bracket unit
4 N m (0.4 kgf m, 3.0 ft lb)

17 28 N·m (2.8 kgf·m, 20.7 ft·Ib)
20 N m (2.0 kgf m, 14.8 ft lb)
20 13
18 21
15 15 13
19 22 5 12
16 16
23
4
9 11
8
10
8 14
7
6 1
23 23
24
14
3
25
2
15
8 N m (0.8 kgf m, 5.9 ft lb)

18 O-ring 1 39
19 O-ring 1 39
20 Bolt 1 M6 × 20 mm
21 Plate 1
22 Collar 1
23 Bolt 6 M10 × 45 mm
24 Rubber seal 1
25 Rubber seal 1 39
9-19
Upper case
Disassembling the upper case Bearing puller assembly 9: 90890-06535
1. Remove the engine oil drain bolt 1, Stopper guide stand 0: 90890-06538
cover 2, and damper 3. Stopper guide plate A: 90890-06501
3 Checking the drive shaft bushing

2
1. Check the drive shaft bushing. Replace if
cracked or worn.
1
Checking the PCV
1. Check the PCV. Replace if cracked or
damaged.
Assembling the upper case

2. Remove the bolts 4 and 5 and PCV 6,
and then remove the oil pan assembly
a. Do not reuse a gasket, always replace it
with a new one.
5 4 6
4 4 1. Install the bushing 1, and then install the
circlip 2.
1 2
a 4
5 3
3

90890-06653
Driver rod L3 4: 90890-06652
2. Install the rubber seal 5 into the upper

3. Remove the circlip 7, and then remove
case.
the bushing 8.
5
7
9
0 a
8
9 0
TIP:
Face the “ ” mark a on the rubber seal 5
up.
9-20
BRKT
Bracket unit
3. Install the dowels 6.
Baffle plate screw 8:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
4. Install the baffle plate 7, and then
Oil pan assembly bolt (M8) B:
tighten the baffle plate screws 8 to the
20 N·m (2.0 kgf·m, 14.8 ft·lb)
specified torque.
Oil pan assembly bolt (M10) C:
5. Install the rubber seal 9 into the joint 42 N·m (4.2 kgf·m, 31.0 ft·lb)
hole b of the upper case. PCV F: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
Apron stay G:
6. Install a new rubber seal 0 and the rub- 8 N·m (0.8 kgf·m, 5.9 ft·lb)
ber seal A, and then install the oil pan
11. Install the damper I, the cover J, a new
assembly c.
gasket K, and the engine oil drain bolt
7. Tighten the oil pan assembly bolts B and L, and then tighten the engine oil drain
C to the specified torques. bolt L to the specified torque.
8. Install new O-rings D and E to the PCV I

J
F.
9. Install the PCV F, and then tighten it to

the specified torque. L
10. Install the apron stays G, and then

K
F
B D Engine oil drain bolt L:
E C 28 N·m (2.8 kgf·m, 20.7 ft·lb)
8
6
9 c
7
G
A
H
b 0
H
9
b
TIP:
Make sure to insert the tip of the water pipe
H into the joint hole b of the upper case.
9-21
Upper case / Oil pan and exhaust manifold
Oil pan and exhaust manifold

42 N m(4.2 kgf m, 31.0 ft lb)
1
10
20
12
2 11
11 21
3
13 22
4 4
24
23 25
5 16
6 14 26
17
7
8 15
9 27
18
19
20 N m(2.0 kgf m, 14.8 ft lb)
12 N m(1.2 kgf m, 8.9 ft lb)

1 Bolt 1 M10 × 45 mm
2 Upper exhaust guide 1
3 Gasket 1 39
4 Dowel 2
5 Lower exhaust guide 1
6 Gasket 1 39
7
8
Oil strainer
Collar
1
3 9
9 Bolt 3 M6 × 25 mm
10 Gasket 1 39
11 Dowel 2
12 Rubber seal 1
13 Oil pan 1
14 Gasket 1 39
15 Exhaust manifold 1
16 Bolt 10 M8 × 60 mm
17 Bolt 2 M8 × 35 mm
9-22
BRKT
Bracket unit
42 N m(4.2 kgf m, 31.0 ft lb)
1
10
20
12
2 11
11 21
3
13 22
4 4
24
23 25
5 16
6 14 26
17
7
8 15
9 27
18
19
20 N m(2.0 kgf m, 14.8 ft lb)
12 N m(1.2 kgf m, 8.9 ft lb)

18 Bolt 4 M8 × 90 mm
19 Rubber seal 1 39
20 Gasket 1 39
21 Plate 1
22 Water pipe 1
23 Rubber seal 1
24 Gasket 1 39
25 Dowel 2
26 Muffler 1
27 Bolt 10 M8 × 35 mm
9-23
Disassembling the oil pan and
exhaust manifold 5
1. Remove the oil pan assembly bolt 1.
1 6
2. Remove the muffler 2, plate 3, and

then remove the exhaust manifold 4.
2
4
Checking the oil pan and exhaust
manifold
1. Clean the removed parts.
2. Check the exhaust guides, exhaust man-

ifold, and muffler. Replace if corroded or
cracked.
3 3. Check the oil pan. Replace if corroded or

cracked.
Checking the oil strainer

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

3. Remove the oil pan 5, and then remove
manifold
the oil strainer 6.
Do not reuse a gasket or rubber seal,

always replace it with a new one.
9
and the lower exhaust guide 3.
2. Install a new gasket 4 and the oil

strainer 5, and then tighten the oil
strainer bolts 6 to the specified torque.
9-24
BRKT
Bracket unit
4. Install a new gasket B, the exhaust man-
5
6 ifold C, and a new rubber seal D, and
6 then tighten the exhaust manifold bolts
2 E temporarily.
D
E C
4
1 E
3
a 4
5
5. Tighten the exhaust manifold bolts E
first, and then tighten the oil pan bolts 0
Oil strainer bolt 6: and A to the specified torque.
12 N·m (1.2 kgf·m, 8.9 ft·lb)
Exhaust manifold bolt E:
TIP: 20 N·m (2.0 kgf·m, 14.8 ft·lb)
Make sure to fit the protrusions a on the Oil pan bolt 0 and A:
gasket 4 into the corresponding slots in the 20 N·m (2.0 kgf·m, 14.8 ft·lb)
oil strainer 5.
6. Install the rubber seal F and water pipe
G.
and the oil pan 9, and then tighten the 7. Install the dowels H, a new gasket I,
oil pan bolts 0 and A temporarily. the plate J, and a new gasket K, and
A then install the muffler L.
9 0
8
7
0
9-25
8. Tighten the muffler bolts M to the speci-
fied torque.
L
M M
H H
K
F
I
G
Muffler bolt M:
20 N·m (2.0 kgf·m, 14.8 ft·lb)
9. Tighten the oil pan assembly bolt N to

Oil pan assembly bolt N

42 N·m (4.2 kgf·m, 31.0 ft·lb)
9
9-26
BRKT
Bracket unit
Steering arm
2
3
4
5
2
6
8
7

1 Steering arm 1
2 Washer 2
3 Bushing 2
4 O-ring 1 39
5 Bushing 1
6 Steering yoke 1
7 Circlip 1
8 Grommet 1
9-27
Steering arm
Removing the steering arm
1. Remove the circlip 1, and then remove
the steering yoke 2 by striking it with a
copper hammer.
5
6
7
8
4. Install the steering yoke 9 so that the

1 steering arm and steering yoke 9 are
2 both facing in the same direction (a and
1
b are aligned).
2. Remove the steering arm from the swivel
b
bracket.
Installing the steering arm

with a new one.
1. Install the washer 1 and bushing 2 onto

the steering arm 3.
a
2. Place the bracket assembly 4 in an
upright position, and then install the
steering arm 3.
3 9
4
5. Hold the steering arm 3, and then strike
1
the steering yoke 9 using a copper ham- 9
2 mer until the groove c for installing the
circlip is visible.
6. Install the circlip 0.
3. Install the bushing 5, a new O-ring 6,

the bushing 7, and the washer 8.
9-28
BRKT
Bracket unit
9
c
0 0
7. Inject grease into the grease nipple A

until it comes out from both the upper
and lower bushings d.
9-29
Steering arm / Clamp bracket and swivel bracket
Clamp bracket and swivel bracket

4 5
3
5 6 10
9 8
10 11
2
22 2
12
1
15 16 2
18 2 30
16
4 N m (0.4 kgf m, 3.0 ft lb) 15
2
13
3 N m (0.3 kgf m, 2.2 ft lb) 6
25 2
24 26 24 25 21 17
25 25 24
26 18
24 20
10
27 23
31 19 14
32
29 28
32
34
33 33

1 Clamp bracket (STBD) 1
2 Grease nipple 6
4 Bolt 1 M6 × 14 mm
5 Holder 2
7
8
Trim sensor
Screw
1
2 M6 × 16 mm 9
9 Tilt stop lever 1
10 Bushing 3
11 Tilt stop lever 1
12 Nut 2
13 Through tube 1
14 Clamp bracket (PORT) 1
15 Washer 2
16 Bushing 2
17 Ground lead 1
9-30
BRKT
Bracket unit

4 5
3
5 6 10
9 8
10 11
2
22 2
12
1
15 16 2
18 2 30
16
4 N m (0.4 kgf m, 3.0 ft lb) 15
2
13
3 N m (0.3 kgf m, 2.2 ft lb) 6
25 2
24 26 24 25 21 17
25 25 24
26 18
24 20
10
27 23
31 19 14
32
29 28
32
34
33 33

18 Screw 4 M6 × 10 mm
19 Friction plate 1
20 Trim stopper 2
21 Ground lead 1
22 Friction plate 1
23 Collar 1
24 Distance collar 2
25 Pin 2
26 Pin 1
27 Spring 1
28 Hook 1
29 Bolt 1 M6 × 10 mm
30 Swivel bracket 1
31 Anode 1
32 Plate 2
33 Bolt 4 M6 × 25 mm
34 Ground lead 1
9-31
Removing the clamp bracket
1. Remove the PTT unit. See “Removing
the PTT unit” (9-37).
2. Remove the anode 1. A A

9
3. Remove the ground leads 2 and 3. 0
4. Remove the self-locking nut 4 and

through tube 5, and then disassemble
the clamp brackets 6 and 7.
7. Remove the tilt stop levers B and C,
distance collar assembly a, collar D,
and bushings E.
C E
2
3
a
4 E
B
E
D
7
1 6 5
Checking the clamp bracket anode
1. Check the anode. Replace if eroded.
5. Remove the trim sensor 8.
paint to the anode.
8 Installing the clamp bracket

1. Assemble the distance collar assembly.
a
9
6. Remove the spring 9, hook 0, and pins
A.
Distance a:
30.3–30.4 mm (1.193–1.197 in)
9-32
BRKT
Bracket unit
2. Install the bushings 1, collar 2, distance
collar assembly b, and tilt stop levers 3
and 4.
3
4 0
b
1 6. Install the through tube A with its flat cor-
2
1 ner d pointing down.
7. Tighten the self-locking nut B tempo-

rarily.
8. Install the anode C.

3. Install the pins 5, hook 6, and spring TIP:
7.
Face the top of the “DO NOT PAINT” mark e
5 5 on the anode C forward.
9. Tighten the self-locking nut B to the

c specified torque.
10. Install the grease nipples D, and then

tighten them to the specified torque.
11. Install the friction plates E and F, and

7
5 then tighten the friction plate screws G to
D
6
D
Distance c: 3.0 mm (0.12 in)
D
4. Install the trim sensor 8, and then D
tighten the trim sensor screws 9 tempo-
rarily.
B
A
D
8 G d
F
e
E
9 C A
5. Install the trim stoppers 0.
9-33
Self-locking nut B:
22 N·m (2.2 kgf·m, 16.2 ft·lb)
Grease nipple D: 1
3 N·m (0.3 kgf·m, 2.2 ft·lb)
Friction plate screw G:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
12. Inject grease into the grease nipples until

grease comes out from the bushings f.
2. Loosen the trim sensor screws 2.
3. Adjust the position of trim sensor, and

then tighten the trim sensor screws 2
temporarily.
2
f
b a
TIP:
:
• To decrease the resistance, turn the trim

sensor cam in direction a.
• To increase the resistance, turn the trim
13. Adjust the trim sensor. See “Adjusting sensor cam in direction b.
the trim sensor” (9-34).
14. Install the PTT unit. See “Installing the 4. Fully tilt the swivel bracket down.
PTT unit” (9-41).
5. Measure the trim sensor setting resis-
Adjusting the trim sensor tance. Check that the resistance is within
specification.
After tilting the swivel bracket up, make 9

sure to support it with the tilt stop lever.
Otherwise, the swivel bracket could sud- c d
denly lower.
d
1. Fully tilt the swivel bracket up, and then
support it using the tilt stop lever 1. c
9-34
BRKT
Bracket unit
Trim sensor setting resistance:

Terminal c –Terminal d
9.0–11.0 Ω

support it using the tilt stop lever.
7. Tighten the trim sensor screws 2 to the

specified torque.
Trim sensor screw 2:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
8. Fully tilt the swivel bracket down, and

then check the trim sensor resistance.
9-35
Clamp bracket and swivel bracket / PTT unit
PTT unit
1
2
5
4
4
5
9
9 9
42 N m (4.2 kgf m, 31.0 ft lb)

7
8

1 Shaft 1
2 Circlip 2
3 Plastic tie 4
4 Bushing 2
5 Bushing 2
6 PTT unit 1
7
8
Ground lead
Bolt
1
1 M6 × 10 mm 9
9 Bolt 8 M10 × 45 mm
9-36
BRKT
Bracket unit
Removing the PTT unit
When removing the PTT unit with the 3 3

pend the outboard motor. 3
3
support it using the tilt stop lever 1. a
3. Disconnect the ground lead 4.

1
4. Remove the circlips 5, and shaft 6.
5
4
2
5. Connect the PTT motor leads a to the

battery terminals to fully retract the PTT
rams.
a
TIP:
If the PTT unit does not operate, open the
manual valve 2 by turning it counterclock-
Lg Sb
wise, and then tilt the swivel bracket up man-
ually.
2. Remove the plastic ties 3, and then pull

out the PTT motor lead a from the clamp Battery
Ram PTT motor lead
bracket (STBD). terminal
Light green (Lg)
Down
Sky blue (Sb)
9-37
PTT unit
6. Remove the PTT unit 7.
TIP:
If the fluid is at the proper level, a small
amount of fluid should flow out of the filler
hole.
4. If the fluid is below the proper level, add

the recommended fluid.
Recommended PTT fluid: ATF Dexron II
5. Install the reservoir cap 1, and then

Reservoir cap 1:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
7 6. Loosen the pipe joints 2, and then

remove the pipe joint at end a.
7. Install the special service tool 3.

Checking the hydraulic pressure a
Check the hydraulic pressure. Check the 2
internal parts if out of specification.
3
Before removing the reservoir cap, make
sure that the PTT rams are fully extended.
Otherwise, fluid could be expelled force-
fully from the PTT unit due to internal
pressure.
1. Fully extend the PTT rams.
2. Place the PTT unit in an upright position.

PTT oil pressure gauge assembly 3:
3. Remove the reservoir cap 1, and then 90890-06580
check the fluid level in the reservoir.
TIP:
Place the PTT unit in the drain pan. 9
8. Connect the PTT motor leads to the bat-
tery terminals to fully retract the trim
rams, and then measure the hydraulic
1 pressure when the reading on the pres-
sure gauge stabilizes.
9-38
BRKT
Bracket unit
Pipe joint 2:
15 N·m (1.5 kgf·m, 11.1 ft·lb)

tery terminals to fully retract the PTT
rams.
Lg Sb
13. Loosen the pipe joints 4, and then
remove the pipe joint at end b.
14. Install the special service tool 3.
Battery b
Ram PTT motor lead
terminal
Light green (Lg)
Down
Sky blue (Sb)
4
Hydraulic pressure (down) (reference
data): 6.7–8.7 MPa (67.0–87.0 kgf/cm2, 3
971.5–1261.5 psi)
9. Reverse the PTT motor leads between

the battery terminals to fully extend the
trim rams. PTT oil pressure gauge assembly 3:
90890-06580

tery terminals to fully extend the trim
rams, and then measure the hydraulic
pressure when the reading on the pres-
Sb Lg sure gauge stabilizes.
Sb Lg
Battery
Ram PTT motor lead
terminal
Sky blue (Sb)
Up
Light green (Lg)
10. Remove the special service tool 3.
11. Install the pipe joints 2, and then tighten

9-39
PTT unit
Battery
Ram PTT motor lead
terminal
Sky blue (Sb)
Up
Light green (Lg)
Hydraulic pressure (up) (reference data):

Sb Lg
13.0–15.0 MPa (130.0–150.0
kgf/cm2, 1885.0–2175.0 psi)

the battery terminals to fully retract the
trim rams. 4
Lg Sb 21. Repeat steps 3–5 to check the fluid level.
Bleeding the PTT unit

2. Close the manual valve 1 by turning it

clockwise.
1
Battery
Ram PTT motor lead
terminal
Light green (Lg)
Down
Sky blue (Sb)
17. Remove the special service tool 3.
18. Install the pipe joints 4, and then tighten

Pipe joint 4: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
19. After measuring the hydraulic pressure,

connect the PTT motor leads to the bat-
Manual valve 1:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
9
tery terminals to fully extend the PTT
rams. 3. Check the fluid level. See steps 3–5 in
“Checking the hydraulic pressure” (9-38).

tery terminals to fully retract the PTT
rams.

the battery terminals to fully extend the
PTT rams.
9-40
BRKT
Bracket unit
Lg Sb
Lg Sb
Battery
Ram PTT motor lead
terminal
Light green (Lg)
Down
Sky blue (Sb)
Sb Lg
support it using the tilt stop lever 1.
Battery
Ram PTT motor lead
terminal 1
Light green (Lg)
Down
Sky blue (Sb)
Sky blue (Sb)
Up
Light green (Lg)
TIP:
If the PTT rams do not move up and down
easily, push and pull on the PTT rams to
assist operation.
6. Check the fluid level when the PTT rams

3. Install the bushings 2 and 3 to the tilt
are fully extended. If the fluid level is low,
ram end and swivel bracket.
add sufficient fluid, and then repeat steps
4 and 5. 4. Install the PTT unit 4, and then tighten
the PTT unit bolts 5 to the specified
Installing the PTT unit
torque.
• After tilting the swivel bracket up, make

sure to support it using the tilt stop
lever.
• When installing the PTT unit with the
pend the outboard motor.
1. Connect the PTT motor leads a to the

battery terminals to retract the PTT rams.
9-41
PTT unit
2 7
3
5
23
5
8
5 9. Fasten the PTT motor lead a and trim

4 sensor lead using the plastic ties 9.
PTT unit bolt 5:

42 N·m (4.2 kgf·m, 31.0 ft·lb) 9 9
5. Pass the PTT motor lead a through the 9

hole b in the clamp bracket (STBD).
9
6. Connect the PTT motor leads a to the a
battery terminals to extend the PTT
rams.
a a
Sb Lg
Ram PTT motor lead

Battery
terminal
9
Sky blue (Sb)
Up
Light green (Lg)
7. Insert the shaft 6, and then install the

circlips 7.
8. Connect the ground lead 8.
9-42
BRKT
Bracket unit
PTT motor
7 N m (0.7 kgf m, 5.2 ft lb) 19 N m (1.9 kgf m, 14.0 ft lb) 9
8
8
7 12
9 13
8
8 13
8
8
4 14
6
5 15
3 10
2 16
1
11
15
19
18 17 18
18 18
17 17
20
17
21

1 Spacer 1
2 Filter 1
3 Sheet 1
4 O-ring 1 39
5 Reservoir cap 1
6 O-ring 1 39
7 Reservoir 1
8 Bolt 6 M8 × 20 mm
9 PTT motor assembly 1
10 O-ring 1 39
11 Joint 1
12 Stator 1
13 Bolt 2 M5 × 12 mm
14 Wave washer 1
15 Bearing 2 39
16 Armature 1
17 Brush 4
9-43
PTT motor
7 N m (0.7 kgf m, 5.2 ft lb) 19 N m (1.9 kgf m, 14.0 ft lb) 9

8
8
7 12
9 13
8
8 13
8
8
4 14
6
5 15
3 10
2 16
1
11
15
19
18 17 18
18 18
17 17
20
17
21

18 Spring 4
19 O-ring 1 39
20 Motor base assembly 1
21 Oil seal 1 39
9-44
BRKT
Bracket unit
Removing the reservoir Disassembling the PTT motor
1. Remove the PTT motor bolts 1, and
then remove the stator 2. NOTICE:
Before removing the reservoir, make sure Secure the end of the armature shaft
that the PTT rams are fully extended. Oth- using a pair of pliers, and then remove
erwise, fluid could be expelled forcefully the armature 3 along with the motor
from the PTT unit due to internal pres- base assembly. Otherwise, the arma-
sure. ture could separate from the motor
base assembly due to the magnetic
1. Remove the reservoir 1, O-ring 2, filter force of the stator 2 and damage the
3, and spacer 4. brushes.
2 1
1
2 3
3
2. Remove the armature 3.
4
3. Remove the springs 4 and brushes 5.
5 4
TIP: 4 5
Place a container under the PTT unit to catch
the fluid. 5
4 5 4
Removing the PTT motor
1. Remove the PTT motor assembly 1, O-
ring 2, and joint 3.
1 4. Remove the bearing 6.
2 6
6
3 7
7 7
9-45
PTT motor
Bearing splitter 7:
TIP:
Before removing the bearing, measure and
write down the bearing depth a.
5. Remove the bearing 8.

a
Motor commutator standard diameter a:

9 23.0 mm (0.91 in)
9 8 Wear limit: 22.0 mm (0.87 in)
3. Check the armature for continuity.

8
Replace if out of specifications.
7 7
7
8
b
b
c
d e
Bearing splitter 7:
Bolt 9 (commercially available):
M8 × 15 mm
Armature continuity:
TIP:
b c d e
Before removing the bearing, measure and
write down the bearing depth b. C C
Checking the brush

Checking the armature (PTT motor) 1. Measure the length of each brush.
1. Check the commutator. Clean using 600 Replace the brushes if below specifica-
grit sandpaper and compressed air if tion.
dirty.
a
b 9
Motor brush standard length a:

2. Measure the commutator diameter a. 11.5 mm (0.45 in)
Replace the armature if below specifica- Wear limit b: 4.5 mm (0.18 in)
tion.
9-46
BRKT
Bracket unit
2. Check the motor base assembly for con-
tinuity. Replace the motor base assembly 2
if there is no continuity.
f g
e 1
h
Sb 2. Install the brushes 3 and springs 4.

c
3 4
4 3
3
Lg d 3 4
Sb: Sky blue 4 3

Lg: Light green
4
Motor base assembly continuity:
Terminal c–Terminal e
Terminal c–Terminal g
Terminal e–Terminal g 3. Install a new bearing 5 to the specified
Terminal d–Terminal f depth a.
Terminal d–Terminal h
5
Terminal f–Terminal h
3. Check the motor base assembly exterior.

Replace the motor base assembly if the a
base is cracked or damaged.
Assembling the PTT motor
• Do not reuse a bearing, oil seal, or O-

ring, always replace it with a new one. 5
• Do not apply grease or oil to the com- 5
mutator of the armature.
Depth a (reference data):
1. Install a new oil seal 1 into the motor 20.10 mm (0.79 in)
base assembly 2.
4. Install a new bearing 6 to the specified
depth b.
9-47
PTT motor
7. Install the stator 0, and then tighten the
6 bolts A. NOTICE: Secure the end of
the armature shaft using a pair of pli-
ers, and then install the armature
along with the motor base assembly.
b Otherwise, the armature could sepa-
rate from the motor base assembly
due to the magnetic force of the stator
0 and damage the brushes.
6 6
A
Depth b (reference data):
0.95 mm (0.04 in)
5. Push the brushes 7 into the holders,

and then install the armature 8.
7 Installing the reservoir

8

with a new one.
1. Install the spacer 1, filter 2, and sheet

3.
2. Install a new O-ring 4 and the reservoir

5, and then tighten the reservoir bolts 6
to the specified torque.
7
3. Install a new O-ring 7 and the reservoir
6. Install the wave washer 9. cap 8, and then tighten the reservoir cap
9
5
6
6
9
7
8
4
3
2
9-48
BRKT
Bracket unit
Reservoir bolt 6: 3
19 N·m (1.9 kgf·m, 14.0 ft·lb) b 4
Reservoir cap 8: 1 4
7 N·m (0.7 kgf·m, 5.2 ft·lb) c
Installing the PTT motor 2
• When assembling the PTT unit, do not

use a rag. Otherwise, dust and particles
could get on the PTT unit components, PTT motor bolt 4:
causing poor performance. 19 N·m (1.9 kgf·m, 14.0 ft·lb)
• Do not reuse an O-ring, always replace it
with a new one. TIP:
Align the protrusion b on the armature shaft
1. Install the joint 1. with the slot c in the joint.
2. Fill the gear pump housing with the rec-

ommended fluid to the proper level a.
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 3, and then tighten the PTT motor
bolts 4 to the specified torque.
9-49
PTT motor / PTT gear pump
PTT gear pump
7 N m (0.7 kgf m, 5.2 ft lb)

1 1
5 5
9
2 6
10
3 7 11
8
12
4
1
31
7 N m (0.7 kgf m, 5.2 ft lb)
13 13
32 32 14 14
33 15 18 34
33 16 17
35 17
35
36 36
37 37 20
19 19 21
24
30
22
22 23
38 25
39 25
26 26
40 27
27
30 28
28
2 N m (0.2 kgf m, 1.5 ft lb) 29 29

1 Bolt 3 M5 × 40 mm
2 Plate 1
3 Filter 1
4 Seat 1
5 Screw 2
6 Down-relief spring 1
7
8
Valve support
Relief valve seal
1
1 9
9 Up-relief spring 1
10 Valve support pin 1
11 O-ring 1 39
12 Ball 1
13 Circlip 2
14 Main valve seal 2
15 Down-shuttle piston 1
16 O-ring 1 39
17 Spring 2
9-50
BRKT
Bracket unit
7 N m (0.7 kgf m, 5.2 ft lb)

1 1
5 5
9
2 6
10
3 7 11
8
12
4
1
31
7 N m (0.7 kgf m, 5.2 ft lb)
13 13
32 32 14 14
33 15 18 34
33 16 17
35 17
35
36 36
37 37 20
19 19 21
24
30
22
22 23
38 25
39 25
26 26
40 27
27
30 28
28
2 N m (0.2 kgf m, 1.5 ft lb) 29 29

18 Up-shuttle piston 1
19 Ball 2
20 Relief valve seat 1
21 O-ring 1 39
22 Ball 2
23 Manual release plate 1
24 Filter 1
25 Ball 2
26 Valve pin 2
27 Spring 2
28 Spacer 2
29 O-ring 2 39
30 Pin 2
31 Bracket 1
32 Washer 2
33 Bolt 2 M5 × 25 mm
34 Gear pump assembly 1
9-51
PTT gear pump
7 N m (0.7 kgf m, 5.2 ft lb)

1 1
5 5
9
2 6
10
3 7 11
8
12
4
1
31
7 N m (0.7 kgf m, 5.2 ft lb)
13 13
32 32 14 14
33 15 18 34
33 16 17
35 17
35
36 36
37 37 20
19 19 21
24
30
22
22 23
38 25
39 25
26 26
40 27
27
30 28
28
2 N m (0.2 kgf m, 1.5 ft lb) 29 29

35 O-ring 2 39
36 Spacer 2
37 Filter 2
38 O-ring 1 39
39 Manual valve 1
40 Circlip 1
9-52
BRKT
Bracket unit
Disassembling the gear pump 4. Remove the bracket 6, and then remove
assembly the balls 7 and 8.
1. Remove the PTT motor assembly. See
“Removing the PTT motor” (9-45).
2. Remove the manual valve 1, and then

remove the gear pump assembly 2.
6 7
2
1 5. Remove the gear housing 9, and then
remove the down-shuttle piston 0 and
up-shuttle piston A.
6. Remove the drive gear B, driven gear

3. Remove the screws 3, and then remove C, balls D, and pins E.
the relief valve seal 4 and ball 5. 9
0
3
E
5 A
4
C B
D
È É
b
a
Checking the gear pump
1. Check the drive gear 1 and driven gear
3 3 2. Replace the gear pump assembly if
damaged or excessive worn.
È Down-relief valve 2. Check the up-relief valve 3 and down-

É Up-relief valve relief valve 4. Clean if there is dirt or res-
idue.
TIP:
Before removing the screws 3, measure and 3. Check the main valves 5. Clean if there
write down the screw depth a and screw is dirt or residue.
height b.
4. Check the absorber valves 6 and 7.
Clean if there is dirt or residue.
9-53
PTT gear pump
3. Install the balls 8 and 9, manual
release plate 0, and bracket A, and
4 3 then tighten the gear pump bracket bolts
B temporarily.
1
2 4. Check that the gear pump turns
smoothly, and then tighten the gear
pump bracket bolts B to the specified
torque.
B
6
7
5 5
A 8
9
Assembling the gear pump assembly 8
0

could get on the PTT unit components, Gear pump bracket bolt B:
causing poor performance. 7 N·m (0.7 kgf·m, 5.2 ft·lb)
with a new one. 5. Install the relief valve seal C and ball D,
and then install the screws E.
1. Install the drive gear 1, driven gear 2, E
pins 3, balls 4, down-shuttle piston 5, E
and up-shuttle piston 6.
2. Install the gear housing 7. C

D
7
7
5 3 È É 9
2 b
6 a
1
4 E E
C D
È Down-relief valve
É Up-relief valve
9-54
BRKT
Bracket unit
11. Check the hydraulic pressure. See
Down-relief screw depth a
(reference data):
1.07–1.27 mm (0.042–0.050 in) TIP:
Up-relief screw height b If the hydraulic pressure is out of specifica-
(reference data): tion, adjust the relief lock screws to adjust the
1.95–2.45 mm (0.077–0.096 in) pressure.
TIP:
• Install the screws E to the depth a and
height b that were measured before
removing them.
• If installing new parts, install them accord-
ing to the preceding reference data.
6. Install the filter F to the seal G.
7. Install the filters H, the spacers I, new

O-rings J, and the gear pump assembly
K.
8. Install the filter F, and then tighten the

gear pump bolts L to the specified
torque.
9. Install the manual valve M and circlip N,

and then tighten the manual valve to the
specified torque.
L
J
L
I
J
H I
H F
G
K
M
Gear pump bolt L:

7 N·m (0.7 kgf·m, 5.2 ft·lb)
Manual valve M:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
10. Install the PTT motor. See “Installing the

PTT motor” (9-49).
9-55
PTT gear pump / PTT cylinder
PTT cylinder
65 N m (6.5 kgf m, 47.9 ft lb) 90 N m (9.0 kgf m, 66.4 ft lb) 160 N m (16.0 kgf m, 118.0 ft lb)
21
20
20
21
23
22 22
1
23
24
2 18
2 25
5 29
24
3
4 25
4 6 3 26
5
15 27
14 6 28
7 16
30
8 31
10 13
10
11
11 36 35
17
12
12 32
9 33
13 19
19 34
15 N m (1.5 kgf m, 11.1 ft lb)

7 N m (0.7 kgf m, 5.2 ft lb)
20 N m (2.0 kgf m, 14.8 ft lb)

1 Tilt ram 1
2 Dust seal 1 39
3 Tilt cylinder end screw 1
4 O-ring 1 39
5 Backup ring 1
6 O-ring 1 39
7
8
Spring
Adapter
1
1 9
9 Tilt piston assembly 1
10 Tilt piston 1
11 O-ring 1 39
12 Backup ring 1
13 Ball 5
14 Tilt ram assembly 1
15 Free piston 1
16 O-ring 1 39
17 Tilt cylinder 1
9-56
BRKT
Bracket unit
21
20
20
21
23
22 22
1
23
24
2 18
2 25
5 29
24
3
4 25
4 6 3 26
5
15 27
14 6 28
7 16
30
8 31
10 13
10
11
11 36 35
17
12
12 32
9 33
13 19
19 34
15 N m (1.5 kgf m, 11.1 ft lb)

7 N m (0.7 kgf m, 5.2 ft lb)
20 N m (2.0 kgf m, 14.8 ft lb)

18 Tilt cylinder assembly 1
19 Bushing 2
20 Circlip 2
21 Dust seal 2 39
22 Trim cylinder end screw 2
23 O-ring 2 39
24 Backup ring 2
25 O-ring 2 39
26 Spring 2
27 Adapter 2
28 Circlip 2
29 Trim ram assembly 2
30 Circlip 1
31 Shaft 1
32 O-ring 1 39
33 Adapter 1
34 Pipe 1
9-57
PTT cylinder
21
20
20
21
23
22 22
1
23
24
2 18
2 25
5 29
24
3
4 25
4 6 3 26
5
15 27
14 6 28
7 16
30
8 31
10 13
10
11
11 36 35
17
12
12 32
9 33
13 19
19 34
15 N m (1.5 kgf m, 11.1 ft lb)

7 N m (0.7 kgf m, 5.2 ft lb)
20 N m (2.0 kgf m, 14.8 ft lb)

35 Spacer 1
36 Pipe 1
9-58
BRKT
Bracket unit
Removing the tilt ram 7. Cover the tilt cylinder opening using a
rag 8, and then blow compressed air
through the hole a to remove the free
Before removing the tilt cylinder, make piston 9. WARNING! When removing
sure that the PTT rams are fully extended. the free piston, never look into the tilt
Otherwise, fluid could be expelled force- cylinder opening because the free pis-
fully from the PTT unit due to internal ton and PTT fluid could be expelled
pressure. forcefully.
8
1. Remove the PTT motor assembly. See
“Removing the PTT motor” (9-45). 9
2. Remove the pipes 1 and 2.
3. Remove the circlip 3, shaft 4 and tilt a

cylinder assembly.
Removing the trim ram

3 1. Hold the PTT body 1.
4
2. Loosen the trim cylinder end screws 2,
and then remove the trim ram assem-
blies.
1
2
1
2
4. Hold the tilt cylinder 5 in a vise.
5. Loosen the tilt cylinder end screw 6, and

3
then remove the tilt ram assembly. 2
Cylinder-end screw wrench 3:

90890-06568
7
3. Drain the fluid.
6
Disassembling the tilt ram
1. Hold the tilt ram end.
5
2. Remove the tilt piston bolt 1, and then
remove the tilt piston absorber valves 2.
90890-06568
6. Drain the fluid.
9-59
PTT cylinder
Checking the tilt cylinder and PTT
1 2
body
1. Check the PTT body 1 and tilt cylinder
2. Replace if cracked or corrosion.
2. Check the inner surface of the PTT body

1 and tilt cylinder 2. Replace if
scratched.
3. Check the outer surface of the tilt piston

3, trim piston 4, adapter 5, free piston
6, and dust seals 7 of end screws 8.
Replace if scratched.
4. Check the trim rams 9 and tilt ram 0.

3. Hold the tilt piston with the special ser-
Polish with 400–600 grit sandpaper if
vice tool 3.
there is light rust or, replace if bent or
4. Remove the tilt piston 4. corrosion.
5. Check the pipes A. Replace if cracked

or corrosion.
7
5 8
0
4 9
7 4
1
8 5
3 6
PTT piston vice attachment 3:

90890-06572 3 2
Tilt rod wrench 5: 90890-06569
Disassembling the trim ram

1. Remove the circlip 1, adapter 2, and
spring 3.
A
9
Checking the valve
1. Check the tilt piston absorber valves 1.
Clean if there is dirt or residue.
3
2
1
9-60
BRKT
Bracket unit
4. Tighten the tilt ram 0 to the specified
torque.
1
Assembling the tilt ram

use a rag. Otherwise, dust and particles 9
could get on the PTT unit components,
causing poor performance. PTT piston vice attachment 9:
• Do not reuse a dust seal or O-ring, 90890-06572
always replace it with a new one. Tilt rod wrench A: 90890-06569
1. Install a new dust seal 1, the backup Tilt ram 0: 65 N·m (6.5 kgf·m, 47.9 ft·lb)
ring 2 and new O-rings 3 and 4 to the
5. Hold the tilt ram end.
tilt cylinder end screw 5.
1 2 1 6. Install a new O-ring B and the backup
ring C.
5 7. Install the balls D, absorber valve pins

E, and springs F.
4
8. Install the washers G, plate H, and tilt
2 3 5 4 piston bolt I to the tilt piston 8, and
3 then tighten the tilt piston bolt I to the
specified torque.
2. Install the tilt cylinder end screw 5,
spring 6, adapter 7, and tilt piston 8.
6
7
8
5
3. Hold the tilt piston using the special ser-

vice tool 9.
9-61
PTT cylinder
I 8
G 8 7
9
H 7 0
F
E 0
G 9
C
C A
B
B
8 D
Installing the tilt cylinder
F • When assembling the PTT unit, do not

E use a rag. Otherwise, dust and particles
8 could get on the PTT unit components,
D causing poor performance.
Tilt piston bolt I: with a new one.
7 N·m (0.7 kgf·m, 5.2 ft·lb)
1. Install a new O-ring 1 to the free piston
Assembling the trim ram 2.
2. Push the free piston 2 into the tilt cylin-

• When assembling the PTT unit, do not der 3 until it bottoms out.
could get on the PTT unit components, 3. Install the tilt cylinder 3 to the PTT body
causing poor performance. 4.
• Do not reuse a dust seal or O-ring,
always replace it with a new one. 4. Install a new O-ring 5 and the pipe joint
adapter 6, and then tighten the pipe joint
1. Install the backup ring 1, a new O-ring adapter 6 to the specified torque.
2, the spring 3, the adapter 4, and the
5. Install the pipes 7 and 8, and then
circlip 5 to the trim piston 6.
tighten the pipe joints 9 and 0 to the
specified torque.
1
2 9
3
6 4
1
5
2
2. Install a new dust seal 7, the circlip 8,

and a new O-ring 9 to the trim cylinder
end screw 0, and then install the trim
cylinder end screw 0 onto the trim ram
A.
9-62
BRKT
Bracket unit
3. Install the trim ram assemblies into the
PTT body 1, and then tighten the trim
4 cylinder end screws 2 to the specified
torque.
0 1
2
2
1
8
7 5
3
6 3
2

9 90890-06568
Trim cylinder end screw 2:

Pipe joint adapter 6: 160 N·m (16.0 kgf·m, 118.0 ft·lb)
20 N·m (2.0 kgf·m, 14.8 ft·lb)
Pipe joint 9 and 0: Installing the tilt ram
15 N·m (1.5 kgf·m, 11.1 ft·lb)
Installing the trim ram When assembling the PTT unit, do not use
a rag. Otherwise, dust and particles could
get on the PTT unit components, causing
When assembling the PTT unit, do not use poor performance.
a rag. Otherwise, dust and particles could
get on the PTT unit components, causing
1. Place the tilt cylinder end screw 1 at the
poor performance.
position a.
1. Hold the PTT body 1. 2. Fill the tilt cylinder with the recommended
fluid to the proper level b.
2. Fill the trim cylinders with the recom-
mended fluid to the proper level a. 3. Add a small amount of the recommended
fluid through the PTT body hole c.
a
1
9-63
PTT cylinder
1 a
4. Install the tilt piston assembly into the tilt

cylinder, and then tighten the tilt cylinder
end screw 1 to the specified torque.

90890-06568
Tilt cylinder end screw 1:

90 N·m (9.0 kgf·m, 66.4 ft·lb)
9
5. Install the PTT motor. See “Installing the
PTT motor” (9-49).
6. Check the hydraulic pressure. See

9-64
MNT
Maintenance
Outline ............................................................................... 10-1

Maintenance chart 1................................................................. 10-1
Maintenance chart 2................................................................. 10-3
Predelivery check............................................................. 10-4

Checking battery (for electric start models).............................. 10-4
Checking the cooling water pilot hole....................................... 10-4
Checking the engine oil level.................................................... 10-5
Checking the engine start switch and
engine shut-off switch............................................................... 10-5
Checking the fuel system ......................................................... 10-6
Checking the gear oil level ....................................................... 10-6
Checking the gear shift and throttle operation.......................... 10-6
Checking the outboard motor mounting height ........................ 10-6
Checking the PTT system ........................................................ 10-7
Checking the steering system .................................................. 10-7
Checking the throttle cable and shift cable............................... 10-7
Test run .................................................................................... 10-7
Break-in .................................................................................... 10-7
After test run............................................................................. 10-8
General periodic maintenance ........................................ 10-8

Inspecting and replacing anode(s) ........................................... 10-8
Checking battery (for electric start models).............................. 10-8
Checking for cooling water leakage ......................................... 10-8
Checking the cooling water passage........................................ 10-8
Inspecting idle speed................................................................ 10-9
Changing engine oil.................................................................. 10-9
Checking the engine oil level.................................................. 10-10
Replacing the oil filter ............................................................. 10-10
engine shut-off switch............................................................. 10-11
Checking the fuel joint and fuel hose
(fuel joint to fuel injector) ........................................................ 10-11
Checking the fuel filter............................................................ 10-11
Changing gear oil ................................................................... 10-11
Checking the gear oil level ..................................................... 10-12
Replacing the OCV filter......................................................... 10-12
Greasing................................................................................. 10-13
Checking the PCV .................................................................. 10-14
Checking the PTT fluid level................................................... 10-14
Checking the PTT operation................................................... 10-15
Checking propeller ................................................................. 10-15
Adjusting the shift cable ......................................................... 10-15
Cleaning and adjusting spark plug ......................................... 10-15
Checking the timing belt ......................................................... 10-15
Replacing the timing belt ........................................................ 10-15
Checking the thermostat ........................................................ 10-15
Adjusting the throttle cable ..................................................... 10-15
Checking the top cowling ....................................................... 10-15
Checking the valve clearance ................................................ 10-16
Checking the water pump....................................................... 10-16
10
MNT
Maintenance
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 avail-
able from Yamaha dealers.
• The service intervals provided in the maintenance charts are based upon “typical” operating con-
ditions that include speed variations, sufficient time for engine warm up and cool-down, medium to
light load, and an average cruising speed in the 3000–4000 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 stop-
ping 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 chart 1
F” symbol indicates the check-ups which the owners or operators may carry out themselves.
The “F
U” symbol indicates work to be carried out by a Yamaha dealer.
The “U
Initial Every See
Item Actions 20 hours 100 hours 300 hours 500 hours
(3 months) (1 year) (3 years) (5 years)
page
Inspection or replace- 8-3
Anode(s) (external) F/U
U
ment as necessary 9-32
Anode(s) (cylinder head, Inspection or replace- 7-67
U
thermostat cover) ment as necessary 7-95
Anodes (exhaust cover,
7-32
cooling water passage
Replacement U 7-57
cover, Rectifier Regula-
7-72
tor cover)
Battery (electrolyte level,
Inspection F/U
U F/U
U 10-4
terminal)
Battery (electrolyte level, Fill, charging or replacing
U 10-4
terminal) as necessary
Inspection or replace-
Cooling water leakage U U 10-8
ment as necessary
Cowling lock lever Inspection F/U
U 10-15
Engine starting condi-
Inspection F/U
U F/U
U 10-5
tion/noise
Engine idle speed/noise Inspection F/U
U F/U
U 10-9
Engine oil Replacement F/U
U F/U
U 10-9
10-1
Outline
Initial Every See

page
Engine oil filter (car-
Replacement F/U
U 10-10
tridge)
Fuel filter (can be disas- Inspection or replace-
F/U
U F/U
U 6-14
sembled) ment as necessary
Fuel line (High pressure) Inspection F F 6-1
Fuel line (High pressure) U U 6-1
ment as necessary
Fuel line (Low pressure) Inspection F F 6-1
Fuel line (Low pressure) U U 6-1
ment as necessary
Inspection or replace- 6-32
Fuel pump U
ment as necessary 6-40
6-1
Fuel/engine oil leakage Inspection U U
2-16
Gear oil Replacement F/U
U F/U
U 10-11
Greasing points Greasing F/U
U F/U
U 10-13
Impeller/water pump Inspection or replace-
U 8-9
housing ment as necessary
Impeller/water pump
Replacement U 8-9
housing
OCV (Oil Control Valve)
Replacement U 10-12
filter
Power trim and tilt unit Inspection F/U
U F/U
U 10-15
Propeller/propeller Inspection or replace-
F/U
U F/U
U 8-3
nut/cotter pin ment as necessary
PCV (Pressure Control Inspection or replace-
U 9-20
Valve) ment as necessary
Inspection, adjustment or
3-9
Shift link/shift cable replacement as neces- U U
10-6
sary
Spark plug(s) F/U
U 7-44
ment as necessary
Spark plug caps/spark Inspection or replace-
U U 5-53
plug wires ment as necessary
Water from the cooling
Inspection F/U
U F/U
U 10-4
water pilot hole
Throttle link/throttle
cable/throttle pick-up tim-
Inspection, adjustment or
replacement as neces- U U
3-9
10-6
10
ing sary
Thermostat U 7-85
ment as necessary
Timing belt U 7-39
ment as necessary
Inspection and adjust-
Valve clearance U 7-2
ment
10-2
MNT
Maintenance
Initial Every See

page
Cooling water inlet Inspection F/U
U F/U
U 10-8
Main switch/stop Inspection or replace-
U U 10-5
switch/choke switch ment as necessary
Wire harness connec-
tions/wire coupler con- U U —
ment as necessary
nections
(Yamaha) Meter/gauge Inspection U U (*1)
(*1): See “6Y8 Multifunction Meter set up manual” for the check of 6Y8 Multifunction Meter.
Maintenance chart 2
Every See
Item Actions
1000 hours page
Exhaust guide/exhaust Inspection or replace-
U 9-24
manifold ment as necessary
Timing belt Replacement U 7-37
10-3
Outline / Predelivery check
Predelivery check
To make the delivery process smooth and
efficient, complete the predelivery checks as a
explained in the following procedures.
Checking battery (for electric start

models)
Battery electrolyte is dangerous; it con-

tains sulfuric acid, which is poisonous 2. Check the specific gravity of the electro-
and highly caustic. Always follow these lyte. Fully charge the battery if below
preventive measures: specification.
• Avoid bodily contact with electrolyte as
Representative examples:
it can cause severe burns or permanent
Recommended battery capacity:
eye injury.
CCA/EN: 711.0 A
• Wear protective eye gear when handling
20 HR/IEC: 100.0 Ah
or working near batteries.
Electrolyte specific gravity:
Antidote (EXTERNAL):
1.280 at 20 °C (68 °F)
• SKIN – Wash with water.
• EYES – Flush with water for 15 minutes
TIP:
and get immediate medical attention.
• Batteries vary depending on the manufac-
Antidote (INTERNAL):
turer. The procedures mentioned in this
• Drink large quantities of water or milk
manual may not always apply. Therefore,
followed with milk of magnesia, beaten
see the instruction manual of the battery.
egg, or vegetable oil. Get immediate
• Disconnect the negative battery cable first,
medical attention.
and then disconnect the positive battery
Batteries produce explosive, hydrogen
cable.
gas. Always follow these preventive mea-
• For more information about the battery
sures:
requirements, see “Extension length rec-
• Charge batteries in a well-ventilated
ommendation for battery cable” (3-28).
area.
• Keep batteries away from fire, sparks, or
open flames (for example, welding Checking the cooling water pilot
equipment and lighted cigarettes). hole
• DO NOT SMOKE when charging or han- 1. Start the engine, and then check that
dling batteries. cooling water is discharged from the
KEEP BATTERIES AND ELECTROLYTE cooling water pilot hole.
OUT OF REACH OF CHILDREN.
1. Check the battery electrolyte level. If the

level is at or below the minimum level 10
mark a, add distilled water until the level
is between the maximum and minimum
level marks.
10-4
MNT
Maintenance
Checking the engine oil level Checking the engine start switch and
1. Place the outboard motor in an upright engine shut-off switch
position. NOTICE: If the outboard 1. Check that the engine starts when the
motor is not level, the oil level indi- engine start switch is turned to START.
cated on the dipstick may not be cor-
rect. 2. Check that the engine stops when the
engine start switch is turned to OFF.
È ON
OFF START
É ON
OFF START
2. Start the engine and warm it up for 5–10

minutes.
3. Stop the engine and leave it off for 5–10

minutes.
4. Remove the top cowling.

5. Remove the dipstick 1 and wipe it clean. É 704 remote control model
6. Insert the dipstick 1 completely for a 3. Check that the engine stops when the
correct measurement and remove it clip is removed from the engine shut-off
again. switch.
È
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.
10-5
Predelivery check
É ON Check screw 1: 9 N·m (0.9 kgf·m, 6.6 ft·lb)

OFF START
Checking the gear shift and throttle
operation
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.
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 fuel system
1. Check that the fuel hoses are connected
Checking the outboard motor
securely. To check the fuel hose connec-
tions, see “Fuel hose and blowby hose”
mounting height
1. Check that the anti-cavitation plate a is
(6-1). NOTICE: This outboard motor is
aligned with the bottom b of the boat. If
equipped with a 4-stroke engine.
the mounting height is too high, cavita-
Never use pre-mixed fuel or 2-stroke
tion will occur and propulsion will
outboard motor oil.
decrease. Besides, the engine speed will
Checking the gear oil level increase abnormally and cause the
engine to overheat. If the mounting
height is too low, water resistance will
Do not reuse a gasket, always replace it increase, which will decrease engine effi-
with a new one. ciency and performance.
1. Place the outboard motor in an upright

position.
2. Remove the check screw 1, and then a

check the gear oil level.
b
2
1
TIP:
The appropriate mounting height depends on
the combination of the boat and outboard
motor. To determine the appropriate mount-
ing height, test run the outboard motor at dif-
ferent heights.
10
TIP:
If the oil is at the proper level, a small amount 2. Check that the clamp brackets are
of oil should flow out of the check hole. secured using the clamp bolts.
3. Install a new gasket 2 and the check

screw 1, and then tighten the check
10-6
MNT
Maintenance
Checking the PTT system c
1. Check that the outboard motor tilts up
and down smoothly when the PTT switch
is operated.
1
2. Check that there is no abnormal noise
produced when the outboard motor is
tilted up or down.
3. Check that there is no interference with d

cables, hoses, or leads when the tilted-
Test run
up outboard motor is steered.
1. Start the engine, and then check that the
4. Check that the trim meter points down gear shift operates smoothly.
when the outboard motor is fully tilted
2. Warm up the engine, and then check the
down.
engine idle speed.
Checking the steering system 3. Operate the boat at trolling speed.
1. Check that the steering operates
smoothly. 4. Operate the outboard motor according to
the break-in procedure.
2. Check that there is no interference with
cables, hoses, or leads when the out- 5. Check that the outboard motor does not
board motor is steered. tilt up when the remote control lever is
moved to the R position and that water
Checking the throttle cable and shift does not flow in over the transom.
cable
1. Move the remote control lever to the N 6. Check that the PTT operates smoothly
position. while the outboard motor is running.
2. Check that the accelerator lever a con- TIP:

tacts the stopper b. The test run is part of the break-in operation.
Break-in
b
Operate the engine under load (in gear with a
propeller installed) for 10 hours as follows:
a
1. For the 1st hour a of operation:
Operate the engine at varying speeds up
to 2000 r/min or approximately 1/2 throt-
tle.
3. Check that the pin c is aligned with the 2. For the 2nd hour b of operation:
alignment mark d on the shift bracket Increase engine speed until the boat is
1. on plane (but do not fully open the throt-
tle), and then back off on the throttle
while keeping the boat at a planing
speed.
10-7
Predelivery check / General periodic maintenance
3. For the remaining 8 hours c of opera-
tion: TIP:
Operate the engine at any engine speed. • Replace the anodes or trim tab if eroded. In
However, do not operate the engine at addition, check the ground lead.
full throttle for more than 5 minutes at a • If it is necessary to disassemble the out-
time. board motor to check an anode, refer to the
applicable disassembly procedure in this
4. After the 1st 10 hours of operation: manual.
Operate the engine normally.
Checking battery (for electric start
models)
1. Check the battery. See “Checking battery
a b c (for electric start models)” (10-4).
Checking for cooling water leakage

È0 1 2 10 1. Start the engine and check that no water
leaks from the joints between the
exhaust cover, cylinder head, cylinder
body and so on.
È Hour
Checking the cooling water passage
After test run
1. Remove the water inlet covers 1 and
1. Check for water in the gear oil.
trim tab 2.
2. Check for fuel leakage in the cowling.
2. Check the cooling water inlet covers 1
and water inlets. Clean if clogged.
3. Flush the cooling water passages using
fresh water. NOTICE: When flushing 3 1
the cooling water passages, do not
start the engine. Otherwise, the water
1
pump could be damaged and the
engine could be severely damaged
due to overheating.
TIP:
When using the flushing device (flushing
hose joint adapter), flush the cooling water
passages without starting the engine.
4
General periodic maintenance
2
Inspecting and replacing anode(s) a
10
Do not apply, grease, oil, or paint to the
anodes or the trim tab.
1. Check the anodes and trim tab. Clean

the anodes or trim tab if there are scales,
grease, or oil.
10-8
MNT
Maintenance
TIP:
Mark the trim tab 2 with an identification Change the engine oil after the first 20
mark a at the area shown, and then remove hours of operation or 3 months, and every
it. 100 hours or at 1-year intervals thereafter.
3. Install the water inlet covers 1 and trim 1. Place the outboard motor in an upright
tab 2, and then tighten the water inlet position. NOTICE: If the outboard
cover screw 3 and trim tab bolt 4 to the motor is not level, the oil level indi-
specified torques. cated on the dipstick may not be cor-
rect.
Water inlet cover screw 3:
1 N·m (0.1 kgf·m, 0.7 ft·lb)
Trim tab bolt 4:
minutes.
42 N·m (4.2 kgf·m, 31.0 ft·lb)
3. Stop the engine and leave it off for 5–10
4. Place the lower unit in water, and then
minutes.
start the engine.
4. Remove the top cowling.
5. Check for water flow at the cooling water
pilot hole. If there is no water flow, check
5. Remove the oil filler cap 1. Remove the
the cooling water passages inside the dipstick 2 and extract the engine oil
outboard motor.
using the oil changer 3.
Inspecting idle speed

minutes. 2
2. Check the engine idle speed using the

Yamaha genuine tachometer (on-board
meter) or the YDIS. To connect and
operate the YDIS, see the “YDIS (Ver.
1.33 or later) Instruction Manual.”
Changing engine oil

The engine oil should be extracted using an 3
oil changer.
10-9
6. Fill the engine with the specified amount 11. Start the engine and check that the oil
of the recommended engine oil through pressure alert indicator does not come
the oil filler hole. Install the oil filler cap 1 on. Also, check that there is no oil leak-
and dipstick 2. NOTICE: Do not overfill age. NOTICE: If the oil pressure alert
the engine with engine oil. Otherwise, indicator comes on or if there is oil
the engine could be damaged or oil leakage, stop the engine and find the
could leak. If the engine oil is above cause. Continued operation with a
the upper level, extract the excess problem could cause severe engine
engine oil until the oil is at the proper damage.
level.
Checking the engine oil level
Recommended engine oil:
1. Check the engine oil level. See “Check-
4-stroke motor oil with a combination of
ing the engine oil level” (10-5).
the following SAE and API oil
classifications:
Replacing the oil filter
API: SE, SF, SG, SH, SJ, SL
Do not damage the oil pressure sensor and
SAE: 5W-30, 10W-30, 10W-40
its lead when replacing the oil filter.
(at periodic maintenance): 1. Extract the engine oil using an oil
Without oil filter replacement: changer. See steps 1–5 in “Changing
4.5 L (4.76 US qt, 3.96 lmp qt) engine oil” (10-9).
7. Leave the outboard motor off for 5–10
2. Place a rag under the oil filter, and then
minutes.
remove the oil filter.
8. Remove the dipstick 2 and wipe it clean.
9. Insert the dipstick 2 completely for a

correct measurement and remove it
again.
10. Check that the oil level indicated on the

dipstick 2 is between the upper mark a
and the lower mark b. 1
a Oil filter wrench 1: 90890-06830
TIP:
2
Make sure to clean up any oil spills.
3. Install a new oil filter 2, and then tighten

b it to the specified torque.
10
10-10
MNT
Maintenance
Checking the fuel joint and fuel hose
2
(fuel joint to fuel injector)
1. Check the fuel joint and fuel hose con-
nections. See “Fuel hose and blowby
hose” (6-1).
E
Checking the fuel filter

1. Check the fuel filter. See “Checking the
fuel filter assembly” (6-13).
Changing gear oil
1
Never get under the lower unit while it is
Oil filter 2: 18 N·m (1.8 kgf·m, 13.3 ft·lb) tilted.
4. Fill the engine with the specified amount

of the recommended engine oil through Do not reuse a gasket, always replace it
the oil filler hole. with a new one.
Recommended engine oil:
4-stroke motor oil with a combination of 1. Tilt the outboard motor so that the drain
the following SAE and API oil screw is at the lowest point.
classifications:
API: SE, SF, SG, SH, SJ, SL 2. Place a drain pan under the gear oil drain
SAE: 5W-30, 10W-30, 10W-40 hole.
3. Remove the drain screw 1 and gasket
(at periodic maintenance):
2. NOTICE: If there is a significant
With oil filter replacement:
amount of metal particles on the mag-
4.7 L (4.97 US qt, 4.14 lmp qt)
netic drain screw, the lower unit may
5. Install the oil filler cap and dipstick, and have a problem.
then start the engine and warm it up for
5–10 minutes. 4. Remove the check screw 3 and gasket
4 and let the oil drain completely.
6. Stop the engine, and then leave it off for NOTICE: After the gear oil has been
5–10 minutes. drained, check the used oil. If the oil is
milky, water is getting into the lower
7. Check the oil level. If the oil level is low, case, which can cause gear damage.
add engine oil up to the proper level.

engine shut-off switch
1. Check the engine start switch and engine
shut-off switch. See “Checking the
engine start switch and engine shut-off
switch” (10-5).
10-11
Recommended gear oil:

Hypoid gear oil
API: GL-4
SAE: 90
Oil quantity:
3 4
Regular rotation model:
1.150 L (1.216 US qt, 1.012 lmp qt)
2
Counter rotation model:
1.000 L (1.057 US qt, 0.880 lmp qt)
1
Check screw 3:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
8. Remove the gear oil pump, install a new

gasket 6 and the drain screw 1, and
TIP:
then tighten the drain screw 1 to the
Before installing the magnetic drain screw,
specified torque.
make sure to remove all metal particles.
5. Place the outboard motor in an upright

position.
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 6
check hole and no air bubbles are visible.
1
7. Install a new gasket 5 and the check
screw 3, and then tighten the check Drain screw 1: 9 N·m (0.9 kgf·m, 6.6 ft·lb)
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 assemblies.
5
3
2. Replace the OCV filter 1 of each OCV
assembly.
10
1
3. Install the OCV assemblies. See step 4

in “Installing the cylinder head” (7-68).
10-12
MNT
Maintenance
Greasing
1. Apply water resistant grease to the spec- A
ified lubrication points.
a
A
a
a
A
A
a
10-13
É Checking the PTT fluid level
Never get under the outboard motor while

it is tilted.
A
with a new one.
È F200B and FL200B

1. Fully tilt the outboard motor up, and then
É F250G and FL250G
support it using the tilt stop lever 1.
TIP:
Apply grease to the grease nipple until it
flows from the bushings a.
1
2. Apply low temperature resistant grease
to the specified lubrication points.
2. Remove the reservoir cap 2 and O-ring

3, and then check the fluid level in the
reservoir. WARNING! Before removing
the reservoir cap, make sure that the
PTT rams are fully extended. Other-
wise, fluid could be expelled forcefully
from the unit due to internal pressure.
3. Apply corrosion resistant grease to the
specified lubrication points.
2 3
TIP:
Checking the PCV If the fluid is at the proper level, a small
amount of fluid should flow out of the filler
10
Check the PCV. See “Checking the PCV” (9-
hole when the reservoir cap is removed.
20).
3. If the fluid is below the proper level, add

the recommended fluid.
10-14
MNT
Maintenance
4. Install a new O-ring and the reservoir cap 6. Remove the wiring harness guide. See
2, and then tighten the reservoir cap 2 steps 5–29 in “Removing the wiring har-
to the specified torque. ness” (7-20).
Reservoir cap 2:
7. Remove the timing belt. See steps 6–10
7 N·m (0.7 kgf·m, 5.2 ft·lb)
in “Removing the timing belt” (7-38).
Checking the PTT operation
8. Install a new timing belt. See steps 2–10
1. Fully tilt the outboard motor up and down
in “Installing the timing belt” (7-39).
a few times and check that the outboard
motor tilts up and down smoothly. Check 9. Install the wiring harness guide. See
the PTT fluid level if the tilt operation is steps 13–37 in “Installing the wiring har-
not smooth. ness” (7-23).
2. Check the PTT unit for fluid leakage. 10. Install the fuel rail covers.
Checking propeller 11. Install the stator assembly and flywheel

1. Check the propeller. See “Checking the magnet. See “Installing the flywheel
propeller” (8-3). magnet” (7-17).
Adjusting the shift cable 12. Install the intake silencer. See “Installing
1. Disconnect the shift cable, and then the intake silencer” (6-19).
adjust it. See “Installing the shift cable
and throttle cable” (3-9). 13. Install the high-pressure fuel hose
assembly, and then connect the quick
Cleaning and adjusting spark plug connectors. See “Connecting the quick
1. Check the spark plug. See “Checking the connector” (6-8).
spark plug” (7-44).
Checking the thermostat
Checking the timing belt 1. Check the thermostat. See “Checking the
1. Check the timing belt. See “Checking the thermostat” (7-85).
timing belt” (7-39).
Adjusting the throttle cable
Replacing the timing belt 1. Adjust the throttle cable. See “Installing
1. Reduce the fuel pressure. See “Reduc- the shift cable and throttle cable” (3-9).
Checking the top cowling
2. Disconnect the quick connectors, and 1. Check the fitting by pushing the top cowl-
then remove the high-pressure fuel hose ing. Adjust if there is free play.
assembly. See steps 2–5 in “Disconnect-
ing the quick connector” (6-7).
3. Remove the intake silencer. See steps

2–4 in “Removing the intake silencer” (6-
17).
4. Removing the flywheel magnet and sta-

tor assembly. See “Removing the fly-
wheel magnet” (7-16).
5. Remove the fuel rail covers. 2. Loosen the bolts 1.
10-15
3. Move the hook 2 up or down slightly to
adjust its position. TIP:
When measuring or adjusting the valve clear-
ances, the fuel line must be disconnected, so
a make sure to reduce the fuel pressure before
performing the disassembly procedure.
2 2. Remove the flywheel magnet cover and

1
engine ECM cover.
3. Remove the blowby hose. See step 2 in

b “Removing the intake silencer” (6-17).
TIP: 4. Remove the speed sensor coupler from

• To loosen the fitting, move the hook 2 in the bracket. See step 16 in “Removing
direction a. the power unit” (7-8).
• To tighten the fitting, move the hook 2 in
direction b. 5. Remove the wiring harness from the
engine ECM bracket and holder. See
4. Tighten the bolts 1. steps 5–16 in “Removing the wiring har-
ness” (7-20).
5. Recheck the fitting. Replace the cowling
seal if the free play cannot be adjusted. 6. Remove the ignition coils and spark
plugs.
6. Check the top cowling hose for cracks or
damage. 7. Check the valve clearance. See steps 7–
22 in “Checking the valve clearance” (7-
2).
8. Install the wiring harness to the engine

ECM bracket. See steps 26–37 in
“Installing the wiring harness” (7-23).
9. Install the speed sensor to the bracket.

See step 17 in “Installing the power unit”
(7-11).
Checking the valve clearance 10. Install the blowby hose. See steps 3 and
Measure the valve clearances when the 4 in “Installing the intake silencer” (6-19).
engine is cold.
11. Install the engine ECM cover and fly-
wheel magnet cover.
clockwise. Otherwise, the water pump Checking the water pump
10
impeller could be damaged. 1. Check the water pump housing and
impeller. See “Checking the water pump
1. Reduce the fuel pressure. See “Reduc- and shift rod” (8-9).
10-16
Index
A. Bracket unit........................................1-5, 1-19

Bracket unit technical data ....................... 1-16
Abbreviation ................................................0-5
Break-in .................................................... 10-7
Actuator, sensor, and switch.......................2-3
Adjusting the forward gear shim
(T1) thickness .........................................8-51 C.
Adjusting the forward gear shim Camshaft .................................................. 7-46
(T2) thickness .......................................8-102 Canister, throttle body, and surge tank..... 6-26
Adjusting the reverse gear shim Changing engine oil.................................. 10-9
(T1) thickness .......................................8-106 Changing gear oil ................................... 10-11
Adjusting the reverse gear shim Charging system....................................... 1-10
(T2) thickness .........................................8-55 Charging unit and component .................. 5-50
Adjusting the shift cable ..........................10-15 Charging unit and starting unit....................A-9
Adjusting the throttle cable......................10-15 Checking battery
Adjusting the trim sensor ..........................9-34 (for electric start models) ...............10-4, 10-8
Adjusting the valve clearance .....................7-4 Checking for cooling water leakage.......... 10-8
After test run .............................................10-8 Checking propeller.................................. 10-15
Assembling the cylinder block...................7-95 Checking the air pressure sensor....5-57, 6-28
Assembling the cylinder head ...................7-67 Checking the
Assembling the forward gear .......... 8-27, 8-35 air temperature sensor ..................5-56, 6-18
Assembling the fuel filter assembly...........6-14 Checking the APS .................................... 5-29
Assembling the gear pump assembly .......9-54 Checking the APS circuit .......................... 5-30
Assembling the Checking the armature (PTT motor)......... 9-46
lower case.................. 8-26, 8-35, 8-83, 8-88 Checking the armature (starter motor) ..... 5-71
Assembling the oil pan and Checking the brush................................... 9-46
exhaust manifold.....................................9-24 Checking the brush holder and brush....... 5-71
Assembling the oil pump assembly...........7-77 Checking the cam position sensor............ 5-34
Assembling the Checking the camshaft ............................. 7-50
oil seal housing .......... 8-27, 8-35, 8-84, 8-88 Checking the canister ............................... 6-28
Assembling the Checking the canister check valve ........... 6-23
propeller shaft assembly ............... 8-17, 8-22 Checking the check valve ......................... 6-40
Assembling the propeller shaft Checking the clamp bracket anode .......... 9-32
housing assembly ...... 8-18, 8-22, 8-74, 8-79 Checking the compression pressure .......... 7-1
Assembling the PTT motor .......................9-47 Checking the connecting rod big
Assembling the reverse gear .......... 8-84, 8-88 end side clearance ................................. 7-88
Assembling the shift bracket .......................9-4 Checking the connecting rod
Assembling the starter motor ....................5-72 small end inside diameter and
Assembling the tilt ram..............................9-61 big end inside diameter .......................... 7-88
Assembling the trim ram ...........................9-62 Checking the cooling water passage ........ 10-8
Assembling the upper case.......................9-20 Checking the cooling water
Assembling the vapor separator ...............6-41 passage cover anode ............................. 7-72
Assembling the water Checking the cooling water pilot hole ....... 10-4
pump housing ............ 8-10, 8-13, 8-67, 8-70 Checking the crankcase bolt .................... 7-89
Checking the crankpin oil clearance......... 7-89
B. Checking the crankshaft ........................... 7-88
Checking the
Battery cable routing with house
crankshaft journal oil clearance .............. 7-91
(accessory) battery .................................3-18
Checking the cylinder block anode ........... 7-95
Battery cable routing without
Checking the cylinder bore ....................... 7-86
house (accessory) battery.......................3-16
Checking the cylinder head ...................... 7-62
Battery installation.....................................3-16
Checking the cylinder head anode ........... 7-67
Battery requirement ....................................1-6
Checking the
Bleeding the PTT unit ...............................9-40
drive shaft .................. 8-26, 8-35, 8-83, 8-88
Blowby gas reburning system ...................2-14
Checking the drive shaft bushing ............. 9-20
Bottom cowling................................ 5-18, 9-12
i-1
Index
Checking the electrical component ...........5-26 Checking the outboard motor
Checking the engine ECM circuit..............5-28 mounting height ...................................... 10-6
Checking the engine oil level ........ 10-5, 10-10 Checking the PCV .........................9-20, 10-14
Checking the engine shut-off switch .........5-65 Checking the pinion and
Checking the engine start switch ..............5-66 forward gear ..................................8-26, 8-35
Checking the engine start switch and Checking the pinion and
engine shut-off switch ................. 10-5, 10-11 reverse gear ..................................8-83, 8-88
Checking the Checking the piston diameter ................... 7-86
engine temperature sensor .....................5-59 Checking the piston pin ............................ 7-87
Checking the ETV .....................................6-28 Checking the piston pin
Checking the ETV and TPS ......................5-31 boss inside diameter............................... 7-87
Checking the ETV and TPS circuit............5-33 Checking the piston ring ........................... 7-86
Checking the ETV motor relay ..................5-32 Checking the
Checking the exhaust cover anode...........7-57 piston ring end gap (reference) .............. 7-86
Checking the fuel cup assembly ...............6-14 Checking the piston ring groove ............... 7-87
Checking the fuel filter ............................10-11 Checking the piston ring side clearance... 7-87
Checking the fuel filter assembly ..............6-13 Checking the pressure regulator .............. 6-10
Checking the fuel filter element.................6-14 Checking the primer pump ....................... 6-32
Checking the fuel injector..........................5-44 Checking the
Checking the fuel joint and fuel hose propeller......................... 8-3, 8-6, 8-61, 8-64
(fuel joint to fuel injector).......................10-11 Checking the
Checking the fuel rail ................................6-45 propeller shaft............ 8-17, 8-22, 8-74, 8-79
Checking the fuel system..........................10-6 Checking the propeller
Checking the gear oil level............ 10-6, 10-12 shaft housing ............. 8-17, 8-22, 8-74, 8-79
Checking the gear pump...........................9-53 Checking the PTT fluid level................... 10-14
Checking the gear shift and Checking the PTT operation ................... 10-15
throttle operation .....................................10-6 Checking the PTT relay ............................ 5-74
Checking the high-pressure fuel pump .....6-40 Checking the PTT switch
Checking the high-pressure (bottom cowling) ..................................... 5-75
fuel pump relay .......................................5-47 Checking the PTT system ........................ 10-7
Checking the hydraulic pressure...............9-38 Checking the pulser coil ..................5-55, 7-17
Checking the ignition coil ..........................5-53 Checking the pulser coil air gap ................. 7-1
Checking the ignition spark.......................5-53 Checking the quick connector .................. 6-46
Checking the intake manifold....................6-18 Checking the Rectifier Regulator .............. 5-51
Checking the knock sensor............. 5-64, 7-72 Checking the Rectifier Regulator anode... 7-32
Checking the lighting coil ..........................5-50 Checking the shift cut switch .................... 5-61
Checking the Checking the spark plug ........................... 7-44
lower case.................. 8-26, 8-35, 8-83, 8-88 Checking the speed sensor (optional) ...... 5-41
Checking the Checking the sprocket .............................. 7-49
lower unit anode............. 8-3, 8-6, 8-61, 8-64 Checking the starter motor pinion............. 5-69
Checking the lower unit for Checking the starter relay......................... 5-65
air leakage ................. 8-31, 8-36, 8-85, 8-89 Checking the steering system .................. 10-7
Checking the low-pressure fuel pump.......6-32 Checking the thermostat................7-85, 10-15
Checking the low-pressure fuel Checking the thermoswitch ...................... 5-60
pump and high-pressure fuel pump ........5-46 Checking the throttle
Checking the main relay ...........................5-27 cable and shift cable............................... 10-7
Checking the neutral switch ......................5-63 Checking the tilt cylinder and PTT body ... 9-60
Checking the OCV ....................................5-37 Checking the timing belt ................7-39, 10-15
Checking the oil pan and Checking the top cowling........................ 10-15
exhaust manifold.....................................9-24 Checking the trim sensor.......................... 5-76
Checking the oil pressure ...........................7-1 Checking the vacuum hose ...................... 6-24
Checking the oil pressure sensor..............5-39 Checking the valve ..........................7-62, 9-60
Checking the oil pump assembly ..............7-77 Checking the valve clearance..........7-2, 10-16
Checking the oil strainer ...........................9-24 Checking the valve guide ......................... 7-63
i-2
Index
Checking the valve lifter............................7-49 Disassembling the reverse gear ......8-82, 8-88
Checking the valve seat............................7-64 Disassembling the shift bracket.................. 9-3
Checking the valve spring.........................7-62 Disassembling the starter motor ............... 5-69
Checking the vapor separator...................6-40 Disassembling the tilt ram ........................ 9-59
Checking the vapor shut-off valve... 5-48, 6-28 Disassembling the trim ram ...................... 9-60
Checking the water detection switch.........5-43 Disassembling the upper case ................. 9-20
Checking the water Disassembling the vapor separator .......... 6-39
pressure sensor (optional) ......................5-40 Disassembling the water
Checking the water pump .......................10-16 pump housing .............. 8-9, 8-13, 8-67, 8-70
Checking the water Disassembly and assembly ........................ 0-3
pump and shift rod ....... 8-9, 8-13, 8-67, 8-70 Disconnecting the quick connector............. 6-7
Circuit diagram..........................................5-22 Draining the fuel ....................................... 6-35
Clamp bracket.............................................3-3 Drive shaft and lower case (F200B) ......... 8-24
Clamp bracket and swivel bracket ............9-30 Drive shaft and lower case (F250G)......... 8-33
Cleaning and adjusting spark plug..........10-15 Drive shaft and lower case (FL200B) ....... 8-80
Connecting the communication Drive shaft and lower case (FL250G) ....... 8-86
cable to the outboard motor ......................4-5 Drive shaft spring
Connecting the quick connector..................6-8 (F250G and FL250G) ............................. 2-22
Cooling diagram........................................2-17
Cooling system .........................................2-17 E.
Cooling water hose .....................................6-5
ECM coupler layout .................................. 5-24
Cooling water passage cover....................7-70
Electric shock ............................................. 0-1
Crankcase.................................................7-74
Electrical component .................................. 5-1
Crankcase assembly.................................1-13
Electrical system technical data ................. 1-7
Crankshaft journal
Electronic control system............................ 2-1
bearing selection table ............................7-94
Electronic fuel injection control ................... 2-4
Crate top cover pictograph description .......3-4
Engine control system and component .... 5-27
Cylinder block ...........................................7-81
Engine control system component ............. 2-2
Cylinder head............................................7-58
Engine control unit......................................A-3
Cylinder head assembly............................1-12
Engine ECM ............................................. 7-35
Cylinder head cover ..................................7-42
Engine speed control system ..................... 1-8
ETV control................................................. 2-9
D. Exhaust cover........................................... 7-56
Digital ignition control..................................2-5 Extension length recommendation
Dimension and weight.................................1-4 for battery cable...................................... 3-28
Disassembling the cylinder block..............7-84 External dimensions ................................... 3-2
Disassembling the cylinder head ..............7-61
Disassembling the forward gear ..... 8-25, 8-35 F.
Disassembling the fuel filter assembly......6-14
F200BET, FL200BET,
Disassembling the
F250GET, FL250GET .............................. 3-2
gear pump assembly...............................9-53
Fail-safe control ........................................ 2-10
Disassembling the
Feature ....................................................... 4-1
lower case.................. 8-25, 8-35, 8-82, 8-88
Flywheel magnet ...................................... 7-15
Disassembling the oil pan and
Forward gear shim (T1) selection chart .... 8-53
exhaust manifold.....................................9-24 Forward gear shim
Disassembling the oil pump assembly......7-77 (T2) selection chart............................... 8-104
Disassembling the
Fuel and oil requirement............................. 1-5
oil seal housing .......... 8-25, 8-35, 8-82, 8-88 Fuel control unit and component .............. 5-43
Disassembling the Fuel diagram............................................. 2-12
propeller shaft assembly ............... 8-16, 8-22
Fuel filter assembly................................... 6-11
Disassembling the propeller shaft Fuel hose and blowby hose........................ 6-1
housing assembly ...... 8-16, 8-22, 8-73, 8-79 Fuel injection control system ...................... 1-8
Disassembling the PTT motor...................9-45
Fuel injector .............................................. 6-43
i-3
Index
Fuel system.................... 1-11, 1-17, 2-12, 6-7 Installing the intake silencer ..................... 6-19
Fuel system technical data .......................1-11 Installing the isolator lead (optional) ......... 3-11
Fuel unit ..................................................... A-5 Installing the junction box ......................... 7-33
Function ......................................................4-2 Installing the
Fuse box ...................................................7-29 lower unit ................... 8-31, 8-36, 8-85, 8-89
Fuse holder .................................................5-3 Installing the low-pressure fuel pump ....... 6-33
Installing the oil filter bracket .................... 7-79
G. Installing the oil pump assembly............... 7-78
Installing the power unit............................ 7-11
Gauge/sensor ...........................................1-11
Installing the propeller shaft
General feature ...........................................1-1
housing assembly...... 8-29, 8-35, 8-84, 8-88
General periodic maintenance ..................10-8
Installing the PTT motor ........................... 9-49
General tightening torque .........................1-21
Greasing .................................................10-13 Installing the PTT switch........................... 9-11
Installing the PTT unit............................... 9-41
Installing the Rectifier Regulator............... 7-33
H. Installing the reservoir .............................. 9-48
Handling of gas torch ..................................0-2 Installing the rigging grommet .................. 3-14
Handling of gasoline ...................................0-1 Installing the
Handling of sealant .....................................0-2 shift cable and throttle cable..................... 3-9
Hardware requirement ................................4-1 Installing the shift rod... 8-29, 8-36, 8-84, 8-88
Hose routing................................................6-1 Installing the shift rod and shift bracket ...... 9-4
Hot part .......................................................0-1 Installing the speed sensor (optional)....... 3-12
How to use the wiring diagram................... A-2 Installing the starter motor ...............5-74, 7-28
How to use this manual...............................0-4 Installing the steering arm ........................ 9-28
Installing the throttle body assembly ........ 6-24
I. Installing the tilt cylinder ........................... 9-62
Ignition timing control system......................1-7 Installing the tilt ram.................................. 9-63
Ignition unit................................................. A-7 Installing the timing belt ............................ 7-39
Ignition unit and component......................5-53 Installing the trim ram ............................... 9-63
Inspecting and replacing anode(s)............10-8 Installing the upper case........................... 9-16
Inspecting idle speed ................................10-9 Installing the vapor separator ................... 6-35
Installing the battery cable ........................3-12 Installing the
Installing the camshaft and water pressure sensor (optional) ............ 3-13
driven sprocket........................................7-50 Installing the
Installing the canister, water pump................ 8-30, 8-36, 8-85, 8-88
throttle body, and surge tank ..................6-29 Installing the wiring harness ............3-11, 7-23
Installing the clamp bracket ......................9-32 Intake and exhaust diagram ..................... 2-21
Installing the cooling Intake and exhaust system....................... 2-21
water passage cover...............................7-72 Intake manifold ......................................... 6-15
Installing the cowling lock lever.................9-11
Installing the crankcase cover...................7-78 J.
Installing the cylinder head .......................7-68 Junction box ............................................. 7-30
Installing the cylinder head cover..............7-44
Installing the
drive shaft .................. 8-28, 8-35, 8-84, 8-88
K.
Knock control.............................................. 2-7
Installing the engine ECM .........................7-36
Installing the exhaust cover ......................7-57
Installing the flushing L.
hose and cooling water hose ..................9-10 Lower unit ..........................................1-5, 2-22
Installing the flywheel magnet...................7-17 Lower unit (counter rotation model).......... 1-19
Installing the fuel filter assembly ...............6-14 Lower unit (F200B) ..................................... 8-1
Installing the fuel injector ..........................6-46 Lower unit (F250G)..................................... 8-4
Installing the intake manifold.....................6-18 Lower unit (FL200B) ................................. 8-59
i-4
Index
Lower unit (FL250G) .................................8-62 Predelivery check ..................................... 10-4
Lower unit (regular rotation model) ...........1-19 Propeller ..................................................... 0-1
Lower unit assembly Propeller damper cooling
(counter rotation model)..........................1-15 (F250G and FL250G) ............................. 2-23
Lower unit assembly Propeller selection .................................... 3-29
(regular rotation model)...........................1-15 Propeller shaft housing (F200B) ............... 8-14
Lower unit technical data ..........................1-15 Propeller shaft housing (F250G) .............. 8-20
Low-pressure fuel pump ...........................6-31 Propeller shaft housing (FL200B)............. 8-71
Lubricant, sealant, Propeller shaft housing (FL250G) ............ 8-77
and thread locking agent...........................0-7 Propeller shaft shim
Lubrication diagram ..................................2-16 (T4) selection table ............................... 8-101
Lubrication system ....................................2-16 Propeller size............................................ 3-29
PTT cylinder ............................................. 9-56
M. PTT electrical system ............................... 5-74
PTT fluid requirement ................................. 1-6
Maintenance chart 1 .................................10-1
PTT gear pump......................................... 9-50
Maintenance chart 2 .................................10-3
PTT motor................................................. 9-43
Manual format .............................................0-4
PTT switch and cowling lock lever.............. 9-6
Measuring the forward
PTT system .......................................1-9, 1-16
gear backlash.............................. 8-50, 8-102
PTT unit ...........................................1-20, 9-36
Measuring the forward gear backlash
PTT unit and control unit ..........................A-11
and reverse gear backlash
before disassembly ....................... 8-40, 8-93
Measuring the fuel pressure .......................6-8 R.
Measuring the peak voltage......................5-26 Rear...................................................5-4, 5-12
Measuring the Reducing the fuel pressure......................... 6-7
reverse gear backlash................. 8-55, 8-106 Refacing the valve seat ............................ 7-65
Model data ..................................................1-4 Remote control box and switch
Model designation.......................................1-2 panel installation..................................... 3-15
Model features ............................................1-1 Removing the canister, throttle body,
and surge tank........................................ 6-28
N. Removing the clamp bracket .................... 9-32
Removing the
Non-reusable part .......................................0-3
cooling water passage cover .................. 7-72
Removing the cowling lock lever ................ 9-9
O. Removing the crankcase cover ................ 7-76
Oil pan and exhaust manifold ...................9-22 Removing the cylinder head ..................... 7-61
Outboard motor installation.........................3-1 Removing the cylinder head cover ........... 7-44
Outboard motor mounting ...........................3-6 Removing the
Outboard motor mounting height ................3-8 drive shaft .................. 8-25, 8-35, 8-82, 8-88
Outboard motor troubleshooting .................4-6 Removing the driven
Outline.......................................................10-1 sprocket and camshaft ........................... 7-48
Over-rev control and alert control ...............2-8 Removing the engine ECM....................... 7-36
Removing the exhaust cover .................... 7-57
P. Removing the flushing
Part, lubricant, and sealant .........................0-2 hose and cooling water hose.................... 9-9
Performance ...............................................1-4 Removing the flywheel magnet ................ 7-16
Pinion shim (T3) selection table...... 8-48, 8-99 Removing the fuel filter assembly............. 6-13
Port ..................................................... 5-1, 5-6 Removing the fuel injector ........................ 6-45
Power unit ................................1-4, 1-12, 1-17 Removing the intake manifold .................. 6-17
Power unit (check and adjustment).............7-1 Removing the intake silencer ................... 6-17
Power unit assembly...................................7-6 Removing the junction box ....................... 7-32
Power unit system.....................................2-11 Removing the
Power unit technical data..........................1-12 lower unit ....................... 8-3, 8-6, 8-61, 8-64
i-5
Index
Removing the low-pressure fuel pump .....6-32 Shimming.........................................8-43, 8-97
Removing the oil filter bracket...................7-76 Shimming (counter rotation model) .......... 8-90
Removing the oil pump assembly .............7-76 Shimming (regular rotation model) ........... 8-37
Removing the power unit ............................7-8 Shimming check sheet ....................8-38, 8-91
Removing the propeller shaft Shimming workflow..........................8-37, 8-90
housing assembly ...... 8-16, 8-22, 8-73, 8-79 Single outboard motor application ............ 3-22
Removing the PTT motor..........................9-45 Special service tool..............................0-3, 0-9
Removing the PTT switch ...........................9-9 Specified tightening torque ....................... 1-17
Removing the PTT unit .............................9-37 Starboard.............................................5-2, 5-9
Removing the Rectifier Regulator .............7-32 Starter motor....................................5-67, 7-27
Removing the reservoir.............................9-45 Starting system ......................................... 1-10
Removing the shift rod and shift bracket.....9-3 Starting unit and component..................... 5-65
Removing the starter motor ............ 5-69, 7-28 Steering arm ............................................. 9-27
Removing the steering arm.......................9-28 Symbol........................................................ 0-7
Removing the throttle body assembly.......6-23 System diagram........................................ 3-22
Removing the tilt ram ................................9-59
Removing the timing belt ..........................7-38 T.
Removing the trim ram..............................9-59
Test run .................................................... 10-7
Removing the upper case .........................9-16
Throttle body............................................. 6-21
Removing the vapor separator..................6-35
Tightening torque........................................ 0-3
Removing the water
Timing belt ................................................ 7-37
pump and shift rod ....... 8-9, 8-13, 8-67, 8-70
Top ....................................................5-5, 5-15
Removing the wiring harness....................7-20
Triple outboard motor application ............. 3-26
Replacing the OCV filter .........................10-12
Trouble code and checking step................. 4-9
Replacing the oil filter..............................10-10
Troubleshooting procedure......................... 4-6
Replacing the timing belt.........................10-15
Troubleshooting the lower unit ................. 4-26
Replacing the valve guide.........................7-63
Troubleshooting the power unit
Reverse gear shim
(trouble code not detected)..................... 4-19
(T1) selection chart ...............................8-108
Troubleshooting the power unit using
Reverse gear shim (T2) selection chart ....8-57
the diagnostic flash indicator .................. 4-18
Rigging grommet description ......................3-9
Troubleshooting the
Rigging grommet mounting.........................3-9
power unit using the YDIS ........................ 4-6
Rigging information ...................................1-17
Troubleshooting the PTT unit ................... 4-25
Rigging recommendation ..........................3-28
Twin outboard motor application .............. 3-24
Rotating part ...............................................0-1
U.
S. Uncrating procedure ................................... 3-5
Safety while working ...................................0-1
Upper case ............................................... 9-18
Selecting the crankpin bearing..................7-90 Upper case and mounts ........................... 9-14
Selecting the crankshaft journal bearing...7-92 Using the digital tester .............................. 5-27
Selecting the pinion shim (T3) ........ 8-45, 8-99
Using the YDIS ......................................... 5-26
Selecting the propeller shaft shim (T4) .....8-99
Selecting the
propeller shaft shim (T4) (F250G)...........8-50 V.
Selection ...................................................3-29 Vapor gas hose .......................................... 6-3
Self-protection.............................................0-2 Vapor gas treatment ................................. 2-15
Serial number..............................................1-3 Vapor separator........................................ 6-34
Shift rod and shift bracket ...........................9-1 Vapor separator and
Shim location (F200B) ..............................8-43 high-pressure fuel pump......................... 6-37
Shim location (F250G) ..............................8-44 VCT control................................................. 2-6
Shim location (FL200B) ............................8-97 VCT system ................................................ 1-9
Shim location (FL250G) ............................8-98 Ventilation................................................... 0-1
Shimless valve lifter ..................................2-11
i-6
Index
W.
Water pump and shift rod (F200B)..............8-7
Water pump and shift rod (F250G) ...........8-11
Water pump and shift rod (FL200B)..........8-65
Water pump and shift rod (FL250G) .........8-68
Wiring diagram........................................... A-2
Wiring harness ..........................................7-19
Wiring harness routing ................................5-6
Working with crane .....................................0-2
Y.
YDIS............................................................4-1
i-7
Appendix
Wiring diagram ............................................................................ A-2

How to use the wiring diagram ................................................... A-2
Engine control unit...................................................................... A-3
Fuel unit...................................................................................... A-5
Ignition unit ................................................................................. A-7
Charging unit and starting unit ................................................... A-9
PTT unit and control unit .......................................................... A-11
A
— MEMO —
A-1
Wiring diagram
How to use the wiring diagram

Composition of the wiring diagrams
The wiring diagram consists of five categories. Engine control unit, Fuel unit, Ignition unit, Charging
and starting unit, and PTT unit and control unit.
Legend symbols in the wiring diagrams

1 2 3 4 5
1 Double colors wire

2 No wire connector
3 A wire is not included in the selected wiring unit.
4 Alert buzzer
5 Optional parts
Color Code
B : Black R/Y : Red/Yellow
B/Br : Black/Brown Sb : Sky blue
B/G : Black/Green W : White
B/L : Black/Blue W/B : White/Black
B/O : Black/Orange W/G : White/Green
B/W : Black/White W/L : White/Blue
B/Y : Black/Yellow W/R : White/Red
Br : Brown Y : Yellow
G : Green Y/G : Yellow/Green
G/B : Green/Black
G/R : Green/Red
L : Blue
L/B : Blue/Black
L/G : Blue/Green
L/R : Blue/Red
L/W : Blue/White
L/Y : Blue/Yellow
Lg : Light green
O : Orange
P : Pink
P/B : Pink/Black
P/G : Pink/Green
P/W : Pink/White
Pu : Purple
Pu/B : Purple/Black
Pu/G : Purple/Green
Pu/L : Purple/Blue
Pu/R : Purple/Red
Pu/W : Purple/White
Pu/Y : Purple/Yellow
R : Red
R/G : Red/Green A
A-2
Engine control unit
(*1) Depending on the outboard motor, the locations of terminals 1-10 and 16-22 may vary.
a Fuse (60 A) (house [accessory] battery)

b Fuse (60 A) (starting battery)
c Fuse (30 A) (ignition coil, fuel injector, VCT, engine ECM)
d Fuse (10 A) (ETV, engine ECM)
e Fuse (30 A) (starter relay)
f Fuse (10 A) (low-pressure fuel pump)
g Fuse (20 A) (engine start switch, PTT switch)
h Fuse (15 A) (high-pressure fuel pump)
k Main relay
m ETV motor relay
n Starter relay
p High-pressure fuel pump relay
r Condenser (connect to the cam position sensor [PORT EX])
s Condenser (connect to the air pressure sensor)
È To remote control (703 remote control model)

To remote control and switch panel (704 remote control model)
É If the 6Y8 Multifunction Meter is selected, connect the coupler.
Ê To 6Y8 Multifunction meter
Ë To diagnostic flash indicator B
Ì To YDIS
A-3
Jul. 2011 – ** × 1 CR
(E)
Engine control unit
c d
53 62 70 78
È
B k m
Joint coupler 1
a b
24 12
Fuse box
B
R h
w
P
B
Y
e
n p
Br
G
R
64 Battery 10 1
65 L/R 23 11
66 Y
67 P f g
68 B
69 B
5 1
61 69 77 86 Pulser coil 12 6
Engine ECM 72 P/W
73 P/B
74 L/W
75 B
10
11
16
17
18
19
20
21
22
R/G 11
R/G 12
B B
2
1
2
3
4
5
6
7
8
9
6
7
8
9
76 B W/B W/R 13 1
77 Pu
R/Y
R/Y
R/Y
R/Y
R/Y
Y
Br
B
Y/G
L/R
78 W (*1) B 1
79 R/G 2
80 R/G B
81 G/B B 3
B 4
83 G/R B 5
84 B B 6
85 G/B B 7
86 Pu B 8
B 9
B 10
27 R/Y
28 W/B B 12
B 13
B 14
31 P/W B 15
B 16
B 17
34 R/Y B 18
B 19
36 P/G
37 P/W
38 P
27 34 40 46 40 B
41 B
42 L/B O 24
43 L O 23
44 O O 22
45 P O 21
46 B O 20
47 B
48 O
49 O R/Y 17
50 P/W R/Y 16
51 O 15
33 39 45 52 52 P R/Y
R/Y 14
R 13
1 W/B
2 W/G
3 W/L
5 L/W
6 L/Y
7 Y/G
8 G B 5
B 4
1 8 14 20 B 3
12 L/G B 1
13 Y
24 12
15 B
16 W/B
17 B/Y
R
B
18 B
19 P
P/G
20 W
O
B
B
B
21 L
r
R/Y
R/Y
P/G
G/B
L/W
R/Y
L/W
B/Y
Pu
Pu
7 13 19 26
O
23 B/Y
B
B
B
P/W
G/R
G/B
P/W
L/G
P/W
L/B
W/G
L/Y
W/B
O
W/L
P
B
R/Y
R/Y
R/Y
O
G
s
O
O
B
B
B
B
O
B
P
B
L
B
B
P/W
W/B
B
O
Air pressure
L/W
B
R/Y
P/B
B/Y
W
P
B
sensor
L
B
P/B
P
P
13 1
Ë
B
B
B
Ê Ì
Joint coupler 2
B
É É B OCV OCV (STBD) (PORT)
B (STBD IN) Water
Shift cut Neutral (PORT EX) (STBD) (PORT) Thermoswitch
Alert Knock detection Engine
switch switch Water pressure (PORT IN)
indicator Trim sensor Oil pressure sensor Speed sensor switch temperature Air temperature
sensor (LAN) Cam position sensor ETV (TPS) Vapor shut-off valve
coupler sensor APS (LAN) sensor sensor
A-4
Fuel unit

k Main relay
m ETV motor relay
n Starter relay
s Condenser (connect to the air pressure sensor)

A-5
Fuel unit
c d
È
B k m
a b
53 62 70 78 Fuse box
B
55 Pu/W
h
W
G
R
B
Y
56 Pu/L
Pu/G e
57 n p 10 1
Br
R
58 Pu/Y
59 Pu/R 23 11
60 Pu/B
61 L/W
Battery f g
64 G 5 1 B 1
65 L/R Pulser coil 12 6
66 Y
67 P 24 12
61 69 77 86 68 B
10
11
R/Y 16
R/Y 17
R/Y 18
19
R/Y 20
R/Y 21
R/Y 22
R 10
R/G 11
R/G 12
2
1
2
3
4
5
6
7
8
9
2
3
Br 6
B 7
Y/G 8
L/R 9
69 B B B 6
W/B B 7
Engine ECM
R/Y
R/Y
R/Y
Y
R/Y
R
(*1) B 8
B 9
B 10
75 B B 12
76 B B 13
78 W
79 R/G
80 R/G
81 G/B
B 19
83 G/R
84 B 13 1
85 G/B
Joint coupler 1
27 R/Y
O 24
O 23
31 P/W 24 12
34 R/Y
R/Y 17
36 P/G R/Y 16
R/Y 15
38 P R/Y 14
27 34 40 46 R 13
40 B
41 B
44 O
45 P
46 B
47 B B 5
48 O 13 1
49 O B 3 Joint coupler 2
50 P/W B 2
33 39 45 52 51 O B 1
1 W/B
2 W/G
3 W/L
5 L/W
7 Y/G
1 8 14 20
R
B
13 Y
P/G
P/G
G/B
R/Y
O
B
O
15 B
B
L/W
r
B/Y
16 W/B
P/W
G/R
G/B
L/W
s
R/Y
R
B
B
B
17 B/Y
O
P
B
P/W
18 B
O
O
B
B
B
B
B
B
P
B
W/G
W/B
W/L
R/Y
R/Y
R/Y
B
B
B
Pu/W
Pu/G
Pu/R
Pu/Y
Pu/B
Pu/L
B
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
7 13 19 26
B
Water detection
(STBD IN) (PORT IN) (PORT EX) switch Vapor shut-off valve
#5 #3 #1 #2 #4 #6 Engine temperature High-pressure Low-pressure Air pressure
APS Fuel injector Fuel injector Cam position sensor ETV (TPS) sensor
sensor fuel pump fuel pump
A-6
Ignition unit

k Main relay
m ETV motor relay
n Starter relay

A-7
Ignition unit
c d
53 62 70 78 È
B k m
a b
53 B/Br
54 B/L Fuse box
B
R h
W
G
B
Y
e
Battery n p 10 1
Br
R
23 11
f g
62 B/G
63 B/Y
64 G 5 1
61 69 77 86 65 L/R 12 6
66 Y Pulser coil
67 P
68 B
10
11
16
17
18
R/Y 19
20
21
22
R/G 11
R/G 12
69 B
2
1
2
3
4
5
6
7
8
9
6
7
8
9
Engine ECM 70 B/W B
71 B/O W/B
R
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
Y
Br
B
Y/G
L/R
72 P/W (*1) B 1
73 P/B B 2
B 3
75 B B 4 24 12
76 B B 5
B 6
78 W B 7
79 R/G
80 R/G B 9
B 10
B 12
84 B B 13
B 14
27 R/Y
13 1
Joint coupler 1
34 R/Y
O 24
37 P/W
O 22
27 34 40 46 24 12
R/Y 16
R/Y 15
46 B R/Y 14
R 13
48 O B 12
B 11
B 10
B 9
33 39 45 52 B 8
52 P
B 7
1 W/B B 5
2 W/G 13 1
3 W/L B 3 Joint coupler 2
B 1
1 8 14 20 6 L/Y
7 Y/G
8 G
13 Y
R
B
15 B
16 W/B
B/Y
B/Y
17 B/Y
B/Br
B/W
B/O
B/G
B
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
B/Y
B/L
r
B
B
18 B
B
7 13 19 26
P/W
P
O
B
W/G
L/Y
W/B
W/L
R/Y
R/Y
R/Y
P/W
B
B
B
G
B
P/B
B
23 B/Y
P/B
B
B
B

B
B Shift cut switch
B Ignition Ignition Ignition Ignition Ignition Ignition (STBD IN) (PORT IN) (PORT EX) Engine temperature (STBD) (PORT)
Alert indicator coupler Oil pressure sensor Knock sensor coil #5 coil #3 coil #1 coil #2 coil #4 coil #6 Cam position sensor sensor Thermoswitch
A-8
Charging unit and starting unit

k Main relay
m ETV motor relay
n Starter relay

A-9
Charging unit and starting unit
10 1 5 1
B
È 23 11 12 6
1
2
B
Rectifier Regulator
c d
R
B
k m
w
P
B
Y
Fuse box
a b
B
Br
53 62 70 78
R
Battery
B
G
R
G
G
R
h
e
House n p
(accessory)
battery f g
64 G
65 L/R R
R
66 Y
67 P
68 B
61 69 77 86 B
Br
69
10
11
16
17
18
19
20
21
22
R/G 11
R/G 12
Starter motor
2
1
2
3
4
5
6
7
8
9
1
3
6
7
8
9
G
G
G
Engine ECM
R/Y
R/Y
R/Y
Y
Br
R
Br
B
Y/G
L/R
(*1)
75 B
76 B
78 W
79 R/G
80 R/G
84 B
27 R/Y B 1
24 12
34 R/Y
B 12
27 34 40 46 B 13
46 B
13 1
48 O
Joint coupler 1
33 39 45 52
O 24
24 12
7 Y/G R/Y 16
1 8 14 20
13 Y
18 B B B 5
B 13 1
B B B 3 Joint coupler 2
B 1
B
B
B
7 13 19 26
B
B
B
A-10
PTT unit and control unit

k Main relay
m ETV motor relay
n Starter relay
r Diode (connect to the PTT relay)

É If the 6Y8 Multifunction Meter is selected, connect the coupler
Ê 703 remote control model
Ë 704 remote control model
Ì To power unit
Í To gauge
A-11
PTT unit and control unit 10 1 5 1
B
23 11 12 6 Ê Engine start switch PTT switch
W B R Y Br Engine shut-off switch Sb R Lg
È OFF W B UP
B
ON Set Free
R
c d START Pull DN
k m Fuse box
Lg
Sb
R
a b
Br
W
G
Y
R
B
P
B
Battery
Y
53 62 70 78
W
B
BZ
Lg
Starter motor
Sb
P Y
Br
R
Lg
Sb
R
Sb
Lg
h
B
e
n p
W
B
Y
R R R
f g Í G
Y
G
64 G
65 L/R R PTT relay W
66 Y B Sb
P Ì
R
67 P Sb Sb
68 B Lg Lg Lg
61 69 77 86 L
Br
69 B B B
Br
10
11
16
17
18
19
20
21
22
11
12
1
1
2
3
4
5
6
7
8
9
1
3
4
6
7
8
9
Engine ECM 72 P/W
R
73 P/B
R/Y
R/Y
R/Y
Y
Br
R
R
Br
B
Y/G
L/R
R/G
R/G
(*1) Neutral switch
75 B
R
76 B
78 W
Ë
79 R/G Engine start switch PTT switch
80 R/G
W B R Y Br Engine shut-off switch Sb R Lg
Sb OFF W B UP
84 B B Lg ON Set Free
r START Pull DN
W
B
Br
Lg
W
Sb
R
B
R
BZ
27 R/Y
Y
B
P Y
Ì
Lg
Sb
R
B
Y Y Ì
B Br
34 R/Y Í P
B 1 R W
G G Br
24 12 R Br
27 34 40 46 Neutral switch
46 B B 12
B 13
48 O
33 39 45 52 B 18
13 1
Joint coupler 1
SB
Lg
7 Y/G
O 24
1 8 14 20 24 12
R
13 Y
SB
16
P/W
R/Y
Lg
P/B
P
B
B
B
B
18 B
19 P
P/B
P
7 13 19 26 B
B
B
B
É É B 6
B B 5
B 13 1
B Alert indicator coupler B 3 Joint coupler 2
PTT switch Trim sensor PTT motor B 1
A-12

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F200bet Service Manual PDF

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Available Formats

F200B

F200B, FL200B, F250G, FL250G

Safety while working ..................................................... 0-1

How to use this manual ..................................................... 0-4

Lubricant, sealant, and thread locking agent .................. 0-7

Special service tool............................................................ 0-9

Working with crane

Driver rod LL 3: 90890-06605

Symbol Name Application

Gear oil Lubricant

Water resistant grease Lubricant

Molybdenum disulfide grease Lubricant

Corrosion resistant grease Lubricant

Low temperature resistant grease Lubricant

WR-No.2 grease Lubricant

Symbol Name Application

ThreeBond 1280B Sealant

ThreeBond 1303N Thread locking agent

ThreeBond 1322 Thread locking agent

ThreeBond 1324 Thread locking agent

ThreeBond 1377B Thread locking agent

Symbol Name Application

ThreeBond 1401 Thread locking agent

LOCTITE 242 (blue) Thread locking agent

LOCTITE 271 (red) Thread locking agent

LOCTITE 572 (white) Sealant

Silicone sealant Sealant

Drilling plate Peak voltage adapter

YDIS (CD-ROM, Ver. 1.33) Test harness (3 pins)

YDIS USB adapter and cable Vacuum/pressure pump gauge set

Diagnostic flash indicator B Ignition tester

Digital circuit tester Test harness (2 pins)

Fuel pressure gauge Flywheel puller

Leakage tester Sheave holder

Compression gauge Valve spring compressor

Compression gauge extension Valve spring compressor attachment

Valve guide installer Valve seat cutter 30° (exhaust)

Valve guide reamer Valve seat cutter 45° (intake)

Valve lapper Valve seat cutter 45° (exhaust)

Driver rod L3 Shift rod socket

Needle bearing attachment Bearing housing puller claw L

Needle bearing attachment Stopper guide plate

Piston ring compressor Center bolt

Bearing outer race puller assembly Driver rod SS

Bearing separator Needle bearing attachment

Stopper guide stand Bearing depth plate

Bearing puller assembly Bearing inner race attachment

Drive shaft holder 6 Bearing inner race attachment

Pinion nut holder Bearing outer race attachment

Ball bearing attachment Driver rod LS

Driver rod LL Backlash indicator

Dial gauge set Ball bearing attachment

Magnet base B PTT oil pressure gauge assembly

Pinion height gauge Cylinder-end screw wrench

Puller head PTT piston vice attachment

Model features .................................................................... 1-1

Model data .......................................................................... 1-4

Electrical system technical data ....................................... 1-7

Fuel system technical data ............................................. 1-11

Power unit technical data ................................................ 1-12

Lower unit technical data ................................................ 1-15

Bracket unit technical data ............................................. 1-16

Specified tightening torque............................................. 1-17